Yamaha YZ250M Wartungshandbuch

OWNER’S SERVICE MANUALYZ250T11P8-28199-10LIT-11626-18-34PRINTED IN JAPAN2004.5—2.8 × 1 !(E)YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPANPRIN

EC083000MANUAL FORMATAll of the procedures in this manual are organized in a sequential, step-by-step format. The informa-tion has been complied to pr

4-11ENGCARBURETOR AND REED VALVEEC464401Jet needle1. Inspect:9Jet needle 1Bends/Wear → Replace.9Clip grooveFree play exists/Wear → Replace.9Clip posit

4-12ENGCARBURETOR AND REED VALVEEC465000ASSEMBLY AND INSTALLATIONEC465173Reed valve1. Install:9Reed valve 19Stopper (reed valve) 29Screw (reed valve)

2. Install:9Gasket (reed valve) 1 9Plate (reed valve) 2 9Reed valve assembly 39Reed valve spacer 4NOTE:Install the reed valve spacer with its cha

3. Install:9Pilot air screw 19Throttle stop screw 2*For EUROPE4. Install:9Starter plunger 14-14ENGCARBURETOR AND REED VALVEPilot air screw:1 turn out*

4-15ENGCARBURETOR AND REED VALVE8. Install:9Air vent hose [/=580 mm (22.8 in)] 19Air vent hose [/=400mm (15.7 in)] 29Overflow hose [/=280mm (11.0 in)]

4-16ENGCARBURETOR AND REED VALVE11. Install:9Mixing chamber top 19Screw(mixing chamber top) 2To carburetor 3.NOTE:9Insert the throttle valve into the

4-17ENGCARBURETOR AND REED VALVE2. Tighten:9Screw (carburetor joint) 13. Tighten:9Screw (air cleaner joint) 1NOTE:Place the screw head a with its

4-18CYLINDER HEAD, CYLINDER AND PISTONENGEC470000CYLINDER HEAD, CYLINDER AND PISTONEC478000CYLINDER HEAD AND CYLINDERExtent of removal Order Part name

4-19CYLINDER HEAD, CYLINDER AND PISTONENGEC478100PISTON AND POWER VALVEExtent of removal Order Part name Q’ty RemarksPISTON AND POWER VALVEREMOVAL1 Pi

4-20ENGCYLINDER HEAD, CYLINDER AND PISTONEC473000REMOVAL POINTSEC473220Push rod1. Remove:9Bolt (push rod) 19Push rod 2NOTE:Insert the set pin 3 inclu

EC085002ILLUSTRATED SYMBOLS(Refer to the illustration)Illustrated symbols 1 to 7 are designed asthumb tabs to indicate the chapter’s number andcon

4-21ENGCYLINDER HEAD, CYLINDER AND PISTONEC474000INSPECTIONEC474102Cylinder head1. Eliminate:9Carbon depositsUse a rounded scraper 1.NOTE:Take care

4-22ENGCYLINDER HEAD, CYLINDER AND PISTONEC474201Cylinder1. Eliminate:9Carbon depositsUse a rounded scraper 1.NOTE:Do not use a sharp instrument. Avoi

4-23ENGCYLINDER HEAD, CYLINDER AND PISTON3. Measure:9Piston skirt diameterUse micrometer 1.Measure the specific distance b from thestepped surfac

4-24ENGCYLINDER HEAD, CYLINDER AND PISTONEC474502Piston ring1. Install:9Piston ringInto the cylinder.Push the ring with the piston crown.2. Measure:9E

4-25ENGCYLINDER HEAD, CYLINDER AND PISTONEC474700Combination of piston and cylinder1. Check:9Cylinder mark a2. Check:9Piston mark aPiston clearance:St

4-26ENGCYLINDER HEAD, CYLINDER AND PISTONEC474841Power valve1. Inspect:9Power valve 1, 2 1Wear/Damage → Replace.Carbon deposits → Remove.9Valve holder

4-27ENGCYLINDER HEAD, CYLINDER AND PISTONEC475000ASSEMBLY AND INSTALLATIONEC475193Power valve1. Install:9Power valve 1 19Valve holder 2 29Bolt (valve

4-28CYLINDER HEAD, CYLINDER AND PISTONENG4. Install:9Spring 1 19Link lever 29Pulley 39Spring 2 49Plain washer 59Valve shaft 6NOTE:9Install the spring

4-29CYLINDER HEAD, CYLINDER AND PISTONENG7. Install:9O-ring 19Side holder 29Screw (side holder) 39YPVS breather hose 4NOTE:9Apply the lithium soap

4-30CYLINDER HEAD, CYLINDER AND PISTONENGEC475383Cylinder head and cylinder1. Apply:9Engine oilTo piston 1 piston ring 2 and cylinder sur-face.2. Inst

ENGINECHASSISELECTRICALTUNINGREGULARINSPECTION ANDADJUSTMENTSSPECIFICATIONSEC090000INDEXGENERALINFORMATIONGENINFO1234567SPECINSPADJENGCHASELECTUN1P8-2

4-31CYLINDER HEAD, CYLINDER AND PISTONENG4. Install:9Push rod 19Bolt (push rod) 2NOTE:9Insert the set pin 3 included in owner’s tool kitto install the

4-32CYLINDER HEAD, CYLINDER AND PISTONENG9. Install:9Spark plug 19Spark plug cap 28. Install:9Engine bracket 19Bolt (engine bracket) 29Engine mounting

4-33CLUTCH AND PRIMARY DRIVEN GEARENGExtent of removal Order Part name Q’ty RemarksCLUTCH PLATE ANDFRICTION PLATE REMOVALPreparation for Drain the tr

4-34CLUTCH AND PRIMARY DRIVEN GEARENGExtent of removal Order Part name Q’ty RemarksPRIMARY DRIVEN GEAR, PUSHROD AND PUSH LEVER AXLEREMOVAL1 Push rod 1

4-35CLUTCH AND PRIMARY DRIVEN GEARENGEC493000REMOVAL POINTSEC483211Clutch boss1. Remove:9Nut 19Lock washer 29Clutch boss 3NOTE:Straighten the lock

4-36CLUTCH AND PRIMARY DRIVEN GEARENGEC484500Friction plate1. Measure:9Friction plate thicknessOut of specification → Replace frictionplate as a s

4-37CLUTCH AND PRIMARY DRIVEN GEARENGEC495230Clutch1. Install:9Thrust plate [D=ø 42 mm (1.65 in)] 19Spacer 29Bearing 39Primary driven gear 4NOTE:Apply

4-38CLUTCH AND PRIMARY DRIVEN GEARENG5. Install:9Friction plate 19Clutch plate 2NOTE:9Install the clutch plates and friction plates alter-nately on th

