Yamaha LIT-11616-12-01 manual

SERVICE MANUAL LIT -1 1616-12-01 4XE-F8197-10 YFM250XL(C)[...]

YFM250XL SERVICE MANUAL  1998 by Yamaha Motor Corporation, U.S.A. First Edition, February1998 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-11616-12-01[...]

EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform mainte- nance and repairs on Yamaha machine has a basic understanding of the m[...]

EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual is intended as a handy, easy-to-read reference book for the mechanic. It is divided into chapters, sections and sub-sections. Comprehensive explanations of all installa- tion, removal, disassembly, assembly, repair and inspection procedures are laid out with the individual steps in seq[...]

EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic inspections and adjustments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical 9 Troubleshooting Illustrated symbols 0 to F are used to identify the sp[...]

CHAPTER TITLES GENERAL INFORMATION 1 SPECIFICATIONS SPEC 2 PERIODIC INSPECTION AND ADJUSTMENT 3 ENGINE OVERHAUL ENG 4 CARBURETION CARB 5 DRIVE TRAIN DRIVE 6 CHASSIS CHAS 7 ELECTRICAL ELEC 8 TROUBLESHOOTING 9 GEN INFO INSP ADJ –+ TRBL SHTG[...]

CONTENTS CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ........................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER .................................................. 1-1 MODEL LABEL ...................................................................................... 1-1 IMPORTANT INFORMATION [...]

CHAPTER 3. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION ........................................................................................... 3-1 PERIODIC MAINTENANCE/LUBRICATION ................................................ 3-1 FENDER AND FUEL TANK ........................................................................... 3-3 FRONT [...]

ELECTRICAL ............................................................................................... 3-38 BATTERY INSPECTION ...................................................................... 3-38 FUSE INSPECTION ............................................................................. 3-41 HEADLIGHT BEAM ADJUSTMENT ..................[...]

TIMING CHAIN ................................................................................... 4-30 CAM SPROCKET AND CAM DRIVE SPROCKET ............................... 4-31 TIMING CHAIN GUIDE ....................................................................... 4-31 TIMING CHAIN TENSIONER ........................................................[...]

CHAPTER 5. CARBURETION CARBURETOR .............................................................................................. 5-1 REMOVAL ............................................................................................. 5-2 DISASSEMBLY ..................................................................................... 5-2 INSPECTIO[...]

CHAPTER 7. CHASSIS FRONT WHEELS AND FRONT BRAKE ....................................................... 7-1 REMOVAL ............................................................................................. 7-2 INSPECTION ......................................................................................... 7-3 INSTALLATION ..................[...]

IGNITION SYSTEM ...................................................................................... 8-7 CIRCUIT DIAGRAM .............................................................................. 8-7 TROUBLESHOOTING ........................................................................... 8-8 ELECTRIC STARTING SYSTEM .......................[...]

FAULTY DRIVE TRAIN ................................................................................. 9-3 FAULTY GEAR SHIFTING ............................................................................ 9-4 HARD SHIFTING ................................................................................... 9-4 SHIFT PEDAL DOES NOT MOVE ...............[...]

1 - 1 GEN INFO MACHINE IDENTIFICATION GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame. MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts. 1[...]

1 - 2 GEN INFO IMPORTANT INFORMATION EB101000 IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES 1.Remove all dirt, mud, dust and foreign material before removal and disassembly. 2.Use proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS” section. 3.When disassembling the machine, always keep mated parts together. This include[...]

1 - 3 GEN INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1.Replace all lock washers/plates 1 and cot- ter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. IMPORTANT INFORMATION EB101040 BEARINGS AND OIL SEALS 1.Install bearings and oil seals so that the manufacturer’s mar[...]

1 - 4 GEN INFO CHECKING OF CONNECTIONS EB801000 CHECKING OF CONNECTIONS Check the connectors for stains, rust, mois- ture, etc. 1.Disconnect: ● Connector 2.Check: ● Connector Moisture → Dry each terminal with an air blower. Stains/rust → Connect and disconnect the terminals several times. 3.Check: ● Connector leads Looseness → Bend up t[...]

1 - 5 GEN INFO SPECIAL TOOLS EB102001 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to count[...]

1 - 6 GEN INFO SPECIAL TOOLS 4-B Compression gauge P/N. 90890-03081 Extension P/N. 90890-04082 This gauge is used to measure the engine compression. 5 Fuel level gauge P/N. YM-01312-A P/N. 90890-01312 This gauge is used to measure the fuel level in the float chamber. FOR ENGINE SERVICE 1 Rotor holder P/N. YU-01235 P/N. 90890-01235 This tool is used[...]

1 - 7 GEN INFO SPECIAL TOOLS 7-A Slide hammer set P/N. YU-01083-A These tools are used when removing the rocker arm shaft. 7-B Slide hammer bolt (M6) P/N. 90890-01083 Weight P/N. 90890-01084 These tools are used when removing the rocker arm shaft. 8 Valve spring compressor P/N. YM-04019 P/N. 90890-04019 This tool is useed to remove and install the [...]

1 - 8 GEN INFO SPECIAL TOOLS 13 Sealant (Quick Gasket  ) P/N. ACC-QUICK-GS-KT YAMAHA bond No. 1215  P/N. 90890-85505 This sealant (bond) is used for crankcase mat- ing surface, etc. FOR DRIVE TRAIN SERVICE 1-A Universal joint holder P/N. YM-04062 Attachment P/N. YM-33291 These tools are used to remove and install the universal joint. 1-B Univ[...]

1 - 9 GEN INFO SPECIAL TOOLS FOR CHASSIS SERVICE 1 Yamaha brake grease P/N. 90793-40003 This Yamaha brake grease is used for rear brake dust seal. FOR ELECTRICAL COMPONENTS 1-A Dynamic spark tester P/N. YM-34487 This instrument is necessary for checking the ignition system components. 1-B Ignition checker P/N. 90890-06754 This instrument is necessa[...]

GEN INFO 1 - 10 1[...]

GENERAL SPECIFICATIONS SPEC 2 - 1 SPECIFICA TIONS GENERAL SPECIFICA TIONS Item Standard Model code: 4XE1 (USA) 4XE2 (CAL) 4XE3 (CDN) Dimensions: Overall length 1,940 mm (76.4 in) Overall width 1,005 mm (39.6 in) Overall height 1,118 mm (44.0 in) Seat height 780 mm (30.7 in) Wheelbase 1,170 mm (46.1 in) Minimum ground clearance 155 mm (6.1 in) Minim[...]

GENERAL SPECIFICATIONS SPEC 2 - 2 Fuel: T ype Unleaded fuel Fuel tank capacity 12 L (2.64 Imp gal, 3.17 US gal) Fuel reserve amount 1.6 L (0.35 Imp gal, 0.42 US gal) Carburetor: T ype / quantity BST34/1 Manufacturer MIKUNI Spark plug: T ype DR7EA Manufacturer NGK Spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) Clutch type W et, centrifugal automatic[...]

GENERAL SPECIFICATIONS SPEC 2 - 3 T ire pressure (cold tire): Recommended front 20 kPa (0.20 kg/cm 2 , 2.9 psi) rear 25 kPa (0.25 kg/cm 2 , 3.6psi) Minimum front 17 kPa (0.17 kg/cm 2 , 2.5 psi) rear 22 kPa (0.22 kg/cm 2 , 3.2 psi) Maximum front 23 kPa (0.23 kg/cm 2 , 3.3 psi) rear 28 kPa (0.28 kg/cm 2 , 4.0 psi) Brake: Front brake type Drum brake o[...]

MAINTENANCE SPECIFICATIONS SPEC 2 - 4 MAINTENANCE SPECIFICA TIONS ENGINE Item Standard Limit Cylinder head: W arp limit ---- 0.10 mm (0.004 in) Measuring point Lines indicate straight edge measurement. Cylinder: Bore size 70.97 ~ 71.02 mm (2.794 ~ 2.796 in) 71.10 mm (2.799 in) Measuring point 40 mm (1.6 in) ---- Camshaft: Drive method Chain drive ([...]

MAINTENANCE SPECIFICATIONS SPEC 2 - 5 “C” 6.572 ~ 6.692 mm (0.259 ~ 0.263 in) ---- Camshaft runout limit ---- 0.03 mm (0.0012 in) Cam chain: Cam chain type / No. of links DID25SH/104 ---- Cam chain adjustment method Automatic ---- Rocker arm / rocker arm shaft: Rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) Shaft outside dia[...]

MAINTENANCE SPECIFICATIONS SPEC 2 - 6 Guide inside diameter IN 6.000~ 6.012mm (0.236 ~ 0.237 in) ---- EX 6.000~ 6.012mm (0.236 ~ 0.237 in) ---- Stem-to-guide clearance IN 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.08 mm (0.0031 in) E X 0.025 ~ 0.052 mm (0.001 ~ 0.002 in) 0.10 mm (0.0039 in) Stem runout limit ---- 0.03 mm (0.0012 in) V alve seat width [...]

MAINTENANCE SPECIFICATIONS SPEC 2 - 7 Compressed pressure (installed) IN 162.8 ~ 200.1 N (16.6 ~ 20.4 kg, 36.6 ~ 45.0 lb) ---- EX 162.8 ~ 200.1 N (16.6 ~ 20.4 kg, 36.6 ~ 45.0 lb) ---- T ilt limit IN 2.5˚/1.6 mm (2.5˚/0.06 in) E X 2.5˚/1.6 mm (2.5˚/0.06 in) Direction of winding (top view) IN Clockwise ---- EX Clockwise ---- Piston: Piston to cyl[...]

MAINTENANCE SPECIFICATIONS SPEC 2 - 8 Side clearance (installed) 0.03 ~ 0.07 mm (0.001 ~ 0.003 in) 0.12 mm (0.005 in) 2nd ring: T ype T aper ---- Dimensions (B × T) 1.2 × 2.8 mm (0.047 ~ 0.110 in) ---- End gap (installed) 0.15 ~ 0.30 mm (0.006 ~ 0.012 in) 0.4 mm (0.016 in) Side clearance 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in) 0.12 mm (0.005 in) Oil [...]

MAINTENANCE SPECIFICATIONS SPEC 2 - 9 Clutch plate Thickness 1.45 ~ 1.75mm (0.057 ~ 0.069 in) 0.2 mm (0.008 in) Quantity 4 pcs. ---- Clutch spring Free length 35.1 mm (1.38 in) 32.9 mm (1.30 in) Quantity 4 pcs. ---- Clutch release method Outer push, cam push ---- Automatic centrifugal clutch: Clutch shoe: Thickness 2.0 mm (0.08 in) 1.5 mm (0.06 in)[...]

MAINTENANCE SPECIFICATIONS SPEC 2 - 10 Lubrication system: Oil filter type Wire mesh ---- Oil pump type T rochoid type ---- T ip clearance “A” or “B” 0.15 mm (0.006 in) 0.20 mm (0.008 in) Side clearance 0.04 ~ 0.09 mm (0.002 ~ 0.004 in) 0.09 mm (0.004 in) Bypass valve setting pressure 80 ~ 120 kPa (0.8 ~ 1.2 kg/cm 2 , 11 ~ 17 psi) ---- Sha[...]

MAINTENANCE SPECIFICATIONS SPEC 2 - 11 Item Standard Lubrication chart: Crankcase tightening sequence: Crankcase (left) Crankcase (right) 2[...]

MAINTENANCE SPECIFICATIONS SPEC 2 - 12 Tightening torques Part to be tightened Part name Thread size Q’ ty Tightening torque Remarks Nm m·kg ft·lb Cylinder head (oil gallery plug) Bolt M6 1 7 0.7 5.1 Cylinder head Flange bolt M8 4 22 2.2 16 E Apply oil to the washer Cylinder head and Cylinder Bolt M8 2 22 2.2 16 Cam sprocket cover Screw M6 2 7 [...]

MAINTENANCE SPECIFICATIONS SPEC 2 - 13 Lock nut (clutch release adjuster) Nut M8 1 15 1.5 11 Starter clutch Bolt M8 3 30 3.0 22 LT Stake Starter motor Screw M6 2 7 0.7 5.1 Pinion gear (drive axle) Nut M16 1 60 6.0 43 Stake Bearing retainer (drive axle) Screw M8 3 25 2.5 18 LT Bearing retainer (bearing housing) Nut – 1 60 6.0 43 LT Nut – 1 60 6.[...]

MAINTENANCE SPECIFICATIONS SPEC 2 - 14 CHASSIS Item Standard Limit Steering system: Steering bearing type Ball bearing ---- Front suspension: Shock absorber travel 117 mm (4.61 in) ---- Suspension spring free length 293 mm (11.54 in) ---- Spring rate (K1) 10 N/mm (1.0 kg/mm, 56 lb/in)/ 0 ~ 117 mm (0 ~ 4.61 in) ---- Optional spring No ---- Rear susp[...]

MAINTENANCE SPECIFICATIONS SPEC 2 - 15 Front drum brake: T ype Leading and trailing ---- Drum inside diameter 160 mm (6.30 in) 161 mm (6.34 in) Lining thickness 4.0 mm (0.16 in) 2.0 mm (0.08 in) Shoe spring free length 71.0 mm (2.80 in) ---- Rear drum brake: T ype Leading and trailing ---- Drum inside diameter 160 mm (6.30 in) 161 mm (6.34 in) Lini[...]

MAINTENANCE SPECIFICATIONS SPEC 2 - 16 Tightening torques Part to be tightened Parts name Thread size Q’ ty Tightening torque Remarks Nm m·kg ft·lb Front panel wheel and brake drum Nu t M10 × 1.25 8 55 5.5 40 Front brake drum and steering knuckle Nut M14 × 1.5 2 70 7.0 50 Front brake cam lever and cam shaft Bolt M6 × 1.0 2 9 0.9 6.5 Steering[...]

MAINTENANCE SPECIFICATIONS SPEC 2 - 17 Pivot shaft and nut (right) Nut M22 × 1.5 1 130 13 94 Swingarm and final drive gear case Nut M8 × 1.25 4 48 4.8 35 LT Rear axle housing and final drive gear case Bolt M10 × 1.25 4 55 5.5 40 Rear shock absorber (upper) and frame Nut M12 × 1.25 1 50 5.0 36 Final drive gear case protector Bolt M8 × 1.25 2 17[...]

MAINTENANCE SPECIFICATIONS SPEC 2 - 18 ELECTRICAL Item Standard Limit V oltage: 12 V ---- Ignition system: Ignition timing (B.T .D.C.) 10˚/ 1,000 r/min ---- Advanced timing (B.T .D.C.) 30˚/ 6,000 r/min ---- Advancer type Electrical ---- C.D.I.: Magneto model / manufacturer F4T203/MITSUBISHI ---- Pickup coil resistance / color 189 ~ 231 Ω at 20?[...]

MAINTENANCE SPECIFICATIONS SPEC 2 - 19 Withstand voltage 200 V ---- Battery: Specific Gravity 1.280 Electric starter system: T ype Constant mesh type ---- Starter motor: Model / manufacturer SM-14/MITSUBA ---- Output 0.5 kW ---- Armature coil resistance 0.004 ~ 0.005 Ω at 20˚C (68˚F) ---- Brush overall length 10 mm (0.4 in) 3.5 mm (0.14 in) Sp[...]

2 - 20 SPEC HOW TO USE THE CONVERSION TABLE/ GENERAL TORQUE SPECIFICATIONS EB201000 HOW TO USE THE CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. CONVERSION TABLE METRIC MULTIPLIER IMPERIAL ** mm × 0.03937 = ** in 2 mm × 0.03937 = 0.08[...]

2 - 21 SPEC LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication points (parts name) Lubricant type Oil seal lips (all) LS O-rings (all) LS Bearings (all) E Washer (cylinder head bolt) E Crank pin E Connecting rod (big end) E Piston and piston pin E Piston and piston ring E Buffer boss E Valve stem and va[...]

2 - 22 SPEC CHASSIS Lubrication points Lubricant type Oil seal lips (all)/O-rings (all) LS Steering shaft (Upper and lower with nipple bushes) LS Steering knuckle pivot LS Front lower arm (ball joint) LS Front wheel bearings B Front drum brake: Brake cam shaft Pivot pin Oil seal lips LS Rear drum brake: Brake cam shaft Pivot pin LS Dust seal (rear [...]

2 - 23 SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Drain plug 2 O-ring 3 Compression spring 4 Oil strainer 5 Oil pump gasket 6 Oil pump assembly 7 Oil pump driven gear 8 Oil pump drive gear 9 Camshaft 0 Crank pin A Crankshaft B Main axle C Drive axle D Oil filter 2[...]

2 - 24 SPEC LUBRICATION DIAGRAMS 1 Bypass valve 2 Oil filter 3 Oil filter cover 4 O-ring 5 Collar 6 Camshaft 7 Rocker arm 8 One way bearing (Automatic centrifugal clutch) 9 Crank pin 0 Crankshaft A Main axle B Drive axle 2[...]

2 - 25 SPEC CABLE ROUTING CABLE ROUTING 1 Rear brake lever switch lead 2 Rear brake cable 3 Cable guide 4 Front brake cable 5 Throttle cable 6 Neutral indicator light 7 Reverse indicator light 8 Handlebar switch assembly lead 9 Fuel tank breather hose 0 Headlight leads A Equalizer B Front brake breather hose Å Do not route the handlebar switch ass[...]

2 - 26 SPEC CABLE ROUTING 1 Cable guide 2 Main switch 3 Fuel tank breather hose 4 Rectifier/regulator 5 CDI unit 6 Taillight 7 Final gear case breather hose 8 Carburetor overflow hose 9 Reverse switch lead 0 Neutral switch lead A Starter motor lead B Throttle cable C Rear brake cable D Rear brake breather hose E Carburetor air vent hose F CDI magne[...]

2 - 27 SPEC CABLE ROUTING Î Route the carburetor overflow hose between the engine and upper rear engine mount and then between the engine and swingarm. Make sure that the hose is not pinched. ‰ Bend the cable guide after routing the cables. Ï Fasten the starter motor lead and wire har- ness to the frame with the plastic clamp. Ì Route the rear[...]

2 - 28 SPEC CABLE ROUTING 1 Battery breather hose 2 Spark plug cap 3 Ignition coil 4 Starter motor lead 5 Rear brake cable 6 Rear brake breather hose Å Make sure that the battery breather hose is not kinked or bent. ı Route the rear brake cable through the cable guide on the cyl- inder. Ç Fasten the starter motor lead to the frame with the metal[...]

2 - 29 SPEC CABLE ROUTING 1 Wire harness 2 Starter motor lead 3 Rear brake cable 4 Throttle cable 5 Starter relay 6 Starting circuit cut-off relay 7 Rear brake breather hose 8 Carburetor air vent hose 9 Final gear case breather hose 0 Taillight lead Å 50 mm (2.0 in) ı Route the throttle cable and rear brake cable through the cable guide. Make sur[...]

2 - 30 SPEC 2[...]

INSP ADJ 3 - 1 INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reli- able machine operation and a longer service life. In addition[...]

