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2016
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
WR250FG
2GB-28199-71

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   Summary of Contents for Yamaha WR250F 2016

  • Page 1

    2016 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 WR250FG 2GB-28199-71...

  • 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

    2016 2016 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 WR250FG WR250FG 2GB-28199-71-E0 2GB-28199-71-E0...

  • Page 5

    EAS2GB7002 WR250F WR250FG OWNER’S SERVICE MANUAL ©2015 by Yamaha Motor Co., Ltd. First edition, April 2015 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 EAS2GB7003 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 EAS2GB7005 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 EAS2GB7006 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 EAS2GB7007 The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...

  • Page 11: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS TUNING CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 13: Table Of Contents

    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 INCLUDED PARTS ..................1-6 SPARK PLUG WRENCH ................1-6 NIPPLE WRENCH..................1-6 HANDLEBAR PROTECTOR ..............1-6 FUEL HOSE JOINT COVER ..............1-6 COUPLER FOR CONNECTING OPTIONAL PART........1-6 IMPORTANT INFORMATION ................1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-7 REPLACEMENT PARTS................1-7...

  • Page 14: Table Of Contents

    MULTI-FUNCTION DISPLAY.................1-22 DESCRIPTION ..................1-22 BASIC MODE ...................1-22 CHANGEOVER TO BASIC MODE/RACE MODE........1-23 RACE MODE....................1-24 FUNCTION DIAGRAM ................1-28 STARTING AND BREAK-IN ................1-30 FUEL ......................1-30 HANDLING NOTE ..................1-30 AIR FILTER MAINTENANCE ..............1-30 STARTING A COLD ENGINE ..............1-30 STARTING A WARM ENGINE..............1-31 BREAK-IN PROCEDURES ..............1-32 MAINTENANCE AFTER BREAK-IN ..............1-33 MAJOR MAINTENANCE................1-33 TORQUE-CHECK POINTS ................1-34...

  • Page 15: Location Of Important Labels

    LOCATION OF IMPORTANT LABELS LOCATION OF IMPORTANT LABELS EAS2GB7008 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 EAS2GB7009 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: Included Parts

    INCLUDED PARTS INCLUDED PARTS FUEL HOSE JOINT COVER EAS2GB7014 EAS2GB7018 The fuel hose joint covers “1” are used to pre- EAS2GB7015 SPARK PLUG WRENCH vent mud, dust, and other foreign materials The spark plug wrench “1” is used to remove or from entering the inside when the fuel hose is install the spark plug.

  • Page 21: 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 22: Gaskets, Oil Seals And O-rings

    IMPORTANT INFORMATION GASKETS, OIL SEALS AND O-RINGS EAS2GB7022 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 23: Basic Service Information

    BASIC SERVICE INFORMATION BASIC SERVICE INFORMATION EAS2GB7026 EAS2GB7027 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 24

    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 25

    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 26

    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 27: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS EAS2GB7028 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 28

    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 29

    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 30

    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 31

    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 32

    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. 1-18...

  • Page 33: Control Functions

    Pull the clutch lever toward the handlebar to ing the engine. If this occurs, have a Yamaha disengage the clutch, and release the lever to dealer check the vehicle.

  • Page 34: Shift Pedal

    CONTROL FUNCTIONS SHIFT PEDAL THROTTLE GRIP EAS2GB7034 EAS2GB7036 The shift pedal “1” has adopted a method of 1 The throttle grip “1” is located on the right han- down & 5 ups (press-down & kick-ups). dlebar. The throttle grip accelerates or deceler- Press it down for N (neutral) to 1st, and kick it ates the engine.

  • Page 35: Sidestand

    CONTROL FUNCTIONS SIDESTAND FUEL TANK CAP EAS2GB7039 EAS2GB7041 This sidestand “1” is used to support only the Fuel tank cap “1” is located under the fuel tank machine when standing or transporting it. cap cover “2”. Remove the fuel tank cap cover to open the fuel WARNING tank cap.

  • Page 36: Multi-function Display

    MULTI-FUNCTION DISPLAY MULTI-FUNCTION DISPLAY BASIC MODE EAS2GB7042 EAS2GB7044 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 37

    MULTI-FUNCTION DISPLAY 4. To end the setting, push the “RST” button for CHANGEOVER TO BASIC MODE/RACE EAS2GB7045 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 38: 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 1.

  • Page 39

    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 40

    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 41

    MULTI-FUNCTION DISPLAY 1-27...

  • Page 42: Function Diagram

    MULTI-FUNCTION DISPLAY FUNCTION DIAGRAM EAS2GB7047 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 43

    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 44: 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 premium unleaded gasoline with a pump oc- In order for the ignition circuit cut-off system to tane number [(R+M)/2] of 91 or higher, or a re-...