4-39CLUTCH AND PRIMARY DRIVEN GEARENG10. Install:9O-ring 1To clucth cover.11. Install:9Clutch cover 19Bolt (clutch cover) 2NOTE:Tighten the bolts i

4-40KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEARENGExtent of removal Order Part name Q’ty RemarksRPIMARY DRIVE GEAR REMOVALPreparation for Drain the

EC0A0000CONTENTSCHAPTER 1GENERAL INFORMATIONDESCRIPTION...1-1MACHINE IDENTIFICATION ...1-2

4-41KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEARENGEC4C8100KICK AXLE AND SHIFT SHAFTExtent of removal Order Part name Q’ty RemarksKICK AXLE AND SHIFT

4-42KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEARENGEC4C3000REMOVAL POINTSEC483111Primary drive gear1. Loosen:9Bolt (primary drive gear) 1NOTE:Place a

4-43KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEARENGEC4B4400Shift shaft1. Inspect:9Shift shaft 1Bend/Damage→Replace.9Spring 2Broken→Replace.EC484300Pr

4-44KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEARENG3. Install:9Shift lever assembly 19Shift guide 2NOTE:9The shift lever assembly is installed

4-45KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEARENGEC4C5310Shift shaft1. Install:9Roller 19Plain washer 29Shift shaft 3NOTE:Apply the transmission oi

4-46KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEARENGEC4C5420Kick idle gear1. Install:9Kick idle gear 19Plain washer 29Circlip 3NOTE:9Apply the transmi

4-47KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEARENG5. Install:9Crankcase cover (right) 1NOTE:Mesh the governor gear 2 with the governordrive ge

4-48KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEARENG8. Install:9Shift pedal 19Bolt (shift pedal) 2NOTE:Install the shift pedal so that the top of the

4-49YPVS GOVERNORENGExtent of removal Order Part name Q’ty RemarksYPVS GOVERNOR REMOVALPreparation for Crankcase cover (right)Refer to “KICK AXLE, SH

4-50YPVS GOVERNORENGEC4K5000ASSEMBLY AND INSTALLATIONEC4K5130Governor1. Install:9Governor gear 19Compression spring 29Plate 39Plain washer 49Thrust be

CHAPTER 4ENGINESEAT, FUEL TANK AND SIDECOVERS ...4-1EXHAUST PIPE AND SILENCER ...4-3RADIA

4-51YPVS GOVERNORENG4. Install:9Governor assembly 1NOTE:Align the groove a in the governor with the forkb and set the governor in the crankcase cover.

4-52WATER PUMPENGEC4G0000WATER PUMPExtent of removal: 1 Impeller shaft removal 2 Oil seal removalExtent of removal Order Part name Q’ty RemarksWATER P

4-53WATER PUMPENGEC4G3000REMOVAL POINTSEC4G3110Impeller shaft1. Remove:9Impeller 19Plain washer 29Impeller shaft 3NOTE:Hold the impeller shaft on

4-54WATER PUMPENGEC444300Impeller shaft gear1. Inspect:9Gear teeth aWear/Damage →Replace.EC4H4600Bearing1. Inspect:9Bearing 1Rotate inner race with a

4-55WATER PUMPENGEC4G5220Impeller shaft1. Install:9Impeller shaft 1NOTE:9Take care so that the oil seal lip is not dam-aged or the spring do

4-56CDI MAGNETOENGExtent of removal Order Part name Q’ty RemarksCDI MAGNETO REMOVALPreparation for Seat and fuel tank Refer to “SEAT, FUEL TANK ANDre

4-57CDI MAGNETOENGEC4L5000ASSEMBLY AND INSTALLATIONEC4L5172CDI magneto1. Install:9Stator 19Screw (stator) 2NOTE:Temporarily tighten the screw (sta

4-58CDI MAGNETOENG5. Tighten:9Screw (stator) 16. Check:9Ignition timingRe-check the ignition timing.3. Install:9Plain washer 19Nut (rotor) 2Use the ro

4-59CDI MAGNETOENG7. Connect:9CDI magneto lead 1Refer to “CABLE ROUTING DIAGRAM”section in the CHAPTER 2.8. Install:9Gasket [crankcase cover (left

4-60ENGINE REMOVALENGExtent of removal Order Part name Q’ty RemarksENGINE REMOVALPreparation for Hold the machine by placing theremovalsuitable stand

CHAPTER 6ELECTRICALELECTRICAL COMPONENTS AND WIRING DIAGRAM...6-1IGNITION SYSTEM...

4-61ENGINE REMOVALENGExtent of removal: 1 Engine removalExtent of removal Order Part name Q’ty Remarks1 Chain cover 12 Nut (drive sprocket) 13 Lock wa

4-62ENGINE REMOVALENGEC4M3340Engine removalNOTE:Make sure that the couplers, hoses and cablesare disconnected.1. Lift the engine 1 up to the poi

4-63ENGINE REMOVALENGEC4M5211Brake pedal1. Install:9Spring 19Brake pedal 29O-ring 39Bolt (brake pedal) 49Clip 5NOTE:Apply the lithium soap base greas

4-64ENGINE REMOVALENG4. Install:9Chain guide 19Chain cover 29Screw (chain cover) 32. Install:9Lock washer 19Nut (drive sprocket) 2NOTE:Tighten the nut

4-65CRANKCASE AND CRANKSHAFTENGExtent of removal Order Part name Q’ty RemarksCRANKCASE AND CRANKSHAFTREMOVALPreparation for Engine Refer to “ENGINE

4-66CRANKCASE AND CRANKSHAFTENGNOTE:9Make appropriate bolts 3 as shown availableby yourself and attach the tool with them.9Fully tighten the t

4-67CRANKCASE AND CRANKSHAFTENGEC4N4000INSPECTIONEC4N4101Crankcase1. Inspect:9Contacting surface aScratches→Replace.9Engine mounting boss b, crankcase

4-68CRANKCASE AND CRANKSHAFTENGEC4N5000ASSEMBLY AND INSTALLATIONEC4N5300Crankshaft bearing1. Install:9Bearing 1To crankcase (left and right).NOTE:Inst

4-69CRANKCASE AND CRANKSHAFTENGEC4N5284Crankshaft1. Install:9Crankshaft 1Use the crankshaft installing tool 2, 3, 4.Crankshaft installing tool:Pot 2:Y

4-70CRANKCASE AND CRANKSHAFTENG3. Install:9O-ring 1To crankcase (right) 2.5. Install:9Dowel pin 19Crankcase (right) 2To crankcase (left) 3.NOTE:9Fit

