WR250F-2007 - Off-road motorcycle YAMAHA - Free user manual and instructions

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USER MANUAL WR250F-2007 YAMAHA

©2006 Yamaha Motor Co., Ltd. ©2006 by Yamaha Motor Co., Ltd.

“INTRODUCTION Congratulations on your purchase of a Yamaha WR series. This model is the culmination of Yamaha's vast experience in the production of pace- setting racing machines. It repre- sents the highest grade of craftsmanship and reliability that have made Yamaha a leader. This manual explains operation, inspection, basic maintenance and tuning of your machine. If you have any questions about this manual or your machine, please contact your Yamaha dealer. NOTE: Yamaha continually seeks advance- ments in product design and quality. Therefore, while this manual con- tains the most current product infor- mation available at the time of printing, there may be minor discrep- ancies between your machine and this manual. If you have any ques- tions concerning this manual, please consult your Yamaha dealer. LA WARNING,

PLEASE READ THIS MANUAL

CAREFULLY AND COMPLETELY

BEFORE OPERATING THIS

OPERATE THIS MACHINE UNTIL

FACTORY KNOWLEDGE OF ITS

FEATURES AND UNTIL YOU

COURSE. Itis illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding. mm À SAFETY INFORMATION De

ENCED RIDER ONLY. Do not attempt to operate this machine at maximum power until you are totally familiar with its characteris- tics.

BY THE OPERATOR ONLY. Do not carry passengers on this machine.

3. ALWAYS WEAR PROTEC-

TIVE APPAREL. When operating this machine, always wear an approved helmet with gog- gles or a face shield. Also wear heavy boots, gloves, and protective clothing. Always wear proper fitting clothing that will not be caught in any of the moving parts or controls of the machine.

4. ALWAYS MAINTAIN YOUR

WORKING ORDER. For safety and reliability, the machine must be prop- erly maintained. Always perform the pre-operation checks indicated in this manual. Correcting a mechanical problem before you ride may prevent an accident.

FLAMMABLE. Always turn off the engine while refueling. Take care to not spill any gasoline on the engine or exhaust sys- tem. Never refuel in the i of an open flame, or while smoking. HIGHLY NOTICE IMPORTANTE

3. LLEVE SIEMPRE LA INDU-

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 gaso- line spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes.

WITH ADEQUATE VENTI-

LATION. Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are poison- ous. These fumes contain carbon monoxide, which by itself is odorless and color- less. Carbon monoxide is a dangerous gas which can cause unconsciousness or can be lethal.

THE ENGINE. Always turn off the engine if you are going to leave the machine. Do not park the machine on a slope or soft ground as it may fall over.

PIPE, MUFFLER, AND OIL

TANK WILL BE VERY HOT

AFTER THE ENGINE HAS

BEEN RUN. Be careful not to touch them or to allow any cloth- ing item to contact them during inspection or repair.

MACHINE BEFORE TRANS-

PORTING IT. When transporting the machine in another vehicle, always be sure it is prop- erly secured and in an upright position and that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the car- buretor or fuel tank.

This manual will provide you with a good basic understanding of fea- tures, operation, and basic mainte- nance and inspection items of this machine. Please read this manual carefully and completely before oper- ating your new machine. If you have any questions regarding the opera- tion or maintenance of your machine, please consult your Yamaha dealer. NOTE: This manual should be considered a permanent part of this machine and should remain with it even if the machine is subsequently sold. EC060000 NOTICE Some data in this manual may become outdated due to improve- ments made to this model in the future. If there is any question you have regarding this manual or your machine, please consult your Yamaha dealer. ECo70001

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! À WARNING Failure to follow WARNING instruc- tions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine. CAUTION: A CAUTION indicates special pre- cautions that must be taken to avoid damage to the machine. NOTE: A NOTE provides key information to make procedures easier or clearer. EC082000

1. This manual consists of seven

chapters; “General information”, “Specifications”, “Regular inspection and adjustments”, “Tuning”, “Engine”, “Chassis” and “Electrical”.

2. The table of contents is at the

ECo83000 MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information 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., + Bearings Pitting/damage — Replace. EC084002

HOW TO READ DESCRIPTIONS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

1. An easy-to-see exploded diagram ( is provided for

removal and disassembly jobs.

2. Numbers © are given in the order of the jobs in the

exploded diagram. À number that is enclosed by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an

easy-to-read way by the use of symbol marks ©. The meanings of the symbol marks are given on the next page.

4. À job instruction chart @ accompanies the exploded

diagram, providing the order of jobs, names of parts, notes in jobs, etc.

5. Extent of removal ® is provided in the job instruction

chart to save the trouble of an unnecessary removal job.

6. For jobs requiring more information, the step-by-step

format supplements © are given in addition to the exploded diagram and job instruction chart.

(o} @ A] @ @® a ILLUSTRATED SYMBOLS (Refer to the illustration) lllustrated symbols @ to @ are designed as thumb tabs to indicate the chapter's number and content. General information Specifications Regular inspection and adjustments Tuning Engine Chassis Electrical

lllustrated symbols © to @ are used to identify the specifications appear- ing in the text. With engine mounted Special tool Filling fluid Lubricant Tightening Specified value, Service limit Resistance (Q), Voltage (V), Electric current (A)

TUNING MISE AU POINT

TORQUE-CHECK POINTS. CLEANING AND STORAGE.

KICK SHAFT AND SHIFT

STARTER CLUTCH ENGINE REMOVAI CRANKCASE AND CRANKSHAFT

TRANSMISSION, SHIFT CAM

AND SHIFT FORK …. … 5-245

GEN INFO | GS EC120001 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. lf your machine is stolen, the

authorities will need the number to search for and identify your machine. EC121001 VEHICLE IDENTIFICATION NUMBER The vehicle identification number © is stamped on the right of the steer- ing head pipe. EC123001

ENGINE SERIAL NUMBER

The engine serial number © is stamped into the elevated part of the right-side of the engine. EC124000 MODEL LABEL The model label © is affixed to the frame under the riders seat. This information will be needed to order spare parts.

1. Remove all dirt, mud, dust, and

foreign material before removal and disassembly. When washing the machine with high pressured water, cover the parts follows. + Silencer exhaust port + Side cover air intake port + Water pump housing hole at the bottom head (right side) All electrical components

2. Use proper tools and cleaning

equipment. Refer to “SPECIAL TOOLS” section.

machine, disassembling cylinders, pistons, an assembly or replaced.

4. During the machine disassem-

bly, clean all parts and place them in trays in the order of dis- assembly. This will speed up assembly time and help assure that all parts are correctly rein- stalled.

5. Keep away from fire.

ALL REPLACEMENT PARTS

1. We recommend to use Yamaha

genuine parts for all replace- ments. Use oil and/or grease recommended by Yamaha for assembly and adjustment. Drain hole on the cylinder the keep mated parts together. They include gears, and other mated parts that have been “mated” through normal wear. Mated parts must be reused as INFORMATIONS IMPORTANTES

PREPARATION A LA DEPOSE ET

1. All gaskets, oil seals, and O-

rings should be replaced when an engine is overhauled. All gas- ket surfaces, oil seal lips, and O- rings must be cleaned.

2. Properly oil all mating parts and

bearings during reassembly. Apply grease to the oil seal lips. EC134000

LOCK WASHERS/PLATES AND

1. All lock washers/plates D and

cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the boit or nut flat(s) after the bolt or nut has been properly tightened. EC135001

BEARINGS AND OIL SEALS

1. Install the bearing(s) © and oil

seal(s) © with their manufac- turer's marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of lightweight lithium base grease to the seal lip(s). Oil the bearings liberally when installing. CAUTION: Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces. 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 @, make sure that the sharp- edged corner @ is positioned opposite to the thrust @ it receives. See the sectional view. @ Shaft 1-7

EC1Co001 CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector.

2. Dry each terminal with an air

3. Connect and disconnect the con-

nector two or three times.

4. Pull the lead to check that it will

5. If the terminal comes off, bend

7. Check for continuity with a

SPECIAL TOOLS GEN INFO | GS 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. Refer to the list provided to avoid errors when placing an order. NOTE: + For U.S.A. and Canada, use part number starting with “YM-”, “YU-" or “ACC-". + For others, use part number starting with “90890-". Part number Tool name/How to use Illustration YU-1135-A, 90890-01135 Crankcase separating tool These tool is used to remove the crankshaft from either case. YU-1135-A

Part number Tool name/How to use Illustration YS-1880-A, 90890-01701 Sheave holder This tool is used for when loosening or tightening the flywheel magneto securing nut. YS-1880-A 20890-01701 YU-3112-C, 90890-03112 Pocket tester Use this tool to inspect the coil resistance, output voltage and amperage. YM-33277-A, 90890-03141 Timing light This tool is necessary for checking ignition timing. 90890-03141

GEN INFO | GS EC150000 CONTROL FUNCTIONS MAIN SWITCH Functions of the respective switch positions are as follows: ON: The engine can be started only at this position. OFF: All electrical circuits are switched off. Main switch indicator light The main switch is equipped with an indicator light © to avoid forget- ting to turn it off. This light functions as follows. + It lights up with the main switch “ON”. It goes out when the engine increases its speed after being started. It lights up again when the engine is stopped. NOTE: If the indicator light will not light up with the main switch “ON”, it shows a lack of the battery voltage. Recharge the battery.

The engine stop switch © is located on the left handiebar. Continue push- ing the engine stop switch till the engine comes to a stop. START SWITCH The start switch (D is located on the right handlebar. Push this switch to crank the engine with the starter. EC152000 CLUTCH LEVER The clutch lever © is located on the left handlebar, it disengages or engages the clutch. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth starts. 1-27 FONCTIONS DES COMMANDES

GEN EC153000 SHIFT PEDAL The gear ratios of the constant-mesh 5 speed transmission are ideally spaced. The gears can be shifted by using the shift pedal @ on the left side of the engine. KICKSTARTER CRANK Rotate the kickstarter crank (D away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine. This model has a primary kickstarter crank so the engine can be started in any gear if the clutch is disengaged. In normal practices, however, shift to neutral before starting. EC155001 THROTTLE GRIP The throttle grip © is located on the right handlebar; it accelerates or decelerates the engine. For acceler- ation, turn the grip toward you; for deceleration, turn it away from you. EC156000

The front brake lever (D is located on the right handlebar. Pull it toward the handlebar to activate the front brake. EC157000

GEN INFO | GS FUEL COCK The fuel cock supplies fuel from the tank to carburetor and also filters the fuel. The fuel cock has three posi- tions: OFF: With the lever in this position, fuel will not flow. Always return the lever to this posi- tion when the engine is not running. ON: With the lever in this position fuel flows to the carburetor. Normal riding is done with the lever in this position. RES: With the lever in this position fuel flows to the carburetor from the reserve section of the fuel tank after the main supply of the fuel has been depleted. Normal riding is possible with the lever is in this position, but it is recom- mended to add fuel as soon as possible.

When cold, the engine requires a richer air-fuel mixture for starting. A separate starter circuit, which is con- trolled by the cold starter knob ©, supplies this mixture. Pull the cold starter knob out to open the circuit for starting. When the engine has warmed up, push it in to close the cir- cuit.

The hot starter lever © is used when starting a warm engine. Use the hot starter lever when start- ing the engine again immediately after it was stopped (the engine is still warm). Pulling the hot starter lever injects secondary air to thin the air-fuel mixture temporarily, allowing the engine to be started more easily. 1-31

GEN INFO | GS SIDESTAND This sidestand (© is used to support only the machine when standing or transporting it. À WARNING + Never apply additional force to the sidestand. + Hold up the sidestand before starting out. EC18F000 VALVE JOINT This valve joint © prevents fuel from flowing out and is installed to the fuel tank breather hose. CAUTION: In this installation, make sure the arrow faces the fuel tank and also downward.

This spark plug wrench © is used to remove and install the spark plug. NIPPLE WRENCH This nipple wrench @ is used to tighten the spoke.

MULTI-FUNCTION DISPLAY À WARNING Be sure to stop the machine before making any setting changes to the multi-function dis- play. The multi-function display is equipped with the following: BASIC MODE: + Speedometer + Clock + Two tripmeters (which shows the distance that has been traveled since it was last set to zero) RACE MODE: Timer (which shows the time that has been accumulated since the Start of timer measurement) Tripmeter (which shows the accu- mulated travel distance in timer measurement) Change tripmeter digits (capable of change to any given ones) DESCRIPTION Operation buttons: @ Select button “SLCT 1” © Select button “SLCT 2” © Reset button “RST” Screen display: Tripmeter indicator fY Tripmeter indicator FJ Timer indicator Clock/Timer Speedometer Odometer/Tripmeter 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. ( mm) 66066® BASIC MODE Changing speedometer display (for U.K.)

seconds or more to enter the time setting mode.

2. Push the “RST” button to change

the display for time indication. The display will change in the following order: Hour — Minute — Second — Hour. NOTE: The digits capable of setting go on flashing.

3. Push the “SLCT1” button (plus)

or “SLCT2” button (minus) and change the time. A long push on the button will fast-forward the time.

4. To end the setting, push the

“RST” button for 2 seconds or more. NOTE: + In a 30-second absence of button operation, the setting will come to an end with the indicated time. To reset the seconds, push the “SLCT1” button or “SLCT2” button. Changing odometer and tripmeter AIB (TRIP A/B)

1. Push the “SLCT2” button to

NOTE: NB: Measurement using the timer func- tion can be made in RACE MODE. Indicator £8 will light up as an iden- tifier that shows RACE MODE has been selected. RACE MODE cannot display the functions as in BASIC MODE. Changeover to RACE MODE forces the digits for tripmeter A (TRIP A) in BASIC MODE to be reset. Changeover from BASIC MODE to RACE MODE

1. Push the “SLCT1” button and

1. Check that the timer is not in

1. Check that changeover to RACE

MODE has been made. (Refer to “Changeover from BASIC MODE to RACE MODE”.) NOTE: When the machine is made ready for a run by manual start, & and 3 will start flashing.

2. Start timer measurement by

pushing the “RST" button.

3. When stopping timer measure-

ment, pushing the “SLCT1" but- ton and “SLCT2” button at the same time. NOTE:

4. To resume the measurement,

again push the “SLCT1” button and “SLCT2” button at the same time. 1-41

MULTI-FUNCTION DISPLAY ECRAN MULTIFONCTION GEN INFO | GS En] Ouen Auto start

1. Check that changeover has

been made to RACE MODE. (Refer to “Changeover from BASIC MODE to RACE MODE”.)

2. Make the machine ready for a

en appuyant sur le bouton “SLCT1” pendant 2 secondes minimum. N.B.: When measurement is made ready for a run by auto start, & and f3 will start flashing. Timer display will turn on scrolling from left to right.

3. Run the machine and start timer

4. To stop timer measurement,

5. To resume the measurement,

again pushing the “SLCT1” but- ton and “SLCT2” button at the same time. Resetting measurement data NOTE:

1. Check that the timer is in opera-

tion. If the timer is not in opera- tion, start the timer by pushing the “SLCT1” button and “SLCT2” button at the same time.

2. Reset tripmeter A (TRIP A) dis-

play by pushing the “RST” button for 2 seconds or more. NOTE: If reset, EN and travel distance dis- play will go on flashing for four sec- onds. 1-43 A (TRIP À)

Remise à zéro du totalisateur journalier Resetting tripmeter A (TRIP A) and timer

1. Check that the timer is not in

operation. If the timer is in opera- tion, stop it by pushing the “SLCTI” button and “SLCT2” button at the same time.

2. Reset all measured data by

pushing the “RST” button for 2 seconds or more. NOTE: Resetting will reset the timer dis- play and travel distance display and put measurement on standby. Auto start attempt will put mea- surement on standby as such. Likewise, manual start attempt will put measurement on standby as such. A (TRIP A) et du chronomètre

Change the travel distance dis- play by pushing the “SLCT1” button (plus) or “SLCT2” button (minus). A long push on the but- ton will fast-forward the change. NOTE: ms Change can be made any time while timer measurement is or is not being made. 1-45 Correction du totalisateur journalier A (TRIP A)

FUNCTION DIAGRAM NOTE: The following diagram illustrates the multi-function display regarding the direction and operation condition involved in each of its functions. À short push on the button changes the opera- tion in the arrowed direction. CD [E]. Meter function <= A short push on the button changes the opera- fion in both arrowed directions Function that can be performed whether the À long push on the button changes the opera- time is or is not in operation. tion in the arrowed direction — À long push on the button changes the opera- TE] ion in both arrowed directions Extent to which the meter can operate PCR TI "188888 @ BASIC MODE (ere se88ge "

@ Measurement starts as the RST machine moves © RACE MODE [ @ Timer in operation 6 Cr) @ Correct Na TRIP A @ Timer not in operation SLOTI + SLOT2

GEN INFO | GS STARTING AND BREAK:-IN À 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 oper- ate the machine in a well-venti- lated area.

According to “AIR FILTER CLEAN- ING” section in the CHAPTER 3, apply the foam-air-filter oil or its equivalent to the element. (Excess oil in the element may adversely affect engine starting.)

1. Inspect the coolant level.

2. Turn the fuel cock to “ON”.

3. Push on the main switch to “ON”.

4. Shift the transmission into neu-

6. Start the engine by pushing the

start switch or by kicking the kickstarter crank. 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. If the engine does not start with the starter motor, try using the kickstarter crank. À WARNING If the starter motor will not turn when pushing the start switch, stop pushing it immediately and kick start the engine in order to avoid the load on the motor. Do not open the throttle while kicking the kickstarter crank. Otherwise, the kickstarter crank may kick back.

7. Return the cold starter knob to

its original position and run the engine at 3,000 - 5,000 r/min for 1 or 2 minutes. NOTE: Since this model is equipped with an accelerator pump, if the engine is raced (the throttle opened and closed), the air/fuel mixture will be too rich and the engine may stall. Also unlike a two-stroke engine, this model can idle. CAUTION: Do not warm up the engine for extended periods of time. 1-53

Do not operate the cold starter knob and throttle. Pull the hot starter lever © and start the engine by pushing the start switch or by kicking the kick- starter crank forcefully with a firm stroke. As soon as the engine starts, Release the hot starter lever to close the air passage. Restarting an engine after a fall Pull the hot starter lever and start the engine. As soon as the engine starts, Release the hot starter lever to close the air passage. The engine fails to start Pull the hot starter lever all the way out and while holding the lever, kick the kickstarter crank 10 to 20 times to clear the engine. Then, restart the engine. Refer to “Restarting an engine after a fall”. To Cod | Hot SP | starter | starter per | knob | lever tion’ JAirtemperature = [Opens less than 5 °C or | ON | OFF CR Ames 8 [Airtemperature = SImore than5°C | None | ON | OFF 5 la)

8 [Air temperature & |(normal tempera- ow Bture)= between | None | SM | OFF £ 15°C (41 °F) and à [25°C (77 °F) JAir temperature = more than 25°C | None | OFF | OFF G7°F) Starting an engine after a long period of | None | ON | OFF time Restaring a warm engine Restaring an engine after a fall None | OFF | ON None | OFF | ON *_ Operate the throttle grip before kick starting. CAUTION: Observe the following break-in procedures during tial opera- tion to ensure optimum perfor- mance and avoid engine damage. 1-55

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. Then, restart the engine and check its operation within no more than 5 minutes after it is restarted.

4. Operate the machine in the

lower gears at moderate throttle openings for five to eight min- utes.

5. Check how the engine runs

when the machine is ridden with the throttle 1/4 to 1/2 open (low to medium speed) for about one hour.

