Download Print this page

Yamaha YZ250FX 2017 Owner's Service Manual

Hide thumbs Also See for YZ250FX 2017:

User manual

Advertisement

Quick Links

Download this manual

2017

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

YZ250FX

YZ250FXH

B29-28199-82

Table of Contents

Advertisement

Chapters

Troubleshooting

Need help?

Need help?

Do you have a question about the YZ250FX 2017 and is the answer not in the manual?

Questions and answers

Summary of Contents for Yamaha YZ250FX 2017

Page 1 2017 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 2017 Read this manual carefully before operating this vehicle. Read this manual carefully before operating this vehicle. OWNER’S SERVICE MANUAL OWNER’S SERVICE MANUAL YZ250FX YZ250FXH B29-28199-82-E0...
Page 5 EASB29B002 YZ250FX YZ250FXH OWNER’S SERVICE MANUAL ©2016 by Yamaha Motor Co., Ltd. First edition, May 2016 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 EASB29B003 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 EASB29B005 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 EASB29B006 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 EASB29B007 The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...
Page 11: Table Of Contents
TABLE OF CONTENS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS 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 SPARK PLUG WRENCH ................1-6 NIPPLE WRENCH..................1-6 HANDLEBAR PROTECTOR ..............1-6 FUEL HOSE JOINT COVER ..............1-6 COUPLER FOR CONNECTING OPTIONAL PART........1-6 IMPORTANT INFORMATION ................1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-7 REPLACEMENT PARTS................1-7 GASKETS, OIL SEALS AND O-RINGS .............1-8...
Page 14 STARTING AND BREAK-IN ................1-22 FUEL ......................1-22 HANDLING NOTE ..................1-22 AIR FILTER MAINTENANCE ..............1-22 STARTING A COLD ENGINE ..............1-22 STARTING A WARM ENGINE..............1-23 BREAK-IN PROCEDURES ..............1-23 MAINTENANCE AFTER BREAK-IN ..............1-24 MAJOR MAINTENANCE................1-24 TORQUE-CHECK POINTS ................1-25 MOTORCYCLE CARE AND STORAGE............1-27 CARE......................1-27 STORAGE ....................1-28...
Page 15: Location Of Important Labels
LOCATION OF IMPORTANT LABELS LOCATION OF IMPORTANT LABELS EASB29B008 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 EASB29B009 18 17 16 1. Clutch lever 11. Radiator 2. Engine trouble warning light “ ” 12. Coolant drain bolt 3. Fuel level warning light “ ” 13. Rear brake pedal 4. Front brake lever 14. Air filter 5.
Page 19: Identification
There are two significant reasons for knowing the serial number of your vehicle: 1. When ordering parts, you can give the num- ber to your Yamaha dealer for positive iden- tification of the model you own. 2. If your vehicle is stolen, the authorities will need the number to search for and identify your vehicle.
Page 20: Included Parts
INCLUDED PARTS INCLUDED PARTS FUEL HOSE JOINT COVER EASB29B013 EASB29B017 The fuel hose joint covers “1” are used to pre- EASB29B014 SPARK PLUG WRENCH vent mud, dust, and other foreign materials The spark plug wrench “1” is used to remove or from entering the inside when the fuel hose is install the spark plug.
Page 21: Important Information
2. Use proper special tools and equipment. used for repair of the vehicle, including periodic See “SPECIAL TOOLS”. replacement parts, are new YAMAHA genuine parts and recommended parts. Do not use any used parts, because these may not be genuine though they have similar ap- pearances or because the quality may be changed by aging.
Page 22: Gaskets, Oil Seals And O-Rings
IMPORTANT INFORMATION GASKETS, OIL SEALS AND O-RINGS EASB29B021 1. When overhauling the engine, replace all gaskets and O-rings. All gasket surfaces, oil seal lips, and O-rings must be cleaned so that there may be no dust on them. 2. During assembly, always apply proper oil to bearings and proper grease to oil seal lips before installation.
Page 23: Basic Service Information
BASIC SERVICE INFORMATION BASIC SERVICE INFORMATION EASB29B025 EASB29B026 ELECTRICAL SYSTEM Electrical parts handling NOTICE Never disconnect a battery lead while the engine is running; otherwise, the electrical components could be damaged. NOTICE Be sure to connect the battery leads to the correct battery terminals.
Page 24 BASIC SERVICE INFORMATION NOTICE Checking the electrical system Handle electrical components with special care, and do not subject them to strong Before checking the electrical system, make shocks. sure that the battery voltage is at least 12 V. NOTICE NOTICE Electrical components are very sensitive to Never insert the tester probes into the cou- and can be damaged by static electricity.
Page 25 BASIC SERVICE INFORMATION 2. Check: • Lead • Coupler • Connector Moisture  Dry with compressed air. Rust/stains  Connect and disconnect sev- eral times. Checking the connections Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: •...
Page 26 BASIC SERVICE INFORMATION 4. Connect: • Lead • Coupler • Connector • When connecting a coupler or connector, make sure that both terminals are connected securely. • Make sure all connections are tight. 5. Check: • No continuity Pocket tester 90890-03112 Analog pocket tester YU-03112-C...
Page 27: Special Tools
SPECIAL TOOLS SPECIAL TOOLS EASB29B027 The following special tools are required for accurate and complete adjustment and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and tool number used for the special tool differ by country, so two types are provided.
Page 28 SPECIAL TOOLS Tool name/Part number How to use Illustration Radiator cap tester This tool is used to check the 90890-01325 radiator and the radiator cap. Mityvac cooling system tester YU-24460-A Radiator cap tester adapter This tool is used to check the 90890-01352 radiator and the radiator cap.
Page 29 Test harness– lean angle sensor (6P) YU-03209 FI diagnostic tool sub–lead This tool is used to connect 90890-03212 the Yamaha diagnostic tool FI diagnostic tool sub–lead to a battery. YU-03212 Yamaha diagnostic tool This tool is used to check er-...
Page 30 SPECIAL TOOLS Tool name/Part number How to use Illustration Valve spring compressor This tool is used to discon- 90890-04019 nect or connect the valve and Valve spring compressor the valve spring. YM-04019 YM-04019 Spacer (crankshaft installer) This tool is used to install the 90890-04081 crankshaft.
Page 31 SPECIAL TOOLS Tool name/Part number How to use Illustration Valve lapper This tool is used to remove 90890-04101 the valve lifter or lap the Valve lapping tool valve. YM-A8998 Valve spring compressor at- This tool is used to discon- tachment nect or connect the valve and 90890-04108 the valve spring.
Page 32 Tool name/Part number How to use Illustration Digital tachometer This tool is used to measure 90890-06760 the engine speed. Digital tachometer YU-39951-B Yamaha bond No. 1215 This sealant (Bond) is used 90890-85505 for crankcase mating sur- (Three bond No.1215®) face, etc. 1-18...
Page 33: Control Functions
This warning light comes on or flashes if a prob- with the starter. lem is detected in the electrical circuit monitor- ing the engine. If this occurs, have a Yamaha dealer check the vehicle. The electrical circuit of the warning light can be checked by pushing the start switch.
Page 34: Shift Pedal
CONTROL FUNCTIONS SHIFT PEDAL EASB29B033 The shift pedal “1” has adopted a method of 1 down & 5 ups (press-down & kick-ups). Press it down for N (neutral) to 1st, and kick it up for 2nd to 6th. SIDESTAND EASB29B037 This sidestand “1”...
Page 35: Fuel Tank Cap
CONTROL FUNCTIONS FUEL TANK CAP EASB29B039 Fuel tank cap “1” is located under the fuel tank cap cover “2”. Remove the fuel tank cap cover to open the fuel tank cap. • To remove the fuel tank cap cover, insert fin- gers under part “a”, and then use both hands to lift it up towards the rear of the vehicle.
Page 36: Starting And Break-In
Fuel tank capacity ELEMENT” section in the CHAPTER 3, apply 7.5 L (2.0 US gal, 1.7 Imp.gal) the Yamaha foam air filter oil or other quality Fuel reserve amount foam air filter oil to the element. (Excess oil in 2.1 L (0.55 US gal, 0.46 Imp.gal) the element may adversely affect engine start- ing.)
Page 37: Starting A Warm Engine
STARTING AND BREAK-IN NOTICE If the engine fail to start, fully open the throttle If the starter motor will not turn when the grip and push the start switch few seconds to start switch is pushed, stop pushing it im- clear the engine of the rich air-fuel mixtare re- mediately in order to avoid placing extra tained in it.
Page 38: Maintenance After Break-In
MAINTENANCE AFTER BREAK-IN • Cable MAINTENANCE AFTER BREAK-IN EASB29B047 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 39: Torque-Check Points
TORQUE-CHECK POINTS TORQUE-CHECK POINTS EASB29B049 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 40 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 41: Motorcycle Care And Storage
MOTORCYCLE CARE AND STORAGE • Do not use any harsh chemical products MOTORCYCLE CARE AND STOR- EASB29B050 on plastic parts. Be sure to avoid using cloths or sponges which have been in con- tact with strong or abrasive cleaning prod- CARE EASB29B051 ucts, solvent or thinner, fuel (gasoline),...
Page 42: Storage
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Consult a Yamaha dealer for advice on what 4. Lubricate all control cables and the pivoting points of all levers and pedals as well as of products to use.
Page 43 MOTORCYCLE CARE AND STORAGE 5. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alter- natively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot.
Page 44 MOTORCYCLE CARE AND STORAGE 1-30...
Page 45: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS .................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-10 TIGHTENING TORQUES ................2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-12 ENGINE TIGHTENING TORQUES............2-13 CHASSIS TIGHTENING TORQUES............2-16 LUBRICATION POINTS AND LUBRICANT TYPES ........2-19 ENGINE....................2-19 CHASSIS....................2-20 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-23 LUBRICATION DIAGRAMS ..............2-23 CABLE ROUTING DIAGRAM ................2-31...
Page 46: General Specifications
GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS EASB29B053 Model Model B29B (USA) B29C (CAN) B29D (EUR) B29E (AUS) (NZL) (ZAF) B29F (JPN) Dimensions Overall length 2165 mm (85.2 in) Overall width 825 mm (32.5 in) Overall height 1280 mm (50.4 in) Seat height 965 mm (38.0 in) Wheelbase 1465 mm (57.7 in)
Page 47: Engine Specifications
ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS EASB29B054 Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 250 cm Number of cylinders Single cylinder Bore  stroke 77.0  53.6 mm (3.03  2.11 in) Compression ratio 13.5 : 1 Starting system Electric starter Fuel Recommended fuel Premium unleaded gasoline...
Page 48 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 49 ENGINE SPECIFICATIONS Valve spring Free length (intake) 39.03 mm (1.54 in) Limit 37.08 mm (1.46 in) Free length (exhaust) 35.59 mm (1.40 in) Limit 33.81 mm (1.33 in) Installed length (intake) 32.50 mm (1.28 in) Installed length (exhaust) 29.60 mm (1.17 in) Spring rate K1 (intake) 25.56 N/mm (2.61 kgf/mm, 145.95 lbf/in) Spring rate K2 (intake)
