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Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen. q Leggere attentamente questo manuale prima di utilizzare questo veicolo. OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE FAHRER- UND WARTUNGSHANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO YZ250F YZ250FF 1SM-28199-31...
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Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit être remis avec le véhicule en cas de vente de ce dernier. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
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2015 2015 Read this manual carefully before operating this vehicle. Read this manual carefully before operating this vehicle. OWNER’S SERVICE MANUAL OWNER’S SERVICE MANUAL YZ250F YZ250F YZ250FF YZ250FF 1SM-28199-31-E0 1SM-28199-31-E0...
INTRODUCTION EAS1SM5003 Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.
SAFETY INFORMATION EAS1SM5005 THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding. •...
HOW TO USE THIS MANUAL EAS1SM5006 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”...
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SYMBOLS EAS1SM5007 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...
TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUST- MENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLE SHOOTING TUNING...
GENERAL INFORMATION LOCATION OF IMPORTANT LABELS............1-1 DESCRIPTION....................1-4 IDENTIFICATION .....................1-5 VEHICLE IDENTIFICATION NUMBER ............1-5 ENGINE SERIAL NUMBER ...............1-5 MODEL LABEL...................1-5 FEATURES.......................1-6 OUTLINE OF THE FI SYSTEM..............1-6 FI SYSTEM....................1-7 INCLUDED PARTS ..................1-8 SIDESTAND ....................1-8 SPARK PLUG WRENCH ................1-8 NIPPLE WRENCH..................1-8 HANDLEBAR PROTECTOR ..............1-8 FUEL HOSE JOINT COVER ..............1-8 COUPLER FOR CONNECTING OPTIONAL PART........1-8 IMPORTANT INFORMATION ................1-10...
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STARTING AND BREAK-IN ................1-22 FUEL ......................1-22 STARTING A COLD ENGINE ..............1-22 STARTING A WARM ENGINE..............1-23 BREAK-IN PROCEDURES ..............1-23 MAINTENANCE AFTER BREAK-IN ..............1-24 MAJOR MAINTENANCE................1-24 TORQUE-CHECK POINTS ................1-25 CLEANING AND STORAGE................1-27 CLEANING ....................1-27 STORAGE ....................1-27...
LOCATION OF IMPORTANT LABELS LOCATION OF IMPORTANT LABELS EAS1SM5008 Please read the following important labels carefully before operating this vehicle. 1,2,3 4,5,6 9,10,11...
There are two significant reasons for knowing the serial number of your vehicle: 1. When ordering parts, you can give the num- ber to your Yamaha dealer for positive iden- tification of the model you own. 2. If your vehicle is stolen, the authorities will need the number to search for and identify your vehicle.
FEATURES FEATURES EAS20170 EAS1SM5014 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.
FEATURES FI SYSTEM EAS1SM5015 The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kgf/cm , 47.0 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
INCLUDED PARTS HANDLEBAR PROTECTOR INCLUDED PARTS EAS1SM5016 Install the handlebar protector “1” with the mark “a” facing forward. EAS1SM5017 SIDESTAND The sidestand “1” is used to support only the machine when standing or transporting it. EWA@ WARNING • Never apply additional force to the sides- tand.
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INCLUDED PARTS Part name Part number GYTR Power Tuner 33D-H59C0-V0-00 (For USA) YZ Power Tuner 33D-859C0-10 (Except for USA) The Power Tuner is an optional part.
2. Use proper special tools and equipment. used for repair of the vehicle, including periodic See “SPECIAL TOOLS”. replacement parts, are new YAMAHA genuine parts and recommended parts. Do not use any used parts, because these may not be genuine though they have similar ap- pearances or because the quality may be changed by aging.
IMPORTANT INFORMATION GASKETS, OIL SEALS AND O-RINGS EAS1SM5025 1. When overhauling the engine, replace all gaskets and O-rings. All gasket surfaces, oil seal lips, and O-rings must be cleaned so that there may be no dust on them. 2. During assembly, always apply proper oil to bearings and proper grease to oil seal lips before installation.
BASIC SERVICE INFORMATION BASIC SERVICE INFORMATION EAS1SM5029 EAS1SM5030 ELECTRICAL SYSTEM Electrical parts handling ECA16620 NOTICE Handle electrical components with special care, and do not subject them to strong shocks. ECA16640 NOTICE For waterproof couplers, never insert the tester probes directly into the coupler. When performing any checks using a water- proof coupler, use the specified test har- ness or a suitable commercially available...
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BASIC SERVICE INFORMATION ECA16790 NOTICE When disconnecting a connector, do not pull the leads. Hold both sections of the connector, and then disconnect the con- nector. 4. Connect: • Lead • Coupler • Connector • When connecting a coupler or a connector, 2.
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BASIC SERVICE INFORMATION 5. Check: • No continuity Pocket tester 90890-03112 Analog pocket tester YU-03112-C • If there is no continuity, clean the terminals. • When checking the wire harness, perform steps (1) to (4). • As a quick remedy, use a contact revitalizer available at most part stores.
SPECIAL TOOLS SPECIAL TOOLS EAS1SM5031 The following special tools are required for accurate and complete adjustment and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and tool number used for the special tool differ by country, so two types are provided.
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SPECIAL TOOLS Tool name/Part number How to use Illustration Radiator cap tester This tool is used to check the 90890-01325 radiator and the radiator cap. Mityvac cooling system tester YU-24460-A Radiator cap tester adapter This tool is used to check the 90890-01352 radiator and the radiator cap.
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90890-03207 voltage. YU-03207 FI diagnostic tool sub-lead This tool is used to connect 90890-03212 the Yamaha diagnostic tool YU-03212 to a battery. Yamaha diagnostic tool This tool is used to check er- 90890-03231 ror codes or carry out self-di- Yamaha diagnostic tool (US) agnosis.
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SPECIAL TOOLS Tool name/Part number How to use Illustration Spacer (crankshaft installer) This tool is used to install the 90890-04081 crankshaft. Pot spacer YM-91044 YM-91044 Clutch holder This tool is used to hold the 90890-04086 clutch when removing or in- YM-91042 stalling the clutch boss secur- ing nut.
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SPECIAL TOOLS Tool name/Part number How to use Illustration Valve guide remover (ø4.5) This tool is used to replace 90890-04116 the valve guide. Valve guide remover (4.5 YM-04116 Valve guide installer (ø4.5) This tool is used to replace 90890-04117 the valve guide. Valve guide installer (4.5 YM-04117 Valve guide reamer (ø4.5)
CONTROL FUNCTIONS KICKSTARTER LEVER CONTROL FUNCTIONS EAS1SM5032 The kickstarter lever “1” is in the right of the chassis. EAS1SM5033 ENGINE STOP SWITCH To start the engine, pull out and push down the The engine stop switch “1” is located on the left kickstarter lever with your foot.
CONTROL FUNCTIONS REAR BRAKE PEDAL EAS1SM5039 The rear brake pedal “1” is in the right of the chassis. Press down on the brake pedal to ac- tivate the rear brake. STARTER KNOB/IDLE ADJUSTING SCREW EAS1SM5040 Starting a cold engine requires a larger amount of intake air, which is supplied by the starter knob/idle screw “1”.
Do not open the throttle at the moment when you kick the kickstarter lever, be- Your Yamaha engine has been designed to use cause this may kick back premium unleaded gasoline with a pump oc-...
STARTING AND BREAK-IN 7. To stop the engine, push the engine stop NOTICE switch “1”. After a break-in or after each race, always check the points shown in “TORQUE- Continue pushing the engine stop switch till the CHECK POINTS” for tightening torques and engine comes to a full stop.
MAINTENANCE AFTER BREAK-IN • Cable MAINTENANCE AFTER BREAK-IN EAS1SM5047 Grease and adjust cables. After a break-in, perform careful maintenance • Drive chain to get ready for the next practice or race. Lubricate the drive chain and adjust its ten- Refer to “PRE-OPERATION INSPECTION sion.
TORQUE-CHECK POINTS TORQUE-CHECK POINTS EAS1SM5049 Frame construction Frame to rear frame Frame to engine protector Combined seat and fuel tank Fuel tank to frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Seat Seat to frame Steering Steering stem to handlebar Steering stem to frame...
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TORQUE-CHECK POINTS Plastic cover Tightening of number plate Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake disc cov- Tightening of rear brake caliper cover Concerning the tightening torque, refer to “TIGHTENING TORQUES”...
CLEANING AND STORAGE 3. Remove the drive chain, clean it thoroughly CLEANING AND STORAGE EAS1SM5050 with solvent, and lubricate it Reinstall the drive chain or store it in a plastic bag tied to EAS1SM5051 CLEANING the frame. Frequent cleaning of your vehicle will enhance 4.
ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS EAS1SM5054 Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 250 cm Cylinder arrangement Single cylinder Bore stroke 77.0 53.6 mm (3.0 2.1 in) Compression ratio 13.5:1 Starting system Kickstarter Fuel Recommended fuel Premium unleaded gasoline only Fuel tank capacity 7.5 L (1.98 US gal, 1.65 Imp.gal) Engine oil...
