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2014
q Read this manual carefully before operating this vehicle.
q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule.
q 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 ( E )
1SM-28199-30

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Chapters

Troubleshooting

   Summary of Contents for Yamaha YZ250F(E)

  • Page 1

    2014 q Read this manual carefully before operating this vehicle. q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. q 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...

  • Page 2

    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.

  • Page 3

    2014 2014 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(E) YZ250F(E) 1SM-28199-30-E0 1SM-28199-30-E0...

  • Page 5

    EAS1SM1002 YZ250F(E) 2014 OWNER’S SERVICE MANUAL ©2013 by Yamaha Motor Co., Ltd. First edition, August 2013 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.

  • Page 6: Important Manual Information

    INTRODUCTION EAS1SM1003 Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.

  • Page 7: Safety Information

    SAFETY INFORMATION EAS1SM1005 THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding. •...

  • Page 8: How To Use This Manual

    HOW TO USE THIS MANUAL EAS1SM1006 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 9

    SYMBOLS EAS1SM1007 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 11: Table Of Contents

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

  • Page 13: General Information

    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...

  • Page 14

    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...

  • Page 15: Location Of Important Labels

    LOCATION OF IMPORTANT LABELS LOCATION OF IMPORTANT LABELS EAS1SM1008 Please read the following important labels carefully before operating this vehicle. 1,2,3 4,5,6 9,10,11...

  • Page 16

    LOCATION OF IMPORTANT LABELS...

  • Page 17

    LOCATION OF IMPORTANT LABELS AUS, NZL, ZAF...

  • Page 18: Description

    DESCRIPTION DESCRIPTION EAS1SM1009 16 15 14 1. Clutch lever 10. Coolant drain bolt 2. Front brake lever 11. Rear brake pedal 3. Throttle grip 12. Air filter 4. Radiator cap 13. Drive chain 5. Fuel tank cap 14. Shift pedal 6.

  • Page 19: Identification

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

  • Page 20: Features

    FEATURES FEATURES EAS20170 OUTLINE OF THE FI SYSTEM EAS1SM1014 The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.

  • Page 21: Fi System

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

  • Page 22: Included Parts

    INCLUDED PARTS HANDLEBAR PROTECTOR INCLUDED PARTS EAS1SM1016 Install the handlebar protector “1” with the mark “a” facing forward. EAS1SM1017 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.

  • Page 23

    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.

  • Page 24: Important Information

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

  • Page 25: Gaskets, Oil Seals And O-rings

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

  • Page 26: Basic Service Information

    BASIC SERVICE INFORMATION BASIC SERVICE INFORMATION EAS1SM1029 EAS1SM1030 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...

  • Page 27

    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.

  • Page 28

    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.

  • Page 29: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS EAS1SM1031 The following special tools are required for accurate and complete adjustment and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and tool number used for the special tool differ by country, so two types are provided.

  • Page 30

    SPECIAL TOOLS Tool name/Part number How to use Illustration Radiator cap tester This tool is used to check the 90890-01325 radiator and the radiator cap. Mityvac cooling system tester YU-24460-A Radiator cap tester adapter This tool is used to check the 90890-01352 radiator and the radiator cap.

  • Page 31

    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. Spacer (crankshaft installer) This tool is used to install the 90890-04081 crankshaft. Pot spacer...

  • Page 32

    SPECIAL TOOLS Tool name/Part number How to use Illustration 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. Valve lapper This tool is used to remove 90890-04101 the valve lifter or lap the Valve lapping tool...

  • Page 33

    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)

  • Page 34: Control Functions

    CONTROL FUNCTIONS KICKSTARTER LEVER CONTROL FUNCTIONS EAS1SM1032 The kickstarter lever “1” is in the right of the chassis. EAS1SM1033 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.

  • Page 35: Rear Brake Pedal

    CONTROL FUNCTIONS REAR BRAKE PEDAL 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 SCREW EAS1SM1040 Starting a cold engine requires a larger amount of intake air, which is supplied by the starter knob/idle screw “1”.

  • Page 36: Starting And Break-in

    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-...

  • Page 37: Starting A Warm Engine

    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.

  • Page 38: Maintenance After Break-in

    MAINTENANCE AFTER BREAK-IN • Cable MAINTENANCE AFTER BREAK-IN EAS1SM1046 Grease and adjust cables. After a break-in, perform careful maintenance • Drive chain to get ready for the next practice or race. Lubricate the drive chain and adjust its ten- Refer to “PRE-OPERATION INSPECTION sion.

  • Page 39: Torque-check Points

    TORQUE-CHECK POINTS TORQUE-CHECK POINTS EAS1SM1048 Frame construction Frame to rear frame Frame to engine protector Combined seat and fuel tank Fuel tank to frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Seat Seat to frame Steering Steering stem to handlebar Steering stem to frame...

  • Page 40

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

  • Page 41: Cleaning And Storage

    CLEANING AND STORAGE 3. Remove the drive chain, clean it thoroughly CLEANING AND STORAGE EAS1SM1049 with solvent, and lubricate it Reinstall the drive chain or store it in a plastic bag tied to EAS1SM1050 CLEANING the frame. Frequent cleaning of your vehicle will enhance 4.

  • Page 42

    CLEANING AND STORAGE 1-28...

  • Page 43: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS .................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-8 ELECTRICAL SPECIFICATIONS ..............2-11 TIGHTENING TORQUES ................2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-12 ENGINE TIGHTENING TORQUES............2-13 CHASSIS TIGHTENING TORQUES............2-16 LUBRICATION POINTS AND LUBRICANT TYPES ........2-19 ENGINE....................2-19 CHASSIS....................2-21 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-23 LUBRICATION DIAGRAMS ..............2-23 CABLE ROUTING DIAGRAM ................2-31...

  • Page 44: General Specifications

    GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS EAS1SM1052 Model Model 1SM1 (USA) (CAN) 1SM2 (EUR) 1SM3 (JPN) 1SM4 (AUS) (NZL) (ZAF) Dimensions Overall length 2165 mm (85.2 in) (USA) (CAN) (AUS) (NZL) (ZAF) 2170 mm (85.4 in) (EUR) (JPN) Overall width 825 mm (32.5 in) Overall height 1280 mm (50.4 in) (USA) (CAN) (EUR) (JPN) 1275 mm (50.2 in) (AUS) (NZL) (ZAF)

  • Page 45: Engine Specifications

    ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS EAS1SM1053 Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 250 cm Cylinder arrangement Single cylinder Bore  stroke 77.0  53.6 mm (3.03  2.11 in) Compression ratio 13.50:1 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...

  • Page 46

    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)

  • Page 47

    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)

  • Page 48

    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...

  • Page 49

    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...

  • Page 50

    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-A13M/1 ID mark 1SM1 00 Fuel pressure 324.0 kPa (3.24 kgf/cm , 47.0 psi) Throttle position sensor Resistance...

  • Page 51: Chassis Specifications

    CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS EAS1SM1054 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...

  • Page 52

    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 ...

  • Page 53

    CHASSIS SPECIFICATIONS Compression damping adjusting positions * Position in which the adjuster is turned in finger tight Minimum 20 click (s) out* Standard 8 click (s) out* (USA) (CAN) 6 click (s) out* (EUR) (JPN) (AUS) (NZL) (ZAF) Maximum (hard) Fully turned in Rear suspension Type...

  • Page 54: Electrical Specifications

    Advancer type Digital Ignition timing (B.T.D.C.) 10.0 ° at 2000 r/min Engine control unit Model/manufacturer 1SM0/YAMAHA (USA) (CAN) 1SM1/YAMAHA (EUR) (AUS) (NZL) (ZAF) 1SM2/YAMAHA (JPN) Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64  Primary coil resistance Secondary coil resistance 8.64–12.96 k...

  • Page 55: Tightening Torques

    TIGHTENING TORQUES TIGHTENING TORQUES EAS20320 EAS1SM1056 GENERAL TIGHTENING TORQUE SPECIFI- CATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a criss- cross pattern and progressive stages until the specified tightening torque is reached.

