Yamaha TZR250 (M) (M1) 2000 Owner's manual
5KE-28199-10LIT-11626-13-41
OWNER’S SERVICE MANUAL
TZ250M1/(M)
TZ250M1/(M)
OWNER’S SERVICE MANUAL
©1999 by Yamaha Motor Corporation, U.S.A.
1st Edition, September 1999
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Corporation
U.S.A. is expressly prohibited.
Printed in Japan
P/N. LIT-11626-13-41
EC010000
EC020000
INTRODUCTION
Congratulations on your purchase of a Y amaha
TZ series. This model is the culmination of
Yamaha’s vast experience in the production of
pacesetting racing machines. It represents the
highest grade of craftsmanship and reliability
that have made Yamaha a leader.
This manual explains operation, inspection,
basic maintenance and tuning of your
machine. If you have any questions about this
manual or your machine, please contact your
Yamaha dealer.
NOTE:
As improvements are made on this model,
some data in this manual may become outdated. If you have any questions, please consult
your Yamaha dealer.
W
PLEASE READ THIS MANUAL CAREFULLY
AND COMPLETELY BEFORE OPERATING
THIS MACHINE. DO NOT ATTEMPT TO
OPERATE THIS MACHINE UNTIL YOU
HAVE ATTAINED A SATISFACTORY
KNOWLEDGE OF ITS CONTROLS AND
OPERATING FEATURES AND UNTIL YOU
HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR
INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING
SKILLS, WILL ENSURE THAT YOU SAFELY
ENJOY THE CAPABILITIES AND THE
RELIABILITY OF THIS MACHINE.
EC030010
WARRANTY INFORMATION
This model is sold AS IS, WITHOUT ANY WARRANTIES EXPRESSED OR IMPLIED REGARDLESS OF THE INTENDED USE.
THE PURCHASER OF THIS MACHINE, which is intended for competition purposes, IS RESPONSIBLE FOR ALL COSTS, SERVICE AND/OR REPAIR.
EC040001
IMPORTANT NOTICE
THIS MACHINE IS DESIGNED STRICTLY
FOR COMPETITION USE, ONLY ON A
CLOSED COURSE. It is illegal for this
machine to be operated on any public street,
road, or highway. Off-road use on public lands
may also be illegal. Please check local regulations before riding.
1. THIS MACHINE IS TO BE OPERATED
BY AN EXPERIENCED RIDER ONLY.
Do not attempt to operate this
machine at maximum power until you
are totally familiar with its characteristics.
2. THIS MACHINE IS DESIGNED TO BE
RIDDEN BY THE OPERATOR ONLY.
Do not carry passengers on this
machine.
3. ALWAYS WEAR PROTECTIVE APP AREL.
When operating this machine, always
wear an approved helmet with goggles or a face shield. Also wear heavy
boots, gloves, and protective clothing. Always wear proper fitting clothing that will not be caught in any of
the moving parts or controls of the
machine.
4. ALWAYS MAINTAIN YOUR MACHINE
IN PROPER WORKING ORDER.
For safety and reliability, the machine
must be properly maintained. Always
perform the pre-operation checks
indicated in this manual. Correcting a
mechanical problem before you ride
may prevent an accident.
5. GASOLINE IS HIGHLY FLAMMABLE.
Always turn off the engine while refueling. Take care to not spill any gasoline on the engine or exhaust system.
Never refuel in the vicinity of an open
flame, or while smoking.
&SAFETY INFORMATION
6. GASOLINE CAN CAUSE INJURY.
If you should swallow some gasoline,
inhale excess gasoline vapors, or
allow any gasoline to get into your
eyes, contact a doctor immediately. If
any gasoline spills onto your skin or
clothing, immediately wash skin
areas with soap and water, and
change your clothes.
7. ONLY OPERATE THE MACHINE IN AN
AREA WITH ADEQUATE VENTILATION.
Never start the engine or let it run for
any length of time in an enclosed
area. Exhaust fumes are poisonous.
