Yamaha YZ250F 2016 Owner's Service Manual

Table of Contents

Quick Links

Download this 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.

q Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.

OWNER'S SERVICE MANUAL

MANUEL D'ATELIER DU

PROPRIETAIRE

FAHRER- UND

WARTUNGSHANDBUCH

YZ250F

YZ250FG

1SM-28199-80

Table of Contents

Chapters

Table of Contents

Troubleshooting

Need help?

Do you have a question about the YZ250F 2016 and is the answer not in the manual?

Questions and answers

Summary of Contents for Yamaha YZ250F 2016

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. q Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen. OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE FAHRER- UND...
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. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
Page 3 2016 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 YZ250F YZ250F YZ250FG YZ250FG 1SM-28199-80-E0 1SM-28199-80-E0...
Page 5 EAS1SM9002 YZ250F YZ250FG OWNER’S SERVICE MANUAL ©2015 by Yamaha Motor Co., Ltd. First edition, April 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 EAS1SM9003 Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.
Page 7: Safety Information
SAFETY INFORMATION EAS1SM9005 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 EAS1SM9006 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 EAS1SM9007 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 CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING TUNING...
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 INCLUDED PARTS ..................1-6 SIDESTAND ....................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 ................1-8 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-8 REPLACEMENT PARTS................1-8...
Page 14 STARTING AND BREAK-IN ................1-20 FUEL ......................1-20 STARTING A COLD ENGINE ..............1-20 STARTING A WARM ENGINE..............1-21 BREAK-IN PROCEDURES ..............1-21 MAINTENANCE AFTER BREAK-IN ..............1-22 MAJOR MAINTENANCE................1-22 TORQUE-CHECK POINTS ................1-23 CLEANING AND STORAGE................1-25 CLEANING ....................1-25 STORAGE ....................1-25...
Page 15: Location Of Important Labels
LOCATION OF IMPORTANT LABELS LOCATION OF IMPORTANT LABELS EAS1SM9008 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 EAS1SM9009 16 15 14 1. Clutch lever 10. Coolant drain bolt 2. Front brake lever 11. Rear brake pedal 3. Throttle grip 12. Air filter 4. Radiator cap 13. Drive chain 5. Fuel tank cap 14. Shift pedal 6.
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 HANDLEBAR PROTECTOR EAS1SM9013 EAS1SM9017 Install the handlebar protector “1” with the mark EAS1SM9014 SIDESTAND “a” facing forward. The sidestand “1” is used to support only the machine when standing or transporting it. EWA@ WARNING • Never apply additional force to the sides- tand.
Page 21 INCLUDED PARTS Part name Part number GYTR Power Tuner 33D-H59C0-V0-00 (For USA) YZ Power Tuner 33D-859C0-10 (Except for USA) The Power Tuner is an optional part.
Page 22: 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 23: Gaskets, Oil Seals And O-Rings
IMPORTANT INFORMATION GASKETS, OIL SEALS AND O-RINGS EAS1SM9022 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 24: Basic Service Information
BASIC SERVICE INFORMATION BASIC SERVICE INFORMATION EAS1SM9026 EAS1SM9027 ELECTRICAL SYSTEM Electrical parts handling ECA16620 NOTICE Handle electrical components with special care, and do not subject them to strong shocks. ECA16640 NOTICE For waterproof couplers, never insert the tester probes directly into the coupler. When performing any checks using a water- proof coupler, use the specified test har- ness or a suitable commercially available...
Page 25 BASIC SERVICE INFORMATION ECA16790 NOTICE When disconnecting a connector, do not pull the leads. Hold both sections of the connector, and then disconnect the con- nector. 4. Connect: • Lead • Coupler • Connector • When connecting a coupler or a connector, 2.
Page 26 BASIC SERVICE INFORMATION 5. Check: • No continuity Pocket tester 90890-03112 Analog pocket tester YU-03112-C • If there is no continuity, clean the terminals. • When checking the wire harness, perform steps (1) to (4). • As a quick remedy, use a contact revitalizer available at most part stores.
Page 27: Special Tools
SPECIAL TOOLS SPECIAL TOOLS EAS1SM9028 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 90890-03207 voltage. YU-03207 FI diagnostic tool sub-lead This tool is used to connect 90890-03212 the Yamaha diagnostic tool YU-03212 to a battery. Yamaha diagnostic tool This tool is used to check er- 90890-03231 ror codes or carry out self-di- Yamaha diagnostic tool (US) agnosis.
Page 30 SPECIAL TOOLS Tool name/Part number How to use Illustration Spacer (crankshaft installer) This tool is used to install the 90890-04081 crankshaft. Pot spacer YM-91044 YM-91044 Clutch holder This tool is used to hold the 90890-04086 clutch when removing or in- YM-91042 stalling the clutch boss secur- ing nut.
Page 31 SPECIAL TOOLS Tool name/Part number How to use Illustration Valve guide remover (ø4.5) This tool is used to replace 90890-04116 the valve guide. Valve guide remover (4.5 YM-04116 Valve guide installer (ø4.5) This tool is used to replace 90890-04117 the valve guide. Valve guide installer (4.5 YM-04117 Valve guide reamer (ø4.5)
Page 32: Control Functions
CONTROL FUNCTIONS CONTROL FUNCTIONS KICKSTARTER LEVER EAS1SM9029 EAS1SM9033 The kickstarter lever “1” is in the right of the EAS1SM9030 ENGINE STOP SWITCH chassis. The engine stop switch “1” is located on the left To start the engine, pull out and push down the handlebar.
Page 33: Rear Brake Pedal
CONTROL FUNCTIONS REAR BRAKE PEDAL EAS1SM9036 The rear brake pedal “1” is in the right of the chassis. Press down on the brake pedal to ac- tivate the rear brake. STARTER KNOB/IDLE ADJUSTING SCREW EAS1SM9037 Starting a cold engine requires a larger amount of intake air, which is supplied by the starter knob/idle screw “1”.
Page 34: Starting And Break-In
Do not open the throttle at the moment when you kick the kickstarter lever, be- Your Yamaha engine has been designed to use cause this may kick back premium unleaded gasoline with a pump oc-...
Page 35: Starting A Warm Engine
STARTING AND BREAK-IN 7. To stop the engine, push the engine stop NOTICE switch “1”. After a break-in or after each race, always check the points shown in “TORQUE- Continue pushing the engine stop switch till the CHECK POINTS” for tightening torques and engine comes to a full stop.
Page 36: Maintenance After Break-In
MAINTENANCE AFTER BREAK-IN • Cable MAINTENANCE AFTER BREAK-IN EAS1SM9044 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 37: Torque-Check Points
TORQUE-CHECK POINTS TORQUE-CHECK POINTS EAS1SM9046 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 38 TORQUE-CHECK POINTS Plastic cover Tightening of number plate 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 cover Concerning the tightening torque, refer to “TIGHTENING TORQUES”...
Page 39: Cleaning And Storage
CLEANING AND STORAGE 3. Remove the drive chain, clean it thoroughly CLEANING AND STORAGE EAS1SM9047 with solvent, and lubricate it Reinstall the drive chain or store it in a plastic bag tied to EAS1SM9048 CLEANING the frame. Frequent cleaning of your vehicle will enhance 4.
Page 40 CLEANING AND STORAGE 1-26...
Page 41: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS .................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-10 TIGHTENING TORQUES ................2-11 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-11 ENGINE TIGHTENING TORQUES............2-12 CHASSIS TIGHTENING TORQUES............2-15 LUBRICATION POINTS AND LUBRICANT TYPES ........2-18 ENGINE....................2-18 CHASSIS....................2-20 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-23 LUBRICATION DIAGRAMS ..............2-23 CABLE ROUTING DIAGRAM ................2-31...
Page 42: General Specifications
GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS EAS1SM9050 Model Model 1SM9, 1SMD (USA) (CAN) 1SMA, 1SMF (EUR) 1SMB, 1SMG (JPN) 1SMC, 1SMH (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...
Page 43: Engine Specifications
ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS EAS1SM9051 Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 250 cm Cylinder arrangement Single cylinder Bore  stroke 77.0  53.6 mm (3.0  2.1 in) Compression ratio 13.5:1 Starting system Kickstarter Fuel Recommended fuel Premium unleaded gasoline only Fuel tank capacity 7.5 L (1.98 US gal, 1.65 Imp.gal) Engine oil...
Page 44 ENGINE SPECIFICATIONS Cylinder head Combustion chamber volume 12.07–12.87 cm (0.74–0.79 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 45 ENGINE SPECIFICATIONS Valve spring Free length (intake) 36.69 mm (1.44 in) Limit 34.85 mm (1.37 in) Free length (exhaust) 34.86 mm (1.37 in) Limit 33.11 mm (1.30 in) Installed length (intake) 31.40 mm (1.24 in) Installed length (exhaust) 28.50 mm (1.12 in) Spring rate K1 (intake) 29.65 N/mm (2.99 kgf/mm, 169.30 lbf/in) Spring rate K2 (intake)
Page 46 ENGINE SPECIFICATIONS Balancer Balancer drive method Gear Clutch Clutch type Wet, multiple-disc Clutch release method Inner push, cam push Clutch lever free play 7.0–12.0 mm (0.28–0.47 in) Friction plate thickness 2.90–3.10 mm (0.114–0.122 in) Wear limit 2.85 mm (0.112 in) Plate quantity 9 pcs Clutch plate thickness...
Page 47 ENGINE SPECIFICATIONS Throttle body Type/quantity 30RA-A71S/1 ID mark 1SM5 10 Fuel line pressure at idling 324.0 kPa (3.24 kgf/cm , 47.0 psi) Throttle position sensor Resistance 6.30 k Output voltage (at idle) 0.5 V Fuel injection sensor 228–342  Crankshaft position sensor resistance Intake air pressure sensor output voltage 3.57–3.71 V at 101.3 kPa 290–390 ...
Page 48: Chassis Specifications
CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS EAS1SM9052 Chassis Frame type Semi double cradle Caster angle 27.10 ° Trail 118 mm (4.6 in) Front wheel Wheel type Spoke wheel 21  1.60 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 49 CHASSIS SPECIFICATIONS Brake pad lining thickness (outer) 4.4 mm (0.17 in) Limit 1.0 mm (0.04 in) Master cylinder inside diameter 9.52 mm (0.37 in) 22.65 mm  2 (0.89 in  2) Caliper cylinder inside diameter Specified brake fluid DOT 4 Rear brake Type Single disc brake...
