Yamaha WR250F Owner's Service Manual
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Yamaha WR250F Owner's Service Manual

2015
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Table of Contents

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2015
q Read this manual carefully before operating this vehicle.
q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule.
OWNER'S SERVICE MANUAL
MANUEL D'ATELIER DU
PROPRIETAIRE
WR250F
WR250FF
2GB-28199-70

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Summary of Contents for Yamaha WR250F

  • Page 1 2015 q Read this manual carefully before operating this vehicle. q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE WR250F WR250FF 2GB-28199-70...
  • 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.
  • Page 3 2015 2015 Read this manual carefully before operating this vehicle. Read this manual carefully before operating this vehicle. OWNER’S SERVICE MANUAL OWNER’S SERVICE MANUAL WR250F WR250F WR250FF WR250FF 2GB-28199-70-E0 2GB-28199-70-E0...
  • Page 5 EAS2GB2002 WR250F WR250FF OWNER’S SERVICE MANUAL ©2014 by Yamaha Motor Co., Ltd. First edition, September 2014 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 EAS2GB2003 Congratulations on your purchase of a Yamaha WR series. This model is the culmination of Yama- ha'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 EAS2GB2005 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 EAS2GB2006 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 EAS2GB2007 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

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

  • 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 VEHICLE EMISSION CONTROL INFORMATION LABEL......1-5 FEATURES.......................1-6 OUTLINE OF THE FI SYSTEM..............1-6 FI SYSTEM....................1-7 INCLUDED PARTS ..................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 ................1-9...
  • Page 14 CONTROL FUNCTIONS ................1-21 INDICATOR LIGHTS AND WARNING LIGHTS........1-21 ENGINE STOP SWITCH................1-21 START SWITCH..................1-21 CLUTCH LEVER ..................1-21 SHIFT PEDAL ..................1-22 KICKSTARTER LEVER................1-22 THROTTLE GRIP..................1-22 FRONT BRAKE LEVER ................1-22 REAR BRAKE PEDAL................1-22 SIDESTAND .....................1-23 STARTER KNOB/IDLE ADJUSTING SCREW.........1-23 FUEL TANK CAP ..................1-23 MULTI-FUNCTION DISPLAY.................1-24 DESCRIPTION ..................1-24 BASIC MODE ...................1-24...

  • Page 15: Location Of Important Labels

    LOCATION OF IMPORTANT LABELS LOCATION OF IMPORTANT LABELS EAS2GB2008 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 EAS2GB2009 12 13 20 19 18 1. Clutch lever 12. Headlight 2. Multi-function display 13. Radiator 3. Front brake lever 14. Coolant drain bolt 4. Throttle grip 15. Rear brake pedal 5. Start switch 16. Air filter 6. Radiator cap 17.

  • 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 EAS2GB2014 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.

  • Page 21: Fi System

    FEATURES FI SYSTEM EAS2GB2015 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 FUEL HOSE JOINT COVER INCLUDED PARTS EAS2GB2016 The fuel hose joint covers “1” are used to pre- vent mud, dust, and other foreign materials EAS2GB2017 SPARK PLUG WRENCH from entering the inside when the fuel hose is The spark plug wrench “1” is used to remove or disconnected.

  • Page 23: 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 24: Gaskets, Oil Seals And O-Rings

    IMPORTANT INFORMATION GASKETS, OIL SEALS AND O-RINGS EAS2GB2024 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 25: Basic Service Information

    BASIC SERVICE INFORMATION BASIC SERVICE INFORMATION EAS2GB2028 EAS2GB2029 ELECTRICAL SYSTEM Electrical parts handling NOTICE Never disconnect a battery lead while the engine is running; otherwise, the electrical components could be damaged. NOTICE Be sure to connect the battery leads to the correct battery terminals.
  • Page 26 BASIC SERVICE INFORMATION NOTICE Checking the electrical system Handle electrical components with special care, and do not subject them to strong Before checking the electrical system, make shocks. sure that the battery voltage is at least 12 V. NOTICE NOTICE Electrical components are very sensitive to Never insert the tester probes into the cou- and can be damaged by static electricity.
  • Page 27 BASIC SERVICE INFORMATION 2. Check: • Lead • Coupler • Connector Moisture  Dry with compressed air. Rust/stains  Connect and disconnect sev- eral times. Checking the connections Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: •...
  • Page 28 BASIC SERVICE INFORMATION 4. Connect: • Lead • Coupler • Connector • When connecting a coupler or connector, make sure that both terminals are connected securely. • Make sure all connections are tight. 5. Check: • No continuity Pocket tester 90890-03112 Analog pocket tester YU-03112-C...

  • Page 29: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS EAS2GB2030 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 Test harness– lean angle sensor (6P) FI diagnostic tool sub–lead This tool is used to connect 90890-03212 the Yamaha diagnostic tool FI diagnostic tool sub–lead to a battery. YU-03212 Test harness– speed sensor This tool is used to check the 5TJ (3P) speed sensor output voltage.
  • Page 32 SPECIAL TOOLS Tool name/Part number How to use Illustration Valve spring compressor This tool is used to discon- 90890-04019 nect or connect the valve and Valve spring compressor the valve spring. YM-04019 YM-04019 Spacer (crankshaft installer) This tool is used to install the 90890-04081 crankshaft.
  • Page 33 SPECIAL TOOLS Tool name/Part number How to use Illustration Valve lapper This tool is used to remove 90890-04101 the valve lifter or lap the Valve lapping tool valve. YM-A8998 Valve spring compressor at- This tool is used to discon- tachment nect or connect the valve and 90890-04108 the valve spring.
  • Page 34 Tool name/Part number How to use Illustration Digital tachometer This tool is used to measure 90890-06760 the engine speed. Digital tachometer YU-39951-B Yamaha bond No. 1215 This sealant (Bond) is used 90890-85505 for crankcase mating sur- (Three bond No.1215®) face, etc. 1-20...

  • Page 35: Control Functions

    The clutch lever “1” is located on the left han- lem is detected in the electrical circuit monitor- dlebar. The clutch lever disengages or engag- ing the engine. If this occurs, have a Yamaha es the clutch. dealer check the vehicle.

  • Page 36: Shift Pedal

    CONTROL FUNCTIONS THROTTLE GRIP SHIFT PEDAL EAS2GB2036 The throttle grip “1” is located on the right han- The shift pedal “1” has adopted a method of 1 dlebar. The throttle grip accelerates or deceler- down & 5 ups (press-down & kick-ups). ates the engine.

  • Page 37: Sidestand

    CONTROL FUNCTIONS FUEL TANK CAP SIDESTAND EAS2GB2041 Fuel tank cap “1” is located under the fuel tank This sidestand “1” is used to support only the cap cover “2”. machine when standing or transporting it. Remove the fuel tank cap cover to open the fuel WARNING tank cap.

  • Page 38: Multi-Function Display

    MULTI-FUNCTION DISPLAY MULTI-FUNCTION DISPLAY BASIC MODE EAS2GB2044 EAS2GB2046 Changing speedometer display (for U.K.) WARNING Be sure to stop the machine before making 1. Push the "SLCT2" button for 2 seconds or any setting changes to the multi-function more to change the speedometer units. The display.

  • Page 39: Changeover To Basic Mode/Race Mode

    MULTI-FUNCTION DISPLAY 4. To end the setting, push the “RST” button for CHANGEOVER TO BASIC MODE/RACE EAS2GB2047 2 seconds or more. MODE • In a 30-second absence of button operation, • Measurement using the timer function can be the setting will come to an end with the indi- made in RACE MODE.

  • Page 40: Race Mode

    MULTI-FUNCTION DISPLAY Returning to BASIC MODE from RACE Manual start MODE Initial setting at changeover to RACE MODE It is possible to return to BASIC MODE with tim- will remain for manual start. er measurement at a stop. 1. Check that changeover to RACE MODE has been made.
  • Page 41 MULTI-FUNCTION DISPLAY Resetting tripmeter A (TRIP A) 1. Check that the timer is in operation. If the timer is not in operation, start the timer by pushing the “SLCT1” button and “SLCT2” button at the same time. 2. Reset tripmeter A (TRIP A) display by push- ing the “RST”...
  • Page 42 MULTI-FUNCTION DISPLAY Correcting tripmeter A (TRIP A) 1. Change the travel distance display by push- ing the “SLCT1” button (plus) or “SLCT2” button (minus). A long push on the button will fast-forward the change. Change can be made any time while timer measurement is or is not being made.
  • Page 43 MULTI-FUNCTION DISPLAY 1-29...

  • Page 44: Function Diagram

    MULTI-FUNCTION DISPLAY FUNCTION DIAGRAM A short push on the button changes the operation in the arrowed direction. Meter function A short push on the button changes the operation in both arrowed directions. Function that can be performed whether the time is or is not in operation. A long push on the button changes the operation in the arrowed direction.
  • Page 45 MULTI-FUNCTION DISPLAY A.A short push on the button changes the oper- ation in the arrowed direction. B.A short push on the button changes the oper- ation in both arrowed directions. C.A long push on the button changes the oper- ation in the arrowed direction. D.A long push on the button changes the oper- ation in both arrowed directions.

  • Page 46: Starting And Break-In

    NOTICE For maximum engine life, never accelerate hard when the engine is cold! Your Yamaha engine has been designed to use In order for the ignition circuit cut-off system to premium unleaded gasoline with a pump oc- enable starting, one of the following conditions...

  • Page 47: Starting A Warm Engine

    STARTING AND BREAK-IN Starting with the kickstarter NOTICE When using the kickstarter to start the engine, If the starter motor will not turn when the follow the procedures as described below. start switch is pushed, stop pushing it im- 1. Fold out the kickstarter lever, push it down mediately in order to avoid placing extra lightly with your foot until resistance is felt.

  • Page 48: Break-In Procedures

    STARTING AND BREAK-IN BREAK-IN PROCEDURES EAS2GB2056 A break-in is important so that rotating portion, sliding surfaces, and mounted areas may fit one another, and that the rider may become ac- customed to the machine. NOTICE Before running, do maintenance on the air filter element.

  • Page 49: Maintenance After Break-In

    MAINTENANCE AFTER BREAK-IN • Cable MAINTENANCE AFTER BREAK-IN EAS2GB2057 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 50: Torque-Check Points

    TORQUE-CHECK POINTS TORQUE-CHECK POINTS EAS2GB2059 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 51 TORQUE-CHECK POINTS Fuel system Fuel pump to fuel tank Fuel sender to fuel tank Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake disc cov- Tightening of rear brake caliper...

  • Page 52: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE • Do not use any harsh chemical products MOTORCYCLE CARE AND STOR- EAS2GB2060 on plastic parts. Be sure to avoid using cloths or sponges which have been in con- tact with strong or abrasive cleaning prod- CARE EAS2GB2061 ucts, solvent or thinner, fuel (gasoline),...

  • Page 53: Storage

    MOTORCYCLE CARE AND STORAGE 2. Apply a corrosion protection spray on all metal, including chrome- and nickel-plated, • Consult a Yamaha dealer for advice on what surfaces to prevent corrosion. products to use. • Washing, rainy weather or humid climates After cleaning can cause the headlight lens to fog.
  • Page 54 MOTORCYCLE CARE AND STORAGE e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. WARNING! To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over.

  • Page 55: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS .................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-8 ELECTRICAL SPECIFICATIONS ..............2-11 TIGHTENING TORQUES ................2-13 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-13 ENGINE TIGHTENING TORQUES............2-14 CHASSIS TIGHTENING TORQUES............2-17 LUBRICATION POINTS AND LUBRICANT TYPES ........2-21 ENGINE....................2-21 CHASSIS....................2-22 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-25 LUBRICATION DIAGRAMS ..............2-25 CABLE ROUTING DIAGRAM ................2-33...

  • Page 56: General Specifications

    GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS EAS2GB2063 Model Model 2GB1 (USA) 2GB2 (CAN) 2GB3 (EUR) 2GB4 (AUS) (NZL) (ZAF) Dimensions Overall length 2165 mm (85.2 in) Overall width 825 mm (32.5 in) Overall height 1280 mm (50.4 in) Seat height 965 mm (38.0 in) Wheelbase 1465 mm (57.7 in) Ground clearance...

  • Page 57: Engine Specifications

    ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS EAS2GB2064 Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 250 cm Cylinder arrangement Single cylinder Bore  stroke 77.0  53.6 mm (3.0  2.1 in) Compression ratio 13.5:1 Starting system Electric starter and kickstarter Fuel Recommended fuel Premium unleaded gasoline only Fuel tank capacity...
  • Page 58 ENGINE SPECIFICATIONS Cylinder head Combustion chamber volume 12.07–12.87 cm (0.74–0.79 cu.in) Warpage limit 0.05 mm (0.0020 in) Camshaft Drive system Chain drive (left) Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in) Camshaft journal diameter 21.959–21.972 mm (0.8645–0.8650 in) Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) Camshaft lobe dimensions Intake A...
  • Page 59 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 60 ENGINE SPECIFICATIONS 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 Piston-to-cylinder clearance 0.030–0.055 mm (0.0012–0.0022 in) Limit 0.15 mm (0.006 in) Diameter D 76.955–76.970 mm (3.0297–3.0303 in) Height H...
  • Page 61 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 62 ENGINE SPECIFICATIONS Fuel pump Pump type Electrical Fuel injector Model/quantity 30NA-FZ31/1 12  Resistance Throttle body Type/quantity 30RA-A95R/1 ID mark 2GB1 00 Fuel line pressure at idling 324.0 kPa (3.24 kgf/cm , 47.0 psi) Throttle position sensor Resistance 6.30 k Output voltage (at idle) 0.5 V Fuel injection sensor...