Page 50 4.85 mm (0.1909 in) Decompression device Device type Auto decomp Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil Fuel pump Pump type Electrical Fuel injector Model/quantity 30NA-FZ31/1 12.0 ...
Page 51 ENGINE SPECIFICATIONS Throttle body Type/quantity 30RA-A62U/1 ID mark B291 00 Fuel line pressure (at idle) 300.0–390.0 kPa (3.00–3.90 kgf/cm , 43.5– 56.6 psi) Throttle position sensor Resistance 6.30 k Output voltage (at idle) 0.49–0.51 V Fuel injection sensor 228–342  Crankshaft position sensor resistance Intake air pressure sensor output voltage 3.61–3.67 V at 101.3 kPa (3.61–3.67 V at 1.01...
Page 52: Chassis Specifications
CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS EASB29B055 Chassis Frame type Semi double cradle Caster angle 26.3 ° Trail 114 mm (4.5 in) Front wheel Wheel type Spoke wheel 1.60  21 Rim size Rim material Aluminum Wheel travel 310 mm (12.2 in) Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit...
Page 53 Inner tube outer diameter 48 mm (1.9 in) Inner tube bending limit 0.2 mm (0.01 in) Optional spring available Recommended oil Yamaha Suspension Oil S1 Quantity 526.0 cm (17.78 US oz, 18.55 Imp.oz) (USA) (CAN) (EUR) (AUS) (NZL) (ZAF) 496.0 cm (16.77 US oz, 17.49 Imp.oz) (JPN)
Page 54 CHASSIS SPECIFICATIONS Rear suspension Type Swingarm (link suspension) Spring/shock absorber type Coil spring/Gas-hydraulic damper Rear shock absorber assembly travel 126.0 mm (4.96 in) Spring free length 275.0 mm (10.83 in) Spring installed length 265.0 mm (10.43 in) Spring rate K1 56.00 N/mm (5.71 kgf/mm, 319.76 lbf/in) (USA) (CAN) (EUR) (AUS) (NZL) (ZAF) 48.00 N/mm (4.89 kgf/mm, 274.08 lbf/in) (JPN)
Page 55: Electrical Specifications
Digital Ignition timing (B.T.D.C.) 10.0 ° at 2000 r/min Engine control unit Model/manufacturer B292YAMAHA (USA) (CAN) (EUR) (AUS) (NZL) (ZAF) B293/YAMAHA (JPN) 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 56 ELECTRICAL SPECIFICATIONS Fuel sender unit 1350–1900  Sender unit resistance (thermistor) Starter relay Amperage 180.0 A 4.18–4.62  Coil resistance Starting circuit cut-off relay 75.6–92.5  Coil resistance Fuses Main fuse 15.0 A Spare fuse 15.0 A Radiator fan motor fuse 5.0 A 2-11...
Page 57: Tightening Torques
TIGHTENING TORQUES TIGHTENING TORQUES EAS20320 EASB29B057 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 58: Engine Tightening Torques
TIGHTENING TORQUES ENGINE TIGHTENING TORQUES EASB29B058 - 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 59 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Air filter guide holder screw 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) 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)
Page 60 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size 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) Rotor nut 65 Nm (6.5 m·kgf, 47 ft·lbf) Stator screw...
Page 61: Chassis Tightening Torques
TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES EASB29B059 - 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 62 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Front brake disc bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Rear brake disc bolt 14 Nm (1.4 m·kgf, 10 ft·lbf) Footrest bracket bolt 55 Nm (5.5 m·kgf, 40 ft·lbf) Sidestand bolt 25 Nm (2.5 m·kgf, 18 ft·lbf) Rear brake pedal bolt 26 Nm (2.6 m·kgf, 19 ft·lbf)
Page 63 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 64: Lubrication Points And Lubricant Types
LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES EASB29B060 EASB29B061 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 65: Chassis
LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Starter idle gear inner surface, thrust surfaces Starter clutch drive gear inner surface, thrust surfaces Yamaha bond No.1215 Cylinder head cover gasket (Three bond No.1215®) Yamaha bond No.1215 Crankcase mating surface (Three bond No.1215®)
Page 66 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Clutch lever sliding surface and bolt outer surface Clutch lever adjuster rubber lip Clutch cable end (clutch lever side) Tube guide (throttle grip) inner surface and throttle cable end Front brake caliper piston Front brake caliper piston seal Front brake caliper dust seal Front brake caliper piston outer surface...
Page 67 LUBRICATION POINTS AND LUBRICANT TYPES EASB29B063 2-22...
Page 68: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION DIAGRAMS EASB29B064 2-23...
Page 69 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 70 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25...
Page 71 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Connecting rod 2. Crankshaft 3. Main axle 4. Oil strainer 5. Drive axle 2-26...
Page 72 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
Page 73 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Exhaust camshaft 2. Intake camshaft 3. Oil filter element 4. Oil pump 2-28...
Page 74 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
Page 75 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil pressure check bolt 3. Oil filter element 4. Oil pump 2-30...
Page 76: Cable Routing Diagram
CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM EASB29B065 2-31...
Page 77 CABLE ROUTING DIAGRAM O. Insert the plastic locking tie into the bracket hole 1. Clutch cable and clamp the clutch cable. Clamp it so that the 2. Throttle cable (return) lock of the plastic locking tie faces downward, 3. Throttle cable (pull) and then cut off the end of the plastic locking tie.
Page 78 CABLE ROUTING DIAGRAM 2-33...
Page 79 CABLE ROUTING DIAGRAM 1. Clamp 2. Cylinder head breather hose 3. Throttle position sensor lead 4. Joint coupler 5. Intake air temperature sensor coupler 6. Intake air pressure sensor lead 7. Wire harness 8. Injector lead 9. Throttle body 10. Injector coupler 11.
Page 80 CABLE ROUTING DIAGRAM 2-35...
Page 81 CABLE ROUTING DIAGRAM 1. Cable guide 2. Joint coupler 3. Ground lead 4. Throttle position sensor lead 5. Throttle position sensor coupler 6. Radiator breather hose 7. Cylinder head breather hose 8. Crankcase breather hose 9. Radiator hose 10. Fuel hose 11.
Page 82 CABLE ROUTING DIAGRAM 2-37...
Page 83 CABLE ROUTING DIAGRAM 1. Battery negative lead 2. Fuel hose 3. Fuel pump coupler 4. Resistor 5. Fuel pump lead 6. Resistor coupler 7. Battery positive lead 8. Lean angle sensor 9. Starter motor lead 10. Radiator fan motor relay (blue tape) 11.
Page 84 CABLE ROUTING DIAGRAM 2-39...
Page 85 CABLE ROUTING DIAGRAM 1. Plastic band 2. Clutch cable 3. Clutch switch lead 4. Engine stop switch lead 5. Warning light lead 6. Front brake hose 7. Brake hose guide 8. Number plate 9. Warning light 10. Start switch lead A.
Page 86 CABLE ROUTING DIAGRAM 2-41...
Page 87 CABLE ROUTING DIAGRAM 1. Breather hose 3 (air filter breather hose) 2. Breather hose 1 (cylinder head breather hose) 3. Breather hose 2 (crankcase breather hose) 4. Joint pipe A. Pass the breather hose 3 to the outside the throt- tle cable.
Page 88 CABLE ROUTING DIAGRAM 2-43...
Page 89 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 90 CABLE ROUTING DIAGRAM 2-45...
Page 91: Periodic Checks And Adjustments
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 FREE PLAY........3-10 ADJUSTING THE THROTTLE GRIP FREE PLAY ........3-11...
Page 92 CHECKING AND ADJUSTING THE STEERING HEAD ......3-34 CHECKING AND LUBRICATING THE CABLES ........3-35 LUBRICATING THE LEVERS ..............3-35 LUBRICATING THE PEDAL ..............3-35 LUBRICATING THE DRIVE CHAIN ............3-35 LUBRICATING THE SIDESTAND............3-36 CHECKING THE CHASSIS FASTENERS ..........3-36 ELECTRICAL SYSTEM..................3-37 CHECKING THE SPARK PLUG ..............3-37 CHECKING THE IGNITION TIMING............3-37 CHECKING AND CHARGING THE BATTERY........3-38...
Page 93: Maintenance Intervals
MAINTENANCE INTERVALS MAINTENANCE INTERVALS EASB29B066 EASB29B067 MAINTENANCE INTERVALS 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- 25.) • 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 94 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 95 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 96 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) ENGINE GUARD Replace Breakage FRAME Clean and inspect FUEL TANK, FUEL PUMP Inspect FUEL HOSE Inspect Replace Every four years FRONT FORK LEG Clean Dust seal...
Page 97 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) Retighten brake Check for tightening torques. disc bolts, caliper bolts, master cylin- der bolts and union bolts Replace pads Replace brake flu- Every one year SWINGARM...
Page 98 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) DRIVE CHAIN GUIDE AND DRIVE CHAIN SUPPORT Replace CABLES Routing (Connec- tion) Check and grease Check and clean Check throttle cables on the throttle cable throttle body for dirt and wear.
Page 99: Pre-Operation Inspection And Maintenance
PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE EASB29B068 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 EASB29B069 ITEM inspect Page...
Page 100: Engine
ENGINE ENGINE CHECKING THE COOLING SYSTEM EASB29B070 EASB29B072 1. Remove: EASB29B071 CHECKING THE COOLANT LEVEL • Seat • Side cover (left/right) WARNING • Air scoop (left/right) If coolant seems hot, do not remove the ra- Refer to “GENERAL CHASSIS” on page 4- diator cap.
Page 101: 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 102: Checking The Coolant Circulatory System For Leaks
ENGINE CHECKING THE COOLANT CIRCULATORY ADJUSTING THE CLUTCH LEVER FREE EASB29B076 EASB29B077 SYSTEM FOR LEAKS PLAY 1. Check: 1. Check: • Clutch lever free play “a” • Coolant level Out of specification  Regulate. 2. Install: • Radiator cap tester “1” Clutch lever free play •...
Page 103: Adjusting The Throttle Grip Free Play
ENGINE 2. Adjust: Direction “a” • Throttle grip free play Clutch lever free play is increased. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Direction “b” a. Loosen the locknut “1”. Clutch lever free play is decreased. b. Turn the adjuster “2” until the specified free play is obtained. d.
Page 104: Cleaning The Air Filter Element
ENGINE 2. Lubricate: 2. Remove: • Throttle cable end “a” • Air filter mounting bolt “1” • Air filter element “2” Recommended lubricant • Air filter guide “3” (from the air filter element) Lithium-soap-based grease 3. Wash: • Air filter element 3.
Page 105: Checking The Throttle Body Joint
ENGINE 6. Install: • Air filter guide “1” (to the air filter element) • Air filter element “2” • Air filter mounting bolt “3” Air filter mounting bolt 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) CHECKING THE EXHAUST SYSTEM EASB29B083 1. Remove: •...
Page 106: Checking The Fuel Line
ENGINE CHECKING THE ENGINE OIL LEVEL EASB29B085 1. Stand the vehicle upright on a level surface. 2. Start the engine, warm this up for 3 minutes, and then stop the engine and wait about 5 minute. 3. Check: • Oil level The engine oil level should be between the minimum level mark “a”...
Page 107: Changing The Engine Oil
ENGINE 5. To check the oil strainer, perform the follow- CHANGING THE ENGINE OIL EASB29B086 ing procedure. Stand the vehicle upright on a level surface. 1. Start the engine, warm this up for 3 minutes, ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the oil strainer “1”. and then stop the engine and wait about 5 b.
Page 108: Adjusting The Engine Idling Speed
ENGINE 8. Install: ADJUSTING THE ENGINE IDLING SPEED EASB29B087 • Oil filler cap 9. Check: • Because the air pressure is lower at high alti- • Oil level tudes, the air-fuel mixture will become richer. Refer to “CHECKING THE ENGINE OIL If the idling speed is low, turn the starter knob/ LEVEL”...
