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Yamaha WR250F 2017, Owner'S Service Manual

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Yamaha WR250F 2017 Owner'S Service Manual Download Page 420

TROUBLESHOOTING

10-1

EAS2GBB405

TROUBLESHOOTING

EAS2GBB406

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.

EAS2GBB407

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. Battery

• Discharged battery
• Faulty battery

2. Fuse

• Blown, damaged or incorrect fuse
• Improperly installed fuse

3. Spark plug

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

4. Ignition coil

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

coils

5. Ignition system

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

6. Switches and wiring

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

7. Starting system

• Faulty starter motor
• Faulty starter relay
• Faulty starting circuit cut-off relay
• Faulty starter clutch

EAS2GBB408

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

Summary of Contents for WR250F 2017

Page 1: ...72 PRINTED ON RECYCLED PAPER 2017 WR250F WR250FH 2017 q Read this manual carefully before operating this vehicle q Il convient de lire attentivement ce manuel avant la premi re utilisation du v hicule...

Page 2: ...his manual should stay with this vehicle if it is sold Q Il convient de lire attentivement ce manuel avant la premi re utilisation du v hicule Le manuel doit tre remis avec le v hicule en cas de vente...

Page 3: ...WR250FH 2017 WR250F 2GB 28199 72 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: ...WNER S SERVICE MANUAL 2016 by Yamaha Motor Co Ltd First edition April 2016 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly p...

Page 6: ...mation 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 WA...

Page 7: ...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 GASOLIN...

Page 8: ...he 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 t...

Page 9: ...FINITION 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...

Page 10: ......

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

Page 12: ......

Page 13: ...NFORMATION 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...

Page 14: ...CTION 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 32 BREAK IN PROCEDURES 1 32 MAINTENANCE AFTE...

Page 15: ...LOCATION OF IMPORTANT LABELS 1 1 EAS2GBB008 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: ...e 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...

Page 19: ...B011 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the frame EAS2GBB012 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevat...

Page 20: ...used to pre vent mud dust and other foreign materials from entering the inside when the fuel hose is disconnected EAS2GBB019 COUPLER FOR CONNECTING OPTIONAL PART The coupler 1 is used for connecting t...

Page 21: ...ach 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 li...

Page 22: ...AS2GBB024 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...

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 l...

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...

Page 25: ...e 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 n...

Page 26: ...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 q...

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...

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...

Page 29: ...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 YU 03209 This tool is...

Page 30: ...older YM 91042 This tool is used to hold the clutch when removing or in stalling the clutch boss secur ing nut Valve guide remover 5 90890 04097 Valve guide remover 5 0 mm YM 04097 This tool is used t...

Page 31: ...Valve guide installer 4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 This tool is used to replace the valve guide Valve guide reamer 4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 This tool...

Page 32: ...90 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...

Page 33: ...hould 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 elect...

Page 34: ...ht 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 EAS2GBB037 FRONT BRAKE LEVER The front brake lev...

Page 35: ...ns 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 e...

Page 36: ...1 Select button SLCT 1 2 Select button SLCT 2 3 Reset button RST Screen display 4 Tripmeter indicator 5 Tripmeter indicator 6 Timer indicator 7 Clock Timer 8 Speedometer 9 Odometer Tripmeter TIP The o...

Page 37: ...n the following order Odometer TRIP A TRIP B TRIP A Odometer TIP To reset the digits select the tripmeter involved and push the RST button for 2 seconds or more EAS2GBB045 CHANGEOVER TO BASIC MODE RAC...

Page 38: ...1 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 Changeove...

Page 39: ...g 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 di...

Page 40: ...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 time...

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

Page 42: ...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...

Page 43: ...n 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 BA...

Page 44: ...closed ar ea The exhaust fumes are poisonous they can cause loss of consciousness and death in a very short time Always operate the ma chine in a well ventilated area ECA NOTICE Unlike a two stroke en...

Page 45: ...r two minutes at a steady speed of 3000 to 5000 r min and then return the starter knob idle screw to its original posi tion EWA WARNING Since exhaust gas contains harmful ingre dients do not start or...

Page 46: ...il leaks or other problems 3 Then drive it for about 40 minutes at a throt tle opening of 3 4 or less 4 Make a pit stop again and thoroughly check mounted areas for looseness oil leaks or other proble...

Page 47: ...is 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...

Page 48: ...ink 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 w...

Page 49: ...l 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 Tighten...

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...

Page 51: ...at 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...

Page 52: ...e 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...

Page 53: ...FICATIONS 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...

Page 54: ...AN 2GBD EUR 2GBE AUS NZL ZAF Dimensions Overall length 2165 mm 85 2 in Overall width 825 mm 32 5 in Overall height 1280 mm 50 4 in Seat height 965 mm 38 0 in Wheelbase 1465 mm 57 7 in Ground clearance...

Page 55: ...73 Imp qt With oil filter removal 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 Troch...

Page 56: ...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 widt...

Page 57: ...inder 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 00...

Page 58: ...Transmission 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 Gea...

