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Yamaha WR250F 2017 Owner's Service Manual

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Table of Contents

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2017
q Read this manual carefully before operating this vehicle.
q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule.
OWNER'S SERVICE MANUAL
MANUEL D'ATELIER DU
PROPRIETAIRE
WR250F
WR250FH
2GB-28199-72

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  • Page 1 2017 q Read this manual carefully before operating this vehicle. q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE WR250F WR250FH 2GB-28199-72...
  • Page 2 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit être remis avec le véhicule en cas de vente de ce dernier.
  • Page 3 2017 Read this manual carefully before operating this vehicle. Read this manual carefully before operating this vehicle. OWNER’S SERVICE MANUAL OWNER’S SERVICE MANUAL WR250F WR250FH 2GB-28199-72-E0...
  • Page 5 EAS2GBB002 WR250F WR250FH OWNER’S SERVICE MANUAL ©2016 by Yamaha Motor Co., Ltd. First edition, April 2016 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
  • Page 6 INTRODUCTION EAS2GBB003 Congratulations on your purchase of a Yamaha WR series. This model is the culmination of Yama- ha's vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.
  • Page 7 SAFETY INFORMATION EAS2GBB005 THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding. •...
  • Page 8 HOW TO USE THIS MANUAL EAS2GBB006 In this manual, descriptions of installation, removal, disassembly, assembly, check, and adjustment procedures are laid out with the individual steps in sequential order. • The manual is divided into chapters and each chapter is divided into sections. The current section title “1”...
  • Page 9 SYMBOLS EAS2GBB007 The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...

  • Page 11: Table Of Contents

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

  • Page 13: General Information

    GENERAL INFORMATION LOCATION OF IMPORTANT LABELS............1-1 DESCRIPTION....................1-4 IDENTIFICATION .....................1-5 VEHICLE IDENTIFICATION NUMBER ............1-5 ENGINE SERIAL NUMBER ...............1-5 VEHICLE EMISSION CONTROL INFORMATION LABEL......1-5 INCLUDED PARTS ..................1-6 SPARK PLUG WRENCH ................1-6 NIPPLE WRENCH..................1-6 HANDLEBAR PROTECTOR ..............1-6 FUEL HOSE JOINT COVER ..............1-6 COUPLER FOR CONNECTING OPTIONAL PART........1-6 IMPORTANT INFORMATION ................1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-7 REPLACEMENT PARTS................1-7...
  • Page 14 MULTI-FUNCTION DISPLAY.................1-22 DESCRIPTION ..................1-22 BASIC MODE ...................1-22 CHANGEOVER TO BASIC MODE/RACE MODE........1-23 RACE MODE....................1-24 FUNCTION DIAGRAM ................1-28 STARTING AND BREAK-IN ................1-30 FUEL ......................1-30 HANDLING NOTE ..................1-30 AIR FILTER MAINTENANCE ..............1-30 STARTING A COLD ENGINE ..............1-30 STARTING A WARM ENGINE..............1-32 BREAK-IN PROCEDURES ..............1-32 MAINTENANCE AFTER BREAK-IN ..............1-33 MAJOR MAINTENANCE................1-33 TORQUE-CHECK POINTS ................1-34...

  • Page 15: Location Of Important Labels

    LOCATION OF IMPORTANT LABELS LOCATION OF IMPORTANT LABELS EAS2GBB008 Please read the following important labels carefully before operating this vehicle. 1,2,3 4,5,6 9,10,11...
  • Page 16 LOCATION OF IMPORTANT LABELS...
  • Page 17 LOCATION OF IMPORTANT LABELS AUS, NZL, ZAF...

  • Page 18: Description

    DESCRIPTION DESCRIPTION EAS2GBB009 12 13 20 19 18 1. Clutch lever 12. Headlight 2. Multi-function display 13. Radiator 3. Front brake lever 14. Coolant drain bolt 4. Throttle grip 15. Rear brake pedal 5. Start switch 16. Air filter 6. Radiator cap 17.

  • Page 19: Identification

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

  • Page 20: Included Parts

    INCLUDED PARTS INCLUDED PARTS FUEL HOSE JOINT COVER EAS2GBB014 EAS2GBB018 The fuel hose joint covers “1” are used to pre- EAS2GBB015 SPARK PLUG WRENCH vent mud, dust, and other foreign materials The spark plug wrench “1” is used to remove or from entering the inside when the fuel hose is install the spark plug.

  • Page 21: Important Information

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

  • Page 22: Gaskets, Oil Seals And O-Rings

    IMPORTANT INFORMATION GASKETS, OIL SEALS AND O-RINGS EAS2GBB022 1. When overhauling the engine, replace all gaskets and O-rings. All gasket surfaces, oil seal lips, and O-rings must be cleaned so that there may be no dust on them. 2. During assembly, always apply proper oil to bearings and proper grease to oil seal lips before installation.

  • Page 23: Basic Service Information

    BASIC SERVICE INFORMATION BASIC SERVICE INFORMATION EAS2GBB026 EAS2GBB027 ELECTRICAL SYSTEM Electrical parts handling NOTICE Never disconnect a battery lead while the engine is running; otherwise, the electrical components could be damaged. NOTICE Be sure to connect the battery leads to the correct battery terminals.
  • Page 24 BASIC SERVICE INFORMATION NOTICE Checking the electrical system Handle electrical components with special care, and do not subject them to strong Before checking the electrical system, make shocks. sure that the battery voltage is at least 12 V. NOTICE NOTICE Electrical components are very sensitive to Never insert the tester probes into the cou- and can be damaged by static electricity.
  • Page 25 BASIC SERVICE INFORMATION 2. Check: • Lead • Coupler • Connector Moisture  Dry with compressed air. Rust/stains  Connect and disconnect sev- eral times. Checking the connections Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: •...
  • Page 26 BASIC SERVICE INFORMATION 4. Connect: • Lead • Coupler • Connector • When connecting a coupler or connector, make sure that both terminals are connected securely. • Make sure all connections are tight. 5. Check: • No continuity Pocket tester 90890-03112 Analog pocket tester YU-03112-C...

  • Page 27: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS EAS2GBB028 The following special tools are required for accurate and complete adjustment and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and tool number used for the special tool differ by country, so two types are provided.
  • Page 28 SPECIAL TOOLS Tool name/Part number How to use Illustration Radiator cap tester This tool is used to check the 90890-01325 radiator and the radiator cap. Mityvac cooling system tester YU-24460-A Radiator cap tester adapter This tool is used to check the 90890-01352 radiator and the radiator cap.
  • Page 29 Test harness– lean angle sensor (6P) YU-03209 FI diagnostic tool sub–lead This tool is used to connect 90890-03212 the Yamaha diagnostic tool FI diagnostic tool sub–lead to a battery. YU-03212 Test harness– speed sensor This tool is used to check the 5TJ (3P) speed sensor output voltage.
  • Page 30 SPECIAL TOOLS Tool name/Part number How to use Illustration Valve spring compressor This tool is used to discon- 90890-04019 nect or connect the valve and Valve spring compressor the valve spring. YM-04019 YM-04019 Spacer (crankshaft installer) This tool is used to install the 90890-04081 crankshaft.
  • Page 31 SPECIAL TOOLS Tool name/Part number How to use Illustration Valve lapper This tool is used to remove 90890-04101 the valve lifter or lap the Valve lapping tool valve. YM-A8998 Valve spring compressor at- This tool is used to discon- tachment nect or connect the valve and 90890-04108 the valve spring.
  • Page 32 Tool name/Part number How to use Illustration Digital tachometer This tool is used to measure 90890-06760 the engine speed. Digital tachometer YU-39951-B Yamaha bond No. 1215 This sealant (Bond) is used 90890-85505 for crankcase mating sur- (Three bond No.1215®) face, etc. 1-18...

  • Page 33: Control Functions

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

  • Page 34: Shift Pedal

    CONTROL FUNCTIONS SHIFT PEDAL THROTTLE GRIP EAS2GBB036 The shift pedal “1” has adopted a method of 1 The throttle grip “1” is located on the right han- down & 5 ups (press-down & kick-ups). dlebar. The throttle grip accelerates or deceler- Press it down for N (neutral) to 1st, and kick it ates the engine.

  • Page 35: Sidestand

    CONTROL FUNCTIONS SIDESTAND FUEL TANK CAP EAS2GBB041 This sidestand “1” is used to support only the Fuel tank cap “1” is located under the fuel tank machine when standing or transporting it. cap cover “2”. Remove the fuel tank cap cover to open the fuel WARNING tank cap.

  • Page 36: Multi-Function Display

    MULTI-FUNCTION DISPLAY MULTI-FUNCTION DISPLAY BASIC MODE EAS2GBB042 EAS2GBB044 Changing speedometer display (for U.K.) WARNING Be sure to stop the machine before making 1. Push the “SLCT2” button for 2 seconds or any setting changes to the multi-function more to change the speedometer units. The display.

  • Page 37: Changeover To Basic Mode/Race Mode

    MULTI-FUNCTION DISPLAY 3. Push the “SLCT1” button (plus) or “SLCT2” button (minus) and change the time. A long push on the button will fast-forward the time. CHANGEOVER TO BASIC MODE/RACE EAS2GBB045 MODE 4. To end the setting, push the “RST” button for 2 seconds or more.

  • Page 38: Race Mode

    MULTI-FUNCTION DISPLAY Returning to BASIC MODE from RACE Manual start MODE Initial setting at changeover to RACE MODE will remain for manual start. It is possible to return to BASIC MODE with tim- er measurement at a stop. 1. Check that changeover to RACE MODE has been made.
  • Page 39 MULTI-FUNCTION DISPLAY Resetting tripmeter A (TRIP A) 1. Check that the timer is in operation. If the timer is not in operation, start the timer by pushing the “SLCT1” button and “SLCT2” button at the same time. 2. Reset tripmeter A (TRIP A) display by push- ing the “RST”...
  • Page 40 MULTI-FUNCTION DISPLAY Correcting tripmeter A (TRIP A) 1. Change the travel distance display by push- ing the “SLCT1” button (plus) or “SLCT2” button (minus). A long push on the button will fast-forward the change. Change can be made any time while timer measurement is or is not being made.
  • Page 41 MULTI-FUNCTION DISPLAY 1-27...

  • Page 42: Function Diagram

    MULTI-FUNCTION DISPLAY FUNCTION DIAGRAM A short push on the button changes the operation in the arrowed direction. Meter function A short push on the button changes the operation in both arrowed directions. Function that can be performed whether the time is or is not in operation. A long push on the button changes the operation in the arrowed direction.
  • Page 43 MULTI-FUNCTION DISPLAY A.A short push on the button changes the oper- ation in the arrowed direction. B.A short push on the button changes the oper- ation in both arrowed directions. C.A long push on the button changes the oper- ation in the arrowed direction. D.A long push on the button changes the oper- ation in both arrowed directions.

  • Page 44: Starting And Break-In

    According to “CLEANING THE AIR FILTER 2.1 L (0.55 US gal, 0.46 lmp.gal) ELEMENT” section in the CHAPTER 3, apply the Yamaha foam air filter oil or other quality NOTICE foam air filter oil to the element. (Excess oil in Use only unleaded gasoline.
  • Page 45 STARTING AND BREAK-IN 3. Start the engine by pushing the start switch. If the engine fails to start when using the start switch, release it, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the battery.

  • Page 46: Starting A Warm Engine

    STARTING AND BREAK-IN STARTING A WARM ENGINE EAS2GBB053 Follow the same procedure as for starting a cold engine with the exception that the starter is not required when the engine is warm. If it fails to start, fully open the throttle grip and give 10 to 20 slow kicks to clear the engine of the rich air-fuel mixture retained in it.

  • Page 47: Maintenance After Break-In

    MAINTENANCE AFTER BREAK-IN • Cable MAINTENANCE AFTER BREAK-IN EAS2GBB055 Grease and adjust cables. After a break-in, perform careful maintenance • Drive chain to get ready for the next practice or race. Lubricate the drive chain and adjust its ten- Refer to “PRE-OPERATION INSPECTION sion.

  • Page 48: Torque-Check Points

    TORQUE-CHECK POINTS TORQUE-CHECK POINTS EAS2GBB057 Frame construction Frame to rear frame Frame to engine protector Combined seat and fuel tank Fuel tank to frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Seat Seat to frame Steering Steering stem to handlebar Steering stem to frame...
  • Page 49 TORQUE-CHECK POINTS Fuel system Fuel pump to fuel tank Fuel sender to fuel tank Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake disc cov- Tightening of rear brake caliper...

  • Page 50: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE • Do not use any harsh chemical products MOTORCYCLE CARE AND STOR- EAS2GBB058 on plastic parts. Be sure to avoid using cloths or sponges which have been in con- tact with strong or abrasive cleaning prod- CARE EAS2GBB059 ucts, solvent or thinner, fuel (gasoline),...

  • Page 51: Storage

    MOTORCYCLE CARE AND STORAGE 2. Apply a corrosion protection spray on all metal, including chrome- and nickel-plated, • Consult a Yamaha dealer for advice on what surfaces to prevent corrosion. products to use. • Washing, rainy weather or humid climates After cleaning can cause the headlight lens to fog.
  • Page 52 MOTORCYCLE CARE AND STORAGE e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. WARNING! To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over.

  • Page 53: Specifications

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

  • Page 54: General Specifications

    GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS EAS2GBB061 Model Model 2GBB (USA) 2GBC (CAN) 2GBD (EUR) 2GBE (AUS) (NZL) (ZAF) Dimensions Overall length 2165 mm (85.2 in) Overall width 825 mm (32.5 in) Overall height 1280 mm (50.4 in) Seat height 965 mm (38.0 in) Wheelbase 1465 mm (57.7 in) Ground clearance...

  • Page 55: Engine Specifications

    ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS EAS2GBB062 Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 250 cm Number of cylinders Single cylinder Bore  stroke 77.0  53.6 mm (3.03  2.11 in) Compression ratio 13.5:1 Starting system Electric starter and kickstarter Fuel Recommended fuel Premium unleaded gasoline only...
  • Page 56 ENGINE SPECIFICATIONS Cylinder head Combustion chamber volume 12.07–12.87 cm (0.74–0.79 cu.in) Warpage limit 0.05 mm (0.0020 in) Camshaft Drive system Chain drive (left) Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in) Camshaft journal diameter 21.959–21.972 mm (0.8645–0.8650 in) Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) Camshaft lobe dimensions Lobe height (Intake)
  • Page 57 ENGINE SPECIFICATIONS Valve spring Free length (intake) 36.69 mm (1.44 in) Limit 34.85 mm (1.37 in) Free length (exhaust) 34.86 mm (1.37 in) Limit 33.11 mm (1.30 in) Installed length (intake) 31.40 mm (1.24 in) Installed length (exhaust) 28.50 mm (1.12 in) Spring rate K1 (intake) 29.65 N/mm (3.02 kgf/mm, 169.30 lbf/in) Spring rate K2 (intake)
  • Page 58 4.85 mm (0.1909 in) Decompression device Device type Auto decomp Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil Fuel pump Pump type Electrical Fuel injector Model/quantity 30NA-FZ31/1 12.0 ...
  • Page 59 ENGINE SPECIFICATIONS Throttle body Type/quantity 30RA-A95R/1 ID mark 2GB1 00 Fuel line pressure (at idle) 300.0–390.0 kPa (3.00–3.90 kgf/cm 43.5–56.6 psi) Throttle position sensor Resistance 6.30 k Output voltage (at idle) 0.48–0.52 V Fuel injection sensor 228–342  Crankshaft position sensor resistance Intake air pressure sensor output voltage 3.61–3.67 V at 101.3 kPa (3.61–3.67 V at 1.01 kgf/cm...

