IMPORTANT NOTICE This motorcycle may be equipped either for competition use or general off-road use. It may be illegal to operate this vehicle off-road when it is equipped for competition use. Check your state and local riding area regurations. This vehicle is not manufactured for use on public streets, roads or high ways. Such use is prohibited by law. An off-road riding kit is provided with each vehicle to comply with noise level and spark arrester laws and regulations for installation instructions see directions in this manual. Performance will be substanti ly decreased. Retuning is not required. 1T250D/400D OWNER’S SERVICE MANUAL 1st Edition, December 1976 2nd Printing, July 1978 ALL RIGHTS RESERVED BY YAMAHA MOTOR CORPORATION, U.S. A. BUENA PARK, CALIFORNIA 90620 LIT-11626-00-57“aulysew ay} Guisedas 10 Burjyoadsu! uossad 10 10}e4ad0 aulysew e 0} Aunful PIOAe 02 paMmojjO} oq isnU ey. Se’npadoid jelseds seJedIPul OQNINHYVWM VW ‘auiysew ay} 0} afewep PloAe 0} pamo}joj aq ysnwW Jey} seAnpavoad jeloads saleoIPul NOILNVOD V *42189)9 40 Jalsa seNpsd0id ayeU 0} UOHJeUOJU! Aey SepINosd JLON V ‘DNINYVM iNOLLANWD LON :su0!}e0U Huy Mojo} ay} Aq jenuew siyi U! PaysinBulisip si UOIWeWOLU! JUeLIOdWI Ajse]Nd!V4eq “sajeap Byewe,A pazisoyine 4nOA Woy ajqejleae suoleoljqnd sayy ul puno} 9q ued ‘Ajquuassesip aseo yUeID se Yyons ‘suledai Jofew Bujpsebas uolewsoju! jeUOIIPpY ‘aouewojiad winuui3do pue uoljesedo aaiy ajqno4} aunsul djay ||! Jenuew siy2 U! peqiiosap seinpadosd ay? 0} UO!lUATLe |Nya1eg “soUeUA}UJeW pue a4ed Jadoid Pue uolzeJado Joy UOJIeUOJU! dIseq ay} sapIAoid jenueW ad!AJas s,JaUMO SIYJ “S@UIYORUW eyewe,r snoread uO punoj jou ‘saunjeay Gurpueysyno Auew siajjo 2] “Asn PeOd-4JO yo su0Bl4 au2 Y0q 404 sideulBUa eyeWeA Aq YINq puke pauBlsep aie GOOP/GOSZLI seyeweAr Y3NMO MAN 3HL OLCONTENTS NOMENCLATURE ....... acl MACHINE IDENTIFICATION ... CONTROL FUNCTIONS........ OPERATION .... PERIODIC MAINTENANCE -............ MECHANICAL ADJUSTMENT ...... 0d ENGINE MAINTENANCE AND MINOR REPAIRS ..............0.005 32 CHASSIS MAINTENANCE AND MINORTREPAIR Gacoueecan ie naiutit: 58 ELECTRICAL ..........0cesee eee 78 INTERCHANGEABILITY OF C.D. MAGNETO AND TRANSMISSION ..... 81 INSTALLATION OF THE OFF-ROAD RIDING KIT 0.20... cece eee eee ee MISCELLANEOUS ............. SPECIFICATIONS ............. WARRANTY INFORMATION ..apis puey 427 apis puey 14614 SYNLVTIONAWONMACHINE IDENTIFICATION Frame serial number The frame serial number is stamped on the right side of the steering head stock. 1. Frame serial number Engine serial number The engine serial number is stamped into the raised part of the right rear section of the engine. 1. Engine serial number, NOTE: The first three digits of these numbers are for model identifications; the remaining digits are the unit production number. The engine and frame serial numbers are usually identical. cee ESE CE ee ee ee eee ee eee eeeee ~2-:suolisod easy Buimoyjoy ay} sey yood}ad jany yt “Janj aU} suai]! Os]e pue JOJaINqUed By} OF due} ay) Wo Janj s}onpUod y9OdIad jany ay | yooojed jen yous swig *Z, yous BunysIT “L uwoung dows auibua “¢ "weaq Mo} ay} JOJ uOllsod ,,,, 84} 0} pue weaq yBiy ay Joy uoNisod ,,H,, 94} 02 WINE Yyoums seg ‘uo awod 1461|/12} pue 2YBI Peay ‘psenuoy pausNy s! YouMs 3461] 843 41 youms 6uny6i7 ‘aulGua doys 0} pjoy pue ysng “Jega;puey Ya} ayi uo pazeoo] s! uoring doys aulbue ay) uojjng doys auibuy *suoljouny Buimojj}o} ayi aney Aay, ‘diu6 ajpuey yo} ai JeauU pazed0} ase seyoIMs Jeqa|puey ey] seyoums seqa|puey SNOILONNA TONLNODOFF: With the lever in this position fuel will not flow. Return the lever to this position when the engine is not running. ON: With the lever in this position fuel flows to the carburetor. Normal riding is done with the lever in this po: n. RES: This indicates “RESERVE”. lf you run out of fuel while riding, move the lever to this position. Then, fill the tank at the first opportunity. Front brake lever Located on the right handlebar. The front brake lever actuates the single leading-shoe front brake when the brake lever is squeezed. Rear brake pedal Located directly in front of the right-side rider's foot rest. The rear brake pedal actuates the single-leading shoe rear brake when the pedal is depressed. Clutch lever Located on the left handlebar. The clutch lever will disengage the wet-type, multiplate clutch when the lever is squeezed. Throttle The throttle is the positive return type, and is located on the right handlebar grip. eeeeae “UMOP JaAa] 842 YUM euUlYyoeW ay} apld Janay) “Ajy}OOWS Buln si aulbua ayy Jeye jaf ay} asojo sAempy “jal ay uado 01 umop Jena] ayi ysng *4ana] e Aq pa -yenqoe Ss! i) ‘sues sulBue pjoo Joy aunpaw dre/janj yoii-e4yxa ue Ajddns 0} paubisap si) yef aYL “Ajquiasse soyaanqueo ayi yo apis-343} 841 UO pajzedo] s! af JajIEIs JOJeINqueo ayy (49097) Jef Jeq1e3s 40JeInNqueg, a renren, ‘aujBua ay) JO apis Yo] aur uo jeped afueyo ay2 Bulsn Aq paijiys aq ued sueaB ay} ‘paseds Ajjeapi eve uolssiwsuen Peeds-g ysaui jue}suoo ay} Jo somes sea aul Bunyiys een) “paBeBuesip si yoinja ay} papiaosd ‘1ea6 Aue u! paqieis eq Aew auiBua ayy ‘asoyosoyy vadAy Aseuiiid ay} 40 s1 wusiueyooW 491 aYL ‘seis auiBue Joye ul yUeID ay) ploy ‘eulbue ey) Wels oO} Apysiiq 491 pue ules. @Alip Asewiid ay} aBeBua suea6 ay2 jun umop, ysnd ‘Ajwuly 4 uodn 3003 InoA ssaid ‘ino jueld 842 aje10y aulBua ay2 yo apis seal ‘14614 ay Uo pazeoo] s! yUeID JoZIeIS 4914 euL (4914238 >J91}) JUeI9 491942. Pull the knob and turn it either way for place-by-place reading adjustment. Speedometer The odometer and trip odometer are bi 7 1. Reset knob into the speedometer. The trip odometer can 2. Odometer be reset to “O”’ by turning the reset knob in 3. Trip odometer the following two manners: 1. Turn the knob counter clockwise for resett- ing the entire place numbers to zeros.ay pes r11Q UOIssIWIsUeL | *Z, *soijes Buixius pue uoiedijioeds Bd1AJas JO} Jaqe| 40 do} JaujejUOD ay} 498YD “uNVOL, UO! ealjIU4a9 Ig Jee Pinoys j!o ay ‘edA7 dJayzoue asn pynoys noA uoseas Aue 404 34 (lo aj9A0-Z Busey aqnjewe,) wt, eqnjewe,r :|10 papuawwosay 20 Burxi aurbuy *1 10 Qb's'n LL) ZL :Ayoedeo ue} Jang “2yByU4900 yoveq Paxiui e UJe}e1 JOU Op puke aded ay) JO Bujusow ay} jeny yo yoyeq yseyy e xi Shem “auljoseB puesg-aweu ‘ysai, asn sAemy “1 : OZ 40 01784 |J0/seB e 3 |1O YUM paxIW +06 Jo Bulyes suej}OO ue YU auljoseB Wniwaid asc feng Hoon *L “eouRUa}UIeW dIpPOliad 40 s}UaW -asn[pe ajduiis woj1ad 0} sauMO ayi ajqeua YDIYM S]00} AY} SUIEIUOD 114 JOO} S,18UMO By Joo,Recommended oil: Yamalube 4-cycle Add oil through filler hole. oil or SAE 10W/30 “SE” name-brand motor oil The transmission filler plug is located above the kick starter. 1.Drain plug Transmission oil capacity change | 1,050~ 1,150 cc (1.1~1.2 U.S.qt) Total 1,150~ 1,250 cc (1.2~1.3 U.S.qt) ler plug To check the level, warm the engine up for On the bottom of the engine there a several minutes, stop engine, screw the dip drain plug. Remove it and drain all the oil stick completely out and then just reset from the transmission. Reinstall the drain the stick in the hole. plug (make sure it is tight).sue wiNWUIXeYy °Z vans diq *L “Jaa Puosas Asana paj|ijes pue pauleip aq Pinoys j!0 uolssiwsues ayf “JeAa| 4adosd ayy 02 WANS ppe ual2 “49MO| SI J@AB] B42 4] “OM BY} UBEM}aq 8q Pinoys jae] [0 ay} pue ‘syszeW WNW -Ixew e pue winwiulW e sey 4913s dIP ey ‘s]@a4M Yloq UO pue dn 1yble4s pauolyisod si aulysew ayy auns ag t.LONOPERATION CAUTION: 1. Before riding this motorcycle, become thoroughly familiar with all oper- ating controls and their function. Consult your Yamaha Dealer regarding any control or function you do not thoroughly understand. 2, Observe the break-in procedures to preclude mechanical failures. 3. This model is designed for OFF-ORAD use only. It is not equipped with highway approved lighting, mirrors, horn or directional signals. In most instances, it is illegal to ride this model (either day or night) on any public street or highway. —10—“panjoauy awit} ay} YOM UeY? alow SI Sainsse }! Ajayes pappe ay} pue au} Joys Asan e ul paysi|duosse AjyBnojoy} aq ued uoljdadsul ue Yong ‘pasn si aulYyoeW ay} awl? Yyoea ape aq Pinoys sxDaYy9 UO!