Page 109: Adjusting The Valve Clearance
Turn the crankshaft counterclockwise with a basic knowledge and skill concerning the ser- wrench. vicing of Yamaha motorcycles (e.g., Yamaha b. Align the top dead center (TDC) mark “a” on dealers, service engineers, etc.). Those who the rotor with the alignment mark “b” on the have little knowledge and skill concerning ser- crankcase cover.
Page 110 ENGINE Valve lapper 90890-04101 Valve lapping tool YM-A8998 c. Measure the valve clearance “e” using a thickness gauge “1”. Record the measured reading if the clearance is incorrect. c. Check the number on the originally installed adjusting pad. • The adjusting pad number “a” is indicated on the top of the adjusting pad.
Page 111 ENGINE d. Select an adjusting pad with a proper valve f. Install the camshafts (exhaust and intake). clearance from the adjusting pad selection Refer to “CAMSHAFT” on page 5-12. table. g. Measure the valve clearance again. h. If the valve clearance is out of specification, repeat adjusting the valve clearance until it •...
Page 112 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 113 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 114: Chassis
CHASSIS CHASSIS EASB29B089 EASB29B090 BLEEDING THE BRAKE SYSTEM WARNING Bleed the brake system whenever: • The system is disassembled. • A brake hose is loosened, disconnected, or replaced. • The brake fluid level is very low. • Brake operation is faulty. A.
Page 115: Checking The Brake Hose
CHASSIS CHECKING THE BRAKE HOSE EASB29B091 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 116: Adjusting The Rear Brake
CHASSIS ADJUSTING THE REAR BRAKE EASB29B093 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 117 CHASSIS d. Remove the pad pin and brake pads “4”. i. Install the brake caliper “8” and tighten the pad pin “9”. Bolt (brake caliper) 28 Nm (2.8 m·kgf, 20 ft·lbf) Pad pin 17 Nm (1.7 m·kgf, 12 ft·lbf) e. Connect the plastic hose “5” to the bleed screw “6”...
Page 118: Checking The Rear Brake Pads
CHASSIS d. Remove the pad pin “6” and the brake pads CHECKING THE REAR BRAKE PADS EASB29B095 “7”. 1. Measure: • Brake pad thickness “a” Out of specification  Replace as a set. The pads worn up to the indicator “b” grooves mean that the brake pad thickness limit is reached.
Page 119: Checking The Rear Brake Pad Insulator
CHASSIS i. Install the brake caliper “12” and the rear CHECKING THE REAR BRAKE PAD INSU- EASB29B096 wheel “13”. LATOR Refer to “REAR WHEEL” on page 4-7. 1. Remove: j. Tighten the pad pin “14”. • Brake pads Refer to “REAR BRAKE” on page 4-21. Pad pin 2.
Page 120: 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 121: Checking The Front Fork Legs
CHASSIS CHECKING THE FRONT FORK LEGS CLEANING THE FRONT FORK OIL SEAL EASB29B099 EASB29B101 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 122: Adjusting The Front Fork Legs
CHASSIS 2. Remove the air bleed screw “1” and release the internal pressure from the front fork. 3. Tighten: • Air bleed screw Air bleed screw 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping NOTICE Do not turn the adjuster forcibly beyond its adjusting range.
Page 123: Checking The Swingarm Operation
CHASSIS 1. Remove: CHECKING THE SWINGARM OPERATION EASB29B104 • Rear frame 1. Check: Refer to “REAR SHOCK ABSORBER AS- • Swingarm smooth action SEMBLY” on page 4-56. • Swingarm free play 2. Adjust: Refer to “SWINGARM” on page 4-63. • Spring preload EASB29B105 CHECKING THE REAR SUSPENSION ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 124 CHASSIS e. Tighten the locknut. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Locknut Compression damping (for fast compres- 30 Nm (3.0 m·kgf, 22 ft·lbf) sion damping) NOTICE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Do not turn the adjuster forcibly beyond its 3. Install: adjusting range. • Rear frame Refer to “REAR SHOCK ABSORBER AS- 1.
Page 125: Checking The Tires
CHASSIS Compression damping (for slow compres- sion damping) • Check the tire while it is cold. • Loose bead stoppers allow the tire to slip off NOTICE its position on the rim when the tire pressure Do not turn the adjuster forcibly beyond its is low.
Page 126: Checking The Wheels
CHASSIS 3. Remove: Spoke nipple wrench (6–7) • Handlebar 90890-01521 Refer to “HANDLEBAR” on page 4-31. Spoke nipple wrench (6–7) • Upper bracket YM-01521 Refer to “STEERING HEAD” on page 4-51. 4. Adjust: Spokes • Steering head 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 127: Checking And Lubricating The Cables
CHASSIS d. Loosen the ring nut fully turn and then tight- 2. Check: en it to specification with a steering nut • Cable operation Rough movement  Lubricate. wrench. Recommended lubricant WARNING Engine oil or a suitable cable lu- Do not overtighten the lower ring nut. bricant Ring nut (final tightening torque) 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Page 128: Lubricating The Sidestand
CHASSIS LUBRICATING THE SIDESTAND EASB29B116 Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Recommended lubricant Lithium-soap-based grease EASB29B117 CHECKING THE CHASSIS FASTENERS Make sure that all nuts, bolts, and screws are properly tightened. Refer to “CHASSIS TIGHTENING TORQUES” on page 2-16.
Page 129: Electrical System
ELECTRICAL SYSTEM 5. Clean: ELECTRICAL SYSTEM EASB29B118 • Spark plug (with a spark plug cleaner or a wire brush) EASB29B119 CHECKING THE SPARK PLUG 6. Measure: 1. Remove: • Spark plug gap “a” • Seat Out of specification  Adjust the spark plug •...
Page 130: Checking And Charging The Battery
ELECTRICAL SYSTEM 2. Attach: • Timing light “1” • Digital tachometer “2” To the high tension code “3”. Timing light 90890-03141 Timing light YU-03141 Digital tachometer 90890-06760 Digital tachometer YU-39951-B 3. Adjust: • Engine idling speed Refer to “ADJUSTING THE ENGINE IDLING SPEED”...
Page 131 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 132 HANDLEBAR ....................4-31 REMOVING THE HANDLEBAR...............4-33 CHECKING THE HANDLEBAR ...............4-33 INSTALLING THE HANDLEBAR .............4-33 FRONT FORK....................4-38 REMOVING THE FRONT FORK LEGS...........4-40 DISASSEMBLING THE FRONT FORK LEGS .........4-40 CHECKING THE FRONT FORK LEGS ...........4-41 ASSEMBLING THE FRONT FORK LEGS ..........4-42 INSTALLING THE FRONT FORK LEGS ..........4-49 STEERING HEAD...................4-51 REMOVING THE LOWER BRACKET............4-53 CHECKING THE STEERING HEAD ............4-53...
Page 133: 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 134: Removing The Left Side Cover
GENERAL CHASSIS REMOVING THE LEFT SIDE COVER REMOVING THE NUMBER PLATE EASB29B124 EASB29B126 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 135: Front Wheel
FRONT WHEEL FRONT WHEEL EASB29B127 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 136: Removing The Front Wheel
FRONT WHEEL REMOVING THE FRONT WHEEL EASB29B128 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 137: Disassembling The Front Wheel
FRONT WHEEL DISASSEMBLING THE FRONT WHEEL EASB29B130 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 138: 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 139: Rear Wheel
REAR WHEEL REAR WHEEL EASB29B133 Removing the rear wheel 14 Nm (1.4 m kgf, 10 ft Ibf) 125 Nm (12.5 m kgf, 90 ft lbf) 21 Nm (2.1 m kgf, 15 ft Ibf) 50 Nm (5.0 m kgf, 36 ft Ibf) 21 Nm (2.1 m kgf, 15 ft Ibf) Order Part name...
Page 140: Removing The Rear Wheel
REAR WHEEL 4. Measure: REMOVING THE REAR WHEEL EASB29B134 • 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 141: 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 EASB29B138 1.
Page 142 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” &spc628999; Push the rear wheel “2” forward and install the drive chain.
Page 143: Front Brake
FRONT BRAKE FRONT BRAKE EASB29B140 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 144 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 145 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 146 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 147: Introduction
FRONT BRAKE INTRODUCTION EASB29B141 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 148: Checking The Front Brake Caliper
FRONT BRAKE ASSEMBLING THE FRONT BRAKE CALI- EASB29B146 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 149: 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 150: 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 151: Installing The Front Brake Master Cylinder
FRONT BRAKE INSTALLING THE FRONT BRAKE MASTER EASB29B152 CYLINDER 1. Install: • Brake master cylinder “1” Brake master cylinder holder bolt 9 Nm (0.9 m·kgf, 6.5 ft·lbf) • Install the front brake master cylinder holder 3. Install: with the “UP” mark facing up. •...
Page 152 FRONT BRAKE Turn the handlebar toward right and left to make sure that the brake hose does not touch other parts (e.g., wire harness, cables, leads). Adjust if necessary. 6. Check: • Brake lever free play Refer to “ADJUSTING THE FRONT BRAKE”...
Page 153: Rear Brake
REAR BRAKE REAR BRAKE EASB29B153 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 154 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 155 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 156 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 157: Introduction
REAR BRAKE INTRODUCTION EASB29B154 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 158: Removing The Rear Brake Caliper
REAR BRAKE REMOVING THE REAR BRAKE CALIPER CHECKING THE REAR BRAKE CALIPER EASB29B156 EASB29B158 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 159: Installing The Brake Caliper Piston
REAR BRAKE INSTALLING THE BRAKE CALIPER PISTON INSTALLING THE REAR BRAKE CALIPER EASB29B160 EASB29B161 1. Clean: 1. Install: • Brake caliper • Rear brake caliper • Brake caliper piston seal • Rear brake caliper bracket • Brake caliper piston dust seal 2.
Page 160: Removing The Rear Brake Master Cylinder
REAR BRAKE REMOVING THE REAR BRAKE MASTER EASB29B162 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 161: Assembling The Rear Brake Master Cylinder
REAR BRAKE 3. Install: ASSEMBLING THE REAR BRAKE MASTER EASB29B164 • Spring “1” CYLINDER Install to the brake master cylinder piston WARNING “2”. • Before installation, all internal brake com- ponents should be cleaned and lubricated Install the spring with a smaller inside diameter with clean or new brake fluid.
Page 162 REAR BRAKE 4. Check: WARNING • Brake fluid level Proper brake hose routing is essential to in- The minimum level mark “a” or below  sure safe vehicle operation. Add. Refer to “CHECKING THE BRAKE FLUID NOTICE LEVEL” on page 3-27. Make sure that the pipe portion of the brake hose touches the projection “a”...
Page 163 HANDLEBAR HANDLEBAR EASB29B166 Removing the handlebar Order Part name Q’ty Remarks Number plate Remove the band only. Clutch cable Disconnect. Clutch switch Clutch lever holder Engine stop switch Brake master cylinder Throttle cable cap Throttle cable (pull) Disconnect. Throttle cable (return) Disconnect.
Page 164 HANDLEBAR Removing the handlebar Order Part name Q’ty Remarks For installation, reverse the removal proce- dure. 4-32...
Page 165: Handlebar
HANDLEBAR REMOVING THE HANDLEBAR EASB29B167 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Clutch switch “1” CHECKING THE HANDLEBAR EASB29B168 1. Check: •...
