Yamahaメーカー4XE-F8197-10の使用説明書/サービス説明書
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SERVICE MANUAL LIT -1 1616-12-01 4XE-F8197-10 YFM250XL(C).
YFM250XL SERVICE MANUAL 1998 by Yamaha Motor Corporation, U.S.A. First Edition, February1998 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.
EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in.
EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual is intended as a handy, easy-to-read reference book for the mechanic. It is divided into chapters, sections and sub-sections.
EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic inspection.
CHAPTER TITLES GENERAL INFORMATION 1 SPECIFICATIONS SPEC 2 PERIODIC INSPECTION AND ADJUSTMENT 3 ENGINE OVERHAUL ENG 4 CARBURETION CARB 5 DRIVE TRAIN DRIVE 6 CHASSIS CHAS 7 ELECTRICAL ELEC 8 TROUBLESHO.
CONTENTS CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ........................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER .................................................. 1-1 MODEL LABEL ..............
CHAPTER 3. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION ........................................................................................... 3-1 PERIODIC MAINTENANCE/LUBRICATION ................................................ 3-1 FENDER AND FUEL TANK .
ELECTRICAL ............................................................................................... 3-38 BATTERY INSPECTION ...................................................................... 3-38 FUSE INSPECTION ............................
TIMING CHAIN ................................................................................... 4-30 CAM SPROCKET AND CAM DRIVE SPROCKET ............................... 4-31 TIMING CHAIN GUIDE .........................................................
CHAPTER 5. CARBURETION CARBURETOR .............................................................................................. 5-1 REMOVAL ............................................................................................. 5-2 DISASSEMBLY .
CHAPTER 7. CHASSIS FRONT WHEELS AND FRONT BRAKE ....................................................... 7-1 REMOVAL ............................................................................................. 7-2 INSPECTION ..........................
IGNITION SYSTEM ...................................................................................... 8-7 CIRCUIT DIAGRAM .............................................................................. 8-7 TROUBLESHOOTING .............................
FAULTY DRIVE TRAIN ................................................................................. 9-3 FAULTY GEAR SHIFTING ............................................................................ 9-4 HARD SHIFTING ..............................
1 - 1 GEN INFO MACHINE IDENTIFICATION GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame. MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.
1 - 2 GEN INFO IMPORTANT INFORMATION EB101000 IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES 1.Remove all dirt, mud, dust and foreign material before removal and disassembly. 2.Use proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS” section.
1 - 3 GEN INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1.Replace all lock washers/plates 1 and cot- ter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. IMPORTANT INFORMATION EB101040 BEARINGS AND OIL SEALS 1.
1 - 4 GEN INFO CHECKING OF CONNECTIONS EB801000 CHECKING OF CONNECTIONS Check the connectors for stains, rust, mois- ture, etc. 1.Disconnect: ● Connector 2.Check: ● Connector Moisture → Dry each terminal with an air blower. Stains/rust → Connect and disconnect the terminals several times.
1 - 5 GEN INFO SPECIAL TOOLS EB102001 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques.
1 - 6 GEN INFO SPECIAL TOOLS 4-B Compression gauge P/N. 90890-03081 Extension P/N. 90890-04082 This gauge is used to measure the engine compression. 5 Fuel level gauge P/N. YM-01312-A P/N. 90890-01312 This gauge is used to measure the fuel level in the float chamber.
1 - 7 GEN INFO SPECIAL TOOLS 7-A Slide hammer set P/N. YU-01083-A These tools are used when removing the rocker arm shaft. 7-B Slide hammer bolt (M6) P/N. 90890-01083 Weight P/N. 90890-01084 These tools are used when removing the rocker arm shaft. 8 Valve spring compressor P/N.
1 - 8 GEN INFO SPECIAL TOOLS 13 Sealant (Quick Gasket ) P/N. ACC-QUICK-GS-KT YAMAHA bond No. 1215 P/N. 90890-85505 This sealant (bond) is used for crankcase mat- ing surface, etc. FOR DRIVE TRAIN SERVICE 1-A Universal joint holder P/N. YM-04062 Attachment P/N.
1 - 9 GEN INFO SPECIAL TOOLS FOR CHASSIS SERVICE 1 Yamaha brake grease P/N. 90793-40003 This Yamaha brake grease is used for rear brake dust seal. FOR ELECTRICAL COMPONENTS 1-A Dynamic spark tester P/N. YM-34487 This instrument is necessary for checking the ignition system components.
GEN INFO 1 - 10 1.
GENERAL SPECIFICATIONS SPEC 2 - 1 SPECIFICA TIONS GENERAL SPECIFICA TIONS Item Standard Model code: 4XE1 (USA) 4XE2 (CAL) 4XE3 (CDN) Dimensions: Overall length 1,940 mm (76.4 in) Overall width 1,005 mm (39.6 in) Overall height 1,118 mm (44.0 in) Seat height 780 mm (30.
GENERAL SPECIFICATIONS SPEC 2 - 2 Fuel: T ype Unleaded fuel Fuel tank capacity 12 L (2.64 Imp gal, 3.17 US gal) Fuel reserve amount 1.6 L (0.35 Imp gal, 0.42 US gal) Carburetor: T ype / quantity BST34/1 Manufacturer MIKUNI Spark plug: T ype DR7EA Manufacturer NGK Spark plug gap 0.
GENERAL SPECIFICATIONS SPEC 2 - 3 T ire pressure (cold tire): Recommended front 20 kPa (0.20 kg/cm 2 , 2.9 psi) rear 25 kPa (0.25 kg/cm 2 , 3.6psi) Minimum front 17 kPa (0.17 kg/cm 2 , 2.5 psi) rear 22 kPa (0.22 kg/cm 2 , 3.2 psi) Maximum front 23 kPa (0.
MAINTENANCE SPECIFICATIONS SPEC 2 - 4 MAINTENANCE SPECIFICA TIONS ENGINE Item Standard Limit Cylinder head: W arp limit ---- 0.10 mm (0.004 in) Measuring point Lines indicate straight edge measurement. Cylinder: Bore size 70.97 ~ 71.02 mm (2.794 ~ 2.796 in) 71.
MAINTENANCE SPECIFICATIONS SPEC 2 - 5 “C” 6.572 ~ 6.692 mm (0.259 ~ 0.263 in) ---- Camshaft runout limit ---- 0.03 mm (0.0012 in) Cam chain: Cam chain type / No. of links DID25SH/104 ---- Cam chain adjustment method Automatic ---- Rocker arm / rocker arm shaft: Rocker arm inside diameter 12.
MAINTENANCE SPECIFICATIONS SPEC 2 - 6 Guide inside diameter IN 6.000~ 6.012mm (0.236 ~ 0.237 in) ---- EX 6.000~ 6.012mm (0.236 ~ 0.237 in) ---- Stem-to-guide clearance IN 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.08 mm (0.0031 in) E X 0.025 ~ 0.052 mm (0.
MAINTENANCE SPECIFICATIONS SPEC 2 - 7 Compressed pressure (installed) IN 162.8 ~ 200.1 N (16.6 ~ 20.4 kg, 36.6 ~ 45.0 lb) ---- EX 162.8 ~ 200.1 N (16.6 ~ 20.4 kg, 36.6 ~ 45.0 lb) ---- T ilt limit IN 2.5˚/1.6 mm (2.5˚/0.06 in) E X 2.5˚/1.6 mm (2.5˚/0.
MAINTENANCE SPECIFICATIONS SPEC 2 - 8 Side clearance (installed) 0.03 ~ 0.07 mm (0.001 ~ 0.003 in) 0.12 mm (0.005 in) 2nd ring: T ype T aper ---- Dimensions (B × T) 1.2 × 2.8 mm (0.047 ~ 0.110 in) ---- End gap (installed) 0.15 ~ 0.30 mm (0.006 ~ 0.012 in) 0.
MAINTENANCE SPECIFICATIONS SPEC 2 - 9 Clutch plate Thickness 1.45 ~ 1.75mm (0.057 ~ 0.069 in) 0.2 mm (0.008 in) Quantity 4 pcs. ---- Clutch spring Free length 35.1 mm (1.38 in) 32.9 mm (1.30 in) Quantity 4 pcs. ---- Clutch release method Outer push, cam push ---- Automatic centrifugal clutch: Clutch shoe: Thickness 2.
MAINTENANCE SPECIFICATIONS SPEC 2 - 10 Lubrication system: Oil filter type Wire mesh ---- Oil pump type T rochoid type ---- T ip clearance “A” or “B” 0.15 mm (0.006 in) 0.20 mm (0.008 in) Side clearance 0.04 ~ 0.09 mm (0.002 ~ 0.004 in) 0.09 mm (0.
MAINTENANCE SPECIFICATIONS SPEC 2 - 11 Item Standard Lubrication chart: Crankcase tightening sequence: Crankcase (left) Crankcase (right) 2.
MAINTENANCE SPECIFICATIONS SPEC 2 - 12 Tightening torques Part to be tightened Part name Thread size Q’ ty Tightening torque Remarks Nm m·kg ft·lb Cylinder head (oil gallery plug) Bolt M6 1 7 0.7 5.1 Cylinder head Flange bolt M8 4 22 2.2 16 E Apply oil to the washer Cylinder head and Cylinder Bolt M8 2 22 2.
MAINTENANCE SPECIFICATIONS SPEC 2 - 13 Lock nut (clutch release adjuster) Nut M8 1 15 1.5 11 Starter clutch Bolt M8 3 30 3.0 22 LT Stake Starter motor Screw M6 2 7 0.7 5.1 Pinion gear (drive axle) Nut M16 1 60 6.0 43 Stake Bearing retainer (drive axle) Screw M8 3 25 2.
MAINTENANCE SPECIFICATIONS SPEC 2 - 14 CHASSIS Item Standard Limit Steering system: Steering bearing type Ball bearing ---- Front suspension: Shock absorber travel 117 mm (4.61 in) ---- Suspension spring free length 293 mm (11.54 in) ---- Spring rate (K1) 10 N/mm (1.
MAINTENANCE SPECIFICATIONS SPEC 2 - 15 Front drum brake: T ype Leading and trailing ---- Drum inside diameter 160 mm (6.30 in) 161 mm (6.34 in) Lining thickness 4.0 mm (0.16 in) 2.0 mm (0.08 in) Shoe spring free length 71.0 mm (2.80 in) ---- Rear drum brake: T ype Leading and trailing ---- Drum inside diameter 160 mm (6.
MAINTENANCE SPECIFICATIONS SPEC 2 - 16 Tightening torques Part to be tightened Parts name Thread size Q’ ty Tightening torque Remarks Nm m·kg ft·lb Front panel wheel and brake drum Nu t M10 × 1.25 8 55 5.5 40 Front brake drum and steering knuckle Nut M14 × 1.
MAINTENANCE SPECIFICATIONS SPEC 2 - 17 Pivot shaft and nut (right) Nut M22 × 1.5 1 130 13 94 Swingarm and final drive gear case Nut M8 × 1.25 4 48 4.8 35 LT Rear axle housing and final drive gear case Bolt M10 × 1.25 4 55 5.5 40 Rear shock absorber (upper) and frame Nut M12 × 1.
MAINTENANCE SPECIFICATIONS SPEC 2 - 18 ELECTRICAL Item Standard Limit V oltage: 12 V ---- Ignition system: Ignition timing (B.T .D.C.) 10˚/ 1,000 r/min ---- Advanced timing (B.
MAINTENANCE SPECIFICATIONS SPEC 2 - 19 Withstand voltage 200 V ---- Battery: Specific Gravity 1.280 Electric starter system: T ype Constant mesh type ---- Starter motor: Model / manufacturer SM-14/MITSUBA ---- Output 0.5 kW ---- Armature coil resistance 0.
2 - 20 SPEC HOW TO USE THE CONVERSION TABLE/ GENERAL TORQUE SPECIFICATIONS EB201000 HOW TO USE THE CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data.
2 - 21 SPEC LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication points (parts name) Lubricant type Oil seal lips (all) LS O-rings (all) LS Bearings (all) E.
2 - 22 SPEC CHASSIS Lubrication points Lubricant type Oil seal lips (all)/O-rings (all) LS Steering shaft (Upper and lower with nipple bushes) LS Steering knuckle pivot LS Front lower arm (ball joint).
2 - 23 SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Drain plug 2 O-ring 3 Compression spring 4 Oil strainer 5 Oil pump gasket 6 Oil pump assembly 7 Oil pump driven gear 8 Oil pump drive gear 9 Cam.
2 - 24 SPEC LUBRICATION DIAGRAMS 1 Bypass valve 2 Oil filter 3 Oil filter cover 4 O-ring 5 Collar 6 Camshaft 7 Rocker arm 8 One way bearing (Automatic centrifugal clutch) 9 Crank pin 0 Crankshaft A Ma.
2 - 25 SPEC CABLE ROUTING CABLE ROUTING 1 Rear brake lever switch lead 2 Rear brake cable 3 Cable guide 4 Front brake cable 5 Throttle cable 6 Neutral indicator light 7 Reverse indicator light 8 Handl.
2 - 26 SPEC CABLE ROUTING 1 Cable guide 2 Main switch 3 Fuel tank breather hose 4 Rectifier/regulator 5 CDI unit 6 Taillight 7 Final gear case breather hose 8 Carburetor overflow hose 9 Reverse switch.
2 - 27 SPEC CABLE ROUTING Î Route the carburetor overflow hose between the engine and upper rear engine mount and then between the engine and swingarm. Make sure that the hose is not pinched. ‰ Bend the cable guide after routing the cables. Ï Fasten the starter motor lead and wire har- ness to the frame with the plastic clamp.
2 - 28 SPEC CABLE ROUTING 1 Battery breather hose 2 Spark plug cap 3 Ignition coil 4 Starter motor lead 5 Rear brake cable 6 Rear brake breather hose Å Make sure that the battery breather hose is not kinked or bent. ı Route the rear brake cable through the cable guide on the cyl- inder.
2 - 29 SPEC CABLE ROUTING 1 Wire harness 2 Starter motor lead 3 Rear brake cable 4 Throttle cable 5 Starter relay 6 Starting circuit cut-off relay 7 Rear brake breather hose 8 Carburetor air vent hose 9 Final gear case breather hose 0 Taillight lead Å 50 mm (2.
2 - 30 SPEC 2.
INSP ADJ 3 - 1 INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reli- able machine operation and a longer service life.
INSP ADJ 3 - 2 *: It is recommended that these items be serviced by a Yamaha dealer. **: Lithium soap base grease. W ARNING Indicates a potential hazard that could result in serious injury or death. Steering shaft* • Lubricate every 6 months.** Fittings and Fasten- ers* • Check all chassis fittings and fasteners.
