3C5-28197-10
XT250X
XT250XC
SERVICE MANUAL
LIT-11616-21-52
2008
EAS20050
©2008 by Yamaha Motor Corporation, U.S.A.
Any reproduction or unauthorized use
XT250X
XT250XC
SERVICE MANUAL
First edition, August 2007
All rights reserved.
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-21-52
EAS20070
● This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
● Designs and specifications are subject to change without notice.
EAS20080
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could result in se
vere injury or death to the
vehicle operator, a bystander or a person checking or repairing the vehicle.
A CAUTION indicates special precautions that must be taken to avoid damage to the
vehicle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
NOTE:
EAS20090
7
2
CLUTCH
5-31
Removing the clutch
Order Job/Parts to remove Q’ty Remarks
1 Clutch spring 5
2 Pressure plate 1
3 Adjusting screw 1
4 Push plate 1
5 Friction plate 6
6 Clutch plate 5
7 Clutch damper spring 1
8 Clutch damper spring seat 1
9 Primary drive gear nut 1
10 Lock washer 1
11 Claw washer 1
12 Clutch boss nut 1
13 Lock washer 1
14 Clutch boss 1
15 Thrust washer 1
16 Clutch housing 1
17 Ball 1
18 Clutch push rod 1
19 Primary drive gear 1
For installation, reverse the removal procedure.
New
New
E
T
R
.
.
8 Nm (0.8 m • kg, 5.8 ft •Ib)
T
R
.
.
75 Nm (7.5 m • kg, 54 ft •Ib)
T
R
.
.
80 Nm (8.0 m • kg, 58 ft •Ib)
1
2
5
6
7
8
12
13
15
16
17
9
10
11
19
18
14
3
4
(5)
3
4
5
6
1
CLUTCH
5-33
EAS25070
REMOVING THE CLUTCH
1. Straighten the lock washer tab.
2. Loosen:
Primary drive gear nut “1”
NOTE:
Insert aluminum plate “a” between primary drive
gear “2” and primary driven gear “3”, and loosen
the primary drive gear nut.
3. Loosen:
Clutch boss nut “1”
NOTE:
While holding the clutch boss “1” with the universal clutch holder “2”, loosen the clutch boss nut.
EAS25100
CHECKING THE FRICTION PLATES
The following procedure applies to all of the friction plates.
1. Check:
Friction plate
Damage/wear Replace the friction plates
as a set.
2. Measure:
Friction plate thickness
Out of specification Replace the friction
plates as a set.
NOTE:
Measure the friction plate at four places.
EAS25110
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the
clutch plates.
1. Check:
Clutch plate
Damage Replace the clutch plates as a
set.
2. Measure:
Clutch plate warpage
(with a surface plate and thickness gauge “1”)
Out of specification Replace the clutch
plates as a set.
EAS25140
CHECKING THE CLUTCH SPRINGS
The following procedure applies to all of the
clutch springs.
1. Check:
Clutch spring
Damage Replace the clutch springs as a
set.
2. Measure:
Universal clutch holder
90890-04086
YM-91042
2
1
3
Friction plate thickness
2.70—2.90 mm (0.106—0.114 in)
Wear limit
2.60 mm (0.1024 in)
Warpage limit
0.20 mm (0.0079 in)
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
● The manual is divided into chapters and each chapter is divided into sections. The current section title
is shown at the top of each page “1”.
Sub-section titles appear in smaller print than the section title “2”.
●
● To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section “3”.
● Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassem-
bly step “4”.
● Symbols indicate parts to be lubricated or replaced “5”.
Refer to “SYMBOLS”.
● A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc “6”.
● Jobs requiring more information (such as special tools and technical data) are described sequentially
“7”.
EAS20100
The following symbols are not relevant to every
vehicle.
G
M
E
B
LS
M
9 10
11 12
13 14
15 16
17 18
LT
New
BF
S
T
R
.
.
1 2 3
4 5 6
7 8
1. Serviceable with engine mounted
2. Filling fluid
3. Lubricant
4. Special tool
5. Tightening torque
6. Wear limit, clearance
7. Engine speed
8. Electrical data
9. Engine oil
10. Gear oil
11. Molybdenum-disulfide oil
12. Brake fluid
13. Wheel-bearing grease
14. Lithium-soap-based grease
15. Molybdenum-disulfide grease
16. Silicone grease
17. Apply locking agent (LOCTITE®)
18. Replace the part
SYMBOLS
The following symbols are used in this manual
for easier understanding.
