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Yamaha YZ 2020 Series Owner's Service Manual

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2020
OWNER'S SERVICE MANUAL
YZ250FX
Read this manual carefully before operating this vehicle.
YZ250FXL1
LIT-11626-33-34
BAJ-28199-10

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  • Page 1 2020 OWNER’S SERVICE MANUAL YZ250FX Read this manual carefully before operating this vehicle. YZ250FXL1 LIT-11626-33-34 BAJ-28199-10...
  • 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 EAM20161 Read this manual carefully Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. FCC CAUTION Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment.
  • Page 4 EAM20080 YZ250FXL1 OWNER’S SERVICE MANUAL ©2020 by Yamaha Motor Corporation, U.S.A. First edition, July 2019 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-11626-33-34...
  • Page 5 EAM20180 IMPORTANT Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.
  • Page 6 EAM20162 YAMAHA MOTOR CORPORATION, U.S.A. YZ MOTORCYCLE LIMITED WARRANTY...
  • Page 7 EAM20082 HOW TO USE THIS MANUAL In this manual, descriptions of installation, removal, disassembly, assembly, check, and adjustment procedures are laid out with the individual steps in sequential order. • The manual is divided into chapters and each chapter is divided into sections. The current section title “1”...
  • Page 8 EAM20083 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...

  • Page 9: Table Of Contents

    TABLE OF CONTENTS EAM10003 GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING TUNING...
  • Page 11 GENERAL INFORMATION SAFETY INFORMATION ..................1-1 FOR SAFETY, BE SURE TO OBEY THE FOLLOWING:......1-1 LOCATION OF IMPORTANT LABELS.............1-4 DESCRIPTION....................1-5 IDENTIFICATION ....................1-6 VEHICLE IDENTIFICATION NUMBER ............1-6 ENGINE SERIAL NUMBER................1-6 INCLUDED PARTS ...................1-7 NIPPLE WRENCH ..................1-7 HANDLEBAR PROTECTOR ..............1-7 FUEL HOSE JOINT COVER ..............1-7 POWER TUNER ..................1-7 IMPORTANT INFORMATION ................1-9 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-9...
  • Page 12 STARTING A WARM ENGINE ..............1-26 BREAK-IN PROCEDURES ..............1-26 ENGINE STARTING PRECAUTION ............1-26 MAINTENANCE AFTER BREAK-IN ..............1-27 MAJOR MAINTENANCE ................1-27 AIR FILTER MAINTENANCE ..............1-27 TORQUE-CHECK POINTS................1-28 MOTORCYCLE CARE AND STORAGE............1-30 CARE ......................1-30 STORAGE ....................1-31...

  • Page 13: Safety Information

    Yamaha machine, and take care to maintain it accidents. Many accidents have been properly and operate it safely. caused by an automobile driver who did not see the motorcycle.
  • Page 14 1. Always wear an approved helmet. Yamaha can neither endorse nor recommend 2. Wear a face shield or goggles. Wind in your the use of accessories not sold by Yamaha or unprotected eyes could contribute to an im- modifications not specifically recommended by...
  • Page 15 SAFETY INFORMATION cause a dangerous loss of lights or engine power. Aftermarket Tires and Rims The tires and rims that came with your motorcy- cle were designed to match the performance ca- pabilities and to provide the best combination of handling, braking, and comfort.

  • Page 16: Location Of Important Labels

    LOCATION OF IMPORTANT LABELS EAM20085 LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle. 3, 4 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...

  • Page 17: Description

    DESCRIPTION EAM20086 DESCRIPTION 2, 3 15 14 1. Clutch lever 11.Fuel tank 12.Radiator 2. Engine trouble warning light “ ” 13.Coolant drain bolt 3. Fuel level warning light “ ” 14.Oil level check window 4. Front brake lever 15.Rear brake pedal 5.

  • Page 18: Identification

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

  • Page 19: Included Parts

    INCLUDED PARTS EAM20088 EWA20460 INCLUDED PARTS WARNING • Do not operate the engine in a closed area. EAM30005 The exhaust gas is poisonous. NIPPLE WRENCH • Never let flames near the servicing area. The nipple wrench “1” is used to tighten the spoke.
  • Page 20 INCLUDED PARTS 2. Remove the CCU and record the CCU serial 1. Turn on the smartphone. number. 2. For two minutes after the start switch is pressed or while the engine is running (the CCU is activated), input the CCU serial num- ber into your smartphone and establish a wireless connection.

  • Page 21: Important Information

    2. Use proper special tools and equipment. Re- used for repair of the vehicle, including periodic fer to “SPECIAL TOOLS” on page 1-15. replacement parts, are new YAMAHA genuine parts and recommended parts. Do not use any used parts, because these may...

  • Page 22: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION 1. Oil 2. Lip 3. Spring 4. Grease EAM30012 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace lock washers/plates “1” and cotter pins with new ones. After the bolt or nut has been tightened to specification, firmly bend the lock tabs along a flat of the bolt or nut. EAM30014 CIRCLIPS When assembling parts, always use new cir-...

  • Page 23: Basic Service Information

    BASIC SERVICE INFORMATION EAM20120 BASIC SERVICE INFORMATION EAM30181 ELECTRICAL SYSTEM Electrical parts handling ECA16600 NOTICE Never disconnect a battery lead while the en- gine is running; otherwise, the electrical components could be damaged. ECA16760 NOTICE Be sure to connect the battery leads to the correct battery terminals.
  • Page 24 BASIC SERVICE INFORMATION ECA16630 ECA14371 NOTICE NOTICE Electrical components are very sensitive to Never insert the tester probes into the cou- and can be damaged by static electricity. pler terminal slots. Always insert the probes Therefore, never touch the terminals and be from the opposite end “a”...
  • Page 25 BASIC SERVICE INFORMATION ECA16780 NOTICE • When disconnecting a coupler, release the coupler lock, hold both sections of the cou- pler securely, and then disconnect the cou- pler. • There are many types of coupler locks; therefore, be sure to check the type of cou- pler lock before disconnecting the coupler.
  • Page 26 BASIC SERVICE INFORMATION 5. Check: • No continuity Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachom- eter YU-A1927 • If there is no continuity, clean the terminals. • When checking the wire harness, perform steps (1) to (4). •...

  • Page 27: Special Tools

    Feeler gauge set YU-26900-9 Valve lapper (ø14) 3-7, 5-27 90890-04101 90890-04101 Valve lapping tool (14mm) YM-A8998 YM-A8998 Yamaha diagnostic tool USB (US) 3-11, 7-8, 8-21 90890-03269 Yamaha diagnostic tool (A/I) 3-11, 7-8, 8-21 90890-03262 FI diagnostic tool sub–lead 3-11, 7-8, 8-21 90890-03212 FI diagnostic tool sub–lead...
  • Page 28 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages OBD/ GST Leadwire kit 3-11, 7-8, 8-21 90890-03249 Digital tachometer 3-11, 3-35, 8-54 90890-06760 Digital tachometer YU-39951-B Steering nut wrench 3-27, 4-55 90890-01403 Exhaust flange nut wrench YU-A9472 Spoke nipple wrench (6–7) 3-33 90890-01521 Spoke nipple wrench (6–7)
  • Page 29 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Boots band installation tool 90890-01526 Boots band installation tool YM-01526 Yamaha bond No. 1215 5-20, 5-39, 5-69 90890-85505 (Three bond No.1215®) Valve spring compressor 5-27, 5-32 90890-04019 Valve spring compressor YM-04019 Valve spring compressor attachment...
  • Page 30 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide installer (ø4.5) 5-29 90890-04117 Valve guide installer (4.5 mm) YM-04117 Valve guide reamer (ø4.5) 5-29 90890-04118 Valve guide reamer (4.5 mm) YM-04118 Piston pin puller set 5-34 90890-01304 Piston pin puller YU-01304 YU-01304 Rotor puller...
  • Page 31 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Crankcase separating tool 5-71 90890-04152 Crankcase separating tool YU-A9642 Crankshaft installer pot 5-72 90890-01274 Installing pot YU-90058 YU-90058/YU-90059 Crankshaft installer bolt 5-72 90890-01275 Bolt YU-90060 Adapter (M12) 5-72 90890-01278 Adapter #3 YU-90063 Spacer (crankshaft installer) 5-72 90890-04081...
  • Page 32 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester 6-4, 6-4 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter 6-4, 6-4 90890-01352 Pressure tester adapter YU-33984 YU-33984 Pressure gauge 90890-03153 Pressure gauge YU-03153 Fuel pressure adapter 90890-03186 Fuel pressure adapter YM-03186...
  • Page 33 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Test harness S– pressure sensor (3P) 8-55 90890-03207 Test harness S– pressure sensor (3P) YU-03207 1-21...

  • Page 34: Instrument And 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 35: Shift Pedal

    INSTRUMENT AND CONTROL FUNCTIONS EWA18980 WARNING You can use the Power Tuner app to adjust the • Never apply additional force to the sides- map settings. tand. When the mode switch “1” is illuminated, map 2 • Hold up the sidestand before starting out. is selected.

  • Page 36: Fuel Tank Cap

    INSTRUMENT AND 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 37: Starting And Break-In

    (of 3000 to 5000 r/min), and then return the start- Your Yamaha engine has been designed to use er knob to its original position. premium unleaded gasoline with a pump octane...

  • Page 38: Starting A Warm Engine

    STARTING AND BREAK-IN check the points shown in “TORQUE- CHECK POINTS” for tightening torques and retighten them. Also when the following parts are replaced, a break-in is required. • Cylinder and Crankshaft: A break-in is re- quired for about an hour. •...

  • Page 39: Maintenance After Break-In

    EMENT” section in the CHAPTER 3, apply the • Generator Yamaha foam air filter oil or other quality foam Check for looseness in mounted areas of the air filter oil to the element. (Excess oil in the ele- generator rotor and the stator coil assembly.

  • Page 40: 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 41 TORQUE-CHECK POINTS Shift pedal Shift pedal to shift shaft Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake disc cover Tightening of rear brake caliper cover...

  • Page 42: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE any longer than instructed. Also, thorough- EAM20126 MOTORCYCLE CARE AND STOR- ly rinse the area off with water, immediately dry it, and then apply a corrosion protec- tion spray. • Improper cleaning can damage plastic EAM30200 CARE parts (such as cowlings, panels, wind- While the open design of a motorcycle reveals...

  • Page 43: Storage

    Salt sprayed on roads in the winter may remain well into spring. • Consult a Yamaha dealer for advice on what 1. Clean the motorcycle with cold water and a products to use.
  • Page 44 MOTORCYCLE CARE AND STORAGE stored. Long-term Before storing your motorcycle for several months: 1. Follow all the instructions in the “CARE” sec- tion of this chapter. 2. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating.

  • Page 45: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-6 ELECTRICAL SPECIFICATIONS..............2-9 TIGHTENING TORQUES................2-10 GENERAL TIGHTENING TORQUE SPECIFICATIONS ......2-10 ENGINE TIGHTENING TORQUES ............2-11 CHASSIS TIGHTENING TORQUES ............2-14 CABLE ROUTING DIAGRAM ................2-17...

  • Page 46: General Specifications

    GENERAL SPECIFICATIONS EAM20127 GENERAL SPECIFICATIONS Model Model BAJ1 Dimensions Overall length 2175 mm (85.6 in) Overall width 825 mm (32.5 in) Overall height 1270 mm (50.0 in) Seat height 955 mm (37.6 in) Wheelbase 1480 mm (58.3 in) Ground clearance 320 mm (12.60 in) Weight Curb weight...

