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Yamaha YZ 2015 Series Owner's Service Manual

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Table of Contents

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2015
q Read this manual carefully before operating this vehicle.
OWNER'S SERVICE MANUAL
YZ250FXF
LIT-11626-28-51
B29-28199-10

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Summary of Contents for Yamaha YZ 2015 Series

  • Page 1 2015 q Read this manual carefully before operating this vehicle. OWNER’S SERVICE MANUAL YZ250FXF LIT-11626-28-51 B29-28199-10...
  • Page 2 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
  • Page 3 EASB291002 YZ250FXF OWNER’S SERVICE MANUAL ©2014 by Yamaha Motor Corporation, U.S.A. 1st Edition, September 2014 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan P/N. LIT-11626-28-51...
  • Page 4 INTRODUCTION EASB291003 Congratulations on your purchase of a Yamaha YZ 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.
  • Page 5 SAFETY INFORMATION EASB291005 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. •...
  • Page 6 YAMAHA MOTOR CORPORATION, U.S.A. EASB291006 YZ MOTORCYCLE LIMITED WARRANTY...
  • Page 7 HOW TO USE THIS MANUAL EASB291007 In this manual, descriptions of installation, removal, disassembly, assembly, check, and adjustment procedures are laid out with the individual steps in sequential order. • The manual is divided into chapters and each chapter is divided into sections. The current section title “1”...
  • Page 8 SYMBOLS EASB291008 The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...

  • Page 9: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUST- MENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING TUNING...

  • Page 11: General Information

    GENERAL INFORMATION LOCATION OF IMPORTANT LABELS............1-1 DESCRIPTION....................1-2 IDENTIFICATION....................1-3 VEHICLE IDENTIFICATION NUMBER ............1-3 ENGINE SERIAL NUMBER................1-3 FEATURES .......................1-4 OUTLINE OF THE FI SYSTEM ..............1-4 FI SYSTEM....................1-5 INCLUDED PARTS...................1-6 SPARK PLUG WRENCH................1-6 NIPPLE WRENCH..................1-6 HANDLEBAR PROTECTOR ..............1-6 FUEL HOSE JOINT COVER ..............1-6 COUPLER FOR CONNECTING OPTIONAL PART........1-6 IMPORTANT INFORMATION................1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-7...
  • Page 12 STARTING AND BREAK-IN................1-22 FUEL......................1-22 HANDLING NOTE ..................1-22 AIR FILTER MAINTENANCE ..............1-22 STARTING A COLD ENGINE ..............1-22 STARTING A WARM ENGINE ..............1-23 BREAK-IN PROCEDURES ..............1-24 MAINTENANCE AFTER BREAK-IN ..............1-25 MAJOR MAINTENANCE ................1-25 TORQUE-CHECK POINTS................1-26 MOTORCYCLE CARE AND STORAGE ............1-28 CARE......................1-28 STORAGE ....................1-29...

  • Page 13: Location Of Important Labels

    LOCATION OF IMPORTANT LABELS LOCATION OF IMPORTANT LABELS EASB291009 Please read the following important labels carefully before operating this vehicle. For use only on a closed course Premium unleaded in sanctioned competition. gasoline only. This motorcycle does not meet 3FB-2415E-02 EPA noise and emissions standards and is not for general off-road recreational riding.

  • Page 14: Description

    DESCRIPTION DESCRIPTION EASB291010 17 16 15 1. Clutch lever 10. Radiator 2. Front brake lever 11. Coolant drain bolt 3. Throttle grip 12. Rear brake pedal 4. Start switch 13. Air filter 5. Radiator cap 14. Drive chain 6. Fuel tank cap 15.

  • Page 15: Identification

    There are two significant reasons for knowing the serial number of your vehicle: 1. When ordering parts, you can give the num- ber to your Yamaha dealer for positive iden- tification of the model you own. 2. If your vehicle is stolen, the authorities will need the number to search for and identify your vehicle.

  • Page 16: Features

    FEATURES FEATURES EAS20170 EASB291014 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.

  • Page 17: Fi System

    FEATURES FI SYSTEM EASB291015 The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kgf/cm , 47.0 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 18: Included Parts

    INCLUDED PARTS FUEL HOSE JOINT COVER INCLUDED PARTS EASB291016 The fuel hose joint covers “1” are used to pre- vent mud, dust, and other foreign materials SPARK PLUG WRENCH EASB291017 from entering the inside when the fuel hose is The spark plug wrench “1” is used to remove or disconnected.

  • Page 19: Important Information

    2. Use proper special tools and equipment. used for repair of the vehicle, including periodic See “SPECIAL TOOLS”. replacement parts, are new YAMAHA genuine parts and recommended parts. Do not use any used parts, because these may not be genuine though they have similar ap- pearances or because the quality may be changed by aging.

  • Page 20: Gaskets, Oil Seals And O-Rings

    IMPORTANT INFORMATION GASKETS, OIL SEALS AND O-RINGS EASB291024 1. When overhauling the engine, replace all gaskets and O-rings. All gasket surfaces, oil seal lips, and O-rings must be cleaned so that there may be no dust on them. 2. During assembly, always apply proper oil to bearings and proper grease to oil seal lips before installation.

  • Page 21: Basic Service Information

    BASIC SERVICE INFORMATION BASIC SERVICE INFORMATION EASB291028 ELECTRICAL SYSTEM EASB291029 Electrical parts handling NOTICE Never disconnect a battery lead while the engine is running; otherwise, the electrical components could be damaged. NOTICE Be sure to connect the battery leads to the correct battery terminals.
  • Page 22 BASIC SERVICE INFORMATION NOTICE Checking the electrical system Handle electrical components with special care, and do not subject them to strong Before checking the electrical system, make shocks. sure that the battery voltage is at least 12 V. NOTICE NOTICE Electrical components are very sensitive to Never insert the tester probes into the cou- and can be damaged by static electricity.
  • Page 23 BASIC SERVICE INFORMATION 2. Check: • Lead • Coupler • Connector Moisture  Dry with compressed air. Rust/stains  Connect and disconnect sev- eral times. Checking the connections Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: •...
  • Page 24 BASIC SERVICE INFORMATION 4. Connect: • Lead • Coupler • Connector • When connecting a coupler or connector, make sure that both terminals are connected securely. • Make sure all connections are tight. 5. Check: • No continuity Pocket tester 90890-03112 Analog pocket tester YU-03112-C...

  • Page 25: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS EASB291030 The following special tools are required for accurate and complete adjustment and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and tool number used for the special tool differ by country, so two types are provided.
  • Page 26 SPECIAL TOOLS Tool name/Part number How to use Illustration Radiator cap tester This tool is used to check the 90890-01325 radiator and the radiator cap. Mityvac cooling system tester YU-24460-A Radiator cap tester adapter This tool is used to check the 90890-01352 radiator and the radiator cap.
  • Page 27 Test harness– lean angle sensor (6P) YU-03209 FI diagnostic tool sub–lead This tool is used to connect 90890-03212 the Yamaha diagnostic tool FI diagnostic tool sub–lead to a battery. YU-03212 Yamaha diagnostic tool This tool is used to check er-...
  • Page 28 SPECIAL TOOLS Tool name/Part number How to use Illustration Valve spring compressor This tool is used to discon- 90890-04019 nect or connect the valve and Valve spring compressor the valve spring. YM-04019 YM-04019 Spacer (crankshaft installer) This tool is used to install the 90890-04081 crankshaft.
  • Page 29 SPECIAL TOOLS Tool name/Part number How to use Illustration Valve lapper This tool is used to remove 90890-04101 the valve lifter or lap the Valve lapping tool valve. YM-A8998 Valve spring compressor at- This tool is used to discon- tachment nect or connect the valve and 90890-04108 the valve spring.
  • Page 30 Tool name/Part number How to use Illustration Digital tachometer This tool is used to measure 90890-06760 the engine speed. Digital tachometer YU-39951-B Yamaha bond No. 1215 This sealant (Bond) is used 90890-85505 for crankcase mating sur- (Three bond No.1215®) face, etc. 1-18...

  • Page 31: Control Functions

    CONTROL FUNCTIONS SHIFT PEDAL CONTROL FUNCTIONS EASB291031 The shift pedal “1” has adopted a method of 1 down & 5 ups (press-down & kick-ups). ENGINE STOP SWITCH EASB291032 Press it down for N (neutral) to 1st, and kick it The engine stop switch “1” is located on the left up for 2nd to 6th.

  • Page 32: Front Brake Lever

    CONTROL FUNCTIONS STARTER KNOB/IDLE ADJUSTING SCREW FRONT BRAKE LEVER EASB291038 Starting a cold engine requires a larger amount The front brake lever “1” is located on the right of intake air, which is supplied by the starter handlebar. Pull it toward the handlebar to acti- knob/idle screw “1”.
  • Page 33 CONTROL FUNCTIONS 1-21...

  • Page 34: Starting And Break-In

    EASB291047 STARTING A COLD ENGINE NOTICE Your Yamaha engine has been designed to use For maximum engine life, never accelerate premium unleaded gasoline with a pump oc- hard when the engine is cold! tane number [(R+M)/2] of 91 or higher, or a re- In order for the ignition circuit cut-off system to search octane number of 95 or higher.

  • Page 35: Starting A Warm Engine

    STARTING AND BREAK-IN Starting with the kickstarter NOTICE When using the kickstarter to start the engine, If the starter motor will not turn when the follow the procedures as described below. start switch is pushed, stop pushing it im- 1. Fold out the kickstarter lever, push it down mediately in order to avoid placing extra lightly with your foot until resistance is felt.

  • Page 36: Break-In Procedures

    STARTING AND BREAK-IN BREAK-IN PROCEDURES EASB291049 A break-in is important so that rotating portion, sliding surfaces, and mounted areas may fit one another, and that the rider may become ac- customed to the machine. NOTICE Before running, do maintenance on the air filter element.

  • Page 37: Maintenance After Break-In

    MAINTENANCE AFTER BREAK-IN • Cable MAINTENANCE AFTER BREAK-IN EASB291050 Grease and adjust cables. After a break-in, perform careful maintenance • Drive chain to get ready for the next practice or race. Lubricate the drive chain and adjust its ten- Refer to “PRE-OPERATION INSPECTION sion.
  • Page 38 TORQUE-CHECK POINTS TORQUE-CHECK POINTS EASB291052 Frame construction Frame to rear frame Frame to engine protector Combined seat and fuel tank Fuel tank to frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Seat Seat to frame Steering Steering stem to handlebar Steering stem to frame...

  • Page 39: Torque-Check Points

    TORQUE-CHECK POINTS Plastic cover Tightening of number plate Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake disc cov- Tightening of rear brake caliper cover Concerning the tightening torque, refer to “TIGHTENING TORQUES”...

  • Page 40: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE • Do not use any harsh chemical products MOTORCYCLE CARE AND STOR- EASB291053 on plastic parts. Be sure to avoid using cloths or sponges which have been in con- tact with strong or abrasive cleaning prod- EASB291054 CARE ucts, solvent or thinner, fuel (gasoline),...

  • Page 41: Storage

    ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Lubricate all control cables and the pivoting Consult a Yamaha dealer for advice on what points of all levers and pedals as well as of products to use. the sidestand/ centerstand.
  • Page 42 MOTORCYCLE CARE AND STORAGE 5. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alter- natively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot.

  • Page 43: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-8 ELECTRICAL SPECIFICATIONS ..............2-11 TIGHTENING TORQUES ................2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS ......2-12 ENGINE TIGHTENING TORQUES ............2-13 CHASSIS TIGHTENING TORQUES ............2-16 LUBRICATION POINTS AND LUBRICANT TYPES........2-19 ENGINE ....................2-19 CHASSIS ....................2-20 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-23 LUBRICATION DIAGRAMS ..............2-23 CABLE ROUTING DIAGRAM ................2-31...

  • Page 44: General Specifications

    GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS EASB291056 Model Model B291 (USA) B292 (CAN) B293 (EUR) B294 (AUS) (NZL) (ZAF) B295 (JPN) Dimensions Overall length 2165 mm (85.2 in) Overall width 825 mm (32.5 in) Overall height 1280 mm (50.4 in) Seat height 965 mm (38.0 in) Wheelbase 1465 mm (57.7 in)

  • Page 45: Engine Specifications

    ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS EASB291057 Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 250 cm Cylinder arrangement Single cylinder Bore  stroke 77.0  53.6 mm (3.0  2.1 in) Compression ratio 13.5:1 Starting system Electric starter and kickstarter Fuel Recommended fuel Premium unleaded gasoline only Fuel tank capacity...
  • Page 46 ENGINE SPECIFICATIONS Spark plug Manufacturer/model NGK/LMAR8G Spark plug gap 0.7–0.8 mm (0.028–0.031 in) Cylinder head Combustion chamber volume 12.07–12.87 cm (0.74–0.79 cu.in) Warpage limit 0.05 mm (0.0020 in) Camshaft Drive system Chain drive (left) Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in) Camshaft journal diameter 21.959–21.972 mm (0.8645–0.8650 in) Camshaft-journal-to-camshaft-cap clearance...
  • Page 47 ENGINE SPECIFICATIONS Valve face width B (intake) 1.697 mm (0.0668 in) Valve face width B (exhaust) 1.909 mm (0.0752 in) Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in) Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Valve margin thickness D (intake) 1.20 mm (0.0472 in) Valve margin thickness D (exhaust) 0.85 mm (0.0335 in)
  • Page 48 ENGINE SPECIFICATIONS Spring tilt (intake) 1.6 mm (0.06 in) Spring tilt (exhaust) 1.5 mm (0.06 in) Winding direction (intake) Clockwise Winding direction (exhaust) Clockwise Cylinder Bore 77.000–77.010 mm (3.0315–3.0319 in) Taper limit 0.050 mm (0.0020 in) Out of round limit 0.050 mm (0.0020 in) Piston Piston-to-cylinder clearance...
  • Page 49 ENGINE SPECIFICATIONS Crankshaft Crank assembly width 55.95–56.00 mm (2.203–2.205 in) Runout limit C 0.030 mm (0.0012 in) Big end side clearance D 0.150–0.450 mm (0.0059–0.0177 in) Balancer Balancer drive method Gear Clutch Clutch type Wet, multiple-disc Clutch release method Inner push, cam push Clutch lever free play 7.0–12.0 mm (0.28–0.47 in) Friction plate thickness...
  • Page 50 ENGINE SPECIFICATIONS Fuel pump Pump type Electrical Fuel injector Model/quantity 30NA-FZ31/1 12.0  Resistance Throttle body Type/quantity 30RA-A62U/1 ID mark B291 00 Fuel line pressure at idling 324.0 kPa (3.24 kgf/cm , 47.0 psi) Throttle position sensor Resistance 6.30 k Output voltage (at idle) 0.5 V Fuel injection sensor...