These fumes contain carbon monoxide, which by itself is odorless and
colorless. Carbon monoxide is a dangerous gas which can cause unconsciousness or can be lethal.
8. PARK THE MACHINE CAREFULLY;
TURN OFF THE ENGINE.
Always turn off the engine if you are
going to leave the machine. Do not
park the machine on a slope or soft
ground as it may fall over.
9. PROPERLY SECURE THE MACHINE
BEFORE TRANSPORTING IT.
When transporting the machine in
another vehicle, always be sure it is
properly secured and in an upright
position and that the fuel cock is in
the “OFF” position. Otherwise, fuel
may leak out of the carburetor or fuel
tank.
EC050000
TO THE NEW OWNER
This manual will provide you with a good basic
understanding of features, operation, and
basic maintenance and inspection items of this
machine. Please read this manual carefully
and completely before operating your new
machine. If you have any questions regarding
the operation or maintenance of your machine,
please consult your Yamaha dealer.
NOTE:
This manual should be considered a permanent part of this machine and should remain
with it even if the machine is subsequently
sold.
EC060000
NOTICE
Some data in this manual may become outdated due to improvements made to this model in
the future. If there is any question you have
regarding this manual or your machine, please
consult your Yamaha dealer.
Weights of machines without fuel
The minimum weights for road race
machines are:
for the class 125 cc . . . . . . . . . . .minimum
70 kg (154 lb)
for the class 250 cc . . . . . . . . . . .minimum
95 kg (209 lb)
for the class 500 cc . . . . . . . . . . .minimum
131 kg (289 lb)
In modifying your machine (e.g., for weight
reduction), take note of the above limits of
weight.
EC070011
F.I.M. MACHINE WEIGHTS:
EC080000
HOW TO USE
THIS MANUAL
EC081000
P ARTICULARLY IMPORT ANT INFORMA TION
!!
The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS
INVOLVED!
W
Failure to follow WARNING instructions could
result in severe injury or death to the machine
operator, a bystander, or a person inspecting
or repairing the machine.
CC
CAUTION:
A CAUTION indicates special precautions that
must be taken to avoid damage to the
machine.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
EC082000
FINDING THE REQUIRED PAGE
1. This manual consists of seven chapters;
“General Information”, “Specifications”,
“Regular inspection and adjustments”,
“Engine”, “Chassis”, “Electrical” and
“Tuning”.
2. The table of contents is at the beginning of
the manual. Look over the general layout of
the book before finding then required chapter and item.
Bend the book at its edge, as shown, to find
the required fore edge symbol mark and go
to a page for required item and description.
EC083000
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the
course of action required will follow the symbol, e.g.,
•Bearings
Pitting/Damage ≥ Replace.
EC084002
HOW TO READ DESCRIPTIONS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
1. An easy-to-see exploded diagram 1 is provided for removal and disassembly jobs.
2. Numbers 2 are given in the order of the jobs in the exploded diagram. Anumber that is enclosed
by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
3. The meanings of the symbol marks are given on the next page.
4. Ajob instruction chart 4 accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. Extent of removal 5 is provided in the job instruction chart to save the trouble of an unneces-
sary removal job.
6. For jobs requiring more information, the step-by-step format supplements 6 are given in addi-
tion to the exploded diagram and job instruction chart.
CLUTCH
4-25
ENG
EC4A8100
CLUTCH HOUSING AND PUSH LEVER AXLE
Extend of removal: 1 Clutch housing removal 2 Push lever axle removal
Extend of removal Order Part name Q’ty Remarks
CLUTCH HOUSING AND
PUSH LEVER AXLE
REMOVAL
1 Nut (clutch boss) 1
2 Lock washer 1
Use special tool.
3 Clutch boss 1
Refer to “REMOVAL POINTS”.