  • Page 56: Engine Tightening Torques

    TIGHTENING TORQUES ENGINE TIGHTENING TORQUES EAS1SM1057 - marked portion shall be checked for torque tightening after break-in or before each race. Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Cylinder head blind plug 28 Nm (2.8 m·kgf, 20 ft·lbf) Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf)

  • Page 57

    TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Air filter guide holder screw 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) Air filter case cap screw 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) Starter knob/Idle screw 2.1 Nm (0.21 m·kgf, 1.5 ft·lbf) Throttle cable nut (pull) 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Throttle cable nut (return)

  • Page 58

    TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Use a lock Drive sprocket nut 75 Nm (7.5 m·kgf, 54 ft·lbf) washer. Segment 30 Nm (3.0 m·kgf, 22 ft·lbf) Shift guide bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Stopper lever bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Shift pedal bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf)

  • Page 59: Chassis Tightening Torques

    TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES - marked portion shall be checked for torque tightening after break-in or before each race. Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Outer tube and upper bracket bolt 21 Nm (2.1 m·kgf, 15 ft·lbf) Outer tube and lower bracket bolt 21 Nm (2.1 m·kgf, 15 ft·lbf) Upper bracket and steering stem 145 Nm (14.5 m·kgf, 105 ft·lbf)

  • Page 60

    TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Front wheel axle pinch bolt 21 Nm (2.1 m·kgf, 15 ft·lbf) Front brake disc bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Rear brake disc bolt 14 Nm (1.4 m·kgf, 10 ft·lbf) Footrest bracket bolt 55 Nm (5.5 m·kgf, 40 ft·lbf) Rear brake pedal bolt...

  • Page 61

    TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Drive chain tensioner bolt (upper 16 Nm (1.6 m·kgf, 12 ft·lbf) side) Drive chain tensioner bolt (lower 16 Nm (1.6 m·kgf, 12 ft·lbf) side) Drive chain support bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Drive chain support nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Drive chain guide bolt...

  • Page 62: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES EAS1SM1059 EAS1SM1060 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...

  • Page 63

    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® EAS1SM1061 2-20...

  • Page 64: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES CHASSIS Lubrication point Lubricant types Upper bearings (steering head) Upper bearings and bearing race cover (steering head) Lower bearings and oil seal lip (steering head) Steering stem threads and nut contacting surface Pivot shaft bearing Swingarm pivot portion (collar side surface and thrust bearing) Swingarm pivot portion (collar outer surface) Swingarm pivot portion (oil seal lip)

  • Page 65

    LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Rear brake caliper pin bolt and boot Rear brake master cylinder push rod end Rear brake master cylinder kit 2-22...

  • Page 66: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION SYSTEM CHART AND DIAGRAMS EAS1SM1062 EAS1SM1063 LUBRICATION DIAGRAMS 2-23...

  • Page 67

    LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Piston 4. Oil nozzle 5. Oil filter element 6. Oil pump 7. Oil strainer 8. Crankshaft 9. Drive axle 10. Main axle 2-24...

  • Page 68

    LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25...

  • Page 69

    LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Connecting rod 2. Crankshaft 3. Main axle 4. Oil strainer 5. Drive axle 2-26...

  • Page 70

    LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...

  • Page 71

    LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Exhaust camshaft 2. Intake camshaft 3. Oil filter element 4. Oil pump 2-28...

  • Page 72

    LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...

  • Page 73

    LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil pressure check bolt 3. Oil filter element 4. Oil pump 2-30...

  • Page 74: Cable Routing Diagram

    CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM EAS1SM1064 2-31...

  • Page 75

    CABLE ROUTING DIAGRAM 1. Clutch cable R. Pass the rectifier/regulator lead to the inside of 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.

  • Page 76

    CABLE ROUTING DIAGRAM 2-33...

  • Page 77

    CABLE ROUTING DIAGRAM 1. Bracket T. Clamp the painted part on the fuel hose by the plastic clamp. Make the lock on the plastic clamp 2. Condenser face the bottom of the vehicle, and cut the end. 3. Coolant temperature sensor 4.

  • Page 78

    CABLE ROUTING DIAGRAM 2-35...

  • Page 79

    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.

  • Page 80

    CABLE ROUTING DIAGRAM 2-37...

  • Page 81

    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.

  • Page 82

    CABLE ROUTING DIAGRAM 2-39...

  • Page 83

    CABLE ROUTING DIAGRAM 1. Brake master cylinder 2. Brake hose holder 3. Brake hoses A. While installing the brake hose, direct a bend in its pipe portion as shown, and bring it into contact with the projection on the brake caliper. B.

  • Page 84

    CABLE ROUTING DIAGRAM 2-41...

  • Page 85: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS MAINTENANCE INTERVALS ................3-1 MAINTENANCE INTERVALS ..............3-1 PRE-OPERATION INSPECTION AND MAINTENANCE.........3-7 GENERAL INSPECTION AND MAINTENANCE........3-7 ENGINE ......................3-8 CHECKING THE COOLANT LEVEL............3-8 CHECKING THE COOLING SYSTEM ............3-8 CHANGING THE COOLANT..............3-8 CHECKING THE RADIATOR CAP ............3-9 CHECKING THE RADIATOR CAP 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...

  • Page 86

    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...

  • Page 87: Maintenance Intervals

    MAINTENANCE INTERVALS MAINTENANCE INTERVALS EAS1SM1065 EAS1SM1066 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.).

  • Page 88

    MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) PISTON RING Inspect Check the end gap of the pis- ton ring. Replace Replace the piston, piston pin, piston pin clip, and piston ring all as a set.

  • Page 89

    MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) NUT (ROTOR) Retighten Check for tightening torques. EXHAUST PIPE, SI- LENCER, PROTEC- Inspect and re- Check for exhaust leaks, and tighten tightening torques.

  • Page 90

    MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) 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...

  • Page 91

    MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) 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...

  • Page 92

    MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) LEVERS Adjust clutch lever free play KICKSTARTER LE- VER, BRAKE PED- AL, FOOTREST Lubricate OUTSIDE NUTS AND BOLTS Retighten Refer to “TORQUE-CHECK POINTS”...

  • Page 93: Pre-operation Inspection And Maintenance

    PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE EAS1SM1067 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 EAS1SM1068 ITEM inspect Page...

  • Page 94: Engine

    ENGINE ENGINE CHECKING THE COOLING SYSTEM EAS1SM1069 EAS1SM1071 1. Remove: EAS1SM1070 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.

  • Page 95: Checking The Radiator Cap

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

  • Page 96: Checking The Coolant Circulatory System For Leaks

    ENGINE CHECKING THE COOLANT CIRCULATORY ADJUSTING THE CLUTCH LEVER POSI- EAS1SM1075 EAS1SM1076 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”...

  • Page 97: Adjusting The Throttle Grip Free Play

    ENGINE ADJUSTING THE THROTTLE GRIP FREE EAS1SM1078 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...

  • Page 98: Lubricating The Throttle Cable

    ENGINE LUBRICATING THE THROTTLE CABLE EAS1SM1079 1. Remove: • Cover (throttle cable cap) “1” • Cover (grip cap) “2” • Throttle grip cap “3” 2. Remove: • Air filter mounting bolt “1” • Air filter element “2” • Air filter guide “3” (from the air filter element) 2.

  • Page 99: Checking The Throttle Body Joint

    ENGINE 4. Check: CHECKING THE THROTTLE BODY JOINT EAS1SM1081 • Air filter element 1. Check: Damage  Replace. • Throttle body joint “1” 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 EAS1SM1082 CHECKING THE BREATHER HOSES...

  • Page 100: Checking The Fuel Line

    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- EAS1SM1085 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle upright on a level surface. 2.

  • Page 101: Changing The Engine Oil

    ENGINE c. Install the new oil filter element and the oil fil- CHANGING THE ENGINE OIL EAS1SM1086 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.

  • Page 102: Adjusting The Engine Idling Speed

    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,...

  • Page 103: Adjusting The Valve Clearance

    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”...

