Yamaha WR250FM - Manuals

EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION!BECOME ALERT! YOUR SAFETY ISINVOLVED! Failure to follow WARNING instructions couldresult in severe injury or death to the machineoperator, a bystander, or a person inspectingor repairi...

ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols 1 to 7 are designed as thumb tabs to indicate the chapter’s numberand content. 1 General information 2 Specifications 3 Regular inspection and adjustments 4 Engine 5 Chassis 6 Electrical 7 Tuning Illustrated symbols 8 to D are used ...

EC090000 INDEX GENERAL INFORMATION 1 SPECIFICATIONS SPEC 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE ENG 4 CHASSIS CHAS 5 ELECTRICAL ELEC 6 TUNING TUN 7 GEN INFO INSP ADJ – +

GEN INFO 1 - 1 DESCRIPTION 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...

1 - 2 GEN INFO MACHINE IDENTIFICATION EC120001 MACHINE IDENTIFICATION There are two significant reasons for knowingthe serial number of your machine:1. When ordering parts, you can give the number to your Yamaha dealer for positiveidentification of the model you own. 2. If your machine is stolen, th...

1 - 3 GEN INFO 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 pres-sured water, cover the parts follows.• Silencer exhaust port...

1 - 4 GEN INFO IMPORTANT INFORMATION EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/orgrease recommended by Yamaha forassembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replac...

1 - 5 GEN INFO IMPORTANT INFORMATION EC136000 CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace pistonpin clips after one use. Replace distortedcirclips. When installing a circlip 1 , make sure that the sharp-edged corner 2 is posi- tioned opposite to the thrus...

1 - 6 GEN INFO CHECKING OF CONNECTION EC1C0001 CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on theconnector.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 c...

GEN INFO 1 - 7 SPECIAL TOOLS SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using thecorrect special tool will help prevent damage caused by the use of improper tools or improvisedtechniques. The shape and part number used for the special tool di...

1 - 10 GEN INFO CONTROL FUNCTIONS EC150000 CONTROL FUNCTIONS MAIN SWITCH Functions of the respective switch positionsare 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 indic...

1 - 11 GEN INFO CONTROL FUNCTIONS EC152000 CLUTCH LEVER The clutch lever 1 is located on the left han- dlebar; it disengages or engages the clutch.Pull the clutch lever to the handlebar to disen-gage the clutch, and release the lever toengage the clutch. The lever should be pulledrapidly and release...

1 - 12 GEN INFO CONTROL FUNCTIONS EC157000 REAR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine. Press down on the brakepedal to activate the rear brake. FUEL COCK The fuel cock supplies fuel from the tank tocarburetor and also filters the fuel. The fuelcock has three ...

1 - 13 GEN INFO 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 breatherhose. CAUTION: In this installation, make sure the arrowfaces the fuel tank and also downward. SPARK PLUG WREN...

1 - 14 GEN INFO FUEL Always use the recommended fuel as statedbelow. Also, be sure to use new gasoline theday of a race. CAUTION: Use only unleaded gasoline. The use ofleaded gasoline will cause severe damageto the engine internal parts such as valves,piston rings, and exhaust system, etc. NOTE: If ...

1 - 15 GEN INFO STARTING AND BREAK-IN STARTING AND BREAK-IN WARNING Never start or run the engine in a closedarea. The exhaust fumes are poisonous;they can cause loss of consciousness anddeath in a very short time. Always operatethe machine in a well-ventilated area. CAUTION: • The carburetor on thi...

1 - 16 GEN INFO STARTING AND BREAK-IN NOTE: If the engine fails to start by pushing the startswitch, release the switch, wait a few seconds,and then try again. Each starting attemptshould be as short as possible to preserve thebattery. Do not crank the engine more than10 seconds on any one attempt. ...

1 - 17 GEN INFO STARTING AND BREAK-IN STARTING A WARM ENGINE Do not operate the cold starter knob and throt-tle. Pull the hot starter lever 1 and start the engine by pushing the start switch or by kick-ing the kickstarter crank forcefully with a firmstroke. As soon as the engine starts, Release the ...

1 - 18 GEN INFO 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 thecontrols and the engine stop switch. Then,restart the engine a...

1 - 20 GEN INFO CLEANING AND STORAGE EC1B0000 CLEANING AND STORAGE EC1B1000 CLEANING Frequent cleaning of your machine willenhance its appearance, maintain good overallperformance, and extend the life of many com-ponents.1. Before washing the machine, block off the end of the exhaust pipe to prevent...

1 - 21 GEN INFO CLEANING AND STORAGE EC1B2001 STORAGE If your machine is to be stored for 60 days ormore, some preventive measures must betaken to avoid deterioration. After cleaning themachine thoroughly, prepare it for storage asfollows:1. Drain the fuel tank, fuel lines, and the car- buretor floa...

SPEC 2 - 1 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...

SPEC 2 - 4 MAINTENANCE SPECIFICATIONS 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 (0.002 in) Camshaft: Drive method Chain drive (Left) ---- Camsh...

SPEC 2 - 12 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 k...

SPEC 2 - 17 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) --...

SPEC 2 - 19 EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasten-ers with standard I.S.O. pitch threads. Torquespecifications for special components orassemblies are included in the applicable sec-tions of this book. To avoid warpage, tightenmulti-fastener assemblie...

2 - 20 SPEC CABLE ROUTING DIAGRAM EC240000 CABLE ROUTING DIAGRAM 1 Fuel tank breather hose 2 Oil tank breather hose 3 Clamp 4 Diode 5 Wire harness 6 Hot starter cable 7 Throttle position sensor lead 8 Neutral switch lead 9 Oil hose 0 Hose guide A AC magneto lead B Cylinder head breather hose C Start...

3 - 1 INSP ADJ MAINTENANCE INTERVALS EC300000 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS The following schedule is intended as a general guide to maintenance and lubrication. Bear in mindthat such factors as weather, terrain, geographical location, and individual usage will alter there...

3 - 4 INSP ADJ 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 operatingcondition.Before using this machine, check the following points. GENERAL INSPECTION AND MAINTE...

3 - 5 INSP ADJ EC350000 ENGINE COOLANT LEVEL INSPECTION WARNING Do not remove the radiator cap 1 , drain bolt and hoses when the engine and radia-tor are hot. Scalding hot fluid and steammay be blown out under pressure, whichcould cause serious injury.When the engine has cooled, place a thicktowel o...

3 - 7 INSP ADJ COOLANT REPLACEMENT 9. Fill: • Radiator• Engine To specified level. CAUTION: • Do not mix more than one type of ethyl- ene glycol antifreeze containing corro-sion inhibitors for aluminum engine. • Do not use water containing impurities or oil. Recommended coolant: High quality ethylen...

3 - 8 INSP ADJ RADIATOR CAP INSPECTION/ RADIATOR CAP OPENING PRESSURE INSPECTION 12. Install: • Coolant reservoir cap 13. Start the engine and let it warm up for sev- eral minutes. 14. Turn off the engine and inspect the coolant level.Refer to “COOLANT LEVEL INSPECTION”section. NOTE: Before checking...

3 - 9 INSP ADJ COOLING SYSTEM INSPECTION/ CLUTCH ADJUSTMENT 2. Apply the specified pressure. 3. Inspect: • Pressure Impossible to maintain the specified pres-sure for 10 seconds → Replace. Radiator cap opening pressure: 110 kPa (1.1 kg/cm 2 , 15.6 psi) COOLING SYSTEM INSPECTION 1. Inspect: • Coolant...

3 - 10 INSP ADJ THROTTLE CABLE ADJUSTMENT 2. Adjust: • Clutch lever free play NOTE: • Make minute adjustment on the lever side using the adjuster 2 . • After adjustment, check proper operation of clutch lever. Clutch lever free play adjustment steps: • Loosen the locknuts 1 . • Adjust the free play ...

3 - 11 INSP ADJ 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) •...

3 - 12 INSP ADJ AIR FILTER CLEANING AIR FILTER CLEANING NOTE: Proper air filter maintenance is the biggest keyto preventing premature engine wear anddamage. CAUTION: Never run the engine without the air filterelement in place; this would allow dirt anddust to enter the engine and cause rapidwear and...

3 - 13 INSP ADJ 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 NOTE: • Squeeze out the exce...

