1. Manuals
  2. Brands
  3. Yamaha Manuals
  4. Motorcycle
  5. YZ 2016 Series
  6. Owner's service manual

Yamaha YZ 2016 Series Owner's Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
2016
q Read this manual carefully before operating this vehicle.
OWNER'S SERVICE MANUAL
YZ250FXG
LIT-11626-29-53
B29-28199-11

Advertisement

Table of Contents
loading

Related Manuals for Yamaha YZ 2016 Series

Summary of Contents for Yamaha YZ 2016 Series

  • Page 1 2016 q Read this manual carefully before operating this vehicle. OWNER’S SERVICE MANUAL YZ250FXG LIT-11626-29-53 B29-28199-11...
  • Page 2 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
  • Page 3 EASB296002 YZ250FXG OWNER’S SERVICE MANUAL ©2015 by Yamaha Motor Corporation, U.S.A. 1st Edition, June 2015 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-11626-29-53...
  • Page 4 INTRODUCTION EASB296003 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 EASB296005 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. EASB296006 YZ MOTORCYCLE LIMITED WARRANTY...
  • Page 7 HOW TO USE THIS MANUAL EASB296007 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 EASB296008 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 ADJUSTMENTS 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 INCLUDED PARTS...................1-4 SPARK PLUG WRENCH................1-4 NIPPLE WRENCH..................1-4 HANDLEBAR PROTECTOR ..............1-4 FUEL HOSE JOINT COVER ..............1-4 COUPLER FOR CONNECTING OPTIONAL PART........1-4 IMPORTANT INFORMATION................1-5 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-5 REPLACEMENT PARTS................1-5 GASKETS, OIL SEALS AND O-RINGS .............1-6 LOCK WASHERS/PLATES AND COTTER PINS ........1-6...
  • Page 12 STARTING AND BREAK-IN................1-20 FUEL......................1-20 HANDLING NOTE ..................1-20 AIR FILTER MAINTENANCE ..............1-20 STARTING A COLD ENGINE ..............1-20 STARTING A WARM ENGINE ..............1-22 BREAK-IN PROCEDURES ..............1-22 MAINTENANCE AFTER BREAK-IN ..............1-23 MAJOR MAINTENANCE ................1-23 TORQUE-CHECK POINTS................1-24 MOTORCYCLE CARE AND STORAGE ............1-26 CARE......................1-26 STORAGE ....................1-27...

  • Page 13: Location Of Important Labels

    LOCATION OF IMPORTANT LABELS LOCATION OF IMPORTANT LABELS EASB296009 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 EASB296010 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: Included Parts

    INCLUDED PARTS FUEL HOSE JOINT COVER INCLUDED PARTS EASB296014 The fuel hose joint covers “1” are used to pre- vent mud, dust, and other foreign materials EASB296015 SPARK PLUG WRENCH from entering the inside when the fuel hose is The spark plug wrench “1” is used to remove or disconnected.

  • Page 17: 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 18: Gaskets, Oil Seals And O-Rings

    IMPORTANT INFORMATION GASKETS, OIL SEALS AND O-RINGS EASB296022 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 19: Basic Service Information

    BASIC SERVICE INFORMATION BASIC SERVICE INFORMATION EASB296026 EASB296027 ELECTRICAL SYSTEM 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 20 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 21 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 22 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 23: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS EASB296028 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 24 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 25 90890-03209 age. YU-03209 FI diagnostic tool sub-lead This tool is used to connect 90890-03212 the Yamaha diagnostic tool YU-03212 to a battery. Yamaha diagnostic tool This tool is used to check er- 90890-03231 ror codes or carry out self-di- Yamaha diagnostic tool (US) agnosis.
  • Page 26 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 YM-04019 the valve spring. YM-04019 Spacer (crankshaft installer) This tool is used to install the 90890-04081 crankshaft.
  • Page 27 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 This tool is used to discon- adapter 22 mm nect or connect the valve and 90890-04108 the valve spring.
  • Page 28 SPECIAL TOOLS Tool name/Part number How to use Illustration Digital tachometer This tool is used to measure 90890-06760 the engine speed. YU-39951-B Three bond No.1215® This sealant (Bond) is used 90890-85505 for crankcase mating sur- face, etc. 1-16...

  • Page 29: Control Functions

    CONTROL FUNCTIONS SHIFT PEDAL CONTROL FUNCTIONS EASB296029 The shift pedal “1” has adopted a method of 1 down & 5 ups (press-down & kick-ups). EASB296030 ENGINE STOP SWITCH 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 30: Front Brake Lever

    CONTROL FUNCTIONS STARTER KNOB/IDLE ADJUSTING SCREW FRONT BRAKE LEVER EASB296036 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 31 CONTROL FUNCTIONS 1-19...

  • Page 32: Starting And Break-In

    STARTING A COLD ENGINE EASB296045 Your Yamaha engine has been designed to use NOTICE premium unleaded gasoline with a pump oc- For maximum engine life, never accelerate tane number [(R+M)/2] of 91 or higher, or a re- hard when the engine is cold! search octane number of 95 or higher.
  • Page 33 STARTING AND BREAK-IN Each starting attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt. If the engine does not start with the starter motor, try using the kickstart- NOTICE If the starter motor will not turn when the start switch is pushed, stop pushing it im-...

  • Page 34: Starting A Warm Engine

    STARTING AND BREAK-IN Observe the condition of the engine careful- STARTING A WARM ENGINE EASB296046 ly during a break-in. Follow the same procedure as for starting a For checkpoints for a break-in, see “MAIN- cold engine with the exception that the starter is TENANCE AFTER BREAK-IN”.

  • Page 35: Maintenance After Break-In

    MAINTENANCE AFTER BREAK-IN • Cable MAINTENANCE AFTER BREAK-IN EASB296048 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 36: Torque-Check Points

    TORQUE-CHECK POINTS TORQUE-CHECK POINTS EASB296050 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 37 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 38: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE • Do not use any harsh chemical products MOTORCYCLE CARE AND STOR- EASB296051 on plastic parts. Be sure to avoid using cloths or sponges which have been in con- tact with strong or abrasive cleaning prod- EASB296052 CARE ucts, solvent or thinner, fuel (gasoline),...

  • Page 39: 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 40 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 41: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-10 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 42: General Specifications

    GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS EASB296054 Model Model B296 (USA) B297 (CAN) B298 (EUR) B299 (AUS) (NZL) (ZAF) B29A (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 43: Engine Specifications

    ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS EASB296055 Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 250 cm Number of cylinders 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...
  • Page 44 ENGINE SPECIFICATIONS Spark plug(s) 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 45 ENGINE SPECIFICATIONS Valve spring Free length (intake) 36.69 mm (1.44 in) Limit 34.85 mm (1.37 in) Free length (exhaust) 34.86 mm (1.37 in) Limit 33.11 mm (1.30 in) Installed length (intake) 31.40 mm (1.24 in) Installed length (exhaust) 28.50 mm (1.12 in) Spring rate K1 (intake) 29.65 N/mm (3.02 kgf/mm, 169.30 lbf/in) Spring rate K2 (intake)
  • Page 46 Shift fork thickness 4.85 mm (0.1909 in) Decompression device Device type Auto decomp Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil Fuel pump Pump type Electrical...
  • Page 47 ENGINE SPECIFICATIONS 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 idle) 300.0–390.0 kPa (3.00–3.90 kgf/cm , 43.5– 56.6 psi) Throttle position sensor Resistance 6.30 k Output voltage (at idle) 0.49–0.51 V Fuel injection sensor 228–342 ...