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ENGINE SPECIFICATIONS Cylinder head Volume 12.07–12.87 cm (0.74–0.79 cu.in) Warpage limit 0.05 mm (0.0020 in) Camshaft Drive system Chain drive (left) Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in) Camshaft journal diameter 21.959–21.972 mm (0.8645–0.8650 in) Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) Camshaft lobe dimensions Intake A 31.730–31.830 mm (1.2492–1.2531 in)
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ENGINE SPECIFICATIONS Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in) Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Valve margin thickness D (intake) 1.20 mm (0.0472 in) Valve margin thickness D (exhaust) 0.85 mm (0.0335 in) Valve stem diameter (intake) 4.975–4.990 mm (0.1959–0.1965 in) Limit 4.945 mm (0.1947 in)
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ENGINE SPECIFICATIONS Spring tilt (intake) 2.5 °/1.6 mm (2.5 °/0.06 in) Spring tilt (exhaust) 2.5 °/1.5 mm (2.5 °/0.06 in) Winding direction (intake) Clockwise Winding direction (exhaust) Clockwise Cylinder Bore 77.000–77.010 mm (3.0315–3.0319 in) Taper limit 0.050 mm (0.0020 in) Out of round limit 0.050 mm (0.0020 in) Piston...
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ENGINE SPECIFICATIONS Crankshaft Width A 55.95–56.00 mm (2.203–2.205 in) Runout limit C 0.030 mm (0.0012 in) Big end side clearance D 0.150–0.450 mm (0.0059–0.0177 in) Balancer Balancer drive method Gear Clutch Clutch type Wet, multiple-disc Clutch release method Inner push, cam push Clutch lever free play 7.0–12.0 mm (0.28–0.47 in) Friction plate thickness...
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ENGINE SPECIFICATIONS Air filter Air filter element Wet element Air filter oil grade Foam air-filter oil Fuel pump Pump type Electrical Fuel injector Model/quantity 30NA-FZ31/1 12 Resistance Throttle body Type/quantity 30RA-A71S/1 ID mark 1SM5 10 Fuel pressure 324.0 kPa (3.24 kgf/cm , 47.0 psi) Throttle position sensor Resistance...
CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS EAS1SM5055 Chassis Frame type Semi double cradle Caster angle 27.08 ° (USA) (CAN) (AUS) (NZL) (ZAF) 26.83 ° (EUR) 27.00 ° (JPN) Trail 118 mm (4.6 in) (USA) (CAN) (EUR) 119 mm (4.7 in) (JPN) (AUS) (NZL) (ZAF) Front wheel Wheel type Spoke wheel...
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CHASSIS SPECIFICATIONS Brake disc thickness limit 2.5 mm (0.10 in) Brake pad lining thickness (inner) 4.4 mm (0.17 in) Limit 1.0 mm (0.04 in) Brake pad lining thickness (outer) 4.4 mm (0.17 in) Limit 1.0 mm (0.04 in) Master cylinder inside diameter 9.52 mm (0.37 in) 22.65 mm ...
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CHASSIS SPECIFICATIONS Compression damping adjusting positions * Position in which the adjuster is turned in finger tight Minimum 20 click (s) out* Standard 10 click (s) out* (USA) (CAN) 6 click (s) out* (EUR) (JPN) (AUS) (NZL) (ZAF) Maximum (hard) Fully turned in Rear suspension Type...
TIGHTENING TORQUES TIGHTENING TORQUES EAS20320 EAS1SM5057 GENERAL TIGHTENING TORQUE SPECIFI- CATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a criss- cross pattern and progressive stages until the specified tightening torque is reached.
LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES EAS1SM5060 EAS1SM5061 ENGINE Lubrication point Lubricant types Oil seal lips Bearing O-ring Cylinder head bolt threads, seats, washers Valve stems Valve stem ends Valve lifter outer surface Camshaft lobe and journal Valve lifter top surface Crankshaft journal Crankshaft big end thrust surfaces...
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LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Three bond Cylinder head cover gasket No.1215® Three bond Crankcase mating surface No.1215® Three bond Stator assembly lead grommet No.1215® 2-20...
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CABLE ROUTING DIAGRAM R. Pass the rectifier/regulator lead to the inside of 1. Clutch cable the tension arm (the side of the vehicle). 2. Throttle cable (pull) S. Pass the main harness to the front of the radiator 3. Throttle cable (return) hose (the front of the vehicle), and to the inside of 4.
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CABLE ROUTING DIAGRAM S. Insert the projection on the plastic locking tie into 1. Bracket the hole in the rear frame. 2. Condenser T. Clamp the painted part on the fuel hose by the 3. Coolant temperature sensor plastic clamp. Make the lock on the plastic clamp 4.
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CABLE ROUTING DIAGRAM 1. Throttle cable 2. Clutch cable 3. Engine stop switch lead 4. Cable guide 5. Head pipe 6. Front brake hose 7. Brake hose guide 8. Number plate A. Number plate band B. Pass the clutch cable to the rear of the number plate band.
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CABLE ROUTING DIAGRAM 1. Main harness 2. Radiator 3. Throttle position sensor lead 4. Joint coupler 5. Intake air temperature sensor lead 6. Intake air pressure sensor lead 7. Frame 8. Fuel hose 9. High tension cord 10. Spark plug cap 11.
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CABLE ROUTING DIAGRAM 1. Brake master cylinder 2. Brake hose holder 3. Brake hoses A. While installing the brake hose, direct a bend in its pipe portion as shown, and bring it into contact with the projection on the brake caliper. B.
PERIODIC CHECKS AND ADJUSTMENTS MAINTENANCE INTERVALS ................3-1 MAINTENANCE INTERVALS ..............3-1 PRE-OPERATION INSPECTION AND MAINTENANCE.........3-7 GENERAL INSPECTION AND MAINTENANCE........3-7 ENGINE ......................3-8 CHECKING THE COOLANT LEVEL............3-8 CHECKING THE COOLING SYSTEM ............3-8 CHANGING THE COOLANT..............3-8 CHECKING THE RADIATOR CAP ............3-9 CHECKING THE RADIATOR CAP OPENING PRESSURE ......3-9 CHECKING THE COOLANT CIRCULATORY SYSTEM FOR LEAKS ..3-10 ADJUSTING THE CLUTCH LEVER POSITION ........3-10 ADJUSTING THE CLUTCH LEVER FREE PLAY........3-10...
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CHECKING THE WHEEL BEARINGS .............3-33 CHECKING AND ADJUSTING THE STEERING HEAD ......3-33 LUBRICATING THE LEVERS ..............3-34 LUBRICATING THE PEDAL ..............3-34 ELECTRICAL SYSTEM..................3-35 CHECKING THE SPARK PLUG ..............3-35 CHECKING THE IGNITION TIMING............3-35...
MAINTENANCE INTERVALS MAINTENANCE INTERVALS EAS1SM5066 EAS1SM5067 MAINTENANCE INTERVALS ECA@ NOTICE • After a break-in or before each race, always check the points shown in “TORQUE-CHECK POINTS” for tightening torques and retighten them. (“TORQUE-CHECK POINTS” on page 1- 25.) • Periodic inspection is essential in making full use of the machine performance. The life of parts varies significantly according to the environment in which the machine runs (e.g., rain, dirt, etc.).
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MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) PISTON RING Inspect Check the end gap of the pis- ton ring. Replace Replace the piston, piston pin, piston pin clip, and piston ring all as a set.
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MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) NUT (ROTOR) Retighten Check for tightening torques. EXHAUST PIPE, SI- LENCER, PROTEC- Inspect and re- Check for exhaust leaks, and tighten tightening torques.
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MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) FUEL TANK, FUEL PUMP Inspect FUEL HOSE Inspect Replace Every four years FRONT FORK LEG Clean Dust seal Inspect and adjust Replace oil Replace oil seal...
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MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) Replace brake flu- Every one year SWINGARM Inspect, lube and Molybdenum disulfide grease retighten RELAY ARM, CON- NECTING ROD Inspect, lube and Molybdenum disulfide grease retighten...
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MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) LEVERS Adjust clutch lever free play KICKSTARTER LE- VER, BRAKE PED- AL, FOOTREST Lubricate OUTSIDE NUTS AND BOLTS Retighten Refer to “TORQUE-CHECK POINTS”...
PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE EAS1SM5068 Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. GENERAL INSPECTION AND MAINTENANCE EAS1SM5069 ITEM inspect Page...
ENGINE ENGINE CHECKING THE COOLING SYSTEM EAS1SM5070 EAS1SM5072 1. Remove: EAS1SM5071 CHECKING THE COOLANT LEVEL • Seat • Side cover (left/right) EWA1DX1003 WARNING • Air scoop (left/right) If coolant seems hot, do not remove the ra- Refer to “GENERAL CHASSIS” on page 4- diator cap.
ENGINE CHECKING THE COOLANT CIRCULATORY ADJUSTING THE CLUTCH LEVER POSI- EAS1SM5076 EAS1SM5077 SYSTEM FOR LEAKS TION 1. Check: 1. Adjust: • Coolant level • Clutch lever position “a” 2. Install: Loosen the locknut “1” and use the adjuster • Radiator cap tester “1” “2”...
ENGINE ADJUSTING THE THROTTLE GRIP FREE PLAY Prior to adjusting throttle grip free play, the en- gine idling speed should be adjusted. 1. Check: • Throttle grip free play “a” Out of specification Regulate. Throttle grip free play 3.0–5.0 mm (0.12–0.20 in) If the clutch lever free play cannot be obtained on the handlebar side, use the adjuster on the clutch cable side.
ENGINE 4. Check: CHECKING THE THROTTLE BODY JOINT • Air filter element 1. Check: Damage Replace. • Throttle body joint 5. Foam-air-filter oil or equivalent oil to the ele- Refer to “CHECKING THE THROTTLE ment BODY JOINT” on page 7-8. Oil application quantify CHECKING THE BREATHER HOSES EAS1SM5083...