}eJ8d0-d1g LON = uonessdo sadoid 105 084 sLHON = iressaoau'se uarybnyiie yooug | Su3N31SVs/SONILLG 99 ~zg sinu apxe/ssaunyony ‘@x10ds/rnouns/ainssaid 24D SIuIL 8 STASHM | ve~ze | sAemje 10 yum dwep pue ueajo aqisnu-adAyweoy | LIS HIV foahegee | as __wonesado ajqeo sadoid 403 yosyD | TLLOYHL | 6z~8z ____ Pauinbes se e9ejdeu 40 ue9|o/uo!1puoo >4984D ON1d NYWdS “Ge~pe | uoneoliqni/iueunsn{pe/iuawUBI|e 4934 NIVHO 3AING fee rae eereeee iH “Pauinbas se yo eueyo | ——NOISSINSNVEL_| Z Xiu Wo/lany sadosd him 11g >NVL 14nd vE~ et uauNsnipe Jane|/Uoneiado 4oa4D HOLATS | ee~12 queunsnipe/uoneiedo 9849 Saved freer elegy FPR Eeerar eer rearrange eereseerere corer wal 4ASI1 NO3SHOD NOILWHAdO"4S udBREAK-IN PROCEDURE 1. Prior to starting, fill tank with a break-in gasoline /oil mixture of 12:1 to 14:1. 2. After fueling and pre-operational checks have been made, refer to Starting and Operation and start engine. 3. Allow engine to warm up. Check engine idle speed. Check operating controls and engine stop button operation. 4. Operate machine in lower gears at moder- are throttle settings for 3 - 5 minutes. Check spark plug condition. 5. Allow engine to cool, Repeat procedure, running for 5 minutes. Very briefly, shift to higher gears (4th or 5th) and check full throttle response. Check spark plug condition. —12- . Allow engine to cool. . Allow engine to cool. Repeat procedure, running for 5 minutes. Full throttle and higher gears may be used, but avoid sus- tained full throttle operation. Check spark plug condition. Remove top end and inspect. Remove “high” spots on piston with No. 600 grit, wet sandpaper. Clean, and -carefully reassemble. Remove break-in fuel/oil mixture from tank. Refill with 20:1 operating fuel/oil mixture. Check entire unit for loose or misadjusted fittings/controls/fasteners. Re-start engine and check through entire Operating range thoroughly. Stop. Check spark plug condition. Re-start. After 10- 15 minutes operation, machine is ready to OFF-ROAD riding.er “spoiied dn -wueM papua}xe 10} auibue ayesedo jou 0G ‘NOLLNVS “yo yof Jay1eys UUM afiq014} 0} Ajjews0U spuodses oulbue ayi J! Bas ‘yoaYyo OL ‘saynuW Z O} | Saxe} Ajjewou ainpasoid siyj = "Wem eujbue eur jauN pauinbas se jaf sayeys ayy Buisn daybiy Ajiysijs 40 ayp) ye auibue eyr unYy dn-weyy vaulBue aly yueis pue seyeys 91 ay abebug “Ay. yBIs ajosy3 usdQ ‘Jef Jayeis ebebua you 0G uuem oulbus wim Buniersg 4 asojyaq uorlisod JeuiBl10 ayy 0} pauunjal si 48A9| (34049) jel sayueys ay) auns axeyy = “satnuluW OM} 40 auo 405 dn Wem ‘seis aulbua ay} Jalyy “7 ‘auibue ey) Leys 0} UIBuaS |]N} YLIM YUBID YI} B42 91>) “E *diu6 9]13014) ayy asojo Aja}a|dwoo pue Jara} (a40Y9) Jef 4sazse}s JOJINq4ed 984} 8}e18dO ‘7 *,NO,, 0} xooojed Jans ayy uN] “| poo Buriers “won -Buado jeijiul JO} sainpasoid ul-yea1q afuasqQ, taLON “ysl y9aYD UONe1ado-a1d Ul Pd3SI] sdajs wojsad ‘auryoeu 94} Buljesedo 0} 401g SST INOILNYS NOILVYad0 GNV SNILYVLSShifting A 5-speed transmission is used. Low gear is at the bottom of the shift pattern; high gear at the top of the shift pattern; neutral is FIFTH . FOURTH located half-way between first and second THIRD. positions. SECOND NEUTRAL The shift mechanism is of the ratcheting type common to most motorcycles. Allow the lever to return to its “at rest’ position prior to selecting another gear. Neutral is selected by pulling up or depressing on the shift lever halfway between first and second gears. With the engine running in the neutral posi- ion, disengage the clutch (pull in clutch lever), press down on the shift lever until low gear is engaged, remove foot from shift lever, increase engine speed slightly, slowly release clutch lever while advancing throttle. Repeat procedure for remaining gears. FIRST aeyes “ease ANOA ul 4ajeaAp WHVWVA eu YM Oe8yo ‘SUOHepUaO.a! ALI} Asay} MOI|O} ued noA Ajasojo Moy 0} se }qnop ul ale NOA 41 ‘aBewep pue ysnJ plore 0} yeyo ey) uo uMoys uey} Ajjuenbasy asow Yon pazedliqn} aq Isnwi sjied je ue Aupiwny yBiy jo ease ue Ul pajesado Ajjenu!}UOd si! 3j9A910}0W aut yi ‘ajdwexa joy “JUawUOLAUa siy YyoeW Ol BjNpeyos uu} Siy} 4azje JAUMO YoRa JeY) Puewap 0} pue} |/2 sasn jenpiAlpul Jo Ajalien e Pue ‘suojje00) jeolydesboab ‘ujeia} ‘ayzeam yey} UO!JeJapIsuOD OJU! aye] IsNW NOA “sjeA 48}! UONeOLIGn) pue aoueua}ule jesauab 07 apin6 e se Aj19143s pasapisuod aq pjnoys yweYd ainpayos uopeoliqn| pue eoueuajujewW ayL SONVNALNIVA OIGOIMAdMAINTENANCE AND LUBRICATION SCHEDULE CHART After Every Ride Every 500 km Every 1,300km After Every Event As Required Recommended | lubricant type WASH MACHINE. (This item is also essential to proper performance) PISTON spect Clean Replace PISTON RINGS Inspect Replace CYLINDER Inspect Head torque Replace CLUTCH Adjust Replace (Plates) TRANSMISSION il change Inspect gears / Shift mech. Replace bearings NO.1 ~16—=a x sBulul) aoejday, x | x ysn{pe 7g 49849 sanvyd Z ON X x aeaugny x x asnipe 7g 4984 s319vo 8 SIOHLNOD "ON x . x ‘aaeognt x x | eeu WuW ONIMS x x vaadsuy w UEAIQ aWvus x azjuoquedap pue UeaID | | x x uaiyBn @ wadsu} | W3LSAS 1SNWHX3 snipe ie x 2 "ioadsut 4HOLSYNSYVD x ypayD uid UoIsig x x yoayp pus |1ewS x x ypaye pus 61g x | yoayo Bursesq uieW, LSVHSANVHD ‘dA yueDTIgN) pauinbey eng w>1008'L ‘wy 00S opi Pepusuiuios9y 3 Arena Jey Aen Auen3 ‘Asong sens | AYVHD JINGSHDS NOILVDINSNT GNV JONVNALNIVAMAINTENANCE AND LUBRICATION SCHEDULE CHART After Every Every Every After Every As Recommended Ride 500 km 1,300km Event Required lubricant type WHEELS & TIRES Check runout x x Check spokes x x Check bearings x : STEERING HEAD Check x x Clean, lube & repair x x(every two events) No.6 DI | T T Check connectors x x AIR FILTER Clean & oil x x No. 3 Replace x SPARK PLUG Check condition x i DRIVE CHAIN Clean & lubricate x x No. 2 Check tension x Replace | x FUEL TANK Clean & flush x x Clean petcock filter x ec: —18——ét— ‘yooidiaem Ajgesajeid — sosmoeynuew Aujenb yo aseaub-Buleaq jeoyM 2yBleM-WNIPI —-9 ‘ON -aseasB aseq winiuail 8s = G “ON "MOZ HO 404 eYeWeA a ~~ “ON aqn| pue ueaig “Ayadoid uoloun oy sowiy je 1 [HO WIM duiep aq isu si914 “WO 1010 ,,3S,, O£/MOL AVS 25M “1!0-1an0 10U oq “api Asana pue raewW Asana e uawE|@ WeO}-S101115 NY “ON “WO 40101 ,,3S,, OE/MOL SVS 40 WeD1IGn| Aesdg aiqeg pue WEY eyeWeA as) Z “ON JOIOW ,,3S,, OF/MOL AVS 40 110 aAry eYeWIEA 8 | “ON ANVOINaN7 G3GN3WWOO3u S"ON x x | ayeo11qn9 SL4VHS a>xVYE B HOLNTO | x ol syeas aoejday v "ON | x x 0 aBueys w ue9i9 S>HO4 LNOYS ai eae aes yoodsu! # ueaID >OOHS HSH [ edAviuesiqn | paunbay | iweng =| wget «| =U ooS | ap papustuwiosay sv Auong ey ‘Aang ‘Auong Aang s2uy ALYVHD JING3SHIS NOILVOIYENT GNV JONVN3LNIVASPECIAL TOOLS The maintenance procedures outlined within this manual require special tools and instru- ments. A list of the special tools is given below. *1. Outside Micrometer (0 - 25 mm) *2,. Outside Micrometer (25 - 50 mm) *3. Outside Micrometer (50 - 75 mm) *4, Magnetic Base (75 - 100 mm) *5. Cylinder Gauge (50 - 100 mm) *6. Vernier Calipers (0 - 150 mm) *7, Torque Wrench *8. Clutch Holding Tool *9. Steering Nut Wrench 10. Measuring Cylinder (0 - 250 cc, 10 cc crements) *11. Dial Gauge *12. 56 mm | Gauge Needle *13. | Gauge Stand #2 *14. Flywheel Puller 15. Thickness Gauge 16. Flywheel Holding Tool 17. Pocket Tester NOTE: These items marked with an asterisk available from Yamaha. —20— (*)—it= sosnipy “1 inuy20) 7 “julod JoAId 4ana] axesq our ye Avid (ul Ze'0 - 70) WU g - G JO okIs aqeo wnunuiW e YIM adoUelejesd 4epli iins 0} paisn{pe aq pjnoys axe1q }UO14 eyesq 2U01y SLNAWLSNCOV TWOINVHOAW “sajeap 4noA 3nsuoo aseajd ‘payou si Aduedasosip 2 4] “ajqejieae se uoos se suajeaq eyewer Pezoyiny {Je 02 papsemioy si saBueyo queoljiuBis BuipseBes uolewsojuy “48UMO. @y} ©} 90130U ynoYWM abueYyo oO} ~alqns ase suoljeoijioads Bujofieso, ayi ‘19e) siy2 Jo BI] Ul “ajqetiAauy e1ojasey) ave suoNed!y -Ipow pue s}uawarosdw] ‘sjapow Je JOayJed saying 0} Bulalzys Ajjenusjuoco aie eyeweA jo sjuewyedeg Buliseulbug pue youeasay ayt '3LONAdjustment is accomplished at one of two. be adjusted with relation to the foot rest, places; either the handle lever holder or the Loosen the locknut and adjust the pedal front brake hub. height by turning the adjusting bolt. 1. Loosen the adjustor locknut. 