Page 59: ...e 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 5400 0 6600 0 at 0 C 5400 0 6600 0 at 32 F 289 391 at 80 C 289 391 at 176 F Cool...

Page 60: ...80 100 21 51M USA CAN 90 90 21 M C 54M M S EUR AUS NZL ZAF Manufacturer model DUNLOP 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...

Page 61: ...43 0 Front suspension Type Telescopic fork Spring shock absorber type Coil spring hydraulic damper Front fork travel 310 mm 12 2 in Fork spring free length 470 0 mm 18 50 in Limit 465 0 mm 18 31 in F...

Page 62: ...n 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 Ful...

Page 63: ...up to operating angle 0 4 1 4 V Output voltage over operating angle 3 7 4 4 V AC magneto Standard output 14 0 V 160 W at 5000 r min Stator coil resistance 0 528 0 792 W W Rectifier regulator Regulato...

Page 64: ...gf 14 11 21 17 oz Commutator diameter 17 6 mm 0 69 in Limit 16 6 mm 0 65 in Mica undercut depth 1 50 mm 0 06 in Fuel sender unit Sender unit resistance thermistor 1350 1900 Starter relay Amperage 180...

Page 65: ...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 specif...

Page 66: ...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 f...

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 k...

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...

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 3...

Page 70: ...r 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...

Page 71: ...ver 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...

Page 72: ...sor 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...

Page 73: ...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 c...

Page 74: ...ace Pivot shaft bearing Swingarm pivot portion collar side surface and thrust bearing Swingarm pivot portion collar outer surface Swingarm pivot portion oil seal lip Pivot shaft outer surface Relay ar...

Page 75: ...ace and throttle cable end Front brake caliper piston Front brake caliper piston seal Front brake caliper dust seal Front brake caliper piston outer surface Front brake caliper pin bolt and boot Front...

Page 76: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EAS2GBB071 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS2GBB072 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 EAS2GBB073 CABLE ROUTING DIAGRAM...

Page 85: ...ine 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 o...

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

Page 87: ...et 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 t...

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

Page 89: ...he 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 h...

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

Page 91: ...upler 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 to...

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...

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

Page 95: ...all 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...

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

Page 97: ...s 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 twi...

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

Page 99: ...LEMENT 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 O...

Page 100: ...JUSTING THE STEERING HEAD 3 37 CHECKING AND LUBRICATING THE CABLES 3 38 LUBRICATING THE LEVERS 3 38 LUBRICATING THE PEDAL 3 38 LUBRICATING THE DRIVE CHAIN 3 38 LUBRICATING THE SIDESTAND 3 39 CHECKING...

Page 101: ...risk 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 300...

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 da...

Page 103: ...se 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 se...

Page 104: ...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 Repl...

Page 105: ...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...

Page 106: ...ARTING AND BREAK IN on page 1 30 AIR FILTER Clean and lubri cate Use Yamaha foam air filter oil or other quality foam air filter oil Replace OIL FILTER Replace ENGINE GUARD Replace Breakage FRAME Clea...

Page 107: ...Every one year FRONT FORKS Inspect and adjust Replace oil Yamaha Suspension Oil S1 Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium soap based grease PROTECTOR GUIDE Replace R...

Page 108: ...y 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 b...

Page 109: ...Check the play of front brake and effect of front and rear brake 3 25 31 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 31 5 69 71 Wheels Check...

Page 110: ...minutes until the coolant has settled EAS2GBB083 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...

Page 111: ...el Refer to CHECKING THE COOLANT LEV EL on page 3 10 EAS2GBB085 CHECKING THE RADIATOR CAP 1 Check Seal radiator cap 1 Valve and valve seat 2 Crack damage Replace Exist fur deposits Clean or replace EA...

Page 112: ...ks Correct or replace Radiator hoses Bulges Replace EWA WARNING When the radiator cap tester is removed coolant will spout therefore cover it with a cloth beforehand EAS2GBB088 ADJUSTING THE CLUTCH LE...

Page 113: ...hould be adjusted 1 Check Throttle grip free play a Out of specification Regulate 2 Adjust Throttle grip free play a Loosen the locknut 1 b Turn the adjuster 2 until the specified free play is obtaine...

Page 114: ...k cap cover 1 Refer to FUEL TANK CAP on page 1 21 Air filter case cover 2 TIP Loosen the quick fastener screw 3 and re move the air filter case cover 2 Remove Air filter mounting bolt 1 Air filter ele...

Page 115: ...ING THE THROTTLE BODY JOINT 1 Check Throttle body joint Refer to CHECKING THE THROTTLE BODY JOINT on page 8 10 EAS2GBB093 CHECKING THE BREATHER HOSES 1 Check Breather hose 1 Crack damage Replace Loose...

Page 116: ...GINE OIL LEVEL 1 Stand the vehicle upright on a level surface 2 Start the engine warm this up for 3 minutes and then stop the engine and wait about 5 minute 3 Check Oil level The engine oil level shou...

Page 117: ...h gasket 3 4 If the oil filter element is also to be replaced perform the following procedure a Remove the oil filter element cover 1 and oil filter element 2 b Replace the O ring 3 c Install the new...