  • Page 45: 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 46: Break-in Procedures

    STARTING AND BREAK-IN BREAK-IN PROCEDURES EAS2GB7054 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 47: Maintenance After Break-in

    MAINTENANCE AFTER BREAK-IN • Cable MAINTENANCE AFTER BREAK-IN EAS2GB7055 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 48: Torque-check Points

    TORQUE-CHECK POINTS TORQUE-CHECK POINTS EAS2GB7057 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 49

    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 50: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE • Do not use any harsh chemical products MOTORCYCLE CARE AND STOR- EAS2GB7058 on plastic parts. Be sure to avoid using cloths or sponges which have been in con- tact with strong or abrasive cleaning prod- CARE EAS2GB7059 ucts, solvent or thinner, fuel (gasoline),...

  • Page 51: 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 52

    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 53

    SPECIFICATIONS GENERAL SPECIFICATIONS .................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-10 TIGHTENING TORQUES ................2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-12 ENGINE TIGHTENING TORQUES............2-13 CHASSIS TIGHTENING TORQUES............2-16 LUBRICATION POINTS AND LUBRICANT TYPES ........2-20 ENGINE....................2-20 CHASSIS....................2-21 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-23 LUBRICATION DIAGRAMS ..............2-23 CABLE ROUTING DIAGRAM ................2-31...

  • Page 54

    GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS EAS2GB7061 Model Model 2GB6 (USA) 2GB7 (CAN) 2GB8 (EUR) 2GB9, 2GBA (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 55

    ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS EAS2GB7062 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 56

    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 Lobe height (Intake)

  • Page 57

    ENGINE SPECIFICATIONS Valve spring Free length (intake) 36.69 mm (1.44 in) Limit 35.69 mm (1.41 in) Free length (exhaust) 34.86 mm (1.37 in) Limit 33.86 mm (1.33 in) Installed length (intake) 31.40 mm (1.24 in) Installed length (exhaust) 28.50 mm (1.12 in) Spring rate K1 (intake) 29.65 N/mm (3.02 kgf/mm, 169.30 lbf/in) Spring rate K2 (intake)

  • Page 58

    ENGINE SPECIFICATIONS 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 2.90–3.10 mm (0.114–0.122 in) Wear limit 2.85 mm (0.112 in) Plate quantity 9 pcs Clutch plate thickness...

  • Page 59

    ENGINE SPECIFICATIONS 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 228–342  (Gy–B) Crankshaft position sensor resistance Intake air pressure sensor output voltage 3.61–3.67 V at 101.3 kPa (3.61–3.67 V at 1.01...

  • Page 60

    CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS EAS2GB7063 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 61

    CHASSIS SPECIFICATIONS Master cylinder inside diameter 9.52 mm (0.37 in) 22.65 mm  2 (0.89 in  2) Caliper cylinder inside diameter Specified brake fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Brake pedal position 5.0 mm (0.20 in) Rear disc brake Disc outside diameter ...

  • Page 62

    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 63

    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 64

    ELECTRICAL SPECIFICATIONS Mica undercut (depth) 1.50 mm (0.06 in) 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...

  • Page 65

    TIGHTENING TORQUES TIGHTENING TORQUES EAS20320 EAS2GB7065 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 66

    TIGHTENING TORQUES ENGINE TIGHTENING TORQUES EAS2GB7066 - 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 67

    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 68

    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 69

    TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES EAS2GB7067 - 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 70

    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 71

    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 72

    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 73

    LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES EAS2GB7068 EAS2GB7069 ENGINE Lubrication point Lubricant types Oil seal lips Bearing O-ring Camshaft cap bolt threads and contacting surface Cylinder head bolt threads, seats, washers Valve stems Valve stem ends Valve lifter outer surface Camshaft lobe and journal Valve lifter top surface...

  • Page 74

    LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Shift lever assembly moving parts Damper assembly shaft, thrust surfaces, washers Starter idle gear inner surface, thrust surfaces Starter clutch drive gear inner surface, thrust surfaces Three bond Cylinder head cover gasket No.1215®...

  • Page 75

    LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Clutch lever adjuster rubber lip Clutch cable end (clutch lever side) Tube guide (throttle grip) inner surface and throttle cable end Front brake caliper piston Front brake caliper piston seal Front brake caliper dust seal Front brake caliper piston outer surface Front brake caliper pin bolt and boot Front brake master cylinder push rod end...

  • Page 76

    LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION SYSTEM CHART AND DIAGRAMS EAS2GB7071 EAS2GB7072 LUBRICATION DIAGRAMS 2-23...

  • Page 77

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

  • Page 78

    LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25...

  • Page 79

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

  • Page 80

    LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...

  • Page 81

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

  • Page 82

    LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...

  • Page 83

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

  • Page 84

    CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM EAS2GB7073 2-31...

  • Page 85

    CABLE ROUTING DIAGRAM N. Place the grommet of the clutch cable so that it 1. Clutch cable 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 86

    CABLE ROUTING DIAGRAM 2-33...

  • Page 87

    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 88

    CABLE ROUTING DIAGRAM 2-35...

  • Page 89

    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 90

    CABLE ROUTING DIAGRAM 2-37...

