Yamaha WR250FR 2002 User Manual [ru]

LIT-11626-16-48

WR250FR

5UM-28199-10

OWNER’S SERVICE MANUAL

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.

OTE:

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.

OTE:

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

WARNING

HOW TO USE

THIS MANUAL

EC081000

PARTICULARLY IMPORTANT
INFORMATION

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

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 “Tun-

ing”.

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 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.

12

GEN

INFO

34

SPEC

INSP

ADJ

56

CHAS

ENG

–+

ELEC

ILLUSTRATED SYMBOLS
(Refer to the illustration)

Illustrated symbols 1 to 7 are designed as
thumb tabs to indicate the chapter’s number
and content.

General information

1

Specifications

2

Regular inspection and adjustments

3

Engine

4

Chassis

5

Electrical

6

Tuning

7

78

TUN

90

AB

T

.

R

.

CD

EF

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

With engine mounted

8

Special tool

9

Filling fluid

0

Lubricant

A

Tightening

B

Specified value, Service limit

C

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

D

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

E

GH

B

IJ

M

M

New

Apply engine oil

E

Apply molybdenum disulfide oil

F

Apply lightweight lithium-soap base grease

G

Apply molybdenum disulfide grease

H

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

®

Apply locking agent (LOCTITE

I

Use new one

J

)

MEMO

EC090000

INDEX

GENERAL INFORMATION

SPECIFICATIONS

REGULAR INSPECTION AND ADJUSTMENTS

ENGINE

CHASSIS

GEN

INFO

SPEC

INSP

ADJ

ENG

CHAS

1

2

3

4

5

ELECTRICAL

TUNING

– +

ELEC

6

TUN

7

EC0A0000

CONTENTS

CHAPTER 1

GENERAL INFORMATION

DESCRIPTION
MACHINE IDENTIFICATION
IMPORTANT INFORMATION
CHECKING OF CONNECTION
SPECIAL TOOLS
CONTROL FUNCTIONS
FUEL
STARTING AND BREAK-IN
TORQUE-CHECK POINTS
CLEANING AND STORAGE

....................................................... 1-14

.......................................... 1-1

.................... 1-2

................... 1-3

................ 1-6

...................................... 1-7

......................... 1-10

................... 1-15

..................... 1-19

.................. 1-20

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
GENERAL TORQUE
SPECIFICATIONS
DEFINITION OF UNITS
CABLE ROUTING DIAGRAM

.................................. 2-19

.......................... 2-19

.................. 2-1

................. 2-20

......... 2-4

CHAPTER 3

REGULAR INSPECTION AND

ADJUSTMENTS

MAINTENANCE INTERVALS
PRE-OPERATION INSPECTION AND
MAINTENANCE
ENGINE
CHASSIS
ELECTRICAL

..................................................... 3-5

................................................. 3-25

........................................ 3-4

.......................................... 3-47

................... 3-1

CHAPTER 4

ENGINE

SEAT, FUEL TANK AND
SIDE COVERS
EXHAUST PIPE AND SILENCER
RADIATOR
CARBURETOR
CAMSHAFTS
CYLINDER HEAD
VALVES AND VALVE SPRINGS
CYLINDER AND PISTON
CLUTCH
OIL FILTER ELEMENT, WATER PUMP
AND RIGHT CRANKCASE COVER
BALANCER
OIL PUMP
KICK SHAFT AND SHIFT SHAFT
AC MAGNETO AND
STARTER CLUTCH
ENGINE REMOVAL
CRANKCASE AND CRANKSHAFT
TRANSMISSION, SHIFT CAM AND
SHIFT FORK

.................................................. 4-50

.......................................... 4-1

............ 4-3

................................................ 4-5

......................................... 4-8

.......................................... 4-22

................................... 4-31

........... 4-34

....................... 4-43

...... 4-57

............................................ 4-64

............................................... 4-67

.......... 4-72

................................ 4-79

................................ 4-86

....... 4-92

......................................... 4-101

CHAPTER 5

CHASSIS

FRONT WHEEL AND REAR WHEEL
FRONT BRAKE AND REAR BRAKE
FRONT FORK
HANDLEBAR
STEERING
SWINGARM
REAR SHOCK ABSORBER

......................................... 5-27

.......................................... 5-40

.............................................. 5-46

............................................ 5-53

................... 5-61

...... 5-1

..... 5-11

CHAPTER 6

ELECTRICAL

ELECTRICAL COMPONENTS AND
WIRING DIAGRAM
MAP-CONTROLLED CDI UNIT
IGNITION SYSTEM
ELECTRIC STARTING SYSTEM
CHARGING SYSTEM
THROTTLE POSITION SENSOR
SYSTEM
LIGHTING SYSTEM

.................................................. 6-19

................................... 6-1

................ 6-2

................................... 6-3

.............. 6-8

............................. 6-17

................................ 6-24

CHAPTER 7

TUNING

ENGINE
CHASSIS

..................................................... 7-1

................................................. 7-11

EC100000

GENERAL INFORMATION

EC110000

DESCRIPTION

1 Clutch lever
2 Hot starter lever
3 Engine stop switch
4 Trip meter
5 Main switch
6 Light switch
7 Start switch
8 Front brake lever
9 Throttle grip
0 Radiator cap
A Fuel tank cap
B Taillight
C Kickstarter crank
D Fuel tank
E Headlight
F Radiator
G Coolant drain bolt
H Rear brake pedal
I Valve joint
J Fuel cock
K Cold starter knob
L Air cleaner
M Drive chain
N Shift pedal
O Oil dipstick
P Front fork

GEN

DESCRIPTION

OTE:

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

• Designs and specifications are subject to
change without notice.

3

2

1

A

INFO

4

5

6

0

7

8

9

1

B

CD

GH

E

F

P

O

IJ

K

L

MN

1 - 1

1

MACHINE IDENTIFICATION

EC120001

MACHINE IDENTIFICATION

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

1. When ordering parts, you can give the

number to your Yamaha dealer for positive
identification of the model you own.

2. If your machine is stolen, the authorities will

need the number to search for and identify
your machine.

EC121001

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is
stamped on the right of the steering head pipe.

GEN

INFO

1

1

EC123001

ENGINE SERIAL NUMBER

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

1 - 2

IMPORTANT INFORMATION

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

GEN

INFO

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

ALL REPLACEMENT PARTS

1. We recommend to use Yamaha genuine

parts for all replacements. Use oil and/or
grease recommended by Yamaha for
assembly and adjustment.

EC133000

GASKETS, OIL SEALS AND O-RINGS

1. All gaskets, oil seals, and O-rings should

be replaced when an engine is overhauled.
All gasket surfaces, oil seal lips, and O­rings must be cleaned.

2. Properly oil all mating parts and bearings

during reassembly. Apply grease to the oil
seal lips.

GEN

INFO

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

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.

Shaft

4

GEN

INFO

1 - 5

CHECKING OF CONNECTION

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.

GEN

INFO

6. Connect:

• Connector

OTE:

The two connectors “click” together.

7. Check for continuity with a tester.

OTE:

• 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

GEN

SPECIAL TOOLS

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.

OTE:

• 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
YU-1256

Dial gauge and stand
Stand

INFO

These tools are used to check each part for runout or
bent.

Crankshaft installing tool
YU-90050, 90890-01274
YU-90050, 90890-01275
YM-91044, 90890-04081
YU-90063, 90890-01278

YU-1304, 90890-01304 Piston pin puller set

YU-24460-01, 90890-01325
YU-33984, 90890-01352

YU-33975, 90890-01403 Steering nut wrench

YM-1423, 90890-01423 Damper rod holder

Crankshaft installing pot

Crankshaft installing bolt

Spacer (crankshaft installer)

Adapter (M12)

These tools are used to install the crankshaft.

This tool is used to remove the piston pin.

Radiator cap tester

Radiator cap tester adapter

These tools are used for checking the cooling sys-

tem.

This tool is used when tighten the steering ring nut to

specification.

Use this tool to remove and install the damper rod.

1 - 7

SPECIAL TOOLS

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

90890-03113

YM-33277-A, 90890-03141 Timing light

Inductive tachometer

Engine tachometer

This tool is needed for observing engine rpm.

GEN

INFO

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
YM-4116, 90890-04116

YM-4112, 90890-04112
YM-4117, 90890-04117

YM-4113, 90890-04113
YM-4118, 90890-04118

Valve guide remover

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.

Valve guide installer

Intake 4.0 mm (0.16 in)
Exhaust 4.5 mm (0.18 in)

This tool is needed to install the valve guide.

Valve guide reamer

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

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

90890-06754

ACC-QUICK-GS-KT

90890-85505

Dynamic spark tester

Ignition checker

This instrument is necessary for checking the ignition

system components.

Quick gasket

YAMAHA Bond No. 1215

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

face, etc.



GEN

INFO

1 - 9

CONTROL FUNCTIONS

EC150000

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.

GEN

INFO

OTE:

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

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.

GEN

INFO

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

CONTROL FUNCTIONS

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.

GEN

INFO

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

CONTROL FUNCTIONS

LIGHT SWITCH

The light switch 1 is located on the handlebar.

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.

GEN

INFO

1

SPARK PLUG WRENCH

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

1

NIPPLE WRENCH

This nipple wrench 1 is used to tighten the
spoke.

1 - 13

GEN

FUEL

FUEL

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.

INFO

OTE:

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.

1 - 14

STARTING AND BREAK-IN

STARTING AND BREAK-IN

WARNING

Never start or run the engine in a closed
area. The exhaust fumes are poisonous;
they can cause loss of consciousness and
death in a very short time. Always operate
the machine in a well-ventilated area.

CAUTION:

• The carburetor on this machine has a
built-in accelerator pump. Therefore,
when starting the engine, do not operate
the throttle or the spark plug will foul.

• Unlike a two-stroke engine, this engine
cannot be kick started when the throttle is
open because the kickstarter may kick
back. Also, if the throttle is open the air/
fuel mixture may be too lean for the
engine to start.

• Before starting the machine, perform the
checks in the pre-operation check list.

GEN

INFO

AIR FILTER MAINTENANCE

According to “AIR FILTER CLEANING” section
in the CHAPTER 3, apply the foam-air-filter oil
or its equivalent to the element. (Excess oil in
the element may adversely affect engine start­ing.)

STARTING A COLD ENGINE

OTE:

This model is equipped with an ignition circuit
cut-off system. The engine can be started
under the following conditions.

• When the transmission is in neutral.

• When the clutch is disengaged with the

transmission in any position. However, it is
recommended to shift into neutral before
starting the engine.

1. Inspect the coolant level.

2. Turn the fuel cock to “ON”.

3. Push on the main switch to “ON”.

4. Shift the transmission into neutral.

5. Fully open the cold starter knob 1.

6. Start the engine by pushing the start switch

or by kicking the kickstarter crank.

1 - 15

STARTING AND BREAK-IN

OTE:

If the engine fails to start by pushing the start
switch, release the switch, wait a few seconds,
and then try again. Each starting attempt
should be as short as possible to preserve the
battery. Do not crank the engine more than
10 seconds on any one attempt. If the engine
does not start with the starter motor, try using
the kickstarter crank.

WARNING

• If the starter motor will not turn when
pushing the start switch, stop pushing it
immediately and kick start the engine in
order to avoid the load on the motor.

• Do not open the throttle while kicking the
kickstarter crank. Otherwise, the kick­starter crank may kick back.

GEN

INFO

7. Return the cold starter knob to its original

position and run the engine at 3,000 ~
5,000 r/min for 1 or 2 minutes.

OTE:

Since this model is equipped with an accelera­tor pump, if the engine is raced (the throttle
opened and closed), the air/fuel mixture will be
too rich and the engine may stall. Also unlike a
two-stroke engine, this model can idle.

CAUTION:

Do not warm up the engine for extended
periods of time.

1 - 16

STARTING AND BREAK-IN

STARTING A WARM ENGINE

Do not operate the cold starter knob and throt­tle. Pull the hot starter lever 1 and start the
engine by pushing the start switch or by kick­ing the kickstarter crank forcefully with a firm
stroke.
As soon as the engine starts, Release the hot
starter lever to close the air passage.

Restarting an engine after a fall

Pull the hot starter lever and start the engine.
As soon as the engine starts, Release the hot
starter lever to close the air passage.

The engine fails to start

Pull the hot starter lever all the way out and
while holding the lever, kick the kickstarter
crank 10 to 20 times to clear the engine.
Then, restart the engine.
Refer to “Restarting an engine after a fall”.

Air temperature = less than
5 °C (41 °F)

Air temperature = more
than 5 °C (41 °F)

Air temperature (normal tem­perature) = between 5 °C
(41 °F) and 25 °C (77 °F)

Air temperature = more

Starting a cold engine

than 25 °C (77 °F)

Starting an engine after a long
period of time

Restarting a warm engine None OFF ON

Restarting an engine after a fall None OFF ON

* Operate the throttle grip before kick starting.