  • Page 47: Engine Specifications

    ENGINE SPECIFICATIONS EAM20128 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train DOHC Displacement 250 cm³ Number of cylinders Single cylinder Bore  stroke 77.0  53.6 mm (3.03  2.11 in) Compression ratio 13.8 : 1 Starting system Electric starter Fuel...
  • Page 48 ENGINE SPECIFICATIONS Limit 0.080 mm (0.0032 in) Camshaft lobe dimensions Lobe height (Intake) 32.230–32.330 mm (1.2689–1.2728 in) Limit 32.130 mm (1.2650 in) Lobe height (Exhaust) 33.850–33.950 mm (1.3327–1.3366 in) Limit 33.750 mm (1.3287 in) Camshaft runout limit 0.030 mm (0.0012 in) Valve, valve seat, valve guide Valve clearance (cold) Intake...
  • Page 49 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 50 ENGINE SPECIFICATIONS Throttle grip free play 3.0–6.0 mm (0.12–0.24 in)
  • Page 51 CHASSIS SPECIFICATIONS EAM20129 CHASSIS SPECIFICATIONS Chassis Frame type Semi double cradle 27.2  Caster angle Trail 116 mm (4.6 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 52: Chassis Specifications

    497.0 mm (19.57 in) Limit 492.0 mm (19.37 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil S1 Quantity (left) 501.0 cm³ (16.94 US oz, 17.67 Imp.oz) Quantity (right) 501.0 cm³ (16.94 US oz, 17.67 Imp.oz) Rebound damping...
  • Page 53 CHASSIS SPECIFICATIONS Fast compression damping Unit for adjustment Turn Adjustment value from the start position (Soft) Adjustment value from the start position 1-1/8 (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)

  • Page 54: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAM20130 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system 8.0–12.0 /2000 r/min Ignition timing (B.T.D.C.) Engine control unit Model BAJ0 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 55: 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 56: Engine Tightening Torques

    TIGHTENING TORQUES EAM30203 ENGINE TIGHTENING TORQUES - marked portion shall be checked for torque tightening after break-in or before each race. Thread Item Q’ty Tightening torques Remarks size Camshaft cap bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) Cylinder head stud bolt (exhaust 7 N·m (0.7 kgf·m, 5.2 lb·ft) pipe)
  • Page 57 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Exhaust pipe nut 10 N·m (1.0 kgf·m, 7.4 lb·ft) Exhaust pipe protector screw 10 N·m (1.0 kgf·m, 7.4 lb·ft) Exhaust pipe bracket bolt 20 N·m (2.0 kgf·m, 15 lb·ft) Silencer bolt (front) 30 N·m (3.0 kgf·m, 22 lb·ft) Silencer bolt (rear) 30 N·m (3.0 kgf·m, 22 lb·ft)
  • Page 58 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Stator coil assembly lead holder bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) Coolant temperature sensor 14 N·m (1.4 kgf·m, 10 lb·ft) Gear position switch bolt 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) Rectifier/regulator bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) ECU bolt...

  • Page 59: 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 Upper bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft)  Lower bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) ...
  • Page 60 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) / Footrest bracket bolt 55 N·m (5.5 kgf·m, 41 lb·ft)
  • Page 61 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size 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) Bolt (drive chain support) 7 N·m (0.7 kgf·m, 5.2 lb·ft) Drive chain support nut 7 N·m (0.7 kgf·m, 5.2 lb·ft) Drive chain guide bolt...

  • Page 62: Cable Routing Diagram

    CABLE ROUTING DIAGRAM EAM20152 CABLE ROUTING DIAGRAM Frame and engine (left side view) 2-17...
  • Page 63 W. Diagram for routing the radiator hose and above the engine stop switch lead. radiator breather hose. B. Insert the Yamaha diagnostic tool coupler into X. Route the radiator breather hose between the the connector, and fix it to the bracket.
  • Page 64 CABLE ROUTING DIAGRAM Frame and engine (right side view) 2-19...
  • Page 65 CABLE ROUTING DIAGRAM K. Route the fuel hose in front of the fuel pump. 1. Negative battery lead L. After connecting the fuel pump coupler, 2. Starter motor lead attach the cover. 3. Coolant temperature sensor coupler M. Fasten the starter relay lead and starter 4.
  • Page 66 CABLE ROUTING DIAGRAM Handlebar (front view) 2-21...
  • Page 67 CABLE ROUTING DIAGRAM 1. Plastic locking tie 2. Number plate band 3. Clutch cable 4. Engine stop switch lead 5. Mode switch lead 6. Warning light lead 7. Front brake hose 8. Cable guide 9. Start switch lead 10.Number plate 11.Warning light A.
  • Page 68 CABLE ROUTING DIAGRAM Frame and engine (top view) 2-23...
  • Page 69 CABLE ROUTING DIAGRAM I. It does not matter if the high tension cord and 1. Clamp grommet do not contact the ECU. 2. Diode J. Pass the wire harness between the ECU and 3. Throttle position sensor lead air filter assembly. 4.
  • Page 70 CABLE ROUTING DIAGRAM Frame and battery (top view) 2-25...
  • Page 71 CABLE ROUTING DIAGRAM 1. Positive battery lead 2. Fuel pump lead 3. Diode 4. Wire harness 5. Main relay (red tape) 6. Joint coupler 7. Radiator fan motor relay 8. Starter relay coupler 9. Starter relay 10.Starter motor lead 11.Resistor 12.Negative battery lead 13.Cross member A.
  • Page 72 CABLE ROUTING DIAGRAM Rear brake (right side view) 2-27...
  • Page 73 CABLE ROUTING DIAGRAM 1. Bleed screw 2. Rear brake caliper 3. Protector 4. Gasket 5. Rear brake hose 6. Brake pedal 7. Rear brake master cylinder assembly 8. Swingarm 9. Spring 10.Frame A. It does not matter whether the spring is installed upward or downward.
  • Page 74 CABLE ROUTING DIAGRAM 2-29...

  • Page 75: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS MAINTENANCE INTERVALS ................3-1 MAINTENANCE INTERVALS..............3-1 PRE-OPERATION INSPECTION AND MAINTENANCE .........3-5 GENERAL INSPECTION AND MAINTENANCE ........3-5 ENGINE......................3-6 ADJUSTING THE VALVE CLEARANCE............3-6 VALVE CLEARANCE SHIM CHART ............3-9 CHECKING THE ENGINE IDLING SPEED..........3-11 CHECKING THE THROTTLE GRIP ............3-11 CHECKING THE SPARK PLUG...............3-12 CHECKING THE ENGINE OIL LEVEL .............3-13 CHANGING THE ENGINE OIL..............3-13 ADJUSTING THE CLUTCH LEVER FREE PLAY ........3-15...
  • Page 76 CHECKING THE WHEELS ..............3-33 CHECKING THE WHEEL BEARINGS .............3-33 CHECKING THE CHASSIS FASTENERS ..........3-33 CHECKING AND LUBRICATING THE CABLES........3-33 LUBRICATING THE BRAKE LEVER ............3-33 LUBRICATING THE CLUTCH LEVER .............3-33 LUBRICATING THE PEDAL..............3-33 CHECKING THE SIDESTAND ..............3-34 LUBRICATING THE SIDESTAND ............3-34 ELECTRICAL SYSTEM..................3-35 CHECKING AND CHARGING THE BATTERY ........3-35 CHECKING THE FUSES................3-35...

  • Page 77: Maintenance Intervals

    (e.g., rain, dirt, etc.). Therefore, earlier inspection is required by reference to the list below. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 78 MAINTENANCE INTERVALS Every Every Every fifth After race third race race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours) • Check the coolant passages for corrosion. • Inspect carbon deposits and elim-  11 * Cylinder head inate them.
  • Page 79 MAINTENANCE INTERVALS Every Every Every fifth After race third race race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours) • Inspect.  30 * Fuel hose • Replace.  Every four years   • Clean. •...
  • Page 80 MAINTENANCE INTERVALS Every Every Every fifth After race third race race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours) • Routing (Connection)   • Check and grease.   Cables • Check throttle cables on the throt- ...

  • Page 81: Pre-Operation Inspection And Maintenance

    PRE-OPERATION INSPECTION AND MAINTENANCE EAM20134 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating con- dition. Before using this machine, check the following points. EAM30209 GENERAL INSPECTION AND MAINTENANCE Item Inspect Page...

  • Page 82: Engine

    Turn the crankshaft counterclockwise with sic knowledge and skill concerning the servic- a wrench. ing of Yamaha motorcycles (e.g., Yamaha b. Align the top dead center (TDC) mark “a” dealers, service engineers, etc.). Those who on the generator rotor with the alignment have little knowledge and skill concerning ser- mark “b”...
  • Page 83 ENGINE c. Check the number on the originally in- stalled adjusting pad. • The adjusting pad number “a” is indicated on the top of the adjusting pad. • For the number on the originally installed ad- justing pad, convert the last digit of adjusting pad number as per the below table.
  • Page 84 ENGINE ECA24310 NOTICE Do not twist adjusting pads and valve lifters forcibly during installation. • Apply the engine oil on the valve lifters. • Apply molybdenum disulfide oil to the valve stem ends. • Check that the valve lifters turn smoothly when rotated with your finger.

  • Page 85: Valve Clearance Shim Chart

    ENGINE EAM30383 VALVE CLEARANCE SHIM CHART INTAKE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.02 0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230...
  • Page 86 ENGINE EXHAUST 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 0.02 0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225...

  • Page 87: Checking The Engine Idling Speed

    2. Measure the coolant temperature using the 5. Adjust: Yamaha diagnostic tool. • Engine idling speed Yamaha diagnostic tool USB (US) a. Turn the idle screw “1” to make an adjust- 90890-03269 ment. Yamaha diagnostic tool (A/I) 90890-03262 FI diagnostic tool sub–lead...

  • Page 88: Checking The Spark Plug

    ENGINE 2. Adjust: ECA24410 NOTICE • Throttle grip free play In order not to allow the dirt accumulated a. Loosen the locknut “1”. around the spark plug to drop from the spark b. Turn the adjuster “2” until the specified plug hole into the cylinder, clean it before re- throttle grip free play is obtained.

  • Page 89: Checking The Engine Oil Level

    ENGINE • Seat • Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1. EAM30224 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle upright on a level surface. 2. Start the engine, warm this up for 2–3 min- utes, and then stop the engine and wait about 1 minute.
  • Page 90 ENGINE Engine oil quantity Oil change 0.73 L (0.77 US qt, 0.64 Imp.qt) With oil filter removal 0.75 L (0.79 US qt, 0.66 Imp.qt) Quantity (disassembled) 0.95 L (1.00 US qt, 0.84 Imp.qt) c. Install the new oil filter element and the oil filter element cover.

  • Page 91: Adjusting The Clutch Lever Free Play

    ENGINE EWA19130 WARNING Always keep the engine idling speed during the checkup without increasing the engine speed. ECA25840 NOTICE If no engine oil seeps out after one minute, immediately turn the engine off so it will not seize. c. If no engine oil seeps out, check the en- If the clutch lever free play cannot be obtained gine oil for leaks, and the engine oil pas- on the handlebar side, use the adjuster on the...

  • Page 92: Cleaning The Air Filter Element

    • Air filter element 2. Turn the plates “1” in direction “a”. Damage  Replace. 6. Apply: Yamaha foam air filter oil or other quality foam air filter oil. Oil application quantify 30 cm³ Squeeze out the excess oil. Element should be wet but not dripping.

  • Page 93: Checking The Throttle Body Joint

    ENGINE • Guide “2” (to the air filter element) curely fitted into the two edges “b” on the air fil- • Air filter element “3” (to the air filter guide) ter case. • Air filter guide “4” • Be sure to carefully align the two ribs “c” locat- ed on the left and right sides of the air filter •...

