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Yamaha YZ250F 2016, Owner'S Service Manual

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Yamaha YZ250F 2016 Owner'S Service Manual Download Page 320

FUEL PUMP SYSTEM

8-34

EAS1SM9330

TROUBLESHOOTING

The fuel pump fails to operate.

TIP

Before troubleshooting, remove the following part(s):
1. Seat
2. Side cover (left/right)
3. Air scoop (left/right)
4. Fuel tank
5. Air filter case cover

1. Check the fuel pump system wire 

harness connections.

NG 

Reconnect.

OK 

2. Check the engine stop switch.

Refer to “CHECKING THE 

SWITCHES” on page 8-38.

NG 

Replace the engine stop switch.

OK 

3. Check fuel pressure.

Refer to “CHECKING THE FUEL 

PRESSURE” on page 7-3.

NG 

Replace the fuel pump.

OK 

4. Check the fuel pump system wire 

harness.

Refer to “CIRCUIT DIAGRAM” on 

page 8-32.

NG 

Repair or replace the wire harness.

OK 

Replace the ECU.

Summary of Contents for YZ250F 2016

Page 1: ... G PRINTED ON RECYCLED PAPER 2016 YZ250F YZ250FG 2016 q Read this manual carefully before operating this vehicle q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule q Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch bevor Sie das Fahrzeug in Betrieb nehmen 1SM 28199 80_cover indd 1 2015 04 22 10 01 06 ...

Page 2: ...anuel avant la première utilisation du véhicule Le manuel doit être remis avec le véhicule en cas de vente de ce dernier Q Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch bevor Sie das Fahrzeug in Betrieb nehmen Diese Bedienungsanleitung muss wenn das Fahrzeug verkauft wird beim Fahrzeug verbleiben 1SM 28199 80_cover indd 2 2015 04 22 10 01 06 ...

Page 3: ... 2016 2016 YZ250F YZ250F 1SM 28199 80 E0 1SM 28199 80 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: ...MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPEC TIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELIABIL...

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 CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING TUNING ...

Page 12: ......

Page 13: ... 1 6 IMPORTANT INFORMATION 1 8 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 8 REPLACEMENT PARTS 1 8 GASKETS OIL SEALS AND O RINGS 1 9 LOCK WASHERS PLATES AND COTTER PINS 1 9 BEARINGS AND OIL SEALS 1 9 CIRCLIPS 1 9 BASIC SERVICE INFORMATION 1 10 ELECTRICAL SYSTEM 1 10 SPECIAL TOOLS 1 13 CONTROL FUNCTIONS 1 18 ENGINE STOP SWITCH 1 18 CLUTCH LEVER 1 18 SHIFT PEDAL 1 18 KICKSTARTER LEVER 1 18 THROTTLE GR...

Page 14: ...20 FUEL 1 20 STARTING A COLD ENGINE 1 20 STARTING A WARM ENGINE 1 21 BREAK IN PROCEDURES 1 21 MAINTENANCE AFTER BREAK IN 1 22 MAJOR MAINTENANCE 1 22 TORQUE CHECK POINTS 1 23 CLEANING AND STORAGE 1 25 CLEANING 1 25 STORAGE 1 25 ...

Page 15: ...LOCATION OF IMPORTANT LABELS 1 1 EAS1SM9008 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: ...ferent from those for the vehicle you have pur chased 1 Clutch lever 10 Coolant drain bolt 2 Front brake lever 11 Rear brake pedal 3 Throttle grip 12 Air filter 4 Radiator cap 13 Drive chain 5 Fuel tank cap 14 Shift pedal 6 Engine stop switch 15 Oil level check window 7 Fuel tank 16 Starter knob idle screw 8 Kickstarter lever 17 Front fork 9 Radiator 2 1 6 7 8 9 5 4 3 11 10 17 1615 14 13 12 ...

Page 19: ...positive iden tification of the model you own 2 If your vehicle is stolen the authorities will need the number to search for and identify your vehicle EAS1SM9011 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the frame EAS1SM9012 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the right side of the engine 1 1...

Page 20: ...the spoke EAS1SM9017 HANDLEBAR PROTECTOR Install the handlebar protector 1 with the mark a facing forward EAS1SM9018 FUEL HOSE JOINT COVER The fuel hose joint covers 1 are used to pre vent mud dust and other foreign materials from entering the inside when the fuel hose is disconnected EAS1SM9019 COUPLER FOR CONNECTING OPTIONAL PART The coupler 1 is used for connecting the op tional Power Tuner and...

Page 21: ...INCLUDED PARTS 1 7 The Power Tuner is an optional part Part name Part number GYTR Power Tuner For USA 33D H59C0 V0 00 YZ Power Tuner Except for USA 33D 859C0 10 ...

Page 22: ...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 23: ...EAS1SM9024 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 24: ...nsert the probes from the opposite end a of the coupler taking care not to loosen or damage the leads ECA16640 NOTICE For waterproof couplers never insert the tester probes directly into the coupler When performing any checks using a water proof coupler use the specified test har ness or a suitable commercially available test harness Checking the connections Check leads couplers and connectors for...

Page 25: ...t stains Connect and disconnect sev eral times 3 Check All connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up After disassembling or assembling a coupler pull on the leads to make sure that they are in stalled securely 4 Connect Lead Coupler Connector TIP When connecting a coupler or a connector make sure that both terminals are connected securel...

Page 26: ...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 Bolts YU 9...

Page 28: ... 01403 Exhaust flange nut wrench YU A9472 This tool is used to remove or tighten the steering nut Cap bolt wrench 90890 01500 YM 01500 This tool is used to remove or tighten the base valve Cap bolt ring wrench 90890 01501 YM 01501 This tool is used to loosen or tighten the damper assem bly Fork seal driver 90890 01502 YM A0948 This tool is used to install the oil seal of the front fork Spoke nippl...

Page 29: ...used to mount the pressure gauge Test harness S pressure sensor 3P 90890 03207 YU 03207 This tool is used to check the throttle position sensor input voltage FI diagnostic tool sub lead 90890 03212 YU 03212 This tool is used to connect the Yamaha diagnostic tool to a battery Yamaha diagnostic tool 90890 03231 Yamaha diagnostic tool US 90890 03234 This tool is used to check er ror codes or carry ou...

Page 30: ... 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 0 mm YM 04099 This tool is used to replace the valve guide Valve lapper 90890 04101 Valve lapping tool YM A8998 This tool is used to remove the valve lifter or lap the valve Valve spring compressor adapter 22...

Page 31: ...o replace the valve guide Rotor puller 90890 04151 YM 04151 This tool is used to remove the rotor Crankcase separating tool 90890 04152 YU A9642 This tool is used to remove the crankshaft Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 This tool is used to check the spark performance of the ig nition coil Digital tachometer 90890 06760 YU 39951 B This tool is used to measure th...

Page 32: ...L The shift pedal 1 has adopted a method of 1 down 4 ups press down kick ups Press it down for N neutral to 1st and kick it up for 2nd to 5th EAS1SM9033 KICKSTARTER LEVER The kickstarter lever 1 is in the right of the chassis To start the engine pull out and push down the kickstarter lever with your foot EAS1SM9034 THROTTLE GRIP The throttle grip 1 is located on the right han dlebar The throttle g...

Page 33: ...ulting 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 EAS1SM9038 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 cover insert fin gers under part a a...

Page 34: ...ning methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems EAS1SM9041 STARTING A COLD ENGINE 1 Press the shift pedal to neutral 2 Pull the starter knob idle screw 1 to its full length TIP When the ambient temperature is 15 C 59 F or below use the starter knob idle screw 3 Push down the kickstarter lever lightly until resistance is felt...

Page 35: ...ke a pit stop and check mounted areas for looseness oil leaks or other problems 3 Then drive it for about 40 minutes at a throt tle opening of 3 4 or less 4 Make a pit stop again and thoroughly check mounted areas for looseness oil leaks or other problems Thorough checks and ad justments are required in particular for stretch of cables free play of the brake stretch of the drive chain looseness of...

Page 36: ...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 37: ...k absorber Link to swingarm Mounting of rear shock absorber Rear shock absorber and frame Mounting of swingarm Tightening of pivot shaft Wheel s Mounting of wheel Front Tightening of wheel axle Tightening of axle holder Tightening of spoke nipple Rear Tightening of wheel axle Wheel to rear wheel sprocket Tightening of spoke nipple Brake s Front Brake caliper to front fork Brake disc to wheel Tight...

Page 38: ...11 Plastic cover Tightening of number plate Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake disc cov er Tightening of rear brake caliper cover ...

Page 39: ... pliable and glossy 8 Automotive wax may be applied to all paint ed or chromed surfaces Avoid using such wax as contains abrasives because it may scratch surfaces 9 After completing the above start the engine and allow it to warm up for several minutes EAS1SM9049 STORAGE If your vehicle is to be stored for 60 days or more some preventive measures must be tak en to avoid deterioration After cleanin...

Page 40: ...CLEANING AND STORAGE 1 26 ...

Page 41: ...IFICATIONS 2 10 TIGHTENING TORQUES 2 11 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 11 ENGINE TIGHTENING TORQUES 2 12 CHASSIS TIGHTENING TORQUES 2 15 LUBRICATION POINTS AND LUBRICANT TYPES 2 18 ENGINE 2 18 CHASSIS 2 20 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 LUBRICATION DIAGRAMS 2 23 CABLE ROUTING DIAGRAM 2 31 ...

Page 42: ...MD USA CAN 1SMA 1SMF EUR 1SMB 1SMG JPN 1SMC 1SMH AUS NZL ZAF Dimensions Overall length 2165 mm 85 2 in Overall width 825 mm 32 5 in Overall height 1280 mm 50 4 in Seat height 965 mm 38 0 in Wheelbase 1475 mm 58 1 in Ground clearance 325 mm 12 80 in Weight Curb weight 105 kg 231 lb ...

