Yamaha WR450F Owner's Service Manual
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Yamaha WR450F Owner's Service Manual

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Table of Contents

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Download this manual See also: Owner's Manual
2016
q Read this manual carefully before operating this vehicle.
q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule.
OWNER'S SERVICE MANUAL
MANUEL D'ATELIER DU
PROPRIETAIRE
WR450F
WR450FG
2GC-28199-70

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Summary of Contents for Yamaha WR450F

  • Page 1 2016 q Read this manual carefully before operating this vehicle. q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE WR450F WR450FG 2GC-28199-70...
  • Page 2 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit être remis avec le véhicule en cas de vente de ce dernier.
  • Page 3 2015 2016 Read this manual carefully before operating this vehicle. Read this manual carefully before operating this vehicle. OWNER’S SERVICE MANUAL OWNER’S SERVICE MANUAL WR450F WR450FG 2GC-28199-70-E0...
  • Page 5 EAS2GC1002 WR450F WR450FG OWNER’S SERVICE MANUAL ©2015 by Yamaha Motor Co., Ltd. First edition, August 2015 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.

  • Page 6: Important Manual Information

    INTRODUCTION EAS2GC1003 Congratulations on your purchase of a Yamaha WR series. This model is the culmination of Yama- ha'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 7: Safety Information

    SAFETY INFORMATION EAS2GC1005 THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding. •...

  • Page 8: How To Use This Manual

    HOW TO USE THIS MANUAL EAS2GC1006 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 9 SYMBOLS EAS2GC1007 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 11: Table Of Contents

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

  • Page 13: General Information

    GENERAL INFORMATION LOCATION OF IMPORTANT LABELS............1-1 DESCRIPTION....................1-4 IDENTIFICATION .....................1-5 VEHICLE IDENTIFICATION NUMBER ............1-5 ENGINE SERIAL NUMBER ...............1-5 VEHICLE EMISSION CONTROL INFORMATION LABEL......1-5 INCLUDED PARTS ..................1-6 SPARK PLUG WRENCH ................1-6 NIPPLE WRENCH..................1-6 HANDLEBAR PROTECTOR ..............1-6 FUEL HOSE JOINT COVER ..............1-6 COUPLER FOR CONNECTING OPTIONAL PART........1-6 IMPORTANT INFORMATION ................1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-7 REPLACEMENT PARTS................1-7...
  • Page 14 MULTI-FUNCTION DISPLAY.................1-21 DESCRIPTION ..................1-21 BASIC MODE ...................1-21 CHANGEOVER TO BASIC MODE/RACE MODE........1-22 RACE MODE....................1-23 FUNCTION DIAGRAM ................1-26 STARTING AND BREAK-IN ................1-28 FUEL ......................1-28 HANDLING NOTE ..................1-28 AIR FILTER MAINTENANCE ..............1-28 STARTING A COLD ENGINE ..............1-28 STARTING A WARM ENGINE..............1-30 BREAK-IN PROCEDURES ..............1-30 MAINTENANCE AFTER BREAK-IN ..............1-31 MAJOR MAINTENANCE................1-31 TORQUE-CHECK POINTS ................1-32...

  • Page 15: Location Of Important Labels

    LOCATION OF IMPORTANT LABELS LOCATION OF IMPORTANT LABELS EAS2GC1008 Please read the following important labels carefully before operating this vehicle. 1,2,3 4,5,6 9,10,11...
  • Page 16 LOCATION OF IMPORTANT LABELS...
  • Page 17 LOCATION OF IMPORTANT LABELS AUS, NZL, ZAF...

  • Page 18: Description

    DESCRIPTION DESCRIPTION EAS2GC1009 12 13 20 19 18 1. Clutch lever 12. Headlight 2. Multi-function display 13. Radiator 3. Front brake lever 14. Coolant drain bolt 4. Throttle grip 15. Rear brake pedal 5. Start switch 16. Air filter 6. Radiator cap 17.

  • 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 INCLUDED PARTS FUEL HOSE JOINT COVER EAS2GC1014 EAS2GC1018 The fuel hose joint covers “1” are used to pre- EAS2GC1015 SPARK PLUG WRENCH vent mud, dust, and other foreign materials The spark plug wrench “1” is used to remove or from entering the inside when the fuel hose is install the spark plug.

  • Page 21: Important Information

    2. Use proper special tools and equipment. used for repair of the vehicle, including periodic See “SPECIAL TOOLS”. replacement parts, are new YAMAHA genuine parts and recommended parts. Do not use any used parts, because these may not be genuine though they have similar ap- pearances or because the quality may be changed by aging.

  • Page 22: Gaskets, Oil Seals And O-Rings

    IMPORTANT INFORMATION GASKETS, OIL SEALS AND O-RINGS EAS2GC1022 1. When overhauling the engine, replace all gaskets and O-rings. All gasket surfaces, oil seal lips, and O-rings must be cleaned so that there may be no dust on them. 2. During assembly, always apply proper oil to bearings and proper grease to oil seal lips before installation.

  • Page 23: Basic Service Information

    BASIC SERVICE INFORMATION BASIC SERVICE INFORMATION EAS2GC1026 EAS2GC1027 ELECTRICAL SYSTEM Electrical parts handling NOTICE Never disconnect a battery lead while the engine is running; otherwise, the electrical components could be damaged. NOTICE Be sure to connect the battery leads to the correct battery terminals.
  • Page 24 BASIC SERVICE INFORMATION NOTICE Checking the electrical system Handle electrical components with special care, and do not subject them to strong Before checking the electrical system, make shocks. sure that the battery voltage is at least 12 V. NOTICE NOTICE Electrical components are very sensitive to Never insert the tester probes into the cou- and can be damaged by static electricity.
  • Page 25 BASIC SERVICE INFORMATION 2. Check: • Lead • Coupler • Connector Moisture  Dry with compressed air. Rust/stains  Connect and disconnect sev- eral times. Checking the connections Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: •...
  • Page 26 BASIC SERVICE INFORMATION 4. Connect: • Lead • Coupler • Connector • When connecting a coupler or connector, make sure that both terminals are connected securely. • Make sure all connections are tight. 5. Check: • No continuity Pocket tester 90890-03112 Analog pocket tester YU-03112-C...

  • Page 27: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS EAS2GC1028 The following special tools are required for accurate and complete adjustment and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and tool number used for the special tool differ by country, so two types are provided.
  • Page 28 SPECIAL TOOLS Tool name/Part number How to use Illustration Radiator cap tester This tool is used to check the 90890-01325 radiator and the radiator cap. Mityvac cooling system tester YU-24460-A Radiator cap tester adapter This tool is used to check the 90890-01352 radiator and the radiator cap.
  • Page 29 Test harness– lean angle sensor (6P) FI diagnostic tool sub–lead This tool is used to connect 90890-03212 the Yamaha diagnostic tool FI diagnostic tool sub–lead to a battery. YU-03212 Test harness– speed sensor This tool is used to check the 5TJ (3P) speed sensor output voltage.
  • Page 30 SPECIAL TOOLS Tool name/Part number How to use Illustration Valve guide remover & in- This tool is used to replace staller set (ø5.5) the valve guide. 90890-04016 Valve guide remover (5.5 YM-01122 Valve guide installer (5.5 YM-04015 Valve guide reamer (5.5 mm) 90890-01196 Valve spring compressor This tool is used to discon-...
  • Page 31 Oppama pet–4000 spark nition coil. checker YM-34487 Digital tachometer This tool is used to measure 90890-06760 the engine speed. Digital tachometer YU-39951-B Yamaha bond No. 1215 This sealant (Bond) is used 90890-85505 for crankcase mating sur- (Three bond No.1215®) face, etc. 1-17...

  • Page 32: Control Functions

    Pull the clutch lever toward the handlebar to ing the engine. If this occurs, have a Yamaha disengage the clutch, and release the lever to dealer check the vehicle.

  • Page 33: Shift Pedal

    CONTROL FUNCTIONS SHIFT PEDAL THROTTLE GRIP EAS2GC1034 EAS2GC1036 The shift pedal “1” has adopted a method of 1 The throttle grip “1” is located on the right han- down & 4 ups (press-down & kick-ups). dlebar. The throttle grip accelerates or deceler- Press it down for N (neutral) to 1st, and kick it ates the engine.

  • Page 34: Sidestand

    CONTROL FUNCTIONS SIDESTAND FUEL TANK CAP EAS2GC1039 EAS2GC1041 This sidestand “1” is used to support only the Fuel tank cap “1” is located under the fuel tank machine when standing or transporting it. cap cover “2”. Remove the fuel tank cap cover to open the fuel WARNING tank cap.

  • Page 35: Multi-Function Display

    MULTI-FUNCTION DISPLAY MULTI-FUNCTION DISPLAY BASIC MODE EAS2GC1042 EAS2GC1044 Changing speedometer display (for U.K.) WARNING Be sure to stop the machine before making 1. Push the “SLCT2” button for 2 seconds or any setting changes to the multi-function more to change the speedometer units. The display.

  • Page 36: Changeover To Basic Mode/Race Mode

    MULTI-FUNCTION DISPLAY 4. To end the setting, push the “RST” button for CHANGEOVER TO BASIC MODE/RACE EAS2GC1045 2 seconds or more. MODE • In a 30-second absence of button operation, • Measurement using the timer function can be the setting will come to an end with the indi- made in RACE MODE.

  • Page 37: Race Mode

    MULTI-FUNCTION DISPLAY Returning to BASIC MODE from RACE Manual start MODE Initial setting at changeover to RACE MODE It is possible to return to BASIC MODE with tim- will remain for manual start. er measurement at a stop. 1. Check that changeover to RACE MODE has 1.
  • Page 38 MULTI-FUNCTION DISPLAY Resetting tripmeter A (TRIP A) 1. Check that the timer is in operation. If the timer is not in operation, start the timer by pushing the “SLCT1” button and “SLCT2” button at the same time. 2. Reset tripmeter A (TRIP A) display by push- ing the “RST”...
  • Page 39 MULTI-FUNCTION DISPLAY Correcting tripmeter A (TRIP A) 1. Change the travel distance display by push- ing the “SLCT1” button (plus) or “SLCT2” button (minus). A long push on the button will fast-forward the change. Change can be made any time while timer measurement is or is not being made.

  • Page 40: Function Diagram

    MULTI-FUNCTION DISPLAY FUNCTION DIAGRAM EAS2GC1047 A short push on the button changes the operation in the arrowed direction. Meter function A short push on the button changes the operation in both arrowed directions. Function that can be performed whether the time is or is not in operation. A long push on the button changes the operation in the arrowed direction.
  • Page 41 MULTI-FUNCTION DISPLAY A. A short push on the button changes the op- eration in the arrowed direction. B. A short push on the button changes the op- eration in both arrowed directions. C. A long push on the button changes the oper- ation in the arrowed direction.

  • Page 42: Starting And Break-In

    Fuel reserve amount ELEMENT” section in the CHAPTER 3, apply 2.0 L (0.5 US gal, 0.4 Imp.gal) the Yamaha foam air filter oil or other quality foam air filter oil to the element. (Excess oil in NOTICE the element may adversely affect engine start- Use only unleaded gasoline.
  • Page 43 STARTING AND BREAK-IN NOTICE If the starter motor will not turn when the start switch is pushed, stop pushing it im- mediately in order to avoid placing extra load on the starter motor, and start the en- gine by using the kickstarter. If the engine fails to start, push the engine stop switch and give the kickstarter 10 to 20 slow kicks at full throttle in order to clear the engine...

  • Page 44: Starting A Warm Engine

    STARTING AND BREAK-IN STARTING A WARM ENGINE EAS2GC1053 NOTICE Follow the same procedure as for starting a After a break-in or after each race, always cold engine with the exception that the starter is check the points shown in “TORQUE- not required when the engine is warm.

  • Page 45: Maintenance After Break-In

    MAINTENANCE AFTER BREAK-IN • Cable MAINTENANCE AFTER BREAK-IN EAS2GC1055 Grease and adjust cables. After a break-in, perform careful maintenance • Drive chain to get ready for the next practice or race. Lubricate the drive chain and adjust its ten- Refer to “PRE-OPERATION INSPECTION sion.

  • Page 46: Torque-Check Points

    TORQUE-CHECK POINTS TORQUE-CHECK POINTS EAS2GC1057 Frame construction Frame to rear frame Frame to engine protector Combined seat and fuel tank Fuel tank to frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Seat Seat to frame Steering Steering stem to handlebar Steering stem to frame...
  • Page 47 TORQUE-CHECK POINTS Fuel system Fuel pump to fuel tank Fuel sender to fuel tank Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake disc cov- Tightening of rear brake caliper...

  • Page 48: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE • Do not use any harsh chemical products MOTORCYCLE CARE AND STOR- EAS2GC1058 on plastic parts. Be sure to avoid using cloths or sponges which have been in con- tact with strong or abrasive cleaning prod- CARE EAS2GC1059 ucts, solvent or thinner, fuel (gasoline),...

  • Page 49: Storage

    MOTORCYCLE CARE AND STORAGE 2. Apply a corrosion protection spray on all metal, including chrome- and nickel-plated, • Consult a Yamaha dealer for advice on what surfaces to prevent corrosion. products to use. • Washing, rainy weather or humid climates After cleaning can cause the headlight lens to fog.
  • Page 50 MOTORCYCLE CARE AND STORAGE e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. WARNING! To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over.

  • Page 51: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS .................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-10 TIGHTENING TORQUES ................2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-12 ENGINE TIGHTENING TORQUES............2-13 CHASSIS TIGHTENING TORQUES............2-17 LUBRICATION POINTS AND LUBRICANT TYPES ........2-21 ENGINE....................2-21 CHASSIS....................2-22 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-25 LUBRICATION DIAGRAMS ..............2-25 CABLE ROUTING DIAGRAM ................2-33...

  • Page 52: General Specifications

    GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS EAS2GC1061 Model Model 2GC1 (USA) 2GC2 (CAN) 2GC3 (EUR) 2GC4, 2GC5 (AUS) (NZL) (ZAF) Dimensions Overall length 2165 mm (85.2 in) Overall width 825 mm (32.5 in) Overall height 1280 mm (50.4 in) Seat height 965 mm (38.0 in) Wheelbase 1465 mm (57.7 in) Ground clearance...

  • Page 53: Engine Specifications

    ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS EAS2GC1062 Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 449 cm Number of cylinders Single cylinder Bore  stroke 97.0  60.8 mm (3.82  2.39 in) Compression ratio 12.5:1 Starting system Electric starter and kickstarter Fuel Recommended fuel Premium unleaded gasoline only...
  • Page 54 ENGINE SPECIFICATIONS Cylinder head Combustion chamber volume 25.98–26.78 cm (1.59–1.63 cu.in) Warpage limit 0.05 mm (0.0020 in) Camshaft Drive system Chain drive (left) Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in) Camshaft journal diameter 21.959–21.972 mm (0.8645–0.8650 in) Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) Camshaft lobe dimensions Lobe height (Intake)
  • Page 55 ENGINE SPECIFICATIONS Valve spring Free length (intake) 40.76 mm (1.60 in) Limit 38.72 mm (1.52 in) Free length (exhaust) 36.94 mm (1.45 in) Limit 35.09 mm (1.38 in) Installed length (intake) 34.78 mm (1.37 in) Installed length (exhaust) 30.83 mm (1.21 in) Spring rate K1 (intake) 31.90 N/mm (3.25 kgf/mm, 182.15 lbf/in) Spring rate K2 (intake)
  • Page 56 0.050 mm (0.0020 in) Shift fork thickness 4.85 mm (0.1909 in) Decompression device Device type Auto decomp Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil...
  • Page 57 ENGINE SPECIFICATIONS Fuel pump Pump type Electrical Fuel injector Model/quantity 1010/1 12  Resistance Throttle body Type/quantity 30RA-A05U/1 ID mark 2GC1 00 Fuel line pressure (at idle) 300.0–390.0 kPa (3.00–3.90 kgf/cm , 43.5– 56.6 psi) Throttle position sensor Resistance 6.30 k Output voltage (at idle) 0.48–0.52 V Fuel injection sensor...