  • Page 51: Chassis Specifications

    CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS EASB291058 Chassis Frame type Semi double cradle Caster angle 26.33 ° Trail 114 mm (4.5 in) Front wheel Wheel type Spoke wheel 21  1.60 Rim size Rim material Aluminum Wheel travel 310 mm (12.2 in) Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit...
  • Page 52 CHASSIS SPECIFICATIONS Rear brake Type Single disc brake Operation Right foot operation Rear disc brake Disc outside diameter  thickness 245  4.0 mm (9.6  0.16 in) Brake disc thickness limit 3.5 mm (0.14 in) Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in) Brake pad lining thickness (inner) 6.4 mm (0.25 in) Limit...
  • Page 53 CHASSIS SPECIFICATIONS Rear suspension Type Swingarm (link suspension) Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel 126.0 mm (4.96 in) Spring free length 275.0 mm (10.83 in) Spring installed length 265.0 mm (10.43 in) Spring rate K1 56.00 N/mm (5.71 kgf/mm, 319.76 lbf/in) (USA) (CAN) (EUR) (AUS) (NZL) (ZAF) 48.00 N/mm (4.89 kgf/mm, 274.08 lbf/in) (JPN)

  • Page 54: Electrical Specifications

    Ignition system Advancer type Digital Ignition timing (B.T.D.C.) 10.0 ° at 2000 r/min Engine control unit Model/manufacturer B290/YAMAHA (USA) (CAN) (EUR) (AUS) (NZL) (ZAF) B291/YAMAHA (JPN) Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64  Primary coil resistance Secondary coil resistance 8.64–12.96 k...

  • Page 55: Tightening Torques

    TIGHTENING TORQUES TIGHTENING TORQUES EAS20320 EASB291060 GENERAL TIGHTENING TORQUE SPECIFI- CATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a criss- cross pattern and progressive stages until the specified tightening torque is reached.

  • Page 56: Engine Tightening Torques

    TIGHTENING TORQUES ENGINE TIGHTENING TORQUES EASB291061 - marked portion shall be checked for torque tightening after break-in or before each race. Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Cylinder head blind plug 28 Nm (2.8 m·kgf, 20 ft·lbf) Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
  • Page 57 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Air filter guide holder screw 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) Air filter case cap screw 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) Starter knob/Idle screw 2.1 Nm (0.21 m·kgf, 1.5 ft·lbf) Throttle cable nut (pull) 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Throttle cable nut (return)
  • Page 58 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Use a Drive sprocket nut 75 Nm (7.5 m·kgf, 54 ft·lbf) lock washer. Segment 30 Nm (3.0 m·kgf, 22 ft·lbf) Shift guide bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Stopper lever bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Shift pedal bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf)

  • Page 59: Chassis Tightening Torques

    TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES EASB291062 - marked portion shall be checked for torque tightening after break-in or before each race. Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Outer tube and upper bracket bolt 21 Nm (2.1 m·kgf, 15 ft·lbf) Outer tube and lower bracket bolt 21 Nm (2.1 m·kgf, 15 ft·lbf) Upper bracket and steering stem nut...
  • Page 60 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Front brake disc bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Rear brake disc bolt 14 Nm (1.4 m·kgf, 10 ft·lbf) Footrest bracket bolt 55 Nm (5.5 m·kgf, 40 ft·lbf) Sidestand bolt 25 Nm (2.5 m·kgf, 18 ft·lbf) Rear brake pedal bolt 26 Nm (2.6 m·kgf, 19 ft·lbf)
  • Page 61 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Drive chain tensioner bolt (lower 16 Nm (1.6 m·kgf, 12 ft·lbf) side) Drive chain support bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Drive chain support nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Drive chain guide bolt 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Rear frame and left cover bolt...

  • Page 62: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES EASB291063 ENGINE EASB291064 Lubrication point Lubricant types Oil seal lips Bearing O-ring Cylinder head bolt threads, seats, washers Valve stems Valve stem ends Valve lifter outer surface Camshaft lobe and journal Valve lifter top surface Crankshaft journal Crankshaft big end thrust surfaces...

  • Page 63: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Starter idle gear inner surface, thrust surfaces Starter clutch drive gear inner surface, thrust surfaces Three bond Cylinder head cover gasket No.1215® Three bond Crankcase mating surface No.1215® Three bond Stator assembly lead grommet No.1215®...
  • Page 64 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Front brake caliper piston Front brake caliper piston seal Front brake caliper dust seal Front brake caliper piston outer surface Front brake caliper pin bolt and boot Front brake master cylinder push rod end Front brake master cylinder kit Rear brake caliper piston Rear brake caliper piston seal...
  • Page 65 LUBRICATION POINTS AND LUBRICANT TYPES EASB291066 2-22...

  • Page 66: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION SYSTEM CHART AND DIAGRAMS EASB291067 LUBRICATION DIAGRAMS 2-23...
  • Page 67 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Piston 4. Oil nozzle 5. Oil filter element 6. Oil pump 7. Oil strainer 8. Crankshaft 9. Drive axle 10. Main axle 2-24...
  • Page 68 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25...
  • Page 69 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Connecting rod 2. Crankshaft 3. Main axle 4. Oil strainer 5. Drive axle 2-26...
  • Page 70 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
  • Page 71 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Exhaust camshaft 2. Intake camshaft 3. Oil filter element 4. Oil pump 2-28...
  • Page 72 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 73 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil pressure check bolt 3. Oil filter element 4. Oil pump 2-30...

  • Page 74: Cable Routing Diagram

    CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM EASB291068 2-31...
  • Page 75 CABLE ROUTING DIAGRAM N. Place the grommet of the clutch cable so that it 1. Clutch cable contacts the radiator hose. Route the clutch cable 2. Throttle cable (return) outside the neutral switch lead, AC magneto lead 3. Throttle cable (pull) and starter motor lead.
  • Page 76 CABLE ROUTING DIAGRAM 2-33...
  • Page 77 CABLE ROUTING DIAGRAM 1. Clamp 2. Cylinder head breather hose 3. Throttle position sensor lead 4. Joint coupler 5. Intake air temperature sensor coupler 6. Intake air pressure sensor lead 7. Wire harness 8. Injector lead 9. Throttle body 10. Injector coupler 11.
  • Page 78 CABLE ROUTING DIAGRAM 2-35...
  • Page 79 CABLE ROUTING DIAGRAM 1. Cable guide 2. Joint coupler 3. Ground lead 4. Throttle position sensor lead 5. Throttle position sensor coupler 6. Radiator breather hose 7. Cylinder head breather hose 8. Crankcase breather hose 9. Radiator hose 10. Fuel hose 11.
  • Page 80 CABLE ROUTING DIAGRAM 2-37...
  • Page 81 CABLE ROUTING DIAGRAM 1. Battery negative lead 2. Fuel hose 3. Fuel pump coupler 4. Fuel pump lead 5. Battery positive lead 6. Lean angle sensor 7. Starter motor lead 8. Radiator fan motor relay (blue tape) 9. Main relay (red tape) 10.
  • Page 82 CABLE ROUTING DIAGRAM 2-39...
  • Page 83 CABLE ROUTING DIAGRAM 1. Plastic band 2. Clutch cable 3. Clutch switch lead 4. Engine stop switch lead 5. Front brake hose 6. Brake hose guide 7. Number plate 8. Start switch lead A. Clamp the engine stop switch lead and clutch switch lead to the handlebar by the plastic band.
  • Page 84 CABLE ROUTING DIAGRAM 2-41...
  • Page 85 CABLE ROUTING DIAGRAM 1. Breather hose 3 (air filter breather hose) 2. Breather hose 1 (cylinder head breather hose) 3. Breather hose 2 (crankcase breather hose) 4. Joint pipe A. Pass the breather hose 3 to the outside the throt- tle cable.
  • Page 86 CABLE ROUTING DIAGRAM 2-43...
  • Page 87 CABLE ROUTING DIAGRAM 1. Brake master cylinder 2. Brake hose holder 3. Brake hoses A. While installing the brake hose, direct a bend in its pipe portion as shown, and bring it into contact with the projection on the brake caliper. B.
  • Page 88 CABLE ROUTING DIAGRAM 2-45...

  • Page 89: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS MAINTENANCE INTERVALS ................3-1 MAINTENANCE INTERVALS..............3-1 PRE-OPERATION INSPECTION AND MAINTENANCE .........3-7 GENERAL INSPECTION AND MAINTENANCE ........3-7 ENGINE......................3-8 CHECKING THE COOLANT LEVEL ............3-8 CHECKING THE COOLING SYSTEM ............3-8 CHANGING THE COOLANT..............3-8 CHECKING THE RADIATOR CAP.............3-9 CHECKING THE RADIATOR CAP OPENING PRESSURE ......3-9 CHECKING THE COOLANT CIRCULATORY SYSTEM FOR LEAKS ..3-10 ADJUSTING THE CLUTCH LEVER FREE PLAY ........3-10 ADJUSTING THE THROTTLE GRIP FREE PLAY........3-11...
  • Page 90 CHECKING AND ADJUSTING THE STEERING HEAD ......3-33 CHECKING AND LUBRICATING THE CABLES........3-34 LUBRICATING THE LEVERS ..............3-34 LUBRICATING THE PEDAL..............3-34 LUBRICATING THE DRIVE CHAIN ............3-35 LUBRICATING THE SIDESTAND............3-35 CHECKING THE CHASSIS FASTENERS ..........3-35 ELECTRICAL SYSTEM..................3-36 CHECKING THE SPARK PLUG...............3-36 CHECKING THE IGNITION TIMING ............3-36 CHECKING AND CHARGING THE BATTERY ........3-37...

  • Page 91: Maintenance Intervals

    MAINTENANCE INTERVALS MAINTENANCE INTERVALS EASB291069 MAINTENANCE INTERVALS EASB291070 NOTICE • After a break-in or before each race, always check the points shown in “TORQUE-CHECK POINTS” for tightening torques and retighten them. (“TORQUE-CHECK POINTS” on page 1- 26.) • Periodic inspection is essential in making full use of the machine performance. The life of parts varies significantly according to the environment in which the machine runs (e.g., rain, dirt, etc.).
  • Page 92 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) PISTON RING Inspect Check the end gap of the pis- ton ring. Replace Replace the piston, piston pin, piston pin clip, and piston ring all as a set.
  • Page 93 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) NUT (ROTOR) Retighten Check for tightening torques. EXHAUST PIPE, SI- LENCER, PROTEC- Inspect and re- Check for exhaust leaks, and tighten tightening torques.
  • Page 94 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) ENGINE GUARD Replace Breakage FRAME Clean and inspect FUEL TANK, FUEL PUMP Inspect FUEL HOSE Inspect Replace Every four years FRONT FORK LEG Clean Dust seal...
  • Page 95 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) BRAKE(S) Adjust lever posi- tion and pedal height Lubricate pivot point Check brake disc surface Check fluid level and leakage Retighten brake Check for tightening torques.
  • Page 96 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) DRIVE CHAIN Use chain oil. Clean, lubricate, slack, alignment Replace DRIVE CHAIN GUIDE Inspect Inspect wear. DRIVE CHAIN GUIDE AND DRIVE CHAIN SUPPORT Replace...

  • Page 97: Pre-Operation Inspection And Maintenance

    PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE EASB291071 Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. EASB291072 GENERAL INSPECTION AND MAINTENANCE ITEM inspect Page...

  • Page 98: Engine

    ENGINE ENGINE CHECKING THE COOLING SYSTEM EASB291073 EASB291075 1. Remove: CHECKING THE COOLANT LEVEL EASB291074 • Seat • Side cover (left/right) WARNING • Air scoop (left/right) If coolant seems hot, do not remove the ra- Refer to “GENERAL CHASSIS” on page 4- diator cap.

  • Page 99: Checking The Radiator Cap

    ENGINE Crack/damage  Replace. 5. Install: Exist fur deposits  Clean or replace. • Copper washer • Coolant drain bolt Coolant drain bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 6. Pour coolant. Recommended coolant High quality ethylene glycol anti-freeze containing anti-cor- rosion for aluminum engine Radiator capacity (including all routes)

  • Page 100: Checking The Coolant Circulatory System For Leaks

    ENGINE CHECKING THE COOLANT CIRCULATORY ADJUSTING THE CLUTCH LEVER FREE EASB291079 EASB291080 SYSTEM FOR LEAKS PLAY 1. Check: 1. Check: • Coolant level • Clutch lever free play “a” Out of specification  Regulate. 2. Install: • Radiator cap tester “1” Clutch lever free play •...

  • Page 101: Adjusting The Throttle Grip Free Play

    ENGINE c. Turn the adjuster “2” in direction “a” or “b” 2. Adjust: until the specified clutch lever free play is ob- • Throttle grip free play tained. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. Direction “a” b. Turn the adjuster “2” until the specified free Clutch lever free play is increased.

  • Page 102: Cleaning The Air Filter Element

    ENGINE 2. Lubricate: 2. Remove: • Throttle cable end “a” • Air filter mounting bolt “1” • Air filter element “2” Recommended lubricant • Air filter guide “3” (from the air filter element) Lithium-soap-based grease 3. Wash: • Air filter element 3.

  • Page 103: Checking The Throttle Body Joint

    ENGINE 6. Install: • Air filter guide “1” (to the air filter element) • Air filter element “2” • Air filter mounting bolt “3” Air filter mounting bolt 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) EASB291086 CHECKING THE EXHAUST SYSTEM 1. Remove: •...