INSP ADJ 3 - 2 *: It is recommended that these items be serviced by a Yamaha dealer. **: Lithium soap base grease. W ARNING Indicates a potential hazard that could result in serious injury or death. Steering shaft* • Lubricate every 6 months.** Fittings and Fasten- ers* • Check all chassis fittings and fasteners. • Correct if necessary. Batte[...]

3 - 3 INSP ADJ FRONT FENDER FENDER AND FUEL TANK FRONT FENDER Removal 1.Place the machine on a level place. 2.Remove: ● Front carrier 1 3.Remove: ● Front bumper skid plate 1 4.Disconnect: ● Dual headlight leads 1 5.Remove: ● Front bumper 2 6.Remove: ● Front fender 1 3[...]

3 - 4 INSP ADJ FRONT FENDER Installation: Reverse the “Removal” procedures. Note the following points. 1.Install: ● Front fender 1 T R . . Bolt 2 (front fender and frame): 7 Nm (0.7 m • kg, 5.1 ft • lb) Nut 3 (front fender and fender stay): 7 Nm (0.7 m • kg, 5.1 ft • lb) 2.Install: ● Front bumper 1 T R . . Bolt (front bumper and fra[...]

3 - 5 INSP ADJ REAR FENDER REAR FENDER Removal 1.Place the machine on a level place. 2.Remove: ● Rear carrier 1 2 with spacer 3.Remove: ● Seat 1 Pull up the seat lock lever 2 , then pull up the seat at the rear. 4.Disconnect: ● Battely leads (negative and positive) W ARNING Disconnect the negative lead 1 first. 5.Remove: ● Starter relay 2 ?[...]

3 - 6 INSP ADJ REAR FENDER Installation Reverse the “Removal” procedure. Note the following points. 1.Install: ● Rear fender 1 T R . . Bolt 2 (rear fender and frame): 7 Nm (0.7 m • kg, 5.1ft • lb) Bolt 3 (rear fender and rear foot- rest plate): 7 Nm (0.7 m • kg, 5.1ft • lb) 2.Install: ● Battery 1 ● Battery breather hose 2 ● Batt[...]

3 - 7 INSP ADJ REAR FENDER/FUEL TANK 6.Install: ● Rear carrier 1 NOTE: Do not forget to attach the spacer at the point where the carrier and bumper are connected. T R . . Bolt 2 (rear carrier and frame): 34 Nm (3.4 m • kg, 25 ft • lb) Bolt 3 (rear carrier and rear bumper): 9 Nm (0.9 m • kg, 6.5 ft • lb) FUEL TANK Removal 1.Place the machi[...]

3 - 8 INSP ADJ FUEL TANK 6.Turn the fuel cock lever to “OFF” position. 7.Disconnect: ● Fuel hose 1 NOTE: Place a rug on the engine to absorb a spilt fuel. W ARNING ● Gasoline is highly flammable. ● Avoid spilling fuel on the hot engine. 8.Remove: ● Bolt 1 (with washer and collar) 9.Disconnect: ● Air duct 2 (with hoses) ● Grommet 3 ([...]

3 - 9 INSP ADJ FUEL TANK 4.Install: ● Fuel tank cover 1 ● Fuel tank cap 2 ● Rivet 3 ● Screw 4 ● Bolt 5 (with flange collar) T R . . Bolt (fuel tank cover and frame): 10 Nm (1.0 m • kg, 7.2 ft • lb) 5.Connect: ● Breather hose 1 6.Install: ● Seat Refer to the “REAR FENDER-Installation” section. 3[...]

3 - 10 INSP ADJ ENGINE VALVE CLEARANCE ADJUSTMENT NOTE: ● The valve clearance must be adjusted when the engine is cool to the touch. ● Adjust the valve clearance when the pis- ton is at the Top Dead Center (T.D.C.) on compression stroke. Removal 1.Place the machine on a level place. 2.Remove: ● Seat ● Fuel tank cover ● Fuel tank Refer to [...]

3 - 11 INSP ADJ VALVE CLEARANCE ADJUSTMENT ● Align the “T” mark 1 on the flywheel with the stationary pointer 2 on the crankcase cover. When the “T” mark is aligned with the stationary pointer, the piston is at Top Dead Center (TDC). NOTE: T.D.C. on compression stroke check: ● Both rocker arms must have a valve clear- ance when the roto[...]

3 - 12 INSP ADJ VALVE CLEARANCE ADJUSTMENT/ TIMING CHAIN TENSIONER ADJUSTMENT ● Once again, measure the valve clearance. ● If the clearance is incorrect, repeat above steps until the proper clearance is obtained. ********************************** Installation Reverse the “Removal” procedure. Note the following points. 1.Install: ● Tappet[...]

3 - 13 INSP ADJ IDLE SPEED ADJUSTMENT 1.Place the machine on a level place. 2.Warm up engine for several minutes. 3.Adjust: ● Engine idle speed ********************************** Adjustment steps: ● Turn the pilot screw 1 clockwise until it is lightly seated. ● Loosen the pilot screw by turning it coun- terclockwise for the specified number o[...]

3 - 14 INSP ADJ THROTTLE CABLE FREE PLAY ADJUSTMENT NOTE: Before adjusting the throttle cable free play, the engine idle speed should be adjusted. 1.Place the machine on a level place. 2.Check: ● Throttle cable free play a Out of specification → Adjust. Throttle cable free play: 3 ~ 5mm (0.12 ~ 0.20 in) a 3.Adjust: ● Throttle cable free play [...]

3 - 15 INSP ADJ W ARNING After adjusting the free play, turn the han- dlebar to right and left, and make sure that the engine idling does not run faster. ********************************** SPEED LIMITER ADJUSTMENT The speed limiter keeps the carburetor throttle from becoming full-open even when the throttle lever is pushed to a maxi- mum. Screwing [...]

3 - 16 INSP ADJ 3.Inspect: ● Spark plug type Incorrect → Replace. Standard spark plug: DR7EA (NGK) SPARK PLUG INSPECTION 4.Inspect: ● Electrode 1 Wear/Damage → Replace. ● Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition. 5.Clean: ● Spark plug Clean the spark plu[...]

3 - 17 INSP ADJ IGNITION TIMING CHECK NOTE: Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing. 1.Place the machine on a level place. 2.Start the engine and let it warm up for several minutes, then stop the engine. 3.Attach: ● Inductive tachometer ● Timing light to spark plug lead. I[...]

3 - 18 INSP ADJ IGNITION TIMING CHECK/ COMPRESSION PRESSURE MEASUREMENT 5.Install: ● Timing plug 6.Detach: ● Timing light ● Inductive tachometer COMPRESSION PRESSURE MEASUREMENT NOTE: ● Insufficient compression pressure will result in performance loss. ● Before measuring the compression pres- sure, the valve clearance should be adjusted. [...]

3 - 19 INSP ADJ COMPRESSION PRESSURE MEASUREMENT/ ENGINE OIL LEVEL INSPECTION ● If pressure falls below the minimum level: 1) Squirt a few drops of oil into the affected cylinder. 2) Measure the compression again. ● Remove the compression gauge. ********************************** 4.Install: ● Spark plug Refer to “SPARK PLUG INSPECTION” se[...]

3 - 20 INSP ADJ ENGINE OIL LEVEL INSPECTION/ ENGINE OIL REPLACEMENT ● Screw the dipstick 1 completely out, and wipe the dipstick clean, then just rest the dipstick in the hole. ● Pull up the dipstick, and inspect the oil level whether or not it is between maxi- mum 2 and minimum level 3 . ● If the level is lower, add the oil up to the proper [...]

3 - 21 INSP ADJ ENGINE OIL REPLACEMENT 6.Inspect: ● O-rings 1 ● Compression spring 2 ● Oil strainer 3 ● Oil filter 4 Damage → Replace. 7.Clean: ● Compression spring 2 ● Oil strainer 3 ● Oil filter 4 ● Drain plug 5 (crankcase) ● Oil filter cover 6 Wash them with a cleaning solvent. 8.Apply: ● Engine oil (light coating) (to the [...]

3 - 22 INSP ADJ ENGINE OIL REPLACEMENT 11.Install: ● Dipstick 12.Warm up the engine for 5 minutes or more, and stop it. 13.Inspect: ● Oil leaks ● Oil level 14.Inspect: ● Oil flow ********************************** Inspection steps: ● Slightly loosen the oil gallery plug 1 in the cylinder head. ● Start the engine and keep it idling until[...]

3 - 23 INSP ADJ CLUTCH ADJUSTMENT/AIR FILTER CLEANING CLUTCH ADJUSTMENT Release lever free play adjustment 1.Adjust: ● Release lever free play ********************************** Adjustment steps: ● Loosen the locknut 1 . ● Slowly turn the adjuster 2 counterclock- wise until resistance is felt, then turn back it 1/8 clockwise, hold the adjuste[...]

3 - 24 INSP ADJ AIR FILTER CLEANING 3.Remove: ● Air filter element 1 ● Foam cover 2 CAUTION: The engine should never be run without the air filter; excessive piston and/or cylin- der wear may result. 4.Inspect: ● Air filter element 1 ● Foam cover 2 Damage → Replace. 5.Clean: ● Air filter element Use compressed air to blow off dust from [...]

3 - 25 INSP ADJ AIR FILTER CLEANING 7.Install: ● Foam cover (to air filter) 8.Install: ● Air filter assembly NOTE: Make sure its sealing surface matches the sealing surface of the case so there is no air leak. 9.Install: ● Cover (air filter case) ● Seat Refer to “REAR FENDER-Installation” sec- tion. 3[...]

3 - 26 INSP ADJ FRONT AND REAR BRAKE LINING INSPECTION/ FRONT BRAKE ADJUSTMENT CHASSIS FRONT AND REAR BRAKE LINING INSPECTION Front brake 1.Apply the front brake. 2.Inspect: ● Wear indicator 1 Indicator reaches the wear limit mark 2 → Replace brake shoes as a set. Refer to the “FRONT WHEEL AND FRONT BRAKE” section in CHAPTER 7. Rear brake 1[...]

3 - 27 INSP ADJ FRONT BRAKE ADJUSTMENT/ REAR BRAKE LEVER AND PEDAL ADJUSTMENT 2.Adjust: ● Front brake lever free play ********************************** Adjustment steps: ● Loosen the locknut 1 and turn the adjuster 2 clockwise to release the ten- sion in the front brake cable. ● Visually check the cable joint 3 in the equalizer 4 to verify i[...]

3 - 28 INSP ADJ REAR BRAKE LEVER AND PEDAL ADJUSTMENT 2.Adjust: ● Brake lever free play ● Brake pedal free play ********************************** Adjustment steps: NOTE: Before adjusting the free play, pump the brake pedal 2 to 3 times. ● Fully loosen the locknut 1 (handlebar) and fully turn in the brake lever adjuster 2 . ● Fully loosen b[...]

3 - 29 INSP ADJ DRIVE SELECT LEVER POSITION ADJUSTMENT/ FINAL DRIVE GEAR OIL LEVEL INSPECTION DRIVE SELECT LEVER POSITION ADJUSTMENT 1.Adjust: ● Drive select lever position ********************************** Adjustment steps: ● Place the machine on a level place. ● Shift the transmission in first gear, and move the select lever 1 to reverse p[...]

3 - 30 INSP ADJ ● If the oil level is low, add the recom- mended oil up to the specified level. Refer to “FINAL DRIVE GEAR OIL REPLACE- MENT” section. ● Inspect the copper washer for damage. If damaged, replace it ● Install the copper washer and filler bolt. NOTE: ● Before installing the filler bolt, do not for- get to fit the copper wa[...]

3 - 31 INSP ADJ FINAL DRIVE GEAR OIL REPLACEMENT/DRIVE SHAFT DUST BOOT INSPECTION/STEERING SYSTEM INSPECTION 7.Install: ● Filler bolt (final drive gear case) NOTE: After filling the oil, inspect the oil leaks. Recommended oil: SAE 80 API “GL-4” hypoid gear oil If desired, and SAE 80W90 hypoid gear oil may be used for all condition. Periodic o[...]

3 - 32 INSP ADJ STEERING SYSTEM INSPECTION/ TOE-IN ADJUSTMENT 4.Raise the front end of the machine so that there is no weight on the front wheels. 5.Check: ● Knuckles and/or wheel bearings Move the wheels laterally back and forth. Excessive free play → Replace the follow- ing parts. 1) Wheel bearings 2) Knuckle shaft(s) 1 3) Cotter pin(s) 2 4) [...]

3 - 33 INSP ADJ TOE-IN ADJUSTMENT ● If the toe-in is incorrect, adjust the toe-in. ********************************** Toe-in: 0 ~ 5 mm (0 ~ 0.2 in) 3.Adjust: ● Toe-in ********************************** Adjustment steps: ● Place a confirmation marks 1 on the both tie-rods end. ● Loosen the rod end locknuts 2 of both tie- rods. ● The same n[...]

3 - 34 INSP ADJ TOE-IN ADJUSTMENT/FRONT AND REAR SHOCK ABSORBERS INSPECTION/REAR SHOCK ABSORBER ADJUSTMENT FRONT AND REAR SHOCK ABSORBERS INSPECTION 1.Place the machine on a level place. 2.Check: ● Ball joint complete 1 (front) Cracks/Damage → Replace as a set. ● Damper rod 2 (rear) Scratch/Damage → Replace as a set. ● Oil leakage 3 Exces[...]

3 - 35 INSP ADJ TIRE INSPECTION TIRE INSPECTION W ARNING This model is equipped with low pressure tires. It is important that they be inflated correctly and maintained at the proper pressures. ● TIRE CHARACTERISTICS 1) Tire characteristics influence the han- dling of ATV’s. The tires listed below have been approved by Yamaha Motor Co., Ltd. for[...]

3 - 36 INSP ADJ TIRE INSPECTION 1.Measure: ● Tire pressure (cold tire pressure) Out of specification → Adjust. NOTE: ● The Low-pressure tire gauge 1 is included in the standard equipment. ● If dust or the like is stuck to this gauge, it does not provide correct readings. There- fore, make two measurements on the tire pressure and get the se[...]

3 - 37 INSP ADJ WHEEL INSPECTION WHEEL INSPECTION 1.Inspect: ● Wheels 1 Cracks/Bends/Damage → Replace. NOTE: Always balance the wheel when a tire or wheel has been changed or replaced. W ARNING Never attempt even small repairs to the wheel. 3[...]

3 - 38 INSP ADJ ELECTRICAL BATTERY INSPECTION W ARNING Battery electrolyte is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive measures: ● Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. ● Wear protective eye gear when handling or worki[...]

3 - 39 INSP ADJ BATTERY INSPECTION 4.Inspect: ● Battery fluid level Battery fluid level low → Fill. Fluid level should be between upper level 1 and lower level 2 marks. CAUTION: Refill with distilled water only; tap water contains minerals harmful to a battery. 5.Inspect: ● Battery fluid specific gravity Out of specification → Charge. *****[...]

3 - 40 INSP ADJ BATTERY INSPECTION 7.Inspect: ● Battery breather hose Obstruction → Remove. Damage → Replace. 8.Install: ● Battery 1 ● Battery breather hose 2 Refer to the “CABLE ROUTING” section in CHAPTER 2. CAUTION: When installing the battery, be sure the breather hose is routed correctly. If the breather hose touches the frame or[...]

3 - 41 INSP ADJ FUSE INSPECTION FUSE INSPECTION CAUTION: Don’t forget to turn off the main switch when checking or replacing the fuse. Other- wise, it may cause accidental shortcircuit- ing. W ARNING Do not use fuses of a higher amperage rat- ing than those recommended. Substitu- tion of a fuse of improper rating can cause extensive electrical sy[...]

3 - 42 INSP ADJ FUSE INSPECTION/HEADLIGHT BEAM ADJUSTMENT/ HEADLIGHT BULB REPLACEMENT 4.Replace: ● Blown fuse ********************************** Blown fuse replacement steps: ● Turn off ignition and the circuit. ● Install a new fuse of proper amperage. ● Turn on the switches and see if the electri- cal device operates. ● Fuse interrupts t[...]

3 - 43 INSP ADJ HEADLIGHT BULB REPLACEMENT 5.Remove: ● Bulb 1 W ARNING Keep flammable products or your hands away from the bulb while it is on, it will be hot. Do not touch the bulb until it cools down. 6.Install: ● Bulb 1 (new) NOTE: Make sure the projection 2 on the bulb is meshed with the slot 3 on the light case. CAUTION: Avoid touching gla[...]

INSP ADJ 3 - 44 3[...]

4 - 1 ENG ENGINE REMOVAL ENGINE OVERHAUL ENGINE REMOVAL NOTE: ● It is not necessary to remove the engine in order to remove the following compo- nents: * Cylinder head * Cylinder * Piston * Primary and secondary clutches * Oil pump * Shift shaft * CDI Magneto ● It is necessary to remove the rear wheel drive assembly in order to remove the engin[...]

4 - 2 ENG ENGINE REMOVAL ENGINE OIL 1.Drain: ● Engine oil Refer to the “ENGINE OIL REPLACE- MENT” section in CHAPTER 3. EXHAUST PIPE AND MUFFLER 1.Remove: ● Exhaust pipe 1 ● Muffler 2 CARBURETOR 1.Drain: ● Fuel (float chamber) NOTE: Place a rag under the over flow hose to absorb a spilt fuel. W ARNING Gasoline is highly flammable. Avoid[...]

4 - 3 ENG ENGINE REMOVAL STARTER MOTOR 1.Disconnect: ● Starter motor lead 1 2.Remove: ● Starter motor bracket 2 ● Starter motor 3 REAR BRAKE CABLES AND FOOTREST 1.Remove: ● Adjusters 1 (brake lever and brake pedal) ● Pins 2 ● Springs 3 2.Disconnect: ● Brake cable 4 (from brake cable bracket 5 . 3.Remove: ● Footrest 1 (left) ● Shif[...]

4 - 4 ENG ENGINE REMOVAL REAR WHEEL DRIVE ASSEMBLY AND SWINGARM 1.Disconnect: ● Breather hose 1 (final gear housing and rear brake drum) (from the cable guides 2 of main frame) 2.Block the front wheels, and elevate the rear wheels by placing the suitable stand under the frame. 3.Remove: ● Bolt 1 (rear shock absorber-top) 4.Remove: ● Clamps 1 [...]

4 - 5 ENG ENGINE DISASSEMBLY ENGINE DISASSEMBLY CYLINDER HEAD ASSEMBLY, CYLINDER AND PISTON NOTE: With the engine mounted cylinder head assembly, cylinder and piston can be main- tained by removing the following parts. ● Fuel tank ● Exhaust pipe ● Carburetor ● Engine stays (top) 1.Remove: ● Recoil starter assembly 1 2.Remove: ● Timing p[...]

4 - 6 ENG ENGINE DISASSEMBLY 5.Align: ● “T” mark on the rotor With the stationary pointer on the crank- case cover. ********************************* TDC alignment steps: ● Turn the crankshaft counterclockwise with wrench. ● Align the “T” mark 1 on the rotor with the stationary pointer 2 on the crankcase cover. When the “T” mark i[...]

