2024

OWNER’S SERVICE MANUAL

YZ250FX
Read this manual carefully before operating this vehicle.

YZ250FXR
LIT-11626-37-35 BAJ-2819U-14
Read this manual carefully
EAM20161

Operating, servicing and

maintaining a passenger vehicle or off-road vehicle can
expose you to chemicals including engine exhaust,
carbon monoxide, phthalates, and lead, which are
known to the State of California to cause cancer and
birth defects or other reproductive harm. To minimize
exposure, avoid breathing exhaust, do not idle the
engine except as necessary, service your vehicle in a
well-ventilated area and wear gloves or wash your
hands frequently when servicing your vehicle. For more
information go to
www.P65Warnings.ca.gov/passenger-vehicle
 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle
if it is sold.

FCC CAUTION
Changes or modifications not expressly approved by the party responsible for compliance could void the user’s
authority to operate the equipment.

This transmitter must not be co-located or operated in conjunction with any other antenna or transmitter.

This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment and
meets the FCC radio frequency (RF) Exposure Guidelines. This equipment has very low levels of RF energy that
is deemed to comply without maximum permissive exposure evaluation (MPE).
EAM20080

YZ250FXR
OWNER’S SERVICE MANUAL
©2024 by Yamaha Motor Corporation, U.S.A.
First edition, April 2023
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
P/N. LIT-11626-37-35
EAM20180

IMPORTANT
Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha’s
vast experience in the production of pacesetting racing machines. It represents the highest grade of
craftsmanship and reliability that have made Yamaha a leader.
This manual explains operation, inspection, basic maintenance and tuning of your machine. If you
have any questions about this manual or your machine, please contact your Yamaha dealer.

• Yamaha continually seeks advancements in product design and quality. Therefore, while this manual
contains the most current product information available at the time of printing, there may be minor
discrepancies between your machine and this manual. If you have any questions concerning this
manual, please consult your Yamaha dealer.
• This manual 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. It may lead to servicing trouble and
mechanical damage.
• This vehicle is primarily designed for off-road endurance use, not for use on motocross courses.
EWA20270

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS
MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A
SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL
YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPEC-
TIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE
THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.

EAM30001

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential per-
sonal injury hazards. Obey all safety messages that follow this symbol
to avoid possible injury or death.

A WARNING indicates a hazardous situation which, if not avoided, could

WARNING result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid

NOTICE damage to the vehicle or other property.

TIP A TIP provides key information to make procedures easier or clearer.

EAM20204

YAMAHA MOTOR CORPORATION, U.S.A. 2020 AND LATER MODEL

YZ/WR MOTORCYCLE LIMITED WARRANTY
EAM20082

HOW TO USE THIS MANUAL

In this manual, descriptions of installation, removal, disassembly, assembly, check, and adjustment
procedures are laid out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section
title “1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of
each removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a remov-
al or a disassembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, the
names of parts, the notes in jobs, etc. This step explains removal and disassembly procedure only.
For installation and assembly procedure, reverse the steps.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
1

2
4

5
6 7

G088877
EAM20083

SYMBOLS
The following symbols are used in this manual for easier understanding.

The following symbols are not relevant to every vehicle.

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

G

Filling fluid Molybdenum disulfide oil

M

Lubricant Brake fluid

BF

Special tool B Wheel bearing grease

Tightening torque LS Lithium-soap-based grease

T.
R.

Wear limit, clearance M Molybdenum disulfide grease

Engine speed S Silicone grease

Electrical data Apply locking agent (LOCTITE®).

LT

Engine oil New Replace the part with a new one.

E
EAM10003

TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL SYSTEM 7
ELECTRICAL SYSTEM 8
TROUBLESHOOTING 9
TUNING 10
 GENERAL INFORMATION

SAFETY INFORMATION ................................................................................. 1-1

FOR SAFETY, BE SURE TO OBEY THE FOLLOWING:............................. 1-1

ABOUT THE BATTERY ................................................................................... 1-4

LITHIUM-ION BATTERY ............................................................................ 1-4
1
LITHIUM-ION BATTERY DEGRADATION.................................................. 1-4

LOCATION OF IMPORTANT LABELS............................................................ 1-5 2

DESCRIPTION................................................................................................. 1-6

IDENTIFICATION............................................................................................. 1-7
VEHICLE IDENTIFICATION NUMBER ....................................................... 1-7
3
ENGINE SERIAL NUMBER ........................................................................ 1-7

INCLUDED PARTS.......................................................................................... 1-8

NIPPLE WRENCH...................................................................................... 1-8
4
HANDLEBAR PROTECTOR....................................................................... 1-8
FUEL HOSE JOINT COVER....................................................................... 1-8
POWER TUNER ......................................................................................... 1-8
5
IMPORTANT INFORMATION........................................................................ 1-10
PREPARATION FOR REMOVAL AND DISASSEMBLY ........................... 1-10
REPLACEMENT PARTS .......................................................................... 1-10
GASKETS, OIL SEALS AND O-RINGS .................................................... 1-10
LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-11
6
BEARINGS AND OIL SEALS ................................................................... 1-11
CIRCLIPS................................................................................................. 1-11

BASIC SERVICE INFORMATION ................................................................. 1-12

7
ELECTRICAL SYSTEM ............................................................................ 1-12

SPECIAL TOOLS........................................................................................... 1-16

8
INSTRUMENT AND CONTROL FUNCTIONS.............................................. 1-22
WARNING LIGHTS .................................................................................. 1-22
ENGINE STOP SWITCH .......................................................................... 1-22
START SWITCH....................................................................................... 1-22
MODE SWITCH ....................................................................................... 1-22
9
SHIFT PEDAL .......................................................................................... 1-23
FRONT BRAKE LEVER ............................................................................ 1-23
SIDESTAND ............................................................................................. 1-23
REAR BRAKE PEDAL .............................................................................. 1-23
STARTER KNOB...................................................................................... 1-23
10
FUEL TANK CAP ..................................................................................... 1-24
STARTING AND BREAK-IN .......................................................................... 1-25
FUEL ........................................................................................................ 1-25
STARTING A COLD ENGINE ................................................................... 1-25
STARTING A WARM ENGINE ................................................................. 1-26
BREAK-IN PROCEDURES....................................................................... 1-26
ENGINE STARTING PRECAUTION ......................................................... 1-26

MAINTENANCE AFTER BREAK-IN ............................................................. 1-27

MAJOR MAINTENANCE.......................................................................... 1-27
AIR FILTER MAINTENANCE.................................................................... 1-27

TORQUE-CHECK POINTS ........................................................................... 1-28

MOTORCYCLE CARE AND STORAGE ....................................................... 1-30

CARE ....................................................................................................... 1-30
STORAGE ................................................................................................ 1-31
 SAFETY INFORMATION

EAM20168
erator only. No passengers.
SAFETY INFORMATION 3. The failure of motorists to detect and recog-
Be sure to read this manual carefully and com- nize motorcycles in traffic is the predominat-
pletely in order to operate the machine safely ing cause of automobile/motorcycle
and correctly prior to riding the Yamaha ma- accidents. Many accidents have been
chine, and take care to maintain it properly and caused by an automobile driver who did not
operate it safely. see the motorcycle. Making yourself con-
EAM30401
spicuous appears to be very effective in re-
FOR SAFETY, BE SURE TO OBEY THE ducing the chance of this type of accident.
FOLLOWING: Therefore:
Be a Responsible Owner • Wear a brightly colored jacket.
As the vehicle’s owner, you are responsible for • Use extra caution when you are approaching
the safe and proper operation of your motorcy- and passing through intersections, since in-
cle. tersections are the most likely places for mo-
Motorcycles are single-track vehicles. torcycle accidents to occur.
Their safe use and operation are dependent • Ride where other motorists can see you.
upon the use of proper riding techniques as well Avoid riding in another motorist’s blind spot.
as the expertise of the operator. Every operator • Never maintain a motorcycle without proper
should know the following requirements before knowledge. Contact an authorized motorcy-
riding this motorcycle. cle dealer to inform you on basic motorcycle
He or she should: maintenance. Certain maintenance can only
1. Obtain thorough instructions from a compe- be carried out by certified staff.
tent source on all aspects of motorcycle op- 4. Many accidents involve inexperienced oper-
eration. ators.
2. Observe the warnings and maintenance re- • Make sure that you are qualified and that you
quirements in this manual. only lend your motorcycle to other qualified
3. Obtain qualified training in safe and proper operators.
riding techniques. • Know your skills and limits. Staying within
4. Obtain professional technical service as indi- your limits may help you to avoid an acci-
cated in this manual and/or when made nec- dent.
essary by mechanical conditions. • We recommend that you practice riding your
5. Never operate a motorcycle without proper motorcycle until you have become thorough-
training or instruction. Take a training course. ly familiar with the motorcycle and all of its
Beginners should receive training from a cer- controls.
tified instructor. Contact an authorized mo- 5. Many accidents have been caused by error
torcycle dealer to find out about the training of the motorcycle operator. A typical error
courses nearest you. made by the operator is veering wide on a
Safe Riding turn due to excessive speed or under corner-
Perform the pre-operation checks each time ing (insufficient lean angle for the speed).
you use the vehicle to make sure it is in safe op- Never travel faster than warranted by condi-
erating condition. Failure to inspect or maintain tions.
the vehicle properly increases the possibility of 6. Ride cautiously in unfamiliar areas. You may
an accident or equipment damage. Refer to encounter hidden obstacles that could
“PRE-OPERATION INSPECTION AND MAIN- cause an accident.
TENANCE” on page 3-6 for a list of pre-opera- 7. The posture of the operator is important for
tion checks. proper control. The operator should keep
1. This motorcycle is designed for off-road use both hands on the handlebar and both feet
only, therefore, it is illegal to operate it on on the operator footrests during operation to
public streets, roads, or highways, even a maintain control of the motorcycle.
dirt or gravel one. Off-road use on public 8. Never ride under the influence of alcohol or
lands may be illegal. Please check local reg- other drugs.
ulations before riding. 9. Be sure the transmission is in neutral before
2. This motorcycle is designed to carry the op- starting the engine.

1-1
 SAFETY INFORMATION

Protective Apparel Many companies with no connection to

The majority of fatalities from motorcycle acci- Yamaha manufacture parts and accessories or
dents are the result of head injuries. The use of offer other modifications for Yamaha vehicles.
a safety helmet is the single most critical factor Yamaha is not in a position to test the products
in the prevention or reduction of head injuries. that these aftermarket companies produce.
1. Always wear an approved helmet. Therefore, Yamaha can neither endorse nor rec-
2. Wear a face shield or goggles. Wind in your ommend the use of accessories not sold by
unprotected eyes could contribute to an im- Yamaha or modifications not specifically rec-
pairment of vision that could delay seeing a ommended by Yamaha, even if sold and in-
hazard. stalled by a Yamaha dealer.
3. The use of a jacket, heavy boots, trousers, Aftermarket Parts, Accessories, and Modifi-
gloves, etc., is effective in preventing or re- cations
ducing abrasions or lacerations. While you may find aftermarket products similar
4. Never wear loose-fitting clothes, otherwise in design and quality to genuine Yamaha acces-
they could catch on the control levers, foot- sories, recognize that some aftermarket acces-
rests, or wheels and cause injury or an acci- sories or modifications are not suitable because
dent. of potential safety hazards to you or others. In-
5. Always wear protective clothing that covers stalling aftermarket products or having other
your legs, ankles, and feet. The engine or ex- modifications performed to your vehicle that
haust system become very hot during or af- change any of the vehicle’s design or operation
ter operation and can cause burns. characteristics can put you and others at great-
Avoid Carbon Monoxide Poisoning er risk of serious injury or death. You are re-
All engine exhaust contains carbon monoxide, a sponsible for injuries related to changes in the
deadly gas. Breathing carbon monoxide can vehicle.
cause headaches, dizziness, drowsiness, nau- Keep the following guidelines in mind, as well as
sea, confusion, and eventually death. those provided under “Loading” when mount-
Carbon Monoxide is a colorless, odorless, ing accessories.
tasteless gas which may be present even if you 1. Never install accessories that would impair
do not see or smell any engine exhaust. Deadly the performance of your motorcycle. Care-
levels of carbon monoxide can collect rapidly fully inspect the accessory before using it to
and you can quickly be overcome and unable to make sure that it does not in any way reduce
save yourself. Also, deadly levels of carbon ground clearance or cornering clearance,
monoxide can linger for hours or days in en- limit suspension travel, steering travel or
closed or poorly ventilated areas. If you experi- control operation.
ence any symptoms of carbon monoxide • Accessories fitted to the handlebar or the
poisoning, leave the area immediately, get fresh front fork area can create instability due to
air, and SEEK MEDICAL TREATMENT. improper weight distribution. If accessories
1. Do not run engine indoors. Even if you try to are added to the handlebar or front fork area,
ventilate engine exhaust with fans or open they must be as lightweight as possible and
windows and doors, carbon monoxide can should be kept to a minimum.
rapidly reach dangerous levels. • Bulky or large accessories may seriously af-
2. Do not run engine in poorly ventilated or par- fect the stability of the motorcycle. Wind may
tially enclosed areas such as barns, garages, attempt to lift the motorcycle, or the motor-
or carports. cycle may become unstable in cross winds.
3. Do not run engine outdoors where engine • Certain accessories can displace the opera-
exhaust can be drawn into a building through tor from his or her normal riding position.
openings such as windows and doors. This improper position limits the freedom of
Genuine Yamaha Accessories movement of the operator and may limit con-
Choosing accessories for your vehicle is an im- trol ability, therefore, such accessories are
portant decision. Genuine Yamaha accessories, not recommended.
which are available only from a Yamaha dealer, 2. Use caution when adding electrical accesso-
have been designed, tested, and approved by ries. If electrical accessories exceed the ca-
Yamaha for use on your vehicle. pacity of the motorcycle’s electrical system,

1-2
 SAFETY INFORMATION

an electric failure could result, which could

cause a dangerous loss of lights or engine
power.
Aftermarket Tires and Rims
The tires and rims that came with your motorcy-
cle were designed to match the performance
capabilities and to provide the best combina-
tion of handling, braking, and comfort. Other
tires, rims, sizes, and combinations may not be
appropriate. Refer to “CHECKING THE TIRES”
on page 3-34 for tire specifications and more in-
formation on replacing your tires.
Transporting the Motorcycle
Be sure to observe following instructions before
transporting the motorcycle in another vehicle.
1. Remove all loose items from the motorcycle.
2. Check that the fuel cock (if equipped) is in
the “OFF” position and that there are no fuel
leaks.
3. Point the front wheel straight ahead on the
trailer or in the truck bed, and choke it in a rail
to prevent movement.
4. Shift the transmission in gear (for models
with a manual transmission).
5. Secure the motorcycle with tie-downs or
suitable straps that are attached to solid
parts of the motorcycle, such as the frame or
upper front fork triple clamp (and not, for ex-
ample, to rubber-mounted handlebars or
turn signals, or parts that could break).
Choose the location for the straps carefully
so the straps will not rub against painted sur-
faces during transport.
6. The suspension should be compressed
somewhat by the tie-downs, if possible, so
that the motorcycle will not bounce exces-
sively during transport.

1-3
 ABOUT THE BATTERY

EAM20203

ABOUT THE BATTERY

EAM30642

LITHIUM-ION BATTERY
The lithium-ion battery used in the vehicle fea-
tures high energy density and has a high voltage
(approximately three times that of nickel-cadmi-
um (Ni-Cd) or nickel-hydrogen (Ni-MH) batter-
ies), meaning it can be made both compact and
lightweight.
Nickel-cadmium and nickel-hydrogen batteries
have a memory effect that causes their capacity
to degrade quickly as a result of repeated partial
discharging and charging, so that they need to
be completely discharged periodically. Lithium-
ion batteries can be repeatedly partially charged
without needing to be fully discharged.
EAM30644

LITHIUM-ION BATTERY DEGRADATION

The charge capacity of the lithium-ion battery
gradually decreases over time and usage. The
rate of capacity degradation varies based on
the usage conditions.

• It is not necessary to use up the battery before

charging.
• Storing the vehicle in an extremely hot or cold
place could degrade the lithium-ion battery
capacity more quickly.
• Even if the lithium-ion battery is not used, it
discharges and degrades gradually over time.

1-4
 LOCATION OF IMPORTANT LABELS

EAM20085

LOCATION OF IMPORTANT LABELS

Please read the following important labels carefully before operating this vehicle.
1 2 3, 4

Premium unleaded For use only on a closed course

gasoline only. in sanctioned competition.
This motorcycle does not meet
EPA noise and emissions
standards and is not for general
off-road recreational riding.
WARNING
This unit contains high pressure nitrogen gas.
Mishandling can cause explosion.
Read owner's manual for instructions.
Do not incinerate, puncture or open.

1-5
 DESCRIPTION

EAM20086

DESCRIPTION

1 2, 3 4

10 9 8 7 6 5
11 12 16

15 14 13 20 19 18 17
1. Clutch lever 11.Fuel tank
2. Engine trouble warning light “ ” 12.Radiator
3. Fuel level warning light “ ” 13.Coolant drain bolt
4. Front brake lever 14.Oil level check window
5. Throttle grip 15.Rear brake pedal
6. Start switch 16.Air filter
7. Radiator cap 17.Drive chain
8. Fuel tank cap 18.Shift pedal
9. Mode switch 19.Starter knob
10.Engine stop switch 20.Front fork

Designs and specifications of the vehicle are subject to change without notice. Therefore, please note
that the descriptions in this manual may be different from those for the vehicle you have purchased.

1-6
 IDENTIFICATION

EAM20087

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.
EAM30002

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is
stamped into the right side of the frame.

EAM30003

ENGINE SERIAL NUMBER

The engine serial number “1” is stamped into
the lower left side of the engine.

1-7
 INCLUDED PARTS

EAM20088 EWA20460

INCLUDED PARTS
• Do not operate the engine in a closed area.
EAM30005

NIPPLE WRENCH The exhaust gas is poisonous.

The nipple wrench “1” is used to tighten the • Never let flames near the servicing area.
spoke. ECA26050

• This application is designed for adjusting

the settings on a standard vehicle. In case
the engine specifications (muffler, com-
pression ratio, etc.) have been changed,
the performance may not match to the ac-
tual settings.
• Do not run the engine with the smartphone
carried with you. Otherwise, the smart-
phone could be damaged.
EAM30006

HANDLEBAR PROTECTOR • Download the Power Tuner app from the

Install the handlebar protector “1” with the mark Google© or Apple© store.
“a” facing forward. • For details about handling the smartphone,
read the owner’s manual of the smartphone.
A Before connecting to the CCU wireless net-
a
work (in case of initial use of the Power Tun-
er app)
1. Remove the bolts and side cover (left).
1
A

1
EAM30007

FUEL HOSE JOINT COVER 2

The fuel hose joint covers “1” are used to pre-
vent mud, dust, and other foreign materials from 1
entering the inside when the fuel hose is discon- 1
nected.
1. Bolt
2. Side cover (left)
2. Remove the CCU and record the CCU serial
number.
1

EAM30443

POWER TUNER
By downloading the Power Tuner app to your
smartphone and wirelessly connecting to the
CCU wireless network, you can adjust various
vehicle settings.

1-8
 INCLUDED PARTS

pressed or while the engine is running (the

CCU is activated), input the CCU serial num-
ber into your smartphone and establish a
wireless connection.
3. Activate the Power Tuner app.
3
If the CCU wireless network cannot be detect-
ed, operate the start switch again.
2
1

1. CCU coupler
2. Holder
3. CCU (Communication Control Unit)

3
COMMUN.CONT.UNIT ASSY.

P/N: - -
S/N:
MAC:

3. CCU (Communication Control Unit)

a. CCU serial number

3. Install the removed CCU and side cover (left).
Connecting to the CCU wireless network
ECA26060

The CCU (Communication Control Unit) uses

weak radio waves. The CCU may not work in
the following situations.
• The CCU is placed in a location exposed to
strong radio waves or other electromag-
netic noise
• There are facilities nearby that are emitting
strong radio waves (TV or radio towers,
power plants, broadcasting stations, air-
ports, etc.)
• You are carrying or using communication
equipment such as radios or mobile
phones in close proximity of the CCU
• The CCU is in contact with or covered by a
metallic object
• Other vehicles equipped with a CCU are
nearby
In such situations, move the CCU to another
location and perform the operation again.
1. Turn on the smartphone.
2. For two minutes after the start switch is

1-9
 IMPORTANT INFORMATION

EAM20089
ceive an injury or a burn on the engine, the
IMPORTANT INFORMATION exhaust pipe, the silencer, or the like.
EAM30009
7. If coolant is left adhered to the chassis, paint
PREPARATION FOR REMOVAL AND and plating will be damaged. Therefore, rinse
DISASSEMBLY it out with water in good time.
EWA18970
1. Before the jobs, completely remove mud,
dust, and the like in order to prevent the entry
of them into the inside during the jobs. Coolant is potentially harmful and should be
Refer to “CARE” on page 1-30. handled with special care.
• If it enters your eyes, wash it away with wa-
ter enough and then get medical attention
• If it splashes on your skin or clothes, quick-
ly wash it away with water and then with
soapy water.
• If it is swallowed, immediately induce vom-
iting and get medical attention.

EAM30010

REPLACEMENT PARTS
Make sure that the parts and grease or oil to be
2. Use proper special tools and equipment. Re- used for repair of the vehicle, including periodic
fer to “SPECIAL TOOLS” on page 1-16. 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.

3. During disassembly, check and measure the

required parts, and make a record of them so
that you may refer to the record when install-
ing them. Moreover, arrange gears, cylin-
ders, pistons, and other parts for each
section so as not to confuse or lose them. EAM30011

GASKETS, OIL SEALS AND O-RINGS

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.

4. During disassembly, clean each of the parts,

and store them in trays for each section.
5. Flammable. Keep servicing areas away from
any source of fire.
6. During servicing, take special care not to re-

1-10
 IMPORTANT INFORMATION

1. Oil
2. Lip
3. Spring
4. Grease
EAM30012

LOCK WASHERS/PLATES AND COTTER

PINS
After removal, replace lock washers/plates “1”
and cotter pins with new ones. After the bolt or
nut has been tightened to specification, firmly
EAM30014
bend the lock tabs along a flat of the bolt or nut.
CIRCLIPS
When assembling parts, always use new cir-
clips. During installation of a circlip, make sure
that the edge “2” of the circlip “1” is positioned
opposite to the force “3” that the circlip re-
ceives. Install the circlip with its end aligned with
the center of the spline, without opening the cir-
clip more than necessary.

EAM30013

BEARINGS AND OIL SEALS

Install bearings “1” and oil seals “2” with their
manufacturer’s marks or size symbols facing
outward. During installation of an oil seal, make
sure that its main lip faces the oil chamber (the
target to be sealed). Before installation, always
apply a light coat of grease to the oil seal lip.
ECA13300

Do not spin the bearing with compressed air

because this will damage the bearing surfac-
es.

1-11
 BASIC SERVICE INFORMATION

EAM20120

BASIC SERVICE INFORMATION

EAM30181

ELECTRICAL SYSTEM
Electrical parts handling
ECA16600

Never disconnect a battery lead while the

engine is running; otherwise, the electrical
components could be damaged.
ECA16760

Be sure to connect the battery leads to the

correct battery terminals. Reversing the bat-
tery lead connections could damage the
electrical components.

ECA16751

When disconnecting the battery leads from

the battery, be sure to disconnect the nega-
tive battery lead first, then the positive bat-
tery lead. If the positive battery lead is
disconnected first and a tool or similar item ECA16771

contacts the vehicle, a spark could be gener-

ated, which is extremely dangerous. When connecting the battery leads to the
battery, be sure to connect the positive bat-
tery lead first, then the negative battery lead.
If the negative battery lead is connected first
and a tool or similar item contacts the vehi-
cle while the positive battery lead is being
connected, a spark could be generated,
which is extremely dangerous.

If a battery lead is difficult to disconnect due to

rust on the battery terminal, remove the rust us-
ing hot water.

ECA16620

Handle electrical components with special

care, and do not subject them to strong
shocks.

1-12
 BASIC SERVICE INFORMATION

ECA16630 ECA14371

Electrical components are very sensitive to Never insert the tester probes into the cou-
and can be damaged by static electricity. pler terminal slots. Always insert the probes
Therefore, never touch the terminals and be from the opposite end “a” of the coupler,
sure to keep the contacts clean. taking care not to loosen or damage the
leads.

Push and hold the engine stop switch to turn off ECA16640

the multi-function display when resetting the

ECU (Engine Control Unit). Disconnect the start- For waterproof couplers, never insert the
er motor lead of the starter relay, and then push tester probes directly into the coupler. When
the starter switch. Be sure to wait for five sec- performing any checks using a waterproof
onds or longer before pushing the start switch coupler, use the specified test harness or a
after the multi-function display goes off. suitable commercially available test har-
ness.

Checking the electrical system

Checking the connections
Before checking the electrical system, make Check the leads, couplers, and connectors for
sure that the battery voltage is at least 12 V. stains, rust, moisture, etc.
1. Disconnect:
• Lead
• Coupler
• Connector

1-13
 BASIC SERVICE INFORMATION

ECA16780

• When disconnecting a coupler, release the

coupler lock, hold both sections of the cou-
pler securely, and then disconnect the cou-
pler.
• There are many types of coupler locks;
therefore, be sure to check the type of cou-
pler lock before disconnecting the coupler.

3. Check:
• All connections
Loose connection  Connect properly.

• If the pin “1” on the terminal is flattened, bend

it up.
• After disassembling or assembling a coupler,
pull on the leads to make sure that they are in-
stalled securely.

ECA16790

When disconnecting a connector, do not pull

the leads. Hold both sections of the connec-
tor securely, and then disconnect the con-
nector.

2. Check:
• Lead
• Coupler
• Connector 4. Connect:
Moisture  Dry with compressed air. • Lead
Rust/stains  Connect and disconnect sev- • Coupler
eral times. • Connector

• When connecting a coupler or connector,

make sure that both terminals are connected
securely.
• Make sure all connections are tight.

1-14
 BASIC SERVICE INFORMATION

5. Check:
• No continuity
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927

• If there is no continuity, clean the terminals.

• When checking the wire harness, perform
steps (1) to (4).
• As a quick remedy, use a contact revitalizer
available at most part stores.

1-15
 SPECIAL TOOLS

EAM20121

SPECIAL TOOLS
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. Refer to the list provided to avoid errors when placing an order.

• For U.S.A. and Canada, use tool number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use tool number starting with “90890-”.

Reference
Tool name/Tool No. Illustration
pages

Digital circuit tester (CD732) 1-15, 5-45, 8-48,

90890-03243 8-49, 8-49, 8-49,
Model 88 Multimeter with tachometer 8-51, 8-52, 8-54,
YU-A1927 8-54, 8-54, 8-54,
8-55, 8-56, 8-56,
8-57, 8-57, 8-58,
8-58, 8-59
Thickness gauge 3-7, 5-50
90890-03268
Feeler gauge set
YU-26900-9

Valve lapper (ø14) 90890-04101

3-8, 5-26
90890-04101
Valve lapper (ø14)
YM-A8998

YM-A8998

Yamaha diagnostic tool USB (US) 3-12, 7-8, 8-21

90890-03269

Yamaha diagnostic tool (A/I) 3-12, 7-8, 8-21

90890-03273

FI diagnostic tool sub–lead 3-12, 7-8, 8-21

90890-03212
FI diagnostic tool sub–lead
YU-03212

1-16
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages

OBD/ GST Leadwire kit 3-12, 7-8, 8-21

90890-03249

Digital tachometer 3-12, 8-56

90890-06760
Digital tachometer
YU-39951-B

Steering nut wrench 3-28, 4-55

90890-01403
Exhaust flange nut wrench
YU-A9472

Spoke nipple wrench (6–7) 3-34

90890-01521
Spoke nipple wrench (6–7)
YM-01521

Cap bolt ring wrench 4-43, 4-43, 4-44,

90890-01501 4-47, 4-50, 4-52
Cap bolt ring wrench
YM-01501

Cap bolt wrench 4-44, 4-47

90890-01500
Cap bolt wrench
YM-01500

Fork seal driver 4-49, 4-49

90890-01502
Fork seal driver (48)
YM-A0948

Yamaha bond No. 1215 5-19, 5-38, 5-68

90890-85505
Three bond No. 1215®

1-17
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages

Valve spring compressor 5-26, 5-30

90890-04200
Valve spring compressor
YM-04019

Valve spring compressor attachment 5-26, 5-30

90890-04108
Valve spring compressor adapter 22 mm
YM-04108

Valve guide remover (ø5) 5-28

90890-04097
Valve guide remover (5.0 mm)
YM-04097

Valve guide installer (ø5) 5-28

90890-04098
Valve guide installer (5.0 mm)
YM-04098

Valve guide reamer (ø5) 5-28

90890-04099
Valve guide reamer (5.0 mm)
YM-04099

Valve guide remover (ø4.5) 5-28

90890-04116
Valve guide remover (4.5 mm)
YM-04116

Valve guide installer (ø4.5) 5-28

90890-04117
Valve guide installer (4.5 mm)
YM-04117

Valve guide reamer (ø4.5) 5-28

90890-04118
Valve guide reamer (4.5 mm)
YM-04118

1-18
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages

Piston pin puller set 5-33

90890-01304
Piston pin puller
YU-01304

YU-01304

Rotor puller 5-38

90890-04151
Rotor puller
YM-04151

Sheave holder 5-41, 5-42

90890-01701
Primary clutch holder
YS-01880-A

Clutch holder 5-50, 5-52

90890-04199
Universal clutch holder
YM-91042

Crankcase separating tool 5-70

90890-04152
Crankcase separating tool
YU-A9642

1-19
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages

Crankshaft installer pot 5-71

90890-01274
Installing pot
YU-90058

YU-90058/YU-90059

Crankshaft installer bolt 5-71

90890-01275
Bolt
YU-90060

Adapter (M12) 5-71

90890-01278
Adapter #3
YU-90063

Spacer (crankshaft installer) 5-71

90890-04081
Pot spacer
YM-91044

YM-91044

Radiator cap tester 6-4, 6-4

90890-01325
Mityvac cooling system tester kit
YU-24460-A

YU-24460-A

1-20
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages

Radiator cap tester adapter 6-4, 6-4

90890-01352
Pressure tester adapter
YU-33984

YU-33984

Pressure gauge 7-8

90890-03153
Pressure gauge
YU-03153

Fuel pressure adapter 7-8

90890-03186
Fuel pressure adapter
YM-03186

Lithium battery charger 8-51, 8-51

90890-05376
Lithium battery charger
DBY-ACC51-70-02

Ignition checker 8-53

90890-06754
Oppama pet–4000 spark checker
YM-34487

Test harness S– pressure sensor (3P) 8-57

90890-03207
Test harness S– pressure sensor (3P)
YU-03207

1-21
 INSTRUMENT AND CONTROL FUNCTIONS

EAM20181

INSTRUMENT AND CONTROL

FUNCTIONS
EAM30400

WARNING LIGHTS

1 2

EAM30183

START SWITCH
The start switch “1” is located on the right han-
dlebar. Push this switch to crank the engine
with the starter.

1. Engine trouble warning light “ ”

2. Fuel level warning light “ ”
Engine trouble warning light “ ”
This warning light comes on or flashes if a prob-
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. The warn- 1
ing light should come on for a few seconds, and EAM30471

then go off. MODE SWITCH

If the warning light does not come on initially The mode switch “1” is located on the left han-
when the start switch is pushed, or if the warn- dlebar.
ing light remains on, have a Yamaha dealer Press the mode switch to change between map
check the electrical circuit. 1 and map 2.

Fuel level warning light “ ”

This warning light comes on when the fuel level
drops below approximately 2.0 L (0.53 US gal,
0.44 Imp.gal). When this occurs, refuel as soon
as possible.
The electrical circuit of the warning light can be
checked by pushing the start switch. The warn-
ing light should come on for a few seconds, and 1
then go off.
If the warning light does not come on initially
To change the mode
when the start switch is pushed, or if the warn-
1. Shift to neutral.
ing light remains on, have a Yamaha dealer
2. Start the engine.
check the electrical circuit.
3. Press the mode switch.
EAM30182 Map 1
ENGINE STOP SWITCH All-around good engine power and throttle re-
The engine stop switch “1” is located on the left sponse.
handlebar. Continue pushing the engine stop Map 2
switch till the engine comes to a stop. Milder throttle response for riding technical sec-
tions.

1-22
 INSTRUMENT AND CONTROL FUNCTIONS

EWA18980

You can use the Power Tuner app to adjust the

map settings. • Never apply additional force to the sides-
When the mode switch “1” is illuminated, map 2 tand.
is selected. • Hold up the sidestand before starting out.

EAM30185 EAM30189

SHIFT PEDAL REAR BRAKE PEDAL

The shift pedal “1” has adopted a method of 1 The rear brake pedal “1” is in the right of the
down & 5 ups (press-down & kick-ups). chassis. Press down on the brake pedal to acti-
Press it down for N (neutral) to 1st, and kick it up vate the rear brake.
for 2nd to 6th.

6
5
4
3
2
N
1 11
1 EAM30444

EAM30188
STARTER KNOB
FRONT BRAKE LEVER Starting a cold engine requires a larger amount
The front brake lever “1” is located on the right of intake air, which is supplied by the starter
handlebar. Pull it toward the handlebar to acti- knob “1”.
vate the front brake. Pushing the knob toward “a” turns ON the start-
er, resulting in a larger angle of throttle valve.

1 When operating the throttle grip in the closing

direction, the starter knob “1” moves in the di-
rection “b” as shown and returns to its original
position.
EWA20470

While handling the starter knob, take care

not to burn yourself on exhaust pipes.
EAM30190

SIDESTAND
This sidestand “1” is used to support only the
machine when standing.

1-23
 INSTRUMENT AND CONTROL FUNCTIONS

2
1
b a

EAM30192

FUEL TANK CAP

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.
• Install the fuel tank cap cover after placing the
bands “3” all the way in under the seat.

1
3
2

1-24
 STARTING AND BREAK-IN

EAM20123
• Do not operate the throttle grip when operat-
STARTING AND BREAK-IN ing the starter knob.
EAM30193

FUEL
Always use the recommended fuel as stated
below. Also, be sure to use new gasoline the
1
day of a race.
Recommended fuel
Unleaded gasoline (E10 accept-
able)
Octane number (R+M)/2
91 or higher
Fuel tank capacity
8.2 L (2.2 US gal, 1.8 Imp.gal) 3. Start the engine by pushing the start switch.
Fuel reserve amount If the engine fails to start when using the start
2.0 L (0.53 US gal, 0.44 Imp.gal) switch, release it, wait a few seconds, and
then try again.
ECA24180
Each starting attempt should be as short as
possible to preserve the battery. Do not
Use only unleaded gasoline. The use of lead- crank the engine more than 10 seconds on
ed gasoline will cause severe damage to the any one attempt.
engine internal parts such as valves, piston 4. When the engine starts running, warm this
rings, and exhaust system, etc. up one or two minutes at a steady speed (of
3000 to 5000 r/min), and then return the
Your Yamaha engine has been designed to use starter knob to its original position.
unleaded gasoline with a pump octane number
[(R+M)/2] of 91 or higher, or a research octane When operating the throttle grip in the closing
number of 95 or higher. If knocking (or pinging) direction, the starter knob “1” moves in the di-
occurs, use a gasoline of a different brand. rection as shown and returns to its original po-
sition.
EWA19010

• For refueling, be sure to stop the engine

and use enough care not to spill any fuel.
Also be sure to avoid refueling close to a 1
fire.
• Refuel after the engine, exhaust pipe, etc.
have cooled off.
Gasohol
There are two types of gasohol: gasohol con-
taining ethanol and that containing methanol.
EWA19030
Gasohol containing ethanol can be used if the
ethanol content does not exceed 10 %. Gaso-
hol containing methanol is not recommended Since exhaust gas contains harmful ingredi-
by Yamaha because it can cause damage to the ents, do not start or warm it up at an illventi-
fuel system or vehicle performance problems. lated place or a closed narrow place.
EAM30196
5. To stop the engine, push the engine stop
STARTING A COLD ENGINE switch “1”.
1. Press the shift pedal to neutral.
2. Push the starter knob “1” completely. Continue pushing the engine stop switch till the
engine comes to a full stop.
• When the ambient temperature is 15 C (59 F)
or below, use the starter knob.

1-25
 STARTING AND BREAK-IN

ECA25821

After a break-in or after each race, always

check the points shown in “TORQUE-
CHECK POINTS” for tightening torques and
retighten them.
Also when the following parts are replaced, a
break-in is required.
• Cylinder and Crankshaft: A break-in is re-
1 quired for about an hour.
• Piston, Piston ring, Valve, Camshaft, and
EAM30197
Gear: A break-in is required for about 30
STARTING A WARM ENGINE
minutes at a throttle opening of 1/2 or less.
Follow the same procedure as for starting a cold
Observe the condition of the engine carefully
engine with the exception that the starter is not
during a break-in.
required when the engine is warm.
For checkpoints for a break-in, see “MAIN-
TENANCE AFTER BREAK-IN”. If any prob-
If the engine fail to start, fully open the throttle
lem is found, immediately stop the engine
grip and push the start switch few seconds to
and make a checkup.
clear the engine of the rich air-fuel mixture re-
tained in it. EAM30468

ENGINE STARTING PRECAUTION

EAM30198
• Make sure the transmission is in neutral or be
BREAK-IN PROCEDURES
sure to pull the clutch lever before pressing the
A break-in is important so that rotating portion,
start switch.
sliding surfaces, and mounted areas may fit one EWA20540

another, and that the rider may become accus-

tomed to the machine. If the clutch lever is not pulled and the start
ECA25811
switch is pressed with the transmission in
gear, the starter motor will cause the rear
Before running, do maintenance on the air
wheel to spin, which may cause injury.
filter element.
• When starting the engine, if only the starter
1. After warming up the engine, drive it for
motor is turning but the engine does not crank,
about 20 minutes at a throttle opening of 1/2
this is a malfunction most likely due to a worn-
or less.
out starter clutch. Replace the starter clutch.
This model is equipped with an engine auto-
stop system. The engine stops automatically if
left idling for 7 minutes. If the engine stops, push
the start switch to restart the engine.
2. Make a pit stop, and check mounted areas
for looseness, oil leaks, or other problems.
3. Then, drive it for about 40 minutes at a throt-
tle opening of 3/4 or less.
4. Make a pit stop again, and thoroughly check
mounted areas for looseness, oil leaks, or
other problems. Thorough checks and ad-
justments are required in particular for
stretch of cables, free play of the brake,
stretch of the drive chain, looseness of the
spoke, and so on.

1-26
 MAINTENANCE AFTER BREAK-IN

EAM20124
• Drive chain
MAINTENANCE AFTER BREAK-IN Lubricate the drive chain and adjust its ten-
After a break-in, perform careful maintenance to sion.
get ready for the next practice or race. • Fuel tank
Refer to “PRE-OPERATION INSPECTION AND Clean the inside of the fuel tank. Check for
MAINTENANCE” on page 3-6. leaks.
EAM30199
• Suspension
MAJOR MAINTENANCE Check for oil leaks in the front fork or the rear
1. For the engine shock absorber. Check that the mounted
• Leaks around the engine conditions are good.
Check for pressure leaks from the cylinder • Sprocket
head or the cylinder, oil leaks from the crank- Check for looseness in the sprocket mount-
case or the case cover, leaks from the cool- ed on the rear wheel.
ant system, and other leaks. • Mounting bolts and nuts
• Check that the valve, the cylinder head, the Check mounted areas for looseness.
ECA25831
cylinder, the piston, and the piston ring fit
one another, and that contact between the
valve and the cylinder head, and that be- After a break-in or before each race, always
tween the cylinder and the piston are correct. check the points shown in “TORQUE-
• Engine oil change CHECK POINTS” for tightening torques and
Drain the oil, and check for dirt and foreign retighten them.
materials such as metal chips. (If any foreign • Greasing and oiling
material is mixed, disassemble and check Always grease or oil the specified points.
the crankcase.)
EAM30195
Pour the specified amount of the recom- AIR FILTER MAINTENANCE
mended oil. Apply the Yamaha foam air filter oil or other
• Generator quality foam air filter oil to the element. (Excess
Check for looseness in mounted areas of the oil in the element may adversely affect engine
generator rotor and the stator coil assembly. starting.) Refer to “CLEANING THE AIR FILTER
Check that the connector is not being dis- ELEMENT” on page 3-16.
connected.
• Silencer
Check the main body and stay for cracks.
Check for leaks.
• Mounting bolts and nuts
Check for looseness in mounted areas of
parts, as well as engine mounting bolts and
engine brackets.
2. For the chassis
• Check welds and mounted areas of the
frame, the swingarm, the link, the bracket,
and so on, for looseness and cracks.
• Wheel(s)
Check the wheel for runout. Check the spoke
for looseness.
• Brake(s)
Check the brake disc mounting bolt for
looseness.
Check that the reservoir contains the speci-
fied amount of brake fluid. Check for leaks.
• Cable
Grease and adjust cables.

1-27
 TORQUE-CHECK POINTS

EAM20125

TORQUE-CHECK POINTS
Frame construction Combined seat and fuel tank Fuel tank to frame
Frame to rear frame
Frame to engine protector
Engine mounting Frame to engine
Engine bracket to engine
Engine bracket to frame
Seat Seat to frame
Steering Steering stem to handlebar Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Suspension Front Steering stem to front fork Front fork to upper bracket
Front fork to lower bracket
Rear Link Assembly of links
Link to frame
Link to rear shock absorber
Link to swingarm
Mounting of rear shock absorber Rear shock absorber and frame
Mounting of swingarm Tightening of pivot shaft
Wheel(s) Mounting of wheel Front Tightening of wheel axle
Tightening of axle holder
Tightening of spoke nipple
Rear Tightening of wheel axle
Wheel to rear wheel sprocket
Tightening of spoke nipple
Brake(s) Front Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to handlebar
Tightening of bleed screw
Tightening of brake hose holder
Rear Brake pedal to frame
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw
Tightening of brake hose holder
Fuel system Fuel pump to fuel tank

1-28
 TORQUE-CHECK POINTS

Shift pedal Shift pedal to shift shaft

Plastic cover Tightening of front fender
Tightening of fork leg protector
Tightening of air scoop
Left cover to rear frame
Tightening of side cover
Tightening of rear fender
Tightening of mud flap
Tightening of rear brake disc cover
Tightening of rear brake caliper
cover

Concerning the tightening torque, refer to “TIGHTENING TORQUES” on page 2-9.

1-29
 MOTORCYCLE CARE AND STORAGE

EAM20126
ucts are used on hard-to-remove dirt, do
MOTORCYCLE CARE AND STOR- not leave the cleaner on the affected area
AGE any longer than instructed. Also, thorough-
ly rinse the area off with water, immediately
EAM30200
dry it, and then apply a corrosion protection
CARE
spray.
While the open design of a motorcycle reveals
• Improper cleaning can damage plastic
the attractiveness of the technology, it also
parts (such as cowlings, panels, wind-
makes it more vulnerable. Rust and corrosion
shields, headlight lenses, meter lenses,
can develop even if high-quality components
etc.) and the mufflers. Use only a soft, clean
are used. A rusty exhaust pipe may go unno-
cloth or sponge with water to clean plastic.
ticed on a car, however, it detracts from the
However, if the plastic parts cannot be
overall appearance of a motorcycle. Frequent
thoroughly cleaned with water, diluted mild
and proper care does not only comply with the
detergent with water may be used. Be sure
terms of the warranty, but it will also keep your
to rinse off any detergent residue using
motorcycle looking good, extend its life and op-
plenty of water, as it is harmful to plastic
timize its performance.
parts.
Before cleaning
• Do not use any harsh chemical products on
plastic parts. Be sure to avoid using cloths
Be sure to confirm that the vehicle is completely
or sponges which have been in contact
cooled.
with strong or abrasive cleaning products,
1. Block or cover the following parts with suit- solvent or thinner, fuel (gasoline), rust re-
able measures. movers or inhibitors, brake fluid, antifreeze
• Air duct “1” or electrolyte.
• Drain hole on the cylinder head (right side) • For motorcycles equipped with a wind-
“2” shield: Do not use strong cleaners or hard
• Hole under the water pump housing “3” sponges as they will cause dulling or
• Muffler outlet “4” scratching. Some cleaning compounds for
plastic may leave scratches on the wind-
1 shield. Test the product on a small hidden
part of the windshield to make sure that it
does not leave any marks. If the windshield
4 is scratched, use a quality plastic polishing
compound after washing.
2 • When cleaning using either a high-pressure
cleaning machine or a water hose, do not
direct the water jet toward the following ar-
3
eas:(Otherwise, it could cause either dam-
age due to the water pressure or
2. Make sure that all caps and covers as well as
malfunction due to water entry.)
all electrical couplers and connectors, in-
Wheels or swing arm bearings
cluding the spark plug cap, are tightly in-
Fork seals or brake seals
stalled.
Electrical parts, such as couplers, switch-
3. Remove extremely stubborn dirt, like oil
es, battery, etc.
burnt onto the crankcase, with a degreasing
Muffler or hoses
agent and a brush, but never apply such
Air cleaner intake port
products onto seals, gaskets, sprockets, the
• Do not clean using a water jet with the seat
drive chain and wheel axles. Always rinse the
or cover removed.
dirt and degreaser off with water.
Cleaning
ECA26730

• Avoid using strong acidic wheel cleaners,

especially on spoked wheels. If such prod-

1-30
 MOTORCYCLE CARE AND STORAGE

6. Touch up minor paint damage caused by

stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely before
storing or covering it.
EWA19050

Contaminants on the brakes or tires can

cause loss of control.
• Make sure that there is no oil or wax on the
brakes or tires.
After normal use • If necessary, clean the brake discs and
Remove dirt with warm water, a mild detergent, brake linings with a regular brake disc
and a soft, clean sponge, and then rinse thor- cleaner or acetone, and wash the tires with
oughly with clean water. Use a toothbrush or warm water and a mild detergent. Before
bottlebrush for hard-to-reach areas. Stubborn riding at higher speeds, test the motorcy-
dirt and insects will come off more easily if the cle’s braking performance and cornering
area is covered with a wet cloth for a few min- behavior.
utes before cleaning.
ECA24240
After riding in the rain, near the sea or on salt-
sprayed roads
Since sea salt or salt sprayed on roads during • Apply spray oil and wax sparingly and make
winter are extremely corrosive in combination sure to wipe off any excess.
with water, carry out the following steps after • Never apply oil or wax to any rubber and
each ride in the rain, near the sea or on salt- plastic parts, but treat them with a suitable
sprayed roads. care product.
• Avoid using abrasive polishing compounds
Salt sprayed on roads in the winter may remain as they will wear away the paint.
well into spring.
• Consult a Yamaha dealer for advice on what
1. Clean the motorcycle with cold water and a
products to use.
mild detergent, after the engine has cooled
• Washing, rainy weather or humid climates can
down.
cause the headlight lens to fog. Turning the
NOTICE: Do not use warm water since it
headlight on for a short period of time will help
increases the corrosive action of the salt.
remove the moisture from the lens.
2. Apply a corrosion protection spray on all
metal, including chrome- and nickel-plated,
EAM30201
surfaces to prevent corrosion. STORAGE
After cleaning Short-term
1. Dry the motorcycle with a chamois or an ab- Always store your motorcycle in a cool, dry
sorbing cloth. place and, if necessary, protect it against dust
2. Immediately dry the drive chain and lubricate with a porous cover. Be sure the engine and the
it to prevent it from rusting. exhaust system are cool before covering the
3. Use a chrome polish to shine chrome, alumi- motorcycle.
num and stainless- steel parts, including the ECA24250

exhaust system. (Even the thermally induced

discoloring of stainless- steel exhaust sys- • Storing the motorcycle in a poorly ventilat-
tems can be removed through polishing.) ed room or covering it with a tarp, while it is
4. To prevent corrosion, it is recommended to still wet, will allow water and humidity to
apply a corrosion protection spray on all seep in and cause rust.
metal, including chrome- and nickel-plated, • To prevent corrosion, avoid damp cellars,
surfaces. stables (because of the presence of ammo-
5. Use spray oil as a universal cleaner to re- nia) and areas where strong chemicals are
move any remaining dirt.

1-31
 MOTORCYCLE CARE AND STORAGE

stored.
Long-term
Before storing your motorcycle for several
months:
1. Follow all the instructions in the “CARE” on
page 1-30.
2. Fill up the fuel tank and add fuel stabilizer (if
available) to prevent the fuel tank from rust-
ing and the fuel from deteriorating.
3. Perform the following steps to protect the
cylinder, piston rings, etc. from corrosion.
a. Remove the spark plug cap and spark
plug.
b. Pour a teaspoonful of engine oil into the
spark plug bore.
c. Install the spark plug cap onto the spark
plug, and then place the spark plug on the
cylinder head so that the electrodes are
grounded. (This will limit sparking during
the next step.)
d. Turn the engine over several times with
the starter. (This will coat the cylinder wall
with oil.)
e. Remove the spark plug cap from the
spark plug, and then install the spark plug
and the spark plug cap. WARNING! To
prevent damage or injury from spark-
ing, make sure to ground the spark
plug electrodes while turning the en-
gine over.
4. Lubricate all control cables and the pivoting
points of all levers and pedals as well as of
the sidestand/centerstand.
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. Alterna-
tively, turn the wheels a little every month in
order to prevent the tires from becoming de-
graded in one spot.
6. Cover the muffler outlet with a plastic bag to
prevent moisture from entering it.
7. Remove the battery and fully charge it. Store
it in a cool, dry place and charge it once a
month. Do not store the battery in an exces-
sively cold or warm place [less than 0 C (32
F) or more than 65 C (149 F)]. For more in-
formation on storing the battery, “CHECK-
ING AND CHARGING THE BATTERY” on
page 8-50.

Make any necessary repairs before storing the

motorcycle.