NOTE:
EAS20110
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
1
2
3
4
5
FUEL SYSTEM
ELECTRICAL SYSTEM
TROUBLESHOOTING
6
7
8
GENERAL INFORMATION
IDENTIFICATION ...........................................................................................1-1
VEHICLE IDENTIFICATION NUMBER....................................................1-1
MODEL LABEL ........................................................................................1-1
IMPORTANT INFORMATION ........................................................................1-2
PREPARATION FOR REMOVAL AND DISASSEMBLY .........................1-2
REPLACEMENT PARTS .........................................................................1-2
GASKETS, OIL SEALS AND O-RINGS ...................................................1-2
LOCK WASHERS/PLATES AND COTTER PINS....................................1-2
BEARINGS AND OIL SEALS...................................................................1-2
CIRCLIPS.................................................................................................1-3
CHECKING THE CONNECTIONS.................................................................1-4
1
2
SPECIAL TOOLS...........................................................................................1-5
3
4
5
6
7
8
9
EAS20130
1
1
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped
into the right side of the steering head pipe.
EAS20150
MODEL LABEL
The model label “1” is affixed to the frame. This
information will be needed to order spare parts.
IDENTIFICATION
1-1
EAS20180
IMPORTANT INFORMATION
EAS20190
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning equipment.
Refer to “SPECIAL TOOLS” on page 1-5.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders, pistons and other parts that have been
“mated” through normal wear. Mated parts
must always be reused or replaced as an assembly.
IMPORTANT INFORMATION
EAS20210
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
EAS20220
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
“1” and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat of the bolt or nut.
4. During disassembly, clean all of the parts and
place them in trays in the order of disassembly. This will speed up assembly and allow for
the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS20200
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
EAS20230
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When
installing oil seals “1”, lubricate the oil seal lips
with a light coat of lithium-soap-based grease.
Oil bearings liberally when installing, if appropriate.
1-2
ECA13300
Do not spin the bearing with compressed air
because this will damage the bearing surfaces.
EAS20240
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Always replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.
CAUTION:
IMPORTANT INFORMATION
1-3
EAS20250
If the pin “1” on the terminal is flattened, bend it
up.
4. Connect:
● Lead
●
Coupler
● Connector
NOTE:
Make sure all connections are tight.
5. Check:
● Continuity
(with the pocket tester)
NOTE:
● If there is no continuity, clean the terminals.
● When checking the wire harness, perform
steps (1) to (3).
● As a quick remedy, use a contact revitalizer
available at most part stores.
Pocket tester
90890-03132
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
● Lead
● Coupler
Connector
●
2. Check:
● Lead
● Coupler
● Connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect several times.
CHECKING THE CONNECTIONS
3. Check:
● All connections
Loose connection → Connect properly.
NOTE:
1-4
SPECIAL TOOLS
For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
For others, use part number starting with “90890-”.