  • Page 94: Checking The Cylinder Head Breather Hose

    ENGINE Refer to “FUEL TANK” on page 7-1. Refer to “ENGINE REMOVAL” on page 5-6. 2. Check: 3. Check: • Fuel hose “1” • Silencer fiber Crack/damage  Replace. Damage  Replace. Loose connection  Connect properly. 4. Replace: • Silencer fiber a.
  • Page 95 ENGINE d. Install the fiber insert “6” to the part “b”. h. Install the fiber insert “12” to the inner pipe. e. Twist the fiber insert “7” onto the inner pipe i. Install the fiber insert “13” to the inside of “c”.

  • Page 96: Checking The Coolant Level

    ENGINE 5. Check: EAM30210 CHECKING THE COOLANT LEVEL • Gasket “1” EWA19070 Damage  Replace. WARNING Refer to “ENGINE REMOVAL” on page 5-6. If coolant seems hot, do not remove the radi- ator cap. 1. Stand the vehicle upright on a level surface. 2.

  • Page 97: Checking The Cooling System

    ENGINE • Coolant drain bolt EAM30211 CHECKING THE COOLING SYSTEM 1. Remove: Coolant drain bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) • Seat • Side cover (left/right) 6. Pour coolant. • Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 4-1. Recommended coolant •...

  • Page 98: Chassis

    CHASSIS EAM20136 ECA13490 CHASSIS NOTICE After adjusting the brake lever position, EAM30479 make sure there is no brake drag. ADJUSTING THE FRONT DISC BRAKE 1. Check: 4. Install: • Brake lever position “a” • Brake lever cover Brake lever position EAM30480 ADJUSTING THE REAR DISC BRAKE 100 mm (3.94 in)

  • Page 99: Checking The Brake Fluid Level

    CHASSIS ing performance to be reduced. EAM30231 CHECKING THE FRONT BRAKE PADS ECA13510 The following procedure applies to all of the NOTICE brake pads. After adjusting the brake pedal position, 1. Operate the brake. make sure there is no brake drag. 2.

  • Page 100: Checking The Rear Brake Hose

    CHASSIS Refer to “FRONT BRAKE” on page 4-13 and “REAR BRAKE” on page 4-24. Drive on the dry road, operate the front and rear brakes separately and check to see if the brakes are operating properly. EAM30477 BLEEDING THE HYDRAULIC BRAKE SYSTEM EWA19140 2.

  • Page 101: Drive Chain Slack

    CHASSIS EAM30481 DRIVE CHAIN SLACK ECA13550 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. Therefore, keep the drive chain slack within the specified lim- its.

  • Page 102: Lubricating The Drive Chain

    CHASSIS b. Loosen both locknuts “2”. EAM30247 CHECKING AND ADJUSTING THE c. Turn the adjusting bolt “3” until the speci- STEERING HEAD fied drive chain slack is obtained. 1. Use a maintenance stand to raise the front wheel off the ground. EWA13120 WARNING Securely support the vehicle so that there is...

  • Page 103: Lubricating The Steering Head

    CHASSIS • Lower bearing Steering nut wrench • Bearing race 90890-01403 Exhaust flange nut wrench Recommended lubricant YU-A9472 Lithium-soap-based grease EAM30338 Ring nut (initial tightening torque) CHECKING THE FRONT FORK LEGS 38 N·m (3.8 kgf·m, 28 lb·ft) 1. Stand the vehicle upright on a level surface. EWA13120 c.

  • Page 104: Adjusting The Front Fork Legs

    CHASSIS • Securely support the vehicle so that there is no danger of it falling over. Rebound damping ECA24340 NOTICE Do not turn the adjuster forcibly beyond its adjusting range. 1. Adjust: • Rebound damping a. Turn the adjuster “1” in the direction of “a” 6.

  • Page 105: Checking The Rear Shock Absorber Assembly

    CHASSIS adjusting range. no danger of it falling over. 1. Adjust: 2. Remove the bleed screw “1” and release the • Compression damping internal pressure from the front fork. a. Turn the adjuster “1” in the direction of “a” 3. Tighten: •...

  • Page 106: Adjusting The Rear Shock Absorber Assembly

    CHASSIS Direction “b” Spring preload is increased (suspen- sion is harder). Direction “c” Spring preload is decreased (suspen- sion is softer). Spring preload adjusting positions Minimum Position in which the spring is turned in 1.5 mm (0.06 in) from EAM30242 its free length.
  • Page 107 CHASSIS a. Turn the adjuster “1” in the direction of “a” Direction “a” or “b” to make an adjustment. Compression damping is increased (suspension is harder). Direction “a” Direction “b” Rebound damping is increased (sus- Compression damping is decreased pension is harder). (suspension is softer).

  • Page 108: Checking The Swingarm Operation

    CHASSIS EAM30243 Slow compression damping CHECKING THE TIRES Minimum (soft) 1. Measure: 20 click(s) in direction “b”* • Tire pressure Standard Out of specification  Regulate. 9 click(s) in direction “b”* Maximum (hard) Tire air pressure (measured on 0 click(s) in direction “b”* cold tires) * With the adjusting screw fully turned in di- Front...
  • Page 109 CHASSIS on page 2-14. EAM30248 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in- ner and outer cables. EWA13270 WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement. Re- place damaged outer cable and inner cables Spoke nipple wrench (6–7) as soon as possible.
  • Page 110 CHASSIS EAM30504 CHECKING THE SIDESTAND 1. Check: • Sidestand operation Check that the sidestand moves smoothly. Rough movement  Repair or replace. EAM30252 LUBRICATING THE SIDESTAND Lubricate the pivoting point, metal-to-metal mov- ing parts and spring contact point of the sides- tand.
  • Page 111 ELECTRICAL SYSTEM 4. Check: EAM20137 ELECTRICAL SYSTEM • Ignition timing Check whether the alignment mark “a” on the EAM30256 left crankcase cover is within the firing range CHECKING AND CHARGING THE BATTERY “b” on the generator rotor. Refer to “CHECKING AND CHARGING THE Incorrect firing range ...
  • Page 112 ELECTRICAL SYSTEM 3-36...
  • Page 113 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE SEAT................4-3 REMOVING THE NUMBER PLATE ............4-3 INSTALLING THE AIR SCOOP..............4-3 REMOVING THE SIDE COVER ..............4-4 INSTALLING THE SIDE COVER ...............4-4 FRONT WHEEL ....................4-5 REMOVING THE FRONT WHEEL .............4-6 DISASSEMBLING THE FRONT WHEEL ...........4-6 CHECKING THE FRONT WHEEL .............4-6 ASSEMBLING THE FRONT WHEEL ............4-7 INSTALLING THE FRONT WHEEL (DISC BRAKE) ........4-8 REAR WHEEL ....................4-9...
  • Page 114 INSTALLING THE REAR BRAKE MASTER CYLINDER ......4-33 HANDLEBAR....................4-35 REMOVING THE HANDLEBAR ...............4-36 CHECKING THE HANDLEBAR..............4-36 INSTALLING THE HANDLEBAR..............4-36 FRONT FORK....................4-41 REMOVING THE FRONT FORK LEGS ...........4-43 DISASSEMBLING THE FRONT FORK LEGS .........4-43 CHECKING THE FRONT FORK LEGS............4-44 ASSEMBLING THE FRONT FORK LEGS ..........4-45 INSTALLING THE FRONT FORK LEGS..........4-51 STEERING HEAD...................4-54 REMOVING THE LOWER BRACKET ............4-55...
  • Page 115 GENERAL CHASSIS EAM20094 GENERAL CHASSIS Removing the seat and battery 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 116 GENERAL CHASSIS Removing the side cover 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 1.3 N ・ m (0.13 kgf ・ m, 0.95 lb ・ ft) 7 N ・...

  • Page 117: General Chassis

    GENERAL CHASSIS EAM30016 REMOVING THE SEAT The fuel tank cap cover and the seat are coupled with each other with a plastic band. When removing the seat, always remove the fuel tank cap cover beforehand. 1. Remove: • Fuel tank cap cover “1” Refer to “FUEL TANK CAP”...

  • Page 118: Removing The Side Cover

    GENERAL CHASSIS EAM30459 REMOVING THE SIDE COVER 1. Remove: • Side cover (right) “1” Remove the side cover (right) from the vehicle by removing the bolts and sliding it as shown. a. Projection b. Slot EAM30460 INSTALLING THE SIDE COVER 1.

  • Page 119: Front Wheel

    FRONT WHEEL EAM20095 FRONT WHEEL Removing the front wheel 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 115 N ・ m (11.5 kgf ・ m, 85 lb ・ ft) 12 N ・...

  • Page 120: Removing The Front Wheel

    FRONT WHEEL EAM30017 REMOVING THE FRONT WHEEL 1. Use a maintenance stand to raise the front wheel off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Front wheel EWA13460 EAM30019 DISASSEMBLING THE FRONT WHEEL...

  • Page 121: Assembling The Front Wheel

    FRONT WHEEL 5. Measure: ECA24420 NOTICE • Radial wheel runout “a” Install the bearing by pressing its outer race • Lateral wheel runout “b” parallel. Out of specification  Repair/replace. Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in) 6.

  • Page 122: Installing The Front Wheel (Disc Brake)

    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 123 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 124: Rear Wheel

    REAR WHEEL Refer to “CHECKING THE TIRES” on page EAM30022 REMOVING THE REAR WHEEL 3-32 and “CHECKING THE WHEELS” on 1. Use a maintenance stand to raise the rear page 3-33. wheel off the ground. 3. Check: EWA13120 • Spoke WARNING Refer to “CHECKING THE FRONT WHEEL”...

  • Page 125: Assembling The Rear Wheel

    REAR WHEEL 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 126 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 127 FRONT BRAKE EAM20097 FRONT BRAKE Removing the front brake caliper 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 28 N ・ m (2.8 kgf ・ m, 21 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 17 N ・...

  • Page 128: Front Brake

    FRONT BRAKE Disassembling the front brake caliper 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw 4-14...
  • Page 129 FRONT BRAKE Removing the front brake master cylinder 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 6 N ・...
  • Page 130 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Push rod Dust boot Circlip Washer Brake master cylinder kit 4-16...

  • Page 131: Introduction

    FRONT BRAKE 3. Measure: EAM30028 INTRODUCTION • Brake disc runout EWA19210 Out of specification  Correct the brake disc WARNING runout or replace the brake disc. If you need to disassemble the disc brake components, observe the following precau- Brake disc runout limit (as mea- tions.

  • Page 132: Replacing The Front Brake Pads

    FRONT BRAKE ment steps until the brake disc runout is 2. Measure: • Brake pad wear limit “a” within specification. Out of specification  Replace the brake g. If the brake disc runout cannot be brought within specification, replace the brake pads as a set.

  • Page 133: Removing The Front Brake Caliper

    FRONT BRAKE EAM30030 REMOVING THE FRONT BRAKE CALIPER Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • Union bolt • Copper washer • Brake hose Put the end of the brake hose into a container e.

  • Page 134: Checking The Front Brake Caliper

    FRONT BRAKE EAM30032 EAM30035 CHECKING THE FRONT BRAKE CALIPER INSTALLING THE FRONT BRAKE CALIPER 1. Check: 1. Install: • Brake caliper piston “1” • Front brake caliper bracket Rust/scratches/wear  Replace the brake • Front brake caliper caliper piston. (temporarily) •...

