1. Manuals
  2. Brands
  3. Yamaha Manuals
  4. Motorcycle
  5. YZ 2019 Series
  6. Owner's service manual

Yamaha YZ 2019 Series Owner's Service Manual

Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
Table of Contents

Advertisement

Quick Links

2019
OWNER'S SERVICE MANUAL
YZ250FX
Read this manual carefully before operating this vehicle.
YZ250FXK
LIT-11626-32-17
B29-28199-14

Advertisement

Table of Contents
loading

Related Manuals for Yamaha YZ 2019 Series

Summary of Contents for Yamaha YZ 2019 Series

  • Page 1 2019 OWNER’S SERVICE MANUAL YZ250FX Read this manual carefully before operating this vehicle. YZ250FXK LIT-11626-32-17 B29-28199-14...
  • Page 2 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. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle in a well-ventilated area and wear gloves or wash your...
  • Page 3 EAM20080 YZ250FXK OWNER’S SERVICE MANUAL ©2019 by Yamaha Motor Corporation, U.S.A 1st Edition, March 2018 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A is expressly prohibited. Printed in Japan. P/N. LIT-11626-32-17...
  • Page 4 EAM20081 INTRODUCTION 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 5 EAM20092 SAFETY INFORMATION THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding. •...
  • Page 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 LOCATION OF IMPORTANT LABELS.............1-1 DESCRIPTION....................1-2 IDENTIFICATION ....................1-3 VEHICLE IDENTIFICATION NUMBER ............1-3 ENGINE SERIAL NUMBER................1-3 INCLUDED PARTS ...................1-4 NIPPLE WRENCH ..................1-4 HANDLEBAR PROTECTOR ..............1-4 FUEL HOSE JOINT COVER ..............1-4 COUPLER FOR CONNECTING OPTIONAL PART ........1-4 IMPORTANT INFORMATION ................1-5 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-5 REPLACEMENT PARTS ................1-5 GASKETS, OIL SEALS AND O-RINGS .............1-6 LOCK WASHERS/PLATES AND COTTER PINS ........1-6...
  • Page 12 BREAK-IN PROCEDURES ..............1-21 MAINTENANCE AFTER BREAK-IN ..............1-22 MAJOR MAINTENANCE ................1-22 TORQUE-CHECK POINTS................1-23 MOTORCYCLE CARE AND STORAGE............1-25 CARE ......................1-25 STORAGE ....................1-26...

  • Page 13: 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 For use only on a closed course in sanctioned competition. gasoline only. This motorcycle does not meet 3FB-2415E-02 EPA noise and emissions standards and is not for general off-road recreational riding.

  • Page 14: Description

    DESCRIPTION EAM20086 DESCRIPTION 18 17 16 11.Radiator 1. Clutch lever 12.Coolant drain bolt 2. Engine trouble warning light “ ” 13.Rear brake pedal 3. Fuel level warning light “ ” 14.Air filter 4. Front brake lever 15.Drive chain 5. Throttle grip 16.Shift pedal 6.

  • Page 15: 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 16: Included Parts

    INCLUDED PARTS EAM20088 ECA24810 INCLUDED PARTS NOTICE When no optional parts, etc. are connected, EAM30005 connect the connection terminal to the origi- NIPPLE WRENCH nal coupler. The nipple wrench “1” is used to tighten the Before disconnecting the coupler, thorough- spoke.

  • Page 17: Important Information

    Make sure that the parts and grease or oil to be used for repair of the vehicle, including periodic 2. Use proper special tools and equipment. Re- replacement parts, are new YAMAHA genuine fer to “SPECIAL TOOLS” on page 1-11. parts and recommended parts.

  • Page 18: Gaskets, Oil Seals And O-Rings

    IMPORTANT INFORMATION EAM30011 GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets and O-rings. All gasket surfaces, oil seal lips, and O-rings must be cleaned so that there may be no dust on them. 2. During assembly, always apply proper oil to bearings and proper grease to oil seal lips be- fore installation.

  • Page 19: 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 20 BASIC SERVICE INFORMATION Checking the electrical system ECA16620 NOTICE Handle electrical components with special Before checking the electrical system, make care, and do not subject them to strong sure that the battery voltage is at least 12 V. shocks. ECA14371 ECA16630 NOTICE NOTICE...
  • Page 21 BASIC SERVICE INFORMATION Checking the connections 2. Check: Check the leads, couplers, and connectors for • Lead • Coupler stains, rust, moisture, etc. 1. Disconnect: • Connector • Lead Moisture  Dry with compressed air. Rust/stains  Connect and disconnect sev- •...
  • Page 22 BASIC SERVICE INFORMATION available at most part stores. 4. Connect: • Lead • Coupler • Connector • When connecting a coupler or connector, make sure that both terminals are connected securely. • Make sure all connections are tight. 5. Check: •...

  • Page 23: Special Tools

    SPECIAL TOOLS EAM20121 SPECIAL TOOLS The following special tools are required for accurate and complete adjustment and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised tech- niques. The shape and tool number used for the special tool differ by country, so two types are provid- ed.
  • Page 24 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve lapper (ø14) 3-17, 5-23 90890-04101 90890-04101 Valve lapping tool (14mm) YM-A8998 YM-A8998 Spoke nipple wrench (6–7) 3-33 90890-01521 Spoke nipple wrench (6–7) YM-01521 Steering nut wrench 3-34, 4-51 90890-01403 Exhaust flange nut wrench YU-A9472 Timing light 3-37...
  • Page 25 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Yamaha bond No. 1215 5-17, 5-61, 5-67 90890-85505 (Three bond No.1215®) Valve spring compressor 5-23, 5-28 90890-04019 Valve spring compressor YM-04019 Valve spring compressor attachment 5-23, 5-28 90890-04108 Valve spring compressor adapter 22 mm YM-04108 Valve guide remover (ø5)
  • Page 26 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide reamer (ø4.5) 5-25 90890-04118 Valve guide reamer (4.5 mm) YM-04118 Piston pin puller set 5-30 90890-01304 Piston pin puller YU-01304 YU-01304 Universal clutch holder 5-42, 5-45 90890-04086 Universal clutch holder YM-91042 Rotor puller 5-60...
  • Page 27 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Crankshaft installer pot 5-71 90890-01274 Installing pot YU-90058 YU-90058/YU-90059 Crankshaft installer bolt 5-71 90890-01275 Bolt YU-90060 Adapter (M12) 5-71 90890-01278 Adapter #3 YU-90063 Spacer (crankshaft installer) 5-71 90890-04081 Pot spacer YM-91044 YM-91044 Pressure gauge 90890-03153 Pressure gauge...
  • Page 28 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Yamaha diagnostic tool USB (US) 7-10, 8-23 90890-03257 Yamaha diagnostic tool (A/I) 7-10, 8-23 90890-03262 FI diagnostic tool sub–lead 8-24 90890-03212 FI diagnostic tool sub–lead YU-03212 Ignition checker 8-61 90890-06754 Oppama pet–4000 spark checker YM-34487 Test harness–...

  • Page 29: Control Functions

    ” This warning light comes on or flashes if a prob- lem is detected in the electrical circuit monitoring the engine. If this occurs, have a Yamaha dealer check the vehicle. The electrical circuit of the warning light can be checked by pushing the start switch.

  • Page 30: Throttle Grip

    CONTROL FUNCTIONS EAM30190 SIDESTAND EAM30187 This sidestand “1” is used to support only the THROTTLE GRIP machine when standing or transporting it. The throttle grip “1” is located on the right han- EWA18980 dlebar. The throttle grip accelerates or deceler- WARNING ates the engine.

  • Page 31: Fuel Tank Cap

    CONTROL FUNCTIONS EAM30192 FUEL TANK CAP Fuel tank cap “1” is located under the fuel tank cap cover “2”. Remove the fuel tank cap cover to open the fuel tank cap. • To remove the fuel tank cap cover, insert fin- gers under part “a”, and then use both hands to lift it up towards the rear of the vehicle.

  • Page 32: Starting And Break-In

    Fuel tank capacity EMENT” section in the CHAPTER 3, apply the 7.5 L (2.0 US gal, 1.7 Imp.gal) Yamaha foam air filter oil or other quality foam Fuel reserve amount air filter oil to the element. (Excess oil in the ele- 2.1 L (0.55 US gal, 0.46 Imp.gal)

  • Page 33: Starting A Warm Engine

    STARTING AND BREAK-IN ECA25920 NOTICE If the engine fail to start, fully open the throttle If the starter motor will not turn when the grip and push the start switch few seconds to start switch is pushed, stop pushing it imme- clear the engine of the rich air-fuel mixture re- diately in order to avoid placing extra load on tained in it.

  • Page 34: Maintenance After Break-In

    MAINTENANCE AFTER BREAK-IN • Drive chain EAM20124 MAINTENANCE AFTER BREAK-IN Lubricate the drive chain and adjust its ten- After a break-in, perform careful maintenance to sion. get ready for the next practice or race. • Fuel tank Refer to “PRE-OPERATION INSPECTION AND Clean the inside of the fuel tank.

  • Page 35: Torque-Check Points

    TORQUE-CHECK POINTS EAM20125 TORQUE-CHECK POINTS Frame construction Frame to rear frame Frame to engine protector Combined seat and fuel tank Fuel tank to frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Seat Seat to frame Steering Steering stem to handlebar Steering stem to frame...
  • Page 36 TORQUE-CHECK POINTS Fuel system Fuel pump to fuel tank Fuel sender to fuel tank Plastic cover Tightening of number plate 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...

  • Page 37: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE solvent or thinner, fuel (gasoline), rust re- EAM20126 MOTORCYCLE CARE AND STOR- movers or inhibitors, brake fluid, antifreeze or electrolyte. • Do not use high-pressure washers or steam-jet cleaners since they cause water EAM30200 CARE seepage and deterioration in the following While the open design of a motorcycle reveals areas: seals (of wheel and swingarm bear- the attractiveness of the technology, it also...

  • Page 38: Storage

    ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Consult a Yamaha dealer for advice on what 4. Lubricate all control cables and the pivoting products to use. points of all levers and pedals as well as of •...
  • Page 39 MOTORCYCLE CARE AND STORAGE month. Do not store the battery in an exces- sively cold or warm place [less than 0 C (30 F) or more than 30 C (90 F)]. For more in- formation on storing the battery, refer to “CHECKING AND CHARGING THE BAT- TERY”...
  • Page 40 MOTORCYCLE CARE AND STORAGE 1-28...

  • Page 41: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-6 ELECTRICAL SPECIFICATIONS..............2-9 TIGHTENING TORQUES................2-11 GENERAL TIGHTENING TORQUE SPECIFICATIONS ......2-11 ENGINE TIGHTENING TORQUES ............2-12 CHASSIS TIGHTENING TORQUES ............2-15 LUBRICATION POINTS AND LUBRICANT TYPES ........2-19 ENGINE ....................2-19 CHASSIS ....................2-20 LUBRICATION SYSTEM CHART AND DIAGRAMS ........2-23 LUBRICATION DIAGRAMS ..............2-23 CABLE ROUTING DIAGRAM ................2-31...

  • Page 42: General Specifications

    GENERAL SPECIFICATIONS EAM20127 GENERAL SPECIFICATIONS Model Model B29M Dimensions Overall length 2165 mm (85.2 in) Overall width 825 mm (32.5 in) Overall height 1280 mm (50.4 in) Seat height 965 mm (38.0 in) Wheelbase 1465 mm (57.7 in) Ground clearance 325 mm (12.80 in) Weight Curb weight...