1-32
 SPECIFICATIONS

GENERAL SPECIFICATIONS ......................................................................... 2-1

ENGINE SPECIFICATIONS............................................................................. 2-2

1
CHASSIS SPECIFICATIONS........................................................................... 2-5

ELECTRICAL SPECIFICATIONS.................................................................... 2-8

2
TIGHTENING TORQUES ................................................................................ 2-9
GENERAL TIGHTENING TORQUE SPECIFICATIONS .............................. 2-9
ENGINE TIGHTENING TORQUES ........................................................... 2-10
CHASSIS TIGHTENING TORQUES......................................................... 2-13 3
CABLE ROUTING DIAGRAM ....................................................................... 2-17

4
5
6
7
8
9
10
 GENERAL SPECIFICATIONS

EAM20127

GENERAL SPECIFICATIONS
Model
Model BAJL
Dimensions
Overall length 2175 mm (85.6 in)
Overall width 825 mm (32.5 in)
Overall height 1280 mm (50.4 in)
Seat height 955 mm (37.6 in)
Wheelbase 1480 mm (58.3 in)
Ground clearance 320 mm (12.60 in)
Weight
Curb weight 111 kg (245 lb)
Riding capacity 1 person

2-1
 ENGINE SPECIFICATIONS

EAM20128

ENGINE SPECIFICATIONS
Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train DOHC
Displacement 250 cm³
Number of cylinders Single cylinder
Bore × stroke 77.0 × 53.6 mm (3.03 × 2.11 in)
Compression ratio 13.8 : 1
Starting system Electric starter
Fuel
Recommended fuel Unleaded gasoline (E10 acceptable)
Octane number (RON) 95
Fuel tank capacity 8.2 L (2.2 US gal, 1.8 Imp.gal)
Fuel reserve amount 2.0 L (0.53 US gal, 0.44 Imp.gal)
Engine oil
Recommended brand YAMALUBE
SAE viscosity grades 10W-40, 10W-50, 15W-40, 20W-40 or 20W-50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Lubrication system Wet sump
Engine oil quantity
Oil change 0.73 L (0.77 US qt, 0.64 Imp.qt)
With oil filter removal 0.75 L (0.79 US qt, 0.66 Imp.qt)
Quantity (disassembled) 0.95 L (1.00 US qt, 0.84 Imp.qt)
Oil filter
Oil filter type Cartridge
Cooling system
Coolant quantity
Radiator (including all routes) 0.93 L (0.98 US qt, 0.82 Imp.qt)
Radiator cap valve opening pressure 107.9–137.3 kPa (1.08–1.37 kgf/cm², 15.6–19.9
psi)
Spark plug(s)
Manufacturer/model NGK/LMAR8E-J
Spark plug gap 0.6–0.7 mm (0.024–0.028 in)
Cylinder head
Warpage limit 0.05 mm (0.0020 in)
Camshaft
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-journal-to-camshaft-cap clearance 0.080 mm (0.0032 in)
limit
Camshaft lobe dimensions
Lobe height limit (Intake) 32.130 mm (1.2650 in)
Lobe height limit (Exhaust) 33.460 mm (1.3173 in)

2-2
 ENGINE SPECIFICATIONS

Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.12–0.19 mm (0.0047–0.0075 in)
Exhaust 0.17–0.24 mm (0.0067–0.0094 in)
Valve dimensions
Valve seat contact width limit (intake) 1.6 mm (0.06 in)
Valve seat contact width limit (exhaust) 1.6 mm (0.06 in)
Valve stem diameter limit (intake) 4.945 mm (0.1947 in)
Valve stem diameter limit (exhaust) 4.430 mm (0.1744 in)
Valve guide inside diameter (intake) 5.000–5.012 mm (0.1969–0.1973 in)
Valve guide inside diameter (exhaust) 4.500–4.512 mm (0.1772–0.1776 in)
Valve-stem-to-valve-guide clearance limit 0.080 mm (0.0032 in)
(intake)
Valve-stem-to-valve-guide clearance limit 0.100 mm (0.0039 in)
(exhaust)
Valve stem runout 0.020 mm (0.0008 in)
Valve spring
Free length limit (intake) 34.94 mm (1.38 in)
Free length limit (exhaust) 33.82 mm (1.33 in)
Cylinder
Bore 77.000–77.010 mm (3.0315–3.0319 in)
Wear limit 77.060 mm (3.0339 in)
Piston
Piston-to-cylinder clearance 0.030–0.055 mm (0.0012–0.0022 in)
Diameter 76.955–76.970 mm (3.0297–3.0303 in)
Measuring point (from piston skirt bottom) 4.0 mm (0.16 in)
Piston pin bore inside diameter limit 16.043 mm (0.6316 in)
Piston pin outside diameter limit 15.971 mm (0.6288 in)
Piston-pin-to-piston-pin-bore clearance 0.002–0.022 mm (0.0001–0.0009 in)
Piston ring
Top ring
End gap limit 0.50 mm (0.0197 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Side clearance limit 0.115 mm (0.0045 in)
Crankshaft
Crank assembly width 55.93–56.00 mm (2.202–2.205 in)
Runout limit 0.030 mm (0.0012 in)
Clutch
Clutch type Wet, multiple-disc
Clutch lever free play 7.0–12.0 mm (0.28–0.47 in)
Friction plate 1 thickness 2.70–2.90 mm (0.106–0.114 in)
Wear limit 2.60 mm (0.102 in)
Plate quantity 2 pcs
Friction plate 2 thickness 2.72–2.88 mm (0.107–0.113 in)
Wear limit 2.62 mm (0.103 in)
Plate quantity 6 pcs
Clutch plate thickness 1.50–1.70 mm (0.059–0.067 in)
Plate quantity 7 pcs
Warpage limit 0.10 mm (0.004 in)

2-3
 ENGINE SPECIFICATIONS

Clutch spring free length 44.50 mm (1.75 in)

Clutch spring free length limit 42.28 mm (1.66 in)
Push rod bending limit 0.30 mm (0.012 in)
Drivetrain
Primary reduction ratio 3.353 (57/17)
Transmission type Constant mesh 6-speed
Gear ratio
1st 2.385 (31/13)
2nd 1.813 (29/16)
3rd 1.444 (26/18)
4th 1.143 (24/21)
5th 0.957 (22/23)
6th 0.815 (22/27)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Secondary reduction ratio 3.923 (51/13)
Final drive Chain
Air filter
Air filter element Wet element
Air filter oil grade Yamaha foam air filter oil or other quality foam
air filter oil
Fuel pump
Maximum consumption amperage 2.4 A
Fuel injector
Resistance 12.0 
Throttle body
ID mark B7B1
Idling condition
Engine idling speed 1900–2100 r/min
Coolant temperature 70–80 C (158–176 F)
Fuel line pressure (at idle) 300–390 kPa (3.0–3.9 kgf/cm², 43.5–56.6 psi)
Throttle grip free play 3.0–6.0 mm (0.12–0.24 in)

2-4
 CHASSIS SPECIFICATIONS

EAM20129

CHASSIS SPECIFICATIONS
Chassis
Caster angle 27.2 
Trail 116 mm (4.6 in)
Front wheel
Wheel type Spoke wheel
Rim size 21 x 1.60
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Wheel axle bending limit 0.50 mm (0.02 in)
Rear wheel
Wheel type Spoke wheel
Rim size 18 x 2.15
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Wheel axle bending limit 0.50 mm (0.02 in)
Front tire
Type With tube
Size 80/100-21 51M
Manufacturer/model DUNLOP/MX33F
Rear tire
Type With tube
Size 110/100-18 64M
Manufacturer/model DUNLOP/MX33
Tire air pressure (measured on cold tires)
Front 100 kPa (1.00 kgf/cm², 15 psi)
Rear 100 kPa (1.00 kgf/cm², 15 psi)
Front brake
Type Hydraulic single disc brake
Brake disc thickness limit 2.5 mm (0.10 in)
Brake disc runout limit (as measured on 0.15 mm (0.0059 in)
wheel)
Brake pad lining thickness limit 1.0 mm (0.04 in)
Master cylinder inside diameter 9.52 mm (0.37 in)
Caliper cylinder inside diameter (Left) 25.40 mm, 25.40 mm (1.00 in, 1.00 in)
Specified brake fluid DOT 4
Rear brake
Type Hydraulic single disc brake
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc runout limit (as measured on 0.15 mm (0.0059 in)
wheel)
Brake pad lining thickness limit 1.0 mm (0.04 in)
Master cylinder inside diameter 11.0 mm (0.43 in)
Caliper cylinder inside diameter 25.40 mm (1.00 in)
Specified brake fluid DOT 4
Front suspension
Type Telescopic fork
Spring Coil spring

2-5
 CHASSIS SPECIFICATIONS

Shock absorber Hydraulic damper

Wheel travel 310 mm (12.2 in)
Fork spring free length limit 492.0 mm (19.37 in)
Inner tube bending limit 0.2 mm (0.01 in)
Recommended oil Yamaha Suspension Oil S1
Quantity (left) 501.0 cm³ (16.94 US oz, 17.67 Imp.oz)
Quantity (right) 501.0 cm³ (16.94 US oz, 17.67 Imp.oz)
Rebound damping
Adjusting system Mechanical adjustable type
Unit for adjustment Click
Adjustment value from the start position 20
(Soft)
Adjustment value from the start position 12
(STD)
Adjustment value from the start position 0
(Hard)
Compression damping
Adjusting system Mechanical adjustable type
Unit for compression damping adjustment Click
Adjustment value from the start position 20
(Soft)
Adjustment value from the start position 12
(STD)
Adjustment value from the start position 0
(Hard)
Rear suspension
Type Swingarm (link suspension)
Spring Coil spring
Shock absorber Gas-hydraulic damper
Wheel travel 317 mm (12.5 in)
Spring preload
Adjusting system Mechanical adjustable type
Adjustment value (Soft) 1.5 mm (0.06 in)
Adjustment value (STD) 6.0 mm (0.24 in)
Adjustment value (Hard) 18.0 mm (0.71 in)
Rebound damping
Adjusting system Mechanical adjustable type
Unit for adjustment Click
Adjustment value from the start position 30
(Soft)
Adjustment value from the start position 11
(STD)
Adjustment value from the start position 0
(Hard)
Compression damping
Adjusting system Mechanical adjustable type
Fast compression damping
Unit for adjustment Turn
Adjustment value from the start position 2
(Soft)
Adjustment value from the start position 1-1/8
(STD)

2-6
 CHASSIS SPECIFICATIONS

Adjustment value from the start position 0

(Hard)
Slow compression damping
Unit for adjustment Click
Adjustment value from the start position 20
(Soft)
Adjustment value from the start position 11
(STD)
Adjustment value from the start position 0
(Hard)
Drive chain
Size 520
Chain type Sealed type
Number of links 114
Drive chain slack (Maintenance Stand) 50.0–60.0 mm (1.97–2.36 in)
15-link length limit 239.3 mm (9.42 in)

2-7
 ELECTRICAL SPECIFICATIONS

EAM20130

ELECTRICAL SPECIFICATIONS
Voltage
System voltage 12 V
Ignition system
Ignition system TCI
Ignition timing (B.T.D.C.) 8.0–12.0 /2000 r/min
Engine control unit
Model BAJ2
Ignition coil
Primary coil resistance 2.16–2.64 
Secondary coil resistance 8.64–12.96 k
Spark plug cap
Resistance 7.50–12.50 k
Charging system
Charging system AC magneto
Standard output 14.0 V, 5.4 A at 5000 r/min
Rectifier/regulator
Regulator type Single-phase
Regulated voltage (DC) 14.0–14.8 V
Battery
Model BR98
Voltage, capacity 12 V, 2.4 Ah (5 HR)
Indicator light
Fuel level warning light 1.7 W
Engine trouble warning light 1.7 W
Starter motor
Brush overall length 7.0 mm (0.28 in)
Brush overall length limit 3.5 mm (0.14 in)
Brush spring force 3.92–5.88 N (400–600 gf, 14.11–21.17 oz)
Mica undercut (depth) 1.50 mm (0.06 in)
Fuel injection sensor
Crankshaft position sensor resistance 228–342 
Intake air temperature sensor resistance 5400–6600  at 0 C (5400–6600  at 32 F)
Intake air temperature sensor resistance 290–390  at 80 C (290–390  at 176 F)
Coolant temperature sensor resistance 2513–2777  at 20 C (2513–2777  at 68 F)
Coolant temperature sensor resistance 210–221  at 100 C (210–221  at 212 F)
Fuse(s)
Main fuse 15.0 A
Radiator fan motor fuse 5.0 A
Spare fuse 15.0 A

2-8
 TIGHTENING TORQUES

EAM20131

TIGHTENING TORQUES
EAM30205

GENERAL TIGHTENING TORQUE

SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special
components or assemblies are provided for
each chapter of this manual. To avoid warpage,
tighten multi-fastener assemblies in a criss-
cross pattern and progressive stages until the
specified tightening torque is reached. Unless
otherwise specified, tightening torque specifi-
cations require clean, dry threads. Components
should be at room temperature.

A. Distance between flats

B. Outside thread diameter

General tightening torques

A (nut) B (bolt)
N·m kgf·m lb·ft

10 mm 6 mm 6 0.6 4.4
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 41
19 mm 14 mm 85 8.5 63
22 mm 16 mm 130 13.0 96

2-9
 TIGHTENING TORQUES

EAM30203

ENGINE TIGHTENING TORQUES

- marked portion shall be checked for torque tightening after break-in or before each race.

Thread
Item Q’ty Tightening torques Remarks
size

Camshaft cap bolt M6 8 10 N·m (1.0 kgf·m, 7.4 lb·ft) E

Spark plug M10 1 13 N·m (1.3 kgf·m, 9.6 lb·ft)

Cylinder head stud bolt (exhaust
pipe) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)

Oil passage plug (cylinder head) M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Cylinder head bolt M9 4 See TIP. M

Cylinder head nut M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Cylinder head cover bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Stud bolt (cylinder head cover) M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

Cylinder bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Oil pressure check bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Balancer weight plate screw M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

Balancer weight gear nut M14 1 50 N·m (5.0 kgf·m, 37 lb·ft)

Balancer nut M10 1 38 N·m (3.8 kgf·m, 28 lb·ft)
Timing chain guide stopper plate M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
(exhaust side) LT

Timing chain tensioner cap bolt M6 1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Timing chain tensioner bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Coolant drain bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Radiator hose clamp screw M6 8 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
Radiator bolt M6 4 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Radiator pipe joint bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Water pump housing cover bolt M6 4 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Water pump impeller M8 1 14 N·m (1.4 kgf·m, 10 lb·ft)
Oil pump assembly bolt M5 2 5 N·m (0.5 kgf·m, 3.7 lb·ft) LT

Oil pump cover bolt M4 1 6 N·m (0.6 kgf·m, 4.4 lb·ft) LT

Oil strainer bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Throttle cable cover bolt M5 1 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
Throttle body joint bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Throttle body joint clamp screw M5 1 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
Air filter case joint clamp screw M5 1 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
Air filter case bolt M6 3 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Clutch cable locknut (clutch cable
M6 1 4.3 N·m (0.43 kgf·m, 3.2 lb·ft)
adjuster)

2-10
 TIGHTENING TORQUES

Thread
Item Q’ty Tightening torques Remarks
size

Clutch cable locknut (engine side) M8 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Exhaust pipe nut M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Exhaust pipe protector screw M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

Exhaust pipe bracket bolt M8 1 20 N·m (2.0 kgf·m, 15 lb·ft)

Silencer bolt (front) M8 1 30 N·m (3.0 kgf·m, 22 lb·ft)
Silencer bolt (rear) M8 1 30 N·m (3.0 kgf·m, 22 lb·ft)
Exhaust pipe clamp bolt M8 2 12 N·m (1.2 kgf·m, 8.9 lb·ft)
Silencer body bolt M5 6 8 N·m (0.8 kgf·m, 5.9 lb·ft) LT

Oil nozzle bolt M5 1 5 N·m (0.5 kgf·m, 3.7 lb·ft) LT

Engine oil drain bolt M10 1 20 N·m (2.0 kgf·m, 15 lb·ft)

Crankcase bolt M6 12 12 N·m (1.2 kgf·m, 8.9 lb·ft)
Clutch cable holder bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

Crankshaft end accessing screw M36 1 10 N·m (1.0 kgf·m, 7.4 lb·ft) E

Timing mark accessing screw M14 1 6 N·m (0.6 kgf·m, 4.4 lb·ft) E

Drive sprocket cover bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)

Crankcase bearing cover plate M8 4 22 N·m (2.2 kgf·m, 16 lb·ft)
screw LT

Bearing plate cover bolt (left side of

the drive axle) M6 2 12 N·m (1.2 kgf·m, 8.9 lb·ft) LT

Plate bolt M6 4 12 N·m (1.2 kgf·m, 8.9 lb·ft) LT

Clutch cover bolt M6 6 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Crankcase cover bolt (left) M6 7 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Crankcase cover bolt (right) M6 9 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Oil filter element cover bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Starter clutch screw M6 8 12 N·m (1.2 kgf·m, 8.9 lb·ft) LT

Primary drive gear nut M16 1 105 N·m (10.5 kgf·m, 77 lb·ft) LT

Clutch spring bolt M6 6 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Stake.
Clutch boss nut M20 1 95 N·m (9.5 kgf·m, 70 lb·ft)
E

Use a lock
Drive sprocket nut M18 1 75 N·m (7.5 kgf·m, 55 lb·ft)
washer.
Segment bolt M8 1 30 N·m (3.0 kgf·m, 22 lb·ft)
Shift guide bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

Stopper lever bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

Shift pedal bolt M6 1 12 N·m (1.2 kgf·m, 8.9 lb·ft) 

Generator rotor nut M12 1 65 N·m (6.5 kgf·m, 48 lb·ft)
Stator coil screw M5 3 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

2-11
 TIGHTENING TORQUES

Thread
Item Q’ty Tightening torques Remarks
size

Crankshaft position sensor bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

Stator coil assembly lead holder bolt M5 1 8 N·m (0.8 kgf·m, 5.9 lb·ft) LT

Coolant temperature sensor M10 1 15 N·m (1.5 kgf·m, 11 lb·ft)

Gear position switch bolt M5 2 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) LT

Rectifier/regulator bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)

ECU bolt M5 2 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
Ignition coil bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Starter motor bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Nut (holder) M6 1 8 N·m (0.8 kgf·m, 5.9 lb·ft)
Throttle position sensor screw M5 1 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
Intake air pressure sensor screw M6 1 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)

Cylinder head bolt

Tighten all the cylinder head bolts evenly in the tightening order to 30 N·m (3.0 kgf·m, 22 lb·ft). Remove
the one bolt according to the tightening order. When doing so, do not remove the other bolts. Retighten
the bolt to 15 N·m (1.5 kgf·m, 11 lb·ft), and then tighten it further to reach the specified angle (60). Re-
move the remaining bolts one by one in the same manner and retighten them. Finally, tighten all the bolts
to reach the specified angle (60). Total tightening angle: 60 + 60 = 120 (The first and second time, be
sure to apply molybdenum disulfide oil to the bolt threads and seats as well as to both sides of the lock
washers.)

FWD
x3 x1

3 2

1 4

2-12
 TIGHTENING TORQUES

EAM30204

CHASSIS TIGHTENING TORQUES

- marked portion shall be checked for torque tightening after break-in or before each race.

Thread
Item Q’ty Tightening torques Remarks
size

Upper bracket pinch bolt M8 4 21 N·m (2.1 kgf·m, 15 lb·ft) 

Lower bracket pinch bolt M8 4 21 N·m (2.1 kgf·m, 15 lb·ft) 
Steering stem nut M24 1 145 N·m (14.5 kgf·m, 107 lb·ft) 
Upper handlebar holder bolt M8 4 28 N·m (2.8 kgf·m, 21 lb·ft) 
Lower handlebar holder nut M10 2 40 N·m (4.0 kgf·m, 30 lb·ft) 
Engine stop switch screw M3 1 0.5 N·m (0.05 kgf·m, 0.37 lb·ft)
Start switch M3 1 0.5 N·m (0.05 kgf·m, 0.37 lb·ft)
Mode switch M3 1 1.3 N·m (0.13 kgf·m, 0.95 lb·ft)
Lower ring nut M28 1 See TIP. 
Damper assembly (front fork) M51 2 30 N·m (3.0 kgf·m, 22 lb·ft)
Inner tube and adjuster M22 2 55 N·m (5.5 kgf·m, 41 lb·ft) LT

Base valve (front fork) M42 2 28 N·m (2.8 kgf·m, 21 lb·ft)

Adjuster (damper assembly) M12 2 29 N·m (2.9 kgf·m, 21 lb·ft)
Bleed screw (front fork) M5 2 1.3 N·m (0.13 kgf·m, 0.95 lb·ft)
Front fork protector bolt M6 6 5 N·m (0.5 kgf·m, 3.7 lb·ft) 
Brake hose holder bolt M6 2 9 N·m (0.9 kgf·m, 6.6 lb·ft) 
Throttle grip cap screw M5 2 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
Clutch lever holder bolt M6 2 5 N·m (0.5 kgf·m, 3.7 lb·ft)
Clutch lever pivot bolt M6 1 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
Clutch lever pivot nut M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Clutch lever position locknut M5 1 4.8 N·m (0.48 kgf·m, 3.5 lb·ft)
Front brake master cylinder holder M6 2 9 N·m (0.9 kgf·m, 6.6 lb·ft) 
bolt
Front brake master cylinder reser-
M4 2 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
voir cap screw
Front brake lever pivot bolt M6 1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Front brake lever pivot nut M6 1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Locknut (front brake lever position) M6 1 5 N·m (0.5 kgf·m, 3.7 lb·ft)
Front brake hose holder bolt M6 1 9 N·m (0.9 kgf·m, 6.6 lb·ft) 
Front brake hose union bolt M10 2 30 N·m (3.0 kgf·m, 22 lb·ft) 
Front brake caliper bolt M8 2 28 N·m (2.8 kgf·m, 21 lb·ft) 
Front brake pad pin M10 1 17 N·m (1.7 kgf·m, 13 lb·ft)
Front brake pad pin plug M10 1 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
Front brake caliper bleed screw M8 1 5 N·m (0.5 kgf·m, 3.7 lb·ft) 

2-13
 TIGHTENING TORQUES

Thread
Item Q’ty Tightening torques Remarks
size

Front wheel axle nut M18 1 115 N·m (11.5 kgf·m, 85 lb·ft) 
Front wheel axle pinch bolt M8 4 21 N·m (2.1 kgf·m, 15 lb·ft) 
Front brake disc bolt M6 6 12 N·m (1.2 kgf·m, 8.9 lb·ft) / LT

Rear brake disc bolt M6 6 12 N·m (1.2 kgf·m, 8.9 lb·ft) / LT

Footrest bracket bolt M10 4 55 N·m (5.5 kgf·m, 41 lb·ft) LT

Rear brake pedal bolt M8 1 26 N·m (2.6 kgf·m, 19 lb·ft) 

Rear brake pedal adjusting locknut M6 1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Rear brake master cylinder bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) 
Rear brake master cylinder reservoir M4 2 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
cap bolt
Rear brake hose union bolt M10 2 30 N·m (3.0 kgf·m, 22 lb·ft) 
Rear brake caliper bleed screw M8 1 5 N·m (0.5 kgf·m, 3.7 lb·ft) 
Rear brake pad pin M10 1 17 N·m (1.7 kgf·m, 13 lb·ft)
Rear brake pad pin plug M10 1 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
Rear wheel axle nut M22 1 125 N·m (12.5 kgf·m, 92 lb·ft) 
Drive chain puller locknut M8 2 21 N·m (2.1 kgf·m, 15 lb·ft)
Rear wheel sprocket nut M8 6 50 N·m (5.0 kgf·m, 37 lb·ft) 
Nipple (spoke) — 72 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) 
Bolt (rear brake disc cover) M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) 
Rear brake caliper protector bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Engine mounting bolt (upper side) M10 2 45 N·m (4.5 kgf·m, 33 lb·ft) 
Engine mounting bolt (front side) M10 1 55 N·m (5.5 kgf·m, 41 lb·ft) 
Engine mounting bolt (lower side) M10 1 53 N·m (5.3 kgf·m, 39 lb·ft) 
Engine bracket bolt (upper side) M8 4 34 N·m (3.4 kgf·m, 25 lb·ft) 
Engine bracket bolt (front side) M8 4 34 N·m (3.4 kgf·m, 25 lb·ft) 
Rear frame bolt M8 4 38 N·m (3.8 kgf·m, 28 lb·ft) 
Engine guard bolt (right side) M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Pivot shaft nut M16 1 85 N·m (8.5 kgf·m, 63 lb·ft) 
Rear shock absorber assembly M10 1 56 N·m (5.6 kgf·m, 41 lb·ft) 
upper nut
Rear shock absorber assembly
M10 1 53 N·m (5.3 kgf·m, 39 lb·ft) 
lower nut
Relay arm nut (swingarm side) M14 1 70 N·m (7.0 kgf·m, 52 lb·ft) 
Connecting arm nut (relay arm side) M14 1 80 N·m (8.0 kgf·m, 59 lb·ft) 
Connecting arm nut (frame side) M14 1 80 N·m (8.0 kgf·m, 59 lb·ft) 
Brake hose holder screw M5 4 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) 
Drive chain tensioner bolt (upper
M8 1 16 N·m (1.6 kgf·m, 12 lb·ft)
side)

2-14
 TIGHTENING TORQUES

Thread
Item Q’ty Tightening torques Remarks
size

Drive chain tensioner bolt (lower

M8 1 16 N·m (1.6 kgf·m, 12 lb·ft)
side)
Bolt (drive chain support) M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Drive chain support nut M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Drive chain guide bolt M5 3 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
Fuel tank bolt (front side) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Fuel tank bolt (rear side) M6 1 9 N·m (0.9 kgf·m, 6.6 lb·ft)
Fuel tank bracket bolt (rear side) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Fuel pump bolt M5 5 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Screw (fuel inlet pipe) M5 2 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
Bolt (fuel tank cap cover) M6 2 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
Seat set bracket screw M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Seat bolt M8 2 22 N·m (2.2 kgf·m, 16 lb·ft) 
Side cover bolt (left) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Side cover bolt (right) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Air scoop bolt (frame) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Air scoop bolt (fuel tank) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Air scoop bolt (radiator guard) M6 4 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Front fender bolt M6 4 10 N·m (1.0 kgf·m, 7.4 lb·ft) 
Rear fender bolt (front side) M6 4 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Rear fender bolt (rear side) M6 2 16 N·m (1.6 kgf·m, 12 lb·ft) 
Screw (mud flap) — 2 1.3 N·m (0.13 kgf·m, 0.95 lb·ft) 
Number plate bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Frame ground bolt (negative battery
M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
lead)

Lower ring nut

1. First, tighten the lower ring nut approximately 38 N·m (3.8 kgf·m, 28 lb·ft) by using the steering nut
wrench, then loosen the lower ring nut one turn.
2. Retighten the lower ring nut 7 N·m (0.7 kgf·m, 5.2 lb·ft).

2-15
 TIGHTENING TORQUES

2-16
 CABLE ROUTING DIAGRAM

EAM20152

CABLE ROUTING DIAGRAM

Frame and engine (left side view)

2-17
 CABLE ROUTING DIAGRAM

1. Clutch cable G. Pass the stator coil assembly lead through

2. Throttle cable (return) back side of the radiator. No pinch is allowed
between the radiator and tension arm.
3. Throttle cable (pull)
H. Insert the clip portion of the clamp of the
4. Cable holder starter motor lead into the hole in the cylin-
5. Warning light lead der head. When doing so, make sure that the
6. Intake air temperature sensor coupler (black) lead is not twisted.
7. Rectifier/regulator coupler I. Route the starter motor lead through the
inside of the engine mounting bracket boss
8. Stator coil assembly lead and the front side area than the back end of
9. Battery band the engine mounting bracket boss.
10.CCU (Communication Control Unit) J. Route the gear position switch lead along the
11.Starter relay diode crankcase without slack.
12.Radiator fan motor fuse K. Pass the gear position switch lead to the
13.Engine mounting bracket boss inside of the lower engine bracket (the side
of the vehicle).
14.Starter motor lead
L. Pass the clutch cable with no downward sag
15.Gear position switch lead allowed.
16.Lower engine bracket M. Bring the protector of the clutch cable into
17.Protector (clutch cable) contact with the radiator hose, and pass it to
18.Radiator hose the outside of the neutral switch lead and the
stator coil assembly lead (the outside of the
19.Gear position switch coupler vehicle).
20.Stator coil assembly coupler N. No pinch is allowed the leads between the
21.Tension arm radiator hose and the tension arm.
22.Rectifier/regulator lead O. After connecting the gear position switch
23.Wire harness coupler, attach the coupler cover.
24.Yamaha diagnostic tool coupler P. After connecting the stator coil assembly
coupler, attach the coupler cover.
25.Tank rail
Q. Pass the rectifier/regulator lead (wire harness
26.Mode switch lead side) to the inside of the tension arm (the
27.Radiator side of the vehicle).
28.Radiator breather hose R. Pass the main harness to the front of the
29.Rectifier/regulator radiator hose (the front of the vehicle), and to
30.Crankcase cover the inside of the throttle cable (the side of the
vehicle).
31.Crankcase
S. Pass the engine stop switch lead between
32.Clamp the Yamaha diagnostic tool coupler and the
33.Frame tank rail.
34.Plate T. Pass the warning light lead under the mode
35.Warning light coupler switch lead.
36.Cylinder head breather hose U. Clamp the clutch cable at the front of the
lead (the front of the vehicle).
37.Clamp
V. Insert the clamp into the hole in the frame.
A. Pass the engine stop switch lead and the Cut off the excess end of the locking portion,
mode switch lead between the frame and the and the locking portion should face toward
cable holder. Pass the mode switch lead the front of the vehicle.
above the engine stop switch lead. W. Diagram for routing the radiator hose and
B. Insert the Yamaha diagnostic tool coupler radiator breather hose.
into the connector, and fix it to the bracket. X. Route the radiator breather hose between
C. Fasten the engine stop switch coupler to the the radiator hose and the cylinder head
bracket of the inside. Fasten the mode breather hose. Then route it between the
switch coupler to the bracket of the outside. down tubes.
Route the mode switch lead under the Y. Route the cylinder head breather hose
bracket. between the radiator and the frame, and in
D. Pass the warning light lead over the wire har- front of the lower boss of the radiator.
ness and radiator hose.
E. Fasten the warning light coupler to the
bracket.
F. Fasten the rectifier/regulator coupler to the
bracket. Attach the coupler cover.

2-18
 CABLE ROUTING DIAGRAM

Frame and engine (right side view)

2-19
 CABLE ROUTING DIAGRAM

1. Cross tube L. After connecting the fuel pump coupler,

2. Starter motor lead attach the cover.
3. Coolant temperature sensor coupler M. Fasten the starter relay lead and starter
motor lead with the plastic locking tie within
4. Coolant temperature sensor lead the range of the cross tube width. Make sure
5. Cylinder head breather hose that the locking portion of the plastic locking
6. Coupler (not used) tie faces to the lower side of the vehicle and
put it inside the rear frame without cutting off
7. Start switch coupler the end.
8. Cable guide N. Route the starter motor lead inside of the
9. Start switch lead rear frame and along the rear fender.
10.Joint coupler O. Place the resistor coupler under the starter
11.Throttle position sensor lead relay.
12.Breather hose P. The routing order of leads not indicated does
13.Clip not matter.
14.3-way joint Q. Fasten the wire harness at the white tape
position using the plastic locking tie.
15.Radiator breather hose
R. Position the lock part of the plastic locking
16.Throttle position sensor coupler tie to downward of the vehicle. Cut the end
17.Radiator hose of the plastic locking tie.
18.Fuel hose S. Fasten the bracket to the tank rail (right)
19.Fuel pump coupler using the rivet.
20.Joint coupler T. When installing the engine ground lead ter-
minal, it can face either way. Make sure that
21.Resistor coupler the terminal does not contact the cylinder
22.Negative battery lead head bolt and that it faces to the rear beyond
23.Wire harness the cylinder ridge line.
24.Fuel tank U. Cylinder head ridge line
25.Rubber damper V. After connecting the coolant temperature
sensor 2-pin coupler (black), install the cou-
26.Rear frame pler cover over the holder securely.
27.Side cover
28.Bracket
29.Holder

A. 20 mm (0.7874 in)
B. Adjust any slack between the rear shock
absorber and the clamp of the side cover.
C. Route the cylinder head breather hose
through the inside of the coolant tempera-
ture sensor lead.
D. Make sure the cable guide has contact with
the stamped location of the vehicle identifi-
cation number, and install it.
E. Insert the joint coupler into the plate and
secure it. After securing it, put the cover over
the joint coupler. The inserted portion of the
coupler should be hidden with the cover.
F. Route the throttle position sensor lead out-
side the vehicle past the breather hose.
G. Install the clips as shown in the illustration.
Then install the lower clip above the radiator
stay.
H. Align the red paint mark on the hose with the
convex mark on the 3-way joint, and then
install the cylinder head breather hoses.
I. Route the radiator breather hose outside the
breather hose. When doing so, cross them at
the bottom of the radiator.
J. After connecting the throttle position sensor
coupler, attach the cover.
K. Route the fuel hose in front of the fuel pump.

2-20
 CABLE ROUTING DIAGRAM

Handlebar (front view)

2-21
 CABLE ROUTING DIAGRAM

1. Plastic locking tie

2. Number plate band
3. Clutch cable
4. Engine stop switch lead
5. Mode switch lead
6. Warning light lead
7. Front brake hose
8. Cable guide
9. Start switch lead
10.Number plate
11.Warning light

A. Fasten the start switch lead to the handlebar

using the plastic locking tie. Do not cut the
end of the plastic locking tie.
B. Pass the clutch cable through the rear side
of the number plate band.
C. Fasten the engine stop switch lead and
mode switch lead to the handlebar using the
plastic locking tie. Do not cut the end of the
plastic locking tie.
D. 30–50
E. Vertical direction of vehicle
F. Pass the engine stop switch lead and mode
switch lead between the frame and the cable
guide.
G. Pass the warning light lead through the cable
guide.
H. Pass the front brake hose through the front
side of the number plate.
I. Pass the clutch cable through the guide of
the number plate.
J. Pass the start switch lead through the cable
guide.
K. Pass the start switch lead through the left
side of the number plate mounting bracket.
L. Insert the warning light into the bracket and
fasten it.

2-22
 CABLE ROUTING DIAGRAM

Frame and engine (top view)

2-23
 CABLE ROUTING DIAGRAM

1. Clamp H. Fasten the starter motor lead along the

2. Diode locating damper.
3. Throttle position sensor lead I. It does not matter if the high tension cord
and grommet do not contact the ECU.
4. Intake air pressure sensor lead
J. Route the fuel injector lead in front of the
5. Joint coupler ECU coupler of the vehicle.
6. Intake air pressure sensor coupler K. Pass the wire harness between the ECU and
7. Wire harness air filter assembly.
8. Clamp (wire harness) L. Insert the clamp into the rib so that it con-
9. Cylinder head breather hose tacts the rib.
10.Fuel injector lead
11.Throttle body
12.Fuel injector coupler
13.Fuel hose
14.Air filter
15.Wire harness
16.Fuel tank bracket
17.Plug cap
18.Cylinder head cover
19.Starter motor lead
20.Cable guide
21.Ignition coil
22.Side core
23.Ignition coil sub-lead
24.Ignition coil lead coupler
25.Warning light lead (wire harness)
26.Warning light coupler
27.Rectifier/regulator lead (wire harness)
28.Warning light lead
29.ECU (Engine Control Unit)
30.High tension cord
31.ECU (engine control unit) coupler
32.Air filter
33.Wire harness
34.Grommet
35.Clamp

A. Fasten the main harness and start switch

lead by the clamp, and insert the clamp pro-
jection into the hole in the sheet metal of the
radiator. The direction of the clamp lock por-
tion does not matter. It is allowed to run the
leads near the radiator cap on the inside.
B. No pinch is allowed the leads between the
tank rail and the air filter joint.
C. Insert the projection of the main harness into
the hole in the frame.
D. Route the cylinder head breather hose out-
side the vehicle past the intake air pressure
sensor lead, and then route it above the vehi-
cle along the intake air pressure sensor lead
connector.
E. Right side of the vehicle.
F. ±10
G. Install the plug cap so it faces to the right
side of the vehicle.

2-24
 CABLE ROUTING DIAGRAM

Frame and battery (top view)

2-25
 CABLE ROUTING DIAGRAM

1. Positive battery lead

2. Fuel pump lead
3. Diode
4. Wire harness
5. Main relay (red tape)
6. Joint coupler
7. Radiator fan motor relay
8. Starter relay coupler
9. Starter relay
10.Starter motor lead
11.Resistor
12.Negative battery lead
13.Cross member

A. Connect the positive battery lead and starter

relay terminal.
B. Install the clamp (wire harness) to the hole of
the battery bracket.
C. After connecting the negative battery cou-
pler, position to the right side of the starter
relay.
D. The position of the starter motor lead and
negative battery lead does not matter.
E. Pass the negative battery lead through lower
side of the cross member.
F. After connecting the positive battery lead in
the direction shown in the illustration, put the
cover over it.
G. Pass the positive battery lead through the
lower side of the cross member.

2-26
 CABLE ROUTING DIAGRAM

Rear brake (right side view)

2-27
 CABLE ROUTING DIAGRAM

1. Protector
2. Rear brake caliper
3. Bleed screw
4. Gasket
5. Rear brake hose
6. Brake pedal
7. Rear brake master cylinder assembly
8. Swingarm
9. Spring
10.Frame

A. It does not matter whether the spring is

installed upward or downward.
B. Pass the rear brake hose into the rear brake
hose holders.
C. Route the rear brake hose so that it is not
bent as shown by the double-dash line.
D. Route the rear brake hose and spring so that
they do not interfere with each other.
E. Make sure that the rear brake hose is not
excessively twisted.
F. Make sure that the metal part of the rear
brake hose contacts the stopper of the rear
brake master cylinder assembly.
G. Install the rear brake hose so that the
bended portion of the metal part of the rear
brake hose faces as shown in the illustration.

2-28
 CABLE ROUTING DIAGRAM

2-29
 PERIODIC CHECKS AND ADJUSTMENTS

SERVICING PARTS ......................................................................................... 3-1

MAINTENANCE INTERVALS.......................................................................... 3-2

MAINTENANCE INTERVALS ..................................................................... 3-2 1
PRE-OPERATION INSPECTION AND MAINTENANCE................................ 3-6
GENERAL INSPECTION AND MAINTENANCE ......................................... 3-6
2
ENGINE............................................................................................................ 3-7
ADJUSTING THE VALVE CLEARANCE..................................................... 3-7
VALVE CLEARANCE SHIM CHART......................................................... 3-10
CHECKING THE ENGINE IDLING SPEED............................................... 3-12
CHECKING THE THROTTLE GRIP.......................................................... 3-12
3
CHECKING THE SPARK PLUG............................................................... 3-13
CHECKING THE ENGINE OIL LEVEL...................................................... 3-14
CHANGING THE ENGINE OIL ................................................................. 3-14
ADJUSTING THE CLUTCH LEVER FREE PLAY...................................... 3-16
ADJUSTING THE CLUTCH LEVER POSITION........................................ 3-16
4
CLEANING THE AIR FILTER ELEMENT .................................................. 3-16
CHECKING THE THROTTLE BODY JOINT ............................................. 3-18
CHECKING THE FUEL LINE.................................................................... 3-18
CHECKING THE CYLINDER HEAD BREATHER HOSE .......................... 3-19
CHECKING THE EXHAUST SYSTEM...................................................... 3-19
5
CHECKING THE COOLANT LEVEL......................................................... 3-21
CHECKING THE COOLING SYSTEM...................................................... 3-22
CHANGING THE COOLANT.................................................................... 3-22
6
CHASSIS ....................................................................................................... 3-24
ADJUSTING THE FRONT DISC BRAKE.................................................. 3-24
ADJUSTING THE REAR DISC BRAKE .................................................... 3-24
CHECKING THE BRAKE FLUID LEVEL................................................... 3-24
CHECKING THE FRONT BRAKE PADS .................................................. 3-25
7
CHECKING THE REAR BRAKE PADS..................................................... 3-25
CHECKING THE FRONT BRAKE HOSE.................................................. 3-25
CHECKING THE REAR BRAKE HOSE .................................................... 3-25
CHECKING THE BRAKE OPERATION .................................................... 3-26
BLEEDING THE HYDRAULIC BRAKE SYSTEM...................................... 3-26
8
DRIVE CHAIN SLACK.............................................................................. 3-27
LUBRICATING THE DRIVE CHAIN .......................................................... 3-28
CHECKING AND ADJUSTING THE STEERING HEAD............................ 3-28
LUBRICATING THE STEERING HEAD .................................................... 3-29
9
CHECKING THE FRONT FORK LEGS..................................................... 3-29
ADJUSTING THE FRONT FORK LEGS ................................................... 3-30
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY...................... 3-31
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY .................... 3-31
CHECKING THE SWINGARM OPERATION ............................................ 3-33
10
LUBRICATING THE SWINGARM PIVOT ................................................. 3-33
CHECKING THE CONNECTING ARM AND RELAY ARM ....................... 3-33
 CHECKING THE TIRES ........................................................................... 3-34
CHECKING AND TIGHTENING THE SPOKES ........................................ 3-34
CHECKING THE WHEELS....................................................................... 3-34
CHECKING THE WHEEL BEARINGS ...................................................... 3-34
CHECKING THE CHASSIS FASTENERS ................................................ 3-35
CHECKING AND LUBRICATING THE CABLES ...................................... 3-35
LUBRICATING THE BRAKE LEVER ........................................................ 3-35
LUBRICATING THE CLUTCH LEVER...................................................... 3-35
LUBRICATING THE PEDAL ..................................................................... 3-35
CHECKING THE SIDESTAND ................................................................. 3-35
LUBRICATING THE SIDESTAND ............................................................ 3-35

ELECTRICAL SYSTEM ................................................................................. 3-36

CHECKING AND CHARGING THE BATTERY ......................................... 3-36
CHECKING THE FUSES.......................................................................... 3-36
 SERVICING PARTS

EAM20202

SERVICING PARTS
Regularly check or replace the servicing parts shown in the illustration.
4 5

3 6

2
7

1 8

* Engine oil, lubricants & greases, care products.

Ref. No. Part No. Part name in parts catalog Q’ty

1 B2W-25805-00 BRAKE PAD KIT 1

2 94701-00444 PLUG, SPARK (NGK LMAR8E-J) 1
3 B2W-83922-00 LEVER 2 1
4 17D-83912-01 LEVER 1 1
5 BR9-82100-48 BATTERY ASSY (BR98) 1
6 B2W-14451-01 ELEMENT, AIR CLEANER 1
7 5D3-13440-02 ELEMENT ASSY, OIL CLEANER 1
8 17D-27200-51 PEDAL, BRAKE 1
9 1C3-W0046-B0 BRAKE PAD KIT 2 1

The part number is subject to change. In that case, order the part from a Yamaha dealer by stating the
identification number of your vehicle.

3-1
 MAINTENANCE INTERVALS

EAM20157

MAINTENANCE INTERVALS
EAM30369

MAINTENANCE INTERVALS
ECA25871

• After a break-in or before each race, always check the points shown in “TORQUE-CHECK
POINTS” for tightening torques and retighten them.
• 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.). Therefore, earlier inspection is required by reference to the list below.

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.

Every Every third Every fifth

After race race race As
No. Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required
hours) hours) hours)

• Check the valve clearances.  

• Check the valve seats and the
1 * Valve 
valve faces for wear.

• Replace. 

• Check the free length. 

2 * Valve spring
• Replace. 

• Check for scratches and wear. 

3 * Valve lifter
• Replace. 

• Inspect the camshaft surface.

• Inspect the decompression sys- 
4 * Camshaft tem.

• Replace. 

• Check for damage and sticking. 

5 * Timing chain • Replace the timing chain and tim-
 
ing chain tensioner as a set.
Timing chain ten- • Replace the timing chain and tim-
6 *  
sioner ing chain tensioner as a set.

• Check for wear on the teeth and 

for damage.
7 * Camshaft sprocket
• Replace. 

• Inspect crack. 

• Inspect carbon deposits and

eliminate them. 
8 * Piston
• Replace the piston, piston pin,
piston pin clip, and piston ring all  
as a set.

• Check the end gap of the piston


ring.
9 * Piston ring • Replace the piston, piston pin,
piston pin clip, and piston ring all  
as a set.

• Inspect. 

10 * Piston pin • Replace the piston, piston pin,

piston pin clip, and piston ring all  
as a set.

3-2
 MAINTENANCE INTERVALS

Every Every third Every fifth

After race race race As
No. Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required
hours) hours) hours)

• Check the coolant passages for

corrosion.
• Inspect carbon deposits and
11 * Cylinder head 
eliminate them.
• Check for warpage, and replace
the gasket.

• Inspect score marks. 

12 * Cylinder
• Inspect wear. 

• Check the engine oil amount.  

13 Engine oil
• Replace.  

14 Oil filter element • Replace.  

15 * Oil strainer • Clean. 

• Inspect housing, friction plate,

 
16 * Clutch clutch plate and spring.
• Replace. 

• Inspect. 
17 * Transmission
• Replace bearings. 

Shift fork, shift drum, • Inspect wear.

18 * 
guide bar

19 * Nut (generator rotor) • Check for tightening torques.  

• Check for exhaust leaks, and

tightening torques.  

• Clean. 
20 * Exhaust pipe,
silencer, protector
• Replace fiver.
(When the exhaust sound
becomes louder or when a per-  
formance drop is felt.)
21 * Crankshaft • Inspect and clean.  

22 * Throttle body • Inspect. 

• Clean and lubricate.  

23 Air filter
• Replace. 
• Check ventilation hose for cracks
or damage and drain any depos- 
24 * Breather system its.

• Replace. Every two years 

• Check the electrodes and the ter-

minals for wear.  
25 Spark plug
• Replace. 

• Check coolant level and leakage.  

• Check radiator cap operation. 

26 * Cooling system • Check radiator cap attached.  

• Change the coolant. Every two years 

• Inspect hoses. 
27 * Engine guard • Replace. 

28 * Frame • Clean and inspect.  

29 * Fuel tank, fuel pump • Inspect.  

3-3
 MAINTENANCE INTERVALS

Every Every third Every fifth

After race race race As
No. Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required
hours) hours) hours)

• Inspect. 
30 * Fuel hose
• Replace. Every four years 

• Clean.  

• Inspect and adjust.  

31 * Front fork leg(s) • Replace oil.  

• Replace oil seal. 

• Clean and grease oil seals and

dust seals.   

32 Protector guide • Replace. 

• Inspect and adjust.  

• Grease pillow balls and bearings.
33 * Rear shock absorber  
(After rain ride)
• Check for tightening torques.  

• Adjust lever position and pedal

position.  

• Lubricate pivot point.  

• Check brake disc surface.  

• Check fluid level and leakage.  
34 * Brake(s)
• Retighten brake disc bolts, cali-
per bolts, master cylinder bolts
 
and union bolts.
(Check for tightening torques.)

• Replace pads. 
• Replace brake fluid. Every one year 

35 * Swingarm • Inspect, lube and retighten.  

36 * Relay arm, connect- • Inspect, lube and retighten.  

ing rod

37 Sidestand • Lubricate. 

• Inspect free play and retighten.

 
(Check for tightening torques.)

38 * Steering head • Clean and lube.


(After rain ride)

• Replace bearings. 

• Inspect air pressure, wheel run-

out, tire wear and spoke loose-  
ness.

• Retighten sprocket bolt.  

39 * Tire, wheels
• Check the bearing. 

• Replace bearings. 

• Lubricate. 

• Clean, lubricate, slack, alignment.  

40 * Drive chain
• Replace. 

41 * Drive chain guide • Inspect wear. 

Drive chain guide and • Replace.

42 * 
drive chain support

3-4
 MAINTENANCE INTERVALS

Every Every third Every fifth

After race race race As
No. Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required
hours) hours) hours)

• Routing (Connection)  

• Check and grease.  

43 Cables
• Check throttle cables on the
 
throttle body for dirt and wear.

44 Levers • Adjust clutch lever free play. 

45 Brake pedal, footrest • Lubricate.  

46 * Outside nuts and • Retighten.  

bolts

47 * Battery • Check terminal for looseness and 

corrosion.

3-5
 PRE-OPERATION INSPECTION AND MAINTENANCE

EAM20134

PRE-OPERATION INSPECTION AND MAINTENANCE

Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
EAM30209

GENERAL INSPECTION AND MAINTENANCE

Item Inspect Page

Coolant Check that coolant is filled up to the radiator cap. Check 3-21, 3-22, 3-22,
the cooling system for leakage. 6-4, 6-4
Check that a fresh gasoline is filled in the fuel tank. Check
Fuel 1-25
the fuel line for leakage.
Check that the oil level is correct. Check the crankcase
Engine oil 3-14, 3-14
and oil line for leakage.
Check that gears can be shifted correctly in order and that
Gear shifter and clutch 3-16, 3-16
the clutch operates smoothly.
Check that the throttle grip operation and free play are cor-
Throttle grip/Housing rectly adjusted. Lubricate the throttle grip and housing, if 3-12, 3-35
necessary.
3-24, 3-24, 3-25,
Check the play of front brake and effect of front and rear
Brakes 3-25, 3-25, 3-24,
brake.
3-26, 3-25
Check drive chain slack and alignment. Check that the 3-27, 4-69, 4-69,
Drive chain
drive chain is lubricated properly. 4-70, 4-70, 4-70
Check for excessive wear and tire pressure. Check for 3-34, 3-34, 3-34,
Wheels
loose spokes and have no excessive play. 3-34
Check that the handlebar can be turned smoothly and
Steering 3-28
have no excessive play.
Front forks and rear Check that they operate smoothly and there is no oil leak- 3-29, 3-30, 3-31,
shock absorber age. 3-31, 3-33
Check that the clutch and throttle cables move smoothly.
Cables (wires) Check that they are not caught when the handlebars are —
turned or when the front forks travel up and down.
Check that the exhaust pipe is tightly mounted and has no
Exhaust pipe 3-19
cracks.
Check that the rear wheel sprocket tightening bolt is not 4-10, 4-10, 4-10,
Rear wheel sprocket
loose. 4-10, 4-11, 4-11
3-35, 3-35, 3-35,
Lubrication Check for smooth operation. Lubricate if necessary. 3-35
Bolts and nuts Check the chassis and engine for loose bolts and nuts. 1-28
Check that the stator coil assembly, ECU and ignition coil
Lead connectors are connected tightly. 1-12

Is the machine set suitably for the condition of the racing 10-1, 10-1, 10-1,
course and weather or by taking into account the results of 10-2, 10-2, 10-3,
Settings
test runs before racing? Are inspection and maintenance 10-3, 10-4, 10-4,
completely done? 10-6, 10-7

Perform usual maintenance enough so that, in the race course, a confirmation of that and simple set-
ting adjustments may only be left, in order to get enough time to use effectively.

3-6
 ENGINE

EAM20135

ENGINE Valve clearance (cold)

Intake
EAM30226 0.12–0.19 mm (0.0047–0.0075 in)
ADJUSTING THE VALVE CLEARANCE Exhaust
0.17–0.24 mm (0.0067–0.0094 in)
• This section is intended for those who have
basic knowledge and skill concerning the ser- a. Turn the crankshaft counterclockwise
vicing of Yamaha motorcycles (e.g., Yamaha with a wrench.
dealers, service engineers, etc.). Those who b. Align the top dead center (TDC) mark “a”
have little knowledge and skill concerning ser- on the generator rotor with the alignment
vicing are requested not to undertake inspec- mark “b” on the crankcase cover.
tion, adjustment, disassembly, or reassembly
only by reference to this manual. It may lead to b
servicing trouble and mechanical damage.
• Make sure that the valve clearance is checked
a
or adjusted while the engine is cold (at room
temperature).
• While the valve clearance is checked or ad-
justed, make sure that the piston is positioned
in the top dead center (TDC).
1. Remove:
• Seat
• Side cover (left/right) Check that the alignment mark “c” on the cam-
• Air scoop (left/right) shaft sprocket and the alignment mark “d” on
Refer to “GENERAL CHASSIS” on page 4-1. the intake camshaft sprocket are aligned with
• Fuel tank the edge of the cylinder head.
Refer to “FUEL TANK” on page 7-1.
• ECU (Engine Control Unit)
d c
2. Remove:
• Spark plug
• Cylinder head cover
Refer to “CAMSHAFT” on page 5-13.
3. Remove:
• Timing mark accessing screw “1”
• Crankshaft end accessing screw “2”
• O-ring

c. Measure the valve clearance using a

thickness gauge “1”.
Thickness gauge
90890-03268
Feeler gauge set
1 YU-26900-9

2
Record the measured reading if the clearance is
4. Check: incorrect.
• Valve clearance
Out of specification  Regulate.

3-7
 ENGINE

1 • The adjusting pad number “a” is indicated on

the top of the adjusting pad.
• For the number on the originally installed ad-
justing pad, convert the last digit of adjusting
pad number as per the below table.

5. Adjust:
• Valve clearance
a. Remove the camshaft (intake and ex-
haust).
Refer to “CAMSHAFT” on page 5-13.
b. Remove the valve lifter “2” and the adjust-
ing pad “3” with a valve lapper “1”.
d. Select an adjusting pad with a proper
valve clearance from the adjusting pad
• Place a cloth in the timing chain space to pre-
selection table.
vent adjusting pads from falling into the crank-
case.
• There are 25 types of adjusting pads, ranging
• Identity each valve lifter and adjusting pad po-
from 1.20 mm (0.0472 in) to 2.40 mm (0.0945
sition very carefully so that they can be rein-
in), in increments of 0.05 mm (0.0020 in).
stalled in their original place.
• The field where the number on the originally in-
stalled adjusting pad and the measured valve
Valve lapper (ø14) clearance intersect shows the adjusting pad
90890-04101
number to replace.
Valve lapper (ø14)
YM-A8998
Last digit of pad num-
ber Rounded value

3 2 1
0, 1 or 2 0
4, 5 or 6 5
8 or 9 10

Example:
Pad number = 148
Rounded value = 150
e. Install the new adjusting pads “4” and the
valve lifters “5”.
ECA24310

Do not twist adjusting pads and valve lifters

forcibly during installation.

2 • Apply the engine oil on the valve lifters.

• Apply molybdenum disulfide oil to the valve
3 stem ends.
• Check that the valve lifters turn smoothly when
rotated with your finger.
c. Check the number on the originally in- • Make sure that valve lifters and adjusting pads
stalled adjusting pad. are installed in place.

3-8
 ENGINE

• Make sure that adjusting pads are installed

with their numbers facing upward.

5 E
4

f. Install the camshafts (exhaust and intake).

Refer to “CAMSHAFT” on page 5-13.
g. Measure the valve clearance again.
h. If the valve clearance is out of specifica-
tion, repeat adjusting the valve clearance
until it is within specification.

3-9
 ENGINE

EAM30383

VALVE CLEARANCE SHIM CHART

INTAKE

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.02 0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.07 0.11 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.12 0.19
0.20 0.24 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.25 0.29 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.30 0.34 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.35 0.39 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.40 0.44 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.45 0.49 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.50 0.54 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.55 0.59 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.60 0.64 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.65 0.69 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.70 0.74 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.75 0.79 180 185 190 195 200 205 210 215 220 225 230 235 240
0.80 0.84 185 190 195 200 205 210 215 220 225 230 235 240
0.85 0.89 190 195 200 205 210 215 220 225 230 235 240
0.90 0.94 195 200 205 210 215 220 225 230 235 240
0.95 0.99 200 205 210 215 220 225 230 235 240
1.00 1.04 205 210 215 220 225 230 235 240
1.05 1.09 210 215 220 225 230 235 240
1.10 1.14 215 220 225 230 235 240
1.15 1.19 220 225 230 235 240
1.20 1.24 225 230 235 240
1.25 1.29 230 235 240
1.30 1.34 235 240
1.35 1.39 240

A. Measured clearance C. Standard clearance

B. Installed pad number

Example:
Valve clearance (cold) 0.12–0.19 mm (0.0047–0.0075 in)
Installed is 175.
Measured clearance 0.27 mm (0.0106 in)
Replace 175 pad with 185 pad.
Pad No. 175 = 1.75 mm (0.0689 in)
Pad No. 185 = 1.85 mm (0.0728 in)

3-10
 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
0.07 0.11 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.12 0.16 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.17 0.24
0.25 0.29 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.30 0.34 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.35 0.39 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.40 0.44 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.45 0.49 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.50 0.54 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.55 0.59 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.60 0.64 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.65 0.69 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.70 0.74 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.75 0.79 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.80 0.84 180 185 190 195 200 205 210 215 220 225 230 235 240
0.85 0.89 185 190 195 200 205 210 215 220 225 230 235 240
0.90 0.94 190 195 200 205 210 215 220 225 230 235 240
0.95 0.99 195 200 205 210 215 220 225 230 235 240
1.00 1.04 200 205 210 215 220 225 230 235 240
1.05 1.09 205 210 215 220 225 230 235 240
1.10 1.14 210 215 220 225 230 235 240
1.15 1.19 215 220 225 230 235 240
1.20 1.24 220 225 230 235 240
1.25 1.29 225 230 235 240
1.30 1.34 230 235 240
1.35 1.39 235 240
1.40 1.44 240

A. Measured clearance C. Standard clearance

B. Installed pad number

Example:
Valve clearance (cold) 0.17–0.24 mm (0.0067–0.0094 in)
Installed is 175.
Measured clearance 0.32 mm (0.0126 in)
Replace 175 pad with 185 pad.
Pad No. 175 = 1.75 mm (0.0689 in)
Pad No. 185 = 1.85 mm (0.0728 in)

3-11
 ENGINE

EAM30412

CHECKING THE ENGINE IDLING SPEED a

• Because the air pressure is lower at high alti-

tudes, the air-fuel mixture will become richer. 1
If the idling speed is low, turn the idle screw 1
clockwise to increase the speed before the
adjustment.
• Before adjusting the engine idling speed,
make sure that the air filter element is not a
clogged, the engine compression is proper,
and the throttle grip free play is proper. 4. Measure:
• Adjust the engine idling speed with the starter • Engine idling speed
knob pulled in completely. Out of specification  Regulate.
1. Start the engine, and warm this up until the Engine idling speed
oil has reached the specified temperature. 1900–2100 r/min
2. Measure the coolant temperature using the
Yamaha diagnostic tool. 5. Adjust:
• Engine idling speed
Yamaha diagnostic tool USB (US) a. Turn the idle screw “1” to make an adjust-
90890-03269 ment.
Yamaha diagnostic tool (A/I)
90890-03273
FI diagnostic tool sub–lead
90890-03212
FI diagnostic tool sub–lead
YU-03212 1
OBD/ GST Leadwire kit
90890-03249

Coolant temperature
70–80 C (158–176 F)
EAM30475

3. Install: CHECKING THE THROTTLE GRIP

• Digital tachometer
Prior to adjusting throttle grip free play, the en-
Digital tachometer gine idling speed should be adjusted.
90890-06760
Digital tachometer 1. Check:
YU-39951-B • Throttle grip free play “a”
Out of specification  Regulate.

Get the high tension cord “1” of the ignition coil Throttle grip free play
pinched in the detector “a” of the digital ta- 3.0–6.0 mm (0.12–0.24 in)
chometer.

3-12
 ENGINE

2. Adjust: ECA24410

• Throttle grip free play

a. Loosen the locknut “1”. In order not to allow the dirt accumulated
b. Turn the adjuster “2” until the specified around the spark plug to drop from the spark
throttle grip free play is obtained. plug hole into the cylinder, clean it before re-
c. Tighten the locknut. moving the spark plug.
EWA18470
3. Check:
• Spark plug type
After adjusting the throttle grip free play, Wrong type  Replace.
start the engine and turn the handlebar to the
right and to the left to ensure that this does Manufacturer/model
not cause the engine idling speed to change. NGK/LMAR8E-J

2 4. Check:
1
• Electrode “1”
Damage/wear  Replace the spark plug.
• Insulator “2”
Abnormal color  Replace the spark plug.
Normal color is medium-to-light tan.
5. Clean:
• Spark plug
(with a spark plug cleaner or a wire brush)
6. Measure:
EAM30254 • Spark plug gap “a”
CHECKING THE SPARK PLUG Out of specification  Adjust the spark plug
1. Remove: gap.
• Seat
• Air scoop (left/right) Spark plug gap
Refer to “GENERAL CHASSIS” on page 4-1. 0.6–0.7 mm (0.024–0.028 in)
• Fuel tank “1”
Refer to “FUEL TANK” on page 7-1.
ECA24400

Do not use too much force to pull the hose.

1 2
Remove the fuel tank, turn this 180 clockwise, 1 1
and put it in the frame “2” as shown.
a a
1 1 2
7. Install:
• Spark plug
Spark plug
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.

Before installing the spark plug, clean the spark

plug and gasket surface.
2. Remove:
8. Install:
• Holder
• Spark plug cap
• Spark plug cap
• Holder
• Spark plug
• Fuel tank
Refer to “CAMSHAFT” on page 5-13.
• Air scoop (left/right)

3-13
 ENGINE

• Seat
• Side cover (left/right)
Refer to “GENERAL CHASSIS” on page 4-1.
EAM30224

CHECKING THE ENGINE OIL LEVEL

1. Stand the vehicle upright on a level surface.
2. Start the engine, warm this up for 2–3 min-
utes, and then stop the engine and wait
about 1 minute.
3. Check:
• Oil level EAM30225

The engine oil level should be between the CHANGING THE ENGINE OIL
minimum level mark “a” and maximum level Stand the vehicle upright on a level surface.
mark “b”. 1. Start the engine, warm this up for several
Below the minimum level mark  Add the minutes, and then stop the engine and wait
recommended engine oil to the proper level. about 5 minutes.

This model is equipped with an engine auto-

b stop system. The engine stops automatically if
left idling for 7 minutes. If the engine stops, push
a
the start switch to restart the engine.
2. Place an oil pan under the drain bolt.
3. Remove:
• Engine guard “1”
• Oil filler cap “2”
• Drain bolt (with gasket) “3”
ECA24290

• Since engine oil also lubricates the clutch,

the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives.
• Do not allow foreign material to enter the
crankcase.

2 1
Recommended brand
YAMALUBE
SAE viscosity grades
10W-40, 10W-50, 15W-40, 20W-
40 or 20W-50
Recommended engine oil grade
API service SG type or higher,
JASO standard MA

3
4. If the oil filter element is also to be replaced,
perform the following procedure.
a. Remove the oil filter element cover “1”
and oil filter element “2”.
b. Replace the new O-ring “3”.

