YFM250XL(C) SERVICE MANUAL LIT-11616-12-01 4XE-F8197-10
YFM250XL SERVICE MANUAL 1998 by Yamaha Motor Corporation, U.S.A. First Edition, February1998 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A.
EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use.
EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual is intended as a handy, easy-to-read reference book for the mechanic. It is divided into chapters, sections and sub-sections. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and inspection procedures are laid out with the individual steps in sequential order. PAGE FEATURES The circled numbers below refer to the features indicated in the sample page.
EB003000 1 ILLUSTRATED SYMBOLS 2 GEN INFO Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter. SPEC 3 1 General information 2 Specifications 3 Periodic inspections and adjustments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical 9 Troubleshooting 4 INSP ADJ ENG 5 6 DRIV CARB 7 8 CHAS ELEC 9 – Illustrated symbols 0 to F are used to identify the specifications appearing in the text.
CHAPTER TITLES GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL CARBURETION DRIVE TRAIN CHASSIS GEN INFO 1 SPEC 2 INSP ADJ 3 ENG 4 CARB 5 DRIVE 6 CHAS 7 – ELECTRICAL TROUBLESHOOTING + ELEC 8 TRBL SHTG 9
CONTENTS CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ........................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER .................................................. 1-1 MODEL LABEL ...................................................................................... 1-1 IMPORTANT INFORMATION ...................................................................... 1-2 PREPARATION FOR REMOVAL PROCEDURES .................................
CHAPTER 3. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION ........................................................................................... 3-1 PERIODIC MAINTENANCE/LUBRICATION ................................................ 3-1 FENDER AND FUEL TANK ........................................................................... 3-3 FRONT FENDER .................................................................................... 3-3 REAR FENDER ......................................................
ELECTRICAL ............................................................................................... 3-38 BATTERY INSPECTION ...................................................................... 3-38 FUSE INSPECTION ............................................................................. 3-41 HEADLIGHT BEAM ADJUSTMENT ................................................... 3-42 HEADLIGHT BULB REPLACEMENT .................................................. 3-42 CHAPTER 4.
TIMING CHAIN ................................................................................... 4-30 CAM SPROCKET AND CAM DRIVE SPROCKET ............................... 4-31 TIMING CHAIN GUIDE ....................................................................... 4-31 TIMING CHAIN TENSIONER .............................................................. 4-31 TAPPET COVER AND CAM SPROCKET COVER ............................... 4-32 CYLINDER AND PISTON .........................................................
CHAPTER 5. CARBURETION CARBURETOR .............................................................................................. 5-1 REMOVAL ............................................................................................. 5-2 DISASSEMBLY ..................................................................................... 5-2 INSPECTION ......................................................................................... 5-4 ASSEMBLY .........................................................
CHAPTER 7. CHASSIS FRONT WHEELS AND FRONT BRAKE ....................................................... 7-1 REMOVAL ............................................................................................. 7-2 INSPECTION ......................................................................................... 7-3 INSTALLATION ..................................................................................... 7-6 GEN INFO 1 SPEC 2 STEERING SYSTEM ...................................................
IGNITION SYSTEM ...................................................................................... 8-7 CIRCUIT DIAGRAM .............................................................................. 8-7 TROUBLESHOOTING ........................................................................... 8-8 ELECTRIC STARTING SYSTEM ................................................................. 8-12 CIRCUIT DIAGRAM ............................................................................
FAULTY DRIVE TRAIN ................................................................................. 9-3 FAULTY GEAR SHIFTING ............................................................................ 9-4 HARD SHIFTING ................................................................................... 9-4 SHIFT PEDAL DOES NOT MOVE ......................................................... 9-4 JUMPS OUT OF GEAR .........................................................................
MACHINE IDENTIFICATION GEN INFO GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame. 1 MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.
IMPORTANT INFORMATION GEN INFO EB101000 IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES 1.Remove all dirt, mud, dust and foreign material before removal and disassembly. 2.Use proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS” section. 3.When disassembling the machine, always keep mated parts together. This includes gears, cylinder, piston and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4.
IMPORTANT INFORMATION GEN INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1.Replace all lock washers/plates 1 and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. EB101040 BEARINGS AND OIL SEALS 1.Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, apply a light coating of lightweight lithium base grease to the seal lips.
CHECKING OF CONNECTIONS GEN INFO EB801000 CHECKING OF CONNECTIONS Check the connectors for stains, rust, moisture, etc. 1.Disconnect: ● Connector 2.Check: ● Connector Moisture → Dry each terminal with an air blower. Stains/rust → Connect and disconnect the terminals several times. 3.Check: ● Connector leads Looseness → Bend up the pin 1 and connect the terminals. 1 4.Connect: ● Connector terminals NOTE: The two terminals “click” together. 5.
SPECIAL TOOLS GEN INFO EB102001 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country. In such a case, two types are provided. When placing an order, refer to the list provided below to avoid any mistakes. For US and CDN P/N.
SPECIAL TOOLS 4-B 1 GEN INFO 5 Compression gauge P/N. 90890-03081 Extension P/N. 90890-04082 Fuel level gauge P/N. YM-01312-A P/N. 90890-01312 This gauge is used to measure the engine compression. This gauge is used to measure the fuel level in the float chamber. 1 Rotor holder P/N. YU-01235 P/N. 90890-01235 FOR ENGINE SERVICE This tool is used to hold the starter pulley and clutch when removing or installing the starter pulley and clutch boss securing nut. 2 3-A Piston pin puller P/N.
SPECIAL TOOLS GEN INFO 7-A 7-B Slide hammer set P/N. YU-01083-A Slide hammer bolt (M6) P/N. 90890-01083 Weight P/N. 90890-01084 These tools are used when removing the rocker arm shaft. These tools are used when removing the rocker arm shaft. 8 9-A Valve spring compressor P/N. YM-04019 P/N. 90890-04019 Valve guide remover and installer 6mm (0.24 in) Valve guide remover P/N. YM-4064-A-1 Valve guide installer P/N. YM-04065-A-2 Valve guide reamer P/N.
SPECIAL TOOLS GEN INFO 13 Sealant (Quick Gasket) P/N. ACC-QUICK-GS-KT YAMAHA bond No. 1215 P/N. 90890-85505 1 This sealant (bond) is used for crankcase mating surface, etc. 1-A Universal joint holder P/N. YM-04062 Attachment P/N. YM-33291 FOR DRIVE TRAIN SERVICE These tools are used to remove and install the universal joint. 1-B 2 Universal joint holder P/N. 90890-04062 Attachment P/N. 90890-04096 Bearing retainer wrench P/N. YM-33289 P/N.
SPECIAL TOOLS GEN INFO 1 Yamaha brake grease P/N. 90793-40003 FOR CHASSIS SERVICE This Yamaha brake grease is used for rear brake dust seal. 1-A Dynamic spark tester P/N. YM-34487 FOR ELECTRICAL COMPONENTS This instrument is necessary for checking the ignition system components. 1-B 2 Ignition checker P/N. 90890-06754 Pocket tester P/N. YU-03112 P/N. 90890-03112 This instrument is necessary for checking the ignition system components.
GEN INFO 1 1 - 10
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: 4XE1 (USA) 4XE2 (CAL) 4XE3 (CDN) Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Basic weight: With oil and full fuel tank Engine: Engine type Cylinder arrangement Displacement Bore × stroke Compression ratio Compression pressure Starting system Lubrication system: Oil type or grade: Engine oil 0° 10° 30° 50° 70° 90° 1,940 mm (7
GENERAL SPECIFICATIONS Item 2 Fuel: Type Fuel tank capacity Fuel reserve amount Carburetor: Type / quantity Manufacturer Spark plug: Type Manufacturer Spark plug gap Clutch type Transmission: Primary reduction system Primary reduction retio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio: 1st 2nd 3rd 4th 5th Reverse gear ratio Chassis: Frame type Caster angle Kingpin angle Trail Tread (STD) Tread (STD) Toe-in Tire: Type Size Manufacturer Type SPEC Standard Unl
GENERAL SPECIFICATIONS Item Tire pressure (cold tire): Recommended Minimum Maximum Brake: Front brake Rear brake Suspension: Front suspension Rear suspension Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system Battery type Battery capacity Headlight type: Bulb wattage × quantity: Headlight Tail light Indicator lights: Neutral Reverse SPEC Standard front rear front rear front rear 20 kPa (0.20 kg/cm2, 2.
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Item Standard Cylinder head: Warp limit 2 Measuring point ---- 0.10 mm (0.004 in) Lines indicate straight edge measurement. * Cylinder: Bore size Measuring point Limit 70.97 ~ 71.02 mm (2.794 ~ 2.796 in) 71.10 mm (2.799 in) 40 mm (1.6 in) ---- * Camshaft: Drive method Cam cap inside diameter Camshaft outside diameter Shaft-to-cap clearance Chain drive (Left) 25.000 ~ 25.033 mm (0.9843 ~ 0.9855 in) 24.96 ~ 24.98 mm (0.9827 ~ 0.
MAINTENANCE SPECIFICATIONS Item “C” Camshaft runout limit Cam chain: Cam chain type / No. of links Cam chain adjustment method Rocker arm / rocker arm shaft: Rocker arm inside diameter Standard 6.572 ~ 6.692 mm (0.259 ~ 0.263 in) ---- Limit ---- DID25SH/104 Automatic ------- 0.03 mm (0.0012 in) 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) 11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) 0.009 ~ 0.037 mm (0.0004 ~ 0.
MAINTENANCE SPECIFICATIONS Item Guide inside diameter IN EX Stem-to-guide clearance IN EX Stem runout limit SPEC Standard 6.000~ 6.012mm (0.236 ~ 0.237 in) 6.000~ 6.012mm (0.236 ~ 0.237 in) 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.025 ~ 0.052 mm (0.001 ~ 0.002 in) ---- 2 Valve seat width Valve spring: Inner spring: Free length Set length (valve closed) Compressed pressure (installed) * Outer spring: Free length Set length (valve closed) ---0.08 mm (0.0031 in) 0.10 mm (0.0039 in) 0.03 mm (0.
MAINTENANCE SPECIFICATIONS Item Compressed pressure (installed) Standard IN 162.8 ~ 200.1 N (16.6 ~ 20.4 kg, 36.6 ~ 45.0 lb) 162.8 ~ 200.1 N (16.6 ~ 20.4 kg, 36.6 ~ 45.0 lb) EX Tilt limit SPEC IN * Limit ------2.5˚/1.6 mm (2.5˚/0.06 in) 2.5˚/1.6 mm (2.5˚/0.06 in) EX 2 Direction of winding (top view) IN EX Piston: Piston to cylinder clearance Piston size “D” Clockwise Clockwise ------- 0.04 ~ 0.06 mm (0.0016 ~ 0.0024 in) 70.92 ~ 70.97 mm (2.792 ~ 2.794 in) 0.15 mm (0.
MAINTENANCE SPECIFICATIONS Item Side clearance (installed) SPEC Standard 0.03 ~ 0.07 mm (0.001 ~ 0.003 in) Limit 0.12 mm (0.005 in) Taper 1.2 × 2.8 mm (0.047 ~ 0.110 in) 0.15 ~ 0.30 mm (0.006 ~ 0.012 in) 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in) ------0.4 mm (0.016 in) 0.12 mm (0.005 in) 2.5 × 2.8 mm (0.098 × 0.110 in) 0.2 ~ 0.7 mm (0.008 ~ 0.028 in) ------- 55.95 ~ 56.00 mm (2.203 ~ 2.
MAINTENANCE SPECIFICATIONS Clutch plate Item Thickness Clutch spring Quantity Free length Standard 1.45 ~ 1.75mm (0.057 ~ 0.069 in) 4 pcs. 35.1 mm (1.38 in) Quantity Clutch release method Automatic centrifugal clutch: Clutch shoe: Thickness 4 pcs. Outer push, cam push Quantity Clutch shoe spring free length Clutch-in revolution Clutch-stall revolution Transmission: Main axle deflection 3 pcs. 32.47 mm (1.278 in) 1,800 ~ 2,100 r/min 3,200 ~ 3,600 r/min 2.0 mm (0.
MAINTENANCE SPECIFICATIONS Item Lubrication system: Oil filter type Oil pump type Tip clearance “A” or “B” Side clearance Bypass valve setting pressure 2 Shaft drive: Middle gear backlash (forward) Middle gear backlash (reverse) Final gear backlash SPEC Standard Wire mesh Trochoid type 0.15 mm (0.006 in) 0.04 ~ 0.09 mm (0.002 ~ 0.004 in) 80 ~ 120 kPa (0.8 ~ 1.2 kg/cm2, 11 ~ 17 psi) 0.1 ~ 0.2 mm (0.004 ~ 0.008 in) 0.10 ~ 0.25 mm (0.004 ~ 0.010 in) 0.1 ~ 0.2 mm (0.004 ~ 0.008 in) 2 - 10 Limit ------0.
MAINTENANCE SPECIFICATIONS Item SPEC Standard Lubrication chart: 2 Crankcase tightening sequence: Crankcase (left) Crankcase (right) 2 - 11
MAINTENANCE SPECIFICATIONS SPEC Tightening torques Part to be tightened Part name Cylinder head (oil gallery plug) Bolt M6 Flange bolt M8 Thread size Q’ty Tightening torque Remarks Nm m·kg ft·lb 1 7 0.7 5.1 4 22 2.2 16 2 2 5 2 1 2 1 1 2 1 2 1 2 3 1 1 2 22 7 10 8 17.5 10 50 50 14 60 10 7 8 7 43 10 10 2.2 0.7 1.0 0.8 1.75 1.0 5.0 5.0 1.4 6.0 1.0 0.7 0.8 0.7 4.3 1.0 1.0 16 5.1 7.2 5.8 Use lock washer 12.5 7.2 36 Use lock washer 36 10 43 7.2 5.1 5.8 5.1 31 7.2 7.2 2 12 1.2 8.
MAINTENANCE SPECIFICATIONS Part to be tightened Lock nut (clutch release adjuster) Starter clutch Part name Thread size Q’ty SPEC Tightening torque Nm m·kg ft·lb Nut M8 1 15 1.5 11 Bolt M8 3 30 3.0 22 Screw Nut M6 M16 2 1 7 60 0.7 6.0 5.1 43 Screw M8 3 25 2.5 18 Nut Nut Nut Bolt Nut – – – M8 M12 1 1 1 4 1 60 60 60 23 60 6.0 6.0 6.0 2.3 6.0 43 43 43 17 43 Bolt M6 2 12 1.2 8.7 Straight screw plug M14 1 15 1.
MAINTENANCE SPECIFICATIONS SPEC CHASSIS Item Steering system: Steering bearing type Front suspension: Shock absorber travel Suspension spring free length Spring rate 2 Standard Ball bearing ---- 117 mm (4.61 in) 293 mm (11.54 in) 10 N/mm (1.0 kg/mm, 56 lb/in)/ 0 ~ 117 mm (0 ~ 4.61 in) No ---------- 85 mm (3.35 in) 263 mm (10.35 in) 244 mm (9.61 in) 49 N/mm (4.9 kg/mm, 279.79 lb/in)/ 0 ~ 85 mm (0 ~ 3.35 in) No ------------- end ---- side ---- 1.0 mm (0.04 in) 1.0 mm (0.
MAINTENANCE SPECIFICATIONS Item Front drum brake: Type Drum inside diameter Lining thickness Shoe spring free length Rear drum brake: Type Drum inside diameter Lining thickness Shoe spring free length Brake lever and brake pedal: Brake lever free play (at lever pivot) Brake lever free play (left) Brake pedal free play Throttle lever free play SPEC Standard Limit Leading and trailing 160 mm (6.30 in) ---161 mm (6.34 in) 2.0 mm (0.08 in) ---- 4.0 mm (0.16 in) 71.0 mm (2.
MAINTENANCE SPECIFICATIONS SPEC Tightening torques Part to be tightened 2 Tightening torque Parts Thread size Q’ty name Nm m·kg ft·lb Front panel wheel and brake drum Nut Front brake drum and steering Nut knuckle Front brake cam lever and cam Bolt shaft Steering knuckle and front shock Nut absorber Front shock absorber and frame Nut Steering knuckle and Tie-rod end Nut Tie-rod and locknut Nut Steering shaft and tie-rod end Nut Steering shaft (lower) and frame Nut Steering shaft holder and frame Bolt St
MAINTENANCE SPECIFICATIONS Part to be tightened SPEC Tightening torque Parts Thread size Q’ty name Nm m·kg ft·lb Pivot shaft and nut (right) Nut Swingarm and final drive gear Nut case Rear axle housing and final drive Bolt gear case Rear shock absorber (upper) and Nut frame Final drive gear case protector Bolt Rear axle housing and swingarm Nut Fuel tank and frame Bolt Fuel tank and fuel cock Screw M22 × 1.5 1 130 13 94 M8 × 1.25 4 48 4.8 35 M10 × 1.25 4 55 5.5 40 M12 × 1.25 1 50 5.
MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Item Standard Voltage: Ignition system: Ignition timing (B.T.D.C.) Advanced timing (B.T.D.C.) Advancer type 2 Limit 12 V ---- 10˚/ 1,000 r/min 30˚/ 6,000 r/min Electrical ---------- Ignition Timing (B.T.D.C.) 30° 20° 10° 0 2 4 6 8 Engine Speed (× 103 r/min) C.D.I.: Magneto model / manufacturer Pickup coil resistance / color Source coil resistance / color C.D.I.
MAINTENANCE SPECIFICATIONS Item Withstand voltage Battery: Specific Gravity Electric starter system: Type Starter motor: Model / manufacturer Output Armature coil resistance Brush overall length Spring force Commutator diameter Mica undercut Starter relay: Model / manufacturer Amperage rating Coil winding resistance/color Starting circuit cut-off relay: Model / manufacturer Coil winding resistance Diode Circuit breaker: Type Amperage for individual circuit: Main fuse Reserve SPEC Standard 200 V Limit ---
HOW TO USE THE CONVERSION TABLE/ GENERAL TORQUE SPECIFICATIONS EB201000 EB202001 HOW TO USE THE CONVERSION TABLE GENERAL TORQUE SPECIFICATIONS All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are provided for each chapter of this manual.
LUBRICATION POINTS AND LUBRICANT TYPES SPEC LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication points (parts name) Lubricant type Oil seal lips (all) LS O-rings (all) LS Bearings (all) E Washer (cylinder head bolt) E Crank pin E Connecting rod (big end) E Piston and piston pin E Piston and piston ring E Buffer boss E Valve stem and valve guide M Oil seal (valve stem end) M Rocker arm shaft and rocker arm M Cam and bearing (camshaft) E O-ring (drain plug) LS Push rod E
LUBRICATION POINTS AND LUBRICANT TYPES SPEC CHASSIS Lubrication points 2 Lubricant type Oil seal lips (all)/O-rings (all) LS Steering shaft (Upper and lower with nipple bushes) LS Steering knuckle pivot LS Front lower arm (ball joint) LS Front wheel bearings B Front drum brake: Brake cam shaft Pivot pin Oil seal lips LS Rear drum brake: Brake cam shaft Pivot pin LS Dust seal (rear backing plate) Yamaha brake grease Sealant (Quick Gasket) Yamaha Bond No.
LUBRICATION DIAGRAMS SPEC LUBRICATION DIAGRAMS 1 Drain plug 2 O-ring 3 Compression spring 4 Oil strainer 5 Oil pump gasket 6 Oil pump assembly 7 Oil pump driven gear 8 Oil pump drive gear 9 Camshaft 0 Crank pin A Crankshaft B Main axle C Drive axle D Oil filter 2 2 - 23
LUBRICATION DIAGRAMS 1 Bypass valve 2 Oil filter 3 Oil filter cover 4 O-ring 5 Collar 6 Camshaft 7 Rocker arm 8 One way bearing (Automatic centrifugal clutch) 9 Crank pin 0 Crankshaft A Main axle B Drive axle 2 2 - 24 SPEC
CABLE ROUTING SPEC CABLE ROUTING 1 Rear brake lever switch lead 2 Rear brake cable 3 Cable guide 4 Front brake cable 5 Throttle cable 6 Neutral indicator light 7 Reverse indicator light 8 Handlebar switch assembly lead 9 Fuel tank breather hose 0 Headlight leads A Equalizer B Front brake breather hose Å Do not route the handlebar switch assembly lead through the lower bracket cable guide.
CABLE ROUTING 1 Cable guide 2 Main switch 3 Fuel tank breather hose 4 Rectifier/regulator 5 CDI unit 6 Taillight 7 Final gear case breather hose 8 Carburetor overflow hose 9 Reverse switch lead 0 Neutral switch lead A Starter motor lead SPEC B Throttle cable C Rear brake cable D Rear brake breather hose E Carburetor air vent hose F CDI magneto lead Å Route the main switch lead and indicator light lead to the side of the cable guide.
CABLE ROUTING Î Route the carburetor overflow hose between the engine and upper rear engine mount and then between the engine and swingarm. Make sure that the hose is not pinched. ‰ Bend the cable guide after routing the cables. Ï Fasten the starter motor lead and wire harness to the frame with the plastic clamp. SPEC Ì Route the rear brake cable and rear brake breather hose through the cable guide. Ó 10 mm (0.4 in) È 100 mm (4.0 in) Ô 40 ~ 50 mm (1.6 ~ 2.
CABLE ROUTING 1 Battery breather hose 2 Spark plug cap 3 Ignition coil 4 Starter motor lead 5 Rear brake cable 6 Rear brake breather hose SPEC Å Make sure that the battery breather hose is not kinked or bent. ı Route the rear brake cable through the cable guide on the cylinder. Ç Fasten the starter motor lead to the frame with the metal clamp. Î Fasten the battery breather hose with plastic clamps to the frame. ‰ 50 ~ 60 mm (2.0 ~ 2.
CABLE ROUTING 1 Wire harness 2 Starter motor lead 3 Rear brake cable 4 Throttle cable 5 Starter relay 6 Starting circuit cut-off relay 7 Rear brake breather hose 8 Carburetor air vent hose 9 Final gear case breather hose 0 Taillight lead SPEC Å 50 mm (2.0 in) ı Route the throttle cable and rear brake cable through the cable guide. Make sure that the throttle cable is routed to the inside of the rear brake cable. Ç Install the starter relay onto the tabs with its terminal side facing down.
SPEC 2 2 - 30
INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION INSP ADJ PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced.
PERIODIC MAINTENANCE/LUBRICATION INSP ADJ INITIAL ITEM Steering shaft* ROUTINE 1 month 3 months • Lubricate every 6 months.** Fittings and Fasten- • Check all chassis fittings and fasteners. ers* • Correct if necessary. Battery* • Check specific gravity. • Check breather pipe for proper operation. • Correct if necessary. *: It is recommended that these items be serviced by a Yamaha dealer. **: Lithium soap base grease.
FRONT FENDER INSP ADJ FENDER AND FUEL TANK FRONT FENDER Removal 1.Place the machine on a level place. 2.Remove: ● Front carrier 1 3.Remove: Front bumper skid plate 1 ● 3 4.Disconnect: Dual headlight leads 1 5.Remove: ● Front bumper 2 ● 6.
FRONT FENDER INSP ADJ Installation: Reverse the “Removal” procedures. Note the following points. 1.Install: ● Front fender 1 T. R. Bolt 2 (front fender and frame): 7 Nm (0.7 m • kg, 5.1 ft • lb) Nut 3 (front fender and fender stay): 7 Nm (0.7 m • kg, 5.1 ft • lb) 3 2.Install: ● Front bumper 1 T. Bolt (front bumper and frame): 16 Nm (1.6 m • kg, 12 ft • lb) R. 3.Install: ● Front bumper skid plate 1 4.Install: ● Front carrier 1 T. R. 3-4 Bolt 2 (front carrier and frame): 34 Nm (3.
