Page 4: How To Use This Manual
EAS20004 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
Page 5 EAS20005 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...
Page 7 EAS10003 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
Page 9: Table Of Contents
GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 MULTI-FUNCTION METER UNIT ............. 1-4 IMPORTANT INFORMATION ................. 1-9 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-9 REPLACEMENT PARTS................1-9 GASKETS, OIL SEALS AND O-RINGS ............ 1-9 LOCK WASHERS/PLATES AND COTTER PINS ........
Page 10: Identification
IDENTIFICATION EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the frame under the passenger seat.
Page 11: Outline Of The Fi System
FEATURES EAS20008 FEATURES EAS30005 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
Page 12: Fi System
FEATURES EAS30617 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at a certain level. Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
Page 13: Multi-Function Meter Unit
FEATURES Tachometer EAS30982 MULTI-FUNCTION METER UNIT 1. Tachometer 1. “SEL” button 2. Tachometer red zone 2. “RES” button The tachometer allows the rider to monitor the 3. Tachometer engine speed and keep it within the ideal power 4. Fuel meter range.
Page 14 FEATURES [To set the clock] Coolant temperature meter 1. Turn the key to “ ”. 2. Push the “SEL” button and “RES” button to- gether for at least two seconds. 3. When the hour digits start flashing, push the “RES” button to set the hours. 4.
Page 15 FEATURES Multi-function display If you do not reset the fuel reserve tripmeter manually, it resets itself automatically and the display returns to the prior mode after refueling and traveling 5 km (3 mi). Instantaneous fuel consumption display 1. Multi-function display The multi-function display is equipped with the following: •...
Page 16 FEATURES • “AVE_ _._ L/100 km”: The average amount of Shift timing indicator light fuel necessary to travel 100 km is shown. To switch between the average fuel consump- tion displays, push the “SEL” button for one sec- ond. To reset the average fuel consumption display, push the “RES”...
Page 17 FEATURES 2. Push the “SEL” button to confirm the selected 1. Push the “RES” button to select the desired flashing pattern. The shift timing indicator engine speed for deactivating the indicator light changes to the activation point setting light. mode. 2.
Page 18: Important Information
5. Keep all parts away from any source of fire. EAS30007 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but...
Page 19: Bearings And Oil Seals
IMPORTANT INFORMATION EAS30010 EAS30012 BEARINGS AND OIL SEALS RUBBER PARTS Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in- manufacturer marks or numbers are visible. spection. Some of the rubber parts are sensitive When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc.
Page 20: Basic Service Information
BASIC SERVICE INFORMATION EAS20010 BASIC SERVICE INFORMATION EAS30013 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. Screw type 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.
Page 21: Electrical System
BASIC SERVICE INFORMATION ECA16760 EAS30014 NOTICE ELECTRICAL SYSTEM Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- Electrical parts handling tery lead connections could damage the ECA16600 NOTICE electrical components. Never disconnect a battery lead while the en- gine is running;...
Page 22 BASIC SERVICE INFORMATION ECA16620 Checking the electrical system NOTICE Handle electrical components with special Before checking the electrical system, make care, and do not subject them to strong sure that the battery voltage is at least 12 V. shocks. ECA14371 ECA16630 NOTICE NOTICE...
Page 23 BASIC SERVICE INFORMATION 2. Check: Checking the connections • Lead Check the leads, couplers, and connectors for • Coupler stains, rust, moisture, etc. • Connector 1. Disconnect: Moisture → Dry with an air blower. • Lead Rust/stains → Connect and disconnect sev- •...
Page 24 BASIC SERVICE INFORMATION • As a quick remedy, use a contact revitalizer available at most part stores. 4. Connect: • Lead • Coupler • Connector • When connecting a coupler or connector, push both sections of the coupler or connector to- gether until they are connected securely.
Page 25 BASIC SERVICE INFORMATION 1-16...
Page 26: Special Tools
SPECIAL TOOLS EAS20012 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
Page 27 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984 YU-33984 Fork seal driver weight 4-67, 4-67 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø41) 4-67, 4-67 90890-01381 Replacement 41 mm YM-A5142-2 Steering nut wrench 3-19, 4-72 90890-01403...
Page 28 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Compression gauge 90890-03081 90890-03081 Engine compression tester YU-33223 YU-33223 Vacuum gauge 90890-03094 Vacuummate YU-44456 YU-44456 Pocket tester 1-15, 8-79, 8-80, 90890-03112 8-80, 8-81, 8-85, Analog pocket tester 8-86, 8-88, 8-88, YU-03112-C 8-88, 8-89, 8-90, 8-91, 8-91, 8-92, 8-93, 8-93, 8-94, 8-94...
Page 29 90890-03209 Test harness– lean angle sensor (6P) YU-03209 Fuel injector pressure adapter 7-11 90890-03210 Fuel injector pressure adapter YU-03210 Yamaha diagnostic tool 3-8, 3-11, 8-34 90890-03231 Valve spring compressor 5-27, 5-32 90890-04019 Valve spring compressor YM-04019 Middle driven shaft bearing driver 90890-04058 Middle drive bearing installer 40 &...
Page 30 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Universal clutch holder 5-52, 5-55 90890-04086 Universal clutch holder YM-91042 Valve lapper 90890-04101 Valve lapping tool YM-A8998 Valve spring compressor attachment 5-27, 5-32 90890-04108 Valve spring compressor adapter 22 mm YM-04108 Valve guide remover (ø4.5) 5-29 90890-04116 Valve guide remover (4.5 mm)
Page 31 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rotor holding tool 5-42, 5-42, 5-43, 90890-04166 5-44 YM-04166 Ignition checker 8-89 90890-06754 Oppama pet–4000 spark checker YM-34487 Yamaha bond No. 1215 5-44, 5-72, 5-73 90890-85505 (Three bond No.1215®) 1-22...
Page 32 SPECIAL TOOLS 1-23...
Page 33 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............2-12 CHASSIS TIGHTENING TORQUES............2-17 LUBRICATION POINTS AND LUBRICANT TYPES ........2-21 ENGINE....................2-21 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-23 ENGINE OIL LUBRICATION CHART .............2-23 LUBRICATION DIAGRAMS ..............
Page 34 GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model 1WD1 Dimensions Overall length 2090 mm (82.3 in) Overall width 720 mm (28.3 in) Overall height 1135 mm (44.7 in) Seat height 780 mm (30.7 in) Wheelbase 1380 mm (54.3 in) Ground clearance 160 mm (6.30 in) Minimum turning radius 2700 mm (106.3 in)
Page 35 ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 249 cm³ Cylinder arrangement Inline 2-cylinder Bore × stroke 60.0 × 44.1 mm (2.36 × 1.74 in) Compression ratio 11.6 : 1 Standard compression pressure (at sea level) Minimum-maximum Starting system Electric starter...
Page 36 ENGINE SPECIFICATIONS Thermostat Valve opening temperature 80.5–83.5 °C (176.90–182.30 °F) Valve full open temperature 95.0 °C (203.00 °F) Valve lift (full open) 3.0 mm (0.12 in) Radiator core Width 145.8 mm (5.74 in) Height 270.0 mm (10.63 in) Depth 24.0 mm (0.94 in) Water pump Water pump type Single suction centrifugal pump...
Page 37 ENGINE SPECIFICATIONS Limit 4.550 mm (0.1791 in) Valve guide inside diameter (exhaust) 4.500–4.512 mm (0.1772–0.1776 in) Limit 4.550 mm (0.1791 in) Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in) Limit 0.100 mm (0.0039 in) Valve stem runout...
Page 38 ENGINE SPECIFICATIONS 2nd ring Ring type Taper End gap (installed) 0.30–0.45 mm (0.0118–0.0177 in) Limit 0.60 mm (0.0236 in) Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in) Limit 0.100 mm (0.0039 in) Oil ring End gap (installed) 0.10–0.35 mm (0.0039–0.0138 in) Connecting rod Oil clearance 0.036–0.060 mm (0.0014–0.0024 in)
Page 39 ENGINE SPECIFICATIONS 0.920 (23/25) Main axle runout limit 0.06 mm (0.0024 in) Drive axle runout limit 0.06 mm (0.0024 in) Shifting mechanism Shift mechanism type Shift drum and guide bar Shift fork guide bar bending limit 0.050 mm (0.0020 in) Shift fork thickness 5.76–5.89 mm (0.2268–0.2319 in) Air filter...
Page 40 CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 25.00 ° Trail 95 mm (3.7 in) Front wheel Wheel type Cast wheel Rim size 17M/C x MT2.75 Rim material Aluminum Wheel travel 130 mm (5.1 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
Page 41 CHASSIS SPECIFICATIONS Brake pad lining thickness (outer) 5.3 mm (0.21 in) Limit 0.8 mm (0.03 in) Master cylinder inside diameter 11.00 mm (0.43 in) Caliper cylinder inside diameter 26.99 mm (1.06 in) Caliper cylinder inside diameter 26.99 mm (1.06 in) Specified brake fluid DOT 4 Rear brake...
Page 42 CHASSIS SPECIFICATIONS Standard Maximum Drive chain Size/manufacturer 520VF/DAIDO Number of links 15-link length limit Drive chain slack 35.0–45.0 mm (1.38–1.77 in) Limit...
Page 43 ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Ignition timing (B.T.D.C.) 5.0 °/1400 r/min Engine control unit Model/manufacturer TBDFH7/DENSO Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64 Ω Primary coil resistance Secondary coil resistance 8.64–12.96 kΩ...
Page 44 ELECTRICAL SPECIFICATIONS Oil pressure warning light High beam indicator light Engine trouble warning light Starter motor Power output 0.40 kW 0.0630–0.0770 Ω Armature coil resistance Brush overall length 7.0 mm (0.28 in) Limit 3.00 mm (0.12 in) Brush spring force 6.08–9.12 N (620–930 gf, 21.89–32.83 oz) Mica undercut (depth) 1.50 mm (0.06 in)
Page 45 TIGHTENING TORQUES EAS20017 TIGHTENING TORQUES EAS30015 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.
Page 46 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Timing chain tensioner bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Timing chain tensioner cap bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Timing mark accessing bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Crankshaft end cover 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) Cylinder head cover bolt...
Page 47 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Gear position switch screw 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Oil filter cartridge 17 Nm (1.7 m·kgf, 12 ft·lbf) Oil filter cartridge union bolt 70 Nm (7.0 m·kgf, 51 ft·lbf) Crankcase breather cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Speed sensor bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Page 48 Tighten the crankcase bolts “1”–“21” in the proper tightening sequence as follows: 1. Lubricate the crankcase bolts “1”–“15” and “17”–“21” threads, mating surfaces with the engine oil. 2. Lubricate the mating surface of the bolt “16” with engine oil and apply Yamaha bond No. 1215 to the bolt threads.
Page 49 TIGHTENING TORQUES ×6 ×2 ×2 2-16...
Page 50 TIGHTENING TORQUES ×3 ×2 ×3 ×3 A. Lower crankcase B. Upper crankcase Connecting rod bolt 1. Lubricate the connecting rod bolts threads and connecting rod nuts mating surface with molybde- num disulfide oil. 2. Tighten the connecting rod bolts to 15 Nm (1.5 m·kgf, 11 ft·lbf), and then tighten them further to reach the specified angle 145–155°.
Page 51 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Passenger seat bracket nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Passenger seat band nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Side panel bolt 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf) Upper tail panel screw 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf) Rear upper side cowling bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Page 52 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear wheel sprocket stud bolt 28 Nm (2.8 m·kgf, 20 ft·lbf) Rear brake disc bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) Brake caliper bleed screw 6 Nm (0.6 m·kgf, 4.3 ft·lbf) Brake master cylinder reservoir cap 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) screw...
Page 53 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Horn bolt 16 Nm (1.6 m·kgf, 12 ft·lbf) Brake hose joint nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Horn bracket bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Cable guide bolt (left) 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Cable guide bolt (right) 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Page 54 LUBRICATION POINTS AND LUBRICANT TYPES EAS20018 LUBRICATION POINTS AND LUBRICANT TYPES EAS30018 ENGINE Lubrication point Lubricant Bearings O-rings Oil seal lips Cylinder head bolt seats, cylinder head bolt threads and washers Crankshaft big ends Connecting rod bolts Generator rotor bolt thread and washer Crankshaft journals Balancer gear and damper Balancer shaft journals...
Page 55 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Transmission gears (wheel and pinion) and collar Transmission gears inner surface (shift fork contact parts) Shift fork and transmission gear contact surface Shift drum assembly Shift forks and shift fork guide bars Shift shaft moving surface Shift shaft washer 2-22...
Page 56: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 2-23...
Page 57 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil filter cartridge 5. Sub gallery 6. Main gallery 7. Crankshaft 8. Oil nozzle 9. Balancer shaft assembly 10. Timing chain tensioner 11. Intake camshaft 12.
