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Yamaha YZ250FX 2021, Owner'S Service Manual

The Yamaha YZ250FX 2021 is a high-performance off-road motorcycle designed for thrill-seekers. Ensuring a smooth ride and ultimate control, this beastly machine is built to conquer any rugged terrain. To further enhance your riding experience, don't forget to download the free Owner's Manual, available at manualshive.com.

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CHECKING THE STARTER CLUTCH .....................................................5-42
INSTALLING THE STARTER CLUTCH ...................................................5-42

ELECTRIC STARTER

.....................................................................................5-44

CHECKING THE STARTER MOTOR ......................................................5-46
ASSEMBLING THE STARTER MOTOR ..................................................5-46

CLUTCH

..........................................................................................................5-48

REMOVING THE CLUTCH ......................................................................5-51
CHECKING THE FRICTION PLATES......................................................5-51
CHECKING THE CLUTCH PLATES ........................................................5-51
CHECKING THE CLUTCH SPRINGS......................................................5-51
CHECKING THE CLUTCH HOUSING .....................................................5-51
CHECKING THE CLUTCH BOSS ............................................................5-52
CHECKING THE PRESSURE PLATE .....................................................5-52
CHECKING THE PUSH LEVER SHAFT ..................................................5-52
CHECKING THE PUSH RODS ................................................................5-52
CHECKING THE PRIMARY DRIVE GEAR ..............................................5-52
CHECKING THE PRIMARY DRIVEN GEAR............................................5-52
INSTALLING THE CLUTCH .....................................................................5-52

SHIFT SHAFT

.................................................................................................5-56

REMOVING THE SEGMENT ...................................................................5-57
CHECKING THE SHIFT SHAFT ..............................................................5-57
CHECKING THE STOPPER LEVER........................................................5-57
INSTALLING THE SHIFT SHAFT ............................................................5-57

OIL PUMP

.......................................................................................................5-60

REMOVING THE BALANCER..................................................................5-62
CHECKING THE OIL PUMP ....................................................................5-62
ASSEMBLING THE OIL PUMP ................................................................5-62
INSTALLING THE OIL PUMP ..................................................................5-63

CRANKCASE

.................................................................................................5-66

DISASSEMBLING THE CRANKCASE.....................................................5-68
CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE)...................5-68
CHECKING THE CRANKCASE ...............................................................5-68
ASSEMBLING THE CRANKCASE...........................................................5-69

CRANKSHAFT AND BALANCER SHAFT

.....................................................5-70

REMOVING THE CRANKSHAFT.............................................................5-71
CHECKING THE CRANKSHAFT .............................................................5-71
INSTALLING THE CRANKSHAFT ...........................................................5-72

TRANSMISSION

.............................................................................................5-73

REMOVING THE TRANSMISSION..........................................................5-74
CHECKING THE SHIFT FORKS..............................................................5-74
CHECKING THE SHIFT DRUM ASSEMBLY ...........................................5-74
CHECKING THE TRANSMISSION ..........................................................5-74
INSTALLING THE TRANSMISSION ........................................................5-75

Summary of Contents for YZ250FX 2021

Page 1: ...Read this manual carefully before operating this vehicle 2021 OWNER S SERVICE MANUAL YZ250FX YZ250FXM LIT 11626 34 54 BAJ 2819U 11 ...

Page 2: ...s and lead which are known to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehicle ...

Page 3: ... user s authority to operate the equipment This transmitter must not be co located or operated in conjunction with any other antenna or transmitter This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment and meets the FCC radio frequency RF Exposure Guidelines This equipment has very low levels of RF energy that is deemed to comply without maximum permi...

Page 4: ...MANUAL 2021 by Yamaha Motor Corporation U S A First edition July 2020 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited P N LIT 11626 34 54 ...

Page 5: ...quested not to undertake inspection adjustment disassem bly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage WARNING EWA20270 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU H...

Page 6: ...EAM20162 YAMAHA MOTOR CORPORATION U S A YZ MOTORCYCLE LIMITED WARRANTY ...

Page 7: ...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 removal or a disassembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction chart 6 accompanies the exploded diagram providing the order of jobs the names of parts the notes in j...

Page 8: ...ITION 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 Apply 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 9: ...GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 TUNING 10 EAM10003 TABLE OF CONTENTS ...

Page 10: ......

Page 11: ...ION 1 9 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 9 REPLACEMENT PARTS 1 9 GASKETS OIL SEALS AND O RINGS 1 9 LOCK WASHERS PLATES AND COTTER PINS 1 10 BEARINGS AND OIL SEALS 1 10 CIRCLIPS 1 10 BASIC SERVICE INFORMATION 1 11 ELECTRICAL SYSTEM 1 11 SPECIAL TOOLS 1 15 INSTRUMENT AND CONTROL FUNCTIONS 1 22 WARNING LIGHTS 1 22 ENGINE STOP SWITCH 1 22 START SWITCH 1 22 MODE SWITCH 1 22 SHIFT PEDAL 1 23 FR...

Page 12: ...1 26 BREAK IN PROCEDURES 1 26 ENGINE STARTING PRECAUTION 1 26 MAINTENANCE AFTER BREAK IN 1 27 MAJOR MAINTENANCE 1 27 AIR FILTER MAINTENANCE 1 27 TORQUE CHECK POINTS 1 28 MOTORCYCLE CARE AND STORAGE 1 30 CARE 1 30 STORAGE 1 31 ...

Page 13: ...re riding 2 This motorcycle is designed to carry the oper ator only No passengers 3 The failure of motorists to detect and recog nize motorcycles in traffic is the predominat ing cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspic uous appears to be very effective in reducing the chance of this type...

Page 14: ... Many companies with no connection to Yamaha manufacture parts and accessories or offer oth er modifications for Yamaha vehicles Yamaha is not in a position to test the products that these aftermarket companies produce Therefore Yamaha can neither endorse nor recommend the use of accessories not sold by Yamaha or modifications not specifically recommended by Yamaha even if sold and installed by a ...

Page 15: ...he fuel cock if equipped is in the OFF position and that there are no fuel leaks 3 Point the front wheel straight ahead on the trailer or in the truck bed and choke it in a rail to prevent movement 4 Shift the transmission in gear for models with a manual transmission 5 Secure the motorcycle with tie downs or suit able straps that are attached to solid parts of the motorcycle such as the frame or ...

Page 16: ...asoline only 3FB 2415E 02 4AA 22259 80 WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open 17D 2812P 00 For use only on a closed course in sanctioned competition This motorcycle does not meet EPA noise and emissions standards and is not for general off road recreational riding ...

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

Page 18: ...er for positive identi fication of the model you own 2 If your vehicle is stolen the authorities will need the number to search for and identify your vehicle EAM30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the frame EAM30003 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the lower left side of the engine 1 1 1 1 ...

Page 19: ...in a closed area The exhaust gas is poisonous Never let flames near the servicing area NOTICE ECA26050 This application is designed for adjusting the settings on a standard vehicle In case the engine specifications muffler com pression ratio etc have been changed the performance may not match to the actu al settings Do not run the engine with the smartphone carried with you Otherwise the smart pho...

Page 20: ... or mobile phones in close proximity of the CCU The CCU is in contact with or covered by a metallic object Other vehicles equipped with a CCU are nearby In such situations move the CCU to another location and perform the operation again 1 Turn on the smartphone 2 For two minutes after the start switch is pressed or while the engine is running the CCU is activated input the CCU serial num ber into ...

Page 21: ...red to the chassis paint and plating will be damaged Therefore rinse it out with water in good time WARNING EWA18970 Coolant is potentially harmful and should be handled with special care If it enters your eyes wash it away with wa ter enough and then get medical attention If it splashes on your skin or clothes quick ly wash it away with water and then with soapy water If it is swallowed immediate...

Page 22: ...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 NOTICE ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfac es EAM30014 CIRCLIPS When assembling parts always use new cir clips During installation of a circlip make sure that the edge 2 of the cir...

Page 23: ...ly dangerous TIP If a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct battery terminals Reversing the bat tery lead connections could damage the electrical components NOTICE ECA16771 When connecting the battery leads to the battery be sure to connect the positive bat ter...

Page 24: ...lti function display goes off Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never insert the tester probes into the cou pler terminal slots Always insert the probes from the opposite end a of the coupler tak ing care not to loosen or damage the leads NOTICE ECA16640 For waterproof couplers never insert t...

Page 25: ...oth sections of the connec tor securely and then disconnect the con nector 2 Check Lead Coupler Connector Moisture Dry with compressed air Rust stains Connect and disconnect sev eral times 3 Check All connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up After disassembling or assembling a coupler pull on the leads to make sure that they are in stal...

Page 26: ...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 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 ...

Page 27: ...starting with YM YU or ACC For others use tool number starting with 90890 Tool name Tool No Illustration Reference pages Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 1 14 5 46 8 48 8 49 8 49 8 49 8 51 8 52 8 54 8 54 8 54 8 54 8 55 8 56 8 56 8 57 8 57 8 58 8 58 8 59 Thickness gauge 90890 03268 Feeler gauge set YU 26900 9 3 6 5 51 Valve lapper ø14 90890 04101...

Page 28: ...2 3 27 4 54 Spoke nipple wrench 6 7 90890 01521 Spoke nipple wrench 6 7 YM 01521 3 33 Timing light 90890 03141 Timing light YU 03141 3 35 Cap bolt ring wrench 90890 01501 Cap bolt ring wrench YM 01501 4 42 4 42 4 43 4 46 4 49 4 51 Cap bolt wrench 90890 01500 Cap bolt wrench YM 01500 4 43 4 46 Fork seal driver 90890 01502 Fork seal driver 48 YM A0948 4 47 4 48 Tool name Tool No Illustration Referen...

Page 29: ... spring compressor attachment 90890 04108 Valve spring compressor adapter 22 mm YM 04108 5 27 5 31 Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 5 29 Valve guide installer ø5 90890 04098 Valve guide installer 5 0 mm YM 04098 5 29 Valve guide reamer ø5 90890 04099 Valve guide reamer 5 0 mm YM 04099 5 29 Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 0411...

Page 30: ... reamer 4 5 mm YM 04118 5 29 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 34 Rotor puller 90890 04151 Rotor puller YM 04151 5 39 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 42 5 43 Universal clutch holder 90890 04086 Universal clutch holder YM 91042 5 51 5 53 Tool name Tool No Illustration Reference pages YU 01304 ...

Page 31: ...shaft installer pot 90890 01274 Installing pot YU 90058 5 72 Crankshaft installer bolt 90890 01275 Bolt YU 90060 5 72 Adapter M12 90890 01278 Adapter 3 YU 90063 5 72 Spacer crankshaft installer 90890 04081 Pot spacer YM 91044 5 72 Tool name Tool No Illustration Reference pages YU 90058 YU 90059 YM 91044 ...

Page 32: ...r YU 33984 6 4 6 4 Pressure gauge 90890 03153 Pressure gauge YU 03153 7 8 Fuel pressure adapter 90890 03186 Fuel pressure adapter YM 03186 7 8 Lithium battery charger 90890 05376 Lithium battery charger DBY ACC51 70 02 8 51 8 51 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 53 Tool name Tool No Illustration Reference pages YU 24460 A YU 33984 ...

Page 33: ...SPECIAL TOOLS 1 21 Test harness S pressure sensor 3P 90890 03207 Test harness S pressure sensor 3P YU 03207 8 57 Tool name Tool No Illustration Reference pages ...

Page 34: ...lectrical circuit of the warning light can be checked by pushing the start switch The warn ing light should come on for a few seconds and then go off If the warning light does not come on initially when the start switch is pushed or if the warning light remains on have a Yamaha dealer check the electrical circuit EAM30182 ENGINE STOP SWITCH The engine stop switch 1 is located on the left handlebar...

Page 35: ...ING EWA18980 Never apply additional force to the sides tand Hold up the sidestand before starting out EAM30189 REAR BRAKE PEDAL The rear brake pedal 1 is in the right of the chassis Press down on the brake pedal to acti vate the rear brake EAM30444 STARTER KNOB Starting a cold engine requires a larger amount of intake air which is supplied by the starter knob 1 Pushing the knob toward a turns ON t...

Page 36: ...ver 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 and then use both hands to lift it up towards the rear of the vehicle Install the fuel tank cap cover after placing the bands 3 all the way in under the seat a a b b 1 1 1 2 3 a a a 2 2 ...

Page 37: ...s EAM30196 STARTING A COLD ENGINE 1 Press the shift pedal to neutral 2 Push the starter knob 1 completely TIP When the ambient temperature is 15 C 59 F or below use the starter knob Do not operate the throttle grip when operating the starter knob 3 Start the engine by pushing the start switch If the engine fails to start when using the start switch release it wait a few seconds and then try again ...

Page 38: ...seness oil leaks or other problems Thorough checks and ad justments are required in particular for stretch of cables free play of the brake stretch of the drive chain looseness of the spoke and so on NOTICE ECA25821 After a break in or after each race always check the points shown in TORQUE CHECK POINTS for tightening torques and retighten them Also when the following parts are replaced a break in...

Page 39: ...s and nuts Check for looseness in mounted areas of parts as well as engine mounting bolts and engine brackets 2 For the chassis Check welds and mounted areas of the frame the swingarm the link the bracket and so on for looseness and cracks Wheel s Check the wheel for runout Check the spoke for looseness Brake s Check the brake disc mounting bolt for loose ness Check that the reservoir contains the...

Page 40: ...e Link to rear shock absorber Link to swingarm Mounting of rear shock absorber Rear shock absorber and frame Mounting of swingarm Tightening of pivot shaft Wheel s Mounting of wheel Front Tightening of wheel axle Tightening of axle holder Tightening of spoke nipple Rear Tightening of wheel axle Wheel to rear wheel sprocket Tightening of spoke nipple Brake s Front Brake caliper to front fork Brake ...

Page 41: ...ft pedal Shift pedal to shift shaft Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake disc cover Tightening of rear brake caliper cover ...

Page 42: ...ly rinse the area off with water immediately dry it and then apply a corrosion protec tion spray Improper cleaning can damage plastic parts such as cowlings panels wind shields headlight lenses meter lenses etc and the mufflers Use only a soft clean cloth or sponge with water to clean plastic However if the plastic parts cannot be thor oughly cleaned with water diluted mild de tergent with water m...

Page 43: ...and nickel plated sur faces 5 Use spray oil as a universal cleaner to re move any remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry completely before storing or covering it WARNING EWA19050 Contaminants on the brakes or tires can cause loss of control Make sure that there is no oil or wax on the brakes or tires If necessary clean ...

Page 44: ...rk plug and then install the spark plug and the spark plug cap WARNING To pre vent damage or injury from sparking make sure to ground the spark plug electrodes while turning the engine over 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so tha...

Page 45: ...CATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 5 ELECTRICAL SPECIFICATIONS 2 8 TIGHTENING TORQUES 2 9 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 9 ENGINE TIGHTENING TORQUES 2 10 CHASSIS TIGHTENING TORQUES 2 13 CABLE ROUTING DIAGRAM 2 17 ...

Page 46: ...odel Model BAJ5 Dimensions Overall length 2175 mm 85 6 in Overall width 825 mm 32 5 in Overall height 1270 mm 50 0 in Seat height 955 mm 37 6 in Wheelbase 1480 mm 58 3 in Ground clearance 320 mm 12 60 in Weight Curb weight 111 kg 245 lb Riding capacity 1 person ...