  • Page 63: Chassis Specifications

    CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS EAS2GB2065 Chassis Frame type Semi double cradle Caster angle 26.33 ° Trail 114 mm (4.5 in) Front wheel Wheel type Spoke wheel 21  1.60 Rim size Rim material Aluminum Wheel travel 310 mm (12.2 in) Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit...
  • Page 64 CHASSIS SPECIFICATIONS 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  2 (0.89 in  2) Caliper cylinder inside diameter Recommended brake fluid DOT 4 Rear brake Type Single disc brake...
  • Page 65 CHASSIS SPECIFICATIONS Rear suspension Type Swingarm (link suspension) Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel 126.0 mm (4.96 in) Spring free length 275.0 mm (10.83 in) Spring installed length 265.0 mm (10.43 in) Spring rate K1 54.00 N/mm (5.51 kgf/mm, 308.34 lbf/in) Spring stroke K1 0.0–150.0 mm (0.00–5.91 in)

  • Page 66: Electrical Specifications

    Advancer type Digital Ignition timing (B.T.D.C.) 10.0 ° at 2000 r/min Engine control unit Model/manufacturer 2GB0/YAMAHA (USA) (CAN) 2GB1/YAMAHA (EUR) (AUS) (NZL) (ZAF) 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 67 ELECTRICAL SPECIFICATIONS Starter relay Amperage 180.0 A 4.18–4.62  Coil resistance Starting circuit cut-off relay 75.6–92.5  Coil resistance Headlight relay 86.4–105.6  Coil resistance Fuses Main fuse 15.0 A Radiator fan motor fuse 5.0 A Spare fuse 15.0 A 2-12...

  • Page 68: Tightening Torques

    TIGHTENING TORQUES TIGHTENING TORQUES EAS20320 EAS2GB2067 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 69: Engine Tightening Torques

    TIGHTENING TORQUES ENGINE TIGHTENING TORQUES EAS2GB2068 - 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 70 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 71 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Use a Clutch boss nut 75 Nm (7.5 m·kgf, 54 ft·lbf) lock washer. Use a Drive sprocket nut 75 Nm (7.5 m·kgf, 54 ft·lbf) lock washer. Segment 30 Nm (3.0 m·kgf, 22 ft·lbf) Shift guide bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Stopper lever bolt...

  • Page 72: Chassis Tightening Torques

    TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES EAS2GB2069 - marked portion shall be checked for torque tightening after break-in or before each race. Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Outer tube and upper bracket bolt 21 Nm (2.1 m·kgf, 15 ft·lbf) Outer tube and lower bracket bolt 21 Nm (2.1 m·kgf, 15 ft·lbf) Upper bracket and steering stem nut...
  • Page 73 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Front brake disc bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Rear brake disc bolt 14 Nm (1.4 m·kgf, 10 ft·lbf) Footrest bracket bolt 55 Nm (5.5 m·kgf, 40 ft·lbf) Sidestand bolt 25 Nm (2.5 m·kgf, 18 ft·lbf) Rear brake pedal bolt 26 Nm (2.6 m·kgf, 19 ft·lbf)
  • Page 74 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Drive chain tensioner bolt (lower 16 Nm (1.6 m·kgf, 12 ft·lbf) side) Drive chain support bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Drive chain support nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Drive chain guide bolt 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Rear frame and left cover bolt...
  • Page 75 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Starter relay and starter motor lead 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) bolt Lean angle sensor bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) Taillight assembly screw — 1.1 Nm (0.11 m·kgf, 0.80 ft·lbf) Taillight lead clamp and rear fender —...

  • Page 76: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES EAS2GB2070 EAS2GB2071 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 77: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Starter idle gear inner surface, thrust surfaces Starter clutch drive gear inner surface, thrust surfaces Three bond Cylinder head cover gasket No.1215® Three bond Crankcase mating surface No.1215® Three bond Stator assembly lead grommet No.1215®...
  • Page 78 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Tube guide (throttle grip) inner surface and throttle cable end Front brake caliper piston Front brake caliper piston seal Front brake caliper dust seal Front brake caliper piston outer surface Front brake caliper pin bolt and boot Front brake master cylinder push rod end Front brake master cylinder kit Rear brake caliper piston...
  • Page 79 LUBRICATION POINTS AND LUBRICANT TYPES EAS2GB2073 2-24...

  • Page 80: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION DIAGRAMS EAS2GB2074 2-25...
  • Page 81 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 2-26...
  • Page 82 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
  • Page 83 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Connecting rod 2. Crankshaft 3. Main axle 4. Oil strainer 5. Drive axle 2-28...
  • Page 84 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 85 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Exhaust camshaft 2. Intake camshaft 3. Oil filter element 4. Oil pump 2-30...
  • Page 86 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
  • Page 87 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil pressure check bolt 3. Oil filter element 4. Oil pump 2-32...

  • Page 88: Cable Routing Diagram

    CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM EAS2GB2075 2-33...
  • Page 89 CABLE ROUTING DIAGRAM 1. Clutch cable N. Place the grommet of the clutch cable so that it contacts the radiator hose. Route the clutch cable 2. Throttle cable (return) outside the neutral switch lead, AC magneto lead 3. Throttle cable (pull) and starter motor lead.
  • Page 90 CABLE ROUTING DIAGRAM 2-35...
  • Page 91 CABLE ROUTING DIAGRAM 1. Clamp 2. Cylinder head breather hose 3. Throttle position sensor lead 4. Joint coupler 5. Intake air temperature sensor coupler 6. Intake air pressure sensor lead 7. Wire harness 8. Injector lead 9. Throttle body 10. Injector coupler 11.
  • Page 92 CABLE ROUTING DIAGRAM 2-37...
  • Page 93 CABLE ROUTING DIAGRAM 1. Cable guide 2. Speed sensor lead 3. Joint coupler 4. Ground lead 5. Throttle position sensor lead 6. Throttle position sensor coupler 7. Radiator breather hose 8. Cylinder head breather hose 9. Crankcase breather hose 10. Radiator hose 11.
  • Page 94 CABLE ROUTING DIAGRAM 2-39...
  • Page 95 CABLE ROUTING DIAGRAM 1. Battery negative lead 2. Fuel hose 3. Fuel pump coupler 4. Fuel pump lead 5. Resistor 6. Resistor coupler 7. Battery positive lead 8. Lean angle sensor 9. Starter motor lead 10. Radiator fan motor relay (blue tape) 11.
  • Page 96 CABLE ROUTING DIAGRAM 2-41...
  • Page 97 CABLE ROUTING DIAGRAM 1. Clutch switch lead 2. Engine stop switch lead 3. Clutch cable 4. Brake hose guide 5. Headlight lead 6. Speed sensor lead 7. Indicator light coupler 8. Meter assembly optional switch coupler 9. Meter assembly coupler 10.
  • Page 98 CABLE ROUTING DIAGRAM 2-43...
  • Page 99 CABLE ROUTING DIAGRAM 1. Breather hose 3 (air filter breather hose) 2. Breather hose 1 (cylinder head breather hose) 3. Breather hose 2 (crankcase breather hose) 4. Joint pipe A. Pass the breather hose 3 to the outside the throt- tle cable.
  • Page 100 CABLE ROUTING DIAGRAM 2-45...
  • Page 101 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 102 CABLE ROUTING DIAGRAM 2-47...

  • Page 103: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM .................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ......3-2 MAINTENANCE INTERVALS FOR COMPETITION USE ......3-4 PRE-OPERATION INSPECTION AND MAINTENANCE.........3-9 GENERAL INSPECTION AND MAINTENANCE........3-9 ENGINE ......................3-10 CHECKING THE COOLANT LEVEL............3-10 CHECKING THE COOLING SYSTEM .............3-10 CHANGING THE COOLANT..............3-10...
  • Page 104 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY....3-33 CHECKING THE TIRES................3-35 CHECKING AND TIGHTENING THE SPOKES........3-35 CHECKING THE WHEELS ..............3-36 CHECKING THE WHEEL BEARINGS .............3-36 CHECKING AND ADJUSTING THE STEERING HEAD ......3-36 CHECKING AND LUBRICATING THE CABLES ........3-37 LUBRICATING THE LEVERS ..............3-37 LUBRICATING THE PEDAL ..............3-37 LUBRICATING THE DRIVE CHAIN ............3-38 LUBRICATING THE SIDESTAND............3-38...

  • Page 105: Periodic Maintenance

    • From 4200 mi (7000 km) or 9 months, repeat the maintenance intervals starting from 1800 mi (3000 km) or 3 months. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

  • Page 106: General Maintenance And Lubrication Chart

    PERIODIC MAINTENANCE GENERAL MAINTENANCE AND LUBRICATION CHART EAS2GB2079 ODOMETER READ- INITIAL INGS 600 mi 1800 mi 3000 mi ITEM CHECKS AND MAINTENANCE JOBS (1000 (3000 (5000 km) or 1 km) or 3 km) or 6 month months months • Check operation. ...
  • Page 107 Rear suspen- • Apply molybdenum disulfide grease   sion link piv- lightly. Control ca- • Apply Yamaha chain and cable lube or    bles engine oil 10W-30 thoroughly. • Check operation and free play. Throttle grip •...

  • Page 108: Maintenance Intervals For Competition Use

    If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. • Periodic inspection is essential in making full use of the machine performance. The service life of the parts varies substantially according to the environment in which the machine runs (e.g., rain,...
  • Page 109 PERIODIC MAINTENANCE Every Every After third fifth Every As re- ITEM break- Remarks race quired 1,000 PISTON PIN Inspect Replace CYLINDER HEAD Inspect carbon deposits and Inspect and clean eliminate them. Change gasket. CYLINDER Inspect score marks. Inspect and clean Inspect wear.
  • Page 110 PERIODIC MAINTENANCE Every Every After third fifth Every As re- ITEM break- Remarks race quired 1,000 COOLING SYSTEM Check coolant lev- el and leakage Check radiator cap operation Replace coolant Every two years Inspect hoses OUTSIDE NUTS AND BOLTS Refer to “STARTING AND Retighten BREAK-IN”...
  • Page 111 PERIODIC MAINTENANCE Every Every After third fifth Every As re- ITEM break- Remarks race quired 1,000 BRAKES Adjust lever posi- tion and pedal height Lubricate pivot point Check brake disc surface Check fluid level and leakage Retighten brake disc bolts, caliper bolts, master cylin- der bolts and union bolts...
  • Page 112 TIRE, WHEELS Inspect air pres- sure, wheel run- out, tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate Lithium-soap-based grease THROTTLE, CON- TROL CABLE Check routing and connection Yamaha cable lube or SAE Lubricate 10W-30 motor oil...

  • Page 113: Pre-Operation Inspection And Maintenance

    PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE EAS2GB2081 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 EAS2GB2082 ITEM inspect Page...

  • Page 114: Engine

    ENGINE ENGINE CHECKING THE COOLING SYSTEM EAS2GB2083 EAS2GB2085 1. Remove: EAS2GB2084 CHECKING THE COOLANT LEVEL • Seat • Side cover (left/right) WARNING • Air scoop (left/right) If coolant seems hot, do not remove the ra- Refer to “GENERAL CHASSIS” on page 5- diator cap.

  • Page 115: Checking The Radiator Cap

    ENGINE Crack/damage  Replace. 5. Install: Exist fur deposits  Clean or replace. • Copper washer • 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 116: Checking The Coolant Circulatory System For Leaks

    ENGINE CHECKING THE COOLANT CIRCULATORY ADJUSTING THE CLUTCH LEVER FREE EAS2GB2089 EAS2GB2090 SYSTEM FOR LEAKS PLAY 1. Check: 1. Check: • Coolant level • Clutch lever free play “a” Out of specification  Regulate. 2. Install: • Radiator cap tester “1” Clutch lever free play •...

  • Page 117: Adjusting The Throttle Grip Free Play

    ENGINE c. Turn the adjuster “2” in direction “a” or “b” 2. Adjust: until the specified clutch lever free play is ob- • Throttle grip free play tained. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. Direction “a” b. Turn the adjuster “2” until the specified free Clutch lever free play is increased.

  • Page 118: Cleaning The Air Filter Element

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

  • Page 119: Checking The Throttle Body Joint

    ENGINE 6. Install: • Air filter guide “1” (to the air filter element) • Air filter element “2” • Air filter mounting bolt “3” Air filter mounting bolt 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) CHECKING THE EXHAUST SYSTEM EAS2GB2096 1. Remove: •...