Page 50 CHASSIS SPECIFICATIONS Compression damping adjusting positions Minimum 20 clicks out* Standard 10 clicks out* (USA) (CAN) 6 clicks out* (EUR) (JPN) (AUS) (NZL) (ZAF) Maximum Fully turned in *With the adjuster fully turned in Rear suspension Type Swingarm (link suspension) Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel...
Page 51: Electrical Specifications
Advancer type Digital Ignition timing (B.T.D.C.) 10.0 ° at 2000 r/min Engine control unit Model/manufacturer 1SM7/YAMAHA (USA) (CAN) 1SM8/YAMAHA (EUR) (JPN) (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 52: Tightening Torques
TIGHTENING TORQUES TIGHTENING TORQUES EAS20320 EAS1SM9054 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 53: Engine Tightening Torques
TIGHTENING TORQUES ENGINE TIGHTENING TORQUES EAS1SM9055 - 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 54 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Air filter case cap screw 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) Starter knob/Idle screw 2.1 Nm (0.21 m·kgf, 1.5 ft·lbf) Throttle cable nut (pull) 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Throttle cable nut (return) 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Clutch cable adjuster and locknut 4.3 Nm (0.43 m·kgf, 3.1 ft·lbf)
Page 55 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Use a Drive sprocket nut 75 Nm (7.5 m·kgf, 54 ft·lbf) lock washer. Segment 30 Nm (3.0 m·kgf, 22 ft·lbf) Shift guide bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Stopper lever bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Shift pedal bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Page 56: Chassis Tightening Torques
TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES EAS1SM9056 - 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 57 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) Rear brake pedal bolt 26 Nm (2.6 m·kgf, 19 ft·lbf) Rear brake pedal position locknut 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Page 58 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 59: Lubrication Points And Lubricant Types
LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES EAS1SM9057 EAS1SM9058 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 60 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Shift lever assembly moving parts Three bond Cylinder head cover gasket No.1215® Three bond Crankcase mating surface No.1215® Three bond Stator assembly lead grommet No.1215® 2-19...
Page 61: Chassis
LUBRICATION POINTS AND LUBRICANT TYPES CHASSIS EAS1SM9059 Lubrication point Lubricant types Upper bearings (steering head) Upper bearings and bearing race cover (steering head) Lower bearings and oil seal lip (steering head) Steering stem threads and nut contacting surface Pivot shaft bearing Swingarm pivot portion (collar side surface and thrust bearing) Swingarm pivot portion (collar outer surface) Swingarm pivot portion (oil seal lip)
Page 62 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Rear brake caliper dust seal Rear brake caliper piston outer surface Rear brake caliper pin bolt and boot Rear brake master cylinder push rod end Rear brake master cylinder kit 2-21...
Page 63 LUBRICATION POINTS AND LUBRICANT TYPES 2-22...
Page 64: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION SYSTEM CHART AND DIAGRAMS EAS1SM9060 EAS1SM9061 LUBRICATION DIAGRAMS 2-23...
Page 65 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 2-24...
Page 66 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25...
Page 67 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Connecting rod 2. Crankshaft 3. Main axle 4. Oil strainer 5. Drive axle 2-26...
Page 68 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
Page 69 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Exhaust camshaft 2. Intake camshaft 3. Oil filter element 4. Oil pump 2-28...
Page 70 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
Page 71 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil pressure check bolt 3. Oil filter element 4. Oil pump 2-30...
Page 72: Cable Routing Diagram
CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM EAS1SM9062 2-31...
Page 73 CABLE ROUTING DIAGRAM R. Pass the rectifier/regulator lead to the inside of 1. Clutch cable the tension arm (the side of the vehicle). 2. Throttle cable (pull) S. Pass the main harness to the front of the radiator 3. Throttle cable (return) hose (the front of the vehicle), and to the inside of 4.
Page 74 CABLE ROUTING DIAGRAM 2-33...
Page 75 CABLE ROUTING DIAGRAM S. Insert the projection on the plastic locking tie into 1. Bracket the hole in the rear frame. 2. Condenser T. Clamp the painted part on the fuel hose by the 3. Coolant temperature sensor plastic clamp. Make the lock on the plastic clamp 4.
Page 76 CABLE ROUTING DIAGRAM 2-35...
Page 77 CABLE ROUTING DIAGRAM 1. Throttle cable 2. Clutch cable 3. Engine stop switch lead 4. Cable guide 5. Head pipe 6. Front brake hose 7. Brake hose guide 8. Number plate A. Number plate band B. Pass the clutch cable to the rear of the number plate band.
Page 78 CABLE ROUTING DIAGRAM 2-37...
Page 79 CABLE ROUTING DIAGRAM 1. Main harness 2. Radiator 3. Throttle position sensor lead 4. Joint coupler 5. Intake air temperature sensor lead 6. Intake air pressure sensor lead 7. Frame 8. Fuel hose 9. High tension cord 10. Spark plug cap 11.
Page 80 CABLE ROUTING DIAGRAM 2-39...
Page 81 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 82 CABLE ROUTING DIAGRAM 2-41...
Page 83 PERIODIC CHECKS AND ADJUSTMENTS MAINTENANCE INTERVALS ................3-1 MAINTENANCE INTERVALS ..............3-1 PRE-OPERATION INSPECTION AND MAINTENANCE.........3-7 GENERAL INSPECTION AND MAINTENANCE........3-7 ENGINE ......................3-8 CHECKING THE COOLANT LEVEL............3-8 CHECKING THE COOLING SYSTEM ............3-8 CHANGING THE COOLANT..............3-8 CHECKING THE RADIATOR CAP ............3-9 CHECKING THE RADIATOR CAP VALVE OPENING PRESSURE ..3-9 CHECKING THE COOLANT CIRCULATORY SYSTEM FOR LEAKS ..3-10 ADJUSTING THE CLUTCH LEVER POSITION ........3-10 ADJUSTING THE CLUTCH LEVER FREE PLAY........3-10...
Page 84 CHECKING THE WHEEL BEARINGS .............3-34 CHECKING AND ADJUSTING THE STEERING HEAD ......3-34 LUBRICATING THE LEVERS ..............3-35 LUBRICATING THE PEDAL ..............3-35 ELECTRICAL SYSTEM..................3-36 CHECKING THE SPARK PLUG ..............3-36 CHECKING THE IGNITION TIMING............3-36...
Page 85: Maintenance Intervals
MAINTENANCE INTERVALS MAINTENANCE INTERVALS EAS1SM9063 EAS1SM9064 MAINTENANCE INTERVALS ECA@ NOTICE • After a break-in or before each race, always check the points shown in “TORQUE-CHECK POINTS” for tightening torques and retighten them. (“TORQUE-CHECK POINTS” on page 1- 23.) • Periodic inspection is essential in making full use of the machine performance. The life of parts varies significantly according to the environment in which the machine runs (e.g., rain, dirt, etc.).
Page 86 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) PISTON RING Inspect Check the end gap of the pis- ton ring. Replace Replace the piston, piston pin, piston pin clip, and piston ring all as a set.
Page 87 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) NUT (ROTOR) Retighten Check for tightening torques. EXHAUST PIPE, SI- LENCER, PROTEC- Inspect and re- Check for exhaust leaks, and tighten tightening torques.
Page 88 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) FUEL TANK, FUEL PUMP Inspect FUEL HOSE Inspect Replace Every four years FRONT FORK LEG Clean Dust seal Inspect and adjust Replace oil Replace oil seal...
Page 89 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) Replace brake flu- Every one year SWINGARM Inspect, lube and Molybdenum disulfide grease retighten RELAY ARM, CON- NECTING ROD Inspect, lube and Molybdenum disulfide grease retighten...
Page 90 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) LEVERS Adjust clutch lever free play KICKSTARTER LE- VER, BRAKE PED- AL, FOOTREST Lubricate OUTSIDE NUTS AND BOLTS Retighten Refer to “TORQUE-CHECK POINTS”...
Page 91: Pre-Operation Inspection And Maintenance
PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE EAS1SM9065 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. GENERAL INSPECTION AND MAINTENANCE EAS1SM9066 ITEM inspect Page...
Page 92: Engine
ENGINE ENGINE CHECKING THE COOLING SYSTEM EAS1SM9067 EAS1SM9069 1. Remove: EAS1SM9068 CHECKING THE COOLANT LEVEL • Seat • Side cover (left/right) EWA1DX1003 WARNING • Air scoop (left/right) If coolant seems hot, do not remove the ra- Refer to “GENERAL CHASSIS” on page 4- diator cap.
Page 93: Checking The Radiator Cap
ENGINE 5. Install: • Valve and valve seat “2” Crack/damage  Replace. • Copper washer Exist fur deposits  Clean or replace. • Coolant drain bolt Coolant drain bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 6. Pour coolant. Recommended coolant High quality ethylene glycol anti-freeze containing anti-cor- rosion for aluminum engine...
Page 94: Checking The Coolant Circulatory System For Leaks
ENGINE CHECKING THE COOLANT CIRCULATORY ADJUSTING THE CLUTCH LEVER POSI- EAS1SM9073 EAS1SM9074 SYSTEM FOR LEAKS TION 1. Check: 1. Adjust: • Coolant level • Clutch lever position “a” 2. Install: Loosen the locknut “1” and use the adjuster • Radiator cap tester “1” “2”...
Page 95: Adjusting The Throttle Grip Free Play
ENGINE ADJUSTING THE THROTTLE GRIP FREE EAS1SM9076 PLAY Prior to adjusting throttle grip free play, the en- gine idling speed should be adjusted. 1. Check: • Throttle grip free play “a” Out of specification  Regulate. Throttle grip free play 3.0–5.0 mm (0.12–0.20 in) If the clutch lever free play cannot be obtained on the handlebar side, use the adjuster on the...
Page 96: Lubricating The Throttle Cable
ENGINE LUBRICATING THE THROTTLE CABLE EAS1SM9077 1. Remove: Loosen the quick fastener screw “3” and re- • Cover (throttle cable cap) “1” move the air filter case cover. • Cover (grip cap) “2” • Throttle grip cap “3” 2. Remove: •...
Page 97: Checking The Throttle Body Joint
ENGINE 4. Check: CHECKING THE THROTTLE BODY JOINT EAS1SM9079 • Air filter element 1. Check: Damage  Replace. • Throttle body joint 5. Foam-air-filter oil or equivalent oil to the ele- Refer to “CHECKING THE THROTTLE ment BODY JOINT” on page 7-8. Oil application quantify EAS1SM9080 CHECKING THE BREATHER HOSES...
Page 98: Checking The Fuel Line
