Yamaha 2011 WR250FA Owner's Service Manual
  1. Manuals
  2. Brands
  3. Yamaha Manuals
  4. Motorcycle
  5. 2011 WR250FA
  6. Owner's service manual

Yamaha 2011 WR250FA Owner's Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

2011
Read this manual carefully before operating this vehicle.
OWNER'S SERVICE MANUAL
WR250FA
1HC-28199-10
LIT-11626-24-20

Advertisement

Table of Contents
loading

Related Manuals for Yamaha 2011 WR250FA

Summary of Contents for Yamaha 2011 WR250FA

  • Page 1 2011 Read this manual carefully before operating this vehicle. OWNER’S SERVICE MANUAL WR250FA 1HC-28199-10 LIT-11626-24-20...
  • Page 2 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
  • Page 3 WR250FA OWNER'S SERVICE MANUAL ©2010 by Yamaha Motor Corporation, U.S.A. 1st Edition, May 2010 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U.S.A. is expressly prohibited. Printed in Japan P/N. LIT-11626-24-20...

  • Page 4: Important Manual Information

    To main- tain these high standards, it is important that you and your Yamaha dealer pay close atten- A NOTICE indicates special precautions tion to the recommended maintenance sched- that must be taken to avoid damage to the ules and operating instructions contained vehicle or other property.

  • Page 5: Safety Information

    SAFETY INFORMATION • PARK THE MACHINE CAREFULLY; TURN OFF THE ENGINE. THIS MACHINE IS DESIGNED STRICTLY Always turn off the engine if you are going to FOR OFF-ROAD USE ONLY. It is illegal for this leave the machine. Do not park the machine machine to be operated on any public street, on a slope or soft ground as it may fall over.
  • Page 6 YAMAHA MOTOR CORPORATION, U.S.A. WR MOTORCYCLE LIMITED WARRANTY...

  • Page 7: General Information

    HOW TO USE THIS MANUAL FINDING THE REQUIRED PAGE 1. This manual consists of seven chapters; "General Information", "Specifications", "Regular inspec- tion and adjustments", "Tuning", "Engine", "Chassis" and "Electrical". 2. The table of contents is at the beginning of the manual. Look over the general layout of the book before finding then required chapter and item.
  • Page 8 HOW TO READ DESCRIPTIONS To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 1. An easy-to-see exploded diagram "1" is provided for removal and disassembly jobs. 2. Numbers "2" are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step.
  • Page 9 ILLUSTRATED SYMBOLS (Refer Illustrated symbols "1" to "7" are used to identi- to the illustration) fy the specifications appearing in the text. 1. With engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening 6. Specified value, Service limit 7.
  • Page 10 MEMO...

  • Page 11: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS TUNING ENGINE CHASSIS ELECTRICAL...

  • Page 12: General Information

    CONTENTS CHAPTER 1 GENERAL INFORMATION LOCATION OF IMPORTANT LABELS ..1-1 DESCRIPTION ........... 1-2 CONSUMER INFORMATION ....1-3 INCLUDED PARTS ........1-4 IMPORTANT INFORMATION ....1-5 CHECKING OF CONNECTION ....1-7 SPECIAL TOOLS........1-8 CONTROL FUNCTIONS ......1-12 MULTI-FUNCTION DISPLAY ....1-15 STARTING AND BREAK-IN ....

  • Page 13: Regular Inspection And Adjustments

    CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ..3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ......3-2 MAINTENANCE INTERVALS FOR COMPETITION USE ........3-4 PRE-OPERATION INSPECTION AND MAINTENANCE ......... 3-9 ENGINE ............ 3-10 CHASSIS..........3-27 ELECTRICAL ...........
  • Page 14 CHAPTER 6 CHASSIS FRONT WHEEL AND REAR WHEEL ..6-1 FRONT BRAKE AND REAR BRAKE..6-10 FRONT FORK .......... 6-24 HANDLEBAR ........... 6-35 STEERING ..........6-42 SWINGARM ..........6-48 REAR SHOCK ABSORBER ....6-55 CHAPTER 7 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ........

  • Page 15: Location Of Important Labels

    LOCATION OF IMPORTANT LABELS GENERAL INFORMATION LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle.

  • Page 16: Description

    DESCRIPTION DESCRIPTION 1. Clutch lever 14. Headlight 2. Hot starter lever 15. Radiator 3. Engine stop switch 16. Coolant drain bolt 4. Multi-function display 17. Rear brake pedal 5. Main switch 18. Valve joint 6. Start switch 19. Fuel cock 7.

  • Page 17: Consumer Information

    "1" is affixed at the location in the illustration. 1. When ordering parts, you can give the num- This label shows specifications related to ex- ber to your Yamaha dealer for positive iden- haust emissions as required by federal law, tification of the model you own.

  • Page 18: Included Parts

    INCLUDED PARTS INCLUDED PARTS VALVE JOINT This valve joint "1" prevents fuel from flowing out and is installed to the fuel tank breather hose. In this installation, make sure the arrow fac- es the fuel tank and also downward. SPARK PLUG WRENCH This spark plug wrench "1"...

  • Page 19: Important Information

    5. Keep away from fire. ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for as- sembly and adjustment.
  • Page 20 IMPORTANT INFORMATION BEARINGS AND OIL SEALS 1. Install the bearing(s) "1" and oil seal(s) "2" with their manufacturer's marks or numbers facing outward. (In other words, the stamped letters must be on the side ex- posed to view.) When installing oil seal(s), apply a light coating of lightweight lithium base grease to the seal lip(s).

  • Page 21: Checking Of Connection

    CHECKING OF CONNECTION CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: • Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off. 5.

  • Page 22: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised tech- niques. The shape and part number used for the special tool differ by country, so two types are pro- vided.
  • Page 23 SPECIAL TOOLS Tool name/Part number How to use Illustration Radiator cap tester These tools are used for YU-24460-01, 90890-01325 checking the cooling system. Radiator cap tester adapter YU-33984, 90890-01352 Steering nut wrench This tool is used when tighten YU-33975, 90890-01403 the steering ring nut to speci- fication.
  • Page 24 SPECIAL TOOLS Tool name/Part number How to use Illustration Pocket tester Use this tool to inspect the YU-3112-C, 90890-03112 coil resistance, output voltage and amperage. Timing light This tool is necessary for YM-33277-A, 90890-03141 checking ignition timing. Valve spring compressor This tool is needed to remove YM-4019, 90890-04019 and install the valve assem-...
  • Page 25 Ignition checker tem components. 90890-06754 Vacuum/pressure pump This tool is used to check the gauge set air induction system. YB-35956-A, 90890-06756 YAMAHA Bond No. 1215 This sealant (Bond) is used ® (ThreeBond No. 1215) for crankcase mating surface, 90890-85505 etc.

  • Page 26: Control Functions

    CONTROL FUNCTIONS CONTROL FUNCTIONS START SWITCH The start switch "1" is located on the right han- MAIN SWITCH dlebar. Push this switch to crank the engine Functions of the respective switch positions are with the starter. as follows: The engine can be started only at this position. OFF: All electrical circuits are switched off.
  • Page 27 CONTROL FUNCTIONS KICKSTARTER CRANK REAR BRAKE PEDAL Rotate the kickstarter crank "1" away from the The rear brake pedal "1" is located on the right engine. Push the starter down lightly with your side of the machine. Press down on the brake foot until the gears engage, then kick smoothly pedal to activate the rear brake.
  • Page 28 CONTROL FUNCTIONS COLD STARTER KNOB SIDESTAND When cold, the engine requires a richer air-fuel This sidestand "1" is used to support only the mixture for starting. A separate starter circuit, machine when standing or transporting it. which is controlled by the cold starter knob "1", supplies this mixture.

  • Page 29: Multi-Function Display

    MULTI-FUNCTION DISPLAY MULTI-FUNCTION DISPLAY Be sure to stop the machine before making any setting changes to the multi-function display. The multi-function display is equipped with the following: BASIC MODE: • Speedometer (which shows current speed) BASIC MODE • Clock Changing speedometer display •...
  • Page 30 MULTI-FUNCTION DISPLAY 3. Push the "SLCT1" button (plus) or "SLCT2" Setting the tire diameter button (minus) and change the time. A long push on the button will fast-forward the time. The outer diameter of a tire varies with tire wear, tire pressure, and course condition. If the outer diameter of a tire varies with tire wear or tire pressure, it can be corrected in the following manner.
  • Page 31 MULTI-FUNCTION DISPLAY Returning to BASIC MODE from RACE MODE It is possible to return to BASIC MODE with tim- 4. Push the "SLCT1" button and "RST" button er measurement at a stop. for 2 seconds or more at the same time will finish the setting.
  • Page 32 MULTI-FUNCTION DISPLAY RACE MODE Auto start Putting measurement on standby 1. Check that changeover has been made to RACE MODE. (Refer to "Changeover from BASIC MODE to RACE MODE".) Starting measurement consists of the following 2. Make the machine ready for a run by push- two starts, either of which can be selected.
  • Page 33 MULTI-FUNCTION DISPLAY Resetting measurement data Resetting can be made in the following three manners. Resetting is possible while timer measurement is made: • Reset average speed (AVS). • Reset average speed (AVS)/tripmeter A. Resetting is possible while timer measurement is not made: •...
  • Page 34 MULTI-FUNCTION DISPLAY Correcting tire diameter • Correction can be made any time while timer measurement is or is not being made. • Change in the travel distance display will be accompanied by the change in the tire's dia- metric percentage. •...
  • Page 35 MULTI-FUNCTION DISPLAY FUNCTION DIAGRAM The following diagram illustrates the multi-function display regarding the direction and operation con- dition involved in each of its functions. 1-21...

  • Page 36: Starting And Break-In

    Gasohol containing ethanol can be used if the ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems. HANDLING NOTE Never start or run the engine in a closed ar- ea.
  • Page 37 STARTING AND BREAK-IN The engine fails to start Pull the hot starter lever all the way out and • If the starter motor will not turn when while holding the lever, kick the kickstarter pushing the start switch, stop pushing it crank 10 to 20 times to clear the engine.
  • Page 38 STARTING AND BREAK-IN 6. Restart the engine and check the operation of the machine throughout its entire operat- ing range. Restart the machine and operate it for about 10 to 15 more minutes. After the break-in or before each ride, you must check the entire machine for loose fit- tings and fasteners as per "TORQUE- CHECK POINTS".

  • Page 39: Torque-Check Points

    TORQUE-CHECK POINTS TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and fuel tank Fuel tank to frame Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Steering stem to handlebar Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar...

  • Page 40: Cleaning And Storage

    CLEANING AND STORAGE CLEANING AND STORAGE STORAGE If your machine is to be stored for 60 days or CLEANING more, some preventive measures must be tak- Frequent cleaning of your machine will en- en to avoid deterioration. After cleaning the ma- hance its appearance, maintain good overall chine thoroughly, prepare it for storage as performance, and extend the life of many com-...

  • Page 41: General Specifications

    GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: WR250FA (USA, CDN, AUS, NZ) WR250F (EUROPE, ZA) Model code number: 1HC1 (USA) 1HC2 (CDN) 1HC3 (EUROPE) 1HC4 (AUS, NZ, ZA) Dimensions: USA, CDN, ZA AUS, NZ EUROPE Overall length 2,165 mm 2,175 mm 2,185 mm (85.24 in) (85.63 in)

  • Page 42: Chassis

    GENERAL SPECIFICATIONS Oil capacity: Engine oil Periodic oil change 1.1 L (0.97 Imp qt, 1.16 US qt) With oil filter replacement 1.2 L (1.06 Imp qt, 1.27 US qt) Total amount 1.4 L (1.23 Imp qt, 1.48 US qt) Coolant capacity (including all routes): 0.99 L (0.87 Imp qt, 1.05 US qt) Air filter: Wet type element...
  • Page 43 GENERAL SPECIFICATIONS Tire: Type With tube Size (front) 80/100-21 51M (For USA, CDN and ZA) 90/90-21 M/C 54M M+S (For EUROPE, AUS and NZ) Size (rear) 100/100-18 59M (For USA, CDN and ZA) 130/90-18 M/C 69M M+S (For EUROPE, AUS and NZ) Tire pressure (front and rear) 100 kPa (1.0 kgf/cm...