GEN

INFO

Throttle

grip

operation*

Open 3

or 4 times

None ON OFF

None ON/OFF OFF

None OFF OFF

None ON OFF

Cold

starter

knob

ON OFF

Hot

starter

lever

CAUTION:

Observe the following break-in procedures
during initial operation to ensure optimum
performance and avoid engine damage.

1 - 17

STARTING AND BREAK-IN

BREAK-IN PROCEDURES

1. Before starting the engine, fill the fuel tank

with the fuel.

2. Perform the pre-operation checks on the

machine.

3. Start and warm up the engine. Check the

idle speed, and check the operation of the
controls and the engine stop switch. Then,
restart the engine and check its operation
within no more than 5 minutes after it is
restarted.

4. Operate the machine in the lower gears at

moderate throttle openings for five to eight
minutes.

5. Check how the engine runs when the

machine is ridden with the throttle 1/4 to 1/2
open (low to medium speed) for about one
hour.

6. Restart the engine and check the operation

of the machine throughout its entire operat­ing range. Restart the machine and oper­ate it for about 10 to 15 more minutes. The
machine will now be ready to race.

GEN

INFO

CAUTION:

• After the break-in or before each race,
you must check the entire machine for
loose fittings and fasteners as per
“TORQUE-CHECK POINTS”.
Tighten all such fasteners as required.

• When any of the following parts have
been replaced, they must be broken in.
CYLINDER AND CRANKSHAFT:
About one hour of break-in operation is
necessary.
PISTON, RING, VALVES, CAMSHAFTS
AND GEARS:
These parts require about 30 minutes of
break-in operation at half-throttle or less.
Observe the condition of the engine care­fully during operation.

1 - 18

TORQUE-CHECK POINTS

TORQUE-CHECK POINTS

GEN

INFO

Frame construction

Combined seat and fuel tank

Exhaust system

Engine mounting

Steering Steering stem to

handlebar

Suspension Front Steering stem to front

fork

Rear For link type

Rear Installation of rear

shock absorber

Frame to rear frame
Fuel tank to frame

Silencer to rear frame

Frame to engine
Engine bracket to engine
Engine bracket to frame

Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar

Front fork to upper bracket
Front fork to lower bracket

Assembly of links
Link to frame
Link to rear shock absorber
Link to swingarm

Rear shock absorber to frame

Rear Installation of swing-

arm

Wheel Installation of wheel Front

Rear

Brake Front

Rear

Fuel system

Lubrication system

Tightening of pivot shaft

Tightening of wheel axle
Tightening of axle holder
Tightening of wheel axle
Wheel to rear wheel sprocket

Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to handlebar
Tightening of bleed screw

Brake pedal to frame
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw

Fuel tank to fuel cock

Tightening of oil hose clamp

OTE:

Concerning the tightening torque, refer to
“MAINTENANCE SPECIFICATIONS” section
in the CHAPTER 2.

1 - 19

CLEANING AND STORAGE

EC1B0000

CLEANING AND STORAGE

EC1B1000

CLEANING

Frequent cleaning of your machine will
enhance its appearance, maintain good overall
performance, and extend the life of many com­ponents.

1. Before washing the machine, block off the

end of the exhaust pipe to prevent water
from entering. A plastic bag secured with a
rubber band may be used for this purpose.

2. If the engine is excessively greasy, apply

some degreaser to it with a paint brush. Do
not apply degreaser to the chain, sprock­ets, or wheel axles.

3. Rinse the dirt and degreaser off with a gar-

den hose; use only enough pressure to do
the job.

GEN

INFO

CAUTION:

Excessive hose pressure may cause water
seepage and contamination of wheel bear­ings, front forks, brakes and transmission
seals. Many expensive repair bills have
resulted from improper high pressure
detergent applications such as those avail­able in coin-operated car washers.

4. After the majority of the dirt has been

hosed off, wash all surfaces with warm
water and a mild detergent. Use an old
toothbrush to clean hard-to-reach places.

5. Rinse the machine off immediately with

clean water, and dry all surfaces with a soft
towel or cloth.

6. Immediately after washing, remove excess

water from the chain with a paper towel
and lubricate the chain to prevent rust.

7. Clean the seat with a vinyl upholstery

cleaner to keep the cover pliable and
glossy.

8. Automotive wax may be applied to all

painted or chromed surfaces. Avoid combi­nation cleaner-waxes, as they may contain
abrasives.

9. After completing the above, start the

engine and allow it to idle for several min­utes.

1 - 20

CLEANING AND STORAGE

EC1B2001

STORAGE

If your machine is to be stored for 60 days or
more, some preventive measures must be
taken to avoid deterioration. After cleaning the
machine thoroughly, prepare it for storage as
follows:

1. Drain the fuel tank, fuel lines, and the car-

buretor float bowl.

2. Remove the spark plug, pour a tablespoon

of SAE 10W-30 motor oil in the spark plug
hole, and reinstall the plug. With the engine
stop switch pushed in, kick the engine over
several times to coat the cylinder walls with
oil.

3. Remove the drive chain, clean it thoroughly

with solvent, and lubricate it. Reinstall the
chain or store it in a plastic bag tied to the
frame.

4. Lubricate all control cables.

5. Block the frame up to raise the wheels off

the ground.

6. Tie a plastic bag over the exhaust pipe out-

let to prevent moisture from entering.

7. If the machine is to be stored in a humid or

salt-air environment, coat all exposed
metal surfaces with a film of light oil. Do not
apply oil to rubber parts or the seat cover.

GEN

INFO

OTE:

Make any necessary repairs before the
machine is stored.

1 - 21

2

GENERAL SPECIFICATIONS

EC200000

SPECIFICATIONS

EC211000

GENERAL SPECIFICATIONS

Model name: WR250FR (USA)

WR250F (EUROPE)
WR250F(R) (CDN, AUS, NZ, ZA)

Model code number: 5UM1 (USA)

5UM2 (EUROPE)
5UM4 (CDN, AUS, NZ, ZA)

Dimensions:

Overall length 2,165 mm (85.2 in)
Overall width 827 mm (32.6 in)
Overall height 1,303 mm (51.3 in)
Seat height 998 mm (39.3 in)
Wheelbase 1,475 mm (58.1 in)
Minimum ground clearance 382 mm (15.0 in)

Basic weight:

With oil and full fuel tank 115.1 kg (253.7 lb)

Engine:

Engine type Liquid cooled 4-stroke, DOHC
Cylinder arrangement Single cylinder, forward inclined
Displacement 249 cm
Bore × stroke 77.0 × 53.6 mm (3.03 × 2.11 in)
Compression ratio 12.5 : 1

Starting system Kick and electric starter
Lubrication system: Dry sump
Oil type or grade:

Engine oil (For USA and CDN)

At 5 °C (40 °F) or higher È
Yamalube 4 (20W-40) or SAE 20W-40 type
SG motor oil
(Non-Friction modified)
At 15 °C (60 °F) or lower É
Yamalube 4 (10W-30) or SAE 10W-30 type
SG motor oil
(Non-Friction modified)
and/or
Yamalube 4-R (15W-50)

-20-4-101403010502068308640 50

˚CTemp.

(Non-Friction modified)

(Except for USA and CDN)

10W-30

10W-40

15W-40

20W-40

20W-50

API “SG” or higher grade

3

(8.76 Imp oz, 8.42 US oz)

SPEC

104

122

˚F

2 - 1

GENERAL SPECIFICATIONS

Oil capacity:

Engine oil

Periodic oil change 1.2 L (1.06 Imp qt, 1.27 US qt)
With oil filter replacement 1.3 L (1.14 Imp qt, 1.37 US qt)

Total amount 1.4 L (1.23 Imp qt, 1.48 US qt)
Coolant capacity (including all routes): 1.3 L (1.14 Imp qt, 1.37 US qt)
Air filter: Wet type element
Fuel:

Type Premium unleaded gasoline only with a

research octane number of 95 or higher.
(Except for ZA)

Premium gasoline (For ZA)
Tank capacity 10 L (2.2 Imp gal, 2.64 US gal)
Reserve 1.2 L (0.26 Imp gal, 0.32 US gal)

Carburetor:

Type FCR-MX37
Manufacturer KEIHIN

Spark plug:

Type/manufacturer CR8E/NGK (resistance type)
Gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)

Clutch type: Wet, multiple-disc
Transmission:

Primary reduction system Gear
Primary reduction ratio 57/17 (3.353)
Secondary reduction system Chain drive
Secondary reduction ratio 52/13 (4.000)
Transmission type Constant mesh, 5-speed
Operation Left foot operation
Gear ratio: 1st 31/13 (2.385)

2nd 28/16 (1.750)
3rd 28/21 (1.333)
4th 25/24 (1.042)
5th 22/27 (0.815)

Chassis:

Frame type Semi double cradle
Caster angle 27.1°
Trail 117.4 mm (4.62 in)

Tire:

Type With tube
Size (front) 80/100-21 51M (For USA, CDN and ZA)

90/90-21 54R (For EUROPE, AUS and NZ)
Size (rear) 100/100-18 59M (For USA, CDN and ZA)

130/90-18 69R (For EUROPE, AUS and NZ)
Tire pressure (front and rear) 100 kPa (1.0 kgf/cm

2

, 15 psi)

SPEC

2

2 - 2

GENERAL SPECIFICATIONS

Brake:

Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation

Suspension:

Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)

Shock absorber:

Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper

Wheel travel:

Front wheel travel 300 mm (11.8 in)
Rear wheel travel 315 mm (12.4 in)

Electrical:

Ignition system CDI
Generator system AC magneto
Battery type YTX5L-BS
Battery voltage/capacity 12 V/4 AH
Specific gravity 1.320

Headlight type: Quartz bulb (halogen)
Bulb wattage × quantity:

Headlight 12 V 60/55 W × 1
Taillight 12 V 21/5 W × 1

SPEC

2 - 3

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Item Standard Limit

Cylinder head:

Warp limit ---- 0.05 mm

(0.002 in)

Cylinder:

Bore size 77.00 ~ 77.01 mm

(3.0315 ~ 3.0319 in)
Out of round limit ---- 0.05 mm

Camshaft:

Drive method Chain drive (Left) ---­Camshaft cap inside diameter 22.000 ~ 22.021 mm

(0.8661 ~ 0.8670 in)
Camshaft outside diameter 21.967 ~ 21.980 mm

(0.8648 ~ 0.8654 in)
Shaft-to-cap clearance 0.020 ~ 0.054 mm

(0.0008 ~ 0.0021 in)
Cam dimensions

----

(0.002 in)

----

----

0.08 mm
(0.003 in)

A

B

Intake “A” 30.296 ~ 30.346 mm

(1.1923 ~ 1.1947 in)

“B” 22.45 ~ 22.55 mm

(0.8839 ~ 0.8878 in)

Exhaust “A” 30.399 ~ 30.499 mm

(1.1968 ~ 1.2007 in)

“B” 22.45 ~ 22.55 mm

(0.8839 ~ 0.8878 in)
Camshaft runout limit ---- 0.03 mm

30.196 mm
(1.1888 in)

22.35 mm
(0.8799 in)

30.299 mm
(1.1929 in)

22.35 mm
(0.8799 in)

(0.0012 in)

2 - 4

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Timing chain:

Timing chain type/No. of links 92RH2010-114M/114 ---­Timing chain adjustment method Automatic ----

Valve, valve seat, valve guide:

Valve clearance (cold) IN 0.10 ~ 0.15 mm

(0.0039 ~ 0.0059 in)

EX 0.17 ~ 0.22 mm

(0.0067 ~ 0.0087 in)
Valve dimensions:

SPEC

----

----

B

A

Head diameter Face width Seat width Margin thickness

“A” head diameter IN 22.9 ~ 23.1 mm

(0.9016 ~ 0.9094 in)

EX 24.4 ~ 24.6 mm

(0.9606 ~ 0.9685 in)

“B” face width IN 2.26 mm (0.089 in) ----

EX 2.26 mm (0.089 in) ----

“C” seat width IN 0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in)

EX 0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in)

“D” margin thickness IN 0.8 mm (0.0315 in) ----

EX 0.7 mm (0.0276 in) ----

Stem outside diameter IN 3.975 ~ 3.990 mm

(0.1565 ~ 0.1571 in)

EX 4.460 ~ 4.475 mm

(0.1756 ~ 0.1762 in)
Guide inside diameter IN 4.000 ~ 4.012 mm

(0.1575 ~ 0.1580 in)

EX 4.500 ~ 4.512 mm

(0.1772 ~ 0.1776 in)
Stem-to-guide clearance IN 0.010 ~ 0.037 mm

(0.0004 ~ 0.0015 in)

EX 0.025 ~ 0.052 mm

(0.0010 ~ 0.0020 in)

C

----

----

1.6 mm
(0.0630 in)

1.6 mm
(0.0630 in)

3.945 mm
(0.1553 in)

4.430 mm
(0.1744 in)

4.050 mm
(0.1594 in)

4.550 mm
(0.1791 in)

0.08 mm
(0.003 in)

