Yamaha WR250FM 2021 Owner's Service Manual
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Yamaha WR250FM 2021 Owner's Service Manual

Yamaha WR250FM 2021 Owner's Service Manual

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Table of Contents

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2021
OWNER'S SERVICE MANUAL
WR250F
Read this manual carefully before operating this vehicle.
WR250FM
LIT-11626-34-56
BAK-2819U-11

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Summary of Contents for Yamaha WR250FM 2021

  • Page 1 2021 OWNER’S SERVICE MANUAL WR250F Read this manual carefully before operating this vehicle. WR250FM LIT-11626-34-56 BAK-2819U-11...
  • Page 2 EAM20161 Read this manual carefully Operating, servicing and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.
  • Page 3 EAM20080 WR250FM OWNER’S SERVICE MANUAL ©2021 by Yamaha Motor Corporation, U.S.A. First edition, July 2020 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. P/N. LIT-11626-34-56...
  • Page 4 EAM20081 IMPORTANT Congratulations on your purchase of a Yamaha WR series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.
  • Page 5 EAM20093 YAMAHA MOTOR CORPORATION, U.S.A. WR MOTORCYCLE LIMITED WARRANTY...
  • Page 6 EAM20082 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 7 EAM20083 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 CONTENTS EAM10003 GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING TUNING...
  • Page 11 GENERAL INFORMATION SAFETY INFORMATION ..................1-1 FOR SAFETY, BE SURE TO OBEY THE FOLLOWING:......1-1 LOCATION OF IMPORTANT LABELS.............1-4 DESCRIPTION....................1-5 IDENTIFICATION ....................1-6 VEHICLE IDENTIFICATION NUMBER ............1-6 ENGINE SERIAL NUMBER................1-6 VEHICLE EMISSION CONTROL INFORMATION LABEL ......1-6 INCLUDED PARTS ...................1-7 NIPPLE WRENCH ..................1-7 HANDLEBAR PROTECTOR ..............1-7 FUEL HOSE JOINT COVER ..............1-7 COUPLER FOR CONNECTING OPTIONAL PART ........1-7 IMPORTANT INFORMATION ................1-8...
  • Page 12 CHANGEOVER TO BASIC MODE/RACE MODE ........1-26 RACE MODE ....................1-27 FUNCTION DIAGRAM ................1-30 STARTING AND BREAK-IN ................1-31 FUEL......................1-31 HANDLING NOTE ..................1-31 STARTING A COLD ENGINE ..............1-31 STARTING A WARM ENGINE ..............1-32 BREAK-IN PROCEDURES ..............1-32 SHIFTING ....................1-32 MAINTENANCE AFTER BREAK-IN ..............1-34 MAJOR MAINTENANCE ................1-34 AIR FILTER MAINTENANCE ..............1-34 TORQUE-CHECK POINTS................1-35 MOTORCYCLE CARE AND STORAGE............1-37...

  • Page 13: Safety Information

    Yamaha ma- accidents. Many accidents have been chine, and take care to maintain it properly and caused by an automobile driver who did not operate it safely.
  • Page 14 1. Always wear an approved helmet. Yamaha can neither endorse nor recommend 2. Wear a face shield or goggles. Wind in your the use of accessories not sold by Yamaha or unprotected eyes could contribute to an im- modifications not specifically recommended by...
  • Page 15 SAFETY INFORMATION Aftermarket Tires and Rims The tires and rims that came with your motorcy- cle were designed to match the performance ca- pabilities and to provide the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate. Refer to “CHECKING THE TIRES”...

  • Page 16: Location Of Important Labels

    LOCATION OF IMPORTANT LABELS EAM20085 LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle. WARNING This unit contains high pressure nitrogen gas. Mishandling can cause explosion. Read owner’s manual for instructions. Do not incinerate, puncture or open. 4AA-22259-80...

  • Page 17: Description

    DESCRIPTION EAM20086 DESCRIPTION 2, 3 17 16 1. Clutch lever 12.Fuel tank 13.Headlight 2. Engine trouble warning light “ ” 14.Radiator 3. Fuel level warning light “ ” 15.Coolant drain bolt 4. Multi-function display 16.Oil level check window 5. Front brake lever 17.Rear brake pedal 6.

  • Page 18: 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 identi- fication 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 19: Included Parts

    INCLUDED PARTS EAM20088 ECA24810 INCLUDED PARTS NOTICE When no optional parts, etc. are connected, EAM30005 connect the connection terminal to the origi- NIPPLE WRENCH nal coupler. The nipple wrench “1” is used to tighten the Before disconnecting the coupler, thorough- spoke.

  • Page 20: Important Information

    2. Use proper special tools and equipment. Re- used for repair of the vehicle, including periodic fer to “SPECIAL TOOLS” on page 1-14. replacement parts, are new YAMAHA genuine parts and recommended parts. Do not use any used parts, because these may...

  • Page 21: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION 1. Oil 2. Lip 3. Spring 4. Grease EAM30012 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace lock washers/plates “1” and cotter pins with new ones. After the bolt or nut has been tightened to specification, firmly bend the lock tabs along a flat of the bolt or nut. EAM30014 CIRCLIPS When assembling parts, always use new cir-...

  • Page 22: Basic Service Information

    BASIC SERVICE INFORMATION EAM20120 BASIC SERVICE INFORMATION EAM30181 ELECTRICAL SYSTEM Electrical parts handling ECA16600 NOTICE Never disconnect a battery lead while the en- gine is running; otherwise, the electrical components could be damaged. ECA16760 NOTICE Be sure to connect the battery leads to the correct battery terminals.
  • Page 23 BASIC SERVICE INFORMATION ECA16630 ECA14371 NOTICE NOTICE Electrical components are very sensitive to Never insert the tester probes into the cou- and can be damaged by static electricity. pler terminal slots. Always insert the probes Therefore, never touch the terminals and be from the opposite end “a”...
  • Page 24 BASIC SERVICE INFORMATION ECA16780 NOTICE • When disconnecting a coupler, release the coupler lock, hold both sections of the cou- pler securely, and then disconnect the cou- pler. • There are many types of coupler locks; therefore, be sure to check the type of cou- pler lock before disconnecting the coupler.
  • Page 25 BASIC SERVICE INFORMATION 5. Check: • No continuity Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachom- eter YU-A1927 • If there is no continuity, clean the terminals. • When checking the wire harness, perform steps (1) to (4). •...

  • Page 26: Special Tools

    Feeler gauge set YU-26900-9 Valve lapper (ø14) 3-8, 5-27 90890-04101 90890-04101 Valve lapper (ø14) YM-A8998 YM-A8998 Yamaha diagnostic tool USB (US) 3-12, 7-8, 8-31 90890-03269 Yamaha diagnostic tool (A/I) 3-12, 7-8, 8-31 90890-03264 FI diagnostic tool sub–lead 3-12, 7-8, 8-31 90890-03212 FI diagnostic tool sub–lead...
  • Page 27 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages OBD/ GST Leadwire kit 3-12, 7-8, 8-31 90890-03249 Digital tachometer 3-12, 3-35, 8-67 90890-06760 Digital tachometer YU-39951-B Steering nut wrench 3-27, 4-57 90890-01403 Exhaust flange nut wrench YU-A9472 Spoke nipple wrench (6–7) 3-33 90890-01521 Spoke nipple wrench (6–7)
  • Page 28 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Boots band installation tool 90890-01526 Boots band installation tool YM-01526 Yamaha bond No. 1215 5-20, 5-39, 5-69 90890-85505 Three bond No. 1215® Valve spring compressor 5-27, 5-31 90890-04019 Valve spring compressor YM-04019...
  • Page 29 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide installer (ø4.5) 5-29 90890-04117 Valve guide installer (4.5 mm) YM-04117 Valve guide reamer (ø4.5) 5-29 90890-04118 Valve guide reamer (4.5 mm) YM-04118 Piston pin puller set 5-34 90890-01304 Piston pin puller YU-01304 YU-01304 Rotor puller...
  • Page 30 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Crankcase separating tool 5-71 90890-04152 Crankcase separating tool YU-A9642 Crankshaft installer pot 5-72 90890-01274 Installing pot YU-90058 YU-90058/YU-90059 Crankshaft installer bolt 5-72 90890-01275 Bolt YU-90060 Adapter (M12) 5-72 90890-01278 Adapter #3 YU-90063 Spacer (crankshaft installer) 5-72 90890-04081...
  • Page 31 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester 6-4, 6-4 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter 6-4, 6-4 90890-01352 Pressure tester adapter YU-33984 YU-33984 Pressure gauge 90890-03153 Pressure gauge YU-03153 Fuel pressure adapter 90890-03186 Fuel pressure adapter YM-03186...
  • Page 32 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Test harness S– pressure sensor (3P) 8-70 90890-03207 Test harness S– pressure sensor (3P) YU-03207 1-20...

  • Page 33: Instrument And Control Functions

    ” This warning light comes on or flashes if a prob- lem is detected in the electrical circuit monitoring 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 34: Front Brake Lever

    INSTRUMENT AND CONTROL FUNCTIONS EAM30190 Shift up points SIDESTAND 1st  2nd This sidestand “1” is used to support only the 20 km/h (12 mph) machine when standing. 2nd  3rd EWA18980 30 km/h (19 mph) WARNING 3rd  4th •...
  • Page 35 INSTRUMENT AND CONTROL FUNCTIONS • 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. • Install the fuel tank cap cover after placing the bands “3”...

  • Page 36: Multi-Function Display

    MULTI-FUNCTION DISPLAY EAM20150 MULTI-FUNCTION DISPLAY EWA19000 WARNING Be sure to stop the machine before making any setting changes to the multi-function display. The multi-function display is equipped with the following: BASIC MODE: • Speedometer (which shows current speed) EAM30327 • Clock BASIC MODE •...
  • Page 37 MULTI-FUNCTION DISPLAY button (minus) and change the time. A long push on the button will fast-forward the time. Setting the tire diameter 4. To end the setting, push the “RST” button for The outer diameter of a tire varies with tire wear, 2 seconds or more.

  • Page 38: Changeover To Basic Mode/Race Mode

    MULTI-FUNCTION DISPLAY Returning to BASIC MODE from RACE MODE It is possible to return to BASIC MODE with timer 4. Push the “SLCT1” button and “RST” button measurement at a stop. for 2 seconds or more at the same time will finish the setting.

  • Page 39: Race Mode

    MULTI-FUNCTION DISPLAY “SLCT1” button and “SLCT2” button at the EAM30329 RACE MODE same time. Putting measurement on standby Auto start 1. Check that changeover has been made to Starting measurement consists of the following RACE MODE. (Refer to “Changeover from two starts, either of which can be selected.
  • Page 40 MULTI-FUNCTION DISPLAY Resetting is possible while timer measurement Resetting average speed (AVS), tripmeter A (TRIP A) and timer is made: • Reset average speed (AVS). 1. Check that the timer is not in operation. If the • Reset average speed (AVS)/tripmeter A. timer is in operation, stop it by pushing the Resetting is possible while timer measurement “SLCT1”...
  • Page 41 MULTI-FUNCTION DISPLAY Correcting tire diameter • Correction can be made any time while timer measurement is or is not being made. • Change in the travel distance display will be accompanied by the change in the tire’s dia- metric percentage. •...

  • Page 42: Function Diagram

    MULTI-FUNCTION DISPLAY EAM30330 FUNCTION DIAGRAM The following diagram illustrates the multi-function display regarding the direction and operation condi- tion involved in each of its functions. 1-30...

  • Page 43: Starting And Break-In

    Your Yamaha engine has been designed to use premium unleaded gasoline with a pump octane number [(R+M)/2] of 91 or higher, or a research octane number of 95 or higher.

  • Page 44: Starting A Warm Engine

    STARTING AND BREAK-IN 1. After warming up the engine, drive it for about 20 minutes at a throttle opening of 1/2 or less. This model is equipped with an engine auto-stop system. The engine stops automatically if left idling for 7 minutes. If the engine stops, push the start switch to restart the engine.
  • Page 45 STARTING AND BREAK-IN stopped. Recommended shift points The recommended shift points during accelera- tion and deceleration are shown in the table be- low. Shift up points 1st  2nd 20 km/h (12 mph) 2nd  3rd 1 1 1 30 km/h (19 mph) 3rd ...

  • Page 46: Maintenance After Break-In

    Pour the specified amount of the recom- AIR FILTER MAINTENANCE mended oil. Apply the Yamaha foam air filter oil or other qual- • Generator ity foam air filter oil to the element. (Excess oil in Check for looseness in mounted areas of the the element may adversely affect engine start- generator rotor and the stator coil assembly.

  • Page 47: Torque-Check Points

    TORQUE-CHECK POINTS EAM20125 TORQUE-CHECK POINTS Frame construction Combined seat and fuel tank Fuel tank to frame Frame to rear frame Frame to engine protector 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 48 TORQUE-CHECK POINTS Shift pedal Shift pedal to shift shaft Plastic cover 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 cover Tightening of rear brake caliper cover...