  • Page 44: Maintenance Specifications

    MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.05 mm (0.002 in) Cylinder: Bore size 77.00–77.01 mm (3.0315–3.0319 ---- Out of round limit ---- 0.05 mm (0.002 in) Camshaft: Drive method Chain drive (Left) ---- Camshaft cap inside diameter 22.000–22.021 mm (0.8661–...
  • Page 45 MAINTENANCE SPECIFICATIONS Item Standard Limit Timing chain: Timing chain type/No. of links 92RH2010-114M/114 ---- Timing chain adjustment method Automatic ---- Valve, valve seat, valve guide: Valve clearance (cold) 0.10–0.15 mm (0.0039–0.0059 in) ---- 0.17–0.22 mm (0.0067–0.0087 in) ---- Valve dimensions: "A"...
  • Page 46 MAINTENANCE SPECIFICATIONS Item Standard Limit Guide inside diameter (IN) 4.000–4.012 mm (0.1575–0.1580 4.050 mm (0.1594 in) Guide inside diameter (EX) 4.500–4.512 mm (0.1772–0.1776 4.550 mm (0.1791 in) Stem-to-guide clearance (IN) 0.010–0.037 mm (0.0004–0.0015 0.08 mm (0.003 in) Stem-to-guide clearance (EX) 0.025–0.052 mm (0.0010–0.0020 0.10 mm (0.004 in)
  • Page 47 MAINTENANCE SPECIFICATIONS Item Standard Limit Piston: Piston to cylinder clearance 0.030–0.055 mm (0.0012–0.0022 0.1 mm (0.004 in) Piston size "D" 76.955–76.970 mm (3.0297– ---- 3.0303 in) Measuring point "H" 8 mm (0.31 in) ---- Piston off-set 0.5 mm (0.020 in)/IN-side ---- Piston pin bore inside diameter 16.002–16.013 mm (0.6300–...
  • Page 48 MAINTENANCE SPECIFICATIONS Item Standard Limit Crankshaft: Crank width "A" 55.95–56.00 mm (2.203–2.205 in) ---- Runout limit "C" 0.03 mm (0.0012 in) 0.05 mm (0.002 in) Big end side clearance "D" 0.15–0.45 mm (0.0059–0.0177 in) 0.50 mm (0.02 in) Small end free play "F" 0.4–1.0 mm (0.02–0.04 in) 2.0 mm (0.08 in)
  • Page 49 MAINTENANCE SPECIFICATIONS Item Standard Limit Carburetor: USA, CDN, ZA, EUROPE AUS, NZ Type/manufacturer FCR-MX37/ ---- ← KEIHIN I. D. mark 5UME E0 5UML L0 ---- Main jet (M.J) #170 #160 ---- Main air jet (M.A.J) #115 ---- ← Jet needle (J.N) NJRU NNGU ----...
  • Page 50 MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing ---- Front suspension: Front fork travel 300 mm (11.8 in) ---- Fork spring free length 460 mm (18.1 in) 455 mm (17.9 in) Spring rate, STD K = 4.4 N/mm (0.449 kg/mm, 25.1 lb/in) ---- Optional spring/spacer...
  • Page 51 MAINTENANCE SPECIFICATIONS Item Standard Limit Wheel: USA, CDN, ZA AUS, NZ, EUROPE Front wheel type Spoke wheel ---- ← Rear wheel type Spoke wheel ---- ← Front rim size/material 21 × 1.60/Alumi- ---- ← Rear rim size/material 18 × 1.85/Alumi- 18 ×...
  • Page 52 4.6–6.8 kΩat 20 °C (68 °F) ---- Charging system: System type AC magneto ---- Model (stator)/manufacturer 5UM 30/YAMAHA ---- Normal output 14 V/120 W at 5,000 r/min ---- Charging coil resistance (color) 0.288–0.432 Ω at 20 °C (68 °F) (White–...
  • Page 53 MAINTENANCE SPECIFICATIONS Item Standard Limit Electric starting system: Type Constant mesh ---- Starter motor: Model/manufacturer 5UM01/YAMAHA ---- Operation voltage 12 V ---- Output 0.35 kW ---- Armature coil resistance 0.0189–0.0231 Ω at 20 °C (68 °F) ---- Brush overall length 7 mm (0.28 in)

  • Page 54: Tightening Torques

    TIGHTENING TORQUES TIGHTENING TORQUES ENGINE △ - marked portion shall be checked for torque tightening after break-in. Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Spark plug M10S × 1.0 Camshaft cap M6 × 1.0 Cylinder head blind plug screw M12 ×...
  • Page 55 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Oil pressure check bolt M6 × 1.0 Carburetor joint M6 × 1.0 Carburetor joint clamp M4 × 0.7 Air filter joint clamp M6 × 1.0 Throttle cable adjust bolt and locknut M6 ×...
  • Page 56 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Clutch boss M16 × 1.0 Clutch cable locknut M8 × 1.25 Push lever shaft M6 × 1.0 Drive sprocket M18 × 1.0 Drive axle oil seal stopper M6 ×...
  • Page 57 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Front brake master cylinder cap M4 × 0.7 △ Front brake hose union bolt M10 × 1.25 △ Front brake caliper M8 × 1.25 △ Front brake caliper and brake hose holder M6 ×...
  • Page 58 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb △ Swingarm and brake hose holder M5 × 0.8 Swingarm and patch M4 × 0.7 Upper drive chain tensioner M8 × 1.25 Lower drive chain tensioner M8 × 1.25 Drive chain support M6 ×...
  • Page 59 TIGHTENING TORQUES ELECTRICAL Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Stator M5 × 0.8 Holder (AC magneto lead) M5× 0.8 Rotor M12 × 1.25 Refer to TIP. Neutral switch M5 × 0.8 Starter motor M6 × 1.0 Starter relay terminal M6 ×...
  • Page 60 TIGHTENING TORQUES GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasten- ers with standard I.S.O. pitch threads. Torque specifications for special components or as- semblies are included in the applicable sec- tions of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fash- ion, in progressive stages, until full torque is reached.
  • Page 61 TIGHTENING TORQUES DEFINITION OF UNITS Unit Read Definition Measure millimeter meter Length centimeter meter Length kilogram gram Weight Newton 1 kg × m/sec Force Newton meter N × m Torque m•kg Meter kilogram m × kg Torque Pascal Pressure N/mm Newton per millimeter N/mm Spring rate...

  • Page 62: Lubrication Diagrams

    LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 2-22...
  • Page 63 LUBRICATION DIAGRAMS 1. Oil filter element 2. Oil pump 3. Drive axle 4. Main axle 5. Intake camshaft 6. Exhaust camshaft 7. Oil tank 8. Oil delivery pipe A. To oil tank 2-23...
  • Page 64 LUBRICATION DIAGRAMS 2-24...
  • Page 65 LUBRICATION DIAGRAMS 1. Crankshaft 2. Oil filter element 3. Oil tank 4. Oil hose A. From oil pump 2-25...

  • Page 66: Cable Routing Diagram

    CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM 2-26...
  • Page 67 CABLE ROUTING DIAGRAM 1. Fuel tank breather hose H. Pass the clutch cable through the cable 2. Clamp guide. 3. Diode Fasten the starter motor lead, AC magneto 4. Hot starter cable lead and neutral switch lead onto the 5. Wire harness frame.
  • Page 68 CABLE ROUTING DIAGRAM 2-28...
  • Page 69 CABLE ROUTING DIAGRAM 1. Throttle cable (pull) 2. Throttle cable (return) 3. Catch tank hose 4. Ignition coil 5. Clamp 6. Air induction hose (air cut-off valve - rear of cylinder head) 7. Catch tank breather hose A. Cross the pull and push throttle cables. B.
  • Page 70 CABLE ROUTING DIAGRAM 2-30...
  • Page 71 CABLE ROUTING DIAGRAM 1. Brake master cylinder 2. Brake hose holder 3. Brake hose A. Install the brake hose so that its pipe por- tion directs as shown and lightly touches the projection on the brake caliper. B. Pass the brake hose into the brake hose holders.
  • Page 72 CABLE ROUTING DIAGRAM 2-32...
  • Page 73 CABLE ROUTING DIAGRAM 1. Clamp L. Fasten the (three) CDI unit leads and tail- 2. Positive battery lead light lead to the rear frame. Locate the 3. Battery clamp end facing toward the lower side of 4. Negative battery lead the frame and cut off the tie end.
  • Page 74 CABLE ROUTING DIAGRAM 2-34...
  • Page 75 CABLE ROUTING DIAGRAM 1. Throttle cable 2. Clamp 3. Brake hose 4. Clutch cable 5. Hose guide 6. Main switch coupler 7. Wire harness 8. Headlight coupler 9. Hot starter cable 10. Multi-function display bracket 11. Main switch 12. Upper bracket 13.

  • Page 76: The Emission Control System

    • From 4,200 mi (7,000 km) or 9 months, repeat the maintenance intervals starting from 1,800 mi (3,000 km) or 3 months. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

  • Page 77: General Maintenance And Lubrication Chart

    GENERAL MAINTENANCE AND LUBRICATION CHART GENERAL MAINTENANCE AND LUBRICATION CHART INI- ODOMETER TIAL READINGS CHECKS AND MAINTENANCE 600 mi 1,800 mi 3,000 mi ITEM JOBS (1,000 (3,000 (5,000 km) or 1 km) or 3 km) or 6 month months months Check operation.
  • Page 78 Replace if necessary. Rear suspension link piv- Apply molybdenum disulfide grease √ √ 18 * lightly. Apply Yamaha chain and cable lube or √ √ √ 19 * Control cables engine oil 10W-30 thoroughly. Check operation and free play. Adjust the throttle cable free play if Throttle grip housing and √...

  • Page 79: Maintenance Intervals For Competition Use

    If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. • Periodic inspection is essential in making full use of the machine performance. The service life of the parts varies substantially according to the environment in which the machine runs (e.g., rain,...
  • Page 80 MAINTENANCE INTERVALS FOR COMPETITION USE Every Every After Every As re- third fifth (or Item break Remarks race quired (or 500 1,000 PISTON RING Inspect Check ring end gap. ● Replace ● ● PISTON PIN Inspect ● Replace ● CYLINDER HEAD Inspect carbon deposits and eliminate them.
  • Page 81 MAINTENANCE INTERVALS FOR COMPETITION USE Every Every After Every As re- third fifth (or Item break Remarks race quired (or 500 1,000 DRIVE CHAIN Use chain lube. Lubricate, slack, align- Chain slack: 48–58 mm (1.9– ● ● ment 2.3 in) Replace ●...
  • Page 82 MAINTENANCE INTERVALS FOR COMPETITION USE Every Every After Every As re- third fifth (or Item break Remarks race quired (or 500 1,000 FRONT FORKS Inspect and adjust ● ● Replace oil Suspension oil "S1" ● ● Replace oil seal ● FRONT FORK OIL SEAL AND DUST SEAL Clean and lube...
  • Page 83 (or Item break Remarks race quired (or 500 1,000 THROTTLE, CONTROL CABLE Check routing and con- ● ● nection Lubricate Yamaha cable lube or SAE ● ● 10W-40 motor oil HOT STARTER, CLUTCH LEVER Inspect free play ●...

  • Page 84: Pre-Operation Inspection And Maintenance

    PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation or practice, make sure the machine is in good operating condi- tion. Before using this machine, check the following points. GENERAL INSPECTION AND MAINTENANCE Item Routine Page Check that coolant is filled up to the radiator cap.