Page 166 HANDLEBAR NOTICE • First, tighten the bolts on the front side of the upper handlebar holder, and then on the rear side. • Turn the handlebar all the way to the left and right. If there is any contact with the fuel tank, adjust the handlebar position.
Page 167 HANDLEBAR 5. Install: • Engine stop switch “1” • Clutch lever “2” • Clutch lever holder “3” • Clamp “4” Engine stop switch screw 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf) Clutch lever holder bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) 7.
Page 168 HANDLEBAR 9. Install: 11.Install: • Throttle cable housings “1” • Start switch “1” • Screw (throttle cable housings) “2” • Front brake master cylinder assembly “2” • Front brake master cylinder holder “3” Screw (throttle cable housings) • Bolt (brake master cylinder holder) “4” 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) •...
Page 169 HANDLEBAR 13.Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LE- VER FREE PLAY” on page 3-10. Clutch lever free play 7.0–12.0 mm (0.28–0.47 in) 14.Adjust: • Throttle grip free play Refer to “ADJUSTING THE THROTTLE GRIP FREE PLAY” on page 3-11. Throttle grip free play 3.0–6.0 mm (0.12–0.24 in) 4-37...
Page 170: Front Fork
FRONT FORK FRONT FORK EASB29B170 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 171 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) 1.3 Nm (0.13 m kgf, 0.94 ft Ibf) 55 Nm (5.5 m kgf, 40 ft Ibf) Order Part name Q’ty...
Page 172: Removing The Front Fork Legs
FRONT FORK REMOVING THE FRONT FORK LEGS EASB29B171 1. Use a suitable stand to raise the front wheel • While compressing the inner tube “2”, set the off the ground. cap bolt ring wrench “4” between the inner tube and locknut “3”. WARNING •...
Page 173: Checking The Front Fork Legs
FRONT FORK The bending value is shown by one half of the dial gauge reading. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Remove: • Base valve “1” (from the damper assembly) Hold the damper assembly with the cap bolt ring wrench “2”...
Page 174: Assembling The Front Fork Legs
• Before assembling the front fork leg, make sure that all of the components are clean. 1. Stretch the damper assembly fully. 2. Fill: • Damper assembly Recommended oil Yamaha Suspension Oil S1 7. Check: Standard oil amount • Adjuster “1” 206 cm (6.96 US oz, 7.27 •...
Page 175 FRONT FORK NOTICE • Be sure to use the recommended oil. Other oils may have an adverse effect on front fork performance. • When disassembling and assembling the front fork leg, take care not to allow any foreign material to enter the front fork. 3.
Page 176 FRONT FORK 7. Install: 10.After filling, pump the damper assembly “1” • Base valve “1” slowly up and down more than 10 times to (to the damper assembly “2”) distribute the fork oil. First bring the damper rod pressure to a maxi- mum.
Page 177 FRONT FORK 15.Install: • Inner tube bushing “1” Install the inner tube bushing onto the slot on inner tube. 14.Install: • Dust seal “1” • Scraper “2” • Oil seal clip “3” • Oil seal “4” • Washer “5” 16.Install: •...
Page 178 FRONT FORK 20.Install: • Scraper “1” • Dust seal “2” Apply lithium-soap-based grease on the inner tube. 18.Install: • Oil seal “1” Using a fork seal driver “2”, press the oil seal in until the stopper ring groove fully appears. Fork seal driver 21.Check: 90890-01502...
Page 179 FRONT FORK 23.Install: • Collar “1” • Fork spring “2” (to the damper assembly “3”) Install the collar with its larger dia. end “a” fac- ing the fork spring. 26.Install: • Damper adjusting rod “1” • Copper washer “2” • Adjuster “3” (to the damper assembly “4”) •...
Page 180 FRONT FORK 30.Fill: • Front fork leg Recommended oil Yamaha Suspension Oil S1 Standard oil amount 330 cm (11.16 US oz, 11.64 lmp.oz) (USA) (CAN) (EUR) (AUS) (NZL) (ZAF) 300 cm (10.14 US oz, 10.58 lmp.oz) (JPN) Extent of adjustment 28.Tighten:...
Page 181: Installing The Front Fork Legs
FRONT FORK 32.Install: • Protector guide “1” 3. Adjust: • Front fork top end “a” Front fork top end (standard) “a” INSTALLING THE FRONT FORK LEGS EASB29B175 3 mm (0.12 in) 1. Install: • Front fork “1” • Temporarily tighten the pinch bolts (lower bracket).
Page 182 FRONT FORK 5. Install: • Protector “1” • Bolt (protector) “2” Bolt (protector) 5 Nm (0.5 m·kgf, 3.6 ft·lbf) 6. Adjust: • Rebound damping force Turn in the damping adjuster “1” finger-tight and then turn out to the originally set position. 7.
Page 183: Steering Head
STEERING HEAD STEERING HEAD EASB29B176 Removing the lower bracket 21 Nm (2.1 m kgf, 15 ft lbf) 145 Nm (14.5 m kgf, 105 ft lbf) 38 Nm (3.8 m kgf, 27 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft lbf) 21 Nm (2.1 m kgf, 15 ft...
Page 184 STEERING HEAD Removing the lower bracket 21 Nm (2.1 m kgf, 15 ft lbf) 145 Nm (14.5 m kgf, 105 ft lbf) 38 Nm (3.8 m kgf, 27 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft lbf) 21 Nm (2.1 m kgf, 15 ft lbf) 9 Nm (0.9 m...
Page 185: Removing The Lower Bracket
STEERING HEAD REMOVING THE LOWER BRACKET EASB29B177 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 186 STEERING HEAD 2. Install: • Bearing races • Upper bearing “1” • Bearing race cover “2” Apply the lithium-soap-based grease on the bearing and bearing race cover lip. 5. Check the steering stem by turning this lock to lock. If there is any binding, remove the steering stem and check the steering bear- ing.
Page 187 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) 8. Install: WARNING • Steering stem nut “1” Tighten the lower bracket to specified torque.
Page 188: Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY REAR SHOCK ABSORBER ASSEMBLY EASB29B180 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 189 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 16 15 14 13 Order Part name Q’ty Remarks Collars O-ring Dust seal Stopper ring Bearing For installation, reverse the removal proce- dure. 4-57...
Page 190 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. 4-58...
Page 191: Handling The Rear Shock Absorber
• To dispose of a damaged or a worn-out rear shock absorber, take the unit to your Yamaha dealer for this disposal proce- 3. Remove: dure. • Rear shock absorber assembly upper bolt •...
Page 192: Checking The Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY • Spring guide Damage/wear  Replace. • Bearing Damage/wear  Replace. • Bolts Bends/damage/wear  Replace. EASB29B186 CHECKING THE CONNECTING ARM AND RELAY ARM 1. Check: • Connecting arm 2. Remove: • Relay arm • Upper bearing “1” Damage/wear ...
Page 193: Installing The Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY 3. Install: 4. Install: • Bearing “1” • Bearing “1” • Oil seals “2” • Bushing “2” (to connecting arm “3”) • Collar “3” • Dust seal “4” Installed depth “a” (to rear shock absorber assembly (lower 0 mm (0 in) side)) Install the dust seals with their lips facing in-...
Page 194 REAR SHOCK ABSORBER ASSEMBLY 7. Tighten: • Rear shock absorber assembly upper bolt Rear shock absorber assembly upper bolt 56 Nm (5.6 m·kgf, 41 ft·lbf) • Connecting arm bolt (frame side) Connecting arm bolt (frame side) 80 Nm (8.0 m·kgf, 58 ft·lbf) •...
Page 195: Swingarm
SWINGARM SWINGARM EASB29B189 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 196: Removing The Swingarm
SWINGARM REMOVING THE SWINGARM EASB29B190 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 197: Installing The Swingarm
SWINGARM INSTALLING THE SWINGARM EASB29B193 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 198: Chain Drive
CHAIN DRIVE CHAIN DRIVE EASB29B194 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 199: Removing The Drive Chain
CHAIN DRIVE REMOVING THE DRIVE CHAIN EAS23420 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated.
Page 200: Checking The Drive Sprocket
CHAIN DRIVE CHECKING THE DRIVE SPROCKET EASB29B195 1. Check: • Drive sprocket More than 1/4 tooth wear “a”  Replace the drive sprocket and the rear wheel sprocket as a set. Bent tooth  Replace the drive sprocket and the rear wheel sprocket as a set. b.
Page 201 CHAIN DRIVE b. After riveting, make sure the diameter be- 4. Adjust: tween the edges “b” of the connecting pin “2” • Drive chain slack is 5.5–5.8 mm (0.22–0.23 in). Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-28. Drive chain slack 50.0–60.0 mm (1.97–2.36 in) NOTICE...
Page 202 CHAIN DRIVE 4-70...
Page 203: Engine
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 ....................5-12...
Page 204 CLUTCH ......................5-41 REMOVING THE CLUTCH ..............5-44 CHECKING THE FRICTION PLATES............5-44 CHECKING THE CLUTCH PLATES ............5-44 CHECKING THE CLUTCH SPRINGS............5-44 CHECKING THE CLUTCH HOUSING .............5-45 CHECKING THE CLUTCH BOSS............5-45 CHECKING THE PRESSURE PLATE .............5-45 CHECKING THE PUSH LEVER SHAFT..........5-45 CHECKING THE CLUTCH PUSH RODS ..........5-45 CHECKING THE PRIMARY DRIVE GEAR..........5-45 CHECKING THE PRIMARY DRIVEN GEAR ...........5-46 INSTALLING THE OIL SEAL ..............5-46...
Page 205 CRANKCASE ....................5-67 DISASSEMBLING THE CRANKCASE.............5-70 REMOVING THE CRANKCASE BEARING ..........5-70 CHECKING THE TIMING CHAIN, TIMING CHAIN GUIDE, OIL STRAINER..................5-70 CHECKING THE CRANKCASE ...............5-70 INSTALLING THE OIL SEAL ..............5-71 ASSEMBLING THE CRANKCASE............5-71 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT .......5-73 REMOVING THE CRANKSHAFT ASSEMBLY ........5-74 CHECKING THE CRANKSHAFT ASSEMBLY.........5-74 INSTALLING THE CRANKSHAFT ASSEMBLY........5-75 INSTALLING THE BALANCER SHAFT ...........5-75...
Page 206: 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 207 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 208 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 209 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 210 ENGINE REMOVAL Removing the engine 55 Nm (5.5 m kgf, 40 ft Ibf) Order Part name Q’ty Remarks Cylinder head breather hose Drive sprocket cover 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...
Page 211: Removing The Silencer
ENGINE REMOVAL REMOVING THE SILENCER EASB29B200 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 EASB29B202 1.
Page 212: Removing The Engine
ENGINE REMOVAL REMOVING THE ENGINE CHECKING THE SILENCER AND EXHAUST EASB29B203 EASB29B204 1. Remove: PIPE • Pivot shaft “1” 1. Check: • Gasket “1” Damage  Replace. 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 213: Installing The Engine
ENGINE REMOVAL 2. Remove: 5. Replace: • Rivet “1” • Fiber “1” • Silencer cap “2” Stuff the fiber into the silencer body by using a flat board “2”. 3. Replace: • Fiber “1” 6. Install: • Silencer cap “1” •...
Page 214: Installing The Brake Pedal
ENGINE REMOVAL • Front engine bracket “4” INSTALLING THE BRAKE PEDAL EASB29B207 • Engine bracket bolt (front side) “5” 1. Install: • Spring “1” Engine bracket bolt (front side) • Brake pedal “2” 34 Nm (3.4 m·kgf, 25 ft·lbf) • O-rings “3” •...
Page 215: Installing The Exhaust Pipe And Muffler
ENGINE REMOVAL Tighten the nut while applying the rear brake. NOTICE Make sure to tighten to specification; other- wise, it may damage the other part that is fastened together. 2. Install: • Clamp • Exhaust pipe 2 “1” • Bolt (exhaust pipe 2) “2” 3.
Page 216 ENGINE REMOVAL Install and temporarily tighten the silencer so that its joint is positioned as shown with respect to the exhaust pipe 2. 2mm (0.08in) 4. Tighten: • Bolt (exhaust pipe 2) Bolt (exhaust pipe 2) 20 Nm (2.0 m·kgf, 14 ft·lbf) •...
Page 217: Camshaft
CAMSHAFT CAMSHAFT EASB29B210 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 218 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 219: Removing The Camshaft