  • Page 60: Chassis Specifications

    CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS EAS2GBB063 Chassis Frame type Semi double cradle Caster angle 26.3 ° Trail 114 mm (4.5 in) Front wheel Wheel type Spoke wheel Rim size 1.60 21 Rim material Aluminum Wheel travel 310 mm (12.2 in) Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in)
  • Page 61 Inner tube outer diameter 48 mm (1.9 in) Inner tube bending limit 0.2 mm (0.01 in) Optional spring available Recommended oil Yamaha Suspension Oil S1 Quantity 540.0 cm (18.26 US oz, 19.05 Imp.oz) Rebound damping adjusting positions Minimum 20 clicks out*...
  • Page 62 CHASSIS SPECIFICATIONS Rear suspension Type Swingarm (link suspension) Spring/shock absorber type Coil spring/gas-hydraulic damper Rear shock absorber assembly travel 126.0 mm (4.96 in) Spring free length 275.0 mm (10.83 in) Spring installed length 265.0 mm (10.43 in) Spring rate K1 54.00 N/mm (5.51 kgf/mm, 308.34 lbf/in) Spring stroke K1 0.0–150.0 mm (0.00–5.91 in)

  • Page 63: Electrical Specifications

    Advancer type Digital Ignition timing (B.T.D.C.) 10.0 ° at 2000 r/min Engine control unit Model/manufacturer 2GB0/YAMAHA (USA) (CAN) 2GB1/YAMAHA (EUR) (AUS) (NZL) (ZAF) Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64  Primary coil resistance Secondary coil resistance 8.64–12.96 k...
  • Page 64 ELECTRICAL SPECIFICATIONS Starter motor Power output 0.35 kW 0.0189–0.0231  Armature coil resistance Brush overall length 7.0 mm (0.28 in) Limit 3.50 mm (0.14 in) Brush spring force 3.92–5.88 N (400–600 gf, 14.11–21.17 oz) Commutator diameter 17.6 mm (0.69 in) Limit 16.6 mm (0.65 in) Mica undercut (depth)

  • Page 65: Tightening Torques

    TIGHTENING TORQUES TIGHTENING TORQUES EAS20320 EAS2GBB065 GENERAL TIGHTENING TORQUE SPECIFI- CATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a criss- cross pattern and progressive stages until the specified tightening torque is reached.

  • Page 66: Engine Tightening Torques

    TIGHTENING TORQUES ENGINE TIGHTENING TORQUES EAS2GBB066 - marked portion shall be checked for torque tightening after break-in or before each race. Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Cylinder head blind plug 28 Nm (2.8 m·kgf, 20 ft·lbf) Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
  • Page 67 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Air filter guide holder screw 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) Air filter case cap screw 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) Starter knob/Idle screw 2.1 Nm (0.21 m·kgf, 1.5 ft·lbf) Throttle cable nut (pull) 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Throttle cable nut (return)
  • Page 68 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Use a lock Clutch boss nut 100 Nm (10 m·kgf, 72 ft·lbf) washer. Use a Drive sprocket nut 75 Nm (7.5 m·kgf, 54 ft·lbf) lock washer. Segment 30 Nm (3.0 m·kgf, 22 ft·lbf) Shift guide bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Stopper lever bolt...

  • Page 69: Chassis Tightening Torques

    TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES EAS2GBB067 - marked portion shall be checked for torque tightening after break-in or before each race. Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Outer tube and upper bracket bolt 21 Nm (2.1 m·kgf, 15 ft·lbf) Outer tube and lower bracket bolt 21 Nm (2.1 m·kgf, 15 ft·lbf) Upper bracket and steering stem nut...
  • Page 70 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Front brake disc bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Rear brake disc bolt 14 Nm (1.4 m·kgf, 10 ft·lbf) Footrest bracket bolt 55 Nm (5.5 m·kgf, 40 ft·lbf) Sidestand bolt 25 Nm (2.5 m·kgf, 18 ft·lbf) Rear brake pedal bolt 26 Nm (2.6 m·kgf, 19 ft·lbf)
  • Page 71 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Drive chain tensioner bolt (lower 16 Nm (1.6 m·kgf, 12 ft·lbf) side) Drive chain support bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Drive chain support nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Drive chain guide bolt 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Rear frame and left cover bolt...
  • Page 72 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Starter relay and starter motor lead 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) bolt Lean angle sensor bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) Taillight assembly screw — 1.1 Nm (0.11 m·kgf, 0.80 ft·lbf) Taillight lead clamp and rear fender —...

  • Page 73: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES EAS2GBB068 EAS2GBB069 ENGINE Lubrication point Lubricant types Oil seal lips Bearing O-ring Camshaft cap bolt threads and contacting surface Cylinder head bolt threads, seats, washers Valve stems Valve stem ends Valve lifter outer surface Camshaft lobe and journal Valve lifter top surface...

  • Page 74: Chassis

    Shift shaft Shift lever assembly moving parts Damper assembly shaft, thrust surfaces, washers Starter idle gear inner surface, thrust surfaces Starter clutch drive gear inner surface, thrust surfaces Yamaha bond No.1215 Cylinder head cover gasket (Three bond No.1215®) Yamaha bond No.1215...
  • Page 75 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Rear wheel axle outer surface Sidestand pivot portion and collar outer surface Brake lever contacting portion (front brake master cylinder) Front brake lever bolt outer surface Clutch lever sliding surface and bolt outer surface Clutch lever adjuster rubber lip Clutch cable end (clutch lever side) Tube guide (throttle grip) inner surface and throttle cable end...

  • Page 76: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION SYSTEM CHART AND DIAGRAMS EAS2GBB071 EAS2GBB072 LUBRICATION DIAGRAMS 2-23...
  • Page 77 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Piston 4. Oil nozzle 5. Oil filter element 6. Oil pump 7. Oil strainer 8. Crankshaft 9. Drive axle 10. Main axle 2-24...
  • Page 78 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25...
  • Page 79 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Connecting rod 2. Crankshaft 3. Main axle 4. Oil strainer 5. Drive axle 2-26...
  • Page 80 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
  • Page 81 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Exhaust camshaft 2. Intake camshaft 3. Oil filter element 4. Oil pump 2-28...
  • Page 82 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 83 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil pressure check bolt 3. Oil filter element 4. Oil pump 2-30...

  • Page 84: Cable Routing Diagram

    CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM EAS2GBB073 2-31...
  • Page 85 CABLE ROUTING DIAGRAM N. Place the grommet of the clutch cable so that it 1. Clutch cable contacts the radiator hose. Route the clutch cable 2. Throttle cable (return) outside the neutral switch lead, AC magneto lead 3. Throttle cable (pull) and starter motor lead.
  • Page 86 CABLE ROUTING DIAGRAM 2-33...
  • Page 87 CABLE ROUTING DIAGRAM 1. Clamp 2. Cylinder head breather hose 3. Throttle position sensor lead 4. Joint coupler 5. Intake air temperature sensor lead 6. Intake air pressure sensor lead 7. Wire harness 8. Injector lead 9. Throttle body 10. Injector coupler 11.
  • Page 88 CABLE ROUTING DIAGRAM 2-35...
  • Page 89 CABLE ROUTING DIAGRAM 1. Cable guide 2. Speed sensor lead 3. Joint coupler 4. Ground lead 5. Throttle position sensor lead 6. Throttle position sensor coupler 7. Radiator breather hose 8. Cylinder head breather hose 9. Crankcase breather hose 10. Radiator hose 11.
  • Page 90 CABLE ROUTING DIAGRAM 2-37...
  • Page 91 CABLE ROUTING DIAGRAM 1. Battery negative lead 2. Fuel hose 3. Fuel pump coupler 4. Fuel pump lead 5. Resistor 6. Resistor coupler 7. Battery positive lead 8. Lean angle sensor 9. Starter motor lead 10. Radiator fan motor relay (blue tape) 11.
  • Page 92 CABLE ROUTING DIAGRAM 2-39...
  • Page 93 CABLE ROUTING DIAGRAM 1. Clutch switch lead 2. Engine stop switch lead 3. Clutch cable 4. Brake hose guide 5. Headlight lead 6. Speed sensor lead 7. Indicator light coupler 8. Meter assembly optional switch coupler 9. Meter assembly coupler 10.
  • Page 94 CABLE ROUTING DIAGRAM 2-41...
  • Page 95 CABLE ROUTING DIAGRAM 1. Breather hose 3 (air filter breather hose) 2. Breather hose 1 (cylinder head breather hose) 3. Breather hose 2 (crankcase breather hose) 4. Joint pipe A. Pass the breather hose 3 to the outside the throt- tle cable.
  • Page 96 CABLE ROUTING DIAGRAM 2-43...
  • Page 97 CABLE ROUTING DIAGRAM 1. Brake master cylinder 2. Brake hose holder 3. Brake hoses A. While installing the brake hose, direct a bend in its pipe portion as shown, and bring it into contact with the projection on the brake caliper. B.
  • Page 98 CABLE ROUTING DIAGRAM 2-45...

  • Page 99: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ......3-2 MAINTENANCE INTERVALS FOR COMPETITION USE ......3-4 PRE-OPERATION INSPECTION AND MAINTENANCE.........3-9 GENERAL INSPECTION AND MAINTENANCE........3-9 ENGINE ......................3-10 CHECKING THE COOLANT LEVEL............3-10 CHECKING THE COOLING SYSTEM .............3-10 CHANGING THE COOLANT..............3-10...
  • Page 100 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY....3-34 CHECKING THE TIRES................3-36 CHECKING AND TIGHTENING THE SPOKES........3-36 CHECKING THE WHEELS ..............3-37 CHECKING THE WHEEL BEARINGS .............3-37 CHECKING AND ADJUSTING THE STEERING HEAD ......3-37 CHECKING AND LUBRICATING THE CABLES ........3-38 LUBRICATING THE LEVERS ..............3-38 LUBRICATING THE PEDAL ..............3-38 LUBRICATING THE DRIVE CHAIN ............3-38 LUBRICATING THE SIDESTAND............3-39...

  • Page 101: Periodic Maintenance

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

  • Page 102: General Maintenance And Lubrication Chart

    PERIODIC MAINTENANCE GENERAL MAINTENANCE AND LUBRICATION CHART EAS2GBB077 ODOMETER READ- INITIAL INGS 600 mi 1800 mi 3000 mi ITEM CHECKS AND MAINTENANCE JOBS (1000 (3000 (5000 km) or 1 km) or 3 km) or 6 month months months • Check operation. ...
  • Page 103 Rear sus- • Apply molybdenum disulfide grease   pension link lightly. pivots Control ca- • Apply Yamaha chain and cable lube or    bles engine oil 10W-30 thoroughly. • Check operation and free play. Throttle grip • Adjust the throttle cable free play if ...

  • Page 104: Maintenance Intervals For Competition Use

    If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. • Periodic inspection is essential in making full use of the machine performance. The service life of the parts varies substantially according to the environment in which the machine runs (e.g., rain,...
  • Page 105 PERIODIC MAINTENANCE Every Every After third fifth Every As re- ITEM break- Remarks race quired 1,000 PISTON PIN Inspect Replace CYLINDER HEAD Inspect carbon deposits and Inspect and clean eliminate them. Change gasket. CYLINDER Inspect score marks. Inspect and clean Inspect wear.
  • Page 106 Every two years Inspect hoses OUTSIDE NUTS AND BOLTS Refer to “STARTING AND Retighten BREAK-IN” on page 1-30. AIR FILTER Use Yamaha foam air filter oil Clean and lubri- or other quality foam air filter cate oil. Replace OIL FILTER Replace...
  • Page 107 Replace pads Replace brake flu- Every one year FRONT FORKS Inspect and adjust Replace oil Yamaha Suspension Oil S1 Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium-soap-based grease PROTECTOR...
  • Page 108 TIRE, WHEELS Inspect air pres- sure, wheel run- out, tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate Lithium-soap-based grease THROTTLE, CON- TROL CABLE Check routing and connection Yamaha cable lube or SAE Lubricate 10W-30 motor oil...

  • Page 109: Pre-Operation Inspection And Maintenance

    PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE EAS2GBB079 Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. EAS2GBB080 GENERAL INSPECTION AND MAINTENANCE ITEM inspect Page...

  • Page 110: Engine

    ENGINE ENGINE CHECKING THE COOLING SYSTEM EAS2GBB081 EAS2GBB083 1. Remove: EAS2GBB082 CHECKING THE COOLANT LEVEL • Seat • Side cover (left/right) WARNING • Air scoop (left/right) If coolant seems hot, do not remove the ra- Refer to “GENERAL CHASSIS” on page 5- diator cap.

  • Page 111: Checking The Radiator Cap

    ENGINE 5. Install: CHECKING THE RADIATOR CAP EAS2GBB085 • Copper washer 1. Check: • Coolant drain bolt • Seal (radiator cap) “1” • Valve and valve seat “2” Coolant drain bolt Crack/damage  Replace. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Exist fur deposits ...

  • Page 112: Checking The Coolant Circulatory System For Leaks

    ENGINE 4. Check: • Pressure value No stay for 5 to 10 seconds at the test pres- sure value  Correct. • Radiator • Radiator hose connections Coolant leaks  Correct or replace. • Radiator hoses Bulges  Replace WARNING ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 113: Adjusting The Throttle Grip Free Play

    ENGINE ADJUSTING THE THROTTLE GRIP FREE EAS2GBB089 PLAY Prior to adjusting throttle grip free play, the en- gine idling speed should be adjusted. 1. Check: • Throttle grip free play “a” Out of specification  Regulate. Throttle grip free play 3.0–6.0 mm (0.12–0.24 in) If the clutch lever free play cannot be obtained on the handlebar side, use the adjuster on the...

  • Page 114: Lubricating The Throttle Cable

    ENGINE LUBRICATING THE THROTTLE CABLE CLEANING THE AIR FILTER ELEMENT EAS2GBB090 EAS2GBB091 1. Remove: 1. Remove: • Cover (throttle cable cap) “1” • Fuel tank cap cover “1” • Cover (grip cap) “2” Refer to “FUEL TANK CAP” on page 1-21. •...