  • Page 120: Checking The Fuel Line

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

  • Page 121: Changing The Engine Oil

    ENGINE 5. To check the oil strainer, perform the follow- CHANGING THE ENGINE OIL EAS2GB2099 ing procedure. Stand the vehicle upright on a level surface. 1. Start the engine, warm this up for 3 minutes, ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the oil strainer “1”. and then stop the engine and wait about 5 b.

  • Page 122: Adjusting The Engine Idling Speed

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

  • Page 123: Adjusting The Valve Clearance

    • This section is intended for those who have Valve clearance (cold) basic knowledge and skill concerning the ser- Intake 0.12–0.19 mm (0.0047–0.0075 in) vicing of Yamaha motorcycles (e.g., Yamaha Exhaust dealers, service engineers, etc.). Those who 0.17–0.24 mm (0.0067–0.0094 in) have little knowledge and skill concerning ser- vicing are requested not to undertake inspec- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 124 ENGINE Check that the alignment mark “c” on the cam- • Place a cloth in the timing chain space to pre- shaft sprocket and the alignment mark “d” on vent adjusting pads from falling into the crank- the intake camshaft sprocket are aligned with case.
  • Page 125 ENGINE d. Select an adjusting pad with a proper valve f. Install the camshafts (exhaust and intake). clearance from the adjusting pad selection Refer to “CAMSHAFT” on page 6-11. table. g. Measure the valve clearance again. h. If the valve clearance is out of specification, repeat adjusting the valve clearance until it •...
  • Page 126 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 127: Cleaning The Spark Arrester

    ENGINE CLEANING THE SPARK ARRESTER EAS2GB2102 Refer to “CLEANING THE SPARK ARREST- ER” on page 6-7. 3-23...

  • Page 128: Chassis

    CHASSIS CHASSIS EAS2GB2103 EAS2GB2104 BLEEDING THE BRAKE SYSTEM WARNING Bleed the brake system whenever: • The system is disassembled. • A brake hose is loosened, disconnected, or replaced. • The brake fluid level is very low. • Brake operation is faulty. A.

  • Page 129: Checking The Brake Hose

    CHASSIS CHECKING THE BRAKE HOSE EAS2GB2105 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 130: Adjusting The Rear Brake

    CHASSIS ADJUSTING THE REAR BRAKE EAS2GB2107 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 131 CHASSIS d. Remove the pad pin and brake pads “4”. i. Install the brake caliper “8” and tighten the pad pin “9”. Bolt (brake caliper) 23 Nm (2.3 m·kgf, 17 ft·lbf) Pad pin 17 Nm (1.7 m·kgf, 12 ft·lbf) e. Connect the plastic hose “5” to the bleed screw “6”...

  • Page 132: Checking The Rear Brake Pads

    CHASSIS CHECKING THE REAR BRAKE PADS EAS2GB2109 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 133: Checking The Rear Brake Pad Insulator

    CHASSIS system. Refer to “BLEEDING THE BRAKE SYS- TEM” on page 3-24. CHECKING THE REAR BRAKE PAD INSU- EAS2GB2110 LATOR 1. Remove: • Brake pads Refer to “REAR BRAKE” on page 5-23. 2. Check: • Rear brake pad insulator “1” i.

  • Page 134: Adjusting The Drive Chain Slack

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

  • Page 135: Checking The Front Fork Legs

    CHASSIS CLEANING THE FRONT FORK OIL SEAL CHECKING THE FRONT FORK LEGS EAS2GB2113 AND DUST SEAL 1. Stand the vehicle upright on a level surface. 1. Remove: WARNING • Protector Securely support the vehicle so that there is • Dust seal “1” no danger of it falling over.

  • Page 136: 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 NOTICE Do not turn the adjuster forcibly beyond its adjusting range. EAS2GB2117 ADJUSTING THE FRONT FORK LEGS 1. Adjust: WARNING •...

  • Page 137: Checking The Swingarm Operation

    CHASSIS Spring preload CHECKING THE SWINGARM OPERATION EAS2GB2118 1. Check: NOTICE • Swingarm smooth action Do not turn the adjuster forcibly beyond its • Swingarm free play adjusting range. Refer to “SWINGARM” on page 5-64. 1. Remove: EAS2GB2119 CHECKING THE REAR SUSPENSION •...
  • Page 138 CHASSIS Rebound damping force • Be sure to remove all dirt and mud from Maximum around the locknut and adjusting ring before Turn it in finger-tight. adjustment. Turn it out by 14 clicks.* • The length of the spring (installed) changes Minimum 1.5 mm (0.06 in) per turn of the adjusting ring.

  • Page 139: Checking The Tires

    CHASSIS CHECKING THE TIRES 1. Measure: • Tire pressure Out of specification  Regulate. Tire air pressure (measured on cold tires) 100 kPa (1.00 kgf/cm , 15 psi) • Check the tire while it is cold. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure Low compression damping is low.

  • Page 140: Checking The Wheels

    CHASSIS 2. Tighten: CHECKING AND ADJUSTING THE STEER- • Spokes ING HEAD Use a spoke nipple wrench “1” for tighten- 1. Use a suitable stand to raise the front wheel ing. off the ground. WARNING Securely support the vehicle so that there is no danger of it falling over.

  • Page 141: Checking And Lubricating The Cables

    CHASSIS CHECKING AND LUBRICATING THE CA- Steering nut wrench BLES 90890-01403 The following procedure applies to all of the in- Exhaust flange nut wrench ner and outer cables. YU-A9472 WARNING Damaged outer cable may cause the cable Ring nut (initial tightening torque) to corrode and interfere with its movement.

  • Page 142: Lubricating The Drive Chain

    CHASSIS LUBRICATING THE DRIVE CHAIN EAS2GB2129 The drive chain consists of many interacting parts. If the drive chain is not maintained prop- erly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas. This vehicle has a drive chain with small rubber O-rings between each side plate.

  • Page 143: Electrical System

    ELECTRICAL SYSTEM 5. Clean: ELECTRICAL SYSTEM EAS2GB2132 • Spark plug (with a spark plug cleaner or a wire brush) EAS2GB2133 CHECKING THE SPARK PLUG 6. Measure: 1. Remove: • Spark plug gap “a” • Seat Out of specification  Adjust the spark plug •...

  • Page 144: Checking And Charging The Battery

    ELECTRICAL SYSTEM 2. Attach: CHECKING AND CHARGING THE BATTERY • Timing light “1” Refer to “CHECKING AND CHARGING THE • Digital tachometer “2” BATTERY” on page 9-69. To the high tension code “3”. REPLACING THE HEADLIGHT BULB EAS2GB2136 Timing light WARNING 90890-03141 Since the headlight bulb gets extremely hot,...
  • Page 145 ELECTRICAL SYSTEM 4. Install: • Headlight bulb Fasten the new headlight bulb with the headlight bulb holder. NOTICE Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected.
  • Page 146 ELECTRICAL SYSTEM 3-42...

  • Page 147: Tuning

    TUNING CHASSIS ......................4-1 SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET) ....................4-1 DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS ....4-1 TIRE PRESSURE..................4-1 FRONT FORK SETTING................4-2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL....4-2 SETTING OF SPRING AFTER REPLACEMENT ........4-2 FRONT FORK SETTING PARTS...............4-3 REAR SUSPENSION SETTING ..............4-3 CHOOSING SET LENGTH ................4-3 SETTING OF SPRING AFTER REPLACEMENT ........4-4...

  • Page 148: Chassis

    CHASSIS DRIVE AND REAR WHEEL SPROCKETS CHASSIS EAS2GB2138 SETTING PARTS EAS2GB2139 SELECTION OF THE SECONDARY REDUC- Part name Type Part number TION RATIO (SPROCKET) Drive sprocket “1” Secondary reduction ratio = Number of (STD) 13T 9383B-13218 rear wheel sprocket teeth/Number of Rear wheel sprock- drive sprocket teeth et “2”...

  • Page 149: Front Fork Setting

    CHASSIS • Under a stony or a hard road condition, the tire pressure should be higher to prevent a flat tire. Extent of adjustment 100–120 kPa (1.0–1.2 kgf/cm 15–18 psi) FRONT FORK SETTING EAS2GB2142 The front fork setting should be made depend- ing on the rider’s feeling of an actual run and the circuit conditions.

  • Page 150: Front Fork Setting Parts

    CHASSIS REAR SUSPENSION SETTING The rear shock absorber setting should be Generally a stiff spring gives a stiff riding feel- made depending on the rider’s feeling of an ac- ing. Rebound damping tends to become weak- tual run and the circuit conditions. er, resulting in lack of a sense of contact with The rear suspension setting includes the fol- the road surface or in a vibrating handlebar.

  • Page 151: Setting Of Spring After Replacement

    CHASSIS Length “a” of standard shock • If the machine is new and after it is broken in, 462.5 mm (18.21 in) the same set length of the spring may change because of the initial fatigue, etc. of the spring. Therefore, be sure to make reevalua- tion.
  • Page 152 CHASSIS • Extent of adjustment (spring preload) Maximum Minimum Position in which Position in which the spring is turned the spring is turned in 18 mm (0.71 in) in 1.5 mm (0.06 in) from its free length. from its free length. For the spring preload adjustment, refer to “AD- JUSTING THE REAR SHOCK ABSORBER ASSEMBLY”...

  • Page 153: Suspension Setting (Front Fork)

    CHASSIS SUSPENSION SETTING (FRONT FORK) EAS2GB2150 • 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 154: 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 155 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 156 CHASSIS...
  • Page 157 CHASSIS GENERAL CHASSIS..................5-1 REMOVING THE LEFT SIDE COVER............5-3 REMOVING THE SEAT ................5-3 FRONT WHEEL....................5-4 REMOVING THE FRONT WHEEL.............5-5 CHECKING THE FRONT WHEEL .............5-5 DISASSEMBLING THE FRONT WHEEL...........5-6 ASSEMBLING THE FRONT WHEEL............5-6 INSTALLING THE FRONT WHEEL ............5-7 REAR WHEEL ....................5-9 REMOVING THE REAR WHEEL .............5-10 CHECKING THE REAR WHEEL..............5-10 DISASSEMBLING THE REAR WHEEL ...........5-10 CHECKING AND REPLACING THE REAR WHEEL SPROCKET ..5-10...
  • Page 158 HANDLEBAR ....................5-33 REMOVING THE HANDLEBAR...............5-35 CHECKING THE HANDLEBAR ...............5-35 INSTALLING THE HANDLEBAR .............5-35 FRONT FORK....................5-40 REMOVING THE FRONT FORK LEGS...........5-42 DISASSEMBLING THE FRONT FORK LEGS .........5-42 CHECKING THE FRONT FORK LEGS ...........5-43 ASSEMBLING THE FRONT FORK LEGS ..........5-44 INSTALLING THE FRONT FORK LEGS ..........5-50 STEERING HEAD...................5-53 REMOVING THE LOWER BRACKET............5-54 CHECKING THE STEERING HEAD ............5-54...
  • Page 159 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 160 GENERAL CHASSIS Removing the headlight assembly and multi-function meter 21 Nm (2.1 m kgf, 15 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 21 Nm (2.1 m kgf, 15 ft Ibf) 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) Order...

  • Page 161: General Chassis

    GENERAL CHASSIS REMOVING THE LEFT SIDE COVER EAS2GB2154 1. Remove: • Bolt (side cover) • Side cover “1” Draw the left side cover “1” backward to re- move it because its projection “a” is inserted in the rear frame. EAS2GB2155 REMOVING THE SEAT The fuel tank cap cover and the seat are cou- pled with each other with a plastic band.

  • Page 162: Front Wheel

    FRONT WHEEL FRONT WHEEL EAS2GB2156 Removing the front wheel 21 Nm (2.1 m kgf, 15 ft Ibf) 21 Nm (2.1 m kgf, 15 ft Ibf) 90 Nm (9.0 m kgf, 65 ft lbf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) Order Part name Q’ty...

  • Page 163: Removing The Front Wheel

    FRONT WHEEL REMOVING THE FRONT WHEEL EAS2GB2157 1. Use a suitable stand to raise the front wheel A tight spoke will emit a clear, ringing tone; a off the ground. loose spoke will sound flat. WARNING 4. Tighten: Securely support the vehicle so that there is •...

  • Page 164: Disassembling The Front Wheel

    FRONT WHEEL DISASSEMBLING THE FRONT WHEEL EAS2GB2159 NOTICE 1. Remove: Install the bearing by pressing its outer race • Oil seals parallel. • Bearings ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside of the front wheel hub. b. Remove the oil seals “1” with a flat-head screwdriver.

  • Page 165: Installing The Front Wheel

    FRONT WHEEL 3. Install: 2. Install: • Collar “1” • Front wheel axle “1” Apply the lithium-soap-based grease on the oil Apply the lithium-soap-based grease to the seal lip. front wheel axle. 4. Install: 3. Tighten: • Speed sensor “1” •...
  • Page 166 FRONT WHEEL...

  • Page 167: Rear Wheel

    REAR WHEEL REAR WHEEL EAS2GB2162 Removing the rear wheel 14 Nm (1.4 m kgf, 10 ft Ibf) 125 Nm (12.5 m kgf, 90 ft lbf) 21 Nm (2.1 m kgf, 15 ft Ibf) 50 Nm (5.0 m kgf, 36 ft Ibf) 21 Nm (2.1 m kgf, 15 ft Ibf) Order Part name...

