2023

OWNER’S SERVICE MANUAL

YZ450F
Read this manual carefully before operating this vehicle.

YZ450FP
LIT-11626-36-32 BHR-2819U-10
Read this manual carefully
EAM20161

Operating, servicing and

maintaining a passenger vehicle or off-road vehicle can
expose you to chemicals including engine exhaust,
carbon monoxide, phthalates, 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
 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle
if it is sold.

FCC CAUTION
Changes or modifications not expressly approved by the party responsible for compliance could void the 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 permissive exposure evaluation (MPE).
EAM20080

YZ450FP
OWNER’S SERVICE MANUAL
©2023 by Yamaha Motor Corporation, U.S.A.
First edition, July 2022
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-11626-36-32
EAM20180

IMPORTANT
Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha’s
vast experience in the production of pacesetting racing machines. It represents the highest grade of
craftsmanship and reliability that have made Yamaha a leader.
This manual explains operation, inspection, basic maintenance and tuning of your machine. If you have
any questions about this manual or your machine, please contact your Yamaha dealer.
TIP
• Yamaha continually seeks advancements in product design and quality. Therefore, while this manual
contains the most current product information available at the time of printing, there may be minor dis-
crepancies between your machine and this manual. If you have any questions concerning this man-
ual, please consult your Yamaha dealer.
• This manual is intended for those who have basic knowledge and skill concerning the servicing of
Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl-
edge and skill concerning servicing are requested not to undertake inspection, adjustment, disassem-
bly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical
damage.
EWA20270

WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS
MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A
SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL
YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPEC-
TIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE
THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.

EAM30001

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential per-
sonal injury hazards. Obey all safety messages that follow this symbol
to avoid possible injury or death.

A WARNING indicates a hazardous situation which, if not avoided, could

WARNING result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid

NOTICE damage to the vehicle or other property.

TIP A TIP provides key information to make procedures easier or clearer.

EAM20162

YAMAHA MOTOR CORPORATION, U.S.A. YZ MOTORCYCLE LIMITED

WARRANTY
EAM20082

HOW TO USE THIS MANUAL

In this manual, descriptions of installation, removal, disassembly, assembly, check, and adjustment
procedures are laid out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a 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 jobs, etc. This step explains removal and disassembly procedure only. For in-
stallation and assembly procedure, reverse the steps.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
1

2
4

5
6 7

G088877
EAM20083

SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

G

Filling fluid Molybdenum disulfide oil

M

Lubricant Brake fluid

BF

Special tool B Wheel bearing grease

Tightening torque LS Lithium-soap-based grease

T.
R.

Wear limit, clearance M Molybdenum disulfide grease

Engine speed S Silicone grease

Electrical data Apply locking agent (LOCTITE®).

LT

Engine oil New Replace the part with a new one.

E
 TABLE OF CONTENTS
EAM10003

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
 GENERAL INFORMATION

SAFETY INFORMATION ..................................................................................1-1

FOR SAFETY, BE SURE TO OBEY THE FOLLOWING:...........................1-1

LOCATION OF IMPORTANT LABELS.............................................................1-4 1

DESCRIPTION..................................................................................................1-5

IDENTIFICATION ..............................................................................................1-6
2
VEHICLE IDENTIFICATION NUMBER ......................................................1-6
ENGINE SERIAL NUMBER........................................................................1-6

INCLUDED PARTS ...........................................................................................1-7

SIDESTAND ...............................................................................................1-7
3
NIPPLE WRENCH ......................................................................................1-7

4
HANDLEBAR PROTECTOR ......................................................................1-7
FUEL HOSE JOINT COVER ......................................................................1-7
POWER TUNER .........................................................................................1-7

IMPORTANT INFORMATION ...........................................................................1-9

PREPARATION FOR REMOVAL AND DISASSEMBLY ............................1-9
REPLACEMENT PARTS ............................................................................1-9
GASKETS, OIL SEALS AND O-RINGS .....................................................1-9
5
LOCK WASHERS/PLATES AND COTTER PINS ....................................1-10

6
BEARINGS AND OIL SEALS ...................................................................1-10
CIRCLIPS .................................................................................................1-10

BASIC SERVICE INFORMATION...................................................................1-11

ELECTRICAL SYSTEM ............................................................................1-11

SPECIAL TOOLS............................................................................................1-15
7
8
INSTRUMENT AND CONTROL FUNCTIONS ...............................................1-21
ENGINE STOP SWITCH ..........................................................................1-21
START SWITCH .......................................................................................1-21
LAUNCH CONTROL SYSTEM.................................................................1-21
LAP TIME RECORD MODE .....................................................................1-22

9
DRIVE MODE ...........................................................................................1-22
SHIFT PEDAL...........................................................................................1-23
FRONT BRAKE LEVER ...........................................................................1-23
REAR BRAKE PEDAL..............................................................................1-23
STARTER KNOB ......................................................................................1-23
FUEL TANK CAP......................................................................................1-23

STARTING AND BREAK-IN ...........................................................................1-24

10
FUEL.........................................................................................................1-24
 STARTING A COLD ENGINE ..................................................................1-24
STARTING A WARM ENGINE .................................................................1-25
BREAK-IN PROCEDURES ......................................................................1-25
ENGINE STARTING PRECAUTION ........................................................1-25

MAINTENANCE AFTER BREAK-IN ..............................................................1-26

MAJOR MAINTENANCE ..........................................................................1-26
AIR FILTER MAINTENANCE ...................................................................1-26

TORQUE-CHECK POINTS.............................................................................1-27

MOTORCYCLE CARE AND STORAGE.........................................................1-29

CARE ........................................................................................................1-29
STORAGE ................................................................................................1-30
 SAFETY INFORMATION

EAM20168
ator only. No passengers.
SAFETY INFORMATION 3. The failure of motorists to detect and recog-
Be sure to read this manual carefully and com- nize motorcycles in traffic is the predominat-
pletely in order to operate the machine safely ing cause of automobile/motorcycle
and correctly prior to riding the Yamaha ma- accidents. Many accidents have been
chine, and take care to maintain it properly and caused by an automobile driver who did not
operate it safely. see the motorcycle. Making yourself conspic-
EAM30401
uous appears to be very effective in reducing
FOR SAFETY, BE SURE TO OBEY THE the chance of this type of accident.
FOLLOWING: Therefore:
Be a Responsible Owner • Wear a brightly colored jacket.
As the vehicle’s owner, you are responsible for • Use extra caution when you are approaching
the safe and proper operation of your motorcy- and passing through intersections, since in-
cle. tersections are the most likely places for mo-
Motorcycles are single-track vehicles. torcycle accidents to occur.
Their safe use and operation are dependent • Ride where other motorists can see you.
upon the use of proper riding techniques as well Avoid riding in another motorist’s blind spot.
as the expertise of the operator. Every operator • Never maintain a motorcycle without proper
should know the following requirements before knowledge. Contact an authorized motorcy-
riding this motorcycle. cle dealer to inform you on basic motorcycle
He or she should: maintenance. Certain maintenance can only
1. Obtain thorough instructions from a compe- be carried out by certified staff.
tent source on all aspects of motorcycle oper- 4. Many accidents involve inexperienced opera-
ation. tors.
2. Observe the warnings and maintenance re- • Make sure that you are qualified and that you
quirements in this manual. only lend your motorcycle to other qualified
3. Obtain qualified training in safe and proper operators.
riding techniques. • Know your skills and limits. Staying within
4. Obtain professional technical service as indi- your limits may help you to avoid an accident.
cated in this manual and/or when made nec- • We recommend that you practice riding your
essary by mechanical conditions. motorcycle until you have become thoroughly
5. Never operate a motorcycle without proper familiar with the motorcycle and all of its con-
training or instruction. Take a training course. trols.
Beginners should receive training from a cer- 5. Many accidents have been caused by error of
tified instructor. Contact an authorized motor- the motorcycle operator. A typical error made
cycle dealer to find out about the training by the operator is veering wide on a turn due
courses nearest you. to excessive speed or under cornering (insuf-
Safe Riding ficient lean angle for the speed). Never travel
Perform the pre-operation checks each time you faster than warranted by conditions.
use the vehicle to make sure it is in safe operat- 6. Ride cautiously in unfamiliar areas. You may
ing condition. Failure to inspect or maintain the encounter hidden obstacles that could cause
vehicle properly increases the possibility of an an accident.
accident or equipment damage. Refer to “PRE- 7. The posture of the operator is important for
OPERATION INSPECTION AND MAINTE- proper control. The operator should keep
NANCE” on page 3-6 for a list of pre-operation both hands on the handlebar and both feet on
checks. the operator footrests during operation to
1. This motorcycle is designed for off-road use maintain control of the motorcycle.
only, therefore, it is illegal to operate it on 8. Never ride under the influence of alcohol or
public streets, roads, or highways, even a dirt other drugs.
or gravel one. Off-road use on public lands 9. Be sure the transmission is in neutral before
may be illegal. Please check local regulations starting the engine.
before riding. Protective Apparel
2. This motorcycle is designed to carry the oper- The majority of fatalities from motorcycle acci-

1-1
 SAFETY INFORMATION

dents are the result of head injuries. The use of er modifications for Yamaha vehicles. Yamaha
a safety helmet is the single most critical factor is not in a position to test the products that these
in the prevention or reduction of head injuries. aftermarket companies produce. Therefore,
1. Always wear an approved helmet. Yamaha can neither endorse nor recommend
2. Wear a face shield or goggles. Wind in your the use of accessories not sold by Yamaha or
unprotected eyes could contribute to an im- modifications not specifically recommended by
pairment of vision that could delay seeing a Yamaha, even if sold and installed by a Yamaha
hazard. dealer.
3. The use of a jacket, heavy boots, trousers, Aftermarket Parts, Accessories, and Modifi-
gloves, etc., is effective in preventing or re- cations
ducing abrasions or lacerations. While you may find aftermarket products similar
4. Never wear loose-fitting clothes, otherwise in design and quality to genuine Yamaha acces-
they could catch on the control levers, foot- sories, recognize that some aftermarket acces-
rests, or wheels and cause injury or an acci- sories or modifications are not suitable because
dent. of potential safety hazards to you or others. In-
5. Always wear protective clothing that covers stalling aftermarket products or having other
your legs, ankles, and feet. The engine or ex- modifications performed to your vehicle that
haust system become very hot during or after change any of the vehicle’s design or operation
operation and can cause burns. characteristics can put you and others at greater
Avoid Carbon Monoxide Poisoning risk of serious injury or death. You are responsi-
All engine exhaust contains carbon monoxide, a ble for injuries related to changes in the vehicle.
deadly gas. Breathing carbon monoxide can Keep the following guidelines in mind, as well as
cause headaches, dizziness, drowsiness, nau- those provided under “Loading” when mounting
sea, confusion, and eventually death. accessories.
Carbon Monoxide is a colorless, odorless, taste- 1. Never install accessories that would impair
less gas which may be present even if you do the performance of your motorcycle. Careful-
not see or smell any engine exhaust. Deadly lev- ly inspect the accessory before using it to
els of carbon monoxide can collect rapidly and make sure that it does not in any way reduce
you can quickly be overcome and unable to save ground clearance or cornering clearance, lim-
yourself. Also, deadly levels of carbon monoxide it suspension travel, steering travel or control
can linger for hours or days in enclosed or poorly operation.
ventilated areas. If you experience any symp- • Accessories fitted to the handlebar or the
toms of carbon monoxide poisoning, leave the front fork area can create instability due to im-
area immediately, get fresh air, and SEEK MED- proper weight distribution. If accessories are
ICAL TREATMENT. added to the handlebar or front fork area,
1. Do not run engine indoors. Even if you try to they must be as lightweight as possible and
ventilate engine exhaust with fans or open should be kept to a minimum.
windows and doors, carbon monoxide can • Bulky or large accessories may seriously af-
rapidly reach dangerous levels. fect the stability of the motorcycle. Wind may
2. Do not run engine in poorly ventilated or par- attempt to lift the motorcycle, or the motorcy-
tially enclosed areas such as barns, garages, cle may become unstable in cross winds.
or carports. • Certain accessories can displace the opera-
3. Do not run engine outdoors where engine ex- tor from his or her normal riding position. This
haust can be drawn into a building through improper position limits the freedom of move-
openings such as windows and doors. ment of the operator and may limit control
Genuine Yamaha Accessories ability, therefore, such accessories are not
Choosing accessories for your vehicle is an im- recommended.
portant decision. Genuine Yamaha accessories, 2. Use caution when adding electrical accesso-
which are available only from a Yamaha dealer, ries. If electrical accessories exceed the ca-
have been designed, tested, and approved by pacity of the motorcycle’s electrical system,
Yamaha for use on your vehicle. an electric failure could result, which could
Many companies with no connection to Yamaha cause a dangerous loss of lights or engine
manufacture parts and accessories or offer oth- power.

1-2
 SAFETY INFORMATION

Aftermarket Tires and Rims

The tires and rims that came with your motorcy-
cle were designed to match the performance ca-
pabilities and to provide the best combination of
handling, braking, and comfort. Other tires, rims,
sizes, and combinations may not be appropriate.
Refer to “CHECKING THE TIRES” on page 3-33
for tire specifications and more information on
replacing your tires.
Transporting the Motorcycle
Be sure to observe following instructions before
transporting the motorcycle in another vehicle.
1. Remove all loose items from the motorcycle.
2. Check that the 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 upper
front fork triple clamp (and not, for example,
to rubber-mounted handlebars or turn sig-
nals, or parts that could break). Choose the
location for the straps carefully so the straps
will not rub against painted surfaces during
transport.
6. The suspension should be compressed
somewhat by the tie-downs, if possible, so
that the motorcycle will not bounce exces-
sively during transport.

1-3
 LOCATION OF IMPORTANT LABELS

EAM20085

LOCATION OF IMPORTANT LABELS

Please read the following important labels carefully before operating this vehicle.

1 2 3 4, 5

Premium unleaded
gasoline only.
3FB-2415E-03

WARNING
This unit contains high pressure nitrogen gas.
Mishandling can cause explosion.
Read owner's manual for instructions. 5PA-2118K-01

Do not incinerate, puncture or open.

4AA-22259-80

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.
17D-2812P-00

3RV-21668-A1

1-4
 DESCRIPTION

EAM20086

DESCRIPTION

1 2

8 7 6 5 4 3

9 10 14

13 12 11 18 17 16 15
1. Clutch lever 10.Radiator
2. Front brake lever 11.Coolant drain bolt
3. Throttle grip 12.Oil level check window
4. Start switch 13.Rear brake pedal
5. Radiator cap 14.Air filter
6. Fuel tank cap 15.Drive chain
7. Engine stop switch 16.Shift pedal
8. Mode switch 17.Starter knob
9. Fuel tank 18.Front fork

TIP
Designs and specifications of the vehicle are subject to change without notice. Therefore, please note
that the descriptions in this manual may be different from those for the vehicle you have purchased.

1-5
 IDENTIFICATION

EAM20087

IDENTIFICATION
There are two significant reasons for knowing
the serial number of your vehicle:
1. When ordering parts, you can give the num-
ber to your Yamaha dealer 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
elevated part of the right-side of the engine.

1-6
 INCLUDED PARTS

EAM20088

INCLUDED PARTS
EAM30190

SIDESTAND
This sidestand “1” is used to support only the
machine when standing or transporting it.
EWA20260

WARNING
a 1
• Never apply additional force to the sides-
tand.
• Remove this sidestand before starting out.

EAM30007

EAM30005 FUEL HOSE JOINT COVER

NIPPLE WRENCH The fuel hose joint covers “1” are used to pre-
The nipple wrench “1” is used to tighten the vent mud, dust, and other foreign materials from
spoke. entering the inside when the fuel hose is discon-
nected.

EAM30006

HANDLEBAR PROTECTOR EAM30443

Install the handlebar protector “1” so that the POWER TUNER

mark “a” is facing the direction shown in the illus- By downloading the Power Tuner app to your
tration. smartphone and wirelessly connecting to the
CCU wireless network, you can adjust various
vehicle settings.
EWA20460

WARNING
• Do not operate the engine in a closed area.
The exhaust gas is poisonous.
• Never let flames near the servicing area.
ECA26050

NOTICE
• This application is designed for adjusting
the settings on a standard vehicle. In case
the engine specifications (muffler, com-

1-7
 INCLUDED PARTS

pression ratio, etc.) have been changed,

the performance may not match to the actu-
al settings. 3
COMMUN.CONT.UNIT ASSY.
• Do not run the engine with the smartphone
carried with you. Otherwise, the smart-
phone could be damaged.
P/N: - -
TIP S/N:

• Download the Power Tuner app from the

MAC:

a
Google© or Apple© store.
• For details about handling the smartphone,
read the owner’s manual of the smartphone. 3. CCU (Communication Control Unit)
Before connecting to the CCU wireless net- a. CCU serial number
work (in case of initial use of the Power Tun-
er app) 3. Install the removed CCU and side cover (left).
1. Remove the bolts and side cover (left). Connecting to the CCU wireless network
ECA26060

1 NOTICE
1 The CCU (Communication Control Unit) uses
weak radio waves. The CCU may not work in
the following situations.
2 • The CCU is placed in a location exposed to
strong radio waves or other electromagnet-
1
ic noise
• There are facilities nearby that are emitting
strong radio waves (TV or radio towers,
power plants, broadcasting stations, air-
1. Bolt
ports, etc.)
2. Side cover (left)
• You are carrying or using communication
2. Remove the CCU and record the CCU serial equipment such as radios or mobile
number. phones in close proximity of the CCU
• The CCU is in contact with or covered by a
1 metallic object
• Other vehicles equipped with a CCU are
nearby
In such situations, move the CCU to another
3 location and perform the operation again.
2 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-
1. CCU coupler ber into your smartphone and establish a
2. Holder wireless connection.
3. CCU (Communication Control Unit) 3. Activate the Power Tuner app.
TIP
If the CCU wireless network cannot be detected,
operate the start switch again.

1-8
 IMPORTANT INFORMATION

EAM20089
ceive an injury or a burn on the engine, the
IMPORTANT INFORMATION exhaust pipe, the silencer, or the like.
EAM30009
7. If coolant is left adhered to the chassis, paint
PREPARATION FOR REMOVAL AND and plating will be damaged. Therefore, rinse
DISASSEMBLY it out with water in good time.
EWA18970
1. Before the jobs, completely remove mud,
WARNING
dust, and the like in order to prevent the entry
of them into the inside during the jobs. Coolant is potentially harmful and should be
Refer to “CARE” on page 1-29. 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, immediately induce vom-
iting and get medical attention.

EAM30010

REPLACEMENT PARTS
Make sure that the parts and grease or oil to be
2. Use proper special tools and equipment. Re- used for repair of the vehicle, including periodic
fer to “SPECIAL TOOLS” on page 1-15. replacement parts, are new YAMAHA genuine
parts and recommended parts.
Do not use any used parts, because these may
not be genuine though they have similar appear-
ances or because the quality may be changed
by aging.

3. During disassembly, check and measure the

required parts, and make a record of them so
that you may refer to the record when install-
ing them. Moreover, arrange gears, cylin-
ders, pistons, and other parts for each section
so as not to confuse or lose them. EAM30011

GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all
gaskets and O-rings. All gasket surfaces, oil
seal lips, and O-rings must be cleaned so that
there may be no dust on them.
2. During assembly, always apply proper oil to
bearings and proper grease to oil seal lips be-
fore installation.

4. During disassembly, clean each of the parts,

and store them in trays for each section.
5. Flammable. Keep servicing areas away from
any source of fire.
6. During servicing, take special care not to re-

1-9
 IMPORTANT INFORMATION

1. Oil
2. Lip
3. Spring
4. Grease
EAM30012

LOCK WASHERS/PLATES AND COTTER

PINS
After removal, replace lock washers/plates “1”
and cotter pins with new ones. After the bolt or
nut has been tightened to specification, firmly
bend the lock tabs along a flat of the bolt or nut. EAM30014

CIRCLIPS
When assembling parts, always use new cir-
clips. During installation of a circlip, make sure
that the edge “2” of the circlip “1” is positioned
opposite to the force “3” that the circlip receives.
Install the circlip with its end aligned with the
center of the spline, without opening the circlip
more than necessary.

EAM30013

BEARINGS AND OIL SEALS

Install bearings “1” and oil seals “2” with their
manufacturer’s marks or size symbols facing
outward. During installation of an oil seal, make
sure that its main lip faces the oil chamber (the
target to be sealed). Before installation, always
apply a light coat of grease to the oil seal lip.
ECA13300

NOTICE
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.

1-10
 BASIC SERVICE INFORMATION

EAM20120

BASIC SERVICE INFORMATION

EAM30181

ELECTRICAL SYSTEM
Electrical parts handling
ECA16600

NOTICE
Never disconnect a battery lead while the en-
gine is running; otherwise, the electrical
components could be damaged.
ECA16760

NOTICE
Be sure to connect the battery leads to the
correct battery terminals. Reversing the bat-
tery lead connections could damage the
electrical components.

ECA16751

NOTICE
When disconnecting the battery leads from
the battery, be sure to disconnect the nega-
tive battery lead first, then the positive bat-
tery lead. If the positive battery lead is
disconnected first and a tool or similar item ECA16771

contacts the vehicle, a spark could be gener- NOTICE

ated, which is extremely dangerous. When connecting the battery leads to the
battery, be sure to connect the positive bat-
tery lead first, then the negative battery lead.
If the negative battery lead is connected first
and a tool or similar item contacts the vehi-
cle while the positive battery lead is being
connected, a spark could be generated,
which is extremely dangerous.

TIP
If a battery lead is difficult to disconnect due to
rust on the battery terminal, remove the rust us-
ing hot water.

ECA16620

NOTICE
Handle electrical components with special
care, and do not subject them to strong
shocks.

1-11
 BASIC SERVICE INFORMATION

ECA16630 ECA14371

NOTICE NOTICE
Electrical components are very sensitive to Never insert the tester probes into the cou-
and can be damaged by static electricity. pler terminal slots. Always insert the probes
Therefore, never touch the terminals and be from the opposite end “a” of the coupler, tak-
sure to keep the contacts clean. ing care not to loosen or damage the leads.

ECA16640
TIP
To restart the ECU (Engine Control Unit): NOTICE
• Hold the engine stop switch pressed for 1 sec- For waterproof couplers, never insert the
ond or longer. tester probes directly into the coupler. When
• The ECU will shut down 3 seconds after hold- performing any checks using a waterproof
ing the engine stop switch pressed. coupler, use the specified test harness or a
• Press the start switch to restart the ECU. suitable commercially available test har-
ness.

Checking the electrical system

TIP Checking the connections
Before checking the electrical system, make Check the leads, couplers, and connectors for
sure that the battery voltage is at least 12 V. stains, rust, moisture, etc.
1. Disconnect:
• Lead
• Coupler
• Connector

1-12
 BASIC SERVICE INFORMATION

ECA16780

NOTICE
• When disconnecting a coupler, release the
coupler lock, hold both sections of the cou-
pler securely, and then disconnect the cou-
pler.
• There are many types of coupler locks;
therefore, be sure to check the type of cou-
pler lock before disconnecting the coupler.

3. Check:
• All connections
Loose connection  Connect properly.
TIP
• If the pin “1” on the terminal is flattened, bend
it up.
• After disassembling or assembling a coupler,
pull on the leads to make sure that they are in-
stalled securely.

ECA16790

NOTICE
When disconnecting a connector, do not pull
the leads. Hold both sections of the connec-
tor securely, and then disconnect the con-
nector.

2. Check:
• Lead
• Coupler
• Connector 4. Connect:
Moisture  Dry with compressed air. • Lead
Rust/stains  Connect and disconnect sev- • Coupler
eral times. • Connector
TIP
• When connecting a coupler or connector,
make sure that both terminals are connected
securely.
• Make sure all connections are tight.

1-13
 BASIC SERVICE INFORMATION

5. Check:
• No continuity
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with tachom-
eter
YU-A1927

TIP
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (4).
• As a quick remedy, use a contact revitalizer
available at most part stores.

1-14
 SPECIAL TOOLS

EAM20121

SPECIAL TOOLS
The following special tools are required for accurate and complete adjustment and assembly. Using the
correct special tool will help prevent damage caused by the use of improper tools or improvised tech-
niques. The shape and tool number used for the special tool differ by country, so two types are provid-
ed. Refer to the list provided to avoid errors when placing an order.
TIP
• For U.S.A. and Canada, use tool number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use tool number starting with “90890-”.

Reference
Tool name/Tool No. Illustration
pages

Digital circuit tester (CD732) 1-14, 5-42, 8-46,

90890-03243 8-47, 8-49, 8-49,
Model 88 Multimeter with tachometer 8-50, 8-50, 8-51,
YU-A1927 8-51, 8-52, 8-52,
8-53, 8-53, 8-54,
8-54, 8-55

Thickness gauge 3-7, 5-48

90890-03268
Feeler gauge set
YU-26900-9

Valve lapper (ø14) 90890-04101

3-8, 5-24
90890-04101
Valve lapper (ø14)
YM-A8998

YM-A8998

Yamaha diagnostic tool USB (US) 3-12, 7-7, 7-8,

90890-03269 8-17, 8-49

Yamaha diagnostic tool (A/I) 3-12, 7-7, 7-8,

90890-03264 8-17, 8-49

Digital tachometer 3-12, 8-52

90890-06760
Digital tachometer
YU-39951-B

1-15
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages

Steering nut wrench 3-28, 4-60

90890-01403
Exhaust flange nut wrench
YU-A9472

Spoke nipple wrench (6–7) 3-34

90890-01521
Spoke nipple wrench (6–7)
YM-01521

Cap bolt ring wrench 4-48, 4-48, 4-49,

90890-01501 4-51, 4-55, 4-56
Cap bolt ring wrench
YM-01501

Cap bolt wrench 4-49, 4-51

90890-01911

Fork seal driver 4-53, 4-53

90890-01502
Fork seal driver (48)
YM-A0948

Valve spring compressor 5-24, 5-28

90890-04200
Valve spring compressor
YM-04019

Valve spring compressor attachment 5-24, 5-28

90890-04108
Valve spring compressor adapter 22 mm
YM-04108

Valve guide remover & installer set (ø5.5) 5-26

90890-04016
Valve guide remover (5.5 mm)
YM-01122

1-16
 SPECIAL TOOLS

Tool name/Tool No. Illustration Reference

pages

Valve guide installer (ø5.5) 5-26

90890-04015
Valve guide installer (5.5 mm)
YM-04015

Valve guide reamer (5.5 mm) 5-26

90890-01196
Valve guide reamer (5.5 mm)
YM-01196

Piston pin puller set 5-31

90890-01304
Piston pin puller
YU-01304

YU-01304

Rotor puller 5-38

90890-04151
Rotor puller
YM-04151

Yamaha bond No. 1215 5-38, 5-70

90890-85505
Three bond No. 1215®

Clutch holder 5-48, 5-52

90890-04199
Universal clutch holder
YM-91042

1-17
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages

Crankcase separating tool 5-73

90890-04152
Crankcase separating tool
YU-A9642

Crankshaft installer pot 5-74

90890-01274
Installing pot
YU-90058

YU-90058/YU-90059

Crankshaft installer bolt 5-74

90890-01275
Bolt
YU-90060

Adapter (M12) 5-74

90890-01278
Adapter #3
YU-90063

Spacer (crankshaft installer) 5-74

90890-04081
Pot spacer
YM-91044

YM-91044

1-18
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages

Radiator cap tester 6-4, 6-4

90890-01325
Mityvac cooling system tester kit
YU-24460-A

YU-24460-A

Radiator cap tester adapter 6-4, 6-4

90890-01352
Pressure tester adapter
YU-33984

YU-33984

Pressure gauge 7-8

90890-03153
Pressure gauge
YU-03153

Fuel pressure adapter 7-8

90890-03186
Fuel pressure adapter
YM-03186

Lithium battery charger 8-48, 8-48

90890-05376
Lithium battery charger
DBY-ACC51-70-02

Ignition checker 8-50

90890-06754
Oppama pet–4000 spark checker
YM-34487

1-19
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages

Test harness S– pressure sensor (3P) 8-53

90890-03207
Test harness S– pressure sensor (3P)
YU-03207

1-20
 INSTRUMENT AND CONTROL FUNCTIONS

EAM20181
pending on the rider’s operations and road sur-
INSTRUMENT AND CONTROL face conditions.
FUNCTIONS How to operate
1. Put the gear into the neutral position.
EAM30182
2. Start the engine.
ENGINE STOP SWITCH
3. Push the mode switch “1” for more than one
The engine stop switch “1” is located on the left
second to turn on the launch control system.
handlebar. Continue pushing the engine stop
switch till the engine comes to a stop. TIP
• When the launch control system is turned on, it
1 automatically enters Rev. clip mode, and then
the indicator light “2” will flash.
• The drive mode can be changed even when
the launch control system is operating.
• When the indicator light flashes alternately pur-
ple and blue, drive mode 2 is selected.

EAM30183

START SWITCH
The start switch “1” is located on the right han-
dlebar. Push this switch to crank the engine with
the starter.
TIP
1 2
• When the start switch is pushed, the indicator
light on the handlebar switch (left) may illumi-
nate orange for approx. 2 seconds as a self-
check, but this is not a malfunction.
4 4 5
• Indicator light on the handlebar switch (left)
flashes orange  Check or replace any faulty 3
electrical part(s).
Refer to “CHECKING THE INDICATOR
LIGHT” on page 8-56. 6 6

A. Drive mode 1
B. Drive mode 2

3. Push the mode switch

4. Purple
5. Blue
6. Approx. 1 second (4 flashes/second)
1 4. Put the gear into the 1st or 2nd gear for start-
EAM30626 ing off.
LAUNCH CONTROL SYSTEM TIP
When the launch control system is operated, the • When starting off, the system automatically
ignition timing is delayed to reduce slipping at controls the launch.
the rear wheel which occurs when the vehicle • The drive mode can be changed even when
accelerates from a stationary position. the launch control system is operating.
This can be used to starting off in a stable man- • When the indicator light flashes alternately pur-
ner on a slippery road surface. ple and blue, drive mode 2 is selected.
However, the effect may not be adequate de-

1-21
 INSTRUMENT AND CONTROL FUNCTIONS

• Measurement results can be received and

saved on the app.
2 2 3
1

4 4

A. Drive mode 1
B. Drive mode 2 1 2

1. Push the mode switch EAM30627

2. Purple
DRIVE MODE
3. Blue
Push the mode switch “1” to change between
4. 1 second (1 flash/second)
drive mode 1 and drive mode 2.
TIP
5. After starting off, the launch control system Indicator light on the handlebar switch (left)
will turn off automatically when the gear is flashes orange  Check or replace any faulty
shifted into the 3rd gear. electrical part(s).
The launch control system will also turn off Refer to “CHECKING THE INDICATOR LIGHT”
when the engine is stopped or the gear is on page 8-56.
shifted into the 3rd gear or higher.
TIP
• When the launch control system is turned off,
the indicator light “2” will stop flashing.
• Indicator light on the handlebar switch (left)
flashes orange  Check or replace any faulty
electrical part(s).
Refer to “CHECKING THE INDICATOR
LIGHT” on page 8-56.
1
To change the drive mode
1. Shift to neutral.
2. Start the engine.
3. Push the mode switch “1”.
TIP
As shipped from the factory, drive modes 1 and
2 are the same. You must use the Power Tuner
2 app to adjust the map settings.
When the indicator light “2” illuminates blue,
EAM30637
drive mode 2 is selected.
LAP TIME RECORD MODE
Lap time records can be measured by activating
from the Power Tuner app.
Push the mode switch “1” to start or stop mea-
suring.
TIP
• The indicator light “2” flashes blue while the lap
time record mode is on.
• Drive mode cannot be changed while in lap
time record mode. 2
1

1-22
 INSTRUMENT AND CONTROL FUNCTIONS

EAM30185
TIP
SHIFT PEDAL When operating the throttle grip in the closing di-
The shift pedal “1” has adopted a method of 1 rection, the starter knob “1” moves in the direc-
down & 4 ups (press-down & kick-ups). tion “b” as shown and returns to its original
Press it down for N (neutral) to 1st, and kick it up position.
for 2nd to 5th.
EWA20470

WARNING
While handling the starter knob, take care
5
not to burn yourself on exhaust pipes.
4 1
3
2
N
1
1
b a
EAM30188

FRONT BRAKE LEVER

The front brake lever “1” is located on the right
handlebar. Pull it toward the handlebar to acti-
vate the front brake. EAM30192

FUEL TANK CAP

Fuel tank cap is located under the sub-seat.
1 1. Loosen:
• Quick fastener “1”
1

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. 2. Remove the sub-seat “1” to open the fuel
tank cap “2”.
TIP
• When installing the sub-seat, make sure that
the plastic band is not twisted.
• When installing the sub-seat, push down the
quick fastener, rotate it, and then secure the
sub-seat with the quick fastener.

1 2
EAM30444

STARTER KNOB 1
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 the start-
er, resulting in a larger angle of throttle valve.

1-23
 STARTING AND BREAK-IN

EAM20123
the starter knob.
STARTING AND BREAK-IN
EAM30193

FUEL
Always use the recommended fuel as stated be-
low. Also, be sure to use new gasoline the day
of a race. 1

Recommended fuel
Unleaded gasoline (E10 accept-
able)
Octane number (R+M)/2
91 or higher 3. Start the engine by pushing the start switch.
Fuel tank capacity If the engine fails to start when using the start
6.2 L (1.6 US gal, 1.4 Imp.gal) switch, release it, wait a few seconds, and
ECA24180
then try again.
NOTICE Each starting attempt should be as short as
possible to preserve the battery. Do not crank
Use only unleaded gasoline. The use of lead-
the engine more than 10 seconds on any one
ed gasoline will cause severe damage to the
attempt.
engine internal parts such as valves, piston
4. When the engine starts running, warm this up
rings, and exhaust system, etc.
one or two minutes at a steady speed (of
TIP 3000 to 5000 r/min), and then return the start-
Your Yamaha engine has been designed to use er knob to its original position.
unleaded gasoline with a pump octane number TIP
[(R+M)/2] of 91 or higher, or a research octane When operating the throttle grip in the closing di-
number of 95 or higher. If knocking (or pinging) rection, the starter knob “1” moves in the direc-
occurs, use a gasoline of a different brand. tion as shown and returns to its original position.
EWA19010

WARNING
• For refueling, be sure to stop the engine
and use enough care not to spill any fuel.
Also be sure to avoid refueling close to a
fire. 1
• Refuel after the engine, exhaust pipe, etc.
have cooled off.
Gasohol
There are two types of gasohol: gasohol con-
EWA19030
taining ethanol and that containing methanol.
WARNING
Gasohol containing ethanol can be used if the
ethanol content does not exceed 10 %. Gasohol Since exhaust gas contains harmful ingredi-
containing methanol is not recommended by ents, do not start or warm it up at an illventi-
Yamaha because it can cause damage to the lated place or a closed narrow place.
fuel system or vehicle performance problems. 5. To stop the engine, push the engine stop
EAM30196
switch “1”.
STARTING A COLD ENGINE TIP
1. Press the shift pedal to neutral. Continue pushing the engine stop switch till the
2. Push the starter knob “1” completely. engine comes to a full stop.
TIP
• When the ambient temperature is 15 C (59 F)
or below, use the starter knob.
• Do not operate the throttle grip when operating

1-24
 STARTING AND BREAK-IN

CHECK POINTS” for tightening torques and

1 retighten them.
Also when the following parts are replaced, a
break-in is required.
• Cylinder and Crankshaft: A break-in is re-
quired for about an hour.
• Piston, Piston ring, Valve, Camshaft, and
Gear: A break-in is required for about 30
minutes at a throttle opening of 1/2 or less.
Observe the condition of the engine carefully
EAM30197 during a break-in.
STARTING A WARM ENGINE For checkpoints for a break-in, see “MAIN-
Follow the same procedure as for starting a cold TENANCE AFTER BREAK-IN”. If any prob-
engine with the exception that the starter is not lem is found, immediately stop the engine
required when the engine is warm. and make a checkup.
TIP
If the engine fail to start, fully open the throttle EAM30468

grip and push the start switch few seconds to ENGINE STARTING PRECAUTION
clear the engine of the rich air-fuel mixture re- • Make sure the transmission is in neutral or be
tained in it. sure to pull the clutch lever before pressing the
start switch.
EWA20540
EAM30198

BREAK-IN PROCEDURES WARNING

A break-in is important so that rotating portion, If the clutch lever is not pulled and the start
sliding surfaces, and mounted areas may fit one switch is pressed with the transmission in
another, and that the rider may become accus- gear, the starter motor will cause the rear
tomed to the machine. wheel to spin, which may cause injury.
ECA25811

NOTICE • When starting the engine, if only the starter

motor is turning but the engine does not crank,
Before running, do maintenance on the air this is a malfunction most likely due to a worn-
filter element. out starter clutch. Replace the starter clutch.
1. After warming up the engine, drive it for about
20 minutes at a throttle opening of 1/2 or less.
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. Make a pit stop, and check mounted areas for
looseness, oil leaks, or other problems.
3. Then, drive it for about 40 minutes at a throt-
tle opening of 3/4 or less.
4. Make a pit stop again, and thoroughly check
mounted areas for looseness, oil leaks, or
other problems. Thorough checks and ad-
justments are required in particular for stretch
of cables, free play of the brake, stretch of the
drive chain, looseness of the spoke, and so
on.
ECA25821

NOTICE
After a break-in or after each race, always
check the points shown in “TORQUE-

1-25
 MAINTENANCE AFTER BREAK-IN

EAM20124
• Drive chain
MAINTENANCE AFTER BREAK-IN Lubricate the drive chain and adjust its ten-
After a break-in, perform careful maintenance to sion.
get ready for the next practice or race. • Fuel tank
Refer to “PRE-OPERATION INSPECTION AND Clean the inside of the fuel tank. Check for
MAINTENANCE” on page 3-6. leaks.
EAM30199
• Suspension
MAJOR MAINTENANCE Check for oil leaks in the front fork or the rear
1. For the engine shock absorber. Check that the mounted
• Leaks around the engine conditions are good.
Check for pressure leaks from the cylinder • Sprocket
head or the cylinder, oil leaks from the crank- Check for looseness in the sprocket mounted
case or the case cover, leaks from the cool- on the rear wheel.
ant system, and other leaks. • Mounting bolts and nuts
• Check that the valve, the cylinder head, the Check mounted areas for looseness.
ECA25831
cylinder, the piston, and the piston ring fit one
NOTICE
another, and that contact between the valve
and the cylinder head, and that between the After a break-in or before each race, always
cylinder and the piston are correct. check the points shown in “TORQUE-
• Engine oil change CHECK POINTS” for tightening torques and
Drain the oil, and check for dirt and foreign retighten them.
materials such as metal chips. (If any foreign • Greasing and oiling
material is mixed, disassemble and check the Always grease or oil the specified points.
crankcase.)
EAM30195
Pour the specified amount of the recom- AIR FILTER MAINTENANCE
mended oil. Apply the Yamaha foam air filter oil or other qual-
• Generator ity foam air filter oil to the element. (Excess oil in
Check for looseness in mounted areas of the the element may adversely affect engine start-
generator rotor and the stator coil assembly. ing.) Refer to “CLEANING THE AIR FILTER EL-
Check that the connector is not being discon- EMENT” on page 3-16.
nected.
• Silencer
Check the main body and stay for cracks.
Check for leaks.
• Mounting bolts and nuts
Check for looseness in mounted areas of
parts, as well as engine mounting bolts and
engine brackets.
2. For the chassis
• Check welds and mounted areas of the
frame, the swingarm, the link, the bracket,
and so on, for looseness and cracks.
• Wheel(s)
Check the wheel for runout. Check the spoke
for looseness.
• Brake(s)
Check the brake disc mounting bolt for loose-
ness.
Check that the reservoir contains the speci-
fied amount of brake fluid. Check for leaks.
• Cable
Grease and adjust cables.

1-26
 TORQUE-CHECK POINTS

EAM20125

TORQUE-CHECK POINTS
Frame construction Fuel tank to frame
Frame to rear frame
Frame to engine protector
Engine mounting Frame to engine
Engine bracket to engine
Engine bracket to frame
Seat Seat to rear fender
Steering Steering stem to handlebar Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Suspension Front Steering stem to front fork Front fork to upper bracket
Front fork to lower bracket
Rear Link Assembly of links
Link to frame
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 disc to wheel
Tightening of union bolt
Brake master cylinder to handlebar
Tightening of bleed screw
Tightening of brake hose holder
Rear Brake pedal to frame
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw
Tightening of brake hose holder
Fuel system Fuel pump to fuel tank

1-27
 TORQUE-CHECK POINTS

Shift pedal Shift pedal to shift shaft

Plastic cover Tightening of front fender
Tightening of fork leg protector
Tightening of shroud
Tightening of side cover
Tightening of rear fender
Tightening of mud flap
Tightening of rear brake caliper
cover

TIP
Concerning the tightening torque, refer to “TIGHTENING TORQUES” on page 2-9.

1-28
 MOTORCYCLE CARE AND STORAGE

EAM20126
ly rinse the area off with water, immediately
MOTORCYCLE CARE AND STOR- dry it, and then apply a corrosion protec-
AGE tion spray.
• Improper cleaning can damage plastic
EAM30200
parts (such as cowlings, panels, wind-
CARE
shields, headlight lenses, meter lenses,
While the open design of a motorcycle reveals
etc.) and the mufflers. Use only a soft, clean
the attractiveness of the technology, it also
cloth or sponge with water to clean plastic.
makes it more vulnerable. Rust and corrosion
However, if the plastic parts cannot be thor-
can develop even if high-quality components are
oughly cleaned with water, diluted mild de-
used. A rusty exhaust pipe may go unnoticed on
tergent with water may be used. Be sure to
a car, however, it detracts from the overall ap-
rinse off any detergent residue using plenty
pearance of a motorcycle. Frequent and proper
of water, as it is harmful to plastic parts.
care does not only comply with the terms of the
• Do not use any harsh chemical products on
warranty, but it will also keep your motorcycle
plastic parts. Be sure to avoid using cloths
looking good, extend its life and optimize its per-
or sponges which have been in contact
formance.
with strong or abrasive cleaning products,
Before cleaning
solvent or thinner, fuel (gasoline), rust re-
TIP movers or inhibitors, brake fluid, antifreeze
Be sure to confirm that the vehicle is completely
or electrolyte.
cooled.
• For motorcycles equipped with a wind-
1. Block or cover the following parts with suit- shield: Do not use strong cleaners or hard
able measures. sponges as they will cause dulling or
• Air duct “1” scratching. Some cleaning compounds for
(other gaps around shrouds and seats) plastic may leave scratches on the wind-
• Muffler outlet “2” shield. Test the product on a small hidden
part of the windshield to make sure that it
1 does not leave any marks. If the windshield
is scratched, use a quality plastic polishing
compound after washing.
2
• When cleaning using either a high-pres-
sure cleaning machine or a water hose, do
not direct the water jet toward the following
areas:(Otherwise, it could cause either
damage due to the water pressure or mal-
function due to water entry.)
2. Make sure that all caps and covers as well as Wheels or swing arm bearings
all electrical couplers and connectors, includ- Fork seals or brake seals
ing the spark plug cap, are tightly installed. Electrical parts, such as couplers, switch-
3. Remove extremely stubborn dirt, like oil burnt es, battery, etc.
onto the crankcase, with a degreasing agent Muffler or hoses
and a brush, but never apply such products Air cleaner intake port
onto seals, gaskets, sprockets, the drive • Do not clean using a water jet with the seat
chain and wheel axles. Always rinse the dirt or cover removed.
and degreaser off with water.
Cleaning
ECA26730

NOTICE
• Avoid using strong acidic wheel cleaners,
especially on spoked wheels. If such prod-
ucts are used on hard-to-remove dirt, do
not leave the cleaner on the affected area
any longer than instructed. Also, thorough-

1-29
 MOTORCYCLE CARE AND STORAGE

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.
EWA19050

WARNING
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.
After normal use • If necessary, clean the brake discs and
Remove dirt with warm water, a mild detergent, brake linings with a regular brake disc
and a soft, clean sponge, and then rinse thor- cleaner or acetone, and wash the tires with
oughly with clean water. Use a toothbrush or warm water and a mild detergent. Before
bottlebrush for hard-to-reach areas. Stubborn riding at higher speeds, test the motorcy-
dirt and insects will come off more easily if the cle’s braking performance and cornering
area is covered with a wet cloth for a few min- behavior.
utes before cleaning.
ECA24240
After riding in the rain, near the sea or on salt-
NOTICE
sprayed roads
Since sea salt or salt sprayed on roads during • Apply spray oil and wax sparingly and
winter are extremely corrosive in combination make sure to wipe off any excess.
with water, carry out the following steps after • Never apply oil or wax to any rubber and
each ride in the rain, near the sea or on salt- plastic parts, but treat them with a suitable
sprayed roads. care product.
• Avoid using abrasive polishing com-
TIP
Salt sprayed on roads in the winter may remain pounds as they will wear away the paint.
well into spring. TIP
• Consult a Yamaha dealer for advice on what
1. Clean the motorcycle with cold water and a
products to use.
mild detergent, after the engine has cooled
• Washing, rainy weather or humid climates can
down.
cause the headlight lens to fog. Turning the
NOTICE: Do not use warm water since it
headlight on for a short period of time will help
increases the corrosive action of the salt.
remove the moisture from the lens.
2. Apply a corrosion protection spray on all met-
al, including chrome- and nickel-plated, sur-
EAM30201
faces to prevent corrosion. STORAGE
After cleaning Short-term
1. Dry the motorcycle with a chamois or an ab- Always store your motorcycle in a cool, dry place
sorbing cloth. and, if necessary, protect it against dust with a
2. Immediately dry the drive chain and lubricate porous cover. Be sure the engine and the ex-
it to prevent it from rusting. haust system are cool before covering the mo-
3. Use a chrome polish to shine chrome, alumi- torcycle.
num and stainless- steel parts, including the ECA24250

exhaust system. (Even the thermally induced NOTICE

discoloring of stainless- steel exhaust sys- • Storing the motorcycle in a poorly ventilat-
tems can be removed through polishing.) ed room or covering it with a tarp, while it is
4. To prevent corrosion, it is recommended to still wet, will allow water and humidity to
apply a corrosion protection spray on all met- seep in and cause rust.
al, including chrome- and nickel-plated, sur- • To prevent corrosion, avoid damp cellars,
faces. stables (because of the presence of ammo-
5. Use spray oil as a universal cleaner to re- nia) and areas where strong chemicals are
move any remaining dirt.

1-30
 MOTORCYCLE CARE AND STORAGE

stored.
Long-term
Before storing your motorcycle for several
months:
1. Follow all the instructions in the “CARE” on
page 1-29.
2. Fill up the fuel tank and add fuel stabilizer (if
available) to prevent the fuel tank from rusting
and the fuel from deteriorating.
3. Perform the following steps to protect the cyl-
inder, piston rings, etc. from corrosion.
a. Remove the spark plug cap and spark
plug.
b. Pour a teaspoonful of engine oil into the
spark plug bore.
c. Install the spark plug cap onto the spark
plug, and then place the spark plug on the
cylinder head so that the electrodes are
grounded. (This will limit sparking during
the next step.)
d. Turn the engine over several times with
the starter. (This will coat the cylinder wall
with oil.)
e. Remove the spark plug cap from the spark
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 that
both of its wheels are off the ground. Alterna-
tively, turn the wheels a little every month in
order to prevent the tires from becoming de-
graded in one spot.
6. Cover the muffler outlet with a plastic bag to
prevent moisture from entering it.
7. Remove the battery and fully charge it. Store
it in a cool, dry place and charge it once a
month. Do not store the battery in an exces-
sively cold or warm place [less than 0 C (32
F) or more than 65 C (149 F)]. For more in-
formation on storing the battery, “CHECKING
AND CHARGING THE BATTERY” on page
8-47.
TIP
Make any necessary repairs before storing the
motorcycle.

1-31
MOTORCYCLE CARE AND STORAGE

1-32
 SPECIFICATIONS

GENERAL SPECIFICATIONS ..........................................................................2-1

ENGINE SPECIFICATIONS..............................................................................2-2
1
CHASSIS SPECIFICATIONS............................................................................2-5

ELECTRICAL SPECIFICATIONS.....................................................................2-8
2
TIGHTENING TORQUES..................................................................................2-9

3
GENERAL TIGHTENING TORQUE SPECIFICATIONS ............................2-9
ENGINE TIGHTENING TORQUES ..........................................................2-10
CHASSIS TIGHTENING TORQUES ........................................................2-13

CABLE ROUTING DIAGRAM ........................................................................2-17

4
5
6
7
8
9
10
 GENERAL SPECIFICATIONS

EAM20127

GENERAL SPECIFICATIONS
Model
Model BHR1
BHR5
Dimensions
Overall length 2180 mm (85.8 in)
Overall width 825 mm (32.5 in)
Overall height 1275 mm (50.2 in)
Seat height 965 mm (38.0 in)
Wheelbase 1480 mm (58.3 in)
Ground clearance 350 mm (13.78 in)
Weight
Curb weight 109 kg (240 lb)
Riding capacity 1 person

2-1
 ENGINE SPECIFICATIONS

EAM20128

ENGINE SPECIFICATIONS
Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train DOHC
Displacement 450 cm³
Number of cylinders Single cylinder
Bore  stroke 97.0  60.8 mm (3.82  2.39 in)
Compression ratio 13.0 : 1
Starting system Electric starter
Fuel
Recommended fuel Unleaded gasoline (E10 acceptable)
Octane number (RON) 95
Fuel tank capacity 6.2 L (1.6 US gal, 1.4 Imp.gal)
Engine oil
Recommended brand YAMALUBE
SAE viscosity grades 10W-40, 10W-50, 15W-40, 20W-40 or 20W-50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Lubrication system Dry sump
Engine oil quantity
Oil change 0.94 L (0.99 US qt, 0.83 Imp.qt)
With oil filter removal 0.96 L (1.01 US qt, 0.84 Imp.qt)
Quantity (disassembled) 1.20 L (1.27 US qt, 1.06 Imp.qt)
Oil filter
Oil filter type Cartridge
Cooling system
Coolant quantity
Radiator (including all routes) 1.03 L (1.09 US qt, 0.91 Imp.qt)
Radiator cap valve opening pressure 107.9–137.3 kPa (1.08–1.37 kgf/cm², 15.6–19.9
psi)
Spark plug(s)
Manufacturer/model NGK/LMAR8G
Spark plug gap 0.7–0.8 mm (0.028–0.031 in)
Cylinder head
Warpage limit 0.05 mm (0.0020 in)
Camshaft
Camshaft cap inside diameter 22.043–22.064 mm (0.8678–0.8687 in)
Camshaft journal diameter 22.002–22.015 mm (0.8662–0.8667 in)
Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in)
Camshaft-journal-to-camshaft-cap clearance 0.080 mm (0.0032 in)
limit
Camshaft lobe dimensions
Lobe height limit (Intake) 38.030 mm (1.4972 in)
Lobe height limit (Exhaust) 34.170 mm (1.3453 in)
Valve, valve seat, valve guide
Valve clearance (cold)
Intake 0.10–0.17 mm (0.0039–0.0067 in)

2-2
 ENGINE SPECIFICATIONS

Exhaust 0.15–0.22 mm (0.0059–0.0087 in)

Valve dimensions
Valve seat contact width limit (intake) 1.5 mm (0.06 in)
Valve seat contact width limit (exhaust) 1.5 mm (0.06 in)
Valve stem diameter limit (intake) 5.445 mm (0.2144 in)
Valve stem diameter limit (exhaust) 5.435 mm (0.2140 in)
Valve guide inside diameter (intake) 5.500–5.512 mm (0.2165–0.2170 in)
Valve guide inside diameter (exhaust) 5.500–5.512 mm (0.2165–0.2170 in)
Valve-stem-to-valve-guide clearance limit 0.080 mm (0.0032 in)
(intake)
Valve-stem-to-valve-guide clearance limit 0.100 mm (0.0039 in)
(exhaust)
Valve stem runout 0.020 mm (0.0008 in)
Valve spring
Free length limit (intake) 36.65 mm (1.44 in)
Free length limit (exhaust) 37.34 mm (1.47 in)
Cylinder
Bore 97.000–97.010 mm (3.8189–3.8193 in)
Wear limit 97.060 mm (3.8213 in)
Piston
Piston-to-cylinder clearance 0.010–0.045 mm (0.0004–0.0018 in)
Diameter 96.955–96.970 mm (3.8171–3.8177 in)
Measuring point (from piston skirt bottom) 9.0 mm (0.35 in)
Piston pin bore inside diameter limit 18.045 mm (0.7104 in)
Piston pin outside diameter limit 17.981 mm (0.7079 in)
Piston-pin-to-piston-pin-bore clearance 0.004–0.024 mm (0.0002–0.0009 in)
Piston ring
Top ring
End gap limit 0.55 mm (0.0217 in)
Ring side clearance 0.015–0.065 mm (0.0006–0.0026 in)
Side clearance limit 0.120 mm (0.0047 in)
2nd ring
End gap limit 0.85 mm (0.0335 in)
Ring side clearance 0.020–0.060 mm (0.0008–0.0024 in)
Side clearance limit 0.100 mm (0.0039 in)
Connecting rod
Oil clearance 0.028–0.045 mm (0.0011–0.0018 in)
Bearing color code
Code 4 Green
Code 5 Yellow
Crankshaft
Crank assembly width 61.93–62.00 mm (2.438–2.441 in)
Runout limit 0.030 mm (0.0012 in)
Clutch
Clutch type Wet, multiple-disc
Clutch lever free play 7.0–12.0 mm (0.28–0.47 in)
Friction plate 1 thickness 2.12–2.28 mm (0.083–0.090 in)
Wear limit 2.02 mm (0.080 in)
Plate quantity 4 pcs

2-3
 ENGINE SPECIFICATIONS

Friction plate 2 thickness 2.12–2.28 mm (0.083–0.090 in)

Wear limit 2.02 mm (0.080 in)
Plate quantity 4 pcs
Clutch plate 1 thickness 1.35–1.45 mm (0.053–0.057 in)
Plate quantity 7 pcs
Warpage limit 0.10 mm (0.004 in)
Clutch plate 2 thickness 0.93–1.07 mm (0.037–0.042 in)
Plate quantity 2 pcs
Warpage limit 0.10 mm (0.004 in)
Clutch spring free height 5.80 mm (0.228 in)
Clutch spring free height limit 5.51 mm (0.217 in)
Push rod bending limit 0.10 mm (0.004 in)
Drivetrain
Primary reduction ratio 2.481 (67/27)
Transmission type Constant mesh 5-speed
Gear ratio
1st 2.000 (28/14)
2nd 1.625 (26/16)
3rd 1.350 (27/20)
4th 1.136 (25/22)
5th 1.000 (21/21)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Secondary reduction ratio 3.769 (49/13)
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
Maximum consumption amperage 2.4 A
Fuel injector
Resistance 12.0 
Throttle body
ID mark BHR1
Idling condition
Engine idling speed 1900–2100 r/min
Coolant temperature 70–80 C (158–176 F)
Fuel line pressure (at idle) 300–390 kPa (3.0–3.9 kgf/cm², 43.5–56.6 psi)
Throttle grip free play 3.0–6.0 mm (0.12–0.24 in)

2-4
 CHASSIS SPECIFICATIONS

EAM20129

CHASSIS SPECIFICATIONS
Chassis
Caster angle 26.9 
Trail 120 mm (4.7 in)
Front wheel
Wheel type Spoke wheel
Rim size 21x1.6
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Wheel axle bending limit 0.50 mm (0.02 in)
Rear wheel
Wheel type Spoke wheel
Rim size 19x2.15
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Wheel axle bending limit 0.50 mm (0.02 in)
Front tire
Type With tube
Size 80/100-21 51M
Manufacturer/model DUNLOP/MX33
Rear tire
Type With tube
Size 120/80-19 63M
Manufacturer/model DUNLOP/MX33
Tire air pressure (measured on cold tires)
Front 100 kPa (1.00 kgf/cm², 15 psi)
Rear 100 kPa (1.00 kgf/cm², 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 0.15 mm (0.0059 in)
wheel)
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) 25.40 mm, 25.40 mm (1.00 in, 1.00 in)
Specified brake fluid DOT 4
Rear brake
Type Hydraulic single disc brake
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc runout limit (as measured on 0.15 mm (0.0059 in)
wheel)
Brake pad lining thickness limit 1.0 mm (0.04 in)
Master cylinder inside diameter 11.0 mm (0.43 in)
Caliper cylinder inside diameter 25.40 mm (1.00 in)
Specified brake fluid DOT 4
Front suspension
Type Telescopic fork
Spring Coil spring

2-5
 CHASSIS SPECIFICATIONS

Shock absorber Hydraulic damper

Wheel travel 310 mm (12.2 in)
Fork spring free length limit 492.0 mm (19.37 in)
Inner tube bending limit 0.2 mm (0.01 in)
Recommended oil Yamaha Suspension Oil S1
Quantity (left) 476.0 cm³ (16.09 US oz, 16.79 Imp.oz)
Quantity (right) 476.0 cm³ (16.09 US oz, 16.79 Imp.oz)
Rebound damping
Adjusting system Mechanical adjustable type
Unit for adjustment Click
Adjustment value from the start position 20
(Soft)
Adjustment value from the start position 11
(STD)
Adjustment value from the start position 0
(Hard)
Compression damping
Adjusting system Mechanical adjustable type
Unit for compression damping adjustment Click
Adjustment value from the start position 20
(Soft)
Adjustment value from the start position 10
(STD)
Adjustment value from the start position 0
(Hard)
Rear suspension
Type Swingarm (link suspension)
Spring Coil spring
Shock absorber Gas-hydraulic damper
Wheel travel 315 mm (12.4 in)
Spring preload
Adjusting system Mechanical adjustable type
Adjustment value (Soft) 1.5 mm (0.06 in)
Adjustment value (STD) 7.0 mm (0.28 in)
Adjustment value (Hard) 18.0 mm (0.71 in)
Rebound damping
Adjusting system Mechanical adjustable type
Unit for adjustment Click
Adjustment value from the start position 30
(Soft)
Adjustment value from the start position 13
(STD)
Adjustment value from the start position 0
(Hard)
Compression damping
Adjusting system Mechanical adjustable type
Fast compression damping
Unit for adjustment Turn
Adjustment value from the start position 2
(Soft)
Adjustment value from the start position 1
(STD)

2-6
 CHASSIS SPECIFICATIONS

Adjustment value from the start position 0

(Hard)
Slow compression damping
Unit for adjustment Click
Adjustment value from the start position 20
(Soft)
Adjustment value from the start position 10
(STD)
Adjustment value from the start position 0
(Hard)
Drive chain
Size 520
Chain type Non-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 242.9 mm (9.56 in)

2-7
 ELECTRICAL SPECIFICATIONS

EAM20130

ELECTRICAL SPECIFICATIONS
Voltage
System voltage 12 V
Ignition system
Ignition system TCI
Ignition timing (B.T.D.C.) 8.0–12.0 /2000 r/min
Engine control unit
Model BHR0
Ignition coil
Primary coil resistance 1.98–2.42 
Secondary coil resistance 14.64–21.96 k
Spark plug cap
Resistance 10.00 k
Charging system
Charging system AC magneto
Standard output 14.0 V, 7.1 A at 5000 r/min
Stator coil resistance 0.408–0.612 
Rectifier/regulator
Regulator type Single-phase
Regulated voltage (DC) 14.0–14.8 V
Battery
Model BR98
Voltage, capacity 12 V, 2.4 Ah (5 HR)
Starter motor
Brush overall length 11.0 mm (0.43 in)
Brush overall length limit 5.5 mm (0.22 in)
Brush spring force 4.80–7.20 N (489–734 gf, 17.28–25.92 oz)
Mica undercut (depth) 2.40 mm (0.09 in)
Fuel injection sensor
Crankshaft position sensor resistance 228–342 
Intake air temperature sensor resistance 5400–6600  at 0 C (5400–6600  at 32 F)
Intake air temperature sensor resistance 290–390  at 80 C (290–390  at 176 F)
Coolant temperature sensor resistance 2310–2590  at 20 C (2310–2590  at 68 F)
Coolant temperature sensor resistance 310–326  at 80 C (310–326  at 176 F)
Fuse(s)
Main fuse 15.0 A
Spare fuse 15.0 A

2-8
 TIGHTENING TORQUES

EAM20131

TIGHTENING TORQUES
EAM30205

GENERAL TIGHTENING TORQUE

SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special com-
ponents or assemblies are provided for each
chapter of this manual. 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

General tightening torques

A (nut) B (bolt)
N·m kgf·m lb·ft

10 mm 6 mm 6 0.6 4.4
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 41
19 mm 14 mm 85 8.5 63
22 mm 16 mm 130 13.0 96

2-9
 TIGHTENING TORQUES

EAM30203

ENGINE TIGHTENING TORQUES

TIP
- marked portion shall be checked for torque tightening after break-in or before each race.

