Yamaha RAPTOR 250 Service Manual

SERVICE MANUALYFM250RX4D3-28197-10LIT-11616-21-222008

CHECKING AND LUBRICATING THE CABLES . . . . . . . . . . . . . . . . 3-43LUBRICATING THE LEVERS AND PEDALS. . . . . . . . . . . . . . . . . . . 3-44EL

CHKADJ3-39 EBS00111ADJUSTING THE FRONT SHOCK ABSORBERSWARNINGAlways adjust the spring preload of bothfront shock absorbers to the same setting.Un

CHKADJ3-40EBS00111ADJUSTING THE REAR SHOCK ABSORBER1. Adjust:• spring preloada. Elevate the rear wheels by placing a suit-able stand under the frame.b

CHKADJ3-41EBS00114CHECKING THE TIRESWARNINGThis model is equipped with low pressuretires. It is important that they be inflatedcorrectly and maintaine

CHKADJ3-42 1. Measure:• tire pressureOut of specification → Adjust.NOTE:NOTE:• The low-pressure tire gauge is included asstandard equipment. • If du

CHKADJ3-43EBS00116 CHECKING THE WHEELS1. Check:• wheel Damage/bends → Replace.NOTE:NOTE:Always balance the wheel when a tire or wheelhas been changed

CHKADJ3-44EBS00118LUBRICATING THE LEVERS AND PEDALSLubricate the pivoting point and metal-to-metalmoving parts of the levers and pedal.Recommended lub

CHKADJ3-45 EBS00120ELECTRICAL SYSTEMCHECKING AND CHARGING THE BATTERYWARNINGBatteries generate explosive hydrogen gasand contain electrolyte which is

CHKADJ3-46 NOTE:NOTE:Since MF batteries are sealed, it is not possi-ble to check the charge state of the battery bymeasuring the specific gravity of t

CHKADJ3-47Examplec. Open-circuit voltage = 12.0 Vd. Charging time = 6.5 hourse. Charge of the battery = 20 ~ 30%5. Charge:• battery(refer to the appro

CHKADJ3-48• As shown in the following illustration, theopen-circuit voltage of an MF battery sta-bilizes about 30 minutes after charginghas been compl

CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . 4-44CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . .

CHKADJ3-49Charging method using a variable-current (voltage) chargerMeasure the open-circuitvoltage prior to charging. Connect a charger andammeter to

CHKADJ3-50Charging method using a constant voltage chargerMeasure the open-circuitvoltage prior to charging.Connect a charger andammeter to the batter

CHKADJ3-516. Install:• battery7. Connect:• battery leads (to the battery terminals)CAUTION:First, connect the positive battery lead ,and then the neg

CHKADJ3-52EBS00121CHECKING THE FUSESThe following procedure applies to all of thefuses.CAUTION:To avoid a short circuit, always set the mainswitch to

CHKADJ3-53WARNINGNever use a fuse with an amperage ratingother than that specified. Improvising orusing a fuse with the wrong amperage rat-ing may cau

CHKADJ3-54EBS00124REPLACING A HEADLIGHT BULB1. Remove:• headlightRefer to “SEAT, FENDERS AND FUELTANK”. 2. Disconnect:• headlight lead coupler 3. Remo

CHKADJ3-556. Install:• bulb holder• headlight bulb holder cover NOTE:NOTE:After installing the bulb holder cover, makesure that the “TOP” mark is in

ENG4-112345678ENGINEENGINE REMOVALMUFFLER AND EXHAUST PIPEOrder Job/Parts to remove Q’ty RemarksRemoving the muffler and exhaust pipeRemove the parts

ENG4-2INSTALLING THE EXHAUST PIPE AND MUFFLER1. Install:• gasket (to muffler)2. Install:• exhaust pipe protector3. Tighten:• exhaust pipe protector s

ENG4-3LEADS, CABLES AND HOSESOrder Job/Parts to remove Q’ty RemarksRemoving the leads, cables and hosesRemove the parts in the order listed.Engine oil

CHAPTER 5CARBURETORCARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1CHECKING THE CARBURETOR. . .

ENG4-4Order Job/Parts to remove Q’ty Remarks9 Neutral switch connector 1 Disconnect.For installation, reverse the removal procedure.67312984510 Nm (1.

ENG4-5ENGINE MOUNTING BOLTSOrder Job/Parts to remove Q’ty RemarksRemoving the engine mounting boltsRemove the parts in the order listed.1 Crankcase bo

ENG4-6INSTALLING THE ENGINE1. Install:• Engine mounting bolt (rear lower side) • Engine mounting bolt (rear upper side) • Engine bracket bolts (upper

ENG4-7CYLINDER HEADOrder Job/Parts to remove Q’ty RemarksRemoving the cylinder headSeat/front fender/fuel tank/fuel tank shieldRefer to “SEAT, FENDERS

ENG4-8Order Job/Parts to remove Q’ty Remarks9 Cap bolt 1 Loosen.10 Timing chain tensioner/gasket 1/111 Breather pipe 2 112 Camshaft sprocket/dowel pin

ENG4-9REMOVING THE CYLINDER HEAD1. Align:• “I” mark on the Pickup coil rotor (with the stationary pointer on the crank-case cover)a. Turn the Pick

ENG4-10CHECKING THE CYLINDER HEAD1. Eliminate:• Combustion chamber carbon deposits(with a rounded scraper)NOTE:Do not use a sharp instrument to avoid

ENG4-11CHECKING THE TIMING CHAIN GUIDESThe following procedure applies to the cam-shaft sprockets and timing chain guides.1. Check:• Timing chainDamag

ENG4-12b. Remove the screwdriver and slowly releasethe timing chain tensioner rod. c. Make sure that the timing chain tensionerrod comes out of the ti

ENG4-13a. Turn the Pickup coil rotor counterclockwise.b. Align the “I” mark on the Pickup coil rotorwith the stationary pointer on the crank-case

ASSEMBLING THE REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . 6-36INSTALLING THE FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . 6-38I

ENG4-146. Turn:• Crankshaft(several turns counterclockwise)7. Check:• “I” mark Align the “I” mark on the pickup coil rotorwith the stationary pointer

ENG4-15ROCKER ARM, CAMSHAFTOrder Job/Parts to remove Q’ty RemarksRemoving the rocker arms and cam-shaftRemove the parts in the order listed.Cylinder h

ENG4-16REMOVING THE ROCKER ARMS AND CAMSHAFT1. Loosen:• Locknut • Valve clearance adjusting screw 2. Remove:• Stopper plate 3. Remove:• Camshaft • Bea

ENG4-17CHECKING THE CAMSHAFT1. Check:• BearingDamage/wear → Replace.2. Check:• Camshaft lobesBlue discoloration/pitting/scratches →Replace the camsha

ENG4-18CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTSThe following procedure applies to all of therocker arms and rocker arm shafts. 1. Check:• Rocker

ENG4-19INSTALLING THE CAMSHAFT AND ROCKER ARMS1. Lubricate:•Camshaft2. Lubricate: • Rocker arm• Rocker arm shaft3. Install:• Exhaust rocker arm • Exha

ENG4-205. Install:• Camshaft NOTE:NOTE:Screw a 10 mm bolt into the threaded end ofthe camshaft and then install the camshaft.6. Install:• Lock plate7.