  • Page 104: Checking The Fuel Line

    ENGINE CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle upright on a level surface. 2. Start the engine, warm this up for 3 minutes, and then stop the engine and wait about 5 minute. 3. Check: • Oil level The engine oil level should be between the minimum level mark “a”...

  • Page 105: Changing The Engine Oil

    ENGINE 5. To check the oil strainer, perform the follow- CHANGING THE ENGINE OIL EASB291089 ing procedure. Stand the vehicle upright on a level surface. 1. Start the engine, warm this up for 3 minutes, ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the oil strainer “1”. and then stop the engine and wait about 5 b.

  • Page 106: Adjusting The Engine Idling Speed

    ENGINE 8. Install: ADJUSTING THE ENGINE IDLING SPEED • Oil filler cap 9. Check: • Because the air pressure is lower at high alti- • Oil level tudes, the air-fuel mixture will become richer. Refer to “CHECKING THE ENGINE OIL If the idling speed is low, turn the starter knob/ LEVEL”...

  • Page 107: Adjusting The Valve Clearance

    • This section is intended for those who have Valve clearance (cold) basic knowledge and skill concerning the ser- Intake 0.12–0.19 mm (0.0047–0.0075 in) vicing of Yamaha motorcycles (e.g., Yamaha Exhaust dealers, service engineers, etc.). Those who 0.17–0.24 mm (0.0067–0.0094 in) have little knowledge and skill concerning ser- vicing are requested not to undertake inspec- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 108 ENGINE Check that the alignment mark “c” on the cam- • Place a cloth in the timing chain space to pre- shaft sprocket and the alignment mark “d” on vent adjusting pads from falling into the crank- the intake camshaft sprocket are aligned with case.
  • Page 109 ENGINE d. Select an adjusting pad with a proper valve f. Install the camshafts (exhaust and intake). clearance from the adjusting pad selection Refer to “CAMSHAFT” on page 5-12. table. g. Measure the valve clearance again. h. If the valve clearance is out of specification, repeat adjusting the valve clearance until it •...
  • Page 110 ENGINE INTAKE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.02 0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230...

  • Page 111: Chassis

    CHASSIS CHASSIS EASB291092 BLEEDING THE BRAKE SYSTEM EASB291093 WARNING Bleed the brake system whenever: • The system is disassembled. • A brake hose is loosened, disconnected, or replaced. • The brake fluid level is very low. • Brake operation is faulty. A.

  • Page 112: Checking The Brake Hose

    CHASSIS CHECKING THE BRAKE HOSE EASB291094 1. Check: • Brake hose “1” Cracks/damage/wear  Replace. 2. Remove: • Brake lever cover 3. Adjust: • Brake lever position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. b. Turn the adjusting bolt “2” in direction “a” or “b”...

  • Page 113: Adjusting The Rear Brake

    CHASSIS ADJUSTING THE REAR BRAKE EASB291096 NOTICE 1. Check: After adjusting the brake pedal position, • Brake pedal position “a” make sure that there is no brake drag. (distance from the top of the rider footrest to the top of the brake pedal) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 114 CHASSIS d. Remove the pad pin and brake pads “4”. i. Install the brake caliper “8” and tighten the pad pin “9”. Bolt (brake caliper) 28 Nm (2.8 m·kgf, 20 ft·lbf) Pad pin 17 Nm (1.7 m·kgf, 12 ft·lbf) e. Connect the plastic hose “5” to the bleed screw “6”...

  • Page 115: Checking The Rear Brake Pads

    CHASSIS CHECKING THE REAR BRAKE PADS EASB291098 1. Measure: • Brake pad thickness “a” Out of specification  Replace as a set. The pads worn up to the indicator “b” grooves mean that the brake pad thickness limit is reached. Brake pad lining thickness (inner) d.

  • Page 116: Checking The Rear Brake Pad Insulator

    CHASSIS 4. Check: • Brake pedal operation A softy or spongy feeling  Bleed the brake system. Refer to “BLEEDING THE BRAKE SYS- TEM” on page 3-21. EASB291099 CHECKING THE REAR BRAKE PAD INSU- LATOR 1. Remove: • Brake pads i.

  • Page 117: Adjusting The Drive Chain Slack

    CHASSIS WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake flu- ids may result in a harmful chemical reac- tion, leading to poor brake performance.

  • Page 118: Checking The Front Fork Legs

    CHASSIS CLEANING THE FRONT FORK OIL SEAL CHECKING THE FRONT FORK LEGS EASB291102 AND DUST SEAL 1. Stand the vehicle upright on a level surface. 1. Remove: WARNING • Protector Securely support the vehicle so that there is • Dust seal “1” no danger of it falling over.

  • Page 119: Adjusting The Front Fork Legs

    CHASSIS 3. Tighten: • Air bleed screw Air bleed screw 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping force NOTICE Do not turn the adjuster forcibly beyond its adjusting range. ADJUSTING THE FRONT FORK LEGS EASB291106 1. Adjust: WARNING •...

  • Page 120: Checking The Swingarm Operation

    CHASSIS Spring preload CHECKING THE SWINGARM OPERATION EASB291107 1. Check: NOTICE • Swingarm smooth action Do not turn the adjuster forcibly beyond its • Swingarm free play adjusting range. Refer to “SWINGARM” on page 4-63. 1. Remove: CHECKING THE REAR SUSPENSION EASB291108 •...
  • Page 121 CHASSIS Rebound damping force • Be sure to remove all dirt and mud from Maximum around the locknut and adjusting ring before Turn it in finger-tight. adjustment. Turn it out by 11 clicks.* • The length of the spring (installed) changes Minimum 1.5 mm (0.06 in) per turn of the adjusting ring.

  • Page 122: Checking The Tires

    CHASSIS CHECKING THE TIRES 1. Measure: • Tire pressure Out of specification  Regulate. Tire air pressure (measured on cold tires) 100 kPa (1.00 kgf/cm , 15 psi) • Check the tire while it is cold. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure Low compression damping is low.

  • Page 123: Checking The Wheels

    CHASSIS 2. Tighten: CHECKING AND ADJUSTING THE STEER- • Spokes ING HEAD Use a spoke nipple wrench “1” for tighten- 1. Use a suitable stand to raise the front wheel ing. off the ground. WARNING Securely support the vehicle so that there is no danger of it falling over.

  • Page 124: Checking And Lubricating The Cables

    CHASSIS CHECKING AND LUBRICATING THE CA- Steering nut wrench BLES 90890-01403 The following procedure applies to all of the in- Exhaust flange nut wrench ner and outer cables. YU-A9472 WARNING Damaged outer cable may cause the cable Ring nut (initial tightening torque) to corrode and interfere with its movement.

  • Page 125: Lubricating The Drive Chain

    CHASSIS LUBRICATING THE DRIVE CHAIN EASB291118 The drive chain consists of many interacting parts. If the drive chain is not maintained prop- erly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas. This vehicle has a drive chain with small rubber O-rings between each side plate.

  • Page 126: Electrical System

    ELECTRICAL SYSTEM 5. Clean: ELECTRICAL SYSTEM EASB291121 • Spark plug (with a spark plug cleaner or a wire brush) CHECKING THE SPARK PLUG EASB291122 6. Measure: 1. Remove: • Spark plug gap “a” • Seat Out of specification  Adjust the spark plug •...

  • Page 127: Checking And Charging The Battery

    ELECTRICAL SYSTEM 2. Attach: • Timing light “1” • Digital tachometer “2” To the high tension code “3”. Timing light 90890-03141 Timing light YU-03141 Digital tachometer 90890-06760 Digital tachometer YU-39951-B 3. Adjust: • Engine idling speed Refer to “ADJUSTING THE ENGINE IDLING SPEED”...
  • Page 128 ELECTRICAL SYSTEM 3-38...
  • Page 129 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE LEFT SIDE COVER ............4-2 REMOVING THE SEAT................4-2 REMOVING THE NUMBER PLATE ............4-2 FRONT WHEEL ....................4-3 REMOVING THE FRONT WHEEL.............4-4 CHECKING THE FRONT WHEEL .............4-4 DISASSEMBLING THE FRONT WHEEL ...........4-5 ASSEMBLING THE FRONT WHEEL ............4-5 INSTALLING THE FRONT WHEEL ............4-6 REAR WHEEL ....................4-7 REMOVING THE REAR WHEEL ...............4-8 CHECKING THE REAR WHEEL..............4-8...
  • Page 130 HANDLEBAR....................4-32 REMOVING THE HANDLEBAR ...............4-34 CHECKING THE HANDLEBAR..............4-34 INSTALLING THE HANDLEBAR..............4-34 FRONT FORK....................4-39 REMOVING THE FRONT FORK LEGS ...........4-41 DISASSEMBLING THE FRONT FORK LEGS .........4-41 CHECKING THE FRONT FORK LEGS............4-42 ASSEMBLING THE FRONT FORK LEGS ..........4-43 INSTALLING THE FRONT FORK LEGS..........4-49 STEERING HEAD...................4-52 REMOVING THE LOWER BRACKET............4-53 CHECKING THE STEERING HEAD ............4-53...

  • Page 131: General Chassis

    This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.

  • Page 132: Removing The Left Side Cover

    GENERAL CHASSIS REMOVING THE NUMBER PLATE REMOVING THE LEFT SIDE COVER EASB291127 1. Remove: 1. Remove: • Bolt (number plate) • Bolt (side cover) • Number plate “1” • Side cover “1” • The projection “a” is inserted into the band of Draw the left side cover “1”...

  • Page 133: Front Wheel

    FRONT WHEEL FRONT WHEEL EASB291130 Removing the front wheel 21 Nm (2.1 m kgf, 15 ft Ibf) • • 21 Nm (2.1 m kgf, 15 ft Ibf) • • 115 Nm (11.5 m kgf, 83 ft lbf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...

  • Page 134: Removing The Front Wheel

    FRONT WHEEL REMOVING THE FRONT WHEEL EASB291131 1. Use a suitable stand to raise the front wheel A tight spoke will emit a clear, ringing tone; a off the ground. loose spoke will sound flat. WARNING 4. Tighten: Securely support the vehicle so that there is •...

  • Page 135: Disassembling The Front Wheel

    FRONT WHEEL DISASSEMBLING THE FRONT WHEEL EASB291133 NOTICE 1. Remove: Install the bearing by pressing its outer race • Oil seals parallel. • Bearings ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside of the front wheel hub. b. Remove the oil seals “1” with a flat-head screwdriver.

  • Page 136: Installing The Front Wheel

    FRONT WHEEL 3. Install: 3. Tighten: • Collar “1” • Front wheel axle nut “1” Front wheel axle nut Apply the lithium-soap-based grease on the oil 115 Nm (11.5 m·kgf, 83 ft·lbf) seal lip. NOTICE Before tightening the front wheel axle nut, push down hard on the handlebar(s) several times and check if the front fork rebounds smoothly.

  • Page 137: Rear Wheel

    REAR WHEEL REAR WHEEL EASB291136 Removing the rear wheel 14 Nm (1.4 m kgf, 10 ft Ibf) 125 Nm (12.5 m kgf, 90 ft lbf) 21 Nm (2.1 m kgf, 15 ft Ibf) 50 Nm (5.0 m kgf, 36 ft Ibf) 21 Nm (2.1 m kgf, 15 ft Ibf) Order Part name...

  • Page 138: Removing The Rear Wheel

    REAR WHEEL 3. Check: REMOVING THE REAR WHEEL EASB291137 • Spokes 1. Use a suitable stand to raise the rear wheel Refer to “CHECKING THE FRONT WHEEL” off the ground. on page 4-4. WARNING 4. Measure: Securely support the vehicle so that there is •...

  • Page 139: Assembling The Rear Wheel

    REAR WHEEL 2. Replace: NOTICE • Rear wheel sprocket Install the bearing by pressing its outer race ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ parallel. a. Remove the self-locking nuts and the rear wheel sprocket. b. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the sprocket.

  • Page 140: Installing The Rear Wheel

    REAR WHEEL 3. Install: 3. Install: • Left drive chain puller “1” • Collar “1” • Rear wheel axle “2” Apply the lithium-soap-based grease on the oil • Install the left drive chain puller, and insert the seal lip. rear wheel axle from the left side. •...
  • Page 141 REAR WHEEL 6. Tighten: • Rear wheel axle nut “1” Wheel axle nut 125 Nm (12.5 m·kgf, 90 ft·lbf) • Locknut “2” Locknut 21 Nm (2.1 m·kgf, 15 ft·lbf) 4-11...

  • Page 142: Front Brake

    FRONT BRAKE FRONT BRAKE EASB291143 Removing the front brake caliper 30 Nm (3.0 m kgf, 22 ft lbf) 28 Nm (2.8 m kgf, 20 ft lbf) 6 Nm (0.6 m kgf, 4.3 ft lbf) 17 Nm (1.7 m kgf, 12 ft lbf) 2.5 Nm (0.25 m kgf, 1.8 ft...
  • Page 143 FRONT BRAKE Disassembling the front brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) Order Part name Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassemble pro- cedure.
  • Page 144 FRONT BRAKE Removing the front brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft lbf) 6 Nm (0.6 m kgf, 4.3 ft lbf) 6 Nm (0.6 m kgf, 4.3 ft lbf) 30 Nm (3.0 m kgf, 22 ft lbf) Order Part name Q’ty...
  • Page 145 FRONT BRAKE Disassembling the front brake master cylinder Order Part name Q’ty Remarks Push rod Dust boot Circlip Washer Brake master cylinder kit For assembly, reverse the disassemble pro- cedure. 4-15...

  • Page 146: Introduction

    FRONT BRAKE INTRODUCTION EASB291144 Brake disc thickness limit 2.5 mm (0.10 in) WARNING If you need to disassemble the disc brake 4. Install: components, observe the following precau- • Front wheel tions. Refer to “FRONT WHEEL” on page 4-3. • Never disassemble the brake components unless absolutely necessary.

  • Page 147: Checking The Front Brake Caliper

    FRONT BRAKE ASSEMBLING THE FRONT BRAKE CALI- WARNING • Before installation, clean and lubricate the internal parts. Use new brake fluid for cleaning and lubricating. • Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.

