Yamaha MBK MW125 2014 Service Manual
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Yamaha MBK MW125 2014 Service Manual

Yamaha MBK MW125 2014 Service Manual

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SERVICE MANUAL
MW125 2014
MW125F 2015
2CM-F8197-E0

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  • Page 1 SERVICE MANUAL MW125 2014 MW125F 2015 2CM-F8197-E0...
  • Page 2 EAS20002 MW125 2014 MW125F 2015 SERVICE MANUAL ©2014 by Thai Yamaha Motor Co.,Ltd. First edition, May 2014 All rights reserved. Any reproduction or unauthorized use without the written permission of Thai Yamaha Motor Co.,Ltd. is expressly prohibited.
  • Page 3 EAS20003 IMPORTANT This manual was produced by the Thai Yamaha Motor Co., Ltd. primarily for use by Yamaha and MBK dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha and MBK vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
  • Page 4 EAS20004 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
  • Page 5 EAS20005 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...

  • Page 7: Table Of Contents

    EAS10003 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 INSTRUMENT FUNCTIONS ..............1-4 IMPORTANT INFORMATION ................. 1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-7 REPLACEMENT PARTS................1-7 GASKETS, OIL SEALS AND O-RINGS ............ 1-7 LOCK WASHERS/PLATES AND COTTER PINS ........

  • Page 10: Identification

    IDENTIFICATION EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the frame. EAS30003 MODEL LABEL The model label “1” is affixed to the inside of the storage compartment.

  • Page 11: Features

    FEATURES EAS20008 FEATURES EAS30005 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.

  • Page 12: Fi System

    FEATURES EAS30617 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at a certain level. Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 13: Instrument Functions

    EAS30682 INSTRUMENT FUNCTIONS engine trouble warning light remain on during the initial display mode, have the battery Multi-function meter unit charged by a Yamaha dealer. 2 3 4 Speedometer 1. Clock 2. “SELECT” button 3. Fuel level warning indicator “ ”...
  • Page 14 FEATURES Clock • The accuracy of the temperature reading may be affected when riding slowly [approximately under 20 km/h (12 mi/h)] or when stopped at traffic signals, railroad crossings, etc. Odometer and tripmeter modes 1. Clock [To set the clock] 1.
  • Page 15 FEATURES Oil change indicator “OIL CHANGE” This indicator come on at every 20000 km (12500 mi) to indicate that the V-belt should be replaced. If the V-belt replacement indicator has come on, after replacing the V-belt, reset the V-belt re- placement indicator and the V-belt replacement tripmeter.

  • Page 16: Important Information

    5. Keep all parts away from any source of fire. EAS30007 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but...

  • Page 17: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS30010 EAS30012 BEARINGS AND OIL SEALS RUBBER PARTS Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in- manufacturer’s marks or numbers are visible. spection. Some of the rubber parts are sensitive When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc.

  • Page 18: Basic Service Information

    BASIC SERVICE INFORMATION EAS20010 BASIC SERVICE INFORMATION EAS30013 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. Screw type 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.

  • Page 19: Electrical System

    BASIC SERVICE INFORMATION ECA16760 EAS30014 NOTICE ELECTRICAL SYSTEM Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- Electrical parts handling tery lead connections could damage the ECA16600 NOTICE electrical components. Never disconnect a battery lead while the en- gine is running;...
  • Page 20 BASIC SERVICE INFORMATION ECA16620 Checking the electrical system NOTICE Handle electrical components with special Before checking the electrical system, make care, and do not subject them to strong sure that the battery voltage is at least 12 V. shocks. ECA16630 ECA14371 NOTICE NOTICE...
  • Page 21 BASIC SERVICE INFORMATION 2. Check: Checking the connections • Lead Check the leads, couplers, and connectors for • Coupler stains, rust, moisture, etc. • Connector 1. Disconnect: Moisture → Dry with an air blower. • Lead Rust/stains → Connect and disconnect sev- •...
  • Page 22 BASIC SERVICE INFORMATION The resistance values shown were obtained at the standard measuring temperature of 20 °C (68 °F). If the measuring temperature is not 20 °C (68 °F), the specified measuring conditions will be shown. Coolant temperature sensor re- sistance 5166–6314 Ω@0 °C (5166–6314 Ω@32 °F)

  • Page 23: Special Tools

    SPECIAL TOOLS EAS20012 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 24 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Crankshaft installer pot 5-65, 5-66 90890-01274 Installing pot YU-90058 YU-90058/YU-90059 Crankshaft installer bolt 5-65, 5-66 90890-01275 Bolt YU-90060 Adapter (M12) 5-65, 5-66 90890-01278 Adapter #3 YU-90063 Piston pin puller set 5-29 90890-01304 Piston pin puller YU-01304 YU-01304...
  • Page 25 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester 6-3, 6-4 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A T-handle 4-71, 4-72 90890-01326 T-handle 3/8" drive 60 cm long YM-01326 Clutch spring holder 5-39, 5-42 90890-01337 Universal clutch compressor holder YM-33285 Locknut wrench 5-39, 5-43...
  • Page 26 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Fork seal driver weight 4-72, 4-73, 4-73 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø33) 4-72, 4-73 90890-01368 Replacement 33 mm YM-A9409-4 Fork seal driver attachment (ø38) 4-73 90890-01372 Replacement 38 mm YM-A5142-1 Oil seal guide 5-42...
  • Page 27 Model 88 Multimeter with tachometer YU-A1927 Fuel pressure adapter 90890-03181 Fuel pressure adapter YM-03181 Compression gauge extension S 90890-03195 Yamaha diagnostic tool 3-7, 3-8, 7-11, 90890-03231 7-11, 7-11, 7-12, 8-29 Test harness– lean angle sensor 1PA (3P) 8-65 90890-03237 Test harness– lean angle sensor 1PA (3P)
  • Page 28 5-22, 5-27 90890-04108 Valve spring compressor adapter 22 mm YM-04108 Mechanical seal installer 90890-04145 ø30 ø10 Crankshaft installer spacer 5-65 90890-04156 Ignition checker 8-64 90890-06754 Oppama pet–4000 spark checker YM-34487 Yamaha bond No. 1215 5-15, 5-66 90890-85505 (Three bond No.1215®) 1-19...

  • Page 29: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-6 ELECTRICAL SPECIFICATIONS ..............2-9 TIGHTENING TORQUES ................2-11 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-11 ENGINE TIGHTENING TORQUES............2-12 CHASSIS TIGHTENING TORQUES............2-15 LUBRICATION POINTS AND LUBRICANT TYPES ........2-19 ENGINE....................2-19 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-21 ENGINE OIL LUBRICATION CHART .............2-21 LUBRICATION DIAGRAMS ..............

  • Page 30: General Specifications

    GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model 2CM1 (CYP)(FIN)(GRC)(IRL)(POL)(SVK)(SVN)(TUR) 2CM5 (GBR) 2CM7 (AUS)(NZL) Dimensions Overall length 1905 mm (75.0 in) Overall width 735 mm (28.9 in) Overall height 1215 mm (47.8 in) Seat height 780 mm (30.7 in) Wheelbase 1310 mm (51.6 in) Ground clearance 120 mm (4.72 in) Minimum turning radius...

  • Page 31: Engine Specifications

    0.13–0.18 mm (0.0051–0.0071 in) Limit 0.25 mm (0.0098 in) Cooling system Recommended antifreeze YAMAHA GENUINE COOLANT only Radiator capacity (including all routes) 0.37 L (0.39 US qt, 0.33 Imp.qt) Coolant reservoir capacity (up to the maximum level mark) 0.33 L (0.35 US qt, 0.29 Imp.qt) Radiator cap opening pressure 93.3–122.7 kPa (0.93–1.23 kgf/cm², 13.5–17.8...
  • Page 32 ENGINE SPECIFICATIONS Spark plug(s) Manufacturer/model NGK/CR7E Spark plug gap 0.7–0.8 mm (0.028–0.031 in) Cylinder head Warpage limit 0.05 mm (0.0020 in) Camshaft Drive system Chain drive (left) Camshaft lobe dimensions Lobe height (Intake) 30.757–30.857 mm (1.2109–1.2148 in) Limit 30.657 mm (1.2070 in) Base circle diameter (Intake) 26.550–26.650 mm (1.0453–1.0492 in) Lobe height (Exhaust)
  • Page 33 ENGINE SPECIFICATIONS Valve spring Free length (intake) 33.75 mm (1.33 in) Limit 33.40 mm (1.31 in) Free length (exhaust) 33.75 mm (1.33 in) Limit 33.40 mm (1.31 in) Installed length (intake) 26.80 mm (1.06 in) Installed length (exhaust) 26.80 mm (1.06 in) Installed compression spring force (intake) 132.20–152.20 N (13.48–15.52 kgf, 29.72–...
  • Page 34 ENGINE SPECIFICATIONS Big end radial clearance 0.004–0.014 mm (0.0002–0.0006 in) Clutch Clutch type Dry, centrifugal automatic Automatic centrifugal clutch Clutch shoe thickness 3.3 mm (0.13 in) Limit 1.5 mm (0.06 in) Clutch shoe spring free length 29.9 mm (1.18 in) Clutch housing inside diameter 120.0 mm (4.72 in) Limit...

  • Page 35: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Frame type Underbone Caster angle 20.00 ° Trail 68 mm (2.7 in) Front wheel Wheel type Cast wheel Rim size 14M/C x MT2.15 Rim material Aluminum Wheel travel 90 mm (3.5 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
  • Page 36 1.0 mm (0.04 in) Master cylinder inside diameter 14.00 mm (0.55 in) Caliper cylinder inside diameter 33.96 mm (1.34 in) Specified brake fluid YAMAHA GENUINE BRAKE FLUID (DOT 4) Rear brake Type Disc brake Operation Left hand operation Rear brake lever free play 10.0–15.0 mm (0.39–0.59 in)
  • Page 37 CHASSIS SPECIFICATIONS Rear suspension Type Unit swing Spring/shock absorber type Coil spring/oil damper Rear shock absorber assembly travel 97.0 mm (3.82 in) Spring free length 209.6 mm (8.25 in) (CYP)(FIN)(GBR)(GRC)(IRL)(POL)(SVK)(SVN) (TUR) Spring installed length 199.6 mm (7.86 in) Spring rate K1 9.40 N/mm (0.96 kgf/mm, 53.67 lbf/in) Spring stroke K1 0.0–97.0 mm (0.00–3.82 in)

  • Page 38: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Advancer type Digital Ignition timing (B.T.D.C.) 6.5 °/1600 r/min Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64 Ω Primary coil resistance Secondary coil resistance 8.64–12.96 kΩ...
  • Page 39 ELECTRICAL SPECIFICATIONS Starter motor Power output 0.35 kW 0.0315–0.0385 Ω Armature coil resistance Brush overall length 9.5 mm (0.37 in) Limit 3.50 mm (0.14 in) Brush spring force 5.52–8.28 N (563–844 gf, 19.87–29.80 oz) Commutator diameter 22.0 mm (0.87 in) Limit 21.0 mm (0.83 in) Mica undercut (depth)

  • Page 40: Tightening Torques

    TIGHTENING TORQUES EAS20017 TIGHTENING TORQUES EAS30015 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.

  • Page 41: Engine Tightening Torques

    TIGHTENING TORQUES EAS30016 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust pipe nut 20 Nm (2.0 m·kgf, 14 ft·lbf) Muffler bolt 53 Nm (5.3 m·kgf, 38 ft·lbf) Muffler joint bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Muffler protector bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) sensor 25 Nm (2.5 m·kgf, 18 ft·lbf)
  • Page 42 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size V-belt case bearing retainer bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) V-belt case air duct clamp screw 1.2 Nm (0.12 m·kgf, 0.87 ft·lbf) Primary fixed sheave nut 37 Nm (3.7 m·kgf, 27 ft·lbf) Clutch housing nut 35 Nm (3.5 m·kgf, 25 ft·lbf) Secondary sheave nut...
  • Page 43 TIGHTENING TORQUES Cylinder head tightening sequence: Radiator fan case tightening sequence: 2-14...

