Yz450fx 2019

2019
OWNER’S SERVICE MANUAL
YZ450FXK
YZ450FX
Read this manual carefully before operating this vehicle.
2019
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN

YZ450FXK
2018.05-0.3×2 !
(E)
LIT-11626-32-25 B3J-28199-10 ■
B3J-28199-10_2_cover_12mm.indd 1-3 2018/09/14 14:16:15

For your best ownership experience, think Genuine Yamaha!
Genuine Yamaha Parts – Genuine Yamaha replacement parts are the exact same parts as the ones
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?
Genuine Yamaha Accessories – Yamaha only offers accessories that meet our high standards for quality
and performance. Buy with confidence, knowing your Genuine Yamaha Accessories will fit right and
perform right – right out of the box.
Yamalube – Take care of your Yamaha with legendary Yamalube oils, lubricants, and care products.
They're formulated and approved by the toughest judges we know: the Yamaha engineering teams that
know your Yamaha from the inside out.
Genuine Yamaha Service Manuals – Get the same factory manual for your vehicle that the technicians
at your authorized Yamaha dealer use. Service manuals are available through your Yamaha dealer or you
can order them directly through yamahapubs.com.
Genuine Yamaha products are available only from your Yamaha dealer.
Read this manual carefully
EAM20161
Find out more at yamaha-motor.com

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
B3J-28199-10_1_cover_12mm.indd 4-6 2018/07/09 11:12:24

EAM20161
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
YZ450FXK
©2019 by Yamaha Motor Corporation, U.S.A.
First edition, May 2018
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in Japan.
P/N. LIT-11626-32-25
EAM20081
INTRODUCTION
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.

EAM20092
SAFETY INFORMATION
THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED
COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road
use on public lands may also be illegal. Please check local regulations before riding.
• THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY.
Do not attempt to operate this machine at maximum power until you are totally familiar with its char-
acteristics.
• THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY.
Do not carry passengers on this machine.
• ALWAYS WEAR PROTECTIVE APPAREL.
When operating this machine, always wear an approved helmet with goggles or a face shield. Also
wear heavy boots, gloves, and protective clothing. Always wear proper fitting clothing that will not be
caught in any of the moving parts or controls of the machine.
• ALWAYS MAINTAIN YOUR MACHINE IN PROPER WORKING ORDER.
For safety and reliability, the machine must be properly maintained. Always perform the pre-operation
checks indicated in this manual.
Correcting a mechanical problem before you ride may prevent an accident.
• GASOLINE IS HIGHLY FLAMMABLE.
Always turn off the engine while refueling. Take care to not spill any gasoline on the engine or exhaust
system. Never refuel in the vicinity of an open flame, or while smoking.
• GASOLINE CAN CAUSE INJURY.
If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into
your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately
wash skin areas with soap and water, and change your clothes.
• ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILATION.
Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are poi-
sonous. These fumes contain carbon monoxide, which by itself is odorless and colorless. Carbon
monoxide is a dangerous gas which can cause unconsciousness or can be lethal.
• PARK THE MACHINE CAREFULLY; TURN OFF THE ENGINE.
Always turn off the engine if you are going to leave the machine. Do not park the machine on a slope
or soft ground as it may fall over.
• THE ENGINE, EXHAUST PIPE AND MUFFLER WILL BE VERY HOT AFTER THE ENGINE HAS
BEEN RUN.
Be careful not to touch them or to allow any clothing item to contact them during inspection or repair.
• PROPERLY SECURE THE MACHINE BEFORE TRANSPORTING IT.
For safety, drain the gasoline from the fuel tank before transporting the vehicle.
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.
5 1
6
7
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
LOCATION OF IMPORTANT LABELS.............................................................1-1
DESCRIPTION..................................................................................................1-2
1
IDENTIFICATION ..............................................................................................1-3
VEHICLE IDENTIFICATION NUMBER ......................................................1-3
ENGINE SERIAL NUMBER........................................................................1-3
2
INCLUDED PARTS ...........................................................................................1-4
NIPPLE WRENCH ......................................................................................1-4
HANDLEBAR PROTECTOR ......................................................................1-4
FUEL HOSE JOINT COVER ......................................................................1-4
POWER TUNER .........................................................................................1-4
3
4
IMPORTANT INFORMATION ...........................................................................1-6
PREPARATION FOR REMOVAL AND DISASSEMBLY ............................1-6
REPLACEMENT PARTS ............................................................................1-6
GASKETS, OIL SEALS AND O-RINGS .....................................................1-7
LOCK WASHERS/PLATES AND COTTER PINS ......................................1-7
5
BEARINGS AND OIL SEALS .....................................................................1-7
CIRCLIPS ...................................................................................................1-7
BASIC SERVICE INFORMATION.....................................................................1-8
6
ELECTRICAL SYSTEM ..............................................................................1-8
SPECIAL TOOLS............................................................................................1-12
7
CONTROL FUNCTIONS.................................................................................1-18
WARNING LIGHTS ..................................................................................1-18
ENGINE STOP SWITCH ..........................................................................1-18
START SWITCH .......................................................................................1-18
MODE SWITCH ........................................................................................1-18
CLUTCH LEVER ......................................................................................1-19
SHIFT PEDAL...........................................................................................1-19
THROTTLE GRIP .....................................................................................1-19
8
FRONT BRAKE LEVER ...........................................................................1-19
REAR BRAKE PEDAL..............................................................................1-19
SIDESTAND .............................................................................................1-19
STARTER KNOB ......................................................................................1-20
FUEL TANK CAP......................................................................................1-20
9
STARTING AND BREAK-IN ...........................................................................1-21
FUEL.........................................................................................................1-21
AIR FILTER MAINTENANCE ...................................................................1-21
10
STARTING A COLD ENGINE ..................................................................1-21
STARTING A WARM ENGINE .................................................................1-22
BREAK-IN PROCEDURES ......................................................................1-22
ENGINE STARTING PRECAUTION ........................................................1-22
MAINTENANCE AFTER BREAK-IN ..............................................................1-23

MAJOR MAINTENANCE ..........................................................................1-23
TORQUE-CHECK POINTS.............................................................................1-24
MOTORCYCLE CARE AND STORAGE.........................................................1-26

CARE ........................................................................................................1-26
STORAGE ................................................................................................1-27
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-02
WARNING
This unit contains high pressure nitrogen gas.
Mishandling can cause explosion.
Read owner's manual for instructions.
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
1-1
DESCRIPTION
EAM20086
DESCRIPTION
1 2, 3 4
10 9 8 7 6 5
11 12 15
14 13 20 19 18 17 16
1. Clutch lever 11.Fuel tank
2. Engine trouble warning light “ ” 12.Radiator
3. Fuel level warning light “ ” 13.Coolant drain bolt
4. Front brake lever 14.Rear brake pedal
5. Throttle grip 15.Air filter
6. Start switch 16.Drive chain
7. Radiator cap 17.Shift pedal
8. Fuel tank cap 18.Oil level check window
9. Mode switch 19.Starter knob
10.Engine stop switch 20.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.
1-2
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.
1-3
INCLUDED PARTS
EAM20088 EWA20460
INCLUDED PARTS WARNING

• Do not operate the engine in a closed area.
EAM30005
NIPPLE WRENCH The exhaust gas is poisonous.

The nipple wrench “1” is used to tighten the • Never let flames near the servicing area.
spoke. ECA26050
NOTICE
• This application is designed for adjusting
the settings on a standard vehicle. In case
the engine specifications (muffler, com-
pression ratio, etc.) have been changed,
the performance may not match to the actu-
al settings.
• Do not run the engine with the smartphone
carried with you. Otherwise, the smart-
phone could be damaged.
EAM30006
TIP
HANDLEBAR PROTECTOR • Download the Power Tuner app from the
Install the handlebar protector “1” with the mark Google© or Apple© store.
“a” facing forward. • For details about handling the smartphone,
read the owner’s manual of the smartphone.
A Before connecting to the CCU wireless net-
a
work (in case of initial use of the Power Tun-
er app)
1. Remove the bolts and side cover (left).
1
A
1
EAM30007
FUEL HOSE JOINT COVER 2

The fuel hose joint covers “1” are used to pre-
vent mud, dust, and other foreign materials from 1
1
entering the inside when the fuel hose is discon-
nected.
1. Bolt
2. Side cover (left)
2. Remove the CCU and record the CCU serial
number.
1
EAM30443
POWER TUNER
By downloading the Power Tuner app to your
smartphone and wirelessly connecting to the
CCU wireless network, you can adjust various
vehicle settings.
1-4
INCLUDED PARTS
pressed or while the engine is running (the

CCU is activated), input the CCU serial num-
ber into your smartphone and establish a
wireless connection.
3. Activate the Power Tuner app.
TIP
If the CCU wireless network cannot be detected,
operate the start switch again.
3
1 2
1. CCU coupler
2. Holder
3. CCU (Communication Control Unit)
3
COMMUN.CONT.UNIT ASSY.
P/N: - -
S/N:
MAC:
a. CCU serial number

3. Install the removed CCU and side cover (left).
Connecting to the CCU wireless network
ECA26060
NOTICE
The CCU (Communication Control Unit) uses
weak radio waves. The CCU may not work in
the following situations.
• The CCU is placed in a location exposed to
strong radio waves or other electromagnet-
ic noise
• There are facilities nearby that are emitting
strong radio waves (TV or radio towers,
power plants, broadcasting stations, air-
ports, etc.)
• You are carrying or using communication
equipment such as radios or mobile
phones in close proximity of the CCU
• The CCU is in contact with or covered by a
metallic object
• Other vehicles equipped with a CCU are
nearby
In such situations, move the CCU to another
location and perform the operation again.
1. Turn on the smartphone.
2. For two minutes after the start switch is
1-5
IMPORTANT INFORMATION
EAM20089
EAM30009
PREPARATION FOR REMOVAL AND

DISASSEMBLY
1. Before the jobs, completely remove mud,
dust, and the like in order to prevent the entry
of them into the inside during the jobs.
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-
ceive an injury or a burn on the engine, the
exhaust pipe, the silencer, or the like.
7. If coolant is left adhered to the chassis, paint
• Before cleaning with high-pressure water of and plating will be damaged. Therefore, rinse
washers, cover the following parts. it out with water in good time.
EWA18970
Air duct WARNING
Silencer exhaust port
Coolant is potentially harmful and should be
Drain hole on the cylinder head (right side)
handled with special care.
Hole under the water pump housing
• 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 1-12. 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.
1-6
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.
1. Oil
2. Lip EAM30014
3. Spring CIRCLIPS
4. Grease When assembling parts, always use new cir-
EAM30012
clips. During installation of a circlip, make sure
LOCK WASHERS/PLATES AND COTTER that the edge “2” of the circlip “1” is positioned
PINS opposite to the force “3” that the circlip receives.
After removal, replace lock washers/plates “1” Install the circlip with its end aligned with the
and cotter pins with new ones. After the bolt or center of the spline, without opening the circlip
nut has been tightened to specification, firmly more than necessary.
bend the lock tabs along a flat of the bolt or nut.
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.
1-7
BASIC SERVICE INFORMATION
EAM20120

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.
1-8
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
Push and hold the engine stop switch to turn off NOTICE
the multi-function display when resetting the For waterproof couplers, never insert the
ECU (Engine Control Unit). Disconnect the start- tester probes directly into the coupler. When
er motor lead of the starter relay, and then push performing any checks using a waterproof
the starter switch. Be sure to wait for five sec- coupler, use the specified test harness or a
onds or longer before pushing the start switch af- suitable commercially available test har-
ter the multi-function display goes off. ness.
Checking the electrical system Checking the connections

TIP Check the leads, couplers, and connectors for
Before checking the electrical system, make stains, rust, moisture, etc.
sure that the battery voltage is at least 12 V. 1. Disconnect:
• Lead
• Coupler
• Connector
1-9
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.
1-10
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.
1-11
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) 1-11, 5-38, 8-57,

90890-03243 8-58, 8-58, 8-58,
Model 88 Multimeter with tachometer 8-61, 8-61, 8-63,
YU-A1927 8-63, 8-63, 8-64,
8-64, 8-65, 8-65,
8-66, 8-67, 8-67,
8-68, 8-69
Radiator cap tester 3-7, 3-8
90890-01325
Mityvac cooling system tester kit
YU-24460-A
YU-24460-A
Radiator cap tester adapter 3-7, 3-8

90890-01352
Pressure tester adapter
YU-33984
YU-33984
Yamaha diagnostic tool USB (US) 3-15, 7-9, 8-25

90890-03257
Yamaha diagnostic tool (A/I) 3-15, 7-9, 8-25

90890-03262
1-12
SPECIAL TOOLS
Reference
pages
FI diagnostic tool sub–lead 3-15, 7-9, 8-26

90890-03212
FI diagnostic tool sub–lead
YU-03212
OBD/ GST Leadwire kit 3-15, 7-9, 8-25

90890-03249
Digital tachometer 3-16, 3-37, 8-65

90890-06760
Digital tachometer
YU-39951-B
Thickness gauge 3-17, 5-43

90890-03268
Feeler gauge set
YU-26900-9
Valve lapper (ø14) 90890-04101

3-17, 5-25
90890-04101
Valve lapping tool (14mm)
YM-A8998
YM-A8998
Spoke nipple wrench (6–7) 3-33

90890-01521
Spoke nipple wrench (6–7)
YM-01521
Steering nut wrench 3-34, 4-52

90890-01403
Exhaust flange nut wrench
YU-A9472
1-13
SPECIAL TOOLS
Reference
pages
Timing light 3-37

90890-03141
Timing light
YU-03141
Cap bolt ring wrench 4-40, 4-40, 4-41,

90890-01501 4-44, 4-47, 4-49
Cap bolt ring wrench
YM-01501
Cap bolt wrench 4-41, 4-44

90890-01500
Cap bolt wrench
YM-01500
Fork seal driver 4-45, 4-46

90890-01502
Fork seal driver (48)
YM-A0948
Yamaha bond No. 1215 5-18, 5-58, 5-65

90890-85505
(Three bond No.1215®)
Valve spring compressor 5-25, 5-30

90890-04019
Valve spring compressor
YM-04019
Valve spring compressor attachment 5-25, 5-30

90890-04108
Valve spring compressor adapter 22 mm
YM-04108
Valve guide remover & installer set (ø5.5) 5-27

90890-04016
Valve guide remover (5.5 mm)
YM-01122
1-14
SPECIAL TOOLS
Reference
pages
Valve guide installer (ø5.5) 5-27

90890-04015
Valve guide installer (5.5 mm)
YM-04015
Valve guide reamer (5.5 mm) 5-27

90890-01196
Valve guide reamer (5.5 mm)
YM-01196
Piston pin puller set 5-32

90890-01304
Piston pin puller
YU-01304
YU-01304
Universal clutch holder 5-43, 5-46

90890-04086
Universal clutch holder
YM-91042
Rotor puller 5-58

90890-04151
Rotor puller
YM-04151
1-15
SPECIAL TOOLS
Reference
pages
Crankcase separating tool 5-68

90890-04152
Crankcase separating tool
YU-A9642
Crankshaft installer pot 5-69

90890-01274
Installing pot
YU-90058
YU-90058/YU-90059
Crankshaft installer bolt 5-69

90890-01275
Bolt
YU-90060
Adapter (M12) 5-69

90890-01278
Adapter #3
YU-90063
Spacer (crankshaft installer) 5-69

90890-04081
Pot spacer
YM-91044
YM-91044
1-16
SPECIAL TOOLS
Reference
pages
Pressure gauge 7-4

90890-03153
Pressure gauge
YU-03153
Fuel pressure adapter 7-4

90890-03186
Fuel pressure adapter
YM-03186
Lithium battery charger 8-60, 8-60

90890-05376
Lithium battery charger
DBY-ACC51-70-02
Ignition checker 8-62

90890-06754
Oppama pet–4000 spark checker
YM-34487
Test harness S– pressure sensor (3P) 8-67

90890-03207
Test harness S– pressure sensor (3P)
YU-03207
1-17
CONTROL FUNCTIONS
EAM20122
CONTROL FUNCTIONS
EAM30400
WARNING LIGHTS
1 2
EAM30183
START SWITCH
The start switch “1” is located on the right han-
dlebar. Push this switch to crank the engine with
the starter.
1. Engine trouble warning light “ ”
2. Fuel level warning light “ ”
Engine trouble warning light “ ”
This warning light comes on or flashes if a prob-
lem is detected in the electrical circuit monitoring
the engine. If this occurs, have a Yamaha dealer
check the vehicle.
The electrical circuit of the warning light can be
checked by pushing the start switch. The warn-
ing light should come on for a few seconds, and 1
then go off.
EAM30471
If the warning light does not come on initially MODE SWITCH
when the start switch is pushed, or if the warning The mode switch “1” is located on the left han-
light remains on, have a Yamaha dealer check dlebar.
the electrical circuit. Press the mode switch to change between map
1 and map 2.
Fuel level warning light “ ”
This warning light comes on when the fuel level
drops below approximately 2.0 L (0.53 US gal,
0.44 Imp.gal). When this occurs, refuel as soon
as possible.
The electrical circuit of the warning light can be
checked by pushing the start switch. The warn-
ing light should come on for a few seconds, and
then go off. 1
If the warning light does not come on initially
when the start switch is pushed, or if the warning
light remains on, have a Yamaha dealer check To change the mode
the electrical circuit. 1. Shift to neutral.
2. Start the engine.
EAM30182
3. Press the mode switch.
ENGINE STOP SWITCH
Map 1
The engine stop switch “1” is located on the left
All-around good engine power and throttle re-
handlebar. Continue pushing the engine stop
sponse.
switch till the engine comes to a stop.
Map 2
Milder throttle response for riding technical sec-
tions.
1-18
CONTROL FUNCTIONS
EAM30187
TIP
You can use the Power Tuner app to adjust the THROTTLE GRIP
map settings. The throttle grip “1” is located on the right han-
When the mode switch “1” is illuminated, map 2 dlebar. The throttle grip accelerates or deceler-
is selected. ates the engine. For acceleration, turn the grip
toward you; for deceleration, turn it away from
you.
1
EAM30184
CLUTCH LEVER EAM30188
The clutch lever “1” is located on the left handle- FRONT BRAKE LEVER
bar. The clutch lever disengages or engages the The front brake lever “1” is located on the right
clutch. handlebar. Pull it toward the handlebar to acti-
Pull the clutch lever toward the handlebar to dis- vate the front brake.
engage the clutch, and release the lever to en-
gage the clutch.
1
1
EAM30189
REAR BRAKE PEDAL

The rear brake pedal “1” is in the right of the
EAM30185
chassis. Press down on the brake pedal to acti-
SHIFT PEDAL vate the rear brake.
The shift pedal “1” has adopted a method of 1
down & 4 ups (press-down & kick-ups).
Press it down for N (neutral) to 1st, and kick it up
for 2nd to 5th.
5
4 1
3
2 1
N
EAM30190
1
SIDESTAND
This sidestand “1” is used to support only the
machine when standing.
1-19
CONTROL FUNCTIONS
EWA18980
• Install the fuel tank cap cover after placing the
WARNING bands “3” all the way in under the seat.
• Never apply additional force to the sides-
tand.
• Hold up the sidestand before starting out.
1
3
2
1
a
EAM30444
STARTER KNOB
Starting a cold engine requires a larger amount
of intake air, which is supplied by the starter
knob “1”.
Pushing the knob toward “a” turns ON the start-
er, resulting in a larger angle of throttle valve.
TIP
When operating the throttle grip in the closing di-
rection, the starter knob “1” moves in the direc-
tion “b” as shown and returns to its original 2
position.
EWA20470
WARNING
While handling the starter knob, take care
not to burn yourself on exhaust pipes.
1
b a
EAM30192
FUEL TANK CAP

Fuel tank cap “1” is located under the fuel tank
cap cover “2”.
Remove the fuel tank cap cover to open the fuel
tank cap.
TIP
• To remove the fuel tank cap cover, insert fin-
gers under part “a”, and then use both hands to
lift it up towards the rear of the vehicle.
1-20
STARTING AND BREAK-IN
EAM20123 EAM30196
STARTING AND BREAK-IN STARTING A COLD ENGINE

1. Press the shift pedal to neutral.
EAM30193
2. Push the starter knob “1” completely.
FUEL
TIP
Always use the recommended fuel as stated be- • When the ambient temperature is 15 C (59 F)
low. Also, be sure to use new gasoline the day or below, use the starter knob.
of a race. • Do not operate the throttle grip when operating
Recommended fuel the starter knob.
Premium unleaded gasoline
(Gasohol [E10] acceptable)
Fuel tank capacity
8.2 L (2.2 US gal, 1.8 Imp.gal)
Fuel reserve amount
1
2.0 L (0.53 US gal, 0.44 Imp.gal)
ECA24180
NOTICE
Use only unleaded gasoline. The use of lead-
ed gasoline will cause severe damage to the
engine internal parts such as valves, piston
3. Start the engine by pushing the start switch.
rings, and exhaust system, etc.
If the engine fails to start when using the start
TIP switch, release it, wait a few seconds, and
Your Yamaha engine has been designed to use then try again.
premium unleaded gasoline with a pump octane Each starting attempt should be as short as
number [(R+M)/2] of 91 or higher, or a research possible to preserve the battery. Do not crank
octane number of 95 or higher. If knocking (or the engine more than 10 seconds on any one
pinging) occurs, use a gasoline of a different attempt.
brand. 4. When the engine starts running, warm this up
EWA19010 one or two minutes at a steady speed (of
WARNING 3000 to 5000 r/min), and then return the start-
• For refueling, be sure to stop the engine er knob to its original position.
and use enough care not to spill any fuel. TIP
Also be sure to avoid refueling close to a When operating the throttle grip in the closing di-
fire. rection, the starter knob “1” moves in the direc-
• Refuel after the engine, exhaust pipe, etc. tion as shown and returns to its original position.
have cooled off.
Gasohol
There are two types of gasohol: gasohol con-
taining ethanol and that containing methanol.
Gasohol containing ethanol can be used if the 1
ethanol content does not exceed 10 %. Gasohol
containing methanol is not recommended by
Yamaha because it can cause damage to the
fuel system or vehicle performance problems.
EAM30195
AIR FILTER MAINTENANCE EWA19030
According to “CLEANING THE AIR FILTER EL- WARNING

EMENT” section in the CHAPTER 3, apply the Since exhaust gas contains harmful ingredi-
Yamaha foam air filter oil or other quality foam ents, do not start or warm it up at an illventi-
air filter oil to the element. (Excess oil in the ele- lated place or a closed narrow place.
ment may adversely affect engine starting.)
1-21
STARTING AND BREAK-IN
5. To stop the engine, push the engine stop drive chain, looseness of the spoke, and so
switch “1”. on.
ECA25821
TIP
Continue pushing the engine stop switch till the NOTICE
engine comes to a full stop. After a break-in or after each race, always
check the points shown in “TORQUE-
CHECK POINTS” for tightening torques and
retighten them.
Also when the following parts are replaced, a
break-in 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.
1 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
WARNING
BREAK-IN PROCEDURES
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
• When starting the engine, if only the starter
NOTICE
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
1-22
MAINTENANCE AFTER BREAK-IN
EAM20124
Lubricate the drive chain and adjust its ten-
MAINTENANCE AFTER BREAK-IN sion.
After a break-in, perform careful maintenance to • Fuel tank
get ready for the next practice or race. Clean the inside of the fuel tank. Check for
Refer to “PRE-OPERATION INSPECTION AND leaks.
MAINTENANCE” on page 3-5. • Suspension
EAM30199
Check for oil leaks in the front fork or the rear
MAJOR MAINTENANCE shock absorber. Check that the mounted
1. For the engine conditions are good.
• Leaks around the engine • Sprocket
Check for pressure leaks from the cylinder Check for looseness in the sprocket mounted
head or the cylinder, oil leaks from the crank- on the rear wheel.
case or the case cover, leaks from the cool- • Mounting bolts and nuts
ant system, and other leaks. Check mounted areas for looseness.
ECA25831
• Check that the valve, the cylinder head, the
NOTICE
cylinder, the piston, and the piston ring fit one
another, and that contact between the valve After a break-in or before each race, always
and the cylinder head, and that between the check the points shown in “TORQUE-
cylinder and the piston are correct. CHECK POINTS” for tightening torques and
• Engine oil change retighten them.
Drain the oil, and check for dirt and foreign • Greasing and oiling
materials such as metal chips. (If any foreign Always grease or oil the specified points.
material is mixed, disassemble and check the
crankcase.)
Pour the specified amount of the recom-
mended oil.
• AC magneto
Check for looseness in mounted areas of the
rotor and the stator.
Check that the connector is not being discon-
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.
• Drive chain
1-23
TORQUE-CHECK POINTS
EAM20125
TORQUE-CHECK POINTS
Frame construction Frame to rear frame
Frame to engine protector
Combined seat and fuel tank Fuel tank to frame
Engine mounting Frame to engine
Engine bracket to engine
Engine bracket to frame
Seat Seat to frame
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
1-24
TORQUE-CHECK POINTS
Shift pedal Shift pedal to shift shaft

Plastic cover Tightening of front fender
Tightening of fork leg protector
Tightening of air scoop
Left cover to rear frame
Tightening of side cover
Tightening of rear fender
Tightening of mud flap
Tightening of rear brake disc cover
Tightening of rear brake caliper
cover
TIP
Concerning the tightening torque, refer to “TIGHTENING TORQUES” on page 2-10.
1-25
MOTORCYCLE CARE AND STORAGE
EAM20126
solvent or thinner, fuel (gasoline), rust re-
MOTORCYCLE CARE AND STOR- movers or inhibitors, brake fluid, antifreeze
AGE or electrolyte.
• Do not use high-pressure washers or
EAM30200
steam-jet cleaners since they cause water
CARE
seepage and deterioration in the following
While the open design of a motorcycle reveals
areas: seals (of wheel and swingarm bear-
the attractiveness of the technology, it also
ings, fork and brakes), electric components
makes it more vulnerable. Rust and corrosion
(couplers, connectors, instruments,
can develop even if high-quality components are
switches and lights), breather hoses and
used. A rusty exhaust pipe may go unnoticed on
vents.
a car, however, it detracts from the overall ap-
• For motorcycles equipped with a wind-
pearance of a motorcycle. Frequent and proper
shield: Do not use strong cleaners or hard
care does not only comply with the terms of the
sponges as they will cause dulling or
warranty, but it will also keep your motorcycle
scratching. Some cleaning compounds for
looking good, extend its life and optimize its per-
plastic may leave scratches on the wind-
formance.
shield. Test the product on a small hidden
Before cleaning
part of the windshield to make sure that it
1. Cover the muffler outlet with a plastic bag af-
does not leave any marks. If the windshield
ter the engine has cooled down.
is scratched, use a quality plastic polishing
2. Make sure that all caps and covers as well as
compound after washing.
all electrical couplers and connectors, includ-
ing the spark plug cap, are tightly installed. After normal use
3. Remove extremely stubborn dirt, like oil burnt Remove dirt with warm water, a mild detergent,
onto the crankcase, with a degreasing agent and a soft, clean sponge, and then rinse thor-
and a brush, but never apply such products oughly with clean water. Use a toothbrush or
onto seals, gaskets, sprockets, the drive bottlebrush for hard-to-reach areas. Stubborn
chain and wheel axles. Always rinse the dirt dirt and insects will come off more easily if the
and degreaser off with water. area is covered with a wet cloth for a few min-
Cleaning utes before cleaning.
ECA24220
After riding in the rain, near the sea or on salt-
NOTICE sprayed roads
• Avoid using strong acidic wheel cleaners, Since sea salt or salt sprayed on roads during
especially on spoked wheels. If such prod- winter are extremely corrosive in combination
ucts are used on hard-to-remove dirt, do with water, carry out the following steps after
not leave the cleaner on the affected area each ride in the rain, near the sea or on salt-
any longer than instructed. Also, thorough- sprayed roads.
ly rinse the area off with water, immediately TIP
dry it, and then apply a corrosion protec- Salt sprayed on roads in the winter may remain
tion spray. well into spring.
• Improper cleaning can damage plastic
1. Clean the motorcycle with cold water and a
parts (such as cowlings, panels, wind-
mild detergent, after the engine has cooled
shields, headlight lenses, meter lenses,
down.
etc.) and the mufflers. Use only a soft, clean
NOTICE: Do not use warm water since it
cloth or sponge with water to clean plastic.
increases the corrosive action of the salt.
However, if the plastic parts cannot be thor-
2. Apply a corrosion protection spray on all met-
oughly cleaned with water, diluted mild de-
al, including chrome- and nickel-plated, sur-
tergent with water may be used. Be sure to
faces to prevent corrosion.
rinse off any detergent residue using plenty
After cleaning
of water, as it is harmful to plastic parts.
1. Dry the motorcycle with a chamois or an ab-
• Do not use any harsh chemical products on
sorbing cloth.
plastic parts. Be sure to avoid using cloths
2. Immediately dry the drive chain and lubricate
or sponges which have been in contact
it to prevent it from rusting.
with strong or abrasive cleaning products,
1-26
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. stored.
6. Touch up minor paint damage caused by Long-term
stones, etc. Before storing your motorcycle for several
7. Wax all painted surfaces. months:
8. Let the motorcycle dry completely before 1. Follow all the instructions in the “CARE” sec-
storing or covering it. tion of this chapter.
EWA19050
WARNING 2. Fill up the fuel tank and add fuel stabilizer (if
available) to prevent the fuel tank from rusting
Contaminants on the brakes or tires can and the fuel from deteriorating.
cause loss of control. 3. Perform the following steps to protect the cyl-
• Make sure that there is no oil or wax on the inder, piston rings, etc. from corrosion.
brakes or tires.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• If necessary, clean the brake discs and
a. Remove the spark plug cap and spark plug.
brake linings with a regular brake disc
b. Pour a teaspoonful of engine oil into the spark
cleaner or acetone, and wash the tires with
plug bore.
warm water and a mild detergent. Before
c. Install the spark plug cap onto the spark plug,
riding at higher speeds, test the motorcy-
and then place the spark plug on the cylinder
cle’s braking performance and cornering
head so that the electrodes are grounded.
behavior.
(This will limit sparking during the next step.)
ECA24240
d. Turn the engine over several times with the
NOTICE
starter. (This will coat the cylinder wall with
• Apply spray oil and wax sparingly and oil.)
make sure to wipe off any excess. e. Remove the spark plug cap from the spark
• Never apply oil or wax to any rubber and plug, and then install the spark plug and the
plastic parts, but treat them with a suitable spark plug cap. WARNING! To prevent
care product. damage or injury from sparking, make
• Avoid using abrasive polishing com- sure to ground the spark plug electrodes
pounds as they will wear away the paint. while turning the engine over.
TIP ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Consult a Yamaha dealer for advice on what 4. Lubricate all control cables and the pivoting
products to use. points of all levers and pedals as well as of
• Washing, rainy weather or humid climates can the sidestand/centerstand.
cause the headlight lens to fog. Turning the 5. Check and, if necessary, correct the tire air
headlight on for a short period of time will help pressure, and then lift the motorcycle so that
remove the moisture from the lens. both of its wheels are off the ground. Alterna-
tively, turn the wheels a little every month in
EAM30201
order to prevent the tires from becoming de-
STORAGE graded in one spot.
Short-term 6. Cover the muffler outlet with a plastic bag to
Always store your motorcycle in a cool, dry place prevent moisture from entering it.
and, if necessary, protect it against dust with a 7. Remove the battery and fully charge it. Store
porous cover. Be sure the engine and the ex- it in a cool, dry place and charge it once a
haust system are cool before covering the mo-
1-27
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
8-59.
TIP
Make any necessary repairs before storing the
motorcycle.
1-28
SPECIFICATIONS
GENERAL SPECIFICATIONS ..........................................................................2-1
ENGINE SPECIFICATIONS..............................................................................2-2
1
CHASSIS SPECIFICATIONS............................................................................2-6
ELECTRICAL SPECIFICATIONS.....................................................................2-9
2
TIGHTENING TORQUES................................................................................2-10
3
GENERAL TIGHTENING TORQUE SPECIFICATIONS ..........................2-10
ENGINE TIGHTENING TORQUES ..........................................................2-11
CHASSIS TIGHTENING TORQUES ........................................................2-14
LUBRICATION POINTS AND LUBRICANT TYPES ......................................2-17

ENGINE ....................................................................................................2-17
CHASSIS ..................................................................................................2-18 4
LUBRICATION SYSTEM CHART AND DIAGRAMS .....................................2-21
LUBRICATION DIAGRAMS .....................................................................2-21
CABLE ROUTING DIAGRAM ........................................................................2-31

5
6
7
8
9
10
GENERAL SPECIFICATIONS
EAM20127
GENERAL SPECIFICATIONS
Model
Model B3J1
Dimensions
Overall length 2175 mm (85.6 in)
Overall width 825 mm (32.5 in)
Overall height 1270 mm (50.0 in)
Seat height 955 mm (37.6 in)
Wheelbase 1480 mm (58.3 in)
Ground clearance 320 mm (12.60 in)
Weight
Curb weight 116 kg (256 lb)
Riding capacity 1 person
2-1
ENGINE SPECIFICATIONS
EAM20128
Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train DOHC
Displacement 450 cm³
Number of cylinders Single cylinder
Bore  stroke 97.0  60.9 mm (3.82  2.40 in)
Compression ratio 12.8 : 1
Starting system Electric starter
Fuel
Recommended fuel Premium unleaded gasoline (Gasohol [E10] ac-
ceptable)
Fuel tank capacity 8.2 L (2.2 US gal, 1.8 Imp.gal)
Fuel reserve amount 2.0 L (0.53 US gal, 0.44 Imp.gal)
Engine oil
Recommended brand YAMALUBE
SAE viscosity grades SAE 10W-40, SAE 10W-50, SAE 15W-40, SAE
20W-40 or SAE 20W-50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Lubrication system Wet sump
Engine oil quantity
Oil change 0.62 L (0.66 US qt, 0.55 Imp.qt)
With oil filter removal 0.64 L (0.68 US qt, 0.56 Imp.qt)
Quantity (disassembled) 0.90 L (0.95 US qt, 0.79 Imp.qt)
Oil filter
Oil filter type Paper
Oil pump
Inner-rotor-to-outer-rotor-tip clearance 0.000–0.150 mm (0.0000–0.0059 in)
Limit 0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing clearance 0.13–0.18 mm (0.0051–0.0071 in)
Limit 0.25 mm (0.0098 in)
Oil-pump-housing-to-inner-and-outer-rotor 0.06–0.11 mm (0.0024–0.0043 in)
clearance
Limit 0.18 mm (0.0071 in)
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/CPR8EA-9
Spark plug gap 0.8–0.9 mm (0.031–0.035 in)
Cylinder head
Warpage limit 0.05 mm (0.0020 in)
Camshaft
Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in)
2-2
Camshaft journal diameter 21.959–21.972 mm (0.8645–0.8650 in)

Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in)
Limit 0.080 mm (0.0032 in)
Camshaft lobe dimensions
Lobe height (Intake) 38.130–38.230 mm (1.5012–1.5051 in)
Limit 38.030 mm (1.4972 in)
Lobe height (Exhaust) 34.270–34.370 mm (1.3492–1.3531 in)
Limit 34.170 mm (1.3453 in)
Camshaft runout limit 0.030 mm (0.0012 in)
Valve, valve seat, valve guide
Valve clearance (cold)
Intake 0.10–0.17 mm (0.0039–0.0067 in)
Exhaust 0.15–0.22 mm (0.0059–0.0087 in)
Valve dimensions
Valve seat contact width (intake) 0.90–1.10 mm (0.0354–0.0433 in)
Limit 1.5 mm (0.06 in)
Valve seat contact width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)
Limit 1.5 mm (0.06 in)
Valve stem diameter (intake) 5.475–5.490 mm (0.2156–0.2161 in)
Limit 5.445 mm (0.2144 in)
Valve stem diameter (exhaust) 5.465–5.480 mm (0.2152–0.2157 in)
Limit 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 (in- 0.010–0.037 mm (0.0004–0.0015 in)
take)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (ex- 0.020–0.047 mm (0.0008–0.0019 in)
haust)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.010 mm (0.0004 in)
Valve spring
Free length (intake) 40.57 mm (1.60 in)
Limit 38.54 mm (1.52 in)
Free length (exhaust) 37.42 mm (1.47 in)
Limit 35.55 mm (1.40 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 18.004–18.015 mm (0.7088–0.7093 in)
Limit 18.045 mm (0.7104 in)
Piston pin outside diameter 17.991–18.000 mm (0.7083–0.7087 in)
Limit 17.981 mm (0.7079 in)
Piston-pin-to-piston-pin-bore clearance 0.004–0.024 mm (0.0002–0.0009 in)
2-3
Piston ring
Top ring
End gap (installed) 0.20–0.30 mm (0.0079–0.0118 in)
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 (installed) 0.35–0.50 mm (0.0138–0.0197 in)
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)
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 2.92–3.08 mm (0.115–0.121 in)
Plate quantity 6 pcs
Friction plate 2 thickness 2.92–3.08 mm (0.115–0.121 in)
Clutch plate thickness 1.50–1.70 mm (0.059–0.067 in)
Warpage limit 0.10 mm (0.004 in)
Clutch spring free length 48.00 mm (1.89 in)
Limit 45.60 mm (1.80 in)
Push rod bending limit 0.10 mm (0.004 in)
Drivetrain
Primary reduction ratio 2.609 (60/23)
Transmission type Constant mesh 5-speed
Gear ratio
1st 2.416 (29/12)
2nd 1.733 (26/15)
3rd 1.312 (21/16)
4th 1.050 (21/20)
5th 0.840 (21/25)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Secondary reduction ratio 3.846 (50/13)
Final drive Chain
Air filter
Air filter element Wet element
Air filter oil grade Yamaha foam air filter oil or other quality foam
air filter oil
Fuel pump
Pump type Electrical
Maximum consumption amperage 2.4 A
2-4
Fuel injector
Resistance 12.0 
Throttle body
ID mark BR91 00
Idling condition
Engine idling speed 1900–2100 r/min
Coolant temperature 70–90 C (158–194 F)
Engine oil 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)
2-5
CHASSIS SPECIFICATIONS
EAM20129
Chassis
Frame type Semi double cradle
Caster angle 27.2 
Trail 116 mm (4.6 in)
Front wheel
Wheel type Spoke wheel
Rim size 21 x 1.60
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 18 x 2.15
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/MX3SF
Rear tire
Type With tube
Size 120/90-18 65M
Manufacturer/model DUNLOP/MX3S
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
Disc outside diameter  thickness 270.0  3.0 mm (10.63  0.12 in)
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) 22.65 mm, 22.65 mm (0.89 in, 0.89 in)
Specified brake fluid DOT 4
Rear brake
Type Hydraulic single disc brake
Disc outside diameter  thickness 245.0  4.0 mm (9.65  0.16 in)
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 (Left) 25.40 mm (1.00 in)
Specified brake fluid DOT 4
2-6
Front suspension
Type Telescopic fork
Spring Coil spring
Shock absorber Hydraulic damper
Wheel travel 310 mm (12.2 in)
Fork spring free length 497.0 mm (19.57 in)
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) 497.0 cm³ (16.80 US oz, 17.53 Imp.oz)
Quantity (right) 497.0 cm³ (16.80 US oz, 17.53 Imp.oz)
Rebound damping
Adjusting system Mechanical adjustable type
Unit for adjustment Click
Adjustment value from the start position 20
(Soft)
(STD)
(Hard)
Compression damping
(Soft)
(STD)
(Hard)
Rear suspension
Type Swingarm (link suspension)
Spring Coil spring
Shock absorber Gas-hydraulic damper
Spring preload
Adjustment value (Soft) 1.5 mm (0.06 in)
Adjustment value (STD) 6.0 mm (0.24 in)
Adjustment value (Hard) 18.0 mm (0.71 in)
Rebound damping
(Soft)
(STD)
(Hard)
Compression damping
Fast compression damping
Unit for adjustment Turn
2-7

(Soft)
Adjustment value from the start position 1-1/2
(STD)
(Hard)
Slow compression damping
(Soft)
(STD)
(Hard)
Swingarm
Swingarm end free play limit (radial) 1.0 mm (0.04 in)
Swingarm end free play limit (axial) 0.2–0.9 mm (0.01–0.04 in)
Drive chain
Size DID520MXV5
Chain type Sealed type
Number of links 114
Drive chain slack (Maintenance stand) 50.0–60.0 mm (1.97–2.36 in)
15-link length limit 239.3 mm (9.42 in)
2-8
ELECTRICAL SPECIFICATIONS
EAM20130
ELECTRICAL SPECIFICATIONS
Voltage
System voltage 12 V
Ignition system
Ignition system TCI
Ignition timing (B.T.D.C.) 10.0 2000 r/min
Engine control unit
Model B3J0
Ignition coil
Primary coil resistance 2.16–2.64 
Secondary coil resistance 8.64–12.96 k
Spark plug cap
Resistance 7.50–12.50 k
Lean angle sensor
Operating angle 45 
Charging system
Charging system AC magneto
Standard output 14.0 V, 5.4 A at 5000 r/min
Stator coil resistance 0.512–0.768 
Rectifier/regulator
Regulator type Single-phase
Regulated voltage (DC) 14.0–14.8 V
Rectifier capacity (DC) 11.0 A
Battery
Model BR98
Voltage, capacity 12 V, 2.4 Ah (5 HR)
Indicator light
Fuel level warning light 1.7 W
Engine trouble warning light 1.7 W
Starter motor
Power output 0.85 kW
Armature coil resistance 0.008–0.010 
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)
Commutator diameter 80.6 mm (3.17 in)
Commutator diameter limit 79.6 mm (3.13 in)
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 
Coolant temperature sensor resistance 2512–2777 
Coolant temperature sensor resistance 210–220 
Fuse(s)
Main fuse 15.0 A
Radiator fan motor fuse 5.0 A
2-9
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
2-10
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
Cylinder head blind plug M12 1 28 N·m (2.8 kgf·m, 21 lb·ft) LT
Spark plug M10 1 13 N·m (1.3 kgf·m, 9.6 lb·ft)

Cylinder head stud bolt (exhaust
pipe) M6 3 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Oil passage plug (cylinder head) M8 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Cylinder head bolt M10 4 See TIP. M
Cylinder head bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Cylinder head cover bolt M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Cylinder bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Oil pressure check bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Balancer weight plate screw M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT
Balancer weight gear nut M14 1 50 N·m (5.0 kgf·m, 37 lb·ft) Use a lock
washer.
Use a lock
Balancer nut M10 1 45 N·m (4.5 kgf·m, 33 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)
Radiator fan bolt (For JPN) M6 3 8 N·m (0.8 kgf·m, 5.9 lb·ft)
Water pump housing cover bolt M6 4 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Oil pump bolt M5 2 5 N·m (0.5 kgf·m, 3.7 lb·ft) LT
Oil pump cover screw M4 1 2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
Oil strainer bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
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)
2-11
TIGHTENING TORQUES
Thread
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 4 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 bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT
Engine oil drain bolt M10 1 20 N·m (2.0 kgf·m, 15 lb·ft)

Crankcase bolt M6 12 12 N·m (1.2 kgf·m, 8.9 lb·ft)
Clutch cable holder bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT
Crankshaft end accessing screw M36 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Timing mark accessing screw M14 1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Drive sprocket cover bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Crankcase bearing cover plate
M8 4 22 N·m (2.2 kgf·m, 16 lb·ft)
screw LT
Bearing plate cover bolt (left side of M6 2 12 N·m (1.2 kgf·m, 8.9 lb·ft)
the drive axle) LT
Plate bolt M6 4 12 N·m (1.2 kgf·m, 8.9 lb·ft) LT
Starter motor cover bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Clutch cover bolt M6 7 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Crankcase cover bolt (left) M6 7 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Crankcase cover bolt (right) M6 11 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)
Starter clutch idle gear holder bolt M6 3 12 N·m (1.2 kgf·m, 8.9 lb·ft) LT
Primary drive gear nut M20 1 80 N·m (8.0 kgf·m, 59 lb·ft)

Clutch spring bolt M6 6 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Use a lock
Clutch boss nut M20 1 75 N·m (7.5 kgf·m, 55 lb·ft) washer.
E
Use a lock
Drive sprocket nut M20 1 75 N·m (7.5 kgf·m, 55 lb·ft) washer.
Segment 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
Stopper lever bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT
2-12
TIGHTENING TORQUES
Thread
size
Shift pedal bolt M6 1 12 N·m (1.2 kgf·m, 8.9 lb·ft) 

AC magneto 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
AC magneto lead holder bolt M5 1 8 N·m (0.8 kgf·m, 5.9 lb·ft) LT
Coolant temperature sensor M10 1 15 N·m (1.5 kgf·m, 11 lb·ft)

Gear position switch bolt M5 2 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) LT
Rectifier/regulator bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)