  • Page 58: Chassis Specifications

    CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS EAS2GC1063 Chassis Frame type Semi double cradle Caster angle 26.2 ° Trail 114 mm (4.5 in) Front wheel Wheel type Spoke wheel 1.6  21 Rim size Rim material Aluminum Wheel travel 310 mm (12.2 in) Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit...
  • Page 59 Inner tube outer diameter 48 mm (1.9 in) Inner tube bending limit 0.2 mm (0.01 in) Optional spring available Recommended oil Yamaha Suspension Oil S1 Quantity 545.0 cm (18.43 US oz, 19.18 Imp.oz) Rebound damping adjusting positions Minimum 20 clicks out*...
  • Page 60 CHASSIS SPECIFICATIONS Rear suspension Type Swingarm (link suspension) Spring/shock absorber type Coil spring/Gas-hydraulic damper Rear shock absorber assembly travel 126.0 mm (4.96 in) Spring free length 275.0 mm (10.83 in) Spring installed length 263.0 mm (10.35 in) Spring rate K1 56.00 N/mm (5.71 kgf/mm, 319.76 lbf/in) Spring stroke K1 0.0–150.0 mm (0.00–5.91 in)

  • Page 61: Electrical Specifications

    Advancer type Digital Ignition timing (B.T.D.C.) 10.0 ° at 2000 r/min Engine control unit Model/manufacturer 2GC0/YAMAHA (USA) (CAN) 2GC1/YAMAHA (EUR) (AUS) (NZL) (ZAF) Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64  Primary coil resistance Secondary coil resistance 8.64–12.96 k...
  • Page 62 ELECTRICAL SPECIFICATIONS Starter motor Power output 0.48 kW 0.0117–0.0143  Armature coil resistance Brush overall length 7.0 mm (0.28 in) Limit 3.50 mm (0.14 in) Brush spring force 3.92–5.88 N (400–600 gf, 14.11–21.17 oz) Commutator diameter 17.6 mm (0.69 in) Limit 16.6 mm (0.65 in) Mica undercut (depth)

  • Page 63: Tightening Torques

    TIGHTENING TORQUES TIGHTENING TORQUES EAS20320 EAS2GC1065 GENERAL TIGHTENING TORQUE SPECIFI- CATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial 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 64: Engine Tightening Torques

    TIGHTENING TORQUES ENGINE TIGHTENING TORQUES EAS2GC1066 - 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 Nm (1.0 m·kgf, 7.2 ft·lbf) Cylinder head blind plug 28 Nm (2.8 m·kgf, 20 ft·lbf) Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
  • Page 65 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Throttle body joint clamp bolt 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf) Air filter joint clamp bolt 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Air filter case bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Air filter bolt 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) Air filter guide holder screw...
  • Page 66 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Kickstarter lever boss screw 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Primary drive gear nut 100 Nm (10 m·kgf, 72 ft·lbf) Clutch spring bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Clutch boss nut 75 Nm (7.5 m·kgf, 54 ft·lbf) Use a Drive sprocket nut...
  • Page 67 TIGHTENING TORQUES *2:Exhaust pipe nut First temporarily tighten all nuts to 7 Nm (0.7 m·kgf, 5.1 ft·lbf). Then retighten them to 10 Nm (1.0 m·kgf, 7.2 ft·lbf). 2-16...

  • Page 68: Chassis Tightening Torques

    TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES EAS2GC1067 - marked portion shall be checked for torque tightening after break-in or before each race. Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Outer tube and upper bracket bolt 21 Nm (2.1 m·kgf, 15 ft·lbf) Outer tube and lower bracket bolt 21 Nm (2.1 m·kgf, 15 ft·lbf) Upper bracket and steering stem nut...
  • Page 69 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Front brake disc bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Rear brake disc bolt 14 Nm (1.4 m·kgf, 10 ft·lbf) Footrest bracket bolt 55 Nm (5.5 m·kgf, 40 ft·lbf) Sidestand bolt 25 Nm (2.5 m·kgf, 18 ft·lbf) Rear brake pedal bolt 26 Nm (2.6 m·kgf, 19 ft·lbf)
  • Page 70 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Drive chain tensioner bolt (lower 16 Nm (1.6 m·kgf, 12 ft·lbf) side) Drive chain support bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Drive chain support nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Drive chain guide bolt 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Rear frame and left cover bolt...
  • Page 71 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Starter relay and starter motor lead 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) bolt Lean angle sensor bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) Taillight assembly screw — 1.1 Nm (0.11 m·kgf, 0.80 ft·lbf) Taillight lead clamp and rear fender —...

  • Page 72: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES EAS2GC1068 EAS2GC1069 ENGINE Lubrication point Lubricant types Oil seal lips Bearing O-ring Camshaft cap bolt threads and contacting surface Cylinder head bolt threads, seats, washers Valve stems Valve stem ends Valve lifter outer surface Camshaft lobe and journal Valve lifter top surface...

  • Page 73: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Starter idle gear inner surface, thrust surfaces Starter clutch drive gear inner surface, thrust surfaces Yamaha bond No.1215 Cylinder head cover gasket (Three bond No.1215®) Yamaha bond No.1215 Crankcase mating surface (Three bond No.1215®)
  • Page 74 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Clutch lever sliding surface and bolt outer surface Clutch lever adjuster rubber lip Clutch cable end (clutch lever side) Tube guide (throttle grip) inner surface and throttle cable end Front brake caliper piston Front brake caliper piston seal Front brake caliper dust seal Front brake caliper piston outer surface...
  • Page 75 LUBRICATION POINTS AND LUBRICANT TYPES EAS2GC1071 2-24...

  • Page 76: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION DIAGRAMS EAS2GC1072 2-25...
  • Page 77 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Piston 4. Oil nozzle 5. Oil filter element 6. Oil pump 7. Oil strainer 8. Crankshaft 9. Drive axle 10. Main axle 2-26...
  • Page 78 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
  • Page 79 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Connecting rod 2. Crankshaft 3. Main axle 4. Oil strainer 5. Drive axle 2-28...
  • Page 80 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 81 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Exhaust camshaft 2. Intake camshaft 3. Oil filter element 4. Oil pump 2-30...
  • Page 82 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
  • Page 83 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil pressure check bolt 3. Oil filter element 4. Oil pump 2-32...

  • Page 84: Cable Routing Diagram

    CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM EAS2GC1073 2-33...
  • Page 85 CABLE ROUTING DIAGRAM N. Pass the clutch cable with no downward sag al- 1. Clutch cable lowed. 2. Throttle cable (return) O. Place the grommet of the clutch cable so that it 3. Throttle cable (pull) contacts the radiator hose. Route the clutch cable 4.
  • Page 86 CABLE ROUTING DIAGRAM 2-35...
  • Page 87 CABLE ROUTING DIAGRAM Q. Clamp the starter motor lead, point the clamp 1. Clamp downward, and insert it into the frame. 2. Throttle position sensor lead R. Route the radiator breather hose through be- 3. Joint coupler tween the radiator hose, down tube and engine 4.
  • Page 88 CABLE ROUTING DIAGRAM 2-37...
  • Page 89 CABLE ROUTING DIAGRAM 1. Cable guide 2. Speed sensor lead 3. Joint coupler 4. Ground lead 5. Throttle position sensor lead 6. Throttle position sensor coupler 7. Radiator breather hose 8. Radiator hose 9. Fuel hose 10. Coolant temperature sensor coupler 11.
  • Page 90 CABLE ROUTING DIAGRAM 2-39...
  • Page 91 CABLE ROUTING DIAGRAM 1. Battery negative lead 2. Fuel hose 3. Fuel pump coupler 4. Fuel pump lead 5. Resistor 6. Resistor coupler 7. Battery positive lead 8. Lean angle sensor 9. Starter motor lead 10. Radiator fan motor relay (blue tape) 11.
  • Page 92 CABLE ROUTING DIAGRAM 2-41...
  • Page 93 CABLE ROUTING DIAGRAM 1. Clutch switch lead 2. Engine stop switch lead 3. Clutch cable 4. Brake hose guide 5. Headlight lead 6. Speed sensor lead 7. Indicator light coupler 8. Meter assembly optional switch coupler 9. Meter assembly coupler 10.
  • Page 94 CABLE ROUTING DIAGRAM 2-43...
  • Page 95 CABLE ROUTING DIAGRAM 1. Brake master cylinder 2. Brake hose holder 3. Brake hoses A. While installing the brake hose, direct a bend in its pipe portion as shown, and bring it into contact with the projection on the brake caliper. B.
  • Page 96 CABLE ROUTING DIAGRAM 2-45...

  • Page 97: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 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 GENERAL INSPECTION AND MAINTENANCE........3-9 ENGINE ......................3-10 CHECKING THE COOLANT LEVEL............3-10 CHECKING THE COOLING SYSTEM .............3-10 CHANGING THE COOLANT..............3-10...
  • Page 98 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY....3-34 CHECKING THE TIRES................3-36 CHECKING AND TIGHTENING THE SPOKES........3-36 CHECKING THE WHEELS ..............3-37 CHECKING THE WHEEL BEARINGS .............3-37 CHECKING AND ADJUSTING THE STEERING HEAD ......3-37 CHECKING AND LUBRICATING THE CABLES ........3-38 LUBRICATING THE LEVERS ..............3-38 LUBRICATING THE PEDAL ..............3-38 LUBRICATING THE DRIVE CHAIN ............3-39 LUBRICATING THE SIDESTAND............3-39...

  • Page 99: Periodic Maintenance

    • From 4200 mi (7000 km) or 9 months, repeat the maintenance intervals starting from 1800 mi (3000 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 100: General Maintenance And Lubrication Chart

    PERIODIC MAINTENANCE GENERAL MAINTENANCE AND LUBRICATION CHART EAS2GC1077 ODOMETER READ- INITIAL INGS 600 mi 1800 mi 3000 mi ITEM CHECKS AND MAINTENANCE JOBS (1000 (3000 (5000 km) or 1 km) or 3 km) or 6 month months months • Check operation. ...
  • Page 101 Rear sus- • Apply molybdenum disulfide grease   pension link lightly. pivots Control ca- • Apply Yamaha chain and cable lube or    bles engine oil 10W-30 thoroughly. • Check operation and free play. Throttle grip • Adjust the throttle cable free play if ...

  • Page 102: 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 103 PERIODIC MAINTENANCE Every Every After third fifth Every As re- ITEM break- Remarks race quired 1,000 PISTON PIN Inspect Replace CYLINDER HEAD Inspect carbon deposits and Inspect and clean eliminate them. Change gasket. CYLINDER Inspect score marks. Inspect and clean Inspect wear.
  • Page 104 Every two years Inspect hoses OUTSIDE NUTS AND BOLTS Refer to “STARTING AND Retighten BREAK-IN” on page 1-28. AIR FILTER Use Yamaha foam air filter oil Clean and lubri- or other quality foam air filter cate oil. Replace OIL FILTER Replace...
  • Page 105 Replace pads Replace brake flu- Every one year FRONT FORKS Inspect and adjust Replace oil Yamaha Suspension Oil S1 Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium-soap-based grease PROTECTOR...
  • Page 106 TIRE, WHEELS Inspect air pres- sure, wheel run- out, tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate Lithium-soap-based grease THROTTLE, CON- TROL CABLE Check routing and connection Yamaha cable lube or SAE Lubricate 10W-30 motor oil...

  • Page 107: Pre-Operation Inspection And Maintenance

    PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE EAS2GC1079 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. EAS2GC1080 GENERAL INSPECTION AND MAINTENANCE ITEM inspect Page...

  • Page 108: Engine

    ENGINE 5. Check: ENGINE EAS2GC1081 • Coolant level EAS2GC1082 CHECKING THE COOLANT LEVEL Before checking the coolant level, wait a few WARNING minutes until the coolant has settled. If coolant seems hot, do not remove the ra- diator cap. CHECKING THE COOLING SYSTEM EAS2GC1083 1.

  • Page 109: Checking The Radiator Cap

    ENGINE 3. Remove: 8. Start the engine, warm this up for 3 minutes, • Radiator cap stop it, and then wait for it to cool down. Slowly loosen the radiator cap to drain cool- ant. This model is equipped with an engine auto- stop system.

  • Page 110: Checking The Coolant Circulatory System For Leaks

    ENGINE NOTICE Radiator cap tester • Do not apply such a high pressure as ex- 90890-01325 ceeds the test pressure. Mityvac cooling system tester kit • Make sure that a checkup after the cylin- YU-24460-A der head gasket is replaced is made after 3 Radiator cap tester adapter minutes of warm-up.

  • Page 111: Adjusting The Throttle Grip Free Play

    ENGINE 2. Adjust: • Clutch lever free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Handlebar side a. Turn the adjuster “1” in direction “a” or “b” until the specified clutch lever free play is ob- tained. Direction “a” Clutch lever free play is increased. Direction “b” Clutch lever free play is decreased.

  • Page 112: Lubricating The Throttle Cable

    ENGINE 4. Install: • Cover (grip cap) • Cover (throttle cable cap) WARNING Check that the throttle grip moves smooth- ly. If this does not move smoothly, correct the installed positions. CLEANING THE AIR FILTER ELEMENT EAS2GC1091 1. Remove: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ •...

  • Page 113: Checking The Throttle Body Joint

    • Throttle body joint • Air filter element Refer to “CHECKING THE THROTTLE Damage  Replace. BODY JOINT” on page 8-10. 5. Yamaha foam air filter oil or other quality foam air filter oil. EAS2GC1093 CHECKING THE BREATHER HOSES 1. Check:...

  • Page 114: Checking The Fuel Line

    ENGINE 3. Check: • Tightening torques Exhaust pipe bolt 1 and nut “1” 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Exhaust pipe 1 and exhaust pipe 2 bolt “2” 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Exhaust pipe 2 and silencer bolt “3”...

  • Page 115: Changing The Engine Oil

    ENGINE NOTICE • Since engine oil also lubricates the clutch, the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives. • Do not allow foreign material to enter the crankcase. Recommended brand YAMALUBE Type SAE 10W-40, SAE 10W-50, SAE 15W-40, SAE 20W-40 or SAE...
  • Page 116 ENGINE c. Replace the O-ring “2”. 10.Check: • Engine oil pressure ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Slightly loosen the oil pressure check bolt “1”. WARNING When the engine is started with the check bolt removed, oil will spout; therefore, al- ways loosen it before the checkup. d.