REAR FENDER INSP ADJ REAR FENDER Removal 1.Place the machine on a level place. 2.Remove: ● Rear carrier 1 2 with spacer 3.Remove: ● Seat 1 Pull up the seat lock lever 2, then pull up the seat at the rear. 3 4.Disconnect: Battely leads (negative and positive) ● WARNING Disconnect the negative lead 1 first. 5.Remove: Starter relay 2 ● Starting circuit cut-off relay 3 ● 6.Remove: ● Battery bracket 1 ● Battery breather hose 2 ● Battery 3 7.
REAR FENDER INSP ADJ Installation Reverse the “Removal” procedure. Note the following points. 1.Install: ● Rear fender 1 T. R. Bolt 2 (rear fender and frame): 7 Nm (0.7 m • kg, 5.1ft • lb) Bolt 3 (rear fender and rear footrest plate): 7 Nm (0.7 m • kg, 5.1ft • lb) 3 2.Install: ● Battery 1 ● Battery breather hose 2 ● Battery bracket 3 CAUTION: When installing the battery, be sure the breather hose is routed correctly. Refer to the “BATTERY INSPECTION” section. 3.
REAR FENDER/FUEL TANK INSP ADJ 6.Install: ● Rear carrier 1 T. R. Bolt 2 (rear carrier and frame): 34 Nm (3.4 m • kg, 25 ft • lb) Bolt 3 (rear carrier and rear bumper): 9 Nm (0.9 m • kg, 6.5 ft • lb) NOTE: Do not forget to attach the spacer at the point where the carrier and bumper are connected. 3 FUEL TANK Removal 1.Place the machine on a level place. 2.Remove: ● Seat Refer to the “REAR FENDER – Removal” section. 3.Disconnect: ● Breather hose 1 (tank cap side) 4.
FUEL TANK INSP ADJ 6.Turn the fuel cock lever to “OFF” position. 7.Disconnect: ● Fuel hose 1 NOTE: Place a rug on the engine to absorb a spilt fuel. WARNING ● ● Gasoline is highly flammable. Avoid spilling fuel on the hot engine. 8.Remove: ● Bolt 1 (with washer and collar) 9.Disconnect: ● Air duct 2 (with hoses) ● Grommet 3 (with hoses) 10.Remove: ● Fuel tank 4 3 Installation Reverse the “Removal” procedures. Note the following points. 1.Install: ● Fuel tank 1 2.
FUEL TANK INSP ADJ 4.Install: ● Fuel tank cover 1 ● Fuel tank cap 2 ● Rivet 3 ● Screw 4 ● Bolt 5 (with flange collar) T. Bolt (fuel tank cover and frame): 10 Nm (1.0 m • kg, 7.2 ft • lb) R. 3 5.Connect: ● Breather hose 1 6.Install: ● Seat Refer to the “REAR FENDER-Installation” section.
VALVE CLEARANCE ADJUSTMENT INSP ADJ ENGINE VALVE CLEARANCE ADJUSTMENT NOTE: The valve clearance must be adjusted when the engine is cool to the touch. ● Adjust the valve clearance when the piston is at the Top Dead Center (T.D.C.) on compression stroke. ● Removal 1.Place the machine on a level place. 2.Remove: ● Seat ● Fuel tank cover ● Fuel tank Refer to the “FUEL TANK - Removal” section. 3 3.Remove: Timing plug 1 ● Recoil starter assembly 2 ● 4.
VALVE CLEARANCE ADJUSTMENT INSP ADJ ● Align the “T” mark 1 on the flywheel with the stationary pointer 2 on the crankcase cover. When the “T” mark is aligned with the stationary pointer, the piston is at Top Dead Center (TDC). NOTE: T.D.C. on compression stroke check: ● Both rocker arms must have a valve clearance when the rotor match mark 1 is aligned with the stationary pointer match mark 2. ● If not, give the crankshaft one counterclockwise turn to meet above condition.
VALVE CLEARANCE ADJUSTMENT/ TIMING CHAIN TENSIONER ADJUSTMENT INSP ADJ ● Once again, measure the valve clearance. ● If the clearance is incorrect, repeat above steps until the proper clearance is obtained. ********************************** Installation Reverse the “Removal” procedure. Note the following points. 1.Install: ● Tappet cover 1 (exhaust) ● Tappet cover 2 (intake) 3 NOTE: Install the tappet covers with its ridge facing upward 3. ● Check the O-ring 4 for damage. If damaged, replace. ● T.
IDLE SPEED ADJUSTMENT INSP ADJ IDLE SPEED ADJUSTMENT 1.Place the machine on a level place. 2.Warm up engine for several minutes. 3.Adjust: ● Engine idle speed ********************************** Adjustment steps: ● Turn the pilot screw 1 clockwise until it is lightly seated. ● Loosen the pilot screw by turning it counterclockwise for the specified number of turns. Pilot screw: 2 counterclockwise turns ● Turn the throttle stop screw 2 until the Idle speed is in the specified range.
THROTTLE CABLE FREE PLAY ADJUSTMENT INSP ADJ THROTTLE CABLE FREE PLAY ADJUSTMENT NOTE: Before adjusting the throttle cable free play, the engine idle speed should be adjusted. 1.Place the machine on a level place. 2.Check: ● Throttle cable free play a Out of specification → Adjust. 3 Throttle cable free play: 3 ~ 5mm (0.12 ~ 0.20 in) a 3.Adjust: ● Throttle cable free play NOTE: If the throttle cable free play can not be adjusted on the carburetor side, adjust it on the throttle housing side.
SPEED LIMITER ADJUSTMENT/ SPARK PLUG INSPECTION INSP ADJ WARNING a After adjusting the free play, turn the handlebar to right and left, and make sure that the engine idling does not run faster. 1 2 ********************************** SPEED LIMITER ADJUSTMENT The speed limiter keeps the carburetor throttle from becoming full-open even when the throttle lever is pushed to a maximum. Screwing in the adjuster stops the engine speed from increasing. 1.
SPARK PLUG INSPECTION INSP ADJ 3.Inspect: ● Spark plug type Incorrect → Replace. Standard spark plug: DR7EA (NGK) 4.Inspect: ● Electrode 1 Wear/Damage → Replace. ● Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition. 3 5.Clean: ● Spark plug Clean the spark plug with a spark plug cleaner or wire brush. 6.Measure: ● Spark plug gap a Out of specification → Regap. Use a wire gauge. Spark plug gap: 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) 7.
IGNITION TIMING CHECK INSP ADJ IGNITION TIMING CHECK NOTE: Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing. 1.Place the machine on a level place. 2.Start the engine and let it warm up for several minutes, then stop the engine. 3.Attach: ● Inductive tachometer ● Timing light to spark plug lead. Inductive tachometer: P/N. YU-08036-A, 90890-03113 Timing light: P/N. YM-33277-A, 90890-03141 4.
IGNITION TIMING CHECK/ COMPRESSION PRESSURE MEASUREMENT INSP ADJ 5.Install: ● Timing plug 6.Detach: ● Timing light ● Inductive tachometer COMPRESSION PRESSURE MEASUREMENT NOTE: Insufficient compression pressure will result in performance loss. ● Before measuring the compression pressure, the valve clearance should be adjusted. Refer to “VALVE CLEARANCE ADJUSTMENT” section. ● 3 1.Place the machine on a level place. 2.Remove: ● Spark plug 3.
COMPRESSION PRESSURE MEASUREMENT/ ENGINE OIL LEVEL INSPECTION INSP ADJ ● If pressure falls below the minimum level: 1) Squirt a few drops of oil into the affected cylinder. 2) Measure the compression again. Compression pressure (with oil introduced into cylinder) Reading Diagnosis Higher than without oil Worn or damaged cylinder or rings Same as without oil Defective ring(s), valves, cylinder head gasket. Above maximum level Inspect cylinder head, valve surface, or piston crown for carbon deposit.
ENGINE OIL LEVEL INSPECTION/ ENGINE OIL REPLACEMENT INSP ADJ ● Screw the dipstick 1 completely out, and wipe the dipstick clean, then just rest the dipstick in the hole. ● Pull up the dipstick, and inspect the oil level whether or not it is between maximum 2 and minimum level 3. ● If the level is lower, add the oil up to the proper level. Recommended oil: Follow the left chart. NOTE: Recommended oil classification: API service “SE”, “SF” type or equivalent (e.g. “SF–SE–CC”, “SF–SE–SD” etc.
ENGINE OIL REPLACEMENT INSP ADJ 6.Inspect: ● O-rings 1 ● Compression spring 2 ● Oil strainer 3 ● Oil filter 4 Damage → Replace. 7.Clean: ● Compression spring 2 ● Oil strainer 3 ● Oil filter 4 ● Drain plug 5 (crankcase) ● Oil filter cover 6 Wash them with a cleaning solvent. 8.Apply: ● Engine oil (light coating) (to the O-rings) 9.
ENGINE OIL REPLACEMENT INSP ADJ 11.Install: ● Dipstick 12.Warm up the engine for 5 minutes or more, and stop it. 13.Inspect: ● Oil leaks ● Oil level 14.Inspect: Oil flow ● 1 ********************************** Inspection steps: ● Slightly loosen the oil gallery plug 1 in the cylinder head. ● Start the engine and keep it idling until oil begins to seep from the oil gallery plug. If no oil comes out after one minutes, stop the engine immediately so it will not engine stick.
CLUTCH ADJUSTMENT/AIR FILTER CLEANING DECREASE Å INSP ADJ CLUTCH ADJUSTMENT Release lever free play adjustment 1.Adjust: ● Release lever free play INCREASE ı ********************************** 1 Adjustment steps: ● Loosen the locknut 1. ● Slowly turn the adjuster 2 counterclockwise until resistance is felt, then turn back it 1/8 clockwise, hold the adjuster 2 in this position and tighten the locknut 1.
AIR FILTER CLEANING INSP ADJ 3.Remove: ● Air filter element 1 ● Foam cover 2 CAUTION: The engine should never be run without the air filter; excessive piston and/or cylinder wear may result. 4.Inspect: ● Air filter element 1 ● Foam cover 2 Damage → Replace. 3 5.Clean: ● Air filter element Use compressed air to blow off dust from the inner surface of the element. 6.Clean: ● Foam cover ********************************** Cleaning steps: ● Wash the foam cover gently, but thoroughly in water 1.
AIR FILTER CLEANING INSP ADJ 7.Install: ● Foam cover (to air filter) 8.Install: ● Air filter assembly NOTE: Make sure its sealing surface matches the sealing surface of the case so there is no air leak. 9.Install: ● Cover (air filter case) ● Seat Refer to “REAR FENDER-Installation” section.
FRONT AND REAR BRAKE LINING INSPECTION/ FRONT BRAKE ADJUSTMENT INSP ADJ CHASSIS FRONT AND REAR BRAKE LINING INSPECTION Front brake 1.Apply the front brake. 2.Inspect: ● Wear indicator 1 Indicator reaches the wear limit mark 2 → Replace brake shoes as a set. Refer to the “FRONT WHEEL AND FRONT BRAKE” section in CHAPTER 7. 3 Rear brake 1.Depress the Rear brake pedal. 2.Inspect: ● Wear indicator 1 Indicator reaches the wear limit mark 2 → Replace brake shoes as a set.
FRONT BRAKE ADJUSTMENT/ REAR BRAKE LEVER AND PEDAL ADJUSTMENT 2 INSP ADJ 2.Adjust: ● Front brake lever free play 1 ********************************** Adjustment steps: ● Loosen the locknut 1 and turn the adjuster 2 clockwise to release the tension in the front brake cable. ● Visually check the cable joint 3 in the equalizer 4 to verify it is horizontal. ● If not horizontal, turn both adjuster 5 (Front hub — left and right) until the cable joint 3 is horizontal.
REAR BRAKE LEVER AND PEDAL ADJUSTMENT 1 INSP ADJ 2.Adjust: ● Brake lever free play ● Brake pedal free play 2 ********************************** Adjustment steps: NOTE: Before adjusting the free play, pump the brake pedal 2 to 3 times. ● Fully loosen the locknut 1 (handlebar) and fully turn in the brake lever adjuster 2. ● Fully loosen brake lever cable adjuster 3 and brake pedal adjuster 4. ● Tighten the brake pedal adjuster 4 until proper free play is attained.
DRIVE SELECT LEVER POSITION ADJUSTMENT/ FINAL DRIVE GEAR OIL LEVEL INSPECTION INSP ADJ DRIVE SELECT LEVER POSITION ADJUSTMENT 1.Adjust: ● Drive select lever position ********************************** Adjustment steps: ● Place the machine on a level place. ● Shift the transmission in first gear, and move the select lever 1 to reverse position. ● Loosen the locknuts 2. ● Turn the select lever adjuster 3 in or out until lever 4 center line a aligns with match mark b on the crankcase cover.
FINAL DRIVE GEAR OIL LEVEL INSPECTION/ FINAL DRIVE GEAR OIL REPLACEMENT INSP ADJ ● If the oil level is low, add the recommended oil up to the specified level. Refer to “FINAL DRIVE GEAR OIL REPLACEMENT” section. ● Inspect the copper washer for damage. If damaged, replace it ● Install the copper washer and filler bolt. NOTE: Before installing the filler bolt, do not forget to fit the copper washer. ● After installing the filler bolt, inspect the oil leaks. ● T.
FINAL DRIVE GEAR OIL REPLACEMENT/DRIVE SHAFT DUST BOOT INSPECTION/STEERING SYSTEM INSPECTION INSP ADJ Recommended oil: SAE 80 API “GL-4” hypoid gear oil If desired, and SAE 80W90 hypoid gear oil may be used for all condition. Periodic oil change: 0.25 L (0.21 Imp qt, 0.27 US qt) Total amount: 0.27 L (0.24 Imp qt, 0.29 US qt) 7.Install: ● Filler bolt (final drive gear case) NOTE: After filling the oil, inspect the oil leaks. T. Filler bolt (final drive gear case): 23 Nm (2.3 m • kg, 17 ft • lb) R.
STEERING SYSTEM INSPECTION/ TOE-IN ADJUSTMENT INSP ADJ 4.Raise the front end of the machine so that there is no weight on the front wheels. 5.Check: ● Knuckles and/or wheel bearings Move the wheels laterally back and forth. Excessive free play → Replace the following parts. 1) Wheel bearings 2) Knuckle shaft(s) 1 3) Cotter pin(s) 2 4) Stud boll(s) 3 (lower arm) 5) Bushings 4 (lower arm) Refer to the “STEERING SYSTEM” section in CHAPTER 7. 3 TOE-IN ADJUSTMENT 1.Place the machine on a level place. 2.
TOE-IN ADJUSTMENT INSP ADJ Toe-in: 0 ~ 5 mm (0 ~ 0.2 in) ● If the toe-in is incorrect, adjust the toe-in. ********************************** 3.Adjust: ● Toe-in ********************************** Adjustment steps: ● Place a confirmation marks 1 on the both tie-rods end. ● Loosen the rod end locknuts 2 of both tierods. ● The same number of turns should be given to both tie-rods 3 right and left until the specified toe-in is obtained, so that the lengths of the rods will be kept the same.
TOE-IN ADJUSTMENT/FRONT AND REAR SHOCK ABSORBERS INSPECTION/REAR SHOCK ABSORBER ADJUSTMENT INSP ADJ FRONT AND REAR SHOCK ABSORBERS INSPECTION 1.Place the machine on a level place. 2.Check: ● Ball joint complete 1 (front) Cracks/Damage → Replace as a set. ● Damper rod 2 (rear) Scratch/Damage → Replace as a set. ● Oil leakage 3 Excessive oil leakage → Replace as a set. Refer to the “FRONT SHOCK ABSORBER AND LOWER ARM” section or “REAR SHOCK ABSORBER AND SWINGARM” section in CHAPTER 7. 3.
TIRE INSPECTION INSP ADJ TIRE INSPECTION WARNING This model is equipped with low pressure tires. It is important that they be inflated correctly and maintained at the proper pressures. ● TIRE CHARACTERISTICS 1) Tire characteristics influence the handling of ATV’s. The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. If other tire combinations are used, they can adversely affect your machine’s handling characteristics and are therefore not recommended.
TIRE INSPECTION INSP ADJ 1.Measure: ● Tire pressure (cold tire pressure) Out of specification → Adjust. NOTE: The Low-pressure tire gauge 1 is included in the standard equipment. ● If dust or the like is stuck to this gauge, it does not provide correct readings. Therefore, make two measurements on the tire pressure and get the second reading. ● WARNING Uneven or improper tire pressure may adversely affect the handling of this machine and may cause loss of control. ● Maintain proper tire pressures.
WHEEL INSPECTION INSP ADJ WHEEL INSPECTION 1.Inspect: ● Wheels 1 Cracks/Bends/Damage → Replace. NOTE: Always balance the wheel when a tire or wheel has been changed or replaced. WARNING Never attempt even small repairs to the wheel.
BATTERY INSPECTION INSP ADJ ELECTRICAL BATTERY INSPECTION WARNING Battery electrolyte is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive measures: ● Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. ● Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL): ● SKIN-Flush with water. ● EYES-Flush with water for 15 minutes and get immediate medical attention.
BATTERY INSPECTION UPPER LEVEL LOWER LEVEL INSP ADJ 4.Inspect: ● Battery fluid level Battery fluid level low → Fill. Fluid level should be between upper level 1 and lower level 2 marks. 1 2 CAUTION: Refill with distilled water only; tap water contains minerals harmful to a battery. 5.Inspect: ● Battery fluid specific gravity Out of specification → Charge. Charging current: 1.2 amps/10 hrs Specific gravity: 1.
BATTERY INSPECTION INSP ADJ 7.Inspect: ● Battery breather hose Obstruction → Remove. Damage → Replace. 8.Install: Battery 1 ● Battery breather hose 2 Refer to the “CABLE ROUTING” section in CHAPTER 2. ● 3 CAUTION: When installing the battery, be sure the breather hose is routed correctly. If the breather hose touches the frame or exits in such a way as to cause battery electrolyte or gas to exit onto the frame, structual and cosmetic damage to the machine can occur. 3 Battery breather hose guide 9.
FUSE INSPECTION INSP ADJ FUSE INSPECTION CAUTION: Don’t forget to turn off the main switch when checking or replacing the fuse. Otherwise, it may cause accidental shortcircuiting. WARNING Do not use fuses of a higher amperage rating than those recommended. Substitution of a fuse of improper rating can cause extensive electrical system damage and possible fire. Description Amperage Quantity Main 30A 1 Spare 30A 1 1.Remove: ● Seat Refer to the “REAR FENDER-Removal” section. 2.
FUSE INSPECTION/HEADLIGHT BEAM ADJUSTMENT/ HEADLIGHT BULB REPLACEMENT INSP ADJ 4.Replace: ● Blown fuse ********************************** Blown fuse replacement steps: ● Turn off ignition and the circuit. ● Install a new fuse of proper amperage. ● Turn on the switches and see if the electrical device operates. ● Fuse interrupts the circuit again’ Check electrical system. Refer to “CHAPTER 8. ELECTRICAL” for further information. ********************************** 5.
HEADLIGHT BULB REPLACEMENT INSP ADJ 5.Remove: ● Bulb 1 WARNING Keep flammable products or your hands away from the bulb while it is on, it will be hot. Do not touch the bulb until it cools down. 6.Install: ● Bulb 1 (new) NOTE: Make sure the projection 2 on the bulb is meshed with the slot 3 on the light case. CAUTION: Avoid touching glass part of bulb. Also keep it free from oil otherwise, transparency of glass, bulb life and illuminous flux will be adversely affected.
INSP ADJ 3 3 - 44
ENGINE REMOVAL ENG ENGINE OVERHAUL ENGINE REMOVAL NOTE: ● It is not necessary to remove the engine in order to remove the following components: * Cylinder head * Cylinder * Piston * Primary and secondary clutches * Oil pump * Shift shaft * CDI Magneto ● It is necessary to remove the rear wheel drive assembly in order to remove the engine assembly. PREPARATION FOR REMOVAL 1.Remove all dirt, mud, dust and foreign material before removal and disassembly. 2.Use proper tools and cleaning equipment.
ENGINE REMOVAL ENG ENGINE OIL 1.Drain: ● Engine oil Refer to the “ENGINE OIL REPLACEMENT” section in CHAPTER 3. EXHAUST PIPE AND MUFFLER 1.Remove: ● Exhaust pipe 1 ● Muffler 2 4 CARBURETOR 1.Drain: ● Fuel (float chamber) NOTE: Place a rag under the over flow hose to absorb a spilt fuel. WARNING Gasoline is highly flammable. Avoid spilling fuel on the hot engine. 2.Remove: ● Carburetor 1 Refer to the “CARBURETOR” section in the CHAPTER 5.
ENGINE REMOVAL ENG STARTER MOTOR 1.Disconnect: ● Starter motor lead 1 2.Remove: ● Starter motor bracket 2 ● Starter motor 3 REAR BRAKE CABLES AND FOOTREST 1.Remove: ● Adjusters 1 (brake lever and brake pedal) ● Pins 2 ● Springs 3 2.Disconnect: ● Brake cable 4 (from brake cable bracket 5. 3.Remove: ● Footrest 1 (left) ● Shift pedal 2 ● Front fender stay 3 4.Disconnect: ● Footrest 1 (right) ● Spring 2 WIRINGS AND HOSES 1.
ENGINE REMOVAL ENG REAR WHEEL DRIVE ASSEMBLY AND SWINGARM 1.Disconnect: ● Breather hose 1 (final gear housing and rear brake drum) (from the cable guides 2 of main frame) 2.Block the front wheels, and elevate the rear wheels by placing the suitable stand under the frame. 3.Remove: ● Bolt 1 (rear shock absorber-top) 4 4.Remove: ● Clamps 1 (rubber boot) ● Pivot shaft caps 2 ● Locknuts 3 (pivot shaft) ● Pivot shafts 4 (swingarm) 5.
ENGINE DISASSEMBLY ENG ENGINE DISASSEMBLY CYLINDER HEAD ASSEMBLY, CYLINDER AND PISTON NOTE: With the engine mounted cylinder head assembly, cylinder and piston can be maintained by removing the following parts. ● Fuel tank ● Exhaust pipe ● Carburetor ● Engine stays (top) 1.Remove: ● Recoil starter assembly 1 2.Remove: ● Timing plug 1 ● Drive select lever assembly 2 ● Washers CAUTION: Be careful not to lose washers. 3.Remove: ● Carburetor joint 1 ● Cam sprocket cover 2 4.
ENGINE DISASSEMBLY ENG 5.Align: ● “T” mark on the rotor With the stationary pointer on the crankcase cover. ********************************* TDC alignment steps: ●Turn the crankshaft counterclockwise with wrench. ●Align the “T” mark 1 on the rotor with the stationary pointer 2 on the crankcase cover. When the “T” mark is aligned with the stationary pointer, the piston is at Top Dead Center (TDC).
ENGINE DISASSEMBLY ENG 8.Remove: ● Bolt 1 ● Cam sprocket 2 NOTE: ● Fasten a safety wire 3 to the timing chain to prevent if from falling into the crankcase. ● When removing the cam sprocket, it is not necessary to separate the timing chain. ● Hold the starter pulley 4 by the Rotor Holder to loosen the bolt on the cam sprocket. Rotor holder: P/N. YU-01235, 90890-01235 9.Remove: ● Bolts (cylinder head) NOTE: ● Loosen the bolts 1/4 turn each and remove them after all are loosened.
ENGINE DISASSEMBLY ENG 11.Remove: ● Bolts 1 (cylinder) ● Cylinder 2 ● Gasket 3 (cylinder) ● Dowel pins 4 ● O-ring 5 12.Remove: ● Piston pin clip 1 ● Piston pin 2 ● Piston 3 NOTE: ● Before removing the piston pin clip, cover the crankcase with a clean rag so you will not accidentally drop the clip into the crankcase. ● Before removing the piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and piston pin is still difficult to remove, use Piston Pin Puller.
ENGINE DISASSEMBLY ENG 1.Remove: ● Starter pulley 1 NOTE: Hold the starter pulley by the Rotor Holder to loosen the bolt on the starter pulley. Rotor holder: P/N. YU-01235, 90890-01235 2.Remove: ● Crankcase cover 1 3.Remove: ● Gasket 1 ● Dowel pins 2 ● Shaft 3 ● Washer 4 ● Idle gear 5 (starter) 4.Remove: ● CDI magneto 1 NOTE: Use the Flywheel puller 2 and Attachment 3. Flywheel puller: P/N. YU-33270, 90890-01362 Attachment: P/N.
