Yamaha TTR250L User manual

SERVICEMANUAL
LIT-11616-12-57 5GF-28197-E0
TTR250L(C)

TTR250L(C)
SERVICE MANUAL
1999 by Yamaha Motor Corporation, U.S.A.
1st edition, January 1999
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.S.A.
LIT-11616-12-57

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 one manual, so it is assumed that anyone who uses this book to perform mainte-
nance and repairs on Yamaha motorcycles has a basic understanding of the mechanical ideas
and the procedures of motorcycle repair. Repairs attempted by anyone without this knowl-
edge are likely to render the motorcycle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications
and significant changes in specifications or procedures will be forwarded to all authorized
Yamaha dealers and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or
death to the motorcycle operator, a bystander or a person inspecting or
repairing the motorcycle.
A CAUTION indicates special precautions that must be taken to avoid
damage to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:

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. Comprehensive explanations of all installa-
tion, removal, disassembly, assembly, repair and inspection procedures are laid out with the
individual steps in sequential order.
PAGE FEATURES
The circled numbers below refer to the features indicated in the sample page.
1: An abbreviation and symbol in the upper right corner of each page indicates the current
chapter.
2: The current section title is shown at the top of each page.†
3: Sub-section titles appear in smaller print than the section title.†
4: Lines of asterisks (*) mark the beginning and end of a particularly important procedure.
The steps of such procedures are marked with bullets (•).
5: Important information such as fluids, special tools and torques are framed and marked
with a corresponding symbol.
6: A circled number refers to an illustrated part.
7: A circled lower case letter refers to an illustrated dimension or alignment mark.
8: An upper case letter in a box refers to other illustrated details.
9: An arrow mark after a given defect suggests the recommended course of action.
† : In Chapter 3, “Periodic Inspection and Adjustment”, it is usually the current sub-section
title that appears at the top of each page, instead of the current section title.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each disassembly section.

12
34
56
78
90
AB
CDE
FGH
IJK
LM
GEN
INFO SPEC
INSP
ADJ ENG
CARB CHAS
–+
ELEC TRBL
SHTG
T
R
.
.
GM
E
BLS M
LT New
EB003000
ILLUSTRATED SYMBOLS
Illustrated symbols 1to 8are printed on
the top right of each page and indicate the
subject of each chapter.
1General information
2Specifications
3Periodic inspections and adjustments
4Engine overhall
5Carburetor
6Chassis
7Electrical
8Troubleshooting
Illustrated symbols 9to Eare used to
identify the specifications appearing in the
text.
9Filling fluid
0Lubricant
ASpecial tool
BTorque
CWear limit, clearance
DEngine speed
EΩ, V, A
Illustrated symbols Fto Kin the exploded
diagrams indicate the types of lubricants
and lubrication points.
FApply engine oil
GApply gear oil
HApply molybdenum disulfide oil
IApply wheel bearing grease
JApply lightweight lithium-soap base grease
KApply molybdenum disulfide grease
Illustrated symbols Lto Min the exploded
diagrams indicate where to apply a locking
agent Land when to install a new part M.
LApply the locking agent (LOCTITE)
MReplace

TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS
SPEC 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
ENGINE
ENG 4
CARBURETOR
CARB 5
CHASSIS
CHAS 6
ELECTRICAL SYSTEM
ELEC 7
TROUBLESHOOTING 8
GEN
INFO
CHK
ADJ
–+
TRBL
SHTG