  • Page 48: Chassis Specifications

    CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS EASB296056 Chassis Frame type Semi double cradle Caster angle 26.33 ° Trail 114 mm (4.5 in) Front wheel Wheel type Spoke wheel 1.60  21 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 49 Inner tube outer diameter 48 mm (1.9 in) Inner tube bending limit 0.2 mm (0.01 in) Optional spring available Recommended oil Yamaha Suspension Oil S1 Quantity 531.0 cm (17.95 US oz, 18.73 Imp.oz) (USA) (CAN) (EUR) (AUS) (NZL) (ZAF) 509.0 cm (17.21 US oz, 17.95 Imp.oz) (JPN)
  • Page 50 CHASSIS SPECIFICATIONS Rear suspension Type Swingarm (link suspension) Spring/shock absorber type Coil spring/Gas-hydraulic 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 51 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 52: Electrical Specifications

    ELECTRICAL SPECIFICATIONS Starter relay Amperage 180.0 A 4.18–4.62  Coil resistance Starting circuit cut-off relay 75.6–92.5  Coil resistance Fuses Main fuse 15.0 A Spare fuse 15.0 A Radiator fan motor fuse 5.0 A 2-11...

  • Page 53: Tightening Torques

    TIGHTENING TORQUES TIGHTENING TORQUES EAS20320 EASB296058 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 54: Engine Tightening Torques

    TIGHTENING TORQUES ENGINE TIGHTENING TORQUES EASB296059 - 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 55 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 56 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 57: Chassis Tightening Torques

    TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES - 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 145 Nm (14.5 m·kgf, 105 ft·lbf)
  • Page 58 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 59 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 60: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES EASB296061 ENGINE EASB296062 Lubrication point Lubricant types Oil seal lips Bearing O-ring Camshaft cap bolt threads and contacting surface Cylinder head bolt threads, seats, washers Valve stems Valve stem ends Valve lifter outer surface Camshaft lobe and journal Valve lifter top surface...

  • Page 61: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Shift lever assembly moving parts Damper assembly shaft, thrust surfaces, washers Starter idle gear inner surface, thrust surfaces Starter clutch drive gear inner surface, thrust surfaces Three bond Cylinder head cover gasket No.1215®...
  • Page 62 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Clutch cable end (clutch lever side) Tube guide (throttle grip) inner surface and throttle cable end 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...
  • Page 63 LUBRICATION POINTS AND LUBRICANT TYPES 2-22...

  • Page 64: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION SYSTEM CHART AND DIAGRAMS EASB296064 LUBRICATION DIAGRAMS EASB296065 2-23...
  • Page 65 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 66 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25...
  • Page 67 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Connecting rod 2. Crankshaft 3. Main axle 4. Oil strainer 5. Drive axle 2-26...
  • Page 68 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
  • Page 69 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Exhaust camshaft 2. Intake camshaft 3. Oil filter element 4. Oil pump 2-28...
  • Page 70 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 71 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil pressure check bolt 3. Oil filter element 4. Oil pump 2-30...

  • Page 72: Cable Routing Diagram

    CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM EASB296066 2-31...
  • Page 73 CABLE ROUTING DIAGRAM O. 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 74 CABLE ROUTING DIAGRAM 2-33...
  • Page 75 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 76 CABLE ROUTING DIAGRAM 2-35...
  • Page 77 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 78 CABLE ROUTING DIAGRAM 2-37...
  • Page 79 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 80 CABLE ROUTING DIAGRAM 2-39...
  • Page 81 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 82 CABLE ROUTING DIAGRAM 2-41...
  • Page 83 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 84 CABLE ROUTING DIAGRAM 2-43...
  • Page 85 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 86 CABLE ROUTING DIAGRAM 2-45...

  • Page 87: 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 VALVE 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 88 CHECKING AND ADJUSTING THE STEERING HEAD ......3-34 CHECKING AND LUBRICATING THE CABLES........3-35 LUBRICATING THE LEVERS ..............3-35 LUBRICATING THE PEDAL..............3-35 LUBRICATING THE DRIVE CHAIN ............3-35 LUBRICATING THE SIDESTAND............3-36 CHECKING THE CHASSIS FASTENERS ..........3-36 ELECTRICAL SYSTEM..................3-37 CHECKING THE SPARK PLUG...............3-37 CHECKING THE IGNITION TIMING ............3-37 CHECKING AND CHARGING THE BATTERY ........3-38...

  • Page 89: Maintenance Intervals

    MAINTENANCE INTERVALS MAINTENANCE INTERVALS EASB296067 MAINTENANCE INTERVALS EASB296068 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- 24.) • 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 90 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 91 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 92 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 93 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 94 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) Lubricate Lithium-soap-based grease DRIVE CHAIN Use chain oil. Clean, lubricate, slack, alignment Replace DRIVE CHAIN GUIDE Inspect Inspect wear. DRIVE CHAIN GUIDE AND DRIVE CHAIN SUPPORT...

  • Page 95: Pre-Operation Inspection And Maintenance

    PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE EASB296069 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. GENERAL INSPECTION AND MAINTENANCE EASB296070 ITEM inspect Page...

  • Page 96: Engine

    ENGINE ENGINE CHECKING THE COOLING SYSTEM EASB296071 EASB296073 1. Remove: CHECKING THE COOLANT LEVEL EASB296072 • 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 97: Checking The Radiator Cap

    ENGINE 5. Install: • Valve and valve seat “2” Crack/damage  Replace. • Copper washer Exist fur deposits  Clean or replace. • 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...

  • Page 98: Checking The Coolant Circulatory System For Leaks

    ENGINE CHECKING THE COOLANT CIRCULATORY ADJUSTING THE CLUTCH LEVER FREE EASB296077 EASB296078 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 99: Adjusting The Throttle Grip Free Play

    ENGINE 2. Adjust: Direction “a” • Throttle grip free play Clutch lever free play is increased. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Direction “b” a. Loosen the locknut “1”. Clutch lever free play is decreased. b. Turn the adjuster “2” until the specified free play is obtained. d.

  • Page 100: Cleaning The Air Filter Element

    ENGINE 2. Lubricate: • Throttle cable end “a” Recommended lubricant Lithium-soap-based grease 3. Wash: • Air filter element WARNING Do not use gasoline or organic (acid/alka- line) volatile oil for washing. 3. Install: • Throttle grip cap After washing the element with air filter cleaner •...

