Yamaha YP250 5GM2-AE1 2000 User manual

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
YP250. For complete service information procedures it is necessary to use this Supplementary Ser-
vice Manual together with the following manual.
YP250 SERVICE MANUAL: 4UC-AE1
YP250 (K) ’98 SUPPLEMENTARY SERVICE MANUAL: 4UC-AE2
YP250D ’98 SUPPLEMENTARY SERVICE MANUAL: 5DF-AE1
YP250 2000
SUPPLEMENTARY
SERVICE MANUAL
1999 by Yamaha Motor Co., Ltd.
1999 by MBK Industrie
First Edition, November 1999
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

NOTE:
WARNING
CAUTION:
EB001000 NOTICE
ThismanualwasproducedbytheYamahaMotorCompanyprimarilyforusebyYamaha/MBKdealers
andtheirqualifiedmechanics.Itisnotpossibletoincludealltheknowledgeofamechanicinonemanu-
al, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yama-
ha/MBK scooter has a basic understanding of the mechanical ideas and the procedures of scooter
repair.Repairsattemptedbyanyonewithoutthisknowledgearelikelytorenderthescooterunsafeand
unfit for use.
YamahaMotorCompany,Ltd.iscontinuallystrivingtoimproveallitsmodels.Modificationsandsignifi-
cantchangesin specifications or procedureswillbe forwarded to allauthorizedYamaha/MBKdealers
and will appear in future editions of this manual where applicable.
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!
FailuretofollowWARNINGinstructionscouldresultinsevere injury or deathto
thescooteroperator, a bystanderorapersoninspectingor repairing the scoot-
er.
ACAUTIONindicates special precautions thatmustbe taken to avoiddamage
to the scooter.
NOTE: A NOTE provides key information to make procedures easier or clearer.

1
243
5
6
7
6
8
YP002000 HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1: This is the title of the chapter with its symbol on the upper right corner of each page.
2nd title 2: This title indicates the section of the chapter and only appears on the first page of each
section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa-
nied by corresponding illustrations.
EXPLODED DIAGRAMS
Tohepsidentifypartsandclarifyproceduresteps,thereareexplodeddiagramsatstartofeachremov-
al and disassembly section.
1. An easy-to-see exploded diagram 4is provided for disassembly and assembly jobs.
2. Numbers 5aregivenin the orderofjobsintheexplodeddiagram. A numberthatisenclosedbya
circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
6. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. For jobs requiringmore information, thestep-by-step format supplements 8aregiven in addition
to the exploded diagram and the job instruction chart.

22
1
3
5
7
9
2
4
8
6
24 25
2321
19 2018
16 1715
1413
11 12
10
GEN
INFO SPEC
ENG
CARB
ELECCHAS
COOL
INSP
ADJ
TRBL
SHTG
EB003000
ILLUSTRATED SYMBOLS
Illustrated symbols 1to 9are designed as
thumb tabs to indicate the chapter’s number
and content.
1General information
2Specifications
3Periodic inspection and adjustment
4Engine
5Cooling system
6Carburetion
7Chassis
8Electrical
9Troubleshooting
Illustrated symbols 10 to 17 are used to identify
the specifications appearing in the text.
10 Possible to maintain with engine mounted
11 Filling fluid
12 Lubricant
13 Special tool
14 Tightening
15 Wear limit, clearance
16 Engine speed
17 Ω, V, A
Illustratedsymbols 18 to 23 inthe exploded dia-
grams indicate the types of lubricants and lu-
brication points.
18 Apply engine oil
19 Apply gear oil
20 Apply molybdenum disulfide oil
21 Apply wheel bearing grease
22 Apply lightweight lithium-soap base grease
23 Apply molybdenum disulfide grease
Illustratedsymbols 24 to 25 inthe exploded dia-
gramsindicatethewhere to apply lockingagent
24 and when to install new parts 25 .
24 Apply locking agent (LOCTITE)
25 Use new one