CONTENTS
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION ................................................................ 1-1
VEHICLE IDENTIFICATION NUMBER ................................................. 1-1
ENGINE SERIAL NUMBER .................................................................. 1-1
IMPORTANT INFORMATION ...................................................................... 1-2
PREPARATION FOR REMOVAL AND DISASSEMBLY ...................... 1-2
ALL REPLACEMENT PARTS ................................................................ 1-3
GASKETS, OIL SEALS, AND O-RINGS ............................................... 1-3
LOCK WASHERS/PLATES AND COTTER PINS .................................. 1-3
BEARINGS AND OIL SEALS ................................................................ 1-3
SPECIAL TOOLS .......................................................................................... 1-4
FOR TUNE UP ...................................................................................... 1-4
FOR ENGINE SERVICE ......................................................................... 1-5
FOR CHASSIS SERVICE ....................................................................... 1-6
FOR ELECTRICAL COMPONENTS ...................................................... 1-7
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS ....................................................................... 2-1
MAINTENANCE SPECIFICATIONS ............................................................. 2-4
ENGINE ................................................................................................. 2-4
CHASSIS ............................................................................................. 2-12
ELECTRICAL ....................................................................................... 2-16
GENERAL TORQUE SPECIFICATIONS ..................................................... 2-18
LUBRICATION POINTS AND LUBRICANT TYPES ................................... 2-19
ENGINE ............................................................................................... 2-19
CHASSIS ............................................................................................ 2-20
LUBRICATION DIAGRAM .......................................................................... 2-21
CABLE ROUTING ....................................................................................... 2-24

CHAPTER 3.
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION ........................................................................................... 3-1
PERIODIC MAINTENANCE/LUBRICATION ................................................ 3-1
SEAT, FUEL TANK AND COVERS .............................................................. 3-3
REMOVAL ............................................................................................. 3-3
INSTALLATION .................................................................................... 3-4
ENGINE ......................................................................................................... 3-6
VALVE CLEARANCE ADJUSTMENT .................................................. 3-6
TIMING CHAIN ADJUSTMENT ......................................................... 3-13
IDLING SPEED ADJUSTMENT .......................................................... 3-13
THROTTLE CABLE FREE PLAY ADJUSTMENT ............................... 3-14
SPARK PLUG INSPECTION ............................................................... 3-15
IGNITION TIMING CHECK ................................................................. 3-17
COMPRESSION PRESSURE MEASUREMENT ................................ 3-18
ENGINE OIL LEVEL INSPECTION ..................................................... 3-19
ENGINE OIL REPLACEMENT ............................................................ 3-20
OIL PRESSURE INSPECTION ............................................................ 3-24
CLUTCH ADJUSTMENT .................................................................... 3-24
AIR FILTER CLEANING ...................................................................... 3-25
SPARK ARRESTER CLEANING ......................................................... 3-27
CRANKCASE BREATHER HOSE INSPECTION ................................. 3-28
FUEL LINE INSPECTION .................................................................... 3-28
EXHAUST SYSTEM INSPECTION .................................................... 3-28
CARBURETOR JOINT INSPECTION ................................................. 3-28
CHASSIS ..................................................................................................... 3-29
FRONT BRAKE ADJUSTMENT ......................................................... 3-29
REAR BRAKE ADJUSTMENT ............................................................ 3-29
BRAKE FLUID LEVEL INSPECTION ................................................... 3-31
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) .............................. 3-32
BRAKE PAD INSPECTION ................................................................. 3-33
BRAKE HOSE INSPECTION ............................................................... 3-34
DRIVE CHAIN SLACK ADJUSTMENT ............................................... 3-34
DRIVE CHAIN LUBRICATION ............................................................ 3-36
STEERING HEAD ADJUSTMENT ..................................................... 3-36
FRONT FORK INSPECTION ............................................................... 3-38
1
SPEC 2
3
ENG 4
CARB 5
CHAS 6
ELEC 7
8
GEN
INFO
INSP
ADJ
–+
TRBL
SHTG