Page 118: ...ne oil for leaks and the engine oil passage and the oil pump for damage d Check the oil pressure again e Tighten the oil pressure check bolt EAS2GBB098 ADJUSTING THE ENGINE IDLING SPEED TIP Because th...

Page 119: ...ha dealers service engineers etc Those who have little knowledge and skill concerning ser vicing are requested not to undertake inspec tion adjustment disassembly or reassembly only by reference to th...

Page 120: ...TIP Check that the alignment mark c on the cam shaft sprocket and the alignment mark d on the intake camshaft sprocket are aligned with the edge of the cylinder head c Measure the valve clearance e us...

Page 121: ...ncrements of 0 05 mm 0 0020 in The field where the number on the originally installed adjusting pad and the measured valve clearance intersect shows the adjusting pad number to replace Example Pad num...

Page 122: ...ENGINE 3 22 g Measure the valve clearance again h If the valve clearance is out of specification repeat adjusting the valve clearance until it is within specification...

Page 123: ...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 2...

Page 124: ...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 2...

Page 125: ...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 br...

Page 126: ...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 pre...

Page 127: ...leed the brake system Air in the brake system will cause braking performance to be reduced ECA NOTICE After adjusting the brake pedal position make sure that there is no brake drag EAS2GBB106 CHECKING...

Page 128: ...brake pads with their projections 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 1...

Page 129: ...move the pad pin 6 and the brake 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 pi...

Page 130: ...AR BRAKE PAD INSU LATOR 1 Remove Brake pads Refer to REAR BRAKE on page 5 23 2 Check Rear brake pad insulator 1 Damage Replace EAS2GBB109 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle upright on...

Page 131: ...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...

Page 132: ...ification 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 EAS2GBB113 CLEANING THE FRONT FORK OIL SEAL AND DUST...

Page 133: ...nd 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...

Page 134: ...A 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...

Page 135: ...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 dec...

Page 136: ...the tire is considered to be slipping off its position Cor rect the tire position EAS2GBB120 CHECKING AND TIGHTENING THE SPOKES 1 Check Spokes Bend damage Replace Loose Tighten TIP A tight spoke will...

Page 137: ...d 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 gentl...

Page 138: ...into the cable sheath or use a suitable lubricating device EAS2GBB125 LUBRICATING THE LEVERS 1 Lubricate the pivoting points and metal to metal moving parts of the following parts Brake lever Clutch...

Page 139: ...moving parts of the sidestand EAS2GBB129 CHECKING THE CHASSIS FASTENERS Make sure that all nuts bolts and screws are properly tightened Refer to CHASSIS TIGHTENING TORQUES on page 2 16 Recommended lub...

Page 140: ...lug 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 plu...

Page 141: ...HECKING AND CHARGING THE BATTERY on page 9 69 EAS2GBB134 REPLACING THE HEADLIGHT BULB EWA WARNING Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb...

Page 142: ...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...

Page 143: ...T 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...

Page 144: ...ne 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 Rid...

Page 145: ...o 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 t...

Page 146: ...mping force Change the rebound damping force Change the compression damping force EAS2GBB145 CHOOSING SET LENGTH 1 Place a stand or a block under the engine to put the rear wheel above the floor and m...

Page 147: ...pring load Run with the rebound damping force adjuster 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 c...

Page 148: ...BSORBER ASSEMBLY on page 3 34 Spring preload adjusting positions Minimum Position in which the spring is turned in 1 5 mm 0 06 in from its free length Standard Position in which the spring is turned i...

Page 149: ...iceable 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...

Page 150: ...t 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...

Page 151: ...enger 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...

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

Page 153: ...CKING 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 2...

Page 154: ...MBLY 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 ASSEMB...

Page 155: ...mbly only by reference to this manual It may lead to servicing trouble and mechanical damage EAS2GBB151 GENERAL CHASSIS Removing the seat and side cover Order Part name Q ty Remarks 1 Seat 1 2 Air sco...

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 rever...

Page 157: ...ove it because its projection a is inserted in the rear frame EAS2GBB153 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 s...

Page 158: ...l 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...

Page 159: ...CHECKING THE WHEELS on page 3 37 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 Ti...

Page 160: ...cer 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 wit...

Page 161: ...T 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 Fro...

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

Page 163: ...el 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...

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 EAS2GBB163 DISASSEMBLING THE REAR WHEEL 1 Remove Oil seals Bearing...

Page 165: ...stalled 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 diamete...

Page 166: ...rom 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...

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 1 8 Front brake caliper assembly 1 9 Front brake caliper bracket 1 For installation reverse th...

Page 168: ...ke 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...

Page 169: ...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 mas...

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

Page 171: ...ion EAS2GBB169 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...

Page 172: ...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...

Page 173: ...hat 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 WARNIN...

Page 174: ...er cylinder and the end of the brake hose EAS2GBB177 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder 1 Damage scratches wear Replace Brake fluid delivery passages 2 brake master...

Page 175: ...GBB179 INSTALLING THE FRONT BRAKE MASTER 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...

Page 176: ...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 va...

Page 177: ...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...

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...

Page 179: ...age 3 25 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 cy...