11-1DESCRIPTIONGENINFOEC100000GENERAL INFORMATIONEC110000DESCRIPTION1 Clutch lever2 “ENGINE STOP” button3 Front brake lever4 Throttle grip5 Radiator c

4-71CRANKCASE AND CRANKSHAFTENG8. Tighten:9Segment 19Bolt (segment) 2NOTE:9When installing the segment onto the shift cam3, align the punch mark a wit

4-72TRANSMISSION, SHIFT CAM AND SHIFT FORKENGExtent of removal Order Part name Q’ty RemarksTRANSMISSION, SHIFT CAM ANDSHIFT FORK REMOVALPreparation fo

4-73TRANSMISSION, SHIFT CAM AND SHIFT FORKENGEC4H4600Bearing1. Inspect:9Bearing 1Rotate inner race with a finger.Rough spot/Seizure →Replace.2. Inspec

4-74TRANSMISSION, SHIFT CAM AND SHIFT FORKENGEC4H5000ASSEMBLY AND INSTALLATIONEC4H5242Transmission1. Install:95th pinion gear (21T) 193rd pinion gear

4-75TRANSMISSION, SHIFT CAM AND SHIFT FORKENG4. Install:9Spacer 1NOTE:9Apply the lithium soap base grease on the oilseal lip.9When installing

4-76TRANSMISSION, SHIFT CAM AND SHIFT FORKENG5. Install:9Shift fork 1 (L) 19Shift fork 2 (C10) 29Shift fork 3 (R) 39Shift cam 4To main axle and drive

55-1CHASFRONT WHEEL AND REAR WHEELExtent of removal Order Part name Q’ty RemarksFRONT WHEEL REMOVALPreparation forHold the machine by placing theremov

5-2CHASFRONT WHEEL AND REAR WHEELEC598100REAR WHEELExtent of removal: 1 Rear wheel removal 2 Wheel bearing removal 3 Brake disc removalExtent of remov

5-3CHASFRONT WHEEL AND REAR WHEELEC593000REMOVAL POINTSEC523101Rear wheel1. Remove:9Wheel 1NOTE:Push the wheel forward and remove the drivechai

5-4CHASFRONT WHEEL AND REAR WHEELEC514200Wheel axle1. Measure:9Wheel axle bendsOut of specification → Replace.Use the dial gauge 1.NOTE:The bending

GENINFO1-2MACHINE IDENTIFICATIONEC120001MACHINE IDENTIFICATIONThere are two significant reasons for knowingthe serial number of your machine:1.

5-5CHASFRONT WHEEL AND REAR WHEELEC595000ASSEMBLY AND INSTALLATIONEC595101Front wheel1. Install:9Bearing (left) 19Spacer 29Bearing (right) 39Oil seal

5-6CHASFRONT WHEEL AND REAR WHEEL5. Install:9Wheel axle 1NOTE:Apply the lithium soap base grease on the wheelaxle.6. Install:9Nut (wheel axle) 17. Tig

5-7CHASFRONT WHEEL AND REAR WHEELNOTE:9Apply the lithium soap base grease on thebearing and oil seal lip when installing.9Install the bearing w

5-8CHASFRONT WHEEL AND REAR WHEEL3. Install:9Driven sprocket 19Bolt (driven sprocket) 29Plain washer (driven sprocket) 39Nut (driven sprocket) 4NOTE:T

5-9CHASFRONT WHEEL AND REAR WHEEL8. Install:9Chain puller (right) 19Plain washer 29Nut (wheel axle) 3NOTE:Temporarily tighten the nut (wheel axle

5-10CHASFRONT BRAKE AND REAR BRAKE Extent of removal Order Part name Q’ty RemarksFRONT BRAKE REMOVALPreparation forHold the machine by placing theremo

5-11CHASFRONT BRAKE AND REAR BRAKE EC5A8100REAR BRAKEExtent of removal Order Part name Q’ty RemarksREAR BRAKE REMOVALPreparation forHold the machine b

5-12CHASFRONT BRAKE AND REAR BRAKE Extent of removal Order Part name Q’ty RemarksCALIPER DISASSEMBLY AB1 Pad pin 1 12 Brake pad 2 23 Pad support 1 14

5-13CHASFRONT BRAKE AND REAR BRAKE Extent of removal Order Part name Q’ty RemarksMASTER CYLINDER DISASSEMBLY1 Master cylinder cap 12 Diaphragm 13 Rese

5-14CHASFRONT BRAKE AND REAR BRAKE EC5A3000REMOVAL POINTSEC5A3101Brake fluid1. Remove:[Front]9Master cylinder cap 1[Rear]9Master cylinder cap 19Protec

1-3IMPORTANT INFORMATIONGENINFOEC130000IMPORTANT INFORMATIONEC131010PREPARATION FOR REMOVAL AND DISASSEMBLY1. Remove all dirt, mud, dust, and fo

5-15CHASFRONT BRAKE AND REAR BRAKE EC533402Piston seal kit1. Remove:9Dust seal 19Piston seal 2NOTE:Remove the piston seals and dust seals bypus

5-16CHASFRONT BRAKE AND REAR BRAKE 4. Inspect:9Master cylinder piston 19Master cylinder cup 2Wear/Damage/Score marks→Replace mastercylinder kit.A Fron

5-17CHASFRONT BRAKE AND REAR BRAKE EC5A5801Caliper piston1. Clean:9Caliper9Piston seal9Dust seal9Caliper pistonClean them with brake fluid.2. Install:

5-18CHASFRONT BRAKE AND REAR BRAKE EC5A5121Rear caliper1. Install:9Pad support 19Brake pad 29Pad pin 3NOTE:9Install the brake pads with their pr

5-19CHASFRONT BRAKE AND REAR BRAKE EC5A5220Master cylinder kit1. Clean:9Master cylinder9Master cylinder kitClean them with brake fluid.2. Install:9Mas

5-20CHASFRONT BRAKE AND REAR BRAKE 4. Install:[Front]9Master cylinder kit 19Plain washer 29Circlip 39Master cylinder boot 4To master cylinder 5.[Rear]

5-21CHASFRONT BRAKE AND REAR BRAKE EC5A5401Rear master cylinder1. Install:9Copper washer 19Brake hose 29Union bolt 3wAlways use new copper washers.cCI

5-22CHASFRONT BRAKE AND REAR BRAKE 2. Install:9Brake hose holder 19Bolt (brake hose holder) 23. Install:9Brake hose holder 19Nut (brake hose holder) 2

5-23CHASFRONT BRAKE AND REAR BRAKE 4. Pass the brake hose through the cableguide 1.5. Install:9Copper washer 19Brake hose 29Union bolt 3wAlways