  • Page 91

    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 92

    CABLE ROUTING DIAGRAM 2-39...

  • Page 93

    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 94

    CABLE ROUTING DIAGRAM 2-41...

  • Page 95

    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 96

    CABLE ROUTING DIAGRAM 2-43...

  • Page 97

    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 98

    CABLE ROUTING DIAGRAM 2-45...

  • Page 99

    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 100

    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 101

    • 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 102

    PERIODIC MAINTENANCE GENERAL MAINTENANCE AND LUBRICATION CHART EAS2GB7077 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 103

    Rear sus- • Apply molybdenum disulfide grease   pension link lightly. pivots Control ca- • Apply Yamaha chain and cable lube or    bles engine oil 10W-30 thoroughly. • Check operation and free play. Throttle grip • Adjust the throttle cable free play if ...

  • Page 104

    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 105

    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 106

    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 107

    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 108

    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 109

    PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE EAS2GB7079 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 EAS2GB7080 ITEM inspect Page...

  • Page 110

    ENGINE ENGINE CHECKING THE COOLING SYSTEM EAS2GB7081 EAS2GB7083 1. Remove: EAS2GB7082 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 111

    ENGINE Exist fur deposits  Clean or replace. 5. Install: • 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 (including all routes) EAS2GB7086 CHECKING THE RADIATOR CAP VALVE...

  • Page 112

    ENGINE CHECKING THE COOLANT CIRCULATORY ADJUSTING THE CLUTCH LEVER FREE EAS2GB7087 EAS2GB7088 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 113

    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 114

    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 115

    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 EAS2GB7094 1. Remove: •...

  • Page 116

    ENGINE CHECKING THE ENGINE OIL LEVEL EAS2GB7096 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 117

    ENGINE 5. To check the oil strainer, perform the follow- CHANGING THE ENGINE OIL EAS2GB7097 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 118

    ENGINE 8. Install: ADJUSTING THE ENGINE IDLING SPEED EAS2GB7098 • 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 119

    • This section is intended for those who have Valve clearance (cold) basic knowledge and skill concerning the ser- Intake vicing of Yamaha motorcycles (e.g., Yamaha 0.12–0.19 mm (0.0047–0.0075 in) dealers, service engineers, etc.). Those who Exhaust have little knowledge and skill concerning ser- 0.17–0.24 mm (0.0067–0.0094 in)

  • Page 120

    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 121

    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 122

    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 123

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

  • Page 124

    CHASSIS CHASSIS EAS2GB7101 EAS2GB7102 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 125

    CHASSIS CHECKING THE BRAKE HOSE EAS2GB7103 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 126

    CHASSIS ADJUSTING THE REAR BRAKE EAS2GB7105 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 127

    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 128

    CHASSIS CHECKING THE REAR BRAKE PADS EAS2GB7107 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 129

    CHASSIS system. Refer to “BLEEDING THE BRAKE SYS- TEM” on page 3-24. CHECKING THE REAR BRAKE PAD INSU- EAS2GB7108 LATOR 1. Remove: • Brake pads Refer to “REAR BRAKE” on page 5-23. 2. Check: • Rear brake pad insulator “1” i.

  • Page 130

    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 131

    CHASSIS CHECKING THE FRONT FORK LEGS CLEANING THE FRONT FORK OIL SEAL EAS2GB7111 EAS2GB7113 1. Stand the vehicle upright on a level surface. AND DUST SEAL 1. Remove: WARNING • Protector Securely support the vehicle so that there is • Dust seal “1” no danger of it falling over.

  • Page 132

    CHASSIS 3. Tighten: • Air bleed screw Air bleed screw 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping NOTICE Do not turn the adjuster forcibly beyond its adjusting range. EAS2GB7115 ADJUSTING THE FRONT FORK LEGS 1. Adjust: WARNING • Compression damping •...

  • Page 133

    CHASSIS Spring preload CHECKING THE SWINGARM OPERATION EAS2GB7116 1. Check: NOTICE • Swingarm smooth action Do not turn the adjuster forcibly beyond its • Swingarm free play adjusting range. Refer to “SWINGARM” on page 5-65. 1. Remove: EAS2GB7117 CHECKING THE REAR SUSPENSION •...

  • Page 134

    CHASSIS Rebound damping adjusting posi- • Be sure to remove all dirt and mud from tions around the locknut and adjusting ring before Maximum Fully turned in adjustment. Standard • The length of the spring (installed) changes 14 clicks out* 1.5 mm (0.06 in) per turn of the adjusting ring.

  • Page 135

    CHASSIS CHECKING THE TIRES EAS2GB7119 1. Measure: • Tire pressure Out of specification  Regulate. Tire air pressure (measured on cold tires) Front 100 kPa (1.00 kgf/cm , 15 psi) Rear 100 kPa (1.00 kgf/cm , 15 psi) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping (for slow compres- •...