0.10 mm
(0.004 in)

D

2 - 5

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Stem runout limit ---- 0.01 mm

SPEC

(0.0004 in)

Valve seat width IN 0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in)

EX 0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in)

Valve spring:

Free length IN 37.81 mm (1.49 in) 35.9 mm

EX 37.54 mm (1.48 in) 35.7 mm

Set length (valve closed) IN 29.13 mm (1.15 in) ----

EX 29.30 mm (1.15 in) ----

Compressed force (installed) IN 99 ~ 114 N at 29.13 mm

(9.9 ~ 11.4 kg at 29.13 mm,

22.27 ~ 25.57 lb at 1.15 in)

EX 126 ~ 144 N at 29.30 mm

(12.6 ~ 14.4 kg at 29.30 mm,

28.44 ~ 32.41 lb at 1.15 in)

Tilt limit IN ---- 2.5°/ 1.7 mm

*

EX ---- 2.5°/1.6 mm

1.6 mm
(0.0630 in)

1.6 mm
(0.0630 in)

(1.41 in)

(1.41 in)

----

----

(2.5°/0.067 in)

(2.5°/0.063 in)

Direction of winding (top view) IN Clockwise ----

EX Clockwise ----

Piston:

Piston to cylinder clearance 0.040 ~ 0.065 mm

(0.0016 ~ 0.0026 in)
Piston size “D” 76.955 ~ 76.970 mm

(3.0297 ~ 3.0303 in)

H

D

Measuring point “H” 8 mm (0.31 in) ---­Piston off-set 0.5 mm (0.020 in)/IN-side ----

2 - 6

0.1 mm
(0.004 in)

----

MAINTENANCE SPECIFICATIONS

Item Standard Limit

SPEC

Piston pin bore inside diameter 16.002 ~ 16.013 mm

(0.6300 ~ 0.6304 in)
Piston pin outside diameter 15.991 ~ 16.000 mm

(0.6296 ~ 0.6299 in)

Piston rings:

Top ring:

B

T

Type Barrel ---­Dimensions (B × T) 0.90 × 2.75 mm (0.04 × 0.11 in) ---­End gap (installed) 0.15 ~ 0.25 mm

(0.006 ~ 0.010 in)

Side clearance (installed) 0.030 ~ 0.065 mm

(0.0012 ~ 0.0026 in)
2nd ring:

B

T

Type Taper ---­Dimensions (B × T) 0.80 × 2.75 mm (0.03 × 0.11 in) ---­End gap (installed) 0.30 ~ 0.45 mm

(0.012 ~ 0.018 in)

Side clearance 0.020 ~ 0.055 mm

(0.0008 ~ 0.0022 in)
Oil ring:

16.043 mm
(0.6316 in)

15.971 mm
(0.6288 in)

0.50 mm
(0.020 in)

0.12 mm
(0.005 in)

0.80 mm
(0.031 in)

0.12 mm
(0.005 in)

B

T

Dimensions (B × T) 1.50 × 2.25 mm (0.06 × 0.09 in) ---­End gap (installed) 0.10 ~ 0.40 mm

(0.004 ~ 0.016 in)

Crankshaft:

Crank width “A” 55.95 ~ 56.00 mm

(2.203 ~ 2.205 in)
Runout limit “C” 0.03 mm (0.0012 in) 0.05 mm

Big end side clearance “D” 0.15 ~ 0.45 mm

(0.0059 ~ 0.0177 in)
Small end free play “F” 0.4 ~ 1.0 mm (0.02 ~ 0.04 in) 2.0 mm

----

----

(0.002 in)

0.50 mm
(0.02 in)

(0.08 in)

2 - 7

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Clutch:

Friction plate thickness 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 2.7 mm

Quantity 9 ----

Clutch plate thickness 1.1 ~ 1.3 mm (0.043 ~ 0.051 in) ----

Quantity 8 ---­Warp limit ---- 0.1 mm

Clutch spring free length 37.0 mm (1.46 in) 36.0 mm

Quantity 5 ----

Clutch housing thrust clearance 0.10 ~ 0.35 mm

(0.0039 ~ 0.0138 in)
Clutch housing radial clearance 0.010 ~ 0.044 mm

(0.0004 ~ 0.0017 in)
Clutch release method Inner push, cam push ----

Shifter:

Shifter type Cam drum and guide bar ---­Guide bar bending limit ---- 0.05 mm

Kickstarter:

Type Kick and ratchet type ----

Carburetor:

Type/manufacturer FCR-MX37/KEIHIN ←
I. D. mark 5UM1 00 5UM2 10
Main jet (M.J) #185 #172
Main air jet (M.A.J) ø2.0 ←
Jet needle (J.N) OBDVS-4 OBELP-4
Cutaway (C.A) 1.5 ←
Pilot jet (P.J) #40 ←
Pilot air jet (P.A.J) #75 ←
Pilot outlet (P.O) ø0.9 ←
Pilot screw (example) (P.S) 2 1-7/8
Bypass (B.P) ø1.0 ←
Valve seat size (V.S) ø3.8 ←
Starter jet (G.S) #72 ←
Leak jet (Acc.P) #90 ←
Float height (F.H) 8 mm (0.31 in) ←
Engine idle speed 1,900 ~ 2,100 r/min ←
Intake vacuum 26.7 ~ 32.0 kPa

(200 ~ 240 mmHg,

7.87 ~ 9.45 inHg)

Hot starter lever free play 3 ~ 6 mm

(0.12 ~ 0.24 in)

USA

SPEC

(0.106 in)

(0.004 in)

(1.42 in)

----

----

(0.002 in)

EUROPE, CDN,

ZA, AUS, NZ

←

←

2 - 8

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Lubrication system:

Oil filter type Paper type ---­Oil pump type Trochoid type ---­Tip clearance 0.12 mm or less

(0.0047 in or less)
Side clearance 0.09 ~ 0.17 mm

(0.0035 ~ 0.0067 in)
Housing and rotor clearance 0.03 ~ 0.10 mm

(0.0012 ~ 0.0039 in)

Cooling:

Radiator core size

Width 117.8 mm (4.6 in) ---­Height 220 mm (8.7 in) ----

Thickness 32 mm (1.26 in) ---­Radiator cap opening pressure 110 kPa (1.1 kg/cm
Radiator capacity (total) 0.6 L (0.53 Imp qt, 0.63 US qt) ---­Water pump

Type Single-suction centrifugal pump ----

2

, 15.6 psi) ----

SPEC

0.20 mm
(0.008 in)

0.24 mm
(0.009 in)

0.17 mm
(0.0067 in)

2 - 9

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened Thread size Q’ty

Spark plug M10S × 1.0 1 13 1.3 9.4
Camshaft cap M6 × 1.0 10 10 1.0 7.2
Cylinder head blind plug screw M12 × 1.0 1 37 3.7 27
Cylinder head (stud bolt) M6 × 1.0 2 7 0.7 5.1

(stud bolt) M8 × 1.25 1 15 1.5 11
(bolt) M9 × 1.25 4 38 3.8 27

(nut) M6 × 1.0 2 10 1.0 7.2
Cylinder head cover M6 × 1.0 2 10 1.0 7.2
Cylinder M6 × 1.0 1 10 1.0 7.2
Balancer weight M6 × 1.0 2 10 1.0 7.2
Balancer shaft driven gear M14 × 1.0 1 50 5.0 36
Timing chain guide (intake side) M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner cap bolt M6 × 1.0 1 7 0.7 5.1
Impeller M8 × 1.25 1 14 1.4 10
Radiator hose clamp M6 × 1.0 8 2 0.2 1.4
Coolant drain bolt M6 × 1.0 1 10 1.0 7.2
Water pump housing M6 × 1.0 4 10 1.0 7.2
Radiator M6 × 1.0 6 10 1.0 7.2
Radiator guard M6 × 1.0 2 10 1.0 7.2
Radiator pipe M6 × 1.0 1 10 1.0 7.2
Oil pump cover M4 × 0.7 1 2 0.2 1.4
Oil pump M6 × 1.0 3 10 1.0 7.2
Oil filter element drain bolt M6 × 1.0 1 10 1.0 7.2
Oil filter element cover M6 × 1.0 2 10 1.0 7.2
Oil strainer M6 × 1.0 2 10 1.0 7.2
Oil delivery pipe 1 (M10) M10 × 1.25 1 20 2.0 14

(M8) M8 × 1.25 2 18 1.8 13
Oil hose M6 × 1.0 2 10 1.0 7.2
Oil hose clamp — 220.21.4
Oil strainer and frame M14 × 1.5 1 70 7.0 50
Carburetor joint clamp M4 × 0.7 2 3 0.3 2.2
Air filter joint clamp M6 × 1.0 1 3 0.3 2.2
Throttle cable (pull) M6 × 1.0 1 4 0.4 2.9
Throttle cable (return) M12 × 1.0 1 11 1.1 8.0
Throttle cable cover M5 × 0.8 2 4 0.4 2.9
Hot starter plunger M12 × 1.0 1 2 0.2 1.4
Air filter case M6 × 1.0 2 8 0.8 5.8
Air filter joint and air filter case M5 × 0.8 1 4 0.4 2.9
Exhaust pipe (nut) M8 × 1.25 1 13 1.3 9.4

(bolt) M8 × 1.25 1 24 2.4 17

Exhaust pipe protector M6 × 1.0 3 10 1.0 7.2

Tightening torque

Nm m·kg ft·lb

2 - 10

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened Thread size Q’ty

Silencer M8 × 1.25 2 35 3.5 25
Silencer clamp M8 × 1.25 1 19 1.9 13
Spark arrester (for USA) M6 × 1.0 3 10 1.0 7.2
Silencer end pipe (for USA) M6 × 1.0 1 10 1.0 7.2
Crankcase M6 × 1.0 11 12 1.2 8.7
Crankcase bearing stopper M6 × 1.0 11 10 1.0 7.2
Crankcase bearing stopper (crankshaft) M6 × 1.0 4 10 1.0 7.2
Left crankcase cover M6 × 1.0 8 10 1.0 7.2
Idle gear cover (starter motor) M6 × 1.0 3 10 1.0 7.2
Idle gear plate M6 × 1.0 2 10 1.0 7.2
Right crankcase cover M6 × 1.0 8 10 1.0 7.2
Clutch cover M6 × 1.0 7 10 1.0 7.2
Crankcase oil drain bolt M10 × 1.25 1 20 2.0 14
Drive chain sprocket cover M6 × 1.0 2 8 0.8 5.8
Kick shaft ratchet wheel guide M6 × 1.0 2 12 1.2 8.7
Kickstarter crank M8 × 1.25 1 33 3.3 24
Starter clutch M6 × 1.0 6 16 1.6 11
Primary drive gear M18 × 1.0 1 75 7.5 54
Clutch spring M6 × 1.0 5 8 0.8 5.8
Clutch boss M16 × 1.0 1 60 6.0 43
Push lever shaft M6 × 1.0 1 10 1.0 7.2
Drive sprocket M18 × 1.0 1 75 7.5 54
Drive axle oil seal stopper M6 × 1.0 2 10 1.0 7.2
Segment M8 × 1.25 1 30 3.0 22
Shift guide M6 × 1.0 2 10 1.0 7.2
Stopper lever M6 × 1.0 1 10 1.0 7.2
Shift pedal M6 × 1.0 1 12 1.2 8.7

Tightening torque

Nm m·kg ft·lb

OTE:

- marked portion shall be checked for torque tightening after break-in or before each race.

2 - 11

MAINTENANCE SPECIFICATIONS

CHASSIS

Item Standard Limit

Steering system:

Steering bearing type Taper roller bearing ----

Front suspension: USA, CDN EUROPE AUS, NZ, ZA

Front fork travel 300 mm (11.8 in) ←←
Fork spring free length 460 mm (18.1 in) ←←
Spring rate, STD K = 4.31 N/mm

(0.44 kg/mm,

24.6 lb/in)

Optional spring/spacer Yes ←←

3

Oil capacity 568 cm

(20.0 lmp oz,

19.2 US oz)
Oil level 135 mm (5.31 in) 130 mm (5.12 in) 125 mm (4.92 in)
<Min.~Max.>

(From top of outer tube with inner
tube and damper rod fully com­pressed without spring.)