  • Page 43: 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 13.5 : 1 Starting system Electric starter Fuel...
  • Page 44 ENGINE SPECIFICATIONS Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) Limit 0.080 mm (0.0032 in) Camshaft lobe dimensions Lobe height (Intake) 31.830–31.930 mm (1.2531–1.2571 in) Limit 31.730 mm (1.2492 in) Lobe height (Exhaust) 33.870–33.970 mm (1.3335–1.3374 in) Limit 33.770 mm (1.3295 in) Camshaft runout limit 0.030 mm (0.0012 in) Valve, valve seat, valve guide...
  • Page 45 3.923 (51/13) 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 46 ENGINE SPECIFICATIONS 70–80 C (158–176 F) Engine oil temperature Fuel line pressure (at idle) 300–390 kPa (3.0–3.9 kgf/cm², 43.5–56.6 psi) Throttle grip free play 3.0–6.0 mm (0.12–0.24 in) Front brake lever free play 2.7–11.1 mm (0.11–0.44 in)
  • Page 47 CHASSIS SPECIFICATIONS EAM20129 CHASSIS SPECIFICATIONS Chassis Frame type Semi double cradle 26.3  Caster angle Trail 114 mm (4.5 in) Front wheel Wheel type Spoke wheel Rim size 21 x 1.60 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)

  • Page 48: Chassis Specifications

    470.0 mm (18.50 in) Limit 465.0 mm (18.31 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil S1 Quantity (left) 526.0 cm³ (17.78 US oz, 18.55 Imp.oz) Quantity (right) 526.0 cm³ (17.78 US oz, 18.55 Imp.oz) Rebound damping...
  • Page 49 CHASSIS SPECIFICATIONS Adjustment value from the start position (Soft) Adjustment value from the start position 1-1/2 (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)

  • Page 50: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAM20130 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Advancer type Digital 10.0 2000 r/min Ignition timing (B.T.D.C.) Engine control unit Model B292 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 51 ELECTRICAL SPECIFICATIONS 290–389  at 80 C (290–389  at 176 F) Intake air temperature sensor resistance 2513–2777  at 20 C (2513–2777  at 68 F) Coolant temperature sensor resistance 210–221  at 100 C (210–221  at 212 F) Coolant temperature sensor resistance Fuse(s) Main fuse...

  • Page 52: 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 53: 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) Cylinder head blind plug 28 N·m (2.8 kgf·m, 21 lb·ft) Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft)
  • Page 54 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Air filter case cap screw 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) Starter knob/Idle screw 2.1 N·m (0.21 kgf·m, 1.5 lb·ft) Throttle cable nut (pull) 7 N·m (0.7 kgf·m, 5.2 lb·ft) Throttle cable nut (return) 7 N·m (0.7 kgf·m, 5.2 lb·ft) Clutch cable adjuster and locknut 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
  • Page 55 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Stopper lever bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Shift pedal bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft)  Rotor nut 65 N·m (6.5 kgf·m, 48 lb·ft) Stator bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) Crankshaft position sensor bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Damper assembly cover bolt...

  • Page 56: Chassis Tightening Torques

    TIGHTENING TORQUES EAM30204 CHASSIS 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 Outer tube and upper bracket bolt 21 N·m (2.1 kgf·m, 15 lb·ft) ...
  • Page 57 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Front wheel axle pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft)  Front brake disc bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) / Rear brake disc bolt 14 N·m (1.4 kgf·m, 10 lb·ft) /...
  • Page 58 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Swingarm and brake hose holder 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)  screw Drive chain tensioner bolt (upper 16 N·m (1.6 kgf·m, 12 lb·ft) side) Drive chain tensioner bolt (lower 16 N·m (1.6 kgf·m, 12 lb·ft) side) Drive chain support bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft)
  • Page 59 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Rear fender and relay bracket screw — 1.1 N·m (0.11 kgf·m, 0.81 lb·ft) Lower ring nut 1. First, tighten the lower ring nut approximately 38 N·m (3.8 kgf·m, 28 lb·ft) by using the steering nut wrench, then loosen the lower ring nut one turn.

  • Page 60: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES EAM20132 LUBRICATION POINTS AND LUBRICANT TYPES EAM30206 ENGINE Lubrication point Lubricant types Oil seal lips Bearing O-ring Camshaft cap bolt threads and contacting surface Cylinder head bolt threads, seats, washers Valve stems Valve stem ends Valve lifter outer surface Camshaft lobe and journal Valve lifter top surface...

  • Page 61: Chassis

    Shift lever assembly moving parts Damper assembly shaft, thrust surfaces, washers Starter idle gear inner surface, thrust surfaces Starter clutch drive gear inner surface, thrust surfaces Yamaha bond No.1215 Cylinder head cover gasket (Three bond No.1215®) Yamaha bond No.1215 Crankcase mating surface (Three bond No.1215®)
  • Page 62 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Front wheel axle outer surface Rear wheel oil seal lip Rear wheel axle outer surface Sidestand pivot portion and collar outer surface Push rod contacting portion (front brake master cylinder) Front brake lever bolt outer surface Clutch lever sliding surface and bolt outer surface Clutch lever adjuster rubber lip Clutch cable end (clutch lever side)
  • Page 63 LUBRICATION POINTS AND LUBRICANT TYPES 2-22...

  • Page 64: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAM20151 LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30331 LUBRICATION DIAGRAMS 2-23...
  • Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Piston 4. Oil nozzle 5. Oil filter element 6. Oil pump 7. Oil strainer 8. Crankshaft 9. Drive axle 10.Main axle 2-24...
  • Page 66 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25...
  • Page 67 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Connecting rod 2. Crankshaft 3. Main axle 4. Oil strainer 5. Drive axle 2-26...
  • Page 68 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
  • Page 69 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Exhaust camshaft 2. Intake camshaft 3. Oil filter element 4. Oil pump 2-28...
  • Page 70 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 71 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil pressure check bolt 3. Oil filter element 4. Oil pump 2-30...

  • Page 72: Cable Routing Diagram

    CABLE ROUTING DIAGRAM EAM20152 CABLE ROUTING DIAGRAM 2-31...
  • Page 73 CABLE ROUTING DIAGRAM I. Place the rear grommet of the starter motor 1. Clutch cable lead matching the rear end of the side cover 5. 2. Throttle cable (return) J. Insert the radiator fan motor fuse into the pro- 3. Throttle cable (pull) trusion of the holder plate.
  • Page 74 CABLE ROUTING DIAGRAM 2-33...
  • Page 75 CABLE ROUTING DIAGRAM I. Install the spark plug cap with this facing the 1. Clamp right of the vehicle. 2. Cylinder head breather hose J. Push the spark plug cap home, where there 3. Throttle position sensor lead shall be no gap between it and the cylinder 4.
  • Page 76 CABLE ROUTING DIAGRAM 2-35...
  • Page 77 CABLE ROUTING DIAGRAM 1. Cable guide 2. Joint coupler 3. Ground lead 4. Throttle position sensor lead 5. Throttle position sensor coupler 6. Radiator breather hose 7. Cylinder head breather hose 8. Crankcase breather hose 9. Radiator hose 10.Fuel hose 11.Engine ground lead 12.Coolant temperature sensor coupler 13.Intake air pressure sensor coupler...
  • Page 78 CABLE ROUTING DIAGRAM 2-37...
  • Page 79 CABLE ROUTING DIAGRAM 1. Battery negative lead 2. Fuel hose 3. Fuel pump coupler 4. Resistor 5. Fuel pump lead 6. Resistor coupler 7. Battery positive lead 8. Lean angle sensor 9. Starter motor lead 10.Radiator fan motor relay (blue tape) 11.Main relay (red tape) 12.Wire harness 13.Ground lead coupler...
  • Page 80 CABLE ROUTING DIAGRAM 2-39...
  • Page 81 CABLE ROUTING DIAGRAM 1. Plastic band 2. Clutch cable 3. Clutch switch lead 4. Engine stop switch lead 5. Warning light lead 6. Front brake hose 7. Brake hose guide 8. Number plate 9. Warning light 10.Start switch lead A. Clamp the engine stop switch lead and clutch switch lead to the handlebar by the plastic band.
  • Page 82 CABLE ROUTING DIAGRAM 2-41...
  • Page 83 CABLE ROUTING DIAGRAM 1. Breather hose 3 (air filter breather hose) 2. Breather hose 1 (cylinder head breather hose) 3. Breather hose 2 (crankcase breather hose) 4. Joint pipe A. Pass the breather hose 3 to the outside the throttle cable. B.
  • Page 84 CABLE ROUTING DIAGRAM 2-43...
  • Page 85 CABLE ROUTING DIAGRAM 1. Brake master cylinder 2. Brake hose holder 3. Brake hose A. While installing the brake hose, direct a bend in its pipe portion as shown, and bring it into contact with the projection on the brake cali- per.
  • Page 86 CABLE ROUTING DIAGRAM 2-45...

  • Page 87: 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......................3-7 CHECKING THE COOLANT LEVEL ............3-7 CHECKING THE COOLING SYSTEM ............3-7 CHANGING THE COOLANT ..............3-7 CHECKING THE RADIATOR CAP.............3-8 CHECKING THE RADIATOR CAP VALVE OPENING PRESSURE..3-8 CHECKING THE COOLANT CIRCULATORY SYSTEM FOR LEAKS..3-9 ADJUSTING THE CLUTCH LEVER FREE PLAY ........3-9 ADJUSTING THE THROTTLE GRIP FREE PLAY........3-10...
  • Page 88 CHECKING THE WHEEL BEARINGS .............3-33 CHECKING AND ADJUSTING THE STEERING HEAD ......3-33 CHECKING AND LUBRICATING THE CABLES........3-34 LUBRICATING THE LEVERS ..............3-34 LUBRICATING THE PEDAL..............3-34 LUBRICATING THE DRIVE CHAIN ............3-35 LUBRICATING THE SIDESTAND ............3-35 CHECKING THE CHASSIS FASTENERS ..........3-35 ELECTRICAL SYSTEM..................3-36 CHECKING THE SPARK PLUG...............3-36 CHECKING THE IGNITION TIMING ............3-36 CHECKING AND CHARGING THE BATTERY ........3-37...

  • Page 89: Maintenance Intervals

    MAINTENANCE INTERVALS EAM20157 MAINTENANCE INTERVALS EAM30369 MAINTENANCE INTERVALS ECA25871 NOTICE • After a break-in or before each race, always check the points shown in “TORQUE-CHECK POINTS” for tightening torques and retighten them. • Periodic inspection is essential in making full use of the machine performance. The life of parts varies significantly according to the environment in which the machine runs (e.g., rain, dirt, etc.).
  • Page 90   Crankshaft Inspect and clean  Throttle body Inspect Use Yamaha foam air filter oil or   Clean and lubricate other quality foam air filter oil. Air filter  Replace Check ventilation hose for ...
  • Page 91 MAINTENANCE INTERVALS Every Every Every race third fifth Check or After Item (about (about (about Remarks maintenance job break-in required 12.5 hours) hours) hours)   Clean Dust seal   Inspect and adjust   Replace oil Front fork leg(s) ...
  • Page 92 MAINTENANCE INTERVALS Every Every Every race third fifth Check or After Item (about (about (about Remarks maintenance job break-in required 12.5 hours) hours) hours) Drive chain guide and drive chain  Replace support   Routing (Connection)   Check and grease Cables Check and clean Check throttle cables on the...

  • Page 93: 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 94 PRE-OPERATION INSPECTION AND MAINTENANCE Perform usual maintenance enough so that, in the race course, a confirmation of that and simple setting adjustments may only be left, in order to get enough time to use effectively.

  • Page 95: Engine

    ENGINE minutes until the coolant has settled. EAM20135 ENGINE EAM30211 EAM30210 CHECKING THE COOLING SYSTEM CHECKING THE COOLANT LEVEL 1. Remove: EWA19070 • Seat WARNING • Side cover (left/right) If coolant seems hot, do not remove the radi- • Air scoop (left/right) ator cap.

  • Page 96: Checking The Radiator Cap

    ENGINE 5. Install: • Valve and valve seat “2” • Copper washer Crack/damage  Replace. Exist fur deposits  Clean or replace. • Coolant drain bolt Coolant drain bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) 6. Pour coolant. Recommended coolant High quality ethylene glycol anti-freeze containing anti-cor- rosion for aluminum engine...