  • Page 148: Installing The Front Brake Caliper

    FRONT BRAKE 3. Install: 2. Install: • Brake caliper piston “1” • Front brake caliper • Brake pad spring • Brake pad Apply the brake fluid on the piston outer sur- • Brake pad pin face. • Brake hose holder NOTICE Brake pad pin •...

  • Page 149: Removing The Front Brake Master Cylinder

    FRONT BRAKE NOTICE Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Bleed: • Brake system Refer to “BLEEDING THE BRAKE SYS- TEM” on page 3-21. 6. Check: • Brake fluid level 2.

  • Page 150: Installing The Front Brake Master Cylinder

    FRONT BRAKE EASB291155 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Brake master cylinder “1” Brake master cylinder holder bolt 9 Nm (0.9 m·kgf, 6.5 ft·lbf) • Install the front brake master cylinder holder 3. Install: with the “UP” mark facing up. •...
  • Page 151 FRONT BRAKE Turn the handlebar toward right and left to make sure that the brake hose does not touch other parts (e.g., wire harness, cables, leads). Adjust if necessary. 6. Check: • Brake lever free play Refer to “ADJUSTING THE FRONT BRAKE”...

  • Page 152: Rear Brake

    REAR BRAKE REAR BRAKE EASB291156 Removing the rear brake caliper 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf)
  • Page 153 REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) Order Part name Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassemble pro- cedure.
  • Page 154 REAR BRAKE Removing the rear brake master cylinder Order Part name Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE BRAKE SYSTEM” on page 3-21. Union bolt Copper washers Brake hose Split pin Washer Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm plate Brake master cylinder reservoir diaphragm Rear brake master cylinder For installation, reverse the removal proce-...
  • Page 155 REAR BRAKE Disassembling the rear brake master cylinder Order Part name Q’ty Remarks Dust boot Circlip Push rod Brake master cylinder kit For assembly, reverse the disassemble pro- cedure. 4-25...

  • Page 156: Introduction

    REAR BRAKE INTRODUCTION EASB291157 WARNING If you need to disassemble the disc brake components, observe the following precau- tions. • Never disassemble the brake components unless absolutely necessary. • If there is any problem with connections on the hydraulic brake system, perform the following jobs.

  • Page 157: Removing The Rear Brake Caliper

    REAR BRAKE REMOVING THE REAR BRAKE CALIPER CHECKING THE REAR BRAKE CALIPER EASB291159 EASB291161 1. Check: • Brake caliper piston “1” Before disassembling the brake caliper, drain Rust/scratches/wear  Replace the brake the brake fluid from the entire brake system. caliper piston.

  • Page 158: Installing The Brake Caliper Piston

    REAR BRAKE INSTALLING THE REAR BRAKE CALIPER INSTALLING THE BRAKE CALIPER PISTON EASB291163 1. Install: 1. Clean: • Rear brake caliper • Brake caliper • Rear brake caliper bracket • Brake caliper piston seal 2. Install: • Brake caliper piston dust seal •...

  • Page 159: Removing The Rear Brake Master Cylinder

    REAR BRAKE REMOVING THE REAR BRAKE MASTER WARNING CYLINDER • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor Before removing the rear brake master cylin- der, drain the brake fluid from the entire brake brake performance.

  • Page 160: Assembling The Rear Brake Master Cylinder

    REAR BRAKE 3. Install: ASSEMBLING THE REAR BRAKE MASTER EASB291167 • Spring “1” CYLINDER Install to the brake master cylinder piston WARNING “2”. • Before installation, all internal brake com- ponents should be cleaned and lubricated Install the spring with a smaller inside diameter with clean or new brake fluid.
  • Page 161 REAR BRAKE 4. Check: WARNING • Brake fluid level Proper brake hose routing is essential to in- The minimum level mark “a” or below  sure safe vehicle operation. Add. Refer to “CHECKING THE BRAKE FLUID NOTICE LEVEL” on page 3-26. Make sure that the pipe portion of the brake hose touches the projection “a”...
  • Page 162 HANDLEBAR HANDLEBAR EASB291169 Removing the handlebar Order Part name Q’ty Remarks Number plate Remove the band only. Clutch cable Disconnect. Clutch switch Clutch lever holder Engine stop switch Brake master cylinder Throttle cable cap Throttle cable (pull) Disconnect. Throttle cable (return) Disconnect.
  • Page 163 HANDLEBAR Removing the handlebar Order Part name Q’ty Remarks Damper For installation, reverse the removal proce- dure. 4-33...

  • Page 164: Handlebar

    HANDLEBAR REMOVING THE HANDLEBAR EASB291170 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Clutch switch “1” EASB291171 CHECKING THE HANDLEBAR 1. Check: •...
  • Page 165 HANDLEBAR NOTICE • First, tighten the bolts on the front side of the upper handlebar holder, and then on the rear side. • Turn the handlebar all the way to the left and right. If there is any contact with the fuel tank, adjust the handlebar position.
  • Page 166 HANDLEBAR 5. Install: • Engine stop switch “1” • Clutch lever “2” • Clutch lever holder “3” • Clamp “4” Engine stop switch screw 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf) Clutch lever holder bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) 7.
  • Page 167 HANDLEBAR WARNING After tightening the throttle cable housing • Install the brake master cylinder holder with the “UP” mark facing up. screws, check that the throttle grip “3” moves smoothly. If it does not, retighten the • Install in order for the top of the front brake master cylinder assembly to be level.
  • Page 168 HANDLEBAR 14.Adjust: • Throttle grip free play Refer to “ADJUSTING THE THROTTLE GRIP FREE PLAY” on page 3-11. Throttle grip free play 3.0–5.0 mm (0.12–0.20 in) 4-38...

  • Page 169: Front Fork

    FRONT FORK FRONT FORK EASB291173 Removing the front fork legs 21 Nm (2.1 m kgf, 15 ft lbf) 9 Nm (0.9 m kgf, 6.5 ft lbf) 5 Nm (0.5 m kgf, 3.6 ft lbf) 5 Nm (0.5 m kgf, 3.6 ft lbf) Order Part name...
  • Page 170 FRONT FORK Disassembling the front fork leg 30 Nm (3.0 m kgf, 22 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • 55 Nm (5.5 m kgf, 40 ft Ibf) •...

  • Page 171: Removing The Front Fork Legs

    FRONT FORK REMOVING THE FRONT FORK LEGS EASB291174 1. Use a suitable stand to raise the front wheel • While compressing the inner tube “2”, set the off the ground. cap bolt ring wrench “4” between the inner tube and locknut “3”. WARNING •...

  • Page 172: Checking The Front Fork Legs

    FRONT FORK The bending value is shown by one half of the dial gauge reading. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Remove: • Base valve “1” (from the damper assembly) Hold the damper assembly with the cap bolt ring wrench “2”...

  • Page 173: Assembling The Front Fork Legs

    FRONT FORK 5. Check: EASB291177 ASSEMBLING THE FRONT FORK LEGS • Base valve “1” Wear/damage  Replace. WARNING Contamination  Clean. • Make sure the oil levels in both front fork • O-rings “2” legs are equal. Wear/damage  Replace. •...
  • Page 174 FRONT FORK Avoid excessive full stroke. A stroke of 200 mm (7.9 in) or more will cause air to enter. In this case, repeat the steps 1 to 3. 6. Loosen: • Compression damping force adjuster “1” • Before loosening the damping force adjuster, record the setting position.
  • Page 175 FRONT FORK 9. Tighten: • Base valve “1” Base valve 28 Nm (2.8 m·kgf, 20 ft·lbf) Hold the damper assembly with the cap bolt ring wrench “2” and use the cap bolt wrench “3” to tighten the base valve. 12.Allow the overflowing oil to escape at the Cap bolt wrench hole “a”...
  • Page 176 FRONT FORK 16.Install: • Outer tube “1” • Apply the lithium-soap-based grease on the (to the inner tube “2”) dust seal lip and oil seal lip. • Apply the fork oil on the inner tube. • When installing the oil seal, use vinyl seat “a” with fork oil applied to protect the oil seal lip.
  • Page 177 FRONT FORK 18.Install: 21.Check: • Oil seals “1” • Inner tube smooth movement Tightness/binding/rough spots  Repeat the steps 14 to 20. Using a fork seal driver “2”, press the oil seal in until the stopper ring groove fully appears. Fork seal driver 90890-01502 Fork seal driver (48)
  • Page 178 FRONT FORK 24.Install: Cap bolt ring wrench • Damper assembly “1” 90890-01501 (to the inner tube “2”) Cap bolt ring wrench NOTICE YM-01501 Allow the damper assembly to slide slowly down the inner tube until it contacts the bot- tom of the inner tube. Be careful not to dam- age the inner tube.

  • Page 179: Installing The Front Fork Legs

    FRONT FORK 29.Install: 31.Install: • Adjuster “1” • Damper assembly “1” (to the inner tube) (to the outer tube) Adjuster Temporarily tighten the damper assembly. 55 Nm (5.5 m·kgf, 40 ft·lbf) LOCTITE® 32.Install: • Protector guide “1” 30.Fill: • Front fork leg Recommended oil Suspension oil S1 Standard oil amount...
  • Page 180 FRONT FORK 4. Tighten: • Pinch bolt (upper bracket) “1” Upper bracket pinch bolts 21 Nm (2.1 m·kgf, 15 ft·lbf) • Pinch bolt (lower bracket) “2” Lower bracket pinch bolts 21 Nm (2.1 m·kgf, 15 ft·lbf) 2. Tighten: WARNING • Damper assembly “1” Tighten the lower bracket to specified torque.
  • Page 181 FRONT FORK 7. Adjust: • Compression damping force Turn in the damping adjuster “1” finger-tight and then turn out to the originally set position. 4-51...

  • Page 182: Steering Head

    STEERING HEAD STEERING HEAD EASB291179 Removing the lower bracket 21 Nm (2.1 m kgf, 15 ft lbf) 145 Nm (14.5 m kgf, 105 ft lbf) 21 Nm (2.1 m kgf, 15 ft lbf) 38 Nm (3.8 m kgf, 27 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft...

  • Page 183: Removing The Lower Bracket

    STEERING HEAD REMOVING THE LOWER BRACKET EASB291180 NOTICE 1. Use a suitable stand to raise the front wheel If the bearing race is not installed properly, off the ground. the steering head pipe could be damaged. WARNING Securely support the vehicle so that there is Always replace the bearing and the bearing no danger of it falling over.
  • Page 184 STEERING HEAD 2. Install: • Bearing races • Upper bearing “1” • Bearing race cover “2” Apply the lithium-soap-based grease on the bearing and bearing race cover lip. 5. Check the steering stem by turning this lock to lock. If there is any binding, remove the steering stem and check the steering bear- ing.
  • Page 185 STEERING HEAD 11.Tighten: • Pinch bolt (upper bracket) “1” Upper bracket pinch bolts 21 Nm (2.1 m·kgf, 15 ft·lbf) • Pinch bolt (lower bracket) “2” Lower bracket pinch bolts 21 Nm (2.1 m·kgf, 15 ft·lbf) 8. Install: WARNING • Steering stem nut “1” Tighten the lower bracket to specified torque.

  • Page 186: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY REAR SHOCK ABSORBER ASSEMBLY EASB291183 Removing the rear shock absorber assembly 16 15 14 13 Order Part name Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 4-1. Side cover (left / right) Refer to “GENERAL CHASSIS” on page 4-1. Air scoop (left / right) Refer to “GENERAL CHASSIS”...
  • Page 187 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 16 15 14 13 Order Part name Q’ty Remarks O-ring Dust seal Stopper ring Bearing For installation, reverse the removal proce- dure. 4-57...
  • Page 188 REAR SHOCK ABSORBER ASSEMBLY Disassembling the relay arm 80 Nm (8.0 m kgf, 58 ft lbf) Order Part name Q’ty Remarks Relay arm Connecting arm Collars Oil seals Washers Bearing For assembly, reverse the disassemble pro- cedure. 4-58...

  • Page 189: Handling The Rear Shock Absorber

    • To dispose of a damaged or a worn-out rear shock absorber, take the unit to your Yamaha dealer for this disposal proce- 3. Remove: dure. • Rear shock absorber assembly upper bolt •...

  • Page 190: Checking The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY • Spring Damage/wear  Replace. • Spring guide Damage/wear  Replace. • Bearing Damage/wear  Replace. • Bolts Bends/damage/wear  Replace. EASB291189 CHECKING THE CONNECTING ARM AND RELAY ARM 2. Remove: 1. Check: • Upper bearing “1” •...

  • Page 191: Installing The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY 3. Install: 4. Install: • Bearing “1” • Bearing “1” • Oil seals “2” • Bushing “2” (to connecting arm “3”) • Collar “3” • Dust seal “4” Installed depth “a” (to rear shock absorber assembly (lower 0 mm (0 in) side)) Install the dust seals with their lips facing in-...
  • Page 192 REAR SHOCK ABSORBER ASSEMBLY 7. Tighten: • Rear shock absorber assembly upper bolt Rear shock absorber assembly upper bolt 56 Nm (5.6 m·kgf, 41 ft·lbf) • Connecting arm bolt (frame side) Connecting arm bolt (frame side) 80 Nm (8.0 m·kgf, 58 ft·lbf) •...

  • Page 193: Swingarm

    SWINGARM SWINGARM EASB291192 Removing the swingarm 70 Nm (7.0 m kgf, 51 ft lbf) 4.0 Nm (0.40 m kgf, 2.9 ft lbf) Order Part name Q’ty Remarks Use a suitable stand to raise the front wheel off the ground. Brake hose holder Refer to “REAR BRAKE”...

  • Page 194: Removing The Swingarm

    SWINGARM REMOVING THE SWINGARM EASB291193 1. Use a suitable stand to raise the rear wheel off the ground. WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Measure: • Swingarm side play • Swingarm vertical movement ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 195: Installing The Swingarm

    SWINGARM INSTALLING THE SWINGARM EASB291196 1. Lubricate: • Bearing • Collars • Spacers • Oil seal • Pivot shaft Recommended lubricant Molybdenum disulfide grease 2. Install: • Bearing “1” • Oil seals “2” (to the swingarm) Installed depth “a” 0–0.5 mm (0–0.02 in) Installed depth “b”...