Page 58 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30021 LUBRICATION DIAGRAMS Crankcase, cylinder, and cylinder head (right side view) 1. Timing chain tensioner 2. Intake camshaft 2-25...
Page 59 LUBRICATION SYSTEM CHART AND DIAGRAMS 3. Exhaust camshaft 4. Crankshaft 5. Balancer shaft assembly 6. Oil filter cartridge 7. Oil strainer 8. Oil pump 9. Transmission shower 2-26...
Page 60 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankcase and cylinder (left side view) 1. Crankshaft 4. Oil drain bolt 2. Balancer shaft assembly 5. Oil filter cartridge 3. Connecting rod 6. Oil pressure switch 2-27...
Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS Oil pump (right side view) 1. Oil pump 2. Relief valve 2-28...
Page 62 LUBRICATION SYSTEM CHART AND DIAGRAMS Oil strainer (bottom view) 1. Main gallery 4. Oil strainer 2. Oil filter cartridge 3. Sub gallery 2-29...
Page 63 LUBRICATION SYSTEM CHART AND DIAGRAMS Camshaft (top view) 1. Intake camshaft 2. Exhaust camshaft 3. Cylinder head 2-30...
Page 64 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft (rear view) 1. Crankshaft 4. Main gallery 2. Oil nozzle 5. Sub gallery 3. Piston 2-31...
Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft and transmission (top view) 1. Crankshaft 4. Drive axle 2. Balancer shaft assembly 3. Main axle 2-32...
Page 66 COOLING SYSTEM DIAGRAMS EAS20020 COOLING SYSTEM DIAGRAMS 2-33...
Page 67 COOLING SYSTEM DIAGRAMS 1. Radiator 2. Radiator outlet hose 3. Water pump 4. Thermostat 5. Radiator inlet hose 2-34...
Page 68 CABLE ROUTING EAS20021 CABLE ROUTING Handlebar (front view) 1. Throttle cable (accelerator cable) 2. Throttle cable (decelerator cable) 2-35...
Page 69: Cable Routing
CABLE ROUTING 3. Front brake light switch lead 4. Handlebar switch lead (right handlebar switch) 5. Clutch cable 6. Clutch switch lead 7. Handlebar switch lead (left handlebar switch) 8. Horn 9. Main switch lead 10. Horn lead 11. Front brake hose 12.
Page 70 CABLE ROUTING Engine (right side view) 1. Negative battery sub-wire harness coupler 4. Headlight lead (right) 2. Fuel tank drain hose 5. Front turn signal light lead (right turn signal light) 3. Ignition coil lead 6. Coolant reservoir hose 2-37...
Page 71 CABLE ROUTING 7. Air cut-off valve 8. Speed sensor coupler 9. O sensor 10. Coolant temperature sensor coupler 11. Starter motor lead 12. Negative battery sub-wire harness 13. O sensor lead 14. Speed sensor lead 15. Stator coil lead 16. Spark plug lead 17.
Page 72 CABLE ROUTING Rear fender (right side view) 1. Fuse box 4. Rear brake light switch coupler 2. Rear fender 5. Rear brake light switch lead 3. Fuse box lead 6. Fuel tank drain hose 2-39...
Page 73 CABLE ROUTING 7. Down tube 8. Stay 9. Engine stay 10. Frame A. Install the fuse box onto the tab on the rear fender. B. Pass a plastic locking tie through the hole in the frame, and then fasten the fuse box lead to the frame with the tie.
Page 74 CABLE ROUTING Engine (left side view) 1. Auxiliary light lead 4. Coolant reservoir hose 2. Fuel tank breather hose 5. O sensor lead 3. Guide 6. O sensor coupler 2-41...
Page 75 CABLE ROUTING 7. Stator coil lead N. Route the oil pressure switch lead, gear position switch lead, and fuel tank breather 8. Gear position switch lead hose between the projection on the drive 9. Fuel tank drain hose chain cover and the drive chain cover. 10.
Page 76 CABLE ROUTING Rear fender (left side view) 18 19 20 1. Coolant reservoir breather hose 4. Starter motor lead terminal 2. Gear position switch coupler 5. Starter relay coupler 3. Starting circuit cut-off relay 6. Yamaha diagnostic tool coupler 2-43...
Page 77 CABLE ROUTING 7. Tail/brake light lead K. Fasten the wire harness and tail/brake light lead to the frame with a plastic locking tie as 8. Lean angle sensor lead shown in the illustration. Point the end of the 9. Rectifier/regulator coupler plastic locking tie outward.
Page 78 CABLE ROUTING Engine (top view) 26 L 1. Clutch cable 4. Headlight lead (left) 2. Handlebar switch lead (left handlebar switch) 5. Auxiliary light lead 3. Front turn signal light lead (left turn signal 6. Meter assembly light) 2-45...
Page 79 CABLE ROUTING 7. Meter assembly lead K. Fasten the throttle cable (accelerator cable) and throttle cable (decelerator cable) with the 8. Throttle cable (accelerator cable) plastic locking tie. Be sure to route the throttle 9. Throttle cable (decelerator cable) cable (accelerator cable) above the throttle 10.
Page 80 CABLE ROUTING Rear fender (top view) 1. Fuel tank drain hose 4. Frame 2. O sensor lead 5. Rear brake light switch lead 6. Fuse box lead 3. Negative battery sub-wire harness 2-47...
Page 81 D. Route the negative battery sub-wire harness under the ECU (engine control unit). E. Route the rear turn signal light leads, license plate light lead, and Yamaha diagnostic tool coupler lead through the guide on the rear fender. F. Fasten the wire harness to the frame with a plastic locking tie.
Page 82 CABLE ROUTING Front brake (right side view) 1. Front brake hose A. Route the front brake hose over the guide. 2. Front brake caliper B. When installing the brake hose onto the brake caliper, make sure that the brake pipe 3.
Page 83 CABLE ROUTING Rear brake (right side view) 1. Rear brake caliper 4. Rear brake master cylinder 2. Brake hose (rear brake master cylinder to rear brake caliper) 3. Brake fluid reservoir hose 2-50...
Page 84 CABLE ROUTING A. Face the white paint mark on the brake hose (rear brake master cylinder to rear brake caliper) outward. B. When installing the brake hose (rear brake master cylinder to rear brake caliper) on the rear brake master cylinder, make sure that the brake pipe touches the projection on the master cylinder.
Page 85 CABLE ROUTING Fuel tank (left side view) 1. Fuel tank 4. Fuel tank breather hose (fuel tank to hose joint) 2. Fuel hose (fuel tank to fuel rail) 5. Fuel tank breather hose 3. Fuel pump 6. Hose joint 2-52...
Page 86 CABLE ROUTING 7. Fuel tank drain hose 8. Fuel tank drain hose (fuel tank to hose joint) A. Connect the orange connector of the fuel hose (fuel tank to fuel rail) to the fuel pump. B. Forward C. Face the white paint mark on the fuel tank drain hose (fuel tank to hose joint) forward.
Page 87 CABLE ROUTING Throttle bodies (left and right view) 1. ISC (idle speed control) valve inlet hose 4. Crankcase breather cover 2. Air filter case assembly 5. Throttle bodies 3. Crankcase breather hose 6. Fuel hose (fuel tank to fuel rail) 2-54...
Page 88 CABLE ROUTING A. Point the ends of the hose clamp to the left. B. Face the yellow paint mark on the crankcase breather hose to the left. C. Install the hose up to the bend in the hose fitting. D. Make sure not to install the hose clamp on the raised portion of the hose fitting.
Page 89 CABLE ROUTING Air induction system (top view) 1. Reed valve cover 4. Air induction system hose (air filter case to air cut-off valve) 2. Air induction system hose (air cut-off valve to reed valve cover) 5. Air filter case assembly 3.
Page 90 CABLE ROUTING A. Point the ends of the hose clamp upward. B. Face the yellow paint mark on the air induction system hose (air filter case to air cut-off valve) upward. C. Face the white paint mark on the air induction system hose (air filter case to air cut-off valve) upward.
Page 91 CABLE ROUTING Radiator (top view) 1. Radiator 4. Coolant reservoir cap 2. Radiator outlet hose 5. Coolant reservoir breather hose 3. Coolant reservoir hose 6. Coolant reservoir 2-58...
Page 92 CABLE ROUTING 7. Radiator inlet hose 8. Coolant hose A. 13° B. Face the white paint mark on the coolant reservoir hose upward. C. 40° D. 3 mm (0.12 in) or more. Make sure not to install the hose clamp on the raised portion of the hose fitting.
Page 93 CABLE ROUTING Radiator (left side view) 1. Coolant reservoir hose 4. Coolant reservoir breather hose 2. Electrical components tray 5. Frame 3. Coolant reservoir cap 6. Coolant reservoir 2-60...
Page 94 CABLE ROUTING 7. Thermostat cover 8. Radiator inlet hose 9. Radiator A. Insert the end of the coolant reservoir breather hose into the frame pipe. Make sure that the end of the hose protector on the coolant reservoir breather hose contacts the edge of the hole in the frame.
Page 95 CABLE ROUTING Radiator (right side view) 1. Coolant reservoir hose 4. Water pump housing 2. Radiator 3. Radiator outlet hose 2-62...
Page 96 CABLE ROUTING A. Connect the end of the radiator outlet hose that is identified by the white paint mark to the radiator. B. Install the radiator outlet hose completely onto the hose fitting of the water pump housing. C. Outward D.
Page 97 PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .......3-1 CHECKING THE FUEL LINE ..............3-3 CHECKING THE FUEL FILTER..............3-4 CHECKING THE SPARK PLUGS ............. 3-4 ADJUSTING THE VALVE CLEARANCE ..........
Page 98 HOSE ..................... 3-11 CHECKING AND CHARGING THE BATTERY........3-12 ADJUSTING THE CLUTCH LEVER FREE PLAY........3-12 CHECKING THE BRAKE OPERATION ..........3-13 CHECKING THE FRONT BRAKE PADS ..........3-13 CHECKING THE REAR BRAKE PADS ..........3-14 CHECKING THE FRONT BRAKE HOSES ..........3-14 CHECKING THE REAR BRAKE HOSE ..........
Page 100 • From 25000 km or 25 months, repeat the maintenance intervals starting from 5000 km or 5 months. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
Page 101 PERIODIC MAINTENANCE ODOMETER READING (whichever comes first) CHECK OR MAINTENANCE ANNUAL ITEM 1000 km 5000 km 10000 km 15000 km 20000 km CHECK or 1 or 5 or 10 or 15 or 20 month months months months months Air filter check √...
Page 102 • Replace. cartridge • Check coolant level and vehi- √ √ √ √ √ cle for coolant leakage. 25 * Cooling system Yamaha • Change with genu- Every 3 years ine coolant. Front and rear √ √ √ √ √...
Page 103 PERIODIC MAINTENANCE 4. Install: 3. Install: • Front fuel tank bracket bolt (frame) • Fuel filter • Rear fuel tank bracket bolt (frame) Refer to “INSTALLING THE FUEL FILTER” on page 7-4. Rear fuel tank bracket bolt • Fuel tank cover assembly (frame) Refer to “GENERAL CHASSIS (3)”...
Page 104 PERIODIC MAINTENANCE • Rider seat Manufacturer/model Refer to “GENERAL CHASSIS (1)” on page NGK/CR9E 4-1. 5. Check: EAS30622 ADJUSTING THE VALVE CLEARANCE • Electrode “1” The following procedure applies to all of the Damage/wear → Replace the spark plug. valves. •...
Page 105 PERIODIC MAINTENANCE 5. Measure: d. Measure the valve clearance with a thickness • Valve clearance gauge “1”. Out of specification → Adjust. Thickness gauge 90890-03180 Valve clearance (cold) Feeler gauge set Intake YU-26900-9 0.11–0.18 mm (0.0043–0.0071 in) Exhaust 0.21–0.30 mm (0.0083–0.0118 in) ▼...
Page 106 PERIODIC MAINTENANCE Valve lapper 90890-04101 Valve lapping tool YM-A8998 • Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. • Make a note of the position of each valve lifter d. Calculate the sum of the values obtained in “1”...
Page 107 ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the Yamaha diagnostic tool. Camshaft cap bolt Use the diagnostic code number “67”. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Refer to “SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-5.
Page 108 PERIODIC MAINTENANCE If out of specification → Adjust the throttle • Fuel tank Refer to “FUEL TANK” on page 7-1. body synchronization. 3. Remove: ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...
Page 109 PERIODIC MAINTENANCE 2. Remove: • Throttle bodies Refer to “THROTTLE BODIES” on page 7-6. 3. Check: • Throttle body joint “1” Cracks/damage → Replace. A. Throttle body #1 B. Throttle body #2 ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...
Page 110 For more information, refer to the opera- Refer to “CHECKING THE AIR INDUCTION tion manual of the Yamaha diagnostic tool. SYSTEM” on page 7-18. 1. Connect the Yamaha diagnostic tool to the coupler. For information about connecting the EAS31130 REPLACING THE AIR FILTER ELEMENT Yamaha diagnostic tool, refer to “YAMAHA...