  • Page 101: Checking The Throttle Body Joint

    ENGINE CHECKING THE EXHAUST SYSTEM EASB296084 1. Remove: • Exhaust pipe protector 2. Check: • Exhaust pipe 1 • Exhaust pipe 2 • Silencer Crack/damage  Replace. Refer to “ENGINE REMOVAL” on page 5-1. • Exhaust gas 7. Install: Leaks  Replace the gasket. •...

  • Page 102: Checking The Fuel Line

    ENGINE CHECKING THE FUEL LINE EASB296085 1. Remove: • Seat • Side cover (left/right) • Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 4- • Fuel tank Refer to “FUEL TANK” on page 7-1. 2. Check: • Fuel hose “1” NOTICE Crack/damage ...
  • Page 103 ENGINE d. Install the oil strainer. Oil strainer bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • Gasket • Drain bolt Drain bolt 4. If the oil filter element is also to be replaced, 20 Nm (2.0 m·kgf, 14 ft·lbf) perform the following procedure.

  • Page 104: Adjusting The Engine Idling Speed

    ENGINE 10.Check: • Before adjusting the engine idling speed, • Engine oil pressure make sure that the air filter element is not clogged, the engine compression is proper, ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ and the throttle grip free play is proper. a. Slightly loosen the oil pressure check bolt •...

  • Page 105: Adjusting The Valve Clearance

    Align the top dead center (TDC) mark “a” on vicing of Yamaha motorcycles (e.g., Yamaha the rotor with the alignment mark “b” on the dealers, service engineers, etc.). Those who crankcase cover.
  • Page 106 ENGINE Valve lapper 90890-04101 Valve lapping tool YM-A8998 c. Measure the valve clearance “e” using a thickness gauge “1”. Record the measured reading if the clearance is incorrect. c. Check the number on the originally installed adjusting pad. • The adjusting pad number “a” is indicated on the top of the adjusting pad.
  • Page 107 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 108 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 109 ENGINE EXHAUST 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 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...

  • Page 110: Chassis

    CHASSIS CHASSIS EASB296090 BLEEDING THE BRAKE SYSTEM EASB296091 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 111: Checking The Brake Hose

    CHASSIS CHECKING THE BRAKE HOSE EASB296092 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 112: Adjusting The Rear Brake

    CHASSIS ADJUSTING THE REAR BRAKE EASB296094 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 113 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 114: Checking The Rear Brake Pads

    CHASSIS d. Remove the pad pin “6” and the brake pads CHECKING THE REAR BRAKE PADS EASB296096 “7”. 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.

  • Page 115: Checking The Rear Brake Pad Insulator

    CHASSIS i. Install the brake caliper “12” and the rear CHECKING THE REAR BRAKE PAD INSU- wheel “13”. LATOR Refer to “REAR WHEEL” on page 4-7. 1. Remove: j. Tighten the pad pin “14”. • Brake pads Refer to “REAR BRAKE” on page 4-21. Pad pin 2.

  • Page 116: 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 117: Checking The Front Fork Legs

    CHASSIS CLEANING THE FRONT FORK OIL SEAL CHECKING THE FRONT FORK LEGS EASB296100 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 118: 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 NOTICE Do not turn the adjuster forcibly beyond its adjusting range. ADJUSTING THE FRONT FORK LEGS EASB296104 1. Adjust: WARNING • Compression damping •...

  • Page 119: Checking The Swingarm Operation

    CHASSIS 1. Remove: CHECKING THE SWINGARM OPERATION EASB296105 • Rear frame 1. Check: Refer to “REAR SHOCK ABSORBER AS- • Swingarm smooth action SEMBLY” on page 4-55. • Swingarm free play 2. Adjust: Refer to “SWINGARM” on page 4-62. • Spring preload CHECKING THE REAR SUSPENSION EASB296106 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 120 CHASSIS e. Tighten the locknut. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Locknut Compression damping (for fast compres- 30 Nm (3.0 m·kgf, 22 ft·lbf) sion damping) NOTICE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: Do not turn the adjuster forcibly beyond its adjusting range. • Rear frame Refer to “REAR SHOCK ABSORBER AS- 1.

  • Page 121: Checking The Tires

    CHASSIS Compression damping (for slow compres- sion damping) • Check the tire while it is cold. • Loose bead stoppers allow the tire to slip off NOTICE its position on the rim when the tire pressure Do not turn the adjuster forcibly beyond its is low.

  • Page 122: Checking The Wheels

    CHASSIS 3. Remove: Spoke nipple wrench (6–7) • Handlebar 90890-01521 Refer to “HANDLEBAR” on page 4-31. YM-01521 • Upper bracket Refer to “STEERING HEAD” on page 4-51. Spokes 4. Adjust: 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) • Steering head ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.

  • Page 123: Checking And Lubricating The Cables

    CHASSIS d. Loosen the ring nut fully turn and then tight- 2. Check: en it to specification with a steering nut • Cable operation Rough movement  Lubricate. wrench. Recommended lubricant WARNING Engine oil or a suitable cable lu- Do not overtighten the lower ring nut. bricant Ring nut (final tightening torque) 7 Nm (0.7 m·kgf, 5.1 ft·lbf)

  • Page 124: Lubricating The Sidestand

    CHASSIS LUBRICATING THE SIDESTAND EASB296117 Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Recommended lubricant Lithium-soap-based grease CHECKING THE CHASSIS FASTENERS EASB296118 Make sure that all nuts, bolts, and screws are properly tightened. Refer to “CHASSIS TIGHTENING TORQUES” on page 2-16.

  • Page 125: Electrical System

    ELECTRICAL SYSTEM 5. Clean: ELECTRICAL SYSTEM EASB296119 • Spark plug (with a spark plug cleaner or a wire brush) CHECKING THE SPARK PLUG EASB296120 6. Measure: 1. Remove: • Spark plug gap “a” • Seat Out of specification  Adjust the spark plug •...

  • Page 126: 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 YU-03141 Digital tachometer 90890-06760 YU-39951-B 3. Adjust: • Engine idling speed Refer to “ADJUSTING THE ENGINE IDLING SPEED” on page 3-16. 4.
  • Page 127 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 128 HANDLEBAR....................4-31 REMOVING THE HANDLEBAR ...............4-33 CHECKING THE HANDLEBAR..............4-33 INSTALLING THE HANDLEBAR..............4-33 FRONT FORK....................4-38 REMOVING THE FRONT FORK LEGS ...........4-40 DISASSEMBLING THE FRONT FORK LEGS .........4-40 CHECKING THE FRONT FORK LEGS............4-41 ASSEMBLING THE FRONT FORK LEGS ..........4-42 INSTALLING THE FRONT FORK LEGS..........4-49 STEERING HEAD...................4-51 REMOVING THE LOWER BRACKET............4-52 CHECKING THE STEERING HEAD ............4-52...