2. Turn the cable length adjustor in or out until adjustment is suitable. 3. Tighten the adjustor locknut. 1, Adjustor 2, Locknut Rear brake Adjust rear brake pedal play to suit, provid- ing a minimum of 20 - 30 mm (0.80 - 1.20 in) freeplay. Turn the adjusting nut on the Brake pedal posi rear brake ferrule in or out until brake pedal The position of the rear brake pedal should freeplay is suitable. Adjustor 2. Lock nut —22——ez— sosnipy *L anuyx907 “Z oA, 2 (eres a *(uonensny|! 28s) panaiyoe si Aejdaes sera} Jadoud jun 3no JO U! Jaye JO}sN[pe yyHue] ey. WIN] ‘IxEN “ynUyd0| J0Isn{pe yGuUa] aulju! ajqed ay} 40 NU -490] J03sn{pe Jana] ajpuey ay} Jay21a UasCO7 quaunsn{pe Aejdaos4 “49 n3] ajpuey yornjo ay} ye Aejdea.y yo soueus}ueW Ppauinbes juawysn{pe Ajuo ayy ‘paysn[pe Ajsedoid s} wsiueysau ay} aouo ‘AjjeWON “juawabebuasip sadoid JO} ,,MOlU},, YDINJD yO JUNOWe }Da1109 ayy @piAoid 02 pasn si J0}sn[pe Wis}ueyaW YOIN|o ey, ‘suolipuod Buljyeiado snoliea sepun uoljes8do yoynjo sadoud 404 Aejdae.y qUaloijyns old 02 pue Yo}eIs aged Wo oeIS dn aye} 02 pasn ase siojsnipe yiGua; ajqed “Joisn[pe wisiueysaw yoynjo e pue ssoisn[pe yibue, ajqeo yoinjo om) sey jepow siyL yoni soisnipy “L “pajjesuies uay2 pue panowes S| J9ayM 4ea1 410 paysn{pe si uyeyo awzAUe Parjayo aq snus Juau3sn[pe jepad axe1q Jeay ‘LONMechanism adjustment 1. Fully loosen the cable in-line length adjustor locknut and screw in the adjustor until tight. 2. Turn the handle lever adjustor in. 3. Remove the rear brake rod from lever. Remove footrest and brake pedal. Remove kick crank. 4. Drain the transmission oil and remove the crankcase cover (R). 5. Loosen the clutch mechanism adjustor locknut. 2. Locknut 1. Eccentric adjustor 6. Push the push lever toward the front with your finger until it stops. With the push lever in this position, turn the adjustor in until the push lever mark and crankcase match mark are aligned. Tighten locknut. 1. Push lever mark 2. Case match mark 7. Install the crankcase cover, kick crank, and footrest, brake pedal and brake rod. Re- adjust clutch lever freeplay as required. —24——st— “uorisod yO|s wes awes ul pazeniis si axe |!UN ‘qU611 pue 249] yxoq Wed Jaljnd uleyo uiny “E Jayind wreus °z ynu ery *L "Inu 9]xe Jay Jeas ay UVSOO7 *Z “s0jsn[pe areiq 41ea1 ay} Uasoo7 “| quawysn{pe uolsuay UleYyo aAlq (ureyo ay2 Buyyono} you) ‘uo -IsOd paxejel ay} U! Jauo|sua} ey} YM apew @q Pinoys yuaWIsn{pe pue uo!oadsu! UO!sUa| ‘a.LON “uolsua, ujeyo ayi ysn{pe (ul Q'z) WwW Og spaaoxa Yo}a|Jep ay2 J] “(UL O'S - QL) WW Og - Ov Ajazeuxosdde si uoNda}jap jeorten jeWsOU ey, “UO!JeuIsN]I! ey2 UL UMOYs UOT!IISOd 84} 1e UO!sUa} By} 498eYQ “puNoiG 9y2 Bul -yONo} sedi} Y2Oq YUM U!eYD aALIp ay2 yadsu} }98Y9 UOIsUE} UIEYD eALIGNOTE: Before adjusting, rotate rear wheel through several revolutions and check tension several times to find the tightest point. Adjust chain tension with rear wheel in this “tight chain” position. 4. Tighten’ the rear axle nut. Axle nut torque: 9.0 m-kg (64.8 ft-lb) 5. In the final step, adjust the play in the brake pedal. Carburetor Under normal operating conditions, there are only two adjustments to be made to the carburetor. Throttle cable adjustmen’ Check play in turning ection of throttle grip. The play should be 3 - 5 mm (0.12 - 0.20 in) at grip flange, loosen the locknut and turn the wire adjustor to make the nec- essary adjustment. Tighten the adjustor locknut. 3~5mm (0.12 ~0.20 in) ff = 1. Locknut 2. Adjustor Idle speed and idle air adjustments 1. Turn idle air screw in until lightly seated. 2. Back out as specified. Air screw turns out: IT250D ----1.0 1T400D ---- 2-1/4—1z— ‘w'd's OG = OOE'L :Ppeeds e|PI r4no sun, ‘Malos 412 2|P] v/L-% + G00vLI OL :dog7e.i “uoljezisey JNO -UlIM pue pides si uoIIsod ajp! Wosy asuodsel auibua yeu) paisnipe os eq pjnoys smaios quewysnipe paeds ejpl pue aun}xiwi se 3a|p] OO LON ynurjooq °Z__ mouos dows aprosyL “| "widi pesisep ie si peeds a) Jo ul Maids Buijsn[pe paeds ejp! ey} UN] *G ‘widu ysayBiy 3e si paads ajpr |!: 4No JO U! Matos aINIXIW Je a]pl ayr WNL “7 *masos Burisn{[pe a|p! JO Uo}? -uaj}a1 aAlusod 40} payesodsoou! s! yNUxD0] VW ‘LON ‘wdi papuswwode je Ss! 2|p! jun masos Bulsn{pe peads api ey2 unt “€If the engine, when warm, hesitates after adjusting as described, turn the idle air mixture screw in or out in 1/4 turn incre- ments until the problem is eliminated. Spark plug The spark plug in your machine indicates how the engine is operating. If the engine is operating correctly, and the machine is being ridden correctly, then the tip of the white insulator around the center electrode of the spark plug will be a medium to light tan color. If the porcelain is a very dark brown or black color, then a plug with a hotter heat range may be required. This situation is quite common during the engine break-in period. However, use the standard plug. If the insulator tip shows a very light tan or white color or is actually pure white or if the electrodes show signs of melting, then a spark plug with a colder heat range is required. Remember, the insulator must be a medium to-light tan color. If it is not, check car- buretion, timing, and ignition adjustments. If the situation persists, consult your Authd- rized Yamaha Dealer. Do not attempt to experiment with different heat range spark plugs. This takes an exper- ienced eye, to gauge the proper spark plug heat range to use and to determine if the spark plug itself is at fault. For normal operation use: {T250D .. N-2G champion !T400D . N-3G champion 0.7 mm (0.028 —28——ez— Bul] 0} 80e} JOJeO}pul jeIP UO O4az aU} 10S “Ajquuesse efneb je!p ainses 0} pueys abneb J€!P UO Madds yes UaIYBLL *("O"G"L) JeqUe0 Peap-doi ye si uojsid |!}UN 1030) ajelOY “y *4aA09 aseoyueId aulBus 49] BAOWAY “E “pueys ou! (a]peeu) UOIsua}xa (u! Z7°Z) WU 9g e yim Ajquiassyy ained jeiq Wasul ‘Z “a}04 Bnid y4eds oju! puers abnes [81g Medos pue Gnd >Jeds ‘Jayynus anoway “| :SMO}JO} SB paad01g “(uonisod uo: @UIWJelap 03) aBneb je1p e yim Jas aq JsnW Bul? uo!UB] Buin uonuby ‘deB aposjsaja pue ‘10j09 10jejnsu! ‘eam apoujoaja 499Y4Q ‘au|yoeW ayi Bulsn 03 JOLd Paday9 pue paraowas eq ysnw Gnjd >yJeds ayy :anbio1 Bnd y4eds (QI BL) By-w gz *Aysedoid Bnd yeds ay? anbio} pue ‘Bnjd 41eds ay} Jo aoe ans 84} UO JUasaid 9g 1YybiwW yey. aWIIB Aue 430 edim ‘jeyse6 mau e asn ‘adejins eyseb ay uesjo sAemje ‘Enid ay2 Burjjeysu; usu, “H aoejdas ‘Aj}901 -1o9 Bujuojjouny you s! Gnjd >Jeds ay? analjaq NOA uosees Aue JO} JI 40 ‘UJOM 00} aWODeq Ajjeuly Seposzoaje ay2 J! 40 ‘aseasoU! 0} sulbaq uolsose $] “aposa pue UMOP 4eaIq AjMO|s 0} 6njd >4eds Aue asneo jj! Suolipuco aulbuyup exactly with indicator needle. Ro- tate flywheel back and forth to be sure that indicator needle does not go past zero. 5. Starting at TDC, rotate flywheel clockwise until dial gauge reads approximately 3 needle rovolutions before-top-dead-center. 6. Slowly turn flywheel counter-clockwise dial gauge reads ignition advance setting listed in specifications table. n timing (B.T.D.C.) 2.3 mm (0.091 in) 2.7 mm (0.106 !T400D: Flywheel mark 2. Base mark 3. Case mark Then check the marks on the flywheel and crankcase for If they are not aligned or a new crankcase is used for replacement, punch a new mark on the crankcase matching the one on the fly- wheel, —30——te— *panaiyoe s} JuawUBb)|e [JUN Madds Jas aseq ayy Uasoo) ‘pauBI|e JOU ase Aayi 4) “JuawuBiyje 10, aseq pue aseo -UeID BY} UO SyJeW JUaWUBIe aY2 49949 *g “4a|4JNUL PUB JEAOD asedUBIO ||eISUIOY (41-4 BL) By-w FZ :anbio} Gnjd y4eds 4ayind jaaymAj4 *Z [002 Bupjoy jeeyMAls “1 iBnjd yyeds |jeIsueYy “pueys pue Ajquiasse abneb jeip eaowey 6 ‘molos yes eseg *L “]BayMAIL B42 BAOWAY “ZL Jeulas alojaq uollIsod od ay} 21290] 0} ains ag tB.LON 398.409 ay} ul UO!ENGINE MAINTENANCE AND MINOR REPAIRS The following sections provide information for the disassembly, troubleshooting, and maintenance of various components of the machine. If you do not have the necessary tools and an understanding of the mechanical principles involved, please refrain from at- tempting repairs. The use of improper tools and/or procedures can cause major damage to units with resultant additional repair costs. To properly understand the procedures out- lined, we suggest you consult other technical publications. Finally, we suggest you consult your Yamaha Dealer prior to attempting any repair pro- cedures. Air filter Removal 1. Remove the screws and remove the right number plate. 