  • Page 196: Chain Drive

    CHAIN DRIVE CHAIN DRIVE EASB291197 Removing the drive chain 75 Nm (7.5 m kgf, 54 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft lbf) Job Order Part name Q’ty Servicing Information Drive sprocket Refer to “ENGINE REMOVAL” on page 5-1. Drive chain For installation, reverse the removal proce- dure.

  • Page 197: Removing The Drive Chain

    CHAIN DRIVE REMOVING THE DRIVE CHAIN EAS23420 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated.

  • Page 198: Checking The Drive Sprocket

    CHAIN DRIVE CHECKING THE DRIVE SPROCKET 1. Check: • Drive sprocket More than 1/4 tooth wear “a”  Replace the drive sprocket and the rear wheel sprocket as a set. Bent tooth  Replace the drive sprocket and the rear wheel sprocket as a set. b.
  • Page 199 CHAIN DRIVE b. After riveting, make sure the diameter be- 4. Adjust: tween the edges “b” of the connecting pin “2” • Drive chain slack is 5.5–5.8 mm (0.22–0.23 in). Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-27. Drive chain slack 50–60 mm (1.97–2.36 in) NOTICE...
  • Page 200 CHAIN DRIVE 4-70...

  • Page 201: Engine

    ENGINE ENGINE REMOVAL..................5-1 REMOVING THE SILENCER ..............5-6 REMOVING THE EXHAUST PIPE 2............5-6 REMOVING THE DRIVE SPROCKET ............5-6 REMOVING THE ENGINE .................5-7 CHECKING THE SILENCER AND EXHAUST PIPE........5-7 CHANGING THE SILENCER FIBER............5-7 INSTALLING THE ENGINE................5-8 INSTALLING THE BRAKE PEDAL.............5-9 INSTALLING THE DRIVE SPROCKET............5-9 INSTALLING THE EXHAUST PIPE AND MUFFLER .......5-10 CAMSHAFT ....................5-12 REMOVING THE CAMSHAFT ..............5-14...
  • Page 202 CLUTCH......................5-42 REMOVING THE CLUTCH ..............5-45 CHECKING THE FRICTION PLATES............5-45 CHECKING THE CLUTCH PLATES ............5-45 CHECKING THE CLUTCH SPRINGS............5-45 CHECKING THE CLUTCH HOUSING .............5-46 CHECKING THE CLUTCH BOSS ............5-46 CHECKING THE PRESSURE PLATE .............5-46 CHECKING THE PUSH LEVER SHAFT ..........5-46 CHECKING THE CLUTCH PUSH RODS..........5-46 CHECKING THE PRIMARY DRIVE GEAR ..........5-46 CHECKING THE PRIMARY DRIVEN GEAR ...........5-47 INSTALLING THE OIL SEAL..............5-47...
  • Page 203 GENERATOR AND STARTER CLUTCH............5-64 REMOVING THE GENERATOR ..............5-66 CHECKING THE STARTER CLUTCH .............5-66 INSTALLING THE STARTER CLUTCH ...........5-67 INSTALLING THE GENERATOR.............5-67 CRANKCASE ....................5-70 DISASSEMBLING THE CRANKCASE.............5-73 REMOVING THE CRANKCASE BEARING ..........5-73 CHECKING THE TIMING CHAIN, TIMING CHAIN GUIDE, OIL STRAINER ..................5-73 CHECKING THE CRANKCASE ...............5-73 INSTALLING THE OIL SEAL..............5-74 ASSEMBLING THE CRANKCASE............5-74...

  • Page 204: Engine Removal

    This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.
  • Page 205 ENGINE REMOVAL Removing the exhaust pipe 13 Nm (1.3 m kg , 9.4 ft lbf) • • 2nd 20 Nm (2.0 m kgf, 14 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...
  • Page 206 ENGINE REMOVAL Removing the electronic parts Order Part name Q’ty Remarks Use a suitable stand to raise the front wheel off the ground. Seat Refer to “GENERAL CHASSIS” on page 4-1. Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1. Air scoop (left / right) Refer to “GENERAL CHASSIS”...
  • Page 207 ENGINE REMOVAL Removing the engine 55 Nm (5.5 m kgf, 40 ft Ibf) Order Part name Q’ty Remarks Use a suitable stand to raise the front wheel off the ground. Seat Refer to “GENERAL CHASSIS” on page 4-1. Side cover (left/right) Refer to “GENERAL CHASSIS”...
  • Page 208 ENGINE REMOVAL Removing the engine 55 Nm (5.5 m kgf, 40 ft Ibf) Order Part name Q’ty Remarks Cylinder head breather hose Drive sprocket cover Drive chain guide Drive sprocket Upper engine bracket Washer Thickness:2.3 mm (0.09 in) Washer Thickness:1.0 mm (0.04 in) Lower engine bracket Pivot shaft Engine...

  • Page 209: Removing The Silencer

    ENGINE REMOVAL REMOVING THE SILENCER EASB291203 1. Remove: • Rear shock absorber assembly lower bolt “1” • Connecting arm bolt (frame side) “2” • Silencer “3” Move the rear shock absorber to the left side of the chassis, and remove the silencer. EASB291205 REMOVING THE DRIVE SPROCKET 1.

  • Page 210: Removing The Engine

    ENGINE REMOVAL CHECKING THE SILENCER AND EXHAUST REMOVING THE ENGINE EASB291206 PIPE 1. Remove: 1. Check: • Pivot shaft “1” • Gasket “1” Damage  Replace. If the pivot shaft is pulled all the way out, the swingarm will come loose. If possible, insert a shaft of similar diameter into the other side of the swingarm to support it.

  • Page 211: Installing The Engine

    ENGINE REMOVAL 2. Remove: • Rivet “1” • Silencer cap “2” 6. Install: • Silencer cap “1” • Rivet “2” 3. Replace: • Fiber “1” • Apply heat-resistant sealant to the areas “a” shown, making sure that there are no gaps in the beads of sealant.

  • Page 212: Installing The Brake Pedal

    ENGINE REMOVAL • Upper engine bracket “7” • Engine bracket bolt (upper side) “8” Engine bracket bolt (upper side) 34 Nm (3.4 m·kgf, 25 ft·lbf) • Engine mounting bolt (upper side) “9” Engine mounting bolt (upper side) 45 Nm (4.5 m·kgf, 33 ft·lbf) EASB291211 INSTALLING THE DRIVE SPROCKET 1.

  • Page 213: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL 3. Bend the lock washer tab to lock the nut. 4. Install: • Drive sprocket guide • Drive sprocket cover “1” • Bolt (drive sprocket cover) “2” Bolt (drive sprocket cover) 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Install and temporarily tighten the exhaust pipe 2 with its end positioned as shown with respect to the exhaust pipe 1.
  • Page 214 ENGINE REMOVAL 2mm (0.08in) 4. Tighten: • Bolt (exhaust pipe 2) Bolt (exhaust pipe 2) 20 Nm (2.0 m·kgf, 14 ft·lbf) • Clamp Clamp 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Tighten while checking that their front and rear joints are inserted in position. 5-11...

  • Page 215: Camshaft

    CAMSHAFT CAMSHAFT EASB291213 Removing the cylinder head cover 13 Nm (1.3 m kgf, 9.4 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 4-1. Side cover (left/right) Refer to “GENERAL CHASSIS”...
  • Page 216 CAMSHAFT Removing the camshaft 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 6 Nm (0.6 m kgf, 4.3 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 6 Nm (0.6 m kgf, 4.3 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name...

  • Page 217: Removing The Camshaft

    CAMSHAFT 3. Remove: REMOVING THE CAMSHAFT EASB291214 • Timing chain tensioner cap bolt “1” 1. Remove: • Timing chain tensioner “2” • Timing mark accessing screw “1” • Gaskets • Crankshaft end accessing screw “2” 4. Remove: 2. Align: • Bolt (camshaft cap) “1” •...

  • Page 218: Checking The Camshaft

    CAMSHAFT 5. Remove: • Exhaust camshaft “1” • Intake camshaft “2” Attach a wire “3” to the timing chain to prevent it from falling into the crankcase. CHECKING THE CAMSHAFT EASB291215 1. Check: • Camshaft lobes 3. Measure: Blue discoloration/pitting/scratches  Re- •...

  • Page 219: Checking The Timing Chain And Camshaft Sprocket

    CAMSHAFT ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the camshaft into the cylinder head. b. Position a strip of Plastigauge® “1” onto the camshaft journal as shown. EASB291216 CHECKING THE TIMING CHAIN AND CAM- SHAFT SPROCKET 1. Check: • Timing chain “1” c. Install the dowel pins and the camshaft Damage/stiffness ...

  • Page 220: Checking The Decompression System

    CAMSHAFT ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise with a wrench. • Apply molybdenum disulfide oil to the cam- shafts. • Apply the engine oil on the decompression system. b. Align the top dead center (TDC) mark “a” on the rotor with the alignment mark “b” on the ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 221 CAMSHAFT sioner “2”, and the gasket “3”, and tighten NOTICE the bolt “4”. Do not turn the crankshaft during the cam- shaft installation. Damage or improper Bolt (timing chain tensioner) valve timing will result. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) d.
  • Page 222 CAMSHAFT inder head cover gasket. Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 6. Install: • Cylinder head breather hose • Spark plug Spark plug 13 Nm (1.3m·kgf, 9.4 ft·lbf) 5-19...

  • Page 223: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD EASB291220 Removing the cylinder head 33 Nm (3.3 m kgf, 24 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 4-1. Side cover (left/right) Refer to “GENERAL CHASSIS”...
  • Page 224 CYLINDER HEAD Removing the cylinder head 33 Nm (3.3 m kgf, 24 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks For installation, reverse the removal proce- dure.

  • Page 225: Removing The Cylinder Head

    CYLINDER HEAD REMOVING THE CYLINDER HEAD EASB291221 1. Remove: • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAMSHAFT” on page 5-14. 2. Remove: • Cylinder head nuts • Cylinder head bolts 2. Check: • Loosen the bolts in the proper sequence as •...

  • Page 226: Installing The Cylinder Head

    CYLINDER HEAD INSTALLING THE CYLINDER HEAD EASB291224 1. Install: Tighten the bolts and nuts to the specified • Timing chain guide (intake side) “1” torque in two or three steps in the proper tight- • Dowel pin “2” ening sequence as shown. •...
  • Page 227 VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS EASB291225 Removing the valves and valve springs Order Part name Q’ty Remarks Refer to “CYLINDER HEAD” on page 5-20. Cylinder head Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Intake valve...

  • Page 228: Valves And Valve Springs

    VALVES AND VALVE SPRINGS b. Check that the valves are properly sealed. REMOVING THE VALVES EASB291226 Check that there are no kerosene leaks from Before removing the internal parts of the cylin- the valve seat “1”. der head (e.g., valves, valve springs, valve seats), make sure that the valves are properly sealed.

  • Page 229: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS Identify the position of each part very carefully so that it can be reinstalled in its original place. 2. Replace: • Valve guide To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder CHECKING THE VALVES AND VALVE EASB291227 head to 100 °C (212 °F) in an oven.

  • Page 230: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 5. Measure: • Valve margin thickness D “a” Out of specification  Replace the valve. Valve margin thickness D (intake) 1.20 mm (0.0472 in) Valve margin thickness D (ex- haust) 0.85 mm (0.0335 in) After replacing the valve guide, reface the valve seat.
  • Page 231 VALVES AND VALVE SPRINGS 4. Lap: Valve seat width C (intake) • Valve face 0.90–1.10 mm (0.0354–0.0433 in) • Valve seat Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) NOTICE This model uses titanium intake and ex- haust valves. Do not use the valves used for lapping the valve seat.

  • Page 232: Checking The Valve Springs

    VALVES AND VALVE SPRINGS 2. Measure: • Compressed valve spring force “a” Out of specification  Replace the valve spring. h. Install the valve into the cylinder head. i. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion.

  • Page 233: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS CHECKING THE VALVE LIFTERS EASB291230 1. Check: • Make sure each valve is installed in its original • Valve lifter place. Damage/scratches  Replace the valve lift- • Install the valve springs with the larger pitch ers and cylinder head.
  • Page 234 VALVES AND VALVE SPRINGS 6. Lubricate: • Adjusting pad “1” • Valve lifter “2” 7. Install: • Adjusting pad • Valve lifter • Check that the valve lifter turns smoothly when rotated with your finger. • Make sure that the valve lifter and the adjust- ing pad are reinstalled in their original posi- tions.
  • Page 235 CYLINDER AND PISTON CYLINDER AND PISTON EASB291232 Removing the cylinder and piston 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks Refer to “CYLINDER HEAD” on page 5-20. Cylinder head Cylinder body Gaskets...

  • Page 236: Cylinder And Piston

    CYLINDER AND PISTON REMOVING THE PISTON EASB291233 1. Remove: • Piston pin clip “1” • Piston pin “2” • Piston “3” NOTICE Do not use a hammer to drive the piston pin out. • Before removing the piston pin clip, cover the EASB291234 CHECKING THE CYLINDER AND PISTON crankcase opening with a cloth to prevent the...

  • Page 237: Checking The Piston Rings

    CYLINDER AND PISTON b. If out of specification, rebore or replace the Ring side clearance cylinder, and replace the piston and the pis- 0.030–0.065 mm (0.0012–0.0026 ton rings as a set. c. Measure the piston outside diameter D “a” at Limit the measurement position H “b”...

  • Page 238: Checking The Piston Pin

    CYLINDER AND PISTON CHECKING THE PISTON PIN EASB291236 1. Check: Be sure to install the piston ring so that the • Piston pin manufacturer’s marks or numbers face up. Blue discoloration/grooves  Replace the piston pin and then check the lubrication system.
  • Page 239 CYLINDER AND PISTON 3. Lubricate: • Piston • Piston rings • Cylinder 4. Offset: • Piston ring end gap a. Top ring b. Upper oil ring rail c. Oil ring expander d. Lower oil ring rail 5. Install: • Cylinder gasket •...

