Мануал yamaha wr250f 2001

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Page: 1

EC010010
WR250F(P)
OWNER’S SERVICE MANUAL
©2001 by Yamaha Motor Co., Ltd.
1st Edition, September 2001
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan

Page: 2

EC020000
INTRODUCTION
Congratulations on your purchase of a
Yamaha WR series. This model is the culmina-
tion of Yamaha’s vast experience in the pro-
duction of pacesetting racing machines. It
represents the highest grade of craftsmanship
and reliability that have made Yamaha a
leader.
This manual explains operation, inspection,
basic maintenance and tuning of your
machine. If you have any questions about this
manual or your machine, please contact your
Yamaha dealer.
NOTE:
As improvements are made on this model,
some data in this manual may become out-
dated. If you have any questions, please con-
sult your Yamaha dealer.
WARNING
PLEASE READ THIS MANUAL CAREFULLY
AND COMPLETELY BEFORE OPERATING
THIS MACHINE. DO NOT ATTEMPT TO
OPERATE THIS MACHINE UNTIL YOU
HAVE ATTAINED A SATISFACTORY
KNOWLEDGE OF ITS CONTROLS AND
OPERATING FEATURES AND UNTIL YOU
HAVE BEEN TRAINED IN SAFE AND
PROPER RIDING TECHNIQUES. REGULAR
INSPECTIONS AND CAREFUL MAINTE-
NANCE, ALONG WITH GOOD RIDING
SKILLS, WILL ENSURE THAT YOU SAFETY
ENJOY THE CAPABILITIES AND THE RELI-
ABILITY OF THIS MACHINE.

Page: 3

IMPORTANT NOTICE
THIS MACHINE IS DESIGNED STRICTLY
FOR COMPETITION USE, ONLY ON A
CLOSED COURSE. It is illegal for this
machine to be operated on any public street,
road, or highway. Off-road use on public lands
may also be illegal. Please check local regula-
tions before riding.
1. THIS MACHINE IS TO BE OPERATED
BY AN EXPERIENCED RIDER ONLY.
Do not attempt to operate this
machine at maximum power until you
are totally familiar with its character-
istics.
2. THIS MACHINE IS DESIGNED TO BE
RIDDEN BY THE OPERATOR ONLY.
Do not carry passengers on this
machine.
3. ALWAYS WEAR PROTECTIVE
APPAREL.
When operating this machine, always
wear an approved helmet with gog-
gles or a face shield. Also wear heavy
boots, gloves, and protective cloth-
ing. Always wear proper fitting cloth-
ing that will not be caught in any of
the moving parts or controls of the
machine.
4. ALWAYS MAINTAIN YOUR MACHINE
IN PROPER WORKING ORDER.
For safety and reliability, the machine
must be properly maintained. Always
perform the pre-operation checks
indicated in this manual. Correcting a
mechanical problem before you ride
may prevent an accident.
5. GASOLINE IS HIGHLY FLAMMABLE.
Always turn off the engine while refu-
eling. Take care to not spill any gaso-
line on the engine or exhaust system.
Never refuel in the vicinity of an open
flame, or while smoking.
SAFETY INFORMATION

Page: 4

6. GASOLINE CAN CAUSE INJURY.
If you should swallow some gasoline,
inhale excess gasoline vapors, or
allow any gasoline to get into your
eyes, contact a doctor immediately. If
any gasoline spills onto your skin or
clothing, immediately wash skin areas
with soap and water, and change your
clothes.
7. ONLY OPERATE THE MACHINE IN AN
AREA WITH ADEQUATE VENTILA-
TION.
Never start the engine or let it run for
any length of time in an enclosed area.
Exhaust fumes are poisonous. These
fumes contain carbon monoxide,
which by itself is odorless and color-
less. Carbon monoxide is a dangerous
gas which can cause unconscious-
ness or can be lethal.
8. PARK THE MACHINE CAREFULLY;
TURN OFF THE ENGINE.
Always turn off the engine if you are
going to leave the machine. Do not
park the machine on a slope or soft
ground as it may fall over.
9. THE ENGINE, EXHAUST PIPE, MUF-
FLER, AND OIL TANK WILL BE VERY
HOT AFTER THE ENGINE HAS BEEN
RUN.
Be careful not to touch them or to
allow any clothing item to contact
them during inspection or repair.
10. PROPERLY SECURE THE MACHINE
BEFORE TRANSPORTING IT.
When transporting the machine in
another vehicle, always be sure it is
properly secured and in an upright
position and that the fuel cock is in
the “OFF” position. Otherwise, fuel
may leak out of the carburetor or fuel
tank.

Page: 5

EC050000
TO THE NEW OWNER
This manual will provide you with a good basic
understanding of features, operation, and
basic maintenance and inspection items of this
machine. Please read this manual carefully
and completely before operating your new
machine. If you have any questions regarding
the operation or maintenance of your machine,
please consult your Yamaha dealer.
NOTE:
This manual should be considered a perma-
nent part of this machine and should remain
with it even if the machine is subsequently
sold.
EC060000
NOTICE
Some data in this manual may become out-
dated due to improvements made to this
model in the future. If there is any question
you have regarding this manual or your
machine, please consult your Yamaha
dealer.
EC070001
F.I.M. MACHINE WEIGHTS:
Weights of machines without fuel
The minimum weights for motocross
machines are:
for the class 125 cc………………….. minimum
88 kg (194 lb)
for the class 250 cc………………….. minimum
98 kg (216 lb)
for the class 500 cc………………….. minimum
102 kg (225 lb)
In modifying your machine (e.g., for weight
reduction), take note of the above limits of
weight.

Page: 6

EC080000
HOW TO USE
THIS MANUAL
EC081000
PARTICULARLY IMPORTANT
INFORMATION
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 machine
operator, a bystander, or a person inspecting
or repairing the machine.
A CAUTION indicates special precautions that
must be taken to avoid damage to the
machine.
NOTE:
A NOTE provides key information to make pro-
cedures easier or clearer.
WARNING
CAUTION:
EC082000
FINDING THE REQUIRED PAGE
1. This manual consists of seven chapters;
“General information”, “Specifications”,
“Regular inspection and adjustments”,
“Engine”, “Chassis”, “Electrical” and
“Tuning”.
2. The table of contents is at the beginning
of the manual. Look over the general lay-
out of the book before finding then
required chapter and item.
Bend the book at its edge, as shown, to
find the required fore edge symbol mark
and go to a page for required item and
description.

Page: 7

EC083000
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-
tion has been complied to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the
course of action required will follow the symbol, e.g.,
● Bearings
Pitting/damage → Replace.
EC084002
HOW TO READ DESCRIPTIONS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
1. An easy-to-see exploded diagram 1 is provided for removal and disassembly jobs.
2. Numbers 2 are given in the order of the jobs in the exploded diagram. A number that is
enclosed by a 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 3. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 4 accompanies the exploded diagram, providing the order of jobs,
names of parts, notes in jobs, etc.
5. Extent of removal 5 is provided in the job instruction chart to save the trouble of an unneces-
sary removal job.
6. For jobs requiring more information, the step-by-step format supplements 6 are given in addi-
tion to the exploded diagram and job instruction chart.

Page: 8

ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols 1 to 7 are designed as
thumb tabs to indicate the chapter’s number
and content.
1 General information
2 Specifications
3 Regular inspection and adjustments
4 Engine
5 Chassis
6 Electrical
7 Tuning
Illustrated symbols 8 to D are used to identify
the specifications appearing in the text.
8 With engine mounted
9 Special tool
0 Filling fluid
A Lubricant
B Tightening
C Specified value, Service limit
D Resistance (Ω), Voltage (V), Electric current (A)
Illustrated symbols E to H in the exploded
diagrams indicate grade of lubricant and loca-
tion of lubrication point.
E Apply engine oil
F Apply molybdenum disulfide oil
G Apply lightweight lithium-soap base grease
H Apply molybdenum disulfide grease
Illustrated symbols I to J in the exploded
diagrams indicate where to apply a locking
agent and where to install new parts.
I Apply locking agent (LOCTITE®)
J Use new one
1 2
3 4
5 6
7 8
9 0
A B
C D
E F
G H
I J
GEN
INFO SPEC
INSP
ADJ ENG
CHAS – +
ELEC
TUN
T
R
.
.
E M
B M

Page: 9

EC090010
INDEX
GENERAL INFORMATION
SPECIFICATIONS
REGULAR INSPECTION AND ADJUSTMENTS
ENGINE
CHASSIS
ELECTRICAL
TUNING

Page: 10

INDICE
INFORMAZIONI
GENERALI
1
SPECIFICHE
SPEC
2
ISPEZIONI E
REGISTRAZIONI
REGOLARI
3
MOTORE
ENG
4
PARTE CICLISTICA
CHAS
5
IMPIANTO
ELETTRICO
ELEC
6
MESSA A PUNTO
TUN
7
GEN
INFO
INSP
ADJ
– +
INDEX
RENSEIGNEMENTS-
GENERAUX
CARACTERISTI-
QUES
CONTROLES ET
REGLAGES
COURANTS
MOTEUR
PARTIE CYCLE
PARTIE
ELECTRIQUE
MISES AU POINT
INDEX
ALLGEMEINE
ANGABEN
TECHNISCHE
DATEN
REGELMÄSSIGE
INSPEKTION UND
EINSTELLARBEITEN
MOTOR
FAHRWERK
ELEKTRISCHE
ANLAGE
ABSTIMMUNG