Tool name/Tool No. Illustration
Reference
pages
Pocket tester
90890-03132
1-4
,
3-7,3-8
,
5-52,7-35
,
7-36,7-37
,
7-40,7-41
,
7-42,7-43
,
7-44
, 7-45, 7-47
Special thickness gauge
90890-01399
3-5
Tappet adjusting tool
90890-01311
Six piece tappet set
YM-A5970
3-6
Digital tachometer
90890-06760
YU-39951-B
3-7, 3-8, 3-11
Timing light
90890-03141
Inductive clamp timing light
YU-03141
3-11
Compression gauge
90890-03081
Engine compression tester
YU-33223
3-12
EAS20260
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
NOTE:
1-5
SPECIAL TOOLS
YM-A9409-7/YM-A5142-4
Tool name/Tool No. Illustration
Steering nut wrench
90890-01403
Spanner wrench
YU-33975
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
Spoke wrench
90890-01522
Cylinder cup installer
90890-01996
Reference
pages
3-23
3-24, 4-49
3-27
4-22, 4-33
Damper rod holder
90890-01460
T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
Fork seal driver weight
90890-01367
Replacement hammer
YM-A9409-7
4-42, 4-44
4-44
4-44, 4-45
1-6
SPECIAL TOOLS
YU-01083-3
Tool name/Tool No. Illustration
Fork seal driver attachment (ø35)
90890-01369
Replacement 35 mm
YM-A9409-5
Slide hammer bolt
90890-01083
Slide hammer bolt 6 mm
YU-01083-1
Weight
90890-01084
YU-01083-3
Reference
pages
4-44
5-14
5-14
Valve spring compressor
90890-04019
YM-04019
Valve guide remover (ø6)
90890-04064
Valve guide remover (6.0 mm)
YM-04064-A
Valve guide installer (ø6)
90890-04065
Valve guide installer (6.0 mm)
YM-04065-A
Valve guide reamer (ø6)
90890-04066
Valve guide reamer (6.0 mm)
YM-04066
5-18, 5-23
5-20
5-20
5-20
1-7
SPECIAL TOOLS
Tool name/Tool No. Illustration
Universal clutch holder
90890-04086
YM-91042
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
Flywheel puller
90890-01362
Heavy duty puller
YU-33270-B
Reference
pages
5-33, 5-35
5-47, 5-48
5-47
Yamaha bond No. 1215 (Three Bond
No.1215®)
90890-85505
Crankcase separating tool
90890-01135
Crankcase separator
YU-01135-B
5-56
5-59
1-8
SPECIAL TOOLS
YU-90058/YU-90059
Tool name/Tool No. Illustration
Crankshaft installer pot
90890-01274
Installing pot
YU-90058
Crankshaft installer bolt
90890-01275
Bolt
YU-90060
Adapter (M10)
90890-01383
Adapter #2
YU-90062
Reference
pages
5-60
5-60
5-60
Spacer
90890-01288
Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-34487
Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927
5-60
7-43
7-46
1-9
SPECIFICATIONS
GENERAL SPECIFICATIONS .......................................................................2-1
ENGINE SPECIFICATIONS...........................................................................2-2
CHASSIS SPECIFICATIONS.........................................................................2-9
ELECTRICAL SPECIFICATIONS..................................................................2-11
TIGHTENING TORQUES...............................................................................2-13
GENERAL TIGHTENING TORQUE SPECIFICATIONS..........................2-13
ENGINE TIGHTENING TORQUES..........................................................2-13
CHASSIS TIGHTENING TORQUES........................................................2-15
LUBRICATION POINTS AND LUBRICANT TYPES .....................................2-18
ENGINE....................................................................................................2-18
CHASSIS..................................................................................................2-19
LUBRICATION SYSTEM CHART AND DIAGRAMS ....................................2-21