ENGINE DISASSEMBLY ENG 5.Remove: ● Woodruff key 1 ● Driven gear 2 (starter) ● Washer 3 6.Remove: ● Chain guide 1 (intake) ● Timing chain 2 4 MIDDLE DRIVEN PINION GEAR 1.Remove: ● Bolts 1 (bearing housing) 2.Remove: ● Bolts 1 (middle gear case cover) ● Middle gear case cover 2 3.
ENGINE DISASSEMBLY ENG PRIMARY AND SECONDARY CLUTCHES NOTE: With the engine mounted, the primary and secondary clutches can be maintained by removing the following parts: ● Starter motor ● Crankcase cover (right) 1.Remove: ● Oil filter cover 1 ● Oil filter 2 ● O-ring 3 ● Clutch cover protector 4 ● Crankcase cover 5 (right) ● Dowel pins 6 ● Gasket 7 4 2.Remove: ● Spring 1 (clutch release lever) ● Shift guide #1 2 ● Ball holder 3 ● Shift guide #2 4 3.Straighten: ● Lock washer tab 1 4.
ENGINE DISASSEMBLY ENG 5.Remove: ● Lock washer 1 ● Clutch carrier assembly 2 ● Washer 3 ● Clutch housing 4 (primary) ● Washer 5 NOTE: The secondary clutch housing has two grooves 1 machined into it to permit the primary drive gear behind the primary clutch to clear the secondary clutch. Align one of these grooves with the primary gear 2 before removing the primary clutch assembly. 4 6.Flatten: ● Nut tab 1 (drive pinion gear) 7.
ENGINE DISASSEMBLY ENG 9.Straighten: ● Lock washer tab 1 (clutch boss) 10.Remove: ● Nut 2 (clutch boss) NOTE: Hold the clutch boss 3 by the Rotor Holder 4 to loosen the nut. Rotor holder: P/N. YU-01235, 90890-01235 11.
ENGINE DISASSEMBLY ENG 3.Remove: ● Shift lever assembly 1 ● Washer 2 ● Return spring 3 ● Stopper lever 4 ● Washer 5 NOTE: Push the shift pawl and the stopper lever to the arrow direction and remove them from the segment. 4 4.Remove: ● Segment 1 (shift cam) Use the Torx wrench to remove. NOTE: When removing the segment, the dowel pin will fall off. Take care not to lose the pin.
ENGINE DISASSEMBLY ENG 3.Remove: ● Lock washer 1 ● Balancer gear 2 (driven) ● Straight key 3 CRANKCASE (LEFT) 1.Remove: ● Screws (crankcase) NOTE: Working in a crisscross pattern, loosen all screws 1/4 turn each. Remove them after all are loosened. 4 2.Remove: ● Crankcase 1 (left) ● Dowel pins ********************************* Removal steps: ●Attach the Crankcase Separating Tool 2 and Attachment 3 to the left side crankcase. Crankcase Separating Tool: P/N. YU-01135-A, 90890-01135 Attachment: P/N.
ENGINE DISASSEMBLY ENG NOTE: Fully tighten the tool holding bolts, but make sure the tool body is parallel with the case. If necessary, one screw may be backed out slightly to level tool body. ●As pressure is applied, alternately tap on the front engine mounting boss, transmission shafts and balancer shaft. CAUTION: ● ● ● ● ● 4 Use soft hammer to tap on the case half. Tap only on reinforced portions of case. Do not tap on gasket mating surface. Work slowly and carefully.
ENGINE DISASSEMBLY ENG 2.Remove: ● Transmission assembly 1 (main axle and drive axle) ● Washer 2 (drive axle) 3.Remove: ● Circlip 1 4.Remove: ● Balancer drive gear 2 ● Crankshaft 3 (from right crankcase) ● Woodruff key 4 NOTE: Use a hydraulic press to remove the balancer drive gear 2 from the crankshaft. CYLINDER HEAD 1.Straighten: ● Lock washer tabs 1 2.Remove: ● Lock washer 2 ● Retainer 3 (camshaft bushing) 3.
ENGINE DISASSEMBLY ENG 4.Remove: ● Rocker arm shafts 1 ● Rocker arms (intake/exhaust) NOTE: Attach the Slide Hammer Set 2 to the rocker arm shaft, and then slide out the them. Slide hammer set: P/N. YU-01083-A Slide hammer bolt: P/N. 90890-01083 Weight: P/N. 90890-01084 4 VALVE NOTE: Before removing the internal parts (valve, valve spring, valve seat etc.) of the cylinder head, the valve sealing should be checked. 1.
ENGINE DISASSEMBLY ENG 2.Remove: ● Valve cotters 1 NOTE: Attach the Valve Spring Compressor 2 between the valve spring seat and cylinder head to remove the valve cotters. Valve spring compressor: P/N. YM-04019, 90890-04019 3.Remove: ● Valve spring seat 1 (upper) ● Valve spring 2 (outer) ● Valve spring 3 (inner) ● Valve 4 ● Valve stem seal 5 ● Valve spring seat 6 (lower) NOTE: Identify each part position very carefully so that it can be reinstalled in its original place. RECOIL STARTER 1.
INSPECTION AND REPAIR ENG INSPECTION AND REPAIR CYLINDER HEAD 1.Eliminate: ● Carbon deposit Use a rounded scraper 1. NOTE: Do not use a sharp instrument to avoid damaging or scratching: ● Spark plug threads ● Valve seat ● Cylinder head 2.Measure: ● Cylinder head warpage Out of specification → Resurface/Replace. Cylinder head warp: Less than 0.10 mm (0.004 in) 4 INTAKE AND EXHAUST VALVE 1.Check: ● Valve face ● Stem end Wear/Pitting/Out of specification → Replace. Minimum thickness (service limit) a: 0.
INSPECTION AND REPAIR ENG 3.Measure: ● Valve stem runout Out of specification → Replace. Stem runout: Less than: 0.03 mm (0.0012 in) 4.Measure: ● Valve stem clearance Valve stem clearance = Valve guide inside diameter Å – Valve stem diameter ı Out of specification → Replace either valve and/or guide. Use a Micrometer and Bore Gauge 1. Valve stem clearance Limit Intake 0.010 ~ 0.037 mm 0.08 mm (0.0004 ~ 0.0015 in) (0.0031 in) Exhaust 0.025 ~ 0.052 mm 0.10 mm (0.0010 ~ 0.0020 in) (0.
INSPECTION AND REPAIR ENG 3.Install: ● Circlip 1 (new) ● Valve guide 2 (new) Use the Valve Guide Installer 3 with the Valve Guide Remover 4. Valve guide installer: P/N. YM-04065-A, 90890-04065 Valve guide remover (6.0 mm): P/N. YM-04064-A, 90890-04064 4.Bore valve guide 2 to obtain proper valve stem clearance. Use the Valve Guide Reamer 5 (6.0 mm) Valve guide reamer (6.0 mm): P/N. YM-04066, 90890-04066 NOTE: Reface the valve seat after installing the valve guide. 4 VALVE SEAT 1.
INSPECTION AND REPAIR ENG ●Press the valve through the valve guide and onto the valve seat to make a clear pattern. ●Remove the valve from the cylinder head. ●Measure the valve seat width a. When the valve seat and valve face make contact, bluing will be applied to the valve face. Valve seat width Intake Exhaust 0.9 ~ 1.1 mm (0.035 ~ 0.043 in) Limit 1.6 mm (0.063 in) ●If the valve seat width is too wide, too narrow, or seat has not centered. The valve seat must be refaced.
INSPECTION AND REPAIR ENG ı Valve seat is in the middle of the valve face but too narrow. ı Valve seat cutter set Use Desired result To achieve a uniform valve seat 45˚ cutter width of 1.0 mm (0.04 in) Ç Valve seat is too narrow and right up near valve margin. Valve seat cutter set Desired result 30˚ cutter To center the seat and to achieve its Use 45˚ cutter width of 1.0 mm (0.04 in) Ç Î Valve seat is too narrow and is located down near the bottom edge of the valve face.
INSPECTION AND REPAIR ENG ●Apply a 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 compound. NOTE: To obtain the best lapping result, lightly tap the valve seat while rotating the valve back and forth between your hand. ●Apply a fine lapping compound to the valve face and repeat the above steps.
INSPECTION AND REPAIR ENG 2.Measure: ● Valve spring installed force Out of specification → Replace inner and outer springs as a set. a Installed length Valve spring installed force Inner spring 8.4 ~ 10.2 kg (18.5 ~ 22.5 lb) (IN/EX) at 30.5 mm (1.2 in) Outer spring 16.6 ~ 20.4 kg (36.6 ~ 45.0 lb) (IN/EX) at 32.0 mm (1.26 in) 4 VALVE INSTALLATION 1.Lubricate: ● Valve stem 1 ● Oil seal 2 Molybdenum disulfide oil: 2.
INSPECTION AND REPAIR ENG NOTE: All valve springs must be installed with the larger pitch a upward as shown. 1 Outer spring 2 Inner spring 4.Check: ● Valve sealing Leakage at valve seat → Reface, relap or replace valve, relap. Refer to “VALVE SEAT”. ********************************* Valve seat checking steps: ●Pour a clean solvent 1 into the intake and exhaust ports. ●Check the valve sealing, there should be no leakage at the valve seat 2.
INSPECTION AND REPAIR ENG 2.Inspect: ● Cam lobes Pitting/Scratches/Blue discoloration → Replace. 3.Measure: ● Cam lobes Use a Micrometer. Out of specification → Replace. 4 Cam lobe Limit “A” Cam lobe Limit “B” Intake 36.437 mm (1.435 in) 30.031 mm (1.182 in) Exhaust 36.482 mm (1.436 in) 30.152 mm (1.187 in) ROCKER ARM AND ROCKER ARM SHAFT 1.Inspect: ● Rocker arm shafts ● Rocker arms Wear/Damage → Replace.
INSPECTION AND REPAIR ENG ●Calculate the clearance by subtracting the rocker-arm-shaft outside diameter from the rocker-arm inside diameter. Arm-to-shaft clearance = Rocker arm inside diameter a – Rocker arm shaft outside diameter b Out of specification → Replace as a set. Arm-to-shaft clearance: 0.009 ~ 0.037 mm (0.0004 ~ 0.0013 in) : 0.037 mm (0.0015 in) 2.
INSPECTION AND REPAIR ENG 5.Install: ● Camshaft bushing 1 NOTE: The cut-out portion 2 of the bushing must be flush with the cylinder head. CAUTION: Do not cock the bushing during installation. The bushing must be perpendicular to the camshaft during installation. 4 6.Install: ● Retainer 1 (camshaft bushing) ● Lock washer (new) NOTE: Be sure that the projection 2 on the retainer aligns with the cut-out portion 3 on the camshaft busing. 7.Tighten: ● Bolts 1 (camshaft bushing retainer) T.
INSPECTION AND REPAIR ENG CAM SPROCKET AND CAM DRIVE SPROCKET 1.Inspect: ● Cam sprocket ● Cam drive sprocket (crank shaft) Wear/Damage → Replace cam sprocket and timing chain as a set. 1 1/4 tooth 2 Correct 3 Roller 4 Sprocket TIMING CHAIN GUIDE 1.Inspect: ● Timing chain guide 1 (exhaust) ● Timing chain guide 2 (intake) Wear/Damage → Replace. TIMING CHAIN TENSIONER 1.Inspect: ● Chain tensioner rod 1 ● Gaskets 2 Damage/Wear → Replace. 2.
INSPECTION AND REPAIR ENG TAPPET COVER AND CAM SPROCKET COVER 1.Inspect: ● Tappet covers (intake 1 and exhaust 2) ● Cam sprocket cover 3 ● O-rings 4 Cracks/Damage → Replace. CYLINDER AND PISTON 1.Eliminate: ● Carbon deposits (from the piston crown and ring grooves.) 2.Inspect: ● Cylinder and piston walls Vertical scratches → Rebore or replace cylinder and piston. 3.
INSPECTION AND REPAIR ENG 2nd steps ●Measure the piston skirt diameter “P” with a micrometer. b 4 mm (0.16 in) from the piston bottom edge Piston skirt Diameter “P” Standard 70.92 ~ 70.97 mm (2.792 ~ 2.794 in) Oversize 2 71.50 mm (2.815 in) Oversize 4 72.00 mm (2.846 in) ●If out of the specification, replace the piston and piston rings as a set. 3rd steps ●Find the piston-to-cylinder clearance with following formula.
INSPECTION AND REPAIR ENG Side clearance Standard Limit Top ring 0.03 ~ 0.07 mm (0.001 ~ 0.003 in) 0.12 mm (0.005 in) 2nd ring 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in) 0.12 mm (0.005 in) 2.Position: ● Piston ring (into cylinder) NOTE: Insert the ring into the cylinder, and push it approximately 20 mm (0.8 in) into the cylinder. Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore. 4 3.
INSPECTION AND REPAIR ● ENG Oil control ring Expander spacer of bottom ring (oil control ring) is color-coded to identify sizes. Size Color Oversize 2 Blue Oversize 4 Yellow Piston pin 1.Inspect: ● Piston pin Blue discoloration/Grooves → Replace then inspect lubrication system. 2.Measure: ● Outside diameter a (piston pin) Out of specification → Replace. Outside diameter (piston pin): 15.991 ~ 16.000 mm (0.6296 ~ 0.6299 in) 3.
INSPECTION AND REPAIR ENG CRANKSHAFT 1.Measure: ● Crank width A Out of specification → Replace or repair. Crank width: 55.95 ~ 56.00 mm (2.203 ~ 2.205 in) ● Runout c Out of specification → Replace or repair. : C1: 0.03 mm (0.0012 in) C2: 0.06 mm (0.0024 in) ● Side clearance D Out of specification → Replace or repair. Big end side clearance: 0.35 ~ 0.65 mm (0.014 ~ 0.026 in) 4 ● Big end radial clearance E Out of specification → Replace or repair. Big end radial clearance: 0.010 ~ 0.
INSPECTION AND REPAIR ENG ********************************* Crankshaft reassembling point: The crankshaft 1 and the crank pin 2 oil passages must be properly interconnected with a tolerance of less than 1 mm (0.04 in). ********************************* BALANCER DRIVE GEAR AND DRIVEN GEARS 1.Inspect: ● Balancer drive gear teeth 1 ● Balancer driven gear teeth 2 Wear/Damage → Replace both gears. PRIMARY GEARS AND STARTER 1.Inspect: ● Drive gear 1 ● Driven gear 2 Scratches/Wear/Damage → Replace.
INSPECTION AND REPAIR ENG 3.Inspect: ● Bolts 1 (starter clutch) Loose → Replace with a new one, and calk the end of the bolt. Bolts (starter clutch): 30 Nm (3.0 m • kg, 22 ft • lb) LOCTITE Calk the end of the bolt PRIMARY CLUTCH Clutch housing 1.Inspect: ● Clutch housing 1 (inner surface) Heat damage/Wear/Damage → Replace. ● Bearings 2 (clutch housing) Chafing/Wear/Damage → Replace. ********************************* One way clutch operation Be sure that the splined inner collar 1 turns clockwise Å.
INSPECTION AND REPAIR ENG Clutch boss and pressure plate 1.Inspect: ● Clutch boss splines 1 ● Pressure plate splines 2 Scoring/Wear/Damage → Replace clutch boss assembly and/or pressure plate. Friction plates 1.Inspect: ● Friction plate 1 Damage/Wear → Replace friction plate as a set. 2.Measure: ● Friction plate thickness Measure at all four points. Out of specification → Replace friction plate as a set. Wear limit: 2.8 mm (0.110 in) Clutch plates 1.
INSPECTION AND REPAIR ENG Clutch spring 1.Inspect: ● Clutch spring Wear/Damage → Replace. 2.Measure: ● Clutch spring free length a Out of specification → Replace springs as a set. Clutch spring minimum length: 32.9 mm (1.30 in) Clutch release lever 1.Inspect: ● Release lever 1 ● Adjuster 2 ● O-ring 3 Cracks/Wear/Damage → Replace. 4 OIL PUMP 1.Measure: ● Housing 1 /Outer rotor 2 clearance a Use a Feeler Gauge. Out of specification → Replace oil pump assembly. Side clearance limit: 0.09 mm (0.004 in) 2.
INSPECTION AND REPAIR ENG TRANSMISSION AND SHIFTER Shift fork and guide bar 1.Inspect: ● Shift forks On the gear and shift cam contact surfaces. Wear/Chafing/Bends/Damage → Replace. 2.Inspect: ● Guide bars (Roll the guide bar on a flat surface. Bends → Replace. WARNING Do not attempt to straighten a bent guide bar. 3.Check: ● Shift fork movement On its guide bar 1. Unsmooth operation → Replace fork and/ or guide bar. Shift cam 1.Inspect: ● Shift cam grooves 1 Wear/Damage/Scratches → Replace.
INSPECTION AND REPAIR ENG 2.Inspect: ● Gears (transmission 1 and drive pinion 2) ● Mating dogs Cracks/Damage/Wear → Replace. NOTE: When the drive pinion gear is replaced, be sure to adjust the drive pinion gear shim(s), refer to the “DRIVE TRAIN-MIDDLE GEAR SERVICE” section in CHAPTER 6. 3.Check: ● Gear movement (transmission) Unsmooth operation → Replace. 4 Shift shaft and stopper lever 1.Inspect: ● Shift shaft 1 ● Shift pawls 2 Bend/Wear/Damage → Replace. 2.
INSPECTION AND REPAIR ENG MIDDLE GEAR 1.Inspect: ● Middle driven pinion gear 1 ● Bearing 2 ● Middle driven shaft 3 ● Reverse gear 4 ● Bearing housing 5 Damage/Wear → Replace. 2.Check: ● Bearing movement Turns roughly → Replace. NOTE: When the driven pinion gear, reverse gear, middle driven shaft and/or bearing housing are replaced, be sure to adjust the middle gear shim(s). Refer to the “DRIVE TRAIN-MIDDLE GEAR SERVICE” section in CHAPTER 6. BEARINGS AND OIL SEALS 1.
INSPECTION AND REPAIR ENG 3.Inspect: ● Crankcase Cracks/Damage → Replace. ● Oil delivery passages Clog → Blow out with compressed air. NOTE: When the crankcase is replaced, be sure to adjust the middle gear shim(s), refer to “DRIVE TRAIN-MIDDLE GEAR SERVICE” section in CHAPTER 6. 4 RECOIL STARTER 1.Inspect: ● Drive plate 1 Cracks Bends/Damage → Replace. ● Drive pawl 2 ● Spring 3 ● Spring 4 (drive pawl) Wear/Cracks/Damage → Replace. 2.Inspect: ● Spring 1 (starter) Wear/Cracks/Damage → Replace.
ENGINE ASSEMBLY AND ADJUSTMENT ENG ENGINE ASSEMBLY AND ADJUSTMENT RECOIL STARTER 1.Install: ● Starter spring 1 NOTE: Mesh the spring hook 2 wise the case slit, then carefully wind the spring counterclockwise, and fit the spring into the case. 2.Install: ● Plate 1 ● Starter spring case 2 NOTE: Mesh the end 3 of the sheave spring with spring hook 4 on the recoil starter cover. 3.Wind the rope 4-1/2 turns clockwise around the sheave drum, and set the rope onto the drum slit. 4.
ENGINE ASSEMBLY AND ADJUSTMENT ENG 6.Install: ● Spring (drive pawl) 1 ● Drive pawl 2 ● Circlip 3 ● Spring 4 ● Drive plate 5 ● Bolt 6 NOTE: When installing the spring (drive pawl), align the spring end 7 with the groove a on the sheave drum. 4 7.Turn the sheave drum 3-turns clockwise to preload the starter spring. 8.Install: ● Starter handle 1 ● Cap 2 NOTE: ● Pass the rope through the case hole and make knot 3 on the rope so that the rope is not pulled into the case.
ENGINE ASSEMBLY AND ADJUSTMENT ENG CRANKSHAFT/BALANCER 1 Balancer driven gear 2 Bearing 3 Straight key 4 Balancer 5 Oil seal 6 Balancer drive gear 7 Woodruff key 8 Crank (right) 9 Connecting rod 0 Small end bearing A Crank pin B Crank (left) A PISTON TO CYLINDER CLEARANCE: 0.04 ~ 0.06 mm (0.0016 ~ 0.0024 in) B END GAP (INSTALLED): Top ring 0.4 mm (0.016 in) 2nd ring 0.4 mm (0.016 in) Oil ring 0.2 ~ 0.7 mm (0.008 ~ 0.028 in) D BALANCER GEAR INSTALLATION: C CRANKSHAFT: A = 55.
ENGINE ASSEMBLY AND ADJUSTMENT ENG TRANSMISSION 1 Bearing 2 1st wheel gear 3 5th wheel gear 4 Circlip 5 Washer 6 3rd wheel gear 7 4th wheel gear A 8 2nd wheel gear 9 Drive axle 0 Bearing retainer A Main axle B 5th pinion gear C 3rd pinion gear D 4th pinion gear DRIVE/MAIN AXLE RUNOUT: 0.08 mm (0.
ENGINE ASSEMBLY AND ADJUSTMENT ENG SHIFTER 1 Guide bar #1 (long) 2 Shift fork #2 3 Shift fork #3 4 Shift cam segment 5 Pin 6 Bearing 7 Shift cam 8 Guide bar #2 (short) 9 Shift fork #1 4 4 - 49
ENGINE ASSEMBLY AND ADJUSTMENT ENG CRANKSHAFT, TRANSMISSION AND BALANCER SHAFT 1.Install: ● Crankshaft 1 (to right crankcase) NOTE: Hold the connecting rod at top dead center with one hand while installing the crankshaft. 2.Install: ● Transmission assembly 1 (main axle and drive axle) 4 3.Install: ● Balancer shaft 1 ● Shift fork #1 2 ● Shift fork #2 3 ● Shift fork #3 4 ● Shift cam 5 ● Guide bar #2 6 (short) ● Guide bar #1 7 (long) NOTE: Each shift fork is identified by a number cast on its side. 4.
ENGINE ASSEMBLY AND ADJUSTMENT ENG CRANKCASE (LEFT) 1.Apply: ● Sealant 1 (to matching surfaces of both case halves) Sealant (Quick Gasket): ACC-QUICK-GS-KT Yamaha bond No. 1215: 90890-85505 2.Install: ● Dowel pins 2 3.Fit the left crankcase onto the right case. Tap lightly on the case with a soft hammer. CAUTION: Before installing and torquing the crankcase holding screws, be sure to check whether the transmission is functioning properly by manually rotating the shift cam either way. 4.
ENGINE ASSEMBLY AND ADJUSTMENT ENG Crankshaft installer set 1: P/N. YU-90050 Buffer boss installer set 2: P/N. 90890-04088 Adapter #11 3: P/N. YM-33279 Spacer 4 (crankshaft): P/N. YM-90070-A, 90890-04060 2.Install: ● Balancer gear 1 (driven) ● Straight key 2 NOTE: Align the drive gear mark 3 with the driven gear mark 4. 4 3.Install: ● Lock washer 1 ● Nut 2 (driven gear) WARNING Always use a new lock washer. NOTE: Install the lock washer tab 3 into the key way of the balancer shaft 4. 4.