  • Page 97: Checking The Coolant Circulatory System For Leaks

    ENGINE 4. Check: • Pressure value No stay for 5 to 10 seconds at the test pres- sure value  Correct. • Radiator • Radiator hose connections Coolant leaks  Correct or replace. • Radiator hoses Bulges  Replace. EWA19090 WARNING ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 98: Adjusting The Throttle Grip Free Play

    ENGINE gine idling speed should be adjusted. 1. Check: • Throttle grip free play “a” Out of specification  Regulate. Throttle grip free play 3.0–6.0 mm (0.12–0.24 in) If the clutch lever free play cannot be obtained on the handlebar side, use the adjuster on the clutch cable side.

  • Page 99: Cleaning The Air Filter Element

    ENGINE • Cover (grip cap) “2” • Throttle grip cap “3” 2. Remove: • Air filter mounting bolt “1” • Air filter element “2” 2. Lubricate: • Throttle cable end “a” • Air filter guide “3” (from the air filter element) Recommended lubricant Lithium-soap-based grease 3.

  • Page 100: Checking The Throttle Body Joint

    ENGINE 5. Apply: EAM30220 CHECKING THE BREATHER HOSES • Yamaha foam air filter oil or other quality 1. Check: foam air filter oil • Breather hose “1” Crack/damage  Replace. Oil application quantify 50 g Loose connection  Connect properly.

  • Page 101: Checking The Fuel Line

    ENGINE Refer to “FUEL TANK” on page 7-1. • Air scoop (left/right) • 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.

  • Page 102: Changing The Engine Oil

    ENGINE c. Install the new oil filter element and the oil fil- EAM30225 CHANGING THE ENGINE OIL ter element cover. Stand the vehicle upright on a level surface. Oil filter element cover bolt 1. Start the engine, warm this up for 3 minutes, 10 N·m (1.0 kgf·m, 7.4 lb·ft) and then stop the engine and wait about 5 minutes.

  • Page 103: Adjusting The Engine Idling Speed

    ENGINE ECA25840 Engine oil quantity NOTICE Oil change If no engine oil seeps out after one minute, 0.83 L (0.88 US qt, 0.73 Imp.qt) immediately turn the engine off so it will not With oil filter removal seize. 0.85 L (0.90 US qt, 0.75 Imp.qt) Quantity (disassembled) c.

  • Page 104: Adjusting The Valve Clearance

    ENGINE sic knowledge and skill concerning the servic- Digital tachometer ing of Yamaha motorcycles (e.g., Yamaha 90890-06760 dealers, service engineers, etc.). Those who Digital tachometer have little knowledge and skill concerning ser- YU-39951-B vicing are requested not to undertake inspec- tion, adjustment, disassembly, or reassembly only by reference to this manual.
  • Page 105 ENGINE b. Align the top dead center (TDC) mark “a” on the rotor with the alignment mark “b” on the crankcase cover. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Adjust: • Valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Check that the alignment mark “c” on the cam- a. Remove the camshaft (intake and exhaust). shaft sprocket and the alignment mark “d”...
  • Page 106 ENGINE c. Check the number on the originally installed • Make sure that valve lifters and adjusting pads adjusting pad. are installed in place. • Make sure that adjusting pads are installed • The adjusting pad number “a” is indicated on with their numbers facing upward.

  • Page 107: 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 108 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 109: Chassis

    CHASSIS EAM20136 CHASSIS EAM30227 BLEEDING THE BRAKE SYSTEM EWA19140 WARNING Bleed the brake system whenever: • The system is disassembled. • A brake hose is loosened, disconnected, or replaced. • The brake fluid level is very low. A. Front • Brake operation is faulty. B.

  • Page 110: Checking The Brake Hose

    CHASSIS EAM30228 CHECKING THE BRAKE HOSE 1. Check: • Brake hose “1” Cracks/damage/wear  Replace. 2. Remove: • Brake lever cover 3. Adjust: • Brake lever position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. b. Turn the adjusting bolt “2” in direction “a” or “b”...

  • Page 111: Adjusting The Rear Brake

    CHASSIS 4. Install: can indicate the presence of air in the brake • Brake lever cover system. Before running, bleed the brake sys- tem. Air in the brake system will cause brak- EAM30230 ing performance to be reduced. ADJUSTING THE REAR BRAKE 1.
  • Page 112 CHASSIS d. Remove the pad pin and brake pads “4”. i. Install the brake caliper “8” and tighten the pad pin “9”. Bolt (brake caliper) 28 N·m (2.8 kgf·m, 21 lb·ft) Pad pin 17 N·m (1.7 kgf·m, 13 lb·ft) e. Connect the plastic hose “5” to the bleed screw “6”...

  • Page 113: Checking The Rear Brake Pads

    CHASSIS on page 3-21. EAM30232 CHECKING THE REAR BRAKE PADS 1. Measure: • Brake pad lining thickness “a” Out of specification  Replace as a set. The pads worn up to the indicator “b” grooves mean that the brake pad lining thickness limit is reached.

  • Page 114: Checking The Rear Brake Pad Insulator

    CHASSIS A softy or spongy feeling  Bleed the brake system. Refer to “BLEEDING THE BRAKE SYSTEM” on page 3-21. EAM30233 CHECKING THE REAR BRAKE PAD INSULATOR 1. Remove: • Brake pad Refer to “REAR BRAKE” on page 4-21. 2. Check: i.

  • Page 115: Adjusting The Drive Chain Slack

    CHASSIS 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 116: Checking The Front Fork Legs

    CHASSIS Locknut 21 N·m (2.1 kgf·m, 15 lb·ft) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAM30338 CHECKING THE FRONT FORK LEGS 1. Stand the vehicle upright on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. EAM30237 CLEANING THE FRONT FORK OIL SEAL 2.

  • Page 117: Air Bleeding From Front Fork

    CHASSIS EAM30238 Direction “a” AIR BLEEDING FROM FRONT FORK Rebound damping is increased (sus- pension is harder). If the front fork initial movement feels stiff during Direction “b” a run, relieve the front fork internal pressure. Rebound damping is decreased (sus- pension is softer).

  • Page 118: Checking The Swingarm Operation

    CHASSIS Compression damping Minimum (soft) 20 click(s) in direction “b”* Standard 14 click(s) in direction “b”* Maximum (hard) 0 click(s) in direction “b”* * With the adjusting screw fully turned in di- rection “a” EAM30242 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Use a maintenance stand to raise the rear wheel off the ground.
  • Page 119 CHASSIS 1. Adjust: Direction “b” • Rebound damping Spring preload is increased (suspen- sion is harder). ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjuster “1” in the direction of “a” or Direction “c” “b” to make an adjustment. Spring preload is decreased (suspen- sion is softer).

  • Page 120: Checking The Tires

    CHASSIS Fast compression damping Minimum (soft) 2 turn(s) in direction “b”* Standard 1-1/2 turn(s) in direction “b”* Maximum (hard) 0 turn(s) in direction “b”* * With the adjusting screw fully turned in di- rection “a” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAM30243 CHECKING THE TIRES 1.

  • Page 121: Checking The Wheels

    CHASSIS wheel. After replacing a tire or a wheel, always balance the wheel. EAM30246 CHECKING THE WHEEL BEARINGS 1. Check: • Wheel bearing Refer to “CHECKING THE FRONT WHEEL” on page 4-4 and “CHECKING THE REAR WHEEL” on page 4-8. A tight spoke will emit a clear, ringing tone;...

  • Page 122: Checking And Lubricating The Cables

    CHASSIS • Move the steering to the left and right a couple 5. Install: • Upper bracket of times to check that it moves smoothly. Refer to “STEERING HEAD” on page 4-50. • Handlebar Refer to “HANDLEBAR” on page 4-31. EAM30248 CHECKING AND LUBRICATING THE CABLES...

  • Page 123: Lubricating The Drive Chain

    CHASSIS EAM30251 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained proper- ly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas. This vehicle has a drive chain with small rubber O-rings between each side plate.

  • Page 124: Electrical System

    ELECTRICAL SYSTEM 6. Measure: EAM20137 ELECTRICAL SYSTEM • Spark plug gap “a” Out of specification  Adjust the spark plug EAM30254 gap. CHECKING THE SPARK PLUG 1. Remove: Spark plug gap • Seat 0.7–0.8 mm (0.028–0.031 in) • Air scoop (left/right) Refer to “GENERAL CHASSIS”...

  • Page 125: Checking And Charging The Battery

    ELECTRICAL SYSTEM Timing light 90890-03141 Timing light YU-03141 Digital tachometer 90890-06760 Digital tachometer YU-39951-B 3. Adjust: • Engine idling speed Refer to “ADJUSTING THE ENGINE IDLING SPEED” on page 3-15. 4. Check: • Ignition timing Check whether the alignment mark “a” on the left crankcase cover is within the firing range “b”...
  • Page 126 ELECTRICAL SYSTEM 3-38...
  • Page 127 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE LEFT SIDE COVER ............4-2 REMOVING THE SEAT................4-2 REMOVING THE NUMBER PLATE ............4-2 FRONT WHEEL ....................4-3 REMOVING THE FRONT WHEEL .............4-4 CHECKING THE FRONT WHEEL .............4-4 DISASSEMBLING THE FRONT WHEEL ...........4-5 ASSEMBLING THE FRONT WHEEL ............4-5 INSTALLING THE FRONT WHEEL ............4-6 REAR WHEEL ....................4-7 REMOVING THE REAR WHEEL ...............4-8...
  • Page 128 HANDLEBAR....................4-31 REMOVING THE HANDLEBAR ...............4-32 CHECKING THE HANDLEBAR..............4-32 INSTALLING THE HANDLEBAR..............4-32 FRONT FORK....................4-37 REMOVING THE FRONT FORK LEGS ...........4-39 DISASSEMBLING THE FRONT FORK LEGS .........4-39 CHECKING THE FRONT FORK LEGS............4-40 ASSEMBLING THE FRONT FORK LEGS ..........4-41 INSTALLING THE FRONT FORK LEGS..........4-47 STEERING HEAD...................4-50 REMOVING THE LOWER BRACKET ............4-51 CHECKING THE STEERING HEAD ............4-51...
  • Page 129 GENERAL CHASSIS EAM20094 GENERAL CHASSIS Removing the seat and side cover 1.3 N ・ m (0.13 kgf ・ m, 0.95 lb ・ ft) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 1.3 N ・...

  • Page 130: General Chassis

    GENERAL CHASSIS EAM30015 EAM30371 REMOVING THE LEFT SIDE COVER REMOVING THE NUMBER PLATE 1. Remove: 1. Remove: • Bolt (side cover) • Bolt (number plate) • Side cover “1” • Number plate “1” Draw the left side cover “1” backward to remove •...

  • Page 131: 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 132: Removing The Front Wheel

    FRONT WHEEL 4. Tighten: 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 3-32. EWA13120 WARNING Spoke Securely support the vehicle so that there is 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) no danger of it falling over.

  • Page 133: Disassembling The Front Wheel

    FRONT WHEEL EAM30019 DISASSEMBLING THE FRONT WHEEL 1. Remove: • Oil seal • Bearing ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside of the front wheel hub. b. Remove the oil seals “1” with a flat-head screwdriver. To prevent damaging the wheel, place a rag “2” between the screwdriver and the wheel surface.

  • Page 134: Installing The Front Wheel

    FRONT WHEEL 3. Install: 3. Tighten: • Collar “1” • Front wheel axle nut “1” Front wheel axle nut Apply the lithium-soap-based grease on the oil 115 N·m (11.5 kgf·m, 85 lb·ft) seal lip. 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.

  • Page 135: Rear Wheel

    REAR WHEEL EAM20096 REAR WHEEL Removing the rear wheel 14 N ・ m (1.4 kgf ・ m, 10 lb ・ ft) 125 N ・ m (12.5 kgf ・ m, 92 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 50 N ・...

  • Page 136: Removing The Rear Wheel

    REAR WHEEL 4. Measure: EAM30022 REMOVING THE REAR WHEEL • Radial wheel runout 1. Use a maintenance stand to raise the rear • Lateral wheel runout wheel off the ground. Refer to “CHECKING THE FRONT WHEEL” EWA13120 on page 4-4. WARNING Securely support the vehicle so that there is Radial wheel runout limit...