ENG4-21VALVES AND VALVE SPRINGSOrder Job/Parts to remove Q’ty RemarksRemoving the valves and valve springsRemove the parts in the order listed.Cylinde

ENG4-22REMOVING THE VALVESThe following procedure applies to all of thevalves and related components.NOTE:NOTE:Before removing the internal parts of t

ENG4-233. Remove:• Upper spring seat • Inner valve spring • Outer valve spring •Valve • Lower spring seat • Valve stem seal NOTE:NOTE:Identify the pos

CHECKING THE BULBS AND BULB SOCKETS. . . . . . . . . . . . . . . . . . 7-5TYPES OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENG4-242. Replace:• Valve guideNOTE:NOTE:To ease valve guide removal and installation,and to maintain the correct fit, heat the cylinderhead to 100°C

ENG4-255. Measure:• Valve margin thickness D Out of specification → Replace the valve.6. Measure:• Valve stem runoutOut of specification → Replace the

ENG4-263. Measure:• Valve seat width Out of specification → Replace the cylinderhead.a. Apply Mechanic’s blueing dye (Dykem) onto the valve face.b. In

ENG4-27a. Apply a coarse lapping compound to thevalve face.CAUTION:Do not let the lapping compound enter thegap between the valve stem and the valve

ENG4-28CHECKING THE VALVE SPRINGSThe following procedure applies to all of thevalve springs.1. Measure:• Valve spring free length Out of specification

ENG4-293. Measure:• Valve spring tilt Out of specification → Replace the valvespring.INSTALLING THE VALVESThe following procedure applies to all of th

ENG4-304. Install:• Valve cotters NOTE:NOTE:Install the valve cotters by compressing thevalve spring with the valve spring compressorand the valve spr

ENG4-31CYLINDER AND PISTONOrder Job/Parts to remove Q’ty RemarksRemoving the cylinder and piston Remove the parts in the order listed.Cylinder head Re

ENG4-32+REMOVING THE PISTON1. Remove:• Piston pin clips • Piston pin •Piston NOTE:NOTE:• Before removing the piston pin clip, cover thecrankcase openi

ENG4-33a. Measure cylinder bore “C” with the cylinderbore gauge.NOTE:NOTE:Measure cylinder bore “C” by taking side-to-side and front-to-back measureme

CLUTCH SLIPPING/DRAGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3CLUTCH SLIPPING . . . . . . . . . . . . . . . . . . . . . . .

ENG4-34f. If out of specification, rebore or replace thecylinder, and replace the piston and pistonrings as a set.CHECKING THE PISTON RINGS1. Measure:

ENG4-352. Install:•Piston ring(into the cylinder)NOTE:NOTE:Level the piston ring into the cylinder with thepiston crown.40 mm (1.476 in)3. Measure:• P

ENG4-36CHECKING THE PISTON PIN1. Check:• Piston pinBlue discoloration/grooves → Replace thepiston pin and then check the lubricationsystem.2. Measure:

ENG4-37INSTALLING THE PISTON AND CYLINDER1. Install:• Lower oil ring rail • Oil ring expander • Upper oil ring rail • 2nd ring • Top ring NOTE:NOTE:Be

ENG4-385. Offset:• Piston ring end gapsTop ringUpper oil ring railOil ring expanderLower oil ring rail2nd ring20 mm6. Install:• CylinderNOTE:NOTE:• Wh

ENG4-39CLUTCHOrder Job/Parts to remove Q’ty RemarksRemoving the clutch cover Remove the parts in the order listed.Engine oil Drain.1 Cotter pin/Washer

ENG4-40Order Job/Parts to remove Q’ty RemarksRemoving the clutch Remove the parts in the order listed.1 Clutch spring 52 Pressure plate 13 Primary dri

ENG4-41Order Job/Parts to remove Q’ty Remarks15 Push rod 2/Ball 1/1For installation, reverse the removal procedure.80 Nm (8.0 m•kg, 59 ft•lb)8 Nm (0.8

ENG4-42Order Job/Parts to remove Q’ty RemarksRemoving the push lever shaft Remove the parts in the order listed.Shift pedal Refer to “SHIFT SHAFT”.Lef

ENG4-43REMOVING THE CLUTCH1. Remove:•Bolt • Clutch spring NOTE:NOTE:Loosen the bolts in stages and in a crisscrosspattern.2. Straighten the lock washe

GENINFO1-1EBS00009GENERAL INFORMATIONMACHINE IDENTIFICATIONEBS00010VEHICLE IDENTIFICATION NUMBERThe vehicle identification number isstamped into the

ENG4-44CHECKING THE FRICTION PLATESThe following procedure applies to all of thefriction plates.1. Check:• Friction plateDamage/wear → Replace the fri

ENG4-45CHECKING THE CLUTCH SPRINGSThe following procedure applies to all of theclutch springs.1. Check:•Clutch springDamage → Replace the clutch sprin

ENG4-46CHECKING THE CLUTCH PUSH RODS1. Check:• Push lever shaft • Push rod 2 • Ball Cracks/damage/wear → Replace thedefective part(s).CHECKING THE PR

ENG4-473. Tighten:• Clutch boss nut• Primary drive gear nutNOTE:NOTE:• While holding the clutch boss with the univer-sal clutch holder , tighten the

ENG4-487. Install:• Bearing•Oil seal •Circlip • Torsion spring• Push lever shaft•Bolt•Clutch cableNOTE:NOTE:After installing the clutch cable, bend th

ENG4-4911.Adjust:• Push lever positiona. Loosen the locknut .b. Turn the adjusting screw in or out untilthe marks are aligned. c. Hold the adjustin

ENG4-50OIL PUMP AND BLANCER WEIGHT GEAROrder Job/Parts to remove Q’ty RemarksRemoving the oil pump and bal-ancer weight gearRemove the parts in the or

ENG4-51Order Job/Parts to remove Q’ty Remarks14 Balancer drive gear 115 Oil strainer 116 Spacer 1For installation, reverse the removal procedure.6 Nm

ENG4-52Order Job/Parts to remove Q’ty RemarksDisassembling the oil pump Remove the parts in the order listed.Oil pump housing 1Dowel pin 2Outer rotor

ENG4-53REMOVING THE BALANCER WEIGHT GEAR AND OIL PUMP1. Straighten the lock washer tab.2. Remove:• Balancer weight gear nut• Lock washer• Balancer wei

GENINFO1-212345678EBS00013IMPORTANT INFORMATIONPREPARATION FOR REMOVAL AND DISASSEMBLY1. Before removal and disassembly remove alldirt, mud, dust and