Page 180: ...6 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...

Page 181: ...BB182 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 fe...

Page 182: ...185 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 Brak...

Page 183: ...with its side a facing the brake caliper Never force to insert EAS2GBB188 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake caliper Rear brake caliper bracket 2 Install Rear wheel Refer to REAR...

Page 184: ...to CHECKING THE BRAKE FLUID LEVEL on page 3 30 7 Check Brake pedal operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE BRAKE SYS TEM on page 3 25 EAS2GBB189 REMOVING THE R...

Page 185: ...Install to the brake master cylinder piston 2 TIP Install the spring with a smaller inside diameter to the brake master cylinder piston 4 Install Master cylinder kit 1 Push rod 2 Circlip 3 Dust boot 4...

Page 186: ...areful 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 surf...

Page 187: ...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...

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

Page 189: ...GBB196 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...

Page 190: ...ll 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 w...

Page 191: ...f grease or oil on the tube guide surface a with a lac quer thinner 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 cove...

Page 192: ...2 11 Install Start switch 1 Front brake master cylinder assembly 2 Front brake master cylinder holder 3 Bolt brake master cylinder holder 4 Clamp 5 TIP Install the brake master cylinder holder with th...

Page 193: ...e clutch cable end 13 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LE VER FREE PLAY on page 3 12 14 Adjust Throttle grip free play Refer to ADJUSTING THE THROTTLE GRIP FREE PLAY on page...

Page 194: ...he 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...

Page 195: ...n 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 N...

Page 196: ...cap bolt ring wrench 2 3 Remove Front fork leg s EAS2GBB199 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 c...

Page 197: ...ttempt to straighten a bent inner tube as this may dangerously weaken it 2 Check Outer tube Scratches wear damage Replace 3 Measure Fork spring free length a Out of specification Replace 4 Check Dampe...

Page 198: ...er 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 su...

Page 199: ...tting 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...

Page 200: ...o 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 10 cm3 0 34 US oz 0 35 lmp oz 13 Check Damper assembly smooth...

Page 201: ...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 t...

Page 202: ...ement 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 th...

Page 203: ...r 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 Me...

Page 204: ...er tube TIP Temporarily tighten the damper assembly 32 Install Protector guide 1 EAS2GBB202 INSTALLING THE FRONT FORK LEGS 1 Install Front fork 1 TIP Temporarily tighten the pinch bolts lower bracket...

Page 205: ...l 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 6 Install Speed sensor lead 1 Plate 2 2 to the right front fork protector TIP Ins...

Page 206: ...e 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...

Page 207: ...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...

Page 208: ...f 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...

Page 209: ...es 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 N...

Page 210: ...side a facing downward Tighten the steering ring nut with a steering nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 37 5 Check the steering stem by turning this lock to lock...

Page 211: ...k 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...

Page 212: ...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 1 Rear shock absorber assembly lower bolt 1 2 Rear shock absorber assembly upper bolt 1 3 Re...

Page 213: ...ring 2 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...

Page 214: ...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...

Page 215: ...km of run ning EAS2GBB209 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...

Page 216: ...wear Replace Bearing Damage wear Replace Bolts Bends damage wear Replace EAS2GBB213 CHECKING THE CONNECTING ARM AND RELAY ARM 1 Check Connecting arm Relay arm Damage wear Replace 2 Check Bearing Spac...

Page 217: ...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 Insta...

Page 218: ...de Relay arm bolt swingarm side Rear shock absorber assembly lower bolt 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 a...

Page 219: ...ake 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...

Page 220: ...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 EAS2GBB218 REMOVING THE BEARING 1 Remove Bearing 1 TIP Remov...

Page 221: ...ingarm 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 31 Recommended lubr...

Page 222: ...ving 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...

Page 223: ...between the outer sides of the pins on a 15 link sec tion of the drive chain as shown in the illus tration b Calculate the length c of the 15 link section of the drive chain using the following formu...

Page 224: ...chain Drive chain rollers 2 Damage wear Replace the drive chain Drive chain side plates 3 Damage wear Replace the drive chain 5 Lubricate Drive chain EAS2GBB222 CHECKING THE DRIVE SPROCKET 1 Check Dri...

Page 225: ...asher Drive sprocket nut Refer to ENGINE REMOVAL on page 6 1 ECA NOTICE Never install a new drive chain onto worn drive chain sprockets this will dramatically shorten the drive chain s life 4 Adjust D...

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

Page 227: ...NG THE DECOMPRESSION SYSTEM 6 17 INSTALLING THE CAMSHAFTS 6 17 CYLINDER HEAD 6 20 REMOVING THE CYLINDER HEAD 6 22 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 6 22 CHECKING THE CYLINDER HEAD 6 22 INSTA...

Page 228: ...6 52 CHECKING THE KICK GEAR KICK IDLE GEAR AND RATCHET WHEEL 6 52 INSTALLING THE KICK SHAFT ASSEMBLY 6 52 INSTALLING THE KICK IDLE GEAR 6 53 SHIFT SHAFT 6 54 REMOVING THE SHIFT GUIDE AND SHIFT LEVER A...

