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Yamaha YZ 2018 Series Owner's Service Manual

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Table of Contents

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2018
OWNER'S SERVICE MANUAL
YZ250FX
Read this manual carefully before operating this vehicle.
YZ250FXJ
LIT-11626-31-25
B29-28199-13

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Summary of Contents for Yamaha YZ 2018 Series

  • Page 1 2018 OWNER’S SERVICE MANUAL YZ250FX Read this manual carefully before operating this vehicle. YZ250FXJ LIT-11626-31-25 B29-28199-13...
  • Page 2 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
  • Page 3 EASB29B002 YZ250FXJ OWNER’S SERVICE MANUAL ©2017 by Yamaha Motor Corporation, U.S.A. 1st Edition, April 2017 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-11626-31-25...
  • Page 4 EASB29B003 INTRODUCTION 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 EASB29B005 SAFETY INFORMATION 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 EASB916006 YAMAHA MOTOR CORPORATION, U.S.A. YZ MOTORCYCLE LIMITED WARRANTY...
  • Page 7 EASB29B006 HOW TO USE THIS MANUAL 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 EASB29B007 SYMBOLS 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 CONTENS 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 ..............1-21 BREAK-IN PROCEDURES ..............1-21 MAINTENANCE AFTER BREAK-IN ..............1-22 MAJOR MAINTENANCE ................1-22 TORQUE-CHECK POINTS................1-23 MOTORCYCLE CARE AND STORAGE ............1-25 CARE......................1-25 STORAGE ....................1-26...

  • Page 13: Location Of Important Labels

    LOCATION OF IMPORTANT LABELS EASB29B008 LOCATION OF IMPORTANT LABELS 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 EASB29B009 DESCRIPTION 18 17 16 1. Clutch lever 11. Radiator 2. Engine trouble warning light “ ” 12. Coolant drain bolt 3. Fuel level warning light “ ” 13. Rear brake pedal 4. Front brake lever 14. Air filter 5.

  • 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 EASB29B013 EASB29B017 INCLUDED PARTS FUEL HOSE JOINT COVER The fuel hose joint covers “1” are used to pre- EASB29B014 SPARK PLUG WRENCH vent mud, dust, and other foreign materials The spark plug wrench “1” is used to remove or from entering the inside when the fuel hose is install the spark plug.

  • 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 EASB29B021 GASKETS, OIL SEALS AND O-RINGS 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 EASB29B025 BASIC SERVICE INFORMATION EASB29B026 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 Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachometer...

  • Page 23: Special Tools

    SPECIAL TOOLS EASB29B027 SPECIAL TOOLS 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 Test harness– lean angle sensor (6P) YU-03209 FI diagnostic tool sub–lead This tool is used to connect 90890-03212 the Yamaha diagnostic tool FI diagnostic tool sub–lead to a battery. YU-03212 Yamaha diagnostic tool USB This tool is used to check er-...
  • 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 Valve spring compressor 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 90890-04101 the valve lifter or lap the Valve lapping tool valve. YM-A8998 YM-A8998 Valve spring compressor at- This tool is used to discon- tachment nect or connect the valve and 90890-04108...
  • Page 28 Oppama pet–4000 spark nition coil. checker YM-34487 Digital tachometer This tool is used to measure 90890-06760 the engine speed. Digital tachometer YU-39951-B Yamaha bond No. 1215 This sealant (Bond) is used 90890-85505 for crankcase mating sur- (Three bond No.1215®) face, etc. 1-16...

  • Page 29: Control Functions

    This warning light comes on or flashes if a prob- with the starter. lem is detected in the electrical circuit monitor- ing the engine. If this occurs, have a Yamaha dealer check the vehicle. The electrical circuit of the warning light can be checked by pushing the start switch.

  • Page 30: Shift Pedal

    CONTROL FUNCTIONS EASB29B033 SHIFT PEDAL The shift pedal “1” has adopted a method of 1 down & 5 ups (press-down & kick-ups). Press it down for N (neutral) to 1st, and kick it up for 2nd to 6th. EASB29B037 SIDESTAND This sidestand “1”...

  • Page 31: Fuel Tank Cap

    CONTROL FUNCTIONS EASB29B039 FUEL TANK CAP Fuel tank cap “1” is located under the fuel tank cap cover “2”. Remove the fuel tank cap cover to open the fuel tank cap. • To remove the fuel tank cap cover, insert fin- gers under part “a”, and then use both hands to lift it up towards the rear of the vehicle.

  • Page 32: Starting And Break-In

    (Gasohol [E10] acceptable) ELEMENT” section in the CHAPTER 3, apply Fuel tank capacity the Yamaha foam air filter oil or other quality 7.5 L (2.0 US gal, 1.7 Imp.gal) foam air filter oil to the element. (Excess oil in Fuel reserve amount the element may adversely affect engine start- 2.1 L (0.55 US gal, 0.46 Imp.gal)

  • Page 33: Starting A Warm Engine

    STARTING AND BREAK-IN NOTICE If the engine fail to start, fully open the throttle If the starter motor will not turn when the grip and push the start switch few seconds to start switch is pushed, stop pushing it im- clear the engine of the rich air-fuel mixtare re- mediately in order to avoid placing extra tained in it.

  • Page 34: Maintenance After Break-In

    MAINTENANCE AFTER BREAK-IN • Cable EASB29B047 MAINTENANCE AFTER BREAK-IN 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 35: Torque-Check Points

    TORQUE-CHECK POINTS EASB29B049 TORQUE-CHECK POINTS 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 36 TORQUE-CHECK POINTS Fuel system Fuel pump to fuel tank Fuel sender to fuel tank 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-...

  • Page 37: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE • Do not use any harsh chemical products EASB29B050 MOTORCYCLE CARE AND STOR- on plastic parts. Be sure to avoid using cloths or sponges which have been in con- tact with strong or abrasive cleaning prod- EASB29B051 CARE ucts, solvent or thinner, fuel (gasoline),...

  • Page 38: Storage

    ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Lubricate all control cables and the pivoting Consult a Yamaha dealer for advice on what products to use. points of all levers and pedals as well as of the sidestand/ centerstand.
  • Page 39 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 40 MOTORCYCLE CARE AND STORAGE 1-28...

  • Page 41: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-6 ELECTRICAL SPECIFICATIONS ..............2-9 TIGHTENING TORQUES ................2-11 GENERAL TIGHTENING TORQUE SPECIFICATIONS ......2-11 ENGINE TIGHTENING TORQUES ............2-12 CHASSIS TIGHTENING TORQUES ............2-15 LUBRICATION POINTS AND LUBRICANT TYPES........2-18 ENGINE ....................2-18 CHASSIS ....................2-19 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-21 LUBRICATION DIAGRAMS ..............2-21 CABLE ROUTING DIAGRAM ................2-29...

  • Page 42: General Specifications

    GENERAL SPECIFICATIONS EASB29B053 GENERAL SPECIFICATIONS Model Model B29G 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) Ground clearance 325 mm (12.80 in) Weight Curb weight...

  • Page 43: Engine Specifications

    ENGINE SPECIFICATIONS EASB29B054 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train DOHC Displacement 250 cm Number of cylinders Single cylinder Bore  stroke 77.0  53.6 mm (3.03  2.11 in) Compression ratio 13.5 : 1 Starting system Electric starter Fuel...
  • Page 44 ENGINE SPECIFICATIONS 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 0.028–0.062 mm (0.0011–0.0024 in) Limit 0.080 mm (0.0032 in) Camshaft lobe dimensions Lobe height (Intake) 31.830–31.930 mm (1.2531–1.2571 in) Limit 31.730 mm (1.2492 in) Lobe height (Exhaust) 33.870–33.970 mm (1.3335–1.3374 in) Limit...
  • Page 45 Secondary reduction ratio 3.923 (51/13) Final drive Chain 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 Fuel injector 12.0  Resistance...
  • Page 46 ENGINE SPECIFICATIONS Throttle body ID mark 30RA-A62U (B291 00) Idling condition Engine idling speed 1900–2100 r/min Coolant temperature 70–90 °C (158–194 °F) Engine oil temperature 70–80 °C (158–176 °F) Fuel line pressure (at idle) 300–390 kPa (3.0–3.9 kgf/cm , 43.5–56.6 psi) Throttle grip free play 3.0–6.0 mm (0.12–0.24 in)

  • Page 47: Chassis Specifications

    CHASSIS SPECIFICATIONS EASB29B055 CHASSIS SPECIFICATIONS Chassis Frame type Semi double cradle Caster angle 26.3 ° Trail 114 mm (4.5 in) Front wheel Wheel type Spoke wheel 21  1.60 Rim size Rim material Aluminum Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in) Wheel axle bending limit...
  • Page 48 470.0 mm (18.50 in) Limit 465.0 mm (18.31 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil S1 Quantity (left) 526.0 cm (17.78 US oz, 18.55 Imp.oz) Quantity (right) 526.0 cm (17.78 US oz, 18.55 Imp.oz)
  • Page 49 CHASSIS SPECIFICATIONS Swingarm Swingarm end free play limit (radial) 1.0 mm (0.04 in) Swingarm end free play limit (axial) 0.2–0.9 mm (0.01–0.04 in) Drive chain Size DID520VM2 Chain type Sealed type Number of links Drive chain slack (Maintenance stand) 50.0–60.0 mm (1.97–2.36 in) 15-link length limit 239.3 mm (9.42 in)

  • Page 50: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EASB29B056 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Advancer type Digital Ignition timing (B.T.D.C.) 10.0 °/2000 r/min Engine control unit Model B292 Ignition coil 2.16–2.64  Primary coil resistance Secondary coil resistance 8.64–12.96 k Spark plug cap Resistance 7.50–12.50 k...
  • Page 51 ELECTRICAL SPECIFICATIONS Fuse(s) Main fuse 15.0 A Spare fuse 15.0 A Radiator fan motor fuse 5.0 A 2-10...