  • Page 104

    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”...

  • Page 105

    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. •...

  • Page 106

    ENGINE INTAKE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.02 0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230...

  • Page 107: Chassis

    CHASSIS CHASSIS EAS1SM1089 EAS1SM1090 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.

  • Page 108: Checking The Brake Hose

    CHASSIS CHECKING THE BRAKE HOSE EAS1SM1091 1. Check: • Brake hose “1” Cracks/damage/wear  Replace. 2. Remove: • Brake lever cover 3. Adjust: • Brake lever position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. b. Turn the adjusting bolt “2” in direction “a” or “b”...

  • Page 109: Adjusting The Rear Brake

    CHASSIS ADJUSTING THE REAR BRAKE EAS1SM1093 ECA13510 NOTICE 1. Check: After adjusting the brake pedal position, • Brake pedal position “a” make sure that there is no brake drag. (distance from the top of the rider footrest to the top of the brake pedal) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 110

    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)

  • Page 111: Checking The Rear Brake Pads

    CHASSIS CHECKING THE REAR BRAKE PADS EAS1SM1095 1. Measure: • Brake pad thickness “a” Out of specification  Replace as a set. The pads worn up to the indicator “b” grooves mean that the brake pad thickness limit is reached. Brake pad lining thickness (inner) d.

  • Page 112: Checking The Rear Brake Pad Insulator

    CHASSIS 4. Check: • Brake pedal operation A softy or spongy feeling  Bleed the brake system. Refer to “BLEEDING THE BRAKE SYS- TEM” on page 3-21. EAS1SM1096 CHECKING THE REAR BRAKE PAD INSU- LATOR 1. Remove: • Brake pads i.

  • Page 113: Adjusting The Drive Chain Slack

    CHASSIS EWA13090 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake flu- ids may result in a harmful chemical reac- tion, leading to poor brake performance.

  • Page 114: Checking The Front Fork Legs

    CHASSIS CHECKING THE FRONT FORK LEGS CLEANING THE FRONT FORK OIL SEAL EAS1SM1099 EAS1SM1101 1. Stand the vehicle upright on a level surface. AND DUST SEAL 1. Remove: EWA13120 WARNING • Protector Securely support the vehicle so that there is •...

  • Page 115: Adjusting The Front Fork Legs

    CHASSIS 3. Tighten: • Air bleed screw Air bleed screw 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping force ECA13590 NOTICE Do not turn the adjuster forcibly beyond its adjusting range. EAS1SM1103 ADJUSTING THE FRONT FORK LEGS 1. Adjust: EWA32D1006 WARNING •...

  • Page 116: Checking The Swingarm Operation

    CHASSIS 1. Remove: CHECKING THE SWINGARM OPERATION EAS1SM1104 • 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 EAS1SM1105 CHECKING THE REAR SUSPENSION ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 117

    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 ECA13590 30 Nm (3.0 m·kgf, 22 ft·lbf) NOTICE Do not turn the adjuster forcibly beyond its adjusting range.

  • Page 118: Checking The Tires

    CHASSIS CHECKING THE TIRES EAS1SM1107 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 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 119: Checking The Wheels

    CHASSIS 2. Tighten: CHECKING AND ADJUSTING THE STEER- EAS1SM1111 • 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.

  • Page 120: Lubricating The Levers

    CHASSIS 5. Install: • Upper bracket Refer to “STEERING HEAD” on page 4-49. • Handlebar Refer to “HANDLEBAR” on page 4-31. LUBRICATING THE LEVERS EAS1SM1112 1. Lubricate the pivoting points and metal-to- metal moving parts of the following parts. • Brake lever Recommended lubricant Steering nut wrench Silicone grease...

  • Page 121: Electrical System

    ELECTRICAL SYSTEM 5. Clean: ELECTRICAL SYSTEM EAS1SM1114 • Spark plug (with a spark plug cleaner or a wire brush) EAS1SM1115 CHECKING THE SPARK PLUG 6. Measure: 1. Remove: • Spark plug gap “a” • Seat Out of specification  Adjust the spark plug •...

  • Page 122

    ELECTRICAL SYSTEM 2. Attach: • Timing light “1” • Digital tachometer “2” To the high tension code “3”. Timing light 90890-03141 YU-03141 Digital tachometer 90890-06760 YU-39951-B 3. Adjust: • Engine idling speed Refer to “ADJUSTING THE ENGINE IDLING SPEED” on page 3-16. 4.

  • Page 123

    CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE LEFT SIDE COVER............4-2 REMOVING THE SEAT ................4-2 REMOVING THE NUMBER PLATE............4-2 FRONT WHEEL....................4-3 REMOVING THE FRONT WHEEL.............4-4 CHECKING THE FRONT WHEEL .............4-4 DISASSEMBLING THE FRONT WHEEL...........4-5 ASSEMBLING THE FRONT WHEEL............4-5 INSTALLING THE FRONT WHEEL ............4-6 REAR WHEEL ....................4-7 REMOVING THE REAR WHEEL ...............4-8 CHECKING THE REAR WHEEL..............4-8...

  • Page 124

    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...

  • Page 125: General Chassis

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

  • Page 126: Removing The Left Side Cover

    GENERAL CHASSIS REMOVING THE LEFT SIDE COVER REMOVING THE NUMBER PLATE EAS1SM1119 EAS1SM1121 1. Remove: 1. Remove: • Bolt (side cover) • Bolt (number plate) • Side cover “1” • Number plate “1” Draw the left side cover “1” backward to re- •...

  • Page 127: Front Wheel

    FRONT WHEEL FRONT WHEEL EAS1SM1122 Removing the front wheel 21 Nm (2.1 m kgf, 15 ft Ibf) • • 21 Nm (2.1 m kgf, 15 ft Ibf) • • 115 Nm (11.5 m kgf, 83 ft lbf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...

  • Page 128: Removing The Front Wheel

    FRONT WHEEL REMOVING THE FRONT WHEEL EAS1SM1123 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 •...

  • Page 129: Disassembling The Front Wheel

    FRONT WHEEL DISASSEMBLING THE FRONT WHEEL EAS1SM1125 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.

  • Page 130: Installing The Front Wheel

    FRONT WHEEL 3. Install: 3. Tighten: • Collar “1” • Front wheel axle nut “1” Front wheel axle nut Apply the lithium soap 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.

  • Page 131: Rear Wheel

    REAR WHEEL REAR WHEEL EAS1SM1128 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) •...

  • Page 132: Removing The Rear Wheel

    REAR WHEEL 4. Measure: REMOVING THE REAR WHEEL EAS1SM1129 • 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.

  • Page 133: Assembling The Rear Wheel

    REAR WHEEL Tighten the self-locking nuts in stages and in a crisscross pattern. 2. Install: • Brake disc “1” • Brake disc bolt “2” Brake disc bolt ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 14 Nm (1.4 m·kgf, 10 ft·lbf) LOCTITE® ASSEMBLING THE REAR WHEEL EAS1SM1133 1.

  • Page 134

    REAR WHEEL Install the brake disc “1” between the brake Temporarily tighten the nut (rear wheel axle) at pads “2” correctly. this point. 2. Install: 5. Adjust: • Drive chain “1” • Drive chain slack “a” Drive chain slack Push the rear wheel “2” forward and install the 50–60 mm (1.97–2.36 in) drive chain.

  • Page 135: Front Brake

    FRONT BRAKE FRONT BRAKE EAS1SM1135 Removing the front brake caliper 30 Nm (3.0 m kgf, 22 ft lbf) 28 Nm (2.8 m kgf, 20 ft lbf) 6 Nm (0.6 m kgf, 4.3 ft lbf) 17 Nm (1.7 m kgf, 12 ft lbf) 2.5 Nm (0.25 m kgf, 1.8 ft...

  • Page 136

    FRONT BRAKE Disassembling the front brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • Order Part name Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassemble pro- cedure.

