Yamaha YZ250F 2024 Owner's Service Manual
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Yamaha YZ250F 2024 Owner's Service Manual

Yamaha YZ250F 2024 Owner's Service Manual

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2024
OWNER'S SERVICE MANUAL
YZ250F
Read this manual carefully before operating this vehicle.
YZ250FR
LIT-11626-37-44
BMF-2819U-10

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  • Page 1 2024 OWNER’S SERVICE MANUAL YZ250F Read this manual carefully before operating this vehicle. YZ250FR LIT-11626-37-44 BMF-2819U-10...
  • 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. Part 15 of FCC Rules This device complies with Part 15 of FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interfer- ence that may cause undesired operation of this device.
  • Page 4 EAM20080 YZ250FR OWNER’S SERVICE MANUAL ©2024 by Yamaha Motor Corporation, U.S.A. First edition, June 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-11626-37-44...

  • 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 FUEL TANK CAP ..................1-25 STARTING AND BREAK-IN ................1-27 FUEL ......................1-27 STARTING A COLD ENGINE ..............1-27 STARTING A WARM ENGINE ..............1-28 BREAK-IN PROCEDURES............... 1-28 ENGINE STARTING PRECAUTION ............1-28 MAINTENANCE AFTER BREAK-IN ............. 1-29 MAJOR MAINTENANCE................1-29 AIR FILTER MAINTENANCE..............

  • 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 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. Other tires, rims, sizes, and combinations may not be appropriate.

  • 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. 4, 5 Premium unleaded gasoline only. 3FB-2415E-03 WARNING This unit contains high pressure nitrogen gas. Mishandling can cause explosion. Read owner's manual for instructions. 5PA-2118K-01 Do not incinerate, puncture or open.

  • Page 18: Description

    DESCRIPTION EAM20086 DESCRIPTION 10.Radiator 1. Clutch lever 2. Front brake lever 11.Coolant drain bolt 12.Oil level check window 3. Throttle grip 13.Rear brake pedal 4. Start switch 14.Air filter 5. Radiator cap 15.Drive chain 6. Fuel tank cap 16.Shift pedal 7.

  • 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 INCLUDED PARTS EAM30372 SIDESTAND This sidestand “1” is used to support only the machine when standing or transporting it. EWA20260 • Never apply additional force to the sides- tand. • Remove this sidestand before starting out. EAM30007 FUEL HOSE JOINT COVER EAM30005 NIPPLE WRENCH...
  • Page 21 INCLUDED PARTS pression ratio, etc.) have been changed, the performance may not match to the ac- tual settings. COMMUN.CONT.UNIT ASSY. • Do not run the engine with the smartphone carried with you. Otherwise, the smart- phone could be damaged. P/N: S/N: MAC: •...
  • Page 22 INCLUDED PARTS If the CCU wireless network cannot be detect- ed, operate the start switch again. 1-10...

  • Page 23: Important Information

    2. Use proper special tools and equipment. Re- used for repair of the vehicle, including periodic fer to “SPECIAL TOOLS” on page 1-17. replacement parts, are new YAMAHA genuine parts and recommended parts. Do not use any used parts, because these may...

  • Page 24: 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 25: 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 26 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 27 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 28 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 29: 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, 7-8, 90890-03269 8-18, 8-49 Yamaha diagnostic tool (A/I) 3-12, 7-8, 7-8, 90890-03273 8-18, 8-49 Digital tachometer 3-12, 8-52...
  • Page 30 YM-01501 Cap bolt wrench 4-49, 4-51 90890-01911 Fork seal driver 4-53, 4-53 90890-01502 Fork seal driver (48) YM-A0948 Yamaha bond No. 1215 5-19, 5-38, 5-73 90890-85505 Three bond No. 1215® Valve spring compressor 5-26, 5-30 90890-04200 Valve spring compressor YM-04019...
  • Page 31 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide remover (ø5) 5-28 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø5) 5-28 90890-04098 Valve guide installer (5.0 mm) YM-04098 Valve guide reamer (ø5) 5-28 90890-04099 Valve guide reamer (5.0 mm) YM-04099 Valve guide remover (ø4.5) 5-28...
  • Page 32 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rotor puller 5-38 90890-04151 Rotor puller YM-04151 Sheave holder 5-42, 5-43 90890-01903 Primary clutch holder YS-01880-A Clutch holder 5-51, 5-53 90890-04199 Universal clutch holder YM-91042 Crankcase separating tool 5-75 90890-04152 Crankcase separating tool YU-A9642 Crankshaft installer pot 5-76...
  • Page 33 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Crankshaft installer bolt 5-76 90890-01275 Bolt YU-90060 Adapter (M12) 5-76 90890-01278 Adapter #3 YU-90063 Spacer (crankshaft installer) 5-76 90890-04081 Pot spacer YM-91044 YM-91044 Radiator cap tester 6-4, 6-4 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter...
  • Page 34 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pressure gauge 90890-03153 Pressure gauge YU-03153 Fuel pressure adapter 90890-03186 Fuel pressure adapter YM-03186 Lithium battery charger 8-48, 8-48 90890-05376 Lithium battery charger DBY-ACC51-70-02 Ignition checker 8-49 90890-06754 Oppama pet–4000 spark checker YM-34487 Test harness (3P) –...

  • Page 35: Instrument And Control Functions

    INSTRUMENT AND CONTROL FUNCTIONS EAM20181 pending on the rider’s operations and road sur- INSTRUMENT AND CONTROL face conditions. FUNCTIONS How to operate 1. Put the gear into the neutral position. EAM30182 2. Start the engine. ENGINE STOP SWITCH 3. Push the mode switch “1” for more than one The engine stop switch “1”...

  • Page 36: Lap Time Record Mode

    INSTRUMENT AND CONTROL FUNCTIONS • When the indicator light flashes alternately When the mode switch “1” is pressed, the indi- purple and blue, drive mode 2 is selected. cator light “2” will blink in blue and the measure- ment will start. •...

  • Page 37: Shift Pedal

    INSTRUMENT AND CONTROL FUNCTIONS drive mode 2 is selected. 1 1 1 EAM30444 STARTER KNOB EAM30185 Starting a cold engine requires a larger amount SHIFT PEDAL of intake air, which is supplied by the starter The shift pedal “1” has adopted a method of 1 knob “1”.
  • Page 38 INSTRUMENT AND CONTROL FUNCTIONS tank cap “2”. • When installing the sub-seat, make sure that the plastic band is not twisted. • When installing the sub-seat, push down the quick fastener, rotate it, and then secure the sub-seat with the quick fastener. 1-26...

  • Page 39: Starting And Break-In

    10 %. Gaso- hol containing methanol is not recommended Since exhaust gas contains harmful ingredi- by Yamaha because it can cause damage to the ents, do not start or warm it up at an illventi- fuel system or vehicle performance problems.

  • Page 40: Starting A Warm Engine

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

  • Page 41: 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 42: Torque-Check Points

    TORQUE-CHECK POINTS EAM20125 TORQUE-CHECK POINTS Frame construction 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 rear fender Steering Steering stem to handlebar Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar...
  • Page 43 TORQUE-CHECK POINTS Shift pedal Shift pedal to shift shaft Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of shroud Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake caliper cover Concerning the tightening torque, refer to “TIGHTENING TORQUES”...

  • Page 44: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE EAM20126 especially on spoked wheels. If such prod- MOTORCYCLE CARE AND STOR- ucts are used on hard-to-remove dirt, do not leave the cleaner on the affected area any longer than instructed. Also, thorough- EAM30200 ly rinse the area off with water, immediately CARE dry it, and then apply a corrosion protection While the open design of a motorcycle reveals...