ENGINE 3. Install: • Fuel tank Refer to “FUEL TANK” on page 7-1. • Air scoop (left/right) • Seat • Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4- EAS1SM5086 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle upright on a level surface. 2.
ENGINE c. Install the new oil filter element and the oil fil- CHANGING THE ENGINE OIL EAS1SM5087 ter element cover. Stand the vehicle upright on a level surface. Oil filter element cover bolt 1. Start the engine, warm this up for several 10 Nm (1.0 m·kgf, 7.2 ft·lbf) minutes, and then stop the engine and wait about 5 minutes.
ENGINE 7. Pour the specified amount of engine oil into WARNING the oil filler cap hole. Always keep the engine idling speed during the checkup without increasing the engine Engine oil quantity speed. Without oil filter element replace- ment 0.71 L (0.75 US qt, 0.62 Imp.qt) NOTICE With oil filter element replace- If no engine oil seeps out after one minute,...
Digital tachometer basic knowledge and skill concerning the ser- 90890-06760 YU-39951-B vicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowledge and skill concerning ser- vicing are requested not to undertake inspec- Get the high tension cord “1” of the ignition coil tion, adjustment, disassembly, or reassembly pinched in the detector “a”...
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ENGINE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise with a wrench. b. Align the top dead center (TDC) mark “a” on the rotor with the alignment mark “b” on the crankcase cover. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Adjust: • Valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the camshaft (intake and exhaust). Refer to “CAMSHAFT”...
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ENGINE c. Check the number on the originally installed adjusting pad. • Apply the engine oil on the valve lifters. • Apply molybdenum disulfide oil to the valve • The adjusting pad number “a” is indicated on stem ends. the top of the adjusting pad. •...
CHASSIS CHASSIS EAS1SM5090 EAS1SM5091 BLEEDING THE BRAKE SYSTEM EWA13100 WARNING Bleed the brake system whenever: • The system is disassembled. • A brake hose is loosened, disconnected, or replaced. • The brake fluid level is very low. • Brake operation is faulty. A.
CHASSIS CHECKING THE BRAKE HOSE EAS1SM5092 1. Check: • Brake hose “1” Cracks/damage/wear Replace. 2. Remove: • Brake lever cover 3. Adjust: • Brake lever position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. b. Turn the adjusting bolt “2” in direction “a” or “b”...
CHASSIS ADJUSTING THE REAR BRAKE EAS1SM5094 NOTICE 1. Check: After adjusting the brake pedal position, • Brake pedal position “a” make sure that there is no brake drag. (distance from the top of the rider footrest to the top of the brake pedal) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
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CHASSIS b. Loosen the pad pin “2”. c. Remove the brake caliper “3” from the front fork. i. Install the brake caliper “8” and tighten the pad pin “9”. Bolt (brake caliper) d. Remove the pad pin and brake pads “4”. 28 Nm (2.8 m·kgf, 20 ft·lbf) Pad pin 17 Nm (1.7 m·kgf, 12 ft·lbf)
CHASSIS CHECKING THE REAR BRAKE PADS EAS1SM5096 1. Measure: • Brake pad thickness “a” Out of specification Replace as a set. The pads worn up to the indicator “b” grooves mean that the brake pad thickness limit is reached. Brake pad lining thickness (inner) d.
CHASSIS 4. Check: • Brake pedal operation A softy or spongy feeling Bleed the brake system. Refer to “BLEEDING THE BRAKE SYS- TEM” on page 3-21. EAS1SM5097 CHECKING THE REAR BRAKE PAD INSU- LATOR 1. Remove: • Brake pads i.
CHASSIS WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake flu- ids may result in a harmful chemical reac- tion, leading to poor brake performance.
CHASSIS CLEANING THE FRONT FORK OIL SEAL CHECKING THE FRONT FORK LEGS EAS1SM5100 AND DUST SEAL 1. Stand the vehicle upright on a level surface. 1. Remove: EWA13120 WARNING • Protector Securely support the vehicle so that there is • Dust seal “1” no danger of it falling over.
CHASSIS 3. Tighten: • Air bleed screw Air bleed screw 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping force ECA@ NOTICE Do not turn the adjuster forcibly beyond its adjusting range. EAS1SM5104 ADJUSTING THE FRONT FORK LEGS 1. Adjust: EWA32D1006 WARNING •...
CHASSIS 1. Remove: CHECKING THE SWINGARM OPERATION EAS1SM5105 • Rear frame 1. Check: Refer to “REAR SHOCK ABSORBER AS- • Swingarm smooth action SEMBLY” on page 4-53. • Swingarm free play 2. Adjust: Refer to “SWINGARM” on page 4-60. • Spring preload EAS1SM5106 CHECKING THE REAR SUSPENSION ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
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CHASSIS Rebound damping force Maximum Turn it in finger-tight. Turn it out by 14 clicks.* Minimum Turn it out by 30 clicks.* * With the adjuster fully turned ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ e. Tighten the locknut. High compression damping Locknut ECA@ 30 Nm (3.0 m·kgf, 22 ft·lbf) NOTICE Do not turn the adjuster forcibly beyond its adjusting range.
CHASSIS CHECKING THE TIRES 1. Measure: • Tire pressure Out of specification Regulate. Tire pressure 100 kPa (1.0 kgf/cm ,15 psi) • Check the tire while it is cold. • Loose bead stoppers allow the tire to slip off ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
CHASSIS 2. Tighten: CHECKING AND ADJUSTING THE STEER- • Spokes ING HEAD Use a spoke nipple wrench “1” for tighten- 1. Use a suitable stand to raise the front wheel ing. off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over.
CHASSIS LUBRICATING THE LEVERS Steering nut wrench 1. Lubricate the pivoting points and metal-to- 90890-01403 metal moving parts of the following parts. Exhaust flange nut wrench • Brake lever YU-A9472 Recommended lubricant Silicone grease Ring nut (initial tightening torque) 38 Nm (3.8 m·kgf, 27 ft·lbf) •...
ELECTRICAL SYSTEM 5. Clean: ELECTRICAL SYSTEM EAS1SM5115 • Spark plug (with a spark plug cleaner or a wire brush) EAS1SM5116 CHECKING THE SPARK PLUG 6. Measure: 1. Remove: • Spark plug gap “a” • Seat Out of specification Adjust the spark plug •...
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ELECTRICAL SYSTEM 2. Attach: • Timing light “1” • Digital tachometer “2” To the high tension code “3”. Timing light 90890-03141 YU-03141 Digital tachometer 90890-06760 YU-39951-B 3. Adjust: • Engine idling speed Refer to “ADJUSTING THE ENGINE IDLING SPEED” on page 3-16. 4.
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CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE LEFT SIDE COVER............4-2 REMOVING THE SEAT ................4-2 REMOVING THE NUMBER PLATE............4-2 FRONT WHEEL....................4-3 REMOVING THE FRONT WHEEL.............4-4 CHECKING THE FRONT WHEEL .............4-4 DISASSEMBLING THE FRONT WHEEL...........4-5 ASSEMBLING THE FRONT WHEEL............4-5 INSTALLING THE FRONT WHEEL ............4-6 REAR WHEEL ....................4-7 REMOVING THE REAR WHEEL ...............4-8 CHECKING THE REAR WHEEL..............4-8...
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HANDLEBAR ....................4-31 REMOVING THE HANDLEBAR...............4-33 CHECKING THE HANDLEBAR ...............4-33 INSTALLING THE HANDLEBAR .............4-33 FRONT FORK....................4-37 REMOVING THE FRONT FORK LEGS...........4-39 DISASSEMBLING THE FRONT FORK LEGS .........4-39 CHECKING THE FRONT FORK LEGS ...........4-40 ASSEMBLING THE FRONT FORK LEGS ..........4-41 INSTALLING THE FRONT FORK LEGS ..........4-47 STEERING HEAD...................4-49 REMOVING THE LOWER BRACKET............4-50 CHECKING THE STEERING HEAD ............4-50...
This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.
GENERAL CHASSIS REMOVING THE NUMBER PLATE REMOVING THE LEFT SIDE COVER EAS1SM5120 1. Remove: 1. Remove: • Bolt (number plate) • Bolt (side cover) • Number plate “1” • Side cover “1” • The projection “a” is inserted into the band of Draw the left side cover “1”...
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FRONT WHEEL FRONT WHEEL EAS1SM5123 Removing the front wheel 21 Nm (2.1 m kgf, 15 ft Ibf) • • 21 Nm (2.1 m kgf, 15 ft Ibf) • • 115 Nm (11.5 m kgf, 83 ft lbf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...
FRONT WHEEL REMOVING THE FRONT WHEEL EAS1SM5124 1. Use a suitable stand to raise the front wheel A tight spoke will emit a clear, ringing tone; a off the ground. loose spoke will sound flat. EWA13120 WARNING 4. Tighten: Securely support the vehicle so that there is •...
FRONT WHEEL DISASSEMBLING THE FRONT WHEEL EAS1SM5126 1. Remove: • Oil seals • Bearing ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside of the front wheel hub. b. Remove the oil seals “1” with a flat-head screwdriver. To prevent damaging the wheel, place a rag “2” between the screwdriver and the wheel sur- face.
FRONT WHEEL 3. Install: 3. Tighten: • Collar “1” • Front wheel axle nut “1” Front wheel axle nut Apply the lithium soap base grease on the oil 115 Nm (11.5 m·kgf, 83 ft·lbf) seal lip. ECA14140 NOTICE Before tightening the front wheel axle nut, push down hard on the handlebar(s) several times and check if the front fork rebounds smoothly.