Page: 11

EC0A0000
CONTENTS
CHAPTER 1
GENERAL INFORMATION
DESCRIPTION …………………………………… 1-1
MACHINE IDENTIFICATION ……………….. 1-2
IMPORTANT INFORMATION ………………. 1-3
CHECKING OF CONNECTION ……………. 1-6
SPECIAL TOOLS ……………………………….. 1-7
CONTROL FUNCTIONS ……………………. 1-10
FUEL ………………………………………………. 1-14
STARTING AND BREAK-IN ………………. 1-15
TORQUE-CHECK POINTS ………………… 1-19
CLEANING AND STORAGE ……………… 1-20
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ……………… 2-1
MAINTENANCE SPECIFICATIONS ……… 2-4
GENERAL TORQUE
SPECIFICATIONS ……………………………. 2-18
DEFINITION OF UNITS …………………….. 2-18
CABLE ROUTING DIAGRAM ……………. 2-19
CHAPTER 3
REGULAR INSPECTION AND
ADJUSTMENTS
MAINTENANCE INTERVALS ………………. 3-1
PRE-OPERATION INSPECTION
AND MAINTENANCE …………………………. 3-4
ENGINE …………………………………………….. 3-5
CHASSIS …………………………………………. 3-26
ELECTRICAL …………………………………… 3-47

Page: 12

INHALT
KAPITEL 1
ALLGEMEINE
ANGABEN
FAHRZEUGBESCHREIBUNG …1-1
FAHRZEUG-
IDENTIFIZIERUNG …………………1-2
WICHTIGE
INFORMATIONEN ………………….1-3
ANSCHLÜSSE PRÜFEN ………..1-6
SPEZIALWERKZEUGE ………….1-7
ARMATUREN UND DEREN
FUNKTION ………………………….1-10
KRAFTSTOFF ……………………..1-14
ANLASSEN UND
EINFAHREN ………………………..1-15
ANZUGSMOMENTE
KONTROLLIEREN ……………….1-19
REINIGUNG UND
STILLEGUNG ………………………1-20
KAPITEL 2
TECHNISCHE DATEN
ALLGEMEINE TECHNISCHE
DATEN ………………………………….2-1
WARTUNGSDATEN ………………2-4
ALLGEMEINE
ANZUGSMOMENTE …………….2-18
EINHEITEN ………………………….2-18
KABELFÜHRUNG ………………..2-19
KAPITEL 3
REGELMÄSSIGE
INSPEKTION UND
EINSTELLARBEITEN
WARTUNGSINTERVALLE UND
SCHMIERDIENST ………………….3-1
WARTUNGS- UND
EINSTELLARBEITEN VOR
FAHRTBEGINN ……………………..3-4
MOTOR …………………………………3-5
FAHRWERK ………………………..3-26
ELEKTRISCHE ANLAGE ……..3-47
TABLES DES
MATIERES
CHAPITRE 1
RENSEIGNEMENTS
GENERAUX
DESCRIPTION ………………………….1-1
IDENTIFICATION DE LA
MACHINE …………………………………1-2
INFORMATIONS
IMPORTANTES ………………………..1-3
VERIFICATION DES
CONNEXIONS ………………………….1-6
OUTILS SPECIAUX ………………….1-7
FONCTIONS DES
COMMANDES ………………………..1-10
ESSENCE ………………………………..1-14
MISE EN MARCHE
ET RODAGE …………………………..1-15
POINTS DE VERIFICATION DE
COUPLE DE SERRAGE ………….1-19
NETTOYAGE ET
RANGEMENT …………………………1-20
CHAPITRE 2
CARACTERISTIQUES
CARACTERISTIQUES
GENERALES …………………………….2-1
CARACTERISTIQUES
D’ENTRETIEN ………………………….2-4
CARACTERISTIQUES
GENERALES DE COUPLE …….2-18
DEFINITION DES UNITES …….2-18
CHEMINEMENT DES
CABLES ………………………………….2-19
CHAPITRE 3
CONTROLES ET
REGLAGES
COURANTS
PROGRAMME D’ENTRETIEN ..3-1
CONTROLE ET ENTRETIEN
AVANT UTILISATION …………….3-4
MOTEUR ………………………………….3-5
PARTIE CYCLE ……………………..3-26
PARTIE ELECTRIQUE …………..3-47
INDICE
CAPITOLO 1
INFORMAZIONI
GENERALI
DESCRIZIONE ………………………….1-1
IDENTIFICAZIONE DEL
VEICOLO ………………………………….1-2
INFORMAZIONI
IMPORTANTI …………………………..1-3
CONTROLLO DEI
COLLEGAMENTI …………………….1-6
UTENSILI SPECIALI ………………..1-7
FUNZIONI DI COMANDO ………1-10
CARBURANTE ……………………….1-14
AVVIO E RODAGGIO …………….1-15
PUNTI PER IL CONTROLLO
DEL SERRAGGIO …………………..1-19
PULIZIA ED
IMMAGAZZINAGGIO ……………1-20
CAPITOLO 2
SPECIFICHE
SPECIFICHE GENERALI …………2-1
SPECIFICHE DI
MANUTENZIONE …………………….2-4
SPECIFICHE RELATIVE ALLE
COPPIE DI SERRAGGIO
GENERALI ……………………………..2-18
DEFINIZIONE DELLE UNITÀ
DI MISURA ……………………………..2-18
SCHEMA DEL PERCORSO DEI
CAVI ……………………………………….2-19
CAPITOLO 3
ISPEZIONI E
REGISTRAZIONI
REGOLARI
INTERVALLI DI
MANUTENZIONE …………………….3-1
CONTROLLI PRELIMINARI E
MANUTENZIONE …………………….3-4
MOTORE ………………………………….3-5
PARTE CICLISTICA ………………3-26
PARTE ELETTRICA ……………….3-47

Page: 13

CHAPTER 4
ENGINE
SEAT, FUEL TANK
AND SIDE COVERS …………………………… 4-1
EXHAUST PIPE AND SILENCER ………… 4-2
RADIATOR ………………………………………… 4-4
CARBURETOR ………………………………….. 4-7
CAMSHAFTS …………………………………… 4-21
CYLINDER HEAD …………………………….. 4-30
VALVES AND VALVE SPRINGS ……….. 4-34
CYLINDER AND PISTON ………………….. 4-43
CLUTCH ………………………………………….. 4-50
OIL FILTER ELEMENT, WATER PUMP
AND RIGHT CRANKCASE COVER …… 4-57
BALANCER …………………………………….. 4-64
OIL PUMP ……………………………………….. 4-67
KICK SHAFT AND SHIFT SHAFT ………. 4-72
CDI MAGNETO ………………………………… 4-79
ENGINE REMOVAL ………………………….. 4-83
CRANKCASE AND CRANKSHAFT ……. 4-88
TRANSMISSION, SHIFT CAM
AND SHIFT FORK ……………………………. 4-97
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL …… 5-1
FRONT BRAKE AND REAR BRAKE ….. 5-11
FRONT FORK ………………………………….. 5-28
HANDLEBAR …………………………………… 5-41
STEERING ………………………………………. 5-47
SWINGARM …………………………………….. 5-53
REAR SHOCK ABSORBER ………………. 5-60

Page: 14

KAPITEL 4
MOTOR
SITZBANK,
KRAFTSTOFFTANK UND
SEITENABDECKUNGEN ………..4-1
KRÜMMER UND
SCHALLDÄMPFER ………………..4-2
KÜHLER ……………………………….4-4
VERGASER …………………………..4-7
NOCKENWELLE ………………….4-21
ZYLINDERKOPF ………………….4-30
VENTILE UND
VENTILFEDERN ………………….4-34
ZYLINDER UND KOLBEN …….4-43
KUPPLUNG …………………………4-50
ÖLFILTEREINSATZ,
WASSERPUMPE UND
RECHTE KURBELWELLENAB-
DECKUNG …………………………..4-57
AUSGLEICHSWELLE …………..4-64
ÖLPUMPE …………………………..4-67
KICKSTARTER UND
KICKSTARTERWELLE …………4-72
CDI-SCHWUNGRADMAGNETZÜN-
DER ……………………………………4-79
MOTOR DEMONTIEREN ………4-83
KURBELGEHÄUSE UND
KURBELWELLE ………………….4-88
GETRIEBE, SCHALTWALZE
UND SCHALTGABELN ………..4-97
KAPITEL 5
FAHRWERK
VORDER- UND HINTERRAD ….5-1
VORDER- UND
HINTERRADBREMSE ………….5-11
TELESKOPGABEL ………………5-28
LENKER ……………………………..5-41
LKKOPF ……………………………..5-47
SCHWINGE …………………………5-53
FEDERBEIN ………………………..5-60
CHAPITRE 4
MOTEUR
SELLE, RESERVOIR
DE CARBURANT ET
CACHES LATERAUX ………………4-1
TUYAU D’ECHAPPEMENT
ET SILENCIEUX ………………………4-2
RADIATEUR …………………………….4-4
CARBURATEUR ………………………4-7
ARBRES A CAMES …………………4-21
CULASSE ………………………………..4-30
SOUPAPES ET RESSORTS
DE SOUPAPE ………………………….4-34
CYLINDRE ET PISTON ………….4-43
EMBRAYAGE …………………………4-50
ELEMENT DE FILTRE A
HUILE, POMPE A EAU ET
DEMI-CARTER DROIT ………….4-57
BALANCIER …………………………..4-64
POMPE A HUILE ……………………4-67
ARBRE DE KICK ET ARBRE
DE SELECTEUR ……………………..4-72
VOLANT MAGNETIQUE
CDI ………………………………………….4-79
DEPOSE DU MOTEUR ……………4-83
CARTER ET VILEBREQUIN ….4-88
BOITE A VITESSES,
TAMBOUR ET FOURCHETTES
DE SELECTION ……………………..4-97
CHAPITRE 5
PARTIE CYCLE
ROUE AVANT ET ROUE
ARRIERE ………………………………….5-1
FREIN AVANT ET FREIN
ARRIERE ………………………………..5-11
FOURCHE AVANT …………………5-28
GUIDON ………………………………….5-41
DIRECTION ……………………………5-47
BRAS OSCILLANT …………………5-53
AMORTISSEUR ARRIERE …….5-60
CAPITOLO 4
MOTORE
SELLA, SERBATOIO CARBURAN-
TE E CARENATURA
LATERALE ……………………………….4-1
TUBO DI SCARICO E
SILENZIATORE ……………………….4-2
RADIATORE …………………………….4-4
CARBURATORE ………………………4-7
ALBERI A CAMME ………………..4-21
TESTATA DEL CILINDRO …….4-30
VALVOLE E MOLLE
VALVOLE ……………………………….4-34
CILINDRO E PISTONE …………..4-43
FRIZIONE ……………………………….4-50
ELEMENTO FILTRANTE
DELL’OLIO, POMPA DELL’AC-
QUA E COPERCHIO CARTER
DESTRO ………………………………….4-57
BILANCIERE ………………………….4-64
POMPA DELL’OLIO ………………4-67
ALBERO PEDALE E ALBERO
DEL CAMBIO ………………………….4-72
MAGNETE CDI ……………………….4-79
RIMOZIONE DEL MOTORE ….4-83
CARTER E ALBERO
MOTORE ………………………………..4-88
TRASMISSIONE, CAMMA DEL
CAMBIO E FORCELLA DEL
CAMBIO ………………………………….4-97
CAPITOLO 5
PARTE CICLISTICA
RUOTA ANTERIORE E RUOTA
POSTERIORE …………………………..5-1
FRENO ANTERIORE E
POSTERIORE …………………………5-11
FORCELLA ANTERIORE ………5-28
MANUBRIO …………………………….5-41
STERZO ………………………………….5-47
FORCELLONE
OSCILLANTE …………………………5-53
AMMORTIZZATORE
POSTERIORE …………………………5-60