3. Remove the air filter from the filter case. 4. Slip the filter from the guide. —32——ece— "ssa002 JO} PaAOWsl sued pue Ajqueasse Juawaja ay} ||eISUIaYy “9 “yeas Jey) Pue 41809 ased 4a}]1} a4} UBaMjeq jees 14617 ue apiaoid jj! siyy ‘aseal6 1461) yum JUaWA/a 4193/1} 842 JO sabpa Burjeas ayy yeOg “Gg “quawaja 84} OLU! apINB juaweje Ja2j1y ay) Wasul-oy “y “HO yum Burddiap 30U iNg ‘sewl} |Je 12 {10 YIM dwep aq isnw. quaweja ayi ‘Ajsadoid uolj9uNy 0} Japs0 U] tBLON “Jel4ayeus wieoy snosod ay} o}U! AjyBno JOY} 40M PUue jUaWa|a Ja}]1y a4} O}UO {JO Joyow og JO AYQUeNb jews e nog “E “Asp 39] pue juawala ayy JO INO yUanjos ssaoxa ay} azaanbs ‘Z “quaajos Ul ‘AlyBnos0ur ing ‘AjjuaG yuawaja ay) YyseM ‘L potpew Buluea|DNOTE: Each time filter element maintenance is per- formed, check the air inlet to the filter case for obstructions. Check the air cleaner joint rubber to the carburetor and manifold fi for an air-tight seal. ten all fi thoroughly to avoid the possil filtered entering the engine. CAUTION: Never operate the engine with the air filter element removed. This will allow unfiltered air to enter, causing rapid wear and possible engine damage. Additionally, operation with- out the filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating. —34——se— adid Moy 4anQ * adid quan sy Jana] sues By Burysng sa6unid saisers, dep deo saBunig areid Bulids srse1g Bupids sa6unig Ja6unid setsers anu 4907 alos afOsy anu Bunsnipe ayy 2qm apin6 asm * dep * 19%seD dot sequieyo BuIxiN * Tom Buryoeg * Buids anyen aproiys * yeas + Joysem areig * jasessgegegeseg RiRRSSSRSBS Jeysem Bulids alos peayueg 4o198UU0 aug, a1p=eN anjen aprosyt, 3jzz0u we mmaios peayued Jaysem Bulids, eid Bnid mesos 6u-0 Apog soquieyo 18014 e9}se5 Jaquieyo 1e0) 4 areld deg urd ols wue 120) yol4 Asse x08 ane,“ JOYSeM 2888 anieA rol weW soysem raf UI wh rold % Asse s012snqseg * 4 ‘ve "ez te tz ‘oz “él 8b aL “OL “st “eL "eb ue a ‘OL caiddednaa 4oyainquedReplacement of main jet 1. Turn fuel petcock position. 2. Remove the gasoline tank fuel line into from the fitting at the carburetor. 3. Loosen the manifold and inlet joint bands (hose clamps). lever to the “OFF” 4, Rotate carburetor, exposing main jet cover bolt. 5. Remove bolt. behind bolt. WARNING: Removing the main jet cover bolt Main jet is located directly allow the fuel in the float bowl to drain. Do not remove if engine is hot. Place a rag under carburetor to catch overflow. Remove bolt in well-ventilated area. Do not remove near open flame. Always clean and dry machine after reassembly. 6. Remove the main jet. Change as required. Reinstall cover bolt and reassemble, revers- ing steps 1 through 3. IT250D .. IT400D .. # 360 # 350 Main jet: a 1. Main jet Lage 2. Cover bolt—Le— WW | F LSL Jee] 220] 4 Jong] e015 *p “Nse1 IM O4N}2XIW YOLd @ ‘MO] OO} 4] “ANDO {IM aaMXIW jany/s1e ea] e ‘YBIY 002 SI [eA2| yeO}y 242 4] “2YBIey ewes ay2 Je aq IsNW Sue JeOY, yI0g ‘AJessadeuU si! JUaUIsn{[pe Jere] WO]} Aue 4! We yeoYy ay? UO Bued ayi pueg ‘edejins JeyseB Mog IO|} ay? 02 we 320)/} ay} WO. eouelsIp eyi aunseay| [ana] Jeol *L squauysnipy yeas aneA ‘Z A v anen e014 “L “yes @ se sjuauodwod say} aoejdey “uoHeUILUe}UDD 40 eam 40} eas pue anjeA ajpeau jojul yoedsul “E “paoeid -81 aq pinoys Aayi ‘pabewep 40 Bulyjea) ase SJVO|} J] 'SICO|J JO UOIZPUOD sUlLUeXy ‘Z “4Je passeiduiod YUM sjef pue sabessed |je No Mojg ‘suO!INjOs Buluea]d sOJeINqued oNsned asn JOU OG “]UaAJOS paseq wna) -OJJad Ul J0}91NGIeD YSeM ‘PayLUIWe}UOS 4) ‘saBessed jan} pue Apog Jojainqieo au;wex “| uonoedsuy2. Jet needle The mid-range air/fuel supply is affected by the position of the needle in the needle jet. If it is necessary to alter the mid-range air/fuel mixture characteristics of the machine, the jet needle position may be changed. Move the jet needle up for a leaner condition or toward the bottom position for a richer condition. LEAN Ist 2nd 3rd 4th Sth acta RICH Jet needle Troubleshooting A Motocross machine requires immediate, predictable throttle response over a wide operating range. Cylinder porting, combustion chamber compression, ignition timing, muffler design, and carburetor size and component selection are all balanced to achieve this goal. However, variations in temperature, humidity and altitude affect carburetion and con- sequently, engine performance. The following list gives each of the major components of the carburetor that can be readily changed in order to modify perform- ance if required. If you are unfamiliar with carburetor theory, we suggest you refrain from making changes. Quite often, a per- formance problem is caused by another related component, such as the exhaust system, ignition timing or combustion chamber com- pression. —36——6e— “ATLLOWHL (+) v/€ 0 b/L =31GSSN Lar SHL AG G3194454V LSOW JDNVYH ONILVYadO ‘ainyXiw Jay AjBurpuodsasico e antB jm ‘anocoi6 woy0q 4o ‘yijly ay yBnosyr ‘ancos6 do} 40 “say aul WO dijo ajpaeu ay2 Bulaoj = *a|paeu 24} JO 1NO MO} O} Jan} a1OW sMojje a1paeU aur Buisiey “jeyino 9jzzou ule ay) OU! SHJ a]paau ay yo pua paiede} ay] “anjer ajouyr ey. ULYUM pally st ajpasu taf ey. re]peeu ier “ATLLOYHL (+) v/L Ol 8/L TAATVWA AILLOYHL AHL AG GaL0a4d4V LSOW J3DNVY ONILVYSdO *a4un]XIW ay} Jeuea] ayy ‘AemejNd aJOW ay} ‘Jaquinu ay. JeyBiy ey, “Aemejno ayi JO ajBue ay 0} Buipsos9e pasaquinu aie SAAJPA a]IJOIY] ‘“AANIXIW JaUea] Be 9}eAI9 || (,,Aemejzno,, a40W1) e|Bue sepim Vy ‘9[zzou Ue 4} JaA0 Buimoj se }043U09 0} Aeme 4nd aseq ay} JO UO!IOd e seY (apl|s) aAjeA aj17044y3 BY apis) aajen ep.OUYL “ATLLOYHL 8/L OL OYAZ *LAP SIHL AG qgaloassv LSOW 3DNVY ONILWYHadO vaunyxim: sayoid e Buiai6 YINDIID ay} O} Jeny asow saljddns sequinu dayBiy e yim auo 0} Jaf ay} BuiBueyd “yNd419 Q{P] aY2 Ul 412-O1-Jan} JO O12e4 BY sjO4JUOD sf 10}I1d “ATLLOYWHL 8/L OL OYAZ *LNAWLSNPAV SIHL Ag Ggaldadsv LSOW 3DNVY ONILWHAdO ‘aunyxiu! Jayoi e Buyai6 ‘Ajddns 2 aU} Saseaidap Ul Mads eYy} BuluAN| *}INO. Q|P! 242 Ul fenj-o}- }0 o1]e4 ay} sjosjUuOD :MOJ9S BANIXIW JIE IP] ‘sluawsn[pe JOjainqueo |euol “IPpe 40} SINAWLSNPOV TWOINVHOAIN 8S ‘LONThe main jet controls overall fuel flow through the main nozzle. Changing the jet to one with a higher number supplies more fuel to the main nozzle giving a richer mixture. OPERATING RANGE MOST AFFECTED BY THE MAIN JET: 3/4 TO FULL THROTTLE. NOTE: Excessive changes in main jet size can affect performance at all throttle positions. CAUTION: The fuel/air mixture ratio is a governing factor upon engine operating temperature. Any carburetor changes, whatsoever, must be followed by a thorough spark plug test. Reed valve 1. With carburetor removed, remove the four bolts holding the intake manifold and reed valve assembly to the cylinder. Remove the reed valve assembly. 2. Inspect reed petals for signs of fatigue cracks. Reed petals should fit flush or nearly flush against neoprene seats. If in doubt as to sealing ability, apply suction to carburetor side of assembly. Leakage should be slight to moderate. —40—eg “usayed ul pue Ajjenpes6 s3joq Bujsnoas ay} anbsoy “dem Aewi sazeyd Pue syeyse6 meu jjersu! ‘pjojjuew pue Ajq 4addo}s 40 smasos Bulinoes Ue21Y61)-48A0 20U 0G ~Wasse BAJEA pees ay) Jo Ajquiasseas Buling “7 :NOLLAVD “UO!