  • Page 135: Removing The Front Brake Master Cylinder

    FRONT BRAKE stalled with its upper end “a” aligned with the system. paint “b” on the brake hose. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-24. EAM30036 REMOVING THE FRONT BRAKE MASTER CYLINDER Before removing the front brake master cylinder, drain the brake fluid from the entire brake sys- tem.

  • Page 136: Installing The Front Brake Master Cylinder

    FRONT BRAKE ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake com- ponents. Specified brake fluid DOT 4 1. Wash the brake master cylinder and the brake master cylinder kit with brake fluid. 2.
  • Page 137 FRONT BRAKE brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.

  • Page 138: Rear Brake

    REAR BRAKE EAM20098 REAR BRAKE Removing the rear brake caliper 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 13 lb ・ ft) 30 N ・...
  • Page 139 REAR BRAKE Disassembling the rear brake caliper 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw 4-25...
  • Page 140 REAR BRAKE Removing the rear brake master cylinder 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 141 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Push rod Brake master cylinder kit 4-27...

  • Page 142: Introduction

    REAR BRAKE EAM30040 INTRODUCTION Brake disc runout limit (as mea- sured on wheel) EWA19260 0.15 mm (0.0059 in) WARNING If you need to disassemble the disc brake 4. Adjust: components, observe the following precau- • Brake disc runout tions. Refer to “CHECKING THE FRONT BRAKE •...
  • Page 143 REAR BRAKE d. Install the brake pad “3” and the pad pin “4”. • Install the brake pads with their projections “a” into the brake caliper recesses “b”. • Temporarily tighten the pad pin at this point. 2. Measure: • Brake pad wear limit “a” Out of specification ...

  • Page 144: Removing The Rear Brake Caliper

    REAR BRAKE 4. Check: • Brake fluid level Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-23. 5. Check: • Brake pedal operation A softy or spongy feeling  Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-24. b.

  • Page 145: Installing The Rear Brake Caliper

    REAR BRAKE cleaning and lubricating. Brake pad pin • Never use solvents on internal brake com- 17 N·m (1.7 kgf·m, 13 lb·ft) ponents as they will cause the piston seals Brake pad pin plug to swell and distort. 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) •...

  • Page 146: Removing The Rear Brake Master Cylinder

    REAR BRAKE 7. Check: 4. Check: • Brake pedal operation • Brake hose A softy or spongy feeling  Bleed the brake Cracks/damage/wear  Replace. system. EAM30050 Refer to “BLEEDING THE HYDRAULIC ASSEMBLING THE REAR BRAKE MASTER BRAKE SYSTEM” on page 3-24. CYLINDER EWA13520 EAM30048...

  • Page 147: Installing The Rear Brake Master Cylinder

    REAR BRAKE hose touches the projection “a” on the brake caliper. Install the spring with a smaller inside diameter to the brake master cylinder piston. 2. Pour brake fluid to the brake fluid reservoir up to the specified level. 4. Install: •...
  • Page 148 REAR BRAKE 5. Check: • Brake pedal operation A softy or spongy feeling  Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-24. 4-34...

  • Page 149: Handlebar

    HANDLEBAR EAM20099 HANDLEBAR Removing the handlebar 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 0.5 N ・ m (0.05 kgf ・ m, 0.37 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 28 N ・...

  • Page 150: Removing The Handlebar

    HANDLEBAR EAM30052 EWA13120 REMOVING THE HANDLEBAR WARNING 1. Stand the vehicle upright on a level surface. Securely support the vehicle so that there is EWA13120 no danger of it falling over. WARNING 2. Install: Securely support the vehicle so that there is •...
  • Page 151 HANDLEBAR 3. Tighten: • Lower handlebar holder nut Lower handlebar holder nut 40 N·m (4.0 kgf·m, 30 lb·ft) 4. Install: • Clutch lever holder “1” • Clutch lever “2” Clutch lever holder bolt 5 N·m (0.5 kgf·m, 3.7 lb·ft) Clutch lever nut 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) The clutch lever holder “1”...
  • Page 152 HANDLEBAR 6. Install: quer thinner. • Handlebar grip “1” • Install the grip to the tube guide so that the grip a. Slightly coat the handlebar left end with a match mark “b” and tube guide slot “c” form the rubber adhesive.
  • Page 153 HANDLEBAR 12.Install: 14.Install: • Throttle cable housing “1” • Start switch “1” • Screw (throttle cable 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 154 HANDLEBAR Throttle grip free play 3.0–6.0 mm (0.12–0.24 in) 4-40...

  • Page 155: Front Fork

    FRONT FORK EAM20100 FRONT FORK Removing the front fork legs 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 5 N ・...
  • Page 156 FRONT FORK Disassembling the front fork leg 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 29 N ・ m (2.9 kgf ・ m, 21 lb ・ ft) 28 N ・ m (2.8 kgf ・ m, 21 lb ・ ft) 55 N ・...

  • Page 157: Removing The Front Fork Legs

    FRONT FORK • 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 158: Checking The Front Fork Legs

    FRONT FORK 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 159: Assembling The Front Fork Legs

    1. Stretch the damper assembly fully. 2. Fill: • Damper assembly Recommended oil Yamaha Suspension Oil S1 6. Check: Standard oil amount • Upper spring seat “1” 216 cm³ (7.30 US oz, 7.62 Imp.oz) (Contacting surface “a”)
  • Page 160 FRONT FORK 4. Measure: 6. Loosen: • Oil level (left and right) “a” • Compression damping force adjuster “1” Out of specification  Regulate. • Before loosening the damping force adjuster, Standard oil level record the setting position. 145–148 mm (5.71–5.83 in) •...
  • Page 161 FRONT FORK Base valve 28 N·m (2.8 kgf·m, 21 lb·ft) Hold the damper assembly with the cap bolt ring wrench “2” and use the cap bolt wrench “3” to tighten the base valve. Cap bolt wrench 90890-01500 Cap bolt wrench 12.Allow the overflowing oil to escape at the hole YM-01500 “a”...
  • Page 162 FRONT FORK • Apply the lithium-soap-based grease on the dust seal lip and oil seal lip. • Apply the fork oil on the inner tube. • When installing the oil seal, use vinyl seat “a” with fork oil applied to protect the oil seal lip. 17.Install: •...
  • Page 163 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 • Stopper ring “1” “1”...
  • Page 164 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 165: 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 295 cm³ (9.97 US oz, 10.4 Imp.oz) EAM30059 INSTALLING THE FRONT FORK LEGS Extent of adjustment 1. Install: 260–365 cm³...
  • Page 166 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” 5 mm (0.20 in) 6.
  • Page 167 FRONT FORK 4-53...

  • Page 168: Steering Head

    STEERING HEAD EAM20101 STEERING HEAD Removing the lower bracket 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 145 N ・ m (14.5 kgf ・ m, 107 lb ・ ft) 38 N ・ m (3.8 kgf ・ m, 28 lb ・ ft) 7 N ・...

  • Page 169: Removing The Lower Bracket

    STEERING HEAD EAM30060 ECA14270 REMOVING THE LOWER BRACKET NOTICE 1. Use a maintenance stand to raise the front If the bearing race is not installed properly, wheel off the ground. the steering head pipe could be damaged. EWA13120 WARNING Always replace the bearing and the bearing race Securely support the vehicle so that there is as a set.
  • Page 170 STEERING HEAD 2. Install: • Bearing race • Upper bearing “1” • Bearing race cover “2” Apply the lithium-soap-based grease on the bearing and bearing race cover lip. 5. Check the steering stem by turning this lock to lock. If there is any binding, remove the steering stem and check the steering bear- ing.
  • Page 171 STEERING HEAD Upper bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) • Pinch bolt (lower bracket) “2” Lower bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) EWA19330 WARNING Tighten the lower bracket to specified 8. Install: torque. If torqued too much, it may cause the •...

  • Page 172: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAM20102 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 56 N ・ m (5.6 kgf ・ m, 41 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 53 N ・ m (5.3 kgf ・ m, 39 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 173 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 56 N ・ m (5.6 kgf ・ m, 41 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 53 N ・ m (5.3 kgf ・ m, 39 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 174 REAR SHOCK ABSORBER ASSEMBLY Disassembling the relay arm 80 N ・ m (8.0 kgf ・ m, 59 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Relay arm Connecting arm Collar Oil seal Washer Bearing 4-60...

  • Page 175: Handling The Rear Shock Absorber

    • To dispose of a damaged or a worn-out rear shock absorber, take the unit to your EAM30067 CHECKING THE REAR SHOCK ABSORBER Yamaha dealer for this disposal procedure. ASSEMBLY 1. Check: • Rear shock absorber rod Bends/damage  Replace the rear shock absorber assembly.

  • Page 176: Checking The Connecting Arm And Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY EAM30068 CHECKING THE CONNECTING ARM AND RELAY ARM 1. Check: • Connecting arm • Relay arm Damage/wear  Replace. 2. Check: • Bearing • Collar Damage/pitting/scratches  Replace the bearings and collars as a set. EAM30070 INSTALLING THE REAR SHOCK 3.
  • Page 177 REAR SHOCK ABSORBER ASSEMBLY Installed depth “a” Relay arm nut (swingarm side) 4.25 mm (0.17 in) 70 N·m (7.0 kgf·m, 52 lb·ft) • Rear shock absorber assembly lower nut Rear shock absorber assembly lower nut 53 N·m (5.3 kgf·m, 39 lb·ft) 5.

  • Page 178: Swingarm

    SWINGARM EAM20103 SWINGARM Removing the swingarm 70 N ・ m (7.0 kgf ・ m, 52 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 4.0 N ・ m (0.40 kgf ・ m, 3.0 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 179: Removing The Swingarm

    SWINGARM shaft. 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 180 SWINGARM 3. Install: • Swingarm Pivot shaft nut 85 N·m (8.5 kgf·m, 63 lb·ft) Install the pivot shaft from the right. 4. Install: • Rear wheel Refer to “REAR WHEEL” on page 4-9. 5. Adjust: • Drive chain slack Refer to “DRIVE CHAIN SLACK” on page 3-25.

  • Page 181: Chain Drive

    CHAIN DRIVE EAM20104 CHAIN DRIVE Removing the drive chain 75 N ・ m (7.5 kgf ・ m, 55 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Drive sprocket Refer to “ENGINE REMOVAL”...

  • Page 182: Removing The Drive Chain

    CHAIN DRIVE 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 183: Checking The Drive Sprocket

    CHAIN DRIVE b. Correct 1. Drive chain roller 2. Drive sprocket EAM30078 CHECKING THE REAR WHEEL SPROCKET Refer to “CHECKING AND REPLACING THE REAR WHEEL SPROCKET” on page 4-10. EAM30079 INSTALLING THE DRIVE CHAIN 4. Check: 1. Install: • O-ring “1” •...
  • Page 184 CHAIN DRIVE 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. Therefore, keep the drive chain slack within the specified lim- its.

  • Page 185: Engine

    ENGINE LUBRICATION SYSTEM CHART AND DIAGRAMS ........5-1 ENGINE OIL LUBRICATION CHART............5-1 LUBRICATION DIAGRAMS ...............5-2 ENGINE REMOVAL ..................5-6 REMOVING THE ENGINE ...............5-11 INSTALLING THE ENGINE ..............5-11 INSTALLING THE EXHAUST PIPE AND MUFFLER .......5-12 CAMSHAFT ....................5-14 REMOVING THE CAMSHAFT ..............5-16 CHECKING THE CAMSHAFT ..............5-17 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET...5-18 CHECKING THE TIMING CHAIN TENSIONERS........5-18 CHECKING THE DECOMPRESSION SYSTEM ........5-18...
  • Page 186 CHECKING THE STARTER CLUTCH .............5-42 INSTALLING THE STARTER CLUTCH ...........5-42 ELECTRIC STARTER..................5-44 CHECKING THE STARTER MOTOR ............5-46 ASSEMBLING THE STARTER MOTOR ..........5-46 CLUTCH......................5-48 REMOVING THE CLUTCH ..............5-51 CHECKING THE FRICTION PLATES ............5-51 CHECKING THE CLUTCH PLATES ............5-51 CHECKING THE CLUTCH SPRINGS ............5-52 CHECKING THE CLUTCH HOUSING .............5-52 CHECKING THE CLUTCH BOSS ............5-52 CHECKING THE PRESSURE PLATE .............5-52...
  • Page 187 INSTALLING THE TRANSMISSION ............5-75...