6. Restart the engine and check

the operation of the machine throughout its entire operating range. Restart the machine and operate it for about 10 to 15 more minutes. CAUTION: After the break-in or before each ride, you must check the entire machine for loose fittings and fas- teners as per “TORQUE-CHECK POINTS”. Tighten all such fasteners as required. 1-57

GEN INFO TORQUE-CHECK POINTS TORQUE-CHECK POINTS Frame construction Frame to rear frame L Combined seat and fuel tank Fuel tank to frame Silencer to rear frame Exhaust system Frame to engine Engine mounting Steering Suspension Front Rear Steering stem to handiebar L_— Engine bracket to engine L Engine bracket to frame __ Steering stem to frame L__ Steering stem to upper bracket L— Upper bracket to handiebar Steering stem to front ue Front fork to upper bracket Front fork to lower bracket Rear Rear Wheel Brake For link type. Installation of rear Assembly of links — Link to frame — Link to rear shock absorber — Link to swingarm Rear shock absorber to frame shock absorber Installation of swingarm Installation of wheel Tightening of pivot shaft — Front Tightening of wheel axle Tightening of axle holder L_ Rear Tightening of wheel axle L Wheel to rear wheel sprocket Front Brake caliper to front fork -— Brake disc to wheel + Tightening of union bolt -— Brake master cylinder to handlebar + Tightening of bleed screw LE Tightening of brake hose holder L Rear ——— Brake pedal to frame -— Brake disc to wheel k-— Tightening of union boit +-— Brake master cylinder to frame k— Tightening of bleed screw LE Tightening of brake hose holder Fuel tank to fuel cock Fuel system Lubrication system Tightening of oil hose clamp NOTE: Concerning the tightening torque, refer to “MAINTENANCE SPECIFICATIONS” sec- tion in the CHAPTER 2. 1-59

CLEANING AND STORAGE

NETTOYAGE ET REMISAGE

GEN INFO | GS EC180000 CLEANING AND STORAGE EC181000 CLEANING Frequent cleaning of your machine will enhance its appearance, main- tain good overall performance, and extend the life of many components.

1. Before washing the machine,

block off the end of the exhaust pipe to prevent water from enter- ing. À plastic bag secured with a rubber band may be used for this purpose.

2. If the engine is excessively

greasy, apply some degreaser to it with a paint brush. Do not apply degreaser to the chain, sprockets, or wheel axles.

3. Rinse the dirt and degreaser off

with a garden hose; use only enough pressure to do the job. CAUTION: Excessive hose pressure may cause water seepage and contami- nation of wheel bearings, front forks, brakes and transmission seals. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in c operated car washers.

4. After the majority of the dirt has

been hosed off, wash all sur- faces with warm water and a mild detergent. Use an old tooth- brush to clean hard-to-reach places.

5. Rinse the machine off immedi-

ately with clean water, and dry all surfaces with a soft towel or cloth.

6. immediately after washing,

remove excess water from the chain with a paper towel and lubricate the chain to prevent rust.

7. Clean the seat with a vinyl uphol-

stery cleaner to keep the cover pliable and glossy.

8. Automotive wax may be applied

to all painted or chromed sur- faces. Avoid combination cleaner-waxes, as they may con- tain abrasives.

9. After completing the above, start

CLEANING AND STORAGE

NETTOYAGE ET REMISAGE

GEN INFO EC182001 STORAGE If your machine is to be stored for 60 days or more, some preventive mea- sures must be taken to avoid deterio- ration. After cleaning the machine thoroughly, prepare it for storage as follows:

1. Drain the fuel tank, fuel lines,

and the carburetor float bowl.

2. Remove the spark plug, pour a

tablespoon of SAE 10W-30 motor oil in the spark plug hole, and reinstall the plug. With the engine stop switch pushed in, kick the engine over several times to coat the cylinder walls with oil.

3. Remove the drive chain, clean it

thoroughly with solvent, and lubricate it. Reinstall the chain or store it in a plastic bag tied to the frame.

4. Lubricate all control cables.

5. Block the frame up to raise the

wheels off the ground.

6. Tie a plastic bag over the

exhaust pipe outlet to prevent moisture from entering.

7. lfthe machine is to be stored in a

GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model name: WR250F (EUROPE, ZA) WR250FW (USA, CDN, AUS, NZ) Model code number: 5UME (USA) 5UMF (EUROPE) 5UMG (CDN, AUS, NZ, ZA) Dimensions: USA, ZA, CDN EUROPE, AUS, NZ Overall length 2,165 mm (85.24 in) 2,180 mm (85.83 in) Overall width 825 mm (32.48 in) — Overall height 1,300 mm (51.18 in) 1,305 mm (51.38 in) Seat height 980 mm (38.58 in) 990 mm (38.98 in) Wheelbase 1,480 mm (58.27 in) — Minimum ground clearance 365 mm (14.37 in) 370 mm (14.57 in) Dry weight: Without oil and fuel 106.0 kg (233.7 lb) Engine: Engine type Liquid cooled 4-stroke, DOHC Cylinder arrangement Displacement Bore x stroke Compression ratio Starting system Single cylinder, forward inclined 249 cm (8.76 Imp oz, 8.42 US oz)

Oil capacity: Engine oil Periodic oil change With oil filter replacement Total amount

1.1 L (0.97 Imp at, 1.16 US qft)

1.2 L (1.06 Imp qt, 1.27 US at)

1.4 L (1.23 Imp at, 1.48 US qft)

Coolant capacity (including all routes):

0.99 L (0.87 Imp at, 1.05 US a)

Air filter: Wet type element Fuel: Type Premium unleaded gasoline only with a research octane number of 95 or higher. Tank capacity 8.0 L (1.76 Imp gal, 2.11 US gal) Reserve 1.1 L (0.24 Imp gal, 0.29 US gal) Carburetor: Type FCR-MX37 Manufacturer KEIHIN Spark plug: Type/manufacturer CR9IE/NGK (resistance type) Gap 0.7 - 0.8 mm (0.028 - 0.031 in) Clutch type: Wet, multiple-disc Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Gear 57/17 (3.353) Chain drive 50/13 (3.846) Constant mesh, 5-speed Operation Left foot operation Gear ratio: 1st 31/13 (2.385) 2nd 28/16 (1.750) 8rd 23/17 (1.353) Ath 23/21 (1.095) 5th 17/19 (0.895) Chassis: USA, ZA, CDN EUROPE, AUS, NZ Frame type Semi double cradle — Caster angle 27.0° 26.6° Trail 115 mm (4.53 in) 114 mm (4.49 in) Tire: Type With tube Size (front) Size (rear) Tire pressure (front and rear) 80/100-21 51M (For USA, CDN and ZA) 90/90-21 54R (For EUROPE, AUS and NZ) 100/100-18 59M (For USA, CDN and ZA) 130/90-18 69R (For EUROPE, AUS and NZ) 100 kPa (1.0 kgf/cm?, 15 psi)

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 Wheel travel: Front wheel travel 300 mm (11.8 in) Rear wheel travel 310 mm (122in) Electrical: Ignition system CDI Generator system AC magneto Battery type YTX5L-BS Battery voltage/capacity 12 V/4 AH Specific gravity 1.320 Headlight type: Quartz bulb (halogen) Bulb wattage x quantity: Headlight 12 V 35/36.5 W x 1 Taillight 12 V 1.6/0.3 W x 1

MAINTENANCE SPECIFICATIONS SPEC| UV Item Standard Timing chain: Timing chain type/No. of links Timing chain adjustment method 92RH2010-114M/114 Automatic Valve, valve seat, valve guide: Valve clearance (cold) Valve dimensions: E— à —+ Head diameter “A” head diameter “B” face width “C” seat width “D” margin thickness Stem outside diameter Guide inside diameter Stem-to-guide clearance

(0.9606 - 0.9685 in)

Measuring point “H” Piston off-set 8 mm (0.31 in)

Optional spring/spacer Yes <— — Oil capacity 648 cm < = (22.8 Imp oz,

1. First, tighten the steering ring nut approximately 38 Nm (3.8 m + kg, 27 ft + Ib) by using the steer-

Tightening torque Part to be tightened Thread size | Q'ty Nm m-kg ftlb Speed sensor lead holder and lower bracket M6 x 1.0 1 13 1.3 9.4 Headlight body and headlight unit — 2 1 0.1 0.7 Headlight (left and right) M6 x 1.0 2 7 0.7 5.1 Taillight — 3 1 0.1 0.7 Taillight lead clamp and rear fender — 3 0.5 0.05 0.36 Catch tank (upper) M6 x 1.0 1 16 1.6 11 Catch tank (lower) M6 x 1.0 1 7 0.7 5.1 Footrest bracket and frame M10 x 1.25 4 55 5.5 40 Sidestand M10 x 1.25 1 25 2.5 18 NOTE: A - marked portion shall be checked for torque tightening after break-in.

(White — Red) 5UM-E0/YAMAHA (For USA) 5UM-F0/YAMAHA (Except for USA) Ignition coil: Model/manufacturer Minimum spark gap Primary coil resistance Secondary coil resistance 5SUL-10/DENSO 6 mm (0.24 in)

0.08 - 0.10 Q at 20 °C (68 °F)

Charging system: System type Model (stator)/manufacturer Normal output Charging coil resistance (color) Lighting coil resistance (color) AC magneto 5UM 20/YAMAHA 14 V/120 W at 5,000 r/min

(Yellow — Ground) Rectifier/regulator: Regulator type Model/manufacture Regulated voltage (AC) Regulated voltage (DC) Rectifier capacity (AC) Rectifier capacity (DC) Semiconductor short circuit

Electric starting system: Type Starter motor: Model/manufacturer Operation voltage Output Armature coil resistance Brush overall length Brush quantity Spring force Commutator diameter Mica undercut (depth) Constant mesh 5UMO1/YAMAHA 12V

0.0189 - 0.0231 Q at 20 °C (68 °F) 7 mm (0.28 in) 2 pcs.

This chart specifies torque for standard fasten- ers with standard 1.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. Unless otherwise specified, torque specifications call for clean, dry threads. Com- ponents should be at room temperature. A: Distance between flats B: Outside thread diameter TORQUE

LUBRICATION DIAGRAMS SPEC (° nul LUBRICATION DIAGRAMS @ Oil filter element @ Oil pump @ Drive axle @ Main axle © Intake camshaît © Exhaust camshaft @ Oiltank Oil delivery pipe [A] To oil tank

LUBRICATION DIAGRAMS SPEC Crankshaft Oil filter element Oil tank Oil hose From oil pump

@ Fuel tank breather hose Negative battery lead

© Clamp & AC magneto lead @ Diode ® Brake hose @ Hot starter cable @ Rectifier/regulator lead © Wire hamess @ Carburetor breather hose © Hump (frame) @ Carburetor overflow hose @ Cylinder head breather hose @ Catch tank breather hose Throttle position sensor lead © Neutral switch lead @ Oilhose @ Clutch cable @ Starter motor lead @ Cable guide

[A Insert the end of the fuel tank breather hose into the hole in the steering stem. [] Fasten the throtile cable, hot starter cable and rectifier/regula- tor lead onto the frame. Locate the clamp end facing the lower side of the hot starter cable and cut off the tie end. [] Fasten the diode (at the marking), throtile cable and hot starter cable onto the frame. Locate the clamp end facing toward the lower right of the frame and with the tie end facing downward. [D] Fasten the wire harness, throttle position sensor lead, starter motor lead and negative battery lead onto the frame. Pass the clamp through the hole in the stay (air cut-off valve). Locate the clamp end facing toward the lower side of the frame and cut off the tie end. [E] Fasten the throttle position sensor lead onto the frame. Locate the clamp end facing toward the lower side of the frame and cut off the tie end. [F Pass the carburetor breather hoses, carburetor overflow hose and catch tank breather hose between the connecting rod and cross tube (frame). [6] Fasten the neutral switch lead and oil hose together with the plastic locking ties and cut off the tie ends. [1] Fasten the neutral switch lead and AC magneto lead onto the frame. Locate the clamp end facing toward the outside of the frame and tie end facing toward the rear of the frame. 2-103

[ Pass the clutch cable through the cable guide. (] Fasten the starter motor lead, AC magneto lead and neutral switch lead onto the frame. Locate the clamp end facing toward the rear of the frame and cut off the tie end. (K] Fasten the clutch cable, starter motor lead, negative battery lead, AC magneto lead and neutral switch lead onto the frame. Locate the clamp end facing toward the rear of the frame and cut off the tie end. IL] Pass the neutral switch lead and AC magneto lead on the inside of the wire hamess. [M Fasten the clutch cable, AC magneto lead and neutral switch lead onto the frame. Locate the clamp end near the clutch cable and cut off the tie end. [N Pass the clutch cable and wire hamess through the cable guide. [0] Locate the couplers in the frame recess. [F] Pass the carburetor breather hoses, carburetor overflow hose and catch tank breather hose so that the hoses do not contact the rear shock absorber. (] Secure the coupler by pushing it into the hole in the headlight unit.

Throttie cable (pull) Throttie cable (return) Catch tank hose Ignition oil Clamp Ar induction hose (air cut-off valve - rear of cylinder head) Catch tank breather hose

Cross the pull and push throttle cables. Fasten the catch tank hose and air induction hose (air cut-off valve - rear of cylinder head) onto the frame. Locate the clamp end facing toward the lower side of the frame and cut off the tie end. Fasten the catch tank breather hose and carburetor breather hoses together. Pass the carburetor breather hose (of the throttle cable cover) through the hose holder. 2-107

@ Brake master cylinder (A Install the brake hose so that its pipe portion directs as shown @ Brake hose holder and lightly touches the projection on the brake caliper. @ Brake hose Œ Pass the brake hose into the brake hose holders. © If the brake hose contacts the spring (rear shock absorber), correct its twist. [] Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the brake master cylinder. 2-109

Clamp Positive battery lead Battery Negative battery lead Taillight coupler CDI unit coupler (6-pin) CDI unit coupler (3-pin) CDI unit coupler (6-pin) [A] Fasten the wire harness, negative battery lead and starter motor lead to the upper engine bracket (left side). Locate the clamp end facing toward the upper side of the frame with the tie end cut off on the inside of the frame. [B] Fasten the wire harness, negative battery lead and starter motor lead to the upper engine bracket (left side). Locate the clamp end facing toward the upper side of the frame with the tie end cut off on the inside of the frame. Clamp the wire har- ness and negative lead at the marking. IC] Pass the starter motor lead through the hole in the relay holder. Fit the cover securely. Connect the wire hamess to the starter relay. WE]

SPEC| UV [F] Fasten the catch tank breather hose and catch tank hose to the rear frame. Clamp them close to where they are joined to the frame. Fasten the pipe tightiy enough not to crush it. Locate the clamp end facing toward the rear of the frame with the tie end facing downward. [] Fasten the (three) CDI unit leads and taillight lead to the rear frame. Locate the clamp end facing toward the upper side of the frame and cut off the tie end. [H Connect the negative battery lead to the battery negative terminal. Connect the negative battery lead to the wire hamess.

[1 Fasten the wire hamness to the rear frame. Locate the clamp end facing toward the upper side of the frame and the tie end toward the inside of the frame. Clamp the wire harness at the marking. IK] Pass the wire harness, starter relay lead, starting circuit cut-off relay lead and negative battery lead through the hole in the relay holder. [] Fasten the (three) CDI unit leads and taillight lead to the rear frame. Locate the clamp end facing toward the lower side of the frame and cut off the tie end. [M Fasten the tailight lead to the rear frame. Locate the clamp end facing toward the upper side of the frame and cut off the time end. [IN Do not allow the tailight lead to slacken. [©] Locate the CDI unit lead between the CDI unit and rear fender. [F] Locate the CDI unit coupler in the clear- ance between the upper side of the CDI unit and lower side of the catch tank stay. (G] Locate the CDI unit lead between the CDI unit and rear frame. 2-113

[A] Fasten the start switch lead to the handlebar with the plastic bands. [] Fasten the engine stop switch lead and clutch switch lead to the handlebar with the plastic bands. [] Pass the brake hose through the hose guides. [D] Secure the coupler by inserting it into the multi-function display bracket. [E] Pass the throttle cables, clutch cable and hot starter cable between the upper bracket and multi-function display bracket. [F] Fasten the mult-function display leads to the bracket. Cut off the tie end [6] Secure the coupler by pushing it into the hole in the multi-func- tion display bracket. [H Secure the wire hamess clip by pushing it into the hole in the multi-function display bracket on the inside. [] Fasten the wire hamess to the multi-function display bracket. Cut off the tie end. [1 Fasten the main switch lead (wire harness side) to the multi- function display bracket. Locate the clamp end facing toward the lower side of the frame and cut off the tie end (K] Pass the speed sensor lead through the guide on the outside of the front fork.

REGULAR INSPECTION AND ADJUSTMENTS

MAINTENANCE INTERVALS NOTE: 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. EÉverythird | Every fifth Item Dan pu (or (4 requied Remarks 500 km) | 1,000 km) ENGINE OIL Replace e e VALVES Check the valve clearances e e The engine must be cold. Inspect e Check the valve seats and Replace e valve stems for wear. VALVE SPRINGS Inspect e Check the free length and Replace e the tilt. VALVE LIFTERS Inspect e Check for scratches and Replace © wear. CAMSHAFTS Inspect the camshaft Inspect e surface. Replace e Inspect the decompression system. CAMSHAFT SPROCKETS Inspect e Check for wear on the teeth Replace @ jand for damage. PISTON Inspect e © |inspect crack Clean e Inspect carbon deposits and Replace @ |eliminate them. PISTON RING Inspect e Check ring end gap Replace e e PISTON PIN Inspect e Replace e CYLINDER HEAD Inspect carbon deposits and Inspect and clean e eliminate them. Change gasket CYLINDER Inspect and clean e Inspect score marks Replace e Inspect wear CLUTCH Inspect and adjust e e Inspect housing, friction Replace e plate, clutch plate and spring TRANSMISSION Inspect e Replace bearing e

SHIFT FORK, SHIFT CAM, GUIDE BAR

Inspect L] Inspect wear

required Remarks ROTOR NUT Retighten MUFFLER Inspect and retighten Clean Replace CRANK Inspect and clean CARBURETOR Inspect, adjust and clean

COOLING SYSTEM Check coolant level and leakage Check radiator cap operation Replace coolant Inspect hoses Every two years

OUTSIDE NUTS AND BOLTS

Retighten Refer to “STARTING AND BREAK-IN” section in the

AIR FILTER Clean and lubricate Replace Use foam air-filter oil or equivalent oil OIL FILTER Replace OIL STRAINER Clean FRAME Clean and inspect

Clean and inspect BRAKES Adjust lever position and pedal height Lubricate pivot point Check brake disc surface Check fluid level and leakage Retighten brake disc bolts, caliper bolts, master cylinder bolts and union bolts Replace pads Replace brake fluid Every one year

required Remarks FRONT FORKS Inspect and adjust Replace oil Replace oil seal Suspension oil “S1” FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium base grease PROTECTOR GUIDE Replace

Inspect and adjust Lube Retighten Molybdenum disulfide grease

DRIVE CHAIN GUIDE AND ROLLERS

Inspect SWINGARM Inspect, lube and retighten Molybdenum disulfide grease

RELAY ARM, CONNECTING ROD

Inspect, lube and retighten Molybdenum disulfide grease SIDESTAND Lubricate Lithium base grease

Inspect free play and retighten Clean and lube Replace bearing Lithium base grease TIRE, WHEELS Inspect air pressure, wheel run-out, tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate Lithium base grease

THROTTLE, CONTROL CABLE

Check routing and connection Lubricate Yamaha cable lube or SAE 10W-30 motor oil

HOT STARTER, CLUTCH LEVER

Inspect free play BATTERY Check terminal for looseness and corrosion

[CANDELA D'’ACCENSIONE

Before riding for break-in operation, practice, make sure the machine is in good operating condition. Before using this machine, check the following points.