  • Page 52: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EASB29B057 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 53: Engine Tightening Torques

    TIGHTENING TORQUES EASB29B058 ENGINE 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 Camshaft cap bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Cylinder head blind plug 28 N·m (2.8 kgf·m, 21 lb·ft) Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft)
  • Page 54 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Starter knob/Idle screw 2.1 N·m (0.21 kgf·m, 1.5 lb·ft) Throttle cable nut (pull) 7 N·m (0.7 kgf·m, 5.2 lb·ft) Throttle cable nut (return) 7 N·m (0.7 kgf·m, 5.2 lb·ft) Clutch cable adjuster and locknut 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) Clutch cable locknut (engine side) 7 N·m (0.7 kgf·m, 5.2 lb·ft)
  • Page 55 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Rotor nut 65 N·m (6.5 kgf·m, 48 lb·ft) Stator bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) Crankshaft position sensor bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Damper assembly cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Starter clutch bolt 16 N·m (1.6 kgf·m, 12 lb·ft) Starter motor bolt...

  • Page 56: Chassis Tightening Torques

    TIGHTENING TORQUES EASB29B059 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 N·m (2.1 kgf·m, 15 lb·ft) Outer tube and lower bracket bolt 21 N·m (2.1 kgf·m, 15 lb·ft) Upper bracket and steering stem nut...
  • Page 57 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Rear brake disc bolt 14 N·m (1.4 kgf·m, 10 lb·ft) Footrest bracket bolt 55 N·m (5.5 kgf·m, 41 lb·ft) Sidestand bolt 25 N·m (2.5 kgf·m, 18 lb·ft) Rear brake pedal bolt 26 N·m (2.6 kgf·m, 19 lb·ft) Rear brake pedal position locknut 6 N·m (0.6 kgf·m, 4.4 lb·ft)
  • Page 58 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Drive chain support bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) Drive chain support nut 7 N·m (0.7 kgf·m, 5.2 lb·ft) Drive chain guide bolt 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) Rear frame and left cover bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) Fuel tank bolt (front side) 7 N·m (0.7 kgf·m, 5.2 lb·ft)

  • Page 59: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES EASB29B060 LUBRICATION POINTS AND LUBRICANT TYPES EASB29B061 ENGINE 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 60: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Starter idle gear inner surface, thrust surfaces Starter clutch drive gear inner surface, thrust surfaces Yamaha bond No.1215 Cylinder head cover gasket (Three bond No.1215®) Yamaha bond No.1215 Crankcase mating surface (Three bond No.1215®)
  • Page 61 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Clutch lever sliding surface and bolt outer surface Clutch lever adjuster rubber lip 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...

  • Page 62: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION SYSTEM CHART AND DIAGRAMS EASB29B063 EASB29B064 LUBRICATION DIAGRAMS 2-21...
  • Page 63 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 2-22...
  • Page 64 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-23...
  • Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Connecting rod 2. Crankshaft 3. Main axle 4. Oil strainer 5. Drive axle 2-24...
  • Page 66 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25...
  • Page 67 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Exhaust camshaft 2. Intake camshaft 3. Oil filter element 4. Oil pump 2-26...
  • Page 68 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
  • Page 69 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil pressure check bolt 3. Oil filter element 4. Oil pump 2-28...

  • Page 70: Cable Routing Diagram

    CABLE ROUTING DIAGRAM EASB29B065 CABLE ROUTING DIAGRAM 2-29...
  • Page 71 CABLE ROUTING DIAGRAM O. Insert the plastic locking tie into the bracket hole 1. Clutch cable and clamp the clutch cable. Clamp it so that the 2. Throttle cable (return) lock of the plastic locking tie faces downward, 3. Throttle cable (pull) and then cut off the end of the plastic locking tie.
  • Page 72 CABLE ROUTING DIAGRAM 2-31...
  • Page 73 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 74 CABLE ROUTING DIAGRAM 2-33...
  • Page 75 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 76 CABLE ROUTING DIAGRAM 2-35...
  • Page 77 CABLE ROUTING DIAGRAM 1. Battery negative lead 2. Fuel hose 3. Fuel pump coupler 4. Resistor 5. Fuel pump lead 6. Resistor coupler 7. Battery positive lead 8. Lean angle sensor 9. Starter motor lead 10. Radiator fan motor relay (blue tape) 11.
  • Page 78 CABLE ROUTING DIAGRAM 2-37...
  • Page 79 CABLE ROUTING DIAGRAM 1. Plastic band 2. Clutch cable 3. Clutch switch lead 4. Engine stop switch lead 5. Warning light lead 6. Front brake hose 7. Brake hose guide 8. Number plate 9. Warning light 10. Start switch lead A.
  • Page 80 CABLE ROUTING DIAGRAM 2-39...
  • Page 81 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 82 CABLE ROUTING DIAGRAM 2-41...
  • Page 83 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 84 CABLE ROUTING DIAGRAM 2-43...

  • Page 85: 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 86 CHECKING THE WHEEL BEARINGS .............3-34 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 87: Maintenance Intervals

    MAINTENANCE INTERVALS EASB29B066 MAINTENANCE INTERVALS EASB29B067 MAINTENANCE INTERVALS 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- 23.) • 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 88 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 89 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, PROTECTOR Inspect and re- Check for exhaust leaks, and ✓...
  • 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) ENGINE GUARD ✓ Replace Breakage FRAME ✓ ✓ Clean and inspect FUEL TANK, FUEL PUMP ✓ ✓ Inspect FUEL HOSE ✓...
  • 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) ✓ ✓ Retighten brake Check for tightening torques. disc bolts, caliper bolts, master cylin- der bolts and union bolts ✓...
  • 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) DRIVE CHAIN GUIDE AND DRIVE CHAIN SUPPORT ✓ Replace CABLES ✓ ✓ Routing (Connec- tion) ✓ ✓ Check and grease ✓...

  • Page 93: Pre-Operation Inspection And Maintenance

    PRE-OPERATION INSPECTION AND MAINTENANCE EASB29B068 PRE-OPERATION INSPECTION AND MAINTENANCE 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. EASB29B069 GENERAL INSPECTION AND MAINTENANCE ITEM inspect Page...

  • Page 94: Engine

    ENGINE EASB29B070 EASB29B072 ENGINE CHECKING THE COOLING SYSTEM 1. Remove: EASB29B071 CHECKING THE COOLANT LEVEL • 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 95: 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 N·m (1.0 kgf·m, 7.4 lb·ft) 6. Pour coolant. Recommended coolant High quality ethylene glycol anti-freeze containing anti-cor- rosion for aluminum engine...

  • Page 96: Checking The Coolant Circulatory System For Leaks

    ENGINE EASB29B076 EASB29B077 CHECKING THE COOLANT CIRCULATORY ADJUSTING THE CLUTCH LEVER FREE SYSTEM FOR LEAKS PLAY 1. Check: 1. Check: • Clutch lever free play “a” • Coolant level Out of specification  Regulate. 2. Install: • Radiator cap tester “1” Clutch lever free play •...

  • Page 97: 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 98: Cleaning The Air Filter Element

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

  • Page 99: Checking The Throttle Body Joint

    ENGINE 6. Install: • Air filter guide “1” (to the air filter element) • Air filter element “2” • Air filter mounting bolt “3” Air filter mounting bolt 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) EASB29B083 CHECKING THE EXHAUST SYSTEM 1. Remove: •...

  • Page 100: Checking The Fuel Line

    ENGINE EASB29B085 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle upright on a level surface. 2. Start the engine, warm this up for 3 minutes, and then stop the engine and wait about 5 minute. 3. Check: • Oil level The engine oil level should be between the minimum level mark “a”...

  • Page 101: Changing The Engine Oil

    ENGINE 5. To check the oil strainer, perform the follow- EASB29B086 CHANGING THE ENGINE OIL ing procedure. Stand the vehicle upright on a level surface. 1. Start the engine, warm this up for 3 minutes, ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the oil strainer “1”. and then stop the engine and wait about 5 b.

  • Page 102: Adjusting The Engine Idling Speed

    ENGINE 8. Install: EASB29B087 ADJUSTING THE ENGINE IDLING SPEED • Oil filler cap 9. Check: • Because the air pressure is lower at high alti- • Oil level tudes, the air-fuel mixture will become richer. Refer to “CHECKING THE ENGINE OIL If the idling speed is low, turn the starter knob/ LEVEL”...

  • Page 103: Adjusting The Valve Clearance

    Turn the crankshaft counterclockwise with a basic knowledge and skill concerning the ser- wrench. vicing of Yamaha motorcycles (e.g., Yamaha b. Align the top dead center (TDC) mark “a” on dealers, service engineers, etc.). Those who the rotor with the alignment mark “b” on the have little knowledge and skill concerning ser- crankcase cover.
  • Page 104 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 105 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 5-11. table. g. Measure the valve clearance again. h. If the valve clearance is out of specification, repeat adjusting the valve clearance until it •...

  • Page 106: Valve Clearance Shim Chart

    ENGINE VALVE CLEARANCE SHIM CHART 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 107 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 108: Chassis

    CHASSIS EASB29B089 CHASSIS EASB29B090 BLEEDING THE BRAKE SYSTEM 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 109: Checking The Brake Hose

    CHASSIS EASB29B091 CHECKING THE BRAKE HOSE 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 110: Adjusting The Rear Brake

    CHASSIS EASB29B093 ADJUSTING THE REAR BRAKE 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 111 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 N·m (2.8 kgf·m, 21 lb·ft) Pad pin 17 N·m (1.7 kgf·m, 13 lb·ft) e. Connect the plastic hose “5” to the bleed screw “6”...

