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Yamaha YZ250FM 2021 Owner's Service Manual

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2021

OWNER'S SERVICE MANUAL

YZ250F

Read this manual carefully before operating this vehicle.

YZ250FM

LIT-11626-34-25

B7B-2819U-12

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Page 1 2021 OWNER’S SERVICE MANUAL YZ250F Read this manual carefully before operating this vehicle. YZ250FM LIT-11626-34-25 B7B-2819U-12...
Page 2 EAM20161 Read this manual carefully Operating, servicing and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.
Page 3 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. FCC CAUTION Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment. This transmitter must not be co-located or operated in conjunction with any other antenna or transmitter.
Page 4 EAM20080 YZ250FM OWNER’S SERVICE MANUAL ©2021 by Yamaha Motor Corporation, U.S.A. First edition, June 2020 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. P/N. LIT-11626-34-25...
Page 5 EAM20180 IMPORTANT Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.
Page 6 EAM20162 YAMAHA MOTOR CORPORATION, U.S.A. YZ MOTORCYCLE LIMITED WARRANTY...
Page 7 EAM20082 HOW TO USE THIS MANUAL In this manual, descriptions of installation, removal, disassembly, assembly, check, and adjustment procedures are laid out with the individual steps in sequential order. • The manual is divided into chapters and each chapter is divided into sections. The current section title “1”...
Page 8 EAM20083 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 9: Table Of Contents
TABLE OF CONTENTS EAM10003 GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING TUNING...
Page 11 GENERAL INFORMATION SAFETY INFORMATION ..................1-1 FOR SAFETY, BE SURE TO OBEY THE FOLLOWING:......1-1 LOCATION OF IMPORTANT LABELS.............1-4 DESCRIPTION....................1-5 IDENTIFICATION ....................1-6 VEHICLE IDENTIFICATION NUMBER ............1-6 ENGINE SERIAL NUMBER................1-6 INCLUDED PARTS ...................1-7 SIDESTAND ....................1-7 NIPPLE WRENCH ..................1-7 HANDLEBAR PROTECTOR ..............1-7 FUEL HOSE JOINT COVER ..............1-7 POWER TUNER ..................1-7 IMPORTANT INFORMATION ................1-9 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-9...
Page 12 BREAK-IN PROCEDURES ..............1-25 ENGINE STARTING PRECAUTION ............1-25 MAINTENANCE AFTER BREAK-IN ..............1-26 MAJOR MAINTENANCE ................1-26 AIR FILTER MAINTENANCE ..............1-26 TORQUE-CHECK POINTS................1-27 MOTORCYCLE CARE AND STORAGE............1-29 CARE ......................1-29 STORAGE ....................1-30...
Page 13: Safety Information
Yamaha ma- accidents. Many accidents have been chine, and take care to maintain it properly and caused by an automobile driver who did not operate it safely.
Page 14 1. Always wear an approved helmet. Yamaha can neither endorse nor recommend 2. Wear a face shield or goggles. Wind in your the use of accessories not sold by Yamaha or unprotected eyes could contribute to an im- modifications not specifically recommended by...
Page 15 SAFETY INFORMATION Aftermarket Tires and Rims The tires and rims that came with your motorcy- cle were designed to match the performance ca- pabilities and to provide the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate. Refer to “CHECKING THE TIRES”...
Page 16: Location Of Important Labels
LOCATION OF IMPORTANT LABELS EAM20085 LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle. Premium unleaded gasoline only. 3FB-2415E-02 WARNING This unit contains high pressure nitrogen gas. Mishandling can cause explosion. Read owner's manual for instructions. Do not incinerate, puncture or open.
Page 17: Description
DESCRIPTION EAM20086 DESCRIPTION 13 12 1. Clutch lever 10.Radiator 11.Coolant drain bolt 2. Front brake lever 12.Oil level check window 3. Throttle grip 13.Rear brake pedal 4. Start switch 14.Air filter 5. Radiator cap 6. Fuel tank cap 15.Drive chain 16.Shift pedal 7.
Page 18: Identification
There are two significant reasons for knowing the serial number of your vehicle: 1. When ordering parts, you can give the num- ber to your Yamaha dealer for positive identi- fication of the model you own. 2. If your vehicle is stolen, the authorities will need the number to search for and identify your vehicle.
Page 19: Included Parts
INCLUDED PARTS vent mud, dust, and other foreign materials from EAM20088 INCLUDED PARTS entering the inside when the fuel hose is discon- nected. EAM30372 SIDESTAND This sidestand “1” is used to support only the machine when standing or transporting it. EWA20260 WARNING •...
Page 20 INCLUDED PARTS Before connecting to the CCU wireless net- the following situations. work (in case of initial use of the Power Tun- • The CCU is placed in a location exposed to er app) strong radio waves or other electromagnet- ic noise 1.
Page 21: Important Information
2. Use proper special tools and equipment. Re- used for repair of the vehicle, including periodic fer to “SPECIAL TOOLS” on page 1-15. replacement parts, are new YAMAHA genuine parts and recommended parts. Do not use any used parts, because these may...
Page 22: Lock Washers/Plates And Cotter Pins
IMPORTANT INFORMATION 1. Oil 2. Lip 3. Spring 4. Grease EAM30012 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace lock washers/plates “1” and cotter pins with new ones. After the bolt or nut has been tightened to specification, firmly bend the lock tabs along a flat of the bolt or nut. EAM30014 CIRCLIPS When assembling parts, always use new cir-...
Page 23: Basic Service Information
BASIC SERVICE INFORMATION EAM20120 BASIC SERVICE INFORMATION EAM30181 ELECTRICAL SYSTEM Electrical parts handling ECA16600 NOTICE Never disconnect a battery lead while the en- gine is running; otherwise, the electrical components could be damaged. ECA16760 NOTICE Be sure to connect the battery leads to the correct battery terminals.
Page 24 BASIC SERVICE INFORMATION ECA16630 ECA14371 NOTICE NOTICE Electrical components are very sensitive to Never insert the tester probes into the cou- and can be damaged by static electricity. pler terminal slots. Always insert the probes Therefore, never touch the terminals and be from the opposite end “a”...
Page 25 BASIC SERVICE INFORMATION ECA16780 NOTICE • When disconnecting a coupler, release the coupler lock, hold both sections of the cou- pler securely, and then disconnect the cou- pler. • There are many types of coupler locks; therefore, be sure to check the type of cou- pler lock before disconnecting the coupler.
Page 26 BASIC SERVICE INFORMATION 5. Check: • No continuity Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachom- eter YU-A1927 • If there is no continuity, clean the terminals. • When checking the wire harness, perform steps (1) to (4). •...
Page 27: Special Tools
Feeler gauge set YU-26900-9 Valve lapper (ø14) 3-7, 5-27 90890-04101 90890-04101 Valve lapper (ø14) YM-A8998 YM-A8998 Yamaha diagnostic tool USB (US) 3-11, 7-8, 8-15 90890-03269 Yamaha diagnostic tool (A/I) 3-11, 7-8, 8-15 90890-03264 FI diagnostic tool sub–lead 3-11, 7-8, 8-15 90890-03212 FI diagnostic tool sub–lead...
Page 28 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages OBD/ GST Leadwire kit 3-11, 7-8, 8-15 90890-03249 Digital tachometer 3-11, 3-35, 8-49 90890-06760 Digital tachometer YU-39951-B Steering nut wrench 3-27, 4-55 90890-01403 Exhaust flange nut wrench YU-A9472 Spoke nipple wrench (6–7) 3-33 90890-01521 Spoke nipple wrench (6–7)
Page 29 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Boots band installation tool 90890-01526 Boots band installation tool YM-01526 Yamaha bond No. 1215 5-20, 5-39, 5-69 90890-85505 Three bond No. 1215® Valve spring compressor 5-27, 5-31 90890-04019 Valve spring compressor YM-04019...
Page 30 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide installer (ø4.5) 5-29 90890-04117 Valve guide installer (4.5 mm) YM-04117 Valve guide reamer (ø4.5) 5-29 90890-04118 Valve guide reamer (4.5 mm) YM-04118 Piston pin puller set 5-34 90890-01304 Piston pin puller YU-01304 YU-01304 Rotor puller...
Page 31 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Crankcase separating tool 5-71 90890-04152 Crankcase separating tool YU-A9642 Crankshaft installer pot 5-72 90890-01274 Installing pot YU-90058 YU-90058/YU-90059 Crankshaft installer bolt 5-72 90890-01275 Bolt YU-90060 Adapter (M12) 5-72 90890-01278 Adapter #3 YU-90063 Spacer (crankshaft installer) 5-72 90890-04081...
Page 32 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester 6-4, 6-4 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter 6-4, 6-4 90890-01352 Pressure tester adapter YU-33984 YU-33984 Pressure gauge 90890-03153 Pressure gauge YU-03153 Fuel pressure adapter 90890-03186 Fuel pressure adapter YM-03186...
Page 33 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Test harness S– pressure sensor (3P) 8-50 90890-03207 Test harness S– pressure sensor (3P) YU-03207 1-21...
Page 34: Instrument And Control Functions
INSTRUMENT AND CONTROL FUNCTIONS To change the mode EAM20181 INSTRUMENT AND CONTROL 1. Shift to neutral. FUNCTIONS 2. Start the engine. 3. Press the mode switch. EAM30182 ENGINE STOP SWITCH As shipped from the factory, maps 1 and 2 are The engine stop switch “1”...
Page 35: Rear Brake Pedal
INSTRUMENT AND CONTROL FUNCTIONS bands “3” all the way in under the seat. EAM30189 REAR BRAKE PEDAL The rear brake pedal “1” is in the right of the chassis. Press down on the brake pedal to acti- vate the rear brake. a a a EAM30444 STARTER KNOB...
Page 36: Starting And Break-In
4. When the engine starts running, warm this up one or two minutes at a steady speed (of 3000 to 5000 r/min), and then return the start- Your Yamaha engine has been designed to use er knob to its original position. premium unleaded gasoline with a pump octane...
Page 37: Starting A Warm Engine
STARTING AND BREAK-IN check the points shown in “TORQUE- CHECK POINTS” for tightening torques and retighten them. Also when the following parts are replaced, a break-in is required. • Cylinder and Crankshaft: A break-in is re- quired for about an hour. •...
Page 38: Maintenance After Break-In
Pour the specified amount of the recom- AIR FILTER MAINTENANCE mended oil. Apply the Yamaha foam air filter oil or other qual- • Generator ity foam air filter oil to the element. (Excess oil in Check for looseness in mounted areas of the the element may adversely affect engine start- generator rotor and the stator coil assembly.
Page 39: Torque-Check Points
TORQUE-CHECK POINTS EAM20125 TORQUE-CHECK POINTS Frame construction Combined seat and fuel tank Fuel tank to frame Frame to rear frame Frame to engine protector Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Seat Seat to frame Steering Steering stem to handlebar Steering stem to frame...
Page 40 TORQUE-CHECK POINTS Shift pedal Shift pedal to shift shaft Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake disc cover Tightening of rear brake caliper cover...
Page 41: Motorcycle Care And Storage
MOTORCYCLE CARE AND STORAGE any longer than instructed. Also, thorough- EAM20126 MOTORCYCLE CARE AND STOR- ly rinse the area off with water, immediately dry it, and then apply a corrosion protec- tion spray. • Improper cleaning can damage plastic EAM30200 CARE parts (such as cowlings, panels, wind- While the open design of a motorcycle reveals...
Page 42: Storage
Salt sprayed on roads in the winter may remain well into spring. • Consult a Yamaha dealer for advice on what 1. Clean the motorcycle with cold water and a products to use.
Page 43 MOTORCYCLE CARE AND STORAGE stored. Long-term Before storing your motorcycle for several months: 1. Follow all the instructions in the “CARE” on page 1-29. 2. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating.
Page 44 MOTORCYCLE CARE AND STORAGE 1-32...
Page 45: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS ................2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-5 ELECTRICAL SPECIFICATIONS..............2-8 TIGHTENING TORQUES..................2-9 GENERAL TIGHTENING TORQUE SPECIFICATIONS ......2-9 ENGINE TIGHTENING TORQUES ............2-10 CHASSIS TIGHTENING TORQUES ............2-12 CABLE ROUTING DIAGRAM ................2-17...