  • Page 49: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE any longer than instructed. Also, thorough- EAM20126 MOTORCYCLE CARE AND STOR- ly rinse the area off with water, immediately dry it, and then apply a corrosion protec- tion spray. • Improper cleaning can damage plastic EAM30200 CARE parts (such as cowlings, panels, wind- While the open design of a motorcycle reveals...

  • Page 50: Storage

    Salt sprayed on roads in the winter may remain well into spring. • Consult a Yamaha dealer for advice on what 1. Clean the motorcycle with cold water and a products to use.
  • Page 51 MOTORCYCLE CARE AND STORAGE stored. Long-term Before storing your motorcycle for several months: 1. Follow all the instructions in the “CARE” on page 1-37. 2. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating.
  • Page 52 MOTORCYCLE CARE AND STORAGE 1-40...

  • Page 53: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-5 ELECTRICAL SPECIFICATIONS..............2-8 TIGHTENING TORQUES................2-10 GENERAL TIGHTENING TORQUE SPECIFICATIONS ......2-10 ENGINE TIGHTENING TORQUES ............2-11 CHASSIS TIGHTENING TORQUES ............2-14 CABLE ROUTING DIAGRAM ................2-17...

  • Page 54: General Specifications

    GENERAL SPECIFICATIONS EAM20127 GENERAL SPECIFICATIONS Model Model BAK7 Dimensions Overall length 2175 mm (85.6 in) Overall width 825 mm (32.5 in) Overall height 1270 mm (50.0 in) Seat height 955 mm (37.6 in) Wheelbase 1480 mm (58.3 in) Ground clearance 320 mm (12.60 in) Weight Curb weight...

  • Page 55: Engine Specifications

    ENGINE SPECIFICATIONS EAM20128 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train DOHC Displacement 250 cm³ Number of cylinders Single cylinder Bore  stroke 77.0  53.6 mm (3.03  2.11 in) Compression ratio 13.8 : 1 Starting system Electric starter Fuel...
  • Page 56 ENGINE SPECIFICATIONS Exhaust 0.17–0.24 mm (0.0067–0.0094 in) Valve dimensions Valve seat contact width limit (intake) 1.6 mm (0.06 in) Valve seat contact width limit (exhaust) 1.6 mm (0.06 in) Valve stem diameter limit (intake) 4.945 mm (0.1947 in) Valve stem diameter limit (exhaust) 4.430 mm (0.1744 in) Valve guide inside diameter (intake) 5.000–5.012 mm (0.1969–0.1973 in)
  • Page 57 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 Maximum consumption amperage 2.4 A Fuel injector 12.0 ...
  • Page 58 CHASSIS SPECIFICATIONS EAM20129 CHASSIS SPECIFICATIONS Chassis 27.2  Caster angle Trail 116 mm (4.6 in) Front wheel Wheel type Spoke wheel Rim size 21 x 1.60 Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in) Wheel axle bending limit 0.50 mm (0.02 in) Rear wheel...
  • Page 59 Fork spring free length limit 492.0 mm (19.37 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil S1 Quantity (left) 501.0 cm³ (16.94 US oz, 17.67 Imp.oz) Quantity (right) 501.0 cm³ (16.94 US oz, 17.67 Imp.oz)

  • Page 60: Chassis Specifications

    CHASSIS SPECIFICATIONS Adjustment value from the start position (STD) Adjustment value from the start position (Hard) Slow compression damping Unit for adjustment Click Adjustment value from the start position (Soft) Adjustment value from the start position (STD) Adjustment value from the start position (Hard) Drive chain Size...

  • Page 61: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAM20130 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system 8.0–12.0 /2000 r/min Ignition timing (B.T.D.C.) Engine control unit Model BAK2 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 62 ELECTRICAL SPECIFICATIONS Radiator fan motor fuse 5.0 A Spare fuse 15.0 A...

  • Page 63: Tightening Torques

    TIGHTENING TORQUES EAM20131 TIGHTENING TORQUES EAM30205 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.

  • Page 64: Engine Tightening Torques

    TIGHTENING TORQUES EAM30203 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) Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) Cylinder head stud bolt (exhaust 7 N·m (0.7 kgf·m, 5.2 lb·ft) pipe)
  • Page 65 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Clutch cable locknut (clutch cable 4.3 N·m (0.43 kgf·m, 3.2 lb·ft) adjuster) Clutch cable locknut (engine side) 7 N·m (0.7 kgf·m, 5.2 lb·ft) Exhaust pipe nut 10 N·m (1.0 kgf·m, 7.4 lb·ft) Exhaust pipe protector screw 10 N·m (1.0 kgf·m, 7.4 lb·ft) Exhaust pipe bracket bolt...
  • Page 66 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Generator rotor nut 65 N·m (6.5 kgf·m, 48 lb·ft) Stator coil screw 10 N·m (1.0 kgf·m, 7.4 lb·ft) Crankshaft position sensor bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Stator coil assembly lead holder bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) Coolant temperature sensor 15 N·m (1.5 kgf·m, 11 lb·ft)

  • Page 67: Chassis Tightening Torques

    TIGHTENING TORQUES EAM30204 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 Upper bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft)  Lower bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) ...
  • Page 68 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Rear brake disc bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) / Footrest bracket bolt 55 N·m (5.5 kgf·m, 41 lb·ft) Sidestand bolt 35 N·m (3.5 kgf·m, 26 lb·ft) Rear brake pedal bolt 26 N·m (2.6 kgf·m, 19 lb·ft) ...
  • Page 69 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Drive chain tensioner bolt (lower 16 N·m (1.6 kgf·m, 12 lb·ft) side) Bolt (drive chain support) 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) Fuel tank bolt (front side)

  • Page 70: Cable Routing Diagram

    CABLE ROUTING DIAGRAM EAM20152 CABLE ROUTING DIAGRAM Frame and engine (left side view) 2-17...
  • Page 71 W. Insert the clamp into the hole in the cylinder frame and the cable holder. head. B. Insert the Yamaha diagnostic tool coupler into When doing so, the starter motor lead should the connector, and fix it to the bracket.
  • Page 72 CABLE ROUTING DIAGRAM Frame and engine (right side view) 2-19...
  • Page 73 CABLE ROUTING DIAGRAM J. After connecting the fuel pump coupler, 1. Wire harness attach the cover. 2. Bracket K. Fasten the starter relay lead and the starter 3. Joint coupler motor lead together within the width of the 4. Throttle position sensor lead cross tube.
  • Page 74 CABLE ROUTING DIAGRAM Handlebar (front view) 2-21...
  • Page 75 CABLE ROUTING DIAGRAM 1. Clutch cable 2. Clutch switch lead 3. Engine stop switch lead 4. Front brake hose 5. Headlight lead 6. Warning light coupler 7. Start switch lead 8. Multi-function display coupler 9. Speed sensor coupler 10.Plastic locking tie 11.Speed sensor lead 12.Throttle cable 13.Multi-function display...
  • Page 76 CABLE ROUTING DIAGRAM Frame and engine (top view) 2-23...
  • Page 77 CABLE ROUTING DIAGRAM N. Insert the projection of the wire harness into 1. Joint coupler the hole in the frame. 2. Plug cap O. Route the air filter breather hose outside the 3. Cylinder head cover vehicle past the intake air pressure sensor 4.
  • Page 78 CABLE ROUTING DIAGRAM Frame and battery (top view) 2-25...
  • Page 79 CABLE ROUTING DIAGRAM 1. Starter relay 2. Starter motor lead 3. Cross member 4. Resistor 5. Negative battery lead 6. Taillight lead 7. Positive battery lead 8. Diode 9. Fuel pump lead 10.Joint coupler 11.Wire harness 12.Main relay (red tape) 13.Negative lead coupler 14.Radiator fan motor relay 15.Starter relay coupler...
  • Page 80 CABLE ROUTING DIAGRAM Rear brake (right side view) 2-27...
  • Page 81 CABLE ROUTING DIAGRAM 1. Bleed screw 2. Rear brake caliper 3. Protector 4. Gasket 5. Rear brake hose 6. Brake pedal 7. Rear brake master cylinder assembly 8. Swingarm 9. Spring 10.Frame A. It does not matter whether the spring is installed upward or downward.
  • Page 82 CABLE ROUTING DIAGRAM Front brake (front view and right side view) 2-29...
  • Page 83 CABLE ROUTING DIAGRAM 1. Speed sensor lead 2. Front brake hose 3. Clamp 4. Protector 5. Speed sensor 6. Speed sensor bracket A. Clamp the shrinking tube portion of the speed sensor lead. B. Clamp securely the speed sensor lead to the hook of the protector.
  • Page 84 CABLE ROUTING DIAGRAM Taillight (top view and right side view) 2-31...
  • Page 85 CABLE ROUTING DIAGRAM 1. Taillight lead 2. Clamp 3. Taillight A. Pass the taillight lead to the groove of the rear fender. B. There should be no slack of the taillight lead. 2-32...
  • Page 86 CABLE ROUTING DIAGRAM 2-33...

  • Page 87: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ......3-1 MAINTENANCE INTERVALS FOR COMPETITION USE......3-3 PRE-OPERATION INSPECTION AND MAINTENANCE .........3-6 GENERAL INSPECTION AND MAINTENANCE ........3-6 ENGINE......................3-7 ADJUSTING THE VALVE CLEARANCE............3-7 VALVE CLEARANCE SHIM CHART ............3-10 CHECKING THE ENGINE IDLING SPEED..........3-12...
  • Page 88 CHECKING THE CONNECTING ARM AND RELAY ARM ......3-32 CHECKING THE TIRES ................3-33 CHECKING AND TIGHTENING THE SPOKES ........3-33 CHECKING THE WHEELS ..............3-33 CHECKING THE WHEEL BEARINGS .............3-33 CHECKING THE CHASSIS FASTENERS ..........3-34 CHECKING AND LUBRICATING THE CABLES........3-34 LUBRICATING THE BRAKE LEVER ............3-34 LUBRICATING THE CLUTCH LEVER .............3-34 LUBRICATING THE PEDAL..............3-34 CHECKING THE SIDESTAND ..............3-34...

  • Page 89: Periodic Maintenance

    • From 4200 mi (7000 km) or 9 months, repeat the maintenance intervals starting from 1800 mi (3000 km) or 3 months. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 90 • Replace if necessary. Rear suspension • Apply molybdenum disulfide grease lightly. 18 *   link pivots • Apply Yamaha chain and cable lube or engine oil 19 * Control cables    10W-30 thoroughly. • Check operation and free play.

  • Page 91: Maintenance Intervals For Competition Use

    (e.g., rain, dirt, etc.). Therefore, earlier inspection is required by reference to the list below. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 92 PERIODIC MAINTENANCE Every third Every fifth After Every Item Routine race race break-in race required (or 500 km) (or 1000 km) • Inspect score marks.  • Inspect wear. 11 * Cylinder • Replace.  • Inspect housing, friction plate, ...
  • Page 93 PERIODIC MAINTENANCE Every third Every fifth After Every Item Routine race race break-in race required (or 500 km) (or 1000 km) • Inspect and adjust.     30 * Front fork(s) • Replace oil. • Replace oil seal. ...

  • Page 94: Pre-Operation Inspection And Maintenance

    PRE-OPERATION INSPECTION AND MAINTENANCE EAM20134 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating con- dition. Before using this machine, check the following points. EAM30209 GENERAL INSPECTION AND MAINTENANCE Item Inspect Page...

  • Page 95: Engine

    Turn the crankshaft counterclockwise with sic knowledge and skill concerning the servic- a wrench. ing of Yamaha motorcycles (e.g., Yamaha b. Align the top dead center (TDC) mark “a” dealers, service engineers, etc.). Those who on the generator rotor with the alignment have little knowledge and skill concerning ser- mark “b”...
  • Page 96 ENGINE • The adjusting pad number “a” is indicated on the top of the adjusting pad. • For the number on the originally installed ad- justing pad, convert the last digit of adjusting pad number as per the below table. 5.
  • Page 97 ENGINE • Make sure that adjusting pads are installed with their numbers facing upward. f. Install the camshafts (exhaust and intake). Refer to “CAMSHAFT” on page 5-14. g. Measure the valve clearance again. h. If the valve clearance is out of specifica- tion, repeat adjusting the valve clearance until it is within specification.

  • Page 98: Valve Clearance Shim Chart

    ENGINE EAM30383 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 99 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 100: Checking The Engine Idling Speed

    2. Measure the coolant temperature using the 5. Adjust: Yamaha diagnostic tool. • Engine idling speed Yamaha diagnostic tool USB (US) a. Turn the idle screw “1” to make an adjust- 90890-03269 ment. Yamaha diagnostic tool (A/I) 90890-03264 FI diagnostic tool sub–lead...

  • Page 101: Checking The Spark Plug

    ENGINE 2. Adjust: ECA24410 NOTICE • Throttle grip free play In order not to allow the dirt accumulated a. Loosen the locknut “1”. around the spark plug to drop from the spark b. Turn the adjuster “2” until the specified plug hole into the cylinder, clean it before re- throttle grip free play is obtained.