  • Page 85: Engine

    ENGINE ENGINE REMOVING THE SEAT, FUEL TANK AND SIDE COVERS Order Part name Q'ty Remarks Turn the fuel cock to "OFF". Disconnect the fuel hose. Seat Air scoop (left and right) Bolt (fuel tank) Fuel tank Left side cover Open the air filter case cover. Right side cover Refer to removal section.
  • Page 86 ENGINE REMOVING THE SIDE COVER 1. Remove: • Bolt (side cover) • Right side cover "1" Draw the side cover backward to remove it be- cause its claw "a" is inserted in the air filter case. 3-11...
  • Page 87 ENGINE REMOVING THE EXHAUST PIPE AND SILENCER Order Part name Q'ty Remarks Refer to "REMOVING THE SEAT, Right side cover FUEL TANK AND SIDE COVERS" section. Bolt (silencer clamp) Only loosening. Bolt [silencer (front)] Bolt [silencer (rear)] Collar Silencer Silencer clamp Nut (exhaust pipe) Exhaust pipe Gasket...
  • Page 88 ENGINE CHECKING THE SILENCER AND EXHAUST PIPE 1. Inspect: • Gasket "1" Damage → Replace. CHECKING THE COOLANT LEVEL Do not remove the radiator cap "1", drain bolt and hoses when the engine and radia- tor are hot. Scalding hot fluid and steam INSTALLING THE SILENCER AND may be blown out under pressure, which EXHAUST PIPE...
  • Page 89 ENGINE 8. Fill: • Radiator • Engine To specified level. Recommended coolant: High quality ethylene glycol anti- freeze containing anti-corrosion for aluminum engine Coolant "1" and water (soft water) "2" mixing ratio: 1. Radiator 50%/50% Coolant capacity: CHANGING THE COOLANT 0.99 L (0.87 Imp qt, 1.05 US qt) Do not remove the radiator cap when the en- gine is hot.
  • Page 90 ENGINE 10.Check: CHECKING THE COOLING SYSTEM • Coolant level 1. Inspect: Coolant level low → Add coolant. • Coolant level 2. Attach: CHECKING THE RADIATOR CAP • Radiator cap tester "1" and adapter "2" 1. Inspect: • Seal (radiator cap) "1" Radiator cap tester: •...
  • Page 91 ENGINE ADJUSTING THE CLUTCH CABLE FREE ADJUSTING THE THROTTLE CABLE FREE PLAY PLAY 1. Check: 1. Check: • Clutch lever free play "a" • Throttle grip free play "a" Out of specification → Adjust. Out of specification → Adjust. Clutch lever free play "a" : Throttle grip free play "a": 8–13 mm (0.31–0.51 in) 3–5 mm (0.12–0.20 in)
  • Page 92 ENGINE LUBRICATING THE THROTTLE 2. Adjust: 1. Remove: • Hot starter lever free play • Cover (throttle cable cap) "1" • Cover (grip cap) "2" Hot starter lever free play adjustment steps: • Throttle grip cap "3" a. Loosen the locknut "1". b.
  • Page 93 ENGINE 2. Unhook: 5. Inspect: • Binder "1" • Air filter element Damage → Replace. 6. Apply: • Foam-air-filter oil or equivalent oil to the ele- ment • Squeeze out the excess oil. Element should be wet but not dripping. •...
  • Page 94 ENGINE 9. Hook: Recommended brand: YAMALUBE • Binder "1" Recommended engine oil type SAE 10W-30, SAE 10W-40, SAE Hook the binder "1" so that it contacts the filter 10W-50, SAE 15W-40, SAE 20W-40 guide projections "a". or SAE 20W-50 Recommended engine oil grade API service SG type or higher, JASO standard MA CHECKING THE ENGINE OIL LEVEL...
  • Page 95 ENGINE 7. If the oil filter is to be replaced during this oil change, remove the following parts and rein- stall them. Replacement steps: a. Remove the oil filter element cover "1" and oil filter element "2". b. Check the O-rings "3", if cracked or dam- aged, replace them with a new one.
  • Page 96 ENGINE • Oil filter element drain bolt CHECKING THE OIL PRESSURE 1. Check: Oil filter element drain bolt: • Oil pressure 10 Nm (1.0 m•kg, 7.2 ft•lb) • Crankcase oil drain bolt Checking steps: Crankcase oil drain bolt: a. Slightly loosen the oil pressure check bolt 20 Nm (2.0 m•kg, 14 ft•lb) "1".
  • Page 97 This section is intended for those who have ba- Out of specification → Adjust. sic knowledge and skill concerning the servic- Valve clearance (cold): ing of Yamaha motorcycles (e.g., Yamaha Intake valve: dealers, service engineers, etc.) Those who 0.10–0.15 mm (0.0039–0.0059 in)
  • Page 98 ENGINE In order to be sure that the piston is at Top • Place a rag in the timing chain space to pre- Dead Center, the punch mark "c" on the ex- vent pads from falling into the crankcase. haust camshaft and the punch mark "d" on the •...
  • Page 99 ENGINE Last digit of pad Rounded valve number 0, 1 or 2 4, 5 or 6 8 or 9 EXAMPLE: Installed pad number = 148 Rounded off value = 150 Pads can only be selected in 0.05 mm incre- ments. e.
  • Page 100 ENGINE INTAKE INSTALLED PAD NUMBER MEASURED CLEARANCE 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 - 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.05 - 0.09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 0.10 - 0.15...
  • Page 101 ENGINE CLEANING THE SPARK ARRESTER (For 5. Install: USA) • Gasket (spark arrester) • Spark arrester Insert the spark arrester into the silencer • Be sure the exhaust pipe and silencer are and align the bolt holes. cool before cleaning the spark arrester. •...

  • Page 102: Chassis

    CHASSIS CHASSIS d. Place the other end of the tube into a con- tainer. BLEEDING THE HYDRAULIC BRAKE e. Slowly apply the brake lever or pedal sever- SYSTEM al times. f. Pull the lever in or push down on the pedal. Hold the lever or pedal in position.
  • Page 103 CHASSIS 2. Remove: 2. Adjust: • Brake lever cover • Brake pedal height 3. Adjust: • Brake lever position Pedal height adjustment steps: a. Loosen the locknut "1". Brake lever position adjustment steps: b. Turn the adjusting nut "2" until the pedal a.
  • Page 104 CHASSIS CHECKING AND REPLACING THE FRONT d. Remove the pad pin and brake pads "4". BRAKE PADS 1. Inspect: • Brake pad thickness "a" Out of specification → Replace as a set. Brake pad thickness: 4.4 mm (0.17 in) <Limit>: 1.0 mm (0.04 in) e.
  • Page 105 CHASSIS i. Install the brake caliper "8" and tighten the CHECKING AND REPLACING THE REAR pad pin "9". BRAKE PADS 1. Inspect: Bolt (brake caliper): • Brake pad thickness "a" 23 Nm (2.3 m•kg, 17 ft•lb) Out of specification → Replace as a set. Pad pin: 18 Nm (1.8 m•kg, 13 ft•lb) Brake pad thickness:...
  • Page 106 CHASSIS d. Remove the pad pin "6" and brake pads "7". i. Install the brake caliper "12" and rear wheel "13". Refer to "FRONT WHEEL AND REAR WHEEL" section in the CHAPTER 6. j. Tighten the pad pin "14". Pad pin: 18 Nm (1.8 m•kg, 13 ft•lb) e.
  • Page 107 CHASSIS CHECKING THE REAR BRAKE PAD CHECKING THE SPROCKET INSULATOR 1. Inspect: 1. Remove: • Sprocket teeth "a" • Brake pad Excessive wear → Replace. Refer to "CHECKING AND REPLACING THE REAR BRAKE PADS" section. Replace the drive sprocket, rear wheel sprock- 2.
  • Page 108 CHASSIS 3. Clean: 6. Install: • Drive chain • Chain joint "1" Brush off as much dirt as possible. Then • O-ring "2" clean the drive chain using the chain clean- • Drive chain "3" • Link plate "4" When installing the drive chain, apply the lithi- This machine has a drive chain with small um soap base grease on the chain joint and O- rubber O-rings "1"...

  • Page 109: Specifications

    CHASSIS 8. Lubricate: 3. Adjust: • Drive chain • Drive chain slack Drive chain lubricant: Drive chain slack adjustment steps: SAE 10W-40 motor oil or suitable a. Loosen the axle nut "1" and locknuts "2". chain lubricants b. Adjust the drive chain slack by turning the adjusters "3".

  • Page 110: Adjustments

    CHASSIS CHECKING THE FRONT FORK 1. Inspect: • Front fork smooth action Operate the front brake and stroke the front fork. Unsmooth action/oil leakage → Repair or re- place. RELIEVING THE FRONT FORK INTERNAL PRESSURE If the front fork initial movement feels stiff dur- ing a run, relieve the front fork internal pres- sure.
  • Page 111 CHASSIS • STANDARD POSITION: • STANDARD POSITION: This is the position which is back by the spe- This is the position which is back by the spe- cific number of clicks from the fully turned-in cific number of clicks from the fully turned-in position.

  • Page 112: Engine

    CHASSIS ADJUSTING THE REAR SHOCK c. Measure the spring free length "a". ABSORBER SPRING PRELOAD d. Turn the adjuster "2". 1. Elevate the rear wheel by placing the suit- Stiffer →Increase the spring preload. (Turn able stand under the engine. the adjuster "2"...

  • Page 113: Chassis

    CHASSIS ADJUSTING THE REAR SHOCK ADJUSTING THE REAR SHOCK ABSORBER REBOUND DAMPING FORCE ABSORBER LOW COMPRESSION 1. Adjust: DAMPING FORCE • Rebound damping force 1. Adjust: By turning the adjuster "1". • Low compression damping force By turning the adjuster "1". Stiffer "a"...
  • Page 114 CHASSIS ADJUSTING THE REAR SHOCK CHECKING THE TIRE PRESSURE ABSORBER HIGH COMPRESSION 1. Measure: • Tire pressure DAMPING FORCE Out of specification → Adjust. 1. Adjust: • High compression damping force Standard tire pressure: By turning the adjuster "1". 100 kPa (1.0 kgf/cm , 15 psi) Stiffer "a"...
  • Page 115 CHASSIS 2. Check: • Steering stem Be sure to retighten these spokes before and Grasp the bottom of the forks and gently after break-in. rock the fork assembly back and forth. Free play → Adjust steering head. Spoke nipple wrench: YM-01521/90980-01521 3.
  • Page 116 CHASSIS Steering stem nut: • Apply the lithium soap base grease on the 145 Nm (14.5 m•kg, 105 ft•lb) thread of the steering stem. Handlebar upper holder: • Set the torque wrench to the steering nut 28 Nm (2.8 m•kg, 20 ft•lb) wrench so that they form a right angle.
  • Page 117 CHASSIS 3-42...
  • Page 118 CHASSIS LUBRICATION 3-43...
  • Page 119 7. Tube guide cable winding portion 8. Throttle cable end 9. Clutch cable end 10. Hot starter cable end A. Use Yamaha cable lube or equivalent on these areas. B. Use SAE 10W-40 motor oil or suitable chain lubricants. C. Lubricate the following areas with high quality, lightweight lithium-soap base grease.