3 - 14 INSP ADJ ENGINE OIL LEVEL INSPECTION ENGINE OIL LEVEL INSPECTION 1. Start the engine, warm it up for several minutes, and then turn off the engine andwait for five minutes. 2. Place the machine on a level place and hold it up on upright position by placing thesuitable stand under the engine. ...

3 - 15 INSP ADJ ENGINE OIL REPLACEMENT (Except for USA and CDN) CAUTION: • Do not add any chemical additives or use oils with a grade of CD a or higher. • Do not use oils labeled “ENERGY CON- SERVING II” b or higher. Engine oil also lubricates the clutch and additives couldcause clutch slippage. • D...

3 - 16 INSP ADJ 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. 5. Remove: • Lower engine bracket• Oil hose clamp 1 • Bolt (oil hose) 2 • ...

3 - 17 INSP ADJ 8. Install: • Copper washer 1 • Oil strainer (frame) 2 • Oil hose 3 • Bolt (oil hose) 4 • Oil hose clamp 5 • Lower engine bracket 9. Install: • Copper washer• Oil filter element drain bolt • Crankcase oil drain bolt • Frame oil drain bolt 10. Fill: • Engine oil 11. Check: • Oil leaka...

3 - 18 INSP ADJ 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 checkbolt. If no oil comes out after one minute,turn the engine off so it will not s...

3 - 19 INSP ADJ 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. Re...

3 - 20 INSP ADJ VALVE CLEARANCE INSPECTION AND ADJUSTMENT 3. Remove: • Right radiator Refer to “RADIATOR” section in theCHAPTER 4. • Carburetor Refer to “CARBURETOR” section in theCHAPTER 4. • Spark plug • Upper engine bracket• Cylinder head cover Refer to “CAMSHAFTS” section in theCHAPTER 4. 4. Rem...

3 - 21 INSP ADJ VALVE CLEARANCE INSPECTION AND ADJUSTMENT • Measure the valve clearance e using a feeler gauge 1 . NOTE: Record the measured reading if the clear-ance is incorrect. 6. Adjust: • Valve clearance Adjustment steps: • Remove the camshaft (intake and exhaust). Refer to “CAMSHAFTS” section...

3 - 22 INSP ADJ VALVE CLEARANCE INSPECTION AND ADJUSTMENT NOTE: The thickness a of each pad is indicated in hundreths of millimeters on the pad uppersurface. • Round off the last digit of the installed pad number to the nearest increment. Last digit of pad number Rounded value 0, 1 or 2 0 4, 5 or 6 ...

3 - 23 INSP ADJ INTAKE EXHAUST MEASURED CLEARANCE INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.05 ~ 0.09 120 125 130 1...

3 - 24 INSP ADJ 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. 1. Remove: • Bolt (spark arrester) 1 1 1 2. Remove: • Spark arrester 1 Pull the spark arrester out...

3 - 25 INSP ADJ 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 performancemay occur if the ...

3 - 26 INSP ADJ FRONT BRAKE ADJUSTMENT 3. Install: • Protector (rear brake)• Diaphragm• Brake master cylinder cap NOTE: If bleeding is difficult, it may be necessary tolet the brake fluid system stabilize for a fewhours. Repeat the bleeding procedure whenthe tiny bubbles in the system have disap-pea...

3 - 27 INSP ADJ 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...

3 - 28 INSP ADJ 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 con- tainer under its end...

3 - 29 INSP ADJ REAR BRAKE PAD INSPECTION AND REPLACEMENT 3. Inspect: • Brake fluid level Refer to “BRAKE FLUID LEVEL INSPEC-TION” section. • Install the pad pin plug B . T R . . Pad pin plug: 3 Nm (0.3 m • kg, 2.2 ft • lb) 4. Check: • Brake lever operation A softy or spongy feeling → Bleed brake sy...

3 - 31 INSP ADJ 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 BLEED-ING” section. EC36b000...

3 - 32 INSP ADJ SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION SPROCKETS INSPECTION 1. Inspect: • Sprocket teeth a Excessive wear → Replace. NOTE: Replace the drive sprocket, rear wheelsprocket and drive chain as a set. DRIVE CHAIN INSPECTION 1. Remove: • Drive chain 1 NOTE: Remove the drive chain usin...

3 - 33 INSP ADJ DRIVE CHAIN INSPECTION 5. Check: • Drive chain stiffness a Clean and oil the drive chain and hold asillustrated.Stiff → Replace the drive chain. 6. Install: • Chain joint 1 • O-ring 2 • Drive chain 3 NOTE: When installing the drive chain, apply the lith-ium soap base grease on the ch...

3 - 34 INSP ADJ DRIVE CHAIN SLACK ADJUSTMENT DRIVE CHAIN SLACK ADJUSTMENT 1. Elevate the rear wheel by placing the suit- able stand under the engine. 2. Check: • Drive chain slack a Above the seal guard installation bolt.Out of specification → Adjust. NOTE: Before checking and/or adjusting, rotate t...

3 - 35 INSP ADJ FRONT FORK INSPECTION/ FRONT FORK OIL SEAL AND DUST SEAL CLEANING • Tighten the axle nut while pushing down the drive chain. T R . . Axle nut: 125 Nm (12.5 m • kg, 90 ft • lb) • Tighten the locknuts. T R . . Locknut: 16 Nm (1.6 m • kg, 11 ft • lb) EC36C000 FRONT FORK INSPECTION 1. In...

3 - 36 INSP ADJ FRONT FORK INTERNAL PRESSURE RELIEVING/FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT FRONT FORK INTERNAL PRESSURE RELIEVING NOTE: If the front fork initial movement feels stiff dur-ing a run, relieve the front fork internal pres-sure. 1. Elevate the front wheel by placing a suit- able ...

3 - 37 INSP ADJ FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT • STANDARD POSITION: This is the position which is back by the spe-cific number of clicks from the fully turned-inposition. * For EUROPE, AUS, NZ and ZA CAUTION: Do not force the adjuster past the minimumor maximum extent of adjustment....

3 - 38 INSP ADJ REAR SHOCK ABSORBER INSPECTION • STANDARD POSITION: This is the position which is back by the spe-cific number of clicks from the fully turned-inposition. * For EUROPE, AUS, NZ and ZA CAUTION: Do not force the adjuster past the minimumor maximum extent of adjustment. Theadjuster may ...

3 - 39 INSP ADJ REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1. Elevate the rear wheel by placing the suit- able stand under the engine. 2. Remove: • Rear frame 3. Loosen: • Locknut 1 4. Adjust: • Spring preload By turning the adjuster 2 . * For EUROPE ...

3 - 40 INSP ADJ REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT EC36N014 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1. Adjust: • Rebound damping force By turning the adjuster 1 . Stiffer a → Increase the rebound damp- ing force. (Turn the adjuster 1 in.) Softer b → Decrease the reboun...

3 - 41 INSP ADJ EC36c000 REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: • Low compression damping force By turning the adjuster 1 . Stiffer a → Increase the low compres- sion damping force. (Turn the adjuster 1 in.) Softer b → Decrease the low compres- sion damping force. (T...

3 - 42 INSP ADJ REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT EC36d000 REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: • High compression damping force By turning the adjuster 1 . Stiffer a → Increase the high compres- sion damping force. (Turn the adjuster 1...

3 - 43 INSP ADJ TIRE PRESSURE CHECK/SPOKES INSPECTION AND TIGHTENING/WHEEL INSPECTION EC36Q000 TIRE PRESSURE CHECK 1. Measure: • Tire pressure Out of specification → Adjust. NOTE: • Check the tire while it is cold.• Loose bead stoppers allow the tire to slip off its position on the rim when the tire...

3 - 44 INSP ADJ STEERING HEAD INSPECTION AND ADJUSTMENT 2. Inspect: • Bearing free play Exist play → Replace. EC36U013 STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suit- able stand under the engine. 2. Check: • Steering stem Grasp the bottom of the forks and gently...

3 - 45 INSP ADJ • Tighten the steering ring nut 3 using steering nut wrench 4 . NOTE: Set the torque wrench to the steering nutwrench so that they form a right angle. Steering nut wrench: YU-33975/90890-01403 T R . . Steering ring nut (initial tightening): 38 Nm (3.8 m • kg, 27 ft • lb) • Loosen the...