  • Page 44: Chassis Tightening Torques

    TIGHTENING TORQUES EAS30017 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine bracket nut 54 Nm (5.4 m·kgf, 39 ft·lbf) Engine mounting nut (front side) 50 Nm (5.0 m·kgf, 36 ft·lbf) Engine mounting nut (rear side) 28 Nm (2.8 m·kgf, 20 ft·lbf) Center cover screw 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) Storage box bolt...
  • Page 45 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front turn signal light screw 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) Front cowling assembly screw 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) Lower leg shield cover screw 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) Lower leg shield screw (center) 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Lower leg shield screw...
  • Page 46 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front brake pad pin 17 Nm (1.7 m·kgf, 12 ft·lbf) Front brake caliper bleed screw 5 Nm (0.5 m·kgf, 3.6 ft·lbf) Front brake caliper guide pin nut 22 Nm (2.2 m·kgf, 16 ft·lbf) Rear wheel axle nut 125 Nm (12.5 m·kgf, 90 ft·lbf) Rear brake disc bolt...
  • Page 47 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front upper link arm nut 88 Nm (8.8 m·kgf, 64 ft·lbf) Front lower link arm nut 88 Nm (8.8 m·kgf, 64 ft·lbf) Rear lower link arm bolt 88 Nm (8.8 m·kgf, 64 ft·lbf) Rear lower link arm bolt (to front low- 55 Nm (5.5 m·kgf, 40 ft·lbf) er link arm)

  • Page 48: Lubrication Points And Lubricant Types

    Starter clutch idle gear shaft surface Drive axle and bearings Shell Sunlight Grease Oil seal and spacer (primary sheave) 3® Crankshaft threads (primary fixed sheave side) Timing chain tensioner bolts Yamaha bondNo.1215® Crankcase mating surfaces Yamaha bondNo.1215® Crankcase bolt Yamaha bondNo.1215® 2-19...
  • Page 49 LUBRICATION POINTS AND LUBRICANT TYPES 2-20...

  • Page 50: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 2-21...
  • Page 51 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump assembly 3. Crankshaft 4. Oil nozzle 5. Camshaft 6. Valve stem end 7. Rocker arm 2-22...

  • Page 52: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30021 LUBRICATION DIAGRAMS 2-23...
  • Page 53 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump assembly 3. Camshaft 2-24...
  • Page 54 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25...
  • Page 55 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump assembly 3. Crankshaft 4. Camshaft 5. Rocker arm/Valve stem end 2-26...

  • Page 56: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20020 COOLING SYSTEM DIAGRAMS 2-27...
  • Page 57 COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Coolant reservoir hose 3. Cooling system air bleed hose 4. Radiator inlet hose 5. Radiator outlet hose 6. Radiator 7. Water pump assembly 8. Water pump outlet hose 9. Water pump outlet pipe 2-28...

  • Page 58: Cable Routing

    CABLE ROUTING EAS20021 CABLE ROUTING Handlebar (front and rear view) 2-29...
  • Page 59 CABLE ROUTING 1. Throttle cable (accelerator cable) 2. Front brake hose 3. Brake lever cable 4. Rear brake hose 5. Rear brake light switch lead 6. Left handlebar switch lead 7. Wire harness 8. Right handlebar switch lead 9. Front brake light switch lead 10.
  • Page 60 CABLE ROUTING Steering head (left side view) 2-31...
  • Page 61 CABLE ROUTING 1. Speed sensor lead 2. Front brake hose A. Fasten the speed sensor lead to the front brake hose with the holder. Align the holder with the white paint marks on the speed sensor lead and front brake hose. B.
  • Page 62 CABLE ROUTING Front wheel (left side view) 2-33...
  • Page 63 CABLE ROUTING 1. Speed sensor lead 2. Front brake hose 2-34...
  • Page 64 CABLE ROUTING Throttle body and rear wheel (left and right side view) 2-35...
  • Page 65 CABLE ROUTING 1. Cylinder head breather hose 2. Rear brake hose 3. Breather hose (throttle body to cylinder) A. 1–3 mm (0.04–0.12 in) B. Position the end of the hose clamp within the range shown in the illustration. The range is measured from the center of the white paint mark on the cylinder head breather hose.
  • Page 66 CABLE ROUTING Front frame (right side view) 2-37...
  • Page 67 CABLE ROUTING 1. Wire harness 2. Front brake hose 3. Sidestand switch lead 4. Main switch lead 5. Throttle cable (accelerator cable) 6. Throttle cable (decelerator cable) 7. Horn/receiver unit lead 8. Seat lock cable A. Connect the horn connectors to the horn, making sure that the connectors are installed completely.
  • Page 68 CABLE ROUTING Rear frame (right side view) 11 E 2-39...
  • Page 69 D. Align the white tape on the wire harness with the plastic band. E. Bundle the Yamaha diagnostic tool lead, and then fasten the lead with the plastic band. F. Fasten the wire harness, starter motor lead,...
  • Page 70 CABLE ROUTING Front frame (left side view) 2-41...
  • Page 71 CABLE ROUTING 1. Front left turn signal light lead 2. Meter assembly lead 3. Front brake hose 4. Rear brake hose 5. Throttle cable (decelerator cable) 6. Throttle cable (accelerator cable) 7. Seat lock cable 8. Sidestand switch lead 9. Headlight coupler 10.
  • Page 72 CABLE ROUTING Rear frame (left side view) 2-43...
  • Page 73 CABLE ROUTING 1. Fuel hose 2. Seat lock cable 3. Crankshaft position sensor/stator coil assembly lead 4. Starter motor lead 5. Coolant reservoir hose 6. Coolant reservoir breather hose 7. Positive battery lead 8. Negative battery lead 9. Throttle position sensor lead 10.
  • Page 74 CABLE ROUTING Front frame (top view) 2-45...
  • Page 75 CABLE ROUTING 1. Auxiliary light coupler 2. Headlight lead 3. Auxiliary light lead 4. Speed sensor lead 5. Front right turn signal light lead 6. Wire harness 7. Seat lock cable 8. Rear brake hose 9. Sidestand switch lead 10. Throttle cable (accelerator cable) 11.
  • Page 76 CABLE ROUTING Rear frame (top view) 2-47...
  • Page 77 CABLE ROUTING 1. O sensor lead 2. Starter motor lead 3. Positive battery lead 4. Coolant reservoir hose 5. Fuel pump lead 6. Fuel sender lead 7. Frame ground lead 8. Rectifier/regulator lead 9. Rear right turn signal light lead 10.
  • Page 78 CABLE ROUTING 2-49...

  • Page 79: 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 .......3-1 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUG ............... 3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 CHECKING THE BREATHER HOSES .............3-6 CHECKING THE ENGINE IDLING SPEED ..........3-7 CHECKING THE THROTTLE BODY JOINT AND...
  • Page 80 CHECKING THE THROTTLE GRIP OPERATION .........3-24 CHECKING THE SWITCHES, LIGHTS AND SIGNALS ......3-24 ADJUSTING THE HEADLIGHT BEAM ...........3-25 REPLACING THE HEADLIGHT BULB............3-25...

  • Page 82: Periodic Maintenance

    UK, a mileage-based maintenance, is performed instead. • From 20000 km (12000 mi), repeat the maintenance intervals starting from 4000 km (2400 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 83 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 4000 km 8000 km 12000 km 16000 km (600 mi) (2400 mi) (4800 mi) (7200 mi) (9600 mi) • Check operation, fluid level and vehicle for fluid leakage. √...
  • Page 84 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 4000 km 8000 km 12000 km 16000 km (600 mi) (2400 mi) (4800 mi) (7200 mi) (9600 mi) Moving parts and √ √ √ √ √ • Lubricate. cables •...

  • Page 85: Checking The Fuel Line

    PERIODIC MAINTENANCE • Insulator “2” EAS30619 CHECKING THE FUEL LINE Abnormal color → Replace the spark plug. 1. Remove: Normal color is medium-to-light tan. • Center cover • Storage box Refer to “GENERAL CHASSIS (1)” on page 4-1 and “GENERAL CHASSIS (2)” on page 4-3.
  • Page 86 PERIODIC MAINTENANCE • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1.

  • Page 87: Checking The Breather Hoses

    PERIODIC MAINTENANCE d. Hold the adjusting screw to prevent it from moving and tighten the locknut to specifica- tion. Valve clearance adjusting screw locknut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) e. Measure the valve clearance again. f. If the valve clearance is still out of specifica- tion, repeat all of the valve clearance adjust- ▲...

  • Page 88: Checking The Engine Idling Speed

    ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the Yamaha diagnostic tool. routed correctly. Use the diagnostic code number “67”. Refer to “SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-5. Yamaha diagnostic tool 90890-03231 b.

  • Page 89: Checking The Exhaust System

    Refer to “GENERAL CHASSIS (2)” on page tool. For more information, refer to the opera- 4-3. tion manual of the Yamaha diagnostic tool. 1. Connect the Yamaha diagnostic tool to the EAS30625 CHECKING THE EXHAUST SYSTEM connector. For information about connecting 1.

  • Page 90: Cleaning The V-Belt Case Air Filter Element

    PERIODIC MAINTENANCE 2. Check: • Air filter element Damage → Replace. • Replace the air filter element every 20000 km (12500 mi) of operation. • The air filter needs more frequent service if you are riding in unusually wet or dusty areas. •...

  • Page 91: Checking The Brake Operation

    PERIODIC MAINTENANCE 3. Check: EAS30634 CHECKING THE REAR BRAKE PADS • V-belt case air filter element Damage → Replace. The following procedure applies to all of the brake pads. 4. Apply the recommended oil to the entire sur- 1. Operate the brake. face of the V-belt case air filter element and 2.

  • Page 92: Checking The Front Brake Hoses

    • Brake fluid level Below the minimum level mark “a” → Add the specified brake fluid to the proper level. Specified brake fluid YAMAHA GENUINE BRAKE 2. Check: FLUID (DOT 4) • Brake hose holders Loose → Tighten the holder bolt.

  • Page 93: Bleeding The Hydraulic Brake System

    PERIODIC MAINTENANCE • the brake operation is faulty. • Be careful not to spill any brake fluid or allow the brake master cylinder reservoir to overflow. • When bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake.

  • Page 94: Checking The Wheels

    PERIODIC MAINTENANCE Front brake caliper bleed screw 5 Nm (0.5 m·kgf, 3.6 ft·lbf) k. Fill the brake master cylinder reservoir to the proper level with the specified brake fluid. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-11. EWA13110 WARNING After bleeding the hydraulic brake system, f.

  • Page 95: Checking The Tires

    PERIODIC MAINTENANCE EWA13260 EWA13190 WARNING WARNING Never attempt to make any repairs to the It is dangerous to ride with a worn-out tire. wheel. When the tire tread reaches the wear limit, re- place the tire immediately. 2. Check: After a tire or wheel has been changed or re- •...

  • Page 96: Checking The Wheel Bearings

    EWA13120 en if a tire combination other than one WARNING approved by Yamaha is used on this vehicle. Securely support the vehicle so that there is no danger of it falling over. Front tire 2.
  • Page 97 PERIODIC MAINTENANCE 5. Remove: c. Loosen the lower ring nut 1/4 of a turn, and • Front cowling assembly then tighten it to specification with a steering Refer to “GENERAL CHASSIS (7)” on page nut wrench. 4-14. EWA13140 WARNING • Handlebar Do not overtighten the lower ring nut.

