Yamaha YZ250FX 2024 Owner's Service Manual
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Yamaha YZ250FX 2024 Owner's Service Manual

Yamaha YZ250FX 2024 Owner's Service Manual

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2024
OWNER'S SERVICE MANUAL
YZ250FX
Read this manual carefully before operating this vehicle.
YZ250FXR
LIT-11626-37-35
BAJ-2819U-14

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Summary of Contents for Yamaha YZ250FX 2024

  • Page 1 2024 OWNER’S SERVICE MANUAL YZ250FX Read this manual carefully before operating this vehicle. YZ250FXR LIT-11626-37-35 BAJ-2819U-14...
  • Page 2 EAM20161 Read this manual carefully Operating, servicing and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.

  • Page 3: Fcc Caution

    Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. FCC CAUTION Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment. This transmitter must not be co-located or operated in conjunction with any other antenna or transmitter.
  • Page 4 EAM20080 YZ250FXR OWNER’S SERVICE MANUAL ©2024 by Yamaha Motor Corporation, U.S.A. First edition, April 2023 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. P/N. LIT-11626-37-35...

  • Page 5: Important Manual Information

    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 EAM20204 YAMAHA MOTOR CORPORATION, U.S.A. 2020 AND LATER MODEL YZ/WR MOTORCYCLE LIMITED WARRANTY...

  • Page 7: How To Use This Manual

    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: General Information

    EAM10003 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING TUNING...

  • Page 11: Table Of Contents

    GENERAL INFORMATION SAFETY INFORMATION ................. 1-1 FOR SAFETY, BE SURE TO OBEY THE FOLLOWING:......1-1 ABOUT THE BATTERY ................... 1-4 LITHIUM-ION BATTERY ................1-4 LITHIUM-ION BATTERY DEGRADATION..........1-4 LOCATION OF IMPORTANT LABELS............1-5 DESCRIPTION....................1-6 IDENTIFICATION..................... 1-7 VEHICLE IDENTIFICATION NUMBER ............1-7 ENGINE SERIAL NUMBER ................
  • Page 12 STARTING AND BREAK-IN ................1-25 FUEL ......................1-25 STARTING A COLD ENGINE ..............1-25 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 ................

  • Page 13: Safety Information

    Yamaha ma- accidents. Many accidents have been chine, and take care to maintain it properly and caused by an automobile driver who did not operate it safely.
  • Page 14 The use of offer other modifications for Yamaha vehicles. a safety helmet is the single most critical factor Yamaha is not in a position to test the products in the prevention or reduction of head injuries. that these aftermarket companies produce.
  • Page 15 SAFETY INFORMATION an electric failure could result, which could 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 capabilities and to provide the best combina- tion of handling, braking, and comfort.

  • Page 16: About The Battery

    ABOUT THE BATTERY EAM20203 ABOUT THE BATTERY EAM30642 LITHIUM-ION BATTERY The lithium-ion battery used in the vehicle fea- tures high energy density and has a high voltage (approximately three times that of nickel-cadmi- um (Ni-Cd) or nickel-hydrogen (Ni-MH) batter- ies), meaning it can be made both compact and lightweight.

  • Page 17: 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 For use only on a closed course Premium unleaded in sanctioned competition. gasoline only. This motorcycle does not meet EPA noise and emissions standards and is not for general off-road recreational riding.

  • Page 18: Description

    DESCRIPTION EAM20086 DESCRIPTION 2, 3 10 9 11.Fuel tank 1. Clutch lever 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 19: Identification

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

  • Page 20: Included Parts

    INCLUDED PARTS EAM20088 EWA20460 INCLUDED PARTS • 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 21 INCLUDED PARTS 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. 3. Activate the Power Tuner app. If the CCU wireless network cannot be detect- ed, operate the start switch again.

  • Page 22: Important Information

    2. Use proper special tools and equipment. Re- used for repair of the vehicle, including periodic fer to “SPECIAL TOOLS” on page 1-16. replacement parts, are new YAMAHA genuine parts and recommended parts. Do not use any used parts, because these may...

  • Page 23: 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 EAM30014 bend the lock tabs along a flat of the bolt or nut.

  • Page 24: Basic Service Information

    BASIC SERVICE INFORMATION EAM20120 BASIC SERVICE INFORMATION EAM30181 ELECTRICAL SYSTEM Electrical parts handling ECA16600 Never disconnect a battery lead while the engine is running; otherwise, the electrical components could be damaged. ECA16760 Be sure to connect the battery leads to the correct battery terminals.
  • Page 25 BASIC SERVICE INFORMATION ECA16630 ECA14371 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 26 BASIC SERVICE INFORMATION ECA16780 • 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 27 BASIC SERVICE INFORMATION 5. Check: • No continuity Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 • If there is no continuity, clean the terminals. • When checking the wire harness, perform steps (1) to (4). •...

  • Page 28: Special Tools

    Feeler gauge set YU-26900-9 Valve lapper (ø14) 3-8, 5-26 90890-04101 90890-04101 Valve lapper (ø14) YM-A8998 YM-A8998 Yamaha diagnostic tool USB (US) 3-12, 7-8, 8-21 90890-03269 Yamaha diagnostic tool (A/I) 3-12, 7-8, 8-21 90890-03273 FI diagnostic tool sub–lead 3-12, 7-8, 8-21 90890-03212 FI diagnostic tool sub–lead...
  • Page 29 4-47, 4-50, 4-52 Cap bolt ring wrench YM-01501 Cap bolt wrench 4-44, 4-47 90890-01500 Cap bolt wrench YM-01500 Fork seal driver 4-49, 4-49 90890-01502 Fork seal driver (48) YM-A0948 Yamaha bond No. 1215 5-19, 5-38, 5-68 90890-85505 Three bond No. 1215® 1-17...
  • Page 30 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve spring compressor 5-26, 5-30 90890-04200 Valve spring compressor YM-04019 Valve spring compressor attachment 5-26, 5-30 90890-04108 Valve spring compressor adapter 22 mm YM-04108 Valve guide remover (ø5) 5-28 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø5) 5-28...
  • Page 31 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Piston pin puller set 5-33 90890-01304 Piston pin puller YU-01304 YU-01304 Rotor puller 5-38 90890-04151 Rotor puller YM-04151 Sheave holder 5-41, 5-42 90890-01701 Primary clutch holder YS-01880-A Clutch holder 5-50, 5-52 90890-04199 Universal clutch holder YM-91042 Crankcase separating tool...
  • Page 32 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Crankshaft installer pot 5-71 90890-01274 Installing pot YU-90058 YU-90058/YU-90059 Crankshaft installer bolt 5-71 90890-01275 Bolt YU-90060 Adapter (M12) 5-71 90890-01278 Adapter #3 YU-90063 Spacer (crankshaft installer) 5-71 90890-04081 Pot spacer YM-91044 YM-91044 Radiator cap tester 6-4, 6-4 90890-01325...
  • Page 33 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages 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 Lithium battery charger 8-51, 8-51 90890-05376 Lithium battery charger DBY-ACC51-70-02 Ignition checker...

  • Page 34: Instrument And Control Functions

    This warning light comes on or flashes if a prob- lem is detected in the electrical circuit monitor- ing 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 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

    Since exhaust gas contains harmful ingredi- hol containing methanol is not recommended ents, do not start or warm it up at an illventi- by Yamaha because it can cause damage to the lated place or a closed narrow place. fuel system or vehicle performance problems.