  • Page 136

    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 137

    CHASSIS CHECKING AND LUBRICATING THE CA- EAS2GB7124 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) 38 Nm (3.8 m·kgf, 27 ft·lbf) to corrode and interfere with its movement.

  • Page 138

    CHASSIS LUBRICATING THE DRIVE CHAIN EAS2GB7127 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 139

    ELECTRICAL SYSTEM 5. Clean: ELECTRICAL SYSTEM EAS2GB7130 • Spark plug (with a spark plug cleaner or a wire brush) EAS2GB7131 CHECKING THE SPARK PLUG 6. Measure: 1. Remove: • Spark plug gap “a” • Seat Out of specification  Adjust the spark plug •...

  • Page 140

    ELECTRICAL SYSTEM 2. Attach: CHECKING AND CHARGING THE BATTERY EAS2GB7133 • Timing light “1” Refer to “CHECKING AND CHARGING THE • Digital tachometer “2” BATTERY” on page 9-69. To the high tension code “3”. EAS2GB7134 REPLACING THE HEADLIGHT BULB Timing light WARNING 90890-03141 Since the headlight bulb gets extremely hot,...

  • Page 141

    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 142

    ELECTRICAL SYSTEM 3-42...

  • Page 143

    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 144

    CHASSIS CHASSIS DRIVE AND REAR WHEEL SPROCKETS EAS2GB7136 EAS2GB7138 SETTING PARTS EAS2GB7137 SELECTION OF THE SECONDARY REDUC- Part name Type Part number TION RATIO (SPROCKET) Drive sprocket “1” Secondary reduction ratio = Number of (STD) 13T 9383B-13218 rear wheel sprocket teeth/Number of drive sprocket teeth Rear wheel sprock- et “2”...

  • Page 145

    CHASSIS • Under a stony or a hard road condition, the tire pressure should be higher to prevent a flat tire. Extent of adjustment 100–120 kPa (1.00–1.20 kgf/cm 15–18 psi) FRONT FORK SETTING EAS2GB7140 The front fork setting should be made depend- ing on the rider’s feeling of an actual run and the circuit conditions.

  • Page 146

    CHASSIS REAR SUSPENSION SETTING EAS2GB7144 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 147

    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 148

    CHASSIS • Spring preload adjusting positions Spring preload adjusting positions Minimum Position in which the spring is turned in 1.5 mm (0.06 in) from its free length. Standard Position in which the spring is turned in 10 mm (0.39 in) from its free length.

  • Page 149

    CHASSIS SUSPENSION SETTING (FRONT FORK) EAS2GB7148 • 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 150

    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 151

    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 152

    CHASSIS...

  • Page 153

    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 154

    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............5-55 CHECKING THE STEERING HEAD ............5-55...

  • Page 155

    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 156

    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 157: General Chassis

    GENERAL CHASSIS REMOVING THE LEFT SIDE COVER EAS2GB7152 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. EAS2GB7153 REMOVING THE SEAT The fuel tank cap cover and the seat are cou- pled with each other with a plastic band.

  • Page 158

    FRONT WHEEL FRONT WHEEL EAS2GB7154 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 159: Front Wheel

    FRONT WHEEL REMOVING THE FRONT WHEEL EAS2GB7155 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 160

    FRONT WHEEL DISASSEMBLING THE FRONT WHEEL EAS2GB7157 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 161

    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 162

    FRONT WHEEL...

  • Page 163

    REAR WHEEL REAR WHEEL EAS2GB7160 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 164

    REAR WHEEL 4. Measure: REMOVING THE REAR WHEEL EAS2GB7161 • 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 165

    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 EAS2GB7165 1.

  • Page 166

    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 167

    FRONT BRAKE FRONT BRAKE EAS2GB7167 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 168

    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 169

    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 170

    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 171

    FRONT BRAKE INTRODUCTION EAS2GB7168 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 172

    FRONT BRAKE ASSEMBLING THE FRONT BRAKE CALI- EAS2GB7173 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 173

    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 174

    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 175

    FRONT BRAKE INSTALLING THE FRONT BRAKE MASTER EAS2GB7179 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 176

    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 177

    REAR BRAKE REAR BRAKE EAS2GB7180 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 178

    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 179

    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 180

    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 181

    REAR BRAKE INTRODUCTION EAS2GB7181 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 182

    REAR BRAKE REMOVING THE REAR BRAKE CALIPER CHECKING THE REAR BRAKE CALIPER EAS2GB7183 EAS2GB7185 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 183

    REAR BRAKE INSTALLING THE BRAKE CALIPER PISTON INSTALLING THE REAR BRAKE CALIPER EAS2GB7187 EAS2GB7188 1. Clean: 1. Install: • Brake caliper • Rear brake caliper • Brake caliper piston seal • Rear brake caliper bracket • Brake caliper piston dust seal 2.

  • Page 184

    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 185

    REAR BRAKE Specified 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 186

    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 Specified brake fluid system. DOT 4 Refer to “BLEEDING THE BRAKE SYS- TEM”...