Thread
Item Q’ty Tightening torques Remarks
size

Camshaft cap bolt M6 8 10 N·m (1.0 kgf·m, 7.4 lb·ft) E

Spark plug M10 1 13 N·m (1.3 kgf·m, 9.6 lb·ft)

Oil passage plug (cylinder head) M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

Cylinder head bolt M10 4 See TIP. M

Cylinder head bolt M6 2 12 N·m (1.2 kgf·m, 8.9 lb·ft) LT

Cylinder head cover bolt M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Cylinder head stud bolt (exhaust
M6 3 7 N·m (0.7 kgf·m, 5.2 lb·ft)
pipe)
Stud bolt (cylinder head cover) M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

Cylinder head cover breather plate

M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
bolt LT

Oil nozzle (cylinder head) M6 1 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
Cylinder bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Use a lock
Balancer driven gear nut M14 1 50 N·m (5.0 kgf·m, 37 lb·ft)
washer.
Timing chain guide stopper plate
M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
(exhaust side) LT

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 N·m (1.0 kgf·m, 7.4 lb·ft)
Water pump housing cover bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Oil pump assembly bolt M5 2 5 N·m (0.5 kgf·m, 3.7 lb·ft) LT

Oil pump cover bolt M4 1 6 N·m (0.6 kgf·m, 4.4 lb·ft) LT

Oil strainer bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

Throttle cable cover bolt M5 1 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
Throttle body joint bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Throttle body joint clamp screw M5 1 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
Air filter case joint clamp screw M5 1 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
Air filter case bolt M6 3 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Air filter case bracket bolt M6 4 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Intake air temperature sensor screw M5 1 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)

2-10
 TIGHTENING TORQUES

Thread
Item Q’ty Tightening torques Remarks
size

Clutch cable locknut (clutch cable

M6 1 4.3 N·m (0.43 kgf·m, 3.2 lb·ft)
adjuster)
Clutch cable locknut (engine side) M8 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Exhaust pipe nut M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Exhaust pipe protector screw M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

Exhaust pipe bracket bolt M8 1 20 N·m (2.0 kgf·m, 15 lb·ft)

Silencer bolt (front) M8 1 30 N·m (3.0 kgf·m, 22 lb·ft)
Silencer bolt (rear) M8 1 30 N·m (3.0 kgf·m, 22 lb·ft)
Exhaust pipe clamp bolt M8 2 12 N·m (1.2 kgf·m, 8.9 lb·ft)
Silencer body bolt M5 6 8 N·m (0.8 kgf·m, 5.9 lb·ft) LT

Oil nozzle (crankcase) M5 1 0.5 N·m (0.05 kgf·m, 0.37 lb·ft)

Oil nozzle bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

Engine oil drain bolt (crankcase) M10 1 20 N·m (2.0 kgf·m, 15 lb·ft)
Engine oil drain bolt (oil tank) M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Crankcase bolt M6 9 12 N·m (1.2 kgf·m, 8.9 lb·ft)
Crankshaft end accessing screw M36 1 10 N·m (1.0 kgf·m, 7.4 lb·ft) E

Timing mark accessing screw M14 1 6 N·m (0.6 kgf·m, 4.4 lb·ft) E

Drive sprocket cover bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)

Crankcase bearing cover plate
M8 4 30 N·m (3.0 kgf·m, 22 lb·ft)
screw LT

Bearing plate cover bolt (left side of

the drive axle) M6 2 12 N·m (1.2 kgf·m, 8.9 lb·ft) LT

Plate bolt M6 4 12 N·m (1.2 kgf·m, 8.9 lb·ft) LT

Clutch cover bolt M6 6 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Crankcase cover bolt (left) M6 8 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Crankcase cover bolt (right) M6 10 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 lb·ft)
Bolt (holder) M6 2 12 N·m (1.2 kgf·m, 8.9 lb·ft) LT

Primary drive gear nut M20 1 120 N·m (12 kgf·m, 89 lb·ft) E

Bolt (pressure plate 1) M6 6 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Stake.
Clutch boss nut M20 1 105 N·m (10.5 kgf·m, 77 lb·ft)
LT

Bolt (clutch release) M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

Use a lock
Drive sprocket nut M20 1 90 N·m (9.0 kgf·m, 66 lb·ft) washer.
LT

Segment bolt M8 1 30 N·m (3.0 kgf·m, 22 lb·ft)

Shift guide bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

2-11
 TIGHTENING TORQUES

Item Thread Q’ty Tightening torques Remarks

size

Stopper lever bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

Shift pedal bolt M6 1 12 N·m (1.2 kgf·m, 8.9 lb·ft) 

Generator rotor nut M12 1 65 N·m (6.5 kgf·m, 48 lb·ft)
Stator coil screw M5 3 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

Crankshaft position sensor bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

Gear position switch bolt M5 2 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) LT

Rectifier/regulator bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)

Ignition coil bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Starter motor bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Nut (holder) M6 1 8 N·m (0.8 kgf·m, 5.9 lb·ft)
Throttle position sensor screw M5 1 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
Intake air pressure sensor screw M6 1 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)

TIP
Cylinder head bolt
Tighten all the cylinder head bolts evenly in the tightening order to 36 N·m (3.6 kgf·m, 27 lb·ft). Remove
the one bolt according to the tightening order. When doing so, do not remove the other bolts. Retighten
the bolt to 18 N·m (1.8 kgf·m, 13 lb·ft), and then tighten it further to reach the specified angle (90). Re-
move the remaining bolts one by one in the same manner and retighten them. Finally, tighten all the
bolts to reach the specified angle (60). Total tightening angle: 90 + 60 = 150 (The first and second
time, be sure to apply molybdenum disulfide grease to the bolt threads and seats as well as to both
sides of the plain washers.)

FWD

x4

3 2

1 4

2-12
 TIGHTENING TORQUES

EAM30204

CHASSIS TIGHTENING TORQUES

TIP
- marked portion shall be checked for torque tightening after break-in or before each race.

Thread
Item Q’ty Tightening torques Remarks
size

Upper bracket pinch bolt M8 4 21 N·m (2.1 kgf·m, 15 lb·ft) 

Lower bracket pinch bolt M8 4 21 N·m (2.1 kgf·m, 15 lb·ft) 
Steering stem nut M24 1 145 N·m (14.5 kgf·m, 107 lb·ft) 
Upper handlebar holder bolt M8 4 28 N·m (2.8 kgf·m, 21 lb·ft) 
Lower handlebar holder nut M10 2 40 N·m (4.0 kgf·m, 30 lb·ft) 
Handlebar switch screw (left) M4 1 1.3 N·m (0.13 kgf·m, 0.95 lb·ft)
Start switch M3 1 0.5 N·m (0.05 kgf·m, 0.37 lb·ft)
Lower ring nut M28 1 See TIP. 
Damper assembly (front fork) M51 2 30 N·m (3.0 kgf·m, 22 lb·ft)
Inner tube and adjuster M22 2 55 N·m (5.5 kgf·m, 41 lb·ft) LT

Base valve (front fork) M42 2 28 N·m (2.8 kgf·m, 21 lb·ft)

Adjuster (damper assembly) M12 2 29 N·m (2.9 kgf·m, 21 lb·ft)
Bleed screw (front fork) M5 2 1.3 N·m (0.13 kgf·m, 0.95 lb·ft)
Screw (adjuster knob) M4 2 0.6 N·m (0.06 kgf·m, 0.44 lb·ft)
Front fork protector bolt M6 6 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Brake hose holder bolt M6 2 9 N·m (0.9 kgf·m, 6.6 lb·ft) 
Screw (throttle cable housing) 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 cylinder holder M6 2 9 N·m (0.9 kgf·m, 6.6 lb·ft) 
bolt
Front brake master cylinder reservoir
M4 2 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
cap screw
Front brake lever pivot bolt M6 1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Front brake lever pivot nut M6 1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Locknut (front brake lever position) M6 1 5 N·m (0.5 kgf·m, 3.7 lb·ft)
Front brake hose union bolt M10 2 30 N·m (3.0 kgf·m, 22 lb·ft) 
Front brake caliper bolt M8 2 28 N·m (2.8 kgf·m, 21 lb·ft) 
Front brake pad pin M10 1 17 N·m (1.7 kgf·m, 13 lb·ft)
Front brake pad pin plug M10 1 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
Front brake caliper bleed screw M8 1 5 N·m (0.5 kgf·m, 3.7 lb·ft) 
Front wheel axle nut M18 1 115 N·m (11.5 kgf·m, 85 lb·ft) 
Front wheel axle pinch bolt M8 4 21 N·m (2.1 kgf·m, 15 lb·ft) 

2-13
 TIGHTENING TORQUES

Thread
Item Q’ty Tightening torques Remarks
size

Front brake disc bolt M6 6 12 N·m (1.2 kgf·m, 8.9 lb·ft) / LT

Rear brake disc bolt M6 6 12 N·m (1.2 kgf·m, 8.9 lb·ft) / LT

Footrest bracket bolt M10 4 55 N·m (5.5 kgf·m, 41 lb·ft) LT

Rear brake pedal bolt M8 1 26 N·m (2.6 kgf·m, 19 lb·ft) 

Rear brake pedal adjusting locknut M6 1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Rear brake master cylinder bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) 
Rear brake master cylinder reservoir
M4 2 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
cap bolt
Rear brake hose union bolt M10 2 30 N·m (3.0 kgf·m, 22 lb·ft) 
Rear brake caliper bleed screw M8 1 5 N·m (0.5 kgf·m, 3.7 lb·ft) 
Rear brake pad pin M10 1 17 N·m (1.7 kgf·m, 13 lb·ft)
Rear brake pad pin plug M10 1 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
Rear wheel axle nut M22 1 135 N·m (13.5 kgf·m, 100 lb·ft) 
Drive chain puller locknut M8 2 21 N·m (2.1 kgf·m, 15 lb·ft)
Rear wheel sprocket nut M8 6 42 N·m (4.2 kgf·m, 31 lb·ft) 
Nipple (spoke) — 72 2.5 N·m (0.25 kgf·m, 1.8 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) M8 2 34 N·m (3.4 kgf·m, 25 lb·ft) 
Rear frame bolt M8 4 38 N·m (3.8 kgf·m, 28 lb·ft) 
Engine guard bolt (right side) M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Pivot shaft nut M16 1 75 N·m (7.5 kgf·m, 55 lb·ft) / LS

Rear shock absorber assembly

M10 1 56 N·m (5.6 kgf·m, 41 lb·ft) 
upper nut
Rear shock absorber assembly
M10 1 53 N·m (5.3 kgf·m, 39 lb·ft) 
lower nut
Relay arm nut (swingarm side) M14 1 70 N·m (7.0 kgf·m, 52 lb·ft) 
Connecting arm nut (relay arm side) M14 1 80 N·m (8.0 kgf·m, 59 lb·ft) 
Connecting arm nut (frame side) M14 1 80 N·m (8.0 kgf·m, 59 lb·ft) 
Brake hose holder screw M5 4 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) 
Drive chain tensioner bolt (upper
M8 1 16 N·m (1.6 kgf·m, 12 lb·ft)
side)
Drive chain tensioner bolt (lower
M8 1 16 N·m (1.6 kgf·m, 12 lb·ft)
side)
Bolt (drive chain support) M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)

2-14
 TIGHTENING TORQUES

Thread
Item Q’ty Tightening torques Remarks
size

Drive chain support nut M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)

Drive chain guide bolt M5 3 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
Fuel tank bolt (front side) M6 2 8 N·m (0.8 kgf·m, 5.9 lb·ft) 
Screw (fuel tank) M6 1 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
Fuel pump bolt M5 5 7 N·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)
Seat set bracket screw M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Seat bolt M6 2 13 N·m (1.3 kgf·m, 9.6 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) 
Shroud bolt (frame) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Shroud bolt (air filter case) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Shroud bolt (fuel tank) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Shroud bolt (radiator guard) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Front fender bolt M6 4 10 N·m (1.0 kgf·m, 7.4 lb·ft) 
Rear fender bolt (front side) M6 4 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Rear fender bolt (rear side) M6 2 16 N·m (1.6 kgf·m, 12 lb·ft) 
Screw (mud flap) — 2 1.3 N·m (0.13 kgf·m, 0.95 lb·ft) 
Number plate bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Frame ground bolt (negative battery
M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
lead)
Ignition coil bracket bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Starter relay bolt M6 2 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
Battery box bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)

TIP
Lower ring nut
1. First, tighten the lower ring nut approximately 38 N·m (3.8 kgf·m, 28 lb·ft) by using the steering nut
wrench, then loosen the lower ring nut one turn.
2. Retighten the lower ring nut 7 N·m (0.7 kgf·m, 5.2 lb·ft).

2-15
 TIGHTENING TORQUES

2-16
 CABLE ROUTING DIAGRAM

EAM20152

CABLE ROUTING DIAGRAM

Frame and engine (front left side view)

4, A 5, A
3 6
2
1 Q
1

12
11

17, K
18

4, A 5, A
3 6 B
2
1 19
7 8
20, L

9, C

J
10
16

21

15, I
14, H
9 12, G
F

11, N
13
O 12, N
E

12
1, M
11

2-17
 CABLE ROUTING DIAGRAM

1. Clutch cable L. When fastening the starter motor lead with

2. Throttle cable (return) the clamp, close the clamp while applying
tension to the starter motor lead so that the
3. Throttle cable (pull) starter motor lead has no slack.
4. Handlebar switch lead (left) In addition, be careful so that the starter
5. Start switch lead motor lead does not contact the push lever
shaft. However, it does not matter if the
6. Cable holder starter motor lead contacts the crankcase
7. Handlebar switch coupler (left) (black, 6-pin) bolt and timing chain tensioner.
8. Start switch coupler (black, 2-pin) M. Clamp the clutch cable at the front of the lead
9. Rectifier/regulator coupler (the front of the vehicle).
10.Tension arm N. The routing order of the gear position switch
11.Gear position switch lead lead and stator coil assembly lead does not
matter.
12.Stator coil assembly lead
O. Insert the clip portion of the clamp into the
13.Radiator hose frame. The lock part should face toward the
14.Gear position switch coupler (white, 3-pin) front of the vehicle.
15.Stator coil assembly coupler (gray, 2-pin) Cut off the end of the remaining portion.
16.Grommet P. Diagram for routing the radiator hose and
radiator breather hose.
17.Radiator breather hose
Q. When installing the dampers and the lower
18.Down tube handlebar holders in the front hole, be sure to
19.Clamp route the handlebar switch lead (left) as
20.Starter motor lead shown in the illustration.
21.Bracket

A. Adjust slack in the handlebar switch lead

(left) and start switch lead at the vehicle’s
front side of the cable holder.
B. Pass the handlebar switch lead (left) and the
start switch lead between the frame and the
cable holder. Pass the handlebar switch lead
(left) above the start switch lead.
C. Insert the rectifier/regulator 2-pin coupler (not
colored) and rectifier/regulator 3-pin coupler
(not colored) into the bracket and secure
them. After securing, install the cover over
them.
D. Pass the rectifier/regulator lead (wire harness
side) to the inside of the tension arm (the side
of the vehicle).
E. Bring the protector of the clutch cable into
contact with the radiator hose, and pass it to
the outside of the gear position switch lead
and the stator coil assembly lead (the outside
of the vehicle).
F. Make sure that the stator coil assembly lead
does not get caught between the radiator and
the gear position switch 3-pin coupler (white).
G. Pass the stator coil assembly lead behind the
radiator. Be sure the lead will not be pinched
between the radiator and the tension arm.
H. After connecting the gear position switch 3-
pin coupler (white), attach the coupler cover.
I. After connecting the stator coil assembly 2-
pin coupler (gray), attach the coupler cover.
J. Fasten the clutch cable, gear position switch
lead, and stator coil assembly lead over the
grommet with the plastic locking tie. Point the
end of the plastic locking tie to the front side
of the vehicle, and then cut off it.
K. Pass the radiator breather hose through the
down tube.

2-18
 CABLE ROUTING DIAGRAM

Frame (rear left side view)

1 G

4 5, B

3, A

1 2

6, C
7

10, D
11, E
12, F

13
11
10
14
H

2-19
 CABLE ROUTING DIAGRAM

1. Wire harness
2. Rear frame
3. Plastic locking tie
4. Starter relay coupler (black, 4-pin)
5. Starter motor lead
6. Positive battery lead
7. Negative battery lead
8. CCU (Communication Control Unit)
9. Rear fender (projection)
10.Starter relay
11.Starter relay cover
12.CCU coupler
13.Wire harness
14.Diode

A. Fasten the starter motor lead and wire har-

ness to the rear frame at the white tape posi-
tion of the wire harness using the plastic
locking tie. Point the lock portion of the wire
harness to the lower side of the vehicle while
pointing the end of the lock portion to the out-
side of the vehicle, and then cut off the end.
B. Route the starter motor lead between the
starter relay and the rear fender. Adjust any
slack between the starter relay and the plas-
tic locking tie of the rear frame.
C. Route the positive battery lead on the outside
of the projection on the rear fender (outside
the vehicle).
D. Insert the starter relay into the battery
bracket, and secure it.
E. Install the starter relay cover over the starter
relay.
F. Insert the CCU coupler into the battery
bracket so that the coupler is located on the
inside (of the vehicle), and then secure it.
G. Insert the clip portion of the clamp into the
frame. Fasten the starter motor lead and wire
harness at the green tape of the wire har-
ness. Point the end to the lower side of the
vehicle, and then cut off it.
H. Point the starter motor lead to the outside,
and then install it.

2-20
 CABLE ROUTING DIAGRAM

Frame and engine (right side view)

1, A 2, C
B 3

4, D

6, E

7
10
11
9

13

12

2-21
 CABLE ROUTING DIAGRAM

1. Fuel pump coupler (black, 5-pin)

2. Coolant temperature sensor coupler (black,
2-pin)
3. Upper radiator boss
4. Throttle position sensor coupler (black, 3-pin)
5. Lower radiator boss
6. Radiator breather hose
7. Radiator hose
8. CCU (Communication Control Unit)
9. Wire harness (to the negative battery cou-
pler)
10.Positive battery lead
11.ECU (Engine Control Unit)
12.Wire harness
13.CCU sub-lead

A. After connecting, install the cover over the

fuel pump 5-pin coupler (black).
B. When installing the engine ground lead termi-
nal, it can face either way. Point the engine
ground lead to the upper side of the vehicle,
and then install it.
C. After connecting the water temperature sen-
sor 2-pin coupler (black), install the cover
over it.
D. After connecting the throttle position sensor
3-pin coupler (black), install the cover over it.
E. The radiator breather hose should be routed
in the following order and via each mentioned
point.
The upper radiator boss at the rear of the
vehicle 
The lower radiator boss at the front of the
vehicle 
The radiator hose at the front of the vehicle

For routing the remaining leads, refer to the
diagram “P” under “Frame and engine (front
left side view)”.

2-22
 CABLE ROUTING DIAGRAM

Handlebar (front view)

1, A 2, B C 3

5, D

J
10, G H
8

I
F 5
7, E

8 7, E

3
2
9

2-23
 CABLE ROUTING DIAGRAM

1. Throttle cable
2. Start switch lead
3. Handlebar switch lead (left)
4. Clutch cable
5. Front brake hose
6. Number plate
7. Plastic locking tie
8. Handlebar protector
9. Upper bracket
10.Protector

A. Route the throttle cable on the right side of

the number plate mounting bracket.
B. Route the start switch lead on the left side of
the number plate mounting bracket.
C. Route the start switch lead, handlebar switch
lead (left), and clutch cable on the left side of
the number plate mounting bracket between
the upper guide of the number plate and the
upper bracket.
D. Route the front brake hose through the num-
ber plate upper guide.
E. Secure the start switch lead and handlebar
switch lead (left) to the handlebar using the
plastic locking tie. Point the lock portion of the
plastic locking tie to the upper part of the
vehicle while pointing the end to the front side
of the vehicle without cutting off it.
F. Secure the handlebar and handlebar
protector with the plastic locking tie. Point the
lock portion of the plastic locking tie to the
lower side of the vehicle. The direction of the
end does not matter.
G. When installing the protector, the clearance
and direction of it does not matter.
H. Fasten the front brake hose and protector
with the plastic locking tie. Point the lock por-
tion to the inside of the vehicle, and then cut
off the end of the plastic locking tie.
I. Place the lock portion within the area shown
by the arrow.
J. Route the cables according to the instruc-
tions on the number plate.

2-24
 CABLE ROUTING DIAGRAM

Frame and engine (top view)

1, A
8

C
B
7

9 2
3
4

6 5
14
I

C
8 D

14 10, F
11
H
12
13
G

2-25
 CABLE ROUTING DIAGRAM

1. Ignition coil lead

2. Coolant temperature sensor lead
3. Engine ground lead
4. Cylinder head breather hose
5. Intake air pressure sensor coupler (dark blue,
3-pin)
6. Fuel injector coupler (gray, 2-pin)
7. Intake air temperature sensor coupler (black,
2-pin)
8. Tank rail
9. Air filter case
10.Spark plug cap
11.Cylinder head cover
12.Fuel hose
13.Damper
14.Wire harness

A. Install the terminal so that the lead is posi-

tioned above the vehicle. Connect the black
cover of the ignition coil lead to the black ter-
minal of the ignition coil, and the white cover
to the green terminal.
B. Route the coolant temperature sensor lead,
engine ground lead, and high tension cord
outside the vehicle past the cylinder head
breather hose.
C. Insert the projection of the main harness into
the hole in the frame.
D. 0–20
E. Right side of the vehicle.
F. Insert the spark plug cap all the way into the
cylinder head cover so that there is no clear-
ance between the cap and the cover.
G. Route the starter motor lead along the
damper and clamp it.
H. Place the wire harness on the flat surface on
the upper side of the damper. When doing so,
be careful so that the wire harness does not
contact the engine.
I. Insert the clip portion of the clamp into the air
filter assembly.

2-26
 CABLE ROUTING DIAGRAM

Frame and battery (top view)

6, D
2

1 2

3, C

4, E
5 4 3, A

2-27
 CABLE ROUTING DIAGRAM

1. ECU lead
2. Battery
3. Positive battery lead
4. Negative battery lead
5. CCU (Communication Control Unit)
6. ECU (Engine Control Unit)
7. Rear frame

A. Route the positive battery lead under

the vehicle’s negative battery lead.
B. Point the terminal of the negative battery lead
to the inside of the vehicle, and install it.
C. After connecting the positive battery lead in
the direction shown in the illustration, put the
cover over it.
D. After connecting the ECU coupler, put the
coupler cover over it.
E. Install the terminal in the direction shown.

2-28
 CABLE ROUTING DIAGRAM

Rear brake (right side view)

B
C
D

G F

H 4
A
1 2 3

7 6 5

2-29
 CABLE ROUTING DIAGRAM

1. Protector
2. Rear brake caliper
3. Bleed screw
4. Rear brake hose
5. Brake pedal
6. Rear brake master cylinder assembly
7. Swingarm
8. Rear shock absorber assembly

A. It does not matter whether the spring is

installed upward or downward.
B. Pass the rear brake hose into the rear brake
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.
G. Install the rear brake hose so that the bended
portion of the metal part of the rear brake
hose faces as shown in the illustration.
H. Make sure that the metal part of the rear
brake hose contacts the stopper of the rear
brake caliper.

2-30
 CABLE ROUTING DIAGRAM

2-31
 PERIODIC CHECKS AND ADJUSTMENTS

SERVICING PARTS ..........................................................................................3-1

MAINTENANCE INTERVALS ...........................................................................3-2

MAINTENANCE INTERVALS.....................................................................3-2 1
PRE-OPERATION INSPECTION AND MAINTENANCE .................................3-6
GENERAL INSPECTION AND MAINTENANCE ........................................3-6
2
ENGINE.............................................................................................................3-7
ADJUSTING THE VALVE CLEARANCE....................................................3-7
VALVE CLEARANCE SHIM CHART ........................................................3-10
CHECKING THE ENGINE IDLING SPEED..............................................3-12
CHECKING THE THROTTLE GRIP .........................................................3-12
3
CHECKING THE SPARK PLUG...............................................................3-13
CHECKING THE ENGINE OIL LEVEL .....................................................3-13
CHANGING THE ENGINE OIL.................................................................3-14
ADJUSTING THE CLUTCH LEVER FREE PLAY ....................................3-15
ADJUSTING THE CLUTCH LEVER POSITION.......................................3-16
4
CLEANING THE AIR FILTER ELEMENT .................................................3-16
CHECKING THE THROTTLE BODY JOINT ............................................3-18
CHECKING THE FUEL LINE ...................................................................3-18
CHECKING THE CYLINDER HEAD BREATHER HOSE.........................3-19
CHECKING THE EXHAUST SYSTEM .....................................................3-19
5
CHECKING THE COOLANT LEVEL ........................................................3-21

6
CHECKING THE COOLING SYSTEM .....................................................3-22
CHANGING THE COOLANT ....................................................................3-22

CHASSIS ........................................................................................................3-24
ADJUSTING THE FRONT DISC BRAKE .................................................3-24
ADJUSTING THE REAR DISC BRAKE ...................................................3-24
CHECKING THE BRAKE FLUID LEVEL ..................................................3-24
CHECKING THE FRONT BRAKE PADS .................................................3-25
7
CHECKING THE REAR BRAKE PADS....................................................3-25

8
CHECKING THE FRONT BRAKE HOSE .................................................3-25
CHECKING THE REAR BRAKE HOSE ...................................................3-26
CHECKING THE BRAKE OPERATION ...................................................3-26
BLEEDING THE HYDRAULIC BRAKE SYSTEM.....................................3-26
DRIVE CHAIN SLACK ..............................................................................3-27

9
CHECKING AND ADJUSTING THE STEERING HEAD ..........................3-28
LUBRICATING THE STEERING HEAD ...................................................3-29
CHECKING THE FRONT FORK LEGS....................................................3-29
ADJUSTING THE FRONT FORK LEGS ..................................................3-29
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY.....................3-31

10
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ...................3-31
CHECKING THE SWINGARM OPERATION ...........................................3-33
LUBRICATING THE SWINGARM PIVOT ................................................3-33
CHECKING THE CONNECTING ARM AND RELAY ARM ......................3-33
CHECKING THE TIRES ...........................................................................3-33
 CHECKING AND TIGHTENING THE SPOKES .......................................3-34
CHECKING THE WHEELS ......................................................................3-34
CHECKING THE WHEEL BEARINGS .....................................................3-34
CHECKING THE CHASSIS FASTENERS ...............................................3-34
CHECKING AND LUBRICATING THE CABLES......................................3-34
LUBRICATING THE BRAKE LEVER .......................................................3-35
LUBRICATING THE CLUTCH LEVER .....................................................3-35
LUBRICATING THE PEDAL.....................................................................3-35

ELECTRICAL SYSTEM..................................................................................3-36
CHECKING AND CHARGING THE BATTERY ........................................3-36
CHECKING THE FUSES..........................................................................3-36
 SERVICING PARTS

EAM20202

SERVICING PARTS
Regularly check or replace the servicing parts shown in the illustration.
4 5

3 6

2
7

1 8

* Engine oil, lubricants & greases, care products.

Ref. No. Part No. Part name in parts catalog Q’ty

1 B2W-25805-00 BRAKE PAD KIT 1

2 94701-00434 PLUG, SPARK (NGK LMAR8G) 1
3 B2W-83922-00 LEVER 2 1
4 17D-83912-01 LEVER 1 1
5 BR9-82100-48 BATTERY ASSY 1
6 BHR-14451-00 ELEMENT, AIR CLEANER 1
7 5D3-13440-02 ELEMENT ASSY, OIL CLEANER 1
8 BHR-27200-00 PEDAL, BRAKE 1
9 1C3-W0046-50 BRAKE PAD KIT 2 1

TIP
The part number is subject to change. In that case, order the part from a Yamaha dealer by stating the
identification number of your vehicle.

3-1
 MAINTENANCE INTERVALS

EAM20157

MAINTENANCE INTERVALS
EAM30369

MAINTENANCE INTERVALS
ECA25871

NOTICE
• After a break-in or before each race, always check the points shown in “TORQUE-CHECK
POINTS” for tightening torques and retighten them.
• Periodic inspection is essential in making full use of the machine performance. The life of
parts varies significantly according to the environment in which the machine runs (e.g., rain,
dirt, etc.). Therefore, earlier inspection is required by reference to the list below.
TIP
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.

Every Every Every

After race third race fifth race As
No. Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required
hours) hours) hours)

• Check the valve clearances.  

• Check the valve seats and the
1 * Valve 
valve faces for wear.

• Replace. 

• Check the free length. 

2 * Valve spring
• Replace. 

• Check for scratches and wear. 

3 * Valve lifter
• Replace. 

• Inspect the camshaft surface.

• Inspect the decompression sys- 
4 * Camshaft tem.

• Replace. 

• Check for damage and sticking. 

5 * Timing chain
• Replace.  

Timing chain ten- • Replace.

6 * sioner  

• Check for wear on the teeth and


7 * Camshaft sprocket for damage.

• Replace. 

• Inspect crack. 

• Inspect carbon deposits and elim- 

inate them.
8 * Piston
• Replace the piston, piston pin,
piston pin clip, and piston ring all  
as a set.

• Check the end gap of the piston

ring. 

9 * Piston ring
• Replace the piston, piston pin,
piston pin clip, and piston ring all  
as a set.
• Inspect. 

10 * Piston pin • Replace the piston, piston pin,

piston pin clip, and piston ring all  
as a set.

3-2
 MAINTENANCE INTERVALS

Every Every Every

After race third race fifth race As
No. Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required
hours) hours) hours)

• Check the coolant passages for

corrosion.
• Inspect carbon deposits and elim-
11 * Cylinder head 
inate them.
• Check for warpage, and replace
the gasket.

• Inspect score marks. 

12 * Cylinder
• Inspect wear. 

• Check the engine oil amount.  

13 Engine oil
• Replace.  

14 Oil filter element • Replace.  

• Inspect housing, friction plate,  

clutch plate and spring.
15 * Clutch
• Replace. 

• Inspect. 
16 * Transmission
• Replace bearings. 

17 * Shift fork, shift cam, • Inspect wear. 

guide bar

18 * Nut (generator rotor) • Check for tightening torques.  

• Check for exhaust leaks, and

 
tightening torques.
• Clean. 
Exhaust pipe,
19 * silencer, protector
• Replace fiver.
(When the exhaust sound
 
becomes louder or when a perfor-
mance drop is felt.)

20 * Crankshaft • Inspect and clean.  

21 * Throttle body • Inspect. 

• Clean and lubricate.  

22 Air filter
• Replace. 

• Check the electrodes and the ter-

 
23 Spark plug minals for wear.

• Replace. 

• Check coolant level and leakage.  

• Check radiator cap operation. 

24 * Cooling system • Check radiator cap attached.  

• Change the coolant. Every two years 

• Inspect hoses. 
25 * Engine guard • Replace. 

26 * Frame • Clean and inspect.  

27 * Fuel tank, fuel pump • Inspect.  

• Inspect. 
28 * Fuel hose
• Replace. Every four years 

3-3
 MAINTENANCE INTERVALS

Every Every Every

After race third race fifth race As
No. Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required
hours) hours) hours)

• Clean.  

• Inspect and adjust.  

• Replace oil.  
29 * Front fork leg(s)
• Replace oil seal. 

• Clean and grease oil seals and   

dust seals.

30 Protector guide • Replace. 

• Inspect and adjust.  

• Grease pillow balls and bearings.

31 * Rear shock absorber (After rain ride)  

• Check for tightening torques.  

• Adjust lever position and pedal  

position.

• Lubricate pivot point.  

• Check brake disc surface.  

• Check fluid level and leakage.  

32 * Brake(s)
• Retighten brake disc bolts, caliper
bolts, master cylinder bolts and
union bolts.  
(Check for tightening torques.)
• Replace pads. 

• Replace brake fluid. Every one year 

33 * Swingarm • Inspect, lube and retighten.  

Relay arm, connect- • Inspect, lube and retighten.
34 *  
ing rod
• Inspect free play and retighten.
 
(Check for tightening torques.)

35 * Steering head • Clean and lube.


(After rain ride)

• Replace bearings. 

• Inspect air pressure, wheel run-

out, tire wear and spoke loose-  
ness.

• Retighten sprocket bolt.  

36 * Tire, wheels
• Check the bearing. 

• Replace bearings. 

• Lubricate. 

• Clean, lubricate, slack, alignment.  

37 * Drive chain
• Replace. 
38 * Drive chain guide • Inspect wear. 

Drive chain guide and • Replace.

39 * 
drive chain support

• Routing (Connection)  

• Check and grease.  

40 Cables
• Check throttle cables on the throt-  
tle body for dirt and wear.

41 Levers • Adjust clutch lever free play. 

3-4
 MAINTENANCE INTERVALS

Every Every Every

After race third race fifth race As
No. Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required
hours) hours) hours)

42 Brake pedal, footrest • Lubricate.  

Outside nuts and • Retighten.

43 *  
bolts

44 * Battery • Check terminal for looseness and 

corrosion.

3-5
 PRE-OPERATION INSPECTION AND MAINTENANCE

EAM20134

PRE-OPERATION INSPECTION AND MAINTENANCE

Before riding for break-in operation, practice or a race, make sure the machine is in good operating con-
dition.
Before using this machine, check the following points.
EAM30209

GENERAL INSPECTION AND MAINTENANCE

Item Inspect Page

Coolant Check that coolant is filled up to the radiator cap. 3-21, 3-22, 3-22,
Check the cooling system for leakage. 6-4, 6-4
Check that a fresh gasoline is filled in the fuel tank.
Fuel 1-24
Check the fuel line for leakage.
Check that the oil level is correct. Check the crankcase and
Engine oil 3-13, 3-14
oil line for leakage.
Check that gears can be shifted correctly in order and that
Gear shifter and clutch 3-15, 3-16
the clutch operates smoothly.
Check that the throttle grip operation and free play are cor-
Throttle grip/Housing rectly adjusted. Lubricate the throttle grip and housing, if 3-12, 3-34
necessary.
3-24, 3-24, 3-24,
Check the play of front brake and effect of front and rear
Brakes 3-25, 3-25, 3-25,
brake.
3-26, 3-26
Check drive chain slack and alignment. Check that the 3-27, 4-75, 4-75,
Drive chain
drive chain is lubricated properly. 4-76, 4-76, 4-76
Check for excessive wear and tire pressure. Check for 3-33, 3-34, 3-34,
Wheels
loose spokes and have no excessive play. 3-34
Check that the handlebar can be turned smoothly and have
Steering 3-28
no excessive play.
Front forks and rear Check that they operate smoothly and there is no oil leak- 3-29, 3-29, 3-33,
shock absorber age. 3-31, 3-31
Check that the clutch and throttle cables move smoothly.
Cables (wires) Check that they are not caught when the handlebars are —
turned or when the front forks travel up and down.
Check that the exhaust pipe is tightly mounted and has no
Exhaust pipe 3-19
cracks.
Check that the rear wheel sprocket tightening bolt is not 4-13, 4-13, 4-13,
Rear wheel sprocket
loose. 4-13, 4-14, 4-14
3-34, 3-35, 3-35,
Lubrication Check for smooth operation. Lubricate if necessary. 3-35
Bolts and nuts Check the chassis and engine for loose bolts and nuts. 1-27
Check that the stator coil assembly, ECU and ignition coil
Lead connectors are connected tightly. 1-11

Is the machine set suitably for the condition of the racing 10-1, 10-1, 10-1,
course and weather or by taking into account the results of 10-2, 10-2, 10-3,
Settings
test runs before racing? Are inspection and maintenance 10-3, 10-4, 10-4,
completely done? 10-6, 10-7

TIP
Perform usual maintenance enough so that, in the race course, a confirmation of that and simple setting
adjustments may only be left, in order to get enough time to use effectively.

3-6
 ENGINE

EAM20135

ENGINE Valve clearance (cold)

Intake
EAM30226 0.10–0.17 mm (0.0039–0.0067 in)
ADJUSTING THE VALVE CLEARANCE Exhaust
TIP 0.15–0.22 mm (0.0059–0.0087 in)
• This section is intended for those who have ba-
sic knowledge and skill concerning the servic- a. Turn the crankshaft counterclockwise with
ing of Yamaha motorcycles (e.g., Yamaha a wrench.
dealers, service engineers, etc.). Those who b. Align the top dead center (TDC) mark “a”
have little knowledge and skill concerning ser- on the generator rotor with the alignment
vicing are requested not to undertake inspec- mark “b” on the crankcase cover.
tion, adjustment, disassembly, or reassembly
only by reference to this manual. It may lead to b
servicing trouble and mechanical damage.
• Make sure that the valve clearance is checked
or adjusted while the engine is cold (at room
temperature). a
• While the valve clearance is checked or adjust-
ed, make sure that the piston is positioned in
the top dead center (TDC).
1. Remove:
• Seat TIP
Check that the alignment marks “c” on the cam-
• Side cover (left/right)
shaft sprockets are aligned with the edge of the
• Shroud (left/right)
camshaft cap surfaces “d”.
Refer to “GENERAL CHASSIS” on page 4-1.
• Fuel tank
c c
Refer to “FUEL TANK” on page 7-1.
2. Remove:
• Spark plug
• Cylinder head cover
Refer to “CAMSHAFT” on page 5-10. d d
3. Remove:
• Timing mark accessing screw “1”
• Crankshaft end accessing screw “2”
• O-ring
c. Measure the valve clearance using a
thickness gauge “1”.
Thickness gauge
90890-03268
Feeler gauge set
YU-26900-9
1
TIP
2 Record the measured reading if the clearance is
incorrect.
4. Check:
• Valve clearance
Out of specification  Regulate.

3-7
 ENGINE

TIP
1
• The adjusting pad number “a” is indicated on
the top of the adjusting pad.
• For the number on the originally installed ad-
justing pad, convert the last digit of adjusting
pad number as per the below table.

5. Adjust:
• Valve clearance
a. Remove the camshaft (intake and ex-
haust).
Refer to “CAMSHAFT” on page 5-10.
b. Remove the valve lifter “2” and the adjust-
ing pad “3” with a valve lapper “1”.
TIP d. Select an adjusting pad with a proper
• Place a cloth in the timing chain space to pre- valve clearance from the adjusting pad se-
vent adjusting pads from falling into the crank- lection table.
case. TIP
• Identity each valve lifter and adjusting pad po- • There are 25 types of adjusting pads, ranging
sition very carefully so that they can be rein- from 1.20 mm (0.0472 in) to 2.40 mm (0.0945
stalled in their original place. in), in increments of 0.05 mm (0.0020 in).
• The field where the number on the originally in-
Valve lapper (ø14) stalled adjusting pad and the measured valve
90890-04101 clearance intersect shows the adjusting pad
Valve lapper (ø14) number to replace.
YM-A8998
Last digit of pad num-
ber Rounded value
3 2 1
0, 1 or 2 0
4, 5 or 6 5
8 or 9 10

Example:
Pad number = 148
Rounded value = 150
e. Install the new adjusting pads “4” and the
valve lifters “5”.
ECA24310

NOTICE
Do not twist adjusting pads and valve lifters
forcibly during installation.
2 TIP
• Apply the engine oil on the valve lifters.
3 • Apply molybdenum disulfide oil to the valve
stem ends.
• Check that the valve lifters turn smoothly when
c. Check the number on the originally in- rotated with your finger.
stalled adjusting pad. • Make sure that valve lifters and adjusting pads
are installed in place.

3-8
 ENGINE

• Make sure that adjusting pads are installed

with their numbers facing upward.

5
E
4

f. Install the camshafts (exhaust and intake).

Refer to “CAMSHAFT” on page 5-10.
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.

3-9
 ENGINE

EAM30383

VALVE CLEARANCE SHIM CHART

INTAKE

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.02 0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.07 0.09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.10 0.17
0.18 0.24 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.25 0.29 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.30 0.34 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.35 0.39 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.40 0.44 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.45 0.49 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.50 0.54 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.55 0.59 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.60 0.64 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.65 0.69 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
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 1.04 205 210 215 220 225 230 235 240
1.05 1.09 210 215 220 225 230 235 240
1.10 1.14 215 220 225 230 235 240
1.15 1.19 220 225 230 235 240
1.20 1.24 225 230 235 240
1.25 1.29 230 235 240
1.30 1.34 235 240
1.35 1.39 240

A. Measured clearance C. Standard clearance

B. Installed pad number

Example:
Valve clearance (cold) 0.10–0.17 mm (0.0039–0.0067 in)
Installed is 175.
Measured clearance 0.25 mm (0.0098 in)
Replace 175 pad with 185 pad.
Pad No. 175 = 1.75 mm (0.0689 in)
Pad No. 185 = 1.85 mm (0.0728 in)

3-10
 ENGINE

EXHAUST

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.02 0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.07 0.11 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.12 0.14 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.15 0.22
0.23 0.29 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.30 0.34 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.35 0.39 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.40 0.44 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.45 0.49 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.50 0.54 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.55 0.59 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.60 0.64 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.65 0.69 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.70 0.74 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.75 0.79 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.80 0.84 180 185 190 195 200 205 210 215 220 225 230 235 240
0.85 0.89 185 190 195 200 205 210 215 220 225 230 235 240
0.90 0.94 190 195 200 205 210 215 220 225 230 235 240
0.95 0.99 195 200 205 210 215 220 225 230 235 240
1.00 1.04 200 205 210 215 220 225 230 235 240
1.05 1.09 205 210 215 220 225 230 235 240
1.10 1.14 210 215 220 225 230 235 240
1.15 1.19 215 220 225 230 235 240
1.20 1.24 220 225 230 235 240
1.25 1.29 225 230 235 240
1.30 1.34 230 235 240
1.35 1.39 235 240
1.40 1.44 240

A. Measured clearance C. Standard clearance

B. Installed pad number

Example:
Valve clearance (cold) 0.15–0.22 mm (0.0059–0.0087 in)
Installed is 175.
Measured clearance 0.30 mm (0.0118 in)
Replace 175 pad with 185 pad.
Pad No. 175 = 1.75 mm (0.0689 in)
Pad No. 185 = 1.85 mm (0.0728 in)

3-11
 ENGINE

EAM30412

CHECKING THE ENGINE IDLING SPEED Engine idling speed

TIP 1900–2100 r/min
• Because the air pressure is lower at high alti-
tudes, the air-fuel mixture will become richer. If 5. Adjust:
the idling speed is low, turn the idle screw • Engine idling speed
clockwise to increase the speed before the ad- a. Turn the idle screw “1” to make an adjust-
justment. ment.
• Before adjusting the engine idling speed, make
sure that the air filter element is not clogged,
the engine compression is proper, and the 1
throttle grip free play is proper.
• Adjust the engine idling speed with the starter
knob pulled in completely.
1. Start the engine, and warm this up until the oil
has reached the specified temperature.
2. Measure the coolant temperature using the
Yamaha diagnostic tool. EAM30475

CHECKING THE THROTTLE GRIP

Yamaha diagnostic tool USB (US)
90890-03269 TIP
Yamaha diagnostic tool (A/I) Prior to adjusting throttle grip free play, the en-
90890-03264 gine idling speed should be adjusted.
1. Check:
Coolant temperature • Throttle grip free play “a”
70–80 C (158–176 F) Out of specification  Regulate.

3. Install: Throttle grip free play

• Digital tachometer 3.0–6.0 mm (0.12–0.24 in)

Digital tachometer
90890-06760
Digital tachometer
YU-39951-B

TIP
Get the high tension cord “1” of the ignition coil
pinched in the detector “a” of the digital tachom-
eter.

a
2. Adjust:
• Throttle grip free play
1 a. Loosen the locknut “1”.
1 b. Turn the adjuster “2” until the specified
throttle grip free play is obtained.
c. Tighten the locknut.
EWA18470

a WARNING
After adjusting the throttle grip free play,
4. Measure: start the engine and turn the handlebar to the
• Engine idling speed right and to the left to ensure that this does
Out of specification  Regulate. not cause the engine idling speed to change.

3-12
 ENGINE

4. Check:
2 1 • Electrode
Damage/wear  Replace the spark plug.
• Insulator
Abnormal color  Replace the spark plug.
Normal color is medium-to-light tan.
5. Clean:
• Spark plug
(with a spark plug cleaner or a wire brush)
6. Measure:
EAM30254 • Spark plug gap “a”
CHECKING THE SPARK PLUG Out of specification  Adjust the spark plug
1. Remove: gap.
• Seat
• Side cover (left/right) Spark plug gap
• Shroud (left/right) 0.7–0.8 mm (0.028–0.031 in)
Refer to “GENERAL CHASSIS” on page 4-1.
• Fuel tank “1”
Refer to “FUEL TANK” on page 7-1.
ECA24400

NOTICE
Do not use too much force to pull the hose.
TIP
Remove the fuel tank, turn this 180 clockwise,
and put it in the frame “2” as shown.

1
1 7. Install:
• Spark plug
2 Spark plug
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.

TIP
Before installing the spark plug, clean the spark
plug and gasket surface.
2. Remove: 8. Install:
• Spark plug cap • Spark plug cap
• Spark plug • Fuel tank
Refer to “CAMSHAFT” on page 5-10. • Shroud (left/right)
ECA24410 • Side cover (left/right)
NOTICE • Seat
In order not to allow the dirt accumulated Refer to “GENERAL CHASSIS” on page 4-1.
around the spark plug to drop from the spark EAM30224
plug hole into the cylinder, clean it before re- CHECKING THE ENGINE OIL LEVEL
moving the spark plug. 1. Start the engine and warm it up for ten min-
3. Check: utes until the engine oil has reached a normal
• Spark plug type temperature of 60 C (140 F), and then turn
Wrong type  Replace. the engine off.
2. Stand the vehicle upright on a level surface.
Manufacturer/model 3. Start the engine, wait for ten seconds, turn
NGK/LMAR8G the engine off, and then wait a few minutes.

3-13
 ENGINE

4. Check: TIP
• Engine oil level Before checking the engine oil level, wait a few
The engine oil level should be between the minutes until the oil has settled.
minimum level (lower edge of the oil check
window “1”) and the maximum level mark “a”. EAM30225

Below the minimum level  Add the recom- CHANGING THE ENGINE OIL
mended engine oil to the proper level. 1. Stand the vehicle upright on a level surface.
TIP 2. Start the engine, warm it up for several min-
Before checking the engine oil level, wait a few utes, and then turn it off.
minutes until the oil has settled. 3. Place a container under the engine oil drain
bolts.
4. Remove:
a • Oil filler cap
(along with the O-ring)
5. Remove:
• Engine oil drain bolt (crankcase) “1”
(along with the gasket “2”)
• Engine oil drain bolt (oil tank) “3”
(along with the gasket “4”)
1

Recommended brand
YAMALUBE
SAE viscosity grades
10W-40, 10W-50, 15W-40, 20W- 2
40 or 20W-50
Recommended engine oil grade
API service SG type or higher, 1
JASO standard MA

6. Drain:
ECA13361
• Engine oil
NOTICE (completely from the oil tank and crankcase)
• Engine oil also lubricates the clutch and the 7. If the oil filter element is also to be replaced,
wrong oil types or additives could cause perform the following procedure.
clutch slippage. Therefore, do not add any a. Remove the oil filter element cover “1”, oil
chemical additives or use engine oils with a filter element “2”.
grade of “CD” or higher and do not use oils b. Replace the new O-ring “3”.
labeled “ENERGY CONSERVING II”.
• Do not allow foreign materials to enter the
crankcase.
5. Start the engine, warm it up for several min-
utes, and then turn it off.
6. Check the engine oil level again.

3-14
 ENGINE

b. Look at the oil level check window “1”, and

then make sure that the engine oil flows
2 and that the engine oil level decreases.
TIP
1 Check the engine oil level while the engine is at
idling speed.

3 a

c. Install the new oil filter element and the oil

filter element cover.
Oil filter element cover bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

8. Install: 1
• Engine oil drain bolt (oil tank) a. Maximum level mark
(along with the gasket New ) ECA26740
• Engine oil drain bolt (crankcase) NOTICE
(along with the gasket New )
If the engine oil level does not decrease after
Engine oil drain bolt (oil tank) the engine has been started, immediately
10 N·m (1.0 kgf·m, 7.4 lb·ft) turn the engine off. Otherwise, the engine
T.