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REAR WHEEL REAR WHEEL EAS1SM5129 Removing the rear wheel 14 Nm (1.4 m kgf, 10 ft Ibf) • • 135 Nm (13.5 m kgf, 98 ft lbf) • • 21 Nm (2.1 m kgf, 15 ft Ibf) • • 42 Nm (4.2 m kgf, 30 ft Ibf) •...
REAR WHEEL 4. Measure: REMOVING THE REAR WHEEL EAS1SM5130 • Radial wheel runout 1. Use a suitable stand to raise the rear wheel • Lateral wheel runout off the ground. Refer to “CHECKING THE FRONT WHEEL” EWA13120 WARNING on page 4-4. Securely support the vehicle so that there is Radial wheel runout limit no danger of it falling over.
FRONT BRAKE FRONT BRAKE EAS1SM5136 Removing the front brake caliper 30 Nm (3.0 m kgf, 22 ft lbf) 28 Nm (2.8 m kgf, 20 ft lbf) 6 Nm (0.6 m kgf, 4.3 ft lbf) 17 Nm (1.7 m kgf, 12 ft lbf) 2.5 Nm (0.25 m kgf, 1.8 ft...
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FRONT BRAKE Disassembling the front brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) Order Part name Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassemble pro- cedure.
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FRONT BRAKE Removing the front brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft lbf) 6 Nm (0.6 m kgf, 4.3 ft lbf) 6 Nm (0.6 m kgf, 4.3 ft lbf) 30 Nm (3.0 m kgf, 22 ft lbf) Order Part name Q’ty...
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FRONT BRAKE Disassembling the front brake master cylinder Order Part name Q’ty Remarks Push rod Dust boot Circlip Washer Brake master cylinder kit For assembly, reverse the disassemble pro- cedure. 4-14...
FRONT BRAKE INTRODUCTION EAS1SM5137 Brake disc thickness limit EWA14100 WARNING 2.5 mm (0.10 in) If you need to disassemble the disc brake 4. Install: components, observe the following precau- • Front wheel tions. Refer to “FRONT WHEEL” on page 4-3. •...
FRONT BRAKE ASSEMBLING THE FRONT BRAKE CALI- EWA13620 WARNING • Before installation, clean and lubricate the internal parts. Use new brake fluid for cleaning and lubricating. • Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
FRONT BRAKE 3. Install: 2. Install: • Brake caliper piston “1” • Front brake caliper • Brake pad spring • Brake pad Apply the brake fluid on the piston outer sur- • Brake pad pin face. • Brake hose holder ECA33DD047 NOTICE Brake pad pin...
FRONT BRAKE NOTICE Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Bleed: • Brake system Refer to “BLEEDING THE BRAKE SYS- TEM” on page 3-21. 6. Check: • Brake fluid level 2.
FRONT BRAKE INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Brake master cylinder “1” Brake master cylinder holder bolt 9 Nm (0.9 m·kgf, 6.5 ft·lbf) • Install the front brake master cylinder holder with the “UP” mark facing up. 3.
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FRONT BRAKE 3. Pour brake fluid to the brake master cylinder 6. Check: reservoir up to the specified level. • Brake lever free play Refer to “ADJUSTING THE FRONT Recommended brake fluid BRAKE” on page 3-22. DOT 4 • Brake lever operation A softy or spongy feeling ...
REAR BRAKE REAR BRAKE EAS1SM5149 Removing the rear brake caliper 10 Nm (1.0 m kgf, 7.2 ft Ibf) 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf)
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REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) Order Part name Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassemble pro- cedure.
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REAR BRAKE Removing the rear brake master cylinder Order Part name Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE BRAKE SYSTEM” on page 3-21. Union bolt Copper washers Brake hose Split pin Washer Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm plate Brake master cylinder reservoir diaphragm Rear brake master cylinder For installation, reverse the removal proce-...
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REAR BRAKE Disassembling the rear brake master cylinder Order Part name Q’ty Remarks Dust boot Circlip Push rod Brake master cylinder kit For assembly, reverse the disassemble pro- cedure. 4-24...
REAR BRAKE INTRODUCTION EAS1SM5150 EWA14300 WARNING If you need to disassemble the disc brake components, observe the following precau- tions. • Never disassemble the brake components unless absolutely necessary. • If there is any problem with connections on the hydraulic brake system, perform the following jobs.
REAR BRAKE REMOVING THE REAR BRAKE MASTER WARNING CYLINDER • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to Before removing the rear brake master cylin- deteriorate, causing leakage and poor der, drain the brake fluid from the entire brake brake performance.
REAR BRAKE ASSEMBLING THE REAR BRAKE MASTER EAS1SM5160 CYLINDER EWA13520 WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake com- ponents. Recommended brake fluid 4.
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REAR BRAKE 2. Pour brake fluid to the brake fluid reservoir 5. Check: up to the specified level. • Brake pedal operation A softy or spongy feeling Bleed the brake Recommended brake fluid system. DOT 4 Refer to “BLEEDING THE BRAKE SYS- TEM”...
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HANDLEBAR HANDLEBAR EAS1SM5162 Removing the handlebar Order Part name Q’ty Remarks Number plate Remove the band only. Clutch cable Disconnect. Clutch lever holder Engine stop switch Brake master cylinder Throttle cable cap Throttle cable (pull) Disconnect. Throttle cable (return) Disconnect. Right grip Tube guide Collars...
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HANDLEBAR Removing the handlebar Order Part name Q’ty Remarks Handlebar lower holder Damper For installation, reverse the removal proce- dure. 4-32...
HANDLEBAR REMOVING THE HANDLEBAR EAS1SM5163 1. Stand the vehicle upright on a level surface. • Install the lower handlebar holders with them EWA13120 side having the greater distance “a” from the WARNING mounting bolt center facing forward. Securely support the vehicle so that there is •...
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HANDLEBAR 4. Install: • Handlebar grip “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Slightly coat the handlebar left end with a rubber adhesive. b. Install the handlebar grip on the handlebar by pressing the grip from the left side. c. Wipe off any excess adhesive with a clean cloth.
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HANDLEBAR 6. Install: 8. Install: • Right grip “1” • Throttle cables “1” • Collar “2” Apply adhesive to the tube guide “3”. Slightly coat the end of throttle cable and inside of throttle grip with lithium-soap-based grease. • Before applying the adhesive, wipe off grease Then, mount the throttle grip onto the handle- or oil on the tube guide surface “a”...
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HANDLEBAR 12.Install: • Clutch cable “1” Before installation, apply the lithium-soap- based grease to the clutch cable end. 10.Install: • Rubber cover “1” • Cover (throttle cable housings) “2” 13.Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LE- VER FREE PLAY”...
FRONT FORK FRONT FORK EAS1SM5166 Removing the front fork legs 21 Nm (2.1 m kgf, 15 ft lbf) 9 Nm (0.9 m kgf, 6.5 ft lbf) 5 Nm (0.5 m kgf, 3.6 ft lbf) 5 Nm (0.5 m kgf, 3.6 ft lbf) Order Part name...
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FRONT FORK Disassembling the front fork leg 30 Nm (3.0 m kgf, 22 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • 55 Nm (5.5 m kgf, 40 ft Ibf) •...
FRONT FORK REMOVING THE FRONT FORK LEGS EAS1SM5167 NOTICE 1. Use a suitable stand to raise the front wheel Do not scratch the inner tube. off the ground. EWA13120 Cap bolt ring wrench WARNING 90890-01501 Securely support the vehicle so that there is YM-01501 no danger of it falling over.
FRONT FORK 5. Remove: • Base valve “1” (from the damper assembly) Hold the damper assembly with the cap bolt ring wrench “2” and use the cap bolt wrench “3” to remove the base valve. Cap bolt wrench 90890-01500 2. Check: YM-01500 •...
FRONT FORK 5. Check: ASSEMBLING THE FRONT FORK LEGS EAS1SM5170 • Base valve “1” EWA13660 Wear/damage Replace. WARNING Contamination Clean. • Make sure the oil levels in both front fork • O-rings “2” legs are equal. Wear/damage Replace. •...
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FRONT FORK 6. Loosen: • Compression damping force adjuster “1” • Before loosening the damping force adjuster, record the setting position. • Unless the damping force adjuster is fully loosened, correct damping characteristic can- not be obtained after installation. 4. Measure: •...
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FRONT FORK Cap bolt wrench 90890-01500 YM-01500 Cap bolt ring wrench 90890-01501 YM-01501 13.Check: • Damper assembly smooth movement Tightness/binding/rough spots Repeat the steps 1 to 12. 10.After filling, pump the damper assembly “1” slowly up and down more than 10 times to distribute the fork oil.
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FRONT FORK 15.Install: • Inner tube bushing “1” Install the inner tube bushing onto the slot on inner tube. 18.Install: • Oil seals “1” Using a fork seal driver “2”, press the oil seal in until the stopper ring groove fully appears. 16.Install: Fork seal driver •...
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FRONT FORK 20.Install: 23.Install: • Dust seal “1” • Collar “1” • Fork spring “2” (to the damper assembly “3”) Apply lithium-soap-based grease on the inner tube. Install the collar with its larger dia. end “a” fac- ing the fork spring. 21.Check: •...
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FRONT FORK 25.Loosen: Gap “a” between the adjuster and • Rebound damping force adjuster “1” the locknut 0.5–1.0 mm (0.02–0.04 in) • Before loosening the damping force adjuster, record the setting position. • Unless the damping force adjuster is fully If it is installed with a gap out of specification, loosened, correct damping characteristic can- correct damping force cannot be obtained.