  • Page 112: Checking The Rear Brake Pads

    CHASSIS d. Remove the pad pin “6” and the brake pads EASB29B095 CHECKING THE REAR BRAKE PADS “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 113: Checking The Rear Brake Pad Insulator

    CHASSIS i. Install the brake caliper “12” and the rear EASB29B096 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 114: 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 115: Checking The Front Fork Legs

    CHASSIS EASB29B099 EASB29B101 CHECKING THE FRONT FORK LEGS CLEANING THE FRONT FORK OIL SEAL 1. Stand the vehicle upright on a level surface. AND DUST SEAL 1. Remove: WARNING • Protector Securely support the vehicle so that there is • Dust seal “1” no danger of it falling over.

  • Page 116: Adjusting The Front Fork Legs

    CHASSIS 2. Remove the air bleed screw “1” and release the internal pressure from the front fork. 3. Tighten: • Air bleed screw Air bleed screw 1.3 N·m (0.13 kgf·m, 0.95 lb·ft) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping NOTICE Do not turn the adjuster forcibly beyond its adjusting range.

  • Page 117: Checking The Swingarm Operation

    CHASSIS 1. Remove: EASB29B104 CHECKING THE SWINGARM OPERATION • 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 EASB29B105 CHECKING THE REAR SUSPENSION ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 118 CHASSIS e. Tighten the locknut. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Locknut Compression damping (for fast compres- 30 N·m (3.0 kgf·m, 22 lb·ft) sion damping) NOTICE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Do not turn the adjuster forcibly beyond its 3. Install: adjusting range. • Rear frame Refer to “REAR SHOCK ABSORBER AS- 1.

  • Page 119: 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 120: Checking The Wheels

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

  • Page 121: 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. WARNING Recommended lubricant Engine oil or a suitable cable lu- Do not overtighten the lower ring nut. bricant Ring nut (final tightening torque) 7 N·m (0.7 kgf·m, 5.2 lb·ft)

  • Page 122: Lubricating The Sidestand

    CHASSIS EASB29B116 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Recommended lubricant Lithium-soap-based grease EASB29B117 CHECKING THE CHASSIS FASTENERS Make sure that all nuts, bolts, and screws are properly tightened. Refer to “CHASSIS TIGHTENING TORQUES” on page 2-15.

  • Page 123: Electrical System

    ELECTRICAL SYSTEM 5. Clean: EASB29B118 ELECTRICAL SYSTEM • Spark plug EASB29B119 (with a spark plug cleaner or a wire brush) CHECKING THE SPARK PLUG 6. Measure: 1. Remove: • Spark plug gap “a” • Seat Out of specification  Adjust the spark plug •...

  • Page 124: Checking And Charging The Battery

    ELECTRICAL SYSTEM 2. Attach: • Timing light “1” • Digital tachometer “2” To the high tension code “3”. Timing light 90890-03141 Timing light YU-03141 Digital tachometer 90890-06760 Digital tachometer YU-39951-B 3. Adjust: • Engine idling speed Refer to “ADJUSTING THE ENGINE IDLING SPEED”...
  • Page 125 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 126 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 127 GENERAL CHASSIS EASB29B123 GENERAL CHASSIS Removing the seat and side cover 1.3 N ・ m (0.13 kgf ・ m, 0.95 lb ・ ft) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 1.3 N ・...

  • Page 128: General Chassis

    GENERAL CHASSIS EASB29B124 EASB29B126 REMOVING THE LEFT SIDE COVER REMOVING THE NUMBER PLATE 1. Remove: 1. Remove: • Bolt (side cover) • Bolt (number plate) • Side cover “1” • Number plate “1” Draw the left side cover “1” backward to re- •...
  • Page 129 FRONT WHEEL EASB29B127 FRONT WHEEL Removing the front wheel 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 115 N ・ m (11.5 kgf ・ m, 85 lb ・ ft) 12 N ・...

  • Page 130: Front Wheel

    FRONT WHEEL EASB29B128 REMOVING THE FRONT WHEEL 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 131: Disassembling The Front Wheel

    FRONT WHEEL EASB29B130 DISASSEMBLING THE FRONT WHEEL 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 132: 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 N·m (11.5 kgf·m, 85 lb·ft) 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 133 REAR WHEEL EASB29B133 REAR WHEEL Removing the rear wheel 14 N ・ m (1.4 kgf ・ m, 10 lb ・ ft) 125 N ・ m (12.5 kgf ・ m, 92 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 50 N ・...

  • Page 134: Rear Wheel

    REAR WHEEL 4. Measure: EASB29B134 REMOVING THE REAR WHEEL • 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 135: 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 N·m (1.4 kgf·m, 10 lb·ft) EASB29B138 LOCTITE® ASSEMBLING THE REAR WHEEL 1.
  • Page 136 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 (Maintenance Push the rear wheel “2”...

  • Page 137: Front Brake

    FRONT BRAKE EASB29B140 FRONT BRAKE Removing the front brake caliper 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 28 N ・ m (2.8 kgf ・ m, 21 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 17 N ・...
  • Page 138 FRONT BRAKE Disassembling the front brake caliper 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 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 139 FRONT BRAKE Removing the front brake master cylinder 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 30 N ・...
  • Page 140 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 141: Introduction

    FRONT BRAKE EASB29B141 INTRODUCTION Brake disc thickness limit WARNING 2.5 mm (0.10 in) 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 142: Checking The Front Brake Caliper

    FRONT BRAKE EASB29B146 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 143: 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 144: 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 SYSTEM” on page 3-22. 6. Check: • Brake fluid level 2.

  • Page 145: Installing The Front Brake Master Cylinder

    FRONT BRAKE EASB29B152 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Brake master cylinder “1” Brake master cylinder holder bolt 9 N·m (0.9 kgf·m, 6.6 lb·ft) • Install the front brake master cylinder holder 3. Install: with the “UP” mark facing up. •...
  • Page 146 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 147: Rear Brake

    REAR BRAKE EASB29B153 REAR BRAKE Removing the rear brake caliper 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 13 lb ・ ft) 30 N ・...
  • Page 148 REAR BRAKE Disassembling the rear brake caliper 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 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 149 REAR BRAKE Removing the rear brake master cylinder 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) Order Part name Q’ty...
  • Page 150 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 151: Introduction

    REAR BRAKE EASB29B154 INTRODUCTION 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 152: Removing The Rear Brake Caliper

    REAR BRAKE EASB29B156 EASB29B158 REMOVING THE REAR BRAKE CALIPER CHECKING THE REAR BRAKE CALIPER 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 153: Installing The Brake Caliper Piston

    REAR BRAKE EASB29B160 EASB29B161 INSTALLING THE BRAKE CALIPER PISTON INSTALLING THE REAR BRAKE CALIPER 1. Clean: 1. Install: • Brake caliper • Rear brake caliper • Brake caliper piston seal • Rear brake caliper bracket • Brake caliper piston dust seal 2.

  • Page 154: Removing The Rear Brake Master Cylinder

    REAR BRAKE EASB29B162 REMOVING THE REAR BRAKE MASTER WARNING CYLINDER • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to Before removing the rear brake master cylin- deteriorate, causing leakage and poor der, drain the brake fluid from the entire brake brake performance.

  • Page 155: Assembling The Rear Brake Master Cylinder

    REAR BRAKE 3. Install: EASB29B164 ASSEMBLING THE REAR BRAKE MASTER • 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 156 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 157: Handlebar

    HANDLEBAR EASB29B166 HANDLEBAR Removing the handlebar 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 0.5 N ・ m (0.05 kgf ・ m, 0.37 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 3.8 N ・...
  • Page 158 HANDLEBAR Removing the handlebar 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 0.5 N ・ m (0.05 kgf ・ m, 0.37 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 3.8 N ・...

  • Page 159: Removing The Handlebar

    HANDLEBAR EASB29B167 REMOVING THE HANDLEBAR 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” EASB29B168 CHECKING THE HANDLEBAR 1. Check: •...
  • Page 160 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 161 HANDLEBAR 5. Install: • Engine stop switch “1” • Clutch lever “2” • Clutch lever holder “3” • Clamp “4” Engine stop switch screw 0.5 N·m (0.05 kgf·m, 0.37 lb·ft) Clutch lever holder bolt 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) 7.
  • Page 162 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 N·m (0.38 kgf·m, 2.8 lb·ft) •...
  • Page 163 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 164: Front Fork

    FRONT FORK EASB29B170 FRONT FORK Removing the front fork legs 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 5 N ・...
  • Page 165 FRONT FORK Disassembling the front fork leg 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 29 N ・ m (2.9 kgf ・ m, 21 lb ・ ft) 28 N ・ m (2.8 kgf ・ m, 21 lb ・ ft) 1.3 N ・...

