Yamaha WR250F 2016 Owner'S Service Manual Download Page 416 | Manualshive

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TROUBLESHOOTING

10-1

EAS2GB7405

TROUBLESHOOTING

EAS2GB7406

GENERAL INFORMATION

TIP

The following guide for troubleshooting does
not cover all the possible causes of trouble. It
should be helpful, however, as a guide to basic
troubleshooting. Refer to the relative procedure
in this manual for checks, adjustments, and re-
placement of parts.

EAS2GB7407

STARTING FAILURES

Engine

1. Cylinder and cylinder head

• Loose spark plug
• Loose cylinder head or cylinder
• Damaged cylinder head gasket
• Damaged cylinder gasket
• Worn or damaged cylinder
• Incorrect valve clearance
• Improperly sealed valve
• Incorrect valve-to-valve-seat contact
• Incorrect valve timing
• Faulty valve spring
• Seized valve

2. Piston and piston ring(s)

• Improperly installed piston ring
• Damaged, worn or fatigued piston ring
• Seized piston ring
• Seized or damaged piston

3. Air filter

• Improperly installed air filter
• Clogged air filter element

4. Crankcase and crankshaft

• Improperly assembled crankcase
• Seized crankshaft

Fuel system

1. Fuel tank

• Empty fuel tank
• Clogged fuel tank breather hose
• Deteriorated or contaminated fuel
• Clogged or damaged fuel hose

2. Fuel pump

• Faulty fuel pump

3. Throttle body

• Deteriorated or contaminated fuel
• Sucked-in air

Electrical system

1. Spark plug

• Incorrect spark plug gap

• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator

2. Ignition coil

• Cracked or broken ignition coil body
• Broken or shorted primary or secondary

coils

3. Ignition system

• Faulty ECU
• Faulty crankshaft position sensor
• Broken generator rotor woodruff key

4. Switches and wiring

• Faulty ECU
• Faulty engine stop switch
• Broken or shorted wiring
• Faulty neutral switch
• Improperly grounded circuit
• Loose connections

EAS2GB7408

INCORRECT ENGINE IDLING SPEED

Engine

1. Cylinder and cylinder head

• Incorrect valve clearance
• Damaged valve train components

2. Air filter

• Clogged air filter element

Fuel system

1. Throttle body

• Damaged or loose throttle body joint
• Improperly synchronized throttle bodies
• Improper throttle cable free play
• Flooded throttle body

Electrical system

1. Spark plug

• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap

2. Ignition coil

• Broken or shorted primary or secondary

coils

• Cracked or broken ignition coil

3. Ignition system

• Faulty ECU
• Faulty crankshaft position sensor
• Broken generator rotor woodruff key

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Summary of Contents for WR250F 2016

Page 1: ... 71 PRINTED ON RECYCLED PAPER 2016 WR250F WR250FG 2016 q Read this manual carefully before operating this vehicle q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule PRINTED IN JAPAN 2015 04 1 1 1 E F 2GB 28199 71_cover indd 1 2015 04 22 13 04 37 ...

Page 2: ...his manual should stay with this vehicle if it is sold Q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule Le manuel doit être remis avec le véhicule en cas de vente de ce dernier 2GB 28199 70_cover indd 2 2014 08 25 14 54 37 ...

Page 3: ... 2016 2016 WR250F WR250F 2GB 28199 71 E0 2GB 28199 71 E0 OWNER S SERVICE MANUAL OWNER S SERVICE MANUAL Read this manual carefully before operating this vehicle Read this manual carefully before operating this vehicle ...

Page 4: ......

Page 5: ...OWNER S SERVICE MANUAL 2015 by Yamaha Motor Co Ltd First edition April 2015 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Page 6: ...rmation 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 EWA WARNING 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 OPERAT...

Page 7: ...S HIGHLY FLAMMABLE Always turn off the engine while refueling Take care to not spill any gasoline on the engine or ex haust system Never refuel in the vicinity of an open flame or while smoking GASOLINE CAN CAUSE INJURY If you should swallow some gasoline inhale excess gasoline vapors or allow any gasoline to get into your eyes contact a doctor immediately If any gasoline spills onto your skin or ...

Page 8: ...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 re moval or a disassembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction chart 6 accompanies the exploded diagr...

Page 9: ...EFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Locking agent LOCTITE Engine oil Replace the part with a new one G M BF B T R LS M S LT E New ...

Page 10: ......

Page 11: ...1 2 3 4 5 6 7 8 9 10 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS TUNING CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING ...

Page 12: ......

Page 13: ...MATION 1 7 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 7 REPLACEMENT PARTS 1 7 GASKETS OIL SEALS AND O RINGS 1 8 LOCK WASHERS PLATES AND COTTER PINS 1 8 BEARINGS AND OIL SEALS 1 8 CIRCLIPS 1 8 BASIC SERVICE INFORMATION 1 9 ELECTRICAL SYSTEM 1 9 SPECIAL TOOLS 1 13 CONTROL FUNCTIONS 1 19 INDICATOR LIGHTS AND WARNING LIGHTS 1 19 ENGINE STOP SWITCH 1 19 START SWITCH 1 19 CLUTCH LEVER 1 19 SHIFT PEDAL 1 ...

Page 14: ...NCTION DIAGRAM 1 28 STARTING AND BREAK IN 1 30 FUEL 1 30 HANDLING NOTE 1 30 AIR FILTER MAINTENANCE 1 30 STARTING A COLD ENGINE 1 30 STARTING A WARM ENGINE 1 31 BREAK IN PROCEDURES 1 32 MAINTENANCE AFTER BREAK IN 1 33 MAJOR MAINTENANCE 1 33 TORQUE CHECK POINTS 1 34 MOTORCYCLE CARE AND STORAGE 1 36 CARE 1 36 STORAGE 1 37 ...

Page 15: ...LOCATION OF IMPORTANT LABELS 1 1 EAS2GB7008 LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle CAN 9 10 11 7 8 13 12 1 2 3 4 5 6 ...

Page 16: ...LOCATION OF IMPORTANT LABELS 1 2 EUR ...

Page 17: ...LOCATION OF IMPORTANT LABELS 1 3 AUS NZL ZAF ...

Page 18: ...ve pur chased 1 Clutch lever 12 Headlight 2 Multi function display 13 Radiator 3 Front brake lever 14 Coolant drain bolt 4 Throttle grip 15 Rear brake pedal 5 Start switch 16 Air filter 6 Radiator cap 17 Drive chain 7 Fuel tank cap 18 Shift pedal 8 Engine stop switch 19 Oil level check window 9 Taillight 20 Starter knob idle screw 10 Fuel tank 21 Front fork 11 Kickstarter lever 3 2 1 8 10 9 11 12 ...

Page 19: ...B7011 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the frame EAS2GB7012 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the right side of the engine EAS2GB7013 VEHICLE EMISSION CONTROL INFORMA TION LABEL The Vehicle Emission Control Information label 1 is affixed at the location in the illustration This lab...

Page 20: ...sed to pre vent mud dust and other foreign materials from entering the inside when the fuel hose is disconnected EAS2GB7019 COUPLER FOR CONNECTING OPTIONAL PART The coupler 1 is used for connecting the op tional Power Tuner and so on ECA NOTICE When no optional parts etc are connected connect the connection terminal to the orig inal coupler Before disconnecting the coupler thor oughly wipe off any...

Page 21: ...each section 5 Flammable Keep servicing areas away from any source of fire 6 During servicing take special care not to re ceive an injury or a burn on the engine the exhaust pipe the silencer or the like 7 If coolant is left adhered to the chassis paint and plating will be damaged Therefore rinse it out with water in good time EWA WARNING Coolant is potentially harmful and should be handled with s...

Page 22: ...EAS2GB7024 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 ECA NOTICE Do not spin the bearing with compressed air because this will damage the...

Page 23: ... is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water ECA NOTICE Be sure to connect the battery leads to the correct battery terminals Reversing the battery lead connections could damage the electrical components ECA NOTICE When connecting the battery leads to the battery be sure to connect the positive bat tery lead first then the negative battery lead I...

Page 24: ... then push the starter switch Be sure to wait for five seconds or longer before pushing the start switch after the multi function display goes off Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V ECA NOTICE Never insert the tester probes into the cou pler terminal slots Always insert the probes from the opposite end a of t...

Page 25: ...re to check the type of cou pler lock before disconnecting the cou pler ECA NOTICE When disconnecting a connector do not pull the leads Hold both sections of the connector and then disconnect the con nector 2 Check Lead Coupler Connector Moisture Dry with compressed air Rust stains Connect and disconnect sev eral times 3 Check All connections Loose connection Connect properly TIP If the pin 1 on t...

Page 26: ...h terminals are connected securely Make sure all connections are tight 5 Check No continuity TIP 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 Pocket tester 90890 03112 Analog pocket tester YU 03112 C ...

Page 27: ... use tool number starting with YM YU or ACC For others use tool number starting with 90890 Tool name Part number How to use Illustration Dial gauge stand set 90890 01252 Dial gauge set YU 03097 B This tool is used to check parts for runout or bend Crankshaft installer pot 90890 01274 Installing pot YU 90058 This tool is used to install the crankshaft Crankshaft installer bolt 90890 01275 Bolt YU 9...

Page 28: ... This tool is used to remove or tighten the steering nut Cap bolt wrench 90890 01500 Cap bolt wrench YM 01500 This tool is used to remove or tighten the base valve Cap bolt ring wrench 90890 01501 Cap bolt ring wrench YM 01501 This tool is used to loosen or tighten the damper assem bly Fork seal driver 90890 01502 Fork seal driver 48 YM A0948 This tool is used to install the oil seal of the front ...

Page 29: ...ness S pressure sensor 3P YU 03207 This tool is used to check the throttle position sensor input voltage Test harness lean angle sensor 6P 90890 03209 Test harness lean angle sensor 6P This tool is used to check the lean angle sensor output volt age FI diagnostic tool sub lead 90890 03212 FI diagnostic tool sub lead YU 03212 This tool is used to connect the Yamaha diagnostic tool to a battery Test...

Page 30: ...lder YM 91042 This tool is used to hold the clutch when removing or in stalling the clutch boss secur ing nut Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 This tool is used to replace the valve guide Valve guide installer ø5 90890 04098 Valve guide installer 5 0 mm YM 04098 This tool is used to replace the valve guide Valve guide reamer ø5 90890 04099 Valve guide reamer 5...

Page 31: ...Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 This tool is used to replace the valve guide Valve guide reamer ø4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 This tool is used to replace the valve guide Rotor puller 90890 04142 Rotor puller YM 04142 This tool is used to remove the rotor Crankcase separating tool 90890 04152 Crankcase separating tool YU A9642 This...

Page 32: ...890 06760 Digital tachometer YU 39951 B This tool is used to measure the engine speed Yamaha bond No 1215 90890 85505 Three bond No 1215 This sealant Bond is used for crankcase mating sur face etc Tool name Part number How to use Illustration ...

Page 33: ...light should come on for a few seconds and then go off If the warning light does not come on initially when the start switch is pushed or if the warn ing light remains on have a Yamaha dealer check the electrical circuit EAS2GB7031 ENGINE STOP SWITCH The engine stop switch 1 is located on the left handlebar Continue pushing the engine stop switch till the engine comes to a stop After the engine st...

Page 34: ...d on the right han dlebar The throttle grip accelerates or deceler ates the engine For acceleration turn the grip toward you for deceleration turn it away from you EAS2GB7037 FRONT BRAKE LEVER The front brake lever 1 is located on the right handlebar Pull it toward the handlebar to acti vate the front brake EAS2GB7038 REAR BRAKE PEDAL The rear brake pedal 1 is in the right of the chassis Press dow...

Page 35: ...toward a turns ON the start er resulting in a larger amount of intake air Pushing the knob toward b turns OFF the starter EWA WARNING While handling the starter knob idle screw take care not to burn yourself on exhaust pipes EAS2GB7041 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 TIP To remove the fuel tank cap co...

Page 36: ...RST Screen display 4 Tripmeter indicator 5 Tripmeter indicator 6 Timer indicator 7 Clock Timer 8 Speedometer 9 Odometer Tripmeter TIP The operation buttons can be pushed in the fol lowing two manners Short push Push the button Long push Push the button for 2 seconds or more EAS2GB7044 BASIC MODE Changing speedometer display for U K 1 Push the SLCT2 button for 2 seconds or more to change the speedo...

Page 37: ... and push the RST button for 2 seconds or more EAS2GB7045 CHANGEOVER TO BASIC MODE RACE MODE TIP Measurement using the timer function can be made in RACE MODE Indicator will light up as an identifier that shows RACE MODE has been selected RACE MODE cannot display the functions as in BASIC MODE Changeover to RACE MODE forces the digits for tripmeter A TRIP A in BASIC MODE to be reset Changeover fro...

Page 38: ...T1 button will put mea surement on standby Manual start TIP Initial setting at changeover to RACE MODE will remain for manual start 1 Check that changeover to RACE MODE has been made Refer to Changeover from BA SIC MODE to RACE MODE TIP When the machine is made ready for a run by manual start and will start flashing 2 Start timer measurement by pushing the RST button 3 When stopping timer measurem...

Page 39: ...ng tripmeter A TRIP A 1 Check that the timer is in operation If the timer is not in operation start the timer by pushing the SLCT1 button and SLCT2 button at the same time 2 Reset tripmeter A TRIP A display by push ing the RST button for 2 seconds or more TIP If reset and travel distance display will go on flashing for four seconds Resetting tripmeter A TRIP A and timer 1 Check that the timer is n...

Page 40: ...pmeter A TRIP A 1 Change the travel distance display by push ing the SLCT1 button plus or SLCT2 button minus A long push on the button will fast forward the change TIP Change can be made any time while timer measurement is or is not being made ...

Page 41: ...MULTI FUNCTION DISPLAY 1 27 ...

Page 42: ...g push on the button changes the operation in the arrowed direction A long push on the button changes the operation in both arrowed directions Meter function Function that can be performed whether the time is or is not in operation Extent to which the meter can operate Clock BASIC MODE Tripmeter ODO TRIP A TRIP B ODO Speedometer for U K MPH km h MPH Putting measurement on standby Manual start Auto...

Page 43: ...on the button changes the oper ation in both arrowed directions E Meter function F Function that can be performed whether the time is or is not in operation G Extent to which the meter can operate 1 BASIC MODE 2 Clock 3 Trip meter 4 Speedometer for U K 5 RACE MODE 6 Putting measurement on standby 7 Manual start 8 Auto start 9 Measurement starts as the machine moves 10 Timer in operation 11 Reset T...

Page 44: ...NOTICE Unlike a two stroke engine this engine cannot be kick started when the throttle is open because the kickstarter may kick back Also if the throttle is open the air fuel mixture may be too lean for the engine to start Before starting the machine perform the checks in the pre operation check list EAS2GB7051 AIR FILTER MAINTENANCE According to CLEANING THE AIR FILTER ELEMENT section in the CHAP...

Page 45: ...ine stop switch till the engine comes to a full stop Starting with the kickstarter When using the kickstarter to start the engine follow the procedures as described below 1 Fold out the kickstarter lever push it down lightly with your foot until resistance is felt 2 With the throttle fully closed push the kick starter down lightly until the gears engage and then push it down smoothly but forceful ...

Page 46: ...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 ECA NOTICE After a break in or after each race always check the points shown in TORQUE CHECK POINTS for tightening torques and retighten them Refer to TORQUE CHECK POINTS on page 1 34 Als...

Page 47: ...dis 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 Bra...

Page 48: ...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 di...

Page 49: ...el pump to fuel tank Fuel sender to fuel tank Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake disc cov er Tightening of rear brake caliper cover ...

Page 50: ... may be used Be sure to rinse off any detergent residue using plenty of water as it is harmful to plastic parts Do not use any harsh chemical products on plastic parts Be sure to avoid using cloths or sponges which have been in con tact with strong or abrasive cleaning prod ucts solvent or thinner fuel gasoline rust removers or inhibitors brake fluid antifreeze or electrolyte Do not use high press...

Page 51: ...eat them with a suitable care product Avoid using abrasive polishing com pounds as they will wear away the paint TIP Consult a Yamaha dealer for advice on what products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of time will help remove the moisture from the lens EAS2GB7060 STORAGE Short term Always store your moto...

Page 52: ...he tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alter natively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 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 ...

Page 53: ...IFICATIONS 2 10 TIGHTENING TORQUES 2 12 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 12 ENGINE TIGHTENING TORQUES 2 13 CHASSIS TIGHTENING TORQUES 2 16 LUBRICATION POINTS AND LUBRICANT TYPES 2 20 ENGINE 2 20 CHASSIS 2 21 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 LUBRICATION DIAGRAMS 2 23 CABLE ROUTING DIAGRAM 2 31 ...

Page 54: ...N 2GB8 EUR 2GB9 2GBA AUS NZL ZAF Dimensions Overall length 2165 mm 85 2 in Overall width 825 mm 32 5 in Overall height 1280 mm 50 4 in Seat height 965 mm 38 0 in Wheelbase 1465 mm 57 7 in Ground clearance 325 mm 12 8 in Weight Curb weight 117 kg 258 lb USA CAN 118 kg 260 lb EUR AUS NZL ZAF ...

Page 55: ...88 US qt 0 73 Imp qt With oil filter element replacement 0 85 L 0 90 US qt 0 75 Imp qt Oil filter Oil filter type Paper Bypass valve opening pressure 40 0 80 0 kPa 0 40 0 80 kgf cm2 5 8 11 6 psi Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance Less than 0 150 mm 0 0059 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing clearance 0 13 0 18 mm 0 0051 0 0071 in Limit 0...

Page 56: ...7 0 0075 in Exhaust 0 17 0 24 mm 0 0067 0 0094 in Valve dimensions Valve head diameter Intake 30 90 31 10 mm 1 2165 1 2244 in Valve head diameter exhaust 24 90 25 10 mm 0 9803 0 9882 in Valve face width intake 1 697 mm 0 0668 in Valve face width exhaust 1 909 mm 0 0752 in Valve seat contact width intake 0 90 1 10 mm 0 0354 0 0433 in Valve seat contact width exhaust 0 90 1 10 mm 0 0354 0 0433 in Va...