  • Page 137: Assembling The Rear Wheel

    REAR WHEEL the bearing outer race and that of the oil seal. Rear wheel sprocket self-locking 50 N·m (5.0 kgf·m, 37 lb·ft) Tighten the self-locking nuts in stages and in a crisscross pattern. 2. Install: • Brake disc “1” • Brake disc bolt “2” Brake disc bolt 14 N·m (1.4 kgf·m, 10 lb·ft) LOCTITE®...
  • Page 138 REAR WHEEL Install the brake disc “1” between the brake pads Temporarily tighten the nut (rear wheel axle) at “2” correctly. this point. 2. Install: 5. Adjust: • Drive chain “1” • Drive chain slack “a” Drive chain slack (Maintenance Push the rear wheel “2”...

  • Page 139: Front Brake

    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 140 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 4-12...
  • Page 141 FRONT BRAKE Removing the front brake master cylinder 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 ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 30 N ・...
  • Page 142 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 4-14...

  • Page 143: Introduction

    FRONT BRAKE EAM30028 INTRODUCTION Brake disc thickness limit 2.5 mm (0.10 in) EWA19210 WARNING 4. Install: If you need to disassemble the disc brake • Front wheel components, observe the following precau- Refer to “FRONT WHEEL” on page 4-3. tions. •...

  • Page 144: Checking The Front Brake Caliper

    FRONT BRAKE internal parts. Use new brake fluid for cleaning and lubricating. • Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort. • When the brake caliper is disassembled, re- place the brake caliper piston seal and the brake caliper piston dust seal with new ones.

  • Page 145: Installing The Front Brake Caliper

    FRONT BRAKE • Never force to insert. Brake pad pin 17 N·m (1.7 kgf·m, 13 lb·ft) Refer to “CHECKING THE FRONT BRAKE PADS” on page 3-23. 3. Tighten: • Brake hose holder mounting bolt “1” Brake hose holder mounting bolt 9 N·m (0.9 kgf·m, 6.6 lb·ft) Make sure that the brake hose holder “2”...

  • Page 146: Removing The Front Brake Master Cylinder

    FRONT BRAKE Refer to “BLEEDING THE BRAKE SYSTEM” 2. Check: • Brake master cylinder kit on page 3-21. Damage/scratches/wear  Replace. 6. Check: • Brake fluid level 3. Check: The minimum level mark or below  Add. • Brake master cylinder reservoir cap Refer to “CHECKING THE BRAKE FLUID 4.

  • Page 147: Installing The Front Brake Master Cylinder

    FRONT BRAKE EAM30039 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Brake master cylinder “1” Brake master cylinder holder bolt 9 N·m (0.9 kgf·m, 6.6 lb·ft) • Install the front brake master cylinder holder with the “UP” mark facing up. 3.
  • Page 148 FRONT BRAKE 3. Pour brake fluid to the brake master cylinder 6. Check: reservoir up to the specified level. • Brake lever free play Refer to “ADJUSTING THE FRONT BRAKE” Specified brake fluid on page 3-22. DOT 4 • Brake lever operation A softy or spongy feeling ...

  • Page 149: Rear Brake

    REAR BRAKE EAM20098 REAR BRAKE Removing the rear brake caliper 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 13 lb ・ ft) 30 N ・...
  • Page 150 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 4-22...
  • Page 151 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 152 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 4-24...

  • Page 153: Introduction

    REAR BRAKE EAM30040 INTRODUCTION EWA19260 WARNING If you need to disassemble the disc brake components, observe the following precau- tions. • Never disassemble the brake components unless absolutely necessary. • If there is any problem with connections on the hydraulic brake system, perform the following jobs.

  • Page 154: Removing The Rear Brake Caliper

    REAR BRAKE and the brake caliper piston seal. EAM30042 REMOVING THE REAR BRAKE CALIPER ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Before disassembling the brake caliper, drain EAM30044 CHECKING THE REAR BRAKE CALIPER the brake fluid from the entire brake system. 1. Check: 1. Remove: • Brake caliper piston “1” •...

  • Page 155: Installing The Brake Caliper Piston

    REAR BRAKE Specified brake fluid DOT 4 EAM30046 INSTALLING THE BRAKE CALIPER PISTON 1. Clean: • Brake caliper • Brake caliper piston seal • Brake caliper piston dust seal • Brake caliper piston Use brake fluid for cleaning. EAM30047 2. Install: INSTALLING THE REAR BRAKE CALIPER •...

  • Page 156: Removing The Rear Brake Master Cylinder

    REAR BRAKE 7. Check: Brake pad pin • Brake pedal operation 17 N·m (1.7 kgf·m, 13 lb·ft) A softy or spongy feeling  Bleed the brake Brake pad pin plug system. 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) Refer to “BLEEDING THE BRAKE SYSTEM” on page 3-21.

  • Page 157: Assembling The Rear Brake Master Cylinder

    REAR BRAKE 4. Check: • Brake hose Install the spring with a smaller inside diameter Cracks/damage/wear  Replace. to the brake master cylinder piston. EAM30050 ASSEMBLING THE REAR BRAKE MASTER CYLINDER EWA13520 WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid.
  • Page 158 REAR BRAKE hose touches the projection “a” on the brake caliper. 5. Check: • Brake pedal operation A softy or spongy feeling  Bleed the brake 2. Pour brake fluid to the brake fluid reservoir up system. to the specified level. Refer to “BLEEDING THE BRAKE SYSTEM”...

  • Page 159: 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) 3.8 N ・...

  • Page 160: Removing The Handlebar

    HANDLEBAR EAM30052 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Clutch switch “1” EAM30053 CHECKING THE HANDLEBAR 1. Check: •...
  • Page 161 HANDLEBAR ECA14250 NOTICE • First, tighten the bolts on the front side of the handlebar holder, and then on the rear side. • Turn the handlebar all the way to the left and right. If there is any contact with the fuel tank, adjust the handlebar position.
  • Page 162 HANDLEBAR ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: • Engine stop switch “1” • Clutch lever “2” • Clutch lever holder “3” • Clamp “4” Engine stop switch screw 0.5 N·m (0.05 kgf·m, 0.37 lb·ft) Clutch lever holder bolt 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) 7.
  • Page 163 HANDLEBAR 9. Install: 11.Install: • Throttle cable housing “1” • Start switch “1” • Screw (throttle cable housings) “2” • Front brake master cylinder assembly “2” • Front brake master cylinder holder “3” Screw (throttle cable housings) • Bolt (brake master cylinder holder) “4” 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) •...
  • Page 164 HANDLEBAR grease to the clutch cable end. 13.Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-9. Clutch lever free play 7.0–12.0 mm (0.28–0.47 in) 14.Adjust: • Throttle grip free play Refer to “ADJUSTING THE THROTTLE GRIP FREE PLAY”...

  • Page 165: 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 166 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) 1.3 N ・...

  • Page 167: Removing The Front Fork Legs

    FRONT FORK • Hold the locknut and remove the adjuster. EAM30055 REMOVING THE FRONT FORK LEGS 1. Use a maintenance stand to raise the front ECA24520 NOTICE wheel off the ground. Do not remove the locknut as the damper rod EWA13120 may go into the damper assembly and not be WARNING...

  • Page 168: Checking The Front Fork Legs

    FRONT FORK The bending value is shown by one half of the dial gauge reading. EWA13650 WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Remove: • Base valve “1” (from the damper assembly) Hold the damper assembly with the cap bolt ring wrench “2”...

  • Page 169: Assembling The Front Fork Legs

    1. Stretch the damper assembly fully. 2. Fill: • Damper assembly Recommended oil Yamaha Suspension Oil S1 Standard oil amount 7. Check: 206 cm³ (6.96 US oz, 7.27 Imp.oz) • Adjuster “1”...
  • Page 170 FRONT FORK oils may have an adverse effect on front 5. Tighten: fork performance. • Locknut “1” • When disassembling and assembling the front fork leg, take care not to allow any for- Fully finger tighten the locknut onto the damper eign material to enter the front fork.
  • Page 171 FRONT FORK 8. Check: bly. • Damper assembly Not fully stretched  Repeat the steps (1) to (7). 9. Tighten: • Base valve “1” Base valve 28 N·m (2.8 kgf·m, 21 lb·ft) Hold the damper assembly with the cap bolt ring wrench “2”...
  • Page 172 FRONT FORK seal faces bottom side. • Apply the lithium-soap-based grease on the dust seal lip and oil seal lip. • Apply the fork oil on the inner tube. • Install the scraper to the inner tube as shown in the illustration.
  • Page 173 FRONT FORK Fork seal driver 90890-01502 Fork seal driver (48) YM-A0948 22.Measure: • Distance “a” Out of specification  Turn into the locknut. Distance “a” 16 mm (0.63 in) or more 19.Install: Between the damper assembly • Oil seal clip “1” “1”...
  • Page 174 FRONT FORK ECA24560 NOTICE Allow the damper assembly to slide slowly down the inner tube until it contacts the bot- tom of the inner tube. Be careful not to dam- age the inner tube. 27.Measure: • Gap “a” between the adjuster “1” and the locknut “2”...

  • Page 175: Installing The Front Fork Legs

    55 N·m (5.5 kgf·m, 41 lb·ft) LOCTITE® 32.Install: • Protector guide “1” 30.Fill: • Front fork leg Recommended oil Yamaha Suspension Oil S1 Standard oil amount 330 cm³ (11.16 US oz, 11.64 EAM30059 INSTALLING THE FRONT FORK LEGS Imp.oz) 1. Install: Extent of adjustment •...
  • Page 176 FRONT FORK Cap bolt ring wrench 90890-01501 Cap bolt ring wrench YM-01501 5. Install: • Protector “1” • Bolt (protector) “2” Bolt (protector) 5 N·m (0.5 kgf·m, 3.7 lb·ft) 3. Adjust: • Front fork top end “a” Front fork top end (standard) “a” 3 mm (0.12 in) 6.
  • Page 177 FRONT FORK 4-49...

  • Page 178: 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 179: 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 180 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 181 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 182: 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) 16 15 14 13 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 53 N ・...
  • Page 183 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 56 N ・ m (5.6 kgf ・ m, 41 lb ・ ft) 16 15 14 13 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 53 N ・ m (5.3 kgf ・ m, 39 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 184 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 4-56...

  • Page 185: Handling The Rear Shock Absorber

    • To dispose of a damaged or a worn-out rear shock absorber, take the unit to your EAM30066 REMOVING THE BEARING Yamaha dealer for this disposal procedure. 1. Remove: • Stopper ring (upper bearing) “1” Press in the bearing while pressing its outer race and remove the stopper ring.

  • Page 186: Checking The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY 2. Remove: • Relay arm • Upper bearing “1” Damage/wear  Replace. 2. Check: • Bearing Remove the bearing by pressing its outer race. • Spacer Damage/pitting/scratches  Replace the bearings and spacers as a set. 3.

  • Page 187: Installing The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY Installed depth “a” 4.25 mm (0.17 in) EAM30070 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: 5. Lubricate: • Bearing (lower side) • Connecting arm and frame bolt • Dust seal • Relay arm and connecting arm bolt •...
  • Page 188 REAR SHOCK ABSORBER ASSEMBLY Relay arm bolt (swingarm side) 70 N·m (7.0 kgf·m, 52 lb·ft) • Rear shock absorber assembly lower bolt Rear shock absorber assembly lower bolt 53 N·m (5.3 kgf·m, 39 lb·ft) 4-60...

  • Page 189: Swingarm

    SWINGARM EAM20103 SWINGARM Removing the swingarm 70 N ・ m (7.0 kgf ・ m, 52 lb ・ ft) 4.0 N ・ m (0.40 kgf ・ m, 3.0 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Use a maintenance stand to raise the front wheel off the ground.

  • Page 190: Removing The Swingarm

    SWINGARM EAM30071 REMOVING THE SWINGARM 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. Measure: • Swingarm side play •...