ECU bolt M5 2 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
Ignition coil bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Starter motor bolt M6 2 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
First, tighten the cylinder head bolts to 40 N·m (4.0 kgf·m, 30 lb·ft) in the proper tightening sequence
and remove them. Retighten the cylinder head bolts to 22 N·m (2.2 kgf·m, 16 lb·ft) in the proper tight-
ening sequence. Tighten all bolts to reach the specified angle (90) in a diagonal sequence, and then
tighten the cylinder head bolts further to reach the specified angle (No. 1, 2, 3: 60/No. 4 90) in the
proper tightening sequence. (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 washers.)
FWD
x3 x1
3 2
1 4
2-13
TIGHTENING TORQUES
EAM30204
CHASSIS TIGHTENING TORQUES

TIP
- marked portion shall be checked for torque tightening after break-in or before each race.
Thread
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) 
Engine stop switch screw M3 1 0.5 N·m (0.05 kgf·m, 0.37 lb·ft)
Start switch M3 1 0.5 N·m (0.05 kgf·m, 0.37 lb·ft)
Mode switch M3 1 1.3 N·m (0.13 kgf·m, 0.95 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)
Front fork protector bolt M6 6 5 N·m (0.5 kgf·m, 3.7 lb·ft) 
Brake hose holder bolt M6 2 9 N·m (0.9 kgf·m, 6.6 lb·ft) 
Throttle grip cap screw M5 2 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
Clutch lever holder bolt M6 2 5 N·m (0.5 kgf·m, 3.7 lb·ft)
Clutch lever nut M6 1 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
Clutch lever position locknut M5 1 4.8 N·m (0.48 kgf·m, 3.5 lb·ft)
Front brake master cylinder holder M6 2 9 N·m (0.9 kgf·m, 6.6 lb·ft) 
bolt
Front brake master cylinder reservoir
cap screw M4 2 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
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 holder bolt M6 1 9 N·m (0.9 kgf·m, 6.6 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 6 N·m (0.6 kgf·m, 4.4 lb·ft) 
Front wheel axle nut M18 1 115 N·m (11.5 kgf·m, 85 lb·ft) 
2-14
TIGHTENING TORQUES
Thread
size
Front wheel axle pinch bolt M8 4 21 N·m (2.1 kgf·m, 15 lb·ft) 

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
Sidestand bolt M10 1 35 N·m (3.5 kgf·m, 26 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 6 N·m (0.6 kgf·m, 4.4 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 M20 1 125 N·m (12.5 kgf·m, 92 lb·ft) 
Drive chain puller locknut M8 2 21 N·m (2.1 kgf·m, 15 lb·ft)
Rear wheel sprocket nut M8 6 50 N·m (5.0 kgf·m, 37 lb·ft) 
Nipple (spoke) — 72 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) 
Bolt (rear brake disc cover) M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) 
Rear brake caliper protector bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Engine mounting bolt (upper side) M10 2 45 N·m (4.5 kgf·m, 33 lb·ft) 
Engine mounting bolt (front side) M10 1 55 N·m (5.5 kgf·m, 41 lb·ft) 
Engine mounting bolt (lower side) M10 1 53 N·m (5.3 kgf·m, 39 lb·ft) 
Engine bracket bolt (upper side) M8 4 34 N·m (3.4 kgf·m, 25 lb·ft) 
Engine bracket bolt (front side) M8 4 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 M6 3 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Pivot shaft nut M16 1 85 N·m (8.5 kgf·m, 63 lb·ft) 
Rear shock absorber assembly
M10 1 56 N·m (5.6 kgf·m, 41 lb·ft) 
upper bolt
lower bolt M10 1 53 N·m (5.3 kgf·m, 39 lb·ft) 
Locknut (rear shock absorber lock-

M60 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
nut)
Relay arm bolt (swingarm side) M14 1 70 N·m (7.0 kgf·m, 52 lb·ft) 
Connecting arm bolt (relay arm side) M14 1 80 N·m (8.0 kgf·m, 59 lb·ft) 
Connecting arm bolt (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) 
2-15
TIGHTENING TORQUES
Thread
size
Drive chain tensioner bolt (upper M8 1 16 N·m (1.6 kgf·m, 12 lb·ft)

side)
Drive chain tensioner bolt (lower
side) M8 1 16 N·m (1.6 kgf·m, 12 lb·ft)
Bolt (drive chain support) M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)

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)
Bolt (rear frame cover) (left) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Fuel tank bolt (front side) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Fuel tank bolt (boss) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Fuel tank bolt (rear side) M6 1 9 N·m (0.9 kgf·m, 6.6 lb·ft)
Fuel tank bracket bolt M6 2 7 N·m (0.7 kgf·m, 5.2 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)
Bolt (fuel tank cap cover) M6 2 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
Seat set bracket screw M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Seat bolt M8 2 22 N·m (2.2 kgf·m, 16 lb·ft) 
Side cover bolt (left) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Side cover bolt (right) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Air scoop bolt (frame) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Air scoop bolt (fuel tank) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Air scoop bolt (radiator guard) M6 4 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 (battery negative
M5 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
lead)
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).
2-16
LUBRICATION POINTS AND LUBRICANT TYPES
EAM20132

EAM30206
ENGINE
Lubrication point Lubricant types
Oil seal lips LS
Bearing E
O-ring LS
Camshaft cap bolt threads and contacting surface E
Cylinder head bolt threads, seats, washers M
Valve stems M
Valve stem ends M
Valve lifter outer surface E
Camshaft lobe and journal M
Valve lifter top surface E
Crankshaft journal M
Crankshaft big end thrust surfaces E
Piston outer surface E
Piston pin outer surface M
Decompression system moving parts E
Water pump impeller shaft E
Oil pump rotors (inner and outer) E
Oil passage gasket LS
Oil pump shaft E
Primary drive gear nut threads and contacting surface E
Clutch boss nut threads and contacting surface E
Primary driven gear inner surface and end surface E
Clutch push rod washer E
Clutch push rod 1 outer surface E
Clutch push rod 1 thrust surface E
Clutch push rod 2 outer surface E
Push lever shaft washer outer surface E
Transmission gear inner surface (wheel and pinion) and collar M
Transmission gears (shift fork groove) E
Shift cam grooves E
Shift fork and shift fork guide outer surface E
2-17
Shift shaft and collar E
Shift lever assembly moving parts E
Yamaha bond No. 1215

Cylinder head cover gasket
Crankcase mating surface Yamaha bond No. 1215

Stator assembly lead grommet (Three bond No.1215®)
Entire seal lip (air filter element) LS
EAM30207
CHASSIS
Upper bearings (steering head) LS
Upper bearings and bearing race cover (steering head) LS
Lower bearings and oil seal lip (steering head) LS
Steering stem threads and nut contacting surface LS
Pivot shaft bearing M
Swingarm pivot portion (collar side surface and thrust bearing) M
Swingarm pivot portion (collar outer surface) M
Swingarm pivot portion (oil seal lip) M
Pivot shaft outer surface M
Relay arm bearing and oil seal lip M
Relay arm thrust washer surface (both sides) M
Relay arm collar outer surface and bolt outer surface M
Relay arm bolt threads (swingarm side) M
Connecting arm bearing and oil seal lip M
Connecting arm collar outer surface and bolt outer surface M
Rear shock absorber assembly collar outer surface and dust seal lip (upper side) M
Rear shock absorber assembly bearing and dust seal lip (lower side) M
Brake pedal pivot portion (O-ring and bolt outer surface) LS
Front wheel oil seal lip LS
Front wheel axle outer surface LS
Rear wheel oil seal lip LS
Rear wheel axle outer surface LS
Sidestand pivot portion and collar outer surface LS
Push rod contacting portion (front brake master cylinder) S
2-18
Front brake lever bolt outer surface S
Clutch lever sliding surface and bolt outer surface LS
Clutch lever position adjuster end LS
Clutch lever adjuster rubber lip LS
Clutch cable end (clutch lever side) LS
Tube guide (throttle grip) inner surface and throttle cable end LS
Front brake caliper piston

Front brake caliper piston seal S
Front brake caliper dust seal S
Front brake caliper piston outer surface

Front brake caliper pin bolt and boot S
Front brake master cylinder push rod end S
Front brake master cylinder kit

Rear brake caliper piston
Rear brake caliper piston seal S
Rear brake caliper dust seal S
Rear brake caliper piston outer surface

Rear brake caliper pin bolt and boot S
Rear brake master cylinder push rod end S
Rear brake master cylinder kit
2-19
2-20
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAM20151

EAM30331
LUBRICATION DIAGRAMS
2-21
1. Intake camshaft
2. Exhaust camshaft
3. Piston
4. Oil filter element
5. Oil nozzle
6. Oil pump
7. Oil strainer
8. Crankshaft
9. Drive axle
10.Main axle
2-22
2-23
1. Exhaust camshaft
2. Intake camshaft
4. Oil pump
5. Drive axle
2-24
2-25
1. Connecting rod
2. Oil nozzle
3. Crankshaft
2-26
2-27
1. Connecting rod
2. Engine oil check bolt
3. Crankshaft
4. Oil pump
2-28
2-29

2. Oil pump
3. Oil strainer
2-30
CABLE ROUTING DIAGRAM
EAM20152
2-31
1. Clutch cable H. Fasten the starter motor lead to the bracket

2. Throttle cable (return) using the plastic locking tie. Position the lock
part of the plastic locking tie to rear side of
3. Throttle cable (pull) the vehicle. Cut the end of the plastic locking
4. Cable holder tie.
5. Warning light lead I. Route the starter motor lead along the cylin-
6. Intake air temperature sensor coupler (black) der body without slack.
7. Rectifier/regulator coupler J. Route the gear position sensor along the
crankcase without slack.
8. AC magneto lead
K. Pass the gear position switch lead to the
9. Battery band inside of the lower engine bracket (the side of
10.CCU (Communication Control Unit) the vehicle).
11.Starter relay diode L. Pass the clutch cable with no downward sag
12.Radiator fan motor fuse allowed.
13.Starter motor lead M. Bring the protector of the clutch cable into
14.Gear position switch lead contact with the radiator hose, and pass it to
the outside of the neutral switch lead and the
15.Lower engine bracket AC magneto lead (the outside of the vehicle).
16.Protector (clutch cable) N. No pinch is allowed the leads between the
17.Radiator hose radiator and the tension arm.
18.Gear position switch coupler O. After connecting the gear position switch cou-
19.AC magneto coupler pler, attach the coupler cover.
20.Tension arm P. After connecting the AC magneto coupler,
attach the coupler cover.
21.Rectifier/regulator lead
Q. Pass the rectifier/regulator lead to the inside
22.Wire harness of the tension arm (the side of the vehicle).
23.Yamaha diagnostic tool coupler R. Pass the main harness to the front of the radi-
24.Tank rail ator hose (the front of the vehicle), and to the
25.Mode switch lead inside of the throttle cable (the side of the
vehicle).
26.Radiator
S. Pass the engine stop switch lead between the
27.Cylinder head breather hose Yamaha diagnostic tool coupler and the tank
28.Rectifier/regulator rail.
29.Crankcase cover T. Pass the warning light lead under the mode
30.Crankcase switch lead.
31.Clamp U. Clamp the clutch cable at the front of the lead
32.Frame (the front of the vehicle).
33.Plate
34.Warning light coupler
A. Pass the engine stop switch lead and the

mode switch lead between the frame and the
cable holder. Route engine stop switch lead
and the mode switch lead above of the vehi-
cle.
B. Insert the Yamaha diagnostic tool coupler into
the connector, and fix it to the bracket.
C. Fasten the engine stop switch coupler to the
bracket of the inside. Fasten the coupler (not
used) to the bracket of the outside. Route the
mode switch lead under the bracket.
D. Pass the warning light lead over the wire har-
ness and radiator hose.
E. Fasten the warning light coupler to the
bracket.
F. Fasten the rectifier/regulator coupler to the
bracket. Attach the coupler cover.
G. Pass the AC magneto lead through rear side
of the vehicle. No pinch is allowed between
the radiator and the tension arm.
2-32
2-33
1. Battery negative lead L. Fasten the starter relay lead and motor lead
2. Starter motor lead with the plastic locking tie within the range of
the cross tube width (approximately 39 mm).
3. Coolant temperature sensor coupler Make sure that the locking portion of the plas-
4. Radiator fan motor lead (For JPN) tic locking tie faces to the lower side of the
5. Radiator fan motor coupler (For JPN) vehicle and put it inside the rear frame with-
out cutting off the end.
6. Start switch coupler
M. Fasten the wire harness at the white tape
7. Cable guide position using the plastic locking tie.
8. Start switch lead N. Position the lock part of the plastic locking tie
9. Joint coupler to downward of the vehicle. Cut the end of
10.Throttle position sensor lead the plastic locking tie.
11.Throttle position sensor coupler O. Fasten the bracket to the tank rail (right)
12.Radiator breather hose using the rivet.
13.Radiator hose P. Cylinder head ridge line
14.Fuel hose Q. When installing the engine ground lead termi-
nal, it can face either way. Make sure that the
15.Fuel pump coupler terminal does not contact the cylinder head
16.Diode bolt and that it faces to the rear beyond the
17.Resistor coupler cylinder ridge line.
18.Cross tube
19.Wire harness
20.Fuel tank
21.Rubber damper
22.Rear frame
23.Side cover
24.Bracket
A. Adjust any slack between the rear shock

absorber and the clamp of the side cover.
B. Attach the coupler cover to the coolant tem-
perature sensor coupler.
C. Pass the radiator fan motor lead to the inside
of the tension arm (the side of the vehicle). 
Either the radiator fan motor lead or the har-
ness side can face the outside where they
cross each other.
D. Make sure the cable guide has contact with
the stamped location of the vehicle identifica-
tion number, and install it.
E. Insert the joint coupler into the plate and
secure it. After securing it, put the cover over
the joint coupler. It is allowed that the insert
portion of the coupler is hidden with the
cover.
F. After connecting the throttle position sensor
coupler, attach the cover.
G. Route the radiator breather hose as follows: 
Route it over the boss of the upper side of the
radiator toward the rear of the vehicle 
Route it over the boss on the lower side of the
radiator toward the front of the vehicle 
Route it over the radiator hose toward the
front of the vehicle
H. Route the fuel hose in front of the fuel pump.
I. After connecting the fuel pump coupler,
attach the cover.
J. Route the starter motor lead inside of the rear
frame and along the rear fender.
K. Place the resistor coupler under the starter
relay.
2-34
2-35
1. Plastic locking tie

2. Number plate band
3. Clutch cable
4. Engine stop switch lead
5. Mode switch lead
6. Warning light lead
7. Front brake hose
8. Cable guide
9. Start switch lead
10.Number plate
11.Warning light
A. Fasten the start switch lead to the handlebar

using the plastic locking tie. Do not cut the
end of the plastic locking tie.
B. Pass the clutch cable through the rear side of
the number plate band.
C. Fasten the engine stop switch lead and mode
switch lead to the handlebar using the plastic
locking tie. Do not cut the end of the plastic
locking tie.
D. 30–50
E. Vertical direction of vehicle
F. Pass the engine stop switch lead and mode
switch lead between the frame and the cable
guide.
G. Pass the warning light lead through the cable
guide.
H. Pass the front brake hose through the front
side of the number plate.
I. Pass the clutch cable through the guide of the
number plate.
J. Pass the start switch lead through the cable
guide.
K. Pass the start switch lead through the left
side of the number plate bolt.
L. Insert the warning light into the bracket and
fasten it.
2-36
2-37
1. Clamp J. Insert the clamp into the rib so that it contacts

2. Diode the rib.
3. Throttle position sensor lead
4. Intake air pressure sensor lead
5. Joint coupler
6. Intake air pressure sensor coupler
7. Wire harness
8. Clamp (wire harness)
9. Cylinder head breather hose
10.Fuel injector lead
11.Throttle body
12.Fuel injector coupler
13.Fuel hose
14.Air filter assembly
15.Wire harness
16.Fuel tank bracket
17.Plug cap
18.Cylinder head cover
19.Starter motor lead
20.Cable guide
21.Ignition coil
22.Side core
23.Sub-lead wire
24.Sub-lead wire coupler
25.Warning light lead (wire harness)
26.Warning light coupler
27.Rectifier/regulator lead
28.Warning light lead
29.ECU
30.High tension cord
31.Air filter assembly
32.Wire harness
33.Grommet
34.Clamp
A. Fasten the main harness by the clamp, and

insert the clamp projection into the hole in the
sheet metal of the radiator. The direction of
the clamp lock portion does not matter. It is
allowed to run the leads near the radiator cap
on the inside.
B. No pinch is allowed the leads between the
tank rail and the air filter joint.
C. Insert the projection of the main harness into
the hole in the frame.
D. Route the cylinder head breather hose
behind or in front of the fuel injector lead.
E. Right side of the vehicle.
F. ±10
G. Install the plug cap so it faces to the right side
of the vehicle.
H. It does not matter if the high tension cord and
grommet do not contact the ECU.
I. Pass the wire harness between the ECU and
air filter assembly.
2-38
2-39
1. Battery positive lead

2. Fuel pump lead
3. Joint coupler
4. Wire harness
5. Main relay (red tape)
6. Radiator fan motor relay
7. Starter relay coupler
8. Starter relay
9. Starter motor lead
10.Resistor
11.Battery negative lead
12.Cross member
A. Connect the battery positive lead and starter

relay terminal.
B. Install the clamp (wire harness) to the hole of
the battery bracket.
C. After connecting the battery negative coupler,
position to the right side of the starter relay.
D. The position of the starter motor lead and
battery negative lead does not matter.
E. Pass the battery negative lead through lower
side of the cross member.
F. After connecting the battery positive lead in
the direction shown in the illustration, put the
cover over it.
G. Pass the battery positive lead through the
lower side of the cross member.
2-40
2-41
1. Bleed screw
2. Rear brake caliper
3. Protector
4. Gasket
5. Rear brake hose
6. Brake pedal
7. Rear brake master cylinder assembly
8. Swingarm
9. Spring
10.Frame
A. It does not matter whether the spring is

installed upward or downward.
B. Pass the brake hose into the 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.
2-42
2-43
PERIODIC CHECKS AND ADJUSTMENTS
MAINTENANCE INTERVALS ...........................................................................3-1

MAINTENANCE INTERVALS.....................................................................3-1
PRE-OPERATION INSPECTION AND MAINTENANCE .................................3-5

GENERAL INSPECTION AND MAINTENANCE ........................................3-5
1
ENGINE.............................................................................................................3-6
CHECKING THE COOLANT LEVEL ..........................................................3-6
CHECKING THE COOLING SYSTEM .......................................................3-6
2
CHANGING THE COOLANT ......................................................................3-6
CHECKING THE RADIATOR CAP.............................................................3-7
CHECKING THE RADIATOR CAP VALVE OPENING PRESSURE..........3-7
CHECKING THE COOLANT CIRCULATORY SYSTEM FOR LEAKS.......3-8
ADJUSTING THE CLUTCH LEVER POSITION.........................................3-8
3
ADJUSTING THE CLUTCH LEVER FREE PLAY ......................................3-8
4
ADJUSTING THE THROTTLE GRIP FREE PLAY.....................................3-9
LUBRICATING THE THROTTLE CABLE.................................................3-10
CLEANING THE AIR FILTER ELEMENT .................................................3-10
CHECKING THE THROTTLE BODY JOINT ............................................3-12
CHECKING THE BREATHER HOSES ....................................................3-12
5
CHECKING THE EXHAUST SYSTEM .....................................................3-12
CHECKING THE FUEL LINE ...................................................................3-13
CHECKING THE ENGINE OIL LEVEL .....................................................3-13
CHANGING THE ENGINE OIL.................................................................3-14
ADJUSTING THE ENGINE IDLING SPEED ............................................3-15
ADJUSTING THE VALVE CLEARANCE..................................................3-16
VALVE CLEARANCE SHIM CHART ........................................................3-19 6
CHASSIS ........................................................................................................3-21
7
BLEEDING THE BRAKE SYSTEM ..........................................................3-21
CHECKING THE BRAKE HOSES ............................................................3-22
ADJUSTING THE FRONT BRAKE...........................................................3-22
ADJUSTING THE REAR BRAKE .............................................................3-23
CHECKING THE FRONT BRAKE PADS .................................................3-23
CHECKING THE REAR BRAKE PADS....................................................3-25
CHECKING THE REAR BRAKE PAD INSULATOR.................................3-26
CHECKING THE BRAKE FLUID LEVEL ..................................................3-26
8
ADJUSTING THE DRIVE CHAIN SLACK ................................................3-27
CHECKING THE FRONT FORK LEGS....................................................3-28
CHECKING THE FRONT FORK PROTECTOR GUIDE ..........................3-28
CLEANING THE FRONT FORK OIL SEAL AND DUST SEAL ................3-28
AIR BLEEDING FROM FRONT FORK.....................................................3-28
9
ADJUSTING THE FRONT FORK LEGS ..................................................3-29
CHECKING THE SWINGARM OPERATION ...........................................3-30
CHECKING THE REAR SUSPENSION ...................................................3-30
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ...................3-30
CHECKING THE TIRES ...........................................................................3-32
10
CHECKING AND TIGHTENING THE SPOKES .......................................3-32
CHECKING THE WHEELS ......................................................................3-33
CHECKING THE WHEEL BEARINGS .....................................................3-33
CHECKING AND ADJUSTING THE STEERING HEAD ..........................3-33
LUBRICATING THE LEVERS ..................................................................3-34
LUBRICATING THE PEDAL.....................................................................3-34
LUBRICATING THE DRIVE CHAIN .........................................................3-34
LUBRICATING THE SIDESTAND ............................................................3-34
CHECKING THE CHASSIS FASTENERS ...............................................3-35
ELECTRICAL SYSTEM..................................................................................3-36
CHECKING THE SPARK PLUG...............................................................3-36
CHECKING THE IGNITION TIMING ........................................................3-36
CHECKING AND CHARGING THE BATTERY ........................................3-37
MAINTENANCE INTERVALS
EAM20157
EAM30369
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.
Every Every Every

Check or mainte- After race third fifth As
Item (about (about (about Remarks
nance job break-in 2.5 7.5 12.5 required
hours) hours) hours)
Check the valve   The engine must be cold.

clearances
Valve Inspect  Check the valve seats and the

valve faces for wear.
Replace 
Check the free length and the
Inspect 
Valve spring tilt.
Replace 
Inspect  Check for scratches and wear.

Valve lifter
Replace 
• Inspect the camshaft surface.
Inspect  • Inspect the decompression
Camshaft system.
Replace 
Check for wear on the teeth and
Inspect 
Camshaft for damage.
sprocket
Replace 
Inspect  Inspect crack.
Clean  Inspect carbon deposits and

eliminate them.
Piston
Replace the piston, piston pin,
Replace   piston pin clip, and piston ring
all as a set.
Check the end gap of the piston

Inspect 
ring.
Piston ring Replace the piston, piston pin,
all as a set.
Inspect 
Piston pin Replace the piston, piston pin,
all as a set.
• Check the coolant passages

for corrosion.
• Inspect carbon deposits and
Cylinder head Inspect and clean 
eliminate them.
• Check for warpage, and
replace the gasket.
Inspect and clean  Inspect score marks.

Cylinder
Replace  Inspect wear.
3-1
Every Every Every

race third fifth
Item Check or mainte- After (about (about (about As Remarks
nance job break-in required
2.5 7.5 12.5
Inspect   Check the engine oil amount.

Engine oil
Replace  
Oil filter element Replace  
Oil strainer Clean 
Inspect housing, friction plate,

Inspect and adjust   clutch plate and spring.
Clutch
Replace 
Inspect 
Transmission
Replace bearings 
Shift fork, shift

cam, guide bar Inspect  Inspect wear.
Nut (rotor) Retighten   Check for tightening torques.
Inspect and retighten   Check for exhaust leaks, and

tightening torques.
Exhaust pipe,
silencer, Clean 
protector * When the exhaust sound
Replace fiver  * becomes louder or when a per-
formance drop is felt.
Crankshaft Inspect and clean  

Throttle body Inspect 
Use Yamaha foam air filter oil or

Clean and lubricate   other quality foam air filter oil.
Air filter
Replace 
Inspect and clean   Check the electrodes and the

terminals for wear.
Spark plug
Replace 
Check coolant level
 
and leakage
Check radiator cap Use the radiator cap tester for a


operation checkup.
Cooling system Check radiator cap
 
attached
Change the coolant  Every two years
Inspect hoses 
Engine guard Replace  Breakage
Frame Clean and inspect  
Fuel tank, fuel

pump Inspect  
Inspect 
Fuel hose
Replace  Every four years
Clean   Dust seal
Inspect and adjust  
Replace oil  
Front fork legs
Replace oil seal 
Clean and grease oil

   Lithium-soap-based grease
seals and dust seals
3-2
Every Every Every

race third fifth
2.5 7.5 12.5
Protector guide Replace 
Inspect and adjust  
Rear shock Grease pillow balls and bear-

Lubricate  * ings.
absorber *After rain ride
Retighten   Check for tightening torques.
Adjust lever position  

and pedal height
Lubricate pivot point  
Check brake disc sur-

 
face
Check fluid level and

 
Brakes leakage
Retighten brake disc

bolts, caliper bolts,   Check for tightening torques.
master cylinder bolts
and union bolts
Replace pads 
Replace brake fluid  Every one year

Inspect, lube and
Swingarm   Molybdenum disulfide grease
retighten
Relay arm, con- Inspect, lube and

  Molybdenum disulfide grease
necting rod retighten
Sidestand Lubricate  Lithium-soap-based grease
Inspect free play and

retighten   Check for tightening torques.
Steering head
Clean and lube  After rain ride
Inspect air pressure,
wheel run-out, tire  
wear and spoke
looseness
Retighten sprocket
Tire, wheels bolt  
Check the bearing 
Lubricate  Lithium-soap-based grease
Clean, lubricate,
slack, alignment   Use chain oil.
Drive chain
Replace  Use chain oil.
Drive chain guide Inspect  Inspect wear.
Drive chain guide

and drive chain Replace 
support
Routing (Connection)  
Cables Check and grease  
Check and clean Check throttle cables on the

 
throttle cable throttle body for dirt and wear.
Adjust clutch lever

Levers 
free play
3-3
Every Every Every

race third fifth
2.5 7.5 12.5
Brake pedal, foot-

rest Lubricate  
Outside nuts and Refer to “TORQUE-CHECK

Retighten  
bolts POINTS” on page 1-24.
Check terminal for looseness

Battery Inspect 
and corrosion.
3-4
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
Check that coolant is filled up to the radiator cap. 3-6, 3-6, 3-6, 3-7,
Coolant
Check the cooling system for leakage. 3-7, 3-8
Check that a fresh gasoline is filled in the fuel tank.
Fuel 1-21
Check the fuel line for leakage.
Check that the oil level is correct. Check the crankcase
Engine oil 3-13, 3-14
and oil line for leakage.
Check that gears can be shifted correctly in order and that
Gear shifter and clutch the clutch operates smoothly. 3-8, 3-8
Check that the throttle grip operation and free play are
Throttle grip/Housing correctly adjusted. Lubricate the throttle grip and housing, 3-9, 3-10
if necessary.
3-21, 3-22, 3-22,
Check the play of front brake and effect of front and rear
Brakes brake. 3-23, 3-23, 3-25,
3-26, 3-26
Check drive chain slack and alignment. Check that the 3-27, 4-65, 4-65,
Drive chain drive chain is lubricated properly. 4-66, 4-66, 4-66
Check for excessive wear and tire pressure. Check for 3-32, 3-32, 3-33,
Wheels
loose spokes and have no excessive play. 3-33
Check that the handlebar can be turned smoothly and
Steering have no excessive play. 3-33
3-28, 3-28, 3-28,

Front forks and rear Check that they operate smoothly and there is no oil leak-
shock absorber 3-28, 3-29, 3-30,
age.
3-30, 3-30
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 3-12
cracks.
Check that the rear wheel sprocket tightening bolt is not 4-10, 4-10, 4-10,
Rear wheel sprocket
loose. 4-10, 4-11, 4-11
Lubrication Check for smooth operation. Lubricate if necessary. 3-10, 3-34
Bolts and nuts Check the chassis and engine for loose bolts and nuts. 1-24
Check that the AC magneto, ECU and ignition coil are
Lead connectors connected tightly. 1-8
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 10-2, 10-2, 10-3,
Settings of test runs before racing? Are inspection and mainte- 10-3, 10-4, 10-4,
nance 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.
3-5
ENGINE
EAM20135
minutes until the coolant has settled.
ENGINE
EAM30211
EAM30210
CHECKING THE COOLING SYSTEM
CHECKING THE COOLANT LEVEL
EWA19070 1. Remove:
WARNING • Seat
If coolant seems hot, do not remove the radi- • Side cover (left/right)
ator cap. • Air scoop (left/right)
Refer to “GENERAL CHASSIS” on page 4-1.
1. Stand the vehicle upright on a level surface. • Air filter case cover
2. Remove: Refer to “THROTTLE BODY” on page 7-5.
• Radiator cap “1” 2. Check:
• Radiator
• Radiator hose
1 Crack/damage  Replace.
Refer to “RADIATOR” on page 6-1.
3. Install:
• Air filter case cover
Refer to “THROTTLE BODY” on page 7-5.
• Air scoop (left/right)
• Seat
• Side cover (left/right)
3. Check: Refer to “GENERAL CHASSIS” on page 4-1.
• Coolant level EAM30212
Maximum level “a” or below  Add coolant CHANGING THE COOLANT

up to the maximum level. EWA19080
WARNING
If coolant seems hot, do not remove the radi-
ator cap.
1. Place a container under the engine.
2. Remove:
• Coolant drain bolt “1”
1. Radiator
ECA24260
NOTICE
• Adding water instead of coolant lowers the 1
antifreeze content. If, therefore, water is
used instead of coolant, check, and if nec-
essary, adjust the antifreeze concentration. 3. Remove:
• Use only distilled water. However, if dis- • Radiator cap
tilled water is not available, soft water may Slowly loosen the radiator cap to drain cool-
be used. ant.
4. Start the engine, warm this up for several TIP
When the radiator cap is loosened, coolant will
minutes, and then stop it.
gush out transversely; therefore, bring the con-
5. Check:
tainer near to the outlet.
• Coolant level
TIP 4. Thoroughly flush the cooling system with
Before checking the coolant level, wait a few clean tap water.
3-6
ENGINE
5. Install: EAM30213
• Copper washer New CHECKING THE RADIATOR CAP

• Coolant drain bolt 1. Check:
• Seal (radiator cap) “1”
Coolant drain bolt • Valve and valve seat “2”
10 N·m (1.0 kgf·m, 7.4 lb·ft) Crack/damage  Replace.
T.
Exist fur deposits  Clean or replace.

R.
6. Pour coolant.
Recommended coolant
High quality ethylene glycol
anti-freeze containing anti-cor-
rosion for aluminum engine
Radiator (including all routes)
1.03 L (1.09 US qt, 0.91 Imp.qt)
Coolant mixing ratio
1:1 (Coolant:Water)
EWA13040
WARNING EAM30214
• If coolant splashes in your eyes, thorough- CHECKING THE RADIATOR CAP VALVE
ly wash them with water and consult a doc- OPENING PRESSURE
tor. 1. Check:
• If coolant splashes on your clothes, quickly • Radiator cap valve opening pressure
wash it away with water and then with soap ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
and water. a. Install the radiator cap tester adapter “2” and
• If coolant is swallowed, induce vomiting the radiator cap tester “3” to the radiator cap
and get immediate medical attention. “1”, and activate the tester to check whether
ECA13481
it can stay for 5 to 10 seconds within standard
NOTICE pressure values.
• Adding water instead of coolant lowers the TIP
antifreeze content of the coolant. If water is Before attaching the cap to the tester, apply wa-
used instead of coolant, check, and if nec- ter to its sealing surface.
essary, correct the antifreeze concentra-
tion of the coolant. Radiator cap valve opening pres-
• Use only distilled water. However, if dis- sure
107.9–137.3 kPa (1.08–1.37
tilled water is not available, soft water may
kgf/cm², 15.6–19.9 psi)
be used.
• If coolant comes into contact with painted No stay  Replace.
surfaces, immediately wash them with wa-
ter. Radiator cap tester
• Do not mix different types of antifreeze. 90890-01325
7. Install: YU-24460-A
• Radiator cap Radiator cap tester adapter
8. Start the engine, warm this up for several 90890-01352
minutes, stop it, and then wait for it to cool Pressure tester adapter
down. YU-33984
9. Check:
• Coolant level
Refer to “CHECKING THE COOLANT LEV-
EL” on page 3-6.
3-7
ENGINE
4. Check:
• Pressure value
No stay for 5 to 10 seconds at the test pres-
sure value  Correct.
• Radiator
• Radiator hose connections
Coolant leaks  Correct or replace.
• Radiator hoses
Bulges  Replace.
EWA19090
WARNING
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
When the radiator cap tester is removed,
EAM30215
coolant will spout; therefore, cover it with a
CHECKING THE COOLANT CIRCULATORY cloth beforehand.
SYSTEM FOR LEAKS
EAM30370
1. Check:
ADJUSTING THE CLUTCH LEVER POSITION
• Coolant level
1. Adjust:
2. Install:
• Clutch lever position “a”
• Radiator cap tester “1”
Loosen the locknut “1” and use the adjuster
• Radiator cap tester adapter “2”
“2” to adjust the clutch lever position “a” as
Radiator cap tester desired.
90890-01325
YU-24460-A 1 2
Radiator cap tester adapter a
90890-01352
Pressure tester adapter
YU-33984
2. Tighten:
• Locknut
Locknut (clutch lever position)
4.8 N·m (0.48 kgf·m, 3.5 lb·ft)
T.
R.
EAM30216
ADJUSTING THE CLUTCH LEVER FREE

3. Activate the tester to apply the test pressure. PLAY
1. Check:
Test pressure value • Clutch lever free play “a”
196 kPa (1.96 kg/cm2, 27.9 psi) Out of specification  Regulate.
ECA24270
Clutch lever free play
NOTICE 7.0–12.0 mm (0.28–0.47 in)
• 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.
3-8
ENGINE
Clutch cable locknut

4.3 N·m (0.43 kgf·m, 3.2 lb·ft)
T.
R.
e. Return the clutch cable cover to its original
position.
1 a
b
2. Adjust:
• Clutch lever free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2
Handlebar side
a. Turn the adjuster “1” in direction “a” or “b” until
the specified clutch lever free play is ob- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
tained.
EAM30217
Direction “a” ADJUSTING THE THROTTLE GRIP FREE

Clutch lever free play is increased. PLAY
Direction “b” TIP
Clutch lever free play is decreased. Prior to adjusting throttle grip free play, the en-
gine idling speed should be adjusted.
1 1. Check:
b • Throttle grip free play “a”
Out of specification  Regulate.
Throttle grip free play
a 3.0–6.0 mm (0.12–0.24 in)
TIP
If the clutch lever free play cannot be obtained
on the handlebar side, use the adjuster on the
clutch cable side.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Clutch cable side 2. Adjust:
a. Slide the clutch cable cover. • Throttle grip free play
b. Loosen the locknut “1”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
c. Turn the adjuster “2” in direction “a” or “b” until
a. Loosen the locknut “1”.
the specified clutch lever free play is ob-
b. Turn the adjuster “2” in direction “a” or “b” until
tained.
the specified throttle grip free play is ob-
Direction “a” tained.
Clutch lever free play is increased.
Direction “b” Direction “a”
Clutch lever free play is decreased. Throttle grip free play is increased.
Direction “b”
d. Tighten the locknut “1”. Throttle grip free play is decreased.
3-9
ENGINE
c. Tighten the locknut. 3. Install:

EWA18470
• Throttle grip cap
WARNING • Screw (throttle grip cap)
After adjusting the throttle grip free play,
start the engine and turn the handlebar to the Screw (throttle grip cap)
right and to the left to ensure that this does 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
T.
R.
not cause the engine idling speed to change.
4. Install:
• Cover (grip cap)
b 1 • Cover (throttle cable cap)
EWA19100
WARNING
a Check that the throttle grip moves smoothly.
If this does not move smoothly, correct the
2 installed positions.
EAM30219
CLEANING THE AIR FILTER ELEMENT

1. Remove:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Fuel tank cap cover “1”
Refer to “FUEL TANK CAP” on page 1-20.
EAM30218
• Air filter case cover “2”
LUBRICATING THE THROTTLE CABLE
1. Remove: TIP
• Loosen the quick fastener screw “3” and re-
• Cover (throttle cable cap) “1”
move the air filter case cover.
• Cover (grip cap) “2”
• Throttle grip cap “3” • Remove the two ribs “a” located on the left and
right sides of the projections “b” on the air
scoop, and slide the air filter case cover toward
the front of the vehicle to remove it.
3
2
1
2. Lubricate:
• Throttle cable end “a” b
Recommended lubricant
2. Turn the plates “1” in direction “a”.
Lithium-soap-based grease
3. Remove:
• Air filter guide “1”
• Air filter element “2” (from the air filter guide)
3-10
ENGINE
• Guide “3” (from the air filter element) • Air filter element “3” (to the air filter guide)
• Seal “4” (from the air filter element) • Air filter guide “4”
TIP
4 1 • Apply lithium soap-based grease on the entire
2
seal lips when installing the air filter guide.
• Make sure that the two projections “a” at the
3 rear side of the vehicle on the air filter guide are
securely fitted into the two slots “b” in the air fil-
ter case.
• Check that the air filter element is turned up be-
tween the air filter guide and air filter case and
that there is no gap.
Gap  Reinstall.
4. Wash:
• Air filter element
EWA19110
WARNING
Do not use gasoline or organic (acid/alka- 1
line) volatile oil for washing. 4
TIP
After washing the element with air filter cleaner
or kerosene, squeeze and dry it completely. 3
ECA24280
1 a
NOTICE
Do not twist the element when squeezing the
element. 2
b a
8. Turn the plates “1” to the original position.
5. Check:
• Air filter element
Damage  Replace.
6. Apply:
Yamaha foam air filter oil or other quality
foam air filter oil.
Oil application quantify 1
30 cm³
9. Install:
TIP • Air filter case cover “1”
Squeeze out the excess oil. Element should be • Fuel tank breather hose
wet but not dripping. (to the air filter case cover)
7. Install: TIP
• Seal “1” (to the air filter element) • Make sure that the two slots “a” at the rear side
• Guide “2” (to the air filter element) of the vehicle in the air filter case cover are se-
curely fitted into the two edges “b” on the air fil-
3-11
ENGINE
ter case.
• Be sure to carefully align the two ribs “c” locat-
ed on the left and right sides of the air filter
case cover with the projections “d” on the air
scoop, and then install the air filter case cover. 1
1 a
EAM30221
CHECKING THE EXHAUST SYSTEM

b 1. Remove:
• Exhaust pipe protector
2. Check:
• Exhaust pipe 1
• Exhaust pipe 2
1 • Silencer
Crack/damage  Replace.
Refer to “ENGINE REMOVAL” on page 5-1.
• Exhaust gas
c Leaks  Replace the gasket.
3. Check:
d • Tightening torques
Exhaust pipe nut “1”
10.Install: 10 N·m (1.0 kgf·m, 7.4 lb·ft)
• Fuel tank cap cover
T.
Exhaust pipe clamp bolt “2”

R.
EAM30335 12 N·m (1.2 kgf·m, 8.9 lb·ft)

CHECKING THE THROTTLE BODY JOINT Exhaust pipe bolt “3”
1. Check: 12 N·m (1.2 kgf·m, 8.9 lb·ft)
• Throttle body joint Silencer bolt (rear) “4”
Refer to “CHECKING THE THROTTLE 30 N·m (3.0 kgf·m, 22 lb·ft)
BODY JOINT” on page 7-8.
EAM30220
CHECKING THE BREATHER HOSES

1. Check:
• Breather hose “1”
Loose connection  Connect properly. 1
ECA14920
NOTICE
Make sure the cylinder head breather hose is 2
routed correctly.
3-12
ENGINE
1 minute.
4 3. Check:
3 • Oil level
Make sure that the engine oil level is above
the minimum level mark “a” shown for the oil
level check window “1”, and that the engine
oil does not come out by removing the oil
check bolt “2”.
The minimum level mark “a” or below  Add
the engine oil until its level exceeds the mini-
mum level mark “a”.
4. Install:
Engine oil coming out of the oil check bolt 
• Exhaust pipe protector
Drain it until its last drop is out.
Exhaust pipe protector screw
10 N·m (1.0 kgf·m, 7.4 lb·ft)
a
T.
LOCTITE®
R.
EAM30222
CHECKING THE FUEL LINE

1. Remove:
• Seat
• Air scoop (left/right) 2 1
ECA24290
• Fuel tank
NOTICE
Refer to “FUEL TANK” on page 7-1.
2. Check: • Since engine oil also lubricates the clutch,
• Fuel hose “1” the wrong oil types or additives could
Crack/damage  Replace. cause clutch slippage. Therefore, do not
Loose connection  Connect properly. add any chemical additives.
• Do not allow foreign material to enter the
crankcase.
Recommended brand
YAMALUBE
SAE viscosity grades
SAE 10W-40, SAE 10W-50, SAE
1 15W-40, SAE 20W-40 or SAE
20W-50
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
3. Install:
• Fuel tank
• Seat
EAM30224
CHECKING THE ENGINE OIL LEVEL

1. Stand the vehicle upright on a level surface.
2. Start the engine, warm this up for 2–3 min-
utes, and then stop the engine and wait about
3-13
ENGINE
EAM30225
CHANGING THE ENGINE OIL

Stand the vehicle upright on a level surface. 2
1. Start the engine, warm this up for several
minutes, and then stop the engine and wait 1
about 5 minutes.
TIP
This model is equipped with an engine auto-stop
system. The engine stops automatically if left 3
idling for 7 minutes. If the engine stops, push the
start switch or push the start switch to restart the
engine. c. Install the new oil filter element and the oil fil-
ter element cover.
2. Place an oil pan under the drain bolt.
3. Remove: Oil filter element cover bolt
• Engine guard “1” 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
• Oil filler cap “2”
• Drain bolt (with gasket) “3” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. To check the oil strainer, perform the follow-

ing procedure.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the oil strainer “1”.
b. Check the oil strainer.
Damage  Replace.
Clogging due to dirt  Wash with kerosene.
c. Replace the new O-ring “2”.
2
1
1
2
3 d. Install the oil strainer.

