WR250F-2007 - Moto tout-terrain YAMAHA - Free user manual and instructions

USER MANUAL WR250F-2007 YAMAHA

WR250F(W) OWNER'S SERVICE MANUAL

1st Edition, August 2006 All rights reserved.

Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan

©2006 by Yamaha Motor Co. Ltd.

WR250F(W) MANUEL D'ATELIER DU PROPRIETAIRE ©2006 Yamaha Motor Co., Ltd. 1ère édition, août 2006 Tous droits réservés Toute reimpression ou utillisation sans la permission écrite de la Yamaha Motor Co., Ltd. est formellement interdite. Imprimé au Japon

“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 MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATIS- FACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECH- NIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFETY ENJOY THE CAPABILI- TIES AND THE RELIABILITY OF THIS MACHINE.

IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED 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

1. THIS MACHINE IS TO BE OPERATED BY AN EXPERI- ENCED RIDER ONLY. Do not attempt to operate this machine at maximum power until you are totally familiar with its characteris- tics.

2. THIS MACHINE IS DESIGNED TO BE RIDDEN 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

4. ALWAYS MAINTAIN YOUR MACHINE IN PROPER 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.

5. GASOLINE IS 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

GASOLINE CAN CAUSE INJURY.

If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gaso- line spills onto your skin or clothing, immediately wash skin areas with soap and

water, and change your clothes.

ONLY OPERATE THE MACHINE IN AN AREA 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.

PARK THE MACHINE CAREFULLY; TURN OFF 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. THE ENGINE, EXHAUST 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. PROPERLY SECURE THE 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.

Tenga especial cuidado en no tocar estas piezas o per- mitir que una prenda entre en contacto con las mismas durante la inspeccién o la reparaciôn del vehiculo. ASEGURE ADECUADA- MENTE EL VEHICULO AN- TES DE TRANSPORTARLO. Cuando transporte la moto- cicleta en otro vehiculo, asegürese siempre de colo- carla firmemente y en posi- cién vertical y que el grifo del combustible esté en la posicién “OFF”. En caso contrario, el combustible podria derramarse del car- burador o del depésito de combustible.

TO THE NEW OWNER 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.

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 — F..M. MACHINE WEIGHTS: —

Weights of machines without fuel The minimum weights for motocross machines are: for the class 125 cc …. minimum 88 kg (194 Ib) for the class 250 cc …. minimum 98 kg (216 Ib) for the class 500 cc …. minimum 102 kg (225 lb) In modifying your machine (e.g., for weight reduction), take note of the above limits of weight.

HOW TO USE THIS MANUAL EC081000

PARTICULARLY IMPORTANT INFORMATION AN 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.

A CAUTION indicates special pre- cautions that must be taken to avoid damage to the machine.

FINDING THE REQUIRED PAGE

1. This manual consists of seven chapters; “General information”,

“Specifications”, “Regular inspection and adjustments”, “Tuning”, “Engine”, “Chassis”

2. The table of contents is at the

beginning of the manual. Look over the general layout of the book before finding then required chapter and item. Bend the book at its edge, as shown, to find the required fore edge symbol mark and go to a page for required item and description.

COMMENT UTILISER CE MANUEL INFORMATIONS PARTICULIEREMENT IMPORTANTES Le symbole d’alerte de sécurité signifie ATTENTION! SOYEZ VIGILANT! VOTRE SECURITE EST EN JEU!

encuentra al inicio del manual. Consulte el formato general del manual para encontrar el capi- tulo y el item requerido. Doble el libro por el borde, tal y como se indica, para encontrar la marca del simbolo del canal que se requiere y dirigirse a una pägina correspondiente al item y descripcién pertinentes.

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.

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.

FORMAT DU MANUEL Dans ce manuel, toutes les procédures sont décrites pas à pas. Les informations ont été condensées pour fournir au mécani- cien un guide pratique et facile à lire, contenant des explica- tions claires pour toutes les procédures de démontage, réparation, remontage et vérification.

1 1 (o} @ A] @ a @® a

(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

lllustrated symbols © to @ are used to identify the specifications appear- ing in the text.

With engine mounted Special tool

Specified value, Service limit Resistance (Q), Voltage (V), Electric current (A)

lllustrated symbols @ to in the exploded diagrams indicate grade of lubricant and location of lubrication point.

@ Apply molybdenum disulfide oil

@ Apply lightweight lithium-soap base grease

@ Apply molybdenum disulfide grease

lllustrated symbols @ to @ in the exploded diagrams indicate where to apply a locking agent and where to install new parts.

® Apply locking agent (LOCTITE®) @ Use new one

Kickstarter crank Fuel tank

Coolant drain bolt Rear brake pedal Valve joint

Oil level check window Shift pedal

+ The machine you have purchased may differ slightly from those shown in the following.

+ Designs and specifications are subject to change with- out notice.

88P6606666660666066060000606060

Interruptor principal

[0] @ (e] ® (e] (Q © ® ® 1] © e ] ae & &

MACHINE IDENTIFICATION IDENTIFICATION DE LA MOTO 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.

VEHICLE IDENTIFICATION NUMBER The vehicle identification number © is stamped on the right of the steer- ing head pipe.

ENGINE SERIAL NUMBER The engine serial number © is stamped into the elevated part of the right-side of the engine.

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

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

head (right side) All electrical components

2. Use proper tools and cleaning

equipment. Refer to “SPECIAL TOOLS” section.

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.

EC132000 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 AU DEMONTAGE

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.

LOCK WASHERS/PLATES AND COTTER PINS

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.

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.

Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.

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.

CHECKING or connecTION | GEN ES VERIFICATION DES CONNEXIONS IN FO EC1Co001

CHECKING OF CONNECTION Dealing with stains, rust, moisture,

etc. on the connector.

1. Disconnect: + Connector

2. Dry each terminal with an air blower.

3. Connect and disconnect the con- nector two or three times.

4. Pull the lead to check that it will not come off.

5. If the terminal comes off, bend up the pin © and reinsert the ter- minal into the connector.

VERIFICATION DES CONNEXIONS Traitement des taches, de la rouille, de

The two connectors “click” together.

Les deux connecteurs s’encliquètent.

7. Check for continuity with a tester.

7. Vérifier la continuité à l’aide d’un multimètre.

+ lf there in no continuity, clean the terminals.

Be sure to perform the steps 1 to 7 listed above when checking the wire harness.

For a field remedy, use a contact revitalizer available on the market. Use the tester on the connector as shown.

+ S'il n'y a pas de continuité, nettoyer les bornes.

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

+ For U.S.A. and Canada, use part number starting with “YM-”, “YU-" or “ACC-". + For others, use part number starting with “90890-".

Tool name/How to use

YU-1135-A, 90890-01135

These tool is used to remove the crankshaft from either case.

LR YU-3097, 90890-01252 YU-1256

Dial gauge and stand Stand

These tools are used to check each part for runout or bent.

These tools are used to install the crankshaît

This tool is used when install the fork oil seal

Tool name/How to use

YS-1880-A, 90890-01701

This tool is used for when loosening or tightening the flywheel magneto securing nut.

Use this tool to inspect the coil resistance, output voltage and amperage.

YM-33277-A, 90890-03141

This tool is necessary for checking ignition timing.

This tool is needed to remove and install the valve assemblies.

YM-91042, 90890-04086

This tool is used to hold the clutch when removing or installing the clutch boss securing nut.

YM-4111, 90890-04111 YM-4116, 90890-04116

Valve guide remover Intake 4.0 mm (0.16 in) Exhaust 4.5 mm (0.18 in)

This tool is needed to remove and install the valve guide.

This tool is needed to install the valve guide.

This tool is needed to rebore the new valve guide.

This tool is used to remove the flywheel magneto.

Tool name/How to use

This instrument is necessary for checking the ignition system components.

This tool is used to check the air induction system.

This sealant (Bond) is used for crankcase mating surface, etc.

CONTROL FUNCTIONS MAIN SWITCH Functions of the respective switch positions are as follows:

The engine can be started only at this position.

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.

ENGINE STOP SWITCH 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.

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.

CONTROL FUNCTIONS 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.

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.

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

REAR BRAKE PEDAL The rear brake pedal © is located on the right side of the machine. Press down on the brake pedal to activate the rear brake.

PEDAL DE FRENO TRASERO El pedal de freno trasero (D se encuentra en el lado derecho de la mäquina. Pise el pedal para accionar el freno trasero.

CONTROL FUNCTIONS FONCTIONS DES COMMANDES 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.

COLD STARTER KNOB 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.

HOT STARTER LEVER 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.

CONTROL FUNCTIONS FONCTIONS DES COMMANDES GEN INFO | GS SIDESTAND This sidestand (© is used to support only the machine when standing or transporting it.

+ Never apply additional force to the sidestand.

+ Hold up the sidestand before starting out.

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.

SPARK PLUG WRENCH This spark plug wrench © is used to remove and install the spark plug.

NIPPLE WRENCH This nipple wrench @ is used to tighten the spoke.

JET NEEDLE PULL-UP TOOL The jet needle pull-up tool (D is used to pull the jet needle out of the carbu- retor.

® © ©© © ES = sr 190 ti 11 1688

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:

+ Two tripmeters (which shows the distance that has been traveled since it was last set to zero)

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

Change tripmeter digits (capable of

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)

BASIC MODE Changing speedometer display

1. Push the “SLCT2” button for 2 seconds or more to change the speedometer units.

The speedometer display will change in the following order: MPH = km/h — MPH.

© Wähitaste “SLCT 1”

MULTI-FUNCTION pispLay | GEN ES ECRAN MULTIFONCTION IN FO Setting the time

1. Push the “SLCT1” button for 2 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

1. Push the “SLCT2” button to change the tripmeter display. The display will change in the following order:

Odometer — TRIP À — TRIP B — TRIP À - Odometer.

NOTE: To reset the digits, select the tripme- ter involved and push the “RST” but- ton for 2 seconds or more.

MULTI-FUNCTION DISPLAY ECRAN MULTIFONCTION GEN INFO | GS CHANGEOVER TO BASIC MODE/ PASSAGE DU MODE DE BASE AU RACE MODE MODE COURSE 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

1. Push the “SLCT1” button and “SLCT2” button for 2 seconds or more at the same time to change over to RACE MODE.

Changeover to RACE MODE will put manual start measurement on standby causing #8 and Æto flash. (For manual start, refer to “Putting measurement on standby” in “RACE MODE".)

Returning to BASIC MODE from

It is possible to return to BASIC MODE with timer measurement at a stop.

Il est possible de revenir en MODE DE BASE avec la mesure du chronomètre arrêtée.

1. Check that the timer is not in

Starting measurement consists of the following two starts, either of which can be selected.

Starting measurement by the rider himself operating the button. (A long push on “SLCT2" button will put mea- surement on standby.)

Starting timer measurement auto- matically on detection of the move- ment of the machine. (A long push on “SLCT1” button will put measure- ment on standby.)

NOTE: ms Initial setting at changeover to RACE MODE will remain for manual start.

NB Le réglage initial lors du passage en MODE COURSE est conservé pour le démarrage manuel.

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.

If the machine is run while timer measurement is not made, no change will occur to the digit in trip- meter A (TRIP A).

Si le véhicule continue à rouler lorsque la mesure est désactivée, le chiffre du totalisateur journalier A (TRIP A) n’est pas modifié.

4. To resume the measurement, again push the “SLCT1” button and “SLCT2” button at the same time.

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 run by pushing the “SLCT1” but- ton for 2 seconds or more.

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 measurement.

4. To stop timer measurement, pushing the “SLCT1" button and the “SLCT2” button at the same time.

If the machine is run while timer measurement is not made, no change will occur to the digit in trip- meter A (TRIP A).

Si le véhicule continue à rouler lorsque la mesure est désactivée, le chiffre du totalisateur journalier A (TRIP A) n’est pas modifié.

5. To resume the measurement, again pushing the “SLCT1” but- ton and “SLCT2” button at the same time.

Resetting measurement data NOTE:

5. Pour reprendre la mesure, appuyer de nouveau sur les boutons “SLCTI” et “SLCT2” en même temps.

Remise à zéro des données de mesure

Resetting can be made in the follow- ing two manners.

Resetting is possible while timer measurement is made:

+ Reset tripmeter A.

Resetting is possible while timer measurement is not made:

Remise à zéro du totalisateur journalier

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.

MULTI-FUNCTION DISPLAY ECRAN MULTIFONCTION GEN INFO CS 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.

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.

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.

GEN MULTI-FUNCTION DISPLAY | INFO CS FUNCTION DIAGRAM NOTE: The following diagram illustrates the multi-function display regarding the direction and operation condition involved in each

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 "

© Puting measurement on standby SLOT

@ Measurement starts as the

@ Timer in operation

6 Cr) @ Correct Na TRIP A

@ Timer not in operation

CARBURANT GEN INFO FUEL FUEL Always use the recommended fuel as stated below. Also, be sure to use new gasoline.

CARBURANT Toujours utiliser le carburant recom- mandé, comme indiqué ci-après. Tou- jours utiliser de la nouvelle essence.

Recommended fuel: Premium unleaded gasoline only with a research octane number of 95 or higher.

Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine inter- nal parts such as valves, piston rings, and exhaust system, etc.

If knocking or pinging occurs, use a different brand of gasoline or higher octane grade.

En cas de cognement ou de cliquetis, uti- liser une autre marque d’essence ou une essence d’un indice d’octane supérieur.

+ For refueling, be sure to stop the engine and use enough care not to spill any fuel. Also be sure to avoid refueling close to a fire.

+ Refuel after the engine, exhaust pipe, etc. have cooled off.

Gasohol (For Canada)

There are two types of gasohol: gas- ohol containing ethanol and that con- taining methanol. Gasohol containing ethanol can be used if the ethanol content does not exceed 10%. Gaso- hol containing methanol is not rec- ommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems.

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.

MISE EN MARCHE ET RODAGE Ne jamais démarrer ou faire tourner le moteur dans un endroit clos. Les gaz d'échappement sont nocifs et peu- vent entraîner très rapidement un éva- nouissement, voire la mort. Toujours faire tourner le moteur dans un endroit bien ventilé.

CAUTION: The carburetor on this machine has a built-in accelerator pump. Therefore, when starting the engine, do not operate the throt- tle or the spark plug will foul. Unlike a two-stroke engine, this engine cannot be kick started when the throttle is open because the kickstarter may kick back. Also, if the throttle is open the air/fuel mixture may be too lean for the engine to start. Before starting the machine, perform the checks in the pre- operation check list.

AIR FILTER MAINTENANCE 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.)

STARTING À COLD ENGINE NOTE:

MISE EN MARCHE A FROID N.B.:

This model is equipped with an igni- tion circuit cut-off system. The engine can be started under the fol- lowing conditions.

+ When the transmission is in neu- tral.

+ When the clutch is disengaged with the transmission in any posi- tion. However, it is recommended to shift into neutral before starting the engine.

STARTING AND BREAK-IN MISE EN MARCHE ET RODAGE GEN INFO | GS

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- tral.

5. Fully open the cold starter knob

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.

Do not warm up the engine for extended periods of time.

No caliente el motor durante periodos largos.

STARTING AND BREAK-IN MISE EN MARCHE ET RODAGE GEN INFO | GS STARTING À WARM ENGINE 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

SImore than5°C | None | ON | OFF

Bture)= between | None | SM | OFF

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.

Observe the following break-in procedures during tial opera- tion to ensure optimum perfor- mance and avoid engine damage.

STARTING AND BREAK-IN MISE EN MARCHE ET RODAGE GEN INFO | GS BREAK-IN PROCEDURES

1. Before starting the engine, fill the fuel tank with the fuel.

2. Perform the pre-operation checks on the machine.

3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the engine stop switch. 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.

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.

L Combined seat and fuel tank

Silencer to rear frame

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

Installation of rear

— Link to rear shock absorber — Link to swingarm

Rear shock absorber to frame

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

Tightening of oil hose clamp

NOTE: Concerning the tightening torque, refer to “MAINTENANCE SPECIFICATIONS” sec- tion in the CHAPTER 2.

GEN INFO MEMO 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.

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 the engine and allow it to idle for several minutes.

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 humid or salt-air environment, coat all exposed metal surfaces with a film of light oil. Do not apply oil to rubber parts or the seat cover.

Make any necessary repairs before

the machine is stored.

WR250FW (USA, CDN, AUS, NZ)

5UME (USA) 5UMF (EUROPE)

5UMG (CDN, AUS, NZ, ZA)

Without oil and fuel 106.0 kg (233.7 lb)

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) 77.0 x 53.6 mm (3.03 x 2.11 in)

12.5:1 Kick and electric starter

Lubrication system: Dry sump Oil type or grade: Engine oil (For USA and CDN)

0 10 30 50 70 90 110 130 F YAMALUBE 4(10W/30) or SAE 10W-30

API service SG type or higher,

(Except for USA and CDN) SAE10W30, SAE10W40, SAE15W40, SAE20W40 or SAE20W50

API service SG type or higher,

JASO standard MA GENERAL SPECIFICATIONS |[SPEC| U"®

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

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)

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)

Timing chain type/No. of links Timing chain adjustment method

92RH2010-114M/114 Automatic

Valve, valve seat, valve guide:

Valve clearance (cold)

“D” margin thickness

Stem outside diameter

Guide inside diameter

—D Measuring point “H” Piston off-set

MAINTENANCE SPECIFICATIONS [SPEC| U*% ltem Standard Limit Piston pin bore inside diameter 16.002 - 16.013 mm 16.043 mm (0.6300 - 0.6304 in) (0.6316 in) Piston pin outside diameter 15.991 - 16.000 mm 15.971 mm (0.6296 - 0.6299 in) (0.6288 in) Piston rings: Top ring: ) {8 ET Type Barrel _—— Dimensions (B x T) 0.90 x 2.75 mm (0.04 x 0.11 in) | ---- End gap (installed) 0.15 - 0.25 mm 0.50 mm (0.006 - 0.010 in) (0.020 in) Side clearance (installed) 0.030 - 0.065 mm 0.12 mm (0.0012 - 0.0026 in) (0.005 in) 2nd ring: BAM 7 Type Taper _—— Dimensions (B x T) 0.80 x 2.75 mm (0.03 x 0.11 in) | ---- End gap (installed) 0.30 - 0.45 mm 0.80 mm (0.012 - 0.018 in) (0.031 in) Side clearance 0.020 - 0.055 mm 0.12 mm (0.0008 - 0.0022 in) (0.005 in) Oil ring: 1 + = Ë = t LT Dimensions (B x T) 1.50 x 2.25 mm (0.06 x 0.09 in) | ---- End gap (installed) 0.10 - 0.40 mm — (0.004 - 0.016 in) Crankshaft: Crank width “A” EE 55.95 - 56.00 mm _—— (2.203 - 2.205 in) Runout limit “C” S S 0.03 mm (0.0012 in) 0.05 mm (0.002 in) Big end side clearance “D” 0.15 - 0.45 mm 0.50 mm ok (0.0059 - 0.0177 in) (0.02 in) Small end free play “F” À 0.4 - 1.0 mm (0.02 - 0.04 in) 2.0 mm (0.08 in)

Engine idle speed Intake vacuum

Cooling: Radiator core size Width Height Thickness Radiator cap opening pressure Radiator capacity (total) Water pump

Tightening torque Part to be tightened Thread size | Q'ty

Nm m-kg ftlb Hot starter cable adjust bolt and locknut M6 >x 0.75 1 4 0.4 2.9 Air filter case M6 x 1.0 2 8 0.8 5.8 Air filter joint and air filter case M5 x 0.8 1 4 0.4 2.9 Exhaust pipe M8 x 1.25 2 20 2.0 14 Exhaust pipe protector M6 x 1.0 3 10 1.0 7.2 Silencer M8 x 1.25 2 30 3.0 22 Silencer clamp M8 x 1.25 1 16 1.6 11 Spark arrester M5 x 0.8 4 7 0.7 5.1 Silencer cap M5 x 0.8 6 5 0.5 3.6 Air induction pipe M6 x 1.0 1 10 1.0 7.2 Air induction pipe clamp M6 x 1.0 1 4 0.4 2.9 Air cut-off valve assembly and bracket M6 x 1.0 2 10 1.0 7.2 Bracket (air cut-off valve) and frame M6 x 1.0 2 7 0.7 5.1 Crankcase M6 x 1.0 11 12 1.2 8.7 Crankcase bearing stopper M6 x 1.0 11 10 1.0 7.2 Crankcase bearing stopper (crankshaft) M6 x 1.0 4 10 1.0 7.2 Left crankcase cover M6 x 1.0 8 10 1.0 7.2 Idle gear cover (starter motor) M6 x 1.0 3 10 1.0 7.2 Idle gear plate M6 x 1.0 2 10 1.0 7.2 Right crankcase cover M6 x 1.0 6 10 1.0 7.2 Clutch cover M6 x 1.0 7 10 1.0 7.2 Crankcase oil drain bolt M10 x 1.25 L 20 2.0 14 Drive chain sprocket cover M6 x 1.0 2 8 0.8 5.8 Kick shaîft ratchet wheel guide M6 x 1.0 2 12 1.2 8.7 Kickstarter crank M8 x 1.25 L 33 3.3 24 Primary drive gear M18 x 1.0 1 75 7.5 54 Clutch spring M6 x 1.0 5 10 1.0 7.2 Clutch boss M16 x 1.0 L 60 6.0 43 Clutch cable locknut M8 x 1.25 2 7 0.7 5.1 Push lever shaft M6 x 1.0 L 10 1.0 7.2 Drive sprocket M18 x 1.0 1 75 7.5 54 Drive axle oil seal stopper M6 x 1.0 2 10 1.0 7.2 Segment M8 x 1.25 1 30 3.0 22 Shift guide M6 x 1.0 2 10 1.0 7.2 Stopper lever M6 x 1.0 1 10 1.0 7.2 Shift pedal M6 x 1.0 1 12 1.2 8.7 NOTE:

A - marked portion shall be checked for torque tightening after break-in.

