Yamaha YZ250F(Y), Owner'S Service Manual

Page 1: ...ce manuel avant la premi re utilisation du v hicule Read this manual carefully before operating this vehicle Bitte lesen Sie diese Bedienungsanleitung sorgf ltig durch bevor Sie das Fahrzeug in Betri...

Page 2: ...le Le manuel doit tre remis avec le v hicule en cas de vente de ce dernier Bitte lesen Sie diese Bedienungsanleitung sorgf ltig durch bevor Sie das Fahrzeug in Betrieb nehmen Diese Bedienungsanleitung...

Page 3: ...Z250F Y 2009 2009 5XC 28199 35 E0 5XC 28199 35 E0 OWNER S SERVICE MANUAL OWNER S SERVICE MANUAL Read this manual carefully before operating this vehicle Read this manual carefully before operating thi...

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Page 5: ...S SERVICE MANUAL 2008 by Yamaha Motor Co Ltd 1st Edition May 2008 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited P...

Page 6: ...acter istics THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY Do not carry passengers on this machine ALWAYS WEAR PROTECTIVE APPAREL When operating this machine al ways wear an approved helm...

Page 7: ...n to find the required fore edge symbol mark and go to a page for required item and de scription MANUAL FORMAT All of the procedures in this manual are organized in a sequential step by step format Th...

Page 8: ...informa tion the step by step format sup plements 5 are given in addition to the exploded diagram and job instruction chart ILLUSTRATED SYMBOLS Refer to the illustration Illustrated symbols 1 to 7 are...

Page 9: ...TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE 4 CHASSIS 5 ELECTRICAL 6 TUNING 7...

Page 10: ...3 14 ELECTRICAL 3 24 CHAPTER 4 ENGINE SEAT FUEL TANK AND SIDE COVERS 4 1 EXHAUST PIPE AND SILENCER 4 3 RADIATOR 4 5 CARBURETOR 4 7 CAMSHAFTS 4 14 CYLINDER HEAD 4 19 VALVES AND VALVE SPRINGS 4 21 CYLIN...

Page 11: ...t to change without notice 1 Clutch lever 2 Hot starter lever 3 Front brake lever 4 Throttle grip 5 Radiator cap 6 Fuel tank cap 7 Engine stop switch 8 Kickstarter crank 9 Fuel tank 10 Radiator 11 Coo...

Page 12: ...joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose In this installation make sure the arrow faces the fuel tank and also downward SPARK PLUG WRENCH This spark plug...

Page 13: ...mped letters must be on the side exposed to view When in stalling oil seal s apply a light coating of lightweight lithium base grease to the seal lip s Oil the bearings liberally when installing Do no...

Page 14: ...se separating tool YU 1135 A 90890 01135 These tool is used to remove the crankshaft from either case Flywheel puller YM 1189 90890 01189 This tool is used to remove the fly wheel magneto Rotor holdin...

Page 15: ...1500 90890 01500 This tool is used to loosen or tighten the base valve Cap bolt ring wrench YM 01501 90890 01501 This tool is used to loosen or tighten the damper assembly Fork seal driver YM A0948 90...

Page 16: ...ss securing nut Valve guide remover Intake 4 0 mm 0 16 in Exhaust 4 5 mm 0 18 in YM 4111 90890 04111 YM 4116 90890 04116 This tool is needed to remove and install the valve guide Valve guide installer...

Page 17: ...ecessary for checking the ignition system compo nents Digital tachometer YU 39951 B 90890 06760 This tool is needed for observing en gine rpm YAMAHA Bond No 1215 ThreeB ond No 1215 90890 85505 This se...

Page 18: ...AR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine Press down on the brake pedal to activate the rear brake FUEL COCK The fuel cock supplies fuel from the tank to carbur...

Page 19: ...e cold starter knob to its original position and run the en gine at 3 000 5 000 r min for 1 or 2 minutes Since this model is equipped with an accelerator pump if the engine is raced the throttle opene...

Page 20: ...2 open low to me dium speed for about one hour 6 Restart the engine and check the operation of the machine through out its entire operating range Re start the machine and operate it for about 10 to 15...

Page 21: ...nk type Assembly of links Link to frame Link to rear shock absorber Link to swingarm Installation of rear shock absorber Rear shock absorber to frame Installation of swingarm Tightening of pivot shaft...

Page 22: ...in with a paper towel and lubri cate 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...

Page 23: ...Without oil and fuel 92 7 kg 204 lb Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Single cylinder forward inclined Displacement 249 cm3 8 76 Imp oz 8 42 US oz Bore stroke 77 0 5...

Page 24: ...ystem Chain drive Secondary reduction ratio 49 13 3 769 51 13 3 923 Transmission type Constant mesh 5 speed Operation Left foot operation Gear ratio 1st 30 14 2 143 2nd 28 16 1 750 3rd 29 20 1 450 4th...