  • Page 38: Starting A Warm Engine

    STARTING AND BREAK-IN ECA25821 After a break-in or after each race, always 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

    Pour the specified amount of the recom- AIR FILTER MAINTENANCE mended oil. Apply the Yamaha foam air filter oil or other • Generator quality foam air filter oil to the element. (Excess Check for looseness in mounted areas of the oil in the element may adversely affect engine generator rotor and the stator coil assembly.

  • Page 40: Torque-Check Points

    TORQUE-CHECK POINTS EAM20125 TORQUE-CHECK POINTS Frame construction Combined seat and fuel tank Fuel tank to frame Frame to rear frame Frame to engine protector Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Seat Seat to frame Steering Steering stem to handlebar Steering stem to frame...
  • Page 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 EAM20126 ucts are used on hard-to-remove dirt, do MOTORCYCLE CARE AND STOR- not leave the cleaner on the affected area any longer than instructed. Also, thorough- ly rinse the area off with water, immediately EAM30200 dry it, and then apply a corrosion protection CARE spray.

  • 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” on page 1-30. 2. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rust- ing and the fuel from deteriorating.
  • Page 45 SPECIFICATIONS GENERAL SPECIFICATIONS ................. 2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-5 ELECTRICAL SPECIFICATIONS..............2-8 TIGHTENING TORQUES ................2-9 GENERAL TIGHTENING TORQUE SPECIFICATIONS ......2-9 ENGINE TIGHTENING TORQUES ............2-10 CHASSIS TIGHTENING TORQUES............2-13 CABLE ROUTING DIAGRAM ............... 2-17...

  • Page 46: Specifications

    GENERAL SPECIFICATIONS EAM20127 GENERAL SPECIFICATIONS Model Model BAJL Dimensions Overall length 2175 mm (85.6 in) Overall width 825 mm (32.5 in) Overall height 1280 mm (50.4 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 Valve, valve seat, valve guide Valve clearance (cold) Intake 0.12–0.19 mm (0.0047–0.0075 in) Exhaust 0.17–0.24 mm (0.0067–0.0094 in) Valve dimensions Valve seat contact width limit (intake) 1.6 mm (0.06 in) Valve seat contact width limit (exhaust) 1.6 mm (0.06 in) Valve stem diameter limit (intake) 4.945 mm (0.1947 in) Valve stem diameter limit (exhaust)
  • 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 Maximum consumption amperage 2.4 A Fuel injector 12.0  Resistance...

  • Page 50: Chassis Specifications

    CHASSIS SPECIFICATIONS EAM20129 CHASSIS SPECIFICATIONS Chassis 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) Rear wheel...
  • Page 51 Fork spring free length limit 492.0 mm (19.37 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil S1 Quantity (left) 501.0 cm³ (16.94 US oz, 17.67 Imp.oz) Quantity (right) 501.0 cm³ (16.94 US oz, 17.67 Imp.oz)
  • Page 52 CHASSIS SPECIFICATIONS Adjustment value from the start position (Hard) Slow compression damping Unit for adjustment Click Adjustment value from the start position (Soft) Adjustment value from the start position (STD) Adjustment value from the start position (Hard) Drive chain Size Chain type Sealed type Number of links...

  • Page 53: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAM20130 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system 8.0–12.0 /2000 r/min Ignition timing (B.T.D.C.) Engine control unit Model BAJ2 Ignition coil 2.16–2.64  Primary coil resistance Secondary coil resistance 8.64–12.96 k Spark plug cap Resistance 7.50–12.50 k...

  • Page 54: Tightening Torques

    TIGHTENING TORQUES EAM20131 TIGHTENING TORQUES EAM30205 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a criss- cross pattern and progressive stages until the specified tightening torque is reached.

  • Page 55: Engine Tightening Torques

    TIGHTENING TORQUES EAM30203 ENGINE TIGHTENING TORQUES - marked portion shall be checked for torque tightening after break-in or before each race. Thread Item Q’ty Tightening torques Remarks size Camshaft cap bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) Cylinder head stud bolt (exhaust 7 N·m (0.7 kgf·m, 5.2 lb·ft) pipe)
  • Page 56 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Clutch cable locknut (engine side) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 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)
  • Page 57 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Crankshaft position sensor bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Stator coil assembly lead holder bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) Coolant temperature sensor 15 N·m (1.5 kgf·m, 11 lb·ft) Gear position switch bolt 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) Rectifier/regulator bolt...

  • Page 58: 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 59 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size  Front wheel axle nut 115 N·m (11.5 kgf·m, 85 lb·ft)  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 12 N·m (1.2 kgf·m, 8.9 lb·ft)
  • Page 60 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size 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 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) ...
  • Page 61 TIGHTENING TORQUES 2-16...

  • Page 62: Cable Routing Diagram

    CABLE ROUTING DIAGRAM EAM20152 CABLE ROUTING DIAGRAM Frame and engine (left side view) 2-17...
  • Page 63 (the side of the 30.Crankcase cover vehicle). 31.Crankcase S. Pass the engine stop switch lead between 32.Clamp the Yamaha diagnostic tool coupler and the tank rail. 33.Frame 34.Plate T. Pass the warning light lead under the mode switch lead.
  • Page 64 CABLE ROUTING DIAGRAM Frame and engine (right side view) 2-19...
  • Page 65 CABLE ROUTING DIAGRAM L. After connecting the fuel pump coupler, 1. Cross tube attach the cover. 2. Starter motor lead M. Fasten the starter relay lead and starter 3. Coolant temperature sensor coupler motor lead with the plastic locking tie within 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 H. Fasten the starter motor lead along the 1. Clamp locating damper. 2. Diode I. It does not matter if the high tension cord 3. Throttle position sensor lead and grommet do not contact the ECU. 4. Intake air pressure sensor lead J.
  • 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. Protector 2. Rear brake caliper 3. Bleed screw 4. Gasket 5. Rear brake hose 6. Brake pedal 7. Rear brake master cylinder assembly 8. Swingarm 9. Spring 10.Frame A. It does not matter whether the spring is installed upward or downward.
  • Page 74 CABLE ROUTING DIAGRAM 2-29...
  • Page 75 PERIODIC CHECKS AND ADJUSTMENTS SERVICING PARTS ..................3-1 MAINTENANCE INTERVALS................3-2 MAINTENANCE INTERVALS ..............3-2 PRE-OPERATION INSPECTION AND MAINTENANCE........ 3-6 GENERAL INSPECTION AND MAINTENANCE ......... 3-6 ENGINE......................3-7 ADJUSTING THE VALVE CLEARANCE............. 3-7 VALVE CLEARANCE SHIM CHART............3-10 CHECKING THE ENGINE IDLING SPEED..........3-12 CHECKING THE THROTTLE GRIP............
  • Page 76 CHECKING THE TIRES ................3-34 CHECKING AND TIGHTENING THE SPOKES ........3-34 CHECKING THE WHEELS............... 3-34 CHECKING THE WHEEL BEARINGS ............3-34 CHECKING THE CHASSIS FASTENERS ..........3-35 CHECKING AND LUBRICATING THE CABLES ........3-35 LUBRICATING THE BRAKE LEVER ............3-35 LUBRICATING THE CLUTCH LEVER............
  • Page 77 ELEMENT, AIR CLEANER 5D3-13440-02 ELEMENT ASSY, OIL CLEANER 17D-27200-51 PEDAL, BRAKE 1C3-W0046-B0 BRAKE PAD KIT 2 The part number is subject to change. In that case, order the part from a Yamaha dealer by stating the identification number of your vehicle.