MAINTENANCE SPECIFICATIONS [SPEC| U*®

CHASSIS ltem Standard Limit Steering system: Steering bearing type Taper roller bearing _—— Front suspension: USA, CDN EUROPE AUS, NZ, ZA Front fork travel 300 mm (11.8 in) | — Fork spring free length 460 mm (18.1 in) | — Spring rate, STD K= 4.4 Nmm <— — (0.449 kg/mm, 25.1 lb/in) Optional spring/spacer Yes <— — Oil capacity 648 cm < = (22.8 Imp oz, 21.9 US oz) Oil level 132 mm (5.20 in) | — <Min. - Max.> 95 - 150 mm <— <—

(From top of outer tube with inner (8.74 - 5.91 in) tube and damper rod fully com- pressed without spring.)

1. First, tighten the steering ring nut approximately 38 Nm (3.8 m + kg, 27 ft + Ib) by using the steer- ing nut wrench, then loosen the steering ring nut one turn. 2. Retighten the steering ring nut 7 Nm (0.7 m + kg, 5.1 ft + Ib).

A - marked portion shall be checked for torque tightening after break-in.

MAINTENANCE SPECIFICATIONS [SPEC| U*% ELECTRICAL Item Standard Limit Ignition system: Advancer type Electrical _—— CDI:

Pickup coil resistance (color)

CDI unit-model/manufacturer

248 - 372 Q at 20 °C (68 °F) (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

0.08 - 0.10 Q at 20 °C (68 °F) 4.6 - 6.8 kQ at 20 °C (68 °F)

Charging system: System type Model (stator)/manufacturer Normal output Charging coil resistance (color)

Lighting coil resistance (color)

14 V/120 W at 5,000 r/min

0.288 - 0.432 Q at 20 °C (68 °F) (White — Ground)

0.224 - 0.336 Q at 20 °C (68 °F) (Yellow — Ground)

Rectifier/regulator: Regulator type Model/manufacture Regulated voltage (AC) Regulated voltage (DC) Rectifier capacity (AC) Rectifier capacity (DC)

Semiconductor short circuit SH770AA/SHINDENGEN 12.5 - 18.5 V

Starter motor: Model/manufacturer Operation voltage Output Armature coil resistance Brush overall length Brush quantity Spring force

DEFINITION OF UNITS SPEC EC220001

GENERAL TORQUE SPECIFICATIONS 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 A B SPECIFICATION (Nut) (Bolt) Nm mekg | ftelb 10 mm | 6mm 6 0.6 43 12mm | 8mm 15 1.5 11 14mm | 10mm 30 3.0 22 17mm | 12mm|) 55 5.5 40 19mm | 14mm 85 8.5 61 22mm | 16mm 130 13 94 EC230000 DEFINITION OF UNITS Unit Read Definition Measure mm millimeter 10% meter Length cm centimeter 102 meter Length kg kilogram 10$ gram Weight N Newton 1 kg x m/sec? Force Nm Newton meter Nxm Torque m + kg Meter kilogram m x kg Torque Pa Pascal N/m? Pressure N/mm Newton per millimeter | N/mm Spring rate L Liter — Volume or capacity cm° Cubic centimeter — Volume or capacity r/min Revolution per minute — Engine speed

CARACTERISTIQUES GENERALES SPEC CARACTERISTIQUES CARACTERISTIQUES GENERALES Nom du modèle:

WR250FW (USA, CDN, AUS, NZ) WR250F (EUROPE, ZA)

WR250FW (USA, CDN, AUS, NZ)

Modellcode: 5SUME (USA) 5UMF (EUROPE) 5UMG (CDN, AUS, NZ, ZA)

8,0 L (1,76 Imp gal, 2,11 US gal)

WR250FW (USA, CDN, AUS, NZ) WR250F (EUROPE, ZA)

@ Oil filter element @ Oil pump

Oil filter element Oil tank

CABLE ROUTING DIAGRAM SPEC EC240000 CABLE ROUTING DIAGRAM

@ 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

SPEC| UV CABLE ROUTING DIAGRAM

[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.

SPEC| UV CABLE ROUTING DIAGRAM

[ 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.

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.

CABLE ROUTING DIAGRAM SPEC U

@ 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 ΠPass 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.

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

Fit the cover securely.

Connect the wire hamess to the starter relay.

CABLE ROUTING DIAGRAM 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

[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.

Interruptor principal

SPEC| UV CABLE ROUTING DIAGRAM

[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

MAINTENANCE INTERVALS INSP ADJ Item

Every fifth (or 4,000 km)

MUFFLER Inspect and retighten Clean Replace

CRANK Inspect and clean

CARBURETOR Inspect, adjust and clean

AIR INDUCTION SYSTEM Inspect and clean

SPARK PLUG Inspect and clean Replace

DRIVE CHAIN Lubricate, slack, alignment Replace

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

OUTSIDE NUTS AND BOLTS Retighten

Refer to “STARTING AND BREAK-IN” section in the CHAPTER 1.

AIR FILTER Clean and lubricate Replace

Use foam air-filter oil or equivalent oil

FRAME Clean and inspect

FUEL TANK, COCK 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 fifth (or 4,000 km)

FRONT FORKS Inspect and adjust Replace oil Replace oil seal

SWINGARM Inspect, lube and retighten

Molybdenum disulfide grease

RELAY ARM, CONNECTING ROD Inspect, lube and retighten

STEÉERING HEAD Inspect free play and retighten Clean and lube Replace bearing

TIRE, WHEELS Inspect air pressure, wheel run-out, tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate

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

PROGRAMME D'ENTRETIEN CONTROLES ET REGLAGES PERIODIQUES PROGRAMME D'ENTRETIEN N.B.: Le programme suivant est destiné à servir de guide général pour l'entretien et le graissage. Garder à l'esprit que les intervalles d’entre- tien et de graissage varient en fonction des conditions atmosphériques, du terrain, de la situation géographique et de l’utilisation du véhicule. Si une question se pose quant aux fréquences de l’entretien ou de la lubrification du véhicule, demander conseil à son con-

PRE-OPERATION INSPECTION AND MAINTENANCE 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?

CONTROLE ET ENTRETIEN AVANT UTILISATION INSP ADJ

@ Seat removal © Side covers removal

@ Fuel tank removal @ Headlight removal

Preparation for removal

SEAT, FUEL TANK AND SIDE COVERS REMOVAL Tum the fuel cock to “OFF”. Disconnect the fuel hose.

Air scoop (left and right) Bolt (fuel tank)

Right side cover Headlight coupler Headiight

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

INSP ADJ MOTEUR MOTOR MOTEUR SELLE, RESERVOIR DE CARBURANT ET CACHES LATERAUX Organisation de la dépose:

REMOVAL POINTS Side cover 1. Remove:

+ Right side cover D NOTE:

POINTS DE DEPOSE Cache latéral 1. Déposer: + Boulon (cache latéral)

+ Cache latéral droit D N.B.:

Draw the side cover backward to remove it because its claw @ is inserted in the air filter case.

O Nm (1.0 m - kg, 7.2ft » Ib)

Extent of removal © Silencer removal @ Exhaust pipe removal

Extent of removal Order Part name ay Remarks

EXHAUST PIPE AND SILENCER REMOVAL Preparation for removal Right side cover Refer to “SEAT, FUEL TANK AND SIDE COVERS"

@T Bolt (silencer clamp) Only loosening. Bolt [silencer (front)] Bolt [silencer (rear)] Collar

+ _Nut (exhaust pipe) ©

First, temporarily install both nuts, then tighten either of these nuts to 13 Nm (1.3 m + kg, 9.4 ft + Ib) and the other to 20 Nm (2.0 me kg, 14ft + Ib) and then come back to the first one and retighten it to 20 Nm (2.0 m + kg, 14fte lb).

[220 Nin (2,0 m°kg, 14t-1b) ]

COOLANT LEVEL INSPECTION

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.

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. 2. Remove:

+ Radiator cap 3. Check:

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

À WARNING Do not remove the radiator cap when the engine is hot.

Take care so that coolant does not splash on painted surfaces. If it splashes, wash it away with water.

1. Place a container under the engine.

2. Remove: + Seat + Left side cover

3. Remove the catch tank hose from the catch tank and drain the tank of its coolant.

4. Remove: + _Coolant drain bolt © 5. Remove:

+ Radiator cap Drain the coolant completely. 6. Clean: + Cooling system Thoroughly flush the cooling system with clean tap water. 7. Install: + Copper washer + Coolant drain bolt

CA L10 Nm (1.0 m - kg, 7.2ft-1b)

Recommended coolant: High quality ethylene glycol anti-freeze con- taining anti-corrosion for aluminum engine

Coolant (D and water

(soft water) © mixing

+ 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.

+ 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.

9. Install: + Radiator cap Start the engine and warm it up for a several minutes. 10. Check: + Coolant level Coolant level low — Add cool- ant.

Liquide de refroidissement recommandé:

enane | INSP MOTEUR | ADJ E0355000 CONTROLE DU BOUCHON DE RADIATOR CAP INSPECTION RADIATEUR 1. Inspect: 1. Contrôler:

+ Seal (radiator cap) ©

+ Valve and valve seat © Crack/damage — Replace. Exist fur deposits @ — Clean

or replace. RADIATOR CAP OPENING PRESSURE INSPECTION 1. Attach: + Radiator cap tester (D and adapter ©

Radiator cap tester: YU-24460-01/

NOTE: Apply water on the radiator cap seal.

Radiator cap opening pressure: 110 kPa

+ Do not apply pressure more than specified pressure.

+ Radiator should be filled fully.

4. Inspect: + 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 1. Check: + Clutch lever free play @ Out of specification — Adjust.

Adaptateur du testeur de bouchon de radiateur: YU-33984/90890-01352

+ Loosen the locknuts D.

+ Adjust the free play by changing their tightening position.

+ _Tighten the locknuts.

Etapes du réglage du jeu du levier

+ Make minute adjustment on the lever side using the adjuster ©.

+ After adjustment, check proper operation of clutch lever.

THROTTLE CABLE ADJUSTMENT 1. Check: + Throttle grip free play @ Out of specification — Adjust.

+ Pour un réglage ponctuel, utiliser le dispositif de réglage © du côté du levier.

+ Après le réglage, contrôler le fonction- nement du levier d'embrayage.

Throttle grip free play @: 3-5mm

2. Adjust: + Throttle grip free play

+ Slide the adjuster cover.

+ Loosen the locknut ©.

* Tum the adjuster @ until the specified free play is obtained.

NOTE: Before adjusting the throttle cable free play, the engine idle speed should be adjusted.

À WARNING the throttle

After adjusting cable free play, start the engine and turn the handlebar to right and left and make sure that the engine idling does not run faster.

+ Cover (throttle cable cap)

- Tum the adjuster © until free play @ is within the specified limits.

+ _Tighten the locknut.

NOTE: After adjustment, check proper oper- ation of hot starter.

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.

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.

2. Unhook: + Binder @ 3. Remove:

- Air filter element © + Filter guide ©

4. Clean: + Air filter element Clean them with solvent.

After cleaning, remove the remaining solvent by squeezing the element.

Après nettoyage, éliminer l'excès de sol- vant en pressant l'élément.

+ Do not twist the element when squeezing the element.

+ Leaving too much of solvent in the element may result in poor starting.

5. Inspect: + Air filter element Damage — Replace. 6. Apply: + Foam-air-filter oil or equivalent oil to the element

5. Contrôler: + Elément de filtre à air Endommagement — Remplacer. 6. Appliquer: + Huile pour filtre à air mousse ou huile équivalente sur l'élément

+ Squeeze out the excess oil. Ele- ment should be wet but not drip- ping.

+ Wipe off the oil left on the element surface using a clean dry cloth. (Excess oil in the element may adversely affect engine starting.)

7. Monter: + Guide du filtre ©

* 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.

8. Install: - Air filter element ©

Align the projection @ on filter guide with the hole ) in air filter case.

Aligner la saillie @ du guide du filtre et le trou @) du boîtier de filtre à air.

9. Hook: 9. Accrocher: + Binder @ + Fixation © NOTE: NB:

Hook the binder © so that it contacts the filter guide projections @.

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.

+ 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.

(Except for USA and CDN)

API service SG type or higher, JASO standard

MA 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.

4. Install: + Oil tank cap

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 the engine.

Huile recommandée: SAE10W30, SAE10W40, SAE15W40, SAE20W40 ou SAE20W50 API Service de type SG

ENGINE IN S P MOTEUR ADJ Remove: 4. Déposer: + Engine guard © + Protège-carter (D + Bolt (oil tank) @) + Boulon (réservoir d'huile) © + Washer @ + Rondelle @ + Oil filler cap © + Capuchon de l’orifice de remplis- + Oil tank drain bolt sage d'huile @ + Crankcase oil drain bolt © + Boulon de vidange du réservoir + Oil filter element drain bolt @ d'huile @

Drain the crankcase and oil tank of its oil.

Remove: + Oil hose clamp © + Bolt (oil hose) + Oil hose © + Oil strainer © Inspect: + Oil strainer Clogged — Blow. If the oil filter is to be replaced during this oil change, remove the following parts and reinstall them.

Boulon de vidange d’huile du carter moteur @)

+ Remove the oil filter element cover ® and oil filter element ©.

+ Check the O-rings @, if cracked or damaged, replace them with a new one.

+ Install the oil filter element and oil filter element cover.

Etapes de remplacement:

Oil filter element cover: 10 Nm

+ 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 warm it up.

+ Tumn the throttle stop screw © until the specified engine idling speed.

NOTE: Using a digital engine tachometer for idle speed adjustment, detect the engine idling speed by bring- ing the sensing element © of the engine tachometer close to the ignition coil ©.

To increase idle speed — Turn the throttle stop screw © in @.

To decrease idle speed — Turn the throttle stop screw

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 con- cerning servicing are requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. lt may lead to servicing trouble and mechanical damage.

+ 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.

1. Remove: + Seat + Fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. 2. Drain: + Coolant Refer to “COOLANT REPLACEMENT" section. 3. Remove: + Right radiator Refer to “RADIATOR" section in the CHAPTER 5.

+ Carburetor Refer to “CARBURETOR” section in the CHAPTER 5.

Upper engine bracket Cylinder head cover

Refer to “CAMSHAFTS” sec- tion in the CHAPTER 5.

4. Remove: + Timing mark accessing screw

+ 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: ms 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.

+ Measure the valve clearance © using a feeler gauge ©. NOTE:

Record the measured reading if the clearance is incorrect.

Etapes du contrôle: + Tourner le vilebrequin dans le sens inverse des aiguilles d’une montre à l’aide d’une clé.

+ Remove the camshaît (intake and exhaust). Refer to “CAMSHAFTS” section in the CHAPTER 5.

+ Remove the valve lifters © and the pads ©.

+ 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

Pads are available in 0.05 mm increments

NOTE: The thickness @ of each pad is indicated in hundredths of millime- ters on the pad upper surface.

+ Round off the last digit of the installed pad number to the near- est increment.

Last digit of pad Rounded value 0,1or2 0 4,50r6 5

EXAMPLE: installed pad number = 148 Rounded off value = 150

EXEMPLE: Numéro de la plaquette montée = 148 Valeur arrondie = 150

Pads can only be selected in 0.05 mm increments.

Les plaquettes ne peuvent être sélec- tionnées que par pas de 0,05 mm.

+ Locate the rounded-off value and the measured valve clear- ance in the chart “PAD SELEC- TION TABLE”. The field where these two coordinates intersect shows the new pad number to use.

+ Rechercher la valeur arrondie et le jeu aux soupapes mesuré dans le tableau “TABLEAU DE SELEC- TION DES PLAQUETTES”. La case où ces deux coordonnées se coupent indique le nouveau numéro de plaquette à utiliser.

Use the new pad number only as a guide when verifying the valve clearance adjustment.

N'utiliser ce nouveau numéro de pla- quette qu'à titre de guide pour le con- trôle du réglage du jeu aux soupapes.

+ Install the new pads © and the valve lifters @.

+ Monter les nouvelles plaquettes @ et les poussoirs de soupapes ©.

+ Apply the engine oil on the valve lifters.

Apply the molybdenum disulfide oil on the valve stem ends. Valve lifter must turn smoothly when rotated with a finger.

Be careful to reinstall valve lifters and pads in their original place.

Install the camshafts (exhaust and intake). Refer to “CAM- SHAFTS” section in the CHAP- TER5.

+ Appliquer de l'huile moteur sur les poussoirs de soupapes.

INSP ADJ MEMO INSP SE LC |

SPARK ARRESTER CLEANING (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.

NETTOYAGE DU PARE- ETINCELLES (USA)

First tighten the two screws (@) located horizontally apart, and then tighten the others.

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.

1. Remove: + Brake master cylinder cap + Diaphragm + _ Reservoir float (front brake) + Protector (rear brake)

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.

If bleeding is difficult, it may be necessary to let the brake fluid sys- tem stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the sys- tem have disappeared.

Si la purge est difficile, il peut être nécessaire de laisser le circuit du liquide de frein se stabiliser pendant quelques heures. Répéter la procédure de purge quand les petites bulles d’air ont disparu du circuit.

j. Add brake fluid to the level line on the reservoir.

À WARNING Check the operation of the brake after bleeding the brake system.

3. Install: + Protector (rear brake) + _ Reservoir float (front brake) + Diaphragm + Brake master cylinder cap

2. Remove: + Brake lever cover 3. Adjust:

- Turn the adjusting bolt @ until the lever position @ is within specified position.