  • Page 102: Checking The Engine Oil Level

    ENGINE • Seat • Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1. EAM30224 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle upright on a level surface. 2. Start the engine, warm this up for 2–3 min- utes, and then stop the engine and wait about 1 minute.
  • Page 103 ENGINE Engine oil quantity Oil change 0.73 L (0.77 US qt, 0.64 Imp.qt) With oil filter removal 0.75 L (0.79 US qt, 0.66 Imp.qt) Quantity (disassembled) 0.95 L (1.00 US qt, 0.84 Imp.qt) c. Install the new oil filter element and the oil filter element cover.

  • Page 104: Adjusting The Clutch Lever Free Play

    ENGINE Clutch cable side ECA25840 NOTICE a. Slide the clutch cable cover. If no engine oil seeps out after one minute, b. Loosen the locknut “1”. immediately turn the engine off so it will not c. Turn the adjuster “2” until the specified seize.
  • Page 105 • Air filter element Damage  Replace. 6. Apply: • Yamaha foam air filter oil or other quality foam air filter oil a. Put the air filter element into a plastic bag and drip the filter oil into the bag.

  • Page 106: Checking The Throttle Body Joint

    ENGINE 8. Turn the plates “1” to the original position. EAM30222 CHECKING THE FUEL LINE 9. Install: 1. Remove: • Air filter case cover “1” • Seat • Fuel tank breather hose • Side cover (left/right) (to the air filter case cover) •...

  • Page 107: Checking The Exhaust System

    ENGINE c. Remove the tail pipe “3”, tail pipe gasket EAM30221 CHECKING THE EXHAUST SYSTEM “4” and spark arrester “5”. EWA19350 WARNING Pull the spark arrester out of the muffler. • Be sure the exhaust pipe and muffler are d. Remove the spark arrester gasket “6”. cool before cleaning the spark arrester.

  • Page 108: Checking The Coolant Level

    ENGINE 6. Check: 8. Install: • Gasket “1” • Exhaust pipe protector Damage  Replace. Exhaust pipe protector screw 10 N·m (1.0 kgf·m, 7.4 lb·ft) LOCTITE® EAM30210 CHECKING THE COOLANT LEVEL EWA13030 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot.

  • Page 109: Checking The Cooling System

    ENGINE be blown out, which could cause serious in- jury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter- clockwise toward the detent to allow any re- sidual pressure to escape.
  • Page 110 ENGINE EWA13040 WARNING • If coolant splashes in your eyes, thorough- ly wash them with water and consult a doc- tor. • If coolant splashes on your clothes, quickly wash it away with water and then with soap and water. •...

  • Page 111: Chassis

    CHASSIS system. Air in the brake system will consid- EAM20136 CHASSIS erably reduce braking performance. ECA13490 EAM30479 ADJUSTING THE FRONT DISC BRAKE NOTICE After adjusting the brake lever position, There should be no free play at the brake lever make sure there is no brake drag. end.

  • Page 112: Checking The Brake Fluid Level

    CHASSIS can indicate the presence of air in the brake and plastic parts. Therefore, always clean up system. Before running, bleed the brake sys- any spilt brake fluid immediately. tem. Air in the brake system will cause brak- ing performance to be reduced. EAM30231 CHECKING THE FRONT BRAKE PADS ECA13510...

  • Page 113: Checking The Rear Brake Hose

    CHASSIS brake several times. the reservoir to overflow. • Make sure that there is enough brake fluid be- 4. Check: • Brake hose fore applying the brake. Ignoring this precau- Brake fluid leaks  Replace the damaged tion could allow air to enter the brake system, brake hose.

  • Page 114: Drive Chain Slack

    CHASSIS h. Repeat steps (d) to (g) until all of the air bubbles have disappeared from the brake Measure drive chain slack between the drive fluid in the plastic hose. chain guide and the bottom of the chain as shown. During the procedure, keep adding brake fluid to the reservoir.

  • Page 115: Lubricating The Drive Chain

    CHASSIS Drive chain puller locknut 21 N·m (2.1 kgf·m, 15 lb·ft) EAM30251 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained proper- ly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas.

  • Page 116: Lubricating The Steering Head

    CHASSIS 4. Check: Ring nut (final tightening torque) • Front fork operation 7 N·m (0.7 kgf·m, 5.2 lb·ft) Push down hard on the handlebar several times and check if the front fork rebounds e. Check the steering head for looseness or smoothly.

  • Page 117: Adjusting The Front Fork Legs

    CHASSIS be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary. EAM30239 ADJUSTING THE FRONT FORK LEGS EWA19180 WARNING Compression damping • Always adjust the left and right front forks ECA24350 evenly.

  • Page 118: Checking The Rear Shock Absorber Assembly

    CHASSIS 3. Check: • Rear shock absorber assembly smooth ac- tion • Rear suspension link smooth action Sit astride the seat and shake your body up and down several times to check whether the rear shock absorber assembly operates smoothly. Unsmooth operation ...
  • Page 119 CHASSIS Spring preload adjusting positions Rebound damping Minimum Minimum (soft) Position in which the spring is 30 click(s) in direction “b”* turned in 1.5 mm (0.06 in) from Standard its free length. 11 click(s) in direction “b”* Standard Maximum (hard) Position in which the spring is 0 click(s) in direction “a”...

  • Page 120: Checking The Swingarm Operation

    CHASSIS Fast compression damping Slow compression damping Minimum (soft) Minimum (soft) 2 turn(s) in direction “b”* 20 click(s) in direction “b”* Standard Standard 1 turn(s) in direction “b”* 8 click(s) in direction “b”* Maximum (hard) Maximum (hard) 0 turn(s) in direction “b”* 0 click(s) in direction “b”* * With the adjusting screw fully turned in di- * With the adjusting screw fully turned in di-...

  • Page 121: Checking The Tires

    CHASSIS EAM30243 CHECKING THE TIRES A tight spoke will emit a clear, ringing tone; a 1. Measure: loose spoke will sound flat. • Tire pressure 2. Tighten: Out of specification  Regulate. • Spoke Tire air pressure (measured on (with a spoke nipple wrench “1”) cold tires) Front 100 kPa (1.00 kgf/cm², 15 psi)

  • Page 122: Checking The Chassis Fasteners

    CHASSIS EAM30253 CHECKING THE CHASSIS FASTENERS Recommended lubricant Lithium-soap-based grease Make sure that all nuts, bolts, and screws are properly tightened. Refer to “CHASSIS TIGHTENING TORQUES” EAM30504 CHECKING THE SIDESTAND on page 2-14. 1. Check: • Sidestand operation EAM30248 CHECKING AND LUBRICATING THE Check that the sidestand moves smoothly.

  • Page 123: Electrical System

    ELECTRICAL SYSTEM 4. Check: EAM20137 ELECTRICAL SYSTEM • Ignition timing Check whether the alignment mark “a” on the EAM30256 left crankcase cover is within the firing range CHECKING AND CHARGING THE BATTERY “b” on the generator rotor. Refer to “CHECKING AND CHARGING THE Incorrect firing range ...
  • Page 124 ELECTRICAL SYSTEM 3. Remove: • Headlight bulb “1” 4. Install: • Headlight bulb Fasten the new headlight bulb with the head- light bulb holder. ECA13690 NOTICE Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected.
  • Page 125 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE SEAT................4-4 INSTALLING THE AIR SCOOP..............4-4 REMOVING THE SIDE COVER ..............4-4 INSTALLING THE SIDE COVER ...............4-4 FRONT WHEEL ....................4-6 REMOVING THE FRONT WHEEL .............4-7 CHECKING THE FRONT WHEEL SENSOR AND SENSOR ROTOR..4-7 DISASSEMBLING THE FRONT WHEEL ...........4-7 CHECKING THE FRONT WHEEL .............4-8 ASSEMBLING THE FRONT WHEEL ............4-8 INSTALLING THE FRONT WHEEL ............4-10...
  • Page 126 INSTALLING THE REAR BRAKE MASTER CYLINDER ......4-36 HANDLEBAR....................4-37 REMOVING THE HANDLEBAR ...............4-38 CHECKING THE HANDLEBAR..............4-38 INSTALLING THE HANDLEBAR..............4-38 FRONT FORK....................4-43 REMOVING THE FRONT FORK LEGS ...........4-45 DISASSEMBLING THE FRONT FORK LEGS .........4-45 CHECKING THE FRONT FORK LEGS............4-46 ASSEMBLING THE FRONT FORK LEGS ..........4-47 INSTALLING THE FRONT FORK LEGS..........4-53 STEERING HEAD...................4-56 REMOVING THE LOWER BRACKET ............4-57...
  • Page 127 GENERAL CHASSIS EAM20094 GENERAL CHASSIS Removing the seat and battery 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 128 GENERAL CHASSIS Removing the side cover 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 1.3 N ・ m (0.13 kgf ・ m, 0.95 lb ・ ft) 7 N ・...
  • Page 129 GENERAL CHASSIS Removing the headlight assembly and multi-function meter 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 21 N ・...

  • Page 130: General Chassis

    GENERAL CHASSIS EAM30016 REMOVING THE SEAT The fuel tank cap cover and the seat are coupled d d d with each other with a plastic band. When removing the seat, always remove the fuel tank cap cover beforehand. 1. Remove: •...
  • Page 131 GENERAL CHASSIS a a a a. Projection b. Slot c. Rib (side cover) d. Rib (rear fender)

  • Page 132: Front Wheel

    FRONT WHEEL EAM20095 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) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 115 N ・...

  • Page 133: Removing The Front Wheel

    FRONT WHEEL front wheel sensor rotor. EAM30017 REMOVING THE FRONT WHEEL Iron powder/dust/solvent  Clean. ECA22340 NOTICE • The wheel sensor rotor is installed on the inner • Keep any type of magnets (including mag- side of the wheel hub. netic pick-up tools, magnetic screwdrivers, •...

  • Page 134: Checking The Front Wheel

    FRONT WHEEL c. Remove the bearings with a bearing pull- Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit EAM30018 2.0 mm (0.08 in) CHECKING THE FRONT WHEEL 1. Check: 6. Check: • Front wheel axle • Collar Roll the front wheel axle on a flat surface.
  • Page 135 FRONT WHEEL 3. Install: • Bearing (left side) “1” Use a socket “5” that matches the diameter of • Spacer “2” the bearing outer race and that of the oil seal. • Bearing (right side) “3” • Oil seal “4” •...

  • Page 136: Installing The Front Wheel

    FRONT WHEEL 4. Tighten: EAM30021 INSTALLING THE FRONT WHEEL • Front wheel axle nut “1” 1. Install: Front wheel axle nut • Front wheel 115 N·m (11.5 kgf·m, 85 lb·ft) Install the brake disc “1” between the brake pads ECA24430 “2”...
  • Page 137 FRONT WHEEL ing for looseness, and the front wheel sensor and sensor rotor installation conditions (warpage caused by overtorque, wrong in- stallation direction, rotor decentering, LOC- TITE® on the mounting surface of the rotor, deformation caused by an impact during ser- vice and caught foreign materials).
  • Page 138 REAR WHEEL EAM20096 REAR WHEEL Removing the rear wheel 12 N ・ m (1.2 kgf ・ m, 8.9 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 139: Rear Wheel

    REAR WHEEL Refer to “CHECKING THE TIRES” on page EAM30022 REMOVING THE REAR WHEEL 3-33 and “CHECKING THE WHEELS” on 1. Use a maintenance stand to raise the rear page 3-33. wheel off the ground. 3. Check: EWA13120 • Spoke WARNING Refer to “CHECKING AND TIGHTENING Securely support the vehicle so that there is...

  • Page 140: Assembling The Rear Wheel

    REAR WHEEL Rear wheel sprocket self-locking 50 N·m (5.0 kgf·m, 37 lb·ft) Tighten the self-locking nuts in stages and in a crisscross pattern. EAM30026 ASSEMBLING THE REAR WHEEL 1. Install: 2. Install: • Bearing (right side) “1” • Brake disc •...
  • Page 141 REAR WHEEL 2. Install: 5. Adjust: • Drive chain “1” • Drive chain slack “a” Drive chain slack (Maintenance Push the rear wheel “2” forward and install the stand) drive chain. 50.0–60.0 mm (1.97–2.36 in) Refer to “DRIVE CHAIN SLACK” on page 3-26.
  • Page 142 FRONT BRAKE EAM20097 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 143: Front Brake

    FRONT BRAKE Disassembling the front brake caliper 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw 4-17...
  • Page 144 FRONT BRAKE Removing the front brake master cylinder 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 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 ・...
  • Page 145 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Push rod Dust boot Circlip Washer Brake master cylinder kit 4-19...

  • Page 146: Introduction

    FRONT BRAKE b. Remove the brake caliper. EAM30028 INTRODUCTION c. Hold the dial gauge at a right angle against EWA19210 the brake disc surface. WARNING d. Measure the runout 1.5 mm (0.06 in) If you need to disassemble the disc brake above the brake disc edge.
  • Page 147 FRONT BRAKE d. Remove the pad pin and brake pads “4”. Bleed screw 6 N·m (0.6 kgf·m, 4.4 lb·ft) d. Install the brake pads “3” and the pad pin. • Install the brake pads with their projections “a” into the brake caliper recesses “b”. •...