  • Page 78: 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 79 MAINTENANCE INTERVALS Every Every third Every fifth After race 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  11 * Cylinder head eliminate them.
  • Page 80 MAINTENANCE INTERVALS Every Every third Every fifth After race 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 81 MAINTENANCE INTERVALS Every Every third Every fifth After race 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 ...

  • Page 82: 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 condition. Before using this machine, check the following points. EAM30209 GENERAL INSPECTION AND MAINTENANCE Item Inspect Page...

  • Page 83: Engine

    Turn the crankshaft counterclockwise basic knowledge and skill concerning the ser- with a wrench. vicing 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 84 ENGINE • The adjusting pad number “a” is indicated on the top of the adjusting pad. • For the number on the originally installed ad- justing pad, convert the last digit of adjusting pad number as per the below table. 5.
  • Page 85 ENGINE • Make sure that adjusting pads are installed with their numbers facing upward. f. Install the camshafts (exhaust and intake). Refer to “CAMSHAFT” on page 5-13. g. Measure the valve clearance again. h. If the valve clearance is out of specifica- tion, repeat adjusting the valve clearance until it is within specification.

  • Page 86: 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 87 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 88: 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) 90890-03273 FI diagnostic tool sub–lead...

  • Page 89: Checking The Spark Plug

    ENGINE 2. Adjust: ECA24410 • 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 90: 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 91 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 92: Adjusting The Clutch Lever Free Play

    ENGINE ECA25840 Clutch cable side a. Slide the clutch cable cover. If no engine oil seeps out after one minute, b. Loosen the locknut “1”. immediately turn the engine off so it will not c. Turn the adjuster “2” until the specified seize.
  • Page 93 • Air filter element Damage  Replace. 6. Apply: • Yamaha foam air filter oil or other quality foam air filter oil a. Put the air filter element into a plastic bag and drip the filter oil into the bag.

  • Page 94: Checking The Throttle Body Joint

    ENGINE 8. Turn the plates “1” to the original position. 10.Install: • Fuel tank cap cover EAM30335 CHECKING THE THROTTLE BODY JOINT 1. Check: • Throttle body joint “1” Crack/damage  Replace. 9. Install: • Air filter case cover “1” •...

  • Page 95: Checking The Cylinder Head Breather Hose

    ENGINE 4. Check: • Silencer fiber Damage  Replace. 5. Replace: • Silencer fiber a. Remove the bolts “1” and silencer body “2”. ECA25800 Do not hit the silencer stay “a” as it may do damage to the silencer. 3. Install: •...
  • Page 96 ENGINE d. Install the fiber insert “6” to the part “b”. h. Install the fiber insert “12” to the inner e. Twist the fiber insert “7” onto the inner pipe. pipe “c”. i. Install the fiber insert “13” to the inside of the silencer cap “14”.

  • Page 97: Checking The Coolant Level

    ENGINE 6. Check: EAM30210 CHECKING THE COOLANT LEVEL • Gasket “1” EWA13030 Damage  Replace. A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in- jury.

  • Page 98: Checking The Cooling System

    ENGINE tilled water is not available, soft water may be used. 4. Start the engine, warm this up for several minutes, and then stop it. 5. Check: • Coolant level Before checking the coolant level, wait a few minutes until the coolant has settled. 3.
  • Page 99 ENGINE tion of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft water may be used. • If coolant comes into contact with painted surfaces, immediately wash them with wa- ter. • Do not mix different types of antifreeze. 7.

  • Page 100: Chassis

    CHASSIS EAM20136 system. Air in the brake system will consid- CHASSIS erably reduce braking performance. ECA13490 EAM30479 ADJUSTING THE FRONT DISC BRAKE After adjusting the brake lever position, There should be no free play at the brake lever make sure there is no brake drag. end.

  • Page 101: Checking The Front Brake Pads

    CHASSIS Add. Specified brake fluid DOT 4 EAM30232 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. A. Front brake 2. Check: B. Rear brake • Rear brake pad Wear indicator grooves “1” almost touch the EWA13090 brake disc ...

  • Page 102: Checking The Brake Operation

    CHASSIS 2. Check: a. Fill the reservoir to the proper level with • Brake hose holder the recommended brake fluid. Loose connection  Tighten the holder bolt. b. Install the reservoir diaphragm. 3. Hold the vehicle upright and apply the rear c.

  • Page 103: Drive Chain Slack

    CHASSIS plastic parts. Always clean up spilled fluid immediately. i. Tighten the bleed screw. Bleed screw 5 N·m (0.5 kgf·m, 3.7 lb·ft) j. Pour brake fluid to the reservoir up to the specified level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...

  • Page 104: Lubricating The Drive Chain

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

  • Page 105: Lubricating The Steering Head

    CHASSIS 4. Check: Ring nut (final tightening torque) • Front fork operation 7 N·m (0.7 kgf·m, 5.2 lb·ft) Push down hard on the handlebar several times and check if the front fork rebounds e. Check the steering head for looseness or smoothly.

  • Page 106: Adjusting The Front Fork Legs

    CHASSIS be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary. EAM30239 ADJUSTING THE FRONT FORK LEGS EWA19180 Compression damping • Always adjust the left and right front forks ECA24350 evenly.

  • Page 107: Checking The Rear Shock Absorber Assembly

    CHASSIS 3. Check: • Rear shock absorber assembly smooth ac- tion • Rear suspension link smooth action Sit astride the seat and shake your body up and down several times to check whether the rear shock absorber assembly operates smoothly. Unsmooth operation ...
  • Page 108 CHASSIS Spring preload adjusting positions Rebound damping Minimum Minimum (soft) Position in which the spring is 30 click(s) in direction “b”* turned in 1.5 mm (0.06 in) from Standard its free length. 11 click(s) in direction “b”* Standard Maximum (hard) Position in which the spring is 0 click(s) in direction “a”...

  • Page 109: Checking The Swingarm Operation

    CHASSIS Fast compression damping Slow compression damping Minimum (soft) Minimum (soft) 2 turn(s) in direction “b”* 20 click(s) in direction “b”* Standard Standard 1-1/8 turn(s) in direction “b”* 11 click(s) in direction “b”* Maximum (hard) Maximum (hard) 0 turn(s) in direction “b”* 0 click(s) in direction “b”* * With the adjusting screw fully turned in di- * With the adjusting screw fully turned in di-...

  • Page 110: Checking The Tires

    CHASSIS EAM30243 CHECKING THE TIRES A tight spoke will emit a clear, ringing tone; a 1. Measure: loose spoke will sound flat. • Tire pressure Out of specification  Regulate. 2. Tighten: • Spoke Tire air pressure (measured on (with a spoke nipple wrench “1”) cold tires) Front 100 kPa (1.00 kgf/cm², 15 psi)

  • Page 111: Checking The Chassis Fasteners

    CHASSIS EAM30253 CHECKING THE CHASSIS FASTENERS Recommended lubricant Lithium-soap-based grease Make sure that all nuts, bolts, and screws are properly tightened. Refer to “CHASSIS TIGHTENING TORQUES” EAM30504 CHECKING THE SIDESTAND on page 2-13. 1. Check: • Sidestand operation EAM30248 CHECKING AND LUBRICATING THE Check that the sidestand moves smoothly.