  • Page 115: Checking The Throttle Body Joint

    Damage  Replace. CHECKING THE THROTTLE BODY JOINT EAS2GBB092 5. Apply: 1. Check: • Yamaha foam air filter oil or other quality • Throttle body joint foam air filter oil Refer to “CHECKING THE THROTTLE Oil application quantify BODY JOINT” on page 8-10.

  • Page 116: Checking The Fuel Line

    ENGINE 3. Check: 2. Check: • Tightening torques • Fuel hose “1” Crack/damage  Replace. Exhaust pipe 1 bolt and nut “1” Loose connection  Connect properly. 20 Nm (2.0 m·kgf, 14 ft·lbf) Exhaust pipe 1 and exhaust pipe 2 bolt “2” 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Exhaust pipe 2 and silencer bolt “3”...

  • Page 117: Changing The Engine Oil

    ENGINE NOTICE • Since engine oil also lubricates the clutch, the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives. • Do not allow foreign material to enter the crankcase. Recommended brand YAMALUBE 4.

  • Page 118: Adjusting The Engine Idling Speed

    ENGINE d. Install the oil strainer. Oil strainer bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • Gasket • Drain bolt Drain bolt b. Start the engine and keep it idling until oil 20 Nm (2.0 m·kgf, 14 ft·lbf) starts to seep from the oil pressure check 7.

  • Page 119: Adjusting The Valve Clearance

    • This section is intended for those who have basic knowledge and skill concerning the ser- Get the high tension cord “1” of the ignition coil vicing of Yamaha motorcycles (e.g., Yamaha pinched in the detector “a” of the digital tachom- dealers, service engineers, etc.). Those who eter.
  • Page 120 ENGINE 2. Remove: • Spark plug • Cylinder head cover Refer to “CAMSHAFT” on page 6-12. 3. Remove: • Timing mark accessing screw “1” • Crankshaft end accessing screw “2” • O-ring c. Measure the valve clearance “e” using a thickness gauge “1”.
  • Page 121 ENGINE d. Select an adjusting pad with a proper valve clearance from the adjusting pad selection • Place a cloth in the timing chain space to pre- table. vent adjusting pads from falling into the crank- case. • Identity each valve lifter and adjusting pad po- •...
  • Page 122 ENGINE g. Measure the valve clearance again. h. If the valve clearance is out of specification, repeat adjusting the valve clearance until it is within specification. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3-22...
  • Page 123 ENGINE INTAKE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.02 0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230...

  • Page 124: Cleaning The Spark Arrester

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

  • Page 125: Chassis

    CHASSIS CHASSIS EAS2GBB101 EAS2GBB102 BLEEDING THE BRAKE SYSTEM WARNING Bleed the brake system whenever: • The system is disassembled. • A brake hose is loosened, disconnected, or replaced. • The brake fluid level is very low. • Brake operation is faulty. A.

  • Page 126: Checking The Brake Hose

    CHASSIS CHECKING THE BRAKE HOSE EAS2GBB103 1. Check: • Brake hose “1” Cracks/damage/wear  Replace. 2. Remove: • Brake lever cover 3. Adjust: • Brake lever position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. b. Turn the adjusting bolt “2” in direction “a” or “b”...

  • Page 127: Adjusting The Rear Brake

    CHASSIS ADJUSTING THE REAR BRAKE EAS2GBB105 NOTICE 1. Check: After adjusting the brake pedal position, • Brake pedal position “a” make sure that there is no brake drag. (distance from the top of the rider footrest to the top of the brake pedal) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 128 CHASSIS c. Remove the brake caliper “3” from the front fork. i. Install the brake caliper “8” and tighten the pad pin “9”. d. Remove the pad pin and brake pads “4”. Bolt (brake caliper) 23 Nm (2.3 m·kgf, 17 ft·lbf) Pad pin 17 Nm (1.7 m·kgf, 12 ft·lbf) e.

  • Page 129: Checking The Rear Brake Pads

    CHASSIS d. Remove the pad pin “6” and the brake pads CHECKING THE REAR BRAKE PADS EAS2GBB107 “7”. 1. Measure: • Brake pad thickness “a” Out of specification  Replace as a set. The pads worn up to the indicator “b” grooves mean that the brake pad thickness limit is reached.

  • Page 130: Checking The Rear Brake Pad Insulator

    CHASSIS i. Install the brake caliper “12” and the rear CHECKING THE REAR BRAKE PAD INSU- EAS2GBB108 wheel “13”. LATOR Refer to “REAR WHEEL” on page 5-9. 1. Remove: j. Tighten the pad pin “14”. • Brake pads Refer to “REAR BRAKE” on page 5-23. Pad pin 2.

  • Page 131: Adjusting The Drive Chain Slack

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

  • Page 132: Checking The Front Fork Legs

    CHASSIS CHECKING THE FRONT FORK LEGS CLEANING THE FRONT FORK OIL SEAL EAS2GBB111 EAS2GBB113 1. Stand the vehicle upright on a level surface. AND DUST SEAL 1. Remove: WARNING • Protector Securely support the vehicle so that there is • Dust seal “1” no danger of it falling over.

  • Page 133: Adjusting The Front Fork Legs

    CHASSIS 3. Tighten: • Air bleed screw Air bleed screw 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping NOTICE Do not turn the adjuster forcibly beyond its adjusting range. EAS2GBB115 ADJUSTING THE FRONT FORK LEGS 1. Adjust: WARNING • Compression damping •...

  • Page 134: Checking The Swingarm Operation

    CHASSIS 1. Remove: CHECKING THE SWINGARM OPERATION EAS2GBB116 • Rear frame 1. Check: Refer to “REAR SHOCK ABSORBER AS- • Swingarm smooth action SEMBLY” on page 5-58. • Swingarm free play 2. Adjust: Refer to “SWINGARM” on page 5-65. • Spring preload EAS2GBB117 CHECKING THE REAR SUSPENSION ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 135 CHASSIS e. Tighten the locknut. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Locknut Compression damping (for fast compres- 30 Nm (3.0 m·kgf, 22 ft·lbf) sion damping) NOTICE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: Do not turn the adjuster forcibly beyond its • Rear frame adjusting range. Refer to “REAR SHOCK ABSORBER AS- 1.

  • Page 136: Checking The Tires

    CHASSIS Compression damping (for slow compres- sion damping) • Check the tire while it is cold. • Loose bead stoppers allow the tire to slip off NOTICE its position on the rim when the tire pressure Do not turn the adjuster forcibly beyond its is low.

  • Page 137: Checking The Wheels

    CHASSIS WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Check: • Steering head Grasp the bottom of the front fork legs and gently rock the front fork. Blinding/looseness  Adjust the steering head.

  • Page 138: Checking And Lubricating The Cables

    CHASSIS 1. Check: Ring nut (initial tightening torque) • Outer cable 38 Nm (3.8 m·kgf, 27 ft·lbf) Damage  Replace. 2. Check: c. Turn the front fork to the right and left a few • Cable operation times, and make sure that the steering ro- Rough movement ...

  • Page 139: Lubricating The Sidestand

    CHASSIS Recommended lubricant Chain lubricant suitable for O- ring chains LUBRICATING THE SIDESTAND EAS2GBB128 Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Recommended lubricant Lithium-soap-based grease CHECKING THE CHASSIS FASTENERS EAS2GBB129 Make sure that all nuts, bolts, and screws are properly tightened.

  • Page 140: Electrical System

    ELECTRICAL SYSTEM 6. Measure: ELECTRICAL SYSTEM EAS2GBB130 • Spark plug gap “a” Out of specification  Adjust the spark plug EAS2GBB131 CHECKING THE SPARK PLUG gap. 1. Remove: • Seat Spark plug gap • Air scoop (left/right) 0.7–0.8 mm (0.028–0.031 in) Refer to “GENERAL CHASSIS”...

  • Page 141: Checking And Charging The Battery

    ELECTRICAL SYSTEM REPLACING THE HEADLIGHT BULB EAS2GBB134 Timing light 90890-03141 WARNING Timing light Since the headlight bulb gets extremely hot, YU-03141 keep flammable products and your hands Digital tachometer away from the bulb until it has cooled down. 90890-06760 1. Remove: Digital tachometer •...
  • Page 142 ELECTRICAL SYSTEM 4. Install: • Headlight bulb Fasten the new headlight bulb with the headlight bulb holder. NOTICE Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected.

  • Page 143: Tuning

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

  • Page 144: Chassis

    CHASSIS CHASSIS DRIVE AND REAR WHEEL SPROCKETS EAS2GBB136 EAS2GBB138 SETTING PARTS EAS2GBB137 SELECTION OF THE SECONDARY REDUC- Part name Type Part number TION RATIO (SPROCKET) Drive sprocket “1” Secondary reduction ratio = Number of (STD) 13T 9383B-13218 rear wheel sprocket teeth/Number of drive sprocket teeth Rear wheel sprock- et “2”...

  • Page 145: Front Fork Setting

    CHASSIS • Under a stony or a hard road condition, the tire pressure should be higher to prevent a flat tire. Extent of adjustment 100–120 kPa (1.00–1.20 kgf/cm 15–18 psi) FRONT FORK SETTING EAS2GBB140 The front fork setting should be made depend- ing on the rider’s feeling of an actual run and the circuit conditions.

  • Page 146: Front Fork Setting Parts

    CHASSIS REAR SUSPENSION SETTING EAS2GBB144 The rear shock absorber setting should be Generally a stiff spring gives a stiff riding feel- made depending on the rider’s feeling of an ac- ing. Rebound damping tends to become weak- tual run and the circuit conditions. er, resulting in lack of a sense of contact with The rear suspension setting includes the fol- the road surface or in a vibrating handlebar.

  • Page 147: Setting Of Spring After Replacement

    CHASSIS WARNING • If the machine is new and after it is broken in, When using a rear shock absorber other the same set length of the spring may change than currently installed, use the one whose because of the initial fatigue, etc. of the overall length “a”...
  • Page 148 CHASSIS • Spring preload adjusting positions Spring preload adjusting positions Minimum Position in which the spring is turned in 1.5 mm (0.06 in) from its free length. Standard Position in which the spring is turned in 10 mm (0.39 in) from its free length.

  • Page 149: Suspension Setting (Front Fork)

    CHASSIS SUSPENSION SETTING (FRONT FORK) EAS2GBB148 • If any of the following symptoms is experienced with the standard position as the base, make reset- ting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in).

  • Page 150: Suspension Setting (Rear Shock Absorber)

    CHASSIS Section Medi- Symptom Check Adjust Large Small Jump Compression Turn adjuster clockwise (about damping force 2 clicks) to increase damping. Rebound Turn adjuster counterclock- damping force wise (about 2 clicks) to de- crease damping. Low front, tend- ing to lower Balance with Set sunken length for 95–100 front posture...
  • Page 151 CHASSIS Section Medi- Symptom Check Adjust Large Small Jump Rebound Turn adjuster counterclock- damping force wise (about 2 clicks) to de- Heavy and crease damping. dragging Spring Replace with soft spring. Rebound Turn adjuster counterclock- damping force wise (about 2 clicks) to de- crease damping.
  • Page 152 CHASSIS...
  • Page 153 CHASSIS GENERAL CHASSIS..................5-1 REMOVING THE LEFT SIDE COVER............5-3 REMOVING THE SEAT ................5-3 FRONT WHEEL....................5-4 REMOVING THE FRONT WHEEL.............5-5 CHECKING THE FRONT WHEEL .............5-5 DISASSEMBLING THE FRONT WHEEL...........5-6 ASSEMBLING THE FRONT WHEEL............5-6 INSTALLING THE FRONT WHEEL ............5-7 REAR WHEEL ....................5-9 REMOVING THE REAR WHEEL .............5-10 CHECKING THE REAR WHEEL..............5-10 DISASSEMBLING THE REAR WHEEL ...........5-10 CHECKING AND REPLACING THE REAR WHEEL SPROCKET ..5-10...
  • Page 154 HANDLEBAR ....................5-33 REMOVING THE HANDLEBAR...............5-35 CHECKING THE HANDLEBAR ...............5-35 INSTALLING THE HANDLEBAR .............5-35 FRONT FORK....................5-40 REMOVING THE FRONT FORK LEGS...........5-42 DISASSEMBLING THE FRONT FORK LEGS .........5-42 CHECKING THE FRONT FORK LEGS ...........5-43 ASSEMBLING THE FRONT FORK LEGS ..........5-44 INSTALLING THE FRONT FORK LEGS ..........5-50 STEERING HEAD...................5-53 REMOVING THE LOWER BRACKET............5-55 CHECKING THE STEERING HEAD ............5-55...
  • Page 155 This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.
  • Page 156 GENERAL CHASSIS Removing the headlight assembly and multi-function meter 21 Nm (2.1 m kgf, 15 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 21 Nm (2.1 m kgf, 15 ft Ibf) 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) Order...

  • Page 157: General Chassis

    GENERAL CHASSIS REMOVING THE LEFT SIDE COVER EAS2GBB152 1. Remove: • Bolt (side cover) • Side cover “1” Draw the left side cover “1” backward to re- move it because its projection “a” is inserted in the rear frame. EAS2GBB153 REMOVING THE SEAT The fuel tank cap cover and the seat are cou- pled with each other with a plastic band.

  • Page 158: Front Wheel

    FRONT WHEEL FRONT WHEEL EAS2GBB154 Removing the front wheel 21 Nm (2.1 m kgf, 15 ft Ibf) 21 Nm (2.1 m kgf, 15 ft Ibf) 90 Nm (9.0 m kgf, 65 ft lbf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) Order Part name Q’ty...

  • Page 159: Removing The Front Wheel

    FRONT WHEEL REMOVING THE FRONT WHEEL EAS2GBB155 1. Use a suitable stand to raise the front wheel A tight spoke will emit a clear, ringing tone; a off the ground. loose spoke will sound flat. WARNING 4. Tighten: Securely support the vehicle so that there is •...

  • Page 160: Disassembling The Front Wheel

    FRONT WHEEL DISASSEMBLING THE FRONT WHEEL EAS2GBB157 1. Remove: • Oil seals • Bearings ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside of the front wheel hub. b. Remove the oil seals “1” with a flat-head screwdriver. To prevent damaging the wheel, place a rag “2” between the screwdriver and the wheel sur- face.

  • Page 161: Installing The Front Wheel

    FRONT WHEEL 3. Install: 2. Install: • Collar “1” • Front wheel axle “1” Apply the lithium-soap-based grease on the oil Apply the lithium-soap-based grease to the seal lip. front wheel axle. 4. Install: 3. Tighten: • Speed sensor “1” •...
  • Page 162 FRONT WHEEL...

  • Page 163: Rear Wheel

    REAR WHEEL REAR WHEEL EAS2GBB160 Removing the rear wheel 14 Nm (1.4 m kgf, 10 ft Ibf) 125 Nm (12.5 m kgf, 90 ft lbf) 21 Nm (2.1 m kgf, 15 ft Ibf) 50 Nm (5.0 m kgf, 36 ft Ibf) 21 Nm (2.1 m kgf, 15 ft Ibf) Order Part name...