ENGINE OIL LUBRICATION CHART ......................................................2-21
LUBRICATION DIAGRAMS .....................................................................2-23
CABLE ROUTING..........................................................................................2-25
1
2
3
4
5
6
7
8
9
GENERAL SPECIFICATIONS
Model
Model 3C58 (U49)
3C59 (CAL)
Dimensions
Overall length 2150 mm (84.6 in)
Overall width 805 mm (31.7 in)
Overall height 1160 mm (45.7 in)
Seat height 810 mm (31.9 in)
Wheelbase 1360 mm (53.5 in)
Ground clearance 285 mm (11.22 in)
Minimum turning radius 1900 mm (74.8 in)
Weight
With oil and fuel 132.0 kg (291 lb)
Maximum load 160.0 kg (353 lb)
EAS20280
GENERAL SPECIFICATIONS
2-1
ENGINE SPECIFICATIONS
Engine
Engine type Air cooled 4-stroke, SOHC
Displacement 249.0 cm
3
Cylinder arrangement Forward-inclined single cylinder
Bore × stroke 74.0 × 58.0 mm (2.91 × 2.28 in)
Compression ratio 9.50 :1
Starting system Electric starter
Fuel
Recommended fuel Unleaded gasoline only
Fuel tank capacity 9.1 L (2.40 US gal) (2.00 Imp.gal) (CAL)
9.8 L (2.59 US gal) (2.16 Imp.gal) (U49)
Fuel reserve amount 1.9 L (0.50 US gal) (0.42 Imp.gal)
Engine oil
Lubrication system Wet sump
Type YAMALUBE 4, SAE10W30 or SAE20W40
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Engine oil quantity
Total amount 1.40 L (1.48 US qt) (1.23 Imp.qt)
Without oil filter element replacement 1.20 L (1.27 US qt) (1.06 Imp.qt)
With oil filter element replacement 1.30 L (1.37 US qt) (1.14 Imp.qt)
Oil filter type Paper
Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance 0.150 mm (0.0059 in)
Limit 0.200 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.100–0.151 mm (0.0039–0.0059 in)
Limit 0.221 mm (0.0087 in)
Oil-pump-housing-to-inner-and-outer-rotor clearance
0.04–0.09 mm (0.0016–0.0035 in)
Limit 0.16 mm (0.0063 in)
Pressure check location HEAD CYLINDER
Spark plug (s)
Manufacturer/model NGK/DR7EA
Spark plug gap 0.6–0.7 mm (0.024–0.028 in)
Cylinder head
Volume 20.50–21.50 cm3 (1.25–1.31 cu.in)
Warpage limit 0.03 mm (0.0012 in)
Camshaft
Drive system Chain drive (right)
Camshaft journal diameter 25.021–25.039 mm (0.9851–0.9858 in)
EAS20290
ENGINE SPECIFICATIONS
2-2
ENGINE SPECIFICATIONS
Timing chain
Model/number of links DID SCR-0404 SV/104
Tensioning system Automatic
Rocker arm/rocker arm shaft
Rocker arm inside diameter 12.000–12.018 mm (0.4724–0.4731 in)
Limit 12.036 mm (0.4739 in)
Rocker arm shaft outside diameter 11.981–11.991 mm (0.4717–0.4721 in)
Limit 11.950 mm (0.4705 in)
Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.037 mm (0.0004–0.0015 in)
Valve, valve seat, valve guide
Valve clearance (cold)
Intake 0.05–0.10 mm (0.0020–0.0039 in)
Exhaust 0.10–0.15 mm (0.0039–0.0059 in)
Valve dimensions
Valve head diameter A (intake) 33.90–34.10 mm (1.3346–1.3425 in)
Valve head diameter A (exhaust) 28.40–28.60 mm (1.1181–1.1260 in)
Valve face width B (intake) 2.260 mm (0.0890 in)
Valve face width B (exhaust) 2.260 mm (0.0890 in)
Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in)
Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)
A
B
A
B
Camshaft lobe dimensions
Intake A 36.520–36.620 mm (1.4378–1.4417 in)
Limit 36.460 mm (1.4354 in)
Intake B 30.201–30.301 mm (1.1890–1.1930 in)
Limit 30.151 mm (1.1870 in)
Exhaust A 36.564–36.664 mm (1.4395–1.4435 in)
Limit 36.514 mm (1.4376 in)
Exhaust B 30.216–30.316 mm (1.1896–1.1935 in)
Limit 30.166 mm (1.1876 in)
Camshaft runout limit 0.030 mm (0.0012 in)
2-3