3 - 46 INSP ADJ LUBRICATION LUBRICATION To ensure smooth operation of all components,lubricate your machine during setup, afterbreak-in, and after every race. 1 All control cable 2 Clutch lever pivot 3 Shift pedal pivot 4 Footrest pivot 5 Throttle-to-handlebar contact 6 Drive chain 7 Tube guide cabl...

3 - 47 INSP ADJ ELECTRICAL/SPARK PLUG INSPECTION/ IGNITION TIMING CHECK EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: • Spark plug 2. Inspect: • Electrode 1 Wear/damage → Replace. • Insulator color 2 Normal condition is a medium to light tancolor.Distinctly different color → Check th...

3 - 48 INSP ADJ IGNITION TIMING CHECK 2. Attach: • Timing light • Inductive tachometer To the ignition coil lead (orange lead 1 ). Timing light: YM-33277-A/90890-03141 Inductive tachometer: YU-8036-B Engine tachometer: 90890-03113 1 3. Check: • Ignition timing 4. Install: • Timing mark accessing scr...

3 - 49 INSP ADJ BATTERY INSPECTION AND CHARGING WARNING Batteries generate explosive hydrogen gasand contain electrolyte which is made ofpoisonous and highly caustic sulfuric acid. Therefore, always follow these preventivemeasures: • Wear protective eye gear when handling or working near batteries. ...

3 - 50 INSP ADJ BATTERY INSPECTION AND CHARGING NOTE: Since MF batteries are sealed, it is not possi-ble to check the charge state of the battery bymeasuring the specific gravity of the electro-lyte. Therefore, the charge of the battery has tobe checked by measuring the voltage at thebattery termina...

3 - 52 INSP ADJ BATTERY INSPECTION AND CHARGING 5. Charge: • Battery (refer to the appropriate charging methodillustration) WARNING Do not quick charge a battery. CAUTION: • Never remove the MF battery sealing caps. • Do not use a high-rate battery charger since it forces a high-amperage currentinto...

3 - 53 INSP ADJ BATTERY INSPECTION AND CHARGING Charging method using a variable voltage charger

3 - 54 INSP ADJ BATTERY INSPECTION AND CHARGING Charging method using a constant voltage charger

3 - 55 INSP ADJ BATTERY REPLACEMENT/FUSE INSPECTION 6. Install: • Battery• Battery band 7. Connect: • Battery leads (to the battery terminals) CAUTION: First, connect the positive lead 1 , then the negative lead 2 . 8. Check: • Battery terminals Dirt → Clean with a wire brush. Loose connection → Con...

3 - 56 INSP ADJ FUSE INSPECTION 2. Check: • Continuity 2 Reserve fuse Checking steps: • Remove the fuse 1 . • Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “ Ω × 1”. Pocket tester: YU-3112-C/90890-03112 • If the pocket tester indicates “ ∞ ”,...

3 - 57 INSP ADJ REPLACING THE HEADLIGHT BULBS/ ADJUSTING THE HEADLIGHT BEAMS REPLACING THE HEADLIGHT BULBS 1. Remove: • Headlight Refer to “SEAT, FUEL TANK AND SIDECOVERS” section in the CHAPTER 4. 2. Remove: • Headlight bulb holder cover 1 3. Detach: • Headlight bulb holder 1 4. Remove: • Headlight...

4 - 1 ENG EC400000 ENGINE SEAT, FUEL TANK AND SIDE COVERS Extent of removal: 1 Seat removal 2 Fuel tank removal 3 Side covers removal 4 Headlight removal Extent of removal Order Part name Q’ty Remarks SEAT, FUEL TANK AND SIDE COVERS REMOVAL Preparation for removal Turn the fuel cock to “OFF”.Disconn...

4 - 2 ENG REMOVAL POINTSSide cover 1. Remove: • Bolt (side cover)• Left side cover 1 • Right side cover 2 NOTE: Draw the side cover downward to remove itbecause its claws a are inserted in the air fil- ter case. SEAT, FUEL TANK AND SIDE COVERS

4 - 3 ENG EXHAUST PIPE AND SILENCER EC4S0000 EXHAUST PIPE AND SILENCER È Except for USA Extent of removal: 1 Silencer removal 2 Exhaust pipe removal Extent of removal Order Part name Q’ty Remarks EXHAUST PIPE AND SILENCER REMOVAL Preparation for removal Right side cover Refer to “SEAT, FUEL TANK AND...

4 - 5 ENG RADIATOR EC450001 RADIATOR Extent of removal: 1 Radiator removal Extent of removal Order Part name Q’ty Remarks RADIATOR REMOVAL Preparation for removal Drain the coolant. Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3. Seat, fuel tank and left side cover Refer to “SEAT, FUEL TANK...

4 - 6 ENG RADIATOR EC456000 HANDLING NOTE WARNING Do not remove the radiator cap when theengine and radiator are hot. Scalding hotfluid and steam may be blown out underpressure, which could cause seriousinjury.When the engine has cooled, open the radi-ator cap by the following procedure:Place a thic...

4 - 8 ENG CARBURETOR CARBURETOR 9 7 8 1 T R . . 2 Nm (0.2 m • kg, 1.4 ft • Ib) T R . . 11 Nm (1.1 m • kg, 8.0 ft • Ib) T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) 5 1 2 6 6 4 4 3 T R . . 3 Nm (0.3 m • kg, 2.2 ft • Ib) T R . . 3 Nm (0.3 m • kg, 2.2 ft • Ib) T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) Extent of...

4 - 11 ENG CARBURETOR HANDLING NOTE CAUTION: Do not loosen the screws (throttle positionsensor) 1 except when changing the throt- tle position sensor due to failure because itwill cause a drop in engine performance. 1 REMOVAL POINTSPilot screw 1. Remove: • Pilot screw 1 NOTE: To optimize the fuel fl...

4 - 12 ENG CARBURETOR 2. Inspect: • Main jet 1 • Pilot jet 2 • Needle jet 3 • Starter jet 4 • Pilot air jet 5 • Leak jet 6 Damage → Replace. Contamination → Clean. NOTE: • Use a petroleum based solvent for cleaning. Blow out all passages and jets with com-pressed air. • Never use a wire. Needle valv...

4 - 13 ENG CARBURETOR Float height 1. Measure: • Float height a Out of specification → Adjust. Float height: 8.0 mm (0.31 in) Measurement and adjustment steps: • Hold the carburetor in an upside down position. NOTE: • Slowly tilt the carburetor in the opposite direction, then take the measurementwhe...

4 - 14 ENG Starter plunger 1. Inspect: • Cold starter plunger 1 • Hot starter plunger 2 Wear/damage → Replace. Accelerator pump 1. Inspect: • Diaphragm (accelerator pump) 1 • Spring (accelerator pump) 2 • Accelerator pump cover 3 • O-ring 4 • Push rod 5 Tears (diaphragm)/damage → Replace. Dirt → Cle...

4 - 17 ENG CARBURETOR 10. Install: • Starter jet 1 • Pilot jet 2 • Spacer 3 • Needle jet 4 • Main jet 5 11. Install: • Needle valve 1 • Float 2 • Float pin 3 NOTE: • After installing the needle valve to the float, install them to the carburetor. • Check the float for smooth movement. 12. Install: • ...

4 - 19 ENG CARBURETOR 19. Install: • Carburetor breather hose 1 NOTE: Install the carburetor breather hoses to thecarburetor so that the hoses do not bend nearwhere they are installed. Accelerator pump timing adjustment Adjustment steps: NOTE: In order for the throttle valve height a to achieve the ...

4 - 20 ENG 3. Install: • Hot starter plunger 1 T R . . 2 Nm (0.2 m · kg, 1.4 ft · lb) 1 4. Tighten: • Screw (air filter joint) 1 • Screw (carburetor joint) 2 T R . . 3 Nm (0.3 m · kg, 2.2 ft · lb) T R . . 3 Nm (0.3 m · kg, 2.2 ft · lb) 5. Install: • Throttle cable (pull) 1 • Throttle cable (return) ...