3 - 3 INSP ADJ FRONT FENDER FENDER AND FUEL TANK FRONT FENDER Removal 1.Place the machine on a level place. 2.Remove: ● Front carrier 1 3.Remove: ● Front bumper skid plate 1 4.
3 - 4 INSP ADJ FRONT FENDER Installation: Reverse the “Removal” procedures. Note the following points. 1.Install: ● Front fender 1 T R . . Bolt 2 (front fender and frame): 7 Nm (0.7 m • kg, 5.1 ft • lb) Nut 3 (front fender and fender stay): 7 Nm (0.
3 - 5 INSP ADJ REAR FENDER REAR FENDER Removal 1.Place the machine on a level place. 2.Remove: ● Rear carrier 1 2 with spacer 3.Remove: ● Seat 1 Pull up the seat lock lever 2 , then pull up the seat at the rear. 4.Disconnect: ● Battely leads (negative and positive) W ARNING Disconnect the negative lead 1 first.
3 - 6 INSP ADJ REAR FENDER Installation Reverse the “Removal” procedure. Note the following points. 1.Install: ● Rear fender 1 T R . . Bolt 2 (rear fender and frame): 7 Nm (0.7 m • kg, 5.1ft • lb) Bolt 3 (rear fender and rear foot- rest plate): 7 Nm (0.
3 - 7 INSP ADJ REAR FENDER/FUEL TANK 6.Install: ● Rear carrier 1 NOTE: Do not forget to attach the spacer at the point where the carrier and bumper are connected. T R . . Bolt 2 (rear carrier and frame): 34 Nm (3.4 m • kg, 25 ft • lb) Bolt 3 (rear carrier and rear bumper): 9 Nm (0.
3 - 8 INSP ADJ FUEL TANK 6.Turn the fuel cock lever to “OFF” position. 7.Disconnect: ● Fuel hose 1 NOTE: Place a rug on the engine to absorb a spilt fuel. W ARNING ● Gasoline is highly flammable. ● Avoid spilling fuel on the hot engine. 8.Remove: ● Bolt 1 (with washer and collar) 9.
3 - 9 INSP ADJ FUEL TANK 4.Install: ● Fuel tank cover 1 ● Fuel tank cap 2 ● Rivet 3 ● Screw 4 ● Bolt 5 (with flange collar) T R . . Bolt (fuel tank cover and frame): 10 Nm (1.0 m • kg, 7.2 ft • lb) 5.Connect: ● Breather hose 1 6.Install: ● Seat Refer to the “REAR FENDER-Installation” section.
3 - 10 INSP ADJ ENGINE VALVE CLEARANCE ADJUSTMENT NOTE: ● The valve clearance must be adjusted when the engine is cool to the touch. ● Adjust the valve clearance when the pis- ton is at the Top Dead Center (T.D.C.) on compression stroke. Removal 1.
3 - 11 INSP ADJ VALVE CLEARANCE ADJUSTMENT ● Align the “T” mark 1 on the flywheel with the stationary pointer 2 on the crankcase cover. When the “T” mark is aligned with the stationary pointer, the piston is at Top Dead Center (TDC). NOTE: T.
3 - 12 INSP ADJ VALVE CLEARANCE ADJUSTMENT/ TIMING CHAIN TENSIONER ADJUSTMENT ● Once again, measure the valve clearance. ● If the clearance is incorrect, repeat above steps until the proper clearance is obtained. ********************************** Installation Reverse the “Removal” procedure.
3 - 13 INSP ADJ IDLE SPEED ADJUSTMENT 1.Place the machine on a level place. 2.Warm up engine for several minutes. 3.Adjust: ● Engine idle speed ********************************** Adjustment steps: ● Turn the pilot screw 1 clockwise until it is lightly seated.
3 - 14 INSP ADJ THROTTLE CABLE FREE PLAY ADJUSTMENT NOTE: Before adjusting the throttle cable free play, the engine idle speed should be adjusted. 1.Place the machine on a level place. 2.Check: ● Throttle cable free play a Out of specification → Adjust.
3 - 15 INSP ADJ W ARNING After adjusting the free play, turn the han- dlebar to right and left, and make sure that the engine idling does not run faster. ********************************** SPEED LIMITER ADJUSTMENT The speed limiter keeps the carburetor throttle from becoming full-open even when the throttle lever is pushed to a maxi- mum.
3 - 16 INSP ADJ 3.Inspect: ● Spark plug type Incorrect → Replace. Standard spark plug: DR7EA (NGK) SPARK PLUG INSPECTION 4.Inspect: ● Electrode 1 Wear/Damage → Replace. ● Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition.
3 - 17 INSP ADJ IGNITION TIMING CHECK NOTE: Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing. 1.Place the machine on a level place. 2.Start the engine and let it warm up for several minutes, then stop the engine.
3 - 18 INSP ADJ IGNITION TIMING CHECK/ COMPRESSION PRESSURE MEASUREMENT 5.Install: ● Timing plug 6.Detach: ● Timing light ● Inductive tachometer COMPRESSION PRESSURE MEASUREMENT NOTE: ● Insufficient compression pressure will result in performance loss.
3 - 19 INSP ADJ COMPRESSION PRESSURE MEASUREMENT/ ENGINE OIL LEVEL INSPECTION ● If pressure falls below the minimum level: 1) Squirt a few drops of oil into the affected cylinder. 2) Measure the compression again. ● Remove the compression gauge. ********************************** 4.
3 - 20 INSP ADJ ENGINE OIL LEVEL INSPECTION/ ENGINE OIL REPLACEMENT ● Screw the dipstick 1 completely out, and wipe the dipstick clean, then just rest the dipstick in the hole. ● Pull up the dipstick, and inspect the oil level whether or not it is between maxi- mum 2 and minimum level 3 .
3 - 21 INSP ADJ ENGINE OIL REPLACEMENT 6.Inspect: ● O-rings 1 ● Compression spring 2 ● Oil strainer 3 ● Oil filter 4 Damage → Replace. 7.Clean: ● Compression spring 2 ● Oil strainer 3 ● Oil filter 4 ● Drain plug 5 (crankcase) ● Oil filter cover 6 Wash them with a cleaning solvent.
3 - 22 INSP ADJ ENGINE OIL REPLACEMENT 11.Install: ● Dipstick 12.Warm up the engine for 5 minutes or more, and stop it. 13.Inspect: ● Oil leaks ● Oil level 14.Inspect: ● Oil flow ********************************** Inspection steps: ● Slightly loosen the oil gallery plug 1 in the cylinder head.
3 - 23 INSP ADJ CLUTCH ADJUSTMENT/AIR FILTER CLEANING CLUTCH ADJUSTMENT Release lever free play adjustment 1.Adjust: ● Release lever free play ********************************** Adjustment steps: ● Loosen the locknut 1 .
3 - 24 INSP ADJ AIR FILTER CLEANING 3.Remove: ● Air filter element 1 ● Foam cover 2 CAUTION: The engine should never be run without the air filter; excessive piston and/or cylin- der wear may result. 4.Inspect: ● Air filter element 1 ● Foam cover 2 Damage → Replace.
3 - 25 INSP ADJ AIR FILTER CLEANING 7.Install: ● Foam cover (to air filter) 8.Install: ● Air filter assembly NOTE: Make sure its sealing surface matches the sealing surface of the case so there is no air leak. 9.Install: ● Cover (air filter case) ● Seat Refer to “REAR FENDER-Installation” sec- tion.
3 - 26 INSP ADJ FRONT AND REAR BRAKE LINING INSPECTION/ FRONT BRAKE ADJUSTMENT CHASSIS FRONT AND REAR BRAKE LINING INSPECTION Front brake 1.Apply the front brake. 2.Inspect: ● Wear indicator 1 Indicator reaches the wear limit mark 2 → Replace brake shoes as a set.
3 - 27 INSP ADJ FRONT BRAKE ADJUSTMENT/ REAR BRAKE LEVER AND PEDAL ADJUSTMENT 2.Adjust: ● Front brake lever free play ********************************** Adjustment steps: ● Loosen the locknut 1 and turn the adjuster 2 clockwise to release the ten- sion in the front brake cable.
3 - 28 INSP ADJ REAR BRAKE LEVER AND PEDAL ADJUSTMENT 2.Adjust: ● Brake lever free play ● Brake pedal free play ********************************** Adjustment steps: NOTE: Before adjusting the free play, pump the brake pedal 2 to 3 times. ● Fully loosen the locknut 1 (handlebar) and fully turn in the brake lever adjuster 2 .
3 - 29 INSP ADJ DRIVE SELECT LEVER POSITION ADJUSTMENT/ FINAL DRIVE GEAR OIL LEVEL INSPECTION DRIVE SELECT LEVER POSITION ADJUSTMENT 1.Adjust: ● Drive select lever position ********************************** Adjustment steps: ● Place the machine on a level place.
3 - 30 INSP ADJ ● If the oil level is low, add the recom- mended oil up to the specified level. Refer to “FINAL DRIVE GEAR OIL REPLACE- MENT” section. ● Inspect the copper washer for damage. If damaged, replace it ● Install the copper washer and filler bolt.
3 - 31 INSP ADJ FINAL DRIVE GEAR OIL REPLACEMENT/DRIVE SHAFT DUST BOOT INSPECTION/STEERING SYSTEM INSPECTION 7.Install: ● Filler bolt (final drive gear case) NOTE: After filling the oil, inspect the oil leaks. Recommended oil: SAE 80 API “GL-4” hypoid gear oil If desired, and SAE 80W90 hypoid gear oil may be used for all condition.
3 - 32 INSP ADJ STEERING SYSTEM INSPECTION/ TOE-IN ADJUSTMENT 4.Raise the front end of the machine so that there is no weight on the front wheels. 5.Check: ● Knuckles and/or wheel bearings Move the wheels laterally back and forth. Excessive free play → Replace the follow- ing parts.
3 - 33 INSP ADJ TOE-IN ADJUSTMENT ● If the toe-in is incorrect, adjust the toe-in. ********************************** Toe-in: 0 ~ 5 mm (0 ~ 0.2 in) 3.Adjust: ● Toe-in ********************************** Adjustment steps: ● Place a confirmation marks 1 on the both tie-rods end.
3 - 34 INSP ADJ TOE-IN ADJUSTMENT/FRONT AND REAR SHOCK ABSORBERS INSPECTION/REAR SHOCK ABSORBER ADJUSTMENT FRONT AND REAR SHOCK ABSORBERS INSPECTION 1.Place the machine on a level place. 2.Check: ● Ball joint complete 1 (front) Cracks/Damage → Replace as a set.
3 - 35 INSP ADJ TIRE INSPECTION TIRE INSPECTION W ARNING This model is equipped with low pressure tires. It is important that they be inflated correctly and maintained at the proper pressures. ● TIRE CHARACTERISTICS 1) Tire characteristics influence the han- dling of ATV’s.
3 - 36 INSP ADJ TIRE INSPECTION 1.Measure: ● Tire pressure (cold tire pressure) Out of specification → Adjust. NOTE: ● The Low-pressure tire gauge 1 is included in the standard equipment. ● If dust or the like is stuck to this gauge, it does not provide correct readings.
3 - 37 INSP ADJ WHEEL INSPECTION WHEEL INSPECTION 1.Inspect: ● Wheels 1 Cracks/Bends/Damage → Replace. NOTE: Always balance the wheel when a tire or wheel has been changed or replaced.
3 - 38 INSP ADJ ELECTRICAL BATTERY INSPECTION W ARNING Battery electrolyte is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive measures: ● Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury.
3 - 39 INSP ADJ BATTERY INSPECTION 4.Inspect: ● Battery fluid level Battery fluid level low → Fill. Fluid level should be between upper level 1 and lower level 2 marks. CAUTION: Refill with distilled water only; tap water contains minerals harmful to a battery.
3 - 40 INSP ADJ BATTERY INSPECTION 7.Inspect: ● Battery breather hose Obstruction → Remove. Damage → Replace. 8.Install: ● Battery 1 ● Battery breather hose 2 Refer to the “CABLE ROUTING” section in CHAPTER 2. CAUTION: When installing the battery, be sure the breather hose is routed correctly.
3 - 41 INSP ADJ FUSE INSPECTION FUSE INSPECTION CAUTION: Don’t forget to turn off the main switch when checking or replacing the fuse. Other- wise, it may cause accidental shortcircuit- ing. W ARNING Do not use fuses of a higher amperage rat- ing than those recommended.
3 - 42 INSP ADJ FUSE INSPECTION/HEADLIGHT BEAM ADJUSTMENT/ HEADLIGHT BULB REPLACEMENT 4.Replace: ● Blown fuse ********************************** Blown fuse replacement steps: ● Turn off ignition and the circuit. ● Install a new fuse of proper amperage.
3 - 43 INSP ADJ HEADLIGHT BULB REPLACEMENT 5.Remove: ● Bulb 1 W ARNING Keep flammable products or your hands away from the bulb while it is on, it will be hot. Do not touch the bulb until it cools down. 6.Install: ● Bulb 1 (new) NOTE: Make sure the projection 2 on the bulb is meshed with the slot 3 on the light case.
INSP ADJ 3 - 44 3.
4 - 1 ENG ENGINE REMOVAL ENGINE OVERHAUL ENGINE REMOVAL NOTE: ● It is not necessary to remove the engine in order to remove the following compo- nents: * Cylinder head * Cylinder * Piston * Primary .
4 - 2 ENG ENGINE REMOVAL ENGINE OIL 1.Drain: ● Engine oil Refer to the “ENGINE OIL REPLACE- MENT” section in CHAPTER 3. EXHAUST PIPE AND MUFFLER 1.Remove: ● Exhaust pipe 1 ● Muffler 2 CARBURETOR 1.Drain: ● Fuel (float chamber) NOTE: Place a rag under the over flow hose to absorb a spilt fuel.
4 - 3 ENG ENGINE REMOVAL STARTER MOTOR 1.Disconnect: ● Starter motor lead 1 2.Remove: ● Starter motor bracket 2 ● Starter motor 3 REAR BRAKE CABLES AND FOOTREST 1.Remove: ● Adjusters 1 (brake lever and brake pedal) ● Pins 2 ● Springs 3 2.Disconnect: ● Brake cable 4 (from brake cable bracket 5 .
