PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories OWNER’S SERVICE MANUAL TZ250N1/(N) YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN LIT-11626-14-44 PRINTED IN JAPAN 2000.10—0.
EC010000 TZ250N1/(N) OWNER’S SERVICE MANUAL ©2000 by Yamaha Motor Corporation, U.S.A. 1st Edition, September 2000 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U.S.A. is expressly prohibited. Printed in Japan P/N.
EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha TZ series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader. This manual explains operation, inspection, basic maintenance and tuning of your machine. If you have any questions about this manual or your machine, please contact your Yamaha dealer.
EC030010 WARRANTY INFORMATION This model is sold AS IS, WITHOUT ANY WARRANTIES EXPRESSED OR IMPLIED REGARDLESS OF THE INTENDED USE. THE PURCHASER OF THIS MACHINE, which is intended for competition purposes, IS RESPONSIBLE FOR ALL COSTS, SERVICE AND/OR REPAIR.
EC040001 IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding. &SAFETY INFORMATION 1. THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY. Do not attempt to operate this machine at maximum power until you are totally familiar with its characteristics. 2.
. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes. 7. ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILATION. Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are poisonous.
EC050000 TO THE NEW OWNER This manual will provide you with a good basic understanding of features, operation, and basic maintenance and inspection items of this machine. Please read this manual carefully and completely before operating your new machine. If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer.
EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION ! The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! W Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine. CCAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the machine. NOTE: A NOTE provides key information to make procedures easier or clearer.
EC083000 MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., • Bearings Pitting/Damage ≥ Replace.
1 EC085002 2 GEN INFO SPEC 3 4 INSP ADJ ENG 5 6 CHAS ELEC 7 TUN 0 ¡ ™ £ ¢ ∞ § ¶ • ª º ! Illustrated symbols 1 to 7 are designed as thumb tabs to indicate the chapter’s number and content. 1 General information 2 Specifications 3 Regular inspection and adjustments 4 Engine 5 Chassis 6 Electrical 7 Tuning Illustrated symbols 8 to ¢ are used to identify the specifications appearing in the text.
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EC090000 INDEX GENERAL INFORMATION SPECIFICATION REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL TUNING GEN INFO 1 SPEC 2 INSP ADJ 3 ENG 4 CHAS 5 ELEC 6 TUN 7
EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 1-1 MACHINE IDENTIFICATION . . . . . . . . . . . 1-2 IMPORTANT INFORMATION . . . . . . . . . . 1-3 CHECKING OF CONNECTION . . . . . . . . . 1-5 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . 1-6 CONTROL FUNCTIONS . . . . . . . . . . . . . . 1-8 FUEL AND ENGINE MIXING OIL . . . . . . 1-14 INFORMATION BEFORE PRE-OPERATION . . . . . . . . . . . . . . . . . . 1-15 STARTING AND BREAK-IN . . . . . . . .
CHAPTER 4 ENGINE COWLING, INDUCTION GUIDE, SEAT AND FUEL TANK . . . . . . . . . . . . . . . . . . . . 4-1 EXHAUST PIPE AND SILENCER . . . . . . . 4-3 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 CARBURETOR AND REED VALVE . . . . . 4-7 CYLINDER HEAD,CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 7 TUNING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION GEN INFO EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 Clutch lever 2 Valve joint 3 Main switch 4 Water temperature gauge 5 Front brake lever 6 Throttle grip 7 Radiator cap 8 Fuel tank cap 9 Starter lever (Choke) 0 Battery ¡ Fuel pump ™ Fuel cock £ Steering damper ¢ Servomotor ∞ Radiator § Check bolt (Transmission oil level) ¶ Rear brake pedal • Rear shock absorber ª Drive chain º Shift pedal ! CDI magneto @ Front fork NOTE: • The machine you have purchased may differ slightly from th
MACHINE IDENTIFICATION GEN INFO EC120001 MACHINE IDENTIFICATION There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine.
IMPORTANT INFORMATION GEN INFO EC130000 IMPORTANT INFORMATION EC131002 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. Refer to “SPECIAL TOOLS” section. 3. When disassembling the machine, keep mated parts together. They include gears, cylinders, pistons, and other mated parts that have been “mated” through normal wear. Mated parts must be reused as an assembly or replaced. 4.
IMPORTANT INFORMATION GEN INFO EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and Orings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.
CHECKING OF CONNECTION GEN INFO EC1C0001 CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: • Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off. 5. If the terminal comes off, bend up the pin 1 and reinsert the terminal into the connector. 6. Connect: • Connector NOTE: The two connectors “click” together. 7. Check for continuity with a tester.
SPECIAL TOOLS GEN INFO EC140002 SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order. NOTE: • For U.S.A. and Canada, use part number starting with “YM-”, “YU-” or “ACC-”.
SPECIAL TOOLS Part number YM-1425, 90890-01425 Tool name / How to use Damper rod holder GEN INFO Illustration YM-1425 90890-01425 YM-1434 90890-01434 YM-1437 90890-01435 Use this tool to remove and install the damper rod. YM-1434, 90890-01434 Rod holder This tool is used to hold the fork spring. 90890-01435 Rod puller attachment YM-1437, 90890-01437 Rod puller 90890-01437 These tools are used to pull up the fork damper rod.
CONTROL FUNCTIONS GEN INFO EC150000 CONTROL FUNCTIONS EC15W000 MAIN SWITCH While the battery is connected, moving the main switch 1 to “RUN” causes the tachometer, servomotor, fuel pump and solenoid valves to be initially activated. To prevent the battery from being discharge, do not move the main switch to “RUN” except when the engine is started or when electric parts are checked. EC152000 CLUTCH LEVER The clutch lever 1 is located on the left handlebar; it disengages or engages the clutch.
CONTROL FUNCTIONS GEN INFO EC157000 REAR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine. Press down on the brake pedal to activate the rear brake. EC158001 FUEL COCK The fuel cock supplies fuel from the tank to carburetor while filtering the fuel. The fuel cock has the two positions: OFF: With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running.
CONTROL FUNCTIONS GEN INFO NOTE: • If an out-of-step indication takes place, moving the main switch to “OFF” once and then to “RUN”, brings the tachometer back to a normal indication through its corrective action. • There is no functional problem involved with the out-of-step indication, which can be brought back to a normal indication through the corrective action of the tachometer.
CONTROL FUNCTIONS GEN INFO EC15Y000 INDUCTION BOX INTAKE SYSTEM The induction boxes 1 and induction guides 2 are provided for the purpose of applying pressure inside the carburetor float chamber and thereby improving the intake performance. If the machine is run without them, the carburetor settings will become faulty. NOTE: Be sure to fix the induction guides with band 3 or hooks 4 so that they do not come off by wind pressure while running.
CONTROL FUNCTIONS GEN INFO EC15a000 FUEL PUMP STOP SWITCH, FUEL PUMP RELAY The fuel pump stop switch 1 and fuel pump relay 2 are provided so as to control the fuel pump and prevent the carburetor overflowing during a turnover. If the machine is turned over, the fuel pump stop switch is turned “ON” which allow electric current to flow in the coil 3 inside the relay, causing the relay switch 4 to turn “OFF” and shutting of the electric current flow to the fuel pump 5. Thus, the pump comes to a stop.
CONTROL FUNCTIONS GEN INFO EC15Q001 DETACHABLE MAINSTAND This mainstand 1 is used to support only the machine when standing or transporting it. NOTE: The mainstand can be used to support the machine two ways. 1. Hook the bracket of the mainstand onto the swingarm hooks 2. 2. Stand shaft (with supplying parts): Insert the stand shaft 3 through the hole of the mainstand and rear wheel axle. Be sure to install the clip 4 in the end of the stand shaft. W • Never apply additional force to the mainstand.
FUEL AND ENGINE MIXING OIL GEN INFO EC160040 FUEL AND ENGINE MIXING OIL Mix oil with the gas at the ratio specified below. Always use fresh, name-brand gasoline, and mix the oil and gas the day of the race. Do not use premix that is more than a few hours old. Recommended fuel: Except for AUS: Premium unleaded fuel with a research octane number of 95 or higher. For AUS: Unleaded fuel only 5 NOTE: Except for AUS: 1. If knocking or pinging occurs, use a different brand of gasoline or higher octane grade.
INFORMATION BEFORE PRE-OPERATION GEN INFO EC170011 INFORMATION OPERATION BEFORE PRE- 1. The brake disc 1 is coated with a rust inhibitor. Before riding the machine, thoroughly remove it using a lacquer thinner. W • LACQUER THINNER IS HIGHLY FLAMMABLE. Always turn off the engine while using lacquer thinner. Take care not to spill any lacquer thinner on the engine or exhaust system. Never use it in the vicinity of an open flame, or while smoking. • LACQUER THINNER CAN CAUSE INJURY.
STARTING AND BREAK-IN GEN INFO EC190000 STARTING AND BREAK-IN CCAUTION: Before starting the machine, perform the checks in the pre-operation check list. W Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Always operate the machine in a well-ventilated area. EC191032 STARTING A COLD ENGINE 1. Connect the power supply coupler. 2. Turn the fuel cock to “ON” and push the starter lever (CHOKE). 3.
STARTING AND BREAK-IN GEN INFO EC193031 STARTING A WARM ENGINE Do not push the starter lever (CHOKE). Open the throttle slightly and start the engine. CCAUTION: Observe the following break-in procedure during initial operation to ensure optimum performance and avoid engine damage. EC194020 BREAK-IN PROCEDURES 1. Before starting the engine, fill the fuel tank with a break-in oil-fuel mixture as follows. 2 Mixing oil Recommended oil: Castrol A747 Mixing ratio: 30 : 1 2.
STARTING AND BREAK-IN GEN INFO CCAUTION: After the break-in or before each race, you must check the entire machine for loose fittings and fasteners as per “TORQUECHECK POINTS”. Tighten all such fasteners as required. 8. Increase the engine speed up to 10,000 r/min and run about 10 km (6 miles). 9. Increase the engine speed up to 11,000 r/min and run about 10 km (6 miles). 10.Increase the engine speed up to 12,000 r/min and run about 10 km (6 miles). Then do the plug chop.
TORQUE-CHECK POINTS GEN INFO EC1A0060 TORQUE-CHECK POINTS Frame construction Frame to rear frame Engine mounting Frame to engine Steering Steering shaft to handlebar Steering damper stay to front fork Steering shaft to handle crown Front fork to handlebar Suspension Front Steering shaft to front fork Front fork to handle crown Front fork to under bracket Rear For link type Assembly of links Link to frame Link to shock absorber Link to swingarm Rear Installation of shock absorber Shock abs
TORQUE-CHECK POINTS Fuel system GEN INFO Fuel tank to fuel cock NOTE: Concerning the tightening torque, refer to “MAINTENANCE SPECIFICATIONS” section in the CHAPTER 2.
CLEANING AND STORAGE GEN INFO EC1B0000 CLEANING AND STORAGE EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many components. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering. A plastic bag secured with a rubber band may be used for this purpose. 2. If the engine is excessively greasy, apply some degreaser to it with a paint brush.
CLEANING AND STORAGE GEN INFO EC1B2010 STORAGE If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as follows: 1. Drain the fuel tank, fuel lines, and the carburetor float chambers. 2. Remove the spark plugs, pour a tablespoon of SAE 10W30 motor oil in the spark plug hole, and reinstall the plug.
GENERAL SPECIFICATIONS SPEC EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: TZ250N1 (USA) TZ250(N) (OTHERS) Model code number: 5KE2 Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance 1,955 mm (77.0 in) 650 mm (25.6 in) 1,083 mm (42.6 in) 788 mm (31.0 in) 1,342 mm (52.8 in) 112 mm (4.4 in) Basic weight: With oil and full fuel tank 119.
GENERAL SPECIFICATIONS 2 SPEC Transmission: primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio: 1st 2nd 3rd 4th 5th 6th Spur gear 53/21 (2.524) Chain drive 36/14 (2.571) Constant mesh, 6-speed Left foot operation 34/18 (1.889) 31/21 (1.476) 29/23 (1.261) 27/25 (1.080) 26/27 (0.963) 20/22 (0.909) Chassis: Frame type Caster angle Trail Delta box 22˚ 82 mm (3.
MAINTENANCE SPECIFICATIONS SPEC EC212000 MAINTENANCE SPECIFICATIONS EC212112 ENGINE Item Cylinder head: Combustion chamber capacity Piston: Piston clearance Piston offset Piston pin: Piston pin outside diameter Piston ring: Sectional sketch End gap (installed) Side clearance (installed) Standard Limit 9.0 cm3 (0.317 lmp oz, 0.304 US oz) ? 0.090~0.100 mm (0.0035~0.0039 in) 1.0 mm (0.039 in)/EX-side ? 14.995~15.000 mm (0.5904~0.5906 in) 14.975 mm (0.5896 in) Keystone B=1.0 mm (0.039 in) T=2.
MAINTENANCE SPECIFICATIONS Item SPEC Standard Limit Carburetor: Type/Manufacturer I.D. mark (left side/right side) Main jet (M.J.) Jet needle (J.N.) Main nozzle (N.J.) Cutaway (C.A.) Pilot jet (P.J.) Pilot air screw (P.A.S.) Valve seat size (V.S.) Starter jet (G.S.) Power jet (P.W.J.) Float height (F.H.) TMX*38/MIKUNI 5KE2 10L/5KE2 10R #560 6DGJ1 S-4 5.0 #40 1-1/2 1.5 #80 #55 6.0~7.0 mm (0.24~0.
MAINTENANCE SPECIFICATIONS Part to be tightened Spark plug Cylinder head (bolt) Cylinder (nut) (stud) Power valve: Cover Holder (power valve) Pulley Cable stay Air bleeding bolt (cylinder) Balance weight gear Water pump housing cover Air bleeding bolt (water pump) Radiator Radiator and thermo unit Radiator hose clamp Oil pump cover Oil strainer Carburetor joint Clamp (carburetor joint) Reed valve Mixing chamber top Exhaust pipe Silencer Crankcase Crankcase Transmission housing Oil check bolt Oil drain bolt
MAINTENANCE SPECIFICATIONS Part to be tightened Joint rod 1 and shift rod Joint rod 2 and shift rod Joint rod 1,2 Shift pedal pivot bolt Front pedal Thread size M6 M6 M6 M8 M6 X 1.0 X 1.0 X 1.0 X 1.25 X 1.0 Q’ty 1 1 2 1 1 SPEC Tightening torque Nm mdkg ftdlb 9 9 11 22 10 0.9 0.9 1.1 2.2 1.0 6.5 6.5 8.0 16 7.2 Crankcase tightening sequence CCAUTION: The M6 bolt comes in two lengths. Use the correct one for installation. L=30 mm (1.18 in) (green) 7 0 ¡ £ ¢ ∞ Mark $:L=35 mm (1.
MAINTENANCE SPECIFICATIONS SPEC EC212201 CHASSIS Item Steering system: Steering bearing type Front suspension: Front fork travel Fork spring free length Spring rate, STD Optional spring Oil capacity Oil level (From top of outer tube with inner tube and damper rod fully compressed without spring.) Oil grade Inner tube outer diameter Front fork top end Rear suspension: Shock absorber travel Spring free length Fitting length
MAINTENANCE SPECIFICATIONS Item Front disc brake: Disc outside dia.XThickness Pad thickness Master cylinder inside dia. Caliper cylinder inside dia. SPEC Standard Limit 298X5.0 mm (11.73X0.20 in) 5.3 mm (0.21 in) 15.87 mm (0.625 in) 33.96 + 30.23 mm (1.337 + 1.190 in) DOT #4 ? 1.0 mm (0.04 in) ? ? Rear disc brake: Disc outside dia.XThickness Deflection limit Pad thickness Master cylinder inside dia. Caliper cylinder inside dia. Brake fluid type 185X4.0 mm (7.28X0.16 in) ? 4.0 mm (0.16 in) 12.7 mm (0.
MAINTENANCE SPECIFICATIONS ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ Part to be tightened Thread size Q’ty Handle crown and outer tube Under bracket and outer tube Steering shaft and steering shaft nut Handlebar and outer tube Steering ring nut Steering damper and fame Steering damper and damper bracket Steering damper stay and outer tube Steering damper stay and pin Steering stopper bolt and locknut Fuel tank fitting bolt and locknut Clutch lever holder Front master cylinder and master cylinder bracket
MAINTENANCE SPECIFICATIONS Part to be tightened ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ Rear brake caliper and caliper bracket Rear wheel axle and nut Driven sprocket and sprocket damper Rear brake disc and wheel hub Chain puller adjust bolt and locknut Chain puller adjust bolt Engine mounting: Engine and frame (upper) Engine and frame (lower) Engine bracket and frame Engine bracket and engine Pinch bolt (engine mounting collar) Engine mounting adjust bolt Pivot adjust bolt Pivot shaft and nut Relay arm
MAINTENANCE SPECIFICATIONS SPEC EC212300 ELECTRICAL Item Ignition system: Ignition timing (B.T.D.C) Advancer type CDI: Magneto-model/Manufacturer Source coil resistance (color) Pickup coil resistance (left cylinder) (color) (right cylinder) CDI unit-model/Manufacturer Ignition coil: Model/Manufacturer (left cylinder) (right cylinder) Minimum spark gap Primary winding resistance Secondary winding resistance Standard Limit 2.4 mm (0.094 in) Electrical … … 5KE-00 (TLGZ06)/DENSO 2.3~3.