  • Page 164: Removing The Rear Wheel

    REAR WHEEL 4. Measure: REMOVING THE REAR WHEEL EAS2GBB161 • Radial wheel runout 1. Use a suitable stand to raise the rear wheel • Lateral wheel runout off the ground. Refer to “CHECKING THE FRONT WHEEL” WARNING on page 5-5. Securely support the vehicle so that there is Radial wheel runout limit no danger of it falling over.

  • Page 165: Assembling The Rear Wheel

    REAR WHEEL Tighten the self-locking nuts in stages and in a crisscross pattern. 2. Install: • Brake disc “1” • Brake disc bolt “2” Brake disc bolt ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 14 Nm (1.4 m·kgf, 10 ft·lbf) LOCTITE® ASSEMBLING THE REAR WHEEL EAS2GBB165 1.
  • Page 166 REAR WHEEL Install the brake disc “1” between the brake Temporarily tighten the nut (rear wheel axle) at pads “2” correctly. this point. 2. Install: 5. Adjust: • Drive chain “1” • Drive chain slack “a” Drive chain slack (on a suitable Push the rear wheel “2”...

  • Page 167: Front Brake

    FRONT BRAKE FRONT BRAKE EAS2GBB167 Removing the front brake caliper 30 Nm (3.0 m kgf, 22 ft lbf) 23 Nm (2.3 m kgf, 17 ft lbf) 6 Nm (0.6 m kgf, 4.3 ft lbf) 17 Nm (1.7 m kgf, 12 ft lbf) 2.5 Nm (0.25 m kgf, 1.8 ft...
  • Page 168 FRONT BRAKE Disassembling the front brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) Order Part name Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassemble pro- cedure.
  • Page 169 FRONT BRAKE Removing the front brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft lbf) 6 Nm (0.6 m kgf, 4.3 ft lbf) 6 Nm (0.6 m kgf, 4.3 ft lbf) 30 Nm (3.0 m kgf, 22 ft lbf) Order Part name Q’ty...
  • Page 170 FRONT BRAKE Disassembling the front brake master cylinder Order Part name Q’ty Remarks Push rod Dust boot Circlip Washer Brake master cylinder kit For assembly, reverse the disassemble pro- cedure. 5-16...

  • Page 171: Introduction

    FRONT BRAKE INTRODUCTION EAS2GBB168 Brake disc thickness limit WARNING 2.5 mm (0.10 in) If you need to disassemble the disc brake 4. Install: components, observe the following precau- • Front wheel tions. Refer to “FRONT WHEEL” on page 5-4. • Never disassemble the brake components unless absolutely necessary.

  • Page 172: Checking The Front Brake Caliper

    FRONT BRAKE ASSEMBLING THE FRONT BRAKE CALI- EAS2GBB173 WARNING • Before installation, clean and lubricate the internal parts. Use new brake fluid for cleaning and lubricating. • Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.

  • Page 173: Installing The Front Brake Caliper

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

  • Page 174: Removing The Front Brake Master Cylinder

    FRONT BRAKE NOTICE Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Bleed: • Brake system Refer to “BLEEDING THE BRAKE SYS- TEM” on page 3-25. 6. Check: • Brake fluid level 2.

  • Page 175: Installing The Front Brake Master Cylinder

    FRONT BRAKE INSTALLING THE FRONT BRAKE MASTER EAS2GBB179 CYLINDER 1. Install: • Brake master cylinder “1” Brake master cylinder holder bolt 9 Nm (0.9 m·kgf, 6.5 ft·lbf) • Install the front brake master cylinder holder 3. Install: with the “UP” mark facing up. •...
  • Page 176 FRONT BRAKE Turn the handlebar toward right and left to make sure that the brake hose does not touch other parts (e.g., wire harness, cables, leads). Adjust if necessary. 6. Check: • Brake lever free play Refer to “ADJUSTING THE FRONT BRAKE”...

  • Page 177: Rear Brake

    REAR BRAKE REAR BRAKE EAS2GBB180 Removing the rear brake caliper 10 Nm (1.0 m kgf, 7.2 ft Ibf) 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf)
  • Page 178 REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) Order Part name Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassemble pro- cedure.
  • Page 179 REAR BRAKE Removing the rear brake master cylinder Order Part name Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE BRAKE SYSTEM” on page 3-25. Union bolt Copper washers Brake hose Split pin Washer Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm plate Brake master cylinder reservoir diaphragm Rear brake master cylinder For installation, reverse the removal proce-...
  • Page 180 REAR BRAKE Disassembling the rear brake master cylinder Order Part name Q’ty Remarks Dust boot Circlip Push rod Brake master cylinder kit For assembly, reverse the disassemble pro- cedure. 5-26...

  • Page 181: Introduction

    REAR BRAKE INTRODUCTION EAS2GBB181 WARNING If you need to disassemble the disc brake components, observe the following precau- tions. • Never disassemble the brake components unless absolutely necessary. • If there is any problem with connections on the hydraulic brake system, perform the following jobs.

  • Page 182: Removing The Rear Brake Caliper

    REAR BRAKE REMOVING THE REAR BRAKE CALIPER CHECKING THE REAR BRAKE CALIPER EAS2GBB183 EAS2GBB185 1. Check: • Brake caliper piston “1” Before disassembling the brake caliper, drain Rust/scratches/wear  Replace the brake the brake fluid from the entire brake system. caliper piston.

  • Page 183: Installing The Brake Caliper Piston

    REAR BRAKE INSTALLING THE BRAKE CALIPER PISTON INSTALLING THE REAR BRAKE CALIPER EAS2GBB187 EAS2GBB188 1. Clean: 1. Install: • Brake caliper • Rear brake caliper • Brake caliper piston seal • Rear brake caliper bracket • Brake caliper piston dust seal 2.

  • Page 184: Removing The Rear Brake Master Cylinder

    REAR BRAKE REMOVING THE REAR BRAKE MASTER EAS2GBB189 WARNING CYLINDER • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to Before removing the rear brake master cylin- deteriorate, causing leakage and poor der, drain the brake fluid from the entire brake brake performance.

  • Page 185: Assembling The Rear Brake Master Cylinder

    REAR BRAKE ASSEMBLING THE REAR BRAKE MASTER EAS2GBB191 CYLINDER WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake com- ponents. Specified brake fluid 4.
  • Page 186 REAR BRAKE 2. Pour brake fluid to the brake fluid reservoir 5. Check: up to the specified level. • Brake pedal operation A softy or spongy feeling  Bleed the brake Specified brake fluid system. DOT 4 Refer to “BLEEDING THE BRAKE SYS- TEM”...
  • Page 187 HANDLEBAR HANDLEBAR EAS2GBB193 Removing the handlebar Order Part name Q’ty Remarks Clutch cable Disconnect. Clutch switch Clutch lever holder Engine stop switch Brake master cylinder Throttle cable cap Throttle cable (pull) Disconnect. Throttle cable (return) Disconnect. Right grip Tube guide Start switch Left grip Upper handlebar holder...
  • Page 188 HANDLEBAR Removing the handlebar Order Part name Q’ty Remarks Lower handlebar holder Damper For installation, reverse the removal proce- dure. 5-34...

  • Page 189: Handlebar

    HANDLEBAR REMOVING THE HANDLEBAR EAS2GBB194 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Clutch switch “1” CHECKING THE HANDLEBAR EAS2GBB195 1. Check: •...
  • Page 190 HANDLEBAR NOTICE • First, tighten the bolts on the front side of the upper handlebar holder, and then on the rear side. • Turn the handlebar all the way to the left and right. If there is any contact with the fuel tank, adjust the handlebar position.
  • Page 191 HANDLEBAR ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: • Engine stop switch “1” • Clutch lever “2” • Clutch lever holder “3” • Clamp “4” Engine stop switch screw 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf) Clutch lever holder bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) 7.
  • Page 192 HANDLEBAR 9. Install: 11.Install: • Throttle cable housings “1” • Start switch “1” • Screw (throttle cable housings) “2” • Front brake master cylinder assembly “2” • Front brake master cylinder holder “3” Screw (throttle cable housings) • Bolt (brake master cylinder holder) “4” 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) •...
  • Page 193 HANDLEBAR 12.Install: • Clutch cable “1” Before installation, apply the lithium-soap- based grease to the clutch cable end. 13.Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LE- VER FREE PLAY” on page 3-12. Clutch lever free play 7.0–12.0 mm (0.28–0.47 in) 14.Adjust: •...

  • Page 194: Front Fork

    FRONT FORK FRONT FORK EAS2GBB197 Removing the front fork legs Order Part name Q’ty Remarks Use a suitable stand to raise the front wheel off the ground. Front wheel Refer to “FRONT WHEEL” on page 5-4. Front brake caliper Refer to “FRONT BRAKE” on page 5-13. Brake hose holder Protector Upper bracket pinch bolts...
  • Page 195 FRONT FORK Disassembling the front fork leg 30 Nm (3.0 m kgf, 22 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • 55 Nm (5.5 m kgf, 40 ft Ibf) •...

  • Page 196: Removing The Front Fork Legs

    FRONT FORK REMOVING THE FRONT FORK LEGS EAS2GBB198 1. Use a suitable stand to raise the front wheel • While compressing the inner tube “2”, set the off the ground. cap bolt ring wrench “4” between the inner tube and locknut “3”. WARNING •...

  • Page 197: Checking The Front Fork Legs

    FRONT FORK b. Repeat this step until the inner tube can be pulled out from the outer tube. The bending value is shown by one half of the dial gauge reading. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it.

  • Page 198: Assembling The Front Fork Legs

    1. Stretch the damper assembly fully. 2. Fill: • Damper assembly Recommended oil Yamaha Suspension Oil S1 6. Check: Standard oil amount • Contacting surface “a” 210 cm (7.10 US oz, 7.41 Wear/damage ...
  • Page 199 FRONT FORK 4. Measure: 6. Loosen: • Oil level (left and right) “a” • Compression damping force adjuster “1” Out of specification  Regulate. • Before loosening the damping force adjuster, Standard oil level record the setting position. 145–148 mm (5.71–5.83 in) •...
  • Page 200 FRONT FORK 9. Tighten: • Base valve “1” Base valve 28 Nm (2.8 m·kgf, 20 ft·lbf) Hold the damper assembly with the cap bolt ring wrench “2” and use the cap bolt wrench “3” to tighten the base valve. 12.Allow the overflowing oil to escape at the Cap bolt wrench hole “a”...
  • Page 201 FRONT FORK • Apply the lithium-soap-based grease on the dust seal lip and oil seal lip. • Apply the fork oil on the inner tube. • When installing the oil seal, use vinyl seat “a” with fork oil applied to protect the oil seal lip. 17.Install: •...
  • Page 202 FRONT FORK 19.Install: 22.Measure: • Oil seal clip “1” • Distance “a” Out of specification  Turn into the locknut. Fit the oil seal clip correctly in the groove in the Distance “a” outer tube. 16 mm (0.63 in) or more Between the damper assembly “1”...
  • Page 203 FRONT FORK NOTICE Allow the damper assembly to slide slowly down the inner tube until it contacts the bot- tom of the inner tube. Be careful not to dam- age the inner tube. 27.Measure: • Gap “a” between the adjuster “1” and the locknut “2”...

  • Page 204: Installing The Front Fork Legs

    55 Nm (5.5 m·kgf, 40 ft·lbf) LOCTITE® 32.Install: • Protector guide “1” 30.Fill: • Front fork leg Recommended oil Yamaha Suspension Oil S1 Standard oil amount 340 cm (11.50 US oz, 11.99 INSTALLING THE FRONT FORK LEGS EAS2GBB202 lmp.oz) 1. Install: Extent of adjustment •...
  • Page 205 FRONT FORK Use the cap bolt ring wrench “2” to tighten the damper assembly. Cap bolt ring wrench 90890-01501 Cap bolt ring wrench YM-01501 5. Install: • Speed sensor lead “1” • Plate 1 “2” (to the right front fork protector) Plate 1 bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) Install the speed sensor lead so that its paint “a”...
  • Page 206 FRONT FORK 7. Install: • Protector “1” • Bolt (protector) “2” Bolt (protector) 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 8. Adjust: • Rebound damping force Turn in the damping adjuster “1” finger-tight and then turn out to the originally set position. 9.

  • Page 207: Steering Head

    STEERING HEAD STEERING HEAD EAS2GBB203 Removing the lower bracket 145 Nm (14.5 m kgf, 105 ft lbf) 21 Nm (2.1 m kgf, 15 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft lbf) 21 Nm (2.1 m kgf, 15 ft...
  • Page 208 STEERING HEAD Removing the lower bracket 145 Nm (14.5 m kgf, 105 ft lbf) 21 Nm (2.1 m kgf, 15 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft lbf) 21 Nm (2.1 m kgf, 15 ft lbf) 3.8 Nm (0.38 m...

  • Page 209: Removing The Lower Bracket

    STEERING HEAD REMOVING THE LOWER BRACKET EAS2GBB204 1. Use a suitable stand to raise the front wheel Always replace the bearing and the bearing off the ground. race as a set. WARNING Securely support the vehicle so that there is no danger of it falling over.
  • Page 210 STEERING HEAD Apply the lithium-soap-based grease on the bearing and bearing race cover lip. 5. Check the steering stem by turning this lock to lock. If there is any binding, remove the steering stem and check the steering bear- ing. 3.
  • Page 211 STEERING HEAD 11.Tighten: • Pinch bolt (upper bracket) “1” Upper bracket pinch bolts 21 Nm (2.1 m·kgf, 15 ft·lbf) • Pinch bolt (lower bracket) “2” Lower bracket pinch bolts 21 Nm (2.1 m·kgf, 15 ft·lbf) 8. Install: WARNING • Steering stem nut “1” Tighten the lower bracket to specified torque.

  • Page 212: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY REAR SHOCK ABSORBER ASSEMBLY EAS2GBB207 Removing the rear shock absorber assembly 16 15 14 13 Order Part name Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 5-1. Side cover (left/right) Refer to “GENERAL CHASSIS” on page 5-1. Air scoop (left/right) Refer to “GENERAL CHASSIS”...
  • Page 213 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 16 15 14 13 Order Part name Q’ty Remarks Collars O-ring Dust seal Stopper ring Bearing For installation, reverse the removal proce- dure. 5-59...
  • Page 214 REAR SHOCK ABSORBER ASSEMBLY Disassembling the relay arm 80 Nm (8.0 m kgf, 58 ft lbf) Order Part name Q’ty Remarks Relay arm Connecting arm Collars Oil seals Washers Bearing For assembly, reverse the disassemble pro- cedure. 5-60...

  • Page 215: Handling The Rear Shock Absorber

    • Rear shock absorber assembly upper bolt • To dispose of a damaged or a worn-out • Rear shock absorber assembly rear shock absorber, take the unit to your Yamaha dealer for this disposal proce- REMOVING THE BEARING EAS2GBB211 dure.