  • Page 129: 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 130: Removing The Left Side Cover

    GENERAL CHASSIS REMOVING THE NUMBER PLATE REMOVING THE LEFT SIDE COVER EASB296125 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 131: Front Wheel

    FRONT WHEEL FRONT WHEEL EASB296128 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 132: Removing The Front Wheel

    FRONT WHEEL REMOVING THE FRONT WHEEL EASB296129 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 133: Disassembling The Front Wheel

    FRONT WHEEL DISASSEMBLING THE FRONT WHEEL EASB296131 1. Remove: • Oil seals • Bearings ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside of the front wheel hub. b. Remove the oil seals “1” with a flat-head screwdriver. To prevent damaging the wheel, place a rag “2” between the screwdriver and the wheel sur- face.

  • Page 134: 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 135: Rear Wheel

    REAR WHEEL REAR WHEEL EASB296134 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 136: Removing The Rear Wheel

    REAR WHEEL 4. Measure: REMOVING THE REAR WHEEL EASB296135 • Radial wheel runout 1. Use a suitable stand to raise the rear wheel • Lateral wheel runout off the ground. Refer to “CHECKING THE FRONT WHEEL” WARNING on page 4-4. Securely support the vehicle so that there is Radial wheel runout limit no danger of it falling over.

  • Page 137: Assembling The Rear Wheel

    REAR WHEEL Tighten the self-locking nuts in stages and in a crisscross pattern. 2. Install: • Brake disc “1” • Brake disc bolt “2” Brake disc bolt ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 14 Nm (1.4 m·kgf, 10 ft·lbf) LOCTITE® ASSEMBLING THE REAR WHEEL EASB296139 1.
  • Page 138 REAR WHEEL Install the brake disc “1” between the brake Temporarily tighten the nut (rear wheel axle) at pads “2” correctly. this point. 2. Install: 5. Adjust: • Drive chain “1” • Drive chain slack “a” Drive chain slack Push the rear wheel “2” forward and install the 50.0–60.0 mm (1.97–2.36 in) drive chain.

  • Page 139: Front Brake

    FRONT BRAKE FRONT BRAKE EASB296141 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 140 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 141 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 142 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. 4-14...

  • Page 143: Introduction

    FRONT BRAKE INTRODUCTION EASB296142 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 144: 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 145: 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 146: 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 3-22. 6. Check: • Brake fluid level 2.

  • Page 147: Installing The Front Brake Master Cylinder

    FRONT BRAKE EASB296153 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 148 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 149: Rear Brake

    REAR BRAKE REAR BRAKE EASB296154 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 150 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 151 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 3-22. 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 152 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. 4-24...

  • Page 153: Introduction

    REAR BRAKE INTRODUCTION EASB296155 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 154: Removing The Rear Brake Caliper

    REAR BRAKE REMOVING THE REAR BRAKE CALIPER CHECKING THE REAR BRAKE CALIPER EASB296157 EASB296159 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 155: Installing The Brake Caliper Piston

    REAR BRAKE INSTALLING THE REAR BRAKE CALIPER INSTALLING THE BRAKE CALIPER PISTON EASB296161 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 156: 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 157: Assembling The Rear Brake Master Cylinder

    REAR BRAKE 3. Install: ASSEMBLING THE REAR BRAKE MASTER EASB296165 • 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 158 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 3-27. Make sure that the pipe portion of the brake hose touches the projection “a”...
  • Page 159 HANDLEBAR HANDLEBAR EASB296167 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 160 HANDLEBAR Removing the handlebar Order Part name Q’ty Remarks Damper For installation, reverse the removal proce- dure. 4-32...

  • Page 161: Handlebar

    HANDLEBAR REMOVING THE HANDLEBAR EASB296168 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” EASB296169 CHECKING THE HANDLEBAR 1. Check: •...
  • Page 162 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 163 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 164 HANDLEBAR 9. Install: 11.Install: • Throttle cable housings “1” • Start switch “1” • Screw (throttle cable housings) “2” • Front brake master cylinder assembly “2” • Front brake master cylinder holder “3” Screw (throttle cable housings) • Bolt (brake master cylinder holder) “4” 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) •...
  • Page 165 HANDLEBAR 13.Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LE- VER FREE PLAY” on page 3-10. Clutch lever free play 7.0–12.0 mm (0.28–0.47 in) 14.Adjust: • Throttle grip free play Refer to “ADJUSTING THE THROTTLE GRIP FREE PLAY” on page 3-11. Throttle grip free play 3.0–6.0 mm (0.12–0.24 in) 4-37...

  • Page 166: Front Fork

    FRONT FORK FRONT FORK EASB296171 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 167 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 168: Removing The Front Fork Legs

    FRONT FORK REMOVING THE FRONT FORK LEGS EASB296172 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 169: Checking The Front Fork Legs

    FRONT FORK 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) 2. Check: • Outer tube Hold the damper assembly with the cap bolt Scratches/wear/damage ...

  • Page 170: Assembling The Front Fork Legs

    6. Check: 2. Fill: • Contacting surface “a” • Damper assembly Wear/damage  Replace. Recommended oil Yamaha Suspension Oil S1 Standard oil amount 204 cm (6.90 US oz, 7.20 Imp.oz) NOTICE • Be sure to use the recommended oil. Other oils may have an adverse effect on front fork performance.
  • Page 171 FRONT FORK 3. After filling, pump the damper assembly “1” 5. Tighten: slowly up and down (about 200 mm (7.9 in) • Locknut “1” stroke) several times to bleed the damper assembly of air. Fully finger tighten the locknut onto the damper assembly.
  • Page 172 FRONT FORK 8. Check: 11.While protecting the damper assembly “1” • Damper assembly with a cloth and compressing fully, allow ex- Not fully stretched  Repeat the steps 1 to cessive oil to overflow on the base valve side. 9. Tighten: NOTICE •...
  • Page 173 FRONT FORK 14.Install: • Dust seal “1” • Oil seal clip “2” • Oil seals “3” • Washer “4” • Outer tube bushing “5” (to the inner tube “6”) NOTICE Make sure that the numbered side of the oil seal faces bottom side. 16.Install: •...
  • Page 174 FRONT FORK 20.Install: • Dust seal “1” Apply lithium-soap-based grease on the inner tube. 18.Install: • Oil seals “1” Using a fork seal driver “2”, press the oil seal in until the stopper ring groove fully appears. 21.Check: Fork seal driver •...
  • Page 175 FRONT FORK 23.Install: • Collar “1” • Fork spring “2” (to the damper assembly “3”) Install the collar with its larger dia. end “a” fac- ing the fork spring. 26.Install: • Damper adjusting rod “1” • Copper washer “2” • Adjuster “3” (to the damper assembly “4”) •...
  • Page 176 FRONT FORK 30.Fill: • Front fork leg Recommended oil Yamaha Suspension Oil S1 Standard oil amount 335 cm (11.33 US oz, 11.82 lmp.oz) (USA) (CAN) (EUR) (AUS) (NZL) (ZAF) 313 cm (10.58 US oz, 11.04 lmp.oz) (JPN) Extent of adjustment 28.Tighten:...