5-24CHASFRONT BRAKE AND REAR BRAKE 2. Install:9Brake hose holder 19Screw (brake hose holder) 2cCAfter installing the brake hose holders,make sure

1-4IMPORTANT INFORMATIONGENINFOEC133000GASKETS, OIL SEALS AND O-RINGS1. All gaskets, oil seals, and O-rings should bereplaced when an engine is over

5-25CHASFRONT BRAKE AND REAR BRAKE 2. Air bleed:9Brake systemRefer to “BRAKE SYSTEM AIR BLEED-ING” section in the CHAPTER 3.3. Inspect:9Brake flu

5-26CHASFRONT FORKExtent of removal Order Part name Q’ty RemarksFRONT FORK REMOVALPreparation forHold the machine by placing theremovalsuitable stand

5-27CHASFRONT FORKExtent of removal Order Part name Q’ty RemarksFRONT FORK DISASSEMBLY1 Adjuster 1 Drain the fork oil. Use special tool.Refer to “REMO

5-28CHASFRONT FORKEC556000HANDLING NOTENOTE:The front fork requires careful attention. So it isrecommended that the front fork be maintainedat

5-29CHASFRONT FORKAdjuster1. Drain the outer tube of its front fork oil at itstop.2. Loosen:9Adjuster 13. Remove:9Adjuster 1NOTE:9 While compressing

5-30CHASFRONT FORKBase valve1. Remove:9Base valve 1From damper assembly 2.NOTE:Hold the damper assembly with the cap bolt ringwrench 3 and use the

5-31CHASFRONT FORKBase valve1. Inspect:9Base valve 1Wear/Damage→Replace.Contamination→Clean.9O-ring 2Wear/Damage→Replace.9Bush 3Wear/Damage→Replace ba

5-32CHASFRONT FORKEC554600Outer tube1. Inspect:9Outer tube 1Score marks/Wear/Damage→Replace.Adjuster1. Inspect:9Adjuster 19O-ring 2Wear/Damage→Replace

5-33CHASFRONT FORK4. After filling, pump the damper assembly 1slowly up and down (about 200 mm (7.9 in)stroke) several times to bleed the

9. Tighten:9Base valve 1NOTE:Hold the damper assembly with the cap boltring wrench 2 and use the cap bolt wrench 3to tighten the base valve wit

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1-5IMPORTANT INFORMATIONGENINFOEC136000CIRCLIPS1. All circlips should be inspected carefullybefore reassembly. Always replace pistonpin clip

5-35CHASFRONT FORK14. Install:9Dust seal 19Stopper ring 29Oil seal 39Oil seal washer 49Slide metal 5To inner tube 6.NOTE:9Apply the fork oil on the in

5-36CHASFRONT FORK17. Install:9Slide metal 19Oil seal washer 2To outer tube slot.NOTE:Press the slide metal into the outer tube withfork seal

5-37CHASFRONT FORK21. Check:9Inner tube smooth movementTightness/Binding/Rough spots → Repeat thesteps 14 to 20.22. Measure:9Distance aOut of specific

5-38CHASFRONT FORK26. Install:9Push rod 19Copper washer 29Adjuster 3To damper assembly 4.NOTE:9 While compressing the inner tube 5, set thecap

5-39CHASFRONT FORK31. Install:9Damper assembly 1To outer tube.NOTE:Temporarily tighten the damper assembly.32. Install:9Protector guide 1EC5552A1Insta

5-40CHASFRONT FORK6. Adjust:9Rebound damping forceNOTE:Turn in the damping adjuster 1 finger-tight andthen turn out to the originally set position.5.

5-41CHASHANDLEBARExtent of removal Order Part name Q’ty RemarksPreparation for HANDLEBAR REMOVALremovalNumber plate Remove the clamp portion only.1 Cl

5-42CHASHANDLEBARExtent of removal: 1 Throttle disassemblyExtent of removal Order Part name Q’ty RemarksTHROTTLE DISASSEMBLY1 Grip cap (lower) 12 Grip

5-43CHASHANDLEBAREC5B3000REMOVAL POINTSEC5B3100Master cylinder1. Remove:9Master cylinder bracket 19Master cylinder 2cC9Do not let the master cylin

5-44CHASHANDLEBAR2. Install:9Grip cap (upper) 19Grip cap (lower) 29Bolt (grip cap) 3NOTE:Temporarily tighten the bolts (grip cap).EC5B5210Handlebar1.

1-6CHECKING OF CONNECTIONGENINFOEC1C0001CHECKING OF CONNECTIONDealing with stains, rust, moisture, etc. on theconnector.1. Disconnect:9Connecto

5-45CHASHANDLEBAR4. Install:9Throttle cable 1To tube guide 2.NOTE:Apply the lithium soap base grease on the throt-tle cable end and tube guide cable w

5-46CHASHANDLEBAR10. Install:9Bolt (grip cap) 1w9Install the grip cap so that the gaps aandbbetween the bolt (grip cap) and brakelever2are equ

5-47CHASHANDLEBAR14. Clamp the clamp portion a of the numberplate to the handlebar.15. Insert the end of the fuel breather hose 1into th

5-48CHASSTEERINGExtent of removal Order Part name Q’ty RemarksSTEERING REMOVALPreparation forHold the machine by placing theremovalsuitable stand unde

5-49CHASSTEERINGEC563000REMOVAL POINTSEC563202Ring nut1. Remove:9Ring nut 1Use the ring nut wrench 2.wSupport the steering shaft so that it may

5-50CHASSTEERINGEC564101Bearing and bearing race1. Wash the bearings and bearing races with asolvent.2. Inspect:9Bearing 19Bearing racePitting/Damage

5-51CHASSTEERING4. Install:9Ring nut 1Tighten the ring nut using the ring nutwrench 2.Refer to “STEERING HEAD INSPECTIONAND ADJUSTMENT” secti

5-52CHASSTEERING11. Adjust:9Front fork top end a12. Tighten:9Pinch bolt (handle crown) 19Pinch bolt (under bracket) 2cCTighten the under bracket t

5-53CHASSWINGARMExtent of removal Order Part name Q’ty RemarksSWINGARM REMOVALPreparation forHold the machine by placing theremovalsuitable stand unde

5-54CHASSWINGARMExtent of removal Order Part name Q’ty RemarksSWINGARM DISASSEMBLY1 Cap 2 Refer to “REMOVAL POINTS”.2 Relay arm 13 Connecting rod 14

1-7SPECIAL TOOLSGENINFOEC140002SPECIAL TOOLSThe proper special tools are necessary for complete and accurate tune-up and assembly. Using thecorre

5-55CHASSWINGARMEC573201Bearing1. Remove:9Bearing 1NOTE:Remove the bearing by pressing its outer race.EC574010INSPECTIONWash the bearings, bushes, col