Oil strainer bolt
4. If the oil filter element is also to be replaced, 10 N·m (1.0 kgf·m, 7.4 lb·ft)
perform the following procedure.
T.
R.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. Remove the oil filter element cover “1” and oil 6. Install:
filter element “2”. • Gasket New
b. Replace the new O-ring “3”. • Drain bolt
Drain bolt
20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
7. Pour the specified amount of engine oil into

the oil filler cap hole.
3-14
ENGINE
ECA25840
Engine oil quantity NOTICE

Oil change If no engine oil seeps out after one minute,
0.62 L (0.66 US qt, 0.55 Imp.qt) immediately turn the engine off so it will not
With oil filter removal
seize.
0.64 L (0.68 US qt, 0.56 Imp.qt)
Quantity (disassembled) c. If no engine oil seeps out, check the engine
0.90 L (0.95 US qt, 0.79 Imp.qt) oil for leaks, and the engine oil passage and
the oil pump for damage.
d. Check the oil pressure again.
e. Tighten the oil pressure check bolt.
Oil pressure check bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAM30336
ADJUSTING THE ENGINE IDLING SPEED

TIP
8. Install: • Because the air pressure is lower at high alti-
• Oil filler cap tudes, the air-fuel mixture will become richer. If
9. Check: the idling speed is low, turn the idle screw
• Oil level clockwise to increase the speed before the ad-
Refer to “CHECKING THE ENGINE OIL justment.
LEVEL” on page 3-13. • Before adjusting the engine idling speed, make
10.Check: sure that the air filter element is not clogged,
• Engine oil pressure the engine compression is proper, and the
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ throttle grip free play is proper.
a. Slightly loosen the oil pressure check bolt “1”. • Adjust the engine idling speed with the starter
EWA19120 knob pulled in completely.
WARNING
1. Start the engine, and warm this up until the oil
When the engine is started with the check has reached the specified temperature.
bolt removed, oil will spout; therefore, al- 2. Measure the coolant temperature using the
ways loosen it before the checkup. Yamaha diagnostic tool.
Yamaha diagnostic tool USB (US)
90890-03257
Yamaha diagnostic tool (A/I)
1
90890-03262
90890-03212
YU-03212
OBD/ GST Leadwire kit
90890-03249
b. Start the engine and keep it idling until oil
starts to seep from the oil pressure check Coolant temperature
bolt. 70–90 C (158–194 F)
EWA19130
WARNING 3. Install:
Always keep the engine idling speed during • Digital tachometer
the checkup without increasing the engine
speed.
3-15
ENGINE
sic knowledge and skill concerning the servic-

Digital tachometer ing of Yamaha motorcycles (e.g., Yamaha
90890-06760
dealers, service engineers, etc.). Those who
Digital tachometer
YU-39951-B have little knowledge and skill concerning ser-
vicing are requested not to undertake inspec-
TIP tion, adjustment, disassembly, or reassembly
Get the high tension cord “1” of the ignition coil only by reference to this manual. It may lead to
pinched in the detector “a” of the digital tachom- servicing trouble and mechanical damage.
eter. • Make sure that the valve clearance is checked
or adjusted while the engine is cold (at room
temperature).
• While the valve clearance is checked or adjust-
ed, make sure that the piston is positioned in
1 the top dead center (TDC).
1 1. Remove:
• Seat
a • Air scoop (left/right)
a Refer to “GENERAL CHASSIS” on page 4-1.
• Fuel tank
4. Measure: Refer to “FUEL TANK” on page 7-1.
• Engine idling speed • ECU
Out of specification  Regulate. 2. Remove:
Engine idling speed • Spark plug
1900–2100 r/min • Cylinder head cover
Refer to “CAMSHAFT” on page 5-11.
5. Adjust: 3. Remove:
• Engine idling speed • Timing mark accessing screw “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Crankshaft end accessing screw “2”
a. Turn the idle screw “1” in the direction of “a” • O-ring
or “b” to make an adjustment.
b 1
a 1
4. Check:
Engine idling speed  • Valve clearance
Direction “a” Out of specification  Regulate.
Increases.
Engine idling speed  Valve clearance (cold)
Direction “b”
Decreases. Intake
0.10–0.17 mm (0.0039–0.0067 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Exhaust
EAM30226
0.15–0.22 mm (0.0059–0.0087 in)
ADJUSTING THE VALVE CLEARANCE
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
TIP
• This section is intended for those who have ba- a. Turn the crankshaft counterclockwise with a
wrench.
3-16
ENGINE
b. Align the top dead center (TDC) mark “a” on

the rotor with the alignment mark “b” on the 1
crankcase cover.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Adjust:
• Valve clearance
TIP ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Check that the alignment mark “c” on the cam- a. Remove the camshaft (intake and exhaust).
shaft sprocket and the alignment mark “d” on the Refer to “CAMSHAFT” on page 5-11.
intake camshaft sprocket are aligned with the b. Remove the valve lifter “2” and the adjusting
edge of the cylinder head. pad “3” with a valve lapper “1”.
TIP
d c • Place a cloth in the timing chain space to pre-
vent adjusting pads from falling into the crank-
case.
• Identity each valve lifter and adjusting pad po-
sition very carefully so that they can be rein-
stalled in their original place.
Valve lapper (ø14)

90890-04101
Valve lapping tool (14mm)
c. Measure the valve clearance “e” using a YM-A8998
thickness gauge “1”.
Thickness gauge 3 2 1
90890-03268
Feeler gauge set
YU-26900-9
TIP
Record the measured reading if the clearance is
incorrect.
e e
3-17
ENGINE
c. Check the number on the originally installed • Make sure that valve lifters and adjusting pads
adjusting pad. are installed in place.
TIP • Make sure that adjusting pads are installed
• The adjusting pad number “a” is indicated on with their numbers facing upward.
the top of the adjusting pad.
• For the number on the originally installed ad-
justing pad, convert the last digit of adjusting 5 E
pad number as per the below table. 4
f. Install the camshafts (exhaust and intake).

Refer to “CAMSHAFT” on page 5-11.
g. Measure the valve clearance again.
h. If the valve clearance is out of specification,
d. Select an adjusting pad with a proper valve repeat adjusting the valve clearance until it is
clearance from the adjusting pad selection ta- within specification.
ble. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP
• There are 25 types of adjusting pads, ranging
from 1.20 mm (0.0472 in) to 2.40 mm (0.0945
in), in increments of 0.05 mm (0.0020 in).
• The field where the number on the originally in-
stalled adjusting pad and the measured valve
clearance intersect shows the adjusting pad
number to replace.
Last digit of pad num-

Rounded valve
ber
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.
TIP
• Apply the engine oil on the valve lifters.
• Apply molybdenum disulfide oil to the valve
stem ends.
• Check that the valve lifters turn smoothly when
rotated with your finger.
3-18
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 0.10 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.11 0.16
0.17 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)
3-19
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 0.15 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.16 0.21
0.22 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)
3-20
CHASSIS
EAM20136
CHASSIS 2
EAM30227
BLEEDING THE BRAKE SYSTEM

EWA19140
WARNING 1
Bleed the brake system whenever:
• The system is disassembled.
• A brake hose is loosened, disconnected, or
replaced.
• The brake fluid level is very low.
A. Front
• Brake operation is faulty.
B. Rear
1. Remove:
• Brake master cylinder cap d. Slowly apply the brake several times.
• Reservoir diaphragm e. Fully pull the brake lever or fully press down
• Reservoir float (front brake) the brake pedal and hold it in position.
• Protector (rear brake) f. Loosen the bleed screw.
TIP TIP
• Be careful not to spill any brake fluid or allow Loosening the bleed screw will release the pres-
the reservoir to overflow. sure in the brake caliper and cause the brake le-
• Make sure that there is enough brake fluid be- ver to contact the throttle grip or the brake pedal
fore applying the brake. Ignoring this precau- to fully extend.
tion could allow air to enter the brake system, g. Tighten the bleed screw and then release the
considerably lengthening the bleeding proce- brake lever or brake pedal.
dure. h. Repeat steps (d) to (g) until all of the air bub-
• If bleeding is difficult, it may be necessary to let bles have disappeared from the brake fluid in
the brake fluid settle for a few hours. Repeat the plastic hose.
the bleeding procedure when the tiny bubbles TIP
in the hose have disappeared. During the procedure, keep adding brake fluid to
2. Bleed the brake system. the reservoir.
ECA24320
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the reservoir to the proper level with the NOTICE
recommended brake fluid. • Wipe off any brake fluid on the brake discs,
b. Install the reservoir diaphragm. tires, wheels, etc.
c. Connect the plastic hose “1” to the bleed • Brake fluid may erode painted surfaces or
screw “2” securely, and place a container un- plastic parts. Always clean up spilled fluid
der the end of the plastic hose. immediately.
i. Tighten the bleed screw.
Bleed screw
6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
1
R.
j. Pour brake fluid to the reservoir up to the

specified level.
Refer to “CHECKING THE BRAKE FLUID
2 LEVEL” on page 3-26.
EWA13110
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-21
CHASSIS
EAM30228
CHECKING THE BRAKE HOSES

1. Check:
• Brake hose “1”
Cracks/damage/wear  Replace.
2. Remove:
• Brake lever cover
3. Adjust:
• Brake lever position
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b. Turn the adjusting bolt “2” in direction “a” or
“b” until the specified brake lever position is
obtained.
1 Direction “a”
Brake lever position is increased.
Direction “b”
Brake lever position is decreased.
A. Front
B. Rear
a
2. Check:
• Brake hose clamp
Loose connection  Tighten the clamp bolt. b
3. Stand the vehicle upright and apply the front
brake and the rear brake several times.
4. Check:
• Brake hose
Brake fluid leaks  Replace the damaged
c. Tighten the locknut.
brake hose.
Refer to “FRONT BRAKE” on page 4-13. Locknut
Refer to “REAR BRAKE” on page 4-23. 5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
R.
EAM30229 EWA13050
ADJUSTING THE FRONT BRAKE WARNING

1. Check: A soft or spongy feeling in the brake lever
• Brake lever position “a” can indicate the presence of air in the brake
Brake lever position system. Before the vehicle is operated, the
95 mm (3.74 in) air must be removed by bleeding the brake
Extent of adjustment system. Air in the brake system will consid-
86–105 mm (3.39–4.13 in) erably reduce braking performance.
ECA13490
NOTICE
After adjusting the brake lever position,
make sure there is no brake drag.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-22
CHASSIS
4. Install: can indicate the presence of air in the brake

• Brake lever cover system. Before running, bleed the brake sys-
EAM30230
tem. Air in the brake system will cause brak-
ADJUSTING THE REAR BRAKE ing performance to be reduced.
1. Check: ECA13510
• Brake pedal position “a” NOTICE

(distance from the top of the rider footrest to After adjusting the brake pedal position,
the top of the brake pedal) make sure there is no brake drag.
Out of specification  Regulate. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Brake pedal position
5.0 mm (0.20 in)
EAM30231
CHECKING THE FRONT BRAKE PADS

1. Measure:
• Brake pad thickness “a”
Out of specification  Replace as a set.
TIP
The pads worn up to the indicator “b” grooves
mean that the brake pad thickness limit is
reached.
a
Brake pad lining thickness limit
1.0 mm (0.04 in)
2. Adjust:
• Brake pedal position b
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b. Turn the adjusting bolt “2” in direction “a” or
“b” until the specified brake pedal position is
obtained.
Direction “a” a
Brake pedal is raised. a
Direction “b” 2. Replace:
Brake pedal is lowered.
• Brake pad
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the pad pin plug “1”.
a
b
1
1
c. Tighten the locknut.

Locknut b. Loosen the pad pin “2”.
6 N·m (0.6 kgf·m, 4.4 lb·ft) c. Remove the brake caliper “3” from the front
T.
R.
fork.
EWA19150
WARNING
A soft or spongy feeling in the brake pedal
3-23
CHASSIS
3 b a
d. Remove the pad pin and brake pads “4”. i. Install the brake caliper “8” and tighten the
pad pin “9”.
4
Bolt (brake caliper)
28 N·m (2.8 kgf·m, 21 lb·ft)
T.
Pad pin
R.
17 N·m (1.7 kgf·m, 13 lb·ft)
e. Connect the plastic hose “5” to the bleed 8

screw “6” and place a container under the
end of the plastic hose.
6 9
j. Install the pad pin plug “10”.

5
Pad pin plug
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
T.
R.
f. Loosen the bleed screw and push the brake

caliper piston in.
EWA19160
WARNING
Do not reuse the drained brake fluid.
g. Tighten the bleed screw. 10
Bleed screw
6 N·m (0.6 kgf·m, 4.4 lb·ft) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
T.
R.
3. Check:
h. Install the brake pads “7” and the pad pin. • Brake fluid level
TIP Refer to “CHECKING THE BRAKE FLUID
• Install the brake pads with their projections “a” LEVEL” on page 3-26.
into the brake caliper recesses “b”. 4. Check:
• Temporarily tighten the pad pin at this point. • Brake lever operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYSTEM”
3-24
CHASSIS
on page 3-21.
EAM30232 3 4
CHECKING THE REAR BRAKE PADS
1. Measure:
• Brake pad thickness “a”
Out of specification  Replace as a set.
TIP 5
The pads worn up to the indicator “b” grooves
mean that the brake pad thickness limit is
reached.
d. Remove the pad pin “6” and the brake pads
Brake pad lining thickness limit “7”.
1.0 mm (0.04 in)
6 7
a
a
e. Connect the plastic hose “8” to the bleed

2. Replace: screw “9” and place a container under the
• Brake pad end of the plastic hose.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the protector “1” and the pad pin
plug “2”.
2 9
8
1
f. Loosen the bleed screw and push the brake
caliper piston in.
EWA19170
WARNING
b. Loosen the pad pin “3”.
Do not reuse the drained brake fluid.
c. Remove the rear wheel “4” and the brake cal-
iper “5”. g. Tighten the bleed screw.
Refer to “REAR WHEEL” on page 4-9.
Bleed screw
6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
h. Install the brake pad “10” and the pad pin

“11”.
TIP
• Install the brake pads with their projections “a”
into the brake caliper recesses “b”.
• Temporarily tighten the pad pin at this point.
3-25
CHASSIS

11 10 system.
on page 3-21.
EAM30233
CHECKING THE REAR BRAKE PAD

a INSULATOR
b
1. Remove:
• Brake pad
Refer to “REAR BRAKE” on page 4-23.
i. Install the brake caliper “12” and the rear 2. Check:
wheel “13”. • Rear brake pad insulator “1”
Refer to “REAR WHEEL” on page 4-9. Damage  Replace.
j. Tighten the pad pin “14”.
Pad pin
17 N·m (1.7 kgf·m, 13 lb·ft)
T.
R.
14 13
EAM30234
12 CHECKING THE BRAKE FLUID LEVEL
TIP
In order to ensure a correct reading of the brake
k. Install the pad pin plug “15” and the protector fluid level, make sure that the top of the brake
“16”. fluid reservoir is horizontal.
Pad pin plug 2. Check:
2.5 N·m (0.25 kgf·m, 1.8 lb·ft) • Brake fluid level
T.
Bolt (protector)
R.
The minimum level mark “a” or below  Add.

7 N·m (0.7 kgf·m, 5.2 lb·ft)
Specified brake fluid
DOT 4
15
a
16
a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• Brake fluid level A. Front brake
Refer to “CHECKING THE BRAKE FLUID B. Rear brake
LEVEL” on page 3-26. EWA13090
4. Check: WARNING
• Brake pedal operation • Use only the designated brake fluid. Other
3-26
CHASSIS
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 a
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 Drive chain slack (Maintenance
NOTICE stand)
Brake fluid may damage painted surfaces 50.0–60.0 mm (1.97–2.36 in)
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately. 5. Adjust:
• Drive chain slack
EAM30235 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
ADJUSTING THE DRIVE CHAIN SLACK a. Loosen the wheel axle nut “1”.
ECA13550
b. Loosen both locknuts “2”.
NOTICE c. Turn the adjusting bolt “3” in direction “a” or
A drive chain that is too tight will overload “b” until the specified drive chain slack is ob-
the engine and other vital parts, and one that tained.
is too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep Direction “a”
the drive chain slack within the specified lim- The drive chain slack decreases.
its. Direction “b”
The drive chain slack increases.
1. Use a maintenance stand to raise the rear
wheel off the ground.
EWA13120
WARNING
Securely support the vehicle so that there is a
no danger of it falling over.
2. Shift the transmission into the neutral posi- b
tion. 1
3. Pull the drive chain up above the drive chain
2
guide installation bolt with a force of about 50 3
N (5.0 kgf, 36 lbf).
4. Check:
TIP
• Drive chain slack “a”
• To maintain the proper wheel alignment, adjust
both sides evenly.
TIP • Push the rear wheel forward to make sure that
Measure drive chain slack between the drive
there is no clearance between the swingarm
chain guide and the bottom of the chain as
end plates and the ends of the swingarm.
shown.
d. Tighten the wheel axle nut.
Wheel axle nut
125 N·m (12.5 kgf·m, 92 lb·ft)
T.
R.
e. Tighten the drive chain puller locknut.
3-27
CHASSIS
Drive chain puller locknut

T.
R.
21 N·m (2.1 kgf·m, 15 lb·ft)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1
EAM30338
CHECKING THE FRONT FORK LEGS

EWA13120
a
WARNING
Securely support the vehicle so that there is
EAM30237
CLEANING THE FRONT FORK OIL SEAL

2. Check: AND DUST SEAL
• Inner tube 1. Remove:
Damage/scratches  Replace. • Protector
• Front fork leg • Dust seal “1”
Oil leaks between inner tube and outer tube ECA24330
 Replace the oil seal. NOTICE

3. Hold the vehicle upright and apply the front Be careful not to damage the dust seal and
brake. the inner tube by a driver.
4. Check:
• Front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Unsmooth operation  Correct or replace.
Refer to “FRONT FORK” on page 4-38.
2. Clean:
• Dust seal “a”
• Oil seal “b”
TIP
• Clean the dust seal and oil seal after every run.
• Apply lithium-soap-based grease on the inner
tube.
EAM30236
CHECKING THE FRONT FORK PROTECTOR

GUIDE
1. Check:
• Protector guide “1” a
Out of specification  Replace.
TIP
The protector guide reaches the limit of its use b
when it is worn down to the same height “a” as LS
of the outer tube circumference.
EAM30238
AIR BLEEDING FROM FRONT FORK

TIP
If the front fork initial movement feels stiff during
3-28
CHASSIS
a run, relieve the front fork internal pressure.

Rebound damping
1. Use a maintenance stand to raise the front Minimum (soft)
wheel off the ground. 20 click(s) in direction “b”*
EWA13120
Standard
WARNING 10 click(s) in direction “b”*
Securely support the vehicle so that there is Maximum (hard)
no danger of it falling over. 0 click(s) in direction “b”*
* With the adjusting screw fully turned in di-
2. Remove the bleed screw “1” and release the rection “a”
internal pressure from the front fork.
3. Tighten:
• Bleed screw
Bleed screw
1.3 N·m (0.13 kgf·m, 0.95 lb·ft)
T.
R.
1
a b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Compression damping
ECA24350
NOTICE
Do not turn the adjuster forcibly beyond its
EAM30239
adjusting range.
ADJUSTING THE FRONT FORK LEGS 1. Adjust:
EWA19180
• Compression damping
WARNING
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Always adjust the left and right front forks a. Turn the adjuster “1” in the direction of “a” or
evenly. If this is not done, the vehicle may “b” to make an adjustment.
have poor stability.
• Securely support the vehicle so that there Direction “a”
is no danger of it falling over. Compression damping is increased
Rebound damping (suspension is harder).
ECA24340 Direction “b”
NOTICE Compression damping is decreased
(suspension is softer).
adjusting range.
1. Adjust: Compression damping
Minimum (soft)
• Rebound damping
20 click(s) in direction “b”*
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Standard
a. Turn the adjuster “1” in the direction of “a” or 11 click(s) in direction “b”*
“b” to make an adjustment. Maximum (hard)
Direction “a” * With the adjusting screw fully turned in di-
Rebound damping is increased (sus- rection “a”
pension is harder).
Direction “b”
Rebound damping is decreased (sus-
pension is softer).
3-29
CHASSIS
EAM30242
ADJUSTING THE REAR SHOCK ABSORBER

b a ASSEMBLY
Use a maintenance stand to raise the rear wheel
off the ground.
1 EWA13120
WARNING
Spring preload
ECA24360
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ NOTICE
EAM30240
CHECKING THE SWINGARM OPERATION adjusting range.

1. Check: 1. Remove:
• Swingarm smooth action • Rear frame
• Swingarm free play Refer to “REAR SHOCK ABSORBER AS-
Refer to “SWINGARM” on page 4-61. SEMBLY” on page 4-55.
EAM30241
2. Adjust:
CHECKING THE REAR SUSPENSION • Spring preload
1. Stand the vehicle upright on a level surface. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EWA13120 a. Loosen the locknut “1”.
WARNING b. Loosen the adjuster “2” until there is some
Securely support the vehicle so that there is clearance between the spring and the adjust-
no danger of it falling over. er.
c. Measure the spring free length “a”.
2. Check:
• Rear shock absorber assembly
Gas leaks/oil leaks  Replace the rear shock
absorber assembly.
Refer to “REAR SHOCK ABSORBER AS- a
1
SEMBLY” on page 4-55.
3. Check:
2
• Rear shock absorber assembly smooth ac-
tion
• Rear suspension link smooth action
Sit astride the seat and shake your body up
and down several times to check whether the d. Turn the adjuster in the direction of “b” or “c”
rear shock absorber assembly operates to make an adjustment.
smoothly.
Unsmooth operation  Correct or replace. Direction “b”
Refer to “REAR SHOCK ABSORBER AS- Spring preload is increased (suspen-
SEMBLY” on page 4-55. sion is harder).
Direction “c”
Spring preload is decreased (suspen-
sion is softer).
3-30
CHASSIS
Spring preload adjusting positions Direction “a”

Minimum Rebound damping is increased (sus-
Position in which the spring is pension is harder).
turned in 1.5 mm (0.06 in) from Direction “b”
its free length. Rebound damping is decreased (sus-
Standard pension is softer).
Position in which the spring is
turned in 6.0 mm (0.24 in) from Rebound damping
its free length. Minimum (soft)
Maximum 30 click(s) in direction “b”*
Position in which the spring is Standard
turned in 18.0 mm (0.71 in) from 11 click(s) in direction “b”*
its free length. Maximum (hard)
0 click(s) in direction “a”
TIP * With the adjusting screw fully turned in di-
• Be sure to remove all dirt and mud from around rection “a”
the locknut and adjusting ring before adjust-
ment.
• The length of the spring (installed) changes 1.5
mm (0.06 in) per turn of the adjusting ring.
b b
c
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Compression damping (for fast compres-

sion damping)
ECA24370
e. Tighten the locknut. NOTICE
Locknut Do not turn the adjuster forcibly beyond its
10 N·m (1.0 kgf·m, 7.4 lb·ft) adjusting range.
T.
R.
1. Adjust:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Compression damping (for fast compression
3. Install: damping)
• Rear frame ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Refer to “REAR SHOCK ABSORBER AS- a. Turn the adjuster “1” in the direction of “a” or
SEMBLY” on page 4-55. “b” to make an adjustment.
Rebound damping
ECA24370
Direction “a”
NOTICE Compression damping is increased
Do not turn the adjuster forcibly beyond its (suspension is harder).
adjusting range. Direction “b”
Compression damping is decreased
1. Adjust:
• Rebound damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjuster “1” in the direction of “a” or
“b” to make an adjustment.
3-31
CHASSIS
Fast compression damping

Minimum (soft)
2 turn(s) in direction “b”*
Standard b
1-1/2 turn(s) in direction “b”* 1
Maximum (hard) a
0 turn(s) in direction “b”*
* With the adjusting screw fully turned in di-
rection “a”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAM30243
b
1 CHECKING THE TIRES
a 1. Measure:
• Tire pressure
Tire air pressure (measured on
cold tires)
Front
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
100 kPa (1.00 kgf/cm², 15 psi)
Compression damping (for slow compres- Rear
sion damping) 100 kPa (1.00 kgf/cm², 15 psi)
ECA24390
NOTICE TIP
Do not turn the adjuster forcibly beyond its • Check the tire while it is cold.
adjusting range. • Loose bead stoppers allow the tire to slip off its
position on the rim when the tire pressure is
1. Adjust:
low.
• Compression damping (for slow compression
• If the tire valve stem is found tilted, the tire is
damping)
considered to be slipping off its position. Cor-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
rect the tire position.
a. Turn the adjuster “1” in the direction of “a” or
“b” to make an adjustment.
Direction “a”
Compression damping is increased
(suspension is harder).
Direction “b”
Compression damping is decreased
Slow compression damping

Minimum (soft) EAM30244
20 click(s) in direction “b”* CHECKING AND TIGHTENING THE SPOKES
Standard 1. Check:
• Spoke
Maximum (hard)
0 click(s) in direction “b”* Bend/damage  Replace.
* With the adjusting screw fully turned in di- Loose  Tighten.
rection “a”
3-32
CHASSIS
TIP
After replacing a tire or a wheel, always balance
the wheel.
EAM30246
CHECKING THE WHEEL BEARINGS

1. Check:
• Wheel bearing
Refer to “CHECKING THE FRONT WHEEL”
on page 4-6 and “CHECKING THE REAR
WHEEL” on page 4-10.
TIP
A tight spoke will emit a clear, ringing tone; a EAM30247
CHECKING AND ADJUSTING THE

loose spoke will sound flat.
STEERING HEAD
2. Tighten: 1. Use a maintenance stand to raise the front
• Spoke wheel off the ground.
Use a spoke nipple wrench “1” for tightening. EWA13120
WARNING
1 no danger of it falling over.
2. Check:
• Steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Blinding/looseness  Adjust the steering
head.
3. Remove:
• Handlebar
Spoke nipple wrench (6–7) Refer to “HANDLEBAR” on page 4-33.
90890-01521 • Upper bracket
Spoke nipple wrench (6–7) Refer to “STEERING HEAD” on page 4-51.
YM-01521
4. Adjust:
• Steering head
Spokes ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2.5 N·m (0.25 kgf·m, 1.8 lb·ft) a. Remove the washer “1”.
T.
R.
TIP
• Do not give a half turn (180) or more for one 1
tightening.
• Make sure that tightening after a break-in is
done until the initial looseness in nipples disap-
pears.
• Make sure that tightening is done in stages, not
at a time.
EAM30245
CHECKING THE WHEELS b. After loosening the ring nut “2” with a steering
1. Check: nut wrench “3”, tighten it to the specified
• Wheel torque.
Damage/out-of-round  Replace. TIP
EWA13260
• Set the torque wrench at a right angle to the
WARNING
steering nut wrench.
Never attempt to make any repairs to the • Move the steering to the left and right a couple
wheel.
3-33
CHASSIS
of times to check that it moves smoothly. 5. Install:

• Upper bracket
Refer to “STEERING HEAD” on page 4-51.
• Handlebar
3 Refer to “HANDLEBAR” on page 4-33.
EAM30249
LUBRICATING THE LEVERS

1. Lubricate the pivoting points and metal-to-
metal moving parts of the following parts.
2 • Brake lever
Silicone grease
Steering nut wrench
90890-01403 • Clutch lever
YU-A9472 Recommended lubricant
Ring nut (initial tightening torque) EAM30250
38 N·m (3.8 kgf·m, 28 lb·ft) LUBRICATING THE PEDAL

T.
R.
1. Lubricate the pivoting point and metal-to-met-

c. Turn the front fork to the right and left a few al moving parts of the pedal.
times, and make sure that the steering ro-
tates smoothly. If it does not turn smoothly, Recommended lubricant
remove the lower bracket and check the up- Lithium-soap-based grease
per and lower bearings.
Refer to “STEERING HEAD” on page 4-51. EAM30251
LUBRICATING THE DRIVE CHAIN

d. Loosen the ring nut fully turn and then tighten
The drive chain consists of many interacting
it to specification with a steering nut wrench.
EWA13140 parts. If the drive chain is not maintained proper-
WARNING ly, it will wear out quickly. Therefore, the drive
Do not overtighten the lower ring nut. chain should be serviced, especially when the
vehicle is used in dusty areas.
Ring nut (final tightening torque) This vehicle has a drive chain with small rubber
7 N·m (0.7 kgf·m, 5.2 lb·ft) O-rings between each side plate. Steam clean-
ing, high-pressure washing, certain solvents,
T.
R.
e. Check the steering head for looseness or and the use of a coarse brush can damage
binding by turning the front fork all the way in these O-rings. Therefore, use only kerosene to
both directions. If any binding is felt, remove clean the drive chain. Wipe the drive chain dry
the lower bracket and check the upper and and thoroughly lubricate it with engine oil or
lower bearings. chain lubricant that is suitable for O-ring chains.
Refer to “STEERING HEAD” on page 4-51. Do not use any other lubricants on the drive
f. Install the washer “1”. chain since they may contain solvents that could
damage the O-rings.
1 Recommended lubricant
Chain lubricant suitable for O-
ring chains
EAM30252
LUBRICATING THE SIDESTAND

Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-34
CHASSIS
EAM30253
CHECKING THE CHASSIS FASTENERS

Make sure that all nuts, bolts, and screws are
properly tightened.
Refer to “CHASSIS TIGHTENING TORQUES”
on page 2-14.
3-35
ELECTRICAL SYSTEM
EAM20137
6. Measure:
ELECTRICAL SYSTEM • Spark plug gap “a”
EAM30254
Out of specification  Adjust the spark plug
CHECKING THE SPARK PLUG gap.
1. Remove: Spark plug gap
• Seat 0.8–0.9 mm (0.031–0.035 in)
• Fuel tank “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:
2
• Spark plug
Spark plug
T.
R.
13 N·m (1.3 kgf·m, 9.6 lb·ft)
TIP
Before installing the spark plug, clean the spark
plug and gasket surface.
8. Install:
2. Remove: • Spark plug cap
• Spark plug cap • Fuel tank
• Spark plug • Air scoop (left/right)
Refer to “CAMSHAFT” on page 5-11. • Seat
ECA24410
NOTICE • Side cover (left/right)

In order not to allow the dirt accumulated
around the spark plug to drop from the spark EAM30255
plug hole into the cylinder, clean it before re- CHECKING THE IGNITION TIMING
moving the spark plug. 1. Remove:
• Timing mark accessing screw “1”
3. Check:
• Spark plug type
Wrong type  Replace.
Manufacturer/model
NGK/CPR8EA-9
4. Check:
• Electrode 1
Damage/wear  Replace the spark plug.
• Insulator
Abnormal color  Replace the spark plug.
Normal color is medium-to-light tan. 2. Attach:
5. Clean: • Timing light “1”
• Spark plug • Digital tachometer “2”
(with a spark plug cleaner or a wire brush) To the high tension cord “3”.
3-36
ELECTRICAL SYSTEM
Timing light
90890-03141
Timing light
YU-03141
Digital tachometer
90890-06760
Digital tachometer
YU-39951-B
1
3. Adjust:
• Engine idling speed
Refer to “ADJUSTING THE ENGINE IDLING
SPEED” on page 3-15.
4. Check:
• Ignition timing
Check whether the alignment mark “a” on the
left crankcase cover is within the firing range
“b” on the rotor.
Incorrect firing range  Check rotor and
crankshaft position sensor.
b a
5. Install:
• Timing mark accessing screw
Timing mark accessing screw
6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
EAM30256
CHECKING AND CHARGING THE BATTERY

Refer to “CHECKING AND CHARGING THE
BATTERY” on page 8-59.
3-37
ELECTRICAL SYSTEM
3-38
CHASSIS
GENERAL CHASSIS........................................................................................4-1
REMOVING THE SEAT..............................................................................4-3
REMOVING THE NUMBER PLATE ...........................................................4-3
INSTALLING THE AIR SCOOP..................................................................4-3
REMOVING THE SIDE COVER .................................................................4-4
1
INSTALLING THE SIDE COVER ...............................................................4-4
FRONT WHEEL ................................................................................................4-5

REMOVING THE FRONT WHEEL .............................................................4-6 2
CHECKING THE FRONT WHEEL .............................................................4-6
DISASSEMBLING THE FRONT WHEEL ...................................................4-7
3
ASSEMBLING THE FRONT WHEEL .........................................................4-7
INSTALLING THE FRONT WHEEL ...........................................................4-8
REAR WHEEL ..................................................................................................4-9
4
REMOVING THE REAR WHEEL .............................................................4-10
CHECKING THE REAR WHEEL ..............................................................4-10
DISASSEMBLING THE REAR WHEEL ...................................................4-10
CHECKING AND REPLACING THE REAR WHEEL SPROCKET...........4-10
ASSEMBLING THE REAR WHEEL .........................................................4-11
5
INSTALLING THE REAR WHEEL ............................................................4-11
FRONT BRAKE ..............................................................................................4-13

INTRODUCTION ......................................................................................4-17
6
CHECKING THE FRONT BRAKE DISC ..................................................4-17
REMOVING THE FRONT BRAKE CALIPER ...........................................4-17
DISASSEMBLING THE FRONT BRAKE CALIPER .................................4-17
CHECKING THE FRONT BRAKE CALIPER............................................4-18
ASSEMBLING THE FRONT BRAKE CALIPER .......................................4-18
7
INSTALLING THE BRAKE CALIPER PISTON.........................................4-18
INSTALLING THE FRONT BRAKE CALIPER..........................................4-19
REMOVING THE FRONT BRAKE MASTER CYLINDER ........................4-20
CHECKING THE FRONT BRAKE MASTER CYLINDER .........................4-20
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER.....................4-20
INSTALLING THE FRONT BRAKE MASTER CYLINDER .......................4-21
REAR BRAKE ................................................................................................4-23

8
INTRODUCTION ......................................................................................4-27
9
CHECKING THE REAR BRAKE DISC .....................................................4-27
REMOVING THE REAR BRAKE CALIPER .............................................4-28
DISASSEMBLING THE REAR BRAKE CALIPER....................................4-28
CHECKING THE REAR BRAKE CALIPER ..............................................4-28
ASSEMBLING THE REAR BRAKE CALIPER..........................................4-28
10
INSTALLING THE BRAKE CALIPER PISTON.........................................4-29
INSTALLING THE REAR BRAKE CALIPER ............................................4-29
REMOVING THE REAR BRAKE MASTER CYLINDER...........................4-30
CHECKING THE REAR BRAKE MASTER CYLINDER ...........................4-30
ASSEMBLING THE REAR BRAKE MASTER CYLINDER .......................4-31
INSTALLING THE REAR BRAKE MASTER CYLINDER .........................4-31
HANDLEBAR..................................................................................................4-33
REMOVING THE HANDLEBAR ...............................................................4-34
CHECKING THE HANDLEBAR................................................................4-34
INSTALLING THE HANDLEBAR..............................................................4-34
FRONT FORK.................................................................................................4-38
REMOVING THE FRONT FORK LEGS ...................................................4-40
DISASSEMBLING THE FRONT FORK LEGS .........................................4-40
CHECKING THE FRONT FORK LEGS....................................................4-41
ASSEMBLING THE FRONT FORK LEGS ...............................................4-42
INSTALLING THE FRONT FORK LEGS..................................................4-48
STEERING HEAD...........................................................................................4-51
REMOVING THE LOWER BRACKET ......................................................4-52
CHECKING THE STEERING HEAD ........................................................4-52
INSTALLING THE STEERING HEAD ......................................................4-52
REAR SHOCK ABSORBER ASSEMBLY ......................................................4-55

HANDLING THE REAR SHOCK ABSORBER .........................................4-57
DISPOSING OF A REAR SHOCK ABSORBER.......................................4-57
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY ....................4-57
REMOVING THE BEARING .....................................................................4-57
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY.....................4-58
CHECKING THE CONNECTING ARM AND RELAY ARM ......................4-58
INSTALLING THE RELAY ARM ...............................................................4-58
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY...................4-59
SWINGARM ....................................................................................................4-61
REMOVING THE SWINGARM .................................................................4-62
REMOVING THE BEARING .....................................................................4-62
CHECKING THE SWINGARM .................................................................4-62
INSTALLING THE SWINGARM ...............................................................4-62
CHAIN DRIVE .................................................................................................4-64

REMOVING THE DRIVE CHAIN ..............................................................4-65
CHECKING THE DRIVE CHAIN ..............................................................4-65
CHECKING THE DRIVE SPROCKET ......................................................4-66
CHECKING THE REAR WHEEL SPROCKET .........................................4-66
INSTALLING THE DRIVE CHAIN ............................................................4-66
GENERAL CHASSIS
EAM20094
GENERAL CHASSIS
Removing the seat and battery
7 8
10 22 N・m (2.2 kgf・m, 16 lb・ft)

9
11
22 N・m (2.2 kgf・m, 16 lb・ft)
3
4
5 6
2
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 Main relay 1
10 Radiator fan motor relay 1
11 CCU (Communication Control Unit) 1
4-1
GENERAL CHASSIS
Removing the side cover

16 N・m (1.6 kgf・m, 12 lb・ft)
4
6
1 7 N・m (0.7 kgf・m, 5.2 lb・ft)
1.3 N・m (0.13 kgf・m, 0.95 lb・ft)
7 N・m (0.7 kgf・m, 5.2 lb・ft)
2
5
7 N・m (0.7 kgf・m, 5.2 lb・ft) 7 N・m (0.7 kgf・m, 5.2 lb・ft)

Refer to “CLEANING THE AIR FILTER ELE-
1 Air filter case cover 1 MENT” on page 3-10.
2 Air scoop (left) 1
3 Air scoop (right) 1
4 Side cover (right) 1
5 Number plate 1
6 Rear fender 1
4-2
GENERAL CHASSIS
EAM30016
REMOVING THE SEAT

TIP b 2
The fuel tank cap cover and the seat are coupled
with each other with a plastic band.
When removing the seat, always remove the
fuel tank cap cover beforehand.
1. Remove:
• Fuel tank cap cover “1”
Refer to “FUEL TANK CAP” on page 1-20.
1
a
1
c
2. Remove:
• Seat “1”
1
c
EAM30458
INSTALLING THE AIR SCOOP

EAM30371 1. Install:
REMOVING THE NUMBER PLATE • Air scoop (left “1”/right)
1. Remove: TIP
• Bolt (number plate) After inserting the projection “a” on the air scoop
• Number plate “1” (left/right) into the hole “b” in the air filter case, in-
TIP serting the grooves “c” into the ribs “d” of the air
• The projection “a” is inserted into the band of filter case, and inserting the projection “e” into
the number plate. Pull the band off the projec- the slot “f” in the air filter case, install the air
tion before removal. scoop and secure it with the bolts.
• Remove the clutch cable “2” from the cable
guide “b” on the number plate. bf a
• The projection “c” on the lower bracket is in- c
serted into the number plate. Remove the e
number plate by pulling it off the projection. d
• When installing the number plate, insert the
projection on the number plate into the hole in
the upper side of the band. f
4-3
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.
1 b
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
c
a
a. Projection
b. Slot
c. Rib (side cover)
d. Rib (rear fender)
4-4
FRONT WHEEL
EAM20095
FRONT WHEEL
Removing the front wheel
LS 21 N・m (2.1 kgf・m, 15 lb・ft)
3
21 N・m (2.1 kgf・m, 15 lb・ft)
1
5
6 2
7
115 N・m (11.5 kgf・m, 85 lb・ft)
LS 8
LS
4 (6) 7
6
5
LT
12 N・m (1.2 kgf・m, 8.9 lb・ft)
Use a maintenance stand to raise the front
1 Front wheel axle pinch bolt 4 Loosen.
2 Front wheel axle nut 1
3 Front wheel axle 1
4 Front wheel 1
5 Collar 2
6 Oil seal 2
7 Bearing 2
8 Brake disc 1
4-5
FRONT WHEEL
EAM30017
TIP
REMOVING THE FRONT WHEEL A tight spoke will emit a clear, ringing tone; a
1. Use a maintenance stand to raise the front loose spoke will sound flat.
EWA13120
4. Tighten:
WARNING • Spoke
Securely support the vehicle so that there is Refer to “CHECKING AND TIGHTENING
no danger of it falling over. THE SPOKES” on page 3-32.
2. Remove: Spoke
• Front wheel 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
T.
R.
EAM30018
CHECKING THE FRONT WHEEL TIP

1. Check: After tightening the spokes, measure the wheel
• Front wheel axle runout.
Roll the front wheel axle on a flat surface. 5. Measure:
Bends  Replace. • Radial wheel runout “a”
• Lateral wheel runout “b”
Out of specification  Repair/replace.
b
a
EWA13460
WARNING
Do not attempt to straighten a bent wheel ax-
Radial wheel runout limit
le.
2.0 mm (0.08 in)
2. Check: Lateral wheel runout limit
• Tire 2.0 mm (0.08 in)
• Front wheel
Damage/wear  Replace. 6. Check:
Refer to “CHECKING THE TIRES” on page • Collar
3-32 and “CHECKING THE WHEELS” on Damage/wear  Replace.
page 3-33. 7. Check:
3. Check: • Bearing
• Spoke Front wheel turns roughly or is loose  Re-
Bend/damage  Replace. place the wheel bearings.
Loose  Tighten. • Oil seal
Tap the spokes with a screwdriver. Damage/wear  Replace.
4-6
FRONT WHEEL
EAM30019
parallel.
DISASSEMBLING THE FRONT WHEEL
1. Remove:
• Oil seal
• Bearing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside of the front wheel hub. 4
b. Remove the oil seals “1” with a flat-head 3
screwdriver. 2
TIP
To prevent damaging the wheel, place a rag “2”
LS
between the screwdriver and the wheel surface.
LS
2
1
4
1
TIP
c. Remove the bearings with a bearing puller. Use a socket “1” that matches the diameter of
the bearing outer race and that of the oil seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAM30020 2. Install:
ASSEMBLING THE FRONT WHEEL • Brake disc “1”
1. Install: • Brake disc bolt “2”
• Bearing (left side) “1”
Brake disc bolt
• Spacer “2”
12 N·m (1.2 kgf·m, 8.9 lb·ft)
• Bearing (right side) “3”
T.
LOCTITE®
R.
• Oil seal “4” New

TIP TIP
• Apply the lithium-soap-based grease to the Tighten the bolts in stages and in a crisscross
bearing and the oil seal lip when installing. pattern.
• Left side of bearing shall be installed first.
• Install the oil seal with its manufacture’s marks
or numbers facing outward.
ECA24420
NOTICE
Install the bearing by pressing its outer race
4-7
FRONT WHEEL
1 1
LT
3. Install: 3. Tighten:
• Collar “1” • Front wheel axle nut “1”
TIP
Apply the lithium-soap-based grease on the oil Front wheel axle nut
115 N·m (11.5 kgf·m, 85 lb·ft)
seal lip.
T.
R.
ECA24430
NOTICE
1
Before tightening the front wheel axle nut,
push down hard on the handlebar(s) several
times and check if the front fork rebounds
smoothly.
EAM30021
INSTALLING THE FRONT WHEEL

1. Install:
• Front wheel
TIP 1
Install the brake disc “1” between the brake pads
“2” correctly. 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
2. Install:
• Front wheel axle “1”
TIP 1 1
Apply the lithium-soap-based grease to the front
wheel axle.
4-8
REAR WHEEL
EAM20096
REAR WHEEL
Removing the rear wheel
1 3 12 N・m (1.2 kgf・m, 8.9 lb・ft)
125 N・m (12.5 kgf・m, 92 lb・ft)
(6) LT
10
5
7
8
21 N・m (2.1 kgf・m, 15 lb・ft) 9
LS
(6)
50 N・m (5.0 kgf・m, 37 lb・ft)
6
(6) LS
5
3
9
7
2
LS
4
21 N・m (2.1 kgf・m, 15 lb・ft)

Use a maintenance stand to raise the rear
1 Nut (rear wheel axle) 1
2 Rear wheel axle 1
3 Drive chain puller 2
4 Rear wheel 1
5 Collar 2
6 Rear wheel sprocket 1
7 Oil seal 2
8 Circlip 1
9 Bearing 2
10 Brake disc 1
4-9
REAR WHEEL
EAM30022
4. Measure:
REMOVING THE REAR WHEEL • Radial wheel runout
1. Use a maintenance stand to raise the rear • Lateral wheel runout
wheel off the ground. Refer to “CHECKING THE FRONT WHEEL”
EWA13120
WARNING on page 4-6.

Securely support the vehicle so that there is Radial wheel runout limit
no danger of it falling over. 2.0 mm (0.08 in)
2. Remove: Lateral wheel runout limit
2.0 mm (0.08 in)
• Rear wheel axle nut “1”
3. Loosen: EAM30024
• Locknut “2” DISASSEMBLING THE REAR WHEEL
4. Tighten: 1. Remove:
• Adjusting bolt “3” • Oil seal
• Bearing
Refer to “DISASSEMBLING THE FRONT
WHEEL” on page 4-7.
EAM30025
2
CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
1. Check:
3 • 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.
EAM30023
CHECKING THE REAR WHEEL

1. Check:
• Rear wheel axle
• Rear wheel
• Bearing b. Correct
• Oil seal 1. Drive chain roller
Refer to “CHECKING THE FRONT WHEEL” 2. Rear wheel sprocket
on page 4-6.
2. Check: 2. Replace:
• Tire • Rear wheel sprocket
• Rear wheel ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Damage/wear  Replace. a. Remove the self-locking nuts and the rear
Refer to “CHECKING THE TIRES” on page wheel sprocket.
3-32 and “CHECKING THE WHEELS” on b. Clean the rear wheel drive hub with a clean
page 3-33. cloth, especially the surfaces that contact the
3. Check: sprocket.
• Spoke c. Install the new rear wheel sprocket.
Refer to “CHECKING THE FRONT WHEEL”
on page 4-6.
4-10
REAR WHEEL
the bearing outer race and that of the oil seal.