Be sure to tighten the locknut, as it will cause poor brake per- formance.

ATTENTION: Veiller à bien serrer le contre- écrou pour éviter toute baisse d'efficacité du freinage.

4. Install: + Brake lever cover

Pedal height adjustment steps:

+ Loosen the locknut ©.

- Tum the adjusting nut © until the pedal height @ is within specified height.

+ _Tighten the locknut.

+ 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.

FRONT BRAKE PAD INSPECTION AND REPLACEMENT 1. Inspect: + Brake pad thickness @ Out of specification —

Brake pad thickness: 4.4 mm (0.17 in) <Limit>:

Brake pad replacement steps: + Remove the pad pin plug ©.

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.

+ _Tighten the bleed screw.

+ Install the brake pads @ and pad pin.

+ Monter les plaquettes de frein @ et la goupille de plaquette.

+ Install the brake pads with their projections @ into the brake caliper recesses D.

+ Temporarily tighten the pad pin at this point.

+ Monter les plaquettes de frein en insérant leurs ergots @ dans les gorges des étriers de freins ®).

+ A ce stade, serrer provisoirement la goupille de plaquette.

+ Install the brake caliper ®@ and tighten the pad pin @.

+_ Install the pad pin plug ©.

3. Inspect: + Brake fluid level

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

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

Brake pad thickness: 6.4 mm (0.25 in)

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 CHAPTER 6.

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.

Do not reuse the drained brake fluid.

+ _Tighten the bleed screw.

+_ Install the brake pad @ and pad pin ©. NOTE:

+ Monter les plaquettes de frein @ et la goupille de plaquette @.

+ Install the brake pads with their projections @ into the brake caliper recesses D. Temporarily tighten the pad pin at this point.

+ Monter les plaquettes de frein en insérant leurs ergots @ dans les gorges des étriers de freins ®).

À ce stade, serrer provisoirement la goupille de plaquette.

Install the brake caliper @ and rear wheel @.

Refer to “FRONT WHEEL AND REAR WHEEL'" section in the CHAPTER 6.

+ _Tighten the pad pin @.

+ Install the pad pin plug @ and protector @.

1. Place the brake master cylinder so that its top is in a horizontal position.

+ Brake fluid level Fluid at lower level — Fill up. © Lower level

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 1. Inspect: + Sprocket teeth @ Excessive wear — Replace.

Replace the drive sprocket, rear wheel sprocket and drive chain as a set.

Drive chain length (15 link

<Limit>: 239.3 mm (9.42 in)

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.

2. Remove: - Drive chain © NOTE:

Remove the drive chain using a drive chain cutter ©.

3. Clean: + Drive chain Brush off as much dirt as pos- sible. Then clean the drive chain using the chain cleaner.

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.

+ Side plate © Damage/wear — Replace the drive chain.

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

CONTROLE DE LA CHAINE DE TRANSMISSION 1. Mesurer: + Longueur de la chaîne de trans- mission (15 maillons) @ Hors spécifications —> Remplacer.

CHASSIS INSP CHASSIS ADJ 6. Install: 6. Monter: + 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.

7. Install: + 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.

8. Lubricate: + Drive chain

DRIVE CHAIN SLACK ADJUSTMENT 1. Elevate the rear wheel by plac- ing the suitable stand under the engine. 2. Check: + Drive chain slack @ Above the seal guard installa- tion bolt. Out of specification — Adjust.

Before checking and/or adjusting, rotate the rear wheel through several revolutions and check the slack sev- eral times to find the tightest point. Check and/or adjust the drive chain slack with the rear wheel in this “tight chain” position.

Drive chain slack adjustment

+ Loosen the axle nut © and locknuts ©.

+ Adjust the drive chain slack by turning the adjusters ©.

To tighten — Turn the adjuster © counterclockwise.

To loosen — Turn the adjuster © clockwise and push wheel forward.

+ Tum each adjuster exactly the same amount to maintain cor- rect axle alignment. (There are marks @ on each side of the drive chain puller alignment.)

NOTE: Turn the adjuster so that the drive chain is in line with the sprocket, as viewed from the rear.

Too small drive chain slack will overload the engine and other vital parts; keep the slack the specified

+ _Tighten the axle nut while push- ing down the drive chain.

(12.5 m + kg, 90 ft Ib)

+ _Tighten the locknuts.

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

FRONT FORK OIL SEAL AND DUST SEAL CLEANING 1. Remove:

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

2. Clean: + 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.

FRONT FORK INTERNAL PRESSURE RELIEVING NOTE:

If the front fork initial movement feels stiff during a run, relieve the front fork internal pressure.

Si le mouvement initial de la fourche paraît dur, réduire la pression interne de la fourche.

1. Elevate the front wheel by plac- ing a suitable stand under the engine.

2. Remove the air bleed screw @© and release the internal pressure from the front fork.

FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT 1. Adjust: + 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:

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

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.

REGLAGE DE LA FORCE D’AMORTISSEMENT A LA DETENTE DE LA FOURCHE 1. Régler:

1. Remove: + Rubber cap 2. Adjust: + 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:

: 20 clicks out Fully turned in : ue (from maximum position on position)

+ STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position.

+ POSITION STANDARD: Position à laquelle le dispositif de réglage est dévissé du nombre de tours

* 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.

3. Install: + Rubber cap

Damage/oil leakage — Replace. REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1. Elevate the rear wheel by plac- ing the suitable stand under the

+ Rear frame 3. Loosen:

+ Locknut © 4. Adjust:

+ 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)

Extent of Standard length adjustment 249 mm (9.80 in) * 248.5 mm 238.5 - (9.78 in) 258.5 mm #*245.0 mm |(9.39 - 10.18 in) (2.65 in)

** 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.

Never attempt to turn the adjuster beyond the maximum or mini- mum setting.

5. Tighten: + Locknut 6. Install: + _Rear frame (upper)

+ _Rear frame (lower)

REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1. Adjust: + 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:

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.)

REGLAGE DE LA FORCE D’AMORTISSEMENT A LA DETENTE DE L’AMORTISSEUR ARRIERE 1. Régler: + Force détente En tournant réglage ©.

CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged.

1. Adjust: + 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:

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.)

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

CHASSIS INSP cHÂssis | ADJ EC264000 REGLAGE DE LA FORCE REAR SHOCK ABSORBER HIGH D'AMORTISSEMENT À LA COMPRESSION DAMPING FORCE COMPRESSION HAUTE DE ADJUSTMENT L’AMORTISSEUR ARRIERE 1. Adjust: : : 1. Régler: . 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.

1. Measure: -_ Tire pressure Out of specification — Adjust.

Standard tire pressure: 100 kPa

(1.0 kgf/cm?, 15 psi)

NOTE: + Check the tire while it is cold. 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.

SPOKES INSPECTION AND TIGHTENING 1. Inspect: + Spokes D Bend/damage — Replace. Loose spoke — Retighten.

2. Tighten: + Spokes NOTE:

Be sure to retighten these spokes before and after break-in. After a practice check spokes for looseness.

EC36T000 WHEEL INSPECTION

1. Inspect: + Wheel runout Elevate the wheel and turn it. Abnormal runout — Replace.

2. Inspect: + Bearing free play Exist play — Replace.

STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by plac- ing a suitable stand under the engine. 2. Check: Steering stem Grasp the bottom of the forks and gently rock the fork assembly back and forth. Free play — Adjust steering head. 3. Check: + Steering smooth action Tum the handlebar lock to lock. Unsmooth action — Adjust steering ring nut. 4. Adjust: + Steering ring nut

Steering ring nut adjustment

+ Remove the headlight.

+ Remove the handiebar and upper bracket.

+ Loosen the steering ring nut © using the steering nut wrench

+ 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):

ÇA Hakenschlüssel: | YU-33975/90890-01403

NV Ecrou de blocage de la &y| direction (serrage final):

+ Check the steering stem by turning it lock to lock. If there is any binding, remove the steer- ing stem assembly and inspect the steering bearings.

Install the washer ©), collar ©, upper bracket @, washer ©, steering stem nut ©, handlebar @, handiebar upper holder @ and headlight @.

NOTE: + Install the collar © with the larger inside diameter facing downwards.

The handiebar upper holder should be installed with the punched mark @) forward. Install the handiebar so that the marks ® are in place on both sides.

Install the handlebar so that the projection © of the handlebar upper holder is positioned at the mark on the handiebar as shown. Insert the end of the fuel breather hose @ into the hole in the steering stem.

First tighten the bolts on the front side of the handlebar upper holder, and then tighten the bolts on the rear side.

(2.1 me kg, 15ft + Ib) Headlight (left and right):

(0,7 m + kg, 5,1 ft + Ib)

CHASSIS CHASSIS INSP ADJ LUBRICATION To ensure smooth operation of all components, lubricate your machine during setup, after break-in, and after every ride. @ All control cable © Clutch lever pivot @ Shift pedal pivot @ Footrest pivot © Throttle-to-handlebar contact ® Drive chain @ Tube guide cable winding portion Throttle cable end Clutch cable end @ Hot starter cable end a (El (el

Use Yamaha cable lube or equivalent on these areas.

Use SAE 10W-30 motor oil or suitable chain lubricants.

Lubricate the following areas with high quality, lightweight lithium-soap base grease.

Wipe off any excess grease, and avoid getting grease on the brake discs.

+ Spark plug 2. Inspect:

+ 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.

3. Measure: + Plug gap @ Use a wire gauge or thickness gauge. Out of specification — Regap.

Spark plug gap: 0.7 - 0.8 mm

4. Clean the plug with a spark plug cleaner if necessary.

+ Before installing a spark plug, clean the gasket surface and plug surface.

+ Finger-tighten @ the spark plug before torquing to specification ®).

+ Avant de monter une bougie, nettoyer la surface du joint et la surface de la bougie.

+ Serrer la bougie à la main @ avant de la serrer au couple correct ®).

IGNITION TIMING CHECK 1. Remove: + Timing mark accessing screw

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

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-

Charge batteries in a well-venti-

Keep batteries away from fire,

sparks or open flames (e.g.

welding equipment, lighted ciga-

TROLYTE OUT OF REACH OF CHILDREN.

Avoid bodily contact with elec-

trolyte as it can cause severe

burns or permanent eye injury.

FIRST AID IN CASE OF BODILY CONTACT:

+ 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.

2. Disconnect: + Battery leads (from the battery terminals)

First, disconnect the negative bat- tery lead ®, and then the positive battery lead ©.

3. Remove: + Battery band + Battery

Measurement steps: + Connect a pocket tester (D to the battery terminals.

Etapes de la mesure: + Raccorder un multimètre @ aux bornes de la batterie.

Tester positive probe — battery positive terminal

Tester negative probe — battery negative terminal

Sonde positive du multimètre — borne positive de la batterie Sonde négative de la batterie — borne négative de la batterie

NOTE: + The charge state of an MF bat- tery can be checked by measur- ing its open-circuit voltage (i.e., the voltage when the positive terminal is disconnected).

No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.

NB. + On peut contrôler l’état de charge d’une batterie sans entretien (MF) en mesurant la tension entre ses bornes en circuit ouvert (après avoir déconnecté la borne posi- tive).

Inutile de recharger tant que la ten- sion en circuit ouvert est supé- rieure ou égale à 12,8 V.

Check the charge of the battery, as shown in the charts and the following example.

Open-circuit voltage = 12.0 V Charging time = 6.5 hours Charge of the battery = 20 - 30%

Contrôler la charge de la batterie, conformément aux diagrammes et à l'exemple suivant.

Exemple Tension en cireuit ouvert = 12,0 V Temps de charge = 6,5 heures Charge de la batterie = 20 à 30 %

[A] Relationship between the open-circuit voltage and the charging time at 20 °C (68 °F) (These values vary with the temperature, the condition of the battery plates, and the electrolyte level.)

[B] Open-circuit voltage

[©] Charging time (hours)

[E] Charging condition of the battery

ELECTRICAL INSP PARTIE ELECTRIQUE ADJ 5. Charge: 5. Charger: + Battery + batterie

{refer to the appropriate charg- ing method illustration)

À WARNING Do not quick charge a battery.

Never remove the MF battery sealing caps.

Do not use a high-rate battery charger since it forces a high- amperage current into the bat- tery quickly and can cause bat- tery overheating and battery plate damage.

If it is impossible to regulate the charging current on the battery charger, be careful not to over- charge the battery.

When charging a battery, be sure to remove it from the machine. (If charging has to be done with the battery mounted on the machine, disconnect the negative battery lead from the battery terminal.)

To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the bat- tery.

Before removing the battery charger lead clips from the bat- tery terminals, be sure to turn off the battery charger.

Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks.

If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnect- ing it. Hot batteries can explode! As shown in the following illus- tration, the open-circuit voltage of an MF battery stabilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage.

(se reporter à l'illustration de la méthode de charge appropriée)

Como se muestra en la ilustra- ciôn siguiente, el voltaje en ci cuito abierto de una bateria s mantenimiento se estabiliza unos 30 minutos después de que se haya completado la carga. Por tanto, cuando la carga haya finalizado espere 30 minutos antes de medir el voltaje en circuito abierto.

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.

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: O,

Is the amperage higher than the standard charg- NO ing amperage written on the battery?

Adjust the charging voltage to

20 - 25 V. El Adjust the voltage to obtain YES Monitor the amperage for the standard charging amper- 3 - 5 minutes. Is the standard age. charging amperage exceeded?

NO 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.

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.

NO Charge the battery until the charging voltage reaches 15 V.

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.

Constant amperage chargers are not suitable for charging

ELECTRICAL INSP PARTIE ELECTRIQUE ADJ 6. Install: 6. Monter: + Battery + Batterie + Battery band + Sangle de la batterie 7. Connect: 7. Connecter:

+ Battery leads (to the battery terminals) CAUTION:

First, connect the positive lead (D, then the negative lead ©.

+ Câbles de la batterie (aux bornes de la batterie)

8. Check: + Battery terminals Dirt — Clean with a wire

brush. Loose connection — Connect properly. 9. Lubricate: + Battery terminal =: Recommended lubricant: Lithium soap base grease 10. Install: + Seat BATTERY REPLACEMENT 1. Replace: + 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.

FUSE INSPECTION CAUTION:

To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse.

1. Remove: + Seat + Fuse cover

+ Remove the fuse D.

+ Connect the pocket tester to the fuse and check the continuity.

Set the pocket tester selector to “Q x 1”.

Pocket tester: YU-3112-C/

+ lf the pocket tester indicates

+ Set the main switch to “OFF”.

+ Install a new fuse of the correct amperage.

+ Set on the switches to verify if the electrical circuit is opera- tional.

+ lf the fuse immediately blows again, check the electrical cir- cuit.

Items Amperage Q'ty rating Main fuse 10A 1

Eléments | Ampérage | Qté Fusible 10 A 1 principal

À WARNING Never use a fuse with an amper- age rating other than that speci- fied. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the starting and ignition systems to malfunction and could possibly cause a fire.

À AVERTISSEMENT Ne jamais utiliser un fusible d’ampé- rage différent de celui spécifié. Toute improvisation ou la mise en place d’un fusible d’un ampérage incorrect ris- que de gravement endommager le cir- cuit électrique, de provoquer un mauvais fonctionnement des systèmes de démarrage et d'allumage, voire de provoquer un incendie.

4. Install: + Fuse cover + Seat

Remove the headlight bulb holder by pushing it in and turning it counter- clockwise.

Déposer le porte-ampoule de phare en appuyant dessus et en le tournant dans le sens inverse des aiguilles d’une montre.

4. Remove: + 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.

5. Install: + Headlight bulb

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.

6. Install: + Headlight bulb holder 7. Install:

+ Headlight bulb holder cover 8. Install: + Headlight

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.

+ 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.

MISE AU POINT MOTEUR Réglage du carburateur + Le mélange air/catburant varie en fonction des conditions atmosphéri- ques. 11 est donc nécessaire de tenir compte de la pression de l'air, de la température ambiante, de l'humidité, etc., pour le réglage du carburateur. Effectuer un essai de conduite pour contrôler les performances du moteur (par ex. la réponse du moteur) et l’état des bougies (décoloration ou encrasse- ment). Utiliser les valeurs obtenues pour effectuer le meilleur réglage pos- sible du carburateur.

+ No obture nunca la toma de admisién del carburador. Pue- den salir llamas de la tuberia si el motor efectüa un autoencen- dido mientras se est poniendo en marcha. Cuando est des- montado el carburador puede salir gasolina por la tobera de la bomba de aceleracién.

REGLAGE SETTING TUN CAUTION: + The carburetor is extremely sen- sitive to foreign matter (dirt, sand, water, etc.). During instal- lation, do not allow foreign mat- ter to get into the carburetor. Always handle the carburetor and its components carefully. Even slight scratches, bends or damage to carburetor parts may prevent the carburetor from functioning correctly. Carefully perform all servicing with the appropriate tools and without applying excessive force.

When the engine is stopped or when riding at no load, do not open and close the throttle unnecessarily. Otherwise, too much fuel may be discharged, starting may become difficult or the engine may not run well. After installing the carburetor, check that the throttle operates correctly and opens and closes smoothly.

the richness or leanness of the air/ fuel mixture. Therefore, refer to the above table for mixture settings. That is: + Higher temperature expands the air with its resultant reduced den- sity. Higher humidity reduces the amount of oxygen in the air by so much of the water vapor in the same air. Lower atmospheric pressure (at a high altitude) reduces the density of the air.

A Effects of the setting parts on the throttle valve opening

© Throttle valve cutaway

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.

The richness of the air-fuel mixture at full throttle can be set by changing the main jet ©.

If the air-fuel mixture is too rich or too lean, the engine power will drop, resulting in poor acceleration.

Effects of changing the main jet (reference)

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)

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 The engine breathes hard and will not pick up speed quickly. Step down the jet needle clip by one groove and move up the needle to enrich the mixture.

Effects of changing the jet needle groove position (reference)

SETTING REGLAGE TUN Jet needle adjustment The jet needle is adjusted by chang- ing it.

* GDEPR Supplied jet needle

GDEPS Aiguille fournie * GDEPR

* 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

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

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).

* AUS, NZ, CDN et ZA Les sections coniques de toutes les aiguilles ont les mêmes positions de départ, mais les diamètres des parties droites peuvent être différents.

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

1. Le moteur crachote lors de l’ouver- ture rapide des gaz. Sélectionner un gicleur de fuite de calibre inférieur au calibre standard afin d'enrichir le mélange. <Exemple> N°70 — N°65

2. Le moteur manque de souplesse lors de l'ouverture rapide des gaz. Sélectionner un gicleur de fuite de calibre supérieur au calibre standard afin d’appauvrir le mélange. <Exemple> N°70 — N°85

Standard leak jet #70

Relationship with throttle opening The flow of the fuel through the car- buretor main system is controlled by the main jet and then, it is further reg- ulated by the area between the main nozzle and the jet needle.

The fuel flow relates to the diameter of the straight portion of the jet nee- dle with the throttle 1/8 to 1/4 open and relates to the clip position with the throttle 1/8 to 3/4 open. Therefore, the fuel flow is balanced at each stage of throttle opening by the combination of the jet needle straight portion diameter and clip position.

Rich T | #180 |4MX-14943-43]

(STD) J | #42 |amx-14948-04

Lean Ÿ| #40 |4mx-14948-03]

Netneedie À | #EPN |SUM-14916-BN Rich Ÿ | #EPP |5UM-14916-BP|

TUN SETTING Examples of carburetor setting depending on symptom

At full throttle Hard breathing Shearing noise Whitish spark plug Ÿ

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 Ÿ

Decrease main jet calibration no. (Gradually)

Discoloration of spark plug —

If tan color, it is in good condition. If cannot be corrected:

Fuel overflow from carburetor

Lower jet needle clip position. (1 groove down)

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)

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.