3-14
 ENGINE

Engine oil quantity

1 2 Oil change
0.73 L (0.77 US qt, 0.64 Imp.qt)
With oil filter removal
0.75 L (0.79 US qt, 0.66 Imp.qt)
3 Quantity (disassembled)
0.95 L (1.00 US qt, 0.84 Imp.qt)

c. Install the new oil filter element and the oil

filter element cover.
Oil filter element cover bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

5. To check the oil strainer, perform the follow-

ing procedure.
a. Remove the oil strainer “1”.
b. Check the oil strainer. 8. Install:
Damage  Replace. • Oil filler cap
Clogging due to dirt  Wash with kero- 9. Check:
sene. • Oil level
c. Replace the new O-ring “2”. Refer to “CHECKING THE ENGINE OIL LEV-
EL” on page 3-14.
10.Check:
• Engine oil pressure
a. Slightly loosen the oil pressure check bolt
“1”.
EWA19120

1 When the engine is started with the check

2 bolt removed, oil will spout; therefore, al-
ways loosen it before the checkup.

d. Install the oil strainer.

Oil strainer bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

6. Install:
• Gasket New 1
• Drain bolt
Drain bolt
20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.

b. Start the engine and keep it idling until oil

7. Pour the specified amount of engine oil into starts to seep from the oil pressure check
the oil filler cap hole. bolt.
EWA19130

Always keep the engine idling speed during

the checkup without increasing the engine
speed.

3-15
 ENGINE

ECA25840
Clutch cable side
a. Slide the clutch cable cover.
If no engine oil seeps out after one minute, b. Loosen the locknut “1”.
immediately turn the engine off so it will not c. Turn the adjuster “2” until the specified
seize. clutch lever free play is obtained.
c. If no engine oil seeps out, check the en- d. Tighten the locknut “1”.
gine oil for leaks, and the engine oil pas- Clutch cable locknut
sage and the oil pump for damage. 4.3 N·m (0.43 kgf·m, 3.2 lb·ft)

T.
d. Check the oil pressure again.

R.
e. Tighten the oil pressure check bolt. e. Return the clutch cable cover to its origi-
nal position.
Oil pressure check bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft) 1
T.
R.

EAM30216

ADJUSTING THE CLUTCH LEVER FREE

PLAY
1. Check:
• Clutch lever free play “a”
Out of specification  Regulate.
2
Clutch lever free play
7.0–12.0 mm (0.28–0.47 in)
EAM30370

ADJUSTING THE CLUTCH LEVER POSITION

1. Adjust:
• Clutch lever position “a”
Loosen the locknut “1” and use the adjuster
“2” to adjust the clutch lever position “a” as
desired.

1 2
a

2. Adjust:
• Clutch lever free play
Handlebar side
a. Turn the adjuster “1” until the specified
clutch lever free play is obtained.

1 2. Tighten:
• Locknut
Locknut (clutch lever position)
4.8 N·m (0.48 kgf·m, 3.5 lb·ft)
T.
R.

EAM30219

CLEANING THE AIR FILTER ELEMENT

1. Remove:
• Fuel tank cap cover “1”
Refer to “FUEL TANK CAP” on page 1-24.
• Air filter case cover “2”
If the clutch lever free play cannot be obtained
on the handlebar side, use the adjuster on the
• Loosen the quick fastener screw “3” and re-
clutch cable side.
move the air filter case cover.

3-16
 ENGINE

• Remove the two ribs “a” located on the left ECA24280

and right sides of the projections “b” on the air

scoop, and slide the air filter case cover to- Do not twist the element when squeezing the
ward the front of the vehicle to remove it. element.
5. Check:
3 • Air filter element
2 Damage  Replace.
1 6. Apply:
• Yamaha foam air filter oil or other quality
a foam air filter oil
a. Put the air filter element into a plastic bag
and drip the filter oil into the bag.
b. With the element inside the bag, rub it
b thoroughly so that the element is evenly
permeated with the oil.
2. Turn the plates “1” in direction “a”. c. Wrap the element in a clean cloth, rub the
element gently, and wipe off any excess
a oil.

a • The element should be permeated with oil so

that it is wet but not dripping.
• When replacing the element, permeate the el-
ement in oil by using the same procedure as
when cleaning.
1

3. Remove:
• Air filter guide “1”
• Air filter element “2” (from the air filter guide)
• Guide “3” (from the air filter element)
• Seal “4” (from the air filter element)
4 1
2

3 7. Install:
• Seal “1” (to the air filter element)
• Guide “2” (to the air filter element)
• Air filter element “3” (to the air filter guide)
• Air filter guide “4”

• Apply lithium-soap-based grease on the entire

4. Wash: seal lips when installing the air filter guide.
• Air filter element • Make sure that the two projections “a” at the
a. After washing the element with air filter rear side of the vehicle on the air filter guide
cleaner or kerosene, squeeze and dry it are securely fitted into the two slots “b” in the
completely. air filter case.
EWA19110
• Check that the air filter element is turned up
between the air filter guide and air filter case
Do not use gasoline or organic (acid/alka-
and that there is no gap.
line) volatile oil for washing.
Gap  Reinstall.

3-17
 ENGINE

1
a
1
4

3 b

1 a

2
1

b a
c

b
d
8. Turn the plates “1” to the original position.
10.Install:
• Fuel tank cap cover
EAM30335

CHECKING THE THROTTLE BODY JOINT

1. Check:
• Throttle body joint “1”
Crack/damage  Replace.

9. Install:
• Air filter case cover “1”
• Fuel tank breather hose
(to the air filter case cover)

• Make sure that the two slots “a” at the rear 1

side of the vehicle in the air filter case cover
are securely fitted into the two edges “b” on EAM30222

the air filter case. CHECKING THE FUEL LINE

• Be sure to carefully align the two ribs “c” locat- 1. Remove:
ed on the left and right sides of the air filter • Seat
case cover with the projections “d” on the air • Side cover (left/right)
scoop, and then install the air filter case cover. • Air scoop (left/right)
Refer to “GENERAL CHASSIS” on page 4-1.
• Fuel tank
Refer to “FUEL TANK” on page 7-1.
2. Check:
• Fuel hose “1”
Crack/damage  Replace.
Loose connection  Connect properly.

3-18
 ENGINE

4. Check:
• Silencer fiber
Damage  Replace.
5. Replace:
• Silencer fiber
a. Remove the bolts “1” and silencer body
1 “2”.
ECA25800

Do not hit the silencer stay “a” as it may do

damage to the silencer.
3. Install:
• Fuel tank
Refer to “FUEL TANK” on page 7-1. Remove the inner pipe while holding the silenc-
• Air scoop (left/right) er in place with a vise etc.
• Seat
• Side cover (left/right) a
Refer to “GENERAL CHASSIS” on page 4-1.
EAM30476

CHECKING THE CYLINDER HEAD

BREATHER HOSE 1
1. Check:
• Breather hose “1”
Crack/damage  Replace.
Loose connection  Connect properly.
ECA14920

Make sure the cylinder head breather hose is 2

routed correctly.

1
1

b. Remove the rivets “3” and silencer cap

“4”.
1

EAM30221

CHECKING THE EXHAUST SYSTEM

1. Remove:
• Exhaust pipe 1 4
• Exhaust pipe 2
Refer to “ENGINE REMOVAL” on page 5-6. 3
2. Remove:
• Exhaust pipe protector
3. Check:
• Exhaust pipe 1 c. Replace the fiber inserts “5”.
• Exhaust pipe 2
• Silencer
Crack/damage  Replace.

3-19
 ENGINE

11
5 10
d. Install the fiber insert “6” to the part “b”. h. Install the fiber insert “12” to the inner
e. Twist the fiber insert “7” onto the inner pipe.
pipe “c”. i. Install the fiber insert “13” to the inside of
the silencer cap “14”.
b
c

12
6

7
f. Install the silencer body “8” and bolts “9”.
Silencer body bolt
8 N·m (0.8 kgf·m, 5.9 lb·ft) 13
T.
R.

LOCTITE®

14
Apply heat-resistant sealant to the areas “d”
shown, making sure that there are no gaps in
the beads of sealant.

9
j. Install the silencer cap “15” and rivet “16”.

d LT
• Apply heat-resistant sealant to the areas “e”
shown, making sure that there are no gaps in
the beads of sealant.
• Take care not to allow the fiber out of place
8 when installing the silencer body “17”.

g. Install the fiber “10”. 17 17 16 15

Stuff the fiber into the silencer body by using a e

flat board “11”.

15

3-20
 ENGINE

6. Check: EAM30210

• Gasket “1” CHECKING THE COOLANT LEVEL

EWA13030
Damage  Replace.
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en-
1 gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in-
jury. When the engine has cooled, open the
radiator cap as follows:
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap counter-
1 clockwise toward the detent to allow any re-
sidual pressure to escape. When the hissing
7. Check: sound has stopped, press down on the radi-
• Tightening torques ator cap and turn it counterclockwise to re-
move.
Exhaust pipe nut “1”
10 N·m (1.0 kgf·m, 7.4 lb·ft) 1. Stand the vehicle upright on a level surface.
T.
R.

Exhaust pipe clamp bolt “2” 2. Remove:

12 N·m (1.2 kgf·m, 8.9 lb·ft) • Radiator cap “1”
Exhaust pipe clamp bolt “3”
12 N·m (1.2 kgf·m, 8.9 lb·ft)
Silencer bolt (rear) “4”
30 N·m (3.0 kgf·m, 22 lb·ft)
1

3. Check:
2 • Coolant level
Maximum level “a” or below  Add coolant
up to the maximum level.

4
3

1. Radiator
8. Install:
• Exhaust pipe protector ECA24260

Exhaust pipe protector screw • Adding water instead of coolant lowers the
10 N·m (1.0 kgf·m, 7.4 lb·ft) antifreeze content. If, therefore, water is
T.
R.

LOCTITE®
used instead of coolant, check, and if nec-
essary, adjust the antifreeze concentration.
• Use only distilled water. However, if dis-

3-21
 ENGINE

tilled water is not available, soft water may

be used.
4. Start the engine, warm this up for several
minutes, and then stop it.
5. Check:
• Coolant level

Before checking the coolant level, wait a few

1
minutes until the coolant has settled.

EAM30211
3. Remove:
CHECKING THE COOLING SYSTEM • Radiator cap
1. Remove: Slowly loosen the radiator cap to drain cool-
• Seat ant.
• Side cover (left/right)
• Air scoop (left/right) When the radiator cap is loosened, coolant will
Refer to “GENERAL CHASSIS” on page 4-1. gush out transversely; therefore, bring the con-
2. Check: tainer near to the outlet.
• Radiator
• Radiator hose 4. Thoroughly flush the cooling system with
Crack/damage  Replace. clean tap water.
Refer to “RADIATOR” on page 6-2. 5. Install:
3. Install: • Copper washer New
• Air scoop (left/right) • Coolant drain bolt
• Seat
Coolant drain bolt
• Side cover (left/right) 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.

Refer to “GENERAL CHASSIS” on page 4-1.

R.

EAM30212 6. Pour coolant.

CHANGING THE COOLANT
EWA13030 Recommended coolant
High quality ethylene glycol anti-
freeze containing anti-corrosion
A hot radiator is under pressure. Therefore, for aluminum engine
do not remove the radiator cap when the en- Radiator (including all routes)
gine is hot. Scalding hot fluid and steam may 0.93 L (0.98 US qt, 0.82 Imp.qt)
be blown out, which could cause serious in- Coolant mixing ratio
jury. When the engine has cooled, open the 1:1 (Coolant:Water)
radiator cap as follows:
EWA13040
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap counter-
clockwise toward the detent to allow any re- • If coolant splashes in your eyes, thoroughly
sidual pressure to escape. When the hissing wash them with water and consult a doc-
sound has stopped, press down on the radi- tor.
ator cap and turn it counterclockwise to re- • If coolant splashes on your clothes, quickly
move. wash it away with water and then with soap
and water.
1. Place a container under the engine. • If coolant is swallowed, induce vomiting
2. Remove: and get immediate medical attention.
• Coolant drain bolt “1”
ECA13481

• Adding water instead of coolant lowers the

antifreeze content of the coolant. If water is
used instead of coolant, check, and if nec-
essary, correct the antifreeze concentra-

3-22
 ENGINE

tion of the coolant.

• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
• If coolant comes into contact with painted
surfaces, immediately wash them with wa-
ter.
• Do not mix different types of antifreeze.
7. Install:
• Radiator cap
8. Start the engine, warm this up for several
minutes, stop it, and then wait for it to cool
down.
9. Check:
• Coolant level
Refer to “CHECKING THE COOLANT LEV-
EL” on page 3-21.

3-23
 CHASSIS

EAM20136
system. Air in the brake system will consid-
CHASSIS erably reduce braking performance.
ECA13490
EAM30479

ADJUSTING THE FRONT DISC BRAKE

After adjusting the brake lever position,
There should be no free play at the brake lever make sure there is no brake drag.
end.
4. Install:
1. Check: • Brake lever cover
• Brake lever position “a” EAM30480

Brake lever position ADJUSTING THE REAR DISC BRAKE

100 mm (3.94 in) 1. Adjust:
Extent of adjustment • Brake pedal position
86–105 mm (3.39–4.13 in) a. Loosen the locknut “1”.
b. Turn the adjusting bolt “2” until the brake
pedal is in the correct position.

1
2. Remove:
• Brake lever cover c. Tighten the locknut.
3. Adjust:
• Brake lever position Locknut
a. Loosen the locknut “1”. 6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.

b. Turn the adjusting bolt “2” until the spec- EWA19150

ified brake lever position is obtained.

A soft or spongy feeling in the brake pedal
2 can indicate the presence of air in the brake
system. Before running, bleed the brake sys-
tem. Air in the brake system will cause brak-
1 ing performance to be reduced.
ECA13510

After adjusting the brake pedal position,

make sure there is no brake drag.

c. Tighten the locknut. EAM30234

CHECKING THE BRAKE FLUID LEVEL

Locknut 1. Stand the vehicle upright on a level surface.
5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
R.

EWA13050
In order to ensure a correct reading of the brake
fluid level, make sure that the top of the brake
fluid reservoir is horizontal.
A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake 2. Check:
system. Before the vehicle is operated, the • Brake fluid level
air must be removed by bleeding the brake The minimum level mark “a” or below 

3-24
 CHASSIS

Add.
Specified brake fluid
DOT 4

a EAM30232

CHECKING THE REAR BRAKE PADS

The following procedure applies to all of the
brake pads.
1. Operate the brake.
A. Front brake 2. Check:
B. Rear brake • Rear brake pad
EWA13090 Wear indicator grooves “1” almost touch the
brake disc  Replace the brake pads as a
• Use only the designated brake fluid. Other set.
brake fluids may cause the rubber seals to Refer to “REAR BRAKE” on page 4-24.
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction, 1
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
ECA13540
EAM30478

CHECKING THE FRONT BRAKE HOSE

Brake fluid may damage painted surfaces 1. Check:
and plastic parts. Therefore, always clean up • Brake hose
any spilt brake fluid immediately. Cracks/damage/wear  Replace.
2. Check:
EAM30231
• Brake hose clamp
CHECKING THE FRONT BRAKE PADS Loose connection  Tighten the clamp bolt.
The following procedure applies to all of the 3. Stand the vehicle upright and apply the front
brake pads. brake several times.
1. Operate the brake. 4. Check:
2. Check: • Brake hose
• Front brake pad Brake fluid leaks  Replace the damaged
Wear indicator grooves “1” almost touch the brake hose.
brake disc  Replace the brake pads as a Refer to “FRONT BRAKE” on page 4-13.
set.
Refer to “FRONT BRAKE” on page 4-13. EAM30498

CHECKING THE REAR BRAKE HOSE

1. Check:
• Brake hose
Cracks/damage/wear  Replace.

3-25
 CHASSIS

2. Check: a. Fill the reservoir to the proper level with

• Brake hose holder the recommended brake fluid.
Loose connection  Tighten the holder bolt. b. Install the reservoir diaphragm.
3. Hold the vehicle upright and apply the rear c. Connect the plastic hose “1” to the bleed
brake several times. screw “2” securely, and place a container
4. Check: under the end of the plastic hose.
• Brake hose
Brake fluid leakage  Replace the damaged
hose.
Refer to “REAR BRAKE” on page 4-24.
1
EAM30499

CHECKING THE BRAKE OPERATION

1. Check:
• Brake operation 2
Brake not working properly  Check the
brake system.
Refer to “FRONT BRAKE” on page 4-13 and
“REAR BRAKE” on page 4-24.

Drive on the dry road, operate the front and rear

2
brakes separately and check to see if the brakes
are operating properly. 1

EAM30477

BLEEDING THE HYDRAULIC BRAKE

SYSTEM
EWA19140

A. Front
Bleed the brake system whenever: B. Rear
• The system is disassembled.
• A brake hose is loosened, disconnected, or d. Slowly apply the brake several times.
replaced. e. Fully pull the brake lever or fully press
• The brake fluid level is very low. down the brake pedal and hold it in posi-
• Brake operation is faulty. tion.
f. Loosen the bleed screw.
1. Remove:
• Brake master cylinder cap Loosening the bleed screw will release the pres-
• Reservoir diaphragm sure in the brake caliper and cause the brake le-
• Reservoir float (front brake) ver to contact the throttle grip or the brake pedal
• Protector (rear brake) to fully extend.

• Be careful not to spill any brake fluid or allow g. Tighten the bleed screw and then release
the reservoir to overflow. the brake lever or brake pedal.
• Make sure that there is enough brake fluid be- h. Repeat steps (d) to (g) until all of the air
fore applying the brake. Ignoring this precau- bubbles have disappeared from the brake
tion could allow air to enter the brake system, fluid in the plastic hose.
considerably lengthening the bleeding proce-
dure. During the procedure, keep adding brake fluid
• If bleeding is difficult, it may be necessary to to the reservoir.
let the brake fluid settle for a few hours. Re- ECA24320

peat the bleeding procedure when the tiny

bubbles in the hose have disappeared. • Wipe off any brake fluid on the brake discs,
2. Bleed the brake system. tires, wheels, etc.
• Brake fluid may erode painted surfaces or

3-26
 CHASSIS

plastic parts. Always clean up spilled fluid

immediately.
i. Tighten the bleed screw.
a
Bleed screw
5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
R.

j. Pour brake fluid to the reservoir up to the

specified level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-24.
EWA13110
Drive chain slack (Maintenance
Stand)
After bleeding the hydraulic brake system, 50.0–60.0 mm (1.97–2.36 in)
check the brake operation.
Adjusting the drive chain slack
EAM30481 EWA13120
DRIVE CHAIN SLACK
ECA13550
Securely support the vehicle so that there is
no danger of it falling over.
A drive chain that is too tight will overload
the engine and other vital parts, and one that 1. Adjust:
is too loose can skip and damage the swing- • Drive chain slack
arm or cause an accident. Therefore, keep a. Loosen the wheel axle nut “1”.
the drive chain slack within the specified lim- b. Loosen both locknuts “2”.
its. c. Turn the adjusting bolt “3” until the spec-
ified drive chain slack is obtained.
Checking the drive chain slack
1. Use a maintenance stand to raise the rear 3 2
wheel off the ground.
EWA13120

Securely support the vehicle so that there is

no danger of it falling over.
2. Shift the transmission into the neutral posi- 1
tion.
3. Pull the drive chain up above the drive chain
guide installation bolt with a force of about
50 N (5.0 kgf, 37 lbf).
4. Check: • To maintain the proper wheel alignment, ad-
• Drive chain slack “a” just both sides evenly.
Out of specification  Regulate. • Push the rear wheel forward to make sure that
there is no clearance between the swingarm
Measure drive chain slack between the drive end plates and the ends of the swingarm.
chain guide and the bottom of the chain as d. Tighten the wheel axle nut.
shown.
Wheel axle nut
125 N·m (12.5 kgf·m, 92 lb·ft)
T.
R.

e. Tighten the drive chain puller locknut.

Drive chain puller locknut
21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.

3-27
 CHASSIS

EAM30251

LUBRICATING THE DRIVE CHAIN

The drive chain consists of many interacting 1
parts. If the drive chain is not maintained prop-
erly, it will wear out quickly. Therefore, the drive
chain should be serviced, especially when the
vehicle is used in dusty areas.
This vehicle has a drive chain with small rubber
O-rings between each side plate. Steam clean-
ing, high-pressure washing, certain solvents,
and the use of a coarse brush can damage
these O-rings. Therefore, use only kerosene to b. After loosening the ring nut “2” with a
clean the drive chain. Wipe the drive chain dry steering nut wrench “3”, tighten it to the
and thoroughly lubricate it with engine oil or specified torque.
chain lubricant that is suitable for O-ring chains.
Do not use any other lubricants on the drive • Set the torque wrench at a right angle to the
chain since they may contain solvents that steering nut wrench.
could damage the O-rings. • Move the steering to the left and right a couple
of times to check that it moves smoothly.
Recommended lubricant
Chain lubricant suitable for O-
ring chains

EAM30247
3
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Use a maintenance stand to raise the front
wheel off the ground.
EWA13120
2

Securely support the vehicle so that there is

no danger of it falling over. Steering nut wrench
2. Check: 90890-01403
• Steering head Exhaust flange nut wrench
Grasp the bottom of the front fork legs and YU-A9472
gently rock the front fork.
Blinding/looseness  Adjust the steering Ring nut (initial tightening torque)
head. 38 N·m (3.8 kgf·m, 28 lb·ft)
T.
R.

3. Remove:
• Handlebar c. Turn the front fork to the right and left a
Refer to “HANDLEBAR” on page 4-35. few times, and make sure that the steer-
• Upper bracket ing rotates smoothly. If it does not turn
Refer to “STEERING HEAD” on page 4-54. smoothly, remove the lower bracket and
4. Adjust: check the upper and lower bearings.
• Steering head Refer to “STEERING HEAD” on page
a. Remove the washer “1”. 4-54.
d. Loosen the ring nut fully turn and then
tighten it to specification with a steering
nut wrench.
EWA13140

Do not overtighten the lower ring nut.

3-28
 CHASSIS

4. Check:
Ring nut (final tightening torque) • Front fork operation
7 N·m (0.7 kgf·m, 5.2 lb·ft)
Push down hard on the handlebar several
T.
R.

e. Check the steering head for looseness or times and check if the front fork rebounds
binding by turning the front fork all the smoothly.
way in both directions. If any binding is Unsmooth operation  Correct or replace.
felt, remove the lower bracket and check Refer to “FRONT FORK” on page 4-41.
the upper and lower bearings. 5. Check:
Refer to “STEERING HEAD” on page • Protector guide “1”
4-54. Out of specification  Replace.
f. Install the washer “1”.
The protector guide reaches the limit of its use
when it is worn down to the same height “a” as
1 of the outer tube circumference.

5. Install:
• Upper bracket a
Refer to “STEERING HEAD” on page 4-54.
• Handlebar 6. Remove:
Refer to “HANDLEBAR” on page 4-35. • Protector
EAM30502
• Dust seal “1”
ECA24330
LUBRICATING THE STEERING HEAD
1. Lubricate:
• Upper bearing Be careful not to damage the dust seal and
• Lower bearing the inner tube by a driver.
• Bearing race
Recommended lubricant
Lithium-soap-based grease

EAM30338

CHECKING THE FRONT FORK LEGS

1. Stand the vehicle upright on a level surface.
EWA13120

1
Securely support the vehicle so that there is
no danger of it falling over.
7. Clean:
2. Check: • Dust seal “a”
• Inner tube • Scraper “b”
Damage/scratches  Replace. • Oil seal “c”
• Front fork leg
Oil leaks between inner tube and outer tube • Clean the dust seal, scraper and oil seal after
 Replace the oil seal. every run.
3. Hold the vehicle upright and apply the front • Apply lithium-soap-based grease on the inner
brake. tube.

3-29
 CHASSIS

be advisable to check the number of clicks of

b each damping force adjusting mechanism and
to modify the specifications as necessary.
a

c
LS 1

EAM30239

ADJUSTING THE FRONT FORK LEGS a b

EWA19180

• Always adjust the left and right front forks Compression damping
ECA24350
evenly. If this is not done, the vehicle may
have poor stability.
• Securely support the vehicle so that there Do not turn the adjuster forcibly beyond its
is no danger of it falling over. adjusting range.

Rebound damping 1. Adjust:

ECA24340 • Compression damping
a. Turn the adjuster “1” in the direction of “a”
Do not turn the adjuster forcibly beyond its or “b” to make an adjustment.
adjusting range.
Direction “a”
1. Adjust: Compression damping is increased
• Rebound damping (suspension is harder).
a. Turn the adjuster “1” in the direction of “a” Direction “b”
or “b” to make an adjustment. Compression damping is decreased
(suspension is softer).
Direction “a”
Rebound damping is increased (suspen-
sion is harder). Compression damping
Direction “b” Minimum (soft)
Rebound damping is decreased (sus- 20 click(s) in direction “b”*
pension is softer). Standard
12 click(s) in direction “b”*
Maximum (hard)
Rebound damping 0 click(s) in direction “b”*
Minimum (soft) * With the adjusting screw fully turned in di-
20 click(s) in direction “b”* rection “a”
Standard
12 click(s) in direction “b”*
Maximum (hard) Although the total number of clicks of a damp-
0 click(s) in direction “b”* ing force adjusting mechanism may not exactly
* With the adjusting screw fully turned in di- match the above specifications due to small dif-
rection “a” ferences in production, the actual number of
clicks always represents the entire adjusting
range. To obtain a precise adjustment, it would
Although the total number of clicks of a damp- be advisable to check the number of clicks of
ing force adjusting mechanism may not exactly each damping force adjusting mechanism and
match the above specifications due to small dif- to modify the specifications as necessary.
ferences in production, the actual number of
clicks always represents the entire adjusting
range. To obtain a precise adjustment, it would

3-30
 CHASSIS

3. Check:
• Rear shock absorber assembly smooth ac-
b a
tion
• Rear suspension link smooth action
1 Sit astride the seat and shake your body up
and down several times to check whether
the rear shock absorber assembly operates
smoothly.
Unsmooth operation  Correct or replace.
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-58.
Air bleeding from front fork
EAM30242

If the front fork initial movement feels stiff during ADJUSTING THE REAR SHOCK ABSORBER
a run, relieve the front fork internal pressure. ASSEMBLY
Use a maintenance stand to raise the rear wheel
1. Use a maintenance stand to raise the front off the ground.
wheel off the ground. EWA13120
EWA13120

Securely support the vehicle so that there is

Securely support the vehicle so that there is no danger of it falling over.
no danger of it falling over.
Spring preload
2. Remove the bleed screw “1” and release the ECA24360

internal pressure from the front fork.

3. Tighten: Do not turn the adjuster forcibly beyond its
• Bleed screw adjusting range.
Bleed screw 1. Adjust:
1.3 N·m (0.13 kgf·m, 0.95 lb·ft) • Spring preload
T.
R.

a. Loosen the locknut “1”.

b. Loosen the adjuster “2” until there is
some clearance between the spring and
1 the adjuster.
c. Measure the spring free length “a”.

a 1

EAM30482
2
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Stand the vehicle upright on a level surface.
EWA13120
d. Turn the adjuster in the direction of “b” or
“c” to make an adjustment.
Securely support the vehicle so that there is
no danger of it falling over. Direction “b”
2. Check: Spring preload is increased (suspension
• Rear shock absorber assembly is harder).
Gas leaks/oil leaks  Replace the rear shock Direction “c”
Spring preload is decreased (suspen-
absorber assembly.
sion is softer).
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-58.

3-31
 CHASSIS

Spring preload adjusting positions Rebound damping

Minimum Minimum (soft)
Position in which the spring is 30 click(s) in direction “b”*
turned in 1.5 mm (0.06 in) from Standard
its free length. 11 click(s) in direction “b”*
Standard Maximum (hard)
Position in which the spring is 0 click(s) in direction “a”
turned in 6.0 mm (0.24 in) from * With the adjusting screw fully turned in di-
its free length. rection “a”
Maximum
Position in which the spring is
turned in 18.0 mm (0.71 in) from Although the total number of clicks of a damp-
its free length. ing force adjusting mechanism may not exactly
match the above specifications due to small dif-
ferences in production, the actual number of
• Be sure to remove all dirt and mud from clicks always represents the entire adjusting
around the locknut and adjusting ring before range. To obtain a precise adjustment, it would
adjustment. be advisable to check the number of clicks of
• The length of the spring (installed) changes 1.5 each damping force adjusting mechanism and
mm (0.06 in) per turn of the adjusting ring. to modify the specifications as necessary.

b c
a

b
1

e. Tighten the locknut. Compression damping (for fast compres-

Rebound damping sion damping)
ECA24370 ECA24370

Do not turn the adjuster forcibly beyond its Do not turn the adjuster forcibly beyond its
adjusting range. adjusting range.
1. Adjust: 1. Adjust:
• Rebound damping • Compression damping (for fast compression
a. Turn the adjuster “1” in the direction of “a” damping)
or “b” to make an adjustment. a. Turn the adjuster “1” in the direction of “a”
or “b” to make an adjustment.
Direction “a”
Rebound damping is increased (suspen- Direction “a”
sion is harder). Compression damping is increased
Direction “b” (suspension is harder).
Rebound damping is decreased (sus- Direction “b”
pension is softer). Compression damping is decreased
(suspension is softer).

3-32
 CHASSIS

Fast compression damping Slow compression damping

Minimum (soft) Minimum (soft)
2 turn(s) in direction “b”* 20 click(s) in direction “b”*
Standard Standard
1-1/8 turn(s) in direction “b”* 11 click(s) in direction “b”*
Maximum (hard) Maximum (hard)
0 turn(s) in direction “b”* 0 click(s) in direction “b”*
* With the adjusting screw fully turned in di- * With the adjusting screw fully turned in di-
rection “a” rection “a”

To obtain a precise adjustment, it is advisable to Although the total number of clicks of a damp-
check the actual total number of turns of the ing force adjusting mechanism may not exactly
damping force adjusting mechanism. This ad- match the above specifications due to small dif-
justment range may not exactly match the ferences in production, the actual number of
specifications listed due to small differences in clicks always represents the entire adjusting
production. range. To obtain a precise adjustment, it would
be advisable to check the number of clicks of
each damping force adjusting mechanism and
to modify the specifications as necessary.
b
1
a
b
1
a

Compression damping (for slow compres-

sion damping)
ECA24390

EAM30240

Do not turn the adjuster forcibly beyond its CHECKING THE SWINGARM OPERATION
adjusting range. 1. Check:
• Swingarm smooth action
1. Adjust:
• Swingarm free play
• Compression damping (for slow compres-
Refer to “SWINGARM” on page 4-65.
sion damping)
a. Turn the adjuster “1” in the direction of “a” EAM30500

or “b” to make an adjustment. LUBRICATING THE SWINGARM PIVOT

1. Lubricate:
Direction “a” • Oil seal
Compression damping is increased • Collar
(suspension is harder).
Direction “b” Recommended lubricant
Compression damping is decreased Lithium-soap-based grease
(suspension is softer).
Refer to “INSTALLING THE SWINGARM” on
page 4-66.
EAM30501

CHECKING THE CONNECTING ARM AND

RELAY ARM
Refer to “CHECKING THE CONNECTING ARM
AND RELAY ARM” on page 4-62.

3-33
 CHASSIS

EAM30243

CHECKING THE TIRES A tight spoke will emit a clear, ringing tone; a
1. Measure: loose spoke will sound flat.
• Tire pressure
Out of specification  Regulate. 2. Tighten:
• Spoke
Tire air pressure (measured on (with a spoke nipple wrench “1”)
cold tires)
Front
100 kPa (1.00 kgf/cm², 15 psi) 1
Rear
100 kPa (1.00 kgf/cm², 15 psi)

• Check the tire while it is cold.

• Because if the bead stopper tightening nut is
loose when the tire pressure is low, the tire
could slip off the rim, thus be sure to check
and tighten the bead stopper tightening nut
“a”. Spoke nipple wrench (6–7)
• If the tire valve stem “b” is found tilted, the tire 90890-01521
is considered to be slipping off its position. Spoke nipple wrench (6–7)
Correct the tire position. YM-01521

Spoke
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
T.
R.

a • Do not give a half turn (180) or more for one

b tightening.
• Make sure that tightening after a break-in is
done until the initial looseness in nipples dis-
appears.
• Make sure that tightening is done in stages,
a. Bead stopper tightening nut not at a time.
b. Tire valve stem
EAM30245
EAM30244
CHECKING THE WHEELS
CHECKING AND TIGHTENING THE SPOKES 1. Check:
1. Check: • Wheel
• Spoke Damage/out-of-round  Replace.
Bend/damage  Replace. EWA13260

Loose  Tighten.
Tap the spokes with a screwdriver. Never attempt to make any repairs to the
wheel.

EAM30246

CHECKING THE WHEEL BEARINGS

1. Check:
• Wheel bearing
Refer to “CHECKING THE FRONT WHEEL”
on page 4-6 and “CHECKING THE REAR
WHEEL” on page 4-10.

3-34
 CHASSIS

EAM30253

CHECKING THE CHASSIS FASTENERS Recommended lubricant

Make sure that all nuts, bolts, and screws are Lithium-soap-based grease
properly tightened.
Refer to “CHASSIS TIGHTENING TORQUES” EAM30504

on page 2-13. CHECKING THE SIDESTAND

1. Check:
EAM30248
• Sidestand operation
CHECKING AND LUBRICATING THE Check that the sidestand moves smoothly.
CABLES Rough movement  Repair or replace.
The following procedure applies to all of the in-
ner and outer cables. EAM30252

EWA13270 LUBRICATING THE SIDESTAND

Lubricate the pivoting point and metal-to-metal
Damaged outer cable may cause the cable moving parts of the sidestand.
to corrode and interfere with its movement. Recommended lubricant
Replace damaged outer cable and inner ca- Lithium-soap-based grease
bles as soon as possible.
1. Check:
• Outer cable
Damage  Replace.
2. Check:
• Cable operation
Rough movement  Lubricate.
Recommended lubricant
Engine oil or a suitable cable lu-
bricant

Hold the cable end upright and pour a few

drops of lubricant into the cable sheath or use a
suitable lubricating device.

EAM30483

LUBRICATING THE BRAKE LEVER

1. Lubricate the pivoting points and metal-to-
metal moving parts of the following parts.
• Brake lever
Recommended lubricant
Silicone grease

EAM30503

LUBRICATING THE CLUTCH LEVER

1. Lubricate the pivoting points and metal-to-
metal moving parts of the following parts.
• Clutch lever
Recommended lubricant
Lithium-soap-based grease

EAM30250

LUBRICATING THE PEDAL

1. Lubricate the pivoting point and metal-to-
metal moving parts of the pedal.

3-35
 ELECTRICAL SYSTEM

EAM20137

ELECTRICAL SYSTEM
EAM30256

CHECKING AND CHARGING THE BATTERY

Refer to “CHECKING AND CHARGING THE
BATTERY” on page 8-50.
EAM30505

CHECKING THE FUSES

Refer to “CHECKING THE FUSES” on page
8-49.

3-36
 CHASSIS

GENERAL CHASSIS ....................................................................................... 4-1

REMOVING THE SEAT .............................................................................. 4-3
REMOVING THE NUMBER PLATE............................................................ 4-3
INSTALLING THE AIR SCOOP .................................................................. 4-4
REMOVING THE SIDE COVER.................................................................. 4-4
1
INSTALLING THE SIDE COVER ................................................................ 4-4

FRONT WHEEL ............................................................................................... 4-5

REMOVING THE FRONT WHEEL.............................................................. 4-6 2
DISASSEMBLING THE FRONT WHEEL .................................................... 4-6
CHECKING THE FRONT WHEEL .............................................................. 4-6
ASSEMBLING THE FRONT WHEEL.......................................................... 4-6
INSTALLING THE FRONT WHEEL ............................................................ 4-7 3
REAR WHEEL.................................................................................................. 4-9
REMOVING THE REAR WHEEL .............................................................. 4-10
DISASSEMBLING THE REAR WHEEL .................................................... 4-10
CHECKING THE REAR WHEEL............................................................... 4-10 4
CHECKING AND REPLACING THE REAR WHEEL SPROCKET............. 4-10
ASSEMBLING THE REAR WHEEL .......................................................... 4-11
INSTALLING THE REAR WHEEL............................................................. 4-11

FRONT BRAKE ............................................................................................. 4-13

5
INTRODUCTION ...................................................................................... 4-17
CHECKING THE FRONT BRAKE DISC ................................................... 4-17
REPLACING THE FRONT BRAKE PADS................................................. 4-17
REMOVING THE FRONT BRAKE CALIPER ............................................ 4-19
DISASSEMBLING THE FRONT BRAKE CALIPER................................... 4-19
6
CHECKING THE FRONT BRAKE CALIPER............................................. 4-19
ASSEMBLING THE FRONT BRAKE CALIPER ........................................ 4-19
INSTALLING THE FRONT BRAKE CALIPER........................................... 4-20
REMOVING THE FRONT BRAKE MASTER CYLINDER .......................... 4-21
7
CHECKING THE FRONT BRAKE MASTER CYLINDER .......................... 4-21
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ...................... 4-21
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................... 4-22

REAR BRAKE................................................................................................ 4-24

8
INTRODUCTION ...................................................................................... 4-28
CHECKING THE REAR BRAKE DISC...................................................... 4-28
REPLACING THE REAR BRAKE PADS ................................................... 4-28
REMOVING THE REAR BRAKE CALIPER............................................... 4-30
9
DISASSEMBLING THE REAR BRAKE CALIPER ..................................... 4-30
CHECKING THE REAR BRAKE CALIPER ............................................... 4-30
ASSEMBLING THE REAR BRAKE CALIPER........................................... 4-31
INSTALLING THE REAR BRAKE CALIPER ............................................. 4-31
REMOVING THE REAR BRAKE MASTER CYLINDER............................. 4-32
10
CHECKING THE REAR BRAKE MASTER CYLINDER ............................. 4-32
ASSEMBLING THE REAR BRAKE MASTER CYLINDER ........................ 4-32
 INSTALLING THE REAR BRAKE MASTER CYLINDER ........................... 4-33

HANDLEBAR................................................................................................. 4-35
REMOVING THE HANDLEBAR ............................................................... 4-36
CHECKING THE HANDLEBAR................................................................ 4-36
INSTALLING THE HANDLEBAR .............................................................. 4-36

FRONT FORK................................................................................................ 4-41

REMOVING THE FRONT FORK LEGS .................................................... 4-43
DISASSEMBLING THE FRONT FORK LEGS .......................................... 4-43
CHECKING THE FRONT FORK LEGS..................................................... 4-44
ASSEMBLING THE FRONT FORK LEGS ................................................ 4-46
INSTALLING THE FRONT FORK LEGS................................................... 4-52

STEERING HEAD .......................................................................................... 4-54

REMOVING THE LOWER BRACKET....................................................... 4-55
CHECKING THE STEERING HEAD ......................................................... 4-55
INSTALLING THE STEERING HEAD ....................................................... 4-55

REAR SHOCK ABSORBER ASSEMBLY...................................................... 4-58

HANDLING THE REAR SHOCK ABSORBER .......................................... 4-61
DISPOSING OF A REAR SHOCK ABSORBER........................................ 4-61
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY ..................... 4-61
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY...................... 4-61
CHECKING THE CONNECTING ARM AND RELAY ARM ....................... 4-62
INSTALLING THE RELAY ARM ............................................................... 4-62
INSTALLING THE CONNECTING ARM ................................................... 4-62
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY.................... 4-63

SWINGARM................................................................................................... 4-65
REMOVING THE SWINGARM ................................................................. 4-66
CHECKING THE SWINGARM ................................................................. 4-66
INSTALLING THE SWINGARM................................................................ 4-66

CHAIN DRIVE ................................................................................................ 4-68

REMOVING THE DRIVE CHAIN............................................................... 4-69
CHECKING THE DRIVE CHAIN ............................................................... 4-69
CHECKING THE DRIVE SPROCKET ....................................................... 4-70
CHECKING THE REAR WHEEL SPROCKET .......................................... 4-70
INSTALLING THE DRIVE CHAIN ............................................................. 4-70
 GENERAL CHASSIS

EAM20094

GENERAL CHASSIS
Removing the seat and battery

22 N m (2.2 kgf m, 16 lb ft)

8
7 4
22 N m (2.2 kgf m, 16 lb ft)

9 10

5 6
2

7 N m (0.7 kgf m, 5.2 lb ft)

Order Job/Parts to remove Q’ty Remarks

1 Seat 1
2 Side cover (left) 1
3 Negative battery lead 1 Disconnect.
4 Positive battery lead 1 Disconnect.
5 Battery band 1
6 Battery 1
7 Cover 1
8 Starter relay 1
9 Main relay 1
10 CCU (Communication Control Unit) 1

4-1
 GENERAL CHASSIS

Removing the side cover

16 N m (1.6 kgf m, 12 lb ft)

4
6

1 7 N m (0.7 kgf m, 5.2 lb ft)

1.3 N m (0.13 kgf m, 0.95 lb ft)

7 N m (0.7 kgf m, 5.2 lb ft)

2
5

7 N m (0.7 kgf m, 5.2 lb ft) 7 N m (0.7 kgf m, 5.2 lb ft)

Order Job/Parts to remove Q’ty Remarks

Refer to “CLEANING THE AIR FILTER ELE-
1 Air filter case cover 1 MENT” on page 3-16.
2 Air scoop (left) 1
3 Air scoop (right) 1
4 Side cover (right) 1
5 Number plate 1
6 Rear fender 1

4-2
 GENERAL CHASSIS

EAM30016

REMOVING THE SEAT

2
1
The fuel tank cap cover and the seat are cou-
pled with each other with a plastic band.
When removing the seat, always remove the
fuel tank cap cover beforehand.
1. Remove:
• Fuel tank cap cover “1”
Refer to “FUEL TANK CAP” on page 1-24.
EAM30371

REMOVING THE NUMBER PLATE

1. Remove:
1 • Bolt (number plate)
• Number plate “1”

• The projection “a” is inserted into the band of

the number plate. Pull the band off the projec-
tion before removal.
• Remove the clutch cable “2” from the cable
2. Remove: guide “b” on the number plate.
• Seat “1” • The projection “c” on the lower bracket is in-
serted into the number plate. Remove the
number plate by pulling it off the projection.
1 • When installing the number plate, insert the
projection on the number plate into the hole in
the upper side of the band.

3. Check:
• Seal “1”
Damage/wear/detachment  Replace.

4. Replace:
• Seal “1”

• Install the new seal in the original position.

• Make sure that the new seal does not cover
the ducts “2”.

4-3
 GENERAL CHASSIS

EAM30459

REMOVING THE SIDE COVER

b 2 1. Remove:
• Side cover (right) “1”

Remove the side cover (right) from the vehicle

by removing the bolts and sliding it as shown.

1 b

1
a

c
a

a. Projection
b. Slot
EAM30460

INSTALLING THE SIDE COVER

1. Install:
• Side cover (right) “1”

• Install the side cover (right) by sliding it as

a shown and secure it with the bolts to fit it to
the vehicle.
• Install the side cover (right) so that the rib is lo-
cated under the rib of the rear fender.

EAM30458 d b
INSTALLING THE AIR SCOOP
1. Install:
• Air scoop (left “1”/right)
1
After inserting the projection “a” on the air
scoop (left/right) into the hole “b” in the air filter c
case, inserting the grooves “c” into the ribs “d” a
of the air filter case, and inserting the projection
“e” into the slot “f” in the air filter case, install the
air scoop and secure it with the bolts. a. Projection
b. Slot
bf a c. Rib (side cover)
c d. Rib (rear fender)
e
d

4-4
 FRONT WHEEL

EAM20095

FRONT WHEEL
Removing the front wheel

LS 21 N m (2.1 kgf m, 15 lb ft)

3
21 N m (2.1 kgf m, 15 lb ft)
1

6 2
7
115 N m (11.5 kgf m, 85 lb ft)
5

LS 8

LS

5
4 (6)
7
LT
6

12 N m (1.2 kgf m, 8.9 lb ft)

Order Job/Parts to remove Q’ty Remarks

Use a maintenance stand to raise the front
wheel off the ground.
1 Front wheel axle pinch bolt 4 Loosen.
2 Front wheel axle nut 1
3 Front wheel axle 1
4 Front wheel 1
5 Collar 2
6 Oil seal 2
7 Bearing 2
8 Brake disc 1

4-5
 FRONT WHEEL

EAM30017
3. Check:
REMOVING THE FRONT WHEEL • Spoke
1. Use a maintenance stand to raise the front Refer to “CHECKING AND TIGHTENING
wheel off the ground. THE SPOKES” on page 3-34.
EWA13120
4. Tighten:
• Spoke
Securely support the vehicle so that there is
Refer to “CHECKING AND TIGHTENING
no danger of it falling over.
THE SPOKES” on page 3-34.
2. Remove:
• Front wheel Spoke
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)

T.
R.
EAM30019

DISASSEMBLING THE FRONT WHEEL

1. Remove: After tightening the spokes, measure the wheel
• Oil seal runout.
• Bearing
a. Clean the outside of the front wheel hub. 5. Measure:
b. Remove the oil seals “1” with a flat-head • Radial wheel runout “a”
screwdriver. • Lateral wheel runout “b”
Out of specification  Repair/replace.
To prevent damaging the wheel, place a rag “2”
between the screwdriver and the wheel surface.
b

2 a

Radial wheel runout limit

1 2.0 mm (0.08 in)
Lateral wheel runout limit
c. Remove the bearings with a bearing pull- 2.0 mm (0.08 in)
er.
EAM30018
6. Check:
CHECKING THE FRONT WHEEL • Collar
1. Check: Damage/wear  Replace.
• Front wheel axle 7. Check:
Roll the front wheel axle on a flat surface. • Bearing
Bends  Replace. Front wheel turns roughly or is loose  Re-
EWA13460 place the wheel bearings.
• Oil seal
Do not attempt to straighten a bent wheel Damage/wear  Replace.
axle. EAM30020

2. Check: ASSEMBLING THE FRONT WHEEL

• Tire 1. Install:
• Front wheel • Bearing (left side) “1” New
Damage/wear  Replace. • Spacer “2”
Refer to “CHECKING THE TIRES” on page • Bearing (right side) “3” New
3-34 and “CHECKING THE WHEELS” on • Oil seal “4” New
page 3-34.
• Apply the lithium-soap-based grease to the oil
seal lip when installing.

4-6
 FRONT WHEEL

• Left side of bearing shall be installed first. 3. Install:

• Install the oil seal with its manufacture’s marks • Collar “1”
or numbers facing outward.
ECA24420 Apply the lithium-soap-based grease on the oil
seal lip.
Install the bearing by pressing its outer race
parallel. 1

4
3
2

EAM30021

LS INSTALLING THE FRONT WHEEL

1. Install:
LS • Front wheel

Install the brake disc “1” between the brake

pads “2” correctly.
1
4

2
Use a socket “5” that matches the diameter of
the bearing outer race and that of the oil seal.

1
5
2. Install:
• Front wheel axle “1”

Apply the lithium-soap-based grease to the

front wheel axle.

2. Install:
• Brake disc
• Brake disc bolt 1

Brake disc bolt

12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.

LOCTITE®

3. Tighten:
Tighten the bolts in stages and in a crisscross • Front wheel axle nut “1”
pattern.

4-7
 FRONT WHEEL

Front wheel axle nut

T.
R.
115 N·m (11.5 kgf·m, 85 lb·ft)
ECA24430

Before tightening the front wheel axle nut,

push down hard on the handlebar(s) several
times and check if the front fork rebounds
smoothly.

4. Tighten:
• Front wheel axle pinch bolt “1”
Front wheel axle pinch bolt
21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.

1 1

4-8
 REAR WHEEL

EAM20096

REAR WHEEL
Removing the rear wheel
1 12 N m (1.2 kgf m, 8.9 lb ft)
3
125 N m (12.5 kgf m, 92 lb ft) (6)

21 N m (2.1 kgf m, 15 lb ft)

5
7
10
50 N m (5.0 kgf m, 37 lb ft) 8
9

(6)

(6)

7
5
3
9
2
4

21 N m (2.1 kgf m, 15 lb ft)

Order Job/Parts to remove Q’ty Remarks

Use a maintenance stand to raise the rear
wheel off the ground.
1 Rear wheel axle nut 1
2 Rear wheel axle 1
3 Drive chain puller 2
4 Rear wheel 1
5 Collar 2
6 Rear wheel sprocket 1
7 Oil seal 2
8 Circlip 1
9 Bearing 2
10 Brake disc 1

4-9
 REAR WHEEL

EAM30022
Refer to “CHECKING THE TIRES” on page
REMOVING THE REAR WHEEL 3-34 and “CHECKING THE WHEELS” on
1. Use a maintenance stand to raise the rear page 3-34.
wheel off the ground. 3. Check:
EWA13120
• Spoke
Refer to “CHECKING AND TIGHTENING
Securely support the vehicle so that there is
THE SPOKES” on page 3-34.
no danger of it falling over.
4. Measure:
2. Remove: • Radial wheel runout
• Rear wheel axle nut “1” • Lateral wheel runout
3. Loosen: Refer to “CHECKING THE FRONT WHEEL”
• Locknut “2” on page 4-6.
4. Tighten:
• Adjusting bolt “3” Radial wheel runout limit
2.0 mm (0.08 in)
Lateral wheel runout limit
2.0 mm (0.08 in)

EAM30025

CHECKING AND REPLACING THE REAR

2 WHEEL SPROCKET
1. Check:
3 • Rear wheel sprocket
More than 1/4 tooth wear “a”  Replace the
1 rear wheel sprocket and the drive sprocket
5. Remove: as a set.
• Rear wheel axle Bent tooth  Replace the rear wheel sprock-
• Rear wheel et and the drive sprocket as a set.

• Push the rear wheel forward and remove the

drive chain from the rear wheel sprocket.
• Do not depress the brake pedal with the rear
wheel removed.

EAM30024

DISASSEMBLING THE REAR WHEEL

1. Remove:
• Oil seal
• Bearing
b. Correct
Refer to “DISASSEMBLING THE FRONT
WHEEL” on page 4-6. 1. Drive chain roller
EAM30023
2. Rear wheel sprocket
CHECKING THE REAR WHEEL 2. Replace:
1. Check: • Rear wheel sprocket
• Rear wheel axle a. Remove the self-locking nuts and the rear
• Rear wheel wheel sprocket.
• Bearing b. Clean the rear wheel drive hub with a
• Oil seal clean cloth, especially the surfaces that
Refer to “CHECKING THE FRONT WHEEL” contact the sprocket.
on page 4-6. c. Install the new rear wheel sprocket.
2. Check:
• Tire
• Rear wheel
Damage/wear  Replace.

4-10
 REAR WHEEL

Rear wheel sprocket self-locking

T.
R.
nut 6
50 N·m (5.0 kgf·m, 37 lb·ft)

Tighten the self-locking nuts in stages and in a

crisscross pattern.

EAM30026

ASSEMBLING THE REAR WHEEL

1. Install: 2. Install:
• Bearing (right side) “1” New • Brake disc
• Circlip “2” New • Brake disc bolt
• Spacer “3”
• Bearing (left side) “4” New Brake disc bolt
• Oil seal “5” New 12 N·m (1.2 kgf·m, 8.9 lb·ft)

T.
R.
LOCTITE®
• Apply the lithium-soap-based grease to the oil
seal lip when installing.
• Right side of bearing shall be installed first. Tighten the bolts in stages and in a crisscross
• Install the oil seal with its manufacture’s marks pattern.
or numbers facing outward. 3. Install:
ECA24440 • Collar “1”

Install the bearing by pressing its outer race Apply the lithium-soap-based grease on the oil
parallel. seal lip.

5
2 1
1

LS

EAM30027

INSTALLING THE REAR WHEEL

1. Install:
• Rear wheel

3 Install the brake disc “1” between the brake

4
pads “2” correctly.
5

Use a socket “6” that matches the diameter of

the bearing outer race and that of the oil seal.

4-11
 REAR WHEEL

2
2 2

3
1

2. Install: 5. Adjust:
• Drive chain “1” • Drive chain slack “a”

Push the rear wheel “2” forward and install the Drive chain slack (Maintenance
Stand)
drive chain.
50.0–60.0 mm (1.97–2.36 in)

Refer to “DRIVE CHAIN SLACK” on page

3-27.

3. Install:
• Drive chain puller (left) “1”
• Rear wheel axle “2”
6. Tighten:
• Install the drive chain puller (left), and insert the • Rear wheel axle nut “1”
rear wheel axle from the left side.
Wheel axle nut
• Apply the lithium-soap-based grease to the
125 N·m (12.5 kgf·m, 92 lb·ft)
rear wheel axle.
T.
R.

• Locknut “2”

2 Locknut
1 21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.

LS

4. Install:
• Drive chain puller (right) “1” 1 2
• Washer “2”
• Rear wheel axle nut “3”

Temporarily tighten the rear wheel axle nut at

this point.

4-12
 FRONT BRAKE

EAM20097

FRONT BRAKE
Removing the front brake caliper

30 N m (3.0 kgf m, 22 lb ft)

28 N m (2.8 kgf m, 21 lb ft)

5 N m (0.5 kgf m, 3.7 lb ft)

2
8
5
7 4

10
17 N m (1.7 kgf m, 13 lb ft)
6 2.5 N m (0.25 kgf m, 1.8 lb ft)

Order Job/Parts to remove Q’ty Remarks

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-26.
1 Union bolt 1
2 Copper washer 2
3 Front brake hose 1
4 Brake pad pin plug 1
5 Brake pad pin 1
6 Brake pad 2
7 Brake pad spring 1
8 Front brake caliper assembly 1
9 Front brake caliper bracket 1
10 Brake pad spring 1

4-13
 FRONT BRAKE

Disassembling the front brake caliper

5 N m (0.5 kgf m, 3.7 lb ft)

2

.
S

Order Job/Parts to remove Q’ty Remarks

1 Brake caliper piston kit 2
2 Brake caliper piston seal kit 2
3 Bleed screw 1

4-14
 FRONT BRAKE

Removing the front brake master cylinder

9 N m (0.9 kgf m, 6.6 lb ft)

1.5 N m (0.15 kgf m, 1.1 lb ft)

8
5

6
6 N m (0.6 kgf m, 4.4 lb ft)
7
6 N m (0.6 kgf m, 4.4 lb ft)

9
1

2
30 N m (3.0 kgf m, 22 lb ft)

Order Job/Parts to remove Q’ty Remarks

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-26.
1 Brake lever 1
2 Union bolt 1
3 Copper washer 2
4 Front brake hose 1
5 Brake master cylinder reservoir cap 1
6 Brake master cylinder reservoir diaphragm 1
7 Front brake master cylinder float 1
8 Front brake master cylinder holder 1
9 Front brake master cylinder 1

4-15
 FRONT BRAKE

Disassembling the front brake master cylinder

1 New

BF

Order Job/Parts to remove Q’ty Remarks

1 Brake master cylinder kit 1

4-16
 FRONT BRAKE

EAM30028
b. Remove the brake caliper.
INTRODUCTION c. Hold the dial gauge at a right angle
EWA19210
against the brake disc surface.
d. Measure the runout 1.5 mm (0.06 in)
If you need to disassemble the disc brake
above the brake disc edge.
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. Disassemble the brake sys-
tem, drain the brake fluid, and clean it. After
that, add a suitable amount of brake fluid.
Then, bleed it after reassembly. G098641
• Use only brake fluid for washing brake
components. 4. Replace:
• Use new brake fluid for cleaning the brake • Brake disc
components. Refer to “ASSEMBLING THE FRONT
• Immediately wipe off the spilled brake fluid WHEEL” on page 4-6.
to avoid damage to painted surfaces or EAM30519

plastic parts. REPLACING THE FRONT BRAKE PADS

• Handle brake fluid with special care not to
let it enter your eyes so that you may not When replacing the brake pads, it is not neces-
lost your eyesight. sary to disconnect the brake hose or disassem-
• FIRST AID FOR BRAKE FLUID ENTERING ble the brake caliper.
THE EYES: 1. Remove:
• Flush with water for 15 minutes and get im- • Brake pad
mediate medical attention. a. Remove the pad pin plug “1”.
EAM30029

CHECKING THE FRONT BRAKE DISC

1. Check:
• Front brake disc
Damage/galling  Replace.
2. Measure:
• Brake disc thickness
Measure the brake disc thickness at a few 1
different locations.
Out of specification  Replace.
Brake disc thickness limit b. Loosen the pad pin “2”.
2.5 mm (0.10 in) c. Remove the brake caliper “3” from the
front fork.
3. Measure:
• Brake disc runout
Out of specification  Replace the brake
disc.
3
Brake disc runout limit (as mea-
sured on wheel)
0.15 mm (0.0059 in)

a. Place the vehicle on a maintenance stand 2

so that the front wheel is elevated.