  • Page 112: Electrical System

    ELECTRICAL SYSTEM EAM20137 ELECTRICAL SYSTEM EAM30256 CHECKING AND CHARGING THE BATTERY Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-50. EAM30505 CHECKING THE FUSES Refer to “CHECKING THE FUSES” on page 8-49. 3-36...
  • Page 113 CHASSIS GENERAL CHASSIS ..................4-1 REMOVING THE SEAT ................4-3 REMOVING THE NUMBER PLATE............4-3 INSTALLING THE AIR SCOOP ..............4-4 REMOVING THE SIDE COVER..............4-4 INSTALLING THE SIDE COVER ..............4-4 FRONT WHEEL ....................4-5 REMOVING THE FRONT WHEEL.............. 4-6 DISASSEMBLING THE FRONT WHEEL ............
  • 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.............

  • Page 115: General Chassis

    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: Removing The Seat

    GENERAL CHASSIS EAM30016 REMOVING THE SEAT 2 2 2 The fuel tank cap cover and the seat are cou- pled with each other with a plastic band. When removing the seat, always remove the fuel tank cap cover beforehand. 1. Remove: •...

  • Page 118: Installing The Air Scoop

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

  • Page 119: Front Wheel

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

  • Page 120: Removing The Front Wheel

    FRONT WHEEL EAM30017 3. Check: REMOVING THE FRONT WHEEL • Spoke 1. Use a maintenance stand to raise the front Refer to “CHECKING AND TIGHTENING wheel off the ground. THE SPOKES” on page 3-34. EWA13120 4. Tighten: • Spoke Securely support the vehicle so that there is Refer to “CHECKING AND TIGHTENING no danger of it falling over.

  • Page 121: Installing The Front Wheel

    FRONT WHEEL • Left side of bearing shall be installed first. 3. Install: • Install the oil seal with its manufacture’s marks • Collar “1” or numbers facing outward. Apply the lithium-soap-based grease on the oil ECA24420 seal lip. Install the bearing by pressing its outer race parallel.
  • Page 122 FRONT WHEEL Front wheel axle nut 115 N·m (11.5 kgf·m, 85 lb·ft) ECA24430 Before tightening the front wheel axle nut, push down hard on the handlebar(s) several times and check if the front fork rebounds smoothly. 4. Tighten: • Front wheel axle pinch bolt “1” Front wheel axle pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft)

  • Page 123: Rear Wheel

    REAR WHEEL EAM20096 REAR WHEEL Removing the rear wheel 12 N ・ m (1.2 kgf ・ m, 8.9 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: Removing The Rear Wheel

    REAR WHEEL EAM30022 Refer to “CHECKING THE TIRES” on page REMOVING THE REAR WHEEL 3-34 and “CHECKING THE WHEELS” on 1. Use a maintenance stand to raise the rear page 3-34. wheel off the ground. 3. Check: EWA13120 • Spoke Refer to “CHECKING AND TIGHTENING Securely support the vehicle so that there is THE SPOKES”...

  • 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. EAM30026 ASSEMBLING THE REAR WHEEL 1. Install: 2. Install: • Bearing (right side) “1” • Brake disc •...
  • Page 126 REAR WHEEL 2. Install: 5. Adjust: • Drive chain “1” • Drive chain slack “a” Drive chain slack (Maintenance Push the rear wheel “2” forward and install the Stand) drive chain. 50.0–60.0 mm (1.97–2.36 in) Refer to “DRIVE CHAIN SLACK” on page 3-27.

  • Page 127: Front Brake

    FRONT BRAKE EAM20097 FRONT BRAKE Removing the front brake caliper 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 28 N ・ m (2.8 kgf ・ m, 21 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 17 N ・...
  • Page 128 FRONT BRAKE Disassembling the front brake caliper 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake caliper piston kit Brake caliper piston seal kit 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 Brake master cylinder kit 4-16...

  • Page 131: Introduction

    FRONT BRAKE EAM30028 b. Remove the brake caliper. INTRODUCTION c. Hold the dial gauge at a right angle EWA19210 against the brake disc surface. d. Measure the runout 1.5 mm (0.06 in) If you need to disassemble the disc brake above the brake disc edge.
  • Page 132 FRONT BRAKE d. Remove the pad pin and brake pads “4”. Bleed screw 5 N·m (0.5 kgf·m, 3.7 lb·ft) d. Install the brake pads “3” and the pad pin. • Install the brake pads with their projections “a” into the brake caliper recesses “b”. •...

  • Page 133: Removing The Front Brake Caliper

    FRONT BRAKE 4. Check: • Brake fluid level Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-24. 5. Check: • Brake lever operation A softy or spongy feeling  Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-26. b.

  • Page 134: Installing The Front Brake Caliper

    FRONT BRAKE internal parts. Use new brake fluid for Brake pad pin cleaning and lubricating. 17 N·m (1.7 kgf·m, 13 lb·ft) • Never use solvents on internal brake com- ponents as they will cause the piston seals Refer to “CHECKING THE FRONT BRAKE to swell and distort.

  • Page 135: Removing The Front Brake Master Cylinder

    FRONT BRAKE Damage/scratches/wear  Replace. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-26. 3. Check: 6. Check: • Brake hose Cracks/damage/wear  Replace. • Brake fluid level The minimum level mark or below  Add. EAM30038 Refer to “CHECKING THE BRAKE FLUID ASSEMBLING THE FRONT BRAKE MASTER LEVEL”...

  • Page 136: Installing The Front Brake Master Cylinder

    FRONT BRAKE bolt. Install the spring with a smaller inside diameter to the brake master cylinder piston. 2. Install: • Copper washer 4. Install: • Brake hose • Brake master cylinder piston assembly “1” • Union bolt • Washer “2” Brake hose union bolt •...

  • Page 137: Brake System

    FRONT BRAKE EWA13090 • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake 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 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake caliper piston kit Brake caliper piston seal kit 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 Brake master cylinder joint 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) If you need to disassemble the disc brake 4. Replace: components, observe the following precau- • Brake disc tions. Refer to “ASSEMBLING THE REAR WHEEL” •...
  • Page 143 REAR BRAKE Bleed screw 5 N·m (0.5 kgf·m, 3.7 lb·ft) d. Install the brake pads “3” and the pad pin “4”. • Install the brake pads with their projections “a” into the brake caliper recesses “b”. • Temporarily tighten the pad pin at this point. 2.

  • Page 144: Removing The Rear Brake Caliper

    REAR BRAKE EWA13550 • Cover the brake caliper piston with a rag. Be careful not to get injured when the pis- ton is expelled from the brake caliper. • Never try to pry out the brake caliper pis- ton. 4. Check: •...

  • Page 145: Assembling The Rear Brake Caliper

    REAR BRAKE 2. Check: • Brake caliper bracket Crack/damage  Replace. EAM30045 ASSEMBLING THE REAR BRAKE CALIPER EWA19280 • Before installation, clean and lubricate the internal parts. Use new brake fluid for cleaning and lubricating. • Never use solvents on internal brake com- 3.

  • Page 146: Removing The Rear Brake Master Cylinder

    REAR BRAKE 6. Check: • Brake master cylinder reservoir diaphragm Crack/damage  Replace. • Brake fluid level The minimum level mark or below  Add. 3. Check: Refer to “CHECKING THE BRAKE FLUID • Brake hose Cracks/damage/wear  Replace. LEVEL” on page 3-24. 7.

  • Page 147: Installing The Rear Brake Master Cylinder

    REAR BRAKE (to the brake master cylinder piston “2”) sure safe vehicle operation. ECA24500 Install the spring with a smaller inside diameter to the brake master cylinder piston. Make sure that the pipe portion of the brake hose touches the projection “a” on the brake caliper.
  • Page 148 REAR BRAKE A softy or spongy feeling  Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-26. 4-34...