4 - 4 ENG ENGINE REMOVAL REAR WHEEL DRIVE ASSEMBLY AND SWINGARM 1.Disconnect: ● Breather hose 1 (final gear housing and rear brake drum) (from the cable guides 2 of main frame) 2.Block the front wheels, and elevate the rear wheels by placing the suitable stand under the frame.
4 - 5 ENG ENGINE DISASSEMBLY ENGINE DISASSEMBLY CYLINDER HEAD ASSEMBLY, CYLINDER AND PISTON NOTE: With the engine mounted cylinder head assembly, cylinder and piston can be main- tained by removing the following parts. ● Fuel tank ● Exhaust pipe ● Carburetor ● Engine stays (top) 1.
4 - 6 ENG ENGINE DISASSEMBLY 5.Align: ● “T” mark on the rotor With the stationary pointer on the crank- case cover. ********************************* TDC alignment steps: ● Turn the crankshaft counterclockwise with wrench. ● Align the “T” mark 1 on the rotor with the stationary pointer 2 on the crankcase cover.
4 - 7 ENG ENGINE DISASSEMBLY 8.Remove: ● Bolt 1 ● Cam sprocket 2 NOTE: ● Fasten a safety wire 3 to the timing chain to prevent if from falling into the crank- case. ● When removing the cam sprocket, it is not necessary to separate the timing chain.
4 - 8 ENG ENGINE DISASSEMBLY 11.Remove: ● Bolts 1 (cylinder) ● Cylinder 2 ● Gasket 3 (cylinder) ● Dowel pins 4 ● O-ring 5 12.Remove: ● Piston pin clip 1 ● Piston pin 2 ● Piston 3 NOTE: ● Before removing the piston pin clip, cover the crankcase with a clean rag so you will not accidentally drop the clip into the crankcase.
4 - 9 ENG ENGINE DISASSEMBLY 1.Remove: ● Starter pulley 1 NOTE: Hold the starter pulley by the Rotor Holder to loosen the bolt on the starter pulley. Rotor holder: P/N. YU-01235, 90890-01235 2.Remove: ● Crankcase cover 1 3.Remove: ● Gasket 1 ● Dowel pins 2 ● Shaft 3 ● Washer 4 ● Idle gear 5 (starter) 4.
4 - 10 ENG ENGINE DISASSEMBLY 5.Remove: ● Woodruff key 1 ● Driven gear 2 (starter) ● Washer 3 6.Remove: ● Chain guide 1 (intake) ● Timing chain 2 MIDDLE DRIVEN PINION GEAR 1.Remove: ● Bolts 1 (bearing housing) 2.Remove: ● Bolts 1 (middle gear case cover) ● Middle gear case cover 2 3.
4 - 11 ENG ENGINE DISASSEMBLY PRIMARY AND SECONDARY CLUTCHES NOTE: With the engine mounted, the primary and secondary clutches can be maintained by removing the following parts: ● Starter motor ● Crankcase cover (right) 1.
4 - 12 ENG ENGINE DISASSEMBLY 5.Remove: ● Lock washer 1 ● Clutch carrier assembly 2 ● Washer 3 ● Clutch housing 4 (primary) ● Washer 5 NOTE: The secondary clutch housing has two grooves 1 machined into it to permit the primary drive gear behind the primary clutch to clear the secondary clutch.
4 - 13 ENG ENGINE DISASSEMBLY 9.Straighten: ● Lock washer tab 1 (clutch boss) 10.Remove: ● Nut 2 (clutch boss) NOTE: Hold the clutch boss 3 by the Rotor Holder 4 to loosen the nut.
4 - 14 ENG ENGINE DISASSEMBLY 3.Remove: ● Shift lever assembly 1 ● Washer 2 ● Return spring 3 ● Stopper lever 4 ● Washer 5 NOTE: Push the shift pawl and the stopper lever to the arrow direction and remove them from the segment. 4.Remove: ● Segment 1 (shift cam) Use the Torx wrench to remove.
4 - 15 ENG ENGINE DISASSEMBLY 3.Remove: ● Lock washer 1 ● Balancer gear 2 (driven) ● Straight key 3 CRANKCASE (LEFT) 1.Remove: ● Screws (crankcase) NOTE: Working in a crisscross pattern, loosen all screws 1/4 turn each. Remove them after all are loosened.
4 - 16 ENG ENGINE DISASSEMBLY NOTE: Fully tighten the tool holding bolts, but make sure the tool body is parallel with the case. If necessary, one screw may be backed out slightly to level tool body. ● As pressure is applied, alternately tap on the front engine mounting boss, transmis- sion shafts and balancer shaft.
4 - 17 ENG ENGINE DISASSEMBLY 2.Remove: ● Transmission assembly 1 (main axle and drive axle) ● Washer 2 (drive axle) 3.Remove: ● Circlip 1 4.Remove: ● Balancer drive gear 2 ● Crankshaft 3 (from right crankcase) ● Woodruff key 4 NOTE: Use a hydraulic press to remove the bal- ancer drive gear 2 from the crankshaft.
4 - 18 ENG ENGINE DISASSEMBLY 4.Remove: ● Rocker arm shafts 1 ● Rocker arms (intake/exhaust) NOTE: Attach the Slide Hammer Set 2 to the rocker arm shaft, and then slide out the them. Slide hammer set: P/N. YU-01083-A Slide hammer bolt: P/N. 90890-01083 Weight: P/N.
4 - 19 ENG ENGINE DISASSEMBLY 2.Remove: ● Valve cotters 1 NOTE: Attach the Valve Spring Compressor 2 between the valve spring seat and cylinder head to remove the valve cotters.
4 - 20 ENG INSPECTION AND REPAIR INSPECTION AND REPAIR CYLINDER HEAD 1.Eliminate: ● Carbon deposit Use a rounded scraper 1 . NOTE: Do not use a sharp instrument to avoid damaging or scratching: ● Spark plug threads ● Valve seat ● Cylinder head 2.
4 - 21 ENG INSPECTION AND REPAIR 3.Measure: ● Valve stem runout Out of specification → Replace. Stem runout: Less than: 0.03 mm (0.0012 in) 4.Measure: ● Valve stem clearance Out of specification → Replace either valve and/or guide. Use a Micrometer and Bore Gauge 1 .
4 - 22 ENG INSPECTION AND REPAIR 3.Install: ● Circlip 1 (new) ● Valve guide 2 (new) Use the Valve Guide Installer 3 with the Valve Guide Remover 4 . 4.Bore valve guide 2 to obtain proper valve stem clearance. Use the Valve Guide Reamer 5 (6.0 mm) NOTE: Reface the valve seat after installing the valve guide.
4 - 23 ENG INSPECTION AND REPAIR ● Press the valve through the valve guide and onto the valve seat to make a clear pattern. ● Remove the valve from the cylinder head. ● Measure the valve seat width a . When the valve seat and valve face make contact, bluing will be applied to the valve face.
4 - 24 ENG INSPECTION AND REPAIR ı Valve seat is in the middle of the valve face but too narrow. Ç Valve seat is too narrow and right up near valve margin.
4 - 25 ENG INSPECTION AND REPAIR ● Apply a molybdenum disulfide oil to the valve stem. ● Install the valve into the cylinder head. ● Turn the valve until the valve face and valve seat are evenly polished, then clean off all compound.
4 - 26 ENG INSPECTION AND REPAIR 2.Measure: ● Valve spring installed force Out of specification → Replace inner and outer springs as a set. a Installed length Valve spring installed force Inner spring (IN/EX) 8.4 ~ 10.2 kg (18.5 ~ 22.5 lb) at 30.5 mm (1.
4 - 27 ENG INSPECTION AND REPAIR NOTE: All valve springs must be installed with the larger pitch a upward as shown. 1 Outer spring 2 Inner spring 4.Check: ● Valve sealing Leakage at valve seat → Reface, relap or replace valve, relap. Refer to “VALVE SEAT”.
4 - 28 ENG INSPECTION AND REPAIR 2.Inspect: ● Cam lobes Pitting/Scratches/Blue discoloration → Replace. 3.Measure: ● Cam lobes Use a Micrometer. Out of specification → Replace. Cam lobe Limit “A” Cam lobe Limit “B” Intake 36.437 mm (1.
4 - 29 ENG INSPECTION AND REPAIR ● Calculate the clearance by subtracting the rocker-arm-shaft outside diameter from the rocker-arm inside diameter. Out of specification → Replace as a set. Arm-to-shaft clearance = Rocker arm inside diameter a – Rocker arm shaft outside diameter b Arm-to-shaft clearance: 0.
4 - 30 ENG INSPECTION AND REPAIR 5.Install: ● Camshaft bushing 1 NOTE: The cut-out portion 2 of the bushing must be flush with the cylinder head. CAUTION: Do not cock the bushing during installa- tion. The bushing must be perpendicular to the camshaft during installation.
4 - 31 ENG INSPECTION AND REPAIR CAM SPROCKET AND CAM DRIVE SPROCKET 1.Inspect: ● Cam sprocket ● Cam drive sprocket (crank shaft) Wear/Damage → Replace cam sprocket and timing chain as a set. 1 1/4 tooth 2 Correct 3 Roller 4 Sprocket TIMING CHAIN GUIDE 1.
4 - 32 ENG INSPECTION AND REPAIR TAPPET COVER AND CAM SPROCKET COVER 1.Inspect: ● Tappet covers (intake 1 and exhaust 2 ) ● Cam sprocket cover 3 ● O-rings 4 Cracks/Damage → Replace. CYLINDER AND PISTON 1.Eliminate: ● Carbon deposits (from the piston crown and ring grooves.
4 - 33 ENG INSPECTION AND REPAIR 2nd steps ● Measure the piston skirt diameter “P” with a micrometer. b 4 mm (0.16 in) from the piston bottom edge ● If out of the specification, replace the pis- ton and piston rings as a set. 3rd steps ● Find the piston-to-cylinder clearance with following formula.
4 - 34 ENG INSPECTION AND REPAIR Side clearance Standard Limit Top ring 0.03 ~ 0.07 mm (0.001 ~ 0.003 in) 0.12 mm (0.005 in) 2nd ring 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in) 0.12 mm (0.005 in) 2.Position: ● Piston ring (into cylinder) NOTE: Insert the ring into the cylinder, and push it approximately 20 mm (0.
4 - 35 ENG INSPECTION AND REPAIR ● Oil control ring Expander spacer of bottom ring (oil con- trol ring) is color-coded to identify sizes. Size Color Oversize 2 Blue Oversize 4 Yellow Piston pin 1.Inspect: ● Piston pin Blue discoloration/Grooves → Replace then inspect lubrication system.
4 - 36 ENG INSPECTION AND REPAIR CRANKSHAFT 1.Measure: ● Crank width A Out of specification → Replace or repair. ● Runout c Out of specification → Replace or repair. ● Side clearance D Out of specification → Replace or repair. ● Big end radial clearance E Out of specification → Replace or repair.
4 - 37 ENG INSPECTION AND REPAIR ********************************* Crankshaft reassembling point: The crankshaft 1 and the crank pin 2 oil passages must be properly interconnected with a tolerance of less than 1 mm (0.04 in). ********************************* BALANCER DRIVE GEAR AND DRIVEN GEARS 1.
4 - 38 ENG INSPECTION AND REPAIR 3.Inspect: ● Bolts 1 (starter clutch) Loose → Replace with a new one, and calk the end of the bolt. Bolts (starter clutch): 30 Nm (3.0 m • kg, 22 ft • lb) LOCTITE Calk the end of the bolt PRIMARY CLUTCH Clutch housing 1.
4 - 39 ENG INSPECTION AND REPAIR Clutch boss and pressure plate 1.Inspect: ● Clutch boss splines 1 ● Pressure plate splines 2 Scoring/Wear/Damage → Replace clutch boss assembly and/or pressure plate. Friction plates 1.Inspect: ● Friction plate 1 Damage/Wear → Replace friction plate as a set.
4 - 40 ENG INSPECTION AND REPAIR Clutch spring 1.Inspect: ● Clutch spring Wear/Damage → Replace. 2.Measure: ● Clutch spring free length a Out of specification → Replace springs as a set. Clutch release lever 1.Inspect: ● Release lever 1 ● Adjuster 2 ● O-ring 3 Cracks/Wear/Damage → Replace.
4 - 41 ENG INSPECTION AND REPAIR TRANSMISSION AND SHIFTER Shift fork and guide bar 1.Inspect: ● Shift forks On the gear and shift cam contact sur- faces. Wear/Chafing/Bends/Damage → Replace. 2.Inspect: ● Guide bars (Roll the guide bar on a flat surface.
4 - 42 ENG INSPECTION AND REPAIR 2.Inspect: ● Gears (transmission 1 and drive pinion 2 ) ● Mating dogs Cracks/Damage/Wear → Replace. NOTE: When the drive pinion gear is replaced, be sure to adjust the drive pinion gear shim(s), refer to the “DRIVE TRAIN-MIDDLE GEAR SERVICE” section in CHAPTER 6.
4 - 43 ENG INSPECTION AND REPAIR MIDDLE GEAR 1.Inspect: ● Middle driven pinion gear 1 ● Bearing 2 ● Middle driven shaft 3 ● Reverse gear 4 ● Bearing housing 5 Damage/Wear → Replace.
4 - 44 ENG INSPECTION AND REPAIR 3.Inspect: ● Crankcase Cracks/Damage → Replace. ● Oil delivery passages Clog → Blow out with compressed air. NOTE: When the crankcase is replaced, be sure to adjust the middle gear shim(s), refer to “DRIVE TRAIN-MIDDLE GEAR SERVICE” section in CHAPTER 6.
4 - 45 ENG ENGINE ASSEMBLY AND ADJUSTMENT ENGINE ASSEMBLY AND ADJUSTMENT RECOIL STARTER 1.Install: ● Starter spring 1 NOTE: Mesh the spring hook 2 wise the case slit, then carefully wind the spring counterclock- wise, and fit the spring into the case.
4 - 46 ENG ENGINE ASSEMBLY AND ADJUSTMENT 6.Install: ● Spring (drive pawl) 1 ● Drive pawl 2 ● Circlip 3 ● Spring 4 ● Drive plate 5 ● Bolt 6 NOTE: When installing the spring (drive pawl), align the spring end 7 with the groove a on the sheave drum.
4 - 47 ENG ENGINE ASSEMBLY AND ADJUSTMENT CRANKSHAFT/BALANCER 1 Balancer driven gear 2 Bearing 3 Straight key 4 Balancer 5 Oil seal 6 Balancer drive gear 7 Woodruff key 8 Crank (right) 9 Connecting rod 0 Small end bearing A Crank pin B Crank (left) A PISTON TO CYLINDER CLEARANCE: 0.