Rear wheel sprocket self-locking
T. nut
50 N·m (5.0 kgf·m, 37 lb·ft)
R.
1
TIP
Tighten the self-locking nuts in stages and in a
crisscross pattern.
2. Install:
• Brake disc “1”
• Brake disc bolt “2”
Brake disc bolt
12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
LOCTITE®
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAM30026
TIP
ASSEMBLING THE REAR WHEEL Tighten the bolts in stages and in a crisscross
1. Install: pattern.
• Bearing (right side) “1”
• Circlip “2” New
• Spacer “3”
• Bearing (left side) “4”
TIP
• Apply the lithium-soap-based grease to the
bearing and the oil seal lip when installing.
• Install the bearing with seal facing outward.
• Right side of bearing shall be installed first.
• Install the oil seal with its manufacture’s marks
3. Install:
or numbers facing outward.
• Collar “1”
ECA24440
TIP
NOTICE
Apply the lithium-soap-based grease on the oil
Install the bearing by pressing its outer race seal lip.
parallel.
5 2
1
1
LS LS
LS
3
4 5
EAM30027
TIP INSTALLING THE REAR WHEEL

Use a socket “1” that matches the diameter of 1. Install:
• Rear wheel
4-11
REAR WHEEL
TIP TIP
Install the brake disc “1” between the brake pads Temporarily tighten the nut (rear wheel axle) at
“2” correctly. this point.
3 1
2. Install: 5. Adjust:
• Drive chain “1” • Drive chain slack “a”
TIP
Push the rear wheel “2” forward and install the Drive chain slack (Maintenance
stand)
drive chain.
50.0–60.0 mm (1.97–2.36 in)
Refer to “ADJUSTING THE DRIVE CHAIN

SLACK” on page 3-27.
3. Install:
• Left drive chain puller “1”
• Rear wheel axle “2”
TIP 6. Tighten:
• Install the left drive chain puller, and insert the • Rear wheel axle nut “1”
rear wheel axle from the left side.
Wheel axle nut
• Apply the lithium-soap-based grease to the
125 N·m (12.5 kgf·m, 92 lb·ft)
rear wheel axle.
T.
R.
• Locknut “2”
Locknut
21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.
1
2
4. Install:
• Right drive chain puller “1”
• Washer “2”
• Rear wheel axle nut “3”
4-12
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)
6 N・m (0.6 kgf・m, 4.4 lb・ft)
3
9
2
8
7 5
4
17 N・m (1.7 kgf・m, 13 lb・ft)

6 2.5 N・m (0.25 kgf・m, 1.8 lb・ft)

Drain.
Brake fluid Refer to “BLEEDING THE BRAKE
SYSTEM” on page 3-21.
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
4-13
FRONT BRAKE
Disassembling the front brake caliper
BF 6 N・m (0.6 kgf・m, 4.4 lb・ft)
.
1 2 S 4
S
3
BF
S

1 Brake caliper piston 2
2 Brake caliper piston dust seal 2
3 Brake caliper piston seal 2
4 Bleed screw 1
4-14
FRONT BRAKE
Removing the front brake master cylinder

9 N・m (0.9 kgf・m, 6.6 lb・ft)
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
8
5
6
6 N・m (0.6 kgf・m, 4.4 lb・ft)
7
6 N・m (0.6 kgf・m, 4.4 lb・ft)
9
1
2
30 N・m (3.0 kgf・m, 22 lb・ft)

Drain.
1 Brake lever 1
2 Union bolt 1
3 Copper washer 2
4 Front brake hose 1
5 Brake master cylinder reservoir cap 1
6 Brake master cylinder reservoir diaphragm 1
7 Front brake master cylinder float 1
8 Front brake master cylinder holder 1
9 Front brake master cylinder 1
4-15
FRONT BRAKE
Disassembling the front brake master cylinder

1
S
2
3 New
4
5 New
BF

1 Push rod 1
2 Dust boot 1
3 Circlip 1
4 Washer 1
5 Brake master cylinder kit 1
4-16
FRONT BRAKE
EAM30028
INTRODUCTION Brake disc thickness limit

EWA19210
2.5 mm (0.10 in)
WARNING
If you need to disassemble the disc brake 4. Install:
components, observe the following precau- • Front wheel
tions. Refer to “FRONT WHEEL” on page 4-5.
• Never disassemble the brake components EAM30030
unless absolutely necessary. REMOVING THE FRONT BRAKE CALIPER
• If there is any problem with connections on TIP
the hydraulic brake system, perform the Before disassembling the brake caliper, drain
following jobs. Disassemble the brake sys- the brake fluid from the entire brake system.
tem, drain the brake fluid, and clean it. After
that, add a suitable amount of brake fluid. 1. Remove:
Then, bleed it after reassembly. • Union bolt
• Use only brake fluid for washing brake • Copper washer
components. • Brake hose
• Use new brake fluid for cleaning the brake TIP
components. Put the end of the brake hose into a container
• Immediately wipe off the spilled brake fluid and pump out the brake fluid.
to avoid damage to painted surfaces or
plastic parts. EAM30031
DISASSEMBLING THE FRONT BRAKE

• Handle brake fluid with special care not to
CALIPER
let it enter your eyes so that you may not
1. Remove:
lost your eyesight.
• Brake caliper piston “1”
• FIRST AID FOR BRAKE FLUID ENTERING
• Brake caliper piston dust seal “2”
THE EYES:
• Brake caliper piston seal “3”
• Flush with water for 15 minutes and get im-
mediate medical attention. 1
3
EAM30029
CHECKING THE FRONT BRAKE DISC

1. Remove:
• Front wheel
Refer to “FRONT WHEEL” on page 4-5.
2. Check:
• Front brake disc 2
Damage/galling  Replace.
3. Measure: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Brake disc thickness a. Blow compressed air into the brake hose joint
Measure the brake disc thickness at a few dif- opening to force out the piston from the brake
ferent locations. caliper.
Out of specification  Replace. 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.
• Never try to pry out the brake caliper pis-
ton.
4-17
FRONT BRAKE
internal parts. Use new brake fluid for

cleaning and lubricating.
• Never use solvents on internal brake com-
ponents as they will cause the piston seals
to swell and distort.
• When the brake caliper is disassembled, re-
place the brake caliper piston seal and the
brake caliper piston dust seal with new
ones.

b. Remove the brake caliper piston dust seal
DOT 4
and the brake caliper piston seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAM30034
INSTALLING THE BRAKE CALIPER PISTON

EAM30032
1. Clean:
CHECKING THE FRONT BRAKE CALIPER
• Brake caliper
1. Check:
• Brake caliper piston seal
• Brake caliper piston dust seal
Rust/scratches/wear  Replace the brake
• Brake caliper piston
caliper piston.
Use brake fluid for cleaning.
• Brake caliper cylinder “2”
2. Install:
Scratches/wear  Replace the brake caliper
• Brake caliper piston seal “1” New
assembly.
• Brake caliper piston dust seal “2” New
• Brake caliper body “3” EWA19240
Cracks/damage  Replace the brake caliper WARNING

assembly. Always use new brake caliper piston seal
• Brake fluid delivery passages and brake caliper piston dust seal.
(brake caliper body)
Obstruction  Blow out with compressed air. TIP
• Apply the silicone grease on the brake caliper
2 3 piston seal and brake caliper piston dust seal.
• Fit the brake caliper piston seal and the brake
caliper piston dust seal into the grooves in the
brake caliper correctly.
1 S
1 1 1
EWA19220
WARNING
2
When the brake caliper is disassembled, re-
brake caliper piston dust seal with new ones. 2 S
2. Check: 3. Install:
• Brake caliper bracket • Brake caliper piston “1”
Crack/damage  Replace. TIP
EAM30033
Apply the brake fluid on the piston outer surface.
ASSEMBLING THE FRONT BRAKE CALIPER ECA24450
EWA19230
NOTICE
WARNING
• Install the piston with its side “a” facing the
• Before installation, clean and lubricate the brake caliper.
4-18
FRONT BRAKE
• Never force to insert.

Brake pad pin
1 17 N·m (1.7 kgf·m, 13 lb·ft)
T.
R.
BF
Refer to “CHECKING THE FRONT BRAKE
a 1 PADS” on page 3-23.
3. Tighten:
• Brake hose holder bolt “1”
Brake hose holder bolt
9 N·m (0.9 kgf·m, 6.6 lb·ft)
T.
R.
TIP
EAM30035 Make sure that the brake hose holder “2” is in-
INSTALLING THE FRONT BRAKE CALIPER stalled with its upper end “a” aligned with the
1. Install: paint “b” on the brake hose.
• Front brake caliper bracket
• Front brake caliper 2
(temporarily)
• Copper washer New
• Brake hose b
• Union bolt
Front brake caliper bracket
28 N·m (2.8 kgf·m, 21 lb·ft) a
T.
Brake hose union bolt

R.
30 N·m (3.0 kgf·m, 22 lb·ft) 1

EWA13531 4. Pour brake fluid to the brake master cylinder
WARNING reservoir up to the specified level.
Proper brake hose routing is essential to in-
sure safe vehicle operation.
DOT 4
ECA24460
NOTICE EWA13090
Make sure that the pipe portion “a” of the WARNING

brake hose touches the projection “b” on the • Use only the designated brake fluid. Other
brake caliper. brake fluids may cause the rubber seals to
brake performance.
is already in the system. Mixing brake fluids
a not enter the brake fluid reservoir. Water
b will significantly lower the boiling point of
ECA13540
2. Install: NOTICE
• Front brake caliper Brake fluid may damage painted surfaces
• Brake pad spring and plastic parts. Therefore, always clean up
• Brake pad any spilt brake fluid immediately.
• Brake pad pin
• Brake hose holder
4-19
FRONT BRAKE
5. Bleed:
• Brake system
Refer to “BLEEDING THE BRAKE SYSTEM” 1
on page 3-21.
6. Check:
• Brake fluid level
The minimum level mark or below  Add.
LEVEL” on page 3-26. 2
7. Check:
• Brake lever free play
2. Check:
Refer to “ADJUSTING THE FRONT BRAKE”
• Brake master cylinder kit
on page 3-22.
Damage/scratches/wear  Replace.
• Brake lever operation
3. Check:
• Brake master cylinder reservoir cap
system.
4. Check:
• Brake hose
on page 3-21.
EAM30036
REMOVING THE FRONT BRAKE MASTER EAM30038
ASSEMBLING THE FRONT BRAKE MASTER

CYLINDER
CYLINDER
TIP EWA13520
Before removing the front brake master cylinder, WARNING

drain the brake fluid from the entire brake sys- • Before installation, all internal brake com-
tem. ponents should be cleaned and lubricated
1. Remove: with clean or new brake fluid.
• Union bolt • Never use solvents on internal brake com-
• Copper washer ponents.
• Brake hose
TIP Specified brake fluid
To drain any remaining brake fluid, place a con- DOT 4
tainer under the master cylinder and the end of
the brake hose. 1. Wash the brake master cylinder and the
brake master cylinder kit with brake fluid.
EAM30037
2. Install:
CHECKING THE FRONT BRAKE MASTER • Primary cylinder cup “1”
CYLINDER • Secondary cylinder cup “2”
1. Check: Install to the brake master cylinder piston “3”.
• Brake master cylinder “1”
EWA20240
WARNING
Damage/scratches/wear  Replace.
• Brake fluid delivery passages “2” Apply brake fluid to the cylinder cups and in-
(brake master cylinder body) stall them as shown. Wrong orientation in in-
Obstruction  Blow out with compressed air. stallation causes poor braking performance.
4-20
FRONT BRAKE
1 2
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.
Install to the brake master cylinder piston “2”.
TIP
Install the spring with a smaller inside diameter
to the brake master cylinder piston. 1
UP
2. Install:
• Copper washer New
• Brake hose
• Union bolt
4. Install: Brake hose union bolt
• Brake master cylinder kit “1” New 30 N·m (3.0 kgf·m, 22 lb·ft)
• Washer “2”
T.
R.
• Circlip “3” New EWA13531
• Dust boot “4” WARNING

• Push rod “5” Proper brake hose routing is essential to in-
TIP sure safe vehicle operation.
• Before installation, apply brake fluid to the ECA24470
brake master cylinder kit. NOTICE

• Before installation, apply silicone grease to the During installation, bring the brake hose into
push rod end. contact with the brake master cylinder pro-
• Use circlip pliers to install the circlip. jection “a” and make its bent portion “b”
face downward.
4-21
FRONT BRAKE
TIP
Turn the handlebar toward right and left to make
sure that the brake hose does not touch other
parts (e.g., wire harness, cables, leads). Adjust
if necessary.
a
UP
aa
b
6. Check:
• Brake lever free play
Refer to “ADJUSTING THE FRONT BRAKE”
on page 3-22.
a • Brake lever operation
3. Pour brake fluid to the brake master cylinder
system.
reservoir up to the specified level.
Specified brake fluid on page 3-21.
DOT 4
EWA13090
WARNING
• Use only the designated brake fluid. Other
brake performance.
ECA13540
NOTICE
Brake fluid may damage painted surfaces
any spilt brake fluid immediately.
4. Bleed:
• Brake system
on page 3-21.
5. Check:
LEVEL” on page 3-26.
4-22
REAR BRAKE
EAM20098
REAR BRAKE
Removing the rear brake caliper
2.5 N・m (0.25 kgf・m, 1.8 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft) 17 N・m (1.7 kgf・m, 13 lb・ft)
30 N・m (3.0 kgf・m, 22 lb・ft)
S
10
2
9
3
11 4
10 N・m (1.0 kgf・m, 7.4 lb・ft) 5

9
1
7
7
7 N・m (0.7 kgf・m, 5.2 lb・ft)

Drain.
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 disc cover 1
11 Rear brake caliper assembly 1
4-23
REAR BRAKE
Disassembling the rear brake caliper
2
3
BF
6 N・m (0.6 kgf・m, 4.4 lb・ft)

1 Brake caliper piston 1
2 Brake caliper piston dust seal 1
3 Brake caliper piston seal 1
4 Bleed screw 1
4-24
REAR BRAKE
Removing the rear brake master cylinder
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)
30 N・m (3.0 kgf・m, 22 lb・ft)
7
1
8
9 2
10
5
4
Drain.
1 Union bolt 1
2 Copper washer 2
3 Brake hose 1
4 Split pin 1
5 Washer 1
6 Pin 1
7 Brake master cylinder reservoir cap 1
8 Brake master cylinder reservoir diaphragm plate 1
9 Brake master cylinder reservoir diaphragm 1
10 Rear brake master cylinder 1
4-25
REAR BRAKE
Disassembling the rear brake master cylinder
BF
4 New
S 3
2 New

1 Dust boot 1
2 Circlip 1
3 Push rod 1
4 Brake master cylinder kit 1
4-26
REAR BRAKE
EAM30040
INTRODUCTION
EWA19260
WARNING
If you need to disassemble the disc brake
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 Brake disc runout limit (as mea-
that, add a suitable amount of brake fluid. sured on wheel)
Then, bleed it after reassembly. 0.15 mm (0.0059 in)
• Use only brake fluid for washing internal
brake components. 5. Adjust:
• Use new brake fluid for cleaning the brake • Brake disc deflection
components. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Immediately wipe off the spilled brake fluid a. Remove the brake disc.
to avoid damage to painted surfaces or b. Turn the mounted position of the brake disc
plastic parts. by one bolt hole.
• Handle brake fluid with special care not to c. Install the brake disc.
let it enter your eyes so that you may not TIP
lost your eyesight. Tighten the brake disc bolts in stages and in a
• FIRST AID FOR BRAKE FLUID ENTERING crisscross pattern.
THE EYES:
• Flush with water for 15 minutes and get im-
mediate medical attention.
EAM30041
CHECKING THE REAR BRAKE DISC

1. Remove:
• Rear wheel
2. Check:
• Brake disc
Damage/galling  Replace.
3. Measure: Brake disc bolt
• Brake disc thickness 12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
LOCTITE®
R.
Measure the brake disc thickness at a few dif-

ferent locations.
Out of specification  Replace. d. Measure the brake disc deflection.
Refer to “CHECKING THE FRONT BRAKE e. If out of specification, repeat the adjustment
DISC” on page 4-17. steps until the brake disc deflection is within
specification.
Brake disc thickness limit f. If the brake disc deflection cannot be brought
3.5 mm (0.14 in) within specification, replace the brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Measure:
• Brake disc deflection 6. Install:
Out of specification  Correct the brake disc • Rear wheel
deflection or replace the brake disc. Refer to “REAR WHEEL” on page 4-9.
4-27
REAR BRAKE
EAM30042
and the brake caliper piston seal.
REMOVING THE REAR BRAKE CALIPER
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP
Before disassembling the brake caliper, drain EAM30044
the brake fluid from the entire brake system. CHECKING THE REAR BRAKE CALIPER
1. Check:
1. Remove:
• Union bolt
Rust/scratches/wear  Replace the brake
• Copper washer
caliper piston.
• Brake hose
• Brake caliper cylinder “2”
TIP Scratches/wear  Replace the brake caliper
Put the end of the brake hose into a container
assembly.
and pump out the brake fluid.
• Brake caliper body “3”
EAM30043
Cracks/damage  Replace the brake caliper
DISASSEMBLING THE REAR BRAKE assembly.
CALIPER • Brake fluid delivery passages
1. Remove: (brake caliper body)
• Brake caliper piston “1” Obstruction  Blow out with compressed air.
• Brake caliper piston dust seal “2”
• Brake caliper piston seal “3” 2
1
1
2 3 3
EWA19270
WARNING
When the brake caliper is disassembled, re-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose joint
brake caliper piston dust seal with new ones.
opening to force out the piston from the brake
caliper. 2. Check:
EWA13550
• Brake caliper bracket
WARNING Crack/damage  Replace.
• Cover the brake caliper piston with a rag.
EAM30045
Be careful not to get injured when the pis- ASSEMBLING THE REAR BRAKE CALIPER
ton is expelled from the brake caliper. EWA19280
• Never try to pry out the brake caliper pis- WARNING

ton. • Before installation, clean and lubricate the
internal parts. Use new brake fluid for
cleaning and lubricating.
ponents as they will cause the piston seals
to swell and distort.
• When the brake caliper is disassembled, re-
brake caliper piston dust seal with new
ones.
b. Remove the brake caliper piston dust seal
4-28
REAR BRAKE

BF
DOT 4 1
EAM30046
INSTALLING THE BRAKE CALIPER PISTON

1. Clean:
• Brake caliper
• Brake caliper piston seal a 1
• Brake caliper piston dust seal
• Brake caliper piston
Use brake fluid for cleaning. EAM30047
2. Install: INSTALLING THE REAR BRAKE CALIPER

• Brake caliper piston seal “1” New 1. Install:
• Brake caliper piston dust seal “2” New • Rear brake caliper
• Rear brake caliper bracket
EWA19290
WARNING
2. Install:
Always use new brake caliper piston seal • Rear wheel
and brake caliper piston dust seal. Refer to “REAR WHEEL” on page 4-9.
TIP • Copper washer New
• Apply the silicone grease on the brake caliper • Brake hose
piston seal and brake caliper piston dust seal. • Union bolt
• Fit the brake caliper piston seals and brake cal-
iper piston dust seals onto the slot on brake 30 N·m (3.0 kgf·m, 22 lb·ft)
caliper correctly.
T.
R.
EWA13531
WARNING
S Proper brake hose routing is essential to in-
sure safe vehicle operation.
2
ECA24490
NOTICE
1 Make sure that a bend in its pipe portion “a”
S is directed as shown and the brake hose
touches the projection “b” on the brake cali-
per.
3. Install:
• Brake caliper piston “1” b
TIP
Apply the brake fluid on the piston outer surface.
ECA24480
NOTICE
• Install the piston with its side “a” facing the
brake caliper.
• Never force to insert. b a
3. Install:
• Brake pad spring
• Brake pad
• Brake pad pin
• Brake pad pin plug
4-29
REAR BRAKE
7. Check:
Brake pad pin • Brake pedal operation
17 N·m (1.7 kgf·m, 13 lb·ft)
T.
Brake pad pin plug

R.
2.5 N·m (0.25 kgf·m, 1.8 lb·ft) system.

Refer to “CHECKING THE REAR BRAKE on page 3-21.
PADS” on page 3-25. EAM30048
4. Pour brake fluid to the brake fluid reservoir up REMOVING THE REAR BRAKE MASTER
to the specified level. CYLINDER
TIP
Before removing the rear brake master cylinder,
DOT 4
drain the brake fluid from the entire brake sys-
EWA13090 tem.
WARNING
1. Remove:
• Use only the designated brake fluid. Other • Union bolt
brake fluids may cause the rubber seals to • Copper washer
deteriorate, causing leakage and poor • Brake hose
brake performance. TIP
• Refill with the same type of brake fluid that To drain any remaining brake fluid, place a con-
is already in the system. Mixing brake fluids tainer under the master cylinder and the end of
may result in a harmful chemical reaction, the brake hose.
• When refilling, be careful that water does EAM30049
not enter the brake fluid reservoir. Water CHECKING THE REAR BRAKE MASTER
will significantly lower the boiling point of CYLINDER
the brake fluid and could cause vapor lock. 1. Check:
ECA13540 • Brake master cylinder “1”
NOTICE Damage/scratches/wear  Replace.
Brake fluid may damage painted surfaces • Brake fluid delivery passages “2”
and plastic parts. Therefore, always clean up (brake master cylinder body)
any spilt brake fluid immediately. Obstruction  Blow out with compressed air.
5. Bleed:
• Brake system
on page 3-21.
6. Check:
The minimum level mark “a” or below  Add. 1 2
2. Check:
• Brake master cylinder kit
Damage/wear  Replace.
3. Check:
• Master cylinder reservoir cap
a Crack/damage  Replace.
• Brake master cylinder reservoir diaphragm
a holder
• Brake master cylinder reservoir diaphragm
4-30
REAR BRAKE
4. Check: TIP
• Brake hose Install the spring with a smaller inside diameter
Cracks/damage/wear  Replace. to the brake master cylinder piston.
EAM30050
ASSEMBLING THE REAR BRAKE MASTER

CYLINDER
EWA13520
WARNING
• Before installation, all internal brake com- 2
1
ponents should be cleaned and lubricated
with clean or new brake fluid.
ponents.
Specified brake fluid 4. Install:

DOT 4 • Master cylinder kit “1” New
• Push rod “2”
1. Wash the brake master cylinder and the • Circlip “3” New
brake master cylinder kit with brake fluid. • Dust boot “4”
2. Install: TIP
• Primary cylinder cup “1” • Before installation, apply brake fluid to the
• Secondary cylinder cup “2” brake master cylinder kit.
Install to the brake master cylinder piston “3”. • Before installation, apply silicone grease to the
EWA19300
push rod end.
WARNING
• Use circlip pliers to install the circlip.
Apply brake fluid to the cylinder cups and in-
stall them as shown. Wrong orientation in in-
stallation causes poor braking performance.
1 New 3 New
2 4
1
2
3 EAM30051
INSTALLING THE REAR BRAKE MASTER

CYLINDER
1. Install:
2 • Copper washer New
• Brake hose
• Union bolt
1
30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.
3
EWA13531
WARNING
Proper brake hose routing is essential to in-
3. Install: sure safe vehicle operation.
• Spring “1” ECA24500
Install to the brake master cylinder piston “2”. NOTICE

Make sure that the pipe portion of the brake
4-31
REAR BRAKE
hose touches the projection “a” on the brake

caliper.
a
a
5. Check:
• Brake pedal operation
2. Pour brake fluid to the brake fluid reservoir up A softy or spongy feeling  Bleed the brake
to the specified level. system.
Specified brake fluid on page 3-21.
DOT 4
EWA13090
WARNING
• Use only the designated brake fluid. Other
brake performance.
ECA24510
NOTICE
Brake fluid may damage painted surfaces
any spilt brake fluid immediately.
3. Bleed:
• Brake system
on page 3-21.
4. Check:
4-32
HANDLEBAR
EAM20099
HANDLEBAR
Removing the handlebar
3.8 N・m (0.38 kgf・m, 2.8 lb・ft)
9
6
10 0.5 N・m (0.05 kgf・m, 0.37 lb・ft)

8
7 9 N・m (0.9 kgf・m, 6.6 lb・ft)
11 28 N・m (2.8 kgf・m, 21 lb・ft)

1.3 N・m (0.13 kgf・m, 0.95 lb・ft)
5 N・m (0.5 kgf・m, 3.7 lb・ft)
0.5 N・m (0.05 kgf・m, 0.37 lb・ft)
13 4 3
5
14
12
15
16 2
1
16
40 N・m (4.0 kgf・m, 30 lb・ft)
4.0 N・m (0.40 kgf・m, 3.0 lb・ft)

Refer to “GENERAL CHASSIS” on page
Number plate 4-1.
1 Clutch cable 1 Disconnect.
2 Clutch lever holder 1
3 Engine stop switch 1
4 Mode switch 1
5 Brake master cylinder 1
6 Throttle cable cap 1
7 Throttle cable (pull) 1 Disconnect.
8 Throttle cable (return) 1 Disconnect.
9 Right grip 1
10 Tube guide 1
11 Start switch 1
12 Left grip 1
13 Upper handlebar holder 2
14 Handlebar 1
15 Lower handlebar holder 2
16 Damper 4
4-33
HANDLEBAR
EAM30052 EAM30054
REMOVING THE HANDLEBAR INSTALLING THE HANDLEBAR

1. Stand the vehicle upright on a level surface. 1. Stand the vehicle upright on a level surface.
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: 2. Install:
• Grip “1” • Damper “1”
TIP • Lower handlebar holder “2” (temporarily)
Blow in compressed air between the handlebar • Handlebar “3”
or tube guide and the grip. Then remove the grip • Upper handlebar holder “4”
which has become loose.
Upper handlebar holder bolt
28 N·m (2.8 kgf·m, 21 lb·ft)
T.
R.
TIP
• Install the lower handlebar holders with them
side having the greater distance “a” from the
mounting bolt center facing forward.
• Installing the lower handlebar holders in the re-
verse direction allow the front-to-rear offset
amount of the handlebar position to be
changed.
• The upper handlebar holders should be in-
3. Remove: stalled with the punch marks “b” facing for-
• Throttle cable housings “1” ward.
• Throttle grip “2” • When installing the handlebar, make sure that
TIP right and left marks “c” are in place identically
While removing the throttle cable housing, pull on both sides.
back the rubber cover “3”. • 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
• First, tighten the bolts on the front side of
the handlebar holder, and then on the rear
side.
• Turn the handlebar all the way to the left
and right. If there is any contact with the
fuel tank, adjust the handlebar position.
EAM30053
CHECKING THE HANDLEBAR 2

1. Check:
• Handlebar
Bends/cracks/damage  Replace. 1
EWA13690
WARNING
Do not attempt to straighten a bent handle- 1
bar as this may dangerously weaken it.
4-34
HANDLEBAR
3. Tighten:
a • Lower handlebar holder nut
Lower handlebar holder nut
40 N·m (4.0 kgf·m, 30 lb·ft)
T.
R.
4. Install:
• Handlebar grip “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slightly coat the handlebar left end with a rub-
ber adhesive.
b. Install the handlebar grip on the handlebar by
4 4 pressing the grip from the left side.
3
c. Wipe off any excess adhesive with a clean
cloth.
EWA13120
WARNING
TIP
Install the handlebar grip to the handlebar so
that the line “a” between the two arrow marks
faces straight upward.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• Engine stop switch “1”
• Clutch lever “2”
• Clutch lever holder “3”
• Mode switch “4”
• Clamp “5”
Engine stop switch screw
0.5 N·m (0.05 kgf·m, 0.37 lb·ft)
T.
Clutch lever holder bolt

R.
5 N·m (0.5 kgf·m, 3.7 lb·ft)

Screw (mode switch)
1.3 N·m (0.13 kgf·m, 0.95 lb·ft)
TIP
• The engine stop switch, the clutch lever, the
clutch lever holder and the mode switch should
be installed according to the dimensions
shown.
4-35
HANDLEBAR
• Pass the engine stop switch lead through the

middle of the clutch lever holder.
1
2 30 50˚ 2
0 mm
(0 in)
FWD
1 3
0 mm 0 mm 8. Install:
(0 in) (0 in) 4 5
• Throttle cables “1”
6. Install: TIP
Slightly coat the end of throttle cable and inside
• Right grip “1”
of throttle grip with lithium-soap-based grease.
• Collar “2”
Then, mount the throttle grip onto the handlebar.
Apply adhesive to the tube guide “3”.
TIP
• Before applying the adhesive, wipe off grease
or oil on the tube guide surface “a” with a lac-
quer thinner.
• Install the grip to the tube guide so that the grip
match mark “b” and tube guide slot “c” form the
angle as shown.
9. Install:
• Throttle cable housing “1”
• Screw (throttle cable housings) “2”
Screw (throttle cable housings)
3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
T.
R.
EWA19310
WARNING
64 After tightening the throttle cable housing
b screws, check that the throttle grip “3”
moves smoothly. If it does not, retighten the
1 screws for adjustment.
7. Install:
• Start switch
• Rubber cover “1”
• Throttle grip “2”
TIP
Apply the lithium-soap-based grease on the
throttle grip sliding surface.
4-36
HANDLEBAR
10.Install: 12.Install:
• Rubber cover “1” • Clutch cable “1”
• Cover (throttle cable housings) “2” TIP
Before installation, apply the lithium-soap-based
grease to the clutch cable end.
11.Install:
• Start switch “1”
• Front brake master cylinder assembly “2”
13.Adjust:
• Front brake master cylinder holder “3”
• Clutch lever free play
• Bolt (brake master cylinder holder) “4”
Refer to “ADJUSTING THE CLUTCH LEVER
• Clamp “5”
FREE PLAY” on page 3-8.
Front brake master cylinder hold-
Clutch lever free play
er bolt
7.0–12.0 mm (0.28–0.47 in)
T.
9 N·m (0.9 kgf·m, 6.6 lb·ft)

R.
14.Adjust:
TIP • Throttle grip free play
• Install the brake master cylinder holder with the Refer to “ADJUSTING THE THROTTLE
“UP” mark facing up. GRIP FREE PLAY” on page 3-9.
• Install in order for the top of the front brake
master cylinder assembly to be level. Throttle grip free play
• First, tighten the upper bolt, then the lower bolt. 3.0–6.0 mm (0.12–0.24 in)
3
4
1
2
5 4
4-37
FRONT FORK
EAM20100
FRONT FORK
Removing the front fork legs
(2)
2
21 N・m (2.1 kgf・m, 15 lb・ft)

(2)
4
(3)
9 N・m (0.9 kgf・m, 6.6 lb・ft)
5 N・m (0.5 kgf・m, 3.7 lb・ft)

5 N・m (0.5 kgf・m, 3.7 lb・ft)
(3)

Front wheel Refer to “FRONT WHEEL” on page 4-5.
Front brake caliper Refer to “FRONT BRAKE” on page 4-13.
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
4-38
FRONT FORK
Disassembling the front fork leg

30 N・m (3.0 kgf・m, 22 lb・ft)
29 N・m (2.9 kgf・m, 21 lb・ft)
New
7 13
New New
6
2
New 12
8
9
11 New
10
LT
4 New
1 New
28 N・m (2.8 kgf・m, 21 lb・ft)
LS
55 N・m (5.5 kgf・m, 41 lb・ft) 3 1.3 N・m (0.13 kgf・m, 0.95 lb・ft)

1 Adjuster 1
2 Fork spring 1
3 Dust seal 1
4 Stopper ring 1
5 Inner tube 1
6 Outer tube 1
7 Piston metal 1
8 Protector guide 1
9 Slide metal 1
10 Washer 1
11 Oil seal 1
12 Base valve 1
13 Damper assembly 1
4-39
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
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.
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 • Oil seal clip “2”
90890-01501 (with a flat-head screwdriver)
Cap bolt ring wrench ECA14180
YM-01501 NOTICE
Do not scratch the inner tube.
1 2
1
3. Remove: 4. Remove:
• Front fork leg • Inner tube “1”
EAM30056 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
DISASSEMBLING THE FRONT FORK LEGS a. Push in slowly “a” the inner tube just before it
1. Drain: bottoms out and then pull it back 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”.
4-40
FRONT FORK
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:
• Base valve “1”
(from the damper assembly)
TIP
Hold the damper assembly with the cap bolt ring
wrench “2” and use the cap bolt wrench “3” to re-
move the base valve.
2. Check:
• Outer tube
Cap bolt wrench Scratches/wear/damage  Replace.
90890-01500 3. Measure:
Cap bolt wrench
• Fork spring free length “a”
YM-01500
Cap bolt ring wrench Out of specification  Replace.
90890-01501 Fork spring free length
Cap bolt ring wrench 497.0 mm (19.57 in)
YM-01501 Limit
492.0 mm (19.37 in)
3
2
1
EAM30057
CHECKING THE FRONT FORK LEGS

4. Check:
1. Check:
• Damper assembly “1”
• Inner tube surface “a”
Bend/damage  Replace.
Scratches  Repair or replace.
• O-ring “2”
Use #1000 grit wet sandpaper.
Wear/damage  Replace.
Damaged oil lock piece  Replace. ECA14200
• Inner tube bends NOTICE

Out of specification  Replace. • The front fork leg has a built-in damper ad-
Use the dial gauge “1”. justing rod and a very sophisticated inter-
Inner tube bending limit nal construction, which are particularly
0.2 mm (0.01 in) sensitive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
4-41
FRONT FORK
terial to enter the front fork.
1 2 New
EAM30058
ASSEMBLING THE FRONT FORK LEGS

5. Check: EWA13660
• Base valve “1” WARNING

Wear/damage  Replace. • Make sure the oil levels in both front fork
Contamination  Clean. legs are equal.
• O-ring “2” New • Uneven oil levels can result in poor han-
Wear/damage  Replace. dling and a loss of stability.
• Base valve bushing
Wear/damage  Replace. TIP
• Spring “3” • When assembling the front fork leg, be sure to
Damage/fatigue  Replace the base valve. replace the following parts:
• Air bleed screw “4” • Inner tube bushing
Wear/damage  Replace. • Outer tube bushing
• Oil seal
• Copper washer
• Before assembling the front fork leg, make
sure that all of the components are clean.
1. Stretch the damper assembly fully.
New 2 2. Fill:
3 • Damper assembly
4 Recommended oil
New 2 1 Yamaha Suspension Oil S1
Standard oil amount
6. Check: 216 cm³ (7.30 US oz, 7.62 Imp.oz)
• Contacting surface “a”
Wear/damage  Replace. ECA24530
NOTICE
• Be sure to use the recommended oil. Other
oils may have an adverse effect on front
a fork performance.
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” TIP
• O-ring “2” New 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).
4-42
FRONT FORK
4. Measure: 6. Loosen:
• Oil level (left and right) “a” • Compression damping force adjuster “1”
Out of specification  Regulate. TIP
• Before loosening the damping force adjuster,
Standard oil level record the setting position.
145–148 mm (5.71–5.83 in)
• Unless the damping force adjuster is fully loos-
From top of fully stretched
damper assembly. ened, correct damping characteristic cannot be
obtained after installation.
7. Install:
(to the damper assembly “2”)
TIP
First bring the damper rod pressure to a maxi-
mum. Then install the base valve while releasing
the damper rod pressure.
1
5. Tighten:
• Locknut “1”
TIP
Fully finger tighten the locknut onto the damper 2
assembly.
8. Check:
• Damper assembly
Not fully stretched  Repeat the steps (1) to
(7).
9. Tighten:
4-43
FRONT FORK
Base valve
T.
R.
28 N·m (2.8 kgf·m, 21 lb·ft)
TIP
Hold the damper assembly with the cap bolt ring
wrench “2” and use the cap bolt wrench “3” to 1
tighten the base valve.
Cap bolt wrench

90890-01500
Cap bolt wrench 12.Allow the overflowing oil to escape at the hole
YM-01500 “a” in the damper assembly.
Cap bolt ring wrench TIP
90890-01501 The overflow measures about 10 cm³ (0.34 US
oz, 0.35 Imp.oz).
YM-01501
a
3
2
1
13.Check:
10.After filling, pump the damper assembly “1” • Damper assembly smooth movement
slowly up and down more than 10 times to Tightness/binding/rough spots  Repeat the
distribute the fork oil. steps (1) to (12).
11.While protecting the damper assembly “1” 14.Install:

with a cloth and compressing fully, allow ex- • Dust seal “1” New
cessive oil to overflow on the base valve side. • Oil seal clip “2”
ECA24540
NOTICE
• Washer “4”
Take care not to damage the damper assem- • Outer tube bushing “5” New
bly. (to the inner tube “6”)
ECA24550
NOTICE
Make sure that the numbered side of the oil
seal faces bottom side.
4-44
FRONT FORK
TIP
• 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.
17.Install:
• Slide metal “1”
• Washer “2”
(to the outer tube)
LS TIP
Press the slide metal into the outer tube with fork
seal driver “3”.
Fork seal driver

90890-01502
YM-A0948
15.Install:
• Piston metal “1” New
TIP
Install the piston metal onto the slot on inner
tube.
16.Install:
• Outer tube “1” 18.Install:
(to the inner tube “2”) • Oil seal “1” New
TIP
Using a fork seal driver “2”, press the oil seal in
until the stopper ring groove fully appears.
4-45
FRONT FORK
Fork seal driver

90890-01502
YM-A0948
22.Measure:
• Distance “a”
Out of specification  Turn into the locknut.
Distance “a”
16 mm (0.63 in) or more
19.Install: Between the damper assembly
• Stopper ring “1” “1” bottom and locknut “2” bot-
TIP tom.
Fit the stopper ring correctly in the groove in the
outer tube.
2
1 a
23.Install:
• Collar “1”
20.Install:
• Fork spring “2”
• Dust seal “1” New
(to the damper assembly “3”)
TIP
TIP
Apply lithium-soap-based grease on the inner Install the collar with its larger dia. end “a” facing
tube.
the fork spring.
1 2
3 a
21.Check:
24.Install:
• Inner tube smooth movement • Damper assembly “1”
Tightness/binding/rough spots  Repeat the
(to the inner tube “2”)
steps (14) to (20).
4-46
FRONT FORK
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.
1
27.Measure:
• Gap “a” between the adjuster “1” and the
locknut “2”
Out of specification  Retighten and readjust
the locknut.
2
Gap “a” between the adjuster and
25.Loosen: the locknut
• Rebound damping force adjuster “1” 0.5–1.0 mm (0.02–0.04 in)
TIP
• Before loosening the damping force adjuster, TIP
record the setting position. If it is installed with a gap out of specification,
• 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
28.Tighten:
• Adjuster (locknut) “1”
26.Install:
• Damper adjusting rod “1” Adjuster (locknut)
• Copper washer “2” New 29 N·m (2.9 kgf·m, 21 lb·ft)
T.
R.
(to the damper assembly “4”) TIP
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.

90890-01501
YM-01501
4-47
FRONT FORK
29.Install:
(to the inner tube)
Adjuster
55 N·m (5.5 kgf·m, 41 lb·ft)
T.
LOCTITE®
R.
LT 1 32.Install:
• Protector guide “1”
1
30.Fill:
• Front fork leg
Recommended oil
Yamaha Suspension Oil S1
Standard oil amount
290 cm³ (9.80 US oz, 10.23 EAM30059
INSTALLING THE FRONT FORK LEGS

Imp.oz)
Extent of adjustment 1. Install:
260–365 cm³ (8.79–12.34 US oz, • Front fork “1”
9.17–12.87 Imp.oz) TIP
• Temporarily tighten the pinch bolts (lower
ECA24570
bracket).
NOTICE • Do not tighten the pinch bolts (upper bracket)
• Be sure to use the recommended oil. Other yet.
oils may have an adverse effect on front
fork performance.
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
2. Tighten:
• Damper assembly “1”
Damper assembly
30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.
31.Install:
• Damper assembly “1” TIP
(to the outer tube) Use the cap bolt ring wrench “2” to tighten the
damper assembly.
TIP
Temporarily tighten the damper assembly.
4-48
FRONT FORK
Cap bolt ring wrench 1

90890-01501
YM-01501
2
5. Install:
2 • Protector “1”
• Bolt (protector) “2”
Bolt (protector)
5 N·m (0.5 kgf·m, 3.7 lb·ft)
3. Adjust:
T.
R.
• Front fork top end “a”
Front fork top end (standard) “a” 1
5 mm (0.02 in)
2
6. Adjust:
• Rebound damping force
TIP
Turn in the damping adjuster “1” finger-tight and
4. Tighten: then turn out to the originally set position.
• Pinch bolt (upper bracket) “1”
Upper bracket pinch bolt
21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.
1
• Pinch bolt (lower bracket) “2”
Lower bracket pinch bolt
21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.
EWA19320
WARNING
Tighten the lower bracket to specified 7. Adjust:
torque. If torqued too much, it may cause the • Compression damping force
front fork to malfunction. TIP
Turn in the damping adjuster “1” finger-tight and
then turn out to the originally set position.
4-49
FRONT FORK
4-50
STEERING HEAD
EAM20101
STEERING HEAD
Removing the lower bracket
21 N・m (2.1 kgf・m, 15 lb・ft)
145 N・m (14.5 kgf・m, 107 lb・ft)
5 2 LS
4
LS 6
8
7
9
(4)
10
(4)
11
LS
12
1
1st 38 N・m (3.8 kgf・m, 28 lb・ft)
2nd 7 N・m (0.7 kgf・m, 5.2 lb・ft)
21 N・m (2.1 kgf・m, 15 lb・ft)
9 N・m (0.9 kgf・m, 6.6 lb・ft)
(4) 10 N・m (1.0 kgf・m, 7.4 lb・ft)

Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-33.
Number plate 4-1.
Handlebar Refer to “HANDLEBAR” on page 4-33.
1 Front fender 1
2 Steering stem nut 1
3 Front fork leg 2 Refer to “FRONT FORK” on page 4-38.
4 Warning light (engine trouble) 1 Br–Y/W
5 Warning light (fuel level) 1 Br–L/Y
6 Upper bracket 1
7 Steering ring nut 1
8 Lower bracket 1
9 Bearing race cover 1
10 Upper bearing 1
11 Bearing race 2
12 Bearing (lower side) 1
4-51
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
YU-A9472
EWA13730
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Upper bracket
• Lower bracket
EAM30061 (along with the steering stem)
CHECKING THE STEERING HEAD Bends/cracks/damage  Replace.
1. Wash with kerosene: EAM30062
• Bearing INSTALLING THE STEERING HEAD
• Bearing race 1. Install:
2. Check: • Lower bearing “1”
• Bearing TIP
• Bearing race Apply the lithium-soap-based grease on the dust
Damage/pitting  Replace. seal lip and bearing inner circumference.
3. Replace:
• Bearing
• Bearing race
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bearing race from the steering
head pipe with a long rod “1” and a hammer.
b. Remove the bearing race from the lower
bracket with a chisel “2” and a hammer.
c. Install a new bearing race.
4-52
STEERING HEAD
2. Install:
• Bearing race
• Upper bearing “1”
• Bearing race cover “2”
TIP
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
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 pinch bolts (lower
“a” facing downward. bracket).
Tighten the steering ring nut with a steering • Do not tighten the pinch bolts (upper bracket)
nut wrench “2”. yet.
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-33.
4-53
STEERING HEAD
Upper bracket pinch bolt

21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.
• Pinch bolt (lower bracket) “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”
5 mm (0.02 in)
11.Tighten:
• Pinch bolt (upper bracket) “1”
4-54
REAR SHOCK ABSORBER ASSEMBLY
EAM20102

Removing the rear shock absorber assembly
M 56 N・m (5.6 kgf・m, 41 lb・ft)

2
3
12
13
12
10 N・m (1.0 kgf・m, 7.4 lb・ft)
7
9 6
4 10
11
5 10
9
M 1
53 N・m (5.3 kgf・m, 39 lb・ft)

Seat 4-1.
Side cover (left/right) 4-1.
Air scoop (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
6 Lower spring guide 1
7 Upper spring guide 1
8 Spring 1
9 Dust seal 2
10 Collar 2
11 Bushing 1
12 Collar 2
13 Bearing 1
4-55
Disassembling the relay arm
5 4
5
4 6
1 M
5
6
M
5
5 4
80 N・m (8.0 kgf・m, 59 lb・ft)
6 3
5
3
6 6
4
5
4 2
4 M
3
M M
6
M

1 Relay arm 1
2 Connecting arm 1
3 Collar 3
4 Oil seal 6
5 Washer 8
6 Bearing 6
4-56
EAM30063 EWA13120
HANDLING THE REAR SHOCK ABSORBER WARNING

EWA13740
WARNING
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 EAM30066
Yamaha dealer for this disposal procedure. REMOVING THE BEARING

1. Remove:
• Stopper ring (upper bearing) “1”
TIP
Press in the bearing while pressing its outer race
and remove the stopper ring.
EAM30065
REMOVING THE REAR SHOCK ABSORBER

ASSEMBLY
4-57
2. Remove: • Relay arm

• Upper bearing “1” Damage/wear  Replace.
TIP 2. Check:
Remove the bearing by pressing its outer race. • Bearing
• Spacer
Damage/pitting/scratches  Replace the
bearings and spacers as a set.
3. Check:
• Oil seal
Damage/pitting  Replace.
EAM30069
INSTALLING THE RELAY ARM

1. Lubricate:
• Oil seal
• Bearing
3. Remove: • Spacer
• Lower bearing “1” • Washer
TIP • Collar
Remove the bearing by pressing its outer race.
Molybdenum disulfide grease
2. Install:
• Bearing “1”
• Washer “2”
(to relay arm “4”)
1 Installed depth “a”

0 mm (0 in)
EAM30067
CHECKING THE REAR SHOCK ABSORBER a

3 3
ASSEMBLY 2 4
1. Check:
• Rear shock absorber rod 2
1
Bends/damage  Replace the rear shock 1 1
absorber assembly. 2
• Rear shock absorber 2
Gas leaks/oil leaks  Replace the rear shock 3
absorber assembly.
• Spring
Damage/wear  Replace. 3. Install:
• Spring guide • Bearing “1”
Damage/wear  Replace. • Oil seal “2” New
• Bearing (to connecting arm “3”)
Damage/wear  Replace. Installed depth “a”
• Bolt 0 mm (0 in)
Bends/damage/wear  Replace.
EAM30068
CHECKING THE CONNECTING ARM AND

RELAY ARM
1. Check:
• Connecting arm
4-58
Installed depth “a”