Page 25: ...2 in Cylinder Bore size 77 00 77 01 mm 3 0315 3 0319 in Out of round limit 0 05 mm 0 002 in Camshaft Drive method Chain drive Left Camshaft cap inside diameter 22 000 22 021 mm 0 8661 0 8670 in Camsha...

Page 26: ...0 0059 in EX 0 17 0 22 mm 0 0067 0 0087 in Valve dimensions A head diameter IN 22 9 23 1 mm 0 9016 0 9094 in A head diameter EX 24 4 24 6 mm 0 9606 0 9685 in B face width IN 2 26 mm 0 089 in B face w...

Page 27: ...4 in Valve seat width IN 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Valve seat width EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Valve spring Free length IN 37 81 mm 1 49 in 36 81mm 1 45 in Free...

Page 28: ...B T 0 90 2 75 mm 0 04 0 11 in End gap installed 0 15 0 25 mm 0 006 0 010 in 0 50mm 0 020 in Side clearance installed 0 030 0 065 mm 0 0012 0 0026 in 0 12 mm 0 005 in 2nd ring Type Taper Dimensions B...

Page 29: ...44 mm 0 0004 0 0017 in Clutch release method Inner push cam push Shifter Shifter type Cam drum and guide bar Guide bar bending limit 0 05 mm 0 002 in Kickstarter Type Kick and ratchet type Carburetor...

Page 30: ...or capacity total 0 58 L 0 51 Imp qt 0 61 US qt Water pump Type Single suction centrifugal pump Item Standard Limit Item Standard Limit Steering system Steering bearing type Taper roller bearing Front...

Page 31: ...k 50 60 mm 2 0 2 4 in Chain length 15 links 242 9 mm 9 563 in Front disc brake Disc outside dia Thickness 250 3 0 mm 9 84 0 12 in 250 2 5 mm 9 84 0 10 in Pad thickness 4 4 mm 0 17 in 1 0 mm 0 04 in Ma...

Page 32: ...mm 0 24 in Primary coil resistance 0 08 0 10 at 20 C 68 F Secondary coil resistance 4 6 6 8 k at 20 C 68 F Part to be tightened Thread size Q ty Tightening torque Nm m kg ft lb Spark plug M10S 1 0 1...

Page 33: ...0 1 2 0 2 1 4 Hot starter cable adjust bolt and locknut M6 0 75 1 4 0 4 2 9 Air filter case M6 1 0 2 8 0 8 5 8 Air filter joint and air filter case M5 0 8 1 4 0 4 2 9 Air filter element M6 1 0 1 2 0...

Page 34: ...steering ring nut M28 1 0 1 Refer to TIP Front fork and damper assembly M51 1 5 2 30 3 0 22 Front fork and adjuster M22 1 25 2 55 5 5 40 Damper assembly and base valve M42 1 5 2 29 2 9 21 Adjuster and...

Page 35: ...gine bracket and frame M8 1 25 4 38 3 8 27 Engine and engine bracket upper M10 1 25 1 55 5 5 40 Lower engine guard M6 1 0 3 10 1 0 7 2 Right engine guard M6 1 0 1 10 1 0 7 2 CDI unit bracket M6 1 0 2...

Page 36: ...0 4 7 0 7 5 1 Air scoop and fuel tank M6 1 0 6 7 0 7 5 1 Air scoop and radiator guard lower M6 1 0 2 7 0 7 5 1 Front fender M6 1 0 4 7 0 7 5 1 Rear fender front M6 1 0 2 7 0 7 5 1 Rear fender rear M6...

Page 37: ...s should be at room temperature A Distance between flats B Outside thread diameter DEFINITION OF UNITS A Nut B Bolt TORQUE SPECIFI CATION Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm...

Page 38: ...2 16 LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Oil filter element 2 Oil pump 3 Drive axle 4 Main axle 5 Intake camshaft 6 Exhaust camshaft 7 Oil tank 8 Oil delivery pipe A To oil tank...

Page 39: ...2 17 LUBRICATION DIAGRAMS 1 Crankshaft 2 Oil filter element 3 Oil tank 4 Oil hose A From oil pump...

Page 40: ...el hose 12 Carburetor overflow hose A Insert the end of the fuel tank breather hose into the hole in the steering stem B Install the connector cover so that it does not come in between the radiator ho...

Page 41: ...the fuel hose on the out side of throttle position sensor lead H Pass the carburetor breater hos es so that they are not pinched between the upper engine bracket and carburetor I Pass the carburetor...

Page 42: ...ine stop switch lead 14 Sub wire harness 15 CDI unit bracket 16 CDI unit 17 Throttle cable 18 Cylinder head breather hose 19 Hot starter cable protector 20 Rubber cap A Fasten the hot starter cable th...

Page 43: ...t at the white taped portion of the subwire har ness and with the clamp ends facing downward H Locate the clamp ends in the ar rowed range I Fasten the neutral switch lead and CDI magneto lead over th...

Page 44: ...Cylinder head breather hose 6 Clamp 7 Rear arm bracket A Pass the throttle cables over the radiator hose 2 B Pass the cylinder head breather hose so that it does not contact the ignition coil C Fasten...