  • Page 45: 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 46 MOTORCYCLE CARE AND STORAGE stored. Long-term Before storing your motorcycle for several months: 1. Follow all the instructions in the “CARE” on page 1-32. 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 47 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 48: Specifications

    GENERAL SPECIFICATIONS EAM20127 GENERAL SPECIFICATIONS Model Model BMF1 BMF6 Dimensions Overall length 2180 mm (85.8 in) Overall width 825 mm (32.5 in) Overall height 1275 mm (50.2 in) Seat height 970 mm (38.2 in) Wheelbase 1475 mm (58.1 in) Ground clearance 350 mm (13.78 in) Weight Curb weight...

  • Page 49: 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 50 ENGINE SPECIFICATIONS 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) 4.430 mm (0.1744 in) Valve guide inside diameter (intake) 5.000–5.012 mm (0.1969–0.1973 in)
  • Page 51 3.846 (50/13) Final drive Chain Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil Fuel pump Maximum consumption amperage 2.4 A Fuel injector 12.0  Resistance...

  • Page 52: Chassis Specifications

    CHASSIS SPECIFICATIONS EAM20129 CHASSIS SPECIFICATIONS Chassis 26.9  Caster angle Trail 119 mm (4.7 in) Front wheel Wheel type Spoke wheel Rim size 21x1.6 Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in) Wheel axle bending limit 0.50 mm (0.02 in) Rear wheel...
  • Page 53 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) 486.0 cm³ (16.43 US oz, 17.14 Imp.oz) Quantity (right) 486.0 cm³ (16.43 US oz, 17.14 Imp.oz)
  • Page 54 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 Non-sealed type Number of links...

  • Page 55: 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 BMF0 Ignition coil 1.98–2.42  Primary coil resistance Secondary coil resistance 14.64–21.96 k Spark plug cap Resistance 7.50–12.50 k...

  • Page 56: 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 57: 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) Oil passage plug (cylinder head) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Cylinder head bolt...
  • Page 58 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Intake air temperature sensor screw 1.5 N·m (0.15 kgf·m, 1.1 lb·ft) Clutch cable locknut (clutch cable 4.3 N·m (0.43 kgf·m, 3.2 lb·ft) adjuster) 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...
  • Page 59 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size  Shift pedal bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) Generator rotor nut 65 N·m (6.5 kgf·m, 48 lb·ft) Stator coil screw 10 N·m (1.0 kgf·m, 7.4 lb·ft) 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)

  • Page 60: 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 61 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size  Front wheel axle pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) / Front brake disc bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) / Rear brake disc bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) Footrest bracket bolt 55 N·m (5.5 kgf·m, 41 lb·ft) ...
  • Page 62 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size 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)  Fuel tank bolt (front side) 8 N·m (0.8 kgf·m, 5.9 lb·ft) Screw (fuel tank)
  • Page 63 TIGHTENING TORQUES 2-16...

  • Page 64: Cable Routing Diagram

    CABLE ROUTING DIAGRAM EAM20152 CABLE ROUTING DIAGRAM Frame and engine (front left side view) 5, A 4, A 12, N 20, O 5, A 4, A 9, C 17, L 16, K 11, 14 1, Q 12, F 11, E 2-17...
  • Page 65 CABLE ROUTING DIAGRAM I. Pass the stator coil assembly lead behind 1. Clutch cable the radiator. Be sure the lead will not be 2. Throttle cable (return) pinched between the radiator and the ten- 3. Throttle cable (pull) sion arm. 4.
  • Page 66 CABLE ROUTING DIAGRAM Frame and engine (rear left side view) 5, B 3, A 6, C 7, D 10, E 11, F 12, G 5, H 2-19...
  • Page 67 CABLE ROUTING DIAGRAM 1. Wire harness 2. Rear frame 3. Plastic locking tie 4. Starter relay coupler (black, 4-pin) 5. Starter motor lead 6. Positive battery lead 7. Negative battery lead 8. Rear fender (projection) 9. CCU (Communication Control Unit) 10.Starter relay 11.Starter relay cover 12.CCU coupler...
  • Page 68 CABLE ROUTING DIAGRAM Frame and engine (right side view) 1, A 2, C 4, D 6, E 8, F 2-21...
  • Page 69 CABLE ROUTING DIAGRAM 1. Fuel pump coupler (black, 5-pin) 2. Coolant temperature sensor coupler (black, 2-pin) 3. Upper radiator boss 4. Throttle position sensor lead 5. Cylinder head breather hose 6. Throttle position sensor coupler (black, 3- pin) 7. Lower radiator boss 8.
  • Page 70 CABLE ROUTING DIAGRAM Handlebar (front view) 1, A 2, B 6, D 8, E 8, E 2-23...
  • Page 71 CABLE ROUTING DIAGRAM 1. Throttle cable 2. Start switch lead 3. Upper bracket 4. Handlebar switch lead (left) 5. Clutch cable 6. Front brake hose 7. Number plate 8. Plastic locking tie 9. Handlebar protector A. When facing the number plate mounting bracket, route the throttle cable on the right side of the vehicle.
  • Page 72 CABLE ROUTING DIAGRAM Frame and engine (top view) 1, A 4, B 12, H 7, E 12, G 11, F 2-25...
  • Page 73 CABLE ROUTING DIAGRAM 1. Ignition coil lead 2. Intake air pressure sensor coupler (dark blue, 3-pin) 3. Fuel injector coupler (gray, 2-pin) 4. Intake air temperature sensor coupler (black, 2-pin) 5. Tank rail 6. Air filter case 7. Spark plug cap 8.
  • Page 74 CABLE ROUTING DIAGRAM Frame and battery (top view) 6, D 7, E 3, C 3, A 3, A 3, A 4, F 2-27...
  • Page 75 CABLE ROUTING DIAGRAM 1. ECU lead 2. Battery 3. Positive battery lead 4. Negative battery lead 5. CCU (Communication Control Unit) 6. ECU (Engine Control Unit) 7. Holder 8. Battery box bracket 9. Rear frame A. Route the positive battery lead under the vehicle’s negative battery lead.
  • Page 76 CABLE ROUTING DIAGRAM Rear brake (right side view) C C C 2-29...
  • Page 77 CABLE ROUTING DIAGRAM 1. Protector 2. Rear brake caliper 3. Bleed screw 4. Rear brake hose 5. Brake pedal 6. Rear brake master cylinder assembly 7. Swingarm 8. Rear shock absorber assembly A. It does not matter whether the spring is installed upward or downward.
  • Page 78 CABLE ROUTING DIAGRAM Front brake (left side view) 6, H 2-31...
  • Page 79 CABLE ROUTING DIAGRAM 1. Front brake hose 2. Brake hose holder 3. Protector 4. Number plate 5. Front brake caliper 6. Protector 7. Front brake hose (shrinkable tube side) A. Route the front brake hose on the outside of the number plate from the position shown. B.
  • Page 80 CABLE ROUTING DIAGRAM 2-33...
  • Page 81 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 82 CHECKING AND TIGHTENING THE SPOKES ........3-34 CHECKING THE WHEELS............... 3-34 CHECKING THE WHEEL BEARINGS ............3-34 CHECKING THE CHASSIS FASTENERS ..........3-34 CHECKING AND LUBRICATING THE CABLES ........3-34 LUBRICATING THE BRAKE LEVER ............3-35 LUBRICATING THE CLUTCH LEVER............3-35 LUBRICATING THE PEDAL ..............
  • Page 83 ELEMENT, AIR CLEANER 5D3-13440-02 ELEMENT ASSY, OIL CLEANER BHR-27200-00 PEDAL, BRAKE 1C3-W0046-50 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 84: 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 85 MAINTENANCE INTERVALS Every Every Every After race third race fifth race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours) • Check the coolant passages for corrosion. • Inspect carbon deposits and  11 * Cylinder head eliminate them.
  • Page 86 MAINTENANCE INTERVALS Every Every Every After race third race fifth race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours)   • Clean.   • Inspect and adjust.   • Replace oil. 30 * Front fork leg(s) ...
  • Page 87 MAINTENANCE INTERVALS Every Every Every After race third race fifth race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours)   Brake pedal, footrest • Lubricate. Outside nuts and • Retighten.   44 * bolts •...