Oil grade Suspension oil

Inner tube outer diameter 46 mm (1.81 in) ←←
Front fork top end 5 mm (0.20 in) ← 10 mm (0.39 in)

Rear suspension: USA, CDN EUROPE AUS, NZ, ZA

Shock absorber travel 132 mm (5.20 in) ←←
Spring free length
Fitting length 245 mm (9.65 in)
<Min.~Max.> 240.5 ~ 258.5 mm

Spring rate, STD K = 49.0 N/mm

Optional spring Yes ←←
Enclosed gas pressure

Swingarm:

Swingarm free play limit

End ---- 1.0 mm

80 ~ 150 mm
(3.15 ~ 5.91 in)

“01”

260 mm (10.24 in)

(9.47 ~ 10.18 in)

(5.00 kg/mm,

280.0 lb/in)

1,000 kPa
(10 kg/cm

2

, 142 psi)

K = 4.12 N/mm
(0.42 kg/mm,

23.5 lb/in)

573 cm3
(20.2 lmp oz,

19.4 US oz)

←←

←←

←←

246.5 mm (9.70 in)

←←

K = 46.0 N/mm
(4.70 kg/mm,

263.2 lb/in)

←←

SPEC

K = 4.22 N/mm
(0.43 kg/mm,

24.1 lb/in)

578 cm3
(20.3 lmp oz,

19.5 US oz)

245 mm (9.65 in)

K = 50.0 N/mm
(5.10 kg/mm,

285.6 lb/in)

(0.04 in)

2 - 12

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Wheel: USA, CDN, ZA EUROPE, AUS, NZ

Front wheel type Spoke wheel ← ----
Rear wheel type Spoke wheel ← ----
Front rim size/material 21 × 1.60/Aluminum ← ----
Rear rim size/material 18 × 1.85/Aluminum 18 × 2.15/Aluminum ---­Rim runout limit:

Radial ---- ---- 2.0 mm

Lateral ---- ---- 2.0 mm

Drive chain:

Type/manufacturer DID520VM/DAIDO ---­Number of links 113 links + joint ---­Chain slack 40 ~ 50 mm (1.6 ~ 2.0 in) ---­Chain length (10 links) ---- 150.1 mm

Front disc brake:

Disc outside dia. × Thickness 250 × 3.0 mm (9.84 × 0.12 in)

Pad thickness 4.4 mm (0.17 in) 1.0 mm

Master cylinder inside dia. 11.0 mm (0.433 in) ---­Caliper cylinder inside dia. 27.0 mm (1.063 in) × 2 ---­Brake fluid type DOT #4 ----

Rear disc brake:

Disc outside dia. × Thickness 245 × 4.0 mm (9.65 × 0.16 in)

Deflection limit ---- 0.15 mm

Pad thickness 6.4 mm (0.25 in) 1.0 mm

Master cylinder inside dia. 11.0 mm (0.433 in) ---­Caliper cylinder inside dia. 25.4 mm (1.000 in) × 1 ---­Brake fluid type DOT #4 ----

Brake lever and brake pedal:

Brake lever position 95 mm (3.74 in) ---­Brake pedal height

(vertical height above footrest top)
Clutch lever free play (lever end) 8 ~ 13 mm (0.31 ~ 0.51 in) ---­Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----

5 mm (0.20 in) ----

SPEC

(0.08 in)

(0.08 in)

(5.91 in)

250 × 2.5 mm
(9.84

(0.04 in)

245 × 3.5 mm
(9.65

(0.006 in)

(0.04 in)

×

0.10 in)

×

0.14 in)

2 - 13

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened Thread size Q’ty

Upper bracket and outer tube M8 × 1.25 4 23 2.3 17
Lower bracket and outer tube M8 × 1.25 4 20 2.0 14
Upper bracket and steering stem M24 × 1.0 1 145 14.5 105
Handlebar upper holder and upper bracket M8 × 1.25 4 28 2.8 20
Steering stem and steering ring nut M28 × 1.0 1 Refer to NOTE.
Front fork and front fork cap bolt M48 × 1.0 2 30 3.0 22
Front fork and base valve M30 × 1.0 2 55 5.5 40
Front fork cap bolt and damper rod M12 × 1.25 2 29 2.9 21
Front fork bleed screw and front fork cap bolt M5 × 0.8 2 1 0.1 0.7
Front fork and front fork protector M6 × 1.0 6 10 1.0 7.2
Front fork and brake hose holder M6 × 1.0 2 10 1.0 7.2
Front fork and brake hose cover (M8) M8 × 1.25 1 16 1.6 11

(M6) M6 × 1.0 1 7 0.7 5.1
Throttle grip cap M5 × 0.8 2 4 0.4 2.9
Front brake master cylinder M6 × 1.0 2 9 0.9 6.5
Brake lever mounting bolt M6 × 1.0 1 6 0.6 4.3
Brake lever mounting nut M6 × 1.0 1 6 0.6 4.3
Brake lever position locknut M6 × 1.0 1 5 0.5 3.6
Front brake hose guide M5 × 0.8 2 4 0.4 2.9
Clutch lever holder M5 × 0.8 2 4 0.4 2.9
Hot starter lever holder M5 × 0.8 2 4 0.4 2.9
Hot starter lever mounting nut M5 × 0.8 1 2 0.2 1.4
Light switch M4 × 0.7 2 2 0.2 1.4
Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Front brake hose union bolt M10 × 1.25 2 30 3.0 22
Front brake caliper M8 × 1.25 2 23 2.3 17
Pad pin plug M10 × 1.0 2 3 0.3 2.2
Front brake caliper and pad pin M10 × 1.0 1 18 1.8 13
Rear brake caliper and pad pin M10 × 1.0 1 18 1.8 13
Brake caliper and bleed screw M8 × 1.25 2 6 0.6 4.3
Front wheel axle and axle nut M16 × 1.5 1 105 10.5 75
Front wheel axle holder M8 × 1.25 4 23 2.3 17
Front brake disc M6 × 1.0 6 12 1.2 8.7
Rear brake disc M6 × 1.0 6 14 1.4 10
Brake pedal M8 × 1.25 1 26 2.6 19
Rear brake master cylinder M6 × 1.0 2 11 1.1 8.0
Rear brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Rear brake hose union bolt M10 × 1.25 2 30 3.0 22
Rear wheel axle and axle nut M20 × 1.5 1 125 12.5 90

Tightening torque

Nm m·kg ft·lb

OTE:

1. First, tighten the steering nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the steering
nut wrench, then loosen the steering nut one turn.

2. Retighten the steering nut 7 Nm (0.7 m • kg, 5.1 ft • lb).

2 - 14

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened Thread size Q’ty

Nipple (spoke) — 72 3 0.3 2.2
Rear wheel sprocket M8 × 1.25 6 50 5.0 36
Rear brake disc cover M6 × 1.0 2 7 0.7 5.1
Rear brake caliper protector M6 × 1.0 2 7 0.7 5.1
Drive chain puller adjust bolt and locknut M8 × 1.25 2 16 1.6 11
Engine mounting:

Engine and engine bracket (front) M10 × 1.25 1 69 6.9 50
Engine and frame (lower) M10 × 1.25 1 69 6.9 50
Engine bracket and frame M8 × 1.25 6 34 3.4 24

Engine and engine bracket (upper) M10 × 1.25 1 55 5.5 40
Lower engine guard M6 × 1.0 3 10 1.0 7.2
Left engine guard M8 × 1.25 2 23 2.3 17
Right engine guard M8 × 1.25 2 23 2.3 17
Regulator bracket and frame M6 × 1.0 2 7 0.7 5.1
Regulator M6 × 1.0 2 7 0.7 5.1
Pivot shaft and nut M16 × 1.5 1 85 8.5 61
Relay arm and swingarm M14 × 1.5 1 80 8.0 58
Relay arm and connecting rod M14 × 1.5 1 80 8.0 58
Connecting rod and frame M14 × 1.5 1 80 8.0 58
Rear shock absorber and frame M10 × 1.25 1 56 5.6 40
Rear shock absorber and relay arm M10 × 1.25 1 53 5.3 38
Rear frame (upper) M8 × 1.25 1 32 3.2 23
Rear frame (lower) M8 × 1.25 2 29 2.9 21
Swingarm and brake hose holder M5 × 0.8 4 1 0.1 0.7
Swingarm and patch M4 × 0.7 4 2 0.2 1.4
Upper drive chain tensioner M8 × 1.25 1 19 1.9 13
Lower drive chain tensioner M8 × 1.25 1 20 2.0 14
Drive chain support M6 × 1.0 3 7 0.7 5.1
Seal guard and swingarm M5 × 0.8 4 6 0.6 4.3
Fuel tank M6 × 1.0 2 10 1.0 7.2
Fuel cock M6 × 1.0 2 7 0.7 5.1
Seat set bracket and fuel tank M6 × 1.0 1 7 0.7 5.1
Hooking screw (fitting band) and fuel tank M6 × 1.0 1 7 0.7 5.1
Air scoop and fuel tank M6 × 1.0 6 4 0.4 2.9
Air scoop and radiator guard (lower) M6 × 1.0 2 4 0.4 2.9
Front fender M6 × 1.0 4 7 0.7 5.1
Rear fender (front) M6 × 1.0 2 7 0.7 5.1
Rear fender (rear) M6 × 1.0 2 10 1.0 7.2
Side cover M6 × 1.0 2 7 0.7 5.1
Seat M8 × 1.25 2 23 2.3 17
Trip meter M6 × 1.0 2 7 0.7 5.1
Meter cable holder and front fork protector M5 × 0.8 2 4 0.4 2.9
Headlight stay (lower) and lower bracket M8 × 1.25 2 7 0.7 5.1
Headlight body and headlight unit M6 × 1.0 2 7 0.7 5.1

Tightening torque

Nm m·kg ft·lb

2 - 15

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened Thread size Q’ty

Headlight (left and right) M6 × 1.0 2 10 1.0 7.2
Headlight (lower) M6 × 1.0 1 7 0.7 5.1
Taillight M6 × 1.0 3 4 0.4 2.9
Taillight lead clamp and rear fender M4 × 1.59 2 0.5 0.05 0.36
Coolant reservoir M6 × 1.0 2 7 0.7 5.1
Sidestand bracket and frame M10 × 1.25 2 66 6.6 48
Sidestand M10 × 1.25 1 64 6.4 46

OTE:

- marked portion shall be checked for torque tightening after break-in or before each race.

Tightening torque

Nm m·kg ft·lb

2 - 16

MAINTENANCE SPECIFICATIONS

EC212300

ELECTRICAL

Item Standard Limit

Ignition system:

Advancer type Electrical ----

CDI:

Pickup coil resistance (color) 248 ~ 372 Ω at 20 °C (68 °F)

(White – Red)

CDI unit-model/manufacturer 5UM-00/YAMAHA (For USA) ----

5UM-10/YAMAHA (Except for USA) ----

Ignition coil:

Model/manufacturer 5UL-00/DENSO ---­Minimum spark gap 6 mm (0.24 in) ---­Primary coil resistance 0.08 ~ 0.10 Ω at 20 °C (68 °F) ----
Secondary coil resistance 4.6 ~ 6.8 kΩ at 20 °C (68 °F) ----

Charging system:

System type AC magneto ---­Model/manufacturer 5UM-00/YAMAHA ---­Normal output 14 V/120 W at 5,000 r/min ---­Charging coil resistance (color) 0.288 ~ 0.432 Ω at 20 °C (68 °F)

(White – Ground)

Lighting coil resistance (color) 0.224 ~ 0.336 Ω at 20 °C (68 °F)

(Yellow – Ground)

Rectifier/regulator:

Regulator type Semiconductor short circuit ---­Model/manufacture SH712AA/SHINDENGEN ---­Regulated voltage (AC) 13.0 ~ 14.0 V ---­Regulated voltage (DC) 14.1 ~ 14.9 V ---­Rectifier capacity (AC) 12 A ---­Rectifier capacity (DC) 8 A ----

Electric starting system:

Type Constant mesh ---­Starter motor:

Model/manufacturer 5UM00/YAMAHA ---­Operation voltage 12 V ---­Output 0.35 kW ---­Armature coil resistance 0.0189 ~ 0.0231 Ω at 20 °C (68 °F) ----
Brush overall length 7 mm (0.28 in) 3.5 mm (0.14 in)
Brush quantity 2 pcs. ---­Spring force 3.92 ~ 5.88 N

(400 ~ 600 g, 14.1 ~ 21.2 oz)
Commutator diameter 17.6 mm (0.69 in) 16.6 mm (0.65 in)
Mica undercut (depth) 1.5 mm (0.06 in) ----

SPEC

----

----

----

----

2 - 17

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Starter relay:

Model/manufacturer 2768090-A/JIDECO ---­Amperage rating 180 A ---­Coil winding resistance 4.2 ~ 4.6 Ω at 20 °C (68 °F) ----

Starting circuit cut-off relay:

Model/manufacturer ACM33221 M06/MATSUSHITA ---­Coil winding resistance 75.69 ~ 92.51 Ω at 20 °C (68 °F) ----

Fuse (amperage × quantity):

Main fuse 10 A × 1 ---­Reserve fuse 10 A × 1 ----

SPEC

Part to be tightened Thread size Q’ty

Stator M5 × 0.8 2 7 0.7 5.1
Holder (AC magneto lead) M5 × 0.8 2 7 0.7 5.1
Rotor M12 × 1.25 1 70 7.0 50
Neutral switch M5 × 0.8 2 4 0.4 2.9
Starter motor M6 × 1.0 2 10 1.0 7.2
Starter relay terminal M6 × 1.0 2 4 0.4 2.9
Negative lead and cylinder head M6 × 1.0 1 10 1.0 7.2

Tightening torque

Nm m·kg ft·lb

2 - 18

GENERAL TORQUE SPECIFICATIONS/

DEFINITION OF UNITS

EC220001

GENERAL TORQUE SPECIFICATIONS

This chart specifies torque for standard fasten­ers with standard I.S.O. pitch threads. Torque
specifications for special components or
assemblies are included in the applicable sec­tions of this book. To avoid warpage, tighten
multi-fastener assemblies in a crisscross fash­ion, in progressive stages, until full torque is
reached. Unless otherwise specified, torque
specifications call for clean, dry threads. Com­ponents should be at room temperature.