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.

TUN REGLAGE Exemples de réglages du carburateur en fonction des symptômes Symptômes Réglages Contrôles A pleine ouverture des gaz Augmenter (progressivement) le calibre du | Décoloration de la bougie —> Crachotements gicleur principal Brun clair = bon état. Bruit de frottement de pièces Si correction impossible: métalliques Siège de pointeau bouché

Rainure Rainure Rainure Rainure Rainure 5 74 Rainure 67 Rainure 7

CHASSIS Selection of the secondary reduction ratio (Sprocket)

Number of rear wheel sprocket teeth Number of drive sprocket teeth

Secondary reduction = ratio

Standard secondary reduction ratio

<Requirement for selection of sec- ondary gear reduction ratio> + Itis generally said that the second- ary gear ratio should be reduced for a longer straight portion of a speed course and should be increased for a course with many corners. Actually, however, as the speed depends on the ground con- dition of the day of the ride, be sure to run through the circuit to set the machine suitable for the entire course. In actuality, it is very difficult to achieve settings suitable for the entire course and some settings may be sacrificed. Thus, the set- tings should be matched to the portion of the course that has the greatest effect on the ride result. In such a case, run through the entire course while making notes of lap times to find the best balance; then, determine the secondary reduction ratio.

+ If a course has a long straight por- tion where a machine can run at maximum speed, the machine is generally set such that it can develop its maximum revolutions toward the end of the straight line, with care taken to avoid the engine over-revving.

NOTE: Riding technique varies from rider to rider and the performance of a machine also vary from machine to machine. Therefore, do not imitate other rider's settings from the begin- ning but choose your own setting according to the level of your riding technique.

CHASSIS Sélection du taux de réduction secondaire (pignons)

Rear wheel 48T | 5GS-25448-50

sprocket @ *48T | 1C3-25448-00

(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)

AA 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:

60 - 80 kPa (0.6 - 0.8 kgf/cm?, 9.0 - 12 psi)

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

Extent of adjustment:

100 - 120 kPa (1,0 - 1,2 kgf /cm?, 15 - 18 psi)

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.

Change in level and characteristics of fork oil

Damping characteristic near the final stroke can be changed by changing the fork oil amount.

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: 95 - 150 mm (3:74 - 5.91 in) From top of outer tube with inner tube and damper rod fully compressed without spring.

Air spring characteristics in relation to oil level change

The spring preload is adjusted by installing the adjustment washer © between the fork spring © and damper rod @.

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.

quantity: Zero adjustment washers

Extent of adjustment: Zero - 2 adjustment washers

Without adjustment washer (standard)

2 adjustment washers

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.

SETTING REGLAGE TUN EC72P000 Front fork setting parts

+ Adjustment washer D TYPE thickness) PART NUMBER T=2.3mm (0.09 in) 5XE-23364-00

+ Front fork spring ©

Pièces de réglage de la fourche

The 1.D. mark (slits) @ is proved on the end of the spring.

Le repère (fentes) @) se trouve à l’extré- mité du ressort.

CAUTION: _____ When using a spring with a spring rate of 0.469 kg/mm, do not install two or more adjustment washers for each front fork.

SETTING REGLAGE T U N 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.

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 @.

Réglage de la suspension arrière Effectuer le réglage de la suspension arrière en fonction de l’expérience du pilote lors de la conduite ainsi que des conditions du terrain. Les deux réglages de la suspension arrière sont les suivants: 1. Réglage de la précontrainte du res- sort + Régler la longueur du ressort. + Changer de ressort. 2. Réglage de la force d’amortisse- ment + Régler la force d'amortissement à la détente. + Régler la force de compression.

If the machine is new and after it is broken in, the same set length of the spring may change because of the initial fatigue, etc. of the spring. Therefore, be sure to make re- evaluation.

If the standard figure cannot be achieved by adjusting the spring adjuster and changing the spring set length, replace the spring with an optional one and make re- adjustment.

i la moto est nouvelle et après qu’elle a été rodée, la longueur du ressort peut changer en raison de la fatigue initiale, etc., du ressort. Il est donc important de corriger les réglages régulièrement. S'il est impossible d'atteindre la valeur standard à l’aide du dispositif de réglage et en ajustant la longueur du ressort, remplacer le ressort avec un ressort en option et effectuer un nouveau réglage.

SETTING REGLAGE TUN Setting of spring after

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: 488.5 mm (19.23 in)

The I.D. color @ is marked at the end of the spring.

SETTING T U N EC72H002 Suspension setting + Front fork

+ _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

+ _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.

REGLAGE T U N Réglage de la suspension + Fourche

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.

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

Catch tank breather hose Catch tank

RADIATOR 4 RADIATEUR | ENG ©B EC456000 REMARQUES CONCERNANT LA 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 1. Inspect: + Radiator core ® Obstruction — Blow out with compressed air through rear of the radiator. Bent fin — Repair/replace.

ASSEMBLY AND INSTALLATION Radiator

1. Install: + O-ring © + _Radiator pipe 1 © + Bolt (radiator pipe) ©

[10 Nm (1.0 m - Kg, 7.2ft- Ib)

NOTE: Apply the lithium soap base grease on the O-ring.

RADIATOR 4 RADIATEUR | ENG ©B 2. Install: 2. Monter: + Catch tank hose © + Durit du réservoir de récupération + Radiator hose 2 © ©

Radiator hose 3 @ Radiator pipe 2 @

Radiator hose 5 @ Radiator hose 4 © To right radiator @.

3. Install: + Right radiator D + Bolt (right radiator) © + Radiator hose 5 @ Refer to “CABLE ROUTING DIAGRAM" section in the CHAPTER 2.

4. Install: - Left radiator ® + Bolt (left radiator) ©

Durit de radiateur 2 @ Durit de radiateur 3 @ Tuyau de radiateur 2 @ Durit de radiateur 5 @) Durit de radiateur 4 @) Sur le radiateur droit ©. 3. Monter: + Radiateur droit © + Boulon (radiateur droit) @ + Durit de radiateur 5 @ Se reporter à la section “CHEMI-

DIAGRAM" section in the NEMENT DES CABLES” au CHAPTER 2. CHAPITRE 2. 5. Tighten: 5. Serrer: + _Radiator hose clamp © + Collier de durit du radiateur @ LL Nm@2m-kg,14ft-1b) | CAL Nm (0,2 m - kg, 1,481: 1b) ] 6. Install: 6. Monter: + _Radiator guard © + Plaque de protection du radiateur NOTE: © First fit the inner hook portion @ and NB:

then the outer one ®) onto the radia- tor.

7. Install: + Catch tank © + Bolt (catch tank) ©

[7 Nm (0.7 m - Kg, 5.1 #-1b)

+ Bolt (catch tank) @

[T6 Nm (1.6 m - kg, 11 ft Ib)

+ Catcher tank breather hose @ Refer to “CABLE ROUTING DIAGRAM" section in the CHAPTER 2.

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 CHAPTER 6. 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

CARBURATORE ENG N S (]

CARBURATORE VA]S Nm (0.3 mkg, 2.2 ft)

[SR] Nm (0.3 mekg, 2.2

@ Carburetor disassembly

CARBURETOR DISASSEMBLY Carburetor breather hose Valve lever housing cover Screw (throttle shaît)

Accelerator pump cover Spring

Diaphragm (accelerator pump) Air eut valve cover

Spring (air cut valve) Diaphragm (air cut valve) Float chamber

position sensor) (D except when changing the throttle position sen- sor due to failure because it will cause a drop in engine perfor- mance.

Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air. Never use a wire.

+ Ne jamais utiliser de fil métallique.

Main jet D Pilot jet ©

Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air. Never use a wire.

Nettoyer avec un solvant à base de pétrole. Nettoyer tous les conduits et gicleurs à l’air comprimé.

+ Ne jamais utiliser de fil métallique.

Needle valve 1. Inspect: + Needle valve © + Valve seat @ Grooved wear @ — Replace. Dust ® > Clean. + Filter © Clogged — Clean.

CARBURETOR Z caRBURATEUR | ENG ©B Eca6sot Papillon des gaz Throttle valve 1. Contrôler: 1. Check:

+ Free movement Stick — Repair or replace.

NOTE: Insert the throttle valve © into the carburetor body, and check for free movement.

1. Inspect: + Jet needle © Bends/wear — Replace. + Clip groove Free play exists/wear —

Replace. Float height 1. Measure:

+ Float height @ Out of specification — Adjust.

Measurement and adjustment

+ Hold the carburetor in an upside down position.

NOTE: + Slowly tit the carburetor in the opposite direction, then take the measurement when the needle valve aligns with the float arm. If the carburetor is level, the weight of the float will push in the needle valve, resulting in an incorrect measurement.

Etapes de la mesure et du réglage: + Tenir le carburateur à l’envers. NB. + Incliner lentement le carburateur dans le sens opposé puis prendre la mesure lorsque le pointeau s’aligne avec le bras du flotteur.

+ Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers.

+ A l’aide d’un pied à coulisse, mesurer la distance entre la surface de contact de la cuve à niveau constant et le haut du flotteur.

The float arm should be resting on the needle valve, but not com- pressing the needle valve.

If the float height is not within specification, inspect the valve seat and needle valve.

If either is worn, replace them both.

If both are fine, adjust the float height by bending the float tab ® on the float.

Recheck the float height.

1. Inspect: + Float © Damage — Replace.

Starter plunger 1. Inspect: + Cold starter plunger © + Hot starter plunger © Wear/damage — Replace.

Accelerator pump 1. Inspect: + Diaphragm (accelerator pump) © + Spring (accelerator pump) © + Accelerator pump cover @ + O-ring © + Push rod @ Tears (diaphragm)/damage — Replace. Dirt — Clean.

Le bras du flotteur doit reposer sur le pointeau mais sans le comprimer.

+ 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 1. Inspect: + Diaphragm (air cut valve) D + Spring (air cut valve) © + Air cut valve cover @ + O-ring © Tears (diaphragm)/damage — Replace.

ASSEMBLY AND INSTALLATION Carburetor 1. Install:

+ Cold starter plunger ©

+ Main air jet © +_Gicleur d’air principal © 3. Install: 3. Monter:

+ Spring 1 © + Ressort 1 ©

+ Lever 1 © + Levier 1 ©

To lever 2 ©. Sur le levier 2 ©.

Make sure the spring 1 fits on the stopper @ of the lever 2.

Make sure the stopper @ of the spring 2 fits into the recess ) in the carburetor.

Install the bigger hook @ of the spring fits on the stopper ® of the throttle shaft pulley.

Apply the fluorochemical grease on the bearings.

Fit the projection @ on the throttle shaft assembly into the slot ® in the throttle position sensor.

Make sure the stopper © of the spring fits into the recess in the carburetor.

Tu the throttle shaft assembly left while holding down the lever 1 @ and fit the throttle stop screw tip @ to the stopper © of the throttle shaft assembly pulley.

Appliquer de la graisse à base de com- posé fluoré sur les paliers.

10. Install: + Starter jet D + Pilot jet © + Spacer © + Needle jet @ + Main jet ©

+ After installing the needle valve to the float, install them to the carbu- retor.

+ Check the float for smooth move- ment.

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

13. Install: + 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) ©

(accelerator pump) ©

+ O-ring ® + Accelerator pump cover @ + Hose holder (drain hose) @ + Screw (accelerator pump cover) ©

NOTE: Install the diaphragm (accelerator pump) with its mark @ facing the spring.

+ Après avoir monté le pointeau sur le flotteur, les monter sur le carburateur.

CARBURETOR Z caRBURATEUR | ENG ©B 15. Install: 15. Monter: + Jet needle © + Aiguille D + Collar @ + Entretoise épaulée © + Spring © + Ressort @ + Needle holder @ + Support d’aiguille @ + Throttle valve plate © + Papillon d'admission @) To throttle valve ©. Sur le papillon des gaz ©. 16. Install: 16. Monter:

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

17. Install: + O-ring © + Valve lever housing cover + Bolt (valve lever housing cover) ©

+ Carburetor breather hose © NOTE: Install the carburetor breather hoses to the carburetor so that the hoses do not bend near where they are installed.

Accelerator pump timing adjustment

+ Papillon complet ©

Adjustment steps: NOTE:

Étapes du réglage: NB:

In order for the throttle valve height @ to achieve the specified value, tuck under the throttle valve plate © the rod @ etc. with the same outer diameter as the specified value.

Throttle valve height: 0.8 mm (0.03 in)

- Fully turn in the accelerator pump adjusting screw @.

+ Check that the link lever @ has free play ® by pushing lightly onit.

+ Gradually turn out the adjusting screw while moving the link lever until it has no more free

+ Düsennadel © + Spillo del getto D + _Aguja del surtidor D

+ Distanzhülse © + Collarino © + Casquillo

+ Feder © + Molla @ + Muelle ©

+ Nadelsitz @ + Portaspillo @ + Soporte de la aguja ©

CARBURETOR CARBURATEUR ENG Ca

NOTE: Install the projection @ between the carburetor joint slots.

Carburetor installation

Install: + Carburetor joint ©

Montage du carburateur

Tighten: + Bolt (carburetor joint) ©

+ Bolt (air filter joint) ©

LCA NmO3m:kg,22ft-1b) |

Install: + Throttle cable (pull) ©

+ Throttle cable (return) @

+ Throttle grip free play Refer to “THROTTLE CABLE ADJUSTMENT” section in the CHAPTER 3.

Install: + Throttle cable cover © + Bolt (throttle cable cover) ©

[<[4 Nm (0.4 m : kg, 2.9 ft-1b)

+ Throttle position sensor lead coupler D

+ Clamp © Refer to “CABLE ROUTING DIAGRAM" section in the CHAPTER 2.

+ Clamp@© Refer to “CABLE ROUTING DIAGRAM" section in the CHAPTER 2.

ENG | D AIR INDUCTION SYSTEM Extent of removal:

@ Air induction system removal

Extent of removal Order Part name ay Remarks

AIR INDUCTION SYSTEM REMOVAL

3 | Airinduction hose (air cut-off valve - front of 1 cylnder head)

4 | Airinduction pipe 1

6 | Airinduction hose (air cut-off valve - rear of 1 cylnder head)

7 | Airinduction hose (air cut-off valve - air 1 filter case)

SYSTEME D’INDUCTION D’AIR SEKUNDARLUFTSYSTEM ENG Ca

TT INSPECTION Air induction system 1. Inspect: + Air induction hose Crack/damage — Replace. + Air induction pipe Crack/damage — Replace.

+ 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 does not pass.

@ vers ® | L'air passe.

@to® | Air does not pass when specified pressure is on ©).

® vers @ | L'air ne passe pas.

+ Blow in air to check for operation.

+ When using vacuum, check by the use of the vacuum/pressure pump gauge set D.

@ vers ® | L'air ne passe pas lorsque la pression spécifiée est appliquée sur ©.

From air filter To cylinder head (exhaust port) From cylinder head (intake port)

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)

@ Cylinder head cover removal

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.

Cylinder head breather hose Bolt (cylinder head cover) Cylinder head cover Cylinder head cover gasket Timing chain guide (top side)

CAMSHAFTS REMOVAL Timing mark accessing crew Crankshaft end accessing screw Timing chain tensioner cap bolt Timing chain tensioner Camshaft cap

Refer to “REMOVAL POINTS"

CAMSHAFTS ARBRES A CAMES ENG Ca

REMOVAL POINTS Camshaft 1. Remove: + Timing mark accessing screw

© + Crankshaïft end screw @)

+ 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.

3. Remove: + Timing chain tensioner cap bolt +_Timing chain tensioner @ + Gasket

+ Bolt (camshaft cap) D

+ Clip NOTE: Remove the bolts (camshaft cap) in a crisscross pattern, working from the outside in.

The bolts (camshaft cap) must be removed evenly to prevent dam- age to the cylinder head, cam- shafts or camshaft caps.

5. Remove: + Exhaust camshaft © +_Intake camshaft ©

5. Déposer: + Arbre à cames d'échappement D + Arbre à cames d'admission @)

Attach a wire @ to the timing chain to prevent it from falling into the crank- case.

Attacher un fil © à la chaîne de distribu- tion pour l’empêcher de tomber dans le carter moteur.

INSPECTION Camshaft 1. Inspect:

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

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

Cam lobes length: Intake: @

29.65 - 29.75 mm (11673 - 1.1713 in) <Limit>:

3. Measure: + Runout (camshaft) Out of specification —

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

Install the camshaft onto the cylinder head.

Position a strip of Plastigauge © onto the camshaft.

Install the clip, dowel pins and camshaîft caps.

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® ©.

+ Camshaft outside diameter @ Out of specification — Replace the camshaît.

Within specification — Replace camshaft case and camshaft caps as a set.

Camshaft outside diameter:

+ _Camshaft sprocket © Wear/damage — Replace the camshaft assembly and tim- ing chain as a set.

+ Check that the decompression mechanism cam (D moves smoothly.

Check that the decompression mechanism cam lever pin @ projects from the camshaft.

+ 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 Camshaft

Install: + Exhaust camshaft © +_Intake camshaft ©

Monter: + Arbre à cames d'échappement D + Arbre à cames d'admission @)

Installation steps: + Tum the crankshaft counter- clockwise with a wrench.

NOTE: + Apply the molybdenum disulfide oil on the camshafts.

Apply the engine oil on the decompression system. Squeezing the decompression lever allows the crankshaft to be turned easily.

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.

Etapes du montage: + Tourner le vilebrequin dans le sens inverse des aiguilles d’une montre à l’aide d’une clé.

+ Fitthe timing chain © onto both camshaft sprockets and install the camshafts on the cylinder head.

+ Monter la chaîne de distribution @ sur les deux pignons d’arbre à cames et monter les arbres à cames sur la culasse.

The camshafts should be installed onto the cylinder head so that 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.

CAUTION: Do not turn the crankshaft dur- ing the camshaft installation. Damage or improper valve tim- ing will result.

+ Install the clips, camshaft caps © and bolts (camshaft cap) ©.

M Bolt (camshaft cap): | 10 Nm (1.0 me kg, 7.2 ft + Ib)

+ Monter les clips, les chapeaux d'arbres à cames @ et les boulons (chapeau d'arbre à cames) ®.

NOTE: + Before removing the clips, cover the cylinder head with a clean rag to prevent the clips from into the cylinder head cavity.

Apply the molybdenum disulfide oil on the thread of the bolts (camshaft cap).

Tighten the bolts to the specified torque in two or three steps in the proper tightening sequence as shown.

The bolts (camshaft cap) must be tightened evenly, or damage to the cylinder head, camshaft caps, and camshaft will result.

Ve Boulon (chapeau d'arbre à cames):

10 Nm (1,0 m + kg, 7,2 ft + Ib)

2. Install: +_Timing chain tensioner

+ While pressing the tensioner rod lightly with fingers, use a thin screwdriver and wind the tensioner rod up fully clockwise.

(1,0 mekg,7,2ft° Ib)

+ With the rod fully wound and the chain tensioner UP mark @ fac- ing upward, install the gasket D and the timing chain tensioner ©, and tighten the bolt © to the specified torque.

+ La tige étant complètement enrou-

lée et le repère UP @ du tendeur étant orienté vers le haut, monter le joint © et le tendeur de chaîne de distribution @ puis serrer le bou- lon ® au couple spécifié.

Bolt (timing chain tensioner):

10 Nm (1,0 m + kg, 7,2 ft + Ib)

+ Release the screwdriver, check

the tensioner rod to come out and tighten the gasket © and the cap bolt © to the specified torque.