  • Page 88: 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 89: 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 90 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 91 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 92: 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 93 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 94: Checking The Engine Idling Speed

    2. Measure the coolant temperature using the Yamaha diagnostic tool. EAM30475 Yamaha diagnostic tool USB (US) CHECKING THE THROTTLE GRIP 90890-03269 Yamaha diagnostic tool (A/I) Prior to adjusting throttle grip free play, the en- 90890-03273 gine idling speed should be adjusted.

  • Page 95: Checking The Spark Plug

    ENGINE 4. Check: • Electrode “1” Damage/wear  Replace the spark plug. • Insulator “2” Abnormal color  Replace the spark plug. Normal color is medium-to-light tan. 5. Clean: • Spark plug (with a spark plug cleaner or a wire brush) 6.

  • Page 96: Changing The Engine Oil

    ENGINE minimum level mark “a” and maximum level 2. Place an oil pan under the drain bolt. mark “b”. 3. Remove: Below the minimum level mark  Add the • Oil filler cap “1” recommended engine oil to the proper level. •...

  • Page 97: Adjusting The Clutch Lever Free Play

    ENGINE c. Replace the new O-ring “2”. EWA19120 When the engine is started with the check bolt removed, oil will spout; therefore, al- ways loosen it before the checkup. 1 1 1 d. Install the oil strainer. Oil strainer bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) b.

  • Page 98: Adjusting The Clutch Lever Position

    ENGINE EAM30370 ADJUSTING THE CLUTCH LEVER POSITION 1. Adjust: • Clutch lever position “a” Loosen the locknut “1” and use the adjuster “2” to adjust the clutch lever position “a” as desired. 2. Adjust: • Clutch lever free play Handlebar side a.
  • Page 99 • Seal “3” Damage  Replace. (from the air filter element) 5. Apply: • Yamaha foam air filter oil or other quality To remove the air filter element: foam air filter oil • Release the band “a” from the projection “b”, a.

  • Page 100: Checking The Throttle Body Joint

    ENGINE • Fuel tank breather hose “2” (to the air filter case cover) • To install the air filter case cover: • Insert the projection “a” on air filter case cov- er to the hole “b” in the air filter case “3”. •...

  • Page 101: Checking The Fuel Line

    ENGINE Crack/damage  Replace. EAM30221 CHECKING THE EXHAUST SYSTEM EAM30222 CHECKING THE FUEL LINE 1. Remove: 1. Remove: • Exhaust pipe 1 • Seat • Exhaust pipe 2 • Side cover (left/right) Refer to “ENGINE REMOVAL” on page 5-6. • Shroud (left/right) 2.
  • Page 102 ENGINE f. Install the silencer body “8” and bolts “9”. Silencer body bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) LOCTITE® Apply heat-resistant sealant to the areas “d” shown, making sure that there are no gaps in the beads of sealant. b.

  • Page 103: Checking The Coolant Level

    ENGINE 7. Check: • Tightening torques Exhaust pipe nut “1” 10 N·m (1.0 kgf·m, 7.4 lb·ft) Exhaust pipe clamp bolt “2” 12 N·m (1.2 kgf·m, 8.9 lb·ft) Exhaust pipe clamp bolt “3” 12 N·m (1.2 kgf·m, 8.9 lb·ft) Silencer bolt (rear) “4” 30 N·m (3.0 kgf·m, 22 lb·ft) j.

  • Page 104: Checking The Cooling System

    ENGINE ator cap and turn it counterclockwise to re- • Side cover (left/right) move. • Shroud (left/right) Refer to “GENERAL CHASSIS” on page 4-1. 1. Stand the vehicle upright on a level surface. 2. Check: 2. Remove: • Radiator • Radiator cap “1” •...
  • Page 105 ENGINE clean tap water. 5. Install: • Copper washer • Coolant drain bolt Coolant drain bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) 6. Pour coolant. Recommended coolant High quality ethylene glycol anti- freeze containing anti-corrosion for aluminum engine Radiator (including all routes) 0.94 L (0.99 US qt, 0.83 Imp.qt) Coolant mixing ratio 1:1 (Coolant:Water)

  • Page 106: 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 107: 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 108: Checking The Rear Brake Hose

    CHASSIS • Protector (rear brake) • Be careful not to spill any brake fluid or allow the reservoir to overflow. • Make sure that there is enough brake fluid be- fore applying the brake. Ignoring this precau- a a a tion could allow air to enter the brake system, considerably lengthening the bleeding proce- dure.

  • Page 109: Drive Chain Slack

    CHASSIS to fully extend. 4. Check: • Drive chain slack “a” g. Tighten the bleed screw and then release Out of specification  Regulate. the brake lever or brake pedal. h. Repeat steps (d) to (g) until all of the air Measure drive chain slack between the drive bubbles have disappeared from the brake chain guide and the bottom of the chain as...

  • Page 110: Checking And Adjusting The Steering Head

    CHASSIS Wheel axle nut 135 N·m (13.5 kgf·m, 100 lb·ft) e. Tighten the drive chain puller locknut. Drive chain puller locknut 21 N·m (2.1 kgf·m, 15 lb·ft) EAM30247 CHECKING AND ADJUSTING THE STEERING HEAD 1. Use a maintenance stand to raise the front Steering nut wrench wheel off the ground.

  • Page 111: Lubricating The Steering Head

    CHASSIS of the outer tube circumference. 5. Install: • Upper bracket 6. Remove: Refer to “STEERING HEAD” on page 4-58. • Protector • Handlebar • Dust seal “1” Refer to “HANDLEBAR” on page 4-39. ECA24330 EAM30502 Be careful not to damage the dust seal and LUBRICATING THE STEERING HEAD the inner tube by a driver.
  • Page 112 CHASSIS have poor stability. Compression damping • Securely support the vehicle so that there ECA24350 is no danger of it falling over. Do not turn the adjuster forcibly beyond its Rebound damping adjusting range. ECA24340 1. Adjust: Do not turn the adjuster forcibly beyond its •...

  • Page 113: Checking The Rear Shock Absorber Assembly

    CHASSIS EWA13120 EWA13120 Securely support the vehicle so that there is Securely support the vehicle so that there is no danger of it falling over. no danger of it falling over. 2. Remove the bleed screw “1” and release the Spring preload internal pressure from the front fork.
  • Page 114 CHASSIS • The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjusting ring. Compression damping (for fast compres- sion damping) e. Tighten the locknut. ECA24370 Rebound damping Do not turn the adjuster forcibly beyond its ECA24370 adjusting range.

  • Page 115: Checking The Swingarm Operation

    CHASSIS Compression damping (for slow compres- EAM30240 CHECKING THE SWINGARM OPERATION sion damping) 1. Check: ECA24390 • Swingarm smooth action • Swingarm free play Do not turn the adjuster forcibly beyond its Refer to “SWINGARM” on page 4-70. adjusting range. 1.

  • Page 116: Checking And Tightening The Spokes

    CHASSIS Correct the tire position. Spoke 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) • Do not give a half turn (180) or more for one tightening. • Make sure that tightening after a break-in is done until the initial looseness in nipples dis- appears.