FRONT FORK 30.Fill: • Front fork leg Recommended oil Suspension oil S1 Standard oil amount 335 cm (11.33 US oz, 11.82 lmp.oz) (USA) (CAN) 355 cm (12.00 US oz, 12.52 lmp.oz) (EUR) (JPN) (AUS) (NZL) (ZAF) Extent of adjustment INSTALLING THE FRONT FORK LEGS EAS1SM5171 300–365 cm (10.14–12.34 US...
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FRONT FORK 3. Adjust: • Front fork top end “a” Front fork top end (standard) “a” 5 mm (0.20 in) 6. Adjust: • Rebound damping force Turn in the damping adjuster “1” finger-tight and then turn out to the originally set position. 4.
STEERING HEAD STEERING HEAD EAS1SM5172 Removing the lower bracket 21 Nm (2.1 m kgf, 15 ft lbf) 145 Nm (14.5 m kgf, 105 ft lbf) 21 Nm (2.1 m kgf, 15 ft lbf) 38 Nm (3.8 m kgf, 27 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft...
STEERING HEAD REMOVING THE LOWER BRACKET EAS1SM5173 NOTICE 1. Use a suitable stand to raise the front wheel If the bearing race is not installed properly, off the ground. the steering head pipe could be damaged. EWA13120 WARNING Securely support the vehicle so that there is Always replace the bearing and the bearing no danger of it falling over.
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STEERING HEAD 2. Install: • Bearing races • Upper bearing “1” • Bearing race cover “2” Apply the lithium soap base 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.
REAR SHOCK ABSORBER ASSEMBLY REAR SHOCK ABSORBER ASSEMBLY EAS1SM5176 Removing the rear shock absorber assembly 16 15 14 13 Order Part name Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 4-1. Side cover (left / right) Refer to “GENERAL CHASSIS” on page 4-1. Air scoop (left / right) Refer to “GENERAL CHASSIS”...
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REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 16 15 14 13 Order Part name Q’ty Remarks Spring Dust seal Collars Bushing Collars O-ring Dust seal Stopper ring Bearing For installation, reverse the removal proce- dure. 4-54...
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REAR SHOCK ABSORBER ASSEMBLY Disassembling the relay arm 80 Nm (8.0 m kgf, 58 ft lbf) Order Part name Q’ty Remarks Relay arm Connecting arm Collars Oil seals Washers Bearing For assembly, reverse the disassemble pro- cedure. 4-55...
• Rear shock absorber assembly upper bolt • To dispose of a damaged or a worn-out • Rear shock absorber assembly rear shock absorber, take the unit to your Yamaha dealer for this disposal proce- REMOVING THE BEARING EAS1SM5180 dure.
REAR SHOCK ABSORBER ASSEMBLY 2. Remove: CHECKING THE CONNECTING ARM AND • Upper bearing “1” RELAY ARM 1. Check: • Connecting arm Remove the bearing by pressing its outer race. • Relay arm Damage/wear Replace. 2. Check: • Bearing •...
SWINGARM SWINGARM EAS1SM5185 Removing the swingarm 70 Nm (7.0 m kgf, 51 ft lbf) 4.0 Nm (0.40 m kgf, 2.9 ft lbf) Order Part name Q’ty Remarks Use a suitable stand to raise the front wheel off the ground. Brake hose holder Refer to “REAR BRAKE”...
SWINGARM REMOVING THE SWINGARM EAS1SM5186 1. Use a suitable stand to raise the rear wheel off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Measure: • Swingarm side play •...
CHAIN DRIVE CHAIN DRIVE EAS1SM5190 Removing the drive chain 75 Nm (7.5 m kgf, 54 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft lbf) Job Order Part name Q’ty Servicing Information Drive sprocket Refer to “ENGINE REMOVAL” on page 5-1. Drive chain For installation, reverse the removal proce- dure.
CHAIN DRIVE REMOVING THE DRIVE CHAIN EAS1SM5191 1. Use a suitable stand to raise the rear wheel off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Joint clip •...
ENGINE ENGINE REMOVAL ..................5-1 REMOVING THE SILENCER..............5-6 REMOVING THE EXHAUST PIPE 2............5-6 REMOVING THE DRIVE SPROCKET ............5-6 REMOVING THE ENGINE .................5-7 CHECKING THE SILENCER AND EXHAUST PIPE........5-7 CHANGING THE SILENCER FIBER ............5-7 INSTALLING THE ENGINE................5-8 INSTALLING THE BRAKE PEDAL ............5-9 INSTALLING THE DRIVE SPROCKET............5-9 INSTALLING THE EXHAUST PIPE AND MUFFLER.......5-10 CAMSHAFT ....................5-11...
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CLUTCH ......................5-35 REMOVING THE CLUTCH ..............5-38 CHECKING THE FRICTION PLATES............5-38 CHECKING THE CLUTCH PLATES ............5-38 CHECKING THE CLUTCH SPRINGS............5-38 CHECKING THE CLUTCH HOUSING .............5-39 CHECKING THE CLUTCH BOSS............5-39 CHECKING THE PRESSURE PLATE .............5-39 CHECKING THE PUSH LEVER SHAFT..........5-39 CHECKING THE CLUTCH PUSH RODS ..........5-39 CHECKING THE PRIMARY DRIVE GEAR..........5-39 CHECKING THE PRIMARY DRIVEN GEAR ...........5-40 INSTALLING THE OIL SEAL ..............5-40...
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AC MAGNETO....................5-58 REMOVING THE AC MAGNETO.............5-59 CHECKING THE AC MAGNETO .............5-59 CHECKING THE WOODRUFF KEY ............5-59 INSTALLING THE AC MAGNETO ............5-59 CRANKCASE ....................5-61 DISASSEMBLING THE CRANKCASE.............5-64 REMOVING THE CRANKCASE BEARING ..........5-64 CHECKING THE TIMING CHAIN, TIMING CHAIN GUIDE, OIL STRAINER..................5-64 CHECKING THE CRANKCASE ...............5-64 INSTALLING THE OIL SEAL ..............5-65 ASSEMBLING THE CRANKCASE............5-65...
This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.
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ENGINE REMOVAL Removing the exhaust pipe 13 Nm (1.3 m kg , 9.4 ft lbf) • • 2nd 20 Nm (2.0 m kgf, 14 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...
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ENGINE REMOVAL Removing the electronic parts Order Part name Q’ty Remarks Use a suitable stand to raise the front wheel off the ground. Seat Refer to “GENERAL CHASSIS” on page 4-1. Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1. Air scoop (left / right) Refer to “GENERAL CHASSIS”...
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ENGINE REMOVAL Removing the engine 55 Nm (5.5 m kgf, 40 ft Ibf) • • Order Part name Q’ty Remarks Use a suitable stand to raise the front wheel off the ground. Seat Refer to “GENERAL CHASSIS” on page 4-1. Side cover (left/right) Refer to “GENERAL CHASSIS”...
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ENGINE REMOVAL Removing the engine 55 Nm (5.5 m kgf, 40 ft Ibf) • • Order Part name Q’ty Remarks Drive chain guide Drive sprocket Upper engine bracket Washer Thickness:2.3 mm (0.09 in) Washer Thickness:1.0 mm (0.04 in) Lower engine bracket Pivot shaft Engine For installation, reverse the removal proce-...
ENGINE REMOVAL REMOVING THE SILENCER EAS1SM5198 1. Remove: • Rear shock absorber assembly lower bolt “1” • Connecting arm bolt (frame side) “2” • Silencer “3” Move the rear shock absorber to the left side of the chassis, and remove the silencer. REMOVING THE DRIVE SPROCKET EAS1SM5200 1.
ENGINE REMOVAL REMOVING THE ENGINE EAS1SM5201 1. Remove: • Pivot shaft “1” If the pivot shaft is pulled all the way out, the swingarm will come loose. If possible, insert a shaft of similar diameter into the other side of the swingarm to support it.
ENGINE REMOVAL 3. Replace: • Fiber “1” • Apply heat-resistant sealant to the areas “a” shown, making sure that there are no gaps in the beads of sealant. • Take care not to allow the fiber out of place when installing the silencer body “3”. 4.
ENGINE REMOVAL 2. Install: • Lock washer “1” • Nut (drive sprocket) “2” Nut (drive sprocket) 75 Nm (7.5 m·kgf, 54 ft·lbf) Tighten the nut while applying the rear brake. ECA33DD040 NOTICE Make sure to tighten to specification; other- EAS1SM5205 INSTALLING THE BRAKE PEDAL wise, it may damage the other part that is 1.
CAMSHAFT CAMSHAFT EAS1SM5208 Removing the cylinder head cover 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Part name Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 4-1. Side cover (left/right) Refer to “GENERAL CHASSIS”...
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CAMSHAFT Removing the camshaft 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 6 Nm (0.6 m kgf, 4.3 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 6 Nm (0.6 m kgf, 4.3 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name...
CAMSHAFT REMOVING THE CAMSHAFT EAS1SM5209 1. Remove: • Timing mark accessing screw “1” • Crankshaft end accessing screw “2” 4. Remove: • Bolt (camshaft cap) “1” • Camshaft cap “2” • Clip “3” 2. Align: • Alignment mark • Remove the bolts (camshaft cap) in a criss- cross pattern, working from the outside in.
CAMSHAFT 3. Measure: CHECKING THE CAMSHAFT EAS1SM5210 • Camshaft runout 1. Check: Out of specification Replace. • Camshaft lobes Blue discoloration/pitting/scratches Re- Camshaft runout limit 0.030 mm (0.0012 in) place the camshaft. 2. Measure: • Camshaft lobe dimensions “A” and “B” Out of specification ...