  • Page 188: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAM20185 LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30526 ENGINE OIL LUBRICATION CHART 1. Intake camshaft 2. Exhaust camshaft 3. Piston 4. Oil filter element 5. Oil nozzle 6. Relief valve 7. Oil pump 8. Oil strainer 9.

  • Page 189: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30507 LUBRICATION DIAGRAMS 1. Connecting rod 2. Crankshaft 3. Main axle 4. Oil strainer 5. Drive axle...
  • Page 190 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter element 2. Oil pump...
  • Page 191 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft...
  • Page 192 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil pressure check bolt 3. Oil pump 4. Oil filter element...

  • Page 193: Engine Removal

    ENGINE REMOVAL EAM20105 ENGINE REMOVAL Removing the exhaust pipe 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 20 N ・...
  • Page 194 ENGINE REMOVAL Removing the exhaust pipe 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 20 N ・...
  • Page 195 ENGINE REMOVAL Removing the electronic parts 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Use a maintenance stand to raise the front wheel off the ground.
  • Page 196 ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 85 N ・ m (8.5 kgf ・ m, 63 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 53 N ・...
  • Page 197 ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 85 N ・ m (8.5 kgf ・ m, 63 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 53 N ・...

  • Page 198: Removing The Engine

    ENGINE REMOVAL EAM30161 REMOVING THE ENGINE 1. Remove: • Exhaust pipe 2 Put the exhaust pipe 2 into the state as shown by moving this, and then remove it. 2. Remove: • Pivot shaft “1” If the pivot shaft is pulled all the way out, the EAM30164 INSTALLING THE ENGINE swingarm will come loose.

  • Page 199: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL 2. Install: Engine mounting bolt (upper • Clamp side) • Exhaust pipe 2 “1” 45 N·m (4.5 kgf·m, 33 lb·ft) • Bolt (exhaust pipe 2) “2” Apply molybdenum disulfide grease to the pivot shaft. Install and temporarily tighten the exhaust pipe 2 and silencer with its end positioned as shown with respect to the exhaust pipe 1 and 2.
  • Page 200 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 “1” 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.

  • Page 201: Camshaft

    Refer to “FUEL TANK” on page 7-1. Ignition coil Refer to “ENGINE REMOVAL” on page 5-6. Cylinder head breather hose Spark plug Cylinder head cover Timing chain guide (top side) Cylinder head cover gasket * Yamaha bond No. 1215 (Three bond No.1215®) 5-14...
  • Page 202 CAMSHAFT Removing the camshaft 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 10 N ・...

  • Page 203: Removing The Camshaft

    CAMSHAFT EAM30080 REMOVING THE CAMSHAFT 1. Remove: • Timing mark accessing screw “1” • Crankshaft end accessing screw “2” 4. Remove: • Bolt (camshaft cap) “1” • Camshaft cap “2” • Clip “3” 2. Align: • Remove the bolts (camshaft cap) in a criss- •...

  • Page 204: Checking The Camshaft

    CAMSHAFT 4. Measure: EAM30081 CHECKING THE CAMSHAFT • Camshaft-journal-to-camshaft-cap clearance 1. Check: Out of specification  Measure the camshaft • Camshaft lobe journal diameter. Blue discoloration/pitting/scratches  Re- Camshaft-journal-to-camshaft- place the camshaft. cap clearance 2. Measure: 0.028–0.062 mm (0.0011–0.0024 • Camshaft lobe dimensions “A” Out of specification ...

  • Page 205: Checking The Timing Chain And Camshaft Sprocket

    CAMSHAFT a. 1/4 tooth 5. Measure: b. Correct • Camshaft journal diameter “a” Out of specification  Replace the camshaft. 1. Timing chain roller Within specification  Replace the cylinder 2. Camshaft sprocket head and the camshaft caps as a set. EAM30083 CHECKING THE TIMING CHAIN Camshaft journal diameter...

  • Page 206: Installing The Camshafts

    CAMSHAFT 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. Make sure that the alignment mark “c”...
  • Page 207 “1”, the timing Before installation, apply the sealant to the cylin- chain tensioner “2” and tighten the bolts der head cover gasket. “3”. Yamaha bond No. 1215 Bolt (timing chain tensioner) 90890-85505 10 N·m (1.0 kgf·m, 7.4 lb·ft) (Three bond No.1215®) c.

  • Page 208: Cylinder Head

    CYLINDER HEAD EAM20107 CYLINDER HEAD Removing the cylinder head 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 60˚ 60˚ 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・...
  • Page 209 CYLINDER HEAD Removing the cylinder head 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 60˚ 60˚ 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・...

  • Page 210: Removing The Cylinder Head

    CYLINDER HEAD EAM30086 REMOVING THE CYLINDER HEAD 1. Remove: • Cylinder head bolt and nut • Loosen the bolts in the proper sequence as shown. • Loosen each bolt 1/2 of a turn at a time. After fully loosening all the bolts, remove them. •...

  • Page 211: Installing The Cylinder Head

    CYLINDER HEAD d. Tighten the bolts to the specified torque in EAM30089 INSTALLING THE CYLINDER HEAD two or three steps in the proper tightening 1. Install: sequence as shown. • Timing chain guide (intake side) “1” • Dowel pin “2” Bolt “1”–“4”...
  • Page 212 CYLINDER HEAD l. Tighten the nuts to the specified torque. Nut “5”, “6” 10 N·m (1.0 kgf·m, 7.4 lb·ft) i. Tighten the cylinder head tightening bolts further. Bolt “1”, “2”, “3”, “4” Specified angle 60 j. Put a mark on the corner of the bolt (cylin- der head) and the cylinder head.
  • Page 213 VALVES AND VALVE SPRINGS EAM20108 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-21. Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Intake valve...

  • Page 214: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAM30090 REMOVING THE VALVES Check that there are no kerosene leaks from the valve seat “1”. Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure that the valves are properly sealed. 1.

  • Page 215: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS 2. Replace: • Valve guide To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. a. Remove the valve guide with the valve guide remover “1”.

  • Page 216: Checking The Valve Seats

    VALVES AND VALVE SPRINGS After replacing the valve guide, reface the valve seat. Intake Valve guide remover (ø5) 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø5) 90890-04098 EAM30092 Valve guide installer (5.0 mm) CHECKING THE VALVE SEATS YM-04098 1.
  • Page 217 VALVES AND VALVE SPRINGS guide. b. Install the valve into the cylinder head. c. Press the valve through the valve guide b. Apply molybdenum disulfide oil onto the and onto the valve seat to make a clear valve stem. impression. c.

  • Page 218: Checking The Valve Springs

    VALVES AND VALVE SPRINGS EAM30095 INSTALLING THE VALVES 1. Clean: • Valve stem end EAM30093 CHECKING THE VALVE SPRINGS 1. Measure: • Valve spring free length “a” 2. Lubricate: Out of specification  Replace the valve • Valve stem “1” spring.
  • Page 219 VALVES AND VALVE SPRINGS 6. Lubricate: b. Smaller pitch • Adjusting pad “1” 4. Install: • Valve lifter “2” • 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 220: Cylinder And Piston

    CYLINDER AND PISTON EAM20109 CYLINDER AND PISTON Removing the cylinder and piston 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Cylinder head...

  • Page 221: Removing The Piston

    CYLINDER AND PISTON EAM30096 REMOVING THE PISTON 1. Remove: • Piston pin clip “1” • Piston pin “2” • Piston “3” ECA13810 NOTICE Do not use a hammer to drive the piston pin out. • Before removing the piston pin clip, cover the EAM30097 CHECKING THE CYLINDER AND PISTON crankcase opening with a cloth to prevent the...

  • Page 222: Checking The Piston Rings

    CYLINDER AND PISTON Diameter 76.955–76.970 mm (3.0297– 3.0303 in) Measuring point (from piston skirt bottom) 4.0 mm (0.16 in) 2. Install: • Piston ring (into the cylinder) Use the piston crown to level the piston ring near bottom of cylinder “a”, where cylinder wear is lowest.

  • Page 223: Installing The Piston And Cylinder

    CYLINDER AND PISTON 2. Measure: • Piston pin outside diameter “a” Out of specification  Replace the piston pin. Piston pin outside diameter 15.991–16.000 mm (0.6296– 0.6299 in) Limit 15.971 mm (0.6288 in) 3. Measure: 2. Install: • Piston pin bore inside diameter “b” •...
  • Page 224 CYLINDER AND PISTON (exhaust side) through the timing chain cavity. 3. Lubricate: • Piston • Piston ring • Cylinder 4. Offset: • Piston ring end gap a. Top ring b. Upper oil ring rail c. Oil ring expander d. Lower oil ring rail 5.

  • Page 225: Generator

    GENERATOR EAM20183 GENERATOR Removing the stator coil assembly 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 10 N ・...

  • Page 226: Removing The Generator

    • Generator rotor “1” inner surface “a” • Pass the stator coil assembly lead through the • Stator coil assembly “2” outer surface “b” crankcase cover side. Damage  Inspect the crankshaft runout and crankshaft bearing. Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 5-39...
  • Page 227 GENERATOR • Crankcase cover (left) “3” • Lead holder “4” • Bolt (left crankcase cover) “5” Bolt (left crankcase cover) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Tighten the bolts in stages and in a crisscross pattern. 2. Install: • Woodruff key “1” •...

  • Page 228: Starter Clutch

    STARTER CLUTCH EAM20175 STARTER CLUTCH Removing the starter clutch 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Refer to “CHANGING THE ENGINE OIL” on Engine oil page 3-13. Clutch Refer to “CLUTCH” on page 5-48. Clutch housing Starter clutch gear Starter clutch assembly...

  • Page 229: Removing The Starter Clutch

    STARTER CLUTCH EAM30469 REMOVING THE STARTER CLUTCH 1. Remove: • Starter clutch screw “1” While holding the side of the clutch housing “2” with the sheave holder “3” as shown, remove the starter clutch screws “1”. Sheave holder 90890-01701 3. Check: Primary clutch holder YS-01880-A •...
  • Page 230 STARTER CLUTCH toward the primary driven gear. • While holding the side of the clutch housing “1” with the sheave holder “2” as shown, tighten the starter clutch screws “3”. Sheave holder 90890-01701 Primary clutch holder YS-01880-A 2. Install: • Absorber “1” Install the absorber “1”...

  • Page 231: Electric Starter

    ELECTRIC STARTER EAM20110 ELECTRIC STARTER Removing the starter motor 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Exhaust pipe Refer to “ENGINE REMOVAL”...
  • Page 232 ELECTRIC STARTER Disassembling the starter motor 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Starter motor assembly O-ring Starter motor front cover Washer Starter motor front cover...