4 - 48 ENG ENGINE ASSEMBLY AND ADJUSTMENT TRANSMISSION 1 Bearing 2 1st wheel gear 3 5th wheel gear 4 Circlip 5 Washer 6 3rd wheel gear 7 4th wheel gear 8 2nd wheel gear 9 Drive axle 0 Bearing retainer A Main axle B 5th pinion gear C 3rd pinion gear D 4th pinion gear E 2nd pinion gear F Oil seal G Shim A DRIVE/MAIN AXLE RUNOUT: <Limit> 0.
4 - 49 ENG ENGINE ASSEMBLY AND ADJUSTMENT SHIFTER 1 Guide bar #1 (long) 2 Shift fork #2 3 Shift fork #3 4 Shift cam segment 5 Pin 6 Bearing 7 Shift cam 8 Guide bar #2 (short) 9 Shift fork #1 4.
4 - 50 ENG ENGINE ASSEMBLY AND ADJUSTMENT CRANKSHAFT, TRANSMISSION AND BALANCER SHAFT 1.Install: ● Crankshaft 1 (to right crankcase) NOTE: Hold the connecting rod at top dead center with one hand while installing the crank- shaft. 2.Install: ● Transmission assembly 1 (main axle and drive axle) 3.
4 - 51 ENG ENGINE ASSEMBLY AND ADJUSTMENT CRANKCASE (LEFT) 1.Apply: ● Sealant 1 (to matching surfaces of both case halves) Sealant (Quick Gasket ): ACC-QUICK-GS-KT Y amaha bond No. 1215: 90890-85505 2.Install: ● Dowel pins 2 3.Fit the left crankcase onto the right case.
4 - 52 ENG ENGINE ASSEMBLY AND ADJUSTMENT Crankshaft installer set 1 : P/N. YU-90050 Buffer boss installer set 2 : P/N. 90890-04088 Adapter #11 3 : P/N. YM-33279 Spacer 4 (crankshaft): P/N. YM-90070-A, 90890-04060 2.Install: ● Balancer gear 1 (driven) ● Straight key 2 NOTE: Align the drive gear mark 3 with the driven gear mark 4 .
4 - 53 ENG ENGINE ASSEMBLY AND ADJUSTMENT SHIFT SHAFT/OIL PUMP 1 Adjuster 2 Spring 3 Release lever 4 Shift guides 5 Ball holder 6 Shift shaft 7 Torsion spring 8 Stopper lever 9 Return spring 0 Oil sea.
4 - 54 ENG ENGINE ASSEMBLY AND ADJUSTMENT SHIFTER AND OIL PUMP 1.Install: ● Segment 1 ● Pin 2 (long) ● Pin 3 (short) NOTE: Install the pin 2 (long) to the match mark 4 position. 2.Install: ● Segment (shift cam) NOTE: Align the hole 1 of the shift cam with the pin 2 (long) of the segment.
4 - 55 ENG ENGINE ASSEMBLY AND ADJUSTMENT 6.Apply: ● 4-stroke engine oil (to the oil pump inner parts) 7.Install: ● Rotor housing 1 ● Outer rotor 2 ● Inner rotor 3 ● Dowel pins 4 ● Oil pump driven gear 5 ● Dowel pin 6 ● Oil pump cover 7 ● Screw 8 8.
4 - 56 ENG ENGINE ASSEMBLY AND ADJUSTMENT CLUTCH 1 Push rod 2 Bearing 3 Bearing holder 4 Clutch boss 5 Clutch plate 6 Friction plate 7 Pressure plate 8 Washer 9 Clutch housing (secondary) 0 Clutch carrier assembly A Washer B Inner collar C One way bearing D Clutch housing (primary) A CLUTCH SPRING MINIMUM LENGTH: 0.
4 - 57 ENG ENGINE ASSEMBLY AND ADJUSTMENT PRIMARY AND SECONDARY CLUTCHES 1.Install: ● Clutch housing 1 (secondary) ● Washer 2 2.Install: ● Friction plates 1 ● Clutch plates 2 (to clutch boss 3.
4 - 58 ENG ENGINE ASSEMBLY AND ADJUSTMENT NOTE: Hold the clutch boss 2 by the Rotor Holder 3 to tighten the nut. 6.Bend the lock washer tab 4 . Rotor holder: P/N. YU-01235, 90890-01235 7.Install: ● Clutch springs 1 ● Bearing holder 2 ● Bearing 3 ● Push rod 4 T R .
4 - 59 ENG ENGINE ASSEMBLY AND ADJUSTMENT 11.Install: ● Washer 1 ● Clutch housing 2 (primary) ● Washer 3 ● Clutch carrier assembly 4 NOTE: ● The secondary clutch housing has two grooves 1 machined into it permit the primary drive gear behind the primary clutch to clear the secondary clutch.
4 - 60 ENG ENGINE ASSEMBLY AND ADJUSTMENT 15.Install: ● Shift guide #2 1 ● Ball holder 2 ● Shift guide #1 3 ● Spring 4 (clutch release lever) NOTE: ● The slot 5 in the shift guide #2 must engage the shift shaft projection 6 . ● The slot 7 in the shift guide #1 must engage the stopper shaft 8 .
4 - 61 ENG ENGINE ASSEMBLY AND ADJUSTMENT MIDDLE DRIVEN PINION GEAR 1.Install: ● Dowel pins 1 ● Shims 2 (to middle driven shaft) ● Bearing 3 ● Middle driven shaft assembly 4 NOTE: Apply the grease to the O-ring 5 . 2.Apply: ● Sealant 1 (to matching surface of middle shaft case cover) Sealant (Quick Gasket ): P/N.
4 - 62 ENG FWD ENGINE ASSEMBLY AND ADJUSTMENT STARTER PULLEY (EXCEPT FOR USA)/CDI MAGNETO 1 Timing chain 2 Timing chain guide (intake) 3 Woodruff key 4 Washer 5 Starter driven gear 6 Starter clutch 7 .
4 - 63 ENG ENGINE ASSEMBLY AND ADJUSTMENT STARTER PULLEY (EXCEPT FOR USA) AND CDI MAGNETO 1.Inspect: ● Timing chain 1 ● Chain guide 2 (intake) NOTE: Fasten a safety wire 3 to the timing chain to prevent it from falling into the crankcase.
4 - 64 ENG ENGINE ASSEMBLY AND ADJUSTMENT 5.Install: ● Starter pulley 1 NOTE: ● Hold the starter pulley by the Rotor Holder to tighten the bolt. ● Before installing the starter pulley, apply the grease to the oil seal rip 2 and O-ring 3 . T R . .
4 - 65 ENG ENGINE ASSEMBLY AND ADJUSTMENT CYLINDER AND CYLINDER HEAD ASSEMBLY 1 Spark plug 2 Tappet cover (intake) 3 O-ring 4 Tappet cover (exhaust) 5 Cylinder head 6 Bearing retainer 7 Lock washer 8 Cam sprocket cover 9 Oil seal 0 Cylinder A CYLINDER HEAD WARP LIMIT: 0.
4 - 66 ENG ENGINE ASSEMBLY AND ADJUSTMENT PISTON, CAMSHAFT AND TIMING CHAIN 1 Gasket 2 Timing chain tensioner 3 Gasket 4 Timing chain guide (intake) 5 Camshaft 6 Camshaft bushing 7 Cam sprocket 8 Timi.
4 - 67 ENG ENGINE ASSEMBLY AND ADJUSTMENT CYLINDER HEAD ASSEMBLY, CYLINDER AND PISTON 1.Install: ● Piston 1 ● Piston pin 2 ● Piston pin clips 3 NOTE: ● The arrow 4 on the piston must point to the front of the engine.
4 - 68 ENG ENGINE ASSEMBLY AND ADJUSTMENT 5.Install: ● Cylinder 1 ● Bolts (cylinder)-temporary tighten NOTE: ● Install the cylinder with one hand while compressing the piston rings with the other hand. ● Pass the timing chain through the chain cavity.
4 - 69 ENG ENGINE ASSEMBLY AND ADJUSTMENT ● Turn the crankshaft counterclockwise until the TDC mark 3 is aligned with the station- ary pointer 4 on the crankcase cover. ● Place the timing chain onto the cam sprocket. ● Install the cam sprocket onto the cam- shaft, and finger tighten the sprocket bolt.
4 - 70 ENG ENGINE ASSEMBLY AND ADJUSTMENT ● Insert a small screwdriver 3 into the ten- sioner body slit. While pressing the ten- sioner rod, rotate the screwdriver clockwise until it stops turning.
4 - 71 ENG ENGINE ASSEMBLY AND ADJUSTMENT 13.Install: ● Tappet cover 1 (intake) ● Tappet cover 2 (exhaust) ● Spark plug 3 T R . . Bolt (tappet cover): 10 Nm (1.
4 - 72 ENG ENGINE ASSEMBLY AND ADJUSTMENT REMOUNTING ENGINE Reverse the “ENGINE REMOVAL” proce- dure. Note the following points. W ARNING Securely support the machine so there is no danger of it falling over. 1.Install: ● Engine assembly (from right side) 2.
4 - 73 ENG ENGINE ASSEMBLY AND ADJUSTMENT 3.Install: ● Rear wheel drive assembly and swing- arm. NOTE: ● Before installing the swingarm. Lubricate the following parts.
4 - 74 ENG ENGINE ASSEMBLY AND ADJUSTMENT 7.Tighten: ● Bolt 1 (engine mounting - rear lower) ● Bolt 2 (engine mounting - rear upper) ● Bolt 3 (engine mounting - front) ● Bolts 4 (engine mounting - top) ● Pivot shafts 5 (swingarm) ● Locknut (pivot shaft - right) ● Bolt 6 (rear shock absorber - top) 8.
4 - 75 ENG ENGINE ASSEMBLY AND ADJUSTMENT 11.Install: ● Spring 1 ● Footrest 2 (right) T R . . Bolt (footrest): 65 Nm (6.5 m • kg, 47 ft • lb) 12.Install: ● Front fender stay 1 ● Sift pedal 2 ● Footrest 3 (left) NOTE: The center of the shift pedal 2 should be aligned with the top of the footrest 3 .
4 - 76 ENG ENGINE ASSEMBLY AND ADJUSTMENT 17.Install: ● Carburetor 1 Refer to “CARBURETOR” section in the CHAPTER 5. T R . . Hose clamp: 2 Nm (0.2 m • kg, 1.4 ft • lb) 19.Fill: ● Crankcase Refer to the “ENGINE OIL REPLACE- MENT” section in CHAPTER 3.
4 - 77 ENG ENGINE ASSEMBLY AND ADJUSTMENT 22.Install: ● Rear fender ● Rear carrier ● Front fender ● Front bumper ● Front carrier ● Fuel tank ● Seat Refer to the “FENDERS AND FUEL TANK- Installation” section in CHAPTER 3. 23.Inspect: ● Oil leakage 24.
ENG 4 - 78 4.
FWD 5 - 1 CARB CARBURETOR CARBURETION CARBURETOR 1 Vacuum chamber cover 2 Spring 3 Jet needle set 4 Piston valve 5 Pilot air jet 6 Coasting enricher diaphragm 7 Starter plunger assembly 8 Pilot screw set 9 Pilot jet 0 Needle jet A Main jet B Needle valve set C Throttle stop screw D Float pin E Float SPECIFICATIONS ID MARK 4XE1 00 MAIN JET (M.
5 - 2 CARB REMOVAL 1.Turn the fuel cock lever to “OFF”. 2.Remove: ● Air vent hose 1 ● Overflow hose 2 ● Fuel hose 3 3.Loosen: ● Clamp screws 4 4.Remove: ● Carburetor assembly CARBURETOR 5.Remove: ● Throttle valve cover 1 6.Remove: ● Throttle cable end 1 7.
5 - 3 CARB 2.Remove: ● Pilot air jet 1 CARBURETOR 3.Remove: ● Float chamber 1 ● O-ring 2 4.Remove: ● Float pin 1 ● Float 2 ● Needle valve 3 NOTE: Remove the float pin in the direction of the arrow. 5.Remove: ● Throttle stop screw 1 ● Valve seat 2 ● Main jet 3 ● Pilot jet 4 ● Pilot screw set 5 6.
5 - 4 CARB 7.Remove: ● Cover (coasting enricher) 1 ● Spring 2 ● Diaphragm 3 CARBURETOR 8.Remove: ● Starter plunger 1 INSPECTION 1.Inspect: ● Carburetor body ● Starter jet 1 ● Float chamber Cracks/damage → Replace. ● Fuel passage Contamination → Clean as indicated.
5 - 5 CARB 3.Inspect: ● Float 1 ● Float tang 2 Damage → Replace. CARBURETOR 4.Inspect: ● Main jet 1 ● Needle jet 2 ● Pilot jet 3 ● Pilot air jet 4 Wear/damage → Replace.
5 - 6 CARB 8.Inspect: ● Throttle stop screw 1 ● Pilot screw 2 Contamination/wear → Replace. ● O-ring 3 Damage → Replace. CARBURETOR 9.Check: ● Free movement (piston valve) Sticks → Replace. Insert the piston valve into the carburetor body, and check for free movement.
5 - 7 CARB 3.Install: ● O-ring ● Washer ● Spring ● Pilot screw Pilot screw: 2 turns out CARBURETOR 4.Install: ● Needle valve 1 ● Float 2 ● Float pin 3 NOTE: Install the float pin in the direction of the arrow. 5.Measure: ● Float height a Out of specification → Adjust.
5 - 8 CARB 6.Install: ● Piston valve 1 NOTE: Match the tab on the rubber diaphragm to the matching recess in the carburetor body. CARBURETOR INSTALLATION Reverse the “REMOVAL” procedure. Note the following points. 1.Install: ● Carburetor assembly T R .
5 - 9 CARB FUEL LEVEL ADJUSTMENT 1.Measure: ● Fuel level a Out of specification → Adjust. ********************************* Fuel level measurement and adjustment steps: ● Place the machine on a level surface. ● Connect the fuel level gauge 1 to the drain pipe 2 .
CARB 5 - 10 5.
6 - 1 DRIV MIDDLE GEAR SERVICE DRIVE TRAIN MIDDLE GEAR SERVICE MIDDLE GEAR 1 Universal joint 2 Bearing retainer 1 3 Bearing 4 Shims 5 Bearing housing 6 O-ring 7 Reverse gear securing nut 8 Bearing 9 B.