4 Spacer 2 1
5 O-ring (small) 1
6 Clutch housing 1
7 O-ring (large) 1
8 Bearing 1
9 Spacer 1 1
10 Ball 1
11 Push rod 1
12 Bolt (seat plate) 1
13 Seat plate 1
14 Push lever axle 1
T
50 Nm (5.0 mdkg, 36 ftdlb)
T
11 Nm (1.1 mdkg, 8.0 ftdlb)
2
1
CLUTCH
4-26
EC4A3000
REMOVAL POINTS
EC483211
Clutch boss
1. Remove:
•Nut 1
•Lock washer 2
•Clutch boss 3
NOTE:
Straighten the lock washer tab and use the
clutch holding tool 4, 5 to hold the clutch
boss.
Clutch holding tool:
YM-91042 . . . . . . . . . . . . . . . .
44
90890-04086 . . . . . . . . . . . . .
55
B
A For USA and CDN
B Except for USA and CDN
EC4A4000
INSPECTION
EC484100
Clutch housing and boss
1. Inspect:
•Clutch housing 1
Cracks/Wear/Damage ≥ Replace.
•Clutch boss 2
Scoring/Wear/Damage ≥ Replace.
EC4A4100
Clutch housing
1. Check:
•Circumferential play
Free play exists ≥ Replace.
•Gear teeth a
Wear/Damage ≥ Replace.
•O-ring 1
Damage ≥ Replace.
EC484400
Clutch spring
1. Measure:
•Clutch spring free length a
Out of specification ≥ Replace springs as
a set.
Clutch spring free length:
Standard <Limit>
36.0 mm (1.417 in) 35.0 mm (1.378 in)
{
ENG
1
6
2
4
5
3
EC085002
ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols 1 to 7 are designed as
thumb tabs to indicate the chapter’s number
and content.
1 General information
2 Specifications
3 Regular inspection and adjustments
4 Engine
5 Chassis
6 Electrical
7 Tuning
Illustrated symbols 8 to ¢ are used to identify the specifications appearing in the text.
8 With engine mounted
9 Special tool
0 Filling fluid
¡ Lubricant
™ Tightening
£ Specified value, Service limit
¢ Resistance ( Ω ), Voltage ( V ), Electric cur-
rent ( A)
Illustrated symbols ∞ to ª in the exploded dia-
grams indicate grade of lubricant and location
of lubrication point.
∞ Apply transmission oil
§ Apply engine mixing oil
¶ Apply molybdenum disulfide oil
• Apply lightweight lithium-soap base grease
ª Apply molybdenum disulfide grease
Illustrated symbols º to ! in the exploded dia-
grams indicate where to apply a locking agent
and where to install new parts.
º Apply locking agent (LOCTITE
®
)
! Use new one
1
GEN
INFO
3
INSP
ADJ
5
CHAS
7
TUN
8
6
ELEC
4
ENG
2
SPEC
9
¡
£
∞
º!
•
ª
¶§
¢
™
0
MEMO
EC090000
INDEX
GENERAL INFORMATION
GEN
INFO
1
TUNING
TUN
7
CHASSIS
CHAS
5
ELECTRICAL
ELEC
6
ENGINE
ENG
4
REGULAR INSPECTION AND ADJUSTMENTS
INSP
ADJ
3
SPECIFICATION
SPEC
2
EC0A0000
CONTENTS
CHAPTER 1
GENERAL INFORMATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . 1-1
MACHINE IDENTIFICATION . . . . . . . . . . 1-2
IMPORTANT INFORMATION. . . . . . . . . . 1-3
CHECKING OF CONNECTION . . . . . . . . 1-5
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . 1-6
CONTROL FUNCTIONS . . . . . . . . . . . . . 1-9
FUEL AND ENGINE MIXING OIL. . . . . . 1-15
INFORMATION BEFORE
PRE-OPERATION . . . . . . . . . . . . . . . . . 1-16
STARTING AND BREAK-IN . . . . . . . . . . 1-17
TORQUE-CHECK POINTS. . . . . . . . . . . 1-20
CLEANING AND STORAGE . . . . . . . . . 1-21
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . 2-1
MAINTENANCE SPECIFICATIONS . . . . . 2-3
GENERAL TORQUE SPECIFICATIONS 2-12