  • Page 117: Adjusting The Engine Idling Speed

    ENGINE ADJUSTING THE ENGINE IDLING SPEED EAS2GC1098 Get the high tension cord “1” of the ignition coil pinched in the detector “a” of the digital tachom- • Because the air pressure is lower at high alti- eter. tudes, the air-fuel mixture will become richer. If the idling speed is low, turn the starter knob/ idle screw a few clicks counterclockwise to in- crease the speed before the adjustment.

  • Page 118: Adjusting The Valve Clearance

    • This section is intended for those who have basic knowledge and skill concerning the ser- Valve clearance (cold) Intake vicing of Yamaha motorcycles (e.g., Yamaha 0.13–0.20 mm (0.0051–0.0079 in) dealers, service engineers, etc.). Those who Exhaust have little knowledge and skill concerning ser- 0.18–0.25 mm (0.0071–0.0098 in)
  • Page 119 ENGINE c. Check the number on the originally installed adjusting pad. • The adjusting pad number “a” is indicated on the top of the adjusting pad. • For the number on the originally installed ad- justing pad, convert the last digit of adjusting pad number as per the below table.
  • Page 120 ENGINE e. Install the new adjusting pads “4” and the valve lifters “5”. NOTICE Do not twist adjusting pads and valve lifters forcibly during installation. • Apply the engine oil on the valve lifters. • Apply molybdenum disulfide oil to the valve stem ends.
  • Page 121 ENGINE 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 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230...

  • Page 122: Cleaning The Spark Arrester

    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 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 0.03 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225...

  • Page 123: Chassis

    CHASSIS CHASSIS EAS2GC1101 EAS2GC1102 BLEEDING THE BRAKE SYSTEM WARNING Bleed the brake system whenever: • The system is disassembled. • A brake hose is loosened, disconnected, or replaced. • The brake fluid level is very low. • Brake operation is faulty. A.

  • Page 124: Checking The Brake Hose

    CHASSIS CHECKING THE BRAKE HOSE EAS2GC1103 1. Check: • Brake hose “1” Cracks/damage/wear  Replace. 2. Remove: • Brake lever cover 3. Adjust: • Brake lever position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. b. Turn the adjusting bolt “2” in direction “a” or “b”...

  • Page 125: Adjusting The Rear Brake

    CHASSIS ADJUSTING THE REAR BRAKE EAS2GC1105 NOTICE 1. Check: After adjusting the brake pedal position, • Brake pedal position “a” make sure that there is no brake drag. (distance from the top of the rider footrest to the top of the brake pedal) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 126 CHASSIS c. Remove the brake caliper “3” from the front fork. i. Install the brake caliper “8” and tighten the pad pin “9”. d. Remove the pad pin and brake pads “4”. Bolt (brake caliper) 23 Nm (2.3 m·kgf, 17 ft·lbf) Pad pin 17 Nm (1.7 m·kgf, 12 ft·lbf) e.

  • Page 127: Checking The Rear Brake Pads

    CHASSIS d. Remove the pad pin “6” and the brake pads CHECKING THE REAR BRAKE PADS EAS2GC1107 “7”. 1. Measure: • Brake pad thickness “a” Out of specification  Replace as a set. The pads worn up to the indicator “b” grooves mean that the brake pad thickness limit is reached.

  • Page 128: Checking The Rear Brake Pad Insulator

    CHASSIS i. Install the brake caliper “12” and the rear 2. Check: wheel “13”. • Rear brake pad insulator “1” Damage  Replace. Refer to “REAR WHEEL” on page 5-9. j. Tighten the pad pin “14”. Pad pin 17 Nm (1.7 m·kgf, 12 ft·lbf) CHECKING THE BRAKE FLUID LEVEL EAS2GC1109 1.

  • Page 129: Adjusting The Drive Chain Slack

    CHASSIS • When refilling, be careful that water does 5. Adjust: not enter the brake fluid reservoir. Water • Drive chain slack will significantly lower the boiling point of ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ the brake fluid and could cause vapor a. Loosen the wheel axle nut “1”. lock.

  • Page 130: Checking The Front Fork Protector Guide

    CHASSIS 3. Hold the vehicle upright and apply the front brake. 4. Check: • Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Unsmooth operation  Correct or replace. Refer to “FRONT FORK” on page 5-40. 2.

  • Page 131: Adjusting The Front Fork Legs

    CHASSIS 3. Tighten: • Air bleed screw Air bleed screw 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping NOTICE Do not turn the adjuster forcibly beyond its adjusting range. EAS2GC1115 ADJUSTING THE FRONT FORK LEGS 1. Adjust: WARNING • Compression damping •...

  • Page 132: Checking The Swingarm Operation

    CHASSIS Spring preload CHECKING THE SWINGARM OPERATION EAS2GC1116 1. Check: NOTICE • Swingarm smooth action Do not turn the adjuster forcibly beyond its • Swingarm free play adjusting range. Refer to “SWINGARM” on page 5-65. 1. Remove: EAS2GC1117 CHECKING THE REAR SUSPENSION •...
  • Page 133 CHASSIS Rebound damping adjusting posi- • Be sure to remove all dirt and mud from tions around the locknut and adjusting ring before Maximum adjustment. Fully turned in • The length of the spring (installed) changes Standard 1.5 mm (0.06 in) per turn of the adjusting ring. 14 clicks out* Minimum 30 clicks out*...

  • Page 134: Checking The Tires

    CHASSIS CHECKING THE TIRES EAS2GC1119 1. Measure: • Tire pressure Out of specification  Regulate. Tire air pressure (measured on cold tires) Front 100 kPa (1.00 kgf/cm , 15 psi) Rear 100 kPa (1.00 kgf/cm , 15 psi) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping (for slow compres- •...

  • Page 135: Checking The Wheels

    CHASSIS 2. Tighten: CHECKING AND ADJUSTING THE STEER- EAS2GC1123 • Spokes ING HEAD Use a spoke nipple wrench “1” for tighten- 1. Use a suitable stand to raise the front wheel ing. off the ground. WARNING Securely support the vehicle so that there is no danger of it falling over.

  • Page 136: Checking And Lubricating The Cables

    CHASSIS CHECKING AND LUBRICATING THE CA- EAS2GC1124 Steering nut wrench BLES 90890-01403 The following procedure applies to all of the in- Exhaust flange nut wrench ner and outer cables. YU-A9472 WARNING Damaged outer cable may cause the cable Ring nut (initial tightening torque) 38 Nm (3.8 m·kgf, 27 ft·lbf) to corrode and interfere with its movement.

  • Page 137: Lubricating The Drive Chain

    CHASSIS LUBRICATING THE DRIVE CHAIN EAS2GC1127 The drive chain consists of many interacting parts. If the drive chain is not maintained prop- erly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas. This vehicle has a drive chain with small rubber O-rings between each side plate.

  • Page 138: Electrical System

    ELECTRICAL SYSTEM 5. Clean: ELECTRICAL SYSTEM EAS2GC1130 • Spark plug (with a spark plug cleaner or a wire brush) EAS2GC1131 CHECKING THE SPARK PLUG 6. Measure: 1. Remove: • Spark plug gap “a” • Seat Out of specification  Adjust the spark plug •...

  • Page 139: Checking And Charging The Battery

    ELECTRICAL SYSTEM 2. Attach: CHECKING AND CHARGING THE BATTERY EAS2GC1133 • Timing light “1” Refer to “CHECKING AND CHARGING THE • Digital tachometer “2” BATTERY” on page 9-69. To the high tension code “3”. EAS2GC1134 REPLACING THE HEADLIGHT BULB Timing light WARNING 90890-03141 Since the headlight bulb gets extremely hot,...
  • Page 140 ELECTRICAL SYSTEM 4. Install: • Headlight bulb Fasten the new headlight bulb with the headlight bulb holder. NOTICE Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected.

  • Page 141: Tuning

    TUNING CHASSIS ......................4-1 SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET) ....................4-1 DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS ....4-1 TIRE PRESSURE..................4-1 FRONT FORK SETTING................4-2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL....4-2 SETTING OF SPRING AFTER REPLACEMENT ........4-2 FRONT FORK SETTING PARTS...............4-3 REAR SUSPENSION SETTING ..............4-3 CHOOSING SET LENGTH ................4-3 SETTING OF SPRING AFTER REPLACEMENT ........4-4...

  • Page 142: Chassis

    CHASSIS CHASSIS DRIVE AND REAR WHEEL SPROCKETS EAS2GC1136 EAS2GC1138 SETTING PARTS EAS2GC1137 SELECTION OF THE SECONDARY REDUC- Part name Type Part number TION RATIO (SPROCKET) Drive sprocket “1” Secondary reduction ratio = Number of (STD) 13T 9383E-13233 rear wheel sprocket teeth/Number of drive sprocket teeth Rear wheel sprocket “2”...

  • Page 143: Front Fork Setting

    CHASSIS • Under a stony or a hard road condition, the tire pressure should be higher to prevent a flat tire. Extent of adjustment 100–120 kPa (1.00–1.20 kgf/cm 15–18 psi) FRONT FORK SETTING EAS2GC1140 The front fork setting should be made depend- ing on the rider’s feeling of an actual run and the circuit conditions.

  • Page 144: Front Fork Setting Parts

    CHASSIS REAR SUSPENSION SETTING EAS2GC1144 The rear shock absorber setting should be Generally a stiff spring gives a stiff riding feel- made depending on the rider’s feeling of an ac- ing. Rebound damping tends to become weak- tual run and the circuit conditions. er, resulting in lack of a sense of contact with The rear suspension setting includes the fol- the road surface or in a vibrating handlebar.

  • Page 145: Setting Of Spring After Replacement

    CHASSIS Length “a” of standard shock • If the machine is new and after it is broken in, 462.5 mm (18.21 in) the same set length of the spring may change because of the initial fatigue, etc. of the spring. Therefore, be sure to make reevalua- tion.
  • Page 146 CHASSIS • Spring preload adjusting positions Spring preload adjusting positions Minimum Position in which the spring is turned in 1.5 mm (0.06 in) from its free length. Standard Position in which the spring is turned in 12 mm (0.47 in) from its free length.

  • Page 147: Suspension Setting (Front Fork)

    CHASSIS SUSPENSION SETTING (FRONT FORK) EAS2GC1148 • 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 148: Suspension Setting (Rear Shock Absorber)

    CHASSIS Section Medi- Symptom Check Adjust Large Small Jump Compression Turn adjuster clockwise (about damping force 2 clicks) to increase damping. Rebound Turn adjuster counterclock- damping force wise (about 2 clicks) to de- crease damping. Low front, tend- ing to lower Balance with Set sunken length for 95–100 front posture...
  • Page 149 CHASSIS Section Medi- Symptom Check Adjust Large Small Jump Rebound Turn adjuster counterclock- damping force wise (about 2 clicks) to de- Heavy and crease damping. dragging Spring Replace with soft spring. Rebound Turn adjuster counterclock- damping force wise (about 2 clicks) to de- crease damping.
  • Page 150 CHASSIS...
  • Page 151 CHASSIS GENERAL CHASSIS..................5-1 REMOVING THE LEFT SIDE COVER............5-3 REMOVING THE SEAT ................5-3 FRONT WHEEL....................5-4 REMOVING THE FRONT WHEEL.............5-5 CHECKING THE FRONT WHEEL .............5-5 DISASSEMBLING THE FRONT WHEEL...........5-6 ASSEMBLING THE FRONT WHEEL............5-6 INSTALLING THE FRONT WHEEL ............5-7 REAR WHEEL ....................5-9 REMOVING THE REAR WHEEL .............5-10 CHECKING THE REAR WHEEL..............5-10 DISASSEMBLING THE REAR WHEEL ...........5-10 CHECKING AND REPLACING THE REAR WHEEL SPROCKET ..5-10...
  • Page 152 HANDLEBAR ....................5-33 REMOVING THE HANDLEBAR...............5-35 CHECKING THE HANDLEBAR ...............5-35 INSTALLING THE HANDLEBAR .............5-35 FRONT FORK....................5-40 REMOVING THE FRONT FORK LEGS...........5-42 DISASSEMBLING THE FRONT FORK LEGS .........5-42 CHECKING THE FRONT FORK LEGS ...........5-43 ASSEMBLING THE FRONT FORK LEGS ..........5-44 INSTALLING THE FRONT FORK LEGS ..........5-50 STEERING HEAD...................5-53 REMOVING THE LOWER BRACKET............5-55 CHECKING THE STEERING HEAD ............5-55...
  • Page 153 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 154 GENERAL CHASSIS Removing the headlight assembly and multi-function meter 21 Nm (2.1 m kgf, 15 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 21 Nm (2.1 m kgf, 15 ft Ibf) 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) Order...

  • Page 155: General Chassis

    GENERAL CHASSIS REMOVING THE LEFT SIDE COVER EAS2GC1152 1. Remove: • Bolt (side cover) • Side cover “1” Draw the left side cover “1” backward to re- move it because its projection “a” is inserted in the rear frame. EAS2GC1153 REMOVING THE SEAT The fuel tank cap cover and the seat are cou- pled with each other with a plastic band.
  • Page 156 FRONT WHEEL FRONT WHEEL EAS2GC1154 Removing the front wheel 21 Nm (2.1 m kgf, 15 ft Ibf) 21 Nm (2.1 m kgf, 15 ft Ibf) 90 Nm (9.0 m kgf, 65 ft lbf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) Order Part name Q’ty...

  • Page 157: Front Wheel

    FRONT WHEEL REMOVING THE FRONT WHEEL EAS2GC1155 1. Use a suitable stand to raise the front wheel A tight spoke will emit a clear, ringing tone; a off the ground. loose spoke will sound flat. WARNING 4. Tighten: Securely support the vehicle so that there is •...

  • Page 158: Disassembling The Front Wheel

    FRONT WHEEL DISASSEMBLING THE FRONT WHEEL EAS2GC1157 NOTICE 1. Remove: Install the bearing by pressing its outer race • Oil seals parallel. • Bearings ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside of the front wheel hub. b. Remove the oil seals “1” with a flat-head screwdriver.

  • Page 159: Installing The Front Wheel

    FRONT WHEEL 3. Install: 2. Install: • Collar “1” • Front wheel axle “1” Apply the lithium-soap-based grease on the oil Apply the lithium-soap-based grease to the seal lip. front wheel axle. 4. Install: 3. Tighten: • Speed sensor “1” •...
  • Page 160 FRONT WHEEL...
  • Page 161 REAR WHEEL REAR WHEEL EAS2GC1160 Removing the rear wheel 14 Nm (1.4 m kgf, 10 ft Ibf) 125 Nm (12.5 m kgf, 90 ft lbf) 21 Nm (2.1 m kgf, 15 ft Ibf) 50 Nm (5.0 m kgf, 36 ft Ibf) 21 Nm (2.1 m kgf, 15 ft Ibf) Order Part name...

  • Page 162: Rear Wheel

    REAR WHEEL 4. Measure: REMOVING THE REAR WHEEL EAS2GC1161 • Radial wheel runout 1. Use a suitable stand to raise the rear wheel • Lateral wheel runout off the ground. Refer to “CHECKING THE FRONT WHEEL” WARNING on page 5-5. Securely support the vehicle so that there is Radial wheel runout limit no danger of it falling over.