  • Page 137

    FRONT BRAKE Removing the front brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft lbf) 6 Nm (0.6 m kgf, 4.3 ft lbf) 6 Nm (0.6 m kgf, 4.3 ft lbf) 30 Nm (3.0 m kgf, 22 ft lbf) Order Part name Q’ty...

  • Page 138

    FRONT BRAKE Disassembling the front brake master cylinder Order Part name Q’ty Remarks Push rod Dust boot Circlip Washer Brake master cylinder kit For assembly, reverse the disassemble pro- cedure. 4-14...

  • Page 139: Introduction

    FRONT BRAKE INTRODUCTION EAS1SM1136 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. •...

  • Page 140: Checking The Front Brake Caliper

    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.

  • Page 141: Installing The Front Brake Caliper

    FRONT BRAKE 3. Install: 2. Install: • Brake caliper piston “1” • Front brake caliper • Brake pad spring • Brake pad Apply the brake fluid on the piston wall. • Brake pad pin ECA33DD047 • Brake hose holder NOTICE •...

  • Page 142: Removing The Front Brake Master Cylinder

    FRONT BRAKE ECA13540 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: 2. Check: •...

  • Page 143: Installing The Front Brake Master Cylinder

    FRONT BRAKE INSTALLING THE FRONT BRAKE MASTER EAS1SM1147 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.

  • Page 144

    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 ...

  • Page 145: Rear Brake

    REAR BRAKE REAR BRAKE EAS1SM1148 Removing the rear brake caliper 10 Nm (1.0 m kgf, 7.2 ft Ibf) 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf)

  • Page 146

    REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • Order Part name Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassemble pro- cedure.

  • Page 147

    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 Plain washer Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm plate Brake master cylinder reservoir diaphragm Rear brake master cylinder...

  • Page 148

    REAR BRAKE Disassembling the rear brake master cylinder Order Part name Q’ty Remarks Dust boot Circlip Push rod Brake master cylinder kit For assembly, reverse the disassemble pro- cedure. 4-24...

  • Page 149: Introduction

    REAR BRAKE INTRODUCTION EAS1SM1149 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.

  • Page 150: Removing The Rear Brake Caliper

    REAR BRAKE REMOVING THE REAR BRAKE CALIPER CHECKING THE REAR BRAKE CALIPER EAS1SM1151 EAS1SM1153 1. Check: • Brake caliper piston “1” Before disassembling the brake caliper, drain Rust/scratches/wear  Replace the brake the brake fluid from the entire brake system. caliper piston.

  • Page 151: Installing The Brake Caliper Piston

    REAR BRAKE INSTALLING THE BRAKE CALIPER PISTON INSTALLING THE REAR BRAKE CALIPER EAS1SM1155 EAS1SM1156 1. Clean: 1. Install: • Brake caliper • Rear brake caliper • Brake caliper piston seal • Rear brake caliper bracket • Brake caliper piston dust seal 2.

  • Page 152: Removing The Rear Brake Master Cylinder

    REAR BRAKE REMOVING THE REAR BRAKE MASTER EWA13090 WARNING CYLINDER • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to Before removing the rear brake master cylin- deteriorate, causing leakage and poor der, drain the brake fluid from the entire brake brake performance.

  • Page 153: Assembling The Rear Brake Master Cylinder

    REAR BRAKE ASSEMBLING THE REAR BRAKE MASTER CYLINDER EWA13520 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. Recommended brake fluid 4. Install: DOT 4 •...

  • Page 154

    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”...

  • Page 155

    HANDLEBAR HANDLEBAR EAS1SM1161 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...

  • Page 156

    HANDLEBAR Removing the handlebar Order Part name Q’ty Remarks Handlebar lower holder Damper For installation, reverse the removal proce- dure. 4-32...

  • Page 157: Handlebar

    HANDLEBAR REMOVING THE HANDLEBAR EAS1SM1162 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 •...

  • Page 158

    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.

  • Page 159

    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”...

  • Page 160

    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”...

  • Page 161: Front Fork

    FRONT FORK FRONT FORK EAS1SM1165 Removing the front fork legs 21 Nm (2.1 m kgf, 15 ft lbf) 9 Nm (0.9 m kgf, 6.5 ft lbf) 5 Nm (0.5 m kgf, 3.6 ft lbf) 5 Nm (0.5 m kgf, 3.6 ft lbf) Order Part name...

  • Page 162

    FRONT FORK Disassembling the front fork leg 30 Nm (3.0 m kgf, 22 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • 55 Nm (5.5 m kgf, 40 ft Ibf) •...

  • Page 163: Removing The Front Fork Legs

    FRONT FORK REMOVING THE FRONT FORK LEGS EAS1SM1166 1. Use a suitable stand to raise the front wheel • While compressing the inner tube “2”, set the off the ground. cap bolt ring wrench “4” between the inner EWA13120 tube and locknut “3”. WARNING •...

  • Page 164: Checking The Front Fork Legs

    FRONT FORK EWA13650 WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Remove: • Base valve “1” (from the damper assembly) 2. Check: • Outer tube Hold the damper assembly with the cap bolt Scratches/wear/damage ...

  • Page 165: Assembling The Front Fork Legs

    FRONT FORK 5. Check: ASSEMBLING THE FRONT FORK LEGS EAS1SM1169 • 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. •...

  • Page 166

    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: •...

  • Page 167

    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.

  • Page 168

    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 •...

  • Page 169

    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: •...

  • Page 170

    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.

  • Page 171: Installing The Front Fork Legs

    FRONT FORK 30.Fill: • Front fork leg Recommended oil Suspension oil S1 Standard oil amount 330 cm (11.16 US oz, 11.64 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 EAS1SM1170 300–365 cm (10.14–12.34 US...

  • Page 172

    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.

  • Page 173: Steering Head

    STEERING HEAD STEERING HEAD EAS1SM1171 Removing the lower bracket 21 Nm (2.1 m kgf, 15 ft lbf) 145 Nm (14.5 m kgf, 105 ft lbf) 21 Nm (2.1 m kgf, 15 ft lbf) 38 Nm (3.8 m kgf, 27 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft...

  • Page 174: Removing The Lower Bracket

    STEERING HEAD REMOVING THE LOWER BRACKET EAS1SM1172 NOTICE 1. Use a suitable stand to raise the front wheel • Take care not to damage the steering shaft off the ground. thread. EWA13120 • If the bearing race is not installed properly, WARNING the steering head pipe could be damaged.

  • Page 175

    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.

  • Page 176

    STEERING HEAD 11.Tighten: • Pinch bolt (upper bracket) “1” Upper bracket pinch bolts 21 Nm (2.1 m·kgf, 15 ft·lbf) • Pinch bolt (lower bracket) “2” Lower bracket pinch bolts 21 Nm (2.1 m·kgf, 15 ft·lbf) EWA33DD049 8. Install: WARNING • Steering stem nut “1” Tighten the lower bracket to specified torque.

  • Page 177: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY REAR SHOCK ABSORBER ASSEMBLY EAS1SM1175 Removing the rear shock absorber assembly 16 15 14 13 Order Part name Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 4-1. Side cover (left / right) Refer to “GENERAL CHASSIS” on page 4-1. Air scoop (left / right) Refer to “GENERAL CHASSIS”...

  • Page 178

    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...

  • Page 179

    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...

  • Page 180: Handling The Rear Shock Absorber

    • Rear shock absorber assembly upper bolt • To dispose of a damaged or a worn-out • Rear shock absorber assembly (-ies) rear shock absorber, take the unit to your Yamaha dealer for this disposal proce- REMOVING THE BEARING EAS1SM1179 dure.

  • Page 181: Checking The Rear Shock Absorber Assembly

    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 •...

  • Page 182: Installing The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY Install the dust seals with their lips facing in- ward. Installed depth “a” 4.25 mm (0.17 in) INSTALLING THE REAR SHOCK ABSORB- EAS1SM1183 ER ASSEMBLY 1. Lubricate: • Bearing (lower side) • Dust seal • Collars •...