CAMSHAFT REMOVING THE CAMSHAFT EASB29B211 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 220: Checking The Camshaft
CAMSHAFT 3. Measure: CHECKING THE CAMSHAFT EASB29B212 • 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 221: Checking The Timing Chain And Camshaft Sprocket
CAMSHAFT 2. Check: • Camshaft sprocket • Tighten the camshaft cap bolts in a crisscross More than 1/4 tooth wear “a”  Replace the pattern from innermost to outer caps. camshaft and the timing chain as a set. • Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance.
Page 222: Checking The Decompression System
CAMSHAFT CHECKING THE DECOMPRESSION SYS- EASB29B215 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 223 “2”, and tighten the bolt “3”. inder head cover gasket. Bolt (timing chain tensioner) 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) c. Release the screwdriver, check that the ten- sioner rod comes out smoothly, and tighten 6.
Page 224: Cylinder Head
CYLINDER HEAD CYLINDER HEAD EASB29B217 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 225 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 226: Removing The Cylinder Head
CYLINDER HEAD REMOVING THE CYLINDER HEAD EASB29B218 1. Remove: • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAMSHAFT” on page 5-14. 2. Remove: • Cylinder head nuts • Cylinder head bolts 2. Check: • Loosen the bolts in the proper sequence as •...
Page 227: Installing The Cylinder Head
CYLINDER HEAD INSTALLING THE CYLINDER HEAD EASB29B221 1. Install: Tighten the bolts and nuts to the specified • Timing chain guide (intake side) “1” torque in two or three steps in the proper tight- • Dowel pin “2” ening sequence as shown. •...
Page 228: Valves And Valve Springs
VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS EASB29B222 Removing the valves and valve springs Order Part name Q’ty Remarks Refer to “CYLINDER HEAD” on page 5-19. Cylinder head Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Intake valve...
Page 229: Removing The Valves
VALVES AND VALVE SPRINGS REMOVING THE VALVES EASB29B223 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Pour a clean solvent “a” into the intake and exhaust ports. Before removing the internal parts of the cylin- b. Check that the valves are properly sealed. der head (e.g., valves, valve springs, valve seats), make sure that the valves are properly Check that there are no kerosene leaks from sealed.
Page 230: Checking The Valves And Valve Guides
VALVES AND VALVE SPRINGS 4. Remove: • Valve spring retainer “1” • Valve spring “2” • Valve “3” • Valve stem seal “4” • Valve spring seat “5” Identify the position of each part very carefully so that it can be reinstalled in its original place. 2.
Page 231: Checking The Valve Seats
VALVES AND VALVE SPRINGS 5. Measure: • Valve margin thickness “a” Out of specification  Replace the valve. Valve margin thickness (intake) 1.20 mm (0.0472 in) Valve margin thickness (exhaust) 0.85 mm (0.0335 in) After replacing the valve guide, reface the valve seat.
Page 232 VALVES AND VALVE SPRINGS 4. Lap: Valve seat contact width (intake) • Valve face 0.90–1.10 mm (0.0354–0.0433 in) • Valve seat Valve seat contact width (ex- haust) NOTICE 0.90–1.10 mm (0.0354–0.0433 in) This model uses titanium intake and ex- haust valves. Do not use the valves used for lapping the valve seat.
Page 233: 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 234: Checking The Valve Lifters
VALVES AND VALVE SPRINGS CHECKING THE VALVE LIFTERS EASB29B227 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 235 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 236: Cylinder And Piston
CYLINDER AND PISTON CYLINDER AND PISTON EASB29B229 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 5-19. Cylinder head Cylinder body Gaskets...
Page 237: Removing The Piston
CYLINDER AND PISTON REMOVING THE PISTON EASB29B230 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 EASB29B231 crankcase opening with a cloth to prevent the...
Page 238: Checking The Piston Rings
CYLINDER AND PISTON CHECKING THE PISTON RINGS EASB29B232 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 239: 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) EASB29B233 CHECKING THE PISTON PIN INSTALLING THE PISTON AND CYLINDER EASB29B234 1. Check: 1.
Page 240 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 241: Electric Starter
ELECTRIC STARTER ELECTRIC STARTER EASB29B235 Removing the starter motor 12 Nm (1.2 m kgf, 8.7 ft Ibf) Order Job/Parts to remove Q’ty Remarks Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-1. Starter motor For assembly, reverse the disassemble pro- cedure.
Page 242 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks Starter motor front cover Starter motor yoke Armature assembly Starter motor rear cover Brush set For assembly, reverse the disassembly pro- cedure. 5-37...
Page 243: Checking The Starter Motor
ELECTRIC STARTER CHECKING THE STARTER MOTOR EASB29B236 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure the armature assembly resistanc- 1. Check: es with the pocket tester. • Commutator Dirt  Clean with 600 grit sandpaper. Pocket tester 2. Measure: 90890-03112 • Commutator diameter “a” Analog pocket tester Out of specification ...
Page 244: Assembling The Starter Motor
ELECTRIC STARTER 7. Check: • Gear teeth Align the match mark “a” on the starter motor Damage/wear  Replace the starter motor. yoke with the match mark “b” on the starter mo- 8. Check: tor rear cover. • Oil seal Damage/wear ...
Page 245 ELECTRIC STARTER 5. Install: • Bolt “1” • O-ring “2” Apply the lithium-soap-based grease on the O- ring. 5-40...
Page 246 CLUTCH CLUTCH EASB29B238 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 247 CLUTCH Removing the clutch 6 10 Order Part name Q’ty Remarks Cushion spring Friction plate 2 Identification color (purple) Clutch boss Thrust washer Primary driven gear Spacer Bearing Washer Push lever shaft For installation, reverse the removal proce- dure. 5-42...
Page 248 CLUTCH Removing the right crankcase cover Order Part name Q’ty Remarks 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 249: Clutch
CLUTCH REMOVING THE CLUTCH CHECKING THE CLUTCH PLATES EASB29B239 EASB29B241 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 250: Checking The Clutch Housing
CLUTCH CHECKING THE CLUTCH HOUSING EASB29B243 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 EASB29B247 1.
Page 251: Checking The Primary Driven Gear
CLUTCH 2. Install: CHECKING THE PRIMARY DRIVEN GEAR EASB29B249 • 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 252: Installing The Clutch
CLUTCH INSTALLING THE CLUTCH EASB29B252 1. Install: • Apply the engine oil to the threads and con- • Push lever shaft “1” tact surface of the clutch boss nut. • Use the clutch holding tool “3” to hold the clutch boss. •...
Page 253 CLUTCH 8. Install: • Pressure plate “1” a. Identification color 6. Install: 9. Install: • Bearing “1” • Clutch spring • Washer “2” • Clutch spring bolt • Circlip “3” To push rod 1 “4”. Clutch spring bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Apply the engine oil on the bearing and washer.
Page 254 CLUTCH Tighten the bolts in stages and in a crisscross pattern. 5-49...
Page 255: Shift Shaft
SHIFT SHAFT SHIFT SHAFT EASB29B253 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 256 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 257: Removing The Shift Guide And Shift Lever Assembly
SHIFT SHAFT REMOVING THE SHIFT GUIDE AND SHIFT EASB29B254 LEVER ASSEMBLY 1. Remove: • Bolt (shift guide) • Shift guide “1” • Shift lever assembly “2” Make sure that the shift lever assembly is re- moved together with the shift guide. CHECKING THE SHIFT GUIDE AND SHIFT EASB29B257 LEVER ASSEMBLY...
Page 258: Installing The Stopper Lever
SHIFT SHAFT INSTALLING THE STOPPER LEVER INSTALLING THE SHIFT GUIDE AND SHIFT EASB29B259 EASB29B261 1. Install: LEVER ASSEMBLY • Torsion spring “1” 1. Install: • Collar “2” • Spring “1” • Stopper lever “3” • Pawl pin “2” • Bolt (stopper lever) “4” •...
Page 259: Installing The Shift Shaft
SHIFT SHAFT 4. Tighten: • Shift guide bolt “1” Shift guide bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® EASB29B262 INSTALLING THE SHIFT SHAFT 1. Install: • Roller “1” • Shift shaft spring “2” (to shift shaft) • Collar “3” (to shift shaft) •...
Page 260: Oil Pump And Balancer Gear
OIL PUMP AND BALANCER GEAR OIL PUMP AND BALANCER GEAR EASB29B264 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” on page 5-41. Right crankcase cover Refer to “CLUTCH”...
Page 261 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 5-41. Right crankcase cover Refer to “CLUTCH”...
Page 262: Removing The Balancer
OIL PUMP AND BALANCER GEAR REMOVING THE BALANCER EASB29B265 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 263: Assembling The Oil Pump
OIL PUMP AND BALANCER GEAR Inner-rotor-to-outer-rotor-tip • Apply the engine oil on the oil pump drive clearance shaft and inner rotor. 0.000–0.150 mm (0.0000–0.0059 • Fit the dowel pin into the groove in the inner rotor. Limit 0.23 mm (0.0091 in) Outer-rotor-to-oil-pump-housing clearance 0.13–0.18 mm (0.0051–0.0071 in)
Page 264: Installing The Oil Pump And Balancer Gear
OIL PUMP AND BALANCER GEAR INSTALLING THE OIL PUMP AND BALANC- EASB29B270 ER GEAR 1. Install: • Oil pump assembly “1” • Oil pump assembly bolt “2” Oil pump assembly bolt 5 Nm (0.5 m·kgf, 3.6 ft·lbf) LOCTITE® NOTICE 4. Install: After tightening the bolts, make sure that •...
Page 265 OIL PUMP AND BALANCER GEAR 5-60...
Page 266: Generator And Starter Clutch
GENERATOR AND STARTER CLUTCH GENERATOR AND STARTER CLUTCH EASB29B271 Removing the generator Order Job/Parts to remove Q’ty Remarks Refer to “CHANGING THE ENGINE OIL” on Drain the engine oil. page 3-15. Refer to “GENERAL CHASSIS” on page 4-1 Seat and fuel tank and “FUEL TANK”...
Page 267 GENERATOR AND STARTER CLUTCH Removing the generator Order Job/Parts to remove Q’ty Remarks Woodruff key Starter clutch Starter clutch drive gear Crankshaft position sensor Stator For installation, reverse the removal proce- dure. 5-62...
Page 268: Removing The Generator
GENERATOR AND STARTER CLUTCH 2. Check: REMOVING THE GENERATOR EASB29B272 • Starter clutch idle gear 1. Remove: • Starter clutch gear • Generator rotor nut “1” Burrs/chips/roughness/wear  Replace the • Washer defective part (s). 3. Check: • Starter clutch gear Damage/pitting/wear ...
Page 269: Installing The Starter Clutch
“7” under the holder as shown. • Tighten the stator bolt using the T25 bit. • Apply the sealant to the grommet of the AC magneto lead. Yamaha bond No. 1215 Starter clutch bolt 90890-85505 16 Nm (1.6 m·kgf, 12 ft·lbf) (Three bond No.1215®) LOCTITE®...
Page 270 GENERATOR AND STARTER CLUTCH 2. Install: • Washer • Pass the AC magneto lead “4” under the left • Generator rotor nut “1” crankcase cover “a” as shown. • Tighten the bolts in stage, using a crisscross Generator rotor nut pattern.
Page 271 GENERATOR AND STARTER CLUTCH 6. Install: • Cover (damper assembly) “1” • Bracket “2” • Bolt “3” • Breather hose 2 “4” Bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Install the cover (damper assembly) with its mark “a” facing upward. 5-66...
Page 272 CRANKCASE CRANKCASE EASB29B276 Separating the crankcase 5 Nm (0.5 m kgf, 3.6 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty...
Page 273: Crankcase
CRANKCASE Separating the crankcase 5 Nm (0.5 m kgf, 3.6 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty...