Page 57: ...haust Clockwise Cylinder Bore 77 000 77 010 mm 3 0315 3 0319 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in Piston Piston to cylinder clearance 0 030 0 055 mm 0 0012 0 0022 in Limit 0 15 mm 0 006 in Diameter 76 955 76 970 mm 3 0297 3 0303 in Measuring point from piston skirt bottom 6 0 mm 0 24 in Offset 0 00 mm 0 0000 in Piston pin bore inside diameter 16 002 16 013 mm 0 6...

Page 58: ...n type Constant mesh 6 speed Primary reduction system Spur gear Primary reduction ratio 3 353 57 17 Final drive Chain Secondary reduction ratio 3 846 50 13 Operation Left foot operation 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 Shifting mechanism Shift...

Page 59: ...3 61 3 67 V at 101 3 kPa 3 61 3 67 V at 1 01 kgf cm2 3 61 3 67 V at 14 7 psi Intake air temperature sensor resistance 290 390 at 80 C 290 390 176 F Coolant temperature sensor resistance 2 51 2 78 k at 20 C 2 51 2 78 k at 68 F 210 221 at 100 C 210 221 at 212 F Idling condition Engine idling speed 1900 2100 r min CO 3 0 4 0 USA CAN Intake vacuum 25 3 29 3 kPa 190 220 mmHg 7 5 8 7 inHg USA CAN Water ...

Page 60: ... in Front tire Type With tube Size 80 100 21 51M USA CAN 90 90 21 M C 54M M S EUR AUS NZL ZAF Manufacturer model DUNLOP GEOMAX MX51FA USA CAN PIRELLI SIX DAYS EXTREME EUR AUS NZL ZAF Rear tire Type With tube Size 110 100 18 64M USA CAN 130 90 18 M C 69M M S EUR AUS NZL ZAF Manufacturer model DUNLOP GEOMAX MX51 USA CAN PIRELLI SIX DAYS EXTREME EUR AUS NZL ZAF Tire air pressure measured on cold tire...

Page 61: ...ing Steering bearing type Taper roller bearing Center to lock angle left 43 0 Center to lock angle right 43 0 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 310 0 mm 12 20 in Fork spring free length 470 0 mm 18 50 in Limit 465 0 mm 18 31 in Fork spring installed length 470 0 mm 18 50 in Spring rate K1 4 40 N mm 0 45 kgf mm 25 12 lbf in Spr...

Page 62: ... in from its free length Maximum Position in which the spring is turned in 18 mm 0 71 in from its free length Rebound damping adjusting positions Minimum 30 clicks out Standard 14 clicks out Maximum Fully turned in With the adjuster fully turned in Compression damping setting for fast compression damping Minimum 2 turns out Standard 1 1 4 turns out Maximum Fully turned in With the adjuster fully t...

Page 63: ...pe Semi conductor short circuit No load regulated voltage 14 1 14 9 V Rectifier capacity DC 23 0 A Battery Model YTZ7S F Voltage capacity 12 V 6 0 Ah Specific gravity 1 31 Manufacturer GS YUASA Ten hour rate charging current 0 60 A Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 35 W 35 W 1 Tail brake light LED Meter lighting EL Electroluminescent Indicator light Fuel...

Page 64: ...epth 1 50 mm 0 06 in Starter relay Amperage 180 0 A Coil resistance 4 18 4 62 Starting circuit cut off relay Coil resistance 75 6 92 5 Headlight relay Coil resistance 86 4 105 6 Fuses Main fuse 15 0 A Radiator fan motor fuse 5 0 A Spare fuse 15 0 A ...

Page 65: ...l 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 Compo nents should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kgf ft lbf 10 mm 6 mm 6 0...

Page 66: ...t lbf Timing chain guide stopper plate exhaust side M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Timing chain tensioner cap bolt M6 1 6 Nm 0 6 m kgf 4 3 ft lbf Timing chain tensioner bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Coolant drain bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Radiator hose clamp screw M6 8 1 5 Nm 0 15 m kgf 1 1 ft lbf Radiator bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Radiator pipe bolt M6 1 10 Nm 1 0 m ...

Page 67: ...l drain bolt M10 1 20 Nm 2 0 m kgf 14 ft lbf Crankcase bolt M6 12 12 Nm 1 2 m kgf 8 7 ft lbf Clutch cable holder bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Crankshaft end accessing screw M36 1 10 Nm 1 0 m kgf 7 2 ft lbf Timing mark accessing screw M14 1 6 Nm 0 6 m kgf 4 3 ft lbf Drive chain sprocket cover bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Crankcase bearing cover plate screw M6 6 10 Nm 1 0 m kgf 7 2 ft...

Page 68: ...ft lbf Crankshaft position sensor bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Damper assembly cover bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Starter clutch bolt M6 6 16 Nm 1 6 m kgf 12 ft lbf Starter motor bolt M6 1 12 Nm 1 2 m kgf 8 7 ft lbf Coolant temperature sensor M10 1 16 Nm 1 6 m kgf 12 ft lbf Neutral switch bolt M5 2 3 5 Nm 0 35 m kgf 2 5 ft lbf Intake air temperature sensor screw M5 1 1 5 Nm 0 15 m ...

Page 69: ... Nm 0 13 m kgf 0 94 ft lbf Front fork protector bolt M6 6 7 Nm 0 7 m kgf 5 1 ft lbf Front fork protector and brake hose holder nut M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Throttle grip cap screw M5 2 3 8 Nm 0 38 m kgf 2 8 ft lbf Clutch lever holder bolt M6 2 3 8 Nm 0 38 m kgf 2 8 ft lbf Clutch lever nut M6 1 4 0 Nm 0 40 m kgf 2 9 ft lbf Front brake master cylinder holder bolt M6 2 9 Nm 0 9 m kgf 6 5 ft lbf...

Page 70: ...er bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Rear brake caliper protector bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Engine mounting bolt upper side M10 2 45 Nm 4 5 m kgf 33 ft lbf Engine mounting bolt front side M10 1 55 Nm 5 5 m kgf 40 ft lbf Engine mounting bolt lower side M10 1 53 Nm 5 3 m kgf 38 ft lbf Engine bracket bolt upper side M8 4 34 Nm 3 4 m kgf 25 ft lbf Engine bracket bolt front side M8 4 34 Nm...

Page 71: ...over bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Frame and air scoop bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank and air scoop bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Radiator guard and air scoop bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Front fender bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Rear fender bolt front side M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Rear fender bolt rear side M6 2 16 Nm 1 6 m kgf 12 ft lbf Mud flap sc...

Page 72: ...sensor bolt M4 2 3 8 Nm 0 38 m kgf 2 8 ft lbf Taillight assembly screw 3 1 1 Nm 0 11 m kgf 0 80 ft lbf Taillight lead clamp and rear fender 3 0 5 Nm 0 05 m kgf 0 36 ft lbf Battery bracket bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Frame and battery negative lead bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Rear fender and relay bracket screw 2 1 1 Nm 0 11 m kgf 0 80 ft lbf Front reflector nut For Canada M6 2 3 8 ...

Page 73: ...system moving parts Water pump impeller shaft Oil pump rotors inner and outer Oil passage gasket Oil pump shaft Kick gear and ratchet wheel Kick shaft Kick idle gear inner surface Ratchet wheel and ratchet wheel guide contacting portion Primary drive gear nut threads and contacting surface Primary driven gear inner surface and end surface Clutch push rod washer Clutch push rod 1 outer surface Clut...

Page 74: ...il seal lip Pivot shaft outer surface Relay arm bearing and oil seal lip Relay arm thrust washer surface both sides Relay arm collar outer surface and bolt outer surface Relay arm bolt threads swingarm side Connecting arm bearing and oil seal lip Connecting arm collar outer surface and bolt outer surface Rear shock absorber assembly collar outer surface and dust seal lip upper side Rear shock abso...

Page 75: ...dust seal Front brake caliper piston outer surface Front brake caliper pin bolt and boot Front brake master cylinder push rod end Front brake master cylinder kit Rear brake caliper piston Rear brake caliper piston seal Rear brake caliper dust seal Rear brake caliper piston outer surface Rear brake caliper pin bolt and boot Rear brake master cylinder push rod end Rear brake master cylinder kit Lubr...

Page 76: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EAS2GB7071 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS2GB7072 LUBRICATION DIAGRAMS ...

Page 77: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 24 1 Intake camshaft 2 Exhaust camshaft 3 Piston 4 Oil nozzle 5 Oil filter element 6 Oil pump 7 Oil strainer 8 Crankshaft 9 Drive axle 10 Main axle ...

Page 78: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 ...

Page 79: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Connecting rod 2 Crankshaft 3 Main axle 4 Oil strainer 5 Drive axle ...

Page 80: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 ...

Page 81: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Exhaust camshaft 2 Intake camshaft 3 Oil filter element 4 Oil pump ...

Page 82: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 ...

Page 83: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Camshaft 2 Oil pressure check bolt 3 Oil filter element 4 Oil pump ...

Page 84: ...CABLE ROUTING DIAGRAM 2 31 EAS2GB7073 CABLE ROUTING DIAGRAM ...

Page 85: ...ne bracket the side of the vehicle L Insert the plastic locking tie into the bracket hole and clamp the clutch cable Clamp it so that the lock of the plastic locking tie faces downward and then cut off the end of the plastic locking tie M Pass the clutch cable with no downward sag al lowed N Place the grommet of the clutch cable so that it contacts the radiator hose Route the clutch cable outside ...

Page 86: ...CABLE ROUTING DIAGRAM 2 33 ...

Page 87: ...in the sheet metal of the radiator B Route each lead so that the leads are not pinched between the tank rail and air filter joint C Insert the projection of the wire harness into the hole in the frame D Route the cylinder head breather hose without it crossing the starter motor lead E Pass the cylinder head breather hose between the throttle cable and rectifier regulator lead F Connect the sub wir...

Page 88: ...CABLE ROUTING DIAGRAM 2 35 ...

Page 89: ...the throttle position sensor lead to the out side of the tension arm the outside of the vehi cle D After connecting the throttle position sensor cou pler attach the cover E Pass the radiator breather hose to the outside of the tension arm and the throttle position sensor lead the outside of the vehicle and to the inside of the radiator hose the side of the vehicle F 45 G Install the engine ground ...

Page 90: ...CABLE ROUTING DIAGRAM 2 37 ...

Page 91: ...oupler place it on the right side of the battery G After installing the plastic cover to the starter re lay connect the starter relay coupler H Route the diode under the cross member and place it on top of the rear fender I Secure the two ends of the taillight coupler with the starter motor lead J Route the taillight lead so that it does not slack at the rear of the vehicle K Clamp the taillight l...

Page 92: ...CABLE ROUTING DIAGRAM 2 39 ...

Page 93: ... and start switch lead between the cable guide of the meter bracket and handle crown The cables and leads may be routed in any order B Clamp the wire harness clutch switch lead and start switch lead to the meter bracket The clamp shall be located at a position where there is no slack with the handle turned fully to the left C Connect the headlight lead to the headlight D Clamp the start switch lea...

Page 94: ...CABLE ROUTING DIAGRAM 2 41 ...

Page 95: ...tall the two breather hoses so that the yellow paint mark is pointing forwards C Align the white paint mark to the protruding por tion of the pipe to install breather hose 3 D Protruding portion of the pipe E Align the end with the paint mark of the breather hose 3 to the end of the clip to install the clip F Align with the blue paint mark and protruding por tion of the joint pipe to install the b...

Page 96: ...CABLE ROUTING DIAGRAM 2 43 ...

Page 97: ...as shown and bring it into contact with the projection on the brake caliper B Pass the brake hose into the brake hose holders C If the brake hose interferes with the rear shock absorber correct its twist D While installing the brake hose direct a bend in its pipe portion as shown and bring it into contact with the projection on the brake master cylinder ...

Page 98: ...CABLE ROUTING DIAGRAM 2 45 ...

Page 99: ...ELEMENT 3 14 CHECKING THE THROTTLE BODY JOINT 3 15 CHECKING THE BREATHER HOSES 3 15 CHECKING THE EXHAUST SYSTEM 3 15 CHECKING THE FUEL LINE 3 16 CHECKING THE ENGINE OIL LEVEL 3 16 CHANGING THE ENGINE OIL 3 17 ADJUSTING THE ENGINE IDLING SPEED 3 18 ADJUSTING THE VALVE CLEARANCE 3 19 CLEANING THE SPARK ARRESTER 3 23 CHASSIS 3 24 BLEEDING THE BRAKE SYSTEM 3 24 CHECKING THE BRAKE HOSE 3 25 ADJUSTING T...

Page 100: ...DJUSTING THE STEERING HEAD 3 36 CHECKING AND LUBRICATING THE CABLES 3 37 LUBRICATING THE LEVERS 3 37 LUBRICATING THE PEDAL 3 37 LUBRICATING THE DRIVE CHAIN 3 38 LUBRICATING THE SIDESTAND 3 38 CHECKING THE CHASSIS FASTENERS 3 38 ELECTRICAL SYSTEM 3 39 CHECKING THE SPARK PLUG 3 39 CHECKING THE IGNITION TIMING 3 39 CHECKING AND CHARGING THE BATTERY 3 40 REPLACING THE HEADLIGHT BULB 3 40 ...

Page 101: ...d with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills NO ITEM CHECKS AND MAINTENANCE JOBS INITIAL ODOMETER READ INGS 600 mi 1000 km or 1 month 1800 mi 3000 km or 3 months 3000 mi 5000 km or 6 months 1 Fuel line Check fuel hoses for cracks or dam age Replace if necessary 2 Spark plug Check condition Adjust gap and clean 3 Valve clear ance ...

Page 102: ... id leakage Replace brake pads if necessary Replace brake fluid every 1 year Every 1 year 6 Brake hoses Check for cracks or damage Replace Every 4 years 7 Wheels Check runout spoke tightness and for damage Tighten spokes if necessary 8 Tires Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary 9 Wheel bear ings Check bearings for smooth operation Replace if...

Page 103: ...ase lightly 15 Sidestand pivot Check operation Apply lithium soap based grease all purpose grease lightly 16 Front fork Check operation and for oil leakage Replace if necessary 17 Shock ab sorber as sembly Check operation and for oil leakage Replace if necessary 18 Rear sus pension link pivots Apply molybdenum disulfide grease lightly 19 Control ca bles Apply Yamaha chain and cable lube or engine ...

Page 104: ...g rain dirt etc Therefore earlier inspection is required by reference to the list below ITEM After break in Every race Every third or 500 km Every fifth or 1 000 km As re quired Remarks ENGINE OIL Replace VALVES Check the valve clearances The engine must be cold Inspect Check the valve seats and valve stems for wear Replace VALVE SPRINGS Inspect Check the free length and the tilt Replace VALVE LIF...

Page 105: ...te clutch plate and spring Replace TRANSMISSION Inspect Replace bearing SHIFT FORK SHIFT CAM GUIDE BAR Inspect Inspect wear ROTOR NUT Retighten MUFFLER Inspect and re tighten Clean Replace CRANK Inspect and clean THROTTLE BODY Inspect SPARK PLUG Inspect and clean Replace DRIVE CHAIN Use chain lube Lubricate slack alignment Chain slack 50 60 mm 1 97 2 36 in Replace ITEM After break in Every race Ev...

Page 106: ...n Refer to STARTING AND BREAK IN on page 1 30 AIR FILTER Clean and lubri cate Use foam air filter oil or equiv alent oil Replace OIL FILTER Replace ENGINE GUARD Replace Breakage FRAME Clean and inspect FUEL TANK FUEL PUMP Clean and inspect FUEL HOSE Inspect Replace Every four years ITEM After break in Every race Every third or 500 km Every fifth or 1 000 km As re quired Remarks ...

Page 107: ...u id Every one year FRONT FORKS Inspect and adjust Replace oil Suspension oil S1 Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium soap based grease PROTECTOR GUIDE Replace REAR SHOCK AB SORBER After rain ride Inspect and adjust Lube Molybdenum disulfide grease Retighten DRIVE CHAIN GUARD AND ROLL ERS Inspect DRIVE CHAIN STOPPER Inspect ITEM After break in Every race Every ...

Page 108: ...ay and retighten Clean and lube Lithium soap based grease Replace bearing TIRE WHEELS Inspect air pres sure wheel run out tire wear and spoke looseness Retightensprocket bolt Inspect bearings Replace bearings Lubricate Lithium soap based grease THROTTLE CON TROL CABLE Check routing and connection Lubricate Yamaha cable lube or SAE 10W 30 motor oil ITEM After break in Every race Every third or 500 ...

Page 109: ...s Check the play of front brake and effect of front and rear brake 3 24 30 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 30 5 69 70 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play 3 35 36 Steering Check that the handlebar can be turned smoothly and have no excessive play 3 36 37 Front forks ...

Page 110: ...w minutes until the coolant has settled EAS2GB7083 CHECKING THE COOLING SYSTEM 1 Remove Seat Side cover left right Air scoop left right Refer to GENERAL CHASSIS on page 5 1 Air filter case cover Refer to THROTTLE BODY on page 8 7 2 Check Radiator Radiator hoses Crack damage Replace Refer to RADIATOR on page 7 1 3 Install Air filter case cover Refer to THROTTLE BODY on page 8 7 Air scoop left right...

Page 111: ...vel Refer to CHECKING THE COOLANT LEV EL on page 3 10 EAS2GB7085 CHECKING THE RADIATOR CAP 1 Check Seal radiator cap 1 Valve and valve seat 2 Crack damage Replace Exist fur deposits Clean or replace EAS2GB7086 CHECKING THE RADIATOR CAP VALVE OPENING PRESSURE 1 Check Radiator cap valve opening pressure a Install the radiator cap tester adapter 2 and the radiator cap tester 3 to the radiator cap 1 a...

Page 112: ...emoved coolant will spout therefore cover it with a cloth beforehand EAS2GB7088 ADJUSTING THE CLUTCH LEVER FREE PLAY 1 Check Clutch lever free play a Out of specification Regulate 2 Adjust Clutch lever free play Handlebar side a Turn the adjuster 1 in direction a or b until the specified clutch lever free play is ob tained TIP If the clutch lever free play cannot be obtained on the handlebar side ...