4 - 21 ENG 9. Install: • Clamp 1 Refer to “CABLE ROUTING DIAGRAM”section in the CHAPTER 2. 1 CARBURETOR

4 - 22 ENG CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVER Extent of removal: 1 Cylinder head cover removal Extent of removal Order Part name Q’ty Remarks CYLINDER HEAD COVER REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Carburetor Refer to “CARBURETO...

4 - 26 ENG CAMSHAFTS 4. Measure: • Camshaft-to-cap clearance Out of specification → Measure camshaft outside diameter. Camshaft-to-cap clearance: 0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in)<Limit>: 0.08 mm (0.003 in) Measurement steps: • Install the camshaft onto the cylinder head. • Position a stri...

4 - 27 ENG CAMSHAFTS Decompression system 1. Check: • Decompression system Checking steps: • Check that the decompression mecha- nism cam 1 moves smoothly. • Check that the decompression mechanism cam lever pin 2 projects from the camshaft. Timing chain tensioner 1. Check: • While pressing the tensi...

4 - 30 ENG 6. Install: • Timing chain guide (top side) 1 • Cylinder head cover gasket 2 • Cylinder head cover 3 • Bolt (cylinder head cover) 4 NOTE: Apply the sealant on the cylinder head covergasket. 7. Install: • Oil tank breather hose• Cylinder head breather hose • Spark plug T R . . 10 Nm (1.0 m...

4 - 31 ENG CYLINDER HEAD CYLINDER HEAD Extent of removal: 1 Cylinder head removal Extent of removal Order Part name Q’ty Remarks CYLINDER HEAD REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Exhaust pipe and silencer Refer to “EXHAUST PIPE AND S...

4 - 32 ENG CYLINDER HEAD INSPECTIONCylinder head 1. Eliminate: • Carbon deposits (from the combustion chambers)Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damag-ing or scratching:• Spark plug threads• Valve seats 2. Inspect: • Cylinder head Scratches/damage → Replace. 3. Meas...

4 - 34 ENG VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Extent of removal: 1 Valve removal Extent of removal Order Part name Q’ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to “CYLINDER HEAD” section. 1 Valve lifter 5 Use special tool. Refer to “REMOVAL...

4 - 35 ENG VALVES AND VALVE SPRINGS REMOVAL POINTSValve lifter and valve cotter 1. Remove: • Valve lifter 1 • Pad 2 NOTE: Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in theiroriginal place. 2. Check: • Valve sealing Leakage at the valve seat → Inspect the...

4 - 36 ENG VALVES AND VALVE SPRINGS INSPECTIONValve 1. Measure: • Stem-to-guide clearance Out of specification → Replace the valve guide. Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b Clearance (stem to guide): Intake: 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in)<Limit&...

4 - 37 ENG VALVES AND VALVE SPRINGS Valve guide remover: Intake: 4.0 mm (0.16 in) YM-4111/90890-04111 Exhaust: 4.5 mm (0.18 in) YM-4116/90890-04116 Valve guide installer: Intake: 4.0 mm (0.16 in) YM-4112/90890-04112 Exhaust: 4.5 mm (0.18 in) YM-4117/90890-04117 Valve guide reamer: Intake: 4.0 mm (0....

4 - 40 ENG VALVES AND VALVE SPRINGS Valve spring 1. Measure: • Valve spring free length a Out of specification → Replace. 2. Measure: • Compressed spring force a Out of specification → Replace. b Installed length Free length (valve spring): Intake: 37.81 mm (1.49 in)<Limit>: 35.9 mm (1.41 in) ...

4 - 43 ENG CYLINDER AND PISTON CYLINDER AND PISTON Extent of removal: 1 Cylinder removal 2 Piston removal Extent of removal Order Part name Q’ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to “CYLINDER HEAD” section. 1 Bolt (cylinder) 1 2 Cylinder 1 3 Piston pin c...

4 - 44 ENG CYLINDER AND PISTON REMOVAL POINTSPiston and piston ring 1. Remove: • Piston pin clip 1 • Piston pin 2 • Piston 3 NOTE: • Put identification marks on each piston head for reference during reinstallation. • Before removing each piston pin, deburr the clip groove and pin hole area. If the p...

4 - 47 ENG CYLINDER AND PISTON Piston pin 1. Inspect: • Piston pin Blue discoloration/grooves → Replace, then inspect the lubrication system. 2. Measure: • Piston pin-to-piston clearance ASSEMBLY AND INSTALLATIONPiston ring and piston 1. Install: • Piston ring Onto the piston. NOTE: • Be sure to ins...

4 - 48 ENG CYLINDER AND PISTON 2. Position: • Top ring• 2nd ring• Oil ring Offset the piston ring end gaps as shown. a Top ring end b 2nd ring end c Oil ring end (upper) d Oil ring e Oil ring end (lower) 45˚ 135˚ 135˚ a b c e d 3. Install: • Piston 1 • Piston pin 2 • Piston pin clip 3 NOTE: • Apply ...

4 - 49 ENG 3. Install: • Cylinder gasket 1 • Cylinder 2 NOTE: Install the cylinder with one hand while com-pressing the piston rings with the other hand. CAUTION: • Pass the timing chain 3 through the tim- ing chain cavity. • Be careful not to damage the timing chain guide 4 during installation. 4. ...

4 - 50 ENG CLUTCH EC4A0000 CLUTCH Extent of removal: 1 Push rod 1, 2 and push lever shaft removal 2 Push pod 1 disassembly 3 Friction plate and clutch plate removal 4 Primary driven gear removal Extent of removal Order Part name Q’ty Remarks CLUTCH REMOVAL Preparation for removal Drain the engine oi...

4 - 53 ENG CLUTCH Friction plate 1. Measure: • Friction plate thickness Out of specification → Replace friction plate as a set.Measure at all four points. EC484600 Clutch plate 1. Measure: • Clutch plate warpage Out of specification → Replace clutch plate as a set.Use a surface plate 1 and thickness...

4 - 54 ENG CLUTCH EC4A5000 ASSEMBLY AND INSTALLATIONPush lever shaft 1. Install: • Push lever shaft 1 • Bolt (push lever shaft) 2 NOTE: • Apply the lithium soap base grease on the oil seal lip. • Apply the engine oil on the push lever shaft.• Fit the seat plate 3 in the groove a of the push lever sh...

4 - 55 ENG 3. Bend the lock washer 1 tab. 4. Install: • Seat plate 1 • Cushion spring 2 NOTE: • Install the seat plate with its chamfered por- tion a facing the clutch boss 3 . • Install the seat plate so that it is not caught on the step b . • Install the cushion spring with the paint c facing out....

4 - 57 ENG OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER Extent of removal: 1 Oil filter element removal 2 Water pump removal 3 Right crankcase cover removal Extent of removal Order Part name Q’ty Remarks OIL FILTER ELEMENT, WATER P...

4 - 59 ENG OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER REMOVAL POINTSImpeller shaft 1. Remove: • Impeller 1 • Washer 2 • Impeller shaft 3 NOTE: Hold the impeller shaft on its width across theflats a with spanners, etc. and remove the impeller. EC4G3210 Oil seal NOTE: It is not necessary...

4 - 60 ENG OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER EC444200 Impeller shaft 1. Inspect: • Impeller shaft 1 Bend/wear/damage → Replace. Fur deposits → Clean. EC444300 Impeller shaft gear 1. Inspect: • Gear teeth a Wear/damage → Replace. EC4H4600 Bearing 1. Inspect: • Bearing Rotate in...

4 - 62 ENG OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER 2. Install: • Right crankcase cover 1 • Bolt (right crankcase cover) 2 NOTE: • Apply the engine oil on the impeller shaft end. • Mesh the impeller shaft gear 3 with primary drive gear 4 . • Tighten the bolts in stage, using a crissc...

4 - 63 ENG OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER Water pump housing 1. Install: • Dowel pin 1 • O-ring 2 NOTE: Apply the lithium soap base grease on the O-ring. New 2. Install: • Water pump housing 1 • Bolt (water pump housing) 2 T R . . 10 Nm (1.0 m · kg, 7.2 ft · lb) Oil filter ...

4 - 64 ENG BALANCER BALANCER Extent of removal: 1 Balancer shaft drive gear 2 Balancer shaft Extent of removal Order Part name Q’ty Remarks BALANCER REMOVAL Preparation for removal Primary driven gear Refer to “CLUTCH” section. Right crankcase cover Refer to “OIL FILTER ELEMENT, WATER PUMP AND RIGHT...