ENG4-543. Check:• Oil pump operationRough movement → Repeat steps (1) and(2) or replace the defective part(s).CHECKING THE BALANCER WEIGHT GEAR1. Chec

ENG4-55ASSENBLING THE BALANCER DRIVE GEAR1. Assemble:• Dowel pin • Compression spring NOTE:NOTE:Install the dowel pins and compression springsalternat

ENG4-56INSTALLING THE BALANCER WEIGHT GEAR1. Install:• Balancer weight gear• Lock washer • Balancer weight gear nut2. Tighten:• Balancer weight gear n

ENG4-57SHIFT SHAFTOrder Job/Parts to remove Q’ty RemarksRemoving the shift shaft and stopper leverRemove the parts in the order listed.Right crankcase

ENG4-58CHECKING THE SHIFT SHAFT1. Check:• Shift shaft • Shift lever Bends/damage/wear → Replace.• Shift lever springDamage/wear → Replace.CHECKING THE

ENG4-594. Check:• When the gear position is in Neutral, checkthe length ( , ) between the tip of theshift lever and dowel pin are equal.If not → R

ENG4-60PICKUP COIL ROTOR AND STARTER CLUTCHOrder Job/Parts to remove Q’ty RemarksRemoving the pickup coil rotor and starter clutchRemove the parts in

ENG4-61Order Job/Parts to remove Q’ty Remarks12 Bearing 113 Washer 114 Starter clutch assembly 1For installation, reverse the removal procedure.30 Nm

ENG4-62REMOVING THE PICKUPCOIL ROTOR1. Remove:• Pickup coil rotor bolt • WasherNOTE:NOTE:• Loosen the pickup coil rotor bolt whileholding the rotor

ENG4-63CHECKING THE STARTER CLUTCH1. Check:• Starter clutch rollersDamage/wear → Replace the starterclutch.2. Check:• Starter idle gear • Starter whe

GENINFO1-3EBS00017BEARINGS AND OIL SEALSInstall bearings and oil seals so that the manu-facturer’s marks or numbers are visible. Wheninstalling oil se

ENG4-64INSTALLING THE PICKUP COIL ROTOR1. Install:• Washer • Bearing • Starter wheel gear • Starter idle gear 2 2. Install:• Woodruff key • Pickup coi

ENG4-654. Install:• Stater coil • Pickup coil 5. Tighten:• Stater coil bolts • Pickup coil bolts • Left crankcase cover bolt 6. Install:• Dowel pin• C

ENG4-66CRANKCASEOrder Job/Parts to remove Q’ty RemarksSeparating the crankcase Remove the parts in the order listed.Engine Refer to “ENGINE REMOVAL”.C

ENG4-67Order Job/Parts to remove Q’ty Remarks7 Spacer 1For installation, reverse the removal procedure.123455678 Nm (0.8 m•kg, 5.9 ft•lb)20 Nm (2.0 m•

ENG4-68Order Job/Parts to remove Q’ty RemarksRemoving the bearing Remove the parts in the order listed.Crankshaft assembly Refer to “CRANKSHAFT ASSEMB

ENG4-69DISASSEMBLING THE CRANKCASE1. Remove:• Timing chain guide (intake side) • Timing chain • Crankshaft sprocket 2. Remove:• Neutral switch • Crank

ENG4-70CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in amild solvent.2. Thoroughly clean all the gasket surfacesand crankcase mating

ENG4-714. Install:• Crankcase bolts M6 × 70 mm ~ • Copper washers to ~ .• Crankcase bolts M6 × 60 mm , • Crankcase bolts M6 × 55 mm ~ • Crankc

ENG4-72CRANKSHAFT ASSEMBLYOrder Job/Parts to remove Q’ty RemarksRemoving the crankshaft assembly Remove the parts in the order listed.Crankcase Refer

ENG4-73REMOVING THE CRANKSHAFT ASSEMBLY1. Remove:• Balancer weight• Crankshaft assembly NOTE:NOTE:• Remove the crankshaft assembly with thecrankcase s

GENINFO1-4EBS00019CHECKING THE CONNECTIONSCheck the leads, couplers, and connectors forstains, rust, moisture, etc.1. Disconnect:• lead• coupler• conn

ENG4-742. Measure:• Big end side clearanceOut of specification → Replace the big endbearing, crankshaft pin, or connecting rod.3. Measure:• Crankshaft

ENG4-753. Check:• Timing chain guide (intake side)Damage/wear → Replace the timing chainguide (intake side)INSTALLING THE PLUNGER SEAL1. Install:• Com

ENG4-76CAUTION:To avoid scratching the crankshaft and toease the installation procedure, lubricatethe oil seal lips with lithium-soap-basedgrease and

ENG4-77TRANSMISSIONOrder Job/Parts to remove Q’ty RemarksRemoving the transmission, shift drum assembly, and shift forksRemove the parts in the order

ENG4-78Order Job/Parts to remove Q’ty RemarksDisassembling the transmission Remove the parts in the order listed.1 2nd pinion gear 12 5th pinion gear

ENG4-79Order Job/Parts to remove Q’ty Remarks17 Drive axle 1For installation, reverse the removal procedure.78910111213141512543616TRANSMISSION

ENG4-80REMOVING THE TRANSMISSION 1. Remove:• Shift fork guide bar • Shift drum assembly • Shift fork 3 (R) • Shift fork 2 (C)• Shift fork 1 (L) 2. Rem

ENG4-81CHECKING THE SHIFT DRUM ASSEMBLY1. Check:• Shift drum groove Damage/scratches/wear → Replace theshift drum assembly.• Shift drum segment Damag

ENG4-824. Check:• Transmission gear engagement (each pinion gear to its respective wheelgear) Incorrect → Reassemble the transmissionaxle assemblies.

CARB5-112345678EBS00141CARBURETORCARBURETOROrder Job/Part Q’ty RemarksRemoving a carburetorRemove the parts in the order listed. Seat/front fender/rea

YFM250RXSERVICE MANUAL© 2007 by Yamaha MotorCorporation, U.S.A.First Edition, July 2007All rights reserved.Any reproduction or unauthorized usewithout

GENINFO1-5EBS00021SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Useonly the appropriate speci

CARB5-2EBS00144Order Job/Part Q’ty RemarksDisassembling the carburetorRemove the parts in the order listed.Drain hose 1Throttle stop screw 1Cover 1Dia

CARB5-3Order Job/Part Q’ty RemarksFloat 1Needle valve seat set 1Main jet 1Needle jet holder 1Needle jet 1Pilot jet 1Starter jet 1For assembly, reverse

CARB5-4EBS00148CHECKING THE CARBURETOR1. Check:• carburetor body• float chamberCracks/damage → Replace.• fuel passageContamination → Clean as indicate

CARB5-55. Check:• piston valve movementSticks → Replace.Insert the piston valve into the carburetorbody, and check for free movement.6. Check:• thrott