Page 46: General Specifications
GENERAL SPECIFICATIONS EAM20127 GENERAL SPECIFICATIONS Model Model B7BA B7BF Dimensions Overall length 2175 mm (85.6 in) Overall width 825 mm (32.5 in) Overall height 1285 mm (50.6 in) Seat height 970 mm (38.2 in) Wheelbase 1475 mm (58.1 in) Ground clearance 335 mm (13.19 in) Weight Curb weight...
Page 47: Engine Specifications
ENGINE SPECIFICATIONS EAM20128 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train DOHC Displacement 250 cm³ Number of cylinders Single cylinder Bore  stroke 77.0  53.6 mm (3.03  2.11 in) Compression ratio 13.8 : 1 Starting system Electric starter Fuel...
Page 48 ENGINE SPECIFICATIONS Valve dimensions Valve seat contact width limit (intake) 1.6 mm (0.06 in) Valve seat contact width limit (exhaust) 1.6 mm (0.06 in) Valve stem diameter limit (intake) 4.945 mm (0.1947 in) Valve stem diameter limit (exhaust) 4.430 mm (0.1744 in) Valve guide inside diameter (intake) 5.000–5.012 mm (0.1969–0.1973 in) Valve guide inside diameter (exhaust)
Page 49 3.846 (50/13) Final drive Chain Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil Fuel pump Pump type Electrical Maximum consumption amperage 2.4 A Fuel injector 12.0 ...
Page 50 CHASSIS SPECIFICATIONS EAM20129 CHASSIS SPECIFICATIONS Chassis 26.8  Caster angle Trail 119 mm (4.7 in) Front wheel Wheel type Spoke wheel Rim size 21x1.6 Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in) Wheel axle bending limit 0.50 mm (0.02 in) Rear wheel...
Page 51 Fork spring free length limit 492.0 mm (19.37 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil S1 Quantity (left) 501.0 cm³ (16.94 US oz, 17.67 Imp.oz) Quantity (right) 501.0 cm³ (16.94 US oz, 17.67 Imp.oz)
Page 52: Chassis Specifications
CHASSIS SPECIFICATIONS Adjustment value from the start position (STD) Adjustment value from the start position (Hard) Slow compression damping Unit for adjustment Click Adjustment value from the start position (Soft) Adjustment value from the start position (STD) Adjustment value from the start position (Hard) Drive chain Size...
Page 53: Electrical Specifications
ELECTRICAL SPECIFICATIONS EAM20130 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system 8.0–12.0 /2000 r/min Ignition timing (B.T.D.C.) Engine control unit Model B7B6 Ignition coil 2.16–2.64  Primary coil resistance Secondary coil resistance 8.64–12.96 k Spark plug cap Resistance 7.50–12.50 k...
Page 54: Tightening Torques
TIGHTENING TORQUES EAM20131 TIGHTENING TORQUES EAM30205 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 55: Engine Tightening Torques
TIGHTENING TORQUES EAM30203 ENGINE TIGHTENING TORQUES - marked portion shall be checked for torque tightening after break-in or before each race. Thread Item Q’ty Tightening torques Remarks size Camshaft cap bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) Cylinder head stud bolt (exhaust 7 N·m (0.7 kgf·m, 5.2 lb·ft) pipe)
Page 56 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Exhaust pipe nut 10 N·m (1.0 kgf·m, 7.4 lb·ft) Exhaust pipe protector screw 10 N·m (1.0 kgf·m, 7.4 lb·ft) Exhaust pipe bracket bolt 20 N·m (2.0 kgf·m, 15 lb·ft) Silencer bolt (front) 30 N·m (3.0 kgf·m, 22 lb·ft) Silencer bolt (rear) 30 N·m (3.0 kgf·m, 22 lb·ft)
Page 57: Chassis Tightening Torques
TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Stator coil assembly lead holder bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) Coolant temperature sensor 14 N·m (1.4 kgf·m, 10 lb·ft) Gear position switch bolt 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) Rectifier/regulator bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) ECU bolt...
Page 58 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Upper bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft)  Lower bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft)  Steering stem nut 145 N·m (14.5 kgf·m, 107 lb·ft) ...
Page 59 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Footrest bracket bolt 55 N·m (5.5 kgf·m, 41 lb·ft) Rear brake pedal bolt 26 N·m (2.6 kgf·m, 19 lb·ft)  Rear brake pedal adjusting locknut 6 N·m (0.6 kgf·m, 4.4 lb·ft) Rear brake master cylinder bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) ...
Page 60 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Drive chain support nut 7 N·m (0.7 kgf·m, 5.2 lb·ft) Drive chain guide bolt 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) Fuel tank bolt (front side) 7 N·m (0.7 kgf·m, 5.2 lb·ft) ...
Page 61 TIGHTENING TORQUES 2-16...
Page 62: Cable Routing Diagram
CABLE ROUTING DIAGRAM EAM20152 CABLE ROUTING DIAGRAM Frame and engine (left side view) 2-17...
Page 63 Pass the mode switch lead above the breather hose. engine stop switch lead. B. Insert the Yamaha diagnostic tool coupler into the connector, and fix it to the bracket. C. Fasten the engine stop switch coupler to the bracket of the inside. Fasten the mode switch coupler to the bracket of the outside.
Page 64 CABLE ROUTING DIAGRAM Frame and engine (right side view) 2-19...
Page 65 CABLE ROUTING DIAGRAM H. Install the cylinder head breather hose so 1. Negative battery lead that the outlet faces downward. Align the out- 2. Cross tube let with the lower side of the down tube. 3. Starter motor lead I. After connecting the fuel pump coupler, 4.
Page 66 CABLE ROUTING DIAGRAM Handlebar (front view) 2-21...
Page 67 CABLE ROUTING DIAGRAM 1. Plastic locking tie 2. Number plate band 3. Clutch cable 4. Engine stop switch lead 5. Mode switch lead 6. Front brake hose 7. Cable guide 8. Start switch lead 9. Number plate A. Fasten the start switch lead to the handlebar using the plastic locking tie.
Page 68 CABLE ROUTING DIAGRAM Frame and engine (top view) 2-23...
Page 69 CABLE ROUTING DIAGRAM 1. Clamp 2. Diode 3. Throttle position sensor lead 4. Intake air pressure sensor lead 5. Joint coupler 6. Intake air pressure sensor coupler 7. Clamp (wire harness) 8. Wire harness 9. Fuel injector lead 10.Throttle body 11.Fuel injector coupler 12.Fuel hose 13.Rectifier/regulator lead...
Page 70 CABLE ROUTING DIAGRAM Frame and battery (top view) 2-25...
Page 71 CABLE ROUTING DIAGRAM 1. Positive battery lead 2. CCU (Communication Control Unit) 3. Diode 4. Fuel pump lead 5. Fuel hose 6. Wire harness 7. Joint coupler 8. Main relay 9. Starter relay coupler 10.Starter relay 11.Starter motor lead 12.Negative battery lead 13.Cross member A.
Page 72 CABLE ROUTING DIAGRAM Rear brake (right side view) 2-27...
Page 73 CABLE ROUTING DIAGRAM 1. Protector 2. Rear brake caliper 3. Bleed screw 4. Gasket 5. Rear brake hose 6. Brake pedal 7. Rear brake master cylinder assembly 8. Swingarm 9. Spring 10.Frame A. It does not matter whether the spring is installed upward or downward.
Page 74 CABLE ROUTING DIAGRAM 2-29...
Page 75: Periodic Checks And Adjustments
PERIODIC CHECKS AND ADJUSTMENTS MAINTENANCE INTERVALS ................3-1 MAINTENANCE INTERVALS..............3-1 PRE-OPERATION INSPECTION AND MAINTENANCE .........3-5 GENERAL INSPECTION AND MAINTENANCE ........3-5 ENGINE......................3-6 ADJUSTING THE VALVE CLEARANCE............3-6 VALVE CLEARANCE SHIM CHART ............3-9 CHECKING THE ENGINE IDLING SPEED..........3-11 CHECKING THE THROTTLE GRIP ............3-11 CHECKING THE SPARK PLUG...............3-12 CHECKING THE ENGINE OIL LEVEL .............3-13 CHANGING THE ENGINE OIL..............3-13 ADJUSTING THE CLUTCH LEVER FREE PLAY ........3-15...
Page 76 CHECKING THE WHEEL BEARINGS .............3-33 CHECKING THE CHASSIS FASTENERS ..........3-33 CHECKING AND LUBRICATING THE CABLES........3-33 LUBRICATING THE BRAKE LEVER ............3-34 LUBRICATING THE CLUTCH LEVER .............3-34 LUBRICATING THE PEDAL..............3-34 ELECTRICAL SYSTEM..................3-35 CHECKING AND CHARGING THE BATTERY ........3-35 CHECKING THE FUSES................3-35 CHECKING THE IGNITION TIMING ............3-35...
Page 77: Maintenance Intervals
(e.g., rain, dirt, etc.). Therefore, earlier inspection is required by reference to the list below. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
Page 78 MAINTENANCE INTERVALS Every Every Every After race third race fifth race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours) • Check the coolant passages for corrosion. • Inspect carbon deposits and elim-  11 * Cylinder head inate them.
Page 79 MAINTENANCE INTERVALS Every Every Every After race third race fifth race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours) • Clean.   • Inspect and adjust.     • Replace oil. 30 * Front fork leg(s) •...
Page 80 MAINTENANCE INTERVALS Every Every Every After race third race fifth race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours) Brake pedal, footrest • Lubricate.   • Retighten. Outside nuts and   44 * bolts •...
Page 81: Pre-Operation Inspection And Maintenance
PRE-OPERATION INSPECTION AND MAINTENANCE EAM20134 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating con- dition. Before using this machine, check the following points. EAM30209 GENERAL INSPECTION AND MAINTENANCE Item Inspect Page...
Page 82: Engine
Turn the crankshaft counterclockwise with sic knowledge and skill concerning the servic- a wrench. ing of Yamaha motorcycles (e.g., Yamaha b. Align the top dead center (TDC) mark “a” dealers, service engineers, etc.). Those who on the generator rotor with the alignment have little knowledge and skill concerning ser- mark “b”...
Page 83 ENGINE • The adjusting pad number “a” is indicated on the top of the adjusting pad. • For the number on the originally installed ad- justing pad, convert the last digit of adjusting pad number as per the below table. 5.
Page 84 ENGINE • Make sure that adjusting pads are installed with their numbers facing upward. f. Install the camshafts (exhaust and intake). Refer to “CAMSHAFT” on page 5-14. g. Measure the valve clearance again. h. If the valve clearance is out of specifica- tion, repeat adjusting the valve clearance until it is within specification.
Page 85: Valve Clearance Shim Chart
ENGINE EAM30383 VALVE CLEARANCE SHIM CHART INTAKE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.02 0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230...
Page 86 ENGINE EXHAUST 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 0.02 0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225...
Page 87: Checking The Engine Idling Speed
2. Measure the coolant temperature using the 5. Adjust: Yamaha diagnostic tool. • Engine idling speed Yamaha diagnostic tool USB (US) a. Turn the idle screw “1” to make an adjust- 90890-03269 ment. Yamaha diagnostic tool (A/I) 90890-03264 FI diagnostic tool sub–lead...
Page 88: Checking The Spark Plug
ENGINE 2. Adjust: ECA24410 NOTICE • Throttle grip free play In order not to allow the dirt accumulated a. Loosen the locknut “1”. around the spark plug to drop from the spark b. Turn the adjuster “2” until the specified plug hole into the cylinder, clean it before re- throttle grip free play is obtained.
Page 89: Checking The Engine Oil Level
ENGINE • Seat • Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1. EAM30224 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle upright on a level surface. 2. Start the engine, warm this up for 2–3 min- utes, and then stop the engine and wait about 1 minute.
Page 90 ENGINE Engine oil quantity Oil change 0.73 L (0.77 US qt, 0.64 Imp.qt) With oil filter removal 0.75 L (0.79 US qt, 0.66 Imp.qt) Quantity (disassembled) 0.95 L (1.00 US qt, 0.84 Imp.qt) c. Install the new oil filter element and the oil filter element cover.