}E]JEISU] Peed JO UO}IDAJ/P O1 ple se asp ‘eyed 4eddojs pue peas ay} JO 48109 1aMoj| yi Ul 3Nd 984} eAlesqo ‘Ajquiasseas Buling 73.LON “AyyBnosoy? smasos ayy ue14y61 ayy ‘Bul -duem plone 0} Ajjenpes6 smasos ua7y6i 1 ‘smaios sdijjlyd yo speaiyy o2 ,,’erh -)907,, se yons “juabe Buipjoy e Ajddy ‘AjyBnoioy, aejd saddoys pue ‘paar ‘yoo|q paar ueajd ‘Ajquiesseas Bulung “q “apis UES UO |JeISUIaY “Panowias asam aje/d daddojs pue pases ali 490)q peal ay JO OPIS YO!YM WOd aON) “puaq OU Op pue sayoyeis PlOAy “Ajjnjaueo paas ajpueyy *y90]q Paes 0} paas pue ajejd Jaddois Buyanses (Z) sMmasos sdijiyd anowey “e (aru! 6'9) 64-wWo O'g :SMOj}O} se paadoid ‘pasinbas si tenbioy masos Buysnoes Alquiasse aajen paas ay2 Jo Ajquiassesip 41 ‘EMUFFLER AND CYLINDER HEAD REMOVAL (Carburetor Removed) 1. Remove the left side cover. 2. Remove the coil springs at muffler to cylinder joint. 3. Remove the muffler mounting bolts and loosen the muffler joint screws. And remove clutch wire. —42——er— “Bulieeq pua ‘sinu Bulpjoy sapuyjAd ayy anoway ‘1, {ews pue uojsid ay} aaoway ‘apis ajisoddo Woy yno uld ysluM ayy ysng ‘uoIsid TWAOWAY NOLSId GNV Y3GNITAD ay Wood (L) dijo uld ysuM ay} sAOWAY ‘*¢ “yoyseB aseq pue sapurjAo anoway “Bu! ~491U9 WO sajoiued uBles0} JaYy0 pue LIP qUaAeId 0} ‘pos PunoJe ‘ALIAeD asedyUeID oju! Bes doys ueajo e yymig “aseoyueID JegjD SU}ys Japul|AD ayy [LUN JapUljAd ayr asies ‘18}U80 peap do} je uoysid ay? YUM ‘Z “‘Bulaowas 0} 401d (UIN} y/|) as0o] INU YyoRa yea1g *3.LON "yeyseB pue peay sapuljAo aAoway ‘sinu g ‘peay pue sepuljAd Bulinoas synu anoway ‘yNOT! If the pin hangs up, use a wrist pin puller. Do not pound on pin as damage to rod, piston and bearing will result. MAINTENANCE - EXHAUST PIPE 1. Using a rounded scraper, remove excess carbon deposits from manifold area of exhaust pipe. Check muffler gasket con- dition. The gasket seat is located around the cylinder exhaust port. 2. Carbon deposits within the silencer may be removed by lightly tapping the outer shell with a hammer and then blowing out with compressed air. Heavy wire, such as a coat hanger, may be inserted to break loose deposits. Use care. - 3. Reinstall muffler. MAINTENANCE- CYLINDER HEAD 1. Remove spark plug. 2. Using a rounded scraper, remove carbon deposits from combustion chamber. Take care to avoid damaging the spark plug threads. Do not use a sharp instrument. aaa"yuod ysneyxa wo sjisodap — s*— uoqies eaowel ‘Jadesos papunos e Buse ‘Z “Alquiasse anjeA pael aroway “| HAQNITAD - JONVNALNIVI ‘apis BuO Woy [e}Ja}eU YONW 00} Bu! -AOWA1 PIOAR 0} SAI Je1anes Peay 212104 ues 2YB61a-e1nBiy e Gulsn peay e0ej4ns-84 pue ezejd aoelins uo 4sadedpues Asawa 18M 146 909-007 a0e1g ‘Buloey -anse1 Aq 3981109 ‘aBediem ou aq pjnoys aseyl ‘ez2]d aoejins e UO peay ay} adeIq ‘E (WY O'8L) yw gz ‘weyed 6 renbso} nu peay sapuljAd “Alquiasseas Sulinp yeyse6 peay sapuljAo Mou |/eqsu] "9 “Alp ediM pue juanjos ul peay ay} yse\y °G “AjyBnos0yy eoepins Buyzew 1ayse6 Gnd yueds ay) uea|D “yp “adBjANs je} 9Yy} Buryojes9s PlOAY3. Remove cylinder base gasket and clean gasket seat on cylinder and crankcase thoroughly. 4. Check cylinder bore. Using a cylinder gauge set to standard bore size, measure the cylinder. Measure at six points; at top, center, and from bottom of piston, in line with the wrist pin‘and at right angle to pin. Compare to piston a measurements. If over tolerance, and not correctable by honing, rebore to next over-size. Standard bore size: IT250D . 70.00 mm (2.76 in) 1T400D . 85.00 mm (3.35 in) 5. Clean cylinder in solvent, then wash with hot soapy water. Dry. Coat walls with light of film. 6. During re-assembly, always use a new cylinder base gasket. Cylinder holding nut torque: 3.5 m-kg (25.2 ft-lb) Maintenance - Piston 1. Using a rounded scraper, remove carbon deposits from piston crown. —a46—ue -sid eunseaw ‘JezaWO9}W apisino ue Bus; °G “Aap adim pue juanjos ul uojsid yseM “7 *(auly urd uoysid ©} sejbue 1Y614 Ie siuew -d1NSealU OM} WWO}}0q) s}UaWainsealW 240g JapuljAd 0} JazoWeIp UOJs!d aaedWOg “SLs uojsid ay} JO WIO}}0q AY} WO (UI 7°Q) WUE OL ‘sejoy uid uojsid ay2 0} sejGue-2461 12 si jujod Bulinseaw Ajuo ay, “pesede} pue PunosGwies si uoysid ayy “Ja}owelp uo} *Ajaalssaoxe pues 30U 0G “usanjed Yydiey-ssold UI pues ‘uOoIsId JO sapis WwO4JJ syisodep Jenboe] pue s>4Jeus 8100s pues Ajy6y ‘sadedpues 3am 1146 O09 - OOF Buisn *e “aaool6 Bus WO4j Silsodap uoqsed ueaj> pue arocoi6 Buls Buryoies9s plone 0} sabpa sing-eq ‘asenbs Pua aij *OM) u! Bul uoysid pasn e 4ea1g ‘ZPiston clearance = Minimum cylinder dia. Maximum piston If beyond tolerance, replace piston or re- bore cylinder as required. Nominal piston clearance: 0.045 - 0.050 mm (0.0018 - 0.0020 in) Maximum wear limit: 0.1 mm (0.0039 in) 6. During re-assembly, coat the piston skirt areas liberally with two-stroke o 7. Install new piston pin circlips and make sure they are fully seated within their grooves. 8. Take care during installation to av damaging the piston skirts against the crankcase as the cylinder installed. NOTE: The arrow on piston dome must face forward. —48 9. Make sure the ring is properly seated as the cylinder is installed. PISTON RINGS 1. Insert ring into cylinder. Push down approximately 20 mm (0.79 in) using piston crown to maintain right angle to bore. Measure installed end gap. If beyond tolerance, replace ring. Ring end gap, installed (Top and second) 0.3 - 0.5 mm (0.012 - 0.020 in)—6r— (ut 6£0°0 - 9L0'0) Wu OZ - vO 21d jeixe pos Buisauu0g pue 0} |10 yo wy YB e Addy ‘y “Bulseaq pue uid aoejdas ‘punoy 4) ‘syods 3e]} JO suBis 40) ssajjor ay2 y9aYD "JBAM AAISS2DXa JO} aBeo Bulseaq ay} 499YD “E "yzoq soejdas ‘(paniq Ajtneay) anissaoxa 4] “UO!eJOJONSIP jeaYy 40 suBis Joy Bureaq pue uid ayy 9949 ‘Z ‘Buleaq pue aoejdes ‘UapIAa Ss} JeaM Aue | “JeeM 4O suBls 10} ud ay) 49aYD ‘1 qouw SDNILOSNNOO GNV ONIYV34 ‘Nid NOLSId “Aejd jelxe ainseaw pue pos jo do. 4904 “4OJLOIPU! |2IP ay} PJEMO} pos Jo WONG ey Buipjoy ‘pua jews pos Buloeuuco 84} 0} sejBue 7Y611 ye aGneb jeip ayi yuNoy). "Gg *pauinba se l1@ 40 Bulseaq pue uid aoejdey ‘seam pue dajawelp pua jjews pos Buiyauu0s yay ‘sisixa Avid 3) “Aejd jeo1q4en ajqeaolou ou aq pjnoys aieyl, “Aejd 10} 9349 “pua jjews eysu] ‘saoejins Burieaq pos Buljgauu09 ul ‘eanpeooid ul-4ee1q eaulYyoRW Mau JO UO!IOd YSUly MOYO4 “ul-yea1q sauinbas Buls Aan t3.LON “Buls 0} [10 ayO43s-OM} JO Buizeoo jesaqi| Ajddy ‘aa00.6 uoysid ul uid uoljze00| Buli punose payiy Ajsedoid aie spua Guli auns ayew ‘uonejeisul Buiing “¢ ‘Bula e0ejde ‘puno4-}o-1no jou Ss! dapuijAd 4, “sapurjAd y9aY49 ‘pazees Ajjny OU 3] *a40q punoue Buls yo Burjeas ny doy yoyo ‘1461] spsemo} sepuljAd Buipjoy ‘Z6. Remove the dial gauge and slide the con- necting rod to one side. Insert a thickness gauge between the side of the connecting rod big end and the crank wheel. Measure clearance. Connecting rod/crank side clearance: 0.25 - 0.75 mm (0.01 - 0.030 in) 7. \f any of the above measurements exceed tolerance, crankshaft repair is required. Take the machine to your Authorized Yamaha Dealer. 8. During reassembly, apply a liberal coating of two-stroke oil to the piston pin and bearing. Apply several drops of oil to the connecting rod big end. Apply several drops of oil into each crankshaft bearing oil delivery hole. —50—eee ‘suid Jamop ayz Jo uo!sod ayi @10N “4@AOD a4} BAOWAI Pue soe|d Ul 1aA0D @Pls 842 Burpjoy sijoq ualjy ayy anoway “y "yuelO J211e1s PP] 242 eraoway ‘jepad axe1q pue Isai -J00} BAOWaY “PO ayeIg Jead aYyI aNOWAY “¢ ]}0 UOIssiwsues) ayy UleIp ue ‘6njd ulesp pue Bid sajj1y ay2 encway ‘Z *40}98}01d aujBua ay) encway *1 JEAOWAl (44) 48A09 aseayUeID PU J0}1e}S 491) *,Squawysnipy leolueysay,, Ul paieaco s} yuauysn{pe Yyoin|D *a.LON YALYVLS MODI GNV ‘H3L4IHS ‘HOLNI1D a|quiasseay “senoos6 Bus jnoy 40 AyAeo aseo -yue49 OJU! doJp jou seop UOqued 1ey} aue9 e481 ‘UMO1D UO}SId pue peay sapul|Ad eziuoqieseq = -uol}oadsul jensia yBnosoyr ayew pue peay sepulj|A9 eaoway *Ajq -Ulasse Jajsaie y4eds/Jajynu aziuoqieoag *Z ‘pasinbai se uonasnques 10 pue 6njd weds isnfpy ‘Buipeas Bnjd y4eds e ayeyy ‘1 “pesinbei s} Ajquiassesip pus doi 4! azeo1pul jj ainpssoid Buimoj|oy ey Y43744NN GNV GN dOL - SNILOOHSA1EsNOHLClutch and kick axle assembly removal 1. Repeat steps Kick starter and crankcase cover (R) removal. 