Page 111 PERIODIC MAINTENANCE Air filter case side cover screw (left) 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) ECA20710 NOTICE Never operate the engine without the air filter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the 1.
Page 112 PERIODIC MAINTENANCE ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ Handlebar side a. Loosen the locknut “1”. b. Turn the adjusting bolt “2” in direction “a” or “b” until the specified clutch lever free play is obtained.
Page 113 PERIODIC MAINTENANCE EAS30634 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • Rear brake pad Wear indicator grooves “a” almost disap- peared → Replace the brake pads as a set. Refer to “REAR BRAKE”...
Page 114 PERIODIC MAINTENANCE c. Connect a clear plastic hose “1” tightly to the EAS30632 CHECKING THE BRAKE FLUID LEVEL bleed screw “2”. 1. Stand the vehicle on a level surface. • Place the vehicle on a suitable stand. • Make sure the vehicle is upright. 2.
Page 115 PERIODIC MAINTENANCE ECA13540 EWA13180 NOTICE WARNING • The tire pressure should only be checked Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up and regulated when the tire temperature equals the ambient air temperature. any spilt brake fluid immediately. •...
Page 116 4-20 and “CHECKING THE REAR cerning handling characteristics can be giv- WHEEL” on page 4-27. en if a tire combination other than one approved by Yamaha is used on this vehicle. EAS30802 CHECKING THE SWINGARM OPERATION 1. Check: Front tire •...
Page 117 PERIODIC MAINTENANCE 2. Move the rear wheel several times and find the tightest position of the drive chain. • Using the alignment marks “c” on each side of 3. Check: the swingarm, make sure that both drive chain • Drive chain slack pullers “3”...
Page 118 PERIODIC MAINTENANCE these O-rings. Therefore, use only kerosene to Steering nut wrench clean the drive chain. Wipe the drive chain dry 90890-01403 and thoroughly lubricate it with engine oil or Exhaust flange nut wrench chain lubricant that is suitable for O-ring chains. YU-A9472 Do not use any other lubricants on the drive chain since they may contain solvents that could...
Page 119 PERIODIC MAINTENANCE EAS30650 CHECKING THE SIDESTAND 1. Check: • Sidestand operation Check that the sidestand moves smoothly. Rough movement → Repair or replace. EAS30651 LUBRICATING THE SIDESTAND Lubricate the pivoting point, metal-to-metal mov- ing parts and spring contact point of the side- stand.
Page 120 PERIODIC MAINTENANCE EAS30655 EAS30656 ADJUSTING THE REAR SHOCK ABSORBER CHECKING THE ENGINE OIL LEVEL ASSEMBLY 1. Stand the vehicle on a level surface. EWA13120 WARNING • Place the vehicle on a suitable stand. Securely support the vehicle so that there is •...
Page 121 PERIODIC MAINTENANCE chemical additives or use engine oils with a Oil filter wrench grade of “CD” or higher and do not use oils 90890-01426 labeled “ENERGY CONSERVING II”. Oil filter wrench • Do not allow foreign materials to enter the YU-38411 crankcase.
Page 122 PERIODIC MAINTENANCE b. Start the engine and keep it idling until engine oil starts to seep from the oil check bolts. If no engine oil comes out after one minute, turn the engine off so that it will not seize. c.
Page 123 PERIODIC MAINTENANCE sound has stopped, press down on the radi- ator cap and turn it counterclockwise to re- Before checking the coolant level, wait a few move. minutes until it settles. EAS30812 CHECKING THE COOLING SYSTEM 1. Check: • Radiator “1” •...
Page 124 PERIODIC MAINTENANCE ECA13481 NOTICE • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft water may be used.
Page 125 PERIODIC MAINTENANCE EAS30660 CHECKING AND LUBRICATING THE Before checking the coolant level, wait a few CABLES minutes until the coolant has settled. The following procedure applies to all of the in- ner and outer cables. EAS30658 EWA13270 CHECKING THE BRAKE LIGHT SWITCHES WARNING 1.
Page 126 PERIODIC MAINTENANCE 3. Check: EAS30663 CHECKING THE SWITCHES, LIGHTS AND • Throttle grip free play “a” SIGNALS Out of specification → Adjust. 1. Check that all switches operate and that all lights come on. Throttle grip free play Refer to “INSTRUMENT AND CONTROL 3.0–5.0 mm (0.12–0.20 in) FUNCTIONS”...
Page 127 PERIODIC MAINTENANCE EWA13320 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 5. Install: • Headlight bulb Secure the new headlight bulb with the head- light bulb holder. ECA13690 ▲...
Page 128 PERIODIC MAINTENANCE 3-29...
Page 129 CHASSIS GENERAL CHASSIS (1) ................. 4-1 REMOVING THE CENTER COVER ............4-2 INSTALLING THE BATTERY..............4-2 INSTALLING THE RIDER SEAT............... 4-2 INSTALLING THE CENTER COVER............4-2 INSTALLING THE PASSENGER SEAT............ 4-2 GENERAL CHASSIS (2) ................. 4-3 REMOVING THE SIDE PANELS .............. 4-4 INSTALLING THE SIDE PANELS.............
Page 130 REAR WHEEL ....................4-24 REMOVING THE REAR WHEEL ............4-27 DISASSEMBLING THE REAR WHEEL ..........4-27 CHECKING THE REAR WHEEL............. 4-27 CHECKING THE REAR WHEEL DRIVE HUB ........4-27 CHECKING AND REPLACING THE REAR WHEEL SPROCKET ..4-27 ASSEMBLING THE REAR WHEEL ............4-28 ADJUSTING THE REAR WHEEL STATIC BALANCE......
Page 131 STEERING HEAD..................4-70 REMOVING THE LOWER BRACKET.............4-72 CHECKING THE STEERING HEAD ............4-72 INSTALLING THE STEERING HEAD .............4-72 SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY ......4-74 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY....4-76 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....4-76 REMOVING THE SWINGARM..............4-76 CHECKING THE SWINGARM ..............4-76 INSTALLING THE SWINGARM ..............4-77 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ....
Page 132 GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the seats and battery 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Passenger seat Owner’s tool kit Center cover Rider seat...
Page 133 GENERAL CHASSIS (1) EAS31189 REMOVING THE CENTER COVER 1. Remove: • Center cover “1” Unhook the projections “a” on the center cover from the rear upper side cowlings. EAS31190 INSTALLING THE CENTER COVER 1. Install: • Center cover “1” Center cover screw 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf) EAS30697 INSTALLING THE BATTERY...
Page 134 GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the rear side cowlings 7 Nm (0.7 m kgf, 5.1 ft Ibf) 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) •...
Page 135 GENERAL CHASSIS (2) b. Slide the upper tail panel rearward and re- EAS31290 REMOVING THE SIDE PANELS move it. The following procedure applies to both of the side panels. 1. Remove: • Side panel “1” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼...
Page 136 GENERAL CHASSIS (3) EAS20156 GENERAL CHASSIS (3) Removing the fuel tank covers 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) •...
Page 137 GENERAL CHASSIS (3) Removing the cowlings 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 138 GENERAL CHASSIS (3) b. Install the front panel bolts and quick fasten- EAS31352 REMOVING THE FRONT PANELS ers, and then tighten the bolts to specifica- The following procedure applies to both of the tion. front panels. 1. Remove: Front panel bolt •...
Page 139 GENERAL CHASSIS (3) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ EAS31356 REMOVING THE BOTTOM COWLING a. Remove the front bottom cowling bolts. 1. Remove: b. Remove the projection “a” on the front bottom •...
Page 140 GENERAL CHASSIS (3) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the quick fasteners “2”, screw “3”, bolt “4”, and nut “5”. (Left front side cowling assembly) Remove the quick fastener “2”, screw “3”, and bolts “4”.
Page 141 GENERAL CHASSIS (3) EAS31361 INSTALLING THE FRONT SIDE COWLING ASSEMBLY The following procedure applies to both of the front side cowling assembly. 1. Install: • Front side cowling assembly “1” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 142 GENERAL CHASSIS (4) EAS20157 GENERAL CHASSIS (4) Removing the front cowling assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 33 Nm (3.3 m kgf, 24 ft Ibf) •...
Page 143 GENERAL CHASSIS (4) EAS31296 INSTALLING THE FRONT COWLING ASSEMBLY 1. Install: • Front cowling assembly Front cowling assembly bolt 33 Nm (3.3 m·kgf, 24 ft·lbf) Fit the projection “a” on the front cowling assem- bly bracket into the hole “b” in the frame. 4-12...
Page 144 GENERAL CHASSIS (5) EAS20158 GENERAL CHASSIS (5) Disassembling the front cowling assembly 1.3 Nm (0.13 m kgf, 0.94 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) •...
Page 145 GENERAL CHASSIS (5) EAS31374 REMOVING THE WINDSHIELD ASSEMBLY 1. Remove: • Windshield assembly “1” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the windshield assembly screws. b. Slide the windshield assembly in the direction of the arrow shown in the illustration.
Page 146 GENERAL CHASSIS (5) 4-15...
Page 147 GENERAL CHASSIS (6) EAS20159 GENERAL CHASSIS (6) Removing the air filter case 1.3 Nm (0.13 m kgf, 0.94 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) •...
Page 148 GENERAL CHASSIS (6) EAS31303 INSTALLING THE AIR FILTER CASE 1. Install: • Air filter case joint clamps “1” Air filter case joint clamp screw 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) Align the projection “a” on the air filter case joint with the slot “b”...
Page 149 FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake disc 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 52 Nm (5.2 m kgf, 38 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) •...
Page 150 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing (right) Wheel bearing (left) Spacer 4-19...
Page 151 FRONT WHEEL EAS30145 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Front brake hose holder • Front brake caliper ▲...
Page 152 FRONT WHEEL b. Install the spacer. c. Install the new wheel bearing (left side). Place a suitable washer “1” between the socket “2” and the bearing so that both the inner race “3” and outer race “4” are pressed at the same time, and then press the bearing until the inner race makes contact with the spacer “5”.
Page 153 FRONT WHEEL d. Release the front wheel. c. If the heavy spot does not stay in that posi- e. When the wheel stops, put an “X ” mark at tion, install a heavier weight. d. Repeat steps (b) and (c) until the front wheel the bottom of the wheel.
Page 154 FRONT WHEEL ECA14140 NOTICE Before tightening the wheel axle nut, push down hard on the handlebar(s) several times and check if the front fork rebounds smooth- 6. Install: • Front brake caliper • Front brake hose holder “1” Front brake caliper bolt 2.
Page 155 REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel 31 Nm (3.1 m kgf, 22 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) •...
Page 156 REAR WHEEL Removing the rear brake disc and rear wheel sprocket 23 Nm (2.3 m kgf, 17 ft Ibf) • • 68 Nm (6.8 m kgf, 49 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • •...
Page 157 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing (right) Wheel bearing (left) Spacer 4-26...
Page 158 REAR WHEEL • Wheel bearings EAS30156 REMOVING THE REAR WHEEL Refer to “DISASSEMBLING THE FRONT 1. Stand the vehicle on a level surface. WHEEL” on page 4-20. EWA13120 WARNING EAS30159 CHECKING THE REAR WHEEL Securely support the vehicle so that there is 1.
Page 159 REAR WHEEL ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ b. Correct 1. Drive chain roller EAS30163 ASSEMBLING THE REAR WHEEL 2. Rear wheel sprocket 1. Install: 2. Replace: • Wheel bearings •...
Page 160 REAR WHEEL 2. Install: • Rear wheel sprocket Refer to “CHECKING AND REPLACING THE REAR WHEEL SPROCKET” on page 4-27. 3. Check: • Rear brake disc Refer to “CHECKING THE REAR BRAKE DISC” on page 4-48. 4. Lubricate: • Oil seal lips 6.
Page 161 FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 35 Nm (3.5 m kgf, 25 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Front brake caliper bolt Front brake caliper Brake pad clip Brake pad pin...
Page 162 FRONT BRAKE Removing the front brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 163: Front Brake
FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body 4-32...
Page 164 FRONT BRAKE Removing the front brake caliper 35 Nm (3.5 m kgf, 25 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
Page 165 FRONT BRAKE Disassembling the front brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake pad clip Brake pad pin Brake pad (inner) Brake pad (outer) Brake pad spring Front brake caliper bracket Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal...
Page 166 FRONT BRAKE e. Measure the deflection 1.5 mm (0.06 in) be- EAS30168 INTRODUCTION low the edge of the brake disc. EWA14101 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary.
Page 167 FRONT BRAKE d. Measure the brake disc deflection. A. Inner e. If out of specification, repeat the adjustment B. Outer steps until the brake disc deflection is within 2. Install: specification. • Brake pad spring f. If the brake disc deflection cannot be brought •...