Tensioner cap bolt: 7 Nm

Extent of removal: @ Cyinder head removal Extent of removal Order Part name ay Remarks CYLINDER HEAD REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS" section in the CHAPTER 3. Exhaust pipe and silencer Refer to “EXHAUST PIPE AND SILENCER" 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

culasse | ENG » INSPECTION CONTROLE Cylinder head Culasse 1. Eliminate: 1. Eliminer:

+ 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

2. Inspect: + Cylinder head Scratches/damage — Replace.

3. Measure: + 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 Cylinder head 1. Install:

+ Cylinder head gasket ©

+_Timing chain guide (exhaust side) © + Cylinder head @

NOTE: While pulling up the timing chain, install the timing chain guide (exhaust side) and cylinder head.

+ Dépôts de calamine (des chambres de combustion) Utiliser un grattoir arrondi.

+ Cable guide © + Bolts [L=145 mm (5.71 in)] ©

LAT58 Nm (6.8 m-kg,27ft-1b) |

+ Bolts [L=135 mm (5.31 in)] ©

+ Apply the molybdenum disulfide grease on the thread and contact surface of the bolts.

+ Follow the numerical order shown in the illustration. Tighten the bolts and nuts in two stages.

+ Appliquer de la graisse au bisulfure de molybdène sur les filets et les surfaces de contact des boulons.

+ Suivre l’ordre numérique indiqué dans l'illustration. Serrer les boulons et les écrous en deux étapes.

3. Install: + Copper washer D + Oil delivery pipe © + Union bolt (M8) ©

4. Install: + _Radiator pipe D + Bolt (radiator pipe) ©

Preparation for removal

VALVES AND VALVE SPRINGS REMOVAL Cylinder head

Refer to “CYLINDER HEAD" section.

Valve stem seal Valve spring seat Exhaust valve Intake valve

Use special tool. Refer to “REMOVAL POINTS"

REMOVAL POINTS Valve lifter and valve cotter 1. Remove:

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

2. Check: + Valve sealing Leakage at the valve seat — Inspect the valve face, valve seat and valve seat width.

+ 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 ©.

POINTS DE DEPOSE Poussoir de soupape et clavette de soupape 1. Déposer:

Attach a valve spring compressor (D) between the valve spring retainer and the cylinder head to remove the valve cotters.

Stem-to-guide clearance = valve guide inside diameter @ - valve stem diameter ©

Jeu queue-guide = diamètre inté- rieur du guide de soupape @ - diamètre de queue de soupape 6)

Out of specification — Replace the valve guide.

Hors caractéristiques — Rempla- cer le guide de soupape.

Clearance (stem to guide):

To ease guide removal, installa- tion and to maintain correct fit heat the cylinder head in an over to 100 °C (212 °F).

+ Remove the valve guide using a valve guide remover ©.

Install the new valve guide using a valve guide remover ® and valve guide installer ©. After installing the valve guide, bore the valve guide using a valve guide reamer © to obtain proper stem-to-guide clearance.

NOTE: After replacing the valve guide reface the valve seat.

Inspect: + Valve face Pitting/wear — Grind the face. + Valve stem end Mushroom shape or diameter larger than the body of the stem — Replace.

+ Margin thickness @ Out of specification — Replace.

4. Mesurer: + Epaisseur de rebord @ Hors spécifications —> Rempla- cer.

Margin thickness: Intake: 0.8 mm (0.0315 in)

Exhaust: 0.7 mm (0.0276 in)

+ When installing a new valve always replace the guide.

+ lfthe valve is removed or replaced always replace the oil seal.

6. Eliminate: + Carbon deposits (from the valve face and valve seat) 7. Inspect: + Valve seat Pittingwear — Reface the valve seat.

8. Measure: + Valve seat width @ Out of specification — Reface the valve seat.

En cas de pose d’une soupape neuve, toujours remplacer le guide de sou- pape.

+ Apply Mechanic's blueing dye (Dykem) ® to the valve face. Install the valve into the cylinder head.

Press the valve through the valve guide and onto the valve seat to make a clear pattern. Measure the valve seat width. Where the valve seat and valve face made contact, blueing will have been removed.

If the valve seat is too wide, too narrow, or the seat is not cen- tered, the valve seat must be refaced.

Largeur de siège de soupape: Admission:

After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped.

Après rectification du siège de soupape ou remplacement de la soupape et du guide de soupape, le siège et la portée de soupape doivent être rodés.

[OT Lapping steps: + Apply a coarse lapping com- pound to the valve face.

Do not let the compound enter the gap between the valve stem and the guide.

Ne pas laisser la pâte pénétrer entre la queue et le guide de sou- pape.

+ Apply molybdenum disulfide oil to the valve stem.

+_Install the valve into the cylinder head.

+ Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the compound.

NOTE: For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands.

+ Apply a fine lapping compound to the valve face and repeat the above steps.

NOTE: After every lapping operation be sure to clean off all of the com- pound from the valve face and valve seat.

+ Apply Mechanic's blueing dye (Dykem) to the valve face. +_Install the valve into the cylinder head. Press the valve through the valve guide and onto the valve seat to make a clear pattern. Measure the valve seat width again. |f the valve seat width is out of specification, reface and relap the valve seat.

+ Appliquer de l’huile au bisulfure de molybdène sur la queue de sou- pape.

+ Compressed spring force @ Out of specification — Replace.

Compressed spring force:

Scratches/damage — Replace both lifters and cylinder head.

VALVES AND VALVE SPRINGS SOUPAPES ET RESSORTS DE SOUPAPES ENG Ca

ASSEMBLY AND INSTALLATION Valve and valve spring 1. Apply: + Molybdenum disulfide oil Onto the valve stem and valve stem seal.

2. Install: + 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.

While compressing the valve spring with a valve spring compressor install the valve cotters.

4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood.

Hitting the valve tip with excessive force could damage the valve.

+ Valve lifter @ + Poussoir de soupape © NOTE: NB:

+ Apply the molybdenum disulfide oil on the valve stem end.

+ Apply the engine oil on the valve lifters.

+ Valve lifter must turn smoothly when rotated with a finger.

+ Be careful to reinstall valve lifters and pads in their original place.

+ Appliquer de l'huile au bisulfure de molybdène sur les embouts de queues de soupapes.

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 pin @ + Axe de piston @)

+ Piston © + Piston © NOTE:

Put identification marks on each piston head for reference during reinstallation.

Before removing each piston pin, deburr the clip groove and pin hole area. lf the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller set ©.

Placer des repères d'identification sur chaque tête de piston comme référence pour la repose.

Do not use a hammer to drive the piston pin out.

2. Remove: 2. Déposer: + _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 1. Inspect:

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

2. Measure: + Piston-to-cylinder clearance

carter les coupes du segment tout en soulevant le segment de piston par des- sus la calotte du piston, comme illustré.

+ Measure the cylinder bore “C” with a cylinder bore gauge.

NOTE: Measure the cylinder bore “C” in parallel to and at right angles to the crankshaft. Then, find the average of the measurements.

Etapes de la mesure:

© + Kolbenbolzen @ + Kolben ©

“T°” = (Maximum Di or D2) — (Maximum D: or De)

“R° = (Maximum Di, Ds or Ds) — (Minimum D2, Da or Ds)

SR = (Maximum Di, Ds ou Ds) — (Minimum D:, Ds ou De)

+ lf out of specification, replace the cylinder, and replace the piston and piston rings as set.

2nd step: + Measure the piston skirt diame- ter “P” with a micrometer. © 8 mm (0.31 in) from the piston bottom edge

+ lf out of specification, replace the piston and piston rings as a set.

+ Calculate the piston-to-cylinder clearance with following for- mula:

Standard | (30297 à 3,0303 in)

Piston-to-cylinder clearance = Cylinder bore “C” - Piston skirt diameter “P”

+ lf out of specification, replace the cylinder, and replace the piston and piston rings as set.

CYLINDRE ET PISTON » Piston ring Segment 1. Measure: 1. Mesurer:

+ Ring side clearance Use a feeler gauge ©. Out of specification — Replace the piston and rings as a set.

NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance.

+ Jeu latéral du segment

NOTE: NJ Insert a ring into the cylinder and push it approximately 10 mm (0.39 in) into the cylinder. Push the ring with the piston crown so that the ring will be at a right angle to the cyl- inder bore.

You cannot measure the end gap on the expander spacer of the oil control ring. If the oil control ring rails show excessive gap, replace all three rings.

Blue discoloration/grooves — Replace, then inspect the lubrication system. 2. Measure: + _Piston pin-to-piston clearance

+ Measure the inside diameter

Inside diameter (piston): 16.002 - 16.013 mm (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.

ASSEMBLAGE ET MONTAGE Piston et segment de piston 1. Monter: + Segment de piston Sur le piston.

Be sure to install the piston rings so that the manufacturers marks or numbers are located on the upper side of the rings.

Lubricate the piston and piston rings liberally with engine oil.

Veiller à monter les segments de pis- ton en plaçant les repères ou numéros du fabricant du côté supérieur des seg- ments.

Lubrifier généreusement le piston et les segments à l’aide d’huile moteur.

2. Position: 2. Position: + Top ring + Segment de feu + 2ndring + Segment d'étanchéité + Oil ring + Segment racleur d'huile Offset the piston ring end gaps Excentrer les coupes des seg- as shown. ments comme illustré. @ Top ring end @ Extrémité du segment de feu ® 2ndring end ® Extrémité du segment d'étanchéité © Oil ring end (upper) © Extrémité du segment racleur d'huile @ Oitring (supérieur) Oil ring end (lower) @ Segment racleur d'huile Extrémité du segment racleur d'huile inférieur) 3. Install: 3. Monter: + Piston © + Piston D +_Piston pin © + Axe de piston @) + _Piston pin clip © + Agrafe d’axe de piston @ NOTE: : + Apply engine oil onto the piston pin + Appliquer de l'huile moteur sur l’axe and piston. de piston et le piston.

Be sure that the arrow mark @ on the piston points to the exhaust side of the engine.

Before installing the piston pin clip, cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase. Install the piston pin clips with their ends facing downward.

Contrôler que la flèche @ située sur le piston pointe vers le côté échappement du moteur.

Apply a liberal coating of engine oil.

Apply the lithium soap base grease on the O-ring.

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.

4. Install: + Bolt (cylinder) ©

X [TO Nm (1.0 m - Kg, 7.2: Ib)

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

+ Lock washer @ + Clutch boss ©

Straighten the lock washer tab and use the clutch holding tool @ to hold the cluich boss.

[B] Except for USA and CDN EC4n4000

Clutch housing and boss

+ Clutch housing © Cracks/wear/damage — Replace.

+ Clutch boss © Scoring/wear/damage — Replace.

ECa8420i Primary driven gear 1. Check: + Circumferential play Free play exists — Replace. + Gear teeth @ Wear/damage — Replace.

Clutch spring 1. Measure: + Clutch spring free length @ Out of specification — Replace springs as a set.

Clutch spring free length:

37,0 mm (1,46 in) <Limite>: 36,0 mm (1,42 in)

37,0 mm (1,46 in) <Limite>: 36,0 mm (1,42 in)

Friction plate 1. Measure: -_Friction plate thickness Out of specification — Replace friction plate as a set. Measure at all four points.

<Limit>: 2.7 mm (0.106 in)

EC484600 Clutch plate 1. Measure: + Clutch plate warpage Out of specification — Replace clutch plate as a set. Use a surface plate (D and thickness gauge ©.

Warp limit: 0.1 mm (0.004 in)

Push lever shaft 1. Inspect: + Push lever shaft © Wear/damage — Replace.

+ 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).

+ Primary driven gear ©

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

Use the clutch holding tool © to hold the cluich boss.

l'outil de maintien de l'embrayage © pour maintenir la noix d'embrayage.

| Clutch holding tool: YM-91042/90890-04086 [A] For USA and CDN [B] Except for USA and CDN

+ Seat plate D + _Cushion spring @

+ Plaque de siège © + Plaquette de progressivité ©

+ 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.

5. Install: -_Friction plate 1 © + Clutch plate 1 © -_Friction plate 2 © + Clutch plate 2@

5. Monter: + 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.

6. Install: + Bearing © + Washer @ - Circlip © REZ To push rod 1 @.

Apply the engine oil on the bearing and washer.

Appliquer de l'huile moteur sur le roule- ment et la rondelle.

7. Install: 7. Monter: + Pushrod2®@ + Tige de débrayage 2 D + Bal© + Bile© + Push rod 1 © + Tige de débrayage 1 © NOTE: N.

Apply the engine oil on the push rod 1,2 and ball.

CLUTCH EMBRAYAGE ENG N S (]

+ 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

OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER REMOVAL Preparation for removal Drain the engine oil.

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 CHAPTER 3.

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

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" 11. | Oilseal 2 12 | Bearing 1

Hold the impeller shaft on its width across the flats @ with spanners, etc. and remove the impeller.

Maintenir l'arbre d'entraînement en le ant par les côtés plats @ à l’aide d’une clé, etc., et déposer le rotor.

EC4G3210 Oil seal NOTE: — It is not necessary to disassemble the water pump, unless there is an abnormality such as excessive change in coolant level, discoloration of coolant, or milky transmission oil.

+ Bearing © 2. Remove:

+ Oil seal © INSPECTION Oil delivery pipe 1. Inspect:

+ Oil delivery pipe D Bend/damage — Replace. Clogged — Blow.

EC444200 Impeller shaft 1. Inspect: +_Impeller shaît © Bend/wear/damage — Replace. Fur deposits — Clean.

1. Inspect: + Bearing Rotate inner race with a finger.

Rough spot/seizure - Replace. EC444400 Oil seal 1. Inspect: + Oil seal ©

Wear/damage — Replace.

+ 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 ©.

2. Install: + Bearing ©

Install the bearing by pressing its outer race parallel.

Take care so that the oil seal lip is not damaged or the spring does not slip off its position.

When installing the impeller shaîft, apply the lithium soap base grease on the oil seal lip and impeller shaft. And install the shaft while turning it.

Hold the impeller shaft on its width across the flats @ with spanners, etc. and install the impeller.

Right crankcase cover

+ Veiller à ce que la lèvre de la bague d'étanchéité ne soit pas endommagée ou à ce que le ressort ne glisse pas hors de son emplacement.

Apply the lithium soap base grease on the O-ring.

Appliquer de la graisse à savon de lithium sur le joint torique.

2. Install: + Right crankcase cover D + Bolt (right crankcase cover) ©

+ Apply the engine oil on the impeller shaîft end.

+ Mesh the impeller shaft gear © with primary drive gear ©.

+ Tighten the bolts in stage, using a crisscross pattern.

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.

2. Install: + Oil hose D + Bolt (oil hose) ©

A monter de sorte à avoir un jeu @ de 13 mm (0,51 in) ou plus entre la pédale de kick et le cadre, et de manière à ce que la pédale de kick ne soit pas en con- tact avec le couvercle de carter lorsqu'elle est tirée.

3. Install: + Copper washer D REZ + Oil delivery pipe © + Union bolt (M8) ©

+ Dowel pin © + Goujon D

+ O-ing © RE +_ Joint torique © NOTE: N.B.:

Apply the lithium soap base grease on the O-ring.

Appliquer de la graisse à savon de lithium sur le joint torique.

2. Install: + Water pump housing D + Bolt (water pump housing) ©

1. Install: + Oil filter element © * Oring© EE

+ Oil filter element cover @ + Bolt (oil filter element cover)

x [10 Nm (1.0 m - kg, 7.2ft- Ib)

NOTE: Apply the lithium soap base grease on the O-ring.

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".

+_Nut (primary drive gear) D

(balancer shaft driven gear) ©

NOTE: Place an aluminum plate @ between the teeth of the balancer shaft drive gear @ and driven gear @.

When removing the balancer shaîft, align the center @ of the balancer shaft weight along the line connect- ing the centers of the crankshaft and balancer shaft.

Pour déposer l'arbre de balancier, ali- gner le centre @ du contrepoids d'arbre de balancier sur la ligne raccordant les centres du vilebrequin et de l'arbre de balancier.

INSPECTION Primary drive gear, balancer shaft drive gear and balancer shaft driven gear 1. Inspect:

+ Primary drive gear ©

+ Balancer shaft drive gear ©

+ Balancer shaft driven gear @

Wear/damage — Replace.

Balancer shaft 1. Inspect: + Balancer shañt Cracks/damage — Replace.

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.

3. Install: + 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.

4. Install: + 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 5. Bend the lock washer tab.

@ Oil pump disassembly

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.

Oil pump drive gear Oil pump assembly Outer rotor 2

Oil pump cover Outer rotor 1

Oil pump drive shaît Rotor housing

Extent of removal: @ Oil tank removal

Extent of removal Order Part name ay Remarks

OIL TANK REMOVAL Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT" section in the CHAPTER 3.

Oil tank breather hose Oil tank

RÉSERVOIR D'HUILE INSPECTION Oil pump 1. Inspect: + 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.

0.24 mm (0.009 in) Housing and rotor clearance ©:

3. Check: + Unsmooth — Repeat steps #1 and #2 or replace the defec- tive parts.

RÉSERVOIR D'HUILE OIL TANK ENG Ca

ASSEMBLY AND INSTALLATION Oil pump 1. Install: + 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.

2. Install: + Outer rotor 1 ©

Apply the engine oil on the outer rotor 1.

Appliquer de l'huile moteur sur le rotor externe 1.

3. Install: + Oil pump cover © + Screw (oil pump cover) ©

3. Monter: + Couvercle de pompe à huile © + Vis (couvercle de pompe à huile)

[2 Nm (0.2 m - Kg, 1.4 #t-1b) © + Dowel pin @ 4 [2 Nm (0, ft

- Circlip © RE NOTE: ms

+ Apply the engine oil on the inner rotor 2.

+ Fitthe dowel pin into the groove in the inner rotor 2.

4. Install: + Outer rotor 2 © + Dowel pin @ + Oil pump assembly @ + Bolt (oil pump assembly) [L = 25 mm (0.94 in)] @

+ Goujon © + Rotor interne 2 @ + Circlip © N.B.: + Appliquer de rotor interne 2. + Insérer le goujon dans la gorge du rotor interne 2.

+ Bolt (oil pump assembly) [L = 30 mm (1.18 in)] ©

Apply the engine oil on the outer rotor 2.

+ Rotor interior 1 @

+ Olpumpen-Schraube [L = 30 mm (1,18 in)] ©

+ Rotor exterior 2 ©

Apply the engine oil on the oil pump N.B.:

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

KICK SHAFT AND SHIFT SHAFT ENG Ca

Unhook the torsion spring © from the hole @ in the crankcase.

The shift lever assembly is disas- sembled at the same time as the shift guide.

ECANS100 Segment 1. Remove:

+ 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 1. Check: + Ratchet wheel ® smooth movement Unsmooth movement — Replace. + Kick shaft @ Wear/damage — Replace. + Spring @ Broken — Replace.

ENG | D ECAC4300 Kick gear, kick idle gear and ratchet wheel 1. Inspect:

ECa84400 Shift shaft 1. Inspect: + Shift shaft @ Bend/damage — Replace. + Spring © Broken — Replace.

[a [50 Nm (6,0 m kg, 22 1-1) ]

Align the notch @) on the segment with the pin ® on the shift cam.

Aligner l’encoche @) du segment avec la goupille ® du tambour.

If the segment gets an impact, it may be damaged. Take care not to give an impact to the segment when tightening the bolt.

1. Install: + Torsion spring D + Stopper lever © + Bolt (stopper lever) © !!

Align the stopper lever roller with the slot on segment.

Apply the engine oil on the spring, pawi pin and pawl.

+ The shift lever assembly is installed at the same time as the shift guide.

+ Apply the engine oil on the boit (segment) shaft.

4. Install: + Bolt (shift guide) D

== C<[10 Nm (1,0 m-kg,72ft-1b) |

+ Torsion spring © + Shift shaft @

Apply the engine oil on the roller and shift shaft.