Page 45: ...directs as shown and lightly touches the projec tion on the brake caliper B Pass the brake hose into the brake hose holders C If the brake hose contacts the spring rear shock absorber correct its twis...

Page 46: ...hose 8 Hose guide A Fasten the engine stop switch lead to the handlebar B Pass the clutch cable and hot starter cable through the cable guide C Pass the brake hose in front of the number plate D Pass...

Page 47: ...NGINE OIL Replace Inspect OIL FILTER ELEMENT OIL STRAINER Clean VALVES Check the valve clearances The engine must be cold Inspect Check the valve seats and valve stems for wear Replace VALVE SPRINGS I...

Page 48: ...spect and clean CARBURETOR Inspect adjust and clean SPARK PLUG Inspect and clean Replace DRIVE CHAIN Use chain lube Lubricate slack alignment Chain slack 50 60 mm 2 0 2 4 in Replace COOLING SYSTEM Che...

Page 49: ...FRONT FORKS Inspect and adjust Replace oil Suspension oil S1 Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium base grease PROTECTOR GUIDE Replace REAR SHOCK ABSORBER Inspect a...

Page 50: ...et bolt Inspect bearings Replace bearings Lubricate Lithium base grease THROTTLE CONTROL CABLE Check routing and connection Lubricate Yamaha cable lube or SAE 10W 30 motor oil Inspect and clean thrott...

Page 51: ...lack and alignment Check that the drive chain is lubricated properly P 3 17 18 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 20 21 Steering Ch...

Page 52: ...clean tap water 5 Install Copper washer Coolant drain bolt 6 Fill Radiator Engine To specified level Do not mix more than one type of ethylene glycol antifreeze con taining corrosion inhibitors for al...

Page 53: ...UTCH CABLE FREE PLAY 1 Check Clutch lever free play a Out of specification Adjust 2 Adjust Clutch lever free play Clutch lever free play adjustment steps a Loosen the locknuts 1 b Turn the adjuster 2...

Page 54: ...oper ation of hot starter CLEANING THE AIR FILTER ELEMENT Proper air filter maintenance is the biggest key to preventing premature engine wear and damage Never run the engine without the air filter e...

Page 55: ...arm up for several minutes 6 Turn off the engine and inspect the oil level once again Wait a few minutes until the oil settles before inspecting the oil level CHANGING THE ENGINE OIL 1 Start the engin...

Page 56: ...the fuel flow at a smaller throttle opening each machine s pilot screw has been individually set at the factory Before adjusting the pilot screw turn it in fully and count the number of turns Record...

Page 57: ...ve clearance Out of specification Adjust Checking steps a Turn the crankshaft counterclock wise with a wrench b Align the T D C mark a on the rotor with the align mark b on the crankcase cover when pi...

Page 58: ...d number to use Use the new pad number only as a guide when verifying the valve clear ance adjustment f Install the new pads 3 and the valve lifters 4 Apply the engine oil on the valve lift ers Apply...

Page 59: ...3 13 ENGINE INTAKE EXHAUST...

Page 60: ...bleeding procedure when the tiny bubbles in the system have disap peared j Add brake fluid to the level line on the reservoir Check the operation of the brake after bleeding the brake system 3 Install...

Page 61: ...the brake caliper re cesses b Temporarily tighten the pad pin at this point i Install the brake caliper 8 and tighten the pad pin 9 j Install the pad pin plug 10 3 Inspect Brake fluid level Refer to C...

Page 62: ...ion A softy or spongy feeling Bleed brake system Refer to BLEEDING THE HY DRAULIC BRAKE SYSTEM sec tion CHECKING THE REAR BRAKE PAD INSULATOR 1 Remove Brake pad Refer to CHECKING AND RE PLACING THE RE...

Page 63: ...the en gine 2 Check Drive chain slack a Above the seal guard installation bolt Out of specification Adjust Before checking and or adjusting ro tate the rear wheel through several revolutions and check...

Page 64: ...E FRONT FORK REBOUND DAMPING FORCE 1 Adjust Rebound damping force By turning the adjuster 1 STANDARD POSITION This is the position which is back by the specific number of clicks from the fully turned...

Page 65: ...mud from around the locknut and adjust er 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...

Page 66: ...er with the punch mark b on the adjuster body Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged CHECKING THE TIRE PRESSURE 1 Measure Tire pressure...

Page 67: ...h action Adjust steer ing ring nut 4 Adjust Steering ring nut Steering ring nut adjustment steps a Remove the number plate b Remove the handlebar and upper bracket c Loosen the steering ring nut 1 usi...

Page 68: ...older is positioned at the mark on the handlebar as shown Insert the end of the fuel breather hose 12 into the hole in the steer ing stem First tighten the bolts on the front side of the handlebar upp...

Page 69: ...ot 5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding por tion 8 Throttle cable end 9 Clutch cable end 10 Hot starter cable end A Use Yamaha cable lube or equivalent on these are...