2 3 4.25 mm (0.17 in)
1
a
a
1
2
EAM30070
INSTALLING THE REAR SHOCK

ABSORBER ASSEMBLY
1. Lubricate:
5. Lubricate:
• Bearing (lower side)
• Connecting arm and frame bolt
• Dust seal
• Relay arm and connecting arm bolt
• Collar
• Relay arm and swingarm bolt
• Bushing
(circumference and threaded portion)
Recommended lubricant • Rear shock absorber assembly upper bolt
Molybdenum disulfide grease • Rear shock absorber assembly lower bolt
ECA24580 Recommended lubricant
NOTICE Molybdenum disulfide grease
Do not apply the grease to the bearing outer
race because it will wear the rear shock ab- 6. Install:
sorber surface on which the bearing is press • Rear shock absorber assembly
fitted. TIP
• When installing the rear shock absorber as-
2. Lubricate: sembly, lift up the swingarm.
• O-ring • Install the rear shock absorber assembly upper
Recommended lubricant bolt, and connecting arm bolt (frame side) from
Molybdenum disulfide grease the right.
• Install the rear shock absorber assembly lower
3. Install: bolts, connecting arm bolt (relay arm side), and
• Bearing relay arm bolt (swingarm side) from the left.
• Stopper ring New 7. Tighten:
(to rear shock absorber assembly (upper • Rear shock absorber assembly upper bolt
side))
TIP Rear shock absorber assembly
• Install the bearing parallel until the stopper ring upper bolt
T.
56 N·m (5.6 kgf·m, 41 lb·ft)

R.
groove appears by pressing its outer race.

• After installing the stopper ring, push back the
bearing unit it contacts the stopper ring. • Connecting arm bolt (frame side)
4. Install: Connecting arm bolt (frame side)
• Bearing “1” 80 N·m (8.0 kgf·m, 59 lb·ft)
T.
R.
• Bushing “2”
• Collar “3” • Connecting arm bolt (relay arm side)
• Dust seal “4” Connecting arm bolt (relay arm
(to rear shock absorber assembly (lower side)
side))
T.
80 N·m (8.0 kgf·m, 59 lb·ft)

R.
TIP
Install the dust seals with their lips facing inward. • Relay arm bolt (swingarm side)
4-59
Relay arm bolt (swingarm side)

T.
R.
70 N·m (7.0 kgf·m, 52 lb·ft)
• Rear shock absorber assembly lower bolt

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

R.
4-60
SWINGARM
EAM20103
SWINGARM
Removing the swingarm
70 N・m (7.0 kgf・m, 52 lb・ft)
2
1 3
6
4.0 N・m (0.40 kgf・m, 3.0 lb・ft)
6 6
4 3
1
2
4
5

Brake hose holder Refer to “REAR BRAKE” on page 4-23.
Rear brake caliper Refer to “REAR BRAKE” on page 4-23.
Bolt (brake pedal)
Drive chain
1 Collar 2
2 Oil seal 2
3 Thrust bearing 2
4 Bushing 2
5 Oil seal 2
6 Bearing 4
4-61
SWINGARM
EAM30071
REMOVING THE SWINGARM

EWA13120
WARNING
2. Measure:
• Swingarm side play
• Swingarm vertical movement
EAM30073
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING THE SWINGARM
a. Measure the tightening torque of the pivot 1. Check:
shaft nut. • Swingarm
Pivot shaft nut Bends/cracks/damage  Replace.
85 N·m (8.5 kgf·m, 63 lb·ft) 2. Check:
T.
• Pivot shaft
R.
b. Measure the swingarm side play “a” by mov- Roll the pivot shaft on a flat surface.
ing the swingarm from side to side. Bends  Replace.
c. If the swingarm side play is out of specifica- EWA13770
tion, check the spacers, the bearings, and the WARNING

collars. Do not attempt to straighten a bent pivot
d. Check the swingarm vertical movement “b” shaft.
by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers, the
bearings, and the collars.
Swingarm end free play limit (ra-
dial)
1.0 mm (0.04 in)
3. Wash with kerosene:

• Pivot shaft
• Spacer
• Collar
• Bearing
4. Check:
• Oil seal
Damage  Replace.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Bearing
• Spacer
EAM30072 Free play exists/unsmooth revolution/rust 
REMOVING THE BEARING Replace bearing and bushing as a set.
1. Remove:
• Bearing “1” EAM30074
INSTALLING THE SWINGARM

TIP
1. Lubricate:
Remove the bearing by pressing its outer race.
• Bearing
• Collar
• Spacer
• Oil seal New
4-62
SWINGARM
• Pivot shaft
Molybdenum disulfide grease
2. Install:
• Bearing “1”
(to the swingarm)
Installed depth “a”
0–0.5 mm (0–0.02 in)
Installed depth “b”
6.5 mm (0.26 in)
TIP
First install the outer and then the inner bearings
to a specified depth from inside.
a a a a
2 New 2 New 2 New
1 1
b b
3. Install:
• Swingarm
Pivot shaft nut
85 N·m (8.5 kgf·m, 63 lb·ft)
T.
R.
TIP
Install the pivot shaft from the right.
4. Install:
• Rear wheel
5. Adjust:
Drive chain slack (Maintenance
stand)
50.0–60.0 mm (1.97–2.36 in)
4-63
CHAIN DRIVE
EAM20104
CHAIN DRIVE
Removing the drive chain
6
5
3 4
75 N・m (7.5 kgf・m, 55 lb・ft)
7 N・m (0.7 kgf・m, 5.2 lb・ft)

Drive sprocket Refer to “ENGINE REMOVAL” on page 5-1.
1 Drive chain 1
2 Drive sprocket cover 1
3 Bracket 1
4 Drive sprocket nut 1
5 Lock washer 1
6 Drive sprocket 1
4-64
CHAIN DRIVE
EAM30075
REMOVING THE DRIVE CHAIN

1. Stand the vehicle on a level surface.
EWA13120
WARNING
TIP
Place the vehicle on a maintenance stand so
that the rear wheel is elevated.
2. Remove: TIP
• Drive chain • When measuring a 15-link section of the drive
TIP chain, make sure that the drive chain is taut.
Cut the drive chain with the drive chain cut & riv- • Perform this procedure 2–3 times, at a different
et tool. (Use goods on the market.) location each time.
EAM30076
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE DRIVE CHAIN 2. Check:
1. Measure: • Drive chain
• 15-link section of the drive chain Stiffness  Clean, lubricate, or replace.
Out of specification  Replace the drive
chain.
15-link length limit
239.3 mm (9.42 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the length “a” between the inner
sides of the pins and the length “b” between
the outer sides of the pins on a 15-link section
of the drive chain as shown in the illustration.
3. Clean:
• Drive chain
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
ECA19090
NOTICE
b. Calculate the length “c” of the 15-link section • This vehicle has a drive chain with small
of the drive chain using the following formula. rubber O-rings “1” between the drive chain
Drive chain 15-link section length “c” = side plates. Never use high-pressure water
(length “a” between pin inner sides + length or air, steam, gasoline, certain solvents
“b” between pin outer sides)/2 (e.g., benzine), or a coarse brush to clean
the drive chain. High-pressure methods
could force dirt or water into the drive
chain’s internals, and solvents will deterio-
rate the O-rings. A coarse brush can also
damage the O-rings. Therefore, use only
kerosene to clean the drive chain.
• Do not soak the drive chain in kerosene for
4-65
CHAIN DRIVE
more than ten minutes, otherwise the O- drive sprocket and the rear wheel sprocket as
rings can be damaged. a set.
Bent tooth  Replace the drive sprocket and
the rear wheel sprocket as a set.
b. Correct
1. Drive chain roller

2. Drive sprocket
EAM30078
CHECKING THE REAR WHEEL SPROCKET

Refer to “CHECKING AND REPLACING THE
REAR WHEEL SPROCKET” on page 4-10.
EAM30079
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
INSTALLING THE DRIVE CHAIN
• O-rings “1” • Drive chain
Damage  Replace the drive chain. ECA17410
• Drive chain rollers “2” NOTICE

Damage/wear  Replace the drive chain. Be sure to put on safety goggles when work-
• Drive chain side plates “3” ing.
Damage/wear  Replace the drive chain.
TIP
Install the drive chain joint with the drive chain
cut & rivet tool. (Use goods on the market)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. When press fitting the connecting plate “1”,
make sure the space “a” between the end of
the connecting pin “2” and the connecting
plate is 1.2–1.4 mm (0.05–0.06 in).
5. Lubricate:
• Drive chain
ring chains
EAM30077
CHECKING THE DRIVE SPROCKET

1. Check: b. After riveting, make sure the diameter be-
• Drive sprocket tween the edges “b” of the connecting pin “2”
More than 1/4 tooth wear “a”  Replace the is 5.5–5.8 mm (0.22–0.23 in).
4-66
CHAIN DRIVE
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
c. After riveting, make sure the space “c”, which the drive chain slack within the specified lim-
is inside of the connecting link “3” and inside its.
of the connecting plate “1”, is 12.1–12.3 mm
(0.476–0.484 in).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Lubricate:
• Drive chain
ring chains
3. Install:
• Drive sprocket
• Lock washer New
• Drive sprocket nut
Drive sprocket nut
75 N·m (7.5 kgf·m, 55 lb·ft)
T.
R.
ECA14300
NOTICE
Never install a new drive chain onto worn
drive chain sprockets; this will dramatically
shorten the drive chain’s life.
4. Adjust:
4-67
CHAIN DRIVE
4-68
ENGINE
ENGINE REMOVAL ..........................................................................................5-1

REMOVING THE SILENCER .....................................................................5-5
REMOVING THE EXHAUST PIPE 2 ..........................................................5-5
REMOVING THE DRIVE SPROCKET .......................................................5-5
REMOVING THE ENGINE .........................................................................5-5
1
CHECKING THE SILENCER AND EXHAUST PIPE ..................................5-6
CHANGING THE SILENCER FIBER..........................................................5-6
INSTALLING THE ENGINE ........................................................................5-8
INSTALLING THE BRAKE PEDAL.............................................................5-8
INSTALLING THE DRIVE SPROCKET ......................................................5-8
2
INSTALLING THE EXHAUST PIPE AND MUFFLER .................................5-9
CAMSHAFT ....................................................................................................5-11
REMOVING THE CAMSHAFT .................................................................5-13
3
CHECKING THE CAMSHAFT ..................................................................5-14
CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET...........5-15
CHECKING THE TIMING CHAIN TENSIONERS.....................................5-15
CHECKING THE DECOMPRESSION SYSTEM ......................................5-16
INSTALLING THE CAMSHAFTS .............................................................5-16
4
5
CYLINDER HEAD...........................................................................................5-19
REMOVING THE CYLINDER HEAD ........................................................5-21
CHECKING THE TIMING CHAIN GUIDE (INTAKE SIDE).......................5-21
CHECKING THE CYLINDER HEAD ........................................................5-21
INSTALLING THE CYLINDER HEAD ......................................................5-22
VALVES AND VALVE SPRINGS ....................................................................5-24

REMOVING THE VALVES .......................................................................5-25
6
CHECKING THE VALVES AND VALVE GUIDES....................................5-26
7
CHECKING THE VALVE SEATS .............................................................5-27
CHECKING THE VALVE SPRINGS .........................................................5-29
CHECKING THE VALVE LIFTERS ..........................................................5-29
INSTALLING THE VALVES......................................................................5-29
CYLINDER AND PISTON ...............................................................................5-31

REMOVING THE PISTON........................................................................5-32
CHECKING THE CYLINDER AND PISTON.............................................5-32
8
CHECKING THE PISTON RINGS ............................................................5-33
9
CHECKING THE PISTON PIN .................................................................5-34
INSTALLING THE PISTON AND CYLINDER ..........................................5-34
ELECTRIC STARTER.....................................................................................5-36
CHECKING THE STARTER MOTOR ......................................................5-38
ASSEMBLING THE STARTER MOTOR ..................................................5-39
10
CLUTCH..........................................................................................................5-40
REMOVING THE CLUTCH ......................................................................5-43
CHECKING THE FRICTION PLATES ......................................................5-43
CHECKING THE CLUTCH PLATES ........................................................5-43
CHECKING THE CLUTCH SPRINGS ......................................................5-43
CHECKING THE CLUTCH HOUSING .....................................................5-44
CHECKING THE CLUTCH BOSS ............................................................5-44
CHECKING THE PRESSURE PLATE .....................................................5-44
CHECKING THE PUSH LEVER SHAFT ..................................................5-44
CHECKING THE CLUTCH PUSH RODS.................................................5-44
CHECKING THE PRIMARY DRIVE GEAR ..............................................5-44
CHECKING THE PRIMARY DRIVEN GEAR............................................5-45
INSTALLING THE OIL SEAL....................................................................5-45
INSTALLING THE RIGHT CRANKCASE COVER ...................................5-45
INSTALLING THE CLUTCH .....................................................................5-45
SHIFT SHAFT .................................................................................................5-48

REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY .........5-49
REMOVING THE SEGMENT ...................................................................5-49
CHECKING THE SHIFT SHAFT ..............................................................5-49
CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY..........5-49
CHECKING THE STOPPER LEVER........................................................5-49
INSTALLING THE STOPPER LEVER......................................................5-49
INSTALLING THE SEGMENT ..................................................................5-50
INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY........5-50
INSTALLING THE SHIFT SHAFT ............................................................5-51
INSTALLING THE SHIFT PEDAL ............................................................5-51
OIL PUMP AND BALANCER GEAR..............................................................5-52

REMOVING THE BALANCER..................................................................5-54
CHECKING THE PRIMARY DRIVE GEAR, BALANCER DRIVE GEAR, 
AND BALANCER WEIGHT GEAR ..........................................................5-54
CHECKING THE BALANCER ..................................................................5-54
CHECKING THE OIL PUMP ....................................................................5-54
ASSEMBLING THE OIL PUMP ................................................................5-55
INSTALLING THE OIL PUMP AND BALANCER GEAR ..........................5-55
AC MAGNETO ................................................................................................5-57
REMOVING THE AC MAGNETO .............................................................5-58
CHECKING THE AC MAGNETO .............................................................5-58
CHECKING THE WOODRUFF KEY ........................................................5-58
INSTALLING THE AC MAGNETO ...........................................................5-58
STARTER CLUTCH ........................................................................................5-60

CHECKING THE STARTER CLUTCH .....................................................5-61
CRANKCASE .................................................................................................5-62
DISASSEMBLING THE CRANKCASE .....................................................5-64
REMOVING THE CRANKCASE BEARING .............................................5-64
CHECKING THE TIMING CHAIN, TIMING CHAIN GUIDE, OIL 
STRAINER...............................................................................................5-64
CHECKING THE CRANKCASE ...............................................................5-64
INSTALLING THE OIL SEAL....................................................................5-65
ASSEMBLING THE CRANKCASE ...........................................................5-65
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT ................................5-67

REMOVING THE BALANCER SHAFT .....................................................5-68
REMOVING THE CRANKSHAFT ASSEMBLY ........................................5-68
CHECKING THE CRANKSHAFT ASSEMBLY .........................................5-68
INSTALLING THE CRANKSHAFT ASSEMBLY .......................................5-69
TRANSMISSION.............................................................................................5-70
REMOVING THE TRANSMISSION..........................................................5-71
CHECKING THE SHIFT FORKS ..............................................................5-71
CHECKING THE SHIFT DRUM ASSEMBLY ...........................................5-71
CHECKING THE TRANSMISSION ..........................................................5-72
INSTALLING THE TRANSMISSION ........................................................5-72
ENGINE REMOVAL
EAM20105
ENGINE REMOVAL
Removing the exhaust pipe
1st 7 N・m (0.7 kgf・m, 5.2 lb・ft)

9
2nd 10 N・m (1.0 kgf・m, 7.4 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)
20 N・m (2.0 kgf・m, 15 lb・ft)
(8)
LT
5
8 7
LT
(6)
6 New
8 N・m (0.8 kgf・m, 5.9 lb・ft)
30 N・m (3.0 kgf・m, 22 lb・ft)

New 6
30 N・m (3.0 kgf・m, 22 lb・ft) 2
12 N・m (1.2 kgf・m, 8.9 lb・ft)

1 FW
3 D
New 6
4
12 N・m (1.2 kgf・m, 8.9 lb・ft)

Side cover (right) 4-1.
Refer to “REAR SHOCK ABSORBER
Rear shock absorber assembly lower bolt ASSEMBLY” on page 4-55.
Refer to “REAR SHOCK ABSORBER
Connecting arm bolt (frame side) ASSEMBLY” on page 4-55.
1 Silencer clamp 1 Loosen.
2 Silencer 1
3 Exhaust pipe 2 clamp 1 Loosen.
4 Exhaust pipe 2 1
5 Exhaust pipe 1 1
6 Gasket 3
7 Exhaust pipe 1 protector 1
8 Silencer body 1
9 Silencer cap 1
5-1
ENGINE REMOVAL
Removing the electronic parts
FW
D
LT 1
3 2
7 N・m (0.7 kgf・m, 5.2 lb・ft)
3.5 N・m (0.35 kgf・m, 2.6 lb・ft) LT

Seat 4-1.
Refer to “CLEANING THE AIR FILTER ELE-
Air filter case cover MENT” on page 3-10.
Intake air temperature sensor coupler Refer to “THROTTLE BODY” on page 7-5.
ECU Refer to “THROTTLE BODY” on page 7-5.
Ignition coil Refer to “THROTTLE BODY” on page 7-5.
1 Rectifier/regulator 1
2 AC magneto coupler 1 Disconnect.
3 Crankshaft position sensor coupler 1 Disconnect.
4 Coolant temperature sensor coupler 1
5 Gear position switch 1
5-2
ENGINE REMOVAL
Removing the engine
34 N・m (3.4 kgf・m, 25 lb・ft)
12
85 N・m (8.5 kgf・m, 63 lb・ft)
26 N・m (2.6 kgf・m, 19 lb・ft)
53 N・m (5.3 kgf・m, 39 lb・ft)

3
2
55 N・m (5.5 kgf・m, 41 lb・ft)
45 N・m (4.5 kgf・m, 33 lb・ft)
8
11
10 75 N・m (7.5 kgf・m, 55 lb・ft)
34 N・m (3.4 kgf・m, 25 lb・ft)

9
4
1 6 5
7
13
11
10
7 N・m (0.7 kgf・m, 5.2 lb・ft) 34 N・m (3.4 kgf・m, 25 lb・ft) 7 N・m (0.7 kgf・m, 5.2 lb・ft)

Seat 4-1.
Exhaust pipe and silencer Refer to “ENGINE REMOVAL” on page 5-1.
Air filter case Refer to “THROTTLE BODY” on page 7-5.
Throttle body Refer to “THROTTLE BODY” on page 7-5.
Clutch cable Refer to “CLUTCH” on page 5-40.
Refer to “SHIFT SHAFT” on page 5-48.
Shift pedal/Drive chain Refer to “CHAIN DRIVE” on page 4-64.
1 Engine guard 1
2 Brake pedal 1
3 Spring 1
4 Cylinder head breather hose 1
5 Drive sprocket cover 1
6 Drive chain guide 1
7 Drive sprocket 1
5-3
ENGINE REMOVAL
Removing the engine
34 N・m (3.4 kgf・m, 25 lb・ft)
12
85 N・m (8.5 kgf・m, 63 lb・ft)
26 N・m (2.6 kgf・m, 19 lb・ft)
53 N・m (5.3 kgf・m, 39 lb・ft)

3
2
55 N・m (5.5 kgf・m, 41 lb・ft)
45 N・m (4.5 kgf・m, 33 lb・ft)
8
11
10 75 N・m (7.5 kgf・m, 55 lb・ft)
34 N・m (3.4 kgf・m, 25 lb・ft)

9
4
1 6 5
7
13
11
10
7 N・m (0.7 kgf・m, 5.2 lb・ft) 34 N・m (3.4 kgf・m, 25 lb・ft) 7 N・m (0.7 kgf・m, 5.2 lb・ft)

8 Upper engine bracket (right) 1
9 Upper engine bracket (left) 1
10 Lower engine bracket (outside) 2
11 Lower engine bracket (inside) 2
12 Pivot shaft 1
13 Engine 1
5-4
ENGINE REMOVAL
EAM30158
REMOVING THE SILENCER

1. Remove:
• Rear shock absorber assembly lower bolt “1”
• Connecting arm bolt (frame side) “2”
• Silencer “3”
TIP
Move the rear shock absorber to the left side of
the chassis, and remove the silencer.
EAM30160
REMOVING THE DRIVE SPROCKET

1. Straighten the lock washer tab.
2. Remove:
• Nut (drive sprocket) “1”
• Lock washer “2”
TIP
Loosen the nut while applying the rear brake.
2
1
2
1
3. Remove:
• Drive sprocket “1”
3 • Drive chain “2”
TIP
Remove the drive sprocket together with the
drive chain.
EAM30159
REMOVING THE EXHAUST PIPE 2

1. Remove:
• Exhaust pipe 2
TIP
Put the exhaust pipe 2 into the state as shown by
moving this, and then remove it. EAM30161
REMOVING THE ENGINE

1. Remove:
• Pivot shaft “1”
TIP
If the pivot shaft is pulled all the way out, the
swingarm will come loose. If possible, insert a
5-5
ENGINE REMOVAL
shaft of similar diameter into the other side of the

swingarm to support it.
1
1
EAM30373
CHANGING THE SILENCER FIBER

1. Remove:
2. Remove: • Bolt “1”
• Engine “1” • Silencer body “2”
From the right side. ECA25800
TIP NOTICE
• Make sure that the couplers, the hoses, and Do not hit the silencer stay “a” as it may do
the cables are disconnected. damage to the silencer.
• Lift up the engine, and remove this from its low-
er part toward the right of the chassis. TIP
Remove the inner pipe while holding the silencer
in place with a vise etc.
1 a
EAM30163
CHECKING THE SILENCER AND EXHAUST

PIPE 2. Remove:
1. Check: • Rivet “1”
• Gasket “1” • Silencer cap “2”
Damage  Replace.
5-6
ENGINE REMOVAL
2
3. Replace: 1
• Fiber “1”
6. Install:
• Silencer cap “1”
1 • Rivet “2”
TIP
• Apply heat-resistant sealant to the areas “a”
1 shown, making sure that there are no gaps in
the beads of sealant.
• Take care not to allow the fiber out of place
when installing the silencer body “3”.
1
4. Install: 3 1 2 3
• Silencer body “1”
• Bolt “2” a
Silencer body bolt
8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
LOCTITE®
R.
TIP
Apply heat-resistant sealant to the areas “a”
shown, making sure that there are no gaps in the
beads of sealant.
a LT
5. Replace:
• Fiber “1”
TIP
Stuff the fiber into the silencer body by using a
flat board “2”.
5-7
ENGINE REMOVAL
EAM30164
INSTALLING THE ENGINE M

1. Install: 2 9
• Engine “1”
Install the engine from the right side.
• Pivot shaft “2”
Pivot shaft
85 N·m (8.5 kgf·m, 63 lb·ft)
T.
R.
• Engine mounting bolt (lower side) “3”

Engine mounting bolt (lower side) 8
53 N·m (5.3 kgf·m, 39 lb·ft) 3
T.
R.
• Lower engine bracket (inside) “4” 6

5 4
• Lower engine bracket (outside) “5” 8
• Engine bracket bolt (front side) “6” 10
Engine bracket bolt (front side) 1 7
34 N·m (3.4 kgf·m, 25 lb·ft) 4
T.
5 6
R.
• Engine mounting bolt (front side) “7”

EAM30165
Engine mounting bolt (front side) INSTALLING THE BRAKE PEDAL

55 N·m (5.5 kgf·m, 41 lb·ft) 1. Install:
T.
• Spring “1”
R.
• Upper engine bracket “8” • Brake pedal “2”

• Engine bracket bolt (upper side) “9” • O-ring “3” New
• Bolt (brake pedal) “4”
Engine bracket bolt (upper side)
34 N·m (3.4 kgf·m, 25 lb·ft) Bolt (brake pedal)
T.
26 N·m (2.6 kgf·m, 19 lb·ft)

R.
T.
• Engine mounting bolt (upper side) “10”

R.
• Clip “5”
Engine mounting bolt (upper
TIP
side)
Apply the lithium-soap-based grease on the bolt,
T.
45 N·m (4.5 kgf·m, 33 lb·ft)

R.
O-rings and brake pedal bracket.

TIP
2
Apply molybdenum disulfide grease to the pivot 1 5
shaft.
4 LS
EAM30166
INSTALLING THE DRIVE SPROCKET

1. Install:
• Drive sprocket “1”
• Drive chain “2”
TIP
Install the drive sprocket together with the drive
5-8
ENGINE REMOVAL
chain.
1
2
1 2
EAM30167
INSTALLING THE EXHAUST PIPE AND

2. Install: MUFFLER
• Lock washer “1” New 1. Install:
• Nut (drive sprocket) “2” • Gasket New
Nut (drive sprocket) • Exhaust pipe 1 “1”
75 N·m (7.5 kgf·m, 55 lb·ft) • Nut (exhaust pipe 1) “2”
T.
R.
Nut (exhaust pipe)

TIP 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Tighten the nut while applying the rear brake.
T.
R.
ECA24600
TIP
NOTICE First temporarily tighten all nuts to 7 N·m (0.7
Make sure to tighten to specification; other- kgf·m, 5.2 lb·ft). Then retighten them to 10 N·m
wise, it may damage the other part that is fas- (1.0 kgf·m, 7.4 lb·ft).
tened together.
2
1
2
1
2. Install:
3. Bend the lock washer tab to lock the nut. • Clamp
4. Install: • Exhaust pipe 2 “1”
• Drive sprocket guide • Bolt (exhaust pipe 2) “2”
• Drive sprocket cover “1”
• Bolt (drive sprocket cover) “2”
Bolt (drive sprocket cover)
7 N·m (0.7 kgf·m, 5.2 lb·ft) 1
T.
R.
TIP
Make sure that the exhaust pipe band “1” does
not ride on the projection “a” on the exhaust pipe
5-9
ENGINE REMOVAL
“2” or silencer “3”. Be sure to insert the projection

“b” into the slot in the exhaust pipe (or silencer).
A B
2 1 3 1
a a
b b
A. Exhaust pipe 1 and exhaust pipe 2
B. Exhaust pipe 2 and silencer
3. Install:
• Clamp
• Silencer “1”
• Bolt (silencer) “2”
Bolt (silencer)
30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.
4. Tighten:
• Bolt (exhaust pipe 2)
Bolt (exhaust pipe 2)
20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
• Clamp
Clamp
12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
TIP
Tighten while checking that their front and rear
joints are inserted in position.
5-10
CAMSHAFT
EAM20106
CAMSHAFT
Removing the cylinder head cover
13 N・m (1.3 kgf・m, 9.6 lb・ft)
2
10 N・m (1.0 kgf・m, 7.4 lb・ft)
3
1
4
5

Seat 4-1.
Ignition coil Refer to “ENGINE REMOVAL” on page 5-1.
1 Cylinder head breather hose 1
2 Spark plug 1
3 Cylinder head cover 1
4 Timing chain guide (top side) 1
5 Cylinder head cover gasket 1
* Yamaha bond No. 1215 (Three bond No.1215®)
5-11
CAMSHAFT
Removing the camshaft
(4) 10 N・m (1.0 kgf・m, 7.4 lb・ft)

10 N・m (1.0 kgf・m, 7.4 lb・ft)
E
5
(4)
6 E
5 E 8
6 6 N・m (0.6 kgf・m, 4.4 lb・ft)
M
7 4
M 3
10 N・m (1.0 kgf・m, 7.4 lb・ft)
6 N・m (0.6 kgf・m, 4.4 lb・ft)
LS
1 E
LS
10 N・m (1.0 kgf・m, 7.4 lb・ft)

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 Clip 2
7 Intake camshaft 1
8 Exhaust camshaft 1
5-12
CAMSHAFT
EAM30080
• Timing chain tensioner “2”
REMOVING THE CAMSHAFT • Gasket
1. Remove:
• Timing mark accessing screw “1”
• Crankshaft end accessing screw “2” 2
1
4. Remove:
2 • Bolt (camshaft cap) “1”
• Camshaft cap “2”
2. Align: • Clip “3”
• Alignment mark TIP
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Remove the bolts (camshaft cap) in a criss-
a. Turn the crankshaft counterclockwise with a cross pattern, working from the outside in.
wrench. • In order to prevent the clip from falling into the
b. Align the top dead center (TDC) mark “a” on crankcase, remove the camshaft cap.
the rotor with the alignment mark “b” on the ECA24610
crankcase cover. NOTICE

TIP The bolts (camshaft cap) must be removed
Align the alignment mark “c” on the exhaust evenly to prevent damage to the cylinder
camshaft sprocket and the alignment mark “d” head, camshafts or camshaft caps.
on the intake camshaft sprocket with the edge of
the cylinder head.
1
3
d c
5. Remove:
• Exhaust camshaft “1”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Intake camshaft “2”
TIP
3. Remove: Attach a wire “3” to the timing chain to prevent it
• Timing chain tensioner cap bolt “1”
5-13
CAMSHAFT
from falling into the crankcase.
2 1
3
4. Measure:
EAM30081
• Camshaft-journal-to-camshaft-cap clearance
CHECKING THE CAMSHAFT Out of specification  Measure the camshaft
1. Check: journal diameter.
• Camshaft lobe Camshaft-journal-to-camshaft-
Blue discoloration/pitting/scratches  Re- cap clearance
place the camshaft. 0.028–0.062 mm (0.0011–0.0024
2. Measure: in)
• Camshaft lobe dimensions “A”
Out of specification  Replace the camshaft. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the camshaft into the cylinder head.
Camshaft lobe dimensions b. Position a strip of Plastigauge® “1” onto the
Lobe height (Intake)
camshaft journal as shown.
38.130–38.230 mm (1.5012–
1.5051 in)
Limit
38.030 mm (1.4972 in)
Lobe height (Exhaust)
34.270–34.370 mm (1.3492–
1.3531 in)
Limit 1
34.170 mm (1.3453 in)
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)
3. Measure:
T.
R.
• Camshaft runout d. Remove the camshaft caps and then mea-

Out of specification  Replace. sure the width of the Plastigauge® “1”.
Camshaft runout limit
0.030 mm (0.0012 in)
5-14
CAMSHAFT
a 1
b 2
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. 1/4 tooth
b. Correct
5. Measure:
• Camshaft journal diameter “a” 1. Timing chain roller
Out of specification  Replace the camshaft. 2. Camshaft sprocket
Within specification  Replace the cylinder EAM30083
head and the camshaft caps as a set. CHECKING THE TIMING CHAIN
Camshaft journal diameter TENSIONERS
21.959–21.972 mm (0.8645– 1. Check:
0.8650 in) • Timing chain tensioner
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. While pressing the tensioner rod lightly with
your fingers, use a thin screwdriver “1” to
wind the tensioner rod up fully clockwise.
b. When releasing the screwdriver by pressing
lightly with your fingers, make sure that the
tensioner rod will come out smoothly.
c. If not, replace the tensioner assembly.
EAM30082
CHECKING THE TIMING CHAIN AND

CAMSHAFT SPROCKET
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-15
CAMSHAFT
EAM30084
CHECKING THE DECOMPRESSION SYSTEM a a a

1. Check:
• Decompression system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check that the decompressor cam “1” moves
smoothly.
b. Check that the decompressor lever pin “2”
projects from the camshaft.
b. Align the top dead center (TDC) mark “a” on

the rotor with the alignment mark “b” on the
1 crankcase cover.
2 b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAM30085
INSTALLING THE CAMSHAFTS

1. Install:
• Exhaust camshaft “1” c. Fit the timing chain “3” onto both camshaft
• Intake camshaft “2” sprockets and install the camshafts on the
cylinder head.
2 1
TIP
Make sure that the alignment mark “c” on the ex-
haust camshaft sprocket and the alignment
mark “d” on the intake camshaft sprocket are
aligned with the edge of the cylinder head.
E 3
M d c
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise with a
wrench.
TIP
• Apply molybdenum disulfide oil to the cam-
shafts.
• Apply the engine oil on the decompression ECA24620
system. NOTICE
• Fill the cylinder head with engine oil up to the
Do not turn the crankshaft during the cam-
tops “a” of the valve lifters.
shaft installation. Damage or improper valve
timing will result.
d. Install the clips, the camshaft caps and the
bolts (camshaft cap).
Bolt (camshaft cap)
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
5-16
CAMSHAFT
TIP
• Before installing the clips, cover the cylinder 3
head with a clean cloth to prevent the clips a
from coming off into the cylinder head cavity. 4
• Apply the engine oil to the threads and contact
surfaces.
• Tighten the bolts to the specified torque in two 1
or three steps in the proper tightening se- 4 2
quence as shown.
ECA24630
NOTICE c. Release the screwdriver, check that the ten-

The bolts (camshaft cap) must be tightened sioner rod comes out smoothly, and tighten
evenly, or damage to the cylinder head, cam- the gasket “5” and the cap bolt “6”.
shaft caps, and camshaft will result.
Tensioner cap bolt
6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
3 4 8 7
1 2 6 5
5
E
6
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
• Timing chain tensioner ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 3. Turn:
a. While pressing the tensioner rod lightly with • Crankshaft
your fingers, use a thin screwdriver to wind Counterclockwise several turns.
the tensioner rod up fully clockwise. 4. Check:
• Top dead center (TDC) mark on the rotor
Align with the crankcase alignment mark.
• Camshaft match marks
Align with the cylinder head surface.
Out of alignment  Adjust.
5. Install:
• Timing chain guide (top side) “1”
• Cylinder head cover gasket “2” New
• Cylinder head cover “3”
• Bolt (cylinder head cover) “4”
b. With the tensioner rod fully wound and the Bolt (cylinder head cover)
chain tensioner “UP” mark “a” facing upward, 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
install the gasket “1”, the timing chain ten-

R.
sioner “2”, and the gasket “3”, and tighten the TIP
bolt “4”. • Before installation, apply the sealant to the cyl-
inder head cover gasket.
Bolt (timing chain tensioner) • After installing the cylinder head cover gasket
10 N·m (1.0 kgf·m, 7.4 lb·ft) “2” to the cylinder head cover, cut off the “a”
T.
R.
section.
5-17
CAMSHAFT

90890-85505
4
3 1
2
6. Install:
• Cylinder head breather hose
• Spark plug
Spark plug
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
5-18
CYLINDER HEAD
EAM20107
CYLINDER HEAD
Removing the cylinder head
1st 40 N・m (4.0 kgf・m, 30 lb・ft)

2nd 22 N・m (2.2 kgf・m, 16 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft) 3rd 90˚
4th 2: 60˚ 3: 90˚
7 M
10 N・m (1.0 kgf・m, 7.4 lb・ft)
8
10 N・m (1.0 kgf・m, 7.4 lb・ft)

Seat 4-1.
Exhaust pipe and silencer Refer to “ENGINE REMOVAL” on page 5-1.
Radiator hose Disconnect.
Coolant temperature sensor coupler Disconnect.
Throttle body Refer to “THROTTLE BODY” on page 7-5.
Camshaft Refer to “CAMSHAFT” on page 5-11.
Upper engine bracket Refer to “ENGINE REMOVAL” on page 5-1.
1 Bolt (cylinder head) 2
4 Cylinder head 1
5 Cylinder head gasket 1
6 Timing chain guide (intake side) 1
5-19
CYLINDER HEAD
Removing the cylinder head
1st 40 N・m (4.0 kgf・m, 30 lb・ft)

2nd 22 N・m (2.2 kgf・m, 16 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft) 3rd 90˚
4th 2: 60˚ 3: 90˚
7 M
10 N・m (1.0 kgf・m, 7.4 lb・ft)
8
10 N・m (1.0 kgf・m, 7.4 lb・ft)

7 Oil check bolt 2
8 Oil passage plug 1
5-20
CYLINDER HEAD
EAM30086
REMOVING THE CYLINDER HEAD

1. Remove:
• Cylinder head bolt
TIP
• Loosen the bolts in the proper sequence as
shown.
• Loosen each bolt 1/2 of a turn at a time. After
fully loosening all the bolts, remove them.
• M6  35 mm (1.38 in): “1”–“2”
• M10  149 mm (5.87 in): “4”, “5”, “6” 2. Check:
• M10  165 mm (6.49 in): “3” • Cylinder head
Damage/scratches  Replace.
TIP
When replacing the cylinder head, replace also
the valve.
Refer to “CHECKING THE VALVE SEATS” on
page 5-27.
FWD
• Cylinder head coolant passages
x2 x3 x1 Mineral deposits/rust  Eliminate.
3. Measure:
• Cylinder head warpage
Out of specification  Resurface the cylinder
4 5 head.
1
Warpage limit
0.05 mm (0.0020 in)
2
6 3 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge and a thickness gauge
across the cylinder head.
b. Measure the warpage.
EAM30087 c. If the limit is exceeded, resurface the cylinder
CHECKING THE TIMING CHAIN GUIDE head as follows.
(INTAKE SIDE) d. Place a 400–600 grit wet sandpaper on a sur-
1. Check: face plate, and resurface the cylinder head
• Timing chain guide (intake side) using a figure-eight sanding pattern.
Damage/wear  Replace. TIP
EAM30088 To ensure an even surface, turn the cylinder
CHECKING THE CYLINDER HEAD head several times.
1. Eliminate:
• Combustion chamber carbon deposits
TIP
Use a rounded scraper, not a sharp instrument,
in order not to damage or scratch the spark plug
bore threads.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-21
CYLINDER HEAD
EAM30089
INSTALLING THE CYLINDER HEAD Bolt “1”–“4”

1. Install: 1st
T.
40 N·m (4.0 kgf·m, 30 lb·ft)
R.
• Timing chain guide (intake side) “1”
• Dowel pin “2”
• Cylinder head gasket “3” New
• Cylinder head “4”
TIP
While pulling up the timing chain, install the tim-
ing chain guide (intake side) and the cylinder
head.
FWD
4
3 x2 x3 x1
2
3 2
5
1 2
6
1 4
2. Install:
• Washer “1”
• Bolt “2”
• Bolt “3” e. Remove the bolts.
2 2 f. Again apply molybdenum disulfide grease to
the threads and contact surfaces of the bolts
and to both contact surfaces of the washers.
1 g. Retighten the bolts.
M
TIP
3 Tighten the bolts to the specified torque in two or
three steps in the proper tightening sequence as
3 shown.
Bolt “1”–“4”
TIP 2nd
T.
22 N·m (2.2 kgf·m, 16 lb·ft)

R.
Tighten the bolts using the following procedure.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ h. Put a mark on the corner “1” of the bolt (cylin-
a. Wash the threads and contact surfaces of the der head) and the cylinder head “2” as
bolts, the contact surfaces of the washers, shown.
the contact surface of the cylinder head, and
the threads of the crankcase.
b. Apply molybdenum disulfide grease to the 1
threads and contact surfaces of the bolts and
to both contact surfaces of the washers “1”.
c. Install the washers and the bolts.
d. Tighten the bolts to the specified torque in
two or three steps in the proper tightening se- 2
quence as shown.
5-22
CYLINDER HEAD
i. Retighten the cylinder head mounting bolts in

the proper tightening sequence. Bolt “5”, “6”
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
90˚
j. Put a mark on the corner of the bolt (cylinder

head) and the cylinder head.
k. Retighten the cylinder head mounting bolts in
the proper tightening sequence.
TIP
Tighten the bolts in two steps (90 and 60) to
reach the specified angle in the proper tighten-
ing sequence.
Bolt “1”–“4”
3rd
T.
Specified angle
R.
90
Final
Specified angle
Bolt “1”, “2”, “3”: 60 (149 mm
(5.87 in))
Bolt “4”: 90 (165 mm (6.49 in))
l. Tighten the bolts to the specified torque.
5-23
VALVES AND VALVE SPRINGS
EAM20108

Removing the valves and valve springs

Cylinder head Refer to “CYLINDER HEAD” on page 5-19.
1 Valve lifter 4
2 Adjusting pad 4
3 Valve cotter 8
4 Valve spring retainer 4
5 Valve spring 4
6 Valve stem seal 4
7 Valve spring seat 4
8 Intake valve 2
9 Exhaust valve 2
5-24
EAM30090
b. Check that the valves are properly sealed.
REMOVING THE VALVES
TIP
TIP Check that there are no kerosene leaks from the
Before removing the internal parts of the cylinder valve seat “1”.
head (e.g., valves, valve springs, valve seats),
make sure that the valves are properly sealed.
1. Remove:
• Valve lifter “1”
• Adjusting pad “2”
TIP 1
• Place a cloth in the timing chain space to pre- a
vent adjusting pads from falling into the crank- a
case.
• Make a note of the positions of valve lifters and
adjusting pads so that they can be reinstalled
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
in their original places.
3. Remove:
Valve lapper (ø14) • Valve cotter “1”
90890-04101 TIP
Valve lapping tool (14mm) Remove the valve cotters by compressing the
YM-A8998 valve spring with the valve spring compressor
“2” and the valve spring compressor attachment
“3”.
2 1
90890-04019
YM-04019
Valve spring compressor attach-
ment
90890-04108
Valve spring compressor adapter
22 mm
YM-04108
2. Check:
• Valve sealing
Leakage at the valve seat  Check the valve 4. Remove:
face, the valve seat, and the valve seat con- • Valve spring retainer “1”
tact width. • Valve spring “2”
Refer to “CHECKING THE VALVE SEATS” • Valve “3”
on page 5-27. • Valve stem seal “4”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Valve spring seat “5”
a. Pour a clean solvent “a” into the intake and TIP
exhaust ports. Identify the position of each part very carefully so
5-25
that it can be reinstalled in its original place.
2 1
EAM30091
CHECKING THE VALVES AND VALVE

GUIDES
1. Measure:
• Valve-stem-to-valve-guide clearance
Out of specification  Replace the valve
guide.
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” - 2. Replace:
Valve stem diameter “b”
• Valve guide
TIP
Valve-stem-to-valve-guide clear- To ease valve guide removal and installation,
ance (intake) and to maintain the correct fit, heat the cylinder
0.010–0.037 mm (0.0004–0.0015
head to 100 °C (212 °F) in an oven.
in)
Limit ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
0.080 mm (0.0032 in) a. Remove the valve guide with the valve guide
Valve-stem-to-valve-guide clear- remover “1”.
ance (exhaust)
0.020–0.047 mm (0.0008–0.0019
in)
Limit
0.100 mm (0.0039 in)
b. Install the new valve guide with the valve

guide installer “1” and the valve guide remov-
er “2”.
Valve guide installation height “a”
Intake
15.1–15.5 mm (0.59–0.61 in)
Exhaust
11.7–12.1 mm (0.46–0.48 in)
5-26
5. Measure:
• Valve stem runout
Out of specification  Replace the valve.
2
TIP
1 • 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

0.010 mm (0.0004 in)
c. After installing the valve guide, expand the
hole in the valve guide with the valve guide
remover & installer set (ø5.5) “3” to obtain the
proper valve-stem-to-valve-guide clearance.
EAM30092
CHECKING THE VALVE SEATS

1. Eliminate:
TIP • Carbon deposits
After replacing the valve guide, reface the valve (from the valve face and valve seat)
seat. 2. Check:
• Valve seat
Valve guide remover & installer Pitting/wear  Replace the cylinder head.
set (ø5.5) 3. Measure:
90890-04016 • Valve seat contact width “a”
Valve guide remover (5.5 mm) Out of specification  Replace the cylinder
YM-01122 head.
Valve guide installer (ø5.5)
90890-04015 Valve seat contact width (intake)
Valve guide installer (5.5 mm) 0.90–1.10 mm (0.0354–0.0433 in)
YM-04015 Limit
Valve guide reamer (5.5 mm) 1.5 mm (0.06 in)
90890-01196 Valve seat contact width (ex-
Valve guide reamer (5.5 mm) haust)
YM-01196 0.90–1.10 mm (0.0354–0.0433 in)
Limit
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1.5 mm (0.06 in)
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.
5-27
for lapping with new ones.