  • Page 148: Removing The Front Brake Caliper

    FRONT BRAKE 4. Check: • Brake fluid level Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-24. 5. Check: • Brake lever operation A softy or spongy feeling  Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-25. b.

  • Page 149: Installing The Front Brake Caliper

    FRONT BRAKE cleaning and lubricating. Brake pad pin • Never use solvents on internal brake com- 17 N·m (1.7 kgf·m, 13 lb·ft) ponents as they will cause the piston seals to swell and distort. Refer to “CHECKING THE FRONT BRAKE •...

  • Page 150: Removing The Front Brake Master Cylinder

    FRONT BRAKE Refer to “BLEEDING THE HYDRAULIC 3. Check: BRAKE SYSTEM” on page 3-25. • Brake master cylinder reservoir cap 6. Check: 4. Check: • Brake fluid level • Brake hose The minimum level mark or below  Add. Cracks/damage/wear  Replace. Refer to “CHECKING THE BRAKE FLUID EAM30038 LEVEL”...

  • Page 151: Installing The Front Brake Master Cylinder

    FRONT BRAKE (to the brake master cylinder piston “2”) Install the spring with a smaller inside diameter to the brake master cylinder piston. 2. Install: • Copper washer • Brake hose • Union bolt 4. Install: Brake hose union bolt •...
  • Page 152 FRONT BRAKE 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 fluids may result in a harmful chemical reaction, leading to poor brake performance.

  • Page 153: Rear Brake

    REAR BRAKE EAM20098 REAR BRAKE Removing the rear brake caliper 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 13 lb ・ ft) 30 N ・...
  • Page 154 REAR BRAKE Disassembling the rear brake caliper 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw 4-28...
  • Page 155 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 Job/Parts to remove Q’ty...
  • Page 156 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Push rod Brake master cylinder kit 4-30...

  • Page 157: Introduction

    REAR BRAKE EAM30040 INTRODUCTION Brake disc runout limit (as mea- sured on wheel) EWA19260 0.15 mm (0.0059 in) WARNING If you need to disassemble the disc brake 4. Replace: components, observe the following precau- • Brake disc tions. Refer “ASSEMBLING REAR •...
  • Page 158 REAR BRAKE d. Install the brake pads “3” and the pad pin “4”. • Install the brake pads with their projections “a” into the brake caliper recesses “b”. • Temporarily tighten the pad pin at this point. 2. Measure: • Brake pad wear limit “a” Out of specification ...

  • Page 159: Removing The Rear Brake Caliper

    REAR BRAKE 4. Check: • Brake fluid level Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-24. 5. Check: • Brake pedal operation A softy or spongy feeling  Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-25. b.

  • Page 160: Installing The Rear Brake Caliper

    REAR BRAKE cleaning and lubricating. Brake pad pin • Never use solvents on internal brake com- 17 N·m (1.7 kgf·m, 13 lb·ft) ponents as they will cause the piston seals Brake pad pin plug to swell and distort. 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) •...

  • Page 161: Checking The Rear Brake Master Cylinder

    REAR BRAKE tem. Specified brake fluid 1. Remove: DOT 4 • Union bolt 1. Wash the brake master cylinder and the • Copper washer brake master cylinder kit with brake fluid. • Brake hose 2. Install: • Primary cylinder cup “1” To drain any remaining brake fluid, place a con- •...

  • Page 162: Installing The Rear Brake Master Cylinder

    REAR BRAKE 4. Install: to the specified level. • Brake master cylinder kit “1” Specified brake fluid • Push rod “2” DOT 4 • Circlip “3” • Dust boot “4” EWA13090 WARNING • Before installation, apply brake fluid to the •...
  • Page 163 HANDLEBAR EAM20099 HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Headlight 4-1. Clutch cable Disconnect. Clutch switch Clutch lever holder Engine stop switch Brake master cylinder Throttle cable cap Throttle cable (pull) Disconnect.

  • Page 164: Removing The Handlebar

    HANDLEBAR EAM30052 REMOVING THE HANDLEBAR 1. Stand the vehicle upright on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Clutch switch “1” EAM30053 CHECKING THE HANDLEBAR 1.
  • Page 165 HANDLEBAR ECA14250 NOTICE • First, tighten the bolts on the front side of the handlebar holder, and then on the rear side. • Turn the handlebar all the way to the left and right. If there is any contact with the fuel tank, adjust the handlebar position.
  • Page 166 HANDLEBAR Engine stop switch screw 0.5 N·m (0.05 kgf·m, 0.37 lb·ft) • The engine stop switch “1” should be installed according to the dimensions shown. • Pass the engine stop switch lead through the middle of the clutch lever holder. 30 50˚...
  • Page 167 HANDLEBAR Apply the lithium-soap-based grease on the throttle grip sliding surface. 11.Install: • Throttle cable “1” Slightly coat the end of throttle cable and inside of throttle grip with lithium-soap-based grease. Then, mount the throttle grip onto the handlebar. 13.Install: •...
  • Page 168 HANDLEBAR 15.Adjust: • Throttle grip free play Refer to “CHECKING THE THROTTLE GRIP” on page 3-12. Throttle grip free play 3.0–6.0 mm (0.12–0.24 in) 4-42...

  • Page 169: Front Fork

    FRONT FORK EAM20100 FRONT FORK Removing the front fork legs 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 3.8 N ・...
  • Page 170 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) 55 N ・...

  • Page 171: Removing The Front Fork Legs

    FRONT FORK • Hold the locknut and remove the adjuster. EAM30055 REMOVING THE FRONT FORK LEGS 1. Use a maintenance stand to raise the front ECA24520 NOTICE wheel off the ground. Do not remove the locknut as the damper rod EWA13120 may go into the damper assembly and not be WARNING...

  • Page 172: Checking The Front Fork Legs

    FRONT FORK dial gauge reading. EWA13650 WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Check: • Outer tube Scratches/wear/damage  Replace. 3. Measure: • Fork spring free length “a” 5. Remove: Out of specification ...

  • Page 173: Assembling The Front Fork Legs

    1. Stretch the damper assembly fully. 2. Fill: • Damper assembly Recommended oil Yamaha Suspension Oil S1 Standard oil amount 7. Check: 216 cm³ (7.30 US oz, 7.62 Imp.oz) • Adjuster “1”...
  • Page 174 FRONT FORK 4. Measure: 6. Loosen: • Oil level (left and right) “a” • Compression damping force adjuster “1” Out of specification  Regulate. • Before loosening the damping force adjuster, Standard oil level record the setting position. 145–148 mm (5.71–5.83 in) •...
  • Page 175 FRONT FORK Base valve 28 N·m (2.8 kgf·m, 21 lb·ft) Hold the damper assembly with the cap bolt ring wrench “2” and use the cap bolt wrench “3” to tighten the base valve. Cap bolt wrench 90890-01500 Cap bolt wrench 12.Allow the overflowing oil to escape at the hole YM-01500 “a”...
  • Page 176 FRONT FORK • Apply the lithium-soap-based grease on the dust seal lip and oil seal lip. • Apply the fork oil on the inner tube. • Install the scraper to the inner tube as shown in the illustration. • When installing the oil seal, use vinyl seat “a” with fork oil applied to protect the oil seal lip.
  • Page 177 FRONT FORK Fork seal driver 90890-01502 Fork seal driver (48) YM-A0948 22.Measure: • Distance “a” Out of specification  Turn into the locknut. Distance “a” 16 mm (0.63 in) or more 19.Install: Between the damper assembly • Stopper ring “1” “1”...
  • Page 178 FRONT FORK ECA24560 NOTICE Allow the damper assembly to slide slowly down the inner tube until it contacts the bot- tom of the inner tube. Be careful not to dam- age the inner tube. 27.Measure: • Gap “a” between the adjuster “1” and the locknut “2”...

  • Page 179: Installing The Front Fork Legs

    55 N·m (5.5 kgf·m, 41 lb·ft) LOCTITE® 32.Install: • Protector guide “1” 30.Fill: • Front fork leg Recommended oil Yamaha Suspension Oil S1 Standard oil amount 295 cm³ (9.97 US oz, 10.4 Imp.oz) EAM30059 INSTALLING THE FRONT FORK LEGS Extent of adjustment 1. Install: 260–365 cm³...
  • Page 180 FRONT FORK Cap bolt ring wrench 90890-01501 Cap bolt ring wrench YM-01501 5. Install: • Speed sensor lead “1” • Front brake hose “2” • Plate “3” (to the left front fork protector) 3. Adjust: Plate bolt • Front fork top end “a” 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) Front fork top end (standard) “a”...
  • Page 181 FRONT FORK 8. Adjust: • Compression damping force Turn in the damping adjuster “1” finger-tight and then turn out to the originally set position. 4-55...

  • Page 182: Steering Head

    STEERING HEAD EAM20101 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 183: Removing The Lower Bracket

    STEERING HEAD EAM30060 ECA14270 REMOVING THE LOWER BRACKET NOTICE 1. Use a maintenance stand to raise the front If the bearing race is not installed properly, wheel off the ground. the steering head pipe could be damaged. EWA13120 WARNING Always replace the bearing and the bearing race Securely support the vehicle so that there is as a set.
  • Page 184 STEERING HEAD 2. Install: • Bearing race • Upper bearing “1” • Bearing race cover “2” Apply the lithium-soap-based grease on the bearing and bearing race cover lip. 5. Check the steering stem by turning this lock to lock. If there is any binding, remove the steering stem and check the steering bear- ing.
  • Page 185 STEERING HEAD Upper bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) • Pinch bolt (lower bracket) “2” Lower bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) EWA19330 WARNING Tighten the lower bracket to specified 8. Install: torque. If torqued too much, it may cause the •...

  • Page 186: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAM20102 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 56 N ・ m (5.6 kgf ・ m, 41 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 53 N ・ m (5.3 kgf ・ m, 39 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 187 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 56 N ・ m (5.6 kgf ・ m, 41 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 53 N ・ m (5.3 kgf ・ m, 39 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 188 REAR SHOCK ABSORBER ASSEMBLY Disassembling the relay arm 80 N ・ m (8.0 kgf ・ m, 59 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Relay arm Connecting arm Collar Oil seal Washer Bearing 4-62...

  • Page 189: Handling The Rear Shock Absorber

    • To dispose of a damaged or a worn-out rear shock absorber, take the unit to your EAM30067 CHECKING THE REAR SHOCK ABSORBER Yamaha dealer for this disposal procedure. ASSEMBLY 1. Check: • Rear shock absorber rod Bends/damage  Replace the rear shock absorber assembly.

  • Page 190: Checking The Connecting Arm And Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY EAM30068 CHECKING THE CONNECTING ARM AND RELAY ARM 1. Check: • Connecting arm • Relay arm Damage/wear  Replace. 2. Check: • Bearing • Collar Damage/pitting/scratches  Replace the bearings and collars as a set. EAM30070 INSTALLING THE REAR SHOCK 3.
  • Page 191 REAR SHOCK ABSORBER ASSEMBLY • Relay arm nut (swingarm side) Installed depth “a” 4.25 mm (0.17 in) Relay arm nut (swingarm side) 70 N·m (7.0 kgf·m, 52 lb·ft) • Rear shock absorber assembly lower nut Rear shock absorber assembly lower nut 53 N·m (5.3 kgf·m, 39 lb·ft) 5.

  • Page 192: Swingarm

    SWINGARM EAM20103 SWINGARM Removing the swingarm 70 N ・ m (7.0 kgf ・ m, 52 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 4.0 N ・ m (0.40 kgf ・ m, 3.0 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 193: Removing The Swingarm

    SWINGARM • Bearing EAM30071 REMOVING THE SWINGARM 4. Check: 1. Use a maintenance stand to raise the rear • Oil seal wheel off the ground. Damage  Replace. EWA13120 • Bearing WARNING • Bushing Securely support the vehicle so that there is Free play exists/unsmooth revolution/rust ...
  • Page 194 SWINGARM 4. Install: • Rear wheel Refer to “REAR WHEEL” on page 4-12. 5. Adjust: • Drive chain slack Refer to “DRIVE CHAIN SLACK” on page 3-26. Drive chain slack (Maintenance stand) 50.0–60.0 mm (1.97–2.36 in) 4-68...

  • Page 195: Chain Drive

    CHAIN DRIVE EAM20104 CHAIN DRIVE Removing the drive chain Order Job/Parts to remove Q’ty Remarks Drive sprocket Refer to “ENGINE REMOVAL” on page 5-6. Drive chain Drive sprocket cover Bracket Drive sprocket nut Lock washer Drive sprocket 4-69...

  • Page 196: Removing The Drive Chain

    CHAIN DRIVE EAM30075 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a maintenance stand so that the rear wheel is elevated. 2.