CAMSHAFT c. Install the dowel pins and the camshaft 2. Check: caps. • Camshaft sprocket More than 1/4 tooth wear “a” Replace the camshaft and the timing chain as a set. • Tighten the camshaft cap bolts in a crisscross pattern from innermost to outer caps.
CAMSHAFT CHECKING THE DECOMPRESSION SYS- EAS1SM5213 1. Check: • Decompression system ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check that the decompressor cam “1” moves smoothly. b. Check that the decompressor lever pin “2” projects from the camshaft. c. Fit the timing chain “3” onto both camshaft sprockets and install the camshafts on the cylinder head.
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CAMSHAFT ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install: 3. Turn: • Timing chain tensioner • Crankshaft Counterclockwise several turns. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 4. Check: a. While pressing the tensioner rod lightly with • Top dead center (TDC) mark on the rotor your fingers, use a thin screwdriver to wind Align with the crankcase alignment mark.
CYLINDER HEAD CYLINDER HEAD EAS1SM5215 Removing the cylinder head 33 Nm (3.3 m kgf, 24 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Part name Q’ty Remarks...
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CYLINDER HEAD Removing the cylinder head 33 Nm (3.3 m kgf, 24 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Part name Q’ty Remarks Timing chain guide (intake side) Oil check bolt...
CYLINDER HEAD REMOVING THE CYLINDER HEAD EAS1SM5216 1. Remove: • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAMSHAFT” on page 5-13. 2. Remove: • Cylinder head nuts • Cylinder head bolts 2. Check: • Loosen the bolts in the proper sequence as •...
CYLINDER HEAD INSTALLING THE CYLINDER HEAD EAS1SM5219 1. Install: • Apply molybdenum disulfide grease to the • Timing chain guide (intake side) “1” threads and contact surfaces of the bolts and • Dowel pin “2” to both contact surfaces of the washers. •...
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VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS EAS1SM5220 Removing the valves and valve springs Order Part name Q’ty Remarks Refer to “CYLINDER HEAD” on page 5-18. Cylinder head Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Intake valve...
VALVES AND VALVE SPRINGS b. Check that the valves are properly sealed. REMOVING THE VALVES EAS1SM5221 Check that there are no kerosene leaks from Before removing the internal parts of the cylin- the valve seat “1”. der head (e.g., valves, valve springs, valve seats), make sure that the valves are properly sealed.
VALVES AND VALVE SPRINGS 2. Replace: • Valve guide To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve guide with the valve guide remover “1”.
VALVES AND VALVE SPRINGS 6. Measure: • Valve stem runout After replacing the valve guide, reface the valve Out of specification Replace the valve. seat. Intake • When installing a new valve, always replace Valve guide remover (ø5.0) the valve guide. 90890-04097 •...
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VALVES AND VALVE SPRINGS NOTICE Do not let the lapping compound enter the gap between the valve stem and the valve guide. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion.
VALVES AND VALVE SPRINGS Installed compression spring force (intake) 146.00–168.00 N (14.89–17.13 kgf, 32.82–37.77 lbf) Installed compression spring force (exhaust) 137.00–157.00 N (13.97–16.01 kgf, 30.80–35.29 lbf) Installed length (intake) 31.40 mm (1.24 in) Installed length (exhaust) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 28.50 mm (1.12 in) EAS1SM5224 CHECKING THE VALVE SPRINGS 3.
VALVES AND VALVE SPRINGS 4. Install: INSTALLING THE VALVES EAS1SM5226 • Valve cotter “1” 1. Clean: • Valve stem end Install the valve cotters by compressing the valve spring with the valve spring compressor “2” and the valve spring compressor adapter “3”.
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VALVES AND VALVE SPRINGS 6. Lubricate: • Adjusting pad “1” • Valve lifter “2” 7. Install: • Adjusting pad • Valve lifter • Check that the valve lifter turns smoothly when rotated with your finger. • Make sure that the valve lifter and the adjust- ing pad are reinstalled in their original posi- tions.
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CYLINDER AND PISTON CYLINDER AND PISTON EAS1SM5227 Removing the cylinder and piston 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks Refer to “CYLINDER HEAD” on page 5-18. Cylinder head Cylinder body Gaskets...
CYLINDER AND PISTON REMOVING THE PISTON EAS1SM5228 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 CHECKING THE CYLINDER AND PISTON EAS1SM5229 crankcase opening with a cloth to prevent the...
CYLINDER AND PISTON b. If out of specification, rebore or replace the Ring side clearance cylinder, and replace the piston and the pis- 0.030–0.065 mm (0.0012–0.0026 ton rings as a set. c. Measure the piston outside diameter D “a” at Limit the measurement position H “b”...
CYLINDER AND PISTON INSTALLING THE PISTON AND CYLINDER CHECKING THE PISTON PIN EAS1SM5231 1. Install: 1. Check: • Oil ring expander “1” • Piston pin • Lower oil ring rail “2” Blue discoloration/grooves Replace the • Upper oil ring rail “3” piston pin and then check the lubrication •...
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CYLINDER AND PISTON 3. Lubricate: • Piston • Piston rings • Cylinder 4. Offset: • Piston ring end gap a. Top ring b. Upper oil ring rail c. Oil ring expander d. Lower oil ring rail 5. Install: • Cylinder gasket •...
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CLUTCH CLUTCH EAS1SM5233 Removing the clutch 6 10 Order Part name Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-15. Brake pedal Refer to “ENGINE REMOVAL” on page 5-1. Clutch cable Disconnect. Clutch cover Gasket Clutch spring Pressure plate Push rod 1...
CLUTCH Removing the clutch 6 10 Order Part name Q’ty Remarks Friction plate Clutch plate Cushion spring Clutch boss Thrust washer Primary driven gear Spacer Bearing Washer Push lever shaft For installation, reverse the removal proce- dure. 5-36...
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CLUTCH Removing the right crankcase cover Order Part name Q’ty Remarks Right engine guard Refer to “ENGINE REMOVAL” on page 5-1. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-15. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-8.
CLUTCH CHECKING THE PUSH LEVER SHAFT CHECKING THE CLUTCH HOUSING EAS1SM5238 1. Check: 1. Check: • Push lever shaft • Clutch housing dogs “a” Wear/damage Replace. Damage/pitting/wear Deburr the clutch housing dogs or replace the clutch housing. Pitting on the clutch housing dogs will cause er- ratic clutch operation.
CLUTCH INSTALLING THE CLUTCH EAS1SM5247 Clutch holder 1. Install: 90890-04086 • Push lever shaft “1” YM-91042 • Apply the lithium soap base grease on the oil seal lip. • Before installation, apply the engine oil to the push lever shaft sliding surface. 4.
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CLUTCH 6. Install: 9. Install: • Bearing “1” • Clutch spring • Washer “2” • Clutch spring bolt • Circlip “3” Clutch spring bolt To push rod 1 “4”. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Apply the engine oil on the bearing and washer. Tighten the bolts in stages and in a crisscross pattern.
CLUTCH INSTALLING THE KICKSTARTER LEVER EAS1SM5248 1. Install: • Kickstarter lever “1” • Washers • Bolt (kickstarter lever) Bolt (kickstarter lever) 33 Nm (3.3 m·kgf, 24 ft·lbf) Install so that there is a clearance “a” of 5 mm (0.2 in) or more between the kickstarter lever and the frame and that the kickstarter lever does not contact the right crankcase cover when it is pulled.
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KICKSTATER KICKSTATER EAS1SM5249 Removing the kick shaft Order Part name Q’ty Remarks Primary driven gear Refer to “CLUTCH” on page 5-35. Kick idle gear Kick shaft assembly Spring guide Torsion spring Ratchet wheel Kick gear Kick shaft For installation, reverse the removal proce- dure.
KICKSTATER 5. Install: • Torsion spring “1” Turn the torsion spring clockwise and hook into the proper hole “a” in the crankcase. 3. Install: • Spring guide “1” Slide the spring guide into the kick shaft, make sure the groove “a” in the spring guide fits on the stopper of the torsion spring.
SHIFT SHAFT SHIFT SHAFT EAS1SM5255 Removing the shift shaft and stopper lever 10 Nm (1.0 m kgf, 7.2 ft lbf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft lbf) Order Part name Q’ty...
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SHIFT SHAFT Removing the shift shaft and stopper lever 10 Nm (1.0 m kgf, 7.2 ft lbf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft lbf) Order Part name Q’ty...
SHIFT SHAFT INSTALLING THE SHIFT GUIDE AND SHIFT INSTALLING THE STOPPER LEVER EAS1SM5261 LEVER ASSEMBLY 1. Install: 1. Install: • Torsion spring “1” • Spring “1” • Collar “2” • Pawl pin “2” • Stopper lever “3” • Pawl “3” •...
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OIL PUMP AND BALANCER GEAR OIL PUMP AND BALANCER GEAR EAS1SM5266 Removing the oil pump 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • Order Part name Q’ty Remarks Primary driven gear Refer to “CLUTCH”...
OIL PUMP AND BALANCER GEAR Removing the balancer 75 Nm (7.5 m kgf, 54 ft lbf) 50 Nm (5.0 m kgf, 36 ft Ibf) Order Part name Q’ty Remarks Primary driven gear Refer to “CLUTCH” on page 5-35. Right crankcase cover Refer to “CLUTCH”...