Page 70: ...r if necessary 5 Tighten Spark plug Before installing a spark plug clean the gasket surface and plug sur face Finger tighten a the spark plug before torquing to specification b CHECKING THE IGNITION T...

Page 71: ...nspection adjustment disassembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage SEAT FUEL TANK AND SIDE COVERS REMOVING THE SEAT FUEL TANK AND SI...

Page 72: ...a is inserted into the band of the number plate Pull the band off the projection before removal Remove the hot starter cable 2 and clutch cable 3 from the cable guide b on the number plate The projec...

Page 73: ...t name Q ty Remarks A Except for USA and CDN Right side cover Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Bolt silencer clamp 1 Only loosening 2 Bolt silencer front 1 3 Bolt silencer rear 1 4 Co...

Page 74: ...e care not to allow the fiber out of place when installing the inner pipe INSTALLING THE SILENCER AND EXHAUST PIPE 1 Install Gasket Exhaust pipe 1 Nut exhaust pipe 2 First temporarily install both nut...

Page 75: ...NT sec tion in the CHAPTER 3 Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Radiator guard 2 2 Radiator hose clamp 8 Only loosening 3 Radiator hose 1 1 4 Left radiator 1 5 Radiat...

Page 76: ...n Repair replace INSTALLING THE RADIATOR 1 Install O ring 1 Radiator pipe 1 2 Bolt radiator pipe 3 Apply the lithium soap base grease on the O ring 2 Install Radiator breather hose 1 Radiator hose 2 2...

Page 77: ...le 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...

Page 78: ...sing cover 1 3 Screw throttle shaft 1 4 Throttle valve 1 5 Needle holder 1 6 Jet needle 1 7 Accelerator pump cover 1 8 Spring 1 9 Diaphragm accelerator pump 1 10 Float chamber 1 11 Leak jet 1 12 Pilot...

Page 79: ...URETOR 19 Pilot jet 1 20 Starter jet 1 21 Push rod 1 Pull the push rod 22 Throttle shaft assembly 1 23 Push rod link lever assembly 1 24 Pilot air jet 1 25 Cold starter plunger 1 Order Part name Q ty...

Page 80: ...logged Clean CHECKING THE THROTTLE VALVE 1 Check Free movement Stick Repair or replace Insert the throttle valve 1 into the carburetor body and check for free movement CHECKING THE JET NEEDLE 1 Inspec...

Page 81: ...fits on the stopper a of the lever 2 4 Install Spring 2 1 To lever 2 2 5 Install Push rod link lever assembly 1 Make sure the stopper a of the spring 2 fits into the recess b in the carburetor 6 Inst...

Page 82: ...of turns recorded before removing 13 Install O ring Leak jet 1 Float chamber 2 Bolt float chamber 3 Cable holder throttle stop screw cable 4 Hose holder carburetor breather hose 5 14 Install Diaphragm...

Page 83: ...oint 1 2 Install Carburetor 1 Install the projection a between the carburetor joint slots 3 Install Hot starter plunger 1 4 Tighten Bolt carburetor joint 1 Bolt air filter joint 2 5 Install Throttle c...

Page 84: ...Order Part name Q ty Remarks Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Spark plug 1 2 Cylinder head breather hose 1 3 Bolt cylinder head cover 2 4 Cylinder head cover 1 5 Cy...

Page 85: ...haft end accessing screw 1 Refer to removal section 3 Timing chain tensioner cap bolt 1 Refer to removal section 4 Timing chain tensioner 1 Refer to removal section 5 Camshaft cap 2 Refer to removal s...

Page 86: ...ap 2 Clip 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...

Page 87: ...decompression mechanism cam lever pin 2 projects from the camshaft CHECKING THE TIMING CHAIN TENSIONER 1 Check While pressing the tensioner rod lightly with fingers use a thin screwdriver 1 and wind...

Page 88: ...se a thin screwdriver and wind the tension er rod up fully clockwise b With the rod fully wound and the chain tensioner UP mark a fac ing upward install the gasket 1 and the timing chain tensioner 2 a...

Page 89: ...cer Refer to EXHAUST PIPE AND SILENCER section Radiator hose 1 Disconnect at cylinder head side Carburetor Refer to CARBURETOR section Camshaft Refer to CAMSHAFTS section Upper engine bracket Refer to...

Page 90: ...several times INSTALLING THE CYLINDER HEAD 1 Install Dowel pin 1 Cylinder head gasket 2 Timing chain guide exhaust side 3 Cylinder head 4 While pulling up the timing chain in stall the timing chain g...

Page 91: ...e Q ty Remarks Cylinder head Refer to CYLINDER HEAD section 1 Valve lifter 5 Refer to removal section 2 Adjusting pad 5 Refer to removal section 3 Valve cotter 10 Refer to removal section 4 Valve spri...

Page 92: ...to 100 C 212 F a Remove the valve guide using a valve guide remover 1 b Install the new valve guide using a valve guide remover 1 and valve guide installer 2 c After installing the valve guide bore t...

Page 93: ...mpound enter the gap between the valve stem and the guide b Apply molybdenum disulfide oil to the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve...