  • Page 233: Checking The Starter Motor

    ELECTRIC STARTER 4. Measure: EAM30106 CHECKING THE STARTER MOTOR • Brush length “a” 1. Check: Out of specification  Replace the brush set. • Commutator Dirt  Clean with 600 grit sandpaper. Brush overall length limit 3.5 mm (0.14 in) 2.
  • Page 234 ELECTRIC STARTER Install while holding down the brush using a thin screw driver. ECA24650 NOTICE Be careful not to damage the brush during installation. 5. Install: • Bolt “1” • O-ring “2” Apply the lithium-soap-based grease on the O- ring. 3.

  • Page 235: Clutch

    CLUTCH EAM20111 CLUTCH Removing the clutch 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 95 N ・...
  • Page 236 CLUTCH Removing the clutch 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 95 N ・...
  • Page 237 CLUTCH Removing the right crankcase cover 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 238: Removing The Clutch

    CLUTCH EAM30108 REMOVING THE CLUTCH Friction plate 1 thickness 2.70–2.90 mm (0.106–0.114 in) 1. Straighten the clutch boss nut rib “a”. Wear limit 2.60 mm (0.102 in) Friction plate 2 thickness 2.72–2.88 mm (0.107–0.113 in) Wear limit 2.62 mm (0.103 in) 2.

  • Page 239: Checking The Clutch Springs

    CLUTCH EAM30111 CHECKING THE CLUTCH SPRINGS 1. Check: • Clutch spring Damage  Replace the clutch springs as a set. 2. Measure: • Clutch spring free length Out of specification  Replace the clutch springs as a set. Clutch spring free length EAM30114 44.00 mm (1.73 in) CHECKING THE PRESSURE PLATE...

  • Page 240: Checking The Primary Drive Gear

    CLUTCH Push rod bending limit 0.30 mm (0.012 in) EAM30117 CHECKING THE PRIMARY DRIVE GEAR 1. Check: • Primary drive gear Damage/wear  Replace the primary drive and primary driven gears as a set. Excessive noise during operation  Replace the primary drive and primary driven gears as 3.
  • Page 241 CLUTCH plate and ending with a friction plate. ECA24660 NOTICE • From the clutch boss side, install the friction Make sure to tighten to specification; other- plates in order: friction plate 1 (identification wise, it may damage the other part that is fas- color: black) ...
  • Page 242 CLUTCH 4 4 4 9. Install: 11.Install: • Pressure plate “1” • Gasket “1” Making sure to align a “a” on the pressure plate with the punch mark “b” on the clutch housing. 12.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...

  • Page 243: Shift Shaft

    SHIFT SHAFT EAM20113 SHIFT SHAFT Removing the shift shaft and stopper lever 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 10 N ・...

  • Page 244: Removing The Segment

    SHIFT SHAFT EAM30124 REMOVING THE SEGMENT 1. Remove: • Bolt (segment) “1” • Segment “2” Turn the segment counterclockwise until it stops and loosen the bolt. ECA24670 NOTICE If the segment gets an impact, the stopper le- EAM30127 ver may be damaged. Take care not to give CHECKING THE STOPPER LEVER an impact to it when removing the bolt.
  • Page 245 SHIFT SHAFT Segment bolt 30 N·m (3.0 kgf·m, 22 lb·ft) • Align the notch “a” on the segment with the pin “b” on the shift cam. • With the stopper lever pushed down, install the segment. ECA24680 NOTICE 6. Tighten: If the segment gets an impact, the stopper le- •...
  • Page 246 SHIFT SHAFT Align the punch mark “a” on the shift shaft with the punch mark “b” in the shift pedal. 5-59...

  • Page 247: Oil Pump

    OIL PUMP EAM20182 OIL PUMP Removing the oil pump 2.0 N ・ m (0.20 kgf ・ m, 1.5 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Primary driven gear Refer to “CLUTCH”...
  • Page 248 OIL PUMP Removing the balancer 105 N ・ m (10.5 kgf ・ m, 77 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 38 N ・ m (3.8 kgf ・ m, 28 lb ・ ft) 50 N ・...

  • Page 249: Removing The Oil Pump

    OIL PUMP EAM30485 REMOVING THE OIL PUMP 1. Remove: • Oil pump 2. Loosen: • Balancer nut “1” • Primary drive gear nut “2” • Balancer weight gear nut “3” Place an aluminum plate “a” between the teeth of the balancer drive gear “4” and balancer 4.

  • Page 250: Assembling The Oil Pump

    OIL PUMP and inner rotor. Inner-rotor-to-outer-rotor-tip • Fit the dowel pin into the groove in the inner ro- clearance tor. 0.00–0.15 mm (0.0000–0.0059 in) Limit 0.23 mm (0.0091 in) Outer-rotor-to-oil-pump-housing clearance 0.13–0.18 mm (0.0051–0.0071 in) Limit 0.25 mm (0.0098 in) Oil-pump-housing-to-inner-and- outer-rotor clearance 0.06–0.11 mm (0.0024–0.0043 in)
  • Page 251 OIL PUMP • Install the spring “1” and relief valve “2”, and pin “3”. After installing, make sure that the relief valve “2” does not come loose. • Install the relief valve before installing the pri- mary drive gear and collar. 4.
  • Page 252 OIL PUMP 5. Install: 5 7 mm • Conical washer “1” (0.02 0.28 in) • Balancer weight gear nut “2” Balancer weight gear nut 50 N·m (5.0 kgf·m, 37 lb·ft) • Primary drive gear “3” • Conical washer “4” • Primary drive gear nut “5” Primary drive gear nut A.

  • Page 253: Crankcase

    CRANKCASE EAM20116 CRANKCASE Separating the crankcase 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 10 N ・...
  • Page 254 CRANKCASE Removing the bearing and oil seal 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 255: Disassembling The Crankcase

    CRANKCASE EAM30147 DISASSEMBLING THE CRANKCASE 1. Separate: • Right crankcase • Left crankcase a. Remove the crankcase bolts. c. Remove the dowel pins. 2. Remove: • Bearing “1” • Remove the bearing from the crankcase by pressing its inner race. •...

  • Page 256: Assembling The Crankcase

    Install the bearing by pressing its outer race par- allel. 3. Apply: • Sealant (to the crankcase mating surface) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 4. 45 mm (1.77 in) 5. 60 mm (2.36 in) 6. 75 mm (2.95 in) 4.

  • Page 257: Crankshaft And Balancer Shaft

    CRANKSHAFT AND BALANCER SHAFT EAM20184 CRANKSHAFT AND BALANCER SHAFT Removing the crankshaft assembly and balancer shaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-66. Transmission Refer to “TRANSMISSION” on page 5-73. Balancer shaft Crankshaft assembly 5-70...

  • Page 258: Removing The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT Out of specification  Replace the crank- EAM30491 REMOVING THE CRANKSHAFT shaft, bearing or both. 1. Remove: • Balancer shaft “1” Turn the crankshaft slowly. Remove the balancer shaft with its flat side “a” Runout limit facing the crankshaft.

  • Page 259: Installing The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT EAM30493 INSTALLING THE CRANKSHAFT 1. Install: • Crankshaft assembly Install the crankshaft assembly with the crank- shaft installer pot “1”, crankshaft installer bolt “2”, adapter (M12) “3” and spacer “4”. Crankshaft installer pot 90890-01274 Installing pot YU-90058 Crankshaft installer bolt 90890-01275...

  • Page 260: Transmission

    TRANSMISSION EAM20118 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-6. Separate. Crankcase Refer to “CRANKCASE” on page 5-66. Main axle Drive axle Long shift fork guide bar Short shift fork guide bar Spring Shift cam...

  • Page 261: Removing The Transmission

    TRANSMISSION EAM30153 REMOVING THE TRANSMISSION 1. Remove: • Long shift fork guide bar “1” • Short shift fork guide bar “2” • Shift cam “3” • Shift fork 3 “4” • Shift fork 2 “5” • Shift fork 1 “6” •...

  • Page 262: Checking The Transmission

    TRANSMISSION sembly. EAM30157 INSTALLING THE TRANSMISSION 1. Install: EAM30156 CHECKING THE TRANSMISSION • 6th pinion gear (27T) “1” 1. Measure: • 3rd/4th pinion gear (18T/21T) “2” • Main axle runout • Collar “3” (with a centering device and dial gauge “1”) •...
  • Page 263 TRANSMISSION 3. Install: • Drive axle “2” • Washer “1” • Circlip “2” • Install to the left crankcase simultaneously. • Apply engine oil to the main axle and the drive • Be sure the circlip sharp-edged corner “a” is axle bearing.
  • Page 264 TRANSMISSION 7. Install: • Long shift fork guide bar “1” • Short shift fork guide bar “2” • Spring “3” • Screw the spring into the shift fork guide bar lightly beforehand. • Apply the engine oil on the shift fork guide bars. 8.

  • Page 265: Cooling System

    COOLING SYSTEM COOLING SYSTEM DIAGRAMS ..............6-1 RADIATOR......................6-2 CHECKING THE RADIATOR ..............6-4 INSTALLING THE RADIATOR ..............6-4 WATER PUMP ....................6-6 DISASSEMBLING THE WATER PUMP .............6-7 CHECKING THE WATER PUMP ...............6-7 ASSEMBLING THE WATER PUMP ............6-7...

  • Page 266: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAM20186 COOLING SYSTEM DIAGRAMS 1. Radiator hose 1 2. Radiator (right) 3. Radiator hose 4 4. Water pump 5. Radiator hose 3 6. Radiator (left)

  • Page 267: Radiator

    RADIATOR EAM20138 RADIATOR Removing the radiator 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・...
  • Page 268 RADIATOR Removing the radiator 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・...

  • Page 269: Checking The Radiator

    RADIATOR EAM30341 CHECKING THE RADIATOR 1. Check: • Radiator fins “1” Obstructions  Clean. Apply compressed air to the rear of the radia- tor. Damage  Repair or replace. Correct any flattened fins with a thin, flat-head screwdriver. EAM30506 INSTALLING THE RADIATOR 1.
  • Page 270 RADIATOR head gasket is replaced is made after 3 min- utes of warm-up. • Make sure that coolant is filled up to the up- per level beforehand. 5. Check: • Pressure value No stay for 5 to 10 seconds at the test pres- sure value ...

  • Page 271: Water Pump

    WATER PUMP EAM20139 WATER PUMP Removing the water pump 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 14 N ・ m (1.4 kgf ・ m, 10 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 272: Disassembling The Water Pump

    WATER PUMP EAM30494 DISASSEMBLING THE WATER PUMP • Remove the oil seal when the coolant level changes frequently more than usual, coolant has discolored, or engine oil has become milky. • Do not use the removed oil seal. 1. Remove: •...
  • Page 273 WATER PUMP 4. Install: • Dowel pin “1” • Gasket “2” 5. Install: • Water pump housing “1” • Water pump housing bolt “2” Water pump housing bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) • Washer “3” • Coolant drain bolt “4” Coolant drain bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft)
  • Page 274 WATER PUMP...

  • Page 275: Fuel System

    FUEL SYSTEM FUEL TANK ......................7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP ..............7-2 CHECKING THE FUEL PUMP BODY ............7-2 CHECKING THE FUEL PUMP OPERATION ..........7-2 INSTALLING THE FUEL PUMP ..............7-2 INSTALLING THE FUEL TANK ..............7-3 THROTTLE BODY ....................7-4 CHECKING THE INJECTOR..............7-7 CHECKING THE THROTTLE BODY ............7-7 CHECKING THE FUEL PRESSURE............7-7...

  • Page 276: Fuel Tank

    FUEL TANK EAM20140 FUEL TANK Removing the fuel tank 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 4.0 N ・...

  • Page 277: Removing The Fuel Tank

    FUEL TANK EAM30263 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose coupler EWA19370 WARNING Cover the fuel hose connection with a cloth when disconnecting it. This is because re- sidual pressure in the fuel hose could cause fuel to spurt out when the hose is removed.