AC MAGNETO AC MAGNETO EAS1SM5273 Removing the AC magneto 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
AC MAGNETO CHECKING THE WOODRUFF KEY REMOVING THE AC MAGNETO EAS1SM5274 1. Check: 1. Remove: • Woodruff key “1” • Nut (rotor) “1” Damage Replace. • Washers 2. Remove: INSTALLING THE AC MAGNETO EAS1SM5277 • Rotor “1” 1. Install: Use the rotor puller “2”...
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AC MAGNETO 2. Install: • Woodruff key “1” • Rotor “2” • Clean the contact surfaces of the tapered por- tions of the crankshaft and rotor. • When installing the woodruff key, make sure that its flat surface “a” is in parallel with the crankshaft center line “b”.
CRANKCASE CRANKCASE EAS1SM5278 Separating the crankcase 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
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CRANKCASE Separating the crankcase 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
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CRANKCASE Removing the bearing and oil seal 22 Nm (2.2 m kgf, 16 ft Ibf) • • Order Part name Q’ty Remarks Transmission Refer to “TRANSMISSION” on page 5-69. Shift cam and shift fork Refer to “TRANSMISSION” on page 5-69. Circlip Oil seals Bearing...
CRANKCASE DISASSEMBLING THE CRANKCASE EAS1SM5279 1. Separate: • Right crankcase • Left crankcase ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the crankcase bolts. c. Remove the dowel pins and O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ REMOVING THE CRANKCASE BEARING EAS1SM5280 1. Remove: • Bearing “1” • Remove the bearing from the crankcase by pressing its inner race.
CRANKCASE INSTALLING THE OIL SEAL EAS1SM5283 Crankcase bolt 1. Install: 12 Nm (1.2 m·kgf, 8.7 ft·lbf) • Oil seal “1” (to left crankcase) Installed depth “a” • Apply the lithium-soap-based grease on the 4.5–5.0 mm (0.18–0.20 in) O-ring. • Fit the right crankcase onto the left crankcase. Tap lightly on the case with soft hammer.
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EAS1SM5285 Removing the crankshaft assembly and balancer shaft Order Part name Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-61. Transmission Refer to “TRANSMISSION” on page 5-69. Balancer shaft Crankshaft assembly For installation, reverse the removal proce- dure.
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 2. Measure: REMOVING THE CRANKSHAFT ASSEMBLY EAS1SM5286 • Big end side clearance D “a” 1. Remove: Out of specification Replace the big end • Crankshaft assembly “1” bearing, crankshaft pin, or connecting rod. Remove the crankshaft assembly by using the Big end side clearance D 0.150–0.450 mm (0.0059–0.0177 crankcase separating tool “2”.
TRANSMISSION TRANSMISSION EAS1SM5290 Removing the transmission, shift drum assembly, and shift forks Order Part name Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Separate. Crankcase Refer to “CRANKCASE” on page 5-61. Main axle Drive axle Long shift fork guide bar Short shift fork guide bar Spring Shift cam...
COOLING SYSTEM RADIATOR .......................6-1 HANDLING NOTE ..................6-3 CHECKING THE RADIATOR..............6-3 WATER PUMP....................6-4 REMOVING THE OIL SEAL...............6-6 CHECKING THE WATER PUMP ...............6-6 CHECKING THE BEARING ...............6-6 INSTALLING THE OIL SEAL ..............6-6 ASSEMBLING THE WATER PUMP............6-6...
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This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.
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RADIATOR Removing the radiator Order Part name Q’ty Remarks Right radiator Radiator hose 2 Radiator hose 3 Radiator hose 4 Radiator pipe 2 Radiator breather hose Left radiator Radiator hose 1 Radiator pipe 1 Coolant temperature sensor For installation, reverse the removal proce- dure.
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RADIATOR HANDLING NOTE EAS1SM5298 EWA1DX1007 WARNING If coolant seems hot, do not remove the ra- diator cap. CHECKING THE RADIATOR EAS1SM5299 1. Check: • Radiator fins “1” Obstructions Clean. Apply compressed air to the rear of the radi- ator. Damage ...
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WATER PUMP WATER PUMP EAS1SM5300 Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-8. Drain.
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WATER PUMP Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks Bearing Oil seal For installation, reverse the removal proce- dure.
WATER PUMP REMOVING THE OIL SEAL EAS1SM5301 • 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: •...
FUEL SYSTEM FUEL TANK......................7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP ..............7-2 CHECKING THE FUEL PUMP BODY............7-2 INSTALLING THE FUEL PUMP..............7-2 INSTALLING THE FUEL TANK..............7-3 CHECKING THE FUEL PRESSURE ............7-3 CHECKING THE DAMPER ................7-4 CHECKING AND REPLACING THE PROTECTOR ........7-4 THROTTLE BODY....................7-5 CHECKING THE INJECTOR ..............7-8 CHECKING THE THROTTLE BODY ............7-8...
This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.
FUEL TANK REMOVING THE FUEL TANK EAS1SM5308 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose coupler EWA23P1001 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.
FUEL TANK CHECKING AND REPLACING THE PRO- TECTOR 1. Check: • Protector “1” Wear/damage Replace. Affix the protector as shown. e. Start the engine. f. Measure the fuel pressure. Out of specification Replace the fuel pump. Fuel pressure 0 mm 324.0 kPa (3.24 kgf/cm , 47.0...
THROTTLE BODY THROTTLE BODY EAS1SM5316 Removing the throttle body 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) •...
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THROTTLE BODY Removing the throttle body 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) •...
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THROTTLE BODY Removing the injector 3.4 Nm (0.34 m kgf, 2.5 ft lbf) 5 Nm (0.5 m kgf, 3.6 ft lbf) 3.4 Nm (0.34 m kgf, 2.5 ft lbf) Order Part name Q’ty Remarks Fuel inlet pipe Injector Gaskets Throttle position sensor Intake air pressure sensor For installation, reverse the removal proce- dure.
THROTTLE BODY CHECKING THE INJECTOR EAS1SM5317 1. Check: • Injector Obstruction Replace, and check the fuel pump and the fuel injection system. Refer to “FUEL INJECTION SYSTEM” on page 8-10. Deposits Replace. Damage Replace. 2. Check: • Injector resistance Refer to “CHECKING THE FUEL INJEC- TOR”...
Check that the throttle grip is fully closed. d. Connect the throttle position sensor to the wire harness. e. Set the Yamaha diagnostic tool to “diagnos- tic mode”. f. Choose the diagnostic code No. “01”. g. Adjust the throttle position sensor mounted angle until “11?...
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This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.
IGNITION SYSTEM TROUBLESHOOTING EAS1SM5324 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 NG 1.
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IGNITION SYSTEM NG 8. Check the ignition system wire har- ness. Repair or replace the wire harness. Refer to “CIRCUIT DIAGRAM” on page 8-2. OK Replace the ECU.
CHARGING SYSTEM TROUBLESHOOTING EAS1SM5326 The condenser is not being charged. Before troubleshooting, remove the following part (s): 1. Seat 2. Air scoop (left) NG 1. Check the entire charging system’s Reconnect. wiring. OK NG 2. Check the rectifier/regulator. Replace the rectifier/regulator.
FUEL INJECTION SYSTEM YAMAHA DIAGNOSTIC TOOL EAS1SM5329 This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool 90890-03231...
After the check and service of the malfunctioning part have been completed, reset the Yamaha diag- nostic tool display according to the “Reinstatement method”. Fault code No.: To be displayed on the Yamaha diagnostic tool when the engine fails to work nor- mally Diagnostic code No.: To be used when the diagnostic mode is active...
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FUEL INJECTION SYSTEM Fault code Crankshaft position sensor: no normal signals are received Symptom from the crankshaft position sensor. Fail-safe system Unable to start engine Unable to drive vehicle Diagnostic code No. — Diagnostic tool display — Procedure — Probable cause of malfunc- Maintenance job Reinstatement method tion and check...
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Able to start engine 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- Maintenance job Reinstatement method tion and check Improperly connected ...
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Able to start engine 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- Maintenance job Reinstatement method tion and check...
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FUEL INJECTION SYSTEM Fault code Intake air pressure sensor: hose system malfunction (clogged Symptom or detached hose) Defective intake air pressure Execute the diagnostic mode. sensor. (Code No. 03) Atmospheric pressure at the current altitude and weather conditions is indicated. 0 m above sea level: About 101 kPa 1000 m above sea level:...
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FUEL INJECTION SYSTEM Fault code Symptom Throttle position sensor: open or short circuit detected. Improperly connected Connection of sub wire har- Turn “ON” the switch on the ness coupler. Connect the coupler secure- FI diagnostic tool sub-lead. Check the locking condition ly, or repair/replace the sub- Fault code No.
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FUEL INJECTION SYSTEM Fault code Throttle position sensor: stuck throttle position sensor is de- Symptom tected. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the throttle angle. • 11–14 (throttle in fully closed position) •...
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Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the coolant temperature. Procedure Compare the actually measured coolant temperature with the Yamaha diagnostic tool display value. Probable cause of malfunc- Maintenance job Reinstatement method tion and check Improperly connected ...
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Diagnostic code No. Diagnostic tool display Displays the intake air temperature. Procedure Compare the actually measured intake air temperature with the Yamaha diagnostic tool display value. Probable cause of malfunc- Maintenance job Reinstatement method tion and check Improperly connected ...
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FUEL INJECTION SYSTEM Fault code Symptom The vehicle has overturned. Fail-safe system Able to start engine Unable to drive vehicle Diagnostic code No. Diagnostic tool display Displays the lean angle sensor output voltage. • 1.0 V (upright) • 4.0 V (overturned) Procedure Remove the ECU, and incline it 45 °...