  • Page 98: Checking The Tie-Rod Bushings And Front Arm Bushings

    PERIODIC MAINTENANCE EAS31185 CHECKING THE LINK ARM BEARINGS Steering nut wrench 1. Stand the vehicle on a level surface. 90890-01403 EWA13120 Exhaust flange nut wrench WARNING YU-A9472 Securely support the vehicle so that there is no danger of it falling over. Upper ring nut 2.

  • Page 99: Lubricating The Sidestand

    PERIODIC MAINTENANCE EAS30651 LUBRICATING THE SIDESTAND Lubricate the pivoting point, metal-to-metal mov- ing parts, and spring contact point of the side- stand. Recommended lubricant Lithium-soap-based grease EAS30856 CHECKING THE CENTERSTAND 1. Check: EAS30654 • Centerstand operation CHECKING THE REAR SUSPENSION Check that the centerstand moves smoothly.

  • Page 100: Changing The Engine Oil

    PERIODIC MAINTENANCE EAS30657 CHANGING THE ENGINE OIL • Before checking the engine oil level, wait a few 1. Start the engine, warm it up for several min- minutes until the oil has settled. utes, and then turn it off. • Do not screw the dipstick in when inspecting 2.

  • Page 101: Checking The Coolant Level

    PERIODIC MAINTENANCE c. Check the engine oil passages and the oil Oil strainer cover pump for damage or leakage. Refer to “OIL 20 Nm (2.0 m·kgf, 14 ft·lbf) PUMP” on page 5-56. d. Start the engine after solving the problem(s) ▲...

  • Page 102: Checking The Cooling System

    PERIODIC MAINTENANCE Before checking the coolant level, wait a few minutes until the coolant has settled. EAS30812 CHECKING THE COOLING SYSTEM 1. Remove: • Radiator cover Refer to “RADIATOR” on page 6-1. 2. Check: 4. Remove: • Radiator “1” • Radiator cap “1” •...

  • Page 103: Changing The Final Transmission Oil

    • Radiator cap mended coolant) 12.Fill: • Coolant reservoir Recommended antifreeze (with the recommended coolant to the maxi- YAMAHA GENUINE COOLANT mum level mark “a”) only Radiator capacity (including all routes) 0.37 L (0.39 US qt, 0.33 Imp.qt) Coolant reservoir capacity (up to the maximum level mark) 0.33 L (0.35 US qt, 0.29 Imp.qt)

  • Page 104: Replacing The V-Belt

    PERIODIC MAINTENANCE 2. Start the engine, warm it up for several min- 8. Start the engine, warm it up for several min- utes, and then turn it off. utes, and then turn it off. 3. Place a container under the final transmis- 9.

  • Page 105: Checking The Throttle Grip Operation

    PERIODIC MAINTENANCE 2. Check: 4. Adjust: • Cable operation • Throttle grip free play Rough movement → Lubricate. Prior to adjusting the throttle grip free play, the Recommended lubricant engine idling speed should be adjusted properly. Engine oil or a suitable cable lu- bricant ▼...

  • Page 106: Adjusting The Headlight Beam

    PERIODIC MAINTENANCE EAS30664 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: • Headlight beam (vertically) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”.

  • Page 107: Chassis

    CHASSIS GENERAL CHASSIS (1) ................. 4-1 REMOVING THE CENTER COVER ............4-2 INSTALLING THE CENTER COVER............4-2 GENERAL CHASSIS (2) ................. 4-3 REMOVING THE FUSE BOX COVER............4-4 INSTALLING THE FUSE BOX COVER ............ 4-4 GENERAL CHASSIS (3) ................. 4-5 REMOVING THE REAR COVER .............. 4-6 INSTALLING THE REAR COVER.............
  • Page 108 GENERAL CHASSIS (9) ................4-21 REMOVING THE BOTTOM COVERS ............4-22 INSTALLING THE BOTTOM COVERS...........4-22 GENERAL CHASSIS (10) ................4-23 INSTALLING THE AIR FILTER CASE ............4-24 FRONT WHEELS ..................4-25 REMOVING THE FRONT WHEELS ............4-28 DISASSEMBLING THE FRONT WHEELS ..........4-28 CHECKING THE FRONT WHEELS............
  • Page 109 HANDLEBAR ....................4-60 REMOVING THE HANDLEBAR..............4-62 CHECKING THE HANDLEBAR ..............4-62 INSTALLING THE HANDLEBAR ............4-62 FRONT FORKS ..................... 4-65 REMOVING THE FRONT FORK LEGS..........4-70 DISASSEMBLING THE FRONT FORK LEGS ........4-70 CHECKING THE FRONT FORK LEGS ..........4-71 ASSEMBLING THE FRONT FORK LEGS ..........4-71 INSTALLING THE FRONT FORK LEGS ..........
  • Page 110 GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the battery and seat 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Center cover Negative battery lead Disconnect. Positive battery lead Disconnect. Battery Seat...

  • Page 111: General Chassis (1)

    GENERAL CHASSIS (1) EAS31189 REMOVING THE CENTER COVER 1. Remove: • Center cover d. Open the seat. e. Install the screws. Center cover screw ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 112: General Chassis (2)

    GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the storage box 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 3.6 Nm (0.36 m kgf, 2.6 ft Ibf) • • • •...

  • Page 113: Removing The Fuse Box Cover

    GENERAL CHASSIS (2) EAS31260 REMOVING THE FUSE BOX COVER 1. Remove: • Fuse box cover ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 114: General Chassis (3)

    GENERAL CHASSIS (3) EAS20156 GENERAL CHASSIS (3) Removing the side covers 23 Nm (2.3 m kgf, 17 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • •...

  • Page 115: Removing The Rear Cover

    GENERAL CHASSIS (3) EAS31289 REMOVING THE REAR COVER 1. Remove: • Rear cover ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS31264 REMOVING THE SIDE COVERS The following procedure applies to both of the ▼...

  • Page 116: General Chassis (4)

    GENERAL CHASSIS (3) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Fit the projections on the side cover into the grommet in the footrest board, bottom cover, and tail/brake light assembly. b.

  • Page 117: General Chassis (5)

    GENERAL CHASSIS (4) EAS20157 GENERAL CHASSIS (4) Removing the rear fender 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • •...
  • Page 118 GENERAL CHASSIS (5) EAS20158 GENERAL CHASSIS (5) Removing the meter assembly 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 0.4 Nm (0.04 m kgf, 0.29 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • •...

  • Page 119: Removing The Front Upper Panel

    GENERAL CHASSIS (5) EAS31266 REMOVING THE FRONT UPPER PANEL 1. Remove: • Front upper panel c. Install the screws. Front upper panel screw 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...

  • Page 120: Removing The Upper Leg Shield

    GENERAL CHASSIS (5) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ a. Slide the meter assembly cover backward EAS31271 and install it.

  • Page 121: General Chassis (6)

    GENERAL CHASSIS (6) EAS20159 GENERAL CHASSIS (6) Removing the handlebar covers 32 Nm (3.2 m kgf, 23 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • •...

  • Page 122: Removing The Upper Handlebar Cover

    GENERAL CHASSIS (6) EAS31272 REMOVING THE UPPER HANDLEBAR COVER 1. Remove: • Upper handlebar cover b. Install the screws and quick fastener screws. Upper handlebar cover screw 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 123: General Chassis (7)

    GENERAL CHASSIS (7) EAS20193 GENERAL CHASSIS (7) Removing the front cowling assembly 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...

  • Page 124: Removing The Front Lower Panel

    GENERAL CHASSIS (7) EAS31274 REMOVING THE FRONT LOWER PANEL 1. Remove: • Front lower panel b. Install the screws. Front lower panel screw 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...

  • Page 125: Removing The Front Cowling Assembly

    GENERAL CHASSIS (7) 1. Install: • Lower leg shield cover ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS31279 ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...

  • Page 126: Installing The Lower Leg Shield

    GENERAL CHASSIS (7) Lower leg shield screw (center) 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Lower leg shield screw 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 127: General Chassis (8)

    GENERAL CHASSIS (8) EAS20194 GENERAL CHASSIS (8) Disassembling the front cowling assembly 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...

  • Page 128: Removing The Front Center Panels

    GENERAL CHASSIS (8) EAS31282 REMOVING THE FRONT CENTER PANELS The following procedure applies to both of the front center panels. 1. Remove: • Front center panel ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...

  • Page 129: General Chassis (9)

    GENERAL CHASSIS (8) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Fit the projections on the front side panel into the slots in the side cowling. ▲ ▲▲▲ ▲ ▲▲▲ ▲...
  • Page 130 GENERAL CHASSIS (9) EAS20195 GENERAL CHASSIS (9) Removing the footrest board 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • •...

  • Page 131: Removing The Bottom Covers

    GENERAL CHASSIS (9) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ EAS31286 REMOVING THE BOTTOM COVERS a. Fit the projection on the bottom cover into the The following procedure applies to both of the grommet in the front cowling lower inner pan- bottom covers.

  • Page 132: General Chassis (10)

    GENERAL CHASSIS (10) EAS20196 GENERAL CHASSIS (10) Removing the air filter case 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 1.2 Nm (0.12 m kgf, 0.87 ft Ibf) •...

  • Page 133: Installing The Air Filter Case

    GENERAL CHASSIS (10) EAS31288 INSTALLING THE AIR FILTER CASE Fit the projection “a” on the air filter case duct be- 1. Install: tween the projections “b” on the air filter case • Air filter case joint “1” cover “2”. (to the air filter case “2”) •...

  • Page 134: Front Wheels

    FRONT WHEELS EAS20028 FRONT WHEELS Removing the front wheels and brake discs 74 Nm (7.4 m kgf, 54 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) •...
  • Page 135 FRONT WHEELS Removing the front wheels and brake discs 74 Nm (7.4 m kgf, 54 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...
  • Page 136 FRONT WHEELS Disassembling the front wheels Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front wheels. Oil seal Wheel bearing Spacer Wheel bearing 4-27...

  • Page 137: Removing The Front Wheels

    FRONT WHEELS c. Remove the wheel bearings “3” with a gener- EAS30145 REMOVING THE FRONT WHEELS al bearing puller. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2.

  • Page 138: Checking Of The Speed Sensor And Sensor Rotor

    FRONT WHEELS • When cleaning the speed sensor rotor, be careful not to damage the surface of the rotor. 4. Check: • Wheel bearings Front wheel turns roughly or is loose → Re- EAS30151 place the wheel bearings. ASSEMBLING THE FRONT WHEELS •...

  • Page 139: Adjusting The Front Wheel Static Balance

    FRONT WHEELS f. Repeat steps (c) through (e) several times ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ until all the marks come to rest at the same EAS30152 spot. ADJUSTING THE FRONT WHEEL STATIC g.

  • Page 140: Installing The Front Wheels (Front Brake Discs)

    FRONT WHEELS d. Repeat steps (b) and (c) until the front wheel 2. Check: is balanced. • Front brake disc Refer to “CHECKING THE FRONT BRAKE ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...

  • Page 141: Rear Wheel

    REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel and brake disc 23 Nm (2.3 m kgf, 17 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “REAR SHOCK ABSORBER AS- Swingarm SEMBLIES AND SWINGARM” on page 4-88.

  • Page 142: Removing The Rear Wheel (Disc)

    REAR WHEEL EAS30156 REMOVING THE REAR WHEEL (DISC) 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on the centerstand so that the rear wheel is elevated.

  • Page 143: Front Brake

    FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • Order Job/Parts to remove Q’ty...
  • Page 144 FRONT BRAKE Removing the front brake master cylinder 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) •...
  • Page 145 FRONT BRAKE Removing the front brake master cylinder 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) •...
  • Page 146 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body 4-37...
  • Page 147 FRONT BRAKE Removing the front brake calipers 29 Nm (2.9 m kgf, 21 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
  • Page 148 FRONT BRAKE Disassembling the front brake calipers 22 Nm (2.2 m kgf, 16 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) •...