GENERAL INSPECTION AND MAINTENANCE

Item Routine Page Coolant Check that coolant is filed up to the radiator cap. P.3-35 - 41 Check the cooling system for leakage. Fuel Check that a fresh gasoline is filled in the fuel tank. Check the P.1-49 fuel line for leakage. Engine oil Check that the oil level is correct. Check the crankcase and P.3-51 - 59 frame oil line for leakage. Gear shifter and clutch Check that gears can be shifted correctly in order and that the P.3-41 - 43 clutch operates smoothly. à : Check that the throttle grip operation and free play are correctly Throttle grip/Housing adjusted. Lubricate the throttle grip and housing, if necessary. P-8-48 - 45 Brakes Check the play of front brake and effect of front and rear brake. P.3-77 - 89 Drive chain Check drive chain slack and alignment. Check that the drive P.3-91 - 95 chain is lubricated properly. Wheels Check for excessive wear and tire pressure. Check for loose P.3-111- 113 spokes and have no excessive play. Steering Check that the handlebar can be turned smoothly and have no P.3-113 - 117 excessive play. Front forks and rear shock Check that they operate smoothly and there is no oil leakage. P.3-97 - 109 absorber Check that the clutch and throttle cables move smoothly. Check Cables (wires) that they are not caught when the handlebars are turned or when — the front forks travel up and down. Exhaust pipe Check that the exhaust pipe is tightly mounted and has no P.3-27 - 31 cracks. Rear wheel sprocket Check that the rear wheel sprocket tightening boit is not loose. P.3-89 Lubrication Check for smooth operation. Lubricate if necessary. P.3-119 Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-59 Lead connectors Check that the AC magneto, CDI unit, and ignition coil are P.1-9 connected tightly. Is the machine set suitably for the condition of the course and Settings weather or by taking into account the results of test runs before P.4-1 - 40 riding? Are inspection and maintenance completely done?

Extent of removal: @ Seat removal © Side covers removal @ Fuel tank removal @ Headlight removal Extent of removal Order Part name Q'*ty Remarks Preparation for removal

SEAT, FUEL TANK AND SIDE COVERS

REMOVAL Tum the fuel cock to “OFF”. Disconnect the fuel hose. OT L°

oo us&n Seat Air scoop (left and right) Bolt (fuel tank) Fuel tank Left side cover Right side cover Headlight coupler Headiight

Open the air filter case cover. Refer to “REMOVAL POINTS”.

REMOVAL POINTS Side cover

+ Bolt (side cover) + Right side cover D NOTE:

REMOVAL Preparation for removal Right side cover Refer to “SEAT, FUEL TANK AND SIDE COVERS" section.

+ Gasket® + Joint © Damage — Replace.

ASSEMBLY AND INSTALLATION

Silencer and exhaust pipe

À WARNING Do not remove the radiator cap D, drain bolt and hoses when the engine and radiator are hot. Scald- ing hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, place a thick towel over the radia- tor cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any res ual pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it. CAUTION: Hard water or salt water is harmful to the engine parts. You may use distilled water, if you can't get soft water.

1. Place the machine on a level

place, and hold it in an upright position.

+ Coolant level @ Coolant level low — Add cool- ant. © Radiator

INSP ADJ a ENGINE MOTEUR COOLANT REPLACEMENT À WARNING Do not remove the radiator cap when the engine is hot. 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

+ Seat + Left side cover

3. Remove the catch tank hose

from the catch tank and drain the tank of its coolant.

+ _Coolant drain bolt ©

+ Radiator cap Drain the coolant completely.

+ Cooling system Thoroughly flush the cooling system with clean tap water.

CAUTION: + Do not mix more than one type of ethylene glycol antifreeze containing corrosion inhibitors for aluminum engine. + Do not use water containing impurities or oil. Handling notes of coolant: The coolant is harmful so it should be handled with special care. À WARNING + When coolant splashes to your eye. Thoroughly wash your eye with water and see your doc- tor. + When coolant splashes to your clothes. Quickly wash it away with water and then with soap. + When coolant is swallowed. Quickly make him vomit and take him to a doctor.

+ Radiator cap Start the engine and warm it up for a several minutes.

+ Seal (radiator cap) © + Valve and valve seat © Crack/damage — Replace. Exist fur deposits @ — Clean or replace.

+ Radiator cap tester (D and adapter © Radiator cap tester: YU-24460-01/

(1.8 kg/cm?, 25.6 psi) NOTE: + Do not apply pressure more than specified pressure. + Radiator should be filled fully.

+ Pressure Impossible to maintain the specified pressure for 10 sec- onds — Repair. Radiator D Radiator hose joint @) Coolant leakage — Repair or replace. Radiator hose @ Swelling — Replace. CLUTCH ADJUSTMENT

NOTE: N.B.: + Make minute adjustment on the lever side using the adjuster ©. + After adjustment, check proper operation of clutch lever.

THROTTLE CABLE ADJUSTMENT

• Tum the adjuster @ until the specified free play is obtained. + _Tighten the locknut. Locknut: 4 Nm (0.4 m + kg, 2.9 ft + Ib)

+ Lithium soap base grease On the throttle cable end @.

+ Hot starter lever free play @ Out of specification — Adjust.

INSP ENGINE MOTEUR | ADJ AIR FILTER CLEANING NETTOYAGE DU FILTRE A AIR NOTE: N 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.

1. Open the air filter case cover ©

NOTE: Loosen the quick screw @ and pull on it to open the air filter case cover.

- Air filter element © + Filter guide ©

+ Foam-air-filter oil or equivalent oil to the element NOTE:

• Align the projection @ on filter guide with the hole ® in air filter element. + Apply the lithium soap base grease on the matching surface © on air filter element.

Start the engine, warm it up for several minutes, and then turn off the engine and wait for five minutes. Place the machine on a level place and hold it up on upright position by placing the suitable stand under the engine. Inspect: + Oil level Oil should be up to the full level in the check window ©. Level check window is not full. — Add 0.2 L (0.18 Imp at, 0.21 US qf) of oil. (For USA and CDN)

CAUTION: + Do not add any chemical addi- tives. Engine oil also lubricates the clutch and additives could cause clutch slippage. + Do not allow foreign material to enter the crankcase.

CAUTION: Do not add any chemical addi- tives or use oils with a grade of CD @ or higher. Do not use oils labeled “ENERGY CONSERVING 1” ® or higher. Engine oil also lubri- cates the clutch and additives could cause clutch slippage. Do not allow foreign materials to enter the crankcase.

5. Start the engine and let it warm

up for several minutes.

6. Turn off the engine and inspect

the oil level once again. NOTE: Wait a few minutes until the oil set- tles before inspecting the oil level.

ENGINE OIL REPLACEMENT

1. Start the engine and warm it up

for several minutes, and then turn off the engine and wait for five minute.

2. Place the machine on a level

place and hold it on upright posi- tion by placing the suitable stand under the engine.

3. Place a suitable container under

+ 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. If no oil comes out after one minute, turn the engine off so it will not seize. Check oil passages and oil pump for damage or leakage. Start the engine after solving the problem(s) and recheck the oil pressure. Tighten the oil pressure check bolt.

1. Start the engine and thoroughly

AND ADJUSTMENT JEU AUX SOUPAPES

+ The valve clearance should be adjusted when the engine is cool to the touch. The piston must be at Top Dead Center (T.D.C.) on compression stroke to check or adjust the valve clearance.

+ Seat + Fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section.

+ Coolant Refer to “COOLANT REPLACEMENT" section.

+ Right radiator Refer to “RADIATOR" section in the CHAPTER 5. + Carburetor Refer to “CARBURETOR” section in the CHAPTER 5. + Spark plug Upper engine bracket Cylinder head cover Refer to “CAMSHAFTS” sec- tion in the CHAPTER 5.

+ Timing mark accessing screw

(0.0039 - 0.0059 in) Exhaust valve:

+ Valve clearance +_Jeu aux soupapes Adjustment steps: + Remove the camshaît (intake and exhaust). Refer to “CAMSHAFTS” section in the CHAPTER 5. + Remove the valve lifters © and the pads ©. NOTE: Étapes du réglage: + Déposer les arbres à cames (d'admission et d'échappement). Se reporter à la section “ARBRES A CAMES” au CHAPITRE 5. + Déposer les poussoirs de soupapes @ et les plaquettes ©. N.B.: + Place a rag in the timing chain space to prevent pads from fall- ing into the crankcase. Identity each valve lifter and pad position very carefully so that they can be reinstalled in their original place. Select the proper pad using the pad selecting table. Pad Availability: 25 increments Pad range Pads are available in

(For USA) À WARNING Be sure the exhaust silencer are cool before cleaning the spark arrester. Do not start the engine when cleaning the exhaust system.

À WARNING Bleed the brake system i + The system has been disassem- bled. + A brake hose has been loosened or removed. + The brake fluid is very low. + The brake operation is faulty. A dangerous loss of braking per- formance may occur if the brake system is not properly bled.

+ Brake fluid A Front [F] Rear Air bleeding steps: a. Add proper brake fluid to the reservoir. . Install the diaphragm. Be care- ful not to spill any fluid or allow the reservoir to overflow. c. Connect the clear plastic tube © tightly to the caliper bleed screw (D. d. Place the other end of the tube into a container. e. Slowly apply the brake lever or pedal several times. f. Pull the lever in or push down on the pedal. Hold the lever or pedal in position. g. Loosen the bleed screw and allow the lever or pedal to travel towards its limit. . Tighten the bleed screw when the lever or pedal limit has been reachedi; then release the lever or pedal.

M Bleed screw: | 6Nm (0.6 m + kg, 4.3ft Ib)

i. Repeat steps (e) to (h) until of

the air bubbles have been removed from the system. CHÂSSIS

+ Brake lever cover 3-79

+ Brake pedal height Pedal height adjustment steps: + Loosen the locknut ©. - Tum the adjusting nut © until the pedal height @ is within specified height. + _Tighten the locknut. À WARNING + Adjust the pedal between the maximum the minimum [E] as shown. (In this adjustment, the bolt © end ® should protrude out of the threaded portion @ but not be less than 2mm (0.08 in) © away from the brake pedal G)). After the pedal height adjust- ment, make sure that the rear brake does not drag. height

+ Brake pad thickness @ Out of specification — Replace as a set. Brake pad thickness:

INSP ADJ a CHASSIS CHASSIS Loosen the pad pin ©. Remove the brake caliper © from the front fork. Remove the pad pin and brake pads ©. Connect the transparent hose © to the bleed screw © and place the suitable container under its end. Loosen the bleed screw and push the brake caliper piston in. CAUTION: Do not reuse the drained brake fluid. Desserrer la goupille de plaquette

CHASSIS INSP cHÂssis | ADJ

AND REPLACEMENT Inspect: + Brake pad thickness @ Out of specification — Replace as a set. Brake pad thickness:

Remplacer: + Plaquette de frein Brake pad replacement steps: + Remove the protector D and pad pin plug ©. Loosen the pad pin @. Remove the rear wheel © and brake caliper ®. Refer to “FRONT WHEEL AND REAR WHEEL'" section in the

“SPURGO ARIA SISTEMA

+ Brake pedal operation A softy or spongy feeling — Bleed brake system. Refer to “BRAKE SYSTEM AIR BLEEDING” section. EC36b000

“SPURGO ARIA SISTEMA

“CONTROLLO E SOSTITU-

so that its top is in a horizontal position.

+ Brake fluid level Fluid at lower level — Fill up. © Lower level A Front [F] Rear fluid:

DOT #4 Recommended brake

DOT n°4 À WARNING Use only designated quality brake fluid to avoid poor brake performance. Refill with same type and brand of brake fluid; mixing fluids could result in poor brake per- formance. Be sure that water or other con- taminants do not enter master cylinder when refilling. Clean up spilled fluid immedi- ately to avoid erosion of painted surfaces or plastic parts. SPROCKETS INSPECTION

NOTE: + While measuring the drive chain length, push down on the drive chain to increase its tension. Measure the length between drive chain roller ® and @ as shown. Perform this measurement at two or three different places.

- Drive chain © NOTE: Remove the drive chain using a drive chain cutter ©.

+ Drive chain Brush off as much dirt as pos- sible. Then clean the drive chain using the chain cleaner. CAUTION: This machine has a drive chain with small rubber O-rings © between the side plates. Steam cleaning, high-pressure washes, certain solvent and kerosene can damage these O-rings.

+ O-ring © (drive chain) Damage — Replace the drive chain. - Roller @ + Side plate © Damage/wear — Replace the drive chain.

+ Drive chain stiffness @ Clean and oil the drive chain and hold as illustrated. Stiff — Replace the drive chain.

+ Chain joint © + Joint de chaîne D + O-ring © +_ Joint torique © - Drive chain @ + Chaîne de transmission @ NOTE: NJ When installing the drive chain, apply the lithium soap base grease on the chain joint and O-rings.

+ Link plate © NOTE: + Press the link plate onto the chain joint using a drive chain riveter ©. + Rivet the end of the chain joint using a drive chain riveter. + After riveting the chain joint, make sure its movement is smooth.

1. Elevate the rear wheel by plac-

ing the suitable stand under the engine.

CHASSIS INSP cHÂssis | ADJ

+_ Front fork smooth action Operate the front brake and stroke the front fork. Unsmooth action/oil leakage — Repair or replace. EC36D001

+ Protector - Dust seal ® NOTE: Use a thin screw driver, and be care- ful not to damage the inner fork tube and dust seal.

+ Dust seal @ + Oil seal ® NOTE: + Clean the dust seal and oil seal after every run. + Apply the lithium soap base grease on the inner tube.

1. Elevate the front wheel by plac-

and release the internal pressure from the front fork.

DAMPING FORCE ADJUSTMENT

+ Rebound damping force By turning the adjuster ©. Stiffer @ — Increase the rebound damping force. (Turn the adjuster © in.) Softer © — Decrease the rebound damping force. (Turn the adjuster (© out.) Extent of adjustment:

Maximum Minimum 20 clicks out (from maximum position) Fully turned in position + STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. Standard position: 9 clicks out

CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. À WARNING Always adjust each front fork to the same setting. Uneven adjust- ment can cause poor handling and loss of stability.

DAMPING FORCE ADJUSTMENT

+ Compression damping force By turning the adjuster ©. Stiffer @ — Increase the compression damping force. (Turn the adjuster © in.) Softer © — Decrease the compression damping force. (Turn the adjuster © out.) A Extent of adjustment: Maximum Minimum : 20 clicks out Fully turned in : ue (from maximum position on position)

• Except for USA and CDN CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. À WARNING Always adjust each front fork to the same setting. Uneven adjust- ment can cause poor handling and loss of stability.

+ Swingarm smooth action Abnormal noise/unsmooth action — Grease the pivoting points or repair the pivoting points. Damage/oil leakage — Replace.

SPRING PRELOAD ADJUSTMENT

1. Elevate the rear wheel by plac-

ing the suitable stand under the engine.

+ Spring preload By turning the adjuster ©. Stiffer — Increase the spring preload. (Turn the adjuster © in.) Softer — Decrease the spring preload. (Turn the adjuster © out.) Spring length (installed)

• For EUROPE ** For AUS, NZ and ZA NOTE: + Be sure to remove all dirt and mud from around the locknut and adjuster before adjustment. The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjuster. CAUTION: Never attempt to turn the adjuster beyond the maximum or mini- mum setting.

+ _Rear frame (upper) + _Rear frame (lower)

CHASSIS cHÂssis | ADJ

+ Rebound damping force By turning the adjuster ©. Stiffer @ — Increase the rebound damping force. (Turn the adjuster © in.) Softer © — Decrease the rebound damping force. (Turn the adjuster (© out.)

Maximum Extent of adjustment: Minimum 20 clicks out (from maximum position) Fully turned in position + STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. (Which align the punch mark @ on the adjuster with the punch mark @® on the bracket.)

+ Low compression damping force By turning the adjuster ©. Stiffer @ — Increase the low compression damping force. (Turn the adjuster © in.) Softer © — Decrease the low compression damping force. (Turn the adjuster © out.) Extent of adjustment:

Maximum Minimum 20 clicks out (from maximum position) Fully turned in position + STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. (Which align the punch mark @ on the adjuster with the punch mark @® on the high compression damp- ing adjuster.) Standard position: About 12 clicks out

• For AUS, NZ and ZA CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. 3-107 déclics

CHASSIS INSP cHÂssis | ADJ

. dl compression damping + Force d'amortissement à la com- By turning the adjuster ©. Stiffer @ — Increase the high compression damping force. (Turn the adjuster © in.) Softer D — Decrease the high compression damping force. (Turn the adjuster © out.)

Extent of adjustment: Maximum Minimum Fully turned in 2 turns out ue (from maximum position js position) + STANDARD POSITION: This is the position which is back by the specific number of turms from the fully turned-in position. (Which align the punch mark @ on the adjuster with the punch mark @® on the adjuster body.) Standard position: About 1-1/8 turns out

• About 1-1/4 turns out

• For EUROPE CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. 3-109 tour

-_ 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. Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low. A tilted tire valve stem indicates that the tire slips off its position on the rim. If the tire valve stem is found tilted, the tire is considered to be slipping off its position. Correct the tire position. EC365002

+ Spokes D Bend/damage — Replace. Loose spoke — Retighten.

+ Spokes NOTE: Be sure to retighten these spokes before and after break-in. After a practice check spokes for looseness. EC36T000 WHEEL INSPECTION

+ Wheel runout Elevate the wheel and turn it. Abnormal runout — Replace. 3-111 CHASSIS cHÂssis | ADJ

+ Bearing free play Exist play — Replace. EC3u013

STEERING HEAD INSPECTION

1. Elevate the front wheel by plac-

ing a suitable stand under the engine.

Steering stem Grasp the bottom of the forks and gently rock the fork assembly back and forth. Free play — Adjust steering head.

+ Steering smooth action Tum the handlebar lock to lock. Unsmooth action — Adjust steering ring nut.

+ Steering ring nut Steering ring nut adjustment steps: + Remove the headlight. + Remove the handiebar and upper bracket. + Loosen the steering ring nut © using the steering nut wrench

+ Tighten the steering ring nut © using steering nut wrench @. 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. Steering nut wrench: YU-33975/90890-01403 Steering ring nut (initial tightening): 38 Nm (3.8 m + kg, 27 ft + Ib)

+ Electrode D Wear/damage — Replace. +_Insulator color © Normal condition is a medium to light tan color. Distinctly different color — Check the engine condition. NOTE: When the engine runs for many hours at low speeds, the spark plug insulator will become sooty, even if the engine and carburetor are in good operating condition.

4. Clean the plug with a spark plug

IGNITION TIMING CHECK

+ Timing mark accessing screw

+ Timing light + Inductive tachometer To the ïignition coil lead (orange lead ©).

CHARGING À WARNING Batteries generate explosive hydrogen gas and contain electro- lyte 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 batter- ies. Charge batteries in a well-venti- lated area. Keep batteries away from fire, sparks or open flames (e.g. welding equipment, lighted ciga- rettes). DO NOT SMOKE when charging or handling batteries.

CHILDREN. Avoid bodily contact with elec- trolyte as it can cause severe burns or permanent eye injury.