ENGINE SPECIFICATIONS
Valve spring
Inner spring
Free length (intake) 36.17 mm (1.42 in)
Limit 34.47 mm (1.36 in)
Free length (exhaust) 36.17 mm (1.42 in)
Limit 34.47 mm (1.36 in)
Installed length (intake) 30.50 mm (1.20 in)
Installed length (exhaust) 30.50 mm (1.20 in)
Spring rate K1 (intake) 14.70 N/mm (83.94 lb/in) (1.50 kgf/mm)
Spring rate K2 (intake) 19.00 N/mm (108.49 lb/in) (1.94 kgf/mm)
Spring rate K1 (exhaust) 14.70 N/mm (83.94 lb/in) (1.50 kgf/mm)
Spring rate K2 (exhaust) 19.00 N/mm (108.49 lb/in) (1.94 kgf/mm)
Installed compression spring force (intake)
75.00–91.70 N (16.86–20.61 lbf) (7.65–9.35 kgf)
Installed compression spring force (exhaust)
75.00–91.70 N (16.86–20.61 lbf) (7.65–9.35 kgf)
Spring tilt (intake) 2.5 °/1.6 mm
Spring tilt (exhaust) 2.5 °/1.6 mm
C
D
Valve margin thickness D (intake) 0.80–1.20 mm (0.0315–0.0472 in)
Valve margin thickness D (exhaust) 0.80–1.20 mm (0.0315–0.0472 in)
Valve stem diameter (intake) 5.975–5.990 mm (0.2352–0.2358 in)
Limit 5.950 mm (0.2343 in)
Valve stem diameter (exhaust) 5.960–5.975 mm (0.2346–0.2352 in)
Limit 5.935 mm (0.2337 in)
Valve guide inside diameter (intake) 6.000–6.012 mm (0.2362–0.2367 in)
Limit 6.042 mm (0.2379 in)
Valve guide inside diameter (exhaust) 6.000–6.012 mm (0.2362–0.2367 in)
Limit 6.042 mm (0.2379 in)
Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.030 mm (0.0012 in)
Cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in)
Limit 1.7 mm (0.07 in)
Cylinder head valve seat width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)
Limit 1.7 mm (0.07 in)
2-4
ENGINE SPECIFICATIONS
Cylinder
Bore 74.000–74.016 mm (2.9134–2.9140 in)
Wear limit 74.100 mm (2.9173 in)
Taper limit 0.050 mm (0.0020 in)
Out of round limit 0.010 mm (0.0004 in)
Warp limit 0.10 mm (0.0039 in)
Piston
Piston-to-cylinder clearance 0.010–0.025 mm (0.0004–0.0010 in)
Limit 0.15 mm (0.0059 in)
Diameter D 73.983–73.998 mm (2.9127–2.9133 in)
Height H 11.0 mm (0.43 in)
Winding direction (intake) Counter clockwise
Winding direction (exhaust) Counter clockwise
Outer spring
Free length (intake) 36.63 mm (1.44 in)
Limit 34.63 mm (1.36 in)
Free length (exhaust) 36.63 mm (1.44 in)
Limit 34.63 mm (1.36 in)
Installed length (intake) 32.00 mm (1.26 in)
Installed length (exhaust) 32.00 mm (1.26 in)
Spring rate K1 (intake) 30.90 N/mm (176.44 lb/in) (3.15 kgf/mm)
Spring rate K2 (intake) 40.80 N/mm (232.97 lb/in) (4.16 kgf/mm)
Spring rate K1 (exhaust) 30.90 N/mm (176.44 lb/in) (3.15 kgf/mm)
Spring rate K2 (exhaust) 40.80 N/mm (232.97 lb/in) (4.16 kgf/mm)
Installed compression spring force (intake) 128.50–157.90 N (28.89–35.50 lbf)
(13.10–16.10 kgf)
Installed compression spring force (exhaust) 128.50–157.90 N (28.89–35.50 lbf)
(13.10–16.10 kgf)
Spring tilt (intake) 2.5 °/1.6 mm
Spring tilt (exhaust) 2.5 °/1.6 mm
Winding direction (intake) Clockwise
Winding direction (exhaust) Clockwise
2-5
ENGINE SPECIFICATIONS
Piston ring
Top ring
Ring type Barrel
Dimensions (B × T) 0.90
× 2.75 mm (0.04 × 0.11 in)
End gap (installed) 0.19–0.31 mm (0.0075–0.0122 in)
Limit 0.56 mm (0.0220 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Limit 0.115 mm (0.0045 in)
2nd ring
Ring type Taper
Dimensions (B × T) 0.80 × 2.80 mm (0.03 × 0.11 in)
End gap (installed) 0.30–0.45 mm (0.0118–0.0177 in)
Limit 0.80 mm (0.0314 in)
Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in)
Limit 0.115 mm (0.0045 in)
Oil ring
Dimensions (B × T) 1.50 × 2.60 mm (0.06 × 0.10 in)
End gap (installed) 0.10–0.35 mm (0.0039–0.0138 in)
H
D
T
