YAMAHA RAPTOR 250 YFM240 Service Repair Manual 2008 ONWARD

SERVICE MANUAL YFM250RX 4D3-28197-10 LIT-11616-21-22 2008

EBS00002 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 maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use. Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and sig- nificant 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. EBS00003 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 machine operator, a bystander or a person checking or repairing the machine. A CAUTION indicates special precautions that must be taken to avoid dam- age to the machine. A NOTE provides key information to make procedures easier or clearer. WARNING CAUTION: NOTE:

EBS00004 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title : This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title : 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 : This title indicates a sub-section that is followed by step-by-step procedures accompa- nied by corresponding illustrations. EXPLODED DIAGRAMS 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 is provided for removal and disassembly jobs. 2. Numbers 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 . The meanings of the symbol marks are given on the next page. 4. A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5. For jobs requiring more information, the step-by-step format supplements are given in addition to the exploded diagram and the job instruction chart.

GEN INFO CHAS EBS00006 SYMBOLS The following symbols are not relevant to every machine. Symbols to indicate the subject of each chapter. General information Specifications Periodic checks and adjustments Engine Carburetor Chassis Electrical Troubleshooting Symbols to indicate the following Serviceable with engine mounted Filling fluid Lubricant Special tool Torque Wear limit, clearance Engine speed Electrical data (Ω, V, A) Symbols to in the exploded diagrams indicate the types of lubricants and lubrication points. Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply brake fluid Apply wheel bearing grease Apply lithium-soap-based grease Apply molybdenum disulfide grease Apply silicone grease Symbols to in the exploded diagrams indicate where to apply a locking agent and when to install a new part . Apply the locking agent (LOCTITE ® ) Replace

EBS00008 TABLE OF CONTENTS GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 ENGINE ENG 4 CARBURETOR CARB 5 CHASSIS CHAS 6 ELECTRICAL ELEC 7 TROUBLESHOOTING TRBL SHTG 8

CHAPTER 1 GENERAL INFORMATION MACHINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 VEHICLE IDENTIFICATION NUMBER. . . . . . . . . . . . . . . . . . . . . . . . 1-1 MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . . 1-2 REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . 1-2 LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . . . . . . . 1-2 BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 CHASSIS SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 HOW TO USE THE CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . 2-19 GENERAL TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . . 2-19 LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . . 2-20 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 OIL FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 GENERAL MAINTENANCE AND LUBRICATION CHART . . . . . . . . . . 3-2 SEAT, FENDERS AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 SEAT, FRONT FENDER AND HEADLIGHTS . . . . . . . . . . . . . . . . . . 3-4 FOOT PROTECTORS AND ENGINE SKID PLATE . . . . . . . . . . . . . . 3-5 REAR FENDER AND AIR FILLTER CASE. . . . . . . . . . . . . . . . . . . . . 3-6 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . 3-9 ADJUSTING THE ENGINE IDLING SPEED. . . . . . . . . . . . . . . . . . . . 3-11 ADJUSTING THE THROTTLE LEVER FREE PLAY . . . . . . . . . . . . . 3-12 ADJUSTING THE SPEED LIMITER . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 CHECKING THE SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 CHECKING THE IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 MEASURING THE COMPRESSION PRESSURE . . . . . . . . . . . . . . . 3-17 CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . 3-19 CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 ADJUSTING THE CLUTCH CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . 3-23 CLEANING THE SPARK ARRESTER . . . . . . . . . . . . . . . . . . . . . . . . 3-25 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 ADJUSTING THE FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 ADJUSTING THE BRAKE LEVER (For adjustment type model) . . . . 3-26 ADJUSTING THE REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 ADJUSTING THE PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . 3-28 CHECKING THE FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . 3-29 CHECKING THE REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . 3-30 ADJUSTING THE REAR BRAKE LIGHT SWITCH. . . . . . . . . . . . . . . 3-31 CHECKING THE BRAKE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . 3-32 ADJUSTING THE SHIFT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 ADJUSTING THE DRIVE CHAIN SLACK. . . . . . . . . . . . . . . . . . . . . . 3-35 CHECKING THE STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 3-36 ADJUSTING THE TOE-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 CHECKING THE FRONT AND REAR SHOCK ABSORBERS . . . . . . 3-38 ADJUSTING THE FRONT SHOCK ABSORBERS . . . . . . . . . . . . . . . 3-39 ADJUSTING THE REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . 3-40 CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 CHECKING THE WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