A

(Nut)

B

(Bolt)

TORQUE

SPECIFICATION

Nm m•kg ft•lb

SPEC

A: Distance between flats
B: Outside thread diameter

10 mm
12 mm
14 mm
17 mm
19 mm
22 mm

EC230000

6 mm

8 mm
10 mm
12 mm
14 mm
16 mm

6
15
30
55
85

130

0.6

1.5

3.0

5.5

8.5
13

4.3
11
22
40
61
94

DEFINITION OF UNITS

Unit Read Definition Measure

mm
cm

millimeter
centimeter

kg kilogram 10

N Newton 1 kg × m/sec

Nm
m • kg

Newton meter
Meter kilogram

Pa Pascal N/m

N/mm Newton per millimeter N/mm Spring rate

L
cm

3

Liter
Cubic centimeter

r/min Revolution per minute — Engine speed

-3

10

meter

-2

10

meter

3

gram Weight

2

Force

N × m
m × kg

2

—
—

Length
Length

Torque
Torque

Pressure

Volume or capacity
Volume or capacity

2 - 19

EC240000

CABLE ROUTING DIAGRAM

Fuel tank breather hose

1

Oil tank breather hose

2

Clamp

3

Diode

4

Wire harness

5

Hot starter cable

6

Throttle position sensor lead

7

Neutral switch lead

8

Oil hose

9

Hose guide

0

AC magneto lead

A

Cylinder head breather hose

B

Starter motor lead

C

Clutch cable

D

Radiator hose 1

E

Radiator pipe (radiator hose 4)

F

CABLE ROUTING DIAGRAM

Cable guide

G

Negative battery lead

H

Light switch lead

I

Brake hose

J

Carburetor breather hose

K

Carburetor overflow hose

L

Coolant reservoir breather

M

hose

SPEC

2 - 20

CABLE ROUTING DIAGRAM

SPEC

Insert the fuel tank breather hose into the hole in

È

the steering stem cap.
Pass the oil tank breather hose on the outside of

É

the AC magneto lead, neutral switch lead, light
switch lead, wire harness, starter motor lead, neg­ative battery lead and cylinder head breather
hose.
Fasten the diode and rectifier/regulator lead, with

Ê

the diode at its white tape and the rectifier/regula­tor lead at its protecting tube.

Fasten the wire harness, starter motor lead and

Ë

negative battery lead so that the plastic locking tie
ends do not contact the ignition coil lead.
Fasten the wire harness, rectifier/regulator lead,

Ì

coolant reservoir hose, hot starter cable, negative
battery lead and starter motor lead.
Fasten the wire harness, negative battery lead,

Í

starter motor lead, rectifier/regulator lead and
coolant reservoir hose at the white tape for the
negative battery lead.

2 - 21

CABLE ROUTING DIAGRAM

SPEC

Fasten the wire harness at its white tape.

Î

Fasten the wire harness, throttle position sensor

Ï

lead (in the wire harness), starter motor lead and
negative battery lead.
Make sure that the throttle position sensor coupler

Ð

does not go outside the chassis.
Fasten the throttle position sensor lead.

Ñ

Pass the carburetor breather hoses, carburetor

Ò

overflow hose and coolant reservoir breather hose
between the connecting rod and cross tube
(frame).

Fasten the neutral switch lead and oil hose

Ó

together with the plastic locking ties and cut off the
tie ends.
Pass the cylinder head breather hose through the

Ô

hose guide.
Fasten the neutral switch lead.

Õ

Fasten the neutral switch lead and AC magneto

Ö

lead.

2 - 22

CABLE ROUTING DIAGRAM

SPEC

Pass the cylinder head breather hose on the

×

inside of the radiator hose 1 and on the outside of
the radiator pipe (radiator hose 4). Make sure that
the cylinder head breather hose does not go for­ward of the chassis.
Pass the starter motor lead in front of the radiator

Ø

hose 4.
Pass the clutch cable through the cable guide.

Ù

Pass the wire harness on the outside of the neu-

Ú

tral switch lead and AC magneto lead.
Fit the brake hose into the guides on the protector.

Û

Pass the wire harness, clutch cable and light

Ü

switch lead through the cable guide.
Fasten the AC magneto lead, neutral switch lead

Ý

and light switch lead to the cable guide at their
protecting tube with a plastic locking tie and cut off
the tie end.
Pass the carburetor breather hoses, carburetor

Þ

overflow hose and coolant reservoir breather hose
so that the hoses do not contact the rear shock
absorber.

2 - 23

CABLE ROUTING DIAGRAM

SPEC

Hot starter cable

1

Cable guide

2

Throttle cable (return)

3

Throttle cable (pull)

4

Ignition coil

5

Coolant reservoir breather

6

hose
Rectifier/regulator

7

Coolant reservoir hose

8

Rectifier/regulator lead

9

Clamp

0

CDI unit lead

A

CDI unit

B

CDI unit band

C

CDI unit stay

D

Rectifier/regulator bracket

E

Pass the throttle cables and

È

hot starter cable through the
cable guides.

Pass the throttle cables and

É

hot starter cable between the
radiator and frame, then under
the radiator mounting boss.
Pass the throttle cables on the

Ê

outside of the ignition coil.
Pass the carburetor breather

Ë

hose (of the throttle cable
cover) through the hose holder.

2 - 24

CABLE ROUTING DIAGRAM

Fasten the coolant reservoir breather hose and

Ì

carburetor breather hoses together.
Fasten the CDI unit lead.

Í

Insert the CDI unit band over the CDI unit stay as

Î

far as possible.
Fasten the rectifier/regulator lead to the rectifier/

Ï

regulator bracket with a plastic locking tie and cut
off the tie end.

SPEC

2 - 25

CABLE ROUTING DIAGRAM

SPEC

Brake master cylinder

1

Brake hose holder

2

Brake hose

3

Install the brake hose so that its pipe portion

È

directs as shown and lightly touches the projection
on the brake caliper.
Pass the brake hose into the brake hose holders.

É

If the brake hose contacts the spring (rear shock

Ê

absorber), correct its twist.
Install the brake hose so that its pipe portion

Ë

directs as shown and lightly touches the projection
on the brake master cylinder.

2 - 26

CABLE ROUTING DIAGRAM

SPEC

Starter motor lead

1

Negative battery lead

2

Wire harness

3

Clamp

4

Taillight lead

5

Coolant reservoir breather hose

6

Coolant reservoir hose

7

Positive battery lead

8

Starting circuit cut-off relay

9

Battery

0

Position the starter motor lead, negative battery

È

lead and wire harness in the tank damper slit.
Fasten the wire harness.

É

Do not allow the taillight lead to slacken.

Ê

Fasten the coolant reservoir breather hose, cool-

Ë

ant reservoir hose and rectifier/regulator lead.
Fasten the coolant reservoir breather hose and

Ì

coolant reservoir hose.
Pass the coolant reservoir hose on the outside of

Í

the coolant reservoir breather hose.

2 - 27

CABLE ROUTING DIAGRAM

SPEC

Throttle cable

1

Brake hose

2

Clamp

3

Light switch lead

4

Hot starter cable

5

Clutch cable

6

Hose guide

7

Clutch switch lead

8

Engine stop switch lead

9

Trip meter cable

0

Main switch lead

A

Trip meter

B

Main switch

C

Light switch

D

Start switch lead

E

Fasten the start switch lead

È

and light switch lead.
Fasten the engine stop switch

É

lead and clutch switch lead.
Pass the brake hose through

Ê

the hose guide.

Pass the start switch lead in

Ë

front of the main switch lead.
Fasten the start switch lead.

Ì

Pass the hot starter cable,

Í

clutch cable and light switch
lead between the upper
bracket and coupler bracket.
Pass the throttle cables

Î

between the upper bracket and
trip meter.

2 - 28

INSP

MAINTENANCE INTERVALS

EC300000

REGULAR INSPECTION AND ADJUSTMENTS

MAINTENANCE INTERVALS

The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your Yamaha dealer.

ADJ

race

Every third

500 km)

Item

ENGINE OIL

Replace
Inspect

VALVES

Check the valve clearances The engine must be cold.
Inspect
Replace

VALVE SPRINGS

Inspect Check the free length and
Replace

VALVE LIFTERS

Inspect Check for scratches and
Replace

CAMSHAFTS Inspect the camshaft sur-

Inspect
Replace

TIMING CHAIN SPROCKETS, TIMING
CHAIN

Inspect Check for wear on the
Replace

PISTON

Inspect Inspect crack
Clean
Replace

PISTON RING

Inspect Check ring end gap
Replace

PISTON PIN

Inspect
Replace

CYLINDER HEAD Inspect carbon deposits

Inspect and clean

CYLINDER

Inspect and clean Inspect score marks
Replace

CLUTCH Inspect housing, friction

Inspect and adjust
Replace

TRANSMISSION

Inspect
Replace bearing

After

break-in

Every

(or

Every fifth

(or

1,000 km)

As re­quired

Remarks

Check the valve seats
and valve stems for wear.

the tilt.

wear.

face.
Inspect the decompres­sion system.

teeth and for damage.

Inspect carbon deposits
and eliminate them.

and eliminate them.
Change gasket

Inspect wear

plate, clutch plate and
spring

3 - 1

MAINTENANCE INTERVALS

INSP

ADJ

race

Every third

500 km)

Item

SHIFT FORK, SHIFT CAM, GUIDE BAR

Inspect Inspect wear

ROTOR NUT

Retighten
EXHAUST PIPE, SILENCER,
PROTECTOR

Inspect and retighten

Clean

Replace * Whichever comes first
*SPARK ARRESTER

Clean

CRANK

Inspect and clean
CARBURETOR

Inspect, adjust and clean
SPARK PLUG

Inspect and clean

Replace
DRIVE CHAIN Use chain lube

Lubricate, slack, alignment

Replace
COOLING SYSTEM

Check coolant level and leakage

Check radiator cap operation

Replace coolant Every two years

Inspect hoses
OUTSIDE NUTS AND BOLTS Refer to “STARTING

Retighten

AIR FILTER

Clean and lubricate Use foam air-filter oil or

Replace
OIL FILTER

Replace
OIL STRAINER (frame)

Clean
FRAME

Clean and inspect
FUEL TANK, COCK

Clean and inspect
BRAKES

Adjust lever position and pedal height

Lubricate pivot point

Check brake disc surface

Check fluid level and leakage

Retighten brake disc bolts, caliper

bolts, master cylinder bolts and union

bolts

Replace pads

Replace brake fluid Every one year

After

break-in

Every

(or

Every fifth

(or

1,000 km)

As re-

quired

(Every six

months)

Remarks

Chain slack:
40 ~ 50 mm (1.6 ~ 2.0 in)

AND BREAK-IN” section
in the CHAPTER 1.

equivalent oil

3

3 - 2

MAINTENANCE INTERVALS

INSP

ADJ

race

Every third

500 km)

Item

FRONT FORKS

Inspect and adjust

Replace oil Suspension oil “01”

Replace oil seal
FRONT FORK OIL SEAL AND DUST
SEAL

Clean and lube Lithium base grease
REAR SHOCK ABSORBER

Inspect and adjust

Lube

Retighten
DRIVE CHAIN GUIDE AND ROLLERS

Inspect
SWINGARM Molybdenum disulfide

Inspect, lube and retighten
RELAY ARM, CONNECTING ROD Molybdenum disulfide

Inspect, lube and retighten
STEERING HEAD

Inspect free play and retighten

Clean and lube Lithium base grease

Replace bearing
TIRE, WHEELS

Inspect air pressure, wheel run-out,

tire wear and spoke looseness

Retighten sprocket bolt

Inspect bearings

Replace bearings

Lubricate Lithium base grease
THROTTLE, CONTROL CABLE Yamaha cable lube or

Check routing and connection

Lubricate

Inspect and clean (throttle cable)

HOT STARTER, CLUTCH LEVER

Inspect free play
BATTERY

Check terminal for looseness and

corrosion

After

break-in

Every

(or

Every fifth

(or

1,000 km)

As re-

quired

(After

rain ride)

Remarks

Molybdenum disulfide
grease

grease

grease

SAE 10W-30 motor oil
Inspect dirt and wear on
the throttle cable on the
carburetor side.

*marked: For USA

3 - 3

INSP

PRE-OPERATION INSPECTION AND MAINTENANCE

EC320000

PRE-OPERATION INSPECTION AND MAINTENANCE

Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.