5-56CHASSWINGARMEC575000ASSEMBLY AND INSTALLATIONEC575202Bearing and oil seal1. Install:9Bearing 19Oil seal 2To swingarm.NOTE:9Apply the molybdenum di

5-57CHASSWINGARMEC5751B3Swingarm1. Install:9Bush 19Thrust bearing 29Oil seal 39Collar 4To swingarm 5.NOTE:Apply the molybdenum disulfide grease o

5-58CHASSWINGARM5. Install:9Relay arm 19Bolt (relay arm) 29Plain washer 39Nut (relay arm) 4To swingarm.NOTE:9Apply the molybdenum disulfide grease on

5-59CHASSWINGARM10. Tighten:9Nut (connecting rod) 111. Tighten:9Nut (relay arm) 180 Nm (8.0 m•kg, 58 ft•lb)80 Nm (8.0 m•kg, 58 ft•lb)8. Install:9Bolt

5-60CHASSWINGARM13. Install:9Bolt [chain tensioner (lower)] 19Plain washer 29Collar 39Chain tensioner 49Nut [chain tensioner (lower)] 514. Install:9Ch

5-61CHASREAR SHOCK ABSORBERExtent of removal Order Part name Q’ty RemarksREAR SHOCK ABSORBERREMOVALPreparation forHold the machine by placing theremov

5-62CHASREAR SHOCK ABSORBEREC586000HANDLING NOTEwThis shock absorber is provided with aseparate type tank filled with high-pressurenitrogen gas.

5-63CHASREAR SHOCK ABSORBEREC583000REMOVAL POINTSEC583320Bearing1. Remove:9Stopper ring (upper bearing) 1NOTE:Press in the bearing while pressing its

5-64CHASREAR SHOCK ABSORBEREC585111Spring (rear shock absorber)1. Install:9Spring 19Spring guide (upper) 29Spring guide (lower) 32. Tighten:9Adjuster

1-8SPECIAL TOOLSGENINFOPart number Tool name / How to use IIIustrationYU-33975, 90890-01403 Ring nut wrench YU-33975 90890-01403This tool is used when

5-65CHASREAR SHOCK ABSORBEREC5852B5Rear shock absorber1. Install:9Dust seal 19O-ring 29Collar 3NOTE:9 Apply the molybdenum disulfide grease on thebear

5-66CHASREAR SHOCK ABSORBER3. Install:9Rear shock absorber4. Install:9Bolt (rear shock absorber-frame) 19Plain washer 29Nut (rear shock absorber-frame

66-1ELECTRICAL COMPONENTS AND WIRING DIAGRAMELECEC600000ELECTRICALEC610000ELECTRICAL COMPONENTS AND WIRING DIAGRAMEC611000ELECTRICAL COMPONENTS1 CDI u

6-2IGNITION SYSTEMELECEC620000IGNITION SYSTEMEC621003INSPECTION STEPSUse the following steps for checking the possibility of the malfunctioning engine

6-3IGNITION SYSTEMELECEC622001SPARK GAP TEST1. Disconnect the spark plug cap from sparkplug.2. Connect the dynamic spark tester 1 (igni-tio

6-4IGNITION SYSTEMELECEC626003IGNITION COIL INSPECTION1. Inspect:9Primary coil resistanceOut of specification → Replace.2. Inspect:9Secondary coil res

6-5IGNITION SYSTEMELEC2. Inspect:9Source coil 1 resistanceOut of specification → Replace.Tester (+) lead→Black/Red lead 1Tester (–) lead→Black lead 2S

6-6IGNITION SYSTEMELEC3. Inspect:9Source coil 2 resistanceOut of specification → Replace.EC628000CDI UNIT INSPECTIONCheck all electrical components

6-7SOLENOID VALVE SYSTEMELECCheck solenoidvalve operation.Solenoid valvecoilNo goodNo goodCheck each couplers andwire connection.Check solenoid valve.

6-8SOLENOID VALVE SYSTEMELECEC624000COUPLERS AND LEADS CONNECTION INSPECTION1. Check:9Couplers and leads connectionRust/ Dust/ Looseness/Short-circu

1-9CONTROL FUNCTIONSGENINFOEC150000CONTROL FUNCTIONSEC151000“ENGINE STOP” BUTTONThe “ENGINE STOP” button 1 is located on theleft handlebar. Continue

6-9TPS (THROTTLE POSITION SENSOR) SYSTEMELECCheck entire ignition system for connection.Repair or replace.OKOKTPS coilNo goodReplace.Check TPS.OKSourc

6-10TPS (THROTTLE POSITION SENSOR) SYSTEMELECLYB1212EC624000COUPLERS AND LEADS CONNECTION INSPECTION1. Check:9Couplers and leads connectionRust/ Dust

6-11TPS (THROTTLE POSITION SENSOR) SYSTEMELEC32123LYB3. Inspect:9TPS coil variable resistanceCheck that the resistance in increased asthe lever

6-12TPS (THROTTLE POSITION SENSOR) SYSTEMELEC21243LYB4. Install:9TPS 19Screw (TPS) 2NOTE:9Align the slot a in the TPS with the projectionb on the car

6-13TPS (THROTTLE POSITION SENSOR) SYSTEMELEC10. Put the aligning marks a on the TPS andcarburetor.11. Stop the engine.12. Remove:9CarburetorRe

6-14TPS (THROTTLE POSITION SENSOR) SYSTEMELECYLB/L1212EC694000TPS INPUT VOLTAGE INSPECTION1. Disconnect the TPS coupler.2. Start the engine.3. Inspect

77-1SETTINGTUNEC700000TUNINGEC710000ENGINEEC711001Carburetor setting9The role of fuel is to cool the engine, and in thecase of a 2-stroke engine,

7-2SETTINGTUNThat is:9Higher temperature expands the air with itsresultant reduced density.9Higher humidity reduces the amount of oxygenin the

7-3SETTINGTUNEC714032Effects of setting parts in relation to throt-tle valve openingNOTE:The power jet closes at 8,500 rpm of the engine,after which o

7-4SETTINGTUNEC71R010Pilot jet adjustmentThe richness of air - fuel mixture with the throttlefully closed to 1/2 open can be set by turning thepilot j

1-10CONTROL FUNCTIONSGENINFOEC156000FRONT BRAKE LEVERThe front brake lever 1 is located on the righthandlebar. Pull it toward the handleb

7-5SETTINGTUN1. Too rich at intermediate speedsRough engine operation is felt and theengine will not pick up speed smoothly. Inthis case,