Page 47: ...l filter removal 0 75 L 0 79 US qt 0 66 Imp qt Quantity disassembled 0 95 L 1 00 US qt 0 84 Imp qt Oil filter Oil filter type Cartridge Cooling system Coolant quantity Radiator including all routes 0 93 L 0 98 US qt 0 82 Imp qt Radiator cap valve opening pressure 107 9 137 3 kPa 1 08 1 37 kgf cm 15 6 19 9 psi Spark plug s Manufacturer model NGK LMAR8E J Spark plug gap 0 6 0 7 mm 0 024 0 028 in Cyl...

Page 48: ...Diameter 76 955 76 970 mm 3 0297 3 0303 in Measuring point from piston skirt bottom 4 0 mm 0 16 in Piston pin bore inside diameter limit 16 043 mm 0 6316 in Piston pin outside diameter limit 15 971 mm 0 6288 in Piston pin to piston pin bore clearance 0 002 0 022 mm 0 0001 0 0009 in Piston ring Top ring End gap limit 0 50 mm 0 0197 in Ring side clearance 0 030 0 065 mm 0 0012 0 0026 in Side clearan...

Page 49: ...ndary reduction ratio 3 923 51 13 Final drive Chain Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil Fuel pump Pump type Electrical Maximum consumption amperage 2 4 A Fuel injector Resistance 12 0 Throttle body ID mark B7B1 Idling condition Engine idling speed 1900 2100 r min Coolant temperature 70 80 C 158 176 F Fuel li...

Page 50: ... measured on cold tires Front 100 kPa 1 00 kgf cm 15 psi Rear 100 kPa 1 00 kgf cm 15 psi Front brake Type Hydraulic single disc brake Brake disc thickness limit 2 5 mm 0 10 in Brake disc runout limit as measured on wheel 0 15 mm 0 0059 in Brake pad lining thickness limit 1 0 mm 0 04 in Master cylinder inside diameter 9 52 mm 0 37 in Caliper cylinder inside diameter Left 22 65 mm 22 65 mm 0 89 in 0...

Page 51: ...g adjustment Click Adjustment value from the start position Soft 20 Adjustment value from the start position STD 12 Adjustment value from the start position Hard 0 Rear suspension Type Swingarm link suspension Spring Coil spring Shock absorber Gas hydraulic damper Wheel travel 317 mm 12 5 in Spring preload Adjusting system Mechanical adjustable type Adjustment value Soft 1 5 mm 0 06 in Adjustment ...

Page 52: ...n damping Unit for adjustment Click Adjustment value from the start position Soft 20 Adjustment value from the start position STD 9 Adjustment value from the start position Hard 0 Drive chain Size 520 Chain type Sealed type Number of links 114 Drive chain slack Maintenance stand 50 0 60 0 mm 1 97 2 36 in 15 link length limit 239 3 mm 9 42 in ...

Page 53: ...el BR98 Voltage capacity 12 V 2 4 Ah 5 HR Indicator light Fuel level warning light 1 7 W Engine trouble warning light 1 7 W Starter motor Brush overall length 7 0 mm 0 28 in Brush overall length limit 3 5 mm 0 14 in Brush spring force 3 92 5 88 N 400 600 gf 14 11 21 17 oz Mica undercut depth 1 50 mm 0 06 in Fuel injection sensor Crankshaft position sensor resistance 228 342 Intake air temperature ...

Page 54: ...To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques N m kgf m lb ft 10 mm 6 mm 6 0 6...

Page 55: ... 28 lb ft Timing chain guide stopper plate exhaust side M6 1 10 N m 1 0 kgf m 7 4 lb ft Timing chain tensioner cap bolt M6 1 6 N m 0 6 kgf m 4 4 lb ft Timing chain tensioner bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Coolant drain bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft Radiator hose clamp screw M6 8 1 5 N m 0 15 kgf m 1 1 lb ft Radiator bolt M6 4 10 N m 1 0 kgf m 7 4 lb ft Radiator pipe joint bolt M6 1 10...

Page 56: ... cover plate screw M8 4 22 N m 2 2 kgf m 16 lb ft Bearing plate cover bolt left side of the drive axle M6 2 12 N m 1 2 kgf m 8 9 lb ft Plate bolt M6 4 12 N m 1 2 kgf m 8 9 lb ft Clutch cover bolt M6 6 10 N m 1 0 kgf m 7 4 lb ft Crankcase cover bolt left M6 7 10 N m 1 0 kgf m 7 4 lb ft Crankcase cover bolt right M6 9 10 N m 1 0 kgf m 7 4 lb ft Oil filter element cover bolt M6 2 10 N m 1 0 kgf m 7 4...

Page 57: ...il to the bolt threads and seats as well as to both sides of the lock washers Crankshaft position sensor bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Stator coil assembly lead holder bolt M5 1 8 N m 0 8 kgf m 5 9 lb ft Coolant temperature sensor M10 1 15 N m 1 5 kgf m 11 lb ft Gear position switch bolt M5 2 3 5 N m 0 35 kgf m 2 6 lb ft Rectifier regulator bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft ECU bolt M5 2 ...

Page 58: ...5 2 1 3 N m 0 13 kgf m 0 95 lb ft Front fork protector bolt M6 6 5 N m 0 5 kgf m 3 7 lb ft Brake hose holder bolt M6 2 9 N m 0 9 kgf m 6 6 lb ft Throttle grip cap screw M5 2 3 8 N m 0 38 kgf m 2 8 lb ft Clutch lever holder bolt M6 2 5 N m 0 5 kgf m 3 7 lb ft Clutch lever nut M6 1 4 0 N m 0 40 kgf m 3 0 lb ft Clutch lever position locknut M5 1 4 8 N m 0 48 kgf m 3 5 lb ft Front brake master cylinde...

Page 59: ... brake disc cover M6 2 10 N m 1 0 kgf m 7 4 lb ft Rear brake caliper protector bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Engine mounting bolt upper side M10 2 45 N m 4 5 kgf m 33 lb ft Engine mounting bolt front side M10 1 55 N m 5 5 kgf m 41 lb ft Engine mounting bolt lower side M10 1 53 N m 5 3 kgf m 39 lb ft Engine bracket bolt upper side M8 4 34 N m 3 4 kgf m 25 lb ft Engine bracket bolt front side ...

Page 60: ...m 0 7 kgf m 5 2 lb ft Screw fuel inlet pipe M5 2 3 5 N m 0 35 kgf m 2 6 lb ft Bolt fuel tank cap cover M6 2 4 0 N m 0 40 kgf m 3 0 lb ft Seat set bracket screw M6 1 7 N m 0 7 kgf m 5 2 lb ft Seat bolt M8 2 22 N m 2 2 kgf m 16 lb ft Side cover bolt left M6 2 7 N m 0 7 kgf m 5 2 lb ft Side cover bolt right M6 2 7 N m 0 7 kgf m 5 2 lb ft Air scoop bolt frame M6 2 7 N m 0 7 kgf m 5 2 lb ft Air scoop b...

Page 61: ...TIGHTENING TORQUES 2 16 ...

Page 62: ...CABLE ROUTING DIAGRAM 2 17 EAM20152 CABLE ROUTING DIAGRAM Frame and engine left side view ...

Page 63: ...to the hole in the cylinder head When doing so make sure that the lead is not twisted I Route the starter motor lead through the inside of the engine mounting bracket boss and the front side area than the back end of the engine mounting bracket boss J Route the gear position switch lead along the crankcase without slack K Pass the gear position switch lead to the inside of the lower engine bracket...

Page 64: ...CABLE ROUTING DIAGRAM 2 19 Frame and engine right side view ...

Page 65: ...aint mark on the hose with the convex mark on the 3 way joint and then install the cylinder head breather hoses I Route the radiator breather hose outside the breather hose When doing so cross them at the bottom of the radiator J After connecting the throttle position sensor coupler attach the cover K Route the fuel hose in front of the fuel pump L After connecting the fuel pump coupler attach the...

Page 66: ...CABLE ROUTING DIAGRAM 2 21 Handlebar front view ...

Page 67: ... stop switch lead and mode switch lead to the handlebar using the plastic locking tie Do not cut the end of the plastic locking tie D 30 50 E Vertical direction of vehicle F Pass the engine stop switch lead and mode switch lead between the frame and the cable guide G Pass the warning light lead through the cable guide H Pass the front brake hose through the front side of the number plate I Pass th...

Page 68: ...CABLE ROUTING DIAGRAM 2 23 Frame and engine top view ...

Page 69: ...harness and start switch lead by the clamp and insert the clamp pro jection into the hole in the sheet metal of the radiator The direction of the clamp lock por tion does not matter It is allowed to run the leads near the radiator cap on the inside B No pinch is allowed the leads between the tank rail and the air filter joint C Insert the projection of the main harness into the hole in the frame D...

Page 70: ...CABLE ROUTING DIAGRAM 2 25 Frame and battery top view ...

Page 71: ... relay terminal B Install the clamp wire harness to the hole of the battery bracket C After connecting the negative battery coupler position to the right side of the starter relay D The position of the starter motor lead and negative battery lead does not matter E Pass the negative battery lead through lower side of the cross member F After connecting the positive battery lead in the direction sho...

Page 72: ...CABLE ROUTING DIAGRAM 2 27 Rear brake right side view ...

Page 73: ...ke hose holders C Route the rear brake hose so that it is not bent as shown by the double dash line D Route the rear brake hose and spring so that they do not interfere with each other E Make sure that the rear brake hose is not excessively twisted F Make sure that the metal part of the rear brake hose contacts the stopper of the rear brake master cylinder assembly G Install the rear brake hose so...

Page 74: ...CABLE ROUTING DIAGRAM 2 29 ...

Page 75: ...G THE COOLANT LEVEL 3 20 CHECKING THE COOLING SYSTEM 3 21 CHANGING THE COOLANT 3 21 CHASSIS 3 23 ADJUSTING THE FRONT DISC BRAKE 3 23 ADJUSTING THE REAR DISC BRAKE 3 23 CHECKING THE BRAKE FLUID LEVEL 3 24 CHECKING THE FRONT BRAKE PADS 3 24 CHECKING THE REAR BRAKE PADS 3 24 CHECKING THE FRONT BRAKE HOSE 3 24 CHECKING THE REAR BRAKE HOSE 3 25 CHECKING THE BRAKE OPERATION 3 25 BLEEDING THE HYDRAULIC B...

Page 76: ...AND LUBRICATING THE CABLES 3 34 LUBRICATING THE BRAKE LEVER 3 34 LUBRICATING THE CLUTCH LEVER 3 34 LUBRICATING THE PEDAL 3 34 CHECKING THE SIDESTAND 3 34 LUBRICATING THE SIDESTAND 3 34 ELECTRICAL SYSTEM 3 35 CHECKING AND CHARGING THE BATTERY 3 35 CHECKING THE FUSES 3 35 CHECKING THE IGNITION TIMING 3 35 ...

Page 77: ...ce about 12 5 hours As required 1 Valve Check the valve clearances Check the valve seats and the valve faces for wear Replace 2 Valve spring Check the free length Replace 3 Valve lifter Check for scratches and wear Replace 4 Camshaft Inspect the camshaft surface Inspect the decompression sys tem Replace 5 Timing chain Check for damage and sticking Replace the timing chain and tim ing chain tension...

Page 78: ...st leaks and tightening torques Clean Replace fiver When the exhaust sound becomes louder or when a perfor mance drop is felt 21 Crankshaft Inspect and clean 22 Throttle body Inspect 23 Air filter Clean and lubricate Replace 24 Breather system Check ventilation hose for cracks or damage and drain any depos its Replace Every two years 25 Spark plug Check the electrodes and the ter minals for wear R...

Page 79: ...eck for tightening torques Replace pads Replace brake fluid Every one year 35 Swingarm Inspect lube and retighten 36 Relay arm connect ing rod Inspect lube and retighten 37 Sidestand Lubricate 38 Steering head Inspect free play and retighten Check for tightening torques Clean and lube After rain ride Replace bearings 39 Tire wheels Inspect air pressure wheel run out tire wear and spoke loose ness ...

Page 80: ...for dirt and wear 44 Levers Adjust clutch lever free play 45 Brake pedal footrest Lubricate 46 Outside nuts and bolts Retighten 47 Battery Check terminal for looseness and corrosion No Item Routine After break in Every race about 2 5 hours Every third race about 7 5 hours Every fifth race about 12 5 hours As required ...

Page 81: ...23 3 23 3 24 3 24 3 24 3 24 3 25 3 25 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 26 4 67 4 67 4 68 4 68 4 68 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play 3 33 3 33 3 33 3 33 Steering Check that the handlebar can be turned smoothly and have no excessive play 3 27 Front forks and rear sh...

Page 82: ... Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 ECU 2 Remove Spark plug Cylinder head cover Refer to CAMSHAFT on page 5 14 3 Remove Timing mark accessing screw 1 Crankshaft end accessing screw 2 O ring 4 Check Valve clearance Out of specification Regulate a Turn the crankshaft counterclockwise with a wrench b Align the top dead center TDC mark a ...

Page 83: ...oper valve clearance from the adjusting pad se lection table TIP There are 25 types of adjusting pads ranging from 1 20 mm 0 0472 in to 2 40 mm 0 0945 in in increments of 0 05 mm 0 0020 in The field where the number on the originally in stalled adjusting pad and the measured valve clearance intersect shows the adjusting pad number to replace Example Pad number 148 Rounded value 150 e Install the n...

Page 84: ...eir numbers facing upward f Install the camshafts exhaust and intake Refer to CAMSHAFT on page 5 14 g Measure the valve clearance again h If the valve clearance is out of specifica tion repeat adjusting the valve clearance until it is within specification M E 4 5 ...

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

Page 86: ...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 87: ... 3 Install Digital tachometer TIP Get the high tension cord 1 of the ignition coil pinched in the detector a of the digital tachom eter 4 Measure Engine idling speed Out of specification Regulate 5 Adjust Engine idling speed a Turn the idle screw 1 to make an adjust ment EAM30475 CHECKING THE THROTTLE GRIP TIP Prior to adjusting throttle grip free play the en gine idling speed should be adjusted 1...

Page 88: ... Remove Holder Spark plug cap Spark plug Refer to CAMSHAFT on page 5 14 NOTICE ECA24410 In order not to allow the dirt accumulated around the spark plug to drop from the spark plug hole into the cylinder clean it before re moving the spark plug 3 Check Spark plug type Wrong type Replace 4 Check Electrode 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Replace the spark plug Normal ...

Page 89: ...al to enter the crankcase EAM30225 CHANGING THE ENGINE OIL Stand the vehicle upright on a level surface 1 Start the engine warm this up for several minutes and then stop the engine and wait about 5 minutes TIP This model is equipped with an engine auto stop system The engine stops automatically if left idling for 7 minutes If the engine stops push the start switch to restart the engine 2 Place an ...

Page 90: ... a Slightly loosen the oil pressure check bolt 1 WARNING EWA19120 When the engine is started with the check bolt removed oil will spout therefore al ways loosen it before the checkup b Start the engine and keep it idling until oil starts to seep from the oil pressure check bolt WARNING EWA19130 Always keep the engine idling speed during the checkup without increasing the engine speed Oil filter el...

Page 91: ...e Clutch cable side a Slide the clutch cable cover b Loosen the locknut 1 c Turn the adjuster 2 until the specified clutch lever free play is obtained d Tighten the locknut 1 e Return the clutch cable cover to its original position EAM30370 ADJUSTING THE CLUTCH LEVER POSITION 1 Adjust Clutch lever position a Loosen the locknut 1 and use the adjuster 2 to adjust the clutch lever position a as desir...