ENGINE 3. Install: • Fuel tank Refer to “FUEL TANK” on page 7-1. • Air scoop (left/right) • Seat • Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4- EAS1SM9083 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle upright on a level surface. 2.
Page 99: Changing The Engine Oil
ENGINE c. Install the new oil filter element and the oil fil- CHANGING THE ENGINE OIL EAS1SM9084 ter element cover. Stand the vehicle upright on a level surface. Oil filter element cover bolt 1. Start the engine, warm this up for several 10 Nm (1.0 m·kgf, 7.2 ft·lbf) minutes, and then stop the engine and wait about 5 minutes.
Page 100: Adjusting The Engine Idling Speed
ENGINE 7. Pour the specified amount of engine oil into WARNING the oil filler cap hole. Always keep the engine idling speed during Engine oil quantity the checkup without increasing the engine Without oil filter element replace- speed. ment 0.71 L (0.75 US qt, 0.62 Imp.qt) NOTICE With oil filter element replace- If no engine oil seeps out after one minute,...
Page 101: Adjusting The Valve Clearance
• This section is intended for those who have Digital tachometer 90890-06760 basic knowledge and skill concerning the ser- Digital tachometer vicing of Yamaha motorcycles (e.g., Yamaha YU-39951-B dealers, service engineers, etc.). Those who have little knowledge and skill concerning ser- vicing are requested not to undertake inspec- Get the high tension cord “1”...
Page 102 ENGINE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise with a wrench. b. Align the top dead center (TDC) mark “a” on the rotor with the alignment mark “b” on the crankcase cover. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Adjust: • Valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the camshaft (intake and exhaust). Refer to “CAMSHAFT”...
Page 103 ENGINE c. Check the number on the originally installed adjusting pad. • Apply the engine oil on the valve lifters. • Apply molybdenum disulfide oil to the valve • The adjusting pad number “a” is indicated on stem ends. the top of the adjusting pad. •...
Page 104 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 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.02 0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230...
Page 105 ENGINE EXHAUST 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 0.02 0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225...
Page 106: Chassis
CHASSIS CHASSIS EAS1SM9087 EAS1SM9088 BLEEDING THE BRAKE SYSTEM EWA13100 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 107: Checking The Brake Hose
CHASSIS CHECKING THE BRAKE HOSE EAS1SM9089 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 108: Adjusting The Rear Brake
CHASSIS ADJUSTING THE REAR BRAKE EAS1SM9091 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 109 CHASSIS b. Loosen the pad pin “2”. c. Remove the brake caliper “3” from the front fork. i. Install the brake caliper “8” and tighten the pad pin “9”. Bolt (brake caliper) d. Remove the pad pin and brake pads “4”. 28 Nm (2.8 m·kgf, 20 ft·lbf) Pad pin 17 Nm (1.7 m·kgf, 12 ft·lbf)
Page 110: Checking The Rear Brake Pads
CHASSIS CHECKING THE REAR BRAKE PADS EAS1SM9093 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. Brake pad lining thickness (inner) d.
Page 111: Checking The Rear Brake Pad Insulator
CHASSIS 4. Check: • Brake pedal operation A softy or spongy feeling  Bleed the brake system. Refer to “BLEEDING THE BRAKE SYS- TEM” on page 3-22. EAS1SM9094 CHECKING THE REAR BRAKE PAD INSU- LATOR 1. Remove: • Brake pads i.
Page 112: Adjusting The Drive Chain Slack
CHASSIS WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake flu- ids may result in a harmful chemical reac- tion, leading to poor brake performance.
Page 113: Checking The Front Fork Legs
CHASSIS CHECKING THE FRONT FORK LEGS CLEANING THE FRONT FORK OIL SEAL EAS1SM9097 EAS1SM9099 1. Stand the vehicle upright on a level surface. AND DUST SEAL 1. Remove: WARNING • Protector Securely support the vehicle so that there is • Dust seal “1” no danger of it falling over.
Page 114: 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 ECA@ NOTICE Do not turn the adjuster forcibly beyond its adjusting range. EAS1SM9101 ADJUSTING THE FRONT FORK LEGS 1. Adjust: EWA32D1006 WARNING •...
Page 115: Checking The Swingarm Operation
CHASSIS 1. Remove: CHECKING THE SWINGARM OPERATION EAS1SM9102 • Rear frame 1. Check: Refer to “REAR SHOCK ABSORBER AS- • Swingarm smooth action SEMBLY” on page 4-53. • Swingarm free play 2. Adjust: Refer to “SWINGARM” on page 4-60. • Spring preload EAS1SM9103 CHECKING THE REAR SUSPENSION ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 116 CHASSIS e. Tighten the locknut. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Locknut Compression damping (for fast compres- 30 Nm (3.0 m·kgf, 22 ft·lbf) sion damping) ECA@ NOTICE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Do not turn the adjuster forcibly beyond its 3. Install: adjusting range. • Rear frame Refer to “REAR SHOCK ABSORBER AS- 1.
Page 117: Checking The Tires
CHASSIS Compression damping (for slow compres- CHECKING THE TIRES EAS1SM9105 sion damping) 1. Measure: ECA@ • Tire pressure NOTICE Out of specification  Regulate. Do not turn the adjuster forcibly beyond its adjusting range. Tire air pressure (measured on cold tires) 1.
Page 118: Checking The Wheels
CHASSIS 2. Tighten: CHECKING AND ADJUSTING THE STEER- • 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 119: Lubricating The Levers
CHASSIS LUBRICATING THE LEVERS EAS1SM9110 Steering nut wrench 1. Lubricate the pivoting points and metal-to- 90890-01403 metal moving parts of the following parts. Exhaust flange nut wrench • Brake lever YU-A9472 Recommended lubricant Silicone grease Ring nut (initial tightening torque) 38 Nm (3.8 m·kgf, 27 ft·lbf) •...
Page 120: Electrical System
ELECTRICAL SYSTEM 5. Clean: ELECTRICAL SYSTEM EAS1SM9112 • Spark plug (with a spark plug cleaner or a wire brush) EAS1SM9113 CHECKING THE SPARK PLUG 6. Measure: 1. Remove: • Spark plug gap “a” • Seat Out of specification  Adjust the spark plug •...
Page 121 ELECTRICAL SYSTEM 2. Attach: • Timing light “1” • Digital tachometer “2” To the high tension code “3”. Timing light 90890-03141 YU-03141 Digital tachometer 90890-06760 YU-39951-B 3. Adjust: • Engine idling speed Refer to “ADJUSTING THE ENGINE IDLING SPEED” on page 3-16. 4.
Page 122 ELECTRICAL SYSTEM 3-38...
Page 123 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE LEFT SIDE COVER............4-2 REMOVING THE SEAT ................4-2 REMOVING THE NUMBER PLATE............4-2 FRONT WHEEL....................4-3 REMOVING THE FRONT WHEEL.............4-4 CHECKING THE FRONT WHEEL .............4-4 DISASSEMBLING THE FRONT WHEEL...........4-5 ASSEMBLING THE FRONT WHEEL............4-5 INSTALLING THE FRONT WHEEL ............4-6 REAR WHEEL ....................4-7 REMOVING THE REAR WHEEL ...............4-8 CHECKING THE REAR WHEEL..............4-8...
Page 124 HANDLEBAR ....................4-31 REMOVING THE HANDLEBAR...............4-33 CHECKING THE HANDLEBAR ...............4-33 INSTALLING THE HANDLEBAR .............4-33 FRONT FORK....................4-37 REMOVING THE FRONT FORK LEGS...........4-39 DISASSEMBLING THE FRONT FORK LEGS .........4-39 CHECKING THE FRONT FORK LEGS ...........4-40 ASSEMBLING THE FRONT FORK LEGS ..........4-41 INSTALLING THE FRONT FORK LEGS ..........4-47 STEERING HEAD...................4-49 REMOVING THE LOWER BRACKET............4-50 CHECKING THE STEERING HEAD ............4-50...
Page 125: General Chassis
This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.
Page 126: Removing The Left Side Cover
GENERAL CHASSIS REMOVING THE LEFT SIDE COVER REMOVING THE NUMBER PLATE EAS1SM9117 EAS1SM9119 1. Remove: 1. Remove: • Bolt (side cover) • Bolt (number plate) • Side cover “1” • Number plate “1” Draw the left side cover “1” backward to re- •...
Page 127: Front Wheel
FRONT WHEEL FRONT WHEEL EAS1SM9120 Removing the front wheel 21 Nm (2.1 m kgf, 15 ft Ibf) • • 21 Nm (2.1 m kgf, 15 ft Ibf) • • 115 Nm (11.5 m kgf, 83 ft lbf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...
Page 128: Removing The Front Wheel
FRONT WHEEL REMOVING THE FRONT WHEEL EAS1SM9121 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 129: Disassembling The Front Wheel
FRONT WHEEL DISASSEMBLING THE FRONT WHEEL EAS1SM9123 1. Remove: • Oil seals • Bearings ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside of the front wheel hub. b. Remove the oil seals “1” with a flat-head screwdriver. To prevent damaging the wheel, place a rag “2” between the screwdriver and the wheel sur- face.
Page 130: Installing The Front Wheel
FRONT WHEEL 3. Install: 3. Tighten: • Collar “1” • Front wheel axle nut “1” Front wheel axle nut Apply the lithium-soap-based grease on the oil 115 Nm (11.5 m·kgf, 83 ft·lbf) seal lip. NOTICE Before tightening the front wheel axle nut, push down hard on the handlebar(s) several times and check if the front fork rebounds smoothly.
Page 131: Rear Wheel
REAR WHEEL REAR WHEEL EAS1SM9126 Removing the rear wheel 14 Nm (1.4 m kgf, 10 ft Ibf) • • 135 Nm (13.5 m kgf, 98 ft lbf) • • 21 Nm (2.1 m kgf, 15 ft Ibf) • • 42 Nm (4.2 m kgf, 30 ft Ibf) •...
Page 132: Removing The Rear Wheel
REAR WHEEL 4. Measure: REMOVING THE REAR WHEEL EAS1SM9127 • 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 4-4. Securely support the vehicle so that there is Radial wheel runout limit no danger of it falling over.
Page 133: 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 EAS1SM9131 1.
Page 134 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 Push the rear wheel “2” forward and install the 50–60 mm (1.97–2.36 in) drive chain.
Page 135: Front Brake
FRONT BRAKE FRONT BRAKE EAS1SM9133 Removing the front brake caliper 30 Nm (3.0 m kgf, 22 ft lbf) 28 Nm (2.8 m kgf, 20 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 136 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 137 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 138 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. 4-14...
Page 139: Introduction
FRONT BRAKE INTRODUCTION EAS1SM9134 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 4-3. • Never disassemble the brake components unless absolutely necessary.
Page 140: Checking The Front Brake Caliper
FRONT BRAKE ASSEMBLING THE FRONT BRAKE CALI- EAS1SM9139 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 141: 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 142: 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 3-22. 6. Check: • Brake fluid level 2.