DEFINITION OF UNITS . . . . . . . . . . . . . 2-12
CABLE ROUTING DIAGRAM . . . . . . . . 2-13
CHAPTER 3
REGULAR INSPECTION
AND ADJUSTMENTS
MAINTENANCE INTERVALS. . . . . . . . . . 3-1
PRE-OPERATION INSPECTION AND
MAINTENANCE. . . . . . . . . . . . . . . . . . . . 3-4
LOCKING WIRE INSTALLATION GUIDE. 3-5
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . 3-17
ELECTRICAL. . . . . . . . . . . . . . . . . . . . . 3-41
CHAPTER 4
ENGINE
COWLING, INDUCTION GUIDE, SEAT
AND FUEL TANK. . . . . . . . . . . . . . . . . . . 4-1
EXHAUST PIPE AND SILENCER . . . . . . 4-3
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . 4-4
CARBURETOR AND REED VALVE. . . . . 4-7
CYLINDER HEAD,CYLINDER AND
PISTON . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 4-31
PRIMARY DRIVEN GEAR, PRIMARY
DRIVE GEAR AND BALANCER
SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . 4-44
WATER PUMP . . . . . . . . . . . . . . . . . . . . 4-51
TRANSMISSION, SHIFT CAM AND
SHIFT FORK . . . . . . . . . . . . . . . . . . . . . 4-55
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . 4-64
CDI MAGNETO . . . . . . . . . . . . . . . . . . . 4-68
ENGINE REMOVAL . . . . . . . . . . . . . . . . 4-71
CRANKCASE AND CRANKSHAFT. . . . 4-76
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL. . . . 5-1
FRONT BRAKE AND REAR BRAKE. . . 5-10
FRONT FORK . . . . . . . . . . . . . . . . . . . . 5-26
HANDLEBAR. . . . . . . . . . . . . . . . . . . . . 5-40
STEERING . . . . . . . . . . . . . . . . . . . . . . . 5-46
SWINGARM. . . . . . . . . . . . . . . . . . . . . . 5-53
REAR SHOCK ABSORBER. . . . . . . . . . 5-60
CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS AND
WIRING DIAGRAM . . . . . . . . . . . . . . . . . 6-1
IGNITION SYSTEM . . . . . . . . . . . . . . . . . 6-2
CHARGING SYSTEM . . . . . . . . . . . . . . . 6-7
YPVS SYSTEM . . . . . . . . . . . . . . . . . . . 6-10
SOLENOID VALVE SYSTEM . . . . . . . . . 6-12
THERMO UNIT SYSTEM . . . . . . . . . . . . 6-14
FUEL PUMP SYSTEM . . . . . . . . . . . . . . 6-16
CHAPTER 7
TUNING
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . 7-14
DESCRIPTION
1-1
NOTE:
•The machine you have purchased may differ
slightly from those shown in the following.
•Designs and specifications are subject to
change without notice.
GEN
INFO
EC100000
GENERAL INFORMATION
EC110000
DESCRIPTION
1 Clutch lever
2 Valve joint
3 Main switch
4 Water temperature gauge
5 Front brake lever
6 Throttle grip
7 Radiator cap
8 Fuel tank cap
9 Starter lever (Choke)
0 Battery
¡ Fuel pump
™ Fuel cock
£ Steering damper
¢ Servomotor
∞ Radiator
§ Check bolt (Transmission oil level)
¶ Rear brake pedal
• Rear shock absorber
ª Drive chain
º Shift pedal
! CDI magneto
@ Front fork
1
MACHINE IDENTIFICATION
1-2
EC120001
MACHINE IDENTIFICATION
There are two significant reasons for knowing
the serial number of your machine:
1. When ordering parts, you can give the num-
ber to your Yamaha dealer for positive identification of the model you own.
2. If your machine is stolen, the authorities will
need the number to search for and identify
your machine.