Engine oil drain bolt (crankcase) could seize.

R.

20 N·m (2.0 kgf·m, 15 lb·ft)

c. If the engine oil level does not decrease at
9. Fill: the specified level mark, check the engine
• Crankcase oil system for leaks, and the engine oil
(with the specified amount of the recom- passages and oil pump for damage.
mended engine oil) d. Check the oil pressure again.
EAM30216
Engine oil quantity ADJUSTING THE CLUTCH LEVER FREE
Oil change
PLAY
0.94 L (0.99 US qt, 0.83 Imp.qt)
With oil filter removal 1. Check:
0.96 L (1.01 US qt, 0.84 Imp.qt) • Clutch lever free play “a”
Quantity (disassembled) Out of specification  Regulate.
1.20 L (1.27 US qt, 1.06 Imp.qt)
Clutch lever free play
7.0–12.0 mm (0.28–0.47 in)
10.Install:
• Engine oil filler cap
(along with the O-ring New )
11.Check: a
• Oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-13.
12.Check:
• Engine oil pressure
a. Start the engine.
EWA19130

WARNING
Always keep the engine idling speed during 2. Adjust:
the checkup without increasing the engine • Clutch lever free play
speed. Handlebar side
a. Turn the adjuster “1” until the specified

3-15
 ENGINE

clutch lever free play is obtained. 2. Tighten:

• Locknut
1
Locknut (clutch lever position)
4.8 N·m (0.48 kgf·m, 3.5 lb·ft)

T.
R.
EAM30219

CLEANING THE AIR FILTER ELEMENT

1. Remove:
• Sub-seat
Refer to “FUEL TANK CAP” on page 1-23.
• Air filter case cover “1”
TIP TIP
If the clutch lever free play cannot be obtained To remove the air filter case cover:
on the handlebar side, use the adjuster on the • Raise the air filter case cover rear side while
clutch cable side. pushing the side “a” of the air intake duct from
Clutch cable side inside to unhook the ribs “b” on both sides of
a. Slide the clutch cable cover. the air filter case cover from the air filter case
b. Loosen the locknut “1”. “2”.
c. Turn the adjuster “2” until the specified • Slide the air filter case cover to the rear of the
clutch lever free play is obtained. vehicle to remove the projection “c” from the
d. Tighten the locknut “1”. hole “d” in the air filter case.

Clutch cable locknut

4.3 N·m (0.43 kgf·m, 3.2 lb·ft) 1
T.
R.

e. Return the clutch cable cover to its original

a
position.

a
2

c 1

EAM30370

ADJUSTING THE CLUTCH LEVER POSITION d

1. Adjust:
• Clutch lever position “a”
Loosen the locknut “1” and use the adjuster
“2” to adjust the clutch lever position “a” as
desired.
b
1 2
a
2

3-16
 ENGINE

2. Remove: foam air filter oil

• Air filter element guide “1” a. Put the air filter element into a plastic bag
• Air filter element “2” and drip the filter oil into the bag.
(from the air filter element guide) b. With the element inside the bag, rub it
• Seal “3” thoroughly so that the element is evenly
(from the air filter element) permeated with the oil.
TIP c. Wrap the element in a clean cloth, rub the
To remove the air filter element: element gently, and wipe off any excess
• Release the band “a” from the projection “b”, oil.
and then move the air filter case assembly TIP
bracket “4” in the direction of the arrow to re- • The element should be permeated with oil so
lease the projection “c”. that it is wet but not dripping.
• Remove the air filter element and the air filter • When replacing the element, permeate the el-
element guide as a set. ement in oil by using the same procedure as
when cleaning.
3
2

b
6. Install:
• Air filter case assembly bracket
4 (if removed)
Refer to “THROTTLE BODY” on page 7-4.
a • Seal “1”
(to the air filter element)
• Air filter element “2”
c (to the air filter element guide)
• Air filter element guide “3”
3. Wash:
TIP
• Air filter element • Apply lithium-soap-based grease on the entire
a. After washing the element with air filter seal lips when installing the air filter element
cleaner or kerosene, squeeze and dry it guide.
completely. • To install the air filter element:
EWA19110

WARNING • Move the air filter case assembly bracket “4”

to the rear of the vehicle.
Do not use gasoline or organic (acid/alka-
• Set the projection “a” on the air filter element
line) volatile oil for washing.
guide to the air filter case assembly bracket
and insert the projection “b” on the air filter el-
ECA24280

NOTICE
ement guide to the band “c”.
Do not twist the element when squeezing the
element.
4. Check:
• Air filter element
Damage  Replace.
5. Apply:
• Yamaha foam air filter oil or other quality

3-17
 ENGINE

1 a 1
2

b
c
4

c
3

7. Install:
• Air filter case cover “1”
• Fuel tank breather hose “2” e
(to the air filter case cover) d 2
TIP
• To install the air filter case cover:
• Insert the projection “a” on air filter case cover
to the hole “b” in the air filter case “3”.
• Push the rear side of the air filter case cover
to hook the ribs “c” to the air filter case. 1
• Insert the fuel tank breather hose end with the
protector into the steering shaft hole. 8. Install:
• Fit the other end of the fuel tank breather hose • Sub-seat
into the projection on the fuel tank cap. EAM30335
• Route the fuel tank breather hose through the CHECKING THE THROTTLE BODY JOINT
guide “d”, and then fit it into the groove “e” in 1. Check:
the air filter case cover. • Throttle body joint “1”
Crack/damage  Replace.

EAM30222

CHECKING THE FUEL LINE

1. Remove:
• Seat
• Side cover (left/right)

3-18
 ENGINE

• Shroud (left/right) 2. Remove:

Refer to “GENERAL CHASSIS” on page 4-1. • Exhaust pipe protector
• Fuel tank 3. Check:
Refer to “FUEL TANK” on page 7-1. • Exhaust pipe 1
2. Check: • Exhaust pipe 2
• Fuel hose “1” • Silencer
Crack/damage  Replace. Crack/damage  Replace.
Loose connection  Connect properly. 4. Check:
• Silencer fiber
Damage  Replace.
5. Replace:
• Silencer fiber
a. Remove the bolts “1” and silencer body
“2”.
ECA25800

1 NOTICE
Do not hit the silencer stay “a” as it may do
damage to the silencer.
3. Install: TIP
• Fuel tank Remove the inner pipe while holding the silencer
Refer to “FUEL TANK” on page 7-1. in place with a vise etc.
• Shroud (left/right)
• Side cover (left/right)
• Seat a
Refer to “GENERAL CHASSIS” on page 4-1.
EAM30476

CHECKING THE CYLINDER HEAD 1

BREATHER HOSE
1. Check:
• Breather hose “1”
Crack/damage  Replace.
Loose connection  Connect properly.
ECA14920

NOTICE
2
Make sure the cylinder head breather hose is
routed correctly.

b. Remove the rivets “3” and silencer cap “4”.

1

EAM30221

CHECKING THE EXHAUST SYSTEM

1. Remove:
• Exhaust pipe 1
• Exhaust pipe 2
Refer to “ENGINE REMOVAL” on page 5-2.

3-19
 ENGINE

d LT

3
8

c. Replace the fiber inserts “5”. g. Install the fiber “10”.

TIP
Stuff the fiber into the silencer body by using a
5 flat board “11”.

d. Install the fiber insert “6” to the part “b”.

e. Twist the fiber insert “7” onto the inner pipe 11
“c”. 10

b h. Install the fiber insert “12” to the inner pipe.

i. Install the fiber insert “13” to the inside of
c
the silencer cap “14”.

6
12
7
f. Install the silencer body “8” and bolts “9”.
Silencer body bolt
8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.

LOCTITE®
R.

13
TIP
Apply heat-resistant sealant to the areas “d”
shown, making sure that there are no gaps in the
beads of sealant. 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

3-20
 ENGINE

the beads of sealant.

• Take care not to allow the fiber out of place 5
when installing the silencer body “17”.

4
17 17 16 15

15 8. Install:
• Exhaust pipe protector
Exhaust pipe protector screw
6. Check: 10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.
LOCTITE®

R.
• Gasket “1”
Damage  Replace.
EAM30210

CHECKING THE COOLANT LEVEL

1 EWA13030

WARNING
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in-
jury. When the engine has cooled, open the
1 radiator cap as follows:
Place a thick rag or a towel over the radiator
7. Check: cap and slowly turn the radiator cap counter-
• Tightening torques clockwise toward the detent to allow any re-
sidual pressure to escape. When the hissing
Exhaust pipe nut “1”
10 N·m (1.0 kgf·m, 7.4 lb·ft) sound has stopped, press down on the radi-
ator cap and turn it counterclockwise to re-
T.

Exhaust pipe clamp bolt “2”

R.

12 N·m (1.2 kgf·m, 8.9 lb·ft) move.

Exhaust pipe bracket bolt “3” 1. Stand the vehicle upright on a level surface.
20 N·m (2.0 kgf·m, 15 lb·ft) 2. Remove:
Exhaust pipe clamp bolt “4” • Radiator cap “1”
12 N·m (1.2 kgf·m, 8.9 lb·ft)
Silencer bolt “5”
30 N·m (3.0 kgf·m, 22 lb·ft)

1
1

3. Check:
2 • Coolant level
Maximum level “a” or below  Add coolant
up to the maximum level.

3-21
 ENGINE

be blown out, which could cause serious in-

jury. When the engine has cooled, open the
radiator cap as follows:
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap counter-
clockwise toward the detent to allow any re-
sidual pressure to escape. When the hissing
sound has stopped, press down on the radi-
ator cap and turn it counterclockwise to re-
move.
1. Radiator 1. Place a container under the engine.
ECA24260
2. Remove:
NOTICE • Coolant drain bolt “1”
• Copper washer
• Adding water instead of coolant lowers the
antifreeze content. If, therefore, water is
used instead of coolant, check, and if nec-
essary, adjust the antifreeze concentration.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
4. Start the engine, warm this up for several
minutes, and then stop it. 1
5. Check:
• Coolant level 3. Remove:
TIP • Radiator cap
Before checking the coolant level, wait a few Slowly loosen the radiator cap to drain cool-
minutes until the coolant has settled. ant.
TIP
EAM30211
When the radiator cap is loosened, coolant will
CHECKING THE COOLING SYSTEM gush out transversely; therefore, bring the con-
1. Remove: tainer near to the outlet.
• Seat
• Side cover (left/right) 4. Thoroughly flush the cooling system with
• Shroud (left/right) clean tap water.
Refer to “GENERAL CHASSIS” on page 4-1. 5. Install:
2. Check: • Copper washer New
• Radiator • Coolant drain bolt
• Radiator hose
Coolant drain bolt
Crack/damage  Replace. 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Refer to “RADIATOR” on page 6-2.
T.
R.

3. Install: 6. Pour coolant.

• Shroud (left/right)
• Side cover (left/right) Recommended coolant
• Seat High quality ethylene glycol
Refer to “GENERAL CHASSIS” on page 4-1. anti-freeze containing anti-cor-
rosion for aluminum engine
EAM30212 Radiator (including all routes)
CHANGING THE COOLANT 1.03 L (1.09 US qt, 0.91 Imp.qt)
EWA13030
Coolant mixing ratio
WARNING 1:1 (Coolant:Water)
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may

3-22
 ENGINE

EWA13040

WARNING
• If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
tor.
• If coolant splashes on your clothes, quickly
wash it away with water and then with soap
and water.
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
ECA13481

NOTICE
• Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant, check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be 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 3-21.

3-23
 CHASSIS

EAM20136
system. Air in the brake system will consid-
CHASSIS erably reduce braking performance.
ECA13490
EAM30479

ADJUSTING THE FRONT DISC BRAKE NOTICE

TIP After adjusting the brake lever position,
There should be no free play at the brake lever make sure there is no brake drag.
end.
4. Install:
1. Check: • Brake lever cover
• Brake lever position “a” EAM30480

Brake lever position ADJUSTING THE REAR DISC BRAKE

100 mm (3.94 in) 1. Adjust:
Extent of adjustment • Brake pedal position
86–105 mm (3.39–4.13 in) a. Loosen the locknut “1”.
b. Turn the adjusting bolt “2” until the brake
pedal is in the correct position.

2. Remove:
• Brake lever cover c. Tighten the locknut.
3. Adjust: Locknut
• Brake lever position 6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.

a. Loosen the locknut “1”.

R.

b. Turn the adjusting bolt “2” until the speci- EWA19150

fied brake lever position is obtained. WARNING

A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
2
system. Before running, bleed the brake sys-
tem. Air in the brake system will cause brak-
1 ing performance to be reduced.
ECA13510

NOTICE
After adjusting the brake pedal position,
make sure there is no brake drag.

EAM30234
c. Tighten the locknut. CHECKING THE BRAKE FLUID LEVEL
Locknut 1. Stand the vehicle upright on a level surface.
5 N·m (0.5 kgf·m, 3.7 lb·ft) TIP
T.

In order to ensure a correct reading of the brake

R.

EWA13050
fluid level, make sure that the top of the brake
WARNING fluid reservoir is horizontal.
A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake 2. Check:
• Brake fluid level
system. Before the vehicle is operated, the
air must be removed by bleeding the brake The minimum level mark “a” or below  Add.

3-24
 CHASSIS

Specified brake fluid

DOT 4

1
a

a
EAM30232

CHECKING THE REAR BRAKE PADS

The following procedure applies to all of the
brake pads.
A. Front brake 1. Operate the brake.
B. Rear brake 2. Check:
EWA13090 • Rear brake pad
WARNING Wear indicator grooves “1” almost disap-
• Use only the designated brake fluid. Other peared  Replace the brake pads as a set.
brake fluids may cause the rubber seals to Refer to “REAR BRAKE” on page 4-27.
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that 1
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.
ECA13540 EAM30478

NOTICE CHECKING THE FRONT BRAKE HOSE

Brake fluid may damage painted surfaces 1. Check:
and plastic parts. Therefore, always clean up • Brake hose
any spilt brake fluid immediately. Cracks/damage/wear  Replace.
2. Check:
EAM30231 • Brake hose clamp
CHECKING THE FRONT BRAKE PADS Loose connection  Tighten the clamp bolt.
The following procedure applies to all of the 3. Stand the vehicle upright and apply the front
brake pads. brake several times.
1. Operate the brake. 4. Check:
2. Check: • Brake hose
• Front brake pad Brake fluid leaks  Replace the damaged
Wear indicator grooves “1” almost touch the brake hose.
brake disc  Replace the brake pads as a Refer to “FRONT BRAKE” on page 4-16.
set. 5. Check:
Refer to “FRONT BRAKE” on page 4-16. • Protector “1”
Out of specification  Replace.
TIP
The protector reaches the limit of its use when it
is worn down to the same height “a” as of the
plastic locking tie circumference.

3-25
 CHASSIS

• Protector (rear brake)

TIP
1 • Be careful not to spill any brake fluid or allow
the reservoir to overflow.
• Make sure that there is enough brake fluid be-
a 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 to let
EAM30498 the brake fluid settle for a few hours. Repeat
CHECKING THE REAR BRAKE HOSE the bleeding procedure when the tiny bubbles
1. Check: in the hose have disappeared.
• Brake hose
Cracks/damage/wear  Replace. 2. Bleed the brake system.
2. Check: a. Fill the reservoir to the proper level with
• Brake hose holder the recommended brake fluid.
Loose connection  Tighten the holder bolt. b. Install the reservoir diaphragm.
3. Hold the vehicle upright and apply the rear c. Connect the plastic hose “1” to the bleed
brake several times. screw “2” securely, and place a container
4. Check: under the end of the plastic hose.
• Brake hose
Brake fluid leakage  Replace the damaged
hose.
Refer to “REAR BRAKE” on page 4-27. 1

EAM30499

CHECKING THE BRAKE OPERATION

1. Check: 2
• Brake operation
Brake not working properly  Check the
brake system.
Refer to “FRONT BRAKE” on page 4-16 and
“REAR BRAKE” on page 4-27. 2
TIP
Drive on the dry road, operate the front and rear
brakes separately and check to see if the brakes 1
are operating properly.

EAM30477

BLEEDING THE HYDRAULIC BRAKE

SYSTEM
EWA19140 A. Front
WARNING B. Rear
Bleed the brake system whenever: d. Slowly apply the brake several times.
• The system is disassembled. e. Fully pull the brake lever or fully press
• A brake hose is loosened, disconnected, or down the brake pedal and hold it in posi-
replaced. tion.
• The brake fluid level is very low. f. Loosen the bleed screw.
• Brake operation is faulty.
TIP
1. Remove: Loosening the bleed screw will release the pres-
• Brake master cylinder cap sure in the brake caliper and cause the brake le-
• Reservoir diaphragm ver to contact the throttle grip or the brake pedal
• Reservoir float (front brake)

3-26
 CHASSIS

to fully extend. 4. Check:

• Drive chain slack “a”
g. Tighten the bleed screw and then release
Out of specification  Regulate.
the brake lever or brake pedal.
h. Repeat steps (d) to (g) until all of the air TIP
Measure drive chain slack between the drive
bubbles have disappeared from the brake
chain guide and the bottom of the chain as
fluid in the plastic hose.
shown.
TIP
During the procedure, keep adding brake fluid to
the reservoir.
ECA24320

NOTICE a
• Wipe off any brake fluid on the brake discs,
tires, wheels, etc.
• Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.
i. Tighten the bleed screw.
Drive chain slack (Maintenance
Bleed screw Stand)
5 N·m (0.5 kgf·m, 3.7 lb·ft) 50.0–60.0 mm (1.97–2.36 in)
T.
R.

j. Pour brake fluid to the reservoir up to the Adjusting the drive chain slack
specified level. EWA13120

Refer to “CHECKING THE BRAKE FLUID WARNING

LEVEL” on page 3-24. Securely support the vehicle so that there is
EWA13110
no danger of it falling over.
WARNING
After bleeding the hydraulic brake system, 1. Adjust:
check the brake operation. • Drive chain slack
a. Loosen the wheel axle nut “1”.
EAM30481 b. Loosen both locknuts “2”.
DRIVE CHAIN SLACK c. Turn the adjusting bolt “3” until the speci-
ECA13550
fied drive chain slack is obtained.
NOTICE
A drive chain that is too tight will overload 3 2
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.
Checking the drive chain slack 1
1. Use a maintenance stand to raise the rear
wheel off the ground.
EWA13120
TIP
WARNING • To maintain the proper wheel alignment, adjust
Securely support the vehicle so that there is both sides evenly.
no danger of it falling over. • Push the rear wheel forward to make sure that
2. Shift the transmission into the neutral posi- there is no clearance between the swingarm
tion. end plates and the ends of the swingarm.
3. Pull the drive chain up above the drive chain d. Tighten the wheel axle nut.
guide installation bolt with a force of about 50
N (5.0 kgf, 37 lbf).

3-27
 CHASSIS

Wheel axle nut

T.
R.
135 N·m (13.5 kgf·m, 100 lb·ft)
3
e. Tighten the drive chain puller locknut.
Drive chain puller locknut
21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.

EAM30247
2
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Use a maintenance stand to raise the front
Steering nut wrench
wheel off the ground.
EWA13120
90890-01403
WARNING Exhaust flange nut wrench
YU-A9472
Securely support the vehicle so that there is
no danger of it falling over.
Ring nut (initial tightening torque)
2. Check: 38 N·m (3.8 kgf·m, 28 lb·ft)
• Steering head

T.
R.
Grasp the bottom of the front fork legs and c. Turn the front fork to the right and left a few
gently rock the front fork. times, and make sure that the steering ro-
Blinding/looseness  Adjust the steering tates smoothly. If it does not turn smooth-
head. ly, remove the lower bracket and check
3. Remove: the upper and lower bearings.
• Handlebar Refer to “STEERING HEAD” on page
Refer to “HANDLEBAR” on page 4-39. 4-58.
• Upper bracket d. Loosen the ring nut fully turn and then
Refer to “STEERING HEAD” on page 4-58. tighten it to specification with a steering
4. Adjust: nut wrench.
• Steering head EWA13140

a. Remove the washer “1”. WARNING

Do not overtighten the lower ring nut.
1
Ring nut (final tightening torque)
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.

e. Check the steering head for looseness or

binding by turning the front fork all the way
in both directions. If any binding is felt, re-
move the lower bracket and check the up-
per and lower bearings.
Refer to “STEERING HEAD” on page
b. After loosening the ring nut “2” with a 4-58.
steering nut wrench “3”, tighten it to the f. Install the washer “1”.
specified torque.
TIP
• Set the torque wrench at a right angle to the
steering nut wrench.
• Move the steering to the left and right a couple
of times to check that it moves smoothly.

3-28
 CHASSIS

of the outer tube circumference.

1

a
5. Install:
• Upper bracket 6. Remove:
Refer to “STEERING HEAD” on page 4-58. • Protector
• Handlebar • Dust seal “1”
Refer to “HANDLEBAR” on page 4-39. ECA24330

NOTICE
EAM30502

LUBRICATING THE STEERING HEAD Be careful not to damage the dust seal and
1. Lubricate: the inner tube by a driver.
• Upper bearing
• Lower bearing
• Bearing race
Recommended lubricant
Lithium-soap-based grease

EAM30338

CHECKING THE FRONT FORK LEGS

1
1. Stand the vehicle upright on a level surface.
EWA13120

WARNING
7. Clean:
Securely support the vehicle so that there is
• Dust seal “a”
no danger of it falling over.
• Oil seal “b”
2. Check: TIP
• Inner tube • Clean the dust seal and oil seal after every run.
Damage/scratches  Replace. • Apply lithium-soap-based grease on the inner
• Front fork leg tube.
Oil leaks between inner tube and outer tube
 Replace the oil seal.
3. Hold the vehicle upright and apply the front
brake.
4. Check: a
• Front fork operation
Push down hard on the handlebar several
b
times and check if the front fork rebounds
smoothly. LS
Unsmooth operation  Correct or replace.
Refer to “FRONT FORK” on page 4-46.
5. Check: EAM30239

• Protector guide “1” ADJUSTING THE FRONT FORK LEGS

Out of specification  Replace. EWA19180

WARNING
TIP
The protector guide reaches the limit of its use • Always adjust the left and right front forks
when it is worn down to the same height “a” as evenly. If this is not done, the vehicle may

3-29
 CHASSIS

have poor stability. Compression damping

• Securely support the vehicle so that there ECA24350

is no danger of it falling over. NOTICE

Do not turn the adjuster forcibly beyond its
Rebound damping
ECA24340
adjusting range.
NOTICE 1. Adjust:
Do not turn the adjuster forcibly beyond its • Compression damping
adjusting range. a. Turn the adjuster “1” in the direction of “a”
1. Adjust: or “b” to make an adjustment.
• Rebound damping Direction “a”
a. Turn the adjuster “1” in the direction of “a” Compression damping is increased
or “b” to make an adjustment. (suspension is harder).
Direction “b”
Direction “a” Compression damping is decreased
Rebound damping is increased (sus- (suspension is softer).
pension is harder).
Direction “b”
Rebound damping is decreased (sus- Compression damping
pension is softer). Minimum (soft)
20 click(s) in direction “b”*
Standard
Rebound damping 10 click(s) in direction “b”*
Minimum (soft) Maximum (hard)
20 click(s) in direction “b”* 0 click(s) in direction “b”*
Standard * With the adjusting screw fully turned in di-
11 click(s) in direction “b”* rection “a”
Maximum (hard)
0 click(s) in direction “b”* TIP
* With the adjusting screw fully turned in di- Although the total number of clicks of a damping
rection “a” force adjusting mechanism may not exactly
match the above specifications due to small dif-
TIP
Although the total number of clicks of a damping ferences in production, the actual number of
force adjusting mechanism may not exactly clicks always represents the entire adjusting
match the above specifications due to small dif- range. To obtain a precise adjustment, it would
ferences in production, the actual number of be advisable to check the number of clicks of
clicks always represents the entire adjusting each damping force adjusting mechanism and
range. To obtain a precise adjustment, it would to modify the specifications as necessary.
be advisable to check the number of clicks of
each damping force adjusting mechanism and b a
to modify the specifications as necessary.

1
Air bleeding from front fork
a b TIP
If the front fork initial movement feels stiff during
a run, relieve the front fork internal pressure.
1. Use a maintenance stand to raise the front
wheel off the ground.

3-30
 CHASSIS

EWA13120 EWA13120

WARNING WARNING
Securely support the vehicle so that there is Securely support the vehicle so that there is
no danger of it falling over. no danger of it falling over.
2. Remove the bleed screw “1” and release the Spring preload
internal pressure from the front fork. ECA24360

3. Tighten: NOTICE
• Bleed screw Do not turn the adjuster forcibly beyond its
adjusting range.
Bleed screw
1.3 N·m (0.13 kgf·m, 0.95 lb·ft) 1. Adjust:
• Spring preload
T.
R.

a. Loosen the locknut “1”.

b. Loosen the adjuster “2” until there is some
clearance between the spring and the ad-
juster.
1 c. Measure the spring free length “a”.

a
2
EAM30482

CHECKING THE REAR SHOCK ABSORBER 1

ASSEMBLY
1. Stand the vehicle upright on a level surface.
EWA13120

WARNING
d. Turn the adjuster in the direction of “b” or
Securely support the vehicle so that there is “c” to make an adjustment.
no danger of it falling over.
Direction “b”
2. Check:
Spring preload is increased (suspen-
• Rear shock absorber assembly sion is harder).
Gas leaks/oil leaks  Replace the rear shock Direction “c”
absorber assembly. Spring preload is decreased (suspen-
Refer to “REAR SHOCK ABSORBER AS- sion is softer).
SEMBLY” on page 4-63.
3. Check:
• Rear shock absorber assembly smooth ac- Spring preload adjusting positions
tion Minimum
Position in which the spring is
• Rear suspension link smooth action
turned in 1.5 mm (0.06 in) from
Sit astride the seat and shake your body up its free length.
and down several times to check whether the Standard
rear shock absorber assembly operates Position in which the spring is
smoothly. turned in 7.0 mm (0.28 in) from
Unsmooth operation  Correct or replace. its free length.
Refer to “REAR SHOCK ABSORBER AS- Maximum
SEMBLY” on page 4-63. Position in which the spring is
turned in 18.0 mm (0.71 in) from
EAM30242
its free length.
ADJUSTING THE REAR SHOCK ABSORBER
ASSEMBLY
TIP
Use a maintenance stand to raise the rear wheel • Be sure to remove all dirt and mud from around
off the ground. the locknut and adjusting ring before adjust-
ment.

3-31
 CHASSIS

• The length of the spring (installed) changes 1.5

mm (0.06 in) per turn of the adjusting ring.

a
b
c
b
1

Compression damping (for fast compres-

sion damping)
e. Tighten the locknut. ECA24370

Rebound damping NOTICE

ECA24370 Do not turn the adjuster forcibly beyond its
NOTICE adjusting range.
Do not turn the adjuster forcibly beyond its 1. Adjust:
adjusting range. • Compression damping (for fast compression
1. Adjust: damping)
• Rebound damping a. Turn the adjuster “1” in the direction of “a”
a. Turn the adjuster “1” in the direction of “a” or “b” to make an adjustment.
or “b” to make an adjustment.
Direction “a”
Direction “a” Compression damping is increased
Rebound damping is increased (sus- (suspension is harder).
pension is harder). Direction “b”
Direction “b” Compression damping is decreased
Rebound damping is decreased (sus- (suspension is softer).
pension is softer).
Fast compression damping
Rebound damping Minimum (soft)
Minimum (soft) 2 turn(s) in direction “b”*
30 click(s) in direction “b”* Standard
Standard 1 turn(s) in direction “b”*
13 click(s) in direction “b”* Maximum (hard)
Maximum (hard) 0 turn(s) in direction “b”*
0 click(s) in direction “a” * With the adjusting screw fully turned in di-
* ith the adjusting screw fully turned in di- rection “a”
rection “a”
TIP
TIP To obtain a precise adjustment, it is advisable to
Although the total number of clicks of a damping check the actual total number of turns of the
force adjusting mechanism may not exactly damping force adjusting mechanism. This ad-
match the above specifications due to small dif- justment range may not exactly match the spec-
ferences in production, the actual number of ifications listed due to small differences in
clicks always represents the entire adjusting production.
range. To obtain a precise adjustment, it would
be advisable to check the number of clicks of
each damping force adjusting mechanism and
to modify the specifications as necessary.

3-32
 CHASSIS

b b

1 a 1 a

Compression damping (for slow compres- EAM30240

sion damping) CHECKING THE SWINGARM OPERATION

ECA24390 1. Check:
NOTICE • Swingarm smooth action
Do not turn the adjuster forcibly beyond its • Swingarm free play
adjusting range. Refer to “SWINGARM” on page 4-70.
1. Adjust: EAM30500

• Compression damping (for slow compression LUBRICATING THE SWINGARM PIVOT

damping) 1. Lubricate:
a. Turn the adjuster “1” in the direction of “a” • Oil seal
or “b” to make an adjustment. • Collar

Direction “a” Recommended lubricant

Compression damping is increased Lithium-soap-based grease
(suspension is harder).
Direction “b” Refer to “INSTALLING THE SWINGARM” on
Compression damping is decreased page 4-72.
(suspension is softer). EAM30501

CHECKING THE CONNECTING ARM AND

Slow compression damping RELAY ARM
Minimum (soft) Refer to “CHECKING THE CONNECTING ARM
20 click(s) in direction “b”* AND RELAY ARM” on page 4-67.
Standard EAM30243
10 click(s) in direction “b”* CHECKING THE TIRES
Maximum (hard) 1. Measure:
0 click(s) in direction “b”* • Tire pressure
* With the adjusting screw fully turned in di-
Out of specification  Regulate.
rection “a”
Tire air pressure (measured on
TIP cold tires)
Although the total number of clicks of a damping Front
force adjusting mechanism may not exactly 100 kPa (1.00 kgf/cm², 15 psi)
match the above specifications due to small dif- Rear
ferences in production, the actual number of 100 kPa (1.00 kgf/cm², 15 psi)
clicks always represents the entire adjusting
range. To obtain a precise adjustment, it would TIP
be advisable to check the number of clicks of • Check the tire while it is cold.
each damping force adjusting mechanism and • Because if the bead stopper tightening nut is
to modify the specifications as necessary. loose when the tire pressure is low, the tire
could slip off the rim, thus be sure to check and
tighten the bead stopper tightening nut “a”.
• If the tire valve stem “b” is found tilted, the tire
is considered to be slipping off its position. Cor-

3-33
 CHASSIS

rect the tire position.

Spoke
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)

T.
R.
TIP
• Do not give a half turn (180) or more for one
a tightening.
• Make sure that tightening after a break-in is
b
done until the initial looseness in nipples disap-
pears.
• Make sure that tightening is done in stages, not
at a time.

a. Bead stopper tightening nut EAM30245

b. Tire valve stem CHECKING THE WHEELS

EAM30244
1. Check:
CHECKING AND TIGHTENING THE SPOKES • Wheel
1. Check: Damage/out-of-round  Replace.
EWA13260
• Spoke
WARNING
Bend/damage  Replace.
Loose  Tighten. Never attempt to make any repairs to the
Tap the spoke with a screwdriver. wheel.

EAM30246

CHECKING THE WHEEL BEARINGS

1. Check:
• Wheel bearing
Refer to “CHECKING THE FRONT WHEEL”
on page 4-8 and “CHECKING THE REAR
WHEEL” on page 4-13.
EAM30253

CHECKING THE CHASSIS FASTENERS

Make sure that all nuts, bolts, and screws are
TIP
properly tightened.
A tight spoke will emit a clear, ringing tone; a
Refer to “CHASSIS TIGHTENING TORQUES”
loose spoke will sound flat.
on page 2-13.
2. Tighten:
EAM30248
• Spoke CHECKING AND LUBRICATING THE
(with a spoke nipple wrench “1”) CABLES
The following procedure applies to all of the in-
ner and outer cables.
1 EWA13270

WARNING
Damaged outer cable may cause the cable to
corrode and interfere with its movement. Re-
place damaged outer cable and inner cables
as soon as possible.
1. Check:
• Outer cable
Damage  Replace.
Spoke nipple wrench (6–7)
90890-01521 2. Check:
Spoke nipple wrench (6–7) • Cable operation
YM-01521 Rough movement  Lubricate.

3-34
 CHASSIS

Recommended lubricant
Engine oil or a suitable cable lu-
bricant

TIP
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubricating device.

EAM30483

LUBRICATING THE BRAKE LEVER

1. Lubricate the pivoting points and metal-to-
metal moving parts of the following parts.
• Brake lever
Recommended lubricant
Silicone grease

EAM30503

LUBRICATING THE CLUTCH LEVER

1. Lubricate the pivoting points and metal-to-
metal moving parts of the following parts.
• Clutch lever
Recommended lubricant
Lithium-soap-based grease

EAM30250

LUBRICATING THE PEDAL

1. Lubricate the pivoting point and metal-to-met-
al moving parts of the pedal.
Recommended lubricant
Lithium-soap-based grease

3-35
 ELECTRICAL SYSTEM

EAM20137

ELECTRICAL SYSTEM
EAM30256

CHECKING AND CHARGING THE BATTERY

Refer to “CHECKING AND CHARGING THE
BATTERY” on page 8-47.
EAM30505

CHECKING THE FUSES

Refer to “CHECKING THE FUSES” on page
8-47.

3-36
 CHASSIS

GENERAL CHASSIS........................................................................................4-1
REMOVING THE SEAT..............................................................................4-4
REMOVING THE NUMBER PLATE ...........................................................4-4
INSTALLING THE SHROUD ......................................................................4-4
REMOVING THE SIDE COVER .................................................................4-5
1
INSTALLING THE SIDE COVER ...............................................................4-5

FRONT WHEEL ................................................................................................4-6

REMOVING THE FRONT WHEEL .............................................................4-8 2
DISASSEMBLING THE FRONT WHEEL ...................................................4-8
CHECKING THE FRONT WHEEL .............................................................4-8

3
ASSEMBLING THE FRONT WHEEL .........................................................4-8
INSTALLING THE FRONT WHEEL ...........................................................4-9

REAR WHEEL ................................................................................................4-11

4
REMOVING THE REAR WHEEL .............................................................4-13
DISASSEMBLING THE REAR WHEEL ...................................................4-13
CHECKING THE REAR WHEEL ..............................................................4-13
CHECKING AND REPLACING THE REAR WHEEL SPROCKET...........4-13
ASSEMBLING THE REAR WHEEL .........................................................4-14

5
INSTALLING THE REAR WHEEL ............................................................4-14

FRONT BRAKE ..............................................................................................4-16

INTRODUCTION ......................................................................................4-20

6
CHECKING THE FRONT BRAKE DISC ..................................................4-20
REPLACING THE FRONT BRAKE PADS ...............................................4-20
REMOVING THE FRONT BRAKE CALIPER ...........................................4-22
DISASSEMBLING THE FRONT BRAKE CALIPER .................................4-22
CHECKING THE FRONT BRAKE CALIPER............................................4-22

7
ASSEMBLING THE FRONT BRAKE CALIPER .......................................4-22
INSTALLING THE FRONT BRAKE CALIPER..........................................4-23
REMOVING THE FRONT BRAKE MASTER CYLINDER ........................4-24
CHECKING THE FRONT BRAKE MASTER CYLINDER .........................4-24
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER.....................4-24
INSTALLING THE FRONT BRAKE MASTER CYLINDER .......................4-25

REAR BRAKE ................................................................................................4-27

8
INTRODUCTION ......................................................................................4-32

9
CHECKING THE REAR BRAKE DISC .....................................................4-32
REPLACING THE REAR BRAKE PADS ..................................................4-32
REMOVING THE REAR BRAKE CALIPER .............................................4-34
DISASSEMBLING THE REAR BRAKE CALIPER....................................4-34
CHECKING THE REAR BRAKE CALIPER ..............................................4-34

10
ASSEMBLING THE REAR BRAKE CALIPER..........................................4-35
INSTALLING THE REAR BRAKE CALIPER ............................................4-35
REMOVING THE REAR BRAKE MASTER CYLINDER...........................4-36
CHECKING THE REAR BRAKE MASTER CYLINDER ...........................4-36
ASSEMBLING THE REAR BRAKE MASTER CYLINDER .......................4-36
 INSTALLING THE REAR BRAKE MASTER CYLINDER .........................4-37

HANDLEBAR..................................................................................................4-39
REMOVING THE HANDLEBAR ...............................................................4-41
CHECKING THE HANDLEBAR................................................................4-41
INSTALLING THE HANDLEBAR..............................................................4-41

FRONT FORK.................................................................................................4-46
REMOVING THE FRONT FORK LEGS ...................................................4-48
DISASSEMBLING THE FRONT FORK LEGS .........................................4-48
CHECKING THE FRONT FORK LEGS....................................................4-49
ASSEMBLING THE FRONT FORK LEGS ...............................................4-50
INSTALLING THE FRONT FORK LEGS..................................................4-56

STEERING HEAD...........................................................................................4-58
REMOVING THE LOWER BRACKET ......................................................4-60
CHECKING THE STEERING HEAD ........................................................4-60
INSTALLING THE STEERING HEAD ......................................................4-60

REAR SHOCK ABSORBER ASSEMBLY ......................................................4-63

HANDLING THE REAR SHOCK ABSORBER .........................................4-66
DISPOSING OF A REAR SHOCK ABSORBER.......................................4-66
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY ....................4-66
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY.....................4-66
CHECKING THE CONNECTING ARM AND RELAY ARM ......................4-67
INSTALLING THE RELAY ARM ...............................................................4-67
INSTALLING THE CONNECTING ARM ..................................................4-67
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY...................4-68

SWINGARM ....................................................................................................4-70
REMOVING THE SWINGARM .................................................................4-72
CHECKING THE SWINGARM .................................................................4-72
INSTALLING THE SWINGARM ...............................................................4-72

CHAIN DRIVE .................................................................................................4-74

REMOVING THE DRIVE CHAIN ..............................................................4-75
CHECKING THE DRIVE CHAIN ..............................................................4-75
CHECKING THE DRIVE SPROCKET ......................................................4-76
CHECKING THE REAR WHEEL SPROCKET .........................................4-76
INSTALLING THE DRIVE CHAIN ............................................................4-76
 GENERAL CHASSIS

EAM20094

GENERAL CHASSIS
Removing the seat and battery

13 N m (1.3 kgf m, 9.6 lb ft)

10

4 9
3

13 N m (1.3 kgf m, 9.6 lb ft)

5

8 2

3.5 N m (0.35 kgf m, 2.6 lb ft)

7 N m (0.7 kgf m, 5.2 lb ft)

Order Job/Parts to remove Q’ty Remarks

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 CCU (Communication Control Unit) 1
10 Holder 1

4-1
 GENERAL CHASSIS

Removing the side cover

13 N m (1.3 kgf m, 9.6 lb ft)

2

7 N m (0.7 kgf m, 5.2 lb ft)

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)

4 3

Order Job/Parts to remove Q’ty Remarks

1 Side cover (right) 1
2 Rear fender 1
3 ECU (Engine Control Unit) 1
4 Holder 1

4-2
 GENERAL CHASSIS

Removing the shroud

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)

7 N m (0.7 kgf m, 5.2 lb ft)

Order Job/Parts to remove Q’ty Remarks

Refer to “CLEANING THE AIR FILTER ELE-
1 Air filter case cover 1 MENT” on page 3-16.
2 Shroud (left) 1
3 Shroud (right) 1
4 Number plate 1

4-3
 GENERAL CHASSIS

EAM30016

REMOVING THE SEAT

TIP
The sub-seat and the seat are coupled with each 2
other with a plastic band.
When removing the seat, always remove the
sub-seat beforehand.
1. Remove:
• Sub-seat “1” a
Refer to “FUEL TANK CAP” on page 1-23.
1

1
c

2. Remove:
• Seat “1”

1
2

EAM30640

EAM30371 INSTALLING THE SHROUD

REMOVING THE NUMBER PLATE 1. Install:
1. Remove: • Shroud (left “1”/right)
• Bolt (number plate) TIP
• Number plate “1” Insert the projection “a” on the radiator guard
TIP (left/right) into the hole “b” in the shroud
• Remove the brake hose “2” from the upper (left/right), install the shroud, and then secure it
guide “a” and the lower guide “b” on the num- with the bolts.
ber plate.
• The projection “c” on the number plate is insert-
ed into the front fender. Remove the number
plate by pulling it off the front fender. b

a
1

4-4
 GENERAL CHASSIS

EAM30459

REMOVING THE SIDE COVER

1. Remove:
• Side cover (right) “1”
TIP
Remove the side cover (right) from the vehicle
by removing the bolts and sliding it as shown.

a
1

a. Projection
b. Slot
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.

d b

a
1 c

a. Projection
b. Slot
c. Rib (side cover)
d. Rib (rear fender)

4-5
 FRONT WHEEL

EAM20095

FRONT WHEEL
Removing the front wheel
21 N m (2.1 kgf m, 15 lb ft)

3
1
LS

2
115 N m (11.5 kgf m, 85 lb ft)
6

Order Job/Parts to remove Q’ty Remarks

Use a maintenance stand 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 (left) 1
6 Collar (right) 1

4-6
 FRONT WHEEL

Disassembling the front wheel

0 mm
(0 in)

LS

1
2

2
3 1

(6)
LS

12 N m (1.2 kgf m, 8.9 lb ft)

Order Job/Parts to remove Q’ty Remarks

1 Oil seal 2
2 Bearing 2
3 Brake disc 1

4-7
 FRONT WHEEL

EAM30017
3. Check:
REMOVING THE FRONT WHEEL • Spoke
1. Use a maintenance stand to raise the front Refer to “CHECKING AND TIGHTENING
wheel off the ground. THE SPOKES” on page 3-34.
EWA13120

WARNING 4. Tighten:
• Spoke
Securely support the vehicle so that there is
Refer to “CHECKING AND TIGHTENING
no danger of it falling over.
THE SPOKES” on page 3-34.
2. Remove:
• Front wheel Spoke
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)

T.
R.
EAM30019

DISASSEMBLING THE FRONT WHEEL TIP

1. Remove: After tightening the spokes, measure the wheel
• Oil seal runout.
• Bearing
a. Clean the outside of the front wheel hub. 5. Measure:
b. Remove the oil seals “1” with a flat-head • Radial wheel runout “a”
screwdriver. • Lateral wheel runout “b”
TIP Out of specification  Repair/replace.
To prevent damaging the wheel, place a rag “2”
between the screwdriver and the wheel surface.
b

2 a

Radial wheel runout limit

1 2.0 mm (0.08 in)
Lateral wheel runout limit
c. Remove the bearings with a bearing pull- 2.0 mm (0.08 in)
er.
EAM30018
6. Check:
CHECKING THE FRONT WHEEL • Collar
1. Check: Damage/wear  Replace.
• Front wheel axle 7. Check:
Roll the front wheel axle on a flat surface. • Bearing
Bends  Replace. Front wheel turns roughly or is loose  Re-
EWA13460 place the wheel bearings.
WARNING • Oil seal
Do not attempt to straighten a bent wheel ax- Damage/wear  Replace.
le. EAM30020

2. Check: ASSEMBLING THE FRONT WHEEL

• Tire 1. Install:
• Front wheel • Bearing (left side) “1” New
Damage/wear  Replace. • Spacer “2”
Refer to “CHECKING THE TIRES” on page • Bearing (right side) “3” New
3-33 and “CHECKING THE WHEELS” on • Oil seal “4” New
page 3-34. TIP
• Apply the lithium-soap-based grease to the oil
seal lip when installing.

4-8
 FRONT WHEEL

• Left side of bearing shall be installed first. 3. Install:

• Install the oil seal with its manufacture’s marks • Collar “1”
or numbers facing outward. TIP
ECA24420 Apply the lithium-soap-based grease on the oil
NOTICE seal lip.
Install the bearing by pressing its outer race
parallel. 1

4
3
2

EAM30617

LS INSTALLING THE FRONT WHEEL

1. Install:
LS • Front wheel
TIP
Install the brake disc “1” between the brake pads
“2” correctly.
1
4
2

TIP
Use a socket “5” that matches the diameter of
the bearing outer race and that of the oil seal.
1

5 2. Install:
• Front wheel axle “1”
TIP
Apply the lithium-soap-based grease to the front
wheel axle.

2. Install:
• Brake disc 1
• Brake disc bolt
Brake disc bolt
12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.

LOCTITE®
R.

3. Tighten:
TIP • Front wheel axle nut “1”
Tighten the bolts in stages and in a crisscross
pattern.

4-9
 FRONT WHEEL

Front wheel axle nut

T.
R.
115 N·m (11.5 kgf·m, 85 lb·ft)
ECA24430

NOTICE
Before tightening the front wheel axle nut,
push down hard on the handlebar(s) several
times and check if the front fork rebounds
smoothly.

4. Tighten:
• Front wheel axle pinch bolt “1”
Front wheel axle pinch bolt
21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.

1 1

4-10
 REAR WHEEL

EAM20096

REAR WHEEL
Removing the rear wheel
135 N m (13.5 kgf m, 100 lb ft) 1
4
21 N m (2.1 kgf m, 15 lb ft)
6

3
2

21 N m (2.1 kgf m, 15 lb ft)

Order Job/Parts to remove Q’ty Remarks

Use a maintenance stand to raise the rear
wheel off the ground.
1 Rear wheel axle nut 1
2 Rear wheel axle 1
3 Drive chain puller (left) 1
4 Drive chain puller (right) 1
5 Rear wheel 1
6 Collar 2

4-11
 REAR WHEEL

Disassembling the rear wheel

12 N m (1.2 kgf m, 8.9 lb ft) (6)
42 N m (4.2 kgf m, 31 lb ft)
5
2
3
4

(6)

4
4
2

Order Job/Parts to remove Q’ty Remarks

1 Rear wheel sprocket 1
2 Oil seal 2 [“a” = Approx. 1.0 mm (0.04 in)]
3 Circlip 1
4 Bearing 3
5 Brake disc 1

4-12
 REAR WHEEL

EAM30022
Refer to “CHECKING THE TIRES” on page
REMOVING THE REAR WHEEL 3-33 and “CHECKING THE WHEELS” on
1. Use a maintenance stand to raise the rear page 3-34.
wheel off the ground. 3. Check:
EWA13120

WARNING • Spoke
Refer to “CHECKING AND TIGHTENING
Securely support the vehicle so that there is
THE SPOKES” on page 3-34.
no danger of it falling over.
4. Measure:
2. Remove: • Radial wheel runout
• Rear wheel axle nut “1” • Lateral wheel runout
3. Loosen: Refer to “CHECKING THE FRONT WHEEL”
• Locknut “2” on page 4-8.
4. Tighten:
• Adjusting bolt “3” Radial wheel runout limit
2.0 mm (0.08 in)
Lateral wheel runout limit
2.0 mm (0.08 in)

EAM30025
2
CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
3 1. Check:
• Rear wheel sprocket
1 More than 1/4 tooth wear “a”  Replace the
rear wheel sprocket and the drive sprocket as
5. Remove: a set.
• Rear wheel axle Bent tooth  Replace the rear wheel sprock-
• Rear wheel et and the drive sprocket as a set.
TIP
• Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
• Do not depress the brake pedal with the rear
wheel removed.

EAM30024

DISASSEMBLING THE REAR WHEEL

1. Remove:
• Oil seal
• Bearing
Refer to “DISASSEMBLING THE FRONT b. Correct
WHEEL” on page 4-8.
1. Drive chain roller
EAM30023 2. Rear wheel sprocket
CHECKING THE REAR WHEEL
1. Check: 2. Replace:
• Rear wheel axle • Rear wheel sprocket
• Rear wheel a. Remove the self-locking nuts and the rear
• Bearing wheel sprocket.
• Oil seal b. Clean the rear wheel drive hub with a
Refer to “CHECKING THE FRONT WHEEL” clean cloth, especially the surfaces that
on page 4-8. contact the sprocket.
2. Check: c. Install the new rear wheel sprocket.
• Tire
• Rear wheel
Damage/wear  Replace.

4-13
 REAR WHEEL

• Brake disc bolt

Rear wheel sprocket self-locking
T. nut Brake disc bolt
42 N·m (4.2 kgf·m, 31 lb·ft) 12 N·m (1.2 kgf·m, 8.9 lb·ft)
R.

T.
LOCTITE®

R.
TIP
Tighten the self-locking nuts in stages and in a TIP
crisscross pattern. Tighten the bolts in stages and in a crisscross
pattern.
EAM30026

ASSEMBLING THE REAR WHEEL 3. Install:

1. Install: • Collar “1”
• Bearing (right side) “1” New TIP
• Circlip “2” New Apply the lithium-soap-based grease on the oil
• Spacer “3” seal lip.
• Bearing (left side) “4” New
• Oil seal “5” New 1
TIP
• Apply the lithium-soap-based grease to the oil
seal lip when installing.
• Right side of bearing shall be installed first.
• Install the oil seal with its manufacture’s marks
or numbers facing outward.
ECA24440

NOTICE
Install the bearing by pressing its outer race EAM30027
parallel. INSTALLING THE REAR WHEEL
1. Install:
5 2 • Rear wheel
TIP
Install the brake disc “1” between the brake pads
“2” correctly.
1
3
5
2 2
4

TIP
Use a socket “6” that matches the diameter of 1
the bearing outer race and that of the oil seal.

6 2. Install:
• Drive chain “1”
TIP
Push the rear wheel “2” forward and install the
drive chain.

2. Install:
• Brake disc

4-14
 REAR WHEEL

Refer to “DRIVE CHAIN SLACK” on page

3-27.

1
2

3. Install:
• Drive chain puller (left) “1”
• Rear wheel axle “2” 6. Tighten:
TIP • Rear wheel axle nut “1”
• Install the drive chain puller (left), and insert the
rear wheel axle from the left side. Rear wheel axle nut
135 N·m (13.5 kgf·m, 100 lb·ft)
• Apply the lithium-soap-based grease to the

T.
R.
rear wheel axle. • Locknut “2”
Locknut
21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.
1

LS
2
1
2
4. Install:
• Drive chain puller (right) “1”
• Washer “2”
• Rear wheel axle nut “3”
TIP
Temporarily tighten the rear wheel axle nut at
this point.

1
5. Adjust:
• Drive chain slack “a”
Drive chain slack (Maintenance
Stand)
50.0–60.0 mm (1.97–2.36 in)

4-15
 FRONT BRAKE

EAM20097

FRONT BRAKE
Removing the front brake caliper

30 N m (3.0 kgf m, 22 lb ft)

28 N m (2.8 kgf m, 21 lb ft)

5 N m (0.5 kgf m, 3.7 lb ft)

2
1.0 mm
(0.04 in) 8
5
7 4

10

6 17 N m (1.7 kgf m, 13 lb ft)

2.5 N m (0.25 kgf m, 1.8 lb ft)

Order Job/Parts to remove Q’ty Remarks

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-26.
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
10 Brake pad spring 1

4-16
 FRONT BRAKE

Disassembling the front brake caliper

BF 5 N m (0.5 kgf m, 3.7 lb ft)

.
S
4
2
S
3
1

BF
2

S 3

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

4-17
 FRONT BRAKE

Removing the front brake master cylinder

a 9 N m (0.9 kgf m, 6.6 lb ft)

6
1.5 N m (0.15 kgf m, 1.1 lb ft)
7
6 N m (0.6 kgf m, 4.4 lb ft)

3
2 30 N m (3.0 kgf m, 22 lb ft)
6 N m (0.6 kgf m, 4.4 lb ft)

Order Job/Parts to remove Q’ty Remarks

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-26.
1 Brake lever 1
2 Union bolt 1
3 Copper washer 2
4 Front brake hose 1
Adjust the front brake master cylinder so
5 Brake master cylinder reservoir cap 1 that the top “a” of the brake master cylinder
reservoir cap is horizontal.
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

4-18
 FRONT BRAKE

Disassembling the front brake master cylinder

1 New

BF

Order Job/Parts to remove Q’ty Remarks

1 Brake master cylinder kit 1

4-19
 FRONT BRAKE

EAM30028
b. Remove the brake caliper.
INTRODUCTION c. Hold the dial gauge at a right angle against
EWA19210

WARNING the brake disc surface.

d. Measure the runout 1.5 mm (0.06 in)
If you need to disassemble the disc brake
above the brake disc edge.
components, observe the following precau-
tions.
• Never disassemble the brake components
unless absolutely necessary.
• If there is any problem with connections on
the hydraulic brake system, perform the
following jobs. Disassemble the brake sys-
tem, drain the brake fluid, and clean it. After
that, add a suitable amount of brake fluid.
Then, bleed it after reassembly. G098641
• Use only brake fluid for washing brake
components. 4. Replace:
• Use new brake fluid for cleaning the brake • Brake disc
components. Refer to “ASSEMBLING THE FRONT
• Immediately wipe off the spilled brake fluid WHEEL” on page 4-8.
to avoid damage to painted surfaces or EAM30519

plastic parts. REPLACING THE FRONT BRAKE PADS

• Handle brake fluid with special care not to TIP
let it enter your eyes so that you may not When replacing the brake pads, it is not neces-
lost your eyesight. sary to disconnect the brake hose or disassem-
• FIRST AID FOR BRAKE FLUID ENTERING ble the brake caliper.
THE EYES: 1. Remove:
• Flush with water for 15 minutes and get im- • Brake pad
mediate medical attention. a. Remove the pad pin plug “1”.
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- 1
ferent locations.
Out of specification  Replace.
b. Loosen the pad pin “2”.
Brake disc thickness limit c. Remove the brake caliper “3” from the
2.5 mm (0.10 in) front fork.
3. Measure:
• Brake disc runout
Out of specification  Replace the brake
disc. 3

Brake disc runout limit (as mea-

sured on wheel)
0.15 mm (0.0059 in)
2
a. Place the vehicle on a maintenance stand
so that the front wheel is elevated. d. Remove the pad pin and brake pads “4”.

4-20
 FRONT BRAKE

d. Install 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.

b a
2. Measure:
• Brake pad wear limit “a”
Out of specification  Replace the brake
pads as a set.
Brake pad lining thickness limit
1.0 mm (0.04 in) e. Install the brake caliper “4” and tighten the
pad pin “5”.
Front brake caliper bolt
28 N·m (2.8 kgf·m, 21 lb·ft)
T.
Pad pin
R.
a
17 N·m (1.7 kgf·m, 13 lb·ft)

4
3. Install:
• Brake pad
a. Connect the plastic hose “1” to the bleed
screw “2” and place a container under the 5
end of the plastic hose.
2 f. Install the pad pin plug “6”.
Pad pin plug
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
T.
R.

b. Loosen the bleed screw and push the

brake caliper piston in. 6
EWA19160

WARNING
Do not reuse the drained brake fluid.
4. Check:
c. Tighten the bleed screw. • Brake fluid level
Refer to “CHECKING THE BRAKE FLUID
Bleed screw LEVEL” on page 3-24.
5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
R.