  • Page 149: Introduction

    FRONT BRAKE d. Hold the dial gauge at a right angle against EAS30168 INTRODUCTION the brake disc surface. EWA14101 e. Measure the runout 1.5 mm (0.06 in) below WARNING the edge of the brake disc. Disc brake components rarely require disas- sembly.

  • Page 150: Replacing The Front Brake Pads

    FRONT BRAKE f. If the brake disc runout cannot be brought b. Loosen the bleed screw and push the brake within specification, replace the brake disc. caliper piston into the brake caliper with your finger. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲...

  • Page 151: Removing The Front Brake Calipers

    FRONT BRAKE 5. Check: ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Blow compressed air into the brake hose joint • Brake lever operation opening “a” to force out the piston from the Soft or spongy feeling →...

  • Page 152: Assembling The Front Brake Calipers

    Front brake caliper bolt and brake caliper piston seals. 35 Nm (3.5 m·kgf, 25 ft·lbf) Specified brake fluid Refer to “REPLACING THE FRONT BRAKE YAMAHA GENUINE BRAKE PADS” on page 4-41. FLUID (DOT 4) 4. Fill: • Brake master cylinder reservoir...

  • Page 153: Removing The Front Brake Master Cylinder

    FRONT BRAKE EAS30179 REMOVING THE FRONT BRAKE MASTER Specified brake fluid CYLINDER YAMAHA GENUINE BRAKE FLUID (DOT 4) Before removing the front brake master cylinder, EWA13540 drain the brake fluid from the entire brake sys- WARNING tem. • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to 1.

  • Page 154: Assembling The Front Brake Master Cylinder

    • Never use solvents on internal brake com- sure the brake hose does not touch other parts ponents. (e.g., wire harness, cables, leads). Correct if necessary. Specified brake fluid YAMAHA GENUINE BRAKE FLUID (DOT 4) EAS30182 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: •...
  • Page 155 (with the specified amount of the specified brake fluid) tem. Refer to “BLEEDING THE HYDRAULIC Specified brake fluid BRAKE SYSTEM” on page 3-12. YAMAHA GENUINE BRAKE 9. Adjust: FLUID (DOT 4) • Rear brake lever free play Refer to “ADJUSTING THE REAR BRAKE EWA13540 LEVER FREE PLAY”...

  • Page 156: Rear Brake

    REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf)
  • Page 157 REAR BRAKE Removing the rear brake master cylinder 11 Nm (1.1 m kgf, 8.0 ft Ibf) 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) •...
  • Page 158 REAR BRAKE Removing the rear brake master cylinder 11 Nm (1.1 m kgf, 8.0 ft Ibf) 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) •...
  • Page 159 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body 4-50...
  • Page 160 REAR BRAKE Removing the rear brake caliper 29 Nm (2.9 m kgf, 21 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain.
  • Page 161 REAR BRAKE Disassembling the rear brake caliper 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 22 Nm (2.2 m kgf, 16 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) •...

  • Page 162: Introduction

    REAR BRAKE EAS30183 INTRODUCTION Brake disc thickness limit EWA14101 3.5 mm (0.14 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc runout ventive measures: Refer to “CHECKING THE FRONT BRAKE •...

  • Page 163: Removing The Rear Brake Caliper

    REAR BRAKE Rear brake pad pin Always install new brake pads, brake pad 17 Nm (1.7 m·kgf, 12 ft·lbf) spring, and brake pad support as a set. Rear brake pad pin cap 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) ▼ ▼▼▼ ▼...

  • Page 164: Disassembling The Rear Brake Caliper

    REAR BRAKE EAS30188 CHECKING THE REAR BRAKE CALIPER Recommended brake component replacement schedule Brake pads If necessary Piston seal Every two years Piston dust seal Every two years Brake hose Every four years Every two years and Brake fluid whenever the brake is EAS30187 disassembled DISASSEMBLING THE REAR BRAKE...

  • Page 165: Installing The Rear Brake Caliper

    10 Nm (1.0 m·kgf, 7.2 ft·lbf) Rear brake caliper bolt Specified brake fluid 27 Nm (2.7 m·kgf, 20 ft·lbf) YAMAHA GENUINE BRAKE FLUID (DOT 4) Refer to “REPLACING THE REAR BRAKE PADS” on page 4-53. 4. Fill:...

  • Page 166: Removing The Rear Brake Master Cylinder

    The rear brake lever pivot bolt and nut have ponents. left-hand threads. To loosen the pivot bolt and nut, turn them clockwise. Specified brake fluid 2. Remove: YAMAHA GENUINE BRAKE • Brake hose union bolt “1” FLUID (DOT 4) • Copper washers “2” • Brake hose “3” EAS30196...
  • Page 167 “a” as shown. Specified brake fluid YAMAHA GENUINE BRAKE FLUID (DOT 4) Turn the handlebar to the left and right to make sure the brake hose does not touch other parts EWA13540 (e.g., wire harness, cables, leads).
  • Page 168 REAR BRAKE 6. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-12. 7. Check: • Brake fluid level Below the minimum level mark “a” → Add the specified brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...

  • Page 169: Handlebar

    HANDLEBAR EAS20033 HANDLEBAR Removing the handlebar 2.4 Nm (0.24 m kgf, 1.7 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) •...
  • Page 170 HANDLEBAR Removing the handlebar 2.4 Nm (0.24 m kgf, 1.7 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) •...

  • Page 171: Removing The Handlebar

    HANDLEBAR • After installing the handlebar, make sure that EAS30203 REMOVING THE HANDLEBAR there is a gap “c” in the handlebar. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2.
  • Page 172 HANDLEBAR 6. Install: • Throttle grip “1” Make sure that the distance “a” between the end • Throttle cables “2” of the left handlebar switch and the end of the • Right handlebar switch “3” handlebar grip is 0 mm (0 in). Handlebar switch screw (right c.
  • Page 173 HANDLEBAR 8. Adjust: • Throttle grip free play Refer to “CHECKING THE THROTTLE GRIP OPERATION” on page 3-24. Throttle grip free play 3.0–7.0 mm (0.12–0.28 in) 9. Adjust: • Rear brake lever free play Refer to “ADJUSTING THE REAR BRAKE LEVER FREE PLAY”...

  • Page 174: Front Forks

    FRONT FORKS EAS20034 FRONT FORKS Removing the front fork legs 50 Nm (5.0 m kgf, 36 ft Ibf) • • 50 Nm (5.0 m kgf, 36 ft Ibf) • • 50 Nm (5.0 m kgf, 36 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf)
  • Page 175 FRONT FORKS Removing the front fork legs 50 Nm (5.0 m kgf, 36 ft Ibf) • • 50 Nm (5.0 m kgf, 36 ft Ibf) • • 50 Nm (5.0 m kgf, 36 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 176 FRONT FORKS Disassembling the front fork legs 18 Nm (1.8 m kgf, 13 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. ECA21660 NOTICE Front fork leg bolt Do not remove the front fork leg bolts un- less it is necessary to replace the outer tubes.
  • Page 177 FRONT FORKS Disassembling the front fork legs 18 Nm (1.8 m kgf, 13 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Fork spring Main tube side only. Dust seal Oil seal clip Front fork damper rod bolt Main tube side only. Front fork outer tube bolt Guide tube side only.
  • Page 178 FRONT FORKS Disassembling the front fork legs 18 Nm (1.8 m kgf, 13 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Inner tube Oil seal Washer Outer tube bushing Inner tube bushing Spring Main tube side only. Oil flow stopper Main tube side only.

  • Page 179: Removing The Front Fork Legs

    FRONT FORKS EAS30206 EAS30207 REMOVING THE FRONT FORK LEGS DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the The following procedure applies to both of the front fork legs. front fork legs. 1. Stand the vehicle on a level surface. ECA19110 NOTICE EWA13120...

  • Page 180: Checking The Front Fork Legs

    FRONT FORKS EWA13650 WARNING T-handle 90890-01326 Do not attempt to straighten a bent inner T-handle 3/8" drive 60 cm long tube as this may dangerously weaken it. YM-01326 2. Measure (main tube side only): • Fork spring free length “a” Out of specification →...
  • Page 181 FRONT FORKS 1. Install (main tube side only): • Inner tube bushing “1” While holding the damper rod assembly with the • Rebound spring “2” hexagon bit socket (15 mm) “2” and T-handle “3”, tighten the front fork damper rod bolt. •...
  • Page 182 FRONT FORKS 9. Install: • Lubricate the outer surface of the inner tube • Dust seal “1” with fork oil. (with the fork seal driver attachment “2” and • Before installing the oil seal, cover the top of fork seal driver weight “3”) the front fork leg with a plastic bag to protect Fork seal driver weight the oil seal during installation.

  • Page 183: Installing The Front Fork Legs

    FRONT FORKS 11.After filling the front fork leg, slowly stroke the EAS30210 INSTALLING THE FRONT FORK LEGS inner tube “1” up and down (at least ten The following procedure applies to both of the times) to distribute the fork oil. front fork legs.
  • Page 184 FRONT FORKS If the cap bolts are difficult to tighten, slightly loosen the lower bracket pinch bolts. 3. Install: • Front wheels (temporarily) Refer to “FRONT WHEELS” on page 4-25. 4. Tighten: • Front fork leg bolts “1” Front fork leg bolt 50 Nm (5.0 m·kgf, 36 ft·lbf) •...

  • Page 185: Front Arms And Lower Brackets

    FRONT ARMS AND LOWER BRACKETS EAS20188 FRONT ARMS AND LOWER BRACKETS Removing the front arms 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) •...
  • Page 186 FRONT ARMS AND LOWER BRACKETS Removing the lower brackets 75 Nm (7.5 m kgf, 54 ft Ibf) • • 1st 38 Nm (3.8 m kgf, 27 ft Ibf) • • 2nd 16 Nm (1.6 m kgf, 12 ft Ibf) • •...
  • Page 187 FRONT ARMS AND LOWER BRACKETS Removing the lower brackets 75 Nm (7.5 m kgf, 54 ft Ibf) • • 1st 38 Nm (3.8 m kgf, 27 ft Ibf) • • 2nd 16 Nm (1.6 m kgf, 12 ft Ibf) • •...

  • Page 188: Removing The Lower Brackets

    FRONT ARMS AND LOWER BRACKETS EAS31220 EAS31222 REMOVING THE LOWER BRACKETS INSTALLING THE LOWER BRACKETS 1. Stand the vehicle on a level surface. 1. Lubricate: • Upper bearings EWA13120 WARNING • Lower bearings Securely support the vehicle so that there is •...
  • Page 189 FRONT ARMS AND LOWER BRACKETS 2. Install: • Front wheels Refer to “FRONT WHEELS” on page 4-25. 3. Check: • Toe-alignment Out of specification → Repeat step (1). Toe-alignment (with tires touch- ing the ground) -6 mm (-0.24 in) or more Before measuring the toe-alignment, make sure that the tire pressure is correct.

  • Page 190: Steering Head

    STEERING HEAD EAS20035 STEERING HEAD Removing the main switch 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) Ô Ô Ô Ô 16 Nm (1.6 m kgf, 12 ft Ibf) Ô Ô Order Job/Parts to remove Q’ty Remarks...
  • Page 191 STEERING HEAD Removing the link arms and lower bracket pipes 88 Nm (8.8 m kgf, 64 ft Ibf) • • 110 Nm (11 m kgf, 80 ft lbf) • • 88 Nm (8.8 m kgf, 64 ft Ibf) • • 110 Nm (11 m kgf, 80 ft lbf)
  • Page 192 STEERING HEAD Removing the steering column 75 Nm (7.5 m kgf, 54 ft Ibf) • • 1st 38 Nm (3.8 m kgf, 27 ft Ibf) • • 2nd 16 Nm (1.6 m kgf, 12 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Upper ring nut...
  • Page 193 STEERING HEAD Removing the steering column 75 Nm (7.5 m kgf, 54 ft Ibf) • • 1st 38 Nm (3.8 m kgf, 27 ft Ibf) • • 2nd 16 Nm (1.6 m kgf, 12 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Upper bearing inner race...