  • Page 120: Electrical

    ELECTRICAL ELECTRICAL CHECKING THE SPARK PLUG 1. Remove: • Spark plug 2. Inspect: • Electrode "1" Wear/damage → Replace. • Insulator color "2" Normal condition is a medium to light tan color. CHECKING THE IGNITION TIMING Distinctly different color → Check the engine 1.
  • Page 121 ELECTRICAL Since MF batteries are sealed, it is not possible to check the charge state of the battery by mea- suring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the bat- tery terminals.
  • Page 122 ELECTRICAL D. Time (minutes) E. Charging condition of the battery • The charge state of an MF battery can be F. Ambient temperature 20 °C (68 °F) checked by measuring its open-circuit voltage a. Charging (i.e., the voltage when the positive terminal is b.
  • Page 123 ELECTRICAL Charging method using a variable voltage charger 3-48...
  • Page 124 ELECTRICAL Charging method using a constant voltage charger 3-49...
  • Page 125 ELECTRICAL 6. Install: • Battery • Battery band 7. Connect: • Battery leads (to the battery terminals) First, connect the positive lead "1", then the negative lead "2". 2. Reserve fuse c. If the pocket tester indicates " ∞ ", replace the fuse.
  • Page 126 ELECTRICAL REPLACING THE HEADLIGHT BULBS 6. Install: 1. Remove: • Headlight bulb holder • Headlight 7. Install: Refer to "SEAT, FUEL TANK AND SIDE • Headlight bulb holder cover COVERS" section. 8. Install: 2. Remove: • Headlight • Headlight bulb holder cover "1" Headlight: 7 Nm (0.7 m•kg, 5.1 ft•lb) Refer to "SEAT, FUEL TANK AND SIDE...

  • Page 127: Tuning

    CHASSIS TUNING DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS CHASSIS Part name Size Part number SELECTION OF THE SECONDARY Drive sprocket "1" REDUCTION RATIO (SPROCKET) (STD) 9383B-13218 Secondary reduction ratio = Number of Rear wheel rear wheel sprocket teeth/Number of sprocket "2"...
  • Page 128 CHASSIS FRONT FORK SETTING The front fork setting should be made depend- ing on the rider's feeling of an actual run and the circuit conditions. The front fork setting includes the following three factors: 1. Setting of air spring characteristics •...
  • Page 129 CHASSIS FRONT FORK SETTING PARTS • Adjustment washer "1" Always adjust each front fork to the same TYPE (thickness) PART NUMBER setting. Uneven adjustment can cause poor handling and loss of stability. T = 2.3 mm (0.09 in) 5XE-23364-00 • Front fork spring "2" Standard washer quantity: I.D.
  • Page 130 CHASSIS REAR SUSPENSION SETTING The rear suspension setting should be made • If the machine is new and after it is broken in, depending on the rider's feeling of an actual run the same set length of the spring may change and the circuit conditions.
  • Page 131 CHASSIS Length "a" of standard shock: 488.5 mm (19.23 in) REAR SHOCK ABSORBER SETTING PARTS • Rear shock spring "1" SPRING I.D. SPRING PART TYPE MARK/ RATE NUMBER Q'TY (-22212-) SOFT 5UN-00 Brown/1 • Extent of adjustment (spring preload) 5UN-10 Green/1 SPRING PART...
  • Page 132 CHASSIS 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 133 CHASSIS SUSPENSION SETTING (REAR SHOCK ABSORBER) • 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. • Adjust the rebound damping in 2-click increments or decrements. •...

  • Page 134: Engine

    This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.
  • Page 135 RADIATOR Order Part name Q'ty Remarks Radiator hose 3 Radiator pipe 2 Radiator hose 5 Catch tank hose Right radiator Radiator hose 2 Radiator hose 4 Radiator pipe 1 Catch tank breather hose Catch tank...
  • Page 136 RADIATOR HANDLING NOTE Do not remove the radiator cap when the en- gine and radiator are hot. Scalding hot fluid and steam may be blown out under pres- sure, which could cause serious injury. When the engine has cooled, open the radi- ator cap by the following procedure: Place a thick rag, like a towel, over the radi- ator cap, slowly rotate the cap counter-...
  • Page 137 RADIATOR 4. Install: 7. Install: • Left radiator "1" • Catch tank "1" • Bolt (left radiator) "2" • Bolt (catch tank) "2" Bolt (left radiator): Bolt (catch tank): 10 Nm (1.0 m•kg, 7.2 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) •...

  • Page 138: Carburetor

    CARBURETOR CARBURETOR REMOVING THE CARBURETOR 4 Nm (0.4 m kg, 2.9 ft lb) 2 Nm (0.2 m kg, 1.4 ft lb) 11 Nm (1.1 m kg, 8.0 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 3 Nm (0.3 m kg, 2.2 ft lb) 3 Nm (0.3 m kg, 2.2 ft lb) Order...
  • Page 139 CARBURETOR DISASSEMBLING THE CARBURETOR Order Part name Q'ty Remarks Carburetor breather hose Valve lever housing cover Screw (throttle shaft) Throttle valve Needle holder Jet needle Accelerator pump cover Spring Diaphragm (accelerator pump) Air cut valve cover Spring (air cut valve) Diaphragm (air cut valve) Float chamber Leak jet...
  • Page 140 CARBURETOR Order Part name Q'ty Remarks Float Needle valve Main jet Needle jet Spacer Pilot jet Starter jet Push rod Pull the push rod. Throttle shaft assembly Push rod link lever assembly Main air jet Pilot air jet Cold starter plunger...
  • Page 141 CARBURETOR HANDLING NOTE • Use a petroleum based solvent for cleaning. Blow out all passages and jets with com- Do not loosen the screw (throttle position pressed air. sensor) "1" except when changing the • Never use a wire. throttle position sensor due to failure be- cause it will cause a drop in engine perfor- mance.
  • Page 142 CARBURETOR CHECKING THE JET NEEDLE c. If the float height is not within specification, 1. Inspect: inspect the valve seat and needle valve. • Jet needle "1" d. If either is worn, replace them both. Bends/wear → Replace. e. If both are fine, adjust the float height by •...
  • Page 143 CARBURETOR CHECKING THE ACCELERATOR PUMP 1. Inspect: • Diaphragm (accelerator pump) "1" • Spring (accelerator pump) "2" • Accelerator pump cover "3" • O-ring "4" • Push rod "5" Tears (diaphragm)/damage → Replace. Dirt → Clean. ASSEMBLING THE CARBURETOR 1. Install: •...
  • Page 144 CARBURETOR 7. Install: • Spring "1" To throttle shaft "2". Install the bigger hook "a" of the spring fits on the stopper "b" of the throttle shaft pulley. 4. Install: • Spring 2 "1" To lever 2 "2". 8. Install: •...
  • Page 145 CARBURETOR 11.Install: • Needle valve "1" • Float "2" • Float pin "3" • After installing the needle valve to the float, in- stall them to the carburetor. • Check the float for smooth movement. 12.Install: • O-ring 9. Install: •...
  • Page 146 CARBURETOR 14.Install: • Diaphragm (accelerator pump) "1" • Spring "2" • O-ring "3" • Accelerator pump cover "4" • Hose holder (drain hose) "5" • Screw (accelerator pump cover) "6" Install the diaphragm (accelerator pump) with its mark "a" facing the spring. 17.Install: •...
  • Page 147 CARBURETOR ADJUSTING THE ACCELERATOR PUMP INSTALLING THE CARBURETOR TIMING 1. Install: • Carburetor joint "1" Adjustment steps: Carburetor joint: 10 Nm (1.0 m•kg, 7.2 ft•lb) In order for the throttle valve height "a" to achieve the specified value, tuck under the throttle valve plate "1"...
  • Page 148 CARBURETOR 4. Tighten: 7. Install: • Bolt (carburetor joint) "1" • Throttle cable cover "1" • Bolt (throttle cable cover) "2" Bolt (carburetor joint): 3 Nm (0.3 m•kg, 2.2 ft•lb) Bolt (throttle cable cover): 4 Nm (0.4 m•kg, 2.9 ft•lb) •...

  • Page 149: Air Induction System

    AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM REMOVING THE AIR INDUCTION SYSTEM 7 Nm (0.7 m kg, 5.1 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) Order Part name Q'ty Remarks Bracket Air cut-off valve assembly Air induction hose (air cut-off valve -...
  • Page 150 AIR INDUCTION SYSTEM CHECKING THE AIR INDUCTION SYSTEM 1. Inspect: • Air induction hose Crack/damage → Replace. • Air induction pipe Crack/damage → Replace. 2. Check: • Operation of air cut valve Pass air through the pipe and check the air cut valve for operation.

  • Page 151: Camshafts

    CAMSHAFTS CAMSHAFTS REMOVING THE CYLINDER HEAD COVER Order Part name Q'ty Remarks Refer to "REMOVING THE SEAT, Seat and fuel tank FUEL TANK AND SIDE COVERS" section in the CHAPTER 3. Refer to "AIR INDUCTION SYSTEM" Air cut-off valve assembly section.
  • Page 152 CAMSHAFTS REMOVING THE CAMSHAFTS Order Part name Q'ty Remarks Timing mark accessing screw Refer to removal section. Crankshaft end accessing screw Refer to removal section. Timing chain tensioner cap bolt Refer to removal section. Timing chain tensioner Refer to removal section. Camshaft cap Refer to removal section.
  • Page 153 CAMSHAFTS REMOVING THE CAMSHAFT 3. Remove: • Timing chain tensioner cap bolt "1" 1. Remove: • Timing chain tensioner "2" • Timing mark accessing screw "1" • Gasket • Crankshaft end accessing screw "2" 4. Remove: 2. Align: • Bolt (camshaft cap) "1" •...
  • Page 154 CAMSHAFTS CHECKING THE CAMSHAFT 3. Measure: 1. Inspect: • Runout (camshaft) • Cam lobe Out of specification → Replace. Pitting/scratches/blue discoloration → Re- Runout (camshaft): place. Less than 0.03 mm (0.0012 in) 2. Measure: • Cam lobe length "a" and "b" Out of specification →...
  • Page 155 CAMSHAFTS d. Remove the camshaft caps and measure CHECKING THE DECOMPRESSION ® the width of the Plastigauge "1". SYSTEM 1. Check: • Decompression system Checking steps: a. Check that the decompression mechanism cam "1" moves smoothly. b. Check that the decompression mechanism cam lever pin "2"...
  • Page 156 CAMSHAFTS INSTALLING THE CAMSHAFT 1. Install: • Exhaust camshaft "1" • Intake camshaft "2" Do not turn the crankshaft during the cam- shaft installation. Damage or improper valve timing will result. d. Install the clips, camshaft caps "4" and bolts Installation steps: (camshaft cap) "5".
  • Page 157 • Bolt (cylinder head cover) "4" Bolt (cylinder head cover): 10 Nm (1.0 m•kg, 7.2 ft•lb) Apply the sealant on the cylinder head cover gasket. YAMAHA Bond No. 1215 (Three- ® Bond No. 1215): c. Release the screwdriver, check the tension- 90890-85505 er rod to come out and tighten the gasket "4"...
  • Page 158 CAMSHAFTS 7. Install: • Cylinder head breather hose • Spark plug Spark plug: 13 Nm (1.3 m•kg, 9.4 ft•lb) 5-25...

  • Page 159: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD REMOVING THE CYLINDER HEAD Order Part name Q'ty Remarks Refer to "REMOVING THE SEAT, Seat and fuel tank FUEL TANK AND SIDE COVERS" section in the CHAPTER 3. Refer to "REMOVING THE EX- Exhaust pipe and silencer HAUST PIPE AND SILENCER"...
  • Page 160 CYLINDER HEAD Order Part name Q'ty Remarks Bolt [L = 135 mm (5.31 in)] Bolt [L = 145 mm (5.71 in)] Cylinder head Timing chain guide (exhaust side) 5-27...
  • Page 161 CYLINDER HEAD CHECKING THE CYLINDER HEAD 1. Eliminate: • Carbon deposits (from the combustion chambers) Use a rounded scraper. Do not use a sharp instrument to avoid damag- ing or scratching: • Spark plug threads • Valve seats INSTALLING THE CYLINDER HEAD 1.
  • Page 162 CYLINDER HEAD 3. Install: • Copper washer "1" • Oil delivery pipe "2" • Union bolt (M8) "3" Union bolt (M8): 18 Nm (1.8 m•kg, 13 ft•lb) • Union bolt (M10) "4" Union bolt (M10): 20 Nm (2.0 m•kg, 14 ft•lb) First tighten the union bolts temporarily.Then retighten them with the width "a"...