4 - 65 ENG BALANCER REMOVAL POINTSBalancer shaft drive gear and balancer shaft driven gear 1. Straighten the lock washer tab.2. Loosen: • Nut (primary drive gear) 1 • Nut (balancer shaft driven gear) 2 NOTE: Place an aluminum plate a between the teeth of the balancer shaft drive gear 3 and driven ge...

4 - 67 ENG OIL PUMP OIL PUMP Extent of removal: 1 Oil pump removal 2 Oil pump disassembly Extent of removal Order Part name Q’ty Remarks OIL PUMP REMOVAL AND DIS-ASSEMBLY Preparation for removal Primary driven gear Refer to “CLUTCH” section. Right crankcase cover Refer to “OIL FILTER ELEMENT, WATER ...

4 - 69 ENG OIL PUMP INSPECTIONOil pump 1. Inspect: • Oil pump drive gear 1 • Oil pump drive shaft 2 • Rotor housing 3 • Oil pump cover 4 Cracks/wear/damage → Replace. 1 3 2 4 2. Measure: • Tip clearance a (between the inner rotor 1 and outer rotor 2 ) • Side clearance b (between the outer rotor 2 an...

4 - 72 ENG KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT Extent of removal: 1 Kick shaft removal 2 Kick shaft disassembly 3 Shift shaft removal 4 Segment removal Extent of removal Order Part name Q’ty Remarks KICK SHAFT AND SHIFT SHAFT REMOVAL Preparation for removal Oil pump Refer to “OIL P...

4 - 74 ENG KICK SHAFT AND SHIFT SHAFT REMOVAL POINTSKick shaft assembly 1. Remove: • Kick shaft assembly 1 NOTE: Unhook the torsion spring 2 from the hole a in the crankcase. EC4C3101 Shift guide and shift lever assembly 1. Remove: • Bolt (shift guide)• Shift guide 1 • Shift lever assembly 2 NOTE: T...

4 - 75 ENG KICK SHAFT AND SHIFT SHAFT EC4B4400 Shift shaft 1. Inspect: • Shift shaft 1 Bend/damage → Replace. • Spring 2 Broken → Replace. EC4C4100 Shift guide and shift lever assembly 1. Inspect: • Shift guide 1 • Shift lever 2 • Pawl 3 • Pawl pin 4 • Spring 5 Wear/damage → Replace. EC4B4500 Stoppe...

4 - 76 ENG KICK SHAFT AND SHIFT SHAFT EC4B5111 Stopper lever 1. Install: • Torsion spring 1 • Stopper lever 2 • Bolt (stopper lever) 3 NOTE: Align the stopper lever roller with the slot onsegment. Shift guide and shift lever assembly 1. Install: • Spring 1 • Pawl pin 2 • Pawl 3 To shift lever 4 . NO...

4 - 78 ENG KICK SHAFT AND SHIFT SHAFT 3. Install: • Spring guide 1 NOTE: Slide the spring guide into the kick shaft, makesure the groove a in the spring guide fits on the stopper of the torsion spring. 4. Install: • Kick shaft assembly 1 • Washer 2 NOTE: • Apply the molybdenum disulfide grease on th...

4 - 79 ENG AC MAGNETO AND STARTER CLUTCH AC MAGNETO AND STARTER CLUTCH Extent of removal: 1 Starter clutch/wheel gear removal 2 Rotor removal 3 Pickup coil/stator removal Extent of removal Order Part name Q’ty Remarks AC MAGNETO AND STATOR REMOVAL Preparation for removal Drain the engine oil. Refer ...

4 - 81 ENG AC MAGNETO AND STARTER CLUTCH EC4L3000 REMOVAL POINTSRotor 1. Remove: • Nut (rotor) 1 • Plain washer 1 2. Remove: • Rotor 1 Use the rotor puller 2 . Rotor puller: YM-04141/90890-04141 EC4L4000 INSPECTIONAC magneto 1. Inspect: • Rotor inner surface a • Stator outer surface b Damage → Inspe...

4 - 83 ENG AC MAGNETO AND STARTER CLUTCH 2. Install: • Holder 1 • Bolt 2 CAUTION: Pass the pickup coil lead and charging coillead under the holder while taking care notto allow these leads to get caught with eachother. Also take care to pass the leads sothat they do not become loose at the bendof th...

4 - 88 ENG ENGINE REMOVAL EC4M3000 REMOVAL POINTS EC4F3100 Drive sprocket 1. Remove: • Nut (drive sprocket) 1 • Lock washer 2 NOTE: • Straighten the lock washer tab.• Loosen the nut while applying the rear brake. 2. Remove: • Drive sprocket 1 • Drive chain 2 NOTE: Remove the drive sprocket together ...

4 - 89 ENG ENGINE REMOVAL EC4M5000 ASSEMBLY AND INSTALLATIONEngine installation 1. Install: • Engine 1 Install the engine from right side. • Pivot shaft 2 • Engine mounting bolt (lower) 3 • Lower engine bracket 4 • Bolt (engine bracket) 5 • Engine mounting bolt (front) 6 • Upper engine bracket 7 • E...

4 - 90 ENG ENGINE REMOVAL Drive sprocket 1. Install: • Drive sprocket 1 • Drive chain 2 NOTE: Install the drive sprocket together with thedrive chain. 2. Install: • Lock washer 1 • Nut (drive sprocket) 2 NOTE: Tighten the nut while applying the rear brake. T R . . 75 Nm (7.5 m · kg, 54 ft · lb) New ...

4 - 91 ENG ENGINE REMOVAL 2. Install: • Spring 1 • Pin 2 • O-ring 3 • Neutral switch 4 • Screw (neutral switch) 5 NOTE: Apply the lithium soap base grease on the O-ring. T R . . 4 Nm (0.4 m · kg, 2.9 ft · lb) New

4 - 92 ENG CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT Extent of removal: 1 Crankcase separation 2 Crankshaft removal Extent of removal Order Part name Q’ty Remarks CRANKCASE AND CRANK-SHAFT REMOVAL Preparation for removal Engine Refer to “ENGINE REMOVAL” section. Piston Refer to “CYLINDER AND...

4 - 94 ENG CRANKCASE AND CRANKSHAFT CRANKCASE BEARING Extent of removal: 1 Crankcase bearing removal Extent of removal Order Part name Q’ty Remarks CRANKCASE BEARING REMOVAL Preparation for removal Transmission Shift cam and shift fork Refer to “TRANSMISSION, SHIFT CAM AND SHIFT FORK” section. 1 Oil...

4 - 96 ENG CRANKCASE AND CRANKSHAFT Crankshaft 1. Remove: • Crankshaft 1 Use the crankcase separating tool 2 . CAUTION: Do not use a hammer to drive out thecrankshaft. Crankcase bearing 1. Remove: • Bearing 1 NOTE: • Remove the bearing from the crankcase by pressing its inner race. • Do not use the ...

4 - 98 ENG CRANKCASE AND CRANKSHAFT EC4N5000 ASSEMBLY AND INSTALLATIONCrankcase bearing 1. Install: • Bearing • Bearing stopper• Bolt (bearing stopper) • Screw (bearing stopper) • Screw [bearing stopper (crankshaft)] 1 To left and right crankcase. NOTE: • Install the bearing by pressing its outer ra...

4 - 101 ENG TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H0000 TRANSMISSION, SHIFT CAM AND SHIFT FORK Extent of removal: 1 Shift fork, shift cam, main axle and drive axle removal Extent of removal Order Part name Q’ty Remarks TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVAL Preparation for removal Engine...

4 - 103 ENG TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H4810 Shift fork, shift cam and segment 1. Inspect: • Shift fork 1 Wear/damage/scratches → Replace. 2. Inspect: • Shift cam 1 • Segment 2 Wear/damage → Replace. 3. Check: • Shift fork movement Unsmooth operation → Replace shift fork. NOTE: For a ...

5 - 1 CHAS EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL FRONT WHEEL AND REAR WHEEL Extent of removal: 1 Front wheel removal 2 Wheel bearing removal 3 Brake disc removal Extent of removal Order Part name Q’ty Remarks Preparation for removal FRONT WHEEL REMOVAL Hold the ma...