2. Remove the hexagon head screws holding the pressure plate. Remove the clutch springs, pressure plate and push rod 1. Remove the clutch plates and friction plates. NOTE: When removing hexagon head screws, loosen each screw in several stages, working in a crisscross pattern, to avoid any unnecessary warpage. Note the condition of each piece is removed and its location with in the assembly. 3. Bend lock washer tab down. Using the clutch holding tool, remove the ciutch securing nut and lock washer. 4, Remove the clutch boss and driven gear (clutch housing). 1, Clutch holding too! —52——es— 4896 9)P1 9111 ‘eBexee1q pue JeOM 404 Y}88} JkAaB ay YoaYD “YyeYs WOM ay} UO Ajaa4y sjesids sea 4914 ay) 3eUr “aeab aj 88S 01 YO9aYQ *Ajquiasse aujjUa ay} yNo OP] aAowWeas uay2 PUR djjo41I9 ay) aAoWaY “9 Bul]jnd uayp pue esimys0j18,UN0D Yeys 942 “ssgoeds. Buryex01 Aq Ajquiasse a]xe 914 a4) eAoWaL eqed ysnuy2 pue ajejd ysnayy ay2 aaoway uayl "Xeja4 0} U Mol ‘aseoxUeID aly @AOWAl ‘YWeYs UIEW UOIssIWusUes) 98U} ul asod sq1 wo Burds 4914 842 YOoYUN "LZ uo suJeUtas sadeds Bulsnoy YIN] aya 41 °STROUBLESHOOTING - CLUTCH ASSEMBLY 1. Measure the friction plates at three or four points. If their m exceeds tolerance, replace Wear Limit 2.7 mm (0.11 in) 2. Check the plates for signs of warpage and heat damage, replace as required. NOTE: For optimum performance, if any plate re- quires replacement, it is advisable to replace the entire set. 3. Check each clutch plate for signs of heat damage and warpage. Place on surface plate (plate glass is acceptable) and use feeler gauge. Clutch plate warp allowance: 0.05 mm (0.002 in) —54——<6s— “Auessaoau se soejday ‘sted |je ‘seam @AIssaoxe JO suBls 40, yoaYQ “UOI}e}01 YIOOWS JO Y99YD ‘syed [Je UO j!10 yo WyIy UB & YM ad asnayI YoInjo yr W4 6 “uolje18do: YoIN}o o1ela asned jjM ssoq yYoINjo ayy 40 Sauljds ayejd yoynjo 40 Bursnoy yoynjo ey) 30 sBop ajejd uolo14y ay2 404119 UO Burye5 SEES eee LON, “aoejdas ‘esanes }| “dungap ‘ajyesapow 4; “BulyjeB 30 suBls 40} ssoq yoynjo uO seuljds yO8YD “g “aoe|das ‘asanas 4] “ungap ‘alesapow 4} “saipa uo Bul|e6 40 suBls pue sy9e19 410} 4007 *(Bulsnoy yo3n)9) iea6 uantip uo sBop y9aY9 */ “pasinbes se aoejdeay “Buisnoy yoinjo ul se ,,jaej,, awes Ajawewixoidde YUM 4 Pinoys sa9edg “yeys uleW 41aA0 deoeds dij ‘q'| Je0eds Burysnq pue yeys UIELW UOIssiwIsUesT O} [10 40 JeOD UIYI A\ddy ‘9 ‘pasinbei se aoejdas ‘aranas $| ‘oye ‘aBewep yeay ‘Buyjeh yo suBis J0j Jeoeds pue Bulysng ayy 92849 “GS “Buisnoy yoinja 410 sa0eds aoejdes ‘Adessadau 3} “Bulysng ayy ulYyM AjyiooWSs 812101 pjnoys saoeds ay) “314 ssasd-quuny2 “yxoows e aq pjnoys 3] “Bulysnq ay? ou! deseds ay) 114 “Je0eds pue aoeyins Bulysng ay} UO j!0 yo WY 3YBI] e Ajddy ‘sa0eds Pue Buisnoy yoinjo ayy ues] Ajyinooyy y10. Measure each clutch spring. If beyond tolerance, replace. New Minimum Clutch spring 36 mm 35 mm free length (1.42 in) (1.38 in) 11.Stack the clutch spring set on a level surface. Rotate each spring until all are at approximately the same vertical angle and maximum apparent height. Place straightedge across set. If any spring exceeds tolerance, it is advisable to replace the clutch springs as a set. 12. Before installation, apply grease to push rod 1 and ball. SHIFT MECHANISM During installation, match the index mark on change lever 2 and center of change lever 1. Align. —56—29SED) mauas * buses + 1585 10 Jaysem aeid Bulids uolsio4. * Asse Jana] usnd ersid says + ss08ds “gL anu uobexeH} “GL Joysem Bulids “py JOysOM UIBId “EL mang “ZL 4aYSeEM 4907 “LE aAN ‘OL Lposusnd “6 IM URIM M9198 *B uolsseidui0d “2 ered einssaig “9 yaInig “Ss aieid vena “y yornyo ‘ssog “E dos 4836 UoALI AroUut “Z A,S8@ YOINID *L =—6— (ao0rL1) 493n1DCHASSIS MAINTENANCE AND MINOR REPAIRS SPROCKETS AND CHAIN NOTE: Please refer to Maintenance Lubrication Intervals charts. Intervals and Drive sprocket 1. Check sprocket wear. Replace wear decreases tooth height to a point approach- ing the roller center line. 2. Replace if tooth wear shows a pattern such as that the illustration, or as pre- caution and common sense dictate. —58 3. During drive sprocket reassembly, make sure the lock washer splines are properly seated on the drive shaft splines. Tighten securing nut thoroughly to specified torque value. Bend lock washer tab fully against securing nut flat. Drive sprocket securing nut torque: 7.5 m-kg (54 ft-lb)—6s— “peuinbas se soejday *s49|]01 paBewep 10) 49ayYD *sJa]jou pue suid ul sysixa Aejd anlssaoxa }1 29S 0} 499YD “IEAM BIQISIA 10} sazejd apis ay DAUD ‘7 raoejdas ‘ys 8s JL ‘spur ino y40M 0} IdWwaye pue AjyBnosoy} ureyp |19 “ale ainsseud YBiy YM Aup ‘ysnig ajisiaq winipaw YIM ueald ‘uO! “NjOS JUaAJOS UI YeOs ‘y{IIS J] “pazesjsn S€ POH “ssauyyias 40} UIeYD ayy 4DaYD “1 ureyg (1-4 BL) By gz :anbJo} Inu Bulinsas yeyx90Ids UaALG "s}@|} 110g Bulinoes ayz ysujebe Ajjny SJaYSeM 490] Ay} JO Sqe} ay) puag ‘usJa}Ied ssoJossiJ9 e Ul szjOq Bulunosas ay} ualybiL “ueajo ae 1eas yeyYDOI1ds pue Jey90Ids ay) ains ayew ‘Ajqwasseas BulNg ‘Z Ly 30V1dau 4aT10N 440 aI7s ‘aoejdas ‘Juaq Ajasanas 4] ‘ssaid e as— “uajybiesjs 0} sauiWeYy pue jeay JOU og ‘suNd 1 Yey2 aas 01 Jex90Ids ay} 499YD “| yeyoouds uaALig3. During reassembly, the master link clip must be installed with the rounded end facing the direction of travel. Turning direction Troubleshooting With the chain installed on the machine, excessive wear may be roughly determined by attempting to pull the chain away from the rear sprocket. If the chain will lift away more than one-half the length of the sprocket teeth, remove and inspect. If any Portion of the chain shows signs of damage, or if either sprocket shows signs of excessive wear, remove and inspect. HECKING FOR EXCESSIVELY WORN CHAIN —60——19— sued jesBaqu! ue slajqeo ayy yoIYM 40y UOIJas aoUeUa}ULELU Ienpiaipu! ayy as ‘sjeyep Joy “UO!IOes SIL UIYZIM Passnosip aq }OU ||IM JeAOWAaY “pazedi|d -wioouN puke PJeMIOJIYBIeAIs S| |eACWWAI a1q2D “Bulsnoy sii U4 AjG044 BAOW 0} 2/Ge2d ay} Moje 0} UO!eDLIGN| dadoid 410} BuipiAoid pue ‘Buleyjeam pue ysna yBnowy2 uonesoazap Buruanesd yr Pauisou0d Ajlsewiid s! aoueus}uleW aged oe) “UOHBULOJU! JBUOITIPpe JOY sHeYD ajnpayos uopediiqn] pue aoueuazule) 88g LON “yyeqsul-oy "sS20X8 jo adiM ‘sayesjouad jUedIIqGN) auns aye 02 AjyyBnosoy} 4a{J01 Yyoea 410M ‘auIYyoeL YO allyM AjYyBnosoyy aied14qN7, “ue einsseid yBiy ym Aiq ‘wip Bul -ujewias 440 Burysnig ‘juanjos ul uleYyo BOS “7 *s4a]|O1 OU! save ainssaid ybiy YUM HO Mog "4JO UIP sseoxe Yysnug 40 /pue adim ‘uleyo ay} eAowias ‘Aj|ed1IPOled “€ “questiqn Aeids ajqed pue useyd eyewe, asp) yuedlign| Jo uojerjeuad ainsse 0} ainzeled -Wa} WOO 32 aq Pinoys jUedAGn| Pue UleEYD EEE peer eer rere eeeceeeeceerHts iON, "ssa0xe JJ adim = ‘AjyBnosoyy Ajddy ‘seam uaAeun asneo |JIM siyy se uoiod e diys },u0q “uJ2Y9 JO apisyno pue aplsul Yyr0q UO sale|d apis pue Jajjor usamyaq juedgn, Ajddy ‘Z “Bes way) ‘ysniq 241M asn ‘aJanas SI UO!}e] -nuinose 4; ‘Bes doys yim wip yo ediMm"L saulyoeu ay} yO asn Asana saqye payeoiign| eq pjnoys uleyo eyL soueUazuIe||Maintenance 1, Remove the cable. 2. Check for free movement of the cable with its housing. |f movement is obstructed, check for fraying of the cable strands. If fraying is evident, replace the cable assem- bly. 3. To lubricate cable, hold vertical po: tion. Apply lubricant to uppermost end of cable. Leave in vertical position un’ lubricant appears at bottom end. Allow excess to drain and reinstall. Use Yamaha Chain and Cable Spray lubricant. Front wheel removal 1. Elevate the front wheel by placing a suit- able stand under the engine. 2. Disconnect the brake cable at the front brake lever. 3. Remove the cotter pin and front wheel axle nut. 2. Axle nut “1. Cotter pin 4. Turn and pull out the front wheel axle; the wheel assembly can be removed. Rear wheel removal 1. Elevate the rear wheel by pla able stand under the engine. 