  • Page 197: Checking The Drive Sprocket

    CHAIN DRIVE b. Correct 1. Drive chain roller 2. Drive sprocket EAM30078 CHECKING THE REAR WHEEL SPROCKET Refer to “CHECKING AND REPLACING THE REAR WHEEL SPROCKET” on page 4-13. EAM30079 INSTALLING THE DRIVE CHAIN 1. Install: 4. Check: • Drive chain •...
  • Page 198 CHAIN DRIVE ECA24590 NOTICE A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swing- arm or cause an accident. Therefore, keep the drive chain slack within the specified lim- its.

  • Page 199: Engine

    ENGINE LUBRICATION SYSTEM CHART AND DIAGRAMS ........5-1 ENGINE OIL LUBRICATION CHART............5-1 LUBRICATION DIAGRAMS ...............5-2 ENGINE REMOVAL ..................5-6 REMOVING THE ENGINE ...............5-11 INSTALLING THE ENGINE ..............5-11 INSTALLING THE EXHAUST PIPE AND MUFFLER .......5-12 CAMSHAFT ....................5-14 REMOVING THE CAMSHAFT ..............5-16 CHECKING THE CAMSHAFT ..............5-17 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET...5-18 CHECKING THE TIMING CHAIN TENSIONERS........5-18 CHECKING THE DECOMPRESSION SYSTEM ........5-18...
  • Page 200 CHECKING THE STARTER CLUTCH .............5-42 INSTALLING THE STARTER CLUTCH ...........5-42 ELECTRIC STARTER..................5-44 CHECKING THE STARTER MOTOR ............5-46 ASSEMBLING THE STARTER MOTOR ..........5-46 CLUTCH......................5-48 REMOVING THE CLUTCH ..............5-51 CHECKING THE FRICTION PLATES ............5-51 CHECKING THE CLUTCH PLATES ............5-51 CHECKING THE CLUTCH SPRINGS ............5-51 CHECKING THE CLUTCH HOUSING .............5-51 CHECKING THE CLUTCH BOSS ............5-52 CHECKING THE PRESSURE PLATE .............5-52...

  • Page 201: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAM20185 LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30526 ENGINE OIL LUBRICATION CHART 1. Intake camshaft 2. Exhaust camshaft 3. Piston 4. Oil filter element 5. Oil nozzle 6. Relief valve 7. Oil pump 8. Oil strainer 9.

  • Page 202: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30507 LUBRICATION DIAGRAMS 1. Connecting rod 2. Crankshaft 3. Main axle 4. Oil strainer 5. Drive axle...
  • Page 203 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter element 2. Oil pump...
  • Page 204 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft...
  • Page 205 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil pressure check bolt 3. Oil pump 4. Oil filter element...

  • Page 206: Engine Removal

    ENGINE REMOVAL EAM20105 ENGINE REMOVAL Removing the exhaust pipe 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 7 N ・...
  • Page 207 ENGINE REMOVAL Removing the exhaust pipe 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 7 N ・...
  • Page 208 ENGINE REMOVAL Removing the electronic parts 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Use a maintenance stand to raise the front wheel off the ground.
  • Page 209 ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 85 N ・ m (8.5 kgf ・ m, 63 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 53 N ・...
  • Page 210 ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 85 N ・ m (8.5 kgf ・ m, 63 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 53 N ・...

  • Page 211: Removing The Engine

    ENGINE REMOVAL EAM30161 REMOVING THE ENGINE 1. Remove: • Exhaust pipe 2 Put the exhaust pipe 2 into the state as shown by moving this, and then remove it. 2. Remove: • Pivot shaft “1” If the pivot shaft is pulled all the way out, the EAM30164 INSTALLING THE ENGINE swingarm will come loose.

  • Page 212: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL • Engine mounting bolt (upper side) “10” Engine mounting bolt (upper side) 45 N·m (4.5 kgf·m, 33 lb·ft) Apply molybdenum disulfide grease to the pivot shaft. 2. Install: • Clamp • Exhaust pipe 2 “1” • Bolt (exhaust pipe 2) “2” 8 10 Install and temporarily tighten the exhaust pipe 2 and silencer with its end positioned as shown...
  • Page 213 ENGINE REMOVAL A. Exhaust pipe 1 and exhaust pipe 2 Install and temporarily tighten the silencer so B. Exhaust pipe 2 and silencer that its joint is positioned as shown with respect to the exhaust pipe 2. 2 mm (0.08 in) 4.

  • Page 214: Camshaft

    Refer to “FUEL TANK” on page 7-1. Ignition coil Refer to “ENGINE REMOVAL” on page 5-6. Cylinder head breather hose Spark plug Cylinder head cover Timing chain guide (top side) Cylinder head cover gasket * Yamaha bond No. 1215 (Three bond No.1215®) 5-14...
  • Page 215 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 216: Removing The Camshaft

    CAMSHAFT EAM30080 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: • Remove the bolts (camshaft cap) in a criss- •...

  • Page 217: Checking The Camshaft

    CAMSHAFT c. Install the dowel pins and the camshaft EAM30081 CHECKING THE CAMSHAFT caps. 1. Check: • Camshaft lobe • Tighten the camshaft cap bolts in a crisscross Blue discoloration/pitting/scratches  Re- pattern from innermost to outer caps. place the camshaft. •...

  • Page 218: Checking The Timing Chain And Camshaft Sprocket

    CAMSHAFT EAM30082 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET 1. Check: • Timing chain “1” Damage/stiffness  Replace the timing chain and camshaft as a set. 2. Check: • Camshaft sprocket More than 1/4 tooth wear “a”  Replace the timing chain and camshaft as a set.
  • Page 219 CAMSHAFT a. Turn the crankshaft counterclockwise with ECA24620 NOTICE a wrench. Do not turn the crankshaft during the cam- shaft installation. Damage or improper valve • Apply molybdenum disulfide oil to the cam- timing will result. shafts. • Apply the engine oil on the decompression d.
  • Page 220 Before installation, apply the sealant to the cylin- ward, install the gasket “1”, the timing der head cover gasket. chain tensioner “2” and tighten the bolts “3”. Yamaha bond No. 1215 Bolt (timing chain tensioner) 90890-85505 10 N·m (1.0 kgf·m, 7.4 lb·ft) Three bond No. 1215®...

  • Page 221: Cylinder Head

    CYLINDER HEAD EAM20107 CYLINDER HEAD Removing the cylinder head 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 60˚ 60˚ 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・...
  • Page 222 CYLINDER HEAD Removing the cylinder head 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 60˚ 60˚ 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・...

  • Page 223: Removing The Cylinder Head

    CYLINDER HEAD page 5-29. EAM30086 REMOVING THE CYLINDER HEAD • Cylinder head coolant passages 1. Remove: Mineral deposits/rust  Eliminate. • Cylinder head bolt and nut 3. Measure: • Cylinder head warpage • Loosen the bolts in the proper sequence as Out of specification ...
  • Page 224 CYLINDER HEAD 2. Install: • Washer “1” • Bolt (M9  145 mm (5.71 in)) “2” • Bolt (M9  135 mm (5.31 in)) “3” • Nut “4” e. Remove the one bolt according to the tightening order of the bolts. f.
  • Page 225 CYLINDER HEAD Bolt [1], [2], [3], [4] Specified angle 60 j. Put a mark on the corner of the bolt (cylin- der head) and the cylinder head. k. Finally, tighten all bolts (cylinder head) fur- ther according to the tightening order. Tighten the bolts in two steps 60...
  • Page 226 VALVES AND VALVE SPRINGS EAM20108 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-21. Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Intake valve...

  • Page 227: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAM30090 REMOVING THE VALVES Check that there are no kerosene leaks from the valve seat “1”. Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure that the valves are properly sealed. 1.

  • Page 228: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS head to 100 °C (212 °F) in an oven. a. Remove the valve guide with the valve guide remover “1”. EAM30091 CHECKING THE VALVES AND VALVE GUIDES 1. Measure: b. Install the new valve guide with the valve •...

  • Page 229: Checking The Valve Seats

    VALVES AND VALVE SPRINGS Intake Valve guide remover (ø5) 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø5) 90890-04098 Valve guide installer (5.0 mm) YM-04098 Valve guide reamer (ø5) 90890-04099 EAM30092 Valve guide reamer (5.0 mm) CHECKING THE VALVE SEATS YM-04099 1.

  • Page 230: Checking The Valve Springs

    VALVES AND VALVE SPRINGS c. Press the valve through the valve guide b. Apply molybdenum disulfide oil onto the and onto the valve seat to make a clear valve stem. impression. c. Install the valve into the cylinder head. d. Measure the valve seat contact width “c”. d.

  • Page 231: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS Free length limit (intake) 34.94 mm (1.38 in) Free length limit (exhaust) 33.82 mm (1.33 in) 3. Install: • Spring seat “1” • Valve stem seal “2” • Valve “3” • Valve spring “4” • Valve spring retainer “5” EAM30094 (to the cylinder head) CHECKING THE VALVE LIFTERS...
  • Page 232 VALVES AND VALVE SPRINGS 5. To fasten the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. ECA13800 NOTICE Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Adjusting pad “1” •...

  • Page 233: Cylinder And Piston

    CYLINDER AND PISTON EAM20109 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 Job/Parts to remove Q’ty Remarks Cylinder head...

  • Page 234: Removing The Piston

    CYLINDER AND PISTON EAM30096 REMOVING THE PISTON 1. Remove: • Piston pin clip “1” • Piston pin “2” • Piston “3” ECA13810 NOTICE Do not use a hammer to drive the piston pin out. • Before removing the piston pin clip, cover the EAM30097 CHECKING THE CYLINDER AND PISTON crankcase opening with a cloth to prevent the...

  • Page 235: Checking The Piston Rings

    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 236: Installing The Piston And Cylinder

    CYLINDER AND PISTON Piston pin outside diameter limit 15.971 mm (0.6288 in) 3. Measure: • Piston pin bore inside diameter “b” Out of specification  Replace the piston. Piston pin bore inside diameter limit 16.043 mm (0.6316 in) 2. Install: •...
  • Page 237 CYLINDER AND PISTON (exhaust side) through the timing chain cavity. 3. Lubricate: • Piston • Piston ring • 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.

  • Page 238: Generator

    GENERATOR EAM20183 GENERATOR Removing the stator coil assembly 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 10 N ・...

  • Page 239: Removing The Generator

    • Stator coil assembly “2” outer surface “b” the T25 bit. Damage  Inspect the crankshaft runout and • Pass the stator coil assembly lead through the crankshaft bearing. crankcase cover side. Yamaha bond No. 1215 90890-85505 Three bond No. 1215® 5-39...
  • Page 240 GENERATOR • Crankcase cover (left) “3” • Lead holder “4” • Bolt (left crankcase cover) “5” Bolt (left crankcase cover) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Tighten the bolts in stages and in a crisscross pattern. 2. Install: • Woodruff key “1” •...

  • Page 241: Starter Clutch

    STARTER CLUTCH EAM20175 STARTER CLUTCH Removing the starter clutch 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Refer to “CHANGING THE ENGINE OIL” on Engine oil page 3-14. Clutch Refer to “CLUTCH” on page 5-48. Clutch housing Starter clutch gear Starter clutch assembly...

  • Page 242: Removing The Starter Clutch

    STARTER CLUTCH EAM30469 REMOVING THE STARTER CLUTCH 1. Remove: • Starter clutch screw “1” While holding the side of the clutch housing “2” with the sheave holder “3” as shown, remove the starter clutch screws “1”. Sheave holder 90890-01903 3. Check: Primary clutch holder YS-01880-A •...
  • Page 243 STARTER CLUTCH toward the primary driven gear. • While holding the side of the clutch housing “1” with the sheave holder “2” as shown, tighten the starter clutch screws “3”. Sheave holder 90890-01903 Primary clutch holder YS-01880-A 2. Install: • Absorber “1” Install the absorber “1”...

  • Page 244: Electric Starter

    ELECTRIC STARTER EAM20110 ELECTRIC STARTER Removing the starter motor 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Exhaust pipe Refer to “ENGINE REMOVAL”...
  • Page 245 ELECTRIC STARTER Disassembling the starter motor 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Starter motor assembly O-ring Starter motor front cover Washer Starter motor front cover...

  • Page 246: Checking The Starter Motor

    ELECTRIC STARTER EAM30106 CHECKING THE STARTER MOTOR Brush overall length limit 3.5 mm (0.14 in) 1. Check: • Commutator Dirt  Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification  Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator.
  • Page 247 ELECTRIC STARTER ECA24650 NOTICE Be careful not to damage the brush during installation. 5. Install: • Bolt “1” • O-ring “2” Apply the lithium-soap-based grease on the O- 3. Install: ring. • Gasket “1” • Starter motor yoke “2” • Install the starter motor yoke with its groove “a” facing starter motor rear cover.

  • Page 248: Clutch

    CLUTCH EAM20111 CLUTCH Removing the clutch 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) 95 N ・...
  • Page 249 CLUTCH Removing the clutch 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) 95 N ・...
  • Page 250 CLUTCH Removing the right crankcase cover Order Job/Parts to remove Q’ty Remarks Right engine guard Refer to “ENGINE REMOVAL” on page 5-6. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-14. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-21.