B
B
T
B
T
Offset 0.50 mm (0.0197 in)
Offset direction Intake side
Piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in)
Limit 16.043 mm (0.6316 in)
Piston pin outside diameter 15.991–16.000 mm (0.6296–0.6299 in)
Limit 15.971 mm (0.6288 in)
Piston-pin-to-piston-pin-bore clearance 0.002–0.022 mm (0.0001–0.0009 in)
2-6
ENGINE SPECIFICATIONS
Crankshaft
Width A 69.25–69.30 mm (2.726–2.728 in)
Runout limit C 0.030 mm (0.0012 in)
Big end side clearance D 0.350–0.850 mm (0.0138–0.0335 in)
Balancer
Balancer drive method Gear
Clutch
Clutch type Wet, multiple-disc
Clutch release method Inner push, cam push
Clutch lever free play 10.0–15.0 mm (0.39–0.59 in)
Friction plate thickness 2.70–2.90 mm (0.106–0.114 in)
Wear limit 2.60 mm (0.1024 in)
Plate quantity 6 pcs
Clutch plate thickness 1.50–1.70 mm (0.059–0.067 in)
Plate quantity 5 pcs
Warpage limit 0.20 mm (0.0079 in)
Clutch spring free length 40.10 mm (1.58 in)
Limit 38.10 mm (1.50 in)
Spring quantity 5 pcs
Clutch housing thrust clearance 0.100–0.350 mm (0.0039–0.0138 in)
Clutch housing radial clearance 0.010–0.044 mm (0.0004–0.0017 in)
Push rod bending limit 0.500 mm (0.0197 in)
Transmission
Transmission type Constant mesh 5-speed
Primary reduction system Spur gear
Primary reduction ratio 74/24 (3.083)
Secondary reduction system Chain drive
Secondary reduction ratio 48/15 (3.200)
Operation Left foot operation
Gear ratio
1st 37/13 (2.846)
2nd 29/16 (1.812)
3rd 29/22 (1.318)
4th 29/28 (1.035)
5th 23/28 (0.821)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Main axle assembly width 102.20–102.40 mm (4.02–4.03 in)
Shifting mechanism
Shift mechanism type Shift drum and guide bar
Shift fork thickness 4.76–4.89 mm (0.1874–0.1925 in)
C
C
D
A
2-7
ENGINE SPECIFICATIONS
Air filter
Air filter element Oil-coated paper element
Carburetor
Type × quantity MV33 x 1
Manufacturer TEIKEI
ID mark 3C58 00 (U49)
3C59 00 (CAL)
Main jet #135
Main air jet 1.20
Jet needle 5A21-1
Needle jet 2.585
Pilot air jet 1 0.90
Pilot outlet 0.8x1.2
Pilot jet #34
Bypass 1 0.8
Bypass 2 0.8
Bypass 3 0.8
Bypass 4 0.8
Pilot screw turn out 2–1/2
Valve seat size 0.50
Starter jet 1 #90
Starter jet 2 #78
Throttle valve size 33
Float height 11.9 mm (0.47 in)
Idling condition
Engine idling speed 1300–1500 r/min
CO% 0.5–1.5 %
Intake vacuum 29.0–37.0 kPa (8.6–10.9 inHg) (218–278 mm
-
Hg)
Oil temperature 95.0–105.0
°C (203.00–221.00 °F)
Throttle cable free play 3.0–5.0 mm (0.12–0.20 in)
2-8
CHASSIS SPECIFICATIONS
Chassis
Frame type Semi double cradle
Caster angle 26.42 °
Trail 106.0 mm (4.17 in)
Front wheel
Wheel type Spoke wheel
Rim size 21x1.60
Rim material Aluminum
Wheel travel 225.0 mm (8.86 in)
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Wheel axle bending limit 0.25 mm (0.01 in)
Rear wheel
Wheel type Spoke wheel
Rim size 18M/C x MT2.15
Rim material Aluminum
Wheel travel 180.0 mm (7.09 in)
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Wheel axle bending limit 0.25 mm (0.01 in)
Front tire
Type With tube
Size 2.75-21 45P
Manufacturer/model CHENG SHIN/C-6006
Manufacturer/model DUNLOP/D605F
Wear limit (front) 0.8 mm (0.03 in)
Rear tire
Type With tube
Size 120/80-18M/C 62P
Manufacturer/model CHENG SHIN/C-6006
Manufacturer/model DUNLOP/D605
Wear limit (rear) 0.8 mm (0.03 in)
Tire air pressure (measured on cold tires)
Loading condition 0–90 kg (0–198 lb)
Front 125 kPa (18 psi) (1.25 kgf/cm2)
Rear 150 kPa (22 psi) (1.50 kgf/cm2)
Loading condition 90 kg–Maximum load
Front 150 kPa (22 psi) (1.50 kgf/cm
2
)