CARB5-611.Check:• starter plunger • starter plunger spring Bends/cracks/damage → Replace.EBS00150ASSEMBLING THE CARBURETORCAUTION:Before reassembling,

CARB5-7INSTALLING THE CARBURETOR JOINT1. Install:•clampNOTE:NOTE:Align the projection on the carburetor jointwith the slot in the clamp. 2. Instal

CHAS6-1EBS00378CHASSISFRONT AND REAR WHEELSFRONT WHEELSOrder Job/Part Q’ty RemarksRemoving the front wheels Remove the parts in the order listed.The f

CHAS6-212345678Order Job/Part Q’ty Remarks5 Brake caliper assembly 1NOTE:NOTE:Do not squeeze the brake lever when thebrake caliper is off of the brake

CHAS6-3REAR WHEELSOrder Job/Part Q’ty RemarksRemoving the rear wheels Remove the parts in the order listed.Place the machine on a level surface.WARNIN

CHAS6-4EBS00383CHECKING THE WHEELS1. Check:• wheels2. Measure:• wheel runoutOver the specified limit → Replace thewheel or check the wheel bearing pl

GENINFO1-6Tool No. Tool name/Function IllustrationAdapter90890-01383YU-90062Adapter (M10)Adapter #2This tool is used to install the crankshaft.90890-0

CHAS6-52. Check:• wheel bearingsWheel hub play/wheel turns roughly →Replace. a. Clean wheel hub exterior. b. Drive bearing out by pushing spacer aside

CHAS6-6INSTALLING THE FRONT WHEEL HUB BEARINGS1. Install:• bearings NOTE:NOTE:Face the oil seal side of the bearing inward.INSTALLING THE FRONT BRAKE

CHAS6-7EBS00390INSTALLING THE WHEEL HUBS1. Install:• front axle nuts • rear axle nuts • cotter pins NOTE:NOTE:• Do not loosen the axle nut after torq

CHAS6-8EBS00382REAR AXLE AND REAR AXLE HUBOrder Job/Part Q’ty RemarksRemoving the rear axle and rear axle hubRemove the parts in the order listed.Rear

CHAS6-9Order Job/Part Q’ty Remarks5 Brake disc/brake disc bracket 1/16 Rear axle 1 Refer to “REMOVING THE REAR AXLE”.7 Driven sprocket/sprocket bracke

CHAS6-10EBS00393REMOVING THE REAR AXLE1. Place the machine on a level surface.2. Loosen:• bolts 3. Remove:•nut NOTE:NOTE:• Apply the brake pedal so th

CHAS6-11EBS00395CHECKING THE REAR AXLE1. Check:• rear axle runout Out of specification → Replace. WARNINGDo not attempt to straighten a bent axle. CHE

CHAS6-122. Tighten:•nut a. Tighten the nut with PTT wrench 46 or rearaxle nut wrench to specification whileholding the rear axle.b. Tighten bolts .

CHAS6-13EBS00400FRONT AND REAR BRAKESFRONT BRAKE PADSOrder Job/Part Q’ty RemarksRemoving the front brake pads Remove the parts in the order listed.The

CHAS6-14EBS00401REAR BRAKE PADSOrder Job/Part Q’ty RemarksRemoving the rear brake pads Remove the parts in the order listed.1 Brake pad retaining bolt

GENINFO1-7Tool No. Tool name/Function Illustration90890-03081YU-33223Compression gaugeEngine compression testerThis tool is needed to measure the engi

CHAS6-15EBS00402CAUTION:Disc brake components rarely require dis-assembly.DO NOT:• disassemble components unless abso-lutely necessary;• use solvents

CHAS6-162. Install:• brake pads• brake pad springNOTE:NOTE:Always install new brake pads and brake padspring as a set.a. Connect a suitable hose tig

CHAS6-17EBS00405REPLACING THE REAR BRAKE PADSNOTE:NOTE:It is not necessary to disassemble the brakecaliper and brake hose to replace the brakepads.1.

CHAS6-185. Check:• brake lever or brake pedal operationSoft or spongy feeling → Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in

CHAS6-19EBS00407FRONT BRAKE MASTER CYLINDEROrder Job/Part Q’ty RemarksRemoving the front brake master cylinderRemove the parts in the order listed. Br

CHAS6-20EBS00409Order Job/Part Q’ty RemarksDisassembling the front brake master cylinderRemove the parts in the order listed.Dust boot 1Circlip 1Brake

CHAS6-21EBS00410REAR BRAKE MASTER CYLINDEROrder Job/Part Q’ty RemarksRemoving the rear brake master cylinderRemove the parts in the order listed.Right

CHAS6-22Order Job/Part Q’ty Remarks7 Union bolt 18 Copper washer 29 Brake hose 1 Disconnect.10 Brake master cylinder 111 Rear brake light switch 112 R

CHAS6-23EBS00411Order Job/Part Q’ty RemarksDisassembling the rear brake master cylinderRemove the parts in the order listed.Hose joint 1Brake master c

CHAS6-24EBS00413CHECKING THE MASTER CYLINDERS1. Check:• brake master cylinder Wear/scratches → Replace the brake mas-ter cylinder assembly. • brake ma

GENINFO1-8Tool No. Tool name/Function Illustration90890-04065YM-04065-AValve guide installer (φ6)Valve guide installer (6.0 mm) This tool is needed to

CHAS6-25EBS00415ASSEMBLING THE FRONT BRAKE MASTER CYLINDER WARNING• All internal brake components should becleaned and lubricated with new brakefluid

CHAS6-262. Tighten:•nut EBS00418INSTALLING THE FRONT BRAKE MASTER CYLINDER1. Install:• brake master cylinder NOTE:NOTE:• The “UP” mark on the brake ma

CHAS6-273. Fill:• brake fluid reservoirCAUTION:Brake fluid may damage painted surfacesor plastic parts. Always clean up spilledbrake fluid immediately

CHAS6-28EBS00419INSTALLING THE REAR BRAKE MASTER CYLINDER1. Install:• copper washers •brake hose • union bolt CAUTION:When installing the brake hose o

CHAS6-29WARNING• Use only the designated quality brakefluid: other brake fluids may deterioratethe rubber seals, causing leakage andpoor brake perform

CHAS6-30EBS00421FRONT BRAKE CALIPERSOrder Job/Part Q’ty RemarksRemoving the front brake calipers Remove the parts in the order listed.The following pr

CHAS6-31EBS00423Order Job/Part Q’ty RemarksDisassembling the front brake calipersRemove the parts in the order listed.The following procedure applies

CHAS6-32EBS00424REAR BRAKE CALIPEROrder Job/Part Q’ty RemarksRemoving the rear brake caliper Remove the parts in the order listed.Brake fluid Drain.Re

CHAS6-33EBS00425Order Job/Part Q’ty RemarksDisassembling the rear brake caliper Remove the parts in the order listed.Adjusting bolt 1Locknut 1Parking

CHAS6-34REMOVING THE PARKING BRAKE CABLE1. Loosen:•nut• adjusting bolt2. Disconnect:• parking brake cable (from parking brake lever)3. Disconnect: • p