  • Page 177: Installing The Front Fork Legs

    FRONT FORK 32.Install: • Protector guide “1” 3. Adjust: • Front fork top end “a” Front fork top end (standard) “a” INSTALLING THE FRONT FORK LEGS EASB296176 3 mm (0.12 in) 1. Install: • Front fork “1” • Temporarily tighten the pinch bolts (lower bracket).
  • Page 178 FRONT FORK 5. Install: • Protector “1” • Bolt (protector) “2” Bolt (protector) 5 Nm (0.5 m·kgf, 3.6 ft·lbf) 6. Adjust: • Rebound damping force Turn in the damping adjuster “1” finger-tight and then turn out to the originally set position. 7.

  • Page 179: Steering Head

    STEERING HEAD STEERING HEAD EASB296177 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 180: Removing The Lower Bracket

    STEERING HEAD REMOVING THE LOWER BRACKET EASB296178 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 181 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 182 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 183: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY REAR SHOCK ABSORBER ASSEMBLY EASB296181 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 184 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. 4-56...
  • Page 185 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. 4-57...

  • Page 186: 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 187: Checking The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY • Spring guide Damage/wear  Replace. • Bearing Damage/wear  Replace. • Bolts Bends/damage/wear  Replace. EASB296187 CHECKING THE CONNECTING ARM AND RELAY ARM 1. Check: • Connecting arm 2. Remove: • Relay arm • Upper bearing “1” Damage/wear ...

  • Page 188: 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 189 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 190: Swingarm

    SWINGARM SWINGARM EASB296190 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 191: Removing The Swingarm

    SWINGARM REMOVING THE SWINGARM EASB296191 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 192: Installing The Swingarm

    SWINGARM INSTALLING THE SWINGARM EASB296194 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 193: Chain Drive

    CHAIN DRIVE CHAIN DRIVE EASB296195 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 194: 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 195: 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 196 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 3-28. Drive chain slack 50.0–60.0 mm (1.97–2.36 in) NOTICE...

  • Page 197: 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 198 CLUTCH......................5-41 REMOVING THE CLUTCH ..............5-44 CHECKING THE FRICTION PLATES............5-44 CHECKING THE CLUTCH PLATES ............5-44 CHECKING THE CLUTCH SPRINGS............5-44 CHECKING THE CLUTCH HOUSING .............5-45 CHECKING THE CLUTCH BOSS ............5-45 CHECKING THE PRESSURE PLATE .............5-45 CHECKING THE PUSH LEVER SHAFT ..........5-45 CHECKING THE CLUTCH PUSH RODS..........5-45 CHECKING THE PRIMARY DRIVE GEAR ..........5-45 CHECKING THE PRIMARY DRIVEN GEAR ...........5-46 INSTALLING THE OIL SEAL..............5-46...
  • Page 199 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 200: 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 201 ENGINE REMOVAL Removing the exhaust pipe 5 Nm (0.5 m kgf, 3.6 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 9 Nm (0.9 m kgf, 6.5 ft Ibf) 13 Nm (1.3 m , 9.4 ft lbf) 20 Nm (2.0 m kgf, 14 ft lbf) 30 Nm (3.0 m kgf, 22 ft Ibf)
  • Page 202 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 203 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 204 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 205: Removing The Silencer

    ENGINE REMOVAL REMOVING THE SILENCER EASB296201 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. EASB296203 REMOVING THE DRIVE SPROCKET 1.

  • Page 206: Removing The Engine

    ENGINE REMOVAL CHECKING THE SILENCER AND EXHAUST REMOVING THE ENGINE EASB296204 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 207: Installing The Engine

    ENGINE REMOVAL 2. Remove: 5. Replace: • Rivet “1” • Fiber “1” • Silencer cap “2” Stuff the fiber into the silencer body by using a flat board “2”. 3. Replace: • Fiber “1” 6. Install: • Silencer cap “1” •...

  • Page 208: Installing The Brake Pedal

    ENGINE REMOVAL • Front engine bracket “4” INSTALLING THE BRAKE PEDAL • Engine bracket bolt (front side) “5” 1. Install: • Spring “1” Engine bracket bolt (front side) • Brake pedal “2” 34 Nm (3.4 m·kgf, 25 ft·lbf) • O-rings “3” •...

  • Page 209: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL Tighten the nut while applying the rear brake. NOTICE Make sure to tighten to specification; other- wise, it may damage the other part that is fastened together. 2. Install: • Clamp • Exhaust pipe 2 “1” • Bolt (exhaust pipe 2) “2” 3.
  • Page 210 ENGINE REMOVAL Install and temporarily tighten the silencer so that its joint is positioned as shown with respect to the exhaust pipe 2. 2mm (0.08in) 4. Tighten: • Bolt (exhaust pipe 2) Bolt (exhaust pipe 2) 20 Nm (2.0 m·kgf, 14 ft·lbf) •...

  • Page 211: Camshaft

    CAMSHAFT CAMSHAFT EASB296211 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 212 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 213: Removing The Camshaft

    CAMSHAFT REMOVING THE CAMSHAFT EASB296212 1. Remove: • Timing mark accessing screw “1” • Crankshaft end accessing screw “2” 4. Remove: • Bolt (camshaft cap) “1” • Camshaft cap “2” • Clip “3” 2. Align: • Alignment mark • Remove the bolts (camshaft cap) in a criss- cross pattern, working from the outside in.

  • Page 214: Checking The Camshaft

    CAMSHAFT 3. Measure: EASB296213 CHECKING THE CAMSHAFT • Camshaft runout 1. Check: Out of specification  Replace. • Camshaft lobes Blue discoloration/pitting/scratches  Re- Camshaft runout limit 0.030 mm (0.0012 in) place the camshaft. 2. Measure: • Camshaft lobe dimensions “A” and “B” Out of specification ...

  • Page 215: Checking The Timing Chain And Camshaft Sprocket

    CAMSHAFT c. Install the dowel pins and the camshaft 2. Check: caps. • Camshaft sprocket More than 1/4 tooth wear “a”  Replace the camshaft and the timing chain as a set. • Tighten the camshaft cap bolts in a crisscross pattern from innermost to outer caps.

  • Page 216: Checking The Decompression System

    CAMSHAFT CHECKING THE DECOMPRESSION SYS- EASB296216 1. Check: • Decompression system ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check that the decompressor cam “1” moves smoothly. b. Check that the decompressor lever pin “2” projects from the camshaft. c. Fit the timing chain “3” onto both camshaft sprockets and install the camshafts on the cylinder head.
  • Page 217 CAMSHAFT ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install: 3. Turn: • Timing chain tensioner • Crankshaft Counterclockwise several turns. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 4. Check: a. While pressing the tensioner rod lightly with • Top dead center (TDC) mark on the rotor your fingers, use a thin screwdriver to wind Align with the crankcase alignment mark.

  • Page 218: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD EASB296218 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 219 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 220: Removing The Cylinder Head

    CYLINDER HEAD REMOVING THE CYLINDER HEAD EASB296219 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 221: Installing The Cylinder Head

    CYLINDER HEAD INSTALLING THE CYLINDER HEAD EASB296222 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 222 VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS EASB296223 Removing the valves and valve springs Order Part name Q’ty Remarks Refer to “CYLINDER HEAD” on page 5-19. Cylinder head Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Intake valve...