  • Page 191: Installing The Swingarm

    SWINGARM EAM30074 INSTALLING THE SWINGARM 1. Lubricate: • Bearing • Collar • Spacer • Oil seal • Pivot shaft Recommended lubricant Molybdenum disulfide grease 2. Install: • Bearing “1” • Oil seal “2” (to the swingarm) Installed depth “a” 0–0.5 mm (0–0.02 in) Installed depth “b”...

  • Page 192: 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 193: Removing The Drive Chain

    CHAIN DRIVE EAM30075 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a maintenance stand so that the rear wheel is elevated. 2.

  • Page 194: Checking The Drive Sprocket

    CHAIN DRIVE more than ten minutes, otherwise the O- drive sprocket and the rear wheel sprocket as rings can be damaged. a set. Bent tooth  Replace the drive sprocket and the rear wheel sprocket as a set. b. Correct 1.
  • Page 195 CHAIN DRIVE Drive chain slack (Maintenance stand) 50.0–60.0 mm (1.97–2.36 in) ECA24590 NOTICE A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swing- arm or cause an accident.
  • Page 196 CHAIN DRIVE 4-68...

  • Page 197: Engine

    ENGINE ENGINE REMOVAL ..................5-1 REMOVING THE SILENCER ..............5-5 REMOVING THE EXHAUST PIPE 2 ............5-5 REMOVING THE DRIVE SPROCKET ............5-5 REMOVING THE ENGINE .................5-5 CHECKING THE SILENCER AND EXHAUST PIPE ........5-6 CHANGING THE SILENCER FIBER............5-6 INSTALLING THE ENGINE ................5-7 INSTALLING THE BRAKE PEDAL.............5-8 INSTALLING THE DRIVE SPROCKET ............5-8 INSTALLING THE EXHAUST PIPE AND MUFFLER .........5-9 CAMSHAFT ....................5-11...
  • Page 198 CHECKING THE FRICTION PLATES ............5-42 CHECKING THE CLUTCH PLATES ............5-42 CHECKING THE CLUTCH SPRINGS ............5-42 CHECKING THE CLUTCH HOUSING .............5-43 CHECKING THE CLUTCH BOSS ............5-43 CHECKING THE PRESSURE PLATE .............5-43 CHECKING THE PUSH LEVER SHAFT ..........5-43 CHECKING THE CLUTCH PUSH RODS..........5-43 CHECKING THE PRIMARY DRIVE GEAR ..........5-43 CHECKING THE PRIMARY DRIVEN GEAR..........5-44 INSTALLING THE OIL SEAL..............5-44...
  • Page 199 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT ........5-69 REMOVING THE CRANKSHAFT ASSEMBLY ........5-70 CHECKING THE CRANKSHAFT ASSEMBLY .........5-70 INSTALLING THE CRANKSHAFT ASSEMBLY ........5-70 INSTALLING THE BALANCER SHAFT ...........5-71 TRANSMISSION.....................5-72 REMOVING THE TRANSMISSION............5-73 CHECKING THE SHIFT FORKS ..............5-73 CHECKING THE SHIFT DRUM ASSEMBLY ...........5-73 CHECKING THE TRANSMISSION ............5-74 INSTALLING THE TRANSMISSION ............5-74...
  • Page 200 ENGINE REMOVAL EAM20105 ENGINE REMOVAL Removing the exhaust pipe 13 N ・ m (1.3 kgf ・ m, 9.6 lb ・ ft) 20 N ・ m (2.0 kgf ・ m, 15 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 8 N ・...
  • Page 201 ENGINE REMOVAL Removing the electronic parts 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 7 N ・...
  • Page 202 ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 53 N ・...
  • Page 203 ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 53 N ・...
  • Page 204 ENGINE REMOVAL EAM30158 REMOVING THE SILENCER 1. Remove: • Rear shock absorber assembly lower bolt “1” • Connecting arm bolt (frame side) “2” • Silencer “3” Move the rear shock absorber to the left side of the chassis, and remove the silencer. EAM30160 REMOVING THE DRIVE SPROCKET 1.
  • Page 205 ENGINE REMOVAL shaft of similar diameter into the other side of the swingarm to support it. EAM30373 CHANGING THE SILENCER FIBER 1. Remove: 2. Remove: • Bolt “1” • Engine “1” • Silencer body “2” From the right side. ECA25800 NOTICE •...
  • Page 206 ENGINE REMOVAL 3. Replace: 6. Install: • Fiber “1” • Silencer cap “1” • Rivet “2” • Apply heat-resistant sealant to the areas “a” shown, making sure that there are no gaps in the beads of sealant. • Take care not to allow the fiber out of place when installing the silencer body “3”.
  • Page 207 ENGINE REMOVAL • Upper engine bracket “7” • Engine bracket bolt (upper side) “8” Engine bracket bolt (upper side) 34 N·m (3.4 kgf·m, 25 lb·ft) • Engine mounting bolt (upper side) “9” Engine mounting bolt (upper side) 45 N·m (4.5 kgf·m, 33 lb·ft) EAM30166 INSTALLING THE DRIVE SPROCKET Apply molybdenum disulfide grease to the pivot...
  • Page 208 ENGINE REMOVAL 2. Install: • Clamp • Exhaust pipe 2 “1” • Bolt (exhaust pipe 2) “2” 3. Bend the lock washer tab to lock the nut. 4. Install: • Drive sprocket guide • Drive sprocket cover “1” • Bolt (drive sprocket cover) “2” Install and temporarily tighten the exhaust pipe 2 with its end positioned as shown with respect to Bolt (drive sprocket cover)
  • Page 209 ENGINE REMOVAL 2mm (0.08in) 4. Tighten: • Bolt (exhaust pipe 2) Bolt (exhaust pipe 2) 20 N·m (2.0 kgf·m, 15 lb·ft) • Clamp Clamp 12 N·m (1.2 kgf·m, 8.9 lb·ft) Tighten while checking that their front and rear joints are inserted in position. 5-10...
  • Page 210 CAMSHAFT EAM20106 CAMSHAFT Removing the cylinder head cover 13 N ・ m (1.3 kgf ・ m, 9.6 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Seat 4-1.
  • Page 211 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 212 CAMSHAFT • Timing chain tensioner “2” EAM30080 REMOVING THE CAMSHAFT • Gasket 1. Remove: • Timing mark accessing screw “1” • Crankshaft end accessing screw “2” 4. Remove: • Bolt (camshaft cap) “1” • Camshaft cap “2” 2. Align: • Clip “3” •...
  • Page 213 CAMSHAFT from falling into the crankcase. 4. Measure: • Camshaft-journal-to-camshaft-cap clearance EAM30081 Out of specification  Measure the camshaft CHECKING THE CAMSHAFT journal diameter. 1. Check: • Camshaft lobe Camshaft-journal-to-camshaft- Blue discoloration/pitting/scratches  Re- cap clearance place the camshaft. 0.028–0.062 mm (0.0011–0.0024 2.
  • Page 214 CAMSHAFT a. 1/4 tooth ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Correct 5. Measure: • Camshaft journal diameter “a” 1. Timing chain roller Out of specification  Replace the camshaft. 2. Camshaft sprocket Within specification  Replace the cylinder EAM30083 head and the camshaft caps as a set. CHECKING THE TIMING CHAIN TENSIONERS Camshaft journal diameter...
  • Page 215 CAMSHAFT EAM30084 CHECKING THE DECOMPRESSION SYSTEM 1. Check: • Decompression system ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check that the decompressor cam “1” moves smoothly. b. Check that the decompressor lever pin “2” projects from the camshaft. c. Fit the timing chain “3” onto both camshaft sprockets and install the camshafts on the cylinder head.
  • Page 216 Before installation, apply the sealant to the cylin- Bolt (timing chain tensioner) der head cover gasket. 10 N·m (1.0 kgf·m, 7.4 lb·ft) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) c. Release the screwdriver, check that the ten- sioner rod comes out smoothly, and tighten the gasket “4”...
  • Page 217 CAMSHAFT • Spark plug Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) 5-18...
  • Page 218 CYLINDER HEAD EAM20107 CYLINDER HEAD Removing the cylinder head 33 N ・ m (3.3 kgf ・ m, 24 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 219 CYLINDER HEAD EAM30086 REMOVING THE CYLINDER HEAD 1. Remove: • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAMSHAFT” on page 5-13. 2. Remove: • Cylinder head nut • Cylinder head bolt 2. Check: • Loosen the bolts in the proper sequence as •...
  • Page 220 CYLINDER HEAD in two or three steps in the proper tightening se- EAM30089 INSTALLING THE CYLINDER HEAD quence as shown. 1. Install: • Timing chain guide (intake side) “1” • Dowel pin “2” • Cylinder head gasket “3” • Cylinder head “4” •...
  • Page 221 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 5-19. Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Intake valve...
  • Page 222 VALVES AND VALVE SPRINGS b. Check that the valves are properly sealed. EAM30090 REMOVING THE VALVES Check that there are no kerosene leaks from the Before removing the internal parts of the cylinder valve seat “1”. head (e.g., valves, valve springs, valve seats), make sure that the valves are properly sealed.
  • Page 223 VALVES AND VALVE SPRINGS that it can be reinstalled in its original place. EAM30091 CHECKING THE VALVES AND VALVE GUIDES 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification  Replace the valve guide. Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - 2.
  • Page 224 VALVES AND VALVE SPRINGS 3. Eliminate: • Carbon deposits (from the valve face and valve seat) 4. Check: • Valve face Pitting/wear  Grind the valve face. • Valve stem end Mushroom shape or diameter larger than the body of the valve stem  Replace the valve. 5.
  • Page 225 VALVES AND VALVE SPRINGS for lapping with new ones. • When replacing the cylinder head, replace also the valves with new ones without them. • When replacing the valves or the valve guides, use new valves to lap the valve seats, and then replace them with new valves.
  • Page 226 VALVES AND VALVE SPRINGS h. Install the valve into the cylinder head. i. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion. j. Measure the valve seat contact width “c” again. If the valve seat contact width is out of specification, reface and lap the valve seat.
  • Page 227 VALVES AND VALVE SPRINGS facing up. 6. Lubricate: • Adjusting pad “1” b. Smaller pitch • Valve lifter “2” 4. Install: • Valve cotter “1” Install the valve cotters by compressing the valve spring with the valve spring compressor “2” and the valve spring compressor attachment “3”.
  • Page 228 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 229 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 230 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 231 CYLINDER AND PISTON Piston pin outside diameter 15.991–16.000 mm (0.6296– 0.6299 in) 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 2. Install: 16.002–16.013 mm (0.6300–...
  • Page 232 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 233 ELECTRIC STARTER EAM20110 ELECTRIC STARTER Removing the starter motor 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-1. Starter motor 5-34...
  • Page 234 ELECTRIC STARTER Disassembling the starter motor 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Starter motor front cover Starter motor yoke Armature assembly Starter motor rear cover Brush set 5-35...
  • Page 235 ELECTRIC STARTER EAM30106 CHECKING THE STARTER MOTOR Digital circuit tester (CD732) 90890-03243 1. Check: Model 88 Multimeter with tachom- • Commutator eter Dirt  Clean with 600 grit sandpaper. YU-A1927 2. Measure: • Commutator diameter “a” Out of specification  Replace the starter Armature coil resistance motor.
  • Page 236 ELECTRIC STARTER 7. Check: tor rear cover. • Gear teeth Damage/wear  Replace the starter motor. 8. Check: • Oil seal Damage/wear  Replace the defective part(s). EAM30107 ASSEMBLING THE STARTER MOTOR 1. Install: • Brush spring “1” • Brush “2” 4.
  • Page 237 ELECTRIC STARTER 5-38...
  • Page 238 CLUTCH EAM20111 CLUTCH Removing the clutch 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 6 10 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 75 N ・...
  • Page 239 CLUTCH Removing the clutch 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 6 10 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 75 N ・...
  • Page 240 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 241 CLUTCH EAM30108 REMOVING THE CLUTCH 1. Remove: • Clutch boss nut “1” • Lock washer “2” • Clutch boss “3” • Straighten the lock washer tab. • While holding the clutch boss with the univer- sal clutch holder “4”, loosen the clutch boss nut.
  • Page 242 CLUTCH EAM30114 Clutch spring free length CHECKING THE PRESSURE PLATE 47.80 mm (1.88 in) 1. Check: Limit • Pressure plate 45.41 mm (1.79 in) Crack/damage  Replace. EAM30115 CHECKING THE PUSH LEVER SHAFT 1. Check: • Push lever shaft Wear/damage  Replace. EAM30112 CHECKING THE CLUTCH HOUSING 1.
  • Page 243 CLUTCH the primary drive and primary driven gears as a set. 2. Check: • Primary-drive-gear-to-primary-driven-gear free play Free play exists  Replace the primary drive and primary driven gears as a set. EAM30118 CHECKING THE PRIMARY DRIVEN GEAR 1. Check: •...
  • Page 244 CLUTCH • Bearing “2” • Collar “3” • Primary driven gear “4” • Thrust washer “5” • Clutch boss “6” Apply the engine oil on the primary driven gear inner circumference. 3. Install: • Lock washer “1” • Clutch boss nut “2” Clutch boss nut 75 N·m (7.5 kgf·m, 55 lb·ft) ECA24660...
  • Page 245 CLUTCH 5. Install: 7. Install: • Friction plate 1 “1” • Push rod 2 “1” • Clutch plate “2” • Ball “2” • Cushion spring “3” • Push rod 1 “3” • Friction plate 2 “4” Apply the engine oil on the push rod 1, 2 and •...
  • Page 246 CLUTCH 10.Install: • Gasket “1” 11.Install: • Clutch cover “1” • 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 pattern. 5-47...
  • Page 247 SHIFT SHAFT EAM20113 SHIFT SHAFT Removing the shift shaft and stopper lever 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 10 N ・...
  • Page 248 SHIFT SHAFT EAM30123 REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1. Remove: • Bolt (shift guide) • Shift guide “1” • Shift lever assembly “2” Make sure that the shift lever assembly is re- moved together with the shift guide. EAM30126 CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY...
  • Page 249 SHIFT SHAFT • Stopper lever “3” (to the shift lever “4”) • Bolt (stopper lever) “4” Apply the engine oil on the spring, pawl pin and Bolt (stopper lever) pawl. 10 N·m (1.0 kgf·m, 7.4 lb·ft) LOCTITE® 2. Install: • Shift lever assembly “1” (to the shift guide “2”) EAM30129 INSTALLING THE SEGMENT...
  • Page 250 SHIFT SHAFT EAM30131 INSTALLING THE SHIFT SHAFT 1. Install: • Roller “1” • Shift shaft spring “2” (to shift shaft) • Collar “3” (to shift shaft) • Shift shaft “4” Apply the engine oil on the roller, collar and shift shaft.
  • Page 251 OIL PUMP AND BALANCER GEAR EAM20114 OIL PUMP AND BALANCER GEAR 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...
  • Page 252 OIL PUMP AND BALANCER GEAR Removing the balancer 38 N ・ m (3.8 kgf ・ m, 28 lb ・ ft) 75 N ・ m (7.5 kgf ・ m, 55 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 50 N ・...
  • Page 253 OIL PUMP AND BALANCER GEAR EAM30133 REMOVING THE BALANCER 1. Loosen: • Balancer nut “1” • Primary drive gear nut “2” • Balancer weight gear nut “3” Place an aluminum plate “a” between the teeth of the balancer drive gear “4” and balancer weight gear “5”.
  • Page 254 OIL PUMP AND BALANCER GEAR Inner-rotor-to-outer-rotor-tip • Apply the engine oil on the oil pump drive shaft clearance and inner rotor. 0.000–0.150 mm (0.0000–0.0059 • Fit the dowel pin into the groove in the inner ro- tor. Limit 0.23 mm (0.0091 in) Outer-rotor-to-oil-pump-housing clearance 0.13–0.18 mm (0.0051–0.0071 in)
  • Page 255 OIL PUMP AND BALANCER GEAR • Oil pump assembly bolt “2” Oil pump assembly bolt 5 N·m (0.5 kgf·m, 3.7 lb·ft) LOCTITE® ECA13890 NOTICE After tightening the bolts, make sure the oil pump turns smoothly. 2. Install: 4. Install: • Collar “1” •...
  • Page 256 OIL PUMP AND BALANCER GEAR 5-57...
  • Page 257 GENERATOR AND STARTER CLUTCH EAM20115 GENERATOR AND STARTER CLUTCH Removing the generator 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 65 N ・...
  • Page 258 GENERATOR AND STARTER CLUTCH Removing the generator 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 65 N ・...
  • Page 259 GENERATOR AND STARTER CLUTCH Burrs/chips/roughness/wear  Replace the EAM30139 REMOVING THE GENERATOR defective part(s). 1. Remove: 3. Check: • Generator rotor nut “1” • Starter clutch gear • Washer Damage/pitting/wear  Replace the starter clutch gear. 4. Check: • Damper assembly Damage/pitting/wear ...
  • Page 260 “7” under the holder as shown. • Tighten the stator bolt using the T25 bit. • Apply the sealant to the grommet of the AC magneto lead. Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) Starter clutch bolt 16 N·m (1.6 kgf·m, 12 lb·ft) LOCTITE®...
  • Page 261 GENERATOR AND STARTER CLUTCH 2. Install: • Washer • Generator rotor nut “1” Generator rotor nut 65 N·m (6.5 kgf·m, 48 lb·ft) 3. Install: • Starter idle gear shaft “1” • Bearing “2” • Starter idle gear 2 “3” 5. Install: Apply the engine oil on the starter idle gear shaft, •...
  • Page 262 GENERATOR AND STARTER CLUTCH 5-63...
  • Page 263 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) 10 N ・...
  • Page 264 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 265 CRANKCASE EAM30147 DISASSEMBLING THE CRANKCASE 1. Separate: • Right crankcase • Left crankcase ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the crankcase bolts. c. Remove the dowel pins and O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAM30148 REMOVING THE CRANKCASE BEARING 1. Remove: • Bearing “1” Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them.
  • Page 266 Bearing cover plate screw (crank- shaft) 22 N·m (2.2 kgf·m, 16 lb·ft) LOCTITE® Install the bearing by pressing its outer race par- allel. 2. Apply: • Sealant (to the crankcase mating surface) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 5-67...
  • Page 267 CRANKCASE 4. 45 mm (1.77 in) 5. 60 mm (2.36 in) 6. 75 mm (2.95 in) a. Hexagon socket head bolt without flange b. Hexagon socket head bolt with flange 5-68...
  • Page 268 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EAM20117 CRANKSHAFT ASSEMBLY 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 5-64. Transmission Refer to “TRANSMISSION” on page 5-72. Balancer shaft Crankshaft assembly 5-69...
  • Page 269 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EAM30144 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: • Crankshaft assembly “1” Remove the crankshaft assembly by using the crankcase separating tool “2”. Crankcase separating tool 90890-04152 Crankcase separating tool YU-A9642 2. Measure: • Crank assembly width “a” Out of specification ...
  • Page 270 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT adapter (M12) “3” and spacer “4”. EAM30381 INSTALLING THE BALANCER SHAFT 1. Install: Crankshaft installer pot • Balancer shaft “1” 90890-01274 Installing pot Apply the molybdenum grease to the part “a” YU-90058 where the balancer shaft fit into the bearing. Crankshaft installer bolt 90890-01275 ECA25850...
  • Page 271 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 5-1. Separate. Crankcase Refer to “CRANKCASE” on page 5-64. Main axle Drive axle Long shift fork guide bar Short shift fork guide bar Spring Shift cam...
  • Page 272 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 273 TRANSMISSION sembly. • Transmission gear dogs Cracks/damage/rounded edges  Replace the defective gear(s). 4. Check: • Transmission gear movement Rough movement  Replace the defective gear(s). EAM30157 INSTALLING THE TRANSMISSION 1. Install: • 6th pinion gear (27T) “1” • 3rd/4th pinion gear (18T/21T) “2” EAM30156 •...
  • Page 274 TRANSMISSION 5. Install: 3. Install: • Main axle “1” • Washer “1” • Drive axle “2” • Circlip “2” • Install to the left crankcase simultaneously. • Be sure the circlip sharp-edged corner “a” is • Apply engine oil to the main axle and the drive positioned opposite side to the washer and axle bearing.
  • Page 275 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 276 TRANSMISSION 5-77...