  • Page 166: Removing The Front Fork Legs

    FRONT FORK EASB29B171 REMOVING THE FRONT FORK LEGS 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 167: Checking The Front Fork Legs

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

  • Page 168: Assembling The Front Fork Legs

    • Before assembling the front fork leg, make sure that all of the components are clean. 1. Stretch the damper assembly fully. 2. Fill: • Damper assembly Recommended oil Yamaha Suspension Oil S1 7. Check: Standard oil amount • Adjuster “1” 206 cm (6.96 US oz, 7.27 •...
  • Page 169 FRONT FORK NOTICE • Be sure to use the recommended oil. Other oils may have an adverse effect on front fork performance. • When disassembling and assembling the front fork leg, take care not to allow any foreign material to enter the front fork. 3.
  • Page 170 FRONT FORK 7. Install: 10.After filling, pump the damper assembly “1” • Base valve “1” slowly up and down more than 10 times to (to the damper assembly “2”) distribute the fork oil. First bring the damper rod pressure to a maxi- mum.
  • Page 171 FRONT FORK 15.Install: • Inner tube bushing “1” Install the inner tube bushing onto the slot on inner tube. 14.Install: • Dust seal “1” • Scraper “2” • Oil seal clip “3” • Oil seal “4” • Washer “5” 16.Install: •...
  • Page 172 FRONT FORK 20.Install: • Scraper “1” • Dust seal “2” Apply lithium-soap-based grease on the inner tube. 18.Install: • Oil seal “1” Using a fork seal driver “2”, press the oil seal in until the stopper ring groove fully appears. Fork seal driver 21.Check: 90890-01502...
  • Page 173 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 174 FRONT FORK 30.Fill: • Front fork leg Recommended oil Yamaha Suspension Oil S1 Standard oil amount 330 cm (11.16 US oz, 11.64 lmp.oz) Extent of adjustment 300–365 cm (10.14–12.34 US oz, 10.58–12.87 lmp.oz) 28.Tighten: • Adjuster (locknut) “1” NOTICE • Be sure to use the recommended oil. Other...

  • Page 175: Installing The Front Fork Legs

    FRONT FORK 32.Install: • Protector guide “1” 3. Adjust: • Front fork top end “a” EASB29B175 Front fork top end (standard) “a” INSTALLING THE FRONT FORK LEGS 3 mm (0.12 in) 1. Install: • Front fork “1” • Temporarily tighten the pinch bolts (lower bracket).
  • Page 176 FRONT FORK 5. Install: • Protector “1” • Bolt (protector) “2” Bolt (protector) 5 N·m (0.5 kgf·m, 3.7 lb·ft) 6. Adjust: • Rebound damping force Turn in the damping adjuster “1” finger-tight and then turn out to the originally set position. 7.

  • Page 177: Steering Head

    STEERING HEAD EASB29B176 STEERING HEAD Removing the lower bracket 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 145 N ・ m (14.5 kgf ・ m, 107 lb ・ ft) 38 N ・ m (3.8 kgf ・ m, 28 lb ・ ft) 7 N ・...

  • Page 178: Removing The Lower Bracket

    STEERING HEAD EASB29B177 REMOVING THE LOWER BRACKET 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 179 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 180 STEERING HEAD 11.Tighten: • Pinch bolt (upper bracket) “1” Upper bracket pinch bolts 21 N·m (2.1 kgf·m, 15 lb·ft) • Pinch bolt (lower bracket) “2” Lower bracket pinch bolts 21 N·m (2.1 kgf·m, 15 lb·ft) 8. Install: WARNING • Steering stem nut “1” Tighten the lower bracket to specified torque.
  • Page 181 REAR SHOCK ABSORBER ASSEMBLY EASB29B180 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 56 N ・ m (5.6 kgf ・ m, 41 lb ・ ft) 16 15 14 13 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 53 N ・...

  • Page 182: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 56 N ・ m (5.6 kgf ・ m, 41 lb ・ ft) 16 15 14 13 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 53 N ・ m (5.3 kgf ・ m, 39 lb ・ ft) Order Part name Q’ty...
  • Page 183 REAR SHOCK ABSORBER ASSEMBLY Disassembling the relay arm 80 N ・ m (8.0 kgf ・ m, 59 lb ・ ft) Order Part name Q’ty Remarks Relay arm Connecting arm Collars Oil seals Washers Bearing For assembly, reverse the disassemble pro- cedure.

  • Page 184: 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 185: Checking The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY • Spring guide Damage/wear  Replace. • Bearing Damage/wear  Replace. • Bolts Bends/damage/wear  Replace. EASB29B186 CHECKING THE CONNECTING ARM AND RELAY ARM 1. Check: • Connecting arm 2. Remove: • Relay arm • Upper bearing “1” Damage/wear ...

  • Page 186: 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 187 REAR SHOCK ABSORBER ASSEMBLY 7. Tighten: • Rear shock absorber assembly upper bolt Rear shock absorber assembly upper bolt 56 N·m (5.6 kgf·m, 41 lb·ft) • Connecting arm bolt (frame side) Connecting arm bolt (frame side) 80 N·m (8.0 kgf·m, 59 lb·ft) •...

  • Page 188: Swingarm

    SWINGARM EASB29B189 SWINGARM Removing the swingarm 70 N ・ m (7.0 kgf ・ m, 52 lb ・ ft) 4.0 N ・ m (0.40 kgf ・ m, 3.0 lb ・ ft) Order Part name Q’ty Remarks Use a suitable stand to raise the front wheel off the ground.

  • Page 189: Removing The Swingarm

    SWINGARM EASB29B190 REMOVING THE SWINGARM 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 190: Installing The Swingarm

    SWINGARM EASB29B193 INSTALLING THE SWINGARM 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 191: Chain Drive

    CHAIN DRIVE EASB29B194 CHAIN DRIVE Removing the drive chain 75 N ・ m (7.5 kgf ・ m, 55 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Job Order Part name Q’ty Servicing Information Drive sprocket Refer to “ENGINE REMOVAL”...

  • Page 192: Removing The Drive Chain

    CHAIN DRIVE EAS23420 REMOVING THE DRIVE CHAIN 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 193: Checking The Drive Sprocket

    CHAIN DRIVE EASB29B195 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 194 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 (Maintenance stand) 50.0–60.0 mm (1.97–2.36 in)