5 - 2 CHAS EC598100 REAR WHEEL Extent of removal: 1 Rear wheel removal 2 Wheel bearing removal 3 Brake disc removal Extent of removal Order Part name Q’ty Remarks Preparation for removal REAR WHEEL REMOVAL Hold the machine by placing thesuitable stand under the engine. WARNING Support the machine se...

5 - 3 CHAS FRONT WHEEL AND REAR WHEEL EC593000 REMOVAL POINTS EC523101 Rear wheel 1. Remove: • Wheel 1 NOTE: Push the wheel forward and remove the drivechain 2 . EC513201 Wheel bearing (if necessary) 1. Remove: • Bearing 1 NOTE: Remove the bearing using a general bearingpuller 2 . EC594000 INSPECTIO...

5 - 8 CHAS 11. Install: • Trip meter cable 1 1 Rear wheel 1. Install: • Bearing (right) 1 • Circlip 2 • Spacer 3 • Bearing (left) 4 • Oil seal 5 NOTE: • Apply the lithium soap base grease on the bearing and oil seal lip when installing. • Install the bearing with seal facing outward.• Use a socket t...

5 - 10 CHAS FRONT WHEEL AND REAR WHEEL 8. Install: • Right drive chain puller 1 • Washer 2 • Nut (wheel axle) 3 NOTE: Temporarily tighten the nut (wheel axle) at thispoint. 9. Adjust: • Drive chain slack a Refer to “DRIVE CHAIN SLACKADJUSTMENT” section in the CHAPTER3. Drive chain slack: 40 ~ 50 mm ...

5 - 11 CHAS FRONT BRAKE AND REAR BRAKE EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE Extent of removal: 1 Brake hose removal 2 Brake caliper removal 3 Brake master cylinder removal Extent of removal Order Part name Q’ty Remarks Preparation for removal FRONT BRAKE REMOVAL Hold the machine ...

5 - 12 CHAS EC5A8100 REAR BRAKE Extent of removal: 1 Brake master cylinder removal 2 Brake hose removal 3 Brake caliper removal Extent of removal Order Part name Q’ty Remarks Preparation for removal REAR BRAKE REMOVAL Hold the machine by placing thesuitable stand under the engine. WARNING Support th...

5 - 13 CHAS BRAKE CALIPER DISASSEMBLY È Front É Rear Extent of removal: 1 Front brake caliper disassembly 2 Rear brake caliper disassembly Extent of removal Order Part name Q’ty Remarks BRAKE CALIPER DISASSEM-BLY A B 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Brake caliper piston 2 1 Refer to...

5 - 14 CHAS FRONT BRAKE AND REAR BRAKE BRAKE MASTER CYLINDER DISASSEMBLY È Front É Rear Extent of removal: 1 Front brake master cylinder disassembly 2 Rear brake master cylinder disassembly Extent of removal Order Part name Q’ty Remarks BRAKE MASTER CYLINDER DISASSEMBLY 1 Brake master cylinder cap 1...

5 - 15 CHAS FRONT BRAKE AND REAR BRAKE EC5A3000 REMOVAL POINTSBrake fluid 1. Remove: [Front]• Brake master cylinder cap 1 [Rear]• Brake master cylinder cap 1 • Protector NOTE: Do not remove the diaphragm. È Front É Rear 2. Connect the transparent hose 2 to the bleed screw 1 and place a suitable con-...

5 - 16 CHAS FRONT BRAKE AND REAR BRAKE Brake caliper piston seal kit 1. Remove: • Dust seal 1 • Piston seal 2 NOTE: Remove the piston seals and dust seals bypushing them with a finger. CAUTION: Never attempt to pry out piston seals anddust seals. WARNING Replace the piston seals and dust sealswhenev...

5 - 17 CHAS Brake caliper 1. Inspect: • Brake caliper cylinder inner surface a Wear/score marks → Replace brake cali- per assembly. È Front É Rear É È 2. Inspect: • Brake caliper piston 1 Wear/score marks → Replace brake cali- per piston assembly. WARNING Replace the piston seals and dust seals 2 wh...

5 - 18 CHAS 2. Install: • Piston seal 1 • Dust seal 2 WARNING Always use new piston seals and dustseals. NOTE: Fit the piston seals and dust seals onto the sloton brake caliper correctly. È Front É Rear È New New É 3. Install: • Brake caliper piston 1 NOTE: Apply the brake fluid on the piston wall. ...

5 - 19 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: • Copper washer 1 • Union bolt 2 WARNING Always use new copper washers. CAUTION: Install the brake hose so that its pipe por-tion a directs as shown and lightly touches the projection b on the brake cali- per. T R . . 30 Nm (3.0 m · kg, 22 ft · lb) ...

5 - 20 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: • Brake disc cover 1 • Bolt (brake disc cover) 2 T R . . 7 Nm (0.7 m · kg, 5.1 ft · lb) 3. Install: • Brake caliper 1 • Rear wheel 2 Refer to “FRONT WHEEL AND REARWHEEL” section. 4. Tighten: • Pad pin 3 5. Install: • Pad pin plug 4 T R . . 18 Nm (1....

5 - 21 CHAS FRONT BRAKE AND REAR BRAKE 3. Install: • Spring 1 To brake master cylinder piston 2 . NOTE: Install the spring at the smaller dia. side. È Front É Rear È É 4. Install: [Front]• Brake master cylinder kit 1 • Washer 2 • Circlip 3 • Brake master cylinder boot 4 To brake master cylinder 5 . ...

5 - 22 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: • Brake lever 1 • Bolt (brake lever) 2 • Nut (brake lever) 3 NOTE: Apply the lithium soap base grease on thebrake lever sliding surface, bolt and contactingsurface of the brake master cylinder piston. Rear brake master cylinder 1. Install: • Copper ...

5 - 23 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: • Pin 1 • Washer 2 • Cotter pin 3 NOTE: After installing, check the brake pedal height.Refer to “REAR BRAKE ADJUSTMENT” sec-tion in the CHAPTER 3. New Front brake hose 1. Install: • Brake hose 1 To brake hose holder 2 . NOTE: Before tightening the b...

5 - 25 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: • Brake hose holder 1 • Screw (brake hose holder) 2 CAUTION: After installing the brake hose holders,make sure the brake hose does not contactthe spring (rear shock absorber). If it does,correct its twist. T R . . 1 Nm (0.1 m · kg, 0.7 ft · lb) Brak...

5 - 26 CHAS FRONT BRAKE AND REAR BRAKE 2. Air bleed: • Brake system Refer to “BRAKE SYSTEM AIR BLEED-ING” section in the CHAPTER 3. 3. Inspect: • Brake fluid level Fluid at lower level → Fill up. Refer to “BRAKE FLUID LEVEL INSPEC-TION” section in the CHAPTER 3. 4. Install: [Front]• Diaphragm• Brake...

5 - 27 CHAS FRONT FORK EC550000 FRONT FORK Extent of removal: 1 Front fork removal Extent of removal Order Part name Q’ty Remarks Preparation for removal FRONT FORK REMOVAL Hold the machine by placing thesuitable stand under the engine. WARNING Support the machine securely so there is no danger of i...

5 - 32 CHAS Front fork cap bolt 1. Inspect: • Front fork cap bolt 1 • O-ring 2 • Air bleed screw 3 Wear/damage → Replace. EC555000 ASSEMBLY AND INSTALLATIONFront fork assembly 1. Wash the all parts in a clean solvent.2. Install: • Damper rod 1 To inner tube 2 . CAUTION: To install the damper rod int...

5 - 34 CHAS FRONT FORK 9. Install: • Slide metal 1 • Oil seal washer 2 To outer tube slot. NOTE: Press the slide metal into the outer tube withfork seal driver 3 . Fork seal driver: YM-01442/90890-01442 10. Install: • Oil seal 1 NOTE: Press the oil seal into the outer tube with forkseal driver 2 . F...

5 - 35 CHAS FRONT FORK 13. Check: • Inner tube smooth movement Tightness/binding/rough spots → Repeat the steps 2 to 12. 14. Compress the front fork fully. 15. Fill: • Front fork oil Until outer tube top surface with recom-mended fork oil 1 . CAUTION: • Be sure to use recommended fork oil. If other ...