  • Page 163: Valves And Valve Springs

    VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS REMOVING THE VALVES AND VALVE SPRINGS Order Part name Q'ty Remarks Cylinder head Refer to "CYLINDER HEAD" section. Valve lifter Refer to removal section. Adjusting pad Refer to removal section. Valve cotter Refer to removal section.
  • Page 164 VALVES AND VALVE SPRINGS REMOVING THE VALVE LIFTER AND 3. Remove: VALVE COTTER • Valve cotter 1. Remove: • Valve lifter "1" Attach a valve spring compressor "1" between • Pad "2" the valve spring retainer and the cylinder head to remove the valve cotters.
  • Page 165 VALVES AND VALVE SPRINGS 2. Replace: Valve guide remover: • Valve guide Intake:4.0 mm (0.16 in) YM-4111/90890-04111 Replacement steps: Exhaust:4.5 mm (0.18 in) YM-4116/90890-04116 Valve guide installer: To ease guide removal, installation and to Intake:4.0 mm (0.16 in) maintain correct fit heat the cylinder head in an YM-4112/90890-04112 over to 100 °C (212 °F).
  • Page 166 VALVES AND VALVE SPRINGS 5. Measure: • Runout (valve stem) Measurement steps: Out of specification → Replace. a. Apply Mechanic's blueing dye (Dykem) "b" to the valve face. Runout limit: 0.01 mm (0.0004 in) • When installing a new valve always replace the guide.
  • Page 167 VALVES AND VALVE SPRINGS After every lapping operation be sure to clean Lapping steps: off all of the compound from the valve face and a. Apply a coarse lapping compound to the valve seat. valve face. f. Apply Mechanic's blueing dye (Dykem) to the valve face.
  • Page 168 VALVES AND VALVE SPRINGS INSTALLING THE VALVES 1. Apply: • Molybdenum disulfide oil Onto the valve stem and valve stem seal. 2. Install: • Valve "1" • Valve spring seat "2" • Valve stem seal "3" • Valve spring "4" •...
  • Page 169 VALVES AND VALVE SPRINGS 4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood. Hitting the valve tip with excessive force could damage the valve. 5. Install: • Adjusting pad "1" •...

  • Page 170: Cylinder And Piston

    CYLINDER AND PISTON CYLINDER AND PISTON REMOVING THE CYLINDER AND PISTON Order Part name Q'ty Remarks Cylinder head Refer to "CYLINDER HEAD" section. Bolt (cylinder) Cylinder Piston pin clip Refer to removal section. Piston pin Refer to removal section. Piston Refer to removal section.
  • Page 171 CYLINDER AND PISTON REMOVING THE PISTON AND PISTON RING 1. Remove: • Piston pin clip "1" • Piston pin "2" • Piston "3" • Put identification marks on each piston head for reference during reinstallation. • Before removing each piston pin, deburr the clip groove and pin hole area.
  • Page 172 CYLINDER AND PISTON b. If out of specification, replace the cylinder, and replace the piston and piston rings as set. c. Measure the piston skirt diameter "P" with a micrometer. 2. Position: • Piston ring (in cylinder) Insert a ring into the cylinder and push it ap- a.
  • Page 173 CYLINDER AND PISTON CHECKING THE PISTON PIN INSTALLING THE PISTON RING AND 1. Inspect: PISTON • Piston pin 1. Install: Blue discoloration/grooves → Replace, then • Piston ring inspect the lubrication system. Onto the piston. 2. Measure: • Piston pin-to-piston clearance •...
  • Page 174 CYLINDER AND PISTON • Apply engine oil onto the piston pin and pis- ton. • Be sure that the arrow mark "a" on the piston points to the exhaust side of the engine. • Before installing the piston pin clip, cover the crankcase with a clean rag to prevent the pis- ton pin clip from falling into the crankcase.

  • Page 175: Clutch

    CLUTCH CLUTCH REMOVING THE CLUTCH Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE Drain the engine oil. OIL" section in the CHAPTER 3. Refer to "ENGINE REMOVAL" sec- Brake pedal tion. Clutch cable Disconnect at engine side. Clutch cover Clutch spring Pressure plate Push rod 1...
  • Page 176 CLUTCH Order Part name Q'ty Remarks Clutch plate Cushion spring Seat plate Nut (clutch boss) Refer to removal section. Lock washer Refer to removal section. Clutch boss Refer to removal section. Thrust washer Primary driven gear Push lever shaft 5-43...
  • Page 177 CLUTCH REMOVING THE CLUTCH BOSS CHECKING THE PRIMARY DRIVEN GEAR 1. Remove: 1. Check: • Nut "1" • Circumferential play • Lock washer "2" Free play exists → Replace. • Clutch boss "3" • Gear teeth "a" Wear/damage → Replace. Straighten the lock washer tab and use the clutch holding tool "4"...
  • Page 178 CLUTCH CHECKING THE PUSH ROD 1. Inspect: • Push rod 1 "1" • Bearing "2" • Washer "3" • Push rod 2 "4" • Ball "5" Wear/damage/bend → Replace. CHECKING THE CLUTCH PLATES 1. Measure: • Clutch plate warpage Out of specification → Replace clutch plate as a set.
  • Page 179 CLUTCH INSTALLING THE CLUTCH 3. Bend the lock washer "1" tab. 1. Install: • Primary driven gear "1" • Thrust washer "2" • Clutch boss "3" Apply the engine oil on the primary driven gear inner circumference. 4. Install: • Seat plate "1" •...
  • Page 180 CLUTCH 8. Install: • Pressure plate "1" 6. Install: • Bearing "1" • Washer "2" 9. Install: • Circlip "3" • Clutch spring "1" To push rod 1 "4". • Bolt (clutch spring) "2" Bolt (clutch spring): Apply the engine oil on the bearing and washer. 10 Nm (1.0 m•kg, 7.2 ft•lb) Tighten the bolts in stage, using a crisscross pattern.
  • Page 181 CLUTCH 11.Install: • Clutch cover "1" • Bolt (clutch cover) Bolt (clutch cover): 10 Nm (1.0 m•kg, 7.2 ft•lb) Tighten the bolts in stage, using a crisscross pattern. 5-48...

  • Page 182: Oil Filter Element And Water Pump

    OIL FILTER ELEMENT AND WATER PUMP OIL FILTER ELEMENT AND WATER PUMP REMOVING THE OIL FILTER ELEMENT AND WATER PUMP Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE Drain the engine oil. OIL" section in the CHAPTER 3. Refer to "CHANGING THE COOL- Drain the coolant.
  • Page 183 OIL FILTER ELEMENT AND WATER PUMP Order Part name Q'ty Remarks Bolt (oil hose) Kickstarter crank Right crankcase cover Impeller Refer to removal section. Washer Refer to removal section. Impeller shaft Refer to removal section. Oil seal Refer to removal section. Bearing Refer to removal section.
  • Page 184 OIL FILTER ELEMENT AND WATER PUMP REMOVING THE IMPELLER SHAFT 2. Remove: 1. Remove: • Oil seal "1" • Impeller "1" • Washer "2" • Impeller shaft "3" Hold the impeller shaft on its width across the flats "a" with spanners, etc. and remove the im- peller.
  • Page 185 OIL FILTER ELEMENT AND WATER PUMP CHECKING THE BEARING 2. Install: 1. Inspect: • Bearing "1" • Bearing Rotate inner race with a finger. Install the bearing by pressing its outer race Rough spot/seizure → Replace. parallel. CHECKING THE OIL SEAL INSTALLING THE IMPELLER SHAFT 1.
  • Page 186 OIL FILTER ELEMENT AND WATER PUMP INSTALLING THE RIGHT CRANKCASE INSTALLING THE KICKSTARTER CRANK COVER 1. Install: 1. Install: • Kickstarter crank "1" • Dowel pin "1" • Washer • O-ring "2" • Bolt (kickstarter crank) • Collar "3" Bolt (kickstarter crank): •...
  • Page 187 OIL FILTER ELEMENT AND WATER PUMP 2. Install: • Water pump housing "1" • Bolt (water pump housing) "2" Bolt (water pump housing): 10 Nm (1.0 m•kg, 7.2 ft•lb) 3. Install: • Copper washer "1" • Oil delivery pipe "2" •...

  • Page 188: Balancer

    BALANCER BALANCER REMOVING THE BALANCER Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Refer to "OIL FILTER ELEMENT Right crankcase cover AND WATER PUMP" section. Refer to "AC MAGNETO AND Stator STARTER CLUTCH" section. Nut (primary drive gear) Refer to removal section.
  • Page 189 BALANCER REMOVING THE BALANCER CHECKING THE PRIMARY DRIVE GEAR, 1. Straighten the lock washer tab. BALANCER SHAFT DRIVE GEAR AND 2. Loosen: BALANCER SHAFT DRIVEN GEAR • Nut (primary drive gear) "1" 1. Inspect: • Nut (balancer shaft driven gear) "2" •...
  • Page 190 BALANCER 2. Install: • Balancer shaft driven gear "1" • Install the primary drive gear with its stepped side "a" facing the engine. Install the balancer shaft driven gear onto the • Place an aluminum plate "b" between the balancer shaft while aligning the punch mark teeth of the balancer shaft drive gear "6"...

  • Page 191: Oil Pump

    OIL PUMP OIL PUMP REMOVING THE OIL PUMP Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Refer to "OIL FILTER ELEMENT Right crankcase cover AND WATER PUMP" section. Circlip Washer Oil pump drive gear Oil pump assembly Outer rotor 2 Circlip Inner rotor 2...
  • Page 192 OIL PUMP Order Part name Q'ty Remarks Dowel pin Washer Oil pump drive shaft Rotor housing 5-59...
  • Page 193 OIL PUMP REMOVING THE OIL TANK Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE Drain the engine oil. OIL" section in the CHAPTER 3. Oil hose 2 Oil hose 1 Dowel pin Oil tank breather hose Oil tank Oil strainer 5-60...
  • Page 194 OIL PUMP CHECKING THE OIL PUMP 1. Inspect: • Oil pump drive gear "1" • Oil pump drive shaft "2" • Rotor housing "3" • Oil pump cover "4" Cracks/wear/damage → Replace. 2. Measure: • Tip clearance "a" (between the inner rotor "1" and outer rotor "2") 3.
  • Page 195 OIL PUMP 4. Install: • Outer rotor 2 "1" • Dowel pin "2" • Oil pump assembly "3" • Bolt (oil pump assembly) [L = 25 mm (0.94 in)] "4" Bolt (oil pump assembly): 10 Nm (1.0 m•kg, 7.2 ft•lb) •...

  • Page 196: Kick Shaft And Shift Shaft

    KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Remarks Oil pump Refer to "OIL PUMP" section. Kick idle gear Kick shaft assembly Refer to removal section. Spring guide Torsion spring Ratchet wheel Kick gear...
  • Page 197 KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Remarks Shift guide Refer to removal section. Shift lever assembly Refer to removal section. Shift lever Pawl Pawl pin Spring Bolt (stopper lever) Stopper lever Torsion spring Segment Refer to removal section. 5-64...
  • Page 198 KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT ASSEMBLY 1. Remove: • Kick shaft assembly "1" Unhook the torsion spring "2" from the hole "a" in the crankcase. CHECKING THE KICK SHAFT AND RATCHET WHEEL 1. Check: • Ratchet wheel "1" smooth movement Unsmooth movement →...
  • Page 199 KICK SHAFT AND SHIFT SHAFT CHECKING THE SHIFT SHAFT INSTALLING THE SEGMENT 1. Inspect: 1. Install: • Shift shaft "1" • Segment "1" Bend/damage → Replace. • Bolt (segment) • Spring "2" Bolt (segment): Broken → Replace. 30 Nm (3.0 m•kg, 22 ft•lb) Align the notch "a"...
  • Page 200 KICK SHAFT AND SHIFT SHAFT INSTALLING THE SHIFT GUIDE AND SHIFT 4. Install: LEVER ASSEMBLY • Bolt (shift guide) "1" 1. Install: Bolt (shift guide): • Spring "1" 10 Nm (1.0 m•kg, 7.2 ft•lb) • Pawl pin "2" • Pawl "3" To shift lever "4".
  • Page 201 KICK SHAFT AND SHIFT SHAFT • Apply the engine oil on the kick shaft. • Slide the kick shaft assembly into the crank- case and make sure the kick shaft stopper "a" fits into the kick shaft ratchet wheel guide. 2.