4-17
 FRONT BRAKE

d. Remove the pad pin and brake pads “4”.

Bleed screw
4 5 N·m (0.5 kgf·m, 3.7 lb·ft)

T.
R.
d. Install the brake pads “3” and the pad pin.

• Install the brake pads with their projections “a”

into the brake caliper recesses “b”.
• Temporarily tighten the pad pin at this point.

2. Measure:
• Brake pad wear limit “a” b a
Out of specification  Replace the brake
pads as a set.
Brake pad lining thickness limit
1.0 mm (0.04 in)

e. Install the brake caliper “4” and tighten

the pad pin “5”.
a Bolt (brake caliper)
28 N·m (2.8 kgf·m, 21 lb·ft)
T.
R.

Pad pin
17 N·m (1.7 kgf·m, 13 lb·ft)

3. Install:
• Brake pad
4
a. Connect the plastic hose “1” to the bleed
screw “2” and place a container under the
end of the plastic hose.
b. Loosen the bleed screw and push the
brake caliper piston in. 5
EWA19160

f. Install the pad pin plug “6”.

Do not reuse the drained brake fluid.
Pad pin plug
2 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
T.
R.

c. Tighten the bleed screw. 6

4-18
 FRONT BRAKE

4. Check:
• Brake fluid level
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-24.
5. Check:
• Brake lever operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-26.
EAM30030 b. Remove the brake caliper piston dust seal
REMOVING THE FRONT BRAKE CALIPER and the brake caliper piston seal.
EAM30032
Before disassembling the brake caliper, drain
CHECKING THE FRONT BRAKE CALIPER
the brake fluid from the entire brake system.
1. Check:
1. Remove: • Brake caliper piston “1”
• Union bolt Rust/scratches/wear  Replace the brake
• Copper washer caliper piston.
• Brake hose • Brake caliper cylinder “2”
Scratches/wear  Replace the brake caliper
Put the end of the brake hose into a container assembly.
and pump out the brake fluid. • Brake caliper body “3”
Cracks/damage  Replace the brake caliper
EAM30031 assembly.
DISASSEMBLING THE FRONT BRAKE • Brake fluid delivery passages
CALIPER (brake caliper body)
1. Remove: Obstruction  Blow out with compressed
• Brake caliper piston “1” air.
• Brake caliper piston seal kit “2”
2 3

2
2 1 1
EWA19220

a. Blow compressed air into the brake hose

joint opening to force out the piston from When the brake caliper is disassembled, re-
the brake caliper. place the brake caliper piston seal and the
EWA13550
brake caliper piston dust seal with new ones.

• Cover the brake caliper piston with a rag. 2. Check:

Be careful not to get injured when the pis- • Brake caliper bracket
ton is expelled from the brake caliper. Crack/damage  Replace.
• Never try to pry out the brake caliper pis- EAM30033

ton. ASSEMBLING THE FRONT BRAKE CALIPER

EWA19230

• Before installation, clean and lubricate the

4-19
 FRONT BRAKE

internal parts. Use new brake fluid for

cleaning and lubricating. Brake pad pin
17 N·m (1.7 kgf·m, 13 lb·ft)
• Never use solvents on internal brake com-

T.
R.
ponents as they will cause the piston seals Refer to “CHECKING THE FRONT BRAKE
to swell and distort. PADS” on page 3-25.
• When the brake caliper is disassembled, 3. Tighten:
replace the brake caliper piston seal and • Brake hose holder bolt “1”
the brake caliper piston dust seal with new
ones. Brake hose holder bolt
9 N·m (0.9 kgf·m, 6.6 lb·ft)

T.
R.
Specified brake fluid
DOT 4
Make sure that the brake hose holder “2” is in-
EAM30035 stalled with its upper end “a” aligned with the
INSTALLING THE FRONT BRAKE CALIPER paint “b” on the brake hose.
1. Install:
• Front brake caliper bracket 2
• Front brake caliper
(temporarily)
• Copper washer New b
• Brake hose
• Union bolt
Front brake caliper bolt a
28 N·m (2.8 kgf·m, 21 lb·ft)
T.
R.

Brake hose union bolt 1

30 N·m (3.0 kgf·m, 22 lb·ft)
4. Pour brake fluid to the brake master cylinder
EWA13531
reservoir up to the specified level.

Proper brake hose routing is essential to in- Specified brake fluid

sure safe vehicle operation. DOT 4
ECA24460 EWA13090

Make sure that the pipe portion “a” of the • Use only the designated brake fluid. Other
brake hose touches the projection “b” on the brake fluids may cause the rubber seals to
brake caliper. deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
a will significantly lower the boiling point of
b the brake fluid and could cause vapor lock.
ECA13540

2. Install: Brake fluid may damage painted surfaces

• Front brake caliper and plastic parts. Therefore, always clean up
• Brake pad spring any spilt brake fluid immediately.
• Brake pad
• Brake pad pin 5. Bleed:
• Brake hose holder • Brake system

4-20
 FRONT BRAKE

Refer to “BLEEDING THE HYDRAULIC Damage/scratches/wear  Replace.

BRAKE SYSTEM” on page 3-26. 3. Check:
6. Check: • Brake hose
• Brake fluid level Cracks/damage/wear  Replace.
The minimum level mark or below  Add. EAM30038
Refer to “CHECKING THE BRAKE FLUID ASSEMBLING THE FRONT BRAKE MASTER
LEVEL” on page 3-24. CYLINDER
7. Check: EWA13520

• Brake lever operation

A softy or spongy feeling  Bleed the brake • Before installation, all internal brake com-
system. ponents should be cleaned and lubricated
Refer to “BLEEDING THE HYDRAULIC with clean or new brake fluid.
BRAKE SYSTEM” on page 3-26. • Never use solvents on internal brake com-
EAM30036
ponents.
REMOVING THE FRONT BRAKE MASTER
CYLINDER Specified brake fluid
DOT 4
Before removing the front brake master cylin-
der, drain the brake fluid from the entire brake 1. Wash the brake master cylinder with brake
system. fluid.
2. Install:
1. Remove: • Primary cylinder cup “1”
• Union bolt • Secondary cylinder cup “2”
• Copper washer (to the brake master cylinder piston “3”)
• Brake hose EWA20240

To drain any remaining brake fluid, place a con- Apply brake fluid to the cylinder cups and in-
tainer under the master cylinder and the end of stall them as shown. Wrong orientation in in-
the brake hose. stallation causes poor braking performance.

EAM30037

CHECKING THE FRONT BRAKE MASTER

CYLINDER 1 2
1. Check:
• Brake master cylinder “1”
Damage/scratches/wear  Replace the
brake master cylinder assembly.
• Brake fluid delivery passages “2”
(brake master cylinder body) 3
Obstruction  Blow out with compressed
air.

1 2
1

3
2
3. Install:
2. Check: • Spring “1”
• Brake master cylinder reservoir cap (to the brake master cylinder piston “2”)

4-21
 FRONT BRAKE

bolt.
Install the spring with a smaller inside diameter
to the brake master cylinder piston.

UP

2. Install:
• Copper washer New
4. Install: • Brake hose
• Brake master cylinder piston assembly “1” • Union bolt
• Washer “2”
• Circlip “3” Brake hose union bolt
30 N·m (3.0 kgf·m, 22 lb·ft)
• Dust boot “4”

T.
R.
• Push rod “5” EWA13531

• Always install new brake master cylinder kit Proper brake hose routing is essential to in-
“6”. sure safe vehicle operation.
• Before installation, apply brake fluid to the ECA24470
components of the brake master cylinder pis-
ton assembly.
During installation, bring the brake hose into
• Before installation, apply silicone grease to the
contact with the brake master cylinder pro-
push rod end.
jection “a” and make its bent portion “b”
• Before installation, apply brake fluid to the in-
face downward.
side of the brake master cylinder.

Turn the handlebar toward right and left to make

6 New sure that the brake hose does not touch other
parts (e.g., wire harness, cables, leads). Adjust
1
if necessary.

2 3 4 5
aa
b
EAM30039

INSTALLING THE FRONT BRAKE MASTER

CYLINDER
1. Install:
a
• Brake master cylinder “1”
3. Pour brake fluid to the brake master cylinder
Brake master cylinder holder bolt
reservoir up to the specified level.
9 N·m (0.9 kgf·m, 6.6 lb·ft)
T.
R.

Specified brake fluid

DOT 4
• Install the front brake master cylinder holder
with the “UP” mark facing up.
• First, tighten the upper bolt, then the lower

4-22
 FRONT BRAKE

EWA13090

• 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 fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
ECA13540

Brake fluid may damage painted surfaces

and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
4. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-26.
5. Check:
• Brake fluid level
The minimum level mark or below  Add.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-24.
6. Check:
• Brake lever operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-26.

4-23
 REAR BRAKE

EAM20098

REAR BRAKE
Removing the rear brake caliper

10 N m (1.0 kgf m, 7.4 lb ft) 2.5 N m (0.25 kgf m, 1.8 lb ft)

17 N m (1.7 kgf m, 13 lb ft)
30 N m (3.0 kgf m, 22 lb ft) 2

14 3
4
11

15

12

6
S
5

10 N m (1.0 kgf m, 7.4 lb ft) 8 13

1
10

7
10
9
7 N m (0.7 kgf m, 5.2 lb ft)

Order Job/Parts to remove Q’ty Remarks

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-26.
1 Protector 1
2 Union bolt 1
3 Copper washer 2
4 Rear brake hose 1
5 Brake pad pin plug 1
6 Brake pad pin 1
7 Rear brake pad assembly 1
8 Brake pad shim (left) 1
9 Brake pad shim (right) 1
10 Brake pad shim (heat insulator) 2
11 Brake pad spring 1
12 Rear brake caliper bracket 1
13 Brake pad spring 1
14 Rear brake disc cover 1
15 Rear brake caliper assembly 1

4-24
 REAR BRAKE

Disassembling the rear brake caliper

5 N m (0.5 kgf m, 3.7 lb ft)

1
3

BF

Order Job/Parts to remove Q’ty Remarks

1 Brake caliper piston kit 1
2 Brake caliper piston seal kit 1
3 Bleed screw 1

4-25
 REAR BRAKE

Removing the rear brake master cylinder

1.5 N m (0.15 kgf m, 1.1 lb ft)

10 N m (1.0 kgf m, 7.4 lb ft)

30 N m (3.0 kgf m, 22 lb ft)

7
1
8

9 2

10

5
4
Order Job/Parts to remove Q’ty Remarks
Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-26.
1 Union bolt 1
2 Copper washer 2
3 Brake hose 1
4 Split pin 1
5 Washer 1
6 Pin 1
7 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm
8 1
plate
9 Brake master cylinder reservoir diaphragm 1
10 Rear brake master cylinder 1

4-26
 REAR BRAKE

Disassembling the rear brake master cylinder

Order Job/Parts to remove Q’ty Remarks

1 Brake master cylinder joint 1
2 Brake master cylinder kit 1

4-27
 REAR BRAKE

EAM30040

INTRODUCTION Brake disc runout limit (as mea-

EWA19260
sured on wheel)
0.15 mm (0.0059 in)
If you need to disassemble the disc brake
components, observe the following precau- 4. Replace:
tions. • Brake disc
• Never disassemble the brake components Refer to “ASSEMBLING THE REAR WHEEL”
unless absolutely necessary. on page 4-11.
• If there is any problem with connections on EAM30523
the hydraulic brake system, perform the REPLACING THE REAR BRAKE PADS
following jobs. Disassemble the brake sys-
tem, drain the brake fluid, and clean it. After When replacing the brake pads, it is not neces-
that, add a suitable amount of brake fluid. sary to disconnect the brake hose or disassem-
Then, bleed it after reassembly. ble the brake caliper.
• Use only brake fluid for washing internal
brake components. 1. Remove:
• Use new brake fluid for cleaning the brake • Brake pad
components. a. Remove the protector “1” and the pad pin
• Immediately wipe off the spilled brake fluid plug “2”.
to avoid damage to painted surfaces or
plastic parts. 2
• Handle brake fluid with special care not to
let it enter your eyes so that you may not
lost your eyesight.
• FIRST AID FOR BRAKE FLUID ENTERING
THE EYES: 1
• Flush with water for 15 minutes and get im-
mediate medical attention.

EAM30041
b. Loosen the pad pin “3”.
CHECKING THE REAR BRAKE DISC
c. Remove the rear wheel “4” and the brake
1. Check:
caliper “5”.
• Brake disc
Refer to “REAR WHEEL” on page 4-9.
Damage/galling  Replace.
2. Measure: 3
• Brake disc thickness
Measure the brake disc thickness at a few 4
different locations.
Out of specification  Replace.
Refer to “CHECKING THE FRONT BRAKE
DISC” on page 4-17. 5
Brake disc thickness limit
3.5 mm (0.14 in)

3. Measure: d. Remove the pad pin “6” and the brake

• Brake disc runout pads “7”.
Out of specification  Replace the brake
disc.
Refer to “CHECKING THE FRONT BRAKE
DISC” on page 4-17.

4-28
 REAR BRAKE

6 Bleed screw
5 N·m (0.5 kgf·m, 3.7 lb·ft)

T.
R.
7 d. Install the brake pads “3” and the pad pin
“4”.

• Install the brake pads with their projections “a”

into the brake caliper recesses “b”.
• Temporarily tighten the pad pin at this point.

2. Measure: 4
• Brake pad wear limit “a”
Out of specification  Replace the brake
pads as a set. 3
Brake pad lining thickness limit
1.0 mm (0.04 in) a
b

e. Install the brake caliper “5” and the rear

wheel “6”.
Refer to “REAR WHEEL” on page 4-9.
a f. Tighten the pad pin “7”.
Pad pin
17 N·m (1.7 kgf·m, 13 lb·ft)
T.
R.

3. Install: 7
• Brake pad
a. Connect the plastic hose “1” to the bleed 6
screw “2” and place a container under the
end of the plastic hose.
b. Loosen the bleed screw and push the
brake caliper piston in. 5
EWA19170

Do not reuse the drained brake fluid.

g. Install the pad pin plug “8” and the
protector “9”.
Pad pin plug
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
T.
R.

Bolt (protector)
1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
2

c. Tighten the bleed screw.

4-29
 REAR BRAKE

EWA13550

8
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.
9

4. Check:
• Brake fluid level
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-24.
5. Check:
• Brake pedal operation
A softy or spongy feeling  Bleed the brake
system. b. Remove the brake caliper piston dust seal
Refer to “BLEEDING THE HYDRAULIC and the brake caliper piston seal.
BRAKE SYSTEM” on page 3-26.
EAM30044
EAM30042 CHECKING THE REAR BRAKE CALIPER
REMOVING THE REAR BRAKE CALIPER 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.
1. Remove: • Brake caliper cylinder “2”
• Union bolt Scratches/wear  Replace the brake caliper
• Copper washer assembly.
• Brake hose • Brake caliper body “3”
Cracks/damage  Replace the brake caliper
Put the end of the brake hose into a container assembly.
and pump out the brake fluid. • Brake fluid delivery passages
(brake caliper body)
EAM30043 Obstruction  Blow out with compressed
DISASSEMBLING THE REAR BRAKE air.
CALIPER
1. Remove: 2
• Brake caliper piston “1”
• Brake caliper piston seal kit “2” 1
3

1
2 EWA19270

When the brake caliper is disassembled, re-

place the brake caliper piston seal and the
a. Blow compressed air into the brake hose brake caliper piston dust seal with new ones.
joint opening to force out the piston from
the brake caliper.

4-30
 REAR BRAKE

2. Check:
• Brake caliper bracket
Crack/damage  Replace.
EAM30045

ASSEMBLING THE REAR BRAKE CALIPER b

EWA19280

• Before installation, clean and lubricate the a

internal parts. Use new brake fluid for b
cleaning and lubricating.
• Never use solvents on internal brake com- 3. Install:
ponents as they will cause the piston seals • Brake pad spring
to swell and distort. • Brake pad
• When the brake caliper is disassembled, • Brake pad pin
replace the brake caliper piston seal and • Brake pad pin plug
the brake caliper piston dust seal with new
ones. Brake pad pin
17 N·m (1.7 kgf·m, 13 lb·ft)

T.
R.
Specified brake fluid Brake pad pin plug
DOT 4 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)

EAM30047 Refer to “CHECKING THE REAR BRAKE

INSTALLING THE REAR BRAKE CALIPER PADS” on page 3-25.
1. Install: 4. Pour brake fluid to the brake fluid reservoir
• Rear brake caliper up to the specified level.
• Rear brake caliper bracket
Specified brake fluid
2. Install:
DOT 4
• Rear wheel
Refer to “REAR WHEEL” on page 4-9. EWA13090

• Copper washer New

• Brake hose • Use only the designated brake fluid. Other
• Union bolt brake fluids may cause the rubber seals to
Brake hose union bolt deteriorate, causing leakage and poor
30 N·m (3.0 kgf·m, 22 lb·ft) brake performance.
T.

• Refill with the same type of brake fluid that

R.

EWA13531 is already in the system. Mixing brake fluids

may result in a harmful chemical reaction,
Proper brake hose routing is essential to in- leading to poor brake performance.
sure safe vehicle operation. • When refilling, be careful that water does
ECA24490 not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
Make sure that a bend in its pipe portion “a” the brake fluid and could cause vapor lock.
is directed as shown and the brake hose ECA13540

touches the projection “b” on the brake cali-

per. 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 HYDRAULIC
BRAKE SYSTEM” on page 3-26.

4-31
 REAR BRAKE

6. Check: • Brake master cylinder reservoir diaphragm

• Brake fluid level Crack/damage  Replace.
The minimum level mark or below  Add. 3. Check:
Refer to “CHECKING THE BRAKE FLUID • Brake hose
LEVEL” on page 3-24. Cracks/damage/wear  Replace.
7. Check: EAM30050
• Brake pedal operation ASSEMBLING THE REAR BRAKE MASTER
A softy or spongy feeling  Bleed the brake CYLINDER
system. EWA13520

Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM” on page 3-26. • Before installation, all internal brake com-
EAM30048
ponents should be cleaned and lubricated
REMOVING THE REAR BRAKE MASTER with clean or new brake fluid.
CYLINDER • Never use solvents on internal brake com-
ponents.
Before removing the rear brake master cylinder,
drain the brake fluid from the entire brake sys- Specified brake fluid
tem. DOT 4

1. Remove: 1. Wash the brake master cylinder with brake

• Union bolt fluid.
• Copper washer 2. Install:
• Brake hose • Primary cylinder cup “1”
• Secondary cylinder cup “2”
To drain any remaining brake fluid, place a con- (to the brake master cylinder piston “3”)
tainer under the master cylinder and the end of EWA19300

the brake hose.

Apply brake fluid to the cylinder cups and in-
EAM30049 stall them as shown. Wrong orientation in in-
CHECKING THE REAR BRAKE MASTER stallation causes poor braking performance.
CYLINDER
1. Check:
• Brake master cylinder “1” 2
Damage/scratches/wear  Replace.
• Brake fluid delivery passages “2”
(brake master cylinder body) 1
Obstruction  Blow out with compressed
air.
3

1 2
1

3
2. Check:
• Master cylinder reservoir cap
Crack/damage  Replace.
• Brake master cylinder reservoir diaphragm 3. Install:
holder • Spring “1”

4-32
 REAR BRAKE

(to the brake master cylinder piston “2”) sure safe vehicle operation.
ECA24500

Install the spring with a smaller inside diameter

to the brake master cylinder piston. Make sure that the pipe portion of the brake
hose touches the projection “a” on the brake
caliper.

1 2

a
4. Install:
• Brake master cylinder piston assembly “1”
• Push rod “2” 2. Pour brake fluid to the brake fluid reservoir
• Circlip “3” up to the specified level.
• Dust boot “4”
Specified brake fluid
• Always install new brake master cylinder kit DOT 4
“5”. EWA13090
• Before installation, apply brake fluid to the
brake master cylinder piston assembly. • Use only the designated brake fluid. Other
• Before installation, apply silicone grease to the brake fluids may cause the rubber seals to
push rod end. deteriorate, causing leakage and poor
• Before installation, apply brake fluid to the in- brake performance.
side of the brake master cylinder. • Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
5 New may result in a harmful chemical reaction,
leading to poor brake performance.
1 • When refilling, be careful that water does
3 4 not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
ECA24510

2
Brake fluid may damage painted surfaces
EAM30051
and plastic parts. Therefore, always clean up
INSTALLING THE REAR BRAKE MASTER any spilt brake fluid immediately.
CYLINDER
1. Install: 3. Bleed:
• Copper washer New • Brake system
• Brake hose Refer to “BLEEDING THE HYDRAULIC
• Union bolt BRAKE SYSTEM” on page 3-26.
4. Check:
Brake hose union bolt • Brake fluid level
30 N·m (3.0 kgf·m, 22 lb·ft) The minimum level mark or below  Add.
T.
R.

EWA13531
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-24.
5. Check:
Proper brake hose routing is essential to in-
• Brake pedal operation

4-33
 REAR BRAKE

A softy or spongy feeling  Bleed the brake

system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-26.

4-34
 HANDLEBAR

EAM20099

HANDLEBAR
Removing the handlebar
3.8 N m (0.38 kgf m, 2.8 lb ft)
9
6
0.5 N m (0.05 kgf m, 0.37 lb ft)

9 N m (0.9 kgf m, 6.6 lb ft)

10 8 28 N m (2.8 kgf m, 21 lb ft)

7
11
3.0 N m (0.30 kgf m, 2.2 lb ft)
1.3 N m (0.13 kgf m, 0.95 lb ft)
5 N m (0.5 kgf m, 3.7 lb ft)
0.5 N m (0.05 kgf m, 0.37 lb ft)

13 4 3

14
12
15
2
16 1
16

40 N m (4.0 kgf m, 30 lb ft)

7 N m (0.7 kgf m, 5.2 lb ft)

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS” on page
Number plate 4-1.
1 Clutch cable 1 Disconnect.
2 Clutch lever holder 1
3 Engine stop switch 1
4 Mode switch 1
5 Brake master cylinder 1
6 Throttle cable cap 1
7 Throttle cable (pull) 1 Disconnect.
8 Throttle cable (return) 1 Disconnect.
9 Right grip 1
10 Tube guide 1
11 Start switch 1
12 Left grip 1
13 Upper handlebar holder 2
14 Handlebar 1
15 Lower handlebar holder 2
16 Damper 4

4-35
 HANDLEBAR

EAM30052 EWA13120

REMOVING THE HANDLEBAR

1. Stand the vehicle upright on a level surface. Securely support the vehicle so that there is
EWA13120
no danger of it falling over.
Securely support the vehicle so that there is 2. Install:
no danger of it falling over. • Damper “1”
• Lower handlebar holder “2” (temporarily)
2. Remove: • Handlebar “3”
• Grip “1” • Upper handlebar holder “4”
Blow in compressed air between the handlebar Upper handlebar holder bolt
or tube guide and the grip. Then remove the grip 28 N·m (2.8 kgf·m, 21 lb·ft)

T.
R.
which has become loose.

• Install the lower handlebar holders with the

side having the longer distance “a” from the
mounting bolt center facing towards the rear
side of the vehicle.
• Installing the lower handlebar holders in the
reverse direction allow the front-to-rear offset
amount of the handlebar position to be
changed.
• The upper handlebar holders should be in-
stalled with the punch marks “b” facing for-
3. Remove: ward.
• Throttle cable housing “1” • When installing the handlebar, make sure that
• Throttle grip “2” right and left marks “c” are in place identically
on both sides.
While removing the throttle cable housing, pull • Install the handlebar so that the projection “d”
back the rubber cover “3”. of the upper handlebar holders is positioned at
the mark on the handlebar as shown.
ECA14250

• First, tighten the bolts on the front side of

the 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.

EAM30053
2
CHECKING THE HANDLEBAR
1. Check:
• Handlebar
Bends/cracks/damage  Replace. 1
EWA13690

Do not attempt to straighten a bent handle-

bar as this may dangerously weaken it.

EAM30054

INSTALLING THE HANDLEBAR

1. Stand the vehicle upright on a level surface.

4-36
 HANDLEBAR

3. Tighten:
a • Lower handlebar holder nut
Lower handlebar holder nut
40 N·m (4.0 kgf·m, 30 lb·ft)

T.
R.
4. Install:
• Clutch lever holder “1”
• Clutch lever “2”
Clutch lever holder bolt
5 N·m (0.5 kgf·m, 3.7 lb·ft)

T.
R.
4 4 Clutch lever pivot bolt
3 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
Clutch lever pivot nut
7 N·m (0.7 kgf·m, 5.2 lb·ft)

• After tightening the clutch lever pivot bolt,

tighten the clutch lever pivot nut, while holding
the clutch lever pivot bolt to prevent it from
turning.
• The clutch lever holder “1” should be installed
according to the dimensions shown.
b
2

168 mm
(6.61 in)
c
5. Install:
• Engine stop switch “1”
• Mode switch “2”
-2
-1

+1
-2
-1

+1
• Clamp “3”
+2 +2

Engine stop switch screw

0.5 N·m (0.05 kgf·m, 0.37 lb·ft)
T.
R.

Screw (mode switch)

1.3 N·m (0.13 kgf·m, 0.95 lb·ft)

d • The engine stop switch “1” and the mode

switch “2” should be installed according to the
-2
dimensions shown.
-1
• Pass the engine stop switch lead through the
+1
+2 middle of the clutch lever holder.

4-37
 HANDLEBAR

0 mm 30 50˚ Clutch lever free play

(0 in) 7.0–12.0 mm (0.28–0.47 in)

FWD 9. Install:
1 • Right grip “1”
• Collar “2”
Apply adhesive to the tube guide “3”.
0 mm
(0 in) 2 3 • Before applying the adhesive, wipe off grease
or oil on the tube guide surface “a” with a lac-
6. Install: quer thinner.
• Handlebar grip “1” • Install the grip to the tube guide so that the
a. Slightly coat the handlebar left end with a grip match mark “b” and tube guide slot “c”
rubber adhesive. form the angle as shown.
b. Install the handlebar grip on the handlebar
by pressing the grip from the left side.
c. Wipe off any excess adhesive with a clean
cloth.

Install the handlebar grip to the handlebar so

that the line “a” between the two arrow marks
faces straight upward.

64
b
1

7. Install: 3
• Clutch cable “1”
10.Install:
Before installation, apply the lithium-soap- • Rubber cover “1”
based grease to the clutch cable end. • Throttle grip “2”

Apply the lithium-soap-based grease on the

throttle grip sliding surface.
1

1
2

8. Adjust:
• Clutch lever free play
Refer to “ADJUSTING THE CLUTCH LEVER
FREE PLAY” on page 3-16.

4-38
 HANDLEBAR

11.Install: 13.Install:
• Throttle cable “1” • Rubber cover “1”
• Cover (throttle cable housing) “2”
Slightly coat the end of throttle cable and inside
of throttle grip with lithium-soap-based grease.
Then, mount the throttle grip onto the handle-
bar.

14.Install:
• Start switch “1”
• Front brake master cylinder assembly “2”
• Front brake master cylinder holder “3”
• Front brake master cylinder holder bolt “4”
12.Install:
• Clamp “5”
• Throttle cable housing “1”
• Screw (throttle cable housing) “2” Front brake master cylinder hold-
er bolt
Screw (throttle cable housing)
T.
R.

9 N·m (0.9 kgf·m, 6.6 lb·ft)

3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
T.
R.

EWA19310

• Install the brake master cylinder holder with

After tightening the throttle cable housing the “UP” mark facing up.
screws, check that the throttle grip “3” • Install in order for the top of the front brake
moves smoothly. If it does not, retighten the master cylinder assembly to be level.
screws for adjustment. • First, tighten the upper bolt, then the lower
bolt.

3
4
1
2

5 4

4-39
 HANDLEBAR

15.Adjust:
• Throttle grip free play
Refer to “CHECKING THE THROTTLE GRIP”
on page 3-12.
Throttle grip free play
3.0–6.0 mm (0.12–0.24 in)

4-40
 FRONT FORK

EAM20100

FRONT FORK
Removing the front fork legs

(2)
2

21 N m (2.1 kgf m, 15 lb ft)

(2)
4

9 N m (0.9 kgf m, 6.6 lb ft)

(3)

5 N m (0.5 kgf m, 3.7 lb ft)

5 N m (0.5 kgf m, 3.7 lb ft)
(3)

Order Job/Parts to remove Q’ty Remarks

Use a maintenance stand to raise the front
wheel off the ground.
Front wheel Refer to “FRONT WHEEL” on page 4-5.
Front brake caliper Refer to “FRONT BRAKE” on page 4-13.
Refer to “GENERAL CHASSIS” on page
Number plate 4-1.
Refer to “HANDLEBAR” on page 4-35 (with
Lower handlebar holder the handlebar holder).
1 Protector 1
2 Upper bracket pinch bolt 2 Loosen.
3 Damper assembly 1 Loosen.
4 Lower bracket pinch bolt 2 Loosen.
5 Front fork leg 1

4-41
 FRONT FORK

Disassembling the front fork leg

30 N m (3.0 kgf m, 22 lb ft)

29 N m (2.9 kgf m, 21 lb ft)

New 9

15

New New
8
16

2
14
10
New 11 New 3
12
1 6
13 New
5
LT LS New
28 N m (2.8 kgf m, 21 lb ft)
4 New
55 N m (5.5 kgf m, 41 lb ft) 1.3 N m (0.13 kgf m, 0.95 lb ft)

Order Job/Parts to remove Q’ty Remarks

1 Adjuster 1
2 Fork spring 1
3 Damper adjusting rod 1
4 Dust seal 1
5 Scraper 1
6 Stopper ring 1
7 Inner tube 1
8 Outer tube 1
9 Piston metal 1
10 Protector guide 1
11 Slide metal 1
12 Washer 1
13 Oil seal 1
14 Base valve 1
15 Damper assembly 1
16 Upper spring seat 1

4-42
 FRONT FORK

EAM30055

REMOVING THE FRONT FORK LEGS

1. Use a maintenance stand to raise the front
wheel off the ground.
EWA13120

Securely support the vehicle so that there is

1
no danger of it falling over. 2

Record the adjusting screw setting position be-

fore loosening the adjuster and the base valve.
2. Remove:
• Lower handlebar holder (with the handlebar)
3. Loosen:
• Upper bracket pinch bolt
• Damper assembly
• Lower bracket pinch bolt
EWA20350

Before loosening the upper and lower brack-

et pinch bolts, support the front fork leg. 4. Remove:
• Front fork leg
• Before removing the front fork leg from the ve- EAM30056

hicle, loosen the damper assembly “1” with DISASSEMBLING THE FRONT FORK LEGS
the cap bolt ring wrench “2”. 1. Drain:
• It is allowed to remove the lower handlebar • Fork oil
holder with the handlebar installed as shown. 2. Remove:
When doing so, make sure that the handlebar • Adjuster “1”
is secured so that it does not move. (from the inner tube)

Cap bolt ring wrench • While compressing the inner tube “2”, set the
90890-01501 cap bolt ring wrench “4” between the inner
Cap bolt ring wrench tube and locknut “3”.
YM-01501 • Hold the locknut and remove the adjuster.
ECA24520

Do not remove the locknut as the damper

rod may go into the damper assembly and
not be taken out.

Cap bolt ring wrench

90890-01501
Cap bolt ring wrench
YM-01501

4-43
 FRONT FORK

Cap bolt wrench

90890-01500
Cap bolt wrench
1 YM-01500
Cap bolt ring wrench
90890-01501
4 Cap bolt ring wrench
3 YM-01501
2
3
3. Remove:
• Dust seal “1” 2
• Stopper ring “2” 1
(with a flat-head screwdriver)
ECA14180

Do not scratch the inner tube.

1
EAM30057

CHECKING THE FRONT FORK LEGS

1. Check:
• Inner tube surface
Scratches  Repair or replace.
Use #1000 grit wet sandpaper.
2 Damaged oil lock piece  Replace.
• Inner tube bends
Out of specification  Replace.
4. Remove: Use the dial gauge.
• Inner tube “1”
a. Push in slowly “a” the inner tube just be- Inner tube bending limit
0.2 mm (0.01 in)
fore it bottoms out and then pull it back
quickly “b”.
b. Repeat this step until the inner tube can The bending value is shown by one half of the
be pulled out from the outer tube. dial gauge reading.
EWA13650

Do not attempt to straighten a bent inner

tube as this may dangerously weaken it.
2. Check:
• Outer tube
Scratches/wear/damage  Replace.
3. Measure:
• Fork spring free length “a”
5. Remove: Out of specification  Replace.
• Base valve “1” Fork spring free length limit
(from the damper assembly) 492.0 mm (19.37 in)

Hold the damper assembly with the cap bolt

ring wrench “2” and use the cap bolt wrench “3”
to remove the base valve.

4-44
 FRONT FORK

2
3
4
2 1

4. Check: 6. Check:
• Damper assembly “1” • Upper spring seat “1”
Bend/damage  Replace. (contacting surface “a”)
• O-ring “2” Wear/damage  Replace.
Wear/damage  Replace.
ECA14200
1
• The front fork leg has a built-in damper ad- a
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
7. Check:
• Adjuster “1”
• O-ring “2”
Wear/damage  Replace.
1
2

1
2
5. Check:
• Base valve “1”
Wear/damage  Replace.
Contamination  Clean.
• O-ring “2” 8. Check:
Wear/damage  Replace. • Scraper “1”
• Base valve bushing Damage  Replace.
Wear/damage  Replace.
• Fork spring “3”
Damage/fatigue  Replace the base valve. 1
• Bleed screw “4”
Wear/damage  Replace.

4-45
 FRONT FORK

EAM30058
4. Measure:
ASSEMBLING THE FRONT FORK LEGS • Oil level (left and right) “a”
EWA13660
Out of specification  Regulate.
• Make sure the oil levels in both front fork Standard oil level
legs are equal. 145–148 mm (5.71–5.83 in)
• Uneven oil levels can result in poor han- From top of fully stretched
dling and a loss of stability. damper assembly.

• When assembling the front fork leg, be sure to

replace the following parts:
• Inner tube bushing
• Slide metal a
• Oil seal
• Copper washer
• 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
Standard oil amount
216 cm³ (7.30 US oz, 7.62
Imp.oz)
ECA24530

• Be sure to use the recommended oil. Other

oils may have an adverse effect on front 5. Tighten:
fork performance. • Locknut “1”
• When disassembling and assembling the
front fork leg, take care not to allow any for- Fully finger tighten the locknut onto the damper
eign material to enter the front fork. assembly.
3. After filling, pump the damper assembly “1”
slowly up and down (about 200 mm (7.9 in)
stroke) several times to bleed the damper as-
sembly of air.

Avoid excessive full stroke. A stroke of 200 mm

(7.9 in) or more will cause air to enter. In this
case, repeat the steps (1) to (3).

6. Loosen:
• Compression damping force adjuster “1”

• Before loosening the damping force adjuster,

1 record the setting position.
• Unless the damping force adjuster is fully
loosened, correct damping characteristic can-

4-46
 FRONT FORK

not be obtained after installation.

3
2
1

10.After filling, pump the damper assembly “1”

slowly up and down more than 10 times to
7. Install:
distribute the fork oil.
• Base valve “1”
(to the damper assembly “2”)

First bring the damper rod pressure to a maxi-

mum. Then install the base valve while releasing
the damper rod pressure.
1
1

11.While protecting the damper assembly “1”

with a cloth and compressing fully, allow ex-
2
cessive oil to overflow on the base valve
side.
ECA24540

8. Check: Take care not to damage the damper assem-

• Damper assembly bly.
Not fully stretched  Repeat the steps (1) to
(7).
9. Tighten:
• Base valve “1”
Base valve
28 N·m (2.8 kgf·m, 21 lb·ft) 1
T.
R.

Hold the damper assembly with the cap bolt

ring wrench “2” and use the cap bolt wrench “3”
to tighten the base valve. 12.Allow the overflowing oil to escape at the
hole “a” in the damper assembly.
Cap bolt wrench
90890-01500 The overflow measures about 10 cm³ (0.34
Cap bolt wrench
US oz, 0.35 Imp.oz).
YM-01500
Cap bolt ring wrench
90890-01501
Cap bolt ring wrench
YM-01501

4-47
 FRONT FORK

a
4 5 6
3
2
1

LS

13.Check:
• Damper assembly smooth movement
Tightness/binding/rough spots  Repeat
the steps (1) to (12).

15.Install:
• Piston metal “1” New

Install the piston metal onto the slot on inner

14.Install: tube.
• Dust seal “1” New
• Scraper “2”
• Stopper ring “3”
• Oil seal “4” New
• Washer “5”
• Slide metal “6” New
(to the inner tube “7”)
ECA24550

Make sure that the numbered side of the oil

seal faces bottom side.
16.Install:
• Apply the lithium-soap-based grease on the • Outer tube “1”
dust seal lip and oil seal lip. (to the inner tube “2”)
• Apply the fork oil on the inner tube.
• Install the scraper to the inner tube as shown
in the illustration.
• When installing the oil seal, use vinyl seat “a”
with fork oil applied to protect the oil seal lip.

17.Install:
• Slide metal “1” New
• Washer “2”

4-48
 FRONT FORK

(to the outer tube) 19.Install:

• Stopper ring “1”
Press the slide metal into the outer tube with
fork seal driver “3”. Fit the stopper ring correctly in the groove in the
outer tube.
Fork seal driver
90890-01502
Fork seal driver (48)
YM-A0948

2 1 New

20.Install:
• Scraper “1”
• Dust seal “2” New

Apply lithium-soap-based grease on the inner

tube.

18.Install:
• Oil seal “1” New
21.Check:
Using a fork seal driver “2”, press the oil seal in • Inner tube smooth movement
until the stopper ring groove fully appears. Tightness/binding/rough spots  Repeat
the steps (14) to (20).
Fork seal driver
90890-01502
Fork seal driver (48)
YM-A0948

22.Measure:
• Distance “a”
Out of specification  Turn the locknut to
specification.

4-49
 FRONT FORK

Distance “a”
16 mm (0.63 in) or more
Between the damper assembly
“1” bottom and locknut “2” bot- 1
tom.

2
25.Loosen:
• Rebound damping force adjuster “1”
2
1 a • Before loosening the damping force adjuster,
record the setting position.
• Unless the damping force adjuster is fully
23.Install: loosened, correct damping characteristic can-
• Upper spring seat “1” not be obtained after installation.
• Fork spring “2”
(to the damper assembly “3”)
1
Install the upper spring seat with its larger dia.
end “a” facing the fork spring.

1 2

26.Install:
• Damper adjusting rod “1”
3 a • Copper washer “2” New
• Adjuster “3”
(to the damper assembly “4”)
24.Install:
• Damper assembly “1” • While compressing the inner tube “5”, set the
(to the inner tube “2”) cap bolt ring wrench “7” between the inner
ECA24560 tube and locknut “6”.
• Fully finger tighten the adjuster onto the
Allow the damper assembly to slide slowly damper assembly.
down the inner tube until it contacts the bot-
tom of the inner tube. Be careful not to dam- Cap bolt ring wrench
age the inner tube. 90890-01501
Cap bolt ring wrench
YM-01501

4-50
 FRONT FORK

29.Install:
• Adjuster “1”
(to the inner tube)
Adjuster
55 N·m (5.5 kgf·m, 41 lb·ft)

T.
R.
LOCTITE®

27.Measure: 1
• Gap “a” between the adjuster “1” and the
locknut “2”
Out of specification  Retighten and read-
just the locknut.
Gap “a” between the adjuster and
the locknut
0.5–1.0 mm (0.02–0.04 in) 30.Fill:
• Front fork leg

If it is installed with a gap out of specification, Recommended oil

Yamaha Suspension Oil S1
correct damping force cannot be obtained.
Standard oil amount
295 cm³ (9.97 US oz, 10.4
1 Imp.oz)
Extent of adjustment
260–365 cm³ (8.79–12.34 US oz,
a 9.17–12.87 Imp.oz)
ECA24570

2 • Be sure to use the recommended oil. Other

oils may have an adverse effect on front
fork performance.
28.Tighten: • When disassembling and assembling the
• Adjuster (damper assembly) “1” front fork leg, do not allow any foreign ma-
terial to enter the front fork.
Adjuster (damper assembly)
29 N·m (2.9 kgf·m, 21 lb·ft)
T.
R.

Hold the locknut “2” and tighten the adjuster.

31.Install:
• Damper assembly “1”
(to the outer tube)

Temporarily tighten the damper assembly.

4-51
 FRONT FORK

Cap bolt ring wrench

90890-01501
Cap bolt ring wrench
YM-01501

32.Install:
• Protector guide “1” 1

2
1

EAM30059

INSTALLING THE FRONT FORK LEGS

1. Install:
• Front fork “1” 3. Adjust:
• Front fork top end “a”
• Temporarily tighten the lower bracket pinch Front fork top end (standard) “a”
bolts. 5 mm (0.20 in)
• Do not tighten the upper bracket pinch bolts
yet.
a

4. Install:
• Lower handlebar holder (with the handlebar)
2. Tighten:
• Damper assembly “1” Lower handlebar holder nut
40 N·m (4.0 kgf·m, 30 lb·ft)
T.
R.

Damper assembly
30 N·m (3.0 kgf·m, 22 lb·ft) 5. Tighten:
T.
R.

• Upper bracket pinch bolt “1”

Use the cap bolt ring wrench “2” to tighten the Upper bracket pinch bolt
damper assembly. 21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.

• Lower bracket pinch bolt “2”

4-52
 FRONT FORK

8. Adjust:
Lower bracket pinch bolt • Compression damping force
T.
R.
21 N·m (2.1 kgf·m, 15 lb·ft)
EWA19320 Turn in the damping adjuster “1” finger-tight
and then turn out to the originally set position.
Tighten the lower bracket to specified
torque. If torqued too much, it may cause the
front fork to malfunction.
1
1

6. Install:
• Protector “1”
• Bolt (protector) “2”
Bolt (protector)
5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
R.

2
7. Adjust:
• Rebound damping force

Turn in the damping adjuster “1” finger-tight

and then turn out to the originally set position.

4-53
 STEERING HEAD

EAM20101

STEERING HEAD
Removing the lower bracket
21 N m (2.1 kgf m, 15 lb ft)

145 N m (14.5 kgf m, 107 lb ft)

5
2
4 LS

LS

6
8

(4) 9
1 10

11
LS

12

9 N m (0.9 kgf m, 6.6 lb ft)

(4) 21 N m (2.1 kgf m, 15 lb ft) 1st 38 N m (3.8 kgf m, 28 lb ft)

10 N m (1.0 kgf m, 7.4 lb ft) 2nd 7 N m (0.7 kgf m, 5.2 lb ft)

Order Job/Parts to remove Q’ty Remarks

Use a maintenance stand to raise the front
wheel off the ground.
Refer to “GENERAL CHASSIS” on page
Number plate
4-1.
Handlebar Refer to “HANDLEBAR” on page 4-35.
1 Front fender 1
2 Steering stem nut 1
3 Front fork leg 2 Refer to “FRONT FORK” on page 4-41.
4 Warning light (engine trouble) 1 Br–Y/W
5 Warning light (fuel level) 1 Br–L/Y
6 Upper bracket 1
7 Steering ring nut 1
8 Lower bracket 1
9 Bearing race cover 1
10 Upper bearing 1
11 Bearing race 2
12 Lower bearing 1

4-54
 STEERING HEAD

EAM30060 ECA14270

REMOVING THE LOWER BRACKET

1. Use a maintenance stand to raise the front If the bearing race is not installed properly,
wheel off the ground. the steering head pipe could be damaged.
EWA13120

Securely support the vehicle so that there is Always replace the bearing and the bearing race
no danger of it falling over. as a set.
2. Remove:
• Ring nut “1”

Remove the ring nut with the steering nut

wrench “2”.

Steering nut wrench

90890-01403
Exhaust flange nut wrench
YU-A9472
EWA13730

Securely support the lower bracket so that

there is no danger of it falling.

4. Check:
• Upper bracket
• Lower bracket
(along with the steering stem)
Bends/cracks/damage  Replace.
EAM30061

CHECKING THE STEERING HEAD EAM30062

1. Wash with kerosene: INSTALLING THE STEERING HEAD

• Bearing 1. Install:
• Bearing race • Lower bearing “1”
2. Check:
• Bearing Apply the lithium-soap-based grease on the
• Bearing race dust seal lip and bearing inner circumference.
Damage/pitting  Replace.
3. Replace:
• Bearing
• Bearing race
a. Remove the bearing race from the steer-
ing head pipe with a long rod “1” and a
hammer.
b. Remove the bearing race from the lower
bracket with a chisel “2” and a hammer.
c. Install a new bearing race.

4-55
 STEERING HEAD

2. Install:
• Bearing race
• Upper bearing “1”
• Bearing race cover “2”

Apply the lithium-soap-based grease on the

bearing and bearing race cover lip.

5. Check the steering stem by turning this lock

to lock. If there is any binding, remove the
steering stem and check the steering bear-
ing.

3. Install:
• Lower bracket “1”

Apply the lithium-soap-based grease on the

bearing, the portion “a” and thread of the steer-
ing stem.

6. Install:
• Washer “1”
LS

a
LS

4. Install:
• Steering ring nut “1”
Steering ring nut 7. Install:
7 N·m (0.7 kgf·m, 5.2 lb·ft) • Front fork “1”
T.
R.

• Upper bracket “2”

Install the steering ring nut with its stepped side • Temporarily tighten the lower bracket pinch
“a” facing downward. bolts.
Tighten the steering ring nut with a steering • Do not tighten the upper bracket pinch bolts
nut wrench “2”. yet.
Refer to “CHECKING AND ADJUSTING THE
STEERING HEAD” on page 3-28.

4-56
 STEERING HEAD

Upper bracket pinch bolt

21 N·m (2.1 kgf·m, 15 lb·ft)

T.
R.
• Lower bracket pinch bolt “2”
Lower bracket pinch bolt
21 N·m (2.1 kgf·m, 15 lb·ft)

T.
R.
EWA19330

Tighten the lower bracket to specified

8. Install: torque. If torqued too much, it may cause the
• Steering stem nut “1” front fork to malfunction.
Steering stem nut
145 N·m (14.5 kgf·m, 107 lb·ft) 1
T.
R.

Apply the lithium-soap-based grease to the

contact surface of the steering stem nut when 2
installing.

9. After tightening the nut, check the steering

for smooth movement. If not, adjust the
steering by loosening the steering ring nut lit-
tle by little.
10.Adjust:
• Front fork top end “a”
Front fork top end (standard) “a”
5 mm (0.20 in)

11.Tighten:
• Upper bracket pinch bolt “1”

4-57
 REAR SHOCK ABSORBER ASSEMBLY

EAM20102

REAR SHOCK ABSORBER ASSEMBLY

Removing the rear shock absorber assembly
M 56 N m (5.6 kgf m, 41 lb ft)
2
New 3
New

LS
LS
New
M

M
New

7
New
9 6
10 11
4 12
10
5 9 New

M 1
53 N m (5.3 kgf m, 39 lb ft)

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS” on page
Seat 4-1.
Refer to “GENERAL CHASSIS” on page
Side cover (left/right) 4-1.
Refer to “GENERAL CHASSIS” on page
Air scoop (left/right) 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
1 Rear shock absorber assembly lower bolt 1
2 Rear shock absorber assembly upper bolt 1
3 Rear shock absorber assembly 1
4 Locknut 1
5 Adjusting nut 1
6 Lower spring guide 1
7 Upper spring guide 1
8 Spring 1
9 Dust seal 2
10 Collar 2
11 Bushing 1
12 Bearing 1

4-58
 REAR SHOCK ABSORBER ASSEMBLY

Removing the rear shock absorber assembly

M 56 N m (5.6 kgf m, 41 lb ft)

14 New
15 New
13 LS
16 New
LS 17
14
M 13

M
15
New

New

New

M
53 N m (5.3 kgf m, 39 lb ft)

Order Job/Parts to remove Q’ty Remarks

13 Collar 2
14 O-ring 2
15 Dust seal 2
16 Bushing 1
17 Stopper ring 1

4-59
 REAR SHOCK ABSORBER ASSEMBLY

Disassembling the relay arm

5 4
5
4 6
1 M

5
6
M
5
5 4
80 N m (8.0 kgf m, 59 lb ft)
6 3
5
3
6 6
4
5
4 2
4 M
3
M M

6
M

Order Job/Parts to remove Q’ty Remarks

1 Relay arm 1
2 Connecting arm 1
3 Collar 3
4 Oil seal 6
5 Washer 8
6 Bearing 6

4-60
 REAR SHOCK ABSORBER ASSEMBLY

EAM30063 EWA13120

HANDLING THE REAR SHOCK ABSORBER

EWA13740
Securely support the vehicle so that there is
no danger of it falling over.
This rear shock absorber contains highly
compressed nitrogen gas. Before handling 2. Remove:
the rear shock absorber, read and make sure • Rear shock absorber assembly lower bolt
you understand the following information. “1”
The manufacturer cannot be held responsi-
ble for property damage or personal injury While removing the rear shock absorber assem-
that may result from improper handling of bly lower bolt, hold the swingarm so that it does
the rear shock absorber. not drop down.
• Do not tamper or attempt to open the rear
shock absorber.
• Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion due
to excessive gas pressure.
• Do not deform or damage the rear shock
absorber in any way. Rear shock absorber
damage will result in poor damping perfor-
mance.

A break-in is required up to about 50 km of run-

ning.

EAM30064

DISPOSING OF A REAR SHOCK ABSORBER

Before disposing the rear shock absorber, be
sure to extract the nitrogen gas from valve “1”.
EWA19340

• Wear protective glasses to prevent your 1

eyes from damage due to possible gas or
metal chips scattered. 3. Remove:
• To dispose of a damaged or a worn-out • Rear shock absorber assembly upper bolt
rear shock absorber, take the unit to your • Rear shock absorber assembly
Yamaha dealer for this disposal procedure. EAM30067

CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY
1. Check:
• Rear shock absorber rod
Bends/damage  Replace the rear shock
absorber assembly.
1 • Rear shock absorber
Gas leaks/oil leaks  Replace the rear shock
absorber assembly.
• Spring
Damage/wear  Replace.
EAM30065 • Spring guide
REMOVING THE REAR SHOCK ABSORBER Damage/wear  Replace.
ASSEMBLY • Bearing
1. Use a maintenance stand to raise the rear Damage/wear  Replace.
wheel off the ground. • Bolt

4-61
 REAR SHOCK ABSORBER ASSEMBLY

Bends/damage/wear  Replace.
EAM30068
a
CHECKING THE CONNECTING ARM AND
RELAY ARM
1. Check:
• Connecting arm 1
• Relay arm
Damage/wear  Replace.
2. Check: 3 4 3
• Bearing
• Collar 2 2
Damage/pitting/scratches  Replace the
bearings and collars as a set. 1 1
3. Check:
• Oil seal 2 2
Damage/pitting  Replace.
3 5 3
EAM30069

INSTALLING THE RELAY ARM

1. Lubricate:
• Oil seal
• Bearing EAM30625
• Washer INSTALLING THE CONNECTING ARM
• Collar 1. Install:
Recommended lubricant • Bearing “1”
Molybdenum disulfide grease • Oil seal “2” New
(into the connecting arm “3”)
2. Install: • Collar “4”
• Bearing “1”
Installed depth “a”
• Washer “2” 0 mm (0 in)
• Oil seal “3” New
(into the relay arm “4”)
• Collar “5”
Installed depth “a”
0 mm (0 in) 1

4 3
2

4-62
 REAR SHOCK ABSORBER ASSEMBLY

EAM30070

INSTALLING THE REAR SHOCK ABSORBER

ASSEMBLY 2 3 4
1. Lubricate:
• Bearing (lower side) a
• Dust seal
1
Recommended lubricant a
Molybdenum disulfide grease
ECA24580

Do not apply the grease to the bearing outer 5. Lubricate:

race because it will wear the rear shock ab- • Connecting arm and frame bolt
sorber surface on which the bearing is press • Relay arm and connecting arm bolt
fitted. • Relay arm and swingarm bolt
(circumference and threaded portion)
2. Lubricate: • Rear shock absorber assembly upper bolt
• O-ring • Rear shock absorber assembly lower bolt
Recommended lubricant Recommended lubricant
Lithium-soap-based grease Molybdenum disulfide grease
3. Install: 6. Install:
• Bushing • Rear shock absorber assembly
• Stopper ring
(into the rear shock absorber assembly (up- • When installing the rear shock absorber as-
per side)) sembly, lift up the swingarm.
• Install the rear shock absorber assembly up-
• Install the bushing parallel until the stopper per bolt, and connecting arm bolt (frame side)
ring groove appears by pressing its outer race. from the right.
• After installing the stopper ring, push back the • Install the rear shock absorber assembly lower
bushing until it contacts the stopper ring. bolts, connecting arm bolt (relay arm side),
4. Install: and relay arm bolt (swingarm side) from the
• Bearing “1” left.
• Bushing “2” 7. Tighten:
• Collar “3” • Rear shock absorber assembly upper nut
• Dust seal “4” New
(into the rear shock absorber assembly (low- Rear shock absorber assembly
er side)) upper nut
T.
R.

56 N·m (5.6 kgf·m, 41 lb·ft)

Install the dust seals with their lips facing in-
ward. • Connecting arm nut (frame side)
Connecting arm nut (frame side)
Installed depth “a” 80 N·m (8.0 kgf·m, 59 lb·ft)
T.

0.3 mm (0.01 in) or more

R.

• Connecting arm nut (relay arm side)

Connecting arm nut (relay arm
side)
T.
R.

80 N·m (8.0 kgf·m, 59 lb·ft)

• Relay arm nut (swingarm side)

4-63
 REAR SHOCK ABSORBER ASSEMBLY

Relay arm nut (swingarm side)

T.
R.
70 N·m (7.0 kgf·m, 52 lb·ft)

• Rear shock absorber assembly lower nut

Rear shock absorber assembly
lower nut
T.
R.

53 N·m (5.3 kgf·m, 39 lb·ft)

4-64
 SWINGARM

EAM20103

SWINGARM
Removing the swingarm

70 N m (7.0 kgf m, 52 lb ft)

7 N m (0.7 kgf m, 5.2 lb ft)

2
1 3
6

6 6
4 3
1

2
4
5

4.0 N m (0.40 kgf m, 3.0 lb ft)

Order Job/Parts to remove Q’ty Remarks

Use a maintenance stand to raise the rear
wheel off the ground.
Brake hose holder Refer to “REAR BRAKE” on page 4-24.
Rear brake caliper Refer to “REAR BRAKE” on page 4-24.
Bolt (brake pedal) Refer to “ENGINE REMOVAL” on page 5-6.
Drive chain Refer to “CHAIN DRIVE” on page 4-68.
1 Collar 2
2 Oil seal 2
3 Thrust bearing 2
4 Bushing 2
5 Oil seal 2
6 Bearing 4

4-65
 SWINGARM

EAM30071
• Bushing
REMOVING THE SWINGARM • Collar
1. Use a maintenance stand to raise the rear • Bearing
wheel off the ground. 4. Check:
EWA13120
• Oil seal
Damage  Replace.
Securely support the vehicle so that there is
• Bearing
no danger of it falling over.
• Bushing
2. Measure: Free play exists/unsmooth revolution/rust 
• Swingarm side play Replace bearing and bushing as a set.
• Swingarm vertical movement
EAM30074
a. Measure the tightening torque of the pivot
INSTALLING THE SWINGARM
shaft nut.
1. Lubricate:
Pivot shaft nut • Bearing
85 N·m (8.5 kgf·m, 63 lb·ft) • Thrust bearing
T.
R.