ENGINE ASSEMBLY AND ADJUSTMENT ENG SHIFT SHAFT/OIL PUMP 1 Adjuster 2 Spring 3 Release lever 4 Shift guides 5 Ball holder 6 Shift shaft 7 Torsion spring 8 Stopper lever 9 Return spring 0 Oil seal A Shift pedal B Oil pump assembly C Gasket 4 4 - 53
ENGINE ASSEMBLY AND ADJUSTMENT ENG SHIFTER AND OIL PUMP 1.Install: ● Segment 1 ● Pin 2 (long) ● Pin 3 (short) NOTE: Install the pin 2 (long) to the match mark 4 position. 2.Install: ● Segment (shift cam) NOTE: Align the hole 1 of the shift cam with the pin 2 (long) of the segment. 4 3.Tighten: ● Screw 1 (segment) T. R. Screw (segment): 12 Nm (1.2 m • kg, 8.7 ft • lb) Use LOCTITE 4.Install: ● Torsion spring 1 (to shift shaft) ● Washer 2 ● Stopper lever 3 with return spring 4 ● Washer 5 5.
ENGINE ASSEMBLY AND ADJUSTMENT ENG 6.Apply: ● 4-stroke engine oil (to the oil pump inner parts) 7.Install: ● Rotor housing 1 ● Outer rotor 2 ● Inner rotor 3 ● Dowel pins 4 ● Oil pump driven gear 5 ● Dowel pin 6 ● Oil pump cover 7 ● Screw 8 T. Screw: 7 Nm (0.7 m • kg, 5.1 ft • lb) R. 8.Apply: ● 4-stroke engine oil (to the oil passages in the crankcase) CAUTION: Apply a liberal amount of 4-stroke engine oil to the oil pump passages in the crankcase, or the engine may be damaged. 9.
ENGINE ASSEMBLY AND ADJUSTMENT ENG CLUTCH 1 Push rod 2 Bearing 3 Bearing holder 4 Clutch boss 5 Clutch plate 6 Friction plate 7 Pressure plate 8 Washer 9 Clutch housing (secondary) 0 Clutch carrier assembly A Washer B Inner collar C One way bearing D Clutch housing (primary) 4 4 - 56 A CLUTCH SPRING MINIMUM LENGTH: 0.02 mm (0.0008 in) B CLUCTH PLATE WARP LIMIT: 0.2 mm (0.008 in) C FRICTION PLATE WEAR LIMT: 2.8 mm (0.110 in) D CLUTCH SHOE WEAR LIMIT: 1.5 mm (0.
ENGINE ASSEMBLY AND ADJUSTMENT ENG PRIMARY AND SECONDARY CLUTCHES 1.Install: ● Clutch housing 1 (secondary) ● Washer 2 2.Install: ● Friction plates 1 ● Clutch plates 2 (to clutch boss 3) NOTE: Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate. 3.Install: ● Clutch boss 1 ● (to pressure plate assembly 2) NOTE: Align the arrow marks 3 on the clutch boss with the arrow mark 4 on the pressure plate. 4.
ENGINE ASSEMBLY AND ADJUSTMENT ENG NOTE: Hold the clutch boss 2 by the Rotor Holder 3 to tighten the nut. Rotor holder: P/N. YU-01235, 90890-01235 6.Bend the lock washer tab 4. 7.Install: ● Clutch springs 1 ● Bearing holder 2 ● Bearing 3 ● Push rod 4 T. Bolts (clutch spring): 6 Nm (0.6 m • kg, 4.3 ft • lb) R. 4 8.Install: ● Drive pinion gear 1 ● Nut 2 (drive pinion gear) WARNING Always use a new drive pinion gear nut. 9.Tighten: ● Nut 2 (drive pinion gear) T. Nut (drive pinion gear): 60 Nm (6.
ENGINE ASSEMBLY AND ADJUSTMENT ENG 11.Install: ● Washer 1 ● Clutch housing 2 (primary) ● Washer 3 ● Clutch carrier assembly 4 NOTE: ● The secondary clutch housing has two grooves 1 machined into it permit the primary drive gear behind the primary clutch to clear the secondary clutch. ● Align one of these grooves with the primary gear 2 before installing the primary clutch housing. 12.Install: ● Lock washer 1 ● Nut 2 (primary clutch) WARNING Always use a new lock washer.
ENGINE ASSEMBLY AND ADJUSTMENT ENG 15.Install: ● Shift guide #2 1 ● Ball holder 2 ● Shift guide #1 3 ● Spring 4 (clutch release lever) NOTE: ● The slot 5 in the shift guide #2 must engage the shift shaft projection 6. ● The slot 7 in the shift guide #1 must engage the stopper shaft 8. 4 16.Install: ● Dowel pins 1 ● Gasket 2 ● Crankcase cover 3 ● Clutch cover protector 4 ● Oil filter 5 ● O-ring 6 ● Oil filter cover 7 WARNING Always use a new gasket.
ENGINE ASSEMBLY AND ADJUSTMENT ENG MIDDLE DRIVEN PINION GEAR 1.Install: ● Dowel pins 1 ● Shims 2 (to middle driven shaft) ● Bearing 3 ● Middle driven shaft assembly 4 NOTE: Apply the grease to the O-ring 5. 2.Apply: ● Sealant 1 (to matching surface of middle shaft case cover) Sealant (Quick Gasket): P/N. ACC-QUICK-GS-KT Yamaha Bond No. 1215: P/N. 90890-85505 3.Install: ● Case cover 1 (middle driven shaft) T. Bolt (middle shaft case cover): 10 Nm (1.0 m • kg, 7.2 ft • lb) R.
ENGINE ASSEMBLY AND ADJUSTMENT STARTER PULLEY (EXCEPT FOR USA)/CDI MAGNETO 1 Timing chain 2 Timing chain guide (intake) 3 Woodruff key 4 Washer 5 Starter driven gear 6 Starter clutch 7 Dowel pin 8 Starter clutch spring cap 9 Compression spring 0 CDI magneto A Starter idle gear B Shaft C Washer D Circlip E Stator assembly F Crankcase cover (left) G Starter pulley 4 D FW 4 - 62 ENG
ENGINE ASSEMBLY AND ADJUSTMENT ENG STARTER PULLEY (EXCEPT FOR USA) AND CDI MAGNETO 1.Inspect: ● Timing chain 1 ● Chain guide 2 (intake) T. Chain guide (intake): 8 Nm (0.8 m • kg, 5.8 ft • lb) R. NOTE: Fasten a safety wire 3 to the timing chain to prevent it from falling into the crankcase. 2.Install: ● Washer 1 ● Driven gear 2 (starter) ● Woodruff key 3 ● CDI magneto 4 NOTE: ● Clean the tapered portions of the crankshaft and CDI magneto.
ENGINE ASSEMBLY AND ADJUSTMENT ENG 5.Install: ● Starter pulley 1 T. Bolt (starter pulley): 50 Nm (5.0 m • kg, 36 ft • lb) R. NOTE: ● Hold the starter pulley by the Rotor Holder to tighten the bolt. Rotor holder: P/N. YU-01235, 90890-01235 ● 4 4 - 64 Before installing the starter pulley, apply the grease to the oil seal rip 2 and O-ring 3.
ENGINE ASSEMBLY AND ADJUSTMENT ENG CYLINDER AND CYLINDER HEAD ASSEMBLY 1 Spark plug 2 Tappet cover (intake) 3 O-ring 4 Tappet cover (exhaust) 5 Cylinder head 6 Bearing retainer 7 Lock washer A CYLINDER HEAD WARP LIMIT: 0.10 mm (0.004 in) B SPARK PLUG: C TYPE/MANUFACTURER: DR7EA/NGK D SPARK PLUG GAP: 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) 8 Cam sprocket cover 9 Oil seal 0 Cylinder 4 E VALVE CLEARANCE (COLD): INTAKE: 0.05 ~ 0.09 mm (0.002 ~ 0.004 in) EXHAUST:0.11 ~ 0.15 mm (0.004 ~ 0.
ENGINE ASSEMBLY AND ADJUSTMENT PISTON, CAMSHAFT AND TIMING CHAIN 1 Gasket 2 Timing chain tensioner 3 Gasket 4 Timing chain guide (intake) 5 Camshaft 6 Camshaft bushing 7 Cam sprocket 8 Timing chain 9 Timing chain guide (exhaust) 0 Piston ring A Piston pin clip B Piston C Piston pin 4 4 - 66 ENG
ENGINE ASSEMBLY AND ADJUSTMENT ENG CYLINDER HEAD ASSEMBLY, CYLINDER AND PISTON 1.Install: ● Piston 1 ● Piston pin 2 ● Piston pin clips 3 NOTE: ● The arrow 4 on the piston must point to the front of the engine. ● Before installing the piston pin clip, cover the crankcase with a clean towel or rag so you will not accidentally drop the pin clip and material into the crankcase. WARNING Always use a new piston pin clip. 2.
ENGINE ASSEMBLY AND ADJUSTMENT ENG 5.Install: ● Cylinder 1 ● Bolts (cylinder)-temporary tighten NOTE: ● Install the cylinder with one hand while compressing the piston rings with the other hand. ● Pass the timing chain through the chain cavity. 6.Install: ● Chain guide 1 (exhaust) ● Oil seal 2 ● Dowel pins 3 ● Gasket 4 (cylinder head) WARNING Always use a new gasket. 7.Install: ● Cylinder head assembly ● Bolts (cylinder head) 4 NOTE: ● Apply the 4-stroke engine oil onto the washers.
ENGINE ASSEMBLY AND ADJUSTMENT ENG ●Turn the crankshaft counterclockwise until the TDC mark 3 is aligned with the stationary pointer 4 on the crankcase cover. ●Place the timing chain onto the cam sprocket. ●Install the cam sprocket onto the camshaft, and finger tighten the sprocket bolt. NOTE: ● When installing the cam sprocket, keep the timing chain as tense as possible on the exhaust side. ● Align the pelete mark 5 on the cam sprocket with the stationary pointer 2 on the cylinder head.
ENGINE ASSEMBLY AND ADJUSTMENT ENG ●Insert a small screwdriver 3 into the tensioner body slit. While pressing the tensioner rod, rotate the screwdriver clockwise until it stops turning. ●While holding the screwdriver in this position, and install the tensioner assembly 2 (with the gasket) onto the cylinder, then temporary tighten the tensioner assembly holding bolts 4. WARNING Always use a new gasket. ●Remove the screwdriver from the tensioner body, and torque the tensioner assembly holding bolts. T. R.
ENGINE ASSEMBLY AND ADJUSTMENT ENG 13.Install: ● Tappet cover 1 (intake) ● Tappet cover 2 (exhaust) ● Spark plug 3 T. R. Bolt (tappet cover): 10 Nm (1.0 m • kg, 7.2 ft • lb) Spark plug: 17.5 Nm (17.5 m • kg, 12.5 ft • lb) 14.Install: ● Cam sprocket cover 1 ● Carburetor joint 2 T. R. Screw (cam sprocket cover): 7 Nm (0.7 m • kg, 5.1 ft • lb) Bolt (carburetor joint): 12 Nm (1.2 m • kg, 8.7 ft • lb) NOTE: Inspect the O-ring of the carburetor joint. If damaged, replace it. 15.
ENGINE ASSEMBLY AND ADJUSTMENT ENG REMOUNTING ENGINE Reverse the “ENGINE REMOVAL” procedure. Note the following points. WARNING Securely support the machine so there is no danger of it falling over. 1.Install: ● Engine assembly (from right side) 4 2.Install: ● Bolt 1 (engine mounting - rear lower) ● Bolt 2 (engine mounting - rear upper) ● Bolt 3 (engine mounting - front) ● Bolts 4 (engine mounting - top) NOTE: ● All mounting bolts should be installed from the right of the machine.
ENGINE ASSEMBLY AND ADJUSTMENT ENG 3.Install: ● Rear wheel drive assembly and swingarm. NOTE: ● Before installing the swingarm. Lubricate the following parts. Swingarm pivot side: 1) Bearings 1 2) Oil seals 2 3) Collars 3 4) Pivot shafts 4 Drive shaft side: 1) Drive shaft splines 5 2) Coupling gear splines 6 Lithium-soap Base Grease ● ● Before installing the swingarm, do not forget to fit the drive shaft 7. Insert the drive shaft 7 into the universal joint 8 properly. 4.Connect: ● Rubber boot 1 5.
ENGINE ASSEMBLY AND ADJUSTMENT ENG 7.Tighten: ● Bolt 1 (engine mounting - rear lower) ● Bolt 2 (engine mounting - rear upper) ● Bolt 3 (engine mounting - front) ● Bolts 4 (engine mounting - top) ● Pivot shafts 5 (swingarm) ● Locknut (pivot shaft - right) ● Bolt 6 (rear shock absorber - top) T. R. 4 Bolt (engine mounting - rear lower): 33 Nm (3.3 m • kg, 24 ft • lb) Bolt (engine mounting - rear upper): 33 Nm (3.3 m • kg, 24 ft • lb) Bolt (engine mounting - front): 48 Nm (4.
ENGINE ASSEMBLY AND ADJUSTMENT ENG 11.Install: ● Spring 1 ● Footrest 2 (right) T. Bolt (footrest): 65 Nm (6.5 m • kg, 47 ft • lb) R. 12.Install: ● Front fender stay 1 ● Sift pedal 2 ● Footrest 3 (left) T. R. Bolt (shift pedal): 10 Nm (1.0 m • kg, 7.2 ft • lb) Bolt (footrest): 65 Nm (6.5 m • kg, 47 ft • lb) Bolt (footrest plate): 30 Nm (3.0 m • kg, 22 ft • lb) NOTE: The center of the shift pedal 2 should be aligned with the top of the footrest 3. 13.
ENGINE ASSEMBLY AND ADJUSTMENT ENG 17.Install: ● Carburetor 1 Refer to “CARBURETOR” section in the CHAPTER 5. T. Hose clamp: 2 Nm (0.2 m • kg, 1.4 ft • lb) R. 18.Install: ● Exhaust pipe 1 ● Muffler 2 T. R. Bolt (muffler): 34 Nm (3.4 m • kg, 25 ft • lb) Bolt (muffler and exhaust pipe): 20 Nm (2.0 m • kg, 14 ft • lb) Bolt (exhaust pipe): 10 Nm (1.0 m • kg, 7.2 ft • lb) 4 19.Fill: ● Crankcase Total amount: 1.8 L (1.6 Imp qt, 1.9 US qt) Refer to the “ENGINE OIL REPLACEMENT” section in CHAPTER 3. 20.
ENGINE ASSEMBLY AND ADJUSTMENT ENG 22.Install: ● Rear fender ● Rear carrier ● Front fender ● Front bumper ● Front carrier ● Fuel tank ● Seat Refer to the “FENDERS AND FUEL TANKInstallation” section in CHAPTER 3. 23.Inspect: ● Oil leakage 24.Check: ● “NEUTRAL” indicator light operation ● “REVERSE” indicator light operation Poor operation → Repair.
ENG 4 4 - 78
CARBURETOR CARB CARBURETION CARBURETOR 1 Vacuum chamber cover 2 Spring 3 Jet needle set 4 Piston valve 5 Pilot air jet 6 Coasting enricher diaphragm 7 Starter plunger assembly 8 Pilot screw set 9 Pilot jet 0 Needle jet A Main jet B Needle valve set C Throttle stop screw D Float pin E Float SPECIFICATIONS ID MARK 4XE1 00 MAIN JET (M.J.) #95 PILOT JET (P.J.) #42.5 JET NEEDLE (J.N.) 5CE35 NEEDLE JET (N.J.) P-2 (823) PILOT SCREW (P.S.) 2 turns out 12 ~ 14 mm FLOAT HEIGHT (F.H.) FUEL LEVEL Å (F.L.) (0.
CARBURETOR CARB REMOVAL 1.Turn the fuel cock lever to “OFF”. 2.Remove: ● Air vent hose 1 ● Overflow hose 2 ● Fuel hose 3 3.Loosen: ● Clamp screws 4 4.Remove: ● Carburetor assembly 5.Remove: ● Throttle valve cover 1 6.Remove: Throttle cable end 1 ● 5 7.Loosen: ● Throttle cable adjusting nut 1 8.Remove: ● Throttle cable 2 DISASSEMBLY 1.
CARBURETOR CARB 2.Remove: ● Pilot air jet 1 3.Remove: Float chamber 1 ● O-ring 2 ● 4.Remove: ● Float pin 1 ● Float 2 ● Needle valve 3 NOTE: Remove the float pin in the direction of the arrow. 5.Remove: ● Throttle stop screw 1 ● Valve seat 2 ● Main jet 3 ● Pilot jet 4 ● Pilot screw set 5 6.Remove: ● Needle jet 1 NOTE: Remove the needle jet towards the piston valve side.
CARBURETOR CARB 7.Remove: ● Cover (coasting enricher) 1 ● Spring 2 ● Diaphragm 3 8.Remove: ● Starter plunger 1 INSPECTION 1.Inspect: ● Carburetor body ● Starter jet 1 ● Float chamber Cracks/damage → Replace. ● Fuel passage Contamination → Clean as indicated. ● Fuel chamber body Contamination → Clean. 5 ********************************* Cleaning steps: ● Wash the carburetor in a petroleum based solvent. (Do not use any caustic carburetor cleaning solution.
CARBURETOR CARB 3.Inspect: ● Float 1 ● Float tang 2 Damage → Replace. 4.Inspect: ● Main jet 1 ● Needle jet 2 ● Pilot jet 3 ● Pilot air jet 4 Wear/damage → Replace. Contamination → Blow out the jets with compressed air. 5.Inspect: ● Spring 1 ● Spring seat 2 ● Jet needle set 3 ● Piston valve 4 Bends/wear/damage → Replace. 6.Inspect: ● Diaphragm (coasting enricher) 1 ● Spring 2 ● Cover 3 Tears (diaphragm) /damage → Replace. 7.Inspect: ● Starter plunger 1 Bends/wear/damage → Replace.
CARBURETOR CARB 8.Inspect: ● Throttle stop screw 1 ● Pilot screw 2 Contamination/wear → Replace. ● O-ring 3 Damage → Replace. 9.Check: ● Free movement (piston valve) Sticks → Replace. Insert the piston valve into the carburetor body, and check for free movement. 10.Check: ● Free movement (throttle valve) Sticks → Replace. ASSEMBLY Reverse the “DISASSEMBLY” procedure. Note the following points. CAUTION: 5 ● ● Before reassembling, wash all of the parts in a clean petroleum based solvent.
CARBURETOR CARB 3.Install: ● O-ring ● Washer ● Spring ● Pilot screw Pilot screw: 2 turns out 4.Install: ● Needle valve 1 ● Float 2 ● Float pin 3 NOTE: Install the float pin in the direction of the arrow. 5.Measure: ● Float height a Out of specification → Adjust. Float height (F.H.): 12 ~ 14 mm (0.47 ~ 0.55 in) ********************************* Measurement and adjustment steps: ● Hold the carburetor in an upside down position.
CARBURETOR CARB 6.Install: ● Piston valve 1 NOTE: Match the tab on the rubber diaphragm to the matching recess in the carburetor body. INSTALLATION Reverse the “REMOVAL” procedure. Note the following points. 1.Install: ● Carburetor assembly T. Clamp screw: 2 Nm (0.2 m • kg, 1.4 ft • lb) R. 5 2.Adjust: ● Idle speed Refer to “IDLE SPEED ADJUSTMENT” in CHAPTER 3. Engine idle speed: 1,400 ~ 1,500 r/min 3.Adjust: ● Throttle lever free play Refer to “THROTTLE CABLE FREE PLAY ADJUSTMENT” in CHAPTER 3.
CARBURETOR CARB FUEL LEVEL ADJUSTMENT 1.Measure: ● Fuel level a Out of specification → Adjust. Fuel level: 1.0 ~ 2.0 mm (0.04 ~ 0.08 in) Above the float chamber mating surface ********************************* Fuel level measurement and adjustment steps: ● Place the machine on a level surface. ● Connect the fuel level gauge 1 to the drain pipe 2. Fuel level gauge: P/N. YM-01312-A, 90890-01312 ● Loosen the drain screw 3. ● Hold the gauge vertically next to the float chamber line.
CARB 5 5 - 10
MIDDLE GEAR SERVICE DRIV DRIVE TRAIN MIDDLE GEAR SERVICE MIDDLE GEAR 1 Universal joint 2 Bearing retainer 1 3 Bearing 4 Shims 5 Bearing housing 6 O-ring 7 Reverse gear securing nut 8 Bearing 9 Bearing retainer 2 0 Shims A Reverse gear B Dog clutch C Middle driven shaft D Driven pinion gear E Shims F Bearing G Shift fork 4 H Spring I Ball J Shift fork guide bar K O-ring L Lever M Shift lever shaft N Circlip O Shift lever P Stopper shaft Q Drive pinion gear R Shims S Bearing T Middle gear camp 6 6-1
MIDDLE GEAR SERVICE DRIV MIDDLE GEAR SHIMS When the crankcase assembly and/or the middle gear comp., etc. are replaced, be sure to adjust the middle gear shim(s). Refer to the “MIDDLE GEAR SHIM SELECTION” and “MIDDLE GEAR LASH ADJUSTMENT” section.
MIDDLE GEAR SERVICE DRIV REMOVAL NOTE: It is necessary to remove the rear wheel drive assembly and/or engine assembly in order to service the middle gear, refer to the “ENGINE OVERHAUL” section in CHAPTER 4. 1.Drain: Engine oil Refer to the “ENGINE OIL REPLACEMENT” section in CHAPTER 3. 2.Remove: ● Seat ● Fuel tank ● Front carrier ● Front bumper ● Front fender ● Rear carrier ● Rear fender Refer to the “FENDERS AND FUEL TANKRemoval” section in CHAPTER 3. ● 3.
MIDDLE GEAR SERVICE DRIV 2.Remove: ● Bolts 1 (middle gear case cover) ● Middle gear case cover 2 ● Dowel pins 3.Remove: ● Middle driven shaft assembly 1 ● Bearing 2 ● Shim 3 ● Driven pinion gear 4 Middle drive axle 1.Remove: ● Nut 1 (middle drive pinion gear) ● Middle drive pinion gear 2 NOTE: ● Flatten the punched portion of the middle drive gear nut using the drift punch. ● Put the engine in 1st, and carry out the operation. 6 Use the Rotor holder 3 hold the clutch boss 4. Rotor holder: P/N.
MIDDLE GEAR SERVICE DRIV 3.Remove: ● Bearing retainers 1 Use a #40 Torx Driver. 4.Remove: ● Bearing 1 ● Shim 2 DISASSEMBLY Middle driven shaft 1.Remove: ● Universal joint ********************************* Removal steps: ● Remove the circlips 1. ● Place the U-joint in a press. ● With a suitable diameter pipe beneath the yoke, press the bearing into the pipe as shown. NOTE: It may be necessary to lightly tap the yoke with a punch. ● Repeat the steps for the opposite bearing.
MIDDLE GEAR SERVICE DRIV Universal joint holder: P/N. YM-04062, 90890-04062 Attachment: P/N. YM33291, 90890-04096 3.Remove: ● Middle driven shaft 1 ● Dog clutch 2 4.Remove: ● Bearing retainer 1 NOTE: ● Use a Bearing retainer wrench 2. Bearing retainer wrench 32 mm (1.26 in): P/N. YM-33289,90890-04104 Bearing 3 Shim(s) 4 5.Remove: ● Reverse gear securing nut 1 ● 6 ● NOTE: ● The reverse gear securing nut has lefthand threads; turn the nut clockwise to loosen it. ● Use a Ring nut wrench 2.
MIDDLE GEAR SERVICE DRIV 6.Remove: ● Bearing retainer 1 NOTE: ● Use a Ring nut wrench 2. Ring nut wrench: P/N. YM-1391, 90890-01391 Bearing 3 Shift lever 1.Remove: ● Shift fork guide bar 1 ● Shift fork 2 ● Ball 3 ● Spring 4 ● NOTE: When removing the shift fork guide bar, the ball will fall off. Take care not lose the ball. 2.Remove: ● Circlip 1 ● Stopper shaft 2 ● Shift lever 3 ● Shift lever shaft 4 INSPECTION 1.Inspect: ● Gear teeth (all gears) 1 Pitting/Galling/Wear → Replace.