FRONT FORK ADJUSTMENT ............................................................ 3-39
REAR SHOCK ABSORBER ADJUSTMENT ....................................... 3-41
TIRE INSPECTION .............................................................................. 3-43
WHEEL INSPECTION ......................................................................... 3-46
SPOKES INSPECTION AND TIGHTENING ....................................... 3-46
CABLE INSPECTION AND LUBRICATION ........................................ 3-46
LEVER AND PEDAL LUBRICATION .................................................. 3-47
SIDESTAND LUBRICATION .............................................................. 3-47
ELECTRICAL ............................................................................................... 3-48
BATTERY INSPECTION ..................................................................... 3-48
FUSE INSPECTION ............................................................................ 3-54
HEADLIGHT BEAM ADJUSTMENT .................................................. 3-56
HEADLIGHT BULB REPLACEMENT .................................................. 3-56
CHAPTER 4.
ENGINE OVERHAUL
ENGINE REMOVAL ...................................................................................... 4-1
SEAT, FUEL TANK AND COVERS ....................................................... 4-1
CARBURETOR ...................................................................................... 4-1
ENGINE GUARD ................................................................................... 4-1
ENGINE OIL .......................................................................................... 4-1
BATTERY .............................................................................................. 4-2
EXHAUST PIPE ..................................................................................... 4-2
CRANKCASE BREATHER HOSE ......................................................... 4-2
STARTER MOTOR ................................................................................ 4-2
CLUTCH CABLE AND LEADS .............................................................. 4-3
DRIVE SPROCKET ................................................................................ 4-3
FOOTREST AND BRAKE PEDAL ......................................................... 4-4
ENGINE REMOVAL .............................................................................. 4-4
ENGINE DISASSEMBLY .............................................................................. 4-5
CYLINDER HEAD, CAMSHAFTS, CYLINDER AND PISTON .............. 4-5
CLUTCH, OIL PUMP AND BALANCER GEAR .................................... 4-8
SHIFT SHAFT ...................................................................................... 4-10
ROTOR AND STARTER DRIVES ........................................................ 4-10
OIL FILTER .......................................................................................... 4-12
CRANKCASE ...................................................................................... 4-12
BALANCER, TRANSMISSION AND SHIFTER .................................. 4-13
CRANKSHAFT .................................................................................... 4-14
BEARINGS AND OIL SEALS .............................................................. 4-14
VALVE ................................................................................................. 4-14

INSPECTION AND REPAIR ........................................................................ 4-16
CYLINDER HEAD ................................................................................ 4-16
VALVE SEAT ....................................................................................... 4-16
VALVE AND VALVE GUIDE ............................................................... 4-20
VALVE SPRING .................................................................................. 4-21
CAMSHAFT ........................................................................................ 4-22
VALVE LIFTER .................................................................................... 4-24
TIMING CHAIN, SPROCKET AND CHAIN GUIDE ............................ 4-24
CYLINDER AND PISTON ................................................................... 4-25
PISTON RING ..................................................................................... 4-27
PISTON PIN ........................................................................................ 4-27
CRANKSHAFT .................................................................................... 4-28
BALANCER DRIVE GEAR AND BALANCER GEAR .......................... 4-29
PRIMARY DRIVE ................................................................................. 4-30
CLUTCH .............................................................................................. 4-30
TRANSMISSION AND SHIFTER ........................................................ 4-31
OIL PUMP AND STRAINER ............................................................... 4-33
ELECTRIC STARTER DRIVE ............................................................... 4-34
CRANKCASE ...................................................................................... 4-35
BEARING AND OIL SEAL .................................................................. 4-35
CIRCLIP AND WASHER ..................................................................... 4-35
ENGINE ASSEMBLY AND ADJUSTMENT ............................................... 4-36
CRANKSHAFT AND BALANCER ....................................................... 4-36
CRANKSHAFT AND BALANCER SHAFT .......................................... 4-37
TRANSMISSION ................................................................................ 4-38
SHIFTER .............................................................................................. 4-39
TRANSMISSION AND SHIFTER ........................................................ 4-40
CRANKCASE ...................................................................................... 4-42
CRANKCASE (RIGHT) ........................................................................ 4-43
SHIFT SHAFT ...................................................................................... 4-43
OIL PUMP ........................................................................................... 4-45
CLUTCH .............................................................................................. 4-46
OIL PUMP ........................................................................................... 4-47
CLUTCH .............................................................................................. 4-47
OIL FILTER .......................................................................................... 4-50
ROTOR AND STARTER DRIVES ........................................................ 4-51
ROTOR AND STARTER DRIVES ........................................................ 4-52
CYLINDER AND PISTON ................................................................... 4-54
CYLINDER AND PISTON ................................................................... 4-55
CYLINDER HEAD ................................................................................ 4-57
VALVE, CAMSHAFT AND CAM CHAIN ............................................ 4-58
VALVE AND CAMSHAFT ................................................................... 4-59
CYLINDER HEAD ................................................................................ 4-61
REMOUNTING ENGINE ..................................................................... 4-63
1
SPEC 2
3
ENG 4
CARB 5
CHAS 6
ELEC 7
8
GEN
INFO
INSP
ADJ
–+
TRBL
SHTG