7-6SETTINGTUNEC719081Jet needle adjustment(For USA, CDN, ZA, AUS and NZ)On the carburetors used in the YZ250, the mainnozzle is press-fitted, so it

7-7SETTINGTUNEC719081Jet needle adjustment(For EUROPE)On the carburetors used in the YZ250, the mainnozzle is press-fitted, so it can not be rep

7-8SETTINGTUNEC71B011Relationship with throttle openingThe flow of the fuel through the carburetor mainsystem is controlled by the main jet and then,

7-9SETTINGTUNEC71Q000Carburetor setting partsPart name Size Part numberMain jet 1Rich #190 4MX-14943-45#188 4MX-14943-95#185 4MX-14943-44#182 4MX-1494

7-10SETTINGTUNEC71D021Examples of carburetor setting depending on symptomSymptom Setting CheckingAt full throttle Increase main jet calibration No. Di

7-11SETTINGTUNSymptom Setting Checking0~1/4 throttle Use jet needle having a smaller Number of turns-back →Hard breathing diameter. Correct properlyS

7-12SETTINGTUNEC71M010Change of the heat range of spark plugsJudging from the discoloration of spark plugs, ifthey are found improper, it

7-13SETTINGTUNEC720000CHASSISEC71P002Selection of the secondary reduction ratio (Sprocket)SecondaryNumber of driven sprocket teethreduction =ratioNum

7-14SETTINGTUNEC72N000Drive and driven sprockets setting partsEC721003Tire pressureTire pressure should be adjust to suit the roadsurface cond

1-11CONTROL FUNCTIONSGENINFOEC15F000VALVE JOINTThis valve joint 1 prevents fuel from flowing outand is installed to the fuel tank breather hose.cCIn

7-15SETTINGTUNAEC722011Front fork settingThe front fork setting should be made dependingon the rider’s feeling of an actual run and the cir-cuit condi

7-16SETTINGTUNEC727030Spring preload adjustmentThe spring preload is adjusted by installing theadjustment washer 1 between the spacer 2and

7-17SETTINGTUN2. Use of stiff springGenerally a stiff spring gives a stiff ridingfeeling. Rebound damping tends to becomeweaker, resulting

7-18SETTINGTUNEC72P010Front fork setting parts9Adjustment washer 19Front fork spring 2NOTE:The I.D. mark (slits) a is proved on the end ofthe sp

7-19SETTINGTUNEC72B000Rear suspension settingThe rear suspension setting should be madedepending on the rider’s feeling of an actual runand the

7-20SETTINGTUNNOTE:9If the machine is new and after it is broken in,the same set length of the spring may changebecause of the initial fatigue, etc.

7-21SETTINGTUNcCWhen using a rear cushion other than cur-rently installed, use the one whose overalllengthadoes not exceed the standard asit may res

7-22SETTINGTUNEC72Q011Rear shock absorber setting parts9Rear shock spring 1[Equal pitch spring ][Unequal pitch spring ]NOTE:9The unequal pitch spring

7-23SETTINGTUNEC72H010Suspension setting9Front forkNOTE:9If any of the following symptoms is experienced with the standard position as the base, make

7-24SETTINGTUN9Rear shock absorberNOTE:9If any of the following symptoms is experienced with the standard position as the base, make reset-ting by ref

1-12FUEL AND ENGINE MIXING OILGENINFOEC160051FUEL AND ENGINE MIXING OILMix oil with the gas at the ratio specified below.Always use fresh, name-brand

OWNER’S SERVICE MANUALYZ250T11P8-28199-10LIT-11626-18-34PRINTED IN JAPAN2004.5—2.8 × 1 !(E)YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPANPRIN

1-13STARTING AND BREAK-INGENINFOEC190000STARTING AND BREAK-INcCBefore starting the machine, perform thechecks in the pre-operation check list.wNe

1-14STARTING AND BREAK-INGENINFOEC194001BREAK-IN PROCEDURES1. Before starting the engine, fill the fuel tankwith a break-in oil-fuel mixture as

YZ250T1OWNER’S SERVICE MANUAL©2004 by Yamaha Motor Corporation, U.S.A.1st Edition, May 2004All rights reserved. Any reprinting orunauthorized use with

1-15STARTING AND BREAK-INGENINFOcC9After the break-in or before each race, youmust check the entire machine for loose fit-tings and fasteners

1-16TORQUE-CHECK POINTSGENINFOEC1A0013TORQUE-CHECK POINTSFrame construction Frame to rear frameCombined seat and tank Fuel tank to frameEngine mountin

1-17CLEANING AND STORAGEGENINFOEC1B0000CLEANING AND STORAGEEC1B1000CLEANINGFrequent cleaning of your machine will enhanceits appearance, maintain g

1-18CLEANING AND STORAGEGENINFOEC1B2001STORAGEIf your machine is to be stored for 60 days ormore, some preventive measures must be takento

22-1GENERAL SPECIFICATIONSSPECModel name: YZ250T1 (USA, CDN)YZ250 (EUROPE, ZA)YZ250T (AUS, NZ)Model code number: 1P81 (USA, CDN, ZA)1P82 (EUROPE)1P84

2-2GENERAL SPECIFICATIONSSPECCarburetor:Type/Manufacturer PWK38S/KEIHINSpark plug:Type/Manufacturer BR8EG/NGK (resistance type)Gap 0.5~0.6 mm (0.020~0

2-3MAINTENANCE SPECIFICATIONSSPECItem Standard LimitCylinder head: USA, CDN, ZA, EUROPEAUS, NZCombustion chamber capacity 21.0 cm321.5 cm3…(0.739 Imp

2-4MAINTENANCE SPECIFICATIONSSPECItem Standard LimitClutch housing thrust clearance 0.17~0.23 mm (0.007~0.009 in) …Clutch housing radial clearance 0.0

2-5MAINTENANCE SPECIFICATIONSSPECPart to be tightened Thread size Q’tyTightening torqueNm m•kg ft•lbSpark plugM14S× 1.25 1 20 2.0 14Cylinder head (nut

2-6MAINTENANCE SPECIFICATIONSSPECPart to be tightened Thread size Q’tyTightening torqueNm m•kg ft•lbPrimary drive gear M10 × 1.25 1 55 5.5 40Clutch bo

EC020000INTRODUCTIONCongratulations on your purchase of a YamahaYZ series. This model is the culmination ofYamaha’s vast experience in

2-7MAINTENANCE SPECIFICATIONSSPECEC212201CHASSISItem Standard LimitSteering system:Steering bearing type Taper roller bearing…Front suspension:Front f

2-8MAINTENANCE SPECIFICATIONSSPECItem Standard LimitWheel:Front wheel type Spoke wheel…Rear wheel type Spoke wheel…Front rim size/Material 21 × 1.60/A