Page 229: ...IDE OIL STRAINER 6 75 CHECKING THE CRANKCASE 6 75 INSTALLING THE OIL SEAL 6 76 ASSEMBLING THE CRANKCASE 6 76 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 6 78 REMOVING THE CRANKSHAFT ASSEMBLY 6 79 CHECKING...

Page 230: ...AUST PIPE AND MUFFLER on page 6 10 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...

Page 231: ...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...

Page 232: ...S 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 switc...

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 Cl...

Page 234: ...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 O...

Page 235: ...silencer EAS2GBB228 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 EAS2GBB229 REMOVING THE DRIVE SPROCKET 1 St...

Page 236: ...up the engine and remove this from its lower part toward the right of the chassis EAS2GBB231 CLEANING THE SPARK ARRESTER EWA WARNING Be sure the exhaust pipe and muffler are cool before cleaning the s...

Page 237: ...de 3 Front engine 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 molyb...

Page 238: ...e chain 2 Install Lock washer 1 Nut drive sprocket 2 TIP Tighten the nut while applying the rear brake ECA NOTICE Make sure to tighten to specification other wise it may damage the other part that is...

Page 239: ...aust pipe 2 1 Bolt exhaust pipe 2 2 TIP Install and temporarily tighten the exhaust pipe 2 with its end positioned as shown with respect to the exhaust pipe 1 3 Install Clamp Silencer 1 Bolt silencer...

Page 240: ...6 11 4 Tighten Bolt exhaust pipe 2 Clamp TIP Tighten while checking that their front and rear joints are inserted in position Bolt exhaust pipe 2 20 Nm 2 0 m kgf 14 ft lbf Clamp 12 Nm 1 2 m kgf 8 7 f...

Page 241: ...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...

Page 242: ...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...

Page 243: ...et 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 i...

Page 244: ...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 m...

Page 245: ...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 EAS2GBB241 CHECKING THE TIMING...

Page 246: ...sprockets and install the camshafts on the cylinder head TIP Make sure that the alignment mark c on the exhaust camshaft sprocket and the alignment mark d on the intake camshaft sprocket are aligned w...

Page 247: ...rod comes out smoothly and tighten the gasket 4 and the cap bolt 5 3 Turn Crankshaft Counterclockwise several turns 4 Check Top dead center TDC mark on the rotor Align with the crankcase alignment mar...

Page 248: ...CAMSHAFT 6 19 6 Install Cylinder head breather hose Spark plug Spark plug 13 Nm 1 3m kgf 9 4 ft lbf T R...

Page 249: ...EL TANK on page 8 1 Exhaust 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...

Page 250: ...uide intake side 1 6 Oil check bolt 1 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...

Page 251: ...trument 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 V...

Page 252: ...he 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...

Page 253: ...gs Order Part name Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 6 20 1 Valve lifter 4 2 Adjusting pad 4 3 Valve cotter 8 4 Valve spring retainer 4 5 Valve spring 4 6 Valve stem seal 4 7 V...

Page 254: ...e valve seat and the valve seat contact width Refer to CHECKING THE VALVE SEATS on page 6 27 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves are properly sealed TIP...

Page 255: ...ide remover 1 b Install the new valve guide with the valve guide installer 2 and the valve guide re mover 1 c After installing the valve guide expand the hole in the valve guide with the valve guide r...

Page 256: ...THE VALVE SEATS 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat contact width a Out of specification Repla...

Page 257: ...valve guides use new valves to lap the valve seats and then replace them with new valves a Apply a coarse lapping compound a to the valve face ECA NOTICE Do not let the lapping compound enter the gap...

Page 258: ...valve spring 3 Measure Valve spring tilt a Out of specification Replace the valve spring EAS2GBB254 CHECKING THE VALVE LIFTERS 1 Check Valve lifter Damage scratches Replace the valve lift ers and cyli...

Page 259: ...all 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 5 To fasten the valve cotters onto the val...

Page 260: ...sting 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...

Page 261: ...marks Cylinder head Refer to CYLINDER HEAD on page 6 20 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 remov...

Page 262: ...piston crown EAS2GBB258 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...

Page 263: ...place 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 L...

Page 264: ...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 Pisto...

Page 265: ...lip 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 compressi...

Page 266: ...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...

Page 267: ...mbling 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 rever...

Page 268: ...uta 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 start...

Page 269: ...differ ence a with the magnet of the starter mo tor yoke facing the starter motor front cover TIP Align the match mark b on the starter motor yoke with the match mark c on the starter mo tor rear cove...

Page 270: ...ELECTRIC STARTER 6 41...

Page 271: ...al 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...

Page 272: ...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 Ne...

Page 273: ...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 42 1 Oil filter element cover 1 2 Oil filter element 1 3 Radiator pipe...

Page 274: ...BB268 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 t...

Page 275: ...place EAS2GBB273 CHECKING THE PUSH LEVER SHAFT 1 Check Push lever shaft Wear damage Replace EAS2GBB274 CHECKING THE CLUTCH PUSH RODS 1 Check Push rod 1 1 Bearing 2 Washer 3 Push rod 2 4 Ball 5 Cracks...