Page 91: Adjusting The Clutch Lever Free Play
ENGINE Clutch cable side ECA25840 NOTICE a. Slide the clutch cable cover. If no engine oil seeps out after one minute, b. Loosen the locknut “1”. immediately turn the engine off so it will not c. Turn the adjuster “2” until the specified seize.
Page 92 • Air filter element Damage  Replace. 6. Apply: • Yamaha foam air filter oil or other quality foam air filter oil a. Put the air filter element into a plastic bag and drip the filter oil into the bag.
Page 93: Checking The Throttle Body Joint
ENGINE 8. Turn the plates “1” to the original position. 10.Install: • Fuel tank cap cover EAM30335 CHECKING THE THROTTLE BODY JOINT 1. Check: • Throttle body joint “1” Crack/damage  Replace. 9. Install: • Air filter case cover “1” •...
Page 94: Checking The Cylinder Head Breather Hose
ENGINE 4. Check: • Silencer fiber Damage  Replace. 5. Replace: • Silencer fiber a. Remove the bolts “1” and silencer body “2”. ECA25800 NOTICE Do not hit the silencer stay “a” as it may do damage to the silencer. 3.
Page 95 ENGINE d. Install the fiber insert “6” to the part “b”. h. Install the fiber insert “12” to the inner pipe. e. Twist the fiber insert “7” onto the inner pipe i. Install the fiber insert “13” to the inside of “c”.
Page 96: Checking The Coolant Level
ENGINE 6. Check: EAM30210 CHECKING THE COOLANT LEVEL • Gasket “1” EWA13030 Damage  Replace. WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in- jury.
Page 97: Checking The Cooling System
ENGINE tilled water is not available, soft water may be used. 4. Start the engine, warm this up for several minutes, and then stop it. 5. Check: • Coolant level Before checking the coolant level, wait a few minutes until the coolant has settled. 3.
Page 98 ENGINE tion of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft water may be used. • If coolant comes into contact with painted surfaces, immediately wash them with wa- ter. • Do not mix different types of antifreeze. 7.
Page 99: Chassis
CHASSIS system. Air in the brake system will consid- EAM20136 CHASSIS erably reduce braking performance. ECA13490 EAM30479 ADJUSTING THE FRONT DISC BRAKE NOTICE After adjusting the brake lever position, There should be no free play at the brake lever make sure there is no brake drag. end.
Page 100: Checking The Brake Fluid Level
CHASSIS can indicate the presence of air in the brake and plastic parts. Therefore, always clean up system. Before running, bleed the brake sys- any spilt brake fluid immediately. tem. Air in the brake system will cause brak- ing performance to be reduced. EAM30231 CHECKING THE FRONT BRAKE PADS ECA13510...
Page 101: Checking The Rear Brake Hose
CHASSIS brake several times. the reservoir to overflow. • Make sure that there is enough brake fluid be- 4. Check: • Brake hose fore applying the brake. Ignoring this precau- Brake fluid leaks  Replace the damaged tion could allow air to enter the brake system, brake hose.
Page 102: Drive Chain Slack
CHASSIS h. Repeat steps (d) to (g) until all of the air bubbles have disappeared from the brake Measure drive chain slack between the drive fluid in the plastic hose. chain guide and the bottom of the chain as shown. During the procedure, keep adding brake fluid to the reservoir.
Page 103: Checking And Adjusting The Steering Head
CHASSIS Drive chain puller locknut 21 N·m (2.1 kgf·m, 15 lb·ft) EAM30247 CHECKING AND ADJUSTING THE STEERING HEAD 1. Use a maintenance stand to raise the front wheel off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over.
Page 104: Lubricating The Steering Head
CHASSIS of the outer tube circumference. 5. Install: • Upper bracket 6. Remove: Refer to “STEERING HEAD” on page 4-54. • Protector • Handlebar • Dust seal “1” Refer to “HANDLEBAR” on page 4-35. ECA24330 NOTICE EAM30502 LUBRICATING THE STEERING HEAD Be careful not to damage the dust seal and 1.
Page 105 CHASSIS have poor stability. Compression damping • Securely support the vehicle so that there ECA24350 NOTICE is no danger of it falling over. Do not turn the adjuster forcibly beyond its Rebound damping adjusting range. ECA24340 NOTICE 1. Adjust: Do not turn the adjuster forcibly beyond its •...
Page 106: Checking The Rear Shock Absorber Assembly
CHASSIS wheel off the ground. EWA13120 WARNING EWA13120 Securely support the vehicle so that there is WARNING Securely support the vehicle so that there is no danger of it falling over. no danger of it falling over. Spring preload 2. Remove the bleed screw “1” and release the ECA24360 NOTICE internal pressure from the front fork.
Page 107 CHASSIS ment. • The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjusting ring. Compression damping (for fast compres- sion damping) ECA24370 NOTICE e. Tighten the locknut. Do not turn the adjuster forcibly beyond its Rebound damping adjusting range.
Page 108: Checking The Swingarm Operation
CHASSIS Compression damping (for slow compres- EAM30240 CHECKING THE SWINGARM OPERATION sion damping) 1. Check: ECA24390 • Swingarm smooth action NOTICE • Swingarm free play Do not turn the adjuster forcibly beyond its adjusting range. Refer to “SWINGARM” on page 4-64. 1.
Page 109: Checking And Tightening The Spokes
CHASSIS rect the tire position. Spoke nipple wrench (6–7) 90890-01521 Spoke nipple wrench (6–7) YM-01521 Spoke 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) • Do not give a half turn (180) or more for one tightening. • Make sure that tightening after a break-in is a.
Page 110: Lubricating The Brake Lever
CHASSIS 1. Check: • Outer cable Damage  Replace. 2. Check: • Cable operation Rough movement  Lubricate. Recommended lubricant Engine oil or a suitable cable lu- bricant Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit- able lubricating device.
Page 111: Electrical System
ELECTRICAL SYSTEM 4. Check: EAM20137 ELECTRICAL SYSTEM • Ignition timing Check whether the alignment mark “a” on the EAM30256 left crankcase cover is within the firing range CHECKING AND CHARGING THE BATTERY “b” on the generator rotor. Refer to “CHECKING AND CHARGING THE Incorrect firing range ...
Page 112 ELECTRICAL SYSTEM 3-36...
Page 113 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE SEAT................4-3 REMOVING THE NUMBER PLATE ............4-3 INSTALLING THE AIR SCOOP..............4-4 REMOVING THE SIDE COVER ..............4-4 INSTALLING THE SIDE COVER ...............4-4 FRONT WHEEL ....................4-5 REMOVING THE FRONT WHEEL .............4-6 DISASSEMBLING THE FRONT WHEEL ...........4-6 CHECKING THE FRONT WHEEL .............4-6 ASSEMBLING THE FRONT WHEEL ............4-6 INSTALLING THE FRONT WHEEL ............4-7 REAR WHEEL ....................4-9...
Page 114 INSTALLING THE REAR BRAKE MASTER CYLINDER ......4-33 HANDLEBAR....................4-35 REMOVING THE HANDLEBAR ...............4-36 CHECKING THE HANDLEBAR..............4-36 INSTALLING THE HANDLEBAR..............4-36 FRONT FORK....................4-41 REMOVING THE FRONT FORK LEGS ...........4-43 DISASSEMBLING THE FRONT FORK LEGS .........4-43 CHECKING THE FRONT FORK LEGS............4-44 ASSEMBLING THE FRONT FORK LEGS ..........4-45 INSTALLING THE FRONT FORK LEGS..........4-52 STEERING HEAD...................4-54 REMOVING THE LOWER BRACKET ............4-55...
Page 115 GENERAL CHASSIS EAM20094 GENERAL CHASSIS Removing the seat and battery 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 116 GENERAL CHASSIS Removing the side cover 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 1.3 N ・ m (0.13 kgf ・ m, 0.95 lb ・ ft) 7 N ・...
Page 117: General Chassis
GENERAL CHASSIS EAM30016 REMOVING THE SEAT 2 2 2 The fuel tank cap cover and the seat are coupled with each other with a plastic band. When removing the seat, always remove the fuel tank cap cover beforehand. 1. Remove: •...
Page 118: Installing The Air Scoop
GENERAL CHASSIS EAM30459 REMOVING THE SIDE COVER 1. Remove: • Side cover (right) “1” Remove the side cover (right) from the vehicle by removing the bolts and sliding it as shown. a. Projection b. Slot EAM30460 INSTALLING THE SIDE COVER 1.
Page 119: Front Wheel
FRONT WHEEL EAM20095 FRONT WHEEL Removing the front wheel 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 115 N ・ m (11.5 kgf ・ m, 85 lb ・ ft) 12 N ・...
Page 120: Removing The Front Wheel
FRONT WHEEL 3. Check: EAM30017 REMOVING THE FRONT WHEEL • Spoke 1. Use a maintenance stand to raise the front Refer to “CHECKING AND TIGHTENING wheel off the ground. THE SPOKES” on page 3-33. EWA13120 4. Tighten: WARNING • Spoke Securely support the vehicle so that there is Refer to “CHECKING AND TIGHTENING no danger of it falling over.
Page 121: Installing The Front Wheel
FRONT WHEEL • Left side of bearing shall be installed first. 3. Install: • Install the oil seal with its manufacture’s marks • Collar “1” or numbers facing outward. Apply the lithium-soap-based grease on the oil ECA24420 seal lip. NOTICE Install the bearing by pressing its outer race parallel.
Page 122 FRONT WHEEL Front wheel axle nut 115 N·m (11.5 kgf·m, 85 lb·ft) ECA24430 NOTICE Before tightening the front wheel axle nut, push down hard on the handlebar(s) several times and check if the front fork rebounds smoothly. 4. Tighten: • Front wheel axle pinch bolt “1” Front wheel axle pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft)
Page 123 REAR WHEEL EAM20096 REAR WHEEL Removing the rear wheel 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 135 N ・ m (13.5 kgf ・ m, 100 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 42 N ・...
Page 124: Rear Wheel
REAR WHEEL Refer to “CHECKING THE TIRES” on page EAM30022 REMOVING THE REAR WHEEL 3-32 and “CHECKING THE WHEELS” on 1. Use a maintenance stand to raise the rear page 3-33. wheel off the ground. 3. Check: EWA13120 • Spoke WARNING Refer to “CHECKING AND TIGHTENING Securely support the vehicle so that there is...
Page 125: Assembling The Rear Wheel
REAR WHEEL 2. Install: Rear wheel sprocket self-locking • Brake disc • Brake disc bolt 42 N·m (4.2 kgf·m, 31 lb·ft) Brake disc bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) LOCTITE® Tighten the self-locking nuts in stages and in a crisscross pattern.
Page 126 REAR WHEEL Refer to “DRIVE CHAIN SLACK” on page 3-26. 3. Install: • Left drive chain puller “1” • Rear wheel axle “2” 6. Tighten: • Rear wheel axle nut “1” • Install the left drive chain puller, and insert the Wheel axle nut rear wheel axle from the left side.
Page 127 FRONT BRAKE EAM20097 FRONT BRAKE Removing the front brake caliper 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 28 N ・ m (2.8 kgf ・ m, 21 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 17 N ・...
Page 128: Front Brake
FRONT BRAKE Disassembling the front brake caliper 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw 4-14...
Page 129 FRONT BRAKE Removing the front brake master cylinder 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 6 N ・...
Page 130 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Push rod Dust boot Circlip Washer Brake master cylinder kit 4-16...
Page 131: Introduction
FRONT BRAKE b. Remove the brake caliper. EAM30028 INTRODUCTION c. Hold the dial gauge at a right angle against EWA19210 the brake disc surface. WARNING d. Measure the runout 1.5 mm (0.06 in) If you need to disassemble the disc brake above the brake disc edge.
Page 132 FRONT BRAKE d. Remove the pad pin and brake pads “4”. Bleed screw 6 N·m (0.6 kgf·m, 4.4 lb·ft) d. Install the brake pads “3” and the pad pin. • Install the brake pads with their projections “a” into the brake caliper recesses “b”. •...
Page 133: Removing The Front Brake Caliper
FRONT BRAKE 4. Check: • Brake fluid level Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-24. 5. Check: • Brake lever operation A softy or spongy feeling  Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-25. b.
Page 134: Installing The Front Brake Caliper
FRONT BRAKE cleaning and lubricating. Brake pad pin • Never use solvents on internal brake com- 17 N·m (1.7 kgf·m, 13 lb·ft) ponents as they will cause the piston seals to swell and distort. Refer to “CHECKING THE FRONT BRAKE •...