  • Page 240: Electric Starter

    ELECTRIC STARTER ELECTRIC STARTER EASB291238 Removing the starter motor 12 Nm (1.2 m kgf, 8.7 ft Ibf) Order Job/Parts to remove Q’ty Remarks Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-1. Starter motor For assembly, reverse the disassemble pro- cedure.
  • Page 241 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks Starter motor front cover Starter motor yoke Armature assembly Starter motor rear cover Brush set For assembly, reverse the disassembly pro- cedure. 5-38...

  • Page 242: Checking The Starter Motor

    ELECTRIC STARTER CHECKING THE STARTER MOTOR EASB291239 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure the armature assembly resistanc- 1. Check: es with the pocket tester. • Commutator Dirt  Clean with 600 grit sandpaper. Pocket tester 2. Measure: 90890-03112 • Commutator diameter “a” Analog pocket tester Out of specification ...

  • Page 243: Assembling The Starter Motor

    ELECTRIC STARTER 7. Check: • Gear teeth Damage/wear  Replace the starter motor. 8. Check: • Oil seal Damage/wear  Replace the defective part (s). ASSEMBLING THE STARTER MOTOR EASB291240 1. Install: • Brush spring “1” • Brush “2” 4. Install: •...
  • Page 244 ELECTRIC STARTER 5-41...
  • Page 245 CLUTCH CLUTCH EASB291241 Removing the clutch 6 10 Order Part name Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-15. Brake pedal Refer to “ENGINE REMOVAL” on page 5-1. Clutch cable Disconnect. Clutch cover Gasket Clutch spring Pressure plate Push rod 1...
  • Page 246 CLUTCH Removing the clutch 6 10 Order Part name Q’ty Remarks Cushion spring Friction plate 2 Identification color (purple) Clutch boss Thrust washer Primary driven gear Spacer Bearing Washer Push lever shaft For installation, reverse the removal proce- dure. 5-43...
  • Page 247 CLUTCH Removing the right crankcase cover Order Part name Q’ty Remarks Engine guard Refer to “ENGINE REMOVAL” on page 5-1. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-15. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-8.

  • Page 248: Clutch

    CLUTCH REMOVING THE CLUTCH CHECKING THE CLUTCH PLATES EASB291242 EASB291244 1. Remove: 1. Check: • Clutch boss nut “1” • Clutch plate Damage  Replace the clutch plates as a • Lock washer “2” • Clutch boss “3” set. 2. Measure: •...

  • Page 249: Checking The Clutch Housing

    CLUTCH CHECKING THE CLUTCH HOUSING EASB291246 1. Check: • Clutch housing dogs “a” Damage/pitting/wear  Deburr the clutch housing dogs or replace the clutch housing. Pitting on the clutch housing dogs will cause er- ratic clutch operation. EASB291250 CHECKING THE CLUTCH PUSH RODS 1.

  • Page 250: Checking The Primary Driven Gear

    CLUTCH 2. Install: CHECKING THE PRIMARY DRIVEN GEAR EASB291252 • Right crankcase cover “1” 1. Check: • Right crankcase cover bolt “2” • Primary driven gear Damage/wear  Replace the primary drive Right crankcase cover bolt and primary driven gears as a set. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Excessive noise during operation ...
  • Page 251 CLUTCH 2. Install: 4. Bend the lock washer “1” tab. • Washer “1” • Bearing “2” • Collar “3” • Primary driven gear “4” • Thrust washer “5” • Clutch boss “6” Apply the engine oil on the primary driven gear inner circumference.
  • Page 252 CLUTCH 6. Install: 9. Install: • Bearing “1” • Clutch spring • Washer “2” • Clutch spring bolt • Circlip “3” Clutch spring bolt To push rod 1 “4”. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Apply the engine oil on the bearing and washer. Tighten the bolts in stages and in a crisscross pattern.

  • Page 253: Installing The Kickstarter Lever

    CLUTCH INSTALLING THE KICKSTARTER LEVER EASB291256 1. Install: • Kickstarter lever “1” • Washer • Bolt (kickstarter lever) Bolt (kickstarter lever) 33 Nm (3.3 m·kgf, 24 ft·lbf) LOCTITE® Install so that there is a clearance “a” of 5 mm (0.2 in) or more between the kickstarter lever and the frame and that the kickstarter lever does not contact the right crankcase cover when it is pulled.
  • Page 254 KICKSTATER KICKSTATER EASB291257 Removing the kick shaft Order Part name Q’ty Remarks Primary driven gear Refer to “CLUTCH” on page 5-42. Kick idle gear Kick shaft assembly Spring guide Torsion spring Ratchet wheel Kick gear Kick shaft For installation, reverse the removal proce- dure.

  • Page 255: Kickstater

    KICKSTATER REMOVING THE KICK SHAFT ASSEMBLY EASB291258 1. Remove: • Kick shaft assembly “1” Unhook the torsion spring “2” from the hole “a” in the crankcase. EASB291261 INSTALLING THE KICK SHAFT ASSEMBLY 1. Install: • Kick gear “1” • Washer “2” •...

  • Page 256: Installing The Kick Idle Gear

    KICKSTATER 5. Install: • Torsion spring “1” Turn the torsion spring clockwise and hook into the proper hole “a” in the crankcase. 3. Install: • Spring guide “1” Slide the spring guide into the kick shaft, make sure the groove “a” in the spring guide fits on the stopper of the torsion spring.

  • Page 257: Shift Shaft

    SHIFT SHAFT SHIFT SHAFT EASB291263 Removing the shift shaft and stopper lever 10 Nm (1.0 m kgf, 7.2 ft lbf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 30 Nm (3.0 m kgf, 22 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft lbf) Order Part name Q’ty...

  • Page 258: Removing The Shift Guide And Shift Lever Assembly

    SHIFT SHAFT REMOVING THE SHIFT GUIDE AND SHIFT EASB291264 LEVER ASSEMBLY 1. Remove: • Bolt (shift guide) • Shift guide “1” • Shift lever assembly “2” Make sure that the shift lever assembly is re- moved together with the shift guide. EASB291267 CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY...

  • Page 259: Installing The Stopper Lever

    SHIFT SHAFT INSTALLING THE SHIFT GUIDE AND SHIFT INSTALLING THE STOPPER LEVER EASB291269 LEVER ASSEMBLY 1. Install: 1. Install: • Torsion spring “1” • Spring “1” • Collar “2” • Pawl pin “2” • Stopper lever “3” • Pawl “3” •...

  • Page 260: Installing The Shift Shaft

    SHIFT SHAFT 4. Tighten: • Shift guide bolt “1” Shift guide bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® INSTALLING THE SHIFT SHAFT EASB291272 1. Install: • Roller “1” • Shift haft spring “2” (to shift shaft) • Collar “3” (to shift shaft) •...
  • Page 261 OIL PUMP AND BALANCER GEAR OIL PUMP AND BALANCER GEAR EASB291274 Removing the oil pump 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • Order Part name Q’ty Remarks Primary driven gear Refer to “CLUTCH”...

  • Page 262: Oil Pump And Balancer Gear

    OIL PUMP AND BALANCER GEAR Removing the balancer 75 Nm (7.5 m kgf, 54 ft lbf) 50 Nm (5.0 m kgf, 36 ft Ibf) Order Part name Q’ty Remarks Primary driven gear Refer to “CLUTCH” on page 5-42. Right crankcase cover Refer to “CLUTCH”...

  • Page 263: Removing The Balancer

    OIL PUMP AND BALANCER GEAR REMOVING THE BALANCER EASB291275 1. Loosen: • Balancer nut “1” • Primary drive gear nut “2” • Balancer weight gear nut “3” Place an aluminum plate “a” between the teeth of the balancer drive gear “4” and balancer weight gear “5”.

  • Page 264: Assembling The Oil Pump

    OIL PUMP AND BALANCER GEAR 2. Install: • Outer rotor “1” Apply the engine oil on the outer rotor. 3. Install: • Oil pump cover “1” • Oil pump cover screw “2” Oil pump cover screw 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) 1.
  • Page 265 OIL PUMP AND BALANCER GEAR 4. Install: NOTICE • Conical washer “1” After tightening the bolts, make sure that • Balancer weight gear nut “2” the oil pump turns smoothly. Balancer weight gear nut 2. Install: 50 Nm (5.0 m·kgf, 36 ft·lbf) •...
  • Page 266 OIL PUMP AND BALANCER GEAR 5-63...
  • Page 267 GENERATOR AND STARTER CLUTCH GENERATOR AND STARTER CLUTCH EASB291281 Removing the generator Order Job/Parts to remove Q’ty Remarks Refer to “CHANGING THE ENGINE OIL” on Drain the engine oil. page 3-15. Refer to “GENERAL CHASSIS” on page 4-1 Seat and fuel tank and “FUEL TANK”...
  • Page 268 GENERATOR AND STARTER CLUTCH Removing the generator Order Job/Parts to remove Q’ty Remarks Woodruff key Starter clutch Starter clutch drive gear Crankshaft position sensor Stator For installation, reverse the removal proce- dure. 5-65...

  • Page 269: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH 2. Check: REMOVING THE GENERATOR EASB291282 • Starter clutch idle gear 1. Remove: • Starter clutch gear • Generator rotor nut “1” Burrs/chips/roughness/wear  Replace the • Washer defective part (s). 3. Check: • Starter clutch gear Damage/pitting/wear ...

  • Page 270: Installing The Starter Clutch

    To generator rotor “2”. shown. • Tighten the stator bolt using the T25 bit. • Apply the sealant to the grommet of the AC magneto lead. Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) Starter clutch bolt 16 Nm (1.6 m·kgf, 12 ft·lbf) LOCTITE®...
  • Page 271 GENERATOR AND STARTER CLUTCH 4. Install: • Dowel pin • Crankcase cover gasket • Left crankcase cover “1” • Lead holder “2” • Crankcase cover bolt Crankcase cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Neutral switch lead “3” 2.
  • Page 272 GENERATOR AND STARTER CLUTCH 6. Install: • Cover (damper assembly) “1” • Bracket “2” • Bolt “3” • Breather hose 2 “4” Bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Install the cover (damper assembly) with its mark “a” facing upward. 5-69...
  • Page 273 CRANKCASE CRANKCASE EASB291286 Separating the crankcase 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 274: Crankcase

    CRANKCASE Separating the crankcase 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 275 CRANKCASE Removing the bearing and oil seal 22 Nm (2.2 m kgf, 16 ft Ibf) • • Order Part name Q’ty Remarks Transmission Refer to “TRANSMISSION” on page 5-78. Shift cam and shift fork Refer to “TRANSMISSION” on page 5-78. Circlip Oil seals Bearing...

  • Page 276: Disassembling The Crankcase

    CRANKCASE DISASSEMBLING THE CRANKCASE EASB291287 1. Separate: • Right crankcase • Left crankcase ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the crankcase bolts. c. Remove the dowel pins and O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ REMOVING THE CRANKCASE BEARING EASB291288 1. Remove: • Bearing “1” • Remove the bearing from the crankcase by Loosen each bolt 1/4 of a turn at a time and af- pressing its inner race.

  • Page 277: Installing The Oil Seal

    Install the bearing by pressing its outer race parallel. 2. Apply: • Sealant (to the crankcase mating surface) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 3. 45 mm (1.77 in) 4. 60 mm (2.36 in) 5. 75 mm (2.95 in) a.

  • Page 278: Crankshaft Assembly And Balancer Shaft

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EASB291293 Removing the crankshaft assembly and balancer shaft Order Part name Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-70. Transmission Refer to “TRANSMISSION” on page 5-78. Balancer shaft Crankshaft assembly For installation, reverse the removal proce- dure.

  • Page 279: Removing The Crankshaft Assembly

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT REMOVING THE CRANKSHAFT ASSEMBLY EASB291294 1. Remove: • Crankshaft assembly “1” Remove the crankshaft assembly by using the crankcase separating tool “2”. Crankcase separating tool 90890-04152 Crankcase separating tool 2. Measure: YU-A9642 • Big end side clearance D “a” Out of specification ...

  • Page 280: Installing The Crankshaft Assembly

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 4. Check: • Crankshaft sprocket “1” Hold the connecting rod at top dead center Damage  Replace the crankshaft. (TDC) with one hand while turning the nut of the crankshaft installer bolt with the other. Turn the crankshaft installer bolt until the crankshaft as- sembly bottoms against the bearing.

  • Page 281: Transmission

    TRANSMISSION TRANSMISSION EASB291298 Removing the transmission, shift drum assembly, and shift forks Order Part name Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Separate. Crankcase Refer to “CRANKCASE” on page 5-70. Main axle Drive axle Long shift fork guide bar Short shift fork guide bar Spring Shift cam...

  • Page 282: Removing The Transmission

    TRANSMISSION REMOVING THE TRANSMISSION EASB291299 1. Remove: • Long shift fork guide bar “1” • Short shift fork guide bar “2” • Shift cam “3” • Shift fork 3 “4” • Shift fork 2 “5” • Shift fork 1 “6” •...

  • Page 283: Checking The Shift Drum Assembly

    TRANSMISSION CHECKING THE SHIFT DRUM ASSEMBLY EASB291301 1. Check: • Shift drum groove Damage/scratches/wear  Replace the shift drum assembly. • Shift drum segment “1” Damage/wear  Replace the shift drum as- sembly. 3. Check: • Transmission gears Blue discoloration/pitting/wear  Replace the defective gear (s).
  • Page 284 TRANSMISSION 2. Install: • 2nd wheel gear (29T) “1” • 5th wheel gear (22T) “2” • 3rd wheel gear (26T) “3” • 4th wheel gear (24T) “4” • 6th wheel gear (22T) “5” • Collar “6” • 1st wheel gear (31T) “7” •...
  • Page 285 TRANSMISSION 6. Install: 7. Install: • Shift fork 1 (L) “1” • Long shift fork guide bar “1” • Shift fork 2 (C) “2” • Short shift fork guide bar “2” • Shift fork 3 (R) “3” • Spring “3” •...
  • Page 286 TRANSMISSION 5-83...