Appliquer de l'huile moteur sur le rou- leau et l’axe de sélecteur.

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

2. Monter: + Sélecteur Se reporter à la section “ALTER-

ALIMEN ON PERMA- NENTE EMBRAYAGE DU DEMARREUR”. Kick shaft assembly Arbre de kick complet 1. Install: 1. Monter: + Kick gear © + Pignon de kick D + Washer @ + Rondelle @ - Circlip © RE + Circlip © + Ratchet wheel © + Roue à rochet @ + Spring © + Ressort @ + Washer © + Rondelle © - Circlip@ REZ + Cirip© LE To kick shaft ®. Sur l'arbre de kick NOTE: NB:

+ Apply the molybdenum disulfide oil on the inner circumferences of the kick gear and ratchet wheel.

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

2. Install: + Torsion spring D To kick shaft ©.

NOTE: Make sure the stopper @) of the tor- sion spring fits into the hole ® on the kick shaft.

shaît, make sure the groove @ in the spring guide fits on the stopper of the torsion spring.

+ Distanzhülse © + Torsionsfeder ©

Apply the molybdenum disulfide grease on the contacting surfaces of the kick shaft stopper @ and kick shaft ratchet wheel guide ©. Apply the engine oil on the kick shaît.

Slide the kick shaft assembly into the crankcase and make sure the kick shaft stopper @ fits into the kick shaft ratchet wheel guide.

+ Appliquer la graisse au bisulfure de molybdène sur les surfaces de contact de la butée d'arbre de kick @ et du guide de roue à rochet de l'arbre de kick ®.

Turn the torsion spring clockwise and hook into the proper hole @ in the crankcase.

+ Apply the engine oil on the kick idle gear inner circumference.

+ Install the kick idle gear with its depressed side @ toward you.

@ Starter clutchwheel gear removal © Pickup coil/Stator removal

Extent of removal Order Part name ay Remarks AC MAGNETO AND STATOR REMOVAL 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

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 14. | Washer 1 15 | Idie gearplate 1 16 | Idie gear 1 Î 17 | Holder 1 d 18 | Pickup coil 1 l 19 | Stator 1

Insert a thin screwdriver or the like under the convexity @ and remove the starter clutch assembly cover by prying it gently to void damage to the cover.

Insérer un fin tournevis ou un outil ana- logue sous la convexité @ et déposer le couvercle de l'embrayage du démarreur complet en faisant légèrement levier pour ne pas endommager le couvercle.

2. Remove: 2. Déposer: + Starter clutch © + Embrayage du démarreur D NOTE: N.B.:

Using a thin screwdriver or the like, remove the plate @ while prying it upward little by little.

INSPECTION AC magneto 1. Inspect:

+ Rotor inner surface @

+ Stator outer surface D) Damage — Inspect the crank- shaft runout and crankshañt bearing.

If necessary, replace AC mag- neto and/or stator.

ECAL4200 Woodruff key 1. Inspect: + Woodruff key D Damage — Replace.

2. Check: + Idie gear + Starter clutch drive gear Pitting/burrs/chips/roughness/ wear — Replace the defective parts.

3. Check: + 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 1. Check: + Torque limiter Damage/wear — Replace.

+ Bolt (pickup coil) @

+ _Boulon (stator) ©

+_Bobina pickup © + Bullone (bobina pickup) @

+ Support D + Boulon @

LAIT Nm O7 m°kg, 5,114 1b) ]

Pass the pickup coil lead and charging coil lead under the holder while taking care not to allow these leads to get caught with each other. Also take care to pass the leads so that they do not become loose at the bend of the holder @ in order to avoid their contacting the starter clutch drive gear.

Apply the sealant to the grommet of the AC magneto lead.

Apply the engine oil on the idle gear 2.

CAL0 Nm (1,0 m°kg,7,21t-Ib) |

5. Install: + Washer © + Bearing © + Starter clutch drive gear © + Washer @

NOTE: Apply the engine oil on the washer, bearing and starter clutch drive gear inner circumference.

+ Supporto D + Bullone ©

6. Install: 6. Monter: + Starter clutch © + Embrayage du démarreur D To rotor @). Sur le rotor ©. NOTE: N.B.:

+ Install the starter clutch with its plate side upward.

+ While installing the starter clutch, push in the projections @ one by one on the clutch circumference.

+ Push in the starter cluitch until it hits the rotor.

+ Monter l’embrayage du démarreur en

Install the starter clutch assembly cover by fitting its pawls @ into the groove ®) in the rotor.

8. Install: 8. Monter: + Woodruff key D + Clavette demi-lune ®© + Rotor@ + Rotor @

Degrease the contact surfaces of the tapered portions of the crank- shaîft and rotor.

When installing the woodruff key, make sure that its flat surface @ is in parallel with the crankshaft cen- ter line ®.

When installing the rotor, align the keyway © of the rotor with the woodruff key.

+ _Gasket [crankcase cover (left)] + Crankcase cover (left) D + Bolt [crankcase cover (left)] ©

- Bolt [crankcase cover (left)] @

Apply the engine oil to the shaft and washers.

+ Install the cover (idle gear 1) with its mark @ facing upward.

13. Connect: + AC magneto lead Refer to “CABLE ROUTING DIAGRAM" section in the CHAPTER 2.

When installing the shift pedal onto the shift shaft, be sure that the center of the shift pedal is about 1.4 mm (0.06 in) @ above the top of the foot- rest.

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:

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

10 | Upper engine bracket 11 | Lower engine bracket 12 | Engine mounting boit

Refer to “REMOVAL POINTS"

Refer to “REMOVAL POINTS"

Remove the drive sprocket together with the drive chain.

ECausso1 Engine removal 1. Remove:

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.

2. Remove: + Engine © From right side.

Make sure that the couplers, hoses and cables are disconnected.

ASSEMBLY AND INSTALLATION Engine installation

1. Install: + Engine © Install the engine from right side.

+ 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) @

+ Apply the molybdenum disulfide grease on the pivot shaft.

+ Install the patch with the claw @ facing outside the chassis.

1. Install: + 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.

Install the drive sprocket together with the drive chain.

Tighten the nut while applying the rear brake.

3. Bend the lock washer tab to lock the nut. 4. Install: + Drive chain sprocket guide D + Drive chain sprocket cover @ + Screw (drive chain sprocket cover) ©

Neutral switch 1. Install: + Spring © + Pn© * Oring© EE + Neutral switch @ + Screw (neutral switch) @ L N

[DE Nm(0.4m-kg,29ft-lb) |

Apply the lithium soap base grease on the O-ring.

NOTA: Aplique grasa de jabôn de litio a la junta térica.

CRANKCASE AND CRANKSHAFT ENG Ca

CRANKCASE AND CRANKSHAFT

10 Nm (1.0 m-kg,7.2ft- Ib)

@ 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

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 11. | Oitstrainer 1

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

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”.

+ Remove the crankcase bolts ®, hose guide @ and clutch cable holder @.

Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them.

+ Remove the right crankcase @. NOTE:

+ Déposez le carter moteur droit @. N.B.:

+ Place the crankcase with its left side downward and split it by inserting a screwdriver tip into the splitting slit @ in the crank- case.

Lift the right crankcase horizon- tally while lightly patting the case splitting slit and engine mounting boss using a soft hammer, and leave the crank- shaft and transmission with the left crankcase.

CAUTION: Use soft hammer to tap on the case half. Tap only on rein- forced portions of case. Do not tap on gasket mating surface. Work slowly and carefully. Make sure the case halves sep- arate evenly. If the cases do not separate, check for a remaining case bolt or fitting. Do not force.

+ Remove the dowel pins and O- ring.

Do not use a hammer to drive out the crankshaft.

1. Remove: 1. Déposer: + 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 1. Inspect: +_Timing chain Cracks/stiff — Replace the timing chain and camshaft sprocket as a set. 2. Inspect: +_Timing chain guide Wear/damage — Replace.

Crankcase 1. Inspect: + Contacting surface @ Scratches — Replace. + Engine mounting boss ®), crankcase Cracks/damage — Replace.

2. Inspect: + Bearing Rotate inner race with a finger. Rough spot/seizure — Replace. 3. Inspect: + Oil seal Damage — Replace.

+ 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

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

0.039 in) 0.15 - Side 0.45 mm | 0.50 mm clearance: | (0.0059 - | (0.02 in) 0.0177 in) 55.95 - Crack 56.00 mm … width: (2.203 - 2.205 in) Oil strainer 1. Inspect: + Oil strainer

Oil delivery pipe 2 1. Inspect: + Oil delivery pipe 2 © + O-ring © Damage — Replace. + Oil orifice @ Clogged — Blow.

+ Screw [bearing stopper

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.

[B] Except for USA and CDN NOTE: ms Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other. Operate the install- ing tool until the crankshaft bot- toms against the bearing.

Before installing the crankshaft, clean the contacting surface of crankcase.

? | Pot de montage du vilebrequin @: YU-90050/90890-01274 Boulon de montage du vilebrequin @: YU-90050/90890-01275 Adaptateur (M12) @: YU-90063/90890-01278 Entretoise (outil de montage du vilebrequin) ©: YM:-91044/90890-04081

Do not use a hammer to drive in the crankshaft.

CRANKCASE AND CRANKSHAFT CARTER MOTEUR ET VILEBREQUIN AN ENG | D

2. Check: + Shifter operation + Transmission operation Unsmooth operation — Repair.

3. Install: + Oil strainer © + Bolt (oil strainer) ©

2. Contrôler: + Fonctionnement du sélecteur + Fonctionnement de la boîte de vitesses Fonctionnement irrégulier — Remplacer.

Clean the contacting surface of left and right crankcase before applying the sealant.

NOTE: NB: + Apply the lithium soap base grease + Appliquer de la graisse à savon de on the O-ring. lithium sur le joint torique.

Fit the right crankcase onto the left crankcase. Tap lightly on the case with soft hammer.

When installing the crankcase, the connecting rod should be posi- tioned at TDC (top dead center).

Tighten the crankcase tightening bolts in stage, using a crisscross pat- tern.

7. Install: + Oil delivery pipe 2 © * O-ring© EE

+ Bolt (oil delivery pipe 2) ©

Serrer les boulons de serrage du carter par étapes et en procédant en croix.

Apply the lithium soap base grease on the O-rings.

Appliquer de la graisse à savon de lithium sur les joints toriques.

8. Install: +_Timing chain © +_Timing chain guide (intake side) © + Bolt (timing chain guide) ©

8 Monter: + Chaîne de distribution +_Patin de chaîne de distribution (côté admission) © + Boulon (patin de chaîne de distri-

x [10 Nm (1.0 m - kg, 7.2 ft: Ib) bution) © 9. Remove: a [10 Nm (1,0 m + kg, 7,2 ft Ib) + Sealant 9. Déposer:

Forced out on the cylinder mating surface. 10. Apply: + Engine oil To the crank pin, bearing and oil delivery hole. 11. Check: + 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 SHIFT FORK REMOVAL Preparation for removal Engine Refer to “ENGINE REMOVAL section. Separate the crankcase. Refer to “CRANKCASE AND CRANKSHAFT" section.

Drive axle Shift cam

Shift fork 3 Shift fork 2 Shift fork 1 Collar

Refer to “REMOVAL POINTS"

+ 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 1. Inspect: + Matching dog @ + Gear teeth ® +_ Shift fork groove © Wear/damage — Replace.

2. Inspect: + O-ring © Damage — Replace. 3. Check:

+ Gears movement Unsmooth movement — Repair or replace.

ECAH4600 Bearing 1. Inspect: + Bearing © Rotate inner race with a finger. Rough spot/seizure — Replace.

ECaH4810 Shift fork, shift cam and segment 1. Inspect: + Shift fork D Wear/damage/scratches — Replace.

2. Inspect: + Shift cam@ + Segment @ Wear/damage — Replace.

ASSEMBLY AND INSTALLATION Transmission 1. Install:

+_5th pinion gear (19T) ©

+ 3rd pinion gear (177) ©

+ Ath pinion gear (21T) ©

+ 2nd pinion gear (167) ©

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.

+_3° pignone (177) ©

2. Install: + 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 @.

+ 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.

+ Apply the lithium soap base grease

+ Appliquer de l'huile au bisulfure de molybdène sur la surface interne et l'extrémité du pignon fou et sur la sur- face interne du pignon baladeur, puis procéder au montage.

on the O-ring. + Appliquer de la graisse à savon de lithium sur le joint torique. 3. Install: 3. Monter: + 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.

4. Install: + Collar @

+ Entretoise épaulée D N.B.:

+ Apply the lithium soap base grease on the oil seal lip.

+ When installing the collar into the crankcase, pay careful attention to

the crankcase oil seal lip.

5. Install: + 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.

6. Install: + Transmission assembly © To left crankcase ©.

Apply the engine oil on the bearings and guide bars.

Appliquer de l'huile moteur sur les rou- lements et les barres de guidage.

7. Check: + Shifter operation + Transmission operation Unsmooth operation — Repair.

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)

> [Se] 90 Nm (9.0 kgem , 65 ft-ib) 9

6 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

Front wheel Speed sensor Collar

Oil seal Bearing Brake disc

Refer to “REMOVAL POINTS".

® Rear wheel removal © Brake disc removal

@ Wheel bearing removal

Exient of removal Order Par name ay Remaks REAR WHEEL 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. 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

ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS\É

NOTE: Push the wheel forward and remove the drive chain ©.

ECS18201 Wheel bearing (if necessary) 1. Remove:

Remove the bearing using a general bearing puller ©.

EC594000 INSPECTION EC514100 Wheel 1. Measure:

Out of limit — Repair/replace.

Wheel runout limit: Radial ©: 2.0 mm (0.08 in) Lateral ©:

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

Replace the bearings, oil seal and wheel collar as a set.

+ 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 1. Measure: + 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 1. Mesurer:

Rear: <Limit>: 0.15 mm (0.006 in)

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

Brake disc thickness: Front:

2.5 mm (0.10 in) Rear:

FRONT WHEEL AND REAR WHEEL ROUE AVANT ET ROUE ARRIERE CHAS\É

EC595000 ASSEMBLY AND INSTALLATION Front wheel

1. Install: + 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.

Do not strike the inner race of the bearing. Contact should be made only with the outer race.

Apply the lithium soap base grease on the oil seal lip.

+ Speed sensor (D NOTE:

+ Capteur de vitesse (D N.B.:

Apply the lithium soap base grease on the oil seal lip of the speed sen- sor.

Make sure the two projections @) in the wheel hub are meshed with the two slots ® in the speed sensor.

+ Appliquer de la graisse à base de savon au lithium sur la lèvre de bague d'étanchéité du capteur de vit

+ Install the brake disc ® between the brake pads © correctly.

+ Make sure that the projections @ in the speed sensor fits over the stopper ® on the front fork inner tube.

Monter correctement le disque de frein @ entre les plaquettes de frein ©.

+ Veiller à ce que les ergots @ du cap- teur de vitesse se positionnent au-des- sus de la butée O) du tube plongeur de la fourche.

6. Install: + Wheel axle ©

Apply the lithium soap base grease on the wheel axle.

Appliquer de la graisse à savon de lithium sur l’axe de roue.

7. Install: + _Nut (wheel axle) D

Before tightening the bolt, fit the wheel axle to the axle holder by stroking the front fork several times with the front brake applied.

Rear wheel Roue arrière 1. Install: 1. Monter: + Bearing (right) © + Roulement (droit) © - Circlip © REZ + Circlip © + Spacer © + Entretoise © + Bearing (left) © + Roulement (gauche) @ + Oil seal @ + Bague d'étanchéité @ NOTE:

Apply the lithium soap base grease on the bearing and oil seal lip when installing.

Install the bearing with seal facing outward.

Use a socket that matches the out- side diameter of the race of the bearing.

Right side of bearing shall be installed first.

Install the oil seal with its manufac- ture's marks or numbers facing outward.

Appliquer de la graisse à savon de lithium sur le roulement et la lèvre de la bague d'étanchéité lors du montage. Monter le roulement avec son joint dirigé vers l'extérieur.

Do not strike the inner race of the bearing. Contact should be made only with the outer race.

Ne pas frapper sur la cage interne du roulement. Le contact ne peut avoir lieu qu'avec la cage externe.

2. Install: + Brake disc © + Bolt (brake disc) © {

Apply the lithium soap base grease on the oil seal lip.

Install the brake disc ® between the brake pads © correctly.

Monter correctement le disque de frein © entre les plaquettes de frein ©.

6. Install: - Drive chain ©

Push the wheel © forward and install the drive chain.

Pousser la roue © vers l’avant et monter la chaîne de transmission.

7. Install: + _Left drive chain puller © + Wheel axle ©

+ Install the left drive chain puller, and insert the wheel axle from left side.

+ Apply the lithium soap base grease on the wheel axle.

8. Install: + Right drive chain puller © + Washer @ + _Nut (wheel axle) ©

NOTE: Temporarily tighten the nut (wheel axle) at this point.

9. Adjust: + Drive chain slack @

[KT 6 Nm (0.6 m kg, 4.3 ft:1b)]

(Cl 18 Nm (1.8 m - kg, 13 ft- Ib) [RTS Nm (0.3 m + kg, 2.2ft:1b)

30 Nm (3.0 m kg, 22ft-Ib)

Extent of removal: ® Brake hose removal © Brake master cylinder removal

© Brake caliper removal

Extent of removal Order Par name ay Remarks FRONT BRAKE 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. 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

FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN CHAS FREIN AVANT ET FREIN ARRIERE FREIN AVANT Organisation de la dépose:

[KT 6 Nm (0.6 m kg, 4.3 ft:1b)]

® Brake master cylinder removal © Brake caliper removal

@ Brake hose removal

Extent of removal Order Par name ay Remarks REAR BRAKE 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. 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

FREIN AVANT ET FREIN ARRIÈRE |CHAS vo

(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

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 BRAKE MASTER CYLINDER DISASSEMBLY à © Brake master cylinder cap 1 Ÿ @ | Diaphragm 1 @ | Reservoir float 1 à ® Brake master cylinder boot 1 Ÿ © | Circiip 1 Use a long nose circlip pliers. © | Washer 1 à @ | Pushrod 1 (OX Ÿ @ | Brake master cylinder kit 1

EC5A3000 REMOVAL POINTS Brake fluid 1. Remove: [Front] + Brake master cylinder cap © [Rear]

+ Brake master cylinder cap © + Protector

NOTE: Do not remove the diaphragm.

POINTS DE DEPOSE A Front F] Rear

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

3. Loosen the bleed screw and drain the brake fluid while pulling the lever in or pushing down on the pedal.

+ 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 1. Remove: + Brake caliper piston Use compressed air and pro- ceed carefully.

+ Cover piston with rag and use extreme caution when expelling piston from cylinder.

+ Never attempt to pry out piston.

Liquide de frein 1. Déposer: [Avant] + Couvercle de maître-cylindre de frein © [Arrière] + Couvercle de maître-cylindre de frein © + Protection N. Ne pas déposer le diaphragme. (A Avant B] Arrière 2. Raccorder le tuyau transparent © à

+ Ne jamais chasser le cylindre du pis- ton en faisant levier.

Caliper piston removal steps:

+ Insert a piece of rag into the brake caliper to lock one brake caliper.

+ Carefully force the piston out of the brake caliper cylinder with

NOTE: N Remove the piston seals and dust seals by pushing them with a finger.

Déposer les joints de piston et antipous- sière en les poussant avec le doigt.

Never attempt to pry out piston seals and dust seals.

Ne jamais chasser les joints de piston et antipoussière hors du cylindre.

À WARNING Replace the piston seals and dust seals whenever a caliper is disas- sembled.

INSPECTION Brake master cylinder 1. Inspect: + Brake master cylinder inner surface @ Wear/scratches — Replace master cylinder assembly. Stains — Clean.