CONTENTS
GENERAL INFORMATION
SCOOTER IDENTIFICATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBER (for E) 1. . . . . . . . . . . . . . .
FRAME SERIAL NUMBER (except for E) 1. . . . . . . . . . . . . . . . . . .
ENGINE SERIAL NUMBER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MODEL LABEL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
GENERAL SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SPECIFICATIONS 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTNING TORQUES 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTNING TORQUES 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION POINTS AND GRADE OF LUBRICANT 15. . . . . . . . .
ENGINE 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE/LUBRICATION INTERVALS 26. . . . . . . .
COVER AND PANEL 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIDE COVER, SIDE COVER MOLE PASSENGER SEAT 28. . . . .
RIDER SEAT AND MAIN BOX 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIDE COVER MOLE AND FOOTREST BOARD 31. . . . . . . . . . . . .
COWLING, HANDLE COVER, METER ASSEMBLY 32. . . . . . . . . .
LEGSHIELD AND FUEL TANK 33. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL REPLACEMENT 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE FILTER CLEANING 35. . . . . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION SYSTEM INSPECTION 36. . . . . . . . . . . . . . . . . . .
COOLANT REPLACEMENT 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT BEAM ADJUSTMENT 40. . . . . . . . . . . . . . . . . . . . . . . .
ENGIVE OVERHAUL
ENGINE REMOVAL 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIREHARNESS, CABLE AND REAR BRAKE 41. . . . . . . . . . . . . . .
HOSES, AIR FILTER CASE, ENGINE MOUNTING BOLT AND
ENGINE 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 46. . . . . .
CRANKCASE FILTER COVER AND CRANKCASE COVER
(LEFT) 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 47. . . .
TRANSMISSION 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION SYSTEM 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE AND CRANKSHAFT 52. . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE REMOVAL 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT REMOVAL 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT INSTALLATION 52. . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM
RADIATOR 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBURETOR
CARBURETOR 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBURETOR DISASSEMBLY 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THROTTLE POSITION SENSOR ADJUSTMENT 58. . . . . . . . . . . .
CHASSIS
FRONT WHEEL 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPEED SENSOR AND SENSOR ROTOR 59. . . . . . . . . . . . . . . . . .
SPEED SENSOR AND THE SENSOR ROTOR 60. . . . . . . . . . . . . .
SPEED SENSOR REMOVAL 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPEED SENSOR AND SENSOR ROTOR INSPECTION 60. . . . .
SPEED SENSOR ASSEMBLY 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WHEEL 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SHOCK ABSORBER AND SWINGARM 65. . . . . . . . . . . . . . . . .
ELECTRICAL
ELECTRICAL COMPONENTS 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING SWITCHES 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH POSITION AND TERMINAL CONNECTION 69. . . . . . . .
CHECKING STEPS 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH CONNECTION AS SHOWN IN THIS MANUAL 70. . . . . .
IGNITION SYSTEM 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRIC STARTING SYSTEM 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTING SYSTEM 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIGNAL SYSTEM 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIGNAL SYSTEM CHECK 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL PUMP SYSTEM 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUT DIAGRAM 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP CIRCUIT OPERATION 90. . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL PUMP 93. . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM

1
SCOOTER IDENTIFICATION GEN
INFO
NOTE:
NOTE:
YP100000
GENERAL INFORMATION
SCOOTER IDENTIFICATION
YP100010
VEHICLE IDENTIFICATION NUMBER (for E)
Thevehicleidentificationnumber 1isstamped
into the right side of the frame.
The vehicle identification number is used to
identify your scooter and may be used to regis-
ter your scooter with the licensing authority in
your country.
YP100020
FRAME SERIAL NUMBER (except for E)
The frame serial number 1is stamped into the
right side of the frame.
EB100030
ENGINE SERIAL NUMBER
The engine serial number is stamped into the
crankcase.
Designs and specifications are subject to
change without notice.
MODEL LABEL
The model label is affixed under the seat.
This information will be needed to order spare
parts.