Page 94: ...ger pitch d facing upward e Smaller pitch 3 Install Valve cotter While compressing the valve spring with a valve spring compressor 1 in stall the valve cotters 4 To secure the valve cotters onto the v...

Page 95: ...TON Order Part name Q ty Remarks Cylinder head Refer to CYLINDER HEAD section 1 Bolt cylinder 1 2 Cylinder 1 3 Piston pin clip 2 Refer to removal section 4 Piston pin 1 Refer to removal section 5 Pist...

Page 96: ...e piston bottom edge d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with following formula f If out of specification replace the cy...

Page 97: ...ng Offset the piston ring end gaps as shown a Top ring end b 2nd ring end c Oil ring end upper d Oil ring e Oil ring end lower 3 Install Piston 1 Piston pin 2 Piston pin clip 3 Apply engine oil onto t...

Page 98: ...he cylinder with one hand while compressing the piston rings with the other hand Pass the timing chain 3 through the timing chain cavity Be careful not to damage the tim ing chain guide 4 during insta...

Page 99: ...ER 3 Brake pedal Refer to ENGINE REMOVAL section Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Clutch spring 5 3 Pressure plate 1 4 Push rod 1 1 5 Circlip 1 6 Washer 1 7 Bearing 1 8 Ball 1...

Page 100: ...4 30 CLUTCH 14 Clutch boss 1 Refer to removal section 15 Thrust washer 1 16 Primary driven gear 1 17 Spacer 1 18 Washer 1 19 Push lever shaft 1 Order Part name Q ty Remarks...

Page 101: ...1 Measure Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thick ness gauge 2 CHECKING THE PUSH LEVER SHAFT 1 Inspect Push lever shaft 1 Wear damage Re...

Page 102: ...ction plates and clutch plates 5 Install Bearing 1 Washer 2 Circlip 3 To push rod 1 4 Apply the engine oil on the bearing and washer 6 Install Push rod 2 1 Ball 2 Push rod 1 3 Apply the engine oil on...

Page 103: ...the coolant Refer to CHANGING THE COOLANT sec tion in the CHAPTER 3 Radiator hose 3 Disconnect at water pump side Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section Brake pedal Refer to ENGINE RE...

Page 104: ...ER ELEMENT AND WATER PUMP 9 Washer 1 Refer to removal section 10 Impeller shaft 1 Refer to removal section 11 Oil seal 2 Refer to removal section 12 Bearing 1 Refer to removal section Order Part name...

Page 105: ...damage Replace CHECKING THE BEARING 1 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace CHECKING THE OIL SEAL 1 Inspect Oil seal 1 Wear damage Replace INSTALLING THE OIL SEAL...

Page 106: ...t the crankcase cover when it is pulled 2 Install Oil hose 1 Bolt oil hose 2 3 Install Copper washer 1 Oil delivery pipe 2 Union bolt M8 3 Union bolt M10 4 INSTALLING THE WATER PUMP HOUSING 1 Install...

Page 107: ...IL FILTER ELEMENT AND WA TER PUMP section Stator Refer to CDI MAGNETO section 1 Nut primary drive gear 1 Refer to removal section 2 Nut balancer shaft driven gear 1 Refer to removal section 3 Lock was...

Page 108: ...the center a of the balancer shaft weight along the line connect ing the centers of the crankshaft and balancer shaft 2 Install Balancer shaft driven gear 1 Install the balancer shaft driven gear ont...

Page 109: ...ankcase cover Refer to OIL FILTER ELEMENT AND WA TER PUMP section 1 Circlip 1 2 Washer 1 3 Oil pump drive gear 1 4 Oil pump assembly 1 5 Outer rotor 2 1 6 Circlip 1 7 Inner rotor 2 1 8 Dowel pin 1 9 O...

Page 110: ...THE OIL TANK Order Part name Q ty Remarks Drain the engine oil Refer to CHANGING THE ENGINE OIL section in the CHAPTER 3 1 Oil hose 2 1 2 Oil hose 1 1 3 Dowel pin 2 4 Oil tank breather hose 1 5 Oil t...

Page 111: ...tor 1 1 Apply the engine oil on the outer rotor 1 3 Install Oil pump cover 1 Screw oil pump cover 2 Dowel pin 3 Inner rotor 2 4 Circlip 5 Apply the engine oil on the inner ro tor 2 Fit the dowel pin i...

Page 112: ...ection 1 Kick idle gear 1 2 Kick shaft assembly 1 Refer to removal section 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick shaft 1 8 Washer 1 9 Shift pedal 1 10 Shift shaft...

Page 113: ...4 43 KICK SHAFT AND SHIFT SHAFT 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt stopper lever 1 21 Stopper lever 1 22 Torsion spring 1 23 Segment 1 Refer to removal section Order Part name Q ty Remarks...

Page 114: ...KING THE KICK GEAR KICK IDLE GEAR AND RATCHET WHEEL 1 Inspect Kick gear 1 Kick idle gear 2 Ratchet wheel 3 Gear teeth a Ratchet teeth b Wear damage Replace CHECKING THE SHIFT SHAFT 1 Inspect Shift sha...