  • Page 117: Lubricating The Brake Lever

    CHASSIS Recommended lubricant Engine oil or a suitable cable lu- bricant Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device. EAM30483 LUBRICATING THE BRAKE LEVER 1. Lubricate the pivoting points and metal-to- metal moving parts of the following parts.

  • Page 118: Electrical System

    ELECTRICAL SYSTEM EAM20137 ELECTRICAL SYSTEM EAM30256 CHECKING AND CHARGING THE BATTERY Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-47. EAM30505 CHECKING THE FUSES Refer to “CHECKING THE FUSES” on page 8-47. 3-36...
  • Page 119 CHASSIS GENERAL CHASSIS ..................4-1 REMOVING THE SEAT ................4-4 REMOVING THE NUMBER PLATE............4-4 INSTALLING THE SHROUD ..............4-4 REMOVING THE SIDE COVER..............4-5 INSTALLING THE SIDE COVER ..............4-5 FRONT WHEEL ....................4-6 REMOVING THE FRONT WHEEL.............. 4-8 DISASSEMBLING THE FRONT WHEEL ............
  • Page 120 INSTALLING THE REAR BRAKE MASTER CYLINDER ......4-37 HANDLEBAR....................4-39 REMOVING THE HANDLEBAR ............... 4-41 CHECKING THE HANDLEBAR..............4-41 INSTALLING THE HANDLEBAR .............. 4-41 FRONT FORK....................4-46 REMOVING THE FRONT FORK LEGS ............ 4-48 DISASSEMBLING THE FRONT FORK LEGS .......... 4-48 CHECKING THE FRONT FORK LEGS.............

  • Page 121: General Chassis

    GENERAL CHASSIS EAM20094 GENERAL CHASSIS Removing the seat and battery 13 N ・ m (1.3 kgf ・ m, 9.6 lb ・ ft) 13 N ・ m (1.3 kgf ・ m, 9.6 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 7 N ・...
  • Page 122 GENERAL CHASSIS Removing the side cover 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 13 N ・ m (1.3 kgf ・ m, 9.6 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・...
  • Page 123 GENERAL CHASSIS Removing the shroud 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・...

  • Page 124: General Chassis

    GENERAL CHASSIS EAM30016 REMOVING THE SEAT 2 2 2 The sub-seat and the seat are coupled with each other with a plastic band. When removing the seat, always remove the sub-seat beforehand. 1. Remove: a a a • Sub-seat “1” Refer to “FUEL TANK CAP”...

  • Page 125: Removing The Side Cover

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

  • Page 126: Front Wheel

    FRONT WHEEL EAM20095 FRONT WHEEL Removing the front wheel 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 115 N ・ m (11.5 kgf ・ m, 85 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Use a maintenance stand to raise the front wheel off the ground.
  • Page 127 FRONT WHEEL Disassembling the front wheel 0 mm (0 in) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Oil seal Bearing Brake disc...

  • Page 128: 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 129: 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 130 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) 4-10...

  • Page 131: Rear Wheel

    REAR WHEEL EAM20096 REAR WHEEL Removing the rear wheel 135 N ・ m (13.5 kgf ・ m, 100 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 132 REAR WHEEL Disassembling the rear wheel 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 42 N ・ m (4.2 kgf ・ m, 31 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Rear wheel sprocket Oil seal [“a”...

  • Page 133: Removing The Rear Wheel

    REAR WHEEL EAM30022 Refer to “CHECKING THE TIRES” on page REMOVING THE REAR WHEEL 3-33 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 134: Assembling The Rear Wheel

    REAR WHEEL • Brake disc bolt Rear wheel sprocket self-locking Brake disc bolt 42 N·m (4.2 kgf·m, 31 lb·ft) 12 N·m (1.2 kgf·m, 8.9 lb·ft) LOCTITE® Tighten the self-locking nuts in stages and in a crisscross pattern. Tighten the bolts in stages and in a crisscross pattern.
  • Page 135 REAR WHEEL Refer to “DRIVE CHAIN SLACK” on page 3-27. 3. Install: • Drive chain puller (left) “1” • Rear wheel axle “2” 6. Tighten: • Rear wheel axle nut “1” • Install the drive chain puller (left), and insert the Rear wheel axle nut rear wheel axle from the left side.

  • Page 136: 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) 1.0 mm (0.04 in) 17 N ・...
  • Page 137 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 Brake caliper piston dust seal Brake caliper piston seal Bleed screw 4-17...
  • Page 138 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) 30 N ・...
  • Page 139 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit 4-19...

  • Page 140: 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 141 FRONT BRAKE d. Install the brake pads “3” and the pad pin. • Install the brake pads with their projections “a” into the brake caliper recesses “b”. • Temporarily tighten the pad pin at this point. 2. Measure: • Brake pad wear limit “a” Out of specification ...

  • Page 142: Removing The Front Brake Caliper

    FRONT BRAKE 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. EAM30030 REMOVING THE FRONT BRAKE CALIPER Before disassembling the brake caliper, drain the brake fluid from the entire brake system.

  • Page 143: 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- Brake pad pin plug ponents as they will cause the piston seals 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) to swell and distort.

  • Page 144: Removing The Front Brake Master Cylinder

    FRONT BRAKE 5. Bleed: 2. Check: • Brake system • Brake master cylinder reservoir cap 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 ...

  • Page 145: Installing The Front Brake Master Cylinder

    FRONT BRAKE EAM30039 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Brake master cylinder “1” Brake master cylinder holder bolt 9 N·m (0.9 kgf·m, 6.6 lb·ft) • Install the front brake master cylinder holder with the “UP” mark facing up. 3.

  • Page 146: Brake System

    FRONT BRAKE system. Turn the handlebar toward right and left to make Refer to “BLEEDING THE HYDRAULIC sure that the brake hose does not touch other BRAKE SYSTEM” on page 3-26. parts (e.g., wire harness, cables, leads). Adjust if necessary. 3.

  • Page 147: Rear Brake

    REAR BRAKE EAM20098 REAR BRAKE Removing the rear brake caliper 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 13 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 1.0 mm (0.04 in) 7 N ・...
  • Page 148 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 Brake caliper piston dust seal Brake caliper piston seal Bleed screw 4-28...
  • Page 149 REAR BRAKE Removing the rear brake master cylinder 5 mm (0.20 in) 5 mm (0.20 in) 5 mm (0.20 in) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 10 N ・...
  • Page 150 REAR BRAKE Removing the rear brake master cylinder 5 mm (0.20 in) 5 mm (0.20 in) 5 mm (0.20 in) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 10 N ・...
  • Page 151 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder joint Brake master cylinder kit 4-31...

  • Page 152: 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 153 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 154: Removing The Rear Brake Caliper

    REAR BRAKE joint opening to force out the piston from the brake caliper. 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.

  • Page 155: Assembling The Rear Brake Caliper

    REAR BRAKE 2. Check: • Brake caliper bracket Crack/damage  Replace. EAM30045 ASSEMBLING THE REAR BRAKE CALIPER EWA19280 a a a • Before installation, clean and lubricate the internal parts. Use new brake fluid for cleaning and lubricating. 3. Install: •...

  • Page 156: Removing The Rear Brake Master Cylinder

    REAR BRAKE 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. Check: EAM30050 • Brake pedal operation ASSEMBLING THE REAR BRAKE MASTER A softy or spongy feeling ...

  • Page 157: Installing The Rear Brake Master Cylinder

    REAR BRAKE ECA24500 Install the spring with a smaller inside diameter Make sure that the pipe portion of the brake to the brake master cylinder piston. hose touches the projection “a” on the brake caliper. 4. Install: • Brake master cylinder piston assembly “1” 2.
  • Page 158 REAR BRAKE system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-26. 4-38...
  • Page 159 HANDLEBAR EAM20099 HANDLEBAR Removing the handlebar 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 0.5 N ・ m (0.05 kgf ・ m, 0.37 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 28 N ・...
  • Page 160 HANDLEBAR Removing the handlebar 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 0.5 N ・ m (0.05 kgf ・ m, 0.37 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 28 N ・...