  • Page 287: Cooling System

    COOLING SYSTEM RADIATOR .......................6-1 HANDLING NOTE ..................6-3 CHECKING THE RADIATOR ..............6-3 WATER PUMP....................6-4 REMOVING THE OIL SEAL ...............6-6 CHECKING THE WATER PUMP ...............6-6 CHECKING THE BEARING ...............6-6 INSTALLING THE OIL SEAL..............6-6 ASSEMBLING THE WATER PUMP............6-6...
  • Page 288 This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.
  • Page 289 RADIATOR Removing the radiator 8 Nm (0.8 m kgf, 5.8 ft Ibf) Order Part name Q’ty Remarks Right radiator Radiator hose 2 Radiator hose 3 Radiator hose 4 Radiator pipe 2 Radiator breather hose Left radiator Radiator hose 1 Radiator pipe 1 Coolant temperature sensor For installation, reverse the removal proce- dure.
  • Page 290 RADIATOR HANDLING NOTE EASB291306 WARNING If coolant seems hot, do not remove the ra- diator cap. EASB291307 CHECKING THE RADIATOR 1. Check: • Radiator fins “1” Obstructions  Clean. Apply compressed air to the rear of the radi- ator. Damage  Repair or replace. Correct any flattened fins with a thin, flat-head screwdriver.
  • Page 291 WATER PUMP WATER PUMP EASB291308 Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-8. Drain.
  • Page 292 WATER PUMP Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks For installation, reverse the removal proce- dure.
  • Page 293 WATER PUMP REMOVING THE OIL SEAL EASB291309 • Remove the oil seal when the coolant level changes frequently more than usual, coolant has discolored, or engine oil has become milky. • Do not use the removed oil seal. 1. Remove: •...
  • Page 294 WATER PUMP 2. Install: • Dowel pin “1” • Gasket “2” 3. Install: • Water pump housing “1” • Water pump housing bolt “2” Water pump housing bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Washer “3” • Coolant drain bolt “4” Coolant drain bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

  • Page 295: Fuel System

    FUEL SYSTEM FUEL TANK ......................7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP ..............7-2 CHECKING THE FUEL PUMP BODY............7-2 INSTALLING THE FUEL PUMP ..............7-2 INSTALLING THE FUEL TANK..............7-3 CHECKING THE FUEL PRESSURE............7-3 CHECKING THE DAMPER ................7-4 CHECKING AND REPLACING THE PROTECTOR........7-4 THROTTLE BODY....................7-5 CHECKING THE INJECTOR..............7-8 CHECKING THE THROTTLE BODY ............7-8...

  • Page 296: Fuel Tank

    This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.

  • Page 297: Removing The Fuel Tank

    FUEL TANK REMOVING THE FUEL TANK EASB291316 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose coupler WARNING Cover the fuel hose connection with a cloth when disconnecting it. This is because re- sidual pressure in the fuel hose could cause fuel to spurt out when the hose is removed.

  • Page 298: Installing The Fuel Tank

    FUEL TANK 3. Connect: • Fuel pump coupler 4. Install: • Air scoop (left/right) • Seat • Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4- CHECKING THE FUEL PRESSURE EASB291321 1. Check: • Fuel pressure EASB291320 INSTALLING THE FUEL TANK 1.

  • Page 299: Checking The Damper

    FUEL TANK 0 mm (0 in) e. Start the engine. f. Measure the fuel pressure. Out of specification  Replace the fuel pump. Fuel pressure 324.0 kPa (3.24 kgf/cm , 47.0 psi) 15 mm (0.59 in) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EASB291322 CHECKING THE DAMPER A.

  • Page 300: Throttle Body

    THROTTLE BODY THROTTLE BODY EASB291324 Removing the throttle body 7 Nm (0.7 m kgf, 5.1 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) Order Part name...
  • Page 301 THROTTLE BODY Removing the throttle body 7 Nm (0.7 m kgf, 5.1 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) Order Part name Q’ty...
  • Page 302 THROTTLE BODY Removing the injector 3.4 Nm (0.34 m kgf, 2.5 ft lbf) 5 Nm (0.5 m kgf, 3.6 ft lbf) 3.4 Nm (0.34 m kgf, 2.5 ft lbf) Order Part name Q’ty Remarks Fuel inlet pipe Injector Gaskets Throttle position sensor Intake air pressure sensor For installation, reverse the removal proce- dure.

  • Page 303: Checking The Injector

    THROTTLE BODY CHECKING THE INJECTOR EASB291325 1. Check: • Injectors Obstruction  Replace, and check the fuel pump and the fuel injection system. Refer to “FUEL INJECTION SYSTEM” on page 8-20. Deposits  Replace. Damage  Replace. 2. Check: • Injector resistance Refer to “CHECKING THE FUEL INJEC- TOR”...

  • Page 304: Adjusting The Throttle Position Sensor

    Check that the throttle grip is fully closed. d. Connect the throttle position sensor to the wire harness. e. Set the Yamaha diagnostic tool to “diagnos- tic mode”. f. Choose the diagnostic code No. “01”. g. Adjust the throttle position sensor mounted angle until “11”–“14”...

  • Page 305: Electrical System

    CIRCUIT DIAGRAM .................8-12 TROUBLESHOOTING................8-14 COOLING SYSTEM (For JPN)...............8-16 CIRCUIT DIAGRAM .................8-16 TROUBLESHOOTING................8-18 FUEL INJECTION SYSTEM ................8-20 CIRCUIT DIAGRAM .................8-20 YAMAHA DIAGNOSTIC TOOL ..............8-22 TROUBLESHOOTING DETAILS..............8-25 FUEL PUMP SYSTEM..................8-46 CIRCUIT DIAGRAM .................8-46 TROUBLESHOOTING................8-48 ELECTRICAL COMPONENTS...............8-50 CHECKING THE SWITCHES..............8-54 CHECKING THE FUSES................8-57 CHECKING AND CHARGING THE BATTERY ........8-57...
  • Page 306 CHECKING THE INTAKE AIR TEMPERATURE SENSOR .....8-67 CHECKING THE FUEL INJECTOR ............8-68...
  • Page 307 This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.

  • Page 308: Ignition System

    IGNITION SYSTEM IGNITION SYSTEM EASB291330 CIRCUIT DIAGRAM EASB291331...
  • Page 309 IGNITION SYSTEM 1. Joint connector 2. Joint connector 4. AC magneto 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 16.ECU (engine control unit) 17.Ignition coil 18.Spark plug 24.Joint connector 29.Lean angle sensor 30.Engine stop switch 36.Frame ground...

  • Page 310: Troubleshooting

    IGNITION SYSTEM TROUBLESHOOTING EASB291332 The ignition system fails to operate (no spark or intermittent spark). Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 5. Fuel tank NG  1.
  • Page 311 IGNITION SYSTEM NG  8. Check the lean angle sensor. Replace the lean angle sensor. Refer to “CHECKING THE LEAN ANGLE SENSOR” on page 8-63. OK  NG  9. Check the entire ignition system’s Properly connect or repair the ignition sys- wiring.

  • Page 312: Electric Starting System

    ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM EAS27160 CIRCUIT DIAGRAM EASB291333...
  • Page 313 ELECTRIC STARTING SYSTEM 1. Joint connector 2. Joint connector 3. Joint connector 6. Main relay 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 12.Starter motor 13.Starter relay diode 16.ECU (engine control unit) 24.Joint connector 30.Engine stop switch 31.Neutral switch 32.Diode 33.Starting circuit cut-off relay 34.Clutch switch...

  • Page 314: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION EASB291334 The starter motor can only operate if at least one of the following conditions is met: • The transmission is in neutral (the neutral switch is closed). • The clutch lever is pulled to the handlebar (the clutch switch is closed). The starting circuit cut-off relay prevents the starter motor from operating when neither of these con- ditions has been met.
  • Page 315 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main relay 4. Starting circuit cut-off relay 5. Start switch 6. Diode 7. Clutch switch 8.

  • Page 316: Troubleshooting

    ELECTRIC STARTING SYSTEM TROUBLESHOOTING EASB291335 The starter motor fails to turn. Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 5. Fuel tank NG  1. Check the fuse. Replace the fuse(s).
  • Page 317 ELECTRIC STARTING SYSTEM NG  8. Check the main relay. Replace the main relay. Refer to “CHECKING THE RE- LAYS” on page 8-60. OK  NG  9. Check the neutral switch. Replace the neutral switch. Refer to “CHECKING THE SWITCHES”...

  • Page 318: Charging System

    CHARGING SYSTEM CHARGING SYSTEM EAS27200 CIRCUIT DIAGRAM EASB291336 8-12...
  • Page 319 CHARGING SYSTEM 4. AC magneto 5. Rectifier/regulator 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 8-13...

  • Page 320: Troubleshooting

    CHARGING SYSTEM TROUBLESHOOTING EASB291337 The battery is not being charged. Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 1. Check the fuse. NG Refer to “CHECKING THE FUSES” Replace the fuse(s). on page 8-57. OK NG ...
  • Page 321 CHARGING SYSTEM EASB291338 8-15...

  • Page 322: Cooling System (For Jpn)

    COOLING SYSTEM (For JPN) COOLING SYSTEM (For JPN) EASB291339 CIRCUIT DIAGRAM 8-16...
  • Page 323 COOLING SYSTEM (For JPN) 1. Joint connector 2. Joint connector 3. Joint connector 6. Main relay 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 16.ECU (engine control unit) 21.Radiator fan motor relay 22.Radiator fan motor fuse 23.Radiator fan motor 24.Joint connector 26.Coolant temperature sensor 36.Frame ground...

  • Page 324: Troubleshooting

    COOLING SYSTEM (For JPN) TROUBLESHOOTING EASB291340 The radiator fan motor fails to turn. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left) 3. Air scoop (left/right) 4. Fuel tank NG  1. Check the fuse. Replace the fuse(s). Refer to “CHECKING THE FUSES”...
  • Page 325 COOLING SYSTEM (For JPN) EASB291341 8-19...

  • Page 326: Fuel Injection System

    FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM EASB291342 CIRCUIT DIAGRAM 8-20...
  • Page 327 FUEL INJECTION SYSTEM 1. Joint connector 2. Joint connector 3. Joint connector 4. AC magneto 6. Main relay 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 16.ECU (engine control unit) 19.Injector 24.Joint connector 25.Intake air temperature sensor 26.Coolant temperature sensor 27.Throttle position sensor 28.Intake air pressure sensor 29.Lean angle sensor...

  • Page 328: Yamaha Diagnostic Tool

    FUEL INJECTION SYSTEM YAMAHA DIAGNOSTIC TOOL EASB291343 This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool 90890-03231...
  • Page 329 NOTICE In order to avoid short circuit, insulate the battery connection terminals of the FI diagnostic tool sub-lead. For information on how to connect and use the Yamaha diagnostic tool, refer to “YAMAHA DIGNO- STIC TOOL OPERATION MANUAL”. 1. Vehicle 2.
  • Page 330 FUEL INJECTION SYSTEM Operation of the Yamaha diagnostic tool (Malfunction mode) Malfunction results are displayed in the top part of the window area. 1. Recovered The item list of the malfunction detected in the past (already recovered) are displayed. 2. Detected The item list of the malfunction currently occurred are displayed.

  • Page 331: Troubleshooting Details

    FUEL INJECTION SYSTEM 6. Condition The current conditions are displayed. (Detected/Recovered) 7. Symptom The symptoms of the detected malfunction are displayed. 8. Diagnosis code The diagnosis codes related to the detected malfunction are displayed. 9. FFD (only for models that can display freeze frame data) The mark “...
  • Page 332 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received Item from the crankshaft position sensor. Improperly connected  Connection of wire harness Crank the engine. ECU coupler. Connect the coupler securely Fault code number is not dis- played ...
  • Page 333 FUEL INJECTION SYSTEM • If fault code Nos. 13 and 14 are both displayed, perform the checks and maintenance jobs for fault code No. 13 first. • Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Item Intake air pressure sensor: open or short circuit detected.
  • Page 334 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Defective intake air pressure Execute the diagnostic mode. Push the start switch. sensor. (Code No. 03) Fault code number is not dis- played  Service is finished. When engine is stopped: Atmospheric pressure at the Fault code number is dis-...
  • Page 335 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged Item or detached hose). Defective intake air pressure Execute the diagnostic mode. sensor. (Code No. 03) When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is indicated.
  • Page 336 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Improperly connected  Connection of wire harness Push the start switch. ECU coupler. Connect the coupler securely Fault code number is not dis- played  Service is finished. Check the locking condition or repair/replace the wire har- of the coupler.
  • Page 337 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Malfunction in ECU. Replace the ECU. Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Throttle position sensor: stuck throttle position sensor is de- Item tected.
  • Page 338 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the coolant temperature. Procedure Compare the actually measured coolant temperature with the Yamaha diagnostic tool display value. Probable cause of malfunc- Confirmation of service Item Maintenance job tion and check completion Improperly connected ...
  • Page 339 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air temperature. Procedure Compare the actually measured intake air temperature with the Yamaha diagnostic tool display value. Probable cause of malfunc- Confirmation of service Item Maintenance job tion and check completion Improperly connected ...
  • Page 340 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Open or short circuit  Re- Wire harness continuity. Push the start switch. place the wire harness. Fault code number is not dis- played  Service is finished. Between intake air tempera- ture sensor coupler and ECU Fault code number is dis-...
  • Page 341 Unable to drive vehicle Diagnostic code No. Actuation Actuates the ignition coil five times at one-second intervals. The “WARNING” on the Yamaha diagnostic tool screen come on each time the ignition coil is actuated. Procedure Check that a spark is generated five times.
  • Page 342 FUEL INJECTION SYSTEM Fault code No. Ignition coil: open or short circuit detected in the primary lead Item of the ignition coil. Improperly connected  Connection of sub wire har- Start the engine and let it idle ness coupler. Connect the coupler securely for approximately 5 seconds.
  • Page 343 Diagnostic code No. Actuation Actuates injector five times at one-second intervals. The “WARNING” on the Yamaha diagnostic tool screen come on each time the injector is actuated. Procedure Check that injector is actuated five times by listening for the oper- ating sound.
  • Page 344 FUEL INJECTION SYSTEM Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Item Lean angle sensor: open or short circuit detected. Fail-safe system Unable to start engine Able to drive vehicle Diagnostic code No. Diagnostic tool display Lean angle sensor output voltage •...
  • Page 345 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel in- Item jector and fuel pump. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. Diagnostic tool display Fuel system voltage Approximately 12.0 (V) Procedure Disconnect the main relay, and push the start switch or push down...
  • Page 346 FUEL INJECTION SYSTEM Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. EEPROM fault code number: an error is detected while read- Item ing or writing on EEPROM. Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No.
  • Page 347 FUEL INJECTION SYSTEM Fault code No. Item Charging voltage is abnormal. Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No. — Diagnostic tool display — Procedure — Probable cause of malfunc- Confirmation of service Item Maintenance job tion and check completion Improperly connected ...
  • Page 348 Confirmation of service Item Maintenance job tion and check completion Improperly connected  Connection of Yamaha diag- Push the start switch. nostic tool coupler. Connect the coupler securely Fault code number is not dis- played  Service is finished. Check the locking condition or repair/replace the wire har- of the coupler.
  • Page 349 Fault code number is not dis- played  Service is finished. light green–light green Fault code number is dis- played  Go to item 4. Yamaha diagnostic tool mal- Replace the Yamaha diag- Push the start switch. function. nostic tool.
  • Page 350 FUEL INJECTION SYSTEM Fault code No. Er-2 Signals from the ECU cannot be received within the specified Item period of time. Yamaha diagnostic tool mal- Replace the Yamaha diag- Push the start switch. function. nostic tool. Fault code number is not dis- played ...
  • Page 351 FUEL INJECTION SYSTEM Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Er-4 Registered data cannot be received from the Yamaha diagnos- Item tic tool. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No.