Page 135: Removing The Front Brake Master Cylinder
FRONT BRAKE Refer to “BLEEDING THE HYDRAULIC 3. Check: BRAKE SYSTEM” on page 3-25. • Brake master cylinder reservoir cap 6. Check: 4. Check: • Brake fluid level • Brake hose The minimum level mark or below  Add. Cracks/damage/wear  Replace. Refer to “CHECKING THE BRAKE FLUID EAM30038 LEVEL”...
Page 136: Installing The Front Brake Master Cylinder
FRONT BRAKE (to the brake master cylinder piston “2”) Install the spring with a smaller inside diameter to the brake master cylinder piston. 2. Install: • Copper washer • Brake hose • Union bolt 4. Install: Brake hose union bolt •...
Page 137 FRONT BRAKE brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
Page 138: Rear Brake
REAR BRAKE EAM20098 REAR BRAKE Removing the rear brake caliper 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 13 lb ・ ft) 30 N ・...
Page 139 REAR BRAKE Disassembling the rear brake caliper 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw 4-25...
Page 140 REAR BRAKE Removing the rear brake master cylinder 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 141 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Push rod Brake master cylinder kit 4-27...
Page 142: Introduction
REAR BRAKE EAM30040 INTRODUCTION Brake disc runout limit (as mea- sured on wheel) EWA19260 0.15 mm (0.0059 in) WARNING If you need to disassemble the disc brake 4. Replace: components, observe the following precau- • Brake disc tions. Refer “ASSEMBLING REAR •...
Page 143 REAR BRAKE Bleed screw 6 N·m (0.6 kgf·m, 4.4 lb·ft) d. Install the brake pads “3” and the pad pin “4”. • Install the brake pads with their projections “a” into the brake caliper recesses “b”. • Temporarily tighten the pad pin at this point. 2.
Page 144: Removing The Rear Brake Caliper
REAR BRAKE joint opening to force out the piston from the brake caliper. EWA13550 WARNING • Cover the brake caliper piston with a rag. Be careful not to get injured when the pis- ton is expelled from the brake caliper. •...
Page 145: Assembling The Rear Brake Caliper
REAR BRAKE 2. Check: • Brake caliper bracket Crack/damage  Replace. EAM30045 ASSEMBLING THE REAR BRAKE CALIPER EWA19280 WARNING • Before installation, clean and lubricate the internal parts. Use new brake fluid for cleaning and lubricating. • Never use solvents on internal brake com- 3.
Page 146: Removing The Rear Brake Master Cylinder
REAR BRAKE 6. Check: • Brake master cylinder reservoir diaphragm • Brake fluid level holder The minimum level mark or below  Add. • Brake master cylinder reservoir diaphragm Crack/damage  Replace. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-24. 4.
Page 147: Installing The Rear Brake Master Cylinder
REAR BRAKE 3. Install: ECA24500 NOTICE • Spring “1” Make sure that the pipe portion of the brake (to the brake master cylinder piston “2”) hose touches the projection “a” on the brake caliper. Install the spring with a smaller inside diameter to the brake master cylinder piston.
Page 148 REAR BRAKE system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-25. 4-34...
Page 149: Handlebar
HANDLEBAR EAM20099 HANDLEBAR Removing the handlebar 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 0.5 N ・ m (0.05 kgf ・ m, 0.37 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 28 N ・...
Page 150: Removing The Handlebar
HANDLEBAR EAM30052 EAM30054 REMOVING THE HANDLEBAR INSTALLING THE HANDLEBAR 1. Stand the vehicle upright on a level surface. 1. Stand the vehicle upright on a level surface. EWA13120 EWA13120 WARNING WARNING Securely support the vehicle so that there is Securely support the vehicle so that there is no danger of it falling over.
Page 151 HANDLEBAR 3. Tighten: • Lower handlebar holder nut Lower handlebar holder nut 40 N·m (4.0 kgf·m, 30 lb·ft) 4. Install: • Clutch lever holder “1” • Clutch lever “2” Clutch lever holder bolt 5 N·m (0.5 kgf·m, 3.7 lb·ft) Clutch lever nut 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) The clutch lever holder “1”...
Page 152 HANDLEBAR 6. Install: quer thinner. • Handlebar grip “1” • Install the grip to the tube guide so that the grip a. Slightly coat the handlebar left end with a match mark “b” and tube guide slot “c” form the rubber adhesive.
Page 153 HANDLEBAR 12.Install: 14.Install: • Throttle cable housing “1” • Start switch “1” • Screw (throttle cable housing) “2” • Front brake master cylinder assembly “2” • Front brake master cylinder holder “3” Screw (throttle cable housing) • Bolt (brake master cylinder holder) “4” 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) •...
Page 154 HANDLEBAR Throttle grip free play 3.0–6.0 mm (0.12–0.24 in) 4-40...
Page 155: Front Fork
FRONT FORK EAM20100 FRONT FORK Removing the front fork legs 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 5 N ・...
Page 156 FRONT FORK Disassembling the front fork leg 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 29 N ・ m (2.9 kgf ・ m, 21 lb ・ ft) 28 N ・ m (2.8 kgf ・ m, 21 lb ・ ft) 55 N ・...
Page 157: Removing The Front Fork Legs
FRONT FORK EAM30055 REMOVING THE FRONT FORK LEGS 1. Use a maintenance stand to raise the front wheel off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Record the adjusting screw setting position be- fore loosening the adjuster and the base valve.
Page 158: Checking The Front Fork Legs
FRONT FORK Cap bolt wrench 90890-01500 Cap bolt wrench YM-01500 Cap bolt ring wrench 90890-01501 Cap bolt ring wrench YM-01501 3. Remove: • Dust seal “1” • Stopper ring “2” (with a flat-head screwdriver) ECA14180 NOTICE Do not scratch the inner tube. EAM30057 CHECKING THE FRONT FORK LEGS 1.
Page 159: Assembling The Front Fork Legs
FRONT FORK 4. Check: 6. Check: • Damper assembly “1” • Upper spring seat “1” Bend/damage  Replace. (contacting surface “a”) Wear/damage  Replace. • O-ring “2” Wear/damage  Replace. ECA14200 NOTICE • The front fork leg has a built-in damper ad- justing rod and a very sophisticated inter- nal construction, which are particularly sensitive to foreign material.
Page 160 1. Stretch the damper assembly fully. 2. Fill: • Damper assembly Recommended oil Yamaha Suspension Oil S1 Standard oil amount 216 cm³ (7.30 US oz, 7.62 Imp.oz) ECA24530 NOTICE • Be sure to use the recommended oil. Other oils may have an adverse effect on front fork performance.
Page 161 FRONT FORK 7. Install: 10.After filling, pump the damper assembly “1” • Base valve “1” slowly up and down more than 10 times to (to the damper assembly “2”) distribute the fork oil. First bring the damper rod pressure to a maxi- mum.
Page 162 FRONT FORK 13.Check: 15.Install: • Damper assembly smooth movement • Piston metal “1” Tightness/binding/rough spots  Repeat the steps (1) to (12). Install the piston metal onto the slot on inner tube. 14.Install: • Dust seal “1” 16.Install: • Stopper ring “2” •...
Page 163 FRONT FORK 20.Install: • Dust seal “1” Apply lithium-soap-based grease on the inner tube. 18.Install: • Oil seal “1” Using a fork seal driver “2”, press the oil seal in until the stopper ring groove fully appears. 21.Check: Fork seal driver •...
Page 164 FRONT FORK • Unless the damping force adjuster is fully loos- ened, correct damping characteristic cannot be obtained after installation. 23.Install: • Upper spring seat “1” • Fork spring “2” (to the damper assembly “3”) 26.Install: • Damper adjusting rod “1” Install the upper spring seat with its larger dia.
Page 165 FRONT FORK correct damping force cannot be obtained. Recommended oil Yamaha Suspension Oil S1 Standard oil amount 295 cm³ (9.97 US oz, 10.40 Imp.oz) Extent of adjustment 260–365 cm³ (8.79–12.34 US oz, 9.17–12.87 Imp.oz) ECA24570 NOTICE • Be sure to use the recommended oil. Other oils may have an adverse effect on front 28.Tighten:...
Page 166: Installing The Front Fork Legs
FRONT FORK EAM30059 INSTALLING THE FRONT FORK LEGS 1. Install: • Front fork “1” • Temporarily tighten the pinch bolts (lower bracket). • Do not tighten the pinch bolts (upper bracket) yet. 3. Adjust: • Front fork top end “a” Front fork top end (standard) “a”...
Page 167 FRONT FORK then turn out to the originally set position. EWA19320 WARNING Tighten the lower bracket to specified torque. If torqued too much, it may cause the front fork to malfunction. 6. Install: • Protector “1” • Bolt (protector) “2” Bolt (protector) 5 N·m (0.5 kgf·m, 3.7 lb·ft) 7.
Page 168: Steering Head
STEERING HEAD EAM20101 STEERING HEAD Removing the lower bracket 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 145 N ・ m (14.5 kgf ・ m, 107 lb ・ ft) 38 N ・ m (3.8 kgf ・ m, 28 lb ・ ft) 7 N ・...
Page 169: Removing The Lower Bracket
STEERING HEAD EAM30060 ECA14270 REMOVING THE LOWER BRACKET NOTICE 1. Use a maintenance stand to raise the front If the bearing race is not installed properly, wheel off the ground. the steering head pipe could be damaged. EWA13120 WARNING Always replace the bearing and the bearing race Securely support the vehicle so that there is as a set.
Page 170 STEERING HEAD 2. Install: • Bearing race • Upper bearing “1” • Bearing race cover “2” Apply the lithium-soap-based grease on the bearing and bearing race cover lip. 5. Check the steering stem by turning this lock to lock. If there is any binding, remove the steering stem and check the steering bear- ing.
Page 171 STEERING HEAD Upper bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) • Pinch bolt (lower bracket) “2” Lower bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) EWA19330 WARNING Tighten the lower bracket to specified 8. Install: torque. If torqued too much, it may cause the •...
Page 172: Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY EAM20102 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 56 N ・ m (5.6 kgf ・ m, 41 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 53 N ・ m (5.3 kgf ・ m, 39 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 173 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 56 N ・ m (5.6 kgf ・ m, 41 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 53 N ・ m (5.3 kgf ・ m, 39 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 174 REAR SHOCK ABSORBER ASSEMBLY Disassembling the relay arm 80 N ・ m (8.0 kgf ・ m, 59 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Relay arm Connecting arm Collar Oil seal Washer Bearing 4-60...
Page 175: Handling The Rear Shock Absorber
• To dispose of a damaged or a worn-out rear shock absorber, take the unit to your EAM30067 CHECKING THE REAR SHOCK ABSORBER Yamaha dealer for this disposal procedure. ASSEMBLY 1. Check: • Rear shock absorber rod Bends/damage  Replace the rear shock absorber assembly.
Page 176: Checking The Connecting Arm And Relay Arm
REAR SHOCK ABSORBER ASSEMBLY EAM30068 CHECKING THE CONNECTING ARM AND RELAY ARM 1. Check: • Connecting arm • Relay arm Damage/wear  Replace. 2. Check: • Bearing • Collar Damage/pitting/scratches  Replace the bearings and collars as a set. EAM30070 INSTALLING THE REAR SHOCK 3.
Page 177 REAR SHOCK ABSORBER ASSEMBLY Installed depth “a” Relay arm nut (swingarm side) 4.25 mm (0.17 in) 70 N·m (7.0 kgf·m, 52 lb·ft) • Rear shock absorber assembly lower nut Rear shock absorber assembly lower nut 53 N·m (5.3 kgf·m, 39 lb·ft) 5.
Page 178: Swingarm
SWINGARM EAM20103 SWINGARM Removing the swingarm 70 N ・ m (7.0 kgf ・ m, 52 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 4.0 N ・ m (0.40 kgf ・ m, 3.0 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 179: Removing The Swingarm
SWINGARM • Bearing EAM30071 REMOVING THE SWINGARM 4. Check: 1. Use a maintenance stand to raise the rear • Oil seal wheel off the ground. Damage  Replace. EWA13120 • Bearing WARNING • Bushing Securely support the vehicle so that there is Free play exists/unsmooth revolution/rust ...