  • Page 163: Assembling The Rear Wheel

    REAR WHEEL Tighten the self-locking nuts in stages and in a crisscross pattern. 2. Install: • Brake disc “1” • Brake disc bolt “2” Brake disc bolt ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 14 Nm (1.4 m·kgf, 10 ft·lbf) LOCTITE® ASSEMBLING THE REAR WHEEL EAS2GC1165 1.
  • Page 164 REAR WHEEL Install the brake disc “1” between the brake Temporarily tighten the nut (rear wheel axle) at pads “2” correctly. this point. 2. Install: 5. Adjust: • Drive chain “1” • Drive chain slack “a” Drive chain slack (on a suitable Push the rear wheel “2”...

  • Page 165: Front Brake

    FRONT BRAKE FRONT BRAKE EAS2GC1167 Removing the front brake caliper 30 Nm (3.0 m kgf, 22 ft lbf) 23 Nm (2.3 m kgf, 17 ft lbf) 6 Nm (0.6 m kgf, 4.3 ft lbf) 17 Nm (1.7 m kgf, 12 ft lbf) 2.5 Nm (0.25 m kgf, 1.8 ft...
  • Page 166 FRONT BRAKE Disassembling the front brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) Order Part name Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassemble pro- cedure.
  • Page 167 FRONT BRAKE Removing the front brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft lbf) 6 Nm (0.6 m kgf, 4.3 ft lbf) 6 Nm (0.6 m kgf, 4.3 ft lbf) 30 Nm (3.0 m kgf, 22 ft lbf) Order Part name Q’ty...
  • Page 168 FRONT BRAKE Disassembling the front brake master cylinder Order Part name Q’ty Remarks Push rod Dust boot Circlip Washer Brake master cylinder kit For assembly, reverse the disassemble pro- cedure. 5-16...

  • Page 169: Introduction

    FRONT BRAKE INTRODUCTION EAS2GC1168 Brake disc thickness limit WARNING 2.5 mm (0.10 in) If you need to disassemble the disc brake 4. Install: components, observe the following precau- • Front wheel tions. Refer to “FRONT WHEEL” on page 5-4. • Never disassemble the brake components unless absolutely necessary.

  • Page 170: Checking The Front Brake Caliper

    FRONT BRAKE ASSEMBLING THE FRONT BRAKE CALI- EAS2GC1173 WARNING • Before installation, clean and lubricate the internal parts. Use new brake fluid for cleaning and lubricating. • Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.

  • Page 171: Installing The Front Brake Caliper

    FRONT BRAKE 3. Install: 2. Install: • Brake caliper piston “1” • Front brake caliper • Brake pad spring • Brake pad Apply the brake fluid on the piston outer sur- • Brake pad pin face. • Brake hose holder NOTICE Brake pad pin •...

  • Page 172: Removing The Front Brake Master Cylinder

    FRONT BRAKE NOTICE Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Bleed: • Brake system Refer to “BLEEDING THE BRAKE SYS- TEM” on page 3-25. 6. Check: • Brake fluid level 2.

  • Page 173: Installing The Front Brake Master Cylinder

    FRONT BRAKE INSTALLING THE FRONT BRAKE MASTER EAS2GC1179 CYLINDER 1. Install: • Brake master cylinder “1” Brake master cylinder holder bolt 9 Nm (0.9 m·kgf, 6.5 ft·lbf) • Install the front brake master cylinder holder 3. Install: with the “UP” mark facing up. •...
  • Page 174 FRONT BRAKE Turn the handlebar toward right and left to make sure that the brake hose does not touch other parts (e.g., wire harness, cables, leads). Adjust if necessary. 6. Check: • Brake lever free play Refer to “ADJUSTING THE FRONT BRAKE”...

  • Page 175: Rear Brake

    REAR BRAKE REAR BRAKE EAS2GC1180 Removing the rear brake caliper 10 Nm (1.0 m kgf, 7.2 ft Ibf) 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf)
  • Page 176 REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) Order Part name Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassemble pro- cedure.
  • Page 177 REAR BRAKE Removing the rear brake master cylinder Order Part name Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE BRAKE SYSTEM” on page 3-25. Union bolt Copper washers Brake hose Split pin Washer Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm plate Brake master cylinder reservoir diaphragm Rear brake master cylinder For installation, reverse the removal proce-...
  • Page 178 REAR BRAKE Disassembling the rear brake master cylinder Order Part name Q’ty Remarks Dust boot Circlip Push rod Brake master cylinder kit For assembly, reverse the disassemble pro- cedure. 5-26...

  • Page 179: Introduction

    REAR BRAKE INTRODUCTION EAS2GC1181 WARNING If you need to disassemble the disc brake components, observe the following precau- tions. • Never disassemble the brake components unless absolutely necessary. • If there is any problem with connections on the hydraulic brake system, perform the following jobs.

  • Page 180: Removing The Rear Brake Caliper

    REAR BRAKE REMOVING THE REAR BRAKE CALIPER CHECKING THE REAR BRAKE CALIPER EAS2GC1183 EAS2GC1185 1. Check: • Brake caliper piston “1” Before disassembling the brake caliper, drain Rust/scratches/wear  Replace the brake the brake fluid from the entire brake system. caliper piston.

  • Page 181: Installing The Brake Caliper Piston

    REAR BRAKE INSTALLING THE BRAKE CALIPER PISTON INSTALLING THE REAR BRAKE CALIPER EAS2GC1187 EAS2GC1188 1. Clean: 1. Install: • Brake caliper • Rear brake caliper • Brake caliper piston seal • Rear brake caliper bracket • Brake caliper piston dust seal 2.

  • Page 182: Removing The Rear Brake Master Cylinder

    REAR BRAKE 1. Remove: WARNING • Union bolt • Use only the designated brake fluid. Other • Copper washers brake fluids may cause the rubber seals to • Brake hose deteriorate, causing leakage and poor brake performance. To drain any remaining brake fluid, place a con- •...

  • Page 183: Installing The Rear Brake Master Cylinder

    REAR BRAKE Specified brake fluid DOT 4 1. Wash the brake master cylinder and the brake master cylinder kit with brake fluid. 2. Install: • Primary cylinder cup “1” • Secondary cylinder cup “2” Install to the brake master cylinder piston “3”.
  • Page 184 REAR BRAKE 2. Pour brake fluid to the brake fluid reservoir 5. Check: up to the specified level. • Brake pedal operation A softy or spongy feeling  Bleed the brake Specified brake fluid system. DOT 4 Refer to “BLEEDING THE BRAKE SYS- TEM”...
  • Page 185 HANDLEBAR HANDLEBAR EAS2GC1193 Removing the handlebar Order Part name Q’ty Remarks Clutch cable Disconnect. Clutch switch Clutch lever holder Engine stop switch Brake master cylinder Throttle cable cap Throttle cable (pull) Disconnect. Throttle cable (return) Disconnect. Right grip Tube guide Start switch Left grip Handlebar upper holder...
  • Page 186 HANDLEBAR Removing the handlebar Order Part name Q’ty Remarks Handlebar lower holder Damper For installation, reverse the removal proce- dure. 5-34...

  • Page 187: Handlebar

    HANDLEBAR REMOVING THE HANDLEBAR EAS2GC1194 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Clutch switch “1” CHECKING THE HANDLEBAR EAS2GC1195 1. Check: •...
  • Page 188 HANDLEBAR NOTICE • First, tighten the bolts on the front side of the upper handlebar holder, and then on the rear side. • Turn the handlebar all the way to the left and right. If there is any contact with the fuel tank, adjust the handlebar position.
  • Page 189 HANDLEBAR 5. Install: • Engine stop switch “1” • Clutch lever “2” • Clutch lever holder “3” • Clamp “4” Engine stop switch screw 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf) Clutch lever holder bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) 7.
  • Page 190 HANDLEBAR WARNING • Install the brake master cylinder holder with After tightening the throttle cable housing the “UP” mark facing up. screws, check that the throttle grip “3” • Install in order for the top of the front brake moves smoothly. If it does not, retighten the master cylinder assembly to be level.
  • Page 191 HANDLEBAR 14.Adjust: • Throttle grip free play Refer to “ADJUSTING THE THROTTLE GRIP FREE PLAY” on page 3-13. Throttle grip free play 3.0–6.0 mm (0.12–0.24 in) 5-39...

  • Page 192: Front Fork

    FRONT FORK FRONT FORK EAS2GC1197 Removing the front fork legs Order Part name Q’ty Remarks Use a suitable stand to raise the front wheel off the ground. Front wheel Refer to “FRONT WHEEL” on page 5-4. Front brake caliper Refer to “FRONT BRAKE” on page 5-13. Brake hose holder Protector Upper bracket pinch bolts...
  • Page 193 FRONT FORK Disassembling the front fork leg 30 Nm (3.0 m kgf, 22 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • 55 Nm (5.5 m kgf, 40 ft Ibf) •...

  • Page 194: Removing The Front Fork Legs

    FRONT FORK REMOVING THE FRONT FORK LEGS EAS2GC1198 1. Use a suitable stand to raise the front wheel • While compressing the inner tube “2”, set the off the ground. cap bolt ring wrench “4” between the inner tube and locknut “3”. WARNING •...

  • Page 195: Checking The Front Fork Legs

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

  • Page 196: Assembling The Front Fork Legs

    1. Stretch the damper assembly fully. 2. Fill: • Damper assembly Recommended oil Yamaha Suspension Oil S1 6. Check: Standard oil amount • Contacting surface “a” 210 cm (7.10 US oz, 7.39 Wear/damage ...
  • Page 197 FRONT FORK 4. Measure: 6. Loosen: • Oil level (left and right) “a” • Compression damping force adjuster “1” Out of specification  Regulate. • Before loosening the damping force adjuster, Standard oil level record the setting position. 145–148 mm (5.71–5.83 in) •...
  • Page 198 FRONT FORK 9. Tighten: • Base valve “1” Base valve 28 Nm (2.8 m·kgf, 20 ft·lbf) Hold the damper assembly with the cap bolt ring wrench “2” and use the cap bolt wrench “3” to tighten the base valve. 12.Allow the overflowing oil to escape at the Cap bolt wrench hole “a”...
  • Page 199 FRONT FORK • Apply the lithium-soap-based grease on the dust seal lip and oil seal lip. • Apply the fork oil on the inner tube. • When installing the oil seal, use vinyl seat “a” with fork oil applied to protect the oil seal lip. 17.Install: •...
  • Page 200 FRONT FORK 19.Install: 22.Measure: • Oil seal clip “1” • Distance “a” Out of specification  Turn into the locknut. Fit the oil seal clip correctly in the groove in the Distance “a” outer tube. 16 mm (0.63 in) or more Between the damper assembly “1”...
  • Page 201 FRONT FORK 24.Install: Cap bolt ring wrench • Damper assembly “1” 90890-01501 (to the inner tube “2”) Cap bolt ring wrench YM-01501 NOTICE Allow the damper assembly to slide slowly down the inner tube until it contacts the bot- tom of the inner tube. Be careful not to dam- age the inner tube.

  • Page 202: Installing The Front Fork Legs

    55 Nm (5.5 m·kgf, 40 ft·lbf) LOCTITE® 32.Install: • Protector guide “1” 30.Fill: • Front fork leg Recommended oil Yamaha Suspension Oil S1 Standard oil amount 345 cm (11.66 US oz, 12.14 lmp.oz) Extent of adjustment 300–365 cm (10.14–12.34 US oz, 10.58–12.87 lmp.oz)
  • Page 203 FRONT FORK 4. Tighten: • Pinch bolt (upper bracket) “1” Upper bracket pinch bolts 21 Nm (2.1 m·kgf, 15 ft·lbf) • Pinch bolt (lower bracket) “2” Lower bracket pinch bolts 21 Nm (2.1 m·kgf, 15 ft·lbf) 2. Tighten: WARNING • Damper assembly “1” Tighten the lower bracket to specified torque.
  • Page 204 FRONT FORK 6. Install: 9. Adjust: • Speed sensor lead “1” • Compression damping force • Plate 2 “2” (to the right front fork protector) Turn in the damping adjuster “1” finger-tight and then turn out to the originally set position. Plate 2 screw 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf) Install the plate 2 in the direction as shown.

  • Page 205: Steering Head

    STEERING HEAD STEERING HEAD EAS2GC1203 Removing the lower bracket 145 Nm (14.5 m kgf, 105 ft lbf) 21 Nm (2.1 m kgf, 15 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft lbf) 21 Nm (2.1 m kgf, 15 ft...
  • Page 206 STEERING HEAD Removing the lower bracket 145 Nm (14.5 m kgf, 105 ft lbf) 21 Nm (2.1 m kgf, 15 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft lbf) 21 Nm (2.1 m kgf, 15 ft lbf) 3.8 Nm (0.38 m...

  • Page 207: Removing The Lower Bracket

    STEERING HEAD REMOVING THE LOWER BRACKET EAS2GC1204 1. Use a suitable stand to raise the front wheel Always replace the bearing and the bearing off the ground. race as a set. WARNING Securely support the vehicle so that there is no danger of it falling over.
  • Page 208 STEERING HEAD 5. Check the steering stem by turning this lock to lock. If there is any binding, remove the Apply the lithium-soap-based grease on the steering stem and check the steering bear- bearing and bearing race cover lip. ing. 3.
  • Page 209 STEERING HEAD Apply the lithium-soap-based grease to the contact surface of the steering stem nut when installing. 12.Install: • Speed sensor lead holder “1” • Speed sensor lead clamp “2” Speed sensor lead holder bolt 13 Nm (1.3 m·kgf, 9.4 ft·lbf) 9.

  • Page 210: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY REAR SHOCK ABSORBER ASSEMBLY EAS2GC1207 Removing the rear shock absorber assembly 16 15 14 13 Order Part name Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 5-1. Side cover (left / right) Refer to “GENERAL CHASSIS” on page 5-1. Air scoop (left / right) Refer to “GENERAL CHASSIS”...
  • Page 211 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 16 15 14 13 Order Part name Q’ty Remarks Collars O-ring Dust seal Stopper ring Bearing For installation, reverse the removal proce- dure. 5-59...
  • Page 212 REAR SHOCK ABSORBER ASSEMBLY Disassembling the relay arm 80 Nm (8.0 m kgf, 58 ft lbf) Order Part name Q’ty Remarks Relay arm Connecting arm Collars Oil seals Washers Bearing For assembly, reverse the disassemble pro- cedure. 5-60...

  • Page 213: Handling The Rear Shock Absorber

    • To dispose of a damaged or a worn-out rear shock absorber, take the unit to your Yamaha dealer for this disposal proce- 3. Remove: dure. • Rear shock absorber assembly upper bolt •...

  • Page 214: Checking The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY • Spring guide Damage/wear  Replace. • Bearing Damage/wear  Replace. • Bolts Bends/damage/wear  Replace. EAS2GC1213 CHECKING THE CONNECTING ARM AND RELAY ARM 1. Check: • Connecting arm 2. Remove: • Relay arm • Upper bearing “1” Damage/wear ...