  • Page 251: Removing The Clutch

    CLUTCH EAM30108 REMOVING THE CLUTCH Friction plate 1 thickness 2.70–2.90 mm (0.106–0.114 in) 1. Straighten the clutch boss nut rib “a”. Wear limit 2.60 mm (0.102 in) Friction plate 2 thickness 2.72–2.88 mm (0.107–0.113 in) Wear limit 2.62 mm (0.103 in) EAM30110 CHECKING THE CLUTCH PLATES 1.

  • Page 252: Checking The Clutch Boss

    CLUTCH ratic clutch operation. EAM30484 CHECKING THE PUSH RODS 1. Check: • Push rod 1 “1” • Bearing/Washer “2” • Push rod 2 “3” • Ball “4” Cracks/damage/wear  Replace. 1 1 1 EAM30113 CHECKING THE CLUTCH BOSS 1. Check: •...
  • Page 253 CLUTCH • Washer “4” Apply the engine oil on the primary driven gear inner circumference. 2. Install: • Right crankcase cover “1” • Right crankcase cover bolt “2” Right crankcase cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) 5. Install: •...
  • Page 254 CLUTCH (to the push rod 1 “4”) Apply the engine oil on the bearing, washer and push rod 1. 8. Install: • Push rod 2 “1” • Ball “2” • Push rod 1 “3” Apply the engine oil on the push rod 1, 2 and 6.
  • Page 255 CLUTCH 10.Install: • Clutch spring • Clutch spring bolt Clutch spring bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Tighten the bolts in stages and in a crisscross pattern. 11.Install: • Gasket “1” 12.Install: • Clutch cover • 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...

  • Page 256: Shift Shaft

    SHIFT SHAFT EAM20113 SHIFT SHAFT Removing the shift shaft and stopper lever 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 10 N ・...

  • Page 257: Removing The Segment

    SHIFT SHAFT EAM30124 REMOVING THE SEGMENT 1. Remove: • Bolt (segment) “1” • Segment “2” Turn the segment counterclockwise until it stops and loosen the bolt. ECA24670 NOTICE If the segment gets an impact, the stopper le- EAM30127 ver may be damaged. Take care not to give CHECKING THE STOPPER LEVER an impact to it when removing the bolt.
  • Page 258 SHIFT SHAFT Segment bolt 30 N·m (3.0 kgf·m, 22 lb·ft) • Align the notch “a” on the segment with the pin “b” on the shift cam. • With the stopper lever pushed down, install the segment. ECA24680 NOTICE 6. Tighten: If the segment gets an impact, the stopper le- •...
  • Page 259 SHIFT SHAFT Align the punch mark “a” on the shift shaft with the punch mark “b” in the shift pedal. 5-59...

  • Page 260: Oil Pump

    OIL PUMP EAM20182 OIL PUMP 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 Job/Parts to remove Q’ty Remarks Primary driven gear Refer to “CLUTCH”...
  • Page 261 OIL PUMP Removing the balancer Order Job/Parts to remove Q’ty Remarks Primary driven gear Refer to “CLUTCH” on page 5-48. Right crankcase cover Refer to “CLUTCH” on page 5-48. Stator coil assembly Refer to “GENERATOR” on page 5-38. Nut (balancer) Nut (primary drive gear) Nut (balancer weight gear) Conical washer...

  • Page 262: Removing The Balancer

    OIL PUMP EAM30133 REMOVING THE BALANCER 1. Remove: • Oil pump 2. 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 4.

  • Page 263: Installing The Oil Pump

    OIL PUMP mary drive gear and collar. 2. Install: • Outer rotor “1” 2. Install: • Collar “1” Apply the engine oil on the outer rotor. • Balancer weight gear “2” Install the balancer weight gear and balancer shaft with their lower splines “a” aligning with each other.
  • Page 264 OIL PUMP 5. Install: • Conical washer “1” • Balancer weight gear nut “2” Balancer weight gear nut 50 N·m (5.0 kgf·m, 37 lb·ft) • Primary drive gear “3” • Conical washer “4” • Primary drive gear nut “5” Primary drive gear nut 105 N·m (10.5 kgf·m, 77 lb·ft) LOCTITE®...
  • Page 265 OIL PUMP 5 7 mm (0.02 0.28 in) A. Primary drive gear side B. Crankcase cover side 5-65...

  • Page 266: Crankcase

    CRANKCASE EAM20116 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) 12 N ・...
  • Page 267 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 Job/Parts to remove Q’ty...

  • Page 268: Disassembling The Crankcase

    CRANKCASE EAM30147 DISASSEMBLING THE CRANKCASE 1. Separate: • Right crankcase • Left crankcase a. Remove the crankcase bolts. c. Remove the dowel pins. 2. Remove: • Bearing “1” • Remove the bearing from the crankcase by pressing its inner race. •...

  • Page 269: Assembling The Crankcase

    Install the bearing by pressing its outer race par- allel. 3. Apply: • Sealant (to the crankcase mating surface) Yamaha bond No. 1215 90890-85505 Three bond No. 1215® 4. 45 mm (1.77 in) 5. 60 mm (2.36 in) 6. 75 mm (2.95 in) 4.

  • Page 270: Crankshaft And Balancer Shaft

    CRANKSHAFT AND BALANCER SHAFT EAM20184 CRANKSHAFT AND BALANCER SHAFT Removing the crankshaft assembly and balancer shaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-66. Transmission Refer to “TRANSMISSION” on page 5-73. Balancer shaft Crankshaft assembly 5-70...

  • Page 271: Removing The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT Out of specification  Replace the crank- EAM30491 REMOVING THE CRANKSHAFT shaft, bearing or both. 1. Remove: • Balancer shaft “1” Turn the crankshaft slowly. Remove the balancer shaft with its flat side “a” Runout limit facing the crankshaft.

  • Page 272: Installing The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT EAM30493 INSTALLING THE CRANKSHAFT 1. Install: • Crankshaft assembly Install the crankshaft assembly with the crank- shaft installer pot “1”, crankshaft installer bolt “2”, adapter (M12) “3” and spacer “4”. Crankshaft installer pot 90890-01274 Installing pot YU-90058 Crankshaft installer bolt 90890-01275...

  • Page 273: Transmission

    TRANSMISSION EAM20118 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-6. Separate. Crankcase Refer to “CRANKCASE” on page 5-66. Main axle Drive axle Long shift fork guide bar Short shift fork guide bar Spring Shift cam...

  • Page 274: Removing The Transmission

    TRANSMISSION EAM30153 REMOVING THE TRANSMISSION 1. Remove: • Long shift fork guide bar “1” • Short shift fork guide bar “2” • Shift cam “3” • Shift fork 3 “4” • Shift fork 2 “5” • Shift fork 1 “6” •...

  • Page 275: Installing The Transmission

    TRANSMISSION install. 2. Measure: • Drive axle runout 2. Install: (with a centering device and dial gauge “1”) • 2nd wheel gear (29T) “1” Out of specification  Replace the drive axle. • 5th wheel gear (22T) “2” • 3rd wheel gear (26T) “3” Drive axle runout limit •...
  • Page 276 TRANSMISSION 6. Install: • Shift fork 1 (L) “1” • Shift fork 2 (C) “2” • Shift fork 3 (R) “3” • Shift cam “4” (to the main axle and the drive axle) • Apply engine oil to the shift fork grooves. •...
  • Page 277 TRANSMISSION 7. Install: • Long shift fork guide bar “1” • Short shift fork guide bar “2” • Spring “3” • Screw the spring into the shift fork guide bar lightly beforehand. • Apply the engine oil on the shift fork guide bars. 8.
  • Page 278 TRANSMISSION 5-78...

  • Page 279: Cooling System

    COOLING SYSTEM COOLING SYSTEM DIAGRAMS ..............6-1 RADIATOR......................6-2 CHECKING THE RADIATOR ..............6-4 INSTALLING THE RADIATOR ..............6-4 WATER PUMP ....................6-6 DISASSEMBLING THE WATER PUMP .............6-7 CHECKING THE WATER PUMP ...............6-7 ASSEMBLING THE WATER PUMP ............6-7...

  • Page 280: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAM20186 COOLING SYSTEM DIAGRAMS 1. Radiator hose 1 2. Radiator (right) 3. Radiator hose 4 4. Water pump 5. Radiator hose 3 6. Radiator (left)

  • Page 281: Radiator

    RADIATOR EAM20138 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) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 1.5 N ・...
  • Page 282 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) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 1.5 N ・...

  • Page 283: Checking The Radiator

    RADIATOR EAM30341 CHECKING THE RADIATOR Radiator cap valve opening pres- sure EWA13030 107.9–137.3 kPa (1.08–1.37 WARNING kgf/cm², 15.6–19.9 psi) A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- No stay  Replace. gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in- Radiator cap tester jury.
  • Page 284 RADIATOR 4. Activate the tester to apply the test pressure. Test pressure value 137.3 kPa (1.37 kgf/cm², 19.9 psi) ECA24270 NOTICE • Do not apply such a high pressure as ex- ceeds the test pressure. • Make sure that a checkup after the cylinder head gasket is replaced is made after 3 min- utes of warm-up.

  • Page 285: Water Pump

    WATER PUMP EAM20139 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) 14 N ・ m (1.4 kgf ・ m, 10 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 286: Disassembling The Water Pump

    WATER PUMP EAM30494 DISASSEMBLING THE WATER PUMP • 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 287 WATER PUMP 4. Install: • Dowel pin “1” • Gasket “2” 5. 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 288 WATER PUMP...

  • Page 289: 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 CHECKING THE FUEL PUMP OPERATION ..........7-2 INSTALLING THE FUEL PUMP ..............7-3 INSTALLING THE FUEL TANK ..............7-3 THROTTLE BODY ....................7-4 CHECKING THE INJECTOR..............7-7 CHECKING THE THROTTLE BODY ............7-7 CHECKING THE FUEL PRESSURE............7-7...

  • Page 290: Fuel Tank

    FUEL TANK EAM20140 FUEL TANK Removing the fuel tank 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 4.0 N ・...

  • Page 291: Removing The Fuel Tank

    FUEL TANK EAM30263 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose coupler EWA19370 WARNING Cover the fuel hose connection with a cloth when disconnecting it. This is because re- sidual pressure in the fuel hose could cause fuel to spurt out when the hose is removed.

  • Page 292: Installing The Fuel Pump

    FUEL TANK • Take care not to kink or pinch the fuel hose. EAM30266 INSTALLING THE FUEL PUMP 1. Install: • Insert the fuel hose into the fuel pipe securely • Fuel pump gasket until you hear a “click”. • Fuel filter •...

  • Page 293: Throttle Body

    THROTTLE BODY EAM20141 THROTTLE BODY Removing the throttle body 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) 8 N ・...
  • Page 294 THROTTLE BODY Removing the throttle body 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) 8 N ・...
  • Page 295 THROTTLE BODY Removing the injector 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel inlet pipe Injector Gasket Throttle position sensor Intake air pressure sensor...

  • Page 296: Checking The Injector

    THROTTLE BODY EAM30271 CHECKING THE INJECTOR 1. Check: • Injector Obstruction  Replace, and check the fuel pump and the fuel injection system. Refer to “FUEL INJECTION SYSTEM” on page 8-27. Deposits  Replace. Damage  Replace. 2. Check: • Injector resistance Refer to “CHECKING THE INJECTOR”...

  • Page 297: 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 “diag- nostic mode”. f. Choose the diagnostic code No. “01”. g. Adjust the throttle position sensor mount- ed angle until “11”–“14”...
  • Page 298 THROTTLE BODY...

  • Page 299: Electrical System

    TROUBLESHOOTING................8-25 FUEL INJECTION SYSTEM ................8-27 CIRCUIT DIAGRAM .................8-27 ECU SELF-DIAGNOSTIC FUNCTION .............8-29 TROUBLESHOOTING METHOD .............8-30 YAMAHA DIAGNOSTIC TOOL ..............8-31 CONNECTING THE YAMAHA DIAGNOSTIC TOOL .......8-31 TROUBLESHOOTING DETAILS (FAULT CODE)........8-33 FUEL PUMP SYSTEM..................8-53 CIRCUIT DIAGRAM .................8-53 TROUBLESHOOTING................8-55 ELECTRICAL COMPONENTS...............8-56 CHECKING THE SWITCHES..............8-57 CHECKING THE BULBS AND BULB SOCKETS........8-59...
  • Page 300 CHECKING THE IGNITION COIL ............8-65 CHECKING THE CRANKSHAFT POSITION SENSOR ......8-66 CHECKING THE LEAN ANGLE SENSOR ..........8-67 CHECKING THE STARTER MOTOR OPERATION ........8-67 CHECKING THE STATOR COIL..............8-67 CHECKING THE RECTIFIER/REGULATOR ...........8-67 CHECKING THE SPEED SENSOR ............8-68 CHECKING THE FUEL SENDER ............8-68 CHECKING THE RESISTOR ..............8-68 CHECKING THE RADIATOR FAN MOTOR..........8-69 CHECKING THE COOLANT TEMPERATURE SENSOR ......8-69...