Page 143: Installing The Front Brake Master Cylinder
FRONT BRAKE INSTALLING THE FRONT BRAKE MASTER EAS1SM9145 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 with the “UP” mark facing up. 3.
Page 144 FRONT BRAKE 3. Pour brake fluid to the brake master cylinder 6. Check: reservoir up to the specified level. • Brake lever free play Refer to “ADJUSTING THE FRONT Specified brake fluid BRAKE” on page 3-23. DOT 4 • Brake lever operation A softy or spongy feeling ...
Page 145: Rear Brake
REAR BRAKE REAR BRAKE EAS1SM9146 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 146 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 147 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 3-22. 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 148 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. 4-24...
Page 149: Introduction
REAR BRAKE INTRODUCTION EAS1SM9147 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 150: Removing The Rear Brake Caliper
REAR BRAKE REMOVING THE REAR BRAKE CALIPER CHECKING THE REAR BRAKE CALIPER EAS1SM9149 EAS1SM9151 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 151: Installing The Brake Caliper Piston
REAR BRAKE INSTALLING THE REAR BRAKE CALIPER INSTALLING THE BRAKE CALIPER PISTON EAS1SM9153 1. Install: 1. Clean: • Rear brake caliper • Brake caliper • Rear brake caliper bracket • Brake caliper piston seal 2. Install: • Brake caliper piston dust seal •...
Page 152: Removing The Rear Brake Master Cylinder
REAR BRAKE REMOVING THE REAR BRAKE MASTER EAS1SM9155 WARNING CYLINDER • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to Before removing the rear brake master cylin- deteriorate, causing leakage and poor der, drain the brake fluid from the entire brake brake performance.
Page 153: Assembling The Rear Brake Master Cylinder
REAR BRAKE ASSEMBLING THE REAR BRAKE MASTER EAS1SM9157 CYLINDER WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake com- ponents. Specified brake fluid 4.
Page 154 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 155 HANDLEBAR HANDLEBAR EAS1SM9159 Removing the handlebar Order Part name Q’ty Remarks Number plate Remove the band only. Clutch cable Disconnect. Clutch lever holder Engine stop switch Brake master cylinder Throttle cable cap Throttle cable (pull) Disconnect. Throttle cable (return) Disconnect. Right grip Tube guide Collars...
Page 156 HANDLEBAR Removing the handlebar Order Part name Q’ty Remarks Handlebar lower holder Damper For installation, reverse the removal proce- dure. 4-32...
Page 157: Handlebar
HANDLEBAR REMOVING THE HANDLEBAR EAS1SM9160 1. Stand the vehicle upright on a level surface. • Install the lower handlebar holders with them EWA13120 side having the greater distance “a” from the WARNING mounting bolt center facing forward. Securely support the vehicle so that there is •...
Page 158 HANDLEBAR 4. Install: • Handlebar grip “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Slightly coat the handlebar left end with a rubber adhesive. b. Install the handlebar grip on the handlebar by pressing the grip from the left side. c. Wipe off any excess adhesive with a clean cloth.
Page 159 HANDLEBAR 6. Install: 8. Install: • Right grip “1” • Throttle cables “1” • Collar “2” Apply adhesive to the tube guide “3”. Slightly coat the end of throttle cable and inside of throttle grip with lithium-soap-based grease. • Before applying the adhesive, wipe off grease Then, mount the throttle grip onto the handle- or oil on the tube guide surface “a”...
Page 160 HANDLEBAR 12.Install: • Clutch cable “1” Before installation, apply the lithium-soap- based grease to the clutch cable end. 10.Install: • Rubber cover “1” • Cover (throttle cable housings) “2” 13.Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LE- VER FREE PLAY”...
Page 161: Front Fork
FRONT FORK FRONT FORK EAS1SM9163 Removing the front fork legs 21 Nm (2.1 m kgf, 15 ft lbf) 9 Nm (0.9 m kgf, 6.5 ft lbf) 5 Nm (0.5 m kgf, 3.6 ft lbf) 5 Nm (0.5 m kgf, 3.6 ft lbf) Order Part name...
Page 162 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 163: Removing The Front Fork Legs
FRONT FORK REMOVING THE FRONT FORK LEGS EAS1SM9164 NOTICE 1. Use a suitable stand to raise the front wheel Do not scratch the inner tube. off the ground. Cap bolt ring wrench WARNING 90890-01501 Securely support the vehicle so that there is YM-01501 no danger of it falling over.
Page 164: Checking The Front Fork Legs
FRONT FORK 5. Remove: • Base valve “1” (from the damper assembly) Hold the damper assembly with the cap bolt ring wrench “2” and use the cap bolt wrench “3” to remove the base valve. Cap bolt wrench 90890-01500 2. Check: YM-01500 •...
Page 165: Assembling The Front Fork Legs
FRONT FORK 5. Check: EAS1SM9167 ASSEMBLING THE FRONT FORK LEGS • Base valve “1” EWA13660 Wear/damage  Replace. WARNING Contamination  Clean. • Make sure the oil levels in both front fork legs are equal. • O-rings “2” Wear/damage  Replace. •...
Page 166 FRONT FORK 6. Loosen: • Compression damping force adjuster “1” • Before loosening the damping force adjuster, record the setting position. • Unless the damping force adjuster is fully loosened, correct damping characteristic can- not be obtained after installation. 4. Measure: •...
Page 167 FRONT FORK Cap bolt wrench 90890-01500 YM-01500 Cap bolt ring wrench 90890-01501 YM-01501 13.Check: • Damper assembly smooth movement Tightness/binding/rough spots  Repeat the steps 1 to 12. 10.After filling, pump the damper assembly “1” slowly up and down more than 10 times to distribute the fork oil.
Page 168 FRONT FORK 15.Install: • Inner tube bushing “1” Install the inner tube bushing onto the slot on inner tube. 18.Install: • Oil seals “1” Using a fork seal driver “2”, press the oil seal in until the stopper ring groove fully appears. 16.Install: Fork seal driver •...
Page 169 FRONT FORK 20.Install: 23.Install: • Dust seal “1” • Collar “1” • Fork spring “2” (to the damper assembly “3”) Apply lithium-soap-based grease on the inner tube. Install the collar with its larger dia. end “a” fac- ing the fork spring. 21.Check: •...
Page 170 FRONT FORK 25.Loosen: Gap “a” between the adjuster and • Rebound damping force adjuster “1” the locknut 0.5–1.0 mm (0.02–0.04 in) • Before loosening the damping force adjuster, record the setting position. • Unless the damping force adjuster is fully If it is installed with a gap out of specification, loosened, correct damping characteristic can- correct damping force cannot be obtained.
Page 171: Installing The Front Fork Legs
FRONT FORK 30.Fill: • Front fork leg Recommended oil Suspension oil S1 Standard oil amount 330 cm (11.16 US oz, 11.64 lmp.oz) (USA) (CAN) 355 cm (12.00 US oz, 12.52 lmp.oz) (EUR) (JPN) (AUS) (NZL) (ZAF) Extent of adjustment INSTALLING THE FRONT FORK LEGS EAS1SM9168 300–365 cm (10.14–12.34 US...
Page 172 FRONT FORK 3. Adjust: • Front fork top end “a” Front fork top end (standard) “a” 5 mm (0.20 in) 6. Adjust: • Rebound damping force Turn in the damping adjuster “1” finger-tight and then turn out to the originally set position. 4.
Page 173: Steering Head
STEERING HEAD STEERING HEAD EAS1SM9169 Removing the lower bracket 21 Nm (2.1 m kgf, 15 ft lbf) 145 Nm (14.5 m kgf, 105 ft lbf) 21 Nm (2.1 m kgf, 15 ft lbf) 38 Nm (3.8 m kgf, 27 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft...
Page 174: Removing The Lower Bracket
STEERING HEAD REMOVING THE LOWER BRACKET EAS1SM9170 NOTICE 1. Use a suitable stand to raise the front wheel If the bearing race is not installed properly, off the ground. the steering head pipe could be damaged. WARNING Securely support the vehicle so that there is Always replace the bearing and the bearing no danger of it falling over.
Page 175 STEERING HEAD 2. Install: • Bearing races • Upper bearing “1” • Bearing race cover “2” Apply the lithium soap base grease on the bearing and bearing race cover lip. 5. Check the steering stem by turning this lock to lock. If there is any binding, remove the steering stem and check the steering bear- ing.
Page 176 STEERING HEAD 11.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) EWA33DD049 8. Install: WARNING • Steering stem nut “1” Tighten the lower bracket to specified torque.
Page 177: Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY REAR SHOCK ABSORBER ASSEMBLY EAS1SM9173 Removing the rear shock absorber assembly 16 15 14 13 Order Part name Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 4-1. Side cover (left / right) Refer to “GENERAL CHASSIS” on page 4-1. Air scoop (left / right) Refer to “GENERAL CHASSIS”...
Page 178 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 16 15 14 13 Order Part name Q’ty Remarks O-ring Dust seal Stopper ring Bearing For installation, reverse the removal proce- dure. 4-54...
Page 179 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. 4-55...
Page 180: Handling The Rear Shock Absorber
• Rear shock absorber assembly upper bolt • To dispose of a damaged or a worn-out • Rear shock absorber assembly rear shock absorber, take the unit to your Yamaha dealer for this disposal proce- REMOVING THE BEARING EAS1SM9177 dure.
Page 181: Checking The Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY 2. Remove: CHECKING THE CONNECTING ARM AND EAS1SM9179 • Upper bearing “1” RELAY ARM 1. Check: • Connecting arm Remove the bearing by pressing its outer race. • Relay arm Damage/wear  Replace. 2. Check: • Bearing •...
Page 182: Installing The Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY Install the dust seals with their lips facing in- ward. Installed depth “a” 4.25 mm (0.17 in) INSTALLING THE REAR SHOCK ABSORB- EAS1SM9181 ER ASSEMBLY 1. Lubricate: • Bearing (lower side) • Dust seal • Collars •...
Page 183 REAR SHOCK ABSORBER ASSEMBLY • Connecting arm bolt (relay arm side) Connecting arm bolt (relay arm side) 80 Nm (8.0 m·kgf, 58 ft·lbf) • Relay arm bolt (swingarm side) Relay arm bolt (swingarm side) 70 Nm (7.0 m·kgf, 51 ft·lbf) •...
Page 184: Swingarm
SWINGARM SWINGARM EAS1SM9182 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 185: Removing The Swingarm
SWINGARM REMOVING THE SWINGARM EAS1SM9183 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 186: Installing The Swingarm
SWINGARM INSTALLING THE SWINGARM EAS1SM9186 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 187: Chain Drive