  • Page 187

    HANDLEBAR HANDLEBAR EAS2GB7193 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 188

    HANDLEBAR Removing the handlebar Order Part name Q’ty Remarks Handlebar lower holder Damper For installation, reverse the removal proce- dure. 5-34...

  • Page 189

    HANDLEBAR REMOVING THE HANDLEBAR EAS2GB7194 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 EAS2GB7195 1. Check: •...

  • Page 190

    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 191

    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 192

    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 193

    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 194

    FRONT FORK FRONT FORK EAS2GB7197 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 195

    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 196: Front Fork

    FRONT FORK REMOVING THE FRONT FORK LEGS EAS2GB7198 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 197

    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 198

    FRONT FORK 5. Check: ASSEMBLING THE FRONT FORK LEGS EAS2GB7201 • 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 199

    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 200

    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 201

    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 202

    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 203

    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 204

    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 205

    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 206

    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 207

    STEERING HEAD STEERING HEAD EAS2GB7203 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 208

    STEERING HEAD 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 lbf) 3.8 Nm (0.38 m...

  • Page 209

    STEERING HEAD REMOVING THE LOWER BRACKET EAS2GB7204 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 210

    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 211

    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 212

    REAR SHOCK ABSORBER ASSEMBLY REAR SHOCK ABSORBER ASSEMBLY EAS2GB7207 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 213

    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. 5-59...

  • Page 214

    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. 5-60...

  • Page 215: Rear Shock Absorber Assembly

    • 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 216

    REAR SHOCK ABSORBER ASSEMBLY • Spring Damage/wear  Replace. • Spring guide Damage/wear  Replace. • Bearing Damage/wear  Replace. • Bolts Bends/damage/wear  Replace. EAS2GB7213 CHECKING THE CONNECTING ARM AND RELAY ARM 2. Remove: 1. Check: • Upper bearing “1” •...

  • Page 217

    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 218

    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 219

    SWINGARM SWINGARM EAS2GB7216 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 220

    SWINGARM REMOVING THE SWINGARM EAS2GB7217 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 221

    SWINGARM INSTALLING THE SWINGARM EAS2GB7220 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 222

    CHAIN DRIVE CHAIN DRIVE EAS2GB7221 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 223

    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 224

    CHAIN DRIVE b. Correct 1. Drive chain roller 2. Drive sprocket CHECKING THE REAR WHEEL SPROCKET EAS2GB7223 Refer to “CHECKING AND REPLACING THE REAR WHEEL SPROCKET” on page 5-10. EAS2GB7224 INSTALLING THE DRIVE CHAIN 1. Install: • Drive chain ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ NOTICE 4.

  • Page 225

    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 226

    CHAIN DRIVE 5-72...

  • Page 227

    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 228

    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 229

    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 230

    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 231

    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) 20 Nm (2.0 m kgf, 14 ft lbf) 30 Nm (3.0 m kgf, 22 ft Ibf)

  • Page 232

    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 233

    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 234

    ENGINE REMOVAL Removing the engine 55 Nm (5.5 m kgf, 40 ft Ibf) Order Part name Q’ty Remarks 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 For installation, reverse the removal proce-...

  • Page 235

    ENGINE REMOVAL REMOVING THE SILENCER EAS2GB7227 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 EAS2GB7229 1.

  • Page 236: Engine Removal

    ENGINE REMOVAL REMOVING THE ENGINE CLEANING THE SPARK ARRESTER EAS2GB7230 EAS2GB7231 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 237

    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 238

    ENGINE REMOVAL INSTALLING THE BRAKE PEDAL EAS2GB7234 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 239

    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 240

    CAMSHAFT CAMSHAFT EAS2GB7237 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 241

    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 242

    CAMSHAFT REMOVING THE CAMSHAFT EAS2GB7238 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 243

    CAMSHAFT 3. Measure: CHECKING THE CAMSHAFT EAS2GB7239 • 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 244

    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 245

    CAMSHAFT CHECKING THE DECOMPRESSION SYS- EAS2GB7242 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 246

    “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 247

    CYLINDER HEAD CYLINDER HEAD EAS2GB7244 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 248

    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 249

    CYLINDER HEAD REMOVING THE CYLINDER HEAD EAS2GB7245 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 250

    CYLINDER HEAD INSTALLING THE CYLINDER HEAD EAS2GB7248 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 251

    VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS EAS2GB7249 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 252

    VALVES AND VALVE SPRINGS REMOVING THE VALVES EAS2GB7250 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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 253

    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 254

    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 255

    VALVES AND VALVE SPRINGS CHECKING THE VALVE SEATS EAS2GB7252 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 contact width “a” Out of specification ...

  • Page 256

    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 257

    VALVES AND VALVE SPRINGS 3. Install: CHECKING THE VALVE LIFTERS EAS2GB7254 • 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 258

    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 259

    CYLINDER AND PISTON CYLINDER AND PISTON EAS2GB7256 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 260: Cylinder And Piston

    CYLINDER AND PISTON REMOVING THE PISTON EAS2GB7257 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 EAS2GB7258 crankcase opening with a cloth to prevent the...