Page 43: ... L 0 77 US qt 0 64 Imp qt Without oil filter element replacement 0 71 L 0 75 US qt 0 62 Imp qt Oil filter Oil filter type Paper 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 24 mm 0 0094 in Oil pump housing to inner and outer rotor clearanc...

Page 44: ...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 45: ...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 4 0 mm 0 16 in Offset 0 00 mm 0 0000 in Piston pin bore inside diameter 16 002 16 013 mm 0 6...

Page 46: ...ansmission type Constant mesh 5 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 2 143 30 14 2nd 1 750 28 16 3rd 1 444 26 18 4th 1 222 22 18 5th 1 042 25 24 Main axle runout limit 0 08 mm 0 0032 in Drive axle runout limit 0 08 mm 0 0032 in Shifting mechanism Shift mechan...

Page 47: ...or Crankshaft position sensor resistance 228 342 Intake air pressure sensor output voltage 3 57 3 71 V at 101 3 kPa Intake air temperature sensor resistance 290 390 at 80 C 176 F Coolant temperature sensor resistance 2 51 2 78 k at 20 C 68 F 210 221 at 100 C 212 F Idling condition Engine idling speed 1900 2100 r min Water temperature 70 80 C 158 176 F Oil temperature 55 65 C 131 149 F Throttle gri...

Page 48: ...wheel runout limit 2 0 mm 0 08 in Wheel axle bending limit 0 50 mm 0 02 in Front tire Type With tube Size 80 100 21 51M Manufacturer model BRIDGESTONE M403A USA CAN AUS NZL ZAF PIRELLI MID SOFT 32 EUR DUNLOP MX52F JPN Rear tire Type With tube Size 100 90 19 57M Manufacturer model BRIDGESTONE M404 USA CAN AUS NZL ZAF PIRELLI MID SOFT 32 EUR DUNLOP MX52 JPN Tire air pressure measured on cold tires F...

Page 49: ...fied brake fluid DOT 4 Steering 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 497 0 mm 19 57 in Limit 492 0 mm 19 37 in Installed length 497 0 mm 19 57 in Spring rate K1 4 70 N mm 0 48 kgf mm ...

Page 50: ...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 Rebound damping adjusting positions Minimum 30 clicks out Standard 13 clicks out USA CAN 14 clicks out EUR JPN AUS NZL ZAF 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 USA...

Page 51: ...r 1SM7 YAMAHA USA CAN 1SM8 YAMAHA EUR JPN AUS NZL ZAF Ignition coil Minimum ignition spark gap 6 0 mm 0 24 in Primary coil resistance 2 16 2 64 Secondary coil resistance 8 64 12 96 k Spark plug cap Resistance 10 00 k AC magneto Standard output 14 0 V 95 W at 5000 r min Stator coil resistance 0 624 0 936 Rectifier regulator Regulator type Semi conductor short circuit No load regulated voltage 14 1 ...

Page 52: ...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 53: ...ming 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 kgf 7 2 ...

Page 54: ...f 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 lbf Crankcase bearing cover plate screw crankshaft M8 4 22 Nm 2 2 m kgf 16 ft lbf Oil pass...

Page 55: ... Nm 0 8 m kgf 5 8 ft lbf Crankshaft position sensor bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf AC magneto lead holder bolt M5 1 8 Nm 0 8 m kgf 5 8 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 kgf 1 1 ft lbf Rectifier regulator bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf ECU bolt M5 2...

Page 56: ... Nm 0 5 m kgf 3 6 ft lbf Front fork protector and brake hose holder bolt M6 2 9 Nm 0 9 m kgf 6 5 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 5 Nm 0 5 m kgf 3 6 ft lbf Clutch lever nut M6 1 4 0 Nm 0 40 m kgf 2 9 ft lbf Clutch lever position locknut M5 1 4 8 Nm 0 48 m kgf 3 5 ft lbf Front brake master cylinder holder bolt M6 2 9 Nm 0 9 m kgf 6 5 ft ...

Page 57: ...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 3 4 m kgf 25 ft lbf Rear fra...

Page 58: ... tank bracket bolt rear side M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Fuel pump bolt M5 6 4 0 Nm 0 40 m kgf 2 9 ft lbf Fuel inlet pipe screw M5 2 3 4 Nm 0 34 m kgf 2 5 ft lbf Fuel tank cap cover bolt M6 2 4 0 Nm 0 40 m kgf 2 9 ft lbf Seat set bracket and fuel tank screw M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Seat bolt M8 2 22 Nm 2 2 m kgf 16 ft lbf Left side cover bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Right side cove...

Page 59: ...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 60: ...BRICANT TYPES 2 19 Shift lever assembly moving parts Cylinder head cover gasket Three bond No 1215 Crankcase mating surface Three bond No 1215 Stator assembly lead grommet Three bond No 1215 Lubrication point Lubricant types E ...

Page 61: ... outer surface and dust seal lip upper side Rear shock absorber assembly bearing and dust seal lip lower side Brake pedal pivot portion O ring and bolt outer surface Front wheel oil seal lip Front wheel axle outer surface Rear wheel oil seal lip Rear wheel axle outer surface Push rod contacting portion front brake master cylinder Front brake lever bolt outer surface Clutch lever sliding surface an...

Page 62: ...ANT TYPES 2 21 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 Lubrication point Lubricant types S S S ...

Page 63: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 22 ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EAS1SM9060 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS1SM9061 LUBRICATION DIAGRAMS ...

Page 65: ...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 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 ...

Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Connecting rod 2 Crankshaft 3 Main axle 4 Oil strainer 5 Drive axle ...

Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 ...

Page 69: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Exhaust camshaft 2 Intake camshaft 3 Oil filter element 4 Oil pump ...

Page 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 ...

Page 71: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Camshaft 2 Oil pressure check bolt 3 Oil filter element 4 Oil pump ...

Page 72: ...CABLE ROUTING DIAGRAM 2 31 EAS1SM9062 CABLE ROUTING DIAGRAM ...

Page 73: ...Clamp the clutch cable and the AC magneto lead by the plastic locking tie Regardless of the orien tation of the lock on the plastic locking tie cut the end L Pass the clutch cable with no downward sag al lowed M Bring the grommet of the clutch cable into contact with the radiator hose and pass it to the outside of the neutral switch lead and the AC magneto lead the outside of the vehicle N 40 mm 1...

Page 74: ...CABLE ROUTING DIAGRAM 2 33 ...

Page 75: ...se 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 H Pass the protector of the cylinder head breather hose until it touches the holder I Pass the cylinder head breather hose between the engine guard and the crankcase J Install the end of the cylinder head breather hose with it facing d...

Page 76: ...CABLE ROUTING DIAGRAM 2 35 ...

Page 77: ...r of the number plate band C Clamp the engine stop switch lead to the handle bar by the plastic band Do not cut the end of the plastic band D Pass the engine stop switch lead between the head pipe and the cable guide E Pass the front brake hose to the front of the num ber plate F 40 10 G Vertical direction H Pass the engine stop switch lead under the han dlebar I Pass the clutch cable to the guide...

Page 78: ...CABLE ROUTING DIAGRAM 2 37 ...

Page 79: ... sert the projection of the plastic clamp into the hole in the sheet metal of the radiator B Insert the projection of the main harness into the hole in the frame C To the sub wire harness D Pass the high tension cord above the fuel hose E 10 F Install the spark plug cap with this facing the right of the vehicle G Push the spark plug cap home where there shall be no gap between it and the cylinder ...

Page 80: ...CABLE ROUTING DIAGRAM 2 39 ...

Page 81: ...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 82: ...CABLE ROUTING DIAGRAM 2 41 ...

Page 83: ...STEM 3 13 CHECKING THE FUEL LINE 3 14 CHECKING THE ENGINE OIL LEVEL 3 14 CHANGING THE ENGINE OIL 3 15 ADJUSTING THE ENGINE IDLING SPEED 3 16 ADJUSTING THE VALVE CLEARANCE 3 17 CHASSIS 3 22 BLEEDING THE BRAKE SYSTEM 3 22 CHECKING THE BRAKE HOSE 3 23 ADJUSTING THE FRONT BRAKE 3 23 ADJUSTING THE REAR BRAKE 3 24 CHECKING THE FRONT BRAKE PADS 3 24 CHECKING THE REAR BRAKE PADS 3 26 CHECKING THE REAR BRA...

Page 84: ...THE WHEEL BEARINGS 3 34 CHECKING AND ADJUSTING THE STEERING HEAD 3 34 LUBRICATING THE LEVERS 3 35 LUBRICATING THE PEDAL 3 35 ELECTRICAL SYSTEM 3 36 CHECKING THE SPARK PLUG 3 36 CHECKING THE IGNITION TIMING 3 36 ...

Page 85: ... to the list below ITEM After break in Every race about 2 5 hours Every third about 7 5 hours Every fifth about 12 5 hours As re quired Remarks VALVE Check the valve clearances The engine must be cold Inspect Check the valve seats and the valve faces for wear Replace VALVE SPRING Inspect Check the free length and the tilt Replace VALVE LIFTER Inspect Check for scratches and wear Replace CAMSHAFT I...

Page 86: ...nd eliminate them Inspect and clean Check for warpage and re place the gasket CYLINDER Inspect and clean Inspect score marks Replace Inspect wear ENGINE OIL Inspect Check the engine oil amount Replace OIL FILTER ELE MENT Replace OIL STRAINER Clean CLUTCH Inspect and adjust Inspect housing friction plate clutch plate and spring Replace TRANSMISSION Inspect Replace bearings SHIFT FORK SHIFT CAM GUID...

Page 87: ...ER Clean and lubri cate Use foam air filter oil or equiv alent oil Replace SPARK PLUG Inspect and clean Check the electrodes and the terminals for wear Replace COOLING SYSTEM Check coolant lev el and leakage Check radiator cap operation Use the radiator cap tester for a checkup Check radiator cap attached Change the cool ant Every two years Inspect hoses ENGINE GUARD Replace Breakage FRAME Clean a...