SPEC2-1EBS01001SPECIFICATIONSGENERAL SPECIFICATIONSItem StandardModel code 4D314D354D39DimensionsOverall length 1,625 mm (64.0 in)Overall width 1,070

CHAS6-35EBS00429CHECKING THE FRONT AND REAR BRAKE CALIPERS WARNINGAll internal brake components should becleaned in new brake fluid only. Do not useso

CHAS6-36EBS00431ASSEMBLING THE FRONT BRAKE CALIPERSThe following procedure applies to both of thefront brake calipers.WARNING• All internal brake comp

CHAS6-372. Install:• brake caliper piston 3. Install:• lock washer • brake pad retaining bolts 4. Bend the lock washer tabs along a flat sideof the b

CHAS6-38EBS00434INSTALLING THE FRONT BRAKE CALIPERSThe following procedure applies to both of thefront brake calipers. 1. Install:• brake caliper asse

CHAS6-39WARNING• Use only the designated quality brakefluid: other brake fluids may deterioratethe rubber seals, causing leakage andpoor brake perform

CHAS6-40EBS00436INSTALLING THE REAR BRAKE CALIPER1. Install:• brake caliper assembly• brake caliper mounting bolts •brake hose • copper washers • un

CHAS6-41WARNING• Use only the designated quality brakefluid: other brake fluids may deterioratethe rubber seals, causing leakage andpoor brake perform

CHAS6-42EBS00444STEERING SYSTEMHANDLEBAROrder Job/Part Q’ty RemarksRemoving the handlebar Remove the parts in the order listed.1 Handlebar protecter 1

CHAS6-43Order Job/Part Q’ty Remarks11 Handlebar grip 2 Refer to “REMOVING THE HANDLEBAR GRIPS” and “INSTALLING THE HANDLEBAR GRIPS”.12 Handlebar holde

CHAS6-44EBS00446REMOVING THE CLUTCH SWITCH1. Remove:• clutch switch NOTE:NOTE:Push the fastener when removing the clutchswitch out of the clutch lever

SPEC2-212345678Item StandardFuelType Unleaded gasoline onlyFuel tank capacity 9.0 L (1.97 Imp gal, 2.37 US gal)Fuel reserve amount 1.0 L (0.22 Imp gal

CHAS6-45EBS00449INSTALLING THE HANDLEBAR1. Install:• handlebar• handlebar holdersNOTE:NOTE:• Install the handlebar horizontally shown in theillustrati

CHAS6-46 EBS00452INSTALLING THE CLUTCH LEVER1. Install:• handlebar switch •clutch lever• clutch lever bracket NOTE:NOTE:• Install the clutch lever bra

CHAS6-47EBS00454STEERING STEMOrder Job/Part Q’ty RemarksRemoving the steering stem Remove the parts in the order listed.Front fender Refer to “SEAT, F

CHAS6-48EBS00456CHECKING THE STEERING STEM1. Check:• steering stemBends/damage → Replace.WARNINGDo not attempt to straighten a bent stem;this may dang

CHAS6-49EBS00460TIE-RODS AND STEERING KNUCKLESOrder Job/Part Q’ty RemarksRemoving the tie-rods and steering knucklesRemove the parts in the order list

CHAS6-50EBS00461REMOVING THE STEERING KNUCKLES1. Remove:• steering knuckles NOTE:NOTE:Use a general puller to separate the ball joint and steering knu

CHAS6-51EBS00468FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIESOrder Job/Part Q’ty RemarksRemoving the front arms and front shock absorber assembliesRe

CHAS6-52Order Job/Part Q’ty Remarks8Dust cover 69 Spacer 110 Spacer 211 Bushing 6For installation, reverse the removal procedure.31 Nm (3.1 m•kg, 23 f

CHAS6-53EBS00469REMOVING THE FRONT ARMS1. Check:• front arm free playa. Check the front arm side play by movingit from side to side. If side play is

CHAS6-54EBS00472CHECKING THE BALL JOINTSThe following procedure applies to both of thefront arm ball joints.1. Check:• ball jointDamage/pitting → Repl

SPEC2-3Item StandardBrakeFront brake type Dual disc brakeoperation Right hand operationRear brake type Single disc brakeoperation Right foot operation

CHAS6-55REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAINOrder Job/Part Q’ty RemarksRemoving the rear shock absorber, swingarm and drive chainRemove the p

CHAS6-56Order Job/Part Q’ty Remarks9 Drive chain guide 2 110 Drive chain guide 3 111 Nut 112 Lock washer 113 Drive sprocket 114 Drive chain 115 Dust c

CHAS6-57HANDLING THE REAR SHOCK ABSORBERWARNINGThis rear shock absorber contains highlycompressed nitrogen gas. Before handlingthe rear shock absorber

CHAS6-58EBS00487REMOVING THE REAR SHOCK ABSORBER1. Remove:• rear shock absorber lower bolt • rear shock absorber upper boltNOTE:NOTE:While removing th

CHAS6-59b. Check the swingarm side play by mov-ing it from side to side. If side play is noticeable, check the spacer,bearings and frame pivot.c. Ch

CHAS6-604. Check:• oil sealsDamage/wear → Replace.• bearingsDamage/pitting → Replace.EBS00496CHECKING THE DRIVE CHAIN1. Measure:• 15-link section of

CHAS6-613. Clean:•drive chain a. Wipe the drive chain with a clean cloth. b. Put the drive chain in kerosene and removeany remaining dirt. c. Remove t

CHAS6-626. Check:• drive sprocket• driven sprocketMore than 1/4 tooth wear → Replacethe drive chain sprockets as a set. Bent teeth → Replace the dri

ELEC7-1EBS00500ELECTRICALELECTRICAL COMPONENTSMain switchFront brake light switchClutch switchHandlebar switchCDI unitStarter relayFuseBatteryTail/bra

ELEC7-212345678EBS01028CHECKING SWITCH CONTINUITYCheck each switch for continuity with thepocket tester. If the continuity reading is incor-rect, chec

SPEC2-4EBS01002ENGINE SPECIFICATIONSItem Standard LimitCylinder headVolume 20.50 ~ 21.50 cm3 (1.25 ~ 1.31 cu.in) • • •Warp limit • • •0.05 mm(0.0020 i

ELEC7-3EBS01029CHECKING THE SWITCHESCheck each switch for damage or wear, proper connections, and also for continuity between the ter-minals. Refer to

ELEC7-4Light switchEngine stop switchStart switchMain switchFront brake light switchClutch switchFuseNeutral switchRear brake light switchCHECKING THE

ELEC7-5EBS01030CHECKING THE BULBS AND BULB SOCKETSCheck each bulb and bulb socket for damageor wear, proper connections, and also for conti-nuity betw

ELEC7-6WARNINGSince the headlight bulb gets extremelyhot, keep flammable products and yourhands away from the bulb until it hascooled down. CAUTION:•