  • Page 352: Fuel Pump System

    FUEL PUMP SYSTEM FUEL PUMP SYSTEM EASB291346 CIRCUIT DIAGRAM 8-46...
  • Page 353 FUEL PUMP SYSTEM 1. Joint connector 2. Joint connector 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 16.ECU (engine control unit) 20.Fuel pump 24.Joint connector 30.Engine stop switch 36.Frame ground 8-47...

  • Page 354: Troubleshooting

    FUEL PUMP SYSTEM TROUBLESHOOTING EASB291347 The fuel pump fails to operate. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank NG  1. Check the fuse. Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 8-57.
  • Page 355 FUEL PUMP SYSTEM EASB291348 8-49...

  • Page 356: Electrical Components

    ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS EASB291349 8-50...
  • Page 357 ELECTRICAL COMPONENTS 1. Rectifier/regulator 2. Clutch switch 3. Ignition coil 4. ECU (engine control unit) 5. Fuel sender 6. Fuel pump 7. Battery 8. Neutral switch 9. Radiator fan motor (For JPN) 10.Injector 8-51...
  • Page 358 ELECTRICAL COMPONENTS 8-52...
  • Page 359 ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. Intake air pressure sensor 3. Throttle position sensor 4. Starter relay 5. Main fuse 6. Starting circuit cut-off relay 7. Lean angle sensor 8. Radiator fan motor fuse 9. Radiator fan motor relay 10.Main relay 11.Coolant temperature sensor 8-53...

  • Page 360: Checking The Switches

    ELECTRICAL COMPONENTS CHECKING THE SWITCHES EASB291350 8-54...
  • Page 361 ELECTRICAL COMPONENTS 1. Engine stop switch 2. Neutral switch 3. Clutch switch 4. Start switch 8-55...
  • Page 362 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. NOTICE Never insert the tester probes into the coupler terminal slots “1”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

  • Page 363: Checking The Fuses

    ELECTRICAL COMPONENTS 3. Replace: CHECKING THE FUSES EASB291351 • Fuse The following procedure applies to all of the fuses. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the engine off. NOTICE b. Install a new fuse of the correct amperage To avoid a short circuit, always stop the en- rating.
  • Page 364 ELECTRICAL COMPONENTS FIRST AID IN CASE OF BODILY CONTACT: EXTERNAL • Skin — Wash with water. • Eyes — Flush with water for 15 minutes and get immediate medical attention. INTERNAL • Drink large quantities of water or milk fol- lowed with milk of magnesia, beaten egg or vegetable oil.
  • Page 365 ELECTRICAL COMPONENTS • As shown in the following illustration, the open-circuit voltage of a VRLA (Valve Reg- ulated Lead Acid) battery stabilizes about 30 minutes after charging has been com- pleted. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage.

  • Page 366: Checking The Relays

    ELECTRICAL COMPONENTS d. Adjust the voltage so that the current is at 6. Install: the standard charging level. • Battery terminals e. Set the time according to the charging time 7. Connect: suitable for the open-circuit voltage. • Battery leads f.

  • Page 367: Checking The Diode

    ELECTRICAL COMPONENTS Starter relay Result Continuity (between “3” to “4”) Radiator fan motor relay Br/W 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe Br,R/W 4. Negative tester probe Result 1. Positive battery terminal Continuity 2. Negative battery terminal (between “3”...

  • Page 368: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS c. Push the engine stop switch. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ d. Measure the ignition spark gap “a”. a. Disconnect the diode from the wire harness. e. Crank the engine by pushing the start switch b. Connect the pocket tester (  1) to the di- and gradually increase the spark gap until a ode coupler as shown.

  • Page 369: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS b. Measure the secondary coil resistance. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (  1) to the igni- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ tion coil. EASB291358 CHECKING THE CRANKSHAFT POSITION SENSOR Pocket tester 90890-03112 1. Disconnect: Analog pocket tester • Crankshaft position sensor coupler YU-03112-C (from the wire harness) 2.

  • Page 370: Checking The Starter Motor Operation

    ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the lean angle sensor coupler to the wire harness. b. Connect the pocket tester (DC 20 V) to the lean angle sensor coupler as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Test harness– lean angle sensor b.

  • Page 371: Checking The Rectifier/Regulator

    ELECTRICAL COMPONENTS CHECKING THE RADIATOR FAN MOTOR (For JPN) 1. Check: • Radiator fan motor Faulty/rough movement  Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the radiator fan motor coupler from the wire harness. b. Connect the battery (DC 12 V) as shown. •...

  • Page 372: Checking The Throttle Position Sensor

    ELECTRICAL COMPONENTS CHECKING THE THROTTLE POSITION • Positive tester probe  SENSOR Green/White “1” 1. Remove: • Negative tester probe  • Throttle position sensor Black/Blue “2” (from the throttle body) WARNING • Handle the throttle position sensor with special care. •...

  • Page 373: Checking The Throttle Position Sensor Input Voltage

    ELECTRICAL COMPONENTS CHECKING THE THROTTLE POSITION EASB291365 Intake air pressure sensor output SENSOR INPUT VOLTAGE voltage 1. Check: 3.61–3.67 V at 101.3 kPa (3.61– • Throttle position sensor input voltage 3.67 V at 1.01kgf/cm , 3.61–3.67 Out of specification  Replace the ECU. V at 14.7 psi) Throttle position sensor input voltage...
  • Page 374 ELECTRICAL COMPONENTS • Positive tester probe  Intake air temperature sensor re- Injector terminal “1” sistance • Negative tester probe  290–390  at 80 °C (290–390  Injector terminal “2” 176 °F) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (  1k/100) to the intake air temperature sensor terminal.

  • Page 375: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING..................9-1 GENERAL INFORMATION ................9-1 STARTING FAILURES ................9-1 INCORRECT ENGINE IDLING SPEED .............9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 SHIFTING IS DIFFICULT ................9-2 SHIFT PEDAL DOES NOT MOVE .............9-2 JUMPS OUT OF GEAR................9-2 CLUTCH SLIPS ..................9-2 CLUTCH DRAGS ..................9-2 OVERHEATING..................9-2 OVERCOOLING ..................9-3 POOR BRAKING PERFORMANCE ............9-3 FRONT FORK OIL LEAKING ..............9-3 FAULTY FRONT FORK LEGS ..............9-3...

  • Page 376: Troubleshooting

    TROUBLESHOOTING • Incorrect spark plug heat range TROUBLESHOOTING EASB291369 • Fouled spark plug • Worn or damaged electrode GENERAL INFORMATION EASB291370 • Worn or damaged insulator 2. Ignition coil The following guide for troubleshooting does • Cracked or broken ignition coil body not cover all the possible causes of trouble.

  • Page 377: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING CLUTCH SLIPS POOR MEDIUM-AND-HIGH-SPEED PER- EASB291373 FORMANCE Engine Refer to “STARTING FAILURES” on page 9-1. 1. Clutch • Improperly assembled clutch Engine • Loose or fatigued clutch spring 1. Air filter • Worn friction plate • Clogged air filter element •...

  • Page 378: Overcooling

    TROUBLESHOOTING Fuel system FAULTY FRONT FORK LEGS EASB291383 1. Throttle body • Damaged or loose throttle body joint Chassis 2. Air filter 1. Front fork • Clogged air filter element • Bent or damaged inner tube • Bent or damaged outer tube Chassis •...
  • Page 379 8-42 nection Er-2 Signals from the ECU cannot be received within the specified period 8-43 of time. Er-3 Data from the ECU cannot be received correctly. 8-44 Er-4 Registered data cannot be received from the Yamaha diagnostic tool. 8-45...

  • Page 380: List Of Self-Diagnostic And Fail-Safe Actions

    Intake air temperature Displays the intake air tem- Compare the actually mea- perature. sured intake air tempera- ture with the Yamaha diagnostic tool display val- Coolant temperature When engine is cold: Dis- Compare the actually mea- plays temperature closer to sured coolant temperature air temperature.
  • Page 381 Actuates the ignition coil five Check that a spark is gener- times at one-second inter- ated five times. vals. • Connect an ignition “WARNING” on the Yamaha checker. diagnostic tool blinks five times when the ignition coil is actuated. Injector...
  • Page 382 LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS...

  • Page 383: Tuning

    TUNING CHASSIS ......................10-1 SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET)...................10-1 DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS....10-1 TIRE PRESSURE..................10-1 FRONT FORK SETTING................10-2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL ..10-2 SETTING OF SPRING AFTER REPLACEMENT........10-2 FRONT FORK SETTING PARTS.............10-3 REAR SUSPENSION SETTING...............10-3 CHOOSING SET LENGTH...............10-3 SETTING OF SPRING AFTER REPLACEMENT........10-4...

  • Page 384: Chassis

    CHASSIS DRIVE AND REAR WHEEL SPROCKETS CHASSIS EASB291387 SETTING PARTS SELECTION OF THE SECONDARY REDUC- EASB291388 Part name Type Part number TION RATIO (SPROCKET) Drive sprocket “1” Secondary reduction ratio = Number of (STD) 13T 9383B-13218 rear wheel sprocket teeth/Number of Rear wheel drive sprocket teeth sprocket “2”...

  • Page 385: Front Fork Setting

    CHASSIS • Under a stony or a hard road condition, the tire pressure should be higher to prevent a flat tire. Extent of adjustment 100–120 kPa (1.0–1.2 kgf/cm 15–18 psi) EASB291391 FRONT FORK SETTING The front fork setting should be made depend- ing on the rider’s feeling of an actual run and the circuit conditions.

  • Page 386: Front Fork Setting Parts

    CHASSIS REAR SUSPENSION SETTING The rear shock absorber setting should be Generally a stiff spring gives a stiff riding feel- made depending on the rider’s feeling of an ac- ing. Rebound damping tends to become weak- tual run and the circuit conditions. er, resulting in lack of a sense of contact with The rear suspension setting includes the fol- the road surface or in a vibrating handlebar.

  • Page 387: Setting Of Spring After Replacement

    CHASSIS Length “a” of standard shock • If the machine is new and after it is broken in, 462.5 mm (18.21 in) the same set length of the spring may change because of the initial fatigue, etc. of the spring. Therefore, be sure to make reevalua- tion.
  • Page 388 CHASSIS • Extent of adjustment (spring preload) Maximum Minimum Position in which Position in which the spring is turned the spring is turned in 18 mm (0.71 in) in 1.5 mm (0.06 in) from its free length. from its free length. For the spring preload adjustment, refer to “AD- JUSTING THE REAR SHOCK ABSORBER ASSEMBLY”...

  • Page 389: Suspension Setting (Front Fork)

    CHASSIS SUSPENSION SETTING (FRONT FORK) EASB291399 • If any of the following symptoms is experienced with the standard position as the base, make reset- ting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in).

  • Page 390: Suspension Setting (Rear Shock Absorber)

    CHASSIS Section Medi- Symptom Check Adjust Large Small Jump Compression Turn adjuster clockwise (about damping force 2 clicks) to increase damping. Rebound Turn adjuster counterclock- damping force wise (about 2 clicks) to de- crease damping. Low front, tend- ing to lower Balance with Set sunken length for 95–100 front posture...
  • Page 391 CHASSIS Section Medi- Symptom Check Adjust Large Small Jump Rebound Turn adjuster counterclock- damping force wise (about 2 clicks) to de- Heavy and crease damping. dragging Spring Replace with soft spring. Rebound Turn adjuster counterclock- damping force wise (about 2 clicks) to de- crease damping.
  • Page 392 COLOR CODE WIRING DIAGRAM EASB291402 Black YZ250FX/YZ250FXF 2015 1. Joint connector Brown 2. Joint connector Chocolate 3. Joint connector Dark green 4. AC magneto 5. Rectifier/regulator Green 6. Main relay Gray 7. Engine ground Blue 8. Battery 9. Frame ground Light green 10.
  • Page 393 For your best ownership experience, think Genuine Yamaha! Genuine Yamaha Parts – Genuine Yamaha replacement parts are the exact same parts as the ones originally equipped on your vehicle, providing you with the performance and durability you have come to expect.
  • Page 394 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2014.09––0.8 × 1 !
  • Page 395 YZ250FXF 2015 WIRING DIAGRAM Br Br R R R/L Br Br R R R R/L Br Br Br Br B/L Gy (Gy) (Gy) W W W W W W R/L R/B (Gy) Br/W Br/W Br/W,Br Br/W R/W,Br R,R/W Br/W Br/W Br/W L Y B/L L/G L/W...
  • Page 396 YZ250FXF 2015 WIRING DIAGRAM (Gy) (Gy) (Gy)

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