Page 92: ...into a plastic bag and drip the filter oil into the bag b With the element inside the bag rub it thoroughly so that the element is evenly permeated with the oil c Wrap the element in a clean cloth rub the element gently and wipe off any excess oil TIP The element should be permeated with oil so that it is wet but not dripping When replacing the element permeate the el ement in oil by using the sam...

Page 93: ...ocat ed on the left and right sides of the air filter case cover with the projections d on the air scoop and then install the air filter case cover 10 Install Fuel tank cap cover EAM30335 CHECKING THE THROTTLE BODY JOINT 1 Check Throttle body joint 1 Crack damage Replace EAM30222 CHECKING THE FUEL LINE 1 Remove Seat Side cover left right Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fu...

Page 94: ...0221 CHECKING THE EXHAUST SYSTEM 1 Remove Exhaust pipe 1 Exhaust pipe 2 Refer to ENGINE REMOVAL on page 5 6 2 Remove Exhaust pipe protector 3 Check Exhaust pipe 1 Exhaust pipe 2 Silencer Crack damage Replace 4 Check Silencer fiber Damage Replace 5 Replace Silencer fiber a Remove the bolts 1 and silencer body 2 NOTICE ECA25800 Do not hit the silencer stay a as it may do damage to the silencer TIP R...

Page 95: ...the silencer body by using a flat board 11 h Install the fiber insert 12 to the inner pipe i Install the fiber insert 13 to the inside of the silencer cap 14 j Install the silencer cap 15 and rivet 16 TIP Apply heat resistant sealant to the areas e shown making sure that there are no gaps in the beads of sealant Take care not to allow the fiber out of place when installing the silencer body 17 Sil...

Page 96: ...ng sound has stopped press down on the radi ator cap and turn it counterclockwise to re move 1 Stand the vehicle upright on a level surface 2 Remove Radiator cap 1 3 Check Coolant level Maximum level a or below Add coolant up to the maximum level NOTICE ECA24260 Adding water instead of coolant lowers the antifreeze content If therefore water is used instead of coolant check and if nec essary adjus...

Page 97: ...e hissing sound has stopped press down on the radi ator cap and turn it counterclockwise to re move 1 Place a container under the engine 2 Remove Coolant drain bolt 1 3 Remove Radiator cap Slowly loosen the radiator cap to drain cool ant TIP When the radiator cap is loosened coolant will gush out transversely therefore bring the con tainer near to the outlet 4 Thoroughly flush the cooling system w...

Page 98: ... used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 7 Install Radiator cap 8 Start the engine warm this up for several minutes stop it and then wait for it to cool down 9 Check Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 20 ...

Page 99: ... will consid erably reduce braking performance NOTICE ECA13490 After adjusting the brake lever position make sure there is no brake drag 4 Install Brake lever cover EAM30480 ADJUSTING THE REAR DISC BRAKE 1 Check Brake pedal position a distance from the top of the rider footrest to the top of the brake pedal Out of specification Regulate 2 Adjust Brake pedal position a Loosen the locknut 1 b Turn t...

Page 100: ...hen refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately EAM30231 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pad...

Page 101: ...master cylinder cap Reservoir diaphragm Reservoir float front brake Protector rear brake TIP Be careful not to spill any brake fluid or allow the reservoir to overflow Make sure that there is enough brake fluid be fore applying the brake Ignoring this precau tion could allow air to enter the brake system considerably lengthening the bleeding proce dure If bleeding is difficult it may be necessary ...

Page 102: ...off the ground WARNING EWA13120 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 37 lbf 4 Check Drive chain slack a Out of specification Regulate TIP Measure drive chain slack between the drive chain guide and the b...

Page 103: ...ng 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 34 Upper bracket Refer to STEERING HEAD on page 4 53 4 Adjust Steering head a Remove the washer 1 b After loosening the ring nut 2 with a steering nut wrench 3 tighten it to the specified torque TIP Set the torque wrench at a rig...

Page 104: ...fork leg Oil leaks between inner tube and outer tube Replace the oil seal 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Unsmooth operation Correct or replace Refer to FRONT FORK on page 4 40 5 Check Protector guide 1 Out of specification Replace TIP The protector guide re...

Page 105: ...Adjust Compression damping a Turn the adjuster 1 in the direction of a or b to make an adjustment TIP Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small dif ferences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check t...

Page 106: ...tion Rear suspension link smooth action Sit astride the seat and shake your body up and down several times to check whether the rear shock absorber assembly operates smoothly Unsmooth operation Correct or replace Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 57 EAM30242 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Use a maintenance stand to raise the rear wheel off the ground WARNING EWA13120 Sec...

Page 107: ... necessary Compression damping for fast compres sion damping NOTICE ECA24370 Do not turn the adjuster forcibly beyond its adjusting range 1 Adjust Compression damping for fast compression damping a Turn the adjuster 1 in the direction of a or b to make an adjustment Spring preload adjusting positions Minimum Position in which the spring is turned in 1 5 mm 0 06 in from its free length Standard Pos...

Page 108: ... clicks of each damping force adjusting mechanism and to modify the specifications as necessary EAM30240 CHECKING THE SWINGARM OPERATION 1 Check Swingarm smooth action Swingarm free play Refer to SWINGARM on page 4 63 EAM30500 LUBRICATING THE SWINGARM PIVOT 1 Lubricate Oil seal Collar Refer to INSTALLING THE SWINGARM on page 4 64 EAM30501 CHECKING THE CONNECTING ARM AND RELAY ARM Refer to CHECKING...

Page 109: ...ill sound flat 2 Tighten Spoke with a spoke nipple wrench 1 TIP Do not give a half turn 180 or more for one tightening Make sure that tightening after a break in is done until the initial looseness in nipples disap pears Make sure that tightening is done in stages not at a time EAM30245 CHECKING THE WHEELS 1 Check Wheel Damage out of round Replace WARNING EWA13260 Never attempt to make any repairs...

Page 110: ... LUBRICATING THE BRAKE LEVER 1 Lubricate the pivoting points and metal to metal moving parts of the following parts Brake lever EAM30503 LUBRICATING THE CLUTCH LEVER 1 Lubricate the pivoting points and metal to metal moving parts of the following parts Clutch lever EAM30250 LUBRICATING THE PEDAL 1 Lubricate the pivoting point and metal to met al moving parts of the pedal EAM30504 CHECKING THE SIDE...

Page 111: ...he high tension cord 3 3 Adjust Engine idling speed Refer to CHECKING THE ENGINE IDLING SPEED on page 3 11 4 Check Ignition timing Check whether the alignment mark a on the left crankcase cover is within the firing range b on the generator rotor Incorrect firing range Check generator ro tor and crankshaft position sensor 5 Install Timing mark accessing screw Timing light 90890 03141 Timing light Y...

Page 112: ...ELECTRICAL SYSTEM 3 36 ...

Page 113: ...LACING THE FRONT BRAKE PADS 4 17 REMOVING THE FRONT BRAKE CALIPER 4 19 DISASSEMBLING THE FRONT BRAKE CALIPER 4 19 CHECKING THE FRONT BRAKE CALIPER 4 19 ASSEMBLING THE FRONT BRAKE CALIPER 4 19 INSTALLING THE FRONT BRAKE CALIPER 4 20 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 21 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 21 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 21 INSTALLING THE FRONT BRAKE M...

Page 114: ...ING THE STEERING HEAD 4 54 REAR SHOCK ABSORBER ASSEMBLY 4 57 HANDLING THE REAR SHOCK ABSORBER 4 60 DISPOSING OF A REAR SHOCK ABSORBER 4 60 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 60 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 60 CHECKING THE CONNECTING ARM AND RELAY ARM 4 61 INSTALLING THE RELAY ARM 4 61 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 61 SWINGARM 4 63 REMOVING THE SWINGARM 4 64 ...

Page 115: ...ks 1 Seat 1 2 Side cover left 1 3 Negative battery lead 1 Disconnect 4 Positive battery lead 1 Disconnect 5 Battery band 1 6 Battery 1 7 Cover 1 8 Starter relay 1 9 Main relay 1 10 CCU Communication Control Unit 1 6 7 9 1 2 8 5 3 4 10 7 N m 0 7 kgf m 5 2 lb ft 22 N m 2 2 kgf m 16 lb ft 22 N m 2 2 kgf m 16 lb ft ...

Page 116: ... to CLEANING THE AIR FILTER ELE MENT on page 3 15 2 Air scoop left 1 3 Air scoop right 1 4 Side cover right 1 5 Number plate 1 6 Rear fender 1 6 4 1 3 5 2 1 7 N m 0 7 kgf m 5 2 lb ft 16 N m 1 6 kgf m 12 lb ft 1 3 N m 0 13 kgf m 0 95 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft ...

Page 117: ...utch cable 2 from the cable guide b on the number plate The projection c on the lower bracket is in serted into the number plate Remove the number plate by pulling it off the projection When installing the number plate insert the projection on the number plate into the hole in the upper side of the band EAM30458 INSTALLING THE AIR SCOOP 1 Install Air scoop left 1 right TIP After inserting the proj...

Page 118: ...own EAM30460 INSTALLING THE SIDE COVER 1 Install Side cover right 1 TIP Install the side cover right by sliding it as shown and secure it with the bolts to fit it to the vehicle Install the side cover right so that the rib is lo cated under the rib of the rear fender a Projection b Slot a Projection b Slot c Rib side cover d Rib rear fender 1 1 b b a a a a b b 1 1 c c d d ...

Page 119: ... to raise the front wheel off the ground 1 Front wheel axle pinch bolt 4 Loosen 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Oil seal 2 7 Bearing 2 8 Brake disc 1 5 7 6 5 6 7 6 8 2 1 1 3 4 12 N m 1 2 kgf m 8 9 lb ft 21 N m 2 1 kgf m 15 lb ft 115 N m 11 5 kgf m 85 lb ft 21 N m 2 1 kgf m 15 lb ft ...

Page 120: ...ax le 2 Check Tire Front wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 33 and CHECKING THE WHEELS on page 3 33 3 Check Spoke Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 33 4 Tighten Spoke Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 33 TIP After tightening the spokes measure the wheel runout 5 Measure Radial wheel runout a Lateral wheel runout b Out of specific...

Page 121: ...l 2 Install Brake disc Brake disc bolt TIP Tighten the bolts in stages and in a crisscross pattern 3 Install Collar 1 TIP Apply the lithium soap based grease on the oil seal lip EAM30021 INSTALLING THE FRONT WHEEL 1 Install Front wheel TIP Install the brake disc 1 between the brake pads 2 correctly 2 Install Front wheel axle 1 TIP Apply the lithium soap based grease to the front wheel axle 3 Tight...

Page 122: ...el axle nut push down hard on the handlebar s several times and check if the front fork rebounds smoothly 4 Tighten Front wheel axle pinch bolt 1 Front wheel axle nut 115 N m 11 5 kgf m 85 lb ft Front wheel axle pinch bolt 21 N m 2 1 kgf m 15 lb ft T R 1 1 T R 1 1 ...

Page 123: ...the ground 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 10 Brake disc 1 2 5 7 9 6 4 6 1 6 3 LS 8 9 10 7 5 3 21 N m 2 1 kgf m 15 lb ft 12 N m 1 2 kgf m 8 9 lb ft 50 N m 5 0 kgf m 37 lb ft 21 N m 2 1 kgf m 15 lb ft 125 N m 12 5 kgf m 92 lb ft 6 ...

Page 124: ... 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 33 and CHECKING THE WHEELS on page 3 33 3 Check Spoke Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 33 4 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 6 EAM30025 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1 Check Rear wheel sprocket More than 1 4 tooth wear ...

Page 125: ... the bearing by pressing its outer race parallel TIP Use a socket 6 that matches the diameter of the bearing outer race and that of the oil seal 2 Install Brake disc Brake disc bolt TIP Tighten the bolts in stages and in a crisscross pattern 3 Install Collar 1 TIP Apply the lithium soap based grease on the oil seal lip EAM30027 INSTALLING THE REAR WHEEL 1 Install Rear wheel TIP Install the brake d...

Page 126: ...l 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 DRIVE CHAIN SLACK on page 3 26 6 Tighten Rear wheel axle nut 1 Locknut 2 Drive chain slack Maintenance stand 50 0 60 0 mm 1 97 2 36 in 1 2 LS 1 2 3 Wheel axle nut 125 N m 12 5 kgf m 92 lb ft Locknut 21 N m 2 1 kgf m 15 lb ft ...

Page 127: ... SYSTEM on page 3 25 1 Union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Brake pad pin plug 1 5 Brake pad pin 1 6 Brake pad 2 7 Brake pad spring 1 8 Front brake caliper assembly 1 9 Front brake caliper bracket 1 3 9 1 2 8 4 5 7 6 2 5 N m 0 25 kgf m 1 8 lb ft 6 N m 0 6 kgf m 4 4 lb ft 28 N m 2 8 kgf m 21 lb ft 30 N m 3 0 kgf m 22 lb ft 17 N m 1 7 kgf m 13 lb ft ...

Page 128: ...sassembling the front brake caliper Order Job Parts to remove 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 1 2 3 4 S S S 6 N m 0 6 kgf m 4 4 lb ft ...

Page 129: ...ion bolt 1 3 Copper washer 2 4 Front brake hose 1 5 Brake master cylinder reservoir cap 1 6 Brake master cylinder reservoir diaphragm 1 7 Front brake master cylinder float 1 8 Front brake master cylinder holder 1 9 Front brake master cylinder 1 5 6 7 2 3 4 8 9 1 30 N m 3 0 kgf m 22 lb ft 6 N m 0 6 kgf m 4 4 lb ft 6 N m 0 6 kgf m 4 4 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 9 N m 0 9 kgf m 6 6 lb ft ...

Page 130: ...RONT BRAKE 4 16 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Push rod 1 2 Dust boot 1 3 Circlip 1 4 Washer 1 5 Brake master cylinder kit 1 BF 5 4 3 2 1 S New New ...

Page 131: ...minutes and get im mediate medical attention EAM30029 CHECKING THE FRONT BRAKE DISC 1 Check Front brake disc Damage galling Replace 2 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace 3 Measure Brake disc runout Out of specification Replace the brake disc a Place the vehicle on a maintenance stand so that the front wheel is ele...

Page 132: ...reuse the drained brake fluid c Tighten the bleed screw d Install the brake pads 3 and the pad pin TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point e Install the brake caliper 4 and tighten the pad pin 5 f Install the pad pin plug 6 Brake pad lining thickness limit 1 0 mm 0 04 in 4 a 2 1 Bleed screw 6 N m 0 6 kgf m ...

Page 133: ... the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston dust seal and the brake caliper piston seal EAM30032 CHECKING THE FRONT BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scrat...

Page 134: ...h 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 WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may res...

Page 135: ...inder 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 hose Cracks damage wear Replace EAM30038 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER WARNING EWA13520 Before installation all internal brake ...

Page 136: ...pper bolt then the lower bolt 2 Install Copper washer Brake hose Union bolt WARNING EWA13531 Proper brake hose routing is essential to in sure safe vehicle operation NOTICE ECA24470 During installation bring the brake hose into contact with the brake master cylinder pro jection a and make its bent portion b face downward TIP Turn the handlebar toward right and left to make sure that the brake hose...

Page 137: ... Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 5 Check Brake fluid level The minimum level mark or below Add Refer to CHECKING THE BRAKE F...