Page 180 SWINGARM 4. Install: • Rear wheel Refer to “REAR WHEEL” on page 4-9. 5. Adjust: • Drive chain slack Refer to “DRIVE CHAIN SLACK” on page 3-26. Drive chain slack (Maintenance stand) 50.0–60.0 mm (1.97–2.36 in) 4-66...
Page 181: Chain Drive
CHAIN DRIVE EAM20104 CHAIN DRIVE Removing the drive chain 75 N ・ m (7.5 kgf ・ m, 55 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Drive sprocket Refer to “ENGINE REMOVAL”...
Page 182: Removing The Drive Chain
CHAIN DRIVE length “b” between pin outer sides)/2 EAM30075 REMOVING THE DRIVE CHAIN 1. Use a maintenance stand to raise the rear wheel off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2.
Page 183: Checking The Drive Sprocket
CHAIN DRIVE G089069 5. Lubricate: • Drive chain EAM30077 CHECKING THE DRIVE SPROCKET 1. Check: • Drive sprocket More than 1/4 tooth wear “a”  Replace the drive sprocket and the rear wheel sprocket as a set. G089070 Bent tooth  Replace the drive sprocket and 2.
Page 184 CHAIN DRIVE 4-70...
Page 185: Engine
ENGINE LUBRICATION SYSTEM CHART AND DIAGRAMS ........5-1 ENGINE OIL LUBRICATION CHART............5-1 LUBRICATION DIAGRAMS ...............5-2 ENGINE REMOVAL ..................5-6 REMOVING THE ENGINE ...............5-11 INSTALLING THE ENGINE ..............5-11 INSTALLING THE EXHAUST PIPE AND MUFFLER .......5-12 CAMSHAFT ....................5-14 REMOVING THE CAMSHAFT ..............5-16 CHECKING THE CAMSHAFT ..............5-17 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET...5-18 CHECKING THE TIMING CHAIN TENSIONERS........5-18 CHECKING THE DECOMPRESSION SYSTEM ........5-18...
Page 186 CHECKING THE STARTER CLUTCH .............5-42 INSTALLING THE STARTER CLUTCH ...........5-42 ELECTRIC STARTER..................5-44 CHECKING THE STARTER MOTOR ............5-46 ASSEMBLING THE STARTER MOTOR ..........5-46 CLUTCH......................5-48 REMOVING THE CLUTCH ..............5-51 CHECKING THE FRICTION PLATES ............5-51 CHECKING THE CLUTCH PLATES ............5-51 CHECKING THE CLUTCH SPRINGS ............5-51 CHECKING THE CLUTCH HOUSING .............5-51 CHECKING THE CLUTCH BOSS ............5-52 CHECKING THE PRESSURE PLATE .............5-52...
Page 187 INSTALLING THE TRANSMISSION ............5-75...
Page 188: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAM20185 LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30526 ENGINE OIL LUBRICATION CHART 1. Intake camshaft 2. Exhaust camshaft 3. Piston 4. Oil filter element 5. Oil nozzle 6. Relief valve 7. Oil pump 8. Oil strainer 9.
Page 189: Lubrication Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30507 LUBRICATION DIAGRAMS 1. Connecting rod 2. Crankshaft 3. Main axle 4. Oil strainer 5. Drive axle...
Page 190 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter element 2. Oil pump...
Page 191 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft...
Page 192 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil pressure check bolt 3. Oil pump 4. Oil filter element...
Page 193: Engine Removal
ENGINE REMOVAL EAM20105 ENGINE REMOVAL Removing the exhaust pipe 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 20 N ・...
Page 194 ENGINE REMOVAL Removing the exhaust pipe 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 20 N ・...
Page 195 ENGINE REMOVAL Removing the electronic parts 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Use a maintenance stand to raise the front wheel off the ground.
Page 196 ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 85 N ・ m (8.5 kgf ・ m, 63 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 7 N ・...
Page 197 ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 85 N ・ m (8.5 kgf ・ m, 63 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 7 N ・...
Page 198: Removing The Engine
ENGINE REMOVAL EAM30161 REMOVING THE ENGINE 1. Remove: • Exhaust pipe 2 Put the exhaust pipe 2 into the state as shown by moving this, and then remove it. 2. Remove: • Pivot shaft “1” If the pivot shaft is pulled all the way out, the EAM30164 INSTALLING THE ENGINE swingarm will come loose.
Page 199: Installing The Exhaust Pipe And Muffler
ENGINE REMOVAL Engine mounting bolt (upper side) 45 N·m (4.5 kgf·m, 33 lb·ft) ECA27180 NOTICE Install the lower engine brackets with their stamps facing outward. Apply molybdenum disulfide grease to the pivot 2. Install: shaft. • Clamp • Exhaust pipe 2 “1” •...
Page 200 ENGINE REMOVAL A. Exhaust pipe 1 and exhaust pipe 2 Install and temporarily tighten the silencer so B. Exhaust pipe 2 and silencer that its joint is positioned as shown with respect to the exhaust pipe 2. 2 mm (0.08 in) 4.
Page 201: Camshaft
Refer to “FUEL TANK” on page 7-1. Ignition coil Refer to “ENGINE REMOVAL” on page 5-6. Cylinder head breather hose Spark plug Cylinder head cover Timing chain guide (top side) Cylinder head cover gasket * Yamaha bond No. 1215 (Three bond No.1215®) 5-14...
Page 202 CAMSHAFT Removing the camshaft 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 10 N ・...
Page 203: Removing The Camshaft
CAMSHAFT EAM30080 REMOVING THE CAMSHAFT 1. Remove: • Timing mark accessing screw “1” • Crankshaft end accessing screw “2” 4. Remove: • Bolt (camshaft cap) “1” • Camshaft cap “2” • Clip “3” 2. Align: • Remove the bolts (camshaft cap) in a criss- •...
Page 204: Checking The Camshaft
CAMSHAFT c. Install the dowel pins and the camshaft EAM30081 CHECKING THE CAMSHAFT caps. 1. Check: • Camshaft lobe • Tighten the camshaft cap bolts in a crisscross Blue discoloration/pitting/scratches  Re- pattern from innermost to outer caps. place the camshaft. •...
Page 205: Checking The Timing Chain And Camshaft Sprocket
CAMSHAFT EAM30082 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET 1. Check: • Timing chain “1” Damage/stiffness  Replace the timing chain and camshaft as a set. 2. Check: • Camshaft sprocket More than 1/4 tooth wear “a”  Replace the camshaft and the timing chain as a set.
Page 206 CAMSHAFT a. Turn the crankshaft counterclockwise with ECA24620 NOTICE a wrench. Do not turn the crankshaft during the cam- shaft installation. Damage or improper valve • Apply molybdenum disulfide oil to the cam- timing will result. shafts. • Apply the engine oil on the decompression d.
Page 207 Before installation, apply the sealant to the cylin- ward, install the gasket “1”, the timing der head cover gasket. chain tensioner “2” and tighten the bolts “3”. Yamaha bond No. 1215 Bolt (timing chain tensioner) 90890-85505 10 N·m (1.0 kgf·m, 7.4 lb·ft) Three bond No. 1215®...
Page 208: Cylinder Head
CYLINDER HEAD EAM20107 CYLINDER HEAD Removing the cylinder head 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 60˚ 60˚ 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・...
Page 209 CYLINDER HEAD Removing the cylinder head 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 60˚ 60˚ 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・...
Page 210: Removing The Cylinder Head
CYLINDER HEAD page 5-29. EAM30086 REMOVING THE CYLINDER HEAD • Cylinder head coolant passages 1. Remove: Mineral deposits/rust  Eliminate. • Cylinder head bolt and nut 3. Measure: • Cylinder head warpage • Loosen the bolts in the proper sequence as Out of specification ...
Page 211 CYLINDER HEAD 2. Install: • Washer “1” • Bolt “2” • Nut “3” e. Remove the one bolt according to the tightening order of the bolts. f. Again apply molybdenum disulfide grease to the threads and contact surfaces of the bolts and to both contact surfaces of the washers.
Page 212 CYLINDER HEAD Bolt [1], [2], [3], [4] Specified angle 60 j. Put a mark on the corner of the bolt (cylin- der head) and the cylinder head. k. Finally, tighten all cylinder head tightening bolts further according to the tightening or- der.
Page 213 VALVES AND VALVE SPRINGS EAM20108 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-21. Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Intake valve...
Page 214: Valves And Valve Springs
VALVES AND VALVE SPRINGS EAM30090 REMOVING THE VALVES Check that there are no kerosene leaks from the valve seat “1”. Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure that the valves are properly sealed. 1.
Page 215: Checking The Valves And Valve Guides
VALVES AND VALVE SPRINGS head to 100 °C (212 °F) in an oven. a. Remove the valve guide with the valve guide remover “1”. EAM30091 CHECKING THE VALVES AND VALVE GUIDES 1. Measure: b. Install the new valve guide with the valve •...
Page 216: Checking The Valve Seats
VALVES AND VALVE SPRINGS Intake Valve guide remover (ø5) 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø5) 90890-04098 Valve guide installer (5.0 mm) YM-04098 Valve guide reamer (ø5) 90890-04099 EAM30092 Valve guide reamer (5.0 mm) CHECKING THE VALVE SEATS YM-04099 1.
Page 217: Checking The Valve Springs
VALVES AND VALVE SPRINGS c. Press the valve through the valve guide b. Apply molybdenum disulfide oil onto the and onto the valve seat to make a clear valve stem. impression. c. Install the valve into the cylinder head. d. Measure the valve seat contact width “c”. d.
Page 218: Checking The Valve Lifters
VALVES AND VALVE SPRINGS Free length limit (intake) 34.94 mm (1.38 in) Free length limit (exhaust) 33.82 mm (1.33 in) 3. Install: • Spring seat “1” • Valve stem seal “2” • Valve “3” • Valve spring “4” • Valve spring retainer “5” EAM30094 (to the cylinder head) CHECKING THE VALVE LIFTERS...
Page 219 VALVES AND VALVE SPRINGS 5. To fasten the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. ECA13800 NOTICE Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Adjusting pad “1” •...
Page 220: Cylinder And Piston
CYLINDER AND PISTON EAM20109 CYLINDER AND PISTON Removing the cylinder and piston 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Cylinder head...
Page 221: Removing The Piston
CYLINDER AND PISTON EAM30096 REMOVING THE PISTON 1. Remove: • Piston pin clip “1” • Piston pin “2” • Piston “3” ECA13810 NOTICE Do not use a hammer to drive the piston pin out. • Before removing the piston pin clip, cover the EAM30097 CHECKING THE CYLINDER AND PISTON crankcase opening with a cloth to prevent the...
Page 222: Checking The Piston Rings
CYLINDER AND PISTON Diameter 76.955–76.970 mm (3.0297– 3.0303 in) Measuring point (from piston skirt bottom) 4.0 mm (0.16 in) 2. Install: • Piston ring (into the cylinder) Use the piston crown to level the piston ring near bottom of cylinder “a”, where cylinder wear is lowest.
Page 223: Installing The Piston And Cylinder
CYLINDER AND PISTON Piston pin outside diameter limit 15.971 mm (0.6288 in) 3. Measure: • Piston pin bore inside diameter “b” Out of specification  Replace the piston. Piston pin bore inside diameter limit 16.043 mm (0.6316 in) 2. Install: •...
Page 224 CYLINDER AND PISTON (exhaust side) through the timing chain cavity. 3. Lubricate: • Piston • Piston ring • Cylinder 4. Offset: • Piston ring end gap a. Top ring b. Upper oil ring rail c. Oil ring expander d. Lower oil ring rail 5.
Page 225: Generator
GENERATOR EAM20183 GENERATOR Removing the stator coil assembly 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 10 N ・...
Page 226: Removing The Generator
• Tighten the stator coil screws using the T25 bit. • Stator coil assembly “2” outer surface “b” • Pass the stator coil assembly lead through the Damage  Inspect the crankshaft runout and crankcase cover side. crankshaft bearing. Yamaha bond No. 1215 90890-85505 Three bond No. 1215® 5-39...