  • Page 215: Installing The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY 3. Install: 4. Install: • Bearing “1” • Bearing “1” • Oil seals “2” • Bushing “2” (to connecting arm “3”) • Collar “3” • Dust seal “4” Installed depth “a” (to rear shock absorber assembly (lower 0 mm (0 in) side)) Install the dust seals with their lips facing in-...
  • Page 216 REAR SHOCK ABSORBER ASSEMBLY 7. Tighten: • Rear shock absorber assembly upper bolt Rear shock absorber assembly upper bolt 56 Nm (5.6 m·kgf, 41 ft·lbf) • Connecting arm bolt (frame side) Connecting arm bolt (frame side) 80 Nm (8.0 m·kgf, 58 ft·lbf) •...

  • Page 217: Swingarm

    SWINGARM SWINGARM EAS2GC1216 Removing the swingarm 70 Nm (7.0 m kgf, 51 ft lbf) 4.0 Nm (0.40 m kgf, 2.9 ft lbf) Order Part name Q’ty Remarks Use a suitable stand to raise the front wheel off the ground. Brake hose holder Refer to “REAR BRAKE”...

  • Page 218: Removing The Swingarm

    SWINGARM REMOVING THE SWINGARM EAS2GC1217 1. Use a suitable stand to raise the rear wheel off the ground. WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Measure: • Swingarm side play • Swingarm vertical movement ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 219: Installing The Swingarm

    SWINGARM INSTALLING THE SWINGARM EAS2GC1220 1. Lubricate: • Bearing • Collars • Spacers • Oil seal • Pivot shaft Recommended lubricant Molybdenum disulfide grease 2. Install: • Bearing “1” • Oil seals “2” (to the swingarm) Installed depth “a” 0–0.5 mm (0–0.02 in) Installed depth “b”...

  • Page 220: Chain Drive

    CHAIN DRIVE CHAIN DRIVE EAS2GC1221 Removing the drive chain 75 Nm (7.5 m kgf, 54 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft lbf) Job Order Part name Q’ty Servicing Information Drive sprocket Refer to “ENGINE REMOVAL” on page 6-1. Drive chain For installation, reverse the removal proce- dure.

  • Page 221: Removing The Drive Chain

    CHAIN DRIVE REMOVING THE DRIVE CHAIN EAS23420 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated.

  • Page 222: Checking The Drive Sprocket

    CHAIN DRIVE b. Correct 1. Drive chain roller 2. Drive sprocket CHECKING THE REAR WHEEL SPROCKET EAS2GC1223 Refer to “CHECKING AND REPLACING THE REAR WHEEL SPROCKET” on page 5-10. EAS2GC1224 INSTALLING THE DRIVE CHAIN 1. Install: • Drive chain ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ NOTICE 4.
  • Page 223 CHAIN DRIVE NOTICE A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the speci- fied limits.
  • Page 224 CHAIN DRIVE 5-72...

  • Page 225: Engine

    ENGINE ENGINE REMOVAL ..................6-1 REMOVING THE SILENCER..............6-6 REMOVING THE EXHAUST PIPE 2............6-6 REMOVING THE DRIVE SPROCKET ............6-6 REMOVING THE ENGINE .................6-7 CLEANING THE SPARK ARRESTER ............6-7 CHECKING THE SILENCER AND EXHAUST PIPE........6-8 INSTALLING THE ENGINE................6-8 INSTALLING THE BRAKE PEDAL ............6-9 INSTALLING THE DRIVE SPROCKET............6-9 INSTALLING THE EXHAUST PIPE AND MUFFLER.........6-9 CAMSHAFT ....................6-11...
  • Page 226 CLUTCH ......................6-41 REMOVING THE CLUTCH ..............6-44 CHECKING THE FRICTION PLATES............6-44 CHECKING THE CLUTCH PLATES ............6-44 CHECKING THE CLUTCH SPRINGS............6-44 CHECKING THE CLUTCH HOUSING .............6-45 CHECKING THE CLUTCH BOSS............6-45 CHECKING THE PRESSURE PLATE .............6-45 CHECKING THE PUSH LEVER SHAFT..........6-45 CHECKING THE CLUTCH PUSH RODS ..........6-45 CHECKING THE PRIMARY DRIVE GEAR..........6-45 CHECKING THE PRIMARY DRIVEN GEAR ...........6-46 INSTALLING THE OIL SEAL ..............6-46...
  • Page 227 GENERATOR AND STARTER CLUTCH............6-63 REMOVING THE GENERATOR ..............6-65 CHECKING THE STARTER CLUTCH .............6-65 INSTALLING THE STARTER CLUTCH ...........6-66 INSTALLING THE GENERATOR.............6-67 CRANKCASE ....................6-69 DISASSEMBLING THE CRANKCASE.............6-72 REMOVING THE CRANKCASE BEARING ..........6-72 CHECKING THE TIMING CHAIN, TIMING CHAIN GUIDE, OIL STRAINER ....................6-72 CHECKING THE CRANKCASE ...............6-72 INSTALLING THE OIL SEAL ..............6-73 ASSEMBLING THE CRANKCASE............6-73...

  • Page 228: Engine Removal

    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 ENGINE REMOVAL Removing the exhaust pipe 5 Nm (0.5 m kgf, 3.6 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 9 Nm (0.9 m kgf, 6.5 ft Ibf) 7 Nm (0.7 m , 5.1 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 30 Nm (3.0 m kgf, 22 ft Ibf) 30 Nm (3.0 m kgf, 22 ft Ibf) 20 Nm (2.0 m kgf, 14 ft Ibf)
  • Page 230 ENGINE REMOVAL Removing the electronic parts Order Part name Q’ty Remarks Use a suitable stand to raise the front wheel off the ground. Seat Refer to “GENERAL CHASSIS” on page 5-1. Side cover (left/right) Refer to “GENERAL CHASSIS” on page 5-1. Air scoop (left / right) Refer to “GENERAL CHASSIS”...
  • Page 231 ENGINE REMOVAL Removing the engine 55 Nm (5.5 m kgf, 40 ft Ibf) Order Part name Q’ty Remarks Use a suitable stand to raise the front wheel off the ground. Seat Refer to “GENERAL CHASSIS” on page 5-1. Side cover (left/right) Refer to “GENERAL CHASSIS”...
  • Page 232 ENGINE REMOVAL Removing the engine 55 Nm (5.5 m kgf, 40 ft Ibf) Order Part name Q’ty Remarks Drive sprocket cover Drive chain guide Drive sprocket Upper engine bracket Lower engine bracket Pivot shaft Engine For installation, reverse the removal proce- dure.

  • Page 233: Removing The Silencer

    ENGINE REMOVAL REMOVING THE SILENCER EAS2GC1227 1. Remove: • Rear shock absorber assembly lower bolt “1” • Connecting arm bolt (relay arm side) “2” • Silencer “3” Move the rear shock absorber to the left side of the chassis, and remove the silencer. REMOVING THE DRIVE SPROCKET EAS2GC1229 1.

  • Page 234: Removing The Engine

    ENGINE REMOVAL REMOVING THE ENGINE CLEANING THE SPARK ARRESTER EAS2GC1230 EAS2GC1231 1. Remove: WARNING • Pivot shaft “1” • Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. If the pivot shaft is pulled all the way out, the •...

  • Page 235: Checking The Silencer And Exhaust Pipe

    ENGINE REMOVAL 5. Install: • Engine mounting bolt (lower side) “3” • Spark arrester gasket Engine mounting bolt (lower side) • Spark arrester 53 Nm (5.3 m·kgf, 38 ft·lbf) Insert the spark arrester into the muffler and align the bolt holes. •...

  • Page 236: Installing The Brake Pedal

    ENGINE REMOVAL INSTALLING THE BRAKE PEDAL EAS2GC1234 NOTICE 1. Install: Make sure to tighten to specification; other- • Spring “1” wise, it may damage the other part that is • Brake pedal “2” fastened together. • O-rings “3” • Bolt (brake pedal) “4” Bolt (brake pedal) 26 Nm (2.6 m·kgf, 19 ft·lbf) •...
  • Page 237 ENGINE REMOVAL 2. Install: • Clamp Install and temporarily tighten the silencer so • Exhaust pipe 2 “1” that its joint is positioned as shown with respect • Bolt (exhaust pipe 2) “2” to the exhaust pipe 2. 2mm (0.08in) 4.

  • Page 238: Camshaft

    CAMSHAFT CAMSHAFT EAS2GC1237 Removing the cylinder head cover 13 Nm (1.3 m kgf, 9.4 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 5-1. Side cover (left/right) Refer to “GENERAL CHASSIS”...
  • Page 239 CAMSHAFT Removing the camshaft 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 6 Nm (0.6 m kgf, 4.3 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 6 Nm (0.6 m kgf, 4.3 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name...

  • Page 240: Removing The Camshaft

    CAMSHAFT REMOVING THE CAMSHAFT EAS2GC1238 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: • Alignment mark • Remove the bolts (camshaft cap) in a criss- cross pattern, working from the outside in.

  • Page 241: Checking The Camshaft

    CAMSHAFT 3. Measure: CHECKING THE CAMSHAFT EAS2GC1239 • Camshaft runout 1. Check: Out of specification  Replace. • Camshaft lobes Blue discoloration/pitting/scratches  Re- Camshaft runout limit 0.030 mm (0.0012 in) place the camshaft. 2. Measure: • Camshaft lobe dimensions “A” and “B” Out of specification ...

  • Page 242: Checking The Timing Chain And Camshaft Sprocket

    CAMSHAFT c. Install the dowel pins and the camshaft 2. Check: caps. • Camshaft sprocket More than 1/4 tooth wear “a”  Replace the camshaft and the timing chain as a set. • Tighten the camshaft cap bolts in a crisscross pattern from innermost to outer caps.

  • Page 243: Checking The Decompression System

    CAMSHAFT CHECKING THE DECOMPRESSION SYS- EAS2GC1242 1. Check: • Decompression system ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check that the decompressor cam “1” moves smoothly. b. Check that the decompressor lever pin “2” projects from the camshaft. c. Fit the timing chain “3” onto both camshaft sprockets and install the camshafts on the cylinder head.
  • Page 244 “2”, and the gasket “3”, and tighten inder head cover gasket. the bolt “4”. Bolt (timing chain tensioner) Yamaha bond No. 1215 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 90890-85505 (Three bond No.1215®) c. Release the screwdriver, check that the ten- sioner rod comes out smoothly, and tighten 6.

  • Page 245: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD EAS2GC1244 Removing the cylinder head 30 Nm (3.0 m kgf, 22 ft Ibf) 20 Nm (2.0 m kgf, 14 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 15 Nm (1.5 m kgf, 11 ft Ibf) Order Part name...
  • Page 246 CYLINDER HEAD Removing the cylinder head 30 Nm (3.0 m kgf, 22 ft Ibf) 20 Nm (2.0 m kgf, 14 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 15 Nm (1.5 m kgf, 11 ft Ibf) Order Part name Q’ty...

  • Page 247: Removing The Cylinder Head

    CYLINDER HEAD REMOVING THE CYLINDER HEAD EAS2GC1245 1. Remove: • Cylinder head bolts • Loosen the bolts in the proper sequence as shown. • Loosen each bolt 1/2 of a turn at a time. After fully loosening all the bolts, remove them. •...

  • Page 248: Installing The Cylinder Head

    CYLINDER HEAD INSTALLING THE CYLINDER HEAD EAS2GC1248 Bolt “1”–“4” 1. Install: • Timing chain guide (intake side) “1” 30 Nm (3.0 m·kgf, 22 ft·lbf) • Dowel pins “2” • Cylinder head gasket • Dowel head “4” While pulling up the timing chain, install the tim- ing chain guide (intake side) and the cylinder head.
  • Page 249 CYLINDER HEAD i. Retighten the cylinder head mounting bolts 150° in the proper tightening sequence. Tighten the bolts in two steps (90° and 60°) to reach the specified angle in the proper tighten- ing sequence. Bolt “1”–“4” Final Specified angle 150° j.
  • Page 250 VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS EAS2GC1249 Removing the valves and valve springs Order Part name Q’ty Remarks Refer to “CYLINDER HEAD” on page 6-18. Cylinder head Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Intake valve...

  • Page 251: Valves And Valve Springs

    VALVES AND VALVE SPRINGS REMOVING THE VALVES EAS2GC1250 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Pour a clean solvent “a” into the intake and exhaust ports. Before removing the internal parts of the cylin- b. Check that the valves are properly sealed. der head (e.g., valves, valve springs, valve seats), make sure that the valves are properly Check that there are no kerosene leaks from sealed.

  • Page 252: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS 4. Remove: • Valve spring retainer “1” • Valve spring “2” • Valve “3” • Valve stem seal “4” • Valve spring seat “5” Identify the position of each part very carefully so that it can be reinstalled in its original place. 2.

  • Page 253: Checking The Valve Seats

    VALVES AND VALVE SPRINGS c. After installing the valve guide, expand the hole in the valve guide with the valve guide reamer “3” to obtain the proper valve-stem- to-valve-guide clearance. 6. Measure: • Valve stem runout Out of specification  Replace the valve. •...
  • Page 254 VALVES AND VALVE SPRINGS 4. Lap: • Valve face • Valve seat NOTICE This model uses titanium intake and ex- haust valves. Do not use the valves used for lapping the valve seat. Always replace the valves used for lapping with new ones. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 255: Checking The Valve Springs

    VALVES AND VALVE SPRINGS g. Apply Mechanic’s blueing dye (Dykem) “b” onto the valve face. 2. Measure: • Compressed valve spring force “a” Out of specification  Replace the valve h. Install the valve into the cylinder head. i. Press the valve through the valve guide and spring.

  • Page 256: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 3. Install: CHECKING THE VALVE LIFTERS EAS2GC1254 • Spring seat “1” 1. Check: • Valve stem seal “2” • Valve lifter • Valve “3” Damage/scratches  Replace the valve lift- • Valve spring “4” ers and cylinder head. •...
  • Page 257 VALVES AND VALVE SPRINGS 5. To fasten the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. NOTICE Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Adjusting pad “1” •...
  • Page 258 CYLINDER AND PISTON CYLINDER AND PISTON EAS2GC1256 Removing the cylinder and piston 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks Refer to “CYLINDER HEAD” on page 6-18. Cylinder head Cylinder body Gaskets...

  • Page 259: Cylinder And Piston

    CYLINDER AND PISTON REMOVING THE PISTON EAS2GC1257 1. Remove: • Piston pin clips “1” • Piston pin “2” • Piston “3” ECA13810 NOTICE Do not use a hammer to drive the piston pin out. • Before removing the piston pin clip, cover the CHECKING THE CYLINDER AND PISTON EAS2GC1258 crankcase opening with a cloth to prevent the...

  • Page 260: Checking The Piston Rings

    CYLINDER AND PISTON CHECKING THE PISTON RINGS EAS2GC1259 1. Measure: • Piston ring side clearance Out of specification  Replace the piston and piston rings as a set. Before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring grooves and piston rings.

  • Page 261: Checking The Piston Pin

    CYLINDER AND PISTON 3. Measure: 3. Measure: • Piston ring end gap • Piston pin bore inside diameter “b” Out of specification  Replace the piston Out of specification  Replace the piston. ring. Piston pin bore inside diameter 18.004–18.015 mm (0.7088– The oil ring expander’s end gap cannot be 0.7093 in) Limit...
  • Page 262 CYLINDER AND PISTON 2. Install: 5. Install: • Piston “1” • Cylinder gasket • Piston pin “2” • Dowel pin • Piston pin clips “3” • Cylinder Cylinder bolt • Apply molybdenum disulfide oil to the piston 10 Nm (1.0 m·kgf, 7.2 ft·lbf) pin.