Page 138: ...1 3 Copper washer 2 4 Rear brake hose 1 5 Brake pad pin plug 1 6 Brake pad pin 1 7 Rear brake pad assembly 2 8 Rear brake caliper bracket 1 9 Brake pad spring 2 10 Rear brake disc cover 1 11 Rear brake caliper assembly 1 2 3 4 11 5 6 7 9 1 8 9 10 S 7 N m 0 7 kgf m 5 2 lb ft 7 30 N m 3 0 kgf m 22 lb ft 17 N m 1 7 kgf m 13 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf ...

Page 139: ...isassembling the rear brake caliper Order Job Parts to remove 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 1 2 3 4 S BF 6 N m 0 6 kgf m 4 4 lb ft ...

Page 140: ...page 3 25 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Split pin 1 5 Washer 1 6 Pin 1 7 Brake master cylinder reservoir cap 1 8 Brake master cylinder reservoir diaphragm plate 1 9 Brake master cylinder reservoir diaphragm 1 10 Rear brake master cylinder 1 1 2 3 4 7 5 8 6 9 10 30 N m 3 0 kgf m 22 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft ...

Page 141: ...REAR BRAKE 4 27 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Push rod 1 4 Brake master cylinder kit 1 4 3 2 1 BF S New New ...

Page 142: ...Flush with water for 15 minutes and get im mediate medical attention EAM30041 CHECKING THE REAR BRAKE DISC 1 Check Brake disc Damage galling Replace 2 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISC on page 4 17 3 Measure Brake disc runout Out of specification Replace the brake disc Refe...

Page 143: ...ll the brake pads 3 and the pad pin 4 TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point e Install the brake caliper 5 and the rear wheel 6 Refer to REAR WHEEL on page 4 9 f Tighten the pad pin 7 g Install the pad pin plug 8 and the protector 9 Brake pad lining thickness limit 1 0 mm 0 04 in Bleed screw 6 N m 0 6 kgf ...

Page 144: ... the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston dust seal and the brake caliper piston seal EAM30044 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scratc...

Page 145: ...ate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA135...

Page 146: ...Replace 4 Check Brake hose Cracks damage wear Replace EAM30050 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents 1 Wash the brake master cylinder and the brake master cylinder kit with brake fluid 2 Install Primary cylinder cup ...

Page 147: ...ausing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA24510 Br...

Page 148: ...able pull 1 Disconnect 8 Throttle cable return 1 Disconnect 9 Right grip 1 10 Tube guide 1 11 Start switch 1 12 Left grip 1 13 Upper handlebar holder 2 14 Handlebar 1 15 Lower handlebar holder 2 16 Damper 4 12 9 8 7 5 4 1 2 3 10 11 13 14 15 16 16 6 4 0 N m 0 40 kgf m 3 0 lb ft 0 5 N m 0 05 kgf m 0 37 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 5 N m 0 5 kgf m 3 7 lb ft 28 N m 2 8 kgf m 21 lb ft 40 N m 4 0 ...

Page 149: ...over 2 Install Damper 1 Lower handlebar holder 2 temporarily Handlebar 3 Upper handlebar holder 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 re verse direction allow the front to rear offset amount of the handlebar position to be changed The upper handlebar holders s...

Page 150: ...mode switch 2 should be installed according to the dimensions shown Pass the engine stop switch lead through the middle of the clutch lever holder a 3 4 4 Lower handlebar holder nut 40 N m 4 0 kgf m 30 lb ft Clutch lever holder bolt 5 N m 0 5 kgf m 3 7 lb ft Clutch lever nut 4 0 N m 0 40 kgf m 3 0 lb ft Engine stop switch screw 0 5 N m 0 05 kgf m 0 37 lb ft Screw mode switch 1 3 N m 0 13 kgf m 0 9...

Page 151: ... ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 15 9 Install Right grip 1 Collar 2 Apply adhesive to the tube guide 3 TIP Before applying the adhesive wipe off grease or oil on the tube guide surface a with a lac quer thinner Install the grip to the tube guide so that the grip match mark b and tube guide slot c form the angle as shown 10 Install Rubber cover 1 Throttle grip 2 TIP Apply the lithium...

Page 152: ... master cylinder assembly 2 Front brake master cylinder holder 3 Bolt brake master cylinder holder 4 Clamp 5 TIP Install the brake master cylinder holder with the UP mark facing up Install in order for the top of the front brake master cylinder assembly to be level First tighten the upper bolt then the lower bolt 15 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 11 Sc...

Page 153: ...HANDLEBAR 4 39 Throttle grip free play 3 0 6 0 mm 0 12 0 24 in ...

Page 154: ...r to FRONT WHEEL on page 4 5 Front brake caliper Refer to FRONT BRAKE on page 4 13 Number plate Refer to GENERAL CHASSIS on page 4 1 1 Protector 1 2 Upper bracket pinch bolt 2 Loosen 3 Damper assembly 1 Loosen 4 Lower bracket pinch bolt 2 Loosen 5 Front fork leg 1 5 N m 0 5 kgf m 3 7 lb ft 5 N m 0 5 kgf m 3 7 lb ft 9 N m 0 9 kgf m 6 6 lb ft 21 N m 2 1 kgf m 15 lb ft 1 5 4 2 3 3 2 2 3 ...

Page 155: ... 1 7 Inner tube 1 8 Outer tube 1 9 Piston metal 1 10 Protector guide 1 11 Slide metal 1 12 Washer 1 13 Oil seal 1 14 Base valve 1 15 Damper assembly 1 16 Upper spring seat 1 15 2 8 1 7 9 14 New New New New New LT 1 3 N m 0 13 kgf m 0 95 lb ft 28 N m 2 8 kgf m 21 lb ft 29 N m 2 9 kgf m 21 lb ft 30 N m 3 0 kgf m 22 lb ft 55 N m 5 5 kgf m 41 lb ft 16 3 LS 10 12 13 5 4 New 11 New New 6 ...

Page 156: ...nt fork leg EAM30056 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 NOTICE ECA24520 Do not remove the locknut as the damper rod may go into the damper assembly and not be taken out 3 Remove Dust seal 1 Stoppe...

Page 157: ...gerously weaken it 2 Check Outer tube Scratches wear damage Replace 3 Measure Fork spring free length a Out of specification Replace 4 Check Damper assembly 1 Bend damage Replace O ring 2 Wear damage Replace NOTICE ECA14200 The front fork leg has a built in damper ad justing rod and a very sophisticated inter nal construction which are particularly sensitive to foreign material When disassembling ...

Page 158: ... tube bushing Slide metal Oil seal Copper washer Before assembling the front fork leg make sure that all of the components are clean 1 Stretch the damper assembly fully 2 Fill Damper assembly NOTICE ECA24530 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 for eign mate...

Page 159: ...tion Unless the damping force adjuster is fully loos ened correct damping characteristic cannot 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 releasing the damper rod pressure 8 Check Damper assembly Not fully stretched Repeat the steps 1 to 7 9 Tighten Base valve 1 Standard oil...

Page 160: ...he damper assem bly 12 Allow the overflowing oil to escape at the hole a in the damper assembly TIP The overflow measures about 10 cm 0 34 US oz 0 35 Imp oz 13 Check Damper assembly smooth movement Tightness binding rough spots Repeat the steps 1 to 12 14 Install Dust seal 1 Scraper 2 Stopper ring 3 Oil seal 4 Washer 5 Slide metal 6 to the inner tube 7 NOTICE ECA24550 Make sure that the numbered s...

Page 161: ...the oil seal lip 15 Install Piston metal 1 TIP Install the piston metal onto the slot on inner tube 16 Install Outer tube 1 to the inner tube 2 17 Install Slide metal 1 Washer 2 to the outer tube TIP Press the slide metal into the outer tube with fork seal driver 3 18 Install Oil seal 1 TIP Using a fork seal driver 2 press the oil seal in until the stopper ring groove fully appears LS 1 2 3 4 5 6 ...

Page 162: ...s Repeat the steps 14 to 20 22 Measure Distance a Out of specification Turn into the locknut 23 Install Upper spring seat 1 Fork spring 2 to the damper assembly 3 TIP Install the upper spring seat with its larger dia end a facing the fork spring 24 Install Damper assembly 1 to the inner tube 2 Fork seal driver 90890 01502 Fork seal driver 48 YM A0948 New Distance a 16 mm 0 63 in or more Between th...

Page 163: ...r 2 Adjuster 3 to the damper assembly 4 TIP While compressing the inner tube 5 set the cap bolt ring wrench 7 between the inner tube and locknut 6 Fully finger tighten the adjuster onto the damp er assembly 27 Measure Gap a between the adjuster 1 and the locknut 2 Out of specification Retighten and readjust the locknut TIP If it is installed with a gap out of specification correct damping force ca...

Page 164: ...tighten the damper assembly 32 Install Protector guide 1 EAM30059 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 Adjuster 55 N m 5 5 kgf m 41 lb ft LOCTITE Recommended oil Yamaha Suspension Oil S1...

Page 165: ... 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 Cap bolt ring wrench 90890 01501 Cap bolt ring wrench YM 01501 Front fork top end standard a 5 mm 0 20 in Upper bracket pinch bolt 21 N m 2 1 kgf m 15 lb ft Lower bracket...

Page 166: ...FRONT FORK 4 52 1 ...

Page 167: ...ront fender 1 2 Steering stem nut 1 3 Front fork leg 2 Refer to FRONT FORK on page 4 40 4 Warning light 1 5 Upper bracket 1 6 Steering ring nut 1 7 Lower bracket 1 8 Bearing race cover 1 9 Upper bearing 1 10 Lower bearing 1 11 Bearing race 2 2 5 4 6 8 3 1 7 9 10 11 LS LS LS 21 N m 2 1 kgf m 15 lb ft 21 N m 2 1 kgf m 15 lb ft 10 N m 1 0 kgf m 7 4 lb ft 145 N m 14 5 kgf m 107 lb ft 9 N m 0 9 kgf m 6...

Page 168: ...tting Replace 3 Replace Bearing Bearing race a Remove the bearing race from the steer ing head pipe with a long rod 1 and a hammer b Remove the bearing race from the lower bracket with a chisel 2 and a hammer c Install a new bearing race NOTICE ECA14270 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...

Page 169: ...steering ring 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 27 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 th...

Page 170: ...steering ring nut little by lit tle 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 WARNING EWA19330 Tighten the lower bracket to specified torque If torqued too much it may cause the front fork to malfunction Steering stem nut 145 N m 14 5 kgf m 107 lb ft Front fork top end standard a 5 mm 0 20 in T R a Upper bracket pinch bolt 21 N m 2 1 kgf m 15 l...

Page 171: ...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 Collar 2 11 Bushing 1 12 Bearing 1 New 2 4 5 7 6 8 3 9 9 10 10 12 1 M 56 N m 5 6 kgf m 41 lb ft 53 N m ...

Page 172: ...ber assembly Order Job Parts to remove Q ty Remarks 13 Collar 2 14 O ring 2 15 Dust seal 2 16 Bushing 1 17 Stopper ring 1 M 56 N m 5 6 kgf m 41 lb ft 53 N m 5 3 kgf m 39 lb ft 10 N m 1 0 kgf m 7 4 lb ft M M M LS M LS New 13 16 15 14 15 New 14 New New 13 17 New New ...

Page 173: ... Disassembling the relay arm Order Job Parts to remove Q ty Remarks 1 Relay arm 1 2 Connecting arm 1 3 Collar 3 4 Oil seal 6 5 Washer 8 6 Bearing 6 5 3 5 6 1 6 5 4 5 5 4 6 6 5 3 2 4 6 6 3 4 4 M M M M M M M 80 N m 8 0 kgf m 59 lb ft 4 5 ...

Page 174: ...ber be sure to extract the nitrogen gas from valve 1 WARNING EWA19340 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 procedure EAM30065 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Use a maintenance stand to raise the rear wheel off t...

Page 175: ...aring outer race because it will wear the rear shock ab sorber surface on which the bearing is press fitted 2 Lubricate O ring 3 Install Bushing Stopper ring into the rear shock absorber assembly up per side TIP Install the bushing parallel until the stopper ring groove appears by pressing its outer race After installing the stopper ring push back the bushing until it contacts the stopper ring 4 I...

Page 176: ...bsorber assembly lower bolts connecting arm bolt relay arm side and relay arm bolt swingarm side from the left 7 Tighten Rear shock absorber assembly upper nut Connecting arm nut frame side Connecting arm nut relay arm side Relay arm nut swingarm side Rear shock absorber assembly lower nut Installed depth a 4 25 mm 0 17 in Recommended lubricant Molybdenum disulfide grease Rear shock absorber assem...

Page 177: ...wheel off the ground Brake hose holder Refer to REAR BRAKE on page 4 24 Rear brake caliper Refer to REAR BRAKE on page 4 24 Bolt brake pedal Drive chain 1 Collar 2 2 Oil seal 2 3 Thrust bearing 2 4 Bushing 2 5 Oil seal 2 6 Bearing 4 1 2 3 6 4 6 4 1 3 6 2 5 4 0 N m 0 40 kgf m 3 0 lb ft 70 N m 7 0 kgf m 52 lb ft 7 N m 0 7 kgf m 5 2 lb ft ...

Page 178: ...garm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash with kerosene Pivot shaft Bushing Collar Bearing 4 Check Oil seal Damage Replace Bearing Bushing Free play exists unsmooth revolution rust Replace bearing and bushing as a set EAM30074 INSTALLING THE SWINGARM 1 Lubricate B...

Page 179: ...SWINGARM 4 65 4 Install Rear wheel Refer to REAR WHEEL on page 4 9 5 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 26 Drive chain slack Maintenance stand 50 0 60 0 mm 1 97 2 36 in ...

Page 180: ...Order Job Parts to remove Q ty Remarks Drive sprocket Refer to ENGINE REMOVAL on page 5 6 1 Drive chain 1 2 Drive sprocket cover 1 3 Bracket 1 4 Drive sprocket nut 1 5 Lock washer 1 6 Drive sprocket 1 1 2 3 4 5 6 7 N m 0 7 kgf m 5 2 lb ft 75 N m 7 5 kgf m 55 lb ft ...

Page 181: ...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 different location each time 2 Check Drive chain Stiffness Clean lubricate or replace 3 Clean Drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and re move any remaining dirt c Remove the drive ...

Page 182: ...ROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 10 EAM30079 INSTALLING THE DRIVE CHAIN 1 Install Drive chain NOTICE ECA17410 Be sure to put on safety goggles when work ing TIP Install the master link with the drive chain cut rivet tool Use goods on the market a When press fitting the master link plate 1 make sure the space a between the end of the connecting pin 2 and the ...

Page 183: ...prockets this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 26 NOTICE ECA24590 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its Recommended lubricant Chain ...

Page 184: ...CHAIN DRIVE 4 70 ...

Page 185: ...R HEAD 5 23 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 5 23 CHECKING THE CYLINDER HEAD 5 23 INSTALLING THE CYLINDER HEAD 5 23 VALVES AND VALVE SPRINGS 5 26 REMOVING THE VALVES 5 27 CHECKING THE VALVES AND VALVE GUIDES 5 28 CHECKING THE VALVE SEATS 5 29 CHECKING THE VALVE SPRINGS 5 30 CHECKING THE VALVE LIFTERS 5 31 INSTALLING THE VALVES 5 31 CYLINDER AND PISTON 5 33 REMOVING THE PISTON 5 34 CHECK...