Page 88: ...R Inspect and adjust Lubricate After rain ride Grease pillow balls and bear ings Retighten Check for tightening torques BRAKE S Adjust lever posi tion and pedal height Lubricate pivot point Check brake disc surface Check fluid level and leakage Retighten brake disc bolts caliper bolts master cylin der bolts and union bolts Check for tightening torques Replace pads ITEM After break in Every race ab...

Page 89: ... sure wheel run out tire wear and spoke looseness Retightensprocket bolt Check the bearing Replace bearings Lubricate Lithium soap based grease DRIVE CHAIN Use chain oil Clean lubricate slack alignment Replace DRIVE CHAIN GUIDE Inspect Inspect wear DRIVE CHAIN GUIDE AND DRIVE CHAIN SUPPORT Replace CABLES Routing Connec tion Check and grease Check and clean throttle cable Check throttle cables on t...

Page 90: ...e play KICKSTARTER LE VER BRAKE PED AL FOOTREST Lubricate OUTSIDE NUTS AND BOLTS Retighten Refer to TORQUE CHECK POINTS on page 1 23 ITEM After break in Every race about 2 5 hours Every third about 7 5 hours Every fifth about 12 5 hours As re quired Remarks ...

Page 91: ...es Check the play of front brake and effect of front and rear brake 3 22 28 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 28 4 64 65 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play 3 33 34 Steering Check that the handlebar can be turned smoothly and have no excessive play 3 34 35 Front forks...

Page 92: ...t a few minutes until the coolant has settled EAS1SM9069 CHECKING THE COOLING SYSTEM 1 Remove Seat Side cover left right Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Air filter case cover Refer to THROTTLE BODY on page 7 5 2 Check Radiator Radiator hoses Crack damage Replace Refer to RADIATOR on page 6 1 3 Install Air filter case cover Refer to THROTTLE BODY on page 7 5 Air scoop left...

Page 93: ...Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 8 EAS1SM9071 CHECKING THE RADIATOR CAP 1 Check Seal radiator cap 1 Valve and valve seat 2 Crack damage Replace Exist fur deposits Clean or replace EAS1SM9072 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 radiato...

Page 94: ... spout therefore cover it with a cloth beforehand EAS1SM9074 ADJUSTING THE CLUTCH LEVER POSI TION 1 Adjust Clutch lever position a Loosen the locknut 1 and use the adjuster 2 to adjust the clutch lever position a as desired 2 Tighten Locknut EAS1SM9075 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 ...

Page 95: ...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 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 Di...

Page 96: ...nk cap cover 1 Refer to FUEL TANK CAP on page 1 19 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 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 a...

Page 97: ...S 1 Check Breather hose 1 Crack damage Replace Loose connection Connect properly ECA14920 NOTICE Make sure the cylinder head breather hose is routed correctly EAS1SM9081 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 5 1 Exhaust gas Leaks Replace the gasket Refer to ENGINE REMOVAL on pa...

Page 98: ...ne warm this up for 2 3 min utes 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 ECA33DD018 NOTICE Since engine oil also lubricates the clutch the wrong oil types or additives could cause clutch slippage Therefor...

Page 99: ...l filter element cover 1 and oil filter element 2 b Replace the O rings 3 c Install the new oil filter element and the oil fil ter 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 rings 2 d Install the oil strainer 6 Install Engine oil drain bolt Dra...

Page 100: ...n d Tighten the oil pressure check bolt EAS1SM9085 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 n...

Page 101: ...ay lead to servicing trouble and mechanical damage Make sure that the valve clearance is checked or adjusted while the engine is cold at room temperature While the valve clearance is checked or ad justed make sure that the piston is positioned in the top dead center TDC 1 Remove Seat Side cover left right Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on pag...

Page 102: ...e using a thickness gauge 1 TIP Record the measured reading if the clearance is incorrect 5 Adjust Valve clearance a Remove the camshaft intake and exhaust Refer to CAMSHAFT on page 5 11 b Remove the valve lifter 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 adju...

Page 103: ... pad number to replace Example Pad number 148 Rounded value 150 e Install the new adjusting pads 4 and the valve lifters 5 ECA NOTICE 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 val...

Page 104: ...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 105: ...215 220 225 230 235 240 0 70 0 74 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 75 0 79 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 80 0 84 180 185 190 195 200 205 210 215 220 225 230 235 240 0 85 0 89 185 190 195 200 205 210 215 220 225 230 235 240 0 90 0 94 190 195 200 205 210 215 220 225 230 235 240 0 95 0 99 195 200 205 210 215 220 225 230 235 240 1 00 1 04 200 20...

Page 106: ...e reservoir diaphragm c Connect 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 cont...

Page 107: ...urn the adjusting bolt 2 in direction a or b until the specified brake lever position is obtained c Tighten the locknut EWA13050 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 ECA13490 NOT...

Page 108: ... 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 EAS1SM9092 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 ...

Page 109: ...Install the 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 10 3 Check Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 27 4 Check Brake lever operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE BRAKE ...

Page 110: ...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 111: ...KE PAD INSU LATOR 1 Remove Brake pads Refer to REAR BRAKE on page 4 21 2 Check Rear brake pad insulator 1 Damage Replace EAS1SM9095 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 112: ...a suitable stand to raise the rear wheel off the ground EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over 2 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 slac...

Page 113: ...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 EAS1SM9099 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 114: ...ression 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 12 clicks out USA CAN 8 clicks out EUR JPN AUS NZL ZAF Minimum 20 click...

Page 115: ...3120 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 4 53 2 Adjust Spring preload a Loosen the locknut 1 b Loosen the adjuster 2 until there is some clearance between the spring and the ad juster c Measure the s...

Page 116: ...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 Rebound damping adjusting posi tions Maximum Fully turned in Standard 13 clicks out USA CAN 14 clicks out EUR JPN AUS NZL ZAF Minimum 30 clicks out With the adjuster fully turned c b T R Direction a Compression da...

Page 117: ...und tilted the tire is considered to be slipping off its position Cor rect the tire position EAS1SM9106 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 suspension is softer C...

Page 118: ...8 EAS1SM9109 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 4 31 Upper b...

Page 119: ...pper and lower bearings Refer to STEERING HEAD on page 4 49 f Install the washer 1 5 Install Upper bracket Refer to STEERING HEAD on page 4 49 Handlebar Refer to HANDLEBAR on page 4 31 EAS1SM9110 LUBRICATING THE LEVERS 1 Lubricate the pivoting points and metal to metal moving parts of the following parts Brake lever Clutch lever EAS1SM9111 LUBRICATING THE PEDAL 1 Lubricate the pivoting point and m...

Page 120: ...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 121: ...16 4 Check Ignition timing Check whether the alignment mark a on the left crankcase cover is within the firing range b on the rotor Incorrect firing range Check rotor and Crankshaft position sensor 5 Install Timing mark accessing screw Timing light 90890 03141 YU 03141 Digital tachometer 90890 06760 YU 39951 B Timing mark accessing screw 6 Nm 0 6 m kgf 4 3 ft lbf 2 1 3 a b T R ...

Page 122: ...ELECTRICAL SYSTEM 3 38 ...

Page 123: ...IPER 4 15 CHECKING THE FRONT BRAKE CALIPER 4 16 ASSEMBLING THE FRONT BRAKE CALIPER 4 16 INSTALLING THE BRAKE CALIPER PISTON 4 16 INSTALLING THE FRONT BRAKE CALIPER 4 17 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 18 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 18 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 18 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 19 REAR BRAKE 4 21 INTRODUCTION 4 25 CHECKING ...

Page 124: ...EMBLY 4 53 HANDLING THE REAR SHOCK ABSORBER 4 56 DISPOSING OF A REAR SHOCK ABSORBER 4 56 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 56 REMOVING THE BEARING 4 56 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 57 CHECKING THE CONNECTING ARM AND RELAY ARM 4 57 INSTALLING THE RELAY ARM 4 57 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 58 SWINGARM 4 60 REMOVING THE SWINGARM 4 61 REMOVING THE BEARING 4 6...

Page 125: ...o this manual It may lead to servicing trouble and mechanical damage EAS1SM9116 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 Number plate 1 7 Rear fender 1 For installation reverse the removal proce dure 4 2 7 5 1 3 6 2 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf ...

Page 126: ...he seat always remove the fuel tank cap cover beforehand 1 Remove Fuel tank cap cover 1 Refer to FUEL TANK CAP on page 1 19 2 Remove Seat 1 EAS1SM9119 REMOVING THE NUMBER PLATE 1 Remove Bolt number plate Number plate 1 TIP The projection a is inserted into the band of the number plate Pull the band off the projec tion before removal Remove the clutch cable 2 from the cable guide b on the number pl...

Page 127: ... wheel axle pinch bolt 4 Loosen 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Front wheel 1 5 Collars 2 6 Oil seals 2 7 Bearing 2 8 Brake disc 1 For installation reverse the removal proce dure 12 Nm 1 2 m kgf 8 7 ft Ibf T R New New LT LS LS LS 5 7 6 5 6 7 6 8 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 4 115 Nm 11 5 m kgf 83 ft lbf T R ...

Page 128: ...d CHECKING THE WHEELS on page 3 34 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 33 TIP After tightening the spokes measure the wheel runout 5 Measure Wheel radial runout a Wheel lateral runout b Out of specificat...

Page 129: ... 2 Bearing right side 3 Oil seals 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 of ...

Page 130: ...ll 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 pinch bolt 1 1 LS Front wheel axle nut 115 Nm 11 5 m kgf 83 ft lbf Front wheel axle pinch bolt 21 Nm 2 1 m...

Page 131: ...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 42 Nm 4 2 m kgf 30 ft Ibf T R 135 Nm 13 5 m kgf 98 ft lbf T R ...

