Yamaha Aerox155 Service Manual

2017
SERVICE MANUAL
GDR155/GDR155-A
B63-F8197-EZ

EAS20003
IMPORTANT
This manual was produced by the Yamaha Motor VietnamVietna m Co.,Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
Yamaha Motor Vietnam Co.,Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
IP
Designs and specifications are subject to change without notice.
EAS30001
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 personal inju-
ry 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 result

WARNING
in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to
NOTICE the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.
EAS20002
NVX
SERVICE MANUAL
©2016 by Yamaha
Yamaha Motor Vietnam Co.,Ltd.
1st edition, December 2016
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Vietnam Co.,Ltd.
is expressly prohibited.

EAS20004
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check 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
Sub-section titles “2” appear
appear in smaller print than the section
section title.
• To help identify parts and clarify
clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in in the order of the jobs in the exploded diagram. A number iindicates
ndicates a disas-
sembly step.
• Symbols
Symbols “5” indicate
indicate parts to be lubricated
lubricated or replaced.
replaced.
Refer to “SYMBOLS”.
“SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. This step explains removal
re moval and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
3
2
7
6

EAS20005
SYMBOLS
The following symbols are used in this manual for easier understanding.
IP
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 par t with a new one.

E
Silicone fluid
S

EAS10003
TABLE OF CONTENTS
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

GENERAL INFORMATION
IDENTIFICATION ............................................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
ENGINE SERIAL NUMBER ......................................................................1-1
1
IMPORTANT INFORMATION .........................................................................1-2
PREPARATION FOR REMOVAL AND DISASSEMBLY...........................1-2
DISASSEMBLY...........................1-2
REPLACEMENT PARTS...........................................................................1-2
PARTS...........................................................................1-2
GASKETS, OIL SEALS AND O-RINGS ....................................................1-2
LOCK WASHERS/PLATES AND COTTER PINS .....................................1-2
BEARINGS AND OIL SEALS ....................................................................1-3
CIRCLIPS ..................................................................................................1-3
RUBBER PARTS.......................................................................................1-3
PARTS.......................................................................................1-3
BASIC SERVICE INFORMATION ...................................................................1-4

QUICK FASTENERS.................................................................................1-4
FASTENERS .................................................................................1-4
ELECTRICAL SYSTEM.............................................................................1-5
SYSTEM.............................................................................1-5
SPECIAL TOOLS ..........................................................................................1-10

IDENTIFICATION
EAS20007
IDENTIFICATION
EAS30002
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the frame.
EAS30004
ENGINE SERIAL NUMBER

The engine serial number “1” is stamped into the
crankcase.
1-1

IMPORTANT INFORMATION
EAS20009
EAS30006
PREPARATION FOR REMOVAL AND

DISASSEMBLY
1. Before rremoval
emoval and disassembl
disassembly,
y, remove
remove all
dirt, mud, dust and foreign material.
EAS30008
GASKETS, OIL SEALS AND O-RINGS

1. When overhauli
overhaulingng the engine, replace
replace all
gaskets, seals and O-rings. All gasket surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassem
reassembly,
bly, properly
properly oil all
all mating
mating
parts and bearings and lubricate the oil seal
2. Use onl
onlyy the proper
proper tools
tools and cleaning
cleaning equip- lips with grease.
ment.
Refer to “SPECIAL TOOLS” on page 1-10. 1-10.
3. When d disass
isassemblin
embling,
g, always
always keep
keep mated
mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mat-
ed” through normal wear. Mated parts must
always be reused or replaced as an assem-
bly.
1. Oil
2. Lip
3. Spring
4. Grease
EAS30009
LOCK WASHERS/PLATES AND COTTER

PINS
After removal, replace all lock washers/plates
4. During ddisasse
isassembly,
mbly, clean all
all of the parts
parts and “1” and cotter pins. After the bolt or nut has been
place them in trays in the order of disassem- tightened to specification, bend the lock tabs
bly. This will speed up assembly and allow for along a flat of the bolt or nut.
the correct installation of all parts.
5. Keep alalll parts away from
from any source
source of
of fire.
EAS30007
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
1-2

EAS30010 EAS30012
BEARINGS AND OIL SEALS RUBBER PARTS

Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in-
manufacturer’s marks or numbers are visible. spection. Some of the rubber parts are sensitive
When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc. Do not al-
lips with a light coat of lithium-soap-based low any items other than the specified one to
grease. Oil bearings liberally when installing, if contact the parts.
appropriate.
ECA13300
NOTICE
Do not spin the bearing with compressed air

because this will damage the bearing surfac-
es.
EAS30011
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.
1-3