  • Page 149: Handlebar

    HANDLEBAR EAM20099 HANDLEBAR Removing the handlebar 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 28 N ・ m (2.8 kgf ・ m, 21 lb ・ ft) 3.0 N ・...

  • Page 150: Removing The Handlebar

    HANDLEBAR EAM30052 EWA13120 REMOVING THE HANDLEBAR 1. Stand the vehicle upright on a level surface. Securely support the vehicle so that there is EWA13120 no danger of it falling over. 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 pivot bolt 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) Clutch lever pivot nut 7 N·m (0.7 kgf·m, 5.2 lb·ft)
  • Page 152 HANDLEBAR Clutch lever free play 30 50˚ 0 mm 7.0–12.0 mm (0.28–0.47 in) (0 in) 9. Install: • Right grip “1” • Collar “2” Apply adhesive to the tube guide “3”. 0 mm • Before applying the adhesive, wipe off grease (0 in) or oil on the tube guide surface “a”...
  • Page 153 HANDLEBAR 11.Install: 13.Install: • Throttle cable “1” • Rubber cover “1” • Cover (throttle cable housing) “2” Slightly coat the end of throttle cable and inside of throttle grip with lithium-soap-based grease. Then, mount the throttle grip onto the handle- bar.
  • Page 154 HANDLEBAR 15.Adjust: • Throttle grip free play Refer to “CHECKING THE THROTTLE GRIP” on page 3-12. Throttle grip free play 3.0–6.0 mm (0.12–0.24 in) 4-40...

  • Page 155: Front Fork

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

  • Page 157: Removing The Front Fork Legs

    FRONT FORK EAM30055 REMOVING THE FRONT FORK LEGS 1. Use a maintenance stand to raise the front wheel off the ground. EWA13120 Securely support the vehicle so that there is no danger of it falling over. Record the adjusting screw setting position be- fore loosening the adjuster and the base valve.

  • Page 158: Checking The Front Fork Legs

    FRONT FORK Cap bolt wrench 90890-01500 Cap bolt wrench YM-01500 Cap bolt ring wrench 90890-01501 Cap bolt ring wrench YM-01501 3. Remove: • Dust seal “1” • Stopper ring “2” (with a flat-head screwdriver) ECA14180 Do not scratch the inner tube. EAM30057 CHECKING THE FRONT FORK LEGS 1.
  • Page 159 FRONT FORK 4. Check: 6. Check: • Damper assembly “1” • Upper spring seat “1” Bend/damage  Replace. (contacting surface “a”) Wear/damage  Replace. • O-ring “2” Wear/damage  Replace. ECA14200 • The front fork leg has a built-in damper ad- justing rod and a very sophisticated inter- nal construction, which are particularly sensitive to foreign material.

  • Page 160: Assembling The Front Fork Legs

    1. Stretch the damper assembly fully. 2. Fill: • Damper assembly Recommended oil Yamaha Suspension Oil S1 Standard oil amount 216 cm³ (7.30 US oz, 7.62 Imp.oz) ECA24530 • Be sure to use the recommended oil. Other 5.
  • Page 161 FRONT FORK not be obtained after installation. 10.After filling, pump the damper assembly “1” slowly up and down more than 10 times to 7. Install: distribute the fork oil. • Base valve “1” (to the damper assembly “2”) First bring the damper rod pressure to a maxi- mum.
  • Page 162 FRONT FORK 13.Check: • Damper assembly smooth movement Tightness/binding/rough spots  Repeat the steps (1) to (12). 15.Install: • Piston metal “1” Install the piston metal onto the slot on inner 14.Install: tube. • Dust seal “1” • Scraper “2” •...
  • Page 163 FRONT FORK (to the outer tube) 19.Install: • Stopper ring “1” Press the slide metal into the outer tube with fork seal driver “3”. Fit the stopper ring correctly in the groove in the outer tube. Fork seal driver 90890-01502 Fork seal driver (48) YM-A0948 20.Install:...
  • Page 164 FRONT FORK Distance “a” 16 mm (0.63 in) or more Between the damper assembly “1” bottom and locknut “2” bot- tom. 25.Loosen: • Rebound damping force adjuster “1” • Before loosening the damping force adjuster, record the setting position. • Unless the damping force adjuster is fully loosened, correct damping characteristic can- 23.Install: not be obtained after installation.
  • Page 165 0.5–1.0 mm (0.02–0.04 in) 30.Fill: • Front fork leg Recommended oil If it is installed with a gap out of specification, Yamaha Suspension Oil S1 correct damping force cannot be obtained. Standard oil amount 295 cm³ (9.97 US oz, 10.4 Imp.oz) Extent of adjustment 260–365 cm³...

  • Page 166: Installing The Front Fork Legs

    FRONT FORK Cap bolt ring wrench 90890-01501 Cap bolt ring wrench YM-01501 32.Install: • Protector guide “1” EAM30059 INSTALLING THE FRONT FORK LEGS 1. Install: 3. Adjust: • Front fork “1” • Front fork top end “a” • Temporarily tighten the lower bracket pinch Front fork top end (standard) “a”...
  • Page 167 FRONT FORK 8. Adjust: Lower bracket pinch bolt • Compression damping force 21 N·m (2.1 kgf·m, 15 lb·ft) Turn in the damping adjuster “1” finger-tight EWA19320 and then turn out to the originally set position. Tighten the lower bracket to specified torque.

  • 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) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 21 N ・...

  • Page 169: Removing The Lower Bracket

    STEERING HEAD EAM30060 ECA14270 REMOVING THE LOWER BRACKET 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 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) • Lower bracket pinch bolt “2” Lower bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) EWA19330 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) 53 N ・ m (5.3 kgf ・ m, 39 lb ・ ft) Order Job/Parts to remove Q’ty Remarks...
  • Page 173 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 56 N ・ m (5.6 kgf ・ m, 41 lb ・ ft) 53 N ・ m (5.3 kgf ・ m, 39 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Collar O-ring Dust seal...
  • 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

    • Rear shock absorber assembly upper bolt • To dispose of a damaged or a worn-out • Rear shock absorber assembly rear shock absorber, take the unit to your Yamaha dealer for this disposal procedure. EAM30067 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1.

  • Page 176: Checking The Connecting Arm And Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY Bends/damage/wear  Replace. 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. 3.

  • Page 177: Installing The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAM30070 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: • Bearing (lower side) • Dust seal Recommended lubricant Molybdenum disulfide grease ECA24580 5. Lubricate: Do not apply the grease to the bearing outer • Connecting arm and frame bolt race because it will wear the rear shock ab- •...
  • Page 178 REAR SHOCK ABSORBER ASSEMBLY Relay arm nut (swingarm side) 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) 4-64...

  • Page 179: 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 180: Removing The Swingarm

    SWINGARM EAM30071 • Bushing REMOVING THE SWINGARM • Collar 1. Use a maintenance stand to raise the rear • Bearing wheel off the ground. 4. Check: EWA13120 • Oil seal Damage  Replace. Securely support the vehicle so that there is •...
  • Page 181 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 3-27.

  • Page 182: Chain Drive

    CHAIN DRIVE EAM20104 CHAIN DRIVE Removing the drive chain Order Job/Parts to remove Q’ty Remarks Drive sprocket Refer to “ENGINE REMOVAL” on page 5-6. Drive chain Drive sprocket cover Bracket Drive sprocket nut Lock washer Drive sprocket 4-68...