  • Page 223: Valves And Valve Springs

    VALVES AND VALVE SPRINGS REMOVING THE VALVES EASB296224 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Pour a clean solvent “a” into the intake and exhaust ports. Before removing the internal parts of the cylin- b. Check that the valves are properly sealed. der head (e.g., valves, valve springs, valve seats), make sure that the valves are properly Check that there are no kerosene leaks from sealed.

  • Page 224: 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 EASB296225 head to 100 °C (212 °F) in an oven.

  • Page 225: Checking The Valve Seats

    VALVES AND VALVE SPRINGS c. After installing the valve guide, expand the 5. Measure: hole in the valve guide with the valve guide • Valve margin thickness “a” Out of specification  Replace the valve. reamer “3” to obtain the proper valve-stem- to-valve-guide clearance.
  • Page 226 VALVES AND VALVE SPRINGS 4. Lap: Valve seat contact width (intake) • Valve face 0.90–1.10 mm (0.0354–0.0433 in) • Valve seat Valve seat contact width (ex- haust) NOTICE 0.90–1.10 mm (0.0354–0.0433 in) This model uses titanium intake and ex- haust valves. Do not use the valves used for lapping the valve seat.

  • Page 227: 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 228: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS CHECKING THE VALVE LIFTERS EASB296228 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 229 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 230 CYLINDER AND PISTON CYLINDER AND PISTON EASB296230 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 5-19. Cylinder head Cylinder body Gaskets...

  • Page 231: Cylinder And Piston

    CYLINDER AND PISTON REMOVING THE PISTON EASB296231 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 EASB296232 CHECKING THE CYLINDER AND PISTON crankcase opening with a cloth to prevent the...

  • Page 232: Checking The Piston Rings

    CYLINDER AND PISTON CHECKING THE PISTON RINGS 1. Measure: • Piston ring side clearance Out of specification  Replace the piston and piston rings as a set. Before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring grooves and piston rings.

  • Page 233: Checking The Piston Pin

    CYLINDER AND PISTON Piston ring Top ring End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in) Limit 0.50 mm (0.0197 in) Oil ring End gap (installed) 0.10–0.35 mm (0.0039–0.0138 in) EASB296234 CHECKING THE PISTON PIN EASB296235 INSTALLING THE PISTON AND CYLINDER 1. Check: 1.
  • Page 234 CYLINDER AND PISTON 5. Install: • Cylinder gasket • Apply the engine oil to the piston pin. • Dowel pin • Install the piston with the F mark “a” on it • Cylinder pointing to its intake (front) side. • Before installing the piston pin clip, cover the Cylinder bolt crankcase opening with a cloth to prevent the 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

  • Page 235: Electric Starter

    ELECTRIC STARTER ELECTRIC STARTER EASB296236 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 236 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. 5-37...

  • Page 237: Checking The Starter Motor

    ELECTRIC STARTER CHECKING THE STARTER MOTOR EASB296237 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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 238: Assembling The Starter Motor

    ELECTRIC STARTER 7. Check: • Gear teeth Align the match mark “a” on the starter motor Damage/wear  Replace the starter motor. yoke with the match mark “b” on the starter mo- 8. Check: tor rear cover. • Oil seal Damage/wear ...
  • Page 239 ELECTRIC STARTER 5. Install: • Bolt “1” • O-ring “2” Apply the lithium-soap-based grease on the O- ring. 5-40...
  • Page 240 CLUTCH CLUTCH EASB296239 Removing the clutch 6 10 Order Part name Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-14. Brake pedal Refer to “ENGINE REMOVAL” on page 5-1. Clutch cable Disconnect. Clutch cover Gasket Clutch spring Pressure plate Push rod 1...
  • Page 241 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. 5-42...
  • Page 242 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 3-14. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-8.

  • Page 243: Clutch

    CLUTCH CHECKING THE CLUTCH PLATES REMOVING THE CLUTCH EASB296240 1. Check: 1. Remove: • Clutch plate • Clutch boss nut “1” Damage  Replace the clutch plates as a • Lock washer “2” set. • Clutch boss “3” 2. Measure: •...

  • Page 244: Checking The Clutch Housing

    CLUTCH CHECKING THE CLUTCH HOUSING EASB296244 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. EASB296248 CHECKING THE CLUTCH PUSH RODS 1.

  • Page 245: Checking The Primary Driven Gear

    CLUTCH 2. Install: CHECKING THE PRIMARY DRIVEN GEAR EASB296250 • 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 246: Installing The Clutch

    CLUTCH INSTALLING THE CLUTCH EASB296253 1. Install: Use the clutch holding tool “3” to hold the clutch • Push lever shaft “1” boss. • Apply the lithium-soap-based grease on the Clutch holder oil seal lip. 90890-04086 • Before installation, apply the engine oil to the YM-91042 push lever shaft sliding surface.
  • Page 247 CLUTCH 8. Install: • Pressure plate “1” a. Identification color 6. Install: 9. Install: • Bearing “1” • Clutch spring • Washer “2” • Clutch spring bolt • Circlip “3” To push rod 1 “4”. Clutch spring bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Apply the engine oil on the bearing and washer.

  • Page 248: Installing The Kickstarter Lever

    CLUTCH Tighten the bolts in stages and in a crisscross pattern. INSTALLING THE KICKSTARTER LEVER EASB296254 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...
  • Page 249 KICKSTATER KICKSTATER EASB296255 Removing the kick shaft Order Part name Q’ty Remarks Primary driven gear Refer to “CLUTCH” on page 5-41. Kick idle gear Kick shaft assembly Spring guide Torsion spring Ratchet wheel Kick gear Kick shaft For installation, reverse the removal proce- dure.

  • Page 250: Kickstater

    KICKSTATER REMOVING THE KICK SHAFT ASSEMBLY EASB296256 1. Remove: • Kick shaft assembly “1” Unhook the torsion spring “2” from the hole “a” in the crankcase. EASB296259 INSTALLING THE KICK SHAFT ASSEMBLY 1. Install: • Kick gear “1” • Washer “2” •...

  • Page 251: 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 252: Shift Shaft

    SHIFT SHAFT SHIFT SHAFT EASB296261 Removing the shift shaft and stopper lever 10 Nm (1.0 m kgf, 7.2 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 30 Nm (3.0 m kgf, 22 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty...
  • Page 253 SHIFT SHAFT Removing the shift shaft and stopper lever 10 Nm (1.0 m kgf, 7.2 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 30 Nm (3.0 m kgf, 22 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty...

  • Page 254: Removing The Shift Guide And Shift Lever Assembly

    SHIFT SHAFT REMOVING THE SHIFT GUIDE AND SHIFT EASB296262 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. EASB296265 CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY...