6 - 2 DRIV MIDDLE GEAR SERVICE MIDDLE GEAR SHIMS When the crankcase assembly and/or the middle gear comp., etc. are replaced, be sure to adjust the middle gear shim(s). Refer to the “MIDDLE GEAR SHIM SELECTION” and “MIDDLE GEAR LASH ADJUSTMENT” section.
6 - 3 DRIV MIDDLE GEAR SERVICE REMOVAL NOTE: It is necessary to remove the rear wheel drive assembly and/or engine assembly in order to service the middle gear, refer to the “ENGINE OVERHAUL” section in CHAPTER 4. 1.Drain: ● Engine oil Refer to the “ENGINE OIL REPLACE- MENT” section in CHAPTER 3.
6 - 4 DRIV MIDDLE GEAR SERVICE 2.Remove: ● Bolts 1 (middle gear case cover) ● Middle gear case cover 2 ● Dowel pins 3.Remove: ● Middle driven shaft assembly 1 ● Bearing 2 ● Shim 3 ● Driven pinion gear 4 Middle drive axle 1.
6 - 5 DRIV MIDDLE GEAR SERVICE 3.Remove: ● Bearing retainers 1 Use a #40 Torx Driver. 4.Remove: ● Bearing 1 ● Shim 2 DISASSEMBLY Middle driven shaft 1.Remove: ● Universal joint ********************************* Removal steps: ● Remove the circlips 1 .
6 - 6 DRIV MIDDLE GEAR SERVICE Universal joint holder: P/N. YM-04062, 90890-04062 Attachment: P/N. YM33291, 90890-04096 3.Remove: ● Middle driven shaft 1 ● Dog clutch 2 4.Remove: ● Bearing retainer 1 NOTE: ● Use a Bearing retainer wrench 2 . ● Bearing 3 ● Shim(s) 4 5.
6 - 7 DRIV MIDDLE GEAR SERVICE 6.Remove: ● Bearing retainer 1 NOTE: ● Use a Ring nut wrench 2 . ● Bearing 3 Shift lever 1.Remove: ● Shift fork guide bar 1 ● Shift fork 2 ● Ball 3 ● Spring 4 NOTE: When removing the shift fork guide bar, the ball will fall off.
6 - 8 DRIV 3.Check: ● Universal joints 1 ● Yoke 2 ● Bearings 3 Wear/Cracks/Damage → Replace. 4.Inspect: ● Shift fork 4 1 On the dog clutch and shift lever contact surfaces. Wear/Chafing/Bends/Damage → Replace. ● Spring 2 Wear/Damage → Replace.
6 - 9 DRIV MIDDLE GEAR SERVICE 8.Inspect: ● Bearing housing 1 Cracks/Damage → Replace bearing hous- ing assembly. ● O-ring 2 Wear/Damage → Replace. NOTE: When the bearing housing assembly is replaced, be sure to adjust the middle gear shim(s), refer to the “MIDDLE GEAR SHIM SELECTION” section.
6 - 10 DRIV MIDDLE GEAR SERVICE 1 Drive pinion gear 2 Driven pinion gear 3 Reverse gear 4 Middle driven shaft Shim location Å = Drive pinion gear shim ı = Driven pinion gear shim Ç = Reverse gear shim Î = Middle driven shaft shim Å = a - b ı = c - d - e - f Ç = d - g - h - i Î = j + c - e - ı - k - l - 0.
6 - 11 DRIV ********************************* Middle gear shims selection steps: Shim selection Å ● When the crankcase and/or the drive pin- ion gear are replaced, be sure to adjust the drive pinion gear shim Å .
6 - 12 DRIV In the example above, the calculated shim thickness is 0.57 mm. The chart instructs you, however, to round off the 7 to 5, then shim thickness is 0.55 mm. Shim selection ı ● When the crankcase and/or the driven pin- ion gear are replaced, be sure to adjust the driven pinion gear shim ı .
6 - 13 DRIV In the example above, the calculated shim thickness is 0.95 mm. The chart instructs you, however, to round off the 5 to 5, then shim thickness is 0.95 mm. Shim selection Ç ● When the crankcase, reverse gear and/or bearing housing are replaced, be sure to adjust the reverse gear shim Ç .
6 - 14 DRIV Because shims can only be selected in 0.05 mm increments, round off hundredths digit and select appropriate shim(s). In the example above, the calculated shim thickness is 0.51 mm. The chart instructs you, however, to round off the 1 to 0, then shim thickness is 0.
6 - 15 DRIV MIDDLE GEAR SERVICE Example: 1) If the bearing hauging is stamped “–03”. ..... j = 1 – 0.03 = 0.97 2) If the crankcase is stamped “45” ..... c = 110 + 0.45 = 110.45 3) If the pinion gear is stamped “–02” ..... k = 14.5 – 0.
6 - 16 DRIV MIDDLE GEAR SERVICE ASSEMBLY Reverse the “DISASSEMBLY” procedures. Note the following points. Middle driven shaft 1.Apply: ● Lithium base grease To the oil seal and O-ring. 2.Install: ● Shift lever shaft 1 ● Shift lever 2 ● Stopper shaft 3 ● Circlip 4 3.
6 - 17 DRIV MIDDLE GEAR SERVICE 6.Install: ● Bearing 1 (to bearing housing) ● Bearing retainer 2 NOTE: ● Use a Ring nut wrench 3 . Ring nut wrench: P/N. YM-1391, 90890-01391 7.Tighten: ● Bearing retainer T R . . Bearing retainer: 60 Nm (6.0 m • kg, 43 ft • lb) 8.
6 - 18 DRIV MIDDLE GEAR SERVICE 11.Tighten: ● Bearing retainer T R . . Bearing retainer: 60 Nm (6.0 m • kg, 43 ft • lb) Use LOCTITE 12.Install: ● Middle driven shaft 1 ● Dog clutch 2 13.
6 - 19 DRIV MIDDLE GEAR SERVICE 14.Install ● Universal joint ********************************* Installation steps: ● Install the opposite yoke into the U-joint. ● Apply the “Wheel bearing grease” to the bearings. ● Install the bearing 1 onto the yoke.
6 - 20 DRIV MIDDLE GEAR SERVICE 3.Install: ● Middle drive axle assembly 1 Refer to the “ENGINE ASSEMBLY AND ADJUSTMENT-CRANK SHAFT, TRANS- MISSION AND BALANCER SHAFT” sec- tion in CHAPTER 4. 4.Install: ● Middle drive pinion gear 1 ● Nut 2 Use the Rotor Holder 3 to hold the clutch boss 4 .
6 - 21 DRIV MIDDLE GEAR SERVICE 2.Apply: ● Sealant 1 To the mating surface of both case halves. 3.Install: ● Dowel pins ● Middle gear case cover 2 NOTE: Before installing the middle gear case cover onto the crankcase, shift the gear into “FORWARD”.
6 - 22 DRIV MIDDLE GEAR SERVICE 2.Shift: ● Drive select lever For forward drive. 3.Measure: ● Gear lash Gently rotate the middle drive axle from engagement to engagement. Over specified limit → Repair. NOTE: Measure the gear lash at 4 positions.
6 - 23 DRIV MIDDLE GEAR SERVICE 2.Install: ● Rear wheel drive assembly and swingarm Refer to “REMOUNTING ENGINE” section in the CHAPTER 4. 3.Adjust: ● Rear brake Refer to “REAR BRAKE LEVER AND PEDAL ADJUSTMENT” section in the CHAPTER 3. 4.
6 - 24 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT FINAL DRIVE GEAR AND DRIVE SHAFT 1 Bearing housing 2 O-ring 3 Oil seal 4 Bearing 5 Ring gear shim 6 Ring gear 7 Thrust washer 8 Bearing 9 Oil seal 0 Bearin.
6 - 25 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT TROUBLESHOOTING The following conditions may indicate damage drive train components: NOTE: Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite sub- tle and difficult to distinguish from normal machine operating noise.
6 - 26 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT Inspection notes 1.Investigate any unusual noises ********************************* The following “Noises” may indicate a machanical problem: ● A “rolling rumble” noise during coasting, acceleration, or deceleration.
6 - 27 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 3.Inspect: ● Oil leakage By the following inspection steps. ********************************* Oil leakage inspection steps: ● Clean the entire machine thoroughly, then dry it. ● Apply a leak-localizing compound or dry powder spray to the shaft drive.
6 - 28 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT REMOVAL W ARNING Securely support the machine so there is no danger of it falling over. 1.Drain: ● Final gear oil Refer to the “FINAL GEAR OIL REPLACE- MENT” section in CHAPTER 3.
6 - 29 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT NOTE: ● When the final gear case until is removed from the swingarm, the drive shaft 3 may fall off. ● Be careful not to lose these parts. DISASSEMBLY 1.Remove: ● Bolts 1 (8 mm) ● Bolts 2 (10 mm) NOTE: Working in a crisscross pattern, loosen bolt 1/4 turn each.
6 - 30 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 3.Remove: ● Bearing retainer (drive shaft - final) NOTE: Final-drive-shaft-bearing-retainer has left- hand threads. Turn retainer clockwise to loosen it. NOTE: When remounting the bearing retainer, use the Bearing Retainer Wrench 1 .
6 - 31 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 6.Remove: ● Roller bearing 1 (drive pinion gear) ********************************* Removal steps: ● Heat the main housing only to 150˚C (302˚F). ● Remove the roller bearing outer race with an appropriately shaped punch 2 .
6 - 32 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 4.Inspect: ● Final gear case 1 ● Bearing housing 2 (ring gear) Cracks/Damage → Replace. NOTE: When the final gear case and/or ring gear bearing housi.
6 - 33 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT Example: 1) If the “+01” is stamped on the final drive pinion gear, a = 79 + 0.01 = 79.01 2) If the “50” is stamped on the final gear case, b = 78 + 0.50 = 78.50 3) Therefore, “A” is, “A” = 79.
6 - 34 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT ********************************* Shim selection steps: ● To find ring gear shim thickness “B”, use the following formula. c = The stamped number on the final gear case is either added to or subtracted from “42”.
6 - 35 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT ASSEMBLY Reverse the “DISASSEMBLY” procedures. Note the following points. 1.Install: ● Roller bearing (drive pinion gear) ********************************* Installation steps: ● Heat the main housing only to 150˚C (302˚F) ● Install the roller bearing outer race using the proper adapted.
6 - 36 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT Thrust washer selection 1.Measure/Select: ● Ring gear thrust clearance “C” ********************************* Thrust clearance measurement steps: ● Place four pieces of Plastigauge between originally fitted thrust washer and ring gear.
6 - 37 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 2.Install: ● Thrust washer 1 ● Ring gear 2 ● Shim(s) 3 (proper size as calculated) ● Bearing housing 4 NOTE: ● Before installing the ring gear, apply the grease to the oil seal rips. ● Before installing the bearing housing, apply the grease to the O-ring.
6 - 38 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 4.Attach: ● Gear lash measurement tool 1 ● Dial gauge 2 a Measuring point Gear lash measurement tool: P/N. YM-01231, 90890-01231 Dial gauge: P/N. YU-03097, 90890-03097 5.Measure: ● Gear lash Gently rotate the gear coupling from engagement to engagement.
6 - 39 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 3.Adjust: ● Gear lash ********************************* Gear lash adjustment steps: ● Select the suitable shims and thrust washer by the following chart. ********************************* Too-little gear lash → Reduce shim thickness.
6 - 40 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 5.Install: ● 10 mm bolts (bearing housing) ● 8 mm bolts (bearing housing) Refer to the “FINAL DRIVE GEAR AND DRIVE SHAFT – ASSEMBLY” section. 6.Measure: ● Gear lash If the gear lash is incorrect → Repeat.
6 - 41 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 4.Install: ● Final gear case unit 1 NOTE: Before installing the final gear case unit, apply the grease to the O-ring 2 . 5.Connect: ● Breather hose 5 (final gear case) CAUTION: Make sure the final gear case breather hose is routed correctly.
6 - 42 DRIV 6.
7 - 1 CHAS FRONT WHEELS AND FRONT BRAKE CHASSIS FRONT WHEELS AND FRONT BRAKE 1 Brake camshaft lever 2 Wear indicator plate 3 Brake shoe plate 4 Brake shoe plate seal 5 Pivot pin 6 Brake camshaft holde.
7 - 2 CHAS FRONT WHEELS AND FRONT BRAKE REMOVAL Front wheels 1.Place the machine on a level place. 2.Loosen: ● Nuts (front wheel) Apply the parking brake 1 . 3.Elevate the front wheels by placing the suitable stand under the frame. W ARNING Securely support the machine there is no danger of falling over.
7 - 3 CHAS FRONT WHEELS AND FRONT BRAKE 9.Remove: ● Brake camshaft lever 1 ● Wear indicator plate 2 ● Brake camshaft 3 ● Brake camshaft holder 4 ● Pivot pin 5 ● Brake shoe plate 6 INSPECTION 1.Inspect: ● Wheel Refer to the “WHEEL INSPECTION” sec- tion in CHAPTER 3.
7 - 4 CHAS 4.Inspect: ● Brake linings Glazed parts → Sand with coarse sandpa- per. 5.Measure: ● Brake lining thickness a Out of specification → Replace. NOTE: Replace the brake shoes as a set (with shoe springs) if either is found to be worn to the wear limit.
7 - 5 CHAS 9.Inspect: ● Bearings 1 (brake drum) Bearings allow play in the brake drum or the wheel tuns roughly → Replace. ● Oil seal 2 Wear/Damage → Replace. ********************************* Wheel bearing and oil seal replacement steps: ● Clean the outside of the brake drum.
7 - 6 CHAS INSTALLATION Reverse the “REMOVAL” procedure. Note the following points. 1.Lubricate: ● Oil seal lips 1 ● Bearings 2 ● Camshaft 3 ● Pivot pin 4 ● O-ring 5 CAUTION: Install the camshaft and the pivot pin lightly greased. Wipe off the excess grease.
7 - 7 CHAS 4.Install: ● Brake shoes W ARNING Do not apply grease to the brake shoe lin- ings. 5.Connect: ● Front brake breather hose ● Brake cable (to brake shoe plate) 6.Install: ● Circlip 1 ● Spring 2 ● Washer (C-type) 3 ● Spring 4 ● Pin 5 ● Adjuster 6 7.
7 - 8 CHAS 9.Install: ● Front wheel NOTE: Arrow mark 1 on the tire must point toward the rotating direction Å of the wheel. 10.Adjust: ● Front brake cable free play Refer to the “FRONT BRAKE ADJUST- MENT” section in CHAPTER 3. 11.Release the parking brake.