CHAPTER 5.
CARBURETOR
CARBURETOR .............................................................................................. 5-1
REMOVAL ............................................................................................. 5-2
DISASSEMBLY ..................................................................................... 5-3
INSPECTION ......................................................................................... 5-5
ASSEMBLY ........................................................................................... 5-7
INSTALLATION .................................................................................... 5-9
FUEL LEVEL ADJUSTMENT .............................................................. 5-10
THROTTLE VALVE POSITION ............................................................ 5-11
CHAPTER 6.
CHASSIS
FRONT WHEEL ............................................................................................. 6-1
REMOVAL ............................................................................................. 6-2
INSPECTION ......................................................................................... 6-2
INSTALLATION .................................................................................... 6-5
WHEEL STATIC BALANCE ADJUSTMENT ........................................ 6-6
REAR WHEEL ............................................................................................... 6-8
REMOVAL ............................................................................................. 6-9
INSPECTION ......................................................................................... 6-9
INSTALLATION .................................................................................. 6-10
WHEEL STATIC BALANCE ADJUSTMENT ...................................... 6-11
FRONT AND REAR BRAKE ........................................................................ 6-12
BRAKE PAD REPLACEMENT ............................................................. 6-14
CALIPER DISASSEMBLY ................................................................... 6-18
MASTER CYLINDER DISASSEMBLY ................................................ 6-21
INSPECTION AND REPAIR ................................................................ 6-24
CALIPER ASSEMBLY ......................................................................... 6-26
MASTER CYLINDER ASSEMBLY ...................................................... 6-31
FRONT FORK .............................................................................................. 6-35
REMOVAL ........................................................................................... 6-36
DISASSEMBLY ................................................................................... 6-37
INSPECTION ....................................................................................... 6-38
ASSEMBLY ......................................................................................... 6-40
INSTALLATION .................................................................................. 6-44

STEERING HEAD AND HANDLEBAR ....................................................... 6-46
REMOVAL ........................................................................................... 6-48
INSPECTION ....................................................................................... 6-51
INSTALLATION .................................................................................. 6-52
REAR SHOCK ABSORBER AND SWINGARM .......................................... 6-58
HANDLING NOTES ............................................................................ 6-60
NOTES ON DISPOSAL ....................................................................... 6-60
REMOVAL ........................................................................................... 6-61
INSPECTION ....................................................................................... 6-66
INSTALLATION .................................................................................. 6-68
DRIVE CHAIN AND SPROCKETS .............................................................. 6-72
REMOVAL ........................................................................................... 6-73
INSPECTION ....................................................................................... 6-74
INSTALLATION .................................................................................. 6-75
CHAPTER 7.
ELECTRICAL
TTR250L(C) CIRCUIT DIAGRAM ................................................................. 7-1
ELECTRICAL COMPONENTS ...................................................................... 7-3
CHECKING OF CONNECTIONS .................................................................. 7-5
IGNITION SYSTEM ...................................................................................... 7-6
ELECTRICAL STARTING SYSTEM ............................................................ 7-12
STARTING CIRCUIT OPERATION ..................................................... 7-13
STARTER MOTOR .............................................................................. 7-19
CHARGING SYSTEM ................................................................................. 7-23
LIGHTING SYSTEM ................................................................................... 7-26
LIGHTING SYSTEM CHECK .............................................................. 7-29
1
SPEC 2
3
ENG 4
CARB 5
CHAS 6
ELEC 7
8
GEN
INFO
INSP
ADJ
–+
TRBL
SHTG