Page 227 GENERATOR • Crankcase cover (left) “3” • Lead holder “4” • Bolt (left crankcase cover) “5” Bolt (left crankcase cover) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Tighten the bolts in stages and in a crisscross pattern. 2. Install: • Woodruff key “1” •...
Page 228: Starter Clutch
STARTER CLUTCH EAM20175 STARTER CLUTCH Removing the starter clutch 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Refer to “CHANGING THE ENGINE OIL” on Engine oil page 3-13. Clutch Refer to “CLUTCH” on page 5-48. Clutch housing Starter clutch gear Starter clutch assembly...
Page 229: Removing The Starter Clutch
STARTER CLUTCH EAM30469 REMOVING THE STARTER CLUTCH 1. Remove: • Starter clutch screw “1” While holding the side of the clutch housing “2” with the sheave holder “3” as shown, remove the starter clutch screws “1”. Sheave holder 90890-01903 3. Check: Primary clutch holder YS-01880-A •...
Page 230 STARTER CLUTCH toward the primary driven gear. • While holding the side of the clutch housing “1” with the sheave holder “2” as shown, tighten the starter clutch screws “3”. Sheave holder 90890-01903 Primary clutch holder YS-01880-A 2. Install: • Absorber “1” Install the absorber “1”...
Page 231: Electric Starter
ELECTRIC STARTER EAM20110 ELECTRIC STARTER Removing the starter motor 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Exhaust pipe Refer to “ENGINE REMOVAL”...
Page 232 ELECTRIC STARTER Disassembling the starter motor 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Starter motor assembly O-ring Starter motor front cover Washer Starter motor front cover...
Page 233: Checking The Starter Motor
ELECTRIC STARTER EAM30106 CHECKING THE STARTER MOTOR Brush overall length limit 3.5 mm (0.14 in) 1. Check: • Commutator Dirt  Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification  Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator.
Page 234 ELECTRIC STARTER ECA24650 NOTICE Be careful not to damage the brush during installation. 5. Install: • Bolt “1” • O-ring “2” Apply the lithium-soap-based grease on the O- 3. Install: ring. • Gasket “1” • Starter motor yoke “2” • Install the starter motor yoke with its groove “a” facing starter motor rear cover.
Page 235: Clutch
CLUTCH EAM20111 CLUTCH Removing the clutch 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 95 N ・...
Page 236 CLUTCH Removing the clutch 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 95 N ・...
Page 237 CLUTCH Removing the right crankcase cover 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 238: Removing The Clutch
CLUTCH EAM30108 REMOVING THE CLUTCH Friction plate thickness 2.70–2.90 mm (0.106–0.114 in) 1. Straighten the clutch boss nut rib “a”. Wear limit 2.60 mm (0.102 in) EAM30110 CHECKING THE CLUTCH PLATES 1. Check: • Clutch plate Damage  Replace the clutch plates as a set.
Page 239: Checking The Clutch Boss
CLUTCH EAM30484 CHECKING THE PUSH RODS 1. Check: • Push rod 1 “1” • Bearing/Washer “2” • Push rod 2 “3” • Ball “4” Cracks/damage/wear  Replace. EAM30113 CHECKING THE CLUTCH BOSS 1 1 1 1. Check: • Clutch boss splines Damage/pitting/wear ...
Page 240 CLUTCH • Washer “4” Apply the engine oil on the primary driven gear inner circumference. 2. Install: • Right crankcase cover “1” • Right crankcase cover bolt “2” Right crankcase cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) 5. Install: •...
Page 241 CLUTCH a a a 7. Install: • Bearing “1” • Washer “2” • Circlip “3” (to the push rod 1 “4”) Apply the engine oil on the bearing, washer and push rod 1. 6. Install: • Friction plate “1” • Clutch plate “2” •...
Page 242 CLUTCH 10.Install: • Clutch spring • Clutch spring bolt Clutch spring bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Tighten the bolts in stages and in a crisscross pattern. 11.Install: • Gasket “1” 12.Install: • Clutch cover • Clutch cover bolt Clutch cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Tighten the bolts in stages and in a crisscross...
Page 243: Shift Shaft
SHIFT SHAFT EAM20113 SHIFT SHAFT Removing the shift shaft and stopper lever 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 10 N ・...
Page 244: Removing The Segment
SHIFT SHAFT EAM30124 REMOVING THE SEGMENT 1. Remove: • Bolt (segment) “1” • Segment “2” Turn the segment counterclockwise until it stops and loosen the bolt. ECA24670 NOTICE If the segment gets an impact, the stopper le- EAM30127 ver may be damaged. Take care not to give CHECKING THE STOPPER LEVER an impact to it when removing the bolt.
Page 245 SHIFT SHAFT Segment bolt 30 N·m (3.0 kgf·m, 22 lb·ft) • Align the notch “a” on the segment with the pin “b” on the shift cam. • With the stopper lever pushed down, install the segment. ECA24680 NOTICE 6. Tighten: If the segment gets an impact, the stopper le- •...
Page 246 SHIFT SHAFT Align the punch mark “a” on the shift shaft with the punch mark “b” in the shift pedal. 5-59...
Page 247: Oil Pump
OIL PUMP EAM20182 OIL PUMP Removing the oil pump 2.0 N ・ m (0.20 kgf ・ m, 1.5 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Primary driven gear Refer to “CLUTCH”...
Page 248 OIL PUMP Removing the balancer 105 N ・ m (10.5 kgf ・ m, 77 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 38 N ・ m (3.8 kgf ・ m, 28 lb ・ ft) 50 N ・...
Page 249: Removing The Balancer
OIL PUMP EAM30133 REMOVING THE BALANCER 1. Remove: • Oil pump 2. Loosen: • Balancer nut “1” • Primary drive gear nut “2” • Balancer weight gear nut “3” Place an aluminum plate “a” between the teeth of the balancer drive gear “4” and balancer 4.
Page 250: Installing The Oil Pump
OIL PUMP mary drive gear and collar. 2. Install: • Outer rotor “1” 2. Install: • Oil pump assembly “1” Apply the engine oil on the outer rotor. • Oil pump assembly bolt “2” Oil pump assembly bolt 5 N·m (0.5 kgf·m, 3.7 lb·ft) LOCTITE®...
Page 251 OIL PUMP 4. Install: Primary drive gear nut • Balancer drive gear “1” 105 N·m (10.5 kgf·m, 77 lb·ft) • Collar “2” LOCTITE® • Align the punched mark “a” on the balancer • Balancer “6” drive gear with the punched mark “b” on the •...
Page 252 OIL PUMP 5 7 mm (0.02 0.28 in) A. Primary drive gear side B. Crankcase cover side 5-65...
Page 253: Crankcase
CRANKCASE EAM20116 CRANKCASE Separating the crankcase 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 12 N ・...
Page 254 CRANKCASE Removing the bearing and oil seal 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 255: Disassembling The Crankcase
CRANKCASE EAM30147 DISASSEMBLING THE CRANKCASE 1. Separate: • Right crankcase • Left crankcase a. Remove the crankcase bolts. c. Remove the dowel pins. 2. Remove: • Bearing “1” • Remove the bearing from the crankcase by pressing its inner race. •...
Page 256: Assembling The Crankcase
Install the bearing by pressing its outer race par- allel. 3. Apply: • Sealant (to the crankcase mating surface) Yamaha bond No. 1215 90890-85505 Three bond No. 1215® 4. 45 mm (1.77 in) 5. 60 mm (2.36 in) 6. 75 mm (2.95 in) 4.
Page 257: Crankshaft And Balancer Shaft
CRANKSHAFT AND BALANCER SHAFT EAM20184 CRANKSHAFT AND BALANCER SHAFT Removing the crankshaft assembly and balancer shaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-66. Transmission Refer to “TRANSMISSION” on page 5-73. Balancer shaft Crankshaft assembly 5-70...
Page 258: Removing The Crankshaft
CRANKSHAFT AND BALANCER SHAFT Out of specification  Replace the crank- EAM30491 REMOVING THE CRANKSHAFT shaft, bearing or both. 1. Remove: • Balancer shaft “1” Turn the crankshaft slowly. Remove the balancer shaft with its flat side “a” Runout limit facing the crankshaft.
Page 259: Installing The Crankshaft
CRANKSHAFT AND BALANCER SHAFT EAM30493 INSTALLING THE CRANKSHAFT 1. Install: • Crankshaft assembly Install the crankshaft assembly with the crank- shaft installer pot “1”, crankshaft installer bolt “2”, adapter (M12) “3” and spacer “4”. Crankshaft installer pot 90890-01274 Installing pot YU-90058 Crankshaft installer bolt 90890-01275...
Page 260: Transmission
TRANSMISSION EAM20118 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-6. Separate. Crankcase Refer to “CRANKCASE” on page 5-66. Main axle Drive axle Long shift fork guide bar Short shift fork guide bar Spring Shift cam...
Page 261: Removing The Transmission
TRANSMISSION EAM30153 REMOVING THE TRANSMISSION 1. Remove: • Long shift fork guide bar “1” • Short shift fork guide bar “2” • Shift cam “3” • Shift fork 3 “4” • Shift fork 2 “5” • Shift fork 1 “6” •...
Page 262: Checking The Transmission
TRANSMISSION • 3rd pinion gear (18T) “2” EAM30156 CHECKING THE TRANSMISSION • Collar “3” 1. Measure: • 4th pinion gear (18T) “4” • Main axle runout • 2nd pinion gear (16T) “5” (with a centering device and dial gauge “1”) (to the main axle “6”) Out of specification ...
Page 263 TRANSMISSION positioned opposite side to the washer and axle bearing. gear “b”. • Install the circlip with its ends “c” settled evenly on the spline crests. 6. Install: • Shift fork 1 (L) “1” • Shift fork 2 (C) “2” •...
Page 264 TRANSMISSION 7. Install: • Long shift fork guide bar “1” • Short shift fork guide bar “2” • Spring “3” • Screw the spring into the shift fork guide bar lightly beforehand. • Apply the engine oil on the shift fork guide bars. 8.
Page 265: Cooling System
COOLING SYSTEM COOLING SYSTEM DIAGRAMS ..............6-1 RADIATOR......................6-2 CHECKING THE RADIATOR ..............6-4 INSTALLING THE RADIATOR ..............6-4 WATER PUMP ....................6-6 DISASSEMBLING THE WATER PUMP .............6-7 CHECKING THE WATER PUMP ...............6-7 ASSEMBLING THE WATER PUMP ............6-7...
Page 266: Cooling System Diagrams
COOLING SYSTEM DIAGRAMS EAM20186 COOLING SYSTEM DIAGRAMS 1. Radiator hose 1 2. Radiator (right) 3. Radiator hose 4 4. Water pump 5. Radiator hose 3 6. Radiator (left)
Page 267: Radiator
RADIATOR EAM20138 RADIATOR Removing the radiator 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・...
Page 268 RADIATOR Removing the radiator 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・...
Page 269: Checking The Radiator
RADIATOR EAM30341 CHECKING THE RADIATOR Radiator cap valve opening pres- sure EWA13030 107.9–137.3 kPa (1.08–1.37 WARNING kgf/cm², 15.6–19.9 psi) A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- No stay  Replace. gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in- Radiator cap tester jury.
Page 270 RADIATOR 4. Activate the tester to apply the test pressure. Test pressure value 137.3 kPa (1.37 kgf/cm², 19.9 psi) ECA24270 NOTICE • Do not apply such a high pressure as ex- ceeds the test pressure. • Make sure that a checkup after the cylinder head gasket is replaced is made after 3 min- utes of warm-up.
Page 271: Water Pump
WATER PUMP EAM20139 WATER PUMP Removing the water pump 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 14 N ・ m (1.4 kgf ・ m, 10 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 272: Disassembling The Water Pump
WATER PUMP EAM30494 DISASSEMBLING THE WATER PUMP • Remove the oil seal when the coolant level changes frequently more than usual, coolant has discolored, or engine oil has become milky. • Do not use the removed oil seal. 1. Remove: •...
Page 273 WATER PUMP 4. Install: • Dowel pin “1” • Gasket “2” 5. Install: • Water pump housing “1” • Water pump housing bolt “2” Water pump housing bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) • Washer “3” • Coolant drain bolt “4” Coolant drain bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Page 274 WATER PUMP...