  • Page 261

    CYLINDER AND PISTON CHECKING THE PISTON RINGS 1. Measure: • Piston ring side clearance Out of specification  Replace the piston and piston rings as a set. Before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring grooves and piston rings.

  • Page 262

    CYLINDER AND PISTON Piston ring Top ring End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in) Limit 0.50 mm (0.0197 in) Oil ring End gap (installed) 0.10–0.35 mm (0.0039–0.0138 in) EAS2GB7260 CHECKING THE PISTON PIN INSTALLING THE PISTON AND CYLINDER EAS2GB7261 1. Check: 1.

  • Page 263

    CYLINDER AND PISTON 5. Install: • Cylinder gasket • Apply the engine oil to the piston pin. • Dowel pin • Install the piston with the F mark “a” on it • Cylinder pointing to its intake (front) side. • Before installing the piston pin clip, cover the Cylinder bolt crankcase opening with a cloth to prevent the 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

  • Page 264

    ELECTRIC STARTER ELECTRIC STARTER EAS2GB7262 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 265

    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 266

    ELECTRIC STARTER CHECKING THE STARTER MOTOR EAS2GB7263 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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 267

    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 268

    ELECTRIC STARTER 5. Install: • Bolt “1” • O-ring “2” Apply the lithium-soap-based grease on the O- ring. 6-39...

  • Page 269

    CLUTCH CLUTCH EAS2GB7265 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 270

    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 271

    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 272

    CLUTCH REMOVING THE CLUTCH CHECKING THE CLUTCH PLATES EAS2GB7266 EAS2GB7268 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 273

    CLUTCH CHECKING THE CLUTCH HOUSING EAS2GB7270 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 EAS2GB7274 1.

  • Page 274

    CLUTCH • Right crankcase cover bolt “2” CHECKING THE PRIMARY DRIVEN GEAR EAS2GB7276 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 275

    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 276

    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 277

    CLUTCH INSTALLING THE KICKSTARTER LEVER EAS2GB7280 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 278

    KICKSTATER KICKSTATER EAS2GB7281 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 279

    KICKSTATER REMOVING THE KICK SHAFT ASSEMBLY EAS2GB7282 1. Remove: • Kick shaft assembly “1” Unhook the torsion spring “2” from the hole “a” in the crankcase. INSTALLING THE KICK SHAFT ASSEMBLY EAS2GB7285 1. Install: • Kick gear “1” • Washer “2” •...

  • Page 280

    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 281

    SHIFT SHAFT SHIFT SHAFT EAS2GB7287 Removing the shift shaft and stopper lever 10 Nm (1.0 m kgf, 7.2 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 30 Nm (3.0 m kgf, 22 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty...

  • Page 282

    SHIFT SHAFT REMOVING THE SHIFT GUIDE AND SHIFT EAS2GB7288 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 EAS2GB7291 LEVER ASSEMBLY...

  • Page 283

    SHIFT SHAFT INSTALLING THE STOPPER LEVER INSTALLING THE SHIFT GUIDE AND SHIFT EAS2GB7293 EAS2GB7295 1. Install: LEVER ASSEMBLY • Torsion spring “1” 1. Install: • Collar “2” • Spring “1” • Stopper lever “3” • Pawl pin “2” • Bolt (stopper lever) “4” •...

  • Page 284

    SHIFT SHAFT 4. Tighten: • Shift guide bolt “1” Shift guide bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® EAS2GB7296 INSTALLING THE SHIFT SHAFT 1. Install: • Roller “1” • Shift haft spring “2” (to shift shaft) • Collar “3” (to shift shaft) •...

  • Page 285

    OIL PUMP AND BALANCER GEAR OIL PUMP AND BALANCER GEAR EAS2GB7298 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 286

    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 287

    OIL PUMP AND BALANCER GEAR REMOVING THE BALANCER EAS2GB7299 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 288

    OIL PUMP AND BALANCER GEAR ASSEMBLING THE OIL PUMP Inner-rotor-to-outer-rotor-tip 1. Install: clearance • Oil pump drive shaft “1” Less than • Inner rotor “2” 0.150 mm (0.0059 in) • Dowel pin “3” Limit 0.20 mm (0.0079 in) Outer-rotor-to-oil-pump-housing • Apply the engine oil on the oil pump drive clearance shaft and inner rotor.

  • Page 289

    OIL PUMP AND BALANCER GEAR INSTALLING THE OIL PUMP AND BALANC- EAS2GB7304 ER GEAR 1. Install: • Oil pump assembly “1” • Oil pump assembly bolt “2” Oil pump assembly bolt 5 Nm (0.5 m·kgf, 3.6 ft·lbf) LOCTITE® NOTICE 4. Install: After tightening the bolts, make sure that •...

  • Page 290

    OIL PUMP AND BALANCER GEAR 6-61...