BASIC SERVICE INFORMATION
EAS20010

EAS30013
QUICK FASTENERS
Rivet type
1. Rem
Remove:
ove:
• Quick
Quick fastener
fastener
IP
To remove the quick fastener, push its pin with a
screwdriver, then pull the fastener out. Screw type
1. Rem
Remov
ove:
e:
• Quick
Quick fast
fastener
ener
IP
To remove the quick fastener, loosen the screw
with a screwdriver, then pull the fastener out.
2. Inst
Instal
alll:
• Quick
Quick fastener
fastener
IP
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the part to be secured and push 2. In
Inst
stal
all:
l:
the pin in with a screwdriver. Make sure that the • Quick
Quick fast
fastener
ener
pin is flush with the fastener’s head.
IP
To install the quick fastener, insert the fastener
into the part to be secured and tighten the screw.
1-4

ECA16760
EAS30014
NOTICE
ELECTRICAL SYSTEM
Be sure to connect the battery leads to the
Electrical parts handling correct battery terminals. Reversing the bat-
ECA16600 tery lead connections could damage the
NOTICE electrical components.
Never disconnect a battery lead while the en-
gine is running; otherwise, the electrical
components could be damaged.
ECA16771
NOTICE
When connecting the battery leads to the

ECA16751 battery, be sure to connect the positive bat-
NOTICE tery lead first, then the negative battery lead.
When disconnecting the battery leads from If the negative battery lead is connected
conne cted first
the battery, be sure to disconnect the nega- and a tool or similar item contacts the vehi-
tive battery lead first, then the positive bat- cle while the positive battery lead is being
tery lead. If the positive battery lead is connected, a spark could be generated,
disconnected first and a tool or similar item which is extremely dangerous.
contacts the vehicle, a spark could be gener-
ated, which is extremely dangerous.
ECA16610
NOTICE
Turn the main switch to “OFF” before dis-

IP
connecting or connecting an electrical com-
If a battery lead is difficult to disconnect due to
rust on the battery terminal, remove the rust us- ponent.
ing hot water.
1-5

ECA16620
NOTICE Checking the electrical system

Handle electrical components with special IP
care, and do not subject them to strong Before checking the electrical system, make
shocks. sure that the battery voltage is at least 12 V.
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
IP
NOTICE
When resetting the ECU by turning the main
For waterproof couplers, never insert the
switch to “OFF”, be sure to wait approximately 5
tester probes directly into the coupler. When
seconds before turning the main switch back to
performing any checks using a waterproof
“ON”.
coupler, use the specified test harness or a
suitable commercially available test har-
ness.
1-6

2. Che
Check:
Checking the connections • Lead
Check the leads, couplers, and connectors for • Coup
Couple lerr
stains, rust, moisture, etc. • Connec
Connector tor
1. Disc
Discon
onne
nect
ct:: Moisture  Dry with an air blower.
• Lead Rust/stains  Connect and disconnect sev-
• Coup
Couple
lerr eral times.
• Conne
Connecto
ctorr
ECA16780
NOTICE
• When disconnecting
disconnecting a coupler, release
release the
coupler lock, hold both sections of the cou-
pler securely, and then disconnect
disconnec t the cou-
pler.
• There are many
many types of coupler locks;
locks;
therefore, be sure to check the type of cou-
pler lock before disconnecting the coupler.
3. Che
Check:
• All conne
connecti
ctions
ons
Loose connection  Connect properly.
IP
• If the pin “1” on the terminal
terminal is
is flattened,
flattened, bend
it up.
• After disassemb
disassembling
ling and assembling
assembling a coupler,
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.
1-7

• As a quick remedy,
remedy, use a contact revitalize
revitalizerr
available at most part stores.
4. Conn
Connec
ect:t:
• Lead
• Coup
Couple
lerr
• Conne
Connecto
ctorr
IP
• When connecting
connecting a coupler
coupler or connector,
connector, push
both sections of the coupler or connector to-
gether until they are connected securely.
• Make sure
sure all connections
connections are tight.
tight.
6. Che
Check:
• Resis
Resistan
tance
ce
Pocket tester
90890-03112

Analog pocket tester
YU-03112-C
IP
The resistance values shown were obtained at
the standard measuring temperature of 20 °C
(68 °F). If the measuring temperature is not 20
°C (68 °F), the specified measuring conditions
will be shown.
Coolant temperature sensor re-

sistance

2512-2777  at 20 °C (2512-2777
5. Che
Check:  at 68 °F)
• Conti
Continui
nuity
ty Coolant temperature sensor re-
(with the pocket tester) sistance
210–221  at 100 °C (210–221 
Pocket tester at 212 °F)
90890-03112

Analog pocket tester
YU-03112-C
IP
• If there is no continuity,
continuity, clean the ter
terminals
minals..
• When checking
checking the wire
wire harness, perform
perform
steps (1) to (3).
1-8