Page 275: 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 PUMP OPERATION ..........7-2 INSTALLING THE FUEL PUMP ..............7-2 INSTALLING THE FUEL TANK ..............7-3 THROTTLE BODY ....................7-4 CHECKING THE INJECTOR..............7-7 CHECKING THE THROTTLE BODY ............7-7 CHECKING THE FUEL PRESSURE............7-7...
Page 276: Fuel Tank
FUEL TANK EAM20140 FUEL TANK Removing the fuel tank 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 4.0 N ・...
Page 277: Removing The Fuel Tank
FUEL TANK EAM30263 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose coupler EWA19370 WARNING Cover the fuel hose connection with a cloth when disconnecting it. This is because re- sidual pressure in the fuel hose could cause fuel to spurt out when the hose is removed.
Page 278: Installing The Fuel Tank
FUEL TANK • Take care not to damage the installation sur- faces of the fuel tank. • Always use a new fuel pump gasket. • Install the lip on the fuel pump gasket upward. • Install the fuel pump as shown in the figure. •...
Page 279: Throttle Body
THROTTLE BODY EAM20141 THROTTLE BODY Removing the throttle body 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 3.0 N ・...
Page 280 THROTTLE BODY Removing the throttle body 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 3.0 N ・...
Page 281 THROTTLE BODY Removing the injector 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel inlet pipe Injector Gasket Throttle position sensor Intake air pressure sensor...
Page 282: Checking The Injector
THROTTLE BODY EAM30271 CHECKING THE INJECTOR 1. Check: • Injector Obstruction  Replace, and check the fuel pump and the fuel injection system. Refer to “FUEL INJECTION SYSTEM” on page 8-13. Deposits  Replace. Damage  Replace. 2. Check: • Injector resistance Refer to “CHECKING THE INJECTOR”...
Page 283: Adjusting The Throttle Position Sensor
Check that the throttle grip is fully closed. d. Connect the throttle position sensor to the wire harness. e. Set the Yamaha diagnostic tool to “diag- nostic mode”. f. Choose the diagnostic code No. “01”. g. Adjust the throttle position sensor mount- ed angle until “11”–“14”...
Page 284 THROTTLE BODY...
Page 285: Electrical System
CHARGING SYSTEM ..................8-9 CIRCUIT DIAGRAM ...................8-9 TROUBLESHOOTING................8-11 FUEL INJECTION SYSTEM ................8-13 CIRCUIT DIAGRAM .................8-13 YAMAHA DIAGNOSTIC TOOL ..............8-15 CONNECTING THE YAMAHA DIAGNOSTIC TOOL .......8-15 TROUBLESHOOTING DETAILS (FAULT CODE)........8-17 FUEL PUMP SYSTEM..................8-37 CIRCUIT DIAGRAM .................8-37 TROUBLESHOOTING................8-39 ELECTRICAL COMPONENTS...............8-40 CHECKING THE SWITCHES..............8-41 CHECKING THE FUSES................8-43...
Page 286: Ignition System
IGNITION SYSTEM EAM20142 IGNITION SYSTEM EAM30277 CIRCUIT DIAGRAM...
Page 287 IGNITION SYSTEM 1. Crankshaft position sensor 2. AC magneto 3. Rectifier/regulator 4. Joint connector 6. Engine ground 7. Battery 8. Frame ground 9. Fuse 10.Starter relay 11.Starter motor 12.Diode 1 13.Diode 2 14.CCU (Communication Control Unit) 16.ECU (Engine Control Unit) 17.Ignition coil 18.Spark plug 25.Engine stop switch...
Page 288: Troubleshooting
IGNITION SYSTEM EAM30278 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). Before troubleshooting, remove the following part(s): 1. Side cover (left/right) 2. Seat 3. Fuel tank 4. Air scoop (left/right) 5. Air filter case cover 1. Check the ignition system wire har- Reconnect.
Page 289 IGNITION SYSTEM 9. Check the stator coil assembly. Refer to “CHECKING THE STA- Replace the stator coil assembly. NG TOR COIL” on page 8-48. OK 10.Check the ignition system wire har- ness. Repair or replace the wire harness. Refer to “CIRCUIT DIAGRAM” on NG...
Page 290: Electric Starting System
ELECTRIC STARTING SYSTEM EAM20143 ELECTRIC STARTING SYSTEM EAM30279 CIRCUIT DIAGRAM...
Page 291 ELECTRIC STARTING SYSTEM 4. Joint connector 5. Main relay 6. Engine ground 7. Battery 8. Frame ground 9. Fuse 10.Starter relay 11.Starter motor 12.Diode 1 13.Diode 2 16.ECU (Engine Control Unit) 25.Engine stop switch 26.Gear position switch 28.Start switch 29.Diode 3 A.
Page 292: Troubleshooting
ELECTRIC STARTING SYSTEM EAM30281 TROUBLESHOOTING The starter motor fails to turn. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 5. Air filter case cover 1. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse(s).
Page 293 ELECTRIC STARTING SYSTEM 9. Check the start switch. Refer to “CHECKING THE Replace the start switch. NG SWITCHES” on page 8-41. OK 10.Check the entire starting system’s wiring. Properly connect or repair the starting sys- Refer to “CIRCUIT DIAGRAM” on tem’s wiring.
Page 294: Charging System
CHARGING SYSTEM EAM20144 CHARGING SYSTEM EAM30282 CIRCUIT DIAGRAM...
Page 295 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 6. Engine ground 7. Battery 8. Frame ground 9. Fuse A. Battery sub-lead B. Wire harness 8-10...
Page 296: Troubleshooting
CHARGING SYSTEM EAM30283 TROUBLESHOOTING The battery is not being charged. Before troubleshooting, remove the following part(s): 1. Seat 2. Air scoop (left) 1. Check the entire charging system’s Reconnect. wiring. NG OK 2. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse(s).
Page 297 CHARGING SYSTEM 8-12...
Page 298: Fuel Injection System
FUEL INJECTION SYSTEM EAM20145 FUEL INJECTION SYSTEM EAM30284 CIRCUIT DIAGRAM 8-13...
Page 299 3. Rectifier/regulator 4. Joint connector 6. Engine ground 7. Battery 8. Frame ground 9. Fuse 14.CCU (Communication Control Unit) 15.Yamaha diagnostic tool coupler 16.ECU (Engine Control Unit) 17.Ignition coil 18.Spark plug 19.Fuel injector 20.Fuel pump 21.Intake air temperature sensor 22.Coolant temperature sensor 23.Throttle position sensor...
Page 300: Yamaha Diagnostic Tool
• Prepare the fully charged 12 V lead battery for yourself. • Replace the vehicle battery with a lead battery (12 V). • For information on how to connect and use the Yamaha diagnostic tool, refer to “YAMAHA DIAGNOS- TIC TOOL OPERATION MANUAL”.
Page 301 2. Lead battery (12 V) 3. Vehicle battery 4. Vehicle 5. Coupler for connecting optional part 6. FI diagnostic tool sub-lead 7. Sub-harness (included with the Yamaha diag- nostic tool) 8. Vehicle communication cable (included with the Yamaha diagnostic tool) 9. Yamaha diagnostic tool...
Page 302: Troubleshooting Details (Fault Code)
Yamaha diagnostic tool according to the reinstatement method. Fault code No.: Fault code number displayed on the Yamaha diagnostic tool when the engine failed to work normally. Diagnostic code No.: Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC CODE: SENSOR OPERATION TABLE”...
Page 303 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air pressure. Procedure The atmospheric pressure is displayed on the Yamaha diagnostic tool. Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check...
Page 304 Replace the intake air pressure sensor. Faulty ECU. Replace the ECU. Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-19...
Page 305 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air pressure. Procedure The atmospheric pressure is displayed on the Yamaha diagnostic tool. Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check...
Page 306 Disconnect the coupler, and Yamaha diagnostic tool. Condition is “Recovered”  Go check the pins (for bent or bro- ken terminals and locking condi- to item 8 and finish the service.
Page 307 Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. Fault code No. 16 • If fault code numbers 15 and 16 are both displayed, perform checkup and repair jobs for fault code number 15 first.
Page 308 Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the coolant temperature. Compare the actually measured coolant temperature with the Yamaha Procedure diagnostic tool display value. Probable cause of malfunc- Confirmation of service com- Item...
Page 309 Refer to “RADIATOR” on page 6-2. item 6. Faulty ECU. Replace the ECU. Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-24...
Page 310 Fail-safe system Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air temperature. Compare the actually measured intake air temperature with the Yamaha Procedure diagnostic tool display value. Probable cause of malfunc- Confirmation of service com-...
Page 311 Start switch to ON (main relay ON), wait 10 seconds, then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 4 and finish the service. Condition is “Detected”  Go to item 2.
Page 312 Unable to drive vehicle Diagnostic code No. Actuates the ignition coil five times at one-second intervals. Actuation “WARNING” on the Yamaha diagnostic tool blinks five times when the ignition coil is actuated. Check that a spark is generated five times. Procedure •...
Page 313 Check the condition of the fault the coupler. ness. code using the malfunction Disconnect the coupler, and mode of the Yamaha diagnostic check the pins (for bent or bro- tool. Condition is “Recovered”  Go ken terminals and locking condi- tion of the pins).
Page 314 Unable to drive vehicle Diagnostic code No. Actuates injector five times at one-second intervals. Actuation “WARNING” on the Yamaha diagnostic tool blinks five times when the injector is actuated. Check that injector is actuated five times by listening for the operating Procedure sound.
Page 315 Check the condition of the fault check the pins (bent or broken code using the malfunction terminals and locking condition mode of the Yamaha diagnostic of the pins). tool. Condition is “Recovered”  Go to item 6 and finish the service.
Page 316 Check the condition of the fault check the pins (bent or broken code using the malfunction terminals and locking condition mode of the Yamaha diagnostic of the pins). tool. Condition is “Recovered”  Go to item 6 and finish the service.
Page 317 If the same number is indicated, go to item 4. Faulty ECU. Replace the ECU. Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-32...
Page 318 Check the condition of the fault the coupler. code using the malfunction Disconnect the coupler, and mode of the Yamaha diagnostic check the pins (bent or broken tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
Page 319 ECU. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. Fault code No. 50 Before troubleshooting, disconnect the starter motor lead from the starter relay.
Page 320 Engine forcibly stops when the vehicle is left idling for a long period Item of time. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-35...
Page 321 FUEL INJECTION SYSTEM 8-36...
Page 322: Fuel Pump System
FUEL PUMP SYSTEM EAM20146 FUEL PUMP SYSTEM EAM30287 CIRCUIT DIAGRAM 8-37...
Page 323 FUEL PUMP SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Joint connector 6. Engine ground 7. Battery 8. Frame ground 9. Fuse 16.ECU (Engine Control Unit) 20.Fuel pump 25.Engine stop switch A. Battery sub-lead B. Wire harness 8-38...
Page 324: Troubleshooting
FUEL PUMP SYSTEM EAM30288 TROUBLESHOOTING The fuel pump fails to operate. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 5. Air filter case cover 1. Check the fuel pump system wire Reconnect.
Page 325: Electrical Components
ELECTRICAL COMPONENTS EAM20147 ELECTRICAL COMPONENTS 1. Rectifier/regulator 2. Intake air pressure sensor 3. Throttle position sensor 4. Injector 5. Mode switch 6. Intake air temperature sensor 7. ECU (Engine Control Unit) 8. Ignition coil 9. CCU (Communication Control Unit) 10.Starter relay 11.Fuse 12.Battery 13.Gear position switch...
Page 326: Checking The Switches
ELECTRICAL COMPONENTS EAM30289 CHECKING THE SWITCHES Y/W P 1. Engine stop switch 2. Mode switch 3. Gear position switch 4. Engine start switch 8-41...
Page 327 ELECTRICAL COMPONENTS Check each switch for continuity with the digital circuit 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 328: Checking The Fuses
ELECTRICAL COMPONENTS cause a fire. EAM30290 CHECKING THE FUSES 4. Install: The following procedure applies to all of the fus- • Seat Refer to “GENERAL CHASSIS” on page 4-1. 1. Remove: • Seat EAM30291 Refer to “GENERAL CHASSIS” on page 4-1. CHECKING AND CHARGING THE BATTERY 2.
Page 329 When 2. Disconnect: replacing the battery, be sure to use a • Battery lead Yamaha genuine lithium-ion battery. (from the battery terminals) ECA13700 NOTICE Do not check the battery at high temperature of First, disconnect the negative battery lead, 65 C (149 F) or more or low temperatures be-...