7 - 9 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 1 Rear axle 2 Bearing 3 Oil seal 4 Wheel hub 5 Axle nut A TIRE SIZE: AT22 × 10-10 B RIM SIZE: 8 × 10 C WHEEL RUNOUT LIMIT: VERTICAL: 2.0 mm (0.08 in) D TIRE WEAR LIMIT: 2.0 mm (0.08 in) E REAR AXLE RUNOUT LIMIT: 1.
7 - 10 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 1 Brake drum 2 Brake shoe 3 Bearing retainer 4 Brake shoe plate seal 5 Rear brake breather hose 6 Brake shoe plate 7 Brake camshaft 8 Wear indicator plate 9 Brake camshaft lever * Yamaha brake grease A BRAKE LINING WEAR LIMIT: 2.
7 - 11 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE REMOVAL 1.Place the machine on a level place. 2.Loosen: ● Nuts (rear wheel) Apply the parking brake 1 . 3.Block the front wheels, and elevate the rear wheels by placing the suitable stand under the frame.
7 - 12 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 8.Remove: ● Adjusters 1 (brake lever and brake pedal) ● Pins ● Springs 9.Disconnect: ● Brake cable 2 ● Brake rod 3 ● Rear brake breather hose 4 10.Remove: ● Bearing retainer 1 ● Brake shoe plate assembly 2 11.
7 - 13 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE INSPECTION 1.Inspect: ● Wheel Refer to the “WHEEL INSPECTION” sec- tion in CHAPTER 3. 2.Measure: ● Wheel runout ● Tire surfaces Refer to the “FRONT WHEEL AND FRONT BRAKE-INSPECTION” section.
7 - 14 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 8.Inspect: ● Brake drum inner surface 1 Oil/Scratches → Remove. ● Spline 2 Wear/Damage → Replace. Oil Use a rag soaked in lacquer thinner or a solvent. Scratches Use a emery cloth (lightly and evenly polishing).
7 - 15 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 13.Measure: ● Rear axle runout a Out of specification → Replace. W ARNING Do not attempt to straighten a bent axle. Rear axle runout limit: 1.5 mm (0.06 in) 14.Inspect: ● Bearing 1 (rear axle) Bearing allow play in the axle hub or the bearing turns roughly → Replace.
7 - 16 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE INSTALLATION Reverse the “REMOVAL” procedures. Note the following points. 1.Lubricate: ● Oil seal lip 1 (rear axle) ● Bearings 2 (rear axle) ● Axle spline (rear axle) 2.Install: ● Rear axle 1 NOTE: Before installing the rear axle, loosen all the bolts on the final gear case 2 .
7 - 17 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 5.Install: ● Brake camshaft 1 ● Wear indicator plate 2 ● Brake camshaft lever 3 NOTE: ● When installing the wear indicator plate 2 to the brake camshaft 1 align the pro- jection a on the wear indicator plate with the slot b on the brake camshaft.
7 - 18 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 8.Install: ● Brake shoes 9.Lubricate: ● Dust seal 1 (backing plate) CAUTION: Do not apply grease to the brake shoe lin- ings. ● Brake drum spline CAUTION: Do not apply grease on the axle shaft spline, or the extra grease may contami- nate the brake shoes during running.
7 - 19 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 16.Install: ● Cotter pin 1 NOTE: Do not loosen the axle nut after torque tightening. If the axle nut groove is not aligned with the cotter pin hole, align groove with the hole by tightening up on the axle nut.
7 - 20 CHAS STEERING SYSTEM STEERING SYSTEM 1 Handlebar holder (upper) 2 Handlebar holder (lower) 3 Steering shaft 4 Steering bearing 5 Oil seal 6 Collar 7 Cable guide 8 Lock washer 9 Rod end 0 Tie-rod A TOE-IN: 0 ~ 5 mm (0 ~ 0.
7 - 21 CHAS STEERING SYSTEM REMOVAL Handlebar 1.Remove: ● Front carrier ● Front bumper ● Front fender Refer to “FENDERS AND FUEL TANK- FRONT FENDER-Removal” section in CHAPTER 3.
7 - 22 CHAS STEERING SYSTEM Steering shaft 1.Straighten: ● Lock washer tabs 1 2.Remove: ● Bolts 2 ● Lock washer 3 ● Cable guide 4 3.Remove: ● Clip (steering shaft) ● Nut ● Washer 4.Remove: ● Cotter pins ● Nuts ● Tie-rods 1 NOTE: When removing the rod ends from the steering shaft and knuckle arm, use a Gen- eral Bearing Puller.
7 - 23 CHAS STEERING SYSTEM INSPECTION 1.Inspect: ● Handlebar Cracks/Bends/Damage → Replace. 2.Inspect: ● Steering shaft Bends/Damage → Replace. W ARNING Do not attempt to straighten a bent shaft; this may dangerously weaken the shaft. 3.Inspect: ● Steering bearings 1 ● Oil seals 2 Wear/Damage → Replace.
7 - 24 CHAS STEERING SYSTEM 6.Adjust: ● Tie-rod assembly length ********************************* Tie-rod assembly length adjustment steps: ● Loosen the locknuts.
7 - 25 CHAS STEERING SYSTEM 2.Lubricate: ● Steering bearings 1 ● Oil seals 2 Lithium-soap base grease 3.Install: ● Oil seals 1 (to steering shaft) ● Collars 2 ● Steering bearings 3 NOTE: Be careful not to damage the oil seals dur- ing installation.
7 - 26 CHAS STEERING SYSTEM 7.Install: ● Cotter pin 1 NOTE: Do not loosen the axle nut after torque tightening. If the axle nut groove is not aligned with the cotter pin hole, align groove with the hole by tightening up on the axle nut. W ARNING Always use a new cotter pin.
7 - 27 CHAS STEERING SYSTEM Handlebar 1.Install: ● Handlebar holder (lower) 1 ● Handlebar 2 ● Handlebar holders (upper) 3 NOTE: The upper handlebar holder should be installed with the punched mark a forward 2 . CAUTION: Tighten the handlebar bolts so that clear- ances b are spaced evenly.
7 - 28 CHAS FRONT SHOCK ABSORBER AND FRONT ARM FRONT SHOCK ABSORBER AND FRONT ARM 1 Front shock absorber 2 Steering knuckle 3 Lower arm 4 Bushing 7.
7 - 29 CHAS REMOVAL 1.Remove: ● Front carrier ● Front bumper ● Front fender Refer to the “FENDERS AND FUEL TANK- FRONT FENDER - Removal” section in CHAPTER 3. ● Front wheel ● Brake drum ● Brake shoe plate Refer to “FRONT WHEELS AND FRONT BRAKE - Removal” section.
7 - 30 CHAS 7.Inspect: ● Lower arms free play ********************************* Inspection steps: ● Inspect the lower arm brackets 1 of the frame. If bent, cracked or damaged, repair or replace the frame. ● Check the tightening torque of the lower arm securing nuts 2 .
7 - 31 CHAS INSPECTION 1.Inspect: ● Shock absorber Oil leaks → Replace the shock absorber assembly. ● Ball joint Cracks/Damage → Replace the shock absorber assembly. ● Spring Fatigue/Damage → Replace the shock absorber assembly. Move the spring up and down.
7 - 32 CHAS INSTALLATION Reverse the “REMOVAL” procedures. Note the following points. 1.Lubricate: ● Bushings 1 (inner surface) 2.Tighten: ● Nut 2 (lower arm) Lithium-soap base grease T R .
7 - 33 CHAS FRONT SHOCK ABSORBER AND FRONT ARM 5.Install: ● Cotter pin 3 NOTE: Do not loosen the axle nut after torque tightening. If the axle nut groove is not aligned with the cotter pin hole, align groove with the hole by tightening up on the axle nut.
7 - 34 CHAS NOTE: Do not loosen the axle nut after torque tightening. If the axle nut groove is not aligned with the cotter pin hole, align groove with the hole by tightening up on the axle nut.
7 - 35 CHAS REAR SHOCK ABSORBER AND SWINGARM 1 Rear shock absorber 2 Thrust cover 3 Locknut 4 Pivot shaft 5 Collar 6 Oil seal 7 Taper roller bearing 8 Swingarm 9 Rubber boot 0 Final gear case protector A SWINGARM FREE PLAY LIMIT: SIDE” 1.
7 - 36 CHAS REMOVAL 1.Remove: ● Rear wheel (left) ● Wheel hub ● Rear wheel (right) ● Brake drum ● Brake shoe plate ● Rear axle Refer to the “REAR WHEEL/REAR BRAKE AND REAR AXLE - REMOVAL” section. 2.Remove: ● Final gear case protector 1 3.
7 - 37 CHAS 5.Remove: ● Nut 1 (shock absorber - upper) ● Bolt 2 ● Shock absorber 3 REAR SHOCK ABSORBER AND SWINGARM 6.Remove: ● Spring (rear brake pedal) 1 7.
7 - 38 CHAS REAR SHOCK ABSORBER AND SWINGARM 9.Remove: ● Rear axle housing 1 10.Remove: ● Clamp 1 (rubber boot) ● Locknut (right side of pivot shaft) ● Pivot shaft (swingarm) 11.Remove: ● Swingarm 1 INSPECTION 1.Inspect: ● Shock absorber Oil leaks → Replace the shock absorber assembly.
7 - 39 CHAS REAR SHOCK ABSORBER AND SWINGARM 2.Inspect: ● Swingarm Cracks/Bends/Damage → Replace. ● Axle housing Cracks/Bends/Damage → Replace. 3.Inspect: ● Final gear case under cover Cracks/Bends/Damage → Replace. 4.Inspect: ● Pivot shaft 1 (right side) ● Pivot shaft 2 (left side) ● Spacer collar 3 Wear/Damage → Replace.
7 - 40 CHAS REAR SHOCK ABSORBER AND SWINGARM ● Remove the bearings 3 using a general bearing puller. ● Install the new bearings and oil seal by reversing the previous steps. NOTE: Use a socket 4 that matches the outside diameter of the race of the bearing and oil seal.
7 - 41 CHAS REAR SHOCK ABSORBER AND SWINGARM 3.Tighten: ● Pivot shafts (swingarm) ● Locknut (pivot shaft) ********************************* Pivot shaft tightening steps: ● Tighten the pivot shaft 1 (left) to specifi- cation. ● Tighten the pivot shaft 2 (right) until it contacts the collar 3 .
7 - 42 CHAS REAR SHOCK ABSORBER AND SWINGARM 7.Install: ● Clip 8.Install: ● Final gear assembly 1 Refer to the “FINAL DRIVE GEAR AND DRIVE SHAFT - ASSEMBLY - INSTALLA- TION” section in CHAPTER 6.
8 - 1 –+ ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Wire harness 2 Fuses 3 Starter relay 4 Starting circuit cut-off relay 5 Battery 6 CDI unit 7 Rectifier/regulator 8 Rev.
8 - 2 –+ ELEC SWITCH INSPECTION SWITCH INSPECTION SWITCH INSPECTION Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. NOTE: ● Set the pocket tester to “0” before starting the test.
8 - 3 –+ ELEC SWITCH INSPECTION 8.
8 - 4 –+ ELEC SWITCH INSPECTION SWITCH CONTINUITY INSPECTION Refer to “SWITCH INSPECTION” and check for continuity between lead terminals. Poor connection, no continuity → Correct or replace.
8 - 5 –+ ELEC SWITCH INSPECTION 1 Lights switch 2 Lights switch (for New Hampshire and Maine) 3 Engine stop switch 4 Starter switch 5 Main switch 6 Rear brake lever switch 7 Rear brake lever switch .
8 - 6 –+ ELEC CHECKING OF BULBS (FOR HEADLIGHT) CHECKING BULBS CONDITION 1.Remove the bulb. ACHTUNG: CAUTION: Be sure to hold the socket firmly when removing the bulb. Never pull the lead. Otherwise, the lead may be pulled off the terminal in the coupler.
8 - 7 –+ ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM B R B / W Br B / W Br B R W / G W / R Br B O B / W B L / W B R / W O B / W Br B W / G W / R OFF ON OFF LO HI LO HI OFF ON RUN O.
8 - 8 –+ ELEC IGNITION SYSTEM EB802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1.Spark plugs 2.Ignition spark gap 3.Spark plug cap resistance 4.Ignition coil resistance 5.Engine stop switch 6.
8 - 9 –+ ELEC IGNITION SYSTEM for EUR/AUS 2.Ignition spark gap ● Disconnect the spark plug cap from the spark plug. ● Connect the ignition checker 1 as shown. 2 Spark plug cap ● Turn the main switch to “ON”. ● Check the ignition spark gap a .
8 - 10 –+ ELEC IGNITION SYSTEM C0NTINUITY 4.Ignition coil resistance ● Disconnect the ignition coil connector from the wire harness. ● Connect the pocket tester ( Ω × 1) to the ignition coil.
8 - 11 –+ ELEC IGNITION SYSTEM C0NTINUITY 7.Pickup coil resistance ● Disconnect the CDI magneto coupler from the wire harness. ● Connect the pocket tester ( Ω × 100) to the pickup coil terminal.
8 - 12 –+ ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM B R B / W Br B / W Br B R W / G W / R Br B O B / W B L / W B R / W O B / W Br B W / G W / R OFF ON OFF LO HI.
8 - 13 –+ ELEC ELECTRIC STARTING SYSTEM STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, starting circuit cut-off relay, rear brake lever switch, and neutral switch.
8 - 14 –+ ELEC ELECTRIC STARTING SYSTEM EB803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 1.Fuse (main) 2.Battery 3.Starter motor 4.Starting circuit cut-off relay 5.Starter relay 6.Main switch 7.Neutral switch 8.Rear brake lever switch 9.
8 - 15 –+ ELEC ELECTRIC STARTING SYSTEM C0NTINUITY MOVES 3.Starter motor ● Connect the battery positive terminal 1 and starter motor cable 2 using a jumper lead 3 .
8 - 16 –+ ELEC ELECTRIC STARTING SYSTEM C0NTINUITY 5.Starter relay ● Remove the starter relay from the wire harness. ● Connect the pocket tester ( Ω × 1) and the battery (12 V) to the starter relay termi- nals.
8 - 17 –+ ELEC C0NTINUITY CORRECT 8.Rear brake lever switch Refer to “SWITCH INSPECTION”. * INCORRECT Replace the rear brake lever switch. CORRECT 9.Start switch Refer to “SWITCH INSPECTION”. INCORRECT Replace the handlebar switch (left). EB803028 10.
–+ ELEC 8 - 18 ELECTRIC STARTING SYSTEM STARTER MOTOR Order Job name/Part name Q’ty Remarks Starter motor removal Remove the parts in the order below. 1 Starter motor lead 1 2 Starter motor bracket 1 3 Starter motor / O-ring 1/1 Starter motor disassembly Disassemble the parts in the order below.