Inspect: (front brake only) + Reservoir float D Damage — Replace.

FRONT BRAKE AND REAR BRAKE FREIN AVANT ET FREIN ARRIERE CHAS Cyo

4. Inspect: + Brake master cylinder piston © + Brake master cylinder cup © Wear/damage/score marks — Replace brake master cylinder

kit. A Front EF) Rear Brake caliper 1. Inspect: + Brake caliper cylinder inner surface @

Wear/score marks — Replace brake caliper assembly.

À WARNING Replace the piston seals and dust seals © whenever a caliper is dis- assembled.

À AVERTISSEMENT Toujours remplacer les joints de pis- ton et antipoussière @ lors du démon- tage d’un étrier.

EC534301 Brake hose 1. Inspect: + Brake hose © Crack/damage — Replace.

ECS5A5000 ASSEMBLY AND INSTALLATION

+ 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 1. Clean: + Brake caliper + Piston seal + Dust seal + Brake caliper piston Clean them with brake fluid.

2. Install: + Piston seal © + Dust seal @

À WARNING Always use new piston seals and dust seals.

Fit the piston seals and dust seals onto the slot on brake caliper cor- rectly.

Insérer correctement les joints de piston et les joints antipoussière dans la rainure de l'étrier.

A Front (A Avant F] Rear F) Arrière 3. Install: 3. Monter: + Brake caliper piston D + Piston d’étrier de frein @ NOTE: N.B.:

Apply the brake fluid on the piston wall.

Appliquer du liquide de frein sur la paroi du piston.

+ Install the piston with its shal- low depressed side @ facing the brake caliper.

Front brake caliper 1. Install: + Pad support © + Brake pad © + Pad pin ©

+ Install the brake pads with their projections @ into the brake cali- per recesses ®).

+ Temporarily tighten the pad pin at this point.

Monter les plaquettes de frein en insé- rant leurs ergots @ dans les gorges des étriers de freins ®.

Rear brake caliper 1. Install: + Pad support D + Brake pad © + Pad pin ©

+ Install the brake pads with their projections () into the brake cali- per recesses ®).

+ Temporarily tighten the pad pin at this point.

Monter les plaquettes de frein en insé- rant leurs ergots @ dans les gorges des étriers de freins ®.

A ce stade, serrer provisoirement la goupille de plaquette.

2. Install: + Brake disc cover © + Bolt (brake disc cover) ©

2. Monter: + Couvre-disque de frein D + Boulon (couvre-disque de frein)

3. Install: + Brake caliper D + Rear wheel © Refer to “FRONT WHEEL AND REAR WHEEL' section. 4. Tighten: + Pad pin ©

FRONT BRAKE AND REAR BRAKE FREIN AVANT ET FREIN ARRIERE CHAS Cyo

Brake master cylinder kit 1. Clean: + Brake master cylinder + Brake master cylinder kit Clean them with brake fluid. 2. Install: + 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 3. Install: + Spring © To brake master cylinder pis-

NOTE: Install the spring at the smaller dia. side.

+ Brake master cylinder kit @

+ Brake master cylinder kit ©

+ Apply the lithium soap base grease on the tip of the push rod.

FRONT BRAKE AND REAR BRAKE FREIN AVANT ET FREIN ARRIERE CHAS\É

Front brake master cylinder 1. Install: + Brake master cylinder © + Brake master cylinder bracket

+ Bolt (brake master cylinder bracket) ©

Maiître-cylindre de frein avant 1. Monte: + Maître-cylindre de frein @© + Support de maître-cylindre de frein @ + Boulon (support de maître-cylin- dre de frein) ©

Install the bracket so that the arrow mark @ face upward.

First tighten the bolts on the upper side of the brake master cylinder bracket, and then tighten the bolts on the lower side.

2. Install: + Brake lever © + Bolt (brake lever) ©

+ Reposer le demi-palier de manière que la flèche @ soit dirigée vers le haut.

+ _Nut (brake lever) ©

Apply the lithium soap base grease on the brake lever sliding surface, bolt and contacting surface of the brake master cylinder piston.

Enduire de graisse à savon de lithium la surface coulissante du levier de frein, le boulon et la surface de contact du piston du maître-cylindre de frein.

Rear brake master cylinder 1. Install: + Copper washer © + Brake hose © + Union bolt @

À WARNING Always use new copper washers.

CAUTION: Install the brake hose so that its pipe portion @ directs as shown and lightly touches the projection ® on the brake master cylinder.

2. Install: + Brake master cylinder © + Bolt (brake master cylinder) ©

[TO Nm (1.0 m - Kg, 7.2 Ib)

3. Install: + Spring © + Brake pedal © * Oring© EE + Bolt (brake pedal) ©

Apply the lithium soap base grease on the bolt, O-ring and brake pedal bracket.

tion “REGLAGE DU ARRIERE” au CHAPITRE 3.

FREIN Front brake hose

1. Install: + Copper washer © + Brake hose © + Union bolt @

Durit de frein avant 1. Monter: + Rondelle en cuivre ® + Durit de frein © + Boulon de raccord @

À WARNING Always use new copper washers.

CAUTION: Install the brake hose so that its pipe portion @ directs as shown and lightly touches the projection ® on the brake caliper.

2. Install: + Brake hose holder © + Bolt (brake hose holder) ©

[TO Nm (1.0 m - Kg, 7.21: Ib)

e Stift © + Perno@ + Pasador ©

3. Install: + Brake hose holder © + _Nut (brake hose holder) ©

Align the top @ of the brake hose holder with the paint ® of the brake hose.

NB: Aligner le haut @ du support de durit de frein sur la peinture @) de la durit de frein.

4. Pass the brake hose through the front brake hose guides ©.

5. Install: + Copper washer D + Brake hose © + Union bolt @

4. Passer la durit de frein dans les gui- des de durit de frein avant ©.

CAUTION: Install the brake hose so that it contacts the brake master cylinder projection @ and that its bent por- tion ® faces downward.

1. Install: + Copper washer © + Brake hose © + Union bolt @

Install the brake hose so that its pipe portion @ directs as shown and lightly touches the projection ® on the brake caliper.

2. Install: + Brake hose holder © + Screw (brake hose holder) ©

After installing the brake hose holders, make sure the brake hose does not contact the spring (rear Shock absorber). If it does, correct its twist.

Après avoir monté les supports de durits de frein, vérifier que la durit de frein ne soit pas en contact avec le res- sort (amortisseur arrière). Si c’est le cas, en corriger la torsion.

Until the fluid level reaches “LOWER? level line @.

——_———— Use only the designated quality brake fluid:

otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance.

Refill with the same type of brake fluid;

mixing fluids may result in a harmful chemical reaction and lead to poor performance.

Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.

Brake fluid may erode painted sur- faces or plastic parts. Always clean up spilled fluid immediately.

+ Brake fluid level Fluid at lower level — Fill up. Refer to “BRAKE FLUID LEVEL INSPECTION"” section in the CHAPTER 3.

+ Brake master cylinder cap ©

+ Screw (brake master cylinder cap) ©

+ Brake master cylinder cap ©

+ Bolt (brake master cylinder cap) ©

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.

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

Extent of removal: @ Front fork removal Extent of removal Order Part name ay Remarks FRONT FORK 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. 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

@ Damper rod removal

Oil seal washer Oil seal

Base valve Damper rod

Refer to “REMOVAL POINTS". Drain the fork oil.

Refer to “REMOVAL POINTS"

Use special tool. Refer to “REMOVAL POINTS"

FOURCHE TELESKOPGABEL C HAS Cyo

FRONT FORK FOURCHE CHAS TD E0556000 REMARQUES CONCERNANT LA HANDLING NOTE MANIPULATION NOTE: N The front fork requires careful atten- tion. So it is recommended that the front fork be maintained at the deal- ers.

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.

REMOVAL POINTS Front fork cap bolt 1. Remove: Front fork cap bolt © From the outer tube.

NOTE: Before removing the front fork from the machine, loosen the front fork cap bolt.

2. Remove: Front fork cap bolt © NOTE:

+ Stopper ring © Using slotted-head driver.

Take care not to scratch the inner tube.

2. Remove: + 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 1. Remove: + Base valve © + Damper rod @

NOTE: Use a damper rod holder © to lock the damper rod.

1. Inspect: + Damper rod © Bend/damage damper rod.

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.

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

EC554400 Fork spring 1. Measure: +_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 1. Inspect:

+ 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 0.2 mm (0.008 in)

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.

1. Inspect: + Outer tube © Score marks/wear/damage — Replace.

ASSEMBLY AND INSTALLATION Front fork assembly 1. Wash the all parts in a clean sol- vent. 2. Install: + 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.

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

4. Tighten: + Base valve ©

+ Vis de purge d'air © Usure/endommagement — Rem- placer.

+ Use a damper rod holder © to lock the damper rod ©.

+ Apply the LOCTITE® on the base valve thread.

+ Utiliser un outil de maintien de tige d’amortissement @ pour bloquer la tige d'amortissement

Sur la tige d'amortissement ©. N.

Install the spring guide with its smaller dia. end @ facing down- ward.

With its thread ® facing upward, fully finger tighten the locknut onto the damper rod.

+ Monter le guide de ressort en orientant son extrémité de plus petit diamètre @) vers le bas.

Orienter les filets @) vers le haut et serrer complètement à la main le con- tre-écrou sur la tige d'amortissement.

6. Install: - 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.

7. Install: + Piston metal @ BE NOTE:

Install the piston metal onto the slot on inner tube.

8. Install: + Outer tube © To inner tube ©.

+ Oil seal washer @ To outer tube slot.

Press the slide metal into the outer tube with fork seal driver ©.

Fork seal driver: YM-A0948/ 90890-01502

10. Install: + Oil seal ©

Press the oil seal into the outer tube with fork seal driver ©.

Fit the stopper ring correctly in the groove in the outer tube.

Apply the lithium soap base grease on the inner tube.

Appliquer de la graisse à savon de lithium sur le tube plongeur.

13. Check: *_Inner tube smooth movement Tightness/binding/rough spots — Repeat the steps 2 to 12. 14. Compress the front fork fully.

15. Fill: + Front fork oil Until outer tube top surface with recommended fork oil ©.

N? Recommended oi il l

+ 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.

15. Remplir: + Huile de fourche Jusqu'au sommet du fourreau avec l’huile de fourche recom-

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.

16. Après le remplissage, effectuer plus de 10 pompages lents de la tige d’amortissement @, vers le haut et vers le bas, pour distribuer l'huile de fourche.

20. Measure: + Oil level (left and right) @ Out of specification — Adjust.

Standard oil level: 130 mm (5.12 in)

Extent of adjustment: 95 - 150 mm (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.

21. Measure: + Distance @ Out of specification — Turn into the locknut.

Between damper rod © top and locknut ©

Distance @: 18 mm (0,71 in) ou plus Entre le haut de la tige d’amortissement ® et le haut du contre-écrou ©.

top. 22. Desserrer: 22. Loosen: + Dispositif de réglage de l’amor- + Rebound damping adjuster D tissement à la détente (D) NOTE: + Loosen the rebound damping Desserrer à la main le dispositif de adjuster finger tight. réglage de l'amortissement à la

+ Record the set position of the adjuster (the amount of turning out the fully turned in position).

FRONT FORK rourcHe [CHAS Cyo) 23. Install: 23. Monter: + 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.

24. Install: + Spring seat D Front fork cap bolt ©

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

Hold the locknut @ and tighten the front fork cap bolt with specified torque.

Install the protector guide with its wider side @ facing downward.

Installation Montage 1. Install: 1. Monter:

+ Front fork © + Fourche © NOTE:

+ Temporarily tighten the pinch bolts (lower bracket).

+ Do not tighten the pinch bolts (upper bracket) yet.

+ Pinch boit (lower bracket) ©

Ve LI Nm Gi m Kg, 15 F0: Ib)

Tighten the lower bracket to speci- fied torque. If torqued too much, it may cause the front fork to mal- function.

5. Install: + Speed sensor lead © + Plate 1 © + Bolt (plate 1) ©

NOTE: Install the speed sensor lead so that its paint @ directs as shown and align the bottom @) of the plate 1 with the same paint.

NOTE: Install the plate 2 in the direction as shown.

NB Monter la plaque 2 dans le sens indiqué.

7. Monter: + Protection © + Boulon (protection) ©

CAITNm O7 m°kg Sith) ]

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

+ Tornillo (placa 2) ©

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

lanen [CHAS|A GUIDON Organisation de la dépose:

CHAS MANUBRIO MANUBRIO

REMOVAL POINTS Brake master cylinder 1. Remove: + Brake master cylinder bracket

+ 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 1. Remove:

° 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

1. Inspect: + Handlebar © Bends/cracks/damage — Replace.

À WARNING Do not attempt to straighten a bent handlebar as this may dan- gerously weaken the handlebar.

POINTS DE DEPOSE Maître-cylindre de frein 1. Déposer: + Support de maître-cylindre de frein © + Mañtre-cylindre de frein ©

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.

2. Install: + Handlebar © + Handlebar upper holder @ + Bolt (handlebar upper holder) ©

The handiebar upper holder should be installed with the punched mark @ forward.

Install the handlebar so that the marks ® are in place on both sides.

Install the handlebar so that the projection © of the handlebar upper holder is positioned at the mark on the handlebar as shown. First tighten the bolts on the front side of the handiebar upper holder, and then tighten the bolts on the rear side.

Le support supérieur du guidon doit être monté avec son poinçon @ vers l'avant.

4. Install: 4. Monter: + Left grip © + Poignée gauche © Apply the adhesive to the han- Appliquer un agent adhésif sur le diebar ©. guidon @. NOTE:

+ Before applying the adhesive, wipe off grease or oil on the handiebar surface @ with a lacquer thinner.

+_ Install the left grip to the handiebar so that the line ® between the two arrow marks faces straight upward.

+ Avant d'appliquer l'adhésif, essuyer toute trace de graisse ou d'huile de la surface du guidon @ avec un diluant à peinture-laque.

Before applying the adhesive, wipe off grease or oil on the tube guide surface @ with a lacquer thinner. Install the grip to the tube guide so that the grip match mark ® and tube guide slot © form the angle as shown.

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

7. Install: + Throttle cables D To tube guide ©.

NOTE: Apply the lithium soap base grease on the throttle cable end and tube guide cable winding portion.

After tightening the screws, check that the throttle grip © moves smoothly. If it does not, retighten the bolts for adjustment.

9. Install: + Grip cap cover D + Cover (throttle cable cap) ©

10. Install: + Start switch © + Brake master cylinder © + Brake master cylinder bracket

+ Bolt (brake master cylinder bracket) ©

+ The start switch and brake master cylinder bracket should be installed according to the dimensions shown.

Install the bracket so that the arrow mark @ faces upward.

First tighten the bolt on the upper side of the brake master cylinder bracket, and then tighten the bolt on the lower side.

Monter le contacteur du démarreur et le support du maître-cylindre de frein en respectant les dimensions indi- quées.

11. Install: + 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.

Apply the lithium soap base grease on the clutch cable end and hot starter cable end.

Appliquer de la graisse à savon de lithium sur les extrémités du câble d'embrayage et du câble de démarrage à chaud.

+ Clutch lever free play Refer to “CLUTCH ADJUST- MENT" section in the CHAP- TER3.

@ Lower bracket 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

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

Support the steering stem so that it may not fall down.

Steering nut wrench: YU-33975/90890-01403

Lower bearing 1. Remove: + Lower bearing © Use the floor chisel ©.

Take care not to damage the steer- ing shaft thread.

Bearing race 1. Remove: + Bearing race © Remove the bearing race using long rod © and the ham- mer.

INSPECTION Steering stem 1. Inspect: + Steering stem © Bend/damage — Replace.

Bearing and bearing race 1. Wash the bearings and bearing races with a solvent. 2. Inspect: + 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.

ASSEMBLY AND INSTALLATION Lower bracket 1. Install:

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

2. Install: + Bearing race + Upper bearing © + Bearing race cover ©

NOTE: Apply the lithium soap base grease on the bearing and bearing race cover lip.

3. Install: + Lower bracket

Apply the lithium soap base grease on the bearing, the portion @ and thread of the steering stem.

Tighten the steering ring nut using the steering nut wrench

@. Refer to “STEERING HEAD INSPECTION AND ADJUST- MENT" section in the CHAP- TER3.

5. Check the steering stem by turn- ing it lock to lock. If there is any binding, remove the steering stem assembly and inspect the steering bearings.

Serrer l’écrou de direction à l’aide de la clé pour écrou de direction @).

+ Washer © + Rondelle ©

+ Collar @ + Entretoise épaulée © NOTE: N.B.:

Install the collar @ with the larger inside diameter facing downward.

7. Install: + Front fork © + Upper bracket © + Main switch © + Front brake hose guide bracket @

7. Monter: + Fourche D +_Té supérieur @ + Contacteur à clé @ + Support du guide de durit de frein avant @

+ Temporarily tighten the pinch bolts (lower bracket).

+ Do not tighten the pinch bolts (upper bracket) yet.

+ Serrer provisoirement les boulons de pincement (té inférieur).

+ Ne pas encore serrer les boulons de pincement (té supérieur).

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

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

+_Interruptor principal ©

+_Pinch boit (lower bracket) ©

Tighten the lower bracket to speci- fied torque. If torqued too much, it may cause the front fork to mal- function.

Pass the throttle cables ©, clutch cable @ and hot starter cable @ between the multi-function display bracket and upper bracket.

+ Install so that the marking @ on the speed sensor lead aligns with the holder edge.

+ Fasten the speed sensor lead to the holder with the clamp.

+ Le monter de sorte que la marque @ sur le fil du capteur de vitesse soit ali- gnée sur le bord du support.

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

@ 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".

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

EC573200 Bearing 1. Remove:

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

INSPECTION Wash the bearings, bushings and collars in a solvent.

Swingarm 1. Inspect: + Bearing © + Bushing © Free play exists/unsmooth

revolution/rust — Replace bearing and bushing as a set. Inspect: + Oil seal @ Damage — Replace.

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

+ Oil seal @ Damage — Replace.

Barra de uniôn 1. Comprobar: + Cojinete D + Casquillo Holgura/giro no suave/6xido — Cambiar el conjunto de coji- nete y casquillo. 2. Comprobar: + _Junta de aceite @ Daños -; Cambiar.

SWINGARM BRAS OSCILLANT Connecting rod 1. Inspect: + Bearing © + Collar @ Free play exists/unsmooth revolution/rust — Replace bearing and collar as a set. 2. Inspect: + Oil seal @ Damage — Replace.

EC575000 ASSEMBLY AND INSTALLATION Bearing and oil seal

1. Install: + 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: 6.5 mm (0.26 in)

+ Bearing © + Roulement (D

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.

Apply the molybdenum disulfide grease on the washer.

+ Lors de l'installation, enduire le roule- ment de graisse au bisulfure de molyb- dène.

Monter le roulement en pressant sur le côté où sont imprimés la marque ou le numéro du fabricant

installed depth of bearings @:

Profondeur d'installation des roulements @: Zéro mm (zéro in)

3. Install: + Bearing © + Oil seal @ To connecting rod.

3. Monter: + Roulement (D + Bague d'étanchéité © Sur la bielle.

NOTE: + 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.

+ Lors de l'installation, enduire le roule- ment de graisse au bisulfure de molyb- dène.

Monter le roulement en pressant sur le côté où sont imprimés la marque ou le numéro du fabricant.

installed depth of bearings @:

Swingarm 1. Install: + Bushing © + Thrust bearing © + Oil seal @ + Collar @ To swingarm ®.

Apply the molybdenum disulfide grease on the bushings, thrust bear- ings, oil seal lips and contact sur- faces of the collar and thrust bearing.