TIP
• When replacing the cylinder head, replace also
the valves with new ones without them.
• When replacing the valves or the valve guides,
use new valves to lap the valve seats, and then
replace them with new valves.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound “a” to the
valve face.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ECA13790
a. Apply blue layout fluid “b” onto the valve face. NOTICE
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
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 impres-
sion.
d. Measure the valve seat contact width “c”. b. Apply molybdenum disulfide oil onto the
valve stem.
TIP
Where the valve seat and the valve face are in c. Install the valve into the cylinder head.
contact with each other, the blueing will have d. Turn the valve until the valve face and the
been removed. valve seat are evenly polished, then clean off
all of the lapping compound.
TIP
While turning the valve lapper, tap and lap the
valve seat.
c
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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
5-28
h. Install the valve into the cylinder head.

i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat contact width “c”
again. If the valve seat contact width is out of
specification, reface and lap the valve seat.
EAM30095
INSTALLING THE VALVES

1. Clean:
• Valve stem end
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAM30093
CHECKING THE VALVE SPRINGS

1. Measure:
• Valve spring free length “a”
Out of specification  Replace the valve
spring.
2. Lubricate:
Free length (intake) • Valve stem “1”
40.57 mm (1.60 in) • Valve stem seal “2”
Limit
38.54 mm (1.52 in) Recommended lubricant
Free length (exhaust) Molybdenum disulfide oil
37.42 mm (1.47 in)
Limit
35.55 mm (1.40 in)
3. Install:
• Spring seat “1”
• Valve stem seal “2” New
EAM30094
• Valve “3”
CHECKING THE VALVE LIFTERS • Valve spring “4”
1. Check: • Valve spring retainer “5”
• Valve lifter (to the cylinder head)
Damage/scratches  Replace the valve lift-
TIP
ers and cylinder head. • Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch “a”
5-29
facing up.
6. Lubricate:
• Adjusting pad “1”
b. Smaller pitch • Valve lifter “2”
4. Install:
• Valve cotter “1”
2
TIP
Install the valve cotters by compressing the
valve spring with the valve spring compressor
E
“2” and the valve spring compressor attachment
“3”.
1
90890-04019
7. Install:
YM-04019
Valve spring compressor attach- • Adjusting pad
ment • Valve lifter
90890-04108 TIP
Valve spring compressor adapter • Check that the valve lifter turns smoothly when
22 mm rotated with your finger.
YM-04108 • Make sure that the valve lifter and the adjusting
pad are reinstalled in their original positions.
5. To fasten the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
ECA13800
NOTICE
Hitting the valve tip with excessive force
could damage the valve.
5-30
CYLINDER AND PISTON
EAM20109
CYLINDER AND PISTON

Removing the cylinder and piston
10 N・m (1.0 kgf・m, 7.4 lb・ft)

1
E
7
4
6
3 5
E 4
10 N・m (1.0 kgf・m, 7.4 lb・ft)
LT

Cylinder head Refer to “CYLINDER HEAD” on page 5-19.
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
5-31
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 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
YU-01304 a. Measure the cylinder bore “C” with the cylin-
der bore gauge.
TIP
Measure cylinder bore “C” by taking side-to-side
and front-to-back measurements of the cylinder.
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
• 2nd ring b. If out of specification, rebore or replace the
• Oil ring cylinder, and replace the piston and the pis-
ton rings as a set.
TIP
When removing a piston ring, open the end gap c. Measure the piston outside diameter “a” at
with your fingers and lift the opposite end gap of the measuring point (from piston skirt bottom)
“b” with the micrometer.
5-32
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, the 3. Measure:
piston, and the piston rings as a set. • Piston ring end gap
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Out of specification  Replace the piston
ring.
EAM30098
TIP
CHECKING THE PISTON RINGS
The oil ring expander spacer’s end gap cannot
1. Measure:
be measured. If the oil ring rail’s gap is exces-
• Piston ring side clearance
sive, replace all three piston rings.
Out of specification  Replace the piston
and piston rings as a set.
Top ring
TIP End gap limit
Before measuring the piston ring side clearance, 0.55 mm (0.0217 in)
eliminate any carbon deposits from the piston 2nd ring
ring grooves and piston rings. End gap limit
0.85 mm (0.0335 in)
5-33
CYLINDER AND PISTON
b b
b. Upper of cylinder EAM30100
EAM30099
INSTALLING THE PISTON AND CYLINDER
CHECKING THE PISTON PIN 1. Install:
1. Check: • Oil ring expander “1”
• Piston pin • Lower oil ring rail “2”
Blue discoloration/grooves  Replace the • Upper oil ring rail “3”
piston pin and then check the lubrication sys- • 2nd ring “4”
tem. • Top ring “5”
2. Measure: TIP
• Piston pin outside diameter “a” Be sure to install the piston rings so that the
Out of specification  Replace the piston pin. manufacturer’s marks or numbers face up.
Piston pin outside diameter

17.991–18.000 mm (0.7083–
0.7087 in)
Limit
17.981 mm (0.7079 in)
3. Measure:
• Piston pin bore inside diameter “b”
Out of specification  Replace the piston.
Piston pin bore inside diameter 2. Install:
18.004–18.015 mm (0.7088–
• Piston “1”
0.7093 in)
Limit • Piston pin “2”
18.045 mm (0.7104 in) • Piston pin clip “3” New
TIP
• Apply molybdenum disulfide oil to the piston
pin.
• Install the piston with the mark “a” on it pointing
to its exhaust (rear) side.
• Before installing the piston pin clip, cover the
crankcase opening with a cloth to prevent the
5-34
CYLINDER AND PISTON
clip from falling into the crankcase. TIP

• Make sure that the end of the piston pin clip is • While compressing the piston rings with one
not positioned at the cutout in the piston. hand, install the cylinder with the other hand.
• Pass the timing chain and timing chain guide
1 a (exhaust side) through the timing chain cavity.
3. Lubricate:
• Piston
• Piston ring
• Cylinder
4. Offset:
• Piston ring end gap
a c
15 15
d
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:
• Cylinder gasket New
• Dowel pin
• Cylinder
Cylinder bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
5-35
ELECTRIC STARTER
EAM20110
ELECTRIC STARTER
Removing the starter motor
FW
D
1
4
6 N・m (0.6 kgf・m, 4.4 lb・ft)

Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-1.
1 Plastic locking tie 1
2 Starter motor cover (upper) 1
3 Starter motor cover (lower) 1
4 Starter motor 1
When removing or installing the installation
nut of the starter motor lead, be sure to hold
5 Starter motor lead 1 the nut on the starter motor side firmly in
place using a spanner.
5-36
ELECTRIC STARTER
Disassembling the starter motor
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)

D
7 FW
6 1
9
4
8
2
3
4.5 N・m (0.45 kgf・m, 3.3 lb・ft)

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
5-37
ELECTRIC STARTER
EAM30106
CHECKING THE STARTER MOTOR Digital circuit tester (CD732)

1. Check: 90890-03243
• Commutator Model 88 Multimeter with tachom-
Dirt  Clean with 600 grit sandpaper. eter
2. Measure: YU-A1927
• Commutator diameter “a”
Out of specification  Replace the starter Armature coil resistance “1”
motor. 0.008–0.010 
Insulation resistance “2”
Commutator diameter Above 1 M
80.6 mm (3.17 in)
b. If any resistance is out of specification, re-
place the starter motor.
3. Measure:
• Mica undercut “a”
Out of specification  Scrape the mica to the ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
proper measurement with a hacksaw blade 5. Measure:
that has been grounded to fit the commutator. • Brush length “a”
Out of specification  Replace the brush set.
Mica undercut (depth)
2.40 mm (0.09 in) Brush overall length limit
5.5 mm (0.22 in)
TIP
The mica of the commutator must be undercut to
ensure proper operation of the commutator.
6. Measure:
• Brush spring force
4. Measure: Out of specification  Replace the brush set.
• Armature assembly resistances (commutator Brush spring force
and insulation) 4.80–7.20 N (489–734 gf, 17.28–
Out of specification  Replace the starter 25.92 oz)
motor.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 7. Check:
a. Measure the armature assembly resistances • Gear teeth
“1” with the digital circuit tester. Damage/wear  Replace the starter motor.
5-38
ELECTRIC STARTER
8. Check:
• Oil seal a b
Damage/wear  Replace the defective
part(s).
EAM30107
ASSEMBLING THE STARTER MOTOR

1. Install:
• Brush spring “1”
• Brush “2” 1
TIP
Install the brush holder using the screws “a”. 4. Install:
• Bolt
• O-ring New
a
TIP
Apply the lithium-soap-based grease on the O-
2 ring.
5. Install:
2 • Starter motor
1 • Starter motor cover (upper/lower)
a • Starter motor bolt
• Starter motor cover bolt
2. Install: Starter motor bolt
• Starter motor rear cover “1” 10 N·m (1.0 kgf·m, 7.4 lb·ft)
• O-ring New
T.
Starter motor cover bolt

R.
• Starter motor yoke “2” 10 N·m (1.0 kgf·m, 7.4 lb·ft)

TIP
Install the starter motor rear cover with its projec-
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.
5-39
CLUTCH
EAM20111
CLUTCH
Removing the clutch
E E 10 N・m (1.0 kgf・m, 7.4 lb・ft)
18
11 E
10 N・m (1.0 kgf・m, 7.4 lb・ft) 5
10
10 N・m (1.0 kgf・m, 7.4 lb・ft) 4 6 1
9
T .R
8
.
7
2
12
3
E
14 LT
E
E
13
12 17
E
16
15
13
13
E FW
E D
E
75 N・m (7.5 kgf・m, 55 lb・ft)

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-14.
Brake pedal Refer to “ENGINE REMOVAL” on page 5-1.
1 Clutch cable 1 Disconnect.
2 Clutch cover 1
3 O-ring 1
4 Clutch spring 6
5 Pressure plate 1
6 Push rod 1 1
7 Circlip 1
8 Washer 1
9 Bearing 1
10 Ball 1
11 Push rod 2 1
12 Friction plate 1 2
13 Clutch plate 7
14 Friction plate 2 6 Identification color (purple)
15 Clutch boss 1
5-40
CLUTCH
Removing the clutch

E E 10 N・m (1.0 kgf・m, 7.4 lb・ft)
18
11 E
10 N・m (1.0 kgf・m, 7.4 lb・ft) 5
10
10 N・m (1.0 kgf・m, 7.4 lb・ft) 4 6 1
9
T .R
8
.
7
2
12
3
E
14 LT
E
E
13
12 17
E
16
15
13
13
E FW
E D
E
75 N・m (7.5 kgf・m, 55 lb・ft)

16 Thrust washer 1
17 Primary driven gear 1
18 Push lever shaft 1
5-41
CLUTCH
Removing the right crankcase cover
4
6
7
LS
10 N・m (1.0 kgf・m, 7.4 lb・ft)

LS
2 3
10 N・m (1.0 kgf・m, 7.4 lb・ft) 1
LS
10 N・m (1.0 kgf・m, 7.4 lb・ft)
LS

Engine guard Refer to “ENGINE REMOVAL” on page 5-1.
Drain.
page 3-14.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-6.
Brake pedal Refer to “ENGINE REMOVAL” on page 5-1.
Clutch cover Refer to “CLUTCH” on page 5-40.
1 Oil filter element cover 1
2 Oil filter element 1
3 Radiator pipe 2 1
4 Right crankcase cover 1
5 Gasket 1
6 Dowel pin 2
7 Collar 1
5-42
CLUTCH
EAM30108
REMOVING THE CLUTCH

1. Remove:
• Clutch boss nut “1”
• Lock washer “2”
• Clutch boss “3”
TIP
• Straighten the lock washer tab.
• While holding the clutch boss with the univer-
sal clutch holder “4”, loosen the clutch boss
nut.
EAM30110
Universal clutch holder CHECKING THE CLUTCH PLATES

90890-04086 1. Check:
Universal clutch holder • Clutch plate
YM-91042 Damage  Replace the clutch plates as a
set.
2. Measure:
• Clutch plate warpage
1 (with a surface plate and thickness gauge “1”)
2 Out of specification  Replace the clutch
plates as a set.
3
Thickness gauge
90890-03268
Feeler gauge set
4 YU-26900-9
Warpage limit
EAM30109
CHECKING THE FRICTION PLATES

0.10 mm (0.004 in)
1. Check:
• Friction plate
Damage/wear  Replace the friction plates
as a set.
2. Measure:
• Friction plate thickness
Out of specification  Replace the friction
plates as a set.
TIP
Measure it at four points on the friction plate.
Friction plate 1 thickness

2.92–3.08 mm (0.115–0.121 in) EAM30111
Wear limit CHECKING THE CLUTCH SPRINGS

2.82 mm (0.111 in) 1. Check:
Friction plate 2 thickness • Clutch spring
2.92–3.08 mm (0.115–0.121 in) Damage  Replace the clutch springs as a
Wear limit set.
2.82 mm (0.111 in) 2. Measure:
• Clutch spring free length
Out of specification  Replace the clutch
springs as a set.
5-43
CLUTCH
EAM30114
Clutch spring free length CHECKING THE PRESSURE PLATE

48.00 mm (1.89 in) 1. Check:
Limit • Pressure plate
45.60 mm (1.80 in) Crack/damage  Replace.
EAM30115
CHECKING THE PUSH LEVER SHAFT

1. Check:
• Push lever shaft
EAM30112
CHECKING THE CLUTCH HOUSING

1. Check:
• Clutch housing dogs “1”
Damage/pitting/wear  Deburr the clutch
housing dogs or replace the clutch housing.
TIP
Pitting on the clutch housing dogs will cause er- EAM30116
ratic clutch operation. CHECKING THE CLUTCH PUSH RODS

1. Check:
• Push rod 1 “1”
• Bearing “2”
• Washer “3”
• Ball “5”
1
EAM30113
2
CHECKING THE CLUTCH BOSS 4
3
1. Check:
• Clutch boss splines 5
Damage/pitting/wear  Replace the clutch
boss.
TIP 2. Measure:
Pitting on the clutch boss splines will cause er-
• Push rod 2 bending limit
ratic clutch operation.
Push rod bending limit
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.
Excessive noise during operation  Replace
5-44
CLUTCH
the primary drive and primary driven gears as

a set. 2
1
2. Check:
• Primary-drive-gear-to-primary-driven-gear
free play 1
Free play exists  Replace the primary drive
and primary driven gears as a set.
3
EAM30118
CHECKING THE PRIMARY DRIVEN GEAR

4
1. Check:
• Primary driven gear 2. Install:
Damage/wear  Replace the primary drive • Right crankcase cover “1”
and primary driven gears as a set. • Right crankcase cover bolt “2”
Excessive noise during operation  Replace
the primary drive and primary driven gears as Right crankcase cover bolt
a set. 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
EAM30119
TIP
INSTALLING THE OIL SEAL • Apply the engine oil on the impeller shaft end.
1. Install: • When installing the crankcase cover onto the
• Oil seal “1” New crankcase, make sure that the impeller shaft
• Washer “2” end “3” aligns with the balancer end slot “4”.
• Circlip “3” New • Tighten the right crankcase cover bolts in stag-
TIP es and in a crisscross pattern.
• Apply the lithium-soap-based grease on the oil
seal lip.
• Install the oil seal in parallel with its manufac-
ture’s marks or numbers facing inward.
LS
3
2
1 2
EAM30120
INSTALLING THE RIGHT CRANKCASE

COVER
1. Install:
• O-ring “2” New
• Collar “3”
• Gasket “4” New EAM30121
TIP INSTALLING THE CLUTCH

Apply the lithium-soap-based grease on the O- 1. Install:
ring. • Push lever shaft “1”
TIP
seal lip.
• Before installation, apply the engine oil to the
5-45
CLUTCH
push lever shaft sliding surface.

Universal clutch holder
90890-04086
1 Universal clutch holder
YM-91042
a
1
1
2
2
2. Install:
• Primary driven gear “1”
• Thrust washer “2” 3
• Clutch boss “3”
TIP 4. Bend the lock washer “1” tab.
Apply the engine oil on the primary driven gear
inner circumference.
1
1
2
33
5. Install:
E • Friction plate 1 “1”
3
• Clutch plate “2”
3. Install: • Friction plate 2 “3”
• Lock washer “1” New TIP
• Clutch boss nut “2” • Install the clutch plates and friction plates alter-
nately on the clutch boss, starting with a friction
Clutch boss nut plate and ending with a friction plate.
75 N·m (7.5 kgf·m, 55 lb·ft) • From the clutch boss side, install the friction
T.
R.
ECA24660 plates in order: friction plate 1  1, friction plate

NOTICE 2 (identification color: purple)  6, and friction
Make sure to tighten to specification; other- plate 1  1.
wise, it may damage the other part that is fas- • Apply the engine oil on the friction plates and
tened together. clutch plates.
TIP a 1
E
• Align the notch in the lock washer “1” with the
detent rib “a” of the clutch boss.
3
• Apply engine oil to the threads and contact sur-
face of the clutch boss nut. E
E
• Use the universal clutch holder “3” to hold the 2
clutch boss. 1
2
E
2
a. Identification color
5-46
CLUTCH
6. Install:
• Bearing “1” Clutch spring bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
• Washer “2”
T.
R.
TIP
To push rod 1 “4”. Tighten the bolts in stages and in a crisscross
TIP pattern.
Apply the engine oil on the bearing and washer.
1
6 3
4 5
2
10.Install:
7. Install: • O-ring “1” New
TIP
• Ball “2” Apply the lithium-soap-based grease to the O-
• Push rod 1 “3” ring.
TIP
Apply the engine oil on the push rod 1, 2 and
ball.
E
2
11.Install:
E
3 1 • Clutch cover “1”
• Clutch cover bolt
8. Install: Clutch cover bolt
• Pressure plate “1” 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
Tighten the bolts in stages and in a crisscross
pattern.
9. Install:
• Clutch spring
• Clutch spring bolt
5-47
SHIFT SHAFT
EAM20113
SHIFT SHAFT
Removing the shift shaft and stopper lever
LS
3
1
12 N・m (1.2 kgf・m, 8.9 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)

4 14
5 LT 13
2 8
15
10
11
7
12
E 12 30 N・m (3.0 kgf・m, 22 lb・ft)

11 LT
10
6
10 N・m (1.0 kgf・m, 7.4 lb・ft)
E

Primary driven gear Refer to “CLUTCH” on page 5-40.
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
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
5-48
SHIFT SHAFT
EAM30123
REMOVING THE SHIFT GUIDE AND SHIFT

LEVER ASSEMBLY 1
1. Remove:
• Bolt (shift guide)
• Shift guide “1”
• Shift lever assembly “2” 2
TIP
Make sure that the shift lever assembly is re-
moved together with the shift guide.
EAM30126
CHECKING THE SHIFT GUIDE AND SHIFT

LEVER ASSEMBLY
1. Check:
• Shift guide “1”
• Shift lever “2”
1
• Pawl “3”
• Pawl pin “4”
• Spring “5”
2
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
5
NOTICE
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”
• Torsion spring “2”
Broken  Replace.
2
1 2
1
EAM30125
CHECKING THE SHIFT SHAFT

1. Check:
• Shift shaft “1”
Bends/damage/wear  Replace.
EAM30128
INSTALLING THE STOPPER LEVER

• Shift shaft spring “2”
1. Install:
• Torsion spring “1”
• Collar “2”
5-49
SHIFT SHAFT
• Stopper lever “3” (to the shift lever)

• Bolt (stopper lever) “4” TIP
Apply the engine oil on the spring, pawl pin and
Bolt (stopper lever) pawl.
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
LOCTITE®
R.
3
1 2
2 1
3
E
LT
4 2. Install:
• Shift lever assembly
EAM30129 (to the shift guide)
INSTALLING THE SEGMENT 3. Install:
1. Install: • Shift lever assembly “1”
• Segment “1” • Shift guide “2”
• Segment bolt TIP
Segment bolt • The shift lever assembly is installed at the
30 N·m (3.0 kgf·m, 22 lb·ft) same time as the shift guide.
• Apply the engine oil on the segment bolt shaft.
T.
R.
TIP
• Align the notch “a” on the segment with the pin
“b” on the shift cam.
• With the stopper lever pushed down, install the
segment.
ECA24680
2
NOTICE
If the segment gets an impact, the stopper le-
ver may be damaged. Take care not to give E
an impact to it when tightening the bolt. 1
4. Tighten:
2 • Shift guide bolt “1”
2
Shift guide bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
LOCTITE®
R.
1
a b 1
1
EAM30130
INSTALLING THE SHIFT GUIDE AND SHIFT

LEVER ASSEMBLY
1. Install:
• Spring “1” LT
• Pawl pin “2”
• Pawl “3”
5-50
SHIFT SHAFT
EAM30131
INSTALLING THE SHIFT SHAFT

1. Install:
• Roller “1”
• Shift shaft spring “2” (to shift shaft)
• Collar “3” (to shift shaft)
• Shift shaft “4”
TIP
Apply the engine oil on the roller and shift shaft.
1
E 3
2
2. Install:
• Oil seal New
EAM30132
INSTALLING THE SHIFT PEDAL

1. Install:
• Shift pedal “1”
• Shift pedal bolt “2”
Shift pedal bolt
12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
TIP
Align the punch mark “a” on the shift shaft with
the punch mark “b” in the shift pedal.
b
a
1 2
5-51
OIL PUMP AND BALANCER GEAR
EAM20114

Removing the oil pump
2.0 N・m (0.20 kgf・m, 1.5 lb・ft)
2
1
LT 3
4
5 N・m (0.5 kgf・m, 3.7 lb・ft)
5
7

Right crankcase cover Refer to “CLUTCH” on page 5-40.
1 Oil pump assembly 1
2 Oil pump cover 1
3 Outer rotor 1
4 Dowel pin 1
5 Inner rotor 1
6 Oil pump drive shaft 1
7 Oil pump housing 1
5-52
Removing the balancer
80 N・m (8.0 kgf・m, 59 lb・ft)

9
8
7
2
11
10
E 3 6 5
LT
4
1
10 N・m (1.0 kgf・m, 7.4 lb・ft)
50 N・m (5.0 kgf・m, 37 lb・ft) 45 N・m (4.5 kgf・m, 33 lb・ft)

Stator Refer to “AC MAGNETO” on page 5-57.
1 Nut (balancer) 1
2 Nut (primary drive gear) 1
3 Nut (balancer weight gear) 1
4 Lock washer 1
5 Balancer 1
6 Straight key 1
7 Conical washer 1
8 Primary drive gear 1
9 Balancer drive gear 1
10 Lock washer 1
11 Balancer weight gear 1
5-53
EAM30133
REMOVING THE BALANCER 1 2

1. Straighten the lock washer tab. 3
2. Loosen:
• Balancer nut “1”
• Primary drive gear nut “2”
• Balancer weight gear nut “3”
TIP
Place an aluminum plate “a” between the teeth
of the balancer drive gear “4” and balancer
weight gear “5”.
EAM30135
CHECKING THE BALANCER

1. Check:
• Balancer
4
2
EAM30136
5
CHECKING THE OIL PUMP
1. Check:
• Oil pump cover
a • Oil pump drive shaft
• Oil pump housing
Cracks/damage/wear  Replace the defec-
a tive part(s).
4
2. Measure:
• Inner-rotor-to-outer-rotor-tip clearance “a”
• Outer-rotor-to-oil-pump-housing clearance
3 “b”
• Oil-pump-housing-to-inner-rotor-and-outer-
rotor clearance “c”
5 Out of specification  Replace the oil pump.
Inner-rotor-to-outer-rotor-tip
EAM30134
clearance
CHECKING THE PRIMARY DRIVE GEAR, 0.000–0.150 mm (0.0000–0.0059
BALANCER DRIVE GEAR, AND BALANCER in)
Oil-pump-housing-to-inner-and-
WEIGHT GEAR
outer-rotor clearance
1. Check: 0.06–0.11 mm (0.0024–0.0043 in)
• Primary drive gear “1” Limit
• Balancer drive gear “2” 0.18 mm (0.0071 in)
• Balancer weight gear “3”
5-54
TIP
b Apply the engine oil on the outer rotor.
1
1
a E
2
3. Install:
• Oil pump cover “1”
3 • Oil pump cover screw “2”
c
Oil pump cover screw
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
T.
R.
2
1
1. Inner rotor
2. Outer rotor
3. Oil pump housing
3. Check:
• Oil pump operation
Rough movement  Repeat steps (1) and
(2) or replace the defective part(s).
EAM30137
EAM30138
ASSEMBLING THE OIL PUMP
INSTALLING THE OIL PUMP AND
1. Install:
BALANCER GEAR
• Oil pump drive shaft “1”
1. Install:
• Inner rotor “2”
• Oil pump assembly “1”
• Oil pump assembly bolt “2”
TIP
• Apply the engine oil on the oil pump drive shaft Oil pump assembly bolt
and inner rotor. 5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
LOCTITE®
R.
• Fit the dowel pin into the groove in the inner ro-
tor.
1
2
3
LT
1
2
ECA13890
2. Install: NOTICE
• Outer rotor “1” After tightening the bolts, make sure the oil
5-55
pump turns smoothly. • Lock washer “8” New

2. Install: • Balancer nut “9”
• Balancer weight gear “1” Balancer nut
TIP 45 N·m (4.5 kgf·m, 33 lb·ft)
T.
Install the balancer weight gear and balancer
R.
shaft with their lower splines “a” aligning with TIP
each other. • Apply engine oil to the contact surface and
threaded portion of the primary drive gear nut.
• Apply engine oil to the contact surfaces of the
conical washer.
• Place an aluminum plate “a” between the teeth
of the balancer drive gear “10” and balancer
1 weight gear “11”.
• Install the conical washer with its convex sur-
LT
ac face “b” outward.
4 11
3. Install: 10 1
• Balancer drive gear “1”
TIP 2
• Align the punched mark “a” on the balancer
drive gear with the punched mark “b” on the
balancer weight gear. a
• Install the balancer drive gear and crankshaft
with the lower splines “c” aligning with each
other. 5
4 a
1 a b 10
11
3
3 b
c
E
4. Install:
• Lock washer “1” New
• Balancer weight gear nut “2” 9
Balancer weight gear nut 8
50 N·m (5.0 kgf·m, 37 lb·ft) 7
6
T.
R.
• Primary drive gear “3”

• Conical washer “4” New
• Primary drive gear nut “5”
5. Bend the lock washer tab.
Primary drive gear nut
80 N·m (8.0 kgf·m, 59 lb·ft)
T.
R.
• Straight key “6”

• Balancer “7”
5-56
AC MAGNETO
EAM20158
AC MAGNETO
Removing the AC magneto
1 10
2
10 N・m (1.0 kgf・m, 7.4 lb・ft)
12 N・m (1.2 kgf・m, 8.9 lb・ft)
3
LT
(3) 8
6 7
5
LT 4
(2)
LT
9
10 N・m (1.0 kgf・m, 7.4 lb・ft)
8 N・m (0.8 kgf・m, 5.9 lb・ft)
65 N・m (6.5 kgf・m, 48 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)

Drain.
page 3-14.
Seat 4-1.
Air scoop (left) 4-1.
1 AC magneto coupler 1 Disconnect.
2 Crankshaft position sensor coupler 1 Disconnect.
3 Shift pedal 1
4 Crankcase cover (left) 1
5 Gasket 1
6 Dowel pin 2
7 Holder 1
8 Stator assembly 1
9 Rotor 1
10 Woodruff key 1
5-57
AC MAGNETO
EAM30375 EAM30377
REMOVING THE AC MAGNETO CHECKING THE WOODRUFF KEY

1. Remove: 1. Check:
• Nut (rotor) “1” • Woodruff key “1”
• Washer Damage  Replace.
2. Remove: EAM30378
• Rotor “1” INSTALLING THE AC MAGNETO

Use the rotor puller “2” to remove the rotor. 1. Install:
• Woodruff key • Stator “1”
• Screw (stator) “2”
Rotor puller
90890-04151 Screw (stator)
Rotor puller
T.
10 N·m (1.0 kgf·m, 7.4 lb·ft)
YM-04151 LOCTITE®
R.
• Crankshaft position sensor “3”

1 • Bolt (crankshaft position sensor) “4”
• Holder
• Bolt (holder)
Bolt (crankshaft position sensor)
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
LOCTITE®
R.
Holder
2 8 N·m (0.8 kgf·m, 5.9 lb·ft)
LOCTITE®
EAM30376
CHECKING THE AC MAGNETO TIP

1. Check: • Apply the sealant to the grommet of the AC
• Rotor “1” inner surface “a” magneto lead.
• Stator “2” outer surface “b” • Tighten the stator coil screws using the T25 bit.
Damage  Inspect the crankshaft runout and • Pass the AC magneto lead through the crank-
crankshaft bearing. case cover side.
b Yamaha bond No. 1215

2
1 90890-85505
5-58
AC MAGNETO
• Lead holder “4”

• Bolt (left crankcase cover) “5”
LT Bolt (left crankcase cover)

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
2 TIP
4 Tighten the bolts in stages and in a crisscross
1 3 pattern.
4
1
2. Install:
3 5
• Woodruff key “1”
• Rotor “2”
TIP
• Clean the contact surfaces of the tapered por-
tions of the crankshaft and rotor. 4
• When installing the woodruff key, make sure 2 5
1 5
that its flat surface “a” is in parallel with the 4
5 5
crankshaft center line “b”.
• When installing the rotor, align the keyway “c” 5. Connect:
of the rotor with the woodruff key. • AC magneto lead
Refer to “CABLE ROUTING DIAGRAM” on
page 2-31.
1
b 1 a
c
2
3. Install:
• Washer
• Nut (rotor) “1”
Nut (rotor)
65 N·m (6.5 kgf·m, 48 lb·ft)
T.
R.
4. Install:
• Gasket (left crankcase cover) “2” New
• Crankcase cover (left) “3”
5-59
STARTER CLUTCH
EAM20175
STARTER CLUTCH
Removing the starter clutch
3
2
1
LT
12 N・m (1.2 kgf・m, 8.9 lb・ft)

Refer to “CHANGING THE ENGINE OIL” on
Engine oil page 3-14.
Clutch Refer to “CLUTCH” on page 5-40.
1 Holder 1
2 Washer 1
3 Damper assembly 1
4 Starter clutch assembly 1
5-60
STARTER CLUTCH
EAM30140
CHECKING THE STARTER CLUTCH

1. Check:
• Starter clutch assembly
• Starter clutch drive gear
Burrs/chips/roughness/wear  Replace the
starter clutch.
2. Check:
• Starter clutch assembly gear
Damage/pitting/wear  Replace the starter
clutch assembly.
3. Check:
• Starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch drive gear “1” onto
the starter clutch and hold the starter clutch.
b. When turning the starter clutch drive gear
counterclockwise “A”, it should turn freely,
otherwise the starter clutch is faulty and must
be replaced.
c. When turning the starter clutch drive gear
clockwise “B”, the starter clutch and the start-
er clutch drive gear should engage, otherwise
the starter clutch is faulty and must be re-
placed.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-61
CRANKCASE
EAM20116
CRANKCASE
Separating the crankcase
5 6 5 10 N・m (1.0 kgf・m, 7.4 lb・ft)

5
LT
11
6
7
9
4 4
4 10
12 N・m (1.2 kgf・m, 8.9 lb・ft)

8
5
(4)
3
1
2 9
4
(3) 6
(5)
LT
12 N・m (1.2 kgf・m, 8.9 lb・ft)

Engine Refer to “ENGINE REMOVAL” on page 5-1.
Refer to “CYLINDER AND PISTON” on page
Piston 5-31.
Refer to “OIL PUMP AND BALANCER
Balancer GEAR” on page 5-52.
Segment Refer to “SHIFT SHAFT” on page 5-48.
Stator Refer to “AC MAGNETO” on page 5-57.
1 Timing chain guide (exhaust side) 1
2 Timing chain guide stopper plate 1
3 Timing chain 1
4 Bolt [L = 45 mm (1.77 in)] 5
5 Bolt [L = 60 mm (2.36 in)] 4
6 Bolt [L = 75 mm (2.95 in)] 3
7 Right crankcase 1
8 Left crankcase 1
9 Dowel pin 2
10 Crankshaft 1
11 Oil nozzle 1
5-62
CRANKCASE
Removing the bearing and oil seal

12 N・m (1.2 kgf・m, 8.9 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)
LT
1 2 LT
2
3 3
E
3 E 3
3
3
E
3
E
LT
3
E
E
22 N・m (2.2 kgf・m, 16 lb・ft)
3
LT
3 3
LT
12 N・m (1.2 kgf・m, 8.9 lb・ft) E E

Transmission Refer to “TRANSMISSION” on page 5-70.
Shift cam and shift fork Refer to “TRANSMISSION” on page 5-70.
1 Circlip 1
2 Oil seal 3
3 Bearing 11
5-63
CRANKCASE
EAM30147
DISASSEMBLING THE CRANKCASE

1. Separate:
• Right crankcase
• Left crankcase
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the crankcase bolts.
a
c. Remove the dowel pins and O-ring.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAM30148
REMOVING THE CRANKCASE BEARING

1. Remove:
• Bearing “1”
TIP TIP
Loosen each bolt 1/4 of a turn at a time and after • Remove the bearing from the crankcase by
all the bolts are loosened, remove them. pressing its inner race.
• Do not use the removed bearing.
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.
ECA24690
NOTICE EAM30149
Use soft hammer to tap on the case half. Tap CHECKING THE TIMING CHAIN, TIMING
only on reinforced portions of case. Do not CHAIN GUIDE, OIL STRAINER
tap on gasket mating surface. Work slowly 1. Check:
and carefully. Make sure the case halves • Timing chain
separate evenly. If the cases do not separate, Stiffness  Replace the camshaft sprocket,
check for a remaining case bolt or fitting. Do timing chain and crankshaft sprocket as a
not force. set.
2. Check:
• Timing chain guide
EAM30150
1 CHECKING THE CRANKCASE
1. Wash:
• Crankcase
TIP
• Wash the crankcase in a mild solvent.
• Remove any remaining gasket from the crank-
case mating surface.
5-64
CRANKCASE
2. Check:
• Crankcase
• Oil delivery passages
Obstruction  Blow out with compressed air.
EAM30151
INSTALLING THE OIL SEAL

1. Install:
(to left crankcase)
Installed depth “a” 3. Install:
0.0–0.5 mm (0.00–0.02 in) • Oil nozzle “1”
Oil nozzle
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
1 LOCTITE®
R.
• Crankcase “3”
(to the left crankcase)
Crankcase bolt
a 12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
TIP
EAM30152
• Apply the lithium-soap-based grease on the O-
ASSEMBLING THE CRANKCASE ring.
1. Install: • Fit the right crankcase onto the left crankcase.
• Bearing cover plate Tap lightly on the case with soft hammer.
Bearing cover plate • When installing the crankcase, the connecting
12 N·m (1.2 kgf·m, 8.9 lb·ft) rod should be positioned at top dead center
T.
LOCTITE® (TDC).
R.
Bearing cover plate (crankshaft) • Tighten the bolts in a crisscross pattern in two
22 N·m (2.2 kgf·m, 16 lb·ft) stages, with 1/4 turn each.
LOCTITE®
TIP
Install the bearing by pressing its outer race par-
allel.
2. Apply:
• Sealant
(to the crankcase mating surface)
90890-85505
5-65
CRANKCASE
LT 1
5 3
2
4
6
5 6 5
5
6
4
4 4
4. 45 mm (1.77 in)
5. 60 mm (2.36 in)
6. 75 mm (2.95 in)
5-66
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT
EAM20117

Removing the crankshaft assembly and balancer shaft

Separate.
Crankcase Refer to “CRANKCASE” on page 5-62.
Transmission Refer to “TRANSMISSION” on page 5-70.
1 Balancer shaft 1
2 Crankshaft assembly 1
5-67
EAM30143 EAM30145
REMOVING THE BALANCER SHAFT CHECKING THE CRANKSHAFT ASSEMBLY

1. Remove: 1. Measure:
• Balancer shaft “1” • Crankshaft runout
TIP Out of specification  Replace the crank-
Remove the balancer shaft with its flat side “a” shaft, bearing or both.
facing the crankshaft. TIP
Turn the crankshaft slowly.
Runout limit
1 0.030 mm (0.0012 in)
EAM30144
REMOVING THE CRANKSHAFT ASSEMBLY

1. Remove:
• Crankshaft assembly “1”
TIP
2. Measure:
Remove the crankshaft assembly by using the
• Crank assembly width “a”
crankcase separating tool “2”.
Out of specification  Replace the crank-
shaft.
Crankcase separating tool
90890-04152 Crank assembly width
Crankcase separating tool 61.93–62.00 mm (2.438–2.441 in)
YU-A9642
1
3. Check:
• Crankshaft sprocket “1”
Damage  Replace the crankshaft.
5-68
4. Check:
• Crankshaft journal oil passage
Obstruction  Blow out with compressed air.
EAM30146
INSTALLING THE CRANKSHAFT 4

ASSEMBLY 3
1. Install: 1
• Crankshaft assembly 2
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

M
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.
5-69
TRANSMISSION
EAM20118
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
LS
M
2
10
M
M 9
8
7
1 M
5
3 E
4
FW
5 6 D
E
E E

Engine Refer to “ENGINE REMOVAL” on page 5-1.
Separate.
Crankcase Refer to “CRANKCASE” on page 5-62.
1 Main axle 1
2 Drive axle 1
3 Long shift fork guide bar 1
4 Short shift fork guide bar 1
5 Spring 4
6 Shift cam 1
7 Shift fork 3 (R) 1
8 Shift fork 2 (C) 1
9 Shift fork 1 (L) 1
10 Collar 1
5-70
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 “4”
• 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
soft hammer.
2
5
1
6
3. Check:
3 • Shift fork movement
(along the shift fork guide bar)
9 Rough movement  Replace the shift forks
and shift fork guide bar as a set.
EAM30154
CHECKING THE SHIFT FORKS

1. Check:
• Shift fork cam follower “1” EAM30155
• Shift fork pawl “2” CHECKING THE SHIFT DRUM ASSEMBLY

Bends/damage/scoring/wear  Replace the 1. Check:
shift fork. • Shift drum groove
Damage/scratches/wear  Replace the shift
drum assembly.
• Shift drum segment
Damage/wear  Replace the shift drum as-
sembly.
5-71
TRANSMISSION
EAM30156
• 3rd pinion gear (16T) “2”
CHECKING THE TRANSMISSION • Collar “3”
1. Measure: • 4th pinion gear (20T) “4”
• Main axle runout • 2nd pinion gear (15T) “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
M
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”
Drive axle runout limit • 4th wheel gear (21T) “3”
0.08 mm (0.0032 in) • 3rd wheel gear (21T) “4”
• 5th wheel gear (21T) “5”
• Collar “6”
• 1st wheel gear (29T) “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-
3. Check: ring.
• Transmission gears
8
Blue discoloration/pitting/wear  Replace
LS
1 9
the defective gear(s). 2
3
• Transmission gear dogs 5 4
Cracks/damage/rounded edges  Replace 76 New
the defective gear(s).
4. Check:
• Transmission gear movement M
Rough movement  Replace the defective

gear(s). M M
EAM30157
3. Install:
INSTALLING THE TRANSMISSION • Washer “1”
1. Install: • Circlip “2” New
• 5th pinion gear (25T) “1”
5-72
TRANSMISSION
TIP axle bearing.

• Be sure the circlip sharp-edged corner “a” is
positioned opposite side to the washer and
1
gear “b”.
• Install the circlip with its ends “c” settled evenly
on the spline crests.
2
1 b E
2
6. Install:
• Shift fork 1 (L) “1”
2 • Shift fork 2 (C) “2”
a
• Shift fork 3 (R) “3”
• Shift cam “4”
(to the main axle and the drive axle)
TIP
c c • Apply engine oil to the shift fork grooves.
• Apply engine oil to the shift cam groove and the
bearing contact surface.
• Mesh the shift fork 1 (L) with the 4th wheel gear
“5” and 3 (R) with the 5th wheel gear “7” on the
drive axle.
• Mesh the shift fork 2 (C) with the 3rd pinion
gear “6” on the main axle.
4. Install:
• Collar “1” 3
TIP
seal lip.
2
• When installing the collar into the crankcase,
pay careful attention to the crankcase oil seal
lip.
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
5-73
TRANSMISSION
7
E
5 E
2 1
4
E
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.
3
E
1 2
8. Check:
• Operation of shift cam and shift fork
• Transmission operation
Unsmooth operation  Repair.
5-74
TRANSMISSION
5-75
COOLING SYSTEM
RADIATOR........................................................................................................6-1
HANDLING NOTE ......................................................................................6-3
CHECKING THE RADIATOR .....................................................................6-3
WATER PUMP ..................................................................................................6-4

1
REMOVING THE OIL SEAL .......................................................................6-5
2
CHECKING THE WATER PUMP ...............................................................6-5
CHECKING THE BEARING .......................................................................6-5
INSTALLING THE OIL SEAL......................................................................6-5
ASSEMBLING THE WATER PUMP ...........................................................6-5
3
4
5
6
7
8
9
10
RADIATOR
EAM20138
RADIATOR
Removing the radiator
8 N・m (0.8 kgf・m, 5.9 lb・ft)
3 10 N・m (1.0 kgf・m, 7.4 lb・ft)
2 5 2 10
15 N・m (1.5 kgf・m, 11 lb・ft)
1.5 N・m (0.15 kgf・m, 1.1 lb・ft) 9
7 1
4
2
1 2 1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
8 2
2
6
2 10 N・m (1.0 kgf・m, 7.4 lb・ft)

11 LS
13
2 New
New
LS
12
New
10 N・m (1.0 kgf・m, 7.4 lb・ft)

Drain.
page 3-6.
Seat 4-1.
Air filter case Refer to “THROTTLE BODY” on page 7-5.
1 Radiator guard 2
2 Radiator hose clamp 8 Loosen.
3 Radiator fan 1 For JPN
4 Radiator (right) 1
5 Radiator hose 2 1
6 Radiator hose 4 1
7 Radiator hose 3 1
8 Radiator pipe 2 1
9 Radiator breather hose 1
6-1
RADIATOR
Removing the radiator

8 N・m (0.8 kgf・m, 5.9 lb・ft)
3 10 N・m (1.0 kgf・m, 7.4 lb・ft)
2 5 2 10
15 N・m (1.5 kgf・m, 11 lb・ft)
1.5 N・m (0.15 kgf・m, 1.1 lb・ft) 9
7 1
4
2
1 2 1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
8 2
2
6
2 10 N・m (1.0 kgf・m, 7.4 lb・ft)

11 LS
13
2 New
New
LS
12
New
10 N・m (1.0 kgf・m, 7.4 lb・ft)

10 Radiator (left) 1
11 Radiator hose 1 1
12 Radiator pipe 1 1
13 Coolant temperature sensor 1
6-2
RADIATOR
EAM30257
HANDLING NOTE
EWA19360
WARNING
If coolant seems hot, do not remove the radi-
ator cap.
EAM30341
CHECKING THE RADIATOR

1. Check:
• Radiator fins “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.
2. Check:
• Radiator hoses
• Radiator pipes
6-3
WATER PUMP
EAM20139
WATER PUMP
Removing the water pump
4
5
8
3
10 N・m (1.0 kgf・m, 7.4 lb・ft)
1 9
E
2
LS
2
7
LS
6
E
10 N・m (1.0 kgf・m, 7.4 lb・ft)

Drain.
page 3-6.
Drain.
page 3-14.
1 Water pump housing 1
2 Dowel pin 2
3 Gasket 1
4 Collar 1
5 Pin 1
6 Impeller shaft assembly 1
7 Oil seal 1
8 Bearing 1
9 Oil seal 1
6-4
WATER PUMP
EAM30258
REMOVING THE OIL SEAL 1

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. Remove:
• Oil seal “1” 1
2. Install:
• Bearing “1”
TIP
Install the bearing by pressing its outer race par-
1 allel.
EAM30259
CHECKING THE WATER PUMP

1. Check:
• Water pump housing cover 1
• Impeller shaft
EAM30262
EAM30260
CHECKING THE BEARING ASSEMBLING THE WATER PUMP

• Bearing • Impeller shaft assembly “1”
Rotate the inner race with your finger. • Pin “2”
Rough spot/seizure  Replace. • Collar “3”
TIP
• Take care so that the oil seal lip is not dam-
aged or the spring does not slip off its position.
• When installing the impeller shaft, apply the
engine oil to the oil seal lip, the bearing, and the
impeller shaft.
2 3
4
EAM30261
INSTALLING THE OIL SEAL

1. Install:
TIP 1
• Apply the lithium-soap-based grease on the oil E
seal lip.
• Install the oil seal with its manufacture’s marks 2. Install:
or numbers facing the right crankcase cover. • Dowel pin “1”
• Gasket “2” New
6-5
WATER PUMP
1
1
2
3. Install:
• Water pump housing “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.
2
2
4 3
6-6
WATER PUMP
6-7
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
INSTALLING THE FUEL PUMP .................................................................7-2
1
INSTALLING THE FUEL TANK ..................................................................7-3
CHECKING THE FUEL PRESSURE..........................................................7-3
CHECKING THE DAMPER ........................................................................7-4
2
THROTTLE BODY ............................................................................................7-5
CHECKING THE INJECTOR......................................................................7-8
3
CHECKING THE THROTTLE BODY .........................................................7-8
CHECKING THE THROTTLE BODY JOINT ..............................................7-8
ADJUSTING THE THROTTLE POSITION SENSOR .................................7-9
4
5
6
7
8
9
10
FUEL TANK
EAM20140
FUEL TANK
Removing the fuel tank
7 N・m (0.7 kgf・m, 5.2 lb・ft)
4.0 N・m (0.40 kgf・m, 3.0 lb・ft) 7

5
6
4
(2)
2
3
1
(2)
(5)
1
7 N・m (0.7 kgf・m, 5.2 lb・ft)
8
7 N・m (0.7 kgf・m, 5.2 lb・ft)

Seat 4-1.
Side cover (left/right)
Air scoop (left/right)
1 Fuel pump coupler/Fuel hose 1/1 Disconnect.
2 Fuel tank 1
3 Fuel pump bracket 1
4 Fuel pump 1
5 Fuel filter 1
6 Thermistor cover 1
7 Fuel pump gasket 1
8 Rubber damper 4
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:
• Fuel hose coupler
EWA19370
WARNING
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.
ECA26520
NOTICE
• Make sure that the fuel hose is disconnect-
ed by hand. Do not forcefully disconnect 4
the hose with tools. 3
• When removing the fuel tank, handle it
carefully. If the discharge port of the fuel
pump touches the ground or other objects,
the discharge port could be damaged.
TIP 3. Remove:
• To disconnect the fuel hose from the fuel tank, • Side cover (left/right)
remove the fuel hose connector holder “a”, and • Seat
then slide the fuel hose connector cover. • Air scoop (left/right)
• To remove the fuel hose from the fuel rail, slide • Fuel tank
the fuel hose connector cover “1” on the end of TIP
the hose in the direction of the arrow shown, Do not set the fuel tank down on the installation
press the two buttons “2” on the sides of the surface of the fuel pump. Be sure to lean the fuel
connector, and then remove the hose. tank against a wall or the like.
• Before removing the hose, place a few cloths
in the area under where it will be removed. EAM30264
• To prevent sand, dust, and other foreign mate- REMOVING THE FUEL PUMP
rials from entering the fuel pump, install the in- 1. Remove:
cluded fuel hose joint cover 1 “3” and the fuel • Fuel pump
ECA24720
hose joint cover 2 “4” onto the disconnected NOTICE
fuel hose and the fuel pump.
Do not drop the fuel pump or give it a strong
shock.
EAM30265
CHECKING THE FUEL PUMP BODY