  • Page 202: Ac Magneto And Starter Clutch

    AC MAGNETO AND STARTER CLUTCH AC MAGNETO AND STARTER CLUTCH REMOVING THE AC MAGNETO AND STARTER CLUTCH Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE Drain the engine oil. OIL" section in the CHAPTER 3. Refer to "SEAT, FUEL TANK AND Seat and fuel tank SIDE COVERS"...
  • Page 203 AC MAGNETO AND STARTER CLUTCH Order Part name Q'ty Remarks Starter clutch drive gear Starter clutch assembly cover Starter clutch Refer to removal section. Bearing Washer Idle gear plate Idle gear Holder Pickup coil Stator Tighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb), loosen and retighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb).
  • Page 204 AC MAGNETO AND STARTER CLUTCH REMOVING THE ROTOR 2. Remove: 1. Remove: • Starter clutch "1" • Nut (rotor) "1" • Washer Using a thin screwdriver or the like, remove the Use the sheave holder "2". plate "a" while prying it upward little by little. Sheave holder: YS-1880-A/90890-01701 REMOVING THE AC MAGNETO...
  • Page 205 AC MAGNETO AND STARTER CLUTCH CHECKING THE STARTER CLUTCH CHECKING THE TORQUE LIMITER 1. Check: 1. Check: • Starter clutch • Torque limiter Damage/wear → Replace. Damage/wear → Replace. 2. Check: • Idle gear • Starter clutch drive gear Pitting/burrs/chips/roughness/wear → Re- place the defective parts.
  • Page 206 Apply the sealant to the grommet of the AC • Bearing "2" magneto lead. • Starter clutch drive gear "3" • Washer "4" YAMAHA Bond No. 1215 (Three- ® Bond No. 1215): Apply the engine oil on the washer, bearing and 90890-85505 starter clutch drive gear inner circumference.
  • Page 207 AC MAGNETO AND STARTER CLUTCH 8. Install: 10.Install: • Woodruff key "1" • Dowel pin • Rotor "2" • Gasket [crankcase cover (left)] • Crankcase cover (left) "1" • Bolt [crankcase cover (left)] "2" • Degrease the contact surfaces of the tapered portions of the crankshaft and rotor.
  • Page 208 AC MAGNETO AND STARTER CLUTCH 12.Install: • O-ring • Cover (idle gear 1) "1" • Bolt "2" Bolt: 10 Nm (1.0 m•kg, 7.2 ft•lb) • Apply the lithium soap base grease on the O- ring. • Install the cover (idle gear 1) with its mark "a" facing upward.

  • Page 209: Engine Removal

    ENGINE REMOVAL ENGINE REMOVAL REMOVING THE ENGINE Order Part name Q'ty Remarks Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the frame. Refer to "CHANGING THE ENGINE Drain the engine oil. OIL" section in the CHAPTER 3. Refer to "SEAT, FUEL TANK AND Seat and fuel tank SIDE COVERS"...
  • Page 210 ENGINE REMOVAL Order Part name Q'ty Remarks Refer to "AC MAGNETO AND Shift pedal STARTER CLUTCH" section. Cylinder head breather hose Refer to "CAMSHAFTS" section. Oil hose and oil tank breather hose Refer to "OIL PUMP" section. Ignition coil Disconnect the AC magneto lead. Negative battery lead Disconnect at the engine side.
  • Page 211 ENGINE REMOVAL Order Part name Q'ty Remarks Lower engine bracket Engine mounting bolt Pivot shaft Refer to removal section. Engine Refer to removal section. 5-78...
  • Page 212 ENGINE REMOVAL HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE DRIVE SPROCKET 1. Remove: • Nut (drive sprocket) "1" • Lock washer "2" 2. Remove: • Straighten the lock washer tab. •...
  • Page 213 ENGINE REMOVAL • Engine mounting bolt (upper) "10" Engine mounting bolt (upper): 55 Nm (5.5 m•kg, 40 ft•lb) • Lower engine guard "11" • Bolt (lower engine guard) "12" Bolt (lower engine guard): 7 Nm (0.7 m•kg, 5.1 ft•lb) • Apply the molybdenum disulfide grease on INSTALLING THE DRIVE SPROCKET the pivot shaft.
  • Page 214 ENGINE REMOVAL • Bolt (drive chain sprocket cover) "3" Bolt (drive chain sprocket cover): 7 Nm (0.7 m•kg, 5.1 ft•lb) INSTALLING THE NEUTRAL SWITCH 1. Install: • Spring "1" • Pin "2" • O-ring "3" • Neutral switch "4" • Screw (neutral switch) "5" Screw (neutral switch): 4 Nm (0.4 m•kg, 2.9 ft•lb) Apply the lithium soap base grease on the O-...

  • Page 215: Crankcase And Crankshaft

    CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT REMOVING THE CRANKSHAFT Order Part name Q'ty Remarks Refer to "ENGINE REMOVAL" sec- Engine tion. Refer to "CYLINDER AND PISTON" Piston section. Refer to "KICK SHAFT AND SHIFT Kick shaft assembly SHAFT" section. Refer to "KICK SHAFT AND SHIFT Segment SHAFT"...
  • Page 216 CRANKCASE AND CRANKSHAFT Order Part name Q'ty Remarks Bolt [L = 55 mm (2.17 in)] Refer to removal section. Bolt [L = 70 mm (2.76 in)] Refer to removal section. Hose guide Refer to removal section. Clutch cable holder Refer to removal section. Right crankcase Refer to removal section.
  • Page 217 CRANKCASE AND CRANKSHAFT REMOVING THE CRANKCASE BEARING Order Part name Q'ty Remarks Refer to "TRANSMISSION, SHIFT Transmission CAM AND SHIFT FORK" section. Refer to "TRANSMISSION, SHIFT Shift cam and shift fork CAM AND SHIFT FORK" section. Oil seal Bearing Refer to removal section. 5-84...
  • Page 218 CRANKCASE AND CRANKSHAFT DISASSEMBLING THE CRANKCASE 1. Separate: • Right crankcase • Left crankcase Separation steps: a. Remove the crankcase bolts "1", hose guide "2" and clutch cable holder "3". c. Remove the dowel pins and O-ring. REMOVING THE CRANKSHAFT 1.
  • Page 219 CRANKCASE AND CRANKSHAFT CHECKING THE TIMING CHAIN AND CHECKING THE CRANKSHAFT TIMING CHAIN GUIDE 1. Measure: 1. Inspect: • Runout limit "a" • Timing chain • Small end free play limit "b" Cracks/stiff → Replace the timing chain and • Connecting rod big end side clearance "c" camshaft sprocket as a set.
  • Page 220 CRANKCASE AND CRANKSHAFT CHECKING THE OIL STRAINER 1. Inspect: • Install the bearing by pressing its outer race • Oil strainer parallel. Damage → Replace. • To prevent the screw [bearing stopper (crank- shaft)] from becoming loose, crush the screw head periphery "a"...
  • Page 221 CRANKCASE AND CRANKSHAFT 4. Apply: • Sealant On the right crankcase "1". YAMAHA Bond No.1215 (Three- ® Bond No.1215): 90890-85505 Clean the contacting surface of left and right crankcase before applying the sealant. A. For USA and CDN 5. Install: B.
  • Page 222 CRANKCASE AND CRANKSHAFT 9. Remove: • Sealant Tighten the crankcase tightening bolts in stage, Forced out on the cylinder mating surface. using a crisscross pattern. 10.Apply: • Engine oil To the crank pin, bearing and oil delivery hole. 11.Check: • Crankshaft and transmission operation. Unsmooth operation →...

  • Page 223: Transmission, Shift Cam And Shift Fork

    TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION, SHIFT CAM AND SHIFT FORK Order Part name Q'ty Remarks Refer to "ENGINE REMOVAL" sec- Engine tion. Refer to "CRANKCASE AND Separate the crankcase. CRANKSHAFT" section. Main axle Refer to removal section.
  • Page 224 TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION 2. Inspect: 1. Remove: • O-ring "1" • Main axle "1" Damage → Replace. • Drive axle "2" • Shift cam • Shift fork 3 • Shift fork 2 • Shift fork 1 •...
  • Page 225 TRANSMISSION, SHIFT CAM AND SHIFT FORK 2. Inspect: • Shift cam "1" • Segment "2" Wear/damage → Replace. 3. Check: • Shift fork movement Unsmooth operation → Replace shift fork. 2. Install: • 2nd wheel gear (28T) "1" • 4th wheel gear (23T) "2" •...
  • Page 226 TRANSMISSION, SHIFT CAM AND SHIFT FORK 4. Install: • Collar "1" • Apply the lithium soap base grease on the oil seal lip. • When installing the collar into the crankcase, pay careful attention to the crankcase oil seal lip. 5.
  • Page 227 TRANSMISSION, SHIFT CAM AND SHIFT FORK 6. Install: • Transmission assembly "1" To left crankcase "2". Apply the engine oil on the bearings and guide bars. 7. Check: • Shifter operation • Transmission operation Unsmooth operation → Repair. 5-94...

  • Page 228: Chassis

    This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.
  • Page 229 FRONT WHEEL AND REAR WHEEL 21 Nm (2.1 m kg, 15 ft lb) 21 Nm (2.1 m kg, 15 ft lb) 90 Nm (9.0 m kg, 65 ft lb) 12 Nm (1.2 m kg, 8.7 ft lb) Order Part name Q'ty Remarks Oil seal...
  • Page 230 FRONT WHEEL AND REAR WHEEL REMOVING THE REAR WHEEL 14 Nm (1.4 m kg, 10 ft lb) 125 Nm (12.5 m kg, 90 ft lb) 19 Nm (1.9 m kg, 13 ft lb) 50 Nm (5.0 m kg, 36 ft lb) 19 Nm (1.9 m kg, 13 ft lb) Order Part name...
  • Page 231 FRONT WHEEL AND REAR WHEEL HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE REAR WHEEL 1. Remove: • Wheel "1" Push the wheel forward and remove the drive 2. Inspect: chain "2". •...
  • Page 232 FRONT WHEEL AND REAR WHEEL CHECKING THE BRAKE DISC • Use a socket that matches the outside diam- 1. Measure: eter of the race of the bearing. • Brake disc deflection (only rear brake disc) • Left side of bearing shall be installed first. Use the dial gauge "1".
  • Page 233 FRONT WHEEL AND REAR WHEEL 3. Install: • Collar "1" Apply the lithium soap base grease on the oil seal lip. 6. Install: • Wheel axle "1" Apply the lithium soap base grease on the wheel axle. 4. Install: • Speed sensor "1" •...
  • Page 234 FRONT WHEEL AND REAR WHEEL INSTALLING THE REAR WHEEL 2. Install: 1. Install: • Brake disc "1" • Bearing (right) "1" • Bolt (brake disc) "2" • Circlip "2" • Spacer "3" Bolt (brake disc): • Bearing (left) "4" 14 Nm (1.4 m•kg, 10 ft•lb) •...
  • Page 235 FRONT WHEEL AND REAR WHEEL 4. Install: 7. Install: • Collar "1" • Left drive chain puller "1" • Wheel axle "2" Apply the lithium soap base grease on the oil seal lip. • Install the left drive chain puller, and insert the wheel axle from left side.
  • Page 236 FRONT WHEEL AND REAR WHEEL 9. Adjust: • Drive chain slack "a" Drive chain slack: 48–58 mm (1.9–2.3 in) Refer to "ADJUSTING THE DRIVE CHAIN SLACK" section in the CHAPTER 3. 10.Tighten: • Nut (wheel axle) "1" Nut (wheel axle): 125 Nm (12.5 m•kg, 90 ft•lb) •...