CHECKING AND LUBRICATING THE CABLES . . . . . . . . . . . . . . . . 3-43 LUBRICATING THE LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . . 3-44 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 CHECKING AND CHARGING THE BATTERY . . . . . . . . . . . . . . . . . 3-45 CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 ADJUSTING THE HEADLIGHT BEAM . . . . . . . . . . . . . . . . . . . . . . . . 3-53 REPLACING A HEADLIGHT BULB . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54 CHAPTER 4 ENGINE ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 MUFFLER AND EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 INSTALLING THE EXHAUST PIPE AND MUFFLER . . . . . . . . . . . . . 4-2 LEADS, CABLES AND HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ENGINE MOUNTING BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 REMOVING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 CHECKING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 CHECKING THE TIMING CHAIN GUIDES . . . . . . . . . . . . . . . . . . . . 4-11 CHECKING THE TIMING CHAIN TENSIONERS . . . . . . . . . . . . . . . . 4-11 INSTALLING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 ROCKER ARM, CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 REMOVING THE ROCKER ARMS AND CAMSHAFT . . . . . . . . . . . . 4-16 CHECKING THE CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 INSTALLING THE CAMSHAFT AND ROCKER ARMS . . . . . . . . . . . 4-19 VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 REMOVING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 CHECKING THE VALVES AND VALVE GUIDES . . . . . . . . . . . . . . . 4-23 CHECKING THE VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 CHECKING THE VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 INSTALLING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 REMOVING THE PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 CHECKING THE CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . 4-32 CHECKING THE PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 CHECKING THE PISTON PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 INSTALLING THE PISTON AND CYLINDER . . . . . . . . . . . . . . . . . . . 4-37 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39 REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43 CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . . . 4-44

CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . 4-45 CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . 4-45 CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 CHECKING THE PRESSURE PLATE . . . . . . . . . . . . . . . . . . . . . . . . 4-45 CHECKING THE CLUTCH PUSH RODS . . . . . . . . . . . . . . . . . . . . . . 4-46 CHECKING THE PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . 4-46 INSTALLING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46 OIL PUMP AND BLANCER WEIGHT GEAR . . . . . . . . . . . . . . . . . . . . . 4-50 REMOVING THE BALANCER WEIGHT GEAR AND OIL PUMP. . . . 4-53 CHECKING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53 CHECKING THE BALANCER WEIGHT GEAR . . . . . . . . . . . . . . . . . 4-54 ASSENBLING THE BALANCER DRIVE GEAR . . . . . . . . . . . . . . . . . 4-55 INSTALLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55 INSTALLING THE BALANCER WEIGHT GEAR . . . . . . . . . . . . . . . . 4-56 SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57 CHECKING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58 CHECKING THE STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . . 4-58 INSTALLING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58 PICKUP COIL ROTOR AND STARTER CLUTCH . . . . . . . . . . . . . . . . . 4-60 REMOVING THE PICKUPCOIL ROTOR . . . . . . . . . . . . . . . . . . . . . . 4-62 CHECKING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 4-63 INSTALLING THE PICKUP COIL ROTOR . . . . . . . . . . . . . . . . . . . . . 4-64 CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66 DISASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . 4-69 CHECKING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70 ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70 CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72 REMOVING THE CRANKSHAFT ASSEMBLY. . . . . . . . . . . . . . . . . . 4-73 REMOVING THE PLUNGER SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73 CHECKING THE CRANKSHAFT AND CONNECTING ROD . . . . . . . 4-73 CHECKING THE TIMING CHAIN, CRANKSHAFT SPROCKET AND TIMING CHAIN GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74 INSTALLING THE PLUNGER SEAL . . . . . . . . . . . . . . . . . . . . . . . . . 4-75 INSTALLING THE CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . 4-75 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77 REMOVING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80 CHECKING THE SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80 CHECKING THE SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . . 4-81 CHECKING THE TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82

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YAMAHA RAPTOR 250 YFM240 Service Repair Manual 2008 ONWARD

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