1. Check:
• Fuel pump body
a Obstructions  Clean.
Cracks/damage  Replace the fuel pump
assembly.
EAM30266
INSTALLING THE FUEL PUMP

1. Install:
• Fuel pump gasket New
• Fuel filter New
• Fuel pump
7-2
FUEL TANK
• Fuel pump bracket • Install the fuel hose connector holder “a”.
• Check that the fuel hose and the fuel pump
Fuel pump bolt lead are routed through the guide on the cover.
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
TIP
• Take care not to damage the installation sur-
faces of the fuel tank. 1
• 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
2 4 4. Install:
• Seat
5 1 EAM30268
CHECKING THE FUEL PRESSURE

1. Check:
3
• Fuel pressure
EAM30267 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
INSTALLING THE FUEL TANK a. Remove the side cover (left/right), the seat
1. Install: and the air scoop (left/right).
• Fuel tank Refer to “GENERAL CHASSIS” on page 4-1.
2. Connect: b. Remove the fuel tank bolt and lift the fuel
• Fuel hose tank.
ECA24740
c. Disconnect the fuel hose from the fuel pump.
NOTICE
Refer to “REMOVING THE FUEL TANK” on
• Connect the fuel hose securely, and check page 7-2.
that the orientation of the installed fuel EWA19380
hose holder is correct. WARNING

• Take care not to kink or pinch the fuel hose. Cover the fuel hose connection with a cloth
TIP when disconnecting it. This is because re-
• Insert the fuel hose into the fuel pipe securely sidual pressure in the fuel hose could cause
until you hear a “click”. fuel to spurt out when the hose is removed.
• Slide the fuel hose connector cover “1” at the
hose end in the direction of the arrow.
7-3
FUEL TANK
ECA24750
NOTICE 84 mm 115
73 108 mm 3
(3.31 in) (4.53
(2.87 (4.25 in)
Make sure that the fuel hose is disconnected
by hand. Do not forcibly disconnect the hose
with tools. 1
a
d. Connect the pressure gauge “1” and the fuel 2
pressure adapter “2” to the fuel hose.
Pressure gauge 73 mm 115
84 108 mm
90890-03153 1 (2.87 in) (4.53
(3.31 (4.25 in) 3
Pressure gauge
YU-03153
90890-03186
YM-03186
e. Start the engine.

f. Measure the fuel line pressure.
Out of specification  Replace the fuel
pump.
Fuel line pressure (at idle)
300–390 kPa (3.0–3.9 kgf/cm²,
43.5–56.6 psi)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAM30269
CHECKING THE DAMPER

1. Check:
• Damper 1 “1”
TIP
• Affix dampers 1 and 3 with the arrow on each
damper pointing outward.
• Affix the damper 2 with its projection “a” facing
the rear of the vehicle.
7-4
THROTTLE BODY
EAM20141
THROTTLE BODY
Removing the throttle body
3.8 N・m (0.38 kgf・m, 2.8 lb・ft)
7 N・m (0.7 kgf・m, 5.2 lb・ft)
3 5
11 1
(2)
(2)
3.0 N・m (0.30 kgf・m, 2.2 lb・ft) 8 N・m (0.8 kgf・m, 5.9 lb・ft)
(2)
9
8 7
4.0 N・m (0.40 kgf・m, 3.0 lb・ft)
2
11
4 6
10
12
14
13
15
3.0 N・m (0.30 kgf・m, 2.2 lb・ft)

10 N・m (1.0 kgf・m, 7.4 lb・ft)

Seat/Air filter case cover 4-1.
1 ECU 1
2 Ignition coil 1
3 Intake air temperature sensor coupler 1 Disconnect.
4 Breather hose 1
5 Air filter case 1
6 Fuel injector coupler 1 Disconnect.
7 Intake air pressure sensor coupler 1 Disconnect.
8 Throttle position sensor coupler 1 Disconnect.
9 Cover 1
10 Throttle cable cover 1
7-5
THROTTLE BODY
Removing the throttle body

3.8 N・m (0.38 kgf・m, 2.8 lb・ft)
7 N・m (0.7 kgf・m, 5.2 lb・ft)
3 5
11 1
(2)
(2)
(2)
9
8 7
4.0 N・m (0.40 kgf・m, 3.0 lb・ft)
2
11
4 6
10
12
14
13
15
3.0 N・m (0.30 kgf・m, 2.2 lb・ft)

10 N・m (1.0 kgf・m, 7.4 lb・ft)

Install the throttle body so that the paint
marks on the fixed nuts of the throttle cables
11 Throttle cable 2 face to the outside of the vehicle, and then
install the cover.
12 Fuel hose 1
13 Throttle body 1
14 Exhaust pipe bracket 1
15 Throttle body joint 1
7-6
THROTTLE BODY
Removing the injector
3.5 N・m (0.35 kgf・m, 2.6 lb・ft) (2)
5
2
3.5 N・m (0.35 kgf・m, 2.6 lb・ft)

1 Fuel inlet pipe 1
2 Injector 1
3 Gasket 1
4 Throttle position sensor 1
5 Intake air pressure sensor 1
7-7
THROTTLE BODY
EAM30271
CHECKING THE INJECTOR

1. Check:
• Injectors
Obstruction  Replace, and check the fuel
pump and the fuel injection system. 2
1
Refer to “FUEL INJECTION SYSTEM” on
page 8-21.
Deposits  Replace.
Damage  Replace.
2. Check:
• Injector resistance
Refer to “CHECKING THE FUEL INJEC-
TOR” on page 8-68.
EAM30272
CHECKING THE THROTTLE BODY

1. Check:
• Throttle body
Cracks/damage  Replace.
2. Check: 3
• Fuel passages
Obstructions  Clean.
ECA26070
b
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.
• If the throttle body is subject to strong
shocks or dropped during cleaning, re- 4
place it.
• Do not use any caustic carburetor cleaning
solution. 3. Check:
• Do not directly push the throttle valves to • Idle screw “1” passage “c”
open them. Obstruction  Blow out with compressed air.
• Do not loosen the throttle valve stopper
screw “1”, throttle valve pulley nut “2”,
throttle valve screw “3” or starter knob nut
“4”. A loss of performance may occur.
• Do not use compressed air to clean the
throttle body. Foreign materials may ad- 1
here to the intake air pressure sensor pas-
sage “a” and fuel injector “b” in the throttle
body. c
EAM30345
CHECKING THE THROTTLE BODY JOINT

1. Check:
• Throttle body joint “1”
7-8
THROTTLE BODY
h. After adjusting the throttle position sensor

mounted angle, tighten the throttle position
sensor screws “1”.
Throttle position sensor screw
3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
R.
1
EAM30273
ADJUSTING THE THROTTLE POSITION

SENSOR
EWA15950
WARNING
• Handle the throttle position sensor with 1
special care.
• Never subject the throttle position sensor ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
to strong shocks. If the throttle position

sensor is dropped, replace it.
1. Check:
• Throttle position sensor
Refer to “CHECKING THE THROTTLE PO-
SITION SENSOR INPUT VOLTAGE” on
page 8-67.
2. Adjust:
• Throttle position sensor angle
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the Yamaha diagnostic tool.
Refer to “YAMAHA DIAGNOSTIC TOOL” on
page 8-25.
90890-03257
90890-03262
90890-03212
YU-03212
90890-03249
b. Temporary tighten the throttle position sen-

sor.
c. Check that the throttle grip is fully closed.
d. Connect the throttle position sensor to the
wire harness.
e. Set the Yamaha diagnostic tool to “diagnostic
mode”.
f. Choose the diagnostic code No. “01”.
g. Adjust the throttle position sensor mounted
angle until “11”–“14” appears on the Yamaha
diagnostic tool.
7-9
ELECTRICAL SYSTEM
IGNITION SYSTEM...........................................................................................8-1
CIRCUIT DIAGRAM ...................................................................................8-1
TROUBLESHOOTING................................................................................8-3
ELECTRIC STARTING SYSTEM......................................................................8-5

1
CIRCUIT DIAGRAM ...................................................................................8-5
2
TROUBLESHOOTING................................................................................8-7
CHARGING SYSTEM .......................................................................................8-9

CIRCUIT DIAGRAM ...................................................................................8-9
TROUBLESHOOTING..............................................................................8-11
SIGNALING SYSTEM.....................................................................................8-13
3
CIRCUIT DIAGRAM .................................................................................8-13
COOLING SYSTEM (For JPN).......................................................................8-17

4
CIRCUIT DIAGRAM .................................................................................8-17
FUEL INJECTION SYSTEM ...........................................................................8-21

CIRCUIT DIAGRAM .................................................................................8-21
5
ECU SELF-DIAGNOSTIC FUNCTION .....................................................8-23
6
TROUBLESHOOTING METHOD .............................................................8-24
YAMAHA DIAGNOSTIC TOOL ................................................................8-25
FEATURES OF THE YAMAHA DIAGNOSTIC TOOL ..............................8-26
FUNCTIONS OF THE YAMAHA DIAGNOSTIC TOOL ............................8-26
CONNECTING THE YAMAHA DIAGNOSTIC TOOL ...............................8-26
7
TROUBLESHOOTING DETAILS (FAULT CODE)....................................8-28
FUEL PUMP SYSTEM....................................................................................8-47

CIRCUIT DIAGRAM .................................................................................8-47
8
ELECTRICAL COMPONENTS.......................................................................8-51
CHECKING THE SWITCHES...................................................................8-55
CHECKING THE BULBS AND BULB SOCKETS.....................................8-58
CHECKING THE FUSES..........................................................................8-58
CHECKING AND CHARGING THE BATTERY ........................................8-59
CHECKING THE RELAYS .......................................................................8-61
9
CHECKING THE DIODE ..........................................................................8-61
10
CHECKING THE IGNITION SPARK GAP ................................................8-62
CHECKING THE SPARK PLUG CAP ......................................................8-62
CHECKING THE IGNITION COIL ............................................................8-63
CHECKING THE CRANKSHAFT POSITION SENSOR ...........................8-63
CHECKING THE ECU ..............................................................................8-64
CHECKING THE STARTER MOTOR OPERATION ................................8-64
CHECKING THE STATOR COIL..............................................................8-64
CHECKING THE RECTIFIER/REGULATOR ...........................................8-65
CHECKING THE FUEL SENDER ............................................................8-65
CHECKING THE RESISTOR ...................................................................8-65
CHECKING THE RADIATOR FAN MOTOR (For JPN) ............................8-66
CHECKING THE COOLANT TEMPERATURE SENSOR ........................8-66
CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE...8-67
CHECKING THE INTAKE AIR TEMPERATURE SENSOR .....................8-67
CHECKING THE GEAR POSITION SWITCH ..........................................8-68
CHECKING THE FUEL INJECTOR .........................................................8-68
IGNITION SYSTEM
EAM20142
IGNITION SYSTEM
EAM30277
CIRCUIT DIAGRAM
8-1
IGNITION SYSTEM
1. Crankshaft position sensor

2. AC magneto
3. Rectifier/regulator
4. Joint connector
6. Engine ground
7. Battery
8. Frame ground
9. Main fuse
10.Starter relay
11.Starter motor
12.Diode 1
13.Diode 2
14.CCU (Communication Control Unit)
21.ECU (Engine Control Unit)
22.Ignition coil
23.Spark plug
33.Engine stop switch
34.Gear position switch
35.Mode switch
A. Battery sub-lead
B. Wire harness
C. Ignition coil sub-lead
D. CCU sub-lead
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. Side cover (left/right)
2. Seat
3. Fuel tank
4. Air scoop (left/right)
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 8-58. 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 8-59.
OK
4. Check the spark plug.
Refer to “CHECKING THE SPARK Correct or replace the spark plug.
PLUG” on page 3-36. NG
OK
5. Check the ignition spark gap.
Refer to “CHECKING THE IGNI- The ignition system circuit is OK.
TION SPARK GAP” on page 8-62. OK
NG
6. Check the ignition coil.
Refer to “CHECKING THE IGNI- Replace the ignition coil.
TION COIL” on page 8-63. NG
OK
7. Check the engine stop switch.
Refer to “CHECKING THE Replace the engine stop switch.
SWITCHES” on page 8-55. 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 8-63.
OK
8-3
IGNITION SYSTEM
9. Check the stator coil.

Refer to “CHECKING THE STA- Replace the stator coil.
TOR COIL” on page 8-64. 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 mode switch to blink.
TIP
1. Seat
2. Air scoop (left)
1. Check the mode switch coupler

Reconnect.
connections. NG
OK
2. Check the mode switch.
Refer to “CHECKING THE Replace the mode switch.
OK
3. Check the ignition system wire har-
ness.
page 8-1.
OK
Replace the ECU.
8-4
ELECTRIC STARTING SYSTEM
EAM20143

EAM30279
CIRCUIT DIAGRAM
8-5
4. Joint connector
5. Main relay
6. Engine ground
7. Battery
8. Frame ground
9. Main fuse
10.Starter relay
11.Starter motor
12.Diode 1
13.Diode 2
36.Start switch
37.Diode 3
A. Battery sub-lead
B. Wire harness
8-6
EAM30281
TROUBLESHOOTING
The starter motor fails to turn.
TIP
1. Seat
4. Fuel tank
1. Check the fuse.

on page 8-58. NG
OK
page 8-59.
OK
3. Check the main relay.
Refer to “CHECKING THE RE- Replace the main relay.
LAYS” on page 8-61. NG
OK
4. 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).
8-64.
NG
5. Check the starter motor.
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-38. NG
OK
6. Check the diodes.
(Diode 1, diode 2, diode 3)
Replace the diodes.
Refer to “CHECKING THE DIODE” NG
on page 8-61.
OK
7. Check the starter relay.
Refer to “CHECKING THE RE- Replace the starter relay.
OK
OK
8-7
9. Check the start switch.

Refer to “CHECKING THE Replace the start switch.
OK
10.Check the entire starting system’s
wiring. Properly connect or repair the starting sys-
Refer to “CIRCUIT DIAGRAM” on NG tem’s wiring.
page 8-5.
OK
Replace the ECU.
8-8
CHARGING SYSTEM
EAM20144
CHARGING SYSTEM
EAM30282
CIRCUIT DIAGRAM
8-9
CHARGING SYSTEM
2. AC magneto
6. Engine ground
7. Battery
8. Frame ground
9. Main fuse
A. Battery sub-lead
B. Wire harness
8-10
CHARGING SYSTEM
EAM30283
TROUBLESHOOTING
The battery is not being charged.
TIP
1. Seat
2. Air scoop (left)
1. Check the entire charging system’s

Reconnect.
wiring. NG
OK
2. Check the fuse.
on page 8-58. NG
OK
page 8-59.
OK
4. Check the rectifier/regulator.
Refer to “CHECKING THE RECTI- Replace the rectifier/regulator.
FIER/REGULATOR” on page 8-65. NG
OK
5. Check the stator coil.
Refer to “CHECKING THE STA- Replace the stator coil.
TOR COIL” on page 8-64. NG
OK
6. Check the charging system wire
harness.
page 8-9.
OK
This circuit is OK.
8-11
CHARGING SYSTEM
8-12
SIGNALING SYSTEM
EAM20154
SIGNALING SYSTEM
EAM30348
CIRCUIT DIAGRAM
8-13
SIGNALING SYSTEM
4. Joint connector
5. Main relay
7. Battery
8. Frame ground
9. Main fuse
15.Warning light
16.Fuel level warning light
18.Resistor
19.Fuel sender
A. Battery sub-lead
B. Wire harness
8-14
SIGNALING SYSTEM
EAM30349
TROUBLESHOOTING
• The fuel level warning light does not come on.
TIP
1. Seat
4. Fuel tank
1. Check the fuse.

on page 8-58. NG
OK
page 8-59.
OK
OK
4. Check the entire signaling system’s
wiring. Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on NG system’s wiring.
page 8-13.
OK
This circuit is OK.
Check the signaling system

The fuel level warning light fails to come on.
1. Check the fuel level warning light
bulb and socket.
Replace the fuel level warning light bulb,
Refer to “CHECKING THE BULBS
NG socket or both.
AND BULB SOCKETS” on page
8-58.
OK
2. Check the fuel sender.
Refer to “CHECKING THE FUEL Replace the fuel pump assembly.
SENDER” on page 8-65. NG
OK
3. Check the resistor.
Refer to “CHECKING THE RESIS- Replace the resistor.
TOR” on page 8-65. NG
OK
8-15
SIGNALING SYSTEM
4. Check the entire signaling system’s

wiring. Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on NG system’s wiring.
page 8-13.
OK
Replace the ECU.
8-16
COOLING SYSTEM (For JPN)
EAM20155

EAM30350
CIRCUIT DIAGRAM
8-17
4. Joint connector
5. Main relay
7. Battery
8. Frame ground
9. Main fuse
26.Radiator fan motor fuse
27.Radiator fan motor
28.Radiator fan motor relay
30.Coolant temperature sensor
8-18
EAM30351
TROUBLESHOOTING
The radiator fan motor fails to turn.
TIP
1. Seat
2. Side cover (left)
4. Fuel tank
1. Check the fuse.

on page 8-58. NG
OK
page 8-59.
OK
OK
4. Check the radiator fan motor.
Refer to “CHECKING THE RADIA-
Replace the radiator fan motor.
TOR FAN MOTOR (For JPN)” on NG
page 8-66.
OK
5. Check the radiator fan motor relay.
Refer to “CHECKING THE RE- Replace the radiator fan motor relay.
OK
6. Check the coolant temperature sen-
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR” NG
on page 8-66.
OK
7. Check the entire cooling system’s
wiring. Properly connect or repair the cooling sys-
Refer to “CIRCUIT DIAGRAM” on NG tem’s wiring.
page 8-17.
OK
Replace the ECU.
8-19
8-20
FUEL INJECTION SYSTEM
EAM20145

EAM30284
CIRCUIT DIAGRAM
8-21
1. Crankshaft position sensor

2. AC magneto
4. Joint connector
5. Main relay
6. Engine ground
7. Battery
8. Frame ground
9. Main fuse
10.Starter relay
14.CCU (Communication Control Unit)
15.Warning light
17.Engine trouble warning light
20.Yamaha diagnostic tool coupler
22.Ignition coil
23.Spark plug
24.Fuel injector
25.Fuel pump
26.Radiator fan motor fuse
27.Radiator fan motor (For JPN)
28.Radiator fan motor relay
29.Intake air temperature sensor
30.Coolant temperature sensor
31.Throttle position sensor
32.Intake air pressure sensor
A. Battery sub-lead
B. Wire harness
D. CCU sub-lead
8-22
EAM30352
ECU SELF-DIAGNOSTIC FUNCTION

The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is
operating normally. If this function detects a malfunction in the system, it immediately operates the en-
gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider
that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code
number is stored in the memory of the ECU.
• To inform the rider that the fuel injection system is not functioning, the engine trouble warning light
flashes while the start switch is being pushed to start the engine.
• If a malfunction is detected in the system by the self-diagnostic function, the ECU provides an appro-
priate substitute characteristic operation, and alerts the rider of the detected malfunction by illuminat-
ing the engine trouble warning light.
Engine trouble warning light indication and fuel injection system operation
Warning light indica-
ECU operation Fuel injection operation Vehicle operation
tion
Warning provided when

Flashing* unable to start engine Operation stopped Cannot be operated
Operated with substitute Can or cannot be oper-

characteristics in accor-
Remains on Malfunction detected ated depending on the
dance with the descrip- fault code
tion of the malfunction
* The engine trouble warning light flashes when any one of the following conditions is present and the
start switch is pushed:
12: Crankshaft position sensor 41: Lean angle sensor

(open or short circuit)
Lean angle sensor ECU internal malfunction
30: (latch up detected) 50: (faulty ECU memory)
Ignition coil
33: (Malfunction detected in the primary wire of
the ignition coil)
Checking the engine trouble warning light

The engine trouble warning light comes on for around 2 seconds when pushing the start switch to turn
on the engine trouble warning light comes on while the start switch is being pushed.
a b
c d c
a. Start switch is not being pushed.

b. Start switch is being pushed.
c. Engine trouble warning light goes off
d. Engine trouble warning light comes on for
around 2 seconds
8-23
ECU detects an abnormal signal from a sensor

If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-
nates the engine trouble warning light and provides the engine with alternate operating instructions that
are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue operating or stop operating, depending on the conditions.
EAM30353
TROUBLESHOOTING METHOD
The engine operation is not normal and the engine trouble warning light comes on.
1. Check:
• Fault code number
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the Yamaha diagnostic tool. Refer to “YAMAHA DIAGNOSTIC TOOL” on page 8-25.
b. Check the fault code number displayed on the Yamaha diagnostic tool.
c. Identify the faulty system with the fault code number.
d. Identify the probable cause of the malfunction.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check and repair the probable cause of the malfunction.

Fault code No. No fault code No.
Check and repair. Refer to “TROUBLESHOOTING Check and repair.

DETAILS (FAULT CODE)” on page 8-28.
Monitor the operation of the sensors and actuators in
the diagnostic mode. Refer to “TROUBLESHOOT-
ING DETAILS (FAULT CODE)” on page 8-28 and
“LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE
ACTIONS” on page 9-4.
3. Perform the reinstatement action for the fuel injection system. Refer to “Confirmation of service com-
pletion” in the appropriate table in “TROUBLESHOOTING DETAILS (FAULT CODE)” on page 8-28.
4. After pushing the engine stop switch, push the start switch to check whether the fault code number
is displayed.
TIP
If another fault code number is displayed, repeat steps (1) to (4) until no fault code number is displayed.
5. Erase the malfunction history in the diagnostic mode. Refer to “SENSOR OPERATION TABLE” on
page 9-5 (Diagnostic code No. 62).
The engine operation is not normal, but the engine trouble warning light does not come on.
1. Check the operation of the following sensors and actuators in the diagnostic mode. Refer to “TROU-
BLESHOOTING DETAILS (FAULT CODE)” on page 8-28.
01: Throttle position sensor signal (throttle angle)
30: Ignition coil
36: Injector
If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors and actuators, check and repair the inner parts of the
engine.
8-24
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.
90890-03257
90890-03262
TIP
A generic scan tool can also be used to identify malfunctions.

90890-03249
Features of the Yamaha diagnostic tool

You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional meth-
ods.
By connecting the adapter interface, which is connected to the USB port of a computer, to a vehicle’s
ECU using the communication cable, you can display information that is necessary for identifying mal-
functions and for maintenance to display on the computer. The displayed information includes the sen-
sor output data and information recorded in the ECU.
Functions of the Yamaha diagnostic tool
Diagnosis of malfunction: Fault codes recorded on the ECU are read, and the contents are dis-
played.
The freeze frame data (FFD) is the operation data when a malfunction
was detected. This data can be used to identify when the malfunction
occurred and check the engine conditions and running conditions when
it occurred.
Diagnosis of function: Check the operation of the output value of each sensor and actuator.
Dynamic inspection: Check the electric component condition automatically.
Active test: Manually adjust injection duration and/or switch some actuators for
troubleshooting.
Maintenance record: Store the inspection history into the Yamaha diagnostic tool application.
Recall search: Search the recall campaign information.
Monitoring: Displays a graph of sensor output values for actual operating condi-
tions.
Logging: Records and saves the sensor output value in actual driving conditions.
CO adjustment: Adjust the concentration of CO admissions during idling.
Reprogram ECU: If necessary, the ECU is rewritten using ECU rewrite data provided by
Yamaha.
Ignition timing adjustment, etc. cannot be changed from the vehicle’s
original state.
Writing VIN/frame number: Write the VIN/frame number in the ECU.
View logs: Displays the logging data.
However, the Yamaha diagnostic tool cannot be used to freely change the basic vehicle functions, such
as adjusting the ignition timing.
8-25
EAM30354
FEATURES OF THE YAMAHA DIAGNOSTIC TOOL

A diagnosis can be made more quickly than traditional methods with the Yamaha diagnostic tool.
Using this software, ECU and sensor data, as well as fault diagnosis, vehicle maintenance, and any
necessary information can be recorded and displayed on your computer screen through a USB adapter
connected to the computer interface with a communication cable connected to the vehicle’s ECU.
Data obtained in various functions can be saved as vehicle history, and can be accumulated.
EAM30355
FUNCTIONS OF THE YAMAHA DIAGNOSTIC TOOL

Fault codes recorded on the ECU are read, and the contents
Fault diagnosis mode
are displayed.
Check the operation of the output value of each sensor and
Function diagnostic mode actuator.
Determine whether each sensor or actuator is functioning
Inspection mode
properly.
CO adjustment mode Adjust the concentration of CO admissions during idling.
Displays a graph of sensor output values for actual operating
Monitoring mode conditions.
Records and saves the sensor output value in actual driving
Logging mode conditions.
View log Displays the logging data.
If necessary, the ECU is rewritten using the ECU rewrite data
ECU rewrite provided by Yamaha. Ignition timing adjustment, etc. cannot be
changed from the vehicle’s original state.
However, the diagnostic tool cannot be used to freely change the basic vehicle functions, such as ad-
justing the ignition timing.
EAM30356
CONNECTING THE YAMAHA DIAGNOSTIC TOOL

1. Remove the coupler for connecting setting tool.
2. Connect the FI diagnostic tool sub-lead.

90890-03212
YU-03212
3. Connect the FI diagnostic tool sub-lead to the Yamaha diagnostic tool.

EWA20450
WARNING
Never connect the sub-lead (special tool) to the battery. Otherwise, because of excessive cur-
rent flow, the sub-lead can catch fire and the battery could be damaged.
8-26
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 DIAGNO-
STIC TOOL OPERATION MANUAL”.
5 6 7 8
1 9
2
5
3
1. ECU (Engine Control Unit)

2. Lead battery (12 V)
3. Vehicle battery
4. Vehicle
5. Coupler for connecting optional part
6. FI diagnostic tool sub-lead
7. Sub-harness (included with the Yamaha diag-
nostic tool)
8. Vehicle communication cable (included with
the Yamaha diagnostic tool)
9. Yamaha diagnostic tool
8-27
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 “SENSOR OPER-
ATION TABLE” on page 9-5.
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. 12

Fault code No. 12
Item Crankshaft position sensor: no normal signals are received from

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, and then
tion sensor coupler. nect the coupler securely, or check the condition of the fault
Check the locking condition of repair/replace the wire harness. code using the malfunction
the coupler. mode of the Yamaha diagnostic
Disconnect the coupler, and 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, and then
ECU coupler. nect the coupler securely, or check the condition of the fault
Check the locking condition of repair/replace the wire harness. code using the malfunction
the coupler. mode of the Yamaha diagnostic
Disconnect the coupler, and tool.
item 3.
8-28
Fault code No. 12
Item Crankshaft position sensor: no normal signals are received from

the crankshaft position sensor.
3 Wire harness continuity. Open or short circuit  Replace Crank the engine, and then
the wire harness. check the condition of the fault
Between the crankshaft position code using the malfunction
sensor coupler and ECU cou- mode of the Yamaha diagnostic
pler. tool.
gray–gray Condition is “Recovered”  Go
black/blue–black/blue to item 7 and finish the service.
Condition is “Detected”  Go to
item 4.
4 Mounted condition of crankshaft Improperly mounted sensor  Crank the engine, and then
position sensor. Remount or replace the sensor. check the condition of the fault
Check for looseness or pinch- Refer to “AC MAGNETO” on code using the malfunction
ing. page 5-57. mode of the Yamaha diagnostic
Check the gap between the tool.
crankshaft position sensor and Condition is “Recovered”  Go
the pickup rotor. to item 7 and finish the service.
item 5.
5 Defective crankshaft position Check the crankshaft position Crank the engine, and then
sensor. sensor. check the condition of the fault
Refer to “CHECKING THE code using the malfunction
CRANKSHAFT POSITION mode of the Yamaha diagnostic
SENSOR” on page 8-63. tool.
Condition is “Recovered”  Go
to item 7 and finish the service.
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 num-
ber 13 first.
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.
8-29
Fault code No. 13
Item Intake air pressure sensor: open or short circuit detected.
1 Connection of intake air pres- Improperly connected  Con- Start switch to ON (main relay
sure sensor coupler. nect the coupler securely, or ON), 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.
item 2.
2 Connection of wire harness Improperly connected  Con- Start switch to ON (main relay
ECU coupler. nect the coupler securely, or ON), and then check the condi-
item 3.
3 Wire harness continuity. Open or short circuit  Replace Start switch to ON (main relay
the wire harness. ON), and then check the condi-
Between intake air pressure tion of the fault code using the
sensor coupler and ECU cou- malfunction mode of the
pler. Yamaha diagnostic tool.
pink/black–pink/black Condition is “Recovered”  Go
blue–blue to item 7 and finish the service.
black/blue–black/blue Condition is “Detected”  Go to
item 4.
4 Mounted condition of intake air Improperly mounted sensor  Start switch to ON (main relay
pressure sensor. Remount or replace the sensor. ON), and then check the condi-
Check for looseness or pinch- tion of the fault code using the
ing. malfunction mode of the
Check the mounted position for Yamaha diagnostic tool.
correctness. Condition is “Recovered”  Go
item 5.
5 Defective intake air pressure Execute the diagnostic mode. Start switch to ON (main relay
sensor. (Code No. 03) ON), and then check the condi-
Atmospheric pressure at the tion of the fault code using the
current altitude and weather malfunction mode of the
conditions is indicated. Yamaha diagnostic tool.
0 m above sea level: About 101 Condition is “Recovered”  Go
kPa (about 3.63 V) to item 7 and finish the service.
1000 m above sea level: About Condition is “Detected”  Go to
90 kPa (about 3.30 V) item 6.
2000 m above sea level: About
80 kPa (about 3.00 V)
code.
8-30
Fault code No. 14

TIP
ber 13 first.
Fault code No. 14
Intake air pressure sensor: hose system malfunction (clogged or

Item
detached hose).

Fail-safe system
Diagnostic tool display Displays the intake air pressure.
Procedure The atmospheric pressure is displayed on the Yamaha diagnostic tool.
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.
item 2.
2 Defective intake air pressure Execute the diagnostic mode. Service is finished.
sensor. (Code No. 03)
Atmospheric pressure at the
current altitude and weather
conditions is indicated.
0 m above sea level: About 101
kPa (about 3.63 V)
code.
8-31
Fault code No. 15

TIP
ber 15 first.
Fault code No. 15
Item Throttle position sensor: open or short circuit detected.

Fail-safe system
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.
1 Connection of throttle position Improperly connected  Con- Start switch to ON (main relay
sensor coupler. nect the coupler securely, or ON), and then check the condi-
item 2.
item 3.
Between throttle position sensor tion of the fault code using the
coupler and ECU coupler. malfunction mode of the
yellow–yellow Yamaha diagnostic tool.
blue–blue Condition is “Recovered”  Go
item 4.
4 Mounted condition of throttle Improperly mounted sensor  Start switch to ON (main relay
position sensor. Remount or replace the sensor. ON), and then check the condi-
Check for looseness or pinch- Refer to “ADJUSTING THE tion of the fault code using the
ing. THROTTLE POSITION SEN- malfunction mode of the
Check the mounted position for SOR” on page 7-9. Yamaha diagnostic tool.
item 5.
8-32
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 (main relay
tion sensor lead. (black/blue–blue) ON), and then check the condi-
tion of the fault code using the
Location of discon- Output malfunction mode of the
nected lead voltage Yamaha diagnostic tool.
Disconnected 5V to item 8 and finish the service.
ground lead Condition is “Detected”  Go to
Disconnected output 0 V item 6.
lead
Disconnected power 0 V
supply lead
6 Defective throttle position sen- Execute the diagnostic mode. Disconnect the starter relay
sor. (Code No. 01) lead (to the starter motor), and
When the throttle is fully closed, then push the starter switch.
11–14 displays. Start switch to ON (main relay
When the throttle is fully ON), and then check the condi-
opened, 86–92 displays. tion of the fault code using the
Incorrect display range  malfunction mode of the
Replace the throttle position Yamaha diagnostic tool.
sensor. Condition is “Recovered”  Go
item 7.
code.
Fault code No. 16

TIP
ber 15 first.
Fault code No. 16
Item Throttle position sensor: stuck throttle position sensor is detected.

Fail-safe system
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.
8-33
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 (main relay
position sensor. Remount or replace the sensor. ON) and open and close the
Check for looseness or pinch- Refer to “ADJUSTING THE throttle several times.
ing. THROTTLE POSITION SEN- Check the condition of the fault
Check the mounted condition SOR” on page 7-9. code using the malfunction
for correctness. mode of the Yamaha diagnostic
tool.
item 2.
2 Defective throttle position sen- Execute the diagnostic mode. Start switch to ON (main relay
sor. (Code No. 01) ON) and open and close the
When the throttle is fully closed, throttle several times.
11–14 displays. Check the condition of the fault
When the throttle is fully code using the malfunction
opened, 86–92 displays. mode of the Yamaha diagnostic
Incorrect display range  tool.
Replace the throttle position Condition is “Recovered”  Go
sensor. to item 4 and finish the service.
item 3.
code.
Fault code No. 21

TIP
Make sure that the machine is completely cold before checking the coolant temperature sensor.
Fault code No. 21
Item Coolant temperature sensor: open or short circuit detected.

Fail-safe system
Diagnostic tool display Displays the coolant temperature.
Compare the actually measured coolant temperature with the Yamaha
Procedure diagnostic tool display value.
Item Probable cause of malfunc- Maintenance job Confirmation of service com-

1 Connection of coolant tempera- Improperly connected  Con- Start switch to ON (main relay
ture sensor coupler. nect the coupler securely, or ON), and then check the condi-
item 2.
8-34
Fault code No. 21
Item Coolant temperature sensor: open or short circuit detected.
item 3.
Between coolant temperature tion of the fault code using the
green/white–green/white Condition is “Recovered”  Go
item 4.
4 Mounted condition of coolant Improperly mounted sensor  Start switch to ON (main relay
temperature sensor. Remount or replace the sensor. ON), and then check the condi-
item 5.
5 Defective coolant temperature Execute the diagnostic mode. Start switch to ON (main relay
sensor. (Code No. 06) ON), and then check the condi-
When the machine is cold, dis- tion of the fault code using the
played temperature is close to malfunction mode of the
the ambient temperature. Yamaha diagnostic tool.
Improper display  Replace the Condition is “Recovered”  Go
coolant temperature sensor. to item 7 and finish the service.
item 6.
code.
8-35
Fault code No. 22

TIP
Make sure that the machine is completely cold before checking the intake air temperature sensor.
Fault code No. 22
Item Intake air temperature sensor: open or short circuit detected.

Fail-safe system
Diagnostic tool display Displays the intake air temperature.
Compare the actually measured intake air temperature with the Yamaha
Procedure
diagnostic tool display value.
1 Connection of intake air temper- Improperly connected  Con- Start switch to ON (main relay
ature sensor coupler. nect the coupler securely, or ON), and then check the condi-
item 2.
item 3.
Between intake air temperature tion of the fault code using the
brown/white–brown/white Condition is “Recovered”  Go
item 4.
4 Mounted condition of intake air Improperly mounted sensor  Start switch to ON (main relay
temperature sensor. Remount or replace the sensor. ON), and then check the condi-
item 5.
8-36
Fault code No. 22
Item Intake air temperature sensor: open or short circuit detected.
5 Defective intake air tempera- Execute the diagnostic mode. Start switch to ON (main relay
ture sensor. (Code No. 05) ON), and then check the condi-
When the machine is cold, dis- tion of the fault code using the
played temperature is close to malfunction mode of the
the ambient temperature. Yamaha diagnostic tool.
Improper display  Replace the Condition is “Recovered”  Go
intake air temperature sensor. to item 7 and finish the service.
item 6.
code.
Fault code No. 30

Fault code No. 30
Item The vehicle has overturned.

Fail-safe system
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.
1 The vehicle has overturned. Raise the vehicle upright. Start switch to ON (main relay
ON), wait 10 seconds, then
check the condition of the fault
tool.
item 2.
2 Mounted condition of ECU. Improperly mounted ECU  Start switch to ON (main relay
Check for looseness or pinch- Remount the ECU. ON), wait 10 seconds, then
ing. check the condition of the fault
Check the mounted condition code using the malfunction
for correctness. mode of the Yamaha diagnostic
tool.
item 3.
8-37
Fault code No. 30
Item The vehicle has overturned.
3 Faulty ECU. Execute the diagnostic mode. Service is finished.

(Code No. 08)
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.
code.
Fault code No. 33

Fault code No. 33
Item Ignition coil: open or short circuit detected in the primary lead of
the ignition coil.

Fail-safe system
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.

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 8 and finish the service.
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.
item 3.
8-38
Fault code No. 33
Item Ignition coil: open or short circuit detected in the primary lead of
the ignition coil.
3 Connection of sub wire harness 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 sub wire har- Check the condition of the fault
the coupler. ness. code using the malfunction
item 4.
4 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
orange–orange mode of the Yamaha diagnostic
red–red/blue tool.
item 5.
5 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.
item 6.
6 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 8-63. code using the malfunction
tool.
item 7.
7 Faulty ECU. Execute the diagnostic mode. Service is finished.
(Code No. 30)
No spark  Replace the ECU.
code.
8-39
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.

Fail-safe system
Actuates injector five times at one-second intervals.
Actuation “WARNING” on the Yamaha diagnostic tool blinks five times when the
injector is actuated.
Check that injector is actuated five times by listening for the operating
Procedure
sound.
Item tion and check Maintenance job 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
item 2.
2 Defective injector. Check the injector. Start the engine and let it idle for
Refer to “CHECKING THE approximately 5 seconds.
FUEL INJECTOR” on page Check the condition of the fault
8-68. code using the malfunction
tool.
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.
item 4.
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 coupler. Condition is “Recovered”  Go
red/blue–red/blue to item 6 and finish the service.
red/yellow–red/yellow Condition is “Detected”  Go to
red/white–red/white item 5.
red–red
8-40
Fault code No. 39
Item Injector: open or short circuit detected.

code.
Fault code No. 41

Fault code No. 41
Item ECU: built-in lean angle sensor malfunction.

Fail-safe system
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.

Fault code No. 43

Fault code No. 43
Fuel system voltage: incorrect voltage supplied to the main relay

Item
and CCU.

Fail-safe system
Diagnostic tool display Fuel system voltage

Approximately 12.0 (V)
Procedure Disconnect the main relay, and push the start switch.
Item tion and check Maintenance job pletion
1 Connection of main relay cou- Improperly connected  Con- Press the start switch and the
pler. nect the coupler securely or engine stop switch alternately to
Check the locking condition of repair/replace the wire harness. switch the power supply (= main
the coupler. relay) from “ON  OFF  ON”.
Disconnect the coupler and Check the condition of the fault
check the pins (bent or broken code using the malfunction
terminals and locking condition mode of the Yamaha diagnostic
of the pins). tool.
item 2.
8-41
Fault code No. 43
Item Fuel system voltage: incorrect voltage supplied to the main relay
and CCU.
2 Connection of wire harness Improperly connected  Con- Press the start switch and the
ECU coupler. nect the coupler securely or engine stop switch alternately to
Check the locking condition of repair/replace the wire harness. switch the power supply (= main
the coupler. relay) from “ON  OFF  ON”.
Disconnect the coupler and Check the condition of the fault
check the pins (bent or broken code using the malfunction
terminals and locking condition mode of the Yamaha diagnostic
of the pins). tool.
item 3.
3 Wire harness continuity. Open or short circuit  Replace Press the start switch and the
the wire harness. engine stop switch alternately to
Between battery terminal and switch the power supply (= main
ECU coupler. relay) from “ON  OFF  ON”.
red–red Check the condition of the fault
red–red/white code using the malfunction
Between main relay coupler and mode of the Yamaha diagnostic
ECU coupler. tool.
brown–brown Condition is “Recovered”  Go
blue/red–blue/red to item 6 and finish the service.
item 4.
4 Defective main relay. No operating sound  Replace Press the start switch and the
the main relay. engine stop switch alternately to
Execute the diagnostic mode. switch the power supply (= main
(Code No. 09) relay) from “ON  OFF  ON”.
Fuel system voltage is below 3 Check the condition of the fault
V  Replace the main relay. code using the malfunction
tool.
item 5.
5 Malfunction in ECU. Replace the ECU. Service is finished.
code.
8-42
Fault code No. 44

Fault code No. 44
EEPROM fault code number: an error is detected while reading or

Item writing on EEPROM.
Able/Unable to start engine

Fail-safe system
Able/Unable to drive vehicle
Displays the location of the abnormal portion of the EEPROM data.
• 00: No fault
Diagnostic tool display • 01: CO adjustment valve
• 07: Power Tuner injection correction setting 0–8, or Power Tuner igni-
tion timing correction setting 0–8
Procedure —
1 Identification of malfunctioning Execute the diagnostic mode.
point. (Code No. 60)
00: Go to item 4.
01: Go to item 2.
07: Go to item 3.
2 “01” is indicated in diagnostic Change the CO concentration, Start switch to ON (main relay
mode. (Code No. 60) and rewrite in EEPROM. ON), and then check the condi-
EEPROM data error for adjust- After this adjustment, push the tion of the fault code using the
ment of CO concentration. engine stop switch, and then. malfunction mode of the
Yamaha diagnostic tool.
Condition is “Detected” 
Repeat item 1.
If the same number is indicated,
go to item 3.
3 “07” is indicated in diagnostic Erase the setting map in the Start switch to ON (main relay
mode. (Code No. 60) diagnostic mode. (Code No. 65) ON), and then check the condi-
EEPROM data error for setting tion of the fault code using the
tool adjustment values for fuel malfunction mode of the
injection amount or ignition tim- Yamaha diagnostic tool.
ing. Condition is “Recovered”  Go
Condition is “Detected” 
Repeat item 1.
If the same number is indicated,
go to item 4.
code.
8-43
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
Procedure —
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.
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.
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.
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.
item 3.
Between rectifier/regulator cou- Check the condition of the fault
pler and battery terminal. code using the malfunction
red–red mode of the Yamaha diagnostic
black–black tool.
Between rectifier/regulator cou- Condition is “Recovered”  Go
pler and AC magneto coupler. to item 6 and finish the service.
white–white Condition is “Detected”  Go to
item 4.
4 Defective AC magneto. Check the AC magneto. Start the engine and let it idle for
Refer to “CHECKING THE AC approximately 5 seconds.
MAGNETO” on page 5-58. Check the condition of the fault
tool.
item 5.
8-44
Fault code No. 46
Item Vehicle system power supply: normal voltage is not supplied to the
ECU.
code.
Fault code No. 50

Fault code No. 50
Item ECU: faulty ECU memory.

Fail-safe system
Procedure —
1 Faulty ECU. Replace the ECU. Start switch to ON (main relay
ON), and then check the condi-
tion of the fault code using the
malfunction mode of the
Yamaha diagnostic tool.
Check that the fault code num-
ber is not displayed.
Fault code No. 70

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
Procedure —
code.
8-45
8-46
FUEL PUMP SYSTEM
EAM20146
FUEL PUMP SYSTEM

EAM30287
CIRCUIT DIAGRAM
8-47
FUEL PUMP SYSTEM
2. AC magneto
4. Joint connector
6. Engine ground
7. Battery
8. Frame ground
9. Main fuse
25.Fuel pump
A. Battery sub-lead
B. Wire harness
8-48
FUEL PUMP SYSTEM
EAM30288
TROUBLESHOOTING
The fuel pump fails to operate.
TIP
1. Seat
4. Fuel tank
1. Check the fuel pump system wire

Reconnect.
harness connections. NG
OK
2. Check the fuse.
on page 8-58. NG
OK
page 8-59.
OK
OK
5. Check fuel pressure.
Refer to “CHECKING THE FUEL Replace the fuel pump.
PRESSURE” on page 7-3. NG
OK
6. Check the fuel pump system wire
harness connections.
page 8-47.
OK
Replace the ECU.
8-49
FUEL PUMP SYSTEM
8-50
ELECTRICAL COMPONENTS
EAM20147
3
2 4
1 5
6
8 7
8-51
2. Mode switch
3. Intake air temperature sensor
4. Coolant temperature sensor
5. Resistor
6. Radiator fan motor fuse
7. Radiator fan motor relay
8. Main relay
9. Radiator fan motor (For JPN)
8-52
4 5
6
11
9 8 7
10
8-53
1. Intake air pressure sensor

2. Throttle position sensor
3. Injector
4. Ignition coil
5. ECU (Engine Control Unit)
7. Starter relay
8. Main fuse
9. Battery
11.Fuel pump
8-54
EAM30289
CHECKING THE SWITCHES
1
4
2
B/W R/L
B B/R
P Sb Y/W
Y/W P
Sb
8-55
1. Engine stop switch

2. Mode switch
3. Gear position switch
4. Engine start switch
8-56
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.