Page: 15

CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS
AND WIRING DIAGRAM …………………….. 6-1
MAP-CONTROLLED CDI UNIT ……………. 6-2
IGNITION SYSTEM …………………………….. 6-3
THROTTLE POSITION SENSOR
SYSTEM ……………………………………………. 6-7
LIGHTING SYSTEM ………………………….. 6-12
CHAPTER 7
TUNING
ENGINE …………………………………………….. 7-1
CHASSIS …………………………………………. 7-12

Page: 16

KAPITEL 6
ELEKTRISCHE
ANLAGE
ELEKTRISCHE BAUTEILE UND
SCHALTPLAN ……………………….6-1
KENNFELDGESTEUERTES
CDI-ZÜNDSYSTEM ………………..6-2
ZÜNDANLAGE ………………………6-3
DROSSELKLAPPEN-
POSITIONSSENSOR ……………..6-7
LICHTANLAGE ……………………6-12
KAPITEL 7
ABSTIMMUNG
MOTOR …………………………………7-1
FAHRGESTELL …………………..7-12
CHAPITRE 6
PARTIE
ELECTRIQUE
COMPOSANTS ELECTRIQUES
ET SCHEMA DE CABLAGE …….6-1
BLOC CDI CONTROLE PAR
MICROPROCESSEUR ……………..6-2
SYSTEME D’ALLUMAGE ……….6-3
CIRCUIT DU CAPTEUR
DE PAPILLON DES GAZ ………….6-7
SYSTEME D’ECLAIRAGE ……..6-12
CHAPITRE 7
MISES AU POINT
MOTEUR ………………………………….7-1
PARTIE CYCLE ……………………..7-12
CAPITOLO 6
IMPIANTO
ELETTRICO
COMPONENTI ELETTRICI E
SCHEMA DI CABLAGGIO ……….6-1
UNITÀ CDI CONTROLLATA DA
MAPPA ……………………………………..6-2
IMPIANTO DI ACCENSIONE …..6-3
SISTEMA SENSORE DELLA
POSIZIONE DELLA VALVOLA
A FARFALLA ……………………………6-7
IMPIANTO DI
ILLUMINAZIONE …………………..6-12
CAPITOLO 7
MESSA A PUNTO
MOTORE ………………………………….7-1
PARTE CICLISTICA ………………7-12

Page: 17

GEN
INFO
1 — 1
DESCRIPTION
EC100000
GENERAL INFORMATION
EC110000
DESCRIPTION
1 Clutch lever
2 Decompression lever
3 Trip meter
4 Light switch
5 Front brake lever
6 Throttle grip
7 Radiator cap
8 Fuel tank cap
9 Oil tank cap
0 Engine stop switch
A Taillight
B Kickstarter crank
C Fuel tank
D Headlight
E Radiator
F Coolant drain bolt
G Rear brake pedal
H Valve joint
I Fuel cock
J Cold starter knob
K Hot starter knob (red)
L Drive chain
M Air filter
N Shift pedal
O Front fork
NOTE:
● The machine you have purchased may differ
slightly from those shown in the following.
● Designs and specifications are subject to
change without notice.

Page: 18

1 — 2
GEN
INFO
MACHINE IDENTIFICATION
EC120001
MACHINE IDENTIFICATION
There are two significant reasons for knowing
the serial number of your machine:
1. When ordering parts, you can give the
number to your Yamaha dealer for posi-
tive identification of the model you own.
2. If your machine is stolen, the authorities
will need the number to search for and
identify your machine.
EC121001
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is
stamped on the right of the steering head pipe.
EC123001
ENGINE SERIAL NUMBER
The engine serial number 1 is stamped into
the elevated part of the right-side of the
engine.
EC124000
MODEL LABEL
The model label 1 is affixed to the frame
under the rider’s seat. This information will be
needed to order spare parts.

Page: 19

1 — 3
GEN
INFO
IMPORTANT INFORMATION
EC130000
IMPORTANT INFORMATION
EC131010
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Remove all dirt, mud, dust, and foreign
material before removal and disassem-
bly.
When washing the machine with high
pressured water, cover the parts follows.
● Silencer end
● Air filter intake hole
● Water pump housing hole at the bottom
● Carburetor accelerator pump
2. Use proper tools and cleaning equip-
ment. Refer to “SPECIAL TOOLS” sec-
tion.
3. When disassembling the machine, keep
mated parts together. They include
gears, cylinders, pistons, and other
mated parts that have been “mated”
through normal wear. Mated parts must
be reused as an assembly or replaced.
4. During the machine 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.

Page: 20

1 — 4
GEN
INFO
IMPORTANT INFORMATION
EC132000
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuine
parts for all replacements. Use oil and/or
grease recommended by Yamaha for
assembly and adjustment.
EC133000
GASKETS, OIL SEALS AND O-RINGS
1. All gaskets, oil seals, and O-rings should
be replaced when an engine is over-
hauled. 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.
EC134000
LOCK WASHERS/PLATES AND COTTER
PINS
1. All lock washers/plates 1 and 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.
EC135001
BEARINGS AND OIL SEALS
1. Install the bearing(s) 1 and 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
bearings dry. This causes damage to the
bearing surfaces.

Page: 21

1 — 5
GEN
INFO
IMPORTANT INFORMATION
EC136000
CIRCLIPS
1. All circlips should be inspected carefully
before reassembly. Always replace pis-
ton pin clips after one use. Replace dis-
torted circlips. When installing a circlip
1, make sure that the sharp-edged cor-
ner 2 is positioned opposite to the thrust
3 it receives. See the sectional view.
4 Shaft

Page: 22

1 — 6
GEN
INFO
CHECKING OF CONNECTION
EC1C0001
CHECKING OF CONNECTION
Dealing with stains, rust, moisture, etc. on the
connector.
1. Disconnect:
● Connector
2. Dry each terminal with an air blower.
3. Connect and disconnect the connector
two or three times.
4. Pull the lead to check that it will not come
off.
5. If the terminal comes off, bend up the pin
1 and reinsert the terminal into the con-
nector.
6. Connect:
● Connector
NOTE:
The two connectors “click” together.
7. Check for continuity with a tester.
NOTE:
● If there in no continuity, clean the terminals.
● Be sure to perform the steps 1 to 7 listed
above when checking the wire harness.
● For a field remedy, use a contact revitalizer
available on the market.
● Use the tester on the connector as shown.