CHAIN DRIVE CHAIN DRIVE EAS1SM9187 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 5-1. Drive chain For installation, reverse the removal proce- dure.
Page 188: Removing The Drive Chain
CHAIN DRIVE REMOVING THE DRIVE CHAIN EAS1SM9188 1. Use a suitable stand to raise the rear wheel off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Joint clip •...
Page 189: Checking The Drive Sprocket
CHAIN DRIVE 4. Check: • Drive chain rollers “1” Damage/wear  Replace the drive chain. • Drive chain side plates “2” Damage/wear  Replace the drive chain. 2. Lubricate: • Drive chain 3. Install: • Drive sprocket • Lock washer 5.
Page 190 CHAIN DRIVE 4-66...
Page 191 ENGINE ENGINE REMOVAL ..................5-1 REMOVING THE SILENCER..............5-6 REMOVING THE EXHAUST PIPE 2............5-6 REMOVING THE DRIVE SPROCKET ............5-6 REMOVING THE ENGINE .................5-7 CHECKING THE SILENCER AND EXHAUST PIPE........5-7 CHANGING THE SILENCER FIBER ............5-7 INSTALLING THE ENGINE................5-8 INSTALLING THE BRAKE PEDAL ............5-9 INSTALLING THE DRIVE SPROCKET............5-9 INSTALLING THE EXHAUST PIPE AND MUFFLER.......5-10 CAMSHAFT ....................5-11...
Page 192 CLUTCH ......................5-35 REMOVING THE CLUTCH ..............5-38 CHECKING THE FRICTION PLATES............5-38 CHECKING THE CLUTCH PLATES ............5-38 CHECKING THE CLUTCH SPRINGS............5-38 CHECKING THE CLUTCH HOUSING .............5-39 CHECKING THE CLUTCH BOSS............5-39 CHECKING THE PRESSURE PLATE .............5-39 CHECKING THE PUSH LEVER SHAFT..........5-39 CHECKING THE CLUTCH PUSH RODS ..........5-39 CHECKING THE PRIMARY DRIVE GEAR..........5-39 CHECKING THE PRIMARY DRIVEN GEAR ...........5-40 INSTALLING THE OIL SEAL ..............5-40...
Page 193 AC MAGNETO....................5-58 REMOVING THE AC MAGNETO.............5-59 CHECKING THE AC MAGNETO .............5-59 CHECKING THE WOODRUFF KEY ............5-59 INSTALLING THE AC MAGNETO ............5-59 CRANKCASE ....................5-61 DISASSEMBLING THE CRANKCASE.............5-64 REMOVING THE CRANKCASE BEARING ..........5-64 CHECKING THE TIMING CHAIN, TIMING CHAIN GUIDE, OIL STRAINER..................5-64 CHECKING THE CRANKCASE ...............5-64 INSTALLING THE OIL SEAL ..............5-65 ASSEMBLING THE CRANKCASE............5-65...
Page 194: 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 195 ENGINE REMOVAL Removing the exhaust pipe 13 Nm (1.3 m kgf, 9.4 ft lbf) 20 Nm (2.0 m kgf, 14 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 8 Nm (0.8 m kgf, 5.8 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) 12 Nm (1.2 m kgf, 8.7 ft Ibf)
Page 196 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 4-1. Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1. Air scoop (left / right) Refer to “GENERAL CHASSIS”...
Page 197 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 4-1. Side cover (left/right) Refer to “GENERAL CHASSIS”...
Page 198 ENGINE REMOVAL Removing the engine 55 Nm (5.5 m kgf, 40 ft Ibf) • • Order Part name Q’ty Remarks Drive chain guide Drive sprocket Upper engine bracket Washer Thickness:2.3 mm (0.09 in) Washer Thickness:1.0 mm (0.04 in) Lower engine bracket Pivot shaft Engine For installation, reverse the removal proce-...
Page 199: Removing The Silencer
ENGINE REMOVAL REMOVING THE SILENCER EAS1SM9195 1. Remove: • Rear shock absorber assembly lower bolt “1” • Connecting arm bolt (frame side) “2” • Silencer “3” Move the rear shock absorber to the left side of the chassis, and remove the silencer. REMOVING THE DRIVE SPROCKET EAS1SM9197 1.
Page 200: Removing The Engine
ENGINE REMOVAL REMOVING THE ENGINE EAS1SM9198 1. Remove: • Pivot shaft “1” If the pivot shaft is pulled all the way out, the swingarm will come loose. If possible, insert a shaft of similar diameter into the other side of the swingarm to support it.
Page 201: Installing The Engine
ENGINE REMOVAL 3. Replace: • Fiber “1” • Apply heat-resistant sealant to the areas “a” shown, making sure that there are no gaps in the beads of sealant. • Take care not to allow the fiber out of place when installing the silencer body “3”. 4.
Page 202: Installing The Brake Pedal
ENGINE REMOVAL 2. Install: • Lock washer “1” • Nut (drive sprocket) “2” Nut (drive sprocket) 75 Nm (7.5 m·kgf, 54 ft·lbf) Tighten the nut while applying the rear brake. NOTICE Make sure to tighten to specification; other- INSTALLING THE BRAKE PEDAL EAS1SM9202 wise, it may damage the other part that is 1.
Page 203: Installing The Exhaust Pipe And Muffler
ENGINE REMOVAL 3. Install: INSTALLING THE EXHAUST PIPE AND EAS1SM9204 • Clamp MUFFLER • Silencer “1” 1. Install: • Bolt (silencer) “2” • Gasket • Exhaust pipe 1 “1” Bolt (silencer) • Nut (exhaust pipe 1) “2” 30 Nm (3.0 m·kgf, 22 ft·lbf) Nut (exhaust pipe) 20 Nm (2.0 m·kgf, 14 ft·lbf) First temporarily tighten all nuts to 13 Nm (1.3...
Page 204: Camshaft
CAMSHAFT CAMSHAFT EAS1SM9205 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 4-1. Side cover (left/right) Refer to “GENERAL CHASSIS”...
Page 205 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 206: Removing The Camshaft
CAMSHAFT REMOVING THE CAMSHAFT EAS1SM9206 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 207: Checking The Camshaft
CAMSHAFT 3. Measure: CHECKING THE CAMSHAFT EAS1SM9207 • 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 208: 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 209: Checking The Decompression System
CAMSHAFT CHECKING THE DECOMPRESSION SYS- EAS1SM9210 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 210 CAMSHAFT ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install: 3. Turn: • Timing chain tensioner • Crankshaft Counterclockwise several turns. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 4. Check: a. While pressing the tensioner rod lightly with • Top dead center (TDC) mark on the rotor your fingers, use a thin screwdriver to wind Align with the crankcase alignment mark.
Page 211: Cylinder Head
CYLINDER HEAD CYLINDER HEAD EAS1SM9212 Removing the cylinder head 33 Nm (3.3 m kgf, 24 ft Ibf) 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 Seat Refer to “GENERAL CHASSIS” on page 4-1. Side cover (left/right) Refer to “GENERAL CHASSIS”...
Page 212 CYLINDER HEAD Removing the cylinder head 33 Nm (3.3 m kgf, 24 ft Ibf) 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 Timing chain guide (intake side) Oil check bolt For installation, reverse the removal proce- dure.
Page 213: Removing The Cylinder Head
CYLINDER HEAD REMOVING THE CYLINDER HEAD EAS1SM9213 1. Remove: • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAMSHAFT” on page 5-13. 2. Remove: • Cylinder head nuts • Cylinder head bolts 2. Check: • Loosen the bolts in the proper sequence as •...
Page 214: Installing The Cylinder Head
CYLINDER HEAD INSTALLING THE CYLINDER HEAD EAS1SM9216 1. Install: • Apply molybdenum disulfide grease to the • Timing chain guide (intake side) “1” threads and contact surfaces of the bolts and • Dowel pins “2” to both contact surfaces of the washers. •...
Page 215 VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS EAS1SM9217 Removing the valves and valve springs Order Part name Q’ty Remarks Refer to “CYLINDER HEAD” on page 5-18. Cylinder head Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Intake valve...
Page 216: Valves And Valve Springs
VALVES AND VALVE SPRINGS b. Check that the valves are properly sealed. REMOVING THE VALVES EAS1SM9218 Check that there are no kerosene leaks from Before removing the internal parts of the cylin- the valve seat “1”. der head (e.g., valves, valve springs, valve seats), make sure that the valves are properly sealed.
Page 217: Checking The Valves And Valve Guides
VALVES AND VALVE SPRINGS 2. Replace: • Valve guide To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve guide with the valve guide remover “1”.
Page 218: Checking The Valve Seats
VALVES AND VALVE SPRINGS 6. Measure: • Valve stem runout After replacing the valve guide, reface the valve Out of specification  Replace the valve. seat. Intake • When installing a new valve, always replace Valve guide remover (ø5) the valve guide. 90890-04097 •...
Page 219 VALVES AND VALVE SPRINGS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply Mechanic’s blueing dye (Dykem) “b” • When replacing the cylinder head, replace onto the valve face. also the valves with new ones without them. • When replacing the valves or the valve guides, use new valves to lap the valve seats, and then replace them with new valves.
Page 220: Checking The Valve Springs
VALVES AND VALVE SPRINGS 2. Measure: • Compressed valve spring force “a” Out of specification  Replace the valve spring. h. Install the valve into the cylinder head. i. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion.
Page 221: Checking The Valve Lifters
VALVES AND VALVE SPRINGS CHECKING THE VALVE LIFTERS EAS1SM9222 1. Check: • Make sure each valve is installed in its original • Valve lifter place. Damage/scratches  Replace the valve lift- • Install the valve springs with the larger pitch ers and cylinder head.
Page 222 VALVES AND VALVE SPRINGS 6. Lubricate: • Adjusting pad “1” • Valve lifter “2” 7. Install: • Adjusting pad • Valve lifter • Check that the valve lifter turns smoothly when rotated with your finger. • Make sure that the valve lifter and the adjust- ing pad are reinstalled in their original posi- tions.
Page 223 CYLINDER AND PISTON CYLINDER AND PISTON EAS1SM9224 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 5-18. Cylinder head Cylinder body Gaskets...
Page 224: Cylinder And Piston
CYLINDER AND PISTON REMOVING THE PISTON EAS1SM9225 1. Remove: • Piston pin clip “1” • Piston pin “2” • Piston “3” 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 EAS1SM9226 crankcase opening with a cloth to prevent the...
Page 225: Checking The Piston Rings
CYLINDER AND PISTON CHECKING THE PISTON RINGS EAS1SM9227 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 226: Checking The Piston Pin
CYLINDER AND PISTON Piston ring Top ring End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in) Limit 0.50 mm (0.0197 in) Oil ring End gap (installed) 0.10–0.35 mm (0.0039–0.0138 in) EAS1SM9228 CHECKING THE PISTON PIN INSTALLING THE PISTON AND CYLINDER EAS1SM9229 1. Check: 1.