  • Page 216: Checking The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY 2. Remove: CHECKING THE CONNECTING ARM AND EAS2GBB213 • Upper bearing “1” RELAY ARM 1. Check: • Connecting arm Remove the bearing by pressing its outer race. • Relay arm Damage/wear  Replace. 2. Check: • Bearing •...

  • Page 217: Installing The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY Install the dust seals with their lips facing in- ward. Installed depth “a” 4.25 mm (0.17 in) INSTALLING THE REAR SHOCK ABSORB- EAS2GBB215 ER ASSEMBLY 1. Lubricate: • Bearing (lower side) • Dust seal • Collars •...
  • Page 218 REAR SHOCK ABSORBER ASSEMBLY • Connecting arm bolt (relay arm side) Connecting arm bolt (relay arm side) 80 Nm (8.0 m·kgf, 58 ft·lbf) • Relay arm bolt (swingarm side) Relay arm bolt (swingarm side) 70 Nm (7.0 m·kgf, 51 ft·lbf) •...

  • Page 219: Swingarm

    SWINGARM SWINGARM EAS2GBB216 Removing the swingarm 70 Nm (7.0 m kgf, 51 ft lbf) 4.0 Nm (0.40 m kgf, 2.9 ft lbf) Order Part name Q’ty Remarks Use a suitable stand to raise the front wheel off the ground. Brake hose holder Refer to “REAR BRAKE”...

  • Page 220: Removing The Swingarm

    SWINGARM REMOVING THE SWINGARM EAS2GBB217 1. Use a suitable stand to raise the rear wheel off the ground. WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Measure: • Swingarm side play • Swingarm vertical movement ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 221: Installing The Swingarm

    SWINGARM INSTALLING THE SWINGARM EAS2GBB220 1. Lubricate: • Bearing • Collars • Spacers • Oil seal • Pivot shaft Recommended lubricant Molybdenum disulfide grease 2. Install: • Bearing “1” • Oil seals “2” (to the swingarm) Installed depth “a” 0–0.5 mm (0–0.02 in) Installed depth “b”...

  • Page 222: Chain Drive

    CHAIN DRIVE CHAIN DRIVE EAS2GBB221 Removing the drive chain 75 Nm (7.5 m kgf, 54 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft lbf) Job Order Part name Q’ty Servicing Information Drive sprocket Refer to “ENGINE REMOVAL” on page 6-1. Drive chain For installation, reverse the removal proce- dure.

  • Page 223: Removing The Drive Chain

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

  • Page 224: Checking The Drive Sprocket

    CHAIN DRIVE NOTICE • This vehicle has a drive chain with small rubber O-rings “1” between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain sol- vents (e.g., benzine), or a coarse brush to clean the drive chain. High-pressure meth- ods could force dirt or water into the drive chain’s internals, and solvents will deteri- orate the O-rings.
  • Page 225 CHAIN DRIVE 3. Install: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Drive sprocket a. When press fitting the connecting plate “1”, • Lock washer make sure the space “a” between the end of • Drive sprocket nut the connecting pin “2” and the connecting Refer to “ENGINE REMOVAL” on page 6-1. plate is 1.2–1.4 mm (0.05–0.06 in).
  • Page 226 CHAIN DRIVE 5-72...

  • Page 227: Engine

    ENGINE ENGINE REMOVAL ..................6-1 REMOVING THE SILENCER..............6-6 REMOVING THE EXHAUST PIPE 2............6-6 REMOVING THE DRIVE SPROCKET ............6-6 REMOVING THE ENGINE .................6-7 CLEANING THE SPARK ARRESTER ............6-7 CHECKING THE SILENCER AND EXHAUST PIPE........6-8 INSTALLING THE ENGINE................6-8 INSTALLING THE BRAKE PEDAL ............6-9 INSTALLING THE DRIVE SPROCKET............6-9 INSTALLING THE EXHAUST PIPE AND MUFFLER.......6-10 CAMSHAFT ....................6-12...
  • Page 228 CLUTCH ......................6-42 REMOVING THE CLUTCH ..............6-45 CHECKING THE FRICTION PLATES............6-45 CHECKING THE CLUTCH PLATES ............6-45 CHECKING THE CLUTCH SPRINGS............6-45 CHECKING THE CLUTCH HOUSING .............6-46 CHECKING THE CLUTCH BOSS............6-46 CHECKING THE PRESSURE PLATE .............6-46 CHECKING THE PUSH LEVER SHAFT..........6-46 CHECKING THE CLUTCH PUSH RODS ..........6-46 CHECKING THE PRIMARY DRIVE GEAR..........6-46 CHECKING THE PRIMARY DRIVEN GEAR ...........6-47 INSTALLING THE OIL SEAL ..............6-47...
  • Page 229 GENERATOR AND STARTER CLUTCH............6-66 REMOVING THE GENERATOR ..............6-68 CHECKING THE STARTER CLUTCH .............6-68 INSTALLING THE STARTER CLUTCH ...........6-68 INSTALLING THE GENERATOR.............6-69 CRANKCASE ....................6-72 DISASSEMBLING THE CRANKCASE.............6-75 REMOVING THE CRANKCASE BEARING ..........6-75 CHECKING THE TIMING CHAIN, TIMING CHAIN GUIDE, OIL STRAINER ....................6-75 CHECKING THE CRANKCASE ...............6-75 INSTALLING THE OIL SEAL ..............6-76 ASSEMBLING THE CRANKCASE............6-76...

  • Page 230: Engine Removal

    This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.
  • Page 231 ENGINE REMOVAL Removing the exhaust pipe 5 Nm (0.5 m kgf, 3.6 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 9 Nm (0.9 m kgf, 6.5 ft Ibf) 13 Nm (1.3 m , 9.4 ft lbf) 20 Nm (2.0 m kgf, 14 ft lbf) 30 Nm (3.0 m kgf, 22 ft Ibf)
  • Page 232 ENGINE REMOVAL Removing the electronic parts Order Part name Q’ty Remarks Use a suitable stand to raise the front wheel off the ground. Seat Refer to “GENERAL CHASSIS” on page 5-1. Side cover (left/right) Refer to “GENERAL CHASSIS” on page 5-1. Air scoop (left/right) Refer to “GENERAL CHASSIS”...
  • Page 233 ENGINE REMOVAL Removing the engine 55 Nm (5.5 m kgf, 40 ft Ibf) Order Part name Q’ty Remarks Use a suitable stand to raise the front wheel off the ground. Seat Refer to “GENERAL CHASSIS” on page 5-1. Side cover (left/right) Refer to “GENERAL CHASSIS”...
  • Page 234 ENGINE REMOVAL Removing the engine 55 Nm (5.5 m kgf, 40 ft Ibf) Order Part name Q’ty Remarks Drive sprocket cover Drive chain guide Drive sprocket Upper engine bracket Washer Thickness:2.3 mm (0.09 in) Washer Thickness:1.0 mm (0.04 in) Lower engine bracket Pivot shaft Engine For installation, reverse the removal proce-...

  • Page 235: Removing The Silencer

    ENGINE REMOVAL REMOVING THE SILENCER EAS2GBB227 1. Remove: • Rear shock absorber assembly lower bolt “1” • Connecting arm bolt (frame side) “2” • Silencer “3” Move the rear shock absorber to the left side of the chassis, and remove the silencer. REMOVING THE DRIVE SPROCKET EAS2GBB229 1.

  • Page 236: Removing The Engine

    ENGINE REMOVAL REMOVING THE ENGINE CLEANING THE SPARK ARRESTER EAS2GBB230 EAS2GBB231 1. Remove: WARNING • Pivot shaft “1” • Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. If the pivot shaft is pulled all the way out, the •...

  • Page 237: Checking The Silencer And Exhaust Pipe

    ENGINE REMOVAL 5. Install: INSTALLING THE ENGINE EAS2GBB233 • Spark arrester gasket 1. Install: • Spark arrester • Engine “1” Insert the spark arrester into the muffler and Install the engine from the right side. align the bolt holes. • Pivot shaft “2” •...

  • Page 238: Installing The Brake Pedal

    ENGINE REMOVAL INSTALLING THE DRIVE SPROCKET EAS2GBB235 1. Install: • Drive sprocket “1” • Drive chain “2” Install the drive sprocket together with the drive chain. 2. Install: • Lock washer “1” • Nut (drive sprocket) “2” INSTALLING THE BRAKE PEDAL Nut (drive sprocket) EAS2GBB234 75 Nm (7.5 m·kgf, 54 ft·lbf)

  • Page 239: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL Install and temporarily tighten the exhaust pipe 2 with its end positioned as shown with respect to the exhaust pipe 1. 2mm (0.08in) INSTALLING THE EXHAUST PIPE AND EAS2GBB236 MUFFLER 1. Install: • Gasket • Exhaust pipe 1 “1” 3.
  • Page 240 ENGINE REMOVAL 4. Tighten: • Bolt (exhaust pipe 2) Bolt (exhaust pipe 2) 20 Nm (2.0 m·kgf, 14 ft·lbf) • Clamp Clamp 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Tighten while checking that their front and rear joints are inserted in position. 6-11...

  • Page 241: Camshaft

    CAMSHAFT CAMSHAFT EAS2GBB237 Removing the cylinder head cover 13 Nm (1.3 m kgf, 9.4 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 5-1. Side cover (left/right) Refer to “GENERAL CHASSIS”...
  • Page 242 CAMSHAFT Removing the camshaft 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 6 Nm (0.6 m kgf, 4.3 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 6 Nm (0.6 m kgf, 4.3 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name...

  • Page 243: Removing The Camshaft

    CAMSHAFT REMOVING THE CAMSHAFT EAS2GBB238 1. Remove: • Timing mark accessing screw “1” • Crankshaft end accessing screw “2” 4. Remove: • Bolt (camshaft cap) “1” • Camshaft cap “2” • Clip “3” 2. Align: • Alignment mark • Remove the bolts (camshaft cap) in a criss- cross pattern, working from the outside in.

  • Page 244: Checking The Camshaft

    CAMSHAFT 3. Measure: CHECKING THE CAMSHAFT EAS2GBB239 • Camshaft runout 1. Check: Out of specification  Replace. • Camshaft lobes Blue discoloration/pitting/scratches  Re- Camshaft runout limit 0.030 mm (0.0012 in) place the camshaft. 2. Measure: • Camshaft lobe dimensions “A” and “B” Out of specification ...

  • Page 245: Checking The Timing Chain And Camshaft Sprocket

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

  • Page 246: Checking The Decompression System

    CAMSHAFT CHECKING THE DECOMPRESSION SYS- EAS2GBB242 1. Check: • Decompression system ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check that the decompressor cam “1” moves smoothly. b. Check that the decompressor lever pin “2” projects from the camshaft. c. Fit the timing chain “3” onto both camshaft sprockets and install the camshafts on the cylinder head.
  • Page 247 “1” and the timing chain tensioner “2” and tighten the bolt “3”. Before installation, apply the sealant to the cyl- Bolt (timing chain tensioner) inder head cover gasket. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Yamaha bond No.1215 90890-85505 (Three bond No.1215®) 6-18...
  • Page 248 CAMSHAFT 6. Install: • Cylinder head breather hose • Spark plug Spark plug 13 Nm (1.3m·kgf, 9.4 ft·lbf) 6-19...

  • Page 249: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD EAS2GBB244 Removing the cylinder head 33 Nm (3.3 m kgf, 24 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 5-1. Side cover (left/right) Refer to “GENERAL CHASSIS”...
  • Page 250 CYLINDER HEAD Removing the cylinder head 33 Nm (3.3 m kgf, 24 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks Timing chain guide (intake side) Oil check bolt For installation, reverse the removal proce- dure.

  • Page 251: Removing The Cylinder Head

    CYLINDER HEAD REMOVING THE CYLINDER HEAD EAS2GBB245 1. Remove: • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAMSHAFT” on page 6-14. 2. Remove: • Cylinder head nuts • Cylinder head bolts 2. Check: • Loosen the bolts in the proper sequence as •...

  • Page 252: Installing The Cylinder Head

    CYLINDER HEAD INSTALLING THE CYLINDER HEAD EAS2GBB248 1. Install: Tighten the bolts and nuts to the specified • Timing chain guide (intake side) “1” torque in two or three steps in the proper tight- • Dowel pin “2” ening sequence as shown. •...
  • Page 253 VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS EAS2GBB249 Removing the valves and valve springs Order Part name Q’ty Remarks Refer to “CYLINDER HEAD” on page 6-20. Cylinder head Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Intake valve...

  • Page 254: Valves And Valve Springs

    VALVES AND VALVE SPRINGS b. Check that the valves are properly sealed. REMOVING THE VALVES EAS2GBB250 Check that there are no kerosene leaks from Before removing the internal parts of the cylin- the valve seat “1”. der head (e.g., valves, valve springs, valve seats), make sure that the valves are properly sealed.

  • Page 255: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS Identify the position of each part very carefully so that it can be reinstalled in its original place. 2. Replace: • Valve guide To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder CHECKING THE VALVES AND VALVE EAS2GBB251 head to 100 °C (212 °F) in an oven.

  • Page 256: Checking The Valve Seats

    VALVES AND VALVE SPRINGS Valve margin thickness (intake) 1.20 mm (0.0472 in) Valve margin thickness (exhaust) 0.85 mm (0.0335 in) After replacing the valve guide, reface the valve seat. Intake Valve guide remover (ø5) 6. Measure: 90890-04097 • Valve stem runout Valve guide remover (5.0 mm) Out of specification ...
  • Page 257 VALVES AND VALVE SPRINGS NOTICE Valve seat contact width (intake) This model uses titanium intake and ex- 0.90–1.10 mm (0.0354–0.0433 in) haust valves. Valve seat contact width (ex- haust) Do not use the valves used for lapping the 0.90–1.10 mm (0.0354–0.0433 in) valve seat.

  • Page 258: Checking The Valve Springs

    VALVES AND VALVE SPRINGS 2. Measure: • Compressed valve spring force “a” Out of specification  Replace the valve spring. h. Install the valve into the cylinder head. i. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion.

  • Page 259: Installing The Valves

    VALVES AND VALVE SPRINGS b. Smaller pitch INSTALLING THE VALVES EAS2GBB255 4. Install: 1. Clean: • Valve cotter “1” • Valve stem end Install the valve cotters by compressing the valve spring with the valve spring compressor “2” and the valve spring compressor adapter “3”.
  • Page 260 VALVES AND VALVE SPRINGS 6. Lubricate: • Adjusting pad “1” • Valve lifter “2” 7. Install: • Adjusting pad • Valve lifter • Check that the valve lifter turns smoothly when rotated with your finger. • Make sure that the valve lifter and the adjust- ing pad are reinstalled in their original posi- tions.
  • Page 261 CYLINDER AND PISTON CYLINDER AND PISTON EAS2GBB256 Removing the cylinder and piston 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks Refer to “CYLINDER HEAD” on page 6-20. Cylinder head Cylinder body Gaskets...