ELEC7-7CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of thebulb sockets. 1. Check:• bulb socket (for continuity) (

ELEC7-8EBS00503IGNITION SYSTEMCIRCUIT DIAGRAMAAB/YBRBrRBrONOFFOFFLOHIOFFONOFFPUSHR/BLBrR/WGYBR/BLBrL/BYBRRL/BY/BB/YBBBOOB/YBY/BB/YR/BSbGYBGYBGYBGYBWWW

ELEC7-9EBS01045TROUBLESHOOTINGCheck:1. fuse2. battery3. spark plug4. ignition spark gap5. ignition coil resistance6. main switch7. engine stop switch8

ELEC7-10EBS01034 EAS007454. Ignition spark gapThe following procedure applies to all of thespark plugs.• Disconnect the spark plug cap from thespark p

ELEC7-11EBS01038 EBS01041EBS01042EBS010406. Ignition coil resistance• Disconnect the ignition coil coupler from theignition coil.• Connect the pocket

ELEC7-12EBS0104710. Wiring• Check the entire ignition system’s wiring.Refer to “CIRCUIT DIAGRAM”.• Is the ignition system’s wiring properly con-nected

SPEC2-5Item Standard LimitValve, valve seat, valve guideValve clearance (cold) IN 0.05 ~ 0.10 mm (0.0020 ~ 0.0039 in) • • •EX 0.10 ~ 0.15 mm (0.0039 ~

ELEC7-13EBS00506ELECTRIC STARTING SYSTEMCIRCUIT DIAGRAMAAB/YBRBrRBrONOFFOFFLOHIOFFONOFFPUSHR/BLBrR/WGYBR/BLBrL/B࡯YBRRL/BY/BB/YBBBB/YBY/BB/YR/BSbGYBGYB

ELEC7-14EBS00508STARTING CIRCUIT CUT-OFF SYSTEM OPERATIONThe starting circuit on this model consists ofthe starter motor, starter relay, clutch switch

ELEC7-15EBS01050TROUBLESHOOTINGCheck:1. fuse2. battery3. starter motor4. starting circuit cut-off relay5. starting circuit cut-off relay (diode)6. sta

ELEC7-16EBS01052 EBS010534. Starting circuit cut-off relay• Remove the starting circuit cut-off relayfrom the wire harness.• Connect the pocket tester

ELEC7-17EBS01054EBS01041EBS01042EBS01046EBS01056EBS010576. Starter relay• Disconnect the starter relay coupler fromthe wire harness.• Connect the pock

ELEC7-18EBS0105912. Wiring• Check the entire starting system’s wiring.Refer to “CIRCUIT DIAGRAM”.• Is the starting system’s wiring properly con-nected

ELEC7-19EBS01061STARTER MOTOROrder Job/Part Q’ty RemarksRemoving the starter motor Remove the parts in the order listed.Exhaust pipeIdle gear cover an

ELEC7-20EBS01062Order Job/Part Q’ty RemarksDisassembling the starter motor Remove the parts in the order listed.Front bracket 1Tang washer 1Plate wash

ELEC7-21EBS01064CHECKING THE STARTER MOTOR1. Check:•commutatorDirt → Clean with 600-grit sandpaper.2. Measure:• commutator diameter Out of specificati

ELEC7-22b. If any resistance is out of specification,replace the starter motor.5. Measure:• brush length Out of specification → Replace the brushesas

SPEC2-6Item Standard LimitValve springInner springFree length IN 36.17 mm (1.42 in) 34.36 mm (1.35 in)EX 36.17 mm (1.42 in) 34.36 mm (1.35 in)Installe

ELEC7-23EBS00515ASSEMBLING THE STARTER MOTOR1. Install:• brush spring •brush 2. Install:• armature coil 3. Install• O-rings to starter motor yoke .4

ELEC7-24EBS00516CHARGING SYSTEMCIRCUIT DIAGRAMRBrRBrONOFFRRL/BY/BWWWWRW/LW/RWWWR-BWWWW/RW/LWWWWWWBRRBRRRRRRBrY/BL/BBBStator coilRectifier/regulatorBat

ELEC7-25EBS01065TROUBLESHOOTINGCheck:1. fuse2. battery3. charging voltage4. stator coil resistance5. wiring connections(of the entire charging system)

ELEC7-26EBS01066 EBS011003. Charging voltage• Connect the engine tachometer to on to theignition coil.• Connect the pocket tester (DC 20 V) to thebatt

ELEC7-27EBS00518LIGHTING SYSTEMCIRCUIT DIAGRAMAAB/YBRBrRBrONOFFOFFLOHIOFFONOFFPUSHR/BLBrR/WGYBR/BLBrL/B࡯YBRRL/BY/BB/YBBBB/YBY/BB/YR/BSbGYBGYBGYBGYBWWW

ELEC7-28EBS01067TROUBLESHOOTINGCheck:1. light switch2. Stator coil resistance3. wiring connections(of the entire lighting system)NOTE:NOTE:• Before tr

ELEC7-29EBS01069EBS01070CHECKING THE LIGHTING SYSTEM1. The headlights fail to come on.3. Wiring• Check the entire lighting system’s wiring.Refer to “C

ELEC7-302. The tail/brake light fails to come on.1. Tail/brake light bulb and bulb socket(4D31)• Check the tail/brake light bulb and socketfor continu

ELEC7-31EBS00521SIGNAL SYSTEMCIRCUIT DIAGRAMAAB/YBRBrRBrONOFFOFFLOHIOFFONOFFPUSHR/BLBrR/WGYBR/BLBrL/B࡯YBRRL/BY/BB/YBBBB/YBY/BB/YR/BSbGYBGYBGYBGYBWWWWR

ELEC7-32EBS01073TROUBLESHOOTINGCheck:1. fuse2. battery3. main switch4. wiring connections(of the entire signaling system)NOTE:NOTE:• Before troublesho

EBS00002 NOTICEThis manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers andtheir qualified mechanics. It is not possib

SPEC2-7Item Standard LimitTilt limit IN • • • 2.5°/1.60 mm(2.5°/0.063 in)EX • • • 2.5°/1.60 mm(2.5°/0.063 in)Direction of winding(top view) IN Clockwi

ELEC7-33EBS01075CHECKING THE SIGNALING SYSTEMEBS010761. The tail/brake light fails to come on.1. Tail/brake light bulb and bulb socket(4D31)• Check th

ELEC7-34EBS010772. The neutral indicator light fails to come on.1. Neutral indicator light bulb and socket• Check the neutral indicator light bulb and

ELEC7-35EBS010833. The carburetor heater fails to come on.1. Thermo switch• Disconnect the thermo switch from the wire-harness.• Connect the pocket te

TRBLSHTG8-112345678EBS00537 TROUBLESHOOTINGNOTE:The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,

TRBLSHTG8-2COMPRESSION SYSTEMCylinder and cylinder head• Loose spark plug• Loose cylinder head or cylinder• Broken cylinder head gasket• Broken cylind

TRBLSHTG8-3EBS00541FAULTY GEAR SHIFTINGHARD SHIFTINGRefer to “CLUTCH DRAGGING”.SHIFT PEDAL DOES NOT MOVEShift shaft• Bent shift shaftShift drum and sh

TRBLSHTG8-4EBS00547OVERHEATINGOVERHEATINGIgnition system• Improper spark plug gap• Improper spark plug heat range• Faulty CDI unitFuel system• Imprope

TRBLSHTG8-5EBS00552UNSTABLE HANDLINGUNSTABLE HANDLINGHandlebar• Improperly installed or bentSteering• Incorrect toe-in• Bent steering stem• Improperly

SPEC2-8Item Standard LimitPiston ringsTop ringType Barrel • • •Dimensions (B × T) 0.90 × 2.75 mm (0.035 × 0.108 in) • • •End gap (installed) 0.19 ~ 0.

YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPANPRINTED IN U.S.A.

YFM250RX WIRING DIAGRAMPickup coilStator coilRectifier/regulatorMain switchBattery positive leadBatteryFuseStarter relayStarter motorCDI unitIgnition

SPEC2-9Item Standard LimitBalancerBalancer drive method Gear • • •ClutchFriction plate 1 (inside dia.: 104.5 ~ 105.5 mm)Thickness 2.9 ~ 3.1 mm (0.114

SPEC2-10Item Standard LimitCarburetorI. D. mark 4D31 00 • • •Main jet (M.J) #133.8 • • •Main air jet (M.A.J) #140 • • •Jet needle (J.N) 5DH66-1 • • •N

SPEC2-11EBS01003CHASSIS SPECIFICATIONSItem Standard LimitFront suspensionShock absorber travel 90.7 mm (3.57 in) • • •Spring free length 248.5 mm (9.7

SPEC2-12Item Standard LimitFront disc brakeType Dual • • •Disc outside diameter × thickness 161.0 × 3.5 mm (6.34 × 0.14 in) 3.0 mm(0.12 in)Brake disk

SPEC2-13EBS01004ELECTRICAL SPECIFICATIONSItem Standard LimitVoltage 12 V • • •Ignition systemIgnition timing (B.T.D.C.) 10.0°/1,550 r/min • • •Advance

SPEC2-14Item Standard LimitStarter relayModel/manufacturer A4616-051/JIDECO • • •Amperage rating 180 A • • •Coil winding resistance 4.18 ~ 4.62 Ω • •

SPEC2-15EBS01005TIGHTENING TORQUESENGINE TIGHTENING TORQUESPart to be tightenedPart nameThreadsizeQ’tyTightening torqueRemarksNm m•kg ft•lbCylinder he

SPEC2-16NOTE:*1: Apply oil to the bearing surface of (upper) cylinder head bolt.Further, apply molybdenum disulfide grease to thread part.Part to be t

EBS00004HOW TO USE THIS MANUALMANUAL ORGANIZATIONThis manual consists of chapters for the main categories of subjects. (See “symbols”)1st title : Thi

SPEC2-17EBS01006CHASSIS TIGHTENING TORQUESPart to be tightened Thread sizeTightening torqueRemarksNm m•kg ft•lbEngine upper stay and frame M8 33 3.3 2

SPEC2-18Part to be tightened Thread sizeTightening torqueRemarksNm m•kg ft•lbFront brake master cylinder and brake lever M6 6 0.6 4.4Throttle assembly

SPEC2-19EBS00022 HOW TO USE THE CONVERSION TABLEAll specification data in this manual are listedin SI and METRIC UNITS. Use this table to convert METR

SPEC2-20EBS00024LUBRICATION POINTS AND LUBRICANT TYPESENGINELubrication point LubricantOil seal lipsO-ringsBearingsCylinder head bolts (bearing surfac

SPEC2-21Lubrication point LubricantCrankcase mating surfacesSealant (Three Bond No.1215®)Yamaha bond No.1215AC magneto lead grommet (AC magneto cover)

SPEC2-22EBS00026OIL FLOW DIAGRAMSCamshaftOil filter elementOil pumpOil strainerOil cooler Drive axle Main axlePin,with holeCrankshaftOil pumpOil strai

SPEC2-23CamshaftDrive axleMain axlePush lever shaftOil pump assemblyOil strainerCrankshaft assemblyOil filter elementOIL FLOW DIAGRAMS

SPEC2-24Oil coolerOil hose 1Oil hose 2OIL FLOW DIAGRAMS

SPEC2-25EBS00028CABLE ROUTINGFront brake hoseFront brake light switch leadThrottle cablePlastic bandClutch cableParking brake cableClutch switch leadH

SPEC2-26Clamp the front brake light switch lead at thebends of handlebar.Route the front brake hose and throttle cablethrough the guide of the handleb

GENINFOCHASEBS00006SYMBOLSThe following symbols are not relevant to everymachine.Symbols to indicate the subject of eachchapter.General informatio

SPEC2-27Indicator light leadMain switch leadCoupler jointFront brake light switch leadFront brake hose 2Oil cooler hose 1, 2Exhaust pipeEngine bracket

SPEC2-28To the front panelTo the front fenderTo the handlebarTo the right headlight Make sure to route the oil cooler hoses 1and 2through the guide wi

SPEC2-29Route the parking brake cable and the clutch cableunder the cross pipe and right of the steering col-umn as shown in the illustration.Route th

SPEC2-30Rear brake reservoirRear brake light switchClipRear brake reservoir hoseRear brake master cylinderParking brake cableRear brake hoseRear brake

SPEC2-31Make sure that the end of the clip is facing down-ward.Set the rear brake reservoir hose with the position-ing yellow paint mark pointing down

SPEC2-32Clutch switch leadHandlebar switch leadBoltMain harnessAir vent hoseClampBattery negative leadAC magneto leadCarburetor overflow hoseStarter m

SPEC2-33To the front fenderRoute the wire harness above the guide for thedamper plate. Fix point for wire harnessClamp near the hook of the air filter

SPEC2-34Indicator lightCoupler jointMain switch leadFront brake light switch leadThrottle cableRegulatorFlange boltHeadlight leadIndicator light leadC

SPEC2-35Install the indicator light as shown in the illustra-tion.Place the coupler joint above the front fender.Route the front brake light switch le

SPEC2-36Route the cables and leads through the guide ofthe front fender.Route the leads behind the clutch and parkingbrake cable.CABLE ROUTINGNNJJKKJ-

SPEC2-37CDI unitBandBatteryStarter relay leadStarter relayTaillight leadBattery negative leadAC magneto couplerStarter motor leadHeadlight relayNeutra

SPEC2-38Route the starter relay lead under the startermotor lead.Clamp the taillight lead.Do not clamp.When clamping the wire harness, make sure thatt

CHKADJ3-1EBS00029PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended checks and adjustme

CHKADJ3-212345678GENERAL MAINTENANCE AND LUBRICATION CHARTNO. ITEMCHECK OR MAINTENANCE JOBWhichever comes first INITIAL EVERYmonth136612km(mi)320(200)

CHKADJ3-3NOTE:• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.• Hydraulic brake service• Regularly chec

CHKADJ3-4EBS00033SEAT, FENDERS AND FUEL TANKSEAT, FRONT FENDER AND HEADLIGHTSOrder Job/Part Q’ty RemarksRemoving the seat, front fender and headlights

CHKADJ3-5EBS00034FOOT PROTECTORS AND ENGINE SKID PLATEOrder Job/Part Q’ty RemarksRemoving the foot protectors and engine skid plateRemove the parts in

CHKADJ3-6REAR FENDER AND AIR FILLTER CASEOrder Job/Part Q’ty RemarksRemoving the rear fender and air fillter caseRemove the parts in the order listed.