Page 113: ... adjuster 2 until the specified free play is obtained c Tighten the locknut EWA WARNING After adjusting the throttle grip free play turn the handlebar to the right and to the left to ensure that this does not cause the en gine idling speed to change EAS2GB7090 LUBRICATING THE THROTTLE CABLE 1 Remove Cover throttle cable cap 1 Cover grip cap 2 Throttle grip cap 3 Direction a Clutch lever free play ...

Page 114: ...ve Air filter mounting bolt 1 Air filter element 2 Air filter guide 3 from the air filter element 3 Wash Air filter element EWA WARNING Do not use gasoline or organic acid alka line volatile oil for washing TIP After washing the element with air filter cleaner or kerosene squeeze and dry it completely ECA NOTICE Do not twist the element when squeezing the element 4 Check Air filter element Damage ...

Page 115: ...t properly ECA NOTICE Make sure the cylinder head breather hose is routed correctly EAS2GB7094 CHECKING THE EXHAUST SYSTEM 1 Remove Exhaust pipe protector 2 Check Exhaust pipe 1 Exhaust pipe 2 Silencer Crack damage Replace Refer to ENGINE REMOVAL on page 6 1 Exhaust gas Leaks Replace the gasket Refer to ENGINE REMOVAL on page 6 1 3 Check Tightening torques Air filter mounting bolt 2 0 Nm 0 20 m kg...

Page 116: ...engine warm this up for 3 minutes and then stop the engine and wait about 5 minute 3 Check Oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended engine oil to the proper level ECA NOTICE Since engine oil also lubricates the clutch the wrong oil types or additives could cause clutch slippage Therefore do n...

Page 117: ...r element cover 5 To check the oil strainer perform the follow ing procedure a Remove the oil strainer 1 b Check the oil strainer Damage Replace Clogging due to dirt Wash with kerosene c Replace the O ring 2 d Install the oil strainer 6 Install Gasket Drain bolt 7 Pour the specified amount of engine oil into the oil filler cap hole Oil filter element cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 2 3 1 3...

Page 118: ...t EAS2GB7098 ADJUSTING THE ENGINE IDLING SPEED TIP Because the air pressure is lower at high alti tudes the air fuel mixture will become richer If the idling speed is low turn the starter knob idle screw a few clicks counterclockwise to in crease the speed before the adjustment Before adjusting the engine idling speed make sure that the air filter element is not clogged the engine compression is p...

Page 119: ... 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 Air scoop left right Refer to GENERAL CHASSIS on page 5 1 Fuel tank Refer to FUEL TANK on page 8 1 ECU 2 Remove Spark plug Cylinder head cover Refer to CAMSHAFT on page 6 11 3 Remove Timing mark accessing screw ...

Page 120: ...fter 2 and the adjusting pad 3 with a valve lapper 1 TIP Place a cloth in the timing chain space to pre vent adjusting pads from falling into the crank case Identity each valve lifter and adjusting pad po sition very carefully so that they can be rein stalled in their original place c Check the number on the originally installed adjusting pad TIP The adjusting pad number a is indicated on the top ...

Page 121: ... Do not twist adjusting pads and valve lifters forcibly during installation TIP Apply the engine oil on the valve lifters Apply molybdenum disulfide oil to the valve stem ends Check that the valve lifters turn smoothly when rotated with your finger Make sure that valve lifters and adjusting pads are installed in place Make sure that adjusting pads are installed with their numbers facing upward f I...

Page 122: ...0 205 210 215 220 225 230 235 240 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 ...

Page 123: ... 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 ...

Page 124: ...t the plastic hose 1 to the bleed screw 2 securely and place a container under the end of the plastic hose d Slowly apply the brake several times e Fully pull the brake lever or fully press down the brake pedal and hold it in position f Loosen the bleed screw TIP Loosening the bleed screw will release the pressure in the brake caliper and cause the brake lever to contact the throttle grip or the b...

Page 125: ...1 b Turn the adjusting bolt 2 in direction a or b until the specified brake lever position is obtained c Tighten the locknut EWA WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance ECA NOTICE A...

Page 126: ...king performance to be reduced ECA NOTICE After adjusting the brake pedal position make sure that there is no brake drag EAS2GB7106 CHECKING THE FRONT BRAKE PADS 1 Measure Brake pad thickness a Out of specification Replace as a set TIP The pads worn up to the indicator b grooves mean that the brake pad thickness limit is reached 2 Replace Brake pads a Remove the pad pin plug 1 b Loosen the pad pin...

Page 127: ...ojections a into the brake caliper recesses b Temporarily tighten the pad pin at this point i Install the brake caliper 8 and tighten the pad pin 9 j Install the pad pin plug 10 3 Check Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 29 4 Check Brake lever operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE BRAKE SYS TEM on page 3 24 Bleed screw 6 N...

Page 128: ...e pads 7 e Connect the plastic hose 8 to the bleed screw 9 and place a container under the end of the plastic hose f Loosen the bleed screw and push the brake caliper piston in EWA WARNING Do not reuse the drained brake fluid g Tighten the bleed screw h Install the brake pad 10 and the pad pin 11 TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tigh...

Page 129: ...KE PAD INSU LATOR 1 Remove Brake pads Refer to REAR BRAKE on page 5 23 2 Check Rear brake pad insulator 1 Damage Replace EAS2GB7109 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle upright on a level surface TIP In order to ensure a correct reading of the brake fluid level make sure that the top of the brake fluid reservoir is horizontal 2 Check Brake fluid level The minimum level mark a or belo...

Page 130: ...a suitable stand to raise the rear wheel off the ground EWA WARNING Securely support the vehicle so that there is no danger of it falling over 2 Shift the transmission into the neutral posi tion 3 Pull the drive chain up above the drive chain guide installation bolt with a force of about 50 N 5 0 kgf 36 lbf 4 Check Drive chain slack a Out of specification Regulate TIP Measure drive chain slack bet...

Page 131: ...cification Replace TIP The protector guide reaches the limit of its use when it is worn down to the same height a as of the outer tube circumference EAS2GB7113 CLEANING THE FRONT FORK OIL SEAL AND DUST SEAL 1 Remove Protector Dust seal 1 ECA NOTICE Be careful not to damage the dust seal and the inner tube by a driver 2 Clean Dust seal a Oil seal b TIP Clean the dust seal and oil seal after every r...

Page 132: ...ond its adjusting range 1 Adjust Compression damping a Turn the adjuster 1 in the direction of a or b to make an adjustment Air bleed screw 1 3 Nm 0 13 m kgf 0 94 ft lbf Direction a Rebound damping is increased sus pension is harder Direction b Rebound damping is decreased sus pension is softer Rebound damping adjusting posi tions Maximum Fully turned in Standard 10 clicks out Minimum 20 clicks ou...

Page 133: ...HE REAR SHOCK ABSORB ER ASSEMBLY Use a suitable stand to raise the rear wheel off the ground EWA WARNING Securely support the vehicle so that there is no danger of it falling over Spring preload ECA NOTICE Do not turn the adjuster forcibly beyond its adjusting range 1 Remove Rear frame Refer to REAR SHOCK ABSORBER AS SEMBLY on page 5 58 2 Adjust Spring preload a Loosen the locknut 1 b Loosen the a...

Page 134: ...r forcibly beyond its adjusting range 1 Adjust Compression damping for fast compression damping a Turn the adjuster 1 in the direction of a or b to make an adjustment Locknut 30 Nm 3 0 m kgf 22 ft lbf Direction a Rebound damping is increased sus pension is harder Direction b Rebound damping is decreased sus pension is softer c b T R Rebound damping adjusting posi tions Maximum Fully turned in Stan...

Page 135: ...re valve stem is found tilted the tire is considered to be slipping off its position Cor rect the tire position EAS2GB7120 CHECKING AND TIGHTENING THE SPOKES 1 Check Spokes Bend damage Replace Loose Tighten TIP A tight spoke will emit a clear ringing tone a loose spoke will sound flat Direction a Compression damping is increased suspension is harder Direction b Compression damping is decreased sus...

Page 136: ...3 CHECKING AND ADJUSTING THE STEER ING HEAD 1 Use a suitable stand to raise the front wheel off the ground EWA WARNING Securely support the vehicle so that there is no danger of it falling over 2 Check Steering head Grasp the bottom of the front fork legs and gently rock the front fork Blinding looseness Adjust the steering head 3 Remove Handlebar Refer to HANDLEBAR on page 5 33 Upper bracket Refe...

Page 137: ...he in ner and outer cables EWA WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement Replace damaged outer cable and inner ca bles as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate TIP Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device EAS2...

Page 138: ...efore use only kerosene to clean the drive chain Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O ring chains Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O rings EAS2GB7128 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand ...

Page 139: ...moving the spark plug 3 Check Spark plug type Wrong type Replace 4 Check Electrode Damage wear Replace the spark plug Insulator 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 Spark plug gap a Out of specification Adjust the spark plug gap 7 Install Spark plug TIP Before installing the spark plug clean...

Page 140: ...G AND CHARGING THE BATTERY Refer to CHECKING AND CHARGING THE BATTERY on page 9 69 EAS2GB7134 REPLACING THE HEADLIGHT BULB EWA WARNING Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down 1 Remove Headlight unit bolt 1 TIP After you have removed the headlight unit bolts lift and remove the headlight unit 2 Remove Headlight c...

Page 141: ...t bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 5 Install Bulb cover Headlight coupler 6 Install Headlight unit Headlight unit bolt 7 Nm 0 7 m kgf 5 1 ft lbf New T R ...

Page 142: ...ELECTRICAL SYSTEM 3 42 ...

Page 143: ...NT FORK SETTING 4 2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL 4 2 SETTING OF SPRING AFTER REPLACEMENT 4 2 FRONT FORK SETTING PARTS 4 3 REAR SUSPENSION SETTING 4 3 CHOOSING SET LENGTH 4 3 SETTING OF SPRING AFTER REPLACEMENT 4 4 REAR SHOCK ABSORBER SETTING PARTS 4 4 SUSPENSION SETTING FRONT FORK 4 6 SUSPENSION SETTING REAR SHOCK ABSORBER 4 7 ...

Page 144: ...ine can run at maximum speed the ma chine is generally set such that it can develop its maximum revolutions toward the end of the straight line with care taken to avoid the en gine over revving TIP Riding technique varies from rider to rider and the performance of a machine also vary from machine to machine Therefore do not imitate other rider s settings from the beginning but choose your own sett...

Page 145: ...oo large oil amount will cause the air spring characteristics to have a tendency to be stiffer with the consequent deteriorated performance and characteris tics Therefore adjust the front fork within the specified range EAS2GB7142 SETTING OF SPRING AFTER REPLACE MENT As the front fork setting can be easily affected by the rear suspension take care so that the front and the rear are balanced in pos...

Page 146: ...amping force Change the rebound damping force Change the compression damping force EAS2GB7145 CHOOSING SET LENGTH 1 Place a stand or a block under the engine to 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 2 Remove the stand or block from the engine and with a rider astride the seat measure the sunken length b betw...

Page 147: ...uster one or two clicks turned in and readjust it to suit your preference TIP Adjusting the rebound damping force will be fol lowed more or less by a change in the com pression damping force For correction adjust to decrease compression damping force EWA WARNING When using a rear shock absorber other than currently installed use the one whose overall length a does not exceed the stan dard as it ma...

Page 148: ...which the spring is turned in 1 5 mm 0 06 in from its free length Standard Position in which the spring is turned in 10 mm 0 39 in from its free length Maximum Position in which the spring is turned in 18 mm 0 71 in from its free length Maximum Minimum Position in which the spring is turned in 18 mm 0 71 in from its free length Position in which the spring is turned in 1 5 mm 0 06 in from its free...

Page 149: ...ticeable scars etc If any replace affected parts Slide metal Replace with a new one for ex tended use Piston metal Replace with a new one for ex tended use Lower bracket tightening torque Retighten to specified torque Poor initial movement Rebound damping force Turn adjuster counterclock wise about 2 clicks to de crease damping Oil seals Apply grease in oil seal wall Soft over entire range bottom ...

Page 150: ...nt Increase oil amount by about 5 cm3 0 2 US oz 0 2 Imp oz Obtrusive front tending to upper front pos ture Compression damping force Turn adjuster counterclock wise about 2 clicks to de crease damping Balance with rear end Set sunken length for 90 95 mm 3 5 3 7 in when one passenger is astride seat up per rear posture Spring Replace with soft spring Oil amount Decrease oil amount by about 5 10 cm3...

Page 151: ...senger is astride seat Spring Replace with soft spring Bottoming out High compres sion damping Turn adjuster clockwise about 1 6 turn to increase damping Spring set length Set sunken length for 90 100 mm 3 5 3 9 in when one passenger is astride seat Spring Replace with stiff spring Bouncing Rebound damping force Turn adjuster clockwise about 2 clicks to increase damping Spring Replace with soft sp...

Page 152: ...CHASSIS 4 9 ...

Page 153: ...ECKING THE FRONT BRAKE CALIPER 5 18 ASSEMBLING THE FRONT BRAKE CALIPER 5 18 INSTALLING THE BRAKE CALIPER PISTON 5 18 INSTALLING THE FRONT BRAKE CALIPER 5 19 REMOVING THE FRONT BRAKE MASTER CYLINDER 5 20 CHECKING THE FRONT BRAKE MASTER CYLINDER 5 20 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 5 20 INSTALLING THE FRONT BRAKE MASTER CYLINDER 5 21 REAR BRAKE 5 23 INTRODUCTION 5 27 CHECKING THE REAR BRA...

Page 154: ...EMBLY 5 58 HANDLING THE REAR SHOCK ABSORBER 5 61 DISPOSING OF A REAR SHOCK ABSORBER 5 61 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 5 61 REMOVING THE BEARING 5 61 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 5 62 CHECKING THE CONNECTING ARM AND RELAY ARM 5 62 INSTALLING THE RELAY ARM 5 62 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 5 63 SWINGARM 5 65 REMOVING THE SWINGARM 5 66 REMOVING THE BEARING 5 6...

Page 155: ...embly only by reference to this manual It may lead to servicing trouble and mechanical damage EAS2GB7151 GENERAL CHASSIS Removing the seat and side cover Order Part name Q ty Remarks 1 Seat 1 2 Air scoop left 1 3 Air scoop right 1 4 Side cover left 1 5 Side cover right 1 6 Rear fender 1 For installation reverse the removal proce dure 4 2 6 5 1 3 2 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 f...

Page 156: ... function meter coupler 2 Disconnect 6 Multi function meter optional switch coupler 1 Disconnect 7 Indicator light coupler 1 Disconnect 8 Multi function meter 1 9 Meter bracket 1 For installation reverse the removal proce dure 4 2 6 7 8 9 5 1 3 2 21 Nm 2 1 m kgf 15 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 21 Nm 2 1 m kgf 15 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T...

Page 157: ...move it because its projection a is inserted in the rear frame EAS2GB7153 REMOVING THE SEAT TIP 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 21 2 Remove Seat 1 1 a 1 1 1 ...

Page 158: ...el axle pinch bolt 4 Loosen 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Front wheel 1 5 Speed sensor 1 6 Collar 1 7 Oil seal 1 8 Bearing 2 9 Brake disc 1 For installation reverse the removal proce dure 12 Nm 1 2 m kgf 8 7 ft Ibf T R New LT LS LS LS 8 7 8 6 9 1 2 1 3 21 Nm 2 1 m kgf 15 ft Ibf T R 21 Nm 2 1 m kgf 15 ft Ibf T R 4 90 Nm 9 0 m kgf 65 ft lbf T R 5 6 ...

Page 159: ...d CHECKING THE WHEELS on page 3 36 3 Check Spokes Bend damage Replace Loose Tighten Tap the spokes with a screwdriver TIP A tight spoke will emit a clear ringing tone a loose spoke will sound flat 4 Tighten Spokes Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 35 TIP After tightening the spokes measure the wheel runout 5 Measure Wheel radial runout a Wheel lateral runout b Out of specificat...

Page 160: ...acer 2 Bearing right side 3 Oil seal 4 TIP Apply the lithium soap based grease to the bearing and the oil seal lip when installing Left side of bearing shall be installed first Install the oil seal with its manufacture s marks or numbers facing outward ECA NOTICE Install the bearing by pressing its outer race parallel TIP Use a socket 1 that matches the diameter of the bearing outer race and that ...

Page 161: ...NT WHEEL 1 Install Front wheel TIP Install the brake disc 1 between the brake pads 2 correctly 2 Install Front wheel axle 1 TIP Apply the lithium soap based grease to the front wheel axle 3 Tighten Front wheel axle nut 1 ECA NOTICE Before tightening the front wheel axle nut push down hard on the handlebar s several times and check if the front fork rebounds smoothly 4 Tighten Front wheel axle pinc...

Page 162: ...FRONT WHEEL 5 8 1 1 ...

Page 163: ...eel axle 1 3 Drive chain puller 2 4 Rear wheel 1 5 Collars 2 6 Rear wheel sprocket 1 7 Oil seals 2 8 Circlip 1 9 Bearing 3 10 Brake disc 1 For installation reverse the removal proce dure 6 21 Nm 2 1 m kgf 15 ft Ibf T R 2 5 7 9 LS LS 6 4 6 1 6 3 LS 8 9 10 7 5 LT 14 Nm 1 4 m kgf 10 ft Ibf T R 3 21 Nm 2 1 m kgf 15 ft Ibf T R 50 Nm 5 0 m kgf 36 ft Ibf T R 125 Nm 12 5 m kgf 90 ft lbf T R ...

Page 164: ... CHECKING THE FRONT WHEEL on page 5 5 4 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 5 5 EAS2GB7163 DISASSEMBLING THE REAR WHEEL 1 Remove Oil seals Bearing Refer to DISASSEMBLING THE FRONT WHEEL on page 5 6 EAS2GB7164 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1 Check Rear wheel sprocket More than 1 4 tooth wear a Replace the rear wheel sprocket an...

Page 165: ...nstalled first Install the oil seal with its manufacture s marks or numbers facing outward ECA NOTICE Install the bearing by pressing its outer race parallel TIP Use a socket 1 that matches the diameter of the bearing outer race and that of the oil seal 2 Install Brake disc 1 Brake disc bolt 2 TIP Tighten the bolts in stages and in a crisscross pattern 3 Install Collar 1 TIP Apply the lithium soap...