  • Page 195: Engine

    ENGINE ENGINE REMOVAL..................5-1 REMOVING THE SILENCER ..............5-5 REMOVING THE EXHAUST PIPE 2............5-5 REMOVING THE DRIVE SPROCKET ............5-5 REMOVING THE ENGINE .................5-6 CHECKING THE SILENCER AND EXHAUST PIPE........5-6 CHANGING THE SILENCER FIBER............5-6 INSTALLING THE ENGINE................5-7 INSTALLING THE BRAKE PEDAL.............5-8 INSTALLING THE DRIVE SPROCKET............5-8 INSTALLING THE EXHAUST PIPE AND MUFFLER .........5-9 CAMSHAFT ....................5-11 REMOVING THE CAMSHAFT ..............5-13...
  • Page 196 CLUTCH......................5-39 REMOVING THE CLUTCH ..............5-42 CHECKING THE FRICTION PLATES............5-42 CHECKING THE CLUTCH PLATES ............5-42 CHECKING THE CLUTCH SPRINGS............5-42 CHECKING THE CLUTCH HOUSING .............5-43 CHECKING THE CLUTCH BOSS ............5-43 CHECKING THE PRESSURE PLATE .............5-43 CHECKING THE PUSH LEVER SHAFT ..........5-43 CHECKING THE CLUTCH PUSH RODS..........5-43 CHECKING THE PRIMARY DRIVE GEAR ..........5-43 CHECKING THE PRIMARY DRIVEN GEAR ...........5-44 INSTALLING THE OIL SEAL..............5-44...
  • Page 197 CRANKCASE ....................5-65 DISASSEMBLING THE CRANKCASE.............5-68 REMOVING THE CRANKCASE BEARING ..........5-68 CHECKING THE TIMING CHAIN, TIMING CHAIN GUIDE, OIL STRAINER ..................5-68 CHECKING THE CRANKCASE ...............5-68 INSTALLING THE OIL SEAL..............5-69 ASSEMBLING THE CRANKCASE............5-69 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT .......5-71 REMOVING THE CRANKSHAFT ASSEMBLY ........5-72 CHECKING THE CRANKSHAFT ASSEMBLY.........5-72 INSTALLING THE CRANKSHAFT ASSEMBLY........5-73 INSTALLING THE BALANCER SHAFT ...........5-73...
  • Page 198 ENGINE REMOVAL EASB29B199 ENGINE REMOVAL Removing the exhaust pipe 13 N ・ m (1.3 kgf ・ m, 9.6 lb ・ ft) 20 N ・ m (2.0 kgf ・ m, 15 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 8 N ・...
  • Page 199 ENGINE REMOVAL Removing the electronic parts 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 7 N ・...
  • Page 200 ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 53 N ・...
  • Page 201 ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 53 N ・...
  • Page 202 ENGINE REMOVAL EASB29B200 REMOVING THE SILENCER 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. EASB29B202 REMOVING THE DRIVE SPROCKET 1.
  • Page 203 ENGINE REMOVAL EASB29B203 EASB29B204 REMOVING THE ENGINE CHECKING THE SILENCER AND EXHAUST 1. Remove: PIPE • Pivot shaft “1” 1. Check: • 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 204 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 205 ENGINE REMOVAL • Front engine bracket “4” EASB29B207 INSTALLING THE BRAKE PEDAL • Engine bracket bolt (front side) “5” 1. Install: • Spring “1” Engine bracket bolt (front side) • Brake pedal “2” 34 N·m (3.4 kgf·m, 25 lb·ft) • O-rings “3” •...
  • Page 206 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 207 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 N·m (2.0 kgf·m, 15 lb·ft) •...
  • Page 208 CAMSHAFT EASB29B210 CAMSHAFT Removing the cylinder head cover 13 N ・ m (1.3 kgf ・ m, 9.6 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Part name Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 4-1. Side cover (left/right) Refer to “GENERAL CHASSIS”...
  • Page 209 CAMSHAFT Removing the camshaft 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 10 N ・...
  • Page 210 CAMSHAFT EASB29B211 REMOVING THE CAMSHAFT 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 211 CAMSHAFT 4. Measure: EASB29B212 CHECKING THE CAMSHAFT • Camshaft-journal-to-camshaft-cap clear- 1. Check: ance • Camshaft lobes Out of specification  Measure the cam- Blue discoloration/pitting/scratches  Re- shaft journal diameter. place the camshaft. Camshaft-journal-to-camshaft- 2. Measure: cap clearance • Camshaft lobe dimensions “A” Out of specification ...
  • Page 212 CAMSHAFT d. Remove the camshaft caps and then mea- sure the width of the Plastigauge® “1”. a. 1/4 tooth b. Correct ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1. Timing chain roller 5. Measure: 2. Camshaft sprocket • Camshaft journal diameter “a” EASB29B214 CHECKING THE TIMING CHAIN TENSION- Out of specification ...
  • Page 213 CAMSHAFT EASB29B215 CHECKING THE DECOMPRESSION SYSTEM 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 214 “2”, and tighten the bolt “3”. inder head cover gasket. Bolt (timing chain tensioner) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) c. Release the screwdriver, check that the ten- sioner rod comes out smoothly, and tighten 6.
  • Page 215 CYLINDER HEAD EASB29B217 CYLINDER HEAD Removing the cylinder head 33 N ・ m (3.3 kgf ・ m, 24 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Part name Q’ty...
  • Page 216 CYLINDER HEAD Removing the cylinder head 33 N ・ m (3.3 kgf ・ m, 24 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Part name Q’ty...
  • Page 217 CYLINDER HEAD EASB29B218 REMOVING THE CYLINDER HEAD 1. Remove: • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAMSHAFT” on page 5-13. 2. Remove: • Cylinder head nuts • Cylinder head bolts 2. Check: • Loosen the bolts in the proper sequence as •...
  • Page 218 CYLINDER HEAD EASB29B221 INSTALLING THE CYLINDER HEAD 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 219 VALVES AND VALVE SPRINGS EASB29B222 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Part name Q’ty Remarks Refer to “CYLINDER HEAD” on page 5-18. Cylinder head Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Intake valve...
  • Page 220 VALVES AND VALVE SPRINGS EASB29B223 REMOVING THE VALVES ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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 221 VALVES AND VALVE SPRINGS 4. Remove: • Valve spring retainer “1” • Valve spring “2” • Valve “3” • Valve stem seal “4” • Valve spring seat “5” Identify the position of each part very carefully so that it can be reinstalled in its original place. 2.
  • Page 222 VALVES AND VALVE SPRINGS • When installing a new valve, always replace the valve guide. • If the valve is removed or replaced, always re- place the valve stem seal. Valve stem runout 0.010 mm (0.0004 in) After replacing the valve guide, reface the valve seat.
  • Page 223 VALVES AND VALVE SPRINGS a. Apply blue layout fluid “b” onto the valve NOTICE face. Do not let the lapping compound enter the gap between the valve stem and the valve guide. b. Install the valve into the cylinder head. c.
  • Page 224 VALVES AND VALVE SPRINGS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EASB29B227 CHECKING THE VALVE LIFTERS EASB29B226 1. Check: CHECKING THE VALVE SPRINGS • Valve lifter 1. Measure: Damage/scratches  Replace the valve lift- • Valve spring free length “a” Out of specification  Replace the valve ers and cylinder head.
  • Page 225 VALVES AND VALVE SPRINGS 3. Install: 5. To fasten the valve cotters onto the valve • Spring seat “1” stem, lightly tap the valve tip with a soft-face • Valve stem seal “2” hammer. • Valve “3” NOTICE • Valve spring “4” Hitting the valve tip with excessive force •...
  • Page 226 CYLINDER AND PISTON EASB29B229 CYLINDER AND PISTON Removing the cylinder and piston 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Part name Q’ty Remarks Refer to “CYLINDER HEAD”...
  • Page 227 CYLINDER AND PISTON EASB29B230 REMOVING THE PISTON 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 EASB29B231 CHECKING THE CYLINDER AND PISTON crankcase opening with a cloth to prevent the...
  • Page 228 CYLINDER AND PISTON Diameter 76.955–76.970 mm (3.0297– 3.0303 in) Measuring point (from piston skirt bottom) 4.0 mm (0.16 in) 2. Install: • Piston ring (into the cylinder) Use the piston crown to level the piston ring near bottom of cylinder “a”, where cylinder wear is lowest.
  • Page 229 CYLINDER AND PISTON 2. Measure: • Piston pin outside diameter “a” Out of specification  Replace the piston pin. Piston pin outside diameter 15.991–16.000 mm (0.6296– 0.6299 in) Limit 15.971 mm (0.6288 in) 3. Measure: 2. Install: • Piston pin bore inside diameter “b” •...
  • Page 230 CYLINDER AND PISTON 3. Lubricate: • Piston • Piston rings • Cylinder 4. Offset: • Piston ring end gap a. Top ring b. Upper oil ring rail c. Oil ring expander d. Lower oil ring rail 5. Install: • Cylinder gasket •...
  • Page 231 ELECTRIC STARTER EASB29B235 ELECTRIC STARTER Removing the starter motor 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 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 232 ELECTRIC STARTER Disassembling the starter motor 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 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.
  • Page 233 ELECTRIC STARTER EASB29B236 CHECKING THE STARTER MOTOR ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure the armature assembly resistanc- 1. Check: es with the digital circuit tester. • Commutator Dirt  Clean with 600 grit sandpaper. Digital circuit tester (CD732) 2. Measure: 90890-03243 • Commutator diameter “a” Model 88 Multimeter with Out of specification ...
  • Page 234 ELECTRIC STARTER Brush spring force Align the match mark “a” on the starter motor 3.92–5.88 N (400–600 gf, 14.11– 21.17 oz) yoke with the match mark “b” on the starter mo- tor rear cover. 7. Check: • Gear teeth Damage/wear  Replace the starter motor. 8.
  • Page 235 ELECTRIC STARTER 5. Install: • Bolt “1” • O-ring “2” Apply the lithium-soap-based grease on the O- ring. 5-38...
  • Page 236 CLUTCH EASB29B238 CLUTCH Removing the clutch 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 6 10 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 75 N ・...
  • Page 237 CLUTCH Removing the clutch 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 6 10 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 75 N ・...
  • Page 238 CLUTCH Removing the right crankcase cover 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Part name Q’ty...
  • Page 239 CLUTCH EASB29B239 REMOVING THE CLUTCH 1. Remove: • Clutch boss nut “1” • Lock washer “2” • Clutch boss “3” • Straighten the lock washer tab. • While holding the clutch boss with the clutch holder “4”, loosen the clutch boss nut. Universal clutch holder EASB29B241 CHECKING THE CLUTCH PLATES...
  • Page 240 CLUTCH CHECKING THE PRESSURE PLATE 1. Check: • Pressure plate Crack/damage  Replace. EASB29B246 CHECKING THE PUSH LEVER SHAFT 1. Check: • Push lever shaft Wear/damage  Replace. EASB29B243 CHECKING THE CLUTCH HOUSING 1. Check: • Clutch housing dogs “a” Damage/pitting/wear ...
  • Page 241 CLUTCH 2. Check: • Primary-drive-gear-to-primary-driven-gear free play Free play exists  Replace the primary drive and primary driven gears as a set. EASB29B249 CHECKING THE PRIMARY DRIVEN GEAR 1. Check: • Primary driven gear Damage/wear  Replace the primary drive and primary driven gears as a set.
  • Page 242 CLUTCH • Clutch boss nut “2” Clutch boss nut 75 N·m (7.5 kgf·m, 55 lb·ft) NOTICE Make sure to tighten to specification; other- wise, it may damage the other part that is fastened together. EASB29B252 INSTALLING THE CLUTCH • Apply the engine oil to the threads and con- tact surface of the clutch boss nut.
  • Page 243 CLUTCH • From the clutch boss side, install the friction plates in order: friction plate 1  2, friction plate 2 (identification color: purple)  5, and friction plate 1  2. • Apply the engine oil on the friction plates and clutch plates.
  • Page 244 CLUTCH 11.Install: • Clutch cover “1” • Clutch cover bolt Clutch cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Tighten the bolts in stages and in a crisscross pattern. 5-47...
  • Page 245 SHIFT SHAFT EASB29B253 SHIFT SHAFT Removing the shift shaft and stopper lever 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 10 N ・...
  • Page 246 SHIFT SHAFT Removing the shift shaft and stopper lever 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 10 N ・...
  • Page 247 SHIFT SHAFT EASB29B254 REMOVING THE SHIFT GUIDE AND SHIFT 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. EASB29B257 CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY...
  • Page 248 SHIFT SHAFT EASB29B259 EASB29B261 INSTALLING THE STOPPER LEVER INSTALLING THE SHIFT GUIDE AND SHIFT 1. Install: LEVER ASSEMBLY • Torsion spring “1” 1. Install: • Collar “2” • Spring “1” • Stopper lever “3” • Pawl pin “2” • Bolt (stopper lever) “4” •...
  • Page 249 SHIFT SHAFT 4. Tighten: • Shift guide bolt “1” Shift guide bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) LOCTITE® EASB29B262 INSTALLING THE SHIFT SHAFT 1. Install: • Roller “1” • Shift shaft spring “2” (to shift shaft) • Collar “3” (to shift shaft) •...
  • Page 250 OIL PUMP AND BALANCER GEAR EASB29B264 OIL PUMP AND BALANCER GEAR Removing the oil pump 2.0 N ・ m (0.20 kgf ・ m, 1.5 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) Order Part name Q’ty Remarks...
  • Page 251 OIL PUMP AND BALANCER GEAR Removing the balancer 38 N ・ m (3.8 kgf ・ m, 28 lb ・ ft) 75 N ・ m (7.5 kgf ・ m, 55 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 50 N ・...
  • Page 252 OIL PUMP AND BALANCER GEAR EASB29B265 REMOVING THE BALANCER 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 253 OIL PUMP AND BALANCER GEAR Inner-rotor-to-outer-rotor-tip • Apply the engine oil on the oil pump drive clearance shaft and inner rotor. 0.000–0.150 mm (0.0000–0.0059 • Fit the dowel pin into the groove in the inner rotor. Limit 0.23 mm (0.0091 in) Outer-rotor-to-oil-pump-housing clearance 0.13–0.18 mm (0.0051–0.0071 in)
  • Page 254 OIL PUMP AND BALANCER GEAR EASB29B270 INSTALLING THE OIL PUMP AND BALANC- ER GEAR 1. Install: • Oil pump assembly “1” • Oil pump assembly bolt “2” Oil pump assembly bolt 5 N·m (0.5 kgf·m, 3.7 lb·ft) LOCTITE® NOTICE 4. Install: After tightening the bolts, make sure that •...
  • Page 255 OIL PUMP AND BALANCER GEAR 5-58...
  • Page 256 GENERATOR AND STARTER CLUTCH EASB29B271 GENERATOR AND STARTER CLUTCH Removing the generator 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 65 N ・...
  • Page 257 GENERATOR AND STARTER CLUTCH Removing the generator 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 65 N ・...
  • Page 258 GENERATOR AND STARTER CLUTCH 2. Check: EASB29B272 REMOVING THE GENERATOR • Starter clutch idle gear 1. Remove: • Starter clutch gear • Generator rotor nut “1” Burrs/chips/roughness/wear  Replace the • Washer defective part (s). 3. Check: • Starter clutch gear Damage/pitting/wear ...
  • Page 259 “7” under the holder as shown. • Tighten the stator bolt using the T25 bit. • Apply the sealant to the grommet of the AC magneto lead. Yamaha bond No. 1215 Starter clutch bolt 90890-85505 16 N·m (1.6 kgf·m, 12 lb·ft) (Three bond No.1215®) LOCTITE®...
  • Page 260 GENERATOR AND STARTER CLUTCH 2. Install: • Washer • Pass the AC magneto lead “4” under the left • Generator rotor nut “1” crankcase cover “a” as shown. • Tighten the bolts in stage, using a crisscross Generator rotor nut pattern.
  • Page 261 GENERATOR AND STARTER CLUTCH 6. Install: • Cover (damper assembly) “1” • Bracket “2” • Bolt “3” • Breather hose 2 “4” Bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Install the cover (damper assembly) with its mark “a” facing upward. 5-64...
  • Page 262 CRANKCASE EASB29B276 CRANKCASE Separating the crankcase 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 10 N ・...
  • Page 263 CRANKCASE Separating the crankcase 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 10 N ・...
  • Page 264 CRANKCASE Removing the bearing and oil seal 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) Order Part name Q’ty...
  • Page 265 CRANKCASE EASB29B277 DISASSEMBLING THE CRANKCASE 1. Separate: • Right crankcase • Left crankcase ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the crankcase bolts. c. Remove the dowel pins and O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EASB29B278 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 266 2. Check: 2. Apply: • Crankcase • Sealant Crack/damage  Replace. (to the crankcase mating surface) • Oil delivery passages Yamaha bond No. 1215 Obstruction  Blow out with compressed 90890-85505 air. (Three bond No.1215®) EASB29B281 INSTALLING THE OIL SEAL 1.
  • Page 267 CRANKCASE 4. 45 mm (1.77 in) 5. 60 mm (2.36 in) 6. 75 mm (2.95 in) a. Hexagon socket head bolt without flange b. Hexagon socket head bolt with flange 5-70...
  • Page 268 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EASB29B283 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT Removing the crankshaft assembly and balancer shaft Order Part name Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-65. Transmission Refer to “TRANSMISSION” on page 5-74. Balancer shaft Crankshaft assembly For installation, reverse the removal proce- dure.
  • Page 269 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EASB29B284 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: • Crankshaft assembly “1” Remove the crankshaft assembly by using the crankcase separating tool “2”. Crankcase separating tool 90890-04152 Crankcase separating tool 2. Measure: YU-A9642 • Big end side clearance “a” Out of specification ...
  • Page 270 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 4. Check: • Crankshaft sprocket “1” Hold the connecting rod at top dead center Damage  Replace the crankshaft. (TDC) with one hand while turning the nut of the crankshaft installer bolt with the other. Turn the crankshaft installer bolt until the crankshaft as- sembly bottoms against the bearing.
  • Page 271 TRANSMISSION EASB29B288 TRANSMISSION 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 5-65. Main axle Drive axle Long shift fork guide bar Short shift fork guide bar Spring Shift cam...
  • Page 272 TRANSMISSION EASB29B289 EASB29B290 REMOVING THE TRANSMISSION CHECKING THE SHIFT FORKS 1. Remove: 1. Check: • Long shift fork guide bar “1” • Shift fork cam follower “1” • Short shift fork guide bar “2” • Shift fork pawl “2” Bends/damage/scoring/wear  Replace the •...
  • Page 273 TRANSMISSION EASB29B291 CHECKING THE SHIFT DRUM ASSEMBLY 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 274 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 275 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 276 TRANSMISSION 5-79...