CHKADJ3-7Order Job/Part Q’ty Remarks10 Air filter case 1For installation, reverse the removal procedure.7 Nm (0.7 m•kg, 5.2 ft•Ib)7 Nm (0.7 m•kg, 5.2

CHKADJ3-8EBS00042FUEL TANKOrder Job/Part Q’ty RemarksRemoving the fuel tank Remove the parts in the order listed.Seat/front fender Refer to “SEAT, FEN

EBS00008TABLE OF CONTENTSGENERAL INFORMATIONGEN INFO1SPECIFICATIONSSPEC2PERIODIC CHECKS ANDADJUSTMENTSCHKADJ3ENGINEENG4CARBURETORCARB5CHASSISCHAS6ELEC

CHKADJ3-9EAS00048ENGINEADJUSTING THE VALVE CLEARANCEThe following procedure applies to all of thevalves.NOTE:NOTE:• Valve clearance adjustment should

CHKADJ3-10a. Turn the crankshaft counterclockwise.b. When the piston is at the Top Dead Center(TDC) on the compression stroke, align the“I” mark on

CHKADJ3-11d. Measure the valve clearance again.e. If the valve clearance is still out of specifica-tion, repeat all of the valve clearanceadjustment s

CHKADJ3-124. Adjust:• engine idling speeda. Turn the throttle stop screw in direction or until the specified idling speed isobtained.5. Remove:• f

CHKADJ3-132. Adjust:• throttle lever free playFirst step:a. Slide back the rubber cover .b. Loosen the locknut on the carburetorside.c. Turn the ad

CHKADJ3-141. Measure:• Speed limiter length Out of specification → Adjust.2. Adjust:• speed limiter lengtha. Loosen the locknut .b. Turn the adjustin

CHKADJ3-15EBS00057CHECKING THE SPARK PLUG1. Disconnect:• spark plug cap2. Remove: • spark plug3. Check:• spark plug typeIncorrect → Change.4. Check:•

CHKADJ3-16EBS00058CHECKING THE IGNITION TIMINGNOTE:NOTE:Engine idling speed and throttle cable free playshould be adjusted properly before checkingthe

CHKADJ3-17MEASURING THE COMPRESSION PRESSUREThe following procedure applies to the cylinder.NOTE:NOTE:Insufficient compression pressure will result in

CHKADJ3-186. Measure:• Compression pressureOut of specification → Refer to steps (c)and (d).a. Set the main switch to “ON”.b. With the throttle wide o

CHAPTER 1GENERAL INFORMATIONMACHINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1VEHICLE IDENTIFICATION NUMBE

CHKADJ3-197. Install:• Spark plug8. Connect:• Spark plug capEBS01101CHECKING THE ENGINE OIL LEVEL1. Place the machine on a level surface.2. Start the

CHKADJ3-204. Start the engine, warm it up for several min-utes, and then turn it off.5. Check:• engine oil levelNOTE:NOTE:Before checking the engine o

CHKADJ3-218. Install:• engine oil drain bolt gasket • engine oil drain bolt• oil filter element drain bolt9. Fill:• crankcase (with the specified amou

CHKADJ3-2214.Check:• engine oil pressurea. Slightly loosen the oil gallery bolt .b. Start the engine and keep it idling untilengine oil starts to see

CHKADJ3-23EBS00073 CLEANING THE AIR FILTER ELEMENTNOTE:NOTE:There is a check hose at the bottom of theair filter case. If dust and/or water collects

CHKADJ3-245. Clean:• air filter element a. Wash the element gently, but thoroughly insolvent.WARNINGUse a cleaning solvent which is designedto clean p

CHKADJ3-25CLEANING THE SPARK ARRESTER1. Clean:• Spark arresterWARNING• Select a well-ventilated area free of com-bustible materials.• Always let the e

CHKADJ3-26 EBS00080CHASSISADJUSTING THE FRONT BRAKE1. Measure:• brake lever free play Out of specification → Bleed the front brakesystem.Refer to

CHKADJ3-27 2. Adjust:• rear brake pedal heighta. Loosen the locknut .b. Turn the adjusting bolt until the brakepedal height is within the specified

CHKADJ3-28 2. Adjust:• parking brake cable end length a. Loosen the locknut and adjusting bolt.b. Slide back the rubber cover .c. Loosen the locknu

CHAPTER 3PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1PERIODI

CHKADJ3-292. Check:• brake fluid levelBelow the minimum level mark → Addthe recommended brake fluid to the properlevel.Front brakeRear brakeWARNING•

CHKADJ3-302. Check:• brake padsWear indicator groove almost disappeared → Replace the brake pads as a set.Refer to “FRONT AND REAR BRAKES” inchapter 6

CHKADJ3-31ADJUSTING THE REAR BRAKE LIGHT SWITCHNOTE:NOTE:• The rear brake light switch is operated bymovement of the brake pedal.• The rear brake ligh

CHKADJ3-322. Check:• front brake hoses • front brake pipe • rear brake hose Cracks/wear/damage → Replace.3. Check:• brake hose clampsLoosen → Tighten.

CHKADJ3-33NOTE:NOTE:• Be careful not to spill any brake fluid or allowthe brake master cylinder reservoir or brakefluid reservoir to overflow.• When b

CHKADJ3-34j. Tighten the bleed screw to specification.k. Fill the brake fluid reservoir to the properlevel with the recommended brake fluid.Refer to “

CHKADJ3-35ADJUSTING THE DRIVE CHAIN SLACKNOTE:NOTE:• Measure the drive chain slack halfwaybetween the drive axle and the rear axle.• When checking and

CHKADJ3-36CAUTION:Excessive chain slack will overload theengine and other vital parts; keep the slackwithin the specified limits.e. If the chain slack

CHKADJ3-37EBS00108 ADJUSTING THE TOE-IN1. Place the machine on a level surface.2. Measure:• toe-in Out of specification → Adjust.NOTE:NOTE:Before meas

CHKADJ3-38a. Mark both tie-rods ends.This reference point will be needed duringadjustment.b. Loosen the locknuts (tie-rod end) of bothtie-rods.c. Th