4 - 7 ENG ENGINE DISASSEMBLY 8.Remove: ● Bolt 1 ● Cam sprocket 2 NOTE: ● Fasten a safety wire 3 to the timing chain to prevent if from falling into the crank- case. ● When removing the cam sprocket, it is not necessary to separate the timing chain. ● Hold the starter pulley 4 by the Rotor Holder to loosen the bolt on the cam sprocket. Rot[...]

4 - 8 ENG ENGINE DISASSEMBLY 11.Remove: ● Bolts 1 (cylinder) ● Cylinder 2 ● Gasket 3 (cylinder) ● Dowel pins 4 ● O-ring 5 12.Remove: ● Piston pin clip 1 ● Piston pin 2 ● Piston 3 NOTE: ● Before removing the piston pin clip, cover the crankcase with a clean rag so you will not accidentally drop the clip into the crankcase. ● Befo[...]

4 - 9 ENG ENGINE DISASSEMBLY 1.Remove: ● Starter pulley 1 NOTE: Hold the starter pulley by the Rotor Holder to loosen the bolt on the starter pulley. Rotor holder: P/N. YU-01235, 90890-01235 2.Remove: ● Crankcase cover 1 3.Remove: ● Gasket 1 ● Dowel pins 2 ● Shaft 3 ● Washer 4 ● Idle gear 5 (starter) 4.Remove: ● CDI magneto 1 NOTE: [...]

4 - 10 ENG ENGINE DISASSEMBLY 5.Remove: ● Woodruff key 1 ● Driven gear 2 (starter) ● Washer 3 6.Remove: ● Chain guide 1 (intake) ● Timing chain 2 MIDDLE DRIVEN PINION GEAR 1.Remove: ● Bolts 1 (bearing housing) 2.Remove: ● Bolts 1 (middle gear case cover) ● Middle gear case cover 2 3.Remove: ● Middle driven pinion gear assembly 1 ?[...]

4 - 11 ENG ENGINE DISASSEMBLY PRIMARY AND SECONDARY CLUTCHES NOTE: With the engine mounted, the primary and secondary clutches can be maintained by removing the following parts: ● Starter motor ● Crankcase cover (right) 1.Remove: ● Oil filter cover 1 ● Oil filter 2 ● O-ring 3 ● Clutch cover protector 4 ● Crankcase cover 5 (right) ● [...]

4 - 12 ENG ENGINE DISASSEMBLY 5.Remove: ● Lock washer 1 ● Clutch carrier assembly 2 ● Washer 3 ● Clutch housing 4 (primary) ● Washer 5 NOTE: The secondary clutch housing has two grooves 1 machined into it to permit the primary drive gear behind the primary clutch to clear the secondary clutch. Align one of these grooves with the primary g[...]

4 - 13 ENG ENGINE DISASSEMBLY 9.Straighten: ● Lock washer tab 1 (clutch boss) 10.Remove: ● Nut 2 (clutch boss) NOTE: Hold the clutch boss 3 by the Rotor Holder 4 to loosen the nut. 11.Remove: ● Lock washer 1 ● Clutch boss 2 ● Friction plates 3 ● Clutch plates 4 ● Pressure plate 5 ● Washer 6 ● Clutch housing 7 OIL PUMP AND SHIFTER [...]

4 - 14 ENG ENGINE DISASSEMBLY 3.Remove: ● Shift lever assembly 1 ● Washer 2 ● Return spring 3 ● Stopper lever 4 ● Washer 5 NOTE: Push the shift pawl and the stopper lever to the arrow direction and remove them from the segment. 4.Remove: ● Segment 1 (shift cam) Use the Torx  wrench to remove. NOTE: When removing the segment, the dowe[...]

4 - 15 ENG ENGINE DISASSEMBLY 3.Remove: ● Lock washer 1 ● Balancer gear 2 (driven) ● Straight key 3 CRANKCASE (LEFT) 1.Remove: ● Screws (crankcase) NOTE: Working in a crisscross pattern, loosen all screws 1/4 turn each. Remove them after all are loosened. 2.Remove: ● Crankcase 1 (left) ● Dowel pins ********************************* Remo[...]

4 - 16 ENG ENGINE DISASSEMBLY NOTE: Fully tighten the tool holding bolts, but make sure the tool body is parallel with the case. If necessary, one screw may be backed out slightly to level tool body. ● As pressure is applied, alternately tap on the front engine mounting boss, transmis- sion shafts and balancer shaft. CAUTION: ● Use soft hammer [...]

4 - 17 ENG ENGINE DISASSEMBLY 2.Remove: ● Transmission assembly 1 (main axle and drive axle) ● Washer 2 (drive axle) 3.Remove: ● Circlip 1 4.Remove: ● Balancer drive gear 2 ● Crankshaft 3 (from right crankcase) ● Woodruff key 4 NOTE: Use a hydraulic press to remove the bal- ancer drive gear 2 from the crankshaft. CYLINDER HEAD 1.Straigh[...]

4 - 18 ENG ENGINE DISASSEMBLY 4.Remove: ● Rocker arm shafts 1 ● Rocker arms (intake/exhaust) NOTE: Attach the Slide Hammer Set 2 to the rocker arm shaft, and then slide out the them. Slide hammer set: P/N. YU-01083-A Slide hammer bolt: P/N. 90890-01083 Weight: P/N. 90890-01084 VALVE NOTE: Before removing the internal parts (valve, valve spring,[...]

4 - 19 ENG ENGINE DISASSEMBLY 2.Remove: ● Valve cotters 1 NOTE: Attach the Valve Spring Compressor 2 between the valve spring seat and cylinder head to remove the valve cotters. 3.Remove: ● Valve spring seat 1 (upper) ● Valve spring 2 (outer) ● Valve spring 3 (inner) ● Valve 4 ● Valve stem seal 5 ● Valve spring seat 6 (lower) NOTE: Id[...]

4 - 20 ENG INSPECTION AND REPAIR INSPECTION AND REPAIR CYLINDER HEAD 1.Eliminate: ● Carbon deposit Use a rounded scraper 1 . NOTE: Do not use a sharp instrument to avoid damaging or scratching: ● Spark plug threads ● Valve seat ● Cylinder head 2.Measure: ● Cylinder head warpage Out of specification → Resurface/Replace. Cylinder head war[...]

4 - 21 ENG INSPECTION AND REPAIR 3.Measure: ● Valve stem runout Out of specification → Replace. Stem runout: Less than: 0.03 mm (0.0012 in) 4.Measure: ● Valve stem clearance Out of specification → Replace either valve and/or guide. Use a Micrometer and Bore Gauge 1 . VALVE GUIDE NOTE: ● Always replace the valve guide if the valve is repla[...]

4 - 22 ENG INSPECTION AND REPAIR 3.Install: ● Circlip 1 (new) ● Valve guide 2 (new) Use the Valve Guide Installer 3 with the Valve Guide Remover 4 . 4.Bore valve guide 2 to obtain proper valve stem clearance. Use the Valve Guide Reamer 5 (6.0 mm) NOTE: Reface the valve seat after installing the valve guide. V alve guide installer: P/N. YM-04065[...]

4 - 23 ENG INSPECTION AND REPAIR ● Press the valve through the valve guide and onto the valve seat to make a clear pattern. ● Remove the valve from the cylinder head. ● Measure the valve seat width a . When the valve seat and valve face make contact, bluing will be applied to the valve face. ● If the valve seat width is too wide, too nar- r[...]

4 - 24 ENG INSPECTION AND REPAIR ı Valve seat is in the middle of the valve face but too narrow. Ç Valve seat is too narrow and right up near valve margin. Î Valve seat is too narrow and is located down near the bottom edge of the valve face. ********************************* Valve seat cutter set Desired result Use 45˚ cutter To achieve a uni-[...]

4 - 25 ENG INSPECTION AND REPAIR ● Apply a molybdenum disulfide oil to the valve stem. ● Install the valve into the cylinder head. ● Turn the valve until the valve face and valve seat are evenly polished, then clean off all compound. NOTE: To obtain the best lapping result, lightly tap the valve seat while rotating the valve back and forth be[...]

4 - 26 ENG INSPECTION AND REPAIR 2.Measure: ● Valve spring installed force Out of specification → Replace inner and outer springs as a set. a Installed length Valve spring installed force Inner spring (IN/EX) 8.4 ~ 10.2 kg (18.5 ~ 22.5 lb) at 30.5 mm (1.2 in) Outer spring (IN/EX) 16.6 ~ 20.4 kg (36.6 ~ 45.0 lb) at 32.0 mm (1.26 in) VALVE INSTAL[...]

4 - 27 ENG INSPECTION AND REPAIR NOTE: All valve springs must be installed with the larger pitch a upward as shown. 1 Outer spring 2 Inner spring 4.Check: ● Valve sealing Leakage at valve seat → Reface, relap or replace valve, relap. Refer to “VALVE SEAT”. ********************************* Valve seat checking steps: ● Pour a clean solvent[...]

4 - 28 ENG INSPECTION AND REPAIR 2.Inspect: ● Cam lobes Pitting/Scratches/Blue discoloration → Replace. 3.Measure: ● Cam lobes Use a Micrometer. Out of specification → Replace. Cam lobe Limit “A” Cam lobe Limit “B” Intake 36.437 mm (1.435 in) 30.031 mm (1.182 in) Exhaust 36.482 mm (1.436 in) 30.152 mm (1.187 in) ROCKER ARM AND ROCKE[...]

4 - 29 ENG INSPECTION AND REPAIR ● Calculate the clearance by subtracting the rocker-arm-shaft outside diameter from the rocker-arm inside diameter. Out of specification → Replace as a set. Arm-to-shaft clearance = Rocker arm inside diameter a – Rocker arm shaft outside diameter b Arm-to-shaft clearance: 0.009 ~ 0.037 mm (0.0004 ~ 0.0013 in) [...]

4 - 30 ENG INSPECTION AND REPAIR 5.Install: ● Camshaft bushing 1 NOTE: The cut-out portion 2 of the bushing must be flush with the cylinder head. CAUTION: Do not cock the bushing during installa- tion. The bushing must be perpendicular to the camshaft during installation. 6.Install: ● Retainer 1 (camshaft bushing) ● Lock washer (new) NOTE: Be[...]

4 - 31 ENG INSPECTION AND REPAIR CAM SPROCKET AND CAM DRIVE SPROCKET 1.Inspect: ● Cam sprocket ● Cam drive sprocket (crank shaft) Wear/Damage → Replace cam sprocket and timing chain as a set. 1 1/4 tooth 2 Correct 3 Roller 4 Sprocket TIMING CHAIN GUIDE 1.Inspect: ● Timing chain guide 1 (exhaust) ● Timing chain guide 2 (intake) Wear/Damage[...]

4 - 32 ENG INSPECTION AND REPAIR TAPPET COVER AND CAM SPROCKET COVER 1.Inspect: ● Tappet covers (intake 1 and exhaust 2 ) ● Cam sprocket cover 3 ● O-rings 4 Cracks/Damage → Replace. CYLINDER AND PISTON 1.Eliminate: ● Carbon deposits (from the piston crown and ring grooves.) 2.Inspect: ● Cylinder and piston walls Vertical scratches → R[...]

4 - 33 ENG INSPECTION AND REPAIR 2nd steps ● Measure the piston skirt diameter “P” with a micrometer. b 4 mm (0.16 in) from the piston bottom edge ● If out of the specification, replace the pis- ton and piston rings as a set. 3rd steps ● Find the piston-to-cylinder clearance with following formula. ● If out of the specification, rebore [...]

4 - 34 ENG INSPECTION AND REPAIR Side clearance Standard Limit Top ring 0.03 ~ 0.07 mm (0.001 ~ 0.003 in) 0.12 mm (0.005 in) 2nd ring 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in) 0.12 mm (0.005 in) 2.Position: ● Piston ring (into cylinder) NOTE: Insert the ring into the cylinder, and push it approximately 20 mm (0.8 in) into the cylin- der. Push the ring [...]

4 - 35 ENG INSPECTION AND REPAIR ● Oil control ring Expander spacer of bottom ring (oil con- trol ring) is color-coded to identify sizes. Size Color Oversize 2 Blue Oversize 4 Yellow Piston pin 1.Inspect: ● Piston pin Blue discoloration/Grooves → Replace then inspect lubrication system. 2.Measure: ● Outside diameter a (piston pin) Out of sp[...]

4 - 36 ENG INSPECTION AND REPAIR CRANKSHAFT 1.Measure: ● Crank width A Out of specification → Replace or repair. ● Runout c Out of specification → Replace or repair. ● Side clearance D Out of specification → Replace or repair. ● Big end radial clearance E Out of specification → Replace or repair. ● Small end free play F Out of spe[...]

4 - 37 ENG INSPECTION AND REPAIR ********************************* Crankshaft reassembling point: The crankshaft 1 and the crank pin 2 oil passages must be properly interconnected with a tolerance of less than 1 mm (0.04 in). ********************************* BALANCER DRIVE GEAR AND DRIVEN GEARS 1.Inspect: ● Balancer drive gear teeth 1 ● Balanc[...]

4 - 38 ENG INSPECTION AND REPAIR 3.Inspect: ● Bolts 1 (starter clutch) Loose → Replace with a new one, and calk the end of the bolt. Bolts (starter clutch): 30 Nm (3.0 m • kg, 22 ft • lb) LOCTITE  Calk the end of the bolt PRIMARY CLUTCH Clutch housing 1.Inspect: ● Clutch housing 1 (inner surface) Heat damage/Wear/Damage → Replace. ?[...]

4 - 39 ENG INSPECTION AND REPAIR Clutch boss and pressure plate 1.Inspect: ● Clutch boss splines 1 ● Pressure plate splines 2 Scoring/Wear/Damage → Replace clutch boss assembly and/or pressure plate. Friction plates 1.Inspect: ● Friction plate 1 Damage/Wear → Replace friction plate as a set. 2.Measure: ● Friction plate thickness Measure[...]

4 - 40 ENG INSPECTION AND REPAIR Clutch spring 1.Inspect: ● Clutch spring Wear/Damage → Replace. 2.Measure: ● Clutch spring free length a Out of specification → Replace springs as a set. Clutch release lever 1.Inspect: ● Release lever 1 ● Adjuster 2 ● O-ring 3 Cracks/Wear/Damage → Replace. Clutch spring minimum length: 32.9 mm (1.30[...]

4 - 41 ENG INSPECTION AND REPAIR TRANSMISSION AND SHIFTER Shift fork and guide bar 1.Inspect: ● Shift forks On the gear and shift cam contact sur- faces. Wear/Chafing/Bends/Damage → Replace. 2.Inspect: ● Guide bars (Roll the guide bar on a flat surface. Bends → Replace. W ARNING Do not attempt to straighten a bent guide bar. 3.Check: ● Sh[...]

4 - 42 ENG INSPECTION AND REPAIR 2.Inspect: ● Gears (transmission 1 and drive pinion 2 ) ● Mating dogs Cracks/Damage/Wear → Replace. NOTE: When the drive pinion gear is replaced, be sure to adjust the drive pinion gear shim(s), refer to the “DRIVE TRAIN-MIDDLE GEAR SERVICE” section in CHAPTER 6. 3.Check: ● Gear movement (transmission) U[...]

4 - 43 ENG INSPECTION AND REPAIR MIDDLE GEAR 1.Inspect: ● Middle driven pinion gear 1 ● Bearing 2 ● Middle driven shaft 3 ● Reverse gear 4 ● Bearing housing 5 Damage/Wear → Replace. 2.Check: ● Bearing movement Turns roughly → Replace. NOTE: When the driven pinion gear, reverse gear, middle driven shaft and/or bearing housing are rep[...]

4 - 44 ENG INSPECTION AND REPAIR 3.Inspect: ● Crankcase Cracks/Damage → Replace. ● Oil delivery passages Clog → Blow out with compressed air. NOTE: When the crankcase is replaced, be sure to adjust the middle gear shim(s), refer to “DRIVE TRAIN-MIDDLE GEAR SERVICE” section in CHAPTER 6. RECOIL STARTER 1.Inspect: ● Drive plate 1 Cracks[...]

4 - 45 ENG ENGINE ASSEMBLY AND ADJUSTMENT ENGINE ASSEMBLY AND ADJUSTMENT RECOIL STARTER 1.Install: ● Starter spring 1 NOTE: Mesh the spring hook 2 wise the case slit, then carefully wind the spring counterclock- wise, and fit the spring into the case. 2.Install: ● Plate 1 ● Starter spring case 2 NOTE: Mesh the end 3 of the sheave spring with [...]

4 - 46 ENG ENGINE ASSEMBLY AND ADJUSTMENT 6.Install: ● Spring (drive pawl) 1 ● Drive pawl 2 ● Circlip 3 ● Spring 4 ● Drive plate 5 ● Bolt 6 NOTE: When installing the spring (drive pawl), align the spring end 7 with the groove a on the sheave drum. 7.Turn the sheave drum 3-turns clockwise to preload the starter spring. 8.Install: ● Sta[...]

4 - 47 ENG ENGINE ASSEMBLY AND ADJUSTMENT CRANKSHAFT/BALANCER 1 Balancer driven gear 2 Bearing 3 Straight key 4 Balancer 5 Oil seal 6 Balancer drive gear 7 Woodruff key 8 Crank (right) 9 Connecting rod 0 Small end bearing A Crank pin B Crank (left) A PISTON TO CYLINDER CLEARANCE: 0.04 ~ 0.06 mm (0.0016 ~ 0.0024 in) B END GAP (INSTALLED): Top ring &[...]

4 - 48 ENG ENGINE ASSEMBLY AND ADJUSTMENT TRANSMISSION 1 Bearing 2 1st wheel gear 3 5th wheel gear 4 Circlip 5 Washer 6 3rd wheel gear 7 4th wheel gear 8 2nd wheel gear 9 Drive axle 0 Bearing retainer A Main axle B 5th pinion gear C 3rd pinion gear D 4th pinion gear E 2nd pinion gear F Oil seal G Shim A DRIVE/MAIN AXLE RUNOUT: <Limit> 0.08 mm[...]

4 - 49 ENG ENGINE ASSEMBLY AND ADJUSTMENT SHIFTER 1 Guide bar #1 (long) 2 Shift fork #2 3 Shift fork #3 4 Shift cam segment 5 Pin 6 Bearing 7 Shift cam 8 Guide bar #2 (short) 9 Shift fork #1 4[...]

4 - 50 ENG ENGINE ASSEMBLY AND ADJUSTMENT CRANKSHAFT, TRANSMISSION AND BALANCER SHAFT 1.Install: ● Crankshaft 1 (to right crankcase) NOTE: Hold the connecting rod at top dead center with one hand while installing the crank- shaft. 2.Install: ● Transmission assembly 1 (main axle and drive axle) 3.Install: ● Balancer shaft 1 ● Shift fork #1 2[...]