  • Page 194: Removing The Steering Column

    STEERING HEAD ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ EAS31224 REMOVING THE STEERING COLUMN a. Remove the bearing races from the steering 1. Stand the vehicle on a level surface. head pipe “1”...

  • Page 195: Installing The Link Arms And Lower Bracket Pipes

    STEERING HEAD • Do not fully tighten the bolts. • Make sure that the bottom “a” of the luggage hook contacts the frame. EAS31226 INSTALLING THE LINK ARMS AND LOWER BRACKET PIPES 1. Install: • Bearing “1”, “2” 4. Install: (to the front lower link arm) •...
  • Page 196 STEERING HEAD Rear lower link arm bolt 88 Nm (8.8 m·kgf, 64 ft·lbf) Front upper link arm nut 88 Nm (8.8 m·kgf, 64 ft·lbf) Front lower link arm nut 88 Nm (8.8 m·kgf, 64 ft·lbf) Main switch bracket bolt 88 Nm (8.8 m·kgf, 64 ft·lbf) Rear lower link arm bolt (to lower bracket pipe) 110 Nm (11 m·kgf, 80 ft·lbf)

  • Page 197: Rear Shock Absorber Assemblies And Swingarm

    REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM EAS20189 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM Removing the rear shock absorber assemblies and swingarm 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • •...
  • Page 198 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM Removing the rear shock absorber assemblies and swingarm 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • 31 Nm (3.1 m kgf, 22 ft Ibf) •...

  • Page 199: Removing The Rear Shock Absorber Assemblies

    REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM • Spring EAS31227 REMOVING THE REAR SHOCK ABSORBER Damage/wear → Replace the rear shock ab- ASSEMBLIES sorber assembly. 1. Stand the vehicle on a level surface. • Bushings EWA13120 Damage/wear → Replace the rear shock ab- WARNING sorber assembly.
  • Page 200 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM • Swingarm mounting bolt (upper side) “3” (temporarily tighten) • Swingarm mounting bolt (lower side) “4” (temporarily tighten) 4. Tighten: • Rear wheel axle nut “2” • Swingarm mounting bolt (upper side) “3” • Swingarm mounting bolt (lower side) “4” Rear wheel axle nut 125 Nm (12.5 m·kgf, 90 ft·lbf) Swingarm mounting bolt...

  • Page 201: Engine

    ENGINE ENGINE INSPECTION ..................5-1 MEASURING THE COMPRESSION PRESSURE........5-1 ENGINE REMOVAL ..................5-3 INSTALLING THE ENGINE............... 5-7 INSTALLING THE EXHAUST PIPE AND MUFFLER........5-8 CYLINDER HEAD.................... 5-9 REMOVING THE CYLINDER HEAD............5-12 CHECKING THE CYLINDER HEAD ............5-12 CHECKING THE CAMSHAFT SPROCKET..........5-13 CHECKING THE TIMING CHAIN TENSIONER........5-13 INSTALLING THE CYLINDER HEAD .............5-14 CAMSHAFT ....................
  • Page 202 V-BELT AUTOMATIC TRANSMISSION ............5-33 REMOVING THE PRIMARY SHEAVE............5-39 REMOVING THE SECONDARY SHEAVE ..........5-39 DISASSEMBLING THE SECONDARY SHEAVE........5-39 CHECKING THE CLUTCH HOUSING ............5-40 CHECKING THE CLUTCH SHOES ............5-40 CHECKING THE V-BELT................5-40 CHECKING THE PRIMARY SHEAVE ............5-40 CHECKING THE PRIMARY SHEAVE WEIGHTS........5-41 CHECKING THE PRIMARY SHEAVE SLIDERS ........
  • Page 203 CRANKSHAFT ....................5-62 DISASSEMBLING THE CRANKCASE............5-64 REMOVING THE CRANKSHAFT ASSEMBLY ........5-64 CHECKING THE CRANKSHAFT ASSEMBLY........5-64 CHECKING THE CRANKCASE ..............5-65 CHECKING THE BEARING ..............5-65 CHECKING THE OIL PUMP DRIVE GEAR ..........5-65 INSTALLING THE CRANKSHAFT ............5-65 ASSEMBLING THE CRANKCASE............5-66 INSTALLING THE CENTERSTAND ............5-66...

  • Page 204: Engine Inspection

    ENGINE INSPECTION 7. Measure: EAS20041 ENGINE INSPECTION • Compression pressure Out of specification → Refer to steps (c) and EAS30249 (d). MEASURING THE COMPRESSION PRESSURE Standard compression pressure (at sea level) Insufficient compression pressure will result in a 1600 kPa/725 r/min (16.0 loss of performance.
  • Page 205 ENGINE INSPECTION 10.Install: • Center cover Refer to “GENERAL CHASSIS (1)” on page 4-1.

  • Page 206: Engine Removal

    ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the muffler and exhaust pipe 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 53 Nm (5.3 m kgf, 38 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • •...
  • Page 207 ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-19. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-21. Refer to “GENERAL CHASSIS (4)” on page Rear fender flap/Rear fender/Bottom cover/Air 4-8, “GENERAL CHASSIS (9)”...
  • Page 208 ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Refer to “ELECTRIC STARTER” on page Starter motor 5-52. Radiator cover Refer to “RADIATOR” on page 6-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Fuel injector Refer to “FUEL INJECTOR”...
  • Page 209 ENGINE REMOVAL Removing the engine 28 Nm (2.8 m kgf, 20 ft Ibf) • • 54 Nm (5.4 m kgf, 39 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) •...

  • Page 210: Installing The Engine

    ENGINE REMOVAL EAS30251 INSTALLING THE ENGINE Rear shock absorber assembly 1. Install: upper nut • Stoppers “1” 28 Nm (2.8 m·kgf, 20 ft·lbf) Rear shock absorber assembly • Collars “2” lower bolt (to the engine “3”) 16 Nm (1.6 m·kgf, 12 ft·lbf) 2.

  • Page 211: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL • Muffler mounting bolts (temporarily tighten) 4. Tighten: • Exhaust pipe nuts Exhaust pipe nut 20 Nm (2.0 m·kgf, 14 ft·lbf) Tighten each nut to specification in the order of exhaust pipe nut “1” → exhaust pipe nut “2” → exhaust pipe nut “1”.

  • Page 212: Cylinder Head

    10 Nm (1.0 m kgf, 7.2 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • Yamaha * Apply bond No.1215 (90890-85505). Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (9)” on page Footrest board 4-21.
  • Page 213 10 Nm (1.0 m kgf, 7.2 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • Yamaha * Apply bond No.1215 (90890-85505). Order Job/Parts to remove Q’ty Remarks Disconnect. sensor coupler Remove the O sensor only when neces- sary.
  • Page 214 7.2 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • Yamaha * Apply bond No.1215 (90890-85505). Order Job/Parts to remove Q’ty Remarks Cylinder head cover breather plate gasket Rear brake hose guide Timing chain tensioner...

  • Page 215: Removing The Cylinder Head

    CYLINDER HEAD EAS30276 REMOVING THE CYLINDER HEAD To prevent the timing chain from falling into the 1. Align: crankcase, fasten it with a wire. • “I” mark “a” on the AC magneto rotor (with the match mark “b” on the right crank- case) ▼...

  • Page 216: Checking The Camshaft Sprocket

    CYLINDER HEAD To ensure an even surface, rotate the cylinder head several times. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS31232 CHECKING THE CAMSHAFT SPROCKET 1. Check: • Camshaft sprocket More than 1/4 tooth wear “a”...

  • Page 217: Installing The Cylinder Head

    CYLINDER HEAD b. Align the “I” mark “a” on the AC magneto rotor with the match mark “b” on the right crank- case. c. Install the timing chain “1” onto the camshaft sprocket “2”, then the camshaft sprocket onto the camshaft, and then finger tighten the camshaft sprocket bolt.
  • Page 218 • Apply sealant to the threads of the timing chain tensioner bolts. Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) Timing chain tensioner bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 6.
  • Page 219 CYLINDER HEAD ECA20610 NOTICE Be sure to tighten the camshaft sprocket bolt to the specified torque to avoid the possibil- ity of the bolt coming loose and damaging the engine. 7. Measure: • Valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEAR- ANCE”...

  • Page 220: Camshaft

    CAMSHAFT EAS20043 CAMSHAFT Removing the rocker arms and camshaft 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-9. Locknut Adjusting screw Rocker arm shaft...

  • Page 221: Removing The Camshaft

    CAMSHAFT EAS30256 REMOVING THE CAMSHAFT 1. Remove: • Camshaft “1” Remove the camshaft with the slide hammer bolt “2” and weight “3”. Slide hammer bolt 90890-01085 Slide hammer bolt 8 mm YU-01083-2 Weight 90890-01084 Weight YU-01083-3 3. Measure: • Camshaft runout Out of specification →...

  • Page 222: Installing The Camshaft And Rocker Arms

    CAMSHAFT 2. Check: 5. Calculate: • Rocker-arm-to-rocker-arm-shaft clearance • Rocker arm shaft Blue discoloration/excessive wear/pit- ting/scratches → Replace or check the lubri- Calculate the clearance by subtracting the rock- cation system. er arm shaft outside diameter from the rocker 3. Measure: arm inside diameter.
  • Page 223 CAMSHAFT 3. Lubricate: • Rocker arms • Rocker arm shafts Recommended lubricant Rocker arm roller Molybdenum disulfide grease Rocker arm shaft Molybdenum disulfide oil 4. Install: • Rocker arms • Rocker arm shafts Make sure the rocker arm shafts (intake and ex- haust) are completely pushed into the cylinder head.

  • Page 224: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS20045 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-9. Rocker arms/Camshaft Refer to “CAMSHAFT” on page 5-17. Valve cotter Valve spring retainer Valve spring Intake valve...

  • Page 225: Removing The Valves

    VALVES AND VALVE SPRINGS EAS30283 REMOVING THE VALVES The following procedure applies to all of the valves and related components. Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
  • Page 226 VALVES AND VALVE SPRINGS b. Install the new valve guide with the valve Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remover ance (intake) “1”. 0.010–0.037 mm (0.0004–0.0015 Valve guide position Limit Intake 0.080 mm (0.0032 in) 9.55–9.95 mm (0.376–0.392 in) Valve-stem-to-valve-guide clear- Exhaust ance (exhaust)

  • Page 227: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 3. Eliminate: Valve seat contact width (intake) • Carbon deposits 0.90–1.20 mm (0.0354–0.0472 in) (from the valve face and valve seat) Limit 4. Check: 1.6 mm (0.06 in) • Valve face Valve seat contact width (ex- Pitting/wear →...

  • Page 228: Checking The Valve Springs

    VALVES AND VALVE SPRINGS i. Press the valve through the valve guide and ECA13790 NOTICE onto the valve seat to make a clear impres- Do not let the lapping compound enter the sion. gap between the valve stem and the valve j.

  • Page 229: Installing The Valves

    VALVES AND VALVE SPRINGS • Valve stem seal “2” (with the recommended lubricant) Recommended lubricant Engine oil b. Installed length 3. Measure: • Valve spring tilt “a” Out of specification → Replace the valve spring. 3. Install: Spring tilt (intake) •...
  • Page 230 VALVES AND VALVE SPRINGS Install the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment “2”. Valve spring compressor 90890-04019 Valve spring compressor YM-04019 Valve spring compressor attach- ment 90890-04108 Valve spring compressor adapt- er 22 mm YM-04108 5.