EC121001
VEHICLE IDENTIFICATION NUMBER
(For USA, CDN, AUS, NZ and E)
The vehicle identification number 1 is
stamped on the right of the steering head pipe.
EC122001
FRAME SERIAL NUMBER
(Except for USA, CDN, AUS, NZ and E)
The frame serial number 1 is stamped on the
right of the steering head pipe.
EC123020
ENGINE SERIAL NUMBER
The engine serial number 1 is stamped into
the elevated part of the rear-side of the engine.
EC124000
MODEL LABEL
The model label 1 is affixed to the frame
under the rider’s seat. This information will be
needed to order spare parts.
GEN
INFO
1
IMPORTANT INFORMATION
1-3
EC130000
IMPORTANT INFORMATION
EC131002
PREP ARATION FOR REMOVALAND DISASSEMBL Y
1. Remove all dirt, mud, dust, and foreign
material before removal and disassembly.
2. Use proper tools and cleaning equipment.
Refer to “SPECIAL TOOLS” section.
3. When disassembling the machine, keep
mated parts together. They include gears,
cylinders, pistons, and other mated parts
that have been “mated” through normal
wear. Mated parts must be reused as an
assembly or replaced.
4. During the machine disassembly, clean all
parts and place them in trays in the order of
disassembly. This will speed up assembly
time and help assure that all parts are correctly reinstalled.
5. Keep away from fire.
GEN
INFO
IMPORTANT INFORMATION
1-4
EC132000
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuine
parts for all replacements. Use oil and/or
grease recommended by Yamaha for
assembly and adjustment.
EC133000
GASKETS, OIL SEALS AND O-RINGS
1. All gaskets, oil seals, and O-rings should be
replaced when an engine is overhauled. All
gasket surfaces, oil seal lips, and O-rings
must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
EC134000
LOCK WASHERS/PLATES AND COTTER
PINS
1. All lock washers/plates 1 and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt or
nut flat(s) after the bolt or nut has been
properly tightened.
EC135001
BEARINGS AND OIL SEALS
1. Install the bearing(s) 1 and oil seal(s) 2
with their manufacturer’s marks or numbers
facing outward. (In other words, the
stamped letters must be on the side
exposed to view.) When installing oil
seal(s), apply a light coating of light-weight
lithium base grease to the seal lip(s). Oil the
bearings liberally when installing.
CC
CAUTION:
Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.
EC136000
CIRCLIPS
1. All circlips should be inspected carefully
before reassembly. Always replace piston
pin clips after one use. Replace distorted
circlips. When installing a circlip 1, make
sure that the sharp-edged corner 2 is positioned opposite to the thrust 3 it receives.
See the sectional view.
4 Shaft
GEN
INFO
CHECKING OF CONNECTION
1-5
EC1C0001
CHECKING OF CONNECTION
Dealing with stains, rust, moisture, etc. on the
connector.
1. Disconnect:
•Connector
2. Dry each terminal with an air blower.
3. Connect and disconnect the connector two
or three times.
4. Pull the lead to check that it will not come
off.
5. If the terminal comes off, bend up the pin 1
and reinsert the terminal into the connector.
6. Connect:
•Connector
NOTE:
The two connectors “click” together.
7. Check for continuity with a tester.
NOTE:
•If there in no continuity, clean the terminals.
• Be sure to perform the steps 1 to 7 listed
above when checking the wireharness.
• For a field remedy, use a contact revitalizer
available on the market.
•Use the tester on the connector as shown.
GEN
INFO
SPECIAL TOOLS
1-6
GEN
INFO
EC140001
SPECIAL TOOLS
The proper special tools are necessary for complete and accurate tune-up and assembly. Using the
correct special tool will help prevent damage caused by the use of improper tools or improvised
techniques. The shape and part number used for the special tool differ by country, so two types are
provided. Refer to the list provided to avoid errors when placing an order.
NOTE:
•For U.S.A. and Canada, use part number starting with “YM-” or “YU-”.
•For others, use part number starting with “90890-”.