  • Page 277: Cooling System

    COOLING SYSTEM RADIATOR......................6-1 HANDLING NOTE ..................6-3 CHECKING THE RADIATOR ..............6-3 WATER PUMP ....................6-4 REMOVING THE OIL SEAL ...............6-5 CHECKING THE WATER PUMP ...............6-5 CHECKING THE BEARING ...............6-5 INSTALLING THE OIL SEAL..............6-5 ASSEMBLING THE WATER PUMP ............6-5...
  • Page 278 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) 10 N ・...
  • Page 279 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) 10 N ・...
  • Page 280 RADIATOR EAM30257 HANDLING NOTE EWA19360 WARNING If coolant seems hot, do not remove the radi- ator cap. EAM30341 CHECKING THE RADIATOR 1. Check: • Radiator fins “1” Obstructions  Clean. Apply compressed air to the rear of the radia- tor. Damage ...
  • Page 281 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) Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT”...
  • Page 282 WATER PUMP EAM30258 REMOVING THE OIL SEAL • 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 283 WATER PUMP • Gasket “2” 3. 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 284 WATER PUMP...

  • Page 285: 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 INSTALLING THE FUEL PUMP ..............7-2 REMOVING THE FUEL SENDER ..............7-3 CHECKING THE FUEL SENDER ..............7-3 INSTALLING THE FUEL SENDER ............7-3 INSTALLING THE FUEL TANK ..............7-3 CHECKING THE FUEL PRESSURE............7-4 CHECKING THE DAMPER ................7-4...
  • Page 286 FUEL TANK EAM20140 FUEL TANK Removing the fuel tank 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 4.0 N ・...

  • Page 287: Removing The Fuel Tank

    FUEL TANK 3. Remove: EAM30263 REMOVING THE FUEL TANK • Side cover (left/right) 1. Extract the fuel in the fuel tank through the • Seat fuel tank cap with a pump. • Air scoop (left/right) 2. Remove: • Fuel tank •...

  • Page 288: Removing The Fuel Sender

    FUEL TANK EAM30344 INSTALLING THE FUEL SENDER 1. Install: • Fuel sender gasket • Fuel sender Fuel sender bolt 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) • Do not damage the installation surfaces of the fuel tank when installing the fuel sender. •...

  • Page 289: Checking The Fuel Pressure

    FUEL TANK 3. Connect: e. Start the engine. • Fuel pump coupler f. Measure the fuel pressure. Out of specification  Replace the fuel 4. Install: • Air scoop (left/right) pump. • Seat Fuel line pressure (at idle) • Side cover (left/right) 300–390 kPa (3.0–3.9 kgf/cm², Refer to “GENERAL CHASSIS”...
  • Page 290 FUEL TANK 0 mm (0 in) 15 mm (0.59 in) A. Left B. Right...

  • Page 291: Throttle Body

    THROTTLE BODY EAM20141 THROTTLE BODY Removing the throttle body 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 3.5 N ・...
  • Page 292 THROTTLE BODY Removing the throttle body 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 3.5 N ・...
  • Page 293 THROTTLE BODY Removing the injector 3.4 N ・ m (0.34 kgf ・ m, 2.5 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 3.4 N ・ m (0.34 kgf ・ m, 2.5 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 294: Checking The Injector

    THROTTLE BODY EAM30271 CHECKING THE INJECTOR 1. Check: • Injectors Obstruction  Replace, and check the fuel pump and the fuel injection system. Refer to “FUEL INJECTION SYSTEM” on page 8-19. Deposits  Replace. Damage  Replace. 2. Check: • Injector resistance Refer to “CHECKING THE FUEL INJEC- TOR”...