2-9MAINTENANCE SPECIFICATIONSSPEC171410520224021210.77.25.10.72.92.92.96.51.44.34.33.62.92222177.22.2134.375178.71040197.2M 8 × 1.25M 8 × 1.25M24 ×

2-10MAINTENANCE SPECIFICATIONSSPECM 4 × 0.7M10 × 1.25M10 × 1.25M20 × 1.5M 8 × 1.25–M 6 × 1.0M 6 × 1.0M 8 × 1.25M 8 × 1.25M10 × 1.25M10 × 1.25M10

2-12MAINTENANCE SPECIFICATIONSSPECEC212300ELECTRICALPart to be tightened Thread size Q’tyTightening torqueNm m•kg ft•lbStator M 6 × 1.0 3 8 0.8 5.8Ro

2-13GENERAL TORQUE SPECIFICATIONS/DEFINITION OF UNITSSPECThis chart specifies torque for standard faste-ners with standard I.S.O. pitch thr

2-14CABLE ROUTING DIAGRAMSPECEC240000CABLE ROUTING DIAGRAM1 Radiator hose2 Throttle cable3 Clutch cable4 “ENGINE STOP” button lead5 Radiator breather

2-15CABLE ROUTING DIAGRAMSPEC1 Clamp2 Radiator hose3 Solenoid valve lead4 TPS (throttle position sensor)lead5 Air vent hose (left)6 Crankcase breat

2-16CABLE ROUTING DIAGRAMSPEC1 Clamp2 High tension cord3 C.D.I.unit4 “ENGINE STOP” button lead5 Ignition coil lead6 Radiator hose7 Radiator breather h

2-17CABLE ROUTING DIAGRAMSPEC1 Master cylinder2 Brake hose holder3 Brake hoseA Install the brake hose so that its pipe portiondirects as shown and lig

Yamaha Motor Corporation, U.S.A. hereby warrants to the origi-nal retail purchaser that the following components equipped onnew Yamaha YZ o

SPEC2-18CABLE ROUTING DIAGRAM1 Brake hose2 Master cylinder3 “ENGINE STOP” button lead4 “ENGINE STOP” button5 Throttle cable6 Clutch cable7 Clamp8 Cabl

3INSPADJ3-1MAINTENANCE INTERVALSEC300000REGULAR INSPECTION AND ADJUSTMENTSEC310013MAINTENANCE INTERVALSThe following schedule is intended as a genera

INSPADJ3-2MAINTENANCE INTERVALSItem RemarksCOOLING SYSTEMCheck coolant level and leakage ●●Check radiator cap operation ●Replace coolant ● Every two y

3-4PRE-OPERATION INSPECTION AND MAINTENANCEINSPADJEC320000PRE-OPERATION INSPECTION AND MAINTENANCEBefore riding for break-in operation, practice or

INSPADJ3-5ENGINE/COOLANT LEVEL INSPECTION/COOLANT REPLACEMENTEC350000ENGINEEC351011COOLANT LEVEL INSPECTIONwDo not remove the radiator cap 1, dr

INSPADJ3-6COOLANT REPLACEMENTcCTake care so that coolant does not splashon painted surfaces. If it splashes, wash itaway with water.1. Place a contain

INSPADJ3-7RADIATOR CAP INSPECTIONcC9Do not mix more than one type of ethyl-ene glycol antifreeze containing corro-sion inhibitors for aluminum eng

INSPADJ3-8RADIATOR CAP OPENING PRESSURE INSPECTION/COOLING SYSTEM INSPECTIONEC356002RADIATOR CAP OPENING PRESSUREINSPECTION1. Attach:9Radiator cap tes

INSPADJ3-9CLUTCH ADJUSTMENT4. Inspect:9PressureImpossible to maintain the specified pres-sure for 10 seconds→Repair.9Radiator 19Radiator hose joi

INSPADJ3-10THROTTLE CABLE ADJUSTMENT/THROTTLE LUBRICATIONEC35A001THROTTLE CABLE ADJUSTMENT1. Check:9Throttle grip free play aOut of specification→Adju

EC040001IMPORTANT NOTICETHIS MACHINE IS DESIGNED STRICTLY FORCOMPETITION USE, ONLY ON A CLOSEDCOURSE. It is illegal for this machine to b

INSPADJ3-11AIR FILTER CLEANING3. Install:9Throttle cable cap9Cap coverEC35G041AIR FILTER CLEANINGNOTE:Proper air filter maintenance is the bigge

INSPADJ3-12TRANSMISSION OIL LEVEL CHECK3. Inspect:9Air filter elementDamage→Replace.4. Apply:9Foam-air-filter oil or equivalent oilTo the element.NOTE

INSPADJ3-13TRANSMISSION OIL REPLACEMENT3. Check:9Transmission oil levelEC35K002TRANSMISSION OIL REPLACEMENT1. Start the engine and warm it up for

INSPADJ3-14PILOT AIR SCREW ADJUSTMENT4. Remove:9Oil drain bolt 19Oil filler cap 2Drain the transmission oil.5. Install:9Aluminum washer 9Oil drain bol

INSPADJ3-15IDLE SPEED ADJUSTMENT/MUFFLER INSPECTION/SILENCER FIBER REPLACEMENTEC35M001IDLE SPEED ADJUSTMENT1. Start the engine and thoroughly warm it

INSPADJ3-16SILENCER FIBER REPLACEMENT5. Install:9Bolt (fiber) 19Silencer 29Bolt (silencer) 39Side cover (right)10 Nm (1.0 m•kg, 7.2 ft•lb)12 Nm (1.2 m

INSPADJ3-17CHASSIS/BRAKE SYSTEM AIR BLEEDINGEC360000CHASSISEC361030BRAKE SYSTEM AIR BLEEDINGwBleed the brake system if:9The system has been disassembl

INSPADJ3-18FRONT BRAKE ADJUSTMENT3. Install:9Protector (rear brake)9Reservoir float (front brake)9Diaphragm9Master cylinder capEC362041FRONT BRAKE ADJ

3-19REAR BRAKE ADJUSTMENT/FRONT BRAKE PAD INSPECTION AND REPLACEMENTINSPADJEC365080FRONT BRAKE PAD INSPECTION AND REPLACEMENT1. Inspect:9Brake pad thi

3-20FRONT BRAKE PAD INSPECTION AND REPLACEMENTINSPADJ9Loosen the pad pin 2.9Remove the caliper 3 from the front fork.9Remove the pad pin and brake pad

5. GASOLINE IS HIGHLY FLAMMABLE.Always turn off the engine while refuel-ing. Take care to not spill any gasolineon the engine or exhaust system.N