FIRST AID IN CASE OF BODILY

CONTACT: EXTERNAL + Skin — Wash with water. + Eyes — Flush with water for 15 minutes and get immediate med- ical attention. INTERNAL Drink large quantities of water or milk followed with milk of magnesia, beaten egg or vegeta- ble oil. Get immediate medical attention. CAUTION: Charging time, charging amper- age and charging voltage for an MF battery are different from those of conventional batteries. The MF battery should be charged as explained in the charging method illustrations. If the battery is overcharged, the electrolyte level will drop considerably. Therefore, take special care when charging the battery. NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 3-125

+ Battery leads (from the battery terminals) CAUTION: First, disconnect the negative bat- tery lead ®, and then the positive battery lead ©.

+ Battery band + Battery

INSP ELECTRICAL | ADJ Charging method using a variable voltage charger Measure the open-circuit | | NOTE: voltage prior to charging. Leave the battery unused for more than 30 minutes before T measuring its open-circuit voltage. Charger

ammeter to the battery | Set the charging voltage to 16- A and start charging. 17 V. (If the charging voltage is lower, charging will be insuffi- pi cient, if it is higher, the battery will be over-charged.) \ as Connect a charger and| NOTE:

Is the amperage higher than the standard charg- NO ing amperage written on the battery? Adjust the charging voltage to

Adjust the voltage to obtain YES Monitor the amperage for the standard charging amper- 3 - 5 minutes. Is the standard age. charging amperage exceeded?

If the amperage does not Set the timer to the charging exceed the standard charg- time determined by the open- ing amperage after 5 minutes, circuit voltage. replace the battery. Refer to “BATTERY

INSPECTION AND CHARG-

ING” section. If the required charging time exceeds 5 hours, it is advisable to check the charging amperage after 5 hours. lf there is any change in the amperage, readjust the voltage to obtain the standard charging amper- age.

Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage.

12.8 V — Charging is complete.

12.0 - 12.7 V — Recharging is required.

Under 12.0 V — Replace the battery. 3-131

INSP ELECTRICAL | ADJ Charging method using a constant voltage charger YES Measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charg- ing amperage written on the battery? NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage.

Charge the battery until the charging voltage reaches 15 V. NOTE: mum of 20 hours. This type of battery charger cannot charge an MF battery. A variable voltage charger is recommended. Set the charging time to a maxi- voltage.

12.8 V — Charging is complete.

Under 12.0 V — Replace the battery. Leave the battery unused for more than 30 minutes before measuring its open-circuit

12.0 - 12.7 V — Recharging is required.

Voltmeter CAUTION: Constant amperage chargers are not suitable for charging MF batteries. 3-132 Charger

lithium brush. Loose connection — Connect properly.

+ Battery terminal =: Recommended lubricant: Lithium soap base grease

+ Seat BATTERY REPLACEMENT

+ Battery CAUTION: This battery is for YAMAHA WR250F. g the battery with elec- 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. EAS00181 FUSE INSPECTION CAUTION: To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse.

+ Seat + Fuse cover 3-141

+ Fuse cover + Seat 3-143

+ Headlight bulb À WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb unit it has cooled down.

+ Headlight bulb CAUTION: Avoid touching the glass part of the headlight bulb to keep it free form oil, otherwise the transpar- ency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alco- hol or lacquer thinner.

+ Headlight bulb holder

+ Headlight bulb holder cover

IMPIANTO ELETTRICO I N S P

REGLAGE SETTING TUN EC700000 TUNING EC710000 ENGINE Carburetor setting - The air/fuel mixture will vary depending on atmospheric condi- tions. Therefore, it is necessary to take into consideration the air pressure, ambient temperature, humidity, etc., when adjusting the carburetor. Perform a test run to check for proper engine performance (e.g., throttle response) and spark plug(- s) discoloration or fouling. Use these readings to determine the best possible carburetor setting. NOTE: It is recommended to keep a record of all carburetor settings and external conditions (e.g., atmospheric condi- tions, track/surface conditions, lap times) to make future carburetor set- ting easier. À WARNING + The carburetor is a part of the fuel line. Therefore, be sure to install it in a well-ventilated area, away from flammable objects and any sources of fire. + Never look into the carburetor intake. Flames may shoot out from the pipe if the engine back- fires while it is being started. Gasoline may be discharged from the accelerator pump noz- zle when the carburetor has been removed.

Effects of the setting parts on the throttle valve opening [A] Closed [] Fully open @ Pilot jet © Throttle valve cutaway @ Jet needle @ Main jet Main system The FLATCR carburetor has a pri- mary main jet. This type of main jet is perfect for racing machines since it supplies an even flow of fuel, even at full load. Use the main jet and the jet needle to set the carburetor. Jet needle Pilot air jet Needle jet Main jet Pilot jet

10% Pilot jet adjustment The richness of the air-fuel mixture With the throttle open 1/4 or less can be set by adjusting the pilot jet ©. Standard pilot jet #42 Effects of adjusting the pilot jet (reference) Idie Fully open #45 #40 #42 CCRÉITE] Jet needle groove position adjustment NOTE: For setting adjustment, replace the standard jet needle with the one designed for setting. Adjusting the jet needle © position affects the acceleration when the throttle is 1/8 to 3/4 open.

1. Too rich at intermediate speeds

Rough engine operation is felt and the engine will not pick up speed smoothly. In this case, step up the jet needle clip by one groove and move down the nee- die to lean out the mixture.

2. Too lean at intermediate speeds

• For AUS, NZ, CDN and ZA The tapered sections of all jet nee- dles have the same starting posi- tions, but the needles are available With different straight-portion diame- ters. <Example> GDEPS -5 À cip position Diameter @ of straight portion Effects of changing the jet needle (reference) (Diameter of the straight portion) Changing the diameter of the straight portion adjusts the air-fuel mixture when the throttle is 1/8 to 1/4 open. [A] Idle [] Fully open Leak jet adjustment (accelerator pump adjustment) The leak jet © is a setting part that adjusts the flow of fuel discharged by the accelerator pump. Since the accelerator pump operates only when throttle is open, the leak jet is used to adjust a fuel mixture ratio for quick throttle opening and is there- fore different from other setting parts that adjust a fuel mixture for each throttle opening (each engine speed).

1. The engine breathes hard in

quick throttle opening. Select a leak jet having lower calibrating No. than standard to enrich the mixture. <Example> #70 — #65

2. Rough engine operation is felt in

quick throttle opening. Select a leak jet having higher calibrating No. than standard to lean out the mixture. <Example> #70 — #85

TUN SETTING Examples of carburetor setting depending on symptom Symptom Setting Checking At full throttle Hard breathing Shearing noise Whitish spark plug

Lean mixture Increase main jet calibration no. (Gradually) Discoloration of spark plug — If tan color, it is in good condition. If cannot be corrected: Clogged float valve seat Clogged fuel hose Clogged fuel cock Check that the accelerator pump operates smoothly. At full throttle Speed pick-up stops Slow speed pick-up Slow response Sooty spark plug

Rich mixture Decrease main jet calibration no. (Gradually) Discoloration of spark plug — If tan color, it is in good condition. If cannot be corrected: Clogged air filter Fuel overflow from carburetor Lean mixture Lower jet needle clip position. (1 groove down) Rich mixture Raise jet needle clip position. (1 groove up) 1/4 - 3/4 throttle Hard breathing Lack of speed Lower jet needle clip position. (1 groove down) 1/4 - 1/2 throttle Slow speed pick-up Poor acceleration Raise jet needle clip position. (1 groove up) Groove 1 Leaner (Standard)

Richer Jet needie—” The clip position is the jet needle groove on which the clip is installed. The positions are numbered from the top. Check that the accelerator pump operates smoothly. (except for rich mixture symptom). Closed to 1/4 throttle Hard breathing Speed down Use jet needle with a smaller diameter. Slow-speed-circuit passage Clogged — Clean. Overflow from carburetor Closed to 1/4 throttle Poor acceleration Use jet needle with a larger diameter. Raise jet needle clip position. (1 groove up) Poor response in the low to intermediate speeds Raise jet needle clip position. If this has no effect, lower the jet needle clip position. Poor response when throttle is opened quickly Check overall settings. Use main jet with a lower calibration no. Raise jet needle clip position. (1 groove up) Ifthese have no effect, use a main jet with a higher calibration no. and lower the jet needle clip position. Check air filter for fouling. Check that the accelerator pump operates smoothly. % This should be taken simply for an example. It is necessary to set the carburetor while checking the operating condi- tions of the engine.

REGLAGE SETTING TUN EC720000 CHASSIS Selection of the secondary reduction ratio (Sprocket) Number of rear wheel sprocket teeth Number of drive sprocket teeth Secondary reduction = ratio

(STD)| 50T | 5TJ-25450-80

• For AUS and NZ EC721002 Tire pressure Tire pressure should be adjust to suit the road surface condition of the cir- cuit. Standard tire pressure: 100 kPa (1.0 kgf/cm?, 15 psi)

Under a rainy, muddy, sandy, or slippery condition, the tire pressure should be lower for a larger area of contact with the road surface. Extent of adjustment:

+ Under a stony or hard road condi- tion, the tire pressure should be higher to prevent a flat tire. Extent of adjustment:

(STD)| 50T | 57J-25450-80

(1,0 - 1,2 kgf /cm?,

SETTING REGLAGE TUN EC722011 Front fork setting The front fork setting should be made depending on the rider's feeling of an actual run and the circuit conditions. The front fork setting includes the fol- lowing three factors:

1. Setting of air spring characteris-

tics + Change the fork oil level.

2. Setting of spring preload

+ Change the spring. +_Install the adjustment washer.

3. Setting of damping force

+ Change the compression damping. + Change the rebound damping. The spring acts on the load and the damping force acts on the cushion travel speed. EC723001 Change in level and characteristics of fork oil Damping characteristic near the final stroke can be changed by changing the fork oil amount. CAUTION: Adjust the oil level in 5 mm (0.2 in) increments or decrements. Too low oil level causes the front fork to produce a noise at full rebound or the rider to feel some pressure on his hands or body. Alterna- tively, too high oil level will develop unexpectedly early oil lock with the consequent shorter front fork travel and deteriorated performance and characteristics. Therefore, adjust the front fork within the specified range.

Standard oil level: 132 mm (5.20 in) Extent of adjustment:

SETTING REGLAGE TUN Ekg (IbI] [CI mm fin] El] Air spring characteristics in relation to oil level change Load Stroke Max. oil level Standard oil level Min. oil level CLEIE EC727020 Spring preload adjustment The spring preload is adjusted by installing the adjustment washer © between the fork spring © and damper rod @. CAUTION: Do not install three or more adjustment washers for each front fork. À WARNING Always adjust each front fork to the same setting. Uneven adjust- ment can cause poor handling and loss of stability. Standard washer quantity: Zero adjustment washers Extent of adjustment: Zero - 2 adjustment washers

SETTING REGLAGE TUN 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 position, etc.) when setting the front fork.

Use of soft spring Generally a soft spring gives a soft riding feeling. Rebound damping tends to become stron- ger and the front fork may sink deeply over a series of gaps. To set a soft spring: + Change the rebound damping. Turn out one or two clicks. + Change the compression damping. Tum in one or two clicks. Use of stiff spring Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, resulting in lack of a sense of contact with the road surface or in a vibrating handle- bar. To set a stiff spring: + Change the rebound damping. Tum in one or two clicks. + Change the compression damping. Turn out one or two clicks. Réglage du ressort après remplacement La suspension arrière pouvant influencer le réglage de la fourche, il convient donc d'équilibrer l'arrière et l'avant de la machine (la position, etc.) avant d’effec- tuer le réglage de la fourche.

EC728000 Rear suspension setting The rear suspension setting should be made depending on the riders feeling of an actual run and the cir- cuit conditions. The rear suspension setting includes the following two factors:

1. Setting of spring preload

+ Change the set length of the spring. + Change the spring.

2. Setting of damping force

+ Change the rebound damping. + Change the compression damping. EC72c001 Choosing set length

1. Place a stand or block under the

engine to put the rear wheel above the floor, and measure the length @ between the rear wheel axle center and the rear fender holding bot.

2. Remove the stand or block from

the engine and with a rider astride the seat, measure the sunken length ® between the rear wheel axle center and the rear fender holding bolt.

3. Loosen the locknut D and make

adjustment by turning the spring adjuster @ to achieve the stan- dard figure from the subtraction of the length ® from the length

SETTING REGLAGE TUN Setting of spring after replacement After replacement, be sure to adjust the spring to the set length [sunken length 90 - 100 mm (3.5 - 3.9 in)] and set it.

1. Use of soft spring

+ Set the soft spring for less rebound damping to compen- sate for its less spring load. Run with the rebound damping adjuster one or two clicks on the softer side and readjust it to suit your preference.

2. Use of stiff spring

+ Set the soft spring for more rebound damping to compen- sate for its greater spring load. Run with the rebound damping adjuster one or two clicks on the stiffer side and readjust it to suit your preference. x Adjusting the rebound damp- ing will be followed more or less by a change in the com- pression damping. For correc- tion, turn the low compression damping adjuster on the softer side. CAUTION: When using a rear shock absorber other than currently installed, use the one whose overall length @ does not exceed the standard as it may result in faulty performance. Never use one whose overall length is greater than standard. Length @ of standard shock:

NUMBER POINT |LENGTH| BUEUR

EC72H002 Suspension setting + Front fork NOTE: + _lfany 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 Symptom Jump | L2188 Medium} Small Check Adjust gap | gap | gap Compression damping [Turn adjuster counterclockwise (about 2 clicks) to . decrease damping Stif over entire range | © | O | © Oil level (oil amount) Decrease oil level by about 5 - 10 mm (0.2 - 0.4 in). Spring Replace with soft spring. Outer tube Check for any ends, dents, and other noticeable Unsmooth movement | | © | © | © lmertbe scars, ete. If any, replace affected parts. lover entire range Under bracket tightening_|Retighten to specified torque torque Rebound damping FTum adjuster counterciockwise (about 2 clicks) to Poor initial ? o decrease damping movement : n Oil seal Apply grease in oil seal wall Compression damping [Tu adjuster clockwise (about 2 clicks) to increase Soft over entire o lo damping. range, bottoming out Oil level (oil amount) |Increase oil level by about 5 - 10 mm (0.2 - 0.4 in) Spring Replace with stiff spring. sut toward stroke o Oil level (oil amount) Decrease oil level by about 5 mm (0.2 in). Soft toward stroke . | | ; end, bottoming out | © Oil level (oil amount) |Increase oil level by about 5 mm (0.2 in). un . Tum ajuster counterclockwise (about 2 clicks) to Süffinitlal movement | © | © | © | © [Compression dampig [Ércace damping Compression damping [Tu adjuster clockwise (about 2 clicks) to increase damping. Rebound damping Tum adjuster counterciockwise (about 2 clicks) to Low front, tending to o lo decrease damping lower front posture Balance with rear end |Set sunken length for 95 - 100 mm (3.7 - 3.9 in) when one passenger is astride seat (lower rear posture) Oil level (oil amount) |Increase oil level by about 5 mm (0.2 in). Compression damping …|Turm adjuster counterclockwise (about 2 clicks) to decrease damping Obtrusive” front, Balance with rear end |Set sunken length for 90 - 95 mm (3.5 - 3.7 in) ending to upper front o |o when one passenger is astride seat (upper rear posture posture) Spring Replace with soft spring. Oil lever (oil amount) |Decrease oi level by about 5 - 10 mm (0.2 - 0.4 in).

+ Rear shock absorber NOTE: + _lfany 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. + Adjust the low compression damping in 1-click increments or decrements. + Adjust the high compression damping in 1/6 turn increments or decrements. Section Symptom Jump | L2'88 Medium} Small Check Adjust gap | gap | gap Rebound damping FTurn adijuster counterclockwise (about 2 clicks) to ; decrease damping Stiff,tending to sink OQ | © spring set length Set sunken length for 90 - 100 mm (3.5 - 3.9 in) when one passenger is astride seat. Rebound damping Turn adjuster clockwise (about 2 clicks) to increase damping. Spongy and unstable © | © |Low compression Turn adjuster clockwise (about 1 click) to increase damping damping. Spring Replace with stiff spring. Rebound damping FTurn adijuster counterclockwise (about 2 clicks) to Heavy and dragging o | o decrease damping Spring Replace with soft spring. Rebound damping FTurn adijuster counterclockwise (about 2 clicks) to decrease damping Low compression Turn adjuster clockwise (about 1 clicks) to increase damping damping. Poor road gripping © [High compression Turn adjuster clockwise (about 1/6 clicks) to damping increase damping. Spring set length Set sunken length for 90 - 100 mm (3.5 - 3.9 in) when one passenger is astride seat. Spring Replace with soft spring. High compression Turn adjuster clockwise (about 1/6 tu) to increase damping damping. Bottoming out o | o Spring set length Set sunken length for 90 - 100 mm (3.5 - 3.9 in) when one passenger in astride seat. Spring Replace with stiff spring. Rebound damping Turn adjuster clockwise (about 2 clicks) to increase Bouncing o | o damping. Spring Replace with soft spring. High compression Turn adjuster counterclockwise (about 1/6 tum) to damping decrease damping Stiff travel o | o Spring set length Set sunken length for 90 - 100 mm (3.5 - 3.9 in) when one passenger is astride seat. Spring Replace with soft spring.

ENG | D ENGINE EC450001 RADIATOR NOTE: 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 requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage. [KI 7 Nm (0.7 m - kg, 5.1ft + 1b)] [AL 10 Nm (1.0 m + kg, 7.2 ft: lb) Extent of removal: @ Radiator removal Extent of removal Order Part name

Remarks Preparation for removal RADIATOR REMOVAL Drain the coolant. Seat, fuel tank and left side cover Refer to *COOLANT REPLACEMENT" section in the

Refer to “SEAT, FUEL TANK AND SIDE COVERS" section in the CHAPTER 3. Radiator guard Radiator hose clamp Radiator hose 1 Left radiator Radiator hose 3 Radiator pipe 2 Radiator hose 5 Catch tank hose Right radiator Radiator hose 2 Radiator hose 4 Radiator pipe 1 Catch tank breather hose Catch tank Only loosening.

HANDLING NOTE À 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 radiator cap by the following procedure: Place a thick rag, like a towel, over the radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turn- ing counterclockwise and remove it. EC454000 INSPECTION EC444100 Radiator

+ Radiator core ® Obstruction — Blow out with compressed air through rear of the radiator. Bent fin — Repair/replace. EC455000

ASSEMBLY AND INSTALLATION

+ Right radiator D + Bolt (right radiator) © + Radiator hose 5 @ Refer to “CABLE ROUTING DIAGRAM" section in the

+ _Radiator guard © + Plaque de protection du radiateur NOTE: © First fit the inner hook portion @ and NB: then the outer one ®) onto the radia- tor.