Page 330: Checking The Relays
ELECTRICAL COMPONENTS has cooled down to the ambient tempera- Main relay ture. e. Measure the voltage between the battery terminals. 13.25 V or more  The battery is normal. Checking is finished. 10 V or more and less than 13.25 V  Perform from step (c) again.
Page 331: Checking The Ignition Spark Gap
ELECTRICAL COMPONENTS Refer to “TROUBLESHOOTING” on page No continuity 8-3. Tester positive lead  Blue/Green “1” Minimum ignition spark gap Tester negative lead  Blue “2” 6.0 mm (0.24 in) Continuity Tester positive lead  Blue “2” Tester negative lead  If the ignition spark gap is within specification, Blue/Green “1”...
Page 332: Checking The Ignition Coil
ELECTRICAL COMPONENTS Secondary coil resistance 8.64–12.96 k a. Connect the digital circuit tester () to the ignition coil. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachom- eter YU-A1927 b. Measure the spark plug cap resistance. EAM30296 • Positive tester probe  CHECKING THE IGNITION COIL Ignition coil terminal 1 “1”...
Page 333: Checking The Lean Angle Sensor
ELECTRICAL COMPONENTS b. Check the starter motor operation. b. Measure the crankshaft position sensor resistance. EAM30300 CHECKING THE STATOR COIL EAM30298 1. Disconnect: CHECKING THE LEAN ANGLE SENSOR • Stator coil assembly coupler 1. Check: (from the wire harness) • Mounted condition of ECU 2.
Page 334: Checking The Coolant Temperature Sensor
ELECTRICAL COMPONENTS Regulated voltage (DC) Coolant temperature sensor re- 14.0–14.8 V sistance 2513–2777  at 20 C (2513– 2777  at 68 F) a. Set the digital tachometer to the ignition Coolant temperature sensor re- coil. sistance Digital tachometer 210–221  at 100 C (210–221  90890-06760 at 212 F) Digital tachometer...
Page 335: Checking The Throttle Position Sensor Input Voltage
ELECTRICAL COMPONENTS d. Measure the throttle position sensor input voltage. EAM30307 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 1. Remove: • Intake air temperature sensor (from the air filter case) EWA14110 WARNING • Handle the intake air temperature sensor EAM30305 CHECKING THE THROTTLE POSITION with special care.
Page 336: Checking The Gear Position Switch
ELECTRICAL COMPONENTS EAM30467 EAM30496 CHECKING THE GEAR POSITION SWITCH CHECKING THE INJECTOR 1. Remove: 1. Remove: • Gear position switch • Fuel injector 2. Check: Refer to “THROTTLE BODY” on page 7-4. • Gear position switch 2. Check: Out of specification  Replace. •...
Page 337: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING ..................9-1 GENERAL INFORMATION ................9-1 TROUBLESHOOTING OF ENGINE (fault code not detected) ....9-1 TROUBLESHOOTING OF CLUTCH ............9-4 TROUBLESHOOTING OF TRANSMISSION ..........9-6 TROUBLESHOOTING OF COOLING SYSTEM ........9-7 TROUBLESHOOTING OF BRAKE ............9-8 TROUBLESHOOTING OF SUSPENSION ..........9-8 TROUBLESHOOTING OF STEERING/HANDLING.........9-10 TROUBLESHOOTING OF CHARGING SYSTEM........9-11 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE....9-12 SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM) ....................9-12...
Page 338: Troubleshooting
TROUBLESHOOTING EAM20148 TROUBLESHOOTING EAM30309 GENERAL INFORMATION Troubleshooting information provided here does not cover all the trouble symptoms, possible causes, and remedial actions. Some items may not apply depending on the model. Use this information as a guide and quick reference matrix when performing basic troubleshooting. Refer to the each chapter for detailed information on checking, adjustment, and replacement.
Page 339 TROUBLESHOOTING Symptom Possible cause Actions Water or foreign material in fuel, Change fuel. degraded fuel Tighten the spark plug to the spec- Loose spark plug ified torque. Tighten bolts or nuts on cylinder Loose cylinder head or cylinder head and cylinder to the specified torque.
Page 340 TROUBLESHOOTING Symptom Possible cause Actions Worn camshaft lobe Replace the camshaft. Water or foreign material in fuel, Change fuel. degraded fuel Contaminated throttle body or Clean the throttle body. clogged internal passage Incorrectly adjusted throttle cable Adjust the throttle grip free play. Incorrectly adjusted idling speed Adjust the idle screw.
Page 341: Troubleshooting Of Clutch
TROUBLESHOOTING Symptom Possible cause Actions Replace the piston and piston Worn or damaged piston ring rings as a set. Replace the piston and piston Worn or damaged piston rings as a set. Replace the piston and piston pin Worn piston (piston pin hole) as a set.
Page 342 TROUBLESHOOTING Symptom Possible cause Actions Replace the clutch springs as a Faulty clutch spring set. Warped pressure plate Replace the pressure plate. Replace the friction plates as a Swollen friction plate set. Warped clutch plate Replace the clutch plates as a set. Bent pull rod (outer pull type) Replace the pull rod.
Page 343: Troubleshooting Of Transmission
TROUBLESHOOTING EAM30511 TROUBLESHOOTING OF TRANSMISSION Symptom Possible cause Actions Clutch drags Refer to “Clutch drags”. Adjust the shift rod installation Improperly adjusted shift rod length. Bent shift shaft Replace the shift shaft. Foreign object in a shift drum Remove foreign object from shift groove drum groove.
Page 344: Troubleshooting Of Cooling System
TROUBLESHOOTING EAM30512 TROUBLESHOOTING OF COOLING SYSTEM Symptom Possible cause Actions Carbon buildup in piston head and Clean the piston head and com- combustion chamber bustion chamber. Clogged engine cooling water Check and clean the engine cool- passages ing water passages. Adjust the oil level to the specified Incorrect oil level level.
Page 345: Troubleshooting Of Brake
TROUBLESHOOTING EAM30513 TROUBLESHOOTING OF BRAKE Symptom Possible cause Actions Worn brake pad Replace the brake pads as a set. Worn or deflected brake disc Replace the brake disc. Air in hydraulic brake system Bleed the hydraulic brake system. Check the hydraulic brake system Brake fluid leakage and repair or replace faulty parts as necessary.
Page 346 TROUBLESHOOTING Symptom Possible cause Actions Fatigued or broken fork spring Replace the fork spring. Incorrect oil viscosity (low) Change to recommended fork oil. Incorrect oil level (low) Adjust to the specified oil level. Improperly adjusted spring pre- Adjust the spring preload. Front fork is soft load (soft) Improperly adjusted rebound...
Page 347: Troubleshooting Of Steering/Handling
TROUBLESHOOTING Symptom Possible cause Actions Oil leaking from rear shock Replace the rear shock absorber. absorber Gas leaking from rear shock Replace the rear shock absorber. absorber Fatigued or damaged rear shock Replace the rear shock absorber. absorber spring Rear suspension is soft Improperly adjusted rear shock Adjust the spring preload.
Page 348: Troubleshooting Of Charging System
TROUBLESHOOTING Symptom Possible cause Actions Tighten the spoke and adjust the Loose spoke runout. Damaged or worn wheel bearing Replace the wheel bearing. Worn, deformed, or incorrect tire Replace the tire. Tighten the wheel axle nut to the Loose wheel axle nut Rear wheel vibration specified torque.
Page 349: Self-Diagnostic Function And Diagnostic Code Table
Pressure of suction pipe Displays the intake air pressure. The atmospheric pressure is • Check the change of the displayed on the Yamaha intake pressure valve when diagnostic tool. the starter switch is pushed. Intake air temperature Displays the intake air tempera- Compare the actually mea- ture.
Page 350 Coolant temperature Displays the coolant tempera- Compare the actually mea- ture. sured coolant temperature with the Yamaha diagnostic tool display value. Lean angle sensor Displays the output voltage. Remove the ECU, and incline it 45 or more. • Upright •...
Page 351: Diagnostic Code: Actuator Operation Table
Actuates the ignition coil five Check that a spark is gener- times at one-second intervals. ated five times. • Connect an ignition checker. “WARNING” on the Yamaha diagnostic tool blinks five times when the ignition coil is actu- ated. TIP: Before performing this...
Page 352 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9-15...
Page 353: Tuning
TUNING CHASSIS ......................10-1 SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET)...................10-1 DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS....10-1 TIRE PRESSURE ..................10-1 FRONT FORK SETTING ................10-2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL ..10-2 SETTING OF SPRING AFTER REPLACEMENT........10-2 FRONT FORK SETTING PARTS .............10-3 REAR SUSPENSION SETTING...............10-3 CHOOSING SET LENGTH...............10-3 SETTING OF SPRING AFTER REPLACEMENT........10-4...
Page 354: Chassis
CHASSIS EAM20119 Part name Type Part number CHASSIS Rear wheel 17D-25447-50 EAM30168 sprocket “2” SELECTION OF THE SECONDARY 17D-25448-50 REDUCTION RATIO (SPROCKET) 17D-25449-50 Secondary reduction ratio = Number of (STD) 17D-25450-50 rear wheel sprocket teeth/Number of 17D-25451-50 drive sprocket teeth 17D-25452-50 Secondary reduction ratio 3.846 (50/13)
Page 355: Front Fork Setting
(in position etc.) when Recommended oil setting the front fork. Yamaha Suspension Oil S1 1. Use of soft spring Standard oil amount • Change the rebound damping force.
Page 356: Front Fork Setting Parts
CHASSIS and the circuit conditions. Generally a stiff spring gives a stiff riding feeling. The rear suspension setting includes the follow- ing two factors: Rebound damping tends to become weaker, re- sulting in lack of a sense of contact with the road 1.
Page 357: Setting Of Spring After Replacement
CHASSIS • If the standard figure cannot be achieved by adjusting the adjuster and changing the set length, replace the spring with an optional one and make readjustment. EAM30178 REAR SHOCK ABSORBER SETTING PARTS • Rear shock spring “1” STD Spring rate N/mm EAM30177 SETTING OF SPRING AFTER...
Page 358 CHASSIS Spring preload adjusting positions Minimum Position in which the spring is turned in 1.5 mm (0.06 in) from its free length. Standard Position in which the spring is turned in 7.0 mm (0.28 in) from its free length. Maximum Position in which the spring is turned in 18.0 mm (0.71 in) from its free length.
Page 359: Suspension Setting (Front Fork)
CHASSIS EAM30179 SUSPENSION SETTING (FRONT FORK) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in).
Page 360: Suspension Setting (Rear Shock Absorber)
CHASSIS Section Symptom Check Adjust Large Medium Small Jump Compression Turn adjuster clockwise (about 2 damping force clicks) to increase damping. Turn adjuster counterclockwise Rebound damp- (about 2 clicks) to decrease ing force damping. Low front, tend-   ing to lower front Set sunken length for 95–100 posture Balance with rear...
Page 361 CHASSIS Section Symptom Check Adjust Large Medium Small Jump Turn adjuster counterclockwise Rebound damp- (about 2 clicks) to decrease Heavy and drag- ing force   damping. ging Spring Replace with soft spring. Turn adjuster counterclockwise Rebound damp- (about 2 clicks) to decrease ing force damping.
Page 362 CHASSIS 10-9...
Page 363 Black/Orange 12. Diode 1 Black/Red 13. Diode 2 Black/White 14. CCU (Communication Control Black/Yellow Unit) Br/W Brown/White 15. Yamaha diagnostic tool cou- Green/White pler Green/Yellow 16. ECU (Engine Control Unit) Blue/Black 17. Ignition coil Blue/Green 18. Spark plug Blue/Red 19. Fuel injector Blue/White 20.
Page 365 EAM20160 Genuine Yamaha Parts text Genuine Yamaha Parts – Genuine Yamaha replacement parts are the exact same parts as the ones originally equipped on your vehicle, providing you with the performance and durability you have come to expect. Why settle for aftermarket parts that may not provide full confidence and satisfaction? Genuine Yamaha Accessories –...
Page 367 YZ250FM 2021 WIRING DIAGRAM...
Page 368 YZ250FM 2021 WIRING DIAGRAM...

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