5 - 36 CHAS FRONT FORK 19. Wait ten minutes until the air bubbles have been removed from the front fork, and theoil has dispense evenly in system beforesetting recommended oil level. NOTE: Fill with the fork oil up to the top end of theouter tube, or the fork oil will not spread over toevery part of...

5 - 37 CHAS FRONT FORK 21. Measure: • Distance a Out of specification → Turn into the lock- nut. Distance a : 20 mm (0.79 in) or moreBetween damper rod 1 top and locknut 2 top. 22. Loosen: • Rebound damping adjuster 1 NOTE: • Loosen the rebound damping adjuster finger tight. • Record the set positio...

5 - 38 CHAS FRONT FORK 26. Tighten: • Front fork cap bolt (locknut) 1 NOTE: • While compressing the fork spring, set the thin type spanners 2 between the spacer 3 and spring guide 4 . • Hold the locknut 5 and tighten the front fork cap bolt with specified torque. T R . . 29 Nm (2.9 m · kg, 21 ft · l...

5 - 40 CHAS HANDLEBAR EC5B0000 HANDLEBAR Extent of removal: 1 Handlebar removal Extent of removal Order Part name Q’ty Remarks Preparation for removal HANDLEBAR REMOVAL Headlight 1 Hot starter cable 1 Disconnect at the lever side. 2 Hot starter lever holder 1 3 Clutch cable 1 Disconnect at the lever...

5 - 41 CHAS EC5B3000 REMOVAL POINTSBrake master cylinder 1. Remove: • Brake master cylinder bracket 1 • Brake master cylinder 2 CAUTION: • Do not let the brake master cylinder hang on the brake hose. • Keep the brake master cylinder cap side horizontal to prevent air from coming in. EC5B3200 Grip 1....

5 - 43 CHAS HANDLEBAR 4. Install: • Grip cap cover 1 • Throttle grip 2 NOTE: Apply the lithium soap base grease on thethrottle grip sliding surface. 5. Install: • Throttle cables 1 To tube guide 2 . NOTE: Apply the lithium soap base grease on thethrottle cable end and tube guide cable wind-ing porti...

5 - 44 CHAS HANDLEBAR 8. Install: • Start switch 1 • Brake master cylinder 2 • Brake master cylinder bracket 3 • Bolt (brake master cylinder bracket) 4 • Clamp 5 NOTE: • The start switch and brake master cylinder bracket should be installed according to thedimensions shown. • Install the bracket so ...

5 - 46 CHAS EC560000 STEERING Extent of removal: 1 Lower bracket removal 2 Bearing removal Extent of removal Order Part name Q’ty Remarks STEERING REMOVAL WARNING Support the machine securely so there is no danger of it falling over. Preparation for removal Hold the machine by placing thesuitable st...

5 - 48 CHAS EC563000 REMOVAL POINTSSteering ring nut 1. Remove: • Steering ring nut 1 Use the steering nut wrench 2 . WARNING Support the steering stem so that it maynot fall down. Steering nut wrench: YU-33975/90890-01403 Lower bearing 1. Remove: • Lower bearing 1 Use the floor chisel 2 . CAUTION: ...

5 - 49 CHAS EC564101 Bearing and ball race 1. Wash the bearings and ball races with a solvent. 2. Inspect: • Bearing 1 • Ball race Pitting/damage → Replace bearings and ball races as a set.Install the bearing in the ball races. Spinthe bearings by hand. If the bearingshang up or are not smooth in th...

5 - 51 CHAS 8. Install: • Washer 1 • Steering stem nut 2 T R . . 145 Nm (14.5 m · kg, 105 ft · lb) 9. Install: • Steering stem cap 1 10. After tightening the nut, check the steering for smooth movement. If not, adjust thesteering by loosening the steering ring nutlittle by little. 11. Adjust: • Fron...

5 - 52 CHAS STEERING 13. Install: • Trip meter 1 • Bolt (trip meter) 2 NOTE: Install the trip meter over the coupler bracket 3 . T R . . 7 Nm (0.7 m · kg, 5.1 ft · lb)

5 - 53 CHAS SWINGARM EC570000 SWINGARM Extent of removal: 1 Swingarm removal Extent of removal Order Part name Q’ty Remarks SWINGARM REMOVAL WARNING Support the machine securely so there is no danger of it falling over. Preparation for removal Hold the machine by placing thesuitable stand under the ...

5 - 57 CHAS SWINGARM 2. Install: • Bearing 1 • Oil seal 2 To relay arm. NOTE: • Apply the molybdenum disulfide grease on the bearing when installing. • Install the bearing by pressing it on the side having the manufacture’s marks or numbers. 3. Install: • Bearing 1 • Oil seal 2 To connecting rod. NO...

5 - 61 CHAS REAR SHOCK ABSORBER EC580000 REAR SHOCK ABSORBER Extent of removal: 1 Rear shock absorber removal 2 Rear shock absorber disassembly Extent of removal Order Part name Q’ty Remarks REAR SHOCK ABSORBER REMOVAL WARNING Support the machine securely so there is no danger of it falling over. Pr...

5 - 65 CHAS REAR SHOCK ABSORBER EC585000 ASSEMBLY AND INSTALLATION EC585300 Bearing 1. Install: • Upper bearing 1 NOTE: Install the bearing parallel until the stopper ringgroove appears by pressing its outer race. CAUTION: Do not apply the grease on the bearingouter race because it will wear the rea...

5 - 66 CHAS REAR SHOCK ABSORBER 2. Tighten: • Adjuster 1 3. Adjust: • Spring length (installed) a * For EUROPE NOTE: The length of the spring (installed) changes1.5 mm (0.06 in) per turn of the adjuster. CAUTION: Never attempt to turn the adjuster beyondthe maximum or minimum setting. 4. Tighten: • ...

5 - 68 CHAS REAR SHOCK ABSORBER 8. Install: • Plastic band 1 • Starting circuit cut-off relay coupler 2 • Taillight coupler 3 • Locking tie 4 3 2 1 4

6 - 1 – + ELEC ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 Headlight 2 Engine stop switch 3 Clutch switch 4 Diode 5 Starter relay diode 6 Throttle position sen-sor 7 Starter relay 8 Fuse 9 Starting ci...

– + ELEC 6 - 2 MAP-CONTROLLED CDI UNIT MAP-CONTROLLED CDI UNIT A map-controlled, CDI ignition system is used in the WR250F. The microcomputer in the CDI unit detects the engine speed and throttle position, thus determiningthe optimum ignition timing through the entire operating range. In this way, q...

– + ELEC 6 - 3 IGNITION SYSTEM EC620000 IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable toignition system failure and for checking the spark plug which will not spark. *1 marked: Refer to “FUSE INSPECTION” section ...

6 - 5 – + ELEC IGNITION SYSTEM 2. Inspect: • Rubber part a Tears/damage → Replace. a MAIN SWITCH INSPECTION 1. Inspect: • Main switch conduct Continuous while the main switch is moved to“OFF” → Replace. Not continuous while the main switch is movedto “ON” → Replace. Tester (+) lead → Red lead 1 Test...

6 - 7 – + ELEC IGNITION SYSTEM AC MAGNETO INSPECTION 1. Inspect: • Pickup coil resistance Out of specification → Replace. Tester (+) lead → Red lead 1 Tester (–) lead → White lead 2 Pickup coil resistance Tester selector position 248 ~ 372 Ω at 20 °C (68 °F) Ω × 100 R W 1 2 NEUTRAL SWITCH INSPECTION...

6 - 8 – + ELEC ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to “ON”, the startermotor can only operate if at least one of the fol-lowing conditions is met: • The transmission is in neutral (the neutral switch is closed). • The clutch lever is pulled to...

6 - 13 – + ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR 6 7 8 7 8 3 4 5 3 1 2 New B New New 1 Extent of removal: 1 Starter motor disassembly Extent of removal Order Part name Q’ty Remarks STARTER MOTOR REMOVAL Exhaust pipe Refer to “EXHAUST PIPE AND SILENCER” section in the CHAPTER 4. Preparation for...

6 - 14 – + ELEC ELECTRIC STARTING SYSTEM INSPECTION AND REPAIR 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Commutator diameter a Out of specification → Replace the starter motor. 3. Measure: • Mica undercut a Out of specification → Scrape the mica to the proper measure...