GENERAL INSPECTION AND MAINTENANCE

Item Routine Page

Coolant

Fuel

Engine oil

Gear shifter and clutch

Throttle grip/Housing

Brakes Check the play of front brake and effect of front and rear brake. P.3-25 ~ 31

Drive chain

Wheels

Steering

Front forks and rear shock
absorber

Cables (wires)

Exhaust pipe

Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-32
Lubrication Check for smooth operation. Lubricate if necessary. P.3-46
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-19

Lead connectors

Settings

Check that coolant is filled up to the radiator cap.
Check the cooling system for leakage.

Check that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.

Check that the oil level is correct. Check the crankcase and
frame oil line for leakage.

Check that gears can be shifted correctly in order and that the
clutch operates smoothly.

Check that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.

Check drive chain slack and alignment. Check that the drive
chain is lubricated properly.

Check for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.

Check that the handlebar can be turned smoothly and have no
excessive play.

Check that they operate smoothly and there is no oil leakage. P.3-35 ~ 42

Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or
when the front forks travel up and down.

Check that the exhaust pipe is tightly mounted and has no
cracks.

Check that the AC magneto, CDI unit, and ignition coil are con­nected tightly.

Is the machine set suitably for the condition of the racing course
and weather or by taking into account the results of test runs
before racing? Are inspection and maintenance completely
done?

ADJ

P.3-5 ~ 9

P.1-14

P.3-14 ~ 18

P.3-9 ~ 10

P.3-10 ~ 11

P.3-32 ~ 35

P.3-43 ~ 44

P.3-44 ~ 45

—

P.4-3 ~ 4

P.1-6

P.7-1 ~ 22

3 - 4

ENGINE/COOLANT LEVEL INSPECTION/

COOLANT REPLACEMENT

EC350000

ENGINE

COOLANT LEVEL INSPECTION

WARNING

Do not remove the radiator cap 1, drain
bolt and hoses when the engine and radia­tor are hot. Scalding hot fluid and steam
may be blown out under pressure, which
could cause serious injury.
When the engine has cooled, place a thick
towel over the radiator cap, slowly rotate
the cap counterclockwise to the detent.
This procedure allows any residual pres­sure to escape. When the hissing sound
has stopped, press down on the cap while
turning counterclockwise and remove it.

INSP

ADJ

LOW

FULL

COOLANT

a
b

CAUTION:

Hard water or salt water is harmful to the
engine parts. You may use distilled water, if
you can’t get soft water.

1. Place the machine on a level place, and
hold it in an upright position.

2. Inspect:

• Coolant level

Coolant level should be between the
maximum a and minimum b marks.
Coolant level is below the “LOW” level
line → Add soft water (tap water) up to
the proper level.

3. Start the engine and let it warm up for sev­eral minutes.

4. Turn off the engine and check the coolant
level again.

OTE:

Before checking the coolant level, wait a few
minutes until the coolant settles.

COOLANT REPLACEMENT

WARNING

Do not remove the radiator cap when the
engine is hot.

3 - 5

1

LOW

FULL

COOLANT

COOLANT REPLACEMENT

CAUTION:

Take care so that coolant does not splash
on painted surfaces. If it splashes, wash it
away with water.

1. Place a container under the engine.

2. Remove:

• Seat

Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.

3. Disconnect:

• Coolant reservoir hose 1

Drain the coolant completely.

4. Connect:

• Coolant reservoir hose

INSP

ADJ

5. Remove:

• Engine guard 1

• Coolant drain bolt 2

6. Remove:

• Radiator cap

Drain the coolant completely.

7. Clean:

• Cooling system

Thoroughly flush the cooling system with
clean tap water.

8. Install:

• Copper washer

New

• Coolant drain bolt

T

10 Nm (1.0 m · kg, 7.2 ft · lb)

.

R

.

• Engine guard

• Bolt [engine guard (front)]

T

34 Nm (3.4 m · kg, 24 ft · lb)

.

R

.

• Bolt [engine guard (rear)]

T

23 Nm (2.3 m · kg, 17 ft · lb)

.

R

.

3 - 6

COOLANT REPLACEMENT

9. Fill:

• Radiator

• Engine

To specified level.

Recommended coolant:

High quality ethylene glycol
anti-freeze containing
anti-corrosion for

aluminum engine
Coolant 1 and water
(soft water) 2 mixing ratio:

50%/50%
Coolant capacity:

1.3 L (1.14 Imp qt, 1.37 US qt)

CAUTION:

• Do not mix more than one type of ethyl­ene glycol antifreeze containing corro­sion inhibitors for aluminum engine.

• Do not use water containing impurities or oil.

INSP

ADJ

LOW

FULL

COOLANT

Handling notes of coolant:

The coolant is harmful so it should be han­dled with special care.

WARNING

• When coolant splashes to your eye.
Thoroughly wash your eye with water
and see your doctor.

• When coolant splashes to your clothes.
Quickly wash it away with water and
then with soap.

• When coolant is swallowed.
Quickly make him vomit and take him
to a doctor.

10. Install:

• Radiator cap

11. Fill:

• Coolant reservoir tank

Midway a between maximum and mini­mum marks on the tank.

a

3 - 7

RADIATOR CAP INSPECTION/

RADIATOR CAP OPENING PRESSURE INSPECTION

12. Install:

• Coolant reservoir cap

13. Start the engine and let it warm up for sev­eral minutes.

14. Turn off the engine and inspect the coolant
level.
Refer to “COOLANT LEVEL INSPECTION”
section.

OTE:

Before checking the coolant level wait a few
minutes until the coolant settles.

INSP

ADJ

EC355000

RADIATOR CAP INSPECTION

1. Inspect:

• Seal (radiator cap) 1

• Valve and valve seat 2

Crack/damage → Replace.
Exist fur deposits 3 → Clean or replace.

RADIATOR CAP OPENING PRESSURE
INSPECTION

1. Attach:

• Radiator cap tester 1 and adapter 2

Radiator cap tester:

YU-24460-01/90890-01325

Radiator cap tester adapter:

YU-33984/90890-01352

OTE:

Apply water on the radiator cap seal.

3 - 8

Radiator cap

3

COOLING SYSTEM INSPECTION/

CLUTCH ADJUSTMENT

2. Apply the specified pressure.

INSP

ADJ

Radiator cap opening pressure:

110 kPa (1.1 kg/cm

3. Inspect:

• Pressure

Impossible to maintain the specified pres­sure for 10 seconds → Replace.

COOLING SYSTEM INSPECTION

1. Inspect:

• Coolant level

2. Attach:

• Radiator cap tester 1 and adapter 2

Radiator cap tester:

YU-24460-01/90890-01325

Radiator cap tester adapter:

YU-33984/90890-01352

3. Apply the specified pressure.

Standard pressure:

180 kPa (1.8 kg/cm

2

, 15.6 psi)

2

, 25.6 psi)

OTE:

• Do not apply pressure more than specified

pressure.

• Radiator should be filled fully.

4. Inspect:

• Pressure

Impossible to maintain the specified pres­sure for 10 seconds → Repair.

• Radiator 1

• Radiator hose joint 2

Coolant leakage → Repair or replace.

• Radiator hose 3

Swelling → Replace.

CLUTCH ADJUSTMENT

1. Check:

• Clutch lever free play a

Out of specification → Adjust.

Clutch lever free play a:

8 ~ 13 mm (0.31 ~ 0.51 in)

3 - 9

THROTTLE CABLE ADJUSTMENT

2. Adjust:

• Clutch lever free play

Clutch lever free play adjustment steps:

• Loosen the locknuts 1.

• Adjust the free play by changing their tight-

ening position.

• Tighten the locknuts.

OTE:

• Make minute adjustment on the lever side

using the adjuster 2.

• After adjustment, check proper operation of

clutch lever.

INSP

ADJ

2

1

THROTTLE CABLE ADJUSTMENT

1. Check:

• Throttle grip free play a

Out of specification → Adjust.

Throttle grip free play a:

3 ~ 5 mm (0.12 ~ 0.20 in)

2. Adjust:

• Throttle grip free play

Throttle grip free play adjustment steps:

• Slide the adjuster cover.

• Loosen the locknut 1.

• Turn the adjuster 2 until the specified free

play is obtained.

• Tighten the locknut.

OTE:

Before adjusting the throttle cable free play,
the engine idle speed should be adjusted.

3 - 10

WARNING

After adjusting the throttle cable free
play, start the engine and turn the han­dlebar to right and left and make sure
that the engine idling does not run faster.

THROTTLE LUBRICATION/

HOT STARTER LEVER ADJUSTMENT

THROTTLE LUBRICATION

1. Remove:

• Cover (throttle cable cap) 1

• Cover (grip cap) 2

• Throttle grip cap 3

2. Apply:

• Lithium soap base grease

On the throttle cable end a.

3. Install:

• Throttle grip cap

• Screw (throttle grip cap)

T

4 Nm (0.4 m · kg, 2.9 ft · lb)

.

R

.

• Cover (grip cap)

• Cover (throttle cable cap)

INSP

ADJ

HOT STARTER LEVER ADJUSTMENT

1. Check:

• Hot starter lever free play a

Out of specification → Adjust.

Hot starter lever free play a:

3 ~ 6 mm (0.12 ~ 0.24 in)

2. Adjust:

• Hot starter lever free play

Hot starter lever free play adjustment
steps:

• Loosen the locknut 1.

• Turn the adjuster 2 until free play a is

within the specified limits.

• Tighten the locknut.

OTE:

After adjustment, check proper operation of
hot starter.

3 - 11

AIR FILTER CLEANING

AIR FILTER CLEANING

OTE:

Proper air filter maintenance is the biggest key
to preventing premature engine wear and
damage.

CAUTION:

Never run the engine without the air filter
element in place; this would allow dirt and
dust to enter the engine and cause rapid
wear and possible engine damage.

1. Remove:

• Air filter case cover 1

OTE:

Loosen the quick screw 2 and draw the air fil­ter case cover to remove it because its claws
a are inserted in the side cover as shown.

INSP

ADJ

2. Unhook:

• Binder 1

3. Remove:

• Air filter element 1

• Filter guide 2

4. Clean:

• Air filter element

Clean them with solvent.

OTE:

After cleaning, remove the remaining solvent
by squeezing the element.

3 - 12

AIR FILTER CLEANING

CAUTION:

• Do not twist the element when squeezing

the element.

• Leaving too much of solvent in the ele-

ment may result in poor starting.

5. Inspect:

• Air filter element

Damage → Replace.

6. Apply:

• Foam-air-filter oil or equivalent oil to the

element

OTE:

• Squeeze out the excess oil. Element should

be wet but not dripping.

• Wipe off the oil left on the element surface

using a clean dry cloth. (Excess oil in the ele­ment may adversely affect engine starting.)

INSP

ADJ

7. Install:

• Filter guide 1

OTE:

• Align the projection a on filter guide with the

hole b in air filter element.

• Apply the lithium soap base grease on the

matching surface c on air filter element.

8. Install:

• Air filter element 1

OTE:

Align the projection a on filter guide with the
hole b in air filter case.

9. Hook:

• Binder 1

OTE:

Hook the binder 1 so that it contacts the filter
guide projections a.

3 - 13

1

ENGINE OIL LEVEL INSPECTION

ENGINE OIL LEVEL INSPECTION

1. Start the engine, warm it up for several
minutes, and then turn off the engine and
wait for five minutes.

2. Place the machine on a level place and
hold it up on upright position by placing the
suitable stand under the engine.

3. Remove:

• Oil tank cap 1

INSP

ADJ

a

b

4. Inspect:

• Oil level

Oil level should be between maximum a
and minimum b marks.
Oil level is low → Add oil to proper level.

OTE:

When inspecting the oil level, do not screw the
oil tank cap into the oil tank. Insert the gauge
lightly.

(For USA and CDN)

Recommended oil:

At 5 °C (40 °F) or higher È
Yamalube 4 (20W-40) or SAE
20W-40 type SG motor oil
(Non-Friction modified)
At 15 °C (60 °F) or lower É
Yamalube 4 (10W-30) or SAE
10W-30 type SG motor oil
(Non-Friction modified)
and/or
Yamalube 4-R (15W-50)
(Non-Friction modified)

CAUTION:

• Do not add any chemical additives.

Engine oil also lubricates the clutch and
additives could cause clutch slippage.

• Do not allow foreign material to enter the

crankcase.

3 - 14

ENGINE OIL REPLACEMENT

INSP

ADJ

-20-4-101403010502068308640 50

10W-30

10W-40

15W-40

20W-40

20W-50

104

122

a

b

˚CTemp.

(Except for USA and CDN)

Recommended oil:

Refer to the following chart for
selection of oils which are
suited to the atmospheric

temperatures.
Recommended engine oil classi­fication:
API STANDARD:

˚F

API “SG” or higher grade

(Designed primarily for

motorcycles)

CAUTION:

• Do not add any chemical additives or use
oils with a grade of CD a or higher.