  • Page 231: Cylinder And Piston

    CYLINDER AND PISTON EAS20046 CYLINDER AND PISTON Removing the cylinder and piston 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-9. Water pump outlet pipe Refer to “WATER PUMP”...

  • Page 232: Removing The Piston

    CYLINDER AND PISTON EAS30289 REMOVING THE PISTON When removing a piston ring, open the end gap 1. Remove: with your fingers and lift the other side of the ring • Piston pin clips “1” over the piston crown. • Piston pin “2” •...

  • Page 233: Checking The Piston Rings

    CYLINDER AND PISTON EAS30292 CHECKING THE PISTON RINGS 1. Measure: • Piston ring side clearance Out of specification → Replace the piston and piston rings as a set. Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.

  • Page 234: Checking The Piston Pin

    CYLINDER AND PISTON 3. Measure: 3. Measure: • Piston ring end gap • Piston pin bore diameter “b” Out of specification → Replace the piston Out of specification → Replace the piston. ring. Piston pin bore inside diameter 14.002–14.013 mm (0.5513– The oil ring expander spacer end gap cannot be 0.5517 in) measured.
  • Page 235 CYLINDER AND PISTON 135˚ 45˚ 45˚ 45˚ 45˚ 2. Install: a. Top ring • Piston “1” b. 2nd ring • Piston pin “2” c. Upper oil ring rail • Piston pin clips “3” d. Oil ring expander e. Lower oil ring rail A.

  • Page 236: V-Belt Automatic Transmission

    V-BELT AUTOMATIC TRANSMISSION EAS20050 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 1.2 Nm (0.12 m kgf, 0.87 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •...
  • Page 237 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 1.2 Nm (0.12 m kgf, 0.87 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 238 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt, primary sheave and secondary sheave 35 Nm (3.5 m kgf, 25 ft Ibf) • • 37 Nm (3.7 m kgf, 27 ft Ibf) • • ® * Apply Shell dolium grease R ® ** Apply Shell Sunlight Grease 3 Order Job/Parts to remove Q’ty...
  • Page 239 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt, primary sheave and secondary sheave 35 Nm (3.5 m kgf, 25 ft Ibf) • • 37 Nm (3.7 m kgf, 27 ft Ibf) • • ® * Apply Shell dolium grease R ® ** Apply Shell Sunlight Grease 3 Order Job/Parts to remove Q’ty...
  • Page 240 V-BELT AUTOMATIC TRANSMISSION Disassembling the secondary sheave 75 Nm (7.5 m kgf, 54 ft Ibf) • • ® * Apply Shell dolium grease R Order Job/Parts to remove Q’ty Remarks Secondary sheave nut Clip Clutch carrier plate Clutch shoe spring Clutch shoe Damper Clutch carrier...
  • Page 241 V-BELT AUTOMATIC TRANSMISSION Disassembling the secondary sheave 75 Nm (7.5 m kgf, 54 ft Ibf) • • ® * Apply Shell dolium grease R Order Job/Parts to remove Q’ty Remarks Guide pin Secondary sliding sheave O-ring Oil seal Bearing Circlip Bearing Secondary fixed sheave 5-38...

  • Page 242: Removing The Primary Sheave

    V-BELT AUTOMATIC TRANSMISSION 2. Loosen: EAS30310 REMOVING THE PRIMARY SHEAVE • Secondary sheave nut “1” 1. Remove: ECA21820 • Primary fixed sheave nut “1” NOTICE • Conical spring washer Do not remove the secondary sheave nut at • One-way clutch this stage.

  • Page 243: Checking The Clutch Housing

    V-BELT AUTOMATIC TRANSMISSION Clutch shoe thickness 3.3 mm (0.13 in) Limit 1.5 mm (0.06 in) EAS30313 CHECKING THE CLUTCH HOUSING 1. Check: • Clutch housing Damage/wear → Replace. 2. Measure: EAS30315 • Clutch housing inside diameter “a” CHECKING THE V-BELT Out of specification →...

  • Page 244: Checking The Primary Sheave Weights

    V-BELT AUTOMATIC TRANSMISSION EAS30317 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the pri- mary sheave weights. 1. Check: • Primary sheave weight Cracks/damage/wear → Replace. 2. Measure: • Primary sheave weight outside diameter “a” Out of specification → Replace. 4.

  • Page 245: Assembling The Secondary Sheave

    V-BELT AUTOMATIC TRANSMISSION 3. Install: • Guide pins “1” 4. Lubricate: • Guide pin grooves “2” • O-rings “3” (with the recommended lubricant) Recommended lubricant Shell dolium grease R® EAS30321 ASSEMBLING THE SECONDARY SHEAVE 1. Lubricate: • Secondary fixed sheave inner surface “1” •...
  • Page 246 V-BELT AUTOMATIC TRANSMISSION Secondary sheave nut 75 Nm (7.5 m·kgf, 54 ft·lbf) While holding the secondary sheave with the sheave holder “2”, tighten the secondary sheave nut with the locknut wrench “3”. Sheave holder 90890-01701 3. Install: Primary clutch holder •...

  • Page 247: Installing The V-Belt Case

    V-BELT AUTOMATIC TRANSMISSION • Conical spring washer “2” • Primary fixed sheave nut “3” • Install the conical spring washer with the mark “a” facing outward. • Install the V-belt in the primary sheave (when the pulley is at its widest position) and in the secondary sheave (when the pulley is at its narrowest position), and make sure the V-belt is tight.
  • Page 248 V-BELT AUTOMATIC TRANSMISSION 5-45...

  • Page 249: Starter Clutch

    STARTER CLUTCH EAS20049 STARTER CLUTCH Removing the starter clutch 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 250 STARTER CLUTCH Removing the starter clutch 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 251: Checking The Starter Wheel

    STARTER CLUTCH EAS31236 EAS31237 CHECKING THE STARTER WHEEL CHECKING THE TIMING CHAIN 1. Check: 1. Check: • Bearing • Timing chain Damage/wear → Replace. Damage/stiffness → Replace the timing 2. Check: chain and camshaft sprocket as a set. • Starter clutch idle gear •...

  • Page 252: Ac Magneto

    AC MAGNETO EAS20190 AC MAGNETO Removing the stator coil assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • 80 Nm (8.0 m kgf, 58 ft Ibf) • • Order Job/Parts to remove Q’ty...

  • Page 253: Removing The Ac Magneto

    AC MAGNETO EAS31239 REMOVING THE AC MAGNETO 1. Remove: • AC magneto rotor nut “1” • Washer While holding the AC magneto rotor “2” with the rotor holding tool “3”, loosen the AC magneto ro- tor nut. Rotor holding tool EAS31240 INSTALLING THE AC MAGNETO 90890-01235...
  • Page 254 AC MAGNETO While holding the AC magneto rotor “2” with the rotor holding tool “3”, tighten the AC magneto ro- tor nut. Rotor holding tool 90890-01235 Universal magneto and rotor holder YU-01235 5-51...

  • Page 255: Electric Starter

    ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 256 ELECTRIC STARTER Disassembling the starter motor 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Washer O-ring Brush Brush spring Bearing Oil seal...

  • Page 257: Checking The Starter Motor

    ELECTRIC STARTER ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ EAS30325 CHECKING THE STARTER MOTOR a. Measure the armature assembly resistances 1. Check: with the digital circuit tester. • Commutator Dirt →...

  • Page 258: Assembling The Starter Motor

    ELECTRIC STARTER Brush spring force 5.52–8.28 N (563–844 gf, 19.87– 29.80 oz) 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: • Bearing • Oil seal Damage/wear → Replace the defective part(s). EAS30326 ASSEMBLING THE STARTER MOTOR 1.

  • Page 259: Oil Pump

    OIL PUMP EAS20054 OIL PUMP Removing the oil pump 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...

  • Page 260: Checking The Oil Strainer

    OIL PUMP EAS30340 CHECKING THE OIL STRAINER 1. Check: • Oil strainer Damage → Replace. Contaminants → Clean with solvent. EAS30337 CHECKING THE OIL PUMP 1. Check: • Oil pump driven gear • Oil pump housing EAS30342 • Oil pump housing cover ASSEMBLING THE OIL PUMP Cracks/damage/wear →...

  • Page 261: Transmission

    TRANSMISSION EAS20062 TRANSMISSION Removing the transmission 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to “REAR WHEEL” on page 4-32. Drain. Transmission oil Refer to “CHANGING THE FINAL TRANS- MISSION OIL”...
  • Page 262 TRANSMISSION Removing the transmission 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Primary drive gear Bearing 1st wheel gear Drive axle Oil seal Bearing Main axle Primary driven gear Bearing 5-59...

  • Page 263: Checking The Transmission

    TRANSMISSION 5. Check: EAS30433 CHECKING THE TRANSMISSION • Transmission gear movement 1. Measure: Rough movement → Replace the defective • Main axle runout part(s). (with a centering device and dial gauge “1”) Out of specification → Replace the main axle. EAS30438 INSTALLING THE TRANSMISSION Main axle runout limit...
  • Page 264 TRANSMISSION Tighten the transmission case cover bolts in the proper tightening sequence as shown. 5-61...

  • Page 265: Crankshaft

    7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 22 Nm (2.2 m kgf, 16 ft Ibf) • • Yamaha * Apply bond No.1215 (90890-85505). Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-3. Cylinder head Refer to “CYLINDER HEAD”...
  • Page 266 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 22 Nm (2.2 m kgf, 16 ft Ibf) • • Yamaha * Apply bond No.1215 (90890-85505). Order Job/Parts to remove Q’ty Remarks Final transmission oil filler cap Dipstick Spring Centerstand...

  • Page 267: Disassembling The Crankcase

    CRANKSHAFT EAS31241 ECA20630 DISASSEMBLING THE CRANKCASE NOTICE 1. Remove: • To protect the end of the crankshaft, place • Crankcase bolts an appropriate sized socket between the crankcase separating tool bolt and the Loosen each bolt 1/4 of a turn at a time, in stag- crankshaft.

  • Page 268: Checking The Crankcase

    CRANKSHAFT EAS31244 CHECKING THE BEARING 1. Check: • Bearing Clean and lubricate the bearings, and then rotate the inner race with your finger. Rough movement → Replace. EAS31245 CHECKING THE OIL PUMP DRIVE GEAR 1. Check: • Oil pump drive gear 3.

  • Page 269: Assembling The Crankcase

    1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) Do not allow any sealant to come into contact with the oil gallery.
  • Page 270 CRANKSHAFT 5-67...

  • Page 271: Cooling System

    COOLING SYSTEM RADIATOR ...................... 6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR..............6-3 THERMOSTAT ....................6-5 CHECKING THE THERMOSTAT ASSEMBLY ......... 6-6 INSTALLING THE THERMOSTAT ASSEMBLY ........6-6 WATER PUMP....................6-7 DISASSEMBLING THE WATER PUMP............ 6-9 CHECKING THE WATER PUMP .............. 6-9 ASSEMBLING THE WATER PUMP............6-9 INSTALLING THE WATER PUMP ............

  • Page 272: Radiator

    RADIATOR EAS20063 RADIATOR Removing the radiator 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) •...
  • Page 273 RADIATOR Removing the radiator 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) •...

  • Page 274: Checking The Radiator

    RADIATOR EAS30439 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. Straighten any flattened fins with a thin, flathead screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.
  • Page 275 RADIATOR ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Attach the radiator cap tester “1” to the radia- tor. Radiator cap tester 90890-01325 Mityvac cooling system tester kit YU-24460-A b.

  • Page 276: Thermostat

    THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-21. Refer to “GENERAL CHASSIS (1)” on page Center cover 4-1.

  • Page 277: Checking The Thermostat Assembly

    THERMOSTAT EAS31248 CHECKING THE THERMOSTAT ASSEMBLY 1. Check: • Thermostat “1” Does not open at 80–84°C (178–183°F) → 4.5 mm Replace. 82 ± 2.0˚C 95˚C A. Fully closed B. Fully open If the accuracy of the thermostat is in doubt, re- place it.