  • Page 263: Electric Starter

    ELECTRIC STARTER ELECTRIC STARTER EAS2GC1262 Removing the starter motor 12 Nm (1.2 m kgf, 8.7 ft Ibf) Order Job/Parts to remove Q’ty Remarks Exhaust pipe Refer to “ENGINE REMOVAL” on page 6-1. Starter motor cover Starter motor lead Starter motor For assembly, reverse the disassemble pro- cedure.
  • Page 264 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks Starter motor front cover Starter motor yoke Armature assembly Starter motor rear cover Brush set For assembly, reverse the disassembly pro- cedure. 6-37...

  • Page 265: Checking The Starter Motor

    ELECTRIC STARTER CHECKING THE STARTER MOTOR EAS2GC1263 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure the armature assembly resistanc- 1. Check: es with the pocket tester. • Commutator Dirt  Clean with 600 grit sandpaper. Pocket tester 2. Measure: 90890-03112 • Commutator diameter “a” Analog pocket tester Out of specification ...

  • Page 266: Assembling The Starter Motor

    ELECTRIC STARTER 7. Check: • Gear teeth Damage/wear  Replace the starter motor. 8. Check: • Oil seal Damage/wear  Replace the defective part (s). ASSEMBLING THE STARTER MOTOR EAS2GC1264 1. Install: • Brush spring “1” 4. Install: • Brush “2” •...
  • Page 267 ELECTRIC STARTER 6. Install: • Starter motor “1” • Starter motor cover “2” • Starter motor bolt “3” • Starter motor cover bolt “4” Starter motor bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Starter motor cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Pass the AC magneto lead “5”...
  • Page 268 CLUTCH CLUTCH EAS2GC1265 Removing the clutch Order Part name Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-17. Brake pedal Refer to “ENGINE REMOVAL” on page 6-1. Clutch cable Disconnect. Clutch cover O-ring Clutch spring Pressure plate Push rod 1 Circlip...
  • Page 269 CLUTCH Removing the clutch Order Part name Q’ty Remarks Friction plate 2 Identification color (purple) Clutch plate 2 Thickness:1.6 mm (0.063 in) Cushion spring Clutch boss Thrust washer Primary driven gear Push lever shaft For installation, reverse the removal proce- dure.
  • Page 270 CLUTCH Removing the right crankcase cover Order Part name Q’ty Remarks Engine guard Refer to “ENGINE REMOVAL” on page 6-1. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-17. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-10.

  • Page 271: Clutch

    CLUTCH CHECKING THE CLUTCH PLATES REMOVING THE CLUTCH EAS2GC1266 1. Check: 1. Remove: • Clutch plate • Clutch boss nut “1” Damage  Replace the clutch plates as a • Conical washer “2” set. • Clutch boss “3” 2. Measure: •...

  • Page 272: Checking The Clutch Housing

    CLUTCH CHECKING THE CLUTCH HOUSING EAS2GC1270 1. Check: • Clutch housing dogs “a” Damage/pitting/wear  Deburr the clutch housing dogs or replace the clutch housing. Pitting on the clutch housing dogs will cause er- ratic clutch operation. CHECKING THE CLUTCH PUSH RODS EAS2GC1274 1.

  • Page 273: Checking The Primary Driven Gear

    CLUTCH • Right crankcase cover bolt “2” CHECKING THE PRIMARY DRIVEN GEAR EAS2GC1276 1. Check: Right crankcase cover bolt • Primary driven gear 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Damage/wear  Replace the primary drive and primary driven gears as a set. Excessive noise during operation ...
  • Page 274 CLUTCH 2. Install: • Primary driven gear “1” • Thrust washer “2” • Clutch boss “3” Apply the engine oil on the primary driven gear inner circumference. 4. Install: • Friction plate 1 “1” • Clutch plate 2 “2” • Cushion spring “3” •...
  • Page 275 CLUTCH 5. Install: 8. Install: • Bearing “1” • Clutch spring • Washer “2” • Clutch spring bolt • Circlip “3” Clutch spring bolt To push rod 1 “4”. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Apply the engine oil on the bearing and washer. Tighten the bolts in stages and in a crisscross pattern.

  • Page 276: Installing The Kickstarter Lever

    CLUTCH INSTALLING THE KICKSTARTER LEVER EAS2GC1280 1. Install: • Kickstarter lever “1” • Washer • Bolt (kickstarter lever) Bolt (kickstarter lever) 33 Nm (3.3 m·kgf, 24 ft·lbf) LOCTITE® Install so that there is a clearance “a” of 5 mm (0.2 in) or more between the kickstarter lever and the frame and that the kickstarter lever does not contact the right crankcase cover when it is pulled.
  • Page 277 KICKSTATER KICKSTATER EAS2GC1281 Removing the kick shaft Order Part name Q’ty Remarks Primary driven gear Refer to “CLUTCH” on page 6-41. Kick idle gear Kick shaft assembly Spring guide Torsion spring Ratchet wheel Kick gear Kick shaft For installation, reverse the removal proce- dure.

  • Page 278: Kickstater

    KICKSTATER REMOVING THE KICK SHAFT ASSEMBLY EAS2GC1282 1. Remove: • Kick shaft assembly “1” Unhook the torsion spring “2” from the hole “a” in the crankcase. INSTALLING THE KICK SHAFT ASSEMBLY EAS2GC1285 1. Install: • Kick gear “1” • Washer “2” •...

  • Page 279: Installing The Kick Idle Gear

    KICKSTATER 5. Install: • Torsion spring “1” Turn the torsion spring clockwise and hook into the proper hole “a” in the crankcase. 3. Install: • Spring guide “1” Slide the spring guide into the kick shaft, make sure the groove “a” in the spring guide fits on the stopper of the torsion spring.
  • Page 280 SHIFT SHAFT SHIFT SHAFT EAS2GC1287 Removing the shift shaft and stopper lever 10 Nm (1.0 m kgf, 7.2 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 30 Nm (3.0 m kgf, 22 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty...

  • Page 281: Shift Shaft

    SHIFT SHAFT REMOVING THE SHIFT GUIDE AND SHIFT EAS2GC1288 LEVER ASSEMBLY 1. Remove: • Bolt (shift guide) • Shift guide “1” • Shift lever assembly “2” Make sure that the shift lever assembly is re- moved together with the shift guide. CHECKING THE SHIFT GUIDE AND SHIFT EAS2GC1291 LEVER ASSEMBLY...

  • Page 282: Installing The Stopper Lever

    SHIFT SHAFT INSTALLING THE STOPPER LEVER INSTALLING THE SHIFT GUIDE AND SHIFT EAS2GC1293 EAS2GC1295 1. Install: LEVER ASSEMBLY • Torsion spring “1” 1. Install: • Collar “2” • Spring “1” • Stopper lever “3” • Pawl pin “2” • Bolt (stopper lever) “4” •...

  • Page 283: Installing The Shift Shaft

    SHIFT SHAFT 4. Tighten: • Shift guide bolt “1” Shift guide bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® EAS2GC1296 INSTALLING THE SHIFT SHAFT 1. Install: • Roller “1” • Shift haft spring “2” (to shift shaft) • Collar “3” (to shift shaft) •...
  • Page 284 OIL PUMP AND BALANCER GEAR OIL PUMP AND BALANCER GEAR EAS2GC1298 Removing the oil pump 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • Order Part name Q’ty Remarks Primary driven gear Refer to “CLUTCH”...

  • Page 285: Oil Pump And Balancer Gear

    OIL PUMP AND BALANCER GEAR Removing the balancer 45 Nm (4.5 m kgf, 33 ft Ibf) 100 Nm (10 m kgf, 72 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 50 Nm (5.0 m kgf, 36 ft Ibf) Order Part name Q’ty...

  • Page 286: Removing The Balancer

    OIL PUMP AND BALANCER GEAR REMOVING THE BALANCER EAS2GC1299 1. Loosen: • Balancer nut “1” • Primary drive gear nut “2” • Balancer weight gear nut “3” Place an aluminum plate “a” between the teeth of the balancer drive gear “4” and balancer weight gear “5”.

  • Page 287: Assembling The Oil Pump

    OIL PUMP AND BALANCER GEAR ASSEMBLING THE OIL PUMP EAS2GC1303 Inner-rotor-to-outer-rotor-tip 1. Install: clearance • Oil pump drive shaft “1” 0.000–0.150 mm (0.0000–0.0059 • Inner rotor “2” • Dowel pin “3” Limit 0.20 mm (0.0079 in) Outer-rotor-to-oil-pump-housing • Apply the engine oil on the oil pump drive clearance shaft and inner rotor.

  • Page 288: Installing The Oil Pump And Balancer Gear

    OIL PUMP AND BALANCER GEAR INSTALLING THE OIL PUMP AND BALANC- EAS2GC1304 ER GEAR 1. Install: • Oil pump assembly “1” • Oil pump assembly bolt “2” Oil pump assembly bolt 5 Nm (0.5 m·kgf, 3.6 ft·lbf) LOCTITE® ECA1DX1023 NOTICE After tightening the bolts, make sure that 4.
  • Page 289 OIL PUMP AND BALANCER GEAR 5. Bend the lock washer tab. 6-62...
  • Page 290 GENERATOR AND STARTER CLUTCH GENERATOR AND STARTER CLUTCH EAS2GC1305 Removing the generator Order Job/Parts to remove Q’ty Remarks Refer to “CHANGING THE ENGINE OIL” on Drain the engine oil. page 3-17. Refer to “GENERAL CHASSIS” on page 5-1 Seat and fuel tank and “FUEL TANK”...
  • Page 291 GENERATOR AND STARTER CLUTCH Removing the generator Order Job/Parts to remove Q’ty Remarks Starter clutch Starter clutch drive gear Crankshaft position sensor Stator For installation, reverse the removal proce- dure. 6-64...

  • Page 292: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH 3. Check: REMOVING THE GENERATOR EAS2GC1306 • Starter clutch gear 1. Remove: Damage/pitting/wear  Replace the starter • Generator rotor nut “1” clutch gear. • Washer 4. Check: • Damper assembly Damage/pitting/wear  Replace the damp- er assembly.

  • Page 293: Installing The Starter Clutch

    U-shaped space “g”of the gear inner circumference. holder. • Tighten the stator bolt using the T25 bit. • Apply the sealant to the grommet of the AC magneto lead. Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 6-66...

  • Page 294: Installing The Generator

    GENERATOR AND STARTER CLUTCH 3. Install: • Starter clutch “1” To generator rotor “2”. 3. Install: • Starter idle gear shaft “1” • Bearing “2” • Starter idle gear 2 “3” Starter clutch bolt 16 Nm (1.6 m·kgf, 12 ft·lbf) Apply the engine oil on the starter idle gear LOCTITE®...
  • Page 295 GENERATOR AND STARTER CLUTCH 5. Install: • Washer “1” • Damper assembly “2” • Washer “3” Apply the engine oil to the shaft and washers. 6. Install: • Cover (damper assembly) “1” • Bracket “2” • Bolt “3” Bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Install the cover (damper assembly) with its mark “a”...
  • Page 296 CRANKCASE CRANKCASE EAS2GC1310 Separating the crankcase 10 Nm (1.0 m kgf, 7.2 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty...

  • Page 297: Crankcase

    CRANKCASE Separating the crankcase 10 Nm (1.0 m kgf, 7.2 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty...
  • Page 298 CRANKCASE Removing the bearing and oil seal Order Part name Q’ty Remarks Transmission Refer to “TRANSMISSION” on page 6-77. Shift cam and shift fork Refer to “TRANSMISSION” on page 6-77. Circlip Oil seals Bearing For installation, reverse the removal proce- dure.

  • Page 299: Disassembling The Crankcase

    CRANKCASE DISASSEMBLING THE CRANKCASE EAS2GC1311 1. Separate: • Right crankcase • Left crankcase ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the crankcase bolts. c. Remove the dowel pins and O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ REMOVING THE CRANKCASE BEARING EAS2GC1312 1. Remove: • Bearing “1” • Remove the bearing from the crankcase by Loosen each bolt 1/4 of a turn at a time and af- pressing its inner race.

  • Page 300: Installing The Oil Seal

    CRANKCASE • Oil delivery passages Yamaha Bond No.1215 Obstruction  Blow out with compressed 90890-85505 air. (Three Bond No.1215®) INSTALLING THE OIL SEAL EAS2GC1315 1. Install: • Oil seal “1” (to left crankcase) Installed depth “a” 0.0–0.5 mm (0.00–0.02 in) 3.

  • Page 301: Crankshaft Assembly And Balancer Shaft

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EAS2GC1317 Removing the crankshaft assembly and balancer shaft Order Part name Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 6-69. Transmission Refer to “TRANSMISSION” on page 6-77. Balancer shaft Crankshaft assembly For installation, reverse the removal proce- dure.

  • Page 302: Removing The Balancer Shaft

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT REMOVING THE BALANCER SHAFT CHECKING THE CRANKSHAFT ASSEMBLY EAS2GC1318 EAS2GC1320 1. Remove: 1. Measure: • Balancer shaft “1” • Crankshaft runout Out of specification  Replace the crank- shaft, bearing or both. Remove the balancer shaft with its flat side “a” facing the crankshaft.

  • Page 303: Installing The Crankshaft Assembly

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT NOTICE • To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease. • In order to prevent the crankshaft seizure, apply molybdenum disulfide grease. Hold the connecting rod at top dead center 4.
  • Page 304 TRANSMISSION TRANSMISSION EAS2GC1322 Removing the transmission, shift drum assembly, and shift forks Order Part name Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 6-1. Separate. Crankcase Refer to “CRANKCASE” on page 6-69. Main axle Drive axle Long shift fork guide bar Short shift fork guide bar Spring Shift cam...

  • Page 305: Transmission

    TRANSMISSION REMOVING THE TRANSMISSION CHECKING THE SHIFT FORKS EAS2GC1323 EAS2GC1324 1. Remove: 1. Check: • Long shift fork guide bar “1” • Shift fork cam follower “1” • Short shift fork guide bar “2” • Shift fork pawl “2” Bends/damage/scoring/wear  Replace the •...

  • Page 306: Checking The Shift Drum Assembly

    TRANSMISSION CHECKING THE SHIFT DRUM ASSEMBLY EAS2GC1325 1. Check: • Shift drum groove Damage/scratches/wear  Replace the shift drum assembly. • Shift drum segment “1” Damage/wear  Replace the shift drum as- sembly. 3. Check: • Transmission gears Blue discoloration/pitting/wear  Replace the defective gear (s).
  • Page 307 TRANSMISSION 2. Install: • Collar “1” • 2nd wheel gear (26T) “2” • 4th wheel gear (21T) “3” • 3rd wheel gear (21T) “4” • 5th wheel gear (21T) “5” • Collar “6” • 1st wheel gear (29T) “7” • O-rings “8” (to the drive axle “9”) 4.
  • Page 308 TRANSMISSION 6. Install: 7. Install: • Shift fork 1 (L) “1” • Long shift fork guide bar “1” • Shift fork 2 (C) “2” • Short shift fork guide bar “2” • Shift fork 3 (R) “3” • Spring “3” •...