  • Page 168: Removing The Rear Wheel

    REAR WHEEL 4. Measure: REMOVING THE REAR WHEEL EAS2GB2163 • Radial wheel runout 1. Use a suitable stand to raise the rear wheel • Lateral wheel runout off the ground. Refer to “CHECKING THE FRONT WHEEL” WARNING on page 5-5. Securely support the vehicle so that there is Radial wheel runout limit no danger of it falling over.

  • Page 169: 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 EAS2GB2167 1.
  • Page 170 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 171: Front Brake

    FRONT BRAKE FRONT BRAKE EAS2GB2169 Removing the front brake caliper 30 Nm (3.0 m kgf, 22 ft lbf) 23 Nm (2.3 m kgf, 17 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 172 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 173 FRONT BRAKE Removing the front brake master cylinder Order Part name Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE BRAKE SYSTEM” on page 3-24. Brake lever Union bolt Copper washers Front brake hose Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm Front brake master cylinder float Front brake master cylinder holder Front brake master cylinder...
  • Page 174 FRONT BRAKE Disassembling the front brake master cylinder Order Part name Q’ty Remarks Dust boot Circlip Washer Brake master cylinder kit For assembly, reverse the disassemble pro- cedure. 5-16...

  • Page 175: Introduction

    FRONT BRAKE INTRODUCTION EAS2GB2170 Brake disc thickness limit WARNING 2.5 mm (0.10 in) If you need to disassemble the disc brake 4. Install: components, observe the following precau- • Front wheel tions. Refer to “FRONT WHEEL” on page 5-4. • Never disassemble the brake components unless absolutely necessary.

  • Page 176: Checking The Front Brake Caliper

    FRONT BRAKE ASSEMBLING THE FRONT BRAKE CALI- WARNING • Before installation, clean and lubricate the internal parts. Use new brake fluid for cleaning and lubricating. • Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.

  • Page 177: Installing The Front Brake Caliper

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

  • Page 178: Removing The Front Brake Master Cylinder

    FRONT BRAKE NOTICE Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Bleed: • Brake system Refer to “BLEEDING THE BRAKE SYS- TEM” on page 3-24. 6. Check: • Brake fluid level 2.

  • Page 179: Installing The Front Brake Master Cylinder

    FRONT BRAKE INSTALLING THE FRONT BRAKE MASTER EAS2GB2181 CYLINDER 1. Install: • Brake master cylinder “1” Brake master cylinder holder bolt 9 Nm (0.9 m·kgf, 6.5 ft·lbf) • Install the front brake master cylinder holder 3. Install: with the “UP” mark facing up. •...
  • Page 180 FRONT BRAKE Turn the handlebar toward right and left to make sure that the brake hose does not touch other parts (e.g., wire harness, cables, leads). Adjust if necessary. 6. Check: • Brake lever free play Refer to “ADJUSTING THE FRONT BRAKE”...

  • Page 181: Rear Brake

    REAR BRAKE REAR BRAKE EAS2GB2182 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 182 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 183 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 3-24. Union bolt Copper washers Brake hose Split pin Washer Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm plate Brake master cylinder reservoir diaphragm Rear brake master cylinder For installation, reverse the removal proce-...
  • Page 184 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. 5-26...

  • Page 185: Introduction

    REAR BRAKE INTRODUCTION EAS2GB2183 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 186: Removing The Rear Brake Caliper

    REAR BRAKE REMOVING THE REAR BRAKE CALIPER CHECKING THE REAR BRAKE CALIPER EAS2GB2185 EAS2GB2187 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 187: Installing The Brake Caliper Piston

    REAR BRAKE INSTALLING THE REAR BRAKE CALIPER INSTALLING THE BRAKE CALIPER PISTON EAS2GB2189 1. Install: 1. Clean: • Rear brake caliper • Brake caliper • Rear brake caliper bracket • Brake caliper piston seal 2. Install: • Brake caliper piston dust seal •...

  • Page 188: Removing The Rear Brake Master Cylinder

    REAR BRAKE 1. Remove: WARNING • Union bolt • Use only the designated brake fluid. Other • Copper washers brake fluids may cause the rubber seals to • Brake hose deteriorate, causing leakage and poor brake performance. To drain any remaining brake fluid, place a con- •...

  • Page 189: Installing The Rear Brake Master Cylinder

    REAR BRAKE Recommended brake fluid DOT 4 1. Wash the brake master cylinder and the brake master cylinder kit with brake fluid. 2. Install: • Primary cylinder cup “1” • Secondary cylinder cup “2” Install to the brake master cylinder piston “3”.
  • Page 190 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 191 HANDLEBAR HANDLEBAR EAS2GB2195 Removing the handlebar Order Part name Q’ty Remarks Clutch cable Disconnect. Clutch switch Clutch lever holder Engine stop switch Brake master cylinder Throttle cable cap Throttle cable (pull) Disconnect. Throttle cable (return) Disconnect. Right grip Tube guide Start switch Left grip Handlebar upper holder...
  • Page 192 HANDLEBAR Removing the handlebar Order Part name Q’ty Remarks Handlebar lower holder Damper For installation, reverse the removal proce- dure. 5-34...

  • Page 193: Handlebar

    HANDLEBAR REMOVING THE HANDLEBAR EAS2GB2196 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Clutch switch “1” CHECKING THE HANDLEBAR EAS2GB2197 1. Check: •...
  • Page 194 HANDLEBAR NOTICE • First, tighten the bolts on the front side of the upper handlebar holder, and then on the rear side. • Turn the handlebar all the way to the left and right. If there is any contact with the fuel tank, adjust the handlebar position.
  • Page 195 HANDLEBAR 5. Install: • Engine stop switch “1” • Clutch lever “2” • Clutch lever holder “3” • Clamp “4” Engine stop switch screw 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf) Clutch lever holder bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) 7.
  • Page 196 HANDLEBAR WARNING • Install the brake master cylinder holder with After tightening the throttle cable housing the “UP” mark facing up. screws, check that the throttle grip “3” • Install in order for the top of the front brake moves smoothly. If it does not, retighten the master cylinder assembly to be level.
  • Page 197 HANDLEBAR 14.Adjust: • Throttle grip free play Refer to “ADJUSTING THE THROTTLE GRIP FREE PLAY” on page 3-13. Throttle grip free play 3.0–5.0 mm (0.12–0.20 in) 5-39...

  • Page 198: Front Fork

    FRONT FORK FRONT FORK EAS2GB2199 Removing the front fork legs Order Part name Q’ty Remarks Use a suitable stand to raise the front wheel off the ground. Front wheel Refer to “FRONT WHEEL” on page 5-4. Front brake caliper Refer to “FRONT BRAKE” on page 5-13. Brake hose holder Protector Upper bracket pinch bolts...
  • Page 199 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 200: Removing The Front Fork Legs

    FRONT FORK REMOVING THE FRONT FORK LEGS EAS2GB2200 1. Use a suitable stand to raise the front wheel • While compressing the inner tube “2”, set the off the ground. cap bolt ring wrench “4” between the inner tube and locknut “3”. WARNING •...

  • Page 201: Checking The Front Fork Legs

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

  • Page 202: Assembling The Front Fork Legs

    FRONT FORK 5. Check: ASSEMBLING THE FRONT FORK LEGS EAS2GB2203 • Base valve “1” 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 203 FRONT FORK 4. Measure: 6. Loosen: • Oil level (left and right) “a” • Compression damping force adjuster “1” Out of specification  Regulate. • Before loosening the damping force adjuster, Standard oil level record the setting position. 145–148 mm (5.71–5.83 in) •...
  • Page 204 FRONT FORK 9. Tighten: • Base valve “1” Base valve 28 Nm (2.8 m·kgf, 20 ft·lbf) Hold the damper assembly with the cap bolt ring wrench “2” and use the cap bolt wrench “3” to tighten the base valve. 12.Allow the overflowing oil to escape at the Cap bolt wrench hole “a”...
  • Page 205 FRONT FORK • Apply the lithium-soap-based grease on the dust seal lip and oil seal lip. • Apply the fork oil on the inner tube. • When installing the oil seal, use vinyl seat “a” with fork oil applied to protect the oil seal lip. 17.Install: •...
  • Page 206 FRONT FORK 19.Install: 22.Measure: • Oil seal clip “1” • Distance “a” Out of specification  Turn into the locknut. Fit the oil seal clip correctly in the groove in the Distance “a” outer tube. 16 mm (0.63 in) or more Between the damper assembly “1”...
  • Page 207 FRONT FORK 24.Install: Cap bolt ring wrench • Damper assembly “1” 90890-01501 (to the inner tube “2”) Cap bolt ring wrench YM-01501 NOTICE Allow the damper assembly to slide slowly down the inner tube until it contacts the bot- tom of the inner tube. Be careful not to dam- age the inner tube.

  • Page 208: Installing The Front Fork Legs

    FRONT FORK 29.Install: 31.Install: • Adjuster “1” • Damper assembly “1” (to the inner tube) (to the outer tube) Adjuster Temporarily tighten the damper assembly. 55 Nm (5.5 m·kgf, 40 ft·lbf) LOCTITE® 32.Install: • Protector guide “1” 30.Fill: • Front fork leg Recommended oil Suspension oil S1 Standard oil amount...
  • Page 209 FRONT FORK 4. 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) 2. Tighten: WARNING • Damper assembly “1” Tighten the lower bracket to specified torque.
  • Page 210 FRONT FORK 6. Install: 9. Adjust: • Speed sensor lead “1” • Compression damping force • Plate 2 “2” (to the right front fork protector) Turn in the damping adjuster “1” finger-tight and then turn out to the originally set position. Plate 2 screw 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf) Install the plate 2 in the direction as shown.

  • Page 211: Steering Head

    STEERING HEAD STEERING HEAD EAS2GB2205 Removing the lower bracket 145 Nm (14.5 m kgf, 105 ft lbf) 21 Nm (2.1 m kgf, 15 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft lbf) 21 Nm (2.1 m kgf, 15 ft...

  • Page 212: Removing The Lower Bracket

    STEERING HEAD REMOVING THE LOWER BRACKET EAS2GB2206 1. Use a suitable stand to raise the front wheel Always replace the bearing and the bearing off the ground. race as a set. WARNING Securely support the vehicle so that there is no danger of it falling over.
  • Page 213 STEERING HEAD 5. Check the steering stem by turning this lock to lock. If there is any binding, remove the Apply the lithium-soap-based grease on the steering stem and check the steering bear- bearing and bearing race cover lip. ing. 3.
  • Page 214 STEERING HEAD Apply the lithium-soap-based grease to the contact surface of the steering stem nut when installing. 12.Install: • Speed sensor lead holder “1” • Speed sensor lead clamp “2” Speed sensor lead holder bolt 13 Nm (1.3 m·kgf, 9.4 ft·lbf) 9.

  • Page 215: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY REAR SHOCK ABSORBER ASSEMBLY EAS2GB2209 Removing the rear shock absorber assembly 16 15 14 13 Order Part name Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 5-1. Side cover (left / right) Refer to “GENERAL CHASSIS” on page 5-1. Air scoop (left / right) Refer to “GENERAL CHASSIS”...
  • Page 216 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 16 15 14 13 Order Part name Q’ty Remarks O-ring Dust seal Stopper ring Bearing For installation, reverse the removal proce- dure. 5-58...
  • Page 217 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. 5-59...

  • Page 218: Handling The Rear Shock Absorber

    • To dispose of a damaged or a worn-out rear shock absorber, take the unit to your Yamaha dealer for this disposal proce- 3. Remove: dure. • Rear shock absorber assembly upper bolt •...

  • Page 219: Checking The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY • Spring Damage/wear  Replace. • Spring guide Damage/wear  Replace. • Bearing Damage/wear  Replace. • Bolts Bends/damage/wear  Replace. EAS2GB2215 CHECKING THE CONNECTING ARM AND RELAY ARM 2. Remove: 1. Check: • Upper bearing “1” •...

  • Page 220: Installing The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY 3. Install: 4. Install: • Bearing “1” • Bearing “1” • Oil seals “2” • Bushing “2” (to connecting arm “3”) • Collar “3” • Dust seal “4” Installed depth “a” (to rear shock absorber assembly (lower 0 mm (0 in) side)) Install the dust seals with their lips facing in-...
  • Page 221 REAR SHOCK ABSORBER ASSEMBLY • Connecting arm bolt (frame side) Connecting arm bolt (frame side) 80 Nm (8.0 m·kgf, 58 ft·lbf) • Connecting arm bolt (relay arm side) Connecting arm bolt (relay arm side) 80 Nm (8.0 m·kgf, 58 ft·lbf) •...

  • Page 222: Swingarm

    SWINGARM SWINGARM EAS2GB2218 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 223: Removing The Swingarm

    SWINGARM REMOVING THE SWINGARM EAS2GB2219 1. Use a suitable stand to raise the rear wheel off the ground. WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Measure: • Swingarm side play • Swingarm vertical movement ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 224: Installing The Swingarm

    SWINGARM INSTALLING THE SWINGARM EAS2GB2222 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 225: Chain Drive

    CHAIN DRIVE CHAIN DRIVE EAS2GB2223 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 6-1. Drive chain For installation, reverse the removal proce- dure.