“SCHEMA PERCORSO DEI

“DIAGRAMA DE CABLEADO”

“SCHEMA PERCORSO DEI

“DIAGRAMA DE CABLEADO”

“SCHEMA PERCORSO DEI

CAVI” nel CAPITOLO 2. Tornillo (depésito de recupera- ciôn) © o del depésito de recupe- raciôn @ Tubo respiradero del depésito de recuperaciôn 6) Consulte el apartado

“DIAGRAMA DE CABLEADO”

CARBURETOR ENG CARBURETOR ee VA]S Nm (0.3 mkg, 2.2 ft) Extent of removal: © Carburetor removal Extent of removal Order Part name ay Remarks CARBURETOR REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS" section in the CHAPTER 3. Rear shock absorber Refer to *REAR SHOCK ABSORBER" section in the

T 1 Clamp 2 2 | Throttle position sensor lead coupler 1 3 | Throttle cable cover 1 4 | Throttle cable 2 5 | Clamp (air filter joint) 1 Loosen the screw (air filter joint). 6 | Clamp (carburetor joint) 1 Loosen the screws (carburetor joint). 7 | Hotstarter plunger 1 8 | Carburetor assembly 1 | 9 | Carburetor joint 1

EC468000 CARBURETOR DISASSEMBLY Extent of removal: @ Carburetor disassembly Extent of removal Order Part name Remarks 666660606600 060e CARBURETOR DISASSEMBLY Carburetor breather hose Valve lever housing cover Screw (throttle shaît) Throtile valve Needle holder Jet needle Accelerator pump cover Spring Diaphragm (accelerator pump) Air eut valve cover Spring (air cut valve) Diaphragm (air cut valve) Float chamber Leak jet sin ns

MANIPULATION GAUTION: Do not loosen the screws (throttle ATTENTION: position sensor) (D except when changing the throttle position sen- sor due to failure because it will cause a drop in engine perfor- mance. INSPECTION Carburetor

Main jet D Pilot jet © Needle jet © Starter jet © Pilot air jet @ Leak jet © Main air jet © Damage — Replace. Contamination — Clean. NOTE:

+ Needle valve © + Valve seat @ Grooved wear @ — Replace. Dust ® > Clean. + Filter © Clogged — Clean. 5-21 Pointeau

+ Free movement Stick — Repair or replace. NOTE: Insert the throttle valve © into the carburetor body, and check for free movement. ECA64401 Jet needle

+ Jet needle © Bends/wear — Replace. + Clip groove Free play exists/wear — Replace. Float height

+ Cold starter plunger © + Hot starter plunger © Wear/damage — Replace. Accelerator pump

+ Throttle shaft © + Axe du papillon © + Spring © + Ressort @ + Lever 1 @ + Levier 1 @ + Spring 1 © + Ressort 1 @ + Lever2® + Levier 2@ + Spring 2 © + Ressort 2 © Dirt — Clean. Saleté — Nettoyer. Air cut valve

+ Diaphragm (air cut valve) D + Spring (air cut valve) © + Air cut valve cover @ + O-ring © Tears (diaphragm)/damage — Replace.

ASSEMBLY AND INSTALLATION

+ Washer © + Rondelle © + Circlip © + Circlip ©

+ Starter jet D + Pilot jet © + Spacer © + Needle jet @ + Main jet ©

+ Needle valve © + Pointeau ® + Float @ + Flotteur @ +_Float pin © + Axe de flotteur @ NOTE: NB: + After installing the needle valve to the float, install them to the carbu- retor. + Check the float for smooth move- ment.

+ O-ring + Leak jet © + Float chamber © + Bolt (float chamber) @ + Cable holder (throttle stop screw cable) @ + Hose holder (carburetor breather hose) ©

+ Diaphragm (air cut valve) D Spring (air cut valve) © O-ring © Air cut valve cover @ Holder (cylinder head breather hose) © Screw (air cut valve cover) ©

+ Throttle valve assembly D + Screw (throttle shaft) © NOTE: Install the valve lever rollers © into the slits @ of the throttle valve.

+ O-ring © + Valve lever housing cover + Bolt (valve lever housing cover) ©

© J Install: + Throttle position sensor lead coupler D + Clamp © Refer to “CABLE ROUTING DIAGRAM" section in the

Install: + Clamp@© Refer to “CABLE ROUTING DIAGRAM" section in the

“SCHEMA PERCORSO DEI

CAVI” nel CAPITOLO 2. Installare: + Morsetto ® Fare riferimento al paragrafo

“SCHEMA PERCORSO DEI

CAVI” nel CAPITOLO 2. + Acoplador del cable del sensor de posicién del acelerador © + Brida © Consulte el apartado

“DIAGRAMA DE CABLEADO”

del CAPITULO 2. Instalar: + Brida © Consulte el apartado

“DIAGRAMA DE CABLEADO”

Extent of removal: @ Air induction system removal Extent of removal Order Part name ay Remarks

AIR INDUCTION SYSTEM REMOVAL

1 Bracket 1 2 | Aireut-off valve assembly 1 3 | Airinduction hose (air cut-off valve - front of 1 cylnder head) 4 | Airinduction pipe 1 5 | Gasket 1 6 | Airinduction hose (air cut-off valve - rear of 1 cylnder head) 7 | Airinduction hose (air cut-off valve - air 1 filter case)

INSPECTION Air induction system

+ Operation of air cut valve Pass air through the pipe and check the air cut valve for operation. Does not meet the following condition — Replace the air cut valve assembly. @to® | Air passes. CONTROLE Système d’induction d’air

CAUTION: When using vacuum on the pipe ©, take care not to exceed the specified value. From air filter To cylinder head (exhaust port) From cylinder head (intake port) 66® Check for induction from air filter. Check for prevention of backflow into air filter. Check for prevention of afterburn {When throttle is closed at sudden deceleration) QE]

Remarks Preparation for removal

CYLINDER HEAD COVER REMOVAL

Seat and fuel tank Air cut-off valve assembly Refer to “SEAT, FUEL TANK AND SIDE COVERS" section in the CHAPTER 3. Refer to “AIR INDUCTION SYSTEM" section. ou sw = Spark plug Cylinder head breather hose Bolt (cylinder head cover) Cylinder head cover Cylinder head cover gasket Timing chain guide (top side) spas

DEPOSE DU COUVRE-CULASSE

+ Timing mark accessing screw

+ Repère du PMH Avec le repère d’alignement. Checking steps: + Tum the crankshaft counter- clockwise with a wrench. < Align the T.D.C. mark @ on the rotor with the align mark ® on the crankcase cover when pis- ton is at T.D.C. on compression stroke. NOTE: In order to be sure that the piston is at Top Dead Center, the punch mark © on the exhaust camshaft and the punch mark @) on the intake camshaft must align with the cylinder head surface, as shown in the illustration.

+ Timing chain tensioner cap bolt +_Timing chain tensioner @ + Gasket

+ Exhaust camshaft © +_Intake camshaft © NOTE:

+ Cam lobe Pitting/scratches/blue discolor- ation — Replace.

+ Cam lobe length @ and ® Out of specification — Replace. Cam lobes length: Intake:

Measure: + Camshaïft-to-cap clearance Out of specification — Mea-

Measurement steps: Install the camshaft onto the cylinder head. Position a strip of Plastigauge © onto the camshaft. Install the clip, dowel pins and camshaîft caps.

Bolt (camshaft cap): 10 Nm (1.0 mekg,7.2ft+lb) NOTE: Remove the camshaft caps and Tighten the bolts (camshaft cap) in a crisscross pattern from innermost to outer caps. Do not turn the camshaft when measuring clearance with the Plastigauge®. measure the width of the Plasti- gauge® ©. Measure: + Camshaft outside diameter @ Out of specification — Replace the camshaît. Within specification — Replace camshaft case and camshaft caps as a set.

Camshaft outside diameter:

Decompression system

ing chain tensioner Check: + While pressing the tensioner rod lightly with fingers, use a thin screwdriver (D and wind the tensioner rod up fully clockwise. + When releasing the screw- driver by pressing lightly with fingers, make sure that the tensioner rod will come out smoothly. If not, replace the tensioner assembly.

ASSEMBLY AND INSTALLATION

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" section in the CHAPTER 3. Radiator hose 1 Disconnect at cylinder head side. Carburetor Refer to “CARBURETOR' section. Air cut-off valve assembly Refer to “AIR INDUCTION SYSTEM" section. Camshatt Refer to “CAMSHAFTS" section. Upper engine bracket Refer to “ENGINE REMOVAL" section. 1 Radiator pipe 1 2 | Oi delivery pipe 1 3 [Nu 2 Ü 4 | Bolt(L=135 mm (5.81 in)] 2 5 | Bolt(L=145 mm (5.71 in)] 2 6 | Cylnderhead 1 7__| Timing chain guide (exhaust side) 1

+ Carbon deposits (from the combustion cham- bers) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching: + Spark plug threads + Valve seats

+ Cylinder head warpage Out of specification — Resur- face.

Warpage measurement and resurfacing steps: + Place a straightedge and a feeler gauge across the cylinder head. Use a feeler gauge to measure the warpage. If the warpage is out of specifi- cation, resurface the cylinder head. Place a 400 - 600 grit wet sandpaper on the surface plate, and resurface the head using a figure-eight sanding pattern. NOTE: To ensure an even surface rotate the cylinder head several times. Cylinder head warpage: Less than 0.05 mm (0.002 in)

ASSEMBLY AND INSTALLATION

+ Copper washer D + Oil delivery pipe © + Union bolt (M8) ©

+ _Radiator pipe D + Bolt (radiator pipe) ©

Extent of removal: @ Vale removal Extent of removal Order Part name Remarks Preparation for removal

VALVES AND VALVE SPRINGS

REMOVAL Cylinder head Refer to “CYLINDER HEAD" section. cœtoumaswn x Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Exhaust valve Intake valve a &

Sn uumumu Use special tool. Refer to “REMOVAL POINTS"

REMOVAL POINTS Valve lifter and valve cotter

+ Valve lifter © + Pad@ NOTE: Identify each lifter © and pad © position very carefully so that they can be reinstalled in their original place.

+ Valve sealing Leakage at the valve seat — Inspect the valve face, valve seat and valve seat width. Checking steps: + Pour a clean solvent (D into the intake and exhaust ports. + Check that the valve seals properly. There should be no leakage at the valve seat ©.

+ Poussoir de soupape © + Cale ©

Inspect: + Valve face Pitting/wear — Grind the face. + Valve stem end Mushroom shape or diameter larger than the body of the stem — Replace. Measure: + Margin thickness @ Out of specification — Replace.

+ Carbon deposits (from the valve face and valve seat)

+ Valve seat Pittingwear — Reface the valve seat.

(10.50 - 12.09 kg at

(12.85 - 14.68 kg at

+ Valve lifter Scratches/damage — Replace both lifters and cylinder head. Poussoir de soupape

ASSEMBLY AND INSTALLATION

Valve and valve spring

+ Molybdenum disulfide oil Onto the valve stem and valve stem seal.

+ Vave® + Valve spring seat © + Valve stem seal © KE + Valve spring © + Valve spring retainer © To cylinder head. NOTE: ms + Make sure that each valve is installed in its original place, also referring to the painted color as fol- lows. Intake (middle) @): Orange Intake (right/left) @: Green Exhaust: no paint + Install the valve springs with the larger pitch © facing upward. @ Smaller pitch

4. To secure the valve cotters onto

the valve stem, lightly tap the valve tip with a piece of wood. CAUTION: Hitting the valve tip with excessive force could damage the valve.

CYLINDER AND PISTON ee ONm (1.0m-kg,7.2ft-Ib) Extent of removal: @ Cyinder removal @ Piston removal Extent of removal Order Part name ay Remarks

CYLINDER AND PISTON REMOVAL

Preparation for removal Cylnder head Refer to “CYLINDER HEAD” section. à 1 Bolt (cylinder) 1 T [ 2 | Cylnder 1 3 | Pistonpin clip 2 4 Piston pin 1 Use special tool. 5 | Piston 1 Refer to *REMOVAL POINTS" | 6 | Piston ring set 1

+ _Piston ring © + Segment de piston D NOTE: N. Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown, as shown in the illustration. INSPECTION Cylinder and piston

+ Cylinder and piston walls Vertical scratches — Replace cylinder and piston.

1. Measure: 1. Mesurer:

(0.6300 - 0.6304 in) + Calculate the piston pin-to-pis- ton clearance with the following formula. Piston pin-to-piston clearance = Inside diameter (piston) O- Outside diameter (piston pin) + lf out of specification, replace the piston. Piston pin-to-piston clearanc.

ASSEMBLY AND INSTALLATION

Piston ring and piston

+ Joint de cylindre © + Cylindre © N.B.: Install the cylinder with one hand while compressing the piston rings with the other hand. Monter le cylindre à l’aide d'une main, tout en compressant les segments de l’autre. CAUTION: + Pass the timing chain © through the timing chain cavity. - Be careful not to damage the timing chain guide @ during installation.

euuren | ENG D | éluren [8% 10Nm (1.0m-kg, 7.2ft-Ib) Extent of removal: @ Push rod 1, 2 and push lever shaft removal @ Push rod 1 disassembly © Friction plate and clutch plate removal @ Primary driven gear removal Extent of removal Order Part name ay Remarks CLUTCH REMOVAL Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT" 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 Circlip Washer Bearing Ball Push rod 2 CORALIE

EC4n3000 POINTS DE DEPOSE REMOVAL POINTS Noix d'embrayage Clutch boss 1. Déposer:

1. Remove: + Ecrou (D

+ NutO + Lock washer @ + Clutch boss © NOTE: Straighten the lock washer tab and use the clutch holding tool @ to hold the cluich boss. Clutch holding tool: YM-91042/90890-04086

[A] For USA and CDN [B] Except for USA and CDN EC4n4000 INSPECTION ECa84100 Clutch housing and boss

+ Clutch housing © Cracks/wear/damage — Replace. + Clutch boss © Scoring/wear/damage — Replace. ECa8420i Primary driven gear

+ Circumferential play Free play exists — Replace. + Gear teeth @ Wear/damage — Replace. Clutch spring

+ Clutch spring free length @ Out of specification — Replace springs as a set. Clutch spring free length:

-_Friction plate thickness Out of specification — Replace friction plate as a set. Measure at all four points. Friction plate thickness:

+ Clutch plate warpage Out of specification — Replace clutch plate as a set. Use a surface plate (D and thickness gauge ©. Warp limit:

+ Push lever shaft © + Bolt (push lever shaft) © NOTE: + Apply the lithium soap base grease on the oil seal lip. + Apply the engine oil on the push lever shaît. + Fit the seat plate © in the groove @ of the push lever shaft and tighten the boit (seat plate). Clutch

+ Primary driven gear © + Thrust washer © + Clutch boss © NOTE: Apply the engine oil on the primary driven gear inner circumference.

+ Seat plate D + _Cushion spring @ NOTE: + Plaque de siège © + Plaquette de progressivité © N.B.: + Install the seat plate with its cham- fered portion @ facing the clutch boss @). +_Install the seat plate so that it is not caught on the step ®). + Install the cushion spring with the paint © facing out.

+ Disque garni 1 © + Plateau d'embrayage 1 © + Disque garni 2 @ + Plateau d'embrayage 2 © Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate. Use the friction plates 1 for the first and final while paying attention to the difference in surface pattern. Apply the engine oil on the friction plates and clutch plates. Unilike the clutch plate 2, the clutch plate 1 has no surface gloss. Use the clutch plate 1 for the first while paying attention to the difference in surface gloss.

+ Dowel pin © + Goujon D + Gasket (clutch cover) © +_ Joint (cloche d'embrayage) ©

[T8 Nm (0.8 m kg, 5.8 ft: Ib) Extent of removal: @ Oil filter element removal © Right crankcase cover removal @ Water pump removal Extent of removal Order Part name Q'*ty Remarks

OIL FILTER ELEMENT, WATER PUMP

REMOVAL Preparation for removal Drain the engine oil. Drain the coolant. Radiator hose 3 Exhaust pipe Brake pedal Engine guard Refer to “ENGINE OIL REPLACEMENT" section in the CHAPTER 3. Refer to *COOLANT REPLACEMENT" section in the

Disconnect at water pump side. Refer to “EXHAUST PIPE AND SILENCER" section in the CHAPTER 3. Refer to “ENGINE REMOVAL" section. à à 1 Oil filter element cover T 1 2 | Oifiterelement 5-129

4Nm (1.4m-kg, 10ft-Ib) Extent of removal Order Part name ay Remarks T 3 Water pump housing 1 4 | oi delivery pipe 1 5 | Bolt (oil hose) 1 6 | Kickstarter crank 1 j 7 | Right crankcase cover 1 8 | impeller 1 9 | Washer 1 10 | Impeller shaît 1 Refer to ‘REMOVAL POINTS"

+ Oil seal © INSPECTION Oil delivery pipe

+ Bearing Rotate inner race with a finger. Rough spot/seizure - Replace. EC444400 Oil seal

+ Oil seal © Wear/damage — Replace.

ASSEMBLY AND INSTALLATION

+ Oil seal © + Bague d'étanchéité © NOTE: NB: + Apply the lithium soap base grease on the oil seal lip. + Install the oil seal with its manufac- ture's marks or numbers facing the right crankcase cover ©.

+ Right crankcase cover D + Bolt (right crankcase cover) ©

+ Pédale de kick D + Rondelle + Boulon (pédale de kick) L<S5 Nm G3m:kg,24ft-1b) | CAES Nm 63 m°kg,2410-1b) 7] NOTE: N.B.: Install so that there is a clearance @) of 13 mm (0.51 in) or more between the kick starter and frame and that the kick starter does not contact the crankcase cover when it is pulled.

+ Copper washer D REZ + Oil delivery pipe © + Union bolt (M8) ©

+ Water pump housing D + Bolt (water pump housing) © [TO Nm (1.0 m- Kg, 7.2#- Ib)

+ Oil filter element ©

Extent of removal: ® Balancer shaft drive gear © Balancer shaft Extent of removal Order Par name ay 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 CRANKCASE COVER" section. Stator Refer to “AC MAGNETO AND STARTER CLUTCH' section. ' Aux (primary drive gear) ! Refer to ‘REMOVAL POINTS" Of 2 Nut (balancer shaft driven gear) 1 3 | Lock washer 1 4 | Primary drive gear 1 5 | Balancer shaît drive gear 1 d 6 | Lock washer 1 7 | Balancer shaît driven gear 1 [ 8 | Balancer shaît 1 Refer to “REMOVAL POINTS". 5-145

ENG | D REMOVAL POINTS Balancer shaft drive gear and balancer shaft driven gear

1. Straighten the lock washer tab.

+_Nut (primary drive gear) D + Nut (balancer shaft driven gear) © NOTE: Place an aluminum plate @ between the teeth of the balancer shaft drive gear @ and driven gear @. Balancer shaft

+ Primary drive gear © + Balancer shaft drive gear © + Balancer shaft driven gear @ Wear/damage — Replace. Balancer shaft

ASSEMBLY AND INSTALLATION

Balancer shaft, balancer shaft drive gear and balancer shaft driven gear

+ Balancer shaft © NOTE: Apply the engine oil on the bear- ing. When installing the balancer shaîñt, align the center @ of the balancer shaft weight along the line con- necting the centers of the crank- shaîft and balancer shaît.

+ Balancer shaft driven gear D NOTE: Install the balancer shaft driven gear onto the balancer shaft while aligning the punch mark @ on the balancer shaft driven gear with the lower spline ® on the balancer shaît end.

+ Balancer shaft drive gear © NOTE: Align the punched mark @ on the balancer shaft drive gear with the punched mark ® on the balancer shaft driven gear ©. Align the punched mark © on the balancer shaft drive gear with the lower spline @ on the crankshaft end.