  • Page 302: Ignition System

    IGNITION SYSTEM EAM20142 IGNITION SYSTEM EAM30277 CIRCUIT DIAGRAM...
  • Page 303 IGNITION SYSTEM 1. Crankshaft position sensor 2. AC magneto 3. Rectifier/regulator 4. Joint connector 7. Engine ground 8. Battery 9. Frame ground 10.Main fuse 11.Starter relay 12.Starter motor 13.Diode 3 14.Diode 5 22.ECU (Engine Control Unit) 23.Ignition coil 24.Spark plug 35.Engine stop switch A.

  • Page 304: Troubleshooting

    IGNITION SYSTEM EAM30278 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). Before troubleshooting, remove the following part(s): 1. Side cover (left/right) 2. Seat 3. Fuel tank 4. Air scoop (left/right) 5. Air filter case cover 1. Check the ignition system wire har- Reconnect.
  • Page 305 IGNITION SYSTEM 9. Check the stator coil assembly. Refer to “CHECKING THE STA- Replace the stator coil assembly. NG TOR COIL” on page 8-67. OK 10.Check the ignition system wire har- ness. Repair or replace the wire harness. Refer to “CIRCUIT DIAGRAM” on NG...

  • Page 306: Electric Starting System

    ELECTRIC STARTING SYSTEM EAM20143 ELECTRIC STARTING SYSTEM EAM30279 CIRCUIT DIAGRAM...
  • Page 307 ELECTRIC STARTING SYSTEM 4. Joint connector 6. Main relay 7. Engine ground 8. Battery 9. Frame ground 10.Main fuse 11.Starter relay 12.Starter motor 13.Diode 3 14.Diode 5 22.ECU (Engine Control Unit) 35.Engine stop switch 36.Gear position switch 37.Diode 1 38.Starting circuit cut-off relay 39.Clutch switch 40.Start switch 41.Diode 4...

  • Page 308: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAM30280 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the meter light comes on, the starter motor can only operate if at least one of the following conditions is met: • The transmission is in neutral (the neutral circuit of the gear position switch is closed). •...
  • Page 309 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. Diode 3 5. Starting circuit cut-off relay 6. Start switch 7.

  • Page 310: Troubleshooting

    ELECTRIC STARTING SYSTEM EAM30281 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 1. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse(s).
  • Page 311 ELECTRIC STARTING SYSTEM 9. Check the start switch. Refer to “CHECKING THE Replace the start switch. NG SWITCHES” on page 8-57. OK 10.Check the entire starting system’s wiring. Properly connect or repair the starting sys- Refer to “CIRCUIT DIAGRAM” on tem’s wiring.

  • Page 312: Charging System

    CHARGING SYSTEM EAM20144 CHARGING SYSTEM EAM30282 CIRCUIT DIAGRAM 8-11...
  • Page 313 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 7. Engine ground 8. Battery 9. Frame ground 10.Main fuse A. Battery sub-lead B. Wire harness 8-12...

  • Page 314: Troubleshooting

    CHARGING SYSTEM EAM30283 TROUBLESHOOTING The battery is not being charged. Before troubleshooting, remove the following part(s): 1. Seat 2. Air scoop (left) 1. Check the entire charging system’s Reconnect. wiring. NG OK 2. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse(s).
  • Page 315 CHARGING SYSTEM 8-14...

  • Page 316: Signaling System

    SIGNALING SYSTEM EAM20154 SIGNALING SYSTEM EAM30348 CIRCUIT DIAGRAM 8-15...
  • Page 317 SIGNALING SYSTEM 4. Joint connector 6. Main relay 7. Engine ground 8. Battery 9. Frame ground 10.Main fuse 15.Warning light 17.Fuel level warning light 19.Resistor 22.ECU (Engine Control Unit) 26.Fuel sender 43.Multi-function display 44.Speed sensor A. Battery sub-lead B. Wire harness 8-16...

  • Page 318: Troubleshooting

    SIGNALING SYSTEM EAM30349 TROUBLESHOOTING • The speedometer does not operate normally. • 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 1.
  • Page 319 SIGNALING SYSTEM The fuel level warning light fails to come on. 1. Check the fuel level warning light bulb and socket. Replace the fuel level warning light bulb, Refer to “CHECKING THE BULBS socket or both. NG AND BULB SOCKETS” on page 8-59.

  • Page 320: Lighting System

    LIGHTING SYSTEM EAM20153 LIGHTING SYSTEM EAM30346 CIRCUIT DIAGRAM 8-19...
  • Page 321 LIGHTING SYSTEM 4. Joint connector 5. Headlight relay 6. Main relay 7. Engine ground 8. Battery 9. Frame ground 10.Main fuse 22.ECU (Engine Control Unit) 42.Taillight 43.Multi-function display 45.Headlight A. Battery sub-lead B. Wire harness 8-20...

  • Page 322: Troubleshooting

    LIGHTING SYSTEM EAM30347 TROUBLESHOOTING Any of the following fail to light: headlight or meter light. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left) 3. Air scoop (left/right) 4. Fuel tank 1. Check the each bulbs condition. Refer to “CHECKING THE BULBS Replace the bulb(s).
  • Page 323 LIGHTING SYSTEM 8-22...

  • Page 324: Cooling System

    COOLING SYSTEM EAM20155 COOLING SYSTEM EAM30350 CIRCUIT DIAGRAM 8-23...
  • Page 325 COOLING SYSTEM 4. Joint connector 6. Main relay 7. Engine ground 8. Battery 9. Frame ground 10.Main fuse 22.ECU (Engine Control Unit) 28.Radiator fan motor fuse 29.Radiator fan motor 30.Radiator fan motor relay 32.Coolant temperature sensor A. Battery sub-lead B. Wire harness 8-24...

  • Page 326: Troubleshooting

    COOLING SYSTEM EAM30351 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 1. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse(s). NG...
  • Page 327 COOLING SYSTEM 8-26...

  • Page 328: Fuel Injection System

    FUEL INJECTION SYSTEM EAM20145 FUEL INJECTION SYSTEM EAM30284 CIRCUIT DIAGRAM 8-27...
  • Page 329 9. Frame ground 10.Main fuse 11.Starter relay 13.Diode 3 15.Warning light 16.Engine trouble warning light 20.Diode 2 21.Yamaha diagnostic tool coupler 22.ECU (Engine Control Unit) 23.Ignition coil 24.Spark plug 25.Fuel injector 27.Fuel pump 31.Intake air temperature sensor 32.Coolant temperature sensor 33.Throttle position sensor...

  • Page 330: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM EAM30352 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 en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 331: Troubleshooting Method

    1. Check: • Fault code number a. Connect the Yamaha diagnostic tool. Refer to “YAMAHA DIAGNOSTIC TOOL” on page 8-31. b. Check the fault code number displayed on the Yamaha diagnostic tool. c. Identify the faulty system with the fault code number.

  • Page 332: Yamaha Diagnostic Tool

    FUEL INJECTION SYSTEM EAM30285 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) 90890-03269...
  • Page 333 FUEL INJECTION SYSTEM 1. Vehicle 2. Coupler for connecting optional part 3. FI diagnostic tool sub-lead 4. Sub-harness (included with the Yamaha diag- nostic tool) 5. Vehicle communication cable (included with the Yamaha diagnostic tool) 6. Yamaha diagnostic tool 8-32...

  • Page 334: Troubleshooting Details (Fault Code)

    Yamaha diagnostic tool according to the reinstatement method. Fault code No.: Fault code number displayed on the Yamaha diagnostic tool when the engine failed to work normally. Diagnostic code No.: Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC CODE: SENSOR OPERATION TABLE”...
  • Page 335 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air pressure. Procedure The atmospheric pressure is displayed on the Yamaha diagnostic tool. Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check...
  • Page 336 Replace the intake air pressure sensor. Faulty ECU. Replace the ECU. Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-35...
  • Page 337 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air pressure. Procedure The atmospheric pressure is displayed on the Yamaha diagnostic tool. Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check...
  • Page 338 Disconnect the coupler, and Yamaha diagnostic tool. Condition is “Recovered”  Go check the pins (for bent or bro- ken terminals and locking condi- to item 8 and finish the service.
  • Page 339 Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. Fault code No. 16 • If fault code numbers 15 and 16 are both displayed, perform checkup and repair jobs for fault code number 15 first.
  • Page 340 Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the coolant temperature. Compare the actually measured coolant temperature with the Yamaha Procedure diagnostic tool display value. Probable cause of malfunc- Confirmation of service com- Item...
  • Page 341 Refer to “RADIATOR” on page 6-2. item 6. Faulty ECU. Replace the ECU. Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-40...
  • Page 342 Fail-safe system Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air temperature. Compare the actually measured intake air temperature with the Yamaha Procedure diagnostic tool display value. Probable cause of malfunc- Confirmation of service com-...
  • Page 343 Push the start switch (main relay ON), wait 10 seconds, then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 4 and finish the service. Condition is “Detected”  Go to item 2.
  • Page 344 Unable to drive vehicle Diagnostic code No. Actuates the ignition coil five times at one-second intervals. Actuation “WARNING” on the Yamaha diagnostic tool blinks five times when the ignition coil is actuated. Check that a spark is generated five times. Procedure •...
  • Page 345 Check the condition of the fault the coupler. ness. code using the malfunction Disconnect the coupler, and mode of the Yamaha diagnostic check the pins (for bent or bro- tool. Condition is “Recovered”  Go ken terminals and locking condi- tion of the pins).
  • Page 346 Unable to drive vehicle Diagnostic code No. Actuates injector five times at one-second intervals. Actuation “WARNING” on the Yamaha diagnostic tool blinks five times when the injector is actuated. Check that injector is actuated five times by listening for the operating Procedure sound.
  • Page 347 Check the condition of the fault check the pins (bent or broken code using the malfunction terminals and locking condition mode of the Yamaha diagnostic of the pins). tool. Condition is “Recovered”  Go to item 6 and finish the service.
  • Page 348 Check the condition of the fault check the pins (bent or broken code using the malfunction terminals and locking condition mode of the Yamaha diagnostic of the pins). tool. Condition is “Recovered”  Go to item 6 and finish the service.
  • Page 349 If the same number is indicated, go to item 4. Faulty ECU. Replace the ECU. Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-48...
  • Page 350 Check the condition of the fault the coupler. code using the malfunction Disconnect the coupler, and mode of the Yamaha diagnostic check the pins (bent or broken tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
  • Page 351 ECU. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. Fault code No. 50 Before troubleshooting, disconnect the starter motor lead from the starter relay.
  • Page 352 Engine forcibly stops when the vehicle is left idling for a long period Item of time. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-51...
  • Page 353 FUEL INJECTION SYSTEM 8-52...

  • Page 354: Fuel Pump System

    FUEL PUMP SYSTEM EAM20146 FUEL PUMP SYSTEM EAM30287 CIRCUIT DIAGRAM 8-53...
  • Page 355 FUEL PUMP SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Joint connector 7. Engine ground 8. Battery 9. Frame ground 10.Main fuse 22.ECU (Engine Control Unit) 27.Fuel pump 35.Engine stop switch A. Battery sub-lead B. Wire harness 8-54...

  • Page 356: Troubleshooting

    FUEL PUMP SYSTEM EAM30288 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 5. Air filter case cover 1. Check the fuel pump system wire Reconnect.

  • Page 357: Electrical Components

    ELECTRICAL COMPONENTS EAM20147 ELECTRICAL COMPONENTS 1. Intake air pressure sensor 2. Throttle position sensor 3. Injector 4. Rectifier/regulator 5. Intake air temperature sensor 6. ECU (Engine Control Unit) 7. Ignition coil 8. Coolant temperature sensor 9. Resistor 10.Starter relay 11.Main fuse 12.Battery 13.Radiator fan motor fuse 14.Radiator fan motor relay...

  • Page 358: Checking The Switches

    ELECTRICAL COMPONENTS EAM30289 CHECKING THE SWITCHES Y/W P 1. Engine stop switch 2. Gear position switch 3. Engine start switch 4. Clutch switch 8-57...
  • Page 359 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. ECA14371 NOTICE Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end “a”...

  • Page 360: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS however, note the following. EAM30357 CHECKING THE BULBS AND BULB a. Install a good bulb into the bulb socket. SOCKETS b. Connect the digital circuit tester probes to 1. Remove: the respective leads of the bulb socket. • Bulb c.

  • Page 361: Checking And Charging The Battery

    ELECTRICAL COMPONENTS battery. Never remove the sealing caps be- Amperage Fuses Q’ty cause the balance between cells will not be rating maintained and battery performance will Spare 15 A deteriorate. • Charging time, charging amperage and Radiator fan motor charging voltage for a VRLA (Valve Regu- EWA13310 lated Lead Acid) battery are different from WARNING...
  • Page 362 ELECTRICAL COMPONENTS in the charts and the following example. done with the battery mounted on the vehi- cle, disconnect the negative battery lead Example from the battery terminal.) Open-circuit voltage = 12.0 V • To reduce the chance of sparks, do not Charging time = 6.5 hours Charge of the battery = 20–30 % plug in the battery charger until the battery...