Page 186: ...THE CLUTCH 5 52 SHIFT SHAFT 5 56 REMOVING THE SEGMENT 5 57 CHECKING THE SHIFT SHAFT 5 57 CHECKING THE STOPPER LEVER 5 57 INSTALLING THE SHIFT SHAFT 5 57 OIL PUMP 5 60 REMOVING THE BALANCER 5 62 CHECKING THE OIL PUMP 5 62 ASSEMBLING THE OIL PUMP 5 62 INSTALLING THE OIL PUMP 5 63 CRANKCASE 5 66 DISASSEMBLING THE CRANKCASE 5 68 CHECKING THE TIMING CHAIN GUIDE EXHAUST SIDE 5 68 CHECKING THE CRANKCASE ...

Page 187: ...AM20185 LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30526 ENGINE OIL LUBRICATION CHART 1 Intake camshaft 2 Exhaust camshaft 3 Piston 4 Oil filter element 5 Oil nozzle 6 Relief valve 7 Oil pump 8 Oil strainer 9 Crankshaft 10 Drive axle 11 Main axle ...

Page 188: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 2 EAM30507 LUBRICATION DIAGRAMS 1 Connecting rod 2 Crankshaft 3 Main axle 4 Oil strainer 5 Drive axle ...

Page 189: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 3 1 Oil filter element 2 Oil pump ...

Page 190: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 4 1 Intake camshaft 2 Exhaust camshaft ...

Page 191: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 5 1 Camshaft 2 Oil pressure check bolt 3 Oil pump 4 Oil filter element ...

Page 192: ...OCK ABSORBER ASSEMBLY on page 4 57 1 Silencer clamp 1 Loosen 2 Silencer 1 3 Exhaust pipe 2 clamp 1 Loosen 4 Exhaust pipe 2 1 5 Exhaust pipe 1 1 6 Gasket 3 7 Exhaust pipe 1 protector 1 8 Silencer body 1 9 Silencer cap 1 10 Protector bracket 2 LT 9 5 8 2 6 1 6 6 3 4 7 8 6 New New New LT 1st 2nd 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft 30 N m 3 0 kgf m 22 lb ft 30 N m 3 0 kgf m 22 lb ft 3...

Page 193: ... the boots band installation tool 90890 01526 YM 01526 LT 8 6 New New New LT 1st 2nd 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft 30 N m 3 0 kgf m 22 lb ft 30 N m 3 0 kgf m 22 lb ft 30 N m 3 0 kgf m 22 lb ft 20 N m 2 0 kgf m 15 lb ft 12 N m 1 2 kgf m 8 9 lb ft 12 N m 1 2 kgf m 8 9 lb ft 10 N m 1 0 kgf m 7 4 lb ft 8 N m 0 8 kgf m 5 9 lb ft 11 New ...

Page 194: ...Refer to FUEL TANK on page 7 1 Air filter case cover Refer to CLEANING THE AIR FILTER ELE MENT on page 3 15 Intake air temperature sensor coupler Refer to THROTTLE BODY on page 7 4 ECU Refer to THROTTLE BODY on page 7 4 Ignition coil Refer to THROTTLE BODY on page 7 4 1 Rectifier regulator 1 2 Stator coil assembly coupler 1 Disconnect 3 Crankshaft position sensor coupler 1 Disconnect 4 Coolant tem...

Page 195: ...Y on page 7 4 Throttle body Refer to THROTTLE BODY on page 7 4 Clutch cable Refer to CLUTCH on page 5 48 Shift pedal Drive chain Refer to SHIFT SHAFT on page 5 56 Refer to CHAIN DRIVE on page 4 66 1 Engine guard 1 2 Brake pedal 1 3 Spring 1 4 Cylinder head breather hose 1 5 Drive sprocket cover 1 6 Drive chain guide 1 7 Drive sprocket 1 7 N m 0 7 kgf m 5 2 lb ft 34 N m 3 4 kgf m 25 lb ft 85 N m 8 ...

Page 196: ... 2 11 Lower engine bracket inside 2 12 Pivot shaft 1 13 Engine 1 8 9 11 12 13 10 10 11 7 N m 0 7 kgf m 5 2 lb ft 34 N m 3 4 kgf m 25 lb ft 85 N m 8 5 kgf m 63 lb ft 75 N m 7 5 kgf m 55 lb ft 34 N m 3 4 kgf m 25 lb ft 53 N m 5 3 kgf m 39 lb ft 55 N m 5 5 kgf m 41 lb ft 26 N m 2 6 kgf m 19 lb ft 34 N m 3 4 kgf m 25 lb ft 45 N m 4 5 kgf m 33 lb ft 7 N m 0 7 kgf m 5 2 lb ft ...

Page 197: ...ove this from its low er part toward the right of the chassis EAM30164 INSTALLING THE ENGINE 1 Install Engine 1 from the right side Pivot shaft 2 Engine mounting bolt lower side 3 Lower engine bracket inside 4 Lower engine bracket outside 5 Engine bracket bolt front side 6 Engine mounting bolt front side 7 Upper engine bracket 8 Engine bracket bolt upper side 9 Engine mounting bolt upper side 10 1...

Page 198: ... 2 2 TIP Install and temporarily tighten the exhaust pipe 2 and silencer with its end positioned as shown with respect to the exhaust pipe 1 and 2 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 Engine mounting bolt upper side 45 N m 4 5 kgf m 33 lb ft Nut exhaust pipe 1 10 N m 1...

Page 199: ...he exhaust pipe clamp 1 does not ride on the projection a on the ex haust pipe 2 or silencer 3 Be sure to insert the projection b into the slot in the exhaust pipe or silencer Bolt exhaust pipe 2 20 N m 2 0 kgf m 15 lb ft Clamp 12 N m 1 2 kgf m 8 9 lb ft A Exhaust pipe 1 and exhaust pipe 2 B Exhaust pipe 2 and silencer 2 mm 0 08 in T R T R 2 1 a b a b A 3 1 B ...

Page 200: ...r 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 on page 7 1 Ignition coil Refer to ENGINE REMOVAL on page 5 6 1 Cylinder head breather hose 1 2 Spark plug 1 3 Cylinder head cover 1 4 Timing chain guide top side 1 5 Cylinder head cover gasket 1 1 2 3 4 5 10 N m 1 0 kgf m 7 4 lb ft 13 N m 1 3 kgf m 9 6 lb ft ...

Page 201: ...screw 1 3 Timing chain tensioner cap bolt 1 4 Timing chain tensioner 1 5 Camshaft cap 2 6 Clip 2 7 Intake camshaft 1 8 Exhaust camshaft 1 LS 5 8 3 4 1 2 7 6 5 4 4 6 M M E E E 6 N m 0 6 kgf m 4 4 lb ft 6 N m 0 6 kgf m 4 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft E ...

Page 202: ...with the edge of the cylinder head 3 Remove Timing chain tensioner cap bolt 1 Timing chain tensioner 2 Gasket 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 NOTICE ECA24610 The bolts camshaft cap must be removed evenly to pr...

Page 203: ...ap bolts in a crisscross pattern from innermost to outer caps Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 4 Measure Camshaft journal diameter a Out of specification Replace the camshaft Within specification Replace the cylinder head and the camshaft caps as a set Camshaft lobe dim...

Page 204: ...h your fingers use a thin screwdriver 1 to wind the tensioner rod up fully clock wise b When releasing the screwdriver by press ing lightly with your fingers make sure that the tensioner rod will come out smoothly c If not replace the tensioner assembly EAM30084 CHECKING THE DECOMPRESSION SYSTEM 1 Check Decompression system a Check that the decompressor cam 1 moves smoothly b Check that the decomp...

Page 205: ...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 cylinder head with a clean cloth to prevent the clips from coming off into the cylinder head cavity Apply the engine oil to the threads and contact surfaces Tighten the bolts to the specified torque in tw...

Page 206: ...t 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 cylin der head cover gasket 6 Install Cylinder head breather hose Spark plug Bolt timing chain tensioner 10 N m 1 0 kgf m 7 4 lb ft Tensioner ca...

Page 207: ...UEL TANK on page 7 1 Exhaust pipe Silencer Refer to ENGINE REMOVAL on page 5 6 Radiator hose Disconnect Coolant temperature sensor coupler Disconnect Throttle body Refer to THROTTLE BODY on page 7 4 Camshaft Refer to CAMSHAFT on page 5 14 Upper engine bracket Refer to ENGINE REMOVAL on page 5 6 1 Nut cylinder head 2 2 Bolt cylinder head 3 3 Bolt cylinder head 1 4 Cylinder head 1 5 Cylinder head ga...

Page 208: ...der head Order Job Parts to remove Q ty Remarks 6 Timing chain guide intake side 1 7 Oil passage plug 1 M 1st 3rd 4th 2nd 30 N m 3 0 kgf m 22 lb ft 15 N m 1 5 kgf m 11 lb ft 60 60 10 N m 1 0 kgf m 7 4 lb ft 2 10 N m 1 0 kgf m 7 4 lb ft 7 6 ...

Page 209: ...place also the valve Refer to CHECKING THE VALVE SEATS on page 5 29 Cylinder head coolant passages Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge and a thickness gauge across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sa...

Page 210: ...fied torque in two or three steps in the proper tightening sequence as shown e Remove the one bolt according to the tightening order of the bolts f Again apply molybdenum disulfide grease to the threads and contact surfaces of the bolts and to both contact surfaces of the washers g Retighten the bolts TIP Do not remove the other bolts Only remove the bolts one at a time according to the tightening...

Page 211: ...lts further according to the tightening or der TIP Tighten the bolts in two steps 60 to reach the specified angle in the proper tightening se quence Total tightening angle 60 60 120 l Tighten the nuts to the specified torque Bolt 1 2 3 4 3rd Specified angle 60 Bolt 1 2 3 4 Final Specified angle 60 Nut 5 6 10 N m 1 0 kgf m 7 4 lb ft T R T R T R ...

Page 212: ...gs Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 21 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 E 1 1 2 2 3 3 3 3 4 4 5 5 6 6 7 7 8 9 ...

Page 213: ...THE VALVE SEATS on page 5 29 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 attachment 3 4 Remove Valve spring retainer 1 Valve...

Page 214: ...lve guide installer 1 and the valve guide re mover 2 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 TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance limit i...

Page 215: ...e cylinder head 3 Measure Valve seat contact width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cylinder head Intake Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 Valve guide installer ø5 90890 04098 Valve guide installer 5 0 mm YM 04098 Valve guide reamer ø5 90890 04099 Valve guide reamer 5 0...

Page 216: ...ing 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 head d Turn the valve until the valve face and the valve seat are evenly polished then clean off all of the lapping compound TIP While turning the valve lapper tap and lap the valve seat e Apply a fine lapping compound to the valve face an...

Page 217: ...ve is installed in its original place Install the valve springs with the larger pitch a facing up 4 Install Valve cotter 1 TIP Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attachment 3 Free length limit intake 34 94 mm 1 38 in Free length limit exhaust 33 82 mm 1 33 in Recommended lubricant Molybdenum disulfide oil b S...

Page 218: ...E ECA13800 Hitting the valve tip with excessive force could damage the valve 6 Lubricate Adjusting pad 1 Valve lifter 2 7 Install Adjusting pad Valve lifter TIP Check that the valve lifter turns smoothly when rotated with your finger Make sure that the valve lifter and the adjusting pad are reinstalled in their original positions E 1 2 ...

Page 219: ...iston Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 21 1 Cylinder body 1 2 Gasket 1 3 Dowel pin 2 4 Piston pin clip 2 5 Piston pin 1 6 Piston 1 7 Piston ring set 1 1 2 3 4 4 5 6 7 E E LT 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft E ...

Page 220: ...lift the opposite end gap of the piston ring over the piston crown EAM30097 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 C with the cyl inder bore gauge TIP Measure the cylinder bore C by taking side to side and f...

Page 221: ...where cylinder wear is lowest 3 Measure Piston ring end gap Out of specification Replace the piston ring TIP The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings EAM30099 CHECKING THE PISTON PIN 1 Check Piston pin Blue discoloration grooves Replace the piston pin and then check the lubrication sys tem 2 Measure Piston pin...

Page 222: ... 2 Install Piston 1 Piston pin 2 Piston pin clip 3 TIP Apply the engine oil to the piston pin Install the piston with the mark a on it pointing to its exhaust rear side Before installing the piston pin clip cover the crankcase opening with a cloth to prevent the clip from falling into the crankcase Make sure that the end of the piston pin clip is not positioned at the cutout in the piston Piston p...

Page 223: ...er 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 Oil ring expander d Lower oil ring rail Cylinder bolt 10 N m 1 0 kgf m 7 4 lb ft 3 a d b c 15 15 15 New T R ...

Page 224: ...AL CHASSIS on page 4 1 1 Stator coil assembly coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Shift pedal 1 4 Crankcase cover left 1 5 Gasket 1 6 Dowel pin 2 7 Holder 1 8 Stator coil assembly 1 9 Generator rotor 1 10 Woodruff key 1 10 N m 1 0 kgf m 7 4 lb ft 8 N m 0 8 kgf m 5 9 lb ft 12 N m 1 2 kgf m 8 9 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 65 N m 6 ...

Page 225: ...nstall Stator coil assembly 1 Screw stator coil assembly 2 Crankshaft position sensor 3 Bolt crankshaft position sensor 4 Holder Bolt holder TIP Apply the sealant to the grommet of the stator coil assembly lead Tighten the stator coil assembly screws using the T25 bit Pass the stator coil assembly lead through the crankcase cover side Rotor puller 90890 04151 Rotor puller YM 04151 1 1 2 1 a 2 b Sc...

Page 226: ...e keyway c of the generator rotor with the woodruff key 3 Install Washer Nut generator rotor 1 4 Install Dowel pin 1 Gasket left crankcase cover 2 Crankcase cover left 3 Lead holder 4 Bolt left crankcase cover 5 TIP Tighten the bolts in stages and in a crisscross pattern 5 Connect Stator coil assembly lead Refer to CABLE ROUTING DIAGRAM on page 2 17 Nut generator rotor 65 N m 6 5 kgf m 48 lb ft LT...

Page 227: ...Engine oil Refer to CHANGING THE ENGINE OIL on page 3 13 Clutch Refer to CLUTCH on page 5 48 1 Clutch housing 1 2 Starter clutch gear 1 3 Starter clutch assembly 1 4 Side plate 1 5 Absorber 8 6 Primary driven gear 1 7 Spacer 1 8 Collar 1 9 Damper assembly 1 FWD FWD 12 N m 1 2 kgf m 8 9 lb ft 8 9 2 7 6 5 1 8 3 4 ...

Page 228: ...4 Check Starter clutch operation a Install the starter clutch gear 1 onto the primary driven gear 2 and hold the pri mary driven gear b When turning the starter clutch gear clock wise A the starter clutch and the starter clutch gear should engage otherwise the starter clutch is faulty and must be re placed c When turning the starter clutch gear coun terclockwise B it should turn freely oth erwise ...

Page 229: ...starter clutch side 4 Install Starter clutch TIP Install the starter clutch so that the side of the starter clutch assembly with the arrow mark is toward the primary driven gear While holding the side of the clutch housing 1 with the sheave holder 2 as shown tighten the starter clutch screws 3 Starter clutch screw 12 N m 1 2 kgf m 8 9 lb ft LOCTITE a 1 5XC a 1 B7B a 1 T R Sheave holder 90890 01701...