Page 274 CRANKCASE Removing the bearing and oil seal 12 Nm (1.2 m kgf, 8.7 ft Ibf) 22 Nm (2.2 m kgf, 16 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) Order Part name Q’ty Remarks Transmission Refer to “TRANSMISSION” on page 5-76. Shift cam and shift fork Refer to “TRANSMISSION”...
Page 275: Disassembling The Crankcase
CRANKCASE DISASSEMBLING THE CRANKCASE EASB29B277 1. Separate: • Right crankcase • Left crankcase ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the crankcase bolts. c. Remove the dowel pins and O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ REMOVING THE CRANKCASE BEARING EASB29B278 1. Remove: • Bearing “1” • Remove the bearing from the crankcase by Loosen each bolt 1/4 of a turn at a time and af- pressing its inner race.
Page 276: Installing The Oil Seal
2. Check: 2. Apply: • Crankcase • Sealant Crack/damage  Replace. (to the crankcase mating surface) • Oil delivery passages Yamaha bond No. 1215 Obstruction  Blow out with compressed 90890-85505 air. (Three bond No.1215®) EASB29B281 INSTALLING THE OIL SEAL 1.
Page 277 CRANKCASE 4. 45 mm (1.77 in) 5. 60 mm (2.36 in) 6. 75 mm (2.95 in) a. Hexagon socket head bolt without flange b. Hexagon socket head bolt with flange 5-72...
Page 278: Crankshaft Assembly And Balancer Shaft
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EASB29B283 Removing the crankshaft assembly and balancer shaft Order Part name Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-67. Transmission Refer to “TRANSMISSION” on page 5-76. Balancer shaft Crankshaft assembly For installation, reverse the removal proce- dure.
Page 279: Removing The Crankshaft Assembly
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT REMOVING THE CRANKSHAFT ASSEMBLY EASB29B284 1. Remove: • Crankshaft assembly “1” Remove the crankshaft assembly by using the crankcase separating tool “2”. Crankcase separating tool 90890-04152 Crankcase separating tool 2. Measure: YU-A9642 • Big end side clearance “a” Out of specification ...
Page 280: Installing The Crankshaft Assembly
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 4. Check: • Crankshaft sprocket “1” Hold the connecting rod at top dead center Damage  Replace the crankshaft. (TDC) with one hand while turning the nut of the crankshaft installer bolt with the other. Turn the crankshaft installer bolt until the crankshaft as- sembly bottoms against the bearing.
Page 281 TRANSMISSION TRANSMISSION EASB29B288 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 5-67. Main axle Drive axle Long shift fork guide bar Short shift fork guide bar Spring Shift cam...
Page 282: Transmission
TRANSMISSION REMOVING THE TRANSMISSION CHECKING THE SHIFT FORKS EASB29B289 EASB29B290 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 283: Checking The Shift Drum Assembly
TRANSMISSION CHECKING THE SHIFT DRUM ASSEMBLY EASB29B291 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 284 TRANSMISSION 2. Install: • 2nd wheel gear (29T) “1” • 5th wheel gear (22T) “2” • 3rd wheel gear (26T) “3” • 4th wheel gear (24T) “4” • 6th wheel gear (22T) “5” • Collar “6” • 1st wheel gear (31T) “7” •...
Page 285 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 286 TRANSMISSION 5-81...
Page 287: 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 288 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 289 RADIATOR Removing the radiator 8 Nm (0.8 m kgf, 5.8 ft Ibf) Order Part name Q’ty Remarks Right radiator Radiator hose 2 Radiator hose 3 Radiator hose 4 Radiator pipe 2 Radiator breather hose Left radiator Radiator hose 1 Radiator pipe 1 Coolant temperature sensor For installation, reverse the removal proce- dure.
Page 290 RADIATOR HANDLING NOTE EASB29B296 WARNING If coolant seems hot, do not remove the ra- diator cap. CHECKING THE RADIATOR EASB29B297 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 291: Water Pump
WATER PUMP WATER PUMP EASB29B298 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 292 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 293 WATER PUMP REMOVING THE OIL SEAL EASB29B299 • 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 294 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 295: Fuel System
FUEL SYSTEM FUEL TANK......................7-1 REMOVING THE FUEL TANK ..............7-3 REMOVING THE FUEL PUMP ..............7-3 CHECKING THE FUEL PUMP BODY............7-3 INSTALLING THE FUEL PUMP..............7-3 REMOVING THE FUEL SENDER..............7-4 CHECKING THE FUEL SENDER ..............7-4 INSTALLING THE FUEL SENDER ............7-4 INSTALLING THE FUEL TANK..............7-4 CHECKING THE FUEL PRESSURE ............7-5 CHECKING THE DAMPER ................7-5 CHECKING AND REPLACING THE PROTECTOR ........7-6...
Page 296: 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 297 FUEL TANK Removing the fuel tank 7 Nm (0.7 m kgf, 5.1 ft Ibf) 9 Nm (0.9 m kgf, 6.5 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) Order...
Page 298: Removing The Fuel Tank
FUEL TANK REMOVING THE FUEL TANK EASB29B306 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 299: Removing The Fuel Sender
FUEL TANK INSTALLING THE FUEL SENDER EASB29B312 1. Install: • Fuel sender gasket • Fuel sender Fuel sender bolts 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) • Do not damage the installation surfaces of the fuel tank when installing the fuel sender. REMOVING THE FUEL SENDER EASB29B310 •...
Page 300: Checking The Fuel Pressure
FUEL TANK WARNING • Insert the fuel hose into the fuel pipe securely Cover the fuel hose connection with a cloth until you hear a “click”. when disconnecting it. This is because re- • Slide the fuel hose connector cover “1” at the sidual pressure in the fuel hose could cause hose end in the direction of the arrow.
Page 301: Checking And Replacing The Protector
FUEL TANK 84 mm 115 mm (3.31 in) (4.53 in) 84 mm 115 mm (3.31 in) (4.53 in) CHECKING AND REPLACING THE PRO- EASB29B316 TECTOR 1. Check: • Protector “1” Wear/damage  Replace. Affix the protector as shown. 0 mm (0 in) 15 mm (0.59 in)
Page 302: Throttle Body
THROTTLE BODY THROTTLE BODY EASB29B317 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 303 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 304 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 305: Checking The Injector
THROTTLE BODY CHECKING THE INJECTOR EASB29B318 1. Check: • Injectors Obstruction  Replace, and check the fuel pump and the fuel injection system. Refer to “FUEL INJECTION SYSTEM” on page 8-24. Deposits  Replace. Damage  Replace. 2. Check: • Injector resistance Refer to “CHECKING THE FUEL INJEC- TOR”...
Page 306: 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 307: Electrical System
COOLING SYSTEM (For JPN) ..............8-20 CIRCUIT DIAGRAM .................8-20 TROUBLESHOOTING ................8-22 FUEL INJECTION SYSTEM................8-24 CIRCUIT DIAGRAM .................8-24 ECU SELF-DIAGNOSTIC FUNCTION.............8-26 TROUBLESHOOTING METHOD.............8-27 YAMAHA DIAGNOSTIC TOOL ..............8-28 TROUBLESHOOTING DETAILS .............8-31 FUEL PUMP SYSTEM..................8-52 CIRCUIT DIAGRAM .................8-52 TROUBLESHOOTING ................8-54 ELECTRICAL COMPONENTS...............8-56 CHECKING THE SWITCHES ..............8-60 CHECKING THE BULBS AND BULB SOCKETS ........8-63...
Page 308 CHECKING THE STATOR COIL .............8-71 CHECKING THE RECTIFIER/REGULATOR ...........8-72 CHECKING THE FUEL SENDER ............8-72 CHECKING THE RESISTER ..............8-73 CHECKING THE RADIATOR FAN MOTOR (For JPN)......8-73 CHECKING THE COOLANT TEMPERATURE SENSOR......8-73 CHECKING THE THROTTLE POSITION SENSOR ........8-74 CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE ..8-75 CHECKING THE INTAKE AIR PRESSURE SENSOR ......8-75 CHECKING THE INTAKE AIR TEMPERATURE SENSOR .....8-75 CHECKING THE FUEL INJECTOR ............8-76...
Page 309 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 310: Ignition System
IGNITION SYSTEM IGNITION SYSTEM EASB29B323 EASB29B324 CIRCUIT DIAGRAM...
Page 311 IGNITION SYSTEM 1. Joint connector 2. Joint connector 4. AC magneto 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 21.ECU (engine control unit) 22.Ignition coil 23.Spark plug 29.Joint connector 34.Lean angle sensor 35.Engine stop switch 41.Frame ground 42.Ignition coil sub-lead...
Page 312: Troubleshooting
IGNITION SYSTEM TROUBLESHOOTING EASB29B325 The ignition system fails to operate (no spark or intermittent spark). Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 5. Air filter case cover NG ...
Page 313 IGNITION SYSTEM NG  8. Check the lean angle sensor. Replace the lean angle sensor. Refer to “CHECKING THE LEAN ANGLE SENSOR” on page 8-70. OK  NG  9. Check the entire ignition system’s Properly connect or repair the ignition sys- wiring.
Page 314: Electric Starting System
ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM EAS27160 EASB29B326 CIRCUIT DIAGRAM...
Page 315 ELECTRIC STARTING SYSTEM 1. Joint connector 2. Joint connector 3. Joint connector 6. Main relay 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 12.Starter motor 13.Starter relay diode 21.ECU (engine control unit) 29.Joint connector 35.Engine stop switch 36.Neutral switch 37.Diode 38.Starting circuit cut-off relay 39.Clutch switch...
Page 316: Starting Circuit Cut-Off System Operation
ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION EASB29B327 The starter motor can only operate if at least one of the following conditions is met: • The transmission is in neutral (the neutral switch is closed). • The clutch lever is pulled to the handlebar (the clutch switch is closed). The starting circuit cut-off relay prevents the starter motor from operating when neither of these con- ditions has been met.
Page 317 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main relay 4. Starting circuit cut-off relay 5. Start switch 6. Diode 7. Clutch switch 8.
Page 318: Troubleshooting
ELECTRIC STARTING SYSTEM TROUBLESHOOTING EASB29B328 The starter motor fails to turn. Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 5. Air filter case cover NG  1. Check the fuse. Replace the fuse(s).
Page 319 ELECTRIC STARTING SYSTEM NG  8. Check the main relay. Replace the main relay. Refer to “CHECKING THE RE- LAYS” on page 8-67. OK  NG  9. Check the neutral switch. Replace the neutral switch. Refer to “CHECKING THE SWITCHES”...
Page 320: Charging System
CHARGING SYSTEM CHARGING SYSTEM EAS27200 EASB29B329 CIRCUIT DIAGRAM 8-12...
Page 321 CHARGING SYSTEM 4. AC magneto 5. Rectifier/regulator 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 43.Negative battery lead 8-13...
Page 322: Troubleshooting
CHARGING SYSTEM TROUBLESHOOTING EASB29B330 The battery is not being charged. Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 1. Check the fuse. NG Refer to “CHECKING THE FUSES” Replace the fuse(s). on page 8-63. OK NG ...
Page 323 CHARGING SYSTEM 8-15...
Page 324: Signaling System
SIGNALING SYSTEM SIGNALING SYSTEM EAS27270 EASB29B331 CIRCUIT DIAGRAM 8-16...
Page 325 SIGNALING SYSTEM 1. Joint connector 2. Joint connector 3. Joint connector 6. Main relay 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 14.Warning light 16.Fuel level warning light 17.Resistor 18.Fuel sender 21.ECU (engine control unit) 29.Joint connector 41.Frame ground 43.Negative battery lead 8-17...
Page 326: Troubleshooting
SIGNALING SYSTEM TROUBLESHOOTING EASB29B332 • The fuel level warning light does not come on. Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank NG  1. Check the fuse. Replace the fuse(s).