2
SPECIAL TOOLS GEN
INFO
EB102000
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly.
Use only the appropriate special tools; this will help prevent damage caused by the use of inappropri-
ate tools or improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/Usage Illustration
90890-01135
Crankcase separating tool
90890
-
01135
This tool is used to remove the crankshaft.
Installer pot
90890-01274
Bolt
90890-01275
Adaptor
Crankshaft installer pot/bolt/adapter/spacer
90890-01280
90890-01478
Spacer
90890-01016
90890-01288 These tools are used to install the crankshaft.

3
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model YP250
Model code: 5GM2, 5GM3
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
2,140 mm
,780 mm
1,350 mm
,730 mm
1,535 mm
,120 mm
2,700 mm
Basic weight:
With oil and full fuel tank 168 kg
Engine:
Engine type
Cylinder arrangement
Displacement
Bore stroke
Compression ratio
Compression pressure (STD)
Starting system
Lubrication system:
Liquid-cooled 4-stroke, SOHC
Forward-inclined single cylinder
0.249L (249 cm3)
69.0 66.8 mm
10 : 1
1,400 kPa (14 kg/cm2, 14 bar) at 500 r/min
Electric starter
Wet sump
Oil type or grade:
Engine oil API STANDERD:
SE or higher grade
Periodic oil change
Total amount
Transmission oil
Total amount
1.2 L
1.4 L
0.25 L
Radiator capacity:
Total amount (including all routes) 1.4 L
Air filter:
Carburetor side
Crankcase side Wet type element
Dry type element
Fuel:
Type
Fuel tank capacity Regular unleaded gasoline
12 L

4
GENERAL SPECIFICATIONS SPEC
Model YP250
Carburetor:
Type/quantity
Manufacturer Y28V-1E/1
TEIKEI
Spark plug:
Type
Manufacturer
Spark plug gap
DR8EA
NGK
0.6 X0.7 mm
Clutch type: Dry, centrifugal automatic
Transmission:
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Transmission type
Operation
Single speed automatic
Helical gear
40/15 (2.666)
Helical gear
38/15 (2.533)
Single speed automatic (V-belt type)
Centrifugal automatic type
2.44 X0.83:1
Chassis:
Frame type
Caster angle
Trail
Steel tube underbone
28
103 mm
Tire:
Type
Size front
rear
Manufacturer front
rear
Type front
rear
Tubeless
110/90-12 64L
130/70-12 62L
IRC/MICHELN
IRC/MICHELN
MB67/BOPPER
MB67/BOPPER
Tire pressure (cold tire):
Maximum load-except motorcycle
Loading condition A*
front
rear
Loading condition B*
front
rear
High-speed riding
front
rear
187 kg
0 X90 kg
175 kPa (1.75 kg/cm2, 1.75 bar)
200 kPa (2.0 kg/cm2, 2.0 bar)
90 X205 kg
200 kPa (2.0 kg/cm2, 2.0 bar)
225 kPa (2.25 kg/cm2, 2.25 bar)
200 kPa (2.0 kg/cm2, 2.0 bar)
225 kPa (2.25 kg/cm2, 2.25 bar)
*Load is the total weight of cargo, rider, passenger, and accessories.

5
GENERAL SPECIFICATIONS SPEC
Model YP250
Brake:
Front brake type
operation
Rear brake type
operation
Single disc brake
Right hand operation
Single disc brake
Left hand operation
Suspension:
Front suspension
Rear suspension Telescopic fork
Unit swing
Shock absorber:
Front shock absorber
Rear shock absorber Coil spring/Oil damper
Coil spring/Oil damper
Wheel travel:
Front wheel travel
Rear wheel travel 100 mm
90 mm
Electrical:
Ignition system
Generator system
Battery type
Battery capacity
T.C.I. (Digital)
A.C. magneto
GT7B-4
12 V 6.5 AH
Headlight type: Quartz bulb (Halogen)
Bulb wattage quantity:
Headlight (High)
Headlight (Low)
Auxiliary light
Tail/brake light
Flasher light (Front)
Flasher light (Rear)
Meter light
High beam indicator light
Oil indicator light
Turn indicator light
License light
12 V 60 W/55 W 1
12 V 55 W 1
12 V 5 W 1
12 V 5 W/21 W 2
12 V 21 W 2
12 V 16 W 2
12 V 1.7 W 3
12 V 1.7 W 1
12 V 1.7 W 1
12 V 3.4 W 2
12 V 5 W 1

