Yamaha WR250FR 2003 Service Manual

4 (1)

OWNER’S SERVICE MANUAL

WR250FR

LIT-11626-16-48

5UM-28199-10

WR250FR

OWNER’S SERVICE MANUAL

©2002 by Yamaha Motor Corporation, U.S.A. 1st Edition, November 2002

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-11626-16-48

EC020000

INTRODUCTION

Congratulations on your purchase of a Yamaha WR 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As improvements are made on this model, some data in this manual may become outdated.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.

WARNING

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 SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.

IMPORTANT NOTICE

THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding.

SAFETY INFORMATION

1.THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY. Do not attempt to operate this machine at maximum power until you are totally familiar with its characteristics.

2.THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY. Do not carry passengers on this machine.

3.ALWAYS WEAR PROTECTIVE APPAREL.

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 proerly 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.

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.THE ENGINE, EXHAUST PIPE, MUFFLER, AND OIL TANK WILL BE VERY HOT AFTER THE ENGINE HAS BEEN RUN.

Be careful not to touch them or to allow any clothing item to contact them during inspection or repair.

10.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.

EC070001

F.I.M. MACHINE WEIGHTS:

Weights of machines without fuel

The minimum weights for motocross

machines are:

 

for the class 125 cc

....................... minimum

 

88 kg (194 lb)

for the class 250 cc.......................

minimum

 

98 kg (216 lb)

for the class 500 cc.......................

minimum

 

102 kg (225 lb)

In modifying your machine (e.g., for weight reduction), take note of the above limits of weight.

EC080000

HOW TO USE

THIS MANUAL

EC081000

PARTICULARLY IMPORTANT INFORMATION

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

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.

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. A number 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.A job 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 unnecessary removal job.

6.For jobs requiring more information, the step-by-step format supplements 6 are given in addition to the exploded diagram and job instruction chart.

1

2

 

GEN

SPEC

 

INFO

 

 

 

3

4

 

INSP

ENG

 

ADJ

 

 

 

5

6

 

CHAS

ELEC

+

7

8

 

T U N

 

 

9

0

 

A

B

 

 

T

 

 

.

 

 

R

 

 

.

 

C

D

 

E

F

 

E

M

 

G

H

 

B

M

 

I

J

 

 

New

 

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

2Specifications

3Regular inspection and adjustments

4Engine

5Chassis

6Electrical

7Tuning

Illustrated symbols 8 to D are used to identify the specifications appearing in the text.

8 With engine mounted

9 Special tool

0 Filling fluid

ALubricant

BTightening

CSpecified value, Service limit

DResistance (Ω), Voltage (V), Electric current (A)

Illustrated symbols E to H in the exploded diagrams indicate grade of lubricant and location of lubrication point.

E Apply engine oil

F Apply molybdenum disulfide oil

G Apply lightweight lithium-soap base grease H Apply molybdenum disulfide grease

Illustrated symbols I to J in the exploded diagrams indicate where to apply a locking agent and where to install new parts.

IApply locking agent (LOCTITE®)

JUse new one

MEMO

EC090000

INDEX

GENERAL INFORMATION

GEN

1

 

INFO

SPECIFICATIONS

SPEC 2

REGULAR INSPECTION AND ADJUSTMENTS

INSP 3 ADJ

ENGINE

ENG 4

CHASSIS

CHAS 5

– +

ELECTRICAL

ELEC 6

TUNING

TUN 7

EC0A0000

CONTENTS

CHAPTER 1

GENERAL INFORMATION

DESCRIPTION ..........................................

1-1

MACHINE IDENTIFICATION ....................

1-2

IMPORTANT INFORMATION ...................

1-3

CHECKING OF CONNECTION ................

1-6

SPECIAL TOOLS ......................................

1-7

CONTROL FUNCTIONS .........................

1-10

FUEL .......................................................

1-14

STARTING AND BREAK-IN ...................

1-15

TORQUE-CHECK POINTS .....................

1-19

CLEANING AND STORAGE ..................

1-20

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS ..................

2-1

MAINTENANCE SPECIFICATIONS .........

2-4

GENERAL TORQUE

 

SPECIFICATIONS ..................................

2-19

DEFINITION OF UNITS ..........................

2-19

CABLE ROUTING DIAGRAM .................

2-20

CHAPTER 3

REGULAR INSPECTION AND

ADJUSTMENTS

MAINTENANCE INTERVALS ...................