90890-03243
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”.
8-57
EAM30357
however, note the following.
CHECKING THE BULBS AND BULB
SOCKETS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1. Remove: a. Install a good bulb into the bulb socket.
• Bulb b. Connect the digital circuit tester probes to the
ECA25930
respective leads of the bulb socket.
NOTICE c. Check the bulb socket for continuity. If any of
Be sure to hold the socket firmly when re- the readings indicate no continuity, replace
moving the bulb. Never pull the lead, other- the bulb socket.
wise it may be pulled out of the terminal in ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
the coupler.
EAM30290
TIP CHECKING THE FUSES
Bulbs “a” is used for warning light and can be re- The following procedure applies to all of the fus-
moved from their respective socket by carefully es.
pulling them out. 1. Remove:
• Seat
2. Check:
a • Main fuse “1”
• Radiator fan motor fuse “2”
2. Check:
• Bulb (for continuity)
(with the digital circuit tester)
No continuity  Replace.
90890-03243
eter
YU-A1927
TIP
Before checking for continuity, set the digital cir-
cuit tester to “” range.
3. Check: 2
• Bulb socket (for continuity)
(with the digital circuit tester) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
No continuity  Replace. a. Connect the digital circuit tester to the fuse

and check the continuity.
Digital circuit tester (CD732) TIP
90890-03243 Set the digital circuit tester selector to “  ”.
eter
YU-A1927
90890-03243
TIP eter
Check each bulb socket for continuity in the YU-A1927
same manner as described in the bulb section;
8-58
b. If the digital circuit tester indicates “O.L”, re- specified battery charger. Do not use a
place the fuse. charger designed for lead-acid batteries.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Otherwise, the battery could be damaged,
3. Replace: such as from a long period of excessive
• Fuse current or voltage exceeding 16 V.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Avoid excessive current discharge, such
a. Install a new fuse of the correct amperage as pressing the starter switch for a long
rating. time. Wait for more than 10 seconds before
b. Push the start switch to verify if the electrical attempting to start again. Charge the bat-
circuit is operational. tery again as soon as possible. A long state
c. If the fuse immediately blows again, check of discharge below 10 V will damage the
the electrical circuit. battery.
• Do not use the specified battery charger to
Fuses
Amperage
Q’ty charge a battery other than the lithium-ion
rating battery. Otherwise, the battery or charger
Main 15 A 1 could be damaged.
• Be careful not to drop the battery or subject
Spare 15 A 1 it to strong impacts.
Radiator fan motor 5A 1 • Avoid charging the battery at high temper-
EWA13310
atures of 65 C (149 F) or more or low tem-
WARNING peratures under 0 C (32 F). A control
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
systems to malfunction and could possibly F)and 10 C (50 F), battery charging may
cause a fire. stop halfway without the battery becoming
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ fully charged even when the specified bat-
4. Install: tery charger is used. If this occurs, discon-
• Seat nect the battery charger, and then resume
Refer to “GENERAL CHASSIS” on page 4-1. charging again.
EAM30291 TIP
CHECKING AND CHARGING THE BATTERY This model uses a lithium-ion battery. When
EWA20430 new, the battery is supplied in sleep mode to
WARNING minimize current discharging until first-time use.
To avoid sparking, burns, fire, and explo- In the sleep mode, a voltage as low as approxi-
sion: mately 0.1 V can be measured if voltage mea-
• Charge battery only with specified charger. surement is performed. As such the battery
• Use battery only for specified product – no cannot be used, but this is not a malfunction. By
other use. activating the battery as follows, the sleep mode
• Do not place near fire or immerse in water. will be canceled and the battery can be used
• Do not use battery if it has been dropped, normally.
subject to impact, or visibly damaged.
Charging (activation) steps
• Do not disassemble or modify the battery,
1. Remove:
or short across its terminals.
ECA26041
• Seat
NOTICE Refer to “GENERAL CHASSIS” on page 4-1.
To prevent damage to the battery and battery 2. Disconnect:
malfunction: • Battery leads
• Be sure to charge the battery using only the (from the battery terminals)
8-59
ECA13640
Dirt  Clean with a wire brush.
NOTICE Loose connection  Connect properly.
First, disconnect the negative battery lead 9. Lubricate:
“1”, and then positive battery lead “2”. • Battery terminals
Dielectric grease
2
1 10.Install:
• Seat
Checking the battery
ECA26080
NOTICE
The battery has a limited service life. If the
3. Remove:
battery cannot be charged or it is determined
• Battery
that the battery cannot be used after check-
4. Connect the battery charger (special tool) to
ing the battery, it should be replaced. When
the battery.
replacing the battery, be sure to use a
Lithium battery charger Yamaha genuine lithium-ion battery.
90890-05376
TIP
Do not check the battery at high temperature of
DBY-ACC51-70-02
65 C (149 F) or more or low temperatures be-
low 10 C (50 F). Otherwise, the control feature
TIP
• For instructions on charging and handling the preventing battery charging and discharging will
battery charger, refer to the battery charger’s temporarily intervene.
instruction manual. 1. Check:
• Once battery charging starts, the sleep mode • Battery
is canceled. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
5. Charge the battery until it is fully charged. a. If the battery is hot, wait until the battery has
6. Install: cooled down to the ambient temperature.
• Battery terminals b. Measure the voltage between the battery ter-
7. Connect: minals.
• Battery leads 13.25 V or more  The battery is normal.
(to the battery terminals) Checking is finished.
ECA13630 Less than 13.25 V  Go to step (c).
NOTICE c. Connect the battery charger (special tool) to
First, connect the positive battery lead “1”, the battery and charge it.
and then the negative battery lead “2”.
90890-05376
1 DBY-ACC51-70-02
2
TIP
For instructions on charging and handling the
battery charger, refer to the battery charger’s in-
struction manual.
d. If the battery is hot, wait until the battery has
cooled down to the ambient temperature.
8. Check: e. Measure the voltage between the terminals
• Battery terminals of the battery.
8-60
13.25 V or more  The battery is normal. Main relay

Checking is finished.
10 V or more and less than 13.25 V  Per- 3
form from step (c) again.
4
Less than 10 V  Replace the battery.
TIP
Before replacing the battery, make sure that the 2 1
battery temperature is proper (temperature not
more than 65 C (149 F) or less than 0 C (32 L/R R
Br
F)). Otherwise, wait until the battery tempera-
ture is proper and perform the procedure from R,R/W
step (c) again.
1. Positive battery terminal
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Negative battery terminal
3. Positive tester probe
EAM30292
4. Negative tester probe
CHECKING THE RELAYS
Check each switch for continuity with the digital
circuit tester. If the continuity reading is incor- Result
Continuity
rect, replace the relay.
(between “3” to “4”)
90890-03243 Radiator fan motor relay
eter 3
YU-A1927
4
1. Disconnect the relay from the wire harness.
2. Connect the digital circuit tester () and bat- 2
1
tery (12 V) to the relay terminal as shown.
Check the relay operation. P/L
Out of specification  Replace. R/L Br,R/W
Starter relay R/W
1. Positive battery terminal

3
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
R/W R/Y
L Br/W
Result
Continuity
4 (between “3” to “4”)
2 1
EAM30293
1. Positive battery terminal CHECKING THE DIODE

2. Negative battery terminal 1. Check:
3. Positive tester probe • Diode
4. Negative tester probe Out of specification  Replace.
Result Digital circuit tester (CD732)

Continuity 90890-03243
(between “3” to “4”) Model 88 Multimeter with tachom-
eter
YU-A1927
8-61
EAM30294
TIP
The digital circuit tester and the multimeter with CHECKING THE IGNITION SPARK GAP
tachometer readings are shown in the following 1. Check:
table. • Ignition spark gap
Out of specification  Perform the ignition
system troubleshooting, starting with step (5).
No continuity
Refer to “TROUBLESHOOTING” on page
Tester positive lead 
Blue/Green “1” 8-3.
Tester negative lead  Blue “2” Minimum ignition spark gap
Continuity 6.0 mm (0.24 in)
Tester positive lead  Blue “2”
Tester negative lead 
TIP
Blue/Green “1”
If the ignition spark gap is within specification,
No continuity
Tester positive lead  the ignition system circuit is operating normally.
Brown/White, Brown “3” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Tester negative lead  a. Remove the spark plug cap from the spark
Blue/Green, Blue/White “4” plug.
Continuity
b. Connect the ignition checker “1” as shown.
Tester positive lead 
Blue/Green, Blue/White “4” Ignition checker
Tester negative lead  90890-06754
Brown/White, Brown “3” Oppama pet–4000 spark checker
No continuity YM-34487
Tester positive prove 
Blue/Black “5” c. Crank the engine, and measure the ignition
Tester negative prove  spark gap “a”.
Blue/Red “6”
Continuity
Tester positive prove 
Blue/Red “6”
Tester negative prove 
Blue/Black “5”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the diode from the wire harness.
b. Connect the digital circuit tester () to the di-
ode coupler as shown.
c. Check the diode for continuity. 2. Spark plug cap
d. Check the diode for no continuity.
d. Crank the engine, and gradually increase the
spark gap until a misfire occurs.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1 3 5
EAM30295
CHECKING THE SPARK PLUG CAP

L/G Br/W,Br L/B 1. Remove:
L
L/G,
L/R • Spark plug cap
L/W
(from the spark plug lead)
2. Check:
2 4 6 • Spark plug cap resistance
A. Diode 1
B. Diode 2 Resistance
C. Diode 3 7.50–12.50 k
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-62
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the digital circuit tester () to the
spark plug cap.
90890-03243
eter
YU-A1927
b. Measure the primary coil resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• Secondary coil resistance
Secondary coil resistance
8.64–12.96 k
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b. Measure the spark plug cap resistance.
a. Connect the digital circuit tester () to the ig-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
nition coil.
EAM30296
CHECKING THE IGNITION COIL Digital circuit tester (CD732)

90890-03243
1. Disconnect:
• Ignition coil terminal eter
(from the sub wire harness) YU-A1927
• Spark plug cap
(from the ignition coil)
• Positive tester probe 
2. Check: Ignition coil terminal 1 “1”
• Primary coil resistance • Negative tester probe 
Out of specification  Replace. Spark plug lead “2”
Primary coil resistance

2.16–2.64 
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the digital circuit tester () to the ig- 1
nition coil.
90890-03243
eter
YU-A1927 b. Measure the secondary coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Positive tester probe  EAM30297

Ignition coil terminal 1 “1” CHECKING THE CRANKSHAFT POSITION
• Negative tester probe 
Ignition coil terminal 2 “2” SENSOR
1. Disconnect:
• Crankshaft position sensor coupler
(from the wire harness)
2. Check:
• Crankshaft position sensor resistance
8-63
Out of specification  Replace. step (4).

Refer to “TROUBLESHOOTING” on page
Crankshaft position sensor resis- 8-7.
tance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
228–342 
a. Connect the positive battery terminal “1” and
starter motor lead “2” with a jumper lead “3”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EWA13810
a. Connect the digital circuit tester () to the WARNING

crankshaft position sensor coupler. • A wire that is used as a jumper lead must
Digital circuit tester (CD732) have at least the same capacity of the bat-
90890-03243 tery lead, otherwise the jumper lead may
Model 88 Multimeter with tachom- burn.
eter • This check is likely to produce sparks,
YU-A1927 therefore, make sure no flammable gas or
fluid is in the vicinity.
Gray “1”
Black “2”
1 2
Gy B b. Check the starter motor operation.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAM30300
CHECKING THE STATOR COIL

b. Measure the crankshaft position sensor re- 1. Disconnect:
sistance. • Stator coil coupler
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAM30379
2. Check:
CHECKING THE ECU • Stator coil resistance
1. Check: Out of specification  Replace.
• Mounted condition of ECU. Stator coil resistance
Improperly mounted  Remount. 0.512–0.768 
TIP
• The lean angle sensor is built into the ECU. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• The lean angle sensor stops the engine in case a. Connect the digital circuit tester () to the sta-
of a turnover. tor coil coupler.
• To ensure that the lean angle sensor operates
correctly, do not change the installed condition Digital circuit tester (CD732)
of the ECU. 90890-03243
EAM30299 eter
CHECKING THE STARTER MOTOR YU-A1927
OPERATION
1. Check: • Positive tester probe 
• Starter motor operation White “1”
Does not operate  Perform the electric • Negative tester probe 
White “2”
starting system troubleshooting, starting with
8-64
c. Start the engine and let it run at about 5000

r/min.
d. Measure the output voltage.
1 2 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAM30359
CHECKING THE FUEL SENDER

1. Disconnect:
• Starter motor lead
(from the starter relay)
2. Connect:
b. Measure the stator coil resistance. • Fuel pump coupler
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Push the start switch.
4. Check:
EAM30301
• Fuel level warning light
CHECKING THE RECTIFIER/REGULATOR
Out of specification  Replace the fuel
1. Check:
pump.
• Rectifier/regulator output voltage
Out of specification  Replace. Fuel pump is atmosphere “A”
 Fuel level warning light is come on
Regulated voltage (DC)
Fuel pump is soaked in fuel “B”
14.0–14.8 V
 Fuel level warning light is goes off
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the digital tachometer to the ignition coil.
Digital tachometer
90890-06760
Digital tachometer
YU-39951-B
b. Connect the digital circuit tester (DCV) to the

rectifier/regulator coupler.
90890-03243 EAM30360
Model 88 Multimeter with tachom- CHECKING THE RESISTOR

eter 1. Disconnect:
YU-A1927 • Resistor coupler
• Positive tester probe  2. Check:
Red “1” • Resistor resistance
Black “2” Out of specification  Replace the resistor.
Resistor resistance
64.6–71.4 
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the digital circuit tester () to the re-
sistor as shown.
B R Digital circuit tester (CD732)

W W 90890-03243
2 1 Model 88 Multimeter with tachom-
eter
YU-A1927
8-65

with special care.
Black “1” • Never subject the coolant temperature sen-
• Negative tester probe  sor to strong shocks. If the coolant temper-
Black “2” ature sensor is dropped, replace it.
2. Check:
• Coolant temperature sensor resistance
1 Out of specification  Replace.
Coolant temperature sensor re-
sistance
2512–2777 
Coolant temperature sensor re-
2 sistance
210–220 
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b. Measure the resistance of the resistor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. Connect the digital circuit tester () to the
coolant temperature sensor.
EAM30302
CHECKING THE RADIATOR FAN MOTOR Digital circuit tester (CD732)

(For JPN) 90890-03243
1. Check:
eter
• Radiator fan motor YU-A1927
Faulty/rough movement  Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the radiator fan motor coupler Green/White “1”
from the wire harness. • Negative tester probe 
b. Connect the battery (DC 12 V) as shown. Black/Blue “2”
• Positive battery terminal 

Blue “1”
• Negative battery terminal 
Black “2” G/W B/L
1 2 G/W B/L
L B 1 2
b. Immerse the coolant temperature sensor in a

container filled with coolant.
12V
TIP
Make sure the coolant temperature sensor ter-
c. Measure the radiator fan motor movement. minals do not get wet.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. Place a thermometer in the coolant.
EAM30303 d. Slowly heat the coolant, and then let it cool to
CHECKING THE COOLANT TEMPERATURE the specified temperature indicated in the ta-
SENSOR ble.
1. Remove: e. Check the coolant temperature sensor for
• Coolant temperature sensor continuity at the temperatures indicated in the
EWA14130
table.
WARNING
• Handle the coolant temperature sensor
8-66
2 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. Start the engine.
EAM30305
d. Measure the throttle position sensor input
CHECKING THE THROTTLE POSITION voltage.
SENSOR INPUT VOLTAGE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1. Check:
EAM30307
• Throttle position sensor input voltage
CHECKING THE INTAKE AIR
Out of specification  Replace the ECU.
TEMPERATURE SENSOR
Throttle position sensor input 1. Remove:
voltage • Intake air temperature sensor
4–6 V (from the air filter case)
EWA14110
WARNING
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the test harness S– pressure sensor • Handle the intake air temperature sensor
(3P) to the throttle position sensor coupler with special care.
and the wire harness. • Never subject the intake air temperature
b. Connect the digital circuit tester (DCV) to the sensor to strong shocks. If the intake air
test harness S– pressure sensor (3P). temperature sensor is dropped, replace it.
2. Check:
• Intake air temperature sensor resistance
90890-03243
Model 88 Multimeter with tachom- Out of specification  Replace.
eter Intake air temperature sensor re-
YU-A1927 sistance
Test harness S– pressure sensor 5400–6600  at 0 C (5400–6600
(3P)  at 32 F)
90890-03207 Intake air temperature sensor re-
Test harness S– pressure sensor sistance
(3P) 290–390 
YU-03207
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Positive tester probe  a. Connect the digital circuit tester () to the in-
Blue “1” take air temperature sensor terminal.
Black/Blue “2”
90890-03243
eter
YU-A1927

Brown/White “1”
Black/Blue “2”
8-67
Continuity
Positive tester probe 
Sky blue “1”
Negative tester probe 
Sensor terminal “a”
Continuity
Pink “2”
1 2 Negative tester probe 
Sensor terminal “b”
Continuity
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Positive tester probe 
Pink “2”
EAM30467
CHECKING THE GEAR POSITION SWITCH Sensor terminal “c”
1. Remove: Continuity
• Gear position switch Positive tester probe 
2. Check: Yellow/White “3”
• Gear position switch Negative tester probe 
Out of specification  Replace. Sensor terminal “d”
3.
Continuity
Digital circuit tester (CD732) Positive tester probe 
90890-03243 Yellow/White “3”
Model 88 Multimeter with tachom- Negative tester probe 
eter Sensor terminal “e”
YU-A1927 Continuity
Yellow/White “3”
Sensor terminal “f”
f e 3 2
Y/W P
Sb
d
1
b a c
EAM30308
CHECKING THE FUEL INJECTOR

1. Remove:
• Fuel injector
Refer to “THROTTLE BODY” on page 7-5.
2. Check:
• Fuel injector resistance
Resistance
12.0 
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the fuel injector coupler from the
8-68
fuel injector.
b. Connect the digital circuit tester () to the fuel
injector coupler.
90890-03243
eter
YU-A1927

Injector terminal “1”
Injector terminal “2”
1 2
c. Measure the fuel injector resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-69
TROUBLESHOOTING
TROUBLESHOOTING ......................................................................................9-1
GENERAL INFORMATION ........................................................................9-1
STARTING FAILURE .................................................................................9-1
INCORRECT ENGINE IDLING SPEED .....................................................9-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ............................9-2
1
SHIFTING IS DIFFICULT ...........................................................................9-2
SHIFT PEDAL DOES NOT MOVE .............................................................9-2
JUMPS OUT OF GEAR ..............................................................................9-2
CLUTCH SLIPS ..........................................................................................9-2
CLUTCH DRAGS .......................................................................................9-2
2
OVERHEATING..........................................................................................9-2
OVERCOOLING .........................................................................................9-3
POOR BRAKING PERFORMANCE ...........................................................9-3
FRONT FORK OIL LEAKING .....................................................................9-3
FAULTY FRONT FORK LEGS ...................................................................9-3
3
UNSTABLE HANDLING .............................................................................9-3
LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS .............................9-4

LIST OF DIAGNOSTIC CODES .................................................................9-4
4
SENSOR OPERATION TABLE ..................................................................9-5
ACTUATOR OPERATION TABLE .............................................................9-6
5
6
7
8
9
10
TROUBLESHOOTING
EAM20148
• Short main relay
TROUBLESHOOTING 2. Fuse
EAM30309
• Blown, damaged or incorrect fuse
GENERAL INFORMATION • Improperly installed fuse
TIP 3. Spark plug
The following guide for troubleshooting does not • Incorrect spark plug gap
cover all the possible causes of trouble. It should • Incorrect spark plug heat range
be helpful, however, as a guide to basic trouble- • Fouled spark plug
shooting. Refer to the relative procedure in this • Worn or damaged electrode
manual for checks, adjustments, and replace- • Worn or damaged insulator
ment of parts. 4. Ignition coil
• Cracked or broken ignition coil body
EAM30310 • Broken or shorted primary or secondary coils
STARTING FAILURE 5. Ignition system
Engine • Faulty ECU
1. Cylinder and cylinder head • Faulty crankshaft position sensor
• Loose spark plug • Broken generator rotor woodruff key
• Loose cylinder head or cylinder 6. Switches and wiring
• Damaged cylinder head gasket • Faulty ECU
• Damaged cylinder gasket • Faulty engine stop switch
• Worn or damaged cylinder • Broken or shorted wiring
• Incorrect valve clearance • Faulty neutral switch
• Improperly sealed valve • Improperly grounded circuit
• Incorrect valve-to-valve-seat contact • Loose connections
• Incorrect valve timing 7. Starting system
• Faulty valve spring • Faulty starter motor
• Seized valve • Faulty starter relay
2. Piston and piston ring(s) • Faulty main relay
• Improperly installed piston ring • Faulty starter clutch
• Damaged, worn or fatigued piston ring EAM30311
• Seized piston ring INCORRECT ENGINE IDLING SPEED
• Seized or damaged piston Engine
3. Air filter 1. Cylinder and cylinder head
• Improperly installed air filter • Incorrect valve clearance
• Clogged air filter element • Damaged valve train components
4. Crankcase and crankshaft 2. Air filter
• Improperly assembled crankcase • Clogged air filter element
• Seized crankshaft Fuel system
Fuel system 1. Throttle body
1. Fuel tank • Damaged or loose throttle body joint
• Empty fuel tank • Improperly synchronized throttle bodies
• Clogged fuel tank breather hose • Improper throttle cable free play
• Deteriorated or contaminated fuel • Flooded throttle body
• Clogged or damaged fuel hose Electrical system
2. Fuel pump 1. Spark plug
• Faulty fuel pump • Incorrect spark plug gap
3. Throttle body • Incorrect spark plug heat range
• Deteriorated or contaminated fuel • Fouled spark plug
• Sucked-in air • Worn or damaged electrode
Electrical system • Worn or damaged insulator
1. Battery • Faulty spark plug cap
• Discharged battery 2. Ignition coil
• Faulty battery • Broken or shorted primary or secondary coil
9-1
TROUBLESHOOTING
• Cracked or broken ignition coil EAM30316
3. Ignition system CLUTCH SLIPS

• Faulty ECU (Engine Control Unit) Engine
• Faulty crankshaft position sensor 1. Clutch
• Broken generator rotor woodruff key • Improperly assembled clutch
• Loose or fatigued clutch spring
EAM30312
• Worn friction plate
POOR MEDIUM-AND-HIGH-SPEED • Worn clutch plate
PERFORMANCE 2. Engine oil
Refer to “STARTING FAILURE” on page 9-1. • Incorrect oil level
Engine • Incorrect oil viscosity (low)
1. Air filter • Deteriorated oil
• Clogged air filter element
Fuel system EAM30317
1. Fuel pump CLUTCH DRAGS

• Faulty fuel pump Engine
2. Throttle body 1. Clutch
• Defective throttle body • Unevenly tensioned clutch springs
3. ECU (Engine Control Unit) • Warped pressure plate
• Faulty ECU (Engine Control Unit) • Bent clutch plate
• Swollen friction plate
EAM30313
• Bent clutch push rod
SHIFTING IS DIFFICULT • Damaged clutch boss
Refer to “CLUTCH” on page 5-40. • Burnt primary driven gear bushing
EAM30314 2. Engine oil
SHIFT PEDAL DOES NOT MOVE • Incorrect oil level
Engine • Incorrect oil viscosity (high)
1. Shift shaft • Deteriorated oil
• Bent shift shaft EAM30318
2. Shift drum and shift forks OVERHEATING
• Foreign object in a shift drum groove Engine
• Seized shift fork 1. Cylinder head and piston
• Bent shift fork guide bar • Heavy carbon buildup
3. Transmission • Clogged coolant passages
• Seized transmission gear 2. Engine oil
• Foreign object between transmission gears • Incorrect oil level
• Improperly assembled transmission • Incorrect oil viscosity
EAM30315 • Inferior oil quality
JUMPS OUT OF GEAR Cooling system
Engine 1. Coolant
1. Shift shaft • Low coolant level
• Incorrect shift pedal position 2. Radiator
• Improperly returned stopper lever • Damaged or leaking radiator
2. Shift forks • Faulty radiator cap
• Worn shift fork • Bent or damaged radiator fin
3. Shift drum 3. Water pump
• Incorrect axial play • Damaged or faulty water pump
• Worn shift drum groove • Damaged hose
4. Transmission • Improperly connected hose
• Worn gear dog • Damaged pipe
• Improperly connected pipe
9-2
TROUBLESHOOTING
Fuel system EAM30321
1. Throttle body FAULTY FRONT FORK LEGS

• Damaged or loose throttle body joint Chassis
2. Air filter 1. Front fork
• Clogged air filter element • Bent or damaged inner tube
Chassis • Bent or damaged outer tube
1. Brake(s) • Broken fork spring
• Dragging brake • Bent or damaged damper rod
Electrical system • Incorrect oil viscosity
1. Spark plug • Incorrect oil level
• Incorrect spark plug gap EAM30322
• Incorrect spark plug heat range UNSTABLE HANDLING

2. Ignition system Chassis
• Faulty ECU (Engine Control Unit) 1. Handlebar
• Faulty coolant temperature sensor • Bent or improperly installed handlebar
2. Steering head components
EAM30319
OVERCOOLING • Improperly installed upper bracket

Cooling system • Improperly installed lower bracket
1. Coolant temperature sensor (improperly tightened ring nut)
• Faulty coolant temperature sensor • Bent steering stem
• Damaged ball bearing or bearing race
EAM30320
3. Front fork leg(s)
POOR BRAKING PERFORMANCE • Uneven oil levels (both front fork legs)
Chassis • Unevenly tensioned fork spring (both front
1. Brake(s) fork legs)
• Worn brake pad • Broken fork spring
• Worn brake disc • Bent or damaged inner tube
• Air in hydraulic brake system • Bent or damaged outer tube
• Leaking brake fluid 4. Swingarm
• Defective master cylinder kit • Worn bearing or bushing
• Faulty brake caliper kit • Bent or damaged swingarm
• Faulty brake caliper seal 5. Rear shock absorber assembly(-ies)
• Loose union bolt • Faulty rear shock absorber spring
• Damaged brake hose • Leaking oil or gas
• Oil or grease on the brake disc 6. Tire(s)
• Oil or grease on the brake pad • Uneven tire pressures (front and rear)
• Incorrect brake fluid level • Incorrect tire pressure
EAM30361 • Uneven tire wear
FRONT FORK OIL LEAKING 7. Wheel(s)
Chassis • Incorrect wheel balance
1. Front fork • Broken or loose spoke
• Bent, damaged, or rusty inner tube • Damaged wheel bearing
• Cracked or damaged outer tube • Bent or loose wheel axle
• Improperly installed oil seal • Excessive wheel runout
• Damaged oil seal lip 8. Frame
• Incorrect oil level (high) • Bent frame
• Loose damper rod assembly bolt • Damaged steering head pipe
• Damaged damper rod assembly bolt copper • Improperly installed bearing race
washer
• Cracked or damaged cap bolt O-ring
9-3
LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS
EAM20156

EAM30365
LIST OF DIAGNOSTIC CODES

Fault code Item Page
Crankshaft position sensor: no normal signals are received from the crank-
12 8-28
shaft position sensor.
13 Intake air pressure sensor: open or short circuit detected. 8-29
Intake air pressure sensor: hose system malfunction (clogged or detached
14 hose). 8-31
15 Throttle position sensor: open or short circuit detected. 8-32

16 Throttle position sensor: stuck throttle position sensor is detected. 8-33
21 Coolant temperature sensor: open or short circuit detected. 8-34
22 Intake air temperature sensor: open or short circuit detected. 8-36
30 The vehicle has overturned. 8-37
Ignition coil: open or short circuit detected in the primary lead of the ignition
33 coil. 8-38
39 Injector: open or short circuit detected. 8-40

41 ECU: built-in lean angle sensor malfunction. 8-41
43 Fuel system voltage: incorrect voltage supplied to the main relay. 8-41
EEPROM fault code number: an error is detected while reading or writing on
44 8-43
EEPROM.
46 Vehicle system power supply: normal voltage is not supplied to the ECU. 8-44
50 ECU: faulty ECU memory. 8-45
70 Engine forcibly stops when the vehicle is left idling for a long period of time. 8-45
9-4
EAM30367
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 starter 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.
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)
21 Neutral switch Operate the shift pedal.
• Gear in neutral • ON
• Gear not in neutral • OFF
25 Gear position switch Operate the shift pedal.
• Gear in 1st or 2nd • ON
• Gear in other than 1st or 2nd • OFF
60 EEPROM fault code display —
• No fault • 00
• CO adjustment valve • 01
• Power Tuner injection cor- • 07
rection setting 0–8, or Power
Tuner ignition timing correc-
tion setting 0–8
61 Malfunction history () code —
display *1
• There is no history. • 00
• There is some history. • Other: Displays the fault code
of ().
9-5
Diag-
nostic
Item Display Procedure
code
No.
62 Malfunction history () code Replace all () with () by

erasure *1 the operation start process-
ing.
• There is some history. • Other: Displays the total num-
ber of () and ().
64 Setting history display Displays the presence or —
absence of the setting history by
Power Tuner.
• 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. —
*1: Symbols used in the explanations of the malfunction history
: Normal
: There is currently a malfunction or abnormal condition.
: A malfunction or abnormal condition occurred previously, but the affected system or component is
currently operating normally.
EAM30368
ACTUATOR OPERATION TABLE

Diag-
nostic
code Item Actuation Procedure
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.
51 Radiator fan motor relay Actuates the radiator fan motor Check that the radiator fan
relay five times at five-second motor relay is actuated five
intervals. times by listening for the oper-
“WARNING” on the Yamaha ating sound.
diagnostic tool blinks five times
when the radiator fan motor
relay is actuated.
9-6
9-7
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 EAM30169
CHASSIS DRIVE AND REAR WHEEL SPROCKETS

SETTING PARTS
EAM30168
SELECTION OF THE SECONDARY Part name Type Part number

REDUCTION RATIO (SPROCKET) Drive sprocket “1”
Secondary reduction ratio = Number of (STD) 13T 9383E-13233

rear wheel sprocket teeth/Number of Rear wheel sprocket
drive sprocket teeth “2”
47T 17D-25447-50
Secondary reduction ratio 48T 17D-25448-50
3.846 (50/13)
49T 17D-25449-50
<Requirement for selection of secondary gear (STD) 50T 17D-25450-50
reduction ratio>
• It is generally said that the secondary gear ratio 51T 17D-25451-50
should be reduced for a longer straight portion 52T 17D-25452-50
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
machine can run at maximum speed, the ma-
chine is generally set such that it can develop
its maximum revolutions toward the end of the
straight line, with care taken to avoid the en-
gine over-revving.
TIP
Riding technique varies from rider to rider and EAM30170
the performance of a machine also vary from TIRE PRESSURE

machine to machine. Therefore, do not imitate Tire pressure should be adjusted to suit the road
other rider’s settings from the beginning but surface condition of the circuit.
choose your own setting according to the level of
your riding technique. Standard tire pressure
100 kPa (1.00 kgf/cm2, 15 psi)
• Under a rainy, a muddy, a sandy, or a slippery

condition, the tire pressure should be lower for
a larger area of contact with the road surface.
Extent of adjustment
60–80 kPa (0.60–0.80 kgf/cm2, 9–
12 psi)
10-1
CHASSIS
• Under a stony or a hard road condition, the tire

pressure should be higher to prevent a flat tire.
100–120 kPa (1.00–1.20 kgf/cm2,
15–18 psi)
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. A. Air spring characteristics in relation to oil
EAM30172
amount change
CHANGE IN AMOUNT AND B. Load
CHARACTERISTICS OF FORK OIL C. Stroke
Damping characteristic near the final stroke can 1. Max. oil amount
be changed by changing the fork oil amount. 2. Standard oil amount
EWA19190
WARNING 3. Min. oil amount

Adjust the oil amount in 5 cm³ (0.2 US oz, 0.2 EAM30173
Imp.oz) increments or decrements. Too SETTING OF SPRING AFTER

small oil amount causes the front fork to pro- REPLACEMENT
duce a noise at full rebound or the rider to As the front fork setting can be easily affected by
feel some pressure on his hands or body. Al- the rear suspension, take care so that the front
ternatively, too large oil amount will cause and the rear are balanced (in position etc.) when
the air spring characteristics to have a ten- setting the front fork.
dency to be stiffer with the consequent dete- 1. Use of soft spring
riorated performance and characteristics. • Change the rebound damping force.
Therefore, adjust the front fork within the Turn out one or two clicks.
specified range. • Change the compression damping force.
Turn in one or two clicks.
Recommended oil TIP
Yamaha Suspension Oil S1 Generally a soft spring gives a soft riding feeling.
Standard oil amount Rebound damping tends to become stronger
290 cm³ (9.80 US oz, 10.23 and the front fork may sink deeply over a series
Imp.oz) of gaps.
260–365 cm³ (8.79–12.34 US oz, 2. Use of stiff spring
9.17–12.87 Imp.oz) • 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 The rear suspension setting includes the follow-

Generally a stiff spring gives a stiff riding feeling. ing two factors:
Rebound damping tends to become weaker, re- 1. Setting of spring preload
sulting in lack of a sense of contact with the road • Change the set length of the spring.
surface or in a vibrating handlebar. • Change the spring.
2. Setting of damping force
EAM30174 • Change the rebound damping force.
FRONT FORK SETTING PARTS • Change the compression damping force.
• Front fork spring “1”
EAM30176
Spring I.D. CHOOSING SET LENGTH

Type rate Part number Mark 1. Place a stand or a block under the engine to
N/mm (slits)
put the rear wheel above the floor, and mea-
SOFT 4.5 BR9-23141-20 |-|| sure the length “a” between the rear wheel
4.6 BR9-23141-A0 — axle center and the rear fender holding bolt.
STD
4.6 BR9-23141-30 |-|||
4.7 BR9-23141-40 |-||||
4.8 BR9-23141-50 |-|||||
STIFF 4.9 BR9-23141-60 ||-|| a
5.0 BR9-23141-70 ||-|||
5.1 BR9-23141-80 ||-||||
TIP
The I.D. mark (slits) “a” is proved on the end of 2. Remove the stand or block from the engine
the spring. and, with a rider astride the seat, measure the
sunken length “b” between the rear wheel
a axle center and the rear fender holding bolt.
3. Loosen the locknut “1” and make adjustment

by turning the adjuster “2” to achieve the
standard figure from the subtraction of the
length “b” from the length “a”.
Standard figure
1 90–100 mm (3.5–3.9 in)
TIP
EAM30175
• If the machine is new and after it is broken in,
REAR SUSPENSION SETTING the same set length of the spring may change
The rear shock absorber setting should be made because of the initial fatigue, etc. of the spring.
depending on the rider’s feeling of an actual run Therefore, be sure to make reevaluation.
and the circuit conditions. • If the standard figure cannot be achieved by
10-3
CHASSIS
adjusting the adjuster and changing the set

length, replace the spring with an optional one
and make readjustment.
a
1
2
EAM30178
REAR SHOCK ABSORBER SETTING PARTS

• Rear shock spring “1”
EAM30177 Spring
SETTING OF SPRING AFTER Type rate Part number I.D. Mark
N/mm
REPLACEMENT
After replacement, be sure to adjust the spring to BR9-22212-00
the set length [sunken length 90–100 mm (3.5– (Blue)
52 Yellow
3.9 in)] and set it. BR9-22212-50
1. Use of soft spring (Black)
SOFT
• Adjust to decrease rebound damping force to BR9-22212-10
compensate for less spring load. Run with the (Blue)
rebound damping force adjuster one or two 54 Pink
BR9-22212-60
clicks turned out, and readjust it to suit your (Black)
preference.
BR9-22212-20
2. Use of stiff spring (Blue)
• Adjust to increase rebound damping force to STD 56 White
compensate for greater spring load. Run with BR9-22212-70
(Black)
the rebound damping force adjuster one or
two clicks turned in, and readjust it to suit your BR9-22212-30
(Blue)
preference. 58 Silver
TIP BR9-22212-80
Adjusting the rebound damping force will be fol- (Black)
STIFF
lowed more or less by a change in the compres- BR9-22212-40
sion damping force. For correction, adjust to (Blue)
60 Brown
decrease compression damping force. BR9-22212-90
EWA19200 (Black)
WARNING
TIP
When using a rear shock absorber other • The I.D. mark “a” is marked at the end of the
than currently installed, use the one whose spring.
overall length “a” does not exceed the stan- • Spring specification varies according to the
dard as it may result in faulty performance. color of I.D. marks.
Never use one whose overall length is great-
er than standard.
Length “a” of standard shock

460.5 mm (18.1 in)
10-4
CHASSIS
• Spring preload adjusting positions

Spring preload adjusting positions
Minimum
turned in 1.5 mm (0.06 in) from
its free length.
Standard
its free length.
Maximum
its free length.
TIP
For the spring preload adjustment, refer to “AD-
JUSTING THE REAR SHOCK ABSORBER AS-
SEMBLY” on page 3-30.
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 (about 2 clicks) to decrease
damping force
damping.
Stiff over entire
range    Decrease oil amount by about 5–
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- Slide metal Replace with a new one for

ment over entire     extended use.
range Replace with a new one for
Piston metal extended use.
Lower bracket
Retighten to specified torque.
tightening torque
Rebound damp- Turn adjuster counterclockwise

Poor initial move- (about 2 clicks) to decrease
 ing force damping.
ment
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  
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
cm³ (0.2 US oz, 0.2 Imp.oz).
toming out
Stiff initial move- Compression
    (about 2 clicks) to decrease
ment damping force
damping.
10-6
CHASSIS
Section
Large Medium Small
Jump
gap gap gap
Compression Turn adjuster clockwise (about 2

damping force clicks) to increase damping.
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).
Compression (about 2 clicks) to decrease
damping force
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).
Decrease oil amount by about 5–
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
Large Medium Small
Jump
gap gap gap

Rebound damp-
(about 2 clicks) to decrease
ing force damping.
Stiff, tending to
 
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.
10-7
CHASSIS
Section
Large Medium Small
Jump
gap gap gap

Rebound damp- (about 2 clicks) to decrease
Heavy and drag-   ing force
ging damping.
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-
 High compres- Turn adjuster clockwise (about
ping
sion damping 1/6 turn) to increase damping.
Set sunken length for 90–100
High compres- Turn adjuster clockwise (about
sion damping 1/6 turn) to increase damping.
Set sunken length for 90–100
Bottoming out  
Rebound damp- Turn adjuster clockwise (about 2
Bouncing   ing force clicks) to increase damping.
High compres-
(about 1/6 turn) to decrease
sion damping damping.
Stiff travel   Set sunken length for 90–100
10-8
CHASSIS
10-9
EAM20149 EAM30323
WIRING DIAGRAM COLOR CODE

YZ450FXK 2019 B Black
1. Crankshaft position sensor Br Brown
2. AC magneto Gy Gray
3. Rectifier/regulator L Blue
4. Joint connector Lg Light green
5. Main relay O Orange
6. Engine ground P Pink
7. Battery R Red
8. Frame ground Sb Sky blue
9. Main fuse W White
10. Starter relay Y Yellow
11. Starter motor B/L Black/Blue
12. Diode 1 B/O Black/Orange
13. Diode 2 B/R Black/Red
14. CCU (Communication Control B/W Black/White
Unit) B/Y Black/Yellow
15. Warning light Br/W Brown/White
16. Fuel level warning light G/W Green/White
17. Engine trouble warning light G/Y Green/Yellow
18. Resistor L/B Blue/Black
19. Fuel sender L/G Blue/Green
20. Yamaha diagnostic tool cou- L/R Blue/Red
pler L/W Blue/White
21. ECU (Engine Control Unit) L/Y Blue/Yellow
22. Ignition coil P/B Pink/Black
23. Spark plug P/L Pink/Blue
24. Fuel injector R/B Red/Black
25. Fuel pump R/L Red/Blue
26. Radiator fan motor fuse R/W Red/White
27. Radiator fan motor (For JPN) R/Y Red/Yellow
28. Radiator fan motor relay W/B White/Black
29. Intake air temperature sensor W/G White/Green
30. Coolant temperature sensor Y/G Yellow/Green
31. Throttle position sensor Y/R Yellow/Red
32. Intake air pressure sensor Y/W Yellow/White
33. Engine stop switch
34. Gear position switch
35. Mode switch
36. Start switch
37. Diode 3
A. Battery sub-lead
B. Wire harness
D. CCU sub-lead
For your best ownership experience, think Genuine Yamaha!
Genuine Yamaha Parts – Genuine Yamaha replacement parts are the exact same parts as the ones
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?
Genuine Yamaha Accessories – Yamaha only offers accessories that meet our high standards for quality
and performance. Buy with confidence, knowing your Genuine Yamaha Accessories will fit right and
perform right – right out of the box.
Yamalube – Take care of your Yamaha with legendary Yamalube oils, lubricants, and care products.
They're formulated and approved by the toughest judges we know: the Yamaha engineering teams that
know your Yamaha from the inside out.
Genuine Yamaha Service Manuals – Get the same factory manual for your vehicle that the technicians
at your authorized Yamaha dealer use. Service manuals are available through your Yamaha dealer or you
can order them directly through yamahapubs.com.
Genuine Yamaha products are available only from your Yamaha dealer.
Read this manual carefully
EAM20161
Find out more at yamaha-motor.com

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
B3J-28199-10_1_cover_12mm.indd 4-6 2018/07/09 11:12:24

2019
YZ450FXK
YZ450FX
Read this manual carefully before operating this vehicle.
2019
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN

YZ450FXK
2018.05-0.3×2 !
(E)
LIT-11626-32-25 B3J-28199-10 ■
B3J-28199-10_2_cover_12mm.indd 1-3 2018/09/14 14:16:15

YZ450FXK 2019
WIRING DIAGRAM
B3J-28199-10_W.D.indd 1 2018/04/18 11:44:57

YZ450FXK 2019
WIRING DIAGRAM
B3J-28199-10_W.D.indd 2 2018/04/18 11:44:57

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2019

OWNER’S SERVICE MANUAL

PRINTED ON RECYCLED PAPER PRINTED IN JAPAN

B3J-28199-10_2_cover_12mm.indd 1-3 2018/09/14 14:16:15

Find out more at yamaha-motor.com

B3J-28199-10_1_cover_12mm.indd 4-6 2018/07/09 11:12:24

IMPORTANT MANUAL INFORMATION

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

A NOTICE indicates special precautions that must be taken to avoid

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

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

HOW TO USE THIS MANUAL

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

Filling fluid Molybdenum disulfide oil

Lubricant Brake fluid

Special tool B Wheel bearing grease

Tightening torque LS Lithium-soap-based grease

Wear limit, clearance M Molybdenum disulfide grease

Engine speed S Silicone grease

Electrical data Apply locking agent (LOCTITE®).

Engine oil New Replace the part with a new one.

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

BASIC SERVICE INFORMATION.....................................................................1-8

MAINTENANCE AFTER BREAK-IN ..............................................................1-23

MOTORCYCLE CARE AND STORAGE.........................................................1-26

LOCATION OF IMPORTANT LABELS

For use only on a closed course

VEHICLE IDENTIFICATION NUMBER

ENGINE SERIAL NUMBER

INCLUDED PARTS WARNING

NIPPLE WRENCH The exhaust gas is poisonous.

FUEL HOSE JOINT COVER 2

pressed or while the engine is running (the

3. CCU (Communication Control Unit)

a. CCU serial number

PREPARATION FOR REMOVAL AND

4. During disassembly, clean each of the parts,

3. During disassembly, check and measure the

GASKETS, OIL SEALS AND O-RINGS

BEARINGS AND OIL SEALS

BASIC SERVICE INFORMATION

contacts the vehicle, a spark could be gener- NOTICE

Checking the electrical system Checking the connections

Digital circuit tester (CD732) 1-11, 5-38, 8-57,

Radiator cap tester adapter 3-7, 3-8

Yamaha diagnostic tool USB (US) 3-15, 7-9, 8-25

Yamaha diagnostic tool (A/I) 3-15, 7-9, 8-25

FI diagnostic tool sub–lead 3-15, 7-9, 8-26

OBD/ GST Leadwire kit 3-15, 7-9, 8-25

Digital tachometer 3-16, 3-37, 8-65

Thickness gauge 3-17, 5-43

Valve lapper (ø14) 90890-04101

Spoke nipple wrench (6–7) 3-33

Steering nut wrench 3-34, 4-52

Timing light 3-37

Cap bolt ring wrench 4-40, 4-40, 4-41,

Cap bolt wrench 4-41, 4-44

Fork seal driver 4-45, 4-46