Page 132: ... CHECKING THE FRONT WHEEL on page 4 4 4 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 4 EAS1SM9129 DISASSEMBLING THE REAR WHEEL 1 Remove Oil seals Bearing Refer to DISASSEMBLING THE FRONT WHEEL on page 4 5 EAS1SM9130 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 133: ...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 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 134: ...el 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 28 6 Tighten Rear wheel axle nut 1 Locknut 2 1 2 LS Drive chain slack 50 60 mm 1 97 2 36 in Wheel axle n...

Page 135: ... 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 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 28 Nm 2 8 m lbf kgf 20 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 136: ...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 137: ...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 5 6 7 2 3 4 8 9 1 T R 30 Nm 3 0 m lbf kgf 22 ft T R 1 5 Nm 0 15 m lbf kgf 1 1 ft T R 6 Nm 0 6 m lbf kgf 4 3 ft T R 6 Nm 0 6 m lbf kgf 4 ...

Page 138: ...assembling 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 BF 5 4 3 2 1 S New New ...

Page 139: ...tion EAS1SM9135 CHECKING THE FRONT BRAKE DISC 1 Remove Front wheel Refer to FRONT WHEEL on page 4 3 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 4 3 EAS1SM9136 REMOVING THE FRONT BRAKE CALIPER TIP Before disassembling the br...

Page 140: ...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 EAS1SM9140 INSTALLING THE BRAKE CALIPER PISTON 1 Clean Brake caliper Brake...

Page 141: ...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 142: ...ylinder and the end of the brake hose EAS1SM9143 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 wear R...

Page 143: ...er 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 EWA13530 WARNING Proper brake hose routing is essential to in sure safe vehicle operation ECA1DX1007 NOTICE During installation bring the brake hose into contact with the brake master cylinder projection a and make its be...

Page 144: ... the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock ECA13540 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 page 3 22 5 Check Brake fluid level The minimum level mark a or below Ad...

Page 145: ...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 146: ... 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 147: ...page 3 22 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 148: ...24 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 149: ...SM9148 CHECKING THE REAR BRAKE DISC 1 Remove Rear wheel Refer to REAR WHEEL on page 4 7 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 4 15 4 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replac...

Page 150: ...9151 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 151: ...n with its side a facing the brake caliper Never force to insert EAS1SM9154 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake caliper Rear brake caliper bracket 2 Install Rear wheel Refer to REAR WHEEL on page 4 7 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 152: ... to CHECKING THE BRAKE FLUID LEVEL on page 3 27 7 Check Brake pedal operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE BRAKE SYS TEM on page 3 22 EAS1SM9155 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 remaini...

Page 153: ... 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 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 EAS1SM9158 INSTALLI...

Page 154: ...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 22 4 Check Brake fluid level The minimum level ma...

Page 155: ...the band only 1 Clutch cable 1 Disconnect 2 Clutch lever holder 1 3 Engine stop switch 1 4 Brake master cylinder 1 5 Throttle cable cap 1 6 Throttle cable pull 1 Disconnect 7 Throttle cable return 1 Disconnect 8 Right grip 1 9 Tube guide 1 10 Collars 1 11 Left grip 1 12 Handlebar upper holder 2 13 Handlebar 1 ...

Page 156: ...HANDLEBAR 4 32 14 Handlebar lower holder 2 15 Damper 4 For installation reverse the removal proce dure Removing the handlebar Order Part name Q ty Remarks ...

Page 157: ...ders 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 Installing the lower handlebar holders in the reverse direction allow the front to rear offset amount of the handlebar position to be changed The upper handlebar holders should be in stalled with the punch marks b facing for ward When in...

Page 158: ...ver TIP Install the handlebar grip to the handlebar so that the line a between the two arrow marks faces straight upward 5 Install Handlebar grip 1 Handlebar grip 2 Handlebar grip 3 Clamp 4 TIP The engine stop switch the clutch lever and the clutch lever holder should be installed ac cording to the dimensions shown Pass the engine stop switch lead through the middle of the clutch lever holder Lowe...

Page 159: ...ly the lithium soap base 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 handle bar 9 Install Throttle cable housings 1 Screw throttle cable housings 2 EWA1DX5001 WARNING After tightening the throttle cable housing screws check that th...

Page 160: ...sembly 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 VER FREE PLAY on page 3 10 14 Adjust Throttle grip free play Refer to ADJUSTING THE THROTTLE GRIP FREE PLAY on page 3 11 Front brake master cylinder hold er...

Page 161: ...brake caliper Refer to FRONT BRAKE on page 4 11 Number plate Refer to GENERAL CHASSIS on page 4 1 1 Protector 1 2 Upper bracket pinch bolts 2 Loosen 3 Damper assembly 1 Loosen 4 Lower bracket pinch bolts 2 Loosen 5 Front fork leg 1 For installation reverse the removal proce dure 3 2 4 5 1 T R 21 Nm 2 1 m lbf kgf 15 ft T R 9 Nm 0 9 m lbf kgf 6 5 ft T R 5 Nm 0 5 m lbf kgf 3 6 ft T R 5 Nm 0 5 m lbf k...

Page 162: ...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 163: ...embly 1 with the cap bolt ring wrench 2 3 Remove Front fork leg s EAS1SM9165 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...

Page 164: ...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 Damper rod 1 Bend damage Replace Damper rod 2 Wear damage Replace ECA1DX1010 NOTICE The front fork leg has a built in damper ad justing rod and a very sophisticated inter nal construction which are particularly s...

Page 165: ...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 ECA14210 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...

Page 166: ...eristic 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 9 Tighten Base valve 1 TIP Hold the damper assembly with the cap bolt ring wrench 2 and use the cap bolt wrench 3 ...

Page 167: ...t 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 ECA32D1010 NOTICE Make sure that the numbered side of the oil seal faces bottom side TIP Apply the lithium soap based grease on the dust seal lip and oil seal lip Apply the...

Page 168: ...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 19 Install Oil seal clip 1 TIP Fit the oil seal clip correctly in the groove in the outer tube Fork seal driver 90890 01502 YM A0948 New Fork seal driver 90890 01502 YM A0948 New ...

Page 169: ...tall 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 24 Install Damper assembly 1 to the inner tube 2 ECA32D1010 NOTICE Allow the damper assembly to slide slowly down the inner tube until it contacts the bot tom of the inner tube Be careful not to dam age the inner tube Distance a 16 mm 0 63 in or more Between the damper asse...

Page 170: ...er 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 damping force cannot be obtained 28 Tighten Adjuster locknut 1 TIP Hold the locknut 2 and tighten the adjuster 29 Install Adjuster 1 to the i...

Page 171: ...uide 1 EAS1SM9168 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 2 Tighten Damper assembly 1 TIP Use the cap bolt ring wrench 2 to tighten the damper assembly Recommended oil Suspension oil S1 Standard oil amount 330 cm3 11 16 US oz 11 64 lmp oz USA CAN 355 cm3 12 00 US oz 12 52 lmp oz EUR...

Page 172: ... 2 6 Adjust Rebound damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 7 Adjust Compression damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position Front fork top end standard a 5 mm 0 20 in Upper bracket pinch bolts 21 Nm 2 1 m kgf 15 ft lbf Lower bracket pinch bolts 21 Nm 2 1 m kgf ...

Page 173: ...Front fender 1 2 Steering stem nut 1 3 Front fork leg s 2 Refer to FRONT FORK on page 4 37 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 For installation reverse the removal proce dure 2 4 5 7 3 1 6 8 9 10 LS T R LS LS T R 21 Nm 2 1 m lbf kgf 15 ft T R 9 Nm 0 9 m lbf kgf 6 5 ft T R 21 Nm 2 1 m lbf kgf 15...

Page 174: ...ce 3 Replace Bearing Bearing races 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 b...

Page 175: ...e steering nut with its stepped 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 34 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 p...

Page 176: ...eering ring nut little by little 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 EWA33DD049 WARNING Tighten the lower bracket to specified torque If torqued too much it may cause the front fork to malfunction Steering stem nut 145 Nm 14 5 m kgf 105 ft lbf Front fork top end standard a 5 mm 0 20 in T R a Upper bracket pinch bolts 21 Nm 2 1 m kgf 15 ft...

Page 177: ...4 1 Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Rear shock absorber assembly lower bolt 1 2 Rear shock absorber assembly upper bolt 1 3 Rear shock absorber assembly 1 4 Locknut 1 5 Adjusting nut 1 6 Lower spring guide 1 7 Upper spring guide 1 8 Spring 1 9 Dust seal 2 10 Collars 2 11 Bushing 1 12 Collars 2 2 12 16 15 14 13 12 14 4 5 7 6 8 3 9...

Page 178: ... 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 179: ...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 180: ...0 km of run ning EAS1SM9175 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 EAS1SM917...

Page 181: ...e wear Replace Bearing Damage wear Replace Bolts Bends damage wear Replace EAS1SM9179 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 EAS1SM9180 INSTALLING THE RELAY ARM 1 Lubricate Oil seals Bearing Spacers Washers Colla...

Page 182: ... 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 assembly up per bolt and connecting arm bolt frame side f...

Page 183: ...ide 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 absorber assembly lower bolt 53 Nm 5 3 m kgf 38 ft lbf T R T R T R ...

Page 184: ...rake hose holder Refer to REAR BRAKE on page 4 21 Rear brake caliper Refer to REAR BRAKE on page 4 21 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 185: ...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 EAS1SM9184 REMOVING THE BEARING 1 Remove Bearing 1 TIP Remove the bearing by pressing its outer race EAS1SM9185 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 186: ... 3 Install Swingarm TIP Install the pivot shaft from the right 4 Install Rear wheel Refer to REAR WHEEL on page 4 7 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 28 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 187: ...oving the drive chain Job Order Part name Q ty Servicing Information Drive sprocket Refer to ENGINE REMOVAL on page 5 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 188: ...nk 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 la Drive chain 15 link section length c length a between pin inner sides length 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 diffe...