  • Page 278: Installing The Fuel Tank

    FUEL TANK • Take care not to damage the installation sur- faces of the fuel tank. • Always use a new fuel pump gasket. • Install the lip on the fuel pump gasket upward. • Install the fuel pump as shown in the figure. •...

  • Page 279: Throttle Body

    THROTTLE BODY EAM20141 THROTTLE BODY Removing the throttle body 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) 8 N ・...
  • Page 280 THROTTLE BODY Removing the throttle body 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) 8 N ・...
  • Page 281 THROTTLE BODY Removing the injector 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel inlet pipe Injector Gasket Throttle position sensor Intake air pressure sensor...

  • Page 282: Checking The Injector

    THROTTLE BODY EAM30271 CHECKING THE INJECTOR 1. Check: • Injectors Obstruction  Replace, and check the fuel pump and the fuel injection system. Refer to “FUEL INJECTION SYSTEM” on page 8-17. Deposits  Replace. Damage  Replace. 2. Check: • Injector resistance Refer to “CHECKING THE INJECTOR”...

  • Page 283: Adjusting The Throttle Position Sensor

    Check that the throttle grip is fully closed. d. Connect the throttle position sensor to the wire harness. e. Set the Yamaha diagnostic tool to “diag- nostic mode”. f. Choose the diagnostic code No. “01”. g. Adjust the throttle position sensor mount- ed angle until “11”–“14”...
  • Page 284 THROTTLE BODY...

  • Page 285: Electrical System

    TROUBLESHOOTING................8-15 FUEL INJECTION SYSTEM ................8-17 CIRCUIT DIAGRAM .................8-17 ECU SELF-DIAGNOSTIC FUNCTION .............8-19 TROUBLESHOOTING METHOD .............8-20 YAMAHA DIAGNOSTIC TOOL ..............8-21 CONNECTING THE YAMAHA DIAGNOSTIC TOOL .......8-21 TROUBLESHOOTING DETAILS (FAULT CODE)........8-22 FUEL PUMP SYSTEM..................8-41 CIRCUIT DIAGRAM .................8-41 TROUBLESHOOTING................8-43 ELECTRICAL COMPONENTS...............8-44 CHECKING THE SWITCHES..............8-45 CHECKING THE BULBS AND BULB SOCKETS........8-47...
  • Page 286 CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE ....................8-55 CHECKING THE INTAKE AIR TEMPERATURE SENSOR .....8-56 CHECKING THE GEAR POSITION SWITCH ..........8-56 CHECKING THE INJECTOR..............8-57...

  • Page 288: Ignition System

    IGNITION SYSTEM EAM20142 IGNITION SYSTEM EAM30277 CIRCUIT DIAGRAM...
  • Page 289 IGNITION SYSTEM 1. Crankshaft position sensor 2. AC magneto 3. Rectifier/regulator 4. Joint connector 6. Engine ground 7. Battery 8. Frame ground 9. Main fuse 10.Starter relay 11.Starter motor 12.Diode 1 13.Diode 2 14.CCU (Communication Control Unit) 21.ECU (Engine Control Unit) 22.Ignition coil 23.Spark plug 33.Engine stop switch...

  • Page 290: Troubleshooting

    IGNITION SYSTEM EAM30278 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). Before troubleshooting, remove the following part(s): 1. Side cover (left/right) 2. Seat 3. Fuel tank 4. Air scoop (left/right) 5. Air filter case cover 1. Check the ignition system wire har- Reconnect.
  • Page 291 IGNITION SYSTEM 9. Check the stator coil assembly. Refer to “CHECKING THE STA- Replace the stator coil assembly. NG TOR COIL” on page 8-53. OK 10.Check the ignition system wire har- ness. Repair or replace the wire harness. Refer to “CIRCUIT DIAGRAM” on NG...

  • Page 292: Electric Starting System

    ELECTRIC STARTING SYSTEM EAM20143 ELECTRIC STARTING SYSTEM EAM30279 CIRCUIT DIAGRAM...
  • Page 293 ELECTRIC STARTING SYSTEM 4. Joint connector 5. Main relay 6. Engine ground 7. Battery 8. Frame ground 9. Main fuse 10.Starter relay 11.Starter motor 12.Diode 1 13.Diode 2 21.ECU (Engine Control Unit) 33.Engine stop switch 34.Gear position switch 36.Start switch 37.Diode 3 A.

  • Page 294: 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 295 ELECTRIC STARTING SYSTEM 9. Check the start switch. Refer to “CHECKING THE Replace the start switch. NG SWITCHES” on page 8-45. OK 10.Check the entire starting system’s wiring. Properly connect or repair the starting sys- Refer to “CIRCUIT DIAGRAM” on tem’s wiring.

  • Page 296: Charging System

    CHARGING SYSTEM EAM20144 CHARGING SYSTEM EAM30282 CIRCUIT DIAGRAM...
  • Page 297 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 6. Engine ground 7. Battery 8. Frame ground 9. Main fuse A. Battery sub-lead B. Wire harness 8-10...

  • Page 298: Troubleshooting

    CHARGING SYSTEM EAM30283 TROUBLESHOOTING The battery is not being charged. Before troubleshooting, remove the following part(s): 1. Seat 2. Air scoop (left) 1. Check the entire charging system’s Reconnect. wiring. NG OK 2. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse(s).
  • Page 299 CHARGING SYSTEM 8-12...

  • Page 300: Signaling System

    SIGNALING SYSTEM EAM20154 SIGNALING SYSTEM EAM30348 CIRCUIT DIAGRAM 8-13...
  • Page 301 SIGNALING SYSTEM 4. Joint connector 5. Main relay 7. Battery 8. Frame ground 9. Main fuse 15.Warning light 16.Fuel level warning light 18.Resistor 19.Fuel sender 21.ECU (Engine Control Unit) A. Battery sub-lead B. Wire harness 8-14...

  • Page 302: 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 303 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 8-13. OK Replace the ECU. 8-16...

  • Page 304: Fuel Injection System

    FUEL INJECTION SYSTEM EAM20145 FUEL INJECTION SYSTEM EAM30284 CIRCUIT DIAGRAM 8-17...
  • Page 305 7. Battery 8. Frame ground 9. Main fuse 10.Starter relay 14.CCU (Communication Control Unit) 15.Warning light 17.Engine trouble warning light 20.Yamaha diagnostic tool coupler 21.ECU (Engine Control Unit) 22.Ignition coil 23.Spark plug 24.Fuel injector 25.Fuel pump 26.Radiator fan motor fuse 27.Coupler (not used)

  • Page 306: 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 307: Troubleshooting Method

    1. Check: • Fault code number a. Connect the Yamaha diagnostic tool. Refer to “YAMAHA DIAGNOSTIC TOOL” on page 8-21. b. Check the fault code number displayed on the Yamaha diagnostic tool. c. Identify the faulty system with the fault code number.

  • Page 308: Yamaha Diagnostic Tool

    • Prepare the fully charged 12 V lead battery for yourself. • Replace the vehicle battery with a lead battery (12 V). • For information on how to connect and use the Yamaha diagnostic tool, refer to “YAMAHA DIAGNO- STIC TOOL OPERATION MANUAL”.

  • Page 309: Troubleshooting Details (Fault Code)

    Yamaha diagnostic tool according to the reinstatement method. Fault code No.: Fault code number displayed on the Yamaha diagnostic tool when the engine failed to work normally. Diagnostic code No.: Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC CODE: SENSOR OPERATION TABLE”...
  • Page 310 Check the locking condition of repair/replace the wire harness. code using the malfunction the coupler. mode of the Yamaha diagnostic Disconnect the coupler, and tool. Condition is “Recovered”  Go check the pins (for bent or bro- ken terminals and locking condi- to item 7 and finish the service.
  • Page 311 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air pressure. Procedure The atmospheric pressure is displayed on the Yamaha diagnostic tool. Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check pletion Improperly connected ...
  • Page 312 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air pressure. Procedure The atmospheric pressure is displayed on the Yamaha diagnostic tool. Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check...
  • Page 313 Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 3 and finish the service. Condition is “Detected”  Go to item 2.
  • Page 314 Disconnect the coupler, and Yamaha diagnostic tool. Condition is “Recovered”  Go check the pins (for bent or bro- ken terminals and locking condi- to item 8 and finish the service.
  • Page 315 Check the condition of the fault Check the mounted condition SOR” on page 7-8. code using the malfunction for correctness. mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 4 and finish the service. Condition is “Detected”  Go to item 2.
  • Page 316 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 317 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 318 Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. Fault code No. 30 Before troubleshooting, disconnect the starter motor lead from the starter relay.
  • Page 319 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 320 Check the condition of the fault the coupler. code using the malfunction Disconnect the coupler, and mode of the Yamaha diagnostic check the pins (for bent or bro- tool. Condition is “Recovered”  Go ken terminals and locking condi- tion of the pins).
  • Page 321 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 322 5 seconds. INJECTOR” on page 8-57. Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 6 and finish the service. Condition is “Detected”  Go to item 3.
  • Page 323 Check the condition of the fault check the pins (bent or broken code using the malfunction terminals and locking condition mode of the Yamaha diagnostic of the pins). tool. Condition is “Recovered”  Go to item 6 and finish the service.
  • Page 324 Fuel system voltage is below 3 Check the condition of the fault V  Replace the main relay. code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 6 and finish the service.
  • Page 325 Check the condition of the fault the coupler. code using the malfunction Disconnect the coupler and mode of the Yamaha diagnostic check the pins (bent or broken tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
  • Page 326 Check the condition of the fault the coupler. code using the malfunction Disconnect the coupler and mode of the Yamaha diagnostic check the pins (bent or broken tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
  • Page 327 Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check pletion Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-40...

  • Page 328: Fuel Pump System

    FUEL PUMP SYSTEM EAM20146 FUEL PUMP SYSTEM EAM30287 CIRCUIT DIAGRAM 8-41...
  • Page 329 FUEL PUMP SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Joint connector 6. Engine ground 7. Battery 8. Frame ground 9. Main fuse 21.ECU (Engine Control Unit) 25.Fuel pump 33.Engine stop switch A. Battery sub-lead B. Wire harness 8-42...

  • Page 330: Troubleshooting

    FUEL PUMP SYSTEM EAM30288 TROUBLESHOOTING The fuel pump fails to operate. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 5. Air filter case cover 1. Check the fuel pump system wire Reconnect.

  • Page 331: Electrical Components

    ELECTRICAL COMPONENTS EAM20147 ELECTRICAL COMPONENTS 19.Coolant temperature sensor 1. Intake air pressure sensor 2. Throttle position sensor 3. Injector 4. Rectifier/regulator 5. Mode switch 6. Intake air temperature sensor 7. ECU (Engine Control Unit) 8. Ignition coil 9. Resistor 10.CCU (Communication Control Unit) 11.Starter relay 12.Main fuse 13.Battery...

  • Page 332: Checking The Switches

    ELECTRICAL COMPONENTS EAM30289 CHECKING THE SWITCHES Y/W P 1. Engine stop switch 2. Mode switch 3. Gear position switch 4. Engine start switch 8-45...
  • Page 333 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 334: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS however, note the following. EAM30357 CHECKING THE BULBS AND BULB a. Install a good bulb into the bulb socket. SOCKETS b. Connect the digital circuit tester probes to 1. Remove: the respective leads of the bulb socket. • Bulb c.