6
MAINTENANCE SPECIFICATIONS SPEC
1
2
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Cylinder head:
Warp limit  0.05 mm
Cam chain:
Cam chain type/No. of links
Cam chain adjustment method DID SCA-0404A SDH/104
Automatic  
Automatic centrifugal clutch:
Clutch shoe thickness
Clutch housing inside diameter
Clutch shoe spring free length
Weight outside diameter
Clutch – in revolution
Clutch – stall revolution
3.3 mm
135 mm
28.1 mm
20 mm
2,250 2,850 r/min
3,700 4,700 r/min
2.0 mm
135.5 mm

19.5 mm


V-belt:
V-belt width 22.6 mm 21.0 mm
Carburetor:
Type
I.D. mark
Ventuly outside diameter
Main jet (M.J)
Main air jet (M.A.J)
Jet needle (J.N)
Throttle valve size (Th.V)
Pilot air jet (P.A.J.1)
Needle jet (N.J)
Pilot outlet (P.O)
Pilot jet (P.J)
Bypass (B.P)
Pilot screw (P.S)
Valve seat size (V.S)
Starter jet 1 (G.S.1)
Starter jet 2 (G.S.2)
Float height (F.H)
Engine idle speed
Intake vacuum
Oil temperature
Cooling water temperature
Y28V-1E/1
5GM 10
ø28
#128
ø0.9
5D9B-3/5
11
ø1.2
#85
ø0.8
#43
0.7 3
2
1.4
ø0.5
ø0.5
26.5 27.5 mm
1,300 1,500 r/min
29.3 36.0 kPa (220 270 mmHg)
65 75C
80C





















Fuel pump:
Type
Model/manufacturer Electrical
2GV/MITSUBISHI  

7
MAINTENANCE SPECIFICATIONS SPEC
Item Standard Limit
Radiator:
Type
Width/height/thickness
Radiator cap opening pressure
Radiator capacity
Reservoir tank capacity
Cooling fin with electric fan
140/238/24 mm
110 140 kPa (1.1 1.4 kg/cm2,
1.1 1.4 bar)
1.4 L
0.4 L