Page: 23

GEN
INFO
1 — 7
SPECIAL TOOLS
SPECIAL TOOLS
The proper special tools are necessary for complete and accurate tune-up and assembly. Using the
correct special tool will help prevent damage caused by the use of improper tools or improvised
techniques. The shape and part number used for the special tool differ by country, so two types are
provided. Refer to the list provided to avoid errors when placing an order.
NOTE:
● For U.S.A. and Canada, use part number starting with “YM-”, “YU-” or “ACC-”.
● For others, use part number starting with “90890-”.
Part number Tool name/How to use Illustration
YU-1135-A, 90890-01135 Crankcase separating tool
These tool is used to remove the crankshaft from
either case.
YU-1135-A 90890-01135
YU-1235, 90890-01235 Rotor holding tool
This tool is used when loosening or tightening the fly-
wheel magneto securing nut.
YU-1235 90890-01235
YU-3097, 90890-01252
YU-1256
Dial gauge and stand
Stand
These tools are used to check each part for runout or
bent.
YU-3097
YU-1256
90890-01252
YU-90050, 90890-01274
YU-90050, 90890-01275
YU-91044, 90890-04081
YM-1277, 90890-01277
Crankshaft installing tool
Crankshaft installing pot
Crankshaft installing bolt
Spacer (crankshaft installer)
Adapter (M10)
These tools are used to install the crankshaft.
YU-90050
YM-1277
YU-91044
90890-01274
90890-01275
90890-01277
90890-04081
YU-1304, 90890-01304 Piston pin puller set
This tool is used to remove the piston pin.
YU-1304 90890-01304
YU-24460-01, 90890-01325
YU-33984, 90890-01352
Radiator cap tester
Radiator cap tester adapter
These tools are used for checking the cooling sys-
tem.
YU-24460-01
YU-33984
90890-01325
90890-01352
YU-33270-B, 90890-01362 Flywheel puller
This tool is used to remove the flywheel magneto.
YM-33270-B 90890-01362

Page: 24

GEN
INFO
1 — 8
SPECIAL TOOLS
YU-33975, 90890-01403 Steering nut wrench
This tool is used when tighten the steering ring nut to
specification.
YU-33975 90890-01403
YM-1423, 90890-01423 Damper rod holder
Use this tool to remove and install the damper rod.
YM-1423 90890-01423
YM-01442, 90890-01442 Fork seal driver
This tool is used when install the fork oil seal.
YM-01442 90890-01442
YU-3112-C, 90890-03112 Pocket tester
Use this tool to inspect the coil resistance, output
voltage and amperage.
YU-3112-C 90890-03112
YU-8036-B
90890-03113
Inductive tachometer
Engine tachometer
This tool is needed for observing engine rpm.
YU-8036-B 90890-03113
YM-33277-A, 90890-03141 Timing light
This tool is necessary for checking ignition timing.
YM-33277-A 90890-03141
YM-4019, 90890-04019 Valve spring compressor
This tool is needed to remove and install the valve
assemblies.
YM-4019 90890-04019
YM-91042, 90890-04086 Clutch holding tool
This tool is used to hold the clutch when removing or
installing the clutch boss securing nut.
YM-91042 90890-04086
YM-4111, 90890-04111
YM-4116, 90890-04116
Valve guide remover
Intake 4.0 mm (0.16 in)
Exhaust 4.5 mm (0.18 in)
This tool is needed to remove and install the valve
guide.
YM-4111
YM-4116
90890-04111
90890-04116
Part number Tool name/How to use Illustration

Page: 25

GEN
INFO
1 — 9
SPECIAL TOOLS
YM-4112, 90890-04112
YM-4117, 90890-04117
Valve guide installer
Intake 4.0 mm (0.16 in)
Exhaust 4.5 mm (0.18 in)
This tool is needed to install the valve guide.
YM-4112
YM-4117
90890-04112
90890-04117
YM-4113, 90890-04113
YM-4118, 90890-04118
Valve guide reamer
Intake 4.0 mm (0.16 in)
Exhaust 4.5 mm (0.18 in)
This tool is needed to rebore the new valve guide.
YM-4113
YM-4118
90890-04113
90890-04118
YM-34487
90890-06754
Dynamic spark tester
Ignition checker
This instrument is necessary for checking the ignition
system components.
YM-34487 90890-06754
ACC-QUICK-GS-KT
90890-85505
Quick gasket
YAMAHA Bond No. 1215
This sealant (Bond) is used for crankcase mating
surface, etc.
ACC-QUICK-GS-KT 90890-85505
Part number Tool name/How to use Illustration

Page: 26

1 — 10
GEN
INFO
CONTROL FUNCTIONS
EC150000
CONTROL FUNCTIONS
ENGINE STOP SWITCH
The engine stop switch 1 is located on the left
handlebar. Continue pushing the engine stop
switch till the engine comes to a stop.
EC152000
CLUTCH LEVER
The clutch lever 1 is located on the left han-
dlebar; it disengages or engages the clutch.
Pull the clutch lever to the handlebar to disen-
gage the clutch, and release the lever to
engage the clutch. The lever should be pulled
rapidly and released slowly for smooth starts.
EC153000
SHIFT PEDAL
The gear ratios of the constant-mesh 5 speed
transmission are ideally spaced. The gears
can be shifted by using the shift pedal 1 on
the left side of the engine.
KICKSTARTER CRANK
Rotate the kickstarter crank 1 away from the
engine. Push the starter down lightly with your
foot until the gears engage, then kick smoothly
and forcefully to start the engine. This model
has a primary kickstarter crank so the engine
can be started in any gear if the clutch is dis-
engaged. In normal practices, however, shift to
neutral before starting.
1

Page: 27

1 — 11
GEN
INFO
CONTROL FUNCTIONS
DECOMPRESSION LEVER
CAUTION:
Never use the decompression lever after
the engine is started. The engine may be
damaged if you use the decompression
lever while it is running.
The decompression lever 1 is located on the
left handlebar and is used when starting the
engine. Squeezing the decompression lever
presses down on the exhaust valve and
releases the pressure in the cylinder head.
This enables the vehicle to be kickstarted
more easily.
EC155001
THROTTLE GRIP
The throttle grip 1 is located on the right han-
dlebar; it accelerates or decelerates the
engine. For acceleration, turn the grip toward
you; for deceleration, turn it away from you.
EC156000
FRONT BRAKE LEVER
The front brake lever 1 is located on the right
handlebar. Pull it toward the handlebar to acti-
vate the front brake.
EC157000
REAR BRAKE PEDAL
The rear brake pedal 1 is located on the right
side of the machine. Press down on the brake
pedal to activate the rear brake.

Page: 28

1 — 12
GEN
INFO
CONTROL FUNCTIONS
EC158010
FUEL COCK
The fuel cock supplies fuel from the tank to
carburetor while filtering the fuel. The fuel cock
has the three positions:
OFF:With the lever in this position, fuel will not
flow. Always return the lever to this posi-
tion 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 position.
RES:This indicates reserve. If you run out of
fuel while riding, move the lever to this
position. FILL THE TANK AT THE FIRST
OPPORTUNITY. BE SURE TO SET THE
LEVER TO “ON” AFTER REFUELING.
COLD STARTER KNOB
When cold, the engine requires a richer air-fuel
mixture for starting. A separate starter circuit,
which is controlled by the cold starter knob 1,
supplies this mixture. Pull the cold starter knob
out to open the circuit for starting. When the
engine has warmed up, push it in to close the
circuit.
HOT STARTER KNOB
The hot starter knob (red) 1 is used when
starting a warm engine.
Use the hot starter knob when starting the
engine again immediately after it was stopped
(the engine is still warm). Pulling out the hot
starter knob injects secondary air to thin the
air-fuel mixture temporarily, allowing the
engine to be started more easily.
CAUTION:
After the engine has started, be sure to
push the hot starter knob back in.

Page: 29

1 — 13
GEN
INFO
CONTROL FUNCTIONS
EC15F000
VALVE JOINT
This valve joint 1 prevents fuel from flowing
out and is installed to the fuel tank breather
hose.
CAUTION:
In this installation, make sure the arrow
faces the fuel tank and also downward.
LIGHTS SWITCH
The lights switch 1 is located on the handle-
bar.
FLAP
In order to prevent water from entering the car-
buretor while the machine is operated in the
rain, attach the accessory flap 1 to the frame
at the rear of the fuel tank.
NOTE:
Riding with the flap attached when it is not
raining can help keep out dust, dirt and sand.

Page: 30

1 — 14
GEN
INFO
FUEL
Always use the recommended fuel as stated
below. Also, be sure to use new gasoline the
day of a race.
CAUTION:
Use only unleaded gasoline. The use of
leaded gasoline will cause severe damage
to the engine internal parts such as valves,
piston rings, and exhaust system, etc.
NOTE:
If knocking or pinging occurs, use a different
brand of gasoline or higher octane grade.
Recommended fuel:
Except for ZA:
Premium unleaded gasoline
only with a research octane
number of 95 or higher.
For ZA:
Premium gasoline
FUEL

Page: 31

1 — 15
GEN
INFO
STARTING AND BREAK-IN
STARTING AND BREAK-IN
WARNING
Never start or run the engine in a closed
area. The exhaust fumes are poisonous;
they can cause loss of consciousness and
death in a very short time. Always operate
the machine in a well-ventilated area.
CAUTION:
● The carburetor on this motorcycle has a
built-in accelerator pump. Therefore,
when starting the engine, do not operate
the throttle or the spark plug will foul.
● Unlike a two-stroke engine, this engine
cannot be kick started when the throttle is
open because the kick starter may kick
back. Also, if the throttle is open the air/
fuel mixture may be too lean for the
engine to start.
● Never use the decompression lever after
the engine is started. The engine may be
damaged if you use the decompression
lever while it is running.
● Before starting the machine, perform the
checks in the pre-operation check list.
STARTING A COLD ENGINE
1. Inspect the coolant level.
2. Turn the fuel cock to “ON”.
3. Shift the transmission into neutral.
4. Fully open the cold starter knob.
5. Without pulling in the decompression
lever, slowly depress the kickstarter
crank until the compression stroke is
found. When considerable resistance of
the kickstarter crank is felt, the engine is
on the compression stroke. If the engine
is on the exhaust stroke, resistance will
only be felt when the kickstarter crank is
initially depressed, not through the entire
range of depression (as when the engine
is on the compression stroke); therefore,
depress the kickstarter crank a few more
times.