Part number Tool name / How to use Illustration
YM-01189, 90890-01189 Flywheel puller YM-01189 90890-01189
This tool is used to remove the flywheel magneto.
YU-01235, 90890-01235 Rotor holding tool YU-01235 90890-01235
This tool is used when loosening or tightening the
flywheel magneto securing nut.
YU-03097, 90890-01252 Dial gauge and stand YU-03097 90890-01252
YU-01256 Stand YU-01256
These tools are used to set the ignition timing.
YU-01304, 90890-01304 Piston pin puller YU-01304 90890-01304
This tool is used to remove the piston pin.
YM-01312-A, 90890-01312 Fuel level gauge YM-01312-A 90890-01312
YM-01470, 90890-01470 Fuel level gauge adapter YM-01470 90890-01470
This gauge is used to measure the fuel level in the
float chamber.
YU-24460-1, 90890-01325 Radiator cap tester YU-24460-1 90890-01325
YU-33984, 90890-01352 Adapter YU-33984 90890-01352
These tools are used for checking the cooling system.
YM-33975, 90890-01403 Ring nut wrench YM-33975 90890-01403
This tool is used when tighten the steering ring nut
to specification.
SPECIAL TOOLS
1-7
GEN
INFO
Part number Tool name / How to use Illustration
YM-01425, 90890-01425 Damper rod holder YM-01425 90890-01425
Use this tool to remove and install the damper rod.
YM-01434, 90890-01434 Rod holder YM-01434 90890-01434
This tool is used to hold the fork spring.
90890-01435 Rod puller attachment YM-01437 90890-01435
YM-01437, 90890-01437 Rod puller 90890-01437
These tools are used to pull up the fork damper rod.
YM-01441, 90890-01441 Fork spring compressor YM-01441 90890-01441
This tool is used to compress the fork spring.
YM-01442, 90890-01442 Fork seal driver YM-01442 90890-01442
This tool is used when install the fork oil seal.
YM-01455, 90890-01455 Pivot shaft wrench YM-01455 90890-01455
YM-01476, 90890-01476 Pivot shaft wrench adapter YM-01476 90890-01476
These tools are used to loosen or tighten the pivot
adjust bolt.
YU-03112, 90890-03112 Yamaha pocket tester YU-03112 90890-03112
Use this tool to inspect the coil resistance, output
voltage and amperage.
YM-91042, 90890-04086 Clutch holding tool YM-91042 90890-04086
This tool is used to hold the clutch when removing or
installing the clutch boss securing nut.
YM-34487 Dynamic spark tester YM-34487 90890-06754
90890-06754 Ignition checker
This instrument is necessary for checking the ignition
system components.
ACC-11001-05-01 Quick gasket
®
ACC-11001-05-01 90890-85505
90890-85505 YAMAHABond No. 1215
This sealant (Bond) is used for crankcase mating
surface, etc.
SPECIAL TOOLS
1-8
GEN
INFO
Part number Tool name / How to use Illustration
ACC-11001-30-00 Quick gasket
®
ACC-11001-30-00 90890-05143
90890-05143 YAMAHABond No.4
This sealant (Bond) is used for crankcase mating
surface, etc.
CONTROL FUNCTIONS
1-9
EC150000
CONTROL FUNCTIONS
EC15W000
MAIN SWITCH
While the battery is connected, moving the
main switch 1 to “RUN” causes the tachometer, servomotor, fuel pump and solenoid valves
to be initially activated. To prevent the battery
from being discharge, do not move the main
switch to “RUN” except when the engine is
started or when electric parts are checked.
EC152000
CLUTCH LEVER
The clutch lever 1 is located on the left handlebar; it disengages or engages the clutch.
Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to
engage the clutch. The lever should be pulled
rapidly and released slowly for smooth starts.
EC153000
SHIFT PEDAL
The gear ratios of the constant-mesh 6 speed
transmission are ideally spaced. The gears
can be shifted by using the shift pedal 1 on
the left side of the engine.