+ Lock washer © + Nut (balancer shaft driven gear) © + Primary drive gear @ + _Nut (primary drive gear) © NOTE: + Install the primary drive gear with its stepped side @ facing the engine. + Place an aluminum plate ® between the teeth of the balancer shaft drive gear ® and driven gear [OX

OIL PUMP ee 10 Nm (1.0 m: kg, 7.2 ft: Ib) Extent of removal: @ Oil pump removal @ Oil pump disassembly Extent of removal Order Part name

Remarks Preparation for removal

OIL PUMP REMOVAL AND

DISASSEMBLY Primary driven gear Right crankcase cover Refer to “CLUTCH" section. Refer to “OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER" section. Circlip Washer Oil pump drive gear Oil pump assembly Outer rotor 2 Circlip Inner rotor 2 Dowel pin Oil pump cover Outer rotor 1 Inner rotor 1 Dowel pin Washer Oil pump drive shaît Rotor housing 5-153

Extent of removal: @ Oil tank removal Extent of removal Order Part name ay Remarks

Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT" section in the CHAPTER 3. Oil hose 2 Oil hose 1 Dowel pin Oil tank breather hose Oil tank Oil strainer ou sw = iii a = 5-157

+ Oil pump drive gear D + Oil pump drive shaft © + _Rotor housing © + Oil pump cover @ Cracks/wear/damage — Replace.

+ Tip clearance @ (between the inner rotor © and outer rotor @)) Side clearance © (between the outer rotor @ and rotor housing @)) Housing and rotor clearance (between the rotor housing @ and rotors (D @) Out of specification — Replace the oil pump assem- bly.

(0.0047 in or less) <Limit>:

Housing and rotor clearance ©:

+ Unsmooth — Repeat steps #1 and #2 or replace the defec- tive parts. 5-161

ASSEMBLY AND INSTALLATION

+ Oil pump drive shaft D + Washer @ + Dowel pin @ +_Inner rotor 1 © NOTE: + Apply the engine oil on the oil pump drive shaft and inner rotor 1. + Fitthe dowel pin into the groove in the inner rotor 1.

+ Outer rotor 1 © NOTE:

+ Oil pump cover © + Screw (oil pump cover) ©

KICK SHAFT AND SHIFT SHAFT ENG

KICK SHAFT AND SHIFT SHAFT

10Nm (1.0m-kg,7.2ft-1b)] \ []12 Nm (1.2 m kg, 8.7 ft: 1b)| Extent of removal: @ Kick shaît removal @ Kick shaft disassembly © Shift shaft removal @ Segment removal Extent of removal Order Part name ay Remarks

KICK SHAFT AND SHIFT SHAFT

REMOVAL Preparation for removal Oil pump Refer to “OIL PUMP" section: Kick shaft assembly Refer to “REMOVAL POINTS”. Spring guide Torsion spring Ratchet wheel Kick gear Kick shaft Washer Shift pedal Shift shaît Collar nt Kick idle gear

KICK SHAFT AND SHIFT SHAFT ENG

KICK SHAFT AND SHIFT SHAFT

+ Bolt (shift guide) + Shift guide D + Shift lever assembly © NOTE: The shift lever assembly is disas- sembled at the same time as the shift guide. ECANS100 Segment

+ Bolt (segment) © + Segment @ NOTE: Tu the segment counterclockwise until it stops and loosen the boit. CAUTION: If the segment gets an impact, it may be damaged. Take care not to give an impact to the segment when removing the bolt. INSPECTION Kick shaft and ratchet wheel

+ Bullone (segmento) © + Segmento © NOTA:

KICK SHAFT AND SHIFT SHAFT

ENG | D ECAC4300 Kick gear, kick idle gear and ratchet wheel

+ Kick gear © + Kick idle gear © + Ratchet wheel © + Gear teeth @ + Ratchet teeth Œ Wear/damage — Replace. ECa84400 Shift shaft

ASSEMBLY AND INSTALLATION

KICK SHAFT AND SHIFT SHAFT

+ Torsion spring D + Stopper lever © + Bolt (stopper lever) © !! NOTE: Align the stopper lever roller with the slot on segment. Shift guide and shift lever assembly

KICK SHAFT AND SHIFT SHAFT

+ Shift pedal Refer to “AC MAGNETO AND STARTER CLUTCH” section.

• Align the punch mark @ on the ratchet wheel with the punch mark ® on the kick shaft.

KICK SHAFT AND SHIFT SHAFT

Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT" section in the CHAPTER 8. Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS" section in the CHAPTER 3. Disconnect the AC magneto lead 1 Shift pedal 1 2 | Cover (torque limiter) 1 à 3 | Torque limiter 1 Do not disassemble. 4 | Crankcase cover (left) 1 5 | Gasket 1 6 | Dowel pin 2 5-185

10Nm(1.0m-kg,7.2ft-Ib) 7 Nm (0.7 m-kg, 5.1 ft-Ib) 10 Nm (1.0 m: kg, 7.2ft: Ib) 65 Nm (6.5 m - kg, 47 ft Ib) 10 Nm (1.0 m - kg, 7.2 ft: Ib) Extent of removal Order Part name ay Remarks T T 7 Nut (rotor) 1 Refer to NOTE. b 8 | Rotor 1 Use special tool Refer to “REMOVAL POINTS". | 9 | Woodrut key 1 10 | Starter clutch drive gear 1

11. | Starter clutch assembly cover 1

12 | Starterclutch 1 Refer to “REMOVAL POINTS". 13 | Bearing 1

+ Starter clutch assembly cover

+ Starter clutch operation Install the starter clutch drive gear © onto the starter clutch © and hold the starter clutch. When turning the starter clutch drive gear counterclockwise [B], the starter clutch and the starter clutch drive gear should engage. If the starter clutch drive gear and starter clutch do not engage, the starter clutch is faulty and must be replaced. When turning the starter clutch drive gear clockwise , it should turn freely. If the starter clutch drive gear does not turn freely, the starter clutch is faulty and must be replaced. Torque limiter

+ Torque limiter Damage/wear — Replace. ECAL5000

ASSEMBLY AND INSTALLATION

AC magneto and starter clutch

+ Stator ® + Bolt (stator) © + Pickup coil @) + Bolt (pickup coil) @ CA [10 Nm (10m -kg,72ft-1b) 5-197

+ _Idie gear plate © + Bolt (idle gear plate) ©

+ Washer © + Bearing © + Starter clutch drive gear © + Washer @ NOTE: Apply the engine oil on the washer, bearing and starter clutch drive gear inner circumference. 5-199

+ Supporto D + Bullone ©

+ Dowel pin + _Gasket [crankcase cover (left)] + Crankcase cover (left) D + Bolt [crankcase cover (left)] © [10 Nm (1.0 m- Kg, 7.2 Ib) 2 À Clé à sangle: YS-1880-A/90890-01701

+ AC magneto lead Refer to “CABLE ROUTING DIAGRAM" section in the

“SCHEMA PERCORSO DEI

“DIAGRAMA DE CABLEADO”

184 Nm G4m kg, 24-10) 7 Nm (0.7 m - kg, Extent of removal Order Part name ay Remarks ENGINE REMOVAL Preparation for removal Hold the machine by placing the suitable Stand under the frame ——————————— Support the machine securely so there is no danger of it falling over. Drain the engine oil Refer to “ENGINE OIL REPLACEMENT" section in the CHAPTER 8. Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS" section in the CHAPTER 3. Carburetor Refer to “CARBURETOR' section. Exhaust pipe and silencer Refer to “EXHAUST PIPE AND SILENCER" section in the CHAPTER 3. Air cut-off valve assembly Refer to “AIR INDUCTION SYSTEM" section. Clutch cable Disconnect at the engine side. Radiator Refer to “RADIATOR" section. Shift pedal Refer to “AC MAGNETO AND STARTER CLUTCH" section. Cylinder head breather hose Refer to “CAMSHAFTS" section. Oil hose and oil tank breather hose Refer to “OIL PUMP" section: 5-207

Remarks Ignition coil Disconnect the AC magneto lead Starter motor lead Negative battery lead Disconnect at the starter motor side. Disconnect at the engine side Engine guard Neutral switch Drive sprocket

Brake pedal 13 | Pivot shaft 14 | Engine Drive chain sprocket cover Nut (drive sprocket) Bolt (brake pedal) 10 | Upper engine bracket 11 | Lower engine bracket 12 | Engine mounting boit sapin mm um mn Refer to “REMOVAL POINTS" Refer to “REMOVAL POINTS" 5-211

+ _Nut (drive sprocket) D + Lock washer @ NOTE: + Straighten the lock washer tab. + Loosen the nut while applying the rear brake.

+ Pivot shaft © NOTE: If the pivot shaft is pulled all the way out, the swingarm will come loose. If possible, insert a shaft of similar diameter into the other side of the swingarm to support it.

ASSEMBLY AND INSTALLATION

+ Engine © Install the engine from right side. + Pivot shaft @ + Engine mounting bolt (lower)

+ Lower engine bracket (4) + Bolt (lower engine bracket) @) 4 ]84 Nm (3.4 m - kg, 24 ft- Ib) - Patch © + Engine mounting bolt (front) @ + Upper engine bracket + Bolt (upper engine bracket) © + Engine mounting bolt (upper) + Lower engine guard @ + Bolt (lower engine guard) @

+ Spring © + Brake pedal ©

• O-ring@ EE + Bolt (brake pedal) © + Cip® NOTE: Apply the lithium soap base grease on the bolt, O-rings and brake pedal bracket. Drive sprocket

+ Lock washer © + _Nut (drive sprocket) ©

3. Bend the lock washer tab to lock

• Oring© EE + Neutral switch @ + Screw (neutral switch) @ L N

CRANKCASE AND CRANKSHAFT ENG

CRANKCASE AND CRANKSHAFT

10 Nm (1.0 m-kg,7.2ft- Ib) ONm (1.0m-:kg, 7.2ft-1b) 2 Nm(1.2m-kg, 8.7ft- Ib) Extent of removal: @ Crankcase separation @ Crankshaft removal Extent of removal Order Part name ay Remarks

CRANKCASE AND CRANKSHAFT

REMOVAL Preparation for removal Engine Refer to “ENGINE REMOVAL" section. Piston Refer to “CYLINDER AND PISTON" section. Kick shaft assembly Refer to ‘KICK SHAFT AND SHIFT SHAFT" Segment section. Stator Refer to “AC MAGNETO AND STARTER CLUTCH' section. Balancer shaft Refer to “BALANCER" section. d D 1 Timing chain guide (intake side) 1 2 |Timingchain 1 ll l 3 __| Oil delivery pipe 2 1 5-221

CRANKCASE AND CRANKSHAFT ENG

ONm (1.0m-:kg, 7.2ft-1b) 10 Nm (1.0 m-kg,7.2ft- Ib) 2 Nm(1.2m-kg, 8.7ft- Ib) Extent of removal Order Part name ay Remarks T Î 4 Bot [L = 45 mm (1.77 in)] 5 5 |Bolt{L=55 mm(2.17in)] 1 6 | Bolt{L=70 mm (27 in)] 3 7 | Hose guide 1 Refer to ‘REMOVAL POINTS" 8 | Clutch cable holder 1 9 | Right crankcase 1 10 | Left crankcase 1

12 | Crankshatt 1 Use special tool. Refer to “REMOVAL POINTS". 5-225

CRANKCASE AND CRANKSHAFT ENG

CRANKCASE BEARING 40 Nm (1.0 m-kg, 7.2ft- lb) 10 Nm (1.0 m - kg, 7.2 ft: Ib) F4] 10 Nm (1.0 m - kg, 7.2 ft: Ib) 10 Nm(1.0m-kg, 7.2ft-Ib) 10 Nm (1.0 m - kg, 7.2ft- Ib) Extent of removal @ Crankcase bearing removal Extent of removal Order Part name ay Remarks

CRANKCASE BEARING REMOVAL

Preparation for removal Transmission Refer to ‘TRANSMISSION, SHIFT CAM AND Shift cam and shift fork SHIFT FORK" section. a 1 Oil seal ï 2 | Bearing 10 __ | Referto “REMOVAL POINTS”. 5-229

CRANKCASE AND CRANKSHAFT

REMOVAL POINTS Crankcase

CRANKCASE AND CRANKSHAFT

+ Bearing © + Roulement (D NOTE: N.B.: + Remove the bearing from the crankcase by pressing its inner race. + Do not use the removed bearing. INSPECTION Timing chain and timing chain guide

+_Timing chain Cracks/stiff — Replace the timing chain and camshaft sprocket as a set.

+_Timing chain guide Wear/damage — Replace. Crankcase

+ Contacting surface @ Scratches — Replace. + Engine mounting boss ®), crankcase Cracks/damage — Replace.

+ Bearing Rotate inner race with a finger. Rough spot/seizure — Replace.

CRANKCASE AND CRANKSHAFT ENG

+ Runout limit @ + Small end free play limit © + Connecting rod big end side clearance © + Crank width @ Out of specification — Replace. Use the dial gauge and a thickness gauge. Dial gauge and stand: YU-3097/90890-01252 Standard | <Limit>

Small end | 10mm | 2.0mm free play: (0.016 - | (0.08 in)

+ Oil strainer Damage — Replace. Oil delivery pipe 2

+ Oil delivery pipe 2 © + O-ring © Damage — Replace. + Oil orifice @ Clogged — Blow. 5-237 Vilebrequin

CRANKCASE AND CRANKSHAFT

ASSEMBLY AND INSTALLATION

+ Bearing + Bearing stopper + Bolt (bearing stopper) Sa [10 Nm (0 m Ko, 7.2 1) + Screw (bearing stopper) CAT T0 Nm (1.0 m -kg,72ft-1b) + Screw [bearing stopper né )] © Ci RE and right rankoase. NOTE: Install the bearing by pressing its outer race parallel. To prevent the screw [bearing stopper (crankshaft)] from becom- ing loose, crush the screw head periphery @ into the concave ® using a punch etc. In so doing, take care not to damage the screwdriver receiving hole in the screw head. Crankshaft

+ Crankshaft © Use the crankshaft installing tool ©, ©, © and ®.

CRANKCASE AND CRANKSHAFT

+ Shifter operation + Transmission operation Unsmooth operation — Repair.

+ Oil strainer © + Bolt (oil strainer) ©

+ Olsieb © + Olsieb-Schraube ©

CRANKCASE AND CRANKSHAFT

+ Hose guide + Clutch cable holder @ + Bolt (crankcase) ©

+ Oil delivery pipe 2 ©

+ Sealant 9. Déposer: Forced out on the cylinder mating surface.

+ Engine oil To the crank pin, bearing and oil delivery hole.

+ Crankshaft and transmission operation. Unsmooth operation — Repair.

TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG ©B EC4H0000

TRANSMISSION, SHIFT CAM AND SHIFT FORK

Extent of removal: @ Shift fork, shift cam, main axle and drive axle removal Extent of removal Order Part name ay Remarks

TRANSMISSION, SHIFT CAM AND

Preparation for removal Engine Refer to “ENGINE REMOVAL section. Separate the crankcase. Refer to “CRANKCASE AND CRANKSHAFT" section. Main axle Drive axle Shift cam Shift fork 3 Shift fork 2 Shift fork 1 Collar Refer to “REMOVAL POINTS" No uRswnN =

TRANSMISSION, SHIFT CAM AND SHIFT FORK

+ Main axle © + Drive axle © + Shiftcam + Shift fork 3 + Shift fork 2 + Shift fork 1 NOTE: Remove assembly with the collar @ installed to the crankcase. Remove assembly carefully. Note the position of each part. Pay par- ticular attention to the location and direction of shift forks. Remove the main axle, drive axle, shift cam and shift fork all together by tapping lightly on the transmis- sion drive axle with a soft hammer. ECaH4000 INSPECTION ECAH4200 Gears

+ O-ring © Damage — Replace.

+ Gears movement Unsmooth movement — Repair or replace. ECAH4600 Bearing

+ Bearing © Rotate inner race with a finger. Rough spot/seizure — Replace. ECaH4810 Shift fork, shift cam and segment

TRANSMISSION, SHIFT CAM AND SHIFT FORK

ASSEMBLY AND INSTALLATION

+_5th pinion gear (19T) © + 3rd pinion gear (177) © + Collar @ + Ath pinion gear (21T) © + 2nd pinion gear (167) © To main axle ®. NOTE: Apply the molybdenum disulfide oil on the inner and end surface of the idler gear and on the inner surface of the sliding gear, then install. 5-251

TRANSMISSION, SHIFT CAM AND SHIFT FORK

+ 2nd wheel gear (28T) © + Ath wheel gear (23T) @ 3rd wheel gear (23T) © 5th wheel gear (17T) © 1st wheel gear (31T) © O-ring © To drive axle @. NOTE:

+ Washer © + Rondelle © - Circlip © REZ + Circlip © NOTE: NB: + Be sure the circlip sharp-edged corner @ is positioned opposite side to the washer and gear ®. + Install the circlip with its ends © settled evenly on the spline crests.

TRANSMISSION, SHIFT CAM AND SHIFT FORK

+ Shift fork 1 (L) © + Shift fork 2 (C) © +_ Shift fork 3 (R) © + Shift cam @ To main axle and drive axle. NOTE: Apply the molybdenum disulfide oil on the shift fork grooves. Mesh the shift fork #1 (L) with the Ath wheel gear ® and #3 (R) with the 5th wheel gear © on the drive axle. Mesh the shift fork #2 (C) with the 3rd pinion gear @ on the main axle.

+ Shifter operation + Transmission operation Unsmooth operation — Repair. 5-255

FRONT WHEEL AND REAR WHEEL CHAS TD EC500000 NOTE: CHASSIS This section is intended for those who have basic knowledge and skill concerning the EC690oDo 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 AND REAR WHEEL undertake inspection, adjustment, disassembly, or reassembly only by reference to EC598000 this manual. It may lead to servicing trouble and mechanical damage. FRONT WHEEL [al2t Nm (41 kgrm, 15 ft) ] 21 Nm (2.1 kg:m, 15 ft-Ib)

Extent of removal: @ Front wheel removal © Wheel bearing removal © Brake disc removal Extent of removal Order Part name ay Remarks

FRONT WHEEL REMOVAL EN

Preparation for removal Hold the machine by placing the suitable EX Support the machine securely so there is no Stand under the engine. he mi danger of it falling over. Bolt (axie holder) Nut (front wheel axle) Front wheel axle Only loosening. Lil [ll Front wheel Speed sensor Collar Oil seal Bearing Brake disc Refer to “REMOVAL POINTS". cœotouswn

[AL TONm (9m kg, 13ft-1b) [Sa [14Nm (14mkg , 10ft-Ib) Extent of removal: ® Rear wheel removal © Brake disc removal @ Wheel bearing removal Exient of removal Order Par name ay Remaks

Preparation for removal Hold the machine by placing the suitable —————— stand under the engine Support the machine securely so there is no danger of it falling over. 1 | Nut(rearwheel axe) 1 d | 2 | Rear wheel axe 1 3 | Drive chain puller 2 | | 4 | Rearwheel 1 | RefertoREMOVAL POINTS". 5 | Golar 2 6 | Rear wheel sprocket 1 7 |oisea 2 8 | Circip 1 9 | Bearing 2 | Reterto“REMOVAL POINTS". (OI 10 | Brake disc 1

+ Wheel® NOTE: Push the wheel forward and remove the drive chain ©. ECS18201 Wheel bearing (if necessary)

+ Bearing © NOTE: Remove the bearing using a general bearing puller ©. EC594000 INSPECTION EC514100 Wheel

+ Wheel runout Out of limit — Repair/replace. Wheel runout limit: Radial ©:

+ Bearing Rotate inner race with a finger. Rough spot/seizure — Replace. NOTE:

+ Wheel axle bends Out of specification — Replace. Use the dial gauge ©. Wheel axle bending limit:

NOTE: The bending value is shown by one half of the dial gauge reading. À WARNING Do not attempt to straighten a bent axle. EC594200 Brake disc

+ Brake disc deflection (only rear brake disc) Use the dial gauge ©. Out of specification — Inspect wheel runout. If wheel runout is in good con- dition, replace the brake disc. Has Axe de roue

+ Brake disc thickness @ Out of limit — Replace. Brake disc thickness: Front:

ASSEMBLY AND INSTALLATION

+ Bearing (left) D + Spacer @ + Bearing (right) © + Oil seal @ NOTE: Apply the lithium soap base grease on the bearing and oil seal lip when installing. Use a socket that matches the out- side diameter of the race of the bearing. Left side of bearing shall be installed first. Install the oil seal with its manufac- ture's marks or numbers facing outward. CAUTION: Do not strike the inner race of the bearing. Contact should be made only with the outer race.