  • Page 183

    REAR SHOCK ABSORBER ASSEMBLY • Connecting arm bolt (relay arm side) Connecting arm bolt (relay arm side) 80 Nm (8.0 m·kgf, 58 ft·lbf) • Relay arm bolt (swingarm side) Relay arm bolt (swingarm side) 70 Nm (7.0 m·kgf, 51 ft·lbf) •...

  • Page 184: Swingarm

    SWINGARM SWINGARM EAS1SM1184 Removing the swingarm 70 Nm (7.0 m kgf, 51 ft lbf) 4.0 Nm (0.40 m kgf, 2.9 ft lbf) Order Part name Q’ty Remarks Use a suitable stand to raise the front wheel off the ground. Brake hose holder Refer to “REAR BRAKE”...

  • Page 185: Removing The Swingarm

    SWINGARM REMOVING THE SWINGARM EAS1SM1185 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 •...

  • Page 186: Installing The Swingarm

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

  • Page 187: Chain Drive

    CHAIN DRIVE CHAIN DRIVE EAS1SM1189 Removing the drive chain 75 Nm (7.5 m kgf, 54 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft lbf) Job Order Part name Q’ty Servicing Information Drive sprocket Refer to “ENGINE REMOVAL” on page 5-1. Drive chain For installation, reverse the removal proce- dure.

  • Page 188: Removing The Drive Chain

    CHAIN DRIVE REMOVING THE DRIVE CHAIN EAS1SM1190 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 •...

  • Page 189: Checking The Drive Sprocket

    CHAIN DRIVE 4. Check: • Drive chain rollers “1” Damage/wear  Replace the drive chain. • Drive chain side plates “2” Damage/wear  Replace the drive chain. 2. Lubricate: • Drive chain 3. Install: • Drive sprocket • Lock washer 5.

  • Page 190

    CHAIN DRIVE 4-66...

  • Page 191: Engine

    ENGINE ENGINE REMOVAL ..................5-1 REMOVING THE SILENCER..............5-6 REMOVING THE EXHAUST PIPE 2............5-6 REMOVING THE DRIVE SPROCKET ............5-6 REMOVING THE ENGINE .................5-7 CHECKING THE SILENCER AND EXHAUST PIPE........5-7 CHANGING THE SILENCER FIBER ............5-7 INSTALLING THE ENGINE................5-8 INSTALLING THE BRAKE PEDAL ............5-9 INSTALLING THE DRIVE SPROCKET............5-9 INSTALLING THE EXHAUST PIPE AND MUFFLER.......5-10 CAMSHAFT ....................5-11...

  • Page 192

    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...

  • Page 193

    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..................5-66 CHECKING THE CRANKCASE ...............5-64 INSTALLING THE OIL SEAL ..............5-65 ASSEMBLING THE CRANKCASE............5-65...

  • Page 194: Engine Removal

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

  • Page 195

    ENGINE REMOVAL Removing the exhaust pipe 13 Nm (1.3 m kg , 9.4 ft lbf) • • 2nd 20 Nm (2.0 m kgf, 14 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...

  • Page 196

    ENGINE REMOVAL Removing the electronic parts Order Part name Q’ty Remarks Use a suitable stand to raise the front wheel off the ground. Seat Refer to “GENERAL CHASSIS” on page 4-1. Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1. Air scoop (left / right) Refer to “GENERAL CHASSIS”...

  • Page 197

    ENGINE REMOVAL Removing the engine 55 Nm (5.5 m kgf, 40 ft Ibf) • • Order Part name Q’ty Remarks Use a suitable stand to raise the front wheel off the ground. Seat Refer to “GENERAL CHASSIS” on page 4-1. Side cover (left/right) Refer to “GENERAL CHASSIS”...

  • Page 198

    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-...

  • Page 199: Removing The Silencer

    ENGINE REMOVAL REMOVING THE SILENCER EAS1SM1197 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. EAS1SM1199 REMOVING THE DRIVE SPROCKET 1.

  • Page 200: Removing The Engine

    ENGINE REMOVAL REMOVING THE ENGINE 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. EAS1SM1202 CHANGING THE SILENCER FIBER 1.

  • Page 201: Installing The Engine

    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.

  • Page 202: Installing The Brake Pedal

    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- INSTALLING THE BRAKE PEDAL EAS1SM1204 wise, it may damage the other part that is 1.

  • Page 203: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL 3. Install: INSTALLING THE EXHAUST PIPE AND EAS1SM1206 • Clamp MUFFLER • Silencer “1” 1. Install: • Bolt (silencer) “2” • Gasket • Exhaust pipe 1 “1” Bolt (silencer) • Nut (exhaust pipe 1) “2” 30 Nm (3.0 m·kgf, 22 ft·lbf) Nut (exhaust pipe) 20 Nm (2.0 m·kgf, 14 ft·lbf) First temporarily tighten nuts to 13 Nm (1.3...

  • Page 204: Camshaft

    CAMSHAFT CAMSHAFT EAS1SM1207 Removing the cylinder head cover 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Part name Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 4-1. Side cover (left/right) Refer to “GENERAL CHASSIS”...

  • Page 205

    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) •...

  • Page 206: Removing The Camshaft

    CAMSHAFT REMOVING THE CAMSHAFT EAS1SM1208 1. Remove: • Timing mark accessing screw “1” • Crankshaft end accessing screw “2” 4. Remove: • Bolt (camshaft cap) “1” • Camshaft cap “2” • Clip “3” 2. Align: • Alignment mark • Remove the bolts (camshaft cap) in a criss- cross pattern, working from the outside in.

  • Page 207: Checking The Camshaft

    CAMSHAFT 3. Measure: EAS1SM1209 CHECKING THE CAMSHAFT • Camshaft runout 1. Check: Out of specification  Replace. • Camshaft lobes Blue discoloration/pitting/scratches  Re- Camshaft runout limit place the camshaft. 0.030 mm (0.0012 in) 2. Measure: • Camshaft lobe dimensions “A” and “B” Out of specification ...

  • Page 208: Checking The Timing Chain And Camshaft Sprocket

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

  • Page 209: Checking The Decompression System

    CAMSHAFT CHECKING THE DECOMPRESSION SYS- EAS1SM1212 1. Check: • Decompression system ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check that the decompressor cam “1” moves smoothly. b. Check that the decompressor lever pin “2” projects from the camshaft. c. Fit the timing chain “3” onto both camshaft sprockets and install the camshafts on the cylinder head.

  • Page 210

    CAMSHAFT ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install: 3. Turn: • Timing chain tensioner • Crankshaft Counterclockwise several turns. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 4. Check: a. While pressing the tensioner rod lightly with • Top dead center (TDC) mark on the rotor your fingers, use a thin screwdriver to wind Align with the crankcase alignment mark.

  • Page 211: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD EAS1SM1214 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...

  • Page 212

    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...

  • Page 213: Removing The Cylinder Head

    CYLINDER HEAD REMOVING THE CYLINDER HEAD EAS1SM1215 1. Remove: • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAMSHAFT” on page 5-13. 2. Remove: • Cylinder head nuts • Cylinder head bolts 2. Check: • Loosen the bolts in the proper sequence as •...

  • Page 214: Installing The Cylinder Head

    CYLINDER HEAD INSTALLING THE CYLINDER HEAD EAS1SM1218 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. •...

  • Page 215

    VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS EAS1SM1219 Removing the valves and valve springs Order Part name Q’ty Remarks Refer to “CYLINDER HEAD” on page 5-18. Cylinder head Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Intake valve...

  • Page 216: Valves And Valve Springs

    VALVES AND VALVE SPRINGS b. Check that the valves are properly sealed. REMOVING THE VALVES EAS1SM1220 Check that there are no kerosene leaks from Before removing the internal parts of the cylin- the valve seat “1”. der head (e.g., valves, valve springs, valve seats), make sure that the valves are properly sealed.

  • Page 217: Checking The Valves And Valve Guides

    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”.

  • Page 218: Checking The Valve Seats

    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 •...

  • Page 219

    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.

  • Page 220: Checking The Valve Springs

    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) EAS1SM1223 CHECKING THE VALVE SPRINGS 3.