  • Page 277: 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 278 RADIATOR EASB29B295 RADIATOR Removing the radiator 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 1.5 N ・...
  • Page 279 RADIATOR Removing the radiator 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 1.5 N ・...
  • Page 280 RADIATOR EASB29B296 HANDLING NOTE WARNING If coolant seems hot, do not remove the ra- diator cap. EASB29B297 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 281 WATER PUMP EASB29B298 WATER PUMP Removing the water pump 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Part name Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT”...
  • Page 282 WATER PUMP Removing the water pump 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Part name Q’ty Remarks Bearing Oil seal For installation, reverse the removal proce- dure.
  • Page 283 WATER PUMP EASB29B299 REMOVING THE OIL SEAL • 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 284 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 N·m (1.0 kgf·m, 7.4 lb·ft) • Washer “3” • Coolant drain bolt “4” Coolant drain bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft)

  • Page 285: 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 REMOVING THE FUEL SENDER..............7-3 CHECKING THE FUEL SENDER ..............7-3 INSTALLING THE FUEL SENDER ............7-3 INSTALLING THE FUEL TANK..............7-3 CHECKING THE FUEL PRESSURE............7-4 CHECKING THE DAMPER ................7-4 CHECKING AND REPLACING THE PROTECTOR........7-4...

  • Page 286: Fuel Tank

    FUEL TANK EASB29B305 FUEL TANK Removing the fuel tank 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 4.0 N ・...

  • Page 287: Removing The Fuel Tank

    FUEL TANK • Air scoop (left/right) EASB29B306 REMOVING THE FUEL TANK • Fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: Do not set the fuel tank down on the installation •...

  • Page 288: Removing The Fuel Sender

    FUEL TANK • Do not damage the installation surfaces of the fuel tank when installing the fuel sender. • Always use a new fuel sender gasket. • When install the fuel sender, make sure that the projection “a” faces the rear of the vehicle. EASB29B310 REMOVING THE FUEL SENDER 1.

  • Page 289: Checking The Fuel Pressure

    FUEL TANK • Side cover (left/right) Fuel line pressure (at idle) Refer to “GENERAL CHASSIS” on page 4- 300–390 kPa (3.0–3.9 kgf/cm , 43.5–56.6 psi) EASB29B314 CHECKING THE FUEL PRESSURE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1. Check: EASB29B315 • Fuel pressure CHECKING THE DAMPER 1.
  • Page 290 FUEL TANK 0 mm (0 in) 15 mm (0.59 in) A. Left B. Right...
  • Page 291 THROTTLE BODY EASB29B317 THROTTLE BODY Removing the throttle body 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 3.5 N ・...

  • Page 292: Throttle Body

    THROTTLE BODY Removing the throttle body 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 3.5 N ・...
  • Page 293 THROTTLE BODY Removing the injector 3.4 N ・ m (0.34 kgf ・ m, 2.5 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 3.4 N ・ m (0.34 kgf ・ m, 2.5 lb ・ ft) Order Part name Q’ty...

  • Page 294: Checking The Injector

    THROTTLE BODY EASB29B318 CHECKING THE INJECTOR 1. Check: • Injectors Obstruction  Replace, and check the fuel pump and the fuel injection system. Refer to “FUEL INJECTION SYSTEM” on page 8-23. Deposits  Replace. Damage  Replace. 2. Check: • Injector resistance Refer to “CHECKING THE FUEL INJEC- TOR”...

  • Page 295: 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 296 THROTTLE BODY 7-11...

  • Page 297: Electrical System

    FUEL INJECTION SYSTEM ................8-23 CIRCUIT DIAGRAM .................8-23 ECU SELF-DIAGNOSTIC FUNCTION .............8-25 TROUBLESHOOTING METHOD .............8-26 YAMAHA DIAGNOSTIC TOOL ..............8-27 FEATURES OF THE YAMAHA DIAGNOSTIC TOOL ......8-27 FUNCTIONS OF THE YAMAHA DIAGNOSTIC TOOL ......8-27 CONNECTING THE YAMAHA DIAGNOSTIC TOOL .......8-27 TROUBLESHOOTING DETAILS..............8-29 FUEL PUMP SYSTEM..................8-49 CIRCUIT DIAGRAM .................8-49...
  • Page 298 CHECKING THE CRANKSHAFT POSITION SENSOR......8-67 CHECKING THE LEAN ANGLE SENSOR..........8-67 CHECKING THE STARTER MOTOR OPERATION ........8-68 CHECKING THE STATOR COIL..............8-68 CHECKING THE RECTIFIER/REGULATOR ...........8-69 CHECKING THE FUEL SENDER ............8-69 CHECKING THE RESISTER..............8-70 CHECKING THE RADIATOR FAN MOTOR (For JPN) ......8-70 CHECKING THE COOLANT TEMPERATURE SENSOR ......8-70 CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE..8-71 CHECKING THE INTAKE AIR PRESSURE SENSOR......8-71...