Page 230: ...TRIC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks Exhaust pipe Refer to ENGINE REMOVAL on page 5 6 1 Starter motor lead 1 2 Starter motor 1 FWD FWD 10 N m 1 0 kgf m 7 4 lb ft 3 5 N m 0 35 kgf m 2 6 lb ft 1 2 ...

Page 231: ...or assembly 1 2 O ring 1 3 Starter motor front cover 1 4 Washer 1 Starter motor front cover 5 Starter motor yoke 1 6 Gasket 2 7 Armature assembly 1 8 Washer 1 9 Circlip 1 10 Starter motor rear cover 1 11 Brush set 1 FWD FWD 1 2 3 4 5 6 6 7 8 9 10 11 3 5 N m 0 35 kgf m 2 6 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft ...

Page 232: ...Measure Brush length a Out of specification Replace the brush set 5 Measure Brush spring force Out of specification Replace the brush set 6 Check Gear teeth Damage wear Replace the starter motor 7 Check Oil seal Damage wear Replace the defective part s EAM30107 ASSEMBLING THE STARTER MOTOR 1 Install Brush spring 1 Brush 2 TIP Align the corner of brush terminal a with groove b and fit them together...

Page 233: ...r 4 Install Circlip 1 Plain washer 2 Gasket 3 Washer starter motor front cover 4 Starter motor front cover 5 TIP For installation align the projections on the washer with the slots in the front cover Align the match mark a on the starter motor yoke with the match mark b on the starter mo tor front cover 5 Install Bolt 1 O ring 2 TIP Apply the lithium soap based grease on the O ring 6 Install Start...

Page 234: ...ch cover 1 3 Gasket 1 4 Clutch spring 6 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Washer 1 9 Bearing 1 10 Ball 1 11 Push rod 2 1 12 Friction plate 1 2 Identification color black 13 Clutch plate 7 14 Friction plate 2 6 Identification color orange 15 Clutch boss 1 2 3 4 5 7 8 9 6 10 11 12 13 1 E E E E 14 15 95 N m 9 5 kgf m 70 lb ft LT 12 E E E E 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4...

Page 235: ... Job Parts to remove Q ty Remarks 16 Thrust washer 1 17 Primary driven gear 1 18 Push lever shaft 1 T R 18 17 16 E E E E LT E E E E 95 N m 9 5 kgf m 70 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft ...

Page 236: ...INE OIL on page 3 13 Coolant Drain Refer to CHANGING THE COOLANT on page 3 21 Brake pedal Refer to ENGINE REMOVAL on page 5 6 Clutch cover Refer to CLUTCH on page 5 48 1 Oil filter element cover 1 2 Oil filter element 1 3 Radiator pipe 2 1 4 Right crankcase cover 1 5 Gasket 1 6 Dowel pin 2 5 6 6 4 1 2 3 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft ...

Page 237: ... specification Replace the clutch plates as a set EAM30111 CHECKING THE CLUTCH SPRINGS 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure Clutch spring free length Out of specification Replace the clutch springs as a set EAM30112 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs 1 Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing TIP Pit...

Page 238: ...ication Replace EAM30117 CHECKING THE PRIMARY DRIVE GEAR 1 Check Primary drive gear Damage wear Replace the primary drive and primary driven gears as a set Excessive noise during operation Replace the primary drive and primary driven gears as a set 2 Check Primary drive gear to primary driven gear free play Free play exists Replace the primary drive and primary driven gears as a set EAM30118 CHECK...

Page 239: ... Make sure to tighten to specification other wise it may damage the other part that is fas tened together TIP Install the conical washer on the main axle with the OUT mark a facing away from the vehi cle Apply engine oil to the threads and contact sur face of the clutch boss nut Apply engine oil to the contact surfaces of the conical washer Use the universal clutch holder 3 to hold the clutch boss...

Page 240: ...ntification color orange 6 and friction plate 1 identifi cation color black 1 Apply the engine oil on the friction plates and clutch plates 7 Install Bearing 1 Washer 2 Circlip 3 to the push rod 1 4 TIP Apply the engine oil on the bearing washer and push rod 1 8 Install Push rod 2 1 Ball 2 Push rod 1 3 TIP Apply the engine oil on the push rod 1 2 and ball 9 Install Pressure plate 1 TIP Making sure...

Page 241: ...lts in stages and in a crisscross pattern 11 Install Gasket 1 12 Install Clutch cover Clutch cover bolt TIP Tighten the bolts in stages and in a crisscross pattern Clutch spring bolt 10 N m 1 0 kgf m 7 4 lb ft Clutch cover bolt 10 N m 1 0 kgf m 7 4 lb ft a a b b T R New 1 T R ...

Page 242: ...al 1 2 Shift shaft 1 3 Oil seal 1 4 Collar 1 5 Shift shaft spring 1 6 Roller 1 7 Shift guide 1 8 Shift lever assembly 1 9 Shift lever 1 10 Pawl 2 11 Pawl pin 2 12 Spring 2 13 Stopper lever 1 14 Stopper lever spring 1 15 Segment 1 10 10 11 11 12 12 15 13 14 7 9 8 4 5 6 2 1 3 30 N m 3 0 kgf m 22 lb ft 10 N m 1 0 kgf m 7 4 lb ft 12 N m 1 2 kgf m 8 9 lb ft 10 N m 1 0 kgf m 7 4 lb ft ...

Page 243: ...FT 1 Check Shift shaft 1 Bends damage wear Replace Shift shaft spring 2 Damage wear Replace 2 Check Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear damage Replace EAM30127 CHECKING THE STOPPER LEVER 1 Check Stopper lever 1 Wear damage Replace Stopper lever spring 2 Broken Replace EAM30131 INSTALLING THE SHIFT SHAFT 1 Install Stopper lever spring 1 Collar 2 Stopper lever 3 Bolt stopper ...

Page 244: ... lever assembly to the shift guide 5 Install Shift lever assembly 1 Shift guide 2 TIP The shift lever assembly is installed at the same time as the shift guide 6 Tighten Shift guide bolt 1 7 Install Roller 1 Shift shaft spring 2 to the shift shaft Collar 3 to the shift shaft Shift shaft 4 TIP Apply the engine oil on the shift shaft 8 Install Oil seal 9 Install Shift pedal 1 Shift pedal bolt 2 Segm...

Page 245: ...SHIFT SHAFT 5 59 TIP Align the punch mark a on the shift shaft with the punch mark b in the shift pedal 1 1 2 2 a b ...

Page 246: ... driven gear Refer to CLUTCH on page 5 48 Right crankcase cover Refer to CLUTCH on page 5 48 1 Oil pump assembly 1 2 Oil pump cover 1 3 Outer rotor 1 4 Dowel pin 1 5 Inner rotor 1 6 Oil pump drive shaft 1 7 Oil pump housing 1 LT E 3 2 1 4 5 7 6 5 N m 0 5 kgf m 3 7 lb ft 2 0 N m 0 20 kgf m 1 5 lb ft E ...

Page 247: ...er 1 2 Nut primary drive gear 1 3 Nut balancer weight gear 1 4 Conical washer 1 5 Balancer weight 1 6 Conical washer 1 7 Primary drive gear 1 8 Collar 1 9 Balancer drive gear 1 10 Conical washer 1 11 Balancer weight gear 1 12 Balancer weight 1 13 Collar 1 14 Pin 1 15 Relief valve 1 16 Spring 1 10 N m 1 0 kgf m 7 4 lb ft 50 N m 5 0 kgf m 37 lb ft 38 N m 3 8 kgf m 28 lb ft 105 N m 10 5 kgf m 77 lb f...

Page 248: ...ace 4 Check Balancer Crack damage Replace EAM30136 CHECKING THE OIL PUMP 1 Check Oil pump cover Oil pump drive shaft Oil pump housing Cracks damage wear Replace the oil pump assembly 2 Check Oil pump operation Rough movement Repeat step 1 or re place the oil pump assembly EAM30137 ASSEMBLING THE OIL PUMP 1 Install Oil pump drive shaft 1 Inner rotor 2 Dowel pin 3 TIP Apply the engine oil on the oil...

Page 249: ...ome loose Install the relief valve before installing the pri mary drive gear and collar 2 Install Oil pump assembly 1 Oil pump assembly bolt 2 NOTICE ECA13890 After tightening the bolts make sure the oil pump turns smoothly 3 Install Collar 1 Balancer weight gear 2 TIP Install the balancer weight gear and balancer shaft with their lower splines a aligning with each other Oil pump cover screw 2 0 N...

Page 250: ...ine oil to the contact surfaces of the conical washer and the balancer nut 8 Place an aluminum plate a between the teeth of the balancer drive gear 9 and balancer weight gear 10 Install the conical washer with its convex sur face b outward Align the balancer flat portion c with the flat portion d Apply LOCTITE to the primary drive gear nut 5 within the area shown in the illustration Balancer weigh...

Page 251: ...OIL PUMP 5 65 A Primary drive gear side B Crankcase cover side 5 7 mm 0 02 0 28 in 5 c d 6 8 b 8 6 7 E ...

Page 252: ...efer to GENERATOR on page 5 38 1 Timing chain guide stopper plate 1 2 Timing chain guide exhaust side 1 3 Timing chain 1 4 Bolt 7 L 45 mm 1 77 in 5 Bolt 3 L 60 mm 2 36 in 6 Bolt 3 L 75 mm 2 95 in 7 Right crankcase 1 8 Left crankcase 1 9 Dowel pin 2 10 Crankshaft 1 11 Oil nozzle 1 3 1 5 2 6 4 10 5 5 5 4 4 4 9 7 8 11 9 LT LT 12 N m 1 2 kgf m 8 9 lb ft 3 3 7 6 6 5 N m 0 5 kgf m 3 7 lb ft 10 N m 1 0 k...

Page 253: ...ks Transmission Refer to TRANSMISSION on page 5 73 Shift cam Shift fork Refer to TRANSMISSION on page 5 73 1 Circlip 2 2 Oil seal 3 3 Bearing 13 1 2 3 3 3 3 3 3 3 E E E E LT 3 3 3 3 LT E LT E 3 E 1 2 2 LT LT 12 N m 1 2 kgf m 8 9 lb ft 22 N m 2 2 kgf m 16 lb ft 12 N m 1 2 kgf m 8 9 lb ft ...

Page 254: ...only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If the cases do not separate check for a remaining case bolt or fitting Do not force c Remove the dowel pins 2 Remove Bearing 1 TIP Remove the bearing from the crankcase by pressing its inner race Do not use the removed bearing EAM30490 CHECKING THE TIMING CHA...

Page 255: ...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 stages with 1 4 turn each Installed depth a 4 5 5 0 mm 0 18 0 20 in Bearing cover plate 12 N m 1 2 kgf m 8 9 lb ft LOCTITE Bearing cover plate crankshaft 22 N m 2 2 kgf m 16 lb ft LOCTITE Yamaha bond No 1215 90890 85505 Three bond No 1215 New a 1...

Page 256: ... AND BALANCER SHAFT Removing the crankshaft assembly and balancer shaft Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 66 Transmission Refer to TRANSMISSION on page 5 73 1 Balancer shaft 1 2 Crankshaft assembly 1 1 2 ...

Page 257: ...T 1 Measure Crankshaft runout Out of specification Replace the crank shaft bearing or both TIP Turn the crankshaft slowly 2 Measure Crank assembly width a Out of specification Replace the crank shaft 3 Check Crankshaft sprocket 1 Damage Replace the crankshaft 4 Check Crankshaft journal oil passage Obstruction Blow out with compressed air Crankcase separating tool 90890 04152 Crankcase separating t...

Page 258: ...apply molybdenum disulfide grease TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft as sembly bottoms against the bearing Crankshaft installer pot 90890 01274 Installing pot YU 90058 Crankshaft installer bolt 90890 01275 Bolt YU 90060 Adapter M12 90890 01278 ...

Page 259: ... Remarks Engine Refer to ENGINE REMOVAL on page 5 6 Crankcase Separate Refer to CRANKCASE on page 5 66 1 Main axle 1 2 Drive axle 1 3 Long shift fork guide bar 1 4 Short shift fork guide bar 1 5 Spring 4 6 Shift cam 1 7 Shift fork 3 R 1 8 Shift fork 2 C 1 9 Shift fork 1 L 1 10 Collar 1 2 10 1 5 3 4 5 7 8 6 9 M E E E M M M E E M E E ...

Page 260: ...r 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 WARNING EWA12840 Do not attempt to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a set EAM30155 CHECKING THE SHIFT DRUM...

Page 261: ...e oil to the inner and end surface of the idler gear and to the inner surface of the sliding gear then install 2 Install 2nd wheel gear 29T 1 5th wheel gear 22T 2 3rd wheel gear 26T 3 4th wheel gear 24T 4 6th wheel gear 22T 5 Collar 6 1st wheel gear 31T 7 O ring 8 to the drive axle 9 TIP Before installation apply molybdenum disul fide oil to the inner and end surface of the idler gear and the coll...

Page 262: ...case simultaneously Apply engine oil to the main axle and the drive axle bearing 6 Install Shift fork 1 L 1 Shift fork 2 C 2 Shift fork 3 R 3 Shift cam 4 to the main axle and the drive axle TIP Apply engine oil to the shift fork grooves Apply engine oil to the shift cam groove and the bearing contact surface Mesh the shift fork 1 L with the 4th wheel gear 5 and shift fork 3 R with the 5th wheel ge...

Page 263: ...rk 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 Transmission operation Unsmooth operation Repair E E 6 7 5 2 4 3 1 E E E 2 1 3 E 2 ...

Page 264: ...TRANSMISSION 5 78 ...

Page 265: ... 10 COOLING SYSTEM COOLING SYSTEM DIAGRAMS 6 1 RADIATOR 6 2 CHECKING THE RADIATOR 6 4 INSTALLING THE RADIATOR 6 4 WATER PUMP 6 6 DISASSEMBLING THE WATER PUMP 6 7 CHECKING THE WATER PUMP 6 7 ASSEMBLING THE WATER PUMP 6 7 ...

Page 266: ...COOLING SYSTEM DIAGRAMS 6 1 EAM20186 COOLING SYSTEM DIAGRAMS 1 Radiator hose 1 2 Radiator right 3 Radiator hose 4 4 Water pump 5 Radiator hose 3 6 Radiator left ...

Page 267: ... 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to THROTTLE BODY on page 7 4 1 Radiator guard 2 2 Radiator hose clamp 8 Loosen 3 Radiator right 1 4 Radiator hose 2 1 5 Radiator hose 4 1 6 Radiator hose 3 1 7 Radiator pipe 2 1 8 Radiator breather hose 1 9 Radiator left 1 1 2 3 4 5 6 7 8 2 2 2 2 2 2 2 9 1 LS New New New 10 N m 1 0 kgf m 7 4 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 10 N...

Page 268: ...emarks 10 Radiator hose 1 1 11 Radiator pipe 1 1 12 Coolant temperature sensor 1 11 12 10 New LS New New 10 N m 1 0 kgf m 7 4 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 15 N m 1 5 kgf m 11 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft ...

Page 269: ...ce 3 Check Radiator cap valve opening pressure a Install the radiator cap tester adapter 2 and the radiator cap tester 3 to the radi ator cap 1 and activate the tester to check whether it can stay for 5 to 10 sec onds within standard pressure values TIP Before attaching the cap to the tester apply wa ter to its sealing surface No stay Replace EAM30506 INSTALLING THE RADIATOR 1 Fill Cooling system ...