4 - 51 ENG ENGINE ASSEMBLY AND ADJUSTMENT CRANKCASE (LEFT) 1.Apply: ● Sealant 1 (to matching surfaces of both case halves) Sealant (Quick Gasket  ): ACC-QUICK-GS-KT Y amaha bond No. 1215: 90890-85505 2.Install: ● Dowel pins 2 3.Fit the left crankcase onto the right case. Tap lightly on the case with a soft ham- mer. CAUTION: Before installin[...]

4 - 52 ENG ENGINE ASSEMBLY AND ADJUSTMENT Crankshaft installer set 1 : P/N. YU-90050 Buffer boss installer set 2 : P/N. 90890-04088 Adapter #11 3 : P/N. YM-33279 Spacer 4 (crankshaft): P/N. YM-90070-A, 90890-04060 2.Install: ● Balancer gear 1 (driven) ● Straight key 2 NOTE: Align the drive gear mark 3 with the driven gear mark 4 . 3.Install: ?[...]

4 - 53 ENG ENGINE ASSEMBLY AND ADJUSTMENT SHIFT SHAFT/OIL PUMP 1 Adjuster 2 Spring 3 Release lever 4 Shift guides 5 Ball holder 6 Shift shaft 7 Torsion spring 8 Stopper lever 9 Return spring 0 Oil seal A Shift pedal B Oil pump assembly C Gasket 4[...]

4 - 54 ENG ENGINE ASSEMBLY AND ADJUSTMENT SHIFTER AND OIL PUMP 1.Install: ● Segment 1 ● Pin 2 (long) ● Pin 3 (short) NOTE: Install the pin 2 (long) to the match mark 4 position. 2.Install: ● Segment (shift cam) NOTE: Align the hole 1 of the shift cam with the pin 2 (long) of the segment. 3.Tighten: ● Screw 1 (segment) T R . . Screw (segme[...]

4 - 55 ENG ENGINE ASSEMBLY AND ADJUSTMENT 6.Apply: ● 4-stroke engine oil (to the oil pump inner parts) 7.Install: ● Rotor housing 1 ● Outer rotor 2 ● Inner rotor 3 ● Dowel pins 4 ● Oil pump driven gear 5 ● Dowel pin 6 ● Oil pump cover 7 ● Screw 8 8.Apply: ● 4-stroke engine oil (to the oil passages in the crankcase) CAUTION: Appl[...]

4 - 56 ENG ENGINE ASSEMBLY AND ADJUSTMENT CLUTCH 1 Push rod 2 Bearing 3 Bearing holder 4 Clutch boss 5 Clutch plate 6 Friction plate 7 Pressure plate 8 Washer 9 Clutch housing (secondary) 0 Clutch carrier assembly A Washer B Inner collar C One way bearing D Clutch housing (primary) A CLUTCH SPRING MINIMUM LENGTH: 0.02 mm (0.0008 in) B CLUCTH PLATE [...]

4 - 57 ENG ENGINE ASSEMBLY AND ADJUSTMENT PRIMARY AND SECONDARY CLUTCHES 1.Install: ● Clutch housing 1 (secondary) ● Washer 2 2.Install: ● Friction plates 1 ● Clutch plates 2 (to clutch boss 3 ) NOTE: Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate[...]

4 - 58 ENG ENGINE ASSEMBLY AND ADJUSTMENT NOTE: Hold the clutch boss 2 by the Rotor Holder 3 to tighten the nut. 6.Bend the lock washer tab 4 . Rotor holder: P/N. YU-01235, 90890-01235 7.Install: ● Clutch springs 1 ● Bearing holder 2 ● Bearing 3 ● Push rod 4 T R . . Bolts (clutch spring): 6 Nm (0.6 m • kg, 4.3 ft • lb) 8.Install: ● Dr[...]

4 - 59 ENG ENGINE ASSEMBLY AND ADJUSTMENT 11.Install: ● Washer 1 ● Clutch housing 2 (primary) ● Washer 3 ● Clutch carrier assembly 4 NOTE: ● The secondary clutch housing has two grooves 1 machined into it permit the primary drive gear behind the primary clutch to clear the secondary clutch. ● Align one of these grooves with the pri- mar[...]

4 - 60 ENG ENGINE ASSEMBLY AND ADJUSTMENT 15.Install: ● Shift guide #2 1 ● Ball holder 2 ● Shift guide #1 3 ● Spring 4 (clutch release lever) NOTE: ● The slot 5 in the shift guide #2 must engage the shift shaft projection 6 . ● The slot 7 in the shift guide #1 must engage the stopper shaft 8 . 16.Install: ● Dowel pins 1 ● Gasket 2 ?[...]

4 - 61 ENG ENGINE ASSEMBLY AND ADJUSTMENT MIDDLE DRIVEN PINION GEAR 1.Install: ● Dowel pins 1 ● Shims 2 (to middle driven shaft) ● Bearing 3 ● Middle driven shaft assembly 4 NOTE: Apply the grease to the O-ring 5 . 2.Apply: ● Sealant 1 (to matching surface of middle shaft case cover) Sealant (Quick Gasket  ): P/N. ACC-QUICK-GS-KT Y ama[...]

4 - 62 ENG FWD ENGINE ASSEMBLY AND ADJUSTMENT STARTER PULLEY (EXCEPT FOR USA)/CDI MAGNETO 1 Timing chain 2 Timing chain guide (intake) 3 Woodruff key 4 Washer 5 Starter driven gear 6 Starter clutch 7 Dowel pin 8 Starter clutch spring cap 9 Compression spring 0 CDI magneto A Starter idle gear B Shaft C Washer D Circlip E Stator assembly F Crankcase [...]

4 - 63 ENG ENGINE ASSEMBLY AND ADJUSTMENT STARTER PULLEY (EXCEPT FOR USA) AND CDI MAGNETO 1.Inspect: ● Timing chain 1 ● Chain guide 2 (intake) NOTE: Fasten a safety wire 3 to the timing chain to prevent it from falling into the crankcase. 2.Install: ● Washer 1 ● Driven gear 2 (starter) ● Woodruff key 3 ● CDI magneto 4 NOTE: ● Clean th[...]

4 - 64 ENG ENGINE ASSEMBLY AND ADJUSTMENT 5.Install: ● Starter pulley 1 NOTE: ● Hold the starter pulley by the Rotor Holder to tighten the bolt. ● Before installing the starter pulley, apply the grease to the oil seal rip 2 and O-ring 3 . T R . . Bolt (starter pulley): 50 Nm (5.0 m • kg, 36 ft • lb) Rotor holder: P/N. YU-01235, 90890-0123[...]

4 - 65 ENG ENGINE ASSEMBLY AND ADJUSTMENT CYLINDER AND CYLINDER HEAD ASSEMBLY 1 Spark plug 2 Tappet cover (intake) 3 O-ring 4 Tappet cover (exhaust) 5 Cylinder head 6 Bearing retainer 7 Lock washer 8 Cam sprocket cover 9 Oil seal 0 Cylinder A CYLINDER HEAD WARP LIMIT: 0.10 mm (0.004 in) B SPARK PLUG: C TYPE/MANUFACTURER: DR7EA/NGK D SPARK PLUG GAP:[...]

4 - 66 ENG ENGINE ASSEMBLY AND ADJUSTMENT PISTON, CAMSHAFT AND TIMING CHAIN 1 Gasket 2 Timing chain tensioner 3 Gasket 4 Timing chain guide (intake) 5 Camshaft 6 Camshaft bushing 7 Cam sprocket 8 Timing chain 9 Timing chain guide (exhaust) 0 Piston ring A Piston pin clip B Piston C Piston pin 4[...]

4 - 67 ENG ENGINE ASSEMBLY AND ADJUSTMENT CYLINDER HEAD ASSEMBLY, CYLINDER AND PISTON 1.Install: ● Piston 1 ● Piston pin 2 ● Piston pin clips 3 NOTE: ● The arrow 4 on the piston must point to the front of the engine. ● Before installing the piston pin clip, cover the crankcase with a clean towel or rag so you will not accidentally drop th[...]

4 - 68 ENG ENGINE ASSEMBLY AND ADJUSTMENT 5.Install: ● Cylinder 1 ● Bolts (cylinder)-temporary tighten NOTE: ● Install the cylinder with one hand while compressing the piston rings with the other hand. ● Pass the timing chain through the chain cavity. 6.Install: ● Chain guide 1 (exhaust) ● Oil seal 2 ● Dowel pins 3 ● Gasket 4 (cylin[...]

4 - 69 ENG ENGINE ASSEMBLY AND ADJUSTMENT ● Turn the crankshaft counterclockwise until the TDC mark 3 is aligned with the station- ary pointer 4 on the crankcase cover. ● Place the timing chain onto the cam sprocket. ● Install the cam sprocket onto the cam- shaft, and finger tighten the sprocket bolt. NOTE: ● When installing the cam sprocke[...]

4 - 70 ENG ENGINE ASSEMBLY AND ADJUSTMENT ● Insert a small screwdriver 3 into the ten- sioner body slit. While pressing the ten- sioner rod, rotate the screwdriver clockwise until it stops turning. ● While holding the screwdriver in this posi- tion, and install the tensioner assembly 2 (with the gasket) onto the cylinder, then temporary tighten[...]

4 - 71 ENG ENGINE ASSEMBLY AND ADJUSTMENT 13.Install: ● Tappet cover 1 (intake) ● Tappet cover 2 (exhaust) ● Spark plug 3 T R . . Bolt (tappet cover): 10 Nm (1.0 m • kg, 7.2 ft • lb) Spark plug: 17.5 Nm (17.5 m • kg, 12.5 ft • lb) 14.Install: ● Cam sprocket cover 1 ● Carburetor joint 2 NOTE: Inspect the O-ring of the carburetor jo[...]

4 - 72 ENG ENGINE ASSEMBLY AND ADJUSTMENT REMOUNTING ENGINE Reverse the “ENGINE REMOVAL” proce- dure. Note the following points. W ARNING Securely support the machine so there is no danger of it falling over. 1.Install: ● Engine assembly (from right side) 2.Install: ● Bolt 1 (engine mounting - rear lower) ● Bolt 2 (engine mounting - rear [...]

4 - 73 ENG ENGINE ASSEMBLY AND ADJUSTMENT 3.Install: ● Rear wheel drive assembly and swing- arm. NOTE: ● Before installing the swingarm. Lubricate the following parts. Swingarm pivot side: 1) Bearings 1 2) Oil seals 2 3) Collars 3 4) Pivot shafts 4 Drive shaft side: 1) Drive shaft splines 5 2) Coupling gear splines 6 ● Before installing the s[...]

4 - 74 ENG ENGINE ASSEMBLY AND ADJUSTMENT 7.Tighten: ● Bolt 1 (engine mounting - rear lower) ● Bolt 2 (engine mounting - rear upper) ● Bolt 3 (engine mounting - front) ● Bolts 4 (engine mounting - top) ● Pivot shafts 5 (swingarm) ● Locknut (pivot shaft - right) ● Bolt 6 (rear shock absorber - top) 8.Install: ● Pivot shaft caps T R .[...]

4 - 75 ENG ENGINE ASSEMBLY AND ADJUSTMENT 11.Install: ● Spring 1 ● Footrest 2 (right) T R . . Bolt (footrest): 65 Nm (6.5 m • kg, 47 ft • lb) 12.Install: ● Front fender stay 1 ● Sift pedal 2 ● Footrest 3 (left) NOTE: The center of the shift pedal 2 should be aligned with the top of the footrest 3 . 13.Connect: ● Brake cable 1 (rear)[...]

4 - 76 ENG ENGINE ASSEMBLY AND ADJUSTMENT 17.Install: ● Carburetor 1 Refer to “CARBURETOR” section in the CHAPTER 5. T R . . Hose clamp: 2 Nm (0.2 m • kg, 1.4 ft • lb) 19.Fill: ● Crankcase Refer to the “ENGINE OIL REPLACE- MENT” section in CHAPTER 3. 20.Adjust: ● Release lever free play (clutch) Refer to the "CLUTCH ADJUSTMEN[...]

4 - 77 ENG ENGINE ASSEMBLY AND ADJUSTMENT 22.Install: ● Rear fender ● Rear carrier ● Front fender ● Front bumper ● Front carrier ● Fuel tank ● Seat Refer to the “FENDERS AND FUEL TANK- Installation” section in CHAPTER 3. 23.Inspect: ● Oil leakage 24.Check: ● “NEUTRAL” indicator light operation ● “REVERSE” indicator l[...]

ENG 4 - 78 4[...]

FWD 5 - 1 CARB CARBURETOR CARBURETION CARBURETOR 1 Vacuum chamber cover 2 Spring 3 Jet needle set 4 Piston valve 5 Pilot air jet 6 Coasting enricher diaphragm 7 Starter plunger assembly 8 Pilot screw set 9 Pilot jet 0 Needle jet A Main jet B Needle valve set C Throttle stop screw D Float pin E Float SPECIFICATIONS ID MARK 4XE1 00 MAIN JET (M.J.) #9[...]

5 - 2 CARB REMOVAL 1.Turn the fuel cock lever to “OFF”. 2.Remove: ● Air vent hose 1 ● Overflow hose 2 ● Fuel hose 3 3.Loosen: ● Clamp screws 4 4.Remove: ● Carburetor assembly CARBURETOR 5.Remove: ● Throttle valve cover 1 6.Remove: ● Throttle cable end 1 7.Loosen: ● Throttle cable adjusting nut 1 8.Remove: ● Throttle cable 2 DI[...]

5 - 3 CARB 2.Remove: ● Pilot air jet 1 CARBURETOR 3.Remove: ● Float chamber 1 ● O-ring 2 4.Remove: ● Float pin 1 ● Float 2 ● Needle valve 3 NOTE: Remove the float pin in the direction of the arrow. 5.Remove: ● Throttle stop screw 1 ● Valve seat 2 ● Main jet 3 ● Pilot jet 4 ● Pilot screw set 5 6.Remove: ● Needle jet 1 NOTE: R[...]

5 - 4 CARB 7.Remove: ● Cover (coasting enricher) 1 ● Spring 2 ● Diaphragm 3 CARBURETOR 8.Remove: ● Starter plunger 1 INSPECTION 1.Inspect: ● Carburetor body ● Starter jet 1 ● Float chamber Cracks/damage → Replace. ● Fuel passage Contamination → Clean as indicated. ● Fuel chamber body Contamination → Clean. ******************[...]

5 - 5 CARB 3.Inspect: ● Float 1 ● Float tang 2 Damage → Replace. CARBURETOR 4.Inspect: ● Main jet 1 ● Needle jet 2 ● Pilot jet 3 ● Pilot air jet 4 Wear/damage → Replace. Contamination → Blow out the jets with compressed air. 5.Inspect: ● Spring 1 ● Spring seat 2 ● Jet needle set 3 ● Piston valve 4 Bends/wear/damage → Rep[...]

5 - 6 CARB 8.Inspect: ● Throttle stop screw 1 ● Pilot screw 2 Contamination/wear → Replace. ● O-ring 3 Damage → Replace. CARBURETOR 9.Check: ● Free movement (piston valve) Sticks → Replace. Insert the piston valve into the carburetor body, and check for free movement. 10.Check: ● Free movement (throttle valve) Sticks → Replace. AS[...]

5 - 7 CARB 3.Install: ● O-ring ● Washer ● Spring ● Pilot screw Pilot screw: 2 turns out CARBURETOR 4.Install: ● Needle valve 1 ● Float 2 ● Float pin 3 NOTE: Install the float pin in the direction of the arrow. 5.Measure: ● Float height a Out of specification → Adjust. ********************************* Measurement and adjustment st[...]

5 - 8 CARB 6.Install: ● Piston valve 1 NOTE: Match the tab on the rubber diaphragm to the matching recess in the carburetor body. CARBURETOR INSTALLATION Reverse the “REMOVAL” procedure. Note the following points. 1.Install: ● Carburetor assembly T R . . Clamp screw: 2 Nm (0.2 m • kg, 1.4 ft • lb) 2.Adjust: ● Idle speed Refer to “ID[...]

5 - 9 CARB FUEL LEVEL ADJUSTMENT 1.Measure: ● Fuel level a Out of specification → Adjust. ********************************* Fuel level measurement and adjustment steps: ● Place the machine on a level surface. ● Connect the fuel level gauge 1 to the drain pipe 2 . ● Loosen the drain screw 3 . ● Hold the gauge vertically next to the float[...]

CARB 5 - 10 5[...]

6 - 1 DRIV MIDDLE GEAR SERVICE DRIVE TRAIN MIDDLE GEAR SERVICE MIDDLE GEAR 1 Universal joint 2 Bearing retainer 1 3 Bearing 4 Shims 5 Bearing housing 6 O-ring 7 Reverse gear securing nut 8 Bearing 9 Bearing retainer 2 0 Shims A Reverse gear B Dog clutch C Middle driven shaft D Driven pinion gear E Shims F Bearing G Shift fork 4 H Spring I Ball J Sh[...]

6 - 2 DRIV MIDDLE GEAR SERVICE MIDDLE GEAR SHIMS When the crankcase assembly and/or the middle gear comp., etc. are replaced, be sure to adjust the middle gear shim(s). Refer to the “MIDDLE GEAR SHIM SELECTION” and “MIDDLE GEAR LASH ADJUSTMENT” section. 1 Drive pinion gear 2 Driven pinion gear (forward gear) 3 Reverse gear Å Drive pinion g[...]

6 - 3 DRIV MIDDLE GEAR SERVICE REMOVAL NOTE: It is necessary to remove the rear wheel drive assembly and/or engine assembly in order to service the middle gear, refer to the “ENGINE OVERHAUL” section in CHAPTER 4. 1.Drain: ● Engine oil Refer to the “ENGINE OIL REPLACE- MENT” section in CHAPTER 3. 2.Remove: ● Seat ● Fuel tank ● Front[...]

6 - 4 DRIV MIDDLE GEAR SERVICE 2.Remove: ● Bolts 1 (middle gear case cover) ● Middle gear case cover 2 ● Dowel pins 3.Remove: ● Middle driven shaft assembly 1 ● Bearing 2 ● Shim 3 ● Driven pinion gear 4 Middle drive axle 1.Remove: ● Nut 1 (middle drive pinion gear) ● Middle drive pinion gear 2 NOTE: ● Flatten the punched portion[...]

6 - 5 DRIV MIDDLE GEAR SERVICE 3.Remove: ● Bearing retainers 1 Use a #40 Torx Driver. 4.Remove: ● Bearing 1 ● Shim 2 DISASSEMBLY Middle driven shaft 1.Remove: ● Universal joint ********************************* Removal steps: ● Remove the circlips 1 . ● Place the U-joint in a press. ● With a suitable diameter pipe beneath the yoke, pr[...]

6 - 6 DRIV MIDDLE GEAR SERVICE Universal joint holder: P/N. YM-04062, 90890-04062 Attachment: P/N. YM33291, 90890-04096 3.Remove: ● Middle driven shaft 1 ● Dog clutch 2 4.Remove: ● Bearing retainer 1 NOTE: ● Use a Bearing retainer wrench 2 . ● Bearing 3 ● Shim(s) 4 5.Remove: ● Reverse gear securing nut 1 NOTE: ● The reverse gear sec[...]