Page 276: ...NG 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 A...

Page 277: ...lock washer 1 tab 5 Install Friction plate 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 fric...

Page 278: ...ush 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 Clu...

Page 279: ...r 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 crankca...

Page 280: ...haft Order Part name Q ty Remarks Primary driven gear Refer to CLUTCH on page 6 42 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...

Page 281: ...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 EAS2GBB285 INSTALLING THE KICK SHAFT ASSEMBLY 1 Install Kick...

Page 282: ...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 Ins...

Page 283: ...1 3 Oil seal 1 4 Collar 1 5 Shift shaft spring 1 6 Roller 1 7 Shift guide 1 8 Shift lever assembly 1 9 Shift lever 1 10 Pawl 2 11 Pawl pin 2 12 Spring 2 13 Stopper lever 1 14 Stopper lever spring 1 15...

Page 284: ...e dure Removing the shift shaft and stopper lever Order Part name Q ty Remarks 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...

Page 285: ...the stopper lever may be damaged Take care not to give an impact to it when removing the bolt EAS2GBB290 CHECKING THE SHIFT SHAFT 1 Check Shift shaft 1 Bends damage wear Replace Shift shaft spring 2 D...

Page 286: ...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...

Page 287: ...t shaft 4 TIP Apply the engine oil on the roller collar and shift shaft 2 Install Oil seal EAS2GBB297 INSTALLING THE SHIFT PEDAL 1 Install Shift pedal 1 Shift pedal bolt 2 TIP Align the punch mark a o...

Page 288: ...efer to CLUTCH on page 6 42 Right crankcase cover Refer to CLUTCH on page 6 42 1 Oil pump assembly 1 2 Oil pump cover 1 3 Outer rotor 1 4 Dowel pin 1 5 Inner rotor 1 6 Oil pump drive shaft 1 7 Oil pum...

Page 289: ...efer to GENERATOR AND STARTER CLUTCH on page 6 66 1 Nut balancer 1 2 Nut primary drive gear 1 3 Nut balancer weight gear 1 4 Conical washer 1 5 Balancer 1 6 Conical washer 1 7 Primary drive gear 1 8 C...

Page 290: ...ND BALANCER GEAR 6 61 For installation reverse the removal proce dure Removing the balancer Order Part name Q ty Remarks T R 75 Nm 7 5 m kgf 54 ft lbf T R 50 Nm 5 0 m kgf 36 ft Ibf T R New 6 12 7 8 11...

Page 291: ...EAR 1 Check Primary drive gear 1 Balancer drive gear 2 Balancer weight gear 3 Wear damage Replace EAS2GBB301 CHECKING THE BALANCER 1 Check Balancer Crack damage Replace EAS2GBB302 CHECKING THE OIL PUM...

Page 292: ...e outer rotor 3 Install Oil pump cover 1 Oil pump cover screw 2 EAS2GBB304 INSTALLING THE OIL PUMP AND BALANC ER GEAR 1 Install Oil pump assembly 1 Oil pump assembly bolt 2 Inner rotor to outer rotor...

Page 293: ...r 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...

Page 294: ...OIL PUMP AND BALANCER GEAR 6 65 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 295: ...k 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 54 1 Cover Damper assembly 1 2 Damper assembly 1...

Page 296: ...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...

Page 297: ...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...

Page 298: ...or 2 EAS2GBB309 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 wo...

Page 299: ...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 th...

Page 300: ...GENERATOR AND STARTER CLUTCH 6 71 1 a 3 3 2 4...

Page 301: ...HIFT SHAFT on page 6 54 Generator rotor Refer to GENERATOR AND STARTER CLUTCH on page 6 66 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...

Page 302: ...reverse the disassemble pro cedure Separating the crankcase Order Part name Q ty Remarks 3 1 5 2 6 4 10 5 6 4 4 4 4 6 9 11 7 8 9 LT 12 LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R...

Page 303: ...SION on page 6 81 Shift cam and shift fork Refer to TRANSMISSION on page 6 81 1 Circlip 2 2 Oil seals 3 3 Bearing 11 For installation reverse the removal proce dure LT LT 2 3 3 3 3 3 3 3 3 3 New 1 1 2...

Page 304: ...o tap on the case half 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 chec...

Page 305: ...pply the lithium soap based grease on the O ring Fit the right crankcase onto the left crankcase Tap lightly on the case with soft hammer When installing the crankcase the connecting rod should be pos...

Page 306: ...CRANKCASE 6 77 4 45 mm 1 77 in 5 60 mm 2 36 in 6 75 mm 2 95 in a Hexagon socket head bolt without flange b Hexagon socket head bolt with flange 5 4 5 4 4 4 6 6 6 4 a b 2 1 LT 2 3 6...

Page 307: ...R SHAFT Removing the crankshaft assembly and balancer shaft Order Part name Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 6 72 Transmission Refer to TRANSMISSION on page 6 81 1 Balancer s...

Page 308: ...ion Replace the crank shaft bearing or both TIP Turn the crankshaft slowly 2 Measure Big end side clearance a Out of specification Replace the big end bearing crankshaft pin or connecting rod 3 Measur...