8 - 19 –+ ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR INSPECTION 1.Inspect: ● Commutator Dirty → Clean it with #600 grit sandpaper. 2.Measure: ● Commutator diameter a Out of specification → Replace the starter motor. 3.Measure: ● Mica undercut b Out of specification → Scrape the mica using a hacksaw blade.
8 - 20 –+ ELEC ELECTRIC STARTING SYSTEM 5.Measure: ● Brush length a (each) Out of specification → Replace the brush. Brush length: 10 mm (0.39 in) <Wear limit:> 3.5 mm (0.14 in) 6.Measure: ● Brush spring force Fatigue/out of specification → Replace as a set.
8 - 21 –+ ELEC CHARGING SYSTEM EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM B R B / W Br B / W Br B R W / G W / R Br B B B R / W O B / W Br B W / G W / R OFF ON OFF LO HI OFF ON RUN OFF R L / W B G / Y .
8 - 22 –+ ELEC CHARGING SYSTEM EB804010 TROUBLESHOOTING IF THE BATTERY IS NOT CHARGED: Procedure Check: 1.Fuse (main) 2.Battery 3.Charging voltage 4.
8 - 23 –+ ELEC CHARGING SYSTEM OUT OF SPECIFICATION ● Start the engine and accelerate to about 2,000 r/min. Charging voltage: 14 to 15 V at 2,000 r/min NOTE: Use a fully charged battery. MEETS SPECIFICATION The charging circuit is not faulty. EB804012 MEETS SPECIFICATION 4.
8 - 24 –+ ELEC LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM B R B / W Br B / W Br B R W / G W / R Br B O B / W B L / W B R / W O B / W Br B W / G W / R OFF ON OFF LO HI LO HI OFF ON RUN .
8 - 25 –+ ELEC LIGHTING SYSTEM EB805010 TROUBLESHOOTING IF THE HEADLIGHT AND/OR TAILLIGHT FAIL TO COME ON: Procedure Check: 1.Fuse (main) 2.Battery 3.
8 - 26 –+ ELEC LIGHTING SYSTEM C0NTINUITY CORRECT 3.Main switch Refer to “SWITCH INSPECTION”. * INCORRECT Replace the main switch. CORRECT 4.Lights switch Refer to “SWITCH INSPECTION”. Lights switch is faulty, replace the handle- bar switch (left).
8 - 27 –+ ELEC LIGHTING SYSTEM EB805020 LIGHTING SYSTEM CHECK 1.If the headlights fail to come on: CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for conti- nuity. NO CONTINUITY Replace the bulb and/or bulb socket. 2.Voltage ● Connect the pocket tester (DC 20 V) to the headlight couplers.
8 - 28 –+ ELEC LIGHTING SYSTEM 2.If the taillight fails to come on: CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for conti- nuity. NO CONTINUITY Replace the bulb and/or bulb socket. 2.Voltage ● Connect the pocket tester (DC 20 V) to the taillight leads.
8 - 29 –+ ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM B R B / W Br B / W Br B R W / G W / R Br B O B / W B L / W B R / W O B / W Br B W / G W / R OFF ON OFF LO HI LO HI OFF ON RUN OFF .
8 - 30 –+ ELEC SIGNAL SYSTEM EB806010 TROUBLESHOOTING IF THE INDICATOR LIGHT AND/OR BRAKE LIGHT FAILS TO COME ON: Procedure Check: 1.Fuse (main) 2.Battery 3.
8 - 31 –+ ELEC SIGNAL SYSTEM C0NTINUITY CORRECT 3.Main switch Refer to “SWITCH INSPECTION”. * INCORRECT Replace the main switch. EB806011 CORRECT 4.Wiring connections ● Check the connections of the entire sig- nal system. Refer to “CIRCUIT DIAGRAM”.
8 - 32 –+ ELEC SIGNAL SYSTEM SIGNAL SYSTEM CHECK EB806024 1.If the neutral indicator light fails to come on: CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for conti- nuity. NO CONTINUITY Replace the bulb and/or bulb socket. CONTINUITY 2.
8 - 33 –+ ELEC SIGNAL SYSTEM 2.If the reverse indicator light fails to come on: CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for conti- nuity. NO CONTINUITY Replace the bulb and/or bulb socket. CONTINUITY 2.Reverse switch Refer to “SWITCH INSPECTION”.
8 - 34 –+ ELEC SIGNAL SYSTEM 3.If the brake light fails to come on: (for New Hampshire and Maine) CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for conti- nuity. NO CONTINUITY Replace the bulb and/or bulb socket. CONTINUITY 2.
TRBL SHTG 9 - 1 STARTING FAILURE/HARD STARTING TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this man- ual for inspection, adjustment and replacement of parts.
TRBL SHTG 9 - 2 STARTING FAILURE/HARD STARTING/POOR IDLE SPEED PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE COMPRESSION SYSTEM Cylinder and cylinder head ● Loose spark plug ● Loose cylinder .
9 - 3 TRBL SHTG FAULTY DRIVE TRAIN FAULTY DRIVE TRAIN The following conditions may indicate damaged shaft drive components: NOTE: Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite sub- tle and difficult to distinguish from normal machine operating noise.
TRBL SHTG 9 - 4 F AUL TY GEAR SHIFTING/ FAULTY CLUTCH PERFORMANCE FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH SLIPPING/DRAGGING-CLUTCH DRAGGING”.
TRBL SHTG 9 - 5 FAULTY CLUTCH PERFORMANCE/ OVERHEATING/FAULTY BRAKE OVERHEATING OVERHEATING Ignition system ● Improper spark plug gap ● Improper spark plug heat range ● Faulty CDI unit Fuel syst.
TRBL SHTG 9 - 6 UNSTABLE HANDLING SHOCK ABSORBER MALFUNCTION/ UNSTABLE HANDLING/LIGHTING SYSTEM UNSTABLE HANDLING Handlebar ● Improperly installed or bent Steering ● Incorrect toe-in ● Bent stee.
YFM250XL WIRING DIAGRAM 1 Main switch 2 Battery 3 Fuse 4 Starter relay 5 Starter motor 6 Rectifier / regulator 7 CDI magneto 8 CDI unit 9 Ignition coil 0 Spark plug A Starting circuit cut-off relay B .
PRINTED IN U.S.A. Y AMAHA MOT OR CO., L TD. 2500 SHINGAI IWATA SHIZUOKA JAPAN.
SUPPLEMENT AR Y SERVICE MANUAL LIT -1 1616-14-17 4XE-F8197-1 1 YFM250XN.
YFM250XN SUPPLEMENTARY SERVICE MANUAL 2000 by Yamaha Motor Corporation, U.S.A. First Edition, April 2000 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited.
EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in.
EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual is intended as a handy, easy-to-read reference book for the mechanic. It is divided into chapters, sections and sub-sections.
EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic inspection.
CONTENTS GENERAL INFORMATION .............................................................................. 1 MACHINE IDENTIFICATION ................................................................... 1 VEHICLE IDENTIFICATION NUMBER ..................
ELECTRICAL ................................................................................................. 40 ELECTRICAL COMPONENTS .............................................................. 40 IGNITION SYSTEM ...................................
– 1 – GEN INFO MACHINE IDENTIFICATION GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame. MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.
– 2 – SPEC SPECIFICA TIONS GENERAL SPECIFICA TIONS Item Standard Model code: 4XEA (USA) Dimensions: Ov erall length 1,940 mm (76.4 in) Ov erall width 1,005 mm (39.6 in) Ov erall height 1,118 mm (44.0 in) Seat height 780 mm (30.7 in) Wheelbase 1,170 mm (46.
– 3 – SPEC MAINTENANCE SPECIFICA TIONS ENGINE Item Standard Limit Shifter : Shifter type Shift drum and guide bar ---- Guide bar bending limit ---- 0.8 mm (0.032 in) Carburetor: I. D . mark 4XEA 12 ---- Main jet (M.J) #95 ---- Main air jet (M.A.J) 0.
– 4 – SPEC CHASSIS Item Standard Limit Rear suspension: Shock absorber tr av el 85 mm (3.35 in) ---- Suspension spring free length 268 mm (10.55 in) ---- Fitting length 244 mm (9.61 in) ---- Spring rate 3 9 N/mm (3.9 kg/mm, 222.69 lb/in)/ 0 ~ 85 mm (0 ~ 3.
– 5 – SPEC Tightening torques P ar t to be tightened P ar ts name Thread size Q’ty Tightening torque Remar ks Nm m·kg ft·lb Front panel wheel and wheel hub N u t M10 × 1.25 8 55 5.5 40 Wheel hub and steering knuckle Nut M14 × 1.5 2 70 7.0 50 Steering knuckle and brake caliper Bolt M8 × 1.
– 6 – SPEC ELECTRICAL Item Standard Limit C.D.I.: Magneto model/manuf acturer F4T259/MITSUBISHI ---- Pickup coil resistance/color 189 ~ 231 Ω at 20˚C (68˚F)/ White/Green – White/Red ---- Charging/rotor rotation direction detection coil resistance/color 270 ~ 330 Ω at 20˚C (68˚F)/ Red/White/Blue ---- C .
– 7 – SPEC CABLE ROUTING CABLE ROUTING 1 Rear brake lever switch lead 2 Rear brake cable 3 Cable guide 4 Front brake hose 5 Throttle cable 6 Neutral indicator light 7 Reverse indicator light 8 Han.
– 8 – SPEC CABLE ROUTING 1 Cable guide 2 Main switch 3 Fuel tank breather hose 4 Taillight 5 Final gear case breather hose 6 Carburetor overflow hose 7 Reverse switch lead 8 Neutral switch lead 9 .
– 9 – SPEC CABLE ROUTING Ç Make sure that the starter motor lead is not slacked. Î Fasten the starter motor lead and wire harness to the frame with the plastic band. ‰ Fasten the starter motor lead and wire harness to the frame with the plastic clamp.
– 10 – SPEC Ò Fasten the starter motor lead and wire harness to the frame with the plastic clamp. ˜ Route the rear brake cable and rear brake breather hose through the cable guide. ˆ Fasten the rear brake cable and rear brake breather hose to the swingarm with the plastic clips.
– 11 – SPEC CABLE ROUTING 1 Battery breather hose 2 Spark plug cap 3 Ignition coil 4 Starter motor lead 5 Rear brake cable 6 Rear brake breather hose Å Make sure that the battery breather hose is not kinked or bent. ı Route the rear brake cable through the cable guide on the cyl- inder.
– 12 – SPEC CABLE ROUTING 1 Wire harness 2 Starter motor lead 3 Rear brake cable 4 Throttle cable 5 Starter relay 6 Rectifier/regulator 7 CDI unit 8 Starting circuit cut-off relay 9 Rear brake bre.
– 13 – SPEC CABLE ROUTING Ï Fasten the battery breather hose to the rear fender with the plastic clamp and then insert the clamp into the hole in the rear fender. Ì Fasten the battery + lead and starter motor lead to the rear fender with the plastic clamps.
– 14 – INSP ADJ INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life.
– 15 – INSP ADJ PERIODIC MAINTENANCE/LUBRICATION *: It is recommended that these items be serviced by a Yamaha dealer. **: Lithium soap base grease. W ARNING Indicates a potential hazard that could result in serious injury or death. Steering shaft* • Lubricate every 6 months.
– 16 – INSP ADJ SPARK ARRESTER CLEANING ENGINE SPARK ARRESTER CLEANING 1.Clean: ● Spark arrester ********************************************* Cleaning steps: W ARNING ● Select a well-ventilated area free of com- bustible materials. ● Always let the exhaust system cool before performing this operation.
– 17 – INSP ADJ FRONT BRAKE FLUID LEVEL INSPECTION/ FRONT BRAKE PAD INSPECTION CHASSIS FRONT BRAKE FLUID LEVEL INSPECTION 1.Place the machine on a level surface. N OTE: When inspecting the front brake fluid level, make sure that the top of the master cylinder top is horizontal.
– 18 – INSP ADJ BRAKE HOSE INSPECTION/ AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) BRAKE HOSE INSPECTION 1.Remove: ● Front carrier ● Front fender Refer to “FENDER AND FUEL TANK”. 2.Inspect: ● Brake hoses 1 Cracks/wear/damage → Replace. 3.Check: ● Brake hose clamp Loosen → Tighten.
– 19 – INSP ADJ AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) 1.Bleed: ● Brake system ********************************************* Air bleeding steps: a. Add the proper brake fluid to the reservoir. b. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow.
– 20 – CHAS FRONT WHEEL CHASSIS FRONT WHEEL 1 Wheel cap 2 Cotter pin 3 Axle nut 4 Plain washer 5 Wheel nut 6 Front wheel 7 Spacer 8 Oil seal 9 Bearing 0 Front wheel hub A Bearing spacer TIRE AIR PRESSURE Cold Tire Pressure Front Rear Standard 20 kPa (0.
– 21 – CHAS REMOVAL 1.Place the machine on a level surface. 2.Loosen: ● Nuts (front wheel) Apply the front brake. 3.Block the rear wheels, and elevate the front wheels by placing the suitable stand under the frame. 4.Remove: ● Nuts 1 (front wheel) ● Front wheel 2 5.
– 22 – CHAS FRONT WHEEL 8.Remove: ● Front brake disc 1 1 INSPECTION 1.Inspect: ● Wheel hub 1 Cracks/damage → Replace..
– 23 – CHAS FRONT BRAKE FRONT BRAKE 1 Brake master cylinder reservoir cap 2 Brake master cylinder reservoir diaphragm holder 3 Brake master cylinder reservoir diaphragm 4 Brake master cylinder 5 B.
– 24 – CHAS FRONT BRAKE CAUTION: Disc brake components rarely require dis- assembly. DO NOT: ● Disassemble components unless abso- lutely necessary. ● Use solvents on internal brake compo- nents. ● Use contaminated brake fluid for clean- ing.
– 25 – CHAS FRONT BRAKE 5.Remove: ● Brake pads 1 (with pad shim 2 ) ● Pad spring 3 N OTE: ● When pad replacement is required, also replace the pad spring and shim. ● Replace the pads as a set if either is found to be worn to the wear limit a .
– 26 – CHAS FRONT BRAKE 7.Install: ● Retaining bolts ● Front brake caliper 8.Install: ● Front wheel 9.Inspect: ● Brake fluid level Refer to “FRONT BRAKE FLUID LEVEL INSPECTION”. a “LOWER” level line T R . . Retaining bolt: 18 Nm (1.