Page 327 SIGNALING SYSTEM NG  3. Check the resistor. Replace the resistor. Refer to “CHECKING THE RESIST- ER” on page 8-73. OK  NG  4. Check the entire signaling system’s Properly connect or repair the signaling wiring. system’s wiring. Refer to “CIRCUIT DIAGRAM” on page 8-16.
Page 328: Cooling System (For Jpn)
COOLING SYSTEM (For JPN) COOLING SYSTEM (For JPN) EASB29B333 EASB29B334 CIRCUIT DIAGRAM 8-20...
Page 329 COOLING SYSTEM (For JPN) 1. Joint connector 2. Joint connector 3. Joint connector 6. Main relay 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 21.ECU (engine control unit) 26.Radiator fan motor relay 27.Radiator fan motor fuse 28.Radiator fan motor 29.Joint connector 31.Coolant temperature sensor 41.Frame ground...
Page 330: Troubleshooting
COOLING SYSTEM (For JPN) TROUBLESHOOTING EASB29B335 The radiator fan motor fails to turn. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left) 3. Air scoop (left/right) 4. Fuel tank NG  1. Check the fuse. Replace the fuse(s). Refer to “CHECKING THE FUSES”...
Page 331 COOLING SYSTEM (For JPN) 8-23...
Page 332: Fuel Injection System
FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM EASB29B336 EASB29B337 CIRCUIT DIAGRAM 8-24...
Page 333 FUEL INJECTION SYSTEM 1. Joint connector 2. Joint connector 3. Joint connector 4. AC magneto 6. Main relay 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 14.Warning light 15.Engine trouble warning light 21.ECU (engine control unit) 24.Injector 29.Joint connector 30.Intake air temperature sensor 31.Coolant temperature sensor 32.Throttle position sensor...
Page 334: Ecu Self-Diagnostic Function
FUEL INJECTION SYSTEM ECU SELF-DIAGNOSTIC FUNCTION EASB29B338 The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 335: Troubleshooting Method
• Fault code number ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the Yamaha diagnostic tool. Refer to “YAMAHA DIAGNOSTIC TOOL” on page 8-28. b. Check the fault code number displayed on the Yamaha diagnostic tool. c. Identify the faulty system with the fault code number.
Page 336: Yamaha Diagnostic Tool
FUEL INJECTION SYSTEM YAMAHA DIAGNOSTIC TOOL EASB29B340 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 337 NOTICE In order to avoid short circuit, insulate the battery connection terminals of the FI diagnostic tool sub-lead. For information on how to connect and use the Yamaha diagnostic tool, refer to “YAMAHA DIGNO- STIC TOOL OPERATION MANUAL”. 1. Vehicle 2.
Page 338 FUEL INJECTION SYSTEM Operation of the Yamaha diagnostic tool (Malfunction mode) Malfunction results are displayed in the top part of the window area. 1. Recovered The item list of the malfunction detected in the past (already recovered) are displayed. 2. Detected The item list of the malfunction currently occurred are displayed.
Page 339: Troubleshooting Details
FUEL INJECTION SYSTEM 6. Condition The current conditions are displayed. (Detected/Recovered) 7. Symptom The symptoms of the detected malfunction are displayed. 8. Diagnosis code The diagnosis codes related to the detected malfunction are displayed. 9. FFD (only for models that can display freeze frame data) The mark “...
Page 340 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received Item from the crankshaft position sensor. Improperly connected  Connection of wire harness Crank the engine. ECU coupler. Connect the coupler securely Fault code number is not dis- played ...
Page 341 FUEL INJECTION SYSTEM • If fault code numbers 13 and 14 are both displayed, perform the checks and maintenance jobs for fault code number 13 first. • Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Item Intake air pressure sensor: open or short circuit detected.
Page 342 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Defective intake air pressure Execute the diagnostic mode. Push the start switch. sensor. (Code No. 03) Fault code number is not dis- played  Service is finished. When engine is stopped: Atmospheric pressure at the Fault code number is dis-...
Page 343 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged Item or detached hose). Defective intake air pressure Execute the diagnostic mode. sensor. (Code No. 03) When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is indicated.
Page 344 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Improperly connected  Connection of wire harness Push the start switch. ECU coupler. Connect the coupler securely Fault code number is not dis- played  Service is finished. Check the locking condition or repair/replace the wire har- of the coupler.
Page 345 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Malfunction in ECU. Replace the ECU. Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Throttle position sensor: stuck throttle position sensor is de- Item tected.
Page 346 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the coolant temperature. Procedure Compare the actually measured coolant temperature with the Yamaha diagnostic tool display value. Probable cause of malfunc- Confirmation of service Item Maintenance job tion and check completion Improperly connected ...
Page 347 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air temperature. Procedure Compare the actually measured intake air temperature with the Yamaha diagnostic tool display value. Probable cause of malfunc- Confirmation of service Item Maintenance job tion and check completion Improperly connected ...
Page 348 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Open or short circuit  Re- Wire harness continuity. Push the start switch. place the wire harness. Fault code number is not dis- played  Service is finished. Between intake air tempera- ture sensor coupler and ECU Fault code number is dis-...
Page 349 Actuation Actuates the ignition coil five times at one-second intervals. The engine trouble warning light and the “WARNING” on the Yamaha diagnostic tool screen come on each time the ignition coil is actuated. Procedure Check that a spark is generated five times.
Page 350 FUEL INJECTION SYSTEM Fault code No. Ignition coil: open or short circuit detected in the primary lead Item of the ignition coil. Improperly connected  Connection of sub wire har- Start the engine and let it idle ness coupler. Connect the coupler securely for approximately 5 seconds.
Page 351 Actuation Actuates injector five times at one-second intervals. The engine trouble warning light and the “WARNING” on the Yamaha diagnostic tool screen come on each time the injector is actuated. Procedure Check that injector is actuated five times by listening for the oper- ating sound.
Page 352 FUEL INJECTION SYSTEM Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Item Lean angle sensor: open or short circuit detected. Fail-safe system Unable to start engine Able to drive vehicle Diagnostic code No. Diagnostic tool display Lean angle sensor output voltage •...
Page 353 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel in- Item jector and fuel pump. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. Diagnostic tool display Fuel system voltage Approximately 12.0 (V) Procedure Disconnect the main relay, and push the start switch.
Page 354 FUEL INJECTION SYSTEM Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. EEPROM fault code number: an error is detected while read- Item ing or writing on EEPROM. Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No.
Page 355 FUEL INJECTION SYSTEM Fault code No. Item Charging voltage is abnormal. Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No. — Diagnostic tool display — Procedure — Probable cause of malfunc- Confirmation of service Item Maintenance job tion and check completion Improperly connected ...
Page 356 Confirmation of service Item Maintenance job tion and check completion Improperly connected  Connection of Yamaha diag- Push the start switch. nostic tool coupler. Connect the coupler securely Fault code number is not dis- played  Service is finished. Check the locking condition or repair/replace the wire har- of the coupler.
Page 357 Fault code number is not dis- played  Service is finished. light green–light green Fault code number is dis- played  Go to item 4. Yamaha diagnostic tool mal- Replace the Yamaha diag- Push the start switch. function. nostic tool.
Page 358 FUEL INJECTION SYSTEM Fault code No. Er-2 Signals from the ECU cannot be received within the specified Item period of time. Yamaha diagnostic tool mal- Replace the Yamaha diag- Push the start switch. function. nostic tool. Fault code number is not dis- played ...
Page 359 FUEL INJECTION SYSTEM Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. Er-4 Registered data cannot be received from the Yamaha diagnos- Item tic tool. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No.
Page 360: Fuel Pump System
FUEL PUMP SYSTEM FUEL PUMP SYSTEM EASB29B342 EASB29B343 CIRCUIT DIAGRAM 8-52...
Page 361 FUEL PUMP SYSTEM 1. Joint connector 2. Joint connector 8. Battery 9. Frame ground 10.Starter relay 11.Main fuse 21.ECU (engine control unit) 25.Fuel pump 29.Joint connector 35.Engine stop switch 41.Frame ground 8-53...
Page 362: Troubleshooting
FUEL PUMP SYSTEM TROUBLESHOOTING EASB29B344 The fuel pump fails to operate. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank NG  1. Check the fuse. Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 8-63.
Page 363 FUEL PUMP SYSTEM EASB29B345 8-55...
Page 364: Electrical Components
ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS EASB29B346 8-56...
Page 365 ELECTRICAL COMPONENTS 1. Rectifier/regulator 2. Clutch switch 3. Ignition coil 4. ECU (engine control unit) 5. Fuel sender 6. Fuel pump 7. Battery 8. Resistor 9. Neutral switch 10.Radiator fan motor (For JPN) 11.Injector 8-57...
Page 366 ELECTRICAL COMPONENTS 8-58...
Page 367 ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. Intake air pressure sensor 3. Throttle position sensor 4. Starter relay 5. Main fuse 6. Starting circuit cut-off relay 7. Lean angle sensor 8. Radiator fan motor fuse 9. Radiator fan motor relay 10.Main relay 11.Coolant temperature sensor 8-59...
Page 368: Checking The Switches
ELECTRICAL COMPONENTS CHECKING THE SWITCHES EASB29B347 8-60...
Page 369 ELECTRICAL COMPONENTS 1. Engine stop switch 2. Neutral switch 3. Clutch switch 4. Start switch 8-61...
Page 370 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. NOTICE Never insert the tester probes into the coupler terminal slots “1”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Page 371: Checking The Bulbs And Bulb Sockets
ELECTRICAL COMPONENTS CHECKING THE BULBS AND BULB SOCK- EASB29B348 Check each bulb socket for continuity in the 1. Remove: same manner as described in the bulb section; • Bulb however, note the following. NOTICE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Be sure to hold the socket firmly when re- a.
Page 372: Checking And Charging The Battery
ELECTRICAL COMPONENTS CHECKING AND CHARGING THE BATTERY EASB29B350 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester to the fuse and WARNING check the continuity. Batteries generate explosive hydrogen gas and contain electrolyte which is made of Set the pocket tester selector to “ 1”. poisonous and highly caustic sulfuric acid.
Page 373 ELECTRICAL COMPONENTS b. Check the charge of the battery, as shown in the charts and the following example. Since VRLA (Valve Regulated Lead Acid) bat- Example teries are sealed, it is not possible to check the Open-circuit voltage = 12.0 V charge state of the battery by measuring the Charging time = 6.5 hours specific gravity of the electrolyte.