  • Page 226: Removing The Drive Chain

    CHAIN DRIVE REMOVING THE DRIVE CHAIN EAS23420 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated.

  • Page 227: Checking The Drive Sprocket

    CHAIN DRIVE b. Correct 1. Drive chain roller 2. Drive sprocket CHECKING THE REAR WHEEL SPROCKET EAS2GB2225 Refer to “CHECKING AND REPLACING THE REAR WHEEL SPROCKET” on page 5-10. EAS2GB2226 INSTALLING THE DRIVE CHAIN 1. Install: • Drive chain ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ NOTICE 4.
  • Page 228 CHAIN DRIVE NOTICE A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the speci- fied limits.

  • Page 229: Engine

    ENGINE ENGINE REMOVAL ..................6-1 REMOVING THE SILENCER..............6-6 REMOVING THE EXHAUST PIPE 2............6-6 REMOVING THE DRIVE SPROCKET ............6-6 REMOVING THE ENGINE .................6-7 CLEANING THE SPARK ARRESTER ............6-7 CHECKING THE SILENCER AND EXHAUST PIPE........6-8 INSTALLING THE ENGINE................6-8 INSTALLING THE BRAKE PEDAL ............6-9 INSTALLING THE DRIVE SPROCKET............6-9 INSTALLING THE EXHAUST PIPE AND MUFFLER.........6-9 CAMSHAFT ....................6-11...
  • Page 230 CLUTCH ......................6-40 REMOVING THE CLUTCH ..............6-43 CHECKING THE FRICTION PLATES............6-43 CHECKING THE CLUTCH PLATES ............6-43 CHECKING THE CLUTCH SPRINGS............6-43 CHECKING THE CLUTCH HOUSING .............6-44 CHECKING THE CLUTCH BOSS............6-44 CHECKING THE PRESSURE PLATE .............6-44 CHECKING THE PUSH LEVER SHAFT..........6-44 CHECKING THE CLUTCH PUSH RODS ..........6-44 CHECKING THE PRIMARY DRIVE GEAR..........6-44 CHECKING THE PRIMARY DRIVEN GEAR ...........6-45 INSTALLING THE OIL SEAL ..............6-45...
  • Page 231 GENERATOR AND STARTER CLUTCH............6-62 REMOVING THE GENERATOR ..............6-64 CHECKING THE STARTER CLUTCH .............6-64 INSTALLING THE STARTER CLUTCH ...........6-65 INSTALLING THE GENERATOR.............6-65 CRANKCASE ....................6-68 DISASSEMBLING THE CRANKCASE.............6-71 REMOVING THE CRANKCASE BEARING ..........6-71 CHECKING THE TIMING CHAIN, TIMING CHAIN GUIDE, OIL STRAINER..................6-71 CHECKING THE CRANKCASE ...............6-71 INSTALLING THE OIL SEAL ..............6-72 ASSEMBLING THE CRANKCASE............6-72...

  • Page 232: 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 233 ENGINE REMOVAL Removing the exhaust pipe 5 Nm (0.5 m kgf, 3.6 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 9 Nm (0.9 m kgf, 6.5 ft Ibf) 13 Nm (1.3 m , 9.4 ft lbf) 2nd 20 Nm (2.0 m kgf , 14 ft lbf) 30 Nm (3.0 m kgf, 22 ft Ibf) 30 Nm (3.0 m kgf, 22 ft Ibf)
  • Page 234 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 5-1. Side cover (left/right) Refer to “GENERAL CHASSIS” on page 5-1. Air scoop (left / right) Refer to “GENERAL CHASSIS”...
  • Page 235 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 5-1. Side cover (left/right) Refer to “GENERAL CHASSIS”...
  • Page 236 ENGINE REMOVAL Removing the engine 55 Nm (5.5 m kgf, 40 ft Ibf) Order Part name Q’ty Remarks Cylinder head breather hose Drive sprocket cover Drive chain guide Drive sprocket Upper engine bracket Washer Thickness:2.3 mm (0.09 in) Washer Thickness:1.0 mm (0.04 in) Lower engine bracket Pivot shaft Engine...

  • Page 237: Removing The Silencer

    ENGINE REMOVAL REMOVING THE SILENCER EAS2GB2229 1. Remove: • Rear shock absorber assembly lower bolt “1” • Connecting arm bolt (frame side) “2” • Silencer “3” Move the rear shock absorber to the left side of the chassis, and remove the silencer. REMOVING THE DRIVE SPROCKET EAS2GB2231 1.

  • Page 238: Removing The Engine

    ENGINE REMOVAL CLEANING THE SPARK ARRESTER REMOVING THE ENGINE EAS2GB2232 1. Remove: WARNING • Pivot shaft “1” • Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. If the pivot shaft is pulled all the way out, the •...

  • Page 239: Checking The Silencer And Exhaust Pipe

    ENGINE REMOVAL 5. Install: • Engine mounting bolt (lower side) “3” • Spark arrester gasket Engine mounting bolt (lower side) • Spark arrester 53 Nm (5.3 m·kgf, 38 ft·lbf) Insert the spark arrester into the muffler and align the bolt holes. •...

  • Page 240: Installing The Brake Pedal

    ENGINE REMOVAL INSTALLING THE BRAKE PEDAL EAS2GB2236 NOTICE 1. Install: Make sure to tighten to specification; other- • Spring “1” wise, it may damage the other part that is • Brake pedal “2” fastened together. • O-rings “3” • Bolt (brake pedal) “4” Bolt (brake pedal) 26 Nm (2.6 m·kgf, 19 ft·lbf) •...
  • Page 241 ENGINE REMOVAL 2. Install: • Clamp Install and temporarily tighten the silencer so • Exhaust pipe 2 “1” that its joint is positioned as shown with respect • Bolt (exhaust pipe 2) “2” to the exhaust pipe 2. 2mm (0.08in) 4.

  • Page 242: Camshaft

    CAMSHAFT CAMSHAFT EAS2GB2239 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 5-1. Side cover (left/right) Refer to “GENERAL CHASSIS”...
  • Page 243 CAMSHAFT Removing the camshaft 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 6 Nm (0.6 m kgf, 4.3 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 6 Nm (0.6 m kgf, 4.3 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name...

  • Page 244: Removing The Camshaft

    CAMSHAFT REMOVING THE CAMSHAFT EAS2GB2240 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 245: Checking The Camshaft

    CAMSHAFT 3. Measure: CHECKING THE CAMSHAFT EAS2GB2241 • Camshaft runout 1. Check: Out of specification  Replace. • Camshaft lobes Blue discoloration/pitting/scratches  Re- Camshaft runout limit 0.030 mm (0.0012 in) place the camshaft. 2. Measure: • Camshaft lobe dimensions “A” and “B” Out of specification ...

  • Page 246: Checking The Timing Chain And Camshaft Sprocket

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

  • Page 247: Checking The Decompression System

    CAMSHAFT CHECKING THE DECOMPRESSION SYS- EAS2GB2244 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 248 “2”, and the gasket “3”, and tighten inder head cover gasket. the bolt “4”. Bolt (timing chain tensioner) Yamaha bond No. 1215 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 90890-85505 (Three bond No.1215®) c. Release the screwdriver, check that the ten- sioner rod comes out smoothly, and tighten 6.
  • Page 249 CYLINDER HEAD CYLINDER HEAD EAS2GB2246 Removing the cylinder head 33 Nm (3.3 m kgf, 24 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 5-1. Side cover (left/right) Refer to “GENERAL CHASSIS”...

  • Page 250: Cylinder Head

    CYLINDER HEAD Removing the cylinder head 33 Nm (3.3 m kgf, 24 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks For installation, reverse the removal proce- dure.

  • Page 251: Removing The Cylinder Head

    CYLINDER HEAD REMOVING THE CYLINDER HEAD EAS2GB2247 1. Remove: • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAMSHAFT” on page 6-13. 2. Remove: • Cylinder head nuts • Cylinder head bolts 2. Check: • Loosen the bolts in the proper sequence as •...

  • Page 252: Installing The Cylinder Head

    CYLINDER HEAD INSTALLING THE CYLINDER HEAD EAS2GB2250 1. Install: Tighten the bolts and nuts to the specified • Timing chain guide (intake side) “1” torque in two or three steps in the proper tight- • Dowel pin “2” ening sequence as shown. •...
  • Page 253 VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS EAS2GB2251 Removing the valves and valve springs Order Part name Q’ty Remarks Refer to “CYLINDER HEAD” on page 6-18. Cylinder head Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Intake valve...

  • Page 254: Valves And Valve Springs

    VALVES AND VALVE SPRINGS REMOVING THE VALVES EAS2GB2252 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Pour a clean solvent “a” into the intake and exhaust ports. Before removing the internal parts of the cylin- b. Check that the valves are properly sealed. der head (e.g., valves, valve springs, valve seats), make sure that the valves are properly Check that there are no kerosene leaks from sealed.

  • Page 255: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS 4. Remove: • Valve spring retainer “1” • Valve spring “2” • Valve “3” • Valve stem seat “4” • Valve spring seat “5” Identify the position of each part very carefully so that it can be reinstalled in its original place. 2.
  • Page 256 VALVES AND VALVE SPRINGS c. After installing the valve guide, expand the 4. Check: hole in the valve guide with the valve guide • Valve face Pitting/wear  Grind the valve face. reamer “3” to obtain the proper valve-stem- to-valve-guide clearance. •...

  • Page 257: Checking The Valve Seats

    VALVES AND VALVE SPRINGS CHECKING THE VALVE SEATS EAS2GB2254 1. Eliminate: • Carbon deposits (from the valve face and valve seat) 2. Check: • Valve seat Pitting/wear  Replace the cylinder head. 3. Measure: • Valve seat width C “a” Out of specification ...

  • Page 258: Checking The Valve Springs

    VALVES AND VALVE SPRINGS While turning the valve lapper, tap and lap the valve seat. e. Apply a fine lapping compound to the valve face, and repeat the above steps. f. After every lapping step, be sure to clean off all of the lapping compound from the valve face and the valve seat.

  • Page 259: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 3. Install: CHECKING THE VALVE LIFTERS EAS2GB2256 • Spring seat “1” 1. Check: • Valve stem seal “2” • Valve lifter • Valve “3” Damage/scratches  Replace the valve lift- • Valve spring “4” ers and cylinder head. •...
  • Page 260 VALVES AND VALVE SPRINGS 5. To fasten the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. NOTICE Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Adjusting pad “1” •...
  • Page 261 CYLINDER AND PISTON CYLINDER AND PISTON EAS2GB2258 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 6-18. Cylinder head Cylinder body Gaskets...

  • Page 262: Cylinder And Piston

    CYLINDER AND PISTON REMOVING THE PISTON EAS2GB2259 1. Remove: • Piston pin clip “1” • Piston pin “2” • Piston “3” NOTICE Do not use a hammer to drive the piston pin out. • Before removing the piston pin clip, cover the CHECKING THE CYLINDER AND PISTON EAS2GB2260 crankcase opening with a cloth to prevent the...

  • Page 263: 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 264: Checking The Piston Pin

    CYLINDER AND PISTON CHECKING THE PISTON PIN EAS2GB2262 1. Check: Be sure to install the piston ring so that the • Piston pin manufacturer’s marks or numbers face up. Blue discoloration/grooves  Replace the piston pin and then check the lubrication system.
  • Page 265 CYLINDER AND PISTON 3. Lubricate: • Piston • Piston rings • Cylinder 4. Offset: • Piston ring end gap a. Top ring b. Upper oil ring rail c. Oil ring expander d. Lower oil ring rail 5. Install: • Cylinder gasket •...

  • Page 266: Electric Starter

    ELECTRIC STARTER ELECTRIC STARTER EAS2GB2264 Removing the starter motor 12 Nm (1.2 m kgf, 8.7 ft Ibf) Order Job/Parts to remove Q’ty Remarks Exhaust pipe Refer to “ENGINE REMOVAL” on page 6-1. Starter motor For assembly, reverse the disassemble pro- cedure.
  • Page 267 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks Starter motor front cover Starter motor yoke Armature assembly Starter motor rear cover Brush set For assembly, reverse the disassembly pro- cedure. 6-36...

  • Page 268: Checking The Starter Motor

    ELECTRIC STARTER CHECKING THE STARTER MOTOR EAS2GB2265 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure the armature assembly resistanc- 1. Check: es with the pocket tester. • Commutator Dirt  Clean with 600 grit sandpaper. Pocket tester 2. Measure: 90890-03112 • Commutator diameter “a” Analog pocket tester Out of specification ...