  • Page 291

    GENERATOR AND STARTER CLUTCH GENERATOR AND STARTER CLUTCH EAS2GB7305 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 292

    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 293: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH 3. Check: REMOVING THE GENERATOR EAS2GB7306 • 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 294

    “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 295

    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 296

    GENERATOR AND STARTER CLUTCH Install the cover (damper assembly) with its mark “a” facing upward. 6-67...

  • Page 297

    CRANKCASE CRANKCASE EAS2GB7310 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 298

    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 299

    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 300

    CRANKCASE DISASSEMBLING THE CRANKCASE EAS2GB7311 1. Separate: • Right crankcase • Left crankcase ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the crankcase bolts. c. Remove the dowel pins and O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ REMOVING THE CRANKCASE BEARING EAS2GB7312 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 301

    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 302

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EAS2GB7317 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 303

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 2. Measure: REMOVING THE CRANKSHAFT ASSEMBLY EAS2GB7318 • Big end side clearance “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 0.150–0.450 mm (0.0059–0.0177 crankcase separating tool “2”.

  • Page 304

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT INSTALLING THE CRANKSHAFT ASSEM- EAS2GB7320 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 EAS2GB7321 Installing pot...

  • Page 305

    TRANSMISSION TRANSMISSION EAS2GB7322 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 306

    TRANSMISSION REMOVING THE TRANSMISSION CHECKING THE SHIFT FORKS EAS2GB7323 EAS2GB7324 1. Remove: 1. Check: • Long shift fork guide bar “1” • Shift fork cam follower “1” • Short shift fork guide bar “2” • Shift fork pawl “2” Bends/damage/scoring/wear  Replace the •...

  • Page 307

    TRANSMISSION CHECKING THE SHIFT DRUM ASSEMBLY EAS2GB7325 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 308

    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 309

    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 310

    TRANSMISSION 6-81...

  • Page 311

    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 312

    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 313

    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 314

    RADIATOR HANDLING NOTE EAS2GB7330 WARNING If coolant seems hot, do not remove the ra- diator cap. CHECKING THE RADIATOR EAS2GB7331 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 315

    WATER PUMP WATER PUMP EAS2GB7332 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 316

    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 317: Water Pump

    WATER PUMP REMOVING THE OIL SEAL EAS2GB7333 • 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 318

    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 319

    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 320

    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 321

    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 322: Fuel Tank

    FUEL TANK REMOVING THE FUEL TANK EAS2GB7340 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 323

    FUEL TANK INSTALLING THE FUEL SENDER EAS2GB7346 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 EAS2GB7344 •...

  • Page 324

    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 325

    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- EAS2GB7350 TECTOR 1. Check: • Protector “1” Wear/damage  Replace. Affix the protector as shown. 0 mm (0 in) 15 mm (0.59 in)

  • Page 326

    THROTTLE BODY THROTTLE BODY EAS2GB7351 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 327

    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 328

    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 329

    THROTTLE BODY CHECKING THE INJECTOR EAS2GB7352 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 330

    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 331

    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 332

    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 333

    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 334: Ignition System

    IGNITION SYSTEM IGNITION SYSTEM EAS2GB7357 EAS2GB7358 CIRCUIT DIAGRAM...

  • Page 335

    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 49.Ignition coil sub-lead...

  • Page 336

    IGNITION SYSTEM TROUBLESHOOTING EAS2GB7359 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 337

    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 338

    ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM EAS27160 EAS2GB7360 CIRCUIT DIAGRAM...

  • Page 339

    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 340: Electric Starting System

    ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION EAS2GB7361 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 341

    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 342

    ELECTRIC STARTING SYSTEM TROUBLESHOOTING EAS2GB7362 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 343

    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 344: Charging System

    CHARGING SYSTEM CHARGING SYSTEM EAS27200 EAS2GB7363 CIRCUIT DIAGRAM 9-12...

  • Page 345

    CHARGING SYSTEM 4. AC magneto 5. Rectifier/regulator 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 50.Negative battery lead 9-13...

  • Page 346

    CHARGING SYSTEM TROUBLESHOOTING EAS2GB7364 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 347

    CHARGING SYSTEM 9-15...

  • Page 348: Lighting System

    LIGHTING SYSTEM LIGHTING SYSTEM EAS27240 EAS2GB7365 CIRCUIT DIAGRAM 9-16...

  • Page 349

    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 350

    LIGHTING SYSTEM TROUBLESHOOTING EAS2GB7366 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 351

    LIGHTING SYSTEM 9-19...

  • Page 352: Signaling System

    SIGNALING SYSTEM SIGNALING SYSTEM EAS27270 EAS2GB7367 CIRCUIT DIAGRAM 9-20...

  • Page 353

    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 354

    SIGNALING SYSTEM TROUBLESHOOTING EAS2GB7368 • 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 355

    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 356: Cooling System

    COOLING SYSTEM COOLING SYSTEM EAS2GB7369 EAS2GB7370 CIRCUIT DIAGRAM 9-24...