  • Page 300: Ignition System

    IGNITION SYSTEM EASB29B323 IGNITION SYSTEM EASB29B324 CIRCUIT DIAGRAM...
  • Page 301 IGNITION SYSTEM 1. Joint connector 2. Joint connector 4. AC magneto 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 21.ECU (engine control unit) 22.Ignition coil 23.Spark plug 29.Joint connector 34.Lean angle sensor 35.Engine stop switch 41.Frame ground 42.Ignition coil sub-lead...

  • Page 302: Troubleshooting

    IGNITION SYSTEM EASB29B325 TROUBLESHOOTING 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. Air filter case cover NG ...
  • Page 303 IGNITION SYSTEM NG  8. Check the lean angle sensor. Refer to “CHECKING THE LEAN Replace the lean angle sensor. ANGLE SENSOR” on page 8-67. OK  NG  9. Check the entire ignition system’s Properly connect or repair the ignition sys- wiring.

  • Page 304: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EASB29B326 CIRCUIT DIAGRAM...
  • Page 305 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 21.ECU (engine control unit) 29.Joint connector 35.Engine stop switch 36.Neutral switch 37.Diode 38.Starting circuit cut-off relay 39.Clutch switch...

  • Page 306: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EASB29B327 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION 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 307 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 308: Troubleshooting

    ELECTRIC STARTING SYSTEM EASB29B328 TROUBLESHOOTING 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. Air filter case cover NG  1. Check the fuse. Replace the fuse(s).
  • Page 309 ELECTRIC STARTING SYSTEM NG  8. Check the main relay. Refer to “CHECKING THE RE- Replace the main relay. LAYS” on page 8-64. OK  NG  9. Check the neutral switch. Replace the neutral switch. Refer to “CHECKING THE SWITCHES”...

  • Page 310: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EASB29B329 CIRCUIT DIAGRAM 8-11...
  • Page 311 CHARGING SYSTEM 4. AC magneto 5. Rectifier/regulator 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 43.Negative battery lead 8-12...

  • Page 312: Troubleshooting

    CHARGING SYSTEM EASB29B330 TROUBLESHOOTING 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 Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 8-60. OK NG ...
  • Page 313 CHARGING SYSTEM 8-14...

  • Page 314: Signaling System

    SIGNALING SYSTEM SIGNALING SYSTEM EASB29B331 CIRCUIT DIAGRAM 8-15...
  • Page 315 SIGNALING SYSTEM 1. Joint connector 2. Joint connector 3. Joint connector 6. Main relay 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 14.Warning light 16.Fuel level warning light 17.Resistor 18.Fuel sender 21.ECU (engine control unit) 29.Joint connector 41.Frame ground 43.Negative battery lead 8-16...

  • Page 316: Troubleshooting

    SIGNALING SYSTEM EASB29B332 TROUBLESHOOTING • The fuel level warning light does not come on. 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).
  • Page 317 SIGNALING SYSTEM NG  3. Check the resistor. Refer to “CHECKING THE RESIST- Replace the resistor. ER” on page 8-70. OK  NG  4. Check the entire signaling system’s Properly connect or repair the signaling wiring. system’s wiring. Refer to “CIRCUIT DIAGRAM” on page 8-15.

  • Page 318: Cooling System (For Jpn)

    COOLING SYSTEM (For JPN) EASB29B333 COOLING SYSTEM (For JPN) EASB29B334 CIRCUIT DIAGRAM 8-19...
  • 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 21.ECU (engine control unit) 26.Radiator fan motor relay 27.Radiator fan motor fuse 28.Radiator fan motor 29.Joint connector 31.Coolant temperature sensor 41.Frame ground...

  • Page 320: Troubleshooting

    COOLING SYSTEM (For JPN) EASB29B335 TROUBLESHOOTING 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) 8-22...

  • Page 322: Fuel Injection System

    FUEL INJECTION SYSTEM EASB29B336 FUEL INJECTION SYSTEM EASB29B337 CIRCUIT DIAGRAM 8-23...
  • 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 14.Warning light 15.Engine trouble warning light 21.ECU (engine control unit) 24.Injector 29.Joint connector 30.Intake air temperature sensor 31.Coolant temperature sensor 32.Throttle position sensor...

  • Page 324: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM EASB29B338 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 325: Troubleshooting Method

    • Fault code number ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the Yamaha diagnostic tool. Refer to “YAMAHA DIAGNOSTIC TOOL” on page 8-27. b. Check the fault code number displayed on the Yamaha diagnostic tool. c. Identify the faulty system with the fault code number.

  • Page 326: Yamaha Diagnostic Tool

    FUEL INJECTION SYSTEM EASB29B340 YAMAHA DIAGNOSTIC TOOL 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 USB (US) 90890-03257...
  • Page 327 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 328: Troubleshooting Details

    FUEL INJECTION SYSTEM TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the diagnostic tool. Check and service the items or components that are the probable cause of the malfunction following the or- der given. After the check and service of the malfunctioning part have been completed, reset the diagnostic tool display according to the reinstatement method.
  • Page 329 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received Item from the crankshaft position sensor. Defective crankshaft position Check the crankshaft position Crank the engine. sensor. sensor. Fault code number is not dis- played  Service is finished. Refer to “CHECKING THE CRANKSHAFT POSITION Fault code number is dis-...
  • Page 330 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Installed condition of intake Improperly installed sensor Push the start switch.  Reinstall or replace the air pressure sensor. Fault code number is not dis- played ...
  • Page 331 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged Item or detached hose). The intake air pressure sen- Repair or replace the sensor Start the engine and let it idle sor hose is damaged, discon- hose.
  • Page 332 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Improperly connected  Connection of throttle posi- Push the start switch. tion sensor 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. Defective throttle position Check throttle position sen- Push the start switch. sensor. sor signal. Fault code number is not dis- played  Service is finished. Execute the diagnostic mode.
  • 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...
  • Page 336 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Improperly connected  Connection of intake air tem- Push the start switch. perature sensor coupler. Connect the coupler securely Fault code number is not dis- played ...
  • Page 337 Actuation Actuates the ignition coil five times at one-second intervals. The engine trouble warning light and 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 ignition coil Start the engine and let it idle coupler. Connect the coupler securely for approximately 5 seconds.
  • Page 339 Actuation Actuates injector five times at one-second intervals. The engine trouble warning light and 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.
  • 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 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 346 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 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 EASB29B342 FUEL PUMP SYSTEM EASB29B343 CIRCUIT DIAGRAM 8-49...
  • Page 349 FUEL PUMP SYSTEM 1. Joint connector 2. Joint connector 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 21.ECU (engine control unit) 25.Fuel pump 29.Joint connector 35.Engine stop switch 41.Frame ground 8-50...

  • Page 350: Troubleshooting

    FUEL PUMP SYSTEM EASB29B344 TROUBLESHOOTING 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 8-60.
  • Page 351 FUEL PUMP SYSTEM EASB29B345 8-52...

  • Page 352: Electrical Components

    ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS EASB29B346 8-53...
  • Page 353 ELECTRICAL COMPONENTS 1. Rectifier/regulator 2. Clutch switch 3. Ignition coil 4. ECU (engine control unit) 5. Fuel sender 6. Fuel pump 7. Battery 8. Resistor 9. Neutral switch 10.Radiator fan motor (For JPN) 11.Injector 8-54...
  • Page 354 ELECTRICAL COMPONENTS 8-55...
  • 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 8-56...

  • Page 356: Checking The Switches

    ELECTRICAL COMPONENTS EASB29B347 CHECKING THE SWITCHES 8-57...
  • Page 357 ELECTRICAL COMPONENTS 1. Engine stop switch 2. Neutral switch 3. Clutch switch 4. Start switch 8-58...
  • Page 358 ELECTRICAL COMPONENTS Check each switch for continuity with the digital circuit 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. Always insert the probes from the opposite end “a”...

  • Page 359: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS EASB29B348 CHECKING THE BULBS AND BULB SOCK- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install a good bulb into the bulb socket. b. Connect the digital circuit tester probes to 1. Remove: the respective leads of the bulb socket. • Bulb c. Check the bulb socket for continuity. If any of NOTICE the readings indicate no continuity, replace Be sure to hold the socket firmly when re-...

  • Page 360: Checking And Charging The Battery

    ELECTRICAL COMPONENTS EASB29B350 CHECKING AND CHARGING THE BATTERY ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the digital circuit tester to the fuse WARNING and check the continuity. Batteries generate explosive hydrogen gas and contain electrolyte which is made of Set the digital circuit tester to the “” range. poisonous and highly caustic sulfuric acid.
  • Page 361 ELECTRICAL COMPONENTS b. Check the charge of the battery, as shown in the charts and the following example. Since VRLA (Valve Regulated Lead Acid) bat- Example teries are sealed, it is not possible to check the Open-circuit voltage = 12.0 V charge state of the battery by measuring the Charging time = 6.5 hours specific gravity of the electrolyte.
  • Page 362 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTICE Charging method using a variable-cur- • Do not use a high-rate battery charger rent (voltage) charger since it forces a high-amperage current a. Measure the open-circuit voltage prior to into the battery quickly and can cause bat- charging.

  • Page 363: Checking The Relays

    ELECTRICAL COMPONENTS 9. Lubricate: • Battery terminals Voltage should be measured 30 minutes after the engine is stopped. Recommended lubricant Dielectric grease b. Connect a charger and ammeter to the bat- tery and start charging. 10.Install: c. Make sure that the current is higher than the •...

  • Page 364: Checking The Diode

    ELECTRICAL COMPONENTS Main relay Result Continuity (between “3” to “4”) EASB29B352 CHECKING THE DIODE 1. Check: • Diode Out of specification  Replace. Digital circuit tester (CD732) 90890-03243 R,R/W Model 88 Multimeter with 1. Positive battery terminal tachometer 2. Negative battery terminal YU-A1927 3.