Page 189: ...EWA WARNING When installing the joint clip always keep the direction as shown in the figure 2 Lubricate Drive chain 3 Install Drive sprocket Lock washer Drive sprocket nut Refer to ENGINE REMOVAL on page 5 1 ECA1DX1014 NOTICE Never install a new drive chain onto worn drive sprockets this will dramatically short en the drive chain s life 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN...

Page 190: ...CHAIN DRIVE 4 66 ...

Page 191: ...CKING THE TIMING CHAIN TENSIONERS 5 15 CHECKING THE DECOMPRESSION SYSTEM 5 16 INSTALLING THE CAMSHAFTS 5 16 CYLINDER HEAD 5 18 REMOVING THE CYLINDER HEAD 5 20 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 5 20 CHECKING THE CYLINDER HEAD 5 20 INSTALLING THE CYLINDER HEAD 5 21 VALVES AND VALVE SPRINGS 5 22 REMOVING THE VALVES 5 23 CHECKING THE VALVES AND VALVE GUIDES 5 24 CHECKING THE VALVE SEATS 5 25...

Page 192: ...45 CHECKING THE KICK GEAR KICK IDLE GEAR AND RATCHET WHEEL 5 45 INSTALLING THE KICK SHAFT ASSEMBLY 5 45 INSTALLING THE KICK IDLE GEAR 5 46 SHIFT SHAFT 5 47 REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 5 49 REMOVING THE SEGMENT 5 49 CHECKING THE SHIFT SHAFT 5 49 CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 5 49 CHECKING THE STOPPER LEVER 5 49 INSTALLING THE STOPPER LEVER 5 50 INSTALLING T...

Page 193: ...AINER 5 64 CHECKING THE CRANKCASE 5 64 INSTALLING THE OIL SEAL 5 65 ASSEMBLING THE CRANKCASE 5 65 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 5 66 REMOVING THE CRANKSHAFT ASSEMBLY 5 67 CHECKING THE CRANKSHAFT ASSEMBLY 5 67 INSTALLING THE CRANKSHAFT ASSEMBLY 5 68 INSTALLING THE BALANCER SHAFT 5 68 TRANSMISSION 5 69 REMOVING THE TRANSMISSION 5 70 CHECKING THE SHIFT FORKS 5 70 CHECKING THE SHIFT DRUM ASSE...

Page 194: ...TALLING THE EXHAUST PIPE AND MUFFLER on page 5 10 Side cover right Refer to GENERAL CHASSIS on page 4 1 Rear shock absorber assembly lower bolt Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 53 Connecting arm bolt frame side Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 53 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 8 6 30...

Page 195: ...ng the exhaust pipe Order Part name Q ty Remarks 10 5 9 2 6 1 6 6 3 8 4 7 8 6 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 10 Nm 1 0 m kgf 7 2 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 20 Nm 2 0 m kgf 14 ft lbf 13 Nm 1 3 m kgf 9 4 ft lbf T R LT LT LT ...

Page 196: ...ge 4 1 Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case cover 1 Rectifier regulator 1 2 ECU 1 3 Ignition coil 1 4 Condenser 1 5 Neutral switch 1 6 AC magneto coupler 1 Disconnect 7 Crankshaft position sensor coupler 1 Disconnect 8 Coolant temperature sensor coupler 1 Disconnect For installation reverse the removal proce dure T R T R...

Page 197: ... page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Exhaust pipe and silencer Refer to ENGINE REMOVAL on page 5 1 Air filter case Refer to THROTTLE BODY on page 7 5 Throttle body Refer to THROTTLE BODY on page 7 5 Clutch cable Refer to CLUTCH on page 5 35 Shift pedal Refer to SHIFT SHAFT on page 5 47 1 Engine guard 1 2 Brake pedal 1 3 Spring 1 4 Cylinder head breather hose 1 5 Drive sprocket cover ...

Page 198: ... 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 199: ... silencer EAS1SM9196 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 EAS1SM9197 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 200: ...hat the couplers the hoses and the cables are disconnected Lift up the engine and remove this from its lower part toward the right of the chassis EAS1SM9199 CHECKING THE SILENCER AND EXHAUST PIPE 1 Check Gasket 1 Damage Replace EAS1SM9200 CHANGING THE SILENCER FIBER 1 Remove Bolt 1 Silencer body 2 ECA NOTICE Do not hit the silencer stay a as it may do damage to the silencer TIP Remove the inner pi...

Page 201: ...all the engine from the right side Pivot shaft 2 Engine mounting bolt lower side 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 molybdenum disulfide grease to the pivot shaft Silencer body bolt 8 Nm 0 8 m kgf 5 8 ft lbf LOCTITE 1 T R a 1 2 LT 2 1 Pivot sh...

Page 202: ... 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 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 Bolt brake pedal 26 Nm 2 6 m kgf 19 ft lbf M 7 8 9 9 8 7 4...

Page 203: ...nd positioned as shown with respect to the exhaust pipe 1 3 Install Clamp Silencer 1 Bolt 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 Nut exhaust pipe 20 Nm 2 0 m kgf 14 ft lbf New T R 1 ...

Page 204: ...left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Spark plug 1 2 Cylinder head breather hose 1 3 Bolt cylinder head cover 3 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 10 Nm 1 0 m kgf 7 2 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft I...

Page 205: ... 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 206: ... 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 ECA33DD027 NOTICE The bolts camshaft cap must be removed evenly t...

Page 207: ...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 208: ... 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 EAS1SM9209 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 209: ...ure 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 ECA33DD029 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 210: ...ckwise several 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 Cylind...

Page 211: ...UEL TANK on page 7 1 Exhaust pipe and silencer Refer to ENGINE REMOVAL on page 5 1 Radiator hose Disconnect Coolant temperature sensor coupler Disconnect Throttle body Refer to THROTTLE BODY on page 7 5 Camshaft Refer to CAMSHAFT on page 5 11 Upper engine bracket Refer to ENGINE REMOVAL on page 5 1 1 Nut cylinder head 2 2 Bolt cylinder head 4 3 Cylinder head 1 4 Cylinder head gasket 1 6 10 Nm 1 0 ...

Page 212: ...guide 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 T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 213: ...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 5 25 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 214: ...e cylin der head 2 Install Cylinder head 1 Cylinder head bolt 2 Cylinder head nut 3 3 Tighten Cylinder head bolt 1 4 Cylinder head nut 5 6 TIP Apply molybdenum disulfide grease to the threads and contact surfaces of the bolts and to both contact surfaces of the washers 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 215: ...ngs Order Part name Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 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 216: ...alve seat contact width Refer to CHECKING THE VALVE SEATS on page 5 25 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 the valve spring compressor 2 and the valve spring compressor adapter 3...

Page 217: ... 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 reamer 3 to obtain the proper valve stem to valve guide clearance 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 Limit 0 080 mm 0 0032 i...

Page 218: ...1SM9220 CHECKING 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 Replace the cylinder head Intake Valve guide remover ø5 90890 04097 YM 04097 Valve guide installer ø5 90890 04098 YM 04098 Valve guide reamer ø5 90890 04099 YM 04099 Exhaust Valve guide re...

Page 219: ...ves 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 a to the valve face ECA NOTICE Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder he...

Page 220: ...ressed 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 34 85 mm 1 37 in Free length exhaust 34 86 mm 1 37 in Limit 33 11 mm 1 30 in b Installed length Installed compression spring force intake 146 00 168 00 N 14 89 17 13 kgf 32 82 37 77 lbf Installed compression ...

Page 221: ...ed 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 5 To fasten the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer ECA NOTICE Hitting the valve tip with excessive for...

Page 222: ...usting 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 223: ...emarks Cylinder head Refer to CYLINDER HEAD on page 5 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 224: ...e piston crown EAS1SM9226 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 225: ...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 226: ...TALLING THE PISTON AND 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 ...

Page 227: ...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 228: ...INE OIL on page 3 15 Brake pedal Refer to ENGINE REMOVAL on page 5 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 New New New 2 3 4 5 5 6 7 8 9 6 10 11 20 1 12 13 16 17 18 15 14 T R T R T R T R LT 19 ...

Page 229: ...t washer 1 16 Primary driven gear 1 17 Spacer 1 18 Bearing 1 19 Washer 1 20 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 20 1 12 13 16 17 18 15 14 T R T R T R T R LT 19 ...

Page 230: ...ain Refer to CHANGING THE COOLANT on page 3 8 Brake pedal Refer to ENGINE REMOVAL on page 5 1 Clutch cover Refer to CLUTCH on page 5 35 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 ...

Page 231: ... plate EAS1SM9233 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 EAS1SM9234 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 R...

Page 232: ...eplace EAS1SM9238 CHECKING THE PUSH LEVER SHAFT 1 Check Push lever shaft Wear damage Replace EAS1SM9239 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 EAS1SM9240 CHECKING THE PRIMARY DRIVE GEAR 1 Check Primary drive gear Damage wear Replace the primary drive and pri...

Page 233: ...he oil seal in parallel with its manufac ture s marks or numbers facing inward EAS1SM9243 INSTALLING THE RIGHT CRANKCASE COVER 1 Install Dowel pin 1 O rings 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 ...

Page 234: ...h boss nut 2 ECA1DX1020 NOTICE Make sure to tighten to specification other wise it may damage the other part that is fastened together TIP Use the clutch holding tool 3 to hold the clutch boss 4 Bend the lock washer 1 tab 5 Install Friction plates 1 Clutch plate 2 TIP Install the clutch plates and friction plates al ternately on the clutch boss starting with a friction plate and ending with a fric...

Page 235: ...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 236: ...ashers 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 T R 1 a ...

Page 237: ...shaft Order Part name Q ty Remarks Primary driven gear Refer to CLUTCH on page 5 35 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 238: ...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 EAS1SM9250 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 239: ... 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 EAS1SM9251 INSTALLING THE KICK IDLE GEAR 1 Install Kick idle gear 1 Washer 2 Circlip 3 TIP ...