4-21
 FRONT BRAKE

5. Check:
• Brake lever operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-26.
EAM30030

REMOVING THE FRONT BRAKE CALIPER

TIP
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system. b. Remove the brake caliper piston dust seal
1. Remove: and the brake caliper piston seal.
• Union bolt EAM30032

• Copper washer CHECKING THE FRONT BRAKE CALIPER

• Brake hose 1. Check:
TIP • Brake caliper piston “1”
Put the end of the brake hose into a container Rust/scratches/wear  Replace the brake
and pump out the brake fluid. caliper piston.
• Brake caliper cylinder “2”
EAM30031 Scratches/wear  Replace the brake caliper
DISASSEMBLING THE FRONT BRAKE assembly.
CALIPER • Brake caliper body “3”
1. Remove: Cracks/damage  Replace the brake caliper
• Brake caliper piston “1” assembly.
• Brake caliper piston dust seal “2” • Brake fluid delivery passages
• Brake caliper piston seal “3” (brake caliper body)
1 Obstruction  Blow out with compressed air.
2
2 3

1 1
a. Blow compressed air into the brake hose
joint opening to force out the piston from EWA19220

the brake caliper. WARNING

EWA13550
When the brake caliper is disassembled, re-
WARNING
place the brake caliper piston seal and the
• Cover the brake caliper piston with a rag. brake caliper piston dust seal with new ones.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper. 2. Check:
• Never try to pry out the brake caliper pis- • Brake caliper bracket
ton. Crack/damage  Replace.
EAM30033

ASSEMBLING THE FRONT BRAKE CALIPER

EWA19230

WARNING
• Before installation, clean and lubricate the
internal parts. Use new brake fluid for

4-22
 FRONT BRAKE

cleaning and lubricating.

• Never use solvents on internal brake com- Brake pad pin
17 N·m (1.7 kgf·m, 13 lb·ft)
ponents as they will cause the piston seals

T.
Brake pad pin plug

R.
to swell and distort. 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
• When the brake caliper is disassembled, re-
place the brake caliper piston seal and the Refer to “CHECKING THE FRONT BRAKE
brake caliper piston dust seal with new PADS” on page 3-25.
ones. 3. Tighten:
• Brake hose holder bolt “1”
Specified brake fluid
DOT 4 Brake hose holder bolt
9 N·m (0.9 kgf·m, 6.6 lb·ft)

T.
R.
EAM30035

INSTALLING THE FRONT BRAKE CALIPER TIP

1. Install: Make sure that the brake hose holder “2” is in-
• Front brake caliper bracket stalled with its upper end “a” aligned with the
• Front brake caliper paint “b” on the brake hose.
(temporarily)
• Copper washer New
• Brake hose b
• Union bolt
Front brake caliper bracket 2
28 N·m (2.8 kgf·m, 21 lb·ft)
T.

Brake hose union bolt

R.

a
30 N·m (3.0 kgf·m, 22 lb·ft) 1
EWA13531

WARNING
4. Pour brake fluid to the brake master cylinder
Proper brake hose routing is essential to in-
reservoir up to the specified level.
sure safe vehicle operation.
ECA24460 Specified brake fluid
NOTICE DOT 4
Make sure that the pipe portion “a” of the EWA13090
brake hose touches the projection “b” on the WARNING
brake caliper.
• 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 result in a harmful chemical reaction,
a leading to poor brake performance.
b • When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
2. Install: the brake fluid and could cause vapor lock.
• Front brake caliper ECA13540

• Brake pad spring NOTICE

• Brake pad Brake fluid may damage painted surfaces
• Brake pad pin and plastic parts. Therefore, always clean up
• Brake pad pin plug any spilt brake fluid immediately.
• Brake hose holder

4-23
 FRONT BRAKE

5. Bleed: 2. Check:
• Brake system • Brake master cylinder reservoir cap
Refer to “BLEEDING THE HYDRAULIC Damage/scratches/wear  Replace.
BRAKE SYSTEM” on page 3-26. 3. Check:
6. Check: • Brake hose
• Brake fluid level Cracks/damage/wear  Replace.
The minimum level mark or below  Add. • Protector “1”
Refer to “CHECKING THE BRAKE FLUID Out of specification  Replace.
LEVEL” on page 3-24. TIP
7. Check: The protector reaches the limit of its use when it
• Brake lever operation is worn down to the same height “a” as of the
A softy or spongy feeling  Bleed the brake plastic locking tie circumference.
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-26.
1
EAM30036

REMOVING THE FRONT BRAKE MASTER

CYLINDER
a
TIP
Before removing the front brake master cylinder,
drain the brake fluid from the entire brake sys-
tem.
1. Remove: EAM30038

• Union bolt ASSEMBLING THE FRONT BRAKE MASTER

• Copper washer CYLINDER
EWA13520
• Brake hose WARNING
TIP • Before installation, all internal brake com-
To drain any remaining brake fluid, place a con-
ponents should be cleaned and lubricated
tainer under the master cylinder and the end of
with clean or new brake fluid.
the brake hose.
• Never use solvents on internal brake com-
EAM30037
ponents.
CHECKING THE FRONT BRAKE MASTER
CYLINDER Specified brake fluid
1. Check: DOT 4
• Brake master cylinder “1”
1. Wash the brake master cylinder with brake
Damage/scratches/wear  Replace the
fluid.
brake master cylinder assembly.
2. Install:
• Brake fluid delivery passages “2”
• Primary cylinder cup “1”
(brake master cylinder body)
• Secondary cylinder cup “2”
Obstruction  Blow out with compressed air.
(to the brake master cylinder piston “3”)
EWA20240

WARNING
1 Apply brake fluid to the cylinder cups and in-
stall them as shown. Wrong orientation in in-
stallation causes poor braking performance.

4-24
 FRONT BRAKE

1 2 1 New

3 New
2 4 5

EAM30039

INSTALLING THE FRONT BRAKE MASTER

CYLINDER
1 2
1. Install:
• Brake master cylinder “1”
Brake master cylinder holder bolt
9 N·m (0.9 kgf·m, 6.6 lb·ft)

T.
R.
3
TIP
• Install the front brake master cylinder holder
3. Install: with the “UP” mark facing up.
• Spring “1” • First, tighten the upper bolt, then the lower bolt.
(to the brake master cylinder piston “2”)
TIP
Install the spring with a smaller inside diameter
to the brake master cylinder piston. 1

2. Install:
• Copper washer New
• Brake hose
• Union bolt

4. Install: Brake hose union bolt

• Brake master cylinder piston assembly “1” 30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.

New EWA13531
• Washer “2” WARNING
• Circlip “3” New
Proper brake hose routing is essential to in-
• Dust boot “4”
sure safe vehicle operation.
• Push rod “5”
ECA24470
TIP
NOTICE
• Before installation, apply brake fluid to the
components of the brake master cylinder pis- During installation, bring the brake hose into
ton assembly. contact with the brake master cylinder pro-
• Before installation, apply silicone grease to the jection “a” and make its bent portion “b”
push rod end. face downward.
• Before installation, apply brake fluid to the in- TIP
side of the brake master cylinder. Turn the handlebar toward right and left to make

4-25
 FRONT BRAKE

sure that the brake hose does not touch other BRAKE SYSTEM” on page 3-26.
parts (e.g., wire harness, cables, leads). Adjust
if necessary.

aa
b

a
3. Pour brake fluid to the brake master cylinder
reservoir up to the specified level.
Specified brake fluid
DOT 4
EWA13090

WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in 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.
ECA13540

NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
4. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-26.
5. Check:
• Brake fluid level
The minimum level mark or below  Add.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-24.
6. Check:
• Brake lever operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC

4-26
 REAR BRAKE

EAM20098

REAR BRAKE
Removing the rear brake caliper
2.5 N m (0.25 kgf m, 1.8 lb ft)
17 N m (1.7 kgf m, 13 lb ft)

30 N m (3.0 kgf m, 22 lb ft) 2

3
4
9 D
FW

10

6
S
5
1.0 mm 9
(0.04 in) 1
7

7 N m (0.7 kgf m, 5.2 lb ft)

Order Job/Parts to remove Q’ty Remarks

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-26.
Rear wheel Refer to “REAR WHEEL” on page 4-11.
1 Protector 1
2 Union bolt 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 caliper assembly 1

4-27
 REAR BRAKE

Disassembling the rear brake caliper

5 N m (0.5 kgf m, 3.7 lb ft)

1
4
2
3

BF

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

4-28
 REAR BRAKE

Removing the rear brake master cylinder

D
FW
5 mm (0.20 in)

1.5 N m (0.15 kgf m, 1.1 lb ft)

30 N m (3.0 kgf m, 22 lb ft)

1
2

10 N m (1.0 kgf m, 7.4 lb ft)

Order Job/Parts to remove Q’ty Remarks

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-26.
1 Union bolt 1
2 Copper washer 2
3 Brake hose 1

4-29
 REAR BRAKE

Removing the rear brake master cylinder

D
FW
5 mm (0.20 in)

1.5 N m (0.15 kgf m, 1.1 lb ft)

30 N m (3.0 kgf m, 22 lb ft)

7
8
9
10

10 N m (1.0 kgf m, 7.4 lb ft)

5
4
Order Job/Parts to remove Q’ty Remarks
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

4-30
 REAR BRAKE

Disassembling the rear brake master cylinder

2
BF

Order Job/Parts to remove Q’ty Remarks

1 Brake master cylinder joint 1
2 Brake master cylinder kit 1

4-31
 REAR BRAKE

EAM30040

INTRODUCTION Brake disc runout limit (as mea-

EWA19260
sured on wheel)
WARNING 0.15 mm (0.0059 in)
If you need to disassemble the disc brake
components, observe the following precau- 4. Replace:
tions. • Brake disc
• Never disassemble the brake components Refer to “ASSEMBLING THE REAR
unless absolutely necessary. WHEEL” on page 4-14.
• If there is any problem with connections on EAM30523
the hydraulic brake system, perform the REPLACING THE REAR BRAKE PADS
following jobs. Disassemble the brake sys- TIP
tem, drain the brake fluid, and clean it. After When replacing the brake pads, it is not neces-
that, add a suitable amount of brake fluid. sary to disconnect the brake hose or disassem-
Then, bleed it after reassembly. ble the brake caliper.
• Use only brake fluid for washing internal
brake components. 1. Remove:
• Use new brake fluid for cleaning the brake • Brake pad
components. a. Remove the protector “1” and the pad pin
• Immediately wipe off the spilled brake fluid plug “2”.
to avoid damage to painted surfaces or
plastic parts. 2
• Handle brake fluid with special care not to
let it enter your eyes so that you may not
lost your eyesight.
• FIRST AID FOR BRAKE FLUID ENTERING
THE EYES: 1
• Flush with water for 15 minutes and get im-
mediate medical attention.

EAM30041
b. Loosen the pad pin “3”.
CHECKING THE REAR BRAKE DISC
c. Remove the rear wheel “4” and the brake
1. Check:
caliper “5”.
• Brake disc
Refer to “REAR WHEEL” on page 4-11.
Damage/galling  Replace.
2. Measure: 3
• Brake disc thickness
Measure the brake disc thickness at a few dif- 4
ferent locations.
Out of specification  Replace.
Refer to “CHECKING THE FRONT BRAKE
DISC” on page 4-20. 5
Brake disc thickness limit
3.5 mm (0.14 in)

3. Measure: d. Remove the pad pin “6” and the brake

• Brake disc runout pads “7”.
Out of specification  Replace the brake
disc.
Refer to “CHECKING THE FRONT BRAKE
DISC” on page 4-20.

4-32
 REAR BRAKE

6 Bleed screw
5 N·m (0.5 kgf·m, 3.7 lb·ft)

T.
R.
7 d. Install 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.

2. Measure: 4
• Brake pad wear limit “a”
Out of specification  Replace the brake
pads as a set. 3
Brake pad lining thickness limit
1.0 mm (0.04 in) a
b

e. Install the brake caliper “5” and the rear

wheel “6”.
Refer to “REAR WHEEL” on page 4-11.
a f. Tighten the pad pin “7”.
Pad pin
17 N·m (1.7 kgf·m, 13 lb·ft)
T.
R.

3. Install: 7
• Brake pad
a. Connect the plastic hose “1” to the bleed 6
screw “2” and place a container under the
end of the plastic hose.

1 g. Install the pad pin plug “8” and the

2 protector “9”.
Pad pin plug
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
T.

Rear brake caliper protector bolt

R.

7 N·m (0.7 kgf·m, 5.2 lb·ft)

b. Loosen the bleed screw and push the
brake caliper piston in.
EWA19170

WARNING
Do not reuse the drained brake fluid.
c. Tighten the bleed screw.

4-33
 REAR BRAKE

joint opening to force out the piston from

8 the brake caliper.
EWA13550

WARNING
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
9
• Never try to pry out the brake caliper pis-
ton.

4. Check:
• Brake fluid level
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-24.
5. Check:
• Brake pedal operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-26. b. Remove the brake caliper piston dust seal
and the brake caliper piston seal.
EAM30042

REMOVING THE REAR BRAKE CALIPER EAM30044

TIP CHECKING THE REAR BRAKE CALIPER

Before disassembling the brake caliper, drain 1. Check:
the brake fluid from the entire brake system. • Brake caliper piston “1”
Rust/scratches/wear  Replace the brake
1. Remove:
caliper piston.
• Union bolt
• Brake caliper cylinder “2”
• Copper washer
Scratches/wear  Replace the brake caliper
• Brake hose
assembly.
TIP • Brake caliper body “3”
Put the end of the brake hose into a container Cracks/damage  Replace the brake caliper
and pump out the brake fluid. assembly.
• Brake fluid delivery passages
EAM30043

DISASSEMBLING THE REAR BRAKE (brake caliper body)

CALIPER Obstruction  Blow out with compressed air.
1. Remove:
• Brake caliper piston “1” 2
• Brake caliper piston dust seal “2”
• Brake caliper piston seal “3” 3
1

1 EWA19270
2 WARNING
3
When the brake caliper is disassembled, re-
place the brake caliper piston seal and the
brake caliper piston dust seal with new ones.
a. Blow compressed air into the brake hose

4-34
 REAR BRAKE

2. Check:
• Brake caliper bracket
Crack/damage  Replace.
EAM30045

ASSEMBLING THE REAR BRAKE CALIPER b

EWA19280

WARNING
a
• Before installation, clean and lubricate the b
internal parts. Use new brake fluid for
cleaning and lubricating.
• Never use solvents on internal brake com- 3. Install:
ponents as they will cause the piston seals • Brake pad spring
to swell and distort. • Brake pad
• When the brake caliper is disassembled, re- • Brake pad pin
place the brake caliper piston seal and the • Brake pad pin plug
brake caliper piston dust seal with new
Brake pad pin
ones.
17 N·m (1.7 kgf·m, 13 lb·ft)

T.
Brake pad pin plug

R.
Specified brake fluid 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
DOT 4
Refer to “CHECKING THE REAR BRAKE
PADS” on page 3-25.
EAM30047

INSTALLING THE REAR BRAKE CALIPER

4. Pour brake fluid to the brake fluid reservoir up
1. Install:
to the specified level.
• Rear brake caliper
• Rear brake caliper bracket Specified brake fluid
2. Install: DOT 4
• Rear wheel
Refer to “REAR WHEEL” on page 4-11. EWA13090

WARNING
• Copper washer New
• Brake hose • Use only the designated brake fluid. Other
• Union bolt brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
Brake hose union bolt brake performance.
30 N·m (3.0 kgf·m, 22 lb·ft) • Refill with the same type of brake fluid that
T.
R.

EWA13531
is already in the system. Mixing brake fluids
WARNING may result in a harmful chemical reaction,
leading to poor brake performance.
Proper brake hose routing is essential to in-
• When refilling, be careful that water does
sure safe vehicle operation.
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
ECA24490

NOTICE
the brake fluid and could cause vapor lock.
Make sure that a bend in its pipe portion “a” ECA13540
is directed as shown and the brake hose NOTICE
touches the projection “b” on the brake cali-
Brake fluid may damage painted surfaces
per.
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
5. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-26.
6. Check:
• Brake fluid level

4-35
 REAR BRAKE

The minimum level mark or below  Add. 3. Check:

Refer to “CHECKING THE BRAKE FLUID • Brake hose
LEVEL” on page 3-24. Cracks/damage/wear  Replace.
7. Check: EAM30050
• Brake pedal operation ASSEMBLING THE REAR BRAKE MASTER
A softy or spongy feeling  Bleed the brake CYLINDER
system. EWA13520

Refer to “BLEEDING THE HYDRAULIC WARNING

BRAKE SYSTEM” on page 3-26. • Before installation, all internal brake com-
EAM30048
ponents should be cleaned and lubricated
REMOVING THE REAR BRAKE MASTER with clean or new brake fluid.
CYLINDER • Never use solvents on internal brake com-
TIP ponents.
Before removing the rear brake master cylinder,
drain the brake fluid from the entire brake sys- Specified brake fluid
tem. DOT 4

1. Remove: 1. Wash the brake master cylinder with brake

• Union bolt fluid.
• Copper washer 2. Install:
• Brake hose • Primary cylinder cup “1”
TIP • Secondary cylinder cup “2”
To drain any remaining brake fluid, place a con- (to the brake master cylinder piston “3”)
tainer under the master cylinder and the end of EWA19300

the brake hose. WARNING

Apply brake fluid to the cylinder cups and in-
EAM30049 stall them as shown. Wrong orientation in in-
CHECKING THE REAR BRAKE MASTER stallation causes poor braking performance.
CYLINDER
1. Check:
• Brake master cylinder “1” 2
Damage/scratches/wear  Replace.
• Brake fluid delivery passages “2”
(brake master cylinder body) 1
Obstruction  Blow out with compressed air.

2
1 2
1

2. Check: 3
• Master cylinder reservoir cap
Crack/damage  Replace.
• Brake master cylinder reservoir diaphragm
holder 3. Install:
• Brake master cylinder reservoir diaphragm • Spring “1”
Crack/damage  Replace. (to the brake master cylinder piston “2”)

4-36
 REAR BRAKE

ECA24500
TIP
Install the spring with a smaller inside diameter NOTICE
to the brake master cylinder piston. Make sure that the pipe portion of the brake
hose touches the projection “a” on the brake
caliper.

1 2

4. Install:
• Brake master cylinder piston assembly “1”
New 2. Pour brake fluid to the brake fluid reservoir up
• Push rod “2” New to the specified level.
• Circlip “3” New Specified brake fluid
• Dust boot “4” New DOT 4
TIP
• Before installation, apply brake fluid to the EWA13090

brake master cylinder piston assembly. WARNING

• Before installation, apply silicone grease to the • Use only the designated brake fluid. Other
push rod end. brake fluids may cause the rubber seals to
• Before installation, apply brake fluid to the in- deteriorate, causing leakage and poor
side of the brake master cylinder. 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,
1 New 3 New leading to poor brake performance.
• When refilling, be careful that water does
4 New not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
ECA24510

2 New NOTICE
Brake fluid may damage painted surfaces
EAM30051
and plastic parts. Therefore, always clean up
INSTALLING THE REAR BRAKE MASTER
any spilt brake fluid immediately.
CYLINDER
1. Install: 3. Bleed:
• Copper washer New • Brake system
• Brake hose Refer to “BLEEDING THE HYDRAULIC
• Union bolt BRAKE SYSTEM” on page 3-26.
4. Check:
Brake hose union bolt • Brake fluid level
30 N·m (3.0 kgf·m, 22 lb·ft) The minimum level mark or below  Add.
T.
R.

EWA13531
Refer to “CHECKING THE BRAKE FLUID
WARNING LEVEL” on page 3-24.
Proper brake hose routing is essential to in- 5. Check:
sure safe vehicle operation. • Brake pedal operation
A softy or spongy feeling  Bleed the brake

4-37
 REAR BRAKE

system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-26.

4-38
 HANDLEBAR

EAM20099

HANDLEBAR
Removing the handlebar
9 3.8 N m (0.38 kgf m, 2.8 lb ft) 0.5 N m (0.05 kgf m, 0.37 lb ft)
6 9 N m (0.9 kgf m, 6.6 lb ft)

28 N m (2.8 kgf m, 21 lb ft)

10
8
7 1.3 N m (0.13 kgf m, 0.95 lb ft)

5 N m (0.5 kgf m, 3.7 lb ft)

10˚

4
5
6–8 mm (0.24–0.31)
1

2 a

40 N m (4.0 kgf m, 30 lb ft)

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS” on page
Number plate 4-1.
1 Handlebar protector 1
2 Clutch cable 1 Disconnect.
3 Clutch lever holder 1
4 Handlebar switch (left) 1
5 Brake master cylinder 1
6 Throttle cable housing 1
7 Throttle cable (pull) 1 Disconnect.
8 Throttle cable (return) 1 Disconnect.
9 Handlebar grip (right) 1
10 Tube guide 1

4-39
 HANDLEBAR

Removing the handlebar

3.8 N m (0.38 kgf m, 2.8 lb ft) 0.5 N m (0.05 kgf m, 0.37 lb ft)

9 N m (0.9 kgf m, 6.6 lb ft)

28 N m (2.8 kgf m, 21 lb ft)

1.3 N m (0.13 kgf m, 0.95 lb ft)

11
5 N m (0.5 kgf m, 3.7 lb ft)

10˚

13

14
6–8 mm (0.24–0.31)

12

15

a
16
16

40 N m (4.0 kgf m, 30 lb ft)

Order Job/Parts to remove Q’ty Remarks

11 Start switch 1
Install the handlebar grip (left) to the handle-
12 Handlebar grip (left) 1 bar so that the line “a” between the two
arrow marks faces straight upward.
13 Upper handlebar holder 2
14 Handlebar 1
15 Lower handlebar holder 2
16 Damper 4

4-40
 HANDLEBAR

EAM30052 EWA13120

REMOVING THE HANDLEBAR WARNING

1. Stand the vehicle upright on a level surface. Securely support the vehicle so that there is
EWA13120

WARNING
no danger of it falling over.
Securely support the vehicle so that there is 2. Install:
no danger of it falling over. • Damper “1”
• Lower handlebar holder “2” (temporarily)
2. Remove: • Handlebar “3”
• Grip “1” • Upper handlebar holder “4”
TIP
Blow in compressed air between the handlebar Upper handlebar holder bolt
or tube guide and the grip. Then remove the grip 28 N·m (2.8 kgf·m, 21 lb·ft)

T.
R.
which has become loose.
TIP
• Install the lower handlebar holders with the
side having the longer distance “a” from the
mounting bolt center facing towards the front
side of the vehicle.
• Installing the lower handlebar holders in the re-
verse direction allow the front-to-rear offset
amount of the handlebar position to be
changed.
• Installing the lower handlebar holder holes
from the back to the front allows front-to-rear
3. Remove: offset amount of the handlebar position to be
• Throttle cable housing “ 1” changed.
• Throttle grip “2” • When installing the dampers and the lower
TIP handlebar holders in the front hole, be sure to
While removing the throttle cable housing, pull route the handlebar switch lead (left) “5” as
back the rubber cover “3”. shown in the illustration.
• The upper handlebar holders should be in-
stalled with the punch marks “b” facing for-
ward.
• When installing the handlebar, make sure that
right and left marks “c” are in place identically
on both sides.
• Install the handlebar so that the projection “d”
of the upper handlebar holders is positioned at
the mark on the handlebar as shown.
ECA14250

NOTICE
EAM30053
• First, tighten the bolts on the front side of
CHECKING THE HANDLEBAR the handlebar holder, and then on the rear
1. Check: side.
• Handlebar • Turn the handlebar all the way to the left
Bends/cracks/damage  Replace. and right. If there is any contact with the
EWA13690

WARNING fuel tank, adjust the handlebar position.

Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.

EAM30054

INSTALLING THE HANDLEBAR

1. Stand the vehicle upright on a level surface.

4-41
 HANDLEBAR

2
d

-2
1 -1

+1
+2

a
5
A

A. Routing when installing the damper and

3 4 4 lower handlebar in the rear holes
B. Routing when installing the damper and
lower handlebar in the front holes
3. Tighten:
• Lower handlebar holder nut
Lower handlebar holder nut
40 N·m (4.0 kgf·m, 30 lb·ft)
T.
R.

4. Install:
• Clutch lever holder “1”
• Clutch lever “2”
b
Clutch lever holder bolt
5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.

Clutch lever nut

R.

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

TIP
The clutch lever holder “1” should be installed
according to the dimensions shown.

c 2

1
-2 -2
-1 -1

+1 +1
+2 +2

168 mm
(6.61 in)

4-42
 HANDLEBAR

5. Install:
• Handlebar switch (left) “1”
• Clamp “2”
1
Handlebar switch (left)
1.3 N·m (0.13 kgf·m, 0.95 lb·ft)
T.
R.

TIP
• The handlebar switch (left) “1” should be in-
stalled according to the dimensions shown.
• Pass the handlebar switch lead (left) through
the middle of the clutch lever holder. 8. Adjust:
• Clutch lever free play
Refer to “ADJUSTING THE CLUTCH LEVER
FREE PLAY” on page 3-15.
Clutch lever free play
1 7.0–12.0 mm (0.28–0.47 in)

9. Install:
• Handlebar grip (right) “1”
0 mm
2 • Collar “2”
(0 in) Apply adhesive to the tube guide “3”.
6. Install: TIP
• Before applying the adhesive, wipe off grease
• Handlebar grip (left) “1”
or oil on the tube guide surface “a” with a lac-
a. Slightly coat the handlebar left end with a
quer thinner.
rubber adhesive.
• Install the grip to the tube guide so that the grip
b. Install the handlebar grip (left) on the han-
match mark “b” and tube guide slot “c” form the
dlebar by pressing the grip from the left
angle as shown.
side.
c. Wipe off any excess adhesive with a clean
cloth.
TIP
Install the handlebar grip (left) to the handlebar
so that the line “a” between the two arrow marks
faces straight upward.

1
64
b

7. Install: c
• Clutch cable “1”
TIP 3
Before installation, apply the lithium-soap-based
grease to the clutch cable end. 10.Install:
• Rubber cover “1”
• Throttle grip “2”

4-43
 HANDLEBAR

TIP
Apply the lithium-soap-based grease on the
throttle grip sliding surface.

1
2

11.Install:
• Throttle cable “1”
TIP
Slightly coat the end of throttle cable and inside
of throttle grip with lithium-soap-based grease.
Then, mount the throttle grip onto the handlebar.

13.Install:
• Rubber cover “1”
• Cover (throttle cable housings) “2”

12.Install:
• Throttle cable housing “1”
• Screw (throttle cable housing) “2”
Screw (throttle cable housing) 14.Install:
3.8 N·m (0.38 kgf·m, 2.8 lb·ft) • Start switch “1”
T.

• Front brake master cylinder assembly “2”

R.

• Front brake master cylinder holder “3”

EWA19310

WARNING
• Front brake master cylinder holder bolt “4”
After tightening the throttle cable housing • Clamp “5”
screws, check that the throttle grip “3”
moves smoothly. If it does not, retighten the Front brake master cylinder hold-
screws for adjustment. er bolt
T.

9 N·m (0.9 kgf·m, 6.6 lb·ft)

R.

TIP
• Install the front 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.
• Pass the start switch lead through the middle of
the front brake master cylinder holder.

4-44
 HANDLEBAR

2 3 4 1

0 mm (0 in)
5
(0.08 in)
2 mm

3 mm
(0.12 in)

15.Adjust:
• Throttle grip free play
Refer to “CHECKING THE THROTTLE
GRIP” on page 3-12.
Throttle grip free play
3.0–6.0 mm (0.12–0.24 in)

4-45
 FRONT FORK

EAM20100

FRONT FORK
Removing the front fork legs
a
3

(2)
2

21 N m (2.1 kgf m, 15 lb ft)

(2) 4

9 N m (0.9 kgf m, 6.6 lb ft)

(3)

1
7 N m (0.7 kgf m, 5.2 lb ft)
(3) 7 N m (0.7 kgf m, 5.2 lb ft)

Order Job/Parts to remove Q’ty Remarks

Use a maintenance stand to raise the front
wheel off the ground.
Front wheel Refer to “FRONT WHEEL” on page 4-6.
Front brake caliper Refer to “FRONT BRAKE” on page 4-16.
Refer to “GENERAL CHASSIS” on page
Number plate 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 [“a” = 7 mm (0.28 in)]

4-46
 FRONT FORK

Disassembling the front fork leg

29 N m (2.9 kgf m, 21 lb ft) 30 N m (3.0 kgf m, 22 lb ft)
0.6 N m (0.06 kgf m, 0.44 lb ft)

New 8

15

13
6

New
7
New
16
New 14
9 2

10 New
11
LT 3 New
5 12 New
1
28 N m (2.8 kgf m, 21 lb ft)
LS
55 N m (5.5 kgf m, 41 lb ft) 1.3 N m (0.13 kgf m, 0.95 lb ft)
4 New
Order Job/Parts to remove Q’ty Remarks
1 Adjuster 1
2 Fork spring 1
3 Damper adjusting rod 1
4 Dust seal 1
5 Stopper ring 1
6 Inner tube 1
7 Outer tube 1
8 Piston metal 1
9 Protector guide 1
10 Slide metal 1
11 Washer 1
12 Oil seal 1
13 Adjuster knob 1
14 Base valve 1
15 Damper assembly 1
16 Upper spring seat 1

4-47
 FRONT FORK

EAM30055
• Hold the locknut and remove the adjuster.
REMOVING THE FRONT FORK LEGS
1. Use a maintenance stand to raise the front
ECA24520

NOTICE
wheel off the ground.
EWA13120 Do not remove the locknut as the damper rod
WARNING may go into the damper assembly and not be
Securely support the vehicle so that there is taken out.
no danger of it falling over.
Cap bolt ring wrench
TIP 90890-01501
Record the adjusting screw setting position be- Cap bolt ring wrench
fore loosening the adjuster and the base valve. YM-01501
2. Loosen:
• Upper bracket pinch bolt
• Damper assembly
• Lower bracket pinch bolt
EWA20350
1
WARNING
Before loosening the upper and lower brack-
et pinch bolts, support the front fork leg. 4
3
TIP
Before removing the front fork leg from the vehi- 2
cle, loosen the damper assembly “1” with the
cap bolt ring wrench “2”. 3. Remove:
• Dust seal “1”
Cap bolt ring wrench • Stopper ring “2”
90890-01501 (with a flat-head screwdriver)
Cap bolt ring wrench ECA14180

YM-01501 NOTICE
Do not scratch the inner tube.

1 1
2

3. Remove:
• Front fork leg 4. Remove:
• Inner tube “1”
EAM30056
a. Push in slowly “a” the inner tube just be-
DISASSEMBLING THE FRONT FORK LEGS
fore it bottoms out and then pull it back
1. Drain:
quickly “b”.
• Fork oil
b. Repeat this step until the inner tube can be
2. Remove:
pulled out from the outer tube.
• 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”.

4-48
 FRONT FORK

Inner tube bending limit

0.2 mm (0.01 in)

TIP
The bending value is shown by one half of the
dial gauge reading.
EWA13650

WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
5. Remove:
• Adjuster knob 2. Check:
• Base valve “1” • Outer tube
(from the damper assembly) Scratches/wear/damage  Replace.
3. Measure:
TIP
• Before loosening the damping force adjuster, • Fork spring free length “a”
record the setting position. Out of specification  Replace.
• Unless the damping force adjuster is fully loos- Fork spring free length limit
ened, correct damping characteristic cannot be 492.0 mm (19.37 in)
obtained after installation.
• Hold the damper assembly with the cap bolt
ring wrench “2” and use the cap bolt wrench “3”
to remove the base valve.

Cap bolt wrench

90890-01911
Cap bolt ring wrench
90890-01501
Cap bolt ring wrench
YM-01501

4. Check:
3 • Damper assembly “1”
2 Bend/damage  Replace.
• O-ring “2”
1 Wear/damage  Replace.
ECA14200

NOTICE
• The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.
EAM30057
• When disassembling and assembling the
CHECKING THE FRONT FORK LEGS
front fork leg, do not allow any foreign ma-
1. Check:
terial to enter the front fork.
• Inner tube surface
Scratches  Repair or replace.
Use #1000 grit wet sandpaper.
Damaged oil lock piece  Replace.
• Inner tube bends
Out of specification  Replace.
Use the dial gauge.

4-49
 FRONT FORK

1
1
2 2

5. Check: EAM30058

• Base valve “1” ASSEMBLING THE FRONT FORK LEGS

Wear/damage  Replace.
EWA13660

WARNING
Contamination  Clean.
• O-ring “2” • Make sure the oil levels in both front fork
Wear/damage  Replace. legs are equal.
• Base valve bushing • Uneven oil levels can result in poor han-
Wear/damage  Replace. dling and a loss of stability.
• Fork spring “3” TIP
Damage/fatigue  Replace the base valve. • When assembling the front fork leg, be sure to
• Bleed screw “4” replace the following parts:
Wear/damage  Replace. • Inner tube bushing
• Slide metal
• Oil seal
• Copper washer
2 • Before assembling the front fork leg, make
sure that all of the components are clean.
3 1. Stretch the damper assembly fully.
2. Fill:
4 • Damper assembly
2 1
Recommended oil
6. Check: Yamaha Suspension Oil S1
• Upper spring seat “1” Standard oil amount
(contacting surface “a”) 216 cm³ (7.30 US oz, 7.62 Imp.oz)
Wear/damage  Replace.
ECA24530

NOTICE
1 • Be sure to use the recommended oil. Other
a 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 material to enter the front fork.
3. After filling, pump the damper assembly “1”
slowly up and down (about 200 mm (7.9 in)
stroke) several times to bleed the damper as-
7. Check:
sembly of air.
• Adjuster “1”
• O-ring “2” TIP
Avoid excessive full stroke. A stroke of 200 mm
Wear/damage  Replace.
(7.9 in) or more will cause air to enter. In this
case, repeat the steps (1) to (3).

4-50
 FRONT FORK

4. Measure: 6. Install:
• Oil level (left and right) “a” • Base valve “1”
Out of specification  Regulate. (to the damper assembly “2”)
TIP
Standard oil level First bring the damper rod pressure to a maxi-
145–148 mm (5.71–5.83 in)
mum. Then install the base valve while releasing
From top of fully stretched
damper assembly. the damper rod pressure.

7. Check:
• Damper assembly
Not fully stretched  Repeat the steps (1) to
(7).
8. Tighten:
• Base valve “1”
• Screw (adjuster knob)
Base valve
28 N·m (2.8 kgf·m, 21 lb·ft)
T.

Screw (adjuster knob)

R.

0.6 N·m (0.06 kgf·m, 0.44 lb·ft)

5. Tighten:
• Locknut “1” TIP
TIP Hold the damper assembly with the cap bolt ring
Fully finger tighten the locknut onto the damper wrench “2” and use the cap bolt wrench “3” to
assembly. tighten the base valve.

Cap bolt wrench

90890-01911
Cap bolt ring wrench
90890-01501
Cap bolt ring wrench
YM-01501

4-51
 FRONT FORK

3 a
2
1

9. After filling, pump the damper assembly “1” 12.Check:

slowly up and down more than 10 times to • Damper assembly smooth movement
distribute the fork oil. Tightness/binding/rough spots  Repeat the
steps (1) to (12).

10.While protecting the damper assembly “1”

with a cloth and compressing fully, allow ex- 13.Install:
cessive oil to overflow on the base valve side. • Dust seal “1” New
ECA24540
• Stopper ring “2”
NOTICE • Oil seal “3” New
Take care not to damage the damper assem- • Washer “4”
bly. • Slide metal “5” New
(to the inner tube “6”)
ECA24550

NOTICE
Make sure that the numbered side of the oil
seal faces bottom side.
TIP
1 • Apply the lithium-soap-based grease on the
dust seal lip and oil seal lip.
• Apply the fork oil on the inner tube.
• When installing the oil seal, use vinyl seat “a”
with fork oil applied to protect the oil seal lip.
11.Allow the overflowing oil to escape at the hole
“a” in the damper assembly.
TIP
The overflow measures about 10 cm³ (0.34
US oz, 0.35 Imp.oz).

LS

4-52
 FRONT FORK

14.Install:
• Piston metal “1” New
TIP
Install the piston metal onto the slot on inner
tube.

17.Install:
• Oil seal “1” New
TIP
Using a fork seal driver “2”, press the oil seal in
until the stopper ring groove fully appears.
15.Install:
• Outer tube “1” Fork seal driver
90890-01502
(to the inner tube “2”)
Fork seal driver (48)
YM-A0948

16.Install:
• Slide metal “1” New
• Washer “2” 18.Install:
(to the outer tube) • Stopper ring “1”
TIP TIP
Press the slide metal into the outer tube with fork Fit the stopper ring correctly in the groove in the
seal driver “3”. outer tube.

Fork seal driver

90890-01502
Fork seal driver (48)
YM-A0948

4-53
 FRONT FORK

2
1 a

19.Install: 22.Install:
• Dust seal “1” New • Upper spring seat “1”
TIP • Fork spring “2”
Apply lithium-soap-based grease on the inner (to the damper assembly “3”)
tube. TIP
Install the upper spring seat with its larger dia.
end “a” facing the fork spring.

1 2

3 a
20.Check:
• Inner tube smooth movement
Tightness/binding/rough spots  Repeat the 23.Install:
steps (14) to (20). • Damper assembly “1”
(to the inner tube “2”)
ECA24560

NOTICE
Allow the damper assembly to slide slowly
down the inner tube until it contacts the bot-
tom of the inner tube. Be careful not to dam-
age the inner tube.

21.Measure:
1
• Distance “a”
Out of specification  Turn the locknut to
specification.
Distance “a”
16 mm (0.63 in) or more 2
Between the damper assembly
“1” bottom and locknut “2” bot- 24.Loosen:
tom. • Rebound damping force adjuster “1”
TIP
• Before loosening the damping force adjuster,
record the setting position.

4-54
 FRONT FORK

• Unless the damping force adjuster is fully loos- correct damping force cannot be obtained.
ened, correct damping characteristic cannot be
obtained after installation. 1

1
a

27.Tighten:
• Adjuster (damper assembly) “1”
25.Install:
• Damper adjusting rod “1” Adjuster (damper assembly)
29 N·m (2.9 kgf·m, 21 lb·ft)
• Copper washer “2” New

T.
R.
• Adjuster “3”
TIP
(to the damper assembly “4”) Hold the locknut “2” and tighten the adjuster.
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.

Cap bolt ring wrench

90890-01501
Cap bolt ring wrench
YM-01501
28.Install:
• Adjuster “1”
(to the inner tube)
Adjuster
55 N·m (5.5 kgf·m, 41 lb·ft)
T.

LOCTITE®
R.

1
26.Measure:
• Gap “a” between the adjuster “1” and the
locknut “2”
Out of specification  Retighten and readjust
the locknut.
Gap “a” between the adjuster and
the locknut
0.5–1.0 mm (0.02–0.04 in) 29.Fill:
• Front fork leg
TIP
If it is installed with a gap out of specification,

4-55
 FRONT FORK

Recommended oil
Yamaha Suspension Oil S1
Standard oil amount
270 cm³ (9.13 US oz, 9.52 Imp.oz)
Extent of adjustment 1
260–365 cm³ (8.79–12.34 US oz,
9.17–12.87 Imp.oz)
ECA24570

NOTICE
• Be sure to use the recommended oil. Other
oils may have an adverse effect on front
EAM30059

INSTALLING THE FRONT FORK LEGS

fork performance.
1. Install:
• When disassembling and assembling the
• Front fork “1”
front fork leg, do not allow any foreign ma-
TIP
terial to enter the front fork.
• Temporarily tighten the lower bracket pinch
bolts.
• Do not tighten the upper bracket pinch bolts
yet.

30.Install:
• Damper assembly “1”
(to the outer tube)
TIP 2. Tighten:
Temporarily tighten the damper assembly. • Damper assembly “1”
Damper assembly
30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.

TIP
Use the cap bolt ring wrench “2” to tighten the
damper assembly.

Cap bolt ring wrench

90890-01501
Cap bolt ring wrench
YM-01501
31.Install:
• Protector guide “1”

4-56
 FRONT FORK

• Front fork protector bolt “2”

1
Front fork protector bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.
R.
2
1

3. Adjust:
• Front fork top end “a”
Front fork top end (standard) “a” 2
7 mm (0.28 in)
6. Adjust:
• Rebound damping force
a TIP
Turn in the damping adjuster “1” finger-tight and
then turn out to the originally set position.

4. Tighten:
• Upper bracket pinch bolt “1”
Upper bracket pinch bolt
21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.

7. Adjust:
• Lower bracket pinch bolt “2”
• Compression damping force
Lower bracket pinch bolt TIP
21 N·m (2.1 kgf·m, 15 lb·ft) Turn in the damping adjuster “1” finger-tight and
T.
R.

then turn out to the originally set position.

EWA19320

WARNING
Tighten the lower bracket to specified
torque. If torqued too much, it may cause the 1
front fork to malfunction.

5. Install:
• Protector “1”

4-57
 STEERING HEAD

EAM20101

STEERING HEAD
Removing the lower bracket

LS 21 N m (2.1 kgf m, 15 lb ft)

a 145 N m (14.5 kgf m, 107 lb ft)

(4)

LS

1 (4)

21 N m (2.1 kgf m, 15 lb ft)

(4) 1st 38 N m (3.8 kgf m, 28 lb ft)

10 N m (1.0 kgf m, 7.4 lb ft) 2nd 7 N m (0.7 kgf m, 5.2 lb ft)

Order Job/Parts to remove Q’ty Remarks

Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-28.
Use a maintenance stand to raise the front
wheel off the ground.
Refer to “GENERAL CHASSIS” on page
Number plate 4-1.
Handlebar Refer to “HANDLEBAR” on page 4-39.
1 Front fender 1
2 Steering stem nut 1
3 Front fork leg 2 Refer to “FRONT FORK” on page 4-46.

4-58
 STEERING HEAD

Removing the lower bracket

LS 21 N m (2.1 kgf m, 15 lb ft)

a 145 N m (14.5 kgf m, 107 lb ft)

6
4

5
(4)
8 7

9
LS
10

(4)

21 N m (2.1 kgf m, 15 lb ft)

(4) 1st 38 N m (3.8 kgf m, 28 lb ft)

10 N m (1.0 kgf m, 7.4 lb ft) 2nd 7 N m (0.7 kgf m, 5.2 lb ft)

Order Job/Parts to remove Q’ty Remarks

4 Upper bracket 1
5 Steering ring nut 1
6 Lower bracket 1 [“a” = Approx. 20.0 mm (0.79 in)]
7 Bearing race cover 1
8 Upper bearing 1
9 Bearing race 2
10 Lower bearing 1

4-59
 STEERING HEAD

EAM30060 ECA14270

REMOVING THE LOWER BRACKET NOTICE

1. Use a maintenance stand to raise the front If the bearing race is not installed properly,
wheel off the ground. the steering head pipe could be damaged.
EWA13120

WARNING TIP
Securely support the vehicle so that there is Always replace the bearing and the bearing race
no danger of it falling over. as a set.
2. Remove:
• Ring nut “1”
TIP
Remove the ring nut with the steering nut
wrench “2”.

Steering nut wrench

90890-01403
Exhaust flange nut wrench
YU-A9472
EWA13730

WARNING
Securely support the lower bracket so that
there is no danger of it falling.

4. Check:
• Upper bracket
• Lower bracket
(along with the steering stem)
Bends/cracks/damage  Replace.
EAM30061

CHECKING THE STEERING HEAD EAM30062

1. Wash with kerosene: INSTALLING THE STEERING HEAD

• Bearing 1. Install:
• Bearing race • Lower bearing “1”
2. Check: TIP
• Bearing Apply the lithium-soap-based grease on the dust
• Bearing race seal lip and bearing inner circumference.
Damage/pitting  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.

4-60
 STEERING HEAD

2. Install:
• Bearing race
• Upper bearing “1”
• Bearing race cover “2”
TIP
Apply the lithium-soap-based grease on the
bearing and bearing race cover lip.

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.

3. Install:
• Lower bracket “1”
TIP
Apply the lithium-soap-based grease on the
bearing, the portion “a” and thread of the steer-
ing stem.

6. Install:
• Washer “1”
LS

a
LS

4. Install:
• Steering ring nut “1”
Steering ring nut 7. Install:
7 N·m (0.7 kgf·m, 5.2 lb·ft) • Front fork “1”
T.

• Upper bracket “2”

R.

TIP TIP
Install the steering ring nut with its stepped side • Temporarily tighten the lower bracket pinch
“a” facing downward. bolts.
Tighten the steering ring nut with a steering • Do not tighten the upper bracket pinch bolts
nut wrench “2”. yet.
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-28.

4-61
 STEERING HEAD

2 Upper bracket pinch bolt

21 N·m (2.1 kgf·m, 15 lb·ft)

T.
R.
1 • Lower bracket pinch bolt “2”
Lower bracket pinch bolt
21 N·m (2.1 kgf·m, 15 lb·ft)

T.
R.
EWA19330

WARNING
Tighten the lower bracket to specified
8. Install:
torque. If torqued too much, it may cause the
• Steering stem nut “1”
front fork to malfunction.
Steering stem nut
145 N·m (14.5 kgf·m, 107 lb·ft) 1
T.
R.

TIP
Apply the lithium-soap-based grease to the con-
tact surface of the steering stem nut when in- 2
stalling.

9. After tightening the nut, check the steering for

smooth movement. If not, adjust the steering
by loosening the steering ring nut little by lit-
tle.
10.Adjust:
• Front fork top end “a”
Front fork top end (standard) “a”
7 mm (0.28 in)

11.Tighten:
• Upper bracket pinch bolt “1”

4-62
 REAR SHOCK ABSORBER ASSEMBLY

EAM20102

REAR SHOCK ABSORBER ASSEMBLY

Removing the rear shock absorber assembly

2 M 3 56 N m (5.6 kgf m, 41 lb ft)

New

LS
LS
New
New

New
M

a a
4
a a
5 New
New
M
1
53 N m (5.3 kgf m, 39 lb ft) M

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS” on page
Seat 4-1.
Refer to “GENERAL CHASSIS” on page
Side cover (left/right) 4-1.
Refer to “GENERAL CHASSIS” on page
Shroud (left/right) 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

4-63
 REAR SHOCK ABSORBER ASSEMBLY

Removing the rear shock absorber assembly

M 56 N m (5.6 kgf m, 41 lb ft)

15 New

13 LS
LS
14 16 New
17
New 14
13 8

15
New
M

6
a a
10
11
12
a a 10
9 9 New
New
M

53 N m (5.3 kgf m, 39 lb ft) M

Order Job/Parts to remove Q’ty Remarks

6 Lower spring guide 1
7 Upper spring guide 1
8 Spring 1
9 Dust seal 2
10 Collar 2 [“a” = 0.3 mm (0.01 in) or more]
11 Bushing 1
12 Bearing 1
13 Collar 2
14 O-ring 2
15 Dust seal 2
16 Bushing 1
17 Stopper ring 1

4-64
 REAR SHOCK ABSORBER ASSEMBLY

Disassembling the relay arm

M 0 mm (0 in)
6
7
9
10
6
7 9 1
10
0 mm (0 in)
M

80 N m (8.0 kgf m, 59 lb ft) M

3
10
4 5 9
7

8
M 6
2
5

M M

4
0 mm (0 in) 0 mm (0 in)

Order Job/Parts to remove Q’ty Remarks

1 Relay arm 1
2 Connecting arm 1
3 Collar 1
4 Oil seal 2
5 Bearing 2
6 Washer 4
7 Oil seal 4
8 Collar 2
9 Washer 4
10 Bearing 4

4-65
 REAR SHOCK ABSORBER ASSEMBLY

EAM30063 EWA13120

HANDLING THE REAR SHOCK ABSORBER WARNING

EWA13740

WARNING
Securely support the vehicle so that there is
no danger of it falling over.
This rear shock absorber contains highly
compressed nitrogen gas. Before handling 2. Remove:
the rear shock absorber, read and make sure • Rear shock absorber assembly lower bolt “1”
you understand the following information. TIP
The manufacturer cannot be held responsi- While removing the rear shock absorber assem-
ble for property damage or personal injury bly lower bolt, hold the swingarm so that it does
that may result from improper handling of not drop down.
the rear shock absorber.
• Do not tamper or attempt to open the rear
shock absorber.
• Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion due
to excessive gas pressure.
• Do not deform or damage the rear shock
absorber in any way. Rear shock absorber
damage will result in poor damping perfor-
mance.
TIP
A break-in is required up to about 50 km of run-
ning.

EAM30064

DISPOSING OF A REAR SHOCK ABSORBER

Before disposing the rear shock absorber, be
sure to extract the nitrogen gas from valve “1”.
EWA19340

WARNING 1
• Wear protective glasses to prevent your
eyes from damage due to possible gas or 3. Remove:
metal chips scattered. • Rear shock absorber assembly upper bolt
• To dispose of a damaged or a worn-out rear • Rear shock absorber assembly
shock absorber, take the unit to your EAM30067

Yamaha dealer for this disposal procedure. CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:
• Rear shock absorber rod
Bends/damage  Replace the rear shock
absorber assembly.
• Rear shock absorber
1 Gas leaks/oil leaks  Replace the rear shock
absorber assembly.
• Spring
Damage/wear  Replace.
• Spring guide
EAM30065 Damage/wear  Replace.
REMOVING THE REAR SHOCK ABSORBER • Bearing
ASSEMBLY Damage/wear  Replace.
1. Use a maintenance stand to raise the rear • Bolt
wheel off the ground. Bends/damage/wear  Replace.

4-66
 REAR SHOCK ABSORBER ASSEMBLY

EAM30068

CHECKING THE CONNECTING ARM AND

a
RELAY ARM
1. Check:
• Connecting arm
• Relay arm
Damage/wear  Replace.
1 2
2. Check:
• Bearing 2 4
• Collar
Damage/pitting/scratches  Replace the 3
bearings and collars as a set. 3
3. Check: 1 1
• Oil seal
Damage/pitting  Replace. 3
3
EAM30069

INSTALLING THE RELAY ARM 2 5

1. Lubricate:
• Oil seal 2
• Bearing
• Washer
• Collar EAM30625

INSTALLING THE CONNECTING ARM

Recommended lubricant 1. Install:
Molybdenum disulfide grease • Bearing “1”
• Oil seal “2” New
2. Install:
(into the connecting arm “3”)
• Bearing “1”
• Collar “4”
• Washer “2”
• Oil seal “3” New Installed depth “a”
(into the relay arm “4”) 0 mm (0 in)
• Collar “5”
Installed depth “a”
0 mm (0 in)
1

4 3
2

4-67
 REAR SHOCK ABSORBER ASSEMBLY

EAM30070

INSTALLING THE REAR SHOCK

ABSORBER ASSEMBLY 2 3 4
1. Lubricate:
• Bearing (lower side) a
• Dust seal
1
Recommended lubricant a
Molybdenum disulfide grease
ECA24580

NOTICE
Do not apply the grease to the bearing outer 5. Lubricate:
race because it will wear the rear shock ab- • Connecting arm and frame bolt
sorber surface on which the bearing is press • Relay arm and connecting arm bolt
fitted. • Relay arm and swingarm bolt
(circumference and threaded portion)
2. Lubricate: • Rear shock absorber assembly upper bolt
• O-ring • Rear shock absorber assembly lower bolt
Recommended lubricant Recommended lubricant
Lithium-soap-based grease Molybdenum disulfide grease
3. Install: 6. Install:
• Bushing • Rear shock absorber assembly
• Stopper ring TIP
(into the rear shock absorber assembly (up- • When installing the rear shock absorber as-
per side)) sembly, lift up the swingarm.
TIP • Install the rear shock absorber assembly upper
• Install the bushing parallel until the stopper ring bolt, and connecting arm bolt (frame side) from
groove appears by pressing its outer race. the right.
• After installing the stopper ring, push back the • Install the rear shock absorber assembly lower
bushing until it contacts the stopper ring. bolts, connecting arm bolt (relay arm side), and
4. Install: relay arm bolt (swingarm side) from the left.
• Bearing “1” 7. Tighten:
• Bushing “2” • Rear shock absorber assembly upper nut
• Collar “3”
• Dust seal “4” New Rear shock absorber assembly
(into the rear shock absorber assembly (low- upper nut
T.

56 N·m (5.6 kgf·m, 41 lb·ft)

R.

er side))
TIP
Install the dust seals with their lips facing inward. • Connecting arm nut (frame side)
Connecting arm nut (frame side)
Installed depth “a” 80 N·m (8.0 kgf·m, 59 lb·ft)
0.3 mm (0.01 in) or more
T.
R.

• Connecting arm nut (relay arm side)

Connecting arm nut (relay arm
side)
T.

80 N·m (8.0 kgf·m, 59 lb·ft)

R.

• Relay arm nut (swingarm side)

Relay arm nut (swingarm side)
70 N·m (7.0 kgf·m, 52 lb·ft)
T.
R.

4-68
 REAR SHOCK ABSORBER ASSEMBLY

• Rear shock absorber assembly lower nut

Rear shock absorber assembly
lower nut
T.

53 N·m (5.3 kgf·m, 39 lb·ft)

R.

4-69
 SWINGARM

EAM20103

SWINGARM
Removing the swingarm

70 N m (7.0 kgf m, 52 lb ft)

7 N m (0.7 kgf m, 5.2 lb ft)

7 N m (0.7 kgf m, 5.2 lb ft)
0–0.5 mm
(0–0.02 in)

0–0.5 mm 0–0.5 mm
(0–0.02 in) (0–0.02 in) 0–0.5 mm
(0–0.02 in) 4.0 N m (0.40 kgf m, 3.0 lb ft)

6.5 mm 6.5 mm
(0.26 in) (0.26 in)
Order Job/Parts to remove Q’ty Remarks
Use a maintenance stand to raise the rear
wheel off the ground.
Brake hose holder Refer to “REAR BRAKE” on page 4-27.
Rear brake caliper Refer to “REAR BRAKE” on page 4-27.
Bolt (brake pedal) Refer to “ENGINE REMOVAL” on page 5-2.
Drive chain Refer to “CHAIN DRIVE” on page 4-74.