Page 115: ...BLY 1 Install Kick gear 1 Washer 2 Circlip 3 Ratchet wheel 4 Spring 5 Washer 6 Circlip 7 To kick shaft 8 Apply the molybdenum disulfide oil on the inner circumferences of the kick gear and ratchet whe...

Page 116: ...n spring clockwise and hook into the proper hole a in the crankcase INSTALLING THE KICK IDLE GEAR 1 Install Kick idle gear 1 Washer 2 Circlip 3 Apply the engine oil on the kick idle gear inner circumf...

Page 117: ...Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Disconnect the CDI magneto lead Shift pedal Refer to KICK SHAFT AND SHIFT SHAFT section 1 Left crankcase cover 1 2 Nut rotor 1 Refer...

Page 118: ...portions of the crankshaft and rotor When installing the woodruff key make sure that its flat surface a is in parallel with the crankshaft center line b When installing the rotor align the keyway c o...

Page 119: ...ction Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section Clutch cable Disconnect at the engine side Radiator Refer to RADIATOR section Shift pedal Refer to KICK SHAFT AND SHIFT SHAFT...

Page 120: ...val section 5 Lock washer 1 Refer to removal section 6 Drive sprocket 1 Refer to removal section 7 Clip 1 8 Bolt brake pedal 1 9 Brake pedal 1 10 Upper engine bracket 2 11 Lower engine bracket 2 12 En...

Page 121: ...t 4 Bolt lower engine bracket 5 Patch 6 Engine mounting bolt front 7 Upper engine bracket 8 Bolt upper engine bracket 9 Engine mounting bolt upper 10 Lower engine guard 11 Bolt lower engine guard 12 A...

Page 122: ...chain sprocket cov er 3 INSTALLING THE NEUTRAL SWITCH 1 Install Spring 1 Pin 2 O ring 3 Neutral switch 4 Screw neutral switch 5 Apply the lithium soap base grease on the O ring 2 Install Hose guide c...

Page 123: ...KICK SHAFT AND SHIFT SHAFT section Stator Refer to CDI MAGNETO section Balancer shaft Refer to BALANCER section 1 Timing chain guide intake side 1 2 Timing chain 1 3 Oil delivery pipe 2 1 4 Bolt L 45...

Page 124: ...4 54 CRANKCASE AND CRANKSHAFT 10 Left crankcase 1 Refer to removal section 11 Oil strainer 1 12 Crankshaft 1 Refer to removal section Order Part name Q ty Remarks...

Page 125: ...RANKCASE BEARING Order Part name Q ty Remarks Transmission Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section Shift cam and shift fork Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section 1 Oil...

Page 126: ...Do not use a hammer to drive out the crankshaft REMOVING THE CRANKCASE BEARING 1 Remove Bearing 1 Remove the bearing from the crankcase by pressing its inner race Do not use the removed bearing CHECKI...

Page 127: ...center with one hand while turning the nut of the installing tool with the other Operate the installing tool un til the crankshaft bottoms against the bearing Before installing the crankshaft clean th...

Page 128: ...rankcase tightening bolts in stage using a crisscross pat tern 7 Install Oil delivery pipe 2 1 O ring 2 Bolt oil delivery pipe 2 3 Apply the lithium soap base grease on the Orings 8 Install Timing cha...

Page 129: ...Engine Refer to ENGINE REMOVAL section Separate the crankcase Refer to CRANKCASE AND CRANK SHAFT section 1 Main axle 1 Refer to removal section 2 Drive axle 1 Refer to removal section 3 Shift cam 1 R...

Page 130: ...THE SHIFT FORK SHIFT CAM AND SEGMENT 1 Inspect Shift fork 1 Wear damage scratches Re place 2 Inspect Shift cam 1 Segment 2 Wear damage Replace 3 Check Shift fork movement Unsmooth operation Replace s...

Page 131: ...ion to the crankcase oil seal lip 5 Install Shift fork 1 L 1 Shift fork 2 C 2 Shift fork 3 R 3 Shift cam 4 To main axle and drive axle Apply the molybdenum disulfide oil on the shift fork grooves Mesh...

Page 132: ...ertake inspection adjustment disassembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage FRONT WHEEL AND REAR WHEEL REMOVING THE FRONT WHEEL Order...

Page 133: ...hine by placing the suitable stand under the engine Refer to HANDLING NOTE 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 Refer to removal section 5 Collar 2 6 Rear...

Page 134: ...ake disc deflection only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in good condi tion replace the brake disc 2 Measure Brake disc thickness a Ou...

Page 135: ...al 5 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...

Page 136: ...l axle 2 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 1 Washer 2 Nut wheel axle...

Page 137: ...and under the engine Refer to HANDLING NOTE Drain the brake fluid Refer to removal section 1 Brake hose holder protector 2 2 Union bolt 2 3 Brake hose 1 4 Pad pin plug 1 Remove when loosening the pad...