Page 166: ... wheel axle from the left side Apply the lithium soap based grease to the rear wheel axle 4 Install Right drive chain puller 1 Washer 2 Rear wheel axle nut 3 TIP Temporarily tighten the nut rear wheel axle at this point 5 Adjust Drive chain slack a Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 30 6 Tighten Rear wheel axle nut 1 Locknut 2 Drive chain slack 50 60 mm 1 97 2 36 in Wheel axle nut ...

Page 167: ... washers 2 3 Front brake hose 1 4 Brake pad pin plug 1 5 Brake pad pin 1 6 Brake pads 2 7 Brake pad spring 2 8 Front brake caliper assembly 1 9 Front brake caliper bracket 1 For installation reverse the removal proce dure 3 9 1 2 8 4 5 7 6 T R 30 Nm 3 0 m lbf kgf 22 ft T R 23 Nm 2 3 m lbf kgf 17 ft T R 17 Nm 1 7 m lbf kgf 12 ft T R 2 5 Nm 0 25 m lbf kgf 1 8 ft T R 6 Nm 0 6 m lbf kgf 4 3 ft ...

Page 168: ...ake caliper Order Part name Q ty Remarks 1 Brake caliper piston 2 2 Brake caliper piston dust seal 2 3 Brake caliper piston seal 2 4 Bleed screw 1 For assembly reverse the disassemble pro cedure 1 2 3 4 S S BF BF T R S 6 Nm 0 6 m kgf 4 3 ft Ibf ...

Page 169: ...4 1 Brake lever 1 2 Union bolt 1 3 Copper washers 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 For installation reverse the removal proce dure S 1 2 3 4 5 6 8 9 S 7 T R T R T R T R ...

Page 170: ...BRAKE 5 16 Disassembling the front brake master cylinder Order Part name Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Washer 1 4 Brake master cylinder kit 1 For assembly reverse the disassemble pro cedure 4 1 2 3 ...

Page 171: ...tion EAS2GB7169 CHECKING THE FRONT BRAKE DISC 1 Remove Front wheel Refer to FRONT WHEEL on page 5 4 2 Check Front brake disc Damage galling Replace 3 Measure Brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace 4 Install Front wheel Refer to FRONT WHEEL on page 5 4 EAS2GB7170 REMOVING THE FRONT BRAKE CALIPER TIP Before disassembling the br...

Page 172: ...n clean and lubricate the internal parts Use new brake fluid for cleaning and lubricating Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort When the brake caliper is disassembled replace the brake caliper piston seal and the brake caliper piston dust seal with new ones EAS2GB7174 INSTALLING THE BRAKE CALIPER PISTON 1 Clean Brake caliper Brake...

Page 173: ...at the brake hose holder 2 is in stalled with its upper end a aligned with the paint b on the brake hose 4 Pour brake fluid to the brake master cylinder reservoir up to the specified level EWA WARNING Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in...

Page 174: ...r cylinder and the end of the brake hose EAS2GB7177 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder 1 Damage scratches wear Replace Brake fluid delivery passages 2 brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Check Brake master cylinder reservoir cap 4 Check Brake hoses Cracks damage wea...

Page 175: ...STER CYLINDER 1 Install Brake master cylinder 1 TIP Install the front brake master cylinder holder with the UP mark facing up First tighten the upper bolt then the lower bolt 2 Install Copper washers Brake hose Union bolt EWA WARNING Proper brake hose routing is essential to in sure safe vehicle operation ECA NOTICE During installation bring the brake hose into contact with the brake master cylind...

Page 176: ...o poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock ECA NOTICE 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 BRAKE SYS TEM on p...

Page 177: ...e pad pin plug 1 6 Brake pad pin 1 7 Rear brake pad assembly 2 8 Rear brake caliper bracket 1 9 Brake pad springs 2 10 Rear brake disc cover 1 11 Rear brake caliper assembly 1 For installation reverse the removal proce dure 2 3 4 11 5 6 7 9 1 8 9 10 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf...

Page 178: ... brake caliper Order Part name Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 For assembly reverse the disassemble pro cedure 1 2 3 4 S BF T R 6 Nm 0 6 m kgf 4 3 ft Ibf ...

Page 179: ...page 3 24 1 Union bolt 1 2 Copper washers 2 3 Brake hose 1 4 Split pin 1 5 Washer 1 6 Pin 1 7 Brake master cylinder reservoir cap 1 8 Brake master cylinder reservoir diaphragm plate 1 9 Brake master cylinder reservoir diaphragm 1 10 Rear brake master cylinder 1 For installation reverse the removal proce dure 1 2 3 4 7 5 8 6 9 T R T R 10 T R ...

Page 180: ...26 Disassembling the rear brake master cylinder Order Part name Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Push rod 1 4 Brake master cylinder kit 1 For assembly reverse the disassemble pro cedure 4 3 2 1 BF S New New ...

Page 181: ...GB7182 CHECKING THE REAR BRAKE DISC 1 Remove Rear wheel Refer to REAR WHEEL on page 5 9 2 Check Brake disc Damage galling Replace 3 Measure Brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISC on page 5 17 4 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replac...

Page 182: ...7185 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scratches wear Replace the brake cali per assembly Brake caliper body 3 Cracks damage Replace the brake cali per assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air EWA WARNING When the brake caliper is disa...

Page 183: ...n with its side a facing the brake caliper Never force to insert EAS2GB7188 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake caliper Rear brake caliper bracket 2 Install Rear wheel Refer to REAR WHEEL on page 5 9 Copper washers Brake hose Union bolt EWA WARNING Proper brake hose routing is essential to in sure safe vehicle operation ECA NOTICE Make sure that a bend in its pipe portion a is d...

Page 184: ...brake system Refer to BLEEDING THE BRAKE SYS TEM on page 3 24 EAS2GB7189 REMOVING THE REAR BRAKE MASTER CYLINDER TIP Before removing the rear brake master cylin der drain the brake fluid from the entire brake system 1 Remove Union bolt Copper washers Brake hose TIP To drain any remaining brake fluid place a con tainer under the master cylinder and the end of the brake hose EAS2GB7190 CHECKING THE ...

Page 185: ...master cylinder piston 4 Install Master cylinder kit 1 Push rod 2 Circlip 3 Dust boot 4 TIP Before installation apply brake fluid to the brake master cylinder kit Before installation apply silicone grease to the push rod end Use circlip pliers to install the circlip EAS2GB7192 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install Copper washers Brake hose Union bolt EWA WARNING Proper brake hose rou...

Page 186: ...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 ECA NOTICE Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE BRAKE SYS TEM on page 3 24 4 Check Brake fluid level The minimum level ma...

Page 187: ...1 Disconnect 2 Clutch switch 1 3 Clutch lever holder 1 4 Engine stop 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 Handlebar upper holder 2 14 Handlebar 1 ...

Page 188: ...HANDLEBAR 5 34 15 Handlebar lower holder 2 16 Damper 4 For installation reverse the removal proce dure Removing the handlebar Order Part name Q ty Remarks ...

Page 189: ...2GB7196 INSTALLING THE HANDLEBAR 1 Stand the vehicle upright on a level surface EWA WARNING Securely support the vehicle so that there is no danger of it falling over 2 Install Damper 1 Lower handlebar holders 2 temporarily Handlebar 3 Upper handlebar holders 4 TIP Install the lower handlebar holders with them side having the greater distance a from the mounting bolt center facing forward Installi...

Page 190: ...all Handlebar grip 1 a Slightly coat the handlebar left end with a rubber adhesive b Install the handlebar grip on the handlebar by pressing the grip from the left side c Wipe off any excess adhesive with a clean cloth EWA WARNING Securely support the vehicle so that there is no danger of it falling over TIP Install the handlebar grip to the handlebar so that the line a between the two arrow marks...

Page 191: ...r Install the grip to the tube guide so that the grip match mark b and tube guide slot c form the angle as shown 7 Install Rubber cover 1 Throttle grip 2 TIP Apply the lithium soap based grease on the throttle grip sliding surface 8 Install Throttle cables 1 TIP Slightly coat the end of throttle cable and inside of throttle grip with lithium soap based grease Then mount the throttle grip onto the ...

Page 192: ...older 4 Clamp 5 TIP Install the brake master cylinder holder with the UP mark facing up Install in order for the top of the front brake master cylinder assembly to be level First tighten the upper bolt then the lower bolt 12 Install Clutch cable 1 TIP Before installation apply the lithium soap based grease to the clutch cable end 13 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LE VE...

Page 193: ...HANDLEBAR 5 39 14 Adjust Throttle grip free play Refer to ADJUSTING THE THROTTLE GRIP FREE PLAY on page 3 13 Throttle grip free play 3 0 5 0 mm 0 12 0 20 in ...

Page 194: ...the ground Front wheel Refer to FRONT WHEEL on page 5 4 Front brake caliper Refer to FRONT BRAKE on page 5 13 1 Brake hose holder 2 2 Protector 1 3 Upper bracket pinch bolts 2 Loosen 4 Damper assembly 1 Loosen 5 Lower bracket pinch bolts 2 Loosen 6 Front fork leg 1 7 Reflector Stay Nut 1 For Canada For installation reverse the removal proce dure ...

Page 195: ...on metal 1 8 Protector guide 1 9 Slide metal 1 10 Washer 1 11 Oil seals 1 12 Base valve 1 13 Damper assembly 1 For assembly reverse the disassemble pro cedure LS 13 2 6 9 8 10 11 4 3 1 5 7 12 New New New New New New New LT 29 Nm 2 9 m kgf 21 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 1 3 Nm 0 13 m kgf 0 94 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R ...

Page 196: ...bolt ring wrench 2 3 Remove Front fork leg s EAS2GB7199 DISASSEMBLING THE FRONT FORK LEGS 1 Drain Fork oil 2 Remove Adjuster 1 from the inner tube TIP While compressing the inner tube 2 set the cap bolt ring wrench 4 between the inner tube and locknut 3 Hold the locknut and remove the adjuster ECA NOTICE Do not scratch the inner tube 3 Remove Dust seal 1 Oil seal clip 2 with a flat head screwdrive...

Page 197: ... as this may dangerously weaken it 2 Check Outer tube Scratches wear damage Replace 3 Measure Fork spring free length a Out of specification Replace 4 Check Damper assembly 1 Bend damage Replace O ring 2 Wear damage Replace ECA NOTICE The front fork leg has a built in damper ad justing rod and a very sophisticated inter nal construction which are particularly sensitive to foreign material When dis...

Page 198: ...g Outer tube bushing Oil seals Copper washers 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 ECA NOTICE Be sure to use the recommended oil Other oils may have an adverse effect on front fork performance When disassembling and assembling the front fork leg take care not to allow any foreign material to e...

Page 199: ...etting position Unless the damping force adjuster is fully loosened correct damping characteristic can not be obtained after installation 7 Install Base valve 1 to the damper assembly 2 TIP First bring the damper rod pressure to a maxi mum Then install the base valve while releas ing the damper rod pressure 8 Check Damper assembly Not fully stretched Repeat the steps 1 to 7 Standard oil level 145 ...

Page 200: ... to damage the damper assem bly 12 Allow the overflowing oil to escape at the hole a in the damper assembly TIP The overflow measures about 8 cm3 0 27 US oz 0 28 lmp oz 13 Check Damper assembly smooth movement Tightness binding rough spots Repeat the steps 1 to 12 14 Install Dust seal 1 Oil seal clip 2 Oil seals 3 Washer 4 Outer tube bushing 5 to the inner tube 6 ECA NOTICE Make sure that the numb...

Page 201: ...e inner tube bushing onto the slot on inner tube 16 Install Outer tube 1 to the inner tube 2 17 Install Inner tube bushing 1 Washer 2 to the outer tube TIP Press the inner tube bushing into the outer tube with fork seal driver 3 18 Install Oil seals 1 TIP Using a fork seal driver 2 press the oil seal in until the stopper ring groove fully appears LS New Fork seal driver 90890 01502 Fork seal drive...

Page 202: ...heck Inner tube smooth movement Tightness binding rough spots Repeat the steps 14 to 20 22 Measure Distance a Out of specification Turn into the locknut 23 Install Collar 1 Fork spring 2 to the damper assembly 3 TIP Install the collar with its larger dia end a fac ing the fork spring New Distance a 16 mm 0 63 in or more Between the damper assembly 1 bottom and locknut 2 bot tom 1 2 a 1 2 3 a ...

Page 203: ...1 Copper washer 2 Adjuster 3 to the damper assembly 4 TIP While compressing the inner tube 5 set the cap bolt ring wrench 7 between the inner tube and locknut 6 Fully finger tighten the adjuster onto the damper assembly 27 Measure Gap a between the adjuster 1 and the locknut 2 Out of specification Retighten and read just the locknut TIP If it is installed with a gap out of specification correct da...

Page 204: ...k 31 Install Damper assembly 1 to the outer tube TIP Temporarily tighten the damper assembly 32 Install Protector guide 1 EAS2GB7202 INSTALLING THE FRONT FORK LEGS 1 Install Front fork 1 TIP Temporarily tighten the pinch bolts lower bracket Do not tighten the pinch bolts upper bracket yet Adjuster 55 Nm 5 5 m kgf 40 ft lbf LOCTITE Recommended oil Suspension oil S1 Standard oil amount 340 cm3 11 50...

Page 205: ...Install Speed sensor lead 1 Plate 1 2 to the right front fork protector TIP Install the speed sensor lead so that its paint a directs as shown and align the bottom b of the plate 1 with the same paint Damper assembly 30 Nm 3 0 m kgf 22 ft lbf Cap bolt ring wrench 90890 01501 Cap bolt ring wrench YM 01501 Front fork top end standard a 5 mm 0 20 in T R 2 1 a Upper bracket pinch bolts 21 Nm 2 1 m kgf...

Page 206: ...tor 2 8 Adjust Rebound damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 9 Adjust Compression damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position Plate 2 screw 0 5 Nm 0 05 m kgf 0 36 ft lbf Bolt protector 7 Nm 0 7 m kgf 5 1 ft lbf T R 1 2 1 2 T R 1 2 1 1 ...

Page 207: ...g s 2 Refer to FRONT FORK on page 5 40 4 Upper bracket 1 5 Steering ring nut 1 6 Lower bracket 1 7 Bearing race cover 1 8 Upper bearing 1 9 Bearing lower side 1 10 Bearing races 2 2 4 5 7 3 2 2 2 2 2 1 6 8 9 10 LS LS T R 21 Nm 2 1 m lbf kgf 15 ft T R 21 Nm 2 1 m lbf kgf 15 ft T R 21 Nm 2 1 m lbf kgf 15 ft T R 21 Nm 2 1 m lbf kgf 15 ft T R 3 8 Nm 0 38 m lbf kgf 2 8 ft T R 3 8 Nm 0 38 m lbf kgf 2 8 ...

Page 208: ...bf kgf 15 ft T R 21 Nm 2 1 m lbf kgf 15 ft T R 21 Nm 2 1 m lbf kgf 15 ft T R 21 Nm 2 1 m lbf kgf 15 ft T R 3 8 Nm 0 38 m lbf kgf 2 8 ft T R 3 8 Nm 0 38 m lbf kgf 2 8 ft T R 9 Nm 0 9 m lbf kgf 6 5 ft T R 7 Nm 0 7 m lbf kgf 5 1 ft T R 7 Nm 0 7 m lbf kgf 5 1 ft T R 10 Nm 1 0 m lbf kgf 7 2 ft T R 145 Nm 14 5 m lbf kgf 105 ft T R 38 Nm 3 8 m lbf kgf 27 ft 7 Nm 0 7 m lbf kgf 5 1 ft ...

Page 209: ...ces a Remove the bearing race from the steering 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 ECA NOTICE If the bearing race is not installed properly the steering head pipe could be damaged TIP Always replace the bearing and the bearing race as a set 4 Check Upper bracket Lower bracket along with...

Page 210: ...ering ring nut with a steering nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 36 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 6 Install Washer 1 7 Install Front fork 1 Upper bracket 2 TIP Temporarily tighten the pinch bolts lower bracket Do not tighten the pinch bolts upper bracket ...

Page 211: ...he front fork to malfunction 12 Install Speed sensor lead holder 1 Speed sensor lead clamp 2 TIP Insert the end of the speed sensor lead holder in the hole in the lower bracket a Install so that the marking b on the speed sensor lead aligns with the speed sensor lead holder edge Install the speed sensor lead clamp while in serting it in the hole c in the speed sensor lead holder Front fork top end...

Page 212: ...5 1 Air scoop left right Refer to GENERAL CHASSIS on page 5 1 Fuel tank Refer to FUEL TANK on page 8 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 Collars 2 11 Bushing 1 12 Collars 2 2 12 16 15 14 13 12 14 4 5 7 6 8 3 9...

Page 213: ... 14 Dust seal 2 15 Stopper ring 1 16 Bearing 1 For installation reverse the removal proce dure Removing the rear shock absorber assembly Order Part name Q ty Remarks 2 12 16 15 14 13 12 14 4 5 7 6 8 3 9 9 10 10 11 1 New New 13 New LS LS M M M M M ...

Page 214: ...y arm Order Part name Q ty Remarks 1 Relay arm 1 2 Connecting arm 1 3 Collars 3 4 Oil seals 6 5 Washers 8 6 Bearing 6 For assembly reverse the disassemble pro cedure 5 3 5 6 1 6 5 4 5 5 4 5 6 6 5 4 3 2 4 6 6 3 4 4 T R 80 Nm 8 0 m lbf kgf 58 ft M M M M M M M ...

Page 215: ...0 km of run ning EAS2GB7209 DISPOSING OF A REAR SHOCK ABSORB ER Before disposing the rear shock absorber be sure to extract the nitrogen gas from valve 1 EWA WARNING Wear protective glasses to prevent your eyes from damage due to possible gas or metal chips scattered To dispose of a damaged or a worn out rear shock absorber take the unit to your Yamaha dealer for this disposal proce dure EAS2GB721...

Page 216: ...ing Damage wear Replace Spring guide Damage wear Replace Bearing Damage wear Replace Bolts Bends damage wear Replace EAS2GB7213 CHECKING THE CONNECTING ARM AND RELAY ARM 1 Check Connecting arm Relay arm Damage wear Replace 2 Check Bearing Spacers Damage pitting scratches Replace the bearings and spacers as a set 3 Check Oil seals Damage pitting Replace EAS2GB7214 INSTALLING THE RELAY ARM 1 Lubrica...