MIDDLE GEAR SERVICE DRIV 3.Check: ● Universal joints 1 ● Yoke 2 ● Bearings 3 Wear/Cracks/Damage → Replace. 4.Inspect: ● Shift fork 4 1 On the dog clutch and shift lever contact surfaces. Wear/Chafing/Bends/Damage → Replace. ● Spring 2 Wear/Damage → Replace. ● Ball (stopper) 3 Wear/Damage/Scratches → Replace. 5.Inspect: ● Guide bar Roll the guide bar on a flat surface. Bends → Replace. WARNING Do not attempt to straighten a bent guide bar. 6 6.Check: ● Shift fork movement On its guide bar 1.
MIDDLE GEAR SERVICE DRIV 8.Inspect: ● Bearing housing 1 Cracks/Damage → Replace bearing housing assembly. ● O-ring 2 Wear/Damage → Replace. NOTE: When the bearing housing assembly is replaced, be sure to adjust the middle gear shim(s), refer to the “MIDDLE GEAR SHIM SELECTION” section. MIDDLE GEAR SHIM SELECTION Install the crankcase, middle gears and middle driven shaft by using shim(s) with their respective thickness(es) calculated from the numbers specified on the following parts.
DRIV MIDDLE GEAR SERVICE Shim location Å = Drive pinion gear shim ı = Driven pinion gear shim Ç = Reverse gear shim Î = Middle driven shaft shim 1 Drive pinion gear 2 Driven pinion gear 3 Reverse gear 4 Middle driven shaft Replaced parts Adjust shim Crankcase Å Drive pinion gear Å Driven pinion gear ı Ç ı Î Î Reverse gear Ç Î Bearing housing Ç Î Middle driven shaft Î Å=a-b ı=c-d-e-f Ç=d-g-h-i Î = j + c - e - ı - k - l - 0.
MIDDLE GEAR SERVICE DRIV ********************************* Middle gear shims selection steps: Shim selection Å ● When the crankcase and/or the drive pinion gear are replaced, be sure to adjust the drive pinion gear shim Å. ● To find drive pinion gear shim thickness “A” use following formula: Drive pinion gear shim thickness: Å=a–b a= The stamped number on the drive pinion gear is either added to or substracted from “42”. b= The stamped number on the crankcase is added to from “41”.
MIDDLE GEAR SERVICE DRIV In the example above, the calculated shim thickness is 0.57 mm. The chart instructs you, however, to round off the 7 to 5, then shim thickness is 0.55 mm. Shim selection ı ● When the crankcase and/or the driven pinion gear are replaced, be sure to adjust the driven pinion gear shim ı. ● To find driven pinion gear shim thickness “B” use following formula: Driven pinion gear shim thickness: ı=c–d–e–f c= The stamped number on the crankcase is added to from “110”.
MIDDLE GEAR SERVICE Hundredths DRIV Round value 0, 1 0 2, 3 3 4, 5, 6 5 7, 8 8 9 10 In the example above, the calculated shim thickness is 0.95 mm. The chart instructs you, however, to round off the 5 to 5, then shim thickness is 0.95 mm. Shim selection Ç ● When the crankcase, reverse gear and/or bearing housing are replaced, be sure to adjust the reverse gear shim Ç.
MIDDLE GEAR SERVICE DRIV Reverse gear shim Thickness (mm) 0.15 0.20 0.30 0.40 0.50 Because shims can only be selected in 0.05 mm increments, round off hundredths digit and select appropriate shim(s). Hundredths Round value 0, 1 0 2, 3 3 4, 5, 6 5 7, 8 8 9 10 In the example above, the calculated shim thickness is 0.51 mm. The chart instructs you, however, to round off the 1 to 0, then shim thickness is 0.50 mm.
MIDDLE GEAR SERVICE DRIV Example: 1) If the bearing hauging is stamped “–03”. ..... j = 1 – 0.03 = 0.97 2) If the crankcase is stamped “45” ..... c = 110 + 0.45 = 110.45 3) If the pinion gear is stamped “–02” ..... k = 14.5 – 0.02 = 14.48 4) If the middle drive shaft is stamped “03” ..... l = 80.5 + 0.03 = 80.53 5) Therefore, shim thickness Î is, Î = 0.97 + 110.45 – 13.00 – 0.95 – 14.48 – 80.53 – 0.25 = 2.21 mm 6) Shim sizes are supplied in following thickness: Middle driven gear shim Thickness (mm) 1.
MIDDLE GEAR SERVICE DRIV ASSEMBLY Reverse the “DISASSEMBLY” procedures. Note the following points. Middle driven shaft 1.Apply: ● Lithium base grease To the oil seal and O-ring. 2.Install: Shift lever shaft 1 ● Shift lever 2 ● Stopper shaft 3 ● Circlip 4 ● 3.Install: ● Spring 1 (to shift fork 4) ● Ball 2 NOTE: When installing the shift fork 4 onto the shift fork guide bar, place a dowel pin 3 (used for a crank case cover) to hold the ball and spring in place. 6 4.
MIDDLE GEAR SERVICE DRIV 6.Install: ● Bearing 1 (to bearing housing) ● Bearing retainer 2 NOTE: ● Use a Ring nut wrench 3. Ring nut wrench: P/N. YM-1391, 90890-01391 7.Tighten: ● Bearing retainer T. Bearing retainer: 60 Nm (6.0 m • kg, 43 ft • lb) R. 8.Install: ● Shim(s) 1 ● Reverse gear 2 ● Reverse gear securing nut 3 NOTE: ● The reverse gear securing nut has lefthand threads, turn the nut counterclockwise to tighten it. ● Use a Ring nut wrench 4. Ring nut wrench: P/N. YM-1391, 90890-01391 9.
MIDDLE GEAR SERVICE DRIV 11.Tighten: ● Bearing retainer T. R. Bearing retainer: 60 Nm (6.0 m • kg, 43 ft • lb) Use LOCTITE 12.Install: ● Middle driven shaft 1 ● Dog clutch 2 13.Install: ● U-joint 1 ● Washer 2 ● Nut 3 (U-joint) NOTE: Hold the U-joint 1 by the Universal Joint Holder 4 and Attachment 5, and tighten the U-joint securing nut to specification. Universal joint holder: P/N. YM-04062, 90890-04062 Attachment: P/N. YM-33291, 90890-04096 6 T. R. 6 - 18 Nut (U-Joint): 60 Nm (6.
MIDDLE GEAR SERVICE DRIV 14.Install ● Universal joint ********************************* Installation steps: ● Install the opposite yoke into the U-joint. ● Apply the “Wheel bearing grease” to the bearings. ● Install the bearing 1 onto the yoke. CAUTION: Check each bearing. The needles can easily fall out of their races. Slide the yoke back and forth on the bearings; the yoke will not go all the way onto a bearing if a needle is out of place.
MIDDLE GEAR SERVICE DRIV 3.Install: ● Middle drive axle assembly 1 Refer to the “ENGINE ASSEMBLY AND ADJUSTMENT-CRANK SHAFT, TRANSMISSION AND BALANCER SHAFT” section in CHAPTER 4. 4.Install: ● Middle drive pinion gear 1 ● Nut 2 T. Nut (middle drive pinion gear): 60 Nm (6.0 m • kg, 43 ft • lb) R. Use the Rotor Holder 3 to hold the clutch boss 4. Rotor holder: P/N. YU-01235, 90890-01235 NOTE: Put the engine in 1st, and carry out the operation. 5.
MIDDLE GEAR SERVICE DRIV 2.Apply: ● Sealant 1 To the mating surface of both case halves. Sealant (Quick Gasket) P/N. ACC-QUICK-GS-KT Yamaha bond No. 1215 P/N. 90890-85505 3.Install: Dowel pins ● Middle gear case cover 2 ● NOTE: Before installing the middle gear case cover onto the crankcase, shift the gear into “FORWARD”. 4.Tighten: ● Bolts 3 (middle gear case) T. Bolts (middle gear case cover): 10 Nm (1.0 m • kg, 7.2 ft • lb) R. 5.Tighten: Bolts 1 (bearing housing) ● T.
MIDDLE GEAR SERVICE DRIV 2.Shift: ● Drive select lever For forward drive. 3.Measure: ● Gear lash Gently rotate the middle drive axle from engagement to engagement. Over specified limit → Repair. Middle driven gear lash: (using measurement tool): 0.1 ~ 0.2 mm (0.004 ~ 0.008 in) NOTE: Measure the gear lash at 4 positions. Rotate the shaft 90˚ each time. 4.Shift: ● Drive select lever For reverse drive 5.Repeat step 3. Over specified limit → Repair. Reverse gear lash: 0.1 ~ 0.25 mm (0.004 ~ 0.
MIDDLE GEAR SERVICE DRIV 2.Install: ● Rear wheel drive assembly and swingarm Refer to “REMOUNTING ENGINE” section in the CHAPTER 4. 3.Adjust: ● Rear brake Refer to “REAR BRAKE LEVER AND PEDAL ADJUSTMENT” section in the CHAPTER 3. 4.Install: ● Rear fender ● Rear carrier ● Front fender ● Front bumper ● Front carrier ● Fuel tank ● Seat Refer to the “FENDERS AND FUEL TANKInstallation” section in CHAPTER 3. 5.Fill: ● Crankcase Total amount: 1.8 L (1.6 Imp qt, 1.
FINAL DRIVE GEAR AND DRIVE SHAFT DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 1 Bearing housing 2 O-ring 3 Oil seal 4 Bearing 5 Ring gear shim 6 Ring gear 7 Thrust washer 8 Bearing 9 Oil seal 0 Bearing A Drive pinion gear B Final drive gear shim C Bearing D Bearing retainer 6 6 - 24 E O-ring F Oil seal G Collar H Drive shaft I Circlip J Universal joint K Bearing
FINAL DRIVE GEAR AND DRIVE SHAFT DRIV TROUBLESHOOTING The following conditions may indicate damage drive train components: Symptoms Possible causes 1.A pronounced hesitation or “jerky” movement during acceleration, deceleration, or A. Bearing damage. sustained speed. (this must not be confused with engine surging or transmission B. Improper gear lash. characteristics.) C. Gear tooth damage. 2.A “rolling rumble” noticeable at low speed; a high-pitched “whine”; a “clank” from a D. Broken drive shaft.
FINAL DRIVE GEAR AND DRIVE SHAFT DRIV Inspection notes 1.Investigate any unusual noises ********************************* The following “Noises” may indicate a machanical problem: ● A “rolling rumble” noise during coasting, acceleration, or deceleration. The noise increases with rear wheel speed, but it does not increase with higher engine or transmission speeds. Diagnosis: Possible wheel bearing damage. ● A “whining” noise that varies with acceleration and deceleration.
FINAL DRIVE GEAR AND DRIVE SHAFT DRIV 3.Inspect: ● Oil leakage By the following inspection steps. ********************************* Oil leakage inspection steps: ● Clean the entire machine thoroughly, then dry it. ● Apply a leak-localizing compound or dry powder spray to the shaft drive. ● Road test the machine long enough to locate the leak. Leakage → Inspect component housing, gasket, and/or seal for damage. Damage → Replace component.
FINAL DRIVE GEAR AND DRIVE SHAFT DRIV REMOVAL WARNING Securely support the machine so there is no danger of it falling over. 1.Drain: ● Final gear oil Refer to the “FINAL GEAR OIL REPLACEMENT” section in CHAPTER 3. 2.Remove: Seat ● Rear carrier ● Rear fender Refer to the “FENDERS AND FUEL TANKREAR FENDER” section in CHAPTER 3. ● 6 3.Remove: ● Rear wheel (left) ● Wheel hub ● Rear wheel (right) ● Brake drum ● Rear axle ● Refer to “REAR WHEEL/REAR BRAKE AND REAR AXLE - Removal” section in CHAPTER 7. 4.
FINAL DRIVE GEAR AND DRIVE SHAFT DRIV NOTE: ● When the final gear case until is removed from the swingarm, the drive shaft 3 may fall off. ● Be careful not to lose these parts. DISASSEMBLY 1.Remove: ● Bolts 1 (8 mm) ● Bolts 2 (10 mm) NOTE: Working in a crisscross pattern, loosen bolt 1/4 turn each. Remove them after all loosened. 2.
FINAL DRIVE GEAR AND DRIVE SHAFT DRIV 3.Remove: ● Bearing retainer (drive shaft - final) NOTE: Final-drive-shaft-bearing-retainer has lefthand threads. Turn retainer clockwise to loosen it. NOTE: When remounting the bearing retainer, use the Bearing Retainer Wrench 1. Bearing retainer wrench: P/N. YM-04050, 90890-04050 4.Remove: ● Drive pinion gear 1 (together with the shim(s) 2 and bearing 3) Tap lightly on the final drive pinion gear end with a soft hammer.
FINAL DRIVE GEAR AND DRIVE SHAFT DRIV 6.Remove: ● Roller bearing 1 (drive pinion gear) ********************************* Removal steps: ● Heat the main housing only to 150˚C (302˚F). ● Remove the roller bearing outer race with an appropriately shaped punch 2. ● Remove the inner race from the final drive shaft. NOTE: The removal of the final drive shaft roller bearing is difficult and seldom necessary. INSPECTION 1.
FINAL DRIVE GEAR AND DRIVE SHAFT DRIV 4.Inspect: ● Final gear case 1 ● Bearing housing 2 (ring gear) Cracks/Damage → Replace. NOTE: When the final gear case and/or ring gear bearing housing are replaced, be sure to adjust the shim of the final drive pinion gear and/or ring gear, refer to the “FINAL DRIVE GEAR AND RING GEAR SHIM SELECTION” section.
FINAL DRIVE GEAR AND DRIVE SHAFT DRIV Example: 1) If the “+01” is stamped on the final drive pinion gear, a = 79 + 0.01 = 79.01 2) If the “50” is stamped on the final gear case, b = 78 + 0.50 = 78.50 3) Therefore, “A” is, “A” = 79.01 – 78.50 = 0.51 mm 4) Round off hundredths digit and select appropriate shim(s). In the example above, the calculated number is 0.51. The chart instructs you to round off 1 to 0 at the hundredth place. Thus, the shim thickness is 0.50 mm.
FINAL DRIVE GEAR AND DRIVE SHAFT DRIV ********************************* Shim selection steps: ● To find ring gear shim thickness “B”, use the following formula. Ring gear shim thickness: “B” = c + d – (e + f) c= The stamped number on the final gear case is either added to or subtracted from “42”. d= The stamped number on outside of ring gear bearing housing and added to “2”. e= The stamped number on inside of ring gear either added to or subtracted from “33”.
FINAL DRIVE GEAR AND DRIVE SHAFT DRIV ASSEMBLY Reverse the “DISASSEMBLY” procedures. Note the following points. 1.Install: ● Roller bearing (drive pinion gear) ********************************* Installation steps: ● Heat the main housing only to 150˚C (302˚F) ● Install the roller bearing outer race using the proper adapted. ● Install the inner race onto the drive shaft. ********************************* 2.
FINAL DRIVE GEAR AND DRIVE SHAFT DRIV Thrust washer selection 1.Measure/Select: ● Ring gear thrust clearance “C” ********************************* Thrust clearance measurement steps: ● Place four pieces of Plastigauge between originally fitted thrust washer and ring gear. ● Install the ring gear assembly and tighten the bolts to specification. T. R. 10 mm Bolts (bearing housing): 40 Nm (4.0 m • kg, 29 ft • lb) 8 mm Bolts (bearing housing): 23 Nm (2.
FINAL DRIVE GEAR AND DRIVE SHAFT DRIV 2.Install: ● Thrust washer 1 ● Ring gear 2 ● Shim(s) 3 (proper size as calculated) ● Bearing housing 4 NOTE: ● Before installing the ring gear, apply the grease to the oil seal rips. ● Before installing the bearing housing, apply the grease to the O-ring. 3.Install: 10 mm bolts 1 (bearing housing) ● 8 mm bolts 2 (bearing housing) ● NOTE: Tighten the bolts in stage, using a crisscross pattern. T. R. 10 mm Bolts (bearing housing): 40 Nm (4.
FINAL DRIVE GEAR AND DRIVE SHAFT DRIV 4.Attach: ● Gear lash measurement tool 1 ● Dial gauge 2 Gear lash measurement tool: P/N. YM-01231, 90890-01231 Dial gauge: P/N. YU-03097, 90890-03097 a Measuring point 5.Measure: ● Gear lash Gently rotate the gear coupling from engagement to engagement. If the measured value in step 5 is different than that of the calculated value for shim size on page 6-32, repeat the following steps using the measured value in step 5. Final gear gear lash: 0.1 ~ 0.2 mm (0.004 ~ 0.
FINAL DRIVE GEAR AND DRIVE SHAFT DRIV 3.Adjust: ● Gear lash ********************************* Gear lash adjustment steps: ● Select the suitable shims and thrust washer by the following chart. Too-little gear lash → Reduce shim thickness. Too-large gear lash → Increase shim thickness. To add or reduce ring gear shim thickness Increase by more than 0.1 mm (0.004 in) Reduce by more than 0.1 mm (0.004 in) Reduce thrust washer thickness by 0.1 mm (0.004 in) for every 0.
FINAL DRIVE GEAR AND DRIVE SHAFT DRIV 5.Install: ● 10 mm bolts (bearing housing) ● 8 mm bolts (bearing housing) T. R. 10 mm Bolts (bearing housing): 40 Nm (4.0 m • kg, 29 ft • lb) 8 mm Bolts (bearing housing): 23 Nm (2.3 m • kg, 17 ft • lb) Refer to the “FINAL DRIVE GEAR AND DRIVE SHAFT – ASSEMBLY” section. 6.Measure: ● Gear lash If the gear lash is incorrect → Repeat. Final gear lash: 0.1 ~ 0.2 mm (0.004 ~ 0.008 in) INSTALLATION Reverse the “REMOVAL” procedures. Note the following points. 1.
FINAL DRIVE GEAR AND DRIVE SHAFT DRIV 4.Install: ● Final gear case unit 1 NOTE: Before installing the final gear case unit, apply the grease to the O-ring 2. T. R. Bolt (final gear case – axle housing) 3: 55 Nm (5.5 m • kg, 40 ft • lb) Nut (final gear case – swingarm) 4: 48 Nm (4.8 m • kg, 35 ft • lb) 5.Connect: ● Breather hose 5 (final gear case) CAUTION: Make sure the final gear case breather hose is routed correctly. 6.
DRIV 6 6 - 42
FRONT WHEELS AND FRONT BRAKE CHAS CHASSIS FRONT WHEELS AND FRONT BRAKE 1 Brake camshaft lever 2 Wear indicator plate 3 Brake shoe plate 4 Brake shoe plate seal 5 Pivot pin 6 Brake camshaft holder 7 Brake camshaft 8 Brake shoe 9 Bearing 0 Bearing spacer A Front brake drum B Oil seal C Front wheel D Collar TIRE AIR PRESSURE Cold Tire Pressure Front Standard Minimum Maximum 20 kPa (0.20 kg/cm2, 2.8 psi) 17 kPa (0.17 kg/cm2, 2.4 psi) 23 kPa (0.23 kg/cm2, 3.2 psi) Rear 25 kPa (0.25 kg/cm2, 3.
FRONT WHEELS AND FRONT BRAKE CHAS REMOVAL Front wheels 1.Place the machine on a level place. 2.Loosen: ● Nuts (front wheel) Apply the parking brake 1. 3.Elevate the front wheels by placing the suitable stand under the frame. WARNING Securely support the machine there is no danger of falling over. 4.Remove: ● Nuts 1 (front wheel) ● Front wheel 2 5.Remove: ● Cotter pin 1 ● Axle nut 2 ● Plain washer 3 ● Brake drum 4 ● Spacer collar 5 6.
FRONT WHEELS AND FRONT BRAKE CHAS 9.Remove: ● Brake camshaft lever 1 ● Wear indicator plate 2 ● Brake camshaft 3 ● Brake camshaft holder 4 ● Pivot pin 5 ● Brake shoe plate 6 INSPECTION 1.Inspect: ● Wheel Refer to the “WHEEL INSPECTION” section in CHAPTER 3. 2.Measure: ● Wheel runout Over specified limit → Replace wheel or check bearing play 1. Rim runout limits: Vertical 2: 2.0 mm (0.08 in) Lateral 3: 2.0 mm (0.08 in) 3.Inspect: ● Tire surfaces Wear/Damage → Replace.
FRONT WHEELS AND FRONT BRAKE CHAS 4.Inspect: ● Brake linings Glazed parts → Sand with coarse sandpaper. 5.Measure: ● Brake lining thickness a Out of specification → Replace. Brake lining thickness: 4.0 mm (0.16 in) : 2.0 mm (0.08 in) NOTE: Replace the brake shoes as a set (with shoe springs) if either is found to be worn to the wear limit. 6.Inspect: ● Shoe springs 1 Wear/Damage → Replace. 7.Measure: ● Brake drum inside diameter a Out of specification → Replace.
FRONT WHEELS AND FRONT BRAKE CHAS 9.Inspect: ● Bearings 1 (brake drum) Bearings allow play in the brake drum or the wheel tuns roughly → Replace. ● Oil seal 2 Wear/Damage → Replace. ********************************* Wheel bearing and oil seal replacement steps: ● Clean the outside of the brake drum. ● Remove the oil seal 1 use a flat-head screw driver. NOTE: Place a rag 2 on the outer edge to protect this edge. ● Remove the bearings 3 using a general bearing puller.
FRONT WHEELS AND FRONT BRAKE CHAS INSTALLATION Reverse the “REMOVAL” procedure. Note the following points. 1.Lubricate: ● Oil seal lips 1 ● Bearings 2 ● Camshaft 3 ● Pivot pin 4 ● O-ring 5 Lithium-soap base grease CAUTION: Install the camshaft and the pivot pin lightly greased. Wipe off the excess grease. 2.Install: ● Pivot pin 1 ● Brake camshaft holder 2 T. R. Pivot pin bolt 3: 10 Nm (1.0 m • kg, 7.2 ft • lb) Brake camshaft holder bolt 4: 10 Nm (1.0 m • kg, 7.2 ft • lb) 3.
FRONT WHEELS AND FRONT BRAKE CHAS 4.Install: ● Brake shoes WARNING Do not apply grease to the brake shoe linings. 5.Connect: ● Front brake breather hose ● Brake cable (to brake shoe plate) 6.Install: ● Circlip 1 ● Spring 2 ● Washer (C-type) 3 ● Spring 4 ● Pin 5 ● Adjuster 6 7.Install: ● Brake drum 1 ● Spacer collar 2 ● Plain washer 3 ● Axle nut 4 T. Axle nut: 70 Nm (7.0 m • kg, 50 ft • lb) R. 8.Install: ● Cotter pin 1 NOTE: Do not loosen the wheel hub nut after torque tightening.
FRONT WHEELS AND FRONT BRAKE CHAS 9.Install: ● Front wheel T. Nut (front wheel): 55 Nm (5.5 m • kg, 40 ft • lb) R. NOTE: Arrow mark 1 on the tire must point toward the rotating direction Å of the wheel. 10.Adjust: ● Front brake cable free play Refer to the “FRONT BRAKE ADJUSTMENT” section in CHAPTER 3. Front brake free play: 5.0 ~ 8.0 mm (0.20 ~ 0.31 in) at lever pivot 11.Release the parking brake.
REAR WHEELS/REAR BRAKE AND REAR AXLE CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 1 Rear axle 2 Bearing 3 Oil seal 4 Wheel hub 5 Axle nut A TIRE SIZE: AT22 × 10-10 B RIM SIZE: 8 × 10 C WHEEL RUNOUT LIMIT: VERTICAL: 2.0 mm (0.08 in) D TIRE WEAR LIMIT: 2.0 mm (0.08 in) E REAR AXLE RUNOUT LIMIT: 1.5 mm (0.
REAR WHEELS/REAR BRAKE AND REAR AXLE 1 Brake drum 2 Brake shoe 3 Bearing retainer 4 Brake shoe plate seal 5 Rear brake breather hose 6 Brake shoe plate 7 Brake camshaft 8 Wear indicator plate 9 Brake camshaft lever CHAS * Yamaha brake grease 7 7 - 10 A BRAKE LINING WEAR LIMIT: 2.0 mm (0.08 in) B REAR BRAKE DRUM WEAR LIMIT: 161 mm (6.