6 - 7 DRIV MIDDLE GEAR SERVICE 6.Remove: ● Bearing retainer 1 NOTE: ● Use a Ring nut wrench 2 . ● Bearing 3 Shift lever 1.Remove: ● Shift fork guide bar 1 ● Shift fork 2 ● Ball 3 ● Spring 4 NOTE: When removing the shift fork guide bar, the ball will fall off. Take care not lose the ball. Ring nut wrench: P/N. YM-1391, 90890-01391 2.Re[...]

6 - 8 DRIV 3.Check: ● Universal joints 1 ● Yoke 2 ● Bearings 3 Wear/Cracks/Damage → Replace. 4.Inspect: ● Shift fork 4 1 On the dog clutch and shift lever contact surfaces. Wear/Chafing/Bends/Damage → Replace. ● Spring 2 Wear/Damage → Replace. ● Ball (stopper) 3 Wear/Damage/Scratches → Replace. 5.Inspect: ● Guide bar Roll the [...]

6 - 9 DRIV MIDDLE GEAR SERVICE 8.Inspect: ● Bearing housing 1 Cracks/Damage → Replace bearing hous- ing assembly. ● O-ring 2 Wear/Damage → Replace. NOTE: When the bearing housing assembly is replaced, be sure to adjust the middle gear shim(s), refer to the “MIDDLE GEAR SHIM SELECTION” section. MIDDLE GEAR SHIM SELECTION Install the cran[...]

6 - 10 DRIV MIDDLE GEAR SERVICE 1 Drive pinion gear 2 Driven pinion gear 3 Reverse gear 4 Middle driven shaft Shim location Å = Drive pinion gear shim ı = Driven pinion gear shim Ç = Reverse gear shim Î = Middle driven shaft shim Å = a - b ı = c - d - e - f Ç = d - g - h - i Î = j + c - e - ı - k - l - 0.25 1 Crankcase (left) 2 Drive pinio[...]

6 - 11 DRIV ********************************* Middle gear shims selection steps: Shim selection Å ● When the crankcase and/or the drive pin- ion gear are replaced, be sure to adjust the drive pinion gear shim Å . ● To find drive pinion gear shim thickness “A” use following formula: a = The stamped number on the drive pin- ion gear is eith[...]

6 - 12 DRIV In the example above, the calculated shim thickness is 0.57 mm. The chart instructs you, however, to round off the 7 to 5, then shim thickness is 0.55 mm. Shim selection ı ● When the crankcase and/or the driven pin- ion gear are replaced, be sure to adjust the driven pinion gear shim ı . ● To find driven pinion gear shim thickness[...]

6 - 13 DRIV In the example above, the calculated shim thickness is 0.95 mm. The chart instructs you, however, to round off the 5 to 5, then shim thickness is 0.95 mm. Shim selection Ç ● When the crankcase, reverse gear and/or bearing housing are replaced, be sure to adjust the reverse gear shim Ç . ● To find reverse gear shim thickness “C?[...]

6 - 14 DRIV Because shims can only be selected in 0.05 mm increments, round off hundredths digit and select appropriate shim(s). In the example above, the calculated shim thickness is 0.51 mm. The chart instructs you, however, to round off the 1 to 0, then shim thickness is 0.50 mm. Shim selection Î ● When the crankcase, driven pinion gear, reve[...]

6 - 15 DRIV MIDDLE GEAR SERVICE Example: 1) If the bearing hauging is stamped “–03”. ..... j = 1 – 0.03 = 0.97 2) If the crankcase is stamped “45” ..... c = 110 + 0.45 = 110.45 3) If the pinion gear is stamped “–02” ..... k = 14.5 – 0.02 = 14.48 4) If the middle drive shaft is stamped “03” ..... l = 80.5 + 0.03 = 80.53 5) Th[...]

6 - 16 DRIV MIDDLE GEAR SERVICE ASSEMBLY Reverse the “DISASSEMBLY” procedures. Note the following points. Middle driven shaft 1.Apply: ● Lithium base grease To the oil seal and O-ring. 2.Install: ● Shift lever shaft 1 ● Shift lever 2 ● Stopper shaft 3 ● Circlip 4 3.Install: ● Spring 1 (to shift fork 4) ● Ball 2 NOTE: When installi[...]

6 - 17 DRIV MIDDLE GEAR SERVICE 6.Install: ● Bearing 1 (to bearing housing) ● Bearing retainer 2 NOTE: ● Use a Ring nut wrench 3 . Ring nut wrench: P/N. YM-1391, 90890-01391 7.Tighten: ● Bearing retainer T R . . Bearing retainer: 60 Nm (6.0 m • kg, 43 ft • lb) 8.Install: ● Shim(s) 1 ● Reverse gear 2 ● Reverse gear securing nut 3 N[...]

6 - 18 DRIV MIDDLE GEAR SERVICE 11.Tighten: ● Bearing retainer T R . . Bearing retainer: 60 Nm (6.0 m • kg, 43 ft • lb) Use LOCTITE  12.Install: ● Middle driven shaft 1 ● Dog clutch 2 13.Install: ● U-joint 1 ● Washer 2 ● Nut 3 (U-joint) NOTE: Hold the U-joint 1 by the Universal Joint Holder 4 and Attachment 5 , and tighten the U-[...]

6 - 19 DRIV MIDDLE GEAR SERVICE 14.Install ● Universal joint ********************************* Installation steps: ● Install the opposite yoke into the U-joint. ● Apply the “Wheel bearing grease” to the bearings. ● Install the bearing 1 onto the yoke. CAUTION: Check each bearing. The needles can easily fall out of their races. Slide the[...]

6 - 20 DRIV MIDDLE GEAR SERVICE 3.Install: ● Middle drive axle assembly 1 Refer to the “ENGINE ASSEMBLY AND ADJUSTMENT-CRANK SHAFT, TRANS- MISSION AND BALANCER SHAFT” sec- tion in CHAPTER 4. 4.Install: ● Middle drive pinion gear 1 ● Nut 2 Use the Rotor Holder 3 to hold the clutch boss 4 . NOTE: Put the engine in 1st, and carry out the ope[...]

6 - 21 DRIV MIDDLE GEAR SERVICE 2.Apply: ● Sealant 1 To the mating surface of both case halves. 3.Install: ● Dowel pins ● Middle gear case cover 2 NOTE: Before installing the middle gear case cover onto the crankcase, shift the gear into “FORWARD”. 4.Tighten: ● Bolts 3 (middle gear case) 5.Tighten: ● Bolts 1 (bearing housing) NOTE: Wh[...]

6 - 22 DRIV MIDDLE GEAR SERVICE 2.Shift: ● Drive select lever For forward drive. 3.Measure: ● Gear lash Gently rotate the middle drive axle from engagement to engagement. Over specified limit → Repair. NOTE: Measure the gear lash at 4 positions. Rotate the shaft 90˚ each time. Middle driven gear lash: (using measurement tool): 0.1 ~ 0.2 mm ([...]

6 - 23 DRIV MIDDLE GEAR SERVICE 2.Install: ● Rear wheel drive assembly and swingarm Refer to “REMOUNTING ENGINE” section in the CHAPTER 4. 3.Adjust: ● Rear brake Refer to “REAR BRAKE LEVER AND PEDAL ADJUSTMENT” section in the CHAPTER 3. 4.Install: ● Rear fender ● Rear carrier ● Front fender ● Front bumper ● Front carrier ● F[...]

6 - 24 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT FINAL DRIVE GEAR AND DRIVE SHAFT 1 Bearing housing 2 O-ring 3 Oil seal 4 Bearing 5 Ring gear shim 6 Ring gear 7 Thrust washer 8 Bearing 9 Oil seal 0 Bearing A Drive pinion gear B Final drive gear shim C Bearing D Bearing retainer E O-ring F Oil seal G Collar H Drive shaft I Circlip J Universal joint K Be[...]

6 - 25 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT TROUBLESHOOTING The following conditions may indicate damage drive train components: NOTE: Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite sub- tle and difficult to distinguish from normal machine operating noise. If there is reason to believe these components are d[...]

6 - 26 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT Inspection notes 1.Investigate any unusual noises ********************************* The following “Noises” may indicate a machanical problem: ● A “rolling rumble” noise during coasting, acceleration, or deceleration. The noise increases with rear wheel speed, but it does not increase with highe[...]

6 - 27 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 3.Inspect: ● Oil leakage By the following inspection steps. ********************************* Oil leakage inspection steps: ● Clean the entire machine thoroughly, then dry it. ● Apply a leak-localizing compound or dry powder spray to the shaft drive. ● Road test the machine long enough to locate [...]

6 - 28 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT REMOVAL W ARNING Securely support the machine so there is no danger of it falling over. 1.Drain: ● Final gear oil Refer to the “FINAL GEAR OIL REPLACE- MENT” section in CHAPTER 3. 2.Remove: ● Seat ● Rear carrier ● Rear fender Refer to the “FENDERS AND FUEL TANK- REAR FENDER” section in CH[...]

6 - 29 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT NOTE: ● When the final gear case until is removed from the swingarm, the drive shaft 3 may fall off. ● Be careful not to lose these parts. DISASSEMBLY 1.Remove: ● Bolts 1 (8 mm) ● Bolts 2 (10 mm) NOTE: Working in a crisscross pattern, loosen bolt 1/4 turn each. Remove them after all loos- ened. 2[...]

6 - 30 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 3.Remove: ● Bearing retainer (drive shaft - final) NOTE: Final-drive-shaft-bearing-retainer has left- hand threads. Turn retainer clockwise to loosen it. NOTE: When remounting the bearing retainer, use the Bearing Retainer Wrench 1 . Bearing retainer wrench: P/N. YM-04050, 90890-04050 4.Remove: ● Dri[...]

6 - 31 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 6.Remove: ● Roller bearing 1 (drive pinion gear) ********************************* Removal steps: ● Heat the main housing only to 150˚C (302˚F). ● Remove the roller bearing outer race with an appropriately shaped punch 2 . ● Remove the inner race from the final drive shaft. NOTE: The removal of[...]

6 - 32 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 4.Inspect: ● Final gear case 1 ● Bearing housing 2 (ring gear) Cracks/Damage → Replace. NOTE: When the final gear case and/or ring gear bearing housing are replaced, be sure to adjust the shim of the final drive pinion gear and/or ring gear, refer to the “FINAL DRIVE GEAR AND RING GEAR SHIM SELEC[...]

6 - 33 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT Example: 1) If the “+01” is stamped on the final drive pinion gear, a = 79 + 0.01 = 79.01 2) If the “50” is stamped on the final gear case, b = 78 + 0.50 = 78.50 3) Therefore, “A” is, “A” = 79.01 – 78.50 = 0.51 mm 4) Round off hundredths digit and select appropriate shim(s). In the exam[...]

6 - 34 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT ********************************* Shim selection steps: ● To find ring gear shim thickness “B”, use the following formula. c = The stamped number on the final gear case is either added to or subtracted from “42”. d = The stamped number on outside of ring gear bearing housing and added to “2?[...]

6 - 35 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT ASSEMBLY Reverse the “DISASSEMBLY” procedures. Note the following points. 1.Install: ● Roller bearing (drive pinion gear) ********************************* Installation steps: ● Heat the main housing only to 150˚C (302˚F) ● Install the roller bearing outer race using the proper adapted. ● I[...]

6 - 36 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT Thrust washer selection 1.Measure/Select: ● Ring gear thrust clearance “C” ********************************* Thrust clearance measurement steps: ● Place four pieces of Plastigauge  between originally fitted thrust washer and ring gear. ● Install the ring gear assembly and tighten the bolts t[...]

6 - 37 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 2.Install: ● Thrust washer 1 ● Ring gear 2 ● Shim(s) 3 (proper size as calculated) ● Bearing housing 4 NOTE: ● Before installing the ring gear, apply the grease to the oil seal rips. ● Before installing the bearing housing, apply the grease to the O-ring. 3.Install: ● 10 mm bolts 1 (bearing[...]

6 - 38 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 4.Attach: ● Gear lash measurement tool 1 ● Dial gauge 2 a Measuring point Gear lash measurement tool: P/N. YM-01231, 90890-01231 Dial gauge: P/N. YU-03097, 90890-03097 5.Measure: ● Gear lash Gently rotate the gear coupling from engagement to engagement. If the measured value in step 5 is different [...]

6 - 39 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 3.Adjust: ● Gear lash ********************************* Gear lash adjustment steps: ● Select the suitable shims and thrust washer by the following chart. ********************************* Too-little gear lash → Reduce shim thickness. Too-large gear lash → Increase shim thickness. Ring gear shim T[...]

6 - 40 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 5.Install: ● 10 mm bolts (bearing housing) ● 8 mm bolts (bearing housing) Refer to the “FINAL DRIVE GEAR AND DRIVE SHAFT – ASSEMBLY” section. 6.Measure: ● Gear lash If the gear lash is incorrect → Repeat. T R . . 10 mm Bolts (bearing housing): 40 Nm (4.0 m • kg, 29 ft • lb) 8 mm Bolts ([...]

6 - 41 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 4.Install: ● Final gear case unit 1 NOTE: Before installing the final gear case unit, apply the grease to the O-ring 2 . 5.Connect: ● Breather hose 5 (final gear case) CAUTION: Make sure the final gear case breather hose is routed correctly. 6.Install: ● Rear axle ● Final gear case protector ● [...]

6 - 42 DRIV 6[...]

7 - 1 CHAS FRONT WHEELS AND FRONT BRAKE CHASSIS FRONT WHEELS AND FRONT BRAKE 1 Brake camshaft lever 2 Wear indicator plate 3 Brake shoe plate 4 Brake shoe plate seal 5 Pivot pin 6 Brake camshaft holder 7 Brake camshaft 8 Brake shoe 9 Bearing 0 Bearing spacer A Front brake drum B Oil seal C Front wheel D Collar A TIRE SIZE: AT22 × 7-10 B RIM SIZE: [...]

7 - 2 CHAS FRONT WHEELS AND FRONT BRAKE REMOVAL Front wheels 1.Place the machine on a level place. 2.Loosen: ● Nuts (front wheel) Apply the parking brake 1 . 3.Elevate the front wheels by placing the suitable stand under the frame. W ARNING Securely support the machine there is no danger of falling over. 4.Remove: ● Nuts 1 (front wheel) ● Fro[...]

7 - 3 CHAS FRONT WHEELS AND FRONT BRAKE 9.Remove: ● Brake camshaft lever 1 ● Wear indicator plate 2 ● Brake camshaft 3 ● Brake camshaft holder 4 ● Pivot pin 5 ● Brake shoe plate 6 INSPECTION 1.Inspect: ● Wheel Refer to the “WHEEL INSPECTION” sec- tion in CHAPTER 3. 2.Measure: ● Wheel runout Over specified limit → Replace wheel[...]

7 - 4 CHAS 4.Inspect: ● Brake linings Glazed parts → Sand with coarse sandpa- per. 5.Measure: ● Brake lining thickness a Out of specification → Replace. NOTE: Replace the brake shoes as a set (with shoe springs) if either is found to be worn to the wear limit. Brake lining thickness: 4.0 mm (0.16 in) <Wear limit>: 2.0 mm (0.08 in) 6.I[...]

7 - 5 CHAS 9.Inspect: ● Bearings 1 (brake drum) Bearings allow play in the brake drum or the wheel tuns roughly → Replace. ● Oil seal 2 Wear/Damage → Replace. ********************************* Wheel bearing and oil seal replacement steps: ● Clean the outside of the brake drum. ● Remove the oil seal 1 use a flat-head screw driver. NOTE: [...]

7 - 6 CHAS INSTALLATION Reverse the “REMOVAL” procedure. Note the following points. 1.Lubricate: ● Oil seal lips 1 ● Bearings 2 ● Camshaft 3 ● Pivot pin 4 ● O-ring 5 CAUTION: Install the camshaft and the pivot pin lightly greased. Wipe off the excess grease. Lithium-soap base grease 2.Install: ● Pivot pin 1 ● Brake camshaft holder[...]

7 - 7 CHAS 4.Install: ● Brake shoes W ARNING Do not apply grease to the brake shoe lin- ings. 5.Connect: ● Front brake breather hose ● Brake cable (to brake shoe plate) 6.Install: ● Circlip 1 ● Spring 2 ● Washer (C-type) 3 ● Spring 4 ● Pin 5 ● Adjuster 6 7.Install: ● Brake drum 1 ● Spacer collar 2 ● Plain washer 3 ● Axle n[...]

7 - 8 CHAS 9.Install: ● Front wheel NOTE: Arrow mark 1 on the tire must point toward the rotating direction Å of the wheel. 10.Adjust: ● Front brake cable free play Refer to the “FRONT BRAKE ADJUST- MENT” section in CHAPTER 3. 11.Release the parking brake. T R . . Nut (front wheel): 55 Nm (5.5 m • kg, 40 ft • lb) Front brake free play:[...]

7 - 9 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 1 Rear axle 2 Bearing 3 Oil seal 4 Wheel hub 5 Axle nut A TIRE SIZE: AT22 × 10-10 B RIM SIZE: 8 × 10 C WHEEL RUNOUT LIMIT: VERTICAL: 2.0 mm (0.08 in) D TIRE WEAR LIMIT: 2.0 mm (0.08 in) E REAR AXLE RUNOUT LIMIT: 1.5 mm (0.06 in) REAR WHEELS/REAR BRAKE AND REAR AXLE 7[...]

7 - 10 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 1 Brake drum 2 Brake shoe 3 Bearing retainer 4 Brake shoe plate seal 5 Rear brake breather hose 6 Brake shoe plate 7 Brake camshaft 8 Wear indicator plate 9 Brake camshaft lever * Yamaha brake grease A BRAKE LINING WEAR LIMIT: 2.0 mm (0.08 in) B REAR BRAKE DRUM WEAR LIMIT: 161 mm (6.34 in) 7[...]

7 - 11 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE REMOVAL 1.Place the machine on a level place. 2.Loosen: ● Nuts (rear wheel) Apply the parking brake 1 . 3.Block the front wheels, and elevate the rear wheels by placing the suitable stand under the frame. W ARNING Securely support the machine there is no danger of falling over. 4.Remove: ● Nuts 1[...]

7 - 12 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 8.Remove: ● Adjusters 1 (brake lever and brake pedal) ● Pins ● Springs 9.Disconnect: ● Brake cable 2 ● Brake rod 3 ● Rear brake breather hose 4 10.Remove: ● Bearing retainer 1 ● Brake shoe plate assembly 2 11.Remove: ● Spring 1 ● Brake camshaft lever 2 ● Wear indicator plate 3 ?[...]

7 - 13 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE INSPECTION 1.Inspect: ● Wheel Refer to the “WHEEL INSPECTION” sec- tion in CHAPTER 3. 2.Measure: ● Wheel runout ● Tire surfaces Refer to the “FRONT WHEEL AND FRONT BRAKE-INSPECTION” section. 3.Inspect: ● Wheel hub 1 Cracks/Damage → Replace. ● Splines 2 (wheel hub) Wear/Damage → [...]