3-1

PRE-OPERATION INSPECTION AND

 

MAINTENANCE ........................................

3-4

ENGINE .....................................................

3-5

CHASSIS .................................................

3-25

ELECTRICAL ..........................................

3-47

CHAPTER 4

ENGINE

SEAT, FUEL TANK AND

 

SIDE COVERS ..........................................

4-1

EXHAUST PIPE AND SILENCER ............

4-3

RADIATOR ................................................

4-5

CARBURETOR .........................................

4-8

CAMSHAFTS ..........................................

4-22

CYLINDER HEAD ...................................

4-31

VALVES AND VALVE SPRINGS ...........

4-34

CYLINDER AND PISTON .......................

4-43

CLUTCH ..................................................

4-50

OIL FILTER ELEMENT, WATER PUMP

 

AND RIGHT CRANKCASE COVER ......

4-57

BALANCER ............................................

4-64

OIL PUMP ...............................................

4-67

KICK SHAFT AND SHIFT SHAFT ..........

4-72

AC MAGNETO AND

 

STARTER CLUTCH ................................

4-79

ENGINE REMOVAL ................................

4-86

CRANKCASE AND CRANKSHAFT .......

4-92

TRANSMISSION, SHIFT CAM AND

 

SHIFT FORK .........................................

4-101

CHAPTER 5

CHASSIS

FRONT WHEEL AND REAR WHEEL

...... 5-1

FRONT BRAKE AND REAR BRAKE .....

5-11

FRONT FORK .........................................

5-27

HANDLEBAR ..........................................

5-40

STEERING ..............................................

5-46

SWINGARM ............................................

5-53

REAR SHOCK ABSORBER ...................

5-61

CHAPTER 6

ELECTRICAL

ELECTRICAL COMPONENTS AND

 

WIRING DIAGRAM ...................................

6-1

MAP-CONTROLLED CDI UNIT ................

6-2

IGNITION SYSTEM ...................................

6-3

ELECTRIC STARTING SYSTEM ..............

6-8

CHARGING SYSTEM .............................

6-17

THROTTLE POSITION SENSOR

 

SYSTEM ..................................................

6-19

LIGHTING SYSTEM ................................

6-24

 

CHAPTER 7

 

TUNING

ENGINE .....................................................

7-1

CHASSIS .................................................

7-11

GEN

DESCRIPTION INFO

EC100000

GENERAL INFORMATION

EC110000

DESCRIPTION

1Clutch lever

2Hot starter lever

3Engine stop switch

4Trip meter

5Main switch

6Light switch

7Start switch

8Front brake lever

9Throttle grip

0 Radiator cap

AFuel tank cap

BTaillight

CKickstarter crank

DFuel tank

EHeadlight

FRadiator

GCoolant drain bolt

HRear brake pedal

IValve joint

JFuel cock

KCold starter knob

LAir cleaner

MDrive chain

NShift pedal

OOil dipstick

PFront fork

NOTE:

The machine you have purchased may differ slightly from those shown in the following.

Designs and specifications are subject to change without notice.

1 2

3

456 7 8

9

A 0

IJKL B C D E F

1

H G

PO N M

1 - 1

Yamaha WR250FR 2003 Service Manual

MACHINE IDENTIFICATION

EC120001

GEN INFO

MACHINE IDENTIFICATION

There are two significant reasons for knowing the serial number of your machine:

1.When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own.

2.If your machine is stolen, the authorities will need the number to search for and identify your machine.

EC121001

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is

stamped on the right of the steering head pipe.

1

EC123001

ENGINE SERIAL NUMBER

The engine serial number 1 is stamped into 1 the elevated part of the right-side of the

engine.

1

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.

1 - 2

GEN

IMPORTANT INFORMATION INFO

EC130000

IMPORTANT INFORMATION

EC131010

PREPARATION FOR REMOVAL AND

DISASSEMBLY

1.Remove all dirt, mud, dust, and foreign material before removal and disassembly. When washing the machine with high pressured water, cover the parts follows.

Silencer exhaust port

Side cover air intake port

Water pump housing hole at the bottom

Drain hole on the cylinder head (right side)

All electrical components

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.

1 - 3

IMPORTANT INFORMATION

EC132000

GEN INFO

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 lightweight lithium base grease to the seal lip(s). Oil the bearings liberally when installing.

CAUTION:

Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.