  • Page 237: Front Brake And Rear Brake

    FRONT BRAKE AND REAR BRAKE FRONT BRAKE AND REAR BRAKE REMOVING THE FRONT BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the engine. Drain the brake fluid. Refer to removal section. Brake hose holder (protector) Brake hose holder (brake caliper) Union bolt...
  • Page 238 FRONT BRAKE AND REAR BRAKE REMOVING THE REAR BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the engine. Refer to "FRONT WHEEL AND Rear wheel REAR WHEEL" section. Drain the brake fluid.
  • Page 239 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE CALIPER Order Part name Q'ty Remarks A. Front B. Rear Pad pin Brake pad Pad support Brake caliper piston 1 Refer to removal section. Brake caliper piston dust seal 1 Refer to removal section. Brake caliper piston seal 1 Refer to removal section.
  • Page 240 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE MASTER CYLINDER Order Part name Q'ty Remarks A. Front B. Rear Brake master cylinder cap Diaphragm Reservoir float Brake master cylinder boot Circlip Use a long nose circlip pliers. Washer Push rod Brake master cylinder kit 6-13...
  • Page 241 FRONT BRAKE AND REAR BRAKE HANDLING NOTE 3. Loosen the bleed screw and drain the brake fluid while pulling the lever in or pushing down on the pedal. Support the machine securely so there is no danger of it falling over. •...
  • Page 242 FRONT BRAKE AND REAR BRAKE REMOVING THE BRAKE CALIPER PISTON SEAL KIT 1. Remove: • Brake caliper piston dust seal "1" • Brake caliper piston seal "2" Remove the brake caliper piston seals and brake caliper piston dust seals by pushing them with a finger.
  • Page 243 FRONT BRAKE AND REAR BRAKE CHECKING THE BRAKE HOSE 1. Inspect: • Brake hose "1" Crack/damage → Replace. A. Front B. Rear CHECKING THE BRAKE CALIPER 1. Inspect: HANDLING NOTE • Brake caliper cylinder inner surface "a" Wear/score marks → Replace brake caliper assembly.
  • Page 244 FRONT BRAKE AND REAR BRAKE A. Front B. Rear INSTALLING THE FRONT BRAKE CALIPER 1. Install: • Pad support "1" • Brake pad "2" • Pad pin "3" • Install the brake pads with their projections "a" into the brake caliper recesses "b". •...
  • Page 245 FRONT BRAKE AND REAR BRAKE INSTALLING THE REAR BRAKE CALIPER 1. Install: • Pad support "1" • Brake pad "2" • Pad pin "3" • Install the brake pads with their projections "a" into the brake caliper recesses "b". • Temporarily tighten the pad pin at this point. INSTALLING THE BRAKE MASTER CYLINDER KIT 1.
  • Page 246 FRONT BRAKE AND REAR BRAKE 3. Install: A. Front • Spring "1" B. Rear To brake master cylinder piston "2". INSTALLING THE FRONT BRAKE MASTER CYLINDER Install the spring at the smaller dia. side. 1. Install: • Brake master cylinder "1" •...
  • Page 247 FRONT BRAKE AND REAR BRAKE INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • Copper washer "1" • Brake hose "2" • Union bolt "3" Union bolt: 30 Nm (3.0 m•kg, 22 ft•lb) 3. Install: Always use new copper washers. •...
  • Page 248 FRONT BRAKE AND REAR BRAKE INSTALLING THE FRONT BRAKE HOSE 3. Install: 1. Install: • Brake hose holder "1" • Copper washer "1" • Nut (brake hose holder) "2" • Brake hose "2" Nut (brake hose holder): • Union bolt "3" 7 Nm (0.7 m•kg, 5.1 ft •lb) Union bolt: 30 Nm (3.0 m•kg, 22 ft•lb)
  • Page 249 FRONT BRAKE AND REAR BRAKE 2. Install: • Brake hose holder "1" Install the brake hose so that it contacts the • Screw (brake hose holder) "2" brake master cylinder projection "a" and Screw (brake hose holder): that its bent portion "b" faces downward. 3 Nm (0.3 m•kg, 2.2 ft•lb) After installing the brake hose holders, make sure the brake hose does not contact...
  • Page 250 FRONT BRAKE AND REAR BRAKE • Be careful that water does not enter the master cylinder when refilling. Water will After installation, while pulling the brake le- significantly lower the boiling point of the ver in or pushing down on the brake pedal, fluid and may result in vapor lock.

  • Page 251: Front Fork

    FRONT FORK FRONT FORK REMOVING THE FRONT FORK Order Part name Q'ty Remarks A. For CDN Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the engine. Refer to "FRONT WHEEL AND Front wheel REAR WHEEL" section. Refer to "FRONT BRAKE AND Front brake caliper REAR BRAKE"...
  • Page 252 FRONT FORK DISASSEMBLING THE FRONT FORK Order Part name Q'ty Remarks Front fork cap bolt Refer to removal section. Fork spring Drain the fork oil. Dust seal Refer to removal section. Stopper ring Refer to removal section. Inner tube Refer to removal section. Outer tube Piston metal Slide metal...
  • Page 253 FRONT FORK HANDLING NOTE Support the machine securely so there is no danger of it falling over. The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers. REMOVING THE INNER TUBE 1.
  • Page 254 FRONT FORK REMOVING THE DAMPER ROD CHECKING THE BASE VALVE 1. Remove: 1. Inspect: • Base valve "1" • Valve assembly "1" • Damper rod "2" Wear/damage → Replace. • O-ring "2" Damage → Replace. Use a damper rod holder "3" to lock the damper rod.
  • Page 255 FRONT FORK ASSEMBLING THE FRONT FORK 1. Wash the all parts in a clean solvent. Do not attempt to straighten a bent inner 2. Install: tube as this may dangerously weaken the • Damper rod "1" tube. To inner tube "2". To install the damper rod into the inner tube, hold the inner tube aslant.
  • Page 256 FRONT FORK 5. Install: • Spring guide "1" • Locknut "2" To damper rod "3". • Install the spring guide with its smaller dia.end "a" facing downward. • With its thread "b" facing upward, fully finger tighten the locknut onto the damper rod. 7.
  • Page 257 FRONT FORK 9. Install: 11.Install: • Slide metal "1" • Stopper ring "1" • Oil seal washer "2" To outer tube slot. Fit the stopper ring correctly in the groove in the outer tube. Press the slide metal into the outer tube with fork seal driver "3".
  • Page 258 FRONT FORK 19.Wait ten minutes until the air bubbles have been removed from the front fork, and the oil • Be sure to use recommended fork oil. If has dispense evenly in system before set- other oils are used, they may have an ex- ting recommended oil level.
  • Page 259 FRONT FORK 21.Measure: • Distance "a" Out of specification → Turn into the locknut. Distance "a": 18 mm (0.71 in) or more Between damper rod "1" top and locknut "2" top. 24.Install: • Spring seat "1" • Front fork cap bolt "2" Fully finger tighten the front fork cap bolt onto the damper rod.
  • Page 260 FRONT FORK 3. Adjust: • Front fork top end "a" Front fork top end (standard) "a": 5 mm (0.20 in) 27.Install: • Protector guide "1" Install the protector guide with its wider side "a" facing downward. 4. Tighten: • Pinch bolt (upper bracket) "1" Pinch bolt (upper bracket): 21 Nm (2.1 m•kg, 15 ft•lb) •...
  • Page 261 FRONT FORK 6. Install: • Speed sensor lead "1" • Plate 2 "2" • Screw (plate 2) "3" Screw (plate 2): 0.5 Nm (0.05 m•kg, 0.36 ft•lb) To right protector "4". Install the plate 2 in the direction as shown. 7.

  • Page 262: Handlebar

    HANDLEBAR HANDLEBAR REMOVING THE HANDLEBAR Order Part name Q'ty Remarks Headlight Hot starter cable Disconnect at the lever side. Hot starter lever holder Clutch cable Disconnect at the lever side. Clutch lever holder Disconnect the clutch switch lead. Disconnect the engine stop switch Engine stop switch lead.
  • Page 263 HANDLEBAR Order Part name Q'ty Remarks Left grip Refer to removal section. Handlebar upper holder Handlebar Handlebar lower holder 6-36...
  • Page 264 HANDLEBAR REMOVING THE BRAKE MASTER CYLINDER 1. Remove: • Brake master cylinder bracket "1" • Brake master cylinder "2" • Do not let the brake master cylinder hang on the brake hose. • Keep the brake master cylinder cap side horizontal to prevent air from coming in.
  • Page 265 HANDLEBAR 2. Install: • Handlebar "1" • Handlebar upper holder "2" • Bolt (handlebar upper holder) "3" Bolt (handlebar upper holder): 28 Nm (2.8 m•kg, 20 ft•lb) • The handlebar upper holder should be in- stalled with the punched mark "a" forward. •...
  • Page 266 HANDLEBAR 5. Install: 7. Install: • Right grip "1" • Throttle cables "1" • Collar "2" To tube guide "2". Apply the adhesive on the tube guide "3". Apply the lithium soap base grease on the • Before applying the adhesive, wipe off grease throttle cable end and tube guide cable winding or oil on the tube guide surface "a"...
  • Page 267 HANDLEBAR 9. Install: 11.Install: • Grip cap cover "1" • Engine stop switch "1" • Cover (throttle cable cap) "2" • Clutch lever holder "2" • Bolt (clutch lever holder) "3" Bolt (clutch lever holder): 4 Nm (0.4 m•kg, 2.9 ft•lb) •...
  • Page 268 HANDLEBAR 12.Install: • Clutch cable "1" • Hot starter cable "2" Apply the lithium soap base grease on the clutch cable end and hot starter cable end. 13.Adjust: • Clutch lever free play Refer to "ADJUSTING THE CLUTCH CA- BLE FREE PLAY" section in the CHAPTER •...

  • Page 269: Steering

    STEERING STEERING REMOVING THE STEERING Order Part name Q'ty Remarks A. For CDN TIGHTENING STEPS: • Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb) • Loosen it one turn. • Retighten it. 7 Nm (0.7 m•kg, 5.1 ft•lb) Hold the machine by placing the suit- Refer to "HANDLING NOTE".
  • Page 270 STEERING Order Part name Q'ty Remarks Steering stem nut Front fork Refer to "FRONT FORK" section. Upper bracket Steering ring nut Refer to removal section. Lower bracket Bearing race cover Upper bearing Lower bearing Refer to removal section. Bearing race Refer to removal section.
  • Page 271 STEERING HANDLING NOTE REMOVING THE BEARING RACE 1. Remove: • Bearing race "1" Support the machine securely so there is no Remove the bearing race using long rod "2" danger of it falling over. and the hammer. REMOVING THE STEERING RING NUT 1.
  • Page 272 STEERING INSTALLING THE LOWER BRACKET 4. Install: 1. Install: • Steering ring nut "1" • Lower bearing "1" Steering ring nut: 7 Nm (0.7 m•kg, 5.1 ft•lb) Apply the lithium soap base grease on the dust Tighten the steering ring nut using the steer- seal lip and bearing inner circumference.
  • Page 273 STEERING 7. Install: • Front fork "1" • Upper bracket "2" • Main switch "3" • Front brake hose guide bracket "4" • Front reflector (For CDN) "5" • Nut (front reflector) (For CDN) "6" Nut (front reflector) (For CDN): 4 Nm (0.4 m•kg, 2.9 ft•lb) •...
  • Page 274 STEERING 13.Install: • Multi-function display bracket "1" Multi-function display bracket: 7 Nm (0.7 m•kg, 5.1 ft•lb) • Multi-function display "2" Multi-function display: 4 Nm (0.4 m•kg, 2.9 ft•lb) Pass the throttle cables "3", clutch cable "4" and hot starter cable "5" between the multi- function display bracket and upper bracket.