• Collar
b. Check the swingarm side play “a” by • Bushing
moving the swingarm from side to side. If • Oil seal
the swingarm has side-to-side play, • Pivot shaft
check the bushings, the bearings, and the
collars. Recommended lubricant
c. Check the swingarm vertical movement Molybdenum disulfide grease
“b” by moving the swingarm up and
2. Install:
down. • Bearing “1”
If swingarm vertical movement is not
• Oil seal “2” New
smooth or if there is binding, check the
(to the swingarm)
bushings, the bearings, and the collars. • Collar “3”
Installed depth “a”
0–0.5 mm (0–0.02 in)
b Installed depth “b”
6.5 mm (0.26 in)

First install the outer and then the inner bearings

a to a specified depth from inside.

EAM30073

CHECKING THE SWINGARM

1. Check:
• Swingarm
Bends/cracks/damage  Replace.
2. Check:
• Pivot shaft
Roll the pivot shaft on a flat surface.
Bends  Replace.
EWA13770

Do not attempt to straighten a bent pivot

shaft.
3. Wash with kerosene:
• Pivot shaft

4-66
 SWINGARM

2 New 2 New New 2

1 1

3 3

a New 2 a a 2 New a

2 New 1 b b 1 New 2

3. Install:
• Swingarm
Pivot shaft nut
85 N·m (8.5 kgf·m, 63 lb·ft)
T.
R.

Install the pivot shaft from the right.

4. Install:
• Rear wheel
Refer to “REAR WHEEL” on page 4-9.
5. Adjust:
• Drive chain slack
Refer to “DRIVE CHAIN SLACK” on page
3-27.
Drive chain slack (Maintenance
Stand)
50.0–60.0 mm (1.97–2.36 in)

4-67
 CHAIN DRIVE

EAM20104

CHAIN DRIVE
Removing the drive chain

6
5
3 4

75 N m (7.5 kgf m, 55 lb ft)

7 N m (0.7 kgf m, 5.2 lb ft)

Order Job/Parts to remove Q’ty Remarks

Drive sprocket Refer to “ENGINE REMOVAL” on page 5-6.
1 Drive chain 1
2 Drive sprocket cover 1
3 Bracket 1
4 Drive sprocket nut 1
5 Lock washer 1
6 Drive sprocket 1

4-68
 CHAIN DRIVE

EAM30075

REMOVING THE DRIVE CHAIN

1. Stand the vehicle on a level surface.
EWA13120

Securely support the vehicle so that there is

no danger of it falling over.

Place the vehicle on a maintenance stand so

that the rear wheel is elevated.
2. Remove:
• Drive chain • When measuring a 15-link section of the drive
chain, make sure that the drive chain is taut.
Cut the drive chain with the drive chain cut & riv- • Perform this procedure 2–3 times, at a differ-
et tool. (Use goods on the market.) ent location each time.

EAM30076
2. Check:
CHECKING THE DRIVE CHAIN • Drive chain
1. Measure: Stiffness  Clean, lubricate, or replace.
• 15-link section of the drive chain
Out of specification  Replace the drive
chain.
15-link length limit
239.3 mm (9.42 in)

a. Measure the length “a” between the inner

sides of the pins and the length “b” be-
tween the outer sides of the pins on a 15-
link section of the drive chain as shown in
the illustration. 3. Clean:
• Drive chain
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and re-
move any remaining dirt.
c. Remove the drive chain from the kero-
sene and completely dry it.
ECA19090

• This vehicle has a drive chain with small

rubber O-rings “1” between the drive chain
side plates. Never use high-pressure water
b. Calculate the length “c” of the 15-link sec- or air, steam, gasoline, certain solvents
tion of the drive chain using the following (e.g., benzine), or a coarse brush to clean
formula. the drive chain. High-pressure methods
Drive chain 15-link section length “c” = could force dirt or water into the drive
(length “a” between pin inner sides + chain’s internals, and solvents will deterio-
length “b” between pin outer sides)/2 rate the O-rings. A coarse brush can also
damage the O-rings. Therefore, use only
kerosene to clean the drive chain.
• Do not soak the drive chain in kerosene for
more than ten minutes, otherwise the O-
rings can be damaged.

4-69
 CHAIN DRIVE

b. Correct

1. Drive chain roller

2. Drive sprocket
EAM30078

CHECKING THE REAR WHEEL SPROCKET

Refer to “CHECKING AND REPLACING THE
REAR WHEEL SPROCKET” on page 4-10.
EAM30079

INSTALLING THE DRIVE CHAIN

4. Check:
1. Install:
• O-ring “1”
• Drive chain
Damage  Replace the drive chain. ECA17410

• Drive chain roller “2”

Damage/wear  Replace the drive chain. Be sure to put on safety goggles when work-
• Drive chain side plate “3” ing.
Damage/wear  Replace the drive chain.

Install the master link with the drive chain cut &
rivet tool. (Use goods on the market.)
a. When press fitting the master link plate
“1”, make sure the space “a” between the
end of the connecting pin “2” and the
master link plate is 1.2–1.4 mm (0.05–0.06
in).

5. Lubricate:
• Drive chain
Recommended lubricant
Chain lubricant suitable for O-
ring chains

EAM30077

CHECKING THE DRIVE SPROCKET

1. Check: b. After riveting, make sure the diameter be-
• Drive sprocket tween the edges “b” of the connecting pin
More than 1/4 tooth wear “a”  Replace the “2” is 5.5–5.8 mm (0.22–0.23 in).
drive sprocket and the rear wheel sprocket
as a set.
Bent tooth  Replace the drive sprocket and
the rear wheel sprocket as a set.

4-70
 CHAIN DRIVE

ECA24590

A drive chain that is too tight will overload

the engine and other vital parts, and one that
is too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep
the drive chain slack within the specified lim-
its.

c. After riveting, make sure the space “c”,

which is inside of the master link “3” and
inside of the master link plate “1”, is 12.1–
12.3 mm (0.476–0.484 in).

2. Lubricate:
• Drive chain
Recommended lubricant
Chain lubricant suitable for O-
ring chains

3. Install:
• Drive sprocket
• Lock washer New
• Drive sprocket nut
Refer to “ENGINE REMOVAL” on page 5-6.
Drive sprocket nut
75 N·m (7.5 kgf·m, 55 lb·ft)
T.
R.

ECA14300

Never install a new drive chain onto worn

drive chain sprockets; this will dramatically
shorten the drive chain’s life.
4. Adjust:
• Drive chain slack
Refer to “DRIVE CHAIN SLACK” on page
3-27.
Drive chain slack (Maintenance
Stand)
50.0–60.0 mm (1.97–2.36 in)

4-71
 CHAIN DRIVE

4-72
 ENGINE

LUBRICATION SYSTEM CHART AND DIAGRAMS ...................................... 5-1

ENGINE OIL LUBRICATION CHART ......................................................... 5-1
LUBRICATION DIAGRAMS ....................................................................... 5-2

ENGINE REMOVAL ......................................................................................... 5-6

1
REMOVING THE ENGINE........................................................................ 5-10
INSTALLING THE ENGINE ...................................................................... 5-10
INSTALLING THE EXHAUST PIPE AND MUFFLER ................................ 5-11
2
CAMSHAFT ................................................................................................... 5-13
REMOVING THE CAMSHAFT.................................................................. 5-15
CHECKING THE CAMSHAFT .................................................................. 5-16
CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET ............ 5-17
CHECKING THE TIMING CHAIN TENSIONERS ..................................... 5-17
3
CHECKING THE DECOMPRESSION SYSTEM....................................... 5-17
INSTALLING THE CAMSHAFTS.............................................................. 5-17

CYLINDER HEAD.......................................................................................... 5-20

4
REMOVING THE CYLINDER HEAD......................................................... 5-22
CHECKING THE TIMING CHAIN GUIDE (INTAKE SIDE)......................... 5-22
CHECKING THE CYLINDER HEAD ......................................................... 5-22
INSTALLING THE CYLINDER HEAD ....................................................... 5-22 5
VALVES AND VALVE SPRINGS .................................................................... 5-25
REMOVING THE VALVES........................................................................ 5-26
CHECKING THE VALVES AND VALVE GUIDES ..................................... 5-27
CHECKING THE VALVE SEATS .............................................................. 5-28
6
CHECKING THE VALVE SPRINGS.......................................................... 5-29
CHECKING THE VALVE LIFTERS ........................................................... 5-30
INSTALLING THE VALVES ...................................................................... 5-30
7
CYLINDER AND PISTON.............................................................................. 5-32
REMOVING THE PISTON ........................................................................ 5-33
CHECKING THE CYLINDER AND PISTON ............................................. 5-33
CHECKING THE PISTON RINGS ............................................................ 5-34
CHECKING THE PISTON PIN ................................................................. 5-34
8
INSTALLING THE PISTON AND CYLINDER ........................................... 5-35

GENERATOR ................................................................................................. 5-37

REMOVING THE GENERATOR ............................................................... 5-38
9
CHECKING THE GENERATOR................................................................ 5-38
CHECKING THE WOODRUFF KEY ......................................................... 5-38
INSTALLING THE GENERATOR.............................................................. 5-38

STARTER CLUTCH ....................................................................................... 5-40

10
REMOVING THE STARTER CLUTCH...................................................... 5-41
 CHECKING THE STARTER CLUTCH ...................................................... 5-41
INSTALLING THE STARTER CLUTCH .................................................... 5-41

ELECTRIC STARTER .................................................................................... 5-43

CHECKING THE STARTER MOTOR ....................................................... 5-45
ASSEMBLING THE STARTER MOTOR ................................................... 5-45

CLUTCH ........................................................................................................ 5-47

REMOVING THE CLUTCH....................................................................... 5-50
CHECKING THE FRICTION PLATES....................................................... 5-50
CHECKING THE CLUTCH PLATES......................................................... 5-50
CHECKING THE CLUTCH SPRINGS ...................................................... 5-50
CHECKING THE CLUTCH HOUSING ..................................................... 5-50
CHECKING THE CLUTCH BOSS ............................................................ 5-51
CHECKING THE PRESSURE PLATE....................................................... 5-51
CHECKING THE PUSH LEVER SHAFT ................................................... 5-51
CHECKING THE PUSH RODS ................................................................ 5-51
CHECKING THE PRIMARY DRIVE GEAR ............................................... 5-51
CHECKING THE PRIMARY DRIVEN GEAR............................................. 5-51
INSTALLING THE CLUTCH ..................................................................... 5-51

SHIFT SHAFT ................................................................................................ 5-55

REMOVING THE SEGMENT.................................................................... 5-56
CHECKING THE SHIFT SHAFT ............................................................... 5-56
CHECKING THE STOPPER LEVER......................................................... 5-56
INSTALLING THE SHIFT SHAFT ............................................................. 5-56

OIL PUMP...................................................................................................... 5-59

REMOVING THE BALANCER .................................................................. 5-61
CHECKING THE OIL PUMP .................................................................... 5-62
ASSEMBLING THE OIL PUMP ................................................................ 5-62
INSTALLING THE OIL PUMP .................................................................. 5-62

CRANKCASE................................................................................................. 5-65
DISASSEMBLING THE CRANKCASE ..................................................... 5-67
CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE)..................... 5-67
CHECKING THE CRANKCASE................................................................ 5-67
ASSEMBLING THE CRANKCASE ........................................................... 5-68

CRANKSHAFT AND BALANCER SHAFT .................................................... 5-69

REMOVING THE CRANKSHAFT ............................................................. 5-70
CHECKING THE CRANKSHAFT.............................................................. 5-70
INSTALLING THE CRANKSHAFT............................................................ 5-71

TRANSMISSION............................................................................................ 5-72
REMOVING THE TRANSMISSION .......................................................... 5-73
CHECKING THE SHIFT FORKS .............................................................. 5-73
CHECKING THE SHIFT DRUM ASSEMBLY............................................ 5-73
CHECKING THE TRANSMISSION........................................................... 5-74
INSTALLING THE TRANSMISSION......................................................... 5-74
 LUBRICATION SYSTEM CHART AND DIAGRAMS

EAM20185

LUBRICATION SYSTEM CHART AND DIAGRAMS

EAM30526

ENGINE OIL LUBRICATION CHART

1. Intake camshaft
2. Exhaust camshaft
3. Piston
4. Oil filter element
5. Oil nozzle
6. Relief valve
7. Oil pump
8. Oil strainer
9. Crankshaft
10.Drive axle
11.Main axle

5-1
 LUBRICATION SYSTEM CHART AND DIAGRAMS

EAM30507

LUBRICATION DIAGRAMS

1. Connecting rod
2. Crankshaft
3. Main axle
4. Oil strainer
5. Drive axle

5-2
 LUBRICATION SYSTEM CHART AND DIAGRAMS

1. Oil filter element

2. Oil pump

5-3
 LUBRICATION SYSTEM CHART AND DIAGRAMS

1. Intake camshaft
2. Exhaust camshaft

5-4
 LUBRICATION SYSTEM CHART AND DIAGRAMS

1. Camshaft
2. Oil pressure check bolt
3. Oil pump
4. Oil filter element

5-5
 ENGINE REMOVAL

EAM20105

ENGINE REMOVAL
Removing the exhaust pipe

9 1st 7 N m (0.7 kgf m, 5.2 lb ft)

2nd 10 N m (1.0 kgf m, 7.4 lb ft)

10 N m (1.0 kgf m, 7.4 lb ft)

20 N m (2.0 kgf m, 15 lb ft)

LT

(8)
5
8
7
LT

(6)
6
8 N m (0.8 kgf m, 5.9 lb ft) New
30 N m (3.0 kgf m, 22 lb ft)

New 6
2
30 N m (3.0 kgf m, 22 lb ft)
1
3
12 N m (1.2 kgf m, 8.9 lb ft) New 6
4
12 N m (1.2 kgf m, 8.9 lb ft)

Order Job/Parts to remove Q’ty Remarks

Refer to “INSTALLING THE EXHAUST PIPE
AND MUFFLER” on page 5-11.
Refer to “GENERAL CHASSIS” on page
Side cover (right) 4-1.
1 Silencer clamp 1 Loosen.
2 Silencer 1
3 Exhaust pipe 2 clamp 1 Loosen.
4 Exhaust pipe 2 1
5 Exhaust pipe 1 1
6 Gasket 3
7 Exhaust pipe 1 protector 1
8 Silencer body 1
9 Silencer cap 1

5-6
 ENGINE REMOVAL

Removing the electronic parts

(2) 3 2

7 N m (0.7 kgf m, 5.2 lb ft)

LT
5
(2)

3.5 N m (0.35 kgf m, 2.6 lb ft)

Order Job/Parts to remove Q’ty Remarks

Use a maintenance stand to raise the front
wheel off the ground.
Refer to “GENERAL CHASSIS” on page
Seat 4-1.
Refer to “GENERAL CHASSIS” on page
Side cover (left/right) 4-1.
Refer to “GENERAL CHASSIS” on page
Air scoop (left/right) 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Refer to “CLEANING THE AIR FILTER ELE-
Air filter case cover MENT” on page 3-16.
Intake air temperature sensor coupler Refer to “THROTTLE BODY” on page 7-4.
ECU (Engine Control Unit) Refer to “THROTTLE BODY” on page 7-4.
Ignition coil Refer to “THROTTLE BODY” on page 7-4.
1 Rectifier/regulator 1
2 Stator coil assembly coupler 1 Disconnect.
3 Crankshaft position sensor coupler 1 Disconnect.
4 Coolant temperature sensor coupler 1
5 Gear position switch 1

5-7
 ENGINE REMOVAL

Removing the engine

34 N m (3.4 kgf m, 25 lb ft)
85 N m (8.5 kgf m, 63 lb ft)
26 N m (2.6 kgf m, 19 lb ft)

53 N m (5.3 kgf m, 39 lb ft)

3

2
55 N m (5.5 kgf m, 41 lb ft)
45 N m (4.5 kgf m, 33 lb ft)

75 N m (7.5 kgf m, 55 lb ft)

34 N m (3.4 kgf m, 25 lb ft)

6
1 5
4 7

7 N m (0.7 kgf m, 5.2 lb ft) 34 N m (3.4 kgf m, 25 lb ft) 7 N m (0.7 kgf m, 5.2 lb ft)

Order Job/Parts to remove Q’ty Remarks

Use a maintenance stand to raise the front
wheel off the ground.
Refer to “GENERAL CHASSIS” on page
Seat 4-1.
Refer to “GENERAL CHASSIS” on page
Side cover (left/right) 4-1.
Refer to “GENERAL CHASSIS” on page
Air scoop (left/right) 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Exhaust pipe/Silencer Refer to “ENGINE REMOVAL” on page 5-6.
Air filter case Refer to “THROTTLE BODY” on page 7-4.
Throttle body Refer to “THROTTLE BODY” on page 7-4.
Clutch cable Refer to “CLUTCH” on page 5-47.
Refer to “SHIFT SHAFT” on page 5-55.
Shift pedal/Drive chain Refer to “CHAIN DRIVE” on page 4-68.
1 Engine guard 1
2 Brake pedal 1
3 Spring 1
4 Cylinder head breather hose 1
5 Drive sprocket cover 1
6 Drive chain guide 1
7 Drive sprocket 1

5-8
 ENGINE REMOVAL

Removing the engine

34 N m (3.4 kgf m, 25 lb ft) 85 N m (8.5 kgf m, 63 lb ft)
26 N m (2.6 kgf m, 19 lb ft)
12

53 N m (5.3 kgf m, 39 lb ft)

55 N m (5.5 kgf m, 41 lb ft)

45 N m (4.5 kgf m, 33 lb ft)

11 8

10 75 N m (7.5 kgf m, 55 lb ft)

34 N m (3.4 kgf m, 25 lb ft) 9

13
11

10
7 N m (0.7 kgf m, 5.2 lb ft) 34 N m (3.4 kgf m, 25 lb ft) 7 N m (0.7 kgf m, 5.2 lb ft)

Order Job/Parts to remove Q’ty Remarks

8 Upper engine bracket (right) 1
9 Upper engine bracket (left) 1
10 Lower engine bracket (outside) 2
11 Lower engine bracket (inside) 2
12 Pivot shaft 1
13 Engine 1

5-9
 ENGINE REMOVAL

EAM30161

REMOVING THE ENGINE

1. Remove:
• Exhaust pipe 2 1

Put the exhaust pipe 2 into the state as shown

by moving this, and then remove it.

2. Remove:
• Pivot shaft “1”
EAM30164
If the pivot shaft is pulled all the way out, the
INSTALLING THE ENGINE
swingarm will come loose. If possible, insert a
1. Install:
shaft of similar diameter into the other side of
• Engine “1”
the swingarm to support it.
(from the right side)
• Pivot shaft “2”
1 Pivot shaft nut
85 N·m (8.5 kgf·m, 63 lb·ft)
T.
R.

• Engine mounting bolt (lower side) “3”

Engine mounting nut (lower side)
53 N·m (5.3 kgf·m, 39 lb·ft)
T.
R.

• Lower engine bracket (inside) “4”

• Lower engine bracket (outside) “5”
3. Remove: • Engine bracket bolt (front side) “6”
• Engine “1”
(from the right side) Engine bracket bolt (front side)
34 N·m (3.4 kgf·m, 25 lb·ft)
T.
R.

• Make sure that the couplers, the hoses, and

the cables are disconnected. • Engine mounting bolt (front side) “7”
• Lift up the engine, and remove this from its Engine mounting nut (front side)
lower part toward the right of the chassis. 55 N·m (5.5 kgf·m, 41 lb·ft)
T.
R.

• Upper engine bracket “8”

• Engine bracket bolt (upper side) “9”
Engine bracket bolt (upper side)
34 N·m (3.4 kgf·m, 25 lb·ft)
T.
R.

• Engine mounting bolt (upper side) “10”

5-10
 ENGINE REMOVAL

2. Install:
Engine mounting bolt (upper side) • Clamp
45 N·m (4.5 kgf·m, 33 lb·ft)
• Exhaust pipe 2 “1”
T.
R.

• Bolt (exhaust pipe 2) “2”

Apply molybdenum disulfide grease to the pivot
shaft. 2

2 9
1

10 Install and temporarily tighten the exhaust pipe

2 and silencer with its end positioned as shown
8 9 with respect to the exhaust pipe 1 and 2.
3
6 2 mm (0.08 in)
5
4
8 10
7
1
4
5 6
EAM30167
3. Install:
INSTALLING THE EXHAUST PIPE AND
• Clamp
MUFFLER
• Silencer “1”
1. Install:
• Bolt (silencer) “2”
• Gasket New
• Exhaust pipe 1 “1” Bolt (silencer)
• Nut (exhaust pipe 1) “2” 30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.

Nut (exhaust pipe 1)

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

First temporarily tighten all nuts to 7 N·m (0.7 2

kgf·m, 5.2 lb·ft). Then retighten them to 10 N·m
(1.0 kgf·m, 7.4 lb·ft).

Install and temporarily tighten the silencer so

1 that its joint is positioned as shown with respect
to the exhaust pipe 2.

5-11
 ENGINE REMOVAL

2 mm (0.08 in)

4. Tighten:
• Bolt (exhaust pipe 2)
Bolt (exhaust pipe 2)
20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.

• Clamp “1”
Clamp
12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.

• Tighten while checking that their front and rear

joints are inserted in position.
• Make sure that the exhaust pipe clamp “1”
does not ride on the projection “a” on the ex-
haust pipe “2” or silencer “3”. Be sure to insert
the projection “b” into the slot in the exhaust
pipe (or silencer).

A B
2 1 3 1
a a

b b
A. Exhaust pipe 1 and exhaust pipe 2
B. Exhaust pipe 2 and silencer

5-12
 CAMSHAFT

EAM20106

CAMSHAFT
Removing the cylinder head cover
13 N m (1.3 kgf m, 9.6 lb ft)
2

10 N m (1.0 kgf m, 7.4 lb ft)

4
5
1

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS” on page
Seat 4-1.
Refer to “GENERAL CHASSIS” on page
Side cover (left/right) 4-1.
Refer to “GENERAL CHASSIS” on page
Air scoop (left/right) 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Ignition coil Refer to “ENGINE REMOVAL” on page 5-6.
1 Cylinder head breather hose 1
2 Spark plug 1
3 Cylinder head cover 1
4 Timing chain guide (top side) 1
5 Cylinder head cover gasket 1

* Yamaha bond No. 1215 (Three bond No.1215®)

5-13
 CAMSHAFT

Removing the camshaft

(4) 10 N m (1.0 kgf m, 7.4 lb ft)

10 N m (1.0 kgf m, 7.4 lb ft)
E 5

(4)
6
8 E
5 E
6 N m (0.6 kgf m, 4.4 lb ft)
6
M
7
4

3
M
10 N m (1.0 kgf m, 7.4 lb ft)
LS

6 N m (0.6 kgf m, 4.4 lb ft)

10 N m (1.0 kgf m, 7.4 lb ft)

E
1

2
Order Job/Parts to remove Q’ty Remarks
1 Timing mark accessing screw 1
2 Crankshaft end accessing screw 1
3 Timing chain tensioner cap bolt 1
4 Timing chain tensioner 1
5 Camshaft cap 2
6 Clip 2
7 Intake camshaft 1
8 Exhaust camshaft 1

5-14
 CAMSHAFT

EAM30080

REMOVING THE CAMSHAFT

1. Remove:
2
• Timing mark accessing screw “1”
• Crankshaft end accessing screw “2”

4. Remove:
1 • Bolt (camshaft cap) “1”
• Camshaft cap “2”
2 • Clip “3”
2. Align: • Remove the bolts (camshaft cap) in a criss-
• Alignment mark cross pattern, working from the outside in.
a. Turn the crankshaft counterclockwise • In order to prevent the clip from falling into the
with a wrench. crankcase, remove the camshaft cap.
b. Align the top dead center (TDC) mark “a”
ECA24610
on the generator rotor with the alignment
mark “b” on the crankcase cover.
The bolts (camshaft cap) must be removed
Align the alignment mark “c” on the exhaust evenly to prevent damage to the cylinder
camshaft sprocket and the alignment mark “d” head, camshafts or camshaft caps.
on the intake camshaft sprocket with the edge
of the cylinder head. 1

3
d c

5. Remove:
• Exhaust camshaft “1”
• Intake camshaft “2”
3. Remove:
• Timing chain tensioner cap bolt “1” Attach a wire “3” to the timing chain to prevent
• Timing chain tensioner “2” it from falling into the crankcase.
• Gasket

5-15
 CAMSHAFT

2 1
1

EAM30081 c. Install the dowel pins and the camshaft

CHECKING THE CAMSHAFT caps.
1. Check:
• Camshaft lobe • Tighten the camshaft cap bolts in a crisscross
Blue discoloration/pitting/scratches  Re- pattern from innermost to outer caps.
place the camshaft. • Do not turn the camshaft when measuring the
2. Measure: camshaft journal-to-camshaft cap clearance.
• Camshaft lobe dimensions “A”
Out of specification  Replace the cam- Camshaft cap bolt
shaft. 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
Camshaft lobe dimensions
d. Remove the camshaft caps and then
Lobe height limit (Intake)
32.130 mm (1.2650 in) measure the width of the Plastigauge®
Lobe height limit (Exhaust) “1”.
33.460 mm (1.3173 in)

4. Measure:
• Camshaft journal diameter “a”
3. Measure: Out of specification  Replace the cam-
• Camshaft-journal-to-camshaft-cap clear- shaft.
ance Within specification  Replace the cylinder
Out of specification  Measure the cam- head and the camshaft caps as a set.
shaft journal diameter.
Camshaft journal diameter
Camshaft-journal-to-camshaft- 21.959–21.972 mm (0.8645–
cap clearance 0.8650 in)
0.028–0.062 mm (0.0011–0.0024
in)

a. Install the camshaft into the cylinder head.

b. Position a strip of Plastigauge® “1” onto
the camshaft journal as shown.

5-16
 CAMSHAFT

EAM30082

CHECKING THE TIMING CHAIN AND

CAMSHAFT SPROCKET
1. Check:
• Timing chain “1”
Damage/stiffness  Replace the timing
chain and camshaft as a set.
2. Check:
• Camshaft sprocket
More than 1/4 tooth wear “a”  Replace the
camshaft and the timing chain as a set. EAM30084

CHECKING THE DECOMPRESSION

SYSTEM
a 1 1. Check:
• Decompression system
a. Check that the decompressor cam “1”
b 2 moves smoothly.
b. Check that the decompressor lever pin
“2” projects from the camshaft.

a. 1/4 tooth
b. Correct 1
1. Timing chain roller
2. Camshaft sprocket 2
EAM30083

CHECKING THE TIMING CHAIN

TENSIONERS
1. Check: EAM30085

• Timing chain tensioner INSTALLING THE CAMSHAFTS

Crack/damage  Replace. 1. Install:
a. While pressing the tensioner rod lightly • Exhaust camshaft “1”
with your fingers, use a thin screwdriver • Intake camshaft “2”
“1” to wind the tensioner rod up fully
clockwise.
b. When releasing the screwdriver by press-
ing lightly with your fingers, make sure
that the tensioner rod will come out
smoothly.
c. If not, replace the tensioner assembly.

5-17
 CAMSHAFT

2 1 3
d c

E
M

a. Turn the crankshaft counterclockwise ECA24620

with a wrench.
Do not turn the crankshaft during the cam-
• Apply molybdenum disulfide oil to the cam- shaft installation. Damage or improper valve
shafts. timing will result.
• Apply the engine oil on the decompression d. Install the clips, the camshaft caps and
system. the bolts (camshaft cap).
• Fill the cylinder head with engine oil up to the
tops “a” of the valve lifters. Bolt (camshaft cap)
10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.
R.
a a a
• Before installing the clips, cover the cylinder
head with a clean cloth to prevent the clips
from coming off into the cylinder head cavity.
• Apply the engine oil to the threads and contact
surfaces.
• Tighten the bolts to the specified torque in two
or three steps in the proper tightening se-
quence as shown.
b. Align the top dead center (TDC) mark “a” ECA24630

on the generator rotor with the alignment

mark “b” on the crankcase cover. The bolts (camshaft cap) must be tightened
evenly, or damage to the cylinder head, cam-
b shaft caps, and camshaft will result.

a 3 4 8 7

1 2 6 5

c. Fit the timing chain “3” onto both cam- E

shaft sprockets and install the camshafts
on the cylinder head.
2. Install:
• Timing chain tensioner
Make sure that the alignment mark “c” on the a. While pressing the tensioner rod lightly
exhaust camshaft sprocket and the alignment with your fingers, use a thin screwdriver to
mark “d” on the intake camshaft sprocket are wind the tensioner rod up fully clockwise.
aligned with the edge of the cylinder head.

5-18
 CAMSHAFT

Align with the crankcase alignment mark.

• Camshaft match marks
Align with the cylinder head surface.
Out of alignment  Adjust.
5. Install:
• Timing chain guide (top side) “1”
• Cylinder head cover gasket “2” New
• Cylinder head cover “3”
• Bolt (cylinder head cover) “4”
Bolt (cylinder head cover)
b. With the tensioner rod fully wound and the 10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.
R.
chain tensioner “UP” mark “a” facing up-
ward, install the gasket “1”, the timing
chain tensioner “2” and tighten the bolts Before installation, apply the sealant to the cyl-
“3”. inder head cover gasket.

Bolt (timing chain tensioner) Yamaha bond No. 1215

10 N·m (1.0 kgf·m, 7.4 lb·ft) 90890-85505
T.
R.

Three bond No. 1215®

a
4
3

1 3 1
2
3 2

c. Release the screwdriver, check that the

tensioner rod comes out smoothly, and
6. Install:
tighten the gasket “4” and the cap bolt
• Cylinder head breather hose
“5”.
• Spark plug
Timing chain tensioner cap bolt
Spark plug
6 N·m (0.6 kgf·m, 4.4 lb·ft)
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.

T.
R.

5
3. Turn:
• Crankshaft
Counterclockwise several turns.
4. Check:
• Top dead center (TDC) mark on the genera-
tor rotor

5-19
 CYLINDER HEAD

EAM20107

CYLINDER HEAD
Removing the cylinder head

1st 30 N m (3.0 kgf m, 22 lb ft)

2nd 15 N m (1.5 kgf m, 11 lb ft)
3rd 60˚
M 4th 60˚

10 N m (1.0 kgf m, 7.4 lb ft)

(2)

10 N m (1.0 kgf m, 7.4 lb ft)

Order Job/Parts to remove Q’ty Remarks

Refer to “INSTALLING THE CYLINDER
HEAD” on page 5-22.
Refer to “GENERAL CHASSIS” on page
Seat 4-1.
Refer to “GENERAL CHASSIS” on page
Side cover (left/right) 4-1.
Refer to “GENERAL CHASSIS” on page
Air scoop (left/right) 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Exhaust pipe/Silencer Refer to “ENGINE REMOVAL” on page 5-6.
Radiator hose Disconnect.
Coolant temperature sensor coupler Disconnect.
Throttle body Refer to “THROTTLE BODY” on page 7-4.
Camshaft Refer to “CAMSHAFT” on page 5-13.
Upper engine bracket Refer to “ENGINE REMOVAL” on page 5-6.
1 Nut (cylinder head) 2
2 Bolt (cylinder head) 3
3 Bolt (cylinder head) 1
4 Cylinder head 1
5 Cylinder head gasket 1

5-20
 CYLINDER HEAD

Removing the cylinder head

1st 30 N m (3.0 kgf m, 22 lb ft)

2nd 15 N m (1.5 kgf m, 11 lb ft)
3rd 60˚
M 4th 60˚

10 N m (1.0 kgf m, 7.4 lb ft) 7

(2)

10 N m (1.0 kgf m, 7.4 lb ft)

Order Job/Parts to remove Q’ty Remarks

6 Timing chain guide (intake side) 1
7 Oil passage plug 1

5-21
 CYLINDER HEAD

EAM30086
page 5-28.
REMOVING THE CYLINDER HEAD
1. Remove: • Cylinder head coolant passages
• Cylinder head bolt and nut Mineral deposits/rust  Eliminate.
3. Measure:
• Loosen the bolts in the proper sequence as • Cylinder head warpage
shown. Out of specification  Resurface the cylin-
• Loosen each bolt 1/2 of a turn at a time. After der head.
fully loosening all the bolts, remove them.
Warpage limit
• M9 × 135 mm (5.31 in): [4], [5], [6] 0.05 mm (0.0020 in)
• M9 × 145 mm (5.71 in): [3]
a. Place a straightedge and a thickness
gauge across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cyl-
inder head as follows.
d. Place a 400–600 grit wet sandpaper on a
surface plate, and resurface the cylinder
FWD
head using a figure-eight sanding pattern.
x2 x3 x1
To ensure an even surface, turn the cylinder
head several times.

4
1 5

2 3
6

EAM30087

CHECKING THE TIMING CHAIN GUIDE

EAM30089
(INTAKE SIDE)
INSTALLING THE CYLINDER HEAD
1. Check:
1. Install:
• Timing chain guide (intake side)
• Timing chain guide (intake side) “1”
Damage/wear  Replace.
• Dowel pin “2”
EAM30088 • Cylinder head gasket “3” New
CHECKING THE CYLINDER HEAD • Cylinder head “4”
1. Eliminate:
• Combustion chamber carbon deposits • While pulling up the timing chain, install the
timing chain guide (intake side) and the cylin-
Use a rounded scraper, not a sharp instrument, der head.
in order not to damage or scratch the spark plug • Install the cylinder head gasket as shown in
bore threads. the illustration.
2. Check:
• Cylinder head
Damage/scratches  Replace.

When replacing the cylinder head, replace also

the valve.
Refer to “CHECKING THE VALVE SEATS” on

5-22
 CYLINDER HEAD

2 4
3

1
2
FWD

x2 x3 x1

2. Install:
• Washer “1” 3
• Bolt (M9 × 145 mm (5.71 in)) “2” 2
5
• Bolt (M9 × 135 mm (5.31 in)) “3”
• Nut “4”
2 6 4
3 1
3

M 1
e. Remove the one bolt according to the
tightening order of the bolts.
f. Again apply molybdenum disulfide grease
4 to the threads and contact surfaces of the
(2) bolts and to both contact surfaces of the
washers.
g. Retighten the bolts.
• Tighten the bolts using the following proce-
dure. Do not remove the other bolts. Only remove the
• Repeat steps (e) to (j) for each bolt one at a bolts one at a time according to the tightening
time according to the tightening order of the order as shown and retighten them to the spec-
bolts. ified tightening torque.
a. Wash the threads and contact surfaces of
the bolts, the contact surfaces of the Bolt [1], [2], [3], [4]
washers, the contact surface of the cylin- 2nd
T.
R.

der head, and the threads of the crank- 15 N·m (1.5 kgf·m, 11 lb·ft)
case.
b. Apply molybdenum disulfide grease to h. Put a mark on the corner “1” of the bolt
the threads and contact surfaces of the (cylinder head) and the cylinder head “2”
bolts and to both contact surfaces of the as shown.
washers.
c. Install the washers and the bolts. 1
d. Tighten the bolts to the specified torque in
two or three steps in the proper tightening
sequence as shown.
Bolt [1]–[4]
1st
2
T.
R.

30 N·m (3.0 kgf·m, 22 lb·ft)

i. Tighten the bolts (cylinder head) further.

5-23
 CYLINDER HEAD

Bolt [1], [2], [3], [4]

3rd
T.
R.

Specified angle
60

j. Put a mark on the corner of the bolt (cylin-

der head) and the cylinder head.
k. Finally, tighten all bolts (cylinder head) fur-
ther according to the tightening order.

Tighten the bolts in two steps 60 to reach the

specified angle in the proper tightening se-
quence. Total tightening angle: 60 + 60 = 120

Bolt [1], [2], [3], [4]

Final
T.
R.

Specified angle
60

l. Tighten the nuts to the specified torque.

Nut [5], [6]
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

5-24
 VALVES AND VALVE SPRINGS

EAM20108

VALVES AND VALVE SPRINGS

Removing the valves and valve springs
1
1
2
2 3
3 4 3
E
3
4 5

5 6

6 7
7

8
9

Order Job/Parts to remove Q’ty Remarks

Cylinder head Refer to “CYLINDER HEAD” on page 5-20.
1 Valve lifter 4
2 Adjusting pad 4
3 Valve cotter 8
4 Valve spring retainer 4
5 Valve spring 4
6 Valve stem seal 4
7 Valve spring seat 4
8 Intake valve 2
9 Exhaust valve 2

5-25
 VALVES AND VALVE SPRINGS

EAM30090
b. Check that the valves are properly sealed.
REMOVING THE VALVES
Check that there are no kerosene leaks from the
Before removing the internal parts of the cylin- valve seat “1”.
der head (e.g., valves, valve springs, valve
seats), make sure that the valves are properly
sealed.
1. Remove:
• Valve lifter “1”
• Adjusting pad “2” 1
a
• Place a cloth in the timing chain space to pre- a
vent adjusting pads from falling into the crank-
case.
• Make a note of the positions of valve lifters
3. Remove:
and adjusting pads so that they can be rein-
• Valve cotter “1”
stalled in their original places.
Remove the valve cotters by compressing the
Valve lapper (ø14) valve spring with the valve spring compressor
90890-04101
“2” and the valve spring compressor attach-
Valve lapper (ø14)
YM-A8998 ment “3”.

Valve spring compressor

2 90890-04200
1 Valve spring compressor
YM-04019
Valve spring compressor attach-
ment
90890-04108
Valve spring compressor adapter
22 mm
YM-04108

4. Remove:
2. Check:
• Valve spring retainer “1”
• Valve sealing
• Valve spring “2”
Leakage at the valve seat  Check the valve
• Valve “3”
face, the valve seat, and the valve seat con-
• Valve stem seal “4”
tact width.
• Valve spring seat “5”
Refer to “CHECKING THE VALVE SEATS”
on page 5-28.
Identify the position of each part very carefully
a. Pour a clean solvent “a” into the intake
so that it can be reinstalled in its original place.
and exhaust ports.

5-26
 VALVES AND VALVE SPRINGS

head to 100 °C (212 °F) in an oven.

1 a. Remove the valve guide with the valve

2 guide remover “1”.
4

EAM30091
1
CHECKING THE VALVES AND VALVE
GUIDES
1. Measure:
• Valve-stem-to-valve-guide clearance b. Install the new valve guide with the valve
Out of specification  Replace the valve guide installer “1” and the valve guide re-
guide. mover “2”.

Valve-stem-to-valve-guide clearance = Valve guide installation height “a”

Valve guide inside diameter “a” - Intake
Valve stem diameter “b” 10.8–11.2 mm (0.43–0.44 in)
Exhaust
Valve-stem-to-valve-guide clear- 11.2–11.6 mm (0.44–0.46 in)
ance limit (intake)
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
ance limit (exhaust) 2
0.100 mm (0.0039 in)
1

c. After installing the valve guide, expand

the hole in the valve guide with the valve
guide reamer “3” to obtain the proper
valve-stem-to-valve-guide clearance.

2. Replace: After replacing the valve guide, reface the valve

• Valve guide seat.
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder

5-27
 VALVES AND VALVE SPRINGS

Intake
Valve guide remover (ø5)
90890-04097
Valve guide remover (5.0 mm)
YM-04097
Valve guide installer (ø5)
90890-04098
Valve guide installer (5.0 mm)
YM-04098
Valve guide reamer (ø5)
90890-04099 EAM30092

Valve guide reamer (5.0 mm) CHECKING THE VALVE SEATS

YM-04099 1. Eliminate:
Exhaust • Carbon deposits
Valve guide remover (ø4.5) (from the valve face and valve seat)
90890-04116
2. Check:
Valve guide remover (4.5 mm)
YM-04116 • Valve seat
Valve guide installer (ø4.5) Pitting/wear  Replace the cylinder head.
90890-04117 3. Measure:
Valve guide installer (4.5 mm) • Valve seat contact width “a”
YM-04117 Out of specification  Replace the cylinder
Valve guide reamer (ø4.5) head.
90890-04118
Valve guide reamer (4.5 mm) Valve seat contact width limit (in-
YM-04118 take)
1.6 mm (0.06 in)
3. Eliminate: Valve seat contact width limit (ex-
• Carbon deposits haust)
(from the valve face and valve seat) 1.6 mm (0.06 in)
4. Check:
• Valve face
Pitting/wear  Grind the valve face.
• Valve stem end
Mushroom shape or diameter larger than the
body of the valve stem  Replace the valve.
5. Measure:
• Valve stem runout
Out of specification  Replace the valve.

• When installing a new valve, always replace

the valve guide. a. Apply blue layout fluid “b” onto the valve
• If the valve is removed or replaced, always re- face.
place the valve stem seal.

Valve stem runout

0.020 mm (0.0008 in)

b. Install the valve into the cylinder head.

5-28
 VALVES AND VALVE SPRINGS

c. Press the valve through the valve guide b. Apply molybdenum disulfide oil onto the
and onto the valve seat to make a clear valve stem.
impression. c. Install the valve into the cylinder head.
d. Measure the valve seat contact width “c”. d. Turn the valve until the valve face and the
valve seat are evenly polished, then clean
Where the valve seat and the valve face are in off all of the lapping compound.
contact with each other, the blueing will have
been removed. While turning the valve lapper, tap and lap the
valve seat.
e. Apply a fine lapping compound to the
valve face, and repeat the above steps.
c f. After every lapping step, be sure to clean
off all of the lapping compound from the
valve face and the valve seat.
g. Apply blue layout fluid “b” onto the valve
face.

4. Lap:
• Valve face
• Valve seat
ECA24640

This model uses titanium intake and exhaust

valves.
Do not use the valves used for lapping the
valve seat. Always replace the valves used h. Install the valve into the cylinder head.
for lapping with new ones. i. Press the valve through the valve guide
and onto the valve seat to make a clear
• When replacing the cylinder head, replace impression.
also the valves with new ones without them. j. Measure the valve seat contact width “c”
• When replacing the valves or the valve guides, again. If the valve seat contact width is
use new valves to lap the valve seats, and then out of specification, reface and lap the
replace them with new valves. valve seat.

a. Apply a coarse lapping compound “a” to

the valve face.
ECA13790

Do not let the lapping compound enter the

gap between the valve stem and the valve
guide.

EAM30093

CHECKING THE VALVE SPRINGS

1. Measure:
• Valve spring free length “a”
Out of specification  Replace the valve
spring.

5-29
 VALVES AND VALVE SPRINGS

Free length limit (intake)

34.94 mm (1.38 in)
Free length limit (exhaust)
33.82 mm (1.33 in)

3. Install:
• Spring seat “1”
• Valve stem seal “2” New
• Valve “3”
• Valve spring “4”
EAM30094 • Valve spring retainer “5”
CHECKING THE VALVE LIFTERS (to the cylinder head)
1. Check:
• Valve lifter • Make sure each valve is installed in its original
Damage/scratches  Replace the valve lift- place.
ers and cylinder head. • Install the valve springs with the larger pitch
“a” facing up.

EAM30095

INSTALLING THE VALVES

1. Clean: b. Smaller pitch
• Valve stem end 4. Install:
• Valve cotter “1”

Install the valve cotters by compressing the

valve spring with the valve spring compressor
“2” and the valve spring compressor attach-
ment “3”.

Valve spring compressor

90890-04200
Valve spring compressor
YM-04019
2. Lubricate:
Valve spring compressor attach-
• Valve stem “1” ment
• Valve stem seal “2” 90890-04108
Recommended lubricant Valve spring compressor adapter
Molybdenum disulfide oil 22 mm
YM-04108

5-30
 VALVES AND VALVE SPRINGS

5. To fasten the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
ECA13800

Hitting the valve tip with excessive force

could damage the valve.

6. Lubricate:
• Adjusting pad “1”
• 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.

5-31
 CYLINDER AND PISTON

EAM20109

CYLINDER AND PISTON

Removing the cylinder and piston

10 N m (1.0 kgf m, 7.4 lb ft)

1

E 7
4 6
E
5
3 4
E

10 N m (1.0 kgf m, 7.4 lb ft)

LT

Order Job/Parts to remove Q’ty Remarks

Cylinder head Refer to “CYLINDER HEAD” on page 5-20.
1 Cylinder body 1
2 Gasket 1
3 Dowel pin 2
4 Piston pin clip 2
5 Piston pin 1
6 Piston 1
7 Piston ring set 1

5-32
 CYLINDER AND PISTON

EAM30096

REMOVING THE PISTON

1. Remove:
• Piston pin clip “1”
• Piston pin “2”
• Piston “3”
ECA13810

Do not use a hammer to drive the piston pin

out.

EAM30097
• Before removing the piston pin clip, cover the
CHECKING THE CYLINDER AND PISTON
crankcase opening with a cloth to prevent the
1. Check:
piston pin clip from falling into the crankcase.
• Piston wall (Sidewall)
• Before removing the piston pin, deburr the pis-
• Cylinder wall
ton pin clip’s groove and the piston pin’s bore
Vertical scratches  Replace the cylinder,
area. If the piston pin groove is deburred and
and replace the piston and piston rings as a
the piston pin is still difficult to remove, use the
set.
piston pin puller set “4”.
2. Measure:
• Piston-to-cylinder clearance
Piston pin puller set a. Measure the cylinder bore “C” with the
90890-01304 cylinder bore gauge.
Piston pin puller
YU-01304
Measure the cylinder bore “C” by taking side-
to-side and front-to-back measurements of the
cylinder.

Bore
77.000–77.010 mm (3.0315–
3.0319 in)
Wear limit
77.060 mm (3.0339 in)

1 “C” = maximum of D1, D2, D3, D4, D5, D6

2. Remove: b. If out of specification, rebore or replace

• Top ring the cylinder, and replace the piston and
• Oil ring the piston rings as a set.
c. Measure the piston outside diameter “a”
When removing a piston ring, open the end gap at the measuring point (from piston skirt
with your fingers and lift the opposite end gap of bottom) “b” with the micrometer.
the piston ring over the piston crown.

5-33
 CYLINDER AND PISTON

Diameter
76.955–76.970 mm (3.0297–
3.0303 in)
Measuring point (from piston skirt
bottom)
4.0 mm (0.16 in)

b
2. Install:
a
• Piston ring
(into the cylinder)

Use the piston crown to level the piston ring

near bottom of cylinder “a”, where cylinder wear
is lowest.
d. If out of specification, replace the cylin- 3. Measure:
der, the piston, and the piston rings as a
• Piston ring end gap
set.
Out of specification  Replace the piston
e. Calculate the piston-to-cylinder clear- ring.
ance with the following formula.
Piston-to-cylinder clearance = The oil ring expander spacer’s end gap cannot
Cylinder bore “C” - Piston diameter be measured. If the oil ring rail’s gap is exces-
sive, replace the oil ring as a set.
Piston-to-cylinder clearance
0.030–0.055 mm (0.0012–0.0022 Piston ring
in) Top ring
End gap limit
f. If out of specification, replace the cylin- 0.50 mm (0.0197 in)
der, the piston, and the piston rings as a
set.
EAM30098 a
CHECKING THE PISTON RINGS
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- b

ance, eliminate any carbon deposits from the
piston ring grooves and piston rings. b. Upper of cylinder
EAM30099

Ring side clearance CHECKING THE PISTON PIN

0.030–0.065 mm (0.0012–0.0026 1. Check:
in) • Piston pin
Side clearance limit Blue discoloration/grooves  Replace the
0.115 mm (0.0045 in) piston pin and then check the lubrication
system.
2. Measure:
• Piston pin outside diameter “a”
Out of specification  Replace the piston

5-34
 CYLINDER AND PISTON

pin.
Piston pin outside diameter limit
15.971 mm (0.6288 in) 4

3. Measure:
• Piston pin bore inside diameter “b”
Out of specification  Replace the piston.
Piston pin bore inside diameter
limit
16.043 mm (0.6316 in) 2. Install:
• Piston “1”
• Piston pin “2”
• Piston pin clip “3” New

• Apply the engine oil to the piston pin.

• Install the piston with the mark “a” on it point-
ing to its exhaust (rear) side.
• Before installing the piston pin clip, cover the
crankcase opening with a cloth to prevent the
b clip from falling into the crankcase.
• Make sure that the end of the piston pin clip is
EAM30100
not positioned at the cutout in the piston.
INSTALLING THE PISTON AND CYLINDER
1. Install: 1 a
• Oil ring expander “1”
• Lower oil ring rail “2” E
• Upper oil ring rail “3”
• Top ring “4” 3

Be sure to install the piston rings so that the

manufacturer’s marks or numbers face up.
E 2

5-35
 CYLINDER AND PISTON

3. Lubricate:
• Piston
• Piston ring
• Cylinder
4. Offset:
• Piston ring end gap
a

15

15 15

d c b

a. Top ring
b. Upper oil ring rail
c. Oil ring expander
d. Lower oil ring rail
5. Install:
• Gasket New
• Dowel pin
• Cylinder
Cylinder bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

• While compressing the piston rings with one

hand, install the cylinder with the other hand.
• Pass the timing chain and timing chain guide
(exhaust side) through the timing chain cavity.

5-36
 GENERATOR

EAM20183

GENERATOR
Removing the stator coil assembly
1 10

2
10 N m (1.0 kgf m, 7.4 lb ft)

12 N m (1.2 kgf m, 8.9 lb ft)

6 7
8 N m (0.8 kgf m, 5.9 lb ft) (3)
8
5
(2)
4
9

10 N m (1.0 kgf m, 7.4 lb ft)

65 N m (6.5 kgf m, 48 lb ft)

10 N m (1.0 kgf m, 7.4 lb ft)

Order Job/Parts to remove Q’ty Remarks

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-14.
Refer to “GENERAL CHASSIS” on page
Seat 4-1.
Refer to “GENERAL CHASSIS” on page
Air scoop (left) 4-1.
1 Stator coil assembly coupler 1 Disconnect.
2 Crankshaft position sensor coupler 1 Disconnect.
3 Shift pedal 1
4 Crankcase cover (left) 1
5 Gasket 1
6 Dowel pin 2
7 Holder 1
8 Stator coil assembly 1
9 Generator rotor 1
10 Woodruff key 1

5-37
 GENERATOR

EAM30487 EAM30377

REMOVING THE GENERATOR CHECKING THE WOODRUFF KEY

1. Remove: 1. Check:
• Nut (generator rotor) “1” • Woodruff key “1”
• Washer Damage  Replace.

2. Remove: EAM30489

• Generator rotor “1” INSTALLING THE GENERATOR

(with the rotor puller “2”) 1. Install:
• Woodruff key • Stator coil assembly “1”
• Screw (stator coil assembly) “2”
Rotor puller
90890-04151 Screw (stator coil assembly)
Rotor puller
T.
R.
10 N·m (1.0 kgf·m, 7.4 lb·ft)
YM-04151 LOCTITE®

• Crankshaft position sensor “3”

• Bolt (crankshaft position sensor) “4”
1 • Holder
• Bolt (holder)
Bolt (crankshaft position sensor)
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

LOCTITE®
Bolt (holder)
2 8 N·m (0.8 kgf·m, 5.9 lb·ft)
LOCTITE®
EAM30488

CHECKING THE GENERATOR

1. Check: • Apply the sealant to the grommet of the stator
• Generator rotor “1” inner surface “a” coil assembly lead.
• Stator coil assembly “2” outer surface “b” • Tighten the stator coil assembly screws using
Damage  Inspect the crankshaft runout the T25 bit.
and crankshaft bearing. • Pass the stator coil assembly lead through the
crankcase cover side.
2 b
1 Yamaha bond No. 1215
90890-85505
Three bond No. 1215®

5-38
 GENERATOR

• Crankcase cover (left) “3”

• Lead holder “4”
• Bolt (left crankcase cover) “5”
LT 4
Bolt (left crankcase cover)
10 N·m (1.0 kgf·m, 7.4 lb·ft)
2

T.
R.
LT Tighten the bolts in stages and in a crisscross
1
4 pattern.
3
2. Install: 1
• Woodruff key “1”
3
• Generator rotor “2”
5
• Clean the contact surfaces of the tapered por-
tions of the crankshaft and generator rotor.
• When installing the woodruff key, make sure 4
that its flat surface “a” is in parallel with the 5
2 54
crankshaft center line “b”. 1 5
5
• When installing the generator rotor, align the
keyway “c” of the generator rotor with the 5. Connect:
woodruff key. • Stator coil assembly lead
Refer to “CABLE ROUTING DIAGRAM” on
page 2-17.
1

b 1 a

c
2

3. Install:
• Washer
• Nut (generator rotor) “1”
Nut (generator rotor)
65 N·m (6.5 kgf·m, 48 lb·ft)
T.
R.

4. Install:
• Dowel pin “1”
• Gasket (left crankcase cover) “2” New

5-39
 STARTER CLUTCH

EAM20175

STARTER CLUTCH
Removing the starter clutch

8
7
2

3
(8)

FW
D

4
5

6 12 N m (1.2 kgf m, 8.9 lb ft)

Order Job/Parts to remove Q’ty Remarks

Refer to “CHANGING THE ENGINE OIL” on
Engine oil page 3-14.
Clutch Refer to “CLUTCH” on page 5-47.
1 Clutch housing 1
2 Starter clutch gear 1
3 Starter clutch assembly 1
4 Side plate 1
5 Absorber 8
6 Primary driven gear 1
7 Spacer 1
8 Collar 1
9 Damper assembly 1

5-40
 STARTER CLUTCH

EAM30469

REMOVING THE STARTER CLUTCH

1 2
1. Remove:
• Starter clutch screw “1”

While holding the side of the clutch housing “2”

with the sheave holder “3” as shown, remove
the starter clutch screws “1”.

Sheave holder
90890-01701
Primary clutch holder 3. Check:
YS-01880-A • Starter clutch gear’s contacting surfaces
Damage/pitting/wear  Replace the starter
clutch gear.
1 1 4. Check:
• Starter clutch operation
a. Install the starter clutch gear “1” onto the
primary driven gear “2” and hold the pri-
mary driven gear.
b. When turning the starter clutch gear
clockwise “A”, the starter clutch and the
1 2 starter clutch gear should engage, other-
3 wise the starter clutch is faulty and must
EAM30140
be replaced.
CHECKING THE STARTER CLUTCH c. When turning the starter clutch gear
1. Check: counterclockwise “B”, it should turn free-
• Starter clutch roller “1” ly, otherwise the starter clutch is faulty
Damage/wear  Replace. and must be replaced.

A 1
1

B
2

2. Check: EAM30470

• Starter clutch gear “1” INSTALLING THE STARTER CLUTCH

• Damper assembly “2” 1. Install:
Burrs/chips/roughness/wear  Replace the • Primary driven gear “1”
defective part(s).
Install the primary driven gear “1” so that the
portion “a” as shown faces to the starter clutch
side.

5-41
 STARTER CLUTCH

toward the primary driven gear.

• While holding the side of the clutch housing
1 a “1” with the sheave holder “2” as shown, tight-
en the starter clutch screws “3”.

Sheave holder
90890-01701
Primary clutch holder
YS-01880-A

2. Install: 3 3
• Absorber “1”

Install the absorber “1” so that the portion with

the mark “5XC” “a” faces to the side plate side.

1
3 1
5XC 2

3. Install:
• Side plate “1”

Install the side plate “1” so that the portion with

the mark “B7B” “a” faces to the starter clutch
side.