Page 227 CYLINDER AND PISTON 5. Install: • Cylinder gasket • Apply the engine oil to the piston pin. • Dowel pin • Install the piston with the F mark “a” on it • Cylinder pointing to its intake (front) side. • Before installing the piston pin clip, cover the Cylinder bolt crankcase opening with a cloth to prevent the 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Page 228 CLUTCH CLUTCH EAS1SM9230 Removing the clutch 6 10 Order Part name Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-15. Brake pedal Refer to “ENGINE REMOVAL” on page 5-1. Clutch cable Disconnect. Clutch cover Gasket Clutch spring Pressure plate Push rod 1...
Page 229: Clutch
CLUTCH Removing the clutch 6 10 Order Part name Q’ty Remarks Friction plate Clutch plate Clutch boss Thrust washer Primary driven gear Spacer Bearing Washer Push lever shaft For installation, reverse the removal proce- dure. 5-36...
Page 230 CLUTCH Removing the right crankcase cover Order Part name Q’ty Remarks Right engine guard Refer to “ENGINE REMOVAL” on page 5-1. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-15. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-8.
Page 231: Removing The Clutch
CLUTCH REMOVING THE CLUTCH CHECKING THE CLUTCH PLATES EAS1SM9231 EAS1SM9233 1. Remove: 1. Check: • Clutch boss nut “1” • Clutch plate Damage  Replace the clutch plates as a • Lock washer “2” • Clutch boss “3” set. 2. Measure: •...
Page 232: Checking The Clutch Housing
CLUTCH CHECKING THE CLUTCH HOUSING EAS1SM9235 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 EAS1SM9239 1.
Page 233: Checking The Primary Driven Gear
CLUTCH 2. Install: CHECKING THE PRIMARY DRIVEN GEAR EAS1SM9241 • Right crankcase cover “1” 1. Check: • Right crankcase cover bolt “2” • Primary driven gear Damage/wear  Replace the primary drive Right crankcase cover bolt and primary driven gears as a set. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Excessive noise during operation ...
Page 234: Installing The Clutch
CLUTCH INSTALLING THE CLUTCH EAS1SM9244 Clutch holder 1. Install: 90890-04086 • Push lever shaft “1” YM-91042 • Apply the lithium soap base grease on the oil seal lip. • Before installation, apply the engine oil to the push lever shaft sliding surface. 4.
Page 235 CLUTCH 6. Install: 9. 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 236: Installing The Kickstarter Lever
CLUTCH INSTALLING THE KICKSTARTER LEVER EAS1SM9245 1. Install: • Kickstarter lever “1” • Washers • Bolt (kickstarter lever) Bolt (kickstarter lever) 33 Nm (3.3 m·kgf, 24 ft·lbf) 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 237 KICKSTATER KICKSTATER EAS1SM9246 Removing the kick shaft Order Part name Q’ty Remarks Primary driven gear Refer to “CLUTCH” on page 5-35. Kick idle gear Kick shaft assembly Spring guide Torsion spring Ratchet wheel Kick gear Kick shaft For installation, reverse the removal proce- dure.
Page 238: Kickstater
KICKSTATER REMOVING THE KICK SHAFT ASSEMBLY EAS1SM9247 1. Remove: • Kick shaft assembly “1” Unhook the torsion spring “2” from the hole “a” in the crankcase. INSTALLING THE KICK SHAFT ASSEMBLY EAS1SM9250 1. Install: • Kick gear “1” • Washer “2” •...
Page 239: 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: • Transmission 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 240: Shift Shaft
SHIFT SHAFT SHIFT SHAFT EAS1SM9252 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 241 SHIFT SHAFT 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 242: Removing The Shift Guide And Shift Lever Assembly
SHIFT SHAFT REMOVING THE SHIFT GUIDE AND SHIFT CHECKING THE SHIFT SHAFT EAS1SM9253 EAS1SM9255 LEVER ASSEMBLY 1. Check: 1. Remove: • Shift shaft “1” Bends/damage/wear  Replace. • Bolt (shift guide) • Shift guide “1” • Shift shaft spring “2” Damage/wear ...
Page 243: Installing The Stopper Lever
SHIFT SHAFT INSTALLING THE STOPPER LEVER INSTALLING THE SHIFT GUIDE AND SHIFT EAS1SM9258 EAS1SM9260 1. Install: LEVER ASSEMBLY • Torsion spring “1” 1. Install: • Collar “2” • Spring “1” • Stopper lever “3” • Pawl pin “2” • Bolt (stopper lever) “4” •...
Page 244: Installing The Shift Shaft
SHIFT SHAFT 4. Tighten: INSTALLING THE SHIFT PEDAL EAS1SM9262 • Shift guide bolt “1” 1. Install: • Shift pedal “1” Shift guide bolt • Shift pedal bolt “2” 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® Shift pedal bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Align the punch mark “a”...
Page 245 OIL PUMP AND BALANCER GEAR OIL PUMP AND BALANCER GEAR EAS1SM9263 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 246: Oil Pump And Balancer Gear
OIL PUMP AND BALANCER GEAR Removing the balancer 75 Nm (7.5 m kgf, 54 ft lbf) 50 Nm (5.0 m kgf, 36 ft Ibf) Order Part name Q’ty Remarks Primary driven gear Refer to “CLUTCH” on page 5-35. Right crankcase cover Refer to “CLUTCH”...
Page 247: Removing The Balancer
OIL PUMP AND BALANCER GEAR REMOVING THE BALANCER EAS1SM9264 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 248: Assembling The Oil Pump
OIL PUMP AND BALANCER GEAR • Fit the dowel pin into the groove in the inner Inner-rotor-to-outer-rotor-tip rotor. clearance Less than 0.150 mm (0.0059 in) Limit 0.20 mm (0.0079 in) Outer-rotor-to-oil-pump-housing clearance 0.13–0.18 mm (0.0051–0.0071 in) Limit 0.24 mm (0.0094 in) Oil-pump-housing-to-inner-and- outer-rotor clearance 2.
Page 249 OIL PUMP AND BALANCER GEAR NOTICE After tightening the bolts, make sure that the oil pump turns smoothly. 2. Install: • Collar “1” • Balancer weight gear “2” Install the balancer weight gear and balancer shaft with their lower splines “a” aligning with each other.
Page 250 OIL PUMP AND BALANCER GEAR • Apply engine oil to the contact surface and threaded portion of the primary drive gear nut. • Place an aluminum plate “a” between the teeth of the balancer drive gear “9” and bal- ancer weight gear “10”. •...
Page 251: Ac Magneto
AC MAGNETO AC MAGNETO EAS1SM9270 Removing the AC magneto 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 252: Removing The Ac Magneto
AC MAGNETO REMOVING THE AC MAGNETO CHECKING THE WOODRUFF KEY EAS1SM9271 EAS1SM9273 1. Remove: 1. Check: • Woodruff key “1” • Nut (rotor) “1” Damage  Replace. • Washers 2. Remove: INSTALLING THE AC MAGNETO EAS1SM9274 • Rotor “1” 1. Install: Use the rotor puller “2”...
Page 253 AC MAGNETO 2. Install: • Woodruff key “1” • Rotor “2” • Clean the contact surfaces of the tapered por- tions of the crankshaft and rotor. • When installing the woodruff key, make sure that its flat surface “a” is in parallel with the crankshaft center line “b”.
Page 254: Crankcase
CRANKCASE CRANKCASE EAS1SM9275 Separating the crankcase 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) •...
Page 255 CRANKCASE Separating the crankcase 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) •...
Page 256 CRANKCASE Removing the bearing and oil seal 22 Nm (2.2 m kgf, 16 ft Ibf) • • Order Part name Q’ty Remarks Transmission Refer to “TRANSMISSION” on page 5-69. Shift cam and shift fork Refer to “TRANSMISSION” on page 5-69. Circlip Oil seals Bearing...
Page 257: Disassembling The Crankcase
CRANKCASE DISASSEMBLING THE CRANKCASE EAS1SM9276 1. Separate: • Right crankcase • Left crankcase ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the crankcase bolts. c. Remove the dowel pins and O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ REMOVING THE CRANKCASE BEARING EAS1SM9277 1. Remove: • Bearing “1” • Remove the bearing from the crankcase by pressing its inner race.
Page 258: Installing The Oil Seal
Install the bearing by pressing its outer race parallel. 2. Apply: • Sealant (to the crankcase mating surface) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 3. 45 mm (1.77 in) 4. 60 mm (2.36 in) 5. 75 mm (2.95 in) 3.
Page 259: Crankshaft Assembly And Balancer Shaft
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EAS1SM9282 Removing the crankshaft assembly and balancer shaft Order Part name Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-61. Transmission Refer to “TRANSMISSION” on page 5-69. Balancer shaft Crankshaft assembly For installation, reverse the removal proce- dure.
Page 260: Removing The Crankshaft Assembly
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 2. Measure: REMOVING THE CRANKSHAFT ASSEMBLY EAS1SM9283 • Big end side clearance “a” 1. Remove: Out of specification  Replace the big end • Crankshaft assembly “1” bearing, crankshaft pin, or connecting rod. Remove the crankshaft assembly by using the Big end side clearance 0.110–0.690 mm (0.0043–0.0272 crankcase separating tool “2”.
Page 261: Installing The Crankshaft Assembly
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT INSTALLING THE CRANKSHAFT ASSEM- EAS1SM9285 1. Install: • Crankshaft assembly Install the crankshaft assembly with the crank- shaft installer pot “1”, crankshaft installer bolt “2”, adapter (M12) “3” and spacer “4”. Crankshaft installer pot 90890-01274 INSTALLING THE BALANCER SHAFT EAS1SM9286 Installing pot...
Page 262: Transmission
TRANSMISSION TRANSMISSION EAS1SM9287 Removing the transmission, shift drum assembly, and shift forks Order Part name Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Separate. Crankcase Refer to “CRANKCASE” on page 5-61. Main axle Drive axle Long shift fork guide bar Short shift fork guide bar Spring Shift cam...
Page 263: Removing The Transmission
TRANSMISSION REMOVING THE TRANSMISSION CHECKING THE SHIFT FORKS EAS1SM9288 EAS1SM9289 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 264: Checking The Shift Drum Assembly
TRANSMISSION CHECKING THE SHIFT DRUM ASSEMBLY EAS1SM9290 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 265 TRANSMISSION 2. Install: • 2nd wheel gear (28T) “1” • 4th wheel gear (22T) “2” • 3rd wheel gear (26T) “3” • 5th wheel gear (25T) “4” • Collar “5” • 1st wheel gear (30T) “6” • O-rings “7” (to the drive axle “8”) 4.
Page 266 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 267: Cooling System
COOLING SYSTEM RADIATOR .......................6-1 HANDLING NOTE ..................6-3 CHECKING THE RADIATOR..............6-3 WATER PUMP....................6-4 REMOVING THE OIL SEAL...............6-6 CHECKING THE WATER PUMP ...............6-6 CHECKING THE BEARING ...............6-6 INSTALLING THE OIL SEAL ..............6-6 ASSEMBLING THE WATER PUMP............6-6...
Page 268 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 269 RADIATOR Removing the radiator 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 270 RADIATOR HANDLING NOTE EAS1SM9295 WARNING If coolant seems hot, do not remove the ra- diator cap. CHECKING THE RADIATOR EAS1SM9296 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 271 WATER PUMP WATER PUMP EAS1SM9297 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 3-8. Drain.