Page 240: ...dal 1 2 Shift shaft 1 3 Oil seals 1 4 Collars 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 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 7 2 ft Ibf T R ...

Page 241: ... ty Remarks 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 7 2 ft Ibf T R ...

Page 242: ...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 EAS1SM9255 CHECKING THE SHIFT SHAFT 1 Check Shift shaft 1 Bends damage wear Replace Shift shaft spring 2 Damage wear Replace EAS1SM9256 CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1 Check Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 ...

Page 243: ...aged Take care not to give an impact to it when tightening the bolt EAS1SM9260 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 244: ... Apply the engine oil on the roller collar and shift shaft 2 Install Oil seal EAS1SM9262 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 T R 1 1 LT E E 1 2 3 4 New Shift pedal bolt 12 Nm 1 2 m kgf 8 7 ft lbf T R a 1 2 b ...

Page 245: ...r Refer to CLUTCH on page 5 35 Right crankcase cover Refer to CLUTCH on page 5 35 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 246: ...8 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 13 Balancer weight 2 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 New 6 12 11 7...

Page 247: ...rimary drive gear 1 Balancer shaft drive gear 2 Balancer weight gear 3 Wear damage Replace EAS1SM9266 CHECKING THE BALANCER 1 Check Balancer Crack damage Replace EAS1SM9267 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 248: ...ump cover 1 Oil pump cover screw 2 EAS1SM9269 INSTALLING THE OIL PUMP AND BALANC ER GEAR 1 Install Oil pump assembly 1 Oil pump assembly bolt 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...

Page 249: ... mark a on the balancer drive gear with the punched mark b on the balancer weight gear Install the balancer drive gear and crankshaft with the lower splines c aligning with each 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 1 2 LT 2 1 Balancer weight gear nut 50 Nm 5 0 m kgf 36 f...

Page 250: ...um plate a between the teeth of the balancer drive gear 9 and bal ancer weight gear 10 Install the conical washer with its convex sur face b outward Align the balancer flat portion c with the flat portion d Apply the engine oil to the contact surface and threaded portion of the balancer nut a 2 10 b 2 9 1 b 5 3 a 4 10 5 9 3 E c d 6 6 7 8 8 b ...

Page 251: ...coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Shift pedal 1 4 Left crankcase cover 1 5 Gaskets 1 6 Dowel pin 2 7 Holder 1 8 Stator assembly 1 9 Rotor 1 10 Woodruff key 1 For installation reverse the removal proce dure 1 10 2 4 7 5 8 3 9 6 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 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 65 Nm 6 5 m ...

Page 252: ... EAS1SM9274 INSTALLING THE AC MAGNETO 1 Install Stator 1 Screw stator 2 Crankshaft position sensor 3 Bolt crankshaft position sensor 4 Holder 5 Bolt holder 6 TIP Apply the sealant to the grommet of the AC magneto lead Tighten the stator screws using the T25 bit Pass the AC magneto lead a through the crankcase cover side Rotor puller 90890 04151 YM 04151 1 a b Screw stator 8 Nm 0 8 m kgf 5 8ft lbf ...

Page 253: ...otor align the keyway c of the rotor with the woodruff key 3 Install Washers Nut rotor 1 4 Install Dowel pin 1 Gasket left crankcase cover 2 Left crankcase cover 3 Lead holder 4 Bolt left crankcase cover 5 TIP Tighten the bolts in stages and in a crisscross pattern 5 Connect AC magneto lead Refer to CABLE ROUTING DIAGRAM on page 2 31 Nut rotor 65 Nm 6 5 m kgf 47 ft lbf Bolt left crankcase cover 10...

Page 254: ...fer to KICKSTATER on page 5 44 Segment Refer to SHIFT SHAFT on page 5 47 Stator Refer to AC MAGNETO on page 5 58 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 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...

Page 255: ...ueeze nozzle 1 For 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 256: ...s Transmission Refer to TRANSMISSION on page 5 69 Shift cam and shift fork Refer to TRANSMISSION on page 5 69 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 257: ...ions 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 EAS1SM9277 REMOVING THE CRANKCASE BEARING 1 Remove Bearing 1 TIP Remove the bearing from the crankcase by pressing its inner race Do not use the removed bearing EA...

Page 258: ...n 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 LOCTITE Yamaha bond No 1215 90890 8...

Page 259: ...ER SHAFT Removing the crankshaft assembly and balancer shaft Order Part name Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 61 Transmission Refer to TRANSMISSION on page 5 69 1 Balancer shaft 1 2 Crankshaft assembly 1 For installation reverse the removal proce dure M M 1 2 ...

Page 260: ...crankshaft slowly 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 YU A9642 ...

Page 261: ...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 EAS1SM9286 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 262: ...NE REMOVAL on page 5 1 Crankcase Separate Refer to CRANKCASE on page 5 61 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 Collars 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 263: ...ion of shift forks Remove the main axle and the drive axle all together by tapping the drive axle lightly with a soft hammer EAS1SM9289 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 264: ...e 3 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 EAS1SM9292 INSTALLING THE TRANSMISSION 1 Install 5th pinion gear 24T 1 3rd pinion gear 18T 2 Collar 3 4th pinion gear 18T 4 2nd pinion gear 16T 5 to th...

Page 265: ...ing 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 base grease on the oil seal lip When installing the collar into the crankcase pay careful attention to the crankcase oil seal lip 5 Install Main axle ...

Page 266: ... with the 4th wheel gear 5 and 3 R with the 5th wheel gear 7 on the drive axle Mesh the shift fork 2 C with the 3rd pinion 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 Transmissio...

Page 267: ...STEM RADIATOR 6 1 HANDLING NOTE 6 3 CHECKING THE RADIATOR 6 3 WATER PUMP 6 4 REMOVING THE OIL SEAL 6 6 CHECKING THE WATER PUMP 6 6 CHECKING THE BEARING 6 6 INSTALLING THE OIL SEAL 6 6 ASSEMBLING THE WATER PUMP 6 6 ...

Page 268: ... by reference to this manual It may lead to servicing trouble and mechanical damage EAS1SM9294 RADIATOR Removing the radiator Order Part name Q ty Remarks Coolant Drain Refer to CHANGING THE COOLANT on page 3 8 Seat Refer to GENERAL CHASSIS on page 4 1 Side cover left right Refer to GENERAL CHASSIS on page 4 1 Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK o...

Page 269: ...diator hose 4 1 7 Radiator pipe 2 1 8 Radiator breather hose 1 9 Left radiator 1 10 Radiator hose 1 1 11 Radiator pipe 1 1 12 Coolant temperature sensor 1 For installation reverse the removal proce dure Removing the radiator Order Part name Q ty Remarks 11 12 New New New LS LS ...

Page 270: ... ra diator cap EAS1SM9296 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 271: ...e oil Drain Refer to CHANGING THE ENGINE OIL on page 3 15 Right crankcase cover Refer to CLUTCH on page 5 35 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 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 272: ...11 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 New New New E 11 New E LS LS ...

Page 273: ...SM9301 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 EAS1SM9302 ASSEMBLING THE WATER PUMP 1 Install Impeller shaft assembly 1 Washer 2 Pin 3 Gear 4 Collar 5 Circlip...

Page 274: ... 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 275: ...7 2 INSTALLING THE FUEL PUMP 7 2 INSTALLING THE FUEL TANK 7 3 CHECKING THE FUEL PRESSURE 7 3 CHECKING THE DAMPER 7 4 CHECKING AND REPLACING THE PROTECTOR 7 4 THROTTLE BODY 7 5 CHECKING THE INJECTOR 7 8 CHECKING THE THROTTLE BODY 7 8 CHECKING THE THROTTLE BODY JOINT 7 8 ADJUSTING THE THROTTLE POSITION SENSOR 7 9 ...

Page 276: ...d mechanical damage EAS1SM9304 FUEL TANK Removing the fuel tank Order Part name Q ty Remarks Seat Refer to GENERAL CHASSIS on page 4 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 For installation reverse the removal proce dure 4 6 2 2 2 2 2 5 6 3 1 New 4 0 Nm 0 40 m kgf 2...

Page 277: ...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 EAS1SM9306 REMOVING T...

Page 278: ...ight Refer to GENERAL CHASSIS on page 4 1 EAS1SM9310 CHECKING THE FUEL PRESSURE 1 Check Fuel pressure a Remove the side cover left right the seat and the air scoop left right Refer to GENERAL CHASSIS on page 4 1 b Remove the fuel tank bolt and lift the fuel tank c Disconnect the fuel hose from the fuel pump Refer to REMOVING THE FUEL TANK on page 7 2 EWA WARNING Cover the fuel hose connection with...

Page 279: ...ith the arrow on each damper pointing outward Affix the damper 2 with its projection a facing the rear of the vehicle EAS1SM9312 CHECKING AND REPLACING THE PRO TECTOR 1 Check Protector 1 Wear damage Replace TIP Affix the protector as shown Fuel line pressure at idling 324 0 kPa 3 24 kgf cm2 47 0 psi 1 2 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 A Left B Right 1 1 A 0 mm...

Page 280: ...age 5 1 Ignition coil Refer to ENGINE REMOVAL on page 5 1 1 Intake air temperature sensor coupler 1 Disconnect 2 Air filter case 1 3 Fuel injector coupler 1 Disconnect 4 Intake air pressure sensor coupler 1 Disconnect 5 Throttle position sensor coupler 1 Disconnect 6 Throttle cable cover 1 7 Throttle cable 2 8 Fuel hose 1 9 Exhaust pipe bracket 1 2 1 6 10 11 9 8 3 7 5 4 3 5 Nm 0 35 m kgf 2 5 ft Ib...

Page 281: ...tion reverse the removal proce dure Removing the throttle body Order Part name Q ty Remarks 2 1 6 10 11 9 8 3 7 5 4 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 282: ...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 283: ...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 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 air...