  • Page 255: Installing The Stopper Lever

    SHIFT SHAFT INSTALLING THE SHIFT GUIDE AND SHIFT INSTALLING THE STOPPER LEVER EASB296267 LEVER ASSEMBLY 1. Install: 1. Install: • Torsion spring “1” • Spring “1” • Collar “2” • Pawl pin “2” • Stopper lever “3” • Pawl “3” •...

  • Page 256: 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 EASB296270 1. Install: • Roller “1” • Shift haft spring “2” (to shift shaft) • Collar “3” (to shift shaft) •...
  • Page 257 OIL PUMP AND BALANCER GEAR OIL PUMP AND BALANCER GEAR EASB296272 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 258: 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 5-41. Right crankcase cover Refer to “CLUTCH”...

  • Page 259: Removing The Balancer

    OIL PUMP AND BALANCER GEAR REMOVING THE BALANCER EASB296273 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 260: Assembling The Oil Pump

    OIL PUMP AND BALANCER GEAR Out of specification  Replace the oil pump. • Apply the engine oil on the oil pump drive Inner-rotor-to-outer-rotor-tip shaft and inner rotor. clearance 0.000–0.150 mm (0.0000–0.0059 • Fit the dowel pin into the groove in the inner rotor.

  • Page 261: Installing The Oil Pump And Balancer Gear

    OIL PUMP AND BALANCER GEAR INSTALLING THE OIL PUMP AND BALANC- EASB296278 ER GEAR 1. Install: • Oil pump assembly “1” • Oil pump assembly bolt “2” Oil pump assembly bolt 5 Nm (0.5 m·kgf, 3.6 ft·lbf) LOCTITE® NOTICE 4. Install: After tightening the bolts, make sure that •...
  • Page 262 OIL PUMP AND BALANCER GEAR 5-63...
  • Page 263 GENERATOR AND STARTER CLUTCH GENERATOR AND STARTER CLUTCH EASB296279 Removing the generator Order Job/Parts to remove Q’ty Remarks Refer to “CHANGING THE ENGINE OIL” on Drain the engine oil. page 3-14. Refer to “GENERAL CHASSIS” on page 4-1 Seat and fuel tank and “FUEL TANK”...
  • Page 264 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 265: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH 3. Check: REMOVING THE GENERATOR EASB296280 • Starter clutch gear 1. Remove: Damage/pitting/wear  Replace the starter • Generator rotor nut “1” clutch gear. • Washer 4. Check: • Damper assembly Damage/pitting/wear  Replace the damp- er assembly.

  • Page 266: Installing The Starter Clutch

    GENERATOR AND STARTER CLUTCH 2. Install INSTALLING THE STARTER CLUTCH EASB296282 • Starter clutch drive gear “1” 1. Install: • Stator “1” • Stator bolt “2” Apply the engine oil on the starter clutch drive gear inner circumference. Stator bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) LOCTITE®...
  • Page 267 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 268 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 269 CRANKCASE CRANKCASE EASB296284 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 270: 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 271 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 272: Disassembling The Crankcase

    CRANKCASE DISASSEMBLING THE CRANKCASE EASB296285 1. Separate: • Right crankcase • Left crankcase ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the crankcase bolts. c. Remove the dowel pins and O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EASB296286 REMOVING THE CRANKCASE BEARING 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 273: Installing The Oil Seal

    CRANKCASE • Oil delivery passages 3. Install: Obstruction  Blow out with compressed • Dowel pin “1” air. • Crankcase “2” (to the left crankcase) INSTALLING THE OIL SEAL EASB296289 Crankcase bolt 1. Install: 12 Nm (1.2 m·kgf, 8.7 ft·lbf) •...

  • Page 274: Crankshaft Assembly And Balancer Shaft

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EASB296291 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 275: Removing The Crankshaft Assembly

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 2. Measure: REMOVING THE CRANKSHAFT ASSEMBLY EASB296292 • Big end side clearance “a” 1. Remove: Out of specification  Replace the big end • Crankshaft assembly “1” bearing, crankshaft pin, or connecting rod. Remove the crankshaft assembly by using the Big end side clearance 0.150–0.450 mm (0.0059–0.0177 crankcase separating tool “2”.

  • Page 276: Installing The Crankshaft Assembly

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT INSTALLING THE CRANKSHAFT ASSEM- EASB296294 1. Install: • Crankshaft assembly Install the crankshaft assembly with the crank- shaft installer pot “1”, crankshaft installer bolt “2”, adapter (M12) “3” and spacer “4”. Crankshaft installer pot 90890-01274 INSTALLING THE BALANCER SHAFT EASB296295 Installing pot...

  • Page 277: Transmission

    TRANSMISSION TRANSMISSION EASB296296 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 278: Removing The Transmission

    TRANSMISSION CHECKING THE SHIFT FORKS REMOVING THE TRANSMISSION EASB296297 1. Check: 1. Remove: • Shift fork cam follower “1” • Long shift fork guide bar “1” • Shift fork pawl “2” • Short shift fork guide bar “2” Bends/damage/scoring/wear  Replace the •...

  • Page 279: Checking The Shift Drum Assembly

    TRANSMISSION CHECKING THE SHIFT DRUM ASSEMBLY EASB296299 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 280 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 281 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 282 TRANSMISSION 5-83...

  • Page 283: 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 284 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 285 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 286 RADIATOR HANDLING NOTE EASB296304 WARNING If coolant seems hot, do not remove the ra- diator cap. EASB296305 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 287 WATER PUMP WATER PUMP EASB296306 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 288 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 289 WATER PUMP REMOVING THE OIL SEAL EASB296307 • 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 290 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 291: 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 292: 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 293: Removing The Fuel Tank

    FUEL TANK REMOVING THE FUEL TANK EASB296314 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 294: 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 EASB296319 1. Check: • Fuel pressure EASB296318 INSTALLING THE FUEL TANK 1.

  • Page 295: 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 line pressure (at idle) 300.0–390.0 kPa (3.00–3.90 kgf/ , 43.5–56.6 psi) 15 mm ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ (0.59 in) EASB296320 CHECKING THE DAMPER A.

  • Page 296: Throttle Body

    THROTTLE BODY THROTTLE BODY EASB296322 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 297 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 298 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 299: Checking The Injector

    THROTTLE BODY CHECKING THE INJECTOR EASB296323 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 300: 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 301: 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 302 CHECKING THE INTAKE AIR TEMPERATURE SENSOR .....8-68 CHECKING THE FUEL INJECTOR ............8-68...
  • Page 303 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 304: Ignition System

    IGNITION SYSTEM IGNITION SYSTEM EASB296328 CIRCUIT DIAGRAM EASB296329...
  • Page 305 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 37.Ignition coil sub-lead...

  • Page 306: Troubleshooting

    IGNITION SYSTEM TROUBLESHOOTING EASB296330 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 307 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 308: Electric Starting System

    ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM EAS27160 CIRCUIT DIAGRAM EASB296331...
  • Page 309 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 310: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION EASB296332 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 311 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 312: Troubleshooting

    ELECTRIC STARTING SYSTEM TROUBLESHOOTING EASB296333 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 313 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 314: Charging System

    CHARGING SYSTEM CHARGING SYSTEM EAS27200 CIRCUIT DIAGRAM EASB296334 8-12...
  • Page 315 CHARGING SYSTEM 4. AC magneto 5. Rectifier/regulator 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 38.Negative battery lead 8-13...