Page: 32

1 — 16
GEN
INFO
STARTING AND BREAK-IN
6. Pull the decompression lever to the han-
dlebar and depress the kickstarter crank
10 ~ 20˚.
7. Release the decompression lever and
return the kickstarter crank to its original
position and then kick the kickstarter
crank.
WARNING
Do not open the throttle while kicking the
kickstarter crank. Otherwise, the kick
starter may kick back.
8. Return the cold starter knob to its original
position and run the engine at 3,000 ~
5,000 r/min for 1 or 2 minutes.
NOTE:
Since this model is equipped with an accelera-
tor pump, if the engine is raced (the throttle
opened and closed), the air/fuel mixture will be
too rich and the engine may stall. Also unlike a
two-stroke engine, this model can idle.
CAUTION:
Do not warm up the engine for extended
periods of time.

Page: 33

1 — 17
GEN
INFO
STARTING AND BREAK-IN
STARTING A WARM ENGINE
Do not operate the cold starter knob and throt-
tle. Open the hot starter knob (red) and start
the engine by kicking the kickstarter crank
forcefully with a firm stroke.
As soon as the engine starts, push in the hot
starter knob to close the air passage.
Restarting an engine after a fall
Pull the hot starter knob (red) and start the
engine. As soon as the engine starts, push in
the hot starter knob to close the air passage.
The engine fails to start
Pull the hot starter knob (red) all the way out,
pull the decompression lever to the handlebar,
and while holding the lever, kick the kickstarter
crank 10 to 20 times to clear the engine.
Then, restart the engine.
Refer to “Restarting an engine after a fall”.
* Operate the throttle grip before kick starting.
CAUTION:
Observe the following break-in procedures
during initial operation to ensure optimum
performance and avoid engine damage.
Throttle
grip oper-
ation*
Cold
starter
knob
Hot
starter
knob (red)
Starting
a
cold
engine
Air temperature = less than
5 ˚C (41 ˚F)
Open 3
or 4 times
ON OFF
Air temperature = more
than 5 ˚C (41 ˚F)
None ON OFF
Air temperature (normal tem-
perature) = between 5 ˚C
(41 ˚F) and 25 ˚C (77 ˚F)
None ON/OFF OFF
Air temperature = more
than 25 ˚C (77 ˚F)
None OFF OFF
Starting an engine after a long
period of time
None ON OFF
Restarting a warm engine None OFF ON
Restarting an engine after a fall None OFF ON

Page: 34

1 — 18
GEN
INFO
BREAK-IN PROCEDURES
1. Before starting the engine, fill the fuel
tank with the fuel.
2. Perform the pre-operation checks on the
machine.
3. Start and warm up the engine. Check the
idle speed, and check the operation of
the controls and the engine stop switch.
Then, restart the engine and check its
operation within no more than 5 minutes
after it is restarted.
4. Operate the machine in the lower gears
at moderate throttle openings for five to
eight minutes.
5. Check how the engine runs when the
motorcycle is ridden with the throttle 1/4
to 1/2 open (low to medium speed) for
about one hour.
6. Restart the engine and check the opera-
tion of the machine throughout its entire
operating range. Restart the machine
and operate it for about 10 to 15 more
minutes. The machine will now be ready
to race.
CAUTION:
● After the break-in or before each race,
you must check the entire machine for
loose fittings and fasteners as per
“TORQUE-CHECK POINTS”.
Tighten all such fasteners as required.
● When any of the following parts have
been replaced, they must be broken in.
CYLINDER AND CRANKSHAFT:
About one hour of break-in operation is
necessary.
PISTON, RING, VALVES, CAMSHAFTS
AND GEARS:
These parts require about 30 minutes of
break-in operation at half-throttle or less.
Observe the condition of the engine care-
fully during operation.
STARTING AND BREAK-IN

Page: 35

GEN
INFO
1 — 19
TORQUE-CHECK POINTS
TORQUE-CHECK POINTS
Frame construction
Combined seat and fuel tank
Exhaust system
Engine mounting
Steering Steering stem to
handlebar
Suspension Front Steering stem to front
fork
Rear For link type
Rear Installation of rear
shock absorber
Rear Installation of swing-
arm
Wheel Installation of wheel Front
Rear
Brake Front
Rear
Fuel system
Frame to rear frame
Fuel tank to frame
Silencer to rear frame
Frame to engine
Engine bracket to engine
Engine bracket to frame
Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Front fork to upper bracket
Front fork to lower bracket
Assembly of links
Link to frame
Link to rear shock absorber
Link to swingarm
Rear shock absorber to frame
Tightening of pivot shaft
Tightening of wheel axle
Tightening of axle holder
Tightening of wheel axle
Wheel to rear wheel sprocket
Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to handlebar
Tightening of bleed screw
Brake pedal to frame
Brake disc to frame
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw
Fuel tank to fuel cock
NOTE:
Concerning the tightening torque, refer to
“MAINTENANCE SPECIFICATIONS” section
in the CHAPTER 2.

Page: 36

1 — 20
GEN
INFO
CLEANING AND STORAGE
EC1B0000
CLEANING AND STORAGE
EC1B1000
CLEANING
Frequent cleaning of your machine will
enhance its appearance, maintain good over-
all performance, and extend the life of many
components.
1. Before washing the machine, block off
the end of the exhaust pipe to prevent
water from entering. A plastic bag
secured with a rubber band may be used
for this purpose.
2. If the engine is excessively greasy, apply
some degreaser to it with a paint brush.
Do not apply degreaser to the chain,
sprockets, or wheel axles.
3. Rinse the dirt and degreaser off with a
garden hose; use only enough pressure
to do the job.
CAUTION:
Excessive hose pressure may cause water
seepage and contamination of wheel bear-
ings, front forks, brakes and transmission
seals. Many expensive repair bills have
resulted from improper high pressure
detergent applications such as those avail-
able in coin-operated car washers.
4. After the majority of the dirt has been
hosed off, wash all surfaces with warm
water and a mild detergent. Use an old
toothbrush to clean hard-to-reach places.
5. Rinse the machine off immediately with
clean water, and dry all surfaces with a
soft towel or cloth.
6. Immediately after washing, remove
excess water from the chain with a paper
towel and lubricate the chain to prevent
rust.
7. Clean the seat with a vinyl upholstery
cleaner to keep the cover pliable and
glossy.
8. Automotive wax may be applied to all
painted or chromed surfaces. Avoid com-
bination cleaner-waxes, as they may con-
tain abrasives.
9. After completing the above, start the
engine and allow it to idle for several min-
utes.

Page: 37

1 — 21
GEN
INFO
CLEANING AND STORAGE
EC1B2001
STORAGE
If your machine is to be stored for 60 days or
more, some preventive measures must be
taken to avoid deterioration. After cleaning the
machine thoroughly, prepare it for storage as
follows:
1. Drain the fuel tank, fuel lines, and the
carburetor float bowl.
2. Remove the spark plug, pour a table-
spoon of SAE 10W-30 motor oil in the
spark plug hole, and reinstall the plug.
With the engine stop switch pushed in,
kick the engine over several times to coat
the cylinder walls with oil.
3. Remove the drive chain, clean it thor-
oughly with solvent, and lubricate it.
Reinstall the chain or store it in a plastic
bag tied to the frame.
4. Lubricate all control cables.
5. Block the frame up to raise the wheels off
the ground.
6. Tie a plastic bag over the exhaust pipe
outlet to prevent moisture from entering.
7. If the machine is to be stored in a humid
or salt-air environment, coat all exposed
metal surfaces with a film of light oil. Do
not apply oil to rubber parts or the seat
cover.
NOTE:
Make any necessary repairs before the
machine is stored.

Page: 38

SPEC
2 — 1
GENERAL SPECIFICATIONS
EC200000
SPECIFICATIONS
EC211000
GENERAL SPECIFICATIONS
Model name: WR250FP (USA)
WR250F (EUROPE)
WR250F(P) (CDN, AUS, NZ, ZA)
Model code number: 5PH5 (USA)
5PH6 (EUROPE)
5PH8 (CDN, AUS, NZ, ZA)
Dimensions:
Overall length 2,165 mm (85.2 in)
Overall width 827 mm (32.6 in)
Overall height 1,303 mm (51.3 in)
Seat height 998 mm (39.3 in)
Wheelbase 1,475 mm (58.1 in)
Minimum ground clearance 382 mm (15.0 in)
Basic weight:
With oil and full fuel tank 110.0 kg (242.5 lb)
Engine:
Engine type Liquid cooled 4-stroke, DOHC
Cylinder arrangement Single cylinder, forward inclined
Displacement 249 cm3 (8.76 Imp oz, 8.42 US oz)
Bore × stroke 77.0 × 53.6 mm (3.03 × 2.11 in)
Compression ratio 12.5 : 1
Starting system Kickstarter
Lubrication system: Dry sump
Oil type or grade:
Engine oil (For USA and CDN)
At 5 ˚C (40 ˚F) or higher Å
Yamalube 4 (20W-40) or SAE 20W-40 type
SH motor oil
(Non-Friction modified)
At 15 ˚C (60 ˚F) or lower ı
Yamalube 4 (10W-30) or SAE 10W-30 type
SH motor oil
(Non-Friction modified)
and/or
Yamalube 4-R (15W-50)
(Non-Friction modified)
(Except for USA and CDN)
API “SH” or higher grade
-20
-4
-10
14
0
30
10
50
20
68
30
86
40 50
104 122
°C
Temp.
°F
10W-30
10W-40
20W-40
20W-50
15W-40
2