CHAPTER 8.
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING ..................................................... 8-1
FUEL SYSTEM ...................................................................................... 8-1
ELECTRICAL SYSTEM ......................................................................... 8-1
COMPRESSION SYSTEM .................................................................... 8-1
POOR IDLE SPEED PERFORMANCE .......................................................... 8-2
POOR IDLE SPEED PERFORMANCE ................................................... 8-2
POOR MEDIUM AND HIGH SPEED PERFORMANCE ................................ 8-2
POOR MEDIUM AND HIGH SPEED PERFORMANCE ........................ 8-2
FAULTY GEAR SHIFTING ............................................................................ 8-3
HARD SHIFTING ................................................................................... 8-3
SHIFT PEDAL DOES NOT MOVE ........................................................ 8-3
JUMP-OUT GEAR ................................................................................ 8-3
CLUTCH SLIPPING/DRAGGING ................................................................. 8-3
CLUTCH SLIPPING ............................................................................... 8-3
CLUTCH DRAGGING ........................................................................... 8-3
OVERHEATING ............................................................................................ 8-4
OVERHEATING ..................................................................................... 8-4
FAULTY BRAKE ........................................................................................... 8-4
POOR BRAKING EFFECT ..................................................................... 8-4
FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION .......... 8-4
OIL LEAKAGE ....................................................................................... 8-4
MALFUNCTION .................................................................................... 8-4
INSTABLE HANDLING ................................................................................. 8-5
INSTABLE HANDLING ......................................................................... 8-5
FAULTY SIGNAL AND LIGHTING SYSTEM ............................................... 8-6
HEADLIGHT DARK ............................................................................... 8-6
BULB BURNT OUT ............................................................................... 8-6
TTR250L(C) WIRING DIAGRAM

GEN
INFO
1 - 1
MOTORCYCLE IDENTIFICATION
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1is
stamped into the right side of the steering
head.
NOTE:
The vehicle identification number is used to
identify your motorcycle and may be used
to register your motorcycle with the licens-
ing authority in your state.
ENGINE SERIAL NUMBER
The engine serial number 1is stamped
into the elevated part of the right rear sec-
tion of the engine.
NOTE:
●The first three digits of these numbers are
for model identifications; the remaining
digits are the unit production number.
●Designs and specifications are subject to
change without notice.
1

1 - 2
GEN
INFO
IMPORTANT INFORMATION
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1.Remove all dirt, mud, dust, and foreign
material before removing and disassem-
bling.
2.Use proper tools and cleaning equipment.
Refer to “SPECIAL TOOLS”.
3.When disassembling the motorcycle keep
mated parts together. This includes gears,
cylinder, piston and other mated parts
that have been “mated” through normal
wear. Mated parts must be reused as an
assembly or replaced.
4.During the motorcycle disassembly, clean
all parts and place them in trays in the
order of disassembly. This will speed up
assembly time and help assure that all
parts are correctly reinstalled.
5.Keep away from fire.
1

1 - 3
GEN
INFO
IMPORTANT INFORMATION
ALL REPLACEMENT PARTS
1.Use only genuine Yamaha parts for all
replacements. Use oil and/or grease rec-
ommended by Yamaha for assembly and
adjustment. Other brands may be similar
in function and appearance, but inferior in
quality.
GASKETS, OIL SEALS, AND O-RINGS
1.All gaskets, seals and O-rings should be
replaced when an engine is overhauled.
All gasket surfaces oil seal lips and O-
rings must be cleaned.
2.Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
LOCK WASHERS/PLATES AND COTTER
PINS
1.All lock washers/plates 1and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt
or nut flat(s) after the bolt or nut has been
properly tightened.
BEARINGS AND OIL SEALS
1.Install the bearing(s) 1and oil seal(s) 2
with their manufacturer’s marks or num-
bers facing outward. (In other words, the
stamped letters must be on the side
exposed to view.) When installing oil
seal(s), apply a light coating of light-weight
lithium base grease to the seal lip(s). Oil the
bearings liberally when installing.
CAUTION:
Do not use compressed air to spin the bear-
ings dry. This causes damage to the bear-
ing surfaces.