  • Page 221: Installing The Valves

    VALVES AND VALVE SPRINGS INSTALLING THE VALVES 4. Install: 1. Clean: • Valve cotter “1” • 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”.

  • Page 222

    VALVES AND VALVE SPRINGS 6. Lubricate: • Adjusting pad “1” • Valve lifter “2” 7. Install: • Adjusting pad • Valve lifter • Check that the valve lifter turns smoothly when rotated with your finger. • Make sure that the valve lifter and the adjust- ing pad are reinstalled in their original posi- tions.

  • Page 223

    CYLINDER AND PISTON CYLINDER AND PISTON EAS1SM1226 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...

  • Page 224: Cylinder And Piston

    CYLINDER AND PISTON REMOVING THE PISTON EAS1SM1227 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 EAS1SM1228 CHECKING THE CYLINDER AND PISTON crankcase opening with a cloth to prevent the...

  • Page 225: Checking The Piston Rings

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

  • Page 226: Checking The Piston Pin

    CYLINDER AND PISTON CHECKING THE PISTON PIN INSTALLING THE PISTON AND CYLINDER 1. Check: 1. Install: • Piston pin • Oil ring expander “1” Blue discoloration/grooves  Replace the • Lower oil ring rail “2” piston pin and then check the lubrication •...

  • Page 227

    CYLINDER AND PISTON 3. Lubricate: • Piston • Piston rings • Cylinder 4. Offset: • Piston ring end gap a. Top ring end b. Upper oil ring end c. Oil ring end d. Lower oil ring end 5. Install: • Cylinder gasket •...

  • Page 228

    CLUTCH CLUTCH EAS1SM1232 Removing the clutch 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 Circlip...

  • Page 229: Clutch

    CLUTCH Removing the clutch 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...

  • Page 230

    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.

  • Page 231: Removing The Clutch

    CLUTCH CHECKING THE CLUTCH PLATES REMOVING THE CLUTCH EAS1SM1233 1. Check: 1. Remove: • Clutch plate • Clutch boss nut “1” Damage  Replace the clutch plates as a • Lock washer “2” set. • Clutch boss “3” 2. Measure: •...

  • Page 232: Checking The Clutch Housing

    CLUTCH CHECKING THE CLUTCH HOUSING CHECKING THE PUSH LEVER SHAFT 1. Check: 1. Check: • Clutch housing dogs “a” • Push lever shaft Damage/pitting/wear  Deburr the clutch Wear/damage  Replace. housing dogs or replace the clutch housing. Pitting on the clutch housing dogs will cause er- ratic clutch operation.

  • Page 233: Checking The Primary Driven Gear

    CLUTCH CHECKING THE PRIMARY DRIVEN GEAR 2. Install: 1. Check: • Right crankcase cover “1” • Primary driven gear • Right crankcase cover bolt “2” Damage/wear  Replace the primary drive Right crankcase cover bolt and primary driven gears as a set. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Excessive noise during operation ...

  • Page 234: Installing The Clutch

    CLUTCH INSTALLING THE CLUTCH 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.

  • Page 235

    CLUTCH 6. Install: 9. Install: • Bearing “1” • Clutch spring • Washer “2” • Clutch spring bolt • Circlip “3” Clutch spring bolt To push rod 1 “4”. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Apply the engine oil on the bearing and washer. Tighten the bolts in stages and in a crisscross pattern.

  • Page 236: Installing The Kickstarter Lever

    CLUTCH INSTALLING THE KICKSTARTER LEVER EAS1SM1247 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.

  • Page 237

    KICKSTATER KICKSTATER EAS1SM1248 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.

  • Page 238: Kickstater

    KICKSTATER REMOVING THE KICK SHAFT ASSEMBLY EAS1SM1249 1. Remove: • Kick shaft assembly “1” Unhook the torsion spring “2” from the hole “a” in the crankcase. EAS1SM1252 INSTALLING THE KICK SHAFT ASSEMBLY 1. Install: • Kick gear “1” • Washer “2” •...

  • Page 239: Installing The Kick Idle Gear

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

  • Page 240: Shift Shaft

    SHIFT SHAFT SHIFT SHAFT EAS1SM1254 Removing the shift shaft and stopper lever 10 Nm (1.0 m kgf, 7.2 ft lbf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft lbf) Order Part name Q’ty...

  • Page 241

    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...

  • Page 242: Removing The Shift Guide And Shift Lever Assembly

    SHIFT SHAFT CHECKING THE SHIFT SHAFT REMOVING THE SHIFT GUIDE AND SHIFT EAS1SM1255 1. Check: LEVER ASSEMBLY • Shift shaft “1” 1. Remove: Bends/damage/wear  Replace. • Bolt (shift guide) • Shift shaft spring “2” • Shift guide “1” Damage/wear  Replace. •...

  • Page 243: Installing The Stopper Lever

    SHIFT SHAFT INSTALLING THE STOPPER LEVER INSTALLING THE SHIFT GUIDE AND SHIFT 1. Install: LEVER ASSEMBLY • Torsion spring “1” 1. Install: • Collar “2” • Spring “1” • Stopper lever “3” • Pawl pin “2” • Bolt (stopper lever) “4” •...

  • Page 244: Installing The Shift Shaft

    SHIFT SHAFT 4. Tighten: INSTALLING THE SHIFT PEDAL • Shift guide bolt “1” 1. Install: • Shift pedal “1” Shift guide bolt • Shift pedal bolt “2” 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® Shift pedal bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Align the punch mark “a”...

  • Page 245

    OIL PUMP AND BALANCER GEAR OIL PUMP AND BALANCER GEAR EAS1SM1265 Removing the oil pump 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • Order Part name Q’ty Remarks Primary driven gear Refer to “CLUTCH”...

  • Page 246: Oil Pump And Balancer Gear

    OIL PUMP AND BALANCER GEAR Removing the balancer 40 Nm (4.0 m kgf, 29 ft Ibf) • • 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...

  • Page 247: Removing The Balancer

    OIL PUMP AND BALANCER GEAR REMOVING THE BALANCER EAS1SM1266 1. Loosen: • Balancer nut “1” • Primary drive gear nut “2” • Balancer weight gear nut “3” Place an aluminum plate “a” between the teeth of the balancer drive gear “4” and balancer weight gear “5”.

  • Page 248: Assembling The Oil Pump

    OIL PUMP AND BALANCER GEAR 2. Install: • Outer rotor “1” Apply the engine oil on the outer rotor. 3. Install: • Oil pump cover “1” • Oil pump cover screw “2” Oil pump cover screw 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) 1.

  • Page 249

    OIL PUMP AND BALANCER GEAR 4. Install: NOTICE • Conical washer “1” After tightening the bolts, make sure that • Balancer weight gear nut “2” the oil pump turns smoothly. Balancer weight gear nut 2. Install: 50 Nm (5.0 m·kgf, 36 ft·lbf) •...

  • Page 250

    OIL PUMP AND BALANCER GEAR 5-57...

  • Page 251: Ac Magneto

    AC MAGNETO AC MAGNETO EAS1SM1272 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) •...

  • Page 252: Removing The Ac Magneto

    AC MAGNETO CHECKING THE WOODRUFF KEY REMOVING THE AC MAGNETO EAS1SM1273 1. Check: 1. Remove: • Woodruff key “1” • Nut (rotor) “1” Damage  Replace. • Washers 2. Remove: EAS1SM1276 INSTALLING THE AC MAGNETO • Rotor “1” 1. Install: Use the rotor puller “2”...

  • Page 253

    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”.

  • Page 254: Crankcase

    CRANKCASE CRANKCASE EAS1SM1277 Separating the crankcase 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 255

    CRANKCASE Separating the crankcase 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 256

    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...

  • Page 257: Disassembling The Crankcase

    CRANKCASE DISASSEMBLING THE CRANKCASE EAS1SM1278 1. Separate: • Right crankcase • Left crankcase ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the crankcase bolts. c. Remove the dowel pins and O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ REMOVING THE CRANKCASE BEARING EAS1SM1279 1. Remove: • Bearing “1” • Remove the bearing from the crankcase by pressing its inner race.