7 - 14 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 8.Inspect: ● Brake drum inner surface 1 Oil/Scratches → Remove. ● Spline 2 Wear/Damage → Replace. Oil Use a rag soaked in lacquer thinner or a solvent. Scratches Use a emery cloth (lightly and evenly polishing). 9.Inspect: ● Brake shoe plate 1 Cracks/Bends/Damage → Replace. ● Dust seal [...]

7 - 15 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 13.Measure: ● Rear axle runout a Out of specification → Replace. W ARNING Do not attempt to straighten a bent axle. Rear axle runout limit: 1.5 mm (0.06 in) 14.Inspect: ● Bearing 1 (rear axle) Bearing allow play in the axle hub or the bearing turns roughly → Replace. ● Oil seal 2 Wear/Damag[...]

7 - 16 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE INSTALLATION Reverse the “REMOVAL” procedures. Note the following points. 1.Lubricate: ● Oil seal lip 1 (rear axle) ● Bearings 2 (rear axle) ● Axle spline (rear axle) 2.Install: ● Rear axle 1 NOTE: Before installing the rear axle, loosen all the bolts on the final gear case 2 . Hold the r[...]

7 - 17 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 5.Install: ● Brake camshaft 1 ● Wear indicator plate 2 ● Brake camshaft lever 3 NOTE: ● When installing the wear indicator plate 2 to the brake camshaft 1 align the pro- jection a on the wear indicator plate with the slot b on the brake camshaft. ● Align the punched mark c on the brake cams[...]

7 - 18 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 8.Install: ● Brake shoes 9.Lubricate: ● Dust seal 1 (backing plate) CAUTION: Do not apply grease to the brake shoe lin- ings. ● Brake drum spline CAUTION: Do not apply grease on the axle shaft spline, or the extra grease may contami- nate the brake shoes during running. 10.Install: ● Brake dr[...]

7 - 19 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 16.Install: ● Cotter pin 1 NOTE: Do not loosen the axle nut after torque tightening. If the axle nut groove is not aligned with the cotter pin hole, align groove with the hole by tightening up on the axle nut. W ARNING Always use a new cotter pin. 17.Install: ● Rear wheel 1 (right) ● Nuts 2 NOT[...]

7 - 20 CHAS STEERING SYSTEM STEERING SYSTEM 1 Handlebar holder (upper) 2 Handlebar holder (lower) 3 Steering shaft 4 Steering bearing 5 Oil seal 6 Collar 7 Cable guide 8 Lock washer 9 Rod end 0 Tie-rod A TOE-IN: 0 ~ 5 mm (0 ~ 0.39 in) 7[...]

7 - 21 CHAS STEERING SYSTEM REMOVAL Handlebar 1.Remove: ● Front carrier ● Front bumper ● Front fender Refer to “FENDERS AND FUEL TANK- FRONT FENDER-Removal” section in CHAPTER 3. 2.Disconnect: ● Main switch lead ● “NEUTRAL” indicator light leads ● “REVERSE” indicator light leads ● Handlebar switch (left) leads ● Brake sw[...]

7 - 22 CHAS STEERING SYSTEM Steering shaft 1.Straighten: ● Lock washer tabs 1 2.Remove: ● Bolts 2 ● Lock washer 3 ● Cable guide 4 3.Remove: ● Clip (steering shaft) ● Nut ● Washer 4.Remove: ● Cotter pins ● Nuts ● Tie-rods 1 NOTE: When removing the rod ends from the steering shaft and knuckle arm, use a Gen- eral Bearing Puller. 5[...]

7 - 23 CHAS STEERING SYSTEM INSPECTION 1.Inspect: ● Handlebar Cracks/Bends/Damage → Replace. 2.Inspect: ● Steering shaft Bends/Damage → Replace. W ARNING Do not attempt to straighten a bent shaft; this may dangerously weaken the shaft. 3.Inspect: ● Steering bearings 1 ● Oil seals 2 Wear/Damage → Replace. 4.Inspect: ● Tie-rod 1 Bend/[...]

7 - 24 CHAS STEERING SYSTEM 6.Adjust: ● Tie-rod assembly length ********************************* Tie-rod assembly length adjustment steps: ● Loosen the locknuts. ● Adjust the tie-rod assembly length a by turning both tie-rod ends. Å Right-hand-threads ı Left-hand-threads Ç To steering shaft Î To knuckle NOTE: The threads b on both tie-ro[...]

7 - 25 CHAS STEERING SYSTEM 2.Lubricate: ● Steering bearings 1 ● Oil seals 2 Lithium-soap base grease 3.Install: ● Oil seals 1 (to steering shaft) ● Collars 2 ● Steering bearings 3 NOTE: Be careful not to damage the oil seals dur- ing installation. 4.Install: ● Steering shaft 1 (with steering bearings) W ARNING Make sure the brake cable[...]

7 - 26 CHAS STEERING SYSTEM 7.Install: ● Cotter pin 1 NOTE: Do not loosen the axle nut after torque tightening. If the axle nut groove is not aligned with the cotter pin hole, align groove with the hole by tightening up on the axle nut. W ARNING Always use a new cotter pin. 8.Tighten: ● Washer ● Nut ● Clip T R . . Nut (steering shaft): 30 N[...]

7 - 27 CHAS STEERING SYSTEM Handlebar 1.Install: ● Handlebar holder (lower) 1 ● Handlebar 2 ● Handlebar holders (upper) 3 NOTE: The upper handlebar holder should be installed with the punched mark a forward 2 . CAUTION: Tighten the handlebar bolts so that clear- ances b are spaced evenly. T R . . Handlebar holder (upper): 20 Nm (2.0 m • kg,[...]

7 - 28 CHAS FRONT SHOCK ABSORBER AND FRONT ARM FRONT SHOCK ABSORBER AND FRONT ARM 1 Front shock absorber 2 Steering knuckle 3 Lower arm 4 Bushing 7[...]

7 - 29 CHAS REMOVAL 1.Remove: ● Front carrier ● Front bumper ● Front fender Refer to the “FENDERS AND FUEL TANK- FRONT FENDER - Removal” section in CHAPTER 3. ● Front wheel ● Brake drum ● Brake shoe plate Refer to “FRONT WHEELS AND FRONT BRAKE - Removal” section. 2.Remove: ● Cotter pin 1 ● Nut 2 ● Tie-rod end 3 NOTE: When [...]

7 - 30 CHAS 7.Inspect: ● Lower arms free play ********************************* Inspection steps: ● Inspect the lower arm brackets 1 of the frame. If bent, cracked or damaged, repair or replace the frame. ● Check the tightening torque of the lower arm securing nuts 2 . ● Check the lower arm side play Å by mov- ing it from side to side. If [...]

7 - 31 CHAS INSPECTION 1.Inspect: ● Shock absorber Oil leaks → Replace the shock absorber assembly. ● Ball joint Cracks/Damage → Replace the shock absorber assembly. ● Spring Fatigue/Damage → Replace the shock absorber assembly. Move the spring up and down. 2.Inspect: ● Steering knuckle Cracks/Pitting/Damage → Replace. W ARNING Do n[...]

7 - 32 CHAS INSTALLATION Reverse the “REMOVAL” procedures. Note the following points. 1.Lubricate: ● Bushings 1 (inner surface) 2.Tighten: ● Nut 2 (lower arm) Lithium-soap base grease T R . . Nut (lower arm): 45 Nm (4.5 m • kg, 32 ft • lb) NOTE: Be sure to position the front arm securing bolts (front 1 and rear 2 ) so that the bolt head[...]

7 - 33 CHAS FRONT SHOCK ABSORBER AND FRONT ARM 5.Install: ● Cotter pin 3 NOTE: Do not loosen the axle nut after torque tightening. If the axle nut groove is not aligned with the cotter pin hole, align groove with the hole by tightening up on the axle nut. W ARNING Always use a new cotter pin. 6.Install: ● Shock absorber 4 (front) ● Flange nut[...]

7 - 34 CHAS NOTE: Do not loosen the axle nut after torque tightening. If the axle nut groove is not aligned with the cotter pin hole, align groove with the hole by tightening up on the axle nut. W ARNING Always use a new cotter pin. 10.Install: ● Brake shoe plate ● Brake drum ● Front wheel Refer to the “FRONT WHEELS AND FRONT BRAKE-INSTALLA[...]

7 - 35 CHAS REAR SHOCK ABSORBER AND SWINGARM 1 Rear shock absorber 2 Thrust cover 3 Locknut 4 Pivot shaft 5 Collar 6 Oil seal 7 Taper roller bearing 8 Swingarm 9 Rubber boot 0 Final gear case protector A SWINGARM FREE PLAY LIMIT: SIDE” 1.0 mm (0.04 in) REAR SHOCK ABSORBER AND SWINGARM FWD 7[...]

7 - 36 CHAS REMOVAL 1.Remove: ● Rear wheel (left) ● Wheel hub ● Rear wheel (right) ● Brake drum ● Brake shoe plate ● Rear axle Refer to the “REAR WHEEL/REAR BRAKE AND REAR AXLE - REMOVAL” section. 2.Remove: ● Final gear case protector 1 3.Remove: ● Final gear case unit 1 Refer to the “FINAL DRIVE GEAR AN DRIVE SHAFT - REMOVAL?[...]

7 - 37 CHAS 5.Remove: ● Nut 1 (shock absorber - upper) ● Bolt 2 ● Shock absorber 3 REAR SHOCK ABSORBER AND SWINGARM 6.Remove: ● Spring (rear brake pedal) 1 7.Remove: ● Caps (pivot shaft) 8.Inspect: ● Swingarm free play ********************************* Free play inspection steps: ● Check the tightening torque of the pivot shafts 1 and[...]

7 - 38 CHAS REAR SHOCK ABSORBER AND SWINGARM 9.Remove: ● Rear axle housing 1 10.Remove: ● Clamp 1 (rubber boot) ● Locknut (right side of pivot shaft) ● Pivot shaft (swingarm) 11.Remove: ● Swingarm 1 INSPECTION 1.Inspect: ● Shock absorber Oil leaks → Replace the shock absorber assembly. ● Shock absorber rod Bends/Damage → Replace t[...]

7 - 39 CHAS REAR SHOCK ABSORBER AND SWINGARM 2.Inspect: ● Swingarm Cracks/Bends/Damage → Replace. ● Axle housing Cracks/Bends/Damage → Replace. 3.Inspect: ● Final gear case under cover Cracks/Bends/Damage → Replace. 4.Inspect: ● Pivot shaft 1 (right side) ● Pivot shaft 2 (left side) ● Spacer collar 3 Wear/Damage → Replace. 5.Ins[...]

7 - 40 CHAS REAR SHOCK ABSORBER AND SWINGARM ● Remove the bearings 3 using a general bearing puller. ● Install the new bearings and oil seal by reversing the previous steps. NOTE: Use a socket 4 that matches the outside diameter of the race of the bearing and oil seal. CAUTION: Do not strike the center race 5 or balls 6 of the bearing. Contact [...]

7 - 41 CHAS REAR SHOCK ABSORBER AND SWINGARM 3.Tighten: ● Pivot shafts (swingarm) ● Locknut (pivot shaft) ********************************* Pivot shaft tightening steps: ● Tighten the pivot shaft 1 (left) to specifi- cation. ● Tighten the pivot shaft 2 (right) until it contacts the collar 3 . ● Tighten the locknut 4 (right) to specifica- [...]

7 - 42 CHAS REAR SHOCK ABSORBER AND SWINGARM 7.Install: ● Clip 8.Install: ● Final gear assembly 1 Refer to the “FINAL DRIVE GEAR AND DRIVE SHAFT - ASSEMBLY - INSTALLA- TION” section in CHAPTER 6. 9.Install: ● Rear axle ● Brake shoe plate ● Brake drum ● Rear wheel (right) ● Wheel hub (left) ● Rear wheel (left) Refer to the “REA[...]

8 - 1 –+ ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Wire harness 2 Fuses 3 Starter relay 4 Starting circuit cut-off relay 5 Battery 6 CDI unit 7 Rectifier/regulator 8 Reverse switch 9 Neutral switch 0 Spark plug cap A Ignition coil B Main switch C Neutral indicator light D Reverse indicator light 8[...]

8 - 2 –+ ELEC SWITCH INSPECTION SWITCH INSPECTION SWITCH INSPECTION Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. NOTE: ● Set the pocket tester to “0” before starting the test. ● The pocket tester should be set to the “ Ω × 1” range when testing the switch f[...]

8 - 3 –+ ELEC SWITCH INSPECTION 8[...]

8 - 4 –+ ELEC SWITCH INSPECTION SWITCH CONTINUITY INSPECTION Refer to “SWITCH INSPECTION” and check for continuity between lead terminals. Poor connection, no continuity → Correct or replace. * The coupler locations are circled. 8[...]

8 - 5 –+ ELEC SWITCH INSPECTION 1 Lights switch 2 Lights switch (for New Hampshire and Maine) 3 Engine stop switch 4 Starter switch 5 Main switch 6 Rear brake lever switch 7 Rear brake lever switch (for New Hampshire and Maine) 8 Front brake lever switch (for New Hampshire and Maine) 9 Rear brake pedal switch (for New Hampshire and Maine) 0 Rever[...]

8 - 6 –+ ELEC CHECKING OF BULBS (FOR HEADLIGHT) CHECKING BULBS CONDITION 1.Remove the bulb. ACHTUNG: CAUTION: Be sure to hold the socket firmly when removing the bulb. Never pull the lead. Otherwise, the lead may be pulled off the terminal in the coupler. W ARNING Keep flammable products and your hands away from the headlight bulb while it is on.[...]

8 - 7 –+ ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM B R B / W Br B / W Br B R W / G W / R Br B O B / W B L / W B R / W O B / W Br B W / G W / R OFF ON OFF LO HI LO HI OFF ON RUN OFF R L / W B G / Y Sb L / W R / W ı Å Å (BLACK) (GLAY) (GLAY) Br Y BB (BLACK) (BLACK) Y B G Y B G Y B G Y B G Y / R Br L R / W L R / W Br Br / W WW[...]

8 - 8 –+ ELEC IGNITION SYSTEM EB802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1.Spark plugs 2.Ignition spark gap 3.Spark plug cap resistance 4.Ignition coil resistance 5.Engine stop switch 6.Main switch 7.Pickup coil resistance 8.Source coil resistance 9.Wiring connection (the en[...]

8 - 9 –+ ELEC IGNITION SYSTEM for EUR/AUS 2.Ignition spark gap ● Disconnect the spark plug cap from the spark plug. ● Connect the ignition checker 1 as shown. 2 Spark plug cap ● Turn the main switch to “ON”. ● Check the ignition spark gap a . ● Crank the engine by pushing the starter switch and increase the spark gap until a misfire[...]

8 - 10 –+ ELEC IGNITION SYSTEM C0NTINUITY 4.Ignition coil resistance ● Disconnect the ignition coil connector from the wire harness. ● Connect the pocket tester ( Ω × 1) to the ignition coil. * Tester (+) lead → Orange lead terminal Tester (–) lead → Ignition coil base Tester (+) lead → Ignition coil base Tester (–) lead → Spar[...]

8 - 11 –+ ELEC IGNITION SYSTEM C0NTINUITY 7.Pickup coil resistance ● Disconnect the CDI magneto coupler from the wire harness. ● Connect the pocket tester ( Ω × 100) to the pickup coil terminal. Tester (+) lead → White/Green terminal 1 Tester (–) lead → White/Red terminal 2 * Br W / G B W / R 2 1 MEETS SPECIFICATION ● Check the pic[...]

8 - 12 –+ ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM B R B / W Br B / W Br B R W / G W / R Br B O B / W B L / W B R / W O B / W Br B W / G W / R OFF ON OFF LO HI LO HI OFF ON RUN OFF R L / W B G / Y Sb L / W R / W ı Å Å (BLACK) (GLAY) (GLAY) Br Y BB (BLACK) (BLACK) Y B G Y B G Y B G Y B G Y / R Br L R / W L[...]

8 - 13 –+ ELEC ELECTRIC STARTING SYSTEM STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, starting circuit cut-off relay, rear brake lever switch, and neutral switch. If the main switch is on position, the starter motor can be operated only if: The starting circuit cut-off relay prevents t[...]

8 - 14 –+ ELEC ELECTRIC STARTING SYSTEM EB803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 1.Fuse (main) 2.Battery 3.Starter motor 4.Starting circuit cut-off relay 5.Starter relay 6.Main switch 7.Neutral switch 8.Rear brake lever switch 9.Start switch 10.Wiring connection (the entire starting system) NOTE: ● Remove[...]

8 - 15 –+ ELEC ELECTRIC STARTING SYSTEM C0NTINUITY MOVES 3.Starter motor ● Connect the battery positive terminal 1 and starter motor cable 2 using a jumper lead 3 . ● Check the operation of the starter motor. * * 1 M 2 3 R L / W B W ARNING ● A wire that is used as a jumper lead must have the equivalent capacity or more as that of the batter[...]

8 - 16 –+ ELEC ELECTRIC STARTING SYSTEM C0NTINUITY 5.Starter relay ● Remove the starter relay from the wire harness. ● Connect the pocket tester ( Ω × 1) and the battery (12 V) to the starter relay termi- nals. * 3 4 2 1 R B R L / W B CONTINUITY Battery (+) terminal → Blue/White terminal 1 Battery (–) terminal → Black terminal 2 Test[...]

8 - 17 –+ ELEC C0NTINUITY CORRECT 8.Rear brake lever switch Refer to “SWITCH INSPECTION”. * INCORRECT Replace the rear brake lever switch. CORRECT 9.Start switch Refer to “SWITCH INSPECTION”. INCORRECT Replace the handlebar switch (left). EB803028 10.Wiring connection ● Check the connections of the entire start- ing system. Refer to “[...]

–+ ELEC 8 - 18 ELECTRIC STARTING SYSTEM STARTER MOTOR Order Job name/Part name Q’ty Remarks Starter motor removal Remove the parts in the order below. 1 Starter motor lead 1 2 Starter motor bracket 1 3 Starter motor / O-ring 1/1 Starter motor disassembly Disassemble the parts in the order below. 1 Bracket 1 1 Refer to “STARTER MOTOR ASSEM- BL[...]

8 - 19 –+ ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR INSPECTION 1.Inspect: ● Commutator Dirty → Clean it with #600 grit sandpaper. 2.Measure: ● Commutator diameter a Out of specification → Replace the starter motor. 3.Measure: ● Mica undercut b Out of specification → Scrape the mica using a hacksaw blade. NOTE: Scrape the mica to the[...]

8 - 20 –+ ELEC ELECTRIC STARTING SYSTEM 5.Measure: ● Brush length a (each) Out of specification → Replace the brush. Brush length: 10 mm (0.39 in) <Wear limit:> 3.5 mm (0.14 in) 6.Measure: ● Brush spring force Fatigue/out of specification → Replace as a set. Brush spring force: 730 ~ 970 g (7.16 ~ 9.52 N) 7.Inspect: ● Oil seal ●[...]