Page 270: ...es of warm up Make sure that coolant is filled up to the up per level beforehand 5 Check Pressure value No stay for 5 to 10 seconds at the test pres sure value Correct Radiator Radiator hose connection Coolant leaks Correct or replace Radiator hose Bulges Replace WARNING EWA19090 When the radiator cap tester is removed coolant will spout therefore cover it with a cloth beforehand Test pressure val...

Page 271: ...il Drain Refer to CHANGING THE ENGINE OIL on page 3 13 Right crankcase cover Refer to CLUTCH on page 5 48 1 Water pump housing 1 2 Dowel pin 2 3 Gasket 1 4 Impeller 1 5 Circlip 1 6 Washer 2 7 Impeller shaft assembly 1 8 Bearing 1 9 Oil seal 1 10 Oil seal 1 E 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft E 14 N m 1 4 kgf m 10 lb ft 10 4 2 2 3 1 8 7 6 9 6 5 ...

Page 272: ...ce EAM30262 ASSEMBLING THE WATER PUMP 1 Install Oil seal 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 Install Bearing 1 TIP Install the bearing by pressing its outer race par allel 3 Install Impeller shaft assembly 1 Washer 2 Circlip 3 Impeller 4 TIP Take care so that the oil seal lip i...

Page 273: ... Gasket 2 5 Install Water pump housing 1 Water pump housing bolt 2 Washer 3 Coolant drain bolt 4 Water pump housing bolt 10 N m 1 0 kgf m 7 4 lb ft Coolant drain bolt 10 N m 1 0 kgf m 7 4 lb ft New 1 1 1 2 T R New T R 1 4 2 2 3 1 4 2 2 3 ...

Page 274: ...WATER PUMP 6 9 ...

Page 275: ...FUEL PUMP 7 2 CHECKING THE FUEL PUMP BODY 7 2 CHECKING THE FUEL PUMP OPERATION 7 2 INSTALLING THE FUEL PUMP 7 3 INSTALLING THE FUEL TANK 7 3 THROTTLE BODY 7 4 CHECKING THE INJECTOR 7 7 CHECKING THE THROTTLE BODY 7 7 CHECKING THE FUEL PRESSURE 7 7 ADJUSTING THE THROTTLE POSITION SENSOR 7 8 ...

Page 276: ... left right 1 Fuel pump coupler Fuel hose 1 1 Disconnect 2 Fuel tank 1 3 Fuel pump bracket 1 4 Fuel pump 1 5 Fuel filter 1 6 Thermistor cover 1 7 Fuel pump gasket 1 8 Rubber damper 4 3 5 2 2 4 7 2 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 9 N m 0 9 kgf m 6 6 lb ft 7 N m 0 7 kgf m 5 2 lb ft 1 8 8 8 1 7 N m 0 7 kgf m 5 2 lb ft 6 5 4 0 N m 0 40 kgf m 3 0 lb ft ...

Page 277: ...tor cover 1 on the end of the hose in the direction of the arrow shown press the two buttons 2 on the sides of the connector and then remove the hose Before removing the hose place a few cloths in the area under where it will be removed To prevent sand dust and other foreign mate rials from entering the fuel pump install the in cluded fuel hose joint cover 1 3 and the fuel hose joint cover 2 4 ont...

Page 278: ...Install Fuel tank 2 Connect Fuel hose NOTICE ECA24740 Connect the fuel hose securely and check that the orientation of the installed fuel hose holder is correct Take care not to kink or pinch the fuel hose TIP Insert the fuel hose into the fuel pipe securely until you hear a click Slide the fuel hose connector cover 1 at the hose end in the direction of the arrow Install the fuel hose connector ho...

Page 279: ...n coil 1 3 Intake air temperature sensor coupler 1 Disconnect 4 Breather hose 1 5 Air filter case 1 6 Fuel injector coupler 1 Disconnect 7 Intake air pressure sensor coupler 1 Disconnect 8 Throttle position sensor coupler 1 Disconnect 9 Cover 1 10 Throttle cable cover 1 3 2 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 2 2 2 10 6 8 7 9 5 4 1 10 N m 1 0 kgf m 7 4 lb ft 8 N m 0 8 kgf m 5 9 lb ...

Page 280: ...dy 1 14 Exhaust pipe bracket 1 15 Throttle body joint 1 2 2 2 11 11 11 11 13 15 14 12 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft 8 N m 0 8 kgf m 5 9 lb ft 3 5 N m 0 35 kgf m 2 6 lb ft 3 0 N m 0 30 kgf m 2 2 lb ft 4 3 N m 0 43 kgf m 3 2 lb ft 3 0 N m 0 30 kgf m 2 2 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft ...

Page 281: ...g the injector Order Job Parts to remove Q ty Remarks 1 Fuel inlet pipe 1 2 Injector 1 3 Gasket 1 4 Throttle position sensor 1 5 Intake air pressure sensor 1 1 2 2 5 4 3 3 5 N m 0 35 kgf m 2 6 lb ft 3 5 N m 0 35 kgf m 2 6 lb ft ...

Page 282: ...If the throttle body is subject to strong shocks or dropped during cleaning re place it Do not use any caustic carburetor cleaning 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 throttle valve screw 3 or starter knob nut 4 A loss of performance may occur Do not use compressed air to clean the throttle body...

Page 283: ...nsor Refer to CHECKING THE THROTTLE PO SITION SENSOR INPUT VOLTAGE on page 8 57 2 Adjust Throttle position sensor angle a Connect the Yamaha diagnostic tool Refer to YAMAHA DIAGNOSTIC TOOL on page 8 21 b Temporary tighten the throttle position sensor 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 diag no...

Page 284: ...THROTTLE BODY 7 9 ...

Page 285: ...ILS FAULT CODE 8 23 FUEL PUMP SYSTEM 8 43 CIRCUIT DIAGRAM 8 43 TROUBLESHOOTING 8 45 ELECTRICAL COMPONENTS 8 46 CHECKING THE SWITCHES 8 47 CHECKING THE BULBS AND BULB SOCKETS 8 49 CHECKING THE FUSES 8 49 CHECKING AND CHARGING THE BATTERY 8 50 CHECKING THE RELAYS 8 51 CHECKING THE RELAY UNIT DIODE 8 52 CHECKING THE IGNITION SPARK GAP 8 53 CHECKING THE SPARK PLUG CAP 8 53 CHECKING THE IGNITION COIL 8...

Page 286: ...CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 8 57 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 8 58 CHECKING THE GEAR POSITION SWITCH 8 58 CHECKING THE INJECTOR 8 59 ...

Page 287: ......

Page 288: ...IGNITION SYSTEM 8 1 EAM20142 IGNITION SYSTEM EAM30277 CIRCUIT DIAGRAM ...

Page 289: ...7 Battery 8 Frame ground 9 Main fuse 10 Starter relay 11 Starter motor 12 Diode 1 13 Diode 2 14 CCU Communication Control Unit 21 ECU Engine Control Unit 22 Ignition coil 23 Spark plug 33 Engine stop switch 34 Gear position switch 35 Mode switch A Battery sub lead B Wire harness C Ignition coil sub lead D CCU sub lead ...

Page 290: ... page 8 50 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 12 NG Correct or replace the spark plug OK 5 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 53 OK The ignition system circuit is OK NG 6 Check the ignition coil Refer to CHECKING THE IGNI TION COIL on page 8 54 NG Replace t...

Page 291: ...mbly OK 10 Check the ignition system wire har ness Refer to CIRCUIT DIAGRAM on page 8 1 NG Repair or replace the wire harness OK Replace the ECU 1 Check the mode switch coupler connections NG Reconnect OK 2 Check the mode switch Refer to CHECKING THE SWITCHES on page 8 47 NG Replace the mode switch OK 3 Check the ignition system wire har ness Refer to CIRCUIT DIAGRAM on page 8 1 NG Repair or repla...

Page 292: ...ELECTRIC STARTING SYSTEM 8 5 EAM20143 ELECTRIC STARTING SYSTEM EAM30279 CIRCUIT DIAGRAM ...

Page 293: ...ain relay 6 Engine ground 7 Battery 8 Frame ground 9 Main fuse 10 Starter relay 11 Starter motor 12 Diode 1 13 Diode 2 21 ECU Engine Control Unit 33 Engine stop switch 34 Gear position switch 36 Start switch 37 Diode 3 A Battery sub lead B Wire harness ...

Page 294: ...HE RE LAYS on page 8 51 NG Replace the main relay OK 4 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 55 OK Starter motor is OK Perform the electric starting system troubleshooting starting with step 6 NG 5 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 46 NG Repair or replace the starter motor OK 6 Check the diodes Diode 1 diode ...

Page 295: ...rt switch Refer to CHECKING THE SWITCHES on page 8 47 NG Replace the start switch OK 10 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 5 NG Properly connect or repair the starting sys tem s wiring OK Replace the ECU ...

Page 296: ...CHARGING SYSTEM 8 9 EAM20144 CHARGING SYSTEM EAM30282 CIRCUIT DIAGRAM ...

Page 297: ...CHARGING SYSTEM 8 10 2 AC magneto 3 Rectifier regulator 6 Engine ground 7 Battery 8 Frame ground 9 Main fuse A Battery sub lead B Wire harness ...

Page 298: ... battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 50 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 55 NG Replace the rectifier regulator OK 5 Check the stator coil assembly Refer to CHECKING THE STA TOR COIL on page 8 55 NG Replace the stator coil assembly OK 6 Check the charging sy...

Page 299: ...CHARGING SYSTEM 8 12 ...

Page 300: ...SIGNALING SYSTEM 8 13 EAM20154 SIGNALING SYSTEM EAM30348 CIRCUIT DIAGRAM ...

Page 301: ...SYSTEM 8 14 4 Joint connector 5 Main relay 7 Battery 8 Frame ground 9 Main fuse 15 Warning light 16 Fuel level warning light 18 Resistor 19 Fuel sender 21 ECU Engine Control Unit A Battery sub lead B Wire harness ...

Page 302: ...nals Recharge or replace the battery OK 3 Check the main relay Refer to CHECKING THE RE LAYS on page 8 51 NG Replace the main relay OK 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 13 NG Properly connect or repair the signaling system s wiring OK This circuit is OK 1 Check the fuel level warning light bulb and socket Refer to CHECKING THE BULBS AND BULB SOCKETS on...

Page 303: ...SIGNALING SYSTEM 8 16 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 13 NG Properly connect or repair the signaling system s wiring OK Replace the ECU ...

Page 304: ...FUEL INJECTION SYSTEM 8 17 EAM20145 FUEL INJECTION SYSTEM EAM30284 CIRCUIT DIAGRAM ...

Page 305: ...ouble warning light 20 Yamaha diagnostic tool coupler 21 ECU Engine Control Unit 22 Ignition coil 23 Spark plug 24 Fuel injector 25 Fuel pump 26 Radiator fan motor fuse 27 Coupler not used 28 Radiator fan motor relay 29 Intake air temperature sensor 30 Coolant temperature sensor 31 Throttle position sensor 32 Intake air pressure sensor 33 Engine stop switch 34 Gear position switch A Battery sub le...

Page 306: ...cation and fuel injection system operation The engine trouble warning light flashes when any one of the following conditions is present and the start switch is pushed Checking the engine trouble warning light The engine trouble warning light comes on for around 2 seconds when pushing the start switch to turn on the engine trouble warning light comes on while the start switch is being pushed Warnin...

Page 307: ...n system Refer to Confirmation of service com pletion in the appropriate table in TROUBLESHOOTING DETAILS FAULT CODE on page 8 23 4 After pushing the engine stop switch push the start switch to check whether the fault code number is displayed TIP If another fault code number is displayed repeat steps 1 to 4 until no fault code number is displayed 5 Erase the malfunction history in the diagnostic m...

Page 308: ...e FI diagnostic tool sub lead to the Yamaha diagnostic tool WARNING EWA20450 Never connect the sub lead special tool to the battery Otherwise because of excessive cur rent flow the sub lead can catch fire and the battery could be damaged TIP Prepare the fully charged 12 V lead battery for yourself Replace the vehicle battery with a lead battery 12 V For information on how to connect and use the Ya...

Page 309: ...nit 2 Lead battery 12 V 3 Vehicle battery 4 Vehicle 5 Coupler for connecting optional part 6 FI diagnostic tool sub lead 7 Sub harness included with the Yamaha diag nostic tool 8 Vehicle communication cable included with the Yamaha diagnostic tool 9 Yamaha diagnostic tool ...

Page 310: ...2 Item Crankshaft position sensor no normal signals are received from the crankshaft position sensor Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No Diagnostic tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of crankshaft posi tion sensor coupler Check the locking condition of t...

Page 311: ... of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Defective crankshaft position sensor Check the crankshaft position sensor Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on page 8 54 Crank the engine and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Rec...

Page 312: ...de using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 4 4 Mounted condition of intake air pressure sensor Check for looseness or pinch ing Check the mounted position for correctness Improperly mounted sensor Remount or replace the sensor Start switch to ON main relay ON and then check the condi tion o...

Page 313: ... twisted or bent Repair or replace the sensor hose Start the engine and let it idle for approximately 5 seconds fully close the throttle valve Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 3 and finish the service Condition is Detected Go to item 2 2 Defective intake air pressure sensor Execute the diagnostic mode C...

Page 314: ...er Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or bro ken terminals and locking condi tion of the pins Improperly connected Con nect the coupler securely or repair replace the wire harness Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered ...

Page 315: ...ened 86 92 displays Incorrect display range Replace the throttle position sensor Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 7 7 Faulty ECU Replace the ECU Service is finished 8 Delete the fault code Confirm that t...

Page 316: ...ostic tool Condition is Recovered Go to item 4 and finish the service Condition is Detected Go to item 3 3 Faulty ECU Replace the ECU Service is finished 4 Delete the fault code Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No 21 Item Coolant temperature sensor open or short circuit detected Fail safe system Able...

Page 317: ... condition of coolant temperature sensor Check for looseness or pinch ing Check the mounted position for correctness Improperly mounted sensor Remount or replace the sensor Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to it...

Page 318: ...etected Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or bro ken terminals and locking condi tion of the pins Improperly connected Con nect the coupler securely or repair replace the wire harness Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction...

Page 319: ...Unable to drive vehicle Diagnostic code No 08 Diagnostic tool display Displays the lean angle sensor output voltage 0 4 1 4 V upright 3 7 4 4 V overturned Procedure Remove the ECU and incline it 45 or more Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 The vehicle has overturned Raise the vehicle upright Start switch to ON main relay ON wait 10 ...

Page 320: ...tion 1 Connection of ignition coil cou pler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or bro ken terminals and locking condi tion of the pins Improperly connected Con nect the coupler securely or repair replace the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction...

Page 321: ...ion of ignition coil Check for looseness or pinch ing Check the mounted condition for correctness Improperly mounted sensor Remount or replace the ignition coil Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go...

Page 322: ...njector Refer to CHECKING THE INJECTOR on page 8 59 Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 3 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the...

Page 323: ...y and CCU Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 09 Diagnostic tool display Fuel system voltage Approximately 12 0 V Procedure Disconnect the main relay and push the start switch Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of main relay cou pler Check the locking condition of the coupler Disc...

Page 324: ...he engine stop switch alternately to switch the power supply main relay from ON OFF ON Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 4 4 Defective main relay No operating sound Replace the main relay Or execute the diagnostic mode Code No 09 Fuel system volta...

Page 325: ...tion Change the CO concentration and rewrite in EEPROM After this adjustment push the engine stop switch and then push the start switch Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 5 and finish the service Condition is Detected Repeat item 1 If the same number is indicated...