  • Page 275: Swingarm

    SWINGARM SWINGARM REMOVING THE SWINGARM Order Part name Q'ty Remarks Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the engine. Refer to "FRONT BRAKE AND Brake hose holder REAR BRAKE" section. Refer to "FRONT BRAKE AND Rear brake caliper REAR BRAKE"...
  • Page 276 SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q'ty Remarks Refer to removal section. Relay arm Connecting rod Collar Oil seal Thrust bearing Bushing Oil seal Bearing Refer to removal section. 6-49...
  • Page 277 SWINGARM HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE CAP 1. Remove: • Left cap "1" Remove with a slotted-head screwdriver insert- CHECKING THE RELAY ARM ed under the mark "a" on the left cap. 1.
  • Page 278 SWINGARM INSTALLING THE BEARING AND OIL SEAL 1. Install: • Bearing "1" • Oil seal "2" To swingarm. • Apply the molybdenum disulfide grease on the bearing when installing. • Install the bearing by pressing it on the side having the manufacture's marks or numbers. •...
  • Page 279 SWINGARM 4. Install: • Connecting rod "1" Apply the molybdenum disulfide grease on the • Bolt (connecting rod) "2" bushings, thrust bearings, oil seal lips and con- • Washer "3" tact surfaces of the collar and thrust bearing. • Nut (connecting rod) "4" Nut (connecting rod): 80 Nm (8.0 m•kg, 58 ft•lb) To relay arm "5".
  • Page 280 SWINGARM Apply the molybdenum disulfide grease on the bolt. 7. Check: • Swingarm side play "a" Free play exists → Replace thrust bearing. • Swingarm up and down movement "b" 10.Tighten: Unsmooth movement/binding/rough spots • Nut (connecting rod) "1" → Grease or replace bearings, bushings Nut (connecting rod): and collars.
  • Page 281 SWINGARM 13.Install: • Bolt (lower chain tensioner) "1" • Washer "2" • Collar "3" • Lower chain tensioner "4" • Nut (lower chain tensioner) "5" Nut (lower chain tensioner): 16 Nm (1.6 m•kg, 11 ft•lb) 14.Install: • Drive chain support "1" •...

  • Page 282: Rear Shock Absorber

    REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER Order Part name Q'ty Remarks Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the engine. Refer to "REMOVING THE SEAT, Seat and side cover FUEL TANK AND SIDE COVERS"...
  • Page 283 REAR SHOCK ABSORBER Order Part name Q'ty Remarks Refer to "CHECKING AND CHARG- Battery ING THE BATTERY" section in the CHAPTER 3. Disconnect the starter relay coupler. Starter motor lead Disconnect at the starter relay side. Locking tie Taillight coupler CDI unit coupler Plastic band Clamp (air filter joint)
  • Page 284 REAR SHOCK ABSORBER Order Part name Q'ty Remarks Upper spring guide Spring (rear shock absorber) Bearing Refer to removal section. 6-57...
  • Page 285 Remove the bearing by pressing its outer race. • When scrapping the rear shock absorb- er, follow the instructions on disposal. NOTES ON DISPOSAL (YAMAHA DEALERS ONLY) Before disposing the rear shock absorber, be sure to extract the nitrogen gas from valve "1".
  • Page 286 REAR SHOCK ABSORBER INSTALLING THE BEARING 1. Install: • Upper bearing "1" Install the bearing parallel until the stopper ring groove appears by pressing its outer race. Do not apply the grease on the bearing out- er race because it will wear the rear shock CHECKING THE REAR SHOCK ABSORBER absorber surface on which the bearing is 1.
  • Page 287 REAR SHOCK ABSORBER INSTALLING THE SPRING (REAR SHOCK INSTALLING THE REAR SHOCK ABSORBER) ABSORBER 1. Install: 1. Install: • Spring "1" • Dust seal "1" • Upper spring guide "2" • O-ring "2" • Lower spring guide "3" • Collar "3" •...
  • Page 288 REAR SHOCK ABSORBER 3. Install: • Rear shock absorber 4. Install: • Bolt (rear shock absorber-frame) "1" • Washer "2" • Nut (rear shock absorber-frame) "3" Nut (rear shock absorber-frame): 56 Nm (5.6 m•kg, 40 ft•lb) Apply the molybdenum disulfide grease on the 7.

  • Page 289: Electrical

    This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.
  • Page 290 ELECTRICAL COMPONENTS AND WIRING DIAGRAM WIRING DIAGRAM 1. Headlight COLOR CODE 2. Multi-function display Black 3. Engine stop switch Brown 4. Clutch switch Chocolate 5. Diode Dark green 6. Starter relay diode Green 7. Throttle position sensor Gray 8. Starter relay Blue 9.

  • Page 291: Ignition System

    IGNITION SYSTEM IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. *1 Check fuse. No good → Replace fuse and check wire harness. OK ↓...
  • Page 292 IGNITION SYSTEM SPARK GAP TEST 1. Disconnect the ignition coil from spark plug. 2. Remove the ignition coil cap. 3. Connect the dynamic spark tester "1" (igni- tion checker "2") as shown. • Ignition coil "3" • Spark plug "4" CHECKING THE ENGINE STOP SWITCH 1.
  • Page 293 IGNITION SYSTEM CHECKING THE MAIN SWITCH 3. Inspect: 1. Inspect: • Rubber part "a" • Main switch conduction Tears/damage → Replace. Tester (+) lead → Red lead "1" Tester (-) lead → Brown lead "2" Result Conductive (while the main switch is moved to "ON") Not conductive while the main switch is moved to "ON"...
  • Page 294 IGNITION SYSTEM CHECKING THE NEUTRAL SWITCH 1. Inspect: • Neutral switch conduction Tester (+) lead → Sky blue lead "1" Tester (-) lead → Ground "2" Result Conductive (while gear is in neu- tral) Not conductive while it is in neutral → Replace. 4.

  • Page 295: Electric Starting System

    ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to "ON", the starter mo- tor can only operate if at least one of the follow- ing conditions is met: • The transmission is in neutral (the neutral switch is closed).
  • Page 296 ELECTRIC STARTING SYSTEM INSPECTION STEPS If the starter motor will not operate, use the following inspection steps. *1 Check fuse. No good → Replace fuse and check wire harness. OK ↓ *2 Check battery. No good → Recharge or replace. OK ↓...
  • Page 297 ELECTRIC STARTING SYSTEM CHECKING THE COUPLERS AND LEADS CONNECTION Set the tester selection position to "Ω × 1". 1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. CHECKING THE STARTER MOTOR OPERATION 1. Connect the positive battery terminal "1" and starter motor lead "2"...
  • Page 298 ELECTRIC STARTING SYSTEM CHECKING THE CLUTCH SWITCH 1. Inspect: • Clutch switch conduction Tester (+) lead → Black lead "1" Tester (-) lead → Black lead "2" Result Conductive (while the clutch lever is pulled) Not conductive while it is pulled → Replace. CHECKING THE START SWITCH Conductive while it is freed →...
  • Page 299 ELECTRIC STARTING SYSTEM REMOVING THE STARTER MOTOR Order Part name Q'ty Remarks Refer to "EXHAUST PIPE AND SI- Exhaust pipe LENCER" section in the CHAPTER Starter motor 7-11...
  • Page 300 ELECTRIC STARTING SYSTEM DISASSEMBLING THE STARTER MOTOR Order Part name Q'ty Remarks Starter motor front cover Washer (starter motor front cover) Gasket Starter motor yoke Armature assembly Starter motor rear cover Brush Brush spring 7-12...
  • Page 301 ELECTRIC STARTING SYSTEM CHECKING AND REPAIRING THE STARTER MOTOR a. Measure the armature assembly resistanc- 1. Check: es with the pocket tester. • Commutator Pocket tester: Dirt → Clean with 600 grit sandpaper. YU-3112-C/90890-03112 2. Measure: • Commutator diameter "a" Armature assembly: Out of specification →...
  • Page 302 ELECTRIC STARTING SYSTEM ASSEMBLING THE STARTER MOTOR 4. Install: 1. Install: • Gasket "1" • Brush spring "1" • Circlip • Brush "2" • Plain washer "2" • Washer (starter motor front cover) "3" • Starter motor front cover "4" •...

  • Page 303: Charging System

    CHARGING SYSTEM CHARGING SYSTEM INSPECTION STEPS If the battery is not charged, use the following inspection steps. *1 Check fuse. No good → Replace fuse and check wire harness. OK ↓ *2 Check battery. No good → Recharge or replace. OK ↓...
  • Page 304 CHARGING SYSTEM CHECKING THE COUPLERS AND LEADS CONNECTION 1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. CHECKING THE CHARGING VOLTAGE 1. Start the engine. 2. Inspect: • Charging voltage Out of specification → If no failure is found in checking the source coil resistance, replace the rectifier/regulator.

  • Page 305: Throttle Position Sensor System

    THROTTLE POSITION SENSOR SYSTEM THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position sensor will not operate, use the following inspection steps. Check entire ignition system for connec- No good → Repair or replace. tion. OK ↓ Check throttle position sensor. (Throttle No good →...
  • Page 306 THROTTLE POSITION SENSOR SYSTEM HANDLING NOTE 2. Loosen: • Throttle stop screw "1" Do not loosen the screw (throttle position Turn out the throttle stop screw until the throttle sensor) "1" except when changing the shaft is in the full close position. throttle position sensor due to failure be- cause it will cause a drop in engine perfor- mance.
  • Page 307 THROTTLE POSITION SENSOR SYSTEM CHANGING AND ADJUSTING THE Tester (+) lead → Yellow lead "3" THROTTLE POSITION SENSOR Tester (-) lead → Black lead "4" 1. Remove: • Throttle position sensor coupler • Carburetor • Do not insert the electric conductors more 2.
  • Page 308 THROTTLE POSITION SENSOR SYSTEM 10.Put the aligning marks "a" on the throttle po- sition sensor and carburetor. 11.Stop the engine. 12.Remove the carburetor. 13.Tighten: • Screw (throttle position sensor) "1" Tighten the screw (throttle position sensor) us- ing the T25 bit. 14.Install the carburetor.

  • Page 309: Lighting System

    LIGHTING SYSTEM LIGHTING SYSTEM INSPECTION STEPS Refer to the following flow chart when inspecting the lighting system for possible problems. Check the bulb and bulb socket. No good → Replace the bulb and/or bulb socket. OK ↓ Check the taillight (LEDs). No good →...
  • Page 310 LIGHTING SYSTEM CHECKING THE TAILLIGHT (LEDs) CHECKING THE RECTIFIER/REGUALATOR 1. Disconnect the taillight coupler. 1. Connect the battery leads. 2. Connect two jumper leads "1" from the bat- 2. Start the engine. tery terminals to the respective coupler ter- 3. Turn on the headlight and taillight by turning minal as shown.

  • Page 311: Signaling System

    SIGNALING SYSTEM SIGNALING SYSTEM INSPECTION STEPS If the speedometer will not operate, use the following inspection steps. *1 Check battery. No good → Recharge or replace. OK ↓ Check each coupler and wire connec- No good → Repair or replace. tion.
  • Page 312 SIGNALING SYSTEM CHECKING THE COUPLERS AND LEADS Multi-function Tester selector CONNECTION display output position 1. Check: voltage • Couplers and leads connection 4.5 V or more DCV-20 Rust/dust/looseness/short-circuit → Repair or replace. CHECKING THE MULTI-FUNCTION Make sure that a short-circuit does not de- DISPLAY INPUT VOLTAGE velop between the terminals because it may 1.
  • Page 313 SIGNALING SYSTEM 2. Set the main switch to "ON". 3. Measure: • Speed sensor output voltage Output voltage not correct → Replace the speed sensor. Measurement steps: a. Elevate the front wheel and slowly rotate it. b. Measure the voltage (DCV) of white lead and black lead.
  • Page 316 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2010.05-0.3×1 CR 2500 SHINGAI IWATA SHIZUOKA JAPAN...

This manual is also suitable for:

Wr450fa

Table of Contents