  • Page 335: Checking And Charging The Battery

    ELECTRICAL COMPONENTS a. Install a new fuse of the correct amperage attempting to start again. Charge the bat- tery again as soon as possible. A long state rating. b. Push the start switch to verify if the electri- of discharge below 10 V will damage the battery.
  • Page 336 4. Connect the battery charger (special tool) to ing the battery, it should be replaced. When the battery. replacing the battery, be sure to use a Lithium battery charger Yamaha genuine lithium-ion battery. 90890-05376 Lithium battery charger Do not check the battery at high temperature of DBY-ACC51-70-02 65 C (149 F) or more or low temperatures be-...

  • Page 337: Checking The Relays

    ELECTRICAL COMPONENTS Perform from step (c) again. Main relay Less than 10 V  Replace the battery. Before replacing the battery, make sure that the battery temperature is proper (temperature not more than 65 C (149 F) or less than 0 C (32 F)).

  • Page 338: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS EAM30294 CHECKING THE IGNITION SPARK GAP The digital circuit tester and the multimeter with 1. Check: tachometer readings are shown in the following • Ignition spark gap table. Out of specification  Perform the ignition system troubleshooting, starting with step (5). No continuity Refer to “TROUBLESHOOTING”...

  • Page 339: Checking The Ignition Coil

    ELECTRICAL COMPONENTS b. Measure the primary coil resistance. Digital circuit tester (CD732) 3. Check: 90890-03243 • Secondary coil resistance Model 88 Multimeter with tachom- Out of specification  Replace. eter YU-A1927 Secondary coil resistance 8.64–12.96 k a. Connect the digital circuit tester () to the ignition coil.

  • Page 340: Checking The Lean Angle Sensor

    ELECTRICAL COMPONENTS • Positive tester probe  Gray “1” • Negative tester probe  Black “2” b. Check the starter motor operation. EAM30300 CHECKING THE STATOR COIL 1. Disconnect: • Stator coil assembly coupler b. Measure the crankshaft position sensor (from the wire harness) resistance.

  • Page 341: Checking The Fuel Sender

    ELECTRICAL COMPONENTS Fuel pump is atmosphere “A” Regulated voltage (DC)  Fuel level warning light comes on 14.0–14.8 V Fuel pump is soaked in fuel “B”  Fuel level warning light goes off a. Set the digital tachometer to the ignition coil.

  • Page 342: Checking The Coolant Temperature Sensor

    ELECTRICAL COMPONENTS d. Slowly heat the coolant, and then let it cool EAM30303 CHECKING THE COOLANT TEMPERATURE to the specified temperature indicated in SENSOR the table. 1. Remove: e. Check the coolant temperature sensor for • Coolant temperature sensor continuity at the temperatures indicated in EWA14130 the table.

  • Page 343: Checking The Intake Air Temperature Sensor

    ELECTRICAL COMPONENTS c. Start the engine. EAM30467 CHECKING THE GEAR POSITION SWITCH d. Measure the throttle position sensor input 1. Remove: voltage. • Gear position switch EAM30307 2. Check: CHECKING THE INTAKE AIR • Gear position switch TEMPERATURE SENSOR Out of specification  Replace. 1.

  • Page 344: Checking The Injector

    ELECTRICAL COMPONENTS Y/W P EAM30496 CHECKING THE INJECTOR 1. Remove: • Fuel injector Refer to “THROTTLE BODY” on page 7-4. 2. Check: • Fuel injector resistance Out of specification  Replace. Resistance 12.0  a. Disconnect the fuel injector coupler from the fuel injector.

  • Page 345: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING ..................9-1 GENERAL INFORMATION ................9-1 TROUBLESHOOTING OF ENGINE (fault code not detected) ....9-1 TROUBLESHOOTING OF CLUTCH ............9-4 TROUBLESHOOTING OF TRANSMISSION ..........9-6 TROUBLESHOOTING OF COOLING SYSTEM ........9-7 TROUBLESHOOTING OF BRAKE ............9-8 TROUBLESHOOTING OF SUSPENSION ..........9-8 TROUBLESHOOTING OF STEERING/HANDLING.........9-10 TROUBLESHOOTING OF CHARGING SYSTEM........9-11 TROUBLESHOOTING OF SIGNALING SYSTEM ........9-11 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE....9-12 SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION...

  • Page 346: Troubleshooting

    TROUBLESHOOTING EAM20148 TROUBLESHOOTING EAM30309 GENERAL INFORMATION Troubleshooting information provided here does not cover all the trouble symptoms, possible causes, and remedial actions. Some items may not apply depending on the model. Use this information as a guide and quick reference matrix when performing basic troubleshooting. Refer to the each chapter for detailed information on checking, adjustment, and replacement.
  • Page 347 TROUBLESHOOTING Symptom Possible cause Actions Water or foreign material in fuel, Change fuel. degraded fuel Tighten the spark plug to the spec- Loose spark plug ified torque. Tighten bolts or nuts on cylinder Loose cylinder head or cylinder head and cylinder to the specified torque.
  • Page 348 TROUBLESHOOTING Symptom Possible cause Actions Worn camshaft lobe Replace the camshaft. Water or foreign material in fuel, Change fuel. degraded fuel Contaminated throttle body or Clean the throttle body. clogged internal passage Incorrectly adjusted throttle cable Adjust the throttle grip free play. Incorrectly adjusted idling speed Adjust the idle screw.

  • Page 349: Troubleshooting Of Clutch

    TROUBLESHOOTING Symptom Possible cause Actions Replace the piston and piston Worn or damaged piston ring rings as a set. Replace the piston and piston Worn or damaged piston rings as a set. Replace the piston and piston pin Worn piston (piston pin hole) as a set.
  • Page 350 TROUBLESHOOTING Symptom Possible cause Actions Replace the clutch springs as a Faulty clutch spring set. Warped pressure plate Replace the pressure plate. Replace the friction plates as a Swollen friction plate set. Warped clutch plate Replace the clutch plates as a set. Bent pull rod (outer pull type) Replace the pull rod.

  • Page 351: Troubleshooting Of Transmission

    TROUBLESHOOTING EAM30511 TROUBLESHOOTING OF TRANSMISSION Symptom Possible cause Actions Clutch drags Refer to “Clutch drags”. Adjust the shift rod installation Improperly adjusted shift rod length. Bent shift shaft Replace the shift shaft. Foreign object in a shift drum Remove foreign object from shift groove drum groove.

  • Page 352: Troubleshooting Of Cooling System

    TROUBLESHOOTING EAM30512 TROUBLESHOOTING OF COOLING SYSTEM Symptom Possible cause Actions Carbon buildup in piston head and Clean the piston head and com- combustion chamber bustion chamber. Clogged engine cooling water Check and clean the engine cool- passages ing water passages. Adjust the oil level to the specified Incorrect oil level level.

  • Page 353: Troubleshooting Of Brake

    TROUBLESHOOTING EAM30513 TROUBLESHOOTING OF BRAKE Symptom Possible cause Actions Worn brake pad Replace the brake pads as a set. Worn or deflected brake disc Replace the brake disc. Air in hydraulic brake system Bleed the hydraulic brake system. Check the hydraulic brake system Brake fluid leakage and repair or replace faulty parts as necessary.
  • Page 354 TROUBLESHOOTING Symptom Possible cause Actions Fatigued or broken fork spring Replace the fork spring. Incorrect oil viscosity (low) Change to recommended fork oil. Incorrect oil level (low) Adjust to the specified oil level. Improperly adjusted spring pre- Adjust the spring preload. Front fork is soft load (soft) Improperly adjusted rebound...

  • Page 355: Troubleshooting Of Steering/Handling

    TROUBLESHOOTING Symptom Possible cause Actions Oil leaking from rear shock Replace the rear shock absorber. absorber Gas leaking from rear shock Replace the rear shock absorber. absorber Fatigued or damaged rear shock Replace the rear shock absorber. absorber spring Rear suspension is soft Improperly adjusted rear shock Adjust the spring preload.

  • Page 356: Troubleshooting Of Charging System

    TROUBLESHOOTING Symptom Possible cause Actions Incorrect wheel balance Adjust the wheel balance. Tighten the spoke and adjust the Loose spoke runout. Damaged or worn wheel bearing Replace the wheel bearing. Worn, deformed, or incorrect tire Replace the tire. Front wheel vibration Loose wheel axle or wheel axle Tighten the wheel axle or wheel axle nut to the specified torque.

  • Page 357: Self-Diagnostic Function And Diagnostic Code Table

    Pressure of suction pipe Displays the intake air pressure. The atmospheric pressure is • Check the change of the displayed on the Yamaha intake pressure valve when diagnostic tool. the starter switch is pushed. Intake air temperature Displays the intake air tempera- Compare the actually mea- ture.
  • Page 358 Coolant temperature Displays the coolant tempera- Compare the actually mea- ture. sured coolant temperature with the Yamaha diagnostic tool display value. Lean angle sensor Displays the output voltage. Remove the ECU, and incline it 45 or more. • Upright •...

  • Page 359: Diagnostic Code: Actuator Operation Table

    Actuates the ignition coil five Check that a spark is gener- times at one-second intervals. ated five times. • Connect an ignition checker. “WARNING” on the Yamaha diagnostic tool blinks five times when the ignition coil is actu- ated. TIP: Before performing this...
  • Page 360 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9-15...

  • Page 361: 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 362: Chassis

    CHASSIS EAM20119 Part name Type Part number CHASSIS Rear wheel 17D-25447-50 EAM30168 sprocket “2” SELECTION OF THE SECONDARY 17D-25448-50 REDUCTION RATIO (SPROCKET) 17D-25449-50 Secondary reduction ratio = Number of 17D-25450-50 rear wheel sprocket teeth/Number of (STD) 17D-25451-50 drive sprocket teeth 17D-25452-50 Secondary reduction ratio 3.923 (51/13)

  • Page 363: Front Fork Setting

    (in position etc.) when Recommended oil setting the front fork. Yamaha Suspension Oil S1 1. Use of soft spring Standard oil amount • Change the rebound damping force.

  • Page 364: Front Fork Setting Parts

    CHASSIS Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, re- sulting in lack of a sense of contact with the road surface or in a vibrating handlebar. EAM30174 FRONT FORK SETTING PARTS • Front fork spring “1” STD Spring rate N/mm Spring...

  • Page 365: Setting Of Spring After Replacement

    CHASSIS sunken length “b” between the rear wheel 2. Use of stiff spring • Adjust to increase rebound damping force to axle center and the rear fender holding bolt. compensate for greater spring load. Run with the rebound damping force adjuster one or two clicks turned in, and readjust it to suit your preference.

  • Page 366: Rear Shock Absorber Setting Parts

    CHASSIS EAM30178 REAR SHOCK ABSORBER SETTING PARTS Spring preload adjusting positions Minimum • Rear shock spring “1” Position in which the spring is STD Spring rate turned in 1.5 mm (0.06 in) from N/mm its free length. Standard Spring I.D. Type rate Part number...

  • Page 367: 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 368: 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 369 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 370 CHASSIS 10-9...
  • Page 371 16. Fuel level warning light Green/Yellow 17. Engine trouble warning light Blue/Black 18. Resistor Blue/Green 19. Fuel sender Blue/Red 20. Yamaha diagnostic tool cou- Blue/White pler Blue/Yellow 21. ECU (Engine Control Unit) Pink/Black 22. Ignition coil Pink/Blue 23. Spark plug Red/Black 24.
  • Page 373 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. Why settle for aftermarket parts that may not provide full confidence and satisfaction? Genuine Yamaha Accessories –...
  • Page 374 PRINTED IN JAPAN 2019.07-0.8×1 !
  • Page 375 YZ250FXL1 2020 WIRING DIAGRAM...
  • Page 376 YZ250FXL1 2020 WIRING DIAGRAM...

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