GENERAL TORQUE SPECIFICATIONS/ DEFINITION OF UNITS SPEC EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads.
CABLE ROUTING DIAGRAM SPEC EC240000 CABLE ROUTING DIAGRAM 1 Brake hose 2 Clamp 3 Cable 4 Frame 5 Radiator breather hose 6 YPVS cable 1, 2 (right cylinder) 7 Ignition coil lead 8 Starter cable 9 Solenoid valve lead 0 Fuel hose ¡ Clutch cable ™ Fuel pump lead £ Throttle cable ¢ Transmission oil breather hose A Pass the brake hose through the hole in the inner fender. B Cut the clamp so that the protruding portion is less than 5 mm (0.20 in). C Install the clamp with its ends facing backward.
CABLE ROUTING DIAGRAM 1 Fuel pump lead 2 Clamp 3 Fuse holder 4 Servomotor 5 Front brake hose (right) 6 YPVS cable 1, 2 (right cylinder) 7 Clutch cable SPEC A Clamp the fuel hose and clutch cable. Position the upside ends of the clamp inside of the seat rail. B Clamp the radiator hose 3 and ignition coil lead. C Clamp the radiator hose 3 and YPVS cable (right cylinder). D Do not cut the end of the clamp.
CABLE ROUTING DIAGRAM 1 Clamp 2 Throttle cable 3 Fuel tank breather hose 4 Fuel pump stop switch lead 5 Battery lead 6 Fuel pump relay lead 7 Power supply coupler 8 CDI magneto lead 9 Front brake hose (left) SPEC A Clamp the wireharness together with couplers of the fuse lead under the cowling stay mounting bolt so that the tape on the wireharness aligns with the bolt. B Fasten the primary ground lead together with the cowling stay bracket mounting bolt. C Do not cut the end of the clamp.
CABLE ROUTING DIAGRAM 1 Tachometer assembly 2 Coupler for speed shift 3 CDI unit 4 Voltage regulator 5 Servomotor 6 Brake hose holder 7 Reservoir hose 8 Rear brake hose 9 Clamp SPEC A Install the tachometer assembly with its figures standing upright. B Do not make the clamp grip face outside of the chassis. C Position the reservoir hose with its paint mark upward. D Make the clamp grip face inside of the chassis. E Be sure the brake hose is not twisted. F Do not cut the end of the clamp.
MAINTENANCE INTERVALS INSP ADJ EC300000 REGULAR INSPECTION AND ADJUSTMENTS EC310070 MAINTENANCE INTERVALS The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.
MAINTENANCE INTERVALS Item SPARK PLUG Inspect and clean Replace After Every Every Every As rebreak1,000 race 500km quired in km ∂ 3 ∂ (1,500 km) ∂ ∂ ∂ OIL PUMP STRAINER Clean ∂ ∂ ∂ ∂ ∂ ∂ ∂ ∂ FUEL TANK, COCK Clean and inspect ∂ ∂ ∂ ∂ ∂ ∂ ∂ ∂ ∂ ∂ ∂ FRONT FORKS Inspect and adjust Replace oil Replace oil seal ∂ REAR SHOCK ABSORBER Inspect and adjust Lube Retighten ∂ ∂ ∂ ∂ Every one year ∂ Suspension oil “01” ∂ ∂ (After rain race) ∂ CHAIN GUARD Replace Molybdenum disulfide grease
MAINTENANCE INTERVALS Item TIRE, WHEELS Inspect air pressure, wheel run-out and tire wear Inspect bearings Replace bearings Lubricate DRIVE CHAIN Lubricate, slack, alignment Replace After Every Every Every As rebreak1,000 race 500km quired in km ∂ ∂ ∂ ∂ THROTTLE, CONTROL CABLE Check routing and connection Lubricate BATTERY Check battery voltage Replace Remarks ∂ Lithium base grease ∂ ∂ Use chain lube Chain slack: 40~50 mm (1.6~2.
PRE-OPERATION INSPECTION AND MAINTENANCE INSP ADJ EC320010 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. NOTE: • The brake disc is coated with a rush inhibitor. Before pre-operation thoroughly remove it using a lacquer thinner. • For storage, a coolant is used. Before riding the machine remove it with cooling water.
LOCKING WIRE INSTALLATION GUIDE EC340000 LOCKING WIRE INSTALLATION GUIDE Bolt to bolt Bolt YPVS pulley Throttle cable adjuster Oil drain bolt and check bolt Tank rail drain bolt Oil filler cap Starter cable 3-5 INSP ADJ
ENGINE/COOLING WATER LEVEL INSPECTION/ COOLING WATER REPLACEMENT INSP ADJ EC350011 ENGINE CCAUTION: • The cooling system is filled with coolant at the factory to prevent rusting. Be sure to replace coolant with soft water before riding. • Take care so that coolant does not splash on painted surfaces. If it splashes, wash it away with water. EC352000 COOLING WATER LEVEL INSPECTION W Do not remove the radiator cap 1, drain bolt and hoses when the engine and radiator are hot.
COOLING WATER REPLACEMENT INSP ADJ 3. Disconnect: • Radiator hose 2 1 4. Remove: • Radiator cap Drain the cooling water completely. 5. Clean: • Cooling system Thoroughly flush the cooling system with clean tap water. 6. Connect: • Radiator hose 2 T2 Nm (0.2 mdkg, 1.4 ftdlb) 7. Fill: • Radiator • Engine To specified level. 2 Recommended cooling water: Soft water Cooling water capacity: 1.4 L (1.23 Imp qt, 1.
RADIATOR CAP INSPECTION/ RADIATOR CAP OPENING PRESSURE INSPECTION INSP ADJ 12.Fill: • Radiator • Engine To specified level. 13.Install: • Radiator cap Start the engine and warm it up for a several minute. 14.Check: • Cooling water level Cooling water level low ≥ Add cooling water. 15.Install the lower cowl. EC355000 RADIATOR CAP INSPECTION 1. Inspect: • Seal (radiator cap) 1 • Valve and valve seat 2 Crack/Damage ≥ Replace. Exist fur deposits 3 ≥ Clean or replace.
COOLING SYSTEM INSPECTION/CLUTCH CARE INSP ADJ 3. Inspect: • Pressure Impossible to maintain the specified pressure for 10 seconds ≥ Replace. EC357003 COOLING SYSTEM INSPECTION 1. Inspect: • Coolant level 2. Attach: • Radiator cap tester 1 and adapter 2 C a Radiator cap tester: YU-24460-01/90890-01325 Adapter: YU-33984/90890-01352 3. Apply the specified pressure. Standard pressure: 180 kPa (1.8 kg/cm2, 25.6 psi) NOTE: • Do not apply pressure more than specified pressure.
CLUTCH ADJUSTMENT/ THROTTLE CABLE ADJUSTMENT INSP ADJ EC359001 CLUTCH ADJUSTMENT 1. Check: • Clutch lever free play a Out of specification ≥ Adjust. a Clutch lever free play a: 2~3 mm (0.08~0.12 in) 2. Adjust: • Clutch lever free play Clutch lever free play adjustment steps: • Loosen the locknut 1. • Turn the adjuster 2 until free play a is within the specified limits. • Tighten the locknut. NOTE: After adjustment, check proper operation of clutch lever. EC35A040 THROTTLE CABLE ADJUSTMENT 1.
STARTER CABLE ADJUSTMENT INSP ADJ 4. Adjust: • Throttle grip free play Throttle grip free play adjustment steps: • Loosen the locknuts 1, 2, 3. • Turn the adjusters 4, 5, 6 fully in. • Turn out the right carburetor adjuster 5 until the specified free play is obtained. • Tighten the right carburetor locknut 2. • Turn out the left carburetor adjuster 6 until the left throttle valve moves together with the right throttle valve.
YPVS OPEN SIDE CABLE ADJUSTMENT INSP ADJ EC35D012 YPVS OPEN SIDE CABLE ADJUSTMENT 1. Disconnect the fuel pump coupler to prevent the fuel pump operation. 2. Check: • YPVS open side cable free play a Checking steps: • Move the main switch to “RUN”. • The servomotor will be fully opened. NOTE: After the main switch is moved to “RUN”, the servomotor will be operated as follows. 1. The servomotor will be fully closed about 1 second. 2. And then, it will be kept fully opened.
YPVS CLOSE SIDE CABLE ADJUSTMENT/YPVS COMPONENTS RETIGHTENING/TRANSMISSION OIL LEVEL CHECK INSP ADJ EC35E011 YPVS CLOSE SIDE CABLE ADJUSTMENT 1. Disconnect the fuel pump coupler to prevent the fuel pump operation. 2. Check: • YPVS close side cable free play a Checking steps: • Move the main switch to “RUN”. • The servomotor will be fully closed about 1 second. • During this 1 second, move the main switch to “OFF”. • The servomotor will be kept fully closed.
TRANSMISSION OIL REPLACEMENT INSP ADJ 3. Check: • Transmission oil level Transmission oil level checking steps: • Remove the oil check bolt 1. • Inspect the oil level. NOTE: Be sure the machine is positioned straight up when inspecting the oil level. W S Never attempt to remove the checking bolt just after high speed operation. The heated oil could spout out, causing danger. Wait until the oil cools down. Oil flows out ≥ Oil level is correct. Oil does not flow out ≥ Oil level is low.
PILOT AIR SCREW ADJUSTMENT INSP ADJ 4. Remove: • Oil drain bolt 1 • Oil filler cap 2 Drain the transmission oil. 5. Install: • Copper washerN • Oil drain bolt 1 T23 Nm (2.3 mdkg, 17 ftdlb) NOTE: After tightening the oil drain bolt to specified torque, lock it using a wire. 6. Fill: • Transmission oil 3 Recommended oil: Castrol R30 Oil capacity (periodic oil change): 0.50 L (0.44 Imp qt, 0.53 US qt) 7. Check: • Oil leakage 8. Check: • Transmission oil level 9.
MUFFLER INSPECTION/SILENCER INSPECTION INSP ADJ EC35P010 MUFFLER INSPECTION 1. Inspect: • O-ring 1 Damage ≥ Replace. EC35Q001 SILENCER INSPECTION 1. Inspect: • Silencer Inside of silencer loose ≥ Repair. Silencer repair steps: • Drill the silencer for riveting. • Rivet the silencer using the rivet. NOTE: Rivet the silencer in a different area than previously riveted.
CHASSIS/BRAKE SYSTEM AIR BLEEDING INSP ADJ EC360000 CHASSIS EC361002 BRAKE SYSTEM AIR BLEEDING W Bleed the brake system if: • The system has been disassembled. • A brake hose has been loosened or removed. • The brake fluid is very low. • The brake operation is faulty. A dangerous loss of braking performance may occur if the brake system is not properly bleed. 1. Remove: • Reservoir tank cap • Diaphragm 2. Bleed: • Brake fluid A Front B Rear Air bleeding steps: a.
FRONT BRAKE ADJUSTMENT/ REAR BRAKE ADJUSTMENT INSP ADJ NOTE: If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared. j. Add brake fluid to the level line on the reservoir. W Check the operation of the brake after bleeding the brake system. 3. Install: • Diaphragm • Reservoir tank cap EC363020 FRONT BRAKE ADJUSTMENT 1.
INSP ADJ FRONT BRAKE PAD INSPECTION AND REPLACEMENT 2. Adjust: • Brake pedal height Pedal height adjustment steps: • Loosen the locknut 1. • Turn the adjusting nut 2 until the pedal height is within specified height. • Tighten the locknut. EC365050 FRONT BRAKE PAD INSPECTION AND REPLACEMENT 1. Inspect: • Brake pad thickness a Out of specification ≥ Replace as a set. { Brake pad thickness a: Standard 5.3 mm (0.21 in) 1.0 mm (0.04 in) 2.
REAR BRAKE PAD INSPECTION AND REPLACEMENT INSP ADJ • Install the brake pads 9, pad support 0, pad pin ¡ and cotter pin ™. NOTE: • Always use a new cotter pin. • Temporarily tighten the pad pin at this point. ™ • Install the caliper £ and tighten the pad pin ¢. Bolt (caliper): 35 Nm (3.5 m•kg, 25 ft•lb) Pad pin: 18 Nm (1.8 m•kg, 13 ft•lb) 3. Inspect: • Brake fluid level Refer to “BRAKE FLUID LEVEL INSPECTION” section. 4. Check: • Brake lever operation A softy or spongy feeling ≥ Bleed brake system.
REAR BRAKE PAD INSPECTION AND REPLACEMENT INSP ADJ • Remove the cotter pin 3, pad pin 4, pad support 5 and brake pads 6. • Connect the transparent hose 7 to the bleed screw 8 and place the suitable container under its end. • Loosen the bleed screw and push the caliper piston in. CCAUTION: U Do not reuse the drained brake fluid. • Tighten the bleed screw. Bleed screw: 6 Nm (0.6 m•kg, 4.3 ft•lb) • Install the brake pads 9, pad support 0, pad pin ¡ and cotter pin ™. NOTE: • Always use a new cotter pin.
BRAKE FLUID LEVEL INSPECTION/ SPROCKETS INSPECTION INSP ADJ EC367001 BRAKE FLUID LEVEL INSPECTION 1. Place the master cylinder so that its top is in a horizontal position. 2. Inspect: • Brake fluid level Fluid at lower level ≥ Fill up. a Lower level A Front B Rear 0 Recommended brake fluid: DOT #4 W • Use only designated quality brake fluid to avoid poor brake performance. • Refill with same type and brand of brake fluid; mixing fluids could result in poor brake performance.
DRIVE CHAIN INSPECTION INSP ADJ EC369040 DRIVE CHAIN INSPECTION 1. Remove: • Drive chain 1 NOTE: Remove the drive chain using a chain cutter 2. 2. Clean: • Drive chain Brush off as much dirt as possible. Then clean the chain using the chain cleaner. CCAUTION: This machine has a drive chain with small rubber O-rings 1 between the chain plates. Steam cleaning, high-pressure washes, certain solvent and kerosene can damage these O-rings. 3. Inspect: • O-rings 1 (drive chain) Damage ≥ Replace drive chain.
DRIVE CHAIN SLACK ADJUSTMENT INSP ADJ 5. Check: • Drive chain stiffness a Clean and oil the chain and hold as illustrated. Stiff ≥ Replace drive chain. 6. Install: • Chain joint 1N • O-ring 2 • Drive chain 3 NOTE: When installing the drive chain, apply the lithium soap base grease on the chain joint and O-rings. 7. Install: • Link plate 4N NOTE: • Press the link plate onto the chain joint using a chain rivetter 5. • Rivet the end of the chain joint using a chain rivetter 6.
DRIVE CHAIN SLACK ADJUSTMENT INSP ADJ NOTE: Before checking and/or adjusting, rotate the rear wheel through several revolutions and check the slack several times to find the tightest point. Check and/or adjust chain slack with rear wheel in this “tight chain” position. 3. Adjust: • Drive chain slack S S Drive chain slack adjustment steps: • Loosen the axle nut 1 and locknuts 2. • Adjust chain slack by turning the adjusters 3. To tighten ≥ Turn adjuster 3 counterclockwise.
WHEEL ALIGNMENT ADJUSTMENT INSP ADJ EC36B000 WHEEL ALIGNMENT ADJUSTMENT 1. Remove: • Lower cowl 2. Place the machine on a level place and hold it up on upright position. 3. Sit 1~2 m (3.3~6.6 ft) behind the machine and look at both sides of the wheels below the rear wheel axle. 4. Turn the handlebar left and right to make the front wheel straight.
FRONT FORK INSPECTION/ FRONT FORK TOP END ADJUSTMENT INSP ADJ 6. Adjust: • Wheel alignment Turn the chain puller adjuster while paying attention to the drive chain slack and make adjustment while moving the rear wheel. NOTE: • Figure C shows that the wheel alignment has been correctly made (b = c and d = e). • After the adjustment, record the difference in the graduation between the left and right chain pullers as it will provide convenience in your future similar adjustment. 7.
FRONT FORK TOP END ADJUSTMENT INSP ADJ • Adjust the front fork top end a. ≠ Front fork top end a: Standard 13 mm (0.51 in) Extent of adjustment Zero~13 mm (Zero~0.51 in) CCAUTION: Never attempt to install the front fork beyond the maximum or minimum setting. W Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability. • Tighten the pinch bolts (handle crown and under bracket). ¶ Pinch bolt (handle crown): 20 Nm (2.
FRONT FORK SPRING PRELOAD ADJUSTMENT INSP ADJ CCAUTION: Tighten the pinch bolts to specified torque. If torqued too much, it may cause the front fork to malfunction. NOTE: Adjust the installation angle of the steering damper stay so that the dimension d is between 3 mm (0.12 in) and 5 mm (0.20 in) when the handlebar is turned fully to the right. 4. Check: • Steering smooth action Turn the handlebar to make sure no parts are being contacted with others. Contact ≥ Repair. 5.
FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT INSP ADJ • STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-out position. a Standard position: 6 clicks in NOTE: • Fully turn out the adjuster and then turn it in. Specify the position in which the first click is heard as the zero position . If a click is heard just when the adjuster is fully turned out, this position is zero. • Preload is 0.5 mm (0.02 in) changed per click of the adjuster.
FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT INSP ADJ • STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. a Standard position: 12 clicks out NOTE: Fully turn in the adjuster and then turn it out. Specify the position in which the first click is heard as the zero position. If a click is heard just when the adjuster is fully turned in, this position is zero.
REAR SHOCK ABSORBER INSPECTION/ SEAT HEIGHT ADJUSTMENT INSP ADJ • STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. a Standard position: 12 clicks out NOTE: Fully turn in the adjuster and then turn it out. Specify the position in which the first click is heard as the zero position. If a click is heard just when the adjuster is fully turned in, this position is zero.
REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT INSP ADJ Seat height adjustment steps: • Remove the cap 1. • Loosen the lock bolt 2 and locknut 3. • Turn the adjuster 4 in or out. ≠ Adjuster set length a: Standard length 27 mm (1.06 in) Extent of adjustment 21~33 mm (0.83~1.30 in) NOTE: If the adjuster set length a is changed, the seat height will be increased or decreased by twice the change. CCAUTION: Never attempt to turn the adjuster beyond the maximum or minimum length.
REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT INSP ADJ ] Spring length (installed) a: Standard length 137 mm (5.39 in) Extent of adjustment 133~142 mm (5.24~5.59 in) NOTE: The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjuster. CCAUTION: Never attempt to turn the adjuster beyond the maximum or minimum setting. 4. Tighten: • Locknut T20 Nm (2.0 mdkg, 14 ftdlb) EC36N040 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1.
REAR SHOCK ABSORBER COMPRESSION DAMPING FORCE ADJUSTMENT INSP ADJ NOTE: Fully turn in the adjuster and then turn it out. Specify the position in which the first click is heard as the zero position. If a click is heard just when the adjuster is fully turned in, this position is zero. CCAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. EC36P040 REAR SHOCK ABSORBER COMPRESSION DAMPING FORCE ADJUSTMENT 1.
INSP ADJ TIRE PRESSURE CHECK/TIRE INSPECTION/ WHEEL INSPECTION EC36Q011 TIRE PRESSURE CHECK 1. Measure: • Tire pressure Out of specification ≥ Adjust. ] Standard tire pressure: Front 200 kPa (2.0 kg/cm2, 29 psi) Rear 200 kPa (2.0 kg/cm2, 29 psi) NOTE: Check the tire while it is cold. 1Air gauge EC36R000 TIRE INSPECTION 1. Inspect: • Tire surfaces Wear/Damage ≥ Replace. a Minimum tire tread depth a: 2 mm (0.08 in) EC36T000 WHEEL INSPECTION 1. Inspect: • Wheel runout Elevate the wheel and turn it.
STEERING HEAD INSPECTION AND ADJUSTMENT INSP ADJ EC36U060 STEERING HEAD INSPECTION AND ADJUSTMENT 1. Remove the steering damper at front fork side. 2. Elevate the front wheel by placing a suitable stand. 3. Check: • Steering stem Grasp the bottom of the forks and gently rock the fork assembly back and forth. Free play ≥ Adjust steering head. 4. Check: • Steering smooth action Turn the handlebar lock to lock. Unsmooth action ≥ Adjust steering ring nut. 5.
STEERING DAMPER ADJUSTMENT INSP ADJ • Tighten the ring nut 3 using ring nut wrench 4. NOTE: Set the torque wrench to the ring nut wrench so that they form a right angle. ª Ring nut wrench: YU-33975/90890-01403 Ring nut (initial tightening): 46 Nm (4.6 m•kg, 33 ft•lb) • Loosen the ring nut one turn. • Retighten the ring nut using the ring nut wrench. U W Avoid over-tightening. Ring nut (final tightening): 1 Nm (0.1 m•kg, 0.7 ft•lb) • Check the steering shaft by turning it lock to lock.
WIRES, CABLES/ COWLING INSTALLATION INSPECTION INSP ADJ ] Extent of adjustment: Maximum Fully turned-in position Minimum Fully turned-out position • STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-out position. a Standard position: 0 click in NOTE: Fully turn out the adjuster and then turn it in. Specify the position in which the first click is heard as the zero position .
FUEL TANK INSTALLATION INSPECTION INSP ADJ EC36e000 FUEL TANK INSTALLATION INSPECTION 1. Inspect: • Looseness in the installed fuel tank Loose ≥ Adjust. 2. Loose the nut 1 and screw in the bolt 2 a half turn. Then fasten the bolt with the nut. Repeat this until tight. CCAUTION: Take care so that the bolt protruding length a is not 29 mm (1.14 in) or over.
LUBRICATION INSP ADJ A Use Yamaha cable lube or equivalent on these areas. B Use SAE 10W30 motor oil or suitable chain lubricants. C Lubricate the following areas with high quality, lightweight lithium-soap base grease. EC36a023 LUBRICATION To ensure smooth operation of all components lubricate your machine during setup, after break-in, and after every race.
ELECTRICAL/SPARK PLUG INSPECTION INSP ADJ EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: • Spark plug 2. 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. NOTE: When the engine runs for many hours at low speeds, the spark plug insulator will become sooty, even if the engine and carburetor are in good operating condition. 3.
IGNITION TIMING CHECK INSP ADJ EC372071 IGNITION TIMING CHECK NOTE: • The right pick-up coil 1 is provided so that ignition timing can be set for both cylinders by adjusting for the left cylinder only. Therefore, do not loosen the screws (right pick-up coil) 2. • When the portion a of the right pick-up coil aligns with the punch mark b on the stator, the right pick-up coil forms an angle of 90˚ with the left pick-up coil, indicating that the ignition timing is the same for both cylinders. 1.
BATTERY INSPECTION INSP ADJ 6. Check: • Ignition timing Punch mark a on rotor should be aligned with punch mark b on stator. Not aligned ≥ Adjust. NOTE: Be sure to use the punch mark “F1”. 7. Adjust: • Ignition timing T Adjustment steps: • Loosen the screws (stator) 1. • Align the punch marks by turning the stator 2. • Tighten the screws (stator). Screw (stator): 7 Nm (0.7 m•kg, 5.8 ft•lb) EC375000 BATTERY INSPECTION W To prevent danger, read the battery label carefully before handling the battery.
RECHARGING BATTERY INSP ADJ EC376000 RECHARGING BATTERY W • Keep the battery away from fire. • When charging the battery, be sure to remove it from the chassis and use the checking lead (supplying parts). • Be sure to use the specific charging current and voltage when charging the battery. • Do not quick charge the battery. • For battery replacement, be sure to use a sealed type specified for the TZ250. NOTE: Battery can be recharged using either an MF battery devoted charger or automobile battery.
RECHARGING BATTERY INSP ADJ [Using the automobile battery] 1. Remove: • Seat • Battery 2. Connect an automobile battery 1 to the battery 2 using the checking lead (supplying parts) 3, and recharge the battery. & Automobile battery (+) lead ≥ Red lead 4 Automobile battery (-) lead ≥ Black lead 5 Charge time: 3 hours Voltage when charged: 12.8V or more (or 12.5V or more) Voltage of the automobile battery for power supply: 12.8~13.8V (maximum 14.
COWLING, INDUCTION GUIDE, SEAT AND FUEL TANK ENG EC400000 ENGINE EC4V0000 COWLING, INDUCTION GUIDE, SEAT AND FUEL TANK T 4 Nm (0.4 mdkg, 2.9 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) Extend of removal: Extend of removal 1 Cowling removal 3 Seat removal Order 2 Induction guide removal 4 Fuel tank removal Part name Q’ty Remarks COWLING, INDUCTION GUIDE, SEAT AND FUEL TANK REMOVAL Turn the fuel cock to “OFF”. Disconnect the fuel hose.
COWLING, INDUCTION GUIDE, SEAT AND FUEL TANK ENG EC4V3000 REMOVAL POINTS EC4U3100 Fuel tank breather hose 1. Disconnect: • Fuel tank breather hose 1 NOTE: Disconnect the fuel tank breather hose with the valve joint 2 remaining on the fuel tank side so as to prevent fuel from spurting out by the tank inner pressure.
ENG EXHAUST PIPE AND SILENCER EC4S0000 EXHAUST PIPE AND SILENCER T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 21 Nm (2.1 mdkg, 15 ftdlb) T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 21 Nm (2.
RADIATOR ENG EC450001 RADIATOR T 2 Nm (0.2 mdkg, 1.4 ftdlb) T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 2 Nm (0.2 mdkg, 1.4 ftdlb) T 7 Nm (0.7 mdkg, 5.1 ftdlb) T 7 Nm (0.7 mdkg, 5.1 ftdlb) Extend of removal: Extend of removal T 2 Nm (0.2 mdkg, 1.4 ftdlb) 1 Radiator removal Order Part name Q’ty RADIATOR REMOVAL Cowling, induction guide and fuel tank Preparation for removal Refer to “COWLING, INDUCTION GUIDE, SEAT AND FUEL TANK” section. Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3.
RADIATOR ENG EC456000 HANDLING NOTE W Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radiator cap by the following procedure: Place a thick rag, like a towel, over the radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape.
RADIATOR ENG 2. Install: • Radiator breather hose 1 • Radiator hose 3 2 T2 Nm (0.2 mdkg, 1.4 ftdlb) • Radiator hose 4 3 T2 Nm (0.2 mdkg, 1.4 ftdlb) • Radiator hose 2 4 T2 Nm (0.2 mdkg, 1.4 ftdlb) • Gasket 5N • Thermo unit 6T11 Nm (1.1 mdkg, 8.0 ftdlb) • Water temperature gauge lead 7 NOTE: Insert the end of the radiator breather hose into the frame. Refer to “CONTROL FUNCTION” section in the CHAPTER 1.
CARBURETOR AND REED VALVE ENG EC460000 CARBURETOR AND REED VALVE T 2 Nm (0.2 mdkg, 1.4 ftdlb) T 2 Nm (0.2 mdkg, 1.4 ftdlb) T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 1 Nm (0.1 mdkg, 0.7 ftdlb) T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 1 Nm (0.1 mdkg, 0.
ENG CARBURETOR AND REED VALVE T 2 Nm (0.2 mdkg, 1.4 ftdlb) T 2 Nm (0.2 mdkg, 1.4 ftdlb) T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 1 Nm (0.1 mdkg, 0.7 ftdlb) T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 1 Nm (0.1 mdkg, 0.
ENG CARBURETOR AND REED VALVE EC468000 CARBURETOR DISASSEMBLY T2 Nm (0.2 mdkg, 1.4 ftdlb) Extend of removal: 1 Carburetor disassembly Extend of removal Order Part name Q’ty 1 1 2 3 4 5 6 7 8 9 0 ¡ ™ £ ¢ ∞ CARBURETOR DISASSEMBLY Mixing chamber top Throttle valve Needle holder Jet needle Starter plunger Float chamber Power jet Float pin Float Valve seat Main jet Main nozzle Pilot jet Pilot air screw Solenoid valve 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4-9 Remarks Refer to “REMOVAL POINTS”.
CARBURETOR AND REED VALVE ENG EC466010 HANDLING NOTE CCAUTION: Do not disassemble the venturi block 1 because it will cause a drop in carburetor performance. EC463000 REMOVAL POINTS EC463110 Throttle valve 1. Remove: • Throttle valve 1 • Ring 2 • Spring (throttle valve) 3 • Mixing chamber top 4 • Throttle cable 5 NOTE: While compressing the spring (throttle valve), disconnect the throttle cable. EC464000 INSPECTION EC464120 Carburetor 1. Inspect: • Carburetor body Contamination ≥ Clean.
CARBURETOR AND REED VALVE ENG EC464200 Needle valve 1. Inspect: • Needle valve 1 • Valve seat 2 Grooved wear a ≥ Replace. Dust b ≥ Clean. NOTE: Always replace the needle valve and valve seat as a set. EC464301 Throttle valve 1. Check: • Free movement Stick ≥ Repair or replace. NOTE: Insert the throttle valve 1 into the carburetor body, and check for free movement. EC464420 Jet needle 1. Inspect: • Jet needle 1 Bends/Wear ≥ Replace. • Clip groove Free play exists/Wear ≥ Replace.
CARBURETOR AND REED VALVE ENG • Hold the fuel level gauge vertically next to the float chamber mating surface. • Measure the fuel level with the fuel level gauge. NOTE: Keep the carburetor and fuel level gauge vertically when measuring the fuel level. • If the fuel level is not within specification, inspect the valve seat and needle valve. • If either is worn, replace them both. • If both are fine, adjust the fuel level by bending the float tab b on the float. • Recheck the fuel level.
CARBURETOR AND REED VALVE ENG EC464900 Induction box 1. Inspect: • Seal 1 Peeled ≥ Stick using the instantaneous adhesive Crack/Wear/Damage ≥ Replace. EC465000 ASSEMBLY AND INSTALLATION EC465180 Reed valve 1. Install: • Reed valve 1 1 • Reed valve 2 2 • Stopper (reed valve) 3 • Screw (reed valve) 4 GT1 Nm (0.1 mdkg, 0.7 ftdlb) NOTE: • Install the reed valve with the reed valve bending as shown. • Note the cut a in the lower corner of the reed and stopper plate.
CARBURETOR AND REED VALVE ENG 3. Install: • Carburetor joint 1 • Induction box 2 • Bolt {carburetor joint [L=25 mm (0.98 in)]} 3 T11 Nm (1.1 mdkg, 8.0 ftdlb) • Bolt {carburetor joint [L=20 mm (0.79 in)]} 4 T11 Nm (1.1 mdkg, 8.0 ftdlb) EC4652E0 Carburetor 1. Install: • Solenoid valve 1 To carburetor 2. 2. Install: • Pilot air screw 1 Ω Note the following installation points: • Screw in the pilot air screw until it is lightly seated. • Back out it by the specified number of turns.
CARBURETOR AND REED VALVE ENG 4. Install: • Needle valve 1 • Float 2 • Float pin 3 • Screw (float pin) 4 NOTE: • After installing the needle valve to the float, install them to the carburetor. • Check the float for smooth movement. 5. Install: • Power jet 1 To float chamber 2. CCAUTION: Do not tighten the power jet too hard, or you may not remove it when checking and replacing it. 6.
CARBURETOR AND REED VALVE ENG 9. Install: • Collar 1 • Jet needle 2 • Spring guide 3 • Spring 4 • Needle holder 5 To throttle valve 6. 10.Install: • Throttle cable 1 • Mixing chamber top 2 • Spring (throttle valve) 3 • Ring 4 • Throttle valve 5 NOTE: • Install the throttle cable (right cylinder) after passing it through the hole a of the induction cap. Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. • While compressing the spring, connect the throttle cable.
CARBURETOR AND REED VALVE ENG EC465370 Carburetor installation 1. Install: • Carburetor 1 NOTE: Install the projection between the carburetor joint slots. 2. Tighten: • Clamp (carburetor joint) 1 T2 Nm (0.2 mdkg, 1.4 ftdlb) 3. Connect: • Solenoid valve lead 1 NOTE: Install the solenoid valve lead (right cylinder) after passing it through the hole a of the induction cap. Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 4. Install: • Induction cap 1 (left cylinder only) 5.
CYLINDER HEAD, CYLINDER AND PISTON ENG EC470000 CYLINDER HEAD, CYLINDER AND PISTON EC478000 CYLINDER HEAD AND CYLINDER T 19 Nm (1.9 mdkg, 13 ftdlb) T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 20 Nm (2.0 mdkg, 14 ftdlb) T 15 Nm (1.5 mdkg, 11 ftdlb) T 7 Nm (0.7 mdkg, 5.
ENG CYLINDER HEAD, CYLINDER AND PISTON EC478100 PISTON AND POWER VALVE T 12 Nm (1.2 mdkg, 8.7 ftdlb) T 9 Nm (0.9 mdkg, 6.5 ftdlb) T 4 Nm (0.4 mdkg, 2.9 ftdlb) T 4 Nm (0.4 mdkg, 2.
CYLINDER HEAD, CYLINDER AND PISTON ENG EC473000 REMOVAL POINTS EC473310 YPVS cable 1. Remove: • Bolt (cable stay) 1 2. Remove: • YPVS cable 1 From the valve pulley 2. NOTE: Remove the YPVS cable together with the cable stay 3. EC473402 Piston and piston ring 1. Remove: • Piston pin clip 1 NOTE: Before removing the piston pin clip, cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase cavity. 2.
CYLINDER HEAD, CYLINDER AND PISTON ENG 3. Remove: • Piston ring 1 NOTE: Take care not to scratch the piston or damage the piston ring by expanding it more than necessary. EC474000 INSPECTION EC474110 Cylinder head 1. Remove: • Carbon deposits Use #400~600 grit wet sandpaper. 2. Inspect: • Cylinder head water jacket Crust of minerals/Rust ≥ Remove. • Cylinder head contact surface Wear/Damage ≥ Replace.