  • Page 269: Assembling The Starter Motor

    ELECTRIC STARTER 7. Check: • Gear teeth Align the match mark “a” on the starter motor Damage/wear  Replace the starter motor. yoke with the match mark “b” on the starter mo- 8. Check: tor rear cover. • Oil seal Damage/wear ...
  • Page 270 ELECTRIC STARTER 5. Install: • Bolt “1” • O-ring “2” Apply the lithium-soap-based grease on the O- ring. 6-39...
  • Page 271 CLUTCH CLUTCH EAS2GB2267 Removing the clutch 6 10 Order Part name Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-17. Brake pedal Refer to “ENGINE REMOVAL” on page 6-1. Clutch cable Disconnect. Clutch cover Gasket Clutch spring Pressure plate Push rod 1...
  • Page 272 CLUTCH Removing the clutch 6 10 Order Part name Q’ty Remarks Cushion spring Friction plate 2 Identification color (purple) Clutch boss Thrust washer Primary driven gear Spacer Bearing Washer Push lever shaft For installation, reverse the removal proce- dure. 6-41...
  • Page 273 CLUTCH Removing the right crankcase cover Order Part name Q’ty Remarks Engine guard Refer to “ENGINE REMOVAL” on page 6-1. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-17. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-10.

  • Page 274: Clutch

    CLUTCH REMOVING THE CLUTCH CHECKING THE CLUTCH PLATES EAS2GB2268 EAS2GB2270 1. Remove: 1. Check: • Clutch boss nut “1” • Clutch plate Damage  Replace the clutch plates as a • Lock washer “2” • Clutch boss “3” set. 2. Measure: •...

  • Page 275: Checking The Clutch Housing

    CLUTCH CHECKING THE CLUTCH HOUSING EAS2GB2272 1. Check: • Clutch housing dogs “a” Damage/pitting/wear  Deburr the clutch housing dogs or replace the clutch housing. Pitting on the clutch housing dogs will cause er- ratic clutch operation. CHECKING THE CLUTCH PUSH RODS EAS2GB2276 1.

  • Page 276: Checking The Primary Driven Gear

    CLUTCH • Right crankcase cover bolt “2” CHECKING THE PRIMARY DRIVEN GEAR EAS2GB2278 1. Check: Right crankcase cover bolt • Primary driven gear 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Damage/wear  Replace the primary drive and primary driven gears as a set. Excessive noise during operation ...
  • Page 277 CLUTCH 2. Install: 4. Bend the lock washer “1” tab. • Washer “1” • Bearing “2” • Collar “3” • Primary driven gear “4” • Thrust washer “5” • Clutch boss “6” Apply the engine oil on the primary driven gear inner circumference.
  • Page 278 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 279: Installing The Kickstarter Lever

    CLUTCH INSTALLING THE KICKSTARTER LEVER EAS2GB2282 1. Install: • Kickstarter lever “1” • Washer • Bolt (kickstarter lever) Bolt (kickstarter lever) 33 Nm (3.3 m·kgf, 24 ft·lbf) LOCTITE® Install so that there is a clearance “a” of 5 mm (0.2 in) or more between the kickstarter lever and the frame and that the kickstarter lever does not contact the right crankcase cover when it is pulled.
  • Page 280 KICKSTATER KICKSTATER EAS2GB2283 Removing the kick shaft Order Part name Q’ty Remarks Primary driven gear Refer to “CLUTCH” on page 6-40. Kick idle gear Kick shaft assembly Spring guide Torsion spring Ratchet wheel Kick gear Kick shaft For installation, reverse the removal proce- dure.

  • Page 281: Kickstater

    KICKSTATER REMOVING THE KICK SHAFT ASSEMBLY EAS2GB2284 1. Remove: • Kick shaft assembly “1” Unhook the torsion spring “2” from the hole “a” in the crankcase. INSTALLING THE KICK SHAFT ASSEMBLY EAS2GB2287 1. Install: • Kick gear “1” • Washer “2” •...

  • Page 282: 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 283: Shift Shaft

    SHIFT SHAFT SHIFT SHAFT EAS2GB2289 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 284: Removing The Shift Guide And Shift Lever Assembly

    SHIFT SHAFT REMOVING THE SHIFT GUIDE AND SHIFT EAS2GB2290 LEVER ASSEMBLY 1. Remove: • Bolt (shift guide) • Shift guide “1” • Shift lever assembly “2” Make sure that the shift lever assembly is re- moved together with the shift guide. CHECKING THE SHIFT GUIDE AND SHIFT EAS2GB2293 LEVER ASSEMBLY...

  • Page 285: Installing The Stopper Lever

    SHIFT SHAFT INSTALLING THE SHIFT GUIDE AND SHIFT INSTALLING THE STOPPER LEVER EAS2GB2295 LEVER ASSEMBLY 1. Install: 1. Install: • Torsion spring “1” • Spring “1” • Collar “2” • Pawl pin “2” • Stopper lever “3” • Pawl “3” •...

  • Page 286: Installing The Shift Shaft

    SHIFT SHAFT 4. Tighten: • Shift guide bolt “1” Shift guide bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® EAS2GB2298 INSTALLING THE SHIFT SHAFT 1. Install: • Roller “1” • Shift haft spring “2” (to shift shaft) • Collar “3” (to shift shaft) •...
  • Page 287 OIL PUMP AND BALANCER GEAR OIL PUMP AND BALANCER GEAR EAS2GB2300 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 288: Oil Pump And Balancer Gear

    OIL PUMP AND BALANCER GEAR Removing the balancer 75 Nm (7.5 m kgf, 54 ft lbf) 50 Nm (5.0 m kgf, 36 ft Ibf) Order Part name Q’ty Remarks Primary driven gear Refer to “CLUTCH” on page 6-40. Right crankcase cover Refer to “CLUTCH”...

  • Page 289: Removing The Balancer

    OIL PUMP AND BALANCER GEAR REMOVING THE BALANCER EAS2GB2301 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 290: 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 291 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 292 OIL PUMP AND BALANCER GEAR 6-61...
  • Page 293 GENERATOR AND STARTER CLUTCH GENERATOR AND STARTER CLUTCH EAS2GB2307 Removing the generator Order Job/Parts to remove Q’ty Remarks Refer to “CHANGING THE ENGINE OIL” on Drain the engine oil. page 3-17. Refer to “GENERAL CHASSIS” on page 5-1 Seat and fuel tank and “FUEL TANK”...
  • Page 294 GENERATOR AND STARTER CLUTCH Removing the generator Order Job/Parts to remove Q’ty Remarks Woodruff key Starter clutch Starter clutch drive gear Crankshaft position sensor Stator For installation, reverse the removal proce- dure. 6-63...

  • Page 295: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH 3. Check: REMOVING THE GENERATOR EAS2GB2308 • Starter clutch gear 1. Remove: Damage/pitting/wear  Replace the starter • Generator rotor nut “1” clutch gear. • Washer 4. Check: • Damper assembly Damage/pitting/wear  Replace the damp- er assembly.

  • Page 296: Installing The Starter Clutch

    “7” under the holder as shown. • Tighten the stator bolt using the T25 bit. • Apply the sealant to the grommet of the AC magneto lead. Yamaha bond No. 1215 Starter clutch bolt 90890-85505 16 Nm (1.6 m·kgf, 12 ft·lbf) (Three bond No.1215®) LOCTITE®...
  • Page 297 GENERATOR AND STARTER CLUTCH 2. Install: • Washer • Pass the AC magneto lead “4” under the left • Generator rotor nut “1” crankcase cover “a” as shown. • Tighten the bolts in stage, using a crisscross Generator rotor nut pattern.
  • Page 298 GENERATOR AND STARTER CLUTCH Install the cover (damper assembly) with its mark “a” facing upward. 6-67...

  • Page 299: Crankcase

    CRANKCASE CRANKCASE EAS2GB2312 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 300 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 301 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 6-76. Shift cam and shift fork Refer to “TRANSMISSION” on page 6-76. Circlip Oil seals Bearing...

  • Page 302: Disassembling The Crankcase

    CRANKCASE DISASSEMBLING THE CRANKCASE EAS2GB2313 1. Separate: • Right crankcase • Left crankcase ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the crankcase bolts. c. Remove the dowel pins and O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ REMOVING THE CRANKCASE BEARING EAS2GB2314 1. Remove: • Bearing “1” • Remove the bearing from the crankcase by Loosen each bolt 1/4 of a turn at a time and af- pressing its inner race.

  • Page 303: Installing The Oil Seal

    Install the bearing by pressing its outer race parallel. 2. Apply: • Sealant (to the crankcase mating surface) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 3. 45 mm (1.77 in) 4. 60 mm (2.36 in) 5. 75 mm (2.95 in) a.

  • Page 304: Crankshaft Assembly And Balancer Shaft

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EAS2GB2319 Removing the crankshaft assembly and balancer shaft Order Part name Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 6-68. Transmission Refer to “TRANSMISSION” on page 6-76. Balancer shaft Crankshaft assembly For installation, reverse the removal proce- dure.

  • Page 305: Removing The Crankshaft Assembly

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 2. Measure: REMOVING THE CRANKSHAFT ASSEMBLY EAS2GB2320 • 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 crankcase separating tool “2”.

  • Page 306: Installing The Crankshaft Assembly

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT INSTALLING THE CRANKSHAFT ASSEM- EAS2GB2322 1. Install: • Crankshaft assembly Install the crankshaft assembly with the crank- shaft installer pot “1”, crankshaft installer bolt “2”, adapter (M12) “3” and spacer “4”. Crankshaft installer pot 90890-01274 INSTALLING THE BALANCER SHAFT EAS2GB2323 Installing pot...

  • Page 307: Transmission

    TRANSMISSION TRANSMISSION EAS2GB2324 Removing the transmission, shift drum assembly, and shift forks Order Part name Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 6-1. Separate. Crankcase Refer to “CRANKCASE” on page 6-68. Main axle Drive axle Long shift fork guide bar Short shift fork guide bar Spring Shift cam...

  • Page 308: Removing The Transmission

    TRANSMISSION CHECKING THE SHIFT FORKS REMOVING THE TRANSMISSION EAS2GB2325 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 309: Checking The Shift Drum Assembly

    TRANSMISSION CHECKING THE SHIFT DRUM ASSEMBLY EAS2GB2327 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 310 TRANSMISSION 2. Install: • 2nd wheel gear (29T) “1” • 5th wheel gear (22T) “2” • 3rd wheel gear (26T) “3” • 4th wheel gear (24T) “4” • 6th wheel gear (22T) “5” • Collar “6” • 1st wheel gear (31T) “7” •...
  • Page 311 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 312 TRANSMISSION 6-81...

  • Page 313: Cooling System

    COOLING SYSTEM RADIATOR .......................7-1 HANDLING NOTE ..................7-3 CHECKING THE RADIATOR..............7-3 WATER PUMP....................7-4 REMOVING THE OIL SEAL...............7-6 CHECKING THE WATER PUMP ...............7-6 CHECKING THE BEARING ...............7-6 INSTALLING THE OIL SEAL ..............7-6 ASSEMBLING THE WATER PUMP............7-6...
  • Page 314 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 315 RADIATOR Removing the radiator 8 Nm (0.8 m kgf, 5.8 ft Ibf) Order Part name Q’ty Remarks Right radiator Radiator hose 2 Radiator hose 3 Radiator hose 4 Radiator pipe 2 Radiator breather hose Left radiator Radiator hose 1 Radiator pipe 1 Coolant temperature sensor For installation, reverse the removal proce- dure.
  • Page 316 RADIATOR HANDLING NOTE EAS2GB2332 WARNING If coolant seems hot, do not remove the ra- diator cap. CHECKING THE RADIATOR EAS2GB2333 1. Check: • Radiator fins “1” Obstructions  Clean. Apply compressed air to the rear of the radi- ator. Damage  Repair or replace. Correct any flattened fins with a thin, flat-head screwdriver.
  • Page 317 WATER PUMP WATER PUMP EAS2GB2334 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 3-10. Drain.
  • Page 318 WATER PUMP Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks For installation, reverse the removal proce- dure.

  • Page 319: Water Pump

    WATER PUMP REMOVING THE OIL SEAL EAS2GB2335 • 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 320 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 321: Fuel System

    FUEL SYSTEM FUEL TANK......................8-1 REMOVING THE FUEL TANK ..............8-3 REMOVING THE FUEL PUMP ..............8-3 CHECKING THE FUEL PUMP BODY............8-3 INSTALLING THE FUEL PUMP..............8-3 REMOVING THE FUEL SENDER..............8-4 CHECKING THE FUEL SENDER ..............8-4 INSTALLING THE FUEL SENDER ............8-4 INSTALLING THE FUEL TANK..............8-4 CHECKING THE FUEL PRESSURE ............8-5 CHECKING THE DAMPER ................8-5 CHECKING AND REPLACING THE PROTECTOR ........8-6...

  • Page 322: 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 323 FUEL TANK Removing the fuel tank 7 Nm (0.7 m kgf, 5.1 ft Ibf) 9 Nm (0.9 m kgf, 6.5 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) Order...

  • Page 324: Removing The Fuel Tank

    FUEL TANK REMOVING THE FUEL TANK EAS2GB2342 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose coupler WARNING Cover the fuel hose connection with a cloth when disconnecting it. This is because re- sidual pressure in the fuel hose could cause fuel to spurt out when the hose is removed.