+ Wheel axle © NOTE:

+ _Nut (wheel axle) D

- Drive chain © NOTE:

+ _Left drive chain puller © + Wheel axle © 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.

+ Right drive chain puller © + Washer @ + _Nut (wheel axle) © NOTE: Temporarily tighten the nut (wheel axle) at this point.

Preparation for removal Hold the machine by placing the suitable ———— stand under the engine Support the machine securely so there is no danger of it falling over. Drain the brake fluid. Refer to “REMOVAL POINTS". 1 Brake hose holder (protector) 2 d à 2 Brake hose holder (brake caliper) 1 1 (Oh 3 Union bolt 2 | 4 | Brake hose 1 à 5 Pad pin plug 1 Remove when loosening the pad pin. 6 |Padpin 1 Loosen when disassembling the brake caliper. | 7 | Brake caliper 1 à 8 Brake lever 1 9 | Brake master cylinder bracket 1 Il 10 | Brake master cylinder 1

Preparation for removal Hold the machine by placing the suitable ———— stand under the engine Support the machine securely so there is no danger of it falling over. Rear wheel Refer to “FRONT WHEEL AND REAR WHEEL" section. Drain the brake fluid. Refer to “REMOVAL POINTS". a 1 Brake pedal 1 T 2 | Brake master cylnder 1 3 | Brake hose holder 2 (on à (on 4 Union bolt 2 | 5 | Brakehose 1 à 6 Pad pin plug 1 Remove when loosening the pad pin. 7 | Padpin 1 Loosen when disassembling the brake caliper. Il 8 | Brake caliper 1

3 Nm (0.3 m:Kkg, 2.2 ft: Ib) 18 Nm (1.8 m kg, 13ft-Ib) (A Front [5] Rear Extent of removal: @ Front brake caliper disassembly © Rear brake caliper disassembly Extent of removal Order Part name Q'ty Remarks

BRAKE CALIPER DISASSEMBLY A B

© Pad pin Tlu © Brake pad 2 |2 E)] Pad support 1li ® Brake caliper piston 21 (] Dust seal 2 1 Refer to “REMOVAL POINTS" G] Piston seal 21

Nm (0.2 m:kg, 1.4ft-1b) 2Nm(0.2m-kg, 14ft-1b) A Front F] Rear Extent of removal @ Front brake master cylnder disassembly @ Rear brake master cylinder disassembly Extent of removal Order Par name ay Remarks

[Front] + Brake master cylinder cap © [Rear] + Brake master cylinder cap © + Protector NOTE: Do not remove the diaphragm.

Connect the transparent hose @ to the bleed screw ( and place a suitable container under its end. A Front F) Rear

3. Loosen the bleed screw and

drain the brake fluid while pulling the lever in or pushing down on the pedal. CAUTION: + Do not reuse the drained brake fluid. - Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immedi- ately. Brake caliper piston

+ Brake caliper piston Use compressed air and pro- ceed carefully. À WARNING + Cover piston with rag and use extreme caution when expelling piston from cylinder. + Never attempt to pry out piston. Liquide de frein

+ Brake master cylinder inner surface @ Wear/scratches — Replace master cylinder assembly. Stains — Clean. À WARNING Use only new brake fluid. A Front F] Rear

Inspect: + Diaphragm © Crack/damage — Replace. A Front F] Rear

+ Brake caliper cylinder inner surface @ Wear/score marks — Replace brake caliper assembly. A Front EF) Rear

+ Brake caliper piston D Wear/score marks — Replace brake caliper piston assembly. À WARNING Replace the piston seals and dust seals © whenever a caliper is dis- assembled.

+ Brake hose © Crack/damage — Replace. ECS5A5000

ASSEMBLY AND INSTALLATION

À WARNING + All internal parts should be cleaned in new brake fluid only. Internal parts should be lubri- cated with brake fluid when installed. Replace the piston seals and dust seals whenever a caliper is disassembled. Brake caliper piston

+ Piston seal © + Dust seal @ À WARNING Always use new piston seals and dust seals. CHAS\É

+ Brake disc cover © + Bolt (brake disc cover) © [10 Nm (1.0 m - Kg, 7.2ft- Ib)

+ Brake caliper D + Rear wheel © Refer to “FRONT WHEEL AND REAR WHEEL' section.

+ Brake master cylinder + Brake master cylinder kit Clean them with brake fluid.

+ Brake master cylinder cup (primary) © + Brake master cylinder cup (secondary) © To brake master cylinder pis- ton ®. NOTE: ms Apply the brake fluid on the brake master cylinder cup. À WARNING After installing, cylinder cup should be installed as shown direction. Wrong installation cause improper brake perfor- mance. (A Front F) Rear

+ Spring © To brake master cylinder pis- ton ©. NOTE: Install the spring at the smaller dia. side. A Front F] Rear

[Front] + Brake master cylinder kit @ + Washer @ + Circlip © + Brake master cylinder boot (4) To brake master cylinder ©. [Rear] + Brake master cylinder kit © + Push rod @ + Circlip © + Brake master cylinder boot (4) To brake master cylinder ©. NOTE: + Apply the brake fluid on the brake master cylinder kit. + Apply the lithium soap base grease on the tip of the push rod. + When installing the circlip, use a long nose circlip pliers. A Front F] Rear Kit de maître-cylindre de frein

+ Brake master cylinder © + Brake master cylinder bracket + Bolt (brake master cylinder bracket) © Maiître-cylindre de frein avant

+ Spring © + Brake pedal ©

4. Pass the brake hose through the

front brake hose guides ©.

+ Copper washer D + Brake hose © + Union bolt @

+ Brake hose holder © + Screw (brake hose holder) © CHAS\É

Inspect: + Brake fluid level Fluid at lower level — Fill up. Refer to “BRAKE FLUID LEVEL INSPECTION"” section in the CHAPTER 3. Install: [Front] + Reservoir float + Diaphragm + Brake master cylinder cap © + Screw (brake master cylinder cap) © [Rear] + Diaphragm + Brake master cylinder cap © + Bolt (brake master cylinder cap) © CAUTION: 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 Front F] Rear

Install: (rear brake only) + Protector + Bolt (protector) ©

“SPURGO ARIA SISTEMA

Preparation for removal Hold the machine by placing the suitable ——————_— stand under the engine Support the machine securely so there is no danger of it falling over. Front wheel Refer to “FRONT WHEEL AND REAR WHEEL" section. Front brake caliper Refer to “FRONT BRAKE AND REAR BRAKE" section. Headiight Handlebar Refer to “HANDLEBAR' section: 1 Protector 1 2 | Pinch boit (upper bracket) 2 | Onlyloosening. © 3 | Capboit 1 Loosen when disassembling the front fork. 4 | Pinch bolt (lower bracket) 2 | Onlyloosening. 5 | Frontfork 1

DEPOSE DE LA FOURCHE

29 Nm (2.9 m - kg, 21 ft: Ib) 30 Nm (3.0 m «kg, 22 ft: Ib) Extent of removal: @ Oil seal removal @ Damper rod removal Extent of removal Order Part name

Front fork cap bol Fork spring Dust seal Stopper ring Inner tube Outer tube Piston metal Slide metal Oil seal washer Oil seal Spring guide Base valve Damper rod Refer to “REMOVAL POINTS". Drain the fork oil. Refer to “REMOVAL POINTS" Use special tool. Refer to “REMOVAL POINTS"

NOTE: N The front fork requires careful atten- tion. So it is recommended that the front fork be maintained at the deal- ers. CAUTION: To prevent an accidental explo- sion of air, the following instruc- tions should be observed: + The front fork with a built-in pis- ton rod has a very sophisticated internal construction and is par- ticularly sensitive to foreign material. Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled. Before removing the cap bolts or front forks, be sure to extract the air from the air chamber completely. EC553000 REMOVAL POINTS Front fork cap bolt

Front fork cap bolt © From the outer tube. NOTE: Before removing the front fork from the machine, loosen the front fork cap bolt.

+ Dust seal D + Stopper ring © Using slotted-head driver. screw- CAUTION: Take care not to scratch the inner tube.

+ Inner tube © Oil seal removal steps: + Push in slowly @ the inner tube just before it bottoms out and then pull it back quickly ©. + Repeat this step until the inner tube can be pulled out from the outer tube. ECss3s11 Damper rod

+ Damper rod © Bend/damage damper rod. — Replace CAUTION: The front fork with a built-in piston rod has a very sophisticated inter- nal construction and is particu- larly sensitive to foreign material. Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled. 6-71 + Bague d'arrêt @ Se servir d’un tournevis à lame droite. ATTENTION: Veiller à ne pas rayer le tube plon- geur.

+ Valve assembly © Wear/damage — Replace. + O-ring © Damage — Replace. EC554400 Fork spring

+_Fork spring free length @ Out of specification — Replace. Fork spring free length: 460 mm (18.1 in) <Limit>: 455 mm (17.9 in) EC554502 Inner tube

+ Inner tube surface @ Score marks — Repair or replace. Use #1,000 grit wet sandpa- per. Damaged oil lock piece — Replace. Inner tube bends Out of specification — Replace. Use the dial gauge ©. Inner tube bending li

NOTE: The bending value is shown by one half of the dial gauge reading. À WARNING Do not attempt to straighten a bent inner tube as this may dan- gerously weaken the tube. EC554600 Outer tube

ASSEMBLY AND INSTALLATION

1. Wash the all parts in a clean sol-

+ Damper rod © To inner tube ©. CAUTION: To install the damper rod into the inner tube, hold the inner tube aslant. If the inner tube is held ver- tically, the damper rod may fall into it, damaging the valve inside.

+ Copper washer D + O-ring © + Base valve @ To inner tube @.

- Dust seal ® + Stopper ring © + Oil seal @ + Oil seal washer @ + Slide metal © To inner tube @. NOTE: Apply the fork oil on the inner tube. When installing the oil seal, use vinyl seat @ with fork oil applied to protect the oil seal lip. Install the oil seal with its manufac- ture's marks or number facing the axle holder side. Install the oil seal washer with its projections ® facing upward.

+ Outer tube © To inner tube ©.

+ Slide metal © + Bague antifriction © + Oil seal washer @ To outer tube slot. NOTE: Press the slide metal into the outer tube with fork seal driver ©. Fork seal driver: YM-A0948/ 90890-01502

*_Inner tube smooth movement Tightness/binding/rough spots — Repeat the steps 2 to 12.

14. Compress the front fork fully.

+ Front fork oil Until outer tube top surface with recommended fork oil ©. N? Recommended oi il l CAUTION: + Be sure to use recommended fork oil. If other oils are used, they may have an excessively adverse effect on the front fork performance. + Never allow foreign materials to enter the front fork.

16. After filling, pump the damper

rod © slowly up and down more than 10 times to distribute the fork oil.

+ Front fork oil Until outer tube top surface with recommended fork oil once more.

18. After filling, pump the outer tube

© slowly up and down (about 200 mm (7.9 in) stroke) to dis- tribute the fork oil once more. NOTE Be careful not to excessive full stroke. A stroke of 200 mm (7.9 in) or more will cause air to enter. In this case, repeat the steps 15 to 18.

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. Be sure to fill with the fork oil up to the top of the outer tube and bleed the front forks.

+ Oil level (left and right) @ Out of specification — Adjust. Standard oil level: 130 mm (5.12 in) Extent of adjustment:

(3:74 - 5.91 in) From top of outer tube with inner tube and damper rod ( fully compressed without spring. NOTE: — Be sure to install the spring guide © when checking the oil level. À WARNING Never fail to make the oil level adjustment between the maximum and minimum level and always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability.

+ Distance @ Out of specification — Turn into the locknut. CHAS\É

+ Push rod © + Tige de débrayage D + Fork spring © + Ressort de fourche @ NOTE: NB: + Install the fork spring with the damper rod © pulled up. + After installing the fork spring, hold the damper rod end so that it will not go down.

Fully finger tighten the front fork cap bolt onto the damper rod.

+ Front fork cap bolt ©

+ Protector + Bolt (protector) ©

+ Rebound damping force NOTE: Turn in the damping adjuster © fin- ger-tight and then turn out to the orig- inally set position.

HANDLEBAR CHAS Cyo EC5B0000 HANDLEBAR m = kg, 2.9 ft: Ib) [A4 Nm (0.4 m + kg, 2.9 ft * Ib) [12 Nm (0.2 m - kg, 1.4 ft: lb) Extent of removal: @ Handlebar removal Extent of removal Order Part name ay Remarks HANDLEBAR REMOVAL Preparation for removal Headiight 1 Hot starter cable 1 Disconnect at the lever side. 2 | Hotstarter lever holder 1 3 | Clutch cable 1 Disconnect at the lever side. 4 | Clutch leverholder 1 Disconnect the clutch switch lead. 5 | Engine stop switch 1 Disconnect the engine stop switch lead. 6 | Brake master cylinder 1 Refer to “REMOVAL POINTS”. 7 | Start switch 1 Disconnect the start switch lead. 6 8 | Throïtle cable cap 1 9 | Throttie cable #1 (pulled) 1 Disconnect at the throttle side. 10 | Throtile cable #2 (pushed) 1 Disconnect at the throttle side. 11 | Right grip 1 Refer to “REMOVAL POINTS”. 12 | Tube guide 1 13 | Left grip 1 Refer to “REMOVAL POINTS”. 14 | Handiebar upper holder 2 15 | Handiebar 1 16 | Handiebar lower holder 2

+ Brake master cylinder © CAUTION: + Do not let the brake master cyl- inder hang on the brake hose. + Keep the brake master cylinder cap side horizontal to prevent air from coming in. EC583200 Grip

° Gip©O NOTE: Blow in air between the handlebar or tube guide and the grip. Then remove the grip which has become loose. EC584000 INSPECTION EC584100 Handlebar

+ Handlebar © Bends/cracks/damage — Replace. À WARNING Do not attempt to straighten a bent handlebar as this may dan- gerously weaken the handlebar.

NOTE: ms Install the handlebar lower holder with its side having the greater dis- tance @ from the mounting bolt center facing forward. Apply the lithium soap base grease on the thread of the handiebar lower holder. Installing the handlebar lower holder in the reverse direction allows the front-to-rear offset amount of the handiebar position to be changed. Do not tighten the nut yet.

+ Grip cap cover © + Throttle grip © NOTE: Apply the lithium soap base grease on the throttle grip sliding surface.

+ Grip cap cover D + Cover (throttle cable cap) ©

+ Engine stop switch © + Clutch lever holder © + Bolt (clutch lever holder) © + Hot starter lever holder @ + Bolt (hot starter lever holder) @ + Clamp © NOTE: + The engine stop switch, clutch lever holder and clamp should be installed according to the dimen- sions shown. + Pass the engine stop switch lead in the middle of the cluich lever holder.

+ Clutch lever free play Refer to “CLUTCH ADJUST- MENT" section in the CHAP- TER3. + Hot starter lever free play Refer to “HOT STARTER LEVER ADJUSTMENT” sec- tion in the CHAPTER 3. 6-103

• Retighten it. 7 Nm (0.7 m - kg, 5.1 ft- Ib) 21 Nm(2.1m-kg, 15ft-Ib) [1145 Nm (14.5 m - kg, 105 ft: Ib) | El 4 Nm (0.4 m : kg, 2.9 ft + Ib) [7 Nm (0.7 m-kg, 5.1 ft: Ib) Extent of removal: @ Lower bracket removal © Bearing removal Extent of removal Order Part name ay Remarks STEERING REMOVAL Preparation for removal Hold the machine by placing the suitable ——————_— stand under the engine Support the machine securely so there is no Headight danger of it falling over. Handlebar Refer to “HANDLEBAR' section. Front brake hose guide Front fender 1 Mult-function display 1 2 | Multi-function display bracket 1 3 | Main switch 1 Disconnect the main switch lead 4 | Steering stem nut 1 5 | Frontfok 2 | Referto “FRONT FORK" section 6 | Upperbracket 1 7 | Steering ring nut 1 Use special tool. Refer to “REMOVAL POINTS”. 8 | Lowerbracket 1 6-105

• Retighten it. 9 7 Nm (0.7 m - kg, 5.1 ft: Ib) ET (0.4 m : kg, 2.9 ft: Ib) / [7 Nm (0.7 m: kg, 5.1 ft: Ib) [a] 21 Nm (2.1 m + kg, 15 ft: Ib) CE Nm Game ZE) Extent of removal Order Part name ay Remarks î 9 Bearing race cover 1 10 | Upper bearing 1 11 | Lower bearin 1 ne Refer to ‘REMOVAL POINTS" 12 | Bearing race 2 6-109

Support the steering stem so that it may not fall down. Steering nut wrench: YU-33975/90890-01403 Lower bearing

+ Lower bearing © Use the floor chisel ©. CAUTION: Take care not to damage the steer- ing shaft thread.

+ Bearing race © Remove the bearing race using long rod © and the ham- mer. EC564000 INSPECTION Steering stem

+ Steering stem © Bend/damage — Replace. Bearing and bearing race

1. Wash the bearings and bearing

races with a solvent.

+ Bearing © + Bearing race Pitting/damage — Replace bearings and bearing races as a set. Install the bearing in the bear- ing races. Spin the bearings by hand. If the bearings hang up or are not smooth in their operation in the bearing races, replace bearings and bearing races as a set. 6-113 Cage de roulement

ASSEMBLY AND INSTALLATION

+ Lower bearing © NOTE: Apply the lithium soap base grease on the dust seal lip and bearing inner circumference.

+ Bearing race + Upper bearing © + Bearing race cover © NOTE: Apply the lithium soap base grease on the bearing and bearing race cover lip.

+ Steering ring nut ©

Refer to “STEERING HEAD

INSPECTION AND ADJUST-

MENT" section in the CHAP- TER3.

5. Check the steering stem by turn-

+ Front fork © + Upper bracket © + Main switch © + Front brake hose guide bracket @ NOTE:

+ Guide (speed sensor lead) D NOTE: After installing the guide as shown, pass the speed sensor lead through the guide.

the steering for smooth move- ment. If not, adjust the steering by loosening the steering ring nut little by little.