• Do not use oils labeled “ENERGY CON­SERVING II” b or higher. Engine oil also
lubricates the clutch and additives could
cause clutch slippage.

• Do not allow foreign materials to enter the
crankcase.

5. Install:

• Oil tank cap

6. Start the engine and let it warm up for sev-

eral minutes.

7. Turn off the engine and inspect the oil level

once again.

OTE:

Wait a few minutes until the oil settles before
inspecting the oil level.

ENGINE OIL REPLACEMENT

1. Start the engine and warm it up for several

minutes, and then turn off the engine and
wait for five minute.

2. Place the machine on a level place and

hold it on upright position by placing the
suitable stand under the engine.

3. Place a suitable container under the

engine.

3 - 15

1

ENGINE OIL REPLACEMENT

4. Remove:

• Oil tank cap 1

• Oil filler cap 2

• Frame oil drain bolt 3

• Crankcase oil drain bolt 4

• Oil filter element drain bolt 5

Drain the crankcase and oil tank (frame)
of its oil.

INSP

ADJ

5. Remove:

• Lower engine bracket

• Oil hose clamp 1

• Bolt (oil hose) 2

• Oil hose 3

• Oil strainer (frame) 4

6. Inspect:

• Oil strainer (frame)

Clogged → Blow.

7. If the oil filter is to be replaced during this

oil change, remove the following parts and
reinstall them.

Replacement steps:

• Remove the oil filter element cover 1 and
oil filter element 2.

• Check the O-rings 3, if cracked or dam-
aged, replace them with a new one.

• Install the oil filter element and oil filter ele­ment cover.

Oil filter element cover:

T

.

10 Nm (1.0 m • kg, 7.2 ft • lb)

R

.

3 - 16

ENGINE OIL REPLACEMENT

8. Install:

• Copper washer 1

• Oil strainer (frame) 2

T

70 Nm (7.0 m · kg, 50 ft · lb)

.

R

.

• Oil hose 3

• Bolt (oil hose) 4

T

10 Nm (1.0 m · kg, 7.2 ft · lb)

.

R

.

• Oil hose clamp 5

T

2 Nm (0.2 m · kg, 1.4 ft · lb)

.

R

.

• Lower engine bracket

T

10 Nm (1.0 m · kg, 7.2 ft · lb)

.

R

.

9. Install:

• Copper washer

• Oil filter element drain bolt

• Crankcase oil drain bolt

• Frame oil drain bolt

10. Fill:

• Engine oil

New

T

10 Nm (1.0 m · kg, 7.2 ft · lb)

.

R

.

T

20 Nm (2.0 m · kg, 14 ft · lb)

.

R

.

T

23 Nm (2.3 m · kg, 17 ft · lb)

.

R

.

INSP

ADJ

New

Oil quantity:

Total amount:

Periodic oil change:

With oil filter replacement:

11. Check:

• Oil leakage

12. Install:

• Oil tank cap

13. Check:

• Engine oil level

1.4 L (1.23 Imp qt, 1.48 US qt)

1.2 L (1.06 Imp qt, 1.27 US qt)

1.3 L (1.14 Imp qt, 1.37 US qt)

3 - 17

OIL PRESSURE INSPECTION/
PILOT SCREW ADJUSTMENT

OIL PRESSURE INSPECTION

1. Check:

• Oil pressure

Checking steps:

• Slightly loosen the oil pressure check bolt

1.

• Start the engine and keep it idling until oil
starts to seep from the oil pressure check
bolt. If no oil comes out after one minute,
turn the engine off so it will not seize.

• Check oil passages and oil pump for dam­age or leakage.

• Start the engine after solving the prob­lem(s) and recheck the oil pressure.

• Tighten the oil pressure check bolt.

Oil pressure check bolt:

T

.

10 Nm (1.0 m • kg, 7.2 ft • lb)

R

.

INSP

ADJ

PILOT SCREW ADJUSTMENT

1. Adjust:

• Pilot screw 1

Adjustment steps:

OTE:

To optimize the fuel flow at a smaller throttle
opening, each machine’s pilot screw has
been individually set at the factory. Before
adjusting the pilot screw, turn it in fully and
count the number of turns. Record this num­ber as the factory-set number of turns out.

• Turn in the pilot screw until it is lightly
seated.

• Turn out the pilot screw by the factory-set
number of turns.

Pilot screw:

2 turns out (example)
* 1-7/8 turns out

* Except for USA

3 - 18

ENGINE IDLING SPEED ADJUSTMENT/

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

ENGINE IDLING SPEED ADJUSTMENT

1. Start the engine and thoroughly warm it up.

2. Attach:

• Inductive tachometer
To spark plug lead.

3. Adjust:

• Engine idling speed

Adjustment steps:

• Adjust the pilot screw.
Refer to “PILOT SCREW ADJUSTMENT”
section.

• Turn the throttle stop screw 1 until the
engine runs at the lowest possible speed.

To increase idle speed → Turn the throt-

tle stop screw 1 in a.

To decrease idle speed → Turn the throt-

tle stop screw 1 out b.

INSP

ADJ

Inductive tachometer:

YU-8036-B

Engine tachometer:

90890-03113

Engine idling speed:

1,900 ~ 2,100 r/min

VALVE CLEARANCE INSPECTION AND
ADJUSTMENT

OTE:

• The valve clearance should be adjusted
when the engine is cool to the touch.

• The piston must be at Top Dead Center
(T.D.C.) on compression stroke to check or
adjust the valve clearance.

1. Remove:

• Seat

• Fuel tank

Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.

2. Drain:

• Coolant
Refer to “COOLANT REPLACEMENT”
section.

3 - 19

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

3. Remove:

• Right radiator
Refer to “RADIATOR” section in the
CHAPTER 4.

• Carburetor
Refer to “CARBURETOR” section in the
CHAPTER 4.

• Spark plug

• Upper engine bracket

• Cylinder head cover

Refer to “CAMSHAFTS” section in the
CHAPTER 4.

4. Remove:

• Timing mark accessing screw 1

• Crankshaft end accessing screw 2

• O-ring

5. Check:

• Valve clearance
Out of specification → Adjust.

INSP

ADJ

Valve clearance (cold):

Intake valve:

0.10 ~ 0.15 mm
(0.0039 ~ 0.0059 in)

Exhaust valve:

0.17 ~ 0.22 mm
(0.0067 ~ 0.0087 in)

Checking steps:

• Turn the crankshaft counterclockwise with
a wrench.

• Align the T.D.C. mark a on the rotor with
the align mark b on the crankcase cover
when piston is at T.D.C. on compression
stroke.

OTE:

In order to be sure that the piston is at Top
Dead Center, the punch mark c on the
exhaust camshaft and the punch mark d on
the intake camshaft must align with the cyl­inder head surface, as shown in the illustra­tion.

3 - 20

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

• Measure the valve clearance e using a
feeler gauge 1.

OTE:

Record the measured reading if the clear­ance is incorrect.

INSP

ADJ

6. Adjust:

• Valve clearance

Adjustment steps:

• Remove the camshaft (intake and exhaust).
Refer to “CAMSHAFTS” section in the
CHAPTER 4.

• Remove the valve lifters 1 and the pads

2.

OTE:

• Place a rag in the timing chain space to
prevent pads from falling into the crank­case.

• Identity each valve lifter and pad position
very carefully so that they can be rein­stalled in their original place.

• Select the proper pad using the pad select­ing table.

Pad range

No. 120

~

No. 240

1.20 mm
~

2.40 mm

Pad Availability:

25 increments

Pads are available in

0.05 mm increments

3 - 21

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

OTE:

The thickness a of each pad is indicated in
hundreths of millimeters on the pad upper
surface.

• Round off the last digit of the installed pad
number to the nearest increment.

Last digit of pad

number
0, 1 or 2 0
4, 5 or 6 5

8 or 9 10

EXAMPLE:

Installed pad number = 148
Rounded off value = 150

OTE:

Pads can only be selected in 0.05 mm incre­ments.

INSP

ADJ

Rounded value

• Locate the rounded-off value and the mea­sured valve clearance in the chart “PAD
SELECTION TABLE”. The field where
these two coordinates intersect shows the
new pad number to use.

OTE:

Use the new pad number only as a guide
when verifying the valve clearance adjust­ment.

• Install the new pads 3 and the valve lifters

4.

OTE:

• Apply the engine oil on the valve lifters.

• Apply the molybdenum disulfide oil on the

valve stem ends.

• Valve lifter must turn smoothly when
rotated with a finger.

• Be careful to reinstall valve lifters and pads
in their original place.

• Install the camshafts (exhaust and intake).
Refer to “CAMSHAFTS” section in the
CHAPTER 4.

3 - 22

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

INTAKE

INSP

ADJ

MEASURED

CLEARANCE

0.00 ~ 0.04 120 125 130 135 140 145 150 155

0.05 ~ 0.09

0.10 ~ 0.15

0.16 ~ 0.20 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.21 ~ 0.25 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.26 ~ 0.30 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.31 ~ 0.35 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.36 ~ 0.40 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.41 ~ 0.45 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.46 ~ 0.50 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.51 ~ 0.55 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.56 ~ 0.60 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.61 ~ 0.65 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.66 ~ 0.70 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.71 ~ 0.75 180 185 190 195 200 205 210 215 220 225 230 235 240

0.76 ~ 0.80 185 190 195 200 205 210 215 220 225 230 235 240

0.81 ~ 0.85 190 195 200 205 210 215 220 225 230 235 240

0.86 ~ 0.90 195 200 205 210 215 220 225 230 235 240

0.91 ~ 0.95 200 205 210 215 220 225 230 235 240

0.96 ~ 1.00 205 210 215 220 225 230 235 240

1.01 ~ 1.05 210 215 220 225 230 235 240

1.06 ~ 1.10 215 220 225 230 235 240

1.11 ~ 1.15 220 225 230 235 240

1.16 ~ 1.20 225 230 235 240

1.21 ~ 1.25 230 235 240

1.26 ~ 1.30 235 240

1.31 ~ 1.35 240

120 125 130 135 140 145 150 155 160 165 170

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235

INSTALLED PAD NUMBER

175 180 185 190 195 200 205 210 215 220 225 230 235 240

160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

STANDARD CLEARANCE

VALVE CLEARANCE (cold):

0.10 ~ 0.15 mm

Example: Installed is 175

Measured clearance is 0.22 mm

Replace 175 pad with 185 pad

Pad number: (example)
Pad No. 175 = 1.75 mm
Pad No. 185 = 1.85 mm

EXHAUST

MEASURED

CLEARANCE

0.00 ~ 0.04 120 125 130 135 140 145 150 155

0.05 ~ 0.09

0.10 ~ 0.16

0.17 ~ 0.22 STANDARD CLEARANCE

0.23 ~ 0.25 125 130 135 140 145 150 155 160 165 170 175

0.26 ~ 0.30 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.31 ~ 0.35 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.36 ~ 0.40 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.41 ~ 0.45 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.46 ~ 0.50 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.51 ~ 0.55 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.56 ~ 0.60 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.61 ~ 0.65 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.66 ~ 0.70 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.71 ~ 0.75 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.76 ~ 0.80 180 185 190 195 200 205 210 215 220 225 230 235 240

0.81 ~ 0.85 185 190 195 200 205 210 215 220 225 230 235 240

0.86 ~ 0.90 190 195 200 205 210 215 220 225 230 235 240

0.91 ~ 0.95 195 200 205 210 215 220 225 230 235 240

0.96 ~ 1.00 200 205 210 215 220 225 230 235 240

1.01 ~ 1.05 205 210 215 220 225 230 235 240

1.06 ~ 1.10 210 215 220 225 230 235 240

1.11 ~ 1.15 215 220 225 230 235 240

1.16 ~ 1.20 220 225 230 235 240

1.21 ~ 1.25 225 230 235 240

1.26 ~ 1.30 230 235 240

1.31 ~ 1.35 235 240

1.36 ~ 1.40 240

120 125 130 135 140 145 150 155 160 165 170

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235

INSTALLED PAD NUMBER

175 180 185 190 195 200 205 210 215 220 225 230 235 240
160 165 170 175 180 185 190 195 200 205 210 215 220 225

180 185 190 195 200 205 210 215 220 225 230 235 240

VALVE CLEARANCE (cold):

0.17 ~ 0.22 mm

Example: Installed is 175

Measured clearance is 0.27 mm

Replace 175 pad with 185 pad

Pad number: (example)
Pad No. 175 = 1.75 mm
Pad No. 185 = 1.85 mm

3 - 23

SPARK ARRESTER CLEANING (For USA)

SPARK ARRESTER CLEANING (For USA)

WARNING

• Be sure the exhaust pipe and muffler are
cool before cleaning the spark arrester.

• Do not start the engine when cleaning the
exhaust system.

INSP

ADJ

1

1

1

1. Remove:

• Bolt (spark arrester) 1

2. Remove:

• Spark arrester 1

Pull the spark arrester out of the muffler.