Page: 39

SPEC
2 — 2
GENERAL SPECIFICATIONS
Oil capacity:
Engine oil
Periodic oil change 1.5 L (1.32 Imp qt, 1.59 US qt)
With oil filter replacement 1.6 L (1.41 Imp qt, 1.69 US qt)
Total amount 1.7 L (1.50 Imp qt, 1.80 US qt)
Coolant capacity (including all routes): 1.3 L (1.14 Imp qt, 1.37 US qt)
Air filter: Wet type element
Fuel:
Type Premium unleaded gasoline only with a
research octane number of 95 or higher.
(Except for ZA)
Premium gasoline (For ZA)
Tank capacity 12 L (2.64 Imp gal, 3.17 US gal)
(For USA and CDN)
8.0 L (1.76 Imp gal, 2.11 US gal)
(Except for USA and CDN)
Reserve 1.6 L (0.35 Imp gal, 0.42 US gal)
(For USA and CDN)
1.4 L (0.31 Imp gal, 0.37 US gal)
(Except for USA and CDN)
Carburetor:
Type FCR-MX37
Manufacturer KEIHIN
Spark plug:
Type/manufacturer CR8E/NGK
U24ESR-N/DENSO
Gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system Gear
Primary reduction ratio 57/17 (3.353)
Secondary reduction system Chain drive
Secondary reduction ratio 52/13 (4.000)
Transmission type Constant mesh, 5-speed
Operation Left foot operation
Gear ratio: 1st 31/13 (2.385)
2nd 28/16 (1.750)
3rd 28/21 (1.333)
4th 25/24 (1.042)
5th 22/27 (0.815)
Chassis:
Frame type Semi double cradle
Caster angle 27.1˚
Trail 117.4 mm (4.62 in)
2

Page: 40

SPEC
2 — 3
GENERAL SPECIFICATIONS
Tire:
Type With tube
Size (front) 80/100-21 51M (For USA, CDN and ZA)
90/90-21 54R (For EUROPE, AUS and NZ)
Size (rear) 100/100-18 59M (For USA, CDN and ZA)
130/90-18 69R (For EUROPE, AUS and NZ)
Tire pressure (front and rear) 100 kPa (1.0 kgf/cm2, 15 psi)
Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
Wheel travel:
Front wheel travel 300 mm (11.8 in)
Rear wheel travel 315 mm (12.4 in)
Electrical:
Ignition system CDI magneto
Headlight type: Quartz bulb (halogen)
Bulb wattage × quantity:
Headlight 12 V 60/55 W × 1
Taillight 12 V 21/5 W × 1

Page: 41

SPEC
2 — 4
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Cylinder head:
Warp limit —- 0.05 mm
(0.002 in)
Cylinder:
Bore size 77.00 ~ 77.01 mm
(3.0315 ~ 3.0319 in)
—-
Out of round limit —- 0.05 mm
(0.002 in)
Camshaft:
Drive method Chain drive (Left) —-
Camshaft cap inside diameter 22.000 ~ 22.021 mm
(0.8661 ~ 0.8670 in)
—-
Camshaft outside diameter 21.967 ~ 21.980 mm
(0.8648 ~ 0.8654 in)
—-
Shaft-to-cap clearance 0.020 ~ 0.054 mm
(0.0008 ~ 0.0021 in)
0.08 mm
(0.003 in)
Cam dimensions
Intake “A” 30.296 ~ 30.346 mm
(1.1923 ~ 1.1947 in)
30.196 mm
(1.1888 in)
“B” 22.45 ~ 22.55 mm
(0.8839 ~ 0.8878 in)
22.35 mm
(0.8799 in)
Exhaust “A” 30.399 ~ 30.499 mm
(1.1968 ~ 1.2007 in)
30.299 mm
(1.1929 in)
“B” 22.45 ~ 22.55 mm
(0.8839 ~ 0.8878 in)
22.35 mm
(0.8799 in)
Camshaft runout limit —- 0.03 mm
(0.0012 in)
A
B

Page: 42

SPEC
2 — 5
MAINTENANCE SPECIFICATIONS
Timing chain:
Timing chain type/No. of links 92RH2010-114M/114 —-
Timing chain adjustment method Automatic —-
Valve, valve seat, valve guide:
Valve clearance (cold) IN 0.10 ~ 0.15 mm
(0.0039 ~ 0.0059 in)
—-
EX 0.17 ~ 0.22 mm
(0.0067 ~ 0.0087 in)
—-
Valve dimensions:
“A” head diameter IN 22.9 ~ 23.1 mm
(0.9016 ~ 0.9094 in)
—-
EX 24.4 ~ 24.6 mm
(0.9606 ~ 0.9685 in)
—-
“B” face width IN 2.26 mm (0.089 in) —-
EX 2.26 mm (0.089 in) —-
“C” seat width IN 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)
1.6 mm
(0.0630 in)
EX 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)
1.6 mm
(0.0630 in)
“D” margin thickness IN 0.8 mm (0.0315 in) —-
EX 0.7 mm (0.0276 in) —-
Stem outside diameter IN 3.975 ~ 3.990 mm
(0.1565 ~ 0.1571 in)
3.945 mm
(0.1553 in)
EX 4.460 ~ 4.475 mm
(0.1756 ~ 0.1762 in)
4.430 mm
(0.1744 in)
Guide inside diameter IN 4.000 ~ 4.012 mm
(0.1575 ~ 0.1580 in)
4.050 mm
(0.1594 in)
EX 4.500 ~ 4.512 mm
(0.1772 ~ 0.1776 in)
4.550 mm
(0.1791 in)
Stem-to-guide clearance IN 0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
0.08 mm
(0.003 in)
EX 0.025 ~ 0.052 mm
(0.0010 ~ 0.0020 in)
0.10 mm
(0.004 in)
Item Standard Limit
Head Diameter
B
Face Width
C
Seat Width
D
Margin Thickness
A

Page: 43

SPEC
2 — 6
MAINTENANCE SPECIFICATIONS
Stem runout limit —- 0.01 mm
(0.0004 in)
Valve seat width IN 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)
1.6 mm
(0.0630 in)
EX 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)
1.6 mm
(0.0630 in)
Valve spring:
Free length IN 37.81 mm (1.49 in) 35.9 mm
(1.41 in)
EX 37.54 mm (1.48 in) 35.7 mm
(1.41 in)
Set length (valve closed) IN 29.13 mm (1.15 in) —-
EX 29.30 mm (1.15 in) —-
Compressed pressure
(installed) IN 99 ~ 114 N
(10.1 ~ 11.6 kg, 22.27 ~ 25.57 lb)
—-
EX 126 ~ 144 N
(12.9 ~ 14.7 kg, 28.44 ~ 32.41 lb)
—-
Tilt limit IN —- 2.5˚/ 1.7 mm
(2.5˚/0.067 in)
EX —- 2.5˚/1.6 mm
(2.5˚/0.063 in)
Direction of winding
(top view) IN Clockwise —-
EX Clockwise —-
Piston:
Piston to cylinder clearance 0.040 ~ 0.065 mm
(0.0016 ~ 0.0026 in)
0.1 mm
(0.004 in)
Piston size “D” 76.955 ~ 76.970 mm
(3.0297 ~ 3.0303 in)
—-
Measuring point “H” 8 mm (0.31 in) —-
Piston off-set 0.5 mm (0.020 in)/IN-side —-
Item Standard Limit
*
H
D

Page: 44

SPEC
2 — 7
MAINTENANCE SPECIFICATIONS
Piston pin bore inside diameter 16.002 ~ 16.013 mm
(0.6300 ~ 0.6304 in)
16.043 mm
(0.6316 in)
Piston pin outside diameter 15.991 ~ 16.000 mm
(0.6296 ~ 0.6299 in)
15.971 mm
(0.6288 in)
Piston rings:
Top ring:
Type Barrel —-
Dimensions (B × T) 0.90 × 2.75 mm (0.04 × 0.11 in) —-
End gap (installed) 0.15 ~ 0.25 mm
(0.006 ~ 0.010 in)
0.50 mm
(0.020 in)
Side clearance (installed) 0.030 ~ 0.065 mm
(0.0012 ~ 0.0026 in)
0.12 mm
(0.005 in)
2nd ring:
Type Taper —-
Dimensions (B × T) 0.80 × 2.75 mm (0.03 × 0.11 in) —-
End gap (installed) 0.30 ~ 0.45 mm
(0.012 ~ 0.018 in)
0.80 mm
(0.031 in)
Side clearance 0.020 ~ 0.055 mm
(0.0008 ~ 0.0022 in)
0.12 mm
(0.005 in)
Oil ring:
Dimensions (B × T) 1.50 × 2.25 mm (0.06 × 0.09 in) —-
End gap (installed) 0.10 ~ 0.40 mm
(0.004 ~ 0.016 in)
—-
Crankshaft:
Crank width “A” 55.95 ~ 56.00 mm
(2.203 ~ 2.205 in)
—-
Runout limit “C” 0.03 mm (0.0012 in) 0.05 mm
(0.002 in)
Big end side clearance “D” 0.15 ~ 0.45 mm
(0.0059 ~ 0.0177 in)
0.50 mm
(0.02 in)
Small end free play “F” 0.4 ~ 1.0 mm
(0.02 ~ 0.04 in)
2.0 mm
(0.08 in)
Decompression device:
Type Manual —-
Cable free play 5 ~ 9 mm (0.20 ~ 0.35 in) —-
Item Standard Limit
T
B
B
T
B
T