EC155001
THROTTLE GRIP
The throttle grip 1 is located on the right handlebar; it accelerates or decelerates the
engine. For acceleration, turn the grip toward
you; for deceleration, turn it away from you.
EC156000
FRONT BRAKE LEVER
The front brake lever 1 is located on the right
handlebar. Pull it toward the handlebar to activate the front brake.
GEN
INFO
CONTROL FUNCTIONS
1-10
EC157000
REAR BRAKE PEDAL
The rear brake pedal 1 is located on the right
side of the machine. Press down on the brake
pedal to activate the rear brake.
EC158001
FUEL COCK
The fuel cock supplies fuel from the tank to
carburetor while filtering the fuel. The fuel cock
has the two positions:
OFF: With the lever in this position, fuel will
not flow. Always return the lever to this
position when the engine is not running.
ON: With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
EC15A020
STARTER LEVER (CHOKE)
When cold, the engine requires a richer air-fuel
mixture for starting. A separate starter circuit,
which is controlled by the starter lever 1, supplies this mixture. Push the starter lever out to
open the circuit for starting. When the engine
has warmed up pull it in to close the circuit.
EC15V010
TACHOMETER
A stepping motor type tachometer is provided
for greater accuracy of the tachometer 1. This
tachometer features the following:
Sweeping:
Moving the main switch to “RUN”, the
tachometer hand sweeps widely once over the
tachometer face and then returns to the zero
position, as initial operation. This is called
“sweeping”. When the engine is started during
sweeping, the tachometer indicates the correct
revolutions after sweeping is over.
Out-of-step indication:
If this tachometer is subjected to impact, etc, it
may allow its hand to point to the position b
stepping out of the position a where the hand
should be for correct indication. This is called
an “out-of-step” indication. Asimilar phenomenon may take place when the main switch is
moved to “OFF” during sweeping or at high
rpm (as in a plug chop) or while the machine is
transported, though it never happens in normal
riding.
GEN
INFO
CONTROL FUNCTIONS
1-11
GEN
INFO
NOTE:
•If an out-of-step indication takes place, moving the main switch to “OFF” once and then to
“RUN”, brings the tachometer back to a normal indication through its corrective action.
•There is no functional problem involved with
the out-of-step indication, which can be
brought back to a normal indication through
the corrective action of the tachometer.
EC15B010
WATER TEMPERATURE GAUGE
The water temperature gauge 1 displays different indications according to the change in
the water temperature.
NOTE:
Water temperature may be 70 ˚C (158 ˚F)
when engine is operated in good conditions.
Cooling water
Display Conditions
temp.
~19 ˚C
“LO” is display.
(~66 ˚F)
20~119 ˚C Temperature is
(68~247 ˚F) displayed.
120~140 ˚C Temperature
(248~284 ˚F) flash.
141 ˚C~ Message “HI”
(285 ˚F~) flash.
EC15F000
VALVE JOINT
This valve joint 1 prevents fuel from flowing
out and is installed to the fuel tank breather
hose.
CC
CAUTION:
In this installation, make sure the arrow
faces the fuel tank and also downward.
EC15X000
BATTERY
The battery 1 is provided as power supply for
the electric parts. Except when the machine is
run, disconnect the power supply coupler 2 of
the wireharness to prevent battery discharge.
CONTROL FUNCTIONS
1-12
EC15Y000
INDUCTION BOX INTAKE SYSTEM
The induction boxes 1 and induction guides
2 are provided for the purpose of applying
pressure inside the carburetor float chamber
and thereby improving the intake performance.
If the machine is run without them, the carburetor settings will become faulty.
NOTE:
Be sure to fix the induction guides with band 3
or hooks 4 so that they do not come off by
wind pressure while running.
EC15Z000
FUEL PUMP
The fuel pump 1, is provided in order to provide steady supply of fuel even when the pressure inside the carburetor float chamber
becomes higher than inside the fuel tank
because of the induction box intake system.