3-21REAR BRAKE PAD INSPECTION AND REPLACEMENTINSPADJ3. Inspect:9Brake fluid levelRefer to “BRAKE FLUID LEVEL INSPECTION” section.4. Check:9Brake l

3-22REAR BRAKE PAD INSPECTION AND REPLACEMENTINSPADJ9Remove the pad pin 6 and brake pads 7.9Connect the transparent hose 8 to thebleed screw 9

3-23REAR BRAKE PAD INSULATOR INSPECTIONBRAKE FLUID LEVEL INSPECTIONINSPADJEC36b000REAR BRAKE PAD INSULATOR INSPECTION1. Remove:9Brake padRefer to “RE

3-24SPROCKETS INSPECTION/DRIVE CHAIN INSPECTIONINSPADJEC368000SPROCKETS INSPECTION1. Inspect:9Sprocket teeth aExcessive wear → Replace.NOTE:Replace t

3-25DRIVE CHAIN SLACK ADJUSTMENTINSPADJEC36A061DRIVE CHAIN SLACK ADJUSTMENT1. Elevate the rear wheel by placing the suit-able stand under the e

3-26FRONT FORK INSPECTIONINSPADJ3. Adjust:9Drive chain slackEC36C000FRONT FORK INSPECTION1. Inspect:9Front fork smooth actionOperate the front brak

3-27FRONT FORK OIL SEAL AND DUST SEAL CLEANING/FRONT FORK INTERNAL PRESSURE RELIEVING/FRONT FORK REBOUND DAMPING FORCE ADJUSTMENTINSPADJEC36D001FRONT

3-28FRONT FORK COMPRESSION DAMPING FORCEADJUSTMENTINSPADJcCDo not force the adjuster past the minimumor maximum extent of adjustment. The ad-jus

3-29REAR SHOCK ABSORBER INSPECTIONINSPADJ9STANDARD POSITION:This is the position which is back by the spe-cific number of clicks from the fully turned

3-30REAR SHOCK ABSORBER SPRING PRELOADADJUSTMENTINSPADJEC36M014REAR SHOCK ABSORBER SPRINGPRELOAD ADJUSTMENT1. Elevate the rear wheel by placing

EC050000TO THE NEW OWNERThis manual will provide you with a good basicunderstanding of features, operation, and basicmaintenance and inspection items

3-31REAR SHOCK ABSORBER REBOUND DAMPINGFORCE ADJUSTMENTINSPADJEC36N014REAR SHOCK ABSORBER REBOUNDDAMPING FORCE ADJUSTMENT1. Adjust:9Rebound damping fo

3-32REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENTINSPADJEC36c000REAR SHOCK ABSORBER LOWCOMPRESSION DAMPING FORCE ADJUSTMENT1. Adjust:9L

3-33REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENTINSPADJEC36d000REAR SHOCK ABSORBER HIGHCOMPRESSION DAMPING FORCE ADJUSTMENT1. Adjust:

3-34TIRE PRESSURE CHECK/SPOKES INSPECTION ANDTIGHTENING/WHEEL INSPECTIONINSPADJEC36Q001TIRE PRESSURE CHECK1. Measure:9Tire pressureOut of specificatio

3-35STEERING HEAD INSPECTION AND ADJUSTMENTINSPADJ2. Inspect:9Bearing free playExist play → Replace.EC36U070STEERING HEAD INSPECTION ANDADJUSTMENT1. E

3-36STEERING HEAD INSPECTION AND ADJUSTMENTINSPADJ9Loosen the ring nut one turn.9Retighten the ring nut using the ring nutwrench.wAvoid over-ti

3-37LUBRICATIONINSPADJEC36a042LUBRICATIONTo ensure smooth operation of all components,lubricate your machine during setup, after break-in, and a

3-38ELECTRICAL/SPARK PLUG INSPECTIONINSPADJEC370000ELECTRICALEC371001SPARK PLUG INSPECTION1. Remove:9Spark plug2. Inspect:9Electrode 1Wear/Damage → Re

3-39IGNITION TIMING CHECKINSPADJEC372012IGNITION TIMING CHECK1. Remove:9Fuel tankRefer to “SEAT, FUEL TANK AND SIDECOVERS” section in the CHAPTE

3-40IGNITION TIMING CHECKINSPADJ7. Adjust:9Ignition timingAdjustment steps:9Loosen the screws (stator) 1.9Align the punch mark on the rotor wit

EC080000HOW TO USETHIS MANUALEC081000PARTICULARLY IMPORTANT INFORMATIONQThe Safety Alert Symbol means ATTENTION!BECOME ALERT! YOUR SAFETY ISI

44-1SEAT, FUEL TANK AND SIDE COVERSENGEC400000ENGINEEC4R0000SEAT, FUEL TANK AND SIDE COVERSExtent of removal Order Part name Q’ty RemarksSEAT, FUEL TA

4-2ENGSEAT, FUEL TANK AND SIDE COVERSEC4R3000REMOVAL POINTSEC413110Side cover1. Remove:9Bolt (side cover)9Side cover (left and right) 1NOTE:Draw the

4-3EXHAUST PIPE AND SILENCERENGEC4S0000EXHAUST PIPE AND SILENCERExtent of removal: 1Silencer removal2Exhaust pipe removal12 Nm (1.2 m•kg, 8.7 ft•lb)12

4-4RADIATORENGExtent of removal Order Part name Q’ty RemarksRADIATOR REMOVALPreparation for Drain the coolant.Refer to “COOLANT REPLACEMENT”removal s

4-5ENGRADIATOREC456000HANDLING NOTEwDo not remove the radiator cap when theengine and radiator are hot. Scalding hotfluid and steam ma

4-6ENGRADIATOREC455000ASSEMBLY AND INSTALLATIONEC445354Radiator1. Install:9Radiator breather hose 19Radiator hose 2 2To radiator (right) 3.2. Install:

4-7CARBURETOR AND REED VALVEENGEC460000CARBURETOR AND REED VALVEExtent of removal Order Part name Q’ty RemarksCARBURETOR AND REED VALVE REMOVALPrepara

4-8CARBURETOR AND REED VALVEENGEC468000CARBURETOR DISASSEMBLYExtent of removal Order Part name Q’ty RemarksCARBURETOR DISASSEMBLY1 Mixing chamber top

4-9ENGCARBURETOR AND REED VALVEEC466020HANDLING NOTEcCDo not loosen the screws {TPS (throttleposition sensor)} except when changingthe TPS

4-10ENGCARBURETOR AND REED VALVEEC464310Throttle valve1. Check:9Free movementStick → Repair or replace.NOTE:Insert the throttle valve 2 into the