  • Page 161: 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 162 HANDLEBAR A. Routing when installing the damper and lower handlebar in the rear holes B. Routing when installing the damper and lower handlebar in the front holes 3. Tighten: • Lower handlebar holder nut Lower handlebar holder nut 40 N·m (4.0 kgf·m, 30 lb·ft) 4.
  • Page 163 HANDLEBAR a a a 168 mm (6.61 in) 5. Install: 7. Install: • Handlebar switch (left) “1” • Clutch cable “1” • Clamp “2” Before installation, apply the lithium-soap- Handlebar switch (left) based grease to the clutch cable end. 1.3 N·m (0.13 kgf·m, 0.95 lb·ft) •...
  • Page 164 HANDLEBAR 12.Install: • Throttle cable housing “1” • Screw (throttle cable housing) “2” Screw (throttle cable housing) 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) EWA19310 After tightening the throttle cable housing screws, check that the throttle grip “3” 10.Install: moves smoothly. If it does not, retighten the •...
  • Page 165 HANDLEBAR Refer to “CHECKING THE THROTTLE GRIP” on page 3-12. Throttle grip free play 3.0–6.0 mm (0.12–0.24 in) 14.Install: • Start switch “1” • Front brake master cylinder assembly “2” • Front brake master cylinder holder “3” • Front brake master cylinder holder bolt “4” •...

  • Page 166: 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) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・...
  • Page 167 FRONT FORK Disassembling the front fork leg 29 N ・ m (2.9 kgf ・ m, 21 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 0.6 N ・ m (0.06 kgf ・ m, 0.44 lb ・ ft) 28 N ・...

  • Page 168: Removing The Front Fork Legs

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

  • Page 169: Checking The Front Fork Legs

    FRONT FORK Inner tube bending limit 0.2 mm (0.01 in) The bending value is shown by one half of the dial gauge reading. EWA13650 Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 5. Remove: 2.

  • Page 170: Assembling The Front Fork Legs

    1. Stretch the damper assembly fully. 2. Fill: • Damper assembly Recommended oil 6. Check: Yamaha Suspension Oil S1 • Upper spring seat “1” Standard oil amount 216 cm³ (7.30 US oz, 7.62 (contacting surface “a”) Wear/damage  Replace.
  • Page 171 FRONT FORK case, repeat the steps (1) to (3). 6. Install: • Base valve “1” 4. Measure: (to the damper assembly “2”) • Oil level (left and right) “a” Out of specification  Regulate. First bring the damper rod pressure to a maxi- mum.
  • Page 172 FRONT FORK 9. After filling, pump the damper assembly “1” 12.Check: slowly up and down more than 10 times to • Damper assembly smooth movement Tightness/binding/rough spots  Repeat distribute the fork oil. the steps (1) to (12). 10.While protecting the damper assembly “1” with a cloth and compressing fully, allow ex- 13.Install: cessive oil to overflow on the base valve...
  • Page 173 FRONT FORK 14.Install: • Piston metal “1” Install the piston metal onto the slot on inner tube. 17.Install: • Oil seal “1” Using a fork seal driver “2”, press the oil seal in until the stopper ring groove fully appears. 15.Install: Fork seal driver •...
  • Page 174 FRONT FORK 19.Install: 22.Install: • Dust seal “1” • Upper spring seat “1” • Fork spring “2” Apply lithium-soap-based grease on the inner (to the damper assembly “3”) tube. Install the upper spring seat with its larger dia. end “a” facing the fork spring. 20.Check: •...
  • Page 175 FRONT FORK • Unless the damping force adjuster is fully correct damping force cannot be obtained. loosened, correct damping characteristic can- not be obtained after installation. 27.Tighten: • Adjuster (damper assembly) “1” 25.Install: Adjuster (damper assembly) • Damper adjusting rod “1” 29 N·m (2.9 kgf·m, 21 lb·ft) •...

  • Page 176: Installing The Front Fork Legs

    FRONT FORK Recommended oil Yamaha Suspension Oil S1 Standard oil amount 280 cm³ (9.47 US oz, 9.88 Imp.oz) Extent of adjustment 260–365 cm³ (8.79–12.34 US oz, 9.17–12.87 Imp.oz) ECA24570 EAM30059 • Be sure to use the recommended oil. Other INSTALLING THE FRONT FORK LEGS oils may have an adverse effect on front 1.
  • Page 177 FRONT FORK • Front fork protector bolt “2” Front fork protector bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) 3. Adjust: • Front fork top end “a” Front fork top end (standard) “a” 5 mm (0.2 in) 6. Adjust: • Rebound damping force Turn in the damping adjuster “1”...

  • Page 178: Steering Head

    STEERING HEAD EAM20101 STEERING HEAD Removing the lower bracket 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 145 N ・ m (14.5 kgf ・ m, 107 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 38 N ・...
  • Page 179 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) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 38 N ・...

  • Page 180: 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 181 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 182 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 183: 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 184 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 Lower spring guide Upper spring guide Spring...
  • Page 185 REAR SHOCK ABSORBER ASSEMBLY Disassembling the relay arm 0 mm (0 in) 0 mm (0 in) 80 N ・ m (8.0 kgf ・ m, 59 lb ・ ft) 0 mm (0 in) 0 mm (0 in) Order Job/Parts to remove Q’ty Remarks Relay arm...

  • Page 186: 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 187: 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 188: 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 189 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) 4-69...

  • Page 190: 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) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 0–0.5 mm (0–0.02 in) 0–0.5 mm...
  • Page 191 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) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 0–0.5 mm (0–0.02 in) 0–0.5 mm...

  • Page 192: 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 193 SWINGARM 5. Install: 3. Install: • Rear wheel • Swingarm Refer to “REAR WHEEL” on page 4-11. 6. Adjust: Pivot shaft nut • Drive chain slack 85 N·m (8.5 kgf·m, 63 lb·ft) Refer to “DRIVE CHAIN SLACK” on page 3-27. Install the pivot shaft from the right.

  • Page 194: Chain Drive

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

  • Page 195: 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. 2. Remove: • Master link clip • Master link “1” •...

  • Page 196: Checking The Drive Sprocket

    CHAIN DRIVE G089069 5. Lubricate: • Drive chain EAM30077 CHECKING THE DRIVE SPROCKET 1. Check: • Drive sprocket More than 1/4 tooth wear “a”  Replace the drive sprocket and the rear wheel sprocket as a set. G089070 Bent tooth  Replace the drive sprocket and 2.
  • Page 197 CHAIN DRIVE Drive chain slack (Maintenance Stand) 50.0–60.0 mm (1.97–2.36 in) 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 198 CHAIN DRIVE 4-78...
  • Page 199 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 200 CHECKING THE STARTER CLUTCH ............5-42 INSTALLING THE STARTER CLUTCH ............ 5-42 ELECTRIC STARTER ..................5-44 CHECKING THE STARTER MOTOR ............5-46 ASSEMBLING THE STARTER MOTOR ........... 5-46 CLUTCH ......................5-48 REMOVING THE CLUTCH............... 5-51 CHECKING THE FRICTION PLATES............5-51 CHECKING THE CLUTCH PLATES............

  • Page 201: 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 202: 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 203 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter element 2. Oil pump...
  • Page 204 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft...
  • Page 205 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil pressure check bolt 3. Oil pump 4. Oil filter element...