Page 326: ...and locking condition of the pins Improperly connected Con nect the coupler securely or repair replace the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 3 Wire harness continuity Open...

Page 327: ...ode No Diagnostic tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Faulty ECU Replace the ECU Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Check that the fault code num ber is not displayed Fault code No 70 Item Engine forcibly stops...

Page 328: ...the fault code Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No 70 Item Engine forcibly stops when the vehicle is left idling for a long period of time ...

Page 329: ...FUEL INJECTION SYSTEM 8 42 ...

Page 330: ...FUEL PUMP SYSTEM 8 43 EAM20146 FUEL PUMP SYSTEM EAM30287 CIRCUIT DIAGRAM ...

Page 331: ...YSTEM 8 44 2 AC magneto 3 Rectifier regulator 4 Joint connector 6 Engine ground 7 Battery 8 Frame ground 9 Main fuse 21 ECU Engine Control Unit 25 Fuel pump 33 Engine stop switch A Battery sub lead B Wire harness ...

Page 332: ... on page 8 49 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 50 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 47 NG Replace the engine stop switch OK 5 Check fuel pressure Refer to CHECKING THE FUEL PRESSURE on page 7 7 NG Replace the fuel pump OK 6 Check t...

Page 333: ...Rectifier regulator 5 Mode switch 6 Intake air temperature sensor 7 ECU Engine Control Unit 8 Ignition coil 9 Resistor 10 CCU Communication Control Unit 11 Starter relay 12 Main fuse 13 Battery 14 Radiator fan motor fuse 15 Radiator fan motor relay 16 Main relay 17 Gear position switch 18 Fuel pump 19 Coolant temperature sensor ...

Page 334: ...ELECTRICAL COMPONENTS 8 47 EAM30289 CHECKING THE SWITCHES Y W P Sb 3 1 4 2 P Sb B W R L B R Y W B 1 Engine stop switch 2 Mode switch 3 Gear position switch 4 Start switch ...

Page 335: ...hecking 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 terminals i e a closed circuit at each switch positio...

Page 336: ...ver note the following a Install a good bulb into the bulb socket b Connect the digital circuit tester probes to the respective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity re place the bulb socket EAM30290 CHECKING THE FUSES The following procedure applies to all of the fus es 1 Remove Seat Refer to GENERAL CHASSIS on page 4 1 2 Che...

Page 337: ... possible A long state of discharge below 10 V will damage the battery Do not use the specified battery charger to charge a battery other than the lithium ion battery Otherwise the battery or charger could be damaged Be careful not to drop the battery or subject it to strong impacts Avoid charging the battery at high temper atures of 65 C 149 F or more or low tem peratures under 0 C 32 F A control...

Page 338: ...en the battery terminals 13 25 V or more The battery is normal Checking is finished Less than 13 25 V Go to step c c Connect the battery charger special tool to the battery and charge it TIP For instructions on charging and handling the battery charger refer to the battery charger s in struction manual d If the battery is hot wait until the battery has cooled down to the ambient tempera ture e Mea...

Page 339: ...ve battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 to 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 to 4 2 1 3 4 R W Br W R Y L 1 2 3 4 L R Br R R R W 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Conti...

Page 340: ...5 CHECKING THE SPARK PLUG CAP 1 Remove Spark plug cap from the spark plug lead 2 Check Spark plug cap resistance Out of specification Replace a Connect the digital circuit tester to the spark plug cap No continuity Positive tester prove Blue Green 1 Negative tester prove Blue 2 Continuity Positive tester prove Blue 2 Negative tester prove Blue Green 1 No continuity Positive tester prove Brown Whit...

Page 341: ...he wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace a Connect the digital circuit tester to the crankshaft position sensor coupler Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Primary coil resistance 2 16 2 64 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Positive tester probe ...

Page 342: ...at is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAM30300 CHECKING THE STATOR COIL 1 Disconnect Stator coil assembly coupler from the wire harness 2 Check Stator coil assembly resistance O...

Page 343: ...ness 2 Check Resistor resistance Out of specification Replace the resistor a Connect the digital circuit tester to the resistor as shown b Measure the resistance of the resistor Regulated voltage DC 14 0 14 8 V Digital tachometer 90890 06760 Digital tachometer YU 39951 B Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Positive tester probe Red 1 Negative test...

Page 344: ...t the temperatures indicated in the table EAM30305 CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1 Check Throttle position sensor input voltage Out of specification Replace the ECU a Connect the test harness S pressure sen sor 3P to the throttle position sensor cou pler and the wire harness b Connect the digital circuit tester DCV to the test harness S pressure sensor 3P Coolant temperature ...

Page 345: ...ntake air temperature sensor re sistance 5400 6600 at 0 C 5400 6600 at 32 F Intake air temperature sensor re sistance 290 390 at 80 C 290 390 at 176 F Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Positive tester probe Brown White 1 Negative tester probe Black Blue 2 2 1 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 ...

Page 346: ...Disconnect the fuel injector coupler from the fuel injector b Connect the digital circuit tester to the fuel injector coupler c Measure the fuel injector resistance Resistance 12 0 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Positive tester probe Injector terminal 1 Negative tester probe Injector terminal 2 c b a Y W P Sb d e f 3 1 2 1 2 ...

Page 347: ...G OF COOLING SYSTEM 9 7 TROUBLESHOOTING OF BRAKE 9 8 TROUBLESHOOTING OF SUSPENSION 9 8 TROUBLESHOOTING OF STEERING HANDLING 9 10 TROUBLESHOOTING OF CHARGING SYSTEM 9 11 TROUBLESHOOTING OF SIGNALING SYSTEM 9 11 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 12 SELF DIAGNOSTIC FUNCTION TABLE FOR FUEL INJECTION SYSTEM 9 12 DIAGNOSTIC CODE SENSOR OPERATION TABLE 9 12 DIAGNOSTIC CODE ACTUATOR OPE...

Page 348: ...STEM on page 8 5 Starter motor operates but the engine does not crank Starter clutch malfunction Replace the starter clutch Improper oil grade starter clutch slipping Change to recommended engine oil Stuck piston or seized crankshaft Disassemble and check the engine Replace defective parts Symptom Possible cause Actions Spark plug does not produce a spark Refer to TROUBLESHOOTING under IGNITION SY...

Page 349: ...lace the piston and piston rings as a set Seized or damaged piston Replace the piston and piston rings as a set Worn or damaged cylinder bore Replace the cylinder piston and piston rings as a set Symptom Possible cause Actions Spark plug does not produce a spark Incorrect spark plug gap Adjust the spark plug gap Worn or damaged spark plug Replace the spark plug Defective spark plug cap Replace the...

Page 350: ...torque Clogged air filter element Clean or replace the air filter ele ment Incorrect oil level high Adjust the oil level to the specified level Symptom Possible cause Actions Noise heard from around cylinder head Incorrect valve clearance too wide Adjust the valve clearance Fatigued or broken valve spring Replace the valve spring Worn or damaged camshaft lobe Replace the camshaft Worn or damaged v...

Page 351: ...ive gear Replace the balancer drive gear and balancer shaft as a set Worn or damaged big end bearing Replace the big end bearing Worn or damaged crankshaft jour nal bearing Replace the crankshaft journal bearing Worn or damaged balancer shaft journal bearing Replace the balancer shaft journal bearing Symptom Possible cause Actions Clutch slippage Improperly assembled clutch Reassemble the clutch I...

Page 352: ... bushing Replace the clutch housing Improperly installed pull lever Align the match mark on the pull lever before installation Incorrect oil level Adjust the engine oil level to the specified level Incorrect oil viscosity high Change to recommended engine oil Deteriorated oil Change to recommended engine oil Clutch noise Damaged or worn primary driven gear Replace the primary drive gear or cranksh...

Page 353: ...transmis sion gears Remove foreign object from trans mission gears Seized transmission gear Replace the seized gear and the axle as a set Improperly assembled transmis sion Reassemble the transmission axle assembly Jumps out of gear Incorrect shift pedal position Adjust the shift pedal position Improperly returned stopper lever Replace the stopper lever spring Bent or worn shift fork Replace the s...

Page 354: ...Repair the radiator fin or replace the radiator Damaged or faulty water pump Replace the water pump Damaged hoses or pipes Replace the hose or pipe Improperly connected hoses or pipes Connect the hoses and pipes properly Damaged throttle body joint Replace the throttle body joint Loose throttle body joint Tighten the throttle body joint bolts to the specified torque Clogged air filter element Clea...

Page 355: ... Damaged brake hose and brake pipe Replace the brake hose and brake pipe Oil or grease on the brake disc or brake pad Clean the brake disc or brake pad Insufficient lubrication of brake lever or brake pedal pivot Lubricate the brake lever or brake pedal pivot Symptom Possible cause Actions Front fork is hard Bent or damaged inner tube Replace the inner tube Bent or damaged outer tube Replace the o...

Page 356: ...per rod assembly bolt Tighten the damper rod assembly bolt to the specified torque Damaged damper rod assembly bolt copper washer Replace the damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring Replace the cap bolt O ring Rear suspension is hard Bent or damaged rear shock absorber rod Replace the rear shock absorber Bent swingarm pivot shaft Replace the swingarm pivot shaft D...

Page 357: ...ied torque Worn bearing or bearing race Replace the bearing and bearing race as a set Warped front fork Repair or replace the front fork Bent front wheel axle Replace the front wheel axle Incorrect tire pressure Adjust to the specified tire pres sure Worn deformed or incorrect tire Replace the tire Heavy steering Lower ring nut is tightened too tight Tighten the lower ring nut to the specified tor...

Page 358: ...le nut to the specified torque Loose swingarm pivot shaft Tighten the swingarm pivot shaft to the specified torque Bent or damaged swingarm Replace the swingarm bearing Damaged or worn swingarm bear ing or bushing Replace the swingarm bearing or bushing Symptom Possible cause Actions Battery is not charged Refer to TROUBLESHOOTING under CHARGING SYSTEM on page 8 9 Symptom Possible cause Actions In...

Page 359: ...lead of the ignition coil 8 33 39 Injector open or short circuit detected 8 35 41 ECU built in lean angle sensor malfunction 8 36 43 Fuel system voltage incorrect voltage supplied to the main relay and CCU 8 36 44 EEPROM fault code number an error is detected while reading or writing on EEPROM 8 38 46 Vehicle system power supply normal voltage is not supplied to the ECU 8 39 50 ECU faulty ECU memo...

Page 360: ...ar in 1st or 2nd ON Gear in other than 1st or 2nd OFF 60 EEPROM fault code display No fault 00 CO adjustment valve 01 Power Tuner injection cor rection setting 0 8 or Power Tuner ignition timing correc tion setting 0 8 07 61 Malfunction history code display 1 There is no history 00 There is some history Other Displays the fault code of 62 Malfunction history code erasure 1 Replace all with by the ...

Page 361: ...the ignition coil five times at one second intervals WARNING on the Yamaha diagnostic tool blinks five times when the ignition coil is actu ated Check that a spark is gener ated five times Connect an ignition checker 36 Injector Actuates the injector five times at one second intervals WARNING on the Yamaha diagnostic tool blinks five times when the injector is actuated TIP Before performing this o...

Page 362: ...SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 15 ...

Page 363: ...0 1 FRONT FORK SETTING 10 2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL 10 2 SETTING OF SPRING AFTER REPLACEMENT 10 2 FRONT FORK SETTING PARTS 10 3 REAR SUSPENSION SETTING 10 3 CHOOSING SET LENGTH 10 3 SETTING OF SPRING AFTER REPLACEMENT 10 4 REAR SHOCK ABSORBER SETTING PARTS 10 5 SUSPENSION SETTING FRONT FORK 10 6 SUSPENSION SETTING REAR SHOCK ABSORBER 10 7 ...

Page 364: ...he end of the straight line with care taken to avoid the en gine over revving TIP Riding technique varies from rider to rider and the performance of a machine also vary from machine to machine Therefore do not imitate other rider s settings from the beginning but choose your own setting according to the level of your riding technique EAM30169 DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS EAM30170 T...

Page 365: ...he air spring characteristics to have a ten dency to be stiffer with the consequent dete riorated performance and characteristics Therefore adjust the front fork within the specified range EAM30173 SETTING OF SPRING AFTER REPLACEMENT As the front fork setting can be easily affected by the rear suspension take care so that the front and the rear are balanced in position etc when setting the front f...

Page 366: ...et length of the spring Change the spring 2 Setting of damping force Change the rebound damping force Change the compression damping force EAM30176 CHOOSING SET LENGTH 1 Place a stand or a block under the engine to put the rear wheel above the floor and mea sure the length a between the rear wheel axle center and the rear fender holding bolt 2 Remove the stand or block from the engine and with a r...

Page 367: ...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 force adjuster one or two clicks turned in and readju...

Page 368: ... D mark SOFT 50 B3J 22212 00 Blue Green B3J 22212 10 Black 52 BR9 22212 00 Blue Yellow BR9 22212 50 Black 54 BR9 22212 10 Blue Pink BR9 22212 60 Black 56 BR9 22212 20 Blue White BR9 22212 70 Black 58 BR9 22212 30 Blue Silver BR9 22212 80 Black 60 BR9 22212 40 Blue Brown STIFF BR9 22212 90 Black 1 a Spring preload adjusting positions Minimum Position in which the spring is turned in 1 5 mm 0 06 in ...

Page 369: ...oticeable scars etc If any replace affected parts Slide metal Replace with a new one for extended use Piston metal Replace with a new one for extended use Lower bracket tightening torque Retighten to specified torque Poor initial move ment Rebound damp ing force Turn adjuster counterclockwise about 2 clicks to decrease damping Oil seals Apply grease in oil seal wall Soft over entire range bottomin...

Page 370: ...ount Increase oil amount by about 5 cm 0 2 US oz 0 2 Imp oz Obtrusive front tending to upper front posture Compression damping force Turn adjuster counterclockwise about 2 clicks to decrease damping Balance with rear end Set sunken length for 90 95 mm 3 5 3 7 in when one passenger is astride seat upper rear pos ture Spring Replace with soft spring Oil amount Decrease oil amount by about 5 10 cm 0 ...

Page 371: ... senger is astride seat Spring Replace with soft spring Bottoming out High compres sion damping Turn adjuster clockwise about 1 6 turn to increase damping Spring set length Set sunken length for 90 100 mm 3 5 3 9 in when one pas senger is astride seat Spring Replace with stiff spring Bouncing Rebound damp ing force Turn adjuster clockwise about 2 clicks to increase damping Spring Replace with soft...

Page 372: ...CHASSIS 10 9 ...

Page 373: ...elay 29 Intake air temperature sensor 30 Coolant temperature sensor 31 Throttle position sensor 32 Intake air pressure sensor 33 Engine stop switch 34 Gear position switch 35 Mode switch 36 Start switch 37 Diode 3 A Battery sub lead B Wire harness C Ignition coil sub lead D CCU sub lead EAM30323 COLOR CODE B Black Br Brown Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y Y...

Page 374: ......

Page 375: ...ance Buy with confidence knowing your Genuine Yamaha Accessories will fit right and perform right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha from the inside out Genuine Yamaha Service Manuals Get the same factory man...

Page 376: ......

Page 377: ...YZ250FXM 2021 WIRING DIAGRAM BAJ 2819U 11_WD indd 1 2020 06 29 15 46 05 ...

Page 378: ...YZ250FXM 2021 WIRING DIAGRAM BAJ 2819U 11_WD indd 2 2020 06 29 15 46 06 ...

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