  • Page 262: Cylinder And Piston

    CYLINDER AND PISTON REMOVING THE PISTON EAS2GBB257 1. Remove: • Piston pin clip “1” • Piston pin “2” • Piston “3” NOTICE Do not use a hammer to drive the piston pin out. • Before removing the piston pin clip, cover the CHECKING THE CYLINDER AND PISTON EAS2GBB258 crankcase opening with a cloth to prevent the...

  • Page 263: Checking The Piston Rings

    CYLINDER AND PISTON CHECKING THE PISTON RINGS EAS2GBB259 1. Measure: • Piston ring side clearance Out of specification  Replace the piston and piston rings as a set. Before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring grooves and piston rings.

  • Page 264: Checking The Piston Pin

    CYLINDER AND PISTON Piston ring Top ring End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in) Limit 0.50 mm (0.0197 in) Oil ring End gap (installed) 0.10–0.35 mm (0.0039–0.0138 in) EAS2GBB260 CHECKING THE PISTON PIN INSTALLING THE PISTON AND CYLINDER EAS2GBB261 1. Check: 1.
  • Page 265 CYLINDER AND PISTON 5. Install: • Cylinder gasket • Apply the engine oil to the piston pin. • Dowel pin • Install the piston with the F mark “a” on it • Cylinder pointing to its intake (front) side. • Before installing the piston pin clip, cover the Cylinder bolt crankcase opening with a cloth to prevent the 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

  • Page 266: Electric Starter

    ELECTRIC STARTER ELECTRIC STARTER EAS2GBB262 Removing the starter motor 12 Nm (1.2 m kgf, 8.7 ft Ibf) Order Job/Parts to remove Q’ty Remarks Exhaust pipe Refer to “ENGINE REMOVAL” on page 6-1. Starter motor For assembly, reverse the disassemble pro- cedure.
  • Page 267 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks Starter motor front cover Starter motor yoke Armature assembly Starter motor rear cover Brush set For assembly, reverse the disassembly pro- cedure. 6-38...

  • Page 268: Checking The Starter Motor

    ELECTRIC STARTER CHECKING THE STARTER MOTOR EAS2GBB263 Pocket tester 1. Check: 90890-03112 • Commutator Analog pocket tester Dirt  Clean with 600 grit sandpaper. YU-03112-C 2. Measure: • Commutator diameter “a” Armature coil Out of specification  Replace the starter Commutator resistance “1”...

  • Page 269: Assembling The Starter Motor

    ELECTRIC STARTER 8. Check: • Oil seal Damage/wear  Replace the defective part (s). EAS2GBB264 ASSEMBLING THE STARTER MOTOR 1. Install: • Brush spring “1” • Brush “2” 2. Install: • Armature assembly “1” 4. Install: Install while holding down the brush using a •...
  • Page 270 ELECTRIC STARTER 6-41...
  • Page 271 CLUTCH CLUTCH EAS2GBB265 Removing the clutch 6 10 Order Part name Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-17. Brake pedal Refer to “ENGINE REMOVAL” on page 6-1. Clutch cable Disconnect. Clutch cover Gasket Clutch spring Pressure plate Push rod 1...
  • Page 272 CLUTCH Removing the clutch 6 10 Order Part name Q’ty Remarks Cushion spring Friction plate 2 Identification color (purple) Clutch boss Thrust washer Primary driven gear Spacer Bearing Washer Push lever shaft For installation, reverse the removal proce- dure. 6-43...
  • Page 273 CLUTCH Removing the right crankcase cover Order Part name Q’ty Remarks Engine guard Refer to “ENGINE REMOVAL” on page 6-1. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-17. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-10.

  • Page 274: Clutch

    CLUTCH REMOVING THE CLUTCH CHECKING THE CLUTCH PLATES EAS2GBB266 EAS2GBB268 1. Remove: 1. Check: • Clutch boss nut “1” • Clutch plate Damage  Replace the clutch plates as a • Lock washer “2” • Clutch boss “3” set. 2. Measure: •...

  • Page 275: Checking The Clutch Housing

    CLUTCH CHECKING THE CLUTCH HOUSING EAS2GBB270 1. Check: • Clutch housing dogs “a” Damage/pitting/wear  Deburr the clutch housing dogs or replace the clutch housing. Pitting on the clutch housing dogs will cause er- ratic clutch operation. CHECKING THE CLUTCH PUSH RODS EAS2GBB274 1.

  • Page 276: Checking The Primary Driven Gear

    CLUTCH 2. Install: CHECKING THE PRIMARY DRIVEN GEAR EAS2GBB276 • Right crankcase cover “1” 1. Check: • Right crankcase cover bolt “2” • Primary driven gear Damage/wear  Replace the primary drive Right crankcase cover bolt and primary driven gears as a set. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Excessive noise during operation ...
  • Page 277 CLUTCH 2. Install: 4. Bend the lock washer “1” tab. • Washer “1” • Bearing “2” • Collar “3” • Primary driven gear “4” • Thrust washer “5” • Clutch boss “6” Apply the engine oil on the primary driven gear inner circumference.
  • Page 278 CLUTCH 6. Install: 9. Install: • Bearing “1” • Clutch spring • Washer “2” • Clutch spring bolt • Circlip “3” Clutch spring bolt To push rod 1 “4”. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Apply the engine oil on the bearing and washer. Tighten the bolts in stages and in a crisscross pattern.

  • Page 279: Installing The Kickstarter Lever

    CLUTCH INSTALLING THE KICKSTARTER LEVER EAS2GBB280 1. Install: • Kickstarter lever “1” • Washer • Bolt (kickstarter lever) Bolt (kickstarter lever) 33 Nm (3.3 m·kgf, 24 ft·lbf) LOCTITE® Install so that there is a clearance “a” of 5 mm (0.2 in) or more between the kickstarter lever and the frame and that the kickstarter lever does not contact the right crankcase cover when it is pulled.
  • Page 280 KICKSTATER KICKSTATER EAS2GBB281 Removing the kick shaft Order Part name Q’ty Remarks Primary driven gear Refer to “CLUTCH” on page 6-42. Kick idle gear Kick shaft assembly Spring guide Torsion spring Ratchet wheel Kick gear Kick shaft For installation, reverse the removal proce- dure.

  • Page 281: Kickstater

    KICKSTATER REMOVING THE KICK SHAFT ASSEMBLY EAS2GBB282 1. Remove: • Kick shaft assembly “1” Unhook the torsion spring “2” from the hole “a” in the crankcase. INSTALLING THE KICK SHAFT ASSEMBLY EAS2GBB285 1. Install: • Kick gear “1” • Washer “2” •...

  • Page 282: Installing The Kick Idle Gear

    KICKSTATER 5. Install: • Torsion spring “1” Turn the torsion spring clockwise and hook into the proper hole “a” in the crankcase. 3. Install: • Spring guide “1” Slide the spring guide into the kick shaft, make sure the groove “a” in the spring guide fits on the stopper of the torsion spring.
  • Page 283 SHIFT SHAFT SHIFT SHAFT EAS2GBB287 Removing the shift shaft and stopper lever 10 Nm (1.0 m kgf, 7.2 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 30 Nm (3.0 m kgf, 22 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty...

  • Page 284: Shift Shaft

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

  • Page 285: Removing The Shift Guide And Shift Lever Assembly

    SHIFT SHAFT REMOVING THE SHIFT GUIDE AND SHIFT EAS2GBB288 LEVER ASSEMBLY 1. Remove: • Bolt (shift guide) • Shift guide “1” • Shift lever assembly “2” Make sure that the shift lever assembly is re- moved together with the shift guide. CHECKING THE SHIFT GUIDE AND SHIFT EAS2GBB291 LEVER ASSEMBLY...

  • Page 286: Installing The Segment

    SHIFT SHAFT Bolt (stopper lever) Apply the engine oil on the spring, pawl pin and 10 Nm (1.0 m·kgf, 7.2 ft·lbf) pawl. LOCTITE® 2. Install: • Shift lever assembly “1” INSTALLING THE SEGMENT EAS2GBB294 (to the shift guide “2”) 1. Install: •...

  • Page 287: Installing The Shift Shaft

    SHIFT SHAFT INSTALLING THE SHIFT SHAFT EAS2GBB296 1. Install: • Roller “1” • Shift shaft spring “2” (to shift shaft) • Collar “3” (to shift shaft) • Shift shaft “4” Apply the engine oil on the roller, collar and shift shaft. 2.
  • Page 288 OIL PUMP AND BALANCER GEAR OIL PUMP AND BALANCER GEAR EAS2GBB298 Removing the oil pump 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • Order Part name Q’ty Remarks Primary driven gear Refer to “CLUTCH”...

  • Page 289: Oil Pump And Balancer Gear

    OIL PUMP AND BALANCER GEAR Removing the balancer 75 Nm (7.5 m kgf, 54 ft lbf) 50 Nm (5.0 m kgf, 36 ft Ibf) Order Part name Q’ty Remarks Primary driven gear Refer to “CLUTCH” on page 6-42. Right crankcase cover Refer to “CLUTCH”...
  • Page 290 OIL PUMP AND BALANCER GEAR Removing the balancer 75 Nm (7.5 m kgf, 54 ft lbf) 50 Nm (5.0 m kgf, 36 ft Ibf) Order Part name Q’ty Remarks For installation, reverse the removal proce- dure. 6-61...

  • Page 291: Removing The Balancer

    OIL PUMP AND BALANCER GEAR REMOVING THE BALANCER EAS2GBB299 1. Loosen: • Balancer nut “1” • Primary drive gear nut “2” • Balancer weight gear nut “3” Place an aluminum plate “a” between the teeth of the balancer drive gear “4” and balancer weight gear “5”.

  • Page 292: Assembling The Oil Pump

    OIL PUMP AND BALANCER GEAR Inner-rotor-to-outer-rotor-tip • Apply the engine oil on the oil pump drive clearance shaft and inner rotor. 0.000–0.150 mm (0.000–0.0059 • Fit the dowel pin into the groove in the inner rotor. Limit 0.23 mm (0.0091 in) Outer-rotor-to-oil-pump-housing clearance 0.13–0.18 mm (0.0051–0.0071 in)
  • Page 293 OIL PUMP AND BALANCER GEAR Oil pump assembly bolt 5 Nm (0.5 m·kgf, 3.6 ft·lbf) LOCTITE® NOTICE After tightening the bolts, make sure that the oil pump turns smoothly. 2. Install: • Collar “1” 4. Install: • Balancer weight gear “2” •...
  • Page 294 OIL PUMP AND BALANCER GEAR 6-65...
  • Page 295 GENERATOR AND STARTER CLUTCH GENERATOR AND STARTER CLUTCH EAS2GBB305 Removing the generator Order Job/Parts to remove Q’ty Remarks Refer to “CHANGING THE ENGINE OIL” on Drain the engine oil. page 3-17. Refer to “GENERAL CHASSIS” on page 5-1 Seat and fuel tank and “FUEL TANK”...
  • Page 296 GENERATOR AND STARTER CLUTCH Removing the generator Order Job/Parts to remove Q’ty Remarks Woodruff key Starter clutch Starter clutch drive gear Crankshaft position sensor Stator For installation, reverse the removal proce- dure. 6-67...

  • Page 297: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH 3. Check: REMOVING THE GENERATOR EAS2GBB306 • Starter clutch gear 1. Remove: Damage/pitting/wear  Replace the starter • Generator rotor nut “1” clutch gear. • Washer 4. Check: • Damper assembly Damage/pitting/wear  Replace the damp- er assembly.

  • Page 298: Installing The Generator

    “7” under the holder as shown. • Tighten the stator bolt using the T25 bit. • Apply the sealant to the grommet of the AC magneto lead. Yamaha bond No.1215 90890-85505 (Three bond No.1215®) Starter clutch bolt 16 Nm (1.6 m·kgf, 12 ft·lbf) LOCTITE®...
  • Page 299 GENERATOR AND STARTER CLUTCH 2. Install: • Washer • Generator rotor nut “1” Generator rotor nut 65 Nm (6.5 m·kgf, 47 ft·lbf) 3. Install: • Starter idle gear shaft “1” • Bearing “2” • Starter idle gear 2 “3” 5. Install: •...
  • Page 300 GENERATOR AND STARTER CLUTCH 6-71...
  • Page 301 CRANKCASE CRANKCASE EAS2GBB310 Separating the crankcase 5 Nm (0.5 m kgf, 3.6 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) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty...

  • Page 302: Crankcase

    CRANKCASE Separating the crankcase 5 Nm (0.5 m kgf, 3.6 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) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty...
  • Page 303 CRANKCASE Removing the bearing and oil seal 12 Nm (1.2 m kgf, 8.7 ft Ibf) 22 Nm (2.2 m kgf, 16 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) Order Part name Q’ty Remarks Transmission Refer to “TRANSMISSION” on page 6-81. Shift cam and shift fork Refer to “TRANSMISSION”...

  • Page 304: Disassembling The Crankcase

    CRANKCASE DISASSEMBLING THE CRANKCASE EAS2GBB311 1. Separate: • Right crankcase • Left crankcase ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the crankcase bolts. c. Remove the dowel pins and O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ REMOVING THE CRANKCASE BEARING EAS2GBB312 1. Remove: • Bearing “1” • Remove the bearing from the crankcase by Loosen each bolt 1/4 of a turn at a time and af- pressing its inner race.

  • Page 305: Installing The Oil Seal

    (2) stages, with 1/4 turn each. 22 Nm (2.2 m·kgf, 16 ft·lbf) LOCTITE® Install the bearing by pressing its outer race parallel. 2. Apply: • Sealant (to the crankcase mating surface) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 6-76...
  • Page 306 CRANKCASE 4. 45 mm (1.77 in) 5. 60 mm (2.36 in) 6. 75 mm (2.95 in) a. Hexagon socket head bolt without flange b. Hexagon socket head bolt with flange 6-77...

  • Page 307: Crankshaft Assembly And Balancer Shaft

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EAS2GBB317 Removing the crankshaft assembly and balancer shaft Order Part name Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 6-72. Transmission Refer to “TRANSMISSION” on page 6-81. Balancer shaft Crankshaft assembly For installation, reverse the removal proce- dure.

  • Page 308: Removing The Crankshaft Assembly

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT REMOVING THE CRANKSHAFT ASSEMBLY EAS2GBB318 1. Remove: • Crankshaft assembly “1” Remove the crankshaft assembly by using the crankcase separating tool “2”. Crankcase separating tool 90890-04152 Crankcase separating tool 2. Measure: YU-A9642 • Big end side clearance “a” Out of specification ...