If the fuel level is not up to the specified level
in the float chamber, this pump is activated
(with an operation sound) and stops operating
when the specified level is reached.
CC
CAUTION:
Do not idle run the fuel pump with no fuel
flowing as when the fuel tank is empty or
when the fuel cock is “OFF”. It may damage
the fuel pump.
GEN
INFO
CONTROL FUNCTIONS
1-13
EC15a000
FUEL PUMP STOP SWITCH, FUEL PUMP
RELAY
The fuel pump stop switch 1 and fuel pump
relay 2 are provided so as to control the fuel
pump and prevent the carburetor overflowing
during a turnover.
If the machine is turned over, the fuel pump
stop switch is turned “ON” which allow electric
current to flow in the coil 3 inside the relay,
causing the relay switch 4 to turn “OFF” and
shutting of the electric current flow to the fuel
pump 5. Thus, the pump comes to a stop.
Fuel pump Fuel pump
Fuel pump 5
stop switch 1 relay switch 4
During run OFF ON ON
During
ON OFF OFF
turnover
q
NOTE:
•When the machine is picked up from turnover ,
the fuel pump is restored to an operation condition.
•Install the fuel pump stop switch so that
“UPPER” mark a faces upward.
EC15M011
CATCH TANK
Put the tip of the breather hose into the catch
tank 1 and frame 2. Take care not to allow
the fuel, oil and cooling water to spill on the
course.
3 Radiator breather hose
4 Fuel tank breather hose
5 Transmission oil breather hose
NOTE:
When putting in the transmission oil breather
hose, its tip having a cut a should be on the
frame side.
GEN
INFO
CONTROL FUNCTIONS
1-14
EC15Q001
DETACHABLE MAINSTAND
This mainstand 1 is used to support only the
machine when standing or transporting it.
NOTE:
The mainstand can be used to support the
machine two ways.
1. Hook the bracket of the mainstand onto the
swingarm hooks 2.
2. Stand shaft (with supplying parts):
Insert the stand shaft 3 through the hole of
the mainstand and rear wheel axle. Be sure
to install the clip 4 in the end of the stand
shaft.
W
•Never apply additional force to the mainstand.
•Remove this mainstand before starting
out.
EC15R001
DETACHABLE SIDESTAND
This sidestand 1 is used to support only the
machine when standing or transporting it.
W
• Never apply additional force to the sidestand.
•Remove this sidestand before starting out.
EC15T003
FIRE RETARDANT MATERIAL
For racing, be sure to fill the fuel tank 2 com-
pletely with fire retardant material (with supplying parts) 1.
EC15b000
COUPLER FOR SPEED SHIFT
If an after-marked speed shift is installed, the
coupler 1 should be used.
NOTE:
If the speed shift is not installed, be sure to fix
the coupler to the wireharness using a vinyl
tape, for protection against water entry as well
because if the coupler contacts the frame,
sparks will be shut off, causing the engine to
stop.
GEN
INFO
FUEL AND ENGINE MIXING OIL
1-15
EC160040
FUEL AND ENGINE MIXING OIL
Mix oil with the gas at the ratio specified below.
Always use fresh, name-brand gasoline, and
mix the oil and gas the day of the race. Do not
use premix that is more than a few hours old.
Recommended fuel:
Except for AUS:
Premium unleaded fuel with
a research octane number of
95 or higher.
For AUS:
Unleaded fuel only
5
NOTE:
Except for AUS:
1. If knocking or pinging occurs, use a differ-
ent brand of gasoline or higher octane
grade.
2. If unleaded gasoline is not available, then
leaded gasoline can be used.
CC
CAUTION:
Never mix two types of oil in the same
batch; clotting of the oil could result. If you
wish to change oil types, be sure to drain
the fuel tank and the carburetor float bowl
of old premix prior to filling with the new
type.
Fuel tank capacity:
23.0 L (5.06 Imp gal, 6.08 US gal)
0
Mixing oil
Recommended oil:
Castrol A747
Mixing ratio: 30 : 1
2
GEN
INFO
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