1 - 4
GEN
INFO
SPECIAL TOOLS
CIRCLIPS
1.All circlips should be inspected carefully
before reassembly. Always replace piston
pin clips after one use. Replace distorted
circlips. When installing a circlip 1, make
sure that the sharp-edged corner 2is
positioned opposite to the thrust 3it
receives. See the sectional view.
4Shaft
SPECIAL TOOLS
The proper special tools are necessary for
complete and accurate tune-up and assem-
bly. Using the correct special tool will help
prevent damage caused by the use of
improper tools or improvised techniques.
FOR TUNE UP
1
Steering nut wrench
P/N. YU-33975
This tool is used to adjust the spring preload
of rear shock absorber.
2
Inductive tachometer
P/N. YU-8036-A
This tool is needed for detecting engine r/min.
3
Inductive timing light
P/N. YM-33277-A
This tool is necessary for checking ignition
timing.
4
Compression gauge
P/N. YU-33223
Adapter (M12)
P/N. YU-33223-3
These gauges are used to measure the engine
compression.
5
Fuel level gauge
P/N. YM-01312-A
This gauge is used to measure the fuel level in
the float chamber.

1 - 5
GEN
INFO
FOR ENGINE SERVICE
1
Piston pin puller
P/N. YU-01304
This tool is used to remove the piston pin.
2
Sheave holder
P/N. YS-01880
This tool is used to hold the rotor when
removing or installing the rotor securing nut.
3
Rotor puller
P/N. 2K7-85555-00
This tool is used to remove the rotor.
4
Universal clutch holder
P/N. YM-91042
This tool is used to hold the clutch when
removing or installing the clutch boss locknut.
5
Crankcase separating tool
P/N. YU-01135-A
This tool is necessary to remove the crank-
shaft.
6
Valve spring compressor
P/N. YM-04019
This tool is needed to remove and install the
valve assemblies.
7
Valve seat cutter set
P/N. YM-91043
This tool is needed to resurface the valve seat.
8
Valve guide remover 5 mm (0.20 in)
P/N. YM-04097
This tool is used to remove the valve guides.
9
Valve guide reamer 5 mm (0.20 in)
P/N. YM-04099
This tool is used to rebore the new valve
guide.
SPECIAL TOOLS

1 - 6
GEN
INFO
SPECIAL TOOLS
10
Valve guide installer 5 mm (0.20 in)
P/N. YM-04098
This tool is needed to install the valve guides
properly.
11
Crankshaft installing set
P/N. YU-90050
These tools are used to install the crankshaft.
12
Adapter (M10)
P/N. YU-90062
This tool is used to install the crankshaft.
13
Crank pot spacer
P/N. YU-01202
This tool is used to install the crankshaft.
FOR CHASSIS SERVICE
14
Quick Gasket
P/N. ACC-11001-05-01
This sealant (bond) is used for crankcase mat-
ing surfaces, etc.
1
Damper rod holder
P/N. YM-01418
This tool is used to loosen and tighten the
damper rod holding bolt.
2
Front fork seal drive weight
P/N. YM-33963-1
Adapter 43 mm (1.69 in)
P/N. YM-8020-2
These tools are used when installing the fork
oil seal.
3
Rod holder
P/N. YM-01434
This tool is used to hold the fork spring.
4
Rod puller attachment (M10)
P/N. 90890-01436
This tool is used to pull up the fork damper
rod.

1 - 7
GEN
INFO
FOR ELECTRICAL
COMPONENTS
7
Drive chain cutter
P/N. YM-33858
This tool is used to cut and join the drive
chain.
5
Rod puller
P/N. YM-01437
This tool is used to pull up the fork damper
6
Cylinder cup installer
P/N. 90890-01996
This tool is used to install the master cylinder
kit.
1
Dynamic spark tester
P/N. YM-34487
This instrument is necessary for checking the
ignition system components.
2
Pocket tester
P/N. YU-03112
This instrument is used for checking the elec-
trical system.
SPECIAL TOOLS