  • Page 309: Installing The Crankshaft Assembly

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 4. Check: • Crankshaft sprocket “1” Hold the connecting rod at top dead center Damage  Replace the crankshaft. (TDC) with one hand while turning the nut of the crankshaft installer bolt with the other. Turn the crankshaft installer bolt until the crankshaft as- sembly bottoms against the bearing.
  • Page 310 TRANSMISSION TRANSMISSION EAS2GBB322 Removing the transmission, shift drum assembly, and shift forks Order Part name Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 6-1. Separate. Crankcase Refer to “CRANKCASE” on page 6-72. Main axle Drive axle Long shift fork guide bar Short shift fork guide bar Spring Shift cam...

  • Page 311: Transmission

    TRANSMISSION REMOVING THE TRANSMISSION EAS2GBB323 1. Remove: • Long shift fork guide bar “1” • Short shift fork guide bar “2” • Shift cam “3” • Shift fork 3 “4” • Shift fork 2 “5” • Shift fork 1 “6” •...

  • Page 312: Checking The Transmission

    TRANSMISSION 3. Check: • Transmission gears Blue discoloration/pitting/wear  Replace the defective gear (s). • Transmission gear dogs Cracks/damage/rounded edges  Replace the defective gear (s). 4. Check: • Transmission gear movement Rough movement  Replace the defective gear (s). CHECKING THE TRANSMISSION EAS2GBB326 EAS2GBB327...
  • Page 313 TRANSMISSION 3. Install: 5. Install: • Washer “1” • Main axle “1” • Circlip “2” • Drive axle “2” • Be sure the circlip sharp-edged corner “a” is • Install to the left crankcase simultaneously. positioned opposite side to the washer and •...
  • Page 314 TRANSMISSION 8. Check: • Operation of shift cam and shift fork • Transmission operation Unsmooth operation  Repair. 7. Install: • Long shift fork guide bar “1” • Short shift fork guide bar “2” • Spring “3” • Screw the spring into the shift fork guide bar lightly beforehand.

  • Page 315: Cooling System

    COOLING SYSTEM RADIATOR .......................7-1 HANDLING NOTE ..................7-3 CHECKING THE RADIATOR..............7-3 WATER PUMP....................7-4 REMOVING THE OIL SEAL...............7-6 CHECKING THE WATER PUMP ...............7-6 CHECKING THE BEARING ...............7-6 INSTALLING THE OIL SEAL ..............7-6 ASSEMBLING THE WATER PUMP............7-6...
  • Page 316 This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.
  • Page 317 RADIATOR Removing the radiator 8 Nm (0.8 m kgf, 5.8 ft Ibf) Order Part name Q’ty Remarks Right radiator Radiator hose 2 Radiator hose 3 Radiator hose 4 Radiator pipe 2 Radiator breather hose Left radiator Radiator hose 1 Radiator pipe 1 Coolant temperature sensor For installation, reverse the removal proce- dure.
  • Page 318 RADIATOR HANDLING NOTE EAS2GBB330 WARNING If coolant seems hot, do not remove the ra- diator cap. CHECKING THE RADIATOR EAS2GBB331 1. Check: • Radiator fins “1” Obstructions  Clean. Apply compressed air to the rear of the radi- ator. Damage  Repair or replace. Correct any flattened fins with a thin, flat-head screwdriver.
  • Page 319 WATER PUMP WATER PUMP EAS2GBB332 Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-10. Drain.
  • Page 320 WATER PUMP Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks Bearing Oil seal For installation, reverse the removal proce- dure.
  • Page 321 WATER PUMP REMOVING THE OIL SEAL EAS2GBB333 • Remove the oil seal when the coolant level changes frequently more than usual, coolant has discolored, or engine oil has become milky. • Do not use the removed oil seal. 1. Remove: •...
  • Page 322 WATER PUMP 2. Install: • Dowel pin “1” • Gasket “2” 3. Install: • Water pump housing “1” • Water pump housing bolt “2” Water pump housing bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Washer “3” • Coolant drain bolt “4” Coolant drain bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

  • Page 323: Fuel System

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

  • Page 324: Fuel Tank

    This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.
  • Page 325 FUEL TANK Removing the fuel tank 7 Nm (0.7 m kgf, 5.1 ft Ibf) 9 Nm (0.9 m kgf, 6.5 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) Order...

  • Page 326: Removing The Fuel Tank

    FUEL TANK REMOVING THE FUEL TANK EAS2GBB340 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose coupler WARNING Cover the fuel hose connection with a cloth when disconnecting it. This is because re- sidual pressure in the fuel hose could cause fuel to spurt out when the hose is removed.

  • Page 327: Removing The Fuel Sender

    FUEL TANK 5. Connect: • Fuel sender coupler • Take care not to damage the installation sur- 6. Push the start switch. faces of the fuel tank. 7. Check: • Always use a new fuel pump gasket. • Fuel level warning light •...

  • Page 328: Checking The Fuel Pressure

    FUEL TANK 2. Connect: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Fuel hose a. Remove the side cover (left/right), the seat and the air scoop (left/right). NOTICE Refer to “GENERAL CHASSIS” on page 5- • Connect the fuel hose securely, and check that the orientation of the installed fuel b.

  • Page 329: Checking The Damper

    FUEL TANK CHECKING THE DAMPER EAS2GBB349 1. Check: • Damper 1 “1” • Damper 2 “2” • Damper 3 “3” Wear/damage  Replace. • Affix dampers 1 and 3 with the arrow on each damper pointing outward. • Affix the damper 2 with its projection “a” facing the rear of the vehicle.

  • Page 330: Throttle Body

    THROTTLE BODY THROTTLE BODY EAS2GBB351 Removing the throttle body 7 Nm (0.7 m kgf, 5.1 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) Order Part name...
  • Page 331 THROTTLE BODY Removing the throttle body 7 Nm (0.7 m kgf, 5.1 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) Order Part name Q’ty...
  • Page 332 THROTTLE BODY Removing the injector 3.4 Nm (0.34 m kgf, 2.5 ft lbf) 5 Nm (0.5 m kgf, 3.6 ft lbf) 3.4 Nm (0.34 m kgf, 2.5 ft lbf) Order Part name Q’ty Remarks Fuel inlet pipe Injector Gaskets Throttle position sensor Intake air pressure sensor For installation, reverse the removal proce- dure.

  • Page 333: Checking The Injector

    THROTTLE BODY CHECKING THE INJECTOR EAS2GBB352 1. Check: • Injectors Obstruction  Replace, and check the fuel pump and the fuel injection system. Refer to “FUEL INJECTION SYSTEM” on page 9-28. Deposits  Replace. Damage  Replace. 2. Check: • Injector resistance Refer to “CHECKING THE FUEL INJEC- TOR”...

  • Page 334: Adjusting The Throttle Position Sensor

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

  • Page 335: Electrical System

    SIGNALING SYSTEM ..................9-20 CIRCUIT DIAGRAM .................9-20 TROUBLESHOOTING ................9-22 COOLING SYSTEM..................9-24 CIRCUIT DIAGRAM .................9-24 TROUBLESHOOTING ................9-26 FUEL INJECTION SYSTEM................9-28 CIRCUIT DIAGRAM .................9-28 ECU SELF-DIAGNOSTIC FUNCTION.............9-30 TROUBLESHOOTING METHOD.............9-31 YAMAHA DIAGNOSTIC TOOL ..............9-32 TROUBLESHOOTING DETAILS .............9-35 FUEL PUMP SYSTEM..................9-56 CIRCUIT DIAGRAM .................9-56 TROUBLESHOOTING ................9-58...
  • Page 336 ELECTRICAL COMPONENTS...............9-60 CHECKING THE SWITCHES ..............9-64 CHECKING THE BULBS AND BULB SOCKETS ........9-67 CHECKING THE FUSES .................9-68 CHECKING AND CHARGING THE BATTERY........9-69 CHECKING THE RELAYS ...............9-72 CHECKING THE DIODE ................9-73 CHECKING THE IGNITION SPARK GAP..........9-73 CHECKING THE SPARK PLUG CAP ............9-74 CHECKING THE IGNITION COIL ............9-74 CHECKING THE CRANKSHAFT POSITION SENSOR......9-75 CHECKING THE LEAN ANGLE SENSOR..........9-75...
  • Page 337 This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.

  • Page 338: Ignition System

    IGNITION SYSTEM IGNITION SYSTEM EAS2GBB357 EAS2GBB358 CIRCUIT DIAGRAM...
  • Page 339 IGNITION SYSTEM 1. Joint connector 2. Joint connector 4. AC magneto 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 22.ECU (engine control unit) 23.Ignition coil 24.Spark plug 30.Joint connector 35.Lean angle sensor 36.Engine stop switch 48.Frame ground 49.Ignition coil sub-lead...

  • Page 340: Troubleshooting

    IGNITION SYSTEM TROUBLESHOOTING EAS2GBB359 The ignition system fails to operate (no spark or intermittent spark). Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 5. Air filter case cover NG ...
  • Page 341 IGNITION SYSTEM NG  8. Check the lean angle sensor. Replace the lean angle sensor. Refer to “CHECKING THE LEAN ANGLE SENSOR” on page 9-75. OK  NG  9. Check the entire ignition system’s Properly connect or repair the ignition sys- wiring.

  • Page 342: Electric Starting System

    ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM EAS27160 EAS2GBB360 CIRCUIT DIAGRAM...
  • Page 343 ELECTRIC STARTING SYSTEM 1. Joint connector 2. Joint connector 3. Joint connector 7. Main relay 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 13.Starter motor 14.Starter relay diode 22.ECU (engine control unit) 30.Joint connector 36.Engine stop switch 37.Neutral switch 38.Diode 39.Starting circuit cut-off relay 40.Clutch switch 41.Start switch...

  • Page 344: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION EAS2GBB361 If the meter light comes on, the starter motor can only operate if at least one of the following condi- tions is met: • The transmission is in neutral (the neutral switch is closed). •...
  • Page 345 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main relay 4. Starting circuit cut-off relay 5. Start switch 6. Diode 7. Clutch switch 8.

  • Page 346: Troubleshooting

    ELECTRIC STARTING SYSTEM TROUBLESHOOTING EAS2GBB362 The starter motor fails to turn. Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 5. Air filter case cover NG  1. Check the fuse. Replace the fuse(s).
  • Page 347 ELECTRIC STARTING SYSTEM NG  8. Check the main relay. Replace the main relay. Refer to “CHECKING THE RE- LAYS” on page 9-72. OK  NG  9. Check the neutral switch. Replace the neutral switch. Refer to “CHECKING THE SWITCHES”...

  • Page 348: Charging System

    CHARGING SYSTEM CHARGING SYSTEM EAS27200 EAS2GBB363 CIRCUIT DIAGRAM 9-12...
  • Page 349 CHARGING SYSTEM 4. AC magneto 5. Rectifier/regulator 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 50.Negative battery lead 9-13...

  • Page 350: Troubleshooting

    CHARGING SYSTEM TROUBLESHOOTING EAS2GBB364 The battery is not being charged. Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 1. Check the fuse. NG Refer to “CHECKING THE FUSES” Replace the fuse(s). on page 9-68. OK NG ...
  • Page 351 CHARGING SYSTEM 9-15...

  • Page 352: Lighting System

    LIGHTING SYSTEM LIGHTING SYSTEM EAS27240 EAS2GBB365 CIRCUIT DIAGRAM 9-16...
  • Page 353 LIGHTING SYSTEM 1. Joint connector 2. Joint connector 6. Headlight relay 7. Main relay 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 22.ECU (engine control unit) 30.Joint connector 42.Joint connector 43.Taillight 44.Headlight 47.Multi-function display 48.Frame ground 9-17...

  • Page 354: Troubleshooting

    LIGHTING SYSTEM TROUBLESHOOTING EAS2GBB366 Any of the following fail to light: headlight or meter light. Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left) 3. Air scoop (left/right) 4. Fuel tank NG  1. Check the each bulbs condition. Refer to “CHECKING THE BULBS Replace the bulb (s).
  • Page 355 LIGHTING SYSTEM 9-19...

  • Page 356: Signaling System

    SIGNALING SYSTEM SIGNALING SYSTEM EAS27270 EAS2GBB367 CIRCUIT DIAGRAM 9-20...
  • Page 357 SIGNALING SYSTEM 1. Joint connector 2. Joint connector 3. Joint connector 7. Main relay 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 15.Indicator light 17.Fuel level warning light 18.Resistor 19.Fuel sender 22.ECU (engine control unit) 30.Joint connector 42.Joint connector 46.Speed sensor 47.Multi-function display 48.Frame ground 9-21...

  • Page 358: Troubleshooting

    SIGNALING SYSTEM TROUBLESHOOTING EAS2GBB368 • The speedometer does not operate normally. • The fuel indicator light does not come on. Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank NG ...
  • Page 359 SIGNALING SYSTEM The fuel level warning light fails to come on. NG  1. Check the fuel sender. Replace the fuel sender assembly. Refer to “CHECKING THE FUEL SENDER” on page 9-77. OK  NG  2. Check the resistor. Replace the resistor.

  • Page 360: Cooling System

    COOLING SYSTEM COOLING SYSTEM EAS2GBB369 EAS2GBB370 CIRCUIT DIAGRAM 9-24...
  • Page 361 COOLING SYSTEM 1. Joint connector 2. Joint connector 3. Joint connector 7. Main relay 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 22.ECU (engine control unit) 27.Radiator fan motor relay 28.Radiator fan motor fuse 29.Radiator fan motor 30.Joint connector 32.Coolant temperature sensor 48.Frame ground 9-25...

  • Page 362: Troubleshooting

    COOLING SYSTEM TROUBLESHOOTING EAS2GBB371 The radiator fan motor fails to turn. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left) 3. Air scoop (left/right) 4. Fuel tank NG  1. Check the fuse. Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 9-68.
  • Page 363 COOLING SYSTEM 9-27...

  • Page 364: Fuel Injection System

    FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM EAS2GBB372 EAS2GBB373 CIRCUIT DIAGRAM 9-28...
  • Page 365 FUEL INJECTION SYSTEM 1. Joint connector 2. Joint connector 3. Joint connector 4. AC magneto 7. Main relay 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 15.Indicator light 16.Engine trouble warning light 22.ECU (engine control unit) 25.Injector 30.Joint connector 31.Intake air temperature sensor 32.Coolant temperature sensor 33.Throttle position sensor 34.Intake air pressure sensor...

  • Page 366: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM ECU SELF-DIAGNOSTIC FUNCTION EAS2GBB374 The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 367: Troubleshooting Method

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

  • Page 368: Yamaha Diagnostic Tool

    FUEL INJECTION SYSTEM YAMAHA DIAGNOSTIC TOOL EAS2GBB376 This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool 90890-03231...
  • Page 369 NOTICE In order to avoid short circuit, insulate the battery connection terminals of the FI diagnostic tool sub-lead. For information on how to connect and use the Yamaha diagnostic tool, refer to “YAMAHA DIGNO- STIC TOOL OPERATION MANUAL”. 1. Vehicle 2.
  • Page 370 FUEL INJECTION SYSTEM Operation of the Yamaha diagnostic tool (Malfunction mode) Malfunction results are displayed in the top part of the window area. 1. Recovered The item list of the malfunction detected in the past (already recovered) are displayed. 2. Detected The item list of the malfunction currently occurred are displayed.