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Unable to drive vehicle Diagnostic code No. Actuation Actuates the ignition coil five times at one-second intervals. “WARNING” on the Yamaha diagnostic tool blinks five times when- ever the ignition coil is actuated. Procedure Check that a spark is generated five times.
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Unable to drive vehicle Diagnostic code No. Actuation Actuates injector five times at one-second intervals. “WARNING” on the Yamaha diagnostic tool blinks five times when the injector is actuated. Procedure Check that injector is actuated five times by listening for the oper- ating sound.
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FUEL INJECTION SYSTEM Fault code Symptom Injector: open or short circuit detected. Improperly connected Connection of sub wire har- After starting the engine, idle ness coupler. Connect the coupler secure- this and wait about 5 sec- Check the locking condition ly, or repair/replace the sub- onds.
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FUEL INJECTION SYSTEM Fault code EEPROM fault code No.: an error is detected while reading or Symptom writing on EEPROM. Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No. Diagnostic tool display Displays the location of the abnormal portion of the EEPROM data. •...
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FUEL INJECTION SYSTEM Fault code Vehicle system power supply: normal voltage is not supplied Symptom to the ECU. Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No. — Diagnostic tool display — Procedure — Probable cause of malfunc- Maintenance job Reinstatement method tion and check...
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— Probable cause of malfunc- Maintenance job Reinstatement method tion and check Improperly connected Connection of Yamaha diag- Turn “ON” the switch on the nostic tool coupler. Connect the coupler secure- FI diagnostic tool sub-lead. Check the locking condition ly, or repair/replace the wire Fault code No.
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FUEL INJECTION SYSTEM Fault code Waiting for connection Symptom No communication signal is received from the ECU. Yamaha diagnostic tool mal- Replace the Yamaha diag- Turn “ON” the switch on the function nostic tool. FI diagnostic tool sub-lead. Fault code No. is not dis- played ...
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— Probable cause of malfunc- Maintenance job Reinstatement method tion and check Improperly connected Connection of Yamaha diag- Turn “ON” the switch on the nostic tool coupler. Connect the coupler secure- FI diagnostic tool sub-lead. Check the locking condition ly, or repair/replace the wire Fault code No.
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FUEL INJECTION SYSTEM Fault code Er-4 Registered data cannot be received from the Yamaha diagnos- Symptom tic tool. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. — Diagnostic tool display — Procedure — Probable cause of malfunc-...
FUEL PUMP SYSTEM TROUBLESHOOTING EAS1SM5333 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 NG 1. Check the fuel pump system wire Reconnect.
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ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 NOTICE Never insert the tester probes into the coupler terminal slots “1”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
ELECTRICAL COMPONENTS CHECKING THE IGNITION SPARK GAP EAS1SM5337 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( 1k) to the 1. Check: spark plug cap. • Ignition spark gap Out of specification Perform the ignition Pocket tester system troubleshooting. 90890-03112 Refer to “TROUBLESHOOTING”...
ELECTRICAL COMPONENTS CHECKING THE CRANKSHAFT POSITION SENSOR 1. Disconnect: • Crankshaft position sensor coupler (from the wire harness) 2. Check: • Crankshaft position sensor resistance Out of specification Replace. Crankshaft position sensor resis- tance b. Measure the primary coil resistance. 228–342 ...
ELECTRICAL COMPONENTS CHECKING THE RECTIFIER/REGULATOR CHECKING THE ECU EAS1SM5341 1. Check: 1. Check: • Rectifier/regulator output voltage • Mounted condition of ECU. Out of specification Replace. Improperly mounted Remount. Output voltage 14 V or more at 5000 r/min •...
ELECTRICAL COMPONENTS c. Place a thermometer in the coolant. CHECKING THE COOLANT TEMPERATURE EAS1SM5344 d. Slowly heat the coolant, and then let it cool SENSOR to the specified temperature indicated in the 1. Remove: table. • Coolant temperature sensor e. Check the coolant temperature sensor for EWA14130 WARNING continuity at the temperatures indicated in...
ELECTRICAL COMPONENTS 2. Check: CHECKING THE THROTTLE POSITION • Throttle position sensor maximum resis- SENSOR INPUT VOLTAGE tance 1. Check: Out of specification Replace. • Throttle position sensor input voltage Out of specification Replace the ECU. Resistance 6.30 k Throttle position sensor input voltage 4–6 V...
ELECTRICAL COMPONENTS 2. Check: CHECKING THE INTAKE AIR PRESSURE EAS1SM5347 • Intake air temperature sensor resistance SENSOR Out of specification Replace. 1. Check: • Intake air pressure sensor output voltage Intake air temperature sensor re- Out of specification Replace. sistance 290–390 ...
TROUBLESHOOTING Electrical system TROUBLESHOOTING EAS1SM5351 1. Spark plug • Incorrect spark plug gap EAS1SM5352 GENERAL INFORMATION • Incorrect spark plug heat range • Fouled spark plug The following guide for troubleshooting does • Worn or damaged electrode not cover all the possible causes of trouble. It •...
TROUBLESHOOTING Fuel system Malfunction 1. Throttle body • Bent or damaged inner tube • Damaged or loose throttle body joint • Bent or damaged outer tube 2. Air filter • Broken fork spring • Clogged air filter element • Bent or damaged damper rod •...
8-28 nection Er-2 Signals from the ECU cannot be received within the specified period 8-29 of time. Er-3 Data from the ECU cannot be received correctly. 8-30 Er-4 Registered data cannot be received from the Yamaha diagnostic tool. 8-31...
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• Check with throttle fully opened. Pressure of suction pipe Displays the intake air pres- The atmospheric pressure sure. is displayed on the Yamaha diagnostic tool. Intake air temperature Displays the intake air tem- Compare the actually mea- perature. sured intake air tempera-...
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Actuates the ignition coil five Check that a spark is gener- times at one-second inter- ated five times. vals. • Connect an ignition “WARNING” on the Yamaha checker. diagnostic tool blinks five times when the ignition coil is actuated. Injector...
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LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS...
TUNING CHASSIS ......................10-1 SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET) ................10-1 DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS ....10-1 TIRE PRESSURE..................10-2 FRONT FORK SETTING................10-2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL..10-2 SETTING OF SPRING AFTER REPLACEMENT ........10-3 FRONT FORK SETTING PARTS.............10-3 REAR SUSPENSION SETTING ..............10-3 CHOOSING SET LENGTH ..............10-3 SETTING OF SPRING AFTER REPLACEMENT ........10-4...
CHASSIS DRIVE AND REAR WHEEL SPROCKETS CHASSIS EAS1SM5367 SETTING PARTS EAS1SM5368 SELECTION OF THE SECONDARY REDUC- Part name Type Part number TION RATIO (SPROCKET) Drive sprocket “1” Secondary reduction ratio = Number of (STD) 13T 9383B-13218 rear wheel sprocket teeth/Number of Rear wheel drive sprocket teeth sprocket “2”...
CHASSIS TIRE PRESSURE EAS1SM5370 EWA1DX4001 WARNING Tire pressure should be adjusted to suit the Adjust the oil amount in 5 cm (0.2 US oz, road surface condition of the circuit. 0.2 Imp.oz) increments or decrements. Too small oil amount causes the front fork to Standard tire pressure produce a noise at full rebound or the rider 100 kPa (1.0 kgf/cm...
CHASSIS SETTING OF SPRING AFTER REPLACE- EAS1SM5373 MENT As the front fork setting can be easily affected by the rear suspension, take care so that the front and the rear are balanced (in position etc.) when setting the front fork. 1.
CHASSIS 2. Remove the stand or block from the engine SETTING OF SPRING AFTER REPLACE- and, with a rider astride the seat, measure MENT the sunken length “b” between the rear After replacement, be sure to adjust the spring wheel axle center and the rear fender hold- to the set length [sunken length 90–100 mm ing bolt.
CHASSIS SUSPENSION SETTING (FRONT FORK) EAS1SM5379 • If any of the following symptoms is experienced with the standard position as the base, make reset- ting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in).
CHASSIS Section Medi- Symptom Check Adjust Large Small Jump Compression Turn adjuster clockwise (about damping force 2 clicks) to increase damping. Rebound Turn adjuster counterclock- damping force wise (about 2 clicks) to de- crease damping. Low front, tend- ing to lower Balance with Set sunken length for 95–100 front posture...
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CHASSIS Section Medi- Symptom Check Adjust Large Small Jump Rebound Turn adjuster counterclock- damping force wise (about 2 clicks) to de- Heavy and crease damping. dragging Spring Replace with soft spring. Rebound Turn adjuster counterclock- damping force wise (about 2 clicks) to de- crease damping.
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WIRING DIAGRAM EAS1SM5382 YZ250F/YZ250FF 2015 1. Crankshaft position sensor 2. AC magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser 6. Coupler for connecting option- al part 7. Engine stop switch 8. Neutral switch 9. ECU 10. Ignition coil 11. Spark plug 12.
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PRINTED ON RECYCLED PAPER PRINTED IN JAPAN...
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SCHÉMA DE CÂBLAGE SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO SCHEMA ELETTRICO WIRING DIAGRAM WIRING DIAGRAM SCHALTPLAN SCHALTPLAN YZ250F (E) 2014 YZ250F/YZ250FF 2015 YZ250F (E) 2014 YZ250F/YZ250FF 2015 YZ250F (E) 2014 YZ250F/YZ250FF 2015 YZ250F (E) 2014 YZ250F/YZ250FF 2015 B B B B R R...