  • Page 309: Cooling System

    COOLING SYSTEM RADIATOR .......................7-1 HANDLING NOTE ..................7-3 CHECKING THE RADIATOR..............7-3 WATER PUMP....................7-4 REMOVING THE OIL SEAL...............7-5 CHECKING THE WATER PUMP ...............7-5 CHECKING THE BEARING ...............7-5 INSTALLING THE OIL SEAL ..............7-5 ASSEMBLING THE WATER PUMP............7-5...
  • Page 310 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 311 RADIATOR Removing the radiator 8 Nm (0.8 m kgf, 5.8 ft Ibf) Order Part name Q’ty Remarks Right radiator Radiator hose 2 Radiator hose 3 Radiator hose 4 Radiator pipe 2 Radiator breather hose Left radiator Radiator hose 1 Radiator pipe 1 Coolant temperature sensor For installation, reverse the removal proce- dure.
  • Page 312 RADIATOR HANDLING NOTE EAS2GC1330 WARNING If coolant seems hot, do not remove the ra- diator cap. CHECKING THE RADIATOR EAS2GC1331 1. Check: • Radiator fins “1” Obstructions  Clean. Apply compressed air to the rear of the radi- ator. Damage  Repair or replace. Correct any flattened fins with a thin, flat-head screwdriver.
  • Page 313 WATER PUMP WATER PUMP EAS2GC1332 Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-10. Drain.

  • Page 314: Water Pump

    WATER PUMP REMOVING THE OIL SEAL EAS2GC1333 • 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 315 WATER PUMP 2. Install: • Dowel pin “1” • Gasket “2” 3. Install: • Water pump housing “1” • Water pump housing bolt “2” Water pump housing bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Washer “3” • Coolant drain bolt “4” Coolant drain bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
  • Page 316 WATER PUMP...

  • Page 317: Fuel System

    FUEL SYSTEM FUEL TANK......................8-1 REMOVING THE FUEL TANK ..............8-3 REMOVING THE FUEL PUMP ..............8-3 CHECKING THE FUEL PUMP BODY............8-3 INSTALLING THE FUEL PUMP..............8-3 REMOVING THE FUEL SENDER..............8-4 CHECKING THE FUEL SENDER ..............8-4 INSTALLING THE FUEL SENDER ............8-4 INSTALLING THE FUEL TANK..............8-4 CHECKING THE FUEL PRESSURE ............8-5 CHECKING THE DAMPER ................8-5 CHECKING AND REPLACING THE PROTECTOR ........8-6...

  • Page 318: Fuel Tank

    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 319 FUEL TANK Removing the fuel tank 7 Nm (0.7 m kgf, 5.1 ft Ibf) 9 Nm (0.9 m kgf, 6.5 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) Order...

  • Page 320: Removing The Fuel Tank

    FUEL TANK REMOVING THE FUEL TANK EAS2GC1340 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose coupler WARNING Cover the fuel hose connection with a cloth when disconnecting it. This is because re- sidual pressure in the fuel hose could cause fuel to spurt out when the hose is removed.

  • Page 321: Removing The Fuel Sender

    FUEL TANK INSTALLING THE FUEL SENDER EAS2GC1346 1. Install: • Fuel sender gasket • Fuel sender Fuel sender bolts 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) • Do not damage the installation surfaces of the fuel tank when installing the fuel sender. REMOVING THE FUEL SENDER EAS2GC1344 •...

  • Page 322: Checking The Fuel Pressure

    FUEL TANK WARNING • Insert the fuel hose into the fuel pipe securely Cover the fuel hose connection with a cloth until you hear a “click”. when disconnecting it. This is because re- • Slide the fuel hose connector cover “1” at the sidual pressure in the fuel hose could cause hose end in the direction of the arrow.

  • Page 323: Checking And Replacing The Protector

    FUEL TANK 84 mm 115 mm (3.31 in) (4.53 in) 84 mm 115 mm (3.31 in) (4.53 in) CHECKING AND REPLACING THE PRO- EAS2GC1350 TECTOR 1. Check: • Protector “1” Wear/damage  Replace. Affix the protector as shown. 0 mm (0 in) 15 mm (0.59 in)

  • Page 324: Throttle Body

    THROTTLE BODY THROTTLE BODY EAS2GC1351 Removing the throttle body 7 Nm (0.7 m kgf, 5.1 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) Order Part name...
  • Page 325 THROTTLE BODY Removing the throttle body 7 Nm (0.7 m kgf, 5.1 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) Order Part name Q’ty...
  • Page 326 THROTTLE BODY Removing the injector 3.4 Nm (0.34 m kgf, 2.5 ft lbf) 5 Nm (0.5 m kgf, 3.6 ft lbf) 3.4 Nm (0.34 m kgf, 2.5 ft lbf) Order Part name Q’ty Remarks Fuel inlet pipe Injector Gaskets Throttle position sensor Intake air pressure sensor For installation, reverse the removal proce- dure.

  • Page 327: Checking The Injector

    THROTTLE BODY CHECKING THE INJECTOR EAS2GC1352 1. Check: • Injectors Obstruction  Replace, and check the fuel pump and the fuel injection system. Refer to “FUEL INJECTION SYSTEM” on page 9-28. Deposits  Replace. Damage  Replace. 2. Check: • Injector resistance Refer to “CHECKING THE FUEL INJEC- TOR”...

  • Page 328: Adjusting The Throttle Position Sensor

    Check that the throttle grip is fully closed. d. Connect the throttle position sensor to the wire harness. e. Set the Yamaha diagnostic tool to “diagnos- tic mode”. f. Choose the diagnostic code No. “01”. g. Adjust the throttle position sensor mounted angle until “11”–“14”...

  • Page 329: Electrical System

    SIGNALING SYSTEM ..................9-20 CIRCUIT DIAGRAM .................9-20 TROUBLESHOOTING ................9-22 COOLING SYSTEM..................9-24 CIRCUIT DIAGRAM .................9-24 TROUBLESHOOTING ................9-26 FUEL INJECTION SYSTEM................9-28 CIRCUIT DIAGRAM .................9-28 ECU SELF-DIAGNOSTIC FUNCTION.............9-30 TROUBLESHOOTING METHOD.............9-31 YAMAHA DIAGNOSTIC TOOL ..............9-32 TROUBLESHOOTING DETAILS .............9-35 FUEL PUMP SYSTEM..................9-56 CIRCUIT DIAGRAM .................9-56 TROUBLESHOOTING ................9-58...
  • Page 330 ELECTRICAL COMPONENTS...............9-60 CHECKING THE SWITCHES ..............9-64 CHECKING THE BULBS AND BULB SOCKETS ........9-67 CHECKING THE FUSES .................9-68 CHECKING AND CHARGING THE BATTERY........9-69 CHECKING THE RELAYS ...............9-72 CHECKING THE DIODE ................9-73 CHECKING THE IGNITION SPARK GAP..........9-73 CHECKING THE SPARK PLUG CAP ............9-73 CHECKING THE IGNITION COIL ............9-74 CHECKING THE CRANKSHAFT POSITION SENSOR......9-74 CHECKING THE LEAN ANGLE SENSOR..........9-75...
  • Page 331 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 332: Ignition System

    IGNITION SYSTEM IGNITION SYSTEM EAS2GC1358 EAS2GC1359 CIRCUIT DIAGRAM...
  • Page 333 IGNITION SYSTEM 1. Joint connector 2. Joint connector 4. AC magneto 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 22.ECU (engine control unit) 23.Ignition coil 24.Spark plug 30.Joint connector 35.Lean angle sensor 36.Engine stop switch 48.Frame ground 49.Ignition coil sub-lead 50.Negative battery lead...

  • Page 334: Troubleshooting

    IGNITION SYSTEM TROUBLESHOOTING EAS2GC1360 The ignition system fails to operate (no spark or intermittent spark). Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 5. Air filter case cover NG ...
  • Page 335 IGNITION SYSTEM NG  8. Check the lean angle sensor. Replace the lean angle sensor. Refer to “CHECKING THE LEAN ANGLE SENSOR” on page 9-75. OK  NG  9. Check the entire ignition system’s Properly connect or repair the ignition sys- wiring.

  • Page 336: Electric Starting System

    ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM EAS27160 EAS2GC1361 CIRCUIT DIAGRAM...
  • Page 337 ELECTRIC STARTING SYSTEM 1. Joint connector 2. Joint connector 3. Joint connector 7. Main relay 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 13.Starter motor 14.Starter relay diode 22.ECU (engine control unit) 30.Joint connector 36.Engine stop switch 37.Neutral switch 38.Diode 39.Starting circuit cut-off relay 40.Clutch switch 41.Start switch...

  • Page 338: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION EAS2GC1362 If the meter light comes on, the starter motor can only operate if at least one of the following condi- tions is met: • The transmission is in neutral (the neutral switch is closed). •...
  • Page 339 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main relay 4. Starting circuit cut-off relay 5. Start switch 6. Diode 7. Clutch switch 8.

  • Page 340: Troubleshooting

    ELECTRIC STARTING SYSTEM TROUBLESHOOTING EAS2GC1363 The starter motor fails to turn. Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 5. Air filter case cover NG  1. Check the fuse. Replace the fuse(s).
  • Page 341 ELECTRIC STARTING SYSTEM NG  8. Check the main relay. Replace the main relay. Refer to “CHECKING THE RE- LAYS” on page 9-72. OK  NG  9. Check the neutral switch. Replace the neutral switch. Refer to “CHECKING THE SWITCHES”...

  • Page 342: Charging System

    CHARGING SYSTEM CHARGING SYSTEM EAS27200 EAS2GC1364 CIRCUIT DIAGRAM 9-12...
  • Page 343 CHARGING SYSTEM 4. AC magneto 5. Rectifier/regulator 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 50.Negative battery lead 9-13...

  • Page 344: Troubleshooting

    CHARGING SYSTEM TROUBLESHOOTING EAS2GC1365 The battery is not being charged. Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 1. Check the fuse. NG Refer to “CHECKING THE FUSES” Replace the fuse(s). on page 9-68. OK NG ...
  • Page 345 CHARGING SYSTEM EAS27240 9-15...

  • Page 346: Lighting System

    LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM EAS2GC1366 9-16...
  • Page 347 LIGHTING SYSTEM 1. Joint connector 2. Joint connector 6. Headlight relay 7. Main relay 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 22.ECU (engine control unit) 30.Joint connector 42.Joint connector 43.Taillight 44.Headlight 47.Multi-function display 48.Frame ground 50.Negative battery lead 9-17...

  • Page 348: Troubleshooting

    LIGHTING SYSTEM TROUBLESHOOTING EAS2GC1367 Any of the following fail to light: headlight or meter light. Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left) 3. Air scoop (left/right) 4. Fuel tank NG  1. Check the each bulbs condition. Refer to “CHECKING THE BULBS Replace the bulb (s).
  • Page 349 LIGHTING SYSTEM EAS27270 9-19...

  • Page 350: Signaling System

    SIGNALING SYSTEM SIGNALING SYSTEM CIRCUIT DIAGRAM EAS2GC1368 9-20...
  • Page 351 SIGNALING SYSTEM 1. Joint connector 2. Joint connector 3. Joint connector 7. Main relay 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 15.Indicator light 17.Fuel level warning light 18.Resistor 19.Fuel sender 22.ECU (engine control unit) 30.Joint connector 42.Joint connector 46.Speed sensor 47.Multi-function display 48.Frame ground 50.Negative battery lead...

  • Page 352: Troubleshooting

    SIGNALING SYSTEM TROUBLESHOOTING EAS2GC1369 • The speedometer does not operate normally. • The fuel indicator light does not come on. Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank NG ...
  • Page 353 SIGNALING SYSTEM The fuel level warning light fails to come on. NG  1. Check the fuel sender. Replace the fuel sender assembly. Refer to “CHECKING THE FUEL SENDER” on page 9-77. OK  NG  2. Check the resistor. Replace the resistor.

  • Page 354: Cooling System

    COOLING SYSTEM COOLING SYSTEM EAS2GC1370 EAS2GC1371 CIRCUIT DIAGRAM 9-24...
  • Page 355 COOLING SYSTEM 1. Joint connector 2. Joint connector 3. Joint connector 7. Main relay 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 22.ECU (engine control unit) 27.Radiator fan motor relay 28.Radiator fan motor fuse 29.Radiator fan motor 30.Joint connector 32.Coolant temperature sensor 48.Frame ground 50.Negative battery lead 9-25...

  • Page 356: Troubleshooting

    COOLING SYSTEM TROUBLESHOOTING EAS2GC1372 The radiator fan motor fails to turn. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left) 3. Air scoop (left/right) 4. Fuel tank NG  1. Check the fuse. Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 9-68.
  • Page 357 COOLING SYSTEM EAS2GC1373 9-27...

  • Page 358: Fuel Injection System

    FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM CIRCUIT DIAGRAM EAS2GC1374 9-28...
  • Page 359 FUEL INJECTION SYSTEM 1. Joint connector 2. Joint connector 3. Joint connector 4. AC magneto 7. Main relay 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 15.Indicator light 16.Engine trouble warning light 22.ECU (engine control unit) 25.Injector 30.Joint connector 31.Intake air temperature sensor 32.Coolant temperature sensor 33.Throttle position sensor 34.Intake air pressure sensor...

  • Page 360: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM ECU SELF-DIAGNOSTIC FUNCTION EAS2GC1375 The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 361: Troubleshooting Method

    • Fault code number ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the Yamaha diagnostic tool. Refer to “YAMAHA DIAGNOSTIC TOOL” on page 9-32. b. Check the fault code number displayed on the Yamaha diagnostic tool. c. Identify the faulty system with the fault code number.

  • Page 362: Yamaha Diagnostic Tool

    FUEL INJECTION SYSTEM YAMAHA DIAGNOSTIC TOOL EAS2GC1377 This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool 90890-03231...
  • Page 363 NOTICE In order to avoid short circuit, insulate the battery connection terminals of the FI diagnostic tool sub-lead. For information on how to connect and use the Yamaha diagnostic tool, refer to “YAMAHA DIGNO- STIC TOOL OPERATION MANUAL”. 1. Vehicle 2.
  • Page 364 FUEL INJECTION SYSTEM Operation of the Yamaha diagnostic tool (Malfunction mode) Malfunction results are displayed in the top part of the window area. 1. Recovered The item list of the malfunction detected in the past (already recovered) are displayed. 2. Detected The item list of the malfunction currently occurred are displayed.