Page 168 FRONT BRAKE d. Install a new brake pad spring and new brake pads. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • Brake pad pin • Brake pad clips •...
Page 169 FRONT BRAKE • Whenever a brake caliper is disassembled, EAS30173 CHECKING THE FRONT BRAKE CALIPER replace the brake caliper piston dust seals Recommended brake component and brake caliper piston seals. replacement schedule Brake pads If necessary Specified brake fluid DOT 4 Piston seals Every two years Piston dust seals...
Page 170 FRONT BRAKE 4. Fill: EAS30179 REMOVING THE FRONT BRAKE MASTER • Brake master cylinder reservoir CYLINDER (with the specified amount of the specified brake fluid) Before removing the front brake master cylinder, Specified brake fluid drain the brake fluid from the entire brake sys- DOT 4 tem.
Page 171 FRONT BRAKE 4. Check: • Brake hose Cracks/damage/wear → Replace. EAS30181 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER EWA13520 WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. 2. Install: •...
Page 172 FRONT BRAKE 75–85˚ 3. Fill: 6. Check: • Brake master cylinder reservoir • Brake lever operation Soft or spongy feeling → Bleed the brake sys- (with the specified amount of the specified brake fluid) tem. Refer to “BLEEDING THE HYDRAULIC Specified brake fluid BRAKE SYSTEM”...
Page 173 REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake pad pin Rear brake caliper bolt Brake pad (inner) Brake pad shim (inner) Brake pad (outer)
Page 174 REAR BRAKE Removing the rear brake master cylinder 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...
Page 175 REAR BRAKE Removing the rear brake master cylinder 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...
Page 176 REAR BRAKE Disassembling the rear brake master cylinder 17 Nm (1.7 m kgf, 12 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake master cylinder joint Brake master cylinder kit Hose joint Brake master cylinder body 4-45...
Page 177 REAR BRAKE Removing the rear brake caliper 29 Nm (2.9 m kgf, 21 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
Page 178 REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake pad spring Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Brake caliper bleed screw Spacer 4-47...
Page 179 REAR BRAKE EAS30183 INTRODUCTION Brake disc thickness limit EWA14101 4.0 mm (0.16 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •...
Page 180 REAR BRAKE The longer tangs “a” of the brake pad spring must point in the direction of the brake caliper piston. A. Inner B. Outer 2. Install: • Brake pad shims (onto the brake pads) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲...
Page 181 REAR BRAKE Refer to “BLEEDING THE HYDRAULIC • Never try to pry out the brake caliper pis- BRAKE SYSTEM” on page 3-14. ton. EAS30186 REMOVING THE REAR BRAKE CALIPER Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1.
Page 182 REAR BRAKE • Rear brake caliper “1” Refer to “REPLACING THE REAR BRAKE PADS” on page 4-48. • Brake hose gaskets “2” • Brake hose “3” • Rear brake hose union bolt “4” Rear brake caliper bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) Rear brake hose union bolt (brake caliper side) 2.
Page 183 REAR BRAKE EWA13090 WARNING To collect any remaining brake fluid, place a • Use only the designated brake fluid. Other container under the master cylinder and the end brake fluids may cause the rubber seals to of the brake hose. deteriorate, causing leakage and poor brake performance.
Page 184 REAR BRAKE 2. Install: EAS30195 ASSEMBLING THE REAR BRAKE MASTER • Brake hose “1” CYLINDER • Brake hose gaskets “2” EWA13520 WARNING • Brake hose union bolt “3” • Before installation, all internal brake com- Rear brake hose union bolt (mas- ponents should be cleaned and lubricated ter cylinder side) with clean or new brake fluid.
Page 185 REAR BRAKE ECA13540 NOTICE Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-14. 5. Check: • Brake fluid level Below the minimum level mark “a”...
Page 186 HANDLEBARS EAS20033 HANDLEBARS Removing the handlebar (right) 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 21 Nm (2.1 m kgf, 15 ft Ibf) •...
Page 187 HANDLEBARS Removing the handlebar (left) 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 21 Nm (2.1 m kgf, 15 ft Ibf) •...
Page 188 HANDLEBARS EAS30203 REMOVING THE HANDLEBARS Fit the projection “a” on each handlebar weight 1. Stand the vehicle on a level surface. into the hole “b” in the handlebar. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2.
Page 189 HANDLEBARS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply a thin coat of rubber adhesive onto the end of the left handlebar. b. Slide the handlebar grip over the end of the left handlebar.
Page 190 HANDLEBARS • Align the mating surfaces of the front brake master cylinder holder with the punch mark “b” on the handlebar (right), or install the front brake master cylinder so that the distance “c” between the bottom of the handlebar (right) and the bottom of the front brake master cylin- der is 11 mm (0.43 in) as shown in the illustra- tion.
Page 191 HANDLEBARS 11.Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-12. Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) 12.Adjust: • Throttle grip free play Refer to “CHECKING THE THROTTLE GRIP OPERATION” on page 3-26. Throttle grip free play 3.0–5.0 mm (0.12–0.20 in) 4-60...
Page 192 FRONT FORK EAS20034 FRONT FORK Removing the front fork legs 30 Nm (3.0 m kgf, 22 ft Ibf) • • 21 Nm (2.1 m kgf, 15 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf)
Page 193 FRONT FORK Disassembling the front fork legs 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Protector Front fork cap bolt O-ring Spacer Spring seat Fork spring...
Page 194 FRONT FORK Disassembling the front fork legs 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Damper rod Damper rod ring Rebound spring Inner tube Oil seal Washer Outer tube bushing Inner tube bushing Oil flow stopper Spring Outer tube...
Page 195 FRONT FORK EAS30206 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2.
Page 196 FRONT FORK 4. Remove: • Inner tube ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Hold the front fork leg horizontally. b. Securely clamp the brake caliper bracket in a vise with soft jaws.
Page 197 ▲ ▲▲▲ ▲ ▲▲▲ 2. Lubricate: • Inner tube’s outer surface Recommended oil Yamaha fork oil 10WT b. Install the damper rod ring onto the damper rod. 3. Install: • Inner tube (in the outer tube) Fit the damper rod ring into the damper rod 4.
Page 198 FRONT FORK 6. Install: • Outer tube bushing “1” • Washer “2” (with the fork seal driver attachment “3” and fork seal driver weight “4”) Fork seal driver weight 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø41) 90890-01381 Replacement 41 mm YM-A5142-2 8.
Page 199 FRONT FORK 1. Install: Level • Front fork leg “1” 121.0 mm (4.8 in) Temporarily tighten the lower bracket pinch bolt. • While filling the front fork leg, keep it upright. Make sure the inner tube end is flush with the top •...
Page 200 FRONT FORK 4-69...
Page 201 STEERING HEAD EAS20035 STEERING HEAD Removing the upper bracket and lower bracket 95 Nm (9.5 m kgf, 69 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 1st 48 Nm (4.8 m kgf, 35 ft Ibf) •...
Page 202 STEERING HEAD Removing the upper bracket and lower bracket 95 Nm (9.5 m kgf, 69 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 1st 48 Nm (4.8 m kgf, 35 ft Ibf) • • 2nd 18 Nm (1.8 m kgf, 13 ft Ibf)
Page 203: Steering Head
STEERING HEAD ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ EAS30213 REMOVING THE LOWER BRACKET a. Remove the bearing races from the steering 1. Stand the vehicle on a level surface. head pipe “1”...
Page 204 STEERING HEAD Recommended lubricant Lithium-soap-based grease 2. Install: • Lower ring nut “1” • Rubber washer “2” • Upper ring nut “3” • Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-19. 3. Install: • Cable guide (right) “1” •...
Page 205 SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY EAS20197 SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY Removing the swingarm and rear shock absorber assembly 58 Nm (5.8 m kgf, 42 ft Ibf) • • 115 Nm (11.5 m kgf, 83 ft lbf) • •...
Page 206 SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY Removing the swingarm and rear shock absorber assembly 58 Nm (5.8 m kgf, 42 ft Ibf) • • 115 Nm (11.5 m kgf, 83 ft lbf) • • 58 Nm (5.8 m kgf, 42 ft Ibf) •...
Page 207 SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY If the swingarm vertical movement is not EAS31304 REMOVING THE REAR SHOCK ABSORBER smooth or if there is binding, check the pivot ASSEMBLY shaft, spacer, bearings, and dust covers. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is...
Page 208 SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY • Bearings “3” Damage/pitting → Replace. 4. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN EAS31308 INSTALLING THE SWINGARM SLACK” on page 3-17. 1. Lubricate: Drive chain slack • Spacer 35.0–45.0 mm (1.38–1.77 in) •...
Page 209 SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4-78...
Page 210 CHAIN DRIVE EAS20038 CHAIN DRIVE Removing the drive sprocket and drive chain 75 Nm (7.5 m kgf, 54 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (3)” on page Front side cowling assembly (left) 4-5.
Page 211 CHAIN DRIVE EAS30229 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated.
Page 212 CHAIN DRIVE EAS30231 CHECKING THE DRIVE SPROCKET 1. Check: • Drive sprocket More than 1/4 tooth “a” wear → Replace the drive chain sprocket, drive chain, and rear wheel sprocket as a set. Bent teeth → Replace the drive chain sprock- et, drive chain, and rear wheel sprocket as a set.
Page 213 CHAIN DRIVE EAS30234 INSTALLING THE DRIVE CHAIN 1. Install: • Drive chain • Drive chain guide • Drive sprocket cover Route the gear position switch lead, oil pressure switch lead, and fuel tank breather hose through the guide on the drive sprocket cover. Refer to “CABLE ROUTING”...
Page 214 CHAIN DRIVE 4-83...
Page 215 ENGINE ENGINE INSPECTION ..................5-1 MEASURE THE COMPRESSION PRESSURE........5-1 ENGINE REMOVAL ..................5-3 INSTALLING THE ENGINE............... 5-8 ASSEMBLING THE MUFFLER ..............5-9 INSTALLING THE EXHAUST PIPE AND MUFFLER ASSEMBLY ...5-9 CAMSHAFTS....................5-11 REMOVING THE CAMSHAFTS..............5-13 CHECKING THE CAMSHAFTS ..............5-14 CHECKING THE CAMSHAFT SPROCKETS .........5-15 CHECKING THE TIMING CHAIN TENSIONER........
Page 216 ELECTRIC STARTER ...................5-45 CHECKING THE STARTER MOTOR .............5-47 ASSEMBLING THE STARTER MOTOR..........5-48 INSTALLING THE STARTER MOTOR ...........5-48 CLUTCH ......................5-49 REMOVING THE CLUTCH ..............5-52 CHECKING THE FRICTION PLATES.............5-52 CHECKING THE CLUTCH PLATES ............5-53 CHECKING THE CLUTCH SPRINGS.............5-53 CHECKING THE CLUTCH HOUSING ............5-53 CHECKING THE CLUTCH BOSS............
Page 217 CRANKSHAFT AND BALANCER SHAFT ...........5-77 REMOVING THE BALANCER SHAFT JOURNAL BEARINGS ....5-78 REMOVING THE CRANKSHAFT JOURNAL BEARINGS ......5-78 REMOVING THE CONNECTING RODS ..........5-78 CHECKING THE BALANCER SHAFT ASSEMBLY........5-78 CHECKING THE CRANKSHAFT ............5-80 CHECKING THE CONNECTING RODS..........5-81 INSTALLING THE CONNECTING RODS..........
Page 218 ENGINE INSPECTION EAS20041 ENGINE INSPECTION Extension 90890-04136 EAS30249 Compression gauge MEASURE THE COMPRESSION PRESSURE 90890-03081 The following procedure applies to all of the cyl- Engine compression tester inders. YU-33223 Insufficient compression pressure will result in a loss of performance. 1. Measure: •...
Page 219 ENGINE INSPECTION Compression pressure (with oil applied into the cylinder) Reading Diagnosis Piston ring(s) wear or Higher than without oil damage → Repair. Pistons, valves, cylinder head gasket or piston Same as without oil ring(s) possibly defec- tive → Repair. ▲...
Page 220 ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the muffler and exhaust pipe 25 Nm (2.5 m kgf, 18 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • •...
Page 221 ENGINE REMOVAL Removing the muffler and exhaust pipe 25 Nm (2.5 m kgf, 18 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...
Page 222 ENGINE REMOVAL Disconnecting the leads and cable 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Fuel tank cover assembly/Front side cowling as-...
Page 223 ENGINE REMOVAL Disconnecting the leads and cable 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Gear position switch coupler...
Page 224 ENGINE REMOVAL Removing the engine 68 Nm (6.8 m kgf, 49 ft Ibf) • • 68 Nm (6.8 m kgf, 49 ft Ibf) • • 68 Nm (6.8 m kgf, 49 ft Ibf) • • 66 Nm (6.6 m kgf, 48 ft Ibf) •...