4-70
 SWINGARM

Removing the swingarm

70 N m (7.0 kgf m, 52 lb ft)

7 N m (0.7 kgf m, 5.2 lb ft)

7 N m (0.7 kgf m, 5.2 lb ft)
0–0.5 mm
(0–0.02 in)
7
1 2
3
6

4
6 6
3
5 2
6 1
4

0–0.5 mm 0–0.5 mm
(0–0.02 in) (0–0.02 in) 0–0.5 mm
(0–0.02 in) 4.0 N m (0.40 kgf m, 3.0 lb ft)

6.5 mm 6.5 mm
(0.26 in) (0.26 in)
Order Job/Parts to remove Q’ty Remarks
1 Collar 2
2 Oil seal 2
3 Thrust bearing 2
4 Bushing 2
5 Oil seal 2
6 Bearing 4
7 Drive chain support 1
8 Drive chain support cover 1

4-71
 SWINGARM

EAM30071
• Bearing
REMOVING THE SWINGARM 4. Check:
1. Use a maintenance stand to raise the rear • Oil seal
wheel off the ground. Damage  Replace.
EWA13120

WARNING • Bearing
• Bushing
Securely support the vehicle so that there is
Free play exists/unsmooth revolution/rust 
no danger of it falling over.
Replace bearing and bushing as a set.
2. Measure:
EAM30074
• Swingarm side play
INSTALLING THE SWINGARM
• Swingarm vertical movement 1. Lubricate:
a. Measure the tightening torque of the pivot
• Bearing
shaft nut.
• Thrust bearing
Pivot shaft nut • Collar
75 N·m (7.5 kgf·m, 55 lb·ft) • Bushing
T.

• Oil seal
R.

b. Check the swingarm side play “a” by mov- • Pivot shaft

ing the swingarm from side to side. If the
swingarm has side-to-side play, check the Recommended lubricant
Molybdenum disulfide grease
bushings, the bearings, and the collars.
c. Check the swingarm vertical movement 2. Install:
“b” by moving the swingarm up and down.
• Bearing “1”
If swingarm vertical movement is not
• Oil seal “2” New
smooth or if there is binding, check the (to the swingarm)
bushings, the bearings, and the collars.
• Collar “3”
Installed depth “a”
0–0.5 mm (0–0.02 in)
b Installed depth “b”
6.5 mm (0.26 in)

TIP
First install the outer and then the inner bearings
a to a specified depth from inside.

EAM30073

CHECKING THE SWINGARM

1. Check:
• Swingarm
Bends/cracks/damage  Replace.
2. Check:
• Pivot shaft
Roll the pivot shaft on a flat surface.
Bends  Replace.
EWA13770

WARNING
Do not attempt to straighten a bent pivot
shaft.
3. Wash with kerosene:
• Pivot shaft
• Bushing
• Collar

4-72
 SWINGARM

1
2 New 2 New New 2
1 1
a
2

3 3
b

a New 2 a a 2 New a

2 New 1 b b 1 New 2

5. Install:
3. Install: • Rear wheel
• Swingarm Refer to “REAR WHEEL” on page 4-11.
6. Adjust:
Pivot shaft nut
75 N·m (7.5 kgf·m, 55 lb·ft) • Drive chain slack
Refer to “DRIVE CHAIN SLACK” on page
T.
R.

TIP 3-27.
• Install the pivot shaft from the right. Drive chain slack (Maintenance
• Apply lithium-soap-based grease onto the Stand)
threads and contact surface of the pivot shaft 50.0–60.0 mm (1.97–2.36 in)
nut.
4. Install:
• Drive chain support “1”
• Drive chain support cover “2”
Drive chain support nut
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.

Bolt (drive chain support)

R.

7 N·m (0.7 kgf·m, 5.2 lb·ft)

TIP
• Align the projection “a” on the drive chain sup-
port with the part “b” of the drive chain support
cover, and then install.
• Align the slit “c” in the drive chain support with
swingarm stay as shown, and then install the
drive chain support.

4-73
 CHAIN DRIVE

EAM20104

CHAIN DRIVE
Removing the drive chain

5
2 4
3

7 N m (0.7 kgf m, 5.2 lb ft) 90 N m (9.0 kgf m, 66 lb ft)

Order Job/Parts to remove Q’ty Remarks

1 Drive chain 1
2 Drive sprocket cover 1
3 Drive sprocket nut 1
4 Lock washer 1
5 Drive sprocket 1

4-74
 CHAIN DRIVE

EAM30075

REMOVING THE DRIVE CHAIN

1. Stand the vehicle on a level surface.
EWA13120

WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Master link clip
• Master link “1”
• Master link plate “2”
• Drive chain “3” TIP
• When measuring a 15-link section of the drive
1 chain, make sure that the drive chain is taut.
• Perform this procedure 2–3 times, at a different
3
location each time.
2. Check:
• Drive chain
2
Stiffness  Clean, lubricate, or replace.

G089068

EAM30076

CHECKING THE DRIVE CHAIN

1. Measure:
• 15-link section of the drive chain
Out of specification  Replace the drive
chain.
15-link length limit
242.9 mm (9.56 in) 3. Clean:
• Drive chain
a. Measure the length “a” between the inner a. Wipe the drive chain with a clean cloth.
sides of the pins and the length “b” be- b. Put the drive chain in kerosene and re-
tween the outer sides of the pins on a 15- move any remaining dirt.
link section of the drive chain as shown in c. Remove the drive chain from the kerosene
the illustration. and completely dry it.

b. Calculate the length “c” of the 15-link sec- 4. Check:

tion of the drive chain using the following • Drive chain roller “1”
formula. Damage/wear  Replace the drive chain.
Drive chain 15-link section length “c” = • Drive chain side plate “2”
(length “a” between pin inner sides + Damage/wear  Replace the drive chain.
length “b” between pin outer sides)/2

4-75
 CHAIN DRIVE

2
G089069

5. Lubricate:
• Drive chain
EAM30077

CHECKING THE DRIVE SPROCKET

1. Check:
• Drive sprocket
More than 1/4 tooth wear “a”  Replace the
drive sprocket and the rear wheel sprocket as 3
a set. G089070

Bent tooth  Replace the drive sprocket and 2. Lubricate:

the rear wheel sprocket as a set. • Drive chain
3. Install:
• Drive sprocket
• Lock washer New
• Drive sprocket nut
Drive sprocket nut
90 N·m (9.0 kgf·m, 66 lb·ft)
T.

LOCTITE®
R.

ECA14300

NOTICE
b. Correct Never install a new drive chain onto worn
drive chain sprockets; this will dramatically
1. Drive chain roller
shorten the drive chain’s life.
2. Drive sprocket
EAM30078
TIP
CHECKING THE REAR WHEEL SPROCKET After the drive sprocket nut has been tightened
Refer to “CHECKING AND REPLACING THE to specification, firmly bend the lock washer tabs
REAR WHEEL SPROCKET” on page 4-13. “a” along the flat of the drive sprocket nut.

EAM30079

INSTALLING THE DRIVE CHAIN

1. Install:
• Master link “1”
• Master link plate “2”
• Master link clip “3” New
EWA20250

WARNING
a
When installing the joint clip, always keep
the direction as shown in the figure.
4. Adjust:
• Drive chain slack
Refer to “DRIVE CHAIN SLACK” on page

4-76
 CHAIN DRIVE

3-27.
Drive chain slack (Maintenance
Stand)
50.0–60.0 mm (1.97–2.36 in)
ECA24590

NOTICE
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep
the drive chain slack within the specified lim-
its.

4-77
 CHAIN DRIVE

4-78
 ENGINE

LUBRICATION SYSTEM CHART AND DIAGRAMS .......................................5-1

ENGINE OIL LUBRICATION CHART.........................................................5-1

ENGINE REMOVAL ..........................................................................................5-2

REMOVING THE ENGINE .........................................................................5-7
1
INSTALLING THE ENGINE ........................................................................5-7

2
INSTALLING THE EXHAUST PIPE AND MUFFLER .................................5-8

CAMSHAFT ....................................................................................................5-10
REMOVING THE CAMSHAFT .................................................................5-12
CHECKING THE CAMSHAFT ..................................................................5-12
CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET...........5-13
CHECKING THE TIMING CHAIN TENSIONERS.....................................5-14
CHECKING THE DECOMPRESSION SYSTEM ......................................5-14
3
INSTALLING THE CAMSHAFTS .............................................................5-14

CYLINDER HEAD...........................................................................................5-17
REMOVING THE CYLINDER HEAD ........................................................5-19
4
CHECKING THE TIMING CHAIN GUIDE (INTAKE SIDE).......................5-19
CHECKING THE CYLINDER HEAD ........................................................5-19
INSTALLING THE CYLINDER HEAD ......................................................5-19
5
VALVES AND VALVE SPRINGS ....................................................................5-22
REMOVING THE VALVES .......................................................................5-24
CHECKING THE VALVES AND VALVE GUIDES....................................5-25
CHECKING THE VALVE SEATS .............................................................5-26
CHECKING THE VALVE SPRINGS .........................................................5-27
6
CHECKING THE VALVE LIFTERS ..........................................................5-28
INSTALLING THE VALVES......................................................................5-28

CYLINDER AND PISTON ...............................................................................5-30

7
REMOVING THE PISTON........................................................................5-31
CHECKING THE CYLINDER AND PISTON.............................................5-31
CHECKING THE PISTON RINGS ............................................................5-32
CHECKING THE PISTON PIN .................................................................5-33
INSTALLING THE PISTON AND CYLINDER ..........................................5-33
8
9
GENERATOR..................................................................................................5-35
REMOVING THE GENERATOR ..............................................................5-38
CHECKING THE GENERATOR ...............................................................5-38
CHECKING THE WOODRUFF KEY ........................................................5-38
INSTALLING THE GENERATOR .............................................................5-38

ELECTRIC STARTER.....................................................................................5-40
CHECKING THE STARTER MOTOR ......................................................5-42
10
ASSEMBLING THE STARTER MOTOR ..................................................5-42
CLUTCH..........................................................................................................5-44
REMOVING THE CLUTCH ......................................................................5-48
CHECKING THE FRICTION PLATES ......................................................5-48
CHECKING THE CLUTCH PLATES ........................................................5-48
CHECKING THE CLUTCH SPRING ........................................................5-48
CHECKING THE COLLAR .......................................................................5-49
CHECKING THE PRESSURE PLATE .....................................................5-49
CHECKING THE PUSH LEVER SHAFT ..................................................5-49
CHECKING THE PUSH ROD...................................................................5-49
CHECKING THE PRIMARY DRIVE GEAR ..............................................5-49
CHECKING THE PRIMARY DRIVEN GEAR............................................5-49
ASSEMBLING THE CLUTCH RELEASE .................................................5-50
INSTALLING THE CLUTCH RELEASE ...................................................5-50
INSTALLING THE CLUTCH .....................................................................5-50

SHIFT SHAFT .................................................................................................5-54

REMOVING THE SEGMENT ...................................................................5-56
CHECKING THE SHIFT SHAFT ..............................................................5-56
CHECKING THE STOPPER LEVER........................................................5-56
INSTALLING THE SHIFT SHAFT ............................................................5-56

STARTER CLUTCH ........................................................................................5-59

REMOVING THE BALANCER GEAR ......................................................5-61
CHECKING THE STARTER CLUTCH .....................................................5-61
INSTALLING THE BALANCER GEAR .....................................................5-61

OIL PUMP .......................................................................................................5-63

CHECKING THE OIL PUMP ....................................................................5-64
ASSEMBLING THE OIL PUMP ................................................................5-64
INSTALLING THE OIL PUMP ..................................................................5-64

CRANKCASE .................................................................................................5-65
DISASSEMBLING THE CRANKCASE .....................................................5-69
CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE)...................5-69
CHECKING THE CRANKCASE ...............................................................5-69
CHECKING THE OIL STRAINER.............................................................5-70
ASSEMBLING THE CRANKCASE ...........................................................5-70

CRANKSHAFT AND BALANCER SHAFT.....................................................5-72

REMOVING THE CRANKSHAFT.............................................................5-73
CHECKING THE CRANKSHAFT .............................................................5-73
INSTALLING THE CRANKSHAFT ...........................................................5-74

TRANSMISSION.............................................................................................5-75
REMOVING THE TRANSMISSION..........................................................5-78
CHECKING THE SHIFT FORKS ..............................................................5-78
CHECKING THE SHIFT DRUM ASSEMBLY ...........................................5-78
CHECKING THE TRANSMISSION ..........................................................5-79
INSTALLING THE TRANSMISSION ........................................................5-79
 LUBRICATION SYSTEM CHART AND DIAGRAMS

EAM20185

LUBRICATION SYSTEM CHART AND DIAGRAMS

EAM30526

ENGINE OIL LUBRICATION CHART

1. Intake camshaft
2. Exhaust camshaft
3. Piston
4. Oil nozzle
5. Oil filter element
6. Relief valve
7. Oil feed pump
8. Scavenging pump
9. Oil strainer
10.Oil pan
11.Oil pan bolt
12.Oil tank bolt
13.Oil tank
14.Drive axle
15.Main axle

5-1
 ENGINE REMOVAL

EAM20105

ENGINE REMOVAL
Removing the exhaust pipe

1st 7 N m (0.7 kgf m, 5.2 lb ft)

20 N m (2.0 kgf m, 15 lb ft)
2nd 10 N m (1.0 kgf m, 7.4 lb ft)

10 N m (1.0 kgf m, 7.4 lb ft)

11

(8) LT
5

10
7
New 6

LT

(6)

8 N m (0.8 kgf m, 5.9 lb ft)

30 N m (3.0 kgf m, 22 lb ft)
8 New
2
30 N m (3.0 kgf m, 22 lb ft)

1
12 N m (1.2 kgf m, 8.9 lb ft)
3
New 9
4 FW
D
12 N m (1.2 kgf m, 8.9 lb ft)

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS” on page
Side cover (right) 4-1.
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 1
7 Exhaust pipe 1 protector 1
8 Gasket 1
9 Gasket 1
10 Silencer body 1
11 Silencer cap 1

5-2
 ENGINE REMOVAL

Removing the electronic parts

FW
D

7 N m (0.7 kgf m, 5.2 lb ft)

(2)

LT

(2)

3.5 N m (0.35 kgf m, 2.6 lb ft)

Order Job/Parts to remove Q’ty Remarks

Use a maintenance stand to raise the front
wheel off the ground.
Refer to “GENERAL CHASSIS” on page
Seat 4-1.
Refer to “GENERAL CHASSIS” on page
Side cover (left) 4-1.
Refer to “GENERAL CHASSIS” on page
Shroud (left) 4-1.

5-3
 ENGINE REMOVAL

Removing the electronic parts

7
4

FW
D

7 N m (0.7 kgf m, 5.2 lb ft)

(2)

3 2
6

5
LT

(2)

3.5 N m (0.35 kgf m, 2.6 lb ft)

Order Job/Parts to remove Q’ty Remarks

1 Rectifier/regulator 1
2 Stator coil assembly coupler 1 Disconnect.
3 Crankshaft position sensor coupler 1 Disconnect.
4 Coolant temperature sensor coupler 1
5 Gear position switch 1
6 Starter motor lead 1 Disconnect.
7 Engine ground lead terminal 1 Disconnect.

5-4
 ENGINE REMOVAL

Removing the engine

34 N m (3.4 kgf m, 25 lb ft)

75 N m (7.5 kgf m, 55 lb ft)

26 N m (2.6 kgf m, 19 lb ft)

7 N m (0.7 kgf m, 5.2 lb ft)

53 N m (5.3 kgf m, 39 lb ft)

45 N m (4.5 kgf m, 33 lb ft)

34 N m (3.4 kgf m, 25 lb ft)

55 N m (5.5 kgf m, 41 lb ft)

Order Job/Parts to remove Q’ty Remarks

Use a maintenance stand to raise the front
wheel off the ground.
Refer to “GENERAL CHASSIS” on page
Seat 4-1.
Refer to “GENERAL CHASSIS” on page
Side cover (left/right) 4-1.
Refer to “GENERAL CHASSIS” on page
Shroud (left/right) 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Exhaust pipe/Silencer Refer to “ENGINE REMOVAL” on page 5-2.
Air filter case Refer to “THROTTLE BODY” on page 7-4.
Throttle body Refer to “THROTTLE BODY” on page 7-4.
Clutch cable Refer to “CLUTCH” on page 5-44.
Refer to “SHIFT SHAFT” on page 5-54.
Shift pedal/Drive sprocket Refer to “CHAIN DRIVE” on page 4-74.

5-5
 ENGINE REMOVAL

Removing the engine

34 N m (3.4 kgf m, 25 lb ft)

75 N m (7.5 kgf m, 55 lb ft)

8
26 N m (2.6 kgf m, 19 lb ft)
7 N m (0.7 kgf m, 5.2 lb ft)

3
2
53 N m (5.3 kgf m, 39 lb ft)

45 N m (4.5 kgf m, 33 lb ft) 5

6
7
34 N m (3.4 kgf m, 25 lb ft)

55 N m (5.5 kgf m, 41 lb ft)

9
7

Order Job/Parts to remove Q’ty Remarks

Disconnect.
Starter motor Refer to “ELECTRIC STARTER” on page
5-40.
Disconnect.
Spark plug cap Refer to “THROTTLE BODY” on page 7-4.
Disconnect.
Radiator hose 1/3/4 Refer to “RADIATOR” on page 6-2.
1 Engine guard 1
2 Brake pedal 1
3 Spring 1
4 Cylinder head breather hose 1
5 Upper engine bracket (right) 1
6 Upper engine bracket (left) 1
7 Lower engine bracket 4
8 Pivot shaft 1
9 Engine 1

5-6
 ENGINE REMOVAL

EAM30161

REMOVING THE ENGINE

1. Remove:
• Exhaust pipe 2
TIP 1
Put the exhaust pipe 2 into the state as shown by
moving this, and then remove it.

2. Remove:
• Pivot shaft “1”
TIP
If the pivot shaft is pulled all the way out, the
swingarm will come loose. If possible, insert a EAM30164

shaft of similar diameter into the other side of the INSTALLING THE ENGINE
swingarm to support it. 1. Install:
• Engine “1”
(from the right side)
• Pivot shaft “2”
1
Pivot shaft nut
75 N·m (7.5 kgf·m, 55 lb·ft)
T.
R.

• Engine mounting bolt (lower side) “3”

Engine mounting bolt (lower side)
53 N·m (5.3 kgf·m, 39 lb·ft)
T.
R.

3. Remove: • Lower engine bracket “4”

• Engine “1” • Engine bracket bolt (front side) “5”
(from the right side)
Engine bracket bolt (front side)
TIP 34 N·m (3.4 kgf·m, 25 lb·ft)
• Make sure that the couplers, the hoses, and
T.
R.

the cables are disconnected. • Engine mounting bolt (front side) “6”
• Lift up the engine, and remove this from its low-
er part toward the right of the chassis. Engine mounting bolt (front side)
55 N·m (5.5 kgf·m, 41 lb·ft)
T.
R.

• Upper engine bracket “7”

• Engine bracket bolt (upper side) “8”
Engine bracket bolt (upper side)
34 N·m (3.4 kgf·m, 25 lb·ft)
T.
R.

• Engine mounting bolt (upper side) “9”

5-7
 ENGINE REMOVAL

Engine mounting bolt (upper

T. side) 2
45 N·m (4.5 kgf·m, 33 lb·ft)
R.

1
TIP
• Apply molybdenum disulfide grease to the piv-
ot shaft.
• Apply lithium-soap-based grease onto the
threads and contact surface of the pivot shaft
nut.
2. Install:
• Exhaust pipe 2 clamp
2 8
• Exhaust pipe 2 “1”
• Exhaust pipe bracket bolt “2”

M 8
1

2
9

4 7
3
7
TIP
9 Make sure that the clamp “3” does not ride on
the projection “a” on the exhaust pipe “4” or si-
lencer “5”. Be sure to insert the projection “b” into
6
the slot in the exhaust pipe (or silencer).
1
4 5 A B
EAM30167
4 3 5 3
a a
INSTALLING THE EXHAUST PIPE AND
MUFFLER
1. Install:
• Gasket New
• Exhaust pipe 1 “1”
• Exhaust pipe nut “2”
b b
Exhaust pipe nut
10 N·m (1.0 kgf·m, 7.4 lb·ft) A. Exhaust pipe 1 and exhaust pipe 2
T.
R.

B. Exhaust pipe 2 and silencer

TIP
3. Install:
First temporarily tighten all nuts to 7 N·m (0.7
• Silencer clamp
kgf·m, 5.2 lb·ft). Then retighten them to 10 N·m
• Silencer “1”
(1.0 kgf·m, 7.4 lb·ft).
• Silencer bolt “2”
Silencer bolt
30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.

5-8
 ENGINE REMOVAL

4. Tighten:
• Exhaust pipe bracket bolt
Exhaust pipe bracket bolt
20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.

• Exhaust pipe 2 clamp

Exhaust pipe clamp bolt (exhaust
pipe 2 clamp)
T.

12 N·m (1.2 kgf·m, 8.9 lb·ft)

R.

• Silencer clamp
Exhaust pipe clamp bolt (silencer
clamp)
T.

12 N·m (1.2 kgf·m, 8.9 lb·ft)

R.

TIP
Tighten while checking that their front and rear
joints are inserted in position.

5-9
 CAMSHAFT

EAM20106

CAMSHAFT
Removing the cylinder head cover

10 N m (1.0 kgf m, 7.4 lb ft) 13 N m (1.3 kgf m, 9.6 lb ft)

2
10 N m (1.0 kgf m, 7.4 lb ft)

4
1 5

3
6

0–1.0 mm
(0–0.04 in) 7

* Three bond No. 1541C®

Order Job/Parts to remove Q’ty Remarks
Refer to “GENERAL CHASSIS” on page
Seat 4-1.
Refer to “GENERAL CHASSIS” on page
Side cover (left/right) 4-1.
Refer to “GENERAL CHASSIS” on page
Shroud (left/right) 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
1 Cylinder head breather hose 1
2 Spark plug 1
3 Cylinder head cover 1
4 Cylinder head cover breather plate 1
5 Gasket 1
6 Timing chain guide (top side) 1
7 Cylinder head cover gasket 1
8 Gasket 1

5-10
 CAMSHAFT

Removing the camshaft

(4) 10 N m (1.0 kgf m, 7.4 lb ft)

(4)

5 7

5 3.0 N m (0.30 kgf m, 2.2 lb ft)

6 N m (0.6 kgf m, 4.4 lb ft)

8
6 3

4
10 N m (1.0 kgf m, 7.4 lb ft)

6 N m (0.6 kgf m, 4.4 lb ft)

1
10 N m (1.0 kgf m, 7.4 lb ft)

Order Job/Parts to remove Q’ty Remarks

1 Timing mark accessing screw 1
2 Crankshaft end accessing screw 1
3 Timing chain tensioner cap bolt 1
4 Timing chain tensioner 1
5 Camshaft cap 2
6 Intake camshaft 1
7 Exhaust camshaft 1
8 Oil nozzle 1

5-11
 CAMSHAFT

EAM30080

REMOVING THE CAMSHAFT 2

1. Remove:
• Timing mark accessing screw “1”
• Crankshaft end accessing screw “2”

4. Remove:
1 • Camshaft cap bolt “1”
• Camshaft cap “2”
2
TIP
Remove the camshaft cap bolts in a crisscross
2. Align: pattern, working from the outside in.
• Alignment mark
a. Turn the crankshaft counterclockwise with ECA24610

NOTICE
a wrench.
b. Align the top dead center (TDC) mark “a” The bolts (camshaft cap) must be removed
on the generator rotor with the alignment evenly to prevent damage to the cylinder
mark “b” on the crankcase cover. head, camshafts or camshaft caps.

b
1

a 2

TIP 5. Remove:
Check that the alignment marks “c” on the cam- • Exhaust camshaft “1”
shaft sprockets are aligned with the edge of the • Intake camshaft “2”
camshaft cap surfaces “d”. TIP
Attach a wire “3” to the timing chain to prevent it
from falling into the crankcase.
c c

2 1

d d

3
3. Remove:
• Timing chain tensioner cap bolt “1” EAM30081

• Timing chain tensioner “2” CHECKING THE CAMSHAFT

• Gasket 1. Check:
• Camshaft lobe
Blue discoloration/pitting/scratches  Re-

5-12
 CAMSHAFT

place the camshaft. d. Remove the camshaft caps and then mea-
2. Measure: sure the width of the Plastigauge® “1”.
• Camshaft lobe dimensions “A”
Out of specification  Replace the camshaft. 1
Camshaft lobe dimensions
Lobe height limit (Intake)
38.030 mm (1.4972 in)
Lobe height limit (Exhaust)
34.170 mm (1.3453 in)

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 journal diameter
22.002–22.015 mm (0.8662–
0.8667 in)
3. Measure:
• Camshaft-journal-to-camshaft-cap clearance
Out of specification  Measure the camshaft
journal diameter.
Camshaft-journal-to-camshaft-
cap clearance
0.028–0.062 mm (0.0011–0.0024
in)

a. Install the camshaft into the cylinder head.

b. Position a strip of Plastigauge® “1” onto
the camshaft journal as shown. EAM30082

CHECKING THE TIMING CHAIN AND

CAMSHAFT SPROCKET
1 1. Check:
• Timing chain “1”
Damage/stiffness  Replace the timing
chain and camshaft as a set.
2. Check:
• Camshaft sprocket
More than 1/4 tooth wear “a”  Replace the
camshaft and the timing chain as a set.
c. Install the dowel pins and the camshaft
caps.
TIP
• Tighten the camshaft cap bolts in a crisscross
pattern from innermost to outer caps.
• Do not turn the camshaft when measuring the
camshaft journal-to-camshaft cap clearance.

Camshaft cap bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

5-13
 CAMSHAFT

EAM30084

CHECKING THE DECOMPRESSION SYSTEM

1. Check:
a 1 • Decompression system
a. Check that the decompressor cam “1”
b 2 moves smoothly.
b. Check that the decompressor lever pin “2”
projects from the camshaft.

a. 1/4 tooth
b. Correct
1
1. Timing chain roller
2. Camshaft sprocket 2

EAM30083

CHECKING THE TIMING CHAIN

TENSIONERS
EAM30085
1. Check:
INSTALLING THE CAMSHAFTS
• Timing chain tensioner
1. Install:
Crack/damage  Replace.
• Exhaust camshaft “1”
a. While pressing the tensioner rod lightly
• Intake camshaft “2”
with your fingers, use a thin screwdriver
“1” to wind the tensioner rod up fully clock- 2 1
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. M M

a. Turn the crankshaft counterclockwise with

a wrench.
TIP
• Apply molybdenum disulfide oil to the cam-
shafts.
• Apply the engine oil on the decompression
system.
b. Align the top dead center (TDC) mark “a”
on the generator rotor with the alignment
mark “b” on the crankcase cover.

5-14
 CAMSHAFT

c. Fit the timing chain “3” onto both camshaft with your fingers, use a thin screwdriver to
sprockets and install the camshafts on the wind the tensioner rod up fully clockwise.
cylinder head.
TIP
Check that the alignment marks “c” on the cam-
shaft sprockets are aligned with the edge of the
camshaft cap surfaces “d”.

c 3 c

d d b. With the tensioner rod fully wound and the

chain tensioner “UP” mark “a” facing up-
ward, install the gasket “1”, the timing
chain tensioner “2”, and the gasket “3”,
and tighten the bolts “4”.
ECA24620
Timing chain tensioner bolt
NOTICE 10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.
Do not turn the crankshaft during the cam-
R.
shaft installation. Damage or improper valve
timing will result. a 3
d. Install the camshaft caps and the cam-
shaft cap bolts.
4
Camshaft cap bolt 1
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

4
2
TIP
• Apply the engine oil to the threads and contact
surfaces. c. Release the screwdriver, check that the
• Tighten the bolts to the specified torque in two tensioner rod comes out smoothly, and
or three steps in the proper tightening se- tighten the gasket “5” and the cap bolt “6”.
quence as shown.
ECA24630
Timing chain tensioner cap bolt
NOTICE 6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.

The bolts (camshaft cap) must be tightened

evenly, or damage to the cylinder head, cam-
shaft caps, and camshaft will result.
5
8 7 6 5

3. Turn:
1
2 3 4 • Crankshaft
Counterclockwise several turns.
2. Install: 4. Check:
• Timing chain tensioner • Top dead center (TDC) mark on the genera-
a. While pressing the tensioner rod lightly tor rotor

5-15
 CAMSHAFT

Align with the crankcase alignment mark.

• Camshaft match marks
Align with the cylinder head surface.
Out of alignment  Adjust.
5. Install:
• Timing chain guide (top side) “1”
• Cylinder head cover gasket “2” New
• Gasket (spark plug hole) “3” New
• Cylinder head cover “4”
• Bolt (cylinder head cover) “5”
Bolt (cylinder head cover)
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

TIP
Before installation, apply the Three bond No.
1541C® to the cylinder head cover gasket.

5
5

1
4
2
3

6. Install:
• Cylinder head breather hose
• Spark plug
Spark plug
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.

5-16
 CYLINDER HEAD

EAM20107

CYLINDER HEAD
Removing the cylinder head

7 N m (0.7 kgf m, 5.2 lb ft) 1st 36 N m (3.6 kgf m, 27 lb ft)

2nd 18 N m (1.8 kgf m, 13 lb ft)
3rd 90˚
4th 60˚

10 N m (1.0 kgf m, 7.4 lb ft)

12 N m (1.2 kgf m, 8.9 lb ft)

4 1
M

2 3

x4

7 N m (0.7 kgf m, 5.2 lb ft)

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS” on page
Seat 4-1.
Refer to “GENERAL CHASSIS” on page
Side cover (left/right) 4-1.
Refer to “GENERAL CHASSIS” on page
Shroud (left/right) 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Exhaust pipe/Silencer Refer to “ENGINE REMOVAL” on page 5-2.
Radiator hose Disconnect.
Coolant temperature sensor coupler Disconnect.
Throttle body Refer to “THROTTLE BODY” on page 7-4.
Camshaft Refer to “CAMSHAFT” on page 5-10.
Upper engine bracket Refer to “ENGINE REMOVAL” on page 5-2.

5-17
 CYLINDER HEAD

Removing the cylinder head

7 N m (0.7 kgf m, 5.2 lb ft) 1st 36 N m (3.6 kgf m, 27 lb ft)

2 2nd 18 N m (1.8 kgf m, 13 lb ft)
3rd 90˚
4th 60˚
2 10 N m (1.0 kgf m, 7.4 lb ft)
6
12 N m (1.2 kgf m, 8.9 lb ft)

1
6
4 1
M

3
2 3

4
M

x4 7

7 N m (0.7 kgf m, 5.2 lb ft)

Order Job/Parts to remove Q’ty Remarks

1 Bolt (cylinder head) 2
2 Bolt (cylinder head) 4
3 Cylinder head 1
4 Timing chain guide (intake side) 1
5 Cylinder head gasket 1
6 Oil passage plug 2
7 Cylinder head stud bolt 3 Tighten until they contact the bottom.

5-18
 CYLINDER HEAD

EAM30086
Refer to “CHECKING THE VALVE SEATS” on
REMOVING THE CYLINDER HEAD page 5-26.
1. Remove:
• Cylinder head bolt • Cylinder head coolant passages
TIP Mineral deposits/rust  Eliminate.
• Loosen the bolts in the proper sequence as 3. Measure:
shown. • Cylinder head warpage
• Loosen each bolt 1/2 of a turn at a time. After Out of specification  Resurface the cylinder
fully loosening all the bolts, remove them. head.
• M6  45 mm (1.77 in): [1]–[2] Warpage limit
• M10  129 mm (5.08 in): [3], [4], [5], [6] 0.05 mm (0.0020 in)

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 sandpaper on a
FWD surface plate, and resurface the cylinder
head using a figure-eight sanding pattern.
x2 x4
TIP
To ensure an even surface, turn the cylinder
head several times.

4 5
1

2
33
6

EAM30087

CHECKING THE TIMING CHAIN GUIDE

EAM30089
(INTAKE SIDE) INSTALLING THE CYLINDER HEAD
1. Check: 1. Install:
• Timing chain guide (intake side) • Timing chain guide (intake side) “1”
Damage/wear  Replace. • Dowel pin “2”
EAM30088 • Cylinder head gasket “3” New
CHECKING THE CYLINDER HEAD • Cylinder head “4”
1. Eliminate: TIP
• Combustion chamber carbon deposits • While pulling up the timing chain, install the
TIP timing chain guide (intake side) and the cylin-
Use a rounded scraper, not a sharp instrument, der head.
in order not to damage or scratch the spark plug • Install the cylinder head gasket as shown in the
bore threads. illustration.
2. Check:
• Cylinder head
Damage/scratches  Replace.
TIP
When replacing the cylinder head, replace also
the valve.

5-19
 CYLINDER HEAD

4
2
3

2
1 FWD
x2 x4

2. Install:
• Washer “1”
• Bolt “2”
• Bolt “3” 3
2
2 5
2
3
6
M 1 4
1

f. Remove the bolt [1].

TIP
Remove the bolt [1] only without loosening any
TIP other bolt.
Tighten the bolts using the following procedure. g. Again apply molybdenum disulfide grease
a. Wash the threads and contact surfaces of to the thread and contact surface of the
the bolts, the contact surfaces of the bolts and to both contact surface of the
washers, the contact surface of the cylin- washer.
der head, and the threads of the crank- h. Retighten the bolt.
case.
Bolt [1]
b. Apply molybdenum disulfide grease to the 2nd
threads and contact surfaces of the bolts
T.

18 N·m (1.8 kgf·m, 13 lb·ft)

R.

and to both contact surfaces of the wash-

ers. i. Put a mark on the corner “1” of the bolt
c. Install the washers and the bolts. (cylinder head) and the cylinder head “2”
d. Install the bolts in the tightening sequence as shown.
shown until the bolt and washer are lightly
seated against the cylinder head.
e. Tighten the bolts to the specified torque in 1
two or three steps in the proper tightening
sequence as shown.
Bolt [1]–[4]
1st
T.

36 N·m (3.6 kgf·m, 27 lb·ft)

R.

j. Retighten the bolt (cylinder head) in the

proper tightening sequence.

5-20
 CYLINDER HEAD

90˚

Bolt [1]
3rd
T.

Specified angle
R.

90

k. Perform the same procedure with the bolts

[2]–[4] one by one and applying the tight-
ening sequence (f)–(j) as shown for the
bolt [1].
TIP
Do not loosen any other bolt until one bolt is
completely tightened.

Bolt [2]–[4]
2nd
T.

18 N·m (1.8 kgf·m, 13 lb·ft)

R.

3rd
Specified angle
90

l. Retighten the bolt (cylinder head) in the

proper tightening sequence.

Final
Specified angle
T.

60
R.

m. Tighten the bolts to the specified torque.

Bolt [5], [6]
12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.

LOCTITE®
R.

5-21
 VALVES AND VALVE SPRINGS

EAM20108

VALVES AND VALVE SPRINGS

Removing the valves and valve springs
1
1
2
2
3 3
3
4
3 4
5
5

(2) (2)

13.5–13.9 mm 12.2–12.6 mm
(0.53–0.55 in) (0.48–0.50 in)

Order Job/Parts to remove Q’ty Remarks

Cylinder head Refer to “CYLINDER HEAD” on page 5-17.
1 Valve lifter 4
2 Adjusting pad 4
3 Valve cotter 8
4 Valve spring retainer 4
5 Valve spring 4

5-22
 VALVES AND VALVE SPRINGS

Removing the valves and valve springs

6
7
7 6
10
(2) (2) 11

13.5–13.9 mm 12.2–12.6 mm
(0.53–0.55 in) (0.48–0.50 in)

Order Job/Parts to remove Q’ty Remarks

6 Valve stem seal 4
7 Valve spring seat 4
8 Intake valve 2
9 Exhaust valve 2
10 Intake valve guide 2
11 Exhaust valve guide 2

5-23
 VALVES AND VALVE SPRINGS

EAM30090
TIP
REMOVING THE VALVES Check that there are no kerosene leaks from the
TIP valve seat “1”.
Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure that the valves are properly sealed.
1. Remove:
• Valve lifter “1”
• Adjusting pad “2” 1
TIP a
• Place a cloth in the timing chain space to pre- a
vent adjusting pads from falling into the crank-
case.
• Make a note of the positions of valve lifters and
3. Remove:
adjusting pads so that they can be reinstalled
• Valve cotter “1”
in their original places.
TIP
Remove the valve cotters by compressing the
Valve lapper (ø14) valve spring with the valve spring compressor
90890-04101
“2” and the valve spring compressor attachment
Valve lapper (ø14)
YM-A8998 “3”.

Valve spring compressor

2 1 90890-04200
Valve spring compressor
YM-04019
Valve spring compressor attach-
ment
90890-04108
Valve spring compressor adapter
22 mm
YM-04108

4. Remove:
2. Check:
• Valve spring retainer “1”
• Valve sealing
• Valve spring “2”
Leakage at the valve seat  Check the valve
• Valve “3”
face, the valve seat, and the valve seat con-
• Valve stem seal “4”
tact width.
• Valve spring seat “5”
Refer to “CHECKING THE VALVE SEATS”
on page 5-26. TIP
Identify the position of each part very carefully so
a. Pour a clean solvent “a” into the intake and
that it can be reinstalled in its original place.
exhaust ports.
b. Check that the valves are properly sealed.

5-24
 VALVES AND VALVE SPRINGS

head to 100 °C (212 °F) in an oven.

1 a. Remove the valve guide with the valve

2 guide remover “1”.
4

EAM30091
1
CHECKING THE VALVES AND VALVE
GUIDES
1. Measure:
• Valve-stem-to-valve-guide clearance b. Install the new valve guide with the valve
Out of specification  Replace the valve guide installer “1” and the valve guide re-
guide. mover “2”.

Valve-stem-to-valve-guide clearance = Valve guide installation height “a”

Valve guide inside diameter “a” - Intake
Valve stem diameter “b” 13.5–13.9 mm (0.53–0.55 in)
Exhaust
Valve-stem-to-valve-guide clear- 12.2–12.6 mm (0.48–0.50 in)
ance limit (intake)
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
ance limit (exhaust) 2
0.100 mm (0.0039 in)
1

c. After installing the valve guide, expand the

hole in the valve guide with the valve guide
reamer “3” to obtain the proper valve-
stem-to-valve-guide clearance.

TIP
2. Replace: After replacing the valve guide, reface the valve
• Valve guide seat.
TIP
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder

5-25
 VALVES AND VALVE SPRINGS

3. Measure:
Valve guide remover & installer • Valve seat contact width “a”
set (ø5.5)
Out of specification  Replace the cylinder
90890-04016
Valve guide remover (5.5 mm) head.
YM-01122 Valve seat contact width limit (in-
Valve guide installer (ø5.5) take)
90890-04015 1.5 mm (0.06 in)
Valve guide installer (5.5 mm) Valve seat contact width limit (ex-
YM-04015 haust)
Valve guide reamer (5.5 mm) 1.5 mm (0.06 in)
90890-01196
Valve guide reamer (5.5 mm)
YM-01196

3. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
4. Check:
• Valve face
Pitting/wear  Grind the valve face.
• Valve stem end
Mushroom shape or diameter larger than the
body of the valve stem  Replace the valve. a. Apply blue layout fluid “b” onto the valve
5. Measure: face.
• Valve stem runout
Out of specification  Replace the valve.
TIP
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always re-
place the valve stem seal.

Valve stem runout

0.020 mm (0.0008 in)
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide
and onto the valve seat to make a clear
impression.
d. Measure the valve seat contact width “c”.
TIP
Where the valve seat and the valve face are in
contact with each other, the blueing will have
been removed.

EAM30092

CHECKING THE VALVE SEATS c

1. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
2. Check:
• Valve seat
Pitting/wear  Replace the cylinder head.

5-26
 VALVES AND VALVE SPRINGS

4. Lap:
• Valve face
• Valve seat
ECA24640

NOTICE
This model uses titanium intake and exhaust
valves.
Do not use the valves used for lapping the
valve seat. Always replace the valves used
for lapping with new ones.
TIP h. Install the valve into the cylinder head.
• When replacing the cylinder head, replace also i. Press the valve through the valve guide
the valves with new ones without them. and onto the valve seat to make a clear
• When replacing the valves or the valve guides, impression.
use new valves to lap the valve seats, and then j. Measure the valve seat contact width “c”
replace them with new valves. again. If the valve seat contact width is out
a. Apply a coarse lapping compound “a” to of specification, reface and lap the valve
the valve face. seat.
ECA13790

NOTICE
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.

EAM30093

CHECKING THE VALVE SPRINGS

1. Measure:
• Valve spring free length “a”
Out of specification  Replace the valve
spring.
b. Apply molybdenum disulfide oil onto the
valve stem. Free length limit (intake)
c. Install the valve into the cylinder head. 36.65 mm (1.44 in)
d. Turn the valve until the valve face and the Free length limit (exhaust)
valve seat are evenly polished, then clean 37.34 mm (1.47 in)
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, and repeat the above steps.
f. After every lapping step, be sure to clean
off all of the lapping compound from the
valve face and the valve seat.
g. Apply blue layout fluid “b” onto the valve
face.

5-27
 VALVES AND VALVE SPRINGS

EAM30094
(to the cylinder head)
CHECKING THE VALVE LIFTERS
TIP
1. Check: • Make sure each valve is installed in its original
• Valve lifter place.
Damage/scratches  Replace the valve lift- • Install the valve springs with the larger pitch “a”
ers and cylinder head. facing up.

EAM30095

INSTALLING THE VALVES b. Smaller pitch

1. Clean:
• Valve stem end 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”.

Valve spring compressor

90890-04200
Valve spring compressor
YM-04019
2. Lubricate: Valve spring compressor attach-
• Valve stem “1” ment
• Valve stem seal “2” 90890-04108
Valve spring compressor adapter
Recommended lubricant 22 mm
Molybdenum disulfide oil YM-04108

3. Install: 5. To fasten the valve cotters onto the valve

• Spring seat “1” stem, lightly tap the valve tip with a soft-face
• Valve stem seal “2” New hammer.
ECA13800
• Valve “3” NOTICE
• Valve spring “4”
Hitting the valve tip with excessive force
• Valve spring retainer “5”

5-28
 VALVES AND VALVE SPRINGS

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.

5-29
 CYLINDER AND PISTON

EAM20109

CYLINDER AND PISTON

Removing the cylinder and piston

10 N m (1.0 kgf m, 7.4 lb ft)

E 1

E
7
4
6
5
E 3 4

Order Job/Parts to remove Q’ty Remarks

Cylinder head Refer to “CYLINDER HEAD” on page 5-17.
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

5-30
 CYLINDER AND PISTON

EAM30096
the piston ring over the piston crown.
REMOVING THE PISTON
1. Remove:
• Piston pin clip “1”
• Piston pin “2”
• Piston “3”
ECA13810

NOTICE
Do not use a hammer to drive the piston pin
out.
TIP
• Before removing the piston pin clip, cover the
crankcase opening with a cloth to prevent the EAM30097

piston pin clip from falling into the crankcase. CHECKING THE CYLINDER AND PISTON
• Before removing the piston pin, deburr the pis- 1. Check:
ton pin clip’s groove and the piston pin’s bore • Piston wall (Sidewall)
area. If the piston pin groove is deburred and • Cylinder wall
the piston pin is still difficult to remove, use the Vertical scratches  Replace the cylinder,
piston pin puller set “4”. and replace the piston and piston rings as a
set.
Piston pin puller set 2. Measure:
90890-01304 • Piston-to-cylinder clearance
Piston pin puller a. Measure the cylinder bore “C” with the cyl-
YU-01304 inder bore gauge.
TIP
Measure the cylinder bore “C” by taking side-to-
side and front-to-back measurements of the cyl-
inder.

Bore
97.000–97.010 mm (3.8189–
3.8193 in)
Wear limit
97.060 mm (3.8213 in)
1
“C” = maximum of D1, D2, D3, D4, D5, D6

2. Remove:
• Top ring
b. If out of specification, rebore or replace the
• 2nd ring
cylinder, and replace the piston and the
• Oil ring
piston rings as a set.
TIP
c. Measure the piston outside diameter “a” at
When removing a piston ring, open the end gap
the measuring point (from piston skirt bot-
with your fingers and lift the opposite end gap of
tom) “b” with the micrometer.

5-31
 CYLINDER AND PISTON

Diameter Top ring

96.955–96.970 mm (3.8171– Ring side clearance
3.8177 in) 0.015–0.065 mm (0.0006–0.0026
Measuring point (from piston in)
skirt bottom) Side clearance limit
9.0 mm (0.35 in) 0.120 mm (0.0047 in)
2nd ring
Ring side clearance
0.020–0.060 mm (0.0008–0.0024
in)
b Side clearance limit
a 0.100 mm (0.0039 in)

d. If out of specification, replace the cylinder,

the piston, and the piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” - Piston diameter 2. Install:
• Piston ring
Piston-to-cylinder clearance (into the cylinder)
0.010–0.045 mm (0.0004–0.0018 TIP
in) Use the piston crown to level the piston ring near
Limit bottom of cylinder “a”, where cylinder wear is
0.15 mm (0.006 in) lowest.
f. If out of specification, replace the cylinder, 3. Measure:
the piston, and the piston rings as a set. • Piston ring end gap
EAM30098
Out of specification  Replace the piston
CHECKING THE PISTON RINGS ring.
1. Measure: TIP
• Piston ring side clearance The oil ring expander spacer’s end gap cannot
Out of specification  Replace the piston be measured. If the oil ring rail’s gap is exces-
and piston rings as a set. sive, replace the oil ring as a set.
TIP
Before measuring the piston ring side clearance, Top ring
eliminate any carbon deposits from the piston End gap limit
ring grooves and piston rings. 0.55 mm (0.0217 in)
2nd ring
End gap limit
0.85 mm (0.0335 in)

5-32
 CYLINDER AND PISTON

EAM30100

INSTALLING THE PISTON AND CYLINDER

a 1. Install:
• Oil ring expander “1”
• Lower oil ring rail “2”
• Upper oil ring rail “3”
• 2nd ring “4”
• Top ring “5”
TIP
b Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up.
b. Upper of cylinder
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 outside diameter “a”
Out of specification  Replace the piston pin.
Piston pin outside diameter limit
17.981 mm (0.7079 in)

2. Install:
• Piston “1”
• Piston pin “2”
• Piston pin clip “3” New
3. Measure: TIP
• Piston pin bore inside diameter “b” • Apply the engine oil to the piston and piston
Out of specification  Replace the piston. pin.
• Install the piston with the mark “a” on it pointing
Piston pin bore inside diameter
to its exhaust (rear) side.
limit
18.045 mm (0.7104 in) • 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.

5-33
 CYLINDER AND PISTON

(exhaust side) through the timing chain cavity.

1 a

3. Lubricate:
• Piston
• Piston ring
• Cylinder
4. Offset:
• Piston ring end gap
a c

15 15
d
15
15

15 15

e b
a. Top ring
b. 2nd ring
c. Upper oil ring rail
d. Oil ring expander
e. Lower oil ring rail
5. Install:
• Gasket New
• Dowel pin
• Cylinder
Cylinder bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

TIP
• While compressing the piston rings with one
hand, install the cylinder with the other hand.
• Pass the timing chain and timing chain guide

5-34
 GENERATOR

EAM20183

GENERATOR
Removing the stator coil assembly

10 N m (1.0 kgf m, 7.4 lb ft)

12 N m (1.2 kgf m, 8.9 lb ft)

(2)

(3)

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 (6.5 kgf m, 48 lb ft)

* Yamaha bond No. 1215 (Three bond No. 1215®)
Order Job/Parts to remove Q’ty Remarks
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-14.
Refer to “GENERAL CHASSIS” on page
Seat 4-1.
Refer to “GENERAL CHASSIS” on page
Shroud (left) 4-1.

5-35
 GENERATOR

Removing the stator coil assembly

10 N m (1.0 kgf m, 7.4 lb ft)

12 N m (1.2 kgf m, 8.9 lb ft)

(2)

(3)
1
2 5

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 (6.5 kgf m, 48 lb ft)

* Yamaha bond No. 1215 (Three bond No. 1215®)
Order Job/Parts to remove Q’ty Remarks
1 Stator coil assembly coupler 1 Disconnect.
2 Crankshaft position sensor coupler 1 Disconnect.
When installing, align the punch marks on
3 Shift pedal 1 the shift pedal and the shift shaft.
4 Clamp 1 2
5 Clamp 2 1

5-36
 GENERATOR

Removing the stator coil assembly

10 N m (1.0 kgf m, 7.4 lb ft)

12

12 N m (1.2 kgf m, 8.9 lb ft)

(2)
9

(3) 10
8 6

7
10 N m (1.0 kgf m, 7.4 lb ft)

11

10 N m (1.0 kgf m, 7.4 lb ft)

65 N m (6.5 kgf m, 48 lb ft)

* Yamaha bond No. 1215 (Three bond No. 1215®)
Order Job/Parts to remove Q’ty Remarks
6 Crankcase cover (left) 1
7 Gasket 1
8 Dowel pin 2
9 Clamp 3 1
10 Stator coil assembly 1
11 Generator rotor 1
12 Woodruff key 1

5-37
 GENERATOR

EAM30487 EAM30377

REMOVING THE GENERATOR CHECKING THE WOODRUFF KEY

1. Remove: 1. Check:
• Nut (generator rotor) “1” • Woodruff key “1”
• Washer Damage  Replace.

1
2. Remove: EAM30489

• Generator rotor “1” INSTALLING THE GENERATOR

(with the rotor puller “2”) 1. Install:
• Woodruff key • Stator coil assembly “1”
• Screw (stator coil assembly) “2”
Rotor puller
90890-04151 Screw (stator coil assembly)
Rotor puller T. 10 N·m (1.0 kgf·m, 7.4 lb·ft)
YM-04151 LOCTITE®
R.

• Crankshaft position sensor “3”

• Bolt (crankshaft position sensor) “4”
1
Bolt (crankshaft position sensor)
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.

LOCTITE®
R.

TIP
• Apply the sealant to the grommet of the stator
2 coil assembly lead.
• Tighten the stator coil assembly screws using
EAM30488

CHECKING THE GENERATOR the T25 bit.

1. Check: • Pass the stator coil assembly lead through the
• Generator rotor “1” inner surface “a” crankcase cover side.
• Stator coil assembly “2” outer surface “b”
Damage  Inspect the crankshaft runout and Yamaha bond No. 1215
crankshaft bearing. 90890-85505
Three bond No. 1215®
2
4 3 4
b 1
LT

2
a
LT
LT 1

5-38
 GENERATOR

2. Install: TIP
• Woodruff key “1” Tighten the bolts in stages and in a crisscross
• Generator rotor “2” pattern.
TIP
• Clean the contact surfaces of the tapered por-
tions of the crankshaft and generator rotor. 3 4
• When installing the woodruff key, make sure
that its flat surface “a” is in parallel with the 1 5
crankshaft center line “b”.
• When installing the generator rotor, align the 1
keyway “c” of the generator rotor with the 5
woodruff key. 2
5 5
6
1 5. Connect:
• Stator coil assembly lead
b 1 a c Refer to “CABLE ROUTING DIAGRAM” on
page 2-17.

3. Install:
• Washer
• Nut (generator rotor) “1”
Nut (generator rotor)
65 N·m (6.5 kgf·m, 48 lb·ft)
T.
R.

1
4. Install:
• Dowel pin “1”
• Gasket (crankcase cover (left)) “2” New
• Crankcase cover (left) “3”
• Lead holder “4”
• Crankcase cover bolt (left) “5”
• Washer New
• Engine oil drain bolt (oil tank) “6”
Crankcase cover bolt (left)
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.

Engine oil drain bolt (oil tank)

R.

10 N·m (1.0 kgf·m, 7.4 lb·ft)

5-39
 ELECTRIC STARTER

EAM20110

ELECTRIC STARTER
Removing the starter motor

FW
D
10 N m (1.0 kgf m, 7.4 lb ft)

3
1

6 N m (0.6 kgf m, 4.4 lb ft)

Order Job/Parts to remove Q’ty Remarks

Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-2.
1 Clamp 1
When removing or installing the installation
nut of the starter motor lead, be sure to hold
2 Starter motor lead 1 the nut on the starter motor side firmly in
place using a spanner.
3 Starter motor 1

5-40
 ELECTRIC STARTER

Disassembling the starter motor

1.5 N m (0.15 kgf m, 1.1 lb ft)

7 1
6
9

4
8

2
3

6 N m (0.6 kgf m, 4.4 lb ft) 4.5 N m (0.45 kgf m, 3.3 lb ft)

Order Job/Parts to remove Q’ty Remarks

1 Starter motor assembly 1
2 O-ring 1
3 Starter motor front cover 1
4 Starter motor yoke 1
5 Armature assembly 1
6 Gasket 2
7 Brush set 1
8 Brush holder 1
9 Starter motor rear cover 1

5-41
 ELECTRIC STARTER

EAM30106

CHECKING THE STARTER MOTOR Brush overall length limit

1. Check: 5.5 mm (0.22 in)
• Commutator
Dirt  Clean with 600 grit sandpaper.
2. Measure:
• Mica undercut “a”
Out of specification  Scrape the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commutator.
Mica undercut (depth)
2.40 mm (0.09 in)

TIP
The mica of the commutator must be undercut to 5. Measure:
ensure proper operation of the commutator. • Brush spring force
Out of specification  Replace the brush set.
Brush spring force
4.80–7.20 N (489–734 gf, 17.28–
25.92 oz)

6. Check:
• Gear teeth
Damage/wear  Replace the starter motor.
7. Check:
• Oil seal
Damage/wear  Replace the defective
3. Check: part(s).
• Armature assembly
a. Connect the digital circuit tester to the ar- EAM30107

mature coil and check the continuity. ASSEMBLING THE STARTER MOTOR
1. Install:
Digital circuit tester (CD732) • Brush spring “1”
90890-03243 • Brush “2”
Model 88 Multimeter with tachom- TIP
eter Install the brush holder using the screws “a”.
YU-A1927

b. If there is no continuity, replace the starter a

motor.

2
1
a

2. Install:
• Starter motor rear cover “1”
• O-ring New
4. Measure: • Starter motor yoke “2”
• Brush length “a” TIP
Out of specification  Replace the brush set. Install the starter motor rear cover with its projec-

5-42
 ELECTRIC STARTER

tion “a” facing the groove “b” of the starter motor

yoke.

b
2
a

3. Install:
• Circlip
• Plain washer
• O-ring New
• Washer (starter motor front cover)
• Starter motor front cover “1”
TIP
Align the match mark “a” on the starter motor
yoke with the match mark “b” on the starter mo-
tor front cover.

a b

4. Install:
• Bolt
• O-ring New
TIP
Apply the lithium-soap-based grease on the O-
ring.
5. Install:
• Starter motor
• Starter motor bolt
Starter motor bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

5-43
 CLUTCH

EAM20111

CLUTCH
Removing the clutch

10 N m (1.0 kgf m, 7.4 lb ft)

11
4 10
7 9
(6) 8
6
5 E
(2)
3 1
E
2 E

(4) E

FW
D
E 10 N m (1.0 kgf m, 7.4 lb ft)
105 N m (10.5 kgf m, 77 lb ft)

Order Job/Parts to remove Q’ty Remarks

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-14.
1 Clutch cable 1 Disconnect.
2 Clutch cover 1
3 Gasket 1
4 Pressure plate 1 1
5 Clutch spring 1
6 Spring retainer 1
7 Pressure plate 2 1
8 Circlip 1
9 Bearing 1
10 Push rod 1 1
11 Ball 1

5-44
 CLUTCH

Removing the clutch

10 N m (1.0 kgf m, 7.4 lb ft)

(6)
12
13 E
(2)
E
E

15

(4)
E 25
13 24
12 23
14 22
E
21
20
19
18
17
16
FW
D
E 10 N m (1.0 kgf m, 7.4 lb ft)
105 N m (10.5 kgf m, 77 lb ft)

Order Job/Parts to remove Q’ty Remarks

12 Clutch plate 2 2 [Thickness: 1.0 mm (0.04 in)]
Blue paint on the outer circumference of the
13 Friction plate 2 4 pawls.
14 Clutch plate 1 7 [Thickness: 1.4 mm (0.06 in)]
15 Friction plate 1 4
16 Collar 6
17 Washer 1
18 Sleeve 1
19 Absorber 6
20 Clutch boss 1
21 Washer 1
22 Primary driven gear 1
23 Collar 1
24 Idle gear 1
25 Washer 1

5-45
 CLUTCH

Removing the crankcase cover (right)

5
10 N m (1.0 kgf m, 7.4 lb ft)
3
4
6
6

LS

2
1

LS 0 mm FW
(0 in) D
10 N m (1.0 kgf m, 7.4 lb ft)

Order Job/Parts to remove Q’ty Remarks

Right engine guard Refer to “ENGINE REMOVAL” on page 5-2.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-14.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-22.
Brake pedal Refer to “ENGINE REMOVAL” on page 5-2.
Clutch cover Refer to “CLUTCH” on page 5-44.
1 Oil filter element cover 1
2 Oil filter element 1
3 Oil filler cap 1
4 Crankcase cover (right) 1
5 Gasket 1
6 Dowel pin 2

5-46
 CLUTCH

Removing the clutch release

0.1–0.6 mm
(0.004–0.024 in)

6
5 0–0.5 mm
2 (0–0.002 in)

10 N m (1.0 kgf m, 7.4 lb ft)

Order Job/Parts to remove Q’ty Remarks

Drive sprocket cover Refer to “CHAIN DRIVE” on page 4-74.
1 Push lever shaft 1
2 Clutch release 1
3 Oil seal 1
4 Bearing 2
5 Push rod 2 1
6 Oil seal 1

5-47
 CLUTCH

EAM30108

REMOVING THE CLUTCH Friction plate 1 thickness

1. Straighten the clutch boss nut rib “a”. 2.12–2.28 mm (0.083–0.090 in)
Wear limit
2.02 mm (0.080 in)
a Friction plate 2 thickness
2.12–2.28 mm (0.083–0.090 in)
Wear limit
2.02 mm (0.080 in)

EAM30110

CHECKING THE CLUTCH PLATES

1. Check:
• Clutch plate
2. Remove: Damage  Replace the clutch plates as a
• Clutch boss nut “1” set.
• Washer “2” 2. Measure:
• Sleeve “3” • Clutch plate warpage
• Absorber (with a surface plate and thickness gauge)
• Clutch boss Out of specification  Replace the clutch
TIP plates as a set.
While holding the sleeve with the clutch holder
“4”, loosen the clutch boss nut. Thickness gauge
90890-03268
Feeler gauge set
Clutch holder YU-26900-9
90890-04199
Universal clutch holder
YM-91042 Warpage limit
0.10 mm (0.004 in)

1 EAM30111
2 CHECKING THE CLUTCH SPRING
1. Check:
• Pressure plate
Damage  Replace.
2. Check:
3 • Spring retainer
4 Damage  Replace.
3. Check:
EAM30109
• Clutch spring
CHECKING THE FRICTION PLATES Damage  Replace the clutch spring.
1. Check: 4. Measure:
• Friction plate • Clutch spring free height
Damage/wear  Replace the friction plates Out of specification  Replace the clutch
as a set. spring.
2. Measure:
Clutch spring free height
• Friction plate thickness
5.80 mm (0.228 in)
Out of specification  Replace the friction Clutch spring free height limit
plates as a set. 5.51 mm (0.217 in)
TIP
Measure it at four points on the friction plate.

5-48
 CLUTCH

EAM30484

CHECKING THE PUSH ROD

1. Check:
• Push rod 1 “1”
• Bearing “2”
• Ball “3”
• Push rod 2 “4”
Cracks/damage/wear  Replace.

4
EAM30629

CHECKING THE COLLAR 3

1. Check: 1
• Collar “1” 2
Damage/pitting/wear  Replace the collars
as a set.
TIP
Pitting on the collar will cause erratic clutch op-
eration. 2. Measure:
• Push rod 2 bending limit
Out of specification  Replace.
Push rod bending limit
1 0.10 mm (0.004 in)

EAM30117

CHECKING THE PRIMARY DRIVE GEAR

1. Check:
• Primary drive gear
Damage/wear  Replace the primary drive
and primary driven gears as a set.
EAM30114

CHECKING THE PRESSURE PLATE Excessive noise during operation  Replace

1. Check: the primary drive and primary driven gears as
• Pressure plate a set.
Crack/damage  Replace. 2. Check:
• Primary-drive-gear-to-primary-driven-gear
EAM30115
free play
CHECKING THE PUSH LEVER SHAFT Free play exists  Replace the primary drive
1. Check: and primary driven gears as a set.
• Push lever shaft
Wear/damage  Replace. EAM30118

CHECKING THE PRIMARY DRIVEN GEAR

1. Check:
• Primary driven 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 driven gear dogs “1”
Damage/pitting/wear  Deburr the primary
driven gear dogs or replace the primary driv-
en gear.

5-49
 CLUTCH

TIP
Pitting on the primary driven gear dogs will a
cause erratic clutch operation.

2. Install:
• Push rod 2 “1”
1 • Washer “2”
EAM30638
• O-ring “3” New
ASSEMBLING THE CLUTCH RELEASE • Clutch release “4”
1. Install: Bolt (clutch release)
• Bearing “1” New 10 N·m (1.0 kgf·m, 7.4 lb·ft)
• Oil seal “2” New

T.
LOCTITE®

R.
Installed depth “a”
25.3–25.8 mm (1.00–1.02 in) TIP
Installed depth “b” Apply lithium-soap-based grease on the O-ring
5.5–6.0 mm (0.22–0.24 in) and the seal lip.
Installed depth “c”
0.1–0.6 mm (0.004–0.024 in)
1
TIP
• Apply engine oil on the bearings. 3 2
• Apply lithium-soap-based grease on oil seal. 4

c
b 2
a
LT

EAM30639

INSTALLING THE CLUTCH RELEASE

1. Install:
• Oil seal “1” New
Installed depth “a”
EAM30121
0.0–0.5 mm (0.00–0.02 in) INSTALLING THE CLUTCH
1. Install:
• Oil seal “1” New
• Circlip “2” New
• Check ball seat “3”
TIP
• Apply the lithium-soap-based grease on the oil
seal lip.

5-50
 CLUTCH

• Install the oil seal in parallel with its manufac- seal lip.
ture’s marks or numbers facing inward. • Before installation, apply the engine oil to the
bearings (upper side and lower side).
Installed depth “a”
0 mm (0 in)
1
LS 2
a

3
5. Install:
• Washer “1”
2. Install: • Idle gear “2”
• Dowel pin “1” • Collar “3”
• Gasket “2” New • Primary driven gear “4”
• Washer “5”
• Clutch boss “6”
• Absorber “7”
1 • Sleeve “8”
1 • Washer “9”
• Clutch boss nut “10” New

3 2 1
4
2 5
6
7
3. Install: 8
• Crankcase cover (right) “1” 9
• Crankcase cover bolt (right) “2”
Crankcase cover bolt (right)
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

10
TIP
Tighten the crankcase cover bolts (right) in stag-
es and in a crisscross pattern.

2 6. Tighten:
• Clutch boss nut “1” New
1
Clutch boss nut
4. Install: 105 N·m (10.5 kgf·m, 77 lb·ft)
T.

• Push lever shaft “1” LOCTITE®

R.

TIP
• Apply the lithium-soap-based grease on the oil

5-51
 CLUTCH

ECA24660
plates, and clutch plates.
NOTICE
Make sure to tighten to specification; other-
wise, it may damage the other part that is fas- 3
tened together.
TIP 5
• Use the clutch holder “2” to hold the sleeve.
• Stake the clutch boss nut at cutouts “a” in the 2
main axle. 3

Clutch holder
90890-04199
Universal clutch holder 4
YM-91042
2

1
1

LT 8. Install:
2
• Bearing “1”
• Circlip “2” New
(to the push rod 1 “3”)
a TIP
Apply the engine oil on the bearing and push rod
1.

7. Install: 2
• Collar “1” 3
• Clutch plate 2 (thickness: 1.0 mm (0.04 in))
“2” 1
• Friction plate 2 (painted) “3”
• Clutch plate 1 (thickness: 1.4 mm (0.06 in)) 9. Install:
“4” • Ball “1”
• Friction plate 1 (unpainted) “5” • Push rod 1 “2”
TIP TIP
• Friction plate 2 that have blue paint on the out- Apply the engine oil on the push rod 1 and ball.
er circumference of the pawls.
• Install the clutch plates and friction plates alter-
nately on the sleeve, starting with a clutch plate
and ending with a clutch plate.
• From the clutch boss side, install the friction
plates and clutch plates in the order of the illus-
trations.
• Apply the engine oil on the collars, friction

5-52
 CLUTCH

1
2
3
E

E 4
1
2
10.Install:
• Pressure plate 2 “1”

A
1

A. Engine side
11.Install: 12.Install:
• Spring retainer “1” • Gasket “1” New
• Clutch spring “2” • Clutch cover “2”
• Pressure plate 1 “3” • Clutch cover bolt (long) “3”
• Bolt (pressure plate 1) “4” • Clutch cover bolt (short) “4”
Bolt (pressure plate 1) Clutch cover bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

T.
R.

TIP TIP
• Apply the engine oil on the threads and contact Tighten the bolts in stages and in a crisscross
surface of the bolts, and contact surface of the pattern.
pressure plate 1.
• First temporarily tighten all bolts to 4.0 N·m
(0.40 kgf·m, 3.0 lb·ft) in a crisscross pattern. 1
Then retighten them to 10 N·m (1.0 kgf·m, 7.4 2
lb·ft) in a crisscross pattern.
3

5-53
 SHIFT SHAFT

EAM20113

SHIFT SHAFT
Removing the shift shaft and stopper lever
12 N m (1.2 kgfm, 8.9 lb ft)

0–0.1 mm
(0–0.004 in)

10 N m (1.0 kgf m, 7.4 lb ft)

4
5
2

30 N m (3.0 kgf m, 22 lb ft)

E
7
6

E
FW
E
D
Order Job/Parts to remove Q’ty Remarks
Idle gear Refer to “CLUTCH” on page 5-44.
1 Shift pedal 1
2 Shift shaft 1
3 Oil seal 1
4 Collar 1
5 Shift shaft spring 1
6 Roller 1
7 Shift guide 1

5-54
 SHIFT SHAFT

Removing the shift shaft and stopper lever

12 N m (1.2 kgfm, 8.9 lb ft)

0–0.1 mm
(0–0.004 in)

10 N m (1.0 kgf m, 7.4 lb ft)

14
13

8
10 15
11
12
30 N m (3.0 kgf m, 22 lb ft)
9
E
12
11
10
E
FW
E
D
Order Job/Parts to remove Q’ty Remarks
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

5-55
 SHIFT SHAFT

EAM30124

REMOVING THE SEGMENT 1

1. Remove:
• Bolt (segment) “1”
• Segment “2” 2 3
TIP
Turn the segment counterclockwise until it stops
4
and loosen the bolt.
ECA24670

NOTICE 5
If the segment gets an impact, the stopper le-
EAM30127
ver may be damaged. Take care not to give CHECKING THE STOPPER LEVER
an impact to it when removing the bolt. 1. Check:
• Stopper lever “1”
Wear/damage  Replace.
• Stopper lever spring “2”
Broken  Replace.
2

1 2
1

EAM30125

CHECKING THE SHIFT SHAFT

1. Check:
• Shift shaft “1”
Bends/damage/wear  Replace.
EAM30131
• Shift shaft spring “2” INSTALLING THE SHIFT SHAFT
Damage/wear  Replace. 1. Install:
• Stopper lever spring “1”
2 • Collar “2”
1 • Stopper lever “3”
• Bolt (stopper lever) “4”
Bolt (stopper lever)
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.

LOCTITE®
R.

2. Check: 1
• Shift guide “1”
• Shift lever “2” 2
• Pawl “3”
• Pawl pin “4” 3
• Spring “5”
Wear/damage  Replace.
LT 4

2. Install:
• Segment “1”
• Segment bolt

5-56
 SHIFT SHAFT

Segment bolt
T.
R.
30 N·m (3.0 kgf·m, 22 lb·ft)

TIP
• Align the projections “a” on the segment with
the slits “b” on the shift cam.
• With the stopper lever pushed down, install the
segment.
ECA24680 2 1
NOTICE
6. Tighten:
If the segment gets an impact, the stopper le- • Shift guide bolt “1”
ver may be damaged. Take care not to give
an impact to it when tightening the bolt. Shift guide bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.
LOCTITE®

R.
1

1 a b

3. Install: 1
• Spring “1”
• Pawl pin “2” 7. Install:
• Pawl “3” • Dowel pin “1”
(to the shift lever) • Roller “2”
TIP • Shift shaft spring “3” (to the shift shaft)
Apply the engine oil on the spring, pawl pin and • Collar “4” (to the shift shaft)
pawl. • Shift shaft “5”
TIP
Apply the engine oil on the shift shaft.
3
2 1
4
1
3
5 2
E

4. Install:
• Shift lever assembly
(to the shift guide) 8. Install:
5. Install: • Oil seal New
• Shift lever assembly “1” 9. Install:
• Shift guide “2” • Shift pedal “1”
TIP • Shift pedal bolt “2”
The shift lever assembly is installed at the same
Shift pedal bolt
time as the shift guide.
12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.

5-57
 SHIFT SHAFT

TIP
Align the punch mark “a” on the shift shaft with
the punch mark “b” in the shift pedal.

b
a

1 2

5-58
 STARTER CLUTCH

EAM20175

STARTER CLUTCH
Removing the balancer gear

120 N m (12 kgf m, 89 lb ft) 8

7
6

5
4
11 12
3
1
10
2

FW
D
E
50 N m (5.0 kgf m, 37 lb ft)

Order Job/Parts to remove Q’ty Remarks

Idle gear Refer to “CLUTCH” on page 5-44.
Crankcase cover (right) Refer to “CLUTCH” on page 5-44.
1 Primary drive gear nut 1
2 Balancer driven gear nut 1
3 Washer 1
4 Primary drive gear 1
5 Collar 1
6 Starter reduction gear 1
7 Circlip 1
8 Starter clutch assembly 1 [“a”: Manufacturer’s mark]
9 Balancer drive gear 1
10 Lock washer 1
11 Balancer driven gear 1
12 Oil pump drive gear 1

5-59
 STARTER CLUTCH

Removing the damper assembly

12 N m (1.2 kgf m, 8.9 lb ft)

FW
D

Order Job/Parts to remove Q’ty Remarks

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-14.
Clutch Refer to “CLUTCH” on page 5-44.
1 Holder 1
2 Damper assembly 1
3 Washer 1

5-60
 STARTER CLUTCH

EAM30624
2. Check:
REMOVING THE BALANCER GEAR • Starter clutch assembly
1. Straighten the lock washer tab. Burrs/chips/roughness/wear  Replace the
2. Loosen: starter clutch assembly.
• Balancer driven gear nut “1”
• Primary drive gear nut “2”
TIP
Place an aluminum plate “a” between the teeth
of the balancer drive gear “3” and balancer driv-
en gear “4”.

1
3

2
3. Check:
• Starter clutch operation
4
a. Install the starter clutch onto the balancer
drive gear “1”, and then install onto the
a starter reduction gear “2”.
b. When turning the balancer drive gear
counterclockwise “A”, it should turn freely,
otherwise the starter clutch is faulty and
a must be replaced.
3 c. When turning the balancer drive gear
2 clockwise “B”, the starter clutch and the
balancer drive gear should engage, other-
4 wise the starter clutch is faulty and must
be replaced.
1

3. Check: B
• Primary drive gear “1”
• Starter reduction gear “2”
• Balancer drive gear “3” A 1
• Balancer driven gear “4”
• Oil pump drive gear “5”
2
Wear/damage  Replace.

EAM30630
3
INSTALLING THE BALANCER GEAR
2 1. Install:
1 5 • Oil pump drive gear
• Balancer driven gear “1”
4
TIP
Install the balancer driven gear and balancer
shaft with their lower splines “a” aligning with
each other.
EAM30140

CHECKING THE STARTER CLUTCH

1. Remove:
• Starter clutch assembly
Refer to “OIL PUMP” on page 5-63.

5-61
 STARTER CLUTCH

washer.
• Apply engine oil to the contact surface and
threaded portion of the primary drive gear nut.
• Place an aluminum plate “a” between the teeth
1 of the balancer drive gear “10” and balancer
driven gear “11”.
a
c

2. Install:
• Balancer drive gear “1” 3
TIP 4
• Align the punched mark “a” on the balancer 1
5
drive gear with the punched mark “b” on the 6 2
7
balancer driven gear. 9 8
• Install the balancer drive gear and crankshaft
with the lower splines “c” aligning with each
other. 10

9
a b
1
11
2
a
c

a
3. Install: 10
• Lock washer “1” New
9
• Balancer driven gear nut “2”
Balancer driven gear nut 11
50 N·m (5.0 kgf·m, 37 lb·ft)
T.
R.

2
• Starter clutch assembly “3”
• Circlip “4” 4. Bend the lock washer tab.
• Starter reduction gear “5”
• Collar “6”
• Primary drive gear “7”
• Washer “8”
• Primary drive gear nut “9”
Primary drive gear nut
120 N·m (12 kgf·m, 89 lb·ft)
T.
R.

TIP
• Apply engine oil to the starter clutch assembly.
• Install the starter clutch assembly with its man-
ufacturer’s mark facing outward.
• Apply engine oil to the inner surface and the
contact surfaces of the starter reduction gear.
• Apply engine oil to the contact surface of the

5-62
 OIL PUMP

EAM20182

OIL PUMP
Removing the oil pump

0.1–1.0 mm
(0.004–0.039 in)

5 N m (0.5 kgf m, 3.7 lb ft)

1
2

5
LT

6 4
7 E

10
LT

9 8 6 N m (0.6 kgf m, 4.4 lb ft)

FW
D
E

Order Job/Parts to remove Q’ty Remarks

Oil pump drive gear Refer to “STARTER CLUTCH” on page 5-59.
1 Oil pump assembly 1
2 Outer rotor 1 1
3 Inner rotor 1 1
4 Dowel pin 1
5 Oil pump cover 1
6 Outer rotor 2 1
7 Inner rotor 2 1
8 Dowel pin 1
9 Oil pump drive shaft 1
10 Oil pump housing 1

5-63
 OIL PUMP

EAM30136
• Dowel pin “1”
CHECKING THE OIL PUMP • Inner rotor 1 “2”
1. Check: • Outer rotor 1 “3”
• Oil pump cover • Circlip “4”
• Oil pump drive shaft
TIP
• Oil pump housing • Apply the engine oil on the inner rotor 1 and
Cracks/damage/wear  Replace the oil outer rotor 1.
pump assembly. • Fit the dowel pin into the groove in the inner ro-
2. Check: tor 1.
• Oil pump operation
Rough movement  Repeat step (1) or re-
4
place the oil pump assembly.
3
EAM30137

ASSEMBLING THE OIL PUMP 2

1. Install:
• Oil pump drive shaft “1”
• Dowel pin “2” 1
• Inner rotor 2 “3”
• Outer rotor 2 “4”
TIP
• Apply the engine oil on the oil pump drive shaft, EAM30486

INSTALLING THE OIL PUMP

inner rotor 2, and outer rotor 2.
1. Install:
• Fit the dowel pin into the slit in the inner rotor 2.
• Oil pump assembly “1”
• Oil pump assembly bolt “2”
4
Oil pump assembly bolt
3 5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.

LOCTITE®
R.

2. Install:
• Oil pump cover “1”
• Oil pump cover bolt “2”
2
Oil pump cover bolt
1
6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.

LOCTITE®
R.

ECA13890

NOTICE
After tightening the bolts, make sure the oil
2 pump turns smoothly.
1

3. Install:
• Washer

5-64
 CRANKCASE

EAM20116

CRANKCASE
Separating the crankcase

10 N m (1.0 kgf m, 7.4 lb ft)

LT

0.5 N m (0.05 kgf m, 0.37 lb ft)

(3)

3 1 LT

2
10 N m (1.0 kgf m, 7.4 lb ft)
(3)
(3)

LT

12 N m (1.2 kgf m, 8.9 lb ft)

10 N m (1.0 kgf m, 7.4 lb ft)

12 N m (1.2 kgf m, 8.9 lb ft)

* Yamaha bond No. 1215 (Three bond No. 1215®)

Order Job/Parts to remove Q’ty Remarks
Engine Refer to “ENGINE REMOVAL” on page 5-2.
Refer to “CYLINDER AND PISTON” on page
Piston 5-30.
Oil pump Refer to “OIL PUMP” on page 5-63.
Segment Refer to “SHIFT SHAFT” on page 5-54.
Stator coil assembly Refer to “GENERATOR” on page 5-35.
Clutch release/Push rod 2 Refer to “CLUTCH” on page 5-44.
1 Timing chain guide (exhaust side) 1
2 Timing chain guide stopper plate 1
3 Timing chain 1

5-65
 CRANKCASE

Separating the crankcase

13
10 N m (1.0 kgf m, 7.4 lb ft)

7 LT

0.5 N m (0.05 kgf m, 0.37 lb ft)

14
10 9

11
8
12
(3)
9
5

LT

10 N m (1.0 kgf m, 7.4 lb ft)

(3) 6

(3) 4 5 6
LT

12 N m (1.2 kgf m, 8.9 lb ft)

6
10 N m (1.0 kgf m, 7.4 lb ft) 5
12 N m (1.2 kgf m, 8.9 lb ft) 5
4 4
* Yamaha bond No. 1215 (Three bond No. 1215®)
Order Job/Parts to remove Q’ty Remarks
4 Bolt 3 [L = 45 mm (1.77 in)]
5 Bolt 3 [L = 75 mm (2.95 in)]
6 Bolt 3 [L = 60 mm (2.36 in)]
7 Crankcase (left) 1
8 Crankcase (right) 1
9 Dowel pin 2
10 Crankshaft 1
11 Gasket 1
12 Oil strainer 1
13 Oil nozzle 1 1
14 Oil nozzle 2 1

5-66
 CRANKCASE

Removing the bearing and oil seal (left)

2
0 mm (0 in) 0–0.5 mm
(0–0.002 in) 3
12 N m (1.2 kgf m, 8.9 lb ft)
E

LT
1
1

1
1
E
E 1
0 mm (0 in) LT

LT

30 N m (3.0 kgf m, 22 lb ft)

0 mm (0 in)

0 mm (0 in)
0 mm (0 in)

Order Job/Parts to remove Q’ty Remarks

Transmission Refer to “TRANSMISSION” on page 5-75.
Shift cam/Shift fork Refer to “TRANSMISSION” on page 5-75.
1 Bearing 5
2 Collar 1
3 Oil seal 1

5-67
 CRANKCASE

Removing the bearing and oil seal (right)

12 N m (1.2 kgf m, 8.9 lb ft)

0 mm (0 in) 1
E

LT 1 1

LT E LT
E

0 mm (0 in)

30 N m (3.0 kgf m, 22 lb ft)

12 N m (1.2 kgf m, 8.9 lb ft)

0 mm (0 in) 0 mm (0 in) 0 mm (0 in)

Order Job/Parts to remove Q’ty Remarks

1 Bearing 5

5-68
 CRANKCASE

EAM30147

DISASSEMBLING THE CRANKCASE

1. Separate:
• Right crankcase
• Left crankcase
a. Remove the crankcase bolts.

c. Remove the dowel pins and O-ring.

2. Remove:
• Bearing “1”
TIP
• Remove the bearing from the crankcase by
pressing its inner race.
TIP • Do not use the removed bearing.
Loosen each bolt 1/4 of a turn at a time and after
all the bolts are loosened, remove them.
b. Remove the right crankcase “1”.
TIP
• Place the crankcase with its left side downward
and split it by inserting a screwdriver tip into the
splitting slit “a” in the crankcase.
• Lift the right crankcase horizontally while lightly
patting the crankcase splitting slit and the en-
gine mounting boss using a soft hammer, and
leave the crankshaft and the transmission with
the left crankcase. EAM30490

CHECKING THE TIMING CHAIN GUIDE

ECA24690
(EXHAUST SIDE)
NOTICE
1. Check:
Use soft hammer to tap on the case half. Tap • Timing chain
only on reinforced portions of case. Do not Stiffness  Replace the camshaft sprocket,
tap on gasket mating surface. Work slowly timing chain and crankshaft sprocket as a
and carefully. Make sure the case halves set.
separate evenly. If the cases do not separate, 2. Check:
check for a remaining case bolt or fitting. Do • Timing chain guide
not force. Damage/wear  Replace.
EAM30150

CHECKING THE CRANKCASE

1. Wash:
1 • Crankcase
TIP
• Wash the crankcase in a mild solvent.
• Remove any remaining gasket from the crank-
case mating surface.
2. Check:
• Crankcase
Crack/damage  Replace.
• Oil delivery passages
Obstruction  Blow out with compressed air.

5-69
 CRANKCASE

EAM30641

CHECKING THE OIL STRAINER

1. Check:
• Oil strainer
Damage  Replace.
Contaminants  Clean with solvent.
EAM30152

ASSEMBLING THE CRANKCASE

1. Install:
• Oil seal “1” New
(to the left crankcase) 4. Install:
• Oil nozzle 1 “1”
Installed depth “a”
0.0–0.5 mm (0.00–0.02 in) (to the right crankcase)
Oil nozzle bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.
LOCTITE®

R.
1

• Oil nozzle 2 “2”

(to the left crankcase)
Oil nozzle
T.
R.
0.5 N·m (0.05 kgf·m, 0.37 lb·ft)
a
• Dowel pin “3”
• Gasket “4” New
2. Install:
(to the left crankcase)
• Bearing cover plate
• Crankcase “5”
Bearing cover plate bolt (to the left crankcase)
12 N·m (1.2 kgf·m, 8.9 lb·ft)
Crankcase bolt
T.

LOCTITE®
R.

Bearing cover plate screw (crank- 12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.

shaft)
30 N·m (3.0 kgf·m, 22 lb·ft) TIP
LOCTITE® • Fit the right crankcase onto the left crankcase.
Tap lightly on the case with soft hammer.
TIP • When installing the crankcase, the connecting
Install the bearing by pressing its outer race par- rod should be positioned at top dead center
allel. (TDC).
• Tighten the bolts in a crisscross pattern in two
3. Apply:
stages, with 1/4 turn each.
• Sealant
(to the crankcase mating surface)
Yamaha bond No. 1215
90890-85505
Three bond No. 1215®

5-70
 CRANKCASE

1
LT 5
2
4 3
8

7 7

6
8
8
6 7
6
6. 45 mm (1.77 in)
7. 60 mm (2.36 in)
8. 75 mm (2.95 in)

5-71
 CRANKSHAFT AND BALANCER SHAFT

EAM20184

CRANKSHAFT AND BALANCER SHAFT

Removing the crankshaft assembly and balancer shaft

Order Job/Parts to remove Q’ty Remarks

Separate.
Crankcase Refer to “CRANKCASE” on page 5-65.
Transmission Refer to “TRANSMISSION” on page 5-75.
1 Balancer shaft 1
2 Crankshaft assembly 1

5-72
 CRANKSHAFT AND BALANCER SHAFT

EAM30491
shaft.
REMOVING THE CRANKSHAFT
TIP
1. Remove: Turn the crankshaft slowly.
• Balancer shaft “1”
TIP Runout limit
Remove the balancer shaft with its flat side “a” 0.030 mm (0.0012 in)
facing the crankshaft.

a a

2. Remove: 2. Measure:
• Crankshaft assembly “1” • Crank assembly width “a”
TIP Out of specification  Replace the crank-
Remove the crankshaft assembly by using the shaft.
crankcase separating tool “2”. Crank assembly width
61.93–62.00 mm (2.438–2.441 in)
Crankcase separating tool
90890-04152
Crankcase separating tool
YU-A9642

3. Check:
1 • Crankshaft sprocket “1”
Damage  Replace the crankshaft.

EAM30492 4. Check:
CHECKING THE CRANKSHAFT • Crankshaft journal oil passage
1. Measure: Obstruction  Blow out with compressed air.
• Crankshaft runout “a”
Out of specification  Replace the crank-

5-73
 CRANKSHAFT AND BALANCER SHAFT

EAM30493

INSTALLING THE CRANKSHAFT

1. Install:
• Crankshaft assembly
TIP
Install the crankshaft assembly with the crank-
shaft installer pot “1”, crankshaft installer bolt “2”,
adapter (M12) “3” and spacer “4”.

Crankshaft installer pot

90890-01274
Installing pot
YU-90058
Crankshaft installer bolt
90890-01275
Bolt
YU-90060
Adapter (M12)
90890-01278
Adapter #3
YU-90063
Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044
ECA24700

NOTICE
• To avoid scratching the crankshaft and to
ease the installation procedure, lubricate
the oil seal lips with lithium-soap-based
grease.
• In order to prevent the crankshaft seizure,
apply molybdenum disulfide grease.
TIP
Hold the connecting rod at top dead center
(TDC) with one hand while turning the nut of the
crankshaft installer bolt with the other. Turn the
crankshaft installer bolt until the crankshaft as-
sembly bottoms against the bearing.

4
3
1
2

5-74
 TRANSMISSION

EAM20118

TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks

LS

E
M

E E

Order Job/Parts to remove Q’ty Remarks

Engine Refer to “ENGINE REMOVAL” on page 5-2.
Separate.
Crankcase Refer to “CRANKCASE” on page 5-65.

5-75
 TRANSMISSION

Removing the transmission, shift drum assembly, and shift forks

LS
2
M

3 5
E
1 M

5
4
5 E E

Order Job/Parts to remove Q’ty Remarks

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

5-76
 TRANSMISSION

Removing the transmission, shift drum assembly, and shift forks

LS

10

E
9
7 8
M

E
M

E 6 E

Order Job/Parts to remove Q’ty Remarks

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

5-77
 TRANSMISSION

EAM30153

REMOVING THE TRANSMISSION

1. Remove:
• Long shift fork guide bar “1”
• Short shift fork guide bar “2”
• Shift cam “3”
• Shift fork 3 (R) “4”
• Shift fork 2 (C) “5”
• Shift fork 1 (L) “6”
• Main axle “7”
• Drive axle “8”
• Collar “9” 2. Check:
TIP • Shift fork guide bar
• Remove assembly with the collar “9” installed Roll the shift fork guide bar on a flat surface.
to the crankcase. Bends  Replace.
• Make a note of the position of each part. Pay
EWA12840

WARNING
particular attention to the location and direction
of shift forks. Do not attempt to straighten a bent shift fork
• Remove the main axle and the drive axle all to- guide bar.
gether by tapping the drive axle lightly with a 3. Check:
soft hammer. • Shift fork movement
(along the shift fork guide bar)
2 Rough movement  Replace the shift forks
1 5 and shift fork guide bar as a set.

6
3

EAM30155
8
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
• Shift drum groove
Damage/scratches/wear  Replace the shift
7 drum assembly.
• Shift drum segment
EAM30154 Damage/wear  Replace the shift drum as-
CHECKING THE SHIFT FORKS sembly.
1. Check:
• Shift fork cam follower “1”
• Shift fork pawl “2”
Bends/damage/scoring/wear  Replace the
shift fork.

5-78
 TRANSMISSION

EAM30156
• 3rd pinion gear (20T) “2”
CHECKING THE TRANSMISSION • Collar “3”
1. Measure: • 5th pinion gear (21T) “4”
• Main axle runout • 2nd pinion gear (16T) “5”
(with a centering device and dial gauge “1”) (to the main axle “6”)
Out of specification  Replace the main axle.
TIP
Main axle runout limit Before installation, apply molybdenum disulfide
0.08 mm (0.0032 in) oil to the inner and end surface of the idler gear
and to the inner surface of the sliding gear, then
install.

4 5
3
2
1
6

2. Measure:
• Drive axle runout 2. Install:
(with a centering device and dial gauge “1”) • Collar “1”
Out of specification  Replace the drive axle. • 2nd wheel gear (26T) “2”
• 5th wheel gear (21T) “3”
Drive axle runout limit
• 3rd wheel gear (27T) “4”
0.08 mm (0.0032 in)
• 4th wheel gear (25T) “5”
• Collar “6”
• 1st wheel gear (28T) “7”
• O-ring “8” New
(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 collar and to the inner surface of
the sliding gear, then install.
• Apply the lithium-soap-based grease on the O-
ring.
3. Check:
• Transmission gear
1 9 8
Blue discoloration/pitting/wear  Replace 3
2
the defective gear(s). 4
5
• Transmission gear dog 7
6
Cracks/damage/rounded edges  Replace
the defective gear(s).
4. Check:
• Transmission gear movement
Rough movement  Replace the defective
gear(s).
3. Install:
EAM30157
• Washer “1”
INSTALLING THE TRANSMISSION
• Circlip “2” New
1. Install:
TIP
• 4th pinion gear (22T) “1”
• Be sure the circlip sharp-edged corner “a” is

5-79
 TRANSMISSION

positioned opposite side to the washer and

gear “b”. 1
• Install the circlip with its ends “c” settled evenly
on the spline crests.
2

1 b
2
6. Install:
2 • Shift fork 1 (L) “1”
• Shift fork 2 (C) “2”
a • Shift fork 3 (R) “3”
• Shift cam “4”
(to the main axle and the drive axle)
c c 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 5th wheel gear
“5” and shift fork 3 (R) with the 4th wheel gear
“6” on the drive axle.
• Mesh the shift fork 2 (C) with the 3rd pinion
gear “7” on the main axle.
4. Install:
• Collar “1” 3
TIP
• Apply the lithium-soap-based grease on the oil
seal lip.
• When installing the collar into the crankcase, 2
pay careful attention to the crankcase oil seal
lip.
1
1

5. Install:
• Main axle “1”
• Drive axle “2”
TIP
• Install to the left crankcase simultaneously.
• Apply engine oil to the main axle and the drive
axle bearing.

5-80
 TRANSMISSION

7 5

2 3

7. Install:
• Long shift fork guide bar “1”
• Short shift fork guide bar “2”
• Spring “3”
TIP
• Screw the spring into the shift fork guide bar
lightly beforehand.
• Apply the engine oil on the shift fork guide bars.

1 2

8. Check:
• Operation of shift cam and shift fork
• Transmission operation
Unsmooth operation  Repair.

5-81
 TRANSMISSION

5-82
 COOLING SYSTEM

COOLING SYSTEM DIAGRAMS .....................................................................6-1

RADIATOR........................................................................................................6-2
CHECKING THE RADIATOR .....................................................................6-4
INSTALLING THE RADIATOR ...................................................................6-4
1
WATER PUMP ..................................................................................................6-6
DISASSEMBLING THE WATER PUMP .....................................................6-8
CHECKING THE WATER PUMP ...............................................................6-8
2
ASSEMBLING THE WATER PUMP ...........................................................6-8

3
4
5
6
7
8
9
10
 COOLING SYSTEM DIAGRAMS

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)

6-1
 RADIATOR

EAM20138

RADIATOR
Removing the radiator

1.5 N m (0.15 kgf m, 1.1 lb ft) 10 N m (1.0 kgf m, 7.4 lb ft)

4 2
2

3 6
2
1 2 FW
D
2 10 N m (1.0 kgf m, 7.4 lb ft)

2
2 5 LS

LS

1.5 N m (0.15 kgf m, 1.1 lb ft)

LS
2

10 N m (1.0 kgf m, 7.4 lb ft)

Order Job/Parts to remove Q’ty Remarks

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-22.
Refer to “GENERAL CHASSIS” on page
Seat 4-1.
Refer to “GENERAL CHASSIS” on page
Side cover (left/right) 4-1.
Refer to “GENERAL CHASSIS” on page
Shroud (left/right) 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

6-2
 RADIATOR

Removing the radiator

1.5 N m (0.15 kgf m, 1.1 lb ft) 10 N m (1.0 kgf m, 7.4 lb ft)

FW
D
10 N m (1.0 kgf m, 7.4 lb ft)
7
LS
10
13 LS

11 1.5 N m (0.15 kgf m, 1.1 lb ft)

LS
12

10 N m (1.0 kgf m, 7.4 lb ft)

Order Job/Parts to remove Q’ty Remarks

7 Radiator pipe 2 1
8 Radiator breather hose 1
9 Radiator (left) 1
10 Radiator hose 1 1
11 Clip 1
12 Radiator pipe 1 1
13 Coolant temperature sensor 1

6-3
 RADIATOR

EAM30341

CHECKING THE RADIATOR Radiator cap valve opening pres-

EWA13030
sure
WARNING 107.9–137.3 kPa (1.08–1.37
A hot radiator is under pressure. Therefore, kgf/cm², 15.6–19.9 psi)
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may No stay  Replace.
be blown out, which could cause serious in- Radiator cap tester
jury. When the engine has cooled, open the 90890-01325
radiator cap as follows: Mityvac cooling system tester kit
Place a thick rag or a towel over the radiator YU-24460-A
cap and slowly turn the radiator cap counter- Radiator cap tester adapter
clockwise toward the detent to allow any re- 90890-01352
sidual pressure to escape. When the hissing Pressure tester adapter
sound has stopped, press down on the radi- YU-33984
ator cap and turn it counterclockwise to re-
move.
1. Check:
• Radiator fin “1”
Obstructions  Clean.
Apply compressed air to the rear of the radia-
tor.
Damage  Repair or replace.
TIP
Correct any flattened fins with a thin, flat-head
screwdriver.
EAM30506

INSTALLING THE RADIATOR

1. Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-22.
2. Check:
• Cooling system
Leaks  Repair or replace any faulty part.
2. Check: 3. Install:
• Radiator hose • Radiator cap tester “1”
• Radiator pipe • Radiator cap tester adapter “2”
Crack/damage  Replace. Radiator cap tester
3. Check: 90890-01325
• Radiator cap valve opening pressure Mityvac cooling system tester kit
a. Install the radiator cap tester adapter “2” YU-24460-A
and the radiator cap tester “3” to the radi- Radiator cap tester adapter
ator cap “1”, and activate the tester to 90890-01352
check whether it can stay for 5 to 10 sec- Pressure tester adapter
onds within standard pressure values. YU-33984
TIP
Before attaching the cap to the tester, apply wa-
ter to its sealing surface.

6-4
 RADIATOR

4. Activate the tester to apply the test pressure.

Test pressure value
137.3 kPa (1.37 kgf/cm², 19.9 psi)
ECA24270

NOTICE
• Do not apply such a high pressure as ex-
ceeds the test pressure.
• Make sure that a checkup after the cylinder
head gasket is replaced is made after 3 min-
utes 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.
EWA19090

WARNING
When the radiator cap tester is removed,
coolant will spout; therefore, cover it with a
cloth beforehand.

6-5
 WATER PUMP

EAM20139

WATER PUMP
Removing the water pump

10 N m (1.0 kgf m, 7.4 lb ft)

0 mm
(0 in)

4
1

FW
D
LS
2 3

a
3 LS

0 mm
(0 in)
Order Job/Parts to remove Q’ty Remarks
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-22.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-14.
Crankcase cover (right) Refer to “CLUTCH” on page 5-44.
1 Water pump housing cover 1
2 O-ring 1
3 Dowel pin 2
4 Circlip 1

6-6
 WATER PUMP

Removing the water pump

10 N m (1.0 kgf m, 7.4 lb ft)

0 mm
(0 in)
5

13

9
8
7
6 11
10 12 E

FW
D
LS

a
LS

0 mm
(0 in)
Order Job/Parts to remove Q’ty Remarks
5 Impeller shaft assembly 1
6 Circlip 1
7 Impeller 1 1
8 Impeller 2 1
9 Impeller shaft 1
10 Water pump housing 1
11 O-ring 1
Make sure the projections “a” on the oil seal
12 Oil seal 1 point to the outside, and then install the oil
seal.
13 Bearing 2

6-7
 WATER PUMP

EAM30494

DISASSEMBLING THE WATER PUMP a

TIP
• Remove the oil seal when the coolant level
changes frequently more than usual, coolant
has discolored, or engine oil has become
milky.
• Do not use the removed oil seal. 1
1. Remove:
• Oil seal “1”
2. Install:
• Bearing “1” New
TIP
Install the bearings by pressing its outer race
parallel.

EAM30259

CHECKING THE WATER PUMP

1. Check:
• Water pump housing cover 1
• Impeller shaft
• Impeller
Cracks/damage/wear  Replace. 3. Install:
2. Check: • O-ring “1” New
• Bearing • Water pump housing “2”
Rotate the inner race with your finger. • Impeller shaft assembly “3”
Rough spot/seizure  Replace. • Circlip “4” New
TIP
Take care so that the oil seal lip is not damaged
or the spring does not slip off its position.

1 4
2
3

EAM30262

ASSEMBLING THE WATER PUMP

1. Install:
• Oil seal “1” New 4. Install:
TIP • Dowel pin “1”
• Apply the lithium-soap-based grease on the oil • O-ring “2” New
seal lip.
• Make sure the projections “a” on the oil seal
point to the outside, and then install the oil seal.

6-8
 WATER PUMP

5. Install:
• Water pump housing cover “1”
• Water pump housing bolt “2”
Water pump housing bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

• Washer “3” New

• Coolant drain bolt “4”
Coolant drain bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

1
4
2

6-9
 FUEL SYSTEM

FUEL TANK ......................................................................................................7-1

REMOVING THE FUEL TANK ...................................................................7-2
REMOVING THE FUEL PUMP ..................................................................7-2
CHECKING THE FUEL PUMP BODY ........................................................7-2
CHECKING THE FUEL PUMP OPERATION .............................................7-2
1
INSTALLING THE FUEL PUMP .................................................................7-2
INSTALLING THE FUEL TANK ..................................................................7-3

THROTTLE BODY ............................................................................................7-4 2

CHECKING THE INJECTOR......................................................................7-7
CHECKING THE THROTTLE BODY .........................................................7-7

3
CHECKING THE FUEL PRESSURE..........................................................7-8
ADJUSTING THE THROTTLE POSITION SENSOR .................................7-8
INSTALLING THE AIR FILTER CASE ASSEMBLY BRACKET .................7-9

4
5
6
7
8
9
10
 FUEL TANK

EAM20140

FUEL TANK
Removing the fuel tank

4.0 N m (0.40 kgf m, 3.0 lb ft)

1 7 N m (0.7 kgf m, 5.2 lb ft)
7 N m (0.7 kgf m, 5.2 lb ft)
1
8 N m (0.8 kgf m, 5.9 lb ft)
4 3
5

2 2 5
4

3 (5)

7
6 6

8 N m (0.8 kgf m, 5.9 lb ft)

1

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS” on page
Seat 4-1.
Refer to “GENERAL CHASSIS” on page
Side cover (left/right) 4-1.
Refer to “GENERAL CHASSIS” on page
Shroud (left/right) 4-1.
1 Fuel pump coupler/Fuel hose 1/1 Disconnect.
2 Fuel tank 1
3 Fuel pump bracket 1
4 Fuel pump 1
5 Fuel pump gasket 1
6 Rubber damper 4
7 Damper 1

7-1
 FUEL TANK

EAM30263

REMOVING THE FUEL TANK

1. Extract the fuel in the fuel tank through the 2
fuel tank cap with a pump. 1
2. Remove:
• Seat
• Side cover (left/right)
• Shroud (left/right)
Refer to “GENERAL CHASSIS” on page 4-1.
3. Disconnect:
• Fuel pump coupler
• Fuel hose
EWA19370

WARNING
4 3
Cover the fuel hose connection with a cloth
when disconnecting it. This is because re-
sidual pressure in the fuel hose could cause
fuel to spurt out when the hose is removed.
ECA24710

NOTICE
Make sure that the fuel hose is disconnected
by hand. Do not forcefully disconnect the 4. Remove:
hose with tools. • Fuel tank
TIP
TIP Do not set the fuel tank down on the installation
• To disconnect the fuel hose from the fuel tank,
surface of the fuel pump. Be sure to lean the fuel
remove the fuel hose connector holder “a”, and
tank against a wall or the like.
then slide the fuel hose connector cover.
• To remove the fuel hose from the fuel rail, slide EAM30264
the fuel hose connector cover “1” on the end of REMOVING THE FUEL PUMP
the hose in the direction of the arrow shown, 1. Remove:
press the two buttons “2” on the sides of the • Fuel pump
connector, and then remove the hose. ECA24720

• Before removing the hose, place a few cloths NOTICE

in the area under where it will be removed. Do not drop the fuel pump or give it a strong
• To prevent sand, dust, and other foreign mate- shock.
rials from entering the fuel pump, install the in-
cluded fuel hose joint cover 1 “3” and the fuel EAM30265

hose joint cover 2 “4” onto the disconnected CHECKING THE FUEL PUMP BODY
fuel hose and the fuel pump. 1. Check:
• Fuel pump body
Obstructions  Clean.
Cracks/damage  Replace the fuel pump
assembly.
EAM30508
a
CHECKING THE FUEL PUMP OPERATION
1. Check:
• Fuel pump operation
Refer to “CHECKING THE FUEL PRES-
SURE” on page 7-8.
EAM30266

INSTALLING THE FUEL PUMP

1. Install:
• Fuel pump gasket New

7-2
 FUEL TANK

• Fuel pump • Install the fuel hose connector holder “a”.

• Fuel pump bracket • Check that the fuel hose and the fuel pump
lead are routed through the guide on the cover.
Fuel pump bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.

TIP
• Take care not to damage the installation sur- 1
faces of the fuel tank.
• Always use a new fuel pump gasket.
• Install the lip on the fuel pump gasket upward.
• Install the fuel pump as shown in the figure.
• Align the projection “a” on the fuel pump with
the slot “b” in the fuel pump bracket.
• Tighten the fuel pump bolts in the proper tight-
ening sequence as shown.

a a

3. Connect:
• Fuel pump coupler
4 4. Install:
• Shroud (left/right)
2 • Side cover (left/right)
• Seat
1 Refer to “GENERAL CHASSIS” on page 4-1.

5
3
EAM30267

INSTALLING THE FUEL TANK

1. Install:
• Fuel tank
2. Connect:
• Fuel hose
ECA24740

NOTICE
• 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.

7-3
 THROTTLE BODY

EAM20141

THROTTLE BODY
Removing the throttle body

7 N m (0.7 kgf m, 5.2 lb ft)

1
7 N m (0.7 kgf m, 5.2 lb ft)

7 N m (0.7 kgf m, 5.2 lb ft)

(2)
3.0 N m (0.30 kgf m, 2.2 lb ft)
3
5
(2) (2)

(2)
6
7
2
(2)

4.3 N m (0.43 kgf m, 3.2 lb ft) 8 (2)

1.5 N m (0.15 kgf m, 1.1 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) 10 N m (1.0 kgf m, 7.4 lb ft)

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS” on page
Seat 4-1.
Refer to “GENERAL CHASSIS” on page
Side cover (left/right) 4-1.
Refer to “GENERAL CHASSIS” on page
Shroud (left/right) 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
1 Air filter case cover 1
2 Intake air temperature sensor coupler 1 Disconnect.
3 Cylinder head breather hose 1
4 Air filter case 1
5 Air filter case assembly bracket 1
6 Intake air temperature sensor 1
7 Cover 1
8 Throttle cable cover 1

7-4
 THROTTLE BODY

Removing the throttle body

7 N m (0.7 kgf m, 5.2 lb ft)

7 N m (0.7 kgf m, 5.2 lb ft)

16 7 N m (0.7 kgf m, 5.2 lb ft)

17 (2)
3.0 N m (0.30 kgf m, 2.2 lb ft)

(2) (2)

14 (2)
9

(2) 10
15 11
4.3 N m (0.43 kgf m, 3.2 lb ft) (2)

12
1.5 N m (0.15 kgf m, 1.1 lb ft) 13
8 N m (0.8 kgf m, 5.9 lb ft) 3.5 N m (0.35 kgf m, 2.6 lb ft) 10 N m (1.0 kgf m, 7.4 lb ft)

Order Job/Parts to remove Q’ty Remarks

9 Throttle cable 2
10 Fuel hose 1
11 Throttle body 1
12 Exhaust pipe bracket 1
13 Throttle body joint 1
14 Ignition coil bracket 1
15 Ignition coil 1
16 Air filter case bracket (right) 1
17 Air filter case bracket (left) 1

7-5
 THROTTLE BODY

Removing the injector

(2)
3.5 N m (0.35 kgf m, 2.6 lb ft)
1

5
3.5 N m (0.35 kgf m, 2.6 lb ft) 2

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

7-6
 THROTTLE BODY

EAM30271

CHECKING THE INJECTOR

1. Check:
• Injector
Obstruction  Replace, and check the fuel
2 1
pump and the fuel injection system.
Refer to “FUEL INJECTION SYSTEM” on
page 8-15.
Deposits  Replace.
Damage  Replace.
2. Check:
• Injector resistance
Refer to “CHECKING THE INJECTOR” on
page 8-55.
EAM30272

CHECKING THE THROTTLE BODY

1. Check:
• Throttle body
Cracks/damage  Replace.
3
2. Check:
• Fuel passages
Obstructions  Clean. b
ECA26070

NOTICE a
• Before removing the throttle body, clean
the area around the throttle body to prevent
dirt and other foreign material from falling
into the engine. 4
• If the throttle body is subject to strong
shocks or dropped during cleaning, re-
place it.
3. Check:
• Do not use any caustic carburetor cleaning
• Idle screw “1” passage “a”
solution.
Obstruction  Blow out with compressed air.
• 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. 1
• Do not use compressed air to clean the
throttle body. Foreign materials may ad-
here to the intake air pressure sensor pas- a
sage “a” and fuel injector “b” in the throttle
body.
4. Reset:
• Use the diagnostic code number “87”.
Refer to “DIAGNOSTIC CODE: SENSOR
OPERATION TABLE” on page 9-12.
Yamaha diagnostic tool USB (US)
90890-03269
Yamaha diagnostic tool (A/I)
90890-03264

7-7
 THROTTLE BODY

EAM30268

CHECKING THE FUEL PRESSURE Fuel line pressure (at idle)

1. Check: 300–390 kPa (3.0–3.9 kgf/cm²,
• Fuel pressure 43.5–56.6 psi)
a. Remove the side cover (left/right), the seat
and the shroud (left/right). EAM30273

Refer to “GENERAL CHASSIS” on page ADJUSTING THE THROTTLE POSITION

4-1. SENSOR
EWA15950
b. Remove the fuel tank bolt and lift the fuel WARNING
tank.
• Handle the throttle position sensor with
c. Disconnect the fuel hose from the fuel
special care.
pump.
• Never subject the throttle position sensor
Refer to “REMOVING THE FUEL TANK”
to strong shocks. If the throttle position
on page 7-2.
EWA19380 sensor is dropped, replace it.
WARNING 1. Check:
Cover the fuel hose connection with a cloth • Throttle position sensor
when disconnecting it. This is because re- Refer to “CHECKING THE THROTTLE PO-
sidual pressure in the fuel hose could cause SITION SENSOR INPUT VOLTAGE” on
fuel to spurt out when the hose is removed. page 8-53.
ECA24750 2. Adjust:
NOTICE • Throttle position sensor angle
Make sure that the fuel hose is disconnected a. Connect the Yamaha diagnostic tool.
by hand. Do not forcibly disconnect the hose Refer to “YAMAHA DIAGNOSTIC TOOL”
with tools. on page 8-17.
d. Connect the pressure gauge “1” and the Yamaha diagnostic tool USB (US)
fuel pressure adapter “2” to the fuel hose. 90890-03269
Yamaha diagnostic tool (A/I)
Pressure gauge 90890-03264
90890-03153
Pressure gauge b. Temporary tighten the throttle position
YU-03153 sensor.
Fuel pressure adapter c. Check that the throttle grip is fully closed.
90890-03186 d. Connect the throttle position sensor to the
Fuel pressure adapter
wire harness.
YM-03186
e. Set the Yamaha diagnostic tool to “diag-
nostic mode”.
1 2 f. Choose the diagnostic code No. “01”.
g. Adjust the throttle position sensor mount-
ed angle until “11”–“14” appears on the
Yamaha diagnostic tool.
h. After adjusting the throttle position sensor
mounted angle, tighten the throttle posi-
tion sensor screw “1”.
Throttle position sensor screw
3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.

e. Start the engine.

R.

f. Measure the fuel line pressure.

Out of specification  Replace the fuel
pump.

7-8
 THROTTLE BODY

3. Reset:
• Use the diagnostic code number “87”.
Refer to “DIAGNOSTIC CODE: SENSOR
OPERATION TABLE” on page 9-12.
EAM30631

INSTALLING THE AIR FILTER CASE

ASSEMBLY BRACKET
1. Install:
• Air filter case assembly bracket “1”
TIP
Align the projections “a” on the air filter case as-
sembly bracket with the grooves “b” in the air fil-
ter case “2”, and then push down the portion “c”.

1
2
a

7-9
 ELECTRICAL SYSTEM

IGNITION SYSTEM...........................................................................................8-1
CIRCUIT DIAGRAM ...................................................................................8-1
TROUBLESHOOTING................................................................................8-3

ELECTRIC STARTING SYSTEM......................................................................8-7

1
CIRCUIT DIAGRAM ...................................................................................8-7

2
TROUBLESHOOTING................................................................................8-9

CHARGING SYSTEM .....................................................................................8-11

CIRCUIT DIAGRAM .................................................................................8-11
TROUBLESHOOTING..............................................................................8-13

FUEL INJECTION SYSTEM ...........................................................................8-15

3
CIRCUIT DIAGRAM .................................................................................8-15
YAMAHA DIAGNOSTIC TOOL ................................................................8-17
CONNECTING THE YAMAHA DIAGNOSTIC TOOL ...............................8-17
TROUBLESHOOTING DETAILS (FAULT CODE)....................................8-19 4
FUEL PUMP SYSTEM....................................................................................8-41

5
CIRCUIT DIAGRAM .................................................................................8-41
TROUBLESHOOTING..............................................................................8-43

ELECTRICAL COMPONENTS.......................................................................8-44

6
CHECKING THE SWITCHES...................................................................8-45
CHECKING THE FUSES..........................................................................8-47
CHECKING AND CHARGING THE BATTERY ........................................8-47
REPLACING THE ECU (Engine Control Unit)..........................................8-49
CHECKING THE RELAYS .......................................................................8-49

7
CHECKING THE RELAY UNIT (DIODE)..................................................8-49
CHECKING THE IGNITION SPARK GAP ................................................8-50
CHECKING THE SPARK PLUG CAP ......................................................8-50
CHECKING THE IGNITION COIL ............................................................8-50
CHECKING THE CRANKSHAFT POSITION SENSOR ...........................8-51
CHECKING THE LEAN ANGLE SENSOR ...............................................8-51
CHECKING THE STARTER MOTOR OPERATION ................................8-51
CHECKING THE STATOR COIL..............................................................8-52
8
CHECKING THE RECTIFIER/REGULATOR ...........................................8-52
CHECKING THE COOLANT TEMPERATURE SENSOR ........................8-53
CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE...8-53
CHECKING THE INTAKE AIR TEMPERATURE SENSOR .....................8-54
CHECKING THE GEAR POSITION SWITCH ..........................................8-54
9
CHECKING THE INJECTOR....................................................................8-55
CHECKING THE INDICATOR LIGHT ......................................................8-56

10
 IGNITION SYSTEM

EAM20142

IGNITION SYSTEM
EAM30277

CIRCUIT DIAGRAM

8-1
 IGNITION SYSTEM

1. Crankshaft position sensor

2. AC magneto
3. Rectifier/regulator
4. Engine ground
5. Frame ground
6. Battery
7. Fuse
8. Starter relay
9. Starter motor
10.Diode 1
11.CCU (Communication Control Unit)
12.ECU (Engine Control Unit)
13.Ignition coil
14.Spark plug
21.Gear position switch
22.Handlebar switch (left)
23.Indicator light
24.Mode switch
25.Engine stop switch
26.Handlebar switch (right)
27.Start switch

A. Wire harness
B. CCU sub-lead

8-2
 IGNITION SYSTEM

EAM30278

TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
Before troubleshooting, remove the following part(s):
1. Seat
2. Side cover (left/right)
3. Shroud (left/right)
4. Fuel tank
5. Air filter case cover

1. Check the ignition system wire har-

Reconnect.
ness connections. NG
OK
2. Check the fuse(s).
Refer to “CHECKING THE FUSES” Replace the fuse(s).
on page 8-47. NG
OK
3. Check the battery.
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on NG • Recharge or replace the battery.
page 8-47.
OK
4. Check the spark plug.
Refer to “CHECKING THE SPARK Correct or replace the spark plug.
PLUG” on page 3-13. NG
OK
5. Check the ignition spark gap.
Refer to “CHECKING THE IGNI- The ignition system circuit is OK.
TION SPARK GAP” on page 8-50. OK
NG
6. Check the ignition coil.
Refer to “CHECKING THE IGNI- Replace the ignition coil.
TION COIL” on page 8-50. NG
OK
7. Check the engine stop switch.
Refer to “CHECKING THE Replace the handlebar switch (left).
SWITCHES” on page 8-45. NG
OK
8. Check the crankshaft position sen-
sor.
Refer to “CHECKING THE CRANK- Replace the crankshaft position sensor.
SHAFT POSITION SENSOR” on NG
page 8-51.
OK

8-3
 IGNITION SYSTEM

9. Check the stator coil assembly.

Refer to “CHECKING THE STA- Replace the stator coil assembly.
TOR COIL” on page 8-52. NG
OK
10.Check the ignition system wire har-
ness.
Repair or replace the wire harness.
Refer to “CIRCUIT DIAGRAM” on NG
page 8-1.
OK
Replace the ECU.
The indicator light fail to blink.
TIP
Before troubleshooting, remove the following part(s):
1. Seat
2. Side cover (left)
3. Shroud (left)

1. Check the handlebar switch coupler

Reconnect.
(left) connections. NG
OK
2. Check the gear position switch cou-
Reconnect.
pler connections. NG
OK
3. Check the mode switch.
Refer to “CHECKING THE Replace the handlebar switch (left).
SWITCHES” on page 8-45. NG
OK
4. Check the gear position switch.
Refer to “CHECKING THE GEAR Replace the gear position switch.
POSITION SWITCH” on page 8-54. NG
OK
5. Check the fuel ignition system wire
harness.
Repair or replace the wire harness.
Refer to “CIRCUIT DIAGRAM” on NG
page 8-1.
OK
Replace the ECU.
The indicator light to blink.
TIP
Before troubleshooting, remove the following part(s):
1. Seat
2. Side cover (left)
3. Shroud (left)

8-4
 IGNITION SYSTEM

1. Check the handlebar switch coupler

Reconnect.
(left) connections. NG
OK
2. Check the handlebar switch (left).
Refer to “CHECKING THE Replace the handlebar switch (left).
SWITCHES” on page 8-45. NG
OK
3. Check the ignition system wire har-
ness.
Repair or replace the wire harness.
Refer to “CIRCUIT DIAGRAM” on NG
page 8-1.
OK
Replace the ECU.

8-5
 IGNITION SYSTEM

8-6
 ELECTRIC STARTING SYSTEM

EAM20143

ELECTRIC STARTING SYSTEM

EAM30279

CIRCUIT DIAGRAM

8-7
 ELECTRIC STARTING SYSTEM

5. Frame ground
6. Battery
7. Fuse
8. Starter relay
9. Starter motor
10.Diode 1
12.ECU (Engine Control Unit)
21.Gear position switch
22.Handlebar switch (left)
25.Engine stop switch
26.Handlebar switch (right)
27.Start switch

8-8
 ELECTRIC STARTING SYSTEM

EAM30281

TROUBLESHOOTING
The starter motor fails to turn.
TIP
Before troubleshooting, remove the following part(s):
1. Seat
2. Side cover (left/right)
3. Shroud (left/right)
4. Fuel tank
5. Air filter case cover

1. Check the fuse.

Refer to “CHECKING THE FUSES” Replace the fuse(s).
on page 8-47. NG
OK
2. Check the battery.
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on NG • Recharge or replace the battery.
page 8-47.
OK
3. Check the starter motor operation.
Starter motor is OK. Perform the electric
Refer to “CHECKING THE START-
starting system troubleshooting, starting
ER MOTOR OPERATION” on page OK with step (6).
8-51.
NG
4. Check the starter motor.
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-42. NG
OK
5. Check the diode 1.
Refer to “CHECKING THE RELAY Replace the diode 1.
UNIT (DIODE)” on page 8-49. NG
OK
6. Check the starter relay.
Refer to “CHECKING THE RE- Replace the starter relay.
LAYS” on page 8-49. NG
OK
7. Check the engine stop switch.
Refer to “CHECKING THE Replace the handlebar switch (left).
SWITCHES” on page 8-45. NG
OK
8. Check the start switch.
Refer to “CHECKING THE Replace the start switch.
SWITCHES” on page 8-45. NG
OK

8-9
 ELECTRIC STARTING SYSTEM

9. Check the entire starting system’s

wiring. Properly connect or repair the starting sys-
Refer to “CIRCUIT DIAGRAM” on NG tem’s wiring.
page 8-7.
OK
Replace the ECU.

8-10
 CHARGING SYSTEM

EAM20144

CHARGING SYSTEM
EAM30282

CIRCUIT DIAGRAM

8-11
 CHARGING SYSTEM

2. AC magneto
3. Rectifier/regulator
4. Engine ground
5. Frame ground
6. Battery
7. Fuse

8-12
 CHARGING SYSTEM

EAM30283

TROUBLESHOOTING
The battery is not being charged.
TIP
Before troubleshooting, remove the following part(s):
1. Seat
2. Side cover (left)
3. Shroud (left)

1. Check the entire charging system’s

Reconnect.
wiring. NG
OK
2. Check the fuse.
Refer to “CHECKING THE FUSES” Replace the fuse(s).
on page 8-47. NG
OK
3. Check the battery.
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on NG • Recharge or replace the battery.
page 8-47.
OK
4. Check the rectifier/regulator.
Refer to “CHECKING THE RECTI- Replace the rectifier/regulator.
FIER/REGULATOR” on page 8-52. NG
OK
5. Check the stator coil assembly.
Refer to “CHECKING THE STA- Replace the stator coil assembly.
TOR COIL” on page 8-52. NG
OK
6. Check the charging system wire
harness.
Repair or replace the wire harness.
Refer to “CIRCUIT DIAGRAM” on NG
page 8-11.
OK
This circuit is OK.

8-13
 CHARGING SYSTEM

8-14
 FUEL INJECTION SYSTEM

EAM20145

FUEL INJECTION SYSTEM

EAM30284

CIRCUIT DIAGRAM

(B)

8-15
 FUEL INJECTION SYSTEM

1. Crankshaft position sensor

2. AC magneto
3. Rectifier/regulator
4. Engine ground
5. Frame ground
6. Battery
7. Fuse
11.CCU (Communication Control Unit)
12.ECU (Engine Control Unit)
13.Ignition coil
14.Spark plug
15.Fuel injector
16.Fuel pump
17.Intake air temperature sensor
18.Coolant temperature sensor
19.Throttle position sensor
20.Intake air pressure sensor
21.Gear position switch
22.Handlebar switch (left)
23.Indicator light
25.Engine stop switch

A. Wire harness
B. CCU sub-lead

8-16
 FUEL INJECTION SYSTEM

EAM30285

YAMAHA DIAGNOSTIC TOOL

This model uses the Yamaha diagnostic tool to identify malfunctions.
For information about using the Yamaha diagnostic tool, refer to the operation manual that is included
with the tool.
Yamaha diagnostic tool USB (US)
90890-03269
Yamaha diagnostic tool (A/I)
90890-03264

EAM30356

CONNECTING THE YAMAHA DIAGNOSTIC TOOL

1. Disconnect the CCU sub-lead coupler “1”.

2. Connect the Yamaha diagnostic tool.

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 Yamaha diagnostic tool, refer to “YAMAHA DIAGNOS-
TIC TOOL OPERATION MANUAL”.

8-17
 FUEL INJECTION SYSTEM

5 6 7

1 8
2

5
3

1. ECU (Engine Control Unit)

2. Lead battery (12 V)
3. Vehicle battery
4. Vehicle
5. CCU sub-lead coupler
6. Sub-harness (included with the Yamaha diag-
nostic tool)
7. Vehicle communication cable (included with
the Yamaha diagnostic tool)
8. Yamaha diagnostic tool

8-18
 FUEL INJECTION SYSTEM

EAM30286

TROUBLESHOOTING DETAILS (FAULT CODE)

This section describes the measures per fault code number displayed on the Yamaha diagnostic tool.
Check and service the items or components that are the probable cause of the malfunction following
the order given.
After the check and service of the malfunctioning part have been completed, delete the fault codes dis-
played on the Yamaha diagnostic tool according to the reinstatement method.
Fault code No.:
Fault code number displayed on the Yamaha diagnostic tool when the engine failed to work normally.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC
CODE: SENSOR OPERATION TABLE” on page 9-12.

Parts connected to the ECU

The following parts are connected to the ECU.
When checking for a power short circuit, the couplers must be disconnected from all of the following
parts beforehand.
• Crankshaft position sensor • Intake air pressure sensor
• Fuel injector • Coolant temperature sensor
• Ignition coil • Intake air temperature sensor
• Throttle position sensor

Fault code No. 8

Fault code No. 8

Item Gear position switch: open or short circuit detected.

Able to start engine

Fail-safe system
Able to drive vehicle
Diagnostic code No. 25
Displays the gear position.
Diagnostic tool display • N (gear in neutral)
• 1 (gear in 1st or 2nd )
• 3 (gear in other than 1st or 2nd)
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of gear position Improperly connected  Con- Start switch to ON (no need to
switch coupler. nect the coupler securely, or start the engine), change the
Check the locking condition of repair/replace the wire harness. gear position from neutral posi-
the coupler. tion to 1st  2nd  …  5th
Disconnect the coupler, and position. (When doing so, be
check the pins (for bent or bro- sure to hold each position for 10
ken terminals and locking condi- seconds or more.)
tion of the pins). And then check the condition of
the fault code using the mal-
function mode of the Yamaha
diagnostic tool.
Condition is “Recovered”  Go
to item 7 and finish the service.
Condition is “Detected”  Go to
item 2.

8-19
 FUEL INJECTION SYSTEM

Fault code No. 8

Item Gear position switch: open or short circuit detected.

2 Connection of wire harness Improperly connected  Con- Start switch to ON (no need to
ECU coupler. nect the coupler securely, or start the engine), change the
Check the locking condition of repair/replace the wire harness. gear position from neutral posi-
the coupler. tion to 1st  2nd  …  5th
Disconnect the coupler, and position. (When doing so, be
check the pins (for bent or bro- sure to hold each position for 10
ken terminals and locking condi- seconds or more.)
tion of the pins). And then check the condition of
the fault code using the mal-
function mode of the Yamaha
diagnostic tool.
Condition is “Recovered”  Go
to item 7 and finish the service.
Condition is “Detected”  Go to
item 3.
3 Wire harness continuity. Open or short circuit  Replace Start switch to ON (no need to
the wire harness. start the engine), change the
Between gear position switch gear position from neutral posi-
coupler and ECU coupler. tion to 1st  2nd  …  5th
pink–pink position. (When doing so, be
white/blue–white/blue sure to hold each position for 10
yellow/green–yellow/green seconds or more.)
And then check the condition of
the fault code using the mal-
function 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 gear posi- Improperly mounted switch  Start switch to ON (no need to
tion switch. Remount or replace the switch. start the engine), change the
Check for looseness or pinch- Refer to “ENGINE REMOVAL” gear position from neutral posi-
ing. on page 5-2. tion to 1st  2nd  …  5th
position. (When doing so, be
sure to hold each position for 10
seconds or more.)
And then check the condition of
the fault code using the mal-
function mode 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 gear position switch. Execute the diagnostic mode. Start switch to ON (no need to
(Code No. 25) start the engine), change the
The values are indicated gear position from neutral posi-
according to the gear position. tion to 1st  2nd  …  5th
Gear in neutral: N position. (When doing so, be
Gear in 1st or 2nd: 1 sure to hold each position for 10
Gear in other than 1st or 2nd: 3 seconds or more.)
Abnormal display  Gear posi- And then check the condition of
tion switch is defective  the fault code using the mal-
Replace the gear position function mode of the Yamaha
switch. diagnostic tool.
Condition is “Recovered”  Go
to item 7 and finish the service.
Condition is “Detected”  Go to
item 6.
6 Faulty ECU. Replace the ECU. Service is finished.

8-20
 FUEL INJECTION SYSTEM

Fault code No. 8

Item Gear position switch: open or short circuit detected.

7 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. 12

Fault code No. 12

Crankshaft position sensor: no normal signals are received from

Item the crankshaft position sensor.

Unable to start engine

Fail-safe system
Unable to drive vehicle
Diagnostic code No. —
Diagnostic tool display —
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of crankshaft posi- Improperly connected  Con- Crank the engine 2 seconds or
tion sensor coupler. nect the coupler securely, or more, and then check the condi-
Check the locking condition of repair/replace the wire harness. tion of the fault code using the
the coupler. malfunction mode of the
Disconnect the coupler, and Yamaha diagnostic tool.
check the pins (for bent or bro- Condition is “Recovered”  Go
ken terminals and locking condi- to item 7 and finish the service.
tion of the pins). Condition is “Detected”  Go to
item 2.
2 Connection of wire harness Improperly connected  Con- Crank the engine 2 seconds or
ECU coupler. nect the coupler securely, or more, and then check the condi-
Check the locking condition of repair/replace the wire harness. tion of the fault code using the
the coupler. malfunction mode of the
Disconnect the coupler, and Yamaha diagnostic tool.
check the pins (for bent or bro- Condition is “Recovered”  Go
ken terminals and locking condi- to item 7 and finish the service.
tion of the pins). Condition is “Detected”  Go to
item 3.
3 Wire harness continuity. Open or short circuit  Replace Crank the engine 2 seconds or
the wire harness. more, and then check the condi-
Between crankshaft position tion of the fault code using the
sensor coupler and ECU cou- malfunction mode of the
pler. Yamaha diagnostic tool.
gray–gray Condition is “Recovered”  Go
Between crankshaft position to item 7 and finish the service.
sensor coupler and joint con- Condition is “Detected”  Go to
nector. item 4.
black/blue–black/blue
Between joint connector and
ECU coupler.
black/blue–black/blue

8-21
 FUEL INJECTION SYSTEM

Fault code No. 12

Crankshaft position sensor: no normal signals are received from

Item the crankshaft position sensor.

4 Mounted condition of crankshaft Improperly mounted sensor  Crank the engine 2 seconds or
position sensor. Remount or replace the sensor. more, and then check the condi-
Check for looseness or pinch- Refer to “GENERATOR” on tion of the fault code using the
ing. page 5-35. malfunction mode of the
Check the gap (0.85 mm Yamaha diagnostic tool.
(0.0335 in)) between the crank- Condition is “Recovered”  Go
shaft position sensor and the to item 7 and finish the service.
pickup rotor. Condition is “Detected”  Go to
item 5.
5 Defective crankshaft position Check the crankshaft position Crank the engine 2 seconds or
sensor. sensor. more, and then check the condi-
Refer to “CHECKING THE tion of the fault code using the
CRANKSHAFT POSITION malfunction mode of the
SENSOR” on page 8-51. Yamaha diagnostic tool.
Condition is “Recovered”  Go
to item 7 and finish the service.
Condition is “Detected”  Go to
item 6.
6 Faulty ECU. Replace the ECU. Service is finished.
7 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. 13

TIP
• If fault code numbers 13 and 14 are both displayed, perform checkup and repair jobs for fault code
number 13 first.
• Before troubleshooting, disconnect the starter motor lead from the starter relay.

Fault code No. 13

Item Intake air pressure sensor: open or short circuit detected.

Able to start engine

Fail-safe system
Able to drive vehicle
Diagnostic code No. 03
Diagnostic tool display Displays the intake air pressure.
Procedure The atmospheric pressure is displayed on the Yamaha diagnostic tool.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of intake air pres- Improperly connected  Con- Start switch to ON (no need to
sure sensor coupler. nect the coupler securely, or start the engine), and then
Check the locking condition of repair/replace the wire harness. check the condition of the fault
the coupler. code using the malfunction
Disconnect the coupler, and mode of the Yamaha diagnostic
check the pins (for bent or bro- tool.
ken terminals and locking condi- Condition is “Recovered”  Go
tion of the pins). to item 7 and finish the service.
Condition is “Detected”  Go to
item 2.

8-22
 FUEL INJECTION SYSTEM

Fault code No. 13

Item Intake air pressure sensor: open or short circuit detected.

2 Connection of wire harness Improperly connected  Con- Start switch to ON (no need to
ECU coupler. nect the coupler securely, or start the engine), and then
Check the locking condition of repair/replace the wire harness. check the condition of the fault
the coupler. code using the malfunction
Disconnect the coupler, and mode of the Yamaha diagnostic
check the pins (for bent or bro- tool.
ken terminals and locking condi- Condition is “Recovered”  Go
tion of the pins). to item 7 and finish the service.
Condition is “Detected”  Go to
item 3.
3 Wire harness continuity. Open or short circuit  Replace Start switch to ON (no need to
the wire harness. start the engine), and then
Between intake air pressure check the condition of the fault
sensor coupler and ECU cou- code using the malfunction
pler. mode of the Yamaha diagnostic
white–white tool.
blue–blue Condition is “Recovered”  Go
Between intake air pressure to item 7 and finish the service.
sensor coupler and joint con- Condition is “Detected”  Go to
nector. item 4.
black–black
Between joint connector and
ECU coupler.
black/blue–black/blue
4 Mounted condition of intake air Improperly mounted sensor  Start switch to ON (no need to
pressure sensor. Remount or replace the sensor. start the engine), and then
Check for looseness or pinch- check the condition of the fault
ing. code using the malfunction
Check the mounted position for mode of the Yamaha diagnostic
correctness. tool.
Condition is “Recovered”  Go
to item 7 and finish the service.
Condition is “Detected”  Go to
item 5.
5 Defective intake air pressure Execute the diagnostic mode. Start switch to ON (no need to
sensor. (Code No. 03) start the engine), and then
Proper display: check the condition of the fault
Atmospheric pressure at the code using the malfunction
current altitude and weather mode of the Yamaha diagnostic
conditions is indicated while tool.
engine stopping. Condition is “Recovered”  Go
0 m above sea level: About 101 to item 7 and finish the service.
kPa (about 3.63 V) Condition is “Detected”  Go to
1000 m above sea level: About item 6.
90 kPa (about 3.30 V)
2000 m above sea level: About
80 kPa (about 3.00 V)
3000 m above sea level: About
70 kPa (about 2.70 V)
Abnormal display  Intake air
pressure sensor is defective 
Replace the intake air pressure
sensor.
6 Faulty ECU. Replace the ECU. Service is finished.
7 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.

8-23
 FUEL INJECTION SYSTEM

Fault code No. 14

TIP
If fault code numbers 13 and 14 are both displayed, perform checkup and repair jobs for fault code num-
ber 13 first.

Fault code No. 14

Intake air pressure sensor: hose system malfunction (clogged or

Item
detached hose).

Able to start engine

Fail-safe system
Able to drive vehicle
Diagnostic code No. 03
Diagnostic tool display Displays the intake air pressure.
Procedure The atmospheric pressure is displayed on the Yamaha diagnostic tool.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 The intake air pressure sensor Repair or replace the sensor Start the engine and let it idle for
hose is damaged, discon- hose. approximately 5 seconds (fully
nected, clogged, twisted or close the throttle valve).
bent. 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 Execute the diagnostic mode. Start the engine and let it idle for
sensor. (Code No. 03) approximately 5 seconds (fully
Proper display: close the throttle valve).
Atmospheric pressure at the Check the condition of the fault
current altitude and weather code using the malfunction
conditions is indicated while mode of the Yamaha diagnostic
engine stopping. tool.
0 m above sea level: About 101 Condition is “Recovered”  Go
kPa (about 3.63 V) to item 3 and finish the service.
1000 m above sea level: About
90 kPa (about 3.30 V)
2000 m above sea level: About
80 kPa (about 3.00 V)
3000 m above sea level: About
70 kPa (about 2.70 V)
Value does not change during
cranking  Intake air pressure
sensor replacement.
3 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.

8-24
 FUEL INJECTION SYSTEM

Fault code No. 15

TIP
Before troubleshooting, disconnect the starter motor lead from the starter relay.

Fault code No. 15

Item Throttle position sensor: open or short circuit detected.

Able to start engine

Fail-safe system
Able to drive vehicle
Diagnostic code No. 01
Displays the throttle angle.
Diagnostic tool display • 11–14 (throttle in fully closed position)
• 86–92 (throttle in fully opened position)

Procedure • Check with throttle fully closed.

• Check with throttle fully opened.
Probable cause of malfunc- Confirmation of service com-
Item tion and check Maintenance job pletion
1 Connection of throttle position Improperly connected  Con- Start switch to ON (no need to
sensor coupler. nect the coupler securely, or start the engine), and then
Check the locking condition of repair/replace the wire harness. check the condition of the fault
the coupler. code using the malfunction
Disconnect the coupler, and mode of the Yamaha diagnostic
check the pins (for bent or bro- tool.
ken terminals and locking condi- Condition is “Recovered”  Go
tion of the pins). to item 8 and finish the service.
Condition is “Detected”  Go to
item 2.
2 Connection of wire harness Improperly connected  Con- Start switch to ON (no need to
ECU coupler. nect the coupler securely, or start the engine), and then
Check the locking condition of repair/replace the wire harness. check the condition of the fault
the coupler. code using the malfunction
Disconnect the coupler, and mode of the Yamaha diagnostic
check the pins (for bent or bro- tool.
ken terminals and locking condi- Condition is “Recovered”  Go
tion of the pins). to item 8 and finish the service.
Condition is “Detected”  Go to
item 3.
3 Wire harness continuity. Open or short circuit  Replace Start switch to ON (no need to
the wire harness. start the engine), and then
Between throttle position sensor check the condition of the fault
coupler and ECU coupler. code using the malfunction
yellow–yellow mode of the Yamaha diagnostic
blue–blue tool.
Between throttle position sensor Condition is “Recovered”  Go
coupler and joint connector. to item 8 and finish the service.
black–black Condition is “Detected”  Go to
Between joint connector and item 4.
ECU coupler.
black/blue–black/blue
4 Mounted condition of throttle Improperly mounted sensor  Start switch to ON (no need to
position sensor. Remount or replace the sensor. start the engine), and then
Check for looseness or pinch- Refer to “ADJUSTING THE check the condition of the fault
ing. THROTTLE POSITION SEN- code using the malfunction
Check the mounted position for SOR” on page 7-8. mode of the Yamaha diagnostic
correctness. tool.
Condition is “Recovered”  Go
to item 8 and finish the service.
Condition is “Detected”  Go to
item 5.

8-25
 FUEL INJECTION SYSTEM

Fault code No. 15

Item Throttle position sensor: open or short circuit detected.

5 Applied voltage of throttle posi- Check the applied voltage. Start switch to ON (no need to
tion sensor lead. (black–blue) start the engine), and then
check the condition of the fault
Location of discon- Output code using the malfunction
nected lead voltage mode of the Yamaha diagnostic
tool.
Disconnected 5V Condition is “Recovered”  Go
ground lead to item 8 and finish the service.
Disconnected output 0 V Condition is “Detected”  Go to
lead item 6.

Disconnected power 0 V
supply lead
6 Defective throttle position sen- Execute the diagnostic mode. Start switch to ON (no need to
sor. (Code No. 01) start the engine), and then
Correct display range: check the condition of the fault
When the throttle is fully closed, code using the malfunction
11–14 displays. mode of the Yamaha diagnostic
When the throttle is fully tool.
opened, 86–92 displays. Condition is “Recovered”  Go
Incorrect display range  to item 8 and finish the service.
Replace the throttle position Condition is “Detected”  Go to
sensor, and then reset the ECU item 7.
using the diagnostic code num-
ber “87”.
Refer to “DIAGNOSTIC CODE:
SENSOR OPERATION TABLE”
on page 9-12.
7 Faulty ECU. Replace the ECU. Service is finished.
8 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. 16

TIP
• If fault code numbers 15 and 16 are both displayed, perform checkup and repair jobs for fault code
number 15 first.
• Before troubleshooting, disconnect the starter motor lead from the starter relay.

Fault code No. 16

Item Throttle position sensor: stuck throttle position sensor is detected.

Able to start engine

Fail-safe system
Able to drive vehicle
Diagnostic code No. 01
Displays the throttle angle.
Diagnostic tool display • 11–14 (throttle in fully closed position)
• 86–92 (throttle in fully opened position)
• Check with throttle fully closed.
Procedure • Check with throttle fully opened.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion

8-26
 FUEL INJECTION SYSTEM

Fault code No. 16

Item Throttle position sensor: stuck throttle position sensor is detected.

1 Mounted condition of throttle Improperly mounted sensor  Start switch to ON (no need to
position sensor. Remount or replace the sensor. start the engine), and open and
Check for looseness or pinch- Refer to “ADJUSTING THE close the throttle several times.
ing. THROTTLE POSITION SEN- Check the condition of the fault
Check the mounted condition SOR” on page 7-8. code using the malfunction
for correctness. mode of the Yamaha diagnostic
tool.
Condition is “Recovered”  Go
to item 4 and finish the service.
Condition is “Detected”  Go to
item 2.
2 Defective throttle position sen- Execute the diagnostic mode. Start switch to ON (no need to
sor. (Code No. 01) start the engine), and open and
Correct display range: close the throttle several times.
When the throttle is fully closed, Check the condition of the fault
11–14 displays. code using the malfunction
When the throttle is fully mode of the Yamaha diagnostic
opened, 86–92 displays. tool.
Incorrect display range  Condition is “Recovered”  Go
Replace the throttle position to item 4 and finish the service.
sensor, and then reset the ECU Condition is “Detected”  Go to
using the diagnostic code num- item 3.
ber “87”.
Refer to “DIAGNOSTIC CODE:
SENSOR OPERATION TABLE”
on page 9-12.
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

TIP
• Make sure that the machine is completely cold before checking the coolant temperature sensor.
• Before troubleshooting, disconnect the starter motor lead from the starter relay.

Fault code No. 21

Item Coolant temperature sensor: open or short circuit detected.

Able to start engine

Fail-safe system
Able to drive vehicle
Diagnostic code No. 06
Diagnostic tool display Displays the coolant temperature.
Compare the actually measured coolant temperature with the Yamaha
Procedure
diagnostic tool display value.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion

8-27
 FUEL INJECTION SYSTEM

Fault code No. 21

Item Coolant temperature sensor: open or short circuit detected.

1 Connection of coolant tempera- Improperly connected  Con- Start switch to ON (no need to
ture sensor coupler. nect the coupler securely, or start the engine), and then
Check the locking condition of repair/replace the wire harness. check the condition of the fault
the coupler. code using the malfunction
Disconnect the coupler, and mode of the Yamaha diagnostic
check the pins (for bent or bro- tool.
ken terminals and locking condi- Condition is “Recovered”  Go
tion of the pins). to item 7 and finish the service.
Condition is “Detected”  Go to
item 2.
2 Connection of wire harness Improperly connected  Con- Start switch to ON (no need to
ECU coupler. nect the coupler securely, or start the engine), and then
Check the locking condition of repair/replace the wire harness. check the condition of the fault
the coupler. code using the malfunction
Disconnect the coupler, and mode of the Yamaha diagnostic
check the pins (for bent or bro- tool.
ken terminals and locking condi- Condition is “Recovered”  Go
tion of the pins). to item 7 and finish the service.
Condition is “Detected”  Go to
item 3.
3 Wire harness continuity. Open or short circuit  Replace Start switch to ON (no need to
the wire harness. start the engine), and then
Between coolant temperature check the condition of the fault
sensor coupler and ECU cou- code using the malfunction
pler. mode of the Yamaha diagnostic
green–green tool.
Between coolant temperature Condition is “Recovered”  Go
sensor coupler and joint con- to item 7 and finish the service.
nector. Condition is “Detected”  Go to
black–black item 4.
Between joint connector and
ECU coupler.
black/blue–black/blue
4 Mounted condition of coolant Improperly mounted sensor  Start switch to ON (no need to
temperature sensor. Remount or replace the sensor. start the engine), and then
Check for looseness or pinch- check the condition of the fault
ing. code using the malfunction
Check the mounted position for mode of the Yamaha diagnostic
correctness. tool.
Condition is “Recovered”  Go
to item 7 and finish the service.
Condition is “Detected”  Go to
item 5.
5 Defective coolant temperature Execute the diagnostic mode. Start switch to ON (no need to
sensor. (Code No. 06) start the engine), and then
Proper display: check the condition of the fault
When the machine is cold, dis- code using the malfunction
played temperature is close to mode of the Yamaha diagnostic
the ambient temperature. tool.
Improper display  Replace the Condition is “Recovered”  Go
coolant temperature sensor. to item 7 and finish the service.
Refer to “RADIATOR” on page Condition is “Detected”  Go to
6-2. item 6.
6 Faulty ECU. Replace the ECU. Service is finished.
7 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.

8-28
 FUEL INJECTION SYSTEM

Fault code No. 22

TIP
• Make sure that the machine is completely cold before checking the intake air temperature sensor.
• Before troubleshooting, disconnect the starter motor lead from the starter relay.

Fault code No. 22

Item Intake air temperature sensor: open or short circuit detected.

Able to start engine

Fail-safe system
Able to drive vehicle
Diagnostic code No. 05
Diagnostic tool display Displays the intake air temperature.
Compare the actually measured intake air temperature with the Yamaha
Procedure
diagnostic tool display value.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of intake air temper- Improperly connected  Con- Start switch to ON (no need to
ature sensor coupler. nect the coupler securely, or start the engine), and then
Check the locking condition of repair/replace the wire harness. check the condition of the fault
the coupler. code using the malfunction
Disconnect the coupler, and mode of the Yamaha diagnostic
check the pins (for bent or bro- tool.
ken terminals and locking condi- Condition is “Recovered”  Go
tion of the pins). to item 7 and finish the service.
Condition is “Detected”  Go to
item 2.
2 Connection of wire harness Improperly connected  Con- Start switch to ON (no need to
ECU coupler. nect the coupler securely, or start the engine), and then
Check the locking condition of repair/replace the wire harness. check the condition of the fault
the coupler. code using the malfunction
Disconnect the coupler, and mode of the Yamaha diagnostic
check the pins (for bent or bro- tool.
ken terminals and locking condi- Condition is “Recovered”  Go
tion of the pins). to item 7 and finish the service.
Condition is “Detected”  Go to
item 3.
3 Wire harness continuity. Open or short circuit  Replace Start switch to ON (no need to
the wire harness. start the engine), and then
Between intake air temperature check the condition of the fault
sensor coupler and ECU cou- code using the malfunction
pler. mode of the Yamaha diagnostic
brown/white–brown/white tool.
Between intake air temperature Condition is “Recovered”  Go
sensor coupler and joint con- to item 7 and finish the service.
nector. Condition is “Detected”  Go to
black/blue–black/blue item 4.
Between joint connector and
ECU coupler.
black/blue–black/blue

8-29
 FUEL INJECTION SYSTEM

Fault code No. 22

Item Intake air temperature sensor: open or short circuit detected.

4 Mounted condition of intake air Improperly mounted sensor  Start switch to ON (no need to
temperature sensor. Remount or replace the sensor. start the engine), and then
Check for looseness or pinch- check the condition of the fault
ing. code using the malfunction
Check the mounted position for mode of the Yamaha diagnostic
correctness. tool.
Condition is “Recovered”  Go
to item 7 and finish the service.
Condition is “Detected”  Go to
item 5.
5 Defective intake air tempera- Execute the diagnostic mode. Start switch to ON (no need to
ture sensor. (Code No. 05) start the engine), and then
Proper display: check the condition of the fault
When the machine is cold, dis- code using the malfunction
played temperature is close to mode of the Yamaha diagnostic
the ambient temperature. tool.
Improper display  Replace the Condition is “Recovered”  Go
intake air temperature sensor. to item 7 and finish the service.
Condition is “Detected”  Go to
item 6.
6 Faulty ECU. Replace the ECU. Service is finished.
7 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. 30

TIP
• If fault code numbers 8, 15, 16, and 30 are displayed, perform checkup and repair jobs for fault code
number 8, 15, or 16 first.
• Before troubleshooting, disconnect the starter motor lead from the starter relay.

Fault code No. 30

Item The vehicle has overturned.

Unable to start engine

Fail-safe system
Unable to drive vehicle
Diagnostic code No. 08
Displays the lean angle sensor output voltage.
Diagnostic tool display • 0.4–1.4 (V) (upright)
• 3.7–4.4 (V) (overturned)
Procedure Remove the ECU, and incline it 45 or more.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion

8-30
 FUEL INJECTION SYSTEM

Fault code No. 30

Item The vehicle has overturned.

1 The vehicle has overturned. Raise the vehicle upright. Stand the vehicle upright, start
switch to ON (no need to start
the engine), wait 10 seconds,
and then check the condition of
the fault code using the mal-
function mode of the Yamaha
diagnostic tool.
Condition is “Recovered”  Go
to item 4 and finish the service.
Condition is “Detected”  Go to
item 2.
2 Mounted condition of ECU. Improperly mounted ECU  Stand the vehicle upright, start
Check for mounted position and Remount the ECU. switch to ON (no need to start
angle. the engine), wait 10 seconds,
Check the mounted condition and then check the condition of
for correctness. the fault code using the mal-
function mode of the Yamaha
diagnostic tool.
Condition is “Recovered”  Go
to item 4 and finish the service.
Condition is “Detected”  Go to
item 3.
3 Faulty ECU. Execute the diagnostic mode. Service is finished.
(Code No. 08)
Proper display:
When the vehicle is upright:
0.4–1.4 (V)
When the vehicle is overturned:
3.7–4.4 (V)
Improper display  Replace the
ECU.
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. 33

Fault code No. 33

Ignition coil: open or short circuit detected in the primary lead of

Item the ignition coil.

Unable to start engine

Fail-safe system
Unable to drive vehicle
Diagnostic code No. 30
Actuates the ignition coil five times at one-second intervals.
Actuation “WARNING” on the Yamaha diagnostic tool blinks five times when the
ignition coil is actuated.
Check that a spark is generated five times.
Procedure
• Connect an ignition checker.

Item Probable cause of malfunc- Maintenance job Confirmation of service com-

tion and check pletion

8-31
 FUEL INJECTION SYSTEM

Fault code No. 33

Ignition coil: open or short circuit detected in the primary lead of

Item
the ignition coil.

1 Connection of ignition coil cou- Improperly connected  Con- Start the engine and let it idle for
pler. nect the coupler securely, or approximately 5 seconds.
Check the locking condition of repair/replace the wire harness. Check the condition of the fault
the coupler. code using the malfunction
Disconnect the coupler, and mode of the Yamaha diagnostic
check the pins (for bent or bro- tool.
ken terminals and locking condi- Condition is “Recovered”  Go
tion of the pins). to item 7 and finish the service.
Condition is “Detected”  Go to
item 2.
2 Connection of wire harness Improperly connected  Con- Start the engine and let it idle for
ECU coupler. nect the coupler securely, or approximately 5 seconds.
Check the locking condition of repair/replace the wire harness. Check the condition of the fault
the coupler. code using the malfunction
Disconnect the coupler, and mode of the Yamaha diagnostic
check the pins (for bent or bro- tool.
ken terminals and locking condi- Condition is “Recovered”  Go
tion of the pins). to item 7 and finish the service.
Condition is “Detected”  Go to
item 3.
3 Wire harness continuity. Open or short circuit  Replace Start the engine and let it idle for
the wire harness. approximately 5 seconds.
Between ignition coil coupler Check the condition of the fault
and ECU coupler. code using the malfunction
white–white mode of the Yamaha diagnostic
Between ignition coil coupler tool.
and joint connector. Condition is “Recovered”  Go
red–red to item 7 and finish the service.
Between joint connector and Condition is “Detected”  Go to
ECU coupler. item 4.
red–red
4 Mounted condition of ignition Improperly mounted sensor  Start the engine and let it idle for
coil. Remount or replace the ignition approximately 5 seconds.
Check for looseness or pinch- coil. Check the condition of the fault
ing. code using the malfunction
Check the mounted condition mode of the Yamaha diagnostic
for correctness. tool.
Condition is “Recovered”  Go
to item 7 and finish the service.
Condition is “Detected”  Go to
item 5.
5 Defective ignition coil. (test the Check the primary resistance of Start the engine and let it idle for
primary coils for continuity) the ignition coil. approximately 5 seconds.
Refer to “CHECKING THE Check the condition of the fault
IGNITION COIL” on page 8-50. 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
item 6.
6 Faulty ECU. Execute the diagnostic mode. Service is finished.
(Code No. 30)
No spark  Replace the ECU.

8-32
 FUEL INJECTION SYSTEM

Fault code No. 33

Ignition coil: open or short circuit detected in the primary lead of

Item
the ignition coil.

7 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. 39

TIP
Disconnect the fuel pump coupler when this diagnostic tool is used.

Fault code No. 39

Item Injector: open or short circuit detected.

Unable to start engine

Fail-safe system
Unable to drive vehicle
Diagnostic code No. 36
Actuates injector five times at one-second intervals.
Actuation “WARNING” on the Yamaha diagnostic tool blinks five times when the
injector is actuated.

Procedure Check that injector is actuated five times by listening for the operating
sound.

Item Probable cause of malfunc- Maintenance job Confirmation of service com-

tion and check pletion
1 Connection of injector coupler. Improperly connected  Con- Start the engine and let it idle for
Check the locking condition of nect the coupler securely, or approximately 5 seconds.
the coupler. repair/replace the wire harness. Check the condition of the fault
Disconnect the coupler, and code using the malfunction
check the pins (for bent or bro- mode of the Yamaha diagnostic
ken terminals and locking condi- tool.
tion of the pins). Condition is “Recovered”  Go
to item 6 and finish the service.
Condition is “Detected”  Go to
item 2.
2 Defective injector. Check the injector. Start the engine and let it idle for
Refer to “CHECKING THE approximately 5 seconds.
INJECTOR” on page 8-55. 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 Improperly connected  Con- Start the engine and let it idle for
ECU coupler. nect the coupler securely, or approximately 5 seconds.
Check the locking condition of repair/replace the wire harness. Check the condition of the fault
the coupler. code using the malfunction
Disconnect the coupler, and mode of the Yamaha diagnostic
check the pins (for bent or bro- tool.
ken terminals and locking condi- Condition is “Recovered”  Go
tion of the pins). to item 6 and finish the service.
Condition is “Detected”  Go to
item 4.

8-33
 FUEL INJECTION SYSTEM

Fault code No. 39

Item Injector: open or short circuit detected.

4 Wire harness continuity. Open or short circuit  Replace Start the engine and let it idle for
the wire harness. approximately 5 seconds.
Between injector coupler and Check the condition of the fault
ECU coupler. code using the malfunction
red/black–red/black mode of the Yamaha diagnostic
Between injector coupler and tool.
joint connector. Condition is “Recovered”  Go
red–red to item 6 and finish the service.
Between joint connector and Condition is “Detected”  Go to
starter relay. item 5.
red/yellow–red/yellow
Between starter relay and bat-
tery terminal.
red–red
5 Faulty ECU. Replace the ECU. Service is finished.
6 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. 41

Fault code No. 41

Item ECU: built-in lean angle sensor malfunction.

Able to start engine

Fail-safe system
Able to drive vehicle
Diagnostic code No. 08
Displays the lean angle sensor output voltage.
Diagnostic tool display • 0.4–1.4 (V) (upright)
• 3.7–4.4 (V) (overturned)
Procedure Remove the ECU, and incline it 45 or more.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Faulty ECU. Replace the ECU. Service is finished.

Fault code No. 43

Fault code No. 43

Fuel system voltage: incorrect voltage supplied to the CCU, and

Item
incorrect recognition voltage of the motorcycle.

Able to start engine

Fail-safe system
Able to drive vehicle
Diagnostic code No. 09
Fuel system voltage
Diagnostic tool display
Approximately 12.0 (V)
Procedure Disconnect the starter relay, and push the start switch.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion

8-34
 FUEL INJECTION SYSTEM

Fault code No. 43

Fuel system voltage: incorrect voltage supplied to the CCU, and

Item
incorrect recognition voltage of the motorcycle.

1 Wire harness continuity. Open or short circuit  Replace Press the engine stop switch for
the wire harness. 1 second or more, and then
Between battery terminal and press the start switch (no need
starter relay. to start the engine).
red–red Check the condition of the fault
Between starter relay coupler code using the malfunction
and joint connector. mode of the Yamaha diagnostic
red/yellow–red/yellow tool.
Between joint connector and Condition is “Recovered”  Go
ECU coupler. to item 4 and finish the service.
red–red Condition is “Detected”  Go to
Between ECU coupler and CCU item 2.
coupler.
brown–brown
2 Malfunction in CCU. Replace the CCU. Press the engine stop switch for
1 second or more, and then
press the start switch (no need
to start the engine).
Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is “Recovered”  Go
to item 4 and finish the service.
Condition is “Detected”  Go to
item 3.
3 Malfunction in 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. 44

TIP
Before troubleshooting, disconnect the starter motor lead from the starter relay.

Fault code No. 44

EEPROM read error: an error is detected while reading or writing on

Item EEPROM.

Able to start engine

Fail-safe system
Able to drive vehicle
Diagnostic code No. 60
Displays the location of the abnormal portion of the EEPROM data.
• 00: No fault
Diagnostic tool display • 01: CO adjustment value
• 07: Power Tuner injection correction setting 0–8, or Power Tuner igni-
tion timing correction setting 0–8
• 12: Throttle position when fully closed
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion

8-35
 FUEL INJECTION SYSTEM

Fault code No. 44

EEPROM read error: an error is detected while reading or writing on

Item EEPROM.

1 Identification of malfunctioning Execute the diagnostic mode.

point. (Code No. 60)
00: Go to item 5.
01: Go to item 2.
07: Go to item 3.
12: Go to item 4.
2 “01” is indicated in diagnostic Change the CO concentration, Start switch to ON (no need to
mode. (Code No. 60) and rewrite in EEPROM. start the engine), and then
EEPROM read error for adjust- After this adjustment, push the check the condition of the fault
ment of CO concentration. engine stop switch, and then code using the malfunction
push the start switch. mode of the Yamaha diagnostic
tool.
Condition is “Recovered”  Go
to item 6 and finish the service.
Condition is “Detected” 
Repeat item 1.
If the same number is indicated,
go to item 5.
3 “07” is indicated in diagnostic Erase the setting map in the Start switch to ON (no need to
mode. (Code No. 60) diagnostic mode. (Code No. 65) start the engine), and then
EEPROM read error for setting check the condition of the fault
tool adjustment values for fuel code using the malfunction
injection amount or ignition tim- mode of the Yamaha diagnostic
ing. tool.
Condition is “Recovered”  Go
to item 6 and finish the service.
Condition is “Detected” 
Repeat item 1.
If the same number is indicated,
go to item 5.
4 “12” is indicated in diagnostic Press the engine stop switch for Start switch to ON (no need to
mode. (Code No. 60) 1 second or more, and then start the engine), and then
EEPROM read error for throttle press the start switch (no need check the condition of the fault
position when fully closed. to start the engine). code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is “Recovered”  Go
to item 6 and finish the service.
Condition is “Detected” 
Repeat item 1.
If the same number is indicated,
go to item 5.
5 Faulty ECU. Replace the ECU. Service is finished.
6 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.

8-36
 FUEL INJECTION SYSTEM

Fault code No. 46

Fault code No. 46

Vehicle system power supply: normal voltage is not supplied to the

Item ECU.

Able/Unable to start engine

Fail-safe system
Able/Unable to drive vehicle
Diagnostic code No. —
Diagnostic tool display —
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of rectifier/regulator Improperly connected  Con- Start the engine and let it idle for
coupler. nect the coupler securely, or approximately 5 seconds.
Check the locking condition of repair/replace the wire harness. Check the condition of the fault
the coupler. code using the malfunction
Disconnect the coupler, and mode of the Yamaha diagnostic
check the pins (bent or broken tool.
terminals and locking condition Condition is “Recovered”  Go
of the pins). to item 6 and finish the service.
Condition is “Detected”  Go to
item 2.
2 Connection of AC magneto cou- Improperly connected  Con- Start the engine and let it idle for
pler. nect the coupler securely, or approximately 5 seconds.
Check the locking condition of repair/replace the wire harness. Check the condition of the fault
the coupler. code using the malfunction
Disconnect the coupler, and mode of the Yamaha diagnostic
check the pins (bent or broken tool.
terminals and locking condition Condition is “Recovered”  Go
of the pins). to item 6 and finish the service.
Condition is “Detected”  Go to
item 3.
3 Wire harness continuity. Open or short circuit  Replace Start the engine and let it idle for
the wire harness. approximately 5 seconds.
Between rectifier/regulator cou- Check the condition of the fault
pler and starter relay coupler. code using the malfunction
red/white–red/white mode of the Yamaha diagnostic
Between starter relay coupler tool.
and battery terminal. Condition is “Recovered”  Go
red–red to item 6 and finish the service.
Between rectifier/regulator cou- Condition is “Detected”  Go to
pler and engine ground. item 4.
black–black
Between rectifier/regulator cou-
pler and AC magneto coupler.
white–white
4 Defective AC magneto. Check the AC magneto. Start the engine and let it idle for
Refer to “CHECKING THE STA- approximately 5 seconds.
TOR COIL” on page 8-52. 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 5.
5 Faulty ECU. Replace the ECU. Service is finished.

8-37
 FUEL INJECTION SYSTEM

Fault code No. 46

Vehicle system power supply: normal voltage is not supplied to the

Item
ECU.

6 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. 50

TIP
Before troubleshooting, disconnect the starter motor lead from the starter relay.

Fault code No. 50

Item ECU: faulty ECU memory.

Unable to start engine

Fail-safe system
Unable to drive vehicle
Diagnostic code No. —
Diagnostic tool display —
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Faulty ECU. Replace the ECU. Start switch to ON (no need to
start the engine), and then
check the condition 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

TIP
It is not a malfunction.
If the engine is forcibly stopped by leaving idle, the recovered state is recorded by malfunction mode.

Fault code No. 70

Engine forcibly stops when the vehicle is left idling for a long period
Item
of time.

—
Fail-safe system
Unable to drive vehicle
Diagnostic code No. —
Diagnostic tool display —
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion

8-38
 FUEL INJECTION SYSTEM

Fault code No. 70

Engine forcibly stops when the vehicle is left idling for a long period
Item of time.

1 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.

8-39
 FUEL INJECTION SYSTEM

8-40
 FUEL PUMP SYSTEM

EAM20146

FUEL PUMP SYSTEM

EAM30287

CIRCUIT DIAGRAM

8-41
 FUEL PUMP SYSTEM

2. AC magneto
3. Rectifier/regulator
4. Engine ground
5. Frame ground
6. Battery
7. Fuse
12.ECU (Engine Control Unit)
16.Fuel pump
22.Handlebar switch (left)
25.Engine stop switch

8-42
 FUEL PUMP SYSTEM

EAM30288

TROUBLESHOOTING
The fuel pump fails to operate.
TIP
Before troubleshooting, remove the following part(s):
1. Seat
2. Side cover (left/right)
3. Shroud (left/right)
4. Fuel tank
5. Air filter case cover

1. Check the fuel pump system wire

Reconnect.
harness connections. NG
OK
2. Check the fuse.
Refer to “CHECKING THE FUSES” Replace the fuse(s).
on page 8-47. NG
OK
3. Check the battery.
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on NG • Recharge or replace the battery.
page 8-47.
OK
4. Check the engine stop switch.
Refer to “CHECKING THE Replace the handlebar switch (left).
SWITCHES” on page 8-45. NG
OK
5. Check fuel pressure.
Refer to “CHECKING THE FUEL Replace the fuel pump.
PRESSURE” on page 7-8. NG
OK
6. Check the fuel pump system wire
harness connections.
Repair or replace the wire harness.
Refer to “CIRCUIT DIAGRAM” on NG
page 8-41.
OK
Replace the ECU.

8-43
 ELECTRICAL COMPONENTS

EAM20147

ELECTRICAL COMPONENTS

2 3 4
5

1
6

16

15
10

14 13 11
12
1. Rectifier/regulator
2. Mode switch
3. Engine stop switch
4. Intake air temperature sensor
5. Ignition coil
6. Battery
7. Starter relay
8. Fuse
9. ECU (Engine Control Unit)
10.CCU (Communication Control Unit)
11.Fuel pump
12.Gear position switch
13.Coolant temperature sensor
14.Injector
15.Throttle position sensor
16.Intake air pressure sensor

8-44
 ELECTRICAL COMPONENTS

EAM30289

CHECKING THE SWITCHES

2 3

P Sb Y/W
Y/W P
Sb

1. Handlebar switch (left)

2. Mode switch
3. Engine stop switch
4. Start switch
5. Gear position switch

8-45
 ELECTRICAL COMPONENTS

Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check
the wiring connections and if necessary, replace the switch.
ECA14371

NOTICE
Never insert the tester probes into the coupler terminal slots. Always insert the probes from the
opposite end “a” of the coupler, taking care not to loosen or damage the leads.

Digital circuit tester (CD732)

90890-03243
Model 88 Multimeter with tachom-
eter
YU-A1927

TIP
When checking for continuity, switch back and forth between the switch positions a few times.

Terminal connections of the switch are shown in the terminal connection diagram below.
The switch positions “a” are shown in the far left column and the switch lead colors are shown in the
top row in the switch illustration.
TIP
“ ” indicates continuity between switch terminals (i.e., a closed circuit at each switch position).
The example illustration below shows that:
There is continuity between red and brown when the switch is “ON”.

8-46
 ELECTRICAL COMPONENTS

EAM30290
systems to malfunction and could possibly
CHECKING THE FUSES cause a fire.
The following procedure applies to all of the fus-
es. 4. Install:
1. Remove: • Seat
• Seat • Side cover (left)
• Side cover (left) Refer to “GENERAL CHASSIS” on page 4-1.
Refer to “GENERAL CHASSIS” on page 4-1. EAM30291

2. Check: CHECKING AND CHARGING THE BATTERY

• Fuse “1” EWA20430

WARNING
To avoid sparking, burns, fire, and explo-
sion:
• Charge battery only with specified charger.
1 • Use battery only for specified product – no
other use.
• Do not place near fire or immerse in water.
• Do not use battery if it has been dropped,
subject to impact, or visibly damaged.
• Do not disassemble or modify the battery,
a. Connect the digital circuit tester to the fuse or short across its terminals.
and check the continuity. ECA28440

TIP NOTICE
Set the digital circuit tester selector to “  ”. To prevent damage to the battery and battery
malfunction:
Digital circuit tester (CD732) • Be sure to charge the battery using only the
90890-03243 specified battery charger. Do not use a
Model 88 Multimeter with tachom- charger designed for lead-acid batteries.
eter Otherwise, the battery could be damaged,
YU-A1927 such as from a long period of excessive
current or voltage exceeding 16 V.
b. If the digital circuit tester indicates “O.L”,
• Avoid excessive current discharge, such
replace the fuse.
as pressing the start switch for a long time.
3. Replace:
Wait for more than 10 seconds before at-
• Fuse
tempting to start again. Charge the battery
a. Install a new fuse of the correct amperage
again as soon as possible. A long state of
rating.
discharge below 10 V will damage the bat-
b. Push the start switch to verify if the electri-
tery.
cal circuit is operational.
• Do not use the specified battery charger to
c. If the fuse immediately blows again, check
charge a battery other than the lithium-ion
the electrical circuit.
battery. Otherwise, the battery or charger
Amperage could be damaged.
Fuses Q’ty
rating • Be careful not to drop the battery or subject
Main 15 A 1 it to strong impacts.
• Avoid charging the battery at high temper-
Spare 15 A 1 atures of 65 C (149 F) or more or low tem-
EWA13310 peratures under 0 C (32 F). A control
WARNING feature preventing battery charging and
Never use a fuse with an amperage rating discharging will temporarily intervene. The
other than that specified. Improvising or us- battery will discharge at 65 C (149 F) or
ing a fuse with the wrong amperage rating more or low temperatures under -10 C (14
may cause extensive damage to the electri- F).
cal system, cause the lighting and ignition • If the battery is charged between 0 C (32

8-47
 ELECTRICAL COMPONENTS

F)and 10 C (50 F), battery charging may ECA26980

stop halfway without the battery becoming NOTICE

fully charged even when the specified bat- First, connect the positive battery lead, and
tery charger is used. If this occurs, discon- then the negative battery lead.
nect the battery charger, and then resume 8. Check:
charging again. • Battery terminal
TIP Dirt  Clean with a wire brush.
This model uses a lithium-ion battery. When Loose connection  Connect properly.
new, the battery is supplied in sleep mode to 9. Lubricate:
minimize current discharging until first-time use. • Battery terminal
In the sleep mode, a voltage as low as approxi-
Recommended lubricant
mately 0.1 V can be measured if voltage mea- Dielectric grease
surement is performed. As such the battery
cannot be used, but this is not a malfunction. By 10.Install:
activating the battery as follows, the sleep mode • Seat
will be canceled and the battery can be used Refer to “GENERAL CHASSIS” on page 4-1.
normally. Checking the battery
ECA26080
Charging (activation) steps
NOTICE
1. Remove:
• Seat The battery has a limited service life. If the
Refer to “GENERAL CHASSIS” on page 4-1. battery cannot be charged or it is determined
2. Disconnect: that the battery cannot be used after check-
• Battery leads ing the battery, it should be replaced. When
(from the battery terminals) replacing the battery, be sure to use a
ECA13700 Yamaha genuine lithium-ion battery.
NOTICE
TIP
First, disconnect the negative battery lead, Do not check the battery at high temperature of
and then the positive battery lead. 65 C (149 F) or more or low temperatures be-
3. Remove: low 10 C (50 F). Otherwise, the control feature
• Battery preventing battery charging and discharging will
4. Connect the battery charger (special tool) to temporarily intervene.
the battery. 1. Check:
Lithium battery charger • Battery
90890-05376 a. If the battery is hot, wait until the battery
Lithium battery charger has cooled down to the ambient tempera-
DBY-ACC51-70-02 ture.
b. Measure the voltage between the battery
TIP terminals.
• For instructions on charging and handling the 13.25 V or more  The battery is normal.
battery charger, refer to the battery charger’s Checking is finished.
instruction manual. Less than 13.25 V  Go to step (c).
• Once battery charging starts, the sleep mode c. Connect the battery charger (special tool)
is canceled. to the battery and charge it.
5. Charge the battery until it is fully charged. Lithium battery charger
6. Install: 90890-05376
• Battery Lithium battery charger
7. Connect: DBY-ACC51-70-02
• Battery lead
(to the battery terminals) TIP
For instructions on charging and handling the
battery charger, refer to the battery charger’s in-

8-48
 ELECTRICAL COMPONENTS

struction manual. 2. Connect the digital circuit tester () and bat-
tery (12 V) to the relay terminal as shown.
d. If the battery is hot, wait until the battery
Check the relay operation.
has cooled down to the ambient tempera-
Out of specification  Replace.
ture.
Starter relay
e. Measure the voltage between the battery
terminals.
13.25 V or more  The battery is normal. 3
Checking is finished.
10 V or more and less than 13.25 V 
Perform from step (c) again. R/W R/Y

Less than 10 V  Replace the battery.

L Br/W

TIP
Before replacing the battery, make sure that the 4
battery temperature is proper (temperature not 2 1
more than 65 C (149 F) or less than 0 C (32
F)). Otherwise, wait until the battery tempera- 1. Positive battery terminal
ture is proper and perform the procedure from 2. Negative battery terminal
step (c) again. 3. Positive tester probe
4. Negative tester probe
EAM30636

REPLACING THE ECU (Engine Control Unit)

Result
1. Turn off the main switch. Continuity
2. Replace the ECU (Engine Control Unit). (between “3” to “4”)
Refer to “GENERAL CHASSIS” on page 4-1.
3. Reset the ECU (Engine Control Unit). EAM30495
Use the diagnostic code number “87”. CHECKING THE RELAY UNIT (DIODE)
Refer to “DIAGNOSTIC CODE: SENSOR 1. Check:
OPERATION TABLE” on page 9-12. • Diode 1
Out of specification  Replace.
Yamaha diagnostic tool USB (US)
90890-03269 Digital circuit tester (CD732)
Yamaha diagnostic tool (A/I) 90890-03243
90890-03264 Model 88 Multimeter with tachom-
eter
4. Check: YU-A1927
• Engine idling speed
Start the engine, warm it up, and then mea- TIP
sure the engine idling speed. The digital circuit tester and the multimeter with
tachometer readings are shown in the following
Engine idling speed
table.
1900–2100 r/min

EAM30292 No continuity
CHECKING THE RELAYS Positive tester probe 
Check each switch for continuity with the digital Brown/White “1”
circuit tester. If the continuity reading is incor- Negative tester probe 
rect, replace the relay. Blue/White, Blue “2”
Continuity
Digital circuit tester (CD732) Positive tester probe 
90890-03243 Blue/White, Blue “2”
Model 88 Multimeter with tachom- Negative tester probe 
eter Brown/White “1”
YU-A1927
a. Disconnect the diode from the wire har-
1. Disconnect the relay from the wire harness. ness.

8-49
 ELECTRICAL COMPONENTS

b. Connect the digital circuit tester () to the the spark gap until a misfire occurs.
diode coupler as shown. EAM30295
c. Check the diode for continuity. CHECKING THE SPARK PLUG CAP
d. Check the diode for no continuity. 1. Remove:
• Spark plug cap
1 (from the spark plug lead)
2. Check:
• Spark plug cap resistance
Br/W
Out of specification  Replace.
L/W,
L Resistance
10.00 k
2
a. Connect the digital circuit tester () to the
EAM30294
spark plug cap.
CHECKING THE IGNITION SPARK GAP
Digital circuit tester (CD732)
1. Check: 90890-03243
• Ignition spark gap Model 88 Multimeter with tachom-
Out of specification  Perform the ignition eter
system troubleshooting, starting with step (5). YU-A1927
Refer to “TROUBLESHOOTING” on page
8-3.
Minimum ignition spark gap
6.0 mm (0.24 in)

TIP
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
a. Remove the spark plug cap from the spark
plug.
b. Connect the ignition checker “1” as b. Measure the spark plug cap resistance.
shown.
EAM30296

Ignition checker CHECKING THE IGNITION COIL

90890-06754 1. Disconnect:
Oppama pet–4000 spark checker • Ignition coil terminal
YM-34487 (from the wire harness)
• Spark plug cap
c. Crank the engine, and measure the igni- (from the ignition coil)
tion spark gap “a”. 2. Check:
• Primary coil resistance
Out of specification  Replace.
Primary coil resistance
1.98–2.42 

a. Connect the digital circuit tester () to the

ignition coil.
Digital circuit tester (CD732)
90890-03243
2. Spark plug cap Model 88 Multimeter with tachom-
eter
d. Crank the engine, and gradually increase YU-A1927

8-50
 ELECTRICAL COMPONENTS

• Positive tester probe 

2. Check:
Ignition coil terminal 1 “1” • Crankshaft position sensor resistance
• Negative tester probe  Out of specification  Replace.
Ignition coil terminal 2 “2”
Crankshaft position sensor resis-
tance
228–342 

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
b. Measure the primary coil resistance.
3. Check:
• Secondary coil resistance • Positive tester probe 
Gray “1”
Out of specification  Replace. • Negative tester probe 
Black “2”
Secondary coil resistance
14.64–21.96 k

a. Connect the digital circuit tester () to the 1 2

ignition coil.
Digital circuit tester (CD732)
90890-03243
Gy B
Model 88 Multimeter with tachom-
eter
YU-A1927

• Positive tester probe  b. Measure the crankshaft position sensor

Ignition coil terminal 1 “1” resistance.
• Negative tester probe 
Spark plug lead “2” EAM30298

CHECKING THE LEAN ANGLE SENSOR

1. Check:
• Mounted condition of ECU
Improperly mounted  Remount.
1 TIP
• The lean angle sensor is built into the ECU.
• The lean angle sensor stops the engine in case
of a turnover.
• To ensure that the lean angle sensor operates
correctly, do not change the installed condition
of the ECU.
b. Measure the secondary coil resistance.
EAM30297 EAM30299

CHECKING THE CRANKSHAFT POSITION CHECKING THE STARTER MOTOR

SENSOR OPERATION
1. Disconnect: 1. Check:
• Crankshaft position sensor coupler • Starter motor operation
(from the wire harness) Does not operate  Perform the electric
starting system troubleshooting, starting with

8-51
 ELECTRICAL COMPONENTS

step (3).
Refer to “TROUBLESHOOTING” on page
8-9.
a. Connect the positive battery terminal “1” 1 2
and starter motor lead “2” with a jumper
lead “3”.
EWA13810

WARNING
• A wire that is used as a jumper lead must
have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may
burn. b. Measure the stator coil assembly resis-
• This check is likely to produce sparks, tance.
therefore, make sure no flammable gas or EAM30301

fluid is in the vicinity. CHECKING THE RECTIFIER/REGULATOR

1. Check:
• Rectifier/regulator output voltage
Out of specification  Replace.
Regulated voltage (DC)
14.0–14.8 V

a. Set the digital tachometer to the ignition

coil.
Digital tachometer
90890-06760
b. Check the starter motor operation. Digital tachometer
EAM30300 YU-39951-B
CHECKING THE STATOR COIL
1. Disconnect: b. Connect the digital circuit tester (DCV) to
• Stator coil assembly coupler the rectifier/regulator coupler.
(from the wire harness)
Digital circuit tester (CD732)
2. Check: 90890-03243
• Stator coil assembly resistance Model 88 Multimeter with tachom-
Out of specification  Replace. eter
YU-A1927
Stator coil resistance
0.408–0.612 
• Positive tester probe 
a. Connect the digital circuit tester () to the Red “1”
• Negative tester probe 
stator coil assembly coupler. Black “2”
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with tachom-
eter
YU-A1927

• Positive tester probe 

White “1” W W B R
• Negative tester probe 
White “2”
2 1

c. Start the engine and let it run at about

5000 r/min.

8-52
 ELECTRICAL COMPONENTS

d. Measure the output voltage. minals do not get wet.

EAM30303 c. Place a thermometer in the coolant.
CHECKING THE COOLANT TEMPERATURE d. Slowly heat the coolant, and then let it cool
SENSOR to the specified temperature indicated in
1. Remove: the table.
• Coolant temperature sensor e. Check the coolant temperature sensor for
EWA14130
continuity at the temperatures indicated in
WARNING
the table.
• Handle the coolant temperature sensor
with special care.
• Never subject the coolant temperature sen-
sor to strong shocks. If the coolant temper-
ature sensor is dropped, replace it.
2. Check:
• Coolant temperature sensor resistance
Out of specification  Replace.
Coolant temperature sensor re-
sistance EAM30305
2310–2590  at 20 C (2310– CHECKING THE THROTTLE POSITION
2590  at 68 F)
SENSOR INPUT VOLTAGE
Coolant temperature sensor re-
sistance 1. Check:
310–326  at 80 C (310–326  at • Throttle position sensor input voltage
176 F) Out of specification  Replace the throttle
position sensor.
a. Connect the digital circuit tester () to the
Throttle position sensor input
coolant temperature sensor.
voltage
Digital circuit tester (CD732) 4–6 V
90890-03243
Model 88 Multimeter with tachom- a. Connect the test harness S– pressure
eter sensor (3P) to the throttle position sensor
YU-A1927 coupler and the wire harness.
b. Connect the digital circuit tester (DCV) to
• Positive tester probe  the test harness S– pressure sensor (3P).
Green “1”
• Negative tester probe  Digital circuit tester (CD732)
Black “2” 90890-03243
Model 88 Multimeter with tachom-
eter
YU-A1927
G B
Test harness S– pressure sensor
(3P)
90890-03207
G B
Test harness S– pressure sensor
(3P)
YU-03207
1 2
• Positive tester probe 
b. Immerse the coolant temperature sensor Blue “1”
• Negative tester probe 
in a container filled with coolant. Black “2”
TIP
Make sure the coolant temperature sensor ter-

8-53
 ELECTRICAL COMPONENTS

• Positive tester probe 

Brown/White “1”
• Negative tester probe 
Black/Blue “2”

2 1

c. Start the engine.

d. Measure the throttle position sensor input
voltage. 1 2
TIP
If the throttle position sensor is replaced, reset
the ECU using the diagnostic code number “87”. EAM30467

Refer to “DIAGNOSTIC CODE: SENSOR OP- CHECKING THE GEAR POSITION SWITCH
ERATION TABLE” on page 9-12. 1. Remove:
• Gear position switch
EAM30307
2. Check:
CHECKING THE INTAKE AIR • Gear position switch
TEMPERATURE SENSOR Out of specification  Replace.
1. Remove:
Digital circuit tester (CD732)
• Intake air temperature sensor
90890-03243
(from the air filter case) Model 88 Multimeter with tachom-
EWA14110

WARNING eter
YU-A1927
• Handle the intake air temperature sensor
with special care.
• Never subject the intake air temperature
sensor to strong shocks. If the intake air
temperature sensor is dropped, replace it.
2. Check:
• Intake air temperature sensor resistance
Out of specification  Replace.
Intake 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)

a. Connect the digital circuit tester () to the

intake air temperature sensor terminal.
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with tachom-
eter
YU-A1927

8-54
 ELECTRICAL COMPONENTS

b. Connect the digital circuit tester () to the

Continuity fuel injector coupler.
Positive tester probe 
Sky blue “1” Digital circuit tester (CD732)
Negative tester probe  90890-03243
Sensor terminal “a” Model 88 Multimeter with tachom-
Continuity eter
Positive tester probe  YU-A1927
Pink “2”
Negative tester probe 
Sensor terminal “b” • Positive tester probe 
Injector terminal “1”
Continuity • Negative tester probe 
Positive tester probe  Injector terminal “2”
Pink “2”
Negative tester probe 
Sensor terminal “c”
Continuity 1 2
Positive tester probe 
Yellow/White “3”
Negative tester probe 
Sensor terminal “d”
Continuity
Positive tester probe 
Yellow/White “3”
Negative tester probe 
Sensor terminal “e” c. Measure the fuel injector resistance.
Continuity
Positive tester probe 
Yellow/White “3”
Negative tester probe 
Sensor terminal “f”

f e 3 2

Y/W P
Sb
d
1
b a c

EAM30496

CHECKING THE INJECTOR

1. Remove:
• Fuel injector
Refer to “THROTTLE BODY” on page 7-4.
2. Check:
• Fuel injector resistance
Out of specification  Replace.
Resistance
12.0 

a. Disconnect the fuel injector coupler from

the fuel injector.

8-55
 ELECTRICAL COMPONENTS

EAM30632

CHECKING THE INDICATOR LIGHT

If the indicator light flashes orange, check and service the items or components that are the possible
cause of the malfunction.

1 1

2 3

1. Orange 3. 1 second
2. Approx. 1 second

Indicator light flashes orange fast

Fail-safe system Possible cause Actions

Throttle position sensor failure Replace the throttle position sen-

sor.
Intake air pressure sensor failure Replace the intake air pressure
sensor.
Unable to start engine
Unable to cranking engine Ignition coil failure Replace the ignition coil.
Injector failure Replace the injector.
Vehicle has overturned Raise the vehicle upright.
ECU failure Replace the ECU.

Indicator light flashes orange slow

Fail-safe system Possible cause Actions

Defective gear position switch Replace the gear position switch.

Defective intake air pressure sen- Replace the intake air pressure
sor sensor.
Defective throttle position sensor Replace the throttle position sen-
sor.
Defective intake air temperature Replace the intake air tempera-
sensor ture sensor.
Able to drive vehicle
Defective coolant temperature Replace the coolant temperature
sensor sensor.
Defective vehicle system power Replace the wire harness.
supply
Defective fuel system power sup-
ply
Defective writing on EEPROM Replace the ECU.
Defective ECU

8-56
 ELECTRICAL COMPONENTS

8-57
 TROUBLESHOOTING

TROUBLESHOOTING ......................................................................................9-1
GENERAL INFORMATION ........................................................................9-1
TROUBLESHOOTING OF ENGINE (fault code not detected) ...................9-1
TROUBLESHOOTING OF CLUTCH ..........................................................9-4
TROUBLESHOOTING OF TRANSMISSION .............................................9-6
1
TROUBLESHOOTING 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
2
3
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 OPERATION TABLE........................9-14

4
5
6
7
8
9
10
 TROUBLESHOOTING

EAM20148

TROUBLESHOOTING
EAM30309

GENERAL INFORMATION
TIP
Troubleshooting information provided here does not cover all the trouble symptoms, possible causes,
and remedial actions. Some items may not apply depending on the model. Use this information as a
guide and quick reference matrix when performing basic troubleshooting. Refer to the each chapter for
detailed information on checking, adjustment, and replacement.

EAM30509

TROUBLESHOOTING OF ENGINE (fault code not detected)

TIP
If a fault code is detected, refer to the “FUEL INJECTION SYSTEM” on page 8-15.
Engine does not crank.
Symptom Possible cause Actions

Refer to “TROUBLESHOOTING” under “ELECTRIC STARTING

Starter motor does not operate
SYSTEM” on page 8-7.
Starter clutch malfunction Replace the starter clutch.
Improper oil grade (starter clutch Change to recommended engine
Starter motor operates, but the
engine does not crank. slipping) oil.
Disassemble and check the
Stuck piston or seized crankshaft
engine. Replace defective parts.

Engine will not start or is difficult to start, but it cranks.

Symptom Possible cause Actions

Spark plug does not produce a Refer to “TROUBLESHOOTING” under “IGNITION SYSTEM” on page
spark 8-1.
— Measure the fuel pressure.
Empty fuel tank Fill the fuel tank with fuel.
Clogged fuel tank cap breather
hole Clean the fuel tank cap.

Clean, repair, or replace the fuel

Clogged or damaged fuel hose
hose.
Check the fuel passage. Repair or
Fuel leakage
Fuel not supplied replace as necessary.
Clogged fuel pump Clean or replace the fuel pump.
Cracks or damage in fuel pump Replace the fuel pump.
Refer to “TROUBLESHOOTING”
Fuel pump malfunction under “FUEL PUMP SYSTEM” on
page 8-41.
Failed or clogged fuel injector Replace the fuel injector.
ECU failure Replace the ECU.

9-1
 TROUBLESHOOTING

Symptom Possible cause Actions

Water or foreign material in fuel,

Change fuel.
degraded fuel
Tighten the spark plug to the spec-
Loose spark plug
ified torque.
Tighten bolts or nuts on cylinder
Loose cylinder head or cylinder head and cylinder to the specified
torque.
Damaged cylinder head gasket Replace the cylinder head gasket.
Incorrect valve timing Adjust the valve timing.
Incorrect valve clearance Adjust the valve clearance.
— Worn valve guide Replace the valve guide.
Bent, damaged, or stuck valve Replace the valve.
Poor contact between valve and Reface the valve-to-valve-seat
valve seat contact.
Fatigued or broken valve spring Replace the valve spring.
Worn, damaged, or stuck piston Replace the piston and piston
ring rings as a set.
Replace the piston and piston
Seized or damaged piston rings as a set.
Replace the cylinder, piston, and
Worn or damaged cylinder bore
piston rings as a set.

Incorrect idling speed or mid-to-high speed

Symptom Possible cause Actions

Incorrect spark plug gap Adjust the spark plug gap.

Worn or damaged spark plug Replace the spark plug.
Spark plug does not produce a
Defective spark plug cap Replace the spark plug cap.
spark
Defective ignition coil Replace the ignition coil.
ECU failure Replace the ECU.
— Measure the fuel pressure.
Check the fuel passage. Repair or
Fuel leakage
replace as necessary.
Clogged fuel pump Clean or replace the fuel pump.
Low fuel pressure
Cracks or damage in fuel pump Replace the fuel pump.
Refer to “TROUBLESHOOTING”
Fuel pump malfunction under “FUEL PUMP SYSTEM” on
page 8-41.
Failed or clogged fuel injector Replace the fuel injector.
Fuel not supplied
ECU failure Replace the ECU.

9-2
 TROUBLESHOOTING

Symptom Possible cause Actions

Worn camshaft lobe Replace the camshaft.

Water or foreign material in fuel,
Change fuel.
degraded fuel
Contaminated throttle body or
Clean the throttle body.
clogged internal passage
Incorrectly adjusted throttle cable Adjust the throttle grip free play.
Incorrectly adjusted idling speed Adjust the idle screw.
(idle screw)
Incorrect throttle position sensor Adjust the throttle position sensor
angle angle.
Incorrect acceleration position Adjust the acceleration position
— sensor angle sensor angle.
Faulty ECU Replace the ECU.
Clogged vacuum hose Clean the vacuum hose.
Cracks and damage in vacuum
Replace the vacuum hose.
hose
Damaged throttle body joint Replace the throttle body joint.
Tighten the throttle body joint bolts
Loose throttle body joint to the specified torque.
Clean or replace the air filter ele-
Clogged air filter element ment.

Incorrect oil level (high) Adjust the oil level to the specified
level.

Excessive noise from engine

Symptom Possible cause Actions

Incorrect valve clearance (too

Adjust the valve clearance.
wide)
Fatigued or broken valve spring Replace the valve spring.
Worn or damaged camshaft lobe Replace the camshaft.
Noise heard from around cylinder Replace the valve lifter and cylin-
head Worn or damaged valve lifter
der head as a set.
Worn or damaged camshaft jour-
Replace the camshaft.
nal
Worn or damaged cylinder head
Replace the cylinder head.
(camshaft journal)
Replace the timing chain and cam-
Worn or damaged timing chain
shaft sprocket as a set.
Worn or damaged camshaft Replace the timing chain and cam-
Noise heard from around timing sprocket shaft sprocket as a set.
chain Worn or damaged timing chain
Replace the timing chain guide.
guide
Cracked, damaged, or faulty tim- Replace the timing chain ten-
ing chain tensioner sioner.

9-3
 TROUBLESHOOTING

Symptom Possible cause Actions

Replace the piston and piston

Worn or damaged piston ring rings as a set.
Replace the piston and piston
Worn or damaged piston
rings as a set.
Replace the piston and piston pin
Worn piston (piston pin hole)
Noise heard from around piston as a set.
Worn or damaged piston pin Replace the piston pin.
Replace the cylinder, piston, and
Worn or damaged cylinder bore
piston rings as a set.
Carbon buildup in piston head and Clean the piston head and com-
combustion chamber bustion chamber.
Worn or damaged crankshaft jour-
nal or crank pin Replace the crankshaft.

Cracked, worn, or damaged bal- Replace the balancer drive gear

ancer shaft and balancer shaft as a set.
Worn or damaged balancer drive Replace the balancer drive gear
Noise heard from around crank- gear and balancer shaft as a set.
shaft
Worn or damaged big end bearing Replace the big end bearing.
Worn or damaged crankshaft jour- Replace the crankshaft journal
nal bearing bearing.
Worn or damaged balancer shaft Replace the balancer shaft journal
journal bearing bearing.
EAM30510

TROUBLESHOOTING OF CLUTCH
Manual clutch
Symptom Possible cause Actions

Improperly assembled clutch Reassemble the clutch.

Improperly adjusted clutch cable Adjust the clutch lever free play.
Tighten the pressure plate bolts to
Loose clutch spring the specified torque.
Fatigued clutch spring Replace the clutch spring.
Warped pressure plate Replace the pressure plate.
Replace the friction plates as a
Clutch slippage Worn friction plate
set.
Warped or worn clutch plate Replace the clutch plates as a set.
Adjust the engine oil level to the
Incorrect oil level
specified level.
Change to recommended engine
Incorrect oil viscosity (low)
oil.
Change to recommended engine
Deteriorated oil oil.

9-4
 TROUBLESHOOTING

Symptom Possible cause Actions

Faulty clutch spring Replace the clutch spring.

Warped pressure plate Replace the pressure plate.
Replace the friction plates as a
Swollen friction plate set.
Warped clutch plate Replace the clutch plates as a set.
Bent pull rod (outer pull type) Replace the pull rod.
Worn pull rod tooth (outer pull Replace the pull rod and pull lever
type) shaft as a set.
Bent push rod (inner push type) Replace the push rod.
Clutch drags Damaged or worn sleeve Replace the sleeve.
Seized primary driven gear bush-
ing Replace the primary driven gear.

Align the match mark on the pull

Improperly installed pull lever lever before installation.
Adjust the engine oil level to the
Incorrect oil level
specified level.
Change to recommended engine
Incorrect oil viscosity (high)
oil.

Deteriorated oil Change to recommended engine

oil.
Replace the primary drive gear or
Damaged or worn primary driven
crankshaft, and the primary driven
gear
gear as a set.
Tighten the clutch boss nut to the
Loose clutch boss nut
specified torque.
Clutch noise
Fatigued absorber Replace the absorber.
Replace the clutch housing bear-
Worn clutch housing bearing
ing.

Worn pressure plate bearing Replace the pressure plate bear-

ing.

9-5
 TROUBLESHOOTING

EAM30511

TROUBLESHOOTING OF TRANSMISSION
Symptom Possible cause Actions

Clutch drags Refer to “Clutch drags”.

Adjust the shift rod installation
Improperly adjusted shift rod
length.
Bent shift shaft Replace the shift shaft.
Foreign object in a shift drum Remove foreign object from shift
groove drum groove.
Damaged shift drum Replace the shift drum.
Difficult or impossible to shift Replace the shift fork and shift fork
transmission gear Seized shift fork
guide bar as a set.
Bent shift fork guide bar Replace the shift fork guide bar.
Foreign object between transmis- Remove foreign object from trans-
sion gears mission gears.
Replace the seized gear and the
Seized transmission gear
axle as a set.
Improperly assembled transmis- Reassemble the transmission axle
sion assembly.
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 shift fork.
Jumps out of gear
Shift drum incorrect axial play Replace the shift drum.
Worn shift drum groove Replace the shift drum.
Worn transmission gear dog Replace the transmission gear.
Damaged or worn transmission
gear Replace the transmission gear.

Transmission noise Worn main axle spline Replace the main axle.
Worn drive axle spline Replace the drive axle.
Worn bearing Replace the bearing.

9-6
 TROUBLESHOOTING

EAM30512

TROUBLESHOOTING OF COOLING SYSTEM

Symptom Possible cause Actions

Carbon buildup in piston head and Clean the piston head and com-
combustion chamber bustion chamber.
Clogged engine cooling water Check and clean the engine cool-
passages ing water passages.
Adjust the oil level to the specified
Incorrect oil level level.
Change to recommended engine
Incorrect oil viscosity
oil.
Change to recommended engine
Inferior oil quality
oil.
Add recommended coolant to the
Low coolant level
specified level.
Damaged or leaking radiator Replace the radiator.
Faulty radiator cap Replace the radiator cap.
Clogged radiator fin Clean the radiator fin.
Repair the radiator fin or replace
Bent or damaged radiator fin
the radiator.
Overheating
Damaged or faulty water pump Replace the water pump.
Damaged hoses or pipes Replace the hose or pipe.
Improperly connected hoses or Connect the hoses and pipes
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.
Clean or replace the air filter ele-
Clogged air filter element
ment.
Check the brake system and
Brake drags repair or replace faulty parts as
necessary.
Adjust to the specified spark plug
Incorrect spark plug gap
gap.
Replace the spark plug with the
Incorrect spark plug heat range
one of the specified type.
Faulty ECU Replace the ECU.
Contact between the water pump Disassemble the water pump and
housing cover and impeller replace faulty parts.
Noise from water pump
Worn water pump housing bearing Replace
the water pump housing
bearing.

9-7
 TROUBLESHOOTING

EAM30513

TROUBLESHOOTING OF BRAKE
Symptom Possible cause Actions

Worn brake pad Replace the brake pads as a set.

Worn or deflected brake disc Replace the brake disc.
Air in hydraulic brake system Bleed the hydraulic brake system.
Check the hydraulic brake system
Brake fluid leakage and repair or replace faulty parts
as necessary.
Add brake fluid to the specified
Incorrect brake fluid level (low)
level.
Stuck brake caliper piston Replace the caliper piston seal.
Poor performance of disc brake
Stuck brake caliper and slide pin Lubricate the caliper slide pin.
Tighten the union bolt to the speci-
Loose union bolt fied torque.
Damaged brake hose and brake Replace the brake hose and brake
pipe pipe.
Oil or grease on the brake disc or
Clean the brake disc or brake pad.
brake pad
Insufficient lubrication of brake Lubricate the brake lever or brake
lever or brake pedal pivot pedal pivot.

EAM30514

TROUBLESHOOTING OF SUSPENSION
Symptom Possible cause Actions

Bent or damaged inner tube Replace the inner tube.

Bent or damaged outer tube Replace the outer tube.
Damaged or worn slide metal Replace the slide metal.
Bent or damaged damper rod Replace the damper rod.
Bent wheel axle Replace the wheel axle.
Incorrect oil viscosity (high) Change to recommended fork oil.
Front fork is hard
Incorrect oil level (high) Adjust to the specified oil level.
Improperly adjusted spring pre- Adjust the spring preload.
load (hard)
Improperly adjusted rebound
Adjust the rebound damping.
damping (hard)
Improperly adjusted compression
Adjust the compression damping.
damping (hard)

9-8
 TROUBLESHOOTING

Symptom Possible cause Actions

Fatigued or broken fork spring Replace the fork spring.

Incorrect oil viscosity (low) Change to recommended fork oil.
Incorrect oil level (low) Adjust to the specified oil level.
Improperly adjusted spring pre-
Front fork is soft load (soft) Adjust the spring preload.

Improperly adjusted rebound

Adjust the rebound damping.
damping (soft)
Improperly adjusted compression
Adjust the compression damping.
damping (soft)
Bent, damaged, or corroded inner
Replace the inner tube.
tube
Cracked or damaged outer tube Replace the outer tube.
Improperly installed oil seal Replace the oil seal.
Damaged oil seal lip Replace the oil seal.
Leaking oil from front fork Incorrect oil level (high) Adjust to the specified oil level.
Tighten the damper rod assembly
Loose damper rod assembly bolt
bolt to the specified torque.
Damaged damper rod assembly Replace the damper rod assembly
bolt copper washer bolt copper washer.
Cracked or damaged cap bolt O-
Replace the cap bolt O-ring.
ring
Bent or damaged rear shock
Replace the rear shock absorber.
absorber rod
Bent swingarm pivot shaft Replace the swingarm pivot shaft.
Damaged or worn swingarm bear- Replace the swingarm bearing or
ing or bushing bushing.
Damaged or worn relay arm bear-
Replace the relay arm bearing.
ing
Rear suspension is hard Damaged or worn connecting arm Replace the connecting arm bear-
bearing ing.
Improperly adjusted rear shock
Adjust the spring preload.
absorber spring preload (hard)
Improperly adjusted rear shock
Adjust the rebound damping.
absorber rebound damping (hard)
Improperly adjusted rear shock
absorber compression damping Adjust the compression damping.
(hard)

9-9
 TROUBLESHOOTING

Symptom Possible cause Actions

Oil leaking from rear shock

absorber Replace the rear shock absorber.

Gas leaking from rear shock

Replace the rear shock absorber.
absorber
Fatigued or damaged rear shock
Replace the rear shock absorber.
absorber spring
Rear suspension is soft Improperly adjusted rear shock
Adjust the spring preload.
absorber spring preload (soft)
Improperly adjusted rear shock
Adjust the rebound damping.
absorber rebound damping (soft)
Improperly adjusted rear shock
absorber compression damping Adjust the compression damping.
(soft)
Bent, damaged, or corroded rear Replace the rear shock absorber.
Oil leaking from rear shock shock absorber rod
absorber
Damaged oil seal lip Replace the rear shock absorber.
EAM30515

TROUBLESHOOTING OF STEERING/HANDLING
Symptom Possible cause Actions

Tighten the lower ring nut to the

Loose lower ring nut specified torque.
Replace the bearing and bearing
Worn bearing or bearing race
race as a set.

Handlebar wobble Warped front fork Repair or replace the front fork.
Bent front wheel axle Replace the front wheel axle.
Adjust to the specified tire pres-
Incorrect tire pressure
sure.
Worn, deformed, or incorrect tire Replace the tire.
Lower ring nut is tightened too Tighten the lower ring nut to the
tight specified torque.
Bent lower bracket Replace the lower bracket.
Heavy steering Replace the bearing and bearing
Broken bearing or bearing race
race as a set.
Adjust to the specified tire pres-
Incorrect tire pressure
sure.

Loose spoke Tighten the spoke and adjust the

runout.
Damaged or worn wheel bearing Replace the wheel bearing.
Worn, deformed, or incorrect tire Replace the tire.
Front wheel vibration Loose wheel axle or wheel axle Tighten the wheel axle or wheel
nut axle nut to the specified torque.
Tighten the wheel axle pinch bolt
Loose wheel axle pinch bolt
to the specified torque.
Adjust to the specified front fork oil
Incorrect front fork oil level
level.

9-10
 TROUBLESHOOTING

Symptom Possible cause Actions

Tighten the spoke and adjust the

Loose spoke
runout.
Damaged or worn wheel bearing Replace the wheel bearing.
Worn, deformed, or incorrect tire Replace the tire.
Tighten the wheel axle nut to the
Loose wheel axle nut
Rear wheel vibration specified torque.
Tighten the swingarm pivot shaft
Loose swingarm pivot shaft
to the specified torque.
Bent or damaged swingarm Replace the swingarm bearing.
Damaged or worn swingarm bear- Replace the swingarm bearing or
ing or bushing bushing.
EAM30516

TROUBLESHOOTING OF CHARGING SYSTEM

Symptom Possible cause Actions

Battery is not charged Refer to “TROUBLESHOOTING” under “CHARGING SYSTEM” on

page 8-11.

9-11
 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAM20174

SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAM30497

SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM)

Fault code Item Page

8 Gear position switch: open or short circuit detected. 8-19

Crankshaft position sensor: no normal signals are received from the crank-
12 8-21
shaft position sensor.
13 Intake air pressure sensor: open or short circuit detected. 8-22
Intake air pressure sensor: hose system malfunction (clogged or detached
14 8-24
hose).
15 Throttle position sensor: open or short circuit detected. 8-25
16 Throttle position sensor: stuck throttle position sensor is detected. 8-26
21 Coolant temperature sensor: open or short circuit detected. 8-27
22 Intake air temperature sensor: open or short circuit detected. 8-29
30 The vehicle has overturned. 8-30
Ignition coil: open or short circuit detected in the primary lead of the ignition
33 coil. 8-31

39 Injector: open or short circuit detected. 8-33

41 ECU: built-in lean angle sensor malfunction. 8-34
Fuel system voltage: incorrect voltage supplied to the CCU, and incorrect
43 8-34
recognition voltage of the motorcycle.

44 EEPROM read error: an error is detected while reading or writing on 8-35

EEPROM.
46 Vehicle system power supply: normal voltage is not supplied to the ECU. 8-37
50 ECU: faulty ECU memory. 8-38
70 Engine forcibly stops when the vehicle is left idling for a long period of time. 8-38

EAM30425

DIAGNOSTIC CODE: SENSOR OPERATION TABLE

Diag-
nostic
Item Display Procedure
code
No.

01 Throttle angle Displays the throttle angle.

• Fully closed position • 11–14 • Check with throttle fully
closed.
• Fully opened position • 86–92 • Check with throttle fully
opened.
03 Pressure of suction pipe Displays the intake air pressure. The atmospheric pressure is
• Check the change of the displayed on the Yamaha
intake pressure valve when diagnostic tool.
the start switch is pushed.
05 Intake air temperature Displays the intake air tempera- Compare the actually mea-
ture. sured intake air temperature
with the Yamaha diagnostic
tool display value.

9-12
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Diag-
nostic Item Display Procedure
code
No.

06 Coolant temperature Displays the coolant tempera- Compare the actually mea-
ture. sured coolant temperature
with the Yamaha diagnostic
tool display value.
08 Lean angle sensor Displays the output voltage. Remove the ECU, and incline
it 45 or more.
• Upright • 0.4–1.4 (V)
• Overturn • 3.7–4.4 (V)
09 Monitor voltage Displays the voltage of the —
external battery connected to
the Yamaha diagnostic tool.
• Approximately 12.0 (V)
25 Gear position switch Operate the shift pedal.
• Gear in neutral •N
• Gear in 1st or 2nd •1
• Gear in other than 1st or 2nd • 3
60 EEPROM fault code display —
• No fault • 00
• CO adjustment value • 01
• Power Tuner injection cor- • 07
rection setting 0–8, or Power
Tuner ignition timing correc-
tion setting 0–8
• Fully-closed throttle angle • 12
64 Setting history display Displays the presence or —
absence of the setting history by
Power Tuner.
• There is no history. • 00
• There is some history. • 01
• History is unknown (History • 02
data is damaged).
65 Setting map erasure Displays the presence or Erase all setting maps by the
absence of the setting history by operation start processing.
Power Tuner.
• There is no setting. • 00
• There is some setting. • 01
70 Program version number Displays a program version No. —
87 AF control learning data —
• AF control learning data was • 00
cleared.
• AF control learning data was • 01
not cleared.

9-13
 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAM30426

DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

Diag-
nostic
Item Actuation Procedure
code
No.

30 Ignition coil Actuates the ignition coil five Check that a spark is gener-
times at one-second intervals. ated five times.
“WARNING” on the Yamaha • Connect an ignition checker.
diagnostic tool blinks five times
when the ignition coil is actu-
ated.
36 Injector Actuates the injector five times TIP: Before performing this
at one-second intervals. operation, be sure to dis-
“WARNING” on the Yamaha connect the fuel pump cou-
diagnostic tool blinks five times pler.
when the injector is actuated. Check that injector is actuated
five times by listening for the
operating sound.

9-14
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

9-15
 TUNING

CHASSIS ........................................................................................................10-1
SELECTION OF THE SECONDARY REDUCTION RATIO
(SPROCKET)...........................................................................................10-1
DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS.................10-1
TIRE PRESSURE .....................................................................................10-1
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
2
CHOOSING SET LENGTH.......................................................................10-3
SETTING OF SPRING AFTER REPLACEMENT.....................................10-4
REAR SHOCK ABSORBER SETTING PARTS .......................................10-4
SUSPENSION SETTING (FRONT FORK) ...............................................10-6
SUSPENSION SETTING (REAR SHOCK ABSORBER)..........................10-7
3
4
5
6
7
8
9
10
 CHASSIS

EAM20119

CHASSIS Part name Type Part number

EAM30168
Rear wheel 47T 17D-25447-50
sprocket “2”
SELECTION OF THE SECONDARY 48T 17D-25448-50
REDUCTION RATIO (SPROCKET)
(STD) 49T B2W-25449-00
Secondary reduction ratio = Number of 50T B2W-25450-00
rear wheel sprocket teeth/Number of
drive sprocket teeth 51T B2W-25451-00
52T 17D-25452-50
Secondary reduction ratio
3.769 (49/13)

<Requirement for selection of secondary gear

reduction ratio>
• It is generally said that the secondary gear ratio
should be reduced for a longer straight portion
of a speed course and should be increased for
a course with many corners. Actually, howev-
er, as the speed depends on the ground condi-
tion of the day of the race, be sure to run
through the circuit to set the machine suitable
for the entire course.
• In actuality, it is very difficult to achieve settings
suitable for the entire course and some set-
tings may be sacrificed. Thus, the settings
should be matched to the portion of the course
that has the greatest effect on the race result.
In such a case, run through the entire course
while making notes of lap times to find the best
balance; then, determine the secondary reduc-
tion ratio.
• If a course has a long straight portion where a EAM30170

TIRE PRESSURE
machine can run at maximum speed, the ma-
Tire pressure should be adjusted to suit the road
chine is generally set such that it can develop
surface condition of the circuit.
its maximum revolutions toward the end of the
straight line, with care taken to avoid the en- Standard tire pressure
gine over-revving. 100 kPa (1.00 kgf/cm², 15 psi)
TIP
Riding technique varies from rider to rider and • Under a rainy, a muddy, a sandy, or a slippery
the performance of a machine also vary from condition, the tire pressure should be lower for
machine to machine. Therefore, do not imitate a larger area of contact with the road surface.
other rider’s settings from the beginning but
Extent of adjustment
choose your own setting according to the level of
60–80 kPa (0.60–0.80 kgf/cm², 9–
your riding technique. 12 psi)
EAM30169
• Under a stony or a hard road condition, the tire
DRIVE AND REAR WHEEL SPROCKETS
SETTING PARTS pressure should be higher to prevent a flat tire.

Part name Type Part number Extent of adjustment

100–120 kPa (1.00–1.20 kgf/cm²,
Drive 15–18 psi)
(STD) 13T 9383E-13233
sprocket “1”

10-1
 CHASSIS

EAM30171

FRONT FORK SETTING

The front fork setting should be made depending
on the rider’s feeling of an actual run and the cir-
cuit conditions.
The front fork setting includes the following three
factors:
1. Setting of air spring characteristics
• Change the fork oil amount.
2. Setting of spring preload
• Change the spring.
3. Setting of damping force
• Change the compression damping force.
• Change the rebound damping force.
The spring acts on the load and the damping
force acts on the cushion travel speed.
EAM30172

CHANGE IN AMOUNT AND

CHARACTERISTICS OF FORK OIL
Damping characteristic near the final stroke can
be changed by changing the fork oil amount.
EWA19190

WARNING A. Air spring characteristics in relation to oil

amount change
Adjust the oil amount in 5 cm³ (0.2 US oz, 0.2
B. Load
Imp.oz) increments or decrements. Too
C. Stroke
small oil amount causes the front fork to pro-
duce a noise at full rebound or the rider to 1. Max. oil amount
feel some pressure on his hands or body. Al- 2. Standard oil amount
ternatively, too large oil amount will cause 3. Min. oil amount
the air spring characteristics to have a ten-
EAM30173
dency to be stiffer with the consequent dete- SETTING OF SPRING AFTER
riorated performance and characteristics. REPLACEMENT
Therefore, adjust the front fork within the As the front fork setting can be easily affected by
specified range. the rear suspension, take care so that the front
and the rear are balanced (in position etc.) when
Recommended oil setting the front fork.
Yamaha Suspension Oil S1
1. Use of soft spring
Standard oil amount
270 cm³ (9.13 US oz, 9.52 Imp.oz) • Change the rebound damping force.
Extent of adjustment Turn out one or two clicks.
260–365 cm³ (8.79–12.34 US oz, • Change the compression damping force.
9.17–12.87 Imp.oz) Turn in one or two clicks.
TIP
Generally a soft spring gives a soft riding feeling.
Rebound damping tends to become stronger
and the front fork may sink deeply over a series
of gaps.
2. Use of stiff spring
• Change the rebound damping force.
Turn in one or two clicks.
• Change the compression damping force.
Turn out one or two clicks.

10-2
 CHASSIS

TIP
Generally a stiff spring gives a stiff riding feeling.
Rebound damping tends to become weaker, re-
sulting in lack of a sense of contact with the road
surface or in a vibrating handlebar.
a
EAM30174

FRONT FORK SETTING PARTS

• Front fork spring
STD Spring rate
5.0
N/mm 2. Remove the stand or block from the engine
Spring I.D. and, with a rider astride the seat, measure the
Type rate Part number mark sunken length “b” between the rear wheel
N/mm (slits) axle center and “” mark of rear fender.
SOFT 4.5 BR9-23141-20 I-II
4.6 BR9-23141-30 I-III
4.7 BR9-23141-40 I-IIII
4.8 BR9-23141-50 I-IIIII b
4.9 BR9-23141-60 II-II
5.0 BR9-23141-70 II-III
STIFF 5.1 BR9-23141-80 II-IIII
3. Loosen the locknut “1” and make adjustment
TIP
The I.D. mark (slits) is proved on the end of the by turning the adjuster “2” to achieve the
spring. standard figure from the subtraction of the
length “b” from the length “a”.
EAM30175
Standard figure
REAR SUSPENSION SETTING 90–100 mm (3.5–3.9 in)
The rear shock absorber setting should be made
depending on the rider’s feeling of an actual run TIP
and the circuit conditions. • If the machine is new and after it is broken in,
The rear suspension setting includes the follow- the same set length of the spring may change
ing two factors: because of the initial fatigue, etc. of the spring.
1. Setting of spring preload Therefore, be sure to make reevaluation.
• Change the set length of the spring. • If the standard figure cannot be achieved by
• Change the spring. adjusting the adjuster and changing the set
2. Setting of damping force length, replace the spring with an optional one
• Change the rebound damping force. and make readjustment.
• 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- 1
sure the length “a” between the rear wheel
axle center and “” mark of rear fender. 2

10-3
 CHASSIS

EAM30177 EAM30178

SETTING OF SPRING AFTER REAR SHOCK ABSORBER SETTING PARTS

REPLACEMENT • Rear shock spring “1”
After replacement, be sure to adjust the spring to STD Spring rate
the set length [sunken length 90–100 mm (3.5– 58
N/mm
3.9 in)] and set it.
Spring
1. Use of soft spring I.D.
Type rate Part number
• Adjust to decrease rebound damping force to mark
N/mm
compensate for less spring load. Run with the
BR9-22212-00
rebound damping force adjuster one or two SOFT 52 Yellow
(Blue)
clicks turned out, and readjust it to suit your
preference. BR9-22212-10
54 Pink
(Blue)
2. Use of stiff spring
• Adjust to increase rebound damping force to BR9-22212-A0
White
(Silver)
compensate for greater spring load. Run with 56
the rebound damping force adjuster one or BR9-22212-20*
White
two clicks turned in, and readjust it to suit your (Blue)
preference. BR9-22212-B0 Gold
TIP (Silver)
58
Adjusting the rebound damping force will be fol- BR9-22212-30*
lowed more or less by a change in the compres- Silver
(Blue)
sion damping force. For correction, adjust to BR9-22212-40
decrease compression damping force. STIFF 60 Brown
(Blue)
EWA19200

WARNING * For Monster Energy Yamaha Racing Edition

only
When using a rear shock absorber other
than currently installed, use the one whose TIP
• The I.D. mark “a” is marked at the end of the
overall length “a” does not exceed the stan-
spring.
dard as it may result in faulty performance.
• Spring specification varies according to the
Never use one whose overall length is great-
color of I.D. marks.
er than standard.

Length “a” of standard shock

460.5 mm (18.1 in) 1

a
• Spring preload adjusting positions

10-4
 CHASSIS

Spring preload adjusting positions

Minimum
Position in which the spring is
turned in 1.5 mm (0.06 in) from
its free length.
Standard
Position in which the spring is
turned in 7.0 mm (0.28 in) from
its free length.
Maximum
Position in which the spring is
turned in 18.0 mm (0.71 in) from
its free length.

TIP
For the spring preload adjustment, refer to “AD-
JUSTING THE REAR SHOCK ABSORBER AS-
SEMBLY” on page 3-31.

10-5
 CHASSIS

EAM30179

SUSPENSION SETTING (FRONT FORK)

TIP
• If any of the following symptoms is experienced with the standard position as the base, make resetting
by reference to the adjustment procedure given in the same chart.
• Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm
(3.5–3.9 in).

Section
Symptom Check Adjust
Large Medium Small
Jump
gap gap gap

Turn adjuster counterclockwise

Compression
damping force (about 2 clicks) to decrease
damping.
Stiff over entire
   Decrease oil amount by about 5–
range
Oil amount 10 cm³ (0.2–0.3 US oz, 0.2–0.4
Imp.oz).
Spring Replace with soft spring.
Check for any bends, dents, other
Outer tube
noticeable scars, etc. If any,
Inner tube
replace affected parts.

Unsmooth move- Replace with a new one for

Slide metal
ment over entire     extended use.
range Replace with a new one for
Piston metal
extended use.
Lower bracket
Retighten to specified torque.
tightening torque
Turn adjuster counterclockwise
Rebound damp-
Poor initial move- (about 2 clicks) to decrease
 ing force
ment damping.
Oil seals Apply grease in oil seal wall.
Compression Turn adjuster clockwise (about 2
damping force clicks) to increase damping.
Soft over entire
Increase oil amount by about 5–
range, bottoming  
Oil amount 10 cm³ (0.2–0.3 US oz, 0.2–0.4
out
Imp.oz).
Spring Replace with stiff spring.
Stiff toward Decrease oil amount by about 5
 Oil amount
stroke end cm³ (0.2 US oz, 0.2 Imp.oz).
Soft toward
Increase oil amount by about 5
stroke end, bot-  Oil amount
toming out cm³ (0.2 US oz, 0.2 Imp.oz).

Turn adjuster counterclockwise

Stiff initial move- Compression
    (about 2 clicks) to decrease
ment damping force
damping.

10-6
 CHASSIS

Section
Symptom Check Adjust
Large Medium Small
Jump gap gap gap

Compression Turn adjuster clockwise (about 2

damping force clicks) to increase damping.
Turn adjuster counterclockwise
Rebound damp-
(about 2 clicks) to decrease
ing force
Low front, tend- damping.
ing to lower front   Set sunken length for 95–100
posture Balance with rear mm (3.7–3.9 in) when one pas-
end senger is astride seat (lower rear
posture).
Increase oil amount by about 5
Oil amount
cm³ (0.2 US oz, 0.2 Imp.oz).
Turn adjuster counterclockwise
Compression
damping force (about 2 clicks) to decrease
damping.
Set sunken length for 90–95 mm
“Obtrusive” front, Balance with rear (3.5–3.7 in) when one passenger
tending to upper   end is astride seat (upper rear pos-
front posture ture).
Spring Replace with soft spring.
Decrease oil amount by about 5–
Oil amount 10 cm³ (0.2–0.3 US oz, 0.2–0.4
Imp.oz).
EAM30180

SUSPENSION SETTING (REAR SHOCK ABSORBER)

TIP
• If any of the following symptoms is experienced with the standard position as the base, make resetting
by reference to the adjustment procedure given in the same chart.
• Adjust the rebound damping in 2-click increments or decrements.
• Adjust the low compression damping in 1-click increments or decrements.
• Adjust the high compression damping in 1/6 turn increments or decrements.

Section
Symptom Check Adjust
Large Medium Small
Jump
gap gap gap

Turn adjuster counterclockwise

Rebound damp-
(about 2 clicks) to decrease
ing force
Stiff, tending to damping.
sink  
Set sunken length for 90–100
Spring set length mm (3.5–3.9 in) when one pas-
senger is astride seat.
Rebound damp- Turn adjuster clockwise (about 2
ing force clicks) to increase damping.
Spongy and
  Low compres- Turn adjuster clockwise (about 1
unstable
sion damping click) to increase damping.
Spring Replace with stiff spring.

10-7
 CHASSIS

Section
Symptom Check Adjust
Large Medium Small
Jump
gap gap gap

Turn adjuster counterclockwise

Rebound damp-
Heavy and drag- (about 2 clicks) to decrease
  ing force damping.
ging
Spring Replace with soft spring.
Turn adjuster counterclockwise
Rebound damp-
(about 2 clicks) to decrease
ing force
damping.
Low compres- Turn adjuster clockwise (about 1
sion damping click) to increase damping.
Poor road grip-
ping  High compres- Turn adjuster clockwise (about
sion damping 1/6 turn) to increase damping.
Set sunken length for 90–100
Spring set length mm (3.5–3.9 in) when one pas-
senger is astride seat.
Spring Replace with soft spring.
High compres- Turn adjuster clockwise (about
sion damping 1/6 turn) to increase damping.
Set sunken length for 90–100
Bottoming out  
Spring set length mm (3.5–3.9 in) when one pas-
senger is astride seat.
Spring Replace with stiff spring.
Rebound damp- Turn adjuster clockwise (about 2
Bouncing   ing force clicks) to increase damping.
Spring Replace with soft spring.
Turn adjuster counterclockwise
High compres-
sion damping (about 1/6 turn) to decrease
damping.
Stiff travel   Set sunken length for 90–100
Spring set length mm (3.5–3.9 in) when one pas-
senger is astride seat.
Spring Replace with soft spring.

10-8
 CHASSIS

10-9
EAM20149 EAM30323

WIRING DIAGRAM COLOR CODE

YZ450FP 2023 B Black
1. Crankshaft position sensor Br Brown
2. AC magneto Dl Dark blue
3. Rectifier/regulator G Green
4. Engine ground Gy Gray
5. Frame ground L Blue
6. Battery P Pink
7. Fuse R Red
8. Starter relay Sb Sky blue
9. Starter motor W White
10. Diode 1 Y Yellow
11. CCU (Communication Control B/Br Black/Brown
Unit) B/L Black/Blue
12. ECU (Engine Control Unit) B/R Black/Red
13. Ignition coil B/W Black/White
14. Spark plug B/Y Black/Yellow
15. Fuel injector Br/W Brown/White
16. Fuel pump G/B Green/Black
17. Intake air temperature sensor G/Y Green/Yellow
18. Coolant temperature sensor L/B Blue/Black
19. Throttle position sensor L/W Blue/White
20. Intake air pressure sensor R/B Red/Black
21. Gear position switch R/L Red/Blue
22. Handlebar switch (left) R/W Red/White
23. Indicator light R/Y Red/Yellow
24. Mode switch W/B White/Black
25. Engine stop switch W/L White/Blue
26. Handlebar switch (right) Y/G Yellow/Green
27. Start switch Y/W Yellow/White

A. Wire harness
B. CCU sub-lead
For your best ownership experience, think Genuine Yamaha!
Genuine Yamaha Parts text
EAM20160

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originally equipped on your vehicle, providing you with the performance and durability you have come
to expect. Why settle for aftermarket parts that may not provide full confidence and satisfaction?

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quality and performance. Buy with confidence, knowing your Genuine Yamaha Accessories will fit right
and perform right – right out of the box.

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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 manual for your vehicle that the techni-
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dealer or you can order them directly through yamahapubs.com.

Genuine Yamaha products are available only from your Yamaha dealer.

Find out more at yamaha-motor.com

 YZ450FP 2023
WIRING DIAGRAM

(B)

BHR-2819U-10_W.D.indd 1 2022/08/09 13:16:06

 YZ450FP 2023
WIRING DIAGRAM

(B)

ON
OFF
PUSH PUSH
FREE FREE

BHR-2819U-10_W.D.indd 2 2022/08/09 13:16:06