1 - 4

IMPORTANT INFORMATION

EC136000

CIRCLIPS

GEN INFO

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

1 - 5

CHECKING OF CONNECTION

EC1C0001

GEN INFO

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 wire harness.

For a field remedy, use a contact revitalizer available on the market.

Use the tester on the connector as shown.

1 - 6

SPECIAL TOOLS

SPECIAL TOOLS

GEN INFO

The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order.

NOTE:

For U.S.A. and Canada, use part number starting with “YM-”, “YU-” or “ACC-”.

For others, use part number starting with “90890-”.

Part number

Tool name/How to use

Illustration

 

 

 

 

YU-1135-A, 90890-01135

Crankcase separating tool

 

 

 

These tool is used to remove the crankshaft from

 

 

 

either case.

 

 

 

 

 

 

YU-3097, 90890-01252

Dial gauge and stand

 

 

YU-1256

Stand

 

 

 

These tools are used to check each part for runout or

 

 

 

bent.

 

 

 

 

 

 

 

Crankshaft installing tool

 

 

YU-90050, 90890-01274

Crankshaft installing pot

 

 

YU-90050, 90890-01275

Crankshaft installing bolt

 

 

YM-91044, 90890-04081

Spacer (crankshaft installer)

 

 

YU-90063, 90890-01278

Adapter (M12)

 

 

 

These tools are used to install the crankshaft.

 

 

 

 

 

 

YU-1304, 90890-01304

Piston pin puller set

 

 

 

This tool is used to remove the piston pin.

 

 

 

 

 

 

YU-24460-01, 90890-01325

Radiator cap tester

 

 

YU-33984, 90890-01352

Radiator cap tester adapter

 

 

 

These tools are used for checking the cooling sys-

 

 

 

tem.

 

 

 

 

 

 

YU-33975, 90890-01403

Steering nut wrench

 

 

 

This tool is used when tighten the steering ring nut to

 

 

 

specification.

 

 

 

 

 

 

YM-1423, 90890-01423

Damper rod holder

 

 

 

Use this tool to remove and install the damper rod.

 

 

 

 

 

 

 

1 - 7

 

 

 

 

 

 

 

 

 

 

 

SPECIAL TOOLS

 

GEN

 

 

 

 

INFO

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Part number

Tool name/How to use

Illustration

 

 

 

 

 

 

 

 

 

YM-01442, 90890-01442

Fork seal driver

 

 

 

 

 

 

 

This tool is used when install the fork oil seal.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YU-3112-C, 90890-03112

Pocket tester

 

 

 

 

 

 

 

Use this tool to inspect the coil resistance, output

 

 

 

 

 

 

 

voltage and amperage.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YU-8036-B

Inductive tachometer

 

 

 

 

 

 

90890-03113

Engine tachometer

 

 

 

 

 

 

 

This tool is needed for observing engine rpm.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YM-33277-A, 90890-03141

Timing light

 

 

 

 

 

 

 

This tool is necessary for checking ignition timing.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YM-4019, 90890-04019

Valve spring compressor

 

 

 

 

 

 

 

This tool is needed to remove and install the valve

 

 

 

 

 

 

 

assemblies.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YM-91042, 90890-04086

Clutch holding tool

 

 

 

 

 

 

 

This tool is used to hold the clutch when removing or

 

 

 

 

 

 

 

installing the clutch boss securing nut.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YM-4111, 90890-04111

Valve guide remover

 

 

 

 

 

 

YM-4116, 90890-04116

Intake 4.0 mm (0.16 in)

 

 

 

 

 

 

 

Exhaust 4.5 mm (0.18 in)

 

 

 

 

 

 

 

This tool is needed to remove and install the valve

 

 

 

 

 

 

 

guide.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YM-4112, 90890-04112

Valve guide installer

 

 

 

 

 

 

YM-4117, 90890-04117

Intake 4.0 mm (0.16 in)

 

 

 

 

 

 

 

Exhaust 4.5 mm (0.18 in)

 

 

 

 

 

 

 

This tool is needed to install the valve guide.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YM-4113, 90890-04113

Valve guide reamer

 

 

 

 

 

 

YM-4118, 90890-04118

Intake 4.0 mm (0.16 in)

 

 

 

 

 

 

 

Exhaust 4.5 mm (0.18 in)

 

 

 

 

 

 

 

This tool is needed to rebore the new valve guide.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1 - 8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SPECIAL TOOLS