Page 225 ENGINE REMOVAL EAS30251 INSTALLING THE ENGINE Engine mounting nut (rear upper 1. Install: side) • Plates “1” 68 Nm (6.8 m·kgf, 49 ft·lbf) (to the engine) Sidestand bolt 66 Nm (6.6 m·kgf, 48 ft·lbf) • Engine “2” Engine mounting nut (rear lower •...
Page 226 ENGINE REMOVAL 2. Install: • Exhaust pipe “2” • Exhaust pipe nuts “3” • Exhaust pipe bolt “4” Temporarily tighten the bolt and nuts. 3. Tighten: • Exhaust pipe nuts “3” • Exhaust pipe bolt “4” Exhaust pipe nut EAS31309 15 Nm (1.5 m·kgf, 11 ft·lbf) ASSEMBLING THE MUFFLER Exhaust pipe bolt...
Page 227 ENGINE REMOVAL Exhaust pipe protector bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) LOCTITE® 5-10...
Page 228 CAMSHAFTS EAS20043 CAMSHAFTS 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) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)”...
Page 229 CAMSHAFTS Removing the camshafts 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.5 m kgf, 11 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) 2.0 Nm (0.20 m kgf, 1.4 ft...
Page 230 CAMSHAFTS EAS30256 REMOVING THE CAMSHAFTS When the alignment mark “e” on the intake cam- 1. Remove: shaft sprocket and the alignment mark “f” on the • Crankshaft end cover “1” exhaust camshaft sprocket are aligned with the • Timing mark accessing bolt “2” edge “g”...
Page 231 CAMSHAFTS EAS30257 CHECKING THE CAMSHAFTS 1. Check: • Camshaft lobes Blue discoloration/pitting/scratches → Re- place the camshaft. 2. Measure: • Camshaft lobe dimensions “a” and “b” Out of specification → Replace the camshaft. Camshaft lobe dimensions 5. Remove: Lobe height (Intake) •...
Page 232 CAMSHAFTS Camshaft runout limit 0.030 mm (0.0012 in) d. Remove the camshaft caps, and then mea- sure the width of the Plastigauge® “1”. 4. Measure: • Camshaft-journal-to-camshaft-cap clearance Out of specification → Measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance 0.028–0.062 mm (0.0011–0.0024 ▲...
Page 233 CAMSHAFTS a. 1/4 tooth ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ b. Correct EAS30269 INSTALLING THE CAMSHAFTS 1. Timing chain 1. Align: 2. Camshaft sprocket • Marks “a” on the generator rotor EAS30266 (with the slots “b”...
Page 234 CAMSHAFTS Camshaft sprocket bolt The exhaust camshaft is identified by the groove 20 Nm (2.0 m·kgf, 14 ft·lbf) “a” in the portion of the camshaft shown in the il- lustration. ECA19980 NOTICE Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine.
Page 235 CAMSHAFTS Tighten the camshaft cap bolts in the tightening sequence as shown. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Install: • Dwell pins • Exhaust camshaft cap “1” 6.
Page 236 CAMSHAFTS c. Tighten the timing chain tensioner bolts to Refer to the installation steps above. specification. • Timing chain guide Make sure that the timing chain guide and Timing chain tensioner bolt timing chain are positioned correctly. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) d.
Page 237 CAMSHAFTS EAS30274 INSTALLING THE CYLINDER HEAD COVER 1. Install: • Cylinder head cover gasket “1” (to the cylinder head cover “2”) After installing the cylinder head cover gasket to the cylinder head cover, cut off the “a” section. 5-20...
Page 238 CYLINDER HEAD EAS20044 CYLINDER HEAD Removing the cylinder head 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • *3rd 12 Nm (1.2 m kgf, 8.7 ft Ibf)
Page 239 CYLINDER HEAD Removing the cylinder head 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) *3rd...
Page 240 CYLINDER HEAD Removing the cylinder head 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) *3rd...
Page 241 CYLINDER HEAD • Cylinder head water jacket EAS30276 REMOVING THE CYLINDER HEAD Mineral deposits/rust → Eliminate. 1. Remove: 3. Measure: • Cylinder head bolt (M6) (×2) • Cylinder head warpage • Cylinder head bolt (M10) (×6) Out of specification → Resurface the cylinder head.
Page 242 CYLINDER HEAD • Align the projection “c” on the engine mounting bolt cap with the portion “d” of the front cowling Tighten the cylinder head bolts in the tightening assembly stay. sequence as shown and torque them in 3 stag- ×2 ×6 2.
Page 243 VALVES AND VALVE SPRINGS EAS20045 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-21. Valve lifter Valve pad Valve cotter Valve spring retainer Valve spring Intake valve Exhaust valve Valve stem seal...
Page 244 VALVES AND VALVE SPRINGS EAS30283 REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “1” and the valve spring compressor attachment “2”.
Page 245 VALVES AND VALVE SPRINGS 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide. • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) b. Install the new valve guide with the valve 0.010–0.037 mm (0.0004–0.0015 guide installer “2”...
Page 246 VALVES AND VALVE SPRINGS 2. Check: Valve guide remover (ø4.5) • Valve seat 90890-04116 Pitting/wear → Replace the cylinder head. Valve guide remover (4.5 mm) 3. Measure: YM-04116 • Valve seat width “a” Valve guide installer (ø4.5) Out of specification → Replace the cylinder 90890-04117 head.
Page 247 VALVES AND VALVE SPRINGS After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 248 VALVES AND VALVE SPRINGS 2. Measure: EAS30287 CHECKING THE VALVE LIFTERS • Compressed valve spring force “a” Out of specification → Replace the valve The following procedure applies to all of the valve lifters. spring. 1. Check: Installed compression spring •...
Page 249 VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019 Valve spring compressor YM-04019 Valve spring compressor attach- ment 90890-04108 Valve spring compressor adapt- er 22 mm YM-04108 4. Install: • Valve spring seat “1” (into the cylinder head) • Valve stem seal “2” •...
Page 250 VALVES AND VALVE SPRINGS • The valve lifter must move smoothly when ro- tated with a finger. • Each valve lifter and valve pad must be rein- stalled in their original position. 5-33...
Page 251 CYLINDER AND PISTONS EAS20046 CYLINDER AND PISTONS Removing the cylinder and pistons Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-21. Cylinder Cylinder gasket Dowel pin Piston pin clip Piston pin Piston Top ring 2nd ring Oil ring 5-34...
Page 252 CYLINDER AND PISTONS • Oil ring EAS30289 REMOVING THE PISTONS The following procedure applies to both of the When removing a piston ring, open the end gap pistons. with your fingers and lift the other side of the ring 1. Remove: over the piston crown.
Page 253 CYLINDER AND PISTONS 1. Measure: • Piston ring side clearance Out of specification → Replace the piston and piston rings as a set. Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring b.
Page 254 CYLINDER AND PISTONS Piston ring Top ring End gap (installed) 0.10–0.25 mm (0.0039–0.0098 Limit 0.40 mm (0.0157 in) 2nd ring End gap (installed) 0.30–0.45 mm (0.0118–0.0177 3. Measure: Limit • Piston pin bore diameter “b” 0.60 mm (0.0236 in) Out of specification → Replace the piston. Oil ring End gap (installed) Piston pin bore inside diameter...
Page 255 CYLINDER AND PISTONS • Install the oil ring expander as shown in the il- lustration. • Be sure to install the piston rings so that the manufacturer marks “a” face up. 3. Lubricate: • Piston • Piston rings • Cylinder (with the recommended lubricant) 2.
Page 256 CYLINDER AND PISTONS 5-39...
Page 257 GENERATOR AND STARTER CLUTCH EAS20140 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • 60 Nm (6.0 m kgf, 43 ft Ibf) •...
Page 258 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • 60 Nm (6.0 m kgf, 43 ft Ibf) •...
Page 259 GENERATOR AND STARTER CLUTCH • Generator rotor “2” EAS30867 REMOVING THE GENERATOR • Starter clutch “3” 1. Remove: • Generator rotor bolt “1” • While holding the generator rotor with the rotor • Washer holding tool “4”, loosen the starter clutch bolts. •...
Page 260 GENERATOR AND STARTER CLUTCH • Starter clutch gear Burrs/chips/roughness/wear → Replace the defective part(s). 3. Check: • Starter clutch gear contact surfaces Damage/pitting/wear → Replace the starter clutch gear. 4. Check: • Starter clutch operation ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼...
Page 261 • Sealant 1. Install: (onto the stator coil lead grommet) • Woodruff key • Generator rotor assembly Yamaha bond No. 1215 • Washer “1” 90890-85505 • Generator rotor bolt (Three bond No.1215®) • Clean the tapered portion of the crankshaft and the generator rotor hub.
Page 262 ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1.
Page 263 ELECTRIC STARTER Disassembling the starter motor 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Starter motor front cover...
Page 264 ELECTRIC STARTER ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ EAS30325 CHECKING THE STARTER MOTOR a. Measure the armature assembly resistances 1. Check: with the digital circuit tester. • Commutator Dirt →...
Page 265 ELECTRIC STARTER Brush spring force Starter motor bolt 6.08–9.12 N (620–930 gf, 21.89– 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 32.83 oz) Starter motor lead screw 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Install the engine ground lead terminal so that the crimped section “a” of the terminal that se- cures the ground leads is facing forward.
Page 266 CLUTCH EAS20055 CLUTCH Removing the clutch cover and pull lever shaft 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • •...
Page 267 CLUTCH Removing the clutch cover and pull lever shaft 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • Order Job/Parts to remove Q’ty Remarks...
Page 268 CLUTCH Removing the clutch 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 100 Nm (10 m kgf, 72 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Compression spring Pressure plate Pull rod Bearing Friction plate 1 Clutch plate Friction plate 2 Clutch boss nut...
Page 269 CLUTCH 5. Loosen: EAS30346 REMOVING THE CLUTCH • Clutch boss nut “1” 1. Remove: • Clutch cover “1” While holding the clutch boss “2” with the univer- • Clutch cover gasket sal clutch holder “3”, loosen the clutch boss nut. Loosen each bolt 1/4 of a turn at a time, in stag- Universal clutch holder es and in a crisscross pattern.
Page 270 CLUTCH 2. Measure: • Clutch spring free length “a” Out of specification → Replace the clutch springs as a set. Clutch spring free length 49.80 mm (1.96 in) Limit 47.30 mm (1.86 in) A. Friction plate 1 B. Friction plate 2 EAS30349 CHECKING THE CLUTCH PLATES The following procedure applies to all of the...
Page 271 CLUTCH Excessive noise during operation → Replace the crankshaft and clutch housing as a set. EAS30357 CHECKING THE PRIMARY DRIVEN GEAR 1. Check: • Primary driven gear “1” Damage/wear → Replace the clutch housing and crankshaft as a set. Excessive noise during operation → Replace the clutch housing and crankshaft as a set.
Page 272 CLUTCH Clutch boss nut 100 Nm (10 m·kgf, 72 ft·lbf) • Lubricate the lock washer and clutch boss nut threads with engine oil. • While holding the clutch boss with the univer- sal clutch holder “3”, tighten the clutch boss nut.
Page 273 CLUTCH 6. Connect: 5. Install: • Clutch cable “1” • Dowel pins “1” • Clutch cover gasket “2” • Install the clutch cable so that the clutch cable • Clutch cover “3” length “a” is 52.6–64.1 mm (2.07–2.52 in) as •...
Page 274 SHIFT SHAFT EAS20057 SHIFT SHAFT Removing the shift pedal 30 Nm (3.0 m kgf, 22 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...
Page 275 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kgf, 16 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (2)” on page Side panel (right) 4-3. Refer to “GENERAL CHASSIS (3)” on page Front side cowling assemblies 4-5.
Page 276 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kgf, 16 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil seal Bearing 5-59...
Page 277 SHIFT SHAFT EAS30377 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft “1” Bends/damage/wear → Replace. • Shift shaft spring “2” Damage/wear → Replace. 2. Install: • Stopper lever • Collar • Shift shaft spring stopper • Stopper lever spring •...
Page 278 SHIFT SHAFT Align the match mark “a” of the shift shaft with the punch mark “b” of the shift arm. c. Tighten both locknuts. The shift rod locknut (shift pedal side) has left- hand threads. 2. Measure: • Installed shift rod length “a” Shift rod locknut (shift arm side) Incorrect →...
Page 279 OIL PUMP EAS20054 OIL PUMP Removing the oil pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (2)” on page Side panel (right) 4-3. Refer to “GENERAL CHASSIS (3)” on page Front side cowling assembly (right) 4-5.
Page 280 OIL PUMP Disassembling the oil pump 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil pump cover Oil pump driven gear Oil pump rotor assembly Oil pump inner rotor Oil pump outer rotor Hold down the washer when removing the Circlip circlip.