Rear 175 kPa (25 psi) (1.75 kgf/cm2)
Front brake
Type Single disc brake
Operation Right hand operation
Front brake lever free play 2.0–5.0 mm (0.08–0.20 in)
Front disc brake
Disc outside diameter × thickness 245.0 × 3.5 mm (9.65 × 0.14 in)
Brake disc thickness limit 3.0 mm (0.12 in)
EAS20300
CHASSIS SPECIFICATIONS
2-9
CHASSIS SPECIFICATIONS
Rear brake
Type Single disc brake
Operation Right foot operation
Brake pedal position 20.0 mm (0.79 in)
Rear disc brake
Disc outside diameter × thickness 203.0 × 4.5 mm (7.99 × 0.18 in)
Brake disc thickness limit 4.0 mm (0.16 in)
Brake disc deflection limit 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 5.2 mm (0.20 in)
Limit 1.0 mm (0.04 in)
Brake pad lining thickness (outer) 5.2 mm (0.20 in)
Limit 1.0 mm (0.04 in)
Master cylinder inside diameter 12.7 mm (0.50 in)
Caliper cylinder inside diameter 30.23 mm (1.19 in)
Recommended fluid DOT 4
Steering
Steering bearing type Taper roller bearing
Center to lock angle (left) 51.0 °
Center to lock angle (right) 51.0 °
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 225.0 mm (8.86 in)
Fork spring free length 482.0 mm (18.98 in)
Limit 472.3 mm (18.59 in)
Installed length 472.2 mm (18.59 in)
Spring rate K1 3.65 N/mm (20.84 lb/in) (0.37 kgf/mm)
Spring stroke K1 0.0–225.0 mm (0.00–8.86 in)
Optional spring available No
Recommended oil Yamaha fork oil 15WT
Quantity 385.0 cm
3
(13.02 US oz) (13.58 Imp.oz)
Level 125.0 mm (4.92 in)
Swingarm
Swingarm end free play limit (radial) 1.0 mm (0.04 in)
Swingarm end free play limit (axial) 1.0 mm (0.04 in)
Drive chain
Type/manufacturer 428V/DAIDO
Link quantity 128
Drive chain slack 40.0–45.0 mm (1.57–1.77 in)
15-link length limit 191.5 mm (7.54 in)
Brake disc deflection limit 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 5.3 mm (0.21 in)
Limit 0.8 mm (0.03 in)
Brake pad lining thickness (outer) 5.3 mm (0.21 in)
Limit 0.8 mm (0.03 in)
Master cylinder inside diameter 11.00 mm (0.43 in)
Caliper cylinder inside diameter 26.99 mm (1.06 in)
Caliper cylinder inside diameter 22.22 mm (0.87 in)
Recommended fluid DOT 4
2-10
ELECTRICAL SPECIFICATIONS
Voltage
System voltage 12 V
Ignition system
Ignition system CDI
Advancer type Digital
Ignition timing (B.T.D.C.) 10.0 °/1400 r/min
CDI
Magneto model/manufacturer F5XT/YAMAHA
Pickup coil resistance 248–372 Ω (Red–white)
CDI unit model/manufacturer 3C5/YAMAHA
Ignition coil
Model/manufacturer 2JN/YAMAHA
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 0.18–0.28 Ω
Secondary coil resistance 6.32–9.48 kΩ
Spark plug cap
Material Resin
Resistance 10.0 kΩ
AC magneto
Model/manufacturer F5XT/YAMAHA
Standard output 14.0 V, 190 W@5000 r/min
Stator coil resistance 0.688–1.032
Ω (White–white)
Rectifier/regulator
Regulator type Semi conductor-short circuit
Model/manufacturer SH629A-12/SHINDENGEN
No load regulated voltage 14.1–14.9 V
Rectifier capacity 10.0 A
Withstand voltage 200.0 V
Battery
Model YTZ7S
Voltage, capacity 12 V, 6.0 Ah
Specific gravity 1.310
Manufacturer GS YUASA
Ten hour rate amperage 0.60 A
Headlight
Bulb type Halogen bulb
Bulb voltage, wattage × quantity
Headlight 12 V, 60 W/55.0 W × 1
Tail/brake light 12 V, 8.0 W/27.0 W × 1
Front turn signal/position light 12 V, 27 W/5.0 W × 2
Rear turn signal light 12 V, 27.0 W × 2
License plate light 12 V, 8.0 W × 1
Indicator light
Neutral indicator light LED
Turn signal indicator light LED
High beam indicator light LED
EAS20310
ELECTRICAL SPECIFICATIONS
2-11
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