  • Page 325: Removing The Fuel Sender

    FUEL TANK INSTALLING THE FUEL SENDER EAS2GB2348 1. Install: • Fuel sender gasket • Fuel sender Fuel sender bolts 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) • Do not damage the installation surfaces of the fuel tank when installing the fuel sender. REMOVING THE FUEL SENDER EAS2GB2346 •...

  • Page 326: Checking The Fuel Pressure

    FUEL TANK WARNING • Insert the fuel hose into the fuel pipe securely Cover the fuel hose connection with a cloth until you hear a “click”. when disconnecting it. This is because re- • Slide the fuel hose connector cover “1” at the sidual pressure in the fuel hose could cause hose end in the direction of the arrow.

  • Page 327: Checking And Replacing The Protector

    FUEL TANK 84 mm 115 mm (3.31 in) (4.53 in) 84 mm 115 mm (3.31 in) (4.53 in) CHECKING AND REPLACING THE PRO- EAS2GB2352 TECTOR 1. Check: • Protector “1” Wear/damage  Replace. Affix the protector as shown. 0 mm (0 in) 15 mm (0.59 in)

  • Page 328: Throttle Body

    THROTTLE BODY THROTTLE BODY EAS2GB2353 Removing the throttle body 7 Nm (0.7 m kgf, 5.1 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) Order Part name...
  • Page 329 THROTTLE BODY Removing the throttle body 7 Nm (0.7 m kgf, 5.1 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) Order Part name Q’ty...
  • Page 330 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 331: Checking The Injector

    THROTTLE BODY CHECKING THE INJECTOR EAS2GB2354 1. Check: • Injectors Obstruction  Replace, and check the fuel pump and the fuel injection system. Refer to “FUEL INJECTION SYSTEM” on page 9-28. Deposits  Replace. Damage  Replace. 2. Check: • Injector resistance Refer to “CHECKING THE FUEL INJEC- TOR”...

  • Page 332: 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 333: Electrical System

    SIGNALING SYSTEM ..................9-20 CIRCUIT DIAGRAM .................9-20 TROUBLESHOOTING ................9-22 COOLING SYSTEM..................9-24 CIRCUIT DIAGRAM .................9-24 TROUBLESHOOTING ................9-26 FUEL INJECTION SYSTEM................9-28 CIRCUIT DIAGRAM .................9-28 ECU SELF-DIAGNOSTIC FUNCTION.............9-30 TROUBLESHOOTING METHOD.............9-31 YAMAHA DIAGNOSTIC TOOL ..............9-32 TROUBLESHOOTING DETAILS .............9-35 FUEL PUMP SYSTEM..................9-56 CIRCUIT DIAGRAM .................9-56 TROUBLESHOOTING ................9-58...
  • Page 334 ELECTRICAL COMPONENTS...............9-60 CHECKING THE SWITCHES ..............9-64 CHECKING THE BULBS AND BULB SOCKETS ........9-67 CHECKING THE FUSES .................9-68 CHECKING AND CHARGING THE BATTERY........9-69 CHECKING THE RELAYS ...............9-72 CHECKING THE DIODE ................9-73 CHECKING THE IGNITION SPARK GAP..........9-73 CHECKING THE SPARK PLUG CAP ............9-73 CHECKING THE IGNITION COIL ............9-74 CHECKING THE CRANKSHAFT POSITION SENSOR......9-74 CHECKING THE LEAN ANGLE SENSOR..........9-75...
  • Page 335 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 336: Ignition System

    IGNITION SYSTEM IGNITION SYSTEM EAS2GB2359 EAS2GB2360 CIRCUIT DIAGRAM...
  • Page 337 IGNITION SYSTEM 1. Joint connector 2. Joint connector 4. AC magneto 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 22.ECU (engine control unit) 23.Ignition coil 24.Spark plug 30.Joint connector 35.Lean angle sensor 36.Engine stop switch 48.Frame ground...

  • Page 338: Troubleshooting

    IGNITION SYSTEM TROUBLESHOOTING EAS2GB2361 The ignition system fails to operate (no spark or intermittent spark). Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 5. Fuel tank NG  1.
  • Page 339 IGNITION SYSTEM NG  8. Check the lean angle sensor. Replace the lean angle sensor. Refer to “CHECKING THE LEAN ANGLE SENSOR” on page 9-75. OK  NG  9. Check the entire ignition system’s Properly connect or repair the ignition sys- wiring.

  • Page 340: Electric Starting System

    ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM EAS27160 EAS2GB2362 CIRCUIT DIAGRAM...
  • Page 341 ELECTRIC STARTING SYSTEM 1. Joint connector 2. Joint connector 3. Joint connector 7. Main relay 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 13.Starter motor 14.Starter relay diode 22.ECU (engine control unit) 30.Joint connector 36.Engine stop switch 37.Neutral switch 38.Diode 39.Starting circuit cut-off relay 40.Clutch switch 41.Start switch...

  • Page 342: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION EAS2GB2363 If the meter light comes on, the starter motor can only operate if at least one of the following condi- tions is met: • The transmission is in neutral (the neutral switch is closed). •...
  • Page 343 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main relay 4. Starting circuit cut-off relay 5. Start switch 6. Diode 7. Clutch switch 8.

  • Page 344: Troubleshooting

    ELECTRIC STARTING SYSTEM TROUBLESHOOTING EAS2GB2364 The starter motor fails to turn. Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 5. Fuel tank NG  1. Check the fuse. Replace the fuse(s).
  • Page 345 ELECTRIC STARTING SYSTEM NG  8. Check the main relay. Replace the main relay. Refer to “CHECKING THE RE- LAYS” on page 9-72. OK  NG  9. Check the neutral switch. Replace the neutral switch. Refer to “CHECKING THE SWITCHES”...

  • Page 346: Charging System

    CHARGING SYSTEM CHARGING SYSTEM EAS27200 EAS2GB2365 CIRCUIT DIAGRAM 9-12...
  • Page 347 CHARGING SYSTEM 4. AC magneto 5. Rectifier/regulator 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 9-13...

  • Page 348: Troubleshooting

    CHARGING SYSTEM TROUBLESHOOTING EAS2GB2366 The battery is not being charged. Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 1. Check the fuse. NG Refer to “CHECKING THE FUSES” Replace the fuse(s). on page 9-68. OK NG ...
  • Page 349 CHARGING SYSTEM EAS27240 9-15...

  • Page 350: Lighting System

    LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM EAS2GB2367 9-16...
  • Page 351 LIGHTING SYSTEM 1. Joint connector 2. Joint connector 6. Headlight relay 7. Main relay 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 22.ECU (engine control unit) 30.Joint connector 42.Joint connector 43.Taillight 44.Headlight 47.Multi-function display 48.Frame ground 9-17...

  • Page 352: Troubleshooting

    LIGHTING SYSTEM TROUBLESHOOTING EAS2GB2368 Any of the following fail to light: headlight or meter light. Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left) 3. Air scoop (left/right) 4. Fuel tank NG  1. Check the each bulbs condition. Refer to “CHECKING THE BULBS Replace the bulb (s).
  • Page 353 LIGHTING SYSTEM EAS27270 9-19...

  • Page 354: Signaling System

    SIGNALING SYSTEM SIGNALING SYSTEM CIRCUIT DIAGRAM EAS2GB2369 9-20...
  • Page 355 SIGNALING SYSTEM 1. Joint connector 2. Joint connector 3. Joint connector 7. Main relay 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 15.Indicator light 17.Fuel level warning light 18.Resistor 19.Fuel sender 22.ECU (engine control unit) 30.Joint connector 42.Joint connector 46.Speed sensor 47.Multi-function display 48.Frame ground 9-21...

  • Page 356: Troubleshooting

    SIGNALING SYSTEM TROUBLESHOOTING EAS2GB2370 • The speedometer does not operate normally. • The fuel indicator light does not come on. Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank NG ...
  • Page 357 SIGNALING SYSTEM The fuel level warning light fails to come on. NG  1. Check the fuel sender. Replace the fuel sender assembly. Refer to “CHECKING THE FUEL SENDER” on page 9-77. OK  NG  2. Check the resistor. Replace the resistor.

  • Page 358: Cooling System

    COOLING SYSTEM COOLING SYSTEM EAS2GB2371 EAS2GB2372 CIRCUIT DIAGRAM 9-24...
  • Page 359 COOLING SYSTEM 1. Joint connector 2. Joint connector 3. Joint connector 7. Main relay 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 22.ECU (engine control unit) 27.Radiator fan motor relay 28.Radiator fan motor fuse 29.Radiator fan motor 30.Joint connector 32.Coolant temperature sensor 48.Frame ground 9-25...

  • Page 360: Troubleshooting

    COOLING SYSTEM TROUBLESHOOTING EAS2GB2373 The radiator fan motor fails to turn. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left) 3. Air scoop (left/right) 4. Fuel tank NG  1. Check the fuse. Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 9-68.
  • Page 361 COOLING SYSTEM EAS2GB2374 9-27...

  • Page 362: Fuel Injection System

    FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM CIRCUIT DIAGRAM EAS2GB2375 9-28...
  • Page 363 FUEL INJECTION SYSTEM 1. Joint connector 2. Joint connector 3. Joint connector 4. AC magneto 7. Main relay 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 15.Indicator light 16.Engine trouble warning light 22.ECU (engine control unit) 25.Injector 30.Joint connector 31.Intake air temperature sensor 32.Coolant temperature sensor 33.Throttle position sensor 34.Intake air pressure sensor...

  • Page 364: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM ECU SELF-DIAGNOSTIC FUNCTION EAS2GB2376 The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 365: Troubleshooting Method

    • Fault code number ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the Yamaha diagnostic tool. Refer to “YAMAHA DIAGNOSTIC TOOL” on page 9-32. b. Check the fault code number displayed on the Yamaha diagnostic tool. c. Identify the faulty system with the fault code number.

  • Page 366: Yamaha Diagnostic Tool

    FUEL INJECTION SYSTEM YAMAHA DIAGNOSTIC TOOL EAS2GB2378 This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool 90890-03231...
  • Page 367 NOTICE In order to avoid short circuit, insulate the battery connection terminals of the FI diagnostic tool sub-lead. For information on how to connect and use the Yamaha diagnostic tool, refer to “YAMAHA DIGNO- STIC TOOL OPERATION MANUAL”. 1. Vehicle 2.
  • Page 368 FUEL INJECTION SYSTEM Operation of the Yamaha diagnostic tool (Malfunction mode) Malfunction results are displayed in the top part of the window area. 1. Recovered The item list of the malfunction detected in the past (already recovered) are displayed. 2. Detected The item list of the malfunction currently occurred are displayed.

  • Page 369: Troubleshooting Details

    FUEL INJECTION SYSTEM 6. Condition The current conditions are displayed. (Detected/Recovered) 7. Symptom The symptoms of the detected malfunction are displayed. 8. Diagnosis code The diagnosis codes related to the detected malfunction are displayed. 9. FFD (only for models that can display freeze frame data) The mark “...
  • Page 370 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received Item from the crankshaft position sensor. Improperly connected  Connection of wire harness Crank the engine. ECU coupler. Connect the coupler securely Fault code number is not dis- played ...
  • Page 371 FUEL INJECTION SYSTEM • If fault code Nos. 13 and 14 are both displayed, perform the checks and maintenance jobs for fault code No. 13 first. • Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Item Intake air pressure sensor: open or short circuit detected.
  • Page 372 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Defective intake air pressure Execute the diagnostic mode. Push the start switch. sensor. (Code No. 03) Fault code number is not dis- played  Service is finished. When engine is stopped: Atmospheric pressure at the Fault code number is dis-...
  • Page 373 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged Item or detached hose). Defective intake air pressure Execute the diagnostic mode. sensor. (Code No. 03) When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is indicated.
  • Page 374 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Improperly connected  Connection of wire harness Push the start switch. ECU coupler. Connect the coupler securely Fault code number is not dis- played  Service is finished. Check the locking condition or repair/replace the wire har- of the coupler.
  • Page 375 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Malfunction in ECU. Replace the ECU. Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Throttle position sensor: stuck throttle position sensor is de- Item tected.
  • Page 376 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the coolant temperature. Procedure Compare the actually measured coolant temperature with the Yamaha diagnostic tool display value. Probable cause of malfunc- Confirmation of service Item Maintenance job tion and check completion Improperly connected ...
  • Page 377 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air temperature. Procedure Compare the actually measured intake air temperature with the Yamaha diagnostic tool display value. Probable cause of malfunc- Confirmation of service Item Maintenance job tion and check completion Improperly connected ...
  • Page 378 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Open or short circuit  Re- Wire harness continuity. Push the start switch. place the wire harness. Fault code number is not dis- played  Service is finished. Between intake air tempera- ture sensor coupler and ECU Fault code number is dis-...
  • Page 379 Actuation Actuates the ignition coil five times at one-second intervals. The engine trouble warning light and the “WARNING” on the Yamaha diagnostic tool screen come on each time the ignition coil is actuated. Procedure Check that a spark is generated five times.
  • Page 380 FUEL INJECTION SYSTEM Fault code No. Ignition coil: open or short circuit detected in the primary lead Item of the ignition coil. Improperly connected  Connection of sub wire har- Start the engine and let it idle ness coupler.Check the lock- Connect the coupler secure- for approximately 5 seconds.
  • Page 381 Actuation Actuates injector five times at one-second intervals. The engine trouble warning light and the “WARNING” on the Yamaha diagnostic tool screen come on each time the injector is actuated. Procedure Check that injector is actuated five times by listening for the oper- ating sound.
  • Page 382 FUEL INJECTION SYSTEM Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Item Lean angle sensor: open or short circuit detected. Fail-safe system Unable to start engine Able to drive vehicle Diagnostic code No. Diagnostic tool display Lean angle sensor output voltage •...
  • Page 383 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel in- Item jector and fuel pump. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. Diagnostic tool display Fuel system voltage Approximately 12.0 (V) Procedure Disconnect the main relay, and push the start switch or push down...
  • Page 384 FUEL INJECTION SYSTEM Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. EEPROM fault code number: an error is detected while read- Item ing or writing on EEPROM. Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No.
  • Page 385 FUEL INJECTION SYSTEM Fault code No. Item Charging voltage is abnormal. Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No. — Diagnostic tool display — Procedure — Probable cause of malfunc- Confirmation of service Item Maintenance job tion and check completion Improperly connected ...
  • Page 386 Confirmation of service Item Maintenance job tion and check completion Improperly connected  Connection of Yamaha diag- Push the start switch. nostic tool coupler. Connect the coupler securely Fault code number is not dis- played  Service is finished. Check the locking condition or repair/replace the wire har- of the coupler.
  • Page 387 Fault code number is not dis- played  Service is finished. light green–light green Fault code number is dis- played  Go to item 4. Yamaha diagnostic tool mal- Replace the Yamaha diag- Push the start switch. function. nostic tool.
  • Page 388 FUEL INJECTION SYSTEM Fault code No. Er-2 Signals from the ECU cannot be received within the specified Item period of time. Yamaha diagnostic tool mal- Replace the Yamaha diag- Push the start switch. function. nostic tool. Fault code number is not dis- played ...
  • Page 389 FUEL INJECTION SYSTEM Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Er-4 Registered data cannot be received from the Yamaha diagnos- Item tic tool. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No.