Page 309: ...ent the crankshaft seizure apply molybdenum disulfide grease TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn...

Page 310: ...NE REMOVAL on page 6 1 Crankcase Separate Refer to CRANKCASE on page 6 72 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 for...

Page 311: ...e lightly with a soft hammer EAS2GBB324 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...

Page 312: ...pinion gear 27T 1 3rd 4th pinion gear 18T 21T 2 Collar 3 5th pinion gear 23T 4 2nd pinion gear 16T 5 to the main axle 6 TIP Before installation apply molybdenum disulfide oil to the inner and end surf...

Page 313: ...Main axle 1 Drive axle 2 TIP Install to the left crankcase simultaneously Apply engine oil to the main axle and the drive axle bearing 6 Install Shift fork 1 L 1 Shift fork 2 C 2 Shift fork 3 R 3 Shif...

Page 314: ...k 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 Transmissio...

Page 315: ...TEM 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 WA...

Page 316: ...servicing trouble and mechanical damage EAS2GBB329 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 317: ...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 Par...

Page 318: ...ra diator cap EAS2GBB331 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...

Page 319: ...oil Drain Refer to CHANGING THE ENGINE OIL on page 3 17 Right crankcase cover Refer to CLUTCH on page 6 42 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 Imp...

Page 320: ...Oil seal 1 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...

Page 321: ...spot seizure Replace EAS2GBB336 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 f...

Page 322: ...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...

Page 323: ...EL 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 6 CHECKING AND REPLACING THE PROTECTOR 8 6 T...

Page 324: ...cing trouble and mechanical damage EAS2GBB339 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...

Page 325: ...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...

Page 326: ...n the sides of the connector and then remove the hose Before removing the hose place a few cloths in the area under where it will be removed To prevent sand dust and other foreign ma terials from ente...

Page 327: ...ead from starter relay 3 Remove Fuel tank 4 Remove Fuel sender from the fuel tank 5 Connect Fuel sender coupler 6 Push the start switch 7 Check Fuel level warning light Out of specification Replace th...

Page 328: ...r left right the seat and the air scoop left right Refer to GENERAL CHASSIS on page 5 1 b Remove the fuel tank bolt and lift the fuel tank c Disconnect the fuel hose from the fuel pump Refer to REMOVI...

Page 329: ...on each damper pointing outward Affix the damper 2 with its projection a facing the rear of the vehicle EAS2GBB350 CHECKING AND REPLACING THE PRO TECTOR 1 Check Protector 1 Wear damage Replace TIP Aff...

Page 330: ...AL 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 Int...

Page 331: ...int 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...

Page 332: ...ks 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...

Page 333: ...reign 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...

Page 334: ...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 th...

Page 335: ...ROUBLESHOOTING 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 TROUBLESHOOT...

Page 336: ...R 9 75 CHECKING THE LEAN ANGLE SENSOR 9 75 CHECKING THE STARTER MOTOR OPERATION 9 76 CHECKING THE STATOR COIL 9 76 CHECKING THE RECTIFIER REGULATOR 9 76 CHECKING THE SPEED SENSOR 9 77 CHECKING THE FUE...

Page 337: ...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 semb...

Page 338: ...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...

Page 339: ...nt 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 switc...

Page 340: ...ery terminals Recharge or replace the battery OK 3 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 40 NG Re gap or replace the spark plug OK 4 Check the ignition spark gap Refer to CHE...

Page 341: ...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...

Page 342: ...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...

Page 343: ...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 Diod...

Page 344: ...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 t...

Page 345: ...E 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 sw...

Page 346: ...ce the battery OK 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 9 76 OK Starter motor is OK Perform the electric starting system troubleshooting starting w...

Page 347: ...ch 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 engine stop switch OK 12 Check...

Page 348: ...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...

Page 349: ...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 350: ...HARGING 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 assembl...

Page 351: ...CHARGING SYSTEM 9 15...

Page 352: ...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...

Page 353: ...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...

Page 354: ...E 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...

Page 355: ...LIGHTING SYSTEM 9 19...

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...

Page 357: ...ctor 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 Joi...

Page 358: ...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 Ch...

Page 359: ...n page 9 77 NG Replace the fuel sender assembly OK 2 Check the resistor Refer to CHECKING THE RESIST ER on page 9 78 NG Replace the resistor OK 3 Check the entire signaling system s wiring Refer to CI...

Page 360: ...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...

Page 361: ...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...

Page 362: ...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 mot...

Page 363: ...COOLING SYSTEM 9 27...

Page 364: ...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...

Page 365: ...r 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 a...

Page 366: ...ine 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 engin...

Page 367: ...ction 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...

Page 368: ...e 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 to...

Page 369: ...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 conn...

Page 370: ...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 malfunctio...

Page 371: ...d 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 diagnos...

Page 372: ...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...

Page 373: ...pair 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...

Page 374: ...n 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 14 Item Intake...

Page 375: ...nsor 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 positio...

Page 376: ...N 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 Ch...

Page 377: ...ensor 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...

Page 378: ...e 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 conditi...