Page 281 OIL PUMP 3. Check: EAS31312 CHECKING THE OIL PUMP IDLE GEAR • Oil pump operation 1. Check: Rough movement → Repeat steps (1) and • Oil pump drive gear (2) or replace the defective part(s). Damage/wear → Replace the oil pump idle gear, oil pump driven gear and clutch housing as a set.
Page 282 OIL PUMP • Oil pump cover screw “6” Oil pump cover screw 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) Align the pin in the oil pump shaft with the grooves “a” in the inner rotor. 4. Check: • Oil pump operation Refer to “CHECKING THE OIL PUMP”...
Page 283 OIL PAN EAS20177 OIL PAN Removing the oil pan 20 Nm (2.0 m kgf, 14 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • (11) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty...
Page 284 OIL PAN 3. Install: EAS31069 CHECKING THE OIL STRAINER • Gasket “1” 1. Check: • Engine oil drain bolt “2” • Oil strainer Damage → Replace. Engine oil drain bolt Contaminants → Clean with solvent. 20 Nm (2.0 m·kgf, 14 ft·lbf) EAS31070 INSTALLING THE OIL PAN 1.
Page 285 CRANKCASE EAS20059 CRANKCASE Removing the crankcase breather cover and switches 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 70 Nm (7.0 m kgf, 51 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf)
Page 286 CRANKCASE Removing the crankcase breather cover and switches 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 70 Nm (7.0 m kgf, 51 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) •...
Page 287 CRANKCASE Separating the crankcase 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 288 CRANKCASE • M6 × 65 mm bolt (×3) (bolts with copper EAS30389 DISASSEMBLING THE CRANKCASE washers): “4”, “5”, “9” 1. Remove: • M6 × 65 mm bolt (×3): “6”, “10”, “11” • Oil filter cartridge “1” • M8 × 50 mm bolt (×2): “14”, “15” •...
Page 289 • Sealant mating surfaces. Work slowly and carefully (onto the crankcase mating surfaces) and make sure the crankcase halves sepa- rate evenly. Yamaha bond No. 1215 90890-85505 EAS31378 (Three bond No.1215®) CHECKING THE BALANCER DRIVE GEAR 1. Check: ECA20880 •...
Page 290 ×3 ×3 • Lubricate the mating surface of the bolt “16” with engine oil and apply Yamaha bond No. 1215 to the bolt threads. • Finger tighten the crankcase bolts. Yamaha bond No. 1215 90890-85505 (Three bond No.1215®)
Page 291 CRANKCASE Crankcase bolts “1”–“6” 1st: 20 Nm (2.0 m·kgf, 14 ft·lbf) *2nd: 24 Nm (2.4 m·kgf, 17 ft·lbf) Crankcase bolts “7”–“8” ×2 1st: 20 Nm (2.0 m·kgf, 14 ft·lbf) *2nd: 26 Nm (2.6 m·kgf, 19 ft·lbf) * Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque.
Page 292 CRANKCASE 10.Install: 11.Install: • Timing chain guide (lower side) • Holder (O2 sensor lead, gear position switch • Timing chain sprocket lead and crankshaft position sensor lead) “1” • Timing chain • Holder (O sensor lead) “2” • Primary drive gear “1” •...
Page 293 CRANKCASE Install the oil pressure switch lead terminal with the lead routed upward. 2. Install: • O-ring “1” • Gear position switch “2” Gear position switch screw 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) LOCTITE® • Lubricate the O-ring with lithium-soap-based grease.
Page 294 CRANKSHAFT AND BALANCER SHAFT EAS20178 CRANKSHAFT AND BALANCER SHAFT Removing the crankshaft, connecting rod and balancer shaft 1st 15 Nm (1.5 m kgf, 11 ft lbf) • • 2nd Specified angle 145–155˚ Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE”...
Page 295 CRANKSHAFT AND BALANCER SHAFT 2. Measure: EAS31072 REMOVING THE BALANCER SHAFT • Balancer shaft runout JOURNAL BEARINGS Out of specification → Replace the balancer 1. Remove: shaft assembly. • Balancer shaft journal lower bearings (from the lower crankcase) Balancer shaft runout limit •...
Page 296 CRANKSHAFT AND BALANCER SHAFT g. Measure the compressed Plastigauge® width “e” on each balancer shaft journal. Align the projections “a” on the balancer shaft If the balancer shaft-journal-to-balancer journal lower bearings with the notches “b” in the shaft-journal-bearing clearance is out of lower crankcase.
Page 297 CRANKSHAFT AND BALANCER SHAFT Journal oil clearance 0.021–0.045 mm (0.0008–0.0018 ECA13920 NOTICE Do not interchange the crankshaft journal bearings. To obtain the correct crankshaft- journal-to-crankshaft-journal-bearing clear- ance and prevent engine damage, the crank- For example, if the crankcase J and balanc- shaft journal bearings must be installed in their original positions.
Page 298 CRANKSHAFT AND BALANCER SHAFT • Align the projections “c” of the crankshaft jour- nal upper bearings with the notches “d” in the upper crankcase. • Do not move the crankshaft until the clearance measurement has been completed. e. Tighten the bolts to specification in the proper tightening sequence.
Page 299 CRANKSHAFT AND BALANCER SHAFT ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ • Make sure the characters “d” on both the con- The following procedure applies to both of the necting rod and connecting rod cap are connecting rods.
Page 300 CRANKSHAFT AND BALANCER SHAFT • Big end bearings • Connecting rod inner surface (with the recommended lubricant) Recommended lubricant Engine oil 3. Install: • Big end bearings • Connecting rods • Connecting rod caps (onto the crankshaft pins) P1 P2 •...
Page 301 CRANKSHAFT AND BALANCER SHAFT ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ ECA19930 NOTICE EWA13390 WARNING • Do not use a torque wrench to tighten the • Replace the connecting rod bolts and nuts connecting rod nut to the specified angle.
Page 302 CRANKSHAFT AND BALANCER SHAFT EAS31078 INSTALLING THE BALANCER SHAFT ASSEMBLY 1. Install: • Balancer shaft journal upper bearings (into the upper crankcase) • Balancer shaft journal lower bearings (into the lower crankcase) • Align the projections “a” on the balancer shaft journal bearings “1”...
Page 303 TRANSMISSION EAS20062 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE”...
Page 304 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Shift fork “C” Shift drum assembly Oil pump idle gear shaft 5-87...
Page 305 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear 6th pinion gear 3rd pinion gear Circlip Washer 5th pinion gear Circlip Bearing Main axle 5-88...
Page 306 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Washer 1st wheel gear Collar Washer 5th wheel gear Circlip Washer 4th wheel gear 3rd wheel gear 6th wheel gear Circlip Washer 2nd wheel gear Bearing Drive axle 5-89...
Page 307 TRANSMISSION EAS30431 EAS30432 CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY The following procedure applies to all of the shift 1. Check: forks. • Shift drum groove Damage/scratches/wear → Replace the shift 1. Check: • Shift fork cam follower “1” drum assembly.
Page 308 TRANSMISSION 3. Check: 2. Install: • Transmission gears • Circlip “1” Blue discoloration/pitting/wear → Replace the defective gear(s). Align the opening between the ends “a” of the • Transmission gear dogs circlip with a groove “b” in the axle. Cracks/damage/rounded edges → Replace the defective gear(s).
Page 309 TRANSMISSION Shift fork guide bar retainer bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® • The embossed marks on the shift forks should face towards the right side of the engine. • Install the shift fork guide bar retainers with the “OUT”...
Page 310 TRANSMISSION 5-93...
Page 311 COOLING SYSTEM RADIATOR ...................... 6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR..............6-3 THERMOSTAT ....................6-4 CHECKING THE THERMOSTAT.............. 6-5 INSTALLING THE THERMOSTAT............6-5 WATER PUMP....................6-6 DISASSEMBLING THE WATER PUMP............ 6-8 CHECKING THE WATER PUMP .............. 6-8 ASSEMBLING THE WATER PUMP............6-8 INSTALLING THE CLUTCH COVER ............6-9...
Page 312 RADIATOR EAS20063 RADIATOR Removing the radiator 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 2 Nm (0.2 m kg, 1.4 ft • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...
Page 313 RADIATOR Removing the radiator 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 2 Nm (0.2 m kg, 1.4 ft • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...
Page 314 RADIATOR EAS30439 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.
Page 315 THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 17 Nm (1.7 m kgf, 12 ft Ibf) • • • • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)”...
Page 316 THERMOSTAT 2. Check: EAS30443 CHECKING THE THERMOSTAT • Thermostat cover 1. Check: Cracks/damage → Replace. • Thermostat Does not open at 80.5–83.5 °C (176.90– EAS30939 INSTALLING THE THERMOSTAT 182.30 °F) → Replace. 1. Install: • Thermostat “1” (to the thermostat cover) •...
Page 317 WATER PUMP EAS20066 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) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) •...
Page 318 WATER PUMP Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) •...
Page 319 WATER PUMP EAS30446 DISASSEMBLING THE WATER PUMP 1. Remove: • Mechanical seal assembly “1” Remove the mechanical seal assembly from the inside of the clutch cover “2”. 3. Mechanical seal installer 4. Middle driven shaft bearing driver A. Push down EAS30447 CHECKING THE WATER PUMP 1.
Page 320 WATER PUMP 2. Connect: EAS31117 • Clutch cable “1” INSTALLING THE CLUTCH COVER 1. Install: Clutch cable locknut • Dowel pins “1” 7 Nm (0.7 m·kgf, 5.1 ft·lbf) • Clutch cover gasket “2” • Clutch cover “3” • O sensor lead holder •...
Page 321 WATER PUMP 4. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-24. 5. Check: • Cooling system Leaks → Repair or replace the faulty part. 6. Measure: • Radiator cap opening pressure Below the specified pressure →...
Page 322 WATER PUMP 6-11...
Page 323 FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-3 REMOVING THE FUEL PUMP ..............7-3 REMOVING THE FUEL FILTER ............... 7-3 CHECKING THE FUEL PUMP BODY............7-4 CHECKING THE FUEL FILTER..............7-4 INSTALLING THE FUEL FILTER.............. 7-4 INSTALLING THE FUEL PUMP..............7-4 INSTALLING THE FUEL TANK..............7-5 THROTTLE BODIES ..................7-6 CHECKING THE INJECTORS (BEFORE REMOVING) ......
Page 324 FUEL TANK EAS20067 FUEL TANK Removing the fuel tank and fuel pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...
Page 325 FUEL TANK Removing the fuel tank and fuel pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 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) •...
Page 326: Fuel Tank
FUEL TANK EAS30450 ECA14720 REMOVING THE FUEL TANK NOTICE 1. Extract the fuel in the fuel tank through the • Do not drop the fuel pump or give it a fuel tank cap with a pump. strong shock. 2. Remove: •...
Page 327 FUEL TANK c. Install the fuel filter holder 2. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ d. Hook the projection “d” on fuel filter holder 1 EAS30454 onto the portion “e” of the fuel pump. CHECKING THE FUEL PUMP BODY 1.
Page 328 FUEL TANK • Tighten the fuel pump bolts in the proper tight- ening sequence as shown. EAS30457 INSTALLING THE FUEL TANK 1. Install: • Fuel hose ECA18420 NOTICE When installing the fuel hose, make sure that it is securely connected, and that the fuel hose connector cover on the fuel hose is in the correct position;...
Page 329 THROTTLE BODIES EAS20070 THROTTLE BODIES Removing the throttle bodies 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...
Page 330 THROTTLE BODIES Removing the fuel injectors and ISC valve 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks ISC (idle speed control) valve plate ISC (idle speed control) valve Spring Fuel rail...
Page 331 THROTTLE BODIES EAS30475 EAS30479 CHECKING THE INJECTORS (BEFORE CHECKING THE THROTTLE BODIES REMOVING) 1. Check: Before checking the throttle bodies, check the • Injectors following items: Use the diagnostic code numbers “36–37”. • Valve clearance Refer to “SELF-DIAGNOSTIC FUNCTION • Spark plugs AND DIAGNOSTIC CODE TABLE”...
Page 332 Remove the carbon deposits from the inside Recommended cleaning agent: of each throttle body in a downward direction, Yamaha oil & brake cleaner from the air filter case side of the throttle body to the engine side.
Page 333 THROTTLE BODIES ECA21230 NOTICE ISC (idle speed control) valve plate screw • Be sure to use the recommended cleaning 5 Nm (0.5 m·kgf, 3.6 ft·lbf) agent. • Do not spray the cleaning agent directly ECA21861 onto the ISC valve or throttle bodies and do NOTICE not immerse them in the cleaning agent.
Page 334 THROTTLE BODIES 3. Adjust: EAS30481 CHECKING THE INJECTOR PRESSURE • Throttle bodies synchronizing Out of specification → Replace the throttle • After installing the fuel injectors, perform the bodies. following steps to check the injector pressure. Refer to “SYNCHRONIZING THE THROT- •...