Page 272 WATER PUMP 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 Bearing Oil seal For installation, reverse the removal proce- dure.
Page 273: Water Pump
WATER PUMP REMOVING THE OIL SEAL EAS1SM9298 • 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 274 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 275: Fuel System
FUEL SYSTEM FUEL TANK......................7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP ..............7-2 CHECKING THE FUEL PUMP BODY............7-2 INSTALLING THE FUEL PUMP..............7-2 INSTALLING THE FUEL TANK..............7-3 CHECKING THE FUEL PRESSURE ............7-3 CHECKING THE DAMPER ................7-4 CHECKING AND REPLACING THE PROTECTOR ........7-4 THROTTLE BODY....................7-5 CHECKING THE INJECTOR ..............7-8 CHECKING THE THROTTLE BODY ............7-8...
Page 276: 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 277: Removing The Fuel Tank
FUEL TANK REMOVING THE FUEL TANK EAS1SM9305 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 278: Installing The Fuel Tank
FUEL TANK 3. Connect: • Fuel pump coupler 4. Install: • Air scoop (left/right) • Seat • Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4- CHECKING THE FUEL PRESSURE EAS1SM9310 1. Check: • Fuel pressure EAS1SM9309 INSTALLING THE FUEL TANK 1.
Page 279: Checking The Damper
FUEL TANK CHECKING AND REPLACING THE PRO- EAS1SM9312 TECTOR 1. Check: • Protector “1” Wear/damage  Replace. Affix the protector as shown. e. Start the engine. f. Measure the fuel pressure. Out of specification  Replace the fuel pump. Fuel line pressure at idling 0 mm 324.0 kPa (3.24 kgf/cm , 47.0...
Page 280: Throttle Body
THROTTLE BODY THROTTLE BODY EAS1SM9313 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 281 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 282 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 283: Checking The Injector
THROTTLE BODY CHECKING THE INJECTOR EAS1SM9314 1. Check: • Injectors Obstruction  Replace, and check the fuel pump and the fuel injection system. Refer to “FUEL INJECTION SYSTEM” on page 8-10. Deposits  Replace. Damage  Replace. 2. Check: • Injector resistance Refer to “CHECKING THE FUEL INJEC- TOR”...
Page 284: 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 285: Electrical System
CIRCUIT DIAGRAM ...................8-2 TROUBLESHOOTING ................8-4 CHARGING SYSTEM..................8-6 CIRCUIT DIAGRAM ...................8-6 TROUBLESHOOTING ................8-8 FUEL INJECTION SYSTEM................8-10 CIRCUIT DIAGRAM .................8-10 YAMAHA DIAGNOSTIC TOOL ..............8-12 TROUBLESHOOTING DETAILS .............8-13 FUEL PUMP SYSTEM..................8-32 CIRCUIT DIAGRAM .................8-32 TROUBLESHOOTING ................8-34 ELECTRICAL COMPONENTS...............8-36 CHECKING THE SWITCHES ..............8-38 CHECKING THE IGNITION SPARK GAP..........8-41 CHECKING THE SPARK PLUG CAP ............8-41...
Page 287 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 288: Ignition System
IGNITION SYSTEM IGNITION SYSTEM EAS1SM9319 EAS1SM9320 CIRCUIT DIAGRAM...
Page 289 IGNITION SYSTEM 1. Crankshaft position sensor 2. AC magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser 7. Engine stop switch 9. ECU 10.Ignition coil 11.Spark plug 18.Ignition coil sub-lead...
Page 290: Troubleshooting
IGNITION SYSTEM TROUBLESHOOTING EAS1SM9321 The ignition system fails to operate (no spark or intermittent spark). Before troubleshooting, remove the following part(s): 1. Side cover (left/right) 2. Seat 3. Fuel tank 4. Air scoop (left/right) 5. Air filter case cover NG  1.
Page 291 IGNITION SYSTEM NG  8. Check the ignition system wire har- ness. Repair or replace the wire harness. Refer to “CIRCUIT DIAGRAM” on page 8-2. OK  Replace the ECU.
Page 292: Charging System
CHARGING SYSTEM CHARGING SYSTEM EAS27200 EAS1SM9322 CIRCUIT DIAGRAM...
Page 293 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser...
Page 294: Troubleshooting
CHARGING SYSTEM TROUBLESHOOTING EAS1SM9323 The condenser is not being charged. Before troubleshooting, remove the following part (s): 1. Seat 2. Air scoop (left) NG  1. Check the entire charging system’s Reconnect. wiring. OK  NG  2. Check the rectifier/regulator. Replace the rectifier/regulator.
Page 295 CHARGING SYSTEM...
Page 296: Fuel Injection System
FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM EAS1SM9324 EAS1SM9325 CIRCUIT DIAGRAM 8-10...
Page 297 FUEL INJECTION SYSTEM 1. Crankshaft position sensor 2. AC magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser 7. Engine stop switch 8. Neutral switch 9. ECU (electronic control unit) 12.Fuel injector 13.Fuel pump 14.Intake air temperature sensor 15.Coolant temperature sensor 16.Throttle position sensor 17.Intake air temperature sensor 8-11...
Page 298: Yamaha Diagnostic Tool
FUEL INJECTION SYSTEM YAMAHA DIAGNOSTIC TOOL EAS1SM9326 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 299: Troubleshooting Details
After the check and service of the malfunctioning part have been completed, reset the Yamaha diag- nostic tool display according to the “Reinstatement method”. Fault code No.: To be displayed on the Yamaha diagnostic tool when the engine fails to work nor- mally Diagnostic code No.: To be used when the diagnostic mode is active...
Page 300 FUEL INJECTION SYSTEM Fault code Crankshaft position sensor: no normal signals are received Symptom from the crankshaft position sensor. Fail-safe system Unable to start engine Unable to drive vehicle Diagnostic code No. — Diagnostic tool display — Procedure — Probable cause of malfunc- Maintenance job Reinstatement method tion and check...
Page 301 Able to start engine Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air pressure. Procedure The atmospheric pressure is displayed on the Yamaha diagnostic tool. Probable cause of malfunc- Maintenance job Reinstatement method tion and check Improperly connected ...
Page 302 Able to start engine Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air pressure. Procedure The atmospheric pressure is displayed on the Yamaha diagnostic tool. Probable cause of malfunc- Maintenance job Reinstatement method tion and check...
Page 303 FUEL INJECTION SYSTEM Fault code Intake air pressure sensor: hose system malfunction (clogged Symptom or detached hose) Defective intake air pressure Execute the diagnostic mode. sensor. (Code No. 03) Atmospheric pressure at the current altitude and weather conditions is indicated. 0 m above sea level: About 101 kPa 1000 m above sea level:...
Page 304 FUEL INJECTION SYSTEM Fault code Symptom Throttle position sensor: open or short circuit detected. Improperly connected  Connection of sub wire har- Turn “ON” the switch on the ness coupler. Connect the coupler secure- FI diagnostic tool sub-lead. Check the locking condition ly, or repair/replace the sub- Fault code No.
Page 305 FUEL INJECTION SYSTEM Fault code Throttle position sensor: stuck throttle position sensor is de- Symptom tected. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the throttle angle. • 11–14 (throttle in fully closed position) •...
Page 306 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- Maintenance job Reinstatement method tion and check Improperly connected ...
Page 307 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- Maintenance job Reinstatement method tion and check Improperly connected ...
Page 308 FUEL INJECTION SYSTEM Fault code Symptom The vehicle has overturned. Fail-safe system Able to start engine Unable to drive vehicle Diagnostic code No. Diagnostic tool display Displays the lean angle sensor output voltage. • 1.0 V (upright) • 4.0 V (overturned) Procedure Remove the ECU, and incline it 45 °...
Page 309 Unable to drive vehicle Diagnostic code No. Actuation Actuates the ignition coil five times at one-second intervals. “WARNING” on the Yamaha diagnostic tool blinks five times when- ever the ignition coil is actuated. Procedure Check that a spark is generated five times.
Page 310 Unable to drive vehicle Diagnostic code No. Actuation Actuates injector five times at one-second intervals. “WARNING” on the Yamaha diagnostic tool blinks five times when the injector is actuated. Procedure Check that injector is actuated five times by listening for the oper- ating sound.
Page 311 FUEL INJECTION SYSTEM Fault code Symptom Injector: open or short circuit detected. Improperly connected  Connection of sub wire har- After starting the engine, idle ness coupler. Connect the coupler secure- this and wait about 5 sec- Check the locking condition ly, or repair/replace the sub- onds.
Page 312 FUEL INJECTION SYSTEM Fault code EEPROM fault code No.: an error is detected while reading or Symptom writing on EEPROM. Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No. Diagnostic tool display Displays the location of the abnormal portion of the EEPROM data. •...
Page 313 FUEL INJECTION SYSTEM Fault code Vehicle system power supply: normal voltage is not supplied Symptom to the ECU. Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No. — Diagnostic tool display — Procedure — Probable cause of malfunc- Maintenance job Reinstatement method tion and check...
Page 314 — Probable cause of malfunc- Maintenance job Reinstatement method tion and check Improperly connected  Connection of Yamaha diag- Turn “ON” the switch on the nostic tool coupler. Connect the coupler secure- FI diagnostic tool sub-lead. Check the locking condition ly, or repair/replace the wire Fault code No.
Page 315 FUEL INJECTION SYSTEM Fault code Waiting for connection Symptom No communication signal is received from the ECU. Yamaha diagnostic tool mal- Replace the Yamaha diag- Turn “ON” the switch on the function nostic tool. FI diagnostic tool sub-lead. Fault code No. is not dis- played ...
Page 316 — Probable cause of malfunc- Maintenance job Reinstatement method tion and check Improperly connected  Connection of Yamaha diag- Turn “ON” the switch on the nostic tool coupler. Connect the coupler secure- FI diagnostic tool sub-lead. Check the locking condition ly, or repair/replace the wire Fault code No.
Page 317 FUEL INJECTION SYSTEM Fault code Er-4 Registered data cannot be received from the Yamaha diagnos- Symptom tic tool. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. — Diagnostic tool display — Procedure — Probable cause of malfunc-...