 

GEN

 

 

 

 

INFO

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Part number

Tool name/How to use

Illustration

 

 

 

 

 

 

 

 

 

YM-04141, 90890-04141

Rotor puller

 

 

 

 

 

 

 

This tool is used to remove the flywheel magneto.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YM-34487

Dynamic spark tester

 

 

 

 

 

 

90890-06754

Ignition checker

 

 

 

 

 

 

 

This instrument is necessary for checking the ignition

 

 

 

 

 

 

 

system components.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ACC-QUICK-GS-KT

Quick gasket

 

 

 

 

 

 

90890-85505

YAMAHA Bond No. 1215

 

 

 

 

 

 

 

This sealant (Bond) is used for crankcase mating sur-

 

 

 

 

 

 

 

face, etc.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1 - 9

CONTROL FUNCTIONS

EC150000

GEN INFO

CONTROL FUNCTIONS

MAIN SWITCH

Functions of the respective switch positions are as follows:

ON:

The engine can be started only at this position. OFF:

All electrical circuits are switched off.

Main switch indicator light

The main switch 1 is equipped with an indicator light 2 to avoid forgetting to turn it off. This light functions as follows.

It lights up with the main switch “ON”.

It goes out when the engine increases its speed after being started.

It lights up again when the engine is stopped.

NOTE:

If the indicator light will not light up with the main switch “ON”, it shows a lack of the battery voltage. Recharge the battery. If the engine is kick started, turn off the light switch.

ENGINE STOP SWITCH

The engine stop switch 1 is located on the left handlebar. Continue pushing the engine stop switch till the engine comes to a stop.

START SWITCH

The start switch 1 is located on the right handlebar. Push this switch to crank the engine with the starter.

1 - 10

CONTROL FUNCTIONS

EC152000

CLUTCH LEVER

GEN INFO

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 5 speed transmission are ideally spaced. The gears can be shifted by using the shift pedal 1 on the left side of the engine.

1

KICKSTARTER CRANK

Rotate the kickstarter crank 1 away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine. This model has a primary kickstarter crank so the engine can be started in any gear if the clutch is disengaged. In normal practices, however, shift to neutral before starting.

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.

1 - 11

GEN

CONTROL FUNCTIONS INFO

EC157000

REAR BRAKE PEDAL

The rear brake pedal 1 is located on the right side of the machine. Press down on the brake pedal to activate the rear brake.

FUEL COCK

The fuel cock supplies fuel from the tank to carburetor and also filters the fuel. The fuel cock has three 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.

RES:With the lever in this position fuel flows to the carburetor from the reserve section of the fuel tank after the main supply of the fuel has been depleted. Normal riding is possible with the lever is in this position, but it is recommended to add fuel as soon as possible.

COLD STARTER KNOB

When cold, the engine requires a richer air-fuel mixture for starting. A separate starter circuit, which is controlled by the cold starter knob 1, supplies this mixture. Pull the cold starter knob out to open the circuit for starting. When the engine has warmed up, push it in to close the circuit.

HOT STARTER LEVER

The hot starter lever 1 is used when starting a warm engine.

Use the hot starter lever when starting the engine again immediately after it was stopped (the engine is still warm). Pulling the hot starter lever injects secondary air to thin the air-fuel mixture temporarily, allowing the engine to be started more easily.

1 - 12

GEN

CONTROL FUNCTIONS INFO

LIGHT SWITCH

The light switch 1 is located on the handlebar.

1

1

EC15F000

VALVE JOINT

This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose.

CAUTION:

In this installation, make sure the arrow faces the fuel tank and also downward.

SPARK PLUG WRENCH

This spark plug wrench 1 is used to remove and install the spark plug.

NIPPLE WRENCH

This nipple wrench 1 is used to tighten the spoke.

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FUEL

FUEL

GEN INFO

Always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race.

Recommended fuel: Except for ZA:

Premium unleaded gasoline only with a research octane number of 95 or higher.

For ZA:

Premium gasoline

CAUTION:

Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts such as valves, piston rings, and exhaust system, etc.

NOTE:

If knocking or pinging occurs, use a different brand of gasoline or higher octane grade.

WARNING

For refueling, be sure to stop the engine and use enough care not to spill any fuel. Also be sure to avoid refueling close to a fire.

Refuel after the engine, exhaust pipe, etc. have cooled off.

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