  • Page 278: Water Pump

    11 Nm (1.1 m kgf, 8.0 ft Ibf) • • 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • Yamaha * Apply bond No. 1215 (90890-85505). Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-19.
  • Page 279 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • Yamaha * Apply bond No. 1215 (90890-85505). Order Job/Parts to remove Q’ty Remarks Water pump housing cover Dowel pin Water pump housing...

  • Page 280: Disassembling The Water Pump

    WATER PUMP EAS30446 DISASSEMBLING THE WATER PUMP Installed depth of water pump 1. Remove: seal • Water pump seal “1” 0.2–0.7 mm (0.01–0.03 in) Remove the water pump seal from the inside of Mechanical seal installer the water pump housing “2”. 90890-04145 Middle driven shaft bearing driv- 90890-04058...

  • Page 281: Installing The Water Pump

    WATER PUMP • After installation, check that the impeller shaft rotates smoothly. EAS30449 INSTALLING THE WATER PUMP 1. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-21. 2. Check: •...
  • Page 282 WATER PUMP 6-11...

  • Page 283: Fuel System

    FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP ..............7-2 CHECKING THE FUEL PUMP BODY............7-2 CHECKING THE FUEL FILTER..............7-2 INSTALLING THE FUEL PUMP..............7-2 INSTALLING THE FUEL TANK..............7-2 CHECKING THE FUEL PRESSURE ............7-3 FUEL INJECTOR..................... 7-5 REMOVING THE FUEL HOSE ..............7-6 CHECKING THE FUEL INJECTOR ............
  • Page 284 FUEL TANK EAS20067 FUEL TANK Removing the fuel tank 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (2)” on page Storage box/Rear side covers/Center side cov- 4-3 and “GENERAL CHASSIS (3)”...

  • Page 285: Fuel Tank

    FUEL TANK • Do not touch the base section of the fuel EAS30450 REMOVING THE FUEL TANK sender. 1. Extract the fuel in the fuel tank through the fuel tank filler hole with a pump. EAS30454 2. Disconnect: CHECKING THE FUEL PUMP BODY •...

  • Page 286: Checking The Fuel Pressure

    FUEL TANK • Fuel hose connector cover • Although the fuel has been removed from ECA17500 the fuel tank, be careful when removing the NOTICE fuel hose, since there may be fuel remain- When installing the fuel hose, make sure that ing in it.
  • Page 287 FUEL TANK Refer to “INSTALLING THE FUEL TANK” on page 7-2. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲...

  • Page 288: Fuel Injector

    FUEL INJECTOR EAS20191 FUEL INJECTOR Removing the fuel injector 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Fuel injector coupler Disconnect.

  • Page 289: Removing The Fuel Hose

    FUEL INJECTOR EAS31250 • O-ring REMOVING THE FUEL HOSE (to the fuel injector adapter “2”) 1. Disconnect: • Fuel hose • Fuel injector joint gasket “3” EWA17610 (to the fuel injector) WARNING 2. Install: Cover fuel hose connections with a cloth •...

  • Page 290: Throttle Body

    THROTTLE BODY EAS20070 THROTTLE BODY Removing the throttle body 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) •...
  • Page 291 THROTTLE BODY Removing the throttle body 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) •...

  • Page 292: Checking The Throttle Body

    THROTTLE BODY EAS30479 CHECKING THE THROTTLE BODY • Before checking the throttle body, check the following items: • Valve clearance • Spark plug • Air filter element • Intake manifold • Fuel hose • Exhaust system 3. Remove: • Cylinder head breather hose •...
  • Page 293 • Do not allow water to enter the ISC unit and do not allow foreign materials to adhere to Recommended cleaning agent the assembly. Yamaha oil & brake cleaner • Do not touch the terminals of the coupler directly. ECA21790 •...

  • Page 294: Replacing The Throttle Body

    THROTTLE BODY 12.Reset the ISC valve position using the Yamaha diagnostic tool. Execute the diagnostic mode (code No. 54). Refer to “SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-5. Yamaha diagnostic tool 90890-03231 13.Place the vehicle on the centerstand so that 9.

  • Page 295: Installing The Throttle Body

    THROTTLE BODY 4. Reset the ISC valve position using the Yamaha diagnostic tool. • Execute the diagnostic mode (code No. 54). Refer to “SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-5. Yamaha diagnostic tool 90890-03231 5. Place the vehicle on the centerstand so that the rear wheel is elevated.
  • Page 296 THROTTLE BODY 7-13...

  • Page 297: Electrical System

    TROUBLESHOOTING ................8-21 FUEL INJECTION SYSTEM................8-25 CIRCUIT DIAGRAM ................8-25 ECU SELF-DIAGNOSTIC FUNCTION............8-27 TROUBLESHOOTING METHOD............8-28 YAMAHA DIAGNOSTIC TOOL ...............8-29 TROUBLESHOOTING DETAILS ............8-30 ELECTRICAL COMPONENTS..............8-53 CHECKING THE SWITCHES ..............8-55 CHECKING THE BULBS AND BULB SOCKETS ........8-58 CHECKING THE FUSES ................8-59 REPLACING THE ECU (engine control unit) ..........8-59...

  • Page 298: Ignition System

    IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM...
  • Page 299 IGNITION SYSTEM 1. Crankshaft position sensor 4. Main switch 6. Signaling system fuse 8. Battery 9. Negative battery lead connector 10.Main fuse 13.Sidestand switch 22.ECU (engine control unit) 23.Ignition coil 24.Spark plug 28.Engine ground 31.Lean angle sensor 60.Frame ground...

  • Page 300: Troubleshooting

    IGNITION SYSTEM EAS30492 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Fuse box cover 2. Center cover 3. Radiator cover 4. Front upper panel 5. Lower leg shield NG →...
  • Page 301 IGNITION SYSTEM NG → 8. Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. SWITCHES” on page 8-55. OK ↓ NG → 9. Check the lean angle sensor. Refer to “CHECKING THE LEAN Replace the lean angle sensor. ANGLE SENSOR”...

  • Page 302: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM...
  • Page 303 ELECTRIC STARTING SYSTEM 4. Main switch 6. Signaling system fuse 8. Battery 9. Negative battery lead connector 10.Main fuse 11.Starter relay 12.Starter motor 13.Sidestand switch 14.Starting circuit cut-off relay 15.Handlebar switch (Right) 16.Front brake light switch 17.Start switch 53.Rear brake light switch 60.Frame ground...

  • Page 304: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAS30494 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is turned to “ON”, the starter motor can only operate if at least one of the following conditions is met: • The front brake lever is pulled to the handlebar (the front brake light switch is closed) and the side- stand is up (the sidestand switch is closed).

  • Page 305: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Fuse box cover 2. Center cover 3. Storage box 4. Front upper panel 5. Lower leg shield 6. Upper handlebar cover NG →...
  • Page 306 ELECTRIC STARTING SYSTEM NG → 8. Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. SWITCHES” on page 8-55. OK ↓ NG → 9. Check the brake light switch (front and rear). Replace the brake light switch. Refer to “CHECKING THE SWITCHES”...
  • Page 307 ELECTRIC STARTING SYSTEM 8-10...

  • Page 308: Charging System

    CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM 8-11...
  • Page 309 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 8. Battery 9. Negative battery lead connector 10.Main fuse 60.Frame ground 8-12...

  • Page 310: Troubleshooting

    CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Fuse box cover 2. Center cover NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES” on page 8-59. OK ↓...
  • Page 311 CHARGING SYSTEM 8-14...

  • Page 312: Lighting System

    LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM 8-15...
  • Page 313 LIGHTING SYSTEM 4. Main switch 5. Backup fuse 6. Signaling system fuse 7. Headlight fuse 8. Battery 9. Negative battery lead connector 10.Main fuse 22.ECU (engine control unit) 28.Engine ground 34.Meter assembly 35.Multifunction meter 36.Meter light 39.High beam indicator light 42.Tail/brake light assembly 45.Tail/brake light 47.Headlight relay...

  • Page 314: Troubleshooting

    LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlights, high beam indicator light, taillight, auxiliary lights or meter light. • Before troubleshooting, remove the following part(s): 1. Front upper panel 2. Rear covers 3. Fuse box cover 4.
  • Page 315 LIGHTING SYSTEM NG → 7. Check the entire lighting system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-15. OK ↓ Replace the ECU, meter assembly, or headlight assembly. Refer to “RE- PLACING THE ECU (engine control unit)”...

  • Page 316: Signaling System

    SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM 8-19...
  • Page 317 SIGNALING SYSTEM 4. Main switch 5. Backup fuse 6. Signaling system fuse 7. Headlight fuse 8. Battery 9. Negative battery lead connector 10.Main fuse 15.Handlebar switch (Right) 16.Front brake light switch 18.Coolant temperature sensor 22.ECU (engine control unit) 27.Fuel sender 28.Engine ground 33.Speed sensor 34.Meter assembly...

  • Page 318: Troubleshooting

    SIGNALING SYSTEM EAS30501 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or indicator light. • The horn fails to sound. • The fuel meter fails to come on. • The speedometer fails to operate. •...
  • Page 319 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-19. OK ↓ Replace the horn. The tail/brake light fails to come on. NG → 1.
  • Page 320 SIGNALING SYSTEM NG → 3. Check the entire signaling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-19. OK ↓ Replace the meter assembly or head- light assembly. The coolant temperature fails to come on. NG →...
  • Page 321 SIGNALING SYSTEM NG → 2. Check the entire speed sensor wir- Properly connect or replace the wire har- ing. ness. OK ↓ Replace the meter assembly. 8-24...

  • Page 322: Fuel Injection System

    FUEL INJECTION SYSTEM EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM 8-25...
  • Page 323 22.ECU (engine control unit) 23.Ignition coil 24.Spark plug 25.Fuel injector 26.Fuel pump 28.Engine ground 29.ISC (idle speed control) unit 30.O sensor 31.Lean angle sensor 32.Yamaha diagnostic tool 34.Meter assembly 35.Multifunction meter 40.Engine trouble warning light 47.Headlight relay 60.Frame ground 8-26...

  • Page 324: Ecu Self-Diagnostic Function

    • After the engine stops, the engine trouble warning light will display the lowest error code (or it will be displayed on the Yamaha diagnostic tool), which remains stored in ECU memory until deleted. Engine trouble warning light fault code indication Digit of 10: Cycles of 1 sec.

  • Page 325: Troubleshooting Method

    FUEL INJECTION SYSTEM Checking the engine trouble warning light The engine trouble warning light comes on for around 2 seconds after the main switch has been turned to “ON” and it comes on while the start switch is being pushed. If the warning light does not come on under these conditions, the warning light (LED) may be defective.

  • Page 326: Yamaha Diagnostic Tool

    EAS30951 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool 90890-03231 Features of the Yamaha diagnostic tool You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional meth- ods.