REAR WHEELS/REAR BRAKE AND REAR AXLE CHAS REMOVAL 1.Place the machine on a level place. 2.Loosen: ● Nuts (rear wheel) Apply the parking brake 1. 3.Block the front wheels, and elevate the rear wheels by placing the suitable stand under the frame. WARNING Securely support the machine there is no danger of falling over. 4.Remove: ● Nuts 1 (rear wheel) ● Rear wheel 2 (left) ● Cotter pin 3 ● Nut 4 ● Washer 5 ● Wheel hub 6 5.
REAR WHEELS/REAR BRAKE AND REAR AXLE CHAS 8.Remove: ● Adjusters 1 (brake lever and brake pedal) ● Pins ● Springs 9.Disconnect: ● Brake cable 2 ● Brake rod 3 ● Rear brake breather hose 4 10.Remove: ● Bearing retainer 1 ● Brake shoe plate assembly 2 11.Remove: ● Spring 1 ● Brake camshaft lever 2 ● Wear indicator plate 3 ● Brake camshaft 4 12.Remove: ● O-ring 1 ● Washer 2 7 13.
REAR WHEELS/REAR BRAKE AND REAR AXLE CHAS INSPECTION 1.Inspect: ● Wheel Refer to the “WHEEL INSPECTION” section in CHAPTER 3. 2.Measure: ● Wheel runout ● Tire surfaces Refer to the “FRONT WHEEL AND FRONT BRAKE-INSPECTION” section. 3.Inspect: ● Wheel hub 1 Cracks/Damage → Replace. ● Splines 2 (wheel hub) Wear/Damage → Replace. 4.Inspect: ● Brake linings 5.Measure: ● Brake lining thickness Refer to the “FRONT WHEEL AND FRONT BRAKE-INSPECTION” section. Brake lining thickness: 4.0 mm (0.
REAR WHEELS/REAR BRAKE AND REAR AXLE CHAS 8.Inspect: ● Brake drum inner surface 1 Oil/Scratches → Remove. ● Oil Use a rag soaked in lacquer thinner or a solvent. Scratches Use a emery cloth (lightly and evenly polishing). Spline 2 Wear/Damage → Replace. 9.Inspect: ● Brake shoe plate 1 Cracks/Bends/Damage → Replace. ● Dust seal 2 Wear/Damage → Replace. 10.Inspect: ● Brake camshaft 1 Wear/Scratches/Damage → Replace. ● Rear brake breather hose 2 Obstruction → Remove. Damage → Replace. 11.
REAR WHEELS/REAR BRAKE AND REAR AXLE CHAS 13.Measure: ● Rear axle runout a Out of specification → Replace. Rear axle runout limit: 1.5 mm (0.06 in) WARNING Do not attempt to straighten a bent axle. 14.Inspect: ● Bearing 1 (rear axle) Bearing allow play in the axle hub or the bearing turns roughly → Replace. ● Oil seal 2 Wear/Damage → Replace. ********************************* Bearing and oil seal replacement steps: ● Clean the area around the bearing on the final gear case.
REAR WHEELS/REAR BRAKE AND REAR AXLE CHAS INSTALLATION Reverse the “REMOVAL” procedures. Note the following points. 1.Lubricate: ● Oil seal lip 1 (rear axle) ● Bearings 2 (rear axle) ● Axle spline (rear axle) Lithium-soap base grease 2.Install: ● Rear axle 1 NOTE: Before installing the rear axle, loosen all the bolts on the final gear case 2. Hold the rear axle 1 with your hand, and slide it into the ring gear spline on the final gear case. Tap lightly on the left end rear axle with a soft hammer.
REAR WHEELS/REAR BRAKE AND REAR AXLE CHAS 5.Install: ● Brake camshaft 1 ● Wear indicator plate 2 ● Brake camshaft lever 3 NOTE: ● When installing the wear indicator plate 2 to the brake camshaft 1 align the projection a on the wear indicator plate with the slot b on the brake camshaft. ● Align the punched mark c on the brake camshaft 1 with the punched mark d on the brake camshaft lever 3. T. Brake camshaft lever: 9 Nm (0.9 m • kg, 6.5 ft • lb) R. 6.
REAR WHEELS/REAR BRAKE AND REAR AXLE CHAS 8.Install: ● Brake shoes 9.Lubricate: ● Dust seal 1 (backing plate) Yamaha brake grease P/N. 90793-40003 CAUTION: Do not apply grease to the brake shoe linings. ● Brake drum spline Lithium-soap base grease CAUTION: Do not apply grease on the axle shaft spline, or the extra grease may contaminate the brake shoes during running. 10.Install: ● Brake drum 11.Connect: ● Rear brake breather hose 1 ● Brake rod 2 ● Brake cable 3 12.
REAR WHEELS/REAR BRAKE AND REAR AXLE CHAS 16.Install: ● Cotter pin 1 NOTE: Do not loosen the axle nut after torque tightening. If the axle nut groove is not aligned with the cotter pin hole, align groove with the hole by tightening up on the axle nut. WARNING Always use a new cotter pin. 17.Install: ● Rear wheel 1 (right) ● Nuts 2 T. Nuts (wheel panel): 55 Nm (5.5 m • kg, 40 ft • lb) R. NOTE: Arrow mark on the tire must point toward the rotating direction of the wheel.
STEERING SYSTEM CHAS STEERING SYSTEM 1 Handlebar holder (upper) 2 Handlebar holder (lower) 3 Steering shaft 4 Steering bearing 5 Oil seal 6 Collar 7 Cable guide 8 Lock washer 9 Rod end 0 Tie-rod A 7 7 - 20 TOE-IN: 0 ~ 5 mm (0 ~ 0.
STEERING SYSTEM CHAS REMOVAL Handlebar 1.Remove: ● Front carrier ● Front bumper ● Front fender Refer to “FENDERS AND FUEL TANKFRONT FENDER-Removal” section in CHAPTER 3. 2.Disconnect: ● Main switch lead ● “NEUTRAL” indicator light leads ● “REVERSE” indicator light leads ● Handlebar switch (left) leads ● Brake switch leads 3.Remove: ● Handle protector 1 4.Disconnect: ● Front brake cable 1 5.Remove: ● Throttle lever assembly 2 6.Disconnect: ● Brake cable 1 (parking) 7 7.
STEERING SYSTEM CHAS Steering shaft 1.Straighten: ● Lock washer tabs 1 2.Remove: ● Bolts 2 ● Lock washer 3 ● Cable guide 4 3.Remove: ● Clip (steering shaft) ● Nut ● Washer 4.Remove: ● Cotter pins ● Nuts ● Tie-rods 1 NOTE: When removing the rod ends from the steering shaft and knuckle arm, use a General Bearing Puller. 5.Remove: ● Steering shaft 1 (with steering bearings) (from upside) 7 6.
STEERING SYSTEM CHAS INSPECTION 1.Inspect: ● Handlebar Cracks/Bends/Damage → Replace. 2.Inspect: ● Steering shaft Bends/Damage → Replace. WARNING Do not attempt to straighten a bent shaft; this may dangerously weaken the shaft. 3.Inspect: ● Steering bearings 1 ● Oil seals 2 Wear/Damage → Replace. 4.Inspect: ● Tie-rod 1 Bend/Damage → Replace. 7 5.Check: ● Rod end movement Rod end exists free play → Replace. Rod end tuns roughly → Replace. ● Tapered surface (rod end) Pitting/Wear/Damage → Replace.
STEERING SYSTEM CHAS 6.Adjust: ● Tie-rod assembly length ********************************* Tie-rod assembly length adjustment steps: ● Loosen the locknuts. ● Adjust the tie-rod assembly length a by turning both tie-rod ends. Tie-rod assembly length a: 296 mm (11.7 in) Å Right-hand-threads ı Left-hand-threads Ç To steering shaft Î To knuckle NOTE: The threads b on both tie-rod ends must be of the same length. ● Tighten the locknuts. T. Locknut (tie-rod): 30 Nm (3.0 m • kg, 22 ft • lb) R.
STEERING SYSTEM CHAS 2.Lubricate: ● Steering bearings 1 ● Oil seals 2 Lithium-soap base grease 3.Install: ● Oil seals 1 (to steering shaft) ● Collars 2 ● Steering bearings 3 NOTE: Be careful not to damage the oil seals during installation. 4.Install: ● Steering shaft 1 (with steering bearings) WARNING Make sure the brake cables and leads are properly routed, and are not damaged or twisted. 5.
STEERING SYSTEM CHAS 7.Install: ● Cotter pin 1 NOTE: Do not loosen the axle nut after torque tightening. If the axle nut groove is not aligned with the cotter pin hole, align groove with the hole by tightening up on the axle nut. WARNING Always use a new cotter pin. 8.Tighten: ● Washer ● Nut ● Clip T. Nut (steering shaft): 30 Nm (3.0 m • kg, 22 ft • lb) R. 9.Install: ● Cable guide 1 ● Lock washer 2 ● Bolts 3 T. 7 Bolt (bearing holder): 23 Nm (2.3 m • kg, 17 ft • lb) R.
STEERING SYSTEM CHAS Handlebar 1.Install: ● Handlebar holder (lower) 1 ● Handlebar 2 ● Handlebar holders (upper) 3 NOTE: The upper handlebar holder should be installed with the punched mark a forward 2. CAUTION: Tighten the handlebar bolts so that clearances b are spaced evenly. T. Handlebar holder (upper): 20 Nm (2.0 m • kg, 14 ft • lb) R. 2.Install: ● Throttle lever assembly NOTE: Fit the throttle housing projection 1 onto the indent 2 on the front brake lever holder.
FRONT SHOCK ABSORBER AND FRONT ARM FRONT SHOCK ABSORBER AND FRONT ARM 1 Front shock absorber 2 Steering knuckle 3 Lower arm 4 Bushing 7 7 - 28 CHAS
FRONT SHOCK ABSORBER AND FRONT ARM CHAS REMOVAL 1.Remove: ● Front carrier ● Front bumper ● Front fender Refer to the “FENDERS AND FUEL TANKFRONT FENDER - Removal” section in CHAPTER 3. ● Front wheel ● Brake drum ● Brake shoe plate Refer to “FRONT WHEELS AND FRONT BRAKE - Removal” section. 2.Remove: ● Cotter pin 1 ● Nut 2 ● Tie-rod end 3 NOTE: When removing the rod end from the knuckle arm, use a general bearing puller. 3.Remove: ● Circlip (shock absorber upper) 1 4.Loosen: ● Flange nut 2 41 mm (1.6 in) 5.
FRONT SHOCK ABSORBER AND FRONT ARM CHAS 7.Inspect: ● Lower arms free play ********************************* Inspection steps: ● Inspect the lower arm brackets 1 of the frame. If bent, cracked or damaged, repair or replace the frame. ● Check the tightening torque of the lower arm securing nuts 2. T. Nut (lower arm): 45 Nm (4.5 m • kg, 32 ft • lb) R. the lower arm side play Å by moving it from side to side. If side play noticeable, replace the bushings or lower arm as a set.
FRONT SHOCK ABSORBER AND FRONT ARM CHAS INSPECTION 1.Inspect: ● Shock absorber Oil leaks → Replace the shock absorber assembly. ● Ball joint Cracks/Damage → Replace the shock absorber assembly. ● Spring Fatigue/Damage → Replace the shock absorber assembly. Move the spring up and down. 2.Inspect: ● Steering knuckle Cracks/Pitting/Damage → Replace. WARNING Do not attempt to straighten a bent shaft; this may dangerously weaken the shaft. 3.Inspect: ● Lower arm Cracks/Bends/Damage → Replace.
FRONT SHOCK ABSORBER AND FRONT ARM CHAS INSTALLATION Reverse the “REMOVAL” procedures. Note the following points. 1.Lubricate: ● Bushings 1 (inner surface) Lithium-soap base grease 2.Tighten: ● Nut 2 (lower arm) T. Nut (lower arm): 45 Nm (4.5 m • kg, 32 ft • lb) R. NOTE: Be sure to position the front arm securing bolts (front 1 and rear 2) so that the bolt heads will face outward. Å Forward 3.Install: ● Steering knuckle 1 4.Tighten: ● Nut 2 (steering knuckle) T. 7 R.
FRONT SHOCK ABSORBER AND FRONT ARM CHAS 5.Install: ● Cotter pin 3 NOTE: Do not loosen the axle nut after torque tightening. If the axle nut groove is not aligned with the cotter pin hole, align groove with the hole by tightening up on the axle nut. WARNING Always use a new cotter pin. 6.
FRONT SHOCK ABSORBER AND FRONT ARM CHAS NOTE: Do not loosen the axle nut after torque tightening. If the axle nut groove is not aligned with the cotter pin hole, align groove with the hole by tightening up on the axle nut. WARNING Always use a new cotter pin. 10.Install: ● Brake shoe plate ● Brake drum ● Front wheel Refer to the “FRONT WHEELS AND FRONT BRAKE-INSTALLATION” section. 11.Adjust: ● Toe-in Refer to the “TOE-IN ADJUSTMENT” section in CHAPTER 3. 12.
REAR SHOCK ABSORBER AND SWINGARM CHAS REAR SHOCK ABSORBER AND SWINGARM 1 Rear shock absorber 2 Thrust cover 3 Locknut 4 Pivot shaft 5 Collar 6 Oil seal 7 Taper roller bearing 8 Swingarm 9 Rubber boot 0 Final gear case protector A SWINGARM FREE PLAY LIMIT: SIDE” 1.0 mm (0.
REAR SHOCK ABSORBER AND SWINGARM CHAS REMOVAL 1.Remove: ● Rear wheel (left) ● Wheel hub ● Rear wheel (right) ● Brake drum ● Brake shoe plate ● Rear axle Refer to the “REAR WHEEL/REAR BRAKE AND REAR AXLE - REMOVAL” section. 2.Remove: ● Final gear case protector 1 3.Remove: ● Final gear case unit 1 Refer to the “FINAL DRIVE GEAR AN DRIVE SHAFT - REMOVAL” section in CHAPTER 6. 7 4.
REAR SHOCK ABSORBER AND SWINGARM CHAS 5.Remove: ● Nut 1 (shock absorber - upper) ● Bolt 2 ● Shock absorber 3 6.Remove: ● Spring (rear brake pedal) 1 7.Remove: ● Caps (pivot shaft) 8.Inspect: ● Swingarm free play ********************************* Free play inspection steps: ● Check the tightening torque of the pivot shafts 1 and locknut 2 (right side of pivot shaft). T. R. Pivot shaft (left side): 130 Nm (13.0 m • kg, 94 ft • lb) Pivot shaft (right side): 6 Nm (0.6 m • kg, 4.
REAR SHOCK ABSORBER AND SWINGARM CHAS 9.Remove: ● Rear axle housing 1 10.Remove: ● Clamp 1 (rubber boot) ● Locknut (right side of pivot shaft) ● Pivot shaft (swingarm) 11.Remove: ● Swingarm 1 INSPECTION 1.Inspect: ● Shock absorber Oil leaks → Replace the shock absorber assembly. ● Shock absorber rod Bends/Damage → Replace the shock absorber assembly. ● Spring Fatigue/Damage → Replace the shock absorber assembly. Move the spring up and down.
REAR SHOCK ABSORBER AND SWINGARM CHAS 2.Inspect: ● Swingarm Cracks/Bends/Damage → Replace. ● Axle housing Cracks/Bends/Damage → Replace. 3.Inspect: ● Final gear case under cover Cracks/Bends/Damage → Replace. 4.Inspect: ● Pivot shaft 1 (right side) ● Pivot shaft 2 (left side) ● Spacer collar 3 Wear/Damage → Replace. 5.Inspect: ● Bearings 1 (swingarm) Bearings allow play in the swingarm or to the bearing turns roughly → Replace. ● Oil seals 2 Wear/Damage → Replace.
REAR SHOCK ABSORBER AND SWINGARM CHAS ● Remove the bearings 3 using a general bearing puller. ● Install the new bearings and oil seal by reversing the previous steps. NOTE: Use a socket 4 that matches the outside diameter of the race of the bearing and oil seal. CAUTION: Do not strike the center race 5 or balls 6 of the bearing. Contact should be made only with the outer race 7. ********************************* INSTALLATION Reverse the “REMOVAL” procedures. Note the following points. 1.
REAR SHOCK ABSORBER AND SWINGARM CHAS 3.Tighten: ● Pivot shafts (swingarm) ● Locknut (pivot shaft) ********************************* Pivot shaft tightening steps: ● Tighten the pivot shaft 1 (left) to specification. T. Pivot shaft (left): 130 Nm (13.0 m • kg, 94 ft • lb) R. ● Tighten the pivot shaft 2 (right) until it contacts the collar 3. T. Pivot shaft (right): 6 Nm (0.6 m • kg, 4.3 ft • lb) R. ● Tighten the locknut 4 (right) to specifica- tion. T. Locknut (right): 130 Nm (13.
REAR SHOCK ABSORBER AND SWINGARM CHAS 7.Install: ● Clip 8.Install: ● Final gear assembly 1 Refer to the “FINAL DRIVE GEAR AND DRIVE SHAFT - ASSEMBLY - INSTALLATION” section in CHAPTER 6. 9.Install: ● Rear axle ● Brake shoe plate ● Brake drum ● Rear wheel (right) ● Wheel hub (left) ● Rear wheel (left) Refer to the “REAR WHEEL/REAR BRAKE AND REAR AXLE - INSTALLATION” section.
ELECTRICAL COMPONENTS ELEC – + EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Wire harness 2 Fuses 3 Starter relay 4 Starting circuit cut-off relay 5 Battery 6 CDI unit 7 Rectifier/regulator 8 Reverse switch 9 Neutral switch 0 Spark plug cap A Ignition coil B Main switch C Neutral indicator light D Reverse indicator light 8 8-1
SWITCH INSPECTION ELEC – + SWITCH INSPECTION SWITCH INSPECTION Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. Pocket tester: P/N. YU-03112, 90890-03112 NOTE: Set the pocket tester to “0” before starting the test. ● The pocket tester should be set to the “Ω × 1” range when testing the switch for continuity. ● Turn the switch on and off a few times when checking it.
SWITCH INSPECTION ELEC – + 8 8-3
SWITCH INSPECTION ELEC SWITCH CONTINUITY INSPECTION Refer to “SWITCH INSPECTION” and check for continuity between lead terminals. Poor connection, no continuity → Correct or replace. The coupler locations are circled.
SWITCH INSPECTION ELEC – + 1 Lights switch 2 Lights switch (for New Hampshire and Maine) 3 Engine stop switch 4 Starter switch 5 Main switch 6 Rear brake lever switch 7 Rear brake lever switch (for New Hampshire and Maine) 8 Front brake lever switch (for New Hampshire and Maine) 9 Rear brake pedal switch (for New Hampshire and Maine) 0 Reverse switch A Neutral switch B Fuse 8 8-5
CHECKING OF BULBS ELEC – + CHECKING OF BULBS (FOR HEADLIGHT) CHECKING BULBS CONDITION 1.Remove the bulb. CAUTION: ACHTUNG: Be sure to hold the socket firmly when removing the bulb. Never pull the lead. Otherwise, the lead may be pulled off the terminal in the coupler. WARNING Keep flammable products and your hands away from the headlight bulb while it is on. It will be hot. Do not touch the bulb until it cools down. 2.Check the bulb terminals for continuity.
8-7 G/L G/L G/L G/L Br Br R B J I B/W Sb Sb Br B B B R 2 Br R R B/W B 4 R Br B/W B B R L R Br 3 R/W Br/W 5 R B R B Br R/W Y/R L L/W D B L/W RUN OFF E B/W B/W B B OFF ON F R W R/W R/W W Br/W Br W B B Y G B G B Y W/G W/G Y H G Y B W/R Br W/R B W/R Br W/R B H G Y G Y G Y Å 7 B Br W/G G L L W W W W B Br Y/R W W W W G Y HI OFF LO G B 6 W C B W/G Br B L L/W 8 B O R/W B/W L/W (GLAY) B/W O B R
IGNITION SYSTEM ELEC – EB802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1.Spark plugs 2.Ignition spark gap 3.Spark plug cap resistance 4.Ignition coil resistance 5.Engine stop switch 6.Main switch 7.Pickup coil resistance 8.Source coil resistance 9.
IGNITION SYSTEM ELEC – + for EUR/AUS 2.Ignition spark gap ● ● Disconnect the spark plug cap from the spark plug. Connect the ignition checker 1 as shown. 2 Spark plug cap ● ● ● Turn the main switch to “ON”. Check the ignition spark gap a. Crank the engine by pushing the starter switch and increase the spark gap until a misfire occurs. MEETS SPECIFICATION Minimum spark gap: 6.0 mm (0.24 in) OUT OF SPECIFICATION OR NO SPARK The ignition system is not faulty. 3.
IGNITION SYSTEM * ● ● ● Disconnect the ignition coil connector from the wire harness. Connect the pocket tester (Ω × 1) to the ignition coil. Check that the primary coil has the specified resistance. Tester (+) lead → Ignition coil base Tester (–) lead → Spark plug lead Connect the pocket tester (Ω × 1k) to the ignition coil. Check that the secondary coil has the specified resistance. OUT OF SPECIFICATION Secondary coil resistance: 6.3 ~ 9.
IGNITION SYSTEM * – ELEC + C0NTINUITY 7.Pickup coil resistance ● ● Disconnect the CDI magneto coupler from the wire harness. Connect the pocket tester (Ω × 100) to the pickup coil terminal. 1 Br W/G Tester (+) lead → White/Green terminal 1 Tester (–) lead → White/Red terminal 2 B 2 Check the pickup coil for the specified resistance. ● W/R OUT OF SPECIFICATION Pickup coil resistance: 189~ 231 Ω at 20˚C (68˚F) (White/Green – White/Red) Replace the pickup coil. MEETS SPECIFICATION 8.
8 - 12 G/L G/L G/L G/L R B J I B/W R Sb Sb Br B B B R 2 Br R 4 R Br B/W B B R L R Br 3 R/W Br/W 5 R B R B Br R/W Y/R L L/W D B L/W RUN OFF E B/W B/W B B OFF ON F R W R/W R/W W Br/W Br W B B Y G B G B Y W/G W/G Y H G Y B W/R Br W/R C B W/G Br B W/R Br W/R B H G Y G Y G Y Å 7 B Br W/G G L L W W W W B Br Y/R W W W W G Y HI OFF LO G B 6 W B L L/W 8 B O R/W B/W L/W (GLAY) B/W O B O B B G/Y
ELECTRIC STARTING SYSTEM ELEC – + STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, starting circuit cut-off relay, rear brake lever switch, and neutral switch. If the main switch is on position, the starter motor can be operated only if: ● ● The transmission is in neutral (the neutral switch is closed). or You pull in the rear brake lever (the rear brake lever switch is ON).
ELECTRIC STARTING SYSTEM ELEC – EB803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 1.Fuse (main) 2.Battery 3.Starter motor 4.Starting circuit cut-off relay 5.Starter relay 6.Main switch 7.Neutral switch 8.Rear brake lever switch 9.Start switch 10.Wiring connection (the entire starting system) NOTE: Remove the following part(s) before troubleshooting: 1)Seat 2)Front carrier 3)Front fender ● Use the following special tool(s) for troubleshooting. Pocket tester: P/N.
ELECTRIC STARTING SYSTEM * ELEC – + C0NTINUITY * WARNING 3.Starter motor ● ● ● Connect the battery positive terminal 1 and starter motor cable 2 using a jumper lead 3 . Check the operation of the starter motor. * ● 3 2 A wire that is used as a jumper lead must have the equivalent capacity or more as that of the battery lead, otherwise the jumper lead may burn. This check is likely to produce sparks, so be sure that no flammable gas or fluid is in the vicinity.