  • Page 206: 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 207 ENGINE REMOVAL Removing the electronic parts 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 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...
  • Page 208 ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 45 N ・ m (4.5 kgf ・ m, 33 lb ・ ft) 85 N ・ m (8.5 kgf ・ m, 63 lb ・ ft) 26 N ・...
  • Page 209 ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 45 N ・ m (4.5 kgf ・ m, 33 lb ・ ft) 85 N ・ m (8.5 kgf ・ m, 63 lb ・ ft) 26 N ・...

  • Page 210: Removing The Engine

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

  • Page 211: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL Engine mounting bolt (upper side) 45 N·m (4.5 kgf·m, 33 lb·ft) ECA27180 Install the lower engine brackets with their stamps facing outward. Apply molybdenum disulfide grease to the pivot shaft. 2. Install: • Clamp • Exhaust pipe 2 “1” •...
  • Page 212 ENGINE REMOVAL A. Exhaust pipe 1 and exhaust pipe 2 Install and temporarily tighten the silencer so B. Exhaust pipe 2 and silencer that its joint is positioned as shown with respect to the exhaust pipe 2. 2 mm (0.08 in) 4.

  • Page 213: Camshaft

    13 N ・ m (1.3 kgf ・ m, 9.6 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 0–1.0 mm (0–0.04 in) * Yamaha bond No. 1215 (Three bond No. 1215®) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
  • Page 214 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 215: 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 216: 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 217: 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 218 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 219 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 220: 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˚ 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・...
  • Page 221 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˚ 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・...

  • Page 222: 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 223 CYLINDER HEAD 2. Install: • Washer “1” • Bolt “2” • Nut “3” e. Remove the one bolt according to the tightening order of the bolts. f. Again apply molybdenum disulfide grease to the threads and contact surfaces of the bolts and to both contact surfaces of the washers.
  • Page 224 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 225: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAM20108 VALVES AND VALVE SPRINGS Removing the valves and valve springs 11.2–11.6 mm (0.44–0.46 in) 11.8–12.2 mm (0.46–0.48 in) Order Job/Parts to remove Q’ty Remarks Drain. Cylinder head Refer to “CYLINDER HEAD” on page 5-20. Valve lifter Adjusting pad Valve cotter Valve spring retainer...

  • Page 226: 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 227: 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 228: 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 229: 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 230: 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 231 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 232: 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 233: 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 234: 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 235: 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 236 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 237: Generator

    10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 65 N ・ m (6.5 kgf ・ m, 48 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) * Yamaha bond No. 1215 (Three bond No. 1215®) Order Job/Parts to remove Q’ty...

  • Page 238: 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 239 GENERATOR • Crankcase cover (left) “3” • 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 240: 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 5-48. Clutch housing Starter clutch gear 5-40...
  • Page 241 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 Starter clutch assembly Side plate Absorber Primary driven gear Spacer Collar Damper assembly 5-41...

  • Page 242: Removing The Starter Clutch

    STARTER CLUTCH EAM30469 REMOVING THE STARTER CLUTCH 1. Remove: • Starter clutch screw “1” While holding the side of the clutch housing “2” with the sheave holder “3” as shown, remove the starter clutch screws “1”. Sheave holder 90890-01903 3. Check: Primary clutch holder YS-01880-A •...
  • Page 243 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 90890-01903 Primary clutch holder YS-01880-A 2. Install: •...

  • Page 244: 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 245 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 246: 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 247 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 248: 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) 95 N ・ m (9.5 kgf ・ m, 70 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 249 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) 95 N ・ m (9.5 kgf ・ m, 70 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 250 CLUTCH Removing the right crankcase cover 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 251: Removing The Clutch

    CLUTCH EAM30108 REMOVING THE CLUTCH Friction plate thickness 2.70–2.90 mm (0.106–0.114 in) 1. Straighten the clutch boss nut rib “a”. Wear limit 2.60 mm (0.102 in) EAM30110 CHECKING THE CLUTCH PLATES 1. Check: • Clutch plate Damage  Replace the clutch plates as a set.

  • Page 252: Checking The Clutch Boss

    CLUTCH EAM30484 CHECKING THE PUSH RODS 1. Check: • Push rod 1 “1” • Bearing/Washer “2” • Push rod 2 “3” • Ball “4” Cracks/damage/wear  Replace. EAM30113 1 1 1 CHECKING THE CLUTCH BOSS 1. Check: • Clutch boss splines Damage/pitting/wear ...
  • Page 253 CLUTCH • Washer “4” Apply the engine oil on the primary driven gear inner circumference. 2. Install: • Right crankcase cover “1” • Right crankcase cover bolt “2” Right crankcase cover bolt 5. Install: 10 N·m (1.0 kgf·m, 7.4 lb·ft) •...
  • Page 254 CLUTCH a a a 1 1 1 7. Install: • Bearing “1” • Washer “2” • Circlip “3” (to the push rod 1 “4”) Apply the engine oil on the bearing, washer and push rod 1. 6. Install: • Friction plate “1” •...
  • Page 255 CLUTCH a a a 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 256: 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) 0–1.0 mm (0–0.04 in) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 30 N ・...
  • Page 257 SHIFT SHAFT Removing the shift shaft and stopper lever 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 0–1.0 mm (0–0.04 in) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 10 N ・...

  • Page 258: 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 259 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 260 SHIFT SHAFT Align the punch mark “a” on the shift shaft with the punch mark “b” in the shift pedal. 5-60...

  • Page 261: 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 262 OIL PUMP Removing the balancer 105 N ・ m (10.5 kgf ・ m, 77 lb ・ ft) 5–7 mm (0.02–0.28 in) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 38 N ・ m (3.8 kgf ・ m, 28 lb ・ ft) 50 N ・...
  • Page 263 OIL PUMP Removing the balancer 105 N ・ m (10.5 kgf ・ m, 77 lb ・ ft) 5–7 mm (0.02–0.28 in) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 38 N ・ m (3.8 kgf ・ m, 28 lb ・ ft) 50 N ・...

  • Page 264: Oil Pump

    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 265: Installing The Oil Pump

    OIL PUMP • Install the relief valve before installing the pri- mary drive gear and collar. 2. Install: • Outer rotor “1” 2. Install: Apply the engine oil on the outer rotor. • Collar “1” • Balancer weight gear “2” Install the balancer weight gear and balancer shaft with their lower splines “a”...
  • Page 266 OIL PUMP Primary drive gear nut 105 N·m (10.5 kgf·m, 77 lb·ft) LOCTITE® • Balancer “6” • Conical washer “7” • Balancer nut “8” Balancer nut 38 N·m (3.8 kgf·m, 28 lb·ft) • Apply engine oil to the contact surfaces of the conical washer.
  • Page 267 OIL PUMP 5 7 mm (0.02 0.28 in) A. Primary drive gear side B. Crankcase cover side 5-67...

  • Page 268: 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 269 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 270 CRANKCASE Removing the bearing and oil seal (left) 3.0–3.5 mm 8.5–9.0 mm 4.5–5.0 mm (0.12–0.14 in) (0.33–0.35 in) (0.18–0.20 in) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 0 mm (0 in) 0–1.0 mm (0–0.04 in) 0 mm (0 in) 0 mm...
  • Page 271 CRANKCASE Removing the bearing and oil seal (right) 0 mm (0 in) 0 mm (0 in) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 0 mm (0 in) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 0 mm (0 in) 0 mm...

  • Page 272: 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 273: 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 274: 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 5-68. Transmission Refer to “TRANSMISSION” on page 5-77. Balancer shaft Crankshaft assembly 5-74...

  • Page 275: 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 276: 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 277: 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 5-68. Main axle Drive axle 5-77...
  • Page 278 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Long shift fork guide bar Short shift fork guide bar Spring Shift drum Shift fork 3 (R) Shift fork 2 (C) Shift fork 1 (L) Collar 5-78...