Page 335 THROTTLE BODIES Pressure drops → Check the pressure gauge c. Connect the pressure gauge “3” and adapter and adapter. “4” to the fuel hose “2”. Check the seals and O-rings, and then rein- Pressure gauge stall. 90890-03153 Replace the fuel injectors. Pressure gauge ▲...
Page 336 THROTTLE BODIES c. #1 cylinder d. #2 cylinder A. Left B. Right 7-13...
Page 337 THROTTLE BODIES 7-14...
Page 338: Air Induction System
AIR INDUCTION SYSTEM EAS20071 AIR INDUCTION SYSTEM 7-15...
Page 339 AIR INDUCTION SYSTEM 1. Air induction system hose (Air filter case to air cut-off valve) 2. Air cut-off valve 3. Air induction system hose (air cut-off valve to reed valve cover) 4. Reed valve assembly 5. Air filter case 7-16...
Page 340 AIR INDUCTION SYSTEM Removing the air cut-off valve and reed valve 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1.
Page 341 AIR INDUCTION SYSTEM 2. Check: EAS30488 CHECKING THE AIR INDUCTION SYSTEM • Reed valve • Reed valve stopper Air injection • Reed valve seat The air induction system burns unburned ex- Cracks/damage → Replace the reed valve haust gases by injecting fresh air (secondary air) assembly.
Page 342 AIR INDUCTION SYSTEM 7-19...
Page 343 TROUBLESHOOTING ................8-21 COOLING SYSTEM..................8-27 CIRCUIT DIAGRAM ................8-27 TROUBLESHOOTING ................8-29 FUEL INJECTION SYSTEM................8-31 CIRCUIT DIAGRAM ................8-31 ECU SELF-DIAGNOSTIC FUNCTION............8-33 TROUBLESHOOTING METHOD............8-33 YAMAHA DIAGNOSTIC TOOL ...............8-34 TROUBLESHOOTING DETAILS ............8-37 FUEL PUMP SYSTEM...................8-69 CIRCUIT DIAGRAM ................8-69 TROUBLESHOOTING ................8-71...
Page 344 ELECTRICAL COMPONENTS..............8-73 CHECKING THE SWITCHES ..............8-77 CHECKING THE BULBS AND BULB SOCKETS ........8-79 CHECKING THE FUSES ................8-81 REPLACING THE ECU (engine control unit) ..........8-81 REMOVING THE ECU (engine control unit) ...........8-81 INSTALLING THE ECU (engine control unit) ..........8-82 CHECKING AND CHARGING THE BATTERY........
Page 346 IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM...
Page 347 IGNITION SYSTEM 1. Main switch 2. Diode 1 3. Ignition fuse 5. Backup fuse 9. Crankshaft position sensor 11.Battery 12.Engine ground 13.Main fuse 17.Diode 3 27.Lean angle sensor 29.ECU (engine control unit) 30.Ignition coil #1 31.Spark plug 32.Ignition coil #2 51.Gear position switch 67.Handlebar switch (right) 70.Engine stop switch...
Page 348 IGNITION SYSTEM EAS30492 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Passenger seat 2. Center cover 3. Rider seat 4. Side covers 5. Fuel tank NG → 1. Check the fuses. (Ignition, backup, and main) Replace the fuse(s).
Page 349 IGNITION SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-77. OK ↓ NG → 9. Check the engine stop switch. • The engine stop switch is faulty. Refer to “CHECKING THE •...
Page 350: Electric Starting System
ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM...
Page 351 ELECTRIC STARTING SYSTEM 1. Main switch 2. Diode 1 3. Ignition fuse 5. Backup fuse 11.Battery 12.Engine ground 13.Main fuse 14.Starter relay 15.Starter motor 16.Diode 2 17.Diode 3 18.Starting circuit cut-off relay 19.Diode 4 29.ECU (engine control unit) 51.Gear position switch 53.Handlebar switch (left) 58.Clutch switch 67.Handlebar switch (right)
Page 352 ELECTRIC STARTING SYSTEM EAS30494 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
Page 353 ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Passenger seat 2. Center cover 3. Rider seat 4. Side covers 5. Fuel tank 6. Air filter case 7. Throttle bodies NG →...
Page 354 ELECTRIC STARTING SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-77. OK ↓ NG → 9. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch. POSITION SWITCH”...
Page 355 ELECTRIC STARTING SYSTEM 8-10...
Page 356 CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM 8-11...
Page 357 CHARGING SYSTEM 8. AC magneto 10.Rectifier/regulator 11.Battery 12.Engine ground 13.Main fuse A. Wire harness B. Negative battery sub-wire harness 8-12...
Page 358 CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Passenger seat 2. Center cover 3. Rider seat 4. Side cover (left) NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”...
Page 359 CHARGING SYSTEM 8-14...
Page 360 LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM 8-15...
Page 361 LIGHTING SYSTEM 1. Main switch 3. Ignition fuse 4. Signaling system fuse 5. Backup fuse 6. Headlight fuse 11.Battery 12.Engine ground 13.Main fuse 29.ECU (engine control unit) 39.Meter assembly 47.High beam indicator light 49.Meter light 53.Handlebar switch (left) 54.Pass switch 55.Dimmer switch 64.Headlight (right) 65.Headlight (left)
Page 362 LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light, auxiliary light or meter light. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Mudguard assembly cover 3.
Page 363 LIGHTING SYSTEM NG → 7. Check the headlight relay. Refer to “CHECKING THE RE- Replace the headlight relay. LAYS” on page 8-85. OK ↓ NG → 8. Check the entire lighting system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM”...
Page 364 SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM 8-19...
Page 365 11.Battery 12.Engine ground 13.Main fuse 21.Fuel sender 28.Speed sensor 29.ECU (engine control unit) 37.Coolant temperature sensor 38.Yamaha diagnostic tool coupler 39.Meter assembly 40.Oil pressure warning light 41.Neutral indicator light 42.Tachometer 43.Multi-function meter 1 45.Shift timing indicator light 46.Multi-function meter 2 48.Turn signal indicator light...
Page 366 SIGNALING SYSTEM EAS30501 TROUBLESHOOTING • Any of the following fail to light: a turn signal light, the brake light or an indicator light. • The horn fails to sound. • The fuel meter fails to come on. • The speedometer fails to operate. •...
Page 367 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-19. OK ↓ Replace the horn. The tail/brake light fails to come on. NG → 1.
Page 368 SIGNALING SYSTEM Replace the meter assembly. The neutral indicator light fails to come on. NG → 1. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch. POSITION SWITCH” on page 8-93. OK ↓ NG → 2.
Page 369 SIGNALING SYSTEM Replace the oil pressure switch. The fuel meter fails to come on. NG → 1. Check the fuel sender. Refer to “CHECKING THE FUEL Replace the fuel pump assembly. SENDER” on page 8-91. OK ↓ NG → 2. Check the entire signaling system wiring.
Page 370 SIGNALING SYSTEM Replace the ECU or meter assembly. Refer to “REPLACING THE ECU (en- gine control unit)” on page 8-81. The shift timing indicator light fails to come on. NG → 1. Check that the shift timing indicator light is set to come on and that the brightness level of the light is ad- Replace the meter assembly.
Page 371 SIGNALING SYSTEM 8-26...
Page 372 COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM 8-27...
Page 373 COOLING SYSTEM 1. Main switch 3. Ignition fuse 5. Backup fuse 7. Radiator fan motor fuse 11.Battery 12.Engine ground 13.Main fuse 29.ECU (engine control unit) 37.Coolant temperature sensor 76.Radiator fan motor relay 77.Radiator fan motor A. Wire harness B. Negative battery sub-wire harness 8-28...
Page 374 COOLING SYSTEM EAS30503 TROUBLESHOOTING The radiator fan motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Passenger seat 2. Center cover 3. Rider seat 4. Side covers 5. Fuel tank 6. Front panel (left) 7. Front bottom cowling NG →...
Page 375 COOLING SYSTEM NG → 7. Check the entire cooling system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-27. OK ↓ Replace the ECU. Refer to “REPLAC- ING THE ECU (engine control unit)” on page 8-81.
Page 376 FUEL INJECTION SYSTEM EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM 8-31...
Page 377 32.Ignition coil #2 33.Fuel injector #1 34.Fuel injector #2 35.Air induction system solenoid 36.ISC (idle speed control) valve 37.Coolant temperature sensor 38.Yamaha diagnostic tool coupler 39.Meter assembly 43.Multi-function meter 1 44.Engine trouble warning light 51.Gear position switch 53.Handlebar switch (left) 58.Clutch switch...
Page 378 FUEL INJECTION SYSTEM EAS30505 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 379 EAS30951 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool 90890-03231 Features of the Yamaha diagnostic tool You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional meth- ods.
Page 380 Disconnect the Yamaha diagnostic tool coupler “1”, and then connect the Yamaha diagnostic tool “2” to the coupler. When the Yamaha diagnostic tool is connected to the vehicle, “Er-1” or “Er-4” will be displayed on the multi-function meter. Operation of the Yamaha diagnostic tool (Malfunction mode) Malfunction results are displayed in the top part of the window area.
Page 381 FUEL INJECTION SYSTEM 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. 3. Code The following icons and the fault code numbers for the detected malfunctions are displayed. A.
Page 382 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 383 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received from the Item crankshaft position sensor. Improperly connected → Con- Connection of ECU coupler. Crank the engine. Check the locking condition of nect the coupler securely or re- Fault code number is not dis- played →...
Page 384 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check pletion Improperly connected → Con- Connection of intake air pres- Turn the main switch to “ON”.
Page 385 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Malfunction in ECU. Replace the ECU. Refer to “REPLACING THE ECU (engine control unit)” on page 8-81. Fault code No. 14 ECA20500 NOTICE Do not remove the throttle body sensor assembly from the throttle body. If fault code numbers “13”...
Page 386 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged or de- Item tached 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 387 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Improperly connected → Con- Connection of ECU coupler. Turn the main switch to “ON”. Check the locking condition of nect the coupler securely or re- Fault code number is not dis- played →...
Page 388 FUEL INJECTION SYSTEM Fault code No. Throttle position sensor: stuck throttle position sensor is detected. Item (signal from throttle position sensor will not change) • Check with throttle valves fully closed. Procedure • Check with throttle valves fully open. Probable cause of malfunc- Confirmation of service com- Item Maintenance job...
Page 389 FUEL INJECTION SYSTEM Fault code No. Black/red lead of the ECU: a break or disconnection of the black/red Item lead of the ECU is detected. Improperly connected → Con- Connection of main switch cou- Turn the main switch to “ON”. pler.
Page 390 FUEL INJECTION SYSTEM Fault code No. Item Coolant temperature sensor: open or short circuit detected. Open or short circuit → Replace Wire harness continuity. Turn the main switch to “ON”. the wire harness. Fault code number is not dis- played → Service is finished. Between coolant temperature sensor coupler and ECU cou- Fault code number is displayed...
Page 391 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Improperly connected → Con- Connection of throttle body sen- Turn the main switch to “ON”. sor assembly coupler. nect the coupler securely or re- Fault code number is not dis- played →...
Page 392 FUEL INJECTION SYSTEM Fault code No. sensor: no normal signals are received from the O sensor. Item Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check pletion sensor. Improperly installed sensor → Installed condition of O Start the engine, warm it up, Reinstall or replace the sensor.
Page 393 Actuates the cylinder-#1 ignition coil five times at one-second intervals. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times.
Page 394 FUEL INJECTION SYSTEM Fault code No. Cylinder-#1 ignition coil: open or short circuit detected in the prima- Item ry lead of the cylinder-#1 ignition coil. Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check pletion Improperly connected →...
Page 395 Actuates the cylinder-#2 ignition coil five times at one-second intervals. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times.
Page 396 Actuates fuel injector #1 five times at one-second intervals. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Disconnect the fuel pump coupler, and then check that fuel injector #1 is Procedure actuated five times by listening for the operating sound.
Page 397 FUEL INJECTION SYSTEM Fault code No. Item Fuel injector: open or short circuit detected. Open or short circuit → Replace Wire harness continuity. Execute the diagnostic mode. the wire harness. (Code Nos. 36, 37) No operating sound → Go to Between fuel injector coupler and ECU coupler.
Page 398 FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Open or short circuit → Replace Wire harness continuity. Turn the main switch to “ON”, the wire harness. then to “OFF”, and then back to Between lean angle sensor cou- “ON”.
Page 399 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item Gear position switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Improperly connected → Con- Connection of speed sensor Execute the diagnostic mode.
Page 400 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item Gear position switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
Page 401 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item Gear position switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Open or short circuit → Replace Wire harness continuity.
Page 402 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item Gear position switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Delete the fault code. Turn the main switch to “ON”, and then rotate the rear wheel by hand.
Page 403 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item Gear position switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Clutch lever adjustment. Refer to “ADJUSTING THE Execute the diagnostic mode.
Page 404 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item Gear position switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Defective clutch switch. Check the clutch switch. Execute the diagnostic mode.