1
B7B

4. Install:
• Starter clutch
Starter clutch screw
12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.

LOCTITE®

• Install the starter clutch so that the side of the

starter clutch assembly with the arrow mark is

5-42
 ELECTRIC STARTER

EAM20110

ELECTRIC STARTER
Removing the starter motor

FW
D

3.5 N m (0.35 kgf m, 2.6 lb ft)

1
2

10 N m (1.0 kgf m, 7.4 lb ft)

Order Job/Parts to remove Q’ty Remarks

Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-6.
1 Starter motor lead 1
2 Starter motor 1

5-43
 ELECTRIC STARTER

Disassembling the starter motor

D
10
11 FW

6 1
5

1.5 N m (0.15 kgf m, 1.1 lb ft)

7

9
8
4

3.5 N m (0.35 kgf m, 2.6 lb ft)

Order Job/Parts to remove Q’ty Remarks

1 Starter motor assembly 1
2 O-ring 1
3 Starter motor front cover 1
4 Washer 1 Starter motor front cover
5 Starter motor yoke 1
6 Gasket 2
7 Armature assembly 1
8 Washer 1
9 Circlip 1
10 Starter motor rear cover 1
11 Brush set 1

5-44
 ELECTRIC STARTER

EAM30106
Out of specification  Replace the brush
CHECKING THE STARTER MOTOR set.
1. Check:
• Commutator Brush overall length limit
Dirt  Clean with 600 grit sandpaper. 3.5 mm (0.14 in)
2. Measure:
• Mica undercut “a”
Out of specification  Scrape the mica to
the proper measurement with a hacksaw
blade that has been grounded to fit the com-
mutator.
Mica undercut (depth)
1.50 mm (0.06 in)

The mica of the commutator must be undercut

to ensure proper operation of the commutator. 5. Measure:
• Brush spring force
Out of specification  Replace the brush
set.
Brush spring force
3.92–5.88 N (400–600 gf, 14.11–
21.17 oz)

6. Check:
• Gear teeth
Damage/wear  Replace the starter motor.
7. Check:
3. Check: • Oil seal
• Armature assembly Damage/wear  Replace the defective
a. Connect the digital circuit tester to the ar- part(s).
mature coil and check the continuity.
EAM30107

Digital circuit tester (CD732) ASSEMBLING THE STARTER MOTOR

90890-03243 1. Install:
Model 88 Multimeter with ta- • Brush spring “1”
chometer • Brush “2”
YU-A1927
Align the corner of brush terminal “a” with
b. If there is no continuity, replace the starter
groove “b” and fit them together.
motor.

a 1

1
b 2
2
4. Measure: 2. Install:
• Brush length “a” • Armature assembly “1”

5-45
 ELECTRIC STARTER

Install while holding down the brush using a

thin screw driver. a 4 b 5
ECA24650

Be careful not to damage the brush during

installation.

1 1 2 3

5. Install:
• Bolt “1”
• O-ring “2” New

Apply the lithium-soap-based grease on the O-

ring.
3. Install:
• Gasket “1” New 1
• Starter motor yoke “2”
2
• Install the starter motor yoke with its groove
“a” facing starter motor rear cover.
• Align the match mark “b” on the starter motor
yoke with the match mark “c” on the starter
motor rear cover.
1
c a 2 b
6. Install:
• Starter motor
• Starter motor bolt
Starter motor bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

1
4. Install:
• Circlip “1”
• Plain washer “2”
• Gasket “3” New
• Washer (starter motor front cover) “4”
• Starter motor front cover “5”

• For installation, align the projections on the

washer with the slots in the front cover.
• Align the match mark “a” on the starter motor
yoke with the match mark “b” on the starter
motor front cover.

5-46
 CLUTCH

EAM20111

CLUTCH
Removing the clutch
10 N m (1.0 kgf m, 7.4 lb ft)

E
10 N m (1.0 kgf m, 7.4 lb ft) E 5 10
10 N m (1.0 kgf m, 7.4 lb ft)
4 9
6
8
7
2
1
11 E
3
E

13 LT

11
12

E
E
15
14
95 N m (9.5 kgf m, 70 lb ft)

Order Job/Parts to remove Q’ty Remarks

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-14.
Brake pedal Refer to “ENGINE REMOVAL” on page 5-6.
1 Clutch cable 1 Disconnect.
2 Clutch cover 1
3 Gasket 1
4 Clutch spring 6
5 Pressure plate 1
6 Push rod 1 1
7 Circlip 1
8 Bearing 1
9 Ball 1
10 Push rod 2 1
11 Friction plate 1 2 Identification color (black)
12 Clutch plate 7
13 Friction plate 2 6 Identification color (orange)
14 Clutch boss 1
15 Thrust washer 1

5-47
 CLUTCH

Removing the clutch

10 N m (1.0 kgf m, 7.4 lb ft)

E
17
10 N m (1.0 kgf m, 7.4 lb ft) E

10 N m (1.0 kgf m, 7.4 lb ft)

T .R
.

LT

16
E E

95 N m (9.5 kgf m, 70 lb ft)

Order Job/Parts to remove Q’ty Remarks

16 Primary driven gear 1
17 Push lever shaft 1

5-48
 CLUTCH

Removing the right crankcase cover

5
10 N m (1.0 kgf m, 7.4 lb ft)

4 6

6
10 N m (1.0 kgf m, 7.4 lb ft)

2
1

10 N m (1.0 kgf m, 7.4 lb ft)

Order Job/Parts to remove Q’ty Remarks

Right engine guard Refer to “ENGINE REMOVAL” on page 5-6.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-14.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-22.
Brake pedal Refer to “ENGINE REMOVAL” on page 5-6.
Clutch cover Refer to “CLUTCH” on page 5-47.
1 Oil filter element cover 1
2 Oil filter element 1
3 Radiator pipe 2 1
4 Right crankcase cover 1
5 Gasket 1
6 Dowel pin 2

5-49
 CLUTCH

EAM30108

REMOVING THE CLUTCH Friction plate 1 thickness

1. Straighten the clutch boss nut rib “a”. 2.70–2.90 mm (0.106–0.114 in)
Wear limit
a 2.60 mm (0.102 in)
Friction plate 2 thickness
2.72–2.88 mm (0.107–0.113 in)
Wear limit
2.62 mm (0.103 in)

EAM30110

CHECKING THE CLUTCH PLATES

1. Check:
• Clutch plate
2. Remove: Damage  Replace the clutch plates as a
• Clutch boss nut “1” set.
• Conical washer “2” 2. Measure:
• Clutch boss “3” • Clutch plate warpage
(with a surface plate and thickness gauge)
• While holding the clutch boss with the clutch Out of specification  Replace the clutch
holder “4”, loosen the clutch boss nut. plates as a set.
• Do not use an impact wrench for removing the Thickness gauge
clutch boss nut. 90890-03268
Feeler gauge set
Clutch holder YU-26900-9
90890-04199
Universal clutch holder
YM-91042 Clutch plate thickness
1.50–1.70 mm (0.059–0.067 in)
Warpage limit
0.10 mm (0.004 in)
1
EAM30111
2
CHECKING THE CLUTCH SPRINGS
4 1. Check:
• Clutch spring
3 Damage  Replace the clutch springs as a
set.
2. Measure:
• Clutch spring free length
EAM30109
Out of specification  Replace the clutch
CHECKING THE FRICTION PLATES springs as a set.
1. Check:
Clutch spring free length
• Friction plate 44.50 mm (1.75 in)
Damage/wear  Replace the friction plates Clutch spring free length limit
as a set. 42.28 mm (1.66 in)
2. Measure:
• Friction plate thickness EAM30112

Out of specification  Replace the friction CHECKING THE CLUTCH HOUSING

plates as a set. 1. Check:
• Clutch housing dogs “1”
Measure it at four points on the friction plate. Damage/pitting/wear  Deburr the clutch
housing dogs or replace the clutch housing.

Pitting on the clutch housing dogs will cause er-

5-50
 CLUTCH

ratic clutch operation. EAM30484

CHECKING THE PUSH RODS

1. Check:
• Push rod 1 “1”
• Bearing/Washer “2”
• Push rod 2 “3”
• Ball “4”
Cracks/damage/wear  Replace.

1
1
EAM30113 2
CHECKING THE CLUTCH BOSS 3
4
1. Check:
• Clutch boss splines 4
5
Damage/pitting/wear  Replace the clutch
boss.
2. Measure:
Pitting on the clutch boss splines will cause er- • Push rod 2 bending limit
ratic clutch operation. Out of specification  Replace.
Push rod bending limit
0.30 mm (0.012 in)

EAM30117

CHECKING THE PRIMARY DRIVE GEAR

1. Check:
• Primary drive gear
Damage/wear  Replace the primary drive
and primary driven gears as a set.
Excessive noise during operation  Replace
the primary drive and primary driven gears as
EAM30114

CHECKING THE PRESSURE PLATE a set.

1. Check: 2. Check:
• Pressure plate • Primary-drive-gear-to-primary-driven-gear
Crack/damage  Replace. free play
Free play exists  Replace the primary drive
EAM30115
and primary driven gears as a set.
CHECKING THE PUSH LEVER SHAFT
1. Check: EAM30118

• Push lever shaft CHECKING THE PRIMARY DRIVEN GEAR

Wear/damage  Replace. 1. Check:
• Primary driven gear
Damage/wear  Replace the primary drive
and primary driven gears as a set.
Excessive noise during operation  Replace
the primary drive and primary driven gears as
a set.
EAM30121

INSTALLING THE CLUTCH

1. Install:
• Dowel pin “1”
• Gasket “2” New

5-51
 CLUTCH

Apply the engine oil on the primary driven gear

inner circumference.
1

1
1 2
2 3
4
2. Install:
• Right crankcase cover “1”
• Right crankcase cover bolt “2”
Right crankcase cover bolt 5. Install:
10 N·m (1.0 kgf·m, 7.4 lb·ft) • Conical washer “1” New
T.
R.

• Clutch boss nut “2” New

Tighten the right crankcase cover bolts in stag- Clutch boss nut
es and in a crisscross pattern. 95 N·m (9.5 kgf·m, 70 lb·ft)

T.
R.
ECA24660

Make sure to tighten to specification; other-

wise, it may damage the other part that is
fastened together.

1
2 • Install the conical washer on the main axle
with the “OUT” mark “a” facing away from the
vehicle.
• Apply engine oil to the threads and contact
3. Install: surface of the clutch boss nut.
• Push lever shaft “1” • Apply engine oil to the contact surfaces of the
conical washer.
• Apply the lithium-soap-based grease on the • Use the clutch holder “3” to hold the clutch
oil seal lip. boss.
• Before installation, apply the engine oil to the • Do not use an impact wrench for installing the
bearings (upper side and lower side). clutch boss nut.
• Stake the clutch boss nut at cutouts “b” in the
main axle.
1
Clutch holder
90890-04199
Universal clutch holder
YM-91042

4. Install:
• Primary driven gear “1”
• Thrust washer “2”
• Clutch boss “3”
• Washer “4”

5-52
 CLUTCH

(to the push rod 1 “4”)

3 1
Apply the engine oil on the bearing, washer and
push rod 1.
a
1
E

8. Install:
• Push rod 2 “1”
• Ball “2”
• Push rod 1 “3”

Apply the engine oil on the push rod 1, 2 and

6. Install: ball.
• Friction plate 1 “1”
• Clutch plate “2”
• Friction plate 2 “3”

• Install the clutch plates and friction plates al-

ternately on the clutch boss, starting with a
friction plate and ending with a friction plate.
• From the clutch boss side, install the friction
plates in order: friction plate 1 (identification E
2
color: black) × 1, friction plate 2 (identification E 1
3
color: orange) × 6, and friction plate 1 (identifi-
cation color: black) × 1. 9. Install:
• Apply the engine oil on the friction plates and • Pressure plate “1”
clutch plates.
Making sure to align a “a” on the pressure plate
a with the punch mark “b” on the clutch housing.
E 1
3

E
2

a. Identification color 1
7. Install:
• Bearing “1”
• Washer “2”
• Circlip “3” New

5-53
 CLUTCH

a b

10.Install:
• Clutch spring
• Clutch spring bolt
Clutch spring bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

Tighten the bolts in stages and in a crisscross

pattern.
11.Install:
• Gasket “1” New

12.Install:
• Clutch cover
• Clutch cover bolt
Clutch cover bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

Tighten the bolts in stages and in a crisscross

pattern.

5-54
 SHIFT SHAFT

EAM20113

SHIFT SHAFT
Removing the shift shaft and stopper lever

3
1

12 N m (1.2 kgf m, 8.9 lb ft)

10 N m (1.0 kgf m, 7.4 lb ft)

4
5 14
2 13
15

7
8
10
11 30 N m (3.0 kgf m, 22 lb ft)
12
9 12
11
10
10 N m (1.0 kgf m, 7.4 lb ft)
6
Order Job/Parts to remove Q’ty Remarks
Primary driven gear Refer to “CLUTCH” on page 5-47.
1 Shift pedal 1
2 Shift shaft 1
3 Oil seal 1
4 Collar 1
5 Shift shaft spring 1
6 Roller 1
7 Shift guide 1
8 Shift lever assembly 1
9 Shift lever 1
10 Pawl 2
11 Pawl pin 2
12 Spring 2
13 Stopper lever 1
14 Stopper lever spring 1
15 Segment 1

5-55
 SHIFT SHAFT

EAM30124

REMOVING THE SEGMENT 1

1. Remove:
• Segment bolt “1”
• Segment “2” 2 3
Turn the segment counterclockwise until it
4
stops and loosen the segment bolt.
ECA24670

5
If the segment gets an impact, the stopper
EAM30127
lever may be damaged. Take care not to give CHECKING THE STOPPER LEVER
an impact to it when removing the bolt. 1. Check:
• Stopper lever “1”
Wear/damage  Replace.
• Stopper lever spring “2”
Broken  Replace.

1 2

EAM30125

CHECKING THE SHIFT SHAFT

1. Check:
• Shift shaft “1”
Bends/damage/wear  Replace. EAM30131

• Shift shaft spring “2” INSTALLING THE SHIFT SHAFT

Damage/wear  Replace. 1. Install:
• Stopper lever spring “1”
• Collar “2”
1 • Stopper lever “3”
• Bolt (stopper lever) “4”
Bolt (stopper lever)
2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

LOCTITE®

1
2. Check:
• Shift guide “1” 2
• Shift lever “2” 3
• Pawl “3”
• Pawl pin “4”
• Spring “5” LT
Wear/damage  Replace. 4

2. Install:
• Segment “1”
• Segment bolt

5-56
 SHIFT SHAFT

Segment bolt
T.
R.
30 N·m (3.0 kgf·m, 22 lb·ft)

• Align the notch “a” on the segment with the

pin “b” on the shift drum.
• With the stopper lever pushed down, install
the segment.
ECA24680 2 1

If the segment gets an impact, the stopper 6. Tighten:

lever may be damaged. Take care not to give • Shift guide bolt “1”
an impact to it when tightening the bolt. Shift guide bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.
R.
LOCTITE®

1
1
1
a b

3. Install:
LT
• Spring “1”
• Pawl pin “2”
• Pawl “3” 7. Install:
(to the shift lever) • Roller “1”
• Shift shaft spring “2” (to the shift shaft)
Apply the engine oil on the spring, pawl pin and • Collar “3” (to the shift shaft)
pawl. • Shift shaft “4”

Apply the engine oil on the shift shaft.

3
2
E
3
1
1 2

4
E

4. Install:
• Shift lever assembly
(to the shift guide) 8. Install:
5. Install: • Oil seal New
• Shift lever assembly “1” 9. Install:
• Shift guide “2” • Shift pedal “1”
• Shift pedal bolt “2”
The shift lever assembly is installed at the same Shift pedal bolt
time as the shift guide. 12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.

5-57
 SHIFT SHAFT

Align the punch mark “a” on the shift shaft with

the punch mark “b” in the shift pedal.

b
a

1
2

5-58
 OIL PUMP

EAM20182

OIL PUMP
Removing the oil pump

6 N m (0.6 kgf m, 4.4 lb ft)

2
1

3
LT

4
5
5 N m (0.5 kgf m, 3.7 lb ft)
7
LT

Order Job/Parts to remove Q’ty Remarks

Primary driven gear Refer to “CLUTCH” on page 5-47.
Right crankcase cover Refer to “CLUTCH” on page 5-47.
1 Oil pump assembly 1
2 Oil pump cover 1
3 Outer rotor 1
4 Dowel pin 1
5 Inner rotor 1
6 Oil pump drive shaft 1
7 Oil pump housing 1

5-59
 OIL PUMP

Removing the balancer

105 N m (10.5 kgf m, 77 lb ft)

9 14
8
7 16
6 15

2
11 13

5
(2)
4
10
1
3
12
10 N m (1.0 kgf m, 7.4 lb ft)
38 N m (3.8 kgf m, 28 lb ft)
50 N m (5.0 kgf m, 37 lb ft)

Order Job/Parts to remove Q’ty Remarks

Primary driven gear Refer to “CLUTCH” on page 5-47.
Right crankcase cover Refer to “CLUTCH” on page 5-47.
Stator coil assembly Refer to “GENERATOR” on page 5-37.
1 Nut (balancer) 1
2 Nut (primary drive gear) 1
3 Nut (balancer weight gear) 1
4 Conical washer 1
5 Balancer weight 1
6 Conical washer 1
7 Primary drive gear 1
8 Collar 1
9 Balancer drive gear 1
10 Conical washer 1
11 Balancer weight gear 1
12 Balancer weight 1
13 Collar 1
14 Pin 1
15 Relief valve 1
16 Spring 1

5-60
 OIL PUMP

EAM30133

REMOVING THE BALANCER 1

1. Remove: 2
• Oil pump 3
2. Loosen:
• Balancer nut “1”
• Primary drive gear nut “2”
• Balancer weight gear nut “3”

Place an aluminum plate “a” between the teeth

of the balancer drive gear “4” and balancer
weight gear “5”. 4. Check:
• Balancer
Crack/damage  Replace.

5
4

a
4
3

3. Check:
• Primary drive gear “1”
• Balancer drive gear “2”
• Balancer weight gear “3”
Wear/damage  Replace.

5-61
 OIL PUMP

EAM30136

CHECKING THE OIL PUMP Oil pump cover bolt

1. Check: 6 N·m (0.6 kgf·m, 4.4 lb·ft)

T.
R.
• Oil pump cover LOCTITE®
• Oil pump drive shaft
• Oil pump housing
Cracks/damage/wear  Replace the oil 2
pump assembly. LT
2. Check: 1
• Oil pump operation
Rough movement  Repeat step (1) or re-
place the oil pump assembly.
EAM30137

ASSEMBLING THE OIL PUMP

1. Install:
• Oil pump drive shaft “1” EAM30486

• Inner rotor “2” INSTALLING THE OIL PUMP

• Dowel pin “3” 1. Install:
• Spring “1”
• Apply the engine oil on the oil pump drive shaft • Relief valve “2”
and inner rotor. • Pin “3”
• Fit the dowel pin into the groove in the inner
rotor. • Install the spring “1” and relief valve “2”, and
pin “3”. After installing, make sure that the re-
lief valve “2” does not come loose.
1 • Install the relief valve before installing the pri-
2
mary drive gear and collar.
3

3
2. Install:
• Outer rotor “1” 1
2
Apply the engine oil on the outer rotor.
2. Install:
• Collar “1”
• Balancer weight gear “2”
1
Install the balancer weight gear and balancer
shaft with their lower splines “a” aligning with
each other.

3. Install:
• Oil pump cover “1”
• Oil pump cover bolt “2”

5-62
 OIL PUMP

4. Install:
• Oil pump assembly “1”
• Oil pump assembly bolt “2”
Oil pump assembly bolt
1
2 5 N·m (0.5 kgf·m, 3.7 lb·ft)

T.
R.
LOCTITE®

3. Install:
• Balancer drive gear “1”
• Collar “2”
LT
• Install the balancer drive gear and crankshaft
with the lower splines “a” aligning with each 1
2
other.
• Align the punched mark “b” on the balancer ECA13890

drive gear with the punched mark “c” on the

balancer weight gear. After tightening the bolts, make sure the oil
pump turns smoothly.
5. Install:
• Conical washer “1” New
1 • Balancer weight gear nut “2”
2
Balancer weight gear nut
50 N·m (5.0 kgf·m, 37 lb·ft)
T.
R.

• Primary drive gear “3”

• Conical washer “4” New
• Primary drive gear nut “5”
Primary drive gear nut
a b 105 N·m (10.5 kgf·m, 77 lb·ft)
T.
R.

c LOCTITE®

• Balancer “6”
• Conical washer “7” New
• Balancer nut “8”
Balancer nut
1 38 N·m (3.8 kgf·m, 28 lb·ft)
T.
R.

• Apply engine oil to the contact surfaces of the

conical washer and the balancer nut “8”.
• Place an aluminum plate “a” between the
teeth of the balancer drive gear “9” and bal-
ancer weight gear “10”.
• Install the conical washer with its convex sur-
face “b” outward.
• Align the balancer flat portion “c” with the flat
portion “d”.
• Apply LOCTITE® to the primary drive gear nut

5-63
 OIL PUMP

“5” within the area shown in the illustration.

6 b 8

1 10
9 2

6
7
b 2 8
E
a

9 a
4 5 10

3 b
5
LT
E

57 mm
5 (0.020.28 in)

A. Primary drive gear side

B. Crankcase cover side

c d

5-64
 CRANKCASE

EAM20116

CRANKCASE
Separating the crankcase

6 5 5 N m (0.5 kgf m, 3.7 lb ft)

5
LT
5
11
6
7
9
4 4 4
10
12 N m (1.2 kgf m, 8.9 lb ft)

8
5

(3)

2
3
9
1

4
6 (7)
(3) 12 N m (1.2 kgf m, 8.9 lb ft)
LT

10 N m (1.0 kgf m, 7.4 lb ft) 12 N m (1.2 kgf m, 8.9 lb ft)

Order Job/Parts to remove Q’ty Remarks

Engine Refer to “ENGINE REMOVAL” on page 5-6.
Refer to “CYLINDER AND PISTON” on page
Piston 5-32.
Balancer Refer to “OIL PUMP” on page 5-59.
Segment Refer to “SHIFT SHAFT” on page 5-55.
Stator coil assembly Refer to “GENERATOR” on page 5-37.
1 Timing chain guide stopper plate 1
2 Timing chain guide (exhaust side) 1
3 Timing chain 1
4 Bolt 7 [L = 45 mm (1.77 in)]
5 Bolt 3 [L = 60 mm (2.36 in)]
6 Bolt 3 [L = 75 mm (2.95 in)]
7 Right crankcase 1
8 Left crankcase 1
9 Dowel pin 2
10 Crankshaft 1
11 Oil nozzle 1

5-65
 CRANKCASE

Removing the bearing and oil seal

12 N m (1.2 kgf m, 8.9 lb ft)
1
1 2
2
LT
3

3 2
E
3 3
E 3

E 3
3 LT
3

LT E
3

22 N m (2.2 kgf m, 16 lb ft)

3 3
LT
LT
12 N m (1.2 kgf m, 8.9 lb ft) E
E

Order Job/Parts to remove Q’ty Remarks

Transmission Refer to “TRANSMISSION” on page 5-72.
Shift drum/Shift fork Refer to “TRANSMISSION” on page 5-72.
1 Circlip 2
2 Oil seal 3
3 Bearing 13

5-66
 CRANKCASE

EAM30147

DISASSEMBLING THE CRANKCASE

1. Separate:
• Right crankcase
• Left crankcase
a. Remove the crankcase bolts.

a a

c. Remove the dowel pins.

2. Remove:
• Bearing “1”

• Remove the bearing from the crankcase by

pressing its inner race.
• Do not use the removed bearing.
Loosen each bolt 1/4 of a turn at a time and after
all the bolts are loosened, remove them.
b. Remove the right crankcase “1”.

• Place the crankcase with its left side down-

ward, split the crankcase splitting rib “a” while
tap with a soft hammer.
• Lift the right crankcase horizontally while light-
ly patting the crankcase splitting rib and the
engine mounting boss using a soft hammer,
and leave the crankshaft and the transmission
with the left crankcase. EAM30490

CHECKING THE TIMING CHAIN GUIDE

ECA24690
(EXHAUST SIDE)
1. Check:
Use soft hammer to tap on the case half. Tap • Timing chain
only on reinforced portions of case. Do not Stiffness  Replace the camshaft sprocket,
tap on gasket mating surface. Work slowly timing chain and crankshaft sprocket as a
and carefully. Make sure the case halves set.
separate evenly. If the cases do not sepa- 2. Check:
rate, check for a remaining case bolt or fit- • Timing chain guide
ting. Do not force. Damage/wear  Replace.
EAM30150

CHECKING THE CRANKCASE

1. Wash:
• Crankcase
1
• Wash the crankcase in a mild solvent.
• Remove any remaining gasket from the crank-
case mating surface.
2. Check:
• Crankcase
Crack/damage  Replace.
• Oil delivery passages
Obstruction  Blow out with compressed

5-67
 CRANKCASE

air. 4. Install:
EAM30152
• Oil nozzle “1”
ASSEMBLING THE CRANKCASE Oil nozzle bolt
1. Install: 5 N·m (0.5 kgf·m, 3.7 lb·ft)

T.
• Oil seal “1” New

R.
LOCTITE®
(to the left crankcase)
• Dowel pin “2”
Installed depth “a”
4.5–5.0 mm (0.18–0.20 in) • Crankcase “3”
(to the left crankcase)
Crankcase bolt
1 12 N·m (1.2 kgf·m, 8.9 lb·ft)

T.
R.
• Fit the right crankcase onto the left crankcase.
Tap lightly on the case with soft hammer.
• When installing the crankcase, the connecting
rod should be positioned at top dead center
a (TDC).
• Tighten the bolts in a crisscross pattern in two
2. Install: stages, with 1/4 turn each.
• Bearing cover plate
Bearing cover plate bolt LT 1
12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.

LOCTITE® 2
Bearing cover plate screw (crank-
shaft)
22 N·m (2.2 kgf·m, 16 lb·ft) 3
5
LOCTITE®

6
Install the bearing by pressing its outer race par-
allel. 2

3. Apply: 4 6 5
• Sealant 5
(to the crankcase mating surface)
Yamaha bond No. 1215
90890-85505 6
Three bond No. 1215® 4
4 4

4. 45 mm (1.77 in)
5. 60 mm (2.36 in)
6. 75 mm (2.95 in)

5-68
 CRANKSHAFT AND BALANCER SHAFT

EAM20184

CRANKSHAFT AND BALANCER SHAFT

Removing the crankshaft assembly and balancer shaft

Order Job/Parts to remove Q’ty Remarks

Separate.
Crankcase Refer to “CRANKCASE” on page 5-65.
Transmission Refer to “TRANSMISSION” on page 5-72.
1 Balancer shaft 1
2 Crankshaft assembly 1

5-69
 CRANKSHAFT AND BALANCER SHAFT

EAM30491
Out of specification  Replace the crank-
REMOVING THE CRANKSHAFT shaft.
1. Remove:
• Balancer shaft “1” Turn the crankshaft slowly.
Remove the balancer shaft with its flat side “a”
Runout limit
facing the crankshaft. 0.030 mm (0.0012 in)

1
a a

2. Remove: 2. Measure:
• Crankshaft assembly “1” • Crank assembly width “a”
Out of specification  Replace the crank-
Remove the crankshaft assembly by using the shaft.
crankcase separating tool “2”.
Crank assembly width
Crankcase separating tool 55.93–56.00 mm (2.202–2.205 in)
90890-04152
Crankcase separating tool
YU-A9642

3. Check:
1 • Crankshaft sprocket “1”
Damage  Replace the crankshaft.

EAM30492 4. Check:
CHECKING THE CRANKSHAFT • Crankshaft journal oil passage
1. Measure: Obstruction  Blow out with compressed
• Crankshaft runout “a” air.

5-70
 CRANKSHAFT AND BALANCER SHAFT

EAM30493

INSTALLING THE CRANKSHAFT

1. Install:
• Crankshaft assembly
M
Install the crankshaft assembly with the crank-
shaft installer pot “1”, crankshaft installer bolt
“2”, adapter (M12) “3” and spacer “4”.

Crankshaft installer pot

90890-01274
Installing pot
YU-90058
Crankshaft installer bolt
90890-01275
Bolt
YU-90060
Adapter (M12)
90890-01278
Adapter #3
YU-90063
Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044
ECA26470

In order to prevent the crankshaft seizure,

apply molybdenum disulfide grease.

Hold the connecting rod at top dead center

(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.

4
3
1
2

5-71
 TRANSMISSION

EAM20118

TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks

10

2
E
M

9
7
E
M
3

E 5 8
M 6
1
4 E
E
5
E

Order Job/Parts to remove Q’ty Remarks

Engine Refer to “ENGINE REMOVAL” on page 5-6.
Separate.
Crankcase Refer to “CRANKCASE” on page 5-65.
1 Main axle 1
2 Drive axle 1
3 Long shift fork guide bar 1
4 Short shift fork guide bar 1
5 Spring 4
6 Shift drum 1
7 Shift fork 3 (R) 1
8 Shift fork 2 (C) 1
9 Shift fork 1 (L) 1
10 Collar 1

5-72
 TRANSMISSION

EAM30153

REMOVING THE TRANSMISSION

1. Remove:
• Long shift fork guide bar “1”
• Short shift fork guide bar “2”
• Shift drum “3”
• Shift fork 3 “4”
• Shift fork 2 “5”
• Shift fork 1 “6”
• Main axle “7”
• Drive axle “8”
• Collar “9” 2. Check:
• Shift fork guide bar
• Remove assembly with the collar “9” installed Roll the shift fork guide bar on a flat surface.
to the crankcase. Bends  Replace.
EWA12840
• Make a note of the position of each part. Pay
particular attention to the location and direc-
tion of shift forks. Do not attempt to straighten a bent shift fork
• Remove the main axle and the drive axle all to- guide bar.
gether by tapping the drive axle lightly with a 3. Check:
soft hammer. • Shift fork movement
(along the shift fork guide bar)
2 Rough movement  Replace the shift forks
and shift fork guide bar as a set.
5
1

6
3

EAM30155

8 CHECKING THE SHIFT DRUM ASSEMBLY

1. Check:
• Shift drum groove
Damage/scratches/wear  Replace the shift
drum assembly.
7 • Shift drum segment
Damage/wear  Replace the shift drum as-
EAM30154 sembly.
CHECKING THE SHIFT FORKS
1. Check:
• Shift fork cam follower “1”
• Shift fork pawl “2”
Bends/damage/scoring/wear  Replace the
shift fork.

5-73
 TRANSMISSION

EAM30156 EAM30157

CHECKING THE TRANSMISSION INSTALLING THE TRANSMISSION

1. Measure: 1. Install:
• Main axle runout • 6th pinion gear (27T) “1”
(with a centering device and dial gauge “1”) • 3rd/4th pinion gear (18T/21T) “2”
Out of specification  Replace the main ax- • Collar “3”
le. • 5th pinion gear (23T) “4”
• 2nd pinion gear (16T) “5”
Main axle runout limit (to the main axle “6”)
0.08 mm (0.0032 in)
Before installation, apply molybdenum disulfide
oil to the inner and end surface of the idler gear
and to the inner surface of the sliding gear, then
install.

4 5
3
2
1
6
2. Measure:
M
• Drive axle runout
(with a centering device and dial gauge “1”)
Out of specification  Replace the drive ax-
le. 2. Install:
• 2nd wheel gear (29T) “1”
Drive axle runout limit
0.08 mm (0.0032 in) • 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”
• O-ring “8” New
(to the drive axle “9”)

• Before installation, apply molybdenum disul-

fide oil to the inner and end surface of the idler
gear and the collar and to the inner surface of
the sliding gear, then install.
3. Check: • Apply the lithium-soap-based grease on the
• Transmission gear O-ring.
Blue discoloration/pitting/wear  Replace
the defective gear(s). 9
• Transmission gear dog M 1
Cracks/damage/rounded edges  Replace 2 8
the defective gear(s). 3
4
4. Check:
• Transmission gear movement 5
6
Rough movement  Replace the defective 7
gear(s).
M
M

5-74
 TRANSMISSION

3. Install: • Drive axle “2”

• Washer “1”
• Circlip “2” New • Install to the left crankcase simultaneously.
• Apply engine oil to the main axle and the drive
• Be sure the circlip sharp-edged corner “a” is axle bearing.
positioned opposite side to the washer and
gear “b”. 1
• Install the circlip with its ends “c” settled even-
ly on the spline crests.

1 b
E
2

6. Install:
2 a • Shift fork 1 (L) “1”
• Shift fork 2 (C) “2”
• Shift fork 3 (R) “3”
• Shift drum “4”
(to the main axle and the drive axle)
c c
• Apply engine oil to the shift fork grooves.
• Apply engine oil to the shift drum groove and
the bearing contact surface.
• Mesh the shift fork 1 (L) with the 4th wheel
gear “5” and shift fork 3 (R) with the 5th wheel
gear “6” on the drive axle.
• Mesh the shift fork 2 (C) with the 3rd/4th pinion
gear “7” on the main axle.
4. Install:
• Collar “1”
3
• Apply the lithium-soap-based grease on the
oil seal lip.
• When installing the collar into the crankcase,
pay careful attention to the crankcase oil seal 2
lip.
• Install the collar “1” so that the slit “a” faces to
the crankcase side. 1

1 a

5. Install:
• Main axle “1”

5-75
 TRANSMISSION

6 E
E
5

3
E
2
1

4
E
E

7. Install:
• Long shift fork guide bar “1”
• Short shift fork guide bar “2”
• Spring “3”

• Screw the spring into the shift fork guide bar

lightly beforehand.
• Apply the engine oil on the shift fork guide
bars.

3
E

1 2

8. Check:
• Operation of shift drum and shift fork
• Transmission operation
Unsmooth operation  Repair.

5-76
 COOLING SYSTEM

COOLING SYSTEM DIAGRAMS .................................................................... 6-1

RADIATOR....................................................................................................... 6-2
CHECKING THE RADIATOR ..................................................................... 6-4
INSTALLING THE RADIATOR.................................................................... 6-4
1
WATER PUMP ................................................................................................. 6-6
DISASSEMBLING THE WATER PUMP ..................................................... 6-7
CHECKING THE WATER PUMP................................................................ 6-7
2
ASSEMBLING THE WATER PUMP ........................................................... 6-7

3
4
5
6
7
8
9
10
 COOLING SYSTEM DIAGRAMS

EAM20186

COOLING SYSTEM DIAGRAMS

1. Radiator hose 1
2. Radiator (right)
3. Radiator hose 4
4. Water pump
5. Radiator hose 3
6. Radiator (left)

6-1
 RADIATOR

EAM20138

RADIATOR
Removing the radiator

10 N m (1.0 kgf m, 7.4 lb ft)

2 4 2 9
15 N m (1.5 kgf m, 11 lb ft)
1.5 N m (0.15 kgf m, 1.1 lb ft)
8

6 1
3
2
1 1.5 N m (0.15 kgf m, 1.1 lb ft)
2
2
7 2
5
2
10 N m (1.0 kgf m, 7.4 lb ft)
LS
New
New 2

LS

10 N m (1.0 kgf m, 7.4 lb ft) New

Order Job/Parts to remove Q’ty Remarks

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-22.
Refer to “GENERAL CHASSIS” on page
Seat 4-1.
Refer to “GENERAL CHASSIS” on page
Side cover (left/right) 4-1.
Refer to “GENERAL CHASSIS” on page
Air scoop (left/right) 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Air filter case Refer to “THROTTLE BODY” on page 7-4.
1 Radiator guard 2
2 Radiator hose clamp 8 Loosen.
3 Radiator (right) 1
4 Radiator hose 2 1
5 Radiator hose 4 1
6 Radiator hose 3 1
7 Radiator pipe 2 1
8 Radiator breather hose 1
9 Radiator (left) 1

6-2
 RADIATOR

Removing the radiator

10 N m (1.0 kgf m, 7.4 lb ft)

15 N m (1.5 kgf m, 11 lb ft)

1.5 N m (0.15 kgf m, 1.1 lb ft)

1.5 N m (0.15 kgf m, 1.1 lb ft)

10 10 N m (1.0 kgf m, 7.4 lb ft)

12
LS
New
New

11
LS

10 N m (1.0 kgf m, 7.4 lb ft) New

Order Job/Parts to remove Q’ty Remarks

10 Radiator hose 1 1
11 Radiator pipe 1 1
12 Coolant temperature sensor 1

6-3
 RADIATOR

EAM30341

CHECKING THE RADIATOR Radiator cap valve opening pres-

EWA13030
sure
107.9–137.3 kPa (1.08–1.37
A hot radiator is under pressure. Therefore, kgf/cm², 15.6–19.9 psi)
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may No stay  Replace.
be blown out, which could cause serious in- Radiator cap tester
jury. When the engine has cooled, open the 90890-01325
radiator cap as follows: Mityvac cooling system tester kit
Place a thick rag or a towel over the radiator YU-24460-A
cap and slowly turn the radiator cap counter- Radiator cap tester adapter
clockwise toward the detent to allow any re- 90890-01352
sidual pressure to escape. When the hissing Pressure tester adapter
sound has stopped, press down on the radi- YU-33984
ator cap and turn it counterclockwise to re-
move.
1. Check:
• Radiator fin “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.
EAM30506

INSTALLING THE RADIATOR

1. Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-22.
2. Check:
• Cooling system
Leaks  Repair or replace any faulty part.
2. Check: 3. Install:
• Radiator hose • Radiator cap tester “1”
• Radiator pipe • Radiator cap tester adapter “2”
Crack/damage  Replace. Radiator cap tester
3. Check: 90890-01325
• Radiator cap valve opening pressure Mityvac cooling system tester kit
a. Install the radiator cap tester adapter “2” YU-24460-A
and the radiator cap tester “3” to the radi- Radiator cap tester adapter
ator cap “1”, and activate the tester to 90890-01352
check whether it can stay for 5 to 10 sec- Pressure tester adapter
onds within standard pressure values. YU-33984

Before attaching the cap to the tester, apply wa-

ter to its sealing surface.

6-4
 RADIATOR

4. Activate the tester to apply the test pressure.

Test pressure value
137.3 kPa (1.37 kgf/cm², 19.9 psi)
ECA24270

• Do not apply such a high pressure as ex-

ceeds the test pressure.
• Make sure that a checkup after the cylinder
head gasket is replaced is made after 3
minutes of warm-up.
• Make sure that coolant is filled up to the up-
per level beforehand.
5. Check:
• Pressure value
No stay for 5 to 10 seconds at the test pres-
sure value  Correct.
• Radiator
• Radiator hose connection
Coolant leaks  Correct or replace.
• Radiator hose
Bulges  Replace.
EWA19090

When the radiator cap tester is removed,

coolant will spout; therefore, cover it with a
cloth beforehand.

6-5
 WATER PUMP

EAM20139

WATER PUMP
Removing the water pump

7 6
10 N m (1.0 kgf m, 7.4 lb ft)
8
3 5

1 9
E E
2

2
10

6
4

10 N m (1.0 kgf m, 7.4 lb ft) 14 N m (1.4 kgf m, 10 lb ft)

Order Job/Parts to remove Q’ty Remarks

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-22.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-14.
Right crankcase cover Refer to “CLUTCH” on page 5-47.
1 Water pump housing 1
2 Dowel pin 2
3 Gasket 1
4 Impeller 1
5 Circlip 1
6 Washer 2
7 Impeller shaft assembly 1
8 Bearing 1
9 Oil seal 1
10 Oil seal 1

6-6
 WATER PUMP

EAM30494

DISASSEMBLING THE WATER PUMP

1
• 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:
1
• Oil seal “1”
2. Install:
• Bearing “1”

Install the bearing by pressing its outer race par-

allel.
1

EAM30259

CHECKING THE WATER PUMP

1. Check:
1
• Water pump housing cover
• Impeller shaft
• Impeller
Cracks/damage/wear  Replace. 3. Install:
2. Check: • Impeller shaft assembly “1”
• Bearing • Washer “2”
Rotate the inner race with your finger. • Circlip “3” New
Rough spot/seizure  Replace. • Impeller “4”
Impeller
14 N·m (1.4 kgf·m, 10 lb·ft)
T.
R.

• Take care so that the oil seal lip is not dam-

aged or the spring does not slip off its position.
• When installing the impeller shaft, apply the
engine oil to the oil seal lip, the bearing, and
the impeller shaft.

EAM30262

ASSEMBLING THE WATER PUMP 3

1. Install:
• Oil seal “1” New 2
1
• Apply the lithium-soap-based grease on the
E
oil seal lip.
• Install the oil seal with its manufacture’s marks 4
or numbers facing the right crankcase cover. 2

6-7
 WATER PUMP

4. Install:
• Dowel pin “1”
• Gasket “2” New

1
1
2

5. Install:
• Water pump housing “1”
• Water pump housing bolt “2”
Water pump housing bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

• Washer “3” New

• Coolant drain bolt “4”
Coolant drain bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

2
2

4 3

6-8
 WATER PUMP

6-9
 FUEL SYSTEM

FUEL TANK ..................................................................................................... 7-1

REMOVING THE FUEL TANK.................................................................... 7-2
REMOVING THE FUEL PUMP................................................................... 7-2
CHECKING THE FUEL PUMP BODY ........................................................ 7-2
CHECKING THE FUEL PUMP OPERATION.............................................. 7-2
1
INSTALLING THE FUEL PUMP ................................................................. 7-3
INSTALLING THE FUEL TANK .................................................................. 7-3

THROTTLE BODY........................................................................................... 7-4 2

CHECKING THE INJECTOR ...................................................................... 7-7
CHECKING THE THROTTLE BODY .......................................................... 7-7
CHECKING THE FUEL PRESSURE........................................................... 7-7
ADJUSTING THE THROTTLE POSITION SENSOR................................... 7-8 3
4
5
6
7
8
9
10
 FUEL TANK

EAM20140

FUEL TANK
Removing the fuel tank
9 N m (0.9 kgf m, 6.6 lb ft) 7 N m (0.7 kgf m, 5.2 lb ft)

7 N m (0.7 kgf m, 5.2 lb ft)

4.0 N m (0.40 kgf m, 3.0 lb ft) 7

5
6
4

(2)
2

3
1
(2)
(5)
1

7 N m (0.7 kgf m, 5.2 lb ft)

8
7 N m (0.7 kgf m, 5.2 lb ft)

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS” on page
Seat 4-1.
Side cover (left/right)
Air scoop (left/right)
1 Fuel pump coupler/Fuel hose 1/1 Disconnect.
2 Fuel tank 1
3 Fuel pump bracket 1
4 Fuel pump 1
5 Fuel filter 1
6 Thermistor cover 1
7 Fuel pump gasket 1
8 Rubber damper 4

7-1
 FUEL TANK

EAM30263

REMOVING THE FUEL TANK

1. Extract the fuel in the fuel tank through the 2
fuel tank cap with a pump. 1
2. Remove:
• Fuel hose coupler
EWA19370

Cover the fuel hose connection with a cloth

when disconnecting it. This is because resid-
ual pressure in the fuel hose could cause fuel
to spurt out when the hose is removed.
ECA26520

• Make sure that the fuel hose is disconnect-

ed by hand. Do not forcefully disconnect 4
the hose with tools. 3
• When removing the fuel tank, handle it
carefully. If the discharge port of the fuel
pump touches the ground or other objects,
the discharge port could be damaged.
3. Remove:
• To disconnect the fuel hose from the fuel tank, • Side cover (left/right)
remove the fuel hose connector holder “a”, • Seat
and then slide the fuel hose connector cover. • Air scoop (left/right)
• To remove the fuel hose from the fuel rail, slide • Fuel tank
the fuel hose connector cover “1” on the end
of the hose in the direction of the arrow shown, Do not set the fuel tank down on the installation
press the two buttons “2” on the sides of the surface of the fuel pump. Be sure to lean the fuel
connector, and then remove the hose. tank against a wall or the like.
• Before removing the hose, place a few cloths
in the area under where it will be removed. EAM30264

• To prevent sand, dust, and other foreign ma- REMOVING THE FUEL PUMP
terials from entering the fuel pump, install the 1. Remove:
included fuel hose joint cover 1 “3” and the • Fuel pump
ECA24720
fuel hose joint cover 2 “4” onto the discon-
nected fuel hose and the fuel pump.
Do not drop the fuel pump or give it a strong
shock.

EAM30265

CHECKING THE FUEL PUMP BODY

1. Check:
• Fuel pump body
a Obstructions  Clean.
Cracks/damage  Replace the fuel pump
assembly.
EAM30508

CHECKING THE FUEL PUMP OPERATION

1. Check:
• Fuel pump operation
Refer to “CHECKING THE FUEL PRES-
SURE” on page 7-7.

7-2
 FUEL TANK

EAM30266
• Take care not to kink or pinch the fuel hose.
INSTALLING THE FUEL PUMP
1. Install:
• Fuel pump gasket New • Insert the fuel hose into the fuel pipe securely
• Fuel filter New until you hear a “click”.
• Fuel pump • Slide the fuel hose connector cover “1” at the
• Fuel pump bracket hose end in the direction of the arrow.
• Install the fuel hose connector holder “a”.
Fuel pump bolt • Check that the fuel hose and the fuel pump
7 N·m (0.7 kgf·m, 5.2 lb·ft) lead are routed through the guide on the cov-
T.
R.

er.
• Take care not to damage the installation sur-
faces of the fuel tank.
• Always use a new fuel pump gasket.
• Install the lip on the fuel pump gasket upward. 1
• Install the fuel pump as shown in the figure.
• Align the projection “a” on the fuel pump with
the slot “b” in the fuel pump bracket.
• Tighten the fuel pump bolts in the proper tight-
ening sequence as shown.

a
a

2 4 3. Connect:
• Fuel pump coupler
4. Install:
• Air scoop (left/right)
• Seat
1 • Side cover (left/right)
5 Refer to “GENERAL CHASSIS” on page 4-1.

3
EAM30267

INSTALLING THE FUEL TANK

1. Install:
• Fuel tank
2. Connect:
• Fuel hose
ECA24740

• Connect the fuel hose securely, and check

that the orientation of the installed fuel
hose holder is correct.

7-3
 THROTTLE BODY

EAM20141

THROTTLE BODY
Removing the throttle body

7 N m (0.7 kgf m, 5.2 lb ft) 3.8 N m (0.38 kgf m, 2.8 lb ft)

3 5

(2)
1
(2)

3.0 N m (0.30 kgf m, 2.2 lb ft)

8 N m (0.8 kgf m, 5.9 lb ft)

9 (2)

4.3 N m (0.43 kgf m, 3.2 lb ft) 8 7

2

4
6

10

3.5 N m (0.35 kgf m, 2.6 lb ft) 10 N m (1.0 kgf m, 7.4 lb ft)

3.0 N m (0.30 kgf m, 2.2 lb ft) 7 N m (0.7 kgf m, 5.2 lb ft)

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS” on page
Seat/Air filter case cover 4-1.
Refer to “GENERAL CHASSIS” on page
Side cover (left/right) 4-1.
Refer to “GENERAL CHASSIS” on page
Air scoop (left/right) 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
1 ECU (Engine Control Unit) 1
2 Ignition coil 1
3 Intake air temperature sensor coupler 1 Disconnect.
4 Breather hose 1
5 Air filter case 1
6 Fuel injector coupler 1 Disconnect.
7 Intake air pressure sensor coupler 1 Disconnect.
8 Throttle position sensor coupler 1 Disconnect.
9 Cover 1
10 Throttle cable cover 1

7-4
 THROTTLE BODY

Removing the throttle body

7 N m (0.7 kgf m, 5.2 lb ft) 3.8 N m (0.38 kgf m, 2.8 lb ft)

11
(2)

(2)

3.0 N m (0.30 kgf m, 2.2 lb ft)

8 N m (0.8 kgf m, 5.9 lb ft)
(2)

4.3 N m (0.43 kgf m, 3.2 lb ft)

11

13

12 14

15

3.5 N m (0.35 kgf m, 2.6 lb ft) 10 N m (1.0 kgf m, 7.4 lb ft)

3.0 N m (0.30 kgf m, 2.2 lb ft) 7 N m (0.7 kgf m, 5.2 lb ft)

Order Job/Parts to remove Q’ty Remarks

11 Throttle cable 2
12 Fuel hose 1
13 Throttle body 1
14 Exhaust pipe bracket 1
15 Throttle body joint 1

7-5
 THROTTLE BODY

Removing the injector

(2) 1

3.5 N m (0.35 kgf m, 2.6 lb ft)

5
2
3.5 N m (0.35 kgf m, 2.6 lb ft)

Order Job/Parts to remove Q’ty Remarks

1 Fuel inlet pipe 1
2 Injector 1
3 Gasket 1
4 Throttle position sensor 1
5 Intake air pressure sensor 1

7-6
 THROTTLE BODY

EAM30271

CHECKING THE INJECTOR

1. Check:
• Injector
Obstruction  Replace, and check the fuel
pump and the fuel injection system. 2
1
Refer to “FUEL INJECTION SYSTEM” on
page 8-17.
Deposits  Replace.
Damage  Replace.
2. Check:
• Injector resistance
Refer to “CHECKING THE INJECTOR” on
page 8-59.
EAM30272

CHECKING THE THROTTLE BODY

1. Check:
• Throttle body
Cracks/damage  Replace.
2. Check: 3
• Fuel passages
Obstructions  Clean.
ECA26070
b
a
• Before removing the throttle body, clean
the area around the throttle body to prevent
dirt and other foreign material from falling
into the engine.
• If the throttle body is subject to strong
shocks or dropped during cleaning, re- 4
place it.
• Do not use any caustic carburetor cleaning
solution. 3. Check:
• Do not directly push the throttle valves to • Idle screw “1” passage “a”
open them. Obstruction  Blow out with compressed
• Do not loosen the throttle valve stopper air.
screw “1”, throttle valve pulley nut “2”,
throttle valve screw “3” or starter knob nut
“4”. A loss of performance may occur.
• Do not use compressed air to clean the
throttle body. Foreign materials may ad-
here to the intake air pressure sensor pas- 1
sage “a” and fuel injector “b” in the throttle
body.
a

EAM30268

CHECKING THE FUEL PRESSURE

1. Check:
• Fuel pressure
a. Remove the side cover (left/right), the seat
and the air scoop (left/right).
Refer to “GENERAL CHASSIS” on page

7-7
 THROTTLE BODY

4-1. EAM30273

b. Remove the fuel tank bolt and lift the fuel ADJUSTING THE THROTTLE POSITION
tank. SENSOR
EWA15950
c. Disconnect the fuel hose from the fuel
pump.
• Handle the throttle position sensor with
Refer to “REMOVING THE FUEL TANK”
special care.
on page 7-2.
EWA19380
• Never subject the throttle position sensor
to strong shocks. If the throttle position
Cover the fuel hose connection with a cloth sensor is dropped, replace it.
when disconnecting it. This is because resid- 1. Check:
ual pressure in the fuel hose could cause fuel • Throttle position sensor
to spurt out when the hose is removed. Refer to “CHECKING THE THROTTLE POSI-
ECA24750 TION SENSOR INPUT VOLTAGE” on page
8-57.
Make sure that the fuel hose is disconnected 2. Adjust:
by hand. Do not forcibly disconnect the hose • Throttle position sensor angle
with tools. a. Connect the Yamaha diagnostic tool.
Refer to “YAMAHA DIAGNOSTIC TOOL”
d. Connect the pressure gauge “1” and the on page 8-21.
fuel pressure adapter “2” to the fuel hose.
Yamaha diagnostic tool USB (US)
Pressure gauge 90890-03269
90890-03153 Yamaha diagnostic tool (A/I)
Pressure gauge 90890-03273
YU-03153 FI diagnostic tool sub–lead
Fuel pressure adapter 90890-03212
90890-03186 FI diagnostic tool sub–lead
Fuel pressure adapter YU-03212
YM-03186 OBD/ GST Leadwire kit
90890-03249

1 b. Temporary tighten the throttle position

sensor.
c. Check that the throttle grip is fully closed.
d. Connect the throttle position sensor to the
2 wire harness.
e. Set the Yamaha diagnostic tool to “diag-
nostic mode”.
f. Choose the diagnostic code No. “01”.
g. Adjust the throttle position sensor mount-
e. Start the engine. ed angle until “11”–“14” appears on the
f. Measure the fuel line pressure. Yamaha diagnostic tool.
Out of specification  Replace the fuel h. After adjusting the throttle position sensor
pump. mounted angle, tighten the throttle posi-
tion sensor screw “1”.
Fuel line pressure (at idle)
300–390 kPa (3.0–3.9 kgf/cm², Throttle position sensor screw
43.5–56.6 psi) 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
R.

7-8
 THROTTLE BODY

7-9
 ELECTRICAL SYSTEM

IGNITION SYSTEM ......................................................................................... 8-1

CIRCUIT DIAGRAM ................................................................................... 8-1
TROUBLESHOOTING................................................................................ 8-3

ELECTRIC STARTING SYSTEM..................................................................... 8-5

1
CIRCUIT DIAGRAM ................................................................................... 8-5
TROUBLESHOOTING................................................................................ 8-7

CHARGING SYSTEM ...................................................................................... 8-9

2
CIRCUIT DIAGRAM ................................................................................... 8-9
TROUBLESHOOTING.............................................................................. 8-11

SIGNALING SYSTEM.................................................................................... 8-13

3
CIRCUIT DIAGRAM ................................................................................. 8-13
TROUBLESHOOTING.............................................................................. 8-15

FUEL INJECTION SYSTEM.......................................................................... 8-17

4
CIRCUIT DIAGRAM ................................................................................. 8-17
ECU SELF-DIAGNOSTIC FUNCTION...................................................... 8-19
TROUBLESHOOTING METHOD ............................................................. 8-20
YAMAHA DIAGNOSTIC TOOL ................................................................ 8-21
CONNECTING THE YAMAHA DIAGNOSTIC TOOL ................................ 8-21
5
TROUBLESHOOTING DETAILS (FAULT CODE) ..................................... 8-23

FUEL PUMP SYSTEM................................................................................... 8-43

CIRCUIT DIAGRAM ................................................................................. 8-43 6
TROUBLESHOOTING.............................................................................. 8-45

ELECTRICAL COMPONENTS...................................................................... 8-46

CHECKING THE SWITCHES ................................................................... 8-47
CHECKING THE BULBS AND BULB SOCKETS ..................................... 8-49
7
CHECKING THE FUSES.......................................................................... 8-49
CHECKING AND CHARGING THE BATTERY ......................................... 8-50
CHECKING THE RELAYS........................................................................ 8-51
CHECKING THE RELAY UNIT (DIODE) ................................................... 8-52
CHECKING THE IGNITION SPARK GAP................................................. 8-53
8
CHECKING THE SPARK PLUG CAP....................................................... 8-53
CHECKING THE IGNITION COIL............................................................. 8-54
CHECKING THE CRANKSHAFT POSITION SENSOR ............................ 8-54
CHECKING THE LEAN ANGLE SENSOR................................................ 8-55
9
CHECKING THE STARTER MOTOR OPERATION .................................. 8-55
CHECKING THE STATOR COIL .............................................................. 8-55
CHECKING THE RECTIFIER/REGULATOR............................................. 8-55
CHECKING THE FUEL SENDER ............................................................. 8-56
CHECKING THE RESISTOR.................................................................... 8-56
10
CHECKING THE COOLANT TEMPERATURE SENSOR.......................... 8-56
CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE ..... 8-57
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....................... 8-58
CHECKING THE GEAR POSITION SWITCH ........................................... 8-58
CHECKING THE INJECTOR .................................................................... 8-59
 IGNITION SYSTEM

EAM20142

IGNITION SYSTEM
EAM30277

CIRCUIT DIAGRAM

8-1
 IGNITION SYSTEM

1. Crankshaft position sensor

2. AC magneto
3. Rectifier/regulator
4. Joint connector
6. Engine ground
7. Battery
8. Frame ground
9. Main fuse
10.Starter relay
11.Starter motor
12.Diode 1
13.Diode 2
14.CCU (Communication Control Unit)
21.ECU (Engine Control Unit)
22.Ignition coil
23.Spark plug
33.Engine stop switch
34.Gear position switch
35.Mode switch

A. Battery sub-lead
B. Wire harness
C. Ignition coil sub-lead
D. CCU sub-lead

8-2
 IGNITION SYSTEM

EAM30278

TROUBLESHOOTING
• The ignition system fails to operate (no spark or intermittent spark).

Before troubleshooting, remove the following part(s):

1. Side cover (left/right)
2. Seat
3. Fuel tank
4. Air scoop (left/right)
5. Air filter case cover

1. Check the ignition system wire har-

Reconnect.
ness connections. NG
OK
2. Check the fuse(s).
Refer to “CHECKING THE FUSES” Replace the fuse(s).
on page 8-49. NG
OK
3. Check the battery.
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on NG • Recharge or replace the battery.
page 8-50.
OK
4. Check the spark plug.
Refer to “CHECKING THE SPARK Correct or replace the spark plug.
PLUG” on page 3-13. NG
OK
5. Check the ignition spark gap.
Refer to “CHECKING THE IGNI- The ignition system circuit is OK.
TION SPARK GAP” on page 8-53. OK
NG
6. Check the ignition coil.
Refer to “CHECKING THE IGNI- Replace the ignition coil.
TION COIL” on page 8-54. NG
OK
7. Check the engine stop switch.
Refer to “CHECKING THE Replace the engine stop switch.
SWITCHES” on page 8-47. NG
OK
8. Check the crankshaft position sen-
sor.
Refer to “CHECKING THE CRANK- Replace the crankshaft position sensor.
SHAFT POSITION SENSOR” on NG
page 8-54.
OK

8-3
 IGNITION SYSTEM

9. Check the stator coil assembly.

Refer to “CHECKING THE STATOR Replace the stator coil assembly.
COIL” on page 8-55. NG
OK
10.Check the ignition system wire har-
ness.
Repair or replace the wire harness.
Refer to “CIRCUIT DIAGRAM” on NG
page 8-1.
OK
Replace the ECU.
• The mode switch to blink.