  • Page 295: 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 “diagnostic mode”. f. Choose the diagnostic code No. “01”. g. Adjust the throttle position sensor mounted angle until “11”–“14”...
  • Page 296 THROTTLE BODY 7-11...

  • Page 297: Electrical System

    FUEL INJECTION SYSTEM ................8-19 CIRCUIT DIAGRAM .................8-19 ECU SELF-DIAGNOSTIC FUNCTION .............8-21 TROUBLESHOOTING METHOD .............8-22 YAMAHA DIAGNOSTIC TOOL ..............8-23 FEATURES OF THE YAMAHA DIAGNOSTIC TOOL ......8-23 FUNCTIONS OF THE YAMAHA DIAGNOSTIC TOOL ......8-23 CONNECTING THE YAMAHA DIAGNOSTIC TOOL .......8-23 TROUBLESHOOTING DETAILS..............8-25 FUEL PUMP SYSTEM..................8-45 CIRCUIT DIAGRAM .................8-45...
  • Page 298 CHECKING THE RESISTOR ..............8-65 CHECKING THE COOLANT TEMPERATURE SENSOR ......8-66 CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE...8-66 CHECKING THE INTAKE AIR TEMPERATURE SENSOR .....8-67 CHECKING THE FUEL INJECTOR ............8-67...

  • Page 300: Ignition System

    IGNITION SYSTEM EAM20142 IGNITION SYSTEM EAM30277 CIRCUIT DIAGRAM...
  • Page 301 IGNITION SYSTEM 1. Joint connector 2. Joint connector 4. AC magneto 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 21.ECU (Engine Control Unit) 22.Ignition coil 23.Spark plug 29.Joint connector 34.Lean angle sensor 35.Engine stop switch 41.Frame ground 42.Ignition coil sub-lead...

  • Page 302: Troubleshooting

    IGNITION SYSTEM EAM30278 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 5. Air filter case cover 1. Check the fuse. Refer to “CHECKING THE FUSES”...
  • Page 303 IGNITION SYSTEM 9. Check the entire ignition system’s wiring. Properly connect or repair the ignition sys- Refer to “CIRCUIT DIAGRAM” on tem’s wiring. NG page 8-1. OK Replace the ECU.

  • Page 304: Electric Starting System

    ELECTRIC STARTING SYSTEM EAM20143 ELECTRIC STARTING SYSTEM EAM30279 CIRCUIT DIAGRAM...
  • Page 305 ELECTRIC STARTING SYSTEM 1. Joint connector 2. Joint connector 3. Joint connector 6. Main relay 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 12.Starter motor 13.Starter relay diode 21.ECU (Engine Control Unit) 29.Joint connector 35.Engine stop switch 36.Neutral switch 37.Diode 38.Starting circuit cut-off relay 39.Clutch switch...

  • Page 306: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAM30280 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION The starter motor can only operate if at least one of the following conditions is met: • The transmission is in neutral (the neutral switch is closed). • The clutch lever is pulled to the handlebar (the clutch switch is closed). The starting circuit cut-off relay prevents the starter motor from operating when neither of these condi- tions has been met.
  • Page 307 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main relay 4. Starting circuit cut-off relay 5. Start switch 6. Diode 7. Clutch switch 8.

  • Page 308: 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 309 ELECTRIC STARTING SYSTEM 9. Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch. NG SWITCHES” on page 8-53. OK 10.Check the clutch switch. Refer to “CHECKING THE Replace the clutch switch. NG SWITCHES” on page 8-53. OK 11.Check the engine stop switch.

  • Page 310: Charging System

    CHARGING SYSTEM EAM20144 CHARGING SYSTEM EAM30282 CIRCUIT DIAGRAM 8-11...
  • Page 311 CHARGING SYSTEM 4. AC magneto 5. Rectifier/regulator 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 43.Negative battery lead 8-12...

  • Page 312: Troubleshooting

    CHARGING SYSTEM EAM30283 TROUBLESHOOTING The battery is not being charged. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 1. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse(s). NG on page 8-56. OK 2. Check the battery. •...
  • Page 313 CHARGING SYSTEM 8-14...

  • Page 314: Signaling System

    SIGNALING SYSTEM EAM20154 SIGNALING SYSTEM EAM30348 CIRCUIT DIAGRAM 8-15...
  • Page 315 SIGNALING SYSTEM 1. Joint connector 2. Joint connector 3. Joint connector 6. Main relay 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 14.Warning light 16.Fuel level warning light 17.Resistor 18.Fuel sender 21.ECU (Engine Control Unit) 29.Joint connector 41.Frame ground 43.Negative battery lead 8-16...

  • Page 316: Troubleshooting

    SIGNALING SYSTEM EAM30349 TROUBLESHOOTING The fuel level warning light does not come on. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 1. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse(s).
  • Page 317 SIGNALING SYSTEM 4. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. NG page 8-15. OK Replace the ECU. 8-18...

  • Page 318: Fuel Injection System

    FUEL INJECTION SYSTEM EAM20145 FUEL INJECTION SYSTEM EAM30284 CIRCUIT DIAGRAM 8-19...
  • Page 319 FUEL INJECTION SYSTEM 1. Joint connector 2. Joint connector 3. Joint connector 4. AC magneto 6. Main relay 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 14.Warning light 15.Engine trouble warning light 21.ECU (Engine Control Unit) 24.Injector 29.Joint connector 30.Intake air temperature sensor 31.Coolant temperature sensor 32.Throttle position sensor...

  • Page 320: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM EAM30352 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 321: Troubleshooting Method

    • Fault code number ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the Yamaha diagnostic tool. Refer to “YAMAHA DIAGNOSTIC TOOL” on page 8-23. b. Check the fault code number displayed on the Yamaha diagnostic tool. c. Identify the faulty system with the fault code number.

  • Page 322: Yamaha Diagnostic Tool

    FUEL INJECTION SYSTEM EAM30285 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool USB (US) 90890-03257...
  • Page 323 NOTICE In order to avoid short circuit, insulate the battery connection terminals of the FI diagnostic tool sub-lead. For information on how to connect and use the Yamaha diagnostic tool, refer to “YAMAHA DIAGNO- STIC TOOL OPERATION MANUAL”. 1. Vehicle 2.

  • Page 324: Troubleshooting Details

    FUEL INJECTION SYSTEM EAM30286 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the diagnostic tool. Check and service the items or components that are the probable cause of the malfunction following the order giv- After the check and service of the malfunctioning part have been completed, reset the diagnostic tool display according to the reinstatement method.
  • Page 325 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received from Item the crankshaft position sensor. Defective crankshaft position Check the crankshaft position Crank the engine. sensor. sensor. Fault code number is not dis- played  Service is finished. Refer to “CHECKING THE CRANKSHAFT POSITION Fault code number is displayed...
  • Page 326 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Improperly installed sensor  Installed condition of intake air Push the start switch. pressure sensor. Reinstall or replace the sensor. Fault code number is not dis- played ...
  • Page 327 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged or Item detached hose). Defective intake air pressure Execute the diagnostic mode. sensor. (Code No. 03) When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is indicated.
  • Page 328 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Open or short circuit  Replace Wire harness continuity. Push the start switch. the wire harness. Fault code number is not dis- played  Service is finished. Between throttle position sensor coupler and ECU coupler.
  • Page 329 FUEL INJECTION SYSTEM Fault code No. 16 Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Item Throttle position sensor: stuck throttle position sensor is detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 330 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 331 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 332 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Defective intake air tempera- Execute the diagnostic mode. Push the start switch. ture sensor. (Code No. 05) Fault code number is not dis- played  Service is finished. When engine is cold: Displayed temperature is close Fault code number is displayed...
  • Page 333 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 334 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 335 FUEL INJECTION SYSTEM Fault code No. Item Injector: open or short circuit detected. Delete the fault code. — Start the engine and let it idle for approximately 5 seconds. Check that the fault code num- ber is not displayed. Fault code No. 41 Before troubleshooting, disconnect the starter motor lead from the starter relay.
  • Page 336 FUEL INJECTION SYSTEM Fault code No. 43 Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel injector Item and fuel pump. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Fuel system voltage Diagnostic tool display Approximately 12.0 (V) Procedure...
  • Page 337 FUEL INJECTION SYSTEM Fault code No. 44 Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. EEPROM fault code number: an error is detected while reading or Item writing on EEPROM. Able/Unable to start engine Fail-safe system Able/Unable to drive vehicle Diagnostic code No.
  • Page 338 FUEL INJECTION SYSTEM Fault code No. 46 Fault code No. Item Charging voltage is abnormal. Able/Unable to start engine Fail-safe system Able/Unable to drive vehicle Diagnostic code No. — Diagnostic tool display — Procedure — Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check...
  • Page 339 Confirmation of service com- Item Maintenance job tion and check pletion Improperly connected  Con- Connection of Yamaha diagnos- Push the start switch. tic tool coupler. nect the coupler securely or Fault code number is not dis- played  Service is finished.
  • Page 340 Confirmation of service com- Item Maintenance job tion and check pletion Improperly connected  Con- Connection of Yamaha diagnos- Push the start switch. tic tool coupler. nect the coupler securely or Fault code number is not dis- played  Service is finished.
  • Page 341 Confirmation of service com- Item Maintenance job tion and check pletion Improperly connected  Con- Connection of Yamaha diagnos- Push the start switch. tic tool coupler. nect the coupler securely or Fault code number is not dis- played  Service is finished.
  • Page 342 FUEL INJECTION SYSTEM Fault code No. Er-4 Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Er-4 Registered data cannot be received from the Yamaha diagnostic Item tool. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 343 FUEL INJECTION SYSTEM 8-44...

  • Page 344: Fuel Pump System

    FUEL PUMP SYSTEM EAM20146 FUEL PUMP SYSTEM EAM30287 CIRCUIT DIAGRAM 8-45...
  • Page 345 FUEL PUMP SYSTEM 1. Joint connector 2. Joint connector 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 21.ECU (Engine Control Unit) 25.Fuel pump 29.Joint connector 35.Engine stop switch 41.Frame ground 8-46...

  • Page 346: 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 1. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse(s). NG...
  • Page 347 FUEL PUMP SYSTEM 8-48...

  • Page 348: Electrical Components

    ELECTRICAL COMPONENTS EAM20147 ELECTRICAL COMPONENTS 8-49...
  • Page 349 ELECTRICAL COMPONENTS 1. Rectifier/regulator 2. Clutch switch 3. Ignition coil 4. ECU (Engine Control Unit) 5. Fuel sender 6. Fuel pump 7. Battery 8. Resistor 9. Neutral switch 10.Injector 8-50...
  • Page 350 ELECTRICAL COMPONENTS 8-51...
  • Page 351 ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. Intake air pressure sensor 3. Throttle position sensor 4. Starter relay 5. Main fuse 6. Starting circuit cut-off relay 7. Lean angle sensor 8. Radiator fan motor fuse 9. Radiator fan motor relay 10.Main relay 11.Coolant temperature sensor 8-52...

  • Page 352: Checking The Switches

    ELECTRICAL COMPONENTS EAM30289 CHECKING THE SWITCHES 8-53...
  • Page 353 ELECTRICAL COMPONENTS 1. Engine stop switch 2. Neutral switch 3. Clutch switch 4. Start switch 8-54...
  • Page 354 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 355: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS however, note the following. EAM30357 CHECKING THE BULBS AND BULB SOCKETS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install a good bulb into the bulb socket. 1. Remove: • Bulb b. Connect the digital circuit tester probes to the respective leads of the bulb socket. ECA25930 NOTICE c.
  • Page 356 ELECTRICAL COMPONENTS • Charge batteries in a well-ventilated area. Digital circuit tester (CD732) • Keep batteries away from fire, sparks or 90890-03243 open flames (e.g., welding equipment, Model 88 Multimeter with tachom- lighted cigarettes). eter • DO NOT SMOKE when charging or han- YU-A1927 dling batteries.
  • Page 357 ELECTRICAL COMPONENTS ECA13640 NOTICE First, disconnect the negative battery lead “1”, and then positive battery lead “2”. A. Open-circuit voltage (V) B. Charging time (hours) C. Relationship between the open-circuit volt- age and the charging time at 20 C (68 F) D.
  • Page 358 ELECTRICAL COMPONENTS plug in the battery charger until the battery high, the battery will be over-charged. charger leads are connected to the battery. c. Make sure that the current is higher than the • Before removing the battery charger lead standard charging current written on the bat- clips from the battery terminals, be sure to tery.