  • Page 327: Troubleshooting Details

    After the check and service of the malfunctioning part have been completed, reset the Yamaha diag- nostic tool display according to the “Confirmation of service completion”. Fault code No.: Fault code number displayed on the Yamaha diagnostic tool display when the engine failed to work nor- mally. Diagnostic code No.: Diagnostic code number to be used when the diagnostic mode is operated.
  • Page 328 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received from the Item crankshaft position sensor. Improperly connected → Con- Connection of wire harness Crank the engine. ECU coupler. nect the coupler securely or re- Fault code number is not dis- played →...
  • Page 329 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Improperly connected → Con- Connection of throttle body sen- Turn the main switch to “ON”. sor assembly coupler. nect the coupler securely or re- Fault code number is not dis- played →...
  • Page 330 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Malfunction in ECU. Replace the ECU. Refer to “REPLACING THE ECU (engine control unit)” on page 8-59. If fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number “13”...
  • Page 331 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: system malfunction (clogged or de- Item tached). 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 332 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Improperly connected → Con- Connection of wire harness Turn the main switch to “ON”. ECU coupler. nect the coupler securely or re- Fault code number is not dis- played →...
  • Page 333 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor is stuck. Installed condition of throttle po- Check for looseness or pinch- Turn the main switch to “ON” sition sensor. ing. and operate the throttle valve Make sure that the mounting open and close.
  • Page 334 FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the blue/yellow lead of Item the ECU is detected. Open or short circuit → Replace Wire harness continuity. Turn the main switch to “ON”, the wire harness. and then extend and retract the Between relay unit coupler and sidestand.
  • Page 335 FUEL INJECTION SYSTEM Fault code No. Item Coolant temperature sensor: open or short circuit detected. Open or short circuit → Replace Wire harness continuity. Turn the main switch to “ON”. the wire harness. Fault code number is not dis- played → Service is finished. Between coolant temperature sensor coupler and ECU cou- Fault code number is displayed...
  • Page 336 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Improperly connected → Con- Connection of throttle body sen- Turn the main switch to “ON”. sor assembly coupler. nect the coupler securely or re- Fault code number is not dis- played →...
  • Page 337 FUEL INJECTION SYSTEM Fault code No. sensor: no normal signals are received from the O sensor. Item Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check pletion sensor. Improperly installed sensor → Installed condition of O Start the engine, warm it up, Reinstall or replace the sensor.
  • Page 338 FUEL INJECTION SYSTEM Fault code No. Item Latch up detected. Diagnostic code No. Lean angle sensor output voltage Tool display • 0.4–1.4 (upright) • 3.7–4.4 (overturned) Procedure Remove the lean angle sensor and incline it more than 50 degrees. Probable cause of malfunc- Confirmation of service com- Item Maintenance job...
  • Page 339 FUEL INJECTION SYSTEM Fault code No. Item Engine speed is high when the engine is idling. Incorrect speed sensor signal. Check the speed sensor. Start and idle the engine for ap- Execute the diagnostic mode. proximately 10 seconds. (Code No. 07) Fault code number is not dis- played →...
  • Page 340 FUEL INJECTION SYSTEM Fault code No. Item Engine speed is high when the engine is idling. Improperly connected → Con- Connection of wire harness Execute the diagnostic mode. ECU coupler. nect the coupler securely or re- (Code No. 54) Check the locking condition of place the wire harness.
  • Page 341 FUEL INJECTION SYSTEM Fault code No. 39 Fault code No. Item Injector: open or short circuit detected. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. Actuates injector five times at one-second intervals. Actuation Illuminates the engine trouble warning light. Check that injector is actuated five times by listening for the operating Procedure sound.
  • Page 342 FUEL INJECTION SYSTEM Fault code No. 41 Fault code No. Item Lean angle sensor: open or short circuit detected. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. Lean angle sensor output voltage Tool display • 0.4–1.4 (upright) •...
  • Page 343 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sen- Item sor. Diagnostic code No. Speed sensor pulse Tool display 0–999 Check that the number increases when the left front wheel is rotated. Procedure The number is cumulative and does not reset each time the wheel is stopped.
  • Page 344 FUEL INJECTION SYSTEM Fault code No. 44 Fault code No. EEPROM fault code number: an error is detected while reading or Item writing on EEPROM. Able/Unable to start engine Fail-safe system Able/Unable to drive vehicle Diagnostic code No. EEPROM fault code display Tool display •...
  • Page 345 FUEL INJECTION SYSTEM Fault code No. 50 Fault code No. Faulty ECU memory. (When this malfunction is detected in the ECU, Item the fault code number might not appear on the tool display.) Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No.
  • Page 346 Engine idling speed is not high. → Go to item 6. Installed condition of YMJET Check the YMJET sub-pas- Start the engine and let it idle (Yamaha Mixture Jet) sub pas- sage for disconnections, loose- for approximately 10 seconds. sage. ness, and tears.
  • Page 347 FUEL INJECTION SYSTEM Fault code No. Engine speed is high when the Engine is idling. Item Deceleration is poor when the vehicle is ridden. Bad condition of engine or sensor. Air leak in intake air passages. Check the intake air passages Start the engine and let it idle for air leaks.
  • Page 348 FUEL INJECTION SYSTEM Fault code No. Engine speed is high when the Engine is idling. Item Deceleration is poor when the vehicle is ridden. Bad condition of engine or sensor. Bad condition of engine. Refer to “INCORRECT ENGINE Start the engine and let it idle IDLING SPEED”...
  • Page 349 FUEL INJECTION SYSTEM 8-52...

  • Page 350: Electrical Components

    ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 14,15,16 8-53...
  • Page 351 ELECTRICAL COMPONENTS 1. Front brake light switch 2. Rear brake light switch 3. Lean angle sensor 4. Battery 5. Starter relay 6. Main fuse 7. Fuse box 8. Turn signal relay 9. Starting circuit cut-off relay 10. Headlight relay 11. ECU (engine control unit) 12.

  • Page 352: Checking The Switches

    ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES Y L/B Br/W Br/W L/G L/Y R Br 8-55...
  • Page 353 ELECTRICAL COMPONENTS 1. Front brake light switch 2. Start switch 3. Horn switch 4. Dimmer switch 5. Turn signal switch 6. Rear brake light switch 7. Main switch 8. Sidestand switch 8-56...
  • Page 354 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. ECA14371 NOTICE Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end “a”...

  • Page 355: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS EAS30550 EWA17540 CHECKING THE BULBS AND BULB WARNING SOCKETS Since headlight bulbs get extremely hot, keep flammable products and your hands Do not check any of the lights that use LEDs. away from them until they have cooled down.

  • Page 356: Checking The Fuses

    ELECTRICAL COMPONENTS Checking the condition of the bulb sockets b. If the pocket tester indicates “∞”, replace the The following procedure applies to all of the bulb fuse. sockets. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...

  • Page 357: Checking And Charging The Battery

    ELECTRICAL COMPONENTS Engine idling speed Since VRLA (Valve Regulated Lead Acid) bat- 1500–1700 r/min teries are sealed, it is not possible to check the charge state of the battery by measuring the EAS30552 specific gravity of the electrolyte. Therefore, the CHECKING AND CHARGING THE BATTERY charge of the battery has to be checked by mea- EWA13290...
  • Page 358 ELECTRICAL COMPONENTS • When charging a battery, be sure to remove Example it from the vehicle. (If charging has to be Open-circuit voltage = 12.0 V Charging time = 6.5 hours done with the battery mounted on the vehi- Charge of the battery = 20–30% cle, disconnect the negative battery lead from the battery terminal.) •...
  • Page 359 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 charging tery and start charging.

  • Page 360: Checking The Relays

    ELECTRICAL COMPONENTS 10.Install: 2. Negative battery terminal • Center cover 3. Positive tester probe Refer to “GENERAL CHASSIS (1)” on page 4. Negative tester probe 4-1. Result EAS30553 Continuity CHECKING THE RELAYS (between “3” and “4”) Check each switch for continuity with the pocket tester.

  • Page 361: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS Minimum ignition spark gap 6.0 mm (0.24 in) If the ignition spark gap is within specification, the ignition system circuit is operating normally. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 362: Checking The Lean Angle Sensor

    ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe → white/red “1” 50˚ 50˚ • Negative tester probe → white/blue “2” c. Turn the main switch to “ON”. d. Turn the lean angle sensor to 50°. e.

  • Page 363: Checking The Stator Coil

    ELECTRICAL COMPONENTS EAS30566 CHECKING THE STATOR COIL Pocket tester 1. Disconnect: 90890-03112 • Stator coil coupler Analog pocket tester YU-03112-C (from the wire harness) 2. Check: • Positive tester probe → • Stator coil resistance Out of specification → Replace the stator coil. positive battery terminal “1”...

  • Page 364: Checking The Coolant Temperature Sensor

    ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. Immerse the coolant temperature sensor “1” in a container filled with coolant “2”. Make sure that the coolant temperature sensor terminals do not get wet. b. Move the fuel sender float to minimum “3” and maximum “4”...
  • Page 365 ELECTRICAL COMPONENTS • Positive tester probe Injector terminal “1” • Negative tester probe Injector terminal “2” c. Measure the fuel injector resistance. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 8-68...
  • Page 366 ELECTRICAL COMPONENTS 8-69...

  • Page 367: Troubleshooting

    UNSTABLE HANDLING ................9-3 FAULTY LIGHTING OR SIGNALING SYSTEM ........9-3 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE....9-5 SELF-DIAGNOSTIC FUNCTION TABLE ..........9-5 COMMUNICATION ERROR WITH THE YAMAHA DIAGNOSTIC TOOL ............9-5 DIAGNOSTIC CODE: SENSOR OPERATION TABLE ......9-5 DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ......9-7...

  • Page 368: Troubleshooting

    TROUBLESHOOTING Electrical system EAS20090 TROUBLESHOOTING 1. Battery • Discharged battery EAS30599 • Faulty battery GENERAL INFORMATION 2. Fuse(s) • Blown, damaged or incorrect fuse The following guide for troubleshooting does not • Improperly installed fuse cover all the possible causes of trouble. It should 3.

  • Page 369: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING Electrical system Poor starting performance 1. Battery 1. V-belt • Discharged battery • Slipping V-belt • Faulty battery • Oil or grease on the V-belt 2. Spark plug 2. Primary sliding sheave • Incorrect spark plug gap • Faulty operation •...

  • Page 370: Overcooling

    TROUBLESHOOTING Fuel system • Bent or damaged damper rod 1. Throttle body • Incorrect oil viscosity • Damaged or loose throttle body joint • Incorrect oil level 2. Air filter EAS30611 • Clogged air filter element UNSTABLE HANDLING 1. Handlebar Chassis •...
  • Page 371 TROUBLESHOOTING • Faulty battery • Faulty rectifier/regulator • Improperly grounded circuit • Faulty main switch • Headlight bulb life expired Tail/brake light does not come on • Wrong tail/brake light LED • Too many electrical accessories • Incorrect connection Turn signal does not come on •...

  • Page 372: Self-Diagnostic Function And Diagnostic Code Table

    Waiting for con- ECU (engine control unit) internal malfunction (output signal error): signals cannot be nection transmitted between the ECU and the Yamaha diagnostic tool. ECU (engine control unit) internal malfunction (input signal error): non-registered data Er-4 has been received from the Yamaha diagnostic tool.
  • Page 373 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Meter display Procedure code No. Intake air pressure Displays the intake air pres- Operate the throttle while sure. pulling the brake lever and pushing the start switch “ ”. (If the display value changes, the performance is OK.) Intake air temperature Displays the intake air tem-...

  • Page 374: Diagnostic Code: Actuator Operation Table

    ISC (idle speed control) ISC (idle speed control) learning data has been the Yamaha diagnostic tool. learning data erasure erased. It is not necessary to erase the ISC (idle speed control) learning data.
  • Page 375 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE...
  • Page 376 Red/White 29. ISC (idle speed control) unit Red/Yellow 30. O sensor White/Blue 31. Lean angle sensor White/Red 32. Yamaha diagnostic tool Yellow/Black 33. Speed sensor Yellow/Green 34. Meter assembly Yellow/Red 35. Multifunction meter 36. Meter light 37. Turn signal indicator light (left) 38.
  • Page 379 MW125 2014 MW125 2014 MW125 2014 MW125 2014 MW125 2014 MW125F 2015 MW125F 2015 MW125F 2015 MW125F 2015 MW125F 2015 WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO...
  • Page 380 MW125 2014 MW125 2014 MW125 2014 MW125 2014 MW125 2014 MW125F 2015 MW125F 2015 MW125F 2015 MW125F 2015 MW125F 2015 WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO...

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