+ Buchse © + Bussola © + Manguito D

2. Install: + Collar @ + Washer @ To relay arm ©.

Apply the molybdenum disulfide grease on the collars and oil seal lips.

Appliquer de la graisse au bisulfure de molybdène sur les entretoises épaulées et les lèvres des bagues d'étanchéité.

3. Install: + Collar @ To connecting rod ©.

3. Monter: + Entretoise épaulée D Sur la bielle ©.

Apply the molybdenum disulfide grease on the collar and oil seal lips.

5. Install: 5. Monter: + Relay am@ + Bras relais D + Bolt (relay arm) © +_Boulon (bras relais) © + Washer @ + Rondelle @ + _Nut (relay arm) © + Ecrou (bras relais) @ To swingarm. Sur le bras oscillant. NOTE: NB:

+ Apply the molybdenum disulfide grease on the bolt circumference and threaded portion.

+ Do not tighten the nut yet.

+ Appliquer de la graisse au bisulfure de molybdène sur la circonférence du boulon et la partie filetée.

+ Apply the molybdenum disulfide grease on the pivot shaft.

+ 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. 8. Install:

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

9. Install: + Bolt (rear shock absorber- relay arm) © +_Nut (rear shock absorber-relay

CA160 Nm (8,0 m°kg,58ft-1b) |

Install the right cap with its mark @ facing forward.

Installer le capuchon droit avec son repère @ vers l'avant.

+ Bolt (lower chain tensioner) D + Washer @

+ Lower chain tensioner @

+ _Nut (lower chain tensioner) ©

CA [16 Nm (1.6 m kg, 11ft-1b)

+ Drive chain support D + Drive chain support cover @ + Bolt {drive chain support [£ = 50 mm (1.97 in)]} © +_Nut (drive chain support) @ + Bolt {drive chain support cover [£= 10 mm (0.39 in)]} ©

L£ = 50 mm (1,97 in)]} ©

L£ = 50 mm (1,97 in)]} ©

® Rear shock absorber removal

@ Rear shock absorber disassembly

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

Aïr induction hose (air cut-off valve-air filter case)

Cylnder head breather hose

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 CHAPTER 3.

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

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".

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.

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

2. Remove: + Upper bearing © NOTE:

Remove the bearing by pressing its outer race.

POINTS DE DEPOSE Roulement 1. Déposer:

Remove the bearing by pressing its outer race.

Déposer le roulement en appuyant sur sa cage externe.

INSPECTION Rear shock absorber

Bends/damage — Replace rear shock absorber assem- bly.

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

installed depth of the bearing @:

+ Upper spring guide ©

3. Adjust: + Spring length (installed)

1. Install: 1. Monter: - Dust seal ® +_ Joint antipoussière + O-ing © RE +_ Joint torique © + Collar @ + Entretoise épaulée @ NOTE: B.:

+ Apply the molybdenum disulfide grease on the dust seal lips and collars.

+ Apply the lithium soap base grease on the O-rings.

Appliquer de la graisse au bisulfure de molybdène sur les lèvres de joint anti- poussière et les entretoises épaulées. Appliquer de la graisse à base de savon au lithium sur les joints tori- ques.

2. Install: 2. Monter: + Bushing © + Bague D + Collar © + Entretoise épaulée © + Dust seal @ +_ Joint antipoussière @ NOTE: N.B.:

+ Apply the molybdenum disulfide grease on the bearing and dust seal lips.

+ Install the dust seals with their lips facing outward.

+ Appliquer de la graisse au bisulfure de molybdène sur le roulement et les lèvres de joint antipoussière.

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

COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE ELEKTRISCHE BAUTEILE UND SCHALTPLAN COMPONENTI ELETTRICI E SCHEMA ELETTRICO E LEC COMPONENTES Y ESQUEMA ELÉCTRICO PARTIE ELECTRIQUE N.B.: Cette section est destinée aux personnes possédant des connaissances et des compétences de base pour l’entretien des motos Yamaha (par ex.: concessionnaires Yamaha, techniciens d’entretien, etc.). Les personnes non qualifiées ne doivent entreprendre les opérations d'inspection, de réglage, de démontage ou de remontage que s’ils se réfèrent à ce manuel. Sinon, ils pourraient engendrer des problè- mes d’entretien et des dommages mécaniques.

Starting circuit cut-off relay CDI unit

@ Tailight COLOR CODE

@ Neutral switch Black

IGNITION SYSTEM ELEC 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. Lx *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.

OK N d [ Check AC magneto. | Pickup coil ° go OK 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) Seat

Use the following special tools in this inspection.

SPARK GAP TEST 1. Disconnect the ignition coil from spark plug.

2. Remove the ignition coil cap. Connect the dynamic spark tester D (ignition checker ©) as shown.

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: 6.0 mm (0.24 in)

COUPLERS, LEADS AND IGNITION COIL CONNECTION INSPECTION

+ 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 INSPECTION 1. Inspect:

+ Engine stop switch conduct

Tester (+) lead — Black lead D Tester (-) lead — Black lead ©

No continuity while being pushed — Replace. Continuity while being freed — Replace.

IGNITION SYSTEM SYSTEME D’ALLUMAGE ELEC

2. Inspect: + Rubber part @ Tears/damage — Replace.

MAIN SWITCH INSPECTION 1. Inspect: + Main switch conduct

Tester (+) lead — Red lead D Tester (-) lead — Brown lead @

2. Contrôler: + Pièce en caoutchouc @ Déchirures/endommagement — Remplacer.

s Tester Fil (-) du multimètre — fil brun © 0 1] 8 ë selector position = R | Br | Position du Lo | © | © |ecteurau ON OO! 4 multimètre x OFF oN oo Qx1 Continuous while the main switch is OFF

moved to “OFF” — Replace. Not continuous while the main switch is moved to “ON” — Replace.

2. Inspect: + Main switch indicator light Use 12 V battery.

Continuité lorsque le contacteur à clé est placé sur “OFF” —> Remplacer.

Pas de continuité lorsque le contacteur à clé est placé sur “ON” —> Remplacer.

2. Contrôler: + Témoin de l'interrupteur à clé Utiliser une batterie 12 V.

Battery (+) lead — Red/Black lead © Battery (-) lead — Black lead ©

Indicator light does not come on — Replace.

3. Inspect: + Rubber part @ Tears/damage — Replace.

Câble (+) de la batterie — fil rouge/noir ©

3. Comprobar: + Pieza de goma @ Rotura/daños — Cambiar.

IGNITION SYSTEM SYSTEME D’ALLUMAGE ELEC EC626002 IGNITION COIL INSPECTION 1. Remove the ignition coil cap. 2. Inspect: + Primary coil resistance Out of specification — Replace.

Tester (+) lead — Orange lead (D Tester (-) lead — Black lead ©

Gi Primary coil Tester

: selector resistance de position 0.08 - 0.10 Q ax1

3. Inspect: + Secondary coil resistance Out of specification — Replace.

Tester (+) lead — Orange lead (D Tester (-) lead — Spark plug terminal ©

CONTROLE DE LA BOBINE D’ALLUMAGE 1. Déposer le capuchon de la bobine d'allumage. 2. Contrôler: + Résistance de l’enroulement pri- maire Hors spécifications —> Rempla- cer.

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

4. Inspect: + Sealed portion of ignition coil @ + Spark plug terminal pin © + Threaded portion of spark plug ©

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 1. Inspect: + Neutral switch conduct

Tester (+) lead — Sky blue lead © Tester (-) lead — Ground ©

Gi Sb [Ground] TeSter © © selector position NEUTRAL| ©1o Qx1

IN GEAR CONTROLE DE L'ALTERNATEUR AVEC ROTOR A AIMENTATION PERMANENTE 1. Contrôler: + Résistance de la bobine d’excita- tion Hors spécifications —> Remplacer.

No continuity while in neutral — Replace. Continuity while in gear — Replace.

CDI UNIT INSPECTION Check all electrical components. If no fault is found, replace the CDI unit. Then check the electrical com- ponents again.

ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to “ON”, the starter motor can only operate if at least one of the 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.

WHEN THE TRANS- MISSION IS IN NEU-

TRAL WHEN THE CLUTCH LEVER IS PULLED

TO THE HANDLEBAR Battery

Starting circuit cut-off relay

= Batterie Fusible principal

Interruptor principal

Y Replace fuse and check wire harness.

OK Q Check each coupler and wire

Recharge or replace.

[ *3 Check main switch.

[ Check starter motor operation.

[ Check starting circuit cut-off relay.

[ Check starter relay.

[ “4 Check neutral switch.

[ Check clutch switch.

[ Check start switch.

“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.

+ Remove the following parts before inspection.

1) Seat 2) Rear fender

+ Use 12 V battery in this inspection. + Use the following special tools in this inspection.

1. Connect the positive battery ter- minal © and starter motor lead © with a jumper lead ©. Not operate —> Repair or replace the starter motor.

+ 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 INSPECTION 1. Remove: + Starting cirouit cut-off relay 2. Inspect: + Starting circuit cut-off relay conduct

CONTROLE DU RELAIS DE COUPE-CIRCUIT DE DEMARRAGE 1. Déposer: +_ Relais de coupe-circuit de démarrage 2. Contrôler: + Continuité du relais de coupe-cir- cuit de démarrage Utiliser une batterie 12 V.

Battery (+) lead — Blue/Black lead © Battery (-) lead — Brown lead

Tester (+) lead — Blue/White lead @ Tester (-) lead — Black lead @

Câble (+) de la batterie — fil bleu/noir ©

Starter relay terminal © Battery (-) lead —

Starter relay terminal ©

Starter relay terminal © Tester (-) lead —

Starter relay terminal @

CONTROLE DU RELAIS DE DEMARREUR 1. Déposer: + Relais de démarreur 2. Contrôler: + Continuité du relais de démarreur Utiliser une batterie 12 V.

Câble (+) de la batterie — Borne de relais de démarreur (D) Câble (-) de la batterie —> Borne de relais de démarreur ®

Fil (+) du multimètre = Borne de relais de démarreur Fil (-) du multimètre — Borne de relais de démarreur @

[mn Ter- | Ter- | Tester ol minal | minal | selector Position [©] @ {position Borne Borne du sélec- Connected © © ne to battery OO rune Not ext Raccordé à connected la batterie | OO to battery Non Qx1 Continuous while not connected to raccordé à the battery — Replace. la batterie Not continuous while connected to

the battery — Replace.

CLUTCH SWITCH INSPECTION 1. Inspect: + Clutch switch continuity

Tester (+) lead — Black lead D Tester (-) lead — Black lead ©

[mn] Tester o | BB selector

FREE No continuous while being pulled — Replace. Continuous while being freed — Replace.

START SWITCH INSPECTION 1. Inspect: + Start switch continuity

Tester (+) lead — Black lead D Tester (-) lead —> Black lead @)

Hi B B Tester Lo 1] © © selector position PUSH IN | ©—O Qx1

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

2. Inspect: + Rubber part @ Tears/damage — Replace.

Continuité incorrecte — Remplacer.

© | © tor del compro-

Extent of removal Order Part name ay Remarks STARTER MOTOR REMOVAL 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

2. Measure: + Commutator diameter @ Out of specification — Replace the starter motor.

+ Mica undercut @) Out of specification — Scrape the mica to the proper mea- surement with a hacksaw blade which has been grounded to fit the commuta- tor.

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/

[mn] Armature assembly: 0 1) Commutator resistance (D:

0.0189 - 0.0231 Q at

20 °C (68 °F) Insulation resistance @:

+ lfany resistance is out of speci- fication, replace the starter motor.

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

5. Mesurer: + Longueur des balais @ Hors spécifications —> Remplacer ensemble tous les balais.

Min. brush length: 3.5 mm (0.14 in)

Longueur min. des balais: 3,5 mm (0,14 in)

6. Measure: + Brush spring force Out of specification — Replace the brush springs as

+ Armature assembly D Install while holding down the brush using a thin screw driver.

Be careful not to damage the brush during installation.

+ 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.

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

4. Monter: + Joint © + Circlip Rondelle pleine © Rondelle (couvercle avant du démarreur) @ Couvercle avant du démarreur @

For installation, align the projec- tions on the washer with the slots in the front cover.

Align the match mark @ on the starter motor yoke with the match mark ® on the starter motor front cover.

+ Pour le montage, aligner les ergots de la rondelle avec les fentes du couver- cle avant.

+ O-ing © RE +_ Joint torique © NOTE: NB:

Apply the lithium soap base grease on the O-ring.

Appliquer de la graisse à savon de lithium sur le joint torique.

+ Schraube © + Bullone © + Tornillo ©

INSPECTION STEPS If the battery is not charged, use the following inspection steps.

Replace fuse and check

Check each coupler and wire connection.

Recharge or replace.

[ Check charging voltage.

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.

1) Seat 2) Fuel tank

Remove the following parts before inspection.

Use the following special tool in this inspection.

Ge] Pocket tester: YU-3112-C/ 90890-03112

+ Couplers and leads connec- tion Rust/dust/looseness/short-cir- cuit — Repair or replace.

CHARGING VOLTAGE INSPECTION 1. Start the engine. 2. Inspect: + 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 14.0 - 15.0 V at 5,000 r/min | PCV-20

3. Inspect: + Charging coil resistance Out of specification — Replace.

CONTROLE DES CONNEXIONS DES FICHES RAPIDES ET DES FILS

3. Contrôler: + Résistance de la bobine de charge Hors spécifications —> Rempla- cer.

Tester (+) lead — White lead © Tester (-) lead — Ground ©

Gi Charging coil AE resistance ae position (0.288 - 0.432 Q at20°C(68°F) © *1

Fil (+) du multimètre fil blanc © Fil (-) du multimètre — terre ©

Check entire ignition No good system for connection. LE x Throttle position No good Check throttle position sensor. pl sensor coil JL Throttle position Check CDI unit. —æ]| sensor input No good voltage

Use the following special tools in this

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.

COUPLERS AND LEADS CONNECTION INSPECTION 1. Check:

+ Couplers and leads connec- tion Rust/dust/looseness/short-cir- cuit — Repair or replace.

THROTTLE POSITION SENSOR COIL INSPECTION 1. Inspect: + Throttle position sensor coil resistance Out of specification — Replace.

Tester (+) lead — Blue lead © Tester (-) lead — Black lead ©

REMARQUES CONCERNANT LA MANIPULATION ATTENTION:

+ 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 ©

coil variable resistance

Tester selector position

Full Full closed | opened

Zero - 3kQ at 20°C (68 °F)

THROTTLE POSITION SENSOR REPLACEMENT AND ADJUSTMENT 1. Remove: + Throttle position sensor cou- pler + Carburetor 2. Remove: + Screw

(throttle position sensor) D + Throttle position sensor @

NE: Loosen the screw (throttle position sensor) using the T25 bit.

3. Replace: + Throttle position sensor

4. Install: + 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).

Insert the thin electric conduc- tors © (lead) into the throttle position sensor coupler ®, as shown, and connect the tester to them.

Introduire les fins conducteurs élec- triques © (fils) dans la fiche rapide du capteur de position de papillon des gaz (D), comme illustré, et y rac- corder le multimètre.

Tester (+) lead — Yellow lead @

Tester (-) lead — Black lead @

Do not insert the electric con- ductors more than required because it may reduce the waterproof function of the cou- pler.

Make sure that a short-circuit does not develop between the terminals because it may cause damage to electrical compo- nents.

Fil (+) du multimètre fil jaune © Fil (-) du multimètre — fil noir @

8. Start the engine. 9. Adjust: + Throttle position sensor out- put voltage

Adjust the installation angle of the throttle position sensor @ to obtain the specified output volt- age.

Measure the output voltage accu- rately with a digital electronic volt- meter that gives an easy reading of a small voltage.

CORSA ARLES sensor output selector de sition de sélecteur du Pl position P multimètre voltage papillon des gaz 0.58 - 0.78 V DCV 0,58 à 0,78 V DCV

10. Put the aligning marks @ on the throttle position sensor and car- buretor.

11. Stop the engine.

12. Remove the carburetor.

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

Tester (+) lead — Blue lead © Tester (-) lead — Black/Blue lead ©

Drosselklap- Messge- [M \ Tensione in | Posizione Cable negro/azul © pensensor- | ah Lo || entrata sensore | del selet- = Eingangs- schalter posizione far- tore del üi Voltaje de Posiciôn spannung falla tester entrada del | ie selector sensor de del com- 4-6V DCV-20 4-6V DCV-20 posicién del probador acelerador 4-6V DCV-20

LIGHTING SYSTEM E LEC 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. Lx No good Replace the taillight Check the taillight (LEDs). »| assembly. JL 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. 1) Seat 2) Fuel tank

3) Left side cover + Use the following special tool.

ÇA Pocket tester: | YU-3112-C/ 90890-03112

ELEC MEMO LIGHTING SYSTEM ELEC ECLAIRAGE CHECKING THE TAILLIGHT CONTROLE DU FEU ARRIERE (LEDs) DEL) 1. Disconnect the taillight coupler. 1. Débrancher la fiche rapide du feu

2. Connect two jumper leads @ from the battery terminals to the respective coupler terminal as shown.

Battery (+) terminal — Blue lead ©

Battery (-) terminal — Black lead ©

3. Check: + LED (for proper operation) Does not light — Replace the taillight assembly.

+ 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.

Ce contrôle est susceptible de pro- duire des étincelles. Il convient donc d’éloigner tout gaz ou liquide inflammable.

AC MAGNETO INSPECTION 1. Inspect: + Lighting coil resistance Out of specification — Replace.

Tester (+) lead — Yellow lead © Tester (-) lead — Ground ©

Gi Lighting coil AE resistance ee position 0.224 - 0.336 Q at20°C(68°F) © *1

LIGHTING SYSTEM ECLAIRAGE ELEC RECTIFIER/REGULATOR INSPECTION

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 ©

Cable negro © [==] Posiciôn Lo [| Voltaje de |delselector salida del com- probador 12,5-13,5Va , 5.000 r/min ACV-20

SIGNALING SYSTEM ELEC SIGNALING SYSTEM INSPECTION STEPS If the speedometer will not operate, use the following inspection steps.

*1 Check battery. ] No good »| Recharge or replace.

IL Check each coupler and wire No good Repair or replace. connection. > P P l un 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.

+ Remove the following parts before inspection. 1) Headlight

+ Use the following special tools in this inspection.

ZA Pocket tester: YU-3112-C/

2. Setthe main switch to “ON”.

3. Measure: + Multi-function display input voltage Out of specification —

Replace wire harness.

Tester (+) lead — Brown lead D Tester (-) lead — Black lead ©

Fil (+) du multimètre — fil brun © Fil (-) du multimètre — fil noir ©

Ci] Muitifunction | Tester Lo [| display input | selector voltage position

10 V or more | DCV-20

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

MULTI-FUNCTION DISPLAY OUTPUT VOLTAGE INSPECTION

1. Disconnect the multi-function display coupler.

2. Setthe main switch to “ON”.

Tester (+) lead — Red lead D Tester (-) lead — Black/White lead ©

[| n Multi-function | Tester Lo L display output | selector voltage

4.5 V or more | DCV-20

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

SPEED SENSOR OUTPUT VOLTAGE INSPECTION

1. Insert the thin electric conduc- tors © (lead) into the speed sen- sor coupler @, as shown, and connect the tester to them.

Tester (+) lead — White lead © Tester (-) lead — Black lead @

+ Do not insert the electric con- ductors more than required because it may reduce the waterproof function of the cou- pler.

Make sure that a short-circuit does not develop between the terminals because it may cause damage to electrical compo- nents.

Fil (+) du multimètre — fil rouge © Fil (=) du multimètre —

2. Setthe main switch to “ON”.

+ 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.