Page 217: ...with their lips facing in ward 5 Lubricate Connecting arm and frame bolt Relay arm and connecting arm bolt Relay arm and swingarm bolt circumference and threaded portion Rear shock absorber assembly upper bolt Rear shock absorber assembly lower bolt 6 Install Rear shock absorber assembly TIP When installing the rear shock absorber as sembly lift up the swingarm Install the rear shock absorber asse...

Page 218: ...olt swingarm side Rear shock absorber assembly lower bolt Connecting arm bolt frame side 80 Nm 8 0 m kgf 58 ft lbf Connecting arm bolt relay arm side 80 Nm 8 0 m kgf 58 ft lbf Relay arm bolt swingarm side 70 Nm 7 0 m kgf 51 ft lbf Rear shock absorber assembly lower bolt 53 Nm 5 3 m kgf 38 ft lbf T R T R T R T R ...

Page 219: ...rake hose holder Refer to REAR BRAKE on page 5 23 Rear brake caliper Refer to REAR BRAKE on page 5 23 Bolt brake pedal Drive chain 1 Collars 2 2 Oil seals 2 3 Thrust bearing 2 4 Bushing 2 5 Oil seals 2 6 Bearing 4 For installation reverse the removal proce dure 1 2 3 6 4 6 4 1 3 6 2 5 T R 70 Nm 7 0 m lbf kgf 51 ft T R 4 0 Nm 0 40 m lbf kgf 2 9 ft ...

Page 220: ...g the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacers the bearings and the collars EAS2GB7218 REMOVING THE BEARING 1 Remove Bearing 1 TIP Remove the bearing by pressing its outer race EAS2GB7219 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace EWA WAR...

Page 221: ... 3 Install Swingarm TIP Install the pivot shaft from the right 4 Install Rear wheel Refer to REAR WHEEL on page 5 9 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 30 Recommended lubricant Molybdenum disulfide grease Installed depth a 0 0 5 mm 0 0 02 in Installed depth b 6 5 mm 0 26 in Pivot shaft nut 85 Nm 8 5 m kgf 61 ft lbf Drive chain slack 50 60 mm 1 97 2 36 in N...

Page 222: ...oving the drive chain Job Order Part name Q ty Servicing Information Drive sprocket Refer to ENGINE REMOVAL on page 6 1 1 Drive chain 1 For installation reverse the removal proce dure 1 T R 75 Nm 7 5 m lbf kgf 54 ft T R 7 Nm 0 7 m lbf kgf 5 1 ft ...

Page 223: ...ngth b between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a differ ent location each time 2 Check Drive chain Stiffness Clean lubricate or replace 3 Clean Drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and remove any remaining dirt c Remove the drive ch...

Page 224: ...L SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 5 10 EAS2GB7224 INSTALLING THE DRIVE CHAIN 1 Install Drive chain ECA NOTICE Be sure to put on safety goggles when working TIP Install the drive chain joint with the drive chain cut rivet tool Use goods on the market a When press fitting the connecting plate 1 make sure the space a between the end of the connecting pin 2 and...

Page 225: ...ain sprockets this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 30 ECA NOTICE A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swingarm or cause an accident Therefore keep the drive chain slack within the speci fied limits Recommended lub...

Page 226: ...CHAIN DRIVE 5 72 ...

Page 227: ...NG THE DECOMPRESSION SYSTEM 6 16 INSTALLING THE CAMSHAFTS 6 16 CYLINDER HEAD 6 18 REMOVING THE CYLINDER HEAD 6 20 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 6 20 CHECKING THE CYLINDER HEAD 6 20 INSTALLING THE CYLINDER HEAD 6 21 VALVES AND VALVE SPRINGS 6 22 REMOVING THE VALVES 6 23 CHECKING THE VALVES AND VALVE GUIDES 6 24 CHECKING THE VALVE SEATS 6 26 CHECKING THE VALVE SPRINGS 6 27 CHECKING THE...

Page 228: ...50 CHECKING THE KICK GEAR KICK IDLE GEAR AND RATCHET WHEEL 6 50 INSTALLING THE KICK SHAFT ASSEMBLY 6 50 INSTALLING THE KICK IDLE GEAR 6 51 SHIFT SHAFT 6 52 REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 6 53 REMOVING THE SEGMENT 6 53 CHECKING THE SHIFT SHAFT 6 53 CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 6 53 CHECKING THE STOPPER LEVER 6 53 INSTALLING THE STOPPER LEVER 6 54 INSTALLING T...

Page 229: ...UIDE OIL STRAINER 6 71 CHECKING THE CRANKCASE 6 71 INSTALLING THE OIL SEAL 6 72 ASSEMBLING THE CRANKCASE 6 72 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 6 73 REMOVING THE CRANKSHAFT ASSEMBLY 6 74 CHECKING THE CRANKSHAFT ASSEMBLY 6 74 INSTALLING THE CRANKSHAFT ASSEMBLY 6 75 INSTALLING THE BALANCER SHAFT 6 75 TRANSMISSION 6 76 REMOVING THE TRANSMISSION 6 77 CHECKING THE SHIFT FORKS 6 77 CHECKING THE SHI...

Page 230: ...XHAUST PIPE AND MUFFLER on page 6 9 Side cover right Refer to GENERAL CHASSIS on page 5 1 Rear shock absorber assembly lower bolt Refer to REAR SHOCK ABSORBER AS SEMBLY on page 5 58 Connecting arm bolt frame side Refer to REAR SHOCK ABSORBER AS SEMBLY on page 5 58 1 Silencer clamp 1 Loosen 2 Silencer 1 3 Exhaust pipe 2 clamp 1 Loosen 4 Exhaust pipe 2 1 10 5 9 2 6 1 6 6 3 8 4 7 4 6 30 Nm 3 0 m kgf ...

Page 231: ...t pipe Order Part name Q ty Remarks 10 5 9 2 6 1 6 6 3 8 4 7 4 6 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R New LT LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R T R kgf 13 Nm 1 3 m 9 4 ft lbf kgf 14 ft 20...

Page 232: ...IS on page 5 1 Air scoop left right Refer to GENERAL CHASSIS on page 5 1 Fuel tank Refer to FUEL TANK on page 8 1 Air filter case cover 1 Rectifier regulator 1 2 ECU 1 3 Ignition coil 1 4 Neutral switch 1 5 AC magneto coupler 1 Disconnect 6 Crankshaft position sensor coupler 1 Disconnect 7 Coolant temperature sensor coupler 1 Disconnect For installation reverse the removal proce dure T R T R T R T...

Page 233: ... tank Refer to FUEL TANK on page 8 1 Exhaust pipe and silencer Refer to ENGINE REMOVAL on page 6 1 Air filter case Refer to THROTTLE BODY on page 8 7 Throttle body Refer to THROTTLE BODY on page 8 7 Clutch cable Refer to CLUTCH on page 6 40 Shift pedal Refer to SHIFT SHAFT on page 6 52 Starter motor Refer to ELECTRIC STARTER on page 6 35 1 Engine guard 1 2 Brake pedal 1 3 Spring 1 4 Cylinder head ...

Page 234: ...t 2 9 Washer 1 Thickness 2 3 mm 0 09 in 10 Washer 1 Thickness 1 0 mm 0 04 in 11 Lower engine bracket 2 12 Pivot shaft 1 13 Engine 1 For installation reverse the removal proce dure Removing the engine Order Part name Q ty Remarks New New LS M 8 8 7 6 13 4 5 New 1 12 3 2 11 10 9 55 Nm 5 5 m kgf 40 ft Ibf T R ...

Page 235: ... silencer EAS2GB7228 REMOVING THE EXHAUST PIPE 2 1 Remove Exhaust pipe 2 TIP Put the Exhaust pipe 2 into the state as shown by moving this and then remove it EAS2GB7229 REMOVING THE DRIVE SPROCKET 1 Straighten the lock washer tab 2 Remove Nut drive sprocket 1 Lock washer 2 TIP Loosen the nut while applying the rear brake 3 Remove Drive sprocket 1 Drive chain 2 TIP Remove the drive sprocket togethe...

Page 236: ... up the engine and remove this from its lower part toward the right of the chassis EAS2GB7231 CLEANING THE SPARK ARRESTER EWA WARNING Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester Do not start the engine when cleaning the exhaust system 1 Remove Muffler cap screws 1 2 Remove Spark arrester bolts 1 3 Remove Tail pipe 1 Tail pipe gasket 2 Spark arrester 3 Pull the ...

Page 237: ...ine bracket 4 Engine bracket bolt front side 5 Engine mounting bolt front side 6 Upper engine bracket 7 Engine bracket bolt upper side 8 Engine mounting bolt upper side 9 TIP Apply molybdenum disulfide grease to the pivot shaft Spark arrester bolt 9 Nm 0 9 m kgf 6 5 ft lbf Muffler cap screw 5 Nm 0 5 m kgf 3 6 ft lbf Pivot shaft 85 Nm 8 5 m kgf 61 ft lbf New New T R T R 1 1 T R Engine mounting bolt...

Page 238: ...to tighten to specification other wise it may damage the other part that is fastened together 3 Bend the lock washer tab to lock the nut 4 Install Drive sprocket guide Drive sprocket cover 1 Bolt drive sprocket cover 2 EAS2GB7236 INSTALLING THE EXHAUST PIPE AND MUFFLER 1 Install Gasket Exhaust pipe 1 1 Nut exhaust pipe 1 2 TIP First temporarily tighten all nuts to 13 Nm 1 3 m kgf 9 4 ft lbf Then r...

Page 239: ...lt silencer 2 TIP Install and temporarily tighten the silencer so that its joint is positioned as shown with respect to the exhaust pipe 2 4 Tighten Bolt exhaust pipe 2 Clamp TIP Tighten while checking that their front and rear joints are inserted in position Bolt silencer 30 Nm 3 0 m kgf 22 ft lbf 1 2 2 1 2 2mm 0 08in T R Bolt exhaust pipe 2 20 Nm 2 0 m kgf 14 ft lbf Clamp 12 Nm 1 2 m kgf 8 7 ft ...

Page 240: ...p left right Refer to GENERAL CHASSIS on page 5 1 Fuel tank Refer to FUEL TANK on page 8 1 1 Spark plug 1 2 Cylinder head breather hose 1 3 Bolt cylinder head cover 2 4 Cylinder head cover 1 5 Cylinder head cover gasket 1 6 Timing chain guide top side 1 7 Cylinder head cover gasket 1 For installation reverse the removal proce dure 1 4 6 7 5 2 3 10Nm 1 0 m kgf 7 2ft Ibf T R 13Nm 1 3 m kgf 9 4ft Ibf...

Page 241: ... Timing chain tensioner 1 5 Camshaft cap 2 6 Clip 2 7 Intake camshaft 1 8 Exhaust camshaft 1 For installation reverse the removal proce dure 6 Nm 0 6 m kgf 4 3 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 5 8 3 4 1 2 7 6 5 4 4 6 M M E New New New E E ...

Page 242: ...ket with the edge of the cylinder head 3 Remove Timing chain tensioner cap bolt 1 Timing chain tensioner 2 Gaskets 4 Remove Bolt camshaft cap 1 Camshaft cap 2 Clip 3 TIP Remove the bolts camshaft cap in a criss cross pattern working from the outside in In order to prevent the clip from falling into the crankcase remove the camshaft cap ECA NOTICE The bolts camshaft cap must be removed evenly to pr...

Page 243: ...l the camshaft into the cylinder head b Position a strip of Plastigauge 1 onto the camshaft journal as shown Camshaft lobe dimensions Lobe height Intake 31 730 31 830 mm 1 2492 1 2531 in Limit 31 630 mm 1 2453 in Base circle diameter intake 22 450 22 550 mm 0 8839 0 8878 in Limit 22 350 mm 0 8799 in Lobe height Exhaust 33 370 33 470 mm 1 3138 1 3177 in Limit 33 270 mm 1 3098 in Base circle diamete...

Page 244: ... 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 EAS2GB7241 CHECKING THE TIMING CHAIN TENSION ERS 1 Check Timing chain tensioner Crack damage Replace a While pressing the tensioner rod lightly with your fingers use a thin screwdriver 1 to wind the tensioner rod up fully clockwi...

Page 245: ... Make sure that the alignment mark c on the exhaust camshaft sprocket and the alignment mark d on the intake camshaft sprocket are aligned with the edge of the cylinder head ECA NOTICE Do not turn the crankshaft during the cam shaft installation Damage or improper valve timing will result d Install the clips the camshaft caps and the bolts camshaft cap TIP Before installing the clips cover the cyl...

Page 246: ...eral turns 4 Check Top dead center TDC mark on the rotor 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 Cylinder head cover 3 Bolt cylinder head cover 4 TIP Before installation apply the sealant to the cyl inder head cover gasket 6 Install Cylinder head br...

Page 247: ...t pipe and silencer Refer to ENGINE REMOVAL on page 6 1 Radiator hose Disconnect Coolant temperature sensor coupler Disconnect Throttle body Refer to THROTTLE BODY on page 8 7 Camshaft Refer to CAMSHAFT on page 6 11 Upper engine bracket Refer to ENGINE REMOVAL on page 6 1 1 Nut cylinder head 2 2 Bolt cylinder head 4 3 Cylinder head 1 4 Cylinder head gasket 1 5 Timing chain guide intake side 1 6 Oi...

Page 248: ...R HEAD 6 19 For installation reverse the removal proce dure Removing the cylinder head Order Part name Q ty Remarks 6 10 Nm 1 0 m kgf 7 2 ft Ibf T R 33 Nm 3 3 m kgf 24 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 249: ...strument in order not to damage or scratch the spark plug bore threads 2 Check Cylinder head Damage scratches Replace TIP When replacing the cylinder head replace also the valve Refer to CHECKING THE VALVE SEATS on page 6 26 Cylinder head coolant passages Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylin der head a Place a straightedge and a t...

Page 250: ...the cylin der head 2 Install Washer 1 Cylinder head bolt 2 Cylinder head nut 3 TIP Apply molybdenum disulfide grease to the threads and contact surfaces of the bolts and to both contact surfaces of the washers 3 Tighten Cylinder head bolt 1 4 Cylinder head nut 5 6 TIP Tighten the bolts and nuts to the specified torque in two or three steps in the proper tight ening sequence as shown Cylinder head ...

Page 251: ...ngs Order Part name Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 6 18 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 For installation reverse the removal proce dure ...

Page 252: ...eakage at the valve seat Check the valve face the valve seat and the valve seat contact width Refer to CHECKING THE VALVE SEATS on page 6 26 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves are properly sealed TIP Check that there are no kerosene leaks from the valve seat 1 3 Remove Valve cotter 1 TIP Remove the valve cotters by compressing the valve spring with t...

Page 253: ...ion and to maintain the correct fit heat the cylinder head to 100 C 212 F in an oven a Remove the valve guide with the valve guide remover 1 b Install the new valve guide with the valve guide installer 2 and the valve guide re mover 1 Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in L...

Page 254: ...ut Out of specification Replace the valve TIP When installing a new valve always replace the valve guide If the valve is removed or replaced always re place the valve stem seal 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 Valve guide reamer 5 0 mm YM 04099 E...

Page 255: ...odel uses titanium intake and ex haust valves Do not use the valves used for lapping the valve seat Always replace the valves used for lapping with new ones TIP When replacing the cylinder head replace also the valves with new ones without them When replacing the valves or the valve guides use new valves to lap the valve seats and then replace them with new valves a Apply a coarse lapping compound...

Page 256: ...nd lap the valve seat EAS2GB7253 CHECKING THE VALVE SPRINGS 1 Measure Valve spring free length a Out of specification Replace the valve spring 2 Measure Compressed valve spring force a Out of specification Replace the valve spring 3 Measure Valve spring tilt a Out of specification Replace the valve spring Free length intake 36 69 mm 1 44 in Limit 35 69 mm 1 41 in Free length exhaust 34 86 mm 1 37 ...

Page 257: ... 5 to the cylinder head TIP Make sure each valve is installed in its original place Install the valve springs with the larger pitch a facing up 4 Install Valve cotter 1 TIP Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor adapter 3 Recommended lubricant Molybdenum disulfide oil b Smaller pitch Valve spring compressor 90890...

Page 258: ...NOTICE 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 TIP 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 E 1 2 ...

Page 259: ...emarks Cylinder head Refer to CYLINDER HEAD on page 6 18 1 Cylinder body 1 2 Gaskets 1 3 Dowel pin 2 4 Piston pin clip 2 5 Piston pin 1 6 Piston 1 7 Piston ring set 1 For installation reverse the removal proce dure 1 2 3 4 4 5 6 7 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R E E New New New LT E ...

Page 260: ...e piston crown EAS2GB7258 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Sidewall Cylinder wall Vertical scratches Replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure the cylinder bore with the cylinder bore gauge TIP Measure cylinder bore by taking side to side and front to back measurements of the cylin der Piston pin pulle...

Page 261: ...eplace the piston and piston rings as a set TIP Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston rings TIP Level the piston ring into the cylinder with the piston 3 Measure Piston ring end gap Out of specification Replace the piston ring TIP The oil ring expander s end gap cannot be measured If the oil rin...

Page 262: ... CYLINDER 1 Install Oil ring expander 1 Lower oil ring rail 2 Upper oil ring rail 3 Top ring 4 TIP Be sure to install the piston ring so that the manufacturer s marks or numbers face up 2 Install Piston 1 Piston pin 2 Piston pin clip 3 Piston ring Top ring End gap installed 0 15 0 25 mm 0 0059 0 0098 in Limit 0 50 mm 0 0197 in Oil ring End gap installed 0 10 0 35 mm 0 0039 0 0138 in Piston pin out...

Page 263: ...clip ends are 3 mm 0 12 in c or more from the cutout in the piston 3 Lubricate Piston Piston rings Cylinder 4 Offset Piston ring end gap 5 Install Cylinder gasket Dowel pin Cylinder TIP 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 a Top ring b Upper oil ring rail c...

Page 264: ...2 ELECTRIC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks Exhaust pipe Refer to ENGINE REMOVAL on page 6 1 1 Starter motor 1 For assembly reverse the disassemble pro cedure 1 12 Nm 1 2 m kgf 8 7 ft Ibf T R ...