8
MAINTENANCE SPECIFICATIONS SPEC
TIGHTENING TORQUES
ENGINE
Part to be ti
g
htened Part name Thread
size
Q’ty Tightening
torque Remarks
g
size
y
Nm mkg
Oil check bolt
Exhaust pipe stud bolt
Air induction system pipe stud bolt
Spark plug
Cam sprocket cover
Cylinder head and cylinder
Cylinder head and cylinder
(Cam chain side)
Valve cover
Rotor
Valve adjuster locknut
Cam shaft bearing stopper
Cam sprocket
Cam chain tensioner
(Body)
(Plug)
Guide stopper 2
Water pump housing cover
Hose joint
Thermostatic valve cover
Filler neck supporting
Oil pump
Oil pump cover
Oil strainer cover
Carburetor joint
Carburetor joint and carburetor
Air filter assembly
Air filter cover
Exhaust pipe assembly
Muffler
Muffler and exhaust pipe
Protector (Exhaust pipe)
Protector (Muffler end cap)
Air induction system pipe
Air induction system assembly
Air induction system air filter assembly
Crankcase (left and right)
Drain bolt (Engine oil)
Drain bolt (Transmission oil)
Oil filler
Transmission case cover
Crankcase cover (left)
Crankcase filter cover
Crankcase cover protector
Crankcase cover protector
Magnet cover
—
—
—
—
Bolt
Nut
Bolt
Bolt
Nut
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
—
Bolt
Bolt
Screw
Bolt
Bolt
Bolt
Nut
Bolt
Screw
Nut
Bolt
Bolt
Screw
Screw
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
—
Bolt
Screw
—
M6
M8
M6
M12
M6
M8
M6
M6
M16
M6
M6
M10
M6
M8
M6
M6
M6
M6
M5
M6
M3
M35
M6
M6
M6
M5
M8
M10
M8
M6
M6
M6
M6
M6
M6
M12
M8
M14
M8
M6
M5
M6
M6
M6
1
2
2
1
2
4
2
5
1
2
2
1
2
1
1
3
2
2
1
2
1
1
2
2
2
7
2
3
1
2
3
2
2
2
9
1
1
1
6
8
3
1
3
10
7
13
10
18
10
22
10
10
80
14
8
60
10
8
10
10
7
10
5
7
1
32
10
10
7
1
20
53
14
10
10
12
10
7
10
20
22
3
16
10
1.2
7
7
10
0.7
1.3
1.0
1.8
1.0
2.2
1.0
1.0
8.0
1.4
0.8
6.0
1.0
0.8
1.0
1.0
0.7
1.0
0.5
0.7
0.1
3.2
1.0
1.0
0.7
0.1
2.0
5.3
1.4
1.0
1.0
1.2
1.0
0.7
1.0
2.0
2.2
0.3
1.6
1.0
0.12
0.7
0.7
1.0

9
MAINTENANCE SPECIFICATIONS SPEC
Part to be tightened Part name Thread
size
Q’ty Tightening
torque Remarks
g
size
y
Nm mkg
Cover (oil pump)
Timing check plug
One way clutch
Clutch housing
Grease stopper (Primary sheave)
Primary fixed sheave
Clutch carrier assembly
Stator
Pick up coil
Starter motor
Thermo switch
Thermo unit
Bolt
Plug
—
Bolt
—
—
—
—
—
Bolt
—
—
M6
M16
M8
M14
M4
M14
M36
M6
M5
M6
M18
Pt 1/8
2
1
3
1
4
1
1
3
2
2
2
1
12
8
30
60
3
80
90
10
7
10
23
8
1.2
0.8
3.0
6.0
0.3
8.0
9.0
1.0
0.7
1.0
2.3
0.8

10
MAINTENANCE SPECIFICATIONS SPEC
CHASSIS
Item Standard Limit
Front suspension:
Front fork travel
Fork spring free length
Spring rate (K1)
Spring rate (K2)
Stroke (K1)
Stroke (K2)
Oil capacity
Oil level
Oil grade
Inner tube vend limit
100 mm
268 mm
4.82 N/mm (0.49 kg/mm)
8.84 N/mm (0.9 kg/mm)
0 40 mm
40 100 mm
0.142 L (142 cm3)
80 mm
Fork oil 15 WT or equivalent


263 mm







0.2 mm
Rear suspension:
Shock absorber stroke
Spring free length
Spring rate (K1)
(K2)
(K3)
Stroke (K1)
(K2)
(K3)
106 mm
262 mm
7.57 N/mm (0.77 kg/mm)
14 N/mm (1.43 kg/mm)
26.39 N/mm (2.69 kg/mm)
0 40 mm
40 70 mm
70 106 mm

257 mm






Rear disk brake:
Type
Disc outside diameter thickness
Pad thickness
Master cylinder inside diameter
Caliper cylinder outside diameter
Brake fluid type
Single
230 5 mm
5.3 mm
11 mm
22.2 mm 2
DOT #4


0.8 mm



Brake lever:
Brake lever free play (front at lever
side)
Brake lever free play (rear)
Throttle cable free play
2 5 mm
2 5 mm
3 5 mm