  • Page 183: Removing The Drive Chain

    CHAIN DRIVE EAM30075 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 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 184: 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 185 CHAIN DRIVE ECA24590 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 186 CHAIN DRIVE 4-72...
  • Page 187 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................ 5-10 INSTALLING THE ENGINE ..............5-10 INSTALLING THE EXHAUST PIPE AND MUFFLER ........ 5-11 CAMSHAFT ....................5-13 REMOVING THE CAMSHAFT..............
  • Page 188 CHECKING THE STARTER CLUTCH ............5-41 INSTALLING THE STARTER CLUTCH ............ 5-41 ELECTRIC STARTER ..................5-43 CHECKING THE STARTER MOTOR ............5-45 ASSEMBLING THE STARTER MOTOR ........... 5-45 CLUTCH ......................5-47 REMOVING THE CLUTCH............... 5-50 CHECKING THE FRICTION PLATES............5-50 CHECKING THE CLUTCH PLATES............

  • Page 189: 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 190: 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 191 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter element 2. Oil pump...
  • Page 192 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft...
  • Page 193 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil pressure check bolt 3. Oil pump 4. Oil filter element...

  • Page 194: 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 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” EAM30164 If the pivot shaft is pulled all the way out, the INSTALLING THE ENGINE swingarm will come loose.

  • Page 199: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL 2. Install: Engine mounting bolt (upper side) • Clamp 45 N·m (4.5 kgf·m, 33 lb·ft) • Exhaust pipe 2 “1” • 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 2 mm (0.08 in) 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®) 5-13...
  • Page 202 CAMSHAFT Removing the camshaft 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 10 N ・...

  • Page 203: Removing The Camshaft

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

  • Page 204: Checking The Camshaft

    CAMSHAFT c. Install the dowel pins and the camshaft EAM30081 CHECKING THE CAMSHAFT caps. 1. Check: • Camshaft lobe • Tighten the camshaft cap bolts in a crisscross Blue discoloration/pitting/scratches  Re- pattern from innermost to outer caps. place the camshaft. •...

  • Page 205: Checking The Timing Chain And Camshaft Sprocket

    CAMSHAFT EAM30082 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET 1. Check: • Timing chain “1” Damage/stiffness  Replace the timing chain and camshaft as a set. 2. Check: • Camshaft sprocket More than 1/4 tooth wear “a”  Replace the camshaft and the timing chain as a set.
  • Page 206 CAMSHAFT a. Turn the crankshaft counterclockwise ECA24620 with a wrench. Do not turn the crankshaft during the cam- shaft installation. Damage or improper valve • Apply molybdenum disulfide oil to the cam- timing will result. shafts. • Apply the engine oil on the decompression d.
  • Page 207 Before installation, apply the sealant to the cyl- chain tensioner “2” and tighten the bolts inder head cover gasket. “3”. Bolt (timing chain tensioner) Yamaha bond No. 1215 10 N·m (1.0 kgf·m, 7.4 lb·ft) 90890-85505 Three bond No. 1215® c. Release the screwdriver, check that the tensioner rod comes out smoothly, and 6.

  • 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 page 5-28. REMOVING THE CYLINDER HEAD • Cylinder head coolant passages 1. Remove: Mineral deposits/rust  Eliminate. • Cylinder head bolt and nut 3. Measure: • Cylinder head warpage • Loosen the bolts in the proper sequence as Out of specification ...
  • Page 211 CYLINDER HEAD 2. Install: • Washer “1” • Bolt (M9 × 145 mm (5.71 in)) “2” • Bolt (M9 × 135 mm (5.31 in)) “3” • Nut “4” e. Remove the one bolt according to the tightening order of the bolts. f.
  • Page 212 CYLINDER HEAD Bolt [1], [2], [3], [4] Specified angle 60 j. Put a mark on the corner of the bolt (cylin- der head) and the cylinder head. k. Finally, tighten all bolts (cylinder head) fur- ther according to the tightening order. Tighten the bolts in two steps 60...

  • Page 213: Valves And Valve Springs

    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 5-20. Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Intake valve...

  • Page 214: Removing The Valves

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

  • Page 215: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS head to 100 °C (212 °F) in an oven. a. Remove the valve guide with the valve guide remover “1”. EAM30091 CHECKING THE VALVES AND VALVE GUIDES 1. Measure: b. Install the new valve guide with the valve •...

  • Page 216: Checking The Valve Seats

    VALVES AND VALVE SPRINGS Intake Valve guide remover (ø5) 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø5) 90890-04098 Valve guide installer (5.0 mm) YM-04098 Valve guide reamer (ø5) 90890-04099 EAM30092 Valve guide reamer (5.0 mm) CHECKING THE VALVE SEATS YM-04099 1.

  • Page 217: Checking The Valve Springs

    VALVES AND VALVE SPRINGS c. Press the valve through the valve guide b. Apply molybdenum disulfide oil onto the and onto the valve seat to make a clear valve stem. impression. c. Install the valve into the cylinder head. d. Measure the valve seat contact width “c”. d.

  • Page 218: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS Free length limit (intake) 34.94 mm (1.38 in) Free length limit (exhaust) 33.82 mm (1.33 in) 3. Install: • Spring seat “1” • Valve stem seal “2” • Valve “3” • Valve spring “4” • Valve spring retainer “5” EAM30094 (to the cylinder head) CHECKING THE VALVE LIFTERS...
  • Page 219 VALVES AND VALVE SPRINGS 5. To fasten the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. ECA13800 Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Adjusting pad “1” •...

  • Page 220: Cylinder And Piston

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

  • Page 221: Removing The Piston

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

  • 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 pin. Piston pin outside diameter limit 15.971 mm (0.6288 in) 3. Measure: • Piston pin bore inside diameter “b” Out of specification  Replace the piston. Piston pin bore inside diameter limit 2. Install: 16.043 mm (0.6316 in) •...
  • Page 224 CYLINDER AND PISTON 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. Install: • Gasket •...

  • 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

    • Stator coil assembly “2” outer surface “b” Damage  Inspect the crankshaft runout the T25 bit. • Pass the stator coil assembly lead through the and crankshaft bearing. crankcase cover side. Yamaha bond No. 1215 90890-85505 Three bond No. 1215® 5-38...
  • 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 3-14. Clutch Refer to “CLUTCH” on page 5-47. 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, tight- en the starter clutch screws “3”. Sheave holder 90890-01701 Primary clutch holder YS-01880-A 2. Install: •...

  • 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 Out of specification  Replace the brush EAM30106 CHECKING THE STARTER MOTOR set. 1. Check: • Commutator Brush overall length limit Dirt  Clean with 600 grit sandpaper. 3.5 mm (0.14 in) 2. Measure: • Mica undercut “a” Out of specification ...
  • Page 234 ELECTRIC STARTER Install while holding down the brush using a thin screw driver. ECA24650 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. Install: •...

  • 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 Order Job/Parts to remove Q’ty Remarks Right engine guard Refer to “ENGINE REMOVAL” on page 5-6. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-14. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-22.

  • 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) EAM30110 CHECKING THE CLUTCH PLATES 1.