Page 138: ...e Refer to HANDLING NOTE Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Drain the brake fluid Refer to removal section 1 Brake pedal 1 2 Brake master cylinder 1 3 Brake hose holder 2 4 Union b...

Page 139: ...der Part name Q ty Remarks A Front B Rear A B 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Brake caliper piston 2 1 Refer to removal section 5 Brake caliper piston dust seal 2 1 Refer to removal...

Page 140: ...INDER Order Part name Q ty Remarks A Front B Rear 1 Brake master cylinder cap 1 2 Diaphragm 1 3 Reservoir float 1 4 Push rod Front 1 5 Brake master cylinder boot 1 6 Circlip 1 Use a long nose circlip...

Page 141: ...steps a Insert a piece of rag into the brake caliper to lock one brake caliper b Carefully force the piston out of the brake caliper cylinder with compressed air A Front B Rear REMOVING THE BRAKE CAL...

Page 142: ...n Clean them with brake fluid 2 Install Brake caliper piston seal 1 Brake caliper piston dust seal 2 Always use new brake caliper pis ton seals and brake caliper piston dust seals Apply the brake flui...

Page 143: ...g installation cause improper brake performance 3 Install Spring 1 To brake master cylinder piston 2 Install the spring at the smaller dia side 4 Install Brake master cylinder kit 1 Washer front brake...

Page 144: ...Install Pin 1 Washer 2 Cotter pin 3 After installing check the brake pedal height Refer to ADJUSTING THE REAR BRAKE section in the CHAP TER 3 INSTALLING THE FRONT BRAKE HOSE 1 Install Copper washer 1...

Page 145: ...ise 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 perfor...

Page 146: ...r pushing down on the brake pedal check whether there is any brake fluid leaking where the union bolts are installed respectively at the brake master cylinder and brake caliper A Front B Rear 5 Instal...

Page 147: ...to FRONT WHEEL AND REAR WHEEL section Front brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Number plate Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 1 Protector 1 2 Pin...

Page 148: ...ing 1 Refer to removal section 5 Inner tube 1 Refer to removal section 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Oil seal washer 1 10 Oil seal 1 11 Base valve 1 Drain the fork oil Refer to rem...

Page 149: ...the inner tube and locknut 3 Hold the locknut and remove the adjuster Do not remove the locknut as the damper rod may go into the damp er assembly and not be taken out REMOVING THE INNER TUBE 1 Remov...

Page 150: ...damage Re place CHECKING THE ADJUSTER 1 Inspect Adjuster 1 O ring 2 Wear damage Replace ASSEMBLING THE FRONT FORK 1 Wash the all parts in a clean sol vent 2 Stretch the damper assembly ful ly 3 Fill...

Page 151: ...up and down more than 10 times to distribute the fork oil 12 While protecting the damper as sembly 1 with a rag and com pressing fully allow excessive oil to overflow on the base valve side Take care...

Page 152: ...dia end a facing the fork spring 25 Install Damper assembly 1 To inner tube 2 To install the damper assembly into the inner tube hold the inner tube aslant If the inner tube is held vertically the dam...

Page 153: ...n the front fork per formance Never allow foreign materials to enter the front fork 32 Install Damper assembly 1 To outer tube Temporarily tighten the damper as sembly 33 Install Protector guide 1 INS...

Page 154: ...Bolt protector 2 6 Adjust Rebound damping force Turn in the damping adjuster 1 fin ger tight and then turn out to the orig inally set position 7 Adjust Compression damping force Turn in the damping a...

Page 155: ...er side 4 Clutch lever holder 1 5 Engine stop switch 1 6 Brake master cylinder 1 Refer to removal section 7 Throttle cable cap 1 8 Throttle cable 1 pulled 1 Disconnect at the throttle side 9 Throttle...

Page 156: ...ar low er holder Change in the direction back to front and installing position of the handlebar lower holder allows the front to rear offset amount of the handlebar position to be changed Do not tight...

Page 157: ...tighten the bolts for adjustment 9 Install Grip cap cover 1 Cover throttle cable cap 2 10 Install Brake master cylinder 1 Brake master cylinder bracket 2 Bolt brake master cylinder brack et 3 Install...

Page 158: ...m soap base grease on the clutch cable end and hot start er cable end 13 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY section in the CHAPTER 3 Hot starter lever free pla...

Page 159: ...er the engine Refer to HANDLING NOTE Number plate Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Handlebar Refer to HANDLEBAR section Front fender 1 Steering stem nut 1 2 Front fork...

Page 160: ...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 INSTALLING THE LOWER BRACKET 1 Install...

Page 161: ...If not adjust the steering by loosen ing the steering ring nut little by lit tle 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 Tighten the lower brack...

Page 162: ...NG NOTE Brake hose holder Refer to FRONT BRAKE AND REAR BRAKE section Rear brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Bolt brake pedal Shift the brake pedal backward Drive chain 1 Drive...

Page 163: ...SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q ty Remarks 1 Relay arm 1 2 Connecting rod 1 3 Collar 2 4 Oil seal 2 5 Thrust bearing 2 6 Bushing 2 7 Oil seal 8 8 Bearing 10 Refer to removal sec...