Page 405 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel injector Item and fuel pump. Open or short circuit → Replace Wire harness continuity. Start the engine and let it idle for the wire harness. approximately 5 seconds.
Page 406 FUEL INJECTION SYSTEM Fault code No. EEPROM fault code number: an error is detected while reading or Item writing on EEPROM. EEPROM fault code display • 00 (no history) • 01–02: Cylinder fault code number (history exists) If more than one cylinder is defective, the display switches every two Tool display seconds to show the cylinder fault code numbers of all defective cylin- ders in a repeating cycle.
Page 407 FUEL INJECTION SYSTEM Fault code No. Item Charging voltage is abnormal. Tool display — Procedure — Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check pletion Malfunction in charging system. Check the charging system. Start the engine and let it idle for Refer to “CHARGING SYSTEM”...
Page 408 Fault code No. Waiting for connection (Yamaha diagnostic tool) ECU (engine control unit) internal malfunction (output signal error): Item Signals cannot be transmitted between the ECU and Yamaha diag- nostic tool. Able to start engine (unable when ECU is malfunctioning) Fail-safe system Able to drive vehicle (unable when ECU is malfunctioning) Diagnostic code No.
Page 409 Fault code No. Waiting for connection (Yamaha diagnostic tool) ECU (engine control unit) internal malfunction (output signal error): Item Signals cannot be transmitted between the ECU and Yamaha diag- nostic tool. Improperly connected → Con- Connection of Yamaha diagnos- Connect the Yamaha diagnostic tic tool coupler.
Page 410 Turn the main switch to “ON”. the wire harness. Fault code number is not dis- played → Service is finished. Between ECU coupler and Yamaha diagnostic tool coupler. Fault code number is displayed → Go to item 4. yellow/blue–yellow/blue Between Yamaha diagnostic tool coupler and meter assem- bly coupler.
Page 411 Turn the main switch to “ON”. the wire harness. Fault code number is not dis- played → Service is finished. Between ECU coupler and Yamaha diagnostic tool coupler. Fault code number is displayed → Go to item 4. yellow/blue–yellow/blue Between Yamaha diagnostic tool coupler and meter assem- bly coupler.
Page 412 Fault code No. Er-4 (Yamaha diagnostic tool) ECU (engine control unit) internal malfunction (input signal error): Item no normal signals are received from the Yamaha diagnostic tool. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
Page 413 Fault code No. Er-4 (Yamaha diagnostic tool) ECU (engine control unit) internal malfunction (input signal error): Item no normal signals are received from the Yamaha diagnostic tool. Improperly connected → Con- Connection of Yamaha diagnos- Connect the Yamaha diagnostic tic tool coupler.
Page 414 FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM 8-69...
Page 415 FUEL PUMP SYSTEM 1. Main switch 3. Ignition fuse 5. Backup fuse 11.Battery 12.Engine ground 13.Main fuse 20.Fuel pump 29.ECU (engine control unit) 67.Handlebar switch (right) 70.Engine stop switch A. Wire harness B. Negative battery sub-wire harness 8-70...
Page 416 FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Passenger seat 2. Center cover 3. Rider seat 4. Side covers 5. Fuel tank NG → 1. Check the fuses. (Ignition, backup, and main) Replace the fuse(s).
Page 417 FUEL PUMP SYSTEM 8-72...
Page 418: Electrical Components
ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 8-73...
Page 419 ELECTRICAL COMPONENTS 1. Main switch 2. Clutch switch 3. Front brake light switch 4. Ignition coil 5. Fuse box 6. Diode 1 7. Starter relay 8. Main fuse 9. Rectifier/regulator 10. ECU (engine control unit) 11. Diode 2 12. Diode 3 13.
Page 420 ELECTRICAL COMPONENTS 8-75...
Page 421 ELECTRICAL COMPONENTS 1. Headlight relay 2. Radiator fan motor relay 3. Fuel pump 4. Fuel injector 5. Throttle body sensor assembly 6. Lean angle sensor 7. Starting circuit cut-off relay 8. Turn signal relay 9. Speed sensor 10. Crankshaft position sensor 11.
Page 422 ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES Br/R B/R L/Y R Br/R B/R L/Y LOCK R/B Br L/W B Dg Br/W L/B Y L/Y B Br R/W R/B Y L/B L/B Y Br/W Br P 8-77...
Page 423 ELECTRICAL COMPONENTS 1. Main switch 2. Start switch 3. Engine stop switch 4. Front brake light switch 5. Rear brake light switch 6. Horn switch 7. Turn signal switch 8. Pass switch 9. Dimmer switch 10. Clutch switch 8-78...
Page 424 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. ECA18520 NOTICE Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Page 425 ELECTRICAL COMPONENTS Improperly connected → Properly connect. 2. Check: No continuity → Repair or replace the bulb, bulb • Bulb (for continuity) socket or both. (with the pocket tester) No continuity → Replace. Types of bulbs Pocket tester The bulbs used on this vehicle are shown in the 90890-03112 illustration on the left.
Page 426 ELECTRICAL COMPONENTS c. Check the bulb socket for continuity. If any of Amperage Fuses Q’ty the readings indicate no continuity, replace rating the bulb socket. Backup 7.5 A ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...
Page 427 ELECTRICAL COMPONENTS • Eyes — Flush with water for 15 minutes and get immediate medical attention. INTERNAL • Drink large quantities of water or milk fol- lowed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical atten- tion.
Page 428 ELECTRICAL COMPONENTS D. These values vary with the temperature, the condition of the battery plates, and the electrolyte level. 3. Remove: • Battery Refer to “GENERAL CHASSIS (1)” on page 4-1. A. Open-circuit voltage (V) 4. Check: B. Charging condition of the battery (%) •...
Page 429 ELECTRICAL COMPONENTS • If the battery becomes hot to the touch at • Standard charging current is reached any time during the charging process, dis- Battery is good. • Standard charging current is not reached connect the battery charger and let the bat- Replace the battery.
Page 430 ELECTRICAL COMPONENTS 1. Disconnect the relay from the wire harness. 12.8 V or more --- Charging is complete. 2. Connect the pocket tester (Ω × 1) and battery 12.7 V or less --- Recharging is required. Under 12.0 V --- Replace the battery. (12 V) to the relay terminal as shown.
Page 431 ELECTRICAL COMPONENTS Headlight relay 2. Negative battery lead Result Relay operate → OK Relay do not operate → Re- place. EAS30555 CHECKING THE DIODES 1. Check: • Diodes Out of specification → Replace. 1. Positive battery terminal 2. Negative battery terminal Pocket tester 3.
Page 432 ELECTRICAL COMPONENTS Diode 1 Continuity Positive tester probe → sky blue “1” Negative tester probe → blue/yellow “2” Continuity Positive tester probe → sky blue “1” Negative tester probe → yel- low/black “3” No continuity Positive tester probe → blue/yellow “2” Negative tester probe →...
Page 433 ELECTRICAL COMPONENTS EAS30557 • Positive tester probe → CHECKING THE SPARK PLUG CAPS red/black “1” The following procedure applies to all of the • Negative tester probe → spark plug caps. orange or gray/red “2” 1. Check: • Spark plug cap resistance Out of specification →...
Page 434 ELECTRICAL COMPONENTS 2. Check: EAS30556 CHECKING THE IGNITION SPARK GAP • Crankshaft position sensor resistance 1. Check: Out of specification → Replace the stator coil • Ignition spark gap assembly (Stator coil/Crankshaft position Out of specification → Perform the ignition sensor).
Page 435 ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C Test harness– lean angle sensor (6P) 90890-03209 Test harness– lean angle sensor (6P) YU-03209 b. Check the starter motor operation. • Positive tester probe ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...
Page 436 ELECTRICAL COMPONENTS 2. Remove: • Fuel tank 3. Remove: • Fuel pump (from the fuel tank) 4. Check: • Fuel sender resistance Out of specification → Replace the fuel pump assembly. Sender unit resistance (full) b. Measure the stator coil resistance. 10.0–14.0 Ω...
Page 437 ELECTRICAL COMPONENTS EAS31372 CHECKING THE FUEL METER This model is equipped with a self-diagnosis de- vice for the fuel level detection circuit. 1. Check: • Fuel meter “1” (Turn the main switch to “ON”.) Warning light comes on for a few seconds, then goes off →...
Page 438 ELECTRICAL COMPONENTS • Never subject the coolant temperature sen- 3. Install: sor to strong shocks. If the coolant temper- • Coolant temperature sensor ature sensor is dropped, replace it. Coolant temperature sensor 2. Check: 17 Nm (1.7 m·kgf, 12 ft·lbf) •...
Page 439 ELECTRICAL COMPONENTS 2. Check: • Gear position switch Out of specification → Replace the gear posi- tion switch. O Y/W W Sb Pocket tester 90890-03112 Analog pocket tester YU-03112-C Result EAS30681 CHECKING THE FUEL INJECTORS Neutral position The following procedure applies to all of the fuel Continuity Positive tester probe injectors.
Page 440 ELECTRICAL COMPONENTS 8-95...
Page 441: General Information
FAULTY LIGHTING OR SIGNALING SYSTEM ........9-4 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE....9-5 SELF-DIAGNOSTIC FUNCTION TABLE ..........9-5 COMMUNICATION ERROR WITH THE METER OR YAMAHA DIAGNOSTIC TOOL ......................9-5 DIAGNOSTIC CODE: SENSOR OPERATION TABLE ......9-6 DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ......9-8...
Page 442 TROUBLESHOOTING • Sucked-in air EAS20090 TROUBLESHOOTING Electrical system EAS30599 1. Battery GENERAL INFORMATION • Discharged battery • Faulty battery The following guide for troubleshooting does not 2. Fuse(s) cover all the possible causes of trouble. It should • Blown, damaged or incorrect fuse be helpful, however, as a guide to basic trouble- •...
Page 443 TROUBLESHOOTING • Flooded throttle body Transmission • Faulty air induction system • Seized transmission gear • Foreign object between transmission gears Electrical system • Improperly assembled transmission 1. Battery EAS30605 • Discharged battery JUMPS OUT OF GEAR • Faulty battery 2.
Page 444: Chassis
TROUBLESHOOTING • Worn brake disc EAS30607 OVERHEATING • Air in hydraulic brake system • Leaking brake fluid Engine • Faulty brake caliper kit 1. Clogged coolant passages • Faulty brake caliper seal • Cylinder head and piston(s) • Loose union bolt •...
Page 445 TROUBLESHOOTING Swingarm • Burnt-out turn signal bulb • Worn bearing or bushing • Incorrect connection • Bent or damaged swingarm • Damaged or faulty wire harness • Improperly grounded circuit Rear shock absorber assembly • Faulty battery • Faulty rear shock absorber spring •...
Page 446: Engine
Er-1 (fault code display) nals cannot be transmitted between the ECU and the multi-function meter. Waiting for connection (Yamaha ECU (engine control unit) internal malfunction (output signal error): Sig- diagnostic tool) nals cannot be transmitted between the ECU and Yamaha diagnostic tool.
Page 447: Fuel System
Er-4 (fault code display) registered data has been received from the meter. ECU (engine control unit) internal malfunction (input signal error): no nor- Er-4 (Yamaha diagnostic tool) mal signals are received from the Yamaha diagnostic tool. EAS31120 DIAGNOSTIC CODE: SENSOR OPERATION TABLE Diagnostic...
Page 448 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Meter display Procedure code No. Black/red lead of the ECU — • Normal signal • Abnormal signal Neutral switch and clutch Operate the transmission switch and clutch lever. • Transmission is in neutral •...
Page 449 • Connect an ignition check- The “CHECK” indicator and “ ” on the Yamaha diag- nostic tool screen come on each time the ignition coil is actuated. Cylinder-#2 ignition coil Actuates cylinder-#2 ignition...
Page 450 Check that fuel injector #2 is The “CHECK” indicator and actuated five times by listen- ing for the operating sound. “ ” on the Yamaha diag- nostic tool screen come on each time the fuel injector is actuated. Air cut-off valve...
Page 451 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9-10...
Page 452: Wiring Diagram
35. Air induction system solenoid Sky blue 36. ISC (idle speed control) valve White 37. Coolant temperature sensor Yellow Black/Blue 38. Yamaha diagnostic tool coupler Black/Red 39. Meter assembly Black/White 40. Oil pressure warning light Black/Yellow 41. Neutral indicator light...
Page 455 YZF-R25 2014 WIRING DIAGRAM B/W,B LOCK Br/R B/R L/Y Br/R Gy/R Gy/R Br/R R L/Y B/R R/L R/B L/W R/W (Gy) R/B, Br/W Br/R R/B Y/W Br/W Br/W R/L G/B (Br) P/B R/W B Sb/W Br/R R/W Gy/G B/Y,Y/B Br/R...
Page 456 YZF-R25 2014 WIRING DIAGRAM LOCK (Gy) (Br) (Gy)

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