Page 284: ... YAMAHA DIAGNOSTIC TOOL on page 8 12 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 285: ...WITCHES 8 38 CHECKING THE IGNITION SPARK GAP 8 41 CHECKING THE SPARK PLUG CAP 8 41 CHECKING THE IGNITION COIL 8 41 CHECKING THE CRANKSHAFT POSITION SENSOR 8 42 CHECKING THE ECU 8 43 CHECKING THE STATOR COIL 8 43 CHECKING THE RECTIFIER REGULATOR 8 43 CHECKING THE COOLANT TEMPERATURE SENSOR 8 44 CHECKING THE THROTTLE POSITION SENSOR 8 44 CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 8 45 CHECK...

Page 286: ......

Page 287: ... 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 288: ... L W B R B Y B Y B W R B R B B R B R G W P B P B B L B L B L G W Br W Br W B L B L B W Sb P Sb Sb P P P L L L Y Y B B Lg Gy Lg R R R R R R R O O O O W W W W W W W W R B B L Gy B Gy B R R B R Lg B W B R B Y B B B P Y B Sb Sb Y W P B Gy R B W B L L Y P B G W B R R B Lg Br W P O B Y Y B Sb R R B R B R B L Br W B L G W L Y B L B L P B L L L L R R R R R R R B B B B B B L B L B L B L B L B L ...

Page 289: ...IGNITION SYSTEM 8 3 1 Crankshaft position sensor 2 AC magneto 3 Rectifier regulator 4 Joint connector 5 Condenser 7 Engine stop switch 9 ECU 10 Ignition coil 11 Spark plug 18 Ignition coil sub lead ...

Page 290: ...lace the spark plug OK 3 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 41 OK The ignition system circuit is OK NG 4 Check the ignition coil Refer to CHECKING THE IGNI TION COIL on page 8 41 NG Replace the ignition coil OK 5 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 38 NG Replace the engine stop switch OK 6 Check the crankshaft position...

Page 291: ...IGNITION SYSTEM 8 5 8 Check the ignition system wire har ness Refer to CIRCUIT DIAGRAM on page 8 2 NG Repair or replace the wire harness OK Replace the ECU ...

Page 292: ...L W B R B Y B Y B W R B R B B R B R G W P B P B B L B L B L G W Br W Br W B L B L B W Sb P Sb Sb P P P L L L Y Y B B Lg Gy Lg R R R R R R R O O O O W W W W W W W W R B B L Gy B Gy B R R B R Lg B W B R B Y B B B P Y B Sb Sb Y W P B Gy R B W B L L Y P B G W B R R B Lg Br W P O B Y Y B Sb R R B R B R B L Br W B L G W L Y B L B L P B L L L L R R R R R R R B B B B B B L B L B L B L B L B L ...

Page 293: ...CHARGING SYSTEM 8 7 2 AC magneto 3 Rectifier regulator 4 Joint connector 5 Condenser ...

Page 294: ...m s wiring NG Reconnect OK 2 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 43 NG Replace the rectifier regulator OK 3 Check the stator coil Refer to CHECKING THE STA TOR COIL on page 8 43 NG Replace the stator coil OK 4 Check the charging system wire harness Refer to CIRCUIT DIAGRAM on page 8 6 NG Repair or replace the wire harness OK Replace the condenser ...

Page 295: ...CHARGING SYSTEM 8 9 ...

Page 296: ...Y W B Y L W B R B Y B Y B W R B R B B R B R G W P B P B B L B L B L G W Br W Br W B L B L B W Sb P Sb Sb P P P L L L Y Y B B Lg Gy Lg R R R R R R R O O O O W W W W W W W W R B B L Gy B Gy B R R B R Lg B W B R B Y B B B P Y B Sb Sb Y W P B Gy R B W B L L Y P B G W B R R B Lg Br W P O B Y Y B Sb R R B R B R B L Br W B L G W L Y B L B L P B L L L L R R R R R R R B B B B B B L B L B L B L B L B L ...

Page 297: ... Rectifier regulator 4 Joint connector 5 Condenser 7 Engine stop switch 8 Neutral switch 9 ECU electronic control unit 12 Fuel injector 13 Fuel pump 14 Intake air temperature sensor 15 Coolant temperature sensor 16 Throttle position sensor 17 Intake air temperature sensor ...

Page 298: ...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 299: ... the malfunction following the order given in the troubleshooting chart After the check and service of the malfunctioning part have been completed reset the Yamaha diag nostic tool display according to the Reinstatement method Fault code No To be displayed on the Yamaha diagnostic tool when the engine fails to work nor mally Diagnostic code No To be used when the diagnostic mode is active FI diagn...

Page 300: ...tion of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Crank the engine Fault code No is not dis played Repair is finished Fault code No is displayed Go to next order 3 Wire harness continuity Open or short circuit Re place the wire harness Between the crankshaft posi tion sensor coupler and ECU coupler gray gray black blue black blue Crank the engin...

Page 301: ...e pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Turn ON the switch on the FI diagnostic tool sub lead Fault code No is not dis played Repair is finished Fault code No is displayed Go to next order 3 Connection of sub wire har ness coupler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or broken terminals an...

Page 302: ... 7 Faulty ECU Replace the ECU Fault code 14 Symptom 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 pressure Procedure The atmospheric pressure is displayed on the Yamaha diagnostic tool Or der Probable cause of malfunc tion and check Mainten...

Page 303: ... Reinstatement method 1 Connection of throttle posi tion sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or broken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Turn ON the switch on the FI diagnostic tool sub lead Fault code No is not dis played Repair i...

Page 304: ...he sensor Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 7 9 Turn ON the switch on the FI diagnostic tool sub lead Fault code No is not dis played Repair is finished Fault code No is displayed Go to next order 6 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 8 44 Turn ON the switch on the...

Page 305: ...Check for looseness or pinching Check the mounted condition for correctness Improperly mounted sensor Remount or replace the sensor Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 7 9 Turn ON the switch on the FI diagnostic tool sub lead Fault code No is not dis played Repair is finished Fault code No is displayed Go to next order 2 Defective throttle position sensor Execute the diagnosti...

Page 306: ... and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Turn ON the switch on the FI diagnostic tool sub lead Fault code No is not dis played Repair is finished Fault code No is displayed Go to next order 3 Wire harness continuity Open or short circuit Re place the wire harness Betweencoolanttemperature sensor coupler and ECU cou ple...

Page 307: ...s and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Turn ON the switch on the FI diagnostic tool sub lead Fault code No is not dis played Repair is finished Fault code No is displayed Go to next order 3 Wire harness continuity Open or short circuit Re place the wire harness Between intake air tempera ture sensor coupler and ECU ...

Page 308: ...ed Raise the vehicle upright Turn ON the switch on the FI diagnostic tool sub lead Fault code No is not dis played Repair is finished Fault code No is displayed Go to next order 2 Mounted condition of ECU Check for looseness or pinching Check the mounted condition for correctness Improperly mounted ECU Remount the ECU Turn ON the switch on the FI diagnostic tool sub lead Fault code No is not dis p...

Page 309: ... the coupler and check the pins for bent or broken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness After starting the engine idle this and wait about 5 sec onds Fault code No is not dis played Repair is finished Fault code No is displayed Go to next order 3 Wire harness continuity Open or short circuit Re place the w...

Page 310: ... pins Improperly connected Connect the coupler secure ly or repair replace the wire harness After starting the engine idle this and wait about 5 sec onds Fault code No is not dis played Repair is finished Fault code No is displayed Go to next order 2 Defective injector Check the injector CHECKING THE FUEL IN JECTOR on page 8 47 After starting the engine idle this and wait about 5 sec onds Fault co...

Page 311: ... and ECU coupler red black red black Between injector coupler and rectifier regulator coupler red red After starting the engine idle this and wait about 5 sec onds Fault code No is not dis played Repair is finished Fault code No is displayed Go to next order 6 Faulty ECU Replace the ECU Fault code 41 Symptom ECU built in lean angle sensor malfunction Fail safe system Unable to start engine Able to...

Page 312: ...de 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 turn OFF the switch on the FI di agnostic tool sub lead and turn it ON again Memory not recovered Re place the ECU Turn ON the switch on the FI diagnostic tool sub lead Fault code No is not dis played Repair is finished Fault code number is dis played Repeat...

Page 313: ...I diagnostic tool sub lead and wait about 5 sec onds or more Fault code No is not dis played Repair is finished Fault code No is displayed Go to next order 2 Wire harness continuity Open or short circuit Re place the wire harness Between rectifier regulator and ECU coupler red red Between condenser and ECU coupler red red After starting the engine idle this turn OFF the switch on the FI diagnostic...

Page 314: ...ndition of the coupler Disconnect the coupler and check the pins for bent or broken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Turn ON the switch on the FI diagnostic tool sub lead Fault code No is not dis played Repair is finished Fault code No is displayed Go to next order 2 Connection of wire harness ECU coup...

Page 315: ...ad Fault code No is not dis played Repair is finished Fault code No is displayed Go to next order 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or broken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Turn ON the switch on the F...

Page 316: ...er 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or broken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Turn ON the switch on the FI diagnostic tool sub lead Fault code No is not dis played Repair is finished Fault code No is ...

Page 317: ...to next order 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or broken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Turn ON the switch on the FI diagnostic tool sub lead Fault code No is not dis played Repair is finished Fault ...

Page 318: ... Y L W B R B Y B Y B W R B R B B R B R G W P B P B B L B L B L G W Br W Br W B L B L B W Sb P Sb Sb P P P L L L Y Y B B Lg Gy Lg R R R R R R R O O O O W W W W W W W W R B B L Gy B Gy B R R B R Lg B W B R B Y B B B P Y B Sb Sb Y W P B Gy R B W B L L Y P B G W B R R B Lg Br W P O B Y Y B Sb R R B R B R B L Br W B L G W L Y B L B L P B L L L L R R R R R R R B B B B B B L B L B L B L B L B L ...