Page: 45

SPEC
2 — 8
MAINTENANCE SPECIFICATIONS
Clutch:
Friction plate thickness 2.9 ~ 3.1 mm
(0.114 ~ 0.122 in)
2.7 mm
(0.106 in)
Quantity 9 —-
Clutch plate thickness 1.1 ~ 1.3 mm (0.043 ~ 0.051 in) —-
Quantity 8 —-
Warp limit —- 0.1 mm
(0.004 in)
Clutch spring free length 37.0 mm (1.46 in) 36.0 mm
(1.42 in)
Quantity 5 —-
Clutch housing thrust clearance 0.10 ~ 0.35 mm
(0.0039 ~ 0.0138 in)
—-
Clutch housing radial clearance 0.010 ~ 0.044 mm
(0.0004 ~ 0.0017 in)
—-
Clutch release method Inner push, cam push —-
Shifter:
Shifter type Cam drum and guide bar —-
Guide bar bending limit —- 0.05 mm
(0.002 in)
Kickstarter:
Type Kick and ratchet type —-
Carburetor:
USA EUROPE
CDN, ZA,
AUS, NZ
Type/manufacturer FCR-MX37/
KEIHIN
← ←
I. D. mark 5PH5 50 5PH6 60 5PH8 80
Main jet (M.J) #175 #172 #170
Main air jet (M.A.J) #200 ← ←
Jet needle (J.N) OBELQ-3 OBELN-4 OBEKP-3
Cutaway (C.A) 1.5 ← ←
Pilot jet (P.J) #40 ← ←
Pilot air jet (P.A.J) #75 ← ←
Pilot outlet (P.O) ø0.9 ← ←
Pilot screw (example) (P.S) 2 1 1-1/8
Bypass (B.P) ø1.0 ← ←
Valve seat size (V.S) ø3.8 ← ←
Starter jet (G.S) #72 ← ←
Leak jet (Acc.P) #60 #90 #105
Float height (F.H) 8 mm (0.31 in) ← ←
Engine idle speed 1,800 ~
2,100 r/min
← ←
Intake vacuum 26.7 ~ 32.0 kPa
(200 ~ 240 mmHg,
7.87 ~ 9.45 inHg)
← ←
Item Standard Limit

Page: 46

SPEC
2 — 9
MAINTENANCE SPECIFICATIONS
Lubrication system:
Oil filter type Wire mesh type —-
Oil pump type Trochoid type —-
Tip clearance 0.12 mm or less
(0.0047 in or less)
0.20 mm
(0.008 in)
Side clearance 0.09 ~ 0.17 mm
(0.0035 ~ 0.0067 in)
0.24 mm
(0.009 in)
Housing and rotor clearance 0.03 ~ 0.10 mm
(0.0012 ~ 0.0039 in)
0.17 mm
(0.0067 in)
Cooling:
Radiator core size
Width 117.8 mm (4.6 in) —-
Height 220 mm (8.7 in) —-
Thickness 32 mm (1.26 in) —-
Radiator cap opening pressure 110 kPa (1.1 kg/cm2, 15.6 psi) —-
Radiator capacity (total) 0.6 L (0.53 lmp qt, 0.63 US qt) —-
Water pump
Type Single-suction centrifugal pump —-
Item Standard Limit

Page: 47

SPEC
2 — 10
MAINTENANCE SPECIFICATIONS
Part to be tightened Thread size Q’ty
Tightening torque
Nm m·kg ft·lb
Spark plug M10S × 1.0 1 13 1.3 9.4
Camshaft cap M6 × 1.0 10 10 1.0 7.2
Cylinder head blind plug screw M12 × 1.0 1 37 3.7 27
Cylinder head (stud bolt) M6 × 1.0 2 7 0.7 5.1
(stud bolt) M8 × 1.25 1 15 1.5 11
(bolt) M9 × 1.25 4 38 3.8 27
(nut) M6 × 1.0 2 10 1.0 7.2
Cylinder head cover M6 × 1.0 2 10 1.0 7.2
Oil pressure check bolt M6 × 1.0 1 10 1.0 7.2
Cylinder M6 × 1.0 1 10 1.0 7.2
Balancer weight M6 × 1.0 2 10 1.0 7.2
Balancer shaft driven gear M14 × 1.0 1 50 5.0 36
Timing chain guide (intake side) M6 × 1.0 2 10 1.0 7.2
Decompression shaft M6 × 1.0 1 7 0.7 5.1
Decompression cable guide M6 × 1.0 1 10 1.0 7.2
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner cap bolt M6 × 1.0 1 7 0.7 5.1
Impeller M8 × 1.25 1 14 1.4 10
Radiator hose clamp M6 × 1.0 8 2 0.2 1.4
Coolant drain bolt M6 × 1.0 1 10 1.0 7.2
Water pump housing M6 × 1.0 4 10 1.0 7.2
Radiator M6 × 1.0 6 10 1.0 7.2
Radiator guard M6 × 1.0 2 10 1.0 7.2
Radiator pipe M6 × 1.0 1 10 1.0 7.2
Oil pump cover M4 × 0.7 1 3 0.3 2.2
Oil pump M6 × 1.0 3 10 1.0 7.2
Oil filter element drain bolt M6 × 1.0 1 10 1.0 7.2
Oil filter element cover M6 × 1.0 2 10 1.0 7.2
Oil strainer M6 × 1.0 2 10 1.0 7.2
Oil delivery pipe 1 (M10) M10 × 1.25 1 20 2.0 14
(M8) M8 × 1.25 2 18 1.8 13
Oil delivery pipe 2 M6 × 1.0 1 10 1.0 7.2
Oil hose M6 × 1.0 3 10 1.0 7.2
Oil hose clamp — 2 2 0.2 1.4
Oil strainer and frame M18 × 1.5 1 90 9.0 65
Carburetor joint clamp M4 × 0.7 2 3 0.3 2.2
Air filter joint clamp M6 × 1.0 1 3 0.3 2.2
Throttle cable cover M5 × 0.8 1 4 0.4 2.9
Air filter joint M5 × 0.8 2 5 0.5 3.6
Air filter joint and air filter case M5 × 0.8 5 1 0.1 0.7
Air filter element M6 × 1.0 1 2 0.2 1.4
Air filter case cover M6 × 1.0 4 4 0.4 2.9
Exhaust pipe (nut) M8 × 1.25 1 13 1.3 9.4
(bolt) M8 × 1.25 1 24 2.4 17
Exhaust pipe protector M6 × 1.0 3 10 1.0 7.2

Page: 48

SPEC
2 — 11
MAINTENANCE SPECIFICATIONS
NOTE:
— marked portion shall be checked for torque tightening after break-in or before each race.
Silencer M8 × 1.25 2 35 3.5 25
Silencer clamp M8 × 1.25 1 20 2.0 14
Spark arrester (for USA) M6 × 1.0 3 10 1.0 7.2
Silencer end pipe (for USA) M6 × 1.0 1 10 1.0 7.2
Crankcase M6 × 1.0 11 12 1.2 8.7
Crankcase bearing stopper M6 × 1.0 11 10 1.0 7.2
Crankcase bearing stopper (crankshaft) M6 × 1.0 4 10 1.0 7.2
Left crankcase cover M6 × 1.0 8 10 1.0 7.2
Right crankcase cover M6 × 1.0 8 10 1.0 7.2
Clutch cover M6 × 1.0 7 10 1.0 7.2
Crankcase oil drain bolt M10 × 1.25 1 20 2.0 14
Drive chain sprocket cover M6 × 1.0 2 8 0.8 5.8
Kick shaft ratchet wheel guide M6 × 1.0 2 12 1.2 8.7
Kickstarter crank M8 × 1.25 1 33 3.3 24
Primary drive gear M18 × 1.0 1 75 7.5 54
Clutch spring M6 × 1.0 5 8 0.8 5.8
Clutch boss M16 × 1.0 1 60 6.0 43
Push lever shaft M6 × 1.0 1 10 1.0 7.2
Drive sprocket M18 × 1.0 1 75 7.5 54
Drive axle oil seal stopper M6 × 1.0 2 10 1.0 7.2
Segment M8 × 1.25 1 30 3.0 22
Shift guide M6 × 1.0 2 10 1.0 7.2
Stopper lever M6 × 1.0 1 10 1.0 7.2
Part to be tightened Thread size Q’ty
Tightening torque
Nm m·kg ft·lb