  • Page 365: Troubleshooting Details

    FUEL INJECTION SYSTEM 6. Condition The current conditions are displayed. (Detected/Recovered) 7. Symptom The symptoms of the detected malfunction are displayed. 8. Diagnosis code The diagnosis codes related to the detected malfunction are displayed. 9. FFD (only for models that can display freeze frame data) The mark “...
  • Page 366 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received Item from the crankshaft position sensor. Improperly connected  Connection of wire harness Crank the engine. ECU coupler. Connect the coupler securely Fault code number is not dis- played ...
  • Page 367 FUEL INJECTION SYSTEM • If fault code Nos. 13 and 14 are both displayed, perform the checks and maintenance jobs for fault code No. 13 first. • Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Item Intake air pressure sensor: open or short circuit detected.
  • Page 368 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Defective intake air pressure Execute the diagnostic mode. Push the start switch. sensor. (Code No. 03) Fault code number is not dis- played  Service is finished. When engine is stopped: Atmospheric pressure at the Fault code number is dis-...
  • Page 369 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged Item or detached hose). Defective intake air pressure Execute the diagnostic mode. sensor. (Code No. 03) When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is indicated.
  • Page 370 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Improperly connected  Connection of wire harness Push the start switch. ECU coupler. Connect the coupler securely Fault code number is not dis- played  Service is finished. Check the locking condition or repair/replace the wire har- of the coupler.
  • Page 371 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Malfunction in ECU. Replace the ECU. Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Throttle position sensor: stuck throttle position sensor is de- Item tected.
  • Page 372 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the coolant temperature. Procedure Compare the actually measured coolant temperature with the Yamaha diagnostic tool display value. Probable cause of malfunc- Confirmation of service Item Maintenance job tion and check completion Improperly connected ...
  • Page 373 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air temperature. Procedure Compare the actually measured intake air temperature with the Yamaha diagnostic tool display value. Probable cause of malfunc- Confirmation of service Item Maintenance job tion and check completion Improperly connected ...
  • Page 374 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Open or short circuit  Re- Wire harness continuity. Push the start switch. place the wire harness. Fault code number is not dis- played  Service is finished. Between intake air tempera- ture sensor coupler and ECU Fault code number is dis-...
  • Page 375 Actuation Actuates the ignition coil five times at one-second intervals. The engine trouble warning light and the “WARNING” on the Yamaha diagnostic tool screen come on each time the ignition coil is actuated. Procedure Check that a spark is generated five times.
  • Page 376 FUEL INJECTION SYSTEM Fault code No. Ignition coil: open or short circuit detected in the primary lead Item of the ignition coil. Improperly connected  Connection of sub wire har- Start the engine and let it idle ness coupler.Check the lock- Connect the coupler secure- for approximately 5 seconds.
  • Page 377 Actuation Actuates injector five times at one-second intervals. The engine trouble warning light and the “WARNING” on the Yamaha diagnostic tool screen come on each time the injector is actuated. Procedure Check that injector is actuated five times by listening for the oper- ating sound.
  • Page 378 FUEL INJECTION SYSTEM Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Item Lean angle sensor: open or short circuit detected. Fail-safe system Unable to start engine Able to drive vehicle Diagnostic code No. Diagnostic tool display Lean angle sensor output voltage •...
  • Page 379 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel in- Item jector and fuel pump. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. Diagnostic tool display Fuel system voltage Approximately 12.0 (V) Procedure Disconnect the main relay, and push the start switch or push down...
  • Page 380 FUEL INJECTION SYSTEM Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. EEPROM fault code number: an error is detected while read- Item ing or writing on EEPROM. Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No.
  • Page 381 FUEL INJECTION SYSTEM Fault code No. Item Charging voltage is abnormal. Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No. — Diagnostic tool display — Procedure — Probable cause of malfunc- Confirmation of service Item Maintenance job tion and check completion Improperly connected ...
  • Page 382 Confirmation of service Item Maintenance job tion and check completion Improperly connected  Connection of Yamaha diag- Push the start switch. nostic tool coupler. Connect the coupler securely Fault code number is not dis- played  Service is finished. Check the locking condition or repair/replace the wire har- of the coupler.
  • Page 383 Fault code number is not dis- played  Service is finished. light green–light green Fault code number is dis- played  Go to item 4. Yamaha diagnostic tool mal- Replace the Yamaha diag- Push the start switch. function. nostic tool.
  • Page 384 FUEL INJECTION SYSTEM Fault code No. Er-2 Signals from the ECU cannot be received within the specified Item period of time. Yamaha diagnostic tool mal- Replace the Yamaha diag- Push the start switch. function. nostic tool. Fault code number is not dis- played ...
  • Page 385 FUEL INJECTION SYSTEM Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Er-4 Registered data cannot be received from the Yamaha diagnos- Item tic tool. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No.

  • Page 386: Fuel Pump System

    FUEL PUMP SYSTEM FUEL PUMP SYSTEM EAS2GC1379 EAS2GC1380 CIRCUIT DIAGRAM 9-56...
  • Page 387 FUEL PUMP SYSTEM 1. Joint connector 2. Joint connector 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 22.ECU (engine control unit) 26.Fuel pump 30.Joint connector 36.Engine stop switch 48.Frame ground 50.Negative battery lead 9-57...

  • Page 388: Troubleshooting

    FUEL PUMP SYSTEM TROUBLESHOOTING EAS2GC1381 The fuel pump fails to operate. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank NG  1. Check the fuse. Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 9-68.
  • Page 389 FUEL PUMP SYSTEM EAS2GC1382 9-59...

  • Page 390: Electrical Components

    ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS EAS2GC1383 9-60...
  • Page 391 ELECTRICAL COMPONENTS 1. Rectifier/regulator 2. Clutch switch 3. Ignition coil 4. ECU (engine control unit) 5. Fuel sender 6. Fuel pump 7. Battery 8. Resistor 9. Neutral switch 10.Radiator fan motor 11.Injector 9-61...
  • Page 392 ELECTRICAL COMPONENTS 9-62...
  • Page 393 ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. Intake air pressure sensor 3. Throttle position sensor 4. Starter relay 5. Main fuse 6. Headlight relay 7. Starting circuit cut-off relay 8. Lean angle sensor 9. Radiator fan motor fuse 10.Radiator fan motor relay 11.Main relay 12.Coolant temperature sensor 9-63...

  • Page 394: Checking The Switches

    ELECTRICAL COMPONENTS CHECKING THE SWITCHES EAS2GC1384 9-64...
  • Page 395 ELECTRICAL COMPONENTS 1. Engine stop switch 2. Neutral switch 3. Clutch switch 4. Start switch 9-65...
  • Page 396 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. NOTICE Never insert the tester probes into the coupler terminal slots “1”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

  • Page 397: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS CHECKING THE BULBS AND BULB SOCK- EAS27990 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. Do not check any of the lights that use LEDs. Check each bulb and bulb socket for damage NOTICE or wear, proper connections, and also for con-...

  • Page 398: Checking The Fuses

    ELECTRICAL COMPONENTS Checking the condition of the bulb sockets The following procedure applies to all of the bulb sockets. 1. Check: • Bulb socket (for continuity) (with the pocket tester) No continuity  Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 399: Checking And Charging The Battery

    ELECTRICAL COMPONENTS 4. Install: • Seat Since VRLA (Valve Regulated Lead Acid) bat- • Side cover (left/right) teries are sealed, it is not possible to check the Refer to “GENERAL CHASSIS” on page 5- charge state of the battery by measuring the specific gravity of the electrolyte.
  • Page 400 ELECTRICAL COMPONENTS • When charging a battery, be sure to re- Example move it from the vehicle. (If charging has Open-circuit voltage = 12.0 V to be done with the battery mounted on the Charging time = 6.5 hours vehicle, disconnect the negative battery Charge of the battery = 20–30% lead from the battery terminal.) •...
  • Page 401 ELECTRICAL COMPONENTS b. Connect a charger and ammeter to the bat- tery and start charging. If the current is lower than the standard charg- ing current written on the battery, this type of Set the charging voltage to 16–17 V. If the set- battery charger cannot charge the VRLA (Valve ting is lower, charging will be insufficient.

  • Page 402: Checking The Relays

    ELECTRICAL COMPONENTS Starting circuit cut-off relay CHECKING THE RELAYS EAS2GC1387 Check each switch for continuity with the pock- et tester. If the continuity reading is incorrect, replace the relay. Pocket tester 90890-03112 Analog pocket tester YU-03112-C 1. Disconnect the relay from the wire harness. 2.

  • Page 403: Checking The Diode

    ELECTRICAL COMPONENTS CHECKING THE IGNITION SPARK GAP EAS2GC1389 Result 1. Check: Continuity • Ignition spark gap (between “3” to “4”) Out of specification  Perform the ignition system troubleshooting, starting with step 4. EAS2GC1388 CHECKING THE DIODE Refer to “TROUBLESHOOTING” on page 9- 1.

  • Page 404: Checking The Ignition Coil

    ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (  1k) to the spark plug cap. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. Measure the primary coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Check: • Secondary coil resistance Out of specification  Replace. Secondary coil resistance 8.64–12.96 k...

  • Page 405: Checking The Lean Angle Sensor

    ELECTRICAL COMPONENTS Crankshaft position sensor resis- Pocket tester tance 90890-03112 228–342  Analog pocket tester YU-03112-C Test harness– lean angle sensor ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (  100) to the (6P) 90890-03209 crankshaft position sensor coupler. Test harness– lean angle sensor Pocket tester (6P) 90890-03112...

  • Page 406: Checking The Stator Coil

    ELECTRICAL COMPONENTS b. Check the starter motor operation. b. Measure the stator coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE RECTIFIER/REGULATOR CHECKING THE STATOR COIL EAS2GC1395 EAS28150 1. Check: 1. Disconnect: • Charging voltage • Stator coil coupler Out of specification  Replace the rectifier/ (from the wire harness) regulator.

  • Page 407: Checking The Speed Sensor

    ELECTRICAL COMPONENTS 4. Check: CHECKING THE SPEED SENSOR EAS2GC1396 • Fuel sender resistance 1. Check: Out of specification  Replace the fuel • Speed sensor output voltage Out of specification  Replace. sender. Fuel sender resistance Output voltage reading cycle 1.35–1.90 k...

  • Page 408: Checking The Radiator Fan Motor

    ELECTRICAL COMPONENTS 2. Check: • Positive tester probe  • Coolant temperature sensor resistance Black “1” Out of specification  Replace. • Negative tester probe  Black “2” Coolant temperature sensor re- sistance 2512–2777  at 20 °C (2512– 2777  at 68 °F) 210–220 ...

  • Page 409: Checking The Throttle Position Sensor

    ELECTRICAL COMPONENTS • Positive tester probe  Blue “1” • Negative tester probe  Black/Blue “2” b. Check the throttle position sensor maximum resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • Throttle position sensor When mounting the throttle position sensor, ad- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ just its angle properly. Refer to “ADJUSTING EAS2GC1401 CHECKING THE THROTTLE POSITION THE THROTTLE POSITION SENSOR”...

  • Page 410: Checking The Intake Air Pressure Sensor

    ELECTRICAL COMPONENTS • Positive tester probe  Blue “1” • Negative tester probe  Black/Blue “2” b. Start the engine. c. Measure the intake air pressure sensor out- put voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE INTAKE AIR TEMPERA- EAS2GC1404 c. Start the engine. TURE SENSOR d.

  • Page 411: Checking The Fuel Injector

    ELECTRICAL COMPONENTS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS2GC1405 CHECKING THE FUEL INJECTOR 1. Remove: • Fuel injector Refer to “THROTTLE BODY” on page 8-7. 2. Check: • Fuel injector resistance Out of specification  Replace. Resistance 12  ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the fuel injector coupler from the fuel injector.
  • Page 412 ELECTRICAL COMPONENTS 9-82...

  • Page 413: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING..................10-1 GENERAL INFORMATION ..............10-1 STARTING FAILURES................10-1 INCORRECT ENGINE IDLING SPEED ...........10-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......10-2 SHIFTING IS DIFFICULT .................10-2 SHIFT PEDAL DOES NOT MOVE ............10-2 JUMPS OUT OF GEAR................10-2 CLUTCH SLIPS..................10-2 CLUTCH DRAGS ..................10-2 OVERHEATING ..................10-2 OVERCOOLING..................10-3 POOR BRAKING PERFORMANCE............10-3 FRONT FORK OIL LEAKING..............10-3 FAULTY FRONT FORK LEGS..............10-3 UNSTABLE HANDLING ................10-3...

  • Page 414: Troubleshooting

    TROUBLESHOOTING Electrical system TROUBLESHOOTING EAS2GC1406 1. Battery • Discharged battery EAS2GC1407 GENERAL INFORMATION • Faulty battery 2. Fuse The following guide for troubleshooting does • Blown, damaged or incorrect fuse not cover all the possible causes of trouble. It • Improperly installed fuse should be helpful, however, as a guide to basic 3.

  • Page 415: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING Electrical system JUMPS OUT OF GEAR 1. Battery Engine • Discharged battery 1. Shift shaft • Faulty battery • Incorrect shift pedal position 2. Spark plug • Improperly returned stopper lever • Incorrect spark plug gap 2. Shift forks •...

  • Page 416: Overcooling

    TROUBLESHOOTING Cooling system FRONT FORK OIL LEAKING EAS2GC1419 1. Coolant • Low coolant level Chassis 2. Radiator 1. Front fork • Damaged or leaking radiator • Bent, damaged, or rusty inner tube • Faulty radiator cap • Cracked or damaged outer tube •...

  • Page 417: Headlight Does Not Come On

    TROUBLESHOOTING 7. Wheel (s) • Incorrect wheel balance • Broken or loose spoke • Damaged wheel bearing • Bent or loose wheel axle • Excessive wheel runout 8. Frame • Bent frame • Damaged steering head pipe • Improperly installed bearing race HEADLIGHT DOES NOT COME ON EAS2GC1422 Electrical system...
  • Page 418 9-52 nection Er-2 Signals from the ECU cannot be received within the specified period 9-53 of time. Er-3 Data from the ECU cannot be received correctly. 9-54 Er-4 Registered data cannot be received from the Yamaha diagnostic tool. 9-55 10-5...

  • Page 419: List Of Self-Diagnostic And Fail-Safe Actions

    Intake air temperature Displays the intake air tem- Compare the actually mea- perature. sured intake air tempera- ture with the Yamaha diagnostic tool display val- Coolant temperature When engine is cold: Dis- Compare the actually mea- plays temperature closer to sured coolant temperature air temperature.
  • Page 420 LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS Diag- nostic Item Display Procedure code Malfunction history ( Replace all ( ) with ( code No. erasure *1 by the operation start pro- • There is no history. • 00 cessing. • There is some history. •...
  • Page 421 Actuates the ignition coil five Check that a spark is gener- times at one-second inter- ated five times. vals. • Connect an ignition “WARNING” on the Yamaha checker. diagnostic tool blinks five times when the ignition coil is actuated. Injector...
  • Page 422 COLOR CODE WIRING DIAGRAM EAS2GC1427 Black WR450F/WR450FG 2016 1. Joint connector Brown 2. Joint connector Chocolate 3. Joint connector Dark green 4. AC magneto 5. Rectifier/regulator Green 6. Headlight relay Gray 7. Main relay Blue 8. Engine ground 9. Battery Light green 10.
  • Page 424 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN...
  • Page 425 WR450F/WR450FG 2016 WR450F/WR450FG 2016 SCHÉMA DE CÂBLAGE WIRING DIAGRAM B B B R R R Br Br Br B B B R R R/L Br Br B B B B B B R R R R R R/L Br Br Br Br Br...
  • Page 426 WR450F/WR450FG 2016 WR450F/WR450FG 2016 SCHÉMA DE CÂBLAGE WIRING DIAGRAM (Gy) (Gy) (Gy)

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