  • Page 258: Installing The Oil Seal

    CRANKCASE INSTALLING THE OIL SEAL EAS1SM1282 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.

  • Page 259: Crankshaft Assembly And Balancer Shaft

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EAS1SM1284 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.

  • Page 260: Removing The Crankshaft Assembly

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 2. Measure: REMOVING THE CRANKSHAFT ASSEMBLY EAS1SM1285 • 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”.

  • Page 261: Installing The Crankshaft Assembly

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT INSTALLING THE CRANKSHAFT ASSEM- EAS1SM1287 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 EAS1SM1288 INSTALLING THE BALANCER SHAFT Installing pot...

  • Page 262: Transmission

    TRANSMISSION TRANSMISSION EAS1SM1289 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...

  • Page 263: Removing The Transmission

    TRANSMISSION CHECKING THE SHIFT FORKS REMOVING THE TRANSMISSION EAS1SM1290 1. Check: 1. Remove: • Shift fork cam follower “1” • Long shift fork guide bar “1” • Shift fork pawl “2” • Short shift fork guide bar “2” Bends/damage/scoring/wear  Replace the •...

  • Page 264: Checking The Shift Drum Assembly

    TRANSMISSION CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: • Shift drum groove Damage/scratches/wear  Replace the shift drum assembly. • Shift drum segment “1” Damage/wear  Replace the shift drum as- sembly. 3. Check: • Transmission gears Blue discoloration/pitting/wear  Replace the defective gear (s).

  • Page 265

    TRANSMISSION 2. Install: • 2nd wheel gear (28T) “1” • 4th wheel gear (22T) “2” • 3rd wheel gear (26T) “3” • 5th wheel gear (25T) “4” • Collar “5” • 1st wheel gear (30T) “6” • O-rings “7” (to the drive axle “8”) 4.

  • Page 266

    TRANSMISSION 6. Install: 7. Install: • Shift fork 1 (L) “1” • Long shift fork guide bar “1” • Shift fork 2 (C) “2” • Short shift fork guide bar “2” • Shift fork 3 (R) “3” • Spring “3” •...

  • Page 267: Cooling System

    COOLING SYSTEM RADIATOR .......................6-1 HANDLING NOTE ..................6-3 CHECKING THE RADIATOR..............6-3 WATER PUMP....................6-4 REMOVING THE OIL SEAL...............6-6 CHECKING THE WATER PUMP ...............6-6 CHECKING THE BEARING ...............6-6 INSTALLING THE OIL SEAL ..............6-6 ASSEMBLING THE WATER PUMP............6-6...

  • Page 268

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

  • Page 269

    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.

  • Page 270

    RADIATOR HANDLING NOTE EAS1SM1297 EWA1DX1007 WARNING If coolant seems hot, do not remove the ra- diator cap. EAS1SM1298 CHECKING THE RADIATOR 1. Check: • Radiator fins “1” Obstructions  Clean. Apply compressed air to the rear of the radi- ator. Damage ...

  • Page 271

    WATER PUMP WATER PUMP EAS1SM1299 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.

  • Page 272

    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.

  • Page 273: Water Pump

    WATER PUMP REMOVING THE OIL SEAL EAS1SM1300 • 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 274

    WATER PUMP 2. Install: • Dowel pin “1” • Gasket “2” 3. Install: • Water pump housing “1” • Water pump housing bolt “2” Water pump housing bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Washer “3” • Coolant drain bolt “4” Coolant drain bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

  • Page 275: Fuel System

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

  • Page 276: Fuel Tank

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

  • Page 277: Removing The Fuel Tank

    FUEL TANK REMOVING THE FUEL TANK EAS1SM1307 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.

  • Page 278: Installing The Fuel Tank

    FUEL TANK 3. Connect: • Fuel pump coupler 4. Install: • Air scoop (left/right) • Seat • Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4- CHECKING THE FUEL PRESSURE EAS1SM1312 1. Check: • Fuel pressure INSTALLING THE FUEL TANK EAS1SM1311 1.

  • Page 279: Checking The Damper

    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...

  • Page 280: Throttle Body

    THROTTLE BODY THROTTLE BODY EAS1SM1315 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) •...

  • Page 281

    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) •...

  • Page 282

    THROTTLE BODY Removing the injector 3.4 Nm (0.34 m kgf, 2.5 ft lbf) 5 Nm (0.5 m kgf, 3.6 ft lbf) 3.4 Nm (0.34 m kgf, 2.5 ft lbf) Order Part name Q’ty Remarks Fuel inlet pipe Injector Gaskets Throttle position sensor Intake air pressure sensor For installation, reverse the removal proce- dure.

  • Page 283: Checking The Injector

    THROTTLE BODY CHECKING THE INJECTOR EAS1SM1316 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”...

  • Page 284: Adjusting The Throttle Position Sensor

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

  • Page 285: Electrical System

    CIRCUIT DIAGRAM ...................8-2 TROUBLESHOOTING ................8-4 CHARGING SYSTEM..................8-6 CIRCUIT DIAGRAM ...................8-6 TROUBLE SHOOTING ................8-8 FUEL INJECTION SYSTEM................8-10 CIRCUIT DIAGRAM .................8-10 YAMAHA DIAGNOSTIC TOOL ..............8-12 TROUBLESHOOTING DETAILS .............8-13 FUEL PUMP SYSTEM..................8-32 CIRCUIT DIAGRAM .................8-32 TROUBLESHOOTING ................8-34 ELECTRICAL COMPONENTS...............8-36 ........................8-36 CHECKING THE SWITCHES ..............8-38 CHECKING THE IGNITION SPARK GAP..........8-41...

  • Page 287

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

  • Page 288: Ignition System

    IGNITION SYSTEM IGNITION SYSTEM EAS1SM1321 CIRCUIT DIAGRAM EAS1SM1322...

  • Page 289

    IGNITION SYSTEM 1. Crankshaft position sensor 2. AC magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser 7. Engine stop switch 9. ECU 10.Ignition coil 11.Spark plug EAS1SM1323...

  • Page 290: Troubleshooting

    IGNITION SYSTEM 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 NG  1.

  • Page 291

    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.

  • Page 292: Charging System

    CHARGING SYSTEM CHARGING SYSTEM EAS27200 CIRCUIT DIAGRAM EAS1SM1324...

  • Page 293

    CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser EAS1SM1325...

  • Page 294: Trouble Shooting

    CHARGING SYSTEM TROUBLE SHOOTING 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.

  • Page 295

    CHARGING SYSTEM EAS1SM1326...

  • Page 296: Fuel Injection System

    FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM CIRCUIT DIAGRAM EAS1SM1327 8-10...

  • Page 297

    FUEL INJECTION SYSTEM 1. Crankshaft position sensor 2. AC magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser 7. Engine stop switch 8. Neutral switch 9. ECU 12.Fuel injector 14.Intake air temperature sensor 15.Coolant temperature sensor 16.Throttle position sensor 17.Intake air pressure sensor EAS1SM1328 8-11...

  • Page 298: Yamaha Diagnostic Tool

    FUEL INJECTION SYSTEM 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 90890-03215 FEATURES OF THE YAMAHA DIAGNOSTIC TOOL A diagnosis can be made more quickly than traditional methods with the Yamaha diagnostic tool.

  • Page 299: Troubleshooting Details

    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...

  • Page 300

    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...

  • Page 301

    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 ...

  • Page 302

    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...

  • Page 303

    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:...

  • Page 304

    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.

  • Page 305

    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) •...

  • Page 306

    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 ...

  • Page 307

    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 ...

  • Page 308

    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 °...

  • Page 309

    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.

  • Page 310

    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.

  • Page 311

    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.

  • Page 312

    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. •...

  • Page 313

    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...

  • Page 314

    — 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.

  • Page 315

    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 ...

  • Page 316

    — 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.

  • Page 317

    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-...