Page 374 ELECTRICAL COMPONENTS A. Open-circuit voltage (V) NOTICE B. Time (minutes) • Do not use a high-rate battery charger C. Charging since it forces a high-amperage current D. Ambient temperature 20 °C (68 °F) E. Check the open-circuit voltage. into the battery quickly and can cause bat- tery overheating and battery plate dam- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 375: Checking The Relays
ELECTRICAL COMPONENTS 8. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Battery terminals Charging method using a constant volt- Dirt  Clean with a wire brush. age charger Loose connection  Connect properly. a. Measure the open-circuit voltage prior to 9. Lubricate: charging. • Battery terminals Voltage should be measured 30 minutes after Recommended lubricant the engine is stopped.
Page 376: Checking The Diode
ELECTRICAL COMPONENTS Main relay Result Continuity (between “3” to “4”) EASB29B352 CHECKING THE DIODE 1. Check: • Diode Out of specification  Replace. Pocket tester 90890-03112 R,R/W Analog pocket tester 1. Positive battery terminal YU-03112-C 2. Negative battery terminal 3. Positive tester probe 4.
Page 377: Checking The Ignition Spark Gap
ELECTRICAL COMPONENTS CHECKING THE IGNITION SPARK GAP EASB29B353 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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, starting with step 4. 90890-03112 Refer to “TROUBLESHOOTING”...
Page 378: Checking The Crankshaft Position Sensor
ELECTRICAL COMPONENTS Crankshaft position sensor resis- tance 228–342  ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (  100) to the crankshaft position sensor coupler. Pocket tester 90890-03112 Analog pocket tester b. Measure the primary coil resistance. YU-03112-C ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Check: •...
Page 379: Checking The Starter Motor Operation
ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C Test harness– lean angle sensor (6P) 90890-03209 Test harness– lean angle sensor (6P) YU-03209 b. Check the starter motor operation. • Positive tester probe  ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Yellow/Green “1” CHECKING THE STATOR COIL EAS28150 •...
Page 380: Checking The Rectifier/Regulator
ELECTRICAL COMPONENTS c. Start the engine and let it run at approxi- mately 5000 r/min. d. Measure the charging voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE FUEL SENDER EASB29B360 1. Drain the gasoline. 2. Disconnect: • Fuel sender coupler (from the fuel sender) 3.
Page 381: Checking The Resister
ELECTRICAL COMPONENTS CHECKING THE RESISTER EASB29B361 1. Disconnect: • Resister coupler (from the wire harness) 2. Check: • Resister resistance Out of specification  Replace the resister. Resister resistance 64.6–71.4  c. Measure the radiator fan motor movement. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a.
Page 382: Checking The Throttle Position Sensor
ELECTRICAL COMPONENTS WARNING • Handle the throttle position sensor with special care. • Never subject the throttle position sensor to strong shocks. If the throttle position sensor is dropped, replace it. 2. Check: • Throttle position sensor maximum resis- tance Out of specification ...
Page 383: Checking The Throttle Position Sensor Input Voltage
ELECTRICAL COMPONENTS CHECKING THE THROTTLE POSITION CHECKING THE INTAKE AIR PRESSURE EASB29B365 EASB29B366 SENSOR INPUT VOLTAGE SENSOR 1. Check: 1. Check: • Throttle position sensor input voltage • Intake air pressure sensor output voltage Out of specification  Replace the ECU. Out of specification ...
Page 384: Checking The Fuel Injector
ELECTRICAL COMPONENTS 2. Check: Pocket tester • Intake air temperature sensor resistance 90890-03112 Out of specification  Replace. Analog pocket tester YU-03112-C Intake air temperature sensor re- sistance • Positive tester probe  5400.0–6600.0  at 0 °C (5400.0– 6600.0  at 32 °F) Injector terminal “1”...
Page 385: 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 386: Troubleshooting
TROUBLESHOOTING Electrical system TROUBLESHOOTING EASB29B369 1. Battery • Discharged battery EASB29B370 GENERAL INFORMATION • Faulty battery 2. Fuse The following guide for troubleshooting does • Blown, damaged or incorrect fuse not cover all the possible causes of trouble. It • Improperly installed fuse should be helpful, however, as a guide to basic 3.
Page 387: Poor Medium-And-High-Speed Performance
TROUBLESHOOTING Electrical system JUMPS OUT OF GEAR EASB29B376 1. Battery • Discharged battery Engine • Faulty battery 1. Shift shaft 2. Spark plug • Incorrect shift pedal position • Incorrect spark plug gap • Improperly returned stopper lever • Incorrect spark plug heat range 2.
Page 388: Overcooling
TROUBLESHOOTING Cooling system FRONT FORK OIL LEAKING EASB29B382 1. Coolant • Low coolant level Chassis 2. Radiator 1. Front fork • Damaged or leaking radiator • Bent, damaged, or rusty inner tube • Faulty radiator cap • Cracked or damaged outer tube •...
Page 389 TROUBLESHOOTING 7. Wheel (s) • Incorrect wheel balance • Broken or loose spoke • Damaged wheel bearing • Bent or loose wheel axle • Excessive wheel runout 8. Frame • Bent frame • Damaged steering head pipe • Improperly installed bearing race...
Page 390: List Of Self-Diagnostic And Fail-Safe Actions
8-48 nection Er-2 Signals from the ECU cannot be received within the specified period 8-49 of time. Er-3 Data from the ECU cannot be received correctly. 8-50 Er-4 Registered data cannot be received from the Yamaha diagnostic tool. 8-51...
Page 391 Intake air temperature Displays the intake air tem- Compare the actually mea- perature. sured intake air tempera- ture with the Yamaha diagnostic tool display val- Coolant temperature When engine is cold: Dis- Compare the actually mea- plays temperature closer to sured coolant temperature air temperature.
Page 392 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 393: 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..................10-1 FRONT FORK SETTING................10-2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL..10-2 SETTING OF SPRING AFTER REPLACEMENT ........10-2 FRONT FORK SETTING PARTS.............10-3 REAR SUSPENSION SETTING ..............10-3 CHOOSING SET LENGTH ..............10-3 SETTING OF SPRING AFTER REPLACEMENT ........10-4...
Page 394: Chassis
CHASSIS CHASSIS DRIVE AND REAR WHEEL SPROCKETS EASB29B387 EASB29B389 SETTING PARTS EASB29B388 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 395: Front Fork Setting
CHASSIS • Under a stony or a hard road condition, the tire pressure should be higher to prevent a flat tire. Extent of adjustment 100–120 kPa (1.00–1.20 kgf/cm 15–18 psi) FRONT FORK SETTING EASB29B391 The front fork setting should be made depend- ing on the rider’s feeling of an actual run and the circuit conditions.
Page 396: Front Fork Setting Parts
CHASSIS REAR SUSPENSION SETTING EASB29B395 The rear shock absorber setting should be Generally a stiff spring gives a stiff riding feel- made depending on the rider’s feeling of an ac- ing. Rebound damping tends to become weak- tual run and the circuit conditions. er, resulting in lack of a sense of contact with The rear suspension setting includes the fol- the road surface or in a vibrating handlebar.
Page 397: Setting Of Spring After Replacement
CHASSIS Length “a” of standard shock • If the machine is new and after it is broken in, 462.5 mm (18.21 in) the same set length of the spring may change because of the initial fatigue, etc. of the spring. Therefore, be sure to make reevalua- tion.
Page 398 CHASSIS • Spring preload adjusting positions Spring preload adjusting positions Minimum Position in which the spring is turned in 1.5 mm (0.06 in) from its free length. Standard Position in which the spring is turned in 10 mm (0.39 in) from its free length.
Page 399: Suspension Setting (Front Fork)
CHASSIS SUSPENSION SETTING (FRONT FORK) EASB29B399 • 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 400: 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 401 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 402: Kick Starter Kit (Optional Parts)
KICK STARTER KIT (OPTIONAL PARTS) KICK STARTER KIT (OPTIONAL PARTS) EASB29B401 EASB29B402 PARTS LOCATION Order Part name Part number Q’ty Remarks Kick starter kit B29-15602-00 Kick shaft assembly 1SM-15601-00 Kick gear 1SM-15641-00 Washer 90201-20685 Circlip 93410-20038 Ratchet wheel 2S2-15671-00 Spring 90501-160A2 Washer 90201-167P7...
Page 403 KICK STARTER KIT (OPTIONAL PARTS) Order Part name Part number Q’ty Remarks Washer 90201-177G4 Thickness:1.0 mm (0.0394 in) Circlip 99009-17400 Kickstarter lever assembly 1SM-15620-00 Kickstarter lever boss 1SM-15621-00 Spring 90501-147A5 Ball 93507-32009 Screw 90151-06045 O-ring 93210-17570 Bolt 90110-08051 Washer 90201-08048 Crankcase cover gasket 1SM-15462-00 10-10...
Page 404: Setup Procedures
KICK STARTER KIT (OPTIONAL PARTS) SETUP PROCEDURES EASB29B403 Installing the kick shaft 12 Nm (1.2 m kgf, 8.7 ft Ibf) Order Part name Q’ty Remarks Clutch and right crankcase cover. Remove. Refer to “CLUTCH” on page 5-41. Remove. Circlip Do not use the circlip installed originally. Remove.
Page 405 KICK STARTER KIT (OPTIONAL PARTS) Installing the kick shaft 1. Install: • Stopper “1” • Rachet wheel guide “2” • Bolt (rachet wheel guide) “3” Bolt (rachet wheel guide) 12 Nm (1.2 m·kgf, 8.7 ft·lbf) LOCTITE® 4. Install: • Torsion spring “1” Turn the torsion spring clockwise and hook into the proper hole “a”...
Page 406 KICK STARTER KIT (OPTIONAL PARTS) Installing the kickstater lever Order Part name Q’ty Remarks Remove. Plug Do not use the plug installed originally. Oil seal Gasket Right crankcase cover Refer to “CLUTCH” on page 5-41. Kickstarter lever Washer Bolt 10-13...
Page 407: Starting The Engine
KICK STARTER KIT (OPTIONAL PARTS) Installing the kickstarter lever STARTING THE ENGINE EASB29B404 1. Install: • Oil seal “1” Starting with the kickstarter (to the right crank case cover) When using the kickstarter to start the engine, follow the procedures as described below. 1.
Page 408: Maintenance
KICK STARTER KIT (OPTIONAL PARTS) MAINTENANCE EASB29B405 Removing the kick starter kit 1. Remove: • Kick shaft assembly “1” Unhook the torsion spring “2” from the hole “a” in the crankcase. 3. Check: • Kickstarter lever “1” smooth movement Unsmooth movement  Apply the lithium- soap-based grease to the pivoting point and metal-to-metal moving parts.
Page 409 KICK STARTER KIT (OPTIONAL PARTS) 2. Install: • Torsion spring “1” (to the kick shaft “2”) Make sure the stopper “a” of the torsion spring fits into the hole “b” on the kick shaft. 3. Install: • Spring guide “1” Slide the spring guide into the kick shaft, make sure the groove “a”...
Page 410: Wiring Diagram
WIRING DIAGRAM EASB29B407 EASB29B408 COLOR CODE YZ250FX/YZ250FXH 2017 Black 1. Joint connector Brown 2. Joint connector Chocolate 3. Joint connector 4. AC magneto Dark green 5. Rectifier/regulator Green 6. Main relay Gray 7. Engine ground 8. Battery Blue 9. Frame ground Light green 10.
Page 412 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN...
Page 413 YZ250FX/YZ250FXH 2017 YZ250FX/YZ250FXH 2017 YZ250FX/YZ250FXH 2017 SCHÉMA DE CÂBLAGE WIRING DIAGRAM SCHALTPLAN Br Br R R R/L Br Br R R R R/L Br Br Br Br B/L Gy (Gy) (Gy) W W W W W W Br Br Br Br L/Y Y/W R/L R/B (Gy)
Page 414 YZ250FX/YZ250FXH 2017 YZ250FX/YZ250FXH 2017 YZ250FX/YZ250FXH 2017 SCHÉMA DE CÂBLAGE WIRING DIAGRAM SCHALTPLAN (Gy) (Gy) (Gy)

This manual is also suitable for:

Yz250fxh 2017

Save PDF