Before troubleshooting, remove the following part(s):

1. Seat
2. Air scoop (left)

1. Check the mode switch coupler

Reconnect.
connections. NG
OK
2. Check the mode switch.
Refer to “CHECKING THE Replace the mode switch.
SWITCHES” on page 8-47. NG
OK
3. Check the ignition system wire har-
ness.
Repair or replace the wire harness.
Refer to “CIRCUIT DIAGRAM” on NG
page 8-1.
OK
Replace the ECU.

8-4
 ELECTRIC STARTING SYSTEM

EAM20143

ELECTRIC STARTING SYSTEM

EAM30279

CIRCUIT DIAGRAM

8-5
 ELECTRIC STARTING SYSTEM

4. Joint connector
5. Main relay
6. Engine ground
7. Battery
8. Frame ground
9. Main fuse
10.Starter relay
11.Starter motor
12.Diode 1
13.Diode 2
21.ECU (Engine Control Unit)
33.Engine stop switch
34.Gear position switch
36.Start switch
37.Diode 3

A. Battery sub-lead
B. Wire harness

8-6
 ELECTRIC STARTING SYSTEM

EAM30281

TROUBLESHOOTING
The starter motor fails to turn.

Before troubleshooting, remove the following part(s):

1. Seat
2. Side cover (left/right)
3. Air scoop (left/right)
4. Fuel tank
5. Air filter case cover

1. Check the fuse.

Refer to “CHECKING THE FUSES” Replace the fuse(s).
on page 8-49. NG
OK
2. Check the battery.
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on NG • Recharge or replace the battery.
page 8-50.
OK
3. Check the main relay.
Refer to “CHECKING THE RE- Replace the main relay.
LAYS” on page 8-51. NG
OK
4. Check the starter motor operation.
Starter motor is OK. Perform the electric
Refer to “CHECKING THE START-
starting system troubleshooting, starting
ER MOTOR OPERATION” on page OK with step (6).
8-55.
NG
5. Check the starter motor.
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-45. NG
OK
6. Check the diodes.
(Diode 1, diode 2, diode 3)
Replace the diodes.
Refer to “CHECKING THE RELAY NG
UNIT (DIODE)” on page 8-52.
OK
7. Check the starter relay.
Refer to “CHECKING THE RE- Replace the starter relay.
LAYS” on page 8-51. NG
OK
8. Check the engine stop switch.
Refer to “CHECKING THE Replace the engine stop switch.
SWITCHES” on page 8-47. NG
OK

8-7
 ELECTRIC STARTING SYSTEM

9. Check the start switch.

Refer to “CHECKING THE Replace the start switch.
SWITCHES” on page 8-47. NG
OK
10.Check the entire starting system’s
wiring. Properly connect or repair the starting
Refer to “CIRCUIT DIAGRAM” on NG system’s wiring.
page 8-5.
OK
Replace the ECU.

8-8
 CHARGING SYSTEM

EAM20144

CHARGING SYSTEM
EAM30282

CIRCUIT DIAGRAM

8-9
 CHARGING SYSTEM

2. AC magneto
3. Rectifier/regulator
6. Engine ground
7. Battery
8. Frame ground
9. Main fuse

A. Battery sub-lead
B. Wire harness

8-10
 CHARGING SYSTEM

EAM30283

TROUBLESHOOTING
The battery is not being charged.

Before troubleshooting, remove the following part(s):

1. Seat
2. Air scoop (left)

1. Check the entire charging system’s

Reconnect.
wiring. NG
OK
2. Check the fuse.
Refer to “CHECKING THE FUSES” Replace the fuse(s).
on page 8-49. NG
OK
3. Check the battery.
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on NG • Recharge or replace the battery.
page 8-50.
OK
4. Check the rectifier/regulator.
Refer to “CHECKING THE RECTI- Replace the rectifier/regulator.
FIER/REGULATOR” on page 8-55. NG
OK
5. Check the stator coil assembly.
Refer to “CHECKING THE STATOR Replace the stator coil assembly.
COIL” on page 8-55. NG
OK
6. Check the charging system wire
harness.
Repair or replace the wire harness.
Refer to “CIRCUIT DIAGRAM” on NG
page 8-9.
OK
This circuit is OK.

8-11
 CHARGING SYSTEM

8-12
 SIGNALING SYSTEM

EAM20154

SIGNALING SYSTEM
EAM30348

CIRCUIT DIAGRAM

8-13
 SIGNALING SYSTEM

4. Joint connector
5. Main relay
7. Battery
8. Frame ground
9. Main fuse
15.Warning light
16.Fuel level warning light
18.Resistor
19.Fuel sender
21.ECU (Engine Control Unit)

A. Battery sub-lead
B. Wire harness

8-14
 SIGNALING SYSTEM

EAM30349

TROUBLESHOOTING
• 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

1. Check the fuse.

Refer to “CHECKING THE FUSES” Replace the fuse(s).
on page 8-49. NG
OK
2. Check the battery.
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on NG • Recharge or replace the battery.
page 8-50.
OK
3. Check the main relay.
Refer to “CHECKING THE RE- Replace the main relay.
LAYS” on page 8-51. NG
OK
4. Check the entire signaling system’s
wiring. Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on NG system’s wiring.
page 8-13.
OK
This circuit is OK.

Check the signaling system

The fuel level warning light fails to come on.
1. Check the fuel level warning light
bulb and socket.
Replace the fuel level warning light bulb,
Refer to “CHECKING THE BULBS
NG socket or both.
AND BULB SOCKETS” on page
8-49.
OK
2. Check the fuel sender.
Refer to “CHECKING THE FUEL Replace the fuel pump assembly.
SENDER” on page 8-56. NG
OK
3. Check the resistor.
Refer to “CHECKING THE RESIS- Replace the resistor.
TOR” on page 8-56. NG
OK

8-15
 SIGNALING SYSTEM

4. Check the entire signaling system’s

wiring. Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on NG system’s wiring.
page 8-13.
OK
Replace the ECU.

8-16
 FUEL INJECTION SYSTEM

EAM20145

FUEL INJECTION SYSTEM

EAM30284

CIRCUIT DIAGRAM

8-17
 FUEL INJECTION SYSTEM

1. Crankshaft position sensor

2. AC magneto
3. Rectifier/regulator
4. Joint connector
5. Main relay
6. Engine ground
7. Battery
8. Frame ground
9. Main fuse
10.Starter relay
14.CCU (Communication Control Unit)
15.Warning light
17.Engine trouble warning light
20.Yamaha diagnostic tool coupler
21.ECU (Engine Control Unit)
22.Ignition coil
23.Spark plug
24.Fuel injector
25.Fuel pump
26.Radiator fan motor fuse
27.Coupler (not used)
28.Radiator fan motor relay
29.Intake air temperature sensor
30.Coolant temperature sensor
31.Throttle position sensor
32.Intake air pressure sensor
33.Engine stop switch
34.Gear position switch

A. Battery sub-lead
B. Wire harness
C. Ignition coil sub-lead
D. CCU sub-lead

8-18
 FUEL INJECTION SYSTEM

EAM30352

ECU SELF-DIAGNOSTIC FUNCTION

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 rid-
er that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code
number is stored in the memory of the ECU.
• To inform the rider that the fuel injection system is not functioning, the engine trouble warning light
flashes while the start switch is being pushed to start the engine.
• If a malfunction is detected in the system by the self-diagnostic function, the ECU provides an ap-
propriate substitute characteristic operation, and alerts the rider of the detected malfunction by illu-
minating the engine trouble warning light.
Engine trouble warning light indication and fuel injection system operation
Warning light indication ECU operation Fuel injection operation Vehicle operation

Flashing* Warning provided when Operation stopped Cannot be operated

unable to start engine
Operated with substitute
characteristics in accor- Can or cannot be oper-
Remains on Malfunction detected ated depending on the
dance with the descrip- fault code
tion of the malfunction

* The engine trouble warning light flashes when any one of the following conditions is present and
the start switch is pushed:

12: Crankshaft position sensor 41: Lean angle sensor

(open or short circuit)
Lean angle sensor ECU internal malfunction
30: (latch up detected) 50: (faulty ECU memory)
Ignition coil
33: (Malfunction detected in the primary wire of
the ignition coil)

Checking the engine trouble warning light

The engine trouble warning light comes on for around 2 seconds when pushing the start switch to turn
on the engine trouble warning light comes on while the start switch is being pushed.

a b

c d c

a. Start switch is not being pushed.

b. Start switch is being pushed.
c. Engine trouble warning light goes off
d. Engine trouble warning light comes on for
around 2 seconds

8-19
 FUEL INJECTION SYSTEM

ECU detects an abnormal signal from a sensor

If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-
nates the engine trouble warning light and provides the engine with alternate operating instructions
that are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue operating or stop operating, depending on the conditions.
EAM30353

TROUBLESHOOTING METHOD
The engine operation is not normal and the engine trouble warning light comes on.
1. Check:
• Fault code number
a. Connect the Yamaha diagnostic tool. Refer to “YAMAHA DIAGNOSTIC TOOL” on page 8-21.
b. Check the fault code number displayed on the Yamaha diagnostic tool.
c. Identify the faulty system with the fault code number.
d. Identify the probable cause of the malfunction.
2. Check and repair the probable cause of the malfunction.
Fault code No. No fault code No.

Check and repair. Refer to “TROUBLESHOOTING Check and repair.

DETAILS (FAULT CODE)” on page 8-23.
Monitor the operation of the sensors and actuators
in the diagnostic mode. Refer to “TROUBLESHOOT-
ING DETAILS (FAULT CODE)” on page 8-23 and
“SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC
CODE TABLE” on page 9-12.

3. Perform the reinstatement action for the fuel injection system. Refer to “Confirmation of service
completion” in the appropriate table in “TROUBLESHOOTING DETAILS (FAULT CODE)” on page
8-23.
4. After pushing the engine stop switch, push the start switch to check whether the fault code number
is displayed.

If another fault code number is displayed, repeat steps (1) to (4) until no fault code number is displayed.
5. Erase the malfunction history in the diagnostic mode. Refer to “DIAGNOSTIC CODE: SENSOR OP-
ERATION TABLE” on page 9-12 (Diagnostic code No. 62).
The engine operation is not normal, but the engine trouble warning light does not come on.
1. Check the operation of the following sensors and actuators in the diagnostic mode. Refer to
“TROUBLESHOOTING DETAILS (FAULT CODE)” on page 8-23.
01: Throttle position sensor signal (throttle angle)
30: Ignition coil
36: Injector

If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors and actuators, check and repair the inner parts of the
engine.

8-20
 FUEL INJECTION SYSTEM

EAM30285

YAMAHA DIAGNOSTIC TOOL

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 USB (US)
90890-03269
Yamaha diagnostic tool (A/I)
90890-03273

A generic scan tool can also be used to identify malfunctions.

OBD/ GST Leadwire kit

90890-03249

EAM30356

CONNECTING THE YAMAHA DIAGNOSTIC TOOL

1. Remove the coupler for connecting setting tool.

2. Connect the FI diagnostic tool sub-lead.

FI diagnostic tool sub–lead
90890-03212
FI diagnostic tool sub–lead
YU-03212

3. Connect the FI diagnostic tool sub-lead to the Yamaha diagnostic tool.

EWA20450

Never connect the sub-lead (special tool) to the battery. Otherwise, because of excessive cur-
rent flow, the sub-lead can catch fire and the battery could be damaged.

• Prepare the fully charged 12 V lead battery for yourself.

• Replace the vehicle battery with a lead battery (12 V).
• For information on how to connect and use the Yamaha diagnostic tool, refer to “YAMAHA DIAG-
NOSTIC TOOL OPERATION MANUAL”.

8-21
 FUEL INJECTION SYSTEM

5 6 7 8

1 9
2

5
3

1. ECU (Engine Control Unit)

2. Lead battery (12 V)
3. Vehicle battery
4. Vehicle
5. Coupler for connecting optional part
6. FI diagnostic tool sub-lead
7. Sub-harness (included with the Yamaha
diagnostic tool)
8. Vehicle communication cable (included with
the Yamaha diagnostic tool)
9. Yamaha diagnostic tool

8-22
 FUEL INJECTION SYSTEM

EAM30286

TROUBLESHOOTING DETAILS (FAULT CODE)

This section describes the measures per fault code number displayed on the Yamaha diagnostic tool.
Check and service the items or components that are the probable cause of the malfunction following
the order given.
After the check and service of the malfunctioning part have been completed, delete the fault codes
displayed on the Yamaha diagnostic tool according to the reinstatement method.
Fault code No.:
Fault code number displayed on the Yamaha diagnostic tool when the engine failed to work normally.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC
CODE: SENSOR OPERATION TABLE” on page 9-12.

Parts connected to the ECU

The following parts are connected to the ECU.
When checking for a power short circuit, the couplers must be disconnected from all of the following
parts beforehand.
• Crankshaft position sensor • Intake air pressure sensor
• Fuel injector • Coolant temperature sensor
• Ignition coil • Intake air temperature sensor
• Throttle position sensor

Fault code No. 12

Fault code No. 12

Crankshaft position sensor: no normal signals are received from the

Item
crankshaft position sensor.

Unable to start engine

Fail-safe system
Unable to drive vehicle
Diagnostic code No. —
Diagnostic tool display —
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of crankshaft posi- Improperly connected  Con- Crank the engine, and then
tion sensor coupler. nect the coupler securely, or check the condition of the fault
Check the locking condition of repair/replace the wire harness. code using the malfunction
the coupler. mode of the Yamaha diagnostic
Disconnect the coupler, and tool.
check the pins (for bent or bro- Condition is “Recovered”  Go
ken terminals and locking con- to item 7 and finish the service.
dition of the pins). Condition is “Detected”  Go
to item 2.
2 Connection of wire harness Improperly connected  Con- Crank the engine, and then
ECU coupler. nect the coupler securely, or check the condition of the fault
Check the locking condition of repair/replace the wire harness. code using the malfunction
the coupler. mode of the Yamaha diagnostic
Disconnect the coupler, and tool.
check the pins (for bent or bro- Condition is “Recovered”  Go
ken terminals and locking con- to item 7 and finish the service.
dition of the pins). Condition is “Detected”  Go
to item 3.

8-23
 FUEL INJECTION SYSTEM

Fault code No. 12

Crankshaft position sensor: no normal signals are received from the

Item
crankshaft position sensor.

3 Wire harness continuity. Open or short circuit  Crank the engine, and then
Replace the wire harness. check the condition of the fault
Between the crankshaft posi- code using the malfunction
tion sensor coupler and ECU mode of the Yamaha diagnostic
coupler. tool.
gray–gray Condition is “Recovered”  Go
black/blue–black/blue to item 7 and finish the service.
Condition is “Detected”  Go
to item 4.
4 Mounted condition of crank- Improperly mounted sensor  Crank the engine, and then
shaft position sensor. Remount or replace the sensor. check the condition of the fault
Check for looseness or pinch- Refer to “GENERATOR” on code using the malfunction
ing. page 5-37. mode of the Yamaha diagnostic
Check the gap (0.85 mm tool.
(0.0335 in)) between the crank- Condition is “Recovered”  Go
shaft position sensor and the to item 7 and finish the service.
pickup rotor. Condition is “Detected”  Go
to item 5.
5 Defective crankshaft position Check the crankshaft position Crank the engine, and then
sensor. sensor. check the condition of the fault
Refer to “CHECKING THE code using the malfunction
CRANKSHAFT POSITION SEN- mode of the Yamaha diagnostic
SOR” on page 8-54. tool.
Condition is “Recovered”  Go
to item 7 and finish the service.
Condition is “Detected”  Go
to item 6.
6 Faulty ECU. Replace the ECU. Service is finished.
7 Delete the fault code. Confirm that the fault code has
a condition of “Recovered”
using the Yamaha diagnostic
tool, and then delete the fault
code.

Fault code No. 13

• If fault code numbers 13 and 14 are both displayed, perform checkup and repair jobs for fault code
number 13 first.
• Before troubleshooting, disconnect the starter motor lead from the starter relay.

Fault code No. 13

Item Intake air pressure sensor: open or short circuit detected.

Able to start engine

Fail-safe system
Able to drive vehicle
Diagnostic code No. 03
Diagnostic tool display Displays the intake air pressure.
Procedure The atmospheric pressure is displayed on the Yamaha diagnostic tool.

Item Probable cause of malfunc- Maintenance job Confirmation of service com-

tion and check pletion

8-24
 FUEL INJECTION SYSTEM

Fault code No. 13

Item Intake air pressure sensor: open or short circuit detected.

1 Connection of intake air pres- Improperly connected  Con- Start switch to ON (main relay
sure sensor coupler. nect the coupler securely, or ON), and then check the condi-
Check the locking condition of repair/replace the wire harness. tion of the fault code using the
the coupler. malfunction mode of the
Disconnect the coupler, and Yamaha diagnostic tool.
check the pins (for bent or bro- Condition is “Recovered”  Go
ken terminals and locking con- to item 7 and finish the service.
dition of the pins). Condition is “Detected”  Go
to item 2.
2 Connection of wire harness Improperly connected  Con- Start switch to ON (main relay
ECU coupler. nect the coupler securely, or ON), and then check the condi-
Check the locking condition of repair/replace the wire harness. tion of the fault code using the
the coupler. malfunction mode of the
Disconnect the coupler, and Yamaha diagnostic tool.
check the pins (for bent or bro- Condition is “Recovered”  Go
ken terminals and locking con- to item 7 and finish the service.
dition of the pins). Condition is “Detected”  Go
to item 3.
3 Wire harness continuity. Open or short circuit  Start switch to ON (main relay
Replace the wire harness. ON), and then check the condi-
Between intake air pressure tion of the fault code using the
sensor coupler and ECU cou- malfunction mode of the
pler. Yamaha diagnostic tool.
pink/black–pink/black Condition is “Recovered”  Go
blue–blue to item 7 and finish the service.
black/blue–black/blue Condition is “Detected”  Go
to item 4.
4 Mounted condition of intake air Improperly mounted sensor  Start switch to ON (main relay
pressure sensor. Remount or replace the sensor. ON), and then check the condi-
Check for looseness or pinch- tion of the fault code using the
ing. malfunction mode of the
Check the mounted position for Yamaha diagnostic tool.
correctness. Condition is “Recovered”  Go
to item 7 and finish the service.
Condition is “Detected”  Go
to item 5.
5 Defective intake air pressure Execute the diagnostic mode. Start switch to ON (main relay
sensor. (Code No. 03) ON), and then check the condi-
Atmospheric pressure at the tion of the fault code using the
current altitude and weather malfunction mode of the
conditions is indicated. Yamaha diagnostic tool.
0 m above sea level: About 101 Condition is “Recovered”  Go
kPa (about 3.63 V) to item 7 and finish the service.
1000 m above sea level: About Condition is “Detected”  Go
90 kPa (about 3.30 V) to item 6.
2000 m above sea level: About
80 kPa (about 3.00 V)
3000 m above sea level: About
70 kPa (about 2.70 V)
Abnormal display  Intake air
pressure sensor is defective 
Replace the intake air pressure
sensor.
6 Faulty ECU. Replace the ECU. Service is finished.
7 Delete the fault code. Confirm that the fault code has
a condition of “Recovered”
using the Yamaha diagnostic
tool, and then delete the fault
code.

8-25
 FUEL INJECTION SYSTEM

Fault code No. 14

• If fault code numbers 13 and 14 are both displayed, perform checkup and repair jobs for fault code
number 13 first.
• Before troubleshooting, disconnect the starter motor lead from the starter relay.

Fault code No. 14

Intake air pressure sensor: hose system malfunction (clogged or

Item detached hose).

Able to start engine

Fail-safe system
Able to drive vehicle
Diagnostic code No. 03
Diagnostic tool display Displays the intake air pressure.
Procedure The atmospheric pressure is displayed on the Yamaha diagnostic tool.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 The intake air pressure sensor Repair or replace the sensor Start the engine and let it idle
hose is damaged, discon- hose. for approximately 5 seconds
nected, clogged, twisted or (fully close the throttle valve).
bent. Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is “Recovered”  Go
to item 3 and finish the service.
Condition is “Detected”  Go
to item 2.
2 Defective intake air pressure Execute the diagnostic mode. Service is finished.
sensor. (Code No. 03)
Atmospheric pressure at the
current altitude and weather
conditions is indicated.
0 m above sea level: About 101
kPa (about 3.63 V)
1000 m above sea level: About
90 kPa (about 3.30 V)
2000 m above sea level: About
80 kPa (about 3.00 V)
3000 m above sea level: About
70 kPa (about 2.70 V)
Value does not change during
cranking  Intake air pressure
sensor replacement.
3 Delete the fault code. Confirm that the fault code has
a condition of “Recovered”
using the Yamaha diagnostic
tool, and then delete the fault
code.

8-26
 FUEL INJECTION SYSTEM

Fault code No. 15

Before troubleshooting, disconnect the starter motor lead from the starter relay.

Fault code No. 15

Item Throttle position sensor: open or short circuit detected.

Able to start engine

Fail-safe system
Able to drive vehicle
Diagnostic code No. 01
Displays the throttle angle.
Diagnostic tool display • 11–14 (throttle in fully closed position)
• 86–92 (throttle in fully opened position)

Procedure • Check with throttle fully closed.

• Check with throttle fully opened.
Probable cause of malfunc- Confirmation of service com-
Item tion and check Maintenance job pletion
1 Connection of throttle position Improperly connected  Con- Start switch to ON (main relay
sensor coupler. nect the coupler securely, or ON), and then check the condi-
Check the locking condition of repair/replace the wire harness. tion of the fault code using the
the coupler. malfunction mode of the
Disconnect the coupler, and Yamaha diagnostic tool.
check the pins (for bent or bro- Condition is “Recovered”  Go
ken terminals and locking con- to item 8 and finish the service.
dition of the pins). Condition is “Detected”  Go
to item 2.
2 Connection of wire harness Improperly connected  Con- Start switch to ON (main relay
ECU coupler. nect the coupler securely, or ON), and then check the condi-
Check the locking condition of repair/replace the wire harness. tion of the fault code using the
the coupler. malfunction mode of the
Disconnect the coupler, and Yamaha diagnostic tool.
check the pins (for bent or bro- Condition is “Recovered”  Go
ken terminals and locking con- to item 8 and finish the service.
dition of the pins). Condition is “Detected”  Go
to item 3.
3 Wire harness continuity. Open or short circuit  Start switch to ON (main relay
Replace the wire harness. ON), and then check the condi-
Between throttle position sen- tion of the fault code using the
sor coupler and ECU coupler. malfunction mode of the
yellow–yellow Yamaha diagnostic tool.
blue–blue Condition is “Recovered”  Go
black/blue–black/blue to item 8 and finish the service.
Condition is “Detected”  Go
to item 4.
4 Mounted condition of throttle Improperly mounted sensor  Start switch to ON (main relay
position sensor. Remount or replace the sensor. ON), and then check the condi-
Check for looseness or pinch- Refer to “ADJUSTING THE tion of the fault code using the
ing. THROTTLE POSITION SEN- malfunction mode of the
Check the mounted position for SOR” on page 7-8. Yamaha diagnostic tool.
correctness. Condition is “Recovered”  Go
to item 8 and finish the service.
Condition is “Detected”  Go
to item 5.

8-27
 FUEL INJECTION SYSTEM

Fault code No. 15

Item Throttle position sensor: open or short circuit detected.

5 Applied voltage of throttle posi- Check the applied voltage. Start switch to ON (main relay
tion sensor lead. (black/blue–blue) ON), and then check the condi-
tion of the fault code using the
Location of discon- Output malfunction mode of the
nected lead voltage Yamaha diagnostic tool.
Condition is “Recovered”  Go
Disconnected 5V to item 8 and finish the service.
ground lead Condition is “Detected”  Go
Disconnected out- 0V to item 6.
put lead
Disconnected 0V
power supply lead
6 Defective throttle position sen- Execute the diagnostic mode. Start switch to ON (main relay
sor. (Code No. 01) ON), and then check the condi-
When the throttle is fully closed, tion of the fault code using the
11–14 displays. malfunction mode of the
When the throttle is fully Yamaha diagnostic tool.
opened, 86–92 displays. Condition is “Recovered”  Go
Incorrect display range  to item 8 and finish the service.
Replace the throttle position Condition is “Detected”  Go
sensor. to item 7.
7 Faulty ECU. Replace the ECU. Service is finished.
8 Delete the fault code. Confirm that the fault code has
a condition of “Recovered”
using the Yamaha diagnostic
tool, and then delete the fault
code.

Fault code No. 16

• If fault code numbers 15 and 16 are both displayed, perform checkup and repair jobs for fault code
number 15 first.
• Before troubleshooting, disconnect the starter motor lead from the starter relay.

Fault code No. 16

Item Throttle position sensor: stuck throttle position sensor is detected.

Able to start engine

Fail-safe system
Able to drive vehicle
Diagnostic code No. 01
Displays the throttle angle.
Diagnostic tool display • 11–14 (throttle in fully closed position)
• 86–92 (throttle in fully opened position)
• Check with throttle fully closed.
Procedure
• Check with throttle fully opened.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion

8-28
 FUEL INJECTION SYSTEM

Fault code No. 16

Item Throttle position sensor: stuck throttle position sensor is detected.

1 Mounted condition of throttle Improperly mounted sensor  Start switch to ON (main relay
position sensor. Remount or replace the sensor. ON) and open and close the
Check for looseness or pinch- Refer to “ADJUSTING THE throttle several times.
ing. THROTTLE POSITION SEN- Check the condition of the fault
Check the mounted condition SOR” on page 7-8. code using the malfunction
for correctness. mode of the Yamaha diagnostic
tool.
Condition is “Recovered”  Go
to item 4 and finish the service.
Condition is “Detected”  Go
to item 2.
2 Defective throttle position sen- Execute the diagnostic mode. Start switch to ON (main relay
sor. (Code No. 01) ON) and open and close the
When the throttle is fully closed, throttle several times.
11–14 displays. Check the condition of the fault
When the throttle is fully code using the malfunction
opened, 86–92 displays. mode of the Yamaha diagnostic
Incorrect display range  tool.
Replace the throttle position Condition is “Recovered”  Go
sensor. to item 4 and finish the service.
Condition is “Detected”  Go
to item 3.
3 Faulty ECU. Replace the ECU. Service is finished.
4 Delete the fault code. Confirm that the fault code has
a condition of “Recovered”
using the Yamaha diagnostic
tool, and then delete the fault
code.

Fault code No. 21

• Make sure that the machine is completely cold before checking the coolant temperature sensor.
• Before troubleshooting, disconnect the starter motor lead from the starter relay.

Fault code No. 21

Item Coolant temperature sensor: open or short circuit detected.

Able to start engine

Fail-safe system
Able to drive vehicle
Diagnostic code No. 06
Diagnostic tool display Displays the coolant temperature.
Compare the actually measured coolant temperature with the Yamaha
Procedure
diagnostic tool display value.

Item Probable cause of malfunc- Maintenance job Confirmation of service com-

tion and check pletion
1 Connection of coolant tempera- Improperly connected  Con- Start switch to ON (main relay
ture sensor coupler. nect the coupler securely, or ON), and then check the condi-
Check the locking condition of repair/replace the wire harness. tion of the fault code using the
the coupler. malfunction mode of the
Disconnect the coupler, and Yamaha diagnostic tool.
check the pins (for bent or bro- Condition is “Recovered”  Go
ken terminals and locking con- to item 7 and finish the service.
dition of the pins). Condition is “Detected”  Go
to item 2.

8-29
 FUEL INJECTION SYSTEM

Fault code No. 21

Item Coolant temperature sensor: open or short circuit detected.

2 Connection of wire harness Improperly connected  Con- Start switch to ON (main relay
ECU coupler. nect the coupler securely, or ON), and then check the condi-
Check the locking condition of repair/replace the wire harness. tion of the fault code using the
the coupler. malfunction mode of the
Disconnect the coupler, and Yamaha diagnostic tool.
check the pins (for bent or bro- Condition is “Recovered”  Go
ken terminals and locking con- to item 7 and finish the service.
dition of the pins). Condition is “Detected”  Go
to item 3.
3 Wire harness continuity. Open or short circuit  Start switch to ON (main relay
Replace the wire harness. ON), and then check the condi-
Between coolant temperature tion of the fault code using the
sensor coupler and ECU cou- malfunction mode of the
pler. Yamaha diagnostic tool.
green/white–green/white Condition is “Recovered”  Go
black/blue–black/blue to item 7 and finish the service.
Condition is “Detected”  Go
to item 4.
4 Mounted condition of coolant Improperly mounted sensor  Start switch to ON (main relay
temperature sensor. Remount or replace the sensor. ON), and then check the condi-
Check for looseness or pinch- tion of the fault code using the
ing. malfunction mode of the
Check the mounted position for Yamaha diagnostic tool.
correctness. Condition is “Recovered”  Go
to item 7 and finish the service.
Condition is “Detected”  Go
to item 5.
5 Defective coolant temperature Execute the diagnostic mode. Start switch to ON (main relay
sensor. (Code No. 06) ON), and then check the condi-
When the machine is cold, dis- tion of the fault code using the
played temperature is close to malfunction mode of the
the ambient temperature. Yamaha diagnostic tool.
Improper display  Replace Condition is “Recovered”  Go
the coolant temperature sensor. to item 7 and finish the service.
Refer to “RADIATOR” on page Condition is “Detected”  Go
6-2. to item 6.
6 Faulty ECU. Replace the ECU. Service is finished.
7 Delete the fault code. Confirm that the fault code has
a condition of “Recovered”
using the Yamaha diagnostic
tool, and then delete the fault
code.

8-30
 FUEL INJECTION SYSTEM

Fault code No. 22

• Make sure that the machine is completely cold before checking the intake air temperature sensor.
• Before troubleshooting, disconnect the starter motor lead from the starter relay.

Fault code No. 22

Item Intake air temperature sensor: open or short circuit detected.

Able to start engine

Fail-safe system
Able to drive vehicle
Diagnostic code No. 05
Diagnostic tool display Displays the intake air temperature.
Compare the actually measured intake air temperature with the Yamaha
Procedure
diagnostic tool display value.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of intake air tem- Improperly connected  Con- Start switch to ON (main relay
perature sensor coupler. nect the coupler securely, or ON), and then check the condi-
Check the locking condition of repair/replace the wire harness. tion of the fault code using the
the coupler. malfunction mode of the
Disconnect the coupler, and Yamaha diagnostic tool.
check the pins (for bent or bro- Condition is “Recovered”  Go
ken terminals and locking con- to item 7 and finish the service.
dition of the pins). Condition is “Detected”  Go
to item 2.
2 Connection of wire harness Improperly connected  Con- Start switch to ON (main relay
ECU coupler. nect the coupler securely, or ON), and then check the condi-
Check the locking condition of repair/replace the wire harness. tion of the fault code using the
the coupler. malfunction mode of the
Disconnect the coupler, and Yamaha diagnostic tool.
check the pins (for bent or bro- Condition is “Recovered”  Go
ken terminals and locking con- to item 7 and finish the service.
dition of the pins). Condition is “Detected”  Go
to item 3.
3 Wire harness continuity. Open or short circuit  Start switch to ON (main relay
Replace the wire harness. ON), and then check the condi-
Between intake air temperature tion of the fault code using the
sensor coupler and ECU cou- malfunction mode of the
pler. Yamaha diagnostic tool.
brown/white–brown/white Condition is “Recovered”  Go
black/blue–black/blue to item 7 and finish the service.
Condition is “Detected”  Go
to item 4.
4 Mounted condition of intake air Improperly mounted sensor  Start switch to ON (main relay
temperature sensor. Remount or replace the sensor. ON), and then check the condi-
Check for looseness or pinch- tion of the fault code using the
ing. malfunction mode of the
Check the mounted position for Yamaha diagnostic tool.
correctness. Condition is “Recovered”  Go
to item 7 and finish the service.
Condition is “Detected”  Go
to item 5.

8-31
 FUEL INJECTION SYSTEM

Fault code No. 22

Item Intake air temperature sensor: open or short circuit detected.

5 Defective intake air temperature Execute the diagnostic mode. Start switch to ON (main relay
sensor. (Code No. 05) ON), and then check the condi-
When the machine is cold, dis- tion of the fault code using the
played temperature is close to malfunction mode of the
the ambient temperature. Yamaha diagnostic tool.
Improper display  Replace Condition is “Recovered”  Go
the intake air temperature sen- to item 7 and finish the service.
sor. Condition is “Detected”  Go
to item 6.
6 Faulty ECU. Replace the ECU. Service is finished.
7 Delete the fault code. Confirm that the fault code has
a condition of “Recovered”
using the Yamaha diagnostic
tool, and then delete the fault
code.

Fault code No. 30

Before troubleshooting, disconnect the starter motor lead from the starter relay.

Fault code No. 30

Item The vehicle has overturned.

Unable to start engine

Fail-safe system
Unable to drive vehicle
Diagnostic code No. 08
Displays the lean angle sensor output voltage.
Diagnostic tool display • 0.4–1.4 (V) (upright)
• 3.7–4.4 (V) (overturned)
Procedure Remove the ECU, and incline it 45 or more.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 The vehicle has overturned. Raise the vehicle upright. Start switch to ON (main relay
ON), wait 10 seconds, then
check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is “Recovered”  Go
to item 4 and finish the service.
Condition is “Detected”  Go
to item 2.
2 Mounted condition of ECU. Improperly mounted ECU  Start switch to ON (main relay
Check for looseness or pinch- Remount the ECU. ON), wait 10 seconds, then
ing. check the condition of the fault
Check the mounted condition code using the malfunction
for correctness. mode of the Yamaha diagnostic
tool.
Condition is “Recovered”  Go
to item 4 and finish the service.
Condition is “Detected”  Go
to item 3.

8-32
 FUEL INJECTION SYSTEM

Fault code No. 30

Item The vehicle has overturned.

3 Faulty ECU. Execute the diagnostic mode. Service is finished.

(Code No. 08)
When the vehicle is upright:
0.4–1.4 (V)
When the vehicle is overturned:
3.7–4.4 (V)
Improper display  Replace
the ECU.
4 Delete the fault code. Confirm that the fault code has
a condition of “Recovered”
using the Yamaha diagnostic
tool, and then delete the fault
code.

Fault code No. 33

Fault code No. 33

Ignition coil: open or short circuit detected in the primary lead of

Item the ignition coil.

Unable to start engine

Fail-safe system
Unable to drive vehicle
Diagnostic code No. 30
Actuates the ignition coil five times at one-second intervals.
Actuation “WARNING” on the Yamaha diagnostic tool blinks five times when the
ignition coil is actuated.
Check that a spark is generated five times.
Procedure
• Connect an ignition checker.
Probable cause of malfunc- Confirmation of service com-
Item tion and check Maintenance job pletion
1 Connection of ignition coil cou- Improperly connected  Con- Start the engine and let it idle
pler. nect the coupler securely, or for approximately 5 seconds.
Check the locking condition of repair/replace the wire harness. Check the condition of the fault
the coupler. code using the malfunction
Disconnect the coupler, and mode of the Yamaha diagnostic
check the pins (for bent or bro- tool.
ken terminals and locking con- Condition is “Recovered”  Go
dition of the pins). to item 8 and finish the service.
Condition is “Detected”  Go
to item 2.
2 Connection of wire harness Improperly connected  Con- Start the engine and let it idle
ECU coupler. nect the coupler securely, or for approximately 5 seconds.
Check the locking condition of repair/replace the wire harness. Check the condition of the fault
the coupler. code using the malfunction
Disconnect the coupler, and mode of the Yamaha diagnostic
check the pins (for bent or bro- tool.
ken terminals and locking con- Condition is “Recovered”  Go
dition of the pins). to item 8 and finish the service.
Condition is “Detected”  Go
to item 3.

8-33
 FUEL INJECTION SYSTEM

Fault code No. 33

Ignition coil: open or short circuit detected in the primary lead of

Item the ignition coil.

3 Connection of sub wire harness Improperly connected  Con- Start the engine and let it idle
coupler. nect the coupler securely, or for approximately 5 seconds.
Check the locking condition of repair/replace the sub wire har- Check the condition of the fault
the coupler. ness. code using the malfunction
Disconnect the coupler, and mode of the Yamaha diagnostic
check the pins (for bent or bro- tool.
ken terminals and locking con- Condition is “Recovered”  Go
dition of the pins). to item 8 and finish the service.
Condition is “Detected”  Go
to item 4.
4 Wire harness continuity. Open or short circuit  Start the engine and let it idle
Replace the wire harness. for approximately 5 seconds.
Between ignition coil coupler Check the condition of the fault
and ECU coupler. code using the malfunction
orange–orange mode of the Yamaha diagnostic
red–red/blue tool.
Condition is “Recovered”  Go
to item 8 and finish the service.
Condition is “Detected”  Go
to item 5.
5 Mounted condition of ignition Improperly mounted sensor  Start the engine and let it idle
coil. Remount or replace the ignition for approximately 5 seconds.
Check for looseness or pinch- coil. Check the condition of the fault
ing. code using the malfunction
Check the mounted condition mode of the Yamaha diagnostic
for correctness. tool.
Condition is “Recovered”  Go
to item 8 and finish the service.
Condition is “Detected”  Go
to item 6.
6 Defective ignition coil. (test the Check the primary resistance of Start the engine and let it idle
primary coils for continuity) the ignition coil. for approximately 5 seconds.
Refer to “CHECKING THE IGNI- Check the condition of the fault
TION COIL” on page 8-54. code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is “Recovered”  Go
to item 8 and finish the service.
Condition is “Detected”  Go
to item 7.
7 Faulty ECU. Execute the diagnostic mode. Service is finished.
(Code No. 30)
No spark  Replace the ECU.
8 Delete the fault code. Confirm that the fault code has
a condition of “Recovered”
using the Yamaha diagnostic
tool, and then delete the fault
code.

8-34
 FUEL INJECTION SYSTEM

Fault code No. 39

Disconnect the fuel pump coupler when this diagnostic tool is used.

Fault code No. 39

Item Injector: open or short circuit detected.

Unable to start engine

Fail-safe system
Unable to drive vehicle
Diagnostic code No. 36
Actuates injector five times at one-second intervals.
Actuation “WARNING” on the Yamaha diagnostic tool blinks five times when the
injector is actuated.

Procedure Check that injector is actuated five times by listening for the operating
sound.
Probable cause of malfunc- Confirmation of service com-
Item tion and check Maintenance job pletion
1 Connection of injector coupler. Improperly connected  Con- Start the engine and let it idle
Check the locking condition of nect the coupler securely, or for approximately 5 seconds.
the coupler. repair/replace the wire harness. Check the condition of the fault
Disconnect the coupler, and code using the malfunction
check the pins (for bent or bro- mode of the Yamaha diagnostic
ken terminals and locking con- tool.
dition of the pins). Condition is “Recovered”  Go
to item 6 and finish the service.
Condition is “Detected”  Go
to item 2.
2 Defective injector. Check the injector. Start the engine and let it idle
Refer to “CHECKING THE for approximately 5 seconds.
INJECTOR” on page 8-59. Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is “Recovered”  Go
to item 6 and finish the service.
Condition is “Detected”  Go
to item 3.
3 Connection of wire harness Improperly connected  Con- Start the engine and let it idle
ECU coupler. nect the coupler securely, or for approximately 5 seconds.
Check the locking condition of repair/replace the wire harness. Check the condition of the fault
the coupler. code using the malfunction
Disconnect the coupler, and mode of the Yamaha diagnostic
check the pins (for bent or bro- tool.
ken terminals and locking con- Condition is “Recovered”  Go
dition of the pins). to item 6 and finish the service.
Condition is “Detected”  Go
to item 4.
4 Wire harness continuity. Open or short circuit  Start the engine and let it idle
Replace the wire harness. for approximately 5 seconds.
Between injector coupler and Check the condition of the fault
ECU coupler. code using the malfunction
red/black–red/black mode of the Yamaha diagnostic
Between injector coupler and tool.
starter relay. Condition is “Recovered”  Go
red/blue–red/blue to item 6 and finish the service.
red/yellow–red/yellow Condition is “Detected”  Go
red–red to item 5.
5 Faulty ECU. Replace the ECU. Service is finished.

8-35
 FUEL INJECTION SYSTEM

Fault code No. 39

Item Injector: open or short circuit detected.

6 Delete the fault code. Confirm that the fault code has
a condition of “Recovered”
using the Yamaha diagnostic
tool, and then delete the fault
code.

Fault code No. 41

Fault code No. 41

Item ECU: built-in lean angle sensor malfunction.

Unable to start engine

Fail-safe system
Able to drive vehicle
Diagnostic code No. 08
Displays the lean angle sensor output voltage.
Diagnostic tool display • 0.4–1.4 (V) (upright)
• 3.7–4.4 (V) (overturned)
Procedure Remove the ECU, and incline it 45 or more.

Item Probable cause of malfunc- Maintenance job Confirmation of service com-

tion and check pletion
1 Faulty ECU. Replace the ECU. Service is finished.

Fault code No. 43

Fault code No. 43

Item Fuel system voltage: incorrect voltage supplied to the main relay
and CCU.

Able to start engine

Fail-safe system
Able to drive vehicle
Diagnostic code No. 09

Diagnostic tool display Fuel system voltage

Approximately 12.0 (V)
Procedure Disconnect the main relay, and push the start switch.

Item Probable cause of malfunc- Maintenance job Confirmation of service com-

tion and check pletion
1 Connection of main relay cou- Improperly connected  Con- Press the start switch and the
pler. nect the coupler securely, or engine stop switch alternately
Check the locking condition of repair/replace the wire harness. to switch the power supply (=
the coupler. main relay) from “ON  OFF 
Disconnect the coupler, and ON”.
check the pins (bent or broken Check the condition of the fault
terminals and locking condition code using the malfunction
of the pins). mode of the Yamaha diagnostic
tool.
Condition is “Recovered”  Go
to item 6 and finish the service.
Condition is “Detected”  Go
to item 2.

8-36
 FUEL INJECTION SYSTEM

Fault code No. 43

Fuel system voltage: incorrect voltage supplied to the main relay

Item
and CCU.

2 Connection of wire harness Improperly connected  Con- Press the start switch and the
ECU coupler. nect the coupler securely, or engine stop switch alternately
Check the locking condition of repair/replace the wire harness. to switch the power supply (=
the coupler. main relay) from “ON  OFF 
Disconnect the coupler, and ON”.
check the pins (bent or broken Check the condition of the fault
terminals and locking condition code using the malfunction
of the pins). mode of the Yamaha diagnostic
tool.
Condition is “Recovered”  Go
to item 6 and finish the service.
Condition is “Detected”  Go
to item 3.
3 Wire harness continuity. Open or short circuit  Press the start switch and the
Replace the wire harness. engine stop switch alternately
Between battery terminal and to switch the power supply (=
main relay. main relay) from “ON  OFF 
red–red ON”.
red–red/white Check the condition of the fault
Between main relay coupler code using the malfunction
and ECU coupler. mode of the Yamaha diagnostic
brown–brown tool.
blue/red–blue/red Condition is “Recovered”  Go
to item 6 and finish the service.
Condition is “Detected”  Go
to item 4.
4 Defective main relay. No operating sound  Replace Press the start switch and the
the main relay. engine stop switch alternately
Or execute the diagnostic to switch the power supply (=
mode. (Code No. 09) main relay) from “ON  OFF 
Fuel system voltage is below 3 ON”.
V  Replace the main relay. Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is “Recovered”  Go
to item 6 and finish the service.
Condition is “Detected”  Go
to item 5.
5 Malfunction in ECU. Replace the ECU. Service is finished.
6 Delete the fault code. Confirm that the fault code has
a condition of “Recovered”
using the Yamaha diagnostic
tool, and then delete the fault
code.

8-37
 FUEL INJECTION SYSTEM

Fault code No. 44

Before troubleshooting, disconnect the starter motor lead from the starter relay.

Fault code No. 44

EEPROM fault code number: an error is detected while reading or

Item
writing on EEPROM.

Able/Unable to start engine

Fail-safe system
Able/Unable to drive vehicle
Diagnostic code No. 60
Displays the location of the abnormal portion of the EEPROM data.
• 00: No fault
Diagnostic tool display • 01: CO adjustment valve
• 07: Power Tuner injection correction setting 0–8, or Power Tuner igni-
tion timing correction setting 0–8
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Identification of malfunctioning Execute the diagnostic mode.
point. (Code No. 60)
00: Go to item 4.
01: Go to item 2.
07: Go to item 3.
2 “01” is indicated in diagnostic Change the CO concentration, Start switch to ON (main relay
mode. (Code No. 60) and rewrite in EEPROM. ON), and then check the condi-
EEPROM data error for adjust- After this adjustment, push the tion of the fault code using the
ment of CO concentration. engine stop switch, and then malfunction mode of the
push the start switch. Yamaha diagnostic tool.
Condition is “Recovered”  Go
to item 5 and finish the service.
Condition is “Detected” 
Repeat item 1.
If the same number is indicated,
go to item 4.
3 “07” is indicated in diagnostic Erase the setting map in the Start switch to ON (main relay
mode. (Code No. 60) diagnostic mode. (Code No. 65) ON), and then check the condi-
EEPROM data error for setting tion of the fault code using the
tool adjustment values for fuel malfunction mode of the
injection amount or ignition tim- Yamaha diagnostic tool.
ing. Condition is “Recovered”  Go
to item 5 and finish the service.
Condition is “Detected” 
Repeat item 1.
If the same number is indicated,
go to item 4.
4 Faulty ECU. Replace the ECU. Service is finished.
5 Delete the fault code. Confirm that the fault code has
a condition of “Recovered”
using the Yamaha diagnostic
tool, and then delete the fault
code.

8-38
 FUEL INJECTION SYSTEM

Fault code No. 46

Fault code No. 46

Vehicle system power supply: normal voltage is not supplied to the

Item ECU.

Able/Unable to start engine

Fail-safe system
Able/Unable to drive vehicle
Diagnostic code No. —
Diagnostic tool display —
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of rectifier/regulator Improperly connected  Con- Start the engine and let it idle
coupler. nect the coupler securely, or for approximately 5 seconds.
Check the locking condition of repair/replace the wire harness. Check the condition of the fault
the coupler. code using the malfunction
Disconnect the coupler, and mode of the Yamaha diagnostic
check the pins (bent or broken tool.
terminals and locking condition Condition is “Recovered”  Go
of the pins). to item 6 and finish the service.
Condition is “Detected”  Go
to item 2.
2 Connection of AC magneto Improperly connected  Con- Start the engine and let it idle
coupler. nect the coupler securely, or for approximately 5 seconds.
Check the locking condition of repair/replace the wire harness. Check the condition of the fault
the coupler. code using the malfunction
Disconnect the coupler, and mode of the Yamaha diagnostic
check the pins (bent or broken tool.
terminals and locking condition Condition is “Recovered”  Go
of the pins). to item 6 and finish the service.
Condition is “Detected”  Go
to item 3.
3 Wire harness continuity. Open or short circuit  Start the engine and let it idle
Replace the wire harness. for approximately 5 seconds.
Between rectifier/regulator cou- Check the condition of the fault
pler and battery terminal. code using the malfunction
red–red mode of the Yamaha diagnostic
black–black tool.
Between rectifier/regulator cou- Condition is “Recovered”  Go
pler and AC magneto coupler. to item 6 and finish the service.
white–white Condition is “Detected”  Go
to item 4.
4 Defective AC magneto. Check the AC magneto. Start the engine and let it idle
Refer to “CHECKING THE STA- for approximately 5 seconds.
TOR COIL” on page 8-55. Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is “Recovered”  Go
to item 6 and finish the service.
Condition is “Detected”  Go
to item 5.
5 Faulty ECU. Replace the ECU. Service is finished.

8-39
 FUEL INJECTION SYSTEM

Fault code No. 46

Vehicle system power supply: normal voltage is not supplied to the

Item
ECU.

6 Delete the fault code. Confirm that the fault code has
a condition of “Recovered”
using the Yamaha diagnostic
tool, and then delete the fault
code.

Fault code No. 50

Before troubleshooting, disconnect the starter motor lead from the starter relay.

Fault code No. 50

Item ECU: faulty ECU memory.

Unable to start engine

Fail-safe system
Unable to drive vehicle
Diagnostic code No. —
Diagnostic tool display —
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Faulty ECU. Replace the ECU. Start switch to ON (main relay
ON), and then check the condi-
tion of the fault code using the
malfunction mode of the
Yamaha diagnostic tool.
Check that the fault code num-
ber is not displayed.

Fault code No. 70

It is not a malfunction.
If the engine is forcibly stopped by leaving idle, the recovered state is recorded by malfunction mode.

Fault code No. 70

Engine forcibly stops when the vehicle is left idling for a long period
Item
of time.

—
Fail-safe system
Unable to drive vehicle
Diagnostic code No. —
Diagnostic tool display —
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion

8-40
 FUEL INJECTION SYSTEM

Fault code No. 70

Engine forcibly stops when the vehicle is left idling for a long period
Item of time.

1 Delete the fault code. Confirm that the fault code has
a condition of “Recovered”
using the Yamaha diagnostic
tool, and then delete the fault
code.

8-41
 FUEL INJECTION SYSTEM

8-42
 FUEL PUMP SYSTEM

EAM20146

FUEL PUMP SYSTEM

EAM30287

CIRCUIT DIAGRAM

8-43
 FUEL PUMP SYSTEM

2. AC magneto
3. Rectifier/regulator
4. Joint connector
6. Engine ground
7. Battery
8. Frame ground
9. Main fuse
21.ECU (Engine Control Unit)
25.Fuel pump
33.Engine stop switch

A. Battery sub-lead
B. Wire harness

8-44
 FUEL PUMP SYSTEM

EAM30288

TROUBLESHOOTING
The fuel pump fails to operate.

Before troubleshooting, remove the following part(s):

1. Seat
2. Side cover (left/right)
3. Air scoop (left/right)
4. Fuel tank
5. Air filter case cover

1. Check the fuel pump system wire

Reconnect.
harness connections. NG
OK
2. Check the fuse.
Refer to “CHECKING THE FUSES” Replace the fuse(s).
on page 8-49. NG
OK
3. Check the battery.
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on NG • Recharge or replace the battery.
page 8-50.
OK
4. Check the engine stop switch.
Refer to “CHECKING THE Replace the engine stop switch.
SWITCHES” on page 8-47. NG
OK
5. Check fuel pressure.
Refer to “CHECKING THE FUEL Replace the fuel pump.
PRESSURE” on page 7-7. NG
OK
6. Check the fuel pump system wire
harness connections.
Repair or replace the wire harness.
Refer to “CIRCUIT DIAGRAM” on NG
page 8-43.
OK
Replace the ECU.

8-45
 ELECTRICAL COMPONENTS

EAM20147

ELECTRICAL COMPONENTS

1. Intake air pressure sensor 19.Coolant temperature sensor

2. Throttle position sensor
3. Injector
4. Rectifier/regulator
5. Mode switch
6. Intake air temperature sensor
7. ECU (Engine Control Unit)
8. Ignition coil
9. Resistor
10.CCU (Communication Control Unit)
11.Starter relay
12.Main fuse
13.Battery
14.Radiator fan motor fuse
15.Radiator fan motor relay
16.Main relay
17.Gear position switch
18.Fuel pump

8-46
 ELECTRICAL COMPONENTS

EAM30289

CHECKING THE SWITCHES

1
4

2
B/W R/L

B B/R

P Sb Y/W
Y/W P
Sb

1. Engine stop switch

2. Mode switch
3. Gear position switch
4. Start switch

8-47
 ELECTRICAL COMPONENTS

Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect,
check the wiring connections and if necessary, replace the switch.
ECA14371

Never insert the tester probes into the coupler terminal slots. Always insert the probes from the
opposite end “a” of the coupler, taking care not to loosen or damage the leads.

Digital circuit tester (CD732)

90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927

When checking for continuity, switch back and forth between the switch positions a few times.

Terminal connections of the switch are shown in the terminal connection diagram below.
The switch positions “a” are shown in the far left column and the switch lead colors are shown in the
top row in the switch illustration.

“ ” indicates continuity between switch terminals (i.e., a closed circuit at each switch position).
The example illustration below shows that:
There is continuity between red and brown when the switch is “ON”.