Page 265: ...embling the starter motor Order Job Parts to remove Q ty Remarks 1 Starter motor front cover 1 2 Starter motor yoke 1 3 Armature assembly 1 4 Starter motor rear cover 1 5 Brush set 2 For assembly reverse the disassembly pro cedure ...

Page 266: ...ure assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resistanc es with the pocket tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brush set 6 Measure Brush spring force Out of specification Replace the brush set Limit 16 6 mm 0 65 in ...

Page 267: ...1 Starter motor yoke 2 ECA NOTICE Install the part that has a smaller step differ ence a with the magnet of the starter mo tor yoke facing the starter motor front cover TIP Align the match mark a on the starter motor yoke with the match mark b on the starter mo tor rear cover 4 Install Circlip Plain washer 1 O ring 2 Washer starter motor front cover 3 Starter motor front cover 4 TIP For installati...

Page 268: ...ELECTRIC STARTER 6 39 5 Install Bolt 1 O ring 2 TIP Apply the lithium soap based grease on the O ring New ...

Page 269: ...edal Refer to ENGINE REMOVAL on page 6 1 1 Clutch cable 1 Disconnect 2 Clutch cover 1 3 Gasket 1 4 Clutch spring 5 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Washer 1 9 Bearing 1 10 Ball 1 11 Push rod 2 1 12 Friction plate 1 4 13 Clutch plate 8 New New New 2 3 4 5 5 6 7 8 9 6 10 11 12 22 1 15 12 13 13 18 19 20 17 16 14 13 T R T R T R T R LT 21 ...

Page 270: ...17 Thrust washer 1 18 Primary driven gear 1 19 Spacer 1 20 Bearing 1 21 Washer 1 22 Push lever shaft 1 For installation reverse the removal proce dure Removing the clutch Order Part name Q ty Remarks New New New 2 3 4 5 5 6 7 8 9 6 10 11 12 22 1 15 12 13 13 18 19 20 17 16 14 13 T R T R T R T R LT 21 ...

Page 271: ... Refer to CHANGING THE COOLANT on page 3 10 Brake pedal Refer to ENGINE REMOVAL on page 6 1 Clutch cover Refer to CLUTCH on page 6 40 1 Oil filter element cover 1 2 Oil filter element 1 3 Radiator pipe 2 1 4 Kickstarter lever 1 5 Right crankcase cover 1 6 Gaskets 1 7 Dowel pin 2 8 Collar 1 For installation reverse the removal proce dure T R LS New New 6 7 2 5 4 1 7 8 New 3 LS New New LS New New LT...

Page 272: ...GB7268 CHECKING THE CLUTCH PLATES 1 Check Clutch plate Damage Replace the clutch plates as a set 2 Measure Clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clutch plates as a set EAS2GB7269 CHECKING THE CLUTCH SPRINGS 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure Clutch spring free length Out of specification Replace the ...

Page 273: ...eplace EAS2GB7273 CHECKING THE PUSH LEVER SHAFT 1 Check Push lever shaft Wear damage Replace EAS2GB7274 CHECKING THE CLUTCH PUSH RODS 1 Check Push rod 1 1 Bearing 2 Washer 3 Push rod 2 4 Ball 5 Cracks damage wear Replace 2 Measure Push rod 2 bending limit Out of specification Replace EAS2GB7275 CHECKING THE PRIMARY DRIVE GEAR 1 Check Primary drive gear Damage wear Replace the primary drive and pri...

Page 274: ...ING THE RIGHT CRANKCASE COVER 1 Install Dowel pin 1 O ring 2 Collar 3 Gasket 4 TIP Apply the lithium soap based grease on the O ring 2 Install Right crankcase cover 1 Right crankcase cover bolt 2 TIP Apply the engine oil on the impeller shaft end Mesh the impeller shaft gear 3 with primary drive gear 4 Tighten the right crankcase cover bolts in stages and in a crisscross pattern EAS2GB7279 INSTALL...

Page 275: ...ate 1 1 Clutch plate 2 Cushion spring 3 Friction plate 2 4 TIP Install the clutch plates and friction plates al ternately on the clutch boss starting with a friction plate and ending with a friction plate Install the cushion spring 3 in the position as shown From the clutch boss side install the friction plates in order friction plate 1 2 friction plate 2 identification color purple 5 and friction...

Page 276: ...push rod 1 2 and ball 8 Install Pressure plate 1 9 Install Clutch spring Clutch spring bolt TIP Tighten the bolts in stages and in a crisscross pattern 10 Install Gasket 1 11 Install Clutch cover 1 Clutch cover bolt TIP Tighten the bolts in stages and in a crisscross pattern New Clutch spring bolt 10 Nm 1 0 m kgf 7 2 ft lbf Clutch cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf T R 1 2 3 4 5 New T R 1 ...

Page 277: ...er Bolt kickstarter lever TIP Install so that there is a clearance a of 5 mm 0 2 in or more between the kickstarter lever and the frame and that the kickstarter lever does not contact the right crankcase cover when it is pulled Bolt kickstarter lever 33 Nm 3 3 m kgf 24 ft lbf LOCTITE T R 1 a ...

Page 278: ...shaft Order Part name Q ty Remarks Primary driven gear Refer to CLUTCH on page 6 40 1 Kick idle gear 1 2 Kick shaft assembly 1 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick shaft 1 For installation reverse the removal proce dure ...

Page 279: ...k Kick gear 1 Wear damage Replace the kick shaft as sembly Kick idle gear 2 Ratchet wheel 3 Gear teeth a Ratchet teeth b Wear damage Replace EAS2GB7285 INSTALLING THE KICK SHAFT ASSEMBLY 1 Install Kick gear 1 Washer 2 Circlip 3 Ratchet wheel 4 Spring 5 Washer 6 Circlip 7 to the kick shaft 8 TIP Apply molybdenum disulfide oil to the inner circumferences of the kick gear and ratchet wheel Align the ...

Page 280: ...e kick shaft stopper a Apply the engine oil on the kick shaft Slide the kick shaft assembly into the crank case and make sure the kick shaft stopper a fits into the kick shaft ratchet wheel guide 5 Install Torsion spring 1 TIP Turn the torsion spring clockwise and hook into the proper hole a in the crankcase EAS2GB7286 INSTALLING THE KICK IDLE GEAR 1 Install Kick idle gear 1 Washer 2 Circlip 3 TIP...

Page 281: ... 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 For installation reverse the removal proce dure LS 1 3 13 15 14 LT 6 10 11 12 11 8 12 10 4 2 5 LT 7 LT E 12 Nm 1 2 m kgf 8 7 ft Ibf T R 30 Nm 3 0 m kgf 22 ft T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R Ibf 10 Nm 1 0 m kgf...

Page 282: ...loosen the bolt ECA NOTICE If the segment gets an impact the stopper lever may be damaged Take care not to give an impact to it when removing the bolt EAS2GB7290 CHECKING THE SHIFT SHAFT 1 Check Shift shaft 1 Bends damage wear Replace Shift shaft spring 2 Damage wear Replace EAS2GB7291 CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1 Check Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 ...

Page 283: ...aged Take care not to give an impact to it when tightening the bolt EAS2GB7295 INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1 Install Spring 1 Pawl pin 2 Pawl 3 to the shift lever 4 TIP Apply the engine oil on the spring pawl pin and pawl 2 Install Shift lever assembly 1 to the shift guide 2 3 Install Shift lever assembly 1 Shift guide 2 TIP The shift lever assembly is installed at the same...

Page 284: ... Apply the engine oil on the roller collar and shift shaft 2 Install Oil seal EAS2GB7297 INSTALLING THE SHIFT PEDAL 1 Install Shift pedal 1 Shift pedal bolt 2 TIP Align the punch mark a on the shift shaft with the punch mark b in the shift pedal Shift guide bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Shift pedal bolt 12 Nm 1 2 m kgf 8 7 ft lbf T R 1 1 LT E E 1 2 3 4 New T R a 1 2 b ...

Page 285: ...r Refer to CLUTCH on page 6 40 Right crankcase cover Refer to CLUTCH on page 6 40 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 Rotor housing 1 For installation reverse the removal proce dure 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R LT E 3 2 1 4 5 7 6 ...

Page 286: ...TOR AND STARTER CLUTCH on page 6 62 1 Nut balancer 1 2 Nut primary drive gear 1 3 Nut balancer shaft driven gear 1 4 Conical washer 1 5 Balancer 1 6 Conical washer 1 7 Primary drive gear 1 8 Collar 1 9 Balancer shaft drive gear 1 10 Conical washer 1 11 Balancer weight gear 1 12 Collar 1 For installation reverse the removal proce dure T R 75 Nm 7 5 m kgf 54 ft lbf T R 50 Nm 5 0 m kgf 36 ft Ibf T R ...

Page 287: ...rimary drive gear 1 Balancer shaft drive gear 2 Balancer weight gear 3 Wear damage Replace EAS2GB7301 CHECKING THE BALANCER 1 Check Balancer Crack damage Replace EAS2GB7302 CHECKING THE OIL PUMP 1 Check Oil pump drive gear Oil pump driven gear Oil pump housing Oil pump housing cover Cracks damage wear Replace the defec tive part s 2 Measure Inner rotor to outer rotor tip clearance a Outer rotor to...

Page 288: ...r 2 Install Outer rotor 1 TIP Apply the engine oil on the outer rotor 3 Install Oil pump cover 1 Oil pump cover screw 2 Inner rotor to outer rotor tip clearance Less than 0 150 mm 0 0059 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing clearance 0 13 0 18 mm 0 0051 0 0071 in Limit 0 24 mm 0 0094 in Oil pump housing to inner and outer rotor clearance 0 06 0 11 mm 0 0024 0 0043 in Limit 0 ...

Page 289: ...ach other 4 Install Conical washer 1 Balancer weight gear nut 2 Primary drive gear 3 Conical washer 4 Primary drive gear nut 5 Balancer 6 Conical washer 7 Balancer nut 8 TIP Apply engine oil to the contact surface and threaded portion of the primary drive gear nut Place an aluminum plate a between the teeth of the balancer drive gear 9 and bal ancer weight gear 10 Install the conical washer with i...

Page 290: ...OIL PUMP AND BALANCER GEAR 6 61 a 2 10 b 2 9 1 b 5 3 a 4 10 5 9 3 E c d 6 7 8 8 b 6 ...

Page 291: ...nk Refer to GENERAL CHASSIS on page 5 1 and FUEL TANK on page 8 1 Disconnect the AC magneto lead Clutch cable Shift pedal Refer to SHIFT SHAFT on page 6 52 1 Cover Damper assembly 1 2 Damper assembly 1 3 Breather hose 1 4 Left crankcase cover 1 5 Gasket 1 6 Dowel pin 2 7 Starter idle gear 1 8 Bearing 1 9 Starter idle gear shaft 1 10 Generator rotor 1 T R T R 6 6 11 9 8 7 2 3 1 14 4 5 12 10 13 T R ...

Page 292: ... clutch 1 13 Starter clutch drive gear 1 14 Crankshaft position sensor 1 15 Stator 1 For installation reverse the removal proce dure Removing the generator Order Job Parts to remove Q ty Remarks T R T R 6 6 11 9 8 7 2 3 1 14 4 5 12 10 13 T R T R T R LT T R T R 15 ...

Page 293: ...ch gear 4 Check Damper assembly Damage pitting wear Replace the damp er assembly Check the gear of the starter motor arma ture 5 Check Starter clutch operation a Install the starter clutch drive gear 1 onto the starter clutch and hold the starter clutch b When turning the starter clutch drive gear clockwise A the starter clutch and the starter clutch drive gear should engage oth erwise the starter...

Page 294: ...tall Starter clutch 1 To generator rotor 2 EAS2GB7309 INSTALLING THE GENERATOR 1 Install Woodruff key 1 Generator rotor 2 TIP Clean the contact surfaces of the tapered por tions of the crankshaft and generator rotor When installing the woodruff key make sure that its flat surface a is in parallel with the crankshaft center line b When installing the generator rotor align the keyway c of the genera...

Page 295: ...nstall Dowel pin Crankcase cover gasket Left crankcase cover 1 Lead holder 2 Crankcase cover bolt Neutral switch lead 3 TIP Pass the AC magneto lead 4 under the left crankcase cover a as shown Tighten the bolts in stage using a crisscross pattern 5 Install Washer 1 Damper assembly 2 Washer 3 TIP Apply the engine oil to the shaft and washers 6 Install Cover damper assembly 1 Bracket 2 Bolt 3 Breath...

Page 296: ...GENERATOR AND STARTER CLUTCH 6 67 TIP Install the cover damper assembly with its mark a facing upward 1 a 3 3 2 4 ...

Page 297: ... Segment Refer to SHIFT SHAFT on page 6 52 Generator rotor Refer to GENERATOR AND STARTER CLUTCH on page 6 62 1 Timing chain guide exhaust side 1 2 Timing chain guide stopper plate 1 3 Timing chain 1 4 Bolt L 45 mm 1 77 in 7 5 Bolt L 60 mm 2 36 in 2 6 Bolt L 75 mm 2 95 in 3 7 Right crankcase 1 8 Left crankcase 1 9 Dowel pin 2 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 ...

Page 298: ...r assembly reverse the disassemble pro cedure Separating the crankcase Order Part name Q ty Remarks 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 3 1 5 2 6 4 10 5 6 4 4 4 4 6 9 11 7 8 9 LT ...

Page 299: ...s Transmission Refer to TRANSMISSION on page 6 76 Shift cam and shift fork Refer to TRANSMISSION on page 6 76 1 Circlip 2 2 Oil seals 3 3 Bearing 11 For installation reverse the removal proce dure LT LT LT 2 3 3 3 3 3 3 3 3 3 New 1 1 2 3 New New LT 22 Nm 2 2 m kgf 16 ft Ibf T R ...

Page 300: ...alf Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If the cases do not separate check for a remaining case bolt or fitting Do not force c Remove the dowel pins and O ring EAS2GB7312 REMOVING THE CRANKCASE BEARING 1 Remove Bearing 1 TIP Remove the bearing from the crankcase by pressing its inner race Do...

Page 301: ...he left crankcase Tap lightly on the case with soft hammer When installing the crankcase the connecting rod should be positioned at top dead center TDC Tighten the bolts in a crisscross pattern in two 2 stages with 1 4 turn each Installed depth a 4 5 5 0 mm 0 18 0 20 in Bearing cover plate screw 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Bearing cover plate screw crank shaft 22 Nm 2 2 m kgf 16 ft lbf LOCT...

Page 302: ...ER SHAFT Removing the crankshaft assembly and balancer shaft Order Part name Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 6 68 Transmission Refer to TRANSMISSION on page 6 76 1 Balancer shaft 1 2 Crankshaft assembly 1 For installation reverse the removal proce dure M M 1 2 ...

Page 303: ...owly 2 Measure Big end side clearance a Out of specification Replace the big end bearing crankshaft pin or connecting rod 3 Measure Crank assembly width a Out of specification Replace the crank shaft 4 Check Crankshaft sprocket 1 Damage Replace the crankshaft 5 Check Crankshaft journal oil passage Obstruction Blow out with compressed air Crankcase separating tool 90890 04152 Crankcase separating t...

Page 304: ...d 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 EAS2GB7321 INSTALLING THE BALANCER SHAFT 1 Install Balancer shaft 1 TIP Apply the molybdenum grease to the part a where the balancer shaft fit into the bearing ECA NOTICE Do not ...

Page 305: ...INE REMOVAL on page 6 1 Crankcase Separate Refer to CRANKCASE on page 6 68 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 cam 1 7 Shift fork 3 R 1 8 Shift fork 2 C 1 9 Shift fork 1 L 1 10 Collar 1 For installation reverse the removal proce dure 2 10 1 5 3 4 5 7 8 6 9 M M M M M E E E E LS New ...

Page 306: ...ion of shift forks Remove the main axle and the drive axle all together by tapping the drive axle lightly with a soft hammer EAS2GB7324 CHECKING THE SHIFT FORKS 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace EWA WARNING Do not attempt to straighten a bent...

Page 307: ...Check Transmission gears Blue discoloration pitting wear Replace the defective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check Transmission gear movement Rough movement Replace the defective gear s EAS2GB7327 INSTALLING THE TRANSMISSION 1 Install 6th pinion gear 27T 1 3rd 4th pinion gear 18T 21T 2 Collar 3 5th pinion gear 23T 4 2nd pinion gear 16T 5 t...

Page 308: ... the O ring 3 Install Washer 1 Circlip 2 TIP Be sure the circlip sharp edged corner a is positioned opposite side to the washer and gear b Install the circlip with its ends c settled even ly on the spline crests 4 Install Collar 1 TIP 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 lip 5 Install M...

Page 309: ...ith the 5th wheel gear 5 and 3 R with the 6th wheel gear 7 on the drive axle Mesh the shift fork 2 C with the 3rd 4th pin ion gear 6 on the main axle 7 Install Long shift fork guide bar 1 Short shift fork guide bar 2 Spring 3 TIP Screw the spring into the shift fork guide bar lightly beforehand Apply the engine oil on the shift fork guide bars 8 Check Operation of shift cam and shift fork Transmis...

Page 310: ...TRANSMISSION 6 81 ...

Page 311: ...STEM RADIATOR 7 1 HANDLING NOTE 7 3 CHECKING THE RADIATOR 7 3 WATER PUMP 7 4 REMOVING THE OIL SEAL 7 6 CHECKING THE WATER PUMP 7 6 CHECKING THE BEARING 7 6 INSTALLING THE OIL SEAL 7 6 ASSEMBLING THE WATER PUMP 7 6 ...

Page 312: ... servicing trouble and mechanical damage EAS2GB7329 RADIATOR Removing the radiator Order Part name Q ty Remarks Coolant Drain Refer to CHANGING THE COOLANT on page 3 10 Seat Refer to GENERAL CHASSIS on page 5 1 Side cover left right Refer to GENERAL CHASSIS on page 5 1 Air scoop left right Refer to GENERAL CHASSIS on page 5 1 Fuel tank Refer to FUEL TANK on page 8 1 Air filter case Refer to THROTT...

Page 313: ...1 9 Radiator breather hose 1 10 Left radiator 1 11 Radiator hose 1 1 12 Radiator pipe 1 1 13 Coolant temperature sensor 1 For installation reverse the removal proce dure Removing the radiator Order Part name Q ty Remarks 12 13 New New New LS LS 3 4 5 8 Nm 0 8 m kgf 5 8 ft Ibf T R 6 7 8 9 10 11 2 2 2 2 2 2 2 1 1 ...