  • Page 365: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS EASB29B353 CHECKING THE IGNITION SPARK GAP ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the digital circuit tester () to the 1. Check: spark plug cap. • Ignition spark gap Out of specification  Perform the ignition Digital circuit tester (CD732) system troubleshooting, starting with step 4. 90890-03243 Refer to “TROUBLESHOOTING”...

  • Page 366: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS Crankshaft position sensor resis- tance 228–342  ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the digital circuit tester () to the crankshaft position sensor coupler. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with b. Measure the primary coil resistance. tachometer ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ YU-A1927 3.

  • Page 367: Checking The Starter Motor Operation

    ELECTRICAL COMPONENTS Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachometer YU-A1927 Test harness– lean angle sensor (6P) 90890-03209 Test harness– lean angle sensor (6P) b. Check the starter motor operation. YU-03209 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Positive tester probe  EAS28150 CHECKING THE STATOR COIL Yellow/Green “1”...

  • Page 368: Checking The Rectifier/Regulator

    ELECTRICAL COMPONENTS c. Start the engine and let it run at approxi- mately 5000 r/min. d. Measure the charging voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EASB29B360 CHECKING THE FUEL SENDER 1. Drain the gasoline. 2. Disconnect: • Fuel sender coupler (from the fuel sender) 3.

  • Page 369: Checking The Resister

    ELECTRICAL COMPONENTS EASB29B361 CHECKING THE RESISTER 1. Disconnect: • Resister coupler (from the wire harness) 2. Check: • Resister resistance Out of specification  Replace the resister. Resister resistance 64.6–71.4  c. Measure the radiator fan motor movement. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a.

  • Page 370: Checking The Throttle Position Sensor Input Voltage

    ELECTRICAL COMPONENTS Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachometer YU-A1927 Test harness S– pressure sensor (3P) 90890-03207 Test harness S– pressure sensor (3P) YU-03207 b. Immerse the coolant temperature sensor in a container filled with coolant. • Positive tester probe  Blue “1”...

  • Page 371: Checking The Intake Air Temperature Sensor

    ELECTRICAL COMPONENTS • Positive tester probe  • Positive tester probe  Pink “1” Brown/White “1” • Negative tester probe  • Negative tester probe  Black/Blue “2” Black/Blue “2” b. Start the engine. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ c. Measure the intake air pressure sensor out- EASB29B368 CHECKING THE FUEL INJECTOR put voltage.
  • Page 372 ELECTRICAL COMPONENTS c. Measure the fuel injector resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 8-73...

  • Page 373: Troubleshooting

    POOR BRAKING PERFORMANCE ............9-3 FRONT FORK OIL LEAKING ..............9-3 FAULTY FRONT FORK LEGS ..............9-3 UNSTABLE HANDLING ................9-3 LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS......9-5 LIST OF DIAGNOSTIC CODES ..............9-5 COMMUNICATION ERROR WITH YAMAHA DIAGNOSTIC TOOL ..9-5 SENSOR OPERATION TABLE ..............9-6 ACTUATOR OPERATION TABLE .............9-7...

  • Page 374: Troubleshooting

    TROUBLESHOOTING Electrical system EASB29B369 TROUBLESHOOTING 1. Battery EASB29B370 • Discharged battery GENERAL INFORMATION • Faulty battery 2. Fuse The following guide for troubleshooting does • Blown, damaged or incorrect fuse not cover all the possible causes of trouble. It • Improperly installed fuse should be helpful, however, as a guide to basic 3.

  • Page 375: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING Electrical system EASB29B376 JUMPS OUT OF GEAR 1. Battery • Discharged battery Engine • Faulty battery 1. Shift shaft 2. Spark plug • Incorrect shift pedal position • Incorrect spark plug gap • Improperly returned stopper lever • Incorrect spark plug heat range 2.

  • Page 376: Overcooling

    TROUBLESHOOTING Cooling system EASB29B382 FRONT FORK OIL LEAKING 1. Coolant • Low coolant level Chassis 2. Radiator 1. Front fork • Damaged or leaking radiator • Bent, damaged, or rusty inner tube • Faulty radiator cap • Cracked or damaged outer tube •...
  • Page 377 TROUBLESHOOTING 7. Wheel (s) • Incorrect wheel balance • Broken or loose spoke • Damaged wheel bearing • Bent or loose wheel axle • Excessive wheel runout 8. Frame • Bent frame • Damaged steering head pipe • Improperly installed bearing race...

  • Page 378: List Of Self-Diagnostic And Fail-Safe Actions

    8-45 nection Er-2 Signals from the ECU cannot be received within the specified period 8-46 of time. Er-3 Data from the ECU cannot be received correctly. 8-47 Er-4 Registered data cannot be received from the Yamaha diagnostic tool. 8-48...

  • Page 379: Sensor Operation Table

    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 380: Actuator Operation Table

    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 381: 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 382: Chassis

    CHASSIS EASB29B387 EASB29B389 CHASSIS DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS EASB29B388 SELECTION OF THE SECONDARY REDUC- 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 drive sprocket teeth Rear wheel sprocket “2”...

  • Page 383: 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) EASB29B391 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 384: Front Fork Setting Parts

    CHASSIS EASB29B395 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 385 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 386 CHASSIS • Spring preload adjusting positions Spring preload Minimum 1.5 mm (0.06 in) Standard 10.0 mm (0.39 in) Maximum 18.0 mm (0.71 in) For the spring preload adjustment, refer to “AD- JUSTING THE REAR SHOCK ABSORBER ASSEMBLY” on page 3-31. 10-5...

  • Page 387: Suspension Setting (Front Fork)

    CHASSIS EASB29B399 SUSPENSION SETTING (FRONT FORK) • 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 388: 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...
  • Page 389 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 390: Kick Starter Kit (Optional Parts)

    KICK STARTER KIT (OPTIONAL PARTS) EASB29B401 KICK STARTER KIT (OPTIONAL PARTS) EASB29B402 PARTS LOCATION Order Part name Part number Q’ty Remarks Kick starter kit B29-15602-00 Kick shaft assembly 1SM-15601-00 Kick gear 1SM-15641-00 Washer 90201-20685 Circlip 93410-20038 Ratchet wheel 2S2-15671-00 Spring 90501-160A2 Washer 90201-167P7...
  • Page 391 KICK STARTER KIT (OPTIONAL PARTS) Order Part name Part number Q’ty Remarks Washer 90201-177G4 Thickness:1.0 mm (0.0394 in) Circlip 99009-17400 Kickstarter lever assembly 1SM-15620-00 Kickstarter lever boss 1SM-15621-00 Spring 90501-147A5 Ball 93507-32009 Screw 90151-06045 O-ring 93210-17570 Bolt 90110-08051 Washer 90201-08048 Crankcase cover gasket 1SM-15462-00 10-10...

  • Page 392: Setup Procedures

    KICK STARTER KIT (OPTIONAL PARTS) EASB29B403 SETUP PROCEDURES Installing the kick shaft 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) Order Part name Q’ty Remarks Clutch and right crankcase cover. Remove. Refer to “CLUTCH” on page 5-39. Remove.
  • Page 393 KICK STARTER KIT (OPTIONAL PARTS) Installing the kick shaft 1. Install: • Stopper “1” • Rachet wheel guide “2” • Bolt (rachet wheel guide) “3” Bolt (rachet wheel guide) 12 N·m (1.2 kgf·m, 8.9 lb·ft) LOCTITE® 4. Install: • Torsion spring “1” Turn the torsion spring clockwise and hook into the proper hole “a”...
  • Page 394 KICK STARTER KIT (OPTIONAL PARTS) Installing the kickstater lever 33 N ・ m (3.3 kgf ・ m, 24 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Part name Q’ty Remarks Remove. Plug Do not use the plug installed originally.

  • Page 395: Starting The Engine

    KICK STARTER KIT (OPTIONAL PARTS) Installing the kickstarter lever EASB29B404 STARTING THE ENGINE 1. Install: • Oil seal “1” Starting with the kickstarter (to the right crank case cover) When using the kickstarter to start the engine, follow the procedures as described below. 1.

  • Page 396: Maintenance

    KICK STARTER KIT (OPTIONAL PARTS) EASB29B405 MAINTENANCE Removing the kick starter kit 1. Remove: • Kick shaft assembly “1” Unhook the torsion spring “2” from the hole “a” in the crankcase. 3. Check: • Kickstarter lever “1” smooth movement Unsmooth movement  Apply the lithium- soap-based grease to the pivoting point and metal-to-metal moving parts.
  • Page 397 KICK STARTER KIT (OPTIONAL PARTS) 2. Install: • Torsion spring “1” (to the kick shaft “2”) Make sure the stopper “a” of the torsion spring fits into the hole “b” on the kick shaft. 3. Install: • Spring guide “1” Slide the spring guide into the kick shaft, make sure the groove “a”...
  • Page 398 EASB29B407 EASB29B408 WIRING DIAGRAM COLOR CODE YZ250FXJ 2018 Black 1. Joint connector Brown 2. Joint connector Chocolate 3. Joint connector 4. AC magneto Dark green 5. Rectifier/regulator Green 6. Main relay Gray 7. Engine ground 8. Battery Blue 9. Frame ground Light green 10.
  • Page 399 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 400 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2017.04-0.3×1 !
  • Page 401 YZ250FXJ 2018 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 Br Br Br Br L/Y Y/W R/L R/B (Gy) Br/W Br/W Br/W,Br Br/W R/W,Br...
  • Page 402 YZ250FXJ 2018 WIRING DIAGRAM (Gy) (Gy) (Gy)

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