8-48
 ELECTRICAL COMPONENTS

EAM30357
however, note the following.
CHECKING THE BULBS AND BULB
SOCKETS a. Install a good bulb into the bulb socket.
1. Remove: b. Connect the digital circuit tester probes to
• Bulb the respective leads of the bulb socket.
ECA25930 c. Check the bulb socket for continuity. If
any of the readings indicate no continuity,
Be sure to hold the socket firmly when re- replace the bulb socket.
moving the bulb. Never pull the lead, other- EAM30290
wise it may be pulled out of the terminal in CHECKING THE FUSES
the coupler. The following procedure applies to all of the fus-
es.
Bulbs “a” is used for warning light and can be 1. Remove:
removed from their respective socket by care- • Seat
fully pulling them out. Refer to “GENERAL CHASSIS” on page 4-1.
2. Check:
• Main fuse “1”
• Radiator fan motor fuse “2”
a
1

2. Check:
• Bulb (for continuity)
(with the digital circuit tester)
No continuity  Replace.
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927

2
Before checking for continuity, set the digital
circuit tester to the “” range. a. Connect the digital circuit tester to the
fuse and check the continuity.
3. Check:
• Bulb socket (for continuity)
Set the digital circuit tester selector to “  ”.
(with the digital circuit tester)
No continuity  Replace.
Digital circuit tester (CD732)
Digital circuit tester (CD732) 90890-03243
90890-03243 Model 88 Multimeter with ta-
Model 88 Multimeter with ta- chometer
chometer YU-A1927
YU-A1927
b. If the digital circuit tester indicates “O.L”,
replace the fuse.
Check each bulb socket for continuity in the 3. Replace:
same manner as described in the bulb section; • Fuse

8-49
 ELECTRICAL COMPONENTS

a. Install a new fuse of the correct amperage again as soon as possible. A long state of
rating. discharge below 10 V will damage the bat-
b. Push the start switch to verify if the elec- tery.
trical circuit is operational. • Do not use the specified battery charger to
c. If the fuse immediately blows again, charge a battery other than the lithium-ion
check the electrical circuit. battery. Otherwise, the battery or charger
could be damaged.
Amperage
Fuses
rating
Q’ty • Be careful not to drop the battery or subject
it to strong impacts.
Main 15 A 1 • Avoid charging the battery at high temper-
Spare 15 A 1 atures of 65 C (149 F) or more or low tem-
peratures under 0 C (32 F). A control
Radiator fan motor 5A 1 feature preventing battery charging and
EWA13310 discharging will temporarily intervene. The
battery will discharge at 65 C (149 F) or
Never use a fuse with an amperage rating more or low temperatures under -10 C (14
other than that specified. Improvising or us- F).
ing a fuse with the wrong amperage rating • If the battery is charged between 0 C (32
may cause extensive damage to the electri- F)and 10 C (50 F), battery charging may
cal system, cause the lighting and ignition stop halfway without the battery becoming
systems to malfunction and could possibly fully charged even when the specified bat-
cause a fire. tery charger is used. If this occurs, discon-
nect the battery charger, and then resume
4. Install:
charging again.
• Seat
Refer to “GENERAL CHASSIS” on page 4-1.
This model uses a lithium-ion battery. When
EAM30291
new, the battery is supplied in sleep mode to
CHECKING AND CHARGING THE BATTERY
EWA20430 minimize current discharging until first-time use.
In the sleep mode, a voltage as low as approxi-
To avoid sparking, burns, fire, and explosion: mately 0.1 V can be measured if voltage mea-
• Charge battery only with specified charger. surement is performed. As such the battery
• Use battery only for specified product – no cannot be used, but this is not a malfunction. By
other use. activating the battery as follows, the sleep
• Do not place near fire or immerse in water. mode will be canceled and the battery can be
• Do not use battery if it has been dropped, used normally.
subject to impact, or visibly damaged. Charging (activation) steps
• Do not disassemble or modify the battery, 1. Remove:
or short across its terminals. • Side cover (left/right)
ECA26041 • Seat
Refer to “GENERAL CHASSIS” on page 4-1.
To prevent damage to the battery and bat- 2. Disconnect:
tery malfunction: • Battery lead
• Be sure to charge the battery using only the (from the battery terminals)
ECA13700
specified battery charger. Do not use a
charger designed for lead-acid batteries.
Otherwise, the battery could be damaged, First, disconnect the negative battery lead,
such as from a long period of excessive and then the positive battery lead.
current or voltage exceeding 16 V. 3. Remove:
• Avoid excessive current discharge, such as • Battery
pressing the starter switch for a long time. 4. Connect the battery charger (special tool) to
Wait for more than 10 seconds before at- the battery.
tempting to start again. Charge the battery

8-50
 ELECTRICAL COMPONENTS

a. If the battery is hot, wait until the battery

Lithium battery charger has cooled down to the ambient temper-
90890-05376
ature.
Lithium battery charger
DBY-ACC51-70-02 b. Measure the voltage between the battery
terminals.
13.25 V or more  The battery is normal.
• For instructions on charging and handling the Checking is finished.
battery charger, refer to the battery charger’s Less than 13.25 V  Go to step (c).
instruction manual. c. Connect the battery charger (special tool)
• Once battery charging starts, the sleep mode to the battery and charge it.
is canceled. Lithium battery charger
5. Charge the battery until it is fully charged. 90890-05376
6. Install: Lithium battery charger
• Battery DBY-ACC51-70-02
7. Connect:
• Battery lead
For instructions on charging and handling the
(to the battery terminals)
ECA26980 battery charger, refer to the battery charger’s in-
struction manual.
First, connect the positive battery lead, and d. If the battery is hot, wait until the battery
then the negative battery lead. has cooled down to the ambient temper-
8. Check: ature.
• Battery terminal e. Measure the voltage between the battery
Dirt  Clean with a wire brush. terminals.
Loose connection  Connect properly. 13.25 V or more  The battery is normal.
9. Lubricate: Checking is finished.
• Battery terminal 10 V or more and less than 13.25 V  Per-
form from step (c) again.
Recommended lubricant Less than 10 V  Replace the battery.
Dielectric grease
Before replacing the battery, make sure that the
10.Install: battery temperature is proper (temperature not
• Seat more than 65 C (149 F) or less than 0 C (32
• Side cover (left/right) F)). Otherwise, wait until the battery tempera-
Refer to “GENERAL CHASSIS” on page 4-1. ture is proper and perform the procedure from
Checking the battery step (c) again.
ECA26080

EAM30292
The battery has a limited service life. If the CHECKING THE RELAYS
battery cannot be charged or it is deter- Check each switch for continuity with the digital
mined that the battery cannot be used after circuit tester. If the continuity reading is incor-
checking the battery, it should be replaced. rect, replace the relay.
When replacing the battery, be sure to use a
Yamaha genuine lithium-ion battery. Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
Do not check the battery at high temperature of chometer
65 C (149 F) or more or low temperatures be- YU-A1927
low 10 C (50 F). Otherwise, the control feature
preventing battery charging and discharging will 1. Disconnect the relay from the wire harness.
temporarily intervene. 2. Connect the digital circuit tester () and bat-
tery (12 V) to the relay terminal as shown.
1. Check:
Check the relay operation.
• Battery

8-51
 ELECTRICAL COMPONENTS

Out of specification  Replace. Radiator fan motor relay

Starter relay
3
3 4

2 1
R/W R/Y
L Br/W
P/L
R/L Br,R/W
R/W
4
2 1
1. Positive battery terminal
1. Positive battery terminal 2. Negative battery terminal
2. Negative battery terminal 3. Positive tester probe
3. Positive tester probe 4. Negative tester probe
4. Negative tester probe
Result
Result Continuity
Continuity (between “3” to “4”)
(between “3” to “4”)
EAM30495

Main relay CHECKING THE RELAY UNIT (DIODE)

1. Check:
3 • Diode
Out of specification  Replace.
4
Digital circuit tester (CD732)
2 90890-03243
1 Model 88 Multimeter with ta-
chometer
L/R R
Br
YU-A1927

R,R/W
The digital circuit tester and the multimeter with
1. Positive battery terminal tachometer readings are shown in the following
2. Negative battery terminal table.
3. Positive tester probe
4. Negative tester probe

Result
Continuity
(between “3” to “4”)

8-52
 ELECTRICAL COMPONENTS

system troubleshooting, starting with step

No continuity (5).
Positive tester prove 
Refer to “TROUBLESHOOTING” on page
Blue/Green “1”
Negative tester prove  Blue 8-3.
“2” Minimum ignition spark gap
Continuity 6.0 mm (0.24 in)
Positive tester prove  Blue “2”
Negative tester prove 
Blue/Green “1” If the ignition spark gap is within specification,
No continuity
the ignition system circuit is operating normally.
Positive tester prove 
Brown/White, Brown “3” a. Remove the spark plug cap from the
Negative tester prove  spark plug.
Blue/Green, Blue/White “4” b. Connect the ignition checker “1” as
Continuity shown.
Positive tester prove 
Blue/Green, Blue/White “4” Ignition checker
Negative tester prove  90890-06754
Brown/White, Brown “3” Oppama pet–4000 spark checker
No continuity YM-34487
Positive tester prove 
Blue/Black “5” c. Crank the engine, and measure the igni-
Negative tester prove  tion spark gap “a”.
Blue/Red “6”
Continuity
Positive tester prove 
Blue/Red “6”
Negative tester prove 
Blue/Black “5”

a. Disconnect the diode from the wire har-

ness.
b. Connect the digital circuit tester () to the
diode coupler as shown.
c. Check the diode for continuity. 2. Spark plug cap
d. Check the diode for no continuity.
d. Crank the engine, and gradually increase
the spark gap until a misfire occurs.
EAM30295
1 3 5 CHECKING THE SPARK PLUG CAP
1. Remove:
L/G Br/W,Br L/B • Spark plug cap
L/G, (from the spark plug lead)
L L/R
L/W 2. Check:
• Spark plug cap resistance
2 4 6 Out of specification  Replace.

A. Diode 1 Resistance
B. Diode 2 7.50–12.50 k
C. Diode 3
a. Connect the digital circuit tester () to the
EAM30294 spark plug cap.
CHECKING THE IGNITION SPARK GAP
1. Check:
• Ignition spark gap
Out of specification  Perform the ignition

8-53
 ELECTRICAL COMPONENTS

b. Measure the primary coil resistance.

Digital circuit tester (CD732) 3. Check:
90890-03243
• Secondary coil resistance
Model 88 Multimeter with ta-
chometer Out of specification  Replace.
YU-A1927 Secondary coil resistance
8.64–12.96 k

a. Connect the digital circuit tester () to the

ignition coil.
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927

b. Measure the spark plug cap resistance. • Positive tester probe 

Ignition coil terminal 1 “1”
EAM30296 • Negative tester probe 
CHECKING THE IGNITION COIL Spark plug lead “2”
1. Disconnect:
• Ignition coil terminal
(from the sub wire harness)
• Spark plug cap
(from the ignition coil) 1
2. Check:
• Primary coil resistance
Out of specification  Replace.
Primary coil resistance
2.16–2.64 
b. Measure the secondary coil resistance.
a. Connect the digital circuit tester () to the
EAM30297
ignition coil. CHECKING THE CRANKSHAFT POSITION
Digital circuit tester (CD732) SENSOR
90890-03243 1. Disconnect:
Model 88 Multimeter with ta- • Crankshaft position sensor coupler
chometer (from the wire harness)
YU-A1927 2. Check:
• Crankshaft position sensor resistance
• Positive tester probe  Out of specification  Replace.
Ignition coil terminal 1 “1”
• Negative tester probe  Crankshaft position sensor resis-
Ignition coil terminal 2 “2” tance
228–342 

a. Connect the digital circuit tester () to the

crankshaft position sensor coupler.
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927

8-54
 ELECTRICAL COMPONENTS

• Positive tester probe 

Gray “1”
• Negative tester probe 
Black “2”

1 2

Gy B b. Check the starter motor operation.

EAM30300

CHECKING THE STATOR COIL

1. Disconnect:
• Stator coil assembly coupler
b. Measure the crankshaft position sensor
(from the wire harness)
resistance.
2. Check:
EAM30298 • Stator coil assembly
CHECKING THE LEAN ANGLE SENSOR a. Connect the digital circuit tester () to the
1. Check: stator coil assembly coupler.
• Mounted condition of ECU
Improperly mounted  Remount. Digital circuit tester (CD732)
90890-03243
• The lean angle sensor is built into the ECU. Model 88 Multimeter with ta-
chometer
• The lean angle sensor stops the engine in case
YU-A1927
of a turnover.
• To ensure that the lean angle sensor operates
correctly, do not change the installed condi- • Positive tester probe 
White “1”
tion of the ECU. • Negative tester probe 
White “2”
EAM30299

CHECKING THE STARTER MOTOR

OPERATION
1. Check:
• Starter motor operation 1 2
Does not operate  Perform the electric
starting system troubleshooting, starting
with step (4).
Refer to “TROUBLESHOOTING” on page
8-7.
a. Connect the positive battery terminal “1”
and starter motor lead “2” with a jumper
b. Check the stator coil for continuity.
lead “3”.
EWA13810
c. If there is no continuity, replace the stator
coil assembly.
• A wire that is used as a jumper lead must EAM30301

have at least the same capacity of the bat- CHECKING THE RECTIFIER/REGULATOR
tery lead, otherwise the jumper lead may 1. Check:
burn. • Rectifier/regulator output voltage
• This check is likely to produce sparks, Out of specification  Replace.
therefore, make sure no flammable gas or
Regulated voltage (DC)
fluid is in the vicinity. 14.0–14.8 V

8-55
 ELECTRICAL COMPONENTS

a. Set the digital tachometer to the ignition

coil.
Digital tachometer
90890-06760
Digital tachometer
YU-39951-B

b. Connect the digital circuit tester (DCV) to

the rectifier/regulator coupler.
Digital circuit tester (CD732)
EAM30360
90890-03243
Model 88 Multimeter with ta- CHECKING THE RESISTOR
chometer 1. Disconnect:
YU-A1927 • Resistor coupler
(from the wire harness)
2. Check:
• Positive tester probe 
Red “1” • Resistor resistance
• Negative tester probe  Out of specification  Replace the resistor.
Black “2”
Resistor resistance
64.6–71.4 

a. Connect the digital circuit tester () to the

resistor as shown.
Digital circuit tester (CD732)
90890-03243
W W B R Model 88 Multimeter with ta-
chometer
2 1 YU-A1927

c. Start the engine and let it run at about • Positive tester probe 
5000 r/min. Black “1”
• Negative tester probe 
d. Measure the output voltage. Black “2”
EAM30359

CHECKING THE FUEL SENDER

1. Disconnect: 1
• Starter motor lead
(from the starter relay)
2. Connect:
• Fuel pump coupler
3. Push the start switch.
4. Check: 2
• Fuel level warning light
Out of specification  Replace the fuel
pump. b. Measure the resistance of the resistor.
Fuel pump is atmosphere “A” EAM30303

 Fuel level warning light comes on CHECKING THE COOLANT TEMPERATURE

Fuel pump is soaked in fuel “B” SENSOR
 Fuel level warning light goes off 1. Remove:
• Coolant temperature sensor

8-56
 ELECTRICAL COMPONENTS

EWA14130
continuity at the temperatures indicated
in the table.
• Handle the coolant temperature sensor
with special care.
• Never subject the coolant temperature
sensor to strong shocks. If the coolant
temperature sensor is dropped, replace it.
2. Check:
• Coolant temperature sensor resistance
Out of specification  Replace.
Coolant temperature sensor re-
sistance EAM30305
2513–2777  at 20 C (2513–2777 CHECKING THE THROTTLE POSITION
 at 68 F) SENSOR INPUT VOLTAGE
Coolant temperature sensor re- 1. Check:
sistance • Throttle position sensor input voltage
210–221  at 100 C (210–221 
Out of specification  Replace the ECU.
at 212 F)
Throttle position sensor input
a. Connect the digital circuit tester () to the voltage
coolant temperature sensor. 4–6 V
Digital circuit tester (CD732)
90890-03243 a. Connect the test harness S– pressure
Model 88 Multimeter with ta- sensor (3P) to the throttle position sensor
chometer coupler and the wire harness.
YU-A1927 b. Connect the digital circuit tester (DCV) to
the test harness S– pressure sensor (3P).
• Positive tester probe  Digital circuit tester (CD732)
Green/White “1”
• Negative tester probe  90890-03243
Black/Blue “2” Model 88 Multimeter with ta-
chometer
YU-A1927
Test harness S– pressure sensor
G/W B/L (3P)
90890-03207
Test harness S– pressure sensor
(3P)
G/W B/L YU-03207

1 2 • Positive tester probe 

Blue “1”
• Negative tester probe 
Black/Blue “2”
b. Immerse the coolant temperature sensor
in a container filled with coolant.

Make sure the coolant temperature sensor ter-

minals do not get wet.
c. Place a thermometer in the coolant.
d. Slowly heat the coolant, and then let it
cool to the specified temperature indicat-
ed in the table.
e. Check the coolant temperature sensor for

8-57
 ELECTRICAL COMPONENTS

1 2
2 1

c. Start the engine. EAM30467

d. Measure the throttle position sensor input CHECKING THE GEAR POSITION SWITCH
voltage. 1. Remove:
• Gear position switch
EAM30307

CHECKING THE INTAKE AIR 2. Check:

• Gear position switch
TEMPERATURE SENSOR
Out of specification  Replace.
1. Remove: 3.

• Intake air temperature sensor Digital circuit tester (CD732)

(from the air filter case) 90890-03243
EWA14110
Model 88 Multimeter with ta-
chometer
• Handle the intake air temperature sensor YU-A1927
with special care.
• Never subject the intake air temperature
Continuity
sensor to strong shocks. If the intake air Positive tester probe 
temperature sensor is dropped, replace it. Sky blue “1”
2. Check: Negative tester probe 
• Intake air temperature sensor resistance Sensor terminal “a”
Out of specification  Replace. Continuity
Positive tester probe 
Intake air temperature sensor re- Pink “2”
sistance Negative tester probe 
5400–6600  at 0 C (5400–6600 Sensor terminal “b”
 at 32 F) Continuity
Intake air temperature sensor re- Positive tester probe 
sistance Pink “2”
290–390  at 80 C (290–390  at Negative tester probe 
176 F) Sensor terminal “c”
Continuity
a. Connect the digital circuit tester () to the Positive tester probe 
intake air temperature sensor terminal. Yellow/White “3”
Negative tester probe 
Digital circuit tester (CD732) Sensor terminal “d”
90890-03243 Continuity
Model 88 Multimeter with ta- Positive tester probe 
chometer Yellow/White “3”
YU-A1927 Negative tester probe 
Sensor terminal “e”
• Positive tester probe  Continuity
Brown/White “1” Positive tester probe 
• Negative tester probe  Yellow/White “3”
Black/Blue “2” Negative tester probe 
Sensor terminal “f”

8-58
 ELECTRICAL COMPONENTS

f e 3 2

Y/W P
Sb
d
1
b a c

EAM30496

CHECKING THE INJECTOR

1. Remove:
• Fuel injector
Refer to “THROTTLE BODY” on page 7-4.
2. Check:
• Fuel injector resistance
Out of specification  Replace.
Resistance
12.0 

a. Disconnect the fuel injector coupler from

the fuel injector.
b. Connect the digital circuit tester () to the
fuel injector coupler.
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927

• Positive tester probe 

Injector terminal “1”
• Negative tester probe 
Injector terminal “2”

1 2

c. Measure the fuel injector resistance.

8-59
 TROUBLESHOOTING

TROUBLESHOOTING..................................................................................... 9-1
GENERAL INFORMATION......................................................................... 9-1
TROUBLESHOOTING OF ENGINE (fault code not detected) ................... 9-1
TROUBLESHOOTING OF CLUTCH .......................................................... 9-4
TROUBLESHOOTING OF TRANSMISSION .............................................. 9-6
1
TROUBLESHOOTING OF COOLING SYSTEM ......................................... 9-7
TROUBLESHOOTING OF BRAKE ............................................................. 9-8
TROUBLESHOOTING OF SUSPENSION.................................................. 9-8
TROUBLESHOOTING OF STEERING/HANDLING.................................. 9-10
TROUBLESHOOTING OF CHARGING SYSTEM .................................... 9-11
2
TROUBLESHOOTING OF SIGNALING SYSTEM .................................... 9-11

SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE .......... 9-12

SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION
3
SYSTEM)................................................................................................. 9-12
DIAGNOSTIC CODE: SENSOR OPERATION TABLE .............................. 9-12
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ......................... 9-14
4
5
6
7
8
9
10
 TROUBLESHOOTING

EAM20148

TROUBLESHOOTING
EAM30309

GENERAL INFORMATION

Troubleshooting information provided here does not cover all the trouble symptoms, possible causes,
and remedial actions. Some items may not apply depending on the model. Use this information as a
guide and quick reference matrix when performing basic troubleshooting. Refer to the each chapter
for detailed information on checking, adjustment, and replacement.

EAM30509

TROUBLESHOOTING OF ENGINE (fault code not detected)

If a fault code is detected, refer to the “FUEL INJECTION SYSTEM” on page 8-17.
Engine does not crank.
Symptom Possible cause Actions

Refer to “TROUBLESHOOTING” under “ELECTRIC STARTING

Starter motor does not operate
SYSTEM” on page 8-5.
Starter clutch malfunction Replace the starter clutch.
Improper oil grade (starter clutch Change to recommended engine
Starter motor operates, but the
engine does not crank. slipping) oil.
Disassemble and check the
Stuck piston or seized crankshaft
engine. Replace defective parts.

Engine will not start or is difficult to start, but it cranks.

Symptom Possible cause Actions

Spark plug does not produce a Refer to “TROUBLESHOOTING” under “IGNITION SYSTEM” on page
spark 8-1.
— Measure the fuel pressure.
Empty fuel tank Fill the fuel tank with fuel.
Clogged fuel tank cap breather
hole Clean the fuel tank cap.

Clean, repair, or replace the fuel

Clogged or damaged fuel hose
hose.
Check the fuel passage. Repair or
Fuel leakage
Fuel not supplied replace as necessary.
Clogged fuel pump Clean or replace the fuel pump.
Cracks or damage in fuel pump Replace the fuel pump.
Refer to “TROUBLESHOOTING”
Fuel pump malfunction under “FUEL PUMP SYSTEM” on
page 8-43.
Failed or clogged fuel injector Replace the fuel injector.
ECU failure Replace the ECU.

9-1
 TROUBLESHOOTING

Symptom Possible cause Actions

Water or foreign material in fuel,

Change fuel.
degraded fuel
Tighten the spark plug to the
Loose spark plug
specified torque.
Tighten bolts or nuts on cylinder
Loose cylinder head or cylinder head and cylinder to the specified
torque.
Damaged cylinder head gasket Replace the cylinder head gasket.
Incorrect valve timing Adjust the valve timing.
Incorrect valve clearance Adjust the valve clearance.
— Worn valve guide Replace the valve guide.
Bent, damaged, or stuck valve Replace the valve.
Poor contact between valve and Reface the valve-to-valve-seat
valve seat contact.
Fatigued or broken valve spring Replace the valve spring.
Worn, damaged, or stuck piston Replace the piston and piston
ring rings as a set.
Replace the piston and piston
Seized or damaged piston rings as a set.
Replace the cylinder, piston, and
Worn or damaged cylinder bore
piston rings as a set.

Incorrect idling speed or mid-to-high speed

Symptom Possible cause Actions

Incorrect spark plug gap Adjust the spark plug gap.

Worn or damaged spark plug Replace the spark plug.
Spark plug does not produce a
Defective spark plug cap Replace the spark plug cap.
spark
Defective ignition coil Replace the ignition coil.
ECU failure Replace the ECU.
— Measure the fuel pressure.
Check the fuel passage. Repair or
Fuel leakage
replace as necessary.
Clogged fuel pump Clean or replace the fuel pump.
Low fuel pressure
Cracks or damage in fuel pump Replace the fuel pump.
Refer to “TROUBLESHOOTING”
Fuel pump malfunction under “FUEL PUMP SYSTEM” on
page 8-43.
Failed or clogged fuel injector Replace the fuel injector.
Fuel not supplied
ECU failure Replace the ECU.

9-2
 TROUBLESHOOTING

Symptom Possible cause Actions

Worn camshaft lobe Replace the camshaft.

Water or foreign material in fuel,
Change fuel.
degraded fuel
Contaminated throttle body or
Clean the throttle body.
clogged internal passage
Incorrectly adjusted throttle cable Adjust the throttle grip free play.
Incorrectly adjusted idling speed Adjust the idle screw.
(idle screw)
Incorrect throttle position sensor Adjust the throttle position sensor
angle angle.
Incorrect acceleration position Adjust the acceleration position
— sensor angle sensor angle.
Faulty ECU Replace the ECU.
Clogged vacuum hose Clean the vacuum hose.
Cracks and damage in vacuum
Replace the vacuum hose.
hose
Damaged throttle body joint Replace the throttle body joint.
Tighten the throttle body joint
Loose throttle body joint bolts to the specified torque.
Clean or replace the air filter ele-
Clogged air filter element ment.

Incorrect oil level (high) Adjust the oil level to the specified
level.

Excessive noise from engine

Symptom Possible cause Actions

Incorrect valve clearance (too

Adjust the valve clearance.
wide)
Fatigued or broken valve spring Replace the valve spring.
Worn or damaged camshaft lobe Replace the camshaft.
Noise heard from around cylinder Replace the valve lifter and cylin-
head Worn or damaged valve lifter
der head as a set.
Worn or damaged camshaft jour-
Replace the camshaft.
nal
Worn or damaged cylinder head
Replace the cylinder head.
(camshaft journal)
Replace the timing chain, cam-
Worn or damaged timing chain shaft sprocket and camshaft as a
set.
Replace the timing chain, cam-
Worn or damaged camshaft shaft sprocket and camshaft as a
Noise heard from around timing sprocket
chain set.
Worn or damaged timing chain
Replace the timing chain guide.
guide
Cracked, damaged, or faulty tim- Replace the timing chain ten-
ing chain tensioner sioner.

9-3
 TROUBLESHOOTING

Symptom Possible cause Actions

Replace the piston and piston

Worn or damaged piston ring rings as a set.
Replace the piston and piston
Worn or damaged piston
rings as a set.
Replace the piston and piston pin
Worn piston (piston pin hole)
Noise heard from around piston as a set.
Worn or damaged piston pin Replace the piston pin.
Replace the cylinder, piston, and
Worn or damaged cylinder bore
piston rings as a set.
Carbon buildup in piston head Clean the piston head and com-
and combustion chamber bustion chamber.
Worn or damaged crankshaft
journal or crank pin Replace the crankshaft.

Cracked, worn, or damaged bal- Replace the balancer drive gear

ancer shaft and balancer shaft as a set.
Worn or damaged balancer drive Replace the balancer drive gear
Noise heard from around crank- gear and balancer shaft as a set.
shaft
Worn or damaged big end bearing Replace the big end bearing.
Worn or damaged crankshaft Replace the crankshaft journal
journal bearing bearing.
Worn or damaged balancer shaft Replace the balancer shaft journal
journal bearing bearing.
EAM30510

TROUBLESHOOTING OF CLUTCH
Manual clutch
Symptom Possible cause Actions

Improperly assembled clutch Reassemble the clutch.

Improperly adjusted clutch cable Adjust the clutch lever free play.
Tighten the clutch spring bolts to
Loose clutch spring the specified torque.
Replace the clutch springs as a
Fatigued clutch spring
set.
Warped pressure plate Replace the pressure plate.
Clutch slippage Worn friction plate Replace the friction plates as a
set.
Warped or worn clutch plate Replace the clutch plates as a set.

Incorrect oil level Adjust the engine oil level to the

specified level.
Change to recommended engine
Incorrect oil viscosity (low)
oil.
Change to recommended engine
Deteriorated oil
oil.

9-4
 TROUBLESHOOTING

Symptom Possible cause Actions

Replace the clutch springs as a

Faulty clutch spring
set.
Warped pressure plate Replace the pressure plate.
Replace the friction plates as a
Swollen friction plate
set.
Warped clutch plate Replace the clutch plates as a set.
Bent pull rod (outer pull type) Replace the pull rod.
Worn pull rod tooth (outer pull Replace the pull rod and pull lever
type) shaft as a set.
Bent push rod (inner push type) Replace the push rod.
Clutch drags
Damaged or worn clutch boss Replace the clutch boss.
Seized clutch housing bushing Replace the clutch housing.
Align the match mark on the pull
Improperly installed pull lever lever before installation.
Adjust the engine oil level to the
Incorrect oil level
specified level.
Change to recommended engine
Incorrect oil viscosity (high)
oil.
Change to recommended engine
Deteriorated oil oil.
Replace the primary drive gear or
Damaged or worn primary driven
crankshaft, and the clutch hous-
gear
ing as a set.
Tighten the clutch boss nut to the
Loose clutch boss nut
specified torque.
Clutch noise
Fatigued clutch damper Replace the clutch housing.
Replace the clutch housing bear-
Worn clutch housing bearing
ing.

Worn pressure plate bearing Replace the pressure plate bear-

ing.

9-5
 TROUBLESHOOTING

EAM30511

TROUBLESHOOTING OF TRANSMISSION
Symptom Possible cause Actions

Clutch drags Refer to “Clutch drags”.

Adjust the shift rod installation
Improperly adjusted shift rod
length.
Bent shift shaft Replace the shift shaft.
Foreign object in a shift drum Remove foreign object from shift
groove drum groove.
Damaged shift drum Replace the shift drum.
Difficult or impossible to shift Replace the shift fork and shift
transmission gear Seized shift fork
fork guide bar as a set.
Bent shift fork guide bar Replace the shift fork guide bar.
Foreign object between transmis- Remove foreign object from trans-
sion gears mission gears.
Replace the seized gear and the
Seized transmission gear
axle as a set.
Improperly assembled transmis- Reassemble the transmission axle
sion assembly.
Incorrect shift pedal position Adjust the shift pedal position.
Improperly returned stopper lever Replace the stopper lever spring.
Bent or worn shift fork Replace the shift fork.
Jumps out of gear
Shift drum incorrect axial play Replace the shift drum.
Worn shift drum groove Replace the shift drum.
Worn transmission gear dog Replace the transmission gear.
Damaged or worn transmission
gear Replace the transmission gear.

Transmission noise Worn main axle spline Replace the main axle.
Worn drive axle spline Replace the drive axle.
Worn bearing Replace the bearing.

9-6
 TROUBLESHOOTING

EAM30512

TROUBLESHOOTING OF COOLING SYSTEM

Symptom Possible cause Actions

Carbon buildup in piston head Clean the piston head and com-
and combustion chamber bustion chamber.
Clogged engine cooling water Check and clean the engine cool-
passages ing water passages.
Adjust the oil level to the specified
Incorrect oil level level.
Change to recommended engine
Incorrect oil viscosity
oil.
Change to recommended engine
Inferior oil quality
oil.
Add recommended coolant to the
Low coolant level
specified level.
Damaged or leaking radiator Replace the radiator.
Faulty radiator cap Replace the radiator cap.
Clogged radiator fin Clean the radiator fin.
Repair the radiator fin or replace
Bent or damaged radiator fin
the radiator.
Overheating
Damaged or faulty water pump Replace the water pump.
Damaged hoses or pipes Replace the hose or pipe.
Improperly connected hoses or Connect the hoses and pipes
pipes properly.
Damaged throttle body joint Replace the throttle body joint.

Loose throttle body joint Tighten the throttle body joint

bolts to the specified torque.
Clean or replace the air filter ele-
Clogged air filter element
ment.
Check the brake system and
Brake drags repair or replace faulty parts as
necessary.
Adjust to the specified spark plug
Incorrect spark plug gap
gap.
Replace the spark plug with the
Incorrect spark plug heat range
one of the specified type.
Faulty ECU Replace the ECU.
Contact between the water pump Disassemble the water pump and
housing cover and impeller replace faulty parts.
Noise from water pump
Worn water pump housing bear- Replace the water pump housing
ing bearing.

9-7
 TROUBLESHOOTING

EAM30513

TROUBLESHOOTING OF BRAKE
Symptom Possible cause Actions

Worn brake pad Replace the brake pads as a set.

Worn or deflected brake disc Replace the brake disc.
Air in hydraulic brake system Bleed the hydraulic brake system.
Check the hydraulic brake system
Brake fluid leakage and repair or replace faulty parts
as necessary.
Add brake fluid to the specified
Incorrect brake fluid level (low)
level.
Stuck brake caliper piston Replace the caliper piston seal.
Poor performance of disc brake
Stuck brake caliper and slide pin Lubricate the caliper slide pin.
Tighten the union bolt to the spec-
Loose union bolt ified torque.
Damaged brake hose and brake Replace the brake hose and brake
pipe pipe.
Oil or grease on the brake disc or Clean the brake disc or brake
brake pad pad.
Insufficient lubrication of brake Lubricate the brake lever or brake
lever or brake pedal pivot pedal pivot.

EAM30514

TROUBLESHOOTING OF SUSPENSION
Symptom Possible cause Actions

Bent or damaged inner tube Replace the inner tube.

Bent or damaged outer tube Replace the outer tube.
Damaged or worn slide metal Replace the slide metal.
Bent or damaged damper rod Replace the damper rod.
Bent wheel axle Replace the wheel axle.
Incorrect oil viscosity (high) Change to recommended fork oil.
Front fork is hard
Incorrect oil level (high) Adjust to the specified oil level.
Improperly adjusted spring pre- Adjust the spring preload.
load (hard)
Improperly adjusted rebound
Adjust the rebound damping.
damping (hard)
Improperly adjusted compression
Adjust the compression damping.
damping (hard)

9-8
 TROUBLESHOOTING

Symptom Possible cause Actions

Fatigued or broken fork spring Replace the fork spring.

Incorrect oil viscosity (low) Change to recommended fork oil.
Incorrect oil level (low) Adjust to the specified oil level.
Improperly adjusted spring pre-
Front fork is soft load (soft) Adjust the spring preload.

Improperly adjusted rebound

Adjust the rebound damping.
damping (soft)
Improperly adjusted compression
Adjust the compression damping.
damping (soft)
Bent, damaged, or corroded inner
Replace the inner tube.
tube
Cracked or damaged outer tube Replace the outer tube.
Improperly installed oil seal Replace the oil seal.
Damaged oil seal lip Replace the oil seal.
Leaking oil from front fork Incorrect oil level (high) Adjust to the specified oil level.
Tighten the damper rod assembly
Loose damper rod assembly bolt
bolt to the specified torque.
Damaged damper rod assembly Replace the damper rod assembly
bolt copper washer bolt copper washer.
Cracked or damaged cap bolt O-
Replace the cap bolt O-ring.
ring
Bent or damaged rear shock
Replace the rear shock absorber.
absorber rod
Bent swingarm pivot shaft Replace the swingarm pivot shaft.
Damaged or worn swingarm bear- Replace the swingarm bearing or
ing or bushing bushing.
Damaged or worn relay arm bear- Replace the relay arm bearing.
ing
Rear suspension is hard Damaged or worn connecting arm Replace the connecting arm bear-
bearing ing.
Improperly adjusted rear shock
Adjust the spring preload.
absorber spring preload (hard)
Improperly adjusted rear shock
Adjust the rebound damping.
absorber rebound damping (hard)
Improperly adjusted rear shock
absorber compression damping Adjust the compression damping.
(hard)

9-9
 TROUBLESHOOTING

Symptom Possible cause Actions

Oil leaking from rear shock

absorber Replace the rear shock absorber.

Gas leaking from rear shock

Replace the rear shock absorber.
absorber
Fatigued or damaged rear shock
Replace the rear shock absorber.
absorber spring
Rear suspension is soft Improperly adjusted rear shock
Adjust the spring preload.
absorber spring preload (soft)
Improperly adjusted rear shock
Adjust the rebound damping.
absorber rebound damping (soft)
Improperly adjusted rear shock
absorber compression damping Adjust the compression damping.
(soft)
Bent, damaged, or corroded rear Replace the rear shock absorber.
Oil leaking from rear shock shock absorber rod
absorber
Damaged oil seal lip Replace the rear shock absorber.
EAM30515

TROUBLESHOOTING OF STEERING/HANDLING
Symptom Possible cause Actions

Tighten the lower ring nut to the

Loose lower ring nut specified torque.
Replace the bearing and bearing
Worn bearing or bearing race
race as a set.

Handlebar wobble Warped front fork Repair or replace the front fork.
Bent front wheel axle Replace the front wheel axle.
Adjust to the specified tire pres-
Incorrect tire pressure
sure.
Worn, deformed, or incorrect tire Replace the tire.
Lower ring nut is tightened too Tighten the lower ring nut to the
tight. specified torque.
Bent lower bracket Replace the lower bracket.
Heavy steering Replace the bearing and bearing
Broken bearing or bearing race
race as a set.
Adjust to the specified tire pres-
Incorrect tire pressure
sure.

Loose spoke Tighten the spoke and adjust the

runout.
Damaged or worn wheel bearing Replace the wheel bearing.
Worn, deformed, or incorrect tire Replace the tire.
Front wheel vibration Loose wheel axle or wheel axle Tighten the wheel axle or wheel
nut axle nut to the specified torque.
Tighten the wheel axle pinch bolt
Loose wheel axle pinch bolt
to the specified torque.
Adjust to the specified front fork
Incorrect front fork oil level
oil level.

9-10
 TROUBLESHOOTING

Symptom Possible cause Actions

Tighten the spoke and adjust the

Loose spoke
runout.
Damaged or worn wheel bearing Replace the wheel bearing.
Worn, deformed, or incorrect tire Replace the tire.
Tighten the wheel axle nut to the
Loose wheel axle nut
Rear wheel vibration specified torque.
Tighten the swingarm pivot shaft
Loose swingarm pivot shaft
to the specified torque.
Bent or damaged swingarm Replace the swingarm bearing.
Damaged or worn swingarm bear- Replace the swingarm bearing or
ing or bushing bushing.
EAM30516

TROUBLESHOOTING OF CHARGING SYSTEM

Symptom Possible cause Actions

Battery is not charged Refer to “TROUBLESHOOTING” under “CHARGING SYSTEM” on

page 8-9.

EAM30521

TROUBLESHOOTING OF SIGNALING SYSTEM

Symptom Possible cause Actions

Indicator lights do not come on Refer to “TROUBLESHOOTING” under “SIGNALING SYSTEM” on

properly page 8-13.

9-11
 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAM20174

SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAM30497

SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM)

Fault code Item Page

12 Crankshaft position sensor: no normal signals are received from the crank- 8-23
shaft position sensor.
13 Intake air pressure sensor: open or short circuit detected. 8-24
Intake air pressure sensor: hose system malfunction (clogged or detached
14 8-26
hose).
15 Throttle position sensor: open or short circuit detected. 8-27
16 Throttle position sensor: stuck throttle position sensor is detected. 8-28
21 Coolant temperature sensor: open or short circuit detected. 8-29
22 Intake air temperature sensor: open or short circuit detected. 8-31
30 The vehicle has overturned. 8-32
Ignition coil: open or short circuit detected in the primary lead of the ignition
33 8-33
coil.
39 Injector: open or short circuit detected. 8-35
41 ECU: built-in lean angle sensor malfunction. 8-36
43 Fuel system voltage: incorrect voltage supplied to the main relay and CCU. 8-36

44 EEPROM fault code number: an error is detected while reading or writing 8-38
on EEPROM.
46 Vehicle system power supply: normal voltage is not supplied to the ECU. 8-39
50 ECU: faulty ECU memory. 8-40
70 Engine forcibly stops when the vehicle is left idling for a long period of time. 8-40

EAM30425

DIAGNOSTIC CODE: SENSOR OPERATION TABLE

Diag-
nostic
Item Display Procedure
code
No.

01 Throttle angle Displays the throttle angle.

• Fully closed position • 11–14 • Check with throttle fully
closed.
• Fully opened position • 86–92 • Check with throttle fully
opened.
03 Pressure of suction pipe Displays the intake air pressure. The atmospheric pressure is
• Check the change of the displayed on the Yamaha
intake pressure valve when diagnostic tool.
the starter switch is pushed.
05 Intake air temperature Displays the intake air tempera- Compare the actually mea-
ture. sured intake air temperature
with the Yamaha diagnostic
tool display value.

9-12
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Diag-
nostic
Item Display Procedure
code
No.

06 Coolant temperature Displays the coolant tempera- Compare the actually mea-
ture. sured coolant temperature
with the Yamaha diagnostic
tool display value.
08 Lean angle sensor Displays the output voltage. Remove the ECU, and incline
it 45 or more.
• Upright • 0.4–1.4 (V)
• Overturn • 3.7–4.4 (V)
09 Monitor voltage Displays the fuel system volt- —
age.
• Approximately 12.0 (V)
21 Neutral switch Operate the shift pedal.
• Gear in neutral • ON
• Gear not in neutral • OFF
25 Gear position switch Operate the shift pedal.
• Gear in 1st or 2nd • ON
• Gear in other than 1st or • OFF
2nd
60 EEPROM fault code display —
• No fault • 00
• CO adjustment valve • 01
• Power Tuner injection cor- • 07
rection setting 0–8, or
Power Tuner ignition timing
correction setting 0–8
61 Malfunction history () code —
display *1
• There is no history. • 00
• There is some history. • Other: Displays the fault code
of ().
62 Malfunction history () code Replace all () with () by
erasure *1 the operation start process-
ing.
• There is no history. • 00
• There is some history. • Other: Displays the total num-
ber of (×) and ().
64 Setting history display Displays the presence or —
absence of the setting history
by Power Tuner.
• There is no history. • 00
• There is some history. • 01
• History is unknown (History • 02
data is damaged).

9-13
 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Diag-
nostic
Item Display Procedure
code
No.

65 Setting map erasure Displays the presence or Erase all setting maps by the
absence of the setting history operation start processing.
by Power Tuner.
• There is no setting. • 00
• There is some setting. • 01
70 Program version number Displays a program version No. —
*1: Symbols used in the explanations of the malfunction history
: Normal
×: There is currently a malfunction or abnormal condition.
: A malfunction or abnormal condition occurred previously, but the affected system or component
is currently operating normally.
EAM30426

DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

Diag-
nostic
Item Actuation Procedure
code
No.

30 Ignition coil Actuates the ignition coil five Check that a spark is gener-
times at one-second intervals. ated five times.
“WARNING” on the Yamaha • Connect an ignition
diagnostic tool blinks five times checker.
when the ignition coil is actu-
ated.
36 Injector Actuates the injector five times TIP: Before performing this
at one-second intervals. operation, be sure to dis-
“WARNING” on the Yamaha connect the fuel pump cou-
diagnostic tool blinks five times pler.
when the injector is actuated. Check that injector is actu-
ated five times by listening for
the operating sound.
51 Radiator fan motor relay Actuates the radiator fan motor Check that the radiator fan
relay five times at five-second motor relay is actuated five
intervals. times by listening for the
“WARNING” on the Yamaha operating sound.
diagnostic tool blinks five times
when the radiator fan motor
relay is actuated.

9-14
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

9-15
 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
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
2
CHOOSING SET LENGTH....................................................................... 10-3
SETTING OF SPRING AFTER REPLACEMENT....................................... 10-4
REAR SHOCK ABSORBER SETTING PARTS ......................................... 10-4
SUSPENSION SETTING (FRONT FORK)................................................. 10-6
SUSPENSION SETTING (REAR SHOCK ABSORBER)............................ 10-7
3
4
5
6
7
8
9
10
 CHASSIS

EAM20119

CHASSIS Part name Type Part number

EAM30168
Rear wheel 47T 17D-25447-50
sprocket “2”
SELECTION OF THE SECONDARY 48T 17D-25448-50
REDUCTION RATIO (SPROCKET)
49T B2W-25449-00
Secondary reduction ratio = Number of 50T B2W-25450-00
rear wheel sprocket teeth/Number of
drive sprocket teeth (STD) 51T B2W-25451-00
52T 17D-25452-50
Secondary reduction ratio
3.923 (51/13)

<Requirement for selection of secondary gear

reduction ratio>
• It is generally said that the secondary gear ra-
tio should be reduced for a longer straight por-
tion of a speed course and should be
increased for a course with many corners. Ac-
tually, however, as the speed depends on the
ground condition of the day of the race, be
sure to run through the circuit to set the ma-
chine suitable for the entire course.
• In actuality, it is very difficult to achieve set-
tings suitable for the entire course and some
settings may be sacrificed. Thus, the settings
should be matched to the portion of the
course that has the greatest effect on the race
result. In such a case, run through the entire
course while making notes of lap times to find
the best balance; then, determine the second-
ary reduction ratio.
• If a course has a long straight portion where a EAM30170

TIRE PRESSURE
machine can run at maximum speed, the ma-
Tire pressure should be adjusted to suit the
chine is generally set such that it can develop
road surface condition of the circuit.
its maximum revolutions toward the end of the
straight line, with care taken to avoid the en- Standard tire pressure
gine over-revving. 100 kPa (1.00 kgf/cm², 15 psi)

Riding technique varies from rider to rider and • Under a rainy, a muddy, a sandy, or a slippery
the performance of a machine also vary from condition, the tire pressure should be lower for
machine to machine. Therefore, do not imitate a larger area of contact with the road surface.
other rider’s settings from the beginning but
Extent of adjustment
choose your own setting according to the level
60–80 kPa (0.60–0.80 kgf/cm², 9–
of your riding technique. 12 psi)
EAM30169
• Under a stony or a hard road condition, the tire
DRIVE AND REAR WHEEL SPROCKETS
SETTING PARTS pressure should be higher to prevent a flat tire.

Part name Type Part number Extent of adjustment

100–120 kPa (1.00–1.20 kgf/cm²,
Drive 15–18 psi)
(STD) 13T 9383B-13218
sprocket “1”

10-1
 CHASSIS

EAM30171

FRONT FORK SETTING

The front fork setting should be made depend-
ing on the rider’s feeling of an actual run and the
circuit conditions.
The front fork setting includes the following
three factors:
1. Setting of air spring characteristics
• Change the fork oil amount.
2. Setting of spring preload
• Change the spring.
3. Setting of damping force
• Change the compression damping force.
• Change the rebound damping force.
The spring acts on the load and the damping
force acts on the cushion travel speed.
EAM30172

CHANGE IN AMOUNT AND

CHARACTERISTICS OF FORK OIL
Damping characteristic near the final stroke can
be changed by changing the fork oil amount.
EWA19190

A. Air spring characteristics in relation to oil

amount change
Adjust the oil amount in 5 cm³ (0.2 US oz, 0.2
B. Load
Imp.oz) increments or decrements. Too
C. Stroke
small oil amount causes the front fork to pro-
duce a noise at full rebound or the rider to 1. Max. oil amount
feel some pressure on his hands or body. Al- 2. Standard oil amount
ternatively, too large oil amount will cause 3. Min. oil amount
the air spring characteristics to have a ten-
EAM30173
dency to be stiffer with the consequent dete- SETTING OF SPRING AFTER
riorated performance and characteristics. REPLACEMENT
Therefore, adjust the front fork within the As the front fork setting can be easily affected
specified range. by the rear suspension, take care so that the
front and the rear are balanced (in position etc.)
Recommended oil when setting the front fork.
Yamaha Suspension Oil S1
1. Use of soft spring
Standard oil amount
295 cm³ (9.97 US oz, 10.4 • Change the rebound damping force.
Imp.oz) Turn out one or two clicks.
Extent of adjustment • Change the compression damping force.
260–365 cm³ (8.79–12.34 US oz, Turn in one or two clicks.
9.17–12.87 Imp.oz)
Generally a soft spring gives a soft riding feel-
ing. Rebound damping tends to become stron-
ger and the front fork may sink deeply over a
series of gaps.
2. Use of stiff spring
• Change the rebound damping force.
Turn in one or two clicks.
• Change the compression damping force.
Turn out one or two clicks.

10-2
 CHASSIS

Generally a stiff spring gives a stiff riding feeling.

Rebound damping tends to become weaker, re-
sulting in lack of a sense of contact with the
road surface or in a vibrating handlebar.
a
EAM30174

FRONT FORK SETTING PARTS

• Front fork spring
STD Spring rate
4.6
N/mm
2. Remove the stand or block from the engine
Spring I.D. and, with a rider astride the seat, measure
Type rate Part number mark
N/mm (slits)
the sunken length “b” between the rear
wheel axle center and the rear fender holding
SOFT 4.1 B3J-23141-10 III bolt.
4.2 B3J-23141-20 IIII
4.3 B3J-23141-30 IIIII
4.4 B3J-23141-40 I-I
4.5 BR9-23141-20 I-II b
4.6 BR9-23141-30 I-III
4.7 BR9-23141-40 I-IIII
4.8 BR9-23141-50 I-IIIII
4.9 BR9-23141-60 II-II
3. Loosen the locknut “1” and make adjust-
5.0 BR9-23141-70 II-III ment by turning the adjuster “2” to achieve
STIFF 5.1 BR9-23141-80 II-IIII the standard figure from the subtraction of
the length “b” from the length “a”.

The I.D. mark (slits) is proved on the end of the Standard figure
spring. 90–100 mm (3.5–3.9 in)

EAM30175

REAR SUSPENSION SETTING • If the machine is new and after it is broken in,
The rear shock absorber setting should be the same set length of the spring may change
made depending on the rider’s feeling of an ac- because of the initial fatigue, etc. of the spring.
tual run and the circuit conditions. Therefore, be sure to make reevaluation.
The rear suspension setting includes the follow- • If the standard figure cannot be achieved by
ing two factors: adjusting the adjuster and changing the set
1. Setting of spring preload length, replace the spring with an optional one
• Change the set length of the spring. and make readjustment.
• Change the spring.
2. Setting of damping force
• Change the rebound damping force.
• Change the compression damping force.
1
EAM30176

CHOOSING SET LENGTH

1. Place a stand or a block under the engine to 2
put the rear wheel above the floor, and mea-
sure the length “a” between the rear wheel
axle center and the rear fender holding bolt.

10-3
 CHASSIS

EAM30177 EAM30178

SETTING OF SPRING AFTER REAR SHOCK ABSORBER SETTING PARTS

REPLACEMENT • Rear shock spring “1”
After replacement, be sure to adjust the spring STD Spring rate
to the set length [sunken length 90–100 mm 56
N/mm
(3.5–3.9 in)] and set it.
Spring
1. Use of soft spring Type rate Part number
I.D.
• Adjust to decrease rebound damping force mark
N/mm
to compensate for less spring load. Run with
BAJ-22212-00
the rebound damping force adjuster one or SOFT Black
(Blue)
two clicks turned out, and readjust it to suit
your preference. BAJ-22212-10
48 Gray
(Black)
2. Use of stiff spring
• Adjust to increase rebound damping force to BAJ-22212-30
Black
(Silver)
compensate for greater spring load. Run
with the rebound damping force adjuster one B3J-22212-00
or two clicks turned in, and readjust it to suit (Blue)
50 Green
your preference. B3J-22212-10
(Black)
Adjusting the rebound damping force will be fol- BR9-22212-00
lowed more or less by a change in the compres- (Blue)
sion damping force. For correction, adjust to 52 Yellow
BR9-22212-50
decrease compression damping force. (Black)
EWA19200
BR9-22212-10
(Blue)
When using a rear shock absorber other 54 Pink
BR9-22212-60
than currently installed, use the one whose (Black)
overall length “a” does not exceed the stan-
BR9-22212-20
dard as it may result in faulty performance. (Blue)
Never use one whose overall length is great-
er than standard. BR9-22212-70
56 White
(Black)

Length “a” of standard shock BR9-22212-A0

460.5 mm (18.1 in) (Silver)
BR9-22212-30
(Blue)
Silver
BR9-22212-80
58
(Black)
BR9-22212-B0
Gold
(Silver)
BR9-22212-40
a (Blue)
60 Brown
BR9-22212-90
STIFF (Black)

• The I.D. mark “a” is marked at the end of the

spring.
• Spring specification varies according to the
color of I.D. marks.

10-4
 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 6.0 mm (0.24 in) from
its free length.
Maximum
Position in which the spring is
turned in 18.0 mm (0.71 in) from
its free length.

For the spring preload adjustment, refer to “AD-

JUSTING THE REAR SHOCK ABSORBER AS-
SEMBLY” on page 3-31.

10-5
 CHASSIS

EAM30179

SUSPENSION SETTING (FRONT FORK)

• If any of the following symptoms is experienced with the standard position as the base, make reset-
ting by reference to the adjustment procedure given in the same chart.
• Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm
(3.5–3.9 in).

Section
Symptom Check Adjust
Large Medium Small
Jump
gap gap gap

Turn adjuster counterclockwise

Compression
damping force (about 2 clicks) to decrease
damping.
Stiff over entire
   Decrease oil amount by about 5–
range
Oil amount 10 cm³ (0.2–0.3 US oz, 0.2–0.4
Imp.oz).
Spring Replace with soft spring.
Check for any bends, dents,
Outer tube
other noticeable scars, etc. If
Inner tube
any, replace affected parts.

Unsmooth Replace with a new one for

Slide metal
movement over     extended use.
entire range Replace with a new one for
Piston metal
extended use.
Lower bracket
Retighten to specified torque.
tightening torque
Turn adjuster counterclockwise
Rebound damp-
Poor initial (about 2 clicks) to decrease
 ing force
movement damping.
Oil seals Apply grease in oil seal wall.
Compression Turn adjuster clockwise (about 2
damping force clicks) to increase damping.
Soft over entire
Increase oil amount by about 5–
range, bottom-  
Oil amount 10 cm³ (0.2–0.3 US oz, 0.2–0.4
ing out
Imp.oz).
Spring Replace with stiff spring.
Stiff toward Decrease oil amount by about 5
 Oil amount
stroke end cm³ (0.2 US oz, 0.2 Imp.oz).
Soft toward
Increase oil amount by about 5
stroke end, bot-  Oil amount
toming out cm³ (0.2 US oz, 0.2 Imp.oz).

Turn adjuster counterclockwise

Stiff initial move- Compression
    (about 2 clicks) to decrease
ment damping force
damping.

10-6
 CHASSIS

Section
Symptom Check Adjust
Large Medium Small
Jump gap gap gap

Compression Turn adjuster clockwise (about 2

damping force clicks) to increase damping.
Turn adjuster counterclockwise
Rebound damp-
(about 2 clicks) to decrease
ing force
Low front, tend- damping.
ing to lower front   Set sunken length for 95–100
posture Balance with rear mm (3.7–3.9 in) when one pas-
end senger is astride seat (lower rear
posture).
Increase oil amount by about 5
Oil amount
cm³ (0.2 US oz, 0.2 Imp.oz).
Turn adjuster counterclockwise
Compression
damping force (about 2 clicks) to decrease
damping.
Set sunken length for 90–95 mm
“Obtrusive” Balance with rear (3.5–3.7 in) when one passenger
front, tending to end is astride seat (upper rear pos-
 
upper front pos- ture).
ture
Spring Replace with soft spring.
Decrease oil amount by about 5–
Oil amount 10 cm³ (0.2–0.3 US oz, 0.2–0.4
Imp.oz).
EAM30180

SUSPENSION SETTING (REAR SHOCK ABSORBER)

• If any of the following symptoms is experienced with the standard position as the base, make reset-
ting by reference to the adjustment procedure given in the same chart.
• Adjust the rebound damping in 2-click increments or decrements.
• Adjust the low compression damping in 1-click increments or decrements.
• Adjust the high compression damping in 1/6 turn increments or decrements.

Section
Symptom Check Adjust
Large Medium Small
Jump
gap gap gap

Turn adjuster counterclockwise

Rebound damp-
(about 2 clicks) to decrease
ing force
Stiff, tending to damping.
sink  
Set sunken length for 90–100
Spring set length mm (3.5–3.9 in) when one pas-
senger is astride seat.
Rebound damp- Turn adjuster clockwise (about 2
ing force clicks) to increase damping.
Spongy and
  Low compres- Turn adjuster clockwise (about 1
unstable
sion damping click) to increase damping.
Spring Replace with stiff spring.

10-7
 CHASSIS

Section
Symptom Check Adjust
Large Medium Small
Jump
gap gap gap

Turn adjuster counterclockwise

Rebound damp-
Heavy and drag- (about 2 clicks) to decrease
  ing force damping.
ging
Spring Replace with soft spring.
Turn adjuster counterclockwise
Rebound damp-
(about 2 clicks) to decrease
ing force
damping.
Low compres- Turn adjuster clockwise (about 1
sion damping click) to increase damping.
Poor road grip-
ping  High compres- Turn adjuster clockwise (about
sion damping 1/6 turn) to increase damping.
Set sunken length for 90–100
Spring set length mm (3.5–3.9 in) when one pas-
senger is astride seat.
Spring Replace with soft spring.
High compres- Turn adjuster clockwise (about
sion damping 1/6 turn) to increase damping.
Set sunken length for 90–100
Bottoming out  
Spring set length mm (3.5–3.9 in) when one pas-
senger is astride seat.
Spring Replace with stiff spring.
Rebound damp- Turn adjuster clockwise (about 2
Bouncing   ing force clicks) to increase damping.
Spring Replace with soft spring.
Turn adjuster counterclockwise
High compres-
sion damping (about 1/6 turn) to decrease
damping.
Stiff travel   Set sunken length for 90–100
Spring set length mm (3.5–3.9 in) when one pas-
senger is astride seat.
Spring Replace with soft spring.

10-8
 CHASSIS

10-9
EAM20149 EAM30323

WIRING DIAGRAM COLOR CODE

YZ250FXR 2024 B Black
1. Crankshaft position sensor Br Brown
2. AC magneto Gy Gray
3. Rectifier/regulator L Blue
4. Joint connector Lg Light green
5. Main relay O Orange
6. Engine ground P Pink
7. Battery R Red
8. Frame ground Sb Sky blue
9. Main fuse W White
10. Starter relay Y Yellow
11. Starter motor B/L Black/Blue
12. Diode 1 B/O Black/Orange
13. Diode 2 B/R Black/Red
14. CCU (Communication Control B/W Black/White
Unit) B/Y Black/Yellow
15. Warning light Br/W Brown/White
16. Fuel level warning light G/W Green/White
17. Engine trouble warning light G/Y Green/Yellow
18. Resistor L/B Blue/Black
19. Fuel sender L/G Blue/Green
20. Yamaha diagnostic tool cou- L/R Blue/Red
pler L/W Blue/White
21. ECU (Engine Control Unit) L/Y Blue/Yellow
22. Ignition coil P/B Pink/Black
23. Spark plug P/L Pink/Blue
24. Fuel injector R/B Red/Black
25. Fuel pump R/L Red/Blue
26. Radiator fan motor fuse R/W Red/White
27. Coupler (not used) R/Y Red/Yellow
28. Radiator fan motor relay W/B White/Black
29. Intake air temperature sensor W/G White/Green
30. Coolant temperature sensor Y/G Yellow/Green
31. Throttle position sensor Y/R Yellow/Red
32. Intake air pressure sensor Y/W Yellow/White
33. Engine stop switch
34. Gear position switch
35. Mode switch
36. Start switch
37. Diode 3

A. Battery sub-lead
B. Wire harness
C. Ignition coil sub-lead
D. CCU sub-lead
For your best ownership experience, think Genuine Yamaha!
Genuine Yamaha Parts text
EAM20160

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that know your Yamaha from the inside out.

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Find out more at yamaha-motor.com

 YZ250FXR 2024
WIRING DIAGRAM

BAJ-2819U-14_WD.indd 1 2023/03/28 15:58:11

 YZ250FXR 2024
WIRING DIAGRAM

BAJ-2819U-14_WD.indd 2 2023/03/28 15:58:11