SWINGARM EC570000 SWINGARM [Sa] 53Nm (5.3m:kg, 38ft-Ib) [AT BON (8.0m kg, 58ft-1b) Extent of removal: © Swingarm removal CHAS\É Extent of removal Order Part name ay Remarks SWINGARM REMOVAL. Preparation for removal Hold the machine by placing the suitable ——————_— stand under the engine Support the machine securely so there is no danger of it falling over. Brake hose holder Refer to ‘FRONT BRAKE AND REAR BRAKE" Rear brake caliper section. Bolt (brake pedal) Shift the brake pedal backward. Drive chain 1 Drive chain support 1 2 | Lower chain tensioner 1 0 3 | Bolt (rear shock absorber-relay arm) 1 Hold the swingarm 4 | Bolt (connecting rod) 1 5 | Pivotshaft 1 6 | Swingarm 1 6-121

CHAS SWINGARM EC578000 SWINGARM DISASSEMBLY [S:[70 Nm (7.0 m : kg, 50 ft Ib) Extent of removal: @ Swingarm disassembly © Relay arm removal and disassembly @ Connecting rod removal and disassembly Extent of removal Order Part name Q'ty Remarks SWINGARM DISASSEMBLY à © Cap 2 Refer to “REMOVAL POINTS". Ÿ (] Relay arm 1 ©t E)] Connecting rod 1 (O] Collar 2 (O] Oil seal 2 (O] Thrust bearing 2 (] Bushing 2 à à 6] Oil seal 8 J | ©] Bearing 10 Refer to “REMOVAL POINTS". 6-125

+ Left cap © NOTE: Remove with a slotted-head screw- driver inserted under the mark @ on the left cap. EC573200 Bearing

+ Bearing © NOTE: — Remove the bearing by pressing its outer race. INSPECTION Wash the bearings, bushings and collars in a solvent. Swingarm

+ Bearing © + Bushing © Free play exists/unsmooth revolution/rust — Replace bearing and bushing as a set. Inspect: + Oil seal @ Damage — Replace.

+ Bearing © + Collar @ Free play exists/unsmooth revolution/rust — Replace bearing and collar as a set. Inspect: + Oil seal @ Damage — Replace.

+ Bearing © + Collar @ Free play exists/unsmooth revolution/rust — Replace bearing and collar as a set.

+ Oil seal @ Damage — Replace. EC575000

ASSEMBLY AND INSTALLATION

Bearing and oil seal

+ Bearing © + Oil seal @ To swingarm. NOTE: D ® D JG RP OVR

Apply the molybdenum disulfide grease on the bearing when install- ing. Install the bearing by pressing it on the side having the manufacture's marks or numbers. First install the outer and then the inner bearings to a specified depth from inside. installed depth of bearings: Outer @: Zero mm (Zero in) Inner E:

+ Bearing © + Oil seal @ To connecting rod.

+ Bushing © + Thrust bearing © + Oil seal @ + Collar @ To swingarm ®. NOTE: Bras oscillant

+ Collar @ + Washer @ To relay arm ©. NOTE: CHAS\É

+ Collar @ To connecting rod ©. NOTE:

+ Swingarm side play @ Free play exists — Replace thrust bearing. Swingarm up and down move- ment ® Unsmooth movement/binding/ rough spots — Grease or replace bearings, bushings and collars.

+ Bolt (connecting rod) D + Washer @ + _Nut (connecting rod) © NOTE:

+ Bolt (rear shock absorber- relay arm) © +_Nut (rear shock absorber-relay arm) ©

+ _Nut (relay arm) ©

56 Nm (5.6 , 40 ft - Ib) Extent of removal: ® Rear shock absorber removal @ Rear shock absorber disassembly Extent of removal Order Part name

Remarks Preparation for removal

REAR SHOCK ABSORBER REMOVAL

Hold the machine by placing the suitable Stand under the engine. Seat and side covers Silencer Drain the coolant. Catch tank breather hose Catch tank hose Aïr induction hose (air cut-off valve-air filter case) Cylnder head breather hose Battery Disconnect the starter relay coupler. Starter motor lead Support the machine securely so there is no danger of it falling over. Refer to “SEAT, FUEL TANK AND SIDE COVERS" section in the CHAPTER 3. Refer to “EXHAUST PIPE AND SILENCER" section inthe CHAPTER 3. Refer to *COOLANT REPLACEMENT" section in the

Disconnect at the catch tank side. Disconnect at the catch tank side. Disconnect at the air filter case side. Disconnect at the air filter case side. Refer to “BATTERY INSPECTION AND CHARGING" section in the CHAPTER 3. Disconnect at the starter relay side 6-141

REAR SHOCK ABSORBER CHAS Cyo 53 Nm (5.3 m Extent of removal Order Part name ay Remarks Locking tie 4 Tailight coupler 1 3 | CDI unit coupler 3 4 | Plastic band 1 5 | Clamp (air fiter joint) 1 Oniy loosening 6 | Reartrame 1 7 | Bolt (rear shock absorber-relay arm) 1 Hold the swingarm 2 8 | Boit (rear shock absorber-frame) 1 9 | Rear shock absorber 1 10 | Locknut 1 Only loosening. 11 | Adjuster 1 12 | Lower spring guide 1 13 | Upper spring guide 1 14 | Spring (rear shock absorber) 1 15 | Bearing 2 | Referto“REMOVAL POINTS". 6-145

AMORTISSEUR ARRIERE CHAS\É HANDLING NOTE À WARNING This rear shock absorber is pro- vided with a separate type tank filled with high-pressure nitrogen gas. To prevent the danger of explosion, read and understand the following information before handling the shock absorber. The manufacturer can not be held responsible for property damage or personal injury that may result from improper handling.

1. Never tamper or attempt to

disassemble the cylinder or the tank.

2. Never throw the rear shock

absorber into an open flame or other high heat. The rear Shock absorber may explode as a result of nitrogen gas expansion and/or damage to the hose.

3. Be careful not to damage any

part of the gas tank. À dam- aged gas tank will impair the damping performance or cause a malfunction.

4. Take care not to scratch the

contact surface of the piston rod with the cylinder; or oil could leak out.

5. Never attempt to remove the

plug at the bottom of the nitro- gen gas tank. It is very danger- ous to remove the plug.

6. When scrapping the rear

shock absorber, follow the instructions on disposal.

(YAMAHA DEALERS ONLY) Before disposing the rear shock absorber, be sure to extract the nitro- gen gas from valve @. Wear eye protection to prevent eye damage from escaping gas and/or metal chips. À WARNING To dispose of a damaged or worn- out rear shock absorber, take the unit to your Yamaha dealer for this disposal procedure. 6-149

+ Stopper ring (upper bearing) © NOTE: Press in the bearing while pressing its outer race and remove the stop- per ring.

+ Upper bearing © NOTE: Remove the bearing by pressing its outer race.

Damper rod @ Bends/damage — Replace rear shock absorber assem- bly. Shock absorber © Oil leaks — Replace rear shock absorber assembly. Gas leaks — Replace rear shock absorber assembly. Spring © Damage — Replace spring. Fatigue — Replace spring. Move spring up and down. + Spring guide @ Wear/damage — Replace spring guide. + Bearing © Free play exists/unsmooth revolution/rust — Replace. 6-151 CONTROLE Amortisseur arrière

+ Spring © + Upper spring guide © + Lower spring guide ®@

+ Spring length (installed) Refer to “REAR SHOCK

+ Locknut © Rear shock absorber CHAS\É

+ Rahmenheck © + Rahmenheck-Schraube (oben) ©

EC600000 ELECTRICAL NOTE: 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 requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage.

ÉLECTRICAL COMPONENTS AND WIRING DIAGRAM

EC611000 ELECTRICAL COMPONENTS @ Headiight @ Throtile position sensor @ Neutral switch @ Start switch © Multi-function display Starter relay @ Starter motor @ Main switch @ Engine stop switch © Fuse & AC magneto @ Speed sensor @ Clutch switch ® Starting circuit cut-off relay @ Rectifier/regulator @ Battery @ Diode @ CDl unit @ lgnition coil © Starter relay diode @ Tailight @ Spark plug

@ Tailight COLOR CODE @ Neutral switch Black @ Starter motor .Brown & AC magneto Chocolate ® Rectifier/regulator Dark green @ lgnition coil @ Spark plug @ Start switch @ Main switch & Speed sensor @ Battery *1:For USA *2:Except for USA

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. +1 Check fuse. No good >| Replace fuse and check wire harness. *2 Check battery. } No good Recharge or replac LE x Spark *3 Clean or replace spark Spark gap test plug. eu No spark Check entire ignition system for No good connection. »-| Repair or replace. (couplers, leads and ignition coil) LT x Ceno No gens JL & Ce] Ne good

[ Check ignition coil.

N d [ Check AC magneto. | Pickup coil ° go No good Repair or replace. [ Check neutral switch.

[ Replace CDI unit. ] “1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3. *2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3. #3 marked: Only when the ignition checker is used. NOTE: + Remove the following parts before inspection.

1. Disconnect the ignition coil from

2. Remove the ignition coil cap.

Connect the dynamic spark tester D (ignition checker ©) as shown. +_Ignition coil © + Spark plug © For USA and CDN Except for USA and CDN Kick the kickstarter crank. Check the ignition spark gap. Start engine, and increase spark gap until misfire occurs. (for USA and CDN only) SasGE Minimum spark gap:

IGNITION COIL CONNECTION

+ Couplers and leads connec- tion Rust/dust/looseness/short-cir- cuit — Repair or replace. Ignition coil and spark plug as they are fitted Push in the ignition coil until it closely contacts the spark plug hole in the cylinder head cover.

+ Engine stop switch conduct

ACCOPPIATORI, CAVI E BOBINA

+ Rubber part @ Tears/damage — Replace.

MAIN SWITCH INSPECTION

+ Main switch conduct Tester (+) lead — Red lead D Tester (-) lead — Brown lead @

IGNITION COIL INSPECTION

1. Remove the ignition coil cap.

+ Primary coil resistance Out of specification — Replace. Tester (+) lead — Orange lead (D Tester (-) lead — Black lead © Gi Primary coil Tester : selector resistance de position

+ Secondary coil resistance Out of specification — Replace. Tester (+) lead — Orange lead (D Tester (-) lead — Spark plug terminal ©

Tester Gi Secondary selector —] coil resistance ae position 4.6-6.8kQ at 20°C (68°F) | “2*1

+ Sealed portion of ignition coil + Spark plug terminal pin © + Threaded portion of spark plug

+ Pickup coil resistance Out of specification — Replace. Tester (+) lead — Red lead © Tester (-) lead — White lead © ol Pickup coil AE resistance on position 248-372Qat 20°c(68°F) | 2*100

NEUTRAL SWITCH INSPECTION

+ Neutral switch conduct Tester (+) lead — Sky blue lead © Tester (-) lead — Ground © Gi Sb [Ground] TeSter © © selector position NEUTRAL| ©1o Qx1 IN GEAR

SYSTEM OPERATION If the main switch is set to “ON”, the starter motor can only operate if at least one of the following conditions is met: + The transmission is in neutral (the neutral switch is closed). - The clutch lever is pulled to the handlebar (the clutch switch is closed). The starting circuit cut-off relay pre- vents the starter motor from operat- ing when neither of these conditions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the starter motor. When at least one of the above conditions has been met the starting circuit cut-off relay is closed and the engine can be started by pressing the start switch.

Battery Main fuse Main switch Starting circuit cut-off relay Start switch Diode Clutch switch Neutral switch Starter relay Starter motor

ELEC INSPECTION STEPS If the starter motor will not operate, use the following inspection steps. *1 Check fuse. No good

Replace fuse and check wire harness. No good

Check each coupler and wire Recharge or replace. No good

[ *3 Check main switch. Repair or replace. No good

[ Check starter motor operation. No good

[ Check starting circuit cut-off relay. No good

[ Check starter relay. No good

[ “4 Check neutral switch. No good

[ Check clutch switch. No good

[ Check start switch. No good “1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3. *2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3. *3 marked: Refer to “MAIN SWITCH INSPECTION” section. *4 marked: Refer to “NEUTRAL SWITCH INSPECTION” section. NOTE: Replace. Repair or replace. Replace. Replace. Replace. Replace. Replace. Replace. + Remove the following parts before inspection.

+ Use 12 V battery in this inspection. + Use the following special tools in this inspection. ZA Pocket tester: YU-3112-C/ 90890-03112

1. Connect the positive battery ter-

minal © and starter motor lead © with a jumper lead ©. Not operate —> Repair or replace the starter motor. À WARNING + A wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead, otherwise the jumper lead may burn. This check is likely to produce Sparks, therefore make sure nothing flammable is in the vicinity.

+ Starting circuit cut-off relay conduct Use 12 V battery.

+ Starter relay conduct Use 12 V battery. Battery (+) lead — Starter relay terminal © Battery (-) lead — Starter relay terminal © Tester (+) lead — Starter relay terminal © Tester (-) lead — Starter relay terminal @

+ Clutch switch continuity Tester (+) lead — Black lead D Tester (-) lead — Black lead © [mn] Tester o | BB selector

1. Remove the diode from wire har-

+ Start switch continuity Tester (+) lead — Black lead D Tester (-) lead —> Black lead @) Hi B B Tester Lo 1] © © selector position

Qx1 FREE No continuous while being pushed — Replace. Continuous while being freed — Replace.

Preparation for removal Exhaust pipe Refer to “EXHAUST PIPE AND SILENCER" section in the CHAPTER 3. 1 Starter motor 1

STARTER MOTOR DISASSEMBLY

@® | Starter motor front cover 1 @ | Washer (starter motor front cover) 1 © | Gasket 2 @ | Starter motor yoke 1 ® | Armature assembly 1 © | Starter motor rear cover 1 @ |Brush 2 © | Brush spring 2

+ Commutator Dirt — Clean with 600 grit sandpaper.

3. Measure: 3. Mesurer:

The mica must be undercut to ensure proper operation of the commutator.

+ Armature assembly resis- tances (commutator and insu- lation) Out of specification — Replace the starter motor. + Measure the armature assem- bly resistances with the pocket tester. | Pocket tester: YU-3112-C/ 90890-03112 [mn] Armature assembly: 0 1) Commutator resistance (D: 0.0189 - 0.0231 Q at 20 °C (68 °F) Insulation resistance

+ Brush length @ Out of specification — Replace the brushes as a set.

+ Brush spring force Out of specification — Replace the brush springs as

+ Brush spring © - Brush ©

+ Armature assembly D Install while holding down the brush using a thin screw driver. CAUTION: Be careful not to damage the brush during installation.

+ Gasket@ HE + Starter motor yoke © NOTE: + Install the starter motor yoke with its groove @ facing front cover.

• Align the match mark ®) on the starter motor yoke with the match mark © on the starter motor rear cover. MONTAGE

+ Gasket® + Circlip + Plain washer © + Washer (starter motor front cover) @ + Starter motor front cover @ NOTE:

EC680000 CHARGING SYSTEM Ec681001 INSPECTION STEPS If the battery is not charged, use the following inspection steps. *1 Check fuse. No good Replace fuse and check *2 Check battery. No good wire harness. Check each coupler and wire connection. No good Recharge or replace. ur: [ Check charging voltage.

»-| Repair or replace. eu No good [ Check AC magneto. Charging system is good. | Charging coil No good Replace.

[ Replace rectifier/regulator. “1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3. *2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3. NOTE:

Remove the following parts before inspection. Use the following special tool in this inspection. Ge] Pocket tester: YU-3112-C/ 90890-03112

1. Start the engine.

+ Charging voltage Out of specification — lf no failure is found in checking the source coil resistance, replace the rectifier/regulator. Tester (+) lead — Red lead © Tester (-) lead — Black lead © . Tester Gi Charging selector voltage position

at 5,000 r/min | PCV-20

+ Charging coil resistance Out of specification — Replace.

INSPECTION STEPS If the throttle position sensor will not operate, use the following inspection steps. Check entire ignition No good system for connection. LE x Throttle position No good Check throttle position sensor. pl sensor coil Throttle position Check CDI unit. —æ]| sensor input No good voltage NOTE: Repair or replace. Replace. Replace. Use the following special tools in this /| Pocket tester: | YU-3112-C/ 90890-03112 inspection.

SYSTEME DU CAPTEUR DE POSITION DE PAPILLON DES GAZ ELEC HANDLING NOTE CAUTION: Do not loosen the screw (throttle position sensor) (D except when changing the throttle position sen- sor due to failure because it will cause a drop in engine perfor- mance. EC624000

+ Throttle position sensor coil resistance Out of specification — Replace. Tester (+) lead — Blue lead © Tester (-) lead — Black lead ©

+ Throttle position sensor coil variable resistance Check that the resistance in increased as the throttle grip is moved from the full close posi- tion to the full open position. Out of specification — Replace. Tester (+) lead — Yellow lead © Tester (-) lead — Black lead © [mn Throttle ol position sensor coil variable resistance Tester selector position Full Full closed | opened Zero - 3kQ at 20°C (68 °F) a-6kal K2X1 at 20 °C (68 °F)

THROTTLE POSITION SENSOR

REPLACEMENT AND ADJUSTMENT

+ Throttle position sensor cou- pler + Carburetor

+ Screw (throttle position sensor) D + Throttle position sensor @ NE: Loosen the screw (throttle position sensor) using the T25 bit.

+ Throttle position sensor D + Screw (throttle position sensor) © NOTE: - Align the slot @ in the throttle posi- tion sensor with the projection E) on the carburetor. + Temporarily tighten the screw (throttle position sensor).

8. Start the engine.

+ Throttle position sensor out- put voltage

throttle position sensor and car- buretor.

11. Stop the engine.

+ Screw (throttle position sensor) © NOTE: Tighten the screw (throttle position sensor) using the T25 bit.

1. Disconnect the throttle position

2. Start the engine.

+ Throttle position sensor input voltage Out of specification — Replace the CDI unit. Tester (+) lead — Blue lead © Tester (-) lead — Black/Blue lead ©

LIGHTING SYSTEM INSPECTION STEPS Refer to the following flow chart when inspecting the lighting system for possible problems. No good Replace the bulb and/or Check the bulb and bulb socket. | bulb socket. No good Replace the taillight Check the taillight (LEDs). »| assembly. Checkthe AC magneto. _}———æ| Lighting col No good ZX x Check the entire lighting system Improperly connected >. Repair or replace. proper for connections. JL ©& [ Check the rectifier/regulator. | Out-put voltage No good NOTE: + Replace the bulb and/or bulb socket.

2. Connect two jumper leads @

from the battery terminals to the respective coupler terminal as shown. Battery (+) terminal — Blue lead © Battery (-) terminal — Black lead ©

+ LED (for proper operation) Does not light — Replace the taillight assembly. À WARNING + A wire thai used as a jumper lead must have at least the same capacity of the battery lead, oth- erwise the jumper lead may burn. This check is likely to produce Sparks, therefore, make sure no flammable gas or fluid is in the vicinity. arrière.

+ Lighting coil resistance Out of specification — Replace. Tester (+) lead — Yellow lead © Tester (-) lead — Ground © Gi Lighting coil AE resistance ee position

1. Connect the battery leads.

2. Start the engine.

3. Turn on the headiight and tail-

light by turning on the light switch.

+ Out-put voltage Out of specification — Replace rectifier/regulator. Tester (+) lead — Yellow lead © Tester (-) lead — Black lead ©

at 5,000 r/min | ACV-20 5.000 tr/min | ACV-20

SIGNALING SYSTEM INSPECTION STEPS If the speedometer will not operate, use the following inspection steps. *1 Check battery. ] No good »| Recharge or replace.

Check each coupler and wire No good Repair or replace. connection. > P P l Check multi-function display. Input voltage No good Replace wire harness. No good Replace multi-function OK Output voltage display. N d Check speed sensor. ( ° go >| Replace. “1 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3. NOTE: + Remove the following parts before inspection.

+ Use the following special tools in this inspection. ZA Pocket tester: YU-3112-C/ 90890-03112

1. Disconnect the multi-function

2. Setthe main switch to “ON”.

1. Disconnect the multi-function

2. Setthe main switch to “ON”.

4.5 V or more | DCV-20

CAUTION: Make sure that a short-circuit does not develop between the ter- minals because it may cause dam- age to electrical components.

2. Setthe main switch to “ON”.

USCITA SENSORE VELOCITÀ

+ Speed sensor output voltage Output voltage not correct — Replace the speed sensor. Measurement steps: + Elevate the front wheel and slowly rotate it. 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.