  • Page 316: Troubleshooting

    CHARGING SYSTEM TROUBLESHOOTING EASB296335 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 317 CHARGING SYSTEM 8-15...

  • Page 318: Cooling System (For Jpn)

    COOLING SYSTEM (For JPN) COOLING SYSTEM (For JPN) EASB296336 CIRCUIT DIAGRAM EASB296337 8-16...
  • Page 319 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 320: Troubleshooting

    COOLING SYSTEM (For JPN) TROUBLESHOOTING EASB296338 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 321 COOLING SYSTEM (For JPN) 8-19...

  • Page 322: Fuel Injection System

    FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM EASB296339 CIRCUIT DIAGRAM EASB296340 8-20...
  • Page 323 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 324: Yamaha Diagnostic Tool

    FUEL INJECTION SYSTEM YAMAHA DIAGNOSTIC TOOL EASB296341 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 325 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 326 FUEL INJECTION SYSTEM 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. 3. Code The following icons and the fault code numbers for the detected malfunctions are displayed. A.

  • Page 327: 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 328 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 329 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 330 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 331 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 332 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 333 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 334 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 335 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 336 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 337 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 338 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 339 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 340 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 341 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 342 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 343 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 344 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 345 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 346 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 347 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 348: Fuel Pump System

    FUEL PUMP SYSTEM FUEL PUMP SYSTEM EASB296343 CIRCUIT DIAGRAM EASB296344 8-46...
  • Page 349 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 350: Troubleshooting

    FUEL PUMP SYSTEM TROUBLESHOOTING EASB296345 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 351 FUEL PUMP SYSTEM 8-49...

  • Page 352: Electrical Components

    ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS EASB296346 EASB296347 8-50...
  • Page 353 ELECTRICAL COMPONENTS 1. Rectifier/regulator 2. Clutch switch 3. Ignition coil 4. ECU (engine control unit) 5. Fuel pump 6. Battery 7. Neutral switch 8. Radiator fan motor (For JPN) 9. Injector 8-51...
  • Page 354 ELECTRICAL COMPONENTS 8-52...
  • Page 355 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 356: Checking The Switches

    ELECTRICAL COMPONENTS CHECKING THE SWITCHES EASB296348 8-54...
  • Page 357 ELECTRICAL COMPONENTS 1. Engine stop switch 2. Neutral switch 3. Clutch switch 4. Start switch 8-55...
  • Page 358 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 359: Checking The Fuses

    ELECTRICAL COMPONENTS 3. Replace: CHECKING THE FUSES EASB296349 • 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 360 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 361 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 362: 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 363: 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 364: 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 365: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS b. Measure the secondary coil resistance. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (  1) to the igni- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ tion coil. EASB296356 CHECKING THE CRANKSHAFT POSITION Pocket tester SENSOR 90890-03112 1. Disconnect: Analog pocket tester • Crankshaft position sensor coupler YU-03112-C (from the wire harness) 2.

  • Page 366: Checking The Starter Motor Operation

    ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Lean angle sensor output voltage a. Connect the positive battery terminal “1” and Operating angle starter motor lead “2” with a jumper lead “3”. 45 ° Output voltage up to operating WARNING angle • Handle the coolant temperature sensor 3.6–4.4 V with special care.

  • Page 367: Checking The Rectifier/Regulator

    ELECTRICAL COMPONENTS • Positive tester probe  White “2” • Negative tester probe  White “3” c. Start the engine and let it run at approxi- mately 5000 r/min. d. Measure the charging voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Measure the stator coil resistance. EASB296360 CHECKING THE RADIATOR FAN MOTOR (For JPN)

  • Page 368: Checking The Throttle Position Sensor

    ELECTRICAL COMPONENTS 2. Check: • Coolant temperature sensor resistance Out of specification  Replace. Coolant temperature sensor re- sistance 2512–2777  at 20 °C (2512– 2777  at 68 °F) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (  1k/100) to the coolant temperature sensor.

  • Page 369: Checking The Throttle Position Sensor Input Voltage

    ELECTRICAL COMPONENTS • Positive tester probe  • Positive tester probe  Blue “1” Blue “1” • Negative tester probe  • Negative tester probe  Black/Blue “2” Black/Blue “2” b. Check the throttle position sensor maximum c. Start the engine. resistance.
  • Page 370 ELECTRICAL COMPONENTS b. Start the engine. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ c. Measure the intake air pressure sensor out- CHECKING THE FUEL INJECTOR EASB296366 put voltage. 1. Remove: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Fuel injector EASB296365 CHECKING THE INTAKE AIR TEMPERA- Refer to “THROTTLE BODY” on page 7-5. TURE SENSOR 2.

  • Page 371: 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 372: Troubleshooting

    TROUBLESHOOTING • Incorrect spark plug heat range TROUBLESHOOTING EASB296367 • Fouled spark plug • Worn or damaged electrode GENERAL INFORMATION EASB296368 • 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 373: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING 2. Engine oil POOR MEDIUM-AND-HIGH-SPEED PER- EASB296371 • Incorrect oil level FORMANCE • Incorrect oil viscosity (low) Refer to “STARTING FAILURES” on page 9-1. • Deteriorated oil Engine CLUTCH DRAGS EASB296376 1. Air filter • Clogged air filter element Engine 1.

  • Page 374: Overcooling

    TROUBLESHOOTING Chassis FAULTY FRONT FORK LEGS 1. Brake(s) Chassis • Dragging brake 1. Front fork Electrical system • Bent or damaged inner tube 1. Spark plug • Bent or damaged outer tube • Incorrect spark plug gap • Broken fork spring •...
  • Page 375 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 376 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 377 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 378 LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS...

  • Page 379: 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 380: Chassis

    CHASSIS DRIVE AND REAR WHEEL SPROCKETS CHASSIS EASB296385 SETTING PARTS SELECTION OF THE SECONDARY REDUC- EASB296386 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 381: 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 (1.00–1.20 kgf/cm 15–18 psi) EASB296389 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 382: 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 383: 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 384 CHASSIS • Spring preload adjusting positions Spring preload adjusting positions Minimum Position in which the spring is turned in 1.5 mm (0.06 in) from its free length. Standard Position in which the spring is turned in 10 mm (0.39 in) from its free length.

  • Page 385: Suspension Setting (Front Fork)

    CHASSIS SUSPENSION SETTING (FRONT FORK) EASB296397 • 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 386: 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 387 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 388 COLOR CODE WIRING DIAGRAM EASB296400 Black YZ250FXG 2016 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 389 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 390 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2015.07––0.3 × 1 !
  • Page 391 YZ250FXG 2016 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 392 YZ250FXG 2016 WIRING DIAGRAM (Gy) (Gy) (Gy)

This manual is also suitable for:

Yz250fxg 2016

Table of Contents