Page 318: Fuel Pump System
FUEL PUMP SYSTEM FUEL PUMP SYSTEM EAS1SM9328 EAS1SM9329 CIRCUIT DIAGRAM 8-32...
Page 319 FUEL PUMP SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser 7. Engine stop switch 9. ECU (electronic control unit) 13.Fuel pump 8-33...
Page 320: Troubleshooting
FUEL PUMP SYSTEM TROUBLESHOOTING EAS1SM9330 The fuel pump fails to operate. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 5. Air filter case cover NG  1. Check the fuel pump system wire Reconnect.
Page 321 FUEL PUMP SYSTEM 8-35...
Page 322: Electrical Components
ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS EAS1SM9331 EAS1SM9332 8-36...
Page 323 ELECTRICAL COMPONENTS 1. Rectifier/regulator 2. Intake air pressure sensor 3. Throttle position sensor 4. Injector 5. Intake air temperature sensor 6. ECU (electronic control unit) 7. Intake air pressure sensor 8. Condenser 9. Neutral switch 10.Coolant temperature sensor 8-37...
Page 324: Checking The Switches
ELECTRICAL COMPONENTS CHECKING THE SWITCHES EAS1SM9333 Y/W P 8-38...
Page 325 ELECTRICAL COMPONENTS 1. Engine stop switch 2. Neutral switch 8-39...
Page 326 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. ECA14370 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 327: Checking The Ignition Spark Gap
ELECTRICAL COMPONENTS CHECKING THE IGNITION SPARK GAP EAS1SM9334 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (  1k) to the 1. Check: spark plug cap. • Ignition spark gap Out of specification  Perform the ignition Pocket tester system troubleshooting. 90890-03112 Refer to “TROUBLESHOOTING”...
Page 328: Checking The Crankshaft Position Sensor
ELECTRICAL COMPONENTS CHECKING THE CRANKSHAFT POSITION EAS1SM9337 SENSOR 1. Disconnect: • Crankshaft position sensor coupler (from the wire harness) 2. Check: • Crankshaft position sensor resistance Out of specification  Replace. Crankshaft position sensor resis- tance b. Measure the primary coil resistance. 228–342 ...
Page 329: Checking The Ecu
ELECTRICAL COMPONENTS CHECKING THE ECU CHECKING THE RECTIFIER/REGULATOR EAS1SM9338 EAS1SM9340 1. Check: 1. Check: • Mounted condition of ECU. • Rectifier/regulator output voltage Improperly mounted  Remount. Out of specification  Replace. No load regulated voltage • The lean angle sensor is built into the ECU. 14.1–14.9 V •...
Page 330: Checking The Coolant Temperature Sensor
ELECTRICAL COMPONENTS c. Place a thermometer in the coolant. CHECKING THE COOLANT TEMPERATURE EAS1SM9341 d. Slowly heat the coolant, and then let it cool SENSOR to the specified temperature indicated in the 1. Remove: table. • Coolant temperature sensor e. Check the coolant temperature sensor for WARNING continuity at the temperatures indicated in •...
Page 331: Checking The Throttle Position Sensor Input Voltage
ELECTRICAL COMPONENTS 2. Check: CHECKING THE THROTTLE POSITION EAS1SM9343 • Throttle position sensor maximum resis- SENSOR INPUT VOLTAGE tance 1. Check: Out of specification  Replace. • Throttle position sensor input voltage Out of specification  Replace the ECU. Resistance 6.30 k...
Page 332: Checking The Intake Air Pressure Sensor
ELECTRICAL COMPONENTS 2. Check: CHECKING THE INTAKE AIR PRESSURE EAS1SM9344 • Intake air temperature sensor resistance SENSOR Out of specification  Replace. 1. Check: • Intake air pressure sensor output voltage Intake air temperature sensor re- Out of specification  Replace. sistance 290–390 ...
Page 333: Checking The Fuel Injector
ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Continuity a. Disconnect the fuel injector coupler from the Positive tester probe  fuel injector. Sky blue “1” b. Connect the pocket tester (  10) to the Negative tester probe  fuel injector coupler. Sensor terminal “a” Continuity Pocket tester Positive tester probe ...
Page 334 ELECTRICAL COMPONENTS 8-48...
Page 335: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING..................9-1 GENERAL INFORMATION ................9-1 STARTING FAILURES................9-1 INCORRECT ENGINE IDLING SPEED .............9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 SHIFTING IS DIFFICULT ................9-2 SHIFT PEDAL DOES NOT MOVE .............9-2 JUMPS OUT OF GEAR................9-2 CLUTCH SLIPS..................9-2 CLUTCH DRAGS ..................9-2 OVERHEATING ..................9-2 OVERCOOLING..................9-3 POOR BRAKING PERFORMANCE............9-3 FRONT FORK OIL LEAKING..............9-3 FAULTY FRONT FORK LEGS..............9-3 UNSTABLE HANDLING ................9-3...
Page 336: Troubleshooting
TROUBLESHOOTING Electrical system TROUBLESHOOTING EAS1SM9348 1. Spark plug • Incorrect spark plug gap EAS1SM9349 GENERAL INFORMATION • Incorrect spark plug heat range • Fouled spark plug The following guide for troubleshooting does • Worn or damaged electrode not cover all the possible causes of trouble. It •...
Page 337: Poor Medium-And-High-Speed Performance
TROUBLESHOOTING 3. Ignition system CLUTCH SLIPS EAS1SM9356 • Faulty ECU • Faulty crankshaft position sensor Engine • Broken generator rotor woodruff key 1. Clutch • Improperly assembled clutch EAS1SM9352 POOR MEDIUM-AND-HIGH-SPEED PER- • Loose or fatigued clutch spring FORMANCE • Worn friction plate Refer to “STARTING FAILURES”...
Page 338: Overcooling
TROUBLESHOOTING Fuel system FAULTY FRONT FORK LEGS EAS1SM9362 1. Throttle body • Damaged or loose throttle body joint Chassis 2. Air filter 1. Front fork • Clogged air filter element • Bent or damaged inner tube • Bent or damaged outer tube Chassis •...
Page 339: List Of Self-Diagnostic And Fail-Safe Actions
8-28 nection Er-2 Signals from the ECU cannot be received within the specified period 8-29 of time. Er-3 Data from the ECU cannot be received correctly. 8-30 Er-4 Registered data cannot be received from the Yamaha diagnostic tool. 8-31...
Page 340 • Check with throttle fully opened. Pressure of suction pipe Displays the intake air pres- The atmospheric pressure sure. is displayed on the Yamaha diagnostic tool. Intake air temperature Displays the intake air tem- Compare the actually mea- perature. sured intake air tempera-...
Page 341 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 342 LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS...
Page 343: Tuning
TUNING CHASSIS ......................10-1 SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET) ................10-1 DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS ....10-1 TIRE PRESSURE..................10-2 FRONT FORK SETTING................10-2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL..10-2 SETTING OF SPRING AFTER REPLACEMENT ........10-3 FRONT FORK SETTING PARTS.............10-3 REAR SUSPENSION SETTING ..............10-3 CHOOSING SET LENGTH ..............10-3 SETTING OF SPRING AFTER REPLACEMENT ........10-4...
Page 344: Chassis
CHASSIS CHASSIS DRIVE AND REAR WHEEL SPROCKETS EAS1SM9366 EAS1SM9368 SETTING PARTS EAS1SM9367 SELECTION OF THE SECONDARY REDUC- Part name Type Part number TION RATIO (SPROCKET) Drive sprocket “1” Secondary reduction ratio = Number of (STD) 13T 9383B-13218 rear wheel sprocket teeth/Number of drive sprocket teeth Rear wheel sprocket “2”...
Page 345: Tire Pressure
CHASSIS TIRE PRESSURE EAS1SM9369 EWA1DX4001 WARNING Tire pressure should be adjusted to suit the Adjust the oil amount in 5 cm (0.2 US oz, road surface condition of the circuit. 0.2 Imp.oz) increments or decrements. Too small oil amount causes the front fork to Standard tire pressure produce a noise at full rebound or the rider 100 kPa (1.00 kgf/cm...
Page 346: Setting Of Spring After Replacement
CHASSIS SETTING OF SPRING AFTER REPLACE- EAS1SM9372 MENT As the front fork setting can be easily affected by the rear suspension, take care so that the front and the rear are balanced (in position etc.) when setting the front fork. 1.
Page 347: Setting Of Spring After Replacement
CHASSIS 2. Remove the stand or block from the engine SETTING OF SPRING AFTER REPLACE- EAS1SM9376 and, with a rider astride the seat, measure MENT the sunken length “b” between the rear After replacement, be sure to adjust the spring wheel axle center and the rear fender hold- to the set length [sunken length 90–100 mm ing bolt.
Page 348: Rear Shock Absorber Setting Parts
CHASSIS REAR SHOCK ABSORBER SETTING EAS1SM9377 PARTS • Rear shock spring “1” Spring I.D. Type rate N/ Part number Mark 1SL-22212-40 (Blue) SOFT Yellow B11-22212-00 (Yellow) 1SL-22212-60 (Blue) Pink B11-22212-10 (Yellow) 1SL-22212-20 (Blue) White B11-22212-20 (Yellow) 1SL-22212-00 • Spring preload adjusting positions (Blue) STIFF Silver...
Page 349: Suspension Setting (Front Fork)
CHASSIS SUSPENSION SETTING (FRONT FORK) EAS1SM9378 • 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 350: 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 351 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 352 WIRING DIAGRAM EAS1SM9381 YZ250F/YZ250FG 2016 1. Crankshaft position sensor 2. AC magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser 6. Coupler for connecting option- al part 7. Engine stop switch 8. Neutral switch 9. ECU (electronic control unit) 10. Ignition coil 11.
Page 354 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN...
Page 355 YZ250F/YZ250FG 2016 YZ250F/YZ250FG 2016 YZ250F/YZ250FG 2016 SCHÉMA DE CÂBLAGE WIRING DIAGRAM SCHALTPLAN L L L R R R R R R R B B B B B B/L B/L B/L B/L B/L B/L R R R B/L B/L B/L B/L B/L B/L B/L Gy R R/B B/Y B...
Page 356 YZ250F/YZ250FG 2016 YZ250F/YZ250FG 2016 YZ250F/YZ250FG 2016 SCHÉMA DE CÂBLAGE WIRING DIAGRAM SCHALTPLAN...

This manual is also suitable for:

Yz250fg 2016

Yamaha YZ250F 2016 Owner's Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Maintenance Intervals

Pre-Operation Inspection and Maintenance

Engine

Chassis

Electrical System

Chassis

General Chassis

Front Wheel

Rear Wheel

Front Brake

Rear Brake

Handlebar

Front Fork

Steering Head

Rear Shock Absorber Assembly

Swingarm

Chain Drive

Engine

Engine Removal

Camshaft

Cylinder Head

Valves and Valve Springs

Cylinder and Piston

Clutch

Kickstater

Shift Shaft

Oil Pump and Balancer Gear

Ac Magneto

Crankcase

Crankshaft Assembly and Balancer Shaft

Transmission

Fuel System

Fuel Tank

Throttle Body

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

Related Manuals for Yamaha YZ250F 2016

Summary of Contents for Yamaha YZ250F 2016