8 - 21 –+ ELEC CHARGING SYSTEM EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM B R B / W Br B / W Br B R W / G W / R Br B B B R / W O B / W Br B W / G W / R OFF ON OFF LO HI OFF ON RUN OFF R L / W B G / Y Sb Å (BL A (GLAY) ( Y B G Y B G Y B G Y B G Y / R Br L R / W L R / W Br Br / W WW W WW W B C D I K J L EF G HH 1 2 3 4 5 6 78 Br R B B / W B / W L / [...]

8 - 22 –+ ELEC CHARGING SYSTEM EB804010 TROUBLESHOOTING IF THE BATTERY IS NOT CHARGED: Procedure Check: 1.Fuse (main) 2.Battery 3.Charging voltage 4.Stator coil resistance 5.Wiring connections (the entire charging system) NOTE: ● Remove the following part(s) before trou- bleshooting: 1)Seat ● Use the following special tool(s) for trou- blesho[...]

8 - 23 –+ ELEC CHARGING SYSTEM OUT OF SPECIFICATION ● Start the engine and accelerate to about 2,000 r/min. Charging voltage: 14 to 15 V at 2,000 r/min NOTE: Use a fully charged battery. MEETS SPECIFICATION The charging circuit is not faulty. EB804012 MEETS SPECIFICATION 4.Stator coil resistance ● Disconnect the AC magneto coupler from the wi[...]

8 - 24 –+ ELEC LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM B R B / W Br B / W Br B R W / G W / R Br B O B / W B L / W B R / W O B / W Br B W / G W / R OFF ON OFF LO HI LO HI OFF ON RUN OFF R L / W B G / Y Sb L / W R / W ı Å Å (BLACK) (GLAY) (GLAY) Br Y BB (BLACK) (BLACK) Y B G Y B G Y B G Y B G Y / R Br L R / W L R / W Br Br / W W[...]

8 - 25 –+ ELEC LIGHTING SYSTEM EB805010 TROUBLESHOOTING IF THE HEADLIGHT AND/OR TAILLIGHT FAIL TO COME ON: Procedure Check: 1.Fuse (main) 2.Battery 3.Main switch 4.Lights switch 5.Wiring connections (the entire lighting system) NOTE: ● Remove the following part(s) before trou- bleshooting: 1)Seat 2)Front carrier 3)Front fender ● Use the follo[...]

8 - 26 –+ ELEC LIGHTING SYSTEM C0NTINUITY CORRECT 3.Main switch Refer to “SWITCH INSPECTION”. * INCORRECT Replace the main switch. CORRECT 4.Lights switch Refer to “SWITCH INSPECTION”. Lights switch is faulty, replace the handle- bar switch (left). EB805013 CORRECT 5.Wiring connection ● Check the connections of the entire light- ing sys[...]

8 - 27 –+ ELEC LIGHTING SYSTEM EB805020 LIGHTING SYSTEM CHECK 1.If the headlights fail to come on: CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for conti- nuity. NO CONTINUITY Replace the bulb and/or bulb socket. 2.Voltage ● Connect the pocket tester (DC 20 V) to the headlight couplers. Tester (+) lead → Green terminal[...]

8 - 28 –+ ELEC LIGHTING SYSTEM 2.If the taillight fails to come on: CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for conti- nuity. NO CONTINUITY Replace the bulb and/or bulb socket. 2.Voltage ● Connect the pocket tester (DC 20 V) to the taillight leads. Tester (+) lead → Blue terminal 1 Tester (–) lead → Black term[...]

8 - 29 –+ ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM B R B / W Br B / W Br B R W / G W / R Br B O B / W B L / W B R / W O B / W Br B W / G W / R OFF ON OFF LO HI LO HI OFF ON RUN OFF R L / W B G / Y Sb L / W R / W ı Å Å (BLACK) (GLAY) (GLAY) Br Y BB (BLACK) (BLACK) Y B G Y B G Y B G Y B G Y / R Br L R / W L R / W Br Br / W WW W [...]

8 - 30 –+ ELEC SIGNAL SYSTEM EB806010 TROUBLESHOOTING IF THE INDICATOR LIGHT AND/OR BRAKE LIGHT FAILS TO COME ON: Procedure Check: 1.Fuse (main) 2.Battery 3.Main switch 4.Wiring connections (the entire signal system) NOTE: ● Remove the following part(s) before trou- bleshooting: 1)Seat 2)Front carrier 3)Front fender ● Use the following specia[...]

8 - 31 –+ ELEC SIGNAL SYSTEM C0NTINUITY CORRECT 3.Main switch Refer to “SWITCH INSPECTION”. * INCORRECT Replace the main switch. EB806011 CORRECT 4.Wiring connections ● Check the connections of the entire sig- nal system. Refer to “CIRCUIT DIAGRAM”. Check the condition of each of the signal system’s circuits. Refer to “SIGNAL SYSTEM[...]

8 - 32 –+ ELEC SIGNAL SYSTEM SIGNAL SYSTEM CHECK EB806024 1.If the neutral indicator light fails to come on: CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for conti- nuity. NO CONTINUITY Replace the bulb and/or bulb socket. CONTINUITY 2.Neutral switch Refer to “SWITCH INSPECTION”. NO CONTINUITY Replace the neutral switc[...]

8 - 33 –+ ELEC SIGNAL SYSTEM 2.If the reverse indicator light fails to come on: CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for conti- nuity. NO CONTINUITY Replace the bulb and/or bulb socket. CONTINUITY 2.Reverse switch Refer to “SWITCH INSPECTION”. NO CONTINUITY Replace the reverse switch. 3.Voltage ● Connect the [...]

8 - 34 –+ ELEC SIGNAL SYSTEM 3.If the brake light fails to come on: (for New Hampshire and Maine) CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for conti- nuity. NO CONTINUITY Replace the bulb and/or bulb socket. CONTINUITY 2.Brake switch Refer to “SWITCH INSPECTION”. NO CONDITION Replace the brake switches. CONTINUITY [...]

TRBL SHTG 9 - 1 STARTING FAILURE/HARD STARTING TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this man- ual for inspection, adjustment and replacement of parts. STARTING FAILURE/HARD STARTING FUEL [...]

TRBL SHTG 9 - 2 STARTING FAILURE/HARD STARTING/POOR IDLE SPEED PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE COMPRESSION SYSTEM Cylinder and cylinder head ● Loose spark plug ● Loose cylinder head or cylinder ● Broken cylinder head gasket ● Worn, damaged or seized cylinder Piston and piston rings ● Improperly installed piston ring ●[...]

9 - 3 TRBL SHTG FAULTY DRIVE TRAIN FAULTY DRIVE TRAIN The following conditions may indicate damaged shaft drive components: NOTE: Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite sub- tle and difficult to distinguish from normal machine operating noise. If there is reason to believe these components are damaged[...]

TRBL SHTG 9 - 4 F AUL TY GEAR SHIFTING/ FAULTY CLUTCH PERFORMANCE FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH SLIPPING/DRAGGING-CLUTCH DRAGGING”. SHIFT PEDAL DOES NOT MOVE Shift shaft ● Bent shift shaft Shift cam, shift fork ● Groove jammed with impurities ● Seized shift fork ● Bent shift fork guide bar Transmission ● Seized t[...]

TRBL SHTG 9 - 5 FAULTY CLUTCH PERFORMANCE/ OVERHEATING/FAULTY BRAKE OVERHEATING OVERHEATING Ignition system ● Improper spark plug gap ● Improper spark plug heat range ● Faulty CDI unit Fuel system ● Improper carburetor main jet (improper setting) ● Improper fuel level ● Clogged air filter element Compression system ● Heavy carbon buil[...]

TRBL SHTG 9 - 6 UNSTABLE HANDLING SHOCK ABSORBER MALFUNCTION/ UNSTABLE HANDLING/LIGHTING SYSTEM UNSTABLE HANDLING Handlebar ● Improperly installed or bent Steering ● Incorrect toe-in ● Bent steering shaft ● Improperly installed steering shaft ● Damaged bearing or bearing race ● Bent tie rods ● Deformed steering knuckles Tires ● Unev[...]

YFM250XL WIRING DIAGRAM 1 Main switch 2 Battery 3 Fuse 4 Starter relay 5 Starter motor 6 Rectifier / regulator 7 CDI magneto 8 CDI unit 9 Ignition coil 0 Spark plug A Starting circuit cut-off relay B Rear brake lever switch C Tail light D Handlebar switch E Engine stop switch F Starter switch G Lights switch H Headlight I Neutral indicator light J [...]

PRINTED IN U.S.A. Y AMAHA MOT OR CO., L TD. 2500 SHINGAI IWATA SHIZUOKA JAPAN[...]

SUPPLEMENT AR Y SERVICE MANUAL LIT -1 1616-14-17 4XE-F8197-1 1 YFM250XN[...]

YFM250XN SUPPLEMENTARY SERVICE MANUAL  2000 by Yamaha Motor Corporation, U.S.A. First Edition, April 2000 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-11616-14-17 FOREWORD This Supplementary Service Manual has been prepa[...]

EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mec[...]

EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual is intended as a handy, easy-to-read reference book for the mechanic. It is divided into chapters, sections and sub-sections. Comprehensive explanations of all installation, removal, dis- assembly, assembly, repair and inspection procedures are laid out with the individual steps in seq[...]

EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic inspections and adjustments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical 9 Troubleshooting Illustrated symbols 0 to F are used to identify the sp[...]

CONTENTS GENERAL INFORMATION .............................................................................. 1 MACHINE IDENTIFICATION ................................................................... 1 VEHICLE IDENTIFICATION NUMBER ............................................ 1 MODEL LABEL ..........................................................[...]

ELECTRICAL ................................................................................................. 40 ELECTRICAL COMPONENTS .............................................................. 40 IGNITION SYSTEM ............................................................................... 41 CIRCUIT DIAGRAM ...................................[...]

– 1 – GEN INFO MACHINE IDENTIFICATION GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame. MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.[...]

– 2 – SPEC SPECIFICA TIONS GENERAL SPECIFICA TIONS Item Standard Model code: 4XEA (USA) Dimensions: Ov erall length 1,940 mm (76.4 in) Ov erall width 1,005 mm (39.6 in) Ov erall height 1,118 mm (44.0 in) Seat height 780 mm (30.7 in) Wheelbase 1,170 mm (46.1 in) Minimum ground clear ance 150 mm (5.9 in) Minimum turning radius 2,900 mm (114 in) B[...]

– 3 – SPEC MAINTENANCE SPECIFICA TIONS ENGINE Item Standard Limit Shifter : Shifter type Shift drum and guide bar ---- Guide bar bending limit ---- 0.8 mm (0.032 in) Carburetor: I. D . mark 4XEA 12 ---- Main jet (M.J) #95 ---- Main air jet (M.A.J) 0.7 ---- Jet needle (J.N) 5CE35-2 ---- Needle jet (N.J) P-2M (#823) ---- Pilot air jet (P .A.J .1)[...]

– 4 – SPEC CHASSIS Item Standard Limit Rear suspension: Shock absorber tr av el 85 mm (3.35 in) ---- Suspension spring free length 268 mm (10.55 in) ---- Fitting length 244 mm (9.61 in) ---- Spring rate 3 9 N/mm (3.9 kg/mm, 222.69 lb/in)/ 0 ~ 85 mm (0 ~ 3.35 in) ---- Optional spring No ---- F ront wheel: T ype Disc wheel ---- Rim size 10 × 6.0[...]

– 5 – SPEC Tightening torques P ar t to be tightened P ar ts name Thread size Q’ty Tightening torque Remar ks Nm m·kg ft·lb Front panel wheel and wheel hub N u t M10 × 1.25 8 55 5.5 40 Wheel hub and steering knuckle Nut M14 × 1.5 2 70 7.0 50 Steering knuckle and brake caliper Bolt M8 × 1.25 4 30 3.0 22 Brake disc and wheel hub Bolt M8 ×[...]

– 6 – SPEC ELECTRICAL Item Standard Limit C.D.I.: Magneto model/manuf acturer F4T259/MITSUBISHI ---- Pickup coil resistance/color 189 ~ 231 Ω at 20˚C (68˚F)/ White/Green – White/Red ---- Charging/rotor rotation direction detection coil resistance/color 270 ~ 330 Ω at 20˚C (68˚F)/ Red/White/Blue ---- C .D .I. unit model/manuf acturer F[...]

– 7 – SPEC CABLE ROUTING CABLE ROUTING 1 Rear brake lever switch lead 2 Rear brake cable 3 Cable guide 4 Front brake hose 5 Throttle cable 6 Neutral indicator light 7 Reverse indicator light 8 Handlebar switch assembly lead 9 Fuel tank breather hose 0 Headlight leads Å Do not route the handlebar switch assembly lead through the lower bracket c[...]

– 8 – SPEC CABLE ROUTING 1 Cable guide 2 Main switch 3 Fuel tank breather hose 4 Taillight 5 Final gear case breather hose 6 Carburetor overflow hose 7 Reverse switch lead 8 Neutral switch lead 9 Starter motor lead 0 Throttle cable A Rear brake cable B Rear brake breather hose C Carburetor air vent hose D CDI magneto lead Å Route the main swit[...]

– 9 – SPEC CABLE ROUTING Ç Make sure that the starter motor lead is not slacked. Î Fasten the starter motor lead and wire harness to the frame with the plastic band. ‰ Fasten the starter motor lead and wire harness to the frame with the plastic clamp. Ï Route the starter motor lead, wire harness, and battery - lead through the hole in the [...]

– 10 – SPEC Ò Fasten the starter motor lead and wire harness to the frame with the plastic clamp. ˜ Route the rear brake cable and rear brake breather hose through the cable guide. ˆ Fasten the rear brake cable and rear brake breather hose to the swingarm with the plastic clips. Ø Route the rear brake breather hose through the cable guide. [...]

– 11 – SPEC CABLE ROUTING 1 Battery breather hose 2 Spark plug cap 3 Ignition coil 4 Starter motor lead 5 Rear brake cable 6 Rear brake breather hose Å Make sure that the battery breather hose is not kinked or bent. ı Route the rear brake cable through the cable guide on the cyl- inder. Ç Fasten the starter motor lead to the frame with the p[...]

– 12 – SPEC CABLE ROUTING 1 Wire harness 2 Starter motor lead 3 Rear brake cable 4 Throttle cable 5 Starter relay 6 Rectifier/regulator 7 CDI unit 8 Starting circuit cut-off relay 9 Rear brake breather hose 0 Carburetor air vent hose A Final gear case breather hose B Taillight lead Å Fasten the wire harness to the frame with the plastic clamps[...]

– 13 – SPEC CABLE ROUTING Ï Fasten the battery breather hose to the rear fender with the plastic clamp and then insert the clamp into the hole in the rear fender. Ì Fasten the battery + lead and starter motor lead to the rear fender with the plastic clamps. Ó Install the starter circuit cut-off relay onto the tab with its terminal side facin[...]

– 14 – INSP ADJ INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. In add[...]

– 15 – INSP ADJ PERIODIC MAINTENANCE/LUBRICATION *: It is recommended that these items be serviced by a Yamaha dealer. **: Lithium soap base grease. W ARNING Indicates a potential hazard that could result in serious injury or death. Steering shaft* • Lubricate every 6 months.** Fittings and Fasteners* • Check all chassis fittings and fasten[...]

– 16 – INSP ADJ SPARK ARRESTER CLEANING ENGINE SPARK ARRESTER CLEANING 1.Clean: ● Spark arrester ********************************************* Cleaning steps: W ARNING ● Select a well-ventilated area free of com- bustible materials. ● Always let the exhaust system cool before performing this operation. ● Remove the purging bolt 1 . ● [...]

– 17 – INSP ADJ FRONT BRAKE FLUID LEVEL INSPECTION/ FRONT BRAKE PAD INSPECTION CHASSIS FRONT BRAKE FLUID LEVEL INSPECTION 1.Place the machine on a level surface. N OTE: When inspecting the front brake fluid level, make sure that the top of the master cylinder top is horizontal. 2.Inspect: ● Brake fluid level Fluid level is under “LOWER” l[...]

– 18 – INSP ADJ BRAKE HOSE INSPECTION/ AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) BRAKE HOSE INSPECTION 1.Remove: ● Front carrier ● Front fender Refer to “FENDER AND FUEL TANK”. 2.Inspect: ● Brake hoses 1 Cracks/wear/damage → Replace. 3.Check: ● Brake hose clamp Loosen → Tighten. 4.Hold the machine in an upright position and apply th[...]

– 19 – INSP ADJ AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) 1.Bleed: ● Brake system ********************************************* Air bleeding steps: a. Add the proper brake fluid to the reservoir. b. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. c. Connect the clear plastic hose 1 tightly to the calip[...]

– 20 – CHAS FRONT WHEEL CHASSIS FRONT WHEEL 1 Wheel cap 2 Cotter pin 3 Axle nut 4 Plain washer 5 Wheel nut 6 Front wheel 7 Spacer 8 Oil seal 9 Bearing 0 Front wheel hub A Bearing spacer TIRE AIR PRESSURE Cold Tire Pressure Front Rear Standard 20 kPa (0.20 kg/cm 2 , 2.9 psi) 25 kPa (0.25 kg/cm 2 , 3.6 psi) Minimum 17 kPa (0.17 kg/cm 2 , 2.5 psi)[...]

– 21 – CHAS REMOVAL 1.Place the machine on a level surface. 2.Loosen: ● Nuts (front wheel) Apply the front brake. 3.Block the rear wheels, and elevate the front wheels by placing the suitable stand under the frame. 4.Remove: ● Nuts 1 (front wheel) ● Front wheel 2 5.Remove: ● Wheel cap ● Cotter pin 1 ● Axle nut 2 ● Plain washer 3 1[...]

– 22 – CHAS FRONT WHEEL 8.Remove: ● Front brake disc 1 1 INSPECTION 1.Inspect: ● Wheel hub 1 Cracks/damage → Replace.[...]

– 23 – CHAS FRONT BRAKE FRONT BRAKE 1 Brake master cylinder reservoir cap 2 Brake master cylinder reservoir diaphragm holder 3 Brake master cylinder reservoir diaphragm 4 Brake master cylinder 5 Brake master cylinder kit 6 Copper washer 7 Union bolt 8 Brake hose 9 Brake pipe 0 Brake disc A Caliper bleed screw B Retaining bolt C Brake caliper D [...]

– 24 – CHAS FRONT BRAKE CAUTION: Disc brake components rarely require dis- assembly. DO NOT: ● Disassemble components unless abso- lutely necessary. ● Use solvents on internal brake compo- nents. ● Use contaminated brake fluid for clean- ing. Use only clean brake fluid. ● Allow brake fluid to come in contact with the eyes, otherwise eye[...]