  • Page 239: Checking The Clutch Boss

    CLUTCH ratic clutch operation. EAM30484 CHECKING THE PUSH RODS 1. Check: • Push rod 1 “1” • Bearing/Washer “2” • Push rod 2 “3” • Ball “4” Cracks/damage/wear  Replace. 1 1 1 EAM30113 CHECKING THE CLUTCH BOSS 1. Check: •...
  • Page 240 CLUTCH Apply the engine oil on the primary driven gear inner circumference. 2. Install: • Right crankcase cover “1” • Right crankcase cover bolt “2” Right crankcase cover bolt 5. Install: 10 N·m (1.0 kgf·m, 7.4 lb·ft) • Conical washer “1” •...
  • Page 241 CLUTCH (to the push rod 1 “4”) Apply the engine oil on the bearing, washer and push rod 1. 8. Install: • Push rod 2 “1” • Ball “2” • Push rod 1 “3” Apply the engine oil on the push rod 1, 2 and 6.
  • Page 242 CLUTCH 10.Install: • Clutch spring • Clutch spring bolt Clutch spring bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Tighten the bolts in stages and in a crisscross pattern. 11.Install: • Gasket “1” 12.Install: • Clutch cover • Clutch cover bolt Clutch cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Tighten the bolts in stages and in a crisscross...

  • Page 243: Shift Shaft

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

  • Page 244: Removing The Segment

    SHIFT SHAFT EAM30124 REMOVING THE SEGMENT 1. Remove: • Segment bolt “1” • Segment “2” Turn the segment counterclockwise until it stops and loosen the segment bolt. ECA24670 If the segment gets an impact, the stopper EAM30127 lever 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 drum. • With the stopper lever pushed down, install the segment. ECA24680 6. Tighten: If the segment gets an impact, the stopper •...
  • Page 246 SHIFT SHAFT Align the punch mark “a” on the shift shaft with the punch mark “b” in the shift pedal. 5-58...

  • Page 247: Oil Pump

    OIL PUMP EAM20182 OIL PUMP Removing the oil pump 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Primary driven gear Refer to “CLUTCH”...
  • Page 248 OIL PUMP Removing the balancer 105 N ・ m (10.5 kgf ・ m, 77 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 38 N ・ m (3.8 kgf ・ m, 28 lb ・ ft) 50 N ・...

  • Page 249: Removing The Balancer

    OIL PUMP EAM30133 REMOVING THE BALANCER 1. Remove: • Oil pump 2. Loosen: • Balancer nut “1” • Primary drive gear nut “2” • Balancer weight gear nut “3” Place an aluminum plate “a” between the teeth of the balancer drive gear “4” and balancer 4.

  • Page 250: Checking The Oil Pump

    OIL PUMP EAM30136 CHECKING THE OIL PUMP Oil pump cover bolt 6 N·m (0.6 kgf·m, 4.4 lb·ft) 1. Check: LOCTITE® • Oil pump cover • Oil pump drive shaft • Oil pump housing Cracks/damage/wear  Replace the oil pump assembly. 2.
  • Page 251 OIL PUMP 4. Install: • Oil pump assembly “1” • Oil pump assembly bolt “2” Oil pump assembly bolt 5 N·m (0.5 kgf·m, 3.7 lb·ft) LOCTITE® 3. Install: • Balancer drive gear “1” • Collar “2” • Install the balancer drive gear and crankshaft with the lower splines “a”...
  • Page 252 OIL PUMP “5” within the area shown in the illustration. 5 7 mm (0.02 0.28 in) A. Primary drive gear side B. Crankcase cover side 5-64...

  • Page 253: Crankcase

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

  • Page 255: Disassembling The Crankcase

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

  • Page 256: Assembling The Crankcase

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

  • 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 5-65. Transmission Refer to “TRANSMISSION” on page 5-72. Balancer shaft Crankshaft assembly 5-69...

  • Page 258: Removing The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT Out of specification  Replace the crank- EAM30491 REMOVING THE CRANKSHAFT shaft. 1. Remove: • Balancer shaft “1” Turn the crankshaft slowly. Remove the balancer shaft with its flat side “a” Runout limit facing the crankshaft. 0.030 mm (0.0012 in) 2.

  • 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 5-65. Main axle Drive axle Long shift fork guide bar Short shift fork guide bar Spring Shift drum...

  • 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 drum “3” • Shift fork 3 “4” • Shift fork 2 “5” • Shift fork 1 “6” •...

  • Page 262: Checking The Transmission

    TRANSMISSION EAM30156 EAM30157 CHECKING THE TRANSMISSION INSTALLING THE TRANSMISSION 1. Measure: 1. Install: • Main axle runout • 6th pinion gear (27T) “1” (with a centering device and dial gauge “1”) • 3rd/4th pinion gear (18T/21T) “2” Out of specification  Replace the main ax- •...
  • 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.
  • Page 265 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

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

  • Page 267: Radiator

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

  • Page 269: Checking The Radiator

    RADIATOR EAM30341 CHECKING THE RADIATOR Radiator cap valve opening pres- sure EWA13030 107.9–137.3 kPa (1.08–1.37 kgf/cm², 15.6–19.9 psi) A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- No stay  Replace. gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in- Radiator cap tester jury.
  • Page 270 RADIATOR 4. Activate the tester to apply the test pressure. Test pressure value 137.3 kPa (1.37 kgf/cm², 19.9 psi) ECA24270 • Do not apply such a high pressure as ex- ceeds the test pressure. • Make sure that a checkup after the cylinder head gasket is replaced is made after 3 minutes of warm-up.

  • Page 271: Water Pump

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

  • Page 272: Disassembling The Water Pump

    WATER PUMP EAM30494 DISASSEMBLING THE WATER PUMP • Remove the oil seal when the coolant level changes frequently more than usual, coolant has discolored, or engine oil has become milky. • Do not use the removed oil seal. 1. Remove: •...
  • Page 273 WATER PUMP 4. Install: • Dowel pin “1” • Gasket “2” 5. Install: • Water pump housing “1” • Water pump housing bolt “2” Water pump housing bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) • Washer “3” • Coolant drain bolt “4” Coolant drain bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft)
  • Page 274 WATER PUMP...
  • Page 275 FUEL SYSTEM FUEL 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 ..............7-3 INSTALLING THE FUEL TANK ..............7-3 THROTTLE BODY...................

  • 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 Cover the fuel hose connection with a cloth when disconnecting it. This is because resid- ual pressure in the fuel hose could cause fuel to spurt out when the hose is removed.

  • Page 278: Installing The Fuel Pump

    FUEL TANK EAM30266 • Take care not to kink or pinch the fuel hose. INSTALLING THE FUEL PUMP 1. Install: • Insert the fuel hose into the fuel pipe securely • Fuel pump gasket until you hear a “click”. • Fuel filter •...

  • 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: • Injector 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 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) ........8-23 FUEL PUMP SYSTEM................... 8-43 CIRCUIT DIAGRAM ................. 8-43 TROUBLESHOOTING................8-45 ELECTRICAL COMPONENTS..............
  • Page 286 CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....... 8-58 CHECKING THE GEAR POSITION SWITCH ........... 8-58 CHECKING THE INJECTOR ..............8-59...

  • 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.
  • Page 291 IGNITION SYSTEM 9. Check the stator coil assembly. Refer to “CHECKING THE STATOR Replace the stator coil assembly. NG COIL” on page 8-55. 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 8-47. OK 10.Check the entire starting system’s wiring. Properly connect or repair the starting Refer to “CIRCUIT DIAGRAM” on system’s wiring. NG...

  • 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 engine under substitute characteristics and illuminates the engine trouble warning light to alert the rid- er 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 DIAG- NOSTIC TOOL OPERATION MANUAL”.
  • Page 309 2. Lead battery (12 V) 3. Vehicle battery 4. Vehicle 5. Coupler for connecting optional part 6. FI diagnostic tool sub-lead 7. Sub-harness (included with the Yamaha diagnostic tool) 8. Vehicle communication cable (included with the Yamaha diagnostic tool) 9. Yamaha diagnostic tool...