Page 314: ... ra diator cap EAS2GB7331 CHECKING THE RADIATOR 1 Check Radiator fins 1 Obstructions Clean Apply compressed air to the rear of the radi ator Damage Repair or replace TIP Correct any flattened fins with a thin flat head screwdriver 2 Check Radiator hoses Radiator pipes Crack damage Replace ...

Page 315: ...efer to CHANGING THE ENGINE OIL on page 3 17 Right crankcase cover Refer to CLUTCH on page 6 40 1 Water pump housing 1 2 Dowel pin 2 3 Gasket 1 4 Washer 2 5 Collar 1 6 Gear 1 7 Pin 1 8 Impeller shaft assembly 1 9 Oil seal 1 10 Bearing 1 11 Oil seal 1 9 8 2 2 3 1 10 6 7 5 4 4 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R New New New E 11 New E LS LS ...

Page 316: ...For installation reverse the removal proce dure Removing the water pump Order Part name Q ty Remarks 9 8 2 2 3 1 10 6 7 5 4 4 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R New New New E 11 New E LS LS ...

Page 317: ...GB7336 INSTALLING THE OIL SEAL 1 Install Oil seals 1 TIP Apply the lithium soap based grease on the oil seal lip Install the oil seal with its manufacture s marks or numbers facing the right crankcase cover 2 2 Install Bearing 1 TIP Install the bearing by pressing its outer race parallel EAS2GB7337 ASSEMBLING THE WATER PUMP 1 Install Impeller shaft assembly 1 Washer 2 Pin 3 Gear 4 Collar 5 Circlip...

Page 318: ... 1 Gasket 2 3 Install Water pump housing 1 Water pump housing bolt 2 Washer 3 Coolant drain bolt 4 Water pump housing bolt 10 Nm 1 0 m kgf 7 2 ft lbf Coolant drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf New 2 1 1 New T R New T R 2 2 4 3 1 New ...

Page 319: ...UEL SENDER 8 4 CHECKING THE FUEL SENDER 8 4 INSTALLING THE FUEL SENDER 8 4 INSTALLING THE FUEL TANK 8 4 CHECKING THE FUEL PRESSURE 8 5 CHECKING THE DAMPER 8 5 CHECKING AND REPLACING THE PROTECTOR 8 6 THROTTLE BODY 8 7 CHECKING THE INJECTOR 8 10 CHECKING THE THROTTLE BODY 8 10 CHECKING THE THROTTLE BODY JOINT 8 10 ADJUSTING THE THROTTLE POSITION SENSOR 8 11 ...

Page 320: ...icing trouble and mechanical damage EAS2GB7339 FUEL TANK Removing the fuel tank Order Part name Q ty Remarks Seat Refer to GENERAL CHASSIS on page 5 1 Side cover left right Air scoop left right 1 Fuel pump coupler 1 Disconnect 2 Fuel hose 1 Disconnect 3 Fuel tank 1 4 Fuel pump bracket 1 5 Fuel pump 1 6 Fuel pump gasket 1 7 Fuel sender 1 4 6 2 2 2 2 2 5 6 3 1 New 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 ...

Page 321: ... tank Order Part name Q ty Remarks 4 6 2 2 2 2 2 5 6 3 1 New 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 ...

Page 322: ...eign ma terials from entering the fuel pump install the included fuel hose joint cover 1 3 and the fuel hose joint cover 2 4 onto the disconnect ed fuel hose and the fuel pump 3 Remove Side cover left right Seat Air scoop left right Fuel tank TIP Do not set the fuel tank down on the installation surface of the fuel pump Be sure to lean the fuel tank against a wall or the like EAS2GB7341 REMOVING T...

Page 323: ... sender gasket Fuel sender TIP Do not damage the installation surfaces of the fuel tank when installing the fuel sender Always use a new fuel sender gasket Install the fuel sender as shown in the illustra tion When install the fuel sender make sure that the projection a faces the rear of the vehicle EAS2GB7347 INSTALLING THE FUEL TANK 1 Install Fuel tank 2 Connect Fuel hose ECA NOTICE Connect the ...

Page 324: ... THE FUEL TANK on page 8 3 EWA WARNING Cover the fuel hose connection with a cloth when disconnecting it This is because re sidual pressure in the fuel hose could cause fuel to spurt out when the hose is removed ECA NOTICE Make sure that the fuel hose is disconnect ed by hand Do not forcibly disconnect the hose with tools d Connect the pressure gauge 1 and the fuel pressure adapter 2 to the fuel h...

Page 325: ...CKING AND REPLACING THE PRO TECTOR 1 Check Protector 1 Wear damage Replace TIP Affix the protector as shown A Left B Right 3 31 in 4 53 in 84 mm 115 mm 3 1 1 3 a 2 3 31 in 4 53 in 84 mm 115 mm 1 1 A A 0 mm 0 in B 1 1 15 mm 0 59 in ...

Page 326: ...VAL on page 6 1 Ignition coil Refer to ENGINE REMOVAL on page 6 1 1 Intake air temperature sensor coupler 1 Disconnect 2 Breather hose 3 1 3 Air filter case 1 4 Fuel injector coupler 1 Disconnect 5 Intake air pressure sensor coupler 1 Disconnect 6 Throttle position sensor coupler 1 Disconnect 7 Throttle cable cover 1 8 Throttle cable 2 3 1 2 7 11 12 10 9 4 8 6 5 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 ...

Page 327: ...oint 1 For installation reverse the removal proce dure Removing the throttle body Order Part name Q ty Remarks 3 1 2 7 11 12 10 9 4 8 6 5 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 328: ...rks 1 Fuel inlet pipe 1 2 Injector 1 3 Gaskets 1 4 Throttle position sensor 1 5 Intake air pressure sensor 1 For installation reverse the removal proce dure 1 2 2 2 5 4 3 T R 3 4 Nm 0 34 m lbf kgf 2 5 ft T R 5 Nm 0 5 m lbf kgf 3 6 ft T R 3 4 Nm 0 34 m lbf kgf 2 5 ft ...

Page 329: ...oreign material from falling into the engine If the throttle body is subject to strong shocks or dropped during cleaning re place it Do not use any caustic carburetor clean ing solution Do not directly push the throttle valves to open them Do not loosen the throttle valve stopper screw 1 throttle valve pulley nut 2 or throttle valve screw 3 A loss of perfor mance may occur Do not use compressed ai...

Page 330: ... YAMAHA DIAGNOSTIC TOOL on page 9 32 b Temporary tighten the throttle position sen sor c Check that the throttle grip is fully closed d Connect the throttle position sensor to the wire harness e Set the Yamaha diagnostic tool to diagnos tic mode f Choose the diagnostic code No 01 g Adjust the throttle position sensor mounted angle until 11 14 appears on the Yama ha diagnostic tool h After adjustin...

Page 331: ...TROUBLESHOOTING 9 14 LIGHTING SYSTEM 9 16 CIRCUIT DIAGRAM 9 16 TROUBLESHOOTING 9 18 SIGNALING SYSTEM 9 20 CIRCUIT DIAGRAM 9 20 TROUBLESHOOTING 9 22 COOLING SYSTEM 9 24 CIRCUIT DIAGRAM 9 24 TROUBLESHOOTING 9 26 FUEL INJECTION SYSTEM 9 28 CIRCUIT DIAGRAM 9 28 ECU SELF DIAGNOSTIC FUNCTION 9 30 TROUBLESHOOTING METHOD 9 31 YAMAHA DIAGNOSTIC TOOL 9 32 TROUBLESHOOTING DETAILS 9 35 FUEL PUMP SYSTEM 9 56 C...

Page 332: ...OR 9 74 CHECKING THE LEAN ANGLE SENSOR 9 75 CHECKING THE STARTER MOTOR OPERATION 9 75 CHECKING THE STATOR COIL 9 76 CHECKING THE RECTIFIER REGULATOR 9 76 CHECKING THE SPEED SENSOR 9 77 CHECKING THE FUEL SENDER 9 77 CHECKING THE RESISTER 9 77 CHECKING THE RADIATOR FAN MOTOR 9 78 CHECKING THE COOLANT TEMPERATURE SENSOR 9 78 CHECKING THE THROTTLE POSITION SENSOR 9 79 CHECKING THE THROTTLE POSITION SE...

Page 333: ... 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 ...

Page 334: ...B B B O B B B Sb W B Sb Sb G B L G L W L B Br G B G B B B B B B L B B B B Br Br Br Br Br B B L Y B B B B B G B Ch Dg Y B B R W Br R B W B W R W Ch Dg Y B Br R W B W R O O R L B B B B B B B B R R R R R R L Br Br Br Br Br Br Br Br Br Br Br R L R L R L R L R L B L L L P P L Y Y R R Br R L R L R L P L P L R L R L R L R B R B L R L Y L Y Y R Y R G Y G Y G Y G Y B Y B Y R L B L B L B L B L B L Y G Y G B...

Page 335: ...int connector 4 AC magneto 9 Battery 10 Frame ground 11 Starter relay 12 Main fuse 22 ECU engine control unit 23 Ignition coil 24 Spark plug 30 Joint connector 35 Lean angle sensor 36 Engine stop switch 48 Frame ground 49 Ignition coil sub lead ...

Page 336: ...y terminals Recharge or replace the battery OK 3 Check the spark plug Refer to CHECKING THE FUSES on page 9 68 NG Re gap or replace the spark plug OK 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 9 73 OK The ignition system is normal NG 5 Check the ignition coil Refer to CHECKING THE IGNI TION COIL on page 9 74 NG Replace the ignition coil OK 6 Check the cranksha...

Page 337: ...r Refer to CHECKING THE LEAN ANGLE SENSOR on page 9 75 NG Replace the lean angle sensor OK 9 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 9 2 NG Properly connect or repair the ignition sys tem s wiring OK Replace the ECU ...

Page 338: ...L Y G L B B B O B B B Sb W B Sb Sb G B L G L W L B Br G B G B B B B B B L B B B B Br Br Br Br Br B B L Y B B B B B G B Ch Dg Y B B R W Br R B W B W R W Ch Dg Y B Br R W B W R O O R L B B B B B B B B R R R R R R L Br Br Br Br Br Br Br Br Br Br Br R L R L R L R L R L B L L L P P L Y Y R R Br R L R L R L P L P L R L R L R L R B R B L R L Y L Y Y R Y R G Y G Y G Y G Y B Y B Y R L B L B L B L B L B L Y...

Page 339: ... Main relay 9 Battery 10 Frame ground 11 Starter relay 12 Main fuse 13 Starter motor 14 Starter relay diode 22 ECU engine control unit 30 Joint connector 36 Engine stop switch 37 Neutral switch 38 Diode 39 Starting circuit cut off relay 40 Clutch switch 41 Start switch 48 Frame ground ...

Page 340: ... The clutch lever is pulled to the handlebar the clutch switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these con ditions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed a...

Page 341: ...HE TRANSMISSION IS IN NEU TRAL b WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main relay 4 Starting circuit cut off relay 5 Start switch 6 Diode 7 Clutch switch 8 Neutral switch 9 Starter relay 10 Starter motor ...

Page 342: ...e battery OK 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 9 75 OK Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 NG 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 6 37 NG Repair or replace the starter motor OK 5 Check the relay unit Starting circuit cut off relay Refer to CHECKING T...

Page 343: ...tch Refer to CHECKING THE SWITCHES on page 9 64 NG Replace the clutch switch OK 11 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 9 64 NG Replace the start switch OK 12 Check the start switch Refer to CHECKING THE SWITCHES on page 9 64 NG Replace the engine stop switch OK 13 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 9 6 NG Properly connect or r...

Page 344: ...B B B O B B B Sb W B Sb Sb G B L G L W L B Br G B G B B B B B B L B B B B Br Br Br Br Br B B L Y B B B B B G B Ch Dg Y B B R W Br R B W B W R W Ch Dg Y B Br R W B W R O O R L B B B B B B B B R R R R R R L Br Br Br Br Br Br Br Br Br Br Br R L R L R L R L R L B L L L P P L Y Y R R Br R L R L R L P L P L R L R L R L R B R B L R L Y L Y Y R Y R G Y G Y G Y G Y B Y B Y R L B L B L B L B L B L Y G Y G B...

Page 345: ...CHARGING SYSTEM 9 13 4 AC magneto 5 Rectifier regulator 9 Battery 10 Frame ground 11 Starter relay 12 Main fuse 50 Negative battery lead ...

Page 346: ...CHARGING THE BATTERY on page 9 69 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the stator coil Refer to CHECKING THE STA TOR COIL on page 9 76 NG Replace the stator assembly OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 9 76 NG Replace the rectifier regulator OK 5 Check the entire charging system s wiring Refer to CIRCUIT DIAGRAM...

Page 347: ...CHARGING SYSTEM 9 15 ...

Page 348: ...B B B O B B B Sb W B Sb Sb G B L G L W L B Br G B G B B B B B B L B B B B Br Br Br Br Br B B L Y B B B B B G B Ch Dg Y B B R W Br R B W B W R W Ch Dg Y B Br R W B W R O O R L B B B B B B B B R R R R R R L Br Br Br Br Br Br Br Br Br Br Br R L R L R L R L R L B L L L P P L Y Y R R Br R L R L R L P L P L R L R L R L R B R B L R L Y L Y Y R Y R G Y G Y G Y G Y B Y B Y R L B L B L B L B L B L Y G Y G B...

Page 349: ...r 2 Joint connector 6 Headlight relay 7 Main relay 9 Battery 10 Frame ground 11 Starter relay 12 Main fuse 22 ECU engine control unit 30 Joint connector 42 Joint connector 43 Taillight 44 Headlight 47 Multi function display 48 Frame ground ...

Page 350: ...HE FUSES on page 9 68 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 9 69 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the main relay Refer to CHECKING THE RE LAYS on page 9 72 NG Replace the main relay OK 5 Check the headlight relay Refer to CHECKING THE RE LAYS on page 9 72 NG Replace the headlight relay OK 6 Check the...

Page 351: ...LIGHTING SYSTEM 9 19 ...

Page 352: ... B B B O B B B Sb W B Sb Sb G B L G L W L B Br G B G B B B B B B L B B B B Br Br Br Br Br B B L Y B B B B B G B Ch Dg Y B B R W Br R B W B W R W Ch Dg Y B Br R W B W R O O R L B B B B B B B B R R R R R R L Br Br Br Br Br Br Br Br Br Br Br R L R L R L R L R L B L L L P P L Y Y R R Br R L R L R L P L P L R L R L R L R B R B L R L Y L Y Y R Y R G Y G Y G Y G Y B Y B Y R L B L B L B L B L B L Y G Y G ...

Page 353: ...ector 7 Main relay 9 Battery 10 Frame ground 11 Starter relay 12 Main fuse 15 Indicator light 17 Fuel level warning light 18 Resistor 19 Fuel sender 22 ECU engine control unit 30 Joint connector 42 Joint connector 46 Speed sensor 47 Multi function display 48 Frame ground ...

Page 354: ...D CHARGING THE BATTERY on page 9 69 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main relay Refer to CHECKING THE RE LAYS on page 9 72 NG Replace the main relay OK 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 9 20 NG Properly connect or repair the signaling system s wiring OK This circuit is OK 1 Check the speed sensor Refer to CHEC...

Page 355: ...on page 9 77 NG Replace the fuel sender assembly OK 2 Check the resistor Refer to CHECKING THE RESIST ER on page 9 77 NG Replace the resistor OK 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 9 20 NG Properly connect or repair the signaling system s wiring OK Replace the indicator light assembly ...

Page 356: ...B B B O B B B Sb W B Sb Sb G B L G L W L B Br G B G B B B B B B L B B B B Br Br Br Br Br B B L Y B B B B B G B Ch Dg Y B B R W Br R B W B W R W Ch Dg Y B Br R W B W R O O R L B B B B B B B B R R R R R R L Br Br Br Br Br Br Br Br Br Br Br R L R L R L R L R L B L L L P P L Y Y R R Br R L R L R L P L P L R L R L R L R B R B L R L Y L Y Y R Y R G Y G Y G Y G Y B Y B Y R L B L B L B L B L B L Y G Y G B...

Page 357: ... 3 Joint connector 7 Main relay 9 Battery 10 Frame ground 11 Starter relay 12 Main fuse 22 ECU engine control unit 27 Radiator fan motor relay 28 Radiator fan motor fuse 29 Radiator fan motor 30 Joint connector 32 Coolant temperature sensor 48 Frame ground ...

Page 358: ... main relay Refer to CHECKING THE RE LAYS on page 9 72 NG Replace the main relay OK 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 9 78 NG Replace the radiator fan motor OK 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 9 72 NG Replace the radiator fan motor relay OK 6 Check the coolant temperature sen sor Refer to CHECKING THE COOL ANT...

Page 359: ...COOLING SYSTEM 9 27 ...

Page 360: ... Y G L B B B O B B B Sb W B Sb Sb G B L G L W L B Br G B G B B B B B B L B B B B Br Br Br Br Br B B L Y B B B B B G B Ch Dg Y B B R W Br R B W B W R W Ch Dg Y B Br R W B W R O O R L B B B B B B B B R R R R R R L Br Br Br Br Br Br Br Br Br Br Br R L R L R L R L R L B L L L P P L Y Y R R Br R L R L R L P L P L R L R L R L R B R B L R L Y L Y Y R Y R G Y G Y G Y G Y B Y B Y R L B L B L B L B L B L Y ...

Page 361: ...or light 16 Engine trouble warning light 22 ECU engine control unit 25 Injector 30 Joint connector 31 Intake air temperature sensor 32 Coolant temperature sensor 33 Throttle position sensor 34 Intake air pressure sensor 35 Lean angle sensor 36 Engine stop switch 37 Neutral switch 38 Diode 39 Starting circuit cut off relay 40 Clutch switch 42 Joint connector 48 Frame ground ...

Page 362: ...gine trouble warning light indication and fuel injection system operation The warning light flashes when any one of the following conditions is present and the start switch is pushed 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 meter light and the engine trouble warning light comes on while the...