Page 164: ...tall 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 2 Install Bearing 1 Washer 2...

Page 165: ...denum disulfide grease on the pivot shaft Insert the pivot shaft from right side 7 Check Swingarm side play a Free play exists Replace thrust bearing Swingarm up and down move ment b Unsmooth movement...

Page 166: ...stall Drive chain support 1 Drive chain support cover 2 Bolt drive chain support L 50 mm 1 97 in 3 Nut drive chain support 4 Bolt drive chain support cover L 10 mm 0 39 in 5 Nut lower chain tension er...

Page 167: ...section in the CHAPTER 4 Silencer Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 4 1 Clamp air filter joint 1 Only loosening 2 Rear frame 1 3 Bolt rear shock absorber relay arm 1 Hold the...

Page 168: ...k ab sorber be sure to extract the nitrogen gas from valve 1 Wear eye protec tion to prevent eye damage from es caping gas and or metal chips To dispose of a damaged or worn out rear shock absorber ta...

Page 169: ...the molybdenum disulfide grease on the bearing and dust seal lips Install the dust seals with their lips facing outward 3 Install Rear shock absorber 4 Install Bolt rear shock absorber frame 1 Washer...

Page 170: ...rvicing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowledge and skill concerning servicing are request ed not to undertake inspection adjustment disassembly...

Page 171: ...ion sensor 3 Neutral switch 4 CDI magneto 5 Ignition coil 6 Spark plug 7 CDI unit COLOR CODE B Black Br Brown G Green L Blue O Orange P Pink R Red Sb Sky blue W White Y Yellow B L Black Blue B W Black...

Page 172: ...following special tools in this inspection Spark gap test Spark Clean or replace spark plug No spark Check entire ignition system for connection couplers leads and ignition coil No good Repair or rep...

Page 173: ...L 1 Remove the ignition coil cap 2 Inspect Primary coil resistance Out of specification Replace 3 Inspect Secondary coil resistance Out of specification Replace 4 Inspect Sealed portion of ignition co...

Page 174: ...is engaged Re place Set the tester selection position to 1 CHECKING THE CDI UNIT Check all electrical components If no fault is found replace the CDI unit Then check the electrical compo nents again T...

Page 175: ...IGNITION SYSTEM section Use the following special tools in this inspection Check entire ignition system for connection No good Repair or replace OK Check throttle position sensor Throttle position sen...

Page 176: ...osition sensor 1 Screw throttle position sensor 2 Align the slot a in the throttle posi tion sensor with the projection b on the carburetor Temporarily tighten the screw throttle position sensor 5 Ins...

Page 177: ...Tighten the screw throttle position sensor using the T25 bit 14 Install the carburetor CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1 Disconnect the throttle position sensor coupler 2 Start th...

Page 178: ...essarily 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...

Page 179: ...up speed quickly Step down the jet needle clip by one groove and move up the nee dle to enrich the mixture Effects of changing the jet needle groove position reference A Idle B Fully open 1 No 5 groov...

Page 180: ...ard to lean out the mixture Example 70 80 CARBURETOR SETTING PARTS Standard leak jet 70 Main jet Size Part number Rich 188 4MX 14943 95 185 4MX 14943 44 182 4MX 14943 94 180 4MX 14943 43 STD 178 4MX 1...

Page 181: ...aner NFPN 5 NFPP 5 NFPQ 5 NFPR 5 NFPS 5 NFPT 5 NFPU 5 Lean 1 leaner NFLN 5 NFLP 5 NFLQ 5 NHKR 3 NFLS 5 NFLT 5 NFLU 5 Except for USA and CDN Diameter of straight portion Rich Lean N P Q R S T U Rich 1...

Page 182: ...the top Check that the accelerator pump operates smoothly except for rich mixture symp tom Rich mixture Raise jet needle clip position 1 groove up 1 4 3 4 throttle Hard breathing Lack of speed Lower...

Page 183: ...Under a stony or hard road condi tion the tire pressure should be higher to prevent a flat tire FRONT FORK SETTING The front fork setting should be made depending on the rider s feeling of an actual...

Page 184: ...ension 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 com...

Page 185: ...e ti tanium spring The unequal pitch spring is softer in initial characteristic than the equal pitch spring and is difficult to bottom out under full compression The I D mark a is marked at the end of...

Page 186: ...G THE REAR SHOCK ABSORBER SPRING PRELOAD in the CHAPTER 3 Preload adjusting extent is the same for the titanium and steel springs Maximum Minimum Position in which the spring is turned in 13 mm 0 51 i...

Page 187: ...tire range bottoming out Compression damping Turn adjuster clockwise about 2 clicks to in crease damping Oil amount Increase oil amount by about 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Spring Replace wi...

Page 188: ...avy and dragging Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Spring Replace with soft spring Poor road gripping Rebound damping Turn adjuster counterclockwise abo...

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Page 190: ...PRINTED IN JAPAN E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN...