Yamaha WR250F (2011) manuel d'utilisation

1HC-28199-50 WR250F(A) OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE FAHRER- UND WARTUNGSHANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO MANUAL DE SERVICIO DEL PROPIETARIO Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Read this manual carefully before operating this vehicle. Bitte lesen Sie die[...]

Read this manual carefully b efore operating this veh icle. This manual s hould stay with this vehicle if it is sold. Il convient de lire attentivemen t ce manuel av ant la première u tilisation du véhicule . Le manuel doit étre remis avec le véhicu le en cas de vente de ce dernier. Bitte lesen Sie diese Bedienu ngsanleitung sorgfältig d urch,[...]

WR250F(A) WR250F(A) 2011 2011 1HC-28199-50-E0 1HC-28199-50-E0 OWNER’S SERVICE MANUAL OWNER’S SERVICE MANUAL Read this manual carefully before operating this vehicle. Read this manual carefully before operating this vehicle.[...]

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WR250F (A) OWNER'S SERVICE MANUAL ©2010 by Yamaha Motor Co., Ltd. 1st Edition, May 2010 All rights reserved. Any repr inting or unauthorized use wi thout the written permission of Yamaha Motor Co., Ltd. is expressly proh ibited. Printed in Japan[...]

FOREWORD INTRODUCTION Congratul ations on y our purch ase of a Yamaha WR series. This model is the culmination of Yamaha' s vast ex- perience in the production of paceset- ting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yama- ha a leader. This manual explain s operation, in- spection, basic[...]

• PROPERLY SECURE THE MA- CHINE BEFORE TRANSPORTING IT. When transporting the machine in another vehicle, alwa ys be sure it is properly secured and in an upright position and that the fuel cock is in the "OFF" position. Otherwise, fuel may leak out of the carburetor or fuel tank. HOW TO USE THIS MANUAL FINDING THE REQUIRED PAGE 1. This[...]

HOW TO READ DESCRIPTIONS To help identify parts and clarify pro- cedure steps, there are exploded dia - grams at the start of each removal and disassembly section. 1. An easy-to-see exploded diagram "1" is provided for removal and disassembly jobs. 2. Numbers "2" are given in the or- der of the jobs in the exploded di- agram. A [...]

TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 REGULAR INSPECTION AND ADJUSTMENTS 3 TUNING 4 ENGINE 5 CHASSIS 6 ELECTRICAL 7[...]

CONTENTS CHAPTER 1 GENERAL INFOR- MATION LOCATION OF IMPORTANT LABELS ..... 1-1 DESCRIPTION ................. 1-5 CONSUMER INFORMATION................. 1-6 INCLUDED PARTS .......... 1-6 IMPORTANT INFORMATION................. 1-6 CHECKING OF CONNECTION .................. 1-7 SPECIAL TOOLS ............. 1-8 CONTROL FUNCTIONS .. 1-12 MULTI-FUNCTION DI[...]

1-1 LOCATION OF IMPORTANT LABELS GENERAL INFORMATION LOCATION OF IMPORTANT LABELS Please read the following importan t labels carefully before operating th is vehicle. CANADA Essence super sans plomb seulement. 3FB-2415E-12 1[...]

1-2 LOCATION OF IMPORTANT LABELS EUROPE  [...]

1-3 LOCATION OF IMPORTANT LABELS AUS, NZ, ZA[...]

1-4 LOCATION OF IMPORTANT LABELS Familiarize yourself w ith the following pictograms and read the expla natory text. Read Owner's servic e manual. This unit contains high-pressure nitrogen ga s. Mishandling can cause explosion. Do no t incinerate, puncture or open. Turn off the main switch after riding to avoid draining the battery. Use unlead[...]

1-5 DESCRIPTION DESCRIPTION • The machine you have purchased may differ slightly from those shown in the following. • Designs and specifications are subject to chang e without notice. 1. Clutch lever 2. Hot starter lever 3. Engine stop switch 4. Multi-function displ ay 5. Main switch 6. Start switch 7. Front brake lever 8. Throttle grip 9. Radi[...]

1-6 CONSUMER INFORMATION CONSUMER INFORMATION There are two signifi cant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own. 2. If your machine is stolen, the au- thorities will need the number to search for and identify your m[...]

1-7 CHECKING OF CONNECTION 3. When disassemblin g the ma- chine, keep mated pa rts together. They include gears, cylinders, pistons, and othe r mated parts that have been "mated" through normal wear. Mated pa rts must be reused as an assembly or re- placed. 4. During the machine disassembly, clean all parts and place them in trays in the [...]

1-8 SPECIAL TOOLS SPECIAL TOOLS The proper spe cial tools are nece ssary for complete and acc ura te tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of impr oper tools or improvised techniques . The sha pe and part number used for the special tool differ by coun try, so two types are provided. Refer t[...]

1-9 SPECIAL TOOLS Steering nut wren ch YU-33975, 90890-01403 This tool is used when tighten the steering ring nut to specification. Damper rod holder YM-01494, 90890-01494 Use this tool to remove and install the damper rod. Fork seal driver YM-A0948, 90890-01502 This tool is used when install th e fork oil seal. Spoke nipple wrench YM-01521, 90890-[...]

1-10 SPECIAL TOOLS Timing light YM-33277-A, 90890-03141 This tool is necessary for checking ignition timing. Valve spring compressor YM-4019, 90890-04019 This tool is needed to remove and install the valve assembl ies. Clutch holding tool YM-91042, 90890-04086 This tool is used to hold the clutch when removing or installing th e clutch boss securin[...]

1-11 SPECIAL TOOLS Dynamic spark tester YM-34487 Ignition checker 90890-06754 This instrument is necessary for checking the ignition system compo- nents. Vacuum/pressure pump gaug e set YB-35956-A, 90890-06756 This tool is used to check the air in- duction system. YAMAHA Bond No. 1215 (Three- Bond ® No. 1215) 90890-85505 This sealant (Bond) is use[...]

1-12 CONTROL FUNCTIONS CONTROL FUNCTIONS MAIN SWITCH Functions of the respective switch po- sitions are as follows: ON: The engine can be started only at this position. OFF: All electrical circuits are switched off. Main switch indicator light The main switch "1" is equipped with an indicator light "2" to avoid forget- ting to t[...]

1-13 MULTI-FUNCTION DISPLAY COLD STARTER KNOB When cold, the engine requires a richer air-fuel mixture for starting. A separate starter circuit, which i s con- trolled by the cold starter knob "1", supplies this mixture. Pull the cold starter knob out to open the circuit for starting. When the engine has warmed up, push it in to close the[...]

1-14 MULTI-FUNCTION DISPLAY Changing odomete r and tripmeter A/B (TRIP A/B) 1. Push the "SLCT2" button to change the tripmeter display. The display will change in the follow- ing order: Odometer → TRIP A → TRIP B → TRIP A → Odometer. To reset the digits, se lect the tripme- ter involved and push the "RST" but- ton for 2 [...]

1-15 MULTI-FUNCTION DISPLAY 3. Run the machine and start timer measurement. 4. To stop timer measuremen t, pushing the "SLC T1" button a nd "SLCT2" button at the same time. If the machine is run while timer mea - surement is not made, n o change will occur to the digit in tripmeter A (TRIP A). 5. To resume the mea surement, agai[...]

1-16 MULTI-FUNCTION DISPLAY FUNCTION DIAGRAM A short push on the button changes the operation in the arrowed direction. A short push on the button changes the operation in both arrowed directions. A long push on the button changes the operation in the arrowed direction. A long push on the button changes the operation in both arrowed directions. Met[...]

1-17 MULTI-FUNCTION DISPLAY The following diagram illustrates th e multi-function display rega rding the direction and operation condition in- volved in each of its functions. A. A short push on the button changes the operation i n the ar- rowed direction. B. A short push on the button changes the operation i n both arrowed di rections. C. A long p[...]

1-18 STARTING AND BREAK-IN STARTING AND BREAK-IN FUEL Always use the recommended fuel as stated below. Also, be sure to use new gasoline. Use only unleaded gaso line. The use of leaded g asoline will cause severe damage to the engi ne inter- nal parts such as valv es, piston rings, and exhaust system, etc. If knocking or pingi ng occurs, use a diff[...]

1-19 STARTING AND BREAK-IN Restarting an engine after a fall Pull the hot starter lever and start the engine. As soon as the engine starts, Release the hot starter lever to close the air passage. The engine fails to start Pull the hot starter lever all the way out and while holding the lever, kick the kickstarter crank 10 to 20 times to clear the e[...]

1-20 TORQUE-CHECK POINTS TORQUE-CHECK POINTS Concerning the tightening torque, refer to "TIGHTENING TORQUES" section in the CHAPTER 2. Frame construction Frame to rear frame Combined seat and fuel tank Fuel tank to frame Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame [...]

1-21 CLEANING AND STORAGE CLEANING AND STORAGE CLEANING Frequent cleaning of your machine will enhance its appe arance, maintain good overall perfo rmance, and ex- tend the life of many components. 1. Before washing the machine, block off the en d of the exhau st pipe to prevent water from enter- ing. A plastic bag secured with a rubber band may be[...]

2-1 GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: WR250FA (USA, CDN, AUS, NZ) WR250F (EUROPE, ZA) Model code number: 1HC1 (USA) 1HC2 (CDN) 1HC3 (EUROPE) 1HC4 (AUS, NZ, ZA) Dimensions: USA, CDN, ZA AUS, NZ EUROPE Overall length 2,165 mm (85.24 in) 2,175 mm (85.63 in) 2,185 mm (86.02 in) Overall width 825 mm (32.48 in) ←?[...]

2-2 GENERAL SPECIFICATIONS Fuel: Type Premium unleaded gasoline on ly with a re search octane number of 95 or highe r. Tank capaci ty 8.0 L (1.76 Im p gal, 2.11 US ga l) Reserve 1.1 L (0.24 Imp gal , 0.29 US gal) Carburet or: Type FCR-MX37 Manufacturer KEIHIN Spark plug: Type/manufacturer CR9E/NGK (resistance type) Gap 0.7–0.8 mm (0.028–0.031 i[...]

2-3 MAINTENANCE SPECIFICATIONS MAINTENANCE S PECIFICATIONS ENGINE Shock absorber: Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/gas, oil damper Wheel tr avel: Front wheel travel 300 mm (11.8 in) Rear wheel travel 310 mm (12.2 in) Electrical: Ignition system CDI Generator system AC magneto Battery type YTZ7S (F) Battery[...]

2-4 MAINTENANCE SPECIFICATIONS Intake "A" 29.65–29.75 mm (1.1673–1.171 3 in) 29.55 mm (1.1634 in) Intake "B" 22.45–22.55 mm (0.8839–0.887 8 in) 22.35 mm (0.8799 in) Exhaust "A" 30.399–30.499 mm (1.1968– 1.2007 in) 30.299 mm (1.1929 in) Exhaust "B" 22.45–22.55 mm (0.8839–0.8878 in) 22.35 mm (0.[...]

2-5 MAINTENANCE SPECIFICATIONS "D" margin thickness (IN) 0.8 mm (0.0315 in) ---- "D" margin thickness (EX) 0.7 mm (0.0276 in) ---- Stem outside diameter (IN) 3.975–3.990 mm (0 .1565–0.1571 in) 3.945 mm (0.1553 in) Stem outside diameter (EX) 4.46 0–4.475 mm (0.1756–0.1762 in) 4.430 mm (0.1744 in) Guide inside diameter (IN[...]

2-6 MAINTENANCE SPECIFICATIONS Tilt limit* (IN) ---- 2.5°/1.6 mm (2.5°/0.063 in) Tilt limit* (EX) ---- 2.5°/1.6 mm (2.5°/0.063 in) Direction of winding (top view) (IN) Clockwise ---- Direction of winding (top view) (EX) Clockwise ---- Piston: Piston to cylinder clearance 0.030–0.05 5 mm (0.0012–0.0022 in) 0.1 mm (0.0 04 in) Piston size &quo[...]

2-7 MAINTENANCE SPECIFICATIONS Oil ring: Dimensions (B × T) 1.50 × 2.25 mm (0.06 × 0.09 in) ---- End gap (installed) 0.10–0.40 mm (0.004–0.016 in) ---- Crankshaft: Crank width "A" 55.95–56.00 mm (2.203–2.205 in ) ---- Runout limit "C" 0.03 mm (0.0012 in) 0.05 mm (0.002 in) Big end side clearance "D" 0.15–0[...]

2-8 MAINTENANCE SPECIFICATIONS CHASSIS Carburetor: USA, CDN, ZA, AUS, NZ EUROPE Type/manufacturer FCR-MX37/KEIHIN ← ---- I. D. mark 5UME E0 5UML L0 ---- Main jet (M.J) #170 #160 ---- Main air jet (M.A.J) #115 ← ---- Jet needle (J.N) NJRU NNGU ---- Cutaway (C.A) 1.5 ← ---- Pilot jet (P.J) #42 #45 ---- Pilot air jet (P.A.J) #70 ← ---- Pilot o[...]

2-9 MAINTENANCE SPECIFICATIONS Front suspension: Front fork travel 300 mm (11.8 in) ---- Fork spring free length 460 mm (18.1 in) 455 mm (17.9 in) Spring rate, STD K = 4.4 N/mm (0.449 kg/mm, 25.1 lb/in) ---- Optional spring/spacer Yes ---- Oil capacity 648 cm 3 (22.8 lmp oz, 21.9 US oz) ---- Oil level 132 mm (5.20 in) ---- <Min.–Max.> (From[...]

2-10 MAINTENANCE SPECIFICATIONS ELECTRICAL Drive chain: Type/manufacturer DID520VM/DAIDO ---- Number of links 113 links + joint ---- Chain slack 48–58 mm (1.9–2.3 in) ---- Chain length (15 links) ---- 239.3 mm (9.42 in) Front disc brake: Disc outside dia.×Thickness 250 × 3.0 mm (9.84 × 0.12 in) 250 × 2.5 mm (9.84 × 0.10 in) Pad thickness 4[...]

2-11 MAINTENANCE SPECIFICATIONS Charging system: System type AC magneto ---- Model (stator)/manufacturer 5UM 30/YAMAHA ---- Normal output 14 V/120 W at 5,000 r/min ---- Charging coil resistance (color) 0.288–0.432 Ω at 20 °C (68 °F) (White–Ground) ---- Lighting coil resistance (color) 0.224–0.336 Ω at 20 °C (68 °F) (Yell ow–Ground) --[...]

2-12 TIGHTENING TORQUES TIGHTENING TORQUES ENGINE △ - marked portion shall be checke d for torque ti ghtening after break-in or before each race. Part to be tightened Thr ead size Q'ty Tightening torque Nm m•kg ft•lb Spark plug M10S × 1.0 1 13 1.3 9.4 Camshaft cap M6 × 1.0 10 10 1.0 7.2 Cylinder head blind plug screw M12 × 1.0 1 28 2.[...]

2-13 TIGHTENING TORQUES Throttle cable (return) M12 × 1.0 1 11 1.1 8.0 Throttle cable cover M5 × 0.8 2 4 0.4 2.9 Hot starter plunger M12 × 1.0 1 2 0.2 1.4 Hot starter cable adjust bolt a nd locknut M6 × 0.75 1 4 0.4 2.9 △ Air filter case M6 × 1.0 2 8 0.8 5.8 Air filter joint and air filte r case M5 × 0.8 1 4 0.4 2.9 Exhaust pipe M8 × 1.25 [...]

2-14 TIGHTENING TORQUES CHASSIS △ - marked portion shall be checke d for torque ti ghtening after break-in or before each race. Part to be tightened Th read size Q'ty Tightening torque Nm m•kg ft•lb △ Upper bracket and outer tube M8 × 1.25 4 21 2.1 15 △ Lower bracket and outer tube M8 × 1.25 4 21 2.1 15 △ Upper bracket and steeri[...]

2-15 TIGHTENING TORQUES △ Rear wheel sprocket M8 × 1.25 6 50 5.0 36 △ Rear brake disc cover M6 × 1.0 2 10 1.0 7.2 △ Rear brake caliper protector M6 × 1.0 2 7 0.7 5.1 Drive chain pulle r adjust bolt and locknut M8 × 1.25 2 19 1.9 13 Engine mounting: △ Engine and engine bracke t (front) M10 × 1.25 1 53 5.3 38 △ Engine and frame (lower)[...]

2-16 TIGHTENING TORQUES 1. First, tighten the steering ring nut app roximately 38 Nm (3.8 m•kg, 27 ft•l b) by using the steering nut wrench, then loo sen the steering ring nut one turn. 2. Retighten the steering ring nut 7 Nm (0.7 m•kg, 5.1 ft•lb). ELECTRICAL Tighten the rotor nut to 65 Nm (6.5 m•k g, 47 ft•lb), loosen and retighten the[...]

2-17 TIGHTENING TORQUES GENERAL TORQUE SPECIFICA TIONS This chart specifies torque for stan- dard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assem- blies are included in the applicable sections of this book. To avoid war- page, tighten multi -fastener assem- blies in a crisscross fashion, in progre[...]

2-18 TIGHTENING TORQUES[...]

2-19 LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1. Oil filter element 2. Oil pump 3. Drive axle 4. Main axle 5. Intake camshaft 6. Exhaust camshaft 7. Oil tank 8. Oil delivery pipe A. To oil tank[...]

2-20 LUBRICATION DIAGRAMS 1. Crankshaft 2. Oil filter element 3. Oil tank 4. Oil hose A. From oil pump[...]

2-21 CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM 1. Fuel tank breather hose 2. Clamp 3. Diode 4. Hot starter cable 5. Wire harness 6. Hump (frame) 7. Cylinder head breather hose 8. Throttle position sensor lead 9. Neutral switch lead 10. Oil hose 11. Clutch cable 12. Starter motor lead 13. Cable guide 14. Negative battery lead 15. AC magneto lead 1[...]

2-22 CABLE ROUTING DIAGRAM A. Insert the end of the fuel ta nk breather hose into the hole in the steering stem. B. Fasten the throttle cable, hot starter cable and rectifier/regula - tor lead onto the frame. Locate the clamp under the throttle ca- ble on the right side of the frame, and face its ends, as well as the tie ends, dow nward. C. Fasten [...]

2-23 CABLE ROUTING DIAGRAM 1. Throttle cable (pull) 2. Throttle cable (return) 3. Catch tank hose 4. Ignition coil 5. Clamp 6. Air induction hose (air cut-off valve - rear of cylinder he ad) 7. Catch tank breather hose A. Cross the pull and push throttle cables. B. Fasten the catch tank ho se and air induction hose (air cut-off valve-rear of cylind[...]

2-24 CABLE ROUTING DIAGRAM 1. Brake ma ster cylinder 2. Brake hose holder 3. Brake ho se A. Install the brake hose so that its pipe portion directs as shown and lightly touche s the projec- tion on the brake caliper. B. Pass the brake hose into the brake hose holders. C. If the brake hose contacts the spring (rear shock absorber), correct its twist[...]

2-25 CABLE ROUTING DIAGRAM 1. Clamp 2. Positive battery lead 3. Battery 4. Negative battery lead 5. Taillight coupler 6. CDI unit coupler (6-pin) 7. CDI unit coupler (3-pin) 8. CDI unit coupler (6-pin)[...]

2-26 CABLE ROUTING DIAGRAM A. Fasten the wire harness, nega- tive battery lead and starter mo- tor lead to the upper engine bracket (left side) . Locate the clamp end facing toward the up- per side o f the fram e with th e tie end cut off on the inside of the frame. B. Fasten the wire harness, nega- tive battery lead and starter mo- tor lead to the[...]

2-27 CABLE ROUTING DIAGRAM 1. Throttle cable 2. Clamp 3. Brake ho se 4. Clutch cable 5. Hose guide 6. Main switch coupler 7. Wire harness 8. Headlight coupler 9. Hot starter cable 10. Multi-function displ ay bracket 11. Main switch 12. Upper bracket 13. Clutch switch coupler 14. Engine stop switch coupler 15. Multi-function display cou pler 16. Sta[...]

2-28 CABLE ROUTING DIAGRAM A. Fasten the start switch lead to the handlebar with the plas tic bands. B. Fasten the engine stop switch lead and clutch switch lead to the handlebar with the plas tic bands. C. Pass the brake hose through the hose guides. D. Secure the coupl er by inserting it into the multi-function display bracket. E. Pass the thrott[...]

3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM (For Canada) REGULAR INSPECTION AND ADJUSTMENTS PERIODIC MAINTENANCE CHART FO R THE EMISSION CONTRO L SYSTEM (For Canada) • From 4,200 mi (7,000 km) o r 9 months, repeat the maintenanc e in tervals starting from 1,800 mi (3,000 km) or 3 months. • Items marked with an asterisk should[...]

3-2 GENERAL MAINTENANCE AND LUBRICATION CHART (For Canada) GENERAL MAINTENANCE AND LUBRI CATION CHART (For Canada) No. ITEM CHECKS AND MAINTENANCE JOBS INITIAL ODOMETER READINGS 600 mi (1,000 km) or 1 month 1,800 mi (3,000 km) or 3 months 3,000 mi (5,000 km) or 6 months 1 Clutch Check operation. √√√ Adjust or repla ce cable. 2 * Cooling syste[...]

3-3 MAINTENANCE INTERVALS FOR COMPETITION USE • The air filter needs more frequent service if you are riding in un usually wet or dusty areas. • Hydraulic brake service • After disassemblin g the brake master cylinders and calipers, always change the fluid . Regularly check the brake fluid levels and fill the reservoirs as required. • Every[...]

3-4 MAINTENANCE INTERVALS FOR COMPETITION USE VALVE LIFTERS Inspect ● Check for scratches and wear. Replace ● CAMSHAFTS Inspect the camshaft surface. Inspect ● Inspect the decompression system. Replace ● CAMSHAFT SPROCKETS Inspect ● Check for w ear on th e teeth and for damage. Replace ● PISTON Inspect ●● Inspect crack. Clean ● In[...]

3-5 MAINTENANCE INTERVALS FOR COMPETITION USE CRANK Inspect and clean ●● CARBURETOR Inspect, adjust and clean ●● AIR INDUCTION SYSTEM Inspect and clean ●● ●● SPARK PLUG Inspect and clean ●● Replace ● DRIVE CHAIN Use chain lube. Lubricat e, slack, al ignment ●● Chain slack: 48–58 mm (1.9– 2.3 in) Replace ● COOLING SYS[...]

3-6 MAINTENANCE INTERVALS FOR COMPETITION USE FRONT FORKS Inspect and adjust ●● Replace oil ●● Suspension oil "S1" Replace oil seal ● FRONT FORK OIL SEAL AND DUST SEAL Clean and lube ●● Lithium base gr ease PROTECTOR GUIDE Replace ● REAR SHOCK ABSORBER Inspect and adjust ●● Lube ● (After rain ride) ● Molybdenum dis[...]

3-7 PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation or practice, make sure the machine is in goo d operating conditi on. Before using this machine, ch eck the following points. GENERAL INSPECTION AND MAINTENANCE Item Routine Page Coolant Check that coolant is fill ed up to the r[...]

3-8 ENGINE ENGINE REMOVING THE SEAT, FUEL TANK AND SIDE COVERS Order Part name Q'ty Remarks Turn the fuel cock to "OFF". Disconnect the fuel hose. 1S e a t 1 2 Air scoop (left and right) 2 3 Bolt (fuel tank) 2 4 Fuel tank 1 5 Left side cover 1 Open the air filter case cover. 6 Right side cover 1 Refe r to removal section. 7 Headlight[...]

3-9 ENGINE REMOVING THE SIDE COVER 1. Remove: • Bolt (side cover) • Right side cover "1" Draw the side cover backward to re- move it because its claw "a" is insert- ed in the air filter case.[...]

3-10 ENGINE REMOVING THE EXHAUST PIPE AND SILENCER Order Part name Q'ty Remarks Right side cover Refer to "REMOVING THE SEAT, FUEL TANK AND SIDE COVERS" section. 1 Bolt (silencer clamp) 1 Only loosening. 2 Bolt [silencer (front)] 1 3 Bolt [silencer (rear)] 1 4 Collar 1 5 Silencer 1 6 Silencer clamp 1 7 Nut (exhaust pipe) 2 8 Exhaust [...]

3-11 ENGINE CHECKING THE SILENCER AND EXHAUST PIPE 1. Inspect: • Gasket "1" Damage → Replace. INSTALLING THE SILENCER AND EXHAUST PIPE 1. Install: • Gasket • Exhaust pipe "1" • Nut (exhaust pipe) "2" First, temporarily install both nuts, then tighten either of these nuts to 13 Nm (1.3 m•kg, 9.4 ft•lb) and[...]

3-12 ENGINE • Do not mix more than one type of ethylene glycol antifreeze con - taining corrosion in hibitors for aluminum engi ne. • Do not use water co ntaining im- purities or oil. Handling note s of coolant: The coolant is harmful so it should be handled with sp ecial care. • When coola nt splashes to yo ur eye. Thoroughly wash your eye w[...]

3-13 ENGINE ADJUSTING THE THROTTLE CABLE FREE PLAY 1. Check: • Throttl e grip free pla y "a" Out of specification → Adjust. 2. Adjust: • Throttl e grip free pla y Throttle grip free play adj ustment steps: a. Slide the adjuster cover. b. Loosen the locknut "1". c. Tu rn the adjuster "2" until the specified free p[...]

3-14 ENGINE 4. Clean: • Air filter element Clean them with solvent. After cleaning, remo ve the remaining solvent by squeezing the element. • Do not twist the element when squeezing the elem ent. • Leaving too mu ch of solvent in the element may result in poor starting. 5. Inspect: • Air filter element Damage → Replace. 6. Apply: • Foam[...]

3-15 ENGINE 5. Remove: • Oil hose clamp "1" • Bolt (oil hose) • Oil hose "2" • Oil strain er "3" 6. Inspect: • Oil strain er Clogged → Blow. 7. If the oil filter is to be replaced dur- ing this oil change, remove the fol- lowing parts and reinstall them. Replacement steps: a. Remove the oil filter elemen t [...]

3-16 ENGINE ADJUSTING THE PILOT SCREW (For EUROPE) 1. Adjust: • Pilot screw "1" Adjustme nt steps: To optimize the fuel flo w at a smaller throttle opening, e ach machine's pilot screw has been individuall y set at the factory. Before adju sting the pilo t screw, turn it in fully and count the number of turns. Record this number as[...]

3-17 ENGINE 6. Adjust: • Valve clearance Adjustme nt steps: a. Remove the camshaft (intake and exhaust). Refer to "CAMSHAFTS" section in the CHAPTER 5. b. Remove the valve lifters "1" and the pads "2". • Place a rag in the timing chain space to prevent pads from falling into the crankcase. • Identity each valve l[...]

3-18 ENGINE INTAKE EXHAUST MEASURED CLEARANCE INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 165 17 0 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 - 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.05 - 0.09 120 125 130 135 140 145 150 155 160 16 5 170 175 180 185 190 195 2[...]

3-19 CHASSIS CLEANING THE SPARK ARRESTER (For USA) • Be sure the exhaust pipe and si- lencer a re cool b efore cl eaning the spark arre ster. • Do not start the engi ne when cleaning the exhaus t system. 1. Remove: • Screw (silencer cap) "1" 2. Remove: • Bolt (spark arrester) "1" 3. Remove: • Tail pipe "1" ?[...]

3-20 CHASSIS ADJUSTING THE FRONT BRAKE 1. Check: • Brake lever position "a" 2. Remove: • Brake lever cover 3. Adjust: • Brake lever position Brake lever position adjustment steps: a. Loosen the locknut "1". b. Turn the adjusti ng bolt "2" until the lever position "a" is within speci- fied position. c. T[...]

3-21 CHASSIS e. Connect the transparent hose " 5" to the bleed screw "6" and place the suitable container under its end. f. Loosen the b leed screw and push the brake caliper piston in. Do not reuse th e drained brake f lu- id. g. Tighten the bleed screw. h. Install the brake pads "7" a nd pad pin. • Install the brak[...]

3-22 CHASSIS i. Insta ll the brake caliper "12" and rear wheel "13". Refer to "FRONT WHEEL AND REAR WHEEL" section in the CHAPTER 6. j. Ti ghten the pad pin "14". k. Insta ll the pad pin plug "15" and protector "16". 3. Inspect: • Brake fluid level Refer to "CHECKING THE BRAKE FLUID[...]

3-23 CHASSIS 4. Inspect: • O-ring "1" (drive chain) Damage → Replace the drive chain. •R o l l e r " 2 " • Side plate "3" Damage/wear → Replace th e drive chain . 5. Check: • Drive chain stiffness "a" Clean and oil th e drive chain and hold as illustrated. Stiff → Replace the drive chain. 6. Ins[...]

3-24 CHASSIS CLEANING THE FRONT F ORK OIL SEAL AND DUST SEAL 1. Remove: •P r o t e c t o r • Dust seal "1" Use a thin screw driver, and be care- ful not to damage the inner fork tube and dust seal. 2. Clean: • Dust seal "a" • Oil seal "b" • Clean the dust seal and oil seal af- ter every run. • Apply the lit[...]

3-25 CHASSIS ADJUSTING THE REAR SHOCK ABSORBER SPRING PRELOAD 1. Elevate the rear wheel by placing the suitable stand under the en- gine. 2. Remove: • Rear frame 3. Measure: • Spring fitting length The I.D. mark "a" is marked at the end of the spring. 4. Adjust: • Spring preload Adjustme nt steps: a. Loosen the locknut "1"[...]

3-26 CHASSIS • STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. (Which align the punch mark "a" on the adjuster with the punch mark "b" on the high compression damping adjuster.) Do not force the adju ster past the minimum or maximum extent of adjustment.[...]

3-27 CHASSIS 2. Inspect: • Bearing free play Exist play → Replace. CHECKING AND ADJUSTING THE STEERING HEAD 1. Place a stand under the engine to raise the front wheel o ff the ground. WARNING! Securely support the veh icle so that there is no danger o f it fallin g over. 2. Check: • Steering stem Grasp the bottom of the forks and gently rock [...]

3-28 CHASSIS LUBRI CATION To ensure smooth operation of all components, lubricate your machine during setup, afte r break-in, and after every ride. 1. Al l control cable 2. Clutch lever pivot 3. Sh ift pedal pivot 4. Footrest pivot 5. T hrottle-to-handlebar contact 6. D rive chain 7. T ube guide ca ble winding por- tion 8. T hrottle cable end 9. C [...]

3-29 ELECTRICAL ELECTRICAL CHECKING THE SPARK PLUG 1. Remove: • Spark plug 2. Inspect: • Electrode "1" Wear/damage → Replace. • Insulator color "2" Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition. When the engine runs for many hours at low speeds, the spark plug [...]

3-30 ELECTRICAL 1. Remove: • Seat 2. Disconnect: • Battery leads (from the battery terminals) First, disconnect the negative ba t- tery lead "1", and then the positiv e battery lead "2". 3. Remove: • Battery band •B a t t e r y 4. Measure: • Battery charge Measurement steps: a. Connect a pocket tester "1" to [...]

3-31 ELECTRICAL Charging method usin g a variable vo ltage charg er[...]

3-32 ELECTRICAL Charging method usin g a constant voltag e charger[...]

3-33 ELECTRICAL 6. Install: •B a t t e r y • Battery band 7. Connect: • Battery leads (to the batte ry terminals) First, connect the positiv e lead "1", then the negative lead "2". 8. Check: • Battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. 9. Lubricate: • Battery terminal 10.[...]

3-34 ELECTRICAL 6. Install: • Headlight bulb ho lder 7. Install: • Headlight bulb holder cover 8. Install: • Headlight Refer to "REMOVING THE SEAT, FUEL TANK AND SIDE COV- ERS" section. ADJUSTING THE HEADLIGHT BEAMS 1. Adjust: • Headlight beam (ve rtically) Adjusting steps: a. Turn the adjusting screw "1" in di- rection [...]

4-1 ENGINE (Except for Canada) TUNING ENGINE (Except for Canada) CARBURETOR SETTING • The air/fuel mixture will vary de- pending on atmospheric conditi ons. Therefore, it is necessary to take into consideration the air pressure, ambient temperature, hu midity, etc., when adjusting the carburetor. • Perform a test run to check for prop- er engin[...]

4-2 ENGINE (Except for Canada) ADJUSTING THE PILOT JET The richness of the air-fuel mi xture with the throttle open 1/4 or less can be set by adjusti ng the pilot je t "1". Effects of adjusting the pilot jet (reference) A. Idle B. Fully open 1. #45 2. #40 3. #42 ADJUSTING THE JET NEEDLE GROOVE POSITION Adjusting the jet needl e "1&qu[...]

4-3 ENGINE (Except for Canada) CARBURETOR SETTING PARTS Main jet Size Part number (-14943-) Rich #182 4MX-94 #180 4MX-43 #178 4MX-93 #175 4MX-42 #172 4MX-92 (STD) #170 4MX-41 #168 4MX-91 #165 4MX-40 #162 4MX-90 * (STD) #160 4MX-39 Lean #158 4MX-89 Pilot jet S ize Part number (-14948-) Rich #50 4MX-07 #48 4MX-06 * (STD) #45 4MX-05 (STD) #42 4MX-04 L[...]

4-4 ENGINE (Except for Canada) EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM This shou ld be taken simply f or an exam ple. It is necessary to set the carburetor while checking the operating conditions of the engine. Symptom Setting Checking At full throttle Hard breathing Shearing noise Whitish spark plug ↓ Lean mixture Increase main jet c[...]

4-5 CHASSIS CHASSIS SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET) <Requirement for selection of sec- ondary gear reduction ra tio> • It is generally said that the second- ary gear ratio should be reduced for a longer straight portion of a speed course and should be in creased for a course with many corners. Actual - ly, however, as [...]

4-6 CHASSIS A. Air spring characteristics in relation to oil l evel change B. Load C. Stroke 1. Max. oil level 2. Standard oil level 3. Min. oil level ADJUSTING THE SPRING PRELOAD The spring preload is adjusted by in- stalling the adjustment wa sher "1" be- tween the fork spring "2" and damper rod "3". Do not install t[...]

4-7 CHASSIS CHOOSING SET LENGTH 1. Place a stand or bl ock under the engine to put the rear wheel above the floor, and measure the length "a" between the rear wheel axle center and the re ar fender holding bolt. 2. Remove the stand or bl ock from the engine and w ith a rider as tride the seat, measure the sunken length "b" betwe[...]

4-8 CHASSIS • Extent of adjustment (spring pre- load) For the spring preload adjustment, re- fer to "ADJUSTING THE REAR SHOCK ABSORBER SPRING PRE- LOAD" in the C HAPTER 3. SPRING PART NUM- B E R (-22212-) Maximum Minimum 5UN-00 5UN-10 5UN-20 5UN-30 Position in which the spring is turned in 20 mm (0.79 in) from its free length. Position [...]

4-9 CHASSIS SUSPENSION SETTING (FRONT FORK) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure gi ven in the same chart. • Before any change, set t he rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in). Symptom Section[...]

4-10 CHASSIS SUSPENSION SETTING (REAR SHOCK ABSORBER) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure gi ven in the same chart. • Adjust the rebound damping in 2-click increments or decrem ents. • Adjust the low compression damping in 1-click inc[...]

5-1 RADIATOR ENGINE This section is intended for those who have basi c knowled ge and skill concerning th e servicing of Yamaha motorcycles (e.g., Yamaha dealers, se rvice engineers, etc.) Those who have little knowled ge and skill concernin g servicing are request- ed not to undertake inspection , adjustment, disassembly, or reassembly only by ref[...]

5-2 RADIATOR 8 Catch tank hose 1 9 Right radiator 1 10 Radiator hose 2 1 11 Radiator hose 4 1 12 Radiator pipe 1 1 13 Catch tank breather hose 1 14 Catch tank 1 Order Part name Q'ty Remarks 5[...]

5-3 RADIATOR HANDLING NOTE Do not remove the radiator cap when the engine and ra diator are hot. Scaldi ng hot fluid and steam may be blown out under pressure, which could ca use serious in jury. When the engin e has cooled, open the radiator cap by th e following procedure: Place a thick rag, like a towel, over the radiator cap, sl owly rotate the[...]

5-4 CARBURETOR CARBURETOR REMOVING THE CARBURETOR Order Part name Q'ty Remarks Seat and fuel ta nk Refer to "REMOVING THE SEAT, FUEL TANK AND SIDE COVERS" section in the CHAPTER 3. Rear shock absorber Refer to "REAR SHOCK ABSORBER" sec- tion in the CHAPTER 6. 1C l a m p 2 2 Throttle position sensor lead coupler 1 3 Throttle[...]

5-5 CARBURETOR DISASSEMBLING THE CARBURETOR Order Part name Q'ty Remarks 1 Carburetor breather hose 4 2 Valve lever housing cover 1 3 Screw (throttle shaft) 1 4 Throttle valve 1 5 Need le holder 1 6 Jet needle 1 7 Accelerator pump cover 1 8S p r i n g 1 9 Diaphragm (accelerator pump) 1 10 Air cut valve cover 1 11 Spring (air cut valve) 1 12 Di[...]

5-6 CARBURETOR 19 Main jet 1 20 Needle jet 1 21 Spacer 1 22 Pilot jet 1 23 Starter jet 1 24 Push rod 1 Pull the push rod. 25 Throttle shaft assembly 1 26 Push rod link lever assembly 1 27 Main air jet 1 28 Pilot air jet 1 29 Cold starter plunger 1 Order Part name Q'ty Remarks[...]

5-7 CARBURETOR HANDLING NOTE Do not loosen th e screw (throttle position sensor) "1" except when changing the th rottle position sen- sor due to failur e because it will cause a drop in engine pe rfor- mance. REMOVING THE PILOT SCREW (For EUROPE) 1. Remove: • Pilot screw "1" To optimize th e fuel flow at a smal l throttle open[...]

5-8 CARBURETOR e. If both are fine, adjust the float height by bending th e float tab "b" on the float. f. Recheck the float height. CHECKING THE FLOAT 1. Inspect: • Float "1" Damage → Replace. CHECKING THE STARTER PLUNGER 1. Inspect: • Cold starter plunger "1" • Hot starter plunger "2" Wear/damage ?[...]

5-9 CARBURETOR • Apply the fluoro chemical grease on the bearings. • Fit the projection "a" on the throttle shaft assembly into the slot "b" in the throttle posit ion sensor. • Make sure the stopper "c" of the spring fits into the recess in the car- buretor . • Turn the throttle shaft assembl y left while holdi[...]

5-10 CARBURETOR 16. Install: • Jet needle "1" •C o l l a r " 2 " • Spring "3" • Needle holder "4 " • Throttle valve plate "5" To throttle valve "6 ". 17. Install: • Throttle valve assembly "1" • Screw (throttle shaft) "2" Install the valve lever rollers &q[...]

5-11 CARBURETOR 6. Adjust: • Throttle grip free pla y Refer to "ADJUSTING THE THROTTLE CABLE FREE PLAY" section in the CHAPTER 3. 7. Install: • Throttle cable cover "1" • Bolt (throttle cable cover) "2" 8. Install: • Throttle position sensor le ad cou- pler "1" • Clamp " 2" Refer to "[...]

5-12 AIR INDICTOIN SYSTEM AIR INDICTOIN SYSTEM REMOVING THE AIR INDUCTION SYSTEM Order Part name Q'ty Remarks 1 Bracket 1 2 Air cut-off valve assembly 1 3 Air induction hose (ai r cut-off valve - front of cyl- inder head) 1 4 Air induction pipe 1 5 Gasket 1 6 Air induction hose (air cut-off valve - rear of cylin- der head) 1 7 Air induction ho[...]

5-13 AIR INDICTOIN SYSTEM CHECKING THE AIR INDUCTION SYSTEM 1. Inspect: • Air induction hose Crack/damage → Replace. • Air induction pipe Crack/damage → Replace. 2. Check: • Operation of air cut valve Pass air through the pipe and check the air cut valve for opera- tion. Does not meet the followi ng con- dition → Replace the air cut val[...]

5-14 CAMSHAFTS CAMSHAFTS REMOVING THE CYLINDER HEAD COVER Order Part name Q'ty Remarks Seat and fuel ta nk Refer to "REMOVING THE SEAT, FUEL TANK AND SIDE COVERS" section in the CHAPTER 3. Air cut-off valve assembly Refer to "AIR INDUCTION SYSTEM" section. 1 Spark plug 1 2 Cylinder head breath er hose 1 3 Bolt (cylinder hea[...]

5-15 CAMSHAFTS REMOVING THE CAMSHAFTS Order Part name Q'ty Remarks 1 Timing mark accessing screw 1 Refer to removal section. 2 Crankshaft end accessing screw 1 Refer to removal section. 3 Timing chain tensioner cap bolt 1 Refer to removal section. 4 Timing chain tensioner 1 Refer to removal section. 5 Camshaft cap 2 Refer to removal section. 6[...]

5-16 CAMSHAFTS REMOVING THE CAMSHAFT 1. Remove: • Timing mark accessing screw "1" • Crankshaft end accessing screw "2" 2. Align: • T.D.C. mark With align mark. Checking steps: a. Turn the crankshaft counterclock- wise with a wren ch. b. Align the T.D.C. mark "a" on the rotor with the align mark "b" on t[...]

5-17 CAMSHAFTS 4. Measure: • Camshaft-to-cap clearance Out of specification → Measure camshaft outside diamete r. Measurement steps: a. Install the camshaft onto the cylin- der head. b. Position a strip of Pl astigauge ® "1" onto the camshaft. c. Install the clip, dowe l pins and camshaft caps. • Tighten the bolts (camshaft cap) in[...]

5-18 CAMSHAFTS The camshafts should be installed onto the cylinder head so that the punch mark "c" on the exhaust cam- shaft and the punch mark "d" on the intake camshaft must align with the cylinder head surface, as shown in the illustration. Do not turn the cranksha ft during the camshaft insta llation. Damage or improper valv[...]

5-19 CYLINDER HEAD CYLINDER HEAD REMOVING THE CYLINDER HEAD Order Part name Q'ty Remarks Seat and fuel ta nk Refer to "REMOVING THE SEAT, FUEL TANK AND SIDE COVERS" section in the CHAPTER 3. Exhaust pipe and silencer Refer to "REMOVING THE EXHAUST PIPE AND SILENCER" section in the CHAPTER 3. Radiator hose 1 Disconnect at cy[...]

5-20 CYLINDER HEAD CHECKING THE CYLINDER HEAD 1. Eliminate: • Carbon deposits (from the com- bustion chambers) Use a rounded scraper. Do not use a sharp instrument to avoid damaging or scratching: • Spark plug threads • Valve seats 2. Inspect: • Cylinder head Scratches/damage → Replace. Replace the titanium valves with the cylinder head. [...]

5-21 VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS REMOVING THE VALVES AND VALVE SPRINGS Order Part name Q'ty Remarks Cylinder head Refer to "CYLINDER HEAD" section. 1 Valve lifter 5 Refer to removal section. 2 Adjusting pad 5 Refer to removal section. 3 Valve cotter 10 Refer to removal section. 4 Valve spring retainer 5 5 Valve [...]

5-22 VALVES AND VALVE SPRINGS REMOVING THE VALVE LIFTER AND VALVE COTTER 1. Remove: • Valve lifter "1" • Pad "2" Identify each lifter "1" and pad "2" po- sition very carefully so that they can be reinstalled in their original place. 2. Check: • Valve sealing Leakage at the valve seat → In- spect the v[...]

5-23 VALVES AND VALVE SPRINGS 3. Inspect: • Valve face Pitting/wear → Grind the face. • Valve stem end Mushroom shape or diameter larger than the body o f the stem → Replace. 4. Measure: • Margin thickness "a" Out of specification → Replace. 5. Measure: • Runout (valve stem) Out of specification → Replace. • When install[...]

5-24 VALVES AND VALVE SPRINGS h. Press the valve thro ugh the valve guide and onto the valve seat to make a clear pattern. i. Measure the valve seat width again. If the valve seat width is out of specification, reface and relap the valve seat. CHECKING THE VALVE SPRINGS 1. Measure: • Valve spring free length "a" Out of specification →[...]

5-25 CYLINDER AND PISTON CYLINDER AND PISTON REMOVING THE CYLINDER AND PISTON Order Part name Q'ty Remarks Cylinder head Refer to "CYLINDER HEAD" section. 1 Bolt (cylinder) 1 2 Cylinder 1 3 Piston pin clip 2 Refer to removal section. 4 Piston pin 1 Refer to removal section. 5 Piston 1 Refer to removal section. 6 Piston ring set 1 Ref[...]

5-26 CYLINDER AND PISTON REMOVING THE PISTON AND PISTON RING 1. Remove: • Piston pin clip "1" • Piston pin "2" • Piston "3" • Put identification marks on each piston head for reference during re- installation. • Before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groov[...]

5-27 CYLINDER AND PISTON a. 10 mm (0.39 in) 3. Measure: • Ring end gap Out of specification → Replace. You cannot measure the end gap on the expander spacer of the oil control ring. If the oil control ring rails show excessive gap, replace all three rings. CHECKING THE PISTON PIN 1. Inspect: • Piston pin Blue discoloration/gro oves → Re- pl[...]

5-28 CYLINDER AND PISTON INSTALLING THE CYLINDER 1. Lubricate: •P i s t o n • Piston ring • Cylinder Apply a liberal coating of engine oil. 2. Install: • Dowel pin "1" • O-ring "2" Apply the lithium soap base grease on the O-ring. 3. Install: • Cylinder gasket "1" • Cylinder "2" Install the cyl [...]

5-29 CLUTCH CLUTCH REMOVING THE CLUTCH Order Part name Q'ty Remarks Drain the engine oil . Refer to "CHANGING THE ENGINE OIL" section in the CHAPTER 3. Brake pedal Refer to "ENGINE REMOVAL" secti on. Clutch cable Disconnect at engine side. 1 Clutch cover 1 2 Clutch spring 5 3 Pressure plate 1 4 Push rod 1 1 5 Circlip 1 6 Wa[...]

5-30 CLUTCH 14 Nut (clutch boss) 1 Refer to removal section. 15 Lock washer 1 Refer to removal section. 16 Clutch boss 1 Refer to removal section. 17 Thrust washer 1 18 Primary driven gear 1 19 Push lever shaft 1 Order Part name Q'ty Remarks[...]

5-31 CLUTCH REMOVING THE CLUTCH BOSS 1. Remove: •N u t " 1 " • Lock washer "2" • Clutch boss "3" Straighten the lock washer tab and use the clutch holding tool "4" to hold the clutch boss. A. For USA and CDN B. Except for USA and CDN CHECKING THE CLUTCH HOUSING AND BOSS 1. Inspect: • Clutch housing &q[...]

5-32 CLUTCH INSTALLING THE CLUTCH 1. Install: • Primary driven gear " 1" • Thrust washer "2" • Clutch boss "3" Apply the engine oil on the primary driven gear inner circumferen ce. 2. Install: • Lock washer "1" • Nut (clutch boss) "2" Use the clutch holding tool "3" to hold the c[...]

5-33 CLUTCH 10. Install: • Dowel pin "1" • Gasket (clutch cover) "2" 11. Install: • Clutch cover "1" • Bolt (clutch cover) Tighten the bolts in stage, using a crisscross pattern. Bolt (clutch cover): 10 Nm (1.0 m•kg, 7.2 ft•lb)[...]

5-34 OIL FILTER ELEMENT AND WATER PUMP OIL FILTER ELEMENT AND WATER PUMP REMOVING THE OIL FILTER ELEMENT AND WATER PUMP Order Part name Q'ty Remarks Drain the engine oil . Refer to "CHANGING THE ENGINE OIL" section in the CHAPTER 3. Drain the coolant. Refer to "CHANGING THE COOLANT" sec - tion in the CHAPTER 3. Radiator hos[...]

5-35 OIL FILTER ELEMENT AND WATER PUMP 9 Washer 1 Refer to removal section. 10 Impeller shaft 1 Refer to removal sectio n. 11 Oil seal 2 Refer to removal section. 12 Bearing 1 Refer to removal section. Order Part name Q'ty Remarks[...]

5-36 OIL FILTER ELEMENT AND WATER PUMP REMOVING THE IMPELLER SHAFT 1. Remove: • Impeller "1" • Washer "2" • Impeller shaft "3" Hold the impeller shaft on its width across the flats "a" with spanners, etc. and remove the impeller. REMOVING THE OIL SEAL It is not necessary to disassemble the water pump, u[...]

5-37 OIL FILTER ELEMENT AND WATER PUMP INSTALLING THE RIGHT CRANKCASE COVER 1. Install: • Dowel pin "1" • O-ring "2" •C o l l a r " 3 " • Gasket "4" Apply the lithium soap base grease on the O-ring. 2. Install: • Right crankcase cover "1" • Bolt (right crankcase cover) "2" • [...]

5-38 OIL FILTER ELEMENT AND WATER PUMP INSTALLING T HE OIL FILTER ELEMENT 1. Install: • Oil filter element "1" • O-ring "2" • Oil filter element cover "3" • Bolt (oil filter element cover) Apply the lithium soap base grease on the O-ring. Bolt (oil filter element cover): 10 Nm (1.0 m•kg, 7.2 ft•lb)[...]

5-39 BALANCER BALANCER REMOVING THE BALANCER Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" secti on. Right crankcase cover Refer to "OIL FILTER ELEMENT AND WA- TER PUMP" section. Stator Refer to "AC MAGNETO AND STARTER CLUTCH" section. 1 Nut (primary drive gear) 1 R efer to removal section. 2 [...]

5-40 BALANCER REMOVING THE BALANCER 1. Straighten the lock wa sher tab. 2. Loosen: • Nut (primary drive gear) "1" • Nut (balancer shaft driven gear) "2" Place an aluminum plate "a" b etween the teeth of the balancer shaft drive gear "3" and driven gear "4". 3. Remove: • Balancer shaft "1&[...]

5-41 OIL PUMP OIL PUMP REMOVING THE OIL PUMP Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Right crankcase cover Refer to "OIL FILTER ELEMENT AND WA- TER PUMP" section. 1 Circlip 1 2 Washer 1 3 Oil pump drive gear 1 4 Oil pump assembly 1 5 Outer rotor 2 1 6 Circlip 1 7 Inner rotor 2 1 8 Dowel p[...]

5-42 OIL PUMP REMOVING THE OIL TANK Order Part name Q'ty Remarks Drain the engine oil . Refer to "CHANGING THE ENGINE OIL" section in the CHAPTER 3. 1 Oil hose 2 1 2 Oil hose 1 1 3 Dowel pin 2 4 Oil tank breather hose 1 5 Oil tank 1 6 Oil strainer 1[...]

5-43 OIL PUMP CHECKING THE OIL PUMP 1. Inspect: • Oil pump drive gear "1" • Oil pump drive shaft "2" • Rotor housing "3" • Oil pump cover "4" Cracks/wear/damage → Replace. 2. Measure: • Tip clearance "a" (between the inner rotor "1" and outer rotor "2") • Side clear[...]

5-44 KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Remarks Oil pump Refer to "OIL PUMP" section. 1 Kick idle gear 1 2 Kick shaft assembly 1 Ref er to removal section. 3 Spring guide 1 4 Torsion spring 1 5 Ratch et wheel 1 6 Kick gear 1 7 Kick shaft 1 8 Washer 1 9 Sh[...]

5-45 KICK SHAFT AND SHIFT SHAFT 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt (stopper lever) 1 21 Stopper lever 1 22 Torsion spring 1 23 Segment 1 Refer to removal section. Order Part name Q'ty Remarks[...]

5-46 KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT ASSEMBLY 1. Remove: • Kick shaft assembly "1" Unhook the torsion spring "2" from the hole "a" in the crankcase. REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1. Remove: • Bolt (shift guide) • Shift guide "1" • Shift lever assembly "2&quo[...]

5-47 KICK SHAFT AND SHIFT SHAFT INSTALLING THE STOPPER LEVER 1. Install: • Torsion spring "1" • Stopper lever "2" • Bolt (stopper lever) "3" Align the stopper lever ro ller with the slot on segment. INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1. Install: • Spring "1" • Pawl pin "2"[...]

5-48 KICK SHAFT AND SHIFT SHAFT 4. Install: • Kick shaft assembly "1" • Washer "2" • Apply the molybdenum di sulfide grease on th e contacting surfaces of the kick shaft stopper "a" and kick shaft ratchet wheel guide "3". • Apply the engine oil on the kick shaft. • Slide the kick shaft assembly into[...]

5-49 AC MAGNETO AND STARTER CLUTCH AC MAGNETO AND STARTER CLUTCH REMOVING THE AC MAGNETO AND STARTER CLUTCH Order Part name Q'ty Remarks Drain the engine oil . Refer to "CHANGING THE ENGINE OIL" section in the CHAPTER 3. Seat and fuel ta nk Refer to "REMOVING THE SEAT, FUEL TANK AND SIDE COVERS" section in the CHAPTER 3. Di[...]

5-50 AC MAGNETO AND STARTER CLUTCH Tighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb), loosen and retighten th e rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb). 12 Starter clutch 1 Refer to removal section. 13 Bearing 1 14 Washer 1 15 Idle gear plate 1 16 Idle gear 1 17 Holder 1 18 Pickup coil 1 19 Stator 1 Order Part name Q'ty Remarks[...]

5-51 AC MAGNETO AND STARTER CLUTCH REMOVING THE ROTOR 1. Remove: • Nut (rotor) "1" • Washer Use the sheave holder "2". 2. Remove: • Rotor "1" Use the rotor puller "2". REMOVING THE STARTER CLUTCH 1. Remove: • Starter clutch a ssembly cover "1" Insert a thin screwdriver or the like under the [...]

5-52 AC MAGNETO AND STARTER CLUTCH • Pickup coil "3" • Bolt (pickup coil) "4" 2. Install: • Holder "1" •B o l t " 2 " Pass the pickup coil lead an d charging co il lead un der the holder while taking care not to allow these leads to get cau ght with each oth - er. Also take care to pass th e leads so [...]

5-53 AC MAGNETO AND STARTER CLUTCH 10. Install: • Dowel pin • Gasket [crankcase cover (left)] • Crankcase cover (left) "1" • Bolt [crankcase cover (left)] "2" • Bolt [crankcase cover (left)] "3" Tighten the bolts in stage, using a crisscross pattern. 11. Install: • Washer "1" • Torque limi ter &[...]

5-54 ENGINE REMOVAL ENGINE REMOVAL REMOVING THE ENGINE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the frame. Refer to "HANDLING NOTE". Drain the engine oil . Refer to "CHANGING THE ENGINE OIL" section in the CHAPTER 3. Seat and fuel ta nk Refer to "REMOVING THE SEAT, FUEL TANK AND[...]

5-55 ENGINE REMOVAL Disconnect the AC magneto lead. Negative battery lead Disconnect at the engine side. 1 Engine guard 1 2 Neutr al switch 1 3 Drive chain sprocket cover 1 4 Nut (drive sprocket) 1 Ref er to removal section. 5 Lock washer 1 Refer to removal section. 6 Drive sprocket 1 Refer to removal section. 7C l i p 1 8 Bolt (brake pedal) 1 9 Br[...]

5-56 ENGINE REMOVAL HANDLING NOTE Support the machine securely so there is no dange r of it falling over. REMOVING THE DRIVE SPROCKET 1. Remove: • Nut (drive sprocket) "1" • Lock washer "2" • Straighten the lock washer tab . • Loosen the nut while appl ying the rear brake. 2. Remove: • Drive sprocket "1" • [...]

5-57 ENGINE REMOVAL 2. Install: • Lock washer "1" • Nut (drive sprocket) "2" Tighten the nut while applying the rear brake. 3. Bend the lock washer tab to lock the nut. 4. Install: • Drive chain sprocket guide "1" • Drive chain sp rocket cover "2" • Bolt (drive chain sprocket cover) "3" IN[...]

5-58 CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT REMOVING THE CRANKSHAFT Order Part name Q'ty Remarks Engie Refer to "ENGINE REMOVAL" section. Piston Refer to "CYLINDE R AND PISTON" section. Kick shaft assembly Refer to "KICK SHAFT AND SHIFT SHAFT" section. Segment Refer to "KICK SHAFT AND SHIFT SHAFT&q[...]

5-59 CRANKCASE AND CRANKSHAFT 9 Right crankcase 1 Refer to removal section. 10 Left crankcase 1 Refer to removal section. 11 Oil strainer 1 12 Crankshaft 1 Refer to removal section. Order Part name Q'ty Remarks[...]

5-60 CRANKCASE AND CRANKSHAFT REMOVING THE CRANKCASE BEARING Order Part name Q'ty Remarks Transmission Refer to "TRANSMISSION, SHIFT CAM AND SHIFT FORK" section. Shift cam and shift fork Refer to "TRANSMISSION, SHIFT CAM AND SHIFT FORK" section. 1 Oil seal 2 2 Bearing 10 Refer to removal section.[...]

5-61 CRANKCASE AND CRANKSHAFT DISASSEMBLING THE CRANKCASE 1. Separate: • Right crankcase • Left crankcase Separation steps: a. Remove the crankcase bolts "1", hose guide "2 " and clutch cabl e holder "3". Loosen each bolt 1/4 of a turn at a time and after all the bolts are loos- ened, remove them. b. Remove the rig[...]

5-62 CRANKCASE AND CRANKSHAFT CHECKING THE OIL STRAINER 1. Inspect: • Oil strainer Damage → Replace. CHECKING THE OIL DELIVERY PIPE 2 1. Inspect: • Oil delivery pipe 2 "1" • O-ring "2" Damage → Replace. • Oil orifice "a" Clogged → Blow. INSTALLING THE CRANKCASE BEARING 1. Install: • Bearing • Bearing [...]

5-63 CRANKCASE AND CRANKSHAFT 5. Install: • Dowel pin "1" • O-ring "2" • Right crankcase To left crankcase. • Apply the lithium soap ba se grease on the O-ring. • Fit the right crankca se onto the left crankcase. Tap lightly on the case with soft hammer. • When installing the crankcase, the connecting rod should be p[...]

5-64 TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION, SHIFT CAM AND SHIFT FORK Order Part name Q'ty Remarks Engine Refer to "ENGINE REMOVAL" section. Separate the crankcase. Refer to "CRANKCASE AND CRANK- SHAFT" section. 1 Main axle 1 Refer to removal section. 2 Drive [...]

5-65 TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION 1. Remove: • Main axle "1" • Drive axle "2" • Shift cam • Shift fork 3 • Shift fork 2 • Shift fork 1 • Remove assembly with the collar "3" installed to the crankcase. • Remove assembly carefully. Note the position of each part. Pay pa[...]

5-66 TRANSMISSION, SHIFT CAM AND SHIFT FORK 3. Install: • Washer "1" • Circlip "2" • Be sure the circlip sharp-edged cor- ner "a" is po sitioned oppo site side to the washer and gear "b". • Install the circlip with its ends "c" settled evenly on the spline crests. 4. Install: •C o l l a r [...]

6-1 FRONT WHEEL AND REAR WHEEL CHASSIS This section is intended for those who have basi c knowled ge and skill concerning th e servicing of Yamaha motorcycles (e.g., Yamaha dealers, se rvice engineers, etc.) Those who have little knowled ge and skill concernin g servicing are request- ed not to undertake inspection , adjustment, disassembly, or rea[...]

6-2 FRONT WHEEL AND REAR WHEEL REMOVING THE REAR WHEEL Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". 1 Nut (rear wheel axle) 1 2 Rear whe el axle 1 3 Drive chain puller 2 4 Rear wheel 1 Refer to remova l section. 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 [...]

6-3 FRONT WHEEL AND REAR WHEEL HANDLING NOTE Support the machine securely so there is no dange r of it falling over. REMOVING THE REAR WHEEL 1. Remove: • Wheel "1" Push the wheel forward and remove the drive chain "2". REMOVING THE WHEEL BEARING 1. Remove: • Bearing "1" Remove the bearing using a general bearing pu[...]

6-4 FRONT WHEEL AND REAR WHEEL 2. Install: • Brake disc "1" • Bolt (brake disc) "2" Tighten the bolts in stage, using a crisscross pattern. 3. Install: •C o l l a r " 1 " Apply the lithium soap base grease on the oil seal lip. 4. Install: • Speed sensor "1" • Apply the lithium soap ba se grease on t[...]

6-5 FRONT WHEEL AND REAR WHEEL 2. Install: • Brake disc "1" • Bolt (brake disc) "2" Tighten the bolts in stage, using a crisscross pattern. 3. Install: • Rear wheel sprocket "1" • Bolt (rear wheel sprocket) "2" • Washer (rear wheel sprocket) "3" • Nut (rear wheel sprocket) "4" [...]

6-6 FRONT BRAKE AND REAR BRAKE FRONT BRAKE AND REAR BRAKE REMOVING THE FRONT BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Drain the brake fluid. Refer to removal section. 1 Brake hose hold er (protector) 2 2 Brake hose hold er (brake calipe r) 1 3 Union [...]

6-7 FRONT BRAKE AND REAR BRAKE REMOVING THE REAR BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Rear wheel Refer to "FRONT WHEEL AND REAR WHEEL" section. Drain the brake fluid. Refer to removal section. 1 Brake pedal 1 2 Brake master cylinder 1 3[...]

6-8 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE CALIPER Order Part name Q'ty Remarks A. Front B. Rear AB 1P a d p i n 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Brake caliper piston 2 1 R e fer to removal section. 5 Brake caliper piston dust s eal 2 1 Refer to removal section. 6 Brake caliper piston seal 2 1 Refer to removal section.[...]

6-9 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE MASTER CYLINDER Order Part name Q'ty Remarks A. Front B. Rear 1 Brake master cylinder cap 1 2 Diaphragm 1 3 Reserv oir float 1 4 Brake master cylinder boot 1 5 Circlip 1 Use a long nose circlip pliers. 6 Washer 1 7 Push rod 1 8 Brake master cylinder kit 1[...]

6-10 FRONT BRAKE AND REAR BRAKE HANDLING NOTE Support the machine securely so there is no dange r of it falling over. DRAINING THE BRAKE FLUID 1. Remove: • Brake master cylinder cap "1" • Protector (rear brake) Do not remove the diaphragm. A. Front B. Rear 2. Connect the transparent hose " 2" to the bleed screw "1"[...]

6-11 FRONT BRAKE AND REAR BRAKE 3. Inspect: (front brake only) • Reservoir float "1" Damage → Replace. 4. Inspect: • Brake master cylinder piston "1" • Brake master cylinder cup "2" Wear/damage/score marks → Re- place brake master cylinder kit. A. Front B. Rear CHECKING THE BRAKE CALIPER 1. Inspect: • Brake[...]

6-12 FRONT BRAKE AND REAR BRAKE INSTALLING THE FRONT BRAKE CALIPER 1. Install: • Pad support "1" • Brake pad "2" • Pad pin "3" • Install the brake pad s with their pro- jections "a" into the brake caliper re - cesses "b". • Temporarily tighten the pad pin at this point. 2. Install: • Bra[...]

6-13 FRONT BRAKE AND REAR BRAKE A. Front B. Rear INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Brake master cylinder "1" • Brake master cylinder bracket "2" • Bolt (brake master cylinder brack- et) "3" • Install the bracket so that the arrow mark "a" face upward. • First tighten the bolts[...]

6-14 FRONT BRAKE AND REAR BRAKE INSTALLING THE FRONT BRAKE HOSE 1. Install: • Copper washer "1" • Brake hose "2" • Union bolt "3" Always use new copper washers. Install the brake hose so that its pipe portion "a" di rects as shown and lightly touche s the projection "b" on the brake calip er. [...]

6-15 FRONT BRAKE AND REAR BRAKE FILLING TH E BRAKE FLUID 1. Fill: • Brake fluid Until the fluid level reaches "LOWER" level line "a". • Use only the design ated quality brake fluid: otherwise, the rubber seals may deteriorate, causi ng leakage and poor brak e performanc e. • Refill with the same type of brake fluid; mixing[...]

6-16 FRONT FORK FRONT FORK REMOVING THE FRONT FORK Order Part name Q'ty Remarks A. For CDN Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Front wheel Refer to "FRONT WHEEL AND REAR WHEEL" section. Front brake caliper Refer to "FRONT BRAKE AND REAR BRAKE" section. Headlig[...]

6-17 FRONT FORK DISASSEMBLING THE F RONT FORK Order Part name Q'ty Remarks 1 Front fork cap bolt 1 Refer to removal section. 2 Fork spring 1 Drain the fork oil. 3 Dust seal 1 Refer to removal section. 4 Stopper ring 1 Refer to removal section. 5 Inner tube 1 Refer to removal section. 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Oil seal w[...]

6-18 FRONT FORK HANDLING NOTE Support the machine securely so there is no dange r of it falling over. The front fork requires careful atten- tion. So it is recommended that the front fork be maintained at the deal- ers. To prevent an ac cidental explosio n of air, the following instructions should be observed: • The front fork with a built-in pis[...]

6-19 FRONT FORK CHECKING THE INNER TUBE 1. Inspect: • Inner tube surface "a" Score marks → Repair or repl ace. Use #1,000 grit wet sandpaper. Damaged oil lock p iece → Re- place. • Inner tube bends Out of specification → Replace. Use the dial gauge "1". The bending value is shown by one half of the dial gauge reading. [...]

6-20 FRONT FORK 7. Install: • Piston metal "1" Install the piston metal onto th e slot on inner tube. 8. Install: • Outer tube "1" To inner tube "2". 9. Install: • Slide meta l "1" • Oil seal washer "2" To outer tube slot. Press the slide metal into the outer tube with fork seal driver "[...]

6-21 FRONT FORK 19. Wait ten minutes until the a ir bub- bles have been removed fro m the front fork, and the oil has dis- pense evenly in system before setting recommended oil level. Fill with the fork oil up to the top end of the outer tube, or th e fork oil will not spread over to every part of the front forks, thus making it impossible to ob- t[...]

6-22 FRONT FORK INSTALLING T HE FRONT FORK 1. Install: • Front fork "1" • Temporarily tighten the pinch bolts (lower brack et). • Do not tighten the pinch bolts (up- per bracket) yet. 2. Tighten: • Front fork cap bolt 3. Adjust: • Front fork top end "a" 4. Tighten: • Pinch bolt (upper bracket) "1" • Pinch[...]

6-23 HANDLEBAR HANDLEBAR REMOVING THE HANDLEBAR Order Part name Q'ty Remarks Headlight 1 Hot starter cable 1 Disconnect at the lever side. 2 Hot start er lever ho lder 1 3 Clutch cable 1 Disconnect at the lever side . 4 Clutch lever holder 1 Disconnect the clutch switch lead. 5 Engine stop switch 1 Disconnect the engine stop switch lead. 6 Bra[...]

6-24 HANDLEBAR REMOVING THE BRAKE MASTER CYLINDER 1. Remove: • Brake master cylinder bracket "1" • Brake master cylinder "2" • Do not let the brake master cylin- der hang on th e brake hose. • Keep the brake master cylinder cap side horizontal to prevent air from coming in. REMOVING THE GRIP 1. Remove: •G r i p " [...]

6-25 HANDLEBAR 5. Install: • Right grip "1" •C o l l a r " 2 " Apply the adhesive o n the tube guide "3". • Before applying the adhesive, wipe off grease or oil on the tube guide surface "a" with a lacquer thinner. • Install the grip to the tu be guide s o that the grip match mark "b" and tu[...]

6-26 HANDLEBAR • The engine stop switch, cl utch lever holder and clamp sh ould be in- stalled according to the dimen sions shown. • Pass the engine stop switch lead in the middle of the clutch lever ho ld- er. 12. Install: • Clutch cable "1" • Hot starter cable "2" Apply the lithium soap base grease on the clutch cable [...]

6-27 STEERING STEERING REMOVING THE STEERING Order Part name Q'ty Remarks A. For CDN TIGHTENING STEPS: • Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb) • Loosen it one turn. • Retighten it. 7 Nm (0.7 m•kg, 5.1 ft• lb) Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Headlight Hand[...]

6-28 STEERING 8 Lower bracket 1 9 Bearing race cover 1 10 Upper bearing 1 11 Lower bearing 1 Refer to removal sectio n. 12 Bearing race 2 Refer to removal section. Order Part name Q'ty Remarks[...]

6-29 STEERING HANDLING NOTE Support the machine securely so there is no dange r of it falling over. REMOVING THE STEERING RING NUT 1. Remove: • Steering ring nut "1" Use the steering nut wrench "2". Support the steering stem so th at it may not fall d own. REMOVING THE LOWER BEARING 1. Remove: • Lower bearing "1" U[...]

6-30 STEERING 7. Install: • Front fork "1" • Upper bracket "2" • Main switch "3" • Front brake hose guide bracket "4" • Front reflector (For CDN) "5" • Nut (front reflector) (For CDN) "6" • Front reflector bracket (For CDN) "7" • Temporarily tighten the pinch bolt[...]

6-31 SWINGARM SWINGARM REMOVING THE SWINGARM Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Brake hose holder Refer to "FRONT BRAKE AND REAR BRAKE" section. Rear brake caliper Refer to "FRONT BRAKE AND REAR BRAKE" section. Bolt (brake pedal) [...]

6-32 SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q'ty Remarks 1 Cap 2 Refer to removal section. 2 Relay arm 1 3 Connecting rod 1 4 Collar 2 5 Oil seal 2 6 Thrust bearing 2 7 Bushing 2 8 Oil seal 8 9 Bearing 10 Refer to removal section.[...]

6-33 SWINGARM HANDLING NOTE Support the machine securely so there is no dange r of it falling over. REMOVING THE CAP 1. Remove: • Left cap "1" Remove with a slotted-head screw- driver inserted under the mark " a" on the left cap. REMOVING THE BEARING 1. Remove: • Bearing "1" Remove the bearing by pressing its outer[...]

6-34 SWINGARM • Apply the molybdenum di sulfide grease on th e bearing when install- ing. • Install the bearing b y pressing it on the side having the manufacture's marks or numbers. INSTALLING THE SWINGARM 1. Install: • Bushing "1" • Thrust bearing "2" • Oil seal "3" •C o l l a r " 4 " To sw[...]

6-35 SWINGARM 10. Tighten: • Nut (connecting rod) "1" 11. Tighten: • Nut (relay arm) "1" 12. Install: •C a p " 1 " Install the right cap with its mark "a" facing forward. 13. Install: • Bolt (lower chain tensioner) "1" • Washer "2" •C o l l a r " 3 " • Lower chain t[...]

6-36 REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Seat and side cover Refer to "REMOVING THE SEAT, FUEL TANK AND SIDE COVERS" section in the CHAPTER 3. Silencer Refer to "R[...]

6-37 REAR SHOCK ABSORBER 2 Taillight coupler 1 3 CDI unit coupler 3 4 Plastic band 1 5 Clamp (air filter joint) 1 Only loosening. 6R e a r f r a m e 1 7 Bolt (rear shock absorber-relay arm) 1 Hold the swingarm. 8 Bolt (rear shock absorber-frame) 1 9 Rear shock absorber 1 10 Locknut 1 Onl y loosening. 11 Adjuster 1 Only loosening. 12 Lower spring gu[...]

6-38 REAR SHOCK ABSORBER HANDLING NOTE • Support the machin e securely so there is no danger of it falling over. • This rear s hock absorber is pro- vided with a separate type tank filled with high- pressure nitro- gen gas. To pr event the danger of explosion, read and u nder- stand the follow ing information before handli ng the shock ab- sorb[...]

6-39 REAR SHOCK ABSORBER 2. Install: • Stopper ring (upper bearing ) "1" After installing the sto pper ring, push back the bearing until it contacts the stopper ring. 3. Install: • Lower bearing "1" Install the bearing by pressing it on the side having the manufacture' s marks or numbers. INSTALLING THE SPRING (REAR SHO[...]

6-40 REAR SHOCK ABSORBER 7. Tighten: • Screw (air filter joint) "1" 8. Install: • Plastic band • Taillight coupler • Locking tie Screw (air filter joint): 3 Nm (0.3 m•kg, 2.2 ft•lb)[...]

7-1 ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL This section is intended for those who have basi c knowled ge and skill concerning th e servicing of Yamaha motorcycles (e.g., Yamaha dealers, se rvice engineers, etc.) Those who have little knowled ge and skill concernin g servicing are request- ed not to undertake inspection , adjustment, di[...]

7-2 ELECTRICAL COMPONENTS AND WIRING DIAGRAM WIRING DIAGRAM 1. H eadlight 2. Mu lti-functi on display 3. En gine stop switch 4. C lutch switch 5. D iode 6. Starter relay dio de 7. T hrottle position sensor 8. Starter relay 9. F use 10. Starting circuit cut-off relay 11. CDI unit 12. Taillight 13. Neutral switch 14. Starter motor 15. AC magneto 16. [...]

7-3 IGNITION SYSTEM IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfuncti oning engine being attributable to igni tion system failure and for checking the spa rk plug which w ill not spark. *1 marked: Refer to "CHECKING TH E FUSE" section in the CHAPTER 3. *2 marked: Refer to "CHECKING[...]

7-4 IGNITION SYSTEM SPARK GAP TEST 1. Disconnect the ignition coil from spark plug. 2. Remove the ignition co il cap. 3. Connect the dynamic spark tester "1" (ignition ch ecker "2") as shown. • Ignition coil "3" • Spark plug "4" A. For USA and CDN B. Except for USA and CDN 4. Kick the kickstarter crank. 5[...]

7-5 ELECTRIC STARTING SYSTEM 3. Inspect: • Secondary coil resistance Out of specification → Replace. 4. Inspect: • Sealed portion of ignition coil "a" • Spark plug terminal pin "b" • Threaded portion o f spark plug "c" Wear → Rep lace. CHECKING THE AC MAGNETO 1. Inspect: • Pickup coil resistance Out of sp[...]

7-6 ELECTRIC STARTING SYSTEM INSPECTION STEPS If the starter motor will not operate, use the fo llowing inspection steps. *1 marked: Refer to "CHECKING TH E FUSE" section in the CHAPTER 3. *2 marked: Refer to "CHECKING AND CHARGIN G THE BATTERY" section in the CHAPTER 3. *3 marked: Refer to "CHECKING THE MAIN SWITCH" s[...]

7-7 ELECTRIC STARTING SYSTEM CHECKING THE COUPLERS AND LEADS CONNECTION 1. Check: • Couplers and leads con nection Rust/dust/looseness/short-circuit → Repair o r replace. CHECKING THE STARTER MOTOR OPERATION 1. Connect the posi tive battery ter- minal "1" and starter motor lead "2" with a jumper lead " 3". Not oper[...]

7-8 ELECTRIC STARTING SYSTEM CHECKING THE START SWITCH 1. Inspect: • Start switch conduction Not conductive while it is pushed → Replace. Conductive while it is freed → Re- place. Set the tester selection position to " Ω × 1". 2. Inspect: • Rubber part "a" Tears/damage → Replace. Tester (+) lead → Black lead "[...]

7-9 ELECTRIC STARTING SYSTEM REMOVING THE STARTER MOTOR Order Part name Q'ty Remarks Exhaust pipe Refer to "REMOVING THE EXHAUST PIPE AND SILENCER" section in the CHAPTER 3. 1 Starter motor 1[...]

7-10 ELECTRIC STARTING SYSTEM DISASSEMBLING THE STARTER MOTOR Order Part name Q'ty Remarks 1 Starter motor front cover 1 2 Washer (starter motor front cover) 1 3 Gasket 2 4 Starter motor yoke 1 5 Armature assembly 1 6 Starter motor rear cover 1 7 Brush 2 8 Brush spring 2[...]

7-11 ELECTRIC STARTING SYSTEM CHECKING AND REPAIRING THE STARTER MOTOR 1. Check: • Commutator Dirt → Cle an with 600 grit sandpa - per. 2. Measure: • Commutator diameter "a" Out of specification → Replace the starter motor. 3. Measure: • Mica undercut "a" Out of specification → Scrap e the mica to the prope r measure[...]

7-12 ELECTRIC STARTING SYSTEM • For installation, align the proj ec- tions on the washer with the slots in the front cover. • Align the match mark "a" on the starter motor yoke with the match mark "b" on the starter motor front cover. 5. Install: • Gasket •B o l t " 1 " • O-ring "2" Apply the lithiu[...]

7-13 CHARGING SYSTEM CHARGING SYSTEM INSPECTION STEPS If the battery is not charged, use the followin g inspection steps. *1 marked: Refer to "CHECKING TH E FUSE" section in the CHAPTER 3. *2 marked: Refer to "CHECKING AND CHARGIN G THE BATTERY" section in the CHAPTER 3. • Remove the following p arts before i nspection. 1. Sea[...]

7-14 CHARGING SYSTEM CHECKING THE COUPLERS AND LEADS CONNECTION 1. Check: • Couplers and leads con nection Rust/dust/looseness/short-circuit → Repair o r replace. CHECKING THE CHARGING VOLTAGE 1. Start the engine. 2. Inspect: • Charging voltage Out of specification → If no failure is found in checking the source coil resistance, replace the[...]

7-15 THROTTLE POSITION SENSOR SYSTEM THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position senso r will not operate, use the follo wing inspection steps. Use the following special to ols in this inspection. Check entire ignition system for connection. No good → Repair or replace. OK ↓ Check throttle position sen sor.(Throttl[...]

7-16 THROTTLE POSITION SENSOR SYSTEM HANDLING NOTE Do not loosen th e screw (throttle position sensor) "1" except when changing the th rottle position sen- sor due to failur e because it will cause a drop in engine pe rfor- mance. CHECKING THE COUPLERS AND LEADS CONNECTION 1. Check: • Couplers and leads con nection Rust/dust/looseness/s[...]

7-17 THROTTLE POSITION SENSOR SYSTEM 9. Adjust: • Throttle position sensor ou tput voltage Adjustme nt steps: a. Adjust the installa tion angle of the throttle position sensor "1" to ob- tain the specified output voltage. Measure the output voltage accurate- ly with a digital e lectronic voltmeter that gives an easy reading of a small v[...]

7-18 LIGHTING SYSTEM LIGHTING SYSTEM INSPECTION STEPS Refer to th e followin g flow cha rt when in specting t he lightin g system for possible pro blems. • Remove the following p arts before i nspection. 1. Seat 2. Fuel tank 3. Left side cover • Use the following special to ols in this inspection. Check the bulb and bulb socket. No goo d → Re[...]

7-19 LIGHTING SYSTEM CHECKING THE TAILLIGHT (LEDs) 1. Disconnect the taillight coupler. 2. Connect two jumper leads "1" from the battery terminals to the respective coupler terminal as shown. 3. Check: • LED (for proper operation) Does not light → Replace the tail- light assemb ly. • A wire that is used as a jumper lead must have at[...]

7-20 SIGNALING SYSTEM SIGNALING SYSTEM INSPECTION STEPS If the speedometer will not operate , use the following inspection steps. *1 marked: Refer to "CHECKING AND CHARGIN G THE BATTERY" section in the CHAPTER 3. • Remove the following p arts before i nspection. 1. Headlight • Use the following special to ols in this inspection. *1 Ch[...]

7-21 SIGNALING SYSTEM CHECKING THE COUPLERS AND LEADS CONNECTION 1. Check: • Couplers and leads con nection Rust/dust/looseness/short-circuit → Repair o r replace. CHECKING THE MULTI-FUNCTION DISPLAY INPUT VOLTAGE 1. Disconn ect the multi- function dis- play coupler. 2. Set the main switch to "ON". 3. Measure: • Multi-function displ[...]

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PRINTED IN JAPAN (E) PRINTED ON RECYCLED PAPER Y AMAHA MOTOR CO. , L TD. 2500 SHINGAI IW A T A SHIZUOKA JAP AN[...]