CYLINDER HEAD, CYLINDER AND PISTON ENG 3. Inspect: • Travel distance for cylinder 3,000 km (1,800 miles) or more ≥ Replace. EC474B00 Piston 1. Inspect: • Piston crown Damage and crack due to detonation≥Replace. • Piston pin hole Crack≥ Replace. • Contact with cylinder Excessive scuffing, score a ≥ Use #240~320 grit wet sandpaper in a crisscross manner b. • Heat discoloration≥ Replace. 2. Inspect: • Travel distance for piston 500 km (300 miles) or more≥ Replace.
CYLINDER HEAD, CYLINDER AND PISTON ENG EC474402 Piston pin and small end bearing 1. Inspect: • Piston pin • Small end bearing Signs of heat discoloration ≥ Replace. 2. Measure: • Piston pin outside diameter Use micrometer 1. Out of limit ≥ Replace. ] Piston pin outside diameter: Standard 14.995~15.000 mm (0.5904~0.5906 in) 14.975 mm (0.5896 in) 3. Check: • Free play (when the piston pin 1 is in place in the piston 2) There should be no noticeable for the play.
CYLINDER HEAD, CYLINDER AND PISTON ENG EC474530 Piston ring 1. Install: • Piston ring Into the cylinder. Push the ring with the piston crown. 2. Measure: • End gap Use a thickness gauge 1. Out of limit ≥ Replace. ] Ring end gap (installed): Standard 0.22~0.37 mm (0.009~0.015 in) 0.59 mm (0.023 in) 3. Measure: • Side clearance Use a thickness gauge 1. Out of specification ≥ Replace piston and/or ring. ] Side clearance: Standard Zero~0.06 mm (Zero~0.
CYLINDER HEAD, CYLINDER AND PISTON ENG 2. Check: • Piston mark a Piston mark a (color) A (red) B (orange) C (green) * 3. Combination: Combine the piston and cylinder by the following chart. Cylinder mark Piston mark (color) A A(red) B B(orange) C C (green) ( NOTE: When you purchase a cylinder, you cannot designate a specific one. Choose the piston that matches the above chart. EC474821 Power valve 1. Inspect: • Power valve 1 Wear/Damage ≥ Replace. Carbon deposits ≥ Remove.
CYLINDER HEAD, CYLINDER AND PISTON ENG 2. Install: • Solid bush1 • Oil seal 2 • Plain washer 3 • Circlip 4N • Valve pulley 5 • Screw (valve pulley) 6 T4 Nm (0.4 mdkg, 2.9 ftdlb) To valve shaft 7. NOTE: Apply the lithium soap base grease on the valve shaft and oil seal lip. 3. Lock the pulley holding screw using an appropriate wire around the groove on the valve pulley. 4. Install: • Valve shaft 1 • Valve cover 2 • Screw (valve cover) 3 T4 Nm (0.4 mdkg, 2.
CYLINDER HEAD, CYLINDER AND PISTON ENG 5. Check: • Power valve smooth movement Unsmooth movement ≥ Repair or replace. EC475271 Piston ring and piston 1. Install: • Piston ring 1 NOTE: • Take care not to scratch the piston or damage the piston ring by expanding it more than necessary. • Install the piston ring with its mark “N” upward. • Align the piston ring gap with the pin 2. • After installing the piston ring, check the smooth movement of it. 2.
CYLINDER HEAD, CYLINDER AND PISTON ENG 3. Install: • Piston 1 • Piston pin 2 • Piston pin clip 3N NOTE: • The arrow a on the piston dome must point to exhaust side. • Before installing the piston pin clip, cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase cavity. CCAUTION: • When installing the piston pin clip, use the hand so that it may not be distorted. • Do not allow the clip open ends to meet the piston pin slot b.
CYLINDER HEAD, CYLINDER AND PISTON ENG 4. Install: • O-ring 1N • Dowel pin 2 NOTE: Apply the lithium soap base grease on the Orings. 5. Install: • Cylinder head 1 • Copper washer 2 • Bolt (cylinder head) 3 T11 Nm (1.1 mdkg, 8.0 ftdlb) NOTE: • Apply the lithium soap base grease on the thread and contact surface of the bolt (cylinder head). • Tighten the bolts (cylinder head) in stage, using a crisscross pattern. 6.
CYLINDER HEAD, CYLINDER AND PISTON ENG 8. Install: • Cable stay 1 • Bolt (cable stay) 2 T7 Nm (0.7 mdkg, 5.1 ftdlb) 9. Adjust: • YPVS cable Refer to “YPVS OPEN SIDE CABLE ADJUSTMENT” and “YPVS CLOSE SIDE CABLE ADJUSTMENT” section in the CHAPTER 3. 10.Install: • Spark plug 1 T19 Nm (1.9 mdkg, 13 ftdlb) • Spark plug cap 2 • Radiator hose 3 3 T2 Nm (0.2 mdkg, 1.4 ftdlb) • Radiator hose 4 4 T2 Nm (0.2 mdkg, 1.
CLUTCH ENG EC4A0000 CLUTCH EC4A8000 CLUTCH PLATE AND FRICTION PLATE T 6 Nm (0.6 mdkg, 4.3 ftdlb) T 9 Nm (0.9 mdkg, 6.5 ftdlb) Extend of removal: Extend of removal 1 Clutch plate and friction plate removal Order Preparation for removal 1 Part name Q’ty CLUTCH PLATE AND FRICTION PLATE REMOVAL Lower cowl 1 2 3 4 5 Screw (clutch spring) Clutch spring Pressure plate Friction plate Clutch plate 4-31 Remarks Refer to “COWLING, SEAT AND FUEL TANK” section.
ENG CLUTCH EC4A8200 CLUTCH HOUSING AND PUSH ROD T 75 Nm (7.5 mdkg, 54 ftdlb) Extend of removal: Extend of removal 1 2 1 Clutch housing removal Order 1 2 3 4 5 6 7 8 9 10 2 Push rod removal Part name Q’ty CLUTCH HOUSING AND PUSH ROD REMOVAL Nut (clutch boss) Lock washer Clutch boss Plain washer Clutch housing O-ring Bearing Spacer 1 Ball Push rod 4-32 1 1 1 1 1 1 1 1 1 1 Remarks Use special tool. Refer to “REMOVAL POINTS”.
CLUTCH ENG EC4A3000 REMOVAL POINTS EC483211 Clutch boss 1. Remove: • Nut 1 • Lock washer 2 • Clutch boss 3 NOTE: Straighten the lock washer tab and use the clutch holding tool 4, 5 to hold the clutch boss. B Clutch holding tool: YM-91042 . . . . . . . . . . . . . . . .4 90890-04086 . . . . . . . . . . . . . .5 A For USA and CDN B Except for USA and CDN EC4A4000 INSPECTION EC484100 Clutch housing and boss 1. Inspect: • Clutch housing 1 Cracks/Wear/Damage ≥ Replace.
CLUTCH ENG EC484500 Friction plate 1. Measure: • Friction plate thickness Out of specification ≥ Replace friction plate as a set. Measure at all four points. ] Friction plate thickness: Standard 2.9~3.1 mm (0.114~0.122 in) 2.7 mm (0.106 in) EC484600 Clutch plate 1. Measure: • Clutch plate warpage Out of specification ≥ Replace clutch plate as a set. Use a surface plate 1 and thickness gauge 2. a Warp limit: 0.1 mm (0.004 in) EC4A4301 Push rod 1.
CLUTCH ENG EC4A5000 ASSEMBLY AND INSTALLATION EC4A5213 Clutch 1. Install: • Spacer 1 1 • Bearing 2 NOTE: Apply the transmission oil on the spacer 1 and bearing. 2. Install: • O-ring 1N NOTE: Apply the lithium soap base grease on the Oring. 3. Install: • O-ring 1N To clutch housing 2. NOTE: Apply the lithium soap base grease on the Oring. 4. Install: • Clutch housing 1 5.
CLUTCH ENG 6. Install: • Lock washer 1N • Nut (clutch boss) 2 T75 Nm (7.5 mdkg, 54 ftdlb) NOTE: Use the clutch holding tool 3, 4 to hold the clutch boss. CCAUTION: Align the projections on the lock washer with the holes a in the clutch boss. B Clutch holding tool: YM-91042 . . . . . . . . . . . . . . . .3 90890-04086 . . . . . . . . . . . . . .4 A For USA and CDN B Except for USA and CDN 7. Bend the lock washer 1 tab. 8.
CLUTCH ENG 9. Install: • Push rod 1 • Ball 2 NOTE: Apply the lithium soap base grease on the push rod and ball. 10.Install: • Pressure plate 1 NOTE: Align the arrow marks a on the pressure plate the arrow marks b on the clutch boss. 11.Install: • Clutch spring 1 • Screw (clutch spring) 2 T9 Nm (0.9 mdkg, 6.5 ftdlb) NOTE: Tighten the screws in stages, using a crisscross pattern. 12.Check: • Push lever position Push the push lever 1 upward until it stops.
PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT ENG EC4D0002 PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT EC4D8000 PRIMARY DRIVEN GEAR T 11 Nm (1.1 mdkg, 8.0 ftdlb) Extend of removal: Extend of removal 1 Primary driven gear removal Order Part name Q’ty PRIMARY DRIVEN GEAR REMOVAL Cowling Preparation for removal Refer to “COWLING, INDUCTION GUIDE, SEAT AND FUEL TANK” section. Refer to “CLUTCH” section. Refer to “TRANSMISSION OIL REPLACEMENT” section in the CHAPTER 3.
PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT ENG EC4D8100 PRIMARY DRIVE GEAR AND BALANCER SHAFT T 50 Nm (5.0 mdkg, 36 ftdlb) T55 Nm (5.5 mdkg, 40 ftdlb) T 11 Nm (1.1 mdkg, 8.
PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT ENG EC4D3000 REMOVAL POINTS EC4D3101 Primary drive gear and balancer weight gear 1. Loosen: • Bolt (primary drive gear) 1 NOTE: Place an aluminum plate a between the teeth of the balancer drive gear 2 and balancer weight gear 3. 2. Loosen: • Nut (balancer weight gear) 1 NOTE: Straighten the lock washer 2 tab and place an aluminum plate a between the teeth of the balancer drive gear 3 and balancer weight gear 4. 3.
PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT ENG EC4D4200 Balancer weight gear and balancer drive gear 1. Inspect: • Balancer weight gear 1 • Balancer drive gear 2 Wear/Damage ≥ Replace. EC4D4300 Crankcase cover (right) 1. Inspect: • Contacting surface Scratches ≥ Replace. • Crankcase cover (right) Cracks/Damage ≥ Replace. • Oil seal 1 Wear/Damage ≥ Replace. EC4D4500 Balancer shaft 1. Inspect: • Balancer shaft 1 Bend/Wear/Damage ≥ Replace.
PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT ENG 3. Install: • Balancer weight gear 1 NOTE: Align the punch mark a on the balancer shaft with the hole b of the balancer weight gear. 4. Install: • Balancer drive gear 1 NOTE: Align the punch marks, a (balancer drive gear) with b (crankshaft) and c (balancer drive gear) with d (balancer weight gear) as shown. 5.
PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT ENG 8. Tighten: • Bolt (primary drive gear) 1 T55 Nm (5.5 mdkg, 40 ftdlb) NOTE: Place an aluminum plate a between the teeth of the balancer drive gear 2 and balancer weight gear 3. EC4D5212 Primary driven gear 1. Install: • Primary driven gear 1 • Oil pump drive gear 2 To crankcase cover (right) 3. NOTE: Apply the lithium soap base grease on the oil seal lip. 2.
SHIFT SHAFT ENG EC4F0000 SHIFT SHAFT T 9 Nm (0.9 mdkg, 6.5 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 10 Nm (1.0 mdkg, 7.2 ftdlb) T 22 Nm (2.2 mdkg, 16 ftdlb) T 9 Nm (0.9 mdkg, 6.5 ftdlb) T 16 Nm (1.6 mdkg, 11 ftdlb) T 75 Nm (7.5 mdkg, 54 ftdlb) Extend of removal: Extend of removal T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 14 Nm (1.
SHIFT SHAFT ENG EC4F3000 REMOVAL POINTS EC4F3100 Drive sprocket 1. Remove: • Nut (drive sprocket) 1 • Lock washer 2 NOTE: • Straighten the lock washer tab. • Loosen the nut while applying the rear brake. 2. Remove: • Drive sprocket 1 • Drive chain 2 NOTE: Remove the drive sprocket together with the drive chain. EC4F3201 Transmission housing 1.
SHIFT SHAFT ENG 2. Remove: • Circlip 1 • Plain washer 2 • Stopper lever 3 EC4F4000 INSPECTION EC4B4400 Shift shaft 1. Inspect: • Shift shaft 1 Bend/Damage ≥ Replace. • Spring 2 Broken ≥ Replace. EC4C4100 Shift guide and shift lever assembly 1. Inspect: • Shift guide 1 • Shift lever 2 • Pawl 3 • Pawl pin 4 • Spring 5 Wear/Damage ≥ Replace. EC4B4500 Stopper lever 1. Inspect: • Stopper lever 1 Wear/Damage ≥ Replace. • Torsion spring 2 Broken ≥ Replace.
SHIFT SHAFT ENG 2. Install: • Plain washer 1 • Torsion spring 2 • Stopper lever assembly 3 EC4F5202 Shift guide and shift lever assembly 1. Install: • Spring 1 • Pawl pin 2 • Pawl 3 To shift lever 4. NOTE: • When installing the pawl into the shift lever, make sure the chamfered side a face the pawl pin side. • Apply the transmission oil on the pawl pin. 2. Install: • Shift lever assembly 1 To shift guide 2. 3.
SHIFT SHAFT ENG EC4F5302 Shift shaft 1. Install: • Roller 1 • Torsion spring 2 • Shift shaft 3 NOTE: Apply the transmission oil on the roller and shift shaft. 2. Install: • Plain washer 1 • Circlip 2N To shift shaft 3. NOTE: Be sure the circlip sharp-edged corner a is positioned opposite side to the plain washer. 3. Check: • Shift lever position Checking steps: • Attach the collar (with supplying parts) 2 onto the roller 1. • Check the shift lever position. Gaps a and b are not equal ≥ Adjust. 4.
SHIFT SHAFT ENG EC4F5411 Transmission housing 1. Apply: • Transmission oil On the bearing (crankcase lower) and impeller shaft. 2. Install: • Dowel pin 1 • Transmission housing 2 NOTE: When installing the transmission housing, turn the oil pump driven gear 3 until the key end a of the oil pump gear shaft 4 is in the recess b of the impeller shaft 5. 3. Install: • Bolt {transmission housing [L=40 mm (1.57 in)]} 1 T16 Nm (1.6 mdkg, 11 ftdlb) • Bolt {transmission housing [L=30 mm (1.18 in)]} 2 T16 Nm (1.
SHIFT SHAFT ENG EC4F5510 Drive sprocket 1. Install: • Drive sprocket 1 • Drive chain 2 NOTE: • Install the drive sprocket with its depressed side a facing the engine. • Install the drive sprocket together with the drive chain. 2. Install: • Lock washer 1N • Nut (drive sprocket) 2 T75 Nm (7.5 mdkg, 54 ftdlb) NOTE: Tighten the nut while applying the rear brake. 3. Bend the lock washer tab to lock the nut.
WATER PUMP ENG EC4G0000 WATER PUMP T2 Nm (0.2 mdkg, 1.4 ftdlb) T11 Nm (1.1 mdkg, 8.0 ftdlb) Extend of removal: Extend of removal 1 Impeller shaft removal Order 2 Oil seal removal Part name Q’ty WATER PUMP DISASSEMBLY Cowling Preparation for removal Refer to “COWLING, INDUCTION GUIDE, SEAT AND FUEL TANK” section. Refer to “COOLING WATER REPLACEMENT” section in the CHAPTER 3. Refer to “SHIFT SHAFT” section. Drain the cooling water.
WATER PUMP ENG EC4G3000 REMOVAL POINTS EC4G3210 Oil seal NOTE: It is not necessary to disassemble the water pump, unless there is an abnormality such as excessive change in coolant level, discoloration of coolant, or milky transmission oil. 1. Remove: • Bearing 1 2. Remove: • Oil seal 1 EC4G4000 INSPECTION EC444200 Impeller shaft 1. Inspect: • Impeller shaft 1 Bend/Wear/Damage ≥ Replace. Fur deposits ≥ Clean. EC4H4600 Bearing 1. Inspect: • Bearing 1 Rotate inner race with a finger.
WATER PUMP ENG EC444400 Oil seal 1. Inspect: • Oil seal 1 Wear/Damage ≥ Replace. EC4G5000 ASSEMBLY AND INSTALLATION EC4G5120 Oil seal 1. Install: • Oil seal 1N NOTE: • Apply the lithium soap base grease on the oil seal lip. • Install the oil seal with its manufacture’s marks or numbers facing the crankcase 2. 2. Install: • Bearing 1 NOTE: Install the bearing by pressing its outer race parallel. EC4G5203 Impeller shaft 1.