  • Page 390: Fuel Pump System

    FUEL PUMP SYSTEM FUEL PUMP SYSTEM CIRCUIT DIAGRAM EAS2GB2381 9-56...
  • Page 391 FUEL PUMP SYSTEM 1. Joint connector 2. Joint connector 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 22.ECU (engine control unit) 26.Fuel pump 30.Joint connector 36.Engine stop switch 48.Frame ground 9-57...

  • Page 392: Troubleshooting

    FUEL PUMP SYSTEM TROUBLESHOOTING EAS2GB2382 The fuel pump fails to operate. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank NG  1. Check the fuse. Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 9-68.
  • Page 393 FUEL PUMP SYSTEM EAS2GB2383 9-59...

  • Page 394: Electrical Components

    ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS EAS2GB2384 9-60...
  • Page 395 ELECTRICAL COMPONENTS 1. Rectifier/regulator 2. Clutch switch 3. Ignition coil 4. ECU (engine control unit) 5. Fuel sender 6. Fuel pump 7. Battery 8. Resistor 9. Neutral switch 10.Radiator fan motor 11.Injector 9-61...
  • Page 396 ELECTRICAL COMPONENTS 9-62...
  • Page 397 ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. Intake air pressure sensor 3. Throttle position sensor 4. Starter relay 5. Main fuse 6. Headlight relay 7. Starting circuit cut-off relay 8. Lean angle sensor 9. Radiator fan motor fuse 10.Radiator fan motor relay 11.Main relay 12.Coolant temperature sensor 9-63...

  • Page 398: Checking The Switches

    ELECTRICAL COMPONENTS CHECKING THE SWITCHES EAS2GB2385 9-64...
  • Page 399 ELECTRICAL COMPONENTS 1. Engine stop switch 2. Neutral switch 3. Clutch switch 4. Start switch 9-65...
  • Page 400 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. NOTICE Never insert the tester probes into the coupler terminal slots “1”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

  • Page 401: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS CHECKING THE BULBS AND BULB SOCK- EAS27990 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. Do not check any of the lights that use LEDs. Check each bulb and bulb socket for damage NOTICE or wear, proper connections, and also for con-...

  • Page 402: Checking The Fuses

    ELECTRICAL COMPONENTS Checking the condition of the bulb sockets The following procedure applies to all of the bulb sockets. 1. Check: • Bulb socket (for continuity) (with the pocket tester) No continuity  Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 403: Checking And Charging The Battery

    ELECTRICAL COMPONENTS 4. Install: • Seat Since VRLA (Valve Regulated Lead Acid) bat- • Side cover (left/right) teries are sealed, it is not possible to check the Refer to “GENERAL CHASSIS” on page 5- charge state of the battery by measuring the specific gravity of the electrolyte.
  • Page 404 ELECTRICAL COMPONENTS • When charging a battery, be sure to re- Example move it from the vehicle. (If charging has Open-circuit voltage = 12.0 V to be done with the battery mounted on the Charging time = 6.5 hours vehicle, disconnect the negative battery Charge of the battery = 20–30% lead from the battery terminal.) •...
  • Page 405 ELECTRICAL COMPONENTS b. Connect a charger and ammeter to the bat- tery and start charging. If the current is lower than the standard charg- ing current written on the battery, this type of Set the charging voltage to 16–17 V.If the set- battery charger cannot charge the VRLA (Valve ting is lower, charging will be insufficient.

  • Page 406: Checking The Relays

    ELECTRICAL COMPONENTS Starting circuit cut-off relay CHECKING THE RELAYS EAS2GB2388 Check each switch for continuity with the pock- et tester. If the continuity reading is incorrect, replace the relay. Pocket tester 90890-03112 Analog pocket tester YU-03112-C 1. Disconnect the relay from the wire harness. 2.

  • Page 407: Checking The Diode

    ELECTRICAL COMPONENTS CHECKING THE IGNITION SPARK GAP EAS2GB2390 Result 1. Check: Continuity • Ignition spark gap (between “3” to “4”) Out of specification  Perform the ignition system troubleshooting, starting with step 4. EAS2GB2389 CHECKING THE DIODE Refer to “TROUBLESHOOTING” on page 9- 1.

  • Page 408: Checking The Ignition Coil

    ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (  1k) to the spark plug cap. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. Measure the primary coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Check: • Secondary coil resistance Out of specification  Replace. Secondary coil resistance 8.64–12.96 k...

  • Page 409: Checking The Lean Angle Sensor

    ELECTRICAL COMPONENTS lean angle sensor coupler as shown. Crankshaft position sensor resis- Pocket tester tance 90890-03112 228–342  (Gy–B) Analog pocket tester YU-03112-C ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Test harness– lean angle sensor a. Connect the pocket tester (  100) to the (6P) crankshaft position sensor coupler.

  • Page 410: Checking The Stator Coil

    ELECTRICAL COMPONENTS b. Check the starter motor operation. b. Measure the stator coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE STATOR COIL CHECKING THE RECTIFIER/REGULATOR EAS28150 EAS2GB2396 1. Disconnect: 1. Check: • Stator coil coupler • Charging voltage Out of specification  Replace the rectifier/ (from the wire harness) 2.

  • Page 411: Checking The Speed Sensor

    ELECTRICAL COMPONENTS 4. Check: CHECKING THE SPEED SENSOR EAS2GB2397 • Fuel sender resistance 1. Check: Out of specification  Replace the fuel • Speed sensor output voltage sender. Out of specification  Replace. Fuel sender resistance Output voltage reading cycle 1.35–1.90 k...

  • Page 412: Checking The Radiator Fan Motor

    ELECTRICAL COMPONENTS 2. Check: • Positive tester probe  • Coolant temperature sensor resistance Black “1” Out of specification  Replace. • Negative tester probe  Black “2” Coolant temperature sensor re- sistance 2.51–2.78 k at 20 °C (2.51–2.78 k at 68 °F) 210–221 ...

  • Page 413: Checking The Throttle Position Sensor

    ELECTRICAL COMPONENTS • Positive tester probe  Blue “1” • Negative tester probe  Black/Blue “2” b. Check the throttle position sensor maximum resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • Throttle position sensor When mounting the throttle position sensor, ad- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ just its angle properly. Refer to “ADJUSTING EAS2GB2402 CHECKING THE THROTTLE POSITION THE THROTTLE POSITION SENSOR”...

  • Page 414: Checking The Intake Air Pressure Sensor

    ELECTRICAL COMPONENTS • Positive tester probe  Blue “1” • Negative tester probe  Black/Blue “2” b. Start the engine. c. Measure the intake air pressure sensor out- put voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE INTAKE AIR TEMPERA- EAS2GB2405 c. Start the engine. TURE SENSOR d.

  • Page 415: Checking The Fuel Injector

    ELECTRICAL COMPONENTS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS2GB2406 CHECKING THE FUEL INJECTOR 1. Remove: • Fuel injector Refer to “THROTTLE BODY” on page 8-7. 2. Check: • Fuel injector resistance Out of specification  Replace. Fuel injector resistance 12.0  ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the fuel injector coupler from the fuel injector.
  • Page 416 ELECTRICAL COMPONENTS 9-83...

  • Page 417: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING..................10-1 GENERAL INFORMATION ..............10-1 STARTING FAILURES................10-1 INCORRECT ENGINE IDLING SPEED ...........10-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......10-2 SHIFTING IS DIFFICULT .................10-2 SHIFT PEDAL DOES NOT MOVE ............10-2 JUMPS OUT OF GEAR................10-2 CLUTCH SLIPS..................10-2 CLUTCH DRAGS ..................10-2 OVERHEATING ..................10-2 OVERCOOLING..................10-3 POOR BRAKING PERFORMANCE............10-3 FRONT FORK OIL LEAKING..............10-3 FAULTY FRONT FORK LEGS..............10-3 UNSTABLE HANDLING ................10-3...

  • Page 418: Troubleshooting

    TROUBLESHOOTING • Incorrect spark plug heat range TROUBLESHOOTING EAS2GB2407 • Fouled spark plug • Worn or damaged electrode EAS2GB2408 GENERAL INFORMATION • Worn or damaged insulator 2. Ignition coil The following guide for troubleshooting does • Cracked or broken ignition coil body not cover all the possible causes of trouble.

  • Page 419: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING POOR MEDIUM-AND-HIGH-SPEED PER- CLUTCH SLIPS EAS2GB2411 EAS2GB2415 FORMANCE Engine Refer to “STARTING FAILURES” on page 10- 1. Clutch • Improperly assembled clutch Engine • Loose or fatigued clutch spring 1. Air filter • Worn friction plate • Clogged air filter element •...

  • Page 420: Overcooling

    TROUBLESHOOTING Fuel system FAULTY FRONT FORK LEGS EAS2GB2421 1. Throttle body • Damaged or loose throttle body joint Chassis 2. Air filter 1. Front fork • Clogged air filter element • Bent or damaged inner tube • Bent or damaged outer tube Chassis •...

  • Page 421: Headlight Does Not Come On

    TROUBLESHOOTING HEADLIGHT DOES NOT COME ON EAS2GB2423 Electrical system 1. Headlight • Fuse open circuit • Wrong headlight bulb • Too many electrical accessories • Hard charging • Incorrect connection • Improperly grounded circuit • Poor contacts (start switch) • Burnt-out headlight bulb HEADLIGHT BULB BURNT OUT EAS2GB2424 Electrical system...

  • Page 422: List Of Self-Diagnostic And Fail-Safe Actions

    9-52 nection Er-2 Signals from the ECU cannot be received within the specified period 9-53 of time. Er-3 Data from the ECU cannot be received correctly. 9-54 Er-4 Registered data cannot be received from the Yamaha diagnostic tool. 9-55 10-5...
  • Page 423 Intake air temperature Displays the intake air tem- Compare the actually mea- perature. sured intake air tempera- ture with the Yamaha diagnostic tool display val- Coolant temperature When engine is cold: Dis- Compare the actually mea- plays temperature closer to sured coolant temperature air temperature.
  • Page 424 LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS Diag- nostic Item Display Procedure code Malfunction history ( Replace all ( ) with ( code No. erasure *1 by the operation start pro- • There is no history. • 00 cessing. • There is some history. •...
  • Page 425 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 426 WIRING DIAGRAM EAS2GB2428 EAS2GB2429 COLOR CODE WR250F/WR250FF 2015 Black 1. Joint connector Brown 2. Joint connector Chocolate 3. Joint connector 4. AC magneto Dark green 5. Rectifier/regulator Green 6. Headlight relay Gray 7. Main relay 8. Engine ground Blue 9. Battery Light green 10.
  • Page 428 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN...
  • Page 429 WR250F/WR250FF 2015 WR250F/WR250FF 2015 SCHÉMA DE CÂBLAGE WIRING DIAGRAM B B B R R R Br Br Br B B B R R R/L Br Br B B B B B B R R R R R R/L Br Br Br Br Br...
  • Page 430 WR250F/WR250FF 2015 WR250F/WR250FF 2015 SCHÉMA DE CÂBLAGE WIRING DIAGRAM (Gy) (Gy) (Gy)

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