– 25 – CHAS FRONT BRAKE 5.Remove: ● Brake pads 1 (with pad shim 2 ) ● Pad spring 3 N OTE: ● When pad replacement is required, also replace the pad spring and shim. ● Replace the pads as a set if either is found to be worn to the wear limit a . Wear limit a : 1.0 mm (0.04 in) 1 2 3 6.Install: ● Pad shim (onto inside brake pad) ● Pad [...]

– 26 – CHAS FRONT BRAKE 7.Install: ● Retaining bolts ● Front brake caliper 8.Install: ● Front wheel 9.Inspect: ● Brake fluid level Refer to “FRONT BRAKE FLUID LEVEL INSPECTION”. a “LOWER” level line T R . . Retaining bolt: 18 Nm (1.8 m • kg, 13 ft • lb) Bolt (front brake caliper): 30 Nm (3.0 m • kg, 22 ft • lb) UP LOWER [...]

– 27 – CHAS FRONT BRAKE 4.Remove: ● Union bolt 1 ● Copper washers 2 ● Brake hose 3 N OTE: Place the open end of the hose into a con- tainer and pump the oil fluid out carefully. 5.Remove: ● Caliper body 1 ● Caliper bracket 2 N OTE: Before removing the caliper body from the bracket, disconnect the dust boot from the guide shaft on the [...]

– 28 – CHAS FRONT BRAKE 1.Remove: ● Brake lever 1 ● Union bolt 2 ● Copper washers 3 ● Brake hose 4 N OTE: Hold a container under the master cylinder and under the hose end to collect remaining brake fluid. 2.Remove: ● Brake master cylinder reservoir cap 1 ● Brake master cylinder reservoir diaphragm holder ● Brake master cylinder r[...]

– 29 – CHAS FRONT BRAKE 1.Inspect: ● Caliper piston 1 Scratches/rust/wear → Replace caliper assembly. ● Caliper cylinder 2 Wear/scratches → Replace caliper assem- bly. ● Caliper body 3 Cracks/damage → Replace. ● Oil delivery passage (caliper body) Blow out with compressed air. W ARNING Replace the piston seal whenever the cali- pe[...]

– 30 – CHAS FRONT BRAKE 6.Measure: ● Brake pads (thickness) a Out of specification → Replace. N OTE: ● When pad replacement is required, also replace the pad spring and shims. ● Replace the pads as a set if either is found to be worn to the wear limit a . Wear limit a : 1.0 mm (0.04 in) 7.Inspect: ● Brake disc Galling/damage → Repla[...]

– 31 – CHAS FRONT BRAKE N OTE: Tighten the bolts (brake disc) in stage using a crisscross pattern. T R . . Bolt (brake disc): 16 Nm (1.6 m • kg, 12 ft • lb) CALIPER ASSEMBLY W ARNING ● All internal parts should be cleaned in new brake fluid only. ● Internal parts should be lubricated with brake fluid when installed. ● Replace the pist[...]

– 32 – CHAS FRONT BRAKE 3.Install: ● Brake caliper 1 (temporarily) ● Copper washers 2 ● Brake hose 3 ● Union bolt 4 CAUTION: When installing the brake hose on the cali- per, make sure that the brake pipe touches the projection a on the brake caliper. W ARNING ● Proper hose routing is essential to insure safe machine operation. Refer t[...]

– 33 – CHAS FRONT BRAKE 6.Fill: ● Reservoir tank N OTE: If DOT 4 is not available, 3 can be used. CAUTION: Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately. W ARNING ● Use only the designated quality brake fluid: otherwise, the rubber seals may deteriorate, causing leakage and poor brake per[...]

– 34 – CHAS FRONT BRAKE MASTER CYLINDER ASSEMBLY W ARNING ● All internal parts should be cleaned in new brake fluid only. ● Internal parts should be lubricated with brake fluid when installed. ● Replace the piston seals and dust seals whenever a brake master cylinder is dis- assembled. Recommended brake fluid: DOT 4 1.Install: ● Brake m[...]

– 35 – CHAS FRONT BRAKE 3.Install: ● Copper washers ● Brake hose ● Union bolt N OTE: ● Tighten the union bolt while holding the brake hose as shown. ● Check that the brake hose does not touch other parts (throttle cable, wire harness, leads, etc.) by turning the handlebar left and right, and correct if necessary. W ARNING ● Proper h[...]

– 36 – CHAS FRONT BRAKE ● Refill with the same type of brake fluid: mixing fluids may result in a harmful chemical reaction and lead to poor per- formance. ● Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. 6.Air bleed: ● Br[...]

– 37 – CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 1 Rear axle 2 Bearing 3 Oil seal 4 Wheel hub 5 Axle nut A TIRE SIZE: AT22 × 10-10 B TIRE WEAR LIMIT: 2.0 mm (0.08 in) C RIM SIZE: 8 × 10AT D RIM RUNOUT LIMIT: Radial: 2 mm (0.08 in) Lateral: 2 mm (0.08 in) E REAR AXLE RUNOUT LIMIT: 1.5 mm (0.06 in) FWD REAR WHEELS/REAR BRAKE AND REAR AXLE[...]

– 38 – CHAS FRONT SHOCK ABSORBER AND FRONT ARM FRONT SHOCK ABSORBER AND FRONT ARM 1 Front shock absorber 2 Steering knuckle 3 Lower arm 4 Bushing FWD[...]

– 39 – CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM 1 Rear shock absorber 2 Thrust cover 3 Locknut 4 Pivot shaft 5 Collar 6 Oil seal 7 Taper roller bearing 8 Swingarm 9 Rubber boot 0 Final gear case protector A SWINGARM FREE PLAY LIMIT: End: 1.0 mm (0.04 in) Side: 1.0 mm (0.04 in) FWD[...]

– 40 – –+ ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Reverse indicator light 2 Neutral indicator light 3 Main switch 4 Rear brake lever switch 5 Handlebar switch 6 Fuses 7 Starter relay 8 Rectifier/regulator 9 CDI unit 0 Taillight A Battery B Starting circuit cut-off relay C Reverse switch D Neutral switch E Headli[...]

– 41 – –+ ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM B R B / W Br B / W Br B R OFF ON 3 Br Br RR L / WL / B 4 5 6 7 R R B B B B B L / W L / W R R R G / Y Sb L / W R / B (BLACK) (BLACK) (BLACK) (BLACK) 0 A 8 B G / Y Sb O O F CB G / Y B D E OFF LO HI I J L L L OFF RUN G OFF PUSH H R / W B K G Y G Y B B B GY B YG B YG K G Y B [...]

– 42 – –+ ELEC IGNITION SYSTEM EB802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1.Fuse 2.Battery 3.Spark plug 4.Ignition spark gap 5.Spark plug cap resistance 6.Ignition coil resistance 7.Engine stop switch 8.Main switch 9.Pickup coil resistance 10. Charging/rotor rotation dir[...]

– 43 – –+ ELEC IGNITION SYSTEM C0NTINUITY CORRECT Spark plug gap: 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) * INCORRECT Repair or replace the spark plug. OUT OF SPECIFICATION OR NO SPARK 4.Ignition spark gap ● Disconnect the spark plug cap from the spark plug. ● Connect the dynamic spark tester 1 as shown. 2 Spark plug cap 3 Spark plug ● Turn the[...]

– 44 – –+ ELEC IGNITION SYSTEM C0NTINUITY 6.Ignition coil resistance ● Disconnect the ignition coil connector from the wire harness. ● Connect the pocket tester ( Ω × 1) to the ignition coil. * Tester (+) lead → Orange lead terminal Tester (–) lead → Ignition coil base Tester (+) lead → Ignition coil base Tester (–) lead → [...]

– 45 – –+ ELEC IGNITION SYSTEM C0NTINUITY 9.Pickup coil resistance ● Disconnect the CDI magneto coupler from the wire harness. ● Connect the pocket tester ( Ω × 100) to the pickup coil terminal. Tester (+) lead → White/Green terminal 1 Tester (–) lead → White/Red terminal 2 * MEETS SPECIFICATION ● Check the pickup coil for the [...]

– 46 – –+ ELEC IGNITION SYSTEM C0NTINUITY CORRECT 11. Wiring connection ● Check the connections of the entire ignition system. Refer to “CIRCUIT DIAGRAM”. Replace the CDI unit. * POOR CONNECTION Properly connect the ignition system.[...]

– 47 – –+ ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM B R B / W Br B / W Br B R OFF ON 3 Br Br RR L / WL / B 4 5 6 7 R R B B B B B L / W L / W R R R G / Y Sb L / W R / B (BLACK) (BLACK) (BLACK) (BLACK) 0 A 8 B G / Y Sb O O F CB G / Y B D E OFF LO HI I J L L L OFF RUN G OFF PUSH H R / W B K G Y G Y B B B GY [...]

– 48 – –+ ELEC ELECTRIC STARTING SYSTEM STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, starting circuit cut-off relay, rear brake lever switch, and neu- tral switch. If the main switch is on and engine stop switch is in the RUN position, the starter motor can be operated only if: Th[...]

– 49 – –+ ELEC ELECTRIC STARTING SYSTEM EB803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 1.Fuse 2.Battery 3.Starter motor 4.Starting circuit cut-off relay 5.Starter relay 6.Main switch 7.Engine stop switch 8.Neutral switch 9.Rear brake lever switch 10. Start switch 11. Wiring connection (the entire starting sys[...]

– 50 – –+ ELEC ELECTRIC STARTING SYSTEM C0NTINUITY MOVES 3.Starter motor ● Connect the battery positive terminal 1 and starter motor lead 2 using a jumper lead 3 . ● Check the operation of the starter motor. * * 1 M 2 3 R L / W L / B R W ARNING ● A wire that is used as a jumper lead must have the equivalent capacity or more as that of t[...]

– 51 – –+ ELEC ELECTRIC STARTING SYSTEM C0NTINUITY 5.Starter relay ● Remove the starter relay from the wire har- ness. ● Connect the pocket tester ( Ω × 1) and the battery (12 V) to the starter relay terminals. * 3 4 2 1 R B RR L / W L / B CONTINUITY Battery (+) terminal → Blue/White terminal 1 Battery (–) terminal → Blue/Black t[...]

– 52 – –+ ELEC ELECTRIC STARTING SYSTEM C0NTINUITY CORRECT 9.Rear brake lever switch Refer to “SWITCH INSPECTION”. * INCORRECT Replace the rear brake lever switch. CORRECT 10.Start switch Refer to “SWITCH INSPECTION”. INCORRECT Replace the handlebar switch (left). EB803028 11.Wiring connection ● Check the connections of the entire s[...]

PRINTED IN U.S.A. Y AMAHA MO T OR CO. , L TD . 2500 SHINGAI IW A T A SHIZUOKA JAP AN[...]

B R B / W Br B / W Br B R OFF ON 3 Br Br RR L / WL / B 4 5 6 7 R R B B B B B L / W L / W R R R G / Y Sb L / W R / B (BLACK) (BLACK) (BLACK) (BLACK) 0 A 8 B G / Y Sb O O F CB G / Y B D E OFF LO HI I J L L L OFF RUN G OFF PUSH H R / W B K G Y G Y B B B GY B YG B YG K G Y B B GY Sb G / LR / W R / W Br Br Sb G / L G / L G / L Sb G / L G / L Sb Br Br L [...]

YFM250XP SUPPLEMENTARY SERVICE MANUAL LIT-11616-15-03 4XE-F8197-12[...]

FOREWORD This Supplementary Service Manual has been prepared to introd uce new service and new data for the YFM250XP. For complete information on service procedures, it is necessary to use this Supple- mentary Service Manual together with the following manual. YFM250XL(C) SERVICE MANUAL: LIT-11616-12-01 (4XE-F8197-1 0) YFM250XN SUPPLEMENTARY SERVIC[...]

EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not po ssible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to pe rform maintenance and repairs on Yamaha machine has a basic understanding o f the [...]

HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main ca tegories of subjects. (See “Illustrated symb ols”) 1st title 1 : This is a chapter with its symbol on the upper right o f each page. 2nd title 2 : This title appears on the upper of each page on the left of the chapter sym- bol. (For the chapter [...]

EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are pr inted on the top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and ad justments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical 9 Troubleshooting Illustrated symbols 0 to F are used to identify the speci[...]

CONTENTS SPECIFICATIONS ........................................ ................................................... 1 GENERAL SPECIFICATIONS .............. ................................................... 1 MAINTENANCE SPECIFICATION ........................................................... 2 ENGINE ............................................[...]

– 1 – SPEC GENERAL SPECIFICATIONS SPECIFICA TIONS GENERAL SPECIFICATIONS Item Standard Model code: 4XEE (USA) Brake: F ront brak e type Dual disc brake operation Right hand operation Rear brak e type Drum brake (fully sealed) operat ion Left hand and right foot operation Electrical: Ignition system DC.C.D.I. Generator system A.C. magneto Batter[...]

– 2 – SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: W ar p limit ---- 0.03 mm (0.001 in) Measuring point Lines indicate straightedge measurement. Piston: Piston to cylinder clearance 0.04 ~ 0.06 mm (0.0016 ~ 0.0024 in) 0.15 mm (0.0059 in) Piston siz e “ D ” 70.92 ~ 70.97 mm (2.792 ~ 2.7[...]

– 3 – SPEC MAINTENANCE SPECIFICATIONS CHASSIS Tightening torques ELECTRICAL Item Standard Limit Rear suspension: Shoc k absorber tra vel 85 mm (3.35 in) ---- Suspension spring free length 268 mm (10.55 in) ---- Fitting length 244 mm (9.61 in) ---- S p r in g r a t e 39 N/mm (3.9 kg/mm, 222.69 lb /in)/0 ~ 85 mm (0 ~ 3.35 in) ---- Optional spring[...]

– 4 – SPEC CABLE ROUTING 1 Rear brake lever switch lead 2 Rear brake cable 3 Cable guide 4 Front brake ho se 5 Front brake light switch lead 6 Throttle cable 7 Neutral indicator light 8 Reverse indicator light 9 Fuel tank breath er hose 0 Handlebar switch assembly lead A Headlight leads È Do not rou te the han dlebar switch assembly lead throu[...]

– 5 – SPEC 1 Cable guide 2 Main switch 3 Fuel tank breath er hose 4 Carburetor overflow ho se 5 Reverse switch lead 6 Neutral switch lead 7 Starter moto r lead 8 Throttle cable 9 Rear brake cable È Route the main switch lead and indicator light lead to the side of the cable guide. É Insert the carbur etor air vent hose, rear br ake breather h[...]

– 6 – SPEC 1 Tail/brake light 2 Final gear case breather hose 3 Front brake light switch lead 4 Carburetor air vent hose 5 Rear brake breath er hose 6 Rear brake cable 7 CDI magneto lead È Make sure that the star ter motor lead has no slack. É Fasten the star ter motor lead and wire har ness to the frame with the plasti c band. Ê Fasten the [...]

– 7 – SPEC Í Fasten the t ail/brake light lead to the sto rage box with the plastic clamp. Î Fasten the starte r motor lead and wire harnes s to the frame with the plastic clamp. Ï Route the rear brake cable and re ar brake breather hose thr ough the cable guide. Ð Route the rear brake breather h ose through the cable guide. Ñ Route the fi[...]

– 8 – SPEC 1 Battery breat her hose 2 Rear brake cable 3 Spark plug cap 4 Ignition coil 5 Ignition coil lead 6 Starter moto r lead 7 Rear brake light switch 8 Rear brake breath er hose È Make sure that the batt ery breather hose is not kinked or bent. É Route the re ar brake cable t hrough the cable guide on th e cylinder. Ê Fasten the sta r[...]

– 9 – SPEC 1 Rectifier/regulator 2 CDI unit 3 Starting circuit cut- off relay lead 4 Starter relay lead 5 Starter moto r lead 6 Starting circuit cut- off relay 7 Starter relay 8 Rear brake breath er hose 9 Carburetor air vent hose 0 Final gear case breather hose È Fasten the battery + lead and starte r motor lead to the rear fende r with the p[...]

– 10 – SPEC Í Make sure that the grommet is installed with the mark facing forward. Î 5 mm (0.2 in) CABLE ROUTING[...]

– 11 – SPEC 1 Rear brake cable 2 Throttle cable 3 Wire harness 4 Starter moto r lead 5 Tail/brake light lead È Route the throt tle cable and rear brake cable through th e cable guide. Make sure that the throttle cab le is routed to the insi de of the re ar brake cable. É Fasten the wire harne ss to the frame with the plastic clamps. Ê Make s[...]

– 12 – CHK ADJ INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all info rmation necessary to perform recommen ded inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer servi[...]

– 13 – CHK ADJ PERIODIC MAINTENANCE/LUBRICATION INTERVALS * It is recommended that these items be serviced by a Yamaha d ealer. ** Lithium-soap-based grease NOTE: ● Recommended brake fluid: DOT 4 ● Brake fluid replacement: 1.When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the brake fluid level and [...]

– 14 – CHK ADJ ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE LIGHT SWITCH CHASSIS ADJUSTING THE FRONT BRAKE 1.Check: ● Brake lever free play a Out of specification → Bleed the front bra ke system. Refer to “ AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ” . (Manual No.: 4XE-F8197-11) ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: The rear br[...]

– 15 – – + ELEC CHECKING THE SWITCH ELECTRICAL CHECKING THE SWITCH CHECKING THE SWITCH Use a pocket tester to che ck the terminals for continuity. If the continuity is faulty at any point, replace the switch. N OTE: ● Set the pocket tester to “ 0 ” before starting the test. ● The pocket tester should be set to the “ Ω × 1 ” ran[...]

– 16 – – + ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM W / L B B B W / GW / L O W / R RR / B Br Sb Br G / L Sb G / L G / L G / L R / W R / W Sb G / L Br Br G / L Sb W / R W / G W R W / L W / R W / G R / B R / B Sb R W W W W W R W / GR W / RW / L RW / G W / LW / R W WW W WW 1 ON OFF R Br RB r (GRA Y) Br R (GRA Y) 3 4 L / W L / W [...]

– 17 – – + ELEC SIGNAL SYSTEM CHECKING THE SIGNAL SYSTEM 1.If the tail/brake light fails to come on: CONTINUITY 1.Bulb and bulb so cket ● Check the bulb and bulb socket for continu- ity. NO CONTINUITY Replace the bulb and/or bulb socke t. CONTINUITY 2.Brake light switches Refer to “ CHECKING THE SWITCH ” . NO CONTINUITY Replace the brak[...]

Y AMAHA MO T OR CO. , L TD . 2500 SHINGAI IW A T A SHIZUOKA JAP AN PRINTED IN U.S.A.[...]

YFM250XP WIRING DIAGRAM W / L B B B W / GW / L O W / R RR / B Br Sb Br G / L Sb G / L G / L G / L R / W R / W Sb G / L Br Br G / L Sb W / R W / G W R W / L W / R W / G R / B R / B Sb R W W W W W R W / GR W / RW / L RW / G W / LW / R W WW W WW 1 ON OFF R Br RB r (GRA Y) Br R (GRA Y) 3 4 L / W L / W G / Y L / B B B R R R R R B B B 5 6 7 8 O O B 0 A B[...]