  • Page 359: Checking The Relays

    ELECTRICAL COMPONENTS Digital circuit tester (CD732) Set the charging time at 20 hours (maximum). 90890-03243 Model 88 Multimeter with tachom- e. Measure the battery open-circuit voltage after eter leaving the battery unused for more than 30 YU-A1927 minutes. 12.8 V or more --- Charging is complete. 1.

  • Page 360: Checking The Diode

    ELECTRICAL COMPONENTS Starting circuit cut-off relay ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the diode from the wire harness. b. Connect the digital circuit tester () to the di- ode coupler as shown. c. Check the diode for continuity. d. Check the diode for no continuity. L/G,L/W 1.

  • Page 361: Checking The Spark Plug Cap

    ELECTRICAL COMPONENTS EAM30296 CHECKING THE IGNITION COIL 1. Disconnect: • Ignition coil terminal (from the sub wire harness) • Spark plug cap (from the ignition coil) 2. Check: • Primary coil resistance Out of specification  Replace. Primary coil resistance 2.

  • Page 362: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachom- eter YU-A1927 • Positive tester probe  Ignition coil terminal 1 “1” • Negative tester probe  Spark plug lead “2” b. Measure the crankshaft position sensor re- sistance.

  • Page 363: Checking The Starter Motor Operation

    ELECTRICAL COMPONENTS EAM30300 CHECKING THE STATOR COIL 1. Disconnect: • Stator coil coupler (from the wire harness) 2. Check: • Stator coil resistance Out of specification  Replace the stator coil. Stator coil resistance 0.528–0.792  c. Incline the lean angle sensor. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 364: Checking The Fuel Sender

    ELECTRICAL COMPONENTS Regulated voltage (DC) Sender unit resistance (full) 14.1–14.9 V 1350.0–1900.0  ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the digital tachometer to the ignition coil. a. Connect the digital circuit tester () to the fuel sender as shown. Digital tachometer 90890-06760 Digital circuit tester (CD732) Digital tachometer 90890-03243...

  • Page 365: Checking The Coolant Temperature Sensor

    ELECTRICAL COMPONENTS • Positive tester probe  • Positive tester probe  Black “1” Green/White “1” • Negative tester probe  • Negative tester probe  Black “2” Black/Blue “2” b. Measure the resistance of the resister. b. Immerse the coolant temperature sensor in a container filled with coolant.

  • Page 366: Checking The Intake Air Temperature Sensor

    ELECTRICAL COMPONENTS and the wire harness. Intake air temperature sensor re- b. Connect the digital circuit tester (DC) to the sistance test harness S– pressure sensor (3P). 5400–6600  at 0 C (5400–6600  at 32 F) Digital circuit tester (CD732) Intake air temperature sensor re- 90890-03243 sistance...
  • Page 367 ELECTRICAL COMPONENTS Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachom- eter YU-A1927 • Positive tester probe  Injector terminal “1” • Negative tester probe  Injector terminal “2” c. Measure the fuel injector resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 8-68...
  • Page 368 ELECTRICAL COMPONENTS 8-69...

  • Page 369: Troubleshooting

    FRONT FORK OIL LEAKING ..............9-3 FAULTY FRONT FORK LEGS ..............9-3 UNSTABLE HANDLING ................9-3 LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS ......9-4 LIST OF DIAGNOSTIC CODES ..............9-4 COMMUNICATION ERROR WITH YAMAHA DIAGNOSTIC TOOL ..9-4 SENSOR OPERATION TABLE ..............9-5 ACTUATOR OPERATION TABLE .............9-6...

  • Page 370: Troubleshooting

    TROUBLESHOOTING 2. Fuse EAM20148 TROUBLESHOOTING • Blown, damaged or incorrect fuse • Improperly installed fuse EAM30309 3. Spark plug GENERAL INFORMATION • Incorrect spark plug gap • Incorrect spark plug heat range The following guide for troubleshooting does not • Fouled spark plug cover all the possible causes of trouble.

  • Page 371: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING 3. Ignition coil EAM30316 CLUTCH SLIPS • Broken or shorted primary or secondary coils Engine • Cracked or broken ignition coil 1. Clutch 4. Ignition system • Improperly assembled clutch • Faulty ECU • Loose or fatigued clutch spring •...

  • Page 372: Overcooling

    TROUBLESHOOTING Fuel system EAM30321 FAULTY FRONT FORK LEGS 1. Throttle body Chassis • Damaged or loose throttle body joint 1. Front fork 2. Air filter • Bent or damaged inner tube • Clogged air filter element • Bent or damaged outer tube Chassis •...

  • Page 373: Communication Error With Yamaha Diagnostic Tool

    No communication signal is received from the ECU. 8-40 connection Er-2 Signals from the ECU cannot be received within the specified period of time. 8-41 Er-3 Data from the ECU cannot be received correctly. 8-42 Er-4 Registered data cannot be received from the Yamaha diagnostic tool. 8-43...

  • Page 374: Sensor Operation Table

    OK.) Intake air temperature Displays the intake air tempera- Compare the actually mea- ture. sured intake air temperature with the Yamaha diagnostic tool display value. Coolant temperature Displays the coolant tempera- Compare the actually mea- ture. sured coolant temperature with the Yamaha diagnostic tool display value.

  • Page 375: Actuator Operation Table

    Ignition coil Actuates the ignition coil five Check that a spark is gener- times at one-second intervals. ated five times. “WARNING” on the Yamaha • Connect an ignition checker. diagnostic tool blinks five times when the ignition coil is actu- ated.
  • Page 376 LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS...

  • Page 377: 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 378: Chassis

    CHASSIS EAM20119 EAM30169 CHASSIS DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS EAM30168 Part name Type Part number SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET) Drive sprocket “1” (STD) 9383B-13218 Secondary reduction ratio = Number of rear wheel sprocket teeth/Number of Rear wheel sprocket drive sprocket teeth “2”...

  • Page 379: Change In Amount And Characteristics Of Fork Oil

    CHASSIS • Under a stony or a hard road condition, the tire pressure should be higher to prevent a flat tire. Extent of adjustment 100–120 kPa (1.00–1.20 kgf/cm 15–18 psi) EAM30171 FRONT FORK SETTING The front fork setting should be made depending on the rider’s feeling of an actual run and the cir- cuit conditions.

  • Page 380: Rear Suspension Setting

    CHASSIS 2. Setting of damping force • Change the rebound damping force. Generally a stiff spring gives a stiff riding feeling. • Change the compression damping force. Rebound damping tends to become weaker, re- sulting in lack of a sense of contact with the road EAM30176 surface or in a vibrating handlebar.

  • Page 381: Setting Of Spring After Replacement

    CHASSIS EAM30177 EAM30178 SETTING OF SPRING AFTER REAR SHOCK ABSORBER SETTING PARTS REPLACEMENT • Rear shock spring “1” After replacement, be sure to adjust the spring to Spring I.D. the set length [sunken length 90–100 mm (3.5– Type rate Part number Mark 3.9 in)] and set it.
  • Page 382 CHASSIS Spring preload adjusting position Minimum Position in which the spring is turned in 1.5 mm (0.06 in) from its free length. Standard Position in which the spring is turned in 10.0 mm (0.39 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 383: 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 384: 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 385 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 386: Kickstarter Kit (Optional Parts)

    KICKSTARTER KIT (OPTIONAL PARTS) EAM20167 KICKSTARTER KIT (OPTIONAL PARTS) EAM30393 PARTS LOCATION Order Part name Part number Q’ty Remarks Kick starter kit B29-15602-00 Kick shaft assembly 1SM-15601-00 Kick gear 1SM-15641-00 Washer 90201-20685 Circlip 93410-20038 Ratchet wheel 2S2-15671-00 Spring 90501-160A2 Washer 90201-167P7 Thickness: 1.5 mm (0.059 in) Circlip...
  • Page 387 KICKSTARTER KIT (OPTIONAL PARTS) Order Part name Part number Q’ty Remarks Circlip 99009-17400 Kickstarter lever assembly 1SM-15620-00 Kickstarter lever boss 1SM-15621-00 Spring 90501-147A5 Ball 93507-32009 Screw 90151-06045 O-ring 93210-17570 Bolt 90110-08051 Washer 90201-08048 Crankcase cover gasket 1SM-15462-00 10-10...

  • Page 388: Setup Procedures

    KICKSTARTER KIT (OPTIONAL PARTS) EAM30394 SETUP PROCEDURES Installing the kick shaft 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) Order Part name Q’ty Remarks Remove. Clutch and right crankcase cover Refer to “CLUTCH” on page 5-39. Remove.

  • Page 389: Installing The Kick Shaft

    KICKSTARTER KIT (OPTIONAL PARTS) EAM30447 INSTALLING THE KICK SHAFT 1. Install: • Stopper “1” • Ratchet wheel guide “2” • Bolt (ratchet wheel guide) “3” Bolt (ratchet wheel guide) 12 N·m (1.2 kgf·m, 8.9 lb·ft) LOCTITE® 4. Install: • Torsion spring “1” Turn the torsion spring clockwise and hook into the proper hole “a”...

  • Page 390: Setup Procedure (Kickstarter Lever)

    KICKSTARTER KIT (OPTIONAL PARTS) EAM30397 SETUP PROCEDURE (KICKSTARTER LEVER) Installing the kickstarter lever 33 N ・ m (3.3 kgf ・ m, 24 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Part name Q’ty Remarks Remove.

  • Page 391: Installing The Kickstarter Lever

    KICKSTARTER KIT (OPTIONAL PARTS) EAM30446 INSTALLING THE KICKSTARTER LEVER 1. Install: • Oil seal “1” (to the right crank case cover) • Apply the lithium-soap-based grease on the oil seal lip. • Install the oil seal with its numbers facing the outside.
  • Page 392 KICKSTARTER KIT (OPTIONAL PARTS) metal-to-metal moving parts. Check the kickstarter lever movement and lubri- cation for every race. Checking the kickstarter kit 1. Check: • Ratchet wheel “1” smooth movement Unsmooth movement  Replace. • Kick shaft “2” Installing the kickstarter kit Wear/damage ...
  • Page 393 KICKSTARTER KIT (OPTIONAL PARTS) 3. Install: • Spring guide “1” Slide the spring guide into the kick shaft, make sure the groove “a” in the spring guide fits on the stopper of the torsion spring. 4. Install: • Kick shaft assembly Refer to“SETUP PROCEDURES”...
  • Page 394 EAM20149 EAM30323 WIRING DIAGRAM COLOR CODE Black YZ250FXK 2019 Brown 1. Joint connector Green 2. Joint connector Gray 3. Joint connector Blue 4. AC magneto Light green 5. Rectifier/regulator Orange 6. Main relay Pink 7. Engine ground 8. Battery Sky blue 9.
  • Page 395 For your best ownership experience, think Genuine Yamaha! 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.
  • Page 396 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2018.04-0.3×1 !
  • Page 397 YZ250FXK 2019 WIRING DIAGRAM Br Br R R R/L Br Br R R R R/L Br Br Br Br B/L Gy (Gy) (Gy) W W W W W W Br Br Br Br L/Y Y/W R/L R/B (Gy) Br/W Br/W Br/W,Br Br/W R/W,Br...
  • Page 398 YZ250FXK 2019 WIRING DIAGRAM (Gy) (Gy) (Gy)

This manual is also suitable for:

Yz250fx 2019Yz250fxk 2019

Table of Contents