  • Page 357

    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 358

    COOLING SYSTEM TROUBLESHOOTING EAS2GB7371 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 359

    COOLING SYSTEM 9-27...

  • Page 360

    FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM EAS2GB7372 EAS2GB7373 CIRCUIT DIAGRAM 9-28...

  • Page 361

    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 362: Fuel Injection System

    FUEL INJECTION SYSTEM ECU SELF-DIAGNOSTIC FUNCTION EAS2GB7374 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 363

    • 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 364

    FUEL INJECTION SYSTEM YAMAHA DIAGNOSTIC TOOL EAS2GB7376 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 365

    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 366

    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 367

    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 368

    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 369

    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 370

    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 371

    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 372

    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 373

    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 374

    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 375

    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 376

    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 377

    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 378

    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 379

    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 380

    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 381

    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 382

    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 383

    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 384

    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 385

    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 386

    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 387

    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 388: Fuel Pump System

    FUEL PUMP SYSTEM FUEL PUMP SYSTEM EAS2GB7378 EAS2GB7379 CIRCUIT DIAGRAM 9-56...

  • Page 389

    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 390

    FUEL PUMP SYSTEM TROUBLESHOOTING EAS2GB7380 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 391

    FUEL PUMP SYSTEM 9-59...

  • Page 392

    ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS EAS2GB7381 EAS2GB7382 9-60...

  • Page 393

    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 394

    ELECTRICAL COMPONENTS 9-62...

  • Page 395

    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 396

    ELECTRICAL COMPONENTS CHECKING THE SWITCHES EAS2GB7383 9-64...

  • Page 397

    ELECTRICAL COMPONENTS 1. Engine stop switch 2. Neutral switch 3. Clutch switch 4. Start switch 9-65...

  • Page 398

    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 399

    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 400

    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 401

    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 402

    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 403

    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 404

    ELECTRICAL COMPONENTS Starting circuit cut-off relay CHECKING THE RELAYS EAS2GB7386 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 405

    ELECTRICAL COMPONENTS CHECKING THE IGNITION SPARK GAP EAS2GB7388 Result 1. Check: Continuity • Ignition spark gap (between “3” to “4”) Out of specification  Perform the ignition system troubleshooting, starting with step 4. EAS2GB7387 CHECKING THE DIODE Refer to “TROUBLESHOOTING” on page 9- 1.

  • Page 406

    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 407

    ELECTRICAL COMPONENTS Out of specification  Replace. Pocket tester Crankshaft position sensor resis- 90890-03112 tance Analog pocket tester 228–342  (Gy–B) YU-03112-C Test harness– lean angle sensor (6P) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (  100) to the 90890-03209 crankshaft position sensor coupler.

  • Page 408

    ELECTRICAL COMPONENTS b. Measure the stator coil resistance. b. Check the starter motor operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE RECTIFIER/REGULATOR EAS2GB7394 CHECKING THE STATOR COIL EAS28150 1. Check: 1. Disconnect: • Charging voltage • Stator coil coupler Out of specification  Replace the rectifier/ (from the wire harness) regulator.

  • Page 409

    ELECTRICAL COMPONENTS 4. Check: CHECKING THE SPEED SENSOR EAS2GB7395 • 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 410

    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 411: Specifications

    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 EAS2GB7400 CHECKING THE THROTTLE POSITION THE THROTTLE POSITION SENSOR”...

  • Page 412

    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- EAS2GB7403 c. Start the engine. TURE SENSOR d.

  • Page 413

    ELECTRICAL COMPONENTS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS2GB7404 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 414

    ELECTRICAL COMPONENTS 9-82...

  • Page 415: General Information

    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 416

    TROUBLESHOOTING • Incorrect spark plug heat range TROUBLESHOOTING EAS2GB7405 • Fouled spark plug • Worn or damaged electrode EAS2GB7406 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 417: Cooling System

    TROUBLESHOOTING POOR MEDIUM-AND-HIGH-SPEED PER- CLUTCH SLIPS EAS2GB7409 EAS2GB7413 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 418: Chassis

    TROUBLESHOOTING Fuel system FAULTY FRONT FORK LEGS EAS2GB7419 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 419: Troubleshooting

    TROUBLESHOOTING HEADLIGHT DOES NOT COME ON EAS2GB7421 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 EAS2GB7422 Electrical system...

  • Page 420

    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 421

    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 422

    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 423

    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 424

    WIRING DIAGRAM EAS2GB7426 EAS2GB7427 COLOR CODE WR250F/WR250FG 2016 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 426

    PRINTED ON RECYCLED PAPER PRINTED IN JAPAN...

  • Page 427

    WR250F/WR250FG 2016 WR250F/WR250FG 2016 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 B/L Gy (Gy) (Gy)

  • Page 428

    WR250F/WR250FG 2016 WR250F/WR250FG 2016 SCHÉMA DE CÂBLAGE WIRING DIAGRAM (Gy) (Gy) (Gy)

This manual also for:

Wr250fg 2016

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