  • Page 310: 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 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...
  • Page 312 Replace the intake air pressure sensor. Faulty ECU. Replace the ECU. Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-25...
  • Page 313 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 314 Disconnect the coupler, and Yamaha diagnostic tool. Condition is “Recovered”  Go check the pins (for bent or bro- ken terminals and locking con- to item 8 and finish the service.
  • Page 315 Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. Fault code No. 16 • If fault code numbers 15 and 16 are both displayed, perform checkup and repair jobs for fault code number 15 first.
  • Page 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 Refer to “RADIATOR” on page 6-2. to item 6. Faulty ECU. Replace the ECU. Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-30...
  • Page 318 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 319 Start switch to ON (main relay ON), wait 10 seconds, then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 4 and finish the service. Condition is “Detected”  Go to item 2.
  • Page 320 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 321 Check the condition of the fault the coupler. ness. code using the malfunction Disconnect the coupler, and mode of the Yamaha diagnostic check the pins (for bent or bro- tool. Condition is “Recovered”  Go ken terminals and locking con- dition of the pins).
  • Page 322 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 323 Check the condition of the fault terminals and locking condition code using the malfunction of the pins). mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 6 and finish the service. Condition is “Detected”  Go to item 2.
  • Page 324 Check the condition of the fault terminals and locking condition code using the malfunction of the pins). 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 325 If the same number is indicated, go to item 4. Faulty ECU. Replace the ECU. Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-38...
  • 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 ECU. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. Fault code No. 50 Before troubleshooting, disconnect the starter motor lead from the starter relay.
  • Page 328 Engine forcibly stops when the vehicle is left idling for a long period Item of time. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-41...
  • Page 329 FUEL INJECTION SYSTEM 8-42...

  • Page 330: Fuel Pump System

    FUEL PUMP SYSTEM EAM20146 FUEL PUMP SYSTEM EAM30287 CIRCUIT DIAGRAM 8-43...
  • Page 331 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 8-44...

  • Page 332: 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 333: 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 334: Checking The Switches

    ELECTRICAL COMPONENTS EAM30289 CHECKING THE SWITCHES Y/W P 1. Engine stop switch 2. Mode switch 3. Gear position switch 4. Start switch 8-47...
  • Page 335 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 Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end “a”...

  • Page 336: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS EAM30357 however, note the following. 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 337: Checking And Charging The Battery

    ELECTRICAL COMPONENTS a. Install a new fuse of the correct amperage again as soon as possible. A long state of rating. discharge below 10 V will damage the bat- b. Push the start switch to verify if the elec- tery. trical circuit is operational.

  • Page 338: Checking The Relays

    When replacing the battery, be sure to use a Digital circuit tester (CD732) Yamaha genuine lithium-ion battery. 90890-03243 Model 88 Multimeter with ta- Do not check the battery at high temperature of chometer 65 C (149 F) or more or low temperatures be-...

  • Page 339: Checking The Relay Unit (Diode)

    ELECTRICAL COMPONENTS Out of specification  Replace. Radiator fan motor relay Starter relay Br/W Br,R/W 1. Positive battery terminal 1. Positive battery terminal 2. Negative battery terminal 2. Negative battery terminal 3. Positive tester probe 3. Positive tester probe 4. Negative tester probe 4.

  • Page 340: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS system troubleshooting, starting with step No continuity (5). Positive tester prove  Refer to “TROUBLESHOOTING” on page Blue/Green “1” 8-3. Negative tester prove  Blue “2” Minimum ignition spark gap Continuity 6.0 mm (0.24 in) Positive tester prove  Blue “2” Negative tester prove ...

  • Page 341: 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 ta- Out of specification  Replace. chometer YU-A1927 Secondary coil resistance 8.64–12.96 k a. Connect the digital circuit tester () to the ignition coil.

  • Page 342: 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 343: Checking The Fuel Sender

    ELECTRICAL COMPONENTS a. Set the digital tachometer to the ignition coil. Digital tachometer 90890-06760 Digital tachometer YU-39951-B b. Connect the digital circuit tester (DCV) to the rectifier/regulator coupler. Digital circuit tester (CD732) EAM30360 90890-03243 CHECKING THE RESISTOR Model 88 Multimeter with ta- 1.

  • Page 344: Checking The Throttle Position Sensor Input Voltage

    ELECTRICAL COMPONENTS EWA14130 continuity at the temperatures indicated in the table. • Handle the coolant temperature sensor with special care. • Never subject the coolant temperature sensor to strong shocks. If the coolant temperature sensor is dropped, replace it. 2. Check: •...

  • Page 345: 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 346 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 347 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........

  • Page 348: General Information

    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 349 TROUBLESHOOTING Symptom Possible cause Actions Water or foreign material in fuel, Change fuel. degraded fuel Tighten the spark plug to the Loose spark plug specified torque. Tighten bolts or nuts on cylinder Loose cylinder head or cylinder head and cylinder to the specified torque.
  • Page 350 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 351: 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 352 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 353: 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 354: Troubleshooting Of Cooling System

    TROUBLESHOOTING EAM30512 TROUBLESHOOTING OF COOLING SYSTEM Symptom Possible cause Actions Carbon buildup in piston head Clean the piston head and com- and 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 355: 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 356 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 357: 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 358: Troubleshooting Of Charging System

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

  • Page 359: 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 360 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 361: Diagnostic Code: Actuator Operation Table

    Ignition coil Actuates the ignition coil five Check that a spark is gener- times at one-second intervals. ated five times. “WARNING” on the Yamaha • Connect an ignition diagnostic tool blinks five times checker. when the ignition coil is actu- ated.
  • Page 362 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9-15...
  • Page 363 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........

  • Page 364: 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) B2W-25449-00 Secondary reduction ratio = Number of B2W-25450-00 rear wheel sprocket teeth/Number of (STD) B2W-25451-00 drive sprocket teeth 17D-25452-50 Secondary reduction ratio 3.923 (51/13)

  • Page 365: Front Fork Setting

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

  • Page 366: 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 STD Spring rate N/mm 2.

  • Page 367: Setting Of Spring After Replacement

    CHASSIS EAM30177 EAM30178 SETTING OF SPRING AFTER REAR SHOCK ABSORBER SETTING PARTS REPLACEMENT • Rear shock spring “1” After replacement, be sure to adjust the spring STD Spring rate to the set length [sunken length 90–100 mm N/mm (3.5–3.9 in)] and set it. Spring 1.
  • Page 368 CHASSIS • Spring preload adjusting positions Spring preload adjusting positions Minimum Position in which the spring is turned in 1.5 mm (0.06 in) from its free length. Standard Position in which the spring is turned in 6.0 mm (0.24 in) from its free length.

  • Page 369: 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 reset- ting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in).

  • Page 370: 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 371 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 372 CHASSIS 10-9...

  • Page 373: Wiring Diagram

    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 375 EAM20160 Genuine Yamaha Parts text Genuine Yamaha Parts – Genuine Yamaha replacement parts are the exact same parts as the ones originally equipped on your vehicle, providing you with the performance and durability you have come to expect. Why settle for aftermarket parts that may not provide full confidence and satisfaction? Genuine Yamaha Accessories –...
  • Page 377 YZ250FXR 2024 WIRING DIAGRAM...
  • Page 378 YZ250FXR 2024 WIRING DIAGRAM...

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