Page: 49

SPEC
2 — 12
MAINTENANCE SPECIFICATIONS
CHASSIS
Item Standard Limit
Steering system:
Steering bearing type Taper roller bearing —-
Front suspension: USA, CDN EUROPE AUS, NZ, ZA
Front fork travel 300 mm (11.8 in) ← ←
Fork spring free length 460 mm (18.1 in) ← ←
Spring rate, STD K = 4.31 N/mm
(0.44 kg/mm,
24.6 lb/in)
K = 4.12 N/mm
(0.42 kg/mm,
23.5 lb/in)
K = 4.02 N/mm
(0.41 kg/mm,
23 lb/in)
Optional spring/spacer Yes ← ←
Oil capacity 568 cm3
(20.0 lmp oz,
19.2 US oz)
578 cm3
(20.3 lmp oz,
19.5 US oz)
568 cm3
(20.0 lmp oz,
19.2 US oz)
Oil level 140 mm (5.51 in) 130 mm (5.12 in) 140 mm (5.51 in)
<Min.~Max.>
(From top of outer tube with inner
tube and damper rod fully com-
pressed without spring.)
80 ~ 150 mm
(3.15 ~ 5.91 in)
← ←
Oil grade Suspension oil
“01”
← ←
Inner tube outer diameter 46 mm (1.81 in) ← ←
Front fork top end 5 mm (0.20 in) 8 mm (0.31 in) 10.5 mm (0.41 in)
Rear suspension: USA, CDN EUROPE AUS, NZ, ZA
Shock absorber travel 132 mm (5.20 in) ← ←
Spring free length 260 mm (10.24 in) ← ←
Fitting length 244 mm (9.61 in) 247 mm (9.72 in) 243.5 mm (9.59 in)
<Min.~Max.> 240.5 ~ 258.5 mm
(9.47 ~ 10.18 in)
← ←
Spring rate, STD K = 49.0 N/mm
(5.00 kg/mm,
280.0 lb/in)
K = 47.0 N/mm
(4.80 kg/mm,
268.8 lb/in)
←
Optional spring Yes ← ←
Enclosed gas pressure 1,000 kPa
(10 kg/cm2, 142 psi)
← ←
Swingarm:
Swingarm free play limit
End —- 1.0 mm
(0.04 in)

Page: 50

SPEC
2 — 13
MAINTENANCE SPECIFICATIONS
Item Standard Limit
Wheel: USA, CDN, ZA EUROPE, AUS, NZ
Front wheel type Spoke wheel ← —-
Rear wheel type Spoke wheel ← —-
Front rim size/material 21 × 1.60/Aluminum ← —-
Rear rim size/material 18 × 1.85/Aluminum 18 × 2.15/Aluminum —-
Rim runout limit:
Radial —- —- 2.0 mm
(0.08 in)
Lateral —- —- 2.0 mm
(0.08 in)
Drive chain:
Type/manufacturer DID520VM/DAIDO —-
Number of links 113 links + joint —-
Chain slack 40 ~ 50 mm (1.6 ~ 2.0 in) —-
Chain length (10 links) —- 150.1 mm
(5.91 in)
Front disc brake:
Disc outside dia. × Thickness 250 × 3.0 mm (9.84 × 0.12 in) 250 × 2.5 mm
(9.84 × 0.10 in)
Pad thickness 4.4 mm (0.17 in) 1.0 mm
(0.04 in)
Master cylinder inside dia. 11.0 mm (0.433 in) —-
Caliper cylinder inside dia. 27.0 mm (1.063 in) × 2 —-
Brake fluid type DOT #4 —-
Rear disc brake:
Disc outside dia. × Thickness 245 × 4.0 mm (9.65 × 0.16 in) 245 × 3.5 mm
(9.65 × 0.14 in)
Deflection limit —- 0.15 mm
(0.006 in)
Pad thickness 6.4 mm (0.25 in) 1.0 mm
(0.04 in)
Master cylinder inside dia. 12.7 mm (0.500 in) —-
Caliper cylinder inside dia. 27.0 mm (1.063 in) × 1 —-
Brake fluid type DOT #4 —-
Brake lever and brake pedal:
Brake lever position 95 mm (3.74 in) —-
Brake pedal height
(vertical height below footrest top)
5 mm (0.20 in) —-
Clutch lever free play (lever end) 8 ~ 13 mm (0.31 ~ 0.51 in) —-
Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) —-

5PH-28199-30

EC010010

EC020000

INTRODUCTION

Congratulations on your purchase of a Yamaha WR series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.

This manual explains operation, inspection, basic maintenance and tuning of your machine. If you have any questions about this manual or your machine, please contact your Yamaha dealer.

NOTE:

As improvements are made on this model, some data in this manual may become outdated. If you have any questions, please consult your Yamaha dealer.

WARNING

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.

IMPORTANT NOTICE

THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding.

SAFETY INFORMATION

1.THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY. Do not attempt to operate this machine at maximum power until you are totally familiar with its characteristics.

2.THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY. Do not carry passengers on this machine.

3.ALWAYS WEAR PROTECTIVE APPAREL.

When operating this machine, always wear an approved helmet with goggles or a face shield. Also wear heavy boots, gloves, and protective clothing. Always wear proper fitting clothing that will not be caught in any of the moving parts or controls of the machine.

4.ALWAYS MAINTAIN YOUR MACHINE IN PROPER WORKING ORDER.

For safety and reliability, the machine must be properly maintained. Always perform the pre-operation checks indicated in this manual. Correcting a mechanical problem before you ride may prevent an accident.

5.GASOLINE IS HIGHLY FLAMMABLE. Always turn off the engine while refueling. Take care to not spill any gasoline on the engine or exhaust system. Never refuel in the vicinity of an open flame, or while smoking.

6.GASOLINE CAN CAUSE INJURY.

If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes.

7.ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILATION.

Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are poisonous. These fumes contain carbon monoxide, which by itself is odorless and colorless. Carbon monoxide is a dangerous gas which can cause unconsciousness or can be lethal.

8.PARK THE MACHINE CAREFULLY; TURN OFF THE ENGINE.

Always turn off the engine if you are going to leave the machine. Do not park the machine on a slope or soft ground as it may fall over.

9.THE ENGINE EXHAUST PIPE, MUFFLER, AND OIL TANK WILL BE VERY HOT AFTER THE ENGINE HAS BEEN RUN.

Be careful not to touch them or to allow any clothing item to contact them during inspection or repair.

10.PROPERLY SECURE THE MACHINE BEFORE TRANSPORTING IT.

When transporting the machine in another vehicle, always be sure it is properly secured and in an upright position and that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the carburetor or fuel tank.

EC050000

TO THE NEW OWNER

This manual will provide you with a good basic understanding of features, operation, and basic maintenance and inspection items of this machine. Please read this manual carefully and completely before operating your new machine. If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer.

NOTE:

This manual should be considered a permanent part of this machine and should remain with it even if the machine is subsequently sold.

EC060000

NOTICE

Some data in this manual may become outdated due to improvements made to this model in the future. If there is any question you have regarding this manual or your machine, please consult your Yamaha dealer.

EC070001

F.I.M. MACHINE WEIGHTS:

Weights of machines without fuel

The minimum weights for motocross

In modifying your machine (e.g., for weight reduction), take note of the above limits of weight.

EC080000

HOW TO USE

THIS MANUAL

EC081000

PARTICULARLY IMPORTANT INFORMATION

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

EC082000

FINDING THE REQUIRED PAGE

1.This manual consists of seven chapters; “General information”, “Specifications”, “Regular inspection and adjustments”, “Engine”, “Chassis”, “Electrical” and “Tuning”.

2.The table of contents is at the beginning of the manual. Look over the general layout of the book before finding then required chapter and item.

Bend the book at its edge, as shown, to find the required fore edge symbol mark and go to a page for required item and description.

EC083000

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.

In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g.,

●Bearings

Pitting/damage → Replace.

EC084002

HOW TO READ DESCRIPTIONS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

1.An easy-to-see exploded diagram 1 is provided for removal and disassembly jobs.

2.Numbers 2 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a 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 3. The meanings of the symbol marks are given on the next page.

4.A job instruction chart 4 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.

5.Extent of removal 5 is provided in the job instruction chart to save the trouble of an unnecessary removal job.

6.For jobs requiring more information, the step-by-step format supplements 6 are given in addition to the exploded diagram and job instruction chart.

EC090010

INDEX

GENERAL INFORMATION

SPECIFICATIONS

REGULAR INSPECTION AND ADJUSTMENTS

ENGINE

CHASSIS

ELECTRICAL

TUNING

EC0A0000

CONTENTS

CHAPTER 1

GENERAL INFORMATION

CHAPTER 2

SPECIFICATIONS

CHAPTER 3

REGULAR INSPECTION AND

ADJUSTMENTS

CHAPTER 4

ENGINE

CHAPTER 5

CHASSIS

CHAPTER 6

ELECTRICAL

1 — 1

1 — 1

1 — 2

GEN

IMPORTANT INFORMATION INFO

EC130000

IMPORTANT INFORMATION

EC131010

PREPARATION FOR REMOVAL AND

DISASSEMBLY

1.Remove all dirt, mud, dust, and foreign material before removal and disassembly.

When washing the machine with high pressured water, cover the parts follows.

●Silencer end

●Air filter intake hole

●Water pump housing hole at the bottom

●Carburetor accelerator pump

2.Use proper tools and cleaning equipment. Refer to “SPECIAL TOOLS” section.

3.When disassembling the machine, keep mated parts together. They include gears, cylinders, pistons, and other mated parts that have been “mated” through normal wear. Mated parts must be reused as an assembly or replaced.

4.During the machine 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.

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GEN

IMPORTANT INFORMATION INFO

EC136000

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 2 is positioned opposite to the thrust

3 it receives. See the sectional view.

4 Shaft

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GEN

CHECKING OF CONNECTION INFO

EC1C0001

CHECKING OF CONNECTION

Dealing with stains, rust, moisture, etc. on the connector.

1.Disconnect:

●Connector

2.Dry each terminal with an air blower.

3.Connect and disconnect the connector two or three times.

4.Pull the lead to check that it will not come off.

5.If the terminal comes off, bend up the pin 1 and reinsert the terminal into the connector.

6.Connect:

●Connector

NOTE:

The two connectors “click” together.

7. Check for continuity with a tester.

NOTE:

●If there in no continuity, clean the terminals.

●Be sure to perform the steps 1 to 7 listed above when checking the wireharness.

●For a field remedy, use a contact revitalizer available on the market.

●Use the tester on the connector as shown.

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