2. Remove the brake rod from the cam lever by compressing the rod’s spring seat. Then hold it up and place rod on the hook of the rear arm. 1g a suit- —62—ee uid saig “e uld sa0p “Zz anu ary +1 a “pauarybi. Ajsedoid ase synu ajxe ay2 ains are ‘Z SIAQ]D BY BAOWAI UdY] “sUId sIAB]D WoL (QyB4 pue yal) ‘suid 4ay309 ay} eaoway "y “ujeyd saowas pue nu a]xXe ay? UasCO7 ‘¢ ‘aze]d a0ys aryeiq ay UO IO] BuII200] 84} YUMA (we BUIMs 40) eqn} 183nN0 ay} UO Ss0q 84} JO JUeWebebue sadosd 40} 9949 “1 ssjujod Buimo}}o4 ay2 40 aseo Bulye2 ‘einpasoid fPAOWSs ay2 asianss ‘sjaaym Buy|jeIsu! uay uoNe!EIsU! sjeayM “Ajquuasse jaayM 4ea1 ay2 erowes ‘paemr9eq JaayM ay? |INg ‘SsAxle nut torque: 9 m-kg (65 ft-lb) 3. Always use new cotter pins. 4. Adjust the play the brake lever and pedal. 5. When connecting the chain, make certain closed end of master link clip is facing direction of rotation. Checking brake shoe wear Measure the outside diameter at the brake shoe with slide calipers. If it measures less than specified limit replace brake shoes. Minimum brake lining thickness: 2 mm Brake shoe dia. Front | 130 mm (5.12 in) Rear_| 160 mm (6.30 in) Wear limit 126 mm (4.96 in) 156 mm (6.14 in) Measuring points Brake drum Oil or scratches on the inner surface of the brake drum will impair braking performance or result in abnormal noises. Remove oil by jping with a rag soaked in lacquer thinner or solvent. Remove scratches by lightly and evenly rubbing fh emery cloth. Replacing wheel bearings If the bearings allow excessive play in the wheel or if it does not turn smoothly have 64~s9- "WId our Ul 8]0Y e421 JO Ja]U90 a4} Ul Ajaienbs si Ways ayi 2eYy} Bins eyYeW O} YI9Y9 ‘WI ay OJUO Peddijs Ajezajdwoo uaaq sey aun ay) Jaye iyi ‘os|y *Ajquiasseaa yy enulUCD pue Je ay} aseajey “Isixa yYyBiwW yey? saseaio Aue SaAoWlad SIU] “AN BY} aiejju] “WIA ayy OJUO Paddijs Ajeqejduioo uaaq sey aly ay} au0yaq ing ‘pajjejsul uaeq sey aqn) aur Jaye 1YyBid 8g P|noM ainpasoid ul souaayyip AjuO ayy “aanpado.d Ajquiassesip au Buissanas Ag paysi|d -woo9e aq ued Ajquuasse a1} 94} Bul||e]sU!-3y 241} Buryye3suy abpe wis awles 84} 440 241) ay} BuIr40M Aq jeAoWaL aL ysiuly Uay? ‘Jjes}! 2413 ayy BuiGueyo ase NOA 4) t3.LON “ajoy wis ayy 0} INO yoeq a1 Burysnd ayiym ways ay} abewep 01 30U |njaseo AJaA ag "INO eqn? ayy dis ueo noA usu} ‘wid ay} yyo Ajajajdwos a4. ay2 JO apis BuO pax1OM aAeYy NOA sayy “y ‘sly Op NOA se aqni ayy ‘Buryouid Plone 0} aueo aye] “Was 9qn} ay) a11soddo 2081 Suizieys ‘wii ayz yo aBpa ay} 41800 peag ai! ay2 440M 0} ulbaq pue (sabpa Papunos YM) suo! |eAOWAL a4]2 OM} ASF) "ES "JOO, INOA YUM a4} Ud Buiddays Aq (sepis yioq) wid wo. peaq aly aqeredes ‘aqn} jo"yno si se |e Vay 'Z ‘sinu 490] Wid pue ‘yNU >90] Was @AJEA ‘8109 ABAJEA ‘ded AAJeA BAOLUAY “| jeaowas out) ‘asn yoea asojaq payxseyo aq Pinoys seyods ey] “way} eoejdes 40 uaiYybI) *juaq 10 asoo] ase Aayi 4) ‘saxods ayi 49949 sayods “4ajeap eyewe, e Aq auop aq pjnoys pue sjo0} jeIdads $0 asn ayy sasinbar jUewasejdes Buleeg ‘sBuleaq =jaayM ay} adejdas sajeap 4noATire pressure: Front ..... 0.9 kg/cm? (13 Ib/ir?) Rear ....... 1.1 kg/em? (15 Ib/in?) Checking rims and spokes (Front & rear wheels) 1. Checking for loose spokes Loose spokes can be checked by bracing the machine off the ground so that the front wheel can spin freely. Slowly rotate the front wheel and at the same time let the metal shaft of fairly heavy screwdriver bounce off each spoke. If all the spokes are tightened approximately the same then the sound given off by the screwdriver itting the spokes should sound the same. If one spoke makes a dull flat sound, then check it for looseness. 2. Checking rim “run-out’’ While you have the machine up, check the front wheel run-out. “Run-out” is the amount the front wheel deviates from a straight line as it spins. Secure the front forks to keep them from turning. Set up a dial indicator or solidly anchor a pointer about 3 mm (0.12 in) away from the side of the rim. As the wheel spins, the dis- tance between the pointer and the rim should not change more than 2 mm (0.079 in) total. Any greater fluctuation means that you should remove this rim warpage by properly adjusting the spokes. Run-out limits: 2 mm (0.079 in) 66 —Eo maios UIEIQ "tL (20 Sp'g) 99 0SZ 36a) sad Ayueno 404 BYEUE A papuawwosay “Ba] yore ou! JO JUNOWe 3981109 asnseal|| *G 4nod pue “8j0y Ulesp Yea Japun JauleU0d Usdo YIM “pabeuiep 41 e0e|dau ‘s}ayse6 90U9 qn} 4a}NO Yoke WO. Masos UIeIP BAOQWAY 'Z '10N "saqn} 40} JauU! UO sijoq deo eaowel “‘puejs awey ajqeiins e YIM J1OO}} ay) JJO “mass ulep a0e|day “fy —pasjer 410 panowias Je24M JOY ay. YUM'L “yo Bur eBseyd j!0 440} JUOIy -ulewa4 {no duund 0} saqn} Je3no Jamo; pue asjed Aj mojs ‘pauleip sey 10 Jo sow JeuY"E GW3H ONINAILS GNV SYHO4 LNOWS6. After ing, slowly pump the outer tubes up and down to distribute the oil. 7. Inspect O-ring on fork cap bolts and re- place if damaged. —68 — 8. Replace fork cap bolts and torque to specification. Fork cap bolt torque: 2.5 m-kg (18 ft-lb) Steering head adjustment 1. With front wheel elevated, grasp bottoms of fork legs and gently push and pull to check steering head freeplay. There should be no noticeable freeplay. = 2. To adjust, first loosen upper stem pinch bolt.et6pis ‘yepld aya $0 1YyBIeM ay2 JO asinoo Buloes e JO SUOI|PUCd ay} 0} Buipsoose payoajas aq pinoys edAy sedoid y “pjos aue sBuluds 4404 JUO4 adA} Ua ~JOLUIP OM) ‘AdA} Psepuels B42 O} UO!ITIPPe U] juawiesejdes Bulids 410} }U014 ‘sarap eyewe A InoA Aq Pewojied aq isn Ajquiassesip peay Bulsea1g t3.LON (Qi BOL) By-wW gL veanbsoz 3J0q yYyould was ads 0} enbo} “uoleo pue uMmoJd x10} 3e s}10q Yyould uazYBbIL ‘9 (Q-Y Zep) Sy 0'9 ‘anbio} }J0q waIs suoneo j9ads 0} anbso} pue 3j0q ways uazYybI) “G youaim nu Buy “¢, woquiais Z — yoqusuig “L “Bulysqeo 40 Buipuig 3no “YUM 390] 0} 490] WOsy BuIMs ysnU $404 'NOLLNVWS “pejeuuja si Aejdeasy jizun uezYyB1) "mnu ysnfpe uazy6i2 0} youedm nu Buls asp “y “yoq wWa}s Uasoo] “E"1D. marking can be found seared on the top of he song ed REAR SHOCK (MONOCROSS SUSPENSION “DE CARBON” SYSTEM) AND SWING ARM General features: This rear shock absorber, a recent Yamaha development, is of the nitrogen gas enclosed “De Carbon” type. The main features are: 1. The damping performance can be adjusted. 2. The spring fitting load can be adjusted freely. 3. Application of the thermal compensator greatly helps improve fading resistance. These noteworthy improvements have greatly contributed to the improved performance of the shock absorber. WARNING: READ CAREFULLY — This shock absorber contains highly com- pressed nitrogen gas. Read and understand the following informa- tion before handling the shock absorber. The manufacturer cannot be held responsible for Property damage or personal injury that may result from improper handling. 1.Do not temper with or attempt to open the cylinder assembly. Injury may result. 2. Do not subject shock absorber to an open frame or other high heat. This may cause the unit to explode due to excessive gas pressure. 3. Do not deform or damage the cylinder in —~70—ie “J2Q4M Jess BY} BAOWAL PUY “}t @AOwal puke 4Ue} ayy yO JUOY ay dn YT “(440 pawn aq snus Jena] 49093ed) Ue} lang 942 Buipjoy sijoq omy ay} arowiay ‘1 Jeaowies (uoisuadsns ssos20U0W) Jeqsosqe 4yOOYS 4eey “ainpecoid yesodsip siy2 40) sajeap eyewieA 4noA 0} JUN aly aye) ‘saquosqe o0Yys JNOUIOM JO pabewep e 40 asodsip OL [ONINYVM lwonsei01d oho seem, fr (ut 09°0- ov'0) wu st - OL “sdiyd Jejaw 40/pue se6 Buidessa wo. abewep ado quanesd 0} UO!JaIOI1d aha JeaM ‘AUT SIUI IY “sapuljAd ay} JO WO}0g ayi anoge WW GL-OL quiod e 3e jjem sapuljAd ayi yBnosy2 ajoy WW €-Z B |jlIp ‘Os Op OJ ‘Jaqsosqe yOOUS JO Jesodsip auojaq paseajas aq ysnw ainssaid sed, (Ajuo suajeap eyewe,) jesodsip uo sajoK) ynses Aew Ainfuy ‘wox0q depuljAD ay} uo Gnjd ayy arowes s2areny “G ‘aBeyeay [10 asneo [jm uoljiod Bulpljs pos uojsid ayy ut yoxesos 4O 9409S e 40} ‘aueo yeauB YM WY a]puey “y “souewuojiad Guidwep 100d ul 3jnsed jl eBewep JapuljAg “Aem Aue2. Remove the cotter pin and nut. Remove the bolt securing the upper bracket to frame. 