  • Page 363: Checking The Relays

    ELECTRICAL COMPONENTS d. Charge the battery until the battery’s Set the charging voltage to 16–17 V. If the set- charging voltage is 15 V. ting is lower, charging will be insufficient. If too high, the battery will be over-charged. Set the charging time at 20 hours (maximum). c.
  • Page 364 ELECTRICAL COMPONENTS Starter relay Starting circuit cut-off relay Br/W 1. Positive battery terminal 1. Positive battery terminal 2. Negative battery terminal 2. Negative battery terminal 3. Positive tester probe 3. Positive tester probe 4. Negative tester probe 4. Negative tester probe Result Result Continuity...

  • Page 365: Checking The Relay Unit (Diode)

    ELECTRICAL COMPONENTS Radiator fan motor relay No continuity Positive tester probe  Sky blue “1” Negative tester probe  Green/Black “2” Continuity Positive tester probe  Green/Black “2” Negative tester probe  Sky Br,R/W blue “1” No continuity Positive tester probe  Red “3” Negative tester probe ...

  • Page 366: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS 2. Spark plug cap d. Crank the engine, and gradually increase the spark gap until a misfire occurs. EAM30295 CHECKING THE SPARK PLUG CAP Br/W,Br 1. Remove: • Spark plug cap (from the spark plug lead) 2. Check: •...

  • Page 367: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS 2. Check: • Primary coil resistance Out of specification  Replace. Primary coil resistance 2.16–2.64  a. Connect the digital circuit tester () to the ignition coil. Digital circuit tester (CD732) 90890-03243 b. Measure the secondary coil resistance. Model 88 Multimeter with tachom- eter EAM30297...

  • Page 368: Checking The Lean Angle Sensor

    ELECTRICAL COMPONENTS Out of specification  Replace. EAM30298 CHECKING THE LEAN ANGLE SENSOR 1. Check: Stator coil resistance 0.368–0.552  • Mounted condition of ECU Improperly mounted  Remount. a. Connect the digital circuit tester () to the stator coil assembly coupler. •...

  • Page 369: Checking The Speed Sensor

    ELECTRICAL COMPONENTS • Positive tester probe  Red “1” • Negative tester probe  Black “2” c. Push the start switch. d. Elevate the front wheel and slowly turn it. e. Measure the voltage (DC 5 V) of white and black/white.

  • Page 370: Checking The Radiator Fan Motor

    ELECTRICAL COMPONENTS EAM30303 Resistor resistance CHECKING THE COOLANT TEMPERATURE 64.6–71.4  SENSOR 1. Remove: a. Connect the digital circuit tester () to the • Coolant temperature sensor resistor as shown. EWA14130 WARNING Digital circuit tester (CD732) • Handle the coolant temperature sensor 90890-03243 with special care.

  • Page 371: Checking The Throttle Position Sensor Input Voltage

    ELECTRICAL COMPONENTS d. Slowly heat the coolant, and then let it cool to the specified temperature indicated in the table. e. Check the coolant temperature sensor for continuity at the temperatures indicated in the table. c. Start the engine. d. Measure the throttle position sensor input voltage.

  • Page 372: Checking The Gear Position Switch

    ELECTRICAL COMPONENTS Y/W P EAM30496 EAM30467 CHECKING THE INJECTOR CHECKING THE GEAR POSITION SWITCH 1. Remove: 1. Remove: • Fuel injector • Gear position switch Refer to “THROTTLE BODY” on page 7-4. 2. Check: • Gear position switch 2. Check: Out of specification ...

  • Page 373: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING ..................9-1 GENERAL INFORMATION ................9-1 TROUBLESHOOTING OF ENGINE (fault code not detected) ....9-1 TROUBLESHOOTING OF CLUTCH ............9-4 TROUBLESHOOTING OF TRANSMISSION ..........9-6 TROUBLESHOOTING OF COOLING SYSTEM ........9-7 TROUBLESHOOTING OF BRAKE ............9-8 TROUBLESHOOTING OF SUSPENSION ..........9-8 TROUBLESHOOTING OF STEERING/HANDLING.........9-10 TROUBLESHOOTING OF CHARGING SYSTEM........9-11 TROUBLESHOOTING OF LIGHTING SYSTEM ........9-11 TROUBLESHOOTING OF SIGNALING SYSTEM ........9-11 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE....9-12...

  • Page 374: Troubleshooting

    TROUBLESHOOTING EAM20148 TROUBLESHOOTING EAM30309 GENERAL INFORMATION Troubleshooting information provided here does not cover all the trouble symptoms, possible causes, and remedial actions. Some items may not apply depending on the model. Use this information as a guide and quick reference matrix when performing basic troubleshooting. Refer to the each chapter for detailed information on checking, adjustment, and replacement.
  • Page 375 TROUBLESHOOTING Symptom Possible cause Actions Water or foreign material in fuel, Change fuel. degraded fuel Tighten the spark plug to the spec- Loose spark plug ified torque. Tighten bolts or nuts on cylinder Loose cylinder head or cylinder head and cylinder to the specified torque.
  • Page 376 TROUBLESHOOTING Symptom Possible cause Actions Worn camshaft lobe Replace the camshaft. Water or foreign material in fuel, Change fuel. degraded fuel Contaminated throttle body or Clean the throttle body. clogged internal passage Incorrectly adjusted throttle cable Adjust the throttle grip free play. Incorrectly adjusted idling speed Adjust the idle screw.

  • Page 377: Troubleshooting Of Clutch

    TROUBLESHOOTING Symptom Possible cause Actions Replace the piston and piston Worn or damaged piston ring rings as a set. Replace the piston and piston Worn or damaged piston rings as a set. Replace the piston and piston pin Worn piston (piston pin hole) as a set.
  • Page 378 TROUBLESHOOTING Symptom Possible cause Actions Replace the clutch springs as a Faulty clutch spring set. Warped pressure plate Replace the pressure plate. Replace the friction plates as a Swollen friction plate set. Warped clutch plate Replace the clutch plates as a set. Bent pull rod (outer pull type) Replace the pull rod.

  • Page 379: Troubleshooting Of Transmission

    TROUBLESHOOTING EAM30511 TROUBLESHOOTING OF TRANSMISSION Symptom Possible cause Actions Clutch drags Refer to “Clutch drags”. Adjust the shift rod installation Improperly adjusted shift rod length. Bent shift shaft Replace the shift shaft. Foreign object in a shift drum Remove foreign object from shift groove drum groove.

  • Page 380: Troubleshooting Of Cooling System

    TROUBLESHOOTING EAM30512 TROUBLESHOOTING OF COOLING SYSTEM Symptom Possible cause Actions Carbon buildup in piston head and Clean the piston head and com- combustion chamber bustion chamber. Clogged engine cooling water Check and clean the engine cool- passages ing water passages. Adjust the oil level to the specified Incorrect oil level level.

  • Page 381: Troubleshooting Of Brake

    TROUBLESHOOTING EAM30513 TROUBLESHOOTING OF BRAKE Symptom Possible cause Actions Worn brake pad Replace the brake pads as a set. Worn or deflected brake disc Replace the brake disc. Air in hydraulic brake system Bleed the hydraulic brake system. Check the hydraulic brake system Brake fluid leakage and repair or replace faulty parts as necessary.
  • Page 382 TROUBLESHOOTING Symptom Possible cause Actions Fatigued or broken fork spring Replace the fork spring. Incorrect oil viscosity (low) Change to recommended fork oil. Incorrect oil level (low) Adjust to the specified oil level. Improperly adjusted spring pre- Adjust the spring preload. Front fork is soft load (soft) Improperly adjusted rebound...

  • Page 383: Troubleshooting Of Steering/Handling

    TROUBLESHOOTING Symptom Possible cause Actions Oil leaking from rear shock Replace the rear shock absorber. absorber Gas leaking from rear shock Replace the rear shock absorber. absorber Fatigued or damaged rear shock Replace the rear shock absorber. absorber spring Rear suspension is soft Improperly adjusted rear shock Adjust the spring preload.

  • Page 384: Troubleshooting Of Charging System

    TROUBLESHOOTING Symptom Possible cause Actions Tighten the spoke and adjust the Loose spoke runout. Damaged or worn wheel bearing Replace the wheel bearing. Worn, deformed, or incorrect tire Replace the tire. Tighten the wheel axle nut to the Loose wheel axle nut Rear wheel vibration specified torque.

  • Page 385: Self-Diagnostic Function And Diagnostic Code Table

    Pressure of suction pipe Displays the intake air pressure. The atmospheric pressure is • Check the change of the displayed on the Yamaha intake pressure valve when diagnostic tool. the starter switch is pushed. Intake air temperature Displays the intake air tempera- Compare the actually mea- ture.
  • Page 386 Procedure code Coolant temperature Displays the coolant tempera- Compare the actually mea- ture. sured coolant temperature with the Yamaha diagnostic tool display value. Vehicle speed pulses Vehicle speed pulse Check that the number 0–999 increases when the front wheel is rotated. The number...

  • Page 387: Diagnostic Code: Actuator Operation Table

    Ignition coil Actuates the ignition coil five Check that a spark is gener- times at one-second intervals. ated five times. “WARNING” on the Yamaha • Connect an ignition checker. diagnostic tool blinks five times when the ignition coil is actu- ated.
  • Page 388 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9-15...

  • Page 389: 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 ................10-1 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 390: Chassis

    CHASSIS EAM20119 Part name Type Part number CHASSIS Rear wheel 5GS-25448-50 EAM30168 sprocket “2” SELECTION OF THE SECONDARY 5TJ-25450-80 REDUCTION RATIO (SPROCKET) (STD) BAK-25451-00 Secondary reduction ratio = Number of 5TJ-25452-80 rear wheel sprocket teeth/Number of drive sprocket teeth Secondary reduction ratio 3.923 (51/13) <Requirement for selection of secondary gear reduction ratio>...

  • Page 391: Change In Amount And Characteristics Of Fork Oil

    SETTING OF SPRING AFTER REPLACEMENT Recommended oil As the front fork setting can be easily affected by Yamaha Suspension Oil S1 the rear suspension, take care so that the front Standard oil amount and the rear are balanced (in position etc.) when 295 cm³...

  • Page 392: Front Fork Setting Parts

    CHASSIS Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, re- sulting in lack of a sense of contact with the road surface or in a vibrating handlebar. EAM30174 FRONT FORK SETTING PARTS • Front fork spring “1” STD Spring rate N/mm Spring...

  • Page 393: Setting Of Spring After Replacement

    CHASSIS sunken length “b” between the rear wheel 2. Use of stiff spring • Adjust to increase rebound damping force to axle center and the rear fender holding bolt. compensate for greater spring load. Run with the rebound damping force adjuster one or two clicks turned in, and readjust it to suit your preference.

  • Page 394: Rear Shock Absorber Setting Parts

    CHASSIS EAM30178 REAR SHOCK ABSORBER SETTING PARTS Spring preload adjusting positions Minimum • Rear shock spring “1” Position in which the spring is STD Spring rate turned in 1.5 mm (0.06 in) from N/mm its free length. Standard Spring I.D. Type rate Part number...

  • Page 395: Suspension Setting (Front Fork)

    CHASSIS EAM30179 SUSPENSION SETTING (FRONT FORK) • If any of the following symptoms is experienced with the standard position as the base, make resetting 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 396: Suspension Setting (Rear Shock Absorber)

    CHASSIS Section Symptom Check Adjust Large Medium Small Jump Compression Turn adjuster clockwise (about 2 damping force clicks) to increase damping. Turn adjuster counterclockwise Rebound damp- (about 2 clicks) to decrease ing force damping. Low front, tend-   ing to lower front Set sunken length for 95–100 posture Balance with rear...
  • Page 397 CHASSIS Section Symptom Check Adjust Large Medium Small Jump Turn adjuster counterclockwise Rebound damp- (about 2 clicks) to decrease Heavy and drag- ing force   damping. ging Spring Replace with soft spring. Turn adjuster counterclockwise Rebound damp- (about 2 clicks) to decrease ing force damping.
  • Page 398 CHASSIS 10-9...
  • Page 399 Brown/White 17. Fuel level warning light Green/Black 18. Coupler (not used) Green/White 19. Resistor Green/Yellow 20. Diode 2 Blue/Black 21. Yamaha diagnostic tool cou- Blue/Green pler Blue/Red 22. ECU (Engine Control Unit) Blue/White 23. Ignition coil Blue/Yellow 24. Spark plug Pink/Black 25.
  • Page 401 EAM20160 Genuine Yamaha Parts text 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. Why settle for aftermarket parts that may not provide full confidence and satisfaction? Genuine Yamaha Accessories –...
  • Page 403 WR250FM 2021 WIRING DIAGRAM...
  • Page 404 WR250FM 2021 WIRING DIAGRAM...

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