– 27 – CHAS FRONT BRAKE 4.Remove: ● Union bolt 1 ● Copper washers 2 ● Brake hose 3 N OTE: Place the open end of the hose into a con- tainer and pump the oil fluid out carefully.
– 28 – CHAS FRONT BRAKE 1.Remove: ● Brake lever 1 ● Union bolt 2 ● Copper washers 3 ● Brake hose 4 N OTE: Hold a container under the master cylinder and under the hose end to collect remaining brake fluid.
– 29 – CHAS FRONT BRAKE 1.Inspect: ● Caliper piston 1 Scratches/rust/wear → Replace caliper assembly. ● Caliper cylinder 2 Wear/scratches → Replace caliper assem- bly. ● Caliper body 3 Cracks/damage → Replace. ● Oil delivery passage (caliper body) Blow out with compressed air.
– 30 – CHAS FRONT BRAKE 6.Measure: ● Brake pads (thickness) a Out of specification → Replace. N OTE: ● When pad replacement is required, also replace the pad spring and shims. ● Replace the pads as a set if either is found to be worn to the wear limit a .
– 31 – CHAS FRONT BRAKE N OTE: Tighten the bolts (brake disc) in stage using a crisscross pattern. T R . . Bolt (brake disc): 16 Nm (1.6 m • kg, 12 ft • lb) CALIPER ASSEMBLY W ARNING ● All internal parts should be cleaned in new brake fluid only.
– 32 – CHAS FRONT BRAKE 3.Install: ● Brake caliper 1 (temporarily) ● Copper washers 2 ● Brake hose 3 ● Union bolt 4 CAUTION: When installing the brake hose on the cali- per, make sure that the brake pipe touches the projection a on the brake caliper.
– 33 – CHAS FRONT BRAKE 6.Fill: ● Reservoir tank N OTE: If DOT 4 is not available, 3 can be used. CAUTION: Brake fluid may erode painted surfaces or plastic parts.
– 34 – CHAS FRONT BRAKE MASTER CYLINDER ASSEMBLY W ARNING ● All internal parts should be cleaned in new brake fluid only. ● Internal parts should be lubricated with brake fluid when installed. ● Replace the piston seals and dust seals whenever a brake master cylinder is dis- assembled.
– 35 – CHAS FRONT BRAKE 3.Install: ● Copper washers ● Brake hose ● Union bolt N OTE: ● Tighten the union bolt while holding the brake hose as shown. ● Check that the brake hose does not touch other parts (throttle cable, wire harness, leads, etc.
– 36 – CHAS FRONT BRAKE ● Refill with the same type of brake fluid: mixing fluids may result in a harmful chemical reaction and lead to poor per- formance. ● Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.
– 37 – CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 1 Rear axle 2 Bearing 3 Oil seal 4 Wheel hub 5 Axle nut A TIRE SIZE: AT22 × 10-10 B TIRE WEAR LIMIT: 2.0 mm (0.08 in) C RIM SIZE: 8 × 10AT D RIM RUNOUT LIMIT: Radial: 2 mm (0.08 in) Lateral: 2 mm (0.
– 38 – CHAS FRONT SHOCK ABSORBER AND FRONT ARM FRONT SHOCK ABSORBER AND FRONT ARM 1 Front shock absorber 2 Steering knuckle 3 Lower arm 4 Bushing FWD.
– 39 – CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM 1 Rear shock absorber 2 Thrust cover 3 Locknut 4 Pivot shaft 5 Collar 6 Oil seal 7 Taper roller bearing 8 Swingarm 9 Rubber boot 0 Final gear case protector A SWINGARM FREE PLAY LIMIT: End: 1.
– 40 – –+ ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Reverse indicator light 2 Neutral indicator light 3 Main switch 4 Rear brake lever switch 5 Handlebar switch 6 Fu.
– 41 – –+ ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM B R B / W Br B / W Br B R OFF ON 3 Br Br RR L / WL / B 4 5 6 7 R R B B B B B L / W L / W R R R G / Y Sb L / W R / B (BLACK.
– 42 – –+ ELEC IGNITION SYSTEM EB802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1.Fuse 2.Battery 3.Spark plug 4.Ignition spark gap 5.Spark plug cap resistance 6.Ignition coil resistance 7.
– 43 – –+ ELEC IGNITION SYSTEM C0NTINUITY CORRECT Spark plug gap: 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) * INCORRECT Repair or replace the spark plug. OUT OF SPECIFICATION OR NO SPARK 4.Ignition spark gap ● Disconnect the spark plug cap from the spark plug.
– 44 – –+ ELEC IGNITION SYSTEM C0NTINUITY 6.Ignition coil resistance ● Disconnect the ignition coil connector from the wire harness. ● Connect the pocket tester ( Ω × 1) to the ignition coil.
– 45 – –+ ELEC IGNITION SYSTEM C0NTINUITY 9.Pickup coil resistance ● Disconnect the CDI magneto coupler from the wire harness. ● Connect the pocket tester ( Ω × 100) to the pickup coil terminal.
– 46 – –+ ELEC IGNITION SYSTEM C0NTINUITY CORRECT 11. Wiring connection ● Check the connections of the entire ignition system. Refer to “CIRCUIT DIAGRAM”.
– 47 – –+ ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM B R B / W Br B / W Br B R OFF ON 3 Br Br RR L / WL / B 4 5 6 7 R R B B B B B L / W L / W R R R G / Y Sb .
– 48 – –+ ELEC ELECTRIC STARTING SYSTEM STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, starting circuit cut-off relay, rear brake lever switch, and neu- tral switch.
– 49 – –+ ELEC ELECTRIC STARTING SYSTEM EB803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 1.Fuse 2.Battery 3.Starter motor 4.Starting circuit cut-off relay 5.Starter relay 6.Main switch 7.Engine stop switch 8.Neutral switch 9.
– 50 – –+ ELEC ELECTRIC STARTING SYSTEM C0NTINUITY MOVES 3.Starter motor ● Connect the battery positive terminal 1 and starter motor lead 2 using a jumper lead 3 .
– 51 – –+ ELEC ELECTRIC STARTING SYSTEM C0NTINUITY 5.Starter relay ● Remove the starter relay from the wire har- ness. ● Connect the pocket tester ( Ω × 1) and the battery (12 V) to the starter relay terminals.
– 52 – –+ ELEC ELECTRIC STARTING SYSTEM C0NTINUITY CORRECT 9.Rear brake lever switch Refer to “SWITCH INSPECTION”. * INCORRECT Replace the rear brake lever switch. CORRECT 10.Start switch Refer to “SWITCH INSPECTION”. INCORRECT Replace the handlebar switch (left).
PRINTED IN U.S.A. Y AMAHA MO T OR CO. , L TD . 2500 SHINGAI IW A T A SHIZUOKA JAP AN.
B R B / W Br B / W Br B R OFF ON 3 Br Br RR L / WL / B 4 5 6 7 R R B B B B B L / W L / W R R R G / Y Sb L / W R / B (BLACK) (BLACK) (BLACK) (BLACK) 0 A 8 B G / Y Sb O O F CB G / Y B D E OFF LO HI I J .
YFM250XP SUPPLEMENTARY SERVICE MANUAL LIT-11616-15-03 4XE-F8197-12.
FOREWORD This Supplementary Service Manual has been prepared to introd uce new service and new data for the YFM250XP. For complete information on service procedures, it is necessary to use this Supple- mentary Service Manual together with the following manual.
EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not po ssible to include all the knowledge of a mechanic i.
HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main ca tegories of subjects. (See “Illustrated symb ols”) 1st title 1 : This is a chapter with its symbol on the upper right o f each page. 2nd title 2 : This title appears on the upper of each page on the left of the chapter sym- bol.
EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are pr inted on the top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks an.
CONTENTS SPECIFICATIONS ........................................ ................................................... 1 GENERAL SPECIFICATIONS .............. ................................................... 1 MAINTENANCE SPECIFICATION ..............
– 1 – SPEC GENERAL SPECIFICATIONS SPECIFICA TIONS GENERAL SPECIFICATIONS Item Standard Model code: 4XEE (USA) Brake: F ront brak e type Dual disc brake operation Right hand operation Rear brak e type Drum brake (fully sealed) operat ion Left hand and right foot operation Electrical: Ignition system DC.
– 2 – SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: W ar p limit ---- 0.03 mm (0.001 in) Measuring point Lines indicate straightedge measurement. Piston: Piston to cylinder clearance 0.04 ~ 0.
– 3 – SPEC MAINTENANCE SPECIFICATIONS CHASSIS Tightening torques ELECTRICAL Item Standard Limit Rear suspension: Shoc k absorber tra vel 85 mm (3.35 in) ---- Suspension spring free length 268 mm (10.55 in) ---- Fitting length 244 mm (9.61 in) ---- S p r in g r a t e 39 N/mm (3.
– 4 – SPEC CABLE ROUTING 1 Rear brake lever switch lead 2 Rear brake cable 3 Cable guide 4 Front brake ho se 5 Front brake light switch lead 6 Throttle cable 7 Neutral indicator light 8 Reverse in.
– 5 – SPEC 1 Cable guide 2 Main switch 3 Fuel tank breath er hose 4 Carburetor overflow ho se 5 Reverse switch lead 6 Neutral switch lead 7 Starter moto r lead 8 Throttle cable 9 Rear brake cable È Route the main switch lead and indicator light lead to the side of the cable guide.
– 6 – SPEC 1 Tail/brake light 2 Final gear case breather hose 3 Front brake light switch lead 4 Carburetor air vent hose 5 Rear brake breath er hose 6 Rear brake cable 7 CDI magneto lead È Make sure that the star ter motor lead has no slack. É Fasten the star ter motor lead and wire har ness to the frame with the plasti c band.
– 7 – SPEC Í Fasten the t ail/brake light lead to the sto rage box with the plastic clamp. Î Fasten the starte r motor lead and wire harnes s to the frame with the plastic clamp. Ï Route the rear brake cable and re ar brake breather hose thr ough the cable guide.
– 8 – SPEC 1 Battery breat her hose 2 Rear brake cable 3 Spark plug cap 4 Ignition coil 5 Ignition coil lead 6 Starter moto r lead 7 Rear brake light switch 8 Rear brake breath er hose È Make sure that the batt ery breather hose is not kinked or bent.
– 9 – SPEC 1 Rectifier/regulator 2 CDI unit 3 Starting circuit cut- off relay lead 4 Starter relay lead 5 Starter moto r lead 6 Starting circuit cut- off relay 7 Starter relay 8 Rear brake breath .
– 10 – SPEC Í Make sure that the grommet is installed with the mark facing forward. Î 5 mm (0.2 in) CABLE ROUTING.
– 11 – SPEC 1 Rear brake cable 2 Throttle cable 3 Wire harness 4 Starter moto r lead 5 Tail/brake light lead È Route the throt tle cable and rear brake cable through th e cable guide. Make sure that the throttle cab le is routed to the insi de of the re ar brake cable.
– 12 – CHK ADJ INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all info rmation necessary to perform recommen ded inspections and adjust- ments.
– 13 – CHK ADJ PERIODIC MAINTENANCE/LUBRICATION INTERVALS * It is recommended that these items be serviced by a Yamaha d ealer. ** Lithium-soap-based grease NOTE: ● Recommended brake fluid: DOT 4 ● Brake fluid replacement: 1.When disassembling the master cylinder or caliper, replace the brake fluid.
– 14 – CHK ADJ ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE LIGHT SWITCH CHASSIS ADJUSTING THE FRONT BRAKE 1.Check: ● Brake lever free play a Out of specification → Bleed the front bra ke system. Refer to “ AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ” .
– 15 – – + ELEC CHECKING THE SWITCH ELECTRICAL CHECKING THE SWITCH CHECKING THE SWITCH Use a pocket tester to che ck the terminals for continuity. If the continuity is faulty at any point, replace the switch. N OTE: ● Set the pocket tester to “ 0 ” before starting the test.
– 16 – – + ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM W / L B B B W / GW / L O W / R RR / B Br Sb Br G / L Sb G / L G / L G / L R / W R / W Sb G / L Br Br G / L Sb W / R W / G W R.
– 17 – – + ELEC SIGNAL SYSTEM CHECKING THE SIGNAL SYSTEM 1.If the tail/brake light fails to come on: CONTINUITY 1.Bulb and bulb so cket ● Check the bulb and bulb socket for continu- ity. NO CONTINUITY Replace the bulb and/or bulb socke t. CONTINUITY 2.
Y AMAHA MO T OR CO. , L TD . 2500 SHINGAI IW A T A SHIZUOKA JAP AN PRINTED IN U.S.A..
YFM250XP WIRING DIAGRAM W / L B B B W / GW / L O W / R RR / B Br Sb Br G / L Sb G / L G / L G / L R / W R / W Sb G / L Br Br G / L Sb W / R W / G W R W / L W / R W / G R / B R / B Sb R W W W W W R W /.
デバイスYamaha 4XE-F8197-10の購入後に（又は購入する前であっても）重要なポイントは、説明書をよく読むことです。その単純な理由はいくつかあります：
Yamaha 4XE-F8197-10をまだ購入していないなら、この製品の基本情報を理解する良い機会です。まずは上にある説明書の最初のページをご覧ください。そこにはYamaha 4XE-F8197-10の技術情報の概要が記載されているはずです。デバイスがあなたのニーズを満たすかどうかは、ここで確認しましょう。Yamaha 4XE-F8197-10の取扱説明書の次のページをよく読むことにより、製品の全機能やその取り扱いに関する情報を知ることができます。Yamaha 4XE-F8197-10で得られた情報は、きっとあなたの購入の決断を手助けしてくれることでしょう。
Yamaha 4XE-F8197-10を既にお持ちだが、まだ読んでいない場合は、上記の理由によりそれを行うべきです。そうすることにより機能を適切に使用しているか、又はYamaha 4XE-F8197-10の不適切な取り扱いによりその寿命を短くする危険を犯していないかどうかを知ることができます。
ですが、ユーザガイドが果たす重要な役割の一つは、Yamaha 4XE-F8197-10に関する問題の解決を支援することです。そこにはほとんどの場合、トラブルシューティング、すなわちYamaha 4XE-F8197-10デバイスで最もよく起こりうる故障・不良とそれらの対処法についてのアドバイスを見つけることができるはずです。たとえ問題を解決できなかった場合でも、説明書にはカスタマー・サービスセンター又は最寄りのサービスセンターへの問い合わせ先等、次の対処法についての指示があるはずです。