Page 319: ...FUEL PUMP SYSTEM 8 33 2 AC magneto 3 Rectifier regulator 4 Joint connector 5 Condenser 7 Engine stop switch 9 ECU electronic control unit 13 Fuel pump ...

Page 320: ...over 1 Check the fuel pump system wire harness connections NG Reconnect OK 2 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 38 NG Replace the engine stop switch OK 3 Check fuel pressure Refer to CHECKING THE FUEL PRESSURE on page 7 3 NG Replace the fuel pump OK 4 Check the fuel pump system wire harness Refer to CIRCUIT DIAGRAM on page 8 32 NG Repair or replace the wire harne...

Page 321: ...FUEL PUMP SYSTEM 8 35 ...

Page 322: ...ELECTRICAL COMPONENTS 8 36 EAS1SM9331 ELECTRICAL COMPONENTS EAS1SM9332 9 10 1 2 3 4 5 6 7 8 ...

Page 323: ...tifier regulator 2 Intake air pressure sensor 3 Throttle position sensor 4 Injector 5 Intake air temperature sensor 6 ECU electronic control unit 7 Intake air pressure sensor 8 Condenser 9 Neutral switch 10 Coolant temperature sensor ...

Page 324: ...ELECTRICAL COMPONENTS 8 38 EAS1SM9333 CHECKING THE SWITCHES Y W P Sb 1 2 P Sb Y W ...

Page 325: ...ELECTRICAL COMPONENTS 8 39 1 Engine stop switch 2 Neutral switch ...

Page 326: ...ocket 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 ...

Page 327: ...ead 2 Check Spark plug cap resistance Out of specification Replace a Connect the pocket tester 1k to the spark plug cap b Measure the spark plug cap resistance EAS1SM9336 CHECKING THE IGNITION COIL 1 Disconnect Ignition coil terminal from the sub wire harness Spark plug cap from the ignition coil 2 Check Primary coil resistance Out of specification Replace a Connect the pocket tester 1 to the igni...

Page 328: ...Crankshaft position sensor resistance Out of specification Replace a Connect the pocket tester 100 to the crankshaft position sensor coupler b Measure the crankshaft position sensor re sistance Secondary coil resistance 8 64 12 96 k Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Ignition coil terminal 1 1 Negative tester probe Spark plug lead 2 Crankshaft position ...

Page 329: ...l coupler b Measure the stator coil resistance EAS1SM9340 CHECKING THE RECTIFIER REGULATOR 1 Check Rectifier regulator output voltage Out of specification Replace a Set the digital tachometer to the ignition coil b Connect the pocket tester 20 VDC to the rectifier regulator coupler c Start the engine and let it run at about 5000 r min d Measure the output voltage Stator coil resistance 0 624 0 936...

Page 330: ...als 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 continuity at the temperatures indicated in the table EAS1SM9342 CHECKING THE THROTTLE POSITION SENSOR 1 Remove Throttle position sensor from the throttle body EWA WARNING Handle the throttle position s...

Page 331: ...n 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 to the test harness S pressure sensor 3P c Start the engine d Measure the throttle position sensor input voltage Resistance 6 30 k Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positiv...

Page 332: ...he 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 EAS1SM9346 CHECKING THE NEUTRAL SWITCH 1 Remove Neutral switch 2 Check Neutral switch Out of specification Replace Intake air pressure sensor output voltage 3 57 3 71 V at 101 3 kPa Pock...

Page 333: ...terminal a Continuity Positive tester probe Pink 2 Negative tester probe Sensor terminal b Continuity Positive tester probe Pink 2 Negative tester probe Sensor terminal c Continuity Positive tester probe Yellow white 3 Negative tester probe Sensor terminal d Continuity Positive tester probe Yellow white 3 Negative tester probe Sensor terminal e Continuity Positive tester probe Yellow white 3 Negat...

Page 334: ...ELECTRICAL COMPONENTS 8 48 ...

Page 335: ... AND HIGH SPEED PERFORMANCE 9 2 SHIFTING IS DIFFICULT 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 CLUTCH SLIPS 9 2 CLUTCH DRAGS 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FRONT FORK OIL LEAKING 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 LIST OF SELF DIAGNOSTIC AND FAIL SAFE ACTIONS 9 4 ...

Page 336: ...taminated 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 Ignit...

Page 337: ...rks Worn shift fork 3 Shift drum Incorrect axial play Worn shift drum groove 4 Transmission Worn gear dog EAS1SM9356 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 EAS1SM9357 CLUTCH DRAGS Engine 1 Clutch Unevenly tensioned clutch springs Warp...

Page 338: ...t Damaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring EAS1SM9362 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 EAS1SM9363 UNSTABLE HANDLING Chassis 1 Handlebar Bent or improperly installed handlebar 2 Steering head components Im...

Page 339: ...hort circuit detected 8 20 22 Intake air temperature sensor open or short circuit detected 8 21 30 The vehicle has overturned 8 22 33 Ignition coil open or short circuit detected in the primary lead of the ignition coil 8 23 39 Injector open or short circuit detected 8 24 41 ECU built in lean angle sensor malfunction 8 25 44 EEPROM fault code No an error is detected while reading or writing on EEP...

Page 340: ...temper ature Compare the actually mea sured coolant temperature with the Yamaha diagnostic tool display value 08 Lean angle sensor Upright Overturn Displays the output voltage 1 0 V 4 0 V Remove the ECU and in cline it 45 or more 09 Monitor voltage Displays the voltage of the external battery connected to the Yamaha diagnostic tool Approximately 12 0 V 21 Neutral switch Gear in neutral Gear not in...

Page 341: ...tting map 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 version number Displays a program version No Diag nostic code No ITEM Actuation Procedure 30 Ignition coil Actuates the ignition coil five times at one second inter vals WARNING on the Yamaha d...

Page 342: ...LIST OF SELF DIAGNOSTIC AND FAIL SAFE ACTIONS 9 7 ...

Page 343: ... FORK SETTING 10 2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL 10 2 SETTING OF SPRING AFTER REPLACEMENT 10 3 FRONT FORK SETTING PARTS 10 3 REAR SUSPENSION SETTING 10 3 CHOOSING SET LENGTH 10 3 SETTING OF SPRING AFTER REPLACEMENT 10 4 REAR SHOCK ABSORBER SETTING PARTS 10 5 SUSPENSION SETTING FRONT FORK 10 6 SUSPENSION SETTING REAR SHOCK ABSORBER 10 7 ...

Page 344: ...hile making notes of lap times to find the best balance then determine the second ary reduction ratio If a course has a long straight portion where a machine 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 ...

Page 345: ...NT AND CHARACTERIS TICS OF FORK OIL 083Damping characteristic near the final stroke can be changed by changing the fork oil amount EWA1DX4001 WARNING Adjust the oil amount in 5 cm3 0 2 US oz 0 2 Imp oz increments or decrements Too small oil amount causes the front fork to produce a noise at full rebound or the rider to feel some pressure on his hands or body Alternatively too large oil amount will...

Page 346: ... contact with the road surface or in a vibrating handlebar EAS1SM9373 FRONT FORK SETTING PARTS Front fork spring 1 Except for USA and CAN TIP The I D mark slits a is proved on the end of the spring EAS1SM9374 REAR SUSPENSION SETTING The rear shock absorber setting should be made depending on the rider s feeling of an ac tual run and the circuit conditions The rear suspension setting includes the f...

Page 347: ...he set length sunken length 90 100 mm 3 5 3 9 in and set it 1 Use of soft spring Adjust to decrease rebound damping force to compensate for less spring load Run with the rebound damping force adjuster one or two clicks turned out and readjust it to suit your preference 2 Use of stiff spring Adjust to increase rebound damping force to compensate for greater spring load Run with the rebound damping ...

Page 348: ...rt number I D Mark SOFT 52 1SL 22212 40 Blue Yellow B11 22212 00 Yellow STD 54 1SL 22212 60 Blue Pink B11 22212 10 Yellow STIFF 56 1SL 22212 20 Blue White B11 22212 20 Yellow 58 1SL 22212 00 Blue Silver B11 22212 30 Yellow 60 1SL 22212 80 Blue Brown B11 22212 40 Yellow Spring preload adjusting positions Minimum Position in which the spring is turned in 1 5 mm 0 06 in from its free length Standard ...

Page 349: ...oticeable 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 350: ...unt 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 cm...

Page 351: ...ssenger 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 s...

Page 352: ...11 Spark plug 12 Fuel injector 13 Fuel pump 14 Intake air temperature sensor 15 Coolant temperature sensor 16 Throttle position sensor 17 Intake air pressure sensor 18 Ignition coil sub lead EAS1SM9382 COLOR CODE B Black Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue Y Yellow B L Black Blue B R Black Red B W Black White B Y Black Yellow Br W Brown White G W Green White L W Blue Wh...

Page 353: ......

Page 354: ...PRINTED IN JAPAN E PRINTED ON RECYCLED PAPER ...

Page 355: ...Y Y B B Lg Gy Lg R R R R R R R O O O O W W W W W W W W R B B L Gy B Gy B R R B R Lg B W B R B Y B B B P Y B Sb Sb Y W P B Gy R B WB L L Y P B G W B R R B Lg Br W P O B Y Y B Sb R R B R B R B L Br W B L G W L Y B L B L P B L L L L R R R R R R R B B B B B B L B L B L B L B L B L YZ250F YZ250FG 2016 WIRING DIAGRAM YZ250F YZ250FG 2016 SCHÉMA DE CÂBLAGE YZ250F YZ250FG 2016 SCHALTPLAN 1SM 28199 80_W D i...

Page 356: ...ON OFF YZ250F YZ250FG 2016 WIRING DIAGRAM YZ250F YZ250FG 2016 SCHÉMA DE CÂBLAGE YZ250F YZ250FG 2016 SCHALTPLAN 1SM 28199 80_W D indd 2 2015 03 11 14 07 38 ...

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