Page 363: ...njection system Refer to Confirmation of service completion in the appropriate table in TROUBLESHOOTING DETAILS on page 9 35 4 After pushing the engine stop switch push the start switch to check whether the fault code no is displayed TIP If another fault code number is displayed repeat steps 1 to 4 until no fault code number is dis played 5 Erase the malfunction history in the diagnostic mode Refe...

Page 364: ...he diagnostic tool cannot be used to freely change the basic vehicle functions such as adjusting the ignition timing CONNECTING THE YAMAHA DIAGNOSTIC TOOL 1 Remove the coupler for connecting setting tool Yamaha diagnostic tool 90890 03231 Yamaha diagnostic tool US 90890 03234 Fault diagnosis mode Fault codes recorded on the ECU are read and the con tents are displayed Function diagnostic mode Chec...

Page 365: ... to connect and use the Yamaha diagnostic tool refer to YAMAHA DIGNO STIC TOOL OPERATION MANUAL FI diagnostic tool sub lead 90890 03212 FI diagnostic tool sub lead YU 03212 1 Vehicle 2 Coupler for connecting optional part 3 FI diagnostic tool sub lead 4 Sub harness included with the Yamaha di agnostic tool 5 Vehicle communication cable included with the Yamaha diagnostic tool 6 Yamaha diagnostic t...

Page 366: ...n the past already recovered are displayed 2 Detected The item list of the malfunction currently occurred are displayed 3 Code The following icons and the fault code numbers for the detected malfunctions are displayed 4 ECU The types of the control units are displayed 5 Item The item names of the detected malfunction are displayed A Detected malfunction B Recovered malfunction 2 3 1 4 5 6 7 8 9 10...

Page 367: ...nd service the items or components that are the probable cause of the malfunction following the or der given After the check and service of the malfunctioning part have been completed reset the diagnostic tool display according to the reinstatement method Fault code No Fault code number displayed on the diagnostic tool when the engine failed to work normally Diagnostic code No Diagnostic code numb...

Page 368: ... finished Fault code number is dis played Go to item 4 4 Installed condition of crank shaft position sensor Check for looseness or pinching Check the gap between the crankshaft position sensor and the pickup rotor Improperly installed sensor Reinstall or replace the sensor Refer to GENERATOR AND STARTER CLUTCH on page 6 62 Crank the engine Fault code number is not dis played Service is finished Fa...

Page 369: ...r replace the wire har ness Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler securely or repair rep...

Page 370: ...age 9 80 Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 6 6 Malfunction in ECU Replace the ECU Fault code No 14 Item Intake air pressure sensor hose system malfunction clogged or detached hose Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 03 Diagnostic tool display Displays the intake air pre...

Page 371: ...ensor open or short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 01 Diagnostic tool display Throttle position sensor signal 11 14 fully closed position 109 116 fully open position Procedure Check with throttle valve fully closed Check with throttle valve fully open Item Probable cause of malfunc tion and check Maintenance job Confirmation of servi...

Page 372: ...TION SEN SOR on page 8 11 Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 5 5 Applied voltage of throttle po sition sensor lead Check the applied voltage black blue blue Refer to CHECKING THE THROTTLE POSITION SEN SOR on page 9 79 Push the start switch Fault code number is not dis played Service is finished Fault code number ...

Page 373: ...sensor Check for looseness or pinching Improperly installed sensor Reinstall or replace the sensor Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 8 11 Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Defective throttle position sensor Check throttle position sen sor signal Execute the diagnostic mode Code No 01 W...

Page 374: ...re har ness Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler securely or repair replace the wire ha...

Page 375: ...e intake air temperature Procedure Compare the actually measured intake air temperature with the Yamaha diagnostic tool display value Item Probable cause of malfunc tion and check Maintenance job Confirmation of service completion 1 Connection of intake air tem perature sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and...

Page 376: ...e ambient temper ature The displayed temperature is not close to the ambient tem perature Check the intake air temperature sensor Replace if defective Refer to CHECKING THE INTAKE AIR TEMPERA TURE SENSOR on page 9 80 Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 6 6 Malfunction in ECU Replace the ECU Fault code No 30 Item L...

Page 377: ...h time the ignition coil is actuated Procedure Check that a spark is generated five times Connect an ignition checker Item Probable cause of malfunc tion and check Maintenance job Confirmation of service completion 1 Connection of ignition coil coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Im...

Page 378: ...s played Service is finished Fault code number is dis played Go to item 5 5 Installed condition of ignition coil Check for looseness or pinching Improperly installed sensor Reinstall or replace the sensor Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 6 6 Defective ignition coil test th...

Page 379: ...ic mode Code No 36 No operating sound Go to item 2 Operating sound Go to item 6 2 Defective injector Measure the fuel injector re sistance Replace if out of specifica tion Refer to CHECKING THE FUEL INJECTOR on page 9 81 Execute the diagnostic mode Code No 36 No operating sound Go to item 3 Operating sound Go to item 6 3 Connection of wire harness ECU coupler Check the locking condition of the cou...

Page 380: ...rvice is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler securely or repair replace the wire har ness Push the start switch Fault code number is not dis played Service...

Page 381: ...s bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler securely or repair replace the wire har ness Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Wire harness continuity Open or short circuit Re place the wire harness Between battery ...

Page 382: ...d in Diagnostic mode Code No 60 EEP ROM data error for adjust ment of CO concentration Change the CO concentra tion and rewrite in EEPROM After this adjustment push the engine stop switch then push the start switch Memory not recovered Re place the ECU Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Repeat the proce dure in item 1 If th...

Page 383: ...let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Wire harness continuity Open or short circuit Re place the wire harness Between rectifier regulator coupler and ECU coupler red red Between battery terminal and ECU coupler red red Start the engine and let it idle for approximately 5 seconds Fault code numb...

Page 384: ...ctioning Able to drive vehicle Unable when ECU is malfunctioning Diagnostic code No Diagnostic tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service completion 1 Connection of Yamaha diag nostic tool coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of t...

Page 385: ... Yamaha diag nostic tool coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler securely or repair replace the wire har ness Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection ...

Page 386: ...he wire har ness Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler securely or repair replace the wi...

Page 387: ... is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler securely or repair replace the wire har ness Push the start switch Fault code number is n...

Page 388: ...L B B B O B B B Sb W B Sb Sb G B L G L W L B Br G B G B B B B B B L B B B B Br Br Br Br Br B B L Y B B B B B G B Ch Dg Y B B R W Br R B W B W R W Ch Dg Y B Br R W B W R O O R L B B B B B B B B R R R R R R L Br Br Br Br Br Br Br Br Br Br Br R L R L R L R L R L B L L L P P L Y Y R R Br R L R L R L P L P L R L R L R L R B R B L R L Y L Y Y R Y R G Y G Y G Y G Y B Y B Y R L B L B L B L B L B L Y G Y G...

Page 389: ... PUMP SYSTEM 9 57 1 Joint connector 2 Joint connector 9 Battery 10 Frame ground 11 Starter relay 12 Main fuse 22 ECU engine control unit 26 Fuel pump 30 Joint connector 36 Engine stop switch 48 Frame ground ...

Page 390: ...y Refer to CHECKING AND CHARGING THE BATTERY on page 9 69 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 9 64 NG Replace the engine stop switch OK 4 Check fuel pressure Refer to CHECKING THE FUEL PRESSURE on page 8 5 NG Replace the fuel pump OK 5 Check the fuel pump system wire harness connections Refer to CIR...

Page 391: ...FUEL PUMP SYSTEM 9 59 ...

Page 392: ...ELECTRICAL COMPONENTS 9 60 EAS2GB7381 ELECTRICAL COMPONENTS EAS2GB7382 9 10 11 1 3 2 4 5 6 7 8 ...

Page 393: ...LECTRICAL COMPONENTS 9 61 1 Rectifier regulator 2 Clutch switch 3 Ignition coil 4 ECU engine control unit 5 Fuel sender 6 Fuel pump 7 Battery 8 Resistor 9 Neutral switch 10 Radiator fan motor 11 Injector ...

Page 394: ...ELECTRICAL COMPONENTS 9 62 12 11 10 2 3 1 6 7 4 5 8 9 ...

Page 395: ...sor 2 Intake air pressure sensor 3 Throttle position sensor 4 Starter relay 5 Main fuse 6 Headlight relay 7 Starting circuit cut off relay 8 Lean angle sensor 9 Radiator fan motor fuse 10 Radiator fan motor relay 11 Main relay 12 Coolant temperature sensor ...

Page 396: ...ELECTRICAL COMPONENTS 9 64 EAS2GB7383 CHECKING THE SWITCHES 4 1 3 2 E B S E B E B E E B B ...

Page 397: ...ELECTRICAL COMPONENTS 9 65 1 Engine stop switch 2 Neutral switch 3 Clutch switch 4 Start switch ...

Page 398: ...ket tester range to 1 to make a 0 adjustment 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 TIP indicates continuity between switch te...

Page 399: ...bulbs 1 Remove Bulb EWA WARNING Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down ECA NOTICE Be sure to hold the socket firmly when re moving the bulb Never pull the lead oth erwise it may be pulled out of the terminal in the coupler Avoid touching the glass part of the head light bulb to keep it free from oil otherwise t...

Page 400: ... right Seat Refer to GENERAL CHASSIS on page 5 1 2 Check Main fuse 1 Radiator fan motor fuse 2 a Connect the pocket tester to the fuse and check the continuity TIP Set the pocket tester selector to 1 b If the pocket tester indicates replace the fuse 3 Replace Fuse a The meter light goes off b Install a new fuse of the correct amperage rating c Turn on the meter light to verify if the electri cal c...

Page 401: ...ime charging amperage and charging voltage for a VRLA Valve Regu lated Lead Acid battery are different from those of conventional batteries The VRLA Valve Regulated Lead Acid battery should be charged according to the appro priate charging method If the battery is overcharged the electrolyte level will drop considerably Therefore take special care when charging the battery TIP Since VRLA Valve Reg...

Page 402: ...t in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the battery charger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of a VRLA Valve Reg ulated Lead Acid battery stabilizes about 30 minutes after charging ...

Page 403: ...after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery TIP If the current is lower than the standard charg ing current written on the battery this type of battery charger cannot charge the VRLA Valve Regulated Lead Acid battery A variable volt age charger is rec...

Page 404: ...Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 to 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 to 4 2 1 3 4 R W Br W R Y L G 1 2 3 4 L R Br R R R W 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Resu...

Page 405: ...nect the ignition checker 1 as shown c Push the engine stop switch d Measure the ignition spark gap a e Crank the engine by pushing the start switch and gradually increase the spark gap until a misfire occurs EAS2GB7389 CHECKING THE SPARK PLUG CAP 1 Remove Spark plug cap from the spark plug lead 2 Check Spark plug cap resistance Out of specification Replace Result Continuity between 3 to 4 Pocket ...

Page 406: ...the pocket tester 1k to the ig nition coil b Measure the secondary coil resistance EAS2GB7391 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Pocket tester 90890 03112 Analog pocket tester YU 03112 C Primary coil resistance 2 16 2 64 Pocket tester 90890 03112 Analog pocket tester YU 03112 C ...

Page 407: ...ectric starting system troubleshooting starting with step 4 Refer to ELECTRIC STARTING SYSTEM on page 9 6 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 EWA WARNING 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 Crankshaft position ...

Page 408: ... ignition coil b Connect the pocket tester DC 20 V to the rectifier regulator coupler as shown c Start the engine and let it run at approxi mately 5000 r min d Measure the charging voltage Stator coil resistance 0 528 0 792 W W Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe White 1 Negative tester probe White 2 Positive tester probe White 1 Negative tester probe Wh...

Page 409: ...ecification Replace the fuel sender a Connect the pocket tester 1k to the fuel sender as shown b Measure the resistance of the fuel sender EAS2GB7397 CHECKING THE RESISTER 1 Disconnect Resister coupler from the wire harness 2 Check Resister resistance Out of specification Replace the resister a Connect the pocket tester 10 to the re sister as shown Output voltage reading cycle 0 6V to 4 8V to 0 6V...

Page 410: ...place a Connect the pocket tester 1k 100 to the coolant temperature sensor b Immerse the coolant temperature sensor in a container filled with coolant TIP 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 indicated in the table e Check the coolant temperature sensor for...

Page 411: ...ttle position sensor ad just its angle properly Refer to ADJUSTING THE THROTTLE POSITION SENSOR on page 8 11 EAS2GB7401 CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1 Check Throttle position sensor input voltage Out of specification Replace the ECU a Connect the test harness S pressure sensor 3P to the throttle position sensor coupler and the wire harness b Connect the pocket tester 20 VDC ...

Page 412: ...ever subject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification Replace a Connect the pocket tester 1k 100 to the intake air temperature sensor terminal Positive tester probe Blue 1 Negative tester probe Black Blue 2 Intake air pressure sensor output voltage 3 61 3 67 V ...

Page 413: ... specification Replace a Disconnect the fuel injector coupler from the fuel injector b Connect the pocket tester 10 to the fuel injector coupler c Measure the fuel injector resistance Fuel injector resistance 12 0 Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Injector terminal 1 Negative tester probe Injector terminal 2 1 2 1 2 ...

Page 414: ...ELECTRICAL COMPONENTS 9 82 ...

Page 415: ...ULT 10 2 SHIFT PEDAL DOES NOT MOVE 10 2 JUMPS OUT OF GEAR 10 2 CLUTCH SLIPS 10 2 CLUTCH DRAGS 10 2 OVERHEATING 10 2 OVERCOOLING 10 3 POOR BRAKING PERFORMANCE 10 3 FRONT FORK OIL LEAKING 10 3 FAULTY FRONT FORK LEGS 10 3 UNSTABLE HANDLING 10 3 HEADLIGHT DOES NOT COME ON 10 4 HEADLIGHT BULB BURNT OUT 10 4 TAILLIGHT DOES NOT COME ON 10 4 LIST OF SELF DIAGNOSTIC AND FAIL SAFE ACTIONS 10 5 ...

Page 416: ...l pump Faulty fuel pump 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Spark plug Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 2 Ignition coil Cracked or broken ignition coil body Broken or shorted primary or secondary coils 3 Ignition system Faulty ECU Faulty crankshaft position ...

Page 417: ... play Worn shift drum groove 4 Transmission Worn gear dog EAS2GB7413 CLUTCH SLIPS Engine 1 Clutch Improperly assembled clutch Loose or fatigued clutch spring Worn friction plate Worn clutch plate 2 Engine oil Incorrect oil level Incorrect oil viscosity low Deteriorated oil EAS2GB7414 CLUTCH DRAGS Engine 1 Clutch Unevenly tensioned clutch springs Warped pressure plate Bent clutch plate Swollen fric...

Page 418: ...lt Damaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring EAS2GB7419 FAULTY FRONT FORK LEGS Chassis 1 Front fork Bent or damaged inner tube Bent or damaged outer tube Broken fork spring Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS2GB7420 UNSTABLE HANDLING Chassis 1 Handlebar Bent or improperly installed handlebar 2 Steering head components I...

Page 419: ...rcuit Poor contacts start switch Burnt out headlight bulb EAS2GB7422 HEADLIGHT BULB BURNT OUT Electrical system 1 Headlight Wrong headlight bulb Faulty battery Faulty rectifier regulator Improperly grounded circuit Faulty start switch Headlight bulb life expired EAS2GB7423 TAILLIGHT DOES NOT COME ON Electrical system 1 Taillight Wrong taillight LED Too many electrical accessories Incorrect connect...

Page 420: ...rt circuit detected 9 43 30 Latch up detected 9 44 33 Ignition coil open or short circuit detected in the primary lead of the ignition coil 9 45 39 Injector open or short circuit detected 9 47 41 Lean angle sensor open or short circuit detected 9 48 43 Fuel system voltage incorrect voltage supplied to the fuel injector and fuel pump 9 49 44 EEPROM fault code number an error is detected while readi...

Page 421: ...gine is hot Displays current coolant temperature Compare the actually mea sured coolant temperature with the Yamaha diagnostic tool display value 07 Vehicle speed pulses Vehicle speed pulse 0 999 Check that the number in creases when the front wheel is rotated The num ber is cumulative and does not reset each time the wheel is stopped 08 Lean angle sensor Upright Overturned Displays the output vol...

Page 422: ...0 Other Displays the total number of and Replace all with by the operation start pro cessing 64 Setting history display There is no history There is some history History is unknown Histo ry data is damaged Displays the presence or ab sence of the setting history by Power Tuner 00 01 02 65 Setting map erasure There is no setting There is some setting Displays the presence or ab sence of the setting...

Page 423: ...IP Before performing this operation be sure to disconnect the fuel pump coupler Check that injector is actu ated five times by listening for the operating sound 51 Radiator fan motor relay Actuates the radiator fan mo tor relay five times at five sec ond intervals WARNING on the Yamaha diagnostic tool blinks five times when the radiator fan motor relay is actuated Check that the radiator fan motor...

Page 424: ...hrottle position sensor 34 Intake air pressure sensor 35 Lean angle sensor 36 Engine stop switch 37 Neutral switch 38 Diode 39 Starting circuit cut off relay 40 Clutch switch 41 Start switch 42 Joint connector 43 Taillight 44 Headlight 45 Coupler for connecting option al switch 46 Speed sensor 47 Multi function display 48 Frame ground 49 Ignition coil sub lead 50 Negative battery lead EAS2GB7427 C...

Page 425: ......

Page 426: ...PRINTED IN JAPAN E PRINTED ON RECYCLED PAPER ...

Page 427: ...G B L B W B W B B B B B B B R R R R R R L Br Br Br Br Br Gy Gy B L Gy W W W B Gy B R W W W B R R R Y G R Y B R R W Br R L R B R Y R W Br W L G Br W Br L W B B Br Br L Y Y R G Y Br B B Br Br L Y Y W B B B B G G Y R R L R Lg W B B B Gy Br R W B B L L Y P G W B Y R B Lg G Y W Br W O L R Y B B O L B Sb Y R L Y P L Y G Gy R L R B R L B Y R W R L R W Br P L R L R L B B B L L B B R L L B R L R L R L R L ...

Page 428: ...ON OFF ON OFF Gy Gy B B B B B B Gy B B B L L B B B B B B B B B B WR250F WR250FG 2016 WIRING DIAGRAM WR250F WR250FG 2016 SCHÉMA DE CÂBLAGE 2GB 28199 71_W D indd 2 2015 04 23 11 54 37 ...

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