ELECTRIC STARTING SYSTEM * ● 3 Remove the starter relay from the wire harness. Connect the pocket tester (Ω × 1) and the battery (12 V) to the starter relay terminals. R R L/W 1 B 4 Battery (+) terminal → Blue/White terminal 1 Battery (–) terminal → Black terminal 2 NO CONTINUITY Tester (+) lead → Red terminal 3 Tester (–) lead → Black terminal 4 ● – C0NTINUITY 5.Starter relay ● ELEC Replace the starter relay. Check the starter relay for continuity. CONTINUITY INCORRECT 6.
ELECTRIC STARTING SYSTEM * ELEC – + C0NTINUITY 8.Rear brake lever switch INCORRECT Refer to “SWITCH INSPECTION”. CORRECT Replace the rear brake lever switch. INCORRECT 9.Start switch Refer to “SWITCH INSPECTION”. CORRECT Replace the handlebar switch (left). EB803028 POOR CONNECTION 10.Wiring connection ● Check the connections of the entire starting system. Refer to “CIRCUIT DIAGRAM”. Properly connect the starting system.
ELECTRIC STARTING SYSTEM ELEC – + STARTER MOTOR Order 1 2 3 8 1 2 3 4 5 6 7 Job name/Part name Starter motor removal Starter motor lead Starter motor bracket Starter motor / O-ring Starter motor disassembly Q’ty Bracket 1 Washer/shim Bracket 2 Shims Brush/brush spring Armature coil Yoke 1 1/1 1 Remarks Remove the parts in the order below. 1 1 1/1 Disassemble the parts in the order below. 2/2 1 1 Refer to “STARTER MOTOR ASSEMBLY”. For assembly, reverse the disassembly procedure.
ELECTRIC STARTING SYSTEM ELEC – + STARTER MOTOR INSPECTION 1.Inspect: ● Commutator Dirty → Clean it with #600 grit sandpaper. 2.Measure: ● Commutator diameter a Out of specification → Replace the starter motor. Outside diameter: 28 mm (1.10 in) 27 mm (1.06 in) 3.Measure: ● Mica undercut b Out of specification → Scrape the mica using a hacksaw blade. Mica undercut: 0.7 mm (0.
ELECTRIC STARTING SYSTEM ELEC – + 5.Measure: ● Brush length a (each) Out of specification → Replace the brush. Brush length: 10 mm (0.39 in) 3.5 mm (0.14 in) 6.Measure: ● Brush spring force Fatigue/out of specification → Replace as a set. Brush spring force: 730 ~ 970 g (7.16 ~ 9.52 N) 7.Inspect: ● Oil seal ● Bushing ● O-rings Wear/damage → Replace. STARTER MOTOR ASSEMBLY 1.Install: ● Yoke ● Brackets NOTE: Align the match marks a on the yoke with the match marks b on the brackets.
– ELEC CHARGING SYSTEM + EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM 1 OFF ON Br R B B B/W B/W B R Br Br R B/W B/W W/G Br W W W W W Br W/G B R R W W W 6 R W/R B B O R/W B/W B (GLAY) ( W W W W 7 W/R Br Br B W/R B W/R O W/G W/G 8 B R L/W R R 2 3 R L/W B B G/Y Sb B B (BLA 4 L/W L/W B B B 5 G/Y B B/W L R/W D E F B/W RUN OFF B L Br Br Br R/W Br/W Y/R R/W OFF ON G Br L Y/R G Y Br R/W C Br/W B Br G Y I B G Y G/L G/Y HI L B
CHARGING SYSTEM ELEC – EB804010 TROUBLESHOOTING IF THE BATTERY IS NOT CHARGED: Procedure Check: 1.Fuse (main) 2.Battery 3.Charging voltage 4.Stator coil resistance 5.Wiring connections (the entire charging system) NOTE: Remove the following part(s) before troubleshooting: 1)Seat ● Use the following special tool(s) for troubleshooting. Inductive tachometer: P/N. YU-8036-A Engine tachometer: P/N. 90890-03113 Pocket tester: P/N. YU-03112, 90890-03112 ● EB802011 NO CONTINUITY 1.
CHARGING SYSTEM ● ELEC – + Start the engine and accelerate to about 2,000 r/min. MEETS SPECIFICATION Charging voltage: 14 to 15 V at 2,000 r/min NOTE: Use a fully charged battery. The charging circuit is not faulty. OUT OF SPECIFICATION EB804012 4.Stator coil resistance ● ● Disconnect the AC magneto coupler from the wire harness. Connect the pocket tester (Ω × 1) to the stator coils.
8 - 24 G/L G/L G/L G/L R B J I B/W R Sb Sb Br B B B R 2 Br R 4 R Br B/W B B R L R Br 3 R/W Br/W 5 R B R B Br R/W Y/R L L/W D B L/W RUN OFF E B/W B/W B B OFF ON F R W R/W R/W W Br/W Br W B B Y G B G B Y W/G W/G Y H G Y B W/R Br W/R B W/R Br W/R B H G Y G Y G Y Å 7 B Br W/G G L L W W W W B Br Y/R W W W W G Y HI OFF LO G B 6 W C B W/G Br B L L/W 8 B O R/W B/W L/W (GLAY) B/W O B R/W B B G/Y
LIGHTING SYSTEM ELEC – + EB805010 TROUBLESHOOTING IF THE HEADLIGHT AND/OR TAILLIGHT FAIL TO COME ON: Procedure Check: 1.Fuse (main) 2.Battery 3.Main switch 4.Lights switch 5.Wiring connections (the entire lighting system) NOTE: Remove the following part(s) before troubleshooting: 1)Seat 2)Front carrier 3)Front fender ● Use the following special tool(s) for troubleshooting. Pocket tester: P/N. YU-03112, 90890-03112 ● EB802011 NO CONTINUITY 1.Fuse (main) Refer to “SWITCH INSPECTION”.
LIGHTING SYSTEM * ELEC – + C0NTINUITY INCORRECT 3.Main switch Refer to “SWITCH INSPECTION”. CORRECT Replace the main switch. 4.Lights switch Refer to “SWITCH INSPECTION”. CORRECT Lights switch is faulty, replace the handlebar switch (left). EB805013 5.Wiring connection ● POOR CONNECTION Check the connections of the entire lighting system. Refer to “WIRING DIAGRAM”. Properly connect the lighting system. CORRECT Check the condition of each of the lighting system’s circuits.
LIGHTING SYSTEM ELEC – + EB805020 LIGHTING SYSTEM CHECK 1.If the headlights fail to come on: NO CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for continuity. Replace the bulb and/or bulb socket. CONTINUITY 2.Voltage ● Å Connect the pocket tester (DC 20 V) to the headlight couplers. ı Tester (+) lead → Green terminal 1 or Yellow terminal 2 Tester (–) lead → Black terminal 3 Å When the lights switch is on “LO”. ı When the lights switch is on “HI”.
LIGHTING SYSTEM ELEC – + 2.If the taillight fails to come on: 1.Bulb and bulb socket ● NO CONTINUITY Check the bulb and bulb socket for continuity. Replace the bulb and/or bulb socket. CONTINUITY 2.Voltage 1 ● Connect the pocket tester (DC 20 V) to the taillight leads. L L B B Tester (+) lead → Blue terminal 1 Tester (–) lead → Black terminal 2 2 ● ● ● OUT OF SPECIFICATION Turn the main switch to “ON”. Turn the lights switch to “LO” or “HI”.
8 - 29 L K OFF ON 1 G/L G/L G/L G/L Br Br R B J I B/W Sb Sb Br B B B R 2 Br R R B/W B 4 R Br B/W B B R L R Br 3 R/W Br/W 5 R B R B Br R/W Y/R L L/W D B L/W RUN OFF E B/W B/W B B OFF ON F R W R/W R/W W Br/W Br W Y B G B G Br Y/R W W W Y HI OFF LO G B 6 L L W W W W B B H B G B G B Y W/G W/G Y B W/R Br W/R C B W/G Br B W/R Br W/R Br W/G G Y Å 7 W H G Y G Y G Y W B L L/W 8 B O R/W B/W L/W (GLA
SIGNAL SYSTEM ELEC – EB806010 TROUBLESHOOTING IF THE INDICATOR LIGHT AND/OR BRAKE LIGHT FAILS TO COME ON: Procedure Check: 1.Fuse (main) 2.Battery 3.Main switch 4.Wiring connections (the entire signal system) NOTE: Remove the following part(s) before troubleshooting: 1)Seat 2)Front carrier 3)Front fender ● Use the following special tool(s) for troubleshooting. Pocket tester: P/N. YU-03112, 90890-03112 ● EB802011 NO CONTINUITY 1.Fuse (main) Refer to “SWITCH INSPECTION”.
SIGNAL SYSTEM * ELEC – + C0NTINUITY INCORRECT 3.Main switch Refer to “SWITCH INSPECTION”. CORRECT Replace the main switch. EB806011 POOR CONNECTION 4.Wiring connections ● Check the connections of the entire signal system. Refer to “CIRCUIT DIAGRAM”. Properly connect the signal system. CORRECT Check the condition of each of the signal system’s circuits. Refer to “SIGNAL SYSTEM CHECK”.
SIGNAL SYSTEM ELEC – + SIGNAL SYSTEM CHECK EB806024 1.If the neutral indicator light fails to come on: NO CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for continuity. Replace the bulb and/or bulb socket. CONTINUITY NO CONTINUITY 2.Neutral switch Refer to “SWITCH INSPECTION”. CONTINUITY Replace the neutral switch. 3.Voltage ● 1 Connect the pocket tester (DC 20 V) to the bulb socket leads.
SIGNAL SYSTEM ELEC – + 2.If the reverse indicator light fails to come on: NO CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for continuity. Replace the bulb and/or bulb socket. CONTINUITY NO CONTINUITY 2.Reverse switch Refer to “SWITCH INSPECTION”. CONTINUITY Replace the reverse switch. 3.Voltage ● 1 Connect the pocket tester (DC 20 V) to the bulb socket leads.
SIGNAL SYSTEM ELEC – + 3.If the brake light fails to come on: (for New Hampshire and Maine) NO CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for continuity. Replace the bulb and/or bulb socket. CONTINUITY NO CONDITION 2.Brake switch Refer to “SWITCH INSPECTION”. CONTINUITY Replace the brake switches. NO CONDITION 3.Lights switch Refer to “SWITCH INSPECTION”. CONTINUITY Replace the lights switch. 4.Voltage ● 1 Connect the pocket tester (DC 20 V) to the bulb socket leads.
STARTING FAILURE/HARD STARTING TRBL SHTG TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts.
STARTING FAILURE/HARD STARTING/POOR IDLE SPEED PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE COMPRESSION SYSTEM Cylinder and cylinder head ● Loose spark plug ● Loose cylinder head or cylinder ● Broken cylinder head gasket ● Worn, damaged or seized cylinder Piston and piston rings ● Improperly installed piston ring ● Worn, fatigued or broken piston ring ● Seized piston ring ● Seized or damaged piston TRBL SHTG Valve, camshaft and crankshaft ● Improperly sealed valve ● Improperly contacted valve and va
FAULTY DRIVE TRAIN TRBL SHTG FAULTY DRIVE TRAIN The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1.A pronounced hesitation or “jerky” movement during acceleration, deceleration, or sustained speed. (This must not be confused with engine surging or transmission characteristics.) 2.A “rolling rumble” noticeable at low speed; a high-pitched whine; a “clunk” from a shaft drive component or area. 3.
FAULTY GEAR SHIFTING/ FAULTY CLUTCH PERFORMANCE TRBL SHTG FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH SLIPPING/DRAGGING-CLUTCH DRAGGING”.
FAULTY CLUTCH PERFORMANCE/ OVERHEATING/FAULTY BRAKE TRBL SHTG OVERHEATING Engine oil Improper oil level ● Improper oil viscosity ● Inferior oil quality Brake ● Brake drag OVERHEATING Ignition system ● Improper spark plug gap ● Improper spark plug heat range ● Faulty CDI unit Fuel system ● Improper carburetor main jet (improper setting) ● Improper fuel level ● Clogged air filter element Compression system ● Heavy carbon build-up ● FAULTY BRAKE POOR BRAKING EFFECT Drum brake ● Worn brake shoe lining ● Wo
SHOCK ABSORBER MALFUNCTION/ UNSTABLE HANDLING/LIGHTING SYSTEM TRBL SHTG UNSTABLE HANDLING UNSTABLE HANDLING Handlebar ● Improperly installed or bent Steering ● Incorrect toe-in ● Bent steering shaft ● Improperly installed steering shaft ● Damaged bearing or bearing race ● Bent tie rods ● Deformed steering knuckles Tires ● Uneven tire pressures on both sides ● Incorrect tire pressure ● Uneven tire wear Wheels ● Deformed wheel ● Loose bearing ● Bent or loose wheel axle ● Excessive wheel runout Frame ● Bent
YFM250XL WIRING DIAGRAM 1 OFF ON Br R B B B/W B/W B R Br Br R B/W B/W W/G Br W W W W W Br W/G B B O O R/W B/W B B/W L/W W B W W W 6 R W/R W W W 7 W/R (GLAY) Br Br B W/R B W/R W/G W/G (GLAY) O 8 O B 9 B 0 G R R Å L R L/W R R 2 3 R L/W LO HI B B G/Y L/W Sb B B 4 L/W L/W B Y/R R/W G Y (BLACK) R/W B Sb B 5 ı M A G/Y B Y L B L B/W L R/W D E F B/W RUN OFF OFF ON B L Br Br Br R/W Br/W Y/R R/W G B Y Å L L ı OFF LO Br
YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
YFM250XN SUPPLEMENTARY SERVICE MANUAL LIT-11616-14-17 4XE-F8197-11
FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the YFM250XN. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual. YFM250XL(C) SERVICE MANUAL: 4XE-F8197-10 YFM250XN SUPPLEMENTARY SERVICE MANUAL 2000 by Yamaha Motor Corporation, U.S.A. First Edition, April 2000 All rights reserved.
EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use.
EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual is intended as a handy, easy-to-read reference book for the mechanic. It is divided into chapters, sections and sub-sections. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and inspection procedures are laid out with the individual steps in sequential order. PAGE FEATURES The circled numbers below refer to the features indicated in the sample page.
EB003000 1 ILLUSTRATED SYMBOLS 2 GEN INFO Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter. SPEC 3 1 General information 2 Specifications 3 Periodic inspections and adjustments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical 9 Troubleshooting 4 INSP ADJ ENG 5 6 DRIV CARB 7 8 ELEC CHAS – + 0 Illustrated symbols 0 to F are used to identify the specifications appearing in the text.
CONTENTS GENERAL INFORMATION .............................................................................. 1 MACHINE IDENTIFICATION ................................................................... 1 VEHICLE IDENTIFICATION NUMBER ............................................ 1 MODEL LABEL ................................................................................ 1 SPECIFICATIONS ............................................................................................ 2 GENERAL SPECIFICATIONS ....
ELECTRICAL ................................................................................................. 40 ELECTRICAL COMPONENTS .............................................................. 40 IGNITION SYSTEM ............................................................................... 41 CIRCUIT DIAGRAM ....................................................................... 41 TROUBLESHOOTING ................................................................... 42 ELECTRIC STARTING SYSTEM ..........
MACHINE IDENTIFICATION GEN INFO GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 stamped into the left side of the frame. is MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Model code: Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Basic weight: With oil and full fuel tank Tire: Type Size Manufacturer Type Brake: Front brake Rear brake Electrical: Ignition system Generator system Battery type Battery capacity Headlight: Type Bulb type Bulb wattage × quantity: Headlight Tail light Indicator lights: Neutral Reverse Standard 4XEA
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Item Standard Shifter: Shifter type Guide bar bending limit Carburetor: I. D. mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot air jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Valve seat size Starter jet Throttle valve size Float height Fuel level Engine idle speed Intake vacuum (M.J) (M.A.J) (J.N) (N.J) (P.A.J.1) (P.A.J.2) (P.O) (P.J) (B.P.1) (B.P.2) (B.P.3) (V.S) (G.S.1) (G.S.2) (Th.V) (F.H) (F.
MAINTENANCE SPECIFICATIONS SPEC CHASSIS Item Standard Rear suspension: Shock absorber travel Suspension spring free length Fitting length Spring rate Optional spring Front wheel: Type Rim size Rim material Rim runout limit Front disc brake: Type Disc outside diameter × thickness Pad thickness Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Limit 85 mm (3.35 in) 268 mm (10.55 in) 244 mm (9.61 in) 39 N/mm (3.9 kg/mm, 222.69 lb/in)/ 0 ~ 85 mm (0 ~ 3.
MAINTENANCE SPECIFICATIONS SPEC Tightening torques Part to be tightened Front panel wheel and wheel hub Wheel hub and steering knuckle Steering knuckle and brake caliper Brake disc and wheel hub Master cylinder and brake hose Brake caliper and brake hose Brake pipe and brake hose Brake hose and frame Caliper bleed screw Master cylinder and handlebar Brake caliper and caliper bracket Brake pad retaining Steering knuckle and brake disc guard Front lower arm and steering knuckle Engine mounting (upper) Engin
MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Item C.D.I.: Magneto model/manufacturer Pickup coil resistance/color Charging/rotor rotation direction detection coil resistance/color C.D.I.
CABLE ROUTING SPEC CABLE ROUTING 1 Rear brake lever switch lead 2 Rear brake cable 3 Cable guide 4 Front brake hose 5 Throttle cable 6 Neutral indicator light 7 Reverse indicator light 8 Handlebar switch assembly lead 9 Fuel tank breather hose 0 Headlight leads Å Do not route the handlebar switch assembly lead through the lower bracket cable guide. ı Route the fuel tank breather hose through the hole in the handlebar cover and then to the right of the handlebar (below the handlebar, not over it).
CABLE ROUTING 1 Cable guide 2 Main switch 3 Fuel tank breather hose 4 Taillight 5 Final gear case breather hose 6 Carburetor overflow hose 7 Reverse switch lead 8 Neutral switch lead 9 Starter motor lead 0 Throttle cable A Rear brake cable SPEC B Rear brake breather hose C Carburetor air vent hose D CDI magneto lead Å Route the main switch lead and indicator light lead to the side of the cable guide.
CABLE ROUTING Ç Make sure that the starter motor lead is not slacked. Î Fasten the starter motor lead and wire harness to the frame with the plastic band. ‰ Fasten the starter motor lead and wire harness to the frame with the plastic clamp. Ï Route the starter motor lead, wire harness, and battery - lead through the hole in the rear fender. Ì Fasten the taillight lead and wire harness to the frame with the plastic clamp. SPEC Ó Fasten the taillight lead to the box with the plastic clamp.
CABLE ROUTING Ò Fasten the starter motor lead and wire harness to the frame with the plastic clamp. ˜ Route the rear brake cable and rear brake breather hose through the cable guide. ˆ Fasten the rear brake cable and rear brake breather hose to the swingarm with the plastic clips. Ø Route the rear brake breather hose through the cable guide. SPEC ∏ Route the final gear case breather hose through the cable guide. Œ 10 mm (0.4 in)  40 ~ 50 mm (1.6 ~ 2.0 in) Í 100 mm (4.
CABLE ROUTING 1 Battery breather hose 2 Spark plug cap 3 Ignition coil 4 Starter motor lead 5 Rear brake cable 6 Rear brake breather hose SPEC Å Make sure that the battery breather hose is not kinked or bent. ı Route the rear brake cable through the cable guide on the cylinder. Ç Fasten the starter motor lead to the frame with the plastic clamps. Î Fasten the battery breather hose to the frame with the plastic clamps. ‰ 50 ~ 60 mm (2.0 ~ 2.
CABLE ROUTING 1 Wire harness 2 Starter motor lead 3 Rear brake cable 4 Throttle cable 5 Starter relay 6 Rectifier/regulator 7 CDI unit 8 Starting circuit cut-off relay 9 Rear brake breather hose 0 Carburetor air vent hose A Final gear case breather hose B Taillight lead SPEC Å Fasten the wire harness to the frame with the plastic clamps. ı Make sure the starter motor lead and wire harness do not contact the ignition coil.
CABLE ROUTING Ï Fasten the battery breather hose to the rear fender with the plastic clamp and then insert the clamp into the hole in the rear fender. Ì Fasten the battery + lead and starter motor lead to the rear fender with the plastic clamps. Ó Install the starter circuit cut-off relay onto the tab with its terminal side facing down. È Route the throttle cable and rear brake cable through the cable guide. Make sure that the throttle cable is routed to the inside of the rear brake cable.
INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION INSP ADJ PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced.
PERIODIC MAINTENANCE/LUBRICATION INSP ADJ INITIAL ITEM ROUTINE 1 month Steering shaft* • Lubricate every 6 months.** Fittings and Fasteners* • Check all chassis fittings and fasteners. • Correct if necessary. Battery* • Check specific gravity. • Check that the breather hose is working properly. • Correct if necessary. *: **: 3 months EVERY 6 months It is recommended that these items be serviced by a Yamaha dealer. Lithium soap base grease.
SPARK ARRESTER CLEANING INSP ADJ ENGINE SPARK ARRESTER CLEANING 1.Clean: ● Spark arrester ********************************************* Cleaning steps: ● ● WARNING Select a well-ventilated area free of combustible materials. Always let the exhaust system cool before performing this operation. ● Remove the purging bolt 1. ● Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by blocking the end of the muffler with a shop towel.
FRONT BRAKE FLUID LEVEL INSPECTION/ FRONT BRAKE PAD INSPECTION INSP ADJ CHASSIS FRONT BRAKE FLUID LEVEL INSPECTION 1.Place the machine on a level surface. NOTE: When inspecting the front brake fluid level, make sure that the top of the master cylinder top is horizontal. 2.Inspect: Brake fluid level Fluid level is under “LOWER” level line a → Fill up. ● a Recommended brake fluid: DOT 4 LOWER UP NOTE: If DOT 4 is not available, DOT 3 can be used.
BRAKE HOSE INSPECTION/ AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) INSP ADJ BRAKE HOSE INSPECTION 1.Remove: ● Front carrier ● Front fender Refer to “FENDER AND FUEL TANK”. 2.Inspect: ● Brake hoses 1 Cracks/wear/damage → Replace. 3.Check: ● Brake hose clamp Loosen → Tighten. 4.Hold the machine in an upright position and apply the front or rear brake. 5.Check: ● Brake hoses Active the brake lever several times. Fluid leakage → Replace the hose. Refer to “FRONT BRAKE”. 6.
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) INSP ADJ 1.Bleed: ● Brake system 1 ********************************************* 2 Air bleeding steps: a. Add the proper brake fluid to the reservoir. b. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. c. Connect the clear plastic hose 1 tightly to the caliper bleed screw 2. d. Place the other end of the hose into a container. e. Slowly apply the brake lever several times. f. Pull the lever in and hold it. g.
FRONT WHEEL CHAS CHASSIS FRONT WHEEL 1 Wheel cap 2 Cotter pin 3 Axle nut 4 Plain washer 5 Wheel nut 6 Front wheel 7 Spacer 8 Oil seal 9 Bearing 0 Front wheel hub A Bearing spacer TIRE AIR PRESSURE Cold Tire Pressure Front 20 kPa (0.20 kg/cm2, 2.9 psi) 17 kPa (0.17 kg/cm2, 2.5 psi) 23 kPa (0.23 kg/cm2, 3.3 psi) Standard Minimum Maximum D FW – 20 – Rear 25 kPa (0.25 kg/cm2, 3.6 psi) 22 kPa (0.22 kg/cm2, 3.2 psi) 28 kPa (0.28 kg/cm2, 4.0 psi) A TIRE SIZE: AT22 × 7-10 B TIRE WEAR LIMIT: 3 mm (0.
FRONT WHEEL CHAS REMOVAL 1.Place the machine on a level surface. 2.Loosen: ● Nuts (front wheel) Apply the front brake. 3.Block the rear wheels, and elevate the front wheels by placing the suitable stand under the frame. 4.Remove: ● Nuts 1 (front wheel) ● Front wheel 2 5.Remove: ● Wheel cap ● Cotter pin 1 ● Axle nut 2 ● Plain washer 3 2 1 3 6.Remove: ● Front brake caliper 1 1 NOTE: Do not depress the brake lever when the wheel is off the machine otherwise the brake pads will be forced shut. 7.