  • Page 279: 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 280: Checking The Transmission

    TRANSMISSION EAM30156 EAM30157 CHECKING THE TRANSMISSION INSTALLING THE TRANSMISSION 1. Measure: 1. Install: • Main axle runout • 5th pinion gear (24T) “1” (with a centering device and dial gauge “1”) • 3rd pinion gear (18T) “2” Out of specification  Replace the main ax- •...
  • Page 281 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 282 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 283 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 284: 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 285: 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 286 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 287: 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 288 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 289: Water Pump

    WATER PUMP EAM20139 WATER PUMP Removing the water pump 0 mm (0 in) 0 mm (0 in) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 14 N ・...

  • Page 290: 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 291 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 292 WATER PUMP...
  • Page 293 FUEL SYSTEM FUEL TANK ..................... 7-1 REMOVING THE FUEL TANK..............7-2 REMOVING THE FUEL PUMP..............7-2 CHECKING THE FUEL PUMP BODY ............7-2 CHECKING THE FUEL PUMP OPERATION..........7-2 INSTALLING THE FUEL PUMP ..............7-2 INSTALLING THE FUEL TANK ..............7-3 THROTTLE BODY...................
  • Page 294 FUEL TANK EAM20140 FUEL TANK Removing the fuel tank 4.0 N ・ m (0.40 kgf ・ m, 3.0 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 8 N ・...

  • Page 295: 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: • Seat • Side cover (left/right) • Shroud (left/right) Refer to “GENERAL CHASSIS” on page 4-1. 3.

  • Page 296: Installing The Fuel Tank

    FUEL TANK • Fuel pump • Install the fuel hose connector holder “a”. • Fuel pump bracket Fuel pump bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) • Take care not to damage the installation sur- faces of the fuel tank. •...

  • Page 297: Throttle Body

    THROTTLE BODY EAM20141 THROTTLE BODY Removing the air filter case 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 3.0 N ・...
  • Page 298 THROTTLE BODY Removing the throttle body 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) (2) (2) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) 7 N ・...
  • Page 299 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 300: Throttle Body

    THROTTLE BODY EAM30649 screw “1”, throttle valve pulley nut “2”, REMOVING THE AIR FILTER CASE JOINT throttle valve screw “3” or starter knob nut 1. Remove: “4”. A loss of performance may occur. • Air filter case joint “1” (from the air filter case) •...

  • Page 301: Operation Table

    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-...

  • Page 302: Installing The Air Filter Case Joint

    THROTTLE BODY ed angle until “11”–“14” appears on the Yamaha diagnostic tool. h. After adjusting the throttle position sensor c c d mounted angle, tighten the throttle posi- tion sensor screw “1”. c c c Throttle position sensor screw 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) 3.
  • Page 303 FUEL INJECTION SYSTEM................8-15 CIRCUIT DIAGRAM ................. 8-15 CHECKING THE INDICATOR LIGHT............8-17 YAMAHA DIAGNOSTIC TOOL ..............8-18 CONNECTING THE YAMAHA DIAGNOSTIC TOOL ........ 8-18 TROUBLESHOOTING DETAILS (FAULT CODE) ........8-20 FUEL PUMP SYSTEM................... 8-41 CIRCUIT DIAGRAM ................. 8-41 TROUBLESHOOTING................8-43 ELECTRICAL COMPONENTS..............

  • Page 304: Ignition System

    IGNITION SYSTEM EAM20142 IGNITION SYSTEM EAM30277 CIRCUIT DIAGRAM...
  • Page 305 IGNITION SYSTEM 1. Crankshaft position sensor 2. AC magneto 3. Rectifier/regulator 4. Engine ground 5. Frame ground 6. Battery 7. Fuse 8. Starter relay 9. Starter motor 10.Diode 1 11.CCU (Communication Control Unit) 12.ECU (Engine Control Unit) 13.Ignition coil 14.Spark plug 21.Gear position switch 22.Handlebar switch (left) 23.Indicator light...

  • Page 306: Troubleshooting

    IGNITION SYSTEM EAM30278 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3. Shroud (left/right) 4. Fuel tank 5. Air filter case cover 1. Check the ignition system wire har- Reconnect.

  • Page 307: Position Switch

    IGNITION SYSTEM 9. Check the stator coil assembly. Refer to “CHECKING THE STATOR Replace the stator coil assembly. NG COIL” on page 8-51. OK 10.Check the ignition system wire har- ness. Repair or replace the wire harness. Refer to “CIRCUIT DIAGRAM” on NG...
  • Page 308 IGNITION SYSTEM 1. Check the handlebar switch cou- Reconnect. pler (left) connections. NG OK 2. Check the handlebar switch (left). Refer to “CHECKING THE Replace the handlebar switch (left). NG SWITCHES” on page 8-45. OK 3. Check the ignition system wire har- ness.
  • Page 309 IGNITION SYSTEM...

  • Page 310: Electric Starting System

    ELECTRIC STARTING SYSTEM EAM20143 ELECTRIC STARTING SYSTEM EAM30279 CIRCUIT DIAGRAM...
  • Page 311 ELECTRIC STARTING SYSTEM 5. Frame ground 6. Battery 7. Fuse 8. Starter relay 9. Starter motor 10.Diode 1 12.ECU (Engine Control Unit) 21.Gear position switch 22.Handlebar switch (left) 25.Engine stop switch 26.Handlebar switch (right) 27.Start switch...

  • Page 312: 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. Shroud (left/right) 4. Fuel tank 5. Air filter case cover 1. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse(s).
  • Page 313 ELECTRIC STARTING SYSTEM 8-10...

  • Page 314: Charging System

    CHARGING SYSTEM EAM20144 CHARGING SYSTEM EAM30282 CIRCUIT DIAGRAM 8-11...
  • Page 315 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Engine ground 5. Frame ground 6. Battery 7. Fuse 8-12...

  • Page 316: Troubleshooting

    CHARGING SYSTEM EAM30283 TROUBLESHOOTING The battery is not being charged. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left) 3. Shroud (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 317 CHARGING SYSTEM 8-14...

  • Page 318: Fuel Injection System

    FUEL INJECTION SYSTEM EAM20145 FUEL INJECTION SYSTEM EAM30284 CIRCUIT DIAGRAM 8-15...
  • Page 319 FUEL INJECTION SYSTEM 1. Crankshaft position sensor 2. AC magneto 3. Rectifier/regulator 4. Engine ground 5. Frame ground 6. Battery 7. Fuse 11.CCU (Communication Control Unit) 12.ECU (Engine Control Unit) 13.Ignition coil 14.Spark plug 15.Fuel injector 16.Fuel pump 17.Intake air temperature sensor 18.Coolant temperature sensor 19.Throttle position sensor 20.Intake air pressure sensor...

  • Page 320: Checking The Indicator Light

    FUEL INJECTION SYSTEM EAM30645 CHECKING THE INDICATOR LIGHT If the indicator “1” blinks in orange, determine the fault code by using the Yamaha diagnostic tool. Check and repair the detected fault by referring to “TROUBLESHOOTING DETAILS (FAULT CODE)” on page 8-20.

  • Page 321: 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 322 1. ECU (Engine Control Unit) 2. Lead battery (12 V) 3. Vehicle battery 4. Vehicle 5. CCU sub-lead coupler 6. Sub-harness (included with the Yamaha diagnostic tool) 7. Vehicle communication cable (included with the Yamaha diagnostic tool) 8. Yamaha diagnostic tool...