3. Remove the cotter pin and pull out the pivot shaft from the lower bracket. NOTE: Put a proper support under the engine to keep the machine from falling over. 4. Remove the rear shock absorber from the frame. (To remove, pull the rear shock backward while ing up the frame.) NOTE: a. When removing the shock absorber, be careful not to bend the absorber rod. b. Take care so the two washers are not lost. Adjustment When bottoming feels excessive and too soft: a. Increase the spring pre-load b. Make damping performance fer When springing feels excessive and too hard: —72-——eL— “awedy B42 JO APIS Jaye UO YORE 8UO paplAosd ajoy ay? YBnosy) JaALpMmaios Peay-paxojs e YUM Joysnipe ey UNL “daquosqe 490ys ay) Bul “AOWAs INOYM ape aq ued JUaWIsnIpy aouewsoyied. Buidwep Bulbuey9 *Z (ur SOL) uu ¢"192 ————. eseei9eg “py asearouy “¢. anu Bunsnipy -z ynuyoo7 *1 } (ut y°0) wu OL 2® “s}uul] aaoge ayz IM 3sn[pe O} euns ag “WW g'9gz (WNnuUIW) pue Ww g*L7Z (winuuixewW) s| 3ua}xa ajqeisnipy “WW GL 9% 404 Jas st ybua] Buy jeru] ?3.LON (41-4 €y) 6>-wW o'g :anbio} Buyuarybi “ynu90] ay} uaIYBI] 9 “soysn{pe 841 LNO Maids ‘peojaid aseaioap of “40} -sn[pe ay3 Nj] Mass ‘peojaid aseauou! Of 'G “Inux90] JOIsN{[pe ay} uasoo7 “e *(1P] 100} s,tauMO ayi ul) YousuM leioads e YA jUaUNIsN[pe siu WOyeg peojaid Buyids uoisuadsns BuiBueyd "1 4aqjos aouewWJojsed Bujdwep aye, *q peoj-aid Burids 8y} aseaisag “ea.To make it stiffer, screw IN the adjustor. b.To make it softer, screw OUT the adjustor. Make notch by notch adjustment and test it by riding after each adjustment. NOTE: Turn the adjustor. unti Maximum (Minimum) extent can be known by the po: in where turning suddenly feels heavy (light). Do not give any more turns. 1. Alignment mark (Yellow paint) 3. Gas pressure The gas pressure can be adjusted. For this adjustment, take the unit to your Authorized Yamaha dealer. Rear shock spring “B’ replacement In addition to the standard type, two differ- ent type rear shock springs are sold. A proper type should be selected according to the conditions of a racing course or the weight of the rider. =74——s2— “Bulysng wie Buims aoejdes pue uue Bums anowa ‘anissaoxa si Aejdeayy 4) ‘Z (Ul yO'0 - 0) Wu L -O :Aejdaais wie Buims “Aeld 881} JO} D9YO 0} 349] 0} 2YB14 Woy aAow Pue wue ay) jo spua ay dseib ‘panow 841 Sdaquosqe 490Ys pue jaayA Jeal YUM ‘L uonsadsur wie Buimg “g pue vy Buiids jo uoljeulquios ay} UO paseq si anoge paijioads ajes Bulsds ayt ‘7 “Bulids ayi JO pua ay} UO UMOYs SI 40]09 apo "| ‘LON 81'9 =2% ‘ Ped aoe =11 78706" 10S06 wus gL'9=24 7 enia LEE=DI OZpS8-10S06 | PsepueIsS B19 =24 ‘| Mona foesiy | £8P08-10906 aos poo sojog | (UNI ITE | oN seg OdALELECTRICAL General information The IT250D/400D use a flywheel magneto to generate electrical current/voltage for the lighting system and uses CDI system for ignition. There are two coils attached to the magneto backing plate. The righthand coil supplies primary voltage to the ignition coil. The lefthand coil provides alternating current (AC) for operation of the lights. NOTE: If headlight filament burns out while engine is running, the tail lamp filament may also burn out because of excess voltage. Always light operation when replacing head- —~76—0 sone aioos WVYSVIG LINDYIDLIGHTING SYSTEMS Description The lighting system consists of the lighting coil, headlight and taillight. Lighting coils in the flywheel magneto supply alternating current (A.C.) for the headlight, and taillight. WARNING: Use bulbs of the correct capacity for the headlight, and taillight which are directly connected to the flywheel magneto. If large capacity bulbs are used, the voltage will drop, giving a poor light. On the contrary, if smaller capacity bulbs are used, the voltage will rise, shortening the life of bulbs. When the headlight beam switch is operated to change the beam from one to another, the headlight is designed to keep both bulbs burning during the change over. This is to protect other light bulbs from burning out as a result of turning off the head light, even temporarily. If one of these light bulbs is burnt out while the machine is running, it will overload other bulbs and shorten their service life. Reduce engine speed and replace a burnt bulb as quickly as possible. A.C. circuit output test With all A.C. light in operation the circuit will be balanced and the voltage will be the same at all points at a given r.p.m. 1. Switch Pocket Tester to “AC20V" posi- tion. 2. Connect positive (+) test lead to Red/- Yellow connection and negative (—) test lead to a good ground. 3. Connect Engine speeds meter. 4. Start engine, turn on lights switch and check voltage at each engine speed in table below. =js=—6L— “a}eos swyO UO aouelsisal ayy peay ‘eujbua Uo punoib pooh e 0} pea] isa} (—) eaijeBeu pue oxauBew wo1 au MO}|BA, -/P8Y O} pea] jse} (+) anliIsod yaUUOD ‘Z ‘490 0402 pue uolsod ,,, X U,, 0} 42388} Jeyx90d YoUMS “1 oo Bulzy61) ay2 yo sbuipuim 341M Pa1-MO||9A ay} JO aoueIsIse1 ay} 49849 ‘Unowo Buiyybiy “Q"y ul yass0oU! st aBeqOn 4) ayo soue}sIsad 9 Gunysiz wd1 000° / ss2] 10 AOL GOOPLI wd4 909'z / sow 40 AQ'g GOgZ_LI :a6e1j0a ynding. Wnow9 Bunybi] “O"y ay2 INnoYyBnoiy? abe} 00} a4e salioeded qing 40 sqing no pausing ‘sem pabewep ‘suol39auu02 peq 4O} 9aYo ‘Mo| 00} 40 y61y 00} s} abeyjOn painseaw 4} Jarsar 40 aim pea} annisog “py eam pea] anneGen “9 ub {uonisod wer pue 1461) Peay OL “E Az “O'V Ul sarse3 yorauuog Z B43 19g) 48388} 1ay90q “Gg 1109 Bun y6r MOLIOA/POH :A/H “aaoge Palyloads se ewes ay} aq pjnoys sbulpeas ayi pue ynou19 Buys, “O"y ay2 inoybnoiyr qulod Aue je apew aq ued js} ABeIOA siyL t.LON s_ Burzy61; ayz uiny 0} auns ag EEE eee ae OwTOOTH OO et, 1©8 RIY: Red/Yellow Lighting coil Connector Positive lead wire of tester Negative lead wire Pocket tester (Set the tester “Resistance” position) Troubleshooting 1. Check for spark at spark plug — if no spark, check connectors. 2.1f connections are clean and tight, refer to Mechanical Adjustments, Ignition Timing. Ensure that the timing is correct. Any further troubleshooting of the C.D.I. system must be performed by your Yamaha Dealer. Lighting coil resistance: IT250D : 0.390 4 10% at 20C IT400D : 0.532 + 10% at 20°C —80—T T - Tome ieee Boa 91-Lov1. $7£00184 zee00184 adh OL-0ss8-60s | + | oz-opsse-pmi | Lz-orsse-zwi Nid o pa a eo | wo-BxgL | » | qwo-6y8e | wo- 640g lentuau! yo wawoW “ 1Z-00LW zeiseLes Leiseles zLoseLes ada 01-008S8-EMI | Oz-009G8-PML | Oz-oOSSE-SML | Oz-00Sg-9ML Nid Joos sau) | | ororteing | orsusew'ia9 aoszzA | aoarza aosz.Lt door Li 09 Buln yb) ® WIM Papiaoid you Ss! 11 IeYI Jdaoxe GOGZI se ojeubew |qQ awes ay} sey GO0rZA “GOSZLI 243 02 parjdde aq youues QooPZA eu} 4OJ UOHeUIquIOD ayy jeYyr ‘JaAamoy “payou aq pjnoys 3} ‘sauuew siya ul paulquiod yes e se ajqeabueyoiaju! aie Aayy pue ‘mo|aq Palsi| Se UOIeUIqUIOD e ul Japow yoea UO paljeqsul ase yun |GO pue oysubew 1qQQ ojeubew 1qQ “Adessa09U a484M a9UAsaJa1 INOA 104 AyigqeeBueyoiaru! siyi surejdxa Buimoyjoy ayy “sjapow LG/ZA uo pasn Ai|!qeabueysiequ! aq ued GOOP /QOEZL! Woy uolssiusues pue oaubew |GD NOISSINSNVYL CNV OLSNDVW 109 430 ALIMIGVSDNVHOYSLNIIgnition Timing 1. Change from outer to outer roter type a, Using the timing mark on the crankcase, follow the procedure for ignition timing on page 29. b. Apply the same circuitry as on the 1T400D or YZ400D wiring diagram. 2. Change from outer to inner rotor type a. When an inner roter type is installed, align the timing marks on the starter and rotor as originally specified. b. Apply the same circuitry as on the YZ 250D wiring diagram. c. Although the ignition coil is inter- changeable, use of the same brand is recommended, (P/N 565-82310-10) NOTE: For routing of the lead wires, please contact your nearest Yamaha dealer. Transmission The following table shows the transmission gear ratio for each model in the YZ, IT and DT series, and wheel gear and pinion gear (main axle) are interchangeable as a set for varied speeds. Also, transmission ass'y is interchangeable for all from A through E. ed = @ ° e ese! rracoo | vz2s00 | or2sc0 | orso00 sore an Hesteteme | sane | sana | anne | Sommer | sare * [iin ae - nee ana me | pony | commen | zene | sano | Sommen ae ‘ ane 28 eer] 7620 | Comms | aeren | Sones | Soest ae inion ae ™ von [emote ont oan | Carmee | carmen | Cones | commen om avs | zone | auze | commer | commen The drive axle is common for all from A through E. —82—