FRONT WHEEL CHAS 8.Remove: ● Front brake disc 1 1 INSPECTION 1.Inspect: ● Wheel hub 1 Cracks/damage → Replace.
FRONT BRAKE FRONT BRAKE 1 Brake master cylinder reservoir cap 2 Brake master cylinder reservoir diaphragm holder 3 Brake master cylinder reservoir diaphragm 4 Brake master cylinder 5 Brake master cylinder kit 6 Copper washer 7 Union bolt 8 Brake hose 9 Brake pipe A BRAKE FLUID TYPE: DOT 4 B BRAKE PAD WEAR LIMIT: 1.0 mm (0.04 in) C BRAKE DISC WEAR LIMIT: 3.0 mm (0.
FRONT BRAKE CHAS CAUTION: Disc brake components rarely require disassembly. DO NOT: ● Disassemble components unless absolutely necessary. ● Use solvents on internal brake components. ● Use contaminated brake fluid for cleaning. Use only clean brake fluid. ● Allow brake fluid to come in contact with the eyes, otherwise eye injury may occur. ● Allow brake fluid to contact painted surfaces or plastic parts otherwise damage may occur.
FRONT BRAKE 3 2 CHAS 5.Remove: ● Brake pads 1 (with pad shim 2) ● Pad spring 3 1 NOTE: ● When pad replacement is required, also replace the pad spring and shim. ● Replace the pads as a set if either is found to be worn to the wear limit a. Wear limit a: 1.0 mm (0.04 in) 6.Install: ● Pad shim (onto inside brake pad) ● Pad spring ● Brake pads ********************************************* Installation steps: ● Connect a suitable hose 1 tightly to the caliper bleed screw 2.
FRONT BRAKE CHAS 7.Install: ● Retaining bolts ● Front brake caliper T. R. Retaining bolt: 18 Nm (1.8 m • kg, 13 ft • lb) Bolt (front brake caliper): 30 Nm (3.0 m • kg, 22 ft • lb) 8.Install: Front wheel 9.Inspect: ● Brake fluid level Refer to “FRONT BRAKE FLUID LEVEL INSPECTION”. ● a LOWER a “LOWER” level line UP 10.Check: ● Brake lever operation A soft or spongy feeling → Bleed brake system. Refer to “AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)”.
FRONT BRAKE CHAS 4.Remove: ● Union bolt 1 ● Copper washers 2 ● Brake hose 3 NOTE: Place the open end of the hose into a container and pump the oil fluid out carefully. 5.Remove: ● Caliper body 1 ● Caliper bracket 2 2 NOTE: Before removing the caliper body from the bracket, disconnect the dust boot from the guide shaft on the bracket. 1 6.
FRONT BRAKE CHAS 1.Remove: ● Brake lever 1 ● Union bolt 2 ● Copper washers 3 ● Brake hose 4 NOTE: Hold a container under the master cylinder and under the hose end to collect remaining brake fluid. 2.Remove: ● Brake master cylinder reservoir cap 1 ● Brake master cylinder reservoir diaphragm holder ● Brake master cylinder reservoir diaphragm ● Brake master cylinder 2 3.Remove: ● Dust boot 1 ● Circlip 2 ● Brake master cylinder kit 3 Drain the excess fluid.
FRONT BRAKE CHAS 1.Inspect: ● Caliper piston 1 Scratches/rust/wear → Replace caliper assembly. ● Caliper cylinder 2 Wear/scratches → Replace caliper assembly. ● Caliper body 3 Cracks/damage → Replace. ● Oil delivery passage (caliper body) Blow out with compressed air. WARNING Replace the piston seal whenever the caliper is disassembled. 2.Inspect: ● Brake master cylinder Wear/scratches → Replace the brake master cylinder assembly. ● Brake master cylinder body Cracks/damage → Replace.
FRONT BRAKE CHAS 6.Measure: ● Brake pads (thickness) a Out of specification → Replace. NOTE: ● When pad replacement is required, also replace the pad spring and shims. ● Replace the pads as a set if either is found to be worn to the wear limit a. Wear limit a: 1.0 mm (0.04 in) 7.Inspect: ● Brake disc Galling/damage → Replace. 8.Measure: ● Brake disc deflection Out of specification → Inspect wheel runout. If wheel runout is in good condition, replace the brake disc(s). 1 Maximum deflection: 0.15 mm (0.
FRONT BRAKE CHAS NOTE: Tighten the bolts (brake disc) in stage using a crisscross pattern. T. Bolt (brake disc): 16 Nm (1.6 m • kg, 12 ft • lb) R. CALIPER ASSEMBLY ● ● WARNING All internal parts should be cleaned in new brake fluid only. Internal parts should be lubricated with brake fluid when installed. Recommended brake fluid: DOT 4 ● Replace the piston seals whenever a caliper is disassembled. 1.Install: New ● Piston seals 1 ● Piston 2 WARNING Always use new piston seals. 2.
FRONT BRAKE 3.Install: ● Brake caliper 1 (temporarily) New ● Copper washers 2 ● Brake hose 3 ● Union bolt 4 1 3 a 2 New T. Union bolt: 27 Nm (2.7 m • kg, 19 ft • lb) R. 4 CHAS CAUTION: When installing the brake hose on the caliper, make sure that the brake pipe touches the projection a on the brake caliper. ● ● WARNING Proper hose routing is essential to insure safe machine operation. Refer to “CABLE ROUTING”. Always use new copper washers. 4.Remove: Brake caliper 5.
FRONT BRAKE CHAS 6.Fill: ● Reservoir tank Recommended brake fluid: DOT 4 NOTE: If DOT 4 is not available, 3 can be used. CAUTION: Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately. ● ● ● WARNING 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.
FRONT BRAKE CHAS MASTER CYLINDER ASSEMBLY ● ● WARNING All internal parts should be cleaned in new brake fluid only. Internal parts should be lubricated with brake fluid when installed. Recommended brake fluid: DOT 4 ● Replace the piston seals and dust seals whenever a brake master cylinder is disassembled. 1.Install: ● Brake master cylinder kit 1 ● Circlip 2 ● Dust boot 3 2.
FRONT BRAKE CHAS 3.Install: ● Copper washers ● Brake hose ● Union bolt T. Union bolt: 27 Nm (2.7 m • kg, 19 ft • lb) R. NOTE: ● Tighten the union bolt while holding the brake hose as shown. ● Check that the brake hose does not touch other parts (throttle cable, wire harness, leads, etc.) by turning the handlebar left and right, and correct if necessary. ● ● WARNING Proper hose routing is essential to insure safe machine operation. Refer to “CABLE ROUTING”. Always use new copper washers. 4.
FRONT BRAKE ● ● CHAS 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. 6.Air bleed: Brake system Refer to “AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)”. ● a 7.Inspect: ● Brake fluid level Fluid level is under “LOWER” level line → Replenish.
REAR WHEELS/REAR BRAKE AND REAR AXLE CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 1 Rear axle 2 Bearing 3 Oil seal 4 Wheel hub 5 Axle nut D FW – 37 – A TIRE SIZE: AT22 × 10-10 B TIRE WEAR LIMIT: 2.0 mm (0.08 in) C RIM SIZE: 8 × 10AT D RIM RUNOUT LIMIT: Radial: 2 mm (0.08 in) Lateral: 2 mm (0.08 in) E REAR AXLE RUNOUT LIMIT: 1.5 mm (0.
FRONT SHOCK ABSORBER AND FRONT ARM FRONT SHOCK ABSORBER AND FRONT ARM 1 Front shock absorber 2 Steering knuckle 3 Lower arm 4 Bushing D FW – 38 – CHAS
REAR SHOCK ABSORBER AND SWINGARM CHAS REAR SHOCK ABSORBER AND SWINGARM 1 Rear shock absorber 2 Thrust cover 3 Locknut 4 Pivot shaft 5 Collar 6 Oil seal 7 Taper roller bearing 8 Swingarm 9 Rubber boot 0 Final gear case protector A D FW – 39 – SWINGARM FREE PLAY LIMIT: End: 1.0 mm (0.04 in) Side: 1.0 mm (0.
ELECTRICAL COMPONENTS ELEC EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Reverse indicator light 2 Neutral indicator light 3 Main switch 4 Rear brake lever switch 5 Handlebar switch 6 Fuses 7 Starter relay 8 Rectifier/regulator 9 CDI unit 0 Taillight A Battery B Starting circuit cut-off relay C Reverse switch D Neutral switch – 40 – E Headlight F Ignition coil – +
W W – 41 – (GREEN) (GREEN) B L R/B G Y R/W L B L/B R/B Y G Br J 1 R/W Br W L/B W W W/G W R W/L W/R R W/R W/L W/G B L L L HI OFF LO I OFF ON 3 Br Br W W W R B K Y G Y G Br R Y B G Y R Br G B B/W B B/W B W R W W B K Y G 2 Y G B B 4 G Y B B B R R B B R R W OFF PUSH R R L/B L/B B W 5 (BLACK) H 7 6 B B W R R OFF RUN G L/W L/W L/B R/B R/W L/W B F G/Y G/Y 8 R/B W/R W/G W/R W/G R/B Sb Sb G/L W/R R
IGNITION SYSTEM ELEC – + EB802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1.Fuse 2.Battery 3.Spark plug 4.Ignition spark gap 5.Spark plug cap resistance 6.Ignition coil resistance 7.Engine stop switch 8.Main switch 9.Pickup coil resistance 10. Charging/rotor rotation direction detection coil resistance 11.
IGNITION SYSTEM * ELEC C0NTINUITY INCORRECT Spark plug gap: 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) CORRECT Repair or replace the spark plug. 4.Ignition spark gap ● ● Disconnect the spark plug cap from the spark plug. Connect the dynamic spark tester 1 as shown. 2 Spark plug cap 3 Spark plug ● ● ● Turn the main switch to “ON”. Check the ignition spark gap. Crank the engine by pushing the starter switch, and increase the spark gap until a misfiring occurs. MEETS SPECIFICATION Minimum spark gap: 6.
IGNITION SYSTEM * ● ● ● + Tester (+) lead → Orange lead terminal Tester (–) lead → Ignition coil base Disconnect the ignition coil connector from the wire harness. Connect the pocket tester (Ω × 1) to the ignition coil. Check that the primary coil has the specified resistance. Tester (+) lead → Ignition coil base Tester (–) lead → Spark plug lead Primary coil resistance: 0.18 ~ 0.28 Ω at 20 ˚C (68˚F) ● – C0NTINUITY 6.
IGNITION SYSTEM * ELEC – C0NTINUITY 9.Pickup coil resistance ● ● Disconnect the CDI magneto coupler from the wire harness. Connect the pocket tester (Ω × 100) to the pickup coil terminal. Tester (+) lead → White/Green terminal 1 Tester (–) lead → White/Red terminal 2 ● Check the pickup coil for the specified resistance. OUT OF SPECIFICATION Pickup coil resistance: 189~ 231 Ω at 20˚C (68˚F) (White/Green – White/Red) Replace the pickup coil/stator assembly. MEETS SPECIFICATION 10.
IGNITION SYSTEM * C0NTINUITY POOR CONNECTION 11. Wiring connection ● ELEC Check the connections of the entire ignition system. Refer to “CIRCUIT DIAGRAM”. Properly connect the ignition system. CORRECT Replace the CDI unit.
W W – 47 – (GREEN) (GREEN) B L R/B G Y R/W L B L/B R/B Y G Br J 1 R/W Br W L/B W W W/G W R W/L W/R R W/R W/L W/G B L L L HI OFF LO I OFF ON 3 Br Br W W W R B K Y G Y G Br R Y B G Y R Br G B B/W B B/W B W R W W B K Y G 2 Y G B B 4 G Y B B B R R B B R R W OFF PUSH R R L/B L/B B W 5 (BLACK) H 7 6 B B W R R OFF RUN G L/W L/W L/B R/B R/W L/W B F G/Y G/Y 8 R/B W/R W/G W/R W/G R/B Sb Sb G/L W/R R
ELECTRIC STARTING SYSTEM ELEC – + STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, starting circuit cut-off relay, rear brake lever switch, and neutral switch. If the main switch is on and engine stop switch is in the RUN position, the starter motor can be operated only if: ● The transmission is in neutral (the neutral switch is closed). or ● You pull in the rear brake lever (the rear brake lever switch is ON).
ELECTRIC STARTING SYSTEM ELEC – EB803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 1.Fuse 2.Battery 3.Starter motor 4.Starting circuit cut-off relay 5.Starter relay 6.Main switch 7.Engine stop switch 8.Neutral switch 9.Rear brake lever switch 10. Start switch 11. Wiring connection (the entire starting system) NOTE: ● Remove the following part(s) before troubleshooting: 1)Seat 2)Front carrier 3)Front fender ● Use the following special tool(s) for troubleshooting.
ELECTRIC STARTING SYSTEM * ELEC – + C0NTINUITY * 3.Starter motor ● ● ● Connect the battery positive terminal 1 and starter motor lead 2 using a jumper lead 3 . Check the operation of the starter motor. * ● 3 2 WARNING A wire that is used as a jumper lead must have the equivalent capacity or more as that of the battery lead, otherwise the jumper lead may burn. This check is likely to produce sparks, so be sure that no flammable gas or fluid is in the vicinity.
ELEC ELECTRIC STARTING SYSTEM * C0NTINUITY 5.Starter relay ● ● 3 Remove the starter relay from the wire harness. Connect the pocket tester (Ω × 1) and the battery (12 V) to the starter relay terminals. R R R L/W L/B 1 B 4 Battery (+) terminal → Blue/White terminal 1 Battery (–) terminal → Blue/Black terminal 2 NO CONTINUITY Tester (+) lead → Red terminal 3 Tester (–) lead → Black terminal 4 ● – Replace the starter relay. Check the starter relay for continuity. CONTINUITY INCORRECT 6.
ELECTRIC STARTING SYSTEM * ELEC C0NTINUITY 9.Rear brake lever switch INCORRECT Refer to “SWITCH INSPECTION”. CORRECT Replace the rear brake lever switch. INCORRECT 10.Start switch Refer to “SWITCH INSPECTION”. CORRECT Replace the handlebar switch (left). EB803028 POOR CONNECTION 11.Wiring connection ● Check the connections of the entire starting system. Refer to “CIRCUIT DIAGRAM”. Properly connect the starting system.
YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
YFM250XN WIRING DIAGRAM R R W/L W/L W/R W/G W/R W/G O O 9 R R W/R W/L A W/G W/L W/R B 1 W W 0 B R/B W/G 1 CDI magneto 2 Rectifier/regulator 3 Main switch 4 Battery 5 Fuse 6 Starter relay 7 Starter motor 8 Starting circuit cut-off relay 9 CDI unit 0 Ignition coil A Spark plug B Neutral indicator light C Reverse indicator light D Neutral switch E Reverse switch F Rear brake lever switch G Engine stop switch H Starter switch I Lights switch J Headlight K Handlebar switch L Taillight W W W
YFM250XP SUPPLEMENTARY SERVICE MANUAL LIT-11616-15-03 4XE-F8197-12
FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the YFM250XP. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual. YFM250XL(C) SERVICE MANUAL: LIT-11616-12-01 (4XE-F8197-10) YFM250XN SUPPLEMENTARY SERVICE MANUAL: LIT-11616-14-17 (4XE-F8197-11) YFM250XP SUPPLEMENTARY SERVICE MANUAL 2001 by Yamaha Motor Corporation, U.S.A.
EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use.
HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1: This is a chapter with its symbol on the upper right of each page. 2nd title 2: This title appears on the upper of each page on the left of the chapter symbol. (For the chapter “Periodic inspection and adjustment” the 3rd title appears.) 3rd title 3: This is a final title.
1 EB003000 2 GEN INFO ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter. SPEC 3 4 CHK ADJ 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical 9 Troubleshooting ENG 5 6 CARB DRIV 7 8 CHAS – ELEC + 0 Illustrated symbols 0 to F are used to identify the specifications appearing in the text.
CONTENTS SPECIFICATIONS ........................................................................................... 1 GENERAL SPECIFICATIONS ................................................................. 1 MAINTENANCE SPECIFICATION ........................................................... 2 ENGINE ................................................................................................ 2 CHASSIS ..............................................................................................
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Model code: Brake: Front brake Rear brake Electrical: Ignition system Generator system Battery type Battery capacity Bulb wattage × quantity: Headlight Tail/brake light Indicator lights: Neutral Reverse Standard 4XEE (USA) type operation type operation Dual disc brake Right hand operation Drum brake (fully sealed) Left hand and right foot operation DC.C.D.I. A.C.
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Item Standard Cylinder head: Warp limit Measuring point ---- * Limit 0.03 mm (0.001 in) Lines indicate straightedge measurement. Piston: Piston to cylinder clearance Piston size “D” 0.04 ~ 0.06 mm (0.0016 ~ 0.0024 in) 70.92 ~ 70.97 mm (2.792 ~ 2.794 in) 0.15 mm (0.0059 in) ---- 4.0 mm (0.16 in) from bottom line of piston skirt 71.5 mm (2.81 in) 72 mm (2.83 in) 0.5 mm (0.02 in) Intake side 16.002 ~ 16.013 mm (0.6300 ~ 0.
MAINTENANCE SPECIFICATIONS SPEC CHASSIS Item Standard Rear suspension: Shock absorber travel Suspension spring free length Fitting length Spring rate Limit 85 mm (3.35 in) 268 mm (10.55 in) 244 mm (9.61 in) 39 N/mm (3.9 kg/mm, 222.69 lb/in)/0 ~ 85 mm (0 ~ 3.35 in) No Optional spring ---------------- Tightening torques Part to be tightened Master cylinder and brake hose Steering shaft and upper handlebar holder Parts name Thread size Q’ty Bolt Bolt M10 × 1.25 M8 × 1.
CABLE ROUTING SPEC CABLE ROUTING 1 Rear brake lever switch lead È Do not route the handlebar Ë Fasten the handlebar switch assembly lead and rear brake switch assembly lead through 2 Rear brake cable lever switch lead to the handlethe lower bracket cable guide. 3 Cable guide bar with the plastic bands. 4 Front brake hose É Fasten the front brake light switch lead to the handlebar with Ì Fasten the handlebar switch 5 Front brake light switch lead assembly lead to the handlebar the plastic band.
CABLE ROUTING 1 Cable guide 2 Main switch 3 Fuel tank breather hose 4 Carburetor overflow hose 5 Reverse switch lead 6 Neutral switch lead 7 Starter motor lead 8 Throttle cable 9 Rear brake cable SPEC É Insert the carburetor air vent hose, rear brake breather hose, and final gear case breather hose into the air duct after routing them through the fuel tank grommet. Ê Route the carburetor overflow hose between the engine and upper rear engine mount and then between the engine and swingarm.
CABLE ROUTING SPEC È Make sure that the starter motor lead has no slack. É Fasten the starter motor lead and wire harness to the frame with the plastic band. Ê Fasten the starter motor lead and wire harness to the frame with the plastic clamp. Ë Route the starter motor lead, wire harness, and battery - lead through the hole in the rear fender. Ì Fasten the taillight lead and wire harness to the frame with the plastic clamp.
CABLE ROUTING SPEC Ò Fasten the rear brake cable and rear brake breather hose to the swingarm with the plastic clips. Ó 10 mm (0.4 in) Ô 40 ~ 50 mm (1.6 ~ 2.0 in) Õ 100 mm (4.0 in) Í Fasten the tail/brake light lead to the storage box with the plastic clamp. Î Fasten the starter motor lead and wire harness to the frame with the plastic clamp. Ï Route the rear brake cable and rear brake breather hose through the cable guide. Ð Route the rear brake breather hose through the cable guide.
CABLE ROUTING 1 Battery breather hose 2 Rear brake cable 3 Spark plug cap 4 Ignition coil 5 Ignition coil lead 6 Starter motor lead 7 Rear brake light switch 8 Rear brake breather hose SPEC È Make sure that the battery breather hose is not kinked or bent. É Route the rear brake cable through the cable guide on the cylinder. Ê Fasten the starter motor lead to the frame with the plastic clamps. Ë Fasten the battery breather hose to the frame with the plastic clamps. Ì 50 ~ 60 mm (2.0 ~ 2.
CABLE ROUTING 1 Rectifier/regulator 2 CDI unit 3 Starting circuit cut-off relay lead 4 Starter relay lead 5 Starter motor lead 6 Starting circuit cut-off relay 7 Starter relay 8 Rear brake breather hose 9 Carburetor air vent hose 0 Final gear case breather hose SPEC È Fasten the battery + lead and starter motor lead to the rear fender with the plastic clamps. É Install the starter circuit cut-off relay onto the tab with its terminal side facing down.
CABLE ROUTING Í Make sure that the grommet is installed with the mark facing forward. Î 5 mm (0.
CABLE ROUTING SPEC Ê Make sure the starter motor lead and wire harness do not contact the ignition coil. Ë Fasten the wire harness, starter motor lead, and ignition coil lead to the frame with the plastic locking tie. Ì Route the taillight lead through the lead holders on the lid and the bottom of the storage box. Í 50 mm (2.0 in) 1 Rear brake cable 2 Throttle cable 3 Wire harness 4 Starter motor lead 5 Tail/brake light lead È Route the throttle cable and rear brake cable through the cable guide.
INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS EB300000 CHK ADJ PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS INITIAL ITEM ROUTINE Steering system* • • • • Steering shaft* • Lubricate every 6 months.** Fittings and Fasteners* • Check all chassis fittings and fasteners. • Correct if necessary. Battery* • Check specific gravity. • Check that the breather hose is working properly. • Correct if necessary. CHK ADJ EVERY 1 3 6 6 month months months months 1 year Check operation. Correct if damaged. Check toe-in. Adjust if necessary.
ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE LIGHT SWITCH CHK ADJ CHASSIS ADJUSTING THE FRONT BRAKE 1.Check: ● Brake lever free play a Out of specification → Bleed the front brake system. Refer to “AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)”. (Manual No.: 4XE-F8197-11) Brake lever free play (at brake lever end): 0 mm (0 in) ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: The rear brake light switch is operated by movement of the brake pedal.
CHECKING THE SWITCH ELEC – + ELECTRICAL CHECKING THE SWITCH CHECKING THE SWITCH Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. Pocket tester: P/N. YU-03112, 90890-03112 NOTE: ● Set the pocket tester to “0” before starting the test. ● The pocket tester should be set to the “Ω × 1” range when testing the switch for continuity. ● Turn the switch on and off a few times when checking it.
– 16 – Y B Br G/Y B Y (GRAY) B G/Y Br (GRAY) Y Br G/Y N Y W Br (BLACK) W W W W W/R W/L W R W/G W/L W/R W/G R B L B Y Y Y L (BLACK) Br (BLACK) B B Br Br (GRAY) B (BLACK) Y Br R W W K Br ON OFF 3 R W W R W W M 1 Br 2 4 R B B B G Br Y R/B L L/B L G B Y Br R/W R/B I (GRAY) R B B B R W Br R R W J L L/B B Y Y 5 (BLACK) 7 B B OFF LO HI H 6 R R W R R G G L/W Y G Y R/B L/W G/Y 8 R/B G B G Y G B
SIGNAL SYSTEM ELEC – + CHECKING THE SIGNAL SYSTEM 1.If the tail/brake light fails to come on: 1.Bulb and bulb socket ● NO CONTINUITY Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2.Brake light switches Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the brake switch. 3.Voltage ● Connect the pocket tester (DC 20V) to the bulb socket connector.
YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
YFM250XP WIRING DIAGRAM R R W/L W/L O W/R W/R W/G W/G 9 0 O A B R/B W/G R R W/G W/R W/L W/L W/R B 1 W W W W W W W W W W W 2 W W B (BLACK) W/R R R/B B R W R W W/G B W/L O (BLACK) R 3 R R R R R R 4 ON OFF R Br Br (GRAY) R R G/Y L/W L/W L/B R/B 5 B (GRAY) L/W Sb R/B (BLACK) L/W 6 B B Br Sb 8 B L/B 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N A.C.