3. Clean:

• Spark arrester
Tap the spark arrester lightly, then use a
wire brush to remove any carbon depos­its.

4. Install:

• Spark arrester
Insert the spark arrester into the muffler
and align the bolt holes.

• Bolt (spark arrester)

T

10 Nm (1.0 m · kg, 7.2 ft · lb)

.

R

.

3 - 24

È

CHASSIS/BRAKE SYSTEM AIR BLEEDING

EC360000

CHASSIS

EC361012

BRAKE SYSTEM AIR BLEEDING

WARNING

Bleed the brake system if:

• The system has been disassembled.

• A brake hose has been loosened or

removed.

• The brake fluid is very low.

• The brake operation is faulty.

A dangerous loss of braking performance
may occur if the brake system is not prop­erly bled.

1. Remove:

• Brake master cylinder cap

• Diaphragm

• Protector (rear brake)

2. Bleed:

• Brake fluid

Front

È

Rear

É

INSP

ADJ

É

Air bleeding steps:

a. Add 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 tube 2 tightly to

the caliper bleed screw 1.

d. Place the other end of the tube into a con-

tainer.

e. Slowly apply the brake lever or pedal sev-

eral times.

f. Pull the lever in or push down on the

pedal. Hold the lever or pedal in position.

g. Loosen the bleed screw and allow the

lever or pedal to travel towards its limit.

h. Tighten the bleed screw when the lever or

pedal limit has been reached; then
release the lever or pedal.

Bleed screw:

T

.

6 Nm (0.6 m • kg, 4.3 ft • lb)

R

.

3 - 25

i. Repeat steps (e) to (h) until of the air bub-

bles have been removed from the system.

FRONT BRAKE ADJUSTMENT

OTE:

If bleeding is difficult, it may be necessary to
let the brake fluid system stabilize for a few
hours. Repeat the bleeding procedure when
the tiny bubbles in the system have disap­peared.

j. Add brake fluid to the level line on the res-

ervoir.

WARNING

Check the operation of the brake after
bleeding the brake system.

3. Install:

• Protector (rear brake)

• Diaphragm

• Brake master cylinder cap

INSP

ADJ

EC362040

FRONT BRAKE ADJUSTMENT

1. Check:

• Brake lever position a

Brake lever position a:

Standard position Extent of adjustment

95 mm (3.74 in)

76 ~ 97 mm

(2.99 ~ 3.82 in)

2. Remove:

• Brake lever cover

3. Adjust:

• Brake lever position

Brake lever position adjustment steps:

• Loosen the locknut 1.

• Turn the adjusting bolt 2 until the lever

position a is within specified position.

• Tighten the locknut.

3 - 26

Locknut:

T

.

5 Nm (0.5 m • kg, 3.6 ft • lb)

R

.

CAUTION:

Be sure to tighten the locknut, as it will
cause poor brake performance.

4. Install:

• Brake lever cover

REAR BRAKE ADJUSTMENT/

FRONT BRAKE PAD INSPECTION AND REPLACEMENT

EC364002

REAR BRAKE ADJUSTMENT

1. Check:

• Brake pedal height a
Out of specification → Adjust.

Brake pedal height a:

5 mm (0.20 in)

2. Adjust:

• Brake pedal height

Pedal height adjustment steps:

• Loosen the locknut 1.

• Turn the adjusting nut 2 until the pedal

height a is within specified height.

• Tighten the locknut.

INSP

ADJ

È

É

WARNING

• Adjust the pedal height between the
maximum È and the minimum É as
shown. (In this adjustment, the bolt
end b should protrude out of the
threaded portion 4 but not be less than
2 mm (0.08 in) c away from the brake
pedal 5).

• After the pedal height adjustment, make
sure that the rear brake does not drag.

FRONT BRAKE PAD INSPECTION AND
REPLACEMENT

1. Inspect:

• Brake pad thickness a

Out of specification → Replace as a set.

Brake pad thickness:

4.4 mm (0.17 in)
<Limit>: 1.0 mm (0.04 in)

3

3 - 27

2. Replace:

• Brake pad

Brake pad replacement steps:

• Remove the pad pin plug 1.

FRONT BRAKE PAD INSPECTION AND REPLACEMENT

• Loosen the pad pin 2.

• Remove the brake hose holder 3 and

brake caliper 4 from the front fork.

• Remove the pad pin and brake pads 5.

• Connect the transparent hose 6 to the

bleed screw 7 and place the suitable con­tainer under its end.

• Loosen the bleed screw and push the
brake caliper piston in.

CAUTION:

Do not reuse the drained brake fluid.

• Tighten the bleed screw.

Bleed screw:

T

.

6 Nm (0.6 m • kg, 4.3 ft • lb)

R

.

• Install the brake pads 8 and pad pin.

INSP

ADJ

OTE:

• Install the brake pads with their projections

a into the brake caliper recesses b.

• Temporarily tighten the pad pin at this
point.

• Install the brake hose holder 9 and brake
caliper 0 and tighten the pad pin A.

OTE:

Fit the brake hose holder cut c over the
projection d on the front fork and clamp the
brake hose.

Bolt (brake caliper):

T

23 Nm (2.3 m • kg, 17 ft • lb)

.

R

.

Pad pin:

18 Nm (1.8 m • kg, 13 ft • lb)

3 - 28

REAR BRAKE PAD INSPECTION AND REPLACEMENT

• Install the pad pin plug B.

Pad pin plug:

T

.

3 Nm (0.3 m • kg, 2.2 ft • lb)

R

.

3. Inspect:

• Brake fluid level
Refer to “BRAKE FLUID LEVEL INSPEC-
TION” section.

4. Check:

• Brake lever operation
A softy or spongy feeling → Bleed brake
system.
Refer to “BRAKE SYSTEM AIR BLEED­ING” section.

INSP

ADJ

REAR BRAKE PAD INSPECTION AND
REPLACEMENT

1. Inspect:

• Brake pad thickness a
Out of specification → Replace as a set.

Brake pad thickness:

6.4 mm (0.25 in)
<Limit>: 1.0 mm (0.04 in)

2. Replace:

• Brake pad

Brake pad replacement steps:

• Remove the protector 1 and pad pin plug

2.

• Loosen the pad pin 3.

• Remove the rear wheel 4 and brake cali-

per 5.
Refer to “FRONT WHEEL AND REAR
WHEEL” section in the CHAPTER 5.

3 - 29

REAR BRAKE PAD INSPECTION AND REPLACEMENT

• Remove the pad pin 6 and brake pads 7.

• Connect the transparent hose 8 to the

bleed screw 9 and place the suitable con­tainer under its end.

• Loosen the bleed screw and push the
brake caliper piston in.

CAUTION:

Do not reuse the drained brake fluid.

• Tighten the bleed screw.

Bleed screw:

T

.

6 Nm (0.6 m • kg, 4.3 ft • lb)

R

.

• Install the brake pad 0 and pad pin A.

OTE:

• Install the brake pads with their projections

a into the brake caliper recesses b.

• Temporarily tighten the pad pin at this
point.

INSP

ADJ

• Install the brake caliper B and rear wheel
C.

Refer to “FRONT WHEEL AND REAR
WHEEL” section in the CHAPTER 5.

• Tighten the pad pin D.

Pad pin:

T

.

18 Nm (1.8 m • kg, 13 ft • lb)

R

.

• Install the pad pin plug E and protector F.

Pad pin plug:

T

3 Nm (0.3 m • kg, 2.2 ft • lb)

.

R

.

Bolt (protector):

7 Nm (0.7 m • kg, 5.1 ft • lb)

3 - 30

REAR BRAKE PAD INSULATOR INSPECTION/

BRAKE FLUID LEVEL INSPECTION

3. Inspect:

• Brake fluid level
Refer to “BRAKE FLUID LEVEL INSPEC-
TION” section.

4. Check:

• Brake pedal operation
A softy or spongy feeling → Bleed brake
system.
Refer to “BRAKE SYSTEM AIR BLEED­ING” section.

EC36b000

REAR BRAKE PAD INSULATOR
INSPECTION

1. Remove:

• Brake pad
Refer to “REAR BRAKE PAD INSPEC­TION AND REPLACEMENT” section.

2. Inspect:

• Rear brake pad insulator 1
Damage → Replace.

INSP

ADJ

ÈÉ

BRAKE FLUID LEVEL INSPECTION

1. Place the brake master cylinder so that its
top is in a horizontal position.

2. Inspect:

• Brake fluid level

Fluid at lower level → Fill up.

Lower level

a

Front

È

Rear

É

Recommended brake fluid:

DOT #4

WARNING

• Use only designated quality brake fluid to

avoid poor brake performance.

• Refill with same type and brand of brake

fluid; mixing fluids could result in poor
brake performance.

• Be sure that water or other contaminants

do not enter master cylinder when refill­ing.

• Clean up spilled fluid immediately to

avoid erosion of painted surfaces or plas­tic parts.

3 - 31

SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION

SPROCKETS INSPECTION

1. Inspect:

• Sprocket teeth a

Excessive wear → Replace.

OTE:

Replace the drive sprocket, rear wheel
sprocket and drive chain as a set.

DRIVE CHAIN INSPECTION

1. Remove:

• Drive chain 1

OTE:

Remove the drive chain using a drive chain
cutter 2.

2. Clean:

• Drive chain

Brush off as much dirt as possible. Then
clean the drive chain using the chain
cleaner.

1

CAUTION:

This machine has a drive chain with small
rubber O-rings 1 between the side plates.
Steam cleaning, high-pressure washes,
certain solvent and kerosene can damage
these O-rings.

INSP

ADJ

3 - 32

3. Inspect:

• O-ring 1 (drive chain)

Damage → Replace the drive chain.

• Roller 2

• Side plate 3

Damage/wear → Replace the drive
chain.

4. Measure:

• Drive chain length (10 links) a

Out of specification → Replace.

Drive chain length (10 links):

<Limit>: 150.1 mm (5.91 in)

DRIVE CHAIN INSPECTION

5. Check:

• Drive chain stiffness a

Clean and oil the drive chain and hold as
illustrated.
Stiff → Replace the drive chain.

6. Install:

• Chain joint 1

• O-ring 2

• Drive chain 3

OTE:

When installing the drive chain, apply the lith­ium soap base grease on the chain joint and
O-rings.

New

INSP

ADJ

7. Install:

• Link plate 4

OTE:

• Press the link plate onto the chain joint using

a drive chain riveter 5.

• Rivet the end of the chain joint using a drive

chain riveter.

• After riveting the chain joint, make sure its

movement is smooth.

8. Lubricate:

• Drive chain

Drive chain lubricant:

SAE 10W-30 motor oil or
suitable chain lubricants

New

3 - 33

DRIVE CHAIN SLACK ADJUSTMENT

DRIVE CHAIN SLACK ADJUSTMENT

1. Elevate the rear wheel by placing the suit­able stand under the engine.

2. Check:

• Drive chain slack a

Above the seal guard installation bolt.
Out of specification → Adjust.

Drive chain slack:

40 ~ 50 mm (1.6 ~ 2.0 in)

OTE:

Before checking and/or adjusting, rotate the
rear wheel through several revolutions and
check the slack several times to find the tight­est point. Check and/or adjust the drive chain
slack with the rear wheel in this “tight chain”
position.

INSP

ADJ

3. Adjust:

• Drive chain slack

Drive chain slack adjustment steps:

• Loosen the axle nut 1 and locknuts 2.

• Adjust the drive chain slack by turning the

adjusters 3.

To tighten → Turn the adjuster 3 coun-

terclockwise.

To loosen → Turn the adjuster 3 clock-

wise and push wheel forward.

• Turn each adjuster exactly the same
amount to maintain correct axle alignment.
(There are marks a on each side of the
drive chain puller alignment.)

OTE:

Turn the adjuster so that the drive chain is in
line with the sprocket, as viewed from the
rear.

3 - 34

CAUTION:

Too small drive chain slack will overload
the engine and other vital parts; keep the
slack within the specified limits.

FRONT FORK INSPECTION/

FRONT FORK OIL SEAL AND DUST SEAL CLEANING

• Tighten the axle nut while pushing down
the drive chain.

Axle nut:

T

.

125 Nm (12.5 m • kg, 90 ft • lb)

R

.

• Tighten the locknuts.

Locknut:

T

.

16 Nm (1.6 m • kg, 11 ft • lb)

R

.

INSP

ADJ

EC36C000

FRONT FORK INSPECTION

1. Inspect:

• Front fork smooth action
Operate the front brake and stroke the
front fork.
Unsmooth action/oil leakage → Repair or
replace.

EC36D001

FRONT FORK OIL SEAL AND DUST SEAL
CLEANING

1. Remove:

• Protector

• Dust seal 1

OTE:

Use a thin screw driver, and be careful not to
damage the inner fork tube and dust seal.

2. Clean:

• Dust seal a

• Oil seal b

OTE:

• Clean the dust seal and oil seal after every
run.

• Apply the lithium soap base grease on the
inner tube.

3 - 35