  • Page 323: 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 324 10 seconds or more.) dition of the pins). And then check the condition of the fault code using the mal- function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service. Condition is “Detected”  Go to item 3.
  • Page 325 Gear position switch: open or short circuit detected. 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. 12 Fault code No.
  • Page 326 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air pressure. Procedure The atmospheric pressure is displayed on the Yamaha diagnostic tool. Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check pletion Improperly connected ...
  • Page 327 Between intake air pressure check the condition of the fault sensor coupler and ECU cou- code using the malfunction pler. mode of the Yamaha diagnostic white–white tool. Condition is “Recovered”  Go blue–blue black–black/blue to item 7 and finish the service.
  • Page 328 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 329 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 330 Location of discon- Output code using the malfunction nected lead voltage mode of the Yamaha diagnostic tool. Disconnected Condition is “Recovered”  Go ground lead to item 8 and finish the service. Condition is “Detected”  Go Disconnected out- to item 6.
  • Page 331 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 332 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 333 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 334 Proper display: check the condition of the fault When the machine is cold, dis- code using the malfunction played temperature is close to mode of the Yamaha diagnostic the ambient temperature. tool. Improper display  Replace Condition is “Recovered”  Go the intake air temperature sen- to item 7 and finish the service.
  • Page 335 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 336 Check the condition of the fault the coupler. code using the malfunction Disconnect the coupler, and mode of the Yamaha diagnostic check the pins (for bent or bro- tool. Condition is “Recovered”  Go ken terminals and locking con- dition of the pins).
  • Page 337 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. Before performing this operation, be sure to disconnect the fuel pump coupler.
  • Page 338 Item Injector: open or short circuit detected. 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. 41 Fault code No. Item ECU: built-in lean angle sensor malfunction.
  • Page 339 Check the condition of the fault red–red code using the malfunction Between starter relay coupler mode of the Yamaha diagnostic and ECU coupler. tool. Condition is “Recovered”  Go red/yellow–red Between ECU coupler and CCU to item 4 and finish the service.
  • Page 340 CO concentration. engine stop switch, and then code using the malfunction push the start switch. mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 6 and finish the service. Condition is “Detected” ...
  • Page 341 Yamaha diagnostic tool. Condition is “Recovered”  Go to item 6 and finish the service. Condition is “Detected” ...
  • Page 342 5 seconds. Between rectifier/regulator cou- Check the condition of the fault pler and starter relay coupler. code using the malfunction red/white–red/white mode of the Yamaha diagnostic Between starter relay and bat- tool. Condition is “Recovered”  Go tery terminal. red–red to item 6 and finish the service.
  • Page 343 Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check pletion Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-40...

  • Page 344: Fuel Pump System

    FUEL PUMP SYSTEM EAM20146 FUEL PUMP SYSTEM EAM30287 CIRCUIT DIAGRAM 8-41...
  • Page 345 FUEL PUMP SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Engine ground 5. Frame ground 6. Battery 7. Fuse 12.ECU (Engine Control Unit) 16.Fuel pump 22.Handlebar switch (left) 25.Engine stop switch 8-42...

  • Page 346: Troubleshooting

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

  • Page 347: Electrical Components

    ELECTRICAL COMPONENTS EAM20147 ELECTRICAL COMPONENTS 1. Rectifier/regulator 2. Mode switch 3. Engine stop switch 4. Intake air temperature sensor 5. Ignition coil 6. Battery 7. Starter relay 8. Fuse 9. ECU (Engine Control Unit) 10.CCU (Communication Control Unit) 11.Fuel pump 12.Gear position switch 13.Coolant temperature sensor 14.Injector...

  • Page 348: Checking The Switches

    ELECTRICAL COMPONENTS EAM30289 CHECKING THE SWITCHES 1. Handlebar switch (left) 2. Mode switch 3. Engine stop switch 4. Start switch 5. Gear position switch 8-45...
  • Page 349 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 350: Checking The Fuses

    ELECTRICAL COMPONENTS EAM30290 systems to malfunction and could possibly CHECKING THE FUSES cause a fire. The following procedure applies to all of the fus- 4. Install: • Side cover (left) 1. Remove: • Seat • Seat Refer to “GENERAL CHASSIS” on page 4-1. •...
  • Page 351 Refer to “GENERAL CHASSIS” on page 4-1. When replacing the battery, be sure to use a 2. Disconnect: Yamaha genuine lithium-ion battery. • Battery lead (from the battery terminals) ECA13700 Do not check the battery at high temperature of 65 C (149 F) or more or low temperatures be-...

  • Page 352: Replacing The Ecu (Engine Control Unit)

    Refer to “DIAGNOSTIC CODE: SENSOR • Ignition spark gap Out of specification  Perform the ignition OPERATION TABLE” on page 9-12. system troubleshooting, starting with step (5). Yamaha diagnostic tool USB (US) Refer to “TROUBLESHOOTING” on page 90890-03269 8-3. Yamaha diagnostic tool (A/I)

  • Page 353: Checking The Spark Plug Cap

    ELECTRICAL COMPONENTS 2. Check: • Primary coil resistance Out of specification  Replace. Primary coil resistance 1.98–2.42  a. Connect the digital circuit tester () to the ignition coil. Digital circuit tester (CD732) 90890-03243 2. Spark plug cap Model 88 Multimeter with ta- d.

  • Page 354: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS EAM30298 CHECKING THE LEAN ANGLE SENSOR 1. Check: • Mounted condition of ECU Improperly mounted  Remount. • The lean angle sensor is built into the ECU. • The lean angle sensor stops the engine in case of a turnover. •...

  • Page 355: Checking The Rectifier/Regulator

    ELECTRICAL COMPONENTS a. Connect the digital circuit tester () to the • Positive tester probe  stator coil assembly coupler. Red/White “1” • Negative tester probe  Digital circuit tester (CD732) Black “2” 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 •...

  • Page 356: Checking The Throttle Position Sensor Input Voltage

    ELECTRICAL COMPONENTS • Positive tester probe  Digital circuit tester (CD732) Green “1” 90890-03243 • Negative tester probe  Model 88 Multimeter with ta- Black “2” chometer YU-A1927 Test harness (3P) – sub throttle position sensor 90890-03214 • Positive tester probe  Blue “1”...

  • Page 357: Checking The Gear Position Switch

    ELECTRICAL COMPONENTS Intake air temperature sensor re- Continuity Positive tester probe  sistance 5400–6600  at 0 C (5400–6600 Sky blue “1”  at 32 F) Negative tester probe  Intake air temperature sensor re- Sensor terminal “a” sistance Continuity 290–390 ...
  • Page 358 ELECTRICAL COMPONENTS b. Connect the digital circuit tester () to the fuel injector coupler. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 • Positive tester probe  Injector terminal “1” • Negative tester probe  Injector terminal “2” c.
  • Page 359 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 360: 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 361 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 362 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 363: 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 364 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 365: 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 366: 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 367: 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 368 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 369: 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 370: 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 371: 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 start switch is pushed. Intake air temperature Displays the intake air tempera- Compare the actually mea- ture.
  • Page 372 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 373: 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 374 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9-15...
  • Page 375 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 376: 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 (STD) B2W-25450-00 rear wheel sprocket teeth/Number of B2W-25451-00 drive sprocket teeth 17D-25452-50 Secondary reduction ratio 3.846 (50/13)

  • Page 377: 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 378: 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 379: 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 380: 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 381: 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 382 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 383: Wiring Diagram

    EAM20149 EAM30323 WIRING DIAGRAM COLOR CODE Black YZ250FR 2024 Brown 1. Crankshaft position sensor Dark blue 2. AC magneto Green 3. Rectifier/regulator Gray 4. Engine ground Blue 5. Frame ground Pink 6. Battery 7. Fuse Sky blue 8. Starter relay White 9.
  • Page 385 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 387 YZ250FR 2024 WIRING DIAGRAM...
  • Page 388 YZ250FR 2024 WIRING DIAGRAM...

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