Page 379: ...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 Confi...

Page 380: ...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 SENS...

Page 381: ...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 servi...

Page 382: ...t dis 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 th...

Page 383: ...c 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 IN...

Page 384: ...vice 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...

Page 385: ...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...

Page 386: ...7 Go to item 3 2 01 is indicated 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...

Page 387: ...et 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...

Page 388: ...tioning 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 servi...

Page 389: ...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 Co...

Page 390: ...e 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 co...

Page 391: ...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...

Page 392: ...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...

Page 393: ...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 g...

Page 394: ...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...

Page 395: ...FUEL PUMP SYSTEM 9 59...

Page 396: ...ELECTRICAL COMPONENTS 9 60 EAS2GBB381 ELECTRICAL COMPONENTS EAS2GBB382 9 10 11 1 3 2 4 5 6 7 8...

Page 397: ...ECTRICAL 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 Inject...

Page 398: ...ELECTRICAL COMPONENTS 9 62 12 11 10 2 3 1 6 7 4 5 8 9...

Page 399: ...or 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...

Page 400: ...ELECTRICAL COMPONENTS 9 64 EAS2GBB383 CHECKING THE SWITCHES 4 1 3 2 B B Sb B B B B B B B B...

Page 401: ...ELECTRICAL COMPONENTS 9 65 1 Engine stop switch 2 Neutral switch 3 Clutch switch 4 Start switch...

Page 402: ...et 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 con...

Page 403: ...ulbs 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 firm...

Page 404: ...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...

Page 405: ...me 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...

Page 406: ...charger lead clip may generate heat 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...

Page 407: ...rcuit voltage prior to charging TIP Voltage should be measured 30 minutes 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...

Page 408: ...Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 to 4 2 1...

Page 409: ...m circuit is operating normally a Remove the spark plug cap from the spark plug b Connect the ignition checker 1 as shown c Push the engine stop switch d Measure the ignition spark gap a 1 Positive ba...

Page 410: ...istance Out of specification Replace a Connect the pocket tester 1 to the igni tion coil b Measure the primary coil resistance 3 Check Secondary coil resistance Out of specification Replace a Connect...

Page 411: ...pler to the wire harness b Connect the pocket tester DC 20 V to the lean angle sensor coupler as shown c Incline the lean angle sensor d Measure the lean angle sensor output volt age EAS2GBB393 Cranks...

Page 412: ...oil resistance Out of specification Replace the stator coil a Connect the pocket tester 1 to the sta tor coil coupler as shown b Measure the stator coil resistance EAS2GBB394 CHECKING THE RECTIFIER RE...

Page 413: ...V EAS2GBB396 CHECKING THE FUEL SENDER 1 Drain the gasoline 2 Disconnect Fuel sender coupler from the fuel sender 3 Remove Fuel sender from the fuel tank 4 Check Fuel sender resistance Out of specifica...

Page 414: ...sensor 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 2 Chec...

Page 415: ...WA WARNING Handle the throttle position sensor with special care Never subject the throttle position sensor to strong shocks If the throttle position sensor is dropped replace it 2 Check Throttle posi...

Page 416: ...or out put voltage EAS2GBB403 CHECKING THE INTAKE AIR TEMPERA TURE SENSOR 1 Remove Intake air temperature sensor from the air filter case EWA WARNING Handle the intake air temperature sensor with spec...

Page 417: ...njector b Connect the pocket tester 10 to the fuel injector coupler c Measure the fuel injector resistance Intake air temperature sensor re sistance 5400 0 6600 0 at 0 C 5400 0 6600 0 at 32 F 289 391...

Page 418: ...ELECTRICAL COMPONENTS 9 82...

Page 419: ...LT 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 FRO...

Page 420: ...e 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 Battery Discharged bat...

Page 421: ...eized shift fork Bent shift fork guide bar 3 Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS2GBB412 JUMPS OUT OF GEAR Engine 1 Shi...

Page 422: ...evel EAS2GBB418 FRONT FORK OIL LEAKING Chassis 1 Front fork Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high L...

Page 423: ...adlight bulb Too many electrical accessories Hard charging Incorrect connection Improperly grounded circuit Poor contacts start switch Burnt out headlight bulb EAS2GBB422 HEADLIGHT BULB BURNT OUT Elec...

Page 424: ...t 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...

Page 425: ...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 Chec...

Page 426: ...erasure There is no setting There is some setting Displays the presence or ab sence of the setting history by Power Tuner 00 01 Erase all setting maps by the operation start process ing 70 Program ve...

Page 427: ...r relay is actuated Check that the radiator fan motor relay is actuated five times by listening for the op erating sound 52 Headlight relay Actuates the headlight relay five times at five second in te...

Page 428: ...rottle 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 c...

Page 429: ......

Page 430: ...PRINTED IN JAPAN E PRINTED ON RECYCLED PAPER...

Page 431: ...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...

Page 432: ...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 WR250FH 2017 WIRING DIAGRAM WR250F WR250FH 2017 SCH MA DE C BLAGE 2GB 28199 72_W D indd 2 2016 03 24 9 14 24...

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