  • Page 318: Fuel Pump System

    FUEL PUMP SYSTEM FUEL PUMP SYSTEM EAS1SM1330 CIRCUIT DIAGRAM EAS1SM1331 8-32...

  • Page 319

    FUEL PUMP SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser 7. Engine stop switch 9. ECU 13.Fuel pump EAS1SM1332 8-33...

  • Page 320: Troubleshooting

    FUEL PUMP SYSTEM 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 NG  1. Check the fuel pump system wire Reconnect.

  • Page 321

    FUEL PUMP SYSTEM EAS1SM1333 8-35...

  • Page 322: Electrical Components

    ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS EAS1SM1334 8-36...

  • Page 323

    ELECTRICAL COMPONENTS 1. Rectifier/regulator 2. Intake air pressure sensor 3. Throttle position sensor 4. Injector 5. Intake air temperature sensor 6. ECU 7. Ignition coil 8. Condenser 9. Neutral switch 10.Coolant temperature sensor EAS1SM1335 8-37...

  • Page 324: Checking The Switches

    ELECTRICAL COMPONENTS CHECKING THE SWITCHES B/Y P 8-38...

  • Page 325

    ELECTRICAL COMPONENTS 1. Engine stop switch 2. Neutral switch 8-39...

  • Page 326

    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.

  • Page 327: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS CHECKING THE IGNITION SPARK GAP EAS1SM1336 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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”...

  • Page 328: Checking The Crankshaft Position Sensor

    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 ...

  • Page 329: Checking The Ecu

    ELECTRICAL COMPONENTS CHECKING THE ECU CHECKING THE RECTIFIER/REGULATOR 1. Check: 1. Check: • Mounted condition of ECU. • Rectifier/regulator output voltage Improperly mounted  Remount. Out of specification  Replace. Output voltage • The lean angle sensor is built into the ECU. 14 V or more at 5000 r/min •...

  • Page 330: Checking The Coolant Temperature Sensor

    ELECTRICAL COMPONENTS CHECKING THE COOLANT TEMPERATURE c. Place a thermometer in the coolant. SENSOR d. Slowly heat the coolant, and then let it cool 1. Remove: to the specified temperature indicated in the • Coolant temperature sensor table. e. Check the coolant temperature sensor for EWA14130 WARNING continuity at the temperatures indicated in...

  • Page 331: Checking The Throttle Position Sensor Input Voltage

    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...

  • Page 332: Checking The Intake Air Pressure Sensor

    ELECTRICAL COMPONENTS CHECKING THE INTAKE AIR PRESSURE 2. Check: SENSOR • Intake air temperature sensor resistance Out of specification  Replace. 1. Check: • Intake air pressure sensor output voltage Intake air temperature sensor re- Out of specification  Replace. sistance 290–390 ...

  • Page 333: Checking The Fuel Injector

    ELECTRICAL COMPONENTS Continuity Positive tester probe  Sky blue “1” Negative tester probe  Sensor terminal “a” Continuity Positive tester probe  Black/Yellow “2” Negative tester probe  Sensor terminal “b” Continuity c. Measure the fuel injector resistance. Positive tester probe  ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 334

    ELECTRICAL COMPONENTS 8-48...

  • Page 335

    TROUBLE SHOOTING TROUBLE SHOOTING..................9-1 GENERAL INFORMATION ................9-1 STARTING FAILURES................9-1 INCORRECT ENGINE IDLING SPEED .............9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING.................9-2 SHIFT PEDAL DOES NOT MOVE .............9-2 JUMPS OUT OF GEAR................9-2 FAULTY CLUTCH ..................9-2 OVERHEATING ..................9-2 OVERCOOLING..................9-3 POOR BRAKING PERFORMANCE............9-3 FAULTY FRONT FORK LEGS..............9-3 UNSTABLE HANDLING ................9-3 LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS......9-4...

  • Page 336: Trouble Shooting

    TROUBLE SHOOTING Electrical system TROUBLE SHOOTING EAS1SM1350 1. Spark plug GENERAL INFORMATION EAS1SM1351 • Incorrect spark plug gap • 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 •...

  • Page 337: Poor Medium-and-high-speed Performance

    TROUBLE SHOOTING 3. Ignition system FAULTY CLUTCH EAS1SM1358 • Faulty ECU • Faulty crankshaft position sensor Clutch slips • Broken generator rotor woodruff key 1. Clutch • Improperly assembled clutch EAS1SM1354 POOR MEDIUM-AND-HIGH-SPEED PER- • Loose or fatigued clutch spring FORMANCE •...

  • Page 338: Overcooling

    TROUBLE SHOOTING 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 •...

  • Page 339: List Of Self-diagnostic And Fail-safe Actions

    8-29 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...

  • Page 340

    • 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-...

  • Page 341

    Actuates the ignition coil five Check that a spark is gener- times at one-second inter- ated five times. vals. • Connect an ignition “WARNING” on the Yamaha checker. diagnostic tool blinks five times when the ignition coil is actuated. Injector...

  • Page 342

    LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS...

  • Page 343: 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..................10-2 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...

  • Page 344: Chassis

    CHASSIS DRIVE AND REAR WHEEL SPROCKETS CHASSIS EAS1SM1366 SETTING PARTS SELECTION OF THE SECONDARY REDUC- EAS1SM1367 Part name Type Part number TION RATIO (SPROCKET) Drive sprocket “1” Secondary reduction ratio = Number of (STD) 13T 9383B-13218 rear wheel sprocket teeth/Number of Rear wheel drive sprocket teeth sprocket “2”...

  • Page 345: Tire Pressure

    CHASSIS TIRE PRESSURE 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...

  • Page 346: Setting Of Spring After Replacement

    CHASSIS SETTING OF SPRING AFTER REPLACE- 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. Use of soft spring •...

  • Page 347: Setting Of Spring After Replacement

    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.

  • Page 348: Rear Shock Absorber Setting Parts

    CHASSIS REAR SHOCK ABSORBER SETTING PARTS • Rear shock spring “1” Spring I.D. Type rate N/ Part number Mark 1SL-22212-40 (Blue) SOFT Yellow 1SL-22212-50 (Red) 1SL-22212-60 (Blue) STD* Pink 1SL-22212-70 (Red) 1SL-22212-20 (Blue) White 1SL-22212-30 (Red) 1SL-22212-00 • Extent of adjustment (spring preload) (Blue) Silver Maximum...

  • Page 349: Suspension Setting (front Fork)

    CHASSIS SUSPENSION SETTING (FRONT FORK) EAS1SM1378 • If any of the following symptoms is experienced with the standard position as the base, make reset- ting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in).

  • Page 350: Suspension Setting (rear Shock Absorber)

    CHASSIS Section Medi- Symptom Check Adjust Large Small Jump Compression Turn adjuster clockwise (about damping force 2 clicks) to increase damping. Rebound Turn adjuster counterclock- damping force wise (about 2 clicks) to de- crease damping. Low front, tend- ing to lower Balance with Set sunken length for 95–100 front posture...

  • Page 351

    CHASSIS Section Medi- Symptom Check Adjust Large Small Jump Rebound Turn adjuster counterclock- damping force wise (about 2 clicks) to de- Heavy and crease damping. dragging Spring Replace with soft spring. Rebound Turn adjuster counterclock- damping force wise (about 2 clicks) to de- crease damping.

  • Page 352: Wiring Diagram

    WIRING DIAGRAM EAS1SM1381 YZ250F 2014 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.

  • Page 354

    PRINTED ON RECYCLED PAPER PRINTED IN JAPAN...

  • Page 355

    SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN YZ250F (E) 2014 YZ250F (E) 2014 YZ250F (E) 2014 YZ250F (E) 2014 B B B B R R R R R R R B/L B/L B/L B/L B/L B/L P P P L L L R R R R R R R B B B B B/LB/LB/LB/LB/L...

  • Page 356

    SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN YZ250F (E) 2014 YZ250F (E) 2014 YZ250F (E) 2014 YZ250F (E) 2014 (BLACK) (BLACK)

This manual also for:

Yz250f 2014, Yz250fe 2014

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