6 - 15 – + ELEC ELECTRIC STARTING SYSTEM 5. Measure: • Brush length a Out of specification → Replace the brushes as a set. Min. brush length: 3.5 mm (0.14 in) 6. Measure: • Brush spring force Out of specification → Replace the brush springs as a set. Brush spring force: 3.92 ~ 5.88 N (400 ~ 600 gf, ...

– + ELEC 6 - 17 CHARGING SYSTEM EC680000 CHARGING SYSTEM EC681001 INSPECTION STEPS If the battery is not charged, use the following inspection steps. *1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3.*2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3. NOTE: •...

– + ELEC 6 - 19 THROTTLE POSITION SENSOR SYSTEM THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position sensor will not operate, use the following inspection steps. NOTE: Use the following special tools in this inspection. Pocket tester: YU-3112-C/90890-03112 Inductive tachometer: ...

6 - 20 – + ELEC THROTTLE POSITION SENSOR SYSTEM HANDLING NOTE CAUTION: Do not loosen the screws (throttle positionsensor) 1 except when changing the throt- tle position sensor due to failure because itwill cause a drop in engine performance. 1 EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Che...

6 - 21 – + ELEC THROTTLE POSITION SENSOR SYSTEM 3. Inspect: • Throttle position sensor coil variable resistanceCheck that the resistance in increased asthe throttle grip is moved from the fullclose position to the full open position.Out of specification → Replace. Tester (+) lead → Yellow lead 1 Tes...

6 - 23 – + ELEC THROTTLE POSITION SENSOR SYSTEM 8. Tighten: • Screw (throttle position sensor) 1 9. Stop the engine. 1 THROTTLE POSITION SENSOR INPUT VOLTAGE INSPECTION 1. Disconnect the throttle position sensor cou- pler. 2. Start the engine.3. Inspect: • Throttle position sensor input voltage Out ...

– + ELEC 6 - 24 LIGHTING SYSTEM LIGHTING SYSTEM INSPECTION STEPS Refer to the following flow chart when inspecting the ignition system for possible problems. NOTE: • Replace the bulb and/or bulb socket.1) Seat2) Fuel tank• Use the following special tool. Check the bulb and bulb socket. Replace the b...

7 - 1 T U N EC700000 TUNING EC710000 ENGINE Carburetor setting • The air/fuel mixture will vary depending on atmospheric conditions. Therefore, it is nec-essary to take into consideration the air pres-sure, ambient temperature, humidity, etc.,when adjusting the carburetor. • Perform a test run to ch...

7 - 2 T U N CAUTION: • The carburetor is extremely sensitive to foreign matter (dirt, sand, water, etc.).During installation, do not allow foreignmatter to get into the carburetor. • Always handle the carburetor and its components carefully. Even slightscratches, bends or damage to carburetorparts m...

7 - 3 T U N SETTING Effects of the setting parts on the throttle valve opening È Closed É Fully open 1 Pilot screw/pilot jet 2 Throttle valve cutaway 3 Jet needle 4 Main jet 1/2 3/4 1/4 1/8 1 2 3 4 È É Main system The FLATCR carburetor has a primary mainjet. This type of main jet is perfect for raci...

7 - 4 T U N SETTING 1 Jet needle 2 Pilot air jet 3 Needle jet 4 Main jet 5 Pilot jet 6 Pilot screw Main jet adjustment The richness of the air-fuel mixture at full throt-tle can be set by changing the main jet 1 . * Except for USAIf the air-fuel mixture is too rich or too lean, theengine power will ...

7 - 5 T U N SETTING Pilot screw adjustment The richness of the air-fuel mixture with thethrottle fully closed to 1/4 open can be set byturning the pilot screw 1 . Turning in the pilot screw will make the mixture lean at lowspeeds, and turning it out will enrich it. * Except for USA NOTE: • If the en...

7 - 6 T U N SETTING Effects of adjusting the pilot jet (reference) È Idle É Fully open 1/4 1/2 3/4 +5% –5% #42 #38 #40 È É Jet needle groove position adjustment Adjusting the jet needle 1 position affects the acceleration when the throttle is 1/8 to 3/4open.1. Too rich at intermediate speeds Rough e...

7 - 7 T U N Jet needle adjustment The jet needle is adjusted by changing it. * Except for USAThe tapered sections of all jet needles havethe same starting positions, but the needlesare available with different straight-portiondiameters. Standard jet needle OBDVS * OBELP <Example>OBDVS - 4 Clip...

7 - 8 T U N Leak jet adjustment (accelerator pumpadjustment) The leak jet 1 is a setting part that adjusts the flow of fuel discharged by the acceleratorpump. Since the accelerator pump operatesonly when throttle is open, the leak jet is usedto adjust a fuel mixture ratio for quick throttleopening a...

7 - 10 T U N Examples of carburetor setting depending on symptom This should be taken simply for an example. It is necessary to set the carburetor while checkingthe operating conditions of the engine. Symptom Setting Checking At full throttle Hard breathingShearing noiseWhitish spark plug ↓ Lean mix...

7 - 11 T U N EC720000 CHASSIS Selection of the secondary reduction ratio(Sprocket) <Requirement for selection of secondary gearreduction ratio>• It is generally said that the secondary gear ratio should be reduced for a longer straightportion of a speed course and should beincreased for a cour...

7 - 12 T U N SETTING EC72N000 Drive and rear wheel sprockets setting parts * For AUS and NZ Part name Size Part number Drive sprocket 1 (STD) 13T 9383B-13218 Rear wheel sprocket 2 (STD) * (STD) 48T * 48T* 49T 50T * 50T* 51T 52T * 52T 54T 5GS-25448-505NY-25448-005NY-25449-005GS-25450-505NY-25450-005N...

7 - 13 T U N SETTING EC722011 Front fork setting The front fork setting should be made depend-ing on the rider’s feeling of an actual run andthe circuit conditions.The front fork setting includes the followingthree factors:1. Setting of air spring characteristics • Change the fork oil level. 2. Sett...

7 - 14 T U N SETTING È Air spring characteristics in relation to oil levelchange É Load Ê Stroke 1 Max. oil level 2 Standard oil level 3 Min. oil level EC727020 Spring preload adjustment The spring preload is adjusted by installing theadjustment washer 1 between the fork spring 2 and damper rod 3 . ...

7 - 15 T U N EC72A001 Setting of spring after replacement As the front fork setting can be easily affectedby rear suspension, take care so that themachine front and rear are balanced (in posi-tion, etc.) when setting the front fork.1. Use of soft spring Generally a soft spring gives a soft ridingfee...

7 - 16 T U N EC72P000 Front fork setting parts • Adjustment washer 1 • Front fork spring 2 [Equal pitch spring] * For EUROPE** For AUS, NZ and ZA[Unequal pitch spring] NOTE: • The unequal pitch spring is softer in initial characteristic than the equal pitch spring andis difficult to bottom out under...

7 - 17 T U N EC72B000 Rear suspension setting The rear suspension setting should be madedepending on the rider’s feeling of an actualrun and the circuit conditions.The rear suspension setting includes the fol-lowing two factors:1. Setting of spring preload • Change the set length of the spring.• Cha...

7 - 18 T U N SETTING NOTE: • If the machine is new and after it is broken in, the same set length of the spring maychange because of the initial fatigue, etc. ofthe spring. Therefore, be sure to make re-evaluation. • If the standard figure cannot be achieved by adjusting the spring adjuster and chan...

7 - 19 T U N CAUTION: When using a rear shock absorber otherthan currently installed, use the one whoseoverall length a does not exceed the stan- dard as it may result in faulty performance.Never use one whose overall length isgreater than standard. È Coverage of spring by weight É Rider weight 1 So...

7 - 20 T U N SETTING EC72Q000 Rear shock absorber setting parts • Rear shock spring 1 [Equal pitch spring] * For EUROPE** For AUS, NZ and ZA [Unequal pitch spring] NOTE: • The unequal pitch spring is softer in initial characteristic than the equal pitch spring andis difficult to bottom out under ful...

7 - 21 T U N SETTING EC72H002 Suspension setting • Front fork NOTE: • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken lengt...

7 - 22 T U N SETTING • Rear shock absorber NOTE: • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Adjust the rebound damping in 2-click increments or decrements.• Adjust the lo...