WATER PUMP ENG 3. Install: • Dowel pin 1 • Gasket (water pump housing cover) 2N 4. Install: • Water pump housing cover 1 • Bolt (water pump housing cover) 2 T11 Nm (1.1 mdkg, 8.0 ftdlb) • Copper washer 3N • Air bleeding bolt (water pump) 4 T11 Nm (1.1 mdkg, 8.0 ftdlb) 5. Install: • Radiator hose 2 1 T2 Nm (0.2 mdkg, 1.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG EC4H0000 TRANSMISSION, SHIFT CAM AND SHIFT FORK T 23 Nm (2.3 mdkg, 17 ftdlb) T 4 Nm (0.4 mdkg, 2.9 ftdlb) T 10 Nm (1.0 mdkg, 7.2 ftdlb) T 10 Nm (1.0 mdkg, 7.2 ftdlb) T 7 Nm (0.7 mdkg, 5.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG T 23 Nm (2.3 mdkg, 17 ftdlb) T 4 Nm (0.4 mdkg, 2.9 ftdlb) T 10 Nm (1.0 mdkg, 7.2 ftdlb) T 10 Nm (1.0 mdkg, 7.2 ftdlb) T 7 Nm (0.7 mdkg, 5.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG EC4H3000 REMOVAL POINTS EC4H3210 Transmission 1. Remove: • Main axle 1 • Drive axle 2 NOTE: • Remove the main axle together with the drive axle from the transmission housing 3. • Remove assembly carefully. Note the position of each part. Pay particular attention to the location and direction of shift forks. EC4H3400 Segment 1.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG EC4H4300 Shift fork groove 1. Measure: • 3rd/4th pinion gear 1 • 5th wheel gear 2 • 6th wheel gear 3 • Shift fork groove a Out of specification ≥ Replace. ] Shift fork groove a: Standard 5.05~5.18 mm (0.199~0.204 in) 5.35 mm (0.211 in) EC4H4400 Thrust clearance 1. Check: • After assembling the transmission, check whether the idle gear turns smoothly without a thrust.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG EC4H4501 Dog clearance NOTE: • It is necessary to adjust the dog clearance when the transmission gear, axle, washer, circlip, bearing or crankcase is replaced. • If there is any shifting trouble, it is necessary to check the shift fork, shift cam, shift lever and gears. But if there are in good condition, the dog clearance should be inspected. 1. Install the transmission, shift cam and shift fork into the transmission housing. 2.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG EC4H4801 Shift fork, shift cam and segment 1. Inspect: • Shift fork 1 Wear/Damage/Scratches ≥ Replace. 2. Inspect: • Shift cam 1 • Segment 2 • Guide bar 3 Bend/Wear/Damage ≥ Replace. 3. Check: • Shift fork movement On its guide bar. Unsmooth operation ≥ Replace shift fork and/or guide bar. NOTE: For a malfunctioning shift fork, replace not only the shift fork itself but the two gears each adjacent to the shift fork.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG 2. Install: • Segment 1 • Bolt (segment) 2 GT23 Nm (2.3 mdkg, 17 ftdlb) NOTE: • When installing the segment onto the shift cam, align the punch mark a with the dowel pin b. • Clamp the shift cam 3 securely in a vise, using soft protecting material 4 to tighten the bolt (segment). EC4H5232 Transmission 1. Install: • 6th pinion gear (22T) 1 • 3rd/4th pinion gear (23T/25T) 2 • 5th pinion gear (27T) 3 • 2nd pinion gear (21T) 4 To main axle 5.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG 3. Install: • Plain washer 1 • Circlip 2N NOTE: • Be sure the circlip sharp-edged corner a is positioned opposite to the plain washer and gear b. • Be sure the circlip end c is positioned at axle spline groove d.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG 4. Install: • Main axle 1 • Drive axle 2 NOTE: • Apply the transmission oil on the main axle and drive axle bearings. • Install the main axle together with the drive axle into the transmission housing 3. 5. Install: • Shift fork 1 1 • Shift fork 2 2 • Shift fork 3 3 NOTE: • Mesh the shift fork #1 with the 5th wheel gear 4 and #3 with the 6th gear 6 on the drive axle. • Mesh the shift fork #2 with the 3rd/4th pinion gear 5 on the main axle. 6.
OIL PUMP ENG EC4J0000 OIL PUMP T8 Nm (0.8 mdkg, 5.8 ftdlb) T7 Nm (0.7 mdkg, 5.1 ftdlb) Extend of removal: Extend of removal 1 Oil pump removal and disassembly Order Preparation for removal 1 Part name Q’ty OIL PUMP REMOVAL Transmission housing Shift shaft and Stopper lever Transmission and shift fork 1 2 3 4 5 6 7 8 9 Strainer Oil pump cover Outer rotor Inner rotor Dowel pin Plain washer [D=ø15 mm (0.59 in)] Plain washer [D=ø22 mm (0.
OIL PUMP ENG EC4J4000 INSPECTION EC4J4100 Oil pump 1. Measure: • Tip clearance Measure the clearance between the inner rotor 1 and outer rotor 2. Out of limit ≥ Replace the inner rotor and outer rotor as a set. a Tip clearance limit: 0.15 mm (0.0059 in) EC4E4310 Strainer 1. Clean: • Strainer 1 Use compressed air. NOTE: • Clean the strainer every 500 km (300 miles). • If a lot of metallic dust in noticed, disassemble the engine and check. EC4J4200 Oil pump gear shaft 1.
OIL PUMP ENG 2. Install: • Oil delivery pipe 1 NOTE: When installing the oil delivery pipe, fit the projection a of the oil delivery pipe into the hole b on the crankcase. 3. Install: • Plain washer [D=ø22 mm (0.87 in)] 1 • Oil pump gear shaft 2 To transmission housing 3. 4. Install: • Plain washer [D=ø15 mm (0.87 in)] 1 • Dowel pin 2 • Inner rotor 3 • Outer rotor 4 To oil pump gear shaft 5. NOTE: • Apply the transmission oil on the inner rotor and outer rotor.
OIL PUMP ENG 6. Install: • Oil pump cover 1 • Plain washer 2 • Bolt (oil pump cover) 3 T8 Nm (0.8 mdkg, 5.8 ftdlb) NOTE: While turning the oil pump gear shaft, install the oil pump cover. 7. Install: • Strainer 1 • Screw (strainer) 2 T7 Nm (0.7 mdkg, 5.1 ftdlb) NOTE: Strainer is installed with the mesh a facing outward.
CDI MAGNETO ENG EC4L0000 CDI MAGNETO T 7 Nm (0.7 mdkg, 5.1 ftdlb) T 53 Nm (5.3 mdkg, 38 ftdlb) Extend of removal: Extend of removal 1 CDI magneto removal Order Part name Q’ty CDI MAGNETO REMOVAL Cowling and fuel tank Preparation for removal Remarks Refer to “COWLING, INDUCTION GUIDE, SEAT AND FUEL TANK” section. Disconnect the CDI magneto lead. 1 1 2 3 4 Nut (rotor) Rotor Stator Woodruff key 1 1 1 1 4-68 Use special tool. Refer to “REMOVAL POINTS”.
CDI MAGNETO ENG EC4L3000 REMOVAL POINTS EC4L3102 Rotor 1. Remove: • Nut (rotor) 1 • Plain washer 2 Use the rotor holding tool 3. A Rotor holding tool: YU-1235/90890-01235 A 2. Remove: • Rotor 1 Use the flywheel puller 2. Flywheel puller: YM-1189/90890-01189 NOTE: When installing the flywheel puller, turn it counterclockwise. EC4L4000 INSPECTION EC4L4101 CDI magneto 1. Inspect: • Rotor inner surface a • Stator outer surface b Damage ≥ Inspect the crankshaft runout and crankshaft bearing.
CDI MAGNETO ENG 2. Install: • Woodruff key 1 • Rotor 2 NOTE: • Clean the tapered portions of the crankshaft and rotor. • When installing the woodruff key, make sure that its flat surface a is in parallel with the crankshaft center line b. • When installing the rotor, align the keyway c of the rotor with the woodruff key. 3. Install: • Plain washer 1 • Nut (rotor) 2 T53 Nm (5.3 mdkg, 38 ftdlb) Use the rotor holding tool 3. A Rotor holding tool: YU-1235/90890-01235 a 4.
ENGINE REMOVAL ENG EC4M0000 ENGINE REMOVAL T 30 Nm (3.0 mdkg, 22 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) T11 Nm (1.1 mdkg, 8.0 ftdlb) T 23 Nm (2.3 mdkg, 17 ftdlb) T11 Nm (1.1 mdkg, 8.0 ftdlb) T 30 Nm (3.0 mdkg, 22 ftdlb) T 23 Nm (2.3 mdkg, 17 ftdlb) Extend of removal Preparation for removal Order Part name Q’ty ENGINE REMOVAL Hold the machine by placing the suitable stand.
ENG ENGINE REMOVAL T 30 Nm (3.0 mdkg, 22 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) T11 Nm (1.1 mdkg, 8.0 ftdlb) T 23 Nm (2.3 mdkg, 17 ftdlb) T11 Nm (1.1 mdkg, 8.0 ftdlb) T 30 Nm (3.0 mdkg, 22 ftdlb) T 23 Nm (2.3 mdkg, 17 ftdlb) Extend of removal: 1 Engine removal Extend of removal Order Part name Q’ty 1 1 2 3 4 5 6 Pinch bolt (engine mounting collar) Nut (engine mounting bolt) Engine mounting adjust bolt Engine mounting bolt Engine Engine bracket 2 4 2 4 1 2 4-72 Remarks Only loosening.
ENGINE REMOVAL ENG EC4M6000 HANDLING NOTE When the frame alone is stored, insert the engine mounting collars 1 into the brackets and tighten them with the pinch bolts 2 to 6 Nm (0.6 m•kg, 4.3 ft•lb) in order to prevent the brackets a from damage. EC4M3000 REMOVAL POINTS EC4M3331 Engine removal 1. Loosen: • Engine mounting adjust bolt 1 NOTE: Use the adjust bolt wrench 2 to loosen the engine mounting adjust bolt. 2.
ENGINE REMOVAL ENG 2. Install: • Engine 1 NOTE: Install the engine by raising it into the frame with a jack 2. 3. Install: • Engine mounting bolt (upper) 1 • Engine mounting bolt (lower) 2 4. Tighten: • Engine mounting adjust bolt 1 T8 Nm (0.8 mdkg, 5.8 ftdlb) NOTE: • Use the adjust bolt wrench 2 to tighten the engine mounting adjust bolts. • Tighten the adjust bolts to specified torque alternately two times. 5. Install: • Nut (engine mounting bolt) (upper) 1 T30 Nm (3.
ENGINE REMOVAL ENG 6. Install: • Engine mounting collar (left) 1 • Engine mounting bolt (left) 2 • Engine mounting nut (left) 3 T30 Nm (3.0 mdkg, 22 ftdlb) 7. Tighten: • Bolt (engine bracket) (left) 4 T23 Nm (2.3 mdkg, 17 ftdlb) 8. Tighten: • Pinch bolt (engine mounting collar) (left) 5 T11 Nm (1.1 mdkg, 8.0 ftdlb) 9. Install: • Engine mounting collar (right) 1 • Engine mounting bolt (right) 2 • Engine mounting nut (right) 3 T30 Nm (3.0 mdkg, 22 ftdlb) 10.
CRANKCASE AND CRANKSHAFT ENG EC4N0000 CRANKCASE AND CRANKSHAFT T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) T 7 Nm (0.7 mdkg, 5.1 ftdlb) T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 26 Nm (2.6 mdkg, 19 ftdlb) T 50 Nm (5.0 mdkg, 36 ftdlb) Extend of removal Preparation for removal Order Part name Q’ty CRANKCASE AND CRANK SHAFT REMOVAL Engine Reed valve Piston Primary drive gear Rotor and stator Engine bracket 4-76 Remarks Refer to “ENGINE REMOVAL” section.
CRANKCASE AND CRANKSHAFT T 11 Nm (1.1 mdkg, 8.0 ftdlb) ENG T 8 Nm (0.8 mdkg, 5.8 ftdlb) T 7 Nm (0.7 mdkg, 5.1 ftdlb) T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 26 Nm (2.6 mdkg, 19 ftdlb) T 50 Nm (5.0 mdkg, 36 ftdlb) Extend of removal: Extend of removal 1 Crankcase separation 3 Oil seal removal Order 1 2 1 2 3 3 4 4 5 6 7 8 9 10 2 Crankshaft removal 4 Push lever axle removal Part name Q’ty Bolt [crankcase (M6)] [L=30 mm (1.18 in)] Bolt [crankcase (M6)] [L=35 mm (1.
CRANKCASE AND CRANKSHAFT ENG EC4N3000 REMOVAL POINTS EC4N3230 Crankcase 1. Remove: • Bolt [crankcase (M6)] 1 • Bolt [crankcase (M8)] 2 NOTE: • The M6 size bolts should be removed first. • Loosen the bolts from the outer sides inward. 2. Remove: • Crankcase (upper) 1 From crankcase (lower) 2. CCAUTION: 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.
CRANKCASE AND CRANKSHAFT ENG 2. Inspect: • Oil seal 1 Wear/Damage ≥ Replace. 3. Measure: • Runout limit a • Small end free play limit b • Connecting rod big end side clearance c • Crank width (crank pin side) d Out of specification ≥ Replace. Use the dial gauge and thickness gauge. A Dial gauge: YU-3097/90890-01252 Runout limit Small end free play Side clearance Crank width Standard 0.03 mm (0.0012 in) 0.8~1.0 mm (0.031~0.039 in) 0.45~0.95 mm (0.018~0.037 in) 49.975~50.025 mm (1.968~1.
CRANKCASE AND CRANKSHAFT ENG 2. Install: • Circlip 1 To crankcase (lower) 2. 3. Install: • Crankshaft 1 To crankcase (lower) 2. NOTE: • When installing the crankshaft into the crankcase (lower), apply the transmission oil on the oil seal 3 outer circumference. • Align the bearing knock pin with the pin slot a in the crankcase (lower) and the projection of oil seal with the groove b in the crankcase (lower). • After installing the crankshaft, push the oil seal to the crankcase (lower). 4.
CRANKCASE AND CRANKSHAFT ENG 6. Install: • Crankcase (upper) 1 To crankcase (lower). NOTE: After installation, tap the crankcase (upper) with a soft hammar to settle it. 7. Tighten: • Bolt [crankcase (M8)] 1~6 • Bolt [crankcase (M6)] 7~∞ CCAUTION: The M6 bolt comes in two lengths. Use the correct one for installation. L=30 mm (1.18 in) (green) 7 0 ¡ £ ¢ ∞ Mark $:L=35 mm (1.38 in) (silver) 8 9 ™ NOTE: Tighten all bolts in 2 steps as follows and be sure to tighten in numbered order as shown.
CRANKCASE AND CRANKSHAFT ENG EC4A5101 Push lever axle 1. Install: • Seat plate 1 • Torsion spring 2 • Push lever axle 3 NOTE: Apply the lithium soap base grease on the push lever axle, oil seal lip and bearing. 2. Install: • Bolt (seat plate) 1 T7 Nm (0.7 mdkg, 5.1 ftdlb) NOTE: Fit the seat plate 2 in the groove a of the push lever axle 3 and tighten the bolt (seat plate).
CHAS FRONT WHEEL AND REAR WHEEL EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL T 35 Nm (3.5 mdkg, 25 ftdlb) T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 35 Nm (3.5 mdkg, 25 ftdlb) T 80 Nm (8.0 mdkg, 58 ftdlb) T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 20 Nm (2.0 mdkg, 14 ftdlb) 5 T 20 Nm (2.0 mdkg, 14 ftdlb) Extend of removal: Extend of removal 1 Front wheel removal 3 Brake disc removal Order Part name Q’ty FRONT WHEEL REMOVAL Hold the machine by placing the suitable stand.
FRONT WHEEL AND REAR WHEEL CHAS EC598100 REAR WHEEL T 16 Nm (1.6 mdkg, 11 ftdlb) T 80 Nm (8.0 mdkg, 58 ftdlb) T 2 Nm (0.2 mdkg, 1.4 ftdlb) T 23 Nm (2.3 mdkg, 17 ftdlb) T 32 Nm (3.2 mdkg, 23 ftdlb) T 16 Nm (1.6 mdkg, 11 ftdlb) 5 T 2 Nm (0.2 mdkg, 1.4 ftdlb) Extend of removal: Extend of removal 1 Rear wheel removal 3 Brake disc removal Order Part name Q’ty REAR WHEEL REMOVAL Hold the machine by placing the suitable stand.
FRONT WHEEL AND REAR WHEEL CHAS EC593000 REMOVAL POINTS EC523101 Rear wheel 1. Remove: • Wheel 1 NOTE: Push the wheel forward and remove the drive chain 2. EC513300 Collar 1. Remove: • Collar 1 Knock out of wheel on inside. NOTE: Knock the collar out of the wheel gradually not to deform it. EC513201 Wheel bearing (if necessary) 1. Remove: • Bearing 1 NOTE: Remove the bearing using a general bearing puller 2. EC594000 INSPECTION EC514110 Wheel 1. Measure: • Wheel runout Out of limit ≥ Replace.
FRONT WHEEL AND REAR WHEEL CHAS EC514200 Wheel axle 1. Measure: • Wheel axle bends Out of specification ≥ Replace. Use the dial gauge 1. a Wheel axle bending limit: 0.25 mm (0.010 in) NOTE: The bending value is shown by one half of the dial gauge reading. W Do not attempt to straighten a bent axle. EC594100 Brake disc 1. Measure: • Brake disc deflection (only rear brake disc) Use the dial gauge 1. Out of specification ≥ Inspect wheel runout.
FRONT WHEEL AND REAR WHEEL CHAS EC524100 Clutch hub 1. Inspect: • Bearing 1 Rotate inner race with a finger. Rough spot/Seizure ≥ Replace. EC594300 Clucth hub clearance 1. Inspect: • Clucth hub clearance a Out of specification ≥ Adjust by adding the supplyed shim [0.3 mm (0.012 in)]. a Clucth hub clearance: Zero~0.3 mm (Zero~0.012 in) NOTE: • When inspecting the clutch hub clearance, measure it as it is assembled to the body at specified torque.
FRONT WHEEL AND REAR WHEEL CHAS 2. Install: • Brake disc 1 • Bolt (brake disc) 2 GT20 Nm (2.0 mdkg, 14 ftdlb) NOTE: Tighten the bolts in stage, using a crisscross pattern. 3. Install: • Collar 1 NOTE: If the collar is hard to install, apply the lithium soap base grease on the collar and press it in. 4. Install: • Wheel 1 • Caliper 2 • Bolt (caliper) T35 Nm (3.5 mdkg, 25 ftdlb) NOTE: Before installing the wheel axle, install the caliper. 5.
FRONT WHEEL AND REAR WHEEL CHAS 7. Tighten: • Bolt (axle holder) 1 T11 Nm (1.1 mdkg, 8.0 ftdlb) EC5251C0 Rear wheel 1. Install: • Fitting plate (right) 1 • Bearing (right) 2 • Spacer 3 • Fitting plate (left) 4 • Bearing (left) 5 NOTE: • Apply the lithium soap base grease on the bearing when installing. • Use a socket that matches the outside diameter of the race of the bearing. • Right side of bearing shall be installed first. CCAUTION: Do not strike the inner race of the bearing.
FRONT WHEEL AND REAR WHEEL CHAS 4. Install: • Sprocket damper 1 • Nut (sprocket damper) 2 T32 Nm (3.2 mdkg, 23 ftdlb) To driven sprocket 3. NOTE: Make sure that the nut is on the side of the sprocket bearing the manufacturer’s mark a. 5. Install: • Driven sprocket 1 To wheel. NOTE: Apply the lithium soap base grease on the sprocket damper. 6. Install: • Shim 1 • Clutch hub 2 • Collar 3 NOTE: Apply the lithium soap base grease on the shim and clutch hub outer circumference. 7.
FRONT WHEEL AND REAR WHEEL CHAS 9. Install: • Wheel axle 1 NOTE: • Apply the lithium soap base grease on the wheel axle. • Insert the wheel axle from left side. 10.Install: • Plain washer 1 • Nut (wheel axle) 2 NOTE: • Apply the lithium soap base grease on the wheel axle thread. • Temporarily tighten the nut (wheel axle) at this point. a 11.Adjust: • Drive chain slack a Drive chain slack: 40~50 mm (1.6~2.0 in) Refer to “DRIVE CHAIN SLACK ADJUSTMENT” section in the CHAPTER 3. 12.
FRONT BRAKE AND REAR BRAKE CHAS EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE T 1 Nm (0.1 mdkg, 0.7 ftdlb) T 5 Nm (0.5 mdkg, 3.6 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) T 6 Nm (0.6 mdkg, 4.3 ftdlb) T 30 Nm (3.0 mdkg, 22 ftdlb) T 14 Nm (1.4 mdkg, 10 ftdlb) T 14 Nm (1.4 mdkg, 10 ftdlb) T 26 Nm (2.6 mdkg, 19 ftdlb) T 26 Nm (2.6 mdkg, 19 ftdlb) T 35 Nm (3.5 mdkg, 25 ftdlb) T 18 Nm (1.8 mdkg, 13 ftdlb) T 6 Nm (0.6 mdkg, 4.3 ftdlb) T 35 Nm (3.
FRONT BRAKE AND REAR BRAKE CHAS EC5A8100 REAR BRAKE T 7 Nm (0.7 mdkg, 5.1 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) T 14 Nm (1.4 mdkg, 10 ftdlb) T 26 Nm (2.6 mdkg, 19 ftdlb) T 23 Nm (2.3 mdkg, 17 ftdlb) T 30 Nm (3.0 mdkg, 22 ftdlb) T 2 Nm (0.2 mdkg, 1.4 ftdlb) T 12 Nm (1.2 mdkg, 8.7 ftdlb) T 18 Nm (1.8 mdkg, 13 ftdlb) T 6 Nm (0.6 mdkg, 4.3 ftdlb) T 20 Nm (2.
FRONT BRAKE AND REAR BRAKE CHAS EC5A8200 CALIPER DISASSEMBLY A T 6 Nm (0.6 mdkg, 4.3 ftdlb) T 18 Nm (1.8 mdkg, 13 ftdlb) B T 6 Nm (0.6 mdkg, 4.3 ftdlb) T 18 Nm (1.8 mdkg, 13 ftdlb) A Front B Rear Extend of removal: Extend of removal 1 2 1 Front caliper disassembly Order 1 2 3 4 5 6 7 2 Rear caliper disassembly Part name Q’ty CALIPER DISASSEMBLY Cotter pin Pad pin Pad support Brake pad Caliper piston Dust seal Piston seal 5-12 A 1ea. 1ea. 1ea. 2ea. 4ea. 4ea. 4ea.
CHAS FRONT BRAKE AND REAR BRAKE EC5A8300 MASTER CYLINDER DISASSEMBLY A T 6 Nm (0.6 mdkg, 4.3 ftdlb) B A Front B Rear Extend of removal: Extend of removal 1 2 T 2 Nm (0.2 mdkg, 1.
FRONT BRAKE AND REAR BRAKE CHAS EC536000 HANDLING NOTE W The brake components of this machine are suit for closed circuit use only. Never use on any public road. EC5A3000 REMOVAL POINTS EC5A3200 Brake fluid 1. Remove: • Reservoir tank cap 1 NOTE: Do not remove the diaphragm. A Front B Rear 2. Connect the transparent hose 2 to the bleed screw 1 and place a suitable container under its end. A Front B Rear 3.
FRONT BRAKE AND REAR BRAKE CHAS EC533301 Caliper piston 1. Remove: • Caliper piston Use compressed air and proceed carefully. W • Cover piston with rag and use extreme caution when expelling piston from cylinder. • Never attempt to pry out piston. Caliper piston removal steps: • Insert a piece of rag into the caliper to lock one caliper. • Carefully force the piston out of the caliper cylinder with compressed air. A Front B Rear EC543411 Piston seal kit 1.
FRONT BRAKE AND REAR BRAKE CHAS EC5A4000 INSPECTION EC534112 Master cylinder 1. Inspect: • Master cylinder inner surface a Wear/Scratches ≥ Replace master cylinder assembly. Stains ≥ Clean. W Use only new brake fluid. A Front B Rear 2. Inspect: • Diaphragm 1 Crack/Damage ≥ Replace. A Front B Rear 3. Inspect: • Master cylinder piston 1 • Master cylinder cup 2 Wear/Damage/Score marks ≥ Replace master cylinder kit. A Front B Rear EC534214 Caliper 1.
FRONT BRAKE AND REAR BRAKE CHAS 2. Inspect: • Caliper piston 1 Wear/Score marks ≥ Replace caliper piston assembly. W Replace the piston seals and dust seals 2 whenever a caliper is disassembled. EC534301 Brake hose 1. Inspect: • Brake hose 1 Crack/Damage ≥ Replace. EC5A5000 ASSEMBLY AND INSTALLATION W • All internal parts should be cleaned in new brake fluid only. • Internal parts should be lubricated with brake fluid when installed.
FRONT BRAKE AND REAR BRAKE CHAS 3. Install: • Caliper piston 1 NOTE: Apply the brake fluid on the piston wall. CCAUTION: • Install the piston with its shallow depressed side a facing the caliper. • Never force to insert. A Front B Rear EC535241 Front caliper 1. Install: • Brake pad 1 • Pad support 2 • Pad pin 3 • Cotter pin 4N NOTE: Temporarily tighten the pad pin at this point. 2. Install: • Caliper 1 • Bolt (caliper) 2 T35 Nm (3.5 mdkg, 25 ftdlb) 3. Tighten: T18 Nm (1.
FRONT BRAKE AND REAR BRAKE CHAS 2. Install: • Caliper 1 • Bolt (caliper) 2 T23 Nm (2.3 mdkg, 17 ftdlb) 3. Tighten: T18 Nm (1.8 mdkg, 13 ftdlb) • Pad pin 3 EC5A5230 Master cylinder kit 1. Clean: • Master cylinder • Master cylinder kit Clean them with brake fluid. 2. Install: • Master cylinder cup (primary) 1 • Master cylinder cup (secondary) 2 To master cylinder piston 3. NOTE: Apply the brake fluid on the master cylinder cup. W After installing, cylinder cup should be installed as shown direction.
FRONT BRAKE AND REAR BRAKE CHAS 4. Install: • Spring guide 1 • Master cylinder kit 2 • Circlip 3 • Master cylinder boot 4 To master cylinder 5. NOTE: • Apply the brake fluid on the master cylinder kit. • Install the spring guide with the projection a aligning with the master cylinder hole b. • Apply the lithium soap base grease on the tip c of the push rod. • When installing the circlip, use a long nose circlip pliers. A Front B Rear EC545270 Rear master cylinder 1.
FRONT BRAKE AND REAR BRAKE CHAS EC5A5A00 Front brake hose and master cylinder 1. Install: • Copper washer 1N • Brake hose 2 • Union bolt 3 W Always use new copper washers. NOTE: • Position the brake hoses with their paint marks a downward. • Temporarily tighten the union bolt. 2. Install: • Master cylinder 1 • Master cylinder bracket 2 • Bolt (master cylinder bracket) 3 NOTE: • Install the bracket so that the arrow mark a face upward. • Temporarily tighten the bolt (master cylinder bracket).
FRONT BRAKE AND REAR BRAKE CHAS 4. Install: • Copper washer 1N T26 Nm (2.6 mdkg, 19 ftdlb) • Adapter 2 • Brake hose 3 T14 Nm (1.4 mdkg, 10 ftdlb) W Always use a new copper washer. NOTE: When turning the adapter over the brake hose, hold the brake hose so that it may not be twisted. 5. Install: • Reservoir tank 1 • Bolt (reservoir tank) 2 T5 Nm (0.5 mdkg, 3.6 ftdlb) • Reservoir hose 3 6. Install: • Brake lever 1 • Bolt (brake lever) 2 T1 Nm (0.1 mdkg, 0.7 ftdlb) • Nut (brake lever) 3 T6 Nm (0.
FRONT BRAKE AND REAR BRAKE CHAS EC545451 Rear brake hose 1. Install: • Copper washer 1N • Brake hose 2 • Union bolt 3 T30 Nm (3.0 mdkg, 22 ftdlb) W Always use new copper washers. CCAUTION: When installing the brake hose to the master cylinder, lightly touch the brake pipe a with the projection b on the master cylinder. 2. Install: • Copper washer 1N T26 Nm (2.6 mdkg, 19 ftdlb) • Adapter 2 • Brake hose 3 T14 Nm (1.4 mdkg, 10 ftdlb) W Always use a new copper washer.
FRONT BRAKE AND REAR BRAKE CHAS EC5A5610 Brake fluid 1. Fill: • Brake fluid Until the fluid level reaches “LOWER” level line a. 0 Recommended brake fluid: DOT #4 W • Use only the designated quality brake fluid: otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid; mixing fluids may result in a harmful chemical reaction and lead to poor performance. • Be careful that water does not enter the master cylinder when refilling.
FRONT BRAKE AND REAR BRAKE CHAS 4. Install: • Diaphragm • Reservoir tank cap 1 CCAUTION: After installation, while pulling the lever in or pushing down on the pedal, check whether there is any brake fluid leaking where the union bolts are installed respectively at the master cylinder and caliper.
FRONT FORK CHAS EC550000 FRONT FORK T 7 Nm (0.7 mdkg, 5.1 ftdlb) T 20 Nm (2.0 mdkg, 14 ftdlb) T 10 Nm (1.0 mdkg, 7.2 ftdlb) T 23 Nm (2.3 mdkg, 17 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) Extend of removal: Extend of removal 1 Front fork removal Order Part name Q’ty FRONT FORK REMOVAL Hold the machine by placing the suitable stand. Cowling Induction guide (left cylinder) Preparation for removal W Support the machine securely so there is no danger of it falling over.
FRONT FORK CHAS EC558000 FRONT FORK DISASSEMBLY T 23 Nm (2.3 mdkg, 17 ftdlb) T 29 Nm (2.9 mdkg, 21 ftdlb) T 40 Nm (4.0 mdkg, 29 ftdlb) Extend of removal: Extend of removal 1 2 1 Oil seal removal 2 Damper rod removal Order Part name Q’ty 1 FRONT FORK DISASSEMBLY Cap bolt 1 2 3 4 5 6 7 8 9 0 Spacer Spacer guide Fork spring Inner tube Stopper ring Oil seal Oil seal washer Bolt (damper rod) Damper rod 1 1 1 1 1 1 1 1 1 5-27 Remarks Use special tool. Refer to “REMOVAL POINTS”.
FRONT FORK CHAS EC556010 HANDLING NOTE NOTE: • With the 97 or later models, the dampar rod diameter is 12.5 mm (0.49 in). If the dimension a of your dampar rod holders is 12 mm (0.47 in), drill it to expand its diameter to 14 mm (0.55 in). • The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers.
FRONT FORK CHAS 3. Remove: • Cap bolt 1 NOTE: • While pressing down the spacer 3 with the fork spring compressor 2, set the rod holder 5 between the locknut 4 and spacer. • Hold the locknut and remove the cap bolt by turning the spring preload adjuster 6. C Fork spring compressor: YM-1441/90890-01441 Rod holder: YM-1434/90890-01434 EC553212 Oil seal 1. Remove: • Inner tube 1 Pull out the inner tube from the outer tube 2. 2. Remove: • Stopper ring 1 Using slotted-head screwdriver. 3.
FRONT FORK CHAS EC553322 Damper rod 1. Remove: • Locknut 1 2. Remove: • Bolt (damper rod) 1 • Damper rod 2 NOTE: A Use a damper rod holder 3 to lock the damper rod. Damper rod holder: YM-1425/90890-01425 EC554000 INSPECTION EC554100 Damper rod 1. Inspect: • Damper rod 1 Bend/Damage ≥ Replace damper rod. CCAUTION: The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material.
FRONT FORK CHAS EC554502 Inner tube 1. Inspect: • Inner tube surface a Score marks ≥ Repair or replace. Use #1,000 grit wet sandpaper. Damaged oil lock piece ≥ Replace. • Inner tube bends Out of specification ≥ Replace. Use the dial gauge 1. a Inner tube bending limit: 0.2 mm (0.008 in) NOTE: The bending value is shown by one half of the dial gauge reading. W Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube. EC554611 Outer tube 1.
FRONT FORK CHAS EC555000 ASSEMBLY AND INSTALLATION EC555191 Front fork assembly 1. Wash the all parts in a clear solvent. 2. Install: • Damper rod 1 To inner tube 2. CCAUTION: To install the damper rod into the inner tube, hold the inner tube aslant. If the inner tube is held vertically, the damper rod may fall into it, damaging the valve inside. 3. Install: • Copper washer 1N • Bolt (damper rod) 2 To inner tube 3. 4. Tighten: • Bolt (damper rod) 1 GT40 Nm (4.
FRONT FORK CHAS 6. Install: • Stopper ring 1 • Oil seal 2N • Oil seal washer 3 To inner tube 4. NOTE: • Apply the fork oil on the inner tube. • When installing the oil seal, use vinyl seat a with fork oil applied to protect the oil seal lip. • Install the oil seal with its manufacture’s marks or number facing the axle holder side. 7. Install: • Inner tube 1 To outer tube 2.
FRONT FORK CHAS 10.Install: • Stopper ring 1 NOTE: Fit the stopper ring correctly in the groove in the outer tube. 11.Check: • Inner tube smooth movement Tightness/Binding/Rough spots ≥ Repeat the steps 2 to 10. 12.Compress the front fork fully. 13.Fill: • Front fork oil Until outer tube top surface with recommended fork oil 1. 0 Recommended oil: Suspension oil “01” CCAUTION: • Be sure to use recommended fork oil.
FRONT FORK CHAS 15.Fill: • Front fork oil Until outer tube top surface with recommended fork oil once more. 16.After filling, pump the outer tube 1 slowly up and down (about 60 mm (2.4 in) stroke) to distribute the fork oil once more. NOTE: Be careful not to excessive full stroke. A stroke of 60 mm (2.4 in) or more will cause air to enter. In this case, repeat the steps 13 to 16. 17.
FRONT FORK CHAS 19.Install: • Fork spring 1 • Spacer guide 2 • Spacer 3 NOTE: Install the fork spring with its smaller dia. portion upward. 20.Attach: • Rod puller 1 • Rod puller attachment 2 • Fork spring compressor 3 • Rod holder 4 NOTE: • Pull up the damper rod with the rod puller and rod puller attachment. • While pressing down the spacer 5 with the fork spring compressor, set the rod holder between the locknut 6 and spacer.
FRONT FORK CHAS NOTE: Record the set position of the adjuster (the amount of turning in the adjuster to the fully turned in position) before adjusting it. CCAUTION: If the rebound damping adjuster position is out of specification, proper damping force cannot be obtained. 23.Install: • Push rod 1 • Cap bolt 2 NOTE: Turn in the cap bolt fully by holding the spring preload adjuster 4 with your hand until the rebound damping adjuster 3 hits the push rod tip. 24.
FRONT FORK CHAS 26.Install: • Cap bolt 1 To outer tube. NOTE: Temporarily tighten the cap bolt. EC555290 Installation 1. Install: • Front fork 1 • Steering damper stay 2 (right side only) • Handlebar 3 NOTE: • Temporarily tighten the pinch bolt (under bracket). • Do not tighten the pinch bolts (handle crown, steering damper stay and handlebar) yet. 2. Tighten: • Cap bolt 1 T23 Nm (2.3 mdkg, 17 ftdlb) 3.
FRONT FORK CHAS 4. Tighten: • Pinch bolt (handle crown) 1 T20 Nm (2.0 mdkg, 14 ftdlb) • Pinch bolt (under bracket) 2 T23 Nm (2.3 mdkg, 17 ftdlb) • Pinch bolt (handlebar) 3 T7 Nm (0.7 mdkg, 5.1 ftdlb) • Pinch bolt (steering damper stay) 4 (right T10 Nm (1.0 mdkg, 7.2 ftdlb) side only) Refer to “FRONT FORK TOP END ADJUSTMENT” in the CHAPTER 3. 5. Check: • Steering smooth action Turn the handlebar to make sure no parts are being contacted with others. Contact ≥ Repair. 6.
HANDLEBAR CHAS EC5B0000 HANDLEBAR T 7 Nm (0.7 mdkg, 5.1 ftdlb) T 7 Nm (0.7 mdkg, 5.1 ftdlb) T 2 Nm (0.2 mdkg, 1.4 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) Extend of removal: Extend of removal 1 Handlebar removal Order 2 Throttle disassembly Part name Q’ty HANDLEBAR REMOVAL Cowling Induction guide (left cylinder) Preparation for removal Refer to “COWLING, INDUCTION GUIDE, SEAT AND FUEL TANK” section in the CHAPTER 4. Refer to “STEERING” section.
HANDLEBAR CHAS EC5B3000 REMOVAL POINTS EC5B3200 Grip 1. Remove: • Grip 1 NOTE: Blow in air between the handlebar or tube guide and the grip. Then remove the grip which has become loose. EC5B4000 INSPECTION EC5B4100 Handlebar 1. Inspect: • Handlebar 1 Bends/Cracks /Damage ≥ Replace. W Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar. EC5B5000 ASSEMBLY AND INSTALLATION EC5B5110 Throttle assembly 1.
HANDLEBAR CHAS 2. Install: • Throttle cable [carburetor (left cylinder)] 1 • Throttle cable [carburetor (right cylinder)] 2 To grip cap (lower) 3. NOTE: Install the throttle cable [carburetor (left cylinder)] in the grip side slit a in the grip cap (lower). 3. Install: • Throttle 1 NOTE: Apply the lithium soap base grease on the throttle grip sliding surface. 4. Install: • Throttle cable [carburetor (left cylinder)] 1 • Throttle cable [carburetor (right cylinder)] 2 To tube guide 3.
HANDLEBAR CHAS 7. Install: • Master cylinder 1 • Master cylinder bracket 2 • Bolt (master cylinder bracket) 3 T8 Nm (0.8 mdkg, 5.8 ftdlb) NOTE: Install the bracket so that the arrow mark a faces upward. 8. Install: • Starter lever 1 • Screw (starter lever) 2 NOTE: The starter lever should be installed according to the dimension shown. 9. Install: • Starter cable [carburetor (left cylinder)] 1 • Starter cable [carburetor (right cylinder)] 2 To starter lever 3.
HANDLEBAR CHAS 11.Install: • Main switch 1 • Main switch holder 2 • Screw (main switch holder) 3 T2 Nm (0.2 mdkg, 1.4 ftdlb) • Clutch lever holder 4 • Bolt (clutch lever holder) 5 T5 Nm (0.5 mdkg, 3.6 ftdlb) NOTE: The main switch and clutch lever holder should be installed according to the dimensions shown. 12.Install: • Clutch cable 1 NOTE: Apply the lithium soap base grease on the clutch cable end. 13.Install: • Handle crown 1 Refer to “STEERING” section. a 14.
HANDLEBAR CHAS 15.Tighten: • Pinch bolt (handlebar) 1 T7 Nm (0.7 mdkg, 5.1 ftdlb) CCAUTION: Tighten the pinch bolts to specified torpue. If torpue too much, it may cause the front fork to malfunction. 16.Adjust: • Clutch lever free play Refer to “CLUTCH ADJUSTMENT” section in the CHAPTER 3. 17.Lock the throttle cables and starter cables using a locking wire. Refer to “LOCKING WIRE INSTALLATION GUIDE” section in the CHAPTER 3.
CHAS STEERING EC560000 STEERING EC568000 HANDLE CROWN AND STEERING DAMPER T 80 Nm (8.0 mdkg, 58 ftdlb) T 20 Nm (2.0 mdkg, 14 ftdlb) T 5 Nm (0.5 mdkg, 3.6 ftdlb) T 23 Nm (2.3 mdkg, 17 ftdlb) Extend of removal: Extend of removal 1 Handle crown removal Order 2 Steering damper removal Part name Q’ty HANDLE CROWN AND STEERING DAMPER REMOVAL Hold the machine by placing the suitable stand. Preparation for removal Remarks W Support the machine securely so there is no danger of it falling over.
CHAS STEERING EC568100 UNDER BRACKET T 7 Nm (0.7 mdkg, 5.1 ftdlb) t TIGHTENING STEPS: • Tighten ring nut. 46 Nm (4.6 mdkg, 33 ftdlb) • Loosen it one turn. • Retighten it. 1 Nm (0.1 mdkg, 0.7 ftdlb) T 10 Nm (1.0 mdkg, 7.2 ftdlb) T 23 Nm (2.
STEERING CHAS EC563000 REMOVAL POINTS EC563202 Ring nut 1. Remove: • Ring nut 1 Use the ring nut wrench 2. A Ring nut wrench: YU-33975/90890-01403 W Support the steering shaft so that it may not fall down. EC563300 Bearing (lower) 1. Remove: • Bearing (lower) 1 Use the floor chisel 2. CCAUTION: Take care not to damage the steering shaft thread. EC563400 Ball race 1. Remove: • Ball race 1 Remove the ball race using long rod 2 and the hammer. EC564000 INSPECTION EC564200 Steering shaft 1.
STEERING CHAS EC564101 Bearing and ball race 1. Wash the bearings and ball races with a solvent. 2. Inspect: • Bearing 1 • Ball race Pitting/Damage ≥ Replace bearings and ball races as a set. Install the bearing in the ball races. Spin the bearings by hand. If the bearings hang up or are not smooth in their operation in the ball races, replace bearings and ball races as a set. EC564300 Steering damper 1. Inspect: • Steering damper 1 Bend/Damage ≥ Replace. Oil leaks/Unsmooth movement ≥ Replace.
STEERING CHAS 4. Install: • Under bracket 1 NOTE: Apply the lithium soap base grease on the bearing. 5. Install: T1 Nm (0.1 mdkg, 0.7 ftdlb) • Ring nut 1 Tighten the ring nut using the ring nut wrench 2. Refer to “STEERING HEAD INSPECTION AND ADJUSTMENT” section in the CHAPTER 3. 6. Check the steering shaft by turning it lock to lock. If there is any binding, remove the steering shaft assembly and inspect the steering bearings. 7. Install: • Plain washer 1 8.
STEERING CHAS 9. Install: • Plain washer 1 • Steering shaft nut 2 T80 Nm (8.0 mdkg, 58 ftdlb) NOTE: Apply the lithium soap base grease on the steering shaft nut thread. 10.After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the ring nut little by little. 11.Install: • Steering damper bracket 1 • Pinch bolt (steering damper bracket) 2 T5 Nm (0.5 mdkg, 3.6 ftdlb) To steering damper 3.
STEERING CHAS 13.Adjust: • Front fork top end a • Handlebar position b • Steering damper stay position c (right side only) Front fork top end: 13 mm (0.51 in) Handlebar position: 9 mm (0.35 in) Steering damper stay position: 73 mm (2.87 in) e Refer to “FRONT FORK TOP ADJUSTMENT” in the CHAPTER 3. END 14.Tighten: • Pinch bolt (handle crown) 1 T20 Nm (2.0 mdkg, 14 ftdlb) • Pinch bolt (under bracket) 2 T23 Nm (2.3 mdkg, 17 ftdlb) • Pinch bolt (handlebar) 3 T7 Nm (0.7 mdkg, 5.
SWINGARM CHAS EC570000 SWINGARM T 10 Nm (1.0 mdkg, 7.2 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) T115 Nm (11.5 mdkg, 85 ftdlb) T 5 Nm (0.5 mdkg, 3.6 ftdlb) T 34 Nm (3.4 mdkg, 24 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) Extend of removal: Extend of removal 1 Swingarm removal Order 2 Swingarm disassembly Part name Q’ty SWINGARM REMOVAL Hold the machine by placing the suitable stand. Lower cowl and fuel tank Preparation for removal W Support the machine securely so there is no danger of it falling over.
SWINGARM CHAS EC573000 REMOVAL POINTS EC573153 Swingarm 1. Loosen: • Pivot shaft adjust bolt 1 NOTE: Loosen the pivot shaft adjust bolt using the pivot shaft wrench 2 and pivot shaft wrench adapter 3. C Pivot shaft wrench: YM-1455/90890-01455 Pivot shaft wrench adapter: YM-1476/90890-01476 2. Remove: • Pivot shaft 1 • Swingarm 2 EC573210 Bearing 1. Remove: • Bearing 1 Use a general bearing puller 2. EC574010 INSPECTION Wash the bearings, bushes, collars, and covers in a solvent.
SWINGARM CHAS EC574220 Relay arm 1. Inspect: • Bearing 1 • Collar 2 Free play exists/Unsmooth revolution/Rust ≥ Replace bearing and collar as a set. EC574320 Connecting rod 1. Inspect: • Connecting rod 1 Wear/Damage ≥ Replace. EC574520 Swingarm side clearance 1. Measure: • Bush length a 2. Measure: • Thrust bearing (right) thickness b • Thrust bearing (left) thickness c 3.
SWINGARM CHAS 4. Calculate: • Swingarm side clearance “A + B” Out of specification ≥ Adjust side clearance using shim. By using formula given below. % a “A + B” = a – ( b + c + d ) Side clearance “A + B”: 0.05~0.35 mm (0.002~0.014 in) If the side clearance is out of specification, adjust it to specification by installing the adjust shim 1 at position, A and B. NOTE: • The adjust shim is available only in the 0.3 mm (0.012 in)-thick type.
SWINGARM CHAS 2. Install: • Bearing 1 To relay arm. NOTE: • Apply the lithium soap base grease on the bearing when installing. • Install the bearing by pressing it on the side having the manufacture’s marks or numbers. a Installed depth of bearings a: Zero mm (Zero in) EC575142 Swingarm 1. Install: • Collar 1 To relay arm 2. NOTE: Apply the molybdenum disulfide grease on the collars and bearings. 2. Install: • Relay arm 1 • Bolt (relay arm) 2 • Nut (relay arm) 3 T34 Nm (3.
SWINGARM CHAS 4. Install: • Swingarm 1 • Pivot shaft 2 NOTE: • Apply the molybdenum disulfide grease on the pivot shaft. • Insert the pivot shaft from left side. 5. Tighten: • Pivot adjust bolt 1 T5 Nm (0.5 mdkg, 3.6 ftdlb) NOTE: Use the pivot shaft wrench 2 and pivot shaft wrench adapter 3 to tighten the pivot adjust bolt. C Pivot shaft wrench: YM-1455/90890-01455 Pivot shaft wrench adapter: YM-1476/90890-01476 6. Install: • Plain washer 1 • Nut (pivot shaft) 2 T115 Nm (11.5 mdkg, 85 ftdlb) 7.
SWINGARM CHAS 9. Install: • Collar (swingarm) 1 NOTE: Apply the molybdenum disulfide grease on the collars and bearings. 10.Install: • Connecting rod 1 • Bolt (connecting rod) 2 • Nut (connecting rod) 3 T34 Nm (3.4 mdkg, 24 ftdlb) NOTE: • Install the connecting rods with the mark a outward of the chassis. • Apply the molybdenum disulfide grease on the bolts.
REAR SHOCK ABSORBER CHAS EC580000 REAR SHOCK ABSORBER T 38 Nm (3.8 mdkg, 27 ftdlb) T 40 Nm (4.0 mdkg, 29 ftdlb) T 34 Nm (3.4 mdkg, 24 ftdlb) T 20 Nm (2.0 mdkg, 14 ftdlb) T 34 Nm (3.4 mdkg, 24 ftdlb) Extend of removal: Extend of removal 1 Rear shock absorber removal Order Part name 2 Rear shock absorber disassembly Q’ty REAR SHOCK ABSORBER REMOVAL Hold the machine by placing the suitable stand.
REAR SHOCK ABSORBER CHAS EC586000 HANDLING NOTE W This shock absorber is provided with a separate type tank filled with high-pressure nitrogen gas. To prevent the danger of explosion, read and understand the following information before handling the shock absorber. The manufacturer can not be held responsible for property damage or personal injury that may result from improper handling. 1. Never tamper or attempt to disassemble the cylinder or the tank. 2.
REAR SHOCK ABSORBER CHAS EC583000 REMOVAL POINTS EC583160 Rear shock absorber 1. Remove: • Rear shock absorber 1 NOTE: Remove the rear shock absorber between the rear frame and swingarm. EC583221 Spring (rear shock absorber) 1. Remove: •Spring guide 1 •Spring 2 NOTE: Remove the spring guide while compressing the spring by using the spring compressor 3. EC584000 INSPECTION EC584130 Rear shock absorber 1. Inspect: • Damper rod 1 Bends/Damage ≥ Replace absorber assembly.
REAR SHOCK ABSORBER CHAS EC585000 ASSEMBLY AND INSTALLATION EC585143 Spring (rear shock absorber) 1. Install: • Plate 1 • Spring 2 • Spring guide 3 NOTE: Install the spring guide while compressing the spring by using the spring compressor 4. 2. Tighten: • Adjuster 1 3. Adjust: • Spring length (installed) a ] Spring length (installed) a: Standard length 137 mm (5.39 in) Extent of adjustment 133~142 mm (5.24~5.59 in) NOTE: The length of the spring (installed) changes 1.5 mm (0.
REAR SHOCK ABSORBER 4. Tighten: • Locknut 1 CHAS T20 Nm (2.0 mdkg, 14 ftdlb) EC5852A1 Rear shock absorber 1. Install: • Upper bracket 1 • Bolt (rear shock absorber – upper bracket) 2 • Plain washer (rear shock absorber – upper bracket) 3 • Nut (rear shock absorber – upper bracket) 4 T34 Nm (3.4 mdkg, 24 ftdlb) NOTE: Apply the molybdenum disulfide grease on the bolt. 2. Install: • Rear shock absorber 3. Install: • Bolt (upper bracket) 1 T40 Nm (4.0 mdkg, 29 ftdlb) • Cap 2 4.
ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELEC EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 CDI unit Voltage regulator Tachometer assembly Fuse Main switch Ignition coil Solenoid valve Fuel pump 9 0 ¡ ™ £ ¢ ∞ COLOR CODE B . . . . . .Black Br . . . . . .Brown G . . . . . .Green Gy . . . . .Gray O . . . . . .Orange P . . . . . .Pink R . . . . . .Red Y . . . . . .Yellow W . . . . . .White B/Br . . . .
ELEC IGNITION SYSTEM EC620000 IGNITION SYSTEM EC621031 INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. No good Check fuse. Replace fuse and check wireharness. OK No good *1 Check battery Recharge or replace. OK Spark Spark gap test *2 Clean or replace spark plug. No spark No good Check spark plug cap. Replace.
IGNITION SYSTEM ELEC EC629000 FUSE INSPECTION 1. Remove: • Fuse 1 2. Check: • Fuse conduct Use pocket tester (tester selector position Ω X 1). Not continuous ≥ Replace fuse and check that the wireharness is not shorted. EC622020 SPARK GAP TEST 1. Disconnect the fuel pump coupler to prevent the fuel pump operating. 2. Disconnect the spark plug cap from spark plug. 3. Connect the dynamic spark tester 1 (ignition checker 2) as shown.
ELEC IGNITION SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/ Dust/ Looseness/Short-circuit ≥ Repair or replace. EC62A000 % MAIN SWITCH INSPECTION 1. Inspect: • Main switch conduct Tester (+) lead ≥ Red lead 1 Tester (-) lead ≥ Brown lead 2 u R 1 RUN OFF Br 2 Tester selector position ΩX1 Continuous while the main switch is moved to “OFF” ≥ Replace. Not continuous while the main switch is moved to “RUN” ≥ Replace.
IGNITION SYSTEM ELEC % 2. Inspect: • Secondary coil resistance Out of specification ≥ Replace. Tester (+) lead ≥ Spark plug lead 1 Tester (–) lead ≥ Orange (Gray) lead 2 ? Secondary coil resistance 5.0~7.4 kΩ at 20˚C (68˚F) Tester selector position kΩ X 1 NOTE: When inspecting the secondary coil resistance, remove the spark plug cap. EC627031 CDI MAGNETO INSPECTION 1. Inspect: • Pick-up coil resistance (left cylinder) Out of specification ≥ Replace.
IGNITION SYSTEM ELEC % 3. Inspect: • Source coil resistance Out of specification ≥ Replace. Tester (+) lead ≥ White lead 1 Tester (-) lead ≥ White lead 2 ? Source coil resistance 2.3~3.5 Ω at 20˚C (68˚F) Tester selector position ΩX1 EC628000 CDI UNIT INSPECTION Check all electrical components. If no fault is found, replace the CDI unit. Then check the electrical components again.
ELEC CHARGING SYSTEM EC680000 CHARGING SYSTEM EC681001 INSPECTION STEPS If the battery is not charged, use the following inspection steps. No good *1 Check fuse. Replace fuse and check wireharness. OK No good *2 Check battery Recharge or replace. OK No good Check each coupler and wire connection. Repair or replace. OK OK Check charging voltage. Charging system is good. No good *1 Check CDI magneto. Source coil No good Replace. OK Check voltage regulator.
CHARGING SYSTEM ELEC EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/ Dust/ Looseness/Short-circuit ≥ Repair or replace. EC682000 CHARGING VOLTAGE INSPECTION 1. Start the engine. 2. Inspect: • Charging voltage Out of specification ≥ If no failure is found in checking the source coil resistance, check the voltage regulator. % Tester (+) lead ≥ Red lead 1 Tester (-) lead ≥ Black lead 2 ? Charging voltage 14.2~15.
CHARGING SYSTEM ELEC NOTE: If nothing is wrong with the continuity of the voltage regulator and with all the others in the charging system, replace the voltage regulator.
ELEC YPVS SYSTEM EC640000 YPVS SYSTEM EC641021 INSPECTION STEPS If the servomotor will not turn, use the following inspection steps. No good *1 Check fuse. Replace fuse and check wireharness. OK No good *2 Check battery Recharge or replace. OK No good Check each coupler and wire connection. Repair or replace. OK No good *1 Check main switch. Replace. OK Check servomotor operation. No good Check servomotor. No good OK Replace CDI unit. *1 marked : Refer to “IGNITION SYSTEM” section.
YPVS SYSTEM ELEC EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/ Dust/ Looseness/Short-circuit ≥ Repair or replace. EC642020 SERVOMOTOR OPERATION 1. Disconnect the fuel pump coupler to prevent the fuel pump operating. 2. Inspect: • Servomotor 1 Operative when the main switch is moved to “RUN” ≥ OK EC643001 SERVOMOTOR INSPECTION 1. Disconnect the YPVS cable from the servomotor. 2. Disconnect the servomotor lead. 3.
ELEC SOLENOID VALVE SYSTEM EC650001 SOLENOID VALVE SYSTEM EC651021 INSPECTION STEPS If the solenoid valve will not operate, use the following inspection steps. No good *1 Check fuse. Replace fuse and check wireharness. OK No good *2 Check battery Recharge or replace. OK No good Check each coupler and wire connection. Repair or replace. OK No good *1 Check main switch. Replace. OK Check solenoid valve operation. No good Check solenoid valve coil. No good Replace. OK Replace CDI unit.
SOLENOID VALVE SYSTEM ELEC EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/ Dust/ Looseness/Short-circuit ≥ Repair or replace. EC652020 SOLENOID VALVE OPERATION 1. Disconnect the fuel pump and servomotor coupler to prevent the fuel pump and servomotor operating. 2. Inspect: • Solenoid valve 1 Click when the main switch is moved to “RUN” ≥ OK NOTE: Before checking the solenoid valve, disconnect the other solenoid valve lead.
ELEC THERMO UNIT SYSTEM EC6A0000 THERMO UNIT SYSTEM EC6A1011 INSPECTION STEPS If the water temperature gauge (thermo unit) will not operate, use the following inspection steps. *1 Check fuse. No good Replace fuse and check wireharness. OK *2 Check battery No good Recharge or replace. OK Check each coupler and wire connection. No good Repair or replace. OK *1 Check main switch. No good Replace. OK Check thermo unit. No good OK Replace tachometer assembly.
THERMO UNIT SYSTEM ELEC EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/ Dust/ Looseness/Short-circuit ≥ Repair or replace. EC6A2000 THERMO UNIT INSPECTION 1. Drain the cooling water. 2. Remove: • Thermo unit 1 3. Immerse the thermo unit with a tester lead connected in a container containing cooling (tap) water 1 down to the upper threaded portion a. 2 Water temperature gauge 3 Poket tester 4.
ELEC FUEL PUMP SYSTEM EC670000 FUEL PUMP SYSTEM EC671001 INSPECTION STEPS If the fuel pump will not operate, use the following inspection steps. No good *1 Check fuse. Replace fuse and check wireharness. OK No good *2 Check battery Recharge or replace. OK No good Check each coupler and wire connection. Repair or replace. OK No good *1 Check main switch. Replace. OK No good Check fuel pump stop switch. Replace. OK No good Check fuel pump relay. Replace. OK Check fuel pump operation.
ELEC FUEL PUMP SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/ Dust/ Looseness/Short-circuit ≥ Repair or replace. EC672000 FUEL PUMP STOP SWITCH INSPECTION 1. Remove: • Fuel pump stop switch 1 2. Inspect: • Fuel pump stop switch conduct To inspect, tilt the fuel pump stop switch to the right and left.
ELEC FUEL PUMP SYSTEM 2. Inspect: • Fuel pump relay conduct Use 12V battery. & Battery (+) lead ≥ Black lead 1 Battery (-) lead ≥ Green lead 2 Tester (+) lead ≥ Black/Blue lead 3 Tester (-) lead ≥ Brown lead 4 B/L 3 Br 4 Tester selector position v Connected to battery Not connected to battery ΩX1 Continuous while connected to the battery ≥ Replace. Not continuous while not connected to the battery ≥ Replace. 3. Inspect: • Fuel pump relay resistance Out of specification ≥ Replace.
FUEL PUMP SYSTEM ELEC 2. Install: • Drain plug 3. Turn the fuel cock to “ON”. 4. Inspect: • Fuel pump 1 Operation sound when the main switch is moved to “RUN” ≥ OK EC675000 FUEL PUMP COIL INSPECTION 1. Disconnect the fuel pump coupler. 2. Inspect: • Fuel pump coil resistance Out of specification ≥ Replace.
FUEL PUMP SYSTEM ELEC 3. Turn the fuel cock to “ON”. 4. Disconnect the fuel pump coupler. 5. Connect 12V battery to the fuel pump coupler. % Battery (+) lead ≥ Black/Blue lead 1 Battery (-) lead ≥ Black lead 2 6. Inspect: • Fuel pump 1 No fuel flows from the plastic hose 2 ≥ Replace.
SETTING TUN EC700000 TUNING EC710000 ENGINE EC711011 Carburetor setting • The role of fuel is not only to produce motive power but also to cool the engine and, in the case of a 2-stroke engine, to lubricate it. Therefore, too lean a mixture (of air and fuel) tends to cause an abnormal combustion (i.e.
SETTING TUN That is: • Higher temperature expands the air with its resultant reduced density. • Higher humidity reduces the amount of oxygen in the air by so much of the water vapor in the same air. • Lower atmospheric pressure (at a high altitude) reduces the density of the air.
SETTING TUN Next run a few laps of the circuit with this setting and check for any difference in engine revolutions. If no difference is noticed, use a main jet with a much smaller calibration number. w Example: #540 ≥ #500 Factory-set main jet A #560 2. Checking of spark plug and piston for discoloration Repeat the adjustment in the above “1” several times.
SETTING TUN If the main jet is fully adjusted with not much allowance for discoloration, use a main jet which is approximately #20 lager. Run a few laps of the circuit to check the engine for response to revolutions. Also check for the discoloration of the spark plug(s) and piston(s). Use a main jet of a smaller size if good response to engine revolutions is achieved with an allowance for the discoloration of the spark plug(s) and piston(s).
SETTING TUN EC71F002 Carburetor settings by correction coefficient Now you should be able to understand the essentials of basic carburetor setting from an explanation given under “Basic process of carburetor setting” (P7-2). Next is an explanation of how to select a main jet to deal with changes in weather conditions by means of a correction coefficient. NOTE: • Before this correction coefficient can be used, satisfactory carburetor setting must have been made.
SETTING TUN CCAUTION: If a change in conditions require a main jet of a larger size, use the size to which #20 is added for safety. NOTE: • Since this correction coefficient table lacks a column for humidity, it is advisable to check the degree of discoloration of the spark plug(s) for final selection according to an explanation under “Atmospheric conditions and carburetor setting’’ (P7-1).
SETTING TUN EC71H040 Other setting parts 1. Power jet 1 Power jet is not basically changed. Since the areas of the main jet and main nozzle overlap each other, special knowledge is required for a setting change. A larger size results in a richer mixture and a smaller size in a leaner mixture. w Factory-set power jet #55 2. Pilot jet 1 The pilot jet is used in relation to the engine response at small throttle opening. This is changed when the main nozzle setting is not enough.
SETTING TUN EC71Q021 Carburetor setting parts Part name Main jet 1 Lean * Rich Lean * Rich Lean * Jet needle 4 * Power jet 5 * Rich Pilot jet 2 Main nozzle 3 Lean Rich Size #350 #360 #370 #380 #390 #400 #410 #420 #430 #440 #450 #460 #470 #480 #490 #500 #540 #560 #25 #30 #35 #40 R-7 R-8 R-9 S-0 S-1 S-2 S-3 S-4 6DGJ1-63 #50 #55 Part number 137-14143-70 137-14143-72 137-14143-74 137-14143-76 137-14143-78 137-14143-80 137-14143-82 137-14143-84 137-14143-86 137-14143-88 137-14143-90 137-14143-92 13
SETTING TUN EC71J010 Plug chop When checking the discoloration of the spark plug and piston head, move the main switch to “OFF” while running along a straight lane at full throttle, disengage the clutch at the same time and stop the engine. Then let your machine go back to the pit by inertia. This is called a “plug chop”. CCAUTION: • When you do a “plug chop”, pay attention to your surrounding environment to avoid interference with other riders.
SETTING TUN NOTE: • Finish the break-in before changing the gasket. • A change of 0.1 mm (0.004 in) for the gasket causes a change of approximately 0.23 cm3 (0.008 lmp oz, 0.008 US oz) of the combustion chamber volume. • After break-in, change to an appropriate gasket to allow the piston protrusion to be -0.15 mm (-0.006 in) to 0.05 mm (0.002 in). CCAUTION: • Piston protruding amount must be a maximum 0.15 mm (0.006 in). Above this value, the piston and cylinder head may contact each other.
SETTING TUN 2. Loosen the stand installation bolt 1, then rotate the dial gauge stand and set it close to the center of the piston. Tighten the stand installation bolt again. NOTE: Do not loosen the dial gauge installation bolt 2 while doing the above. 3. Set the piston at top dead center (TDC), then measure the piston protrusion. NOTE: For measurement, avoid the top center projected area a on the piston head but measure several positions above the piston pin as close to the center as possible.
SETTING TUN 3rd gear Gear ratio Part number Number of groove 29/23 (1.261) 5KE-17231-00/5KE-17131-00 – 25/21 (1.190) 5KE-17231-20/5KE-17131-10 2/1 26/21 (1.238) 5KE-17231-10/5KE-17131-10 1 Gear ratio Part number Number of groove Factory installed 20/22 (0.909) 5KE-17261-00/5KE-17191-00 1 Supplying part 22/25 (0.
SETTING TUN EC71U011 Transmission setting parts Part name Main axle 1 * 2nd pinion gear 2 ∆ ∆ * 3rd/4th pinion gear 3 * 5th pinion gear 4 * 6th pinion gear 5 * 1st wheel gear 6 3rd wheel gear 8 * ∆ ∆ * ∆ 4th wheel gear 9 5th wheel gear 0 6th wheel gear ¡ * * * * 2nd wheel gear 7 Size Part number 14T 18T 18T 19T 21T 21T/25T 23T/25T 27T 22T 25T 28T 34T 27T 28T 31T 25T 26T 29T 27T 26T 20T 22T 5KE-17411-10 5KE-17411-20 5F7-17121-00 5F7-17121-21 4DP-17121-11 5KE-17131-10 5KE-17131-00 5F7-17151-01 5KE
SETTING TUN EC720000 CHASSIS EC72J001 Chassis setting How to go about setting the chassis • Measure the stroke of the front and rear suspension to get an idea of the operation. • If the time increases, the stroke increases. • If the tire grip becomes firmer, the stroke increases. (On the other hand, the stroke decreases on rainy weather.) • Rider’s position and posture affect the stroke. • Be careful not to allow the suspension to bottom out. • Start the setting with the preload.
SETTING TUN EC72M001 Tire and machine’s posture If a non-designated tire is used, the difference in radius between the front and the rear tire may affect the machine’s posture. To keep the machine in a proper posture, adjust the front fork top end or seat height. Basically, with a larger radius tire, lower the machine’s posture and vice versa. [Front] Tire brand *3.10/4.80 R17 DUNLOP KR106 120/70 R17 DUNLOP MR977 Tire circumference Tire radius Front fork top end About 1,875 mm (73.8 in) About 298.
SETTING TUN EC72K014 Settings For full use of engine performance and safe riding, set the suspension as follows. (Ex-factory settings are intended for a rider approximately 170 cm (66.9 in) in height and approximately 60 kg (132 lb) in weight.) 1. Preparations To check for the remaining stroke in the front and rear suspension, either install a thin insu-lock tie or apply a small amount of grease at the front fork inner tube and at the rear shock absorber rod. 2.
SETTING TUN SETTING CHART ACTUAL RUN Check stroke NOTE: The remaining stroke value is provided just as a guide and may change according to the riding style. Front remaining stroke Rear remaining stroke 5 to 10 mm (0.20 ~ 0.39 in) 10 to 20 mm (0.39 ~ 0.79 in) NO YES NO Poor stroke Too much stroke Decrease the spring preload. •Front Every two clicks [1 mm (0.04 in)] •Rear Every one turn [1.5 mm (0.06 in)] Increase the spring preload. •Front Every two clicks [1 mm (0.
TUN SETTING EC71P011 Selection of the secondary reduction ratio (Sprocket) Secondary Number of driven sprocket teeth reduction = Number of drive sprocket teeth ratio w Factory-set secondary reduction ratio 36/14 (2.571) Driven sprocket Drive sprocket 35T 36T 37T 38T 39T 40T 14T 15T 16T 2.500 2.333 2.188 2.571 2.400 2.250 2.643 2.467 2.313 2.714 2.534 2.375 2.786 2.600 2.438 2.857 2.666 2.
SETTING TUN EC72L003 Chassis setting troubleshooting Chattering (Small rebounds, up-and-down movements) Bottoming (full stroke) • Increase spring preload. • Increase damping force for compression. Further in stroke • Increase damping force for compression, or decrease damping force for rebound. Too stiff (poor stroke) • Decrease spring preload. • Decrease damping force for compression. • Down the oil level (for front fork only).
SETTING TUN Handlebar fluctuating Poor of front load • Decrease spring preload (for front). • Increase front fork top end. • Increase rear height. • Increase spring preload (for rear). Too soft of front • Increase spring preload (for front). • Increase damping force (for front). Machine tends to incline too much backward. (Too big caster angle) • Increase rear height. • Increase spring preload (for rear). • Decrease damping force for rebound (for rear).
SETTING TUN EC740002 Setting record table The data shown here is an example of entry. For your actual use, copy the necessary data.
SETTING TUN Event name Date Weather Place Setting specs: Ignition timing Spark plug Carburetor Main jet Power jet Jet needle Main nozzle Pilot jet Pilot air screw Float height Gearing 1st 2nd 3rd 4th 5th 6th Secondary Front fork Spring rate Spring preload Rebound damping Compression damping Top end Oil capacity Oil level Rear shock Spring fitting length Spring rate Rebound damping Compression damping Seat height Front tire (pressure) Rear tire (pressure) Fuel consumption NOTE: 1.
PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories OWNER’S SERVICE MANUAL TZ250N1/(N) YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN LIT-11626-14-44 PRINTED IN JAPAN 2000.10—0.