  • Page 371: Troubleshooting Details

    FUEL INJECTION SYSTEM 6. Condition The current conditions are displayed. (Detected/Recovered) 7. Symptom The symptoms of the detected malfunction are displayed. 8. Diagnosis code The diagnosis codes related to the detected malfunction are displayed. 9. FFD (only for models that can display freeze frame data) The mark “...
  • Page 372 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received Item from the crankshaft position sensor. Improperly connected  Connection of wire harness Crank the engine. ECU coupler. Connect the coupler securely Fault code number is not dis- played ...
  • Page 373 FUEL INJECTION SYSTEM • If fault code numbers 13 and 14 are both displayed, perform the checks and maintenance jobs for fault code number 13 first. • Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Item Intake air pressure sensor: open or short circuit detected.
  • Page 374 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Defective intake air pressure Execute the diagnostic mode. Push the start switch. sensor. (Code No. 03) Fault code number is not dis- played  Service is finished. When engine is stopped: Atmospheric pressure at the Fault code number is dis-...
  • Page 375 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged Item or detached hose). Defective intake air pressure Execute the diagnostic mode. sensor. (Code No. 03) When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is indicated.
  • Page 376 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Improperly connected  Connection of wire harness Push the start switch. ECU coupler. Connect the coupler securely Fault code number is not dis- played  Service is finished. Check the locking condition or repair/replace the wire har- of the coupler.
  • Page 377 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Malfunction in ECU. Replace the ECU. Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Throttle position sensor: stuck throttle position sensor is de- Item tected.
  • Page 378 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the coolant temperature. Procedure Compare the actually measured coolant temperature with the Yamaha diagnostic tool display value. Probable cause of malfunc- Confirmation of service Item Maintenance job tion and check completion Improperly connected ...
  • Page 379 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air temperature. Procedure Compare the actually measured intake air temperature with the Yamaha diagnostic tool display value. Probable cause of malfunc- Confirmation of service Item Maintenance job tion and check completion Improperly connected ...
  • Page 380 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Open or short circuit  Re- Wire harness continuity. Push the start switch. place the wire harness. Fault code number is not dis- played  Service is finished. Between intake air tempera- ture sensor coupler and ECU Fault code number is dis-...
  • Page 381 Actuation Actuates the ignition coil five times at one-second intervals. The engine trouble warning light and the “WARNING” on the Yamaha diagnostic tool screen come on each time the ignition coil is actuated. Procedure Check that a spark is generated five times.
  • Page 382 FUEL INJECTION SYSTEM Fault code No. Ignition coil: open or short circuit detected in the primary lead Item of the ignition coil. Improperly connected  Connection of sub wire har- Start the engine and let it idle ness coupler.Check the lock- Connect the coupler secure- for approximately 5 seconds.
  • Page 383 Actuation Actuates injector five times at one-second intervals. The engine trouble warning light and the “WARNING” on the Yamaha diagnostic tool screen come on each time the injector is actuated. Procedure Check that injector is actuated five times by listening for the oper- ating sound.
  • Page 384 FUEL INJECTION SYSTEM Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Item Lean angle sensor: open or short circuit detected. Fail-safe system Unable to start engine Able to drive vehicle Diagnostic code No. Diagnostic tool display Lean angle sensor output voltage •...
  • Page 385 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel in- Item jector and fuel pump. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. Diagnostic tool display Fuel system voltage Approximately 12.0 (V) Procedure Disconnect the main relay, and push the start switch or push down...
  • Page 386 FUEL INJECTION SYSTEM Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. EEPROM fault code number: an error is detected while read- Item ing or writing on EEPROM. Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No.
  • Page 387 FUEL INJECTION SYSTEM Fault code No. Item Charging voltage is abnormal. Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No. — Diagnostic tool display — Procedure — Probable cause of malfunc- Confirmation of service Item Maintenance job tion and check completion Improperly connected ...
  • Page 388 Confirmation of service Item Maintenance job tion and check completion Improperly connected  Connection of Yamaha diag- Push the start switch. nostic tool coupler. Connect the coupler securely Fault code number is not dis- played  Service is finished. Check the locking condition or repair/replace the wire har- of the coupler.
  • Page 389 Fault code number is not dis- played  Service is finished. light green–light green Fault code number is dis- played  Go to item 4. Yamaha diagnostic tool mal- Replace the Yamaha diag- Push the start switch. function. nostic tool.
  • Page 390 FUEL INJECTION SYSTEM Fault code No. Er-2 Signals from the ECU cannot be received within the specified Item period of time. Yamaha diagnostic tool mal- Replace the Yamaha diag- Push the start switch. function. nostic tool. Fault code number is not dis- played ...
  • Page 391 FUEL INJECTION SYSTEM Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Er-4 Registered data cannot be received from the Yamaha diagnos- Item tic tool. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No.

  • Page 392: Fuel Pump System

    FUEL PUMP SYSTEM FUEL PUMP SYSTEM EAS2GBB378 EAS2GBB379 CIRCUIT DIAGRAM 9-56...
  • Page 393 FUEL PUMP SYSTEM 1. Joint connector 2. Joint connector 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 22.ECU (engine control unit) 26.Fuel pump 30.Joint connector 36.Engine stop switch 48.Frame ground 9-57...

  • Page 394: Troubleshooting

    FUEL PUMP SYSTEM TROUBLESHOOTING EAS2GBB380 The fuel pump fails to operate. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank NG  1. Check the fuse. Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 9-68.
  • Page 395 FUEL PUMP SYSTEM 9-59...

  • Page 396: Electrical Components

    ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS EAS2GBB381 EAS2GBB382 9-60...
  • Page 397 ELECTRICAL COMPONENTS 1. Rectifier/regulator 2. Clutch switch 3. Ignition coil 4. ECU (engine control unit) 5. Fuel sender 6. Fuel pump 7. Battery 8. Resistor 9. Neutral switch 10.Radiator fan motor 11.Injector 9-61...
  • Page 398 ELECTRICAL COMPONENTS 9-62...
  • Page 399 ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. Intake air pressure sensor 3. Throttle position sensor 4. Starter relay 5. Main fuse 6. Headlight relay 7. Starting circuit cut-off relay 8. Lean angle sensor 9. Radiator fan motor fuse 10.Radiator fan motor relay 11.Main relay 12.Coolant temperature sensor 9-63...

  • Page 400: Checking The Switches

    ELECTRICAL COMPONENTS CHECKING THE SWITCHES EAS2GBB383 9-64...
  • Page 401 ELECTRICAL COMPONENTS 1. Engine stop switch 2. Neutral switch 3. Clutch switch 4. Start switch 9-65...
  • Page 402 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. NOTICE Never insert the tester probes into the coupler terminal slots “1”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

  • Page 403: Checking The Bulbs And Bulb Sockets

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

  • Page 404: Checking The Fuses

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

  • Page 405: Checking And Charging The Battery

    ELECTRICAL COMPONENTS 4. Install: • Seat Since VRLA (Valve Regulated Lead Acid) bat- • Side cover (left/right) teries are sealed, it is not possible to check the Refer to “GENERAL CHASSIS” on page 5- charge state of the battery by measuring the specific gravity of the electrolyte.
  • Page 406 ELECTRICAL COMPONENTS • When charging a battery, be sure to re- Example move it from the vehicle. (If charging has Open-circuit voltage = 12.0 V to be done with the battery mounted on the Charging time = 6.5 hours vehicle, disconnect the negative battery Charge of the battery = 20–30 % lead from the battery terminal.) •...
  • Page 407 ELECTRICAL COMPONENTS c. Make sure that the current is higher than the standard charging current written on the bat- Voltage should be measured 30 minutes after tery. the engine is stopped. b. Connect a charger and ammeter to the bat- If the current is lower than the standard charg- tery and start charging.

  • Page 408: Checking The Relays

    ELECTRICAL COMPONENTS 10.Install: 1. Positive battery terminal • Seat 2. Negative battery terminal 3. Positive tester probe • Side cover (left/right) 4. Negative tester probe Refer to “GENERAL CHASSIS” on page 5- Result Continuity CHECKING THE RELAYS EAS2GBB386 (between “3” to “4”) Check each switch for continuity with the pock- et tester.

  • Page 409: Checking The Diode

    ELECTRICAL COMPONENTS b. Connect the pocket tester (  1) to the di- Radiator fan motor relay ode coupler as shown. c. Check the diode for continuity. d. Check the diode for no continuity. Br,R/W 1. Positive battery terminal 2. Negative battery terminal 3.

  • Page 410: Checking The Spark Plug Cap

    ELECTRICAL COMPONENTS e. Crank the engine by pushing the start switch Pocket tester and gradually increase the spark gap until a 90890-03112 misfire occurs. Analog pocket tester ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ YU-03112-C CHECKING THE SPARK PLUG CAP EAS2GBB389 • Positive tester probe  1.

  • Page 411: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS CHECKING THE CRANKSHAFT POSITION EAS2GBB391 Lean angle sensor output voltage SENSOR Operating angle 1. Disconnect: 45 ° • Crankshaft position sensor coupler Output voltage up to operating (from the wire harness) angle 2. Check: 0.4–1.4 V • Crankshaft position sensor resistance Output voltage over operating an- Out of specification ...

  • Page 412: Checking The Starter Motor Operation

    ELECTRICAL COMPONENTS CHECKING THE STARTER MOTOR OPERA- • Positive tester probe  TION White “1” 1. Check: • Negative tester probe  • Starter motor operation White “2” Does not operate  Perform the electric • Positive tester probe  starting system troubleshooting, starting White “1”...

  • Page 413: Checking The Speed Sensor

    ELECTRICAL COMPONENTS c. Push the start switch. d. Elevate the front wheel and slowly turn it. e. Measure the voltage (DC 5 V) of white and black/white. With the front wheel slowly ro- tating, voltage alternates between 0 V and 5 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 414: Checking The Resister

    ELECTRICAL COMPONENTS CHECKING THE RESISTER EAS2GBB397 1. Disconnect: • Resister coupler (from the wire harness) 2. Check: • Resister resistance Out of specification  Replace the resister. Resister resistance 64.6–71.4  c. Measure the radiator fan motor movement. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a.

  • Page 415: Checking The Throttle Position Sensor

    ELECTRICAL COMPONENTS WARNING • Handle the throttle position sensor with special care. • Never subject the throttle position sensor to strong shocks. If the throttle position sensor is dropped, replace it. 2. Check: • Throttle position sensor maximum resis- tance Out of specification ...

  • Page 416: Checking The Throttle Position Sensor Input Voltage

    ELECTRICAL COMPONENTS CHECKING THE THROTTLE POSITION EAS2GBB401 Intake air pressure sensor output SENSOR INPUT VOLTAGE voltage 1. Check: 3.61–3.67 V at 101.3 kPa (3.61– • Throttle position sensor input voltage 3.67 V at 1.01kgf/cm , 3.61–3.67 Out of specification  Replace the ECU. V at 14.7 psi) Throttle position sensor input voltage...

  • Page 417: Checking The Fuel Injector

    ELECTRICAL COMPONENTS • Positive tester probe  Intake air temperature sensor re- Injector terminal “1” sistance • Negative tester probe  5400.0–6600.0  at 0 °C (5400.0– Injector terminal “2” 6600.0  at 32 °F) 289–391  at 80 °C (289–391  at 176 °F) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 418 ELECTRICAL COMPONENTS 9-82...

  • Page 419: Troubleshooting

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

  • Page 420: Troubleshooting

    TROUBLESHOOTING Electrical system TROUBLESHOOTING EAS2GBB405 1. Battery • Discharged battery EAS2GBB406 GENERAL INFORMATION • Faulty battery 2. Fuse The following guide for troubleshooting does • Blown, damaged or incorrect fuse not cover all the possible causes of trouble. It • Improperly installed fuse should be helpful, however, as a guide to basic 3.

  • Page 421: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING Electrical system JUMPS OUT OF GEAR 1. Battery Engine • Discharged battery 1. Shift shaft • Faulty battery • Incorrect shift pedal position 2. Spark plug • Improperly returned stopper lever • Incorrect spark plug gap 2. Shift forks •...

  • Page 422: Overcooling

    TROUBLESHOOTING Cooling system FRONT FORK OIL LEAKING EAS2GBB418 1. Coolant • Low coolant level Chassis 2. Radiator 1. Front fork • Damaged or leaking radiator • Bent, damaged, or rusty inner tube • Faulty radiator cap • Cracked or damaged outer tube •...

  • Page 423: Headlight Does Not Come On

    TROUBLESHOOTING 7. Wheel (s) • Incorrect wheel balance • Broken or loose spoke • Damaged wheel bearing • Bent or loose wheel axle • Excessive wheel runout 8. Frame • Bent frame • Damaged steering head pipe • Improperly installed bearing race HEADLIGHT DOES NOT COME ON EAS2GBB421 Electrical system...

  • Page 424: List Of Self-Diagnostic And Fail-Safe Actions

    9-52 nection Er-2 Signals from the ECU cannot be received within the specified period 9-53 of time. Er-3 Data from the ECU cannot be received correctly. 9-54 Er-4 Registered data cannot be received from the Yamaha diagnostic tool. 9-55 10-5...
  • Page 425 Intake air temperature Displays the intake air tem- Compare the actually mea- perature. sured intake air tempera- ture with the Yamaha diagnostic tool display val- Coolant temperature When engine is cold: Dis- Compare the actually mea- plays temperature closer to sured coolant temperature air temperature.
  • Page 426 Actuates the ignition coil five Check that a spark is gener- times at one-second inter- ated five times. vals. • Connect an ignition “WARNING” on the Yamaha checker. diagnostic tool blinks five times when the ignition coil is actuated. Injector...
  • Page 427 Check that the radiator fan tor relay five times at five-sec- motor relay is actuated five ond intervals. times by listening for the op- “WARNING” on the Yamaha erating sound. diagnostic tool blinks five times when the radiator fan motor relay is actuated.
  • Page 428 COLOR CODE WIRING DIAGRAM EAS2GBB426 Black WR250F/WR250FH 2017 1. Joint connector Brown 2. Joint connector Chocolate 3. Joint connector Dark green 4. AC magneto 5. Rectifier/regulator Green 6. Headlight relay Gray 7. Main relay Blue 8. Engine ground 9. Battery Light green 10.
  • Page 430 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN...
  • Page 431 WR250F/WR250FH 2017 WR250F/WR250FH 2017 SCHÉMA DE CÂBLAGE WIRING DIAGRAM B B B R R R Br Br Br B B B R R R/L Br Br B B B B B B R R R R R R/L Br Br Br Br Br B/L Gy (Gy) (Gy)
  • Page 432 WR250F/WR250FH 2017 WR250F/WR250FH 2017 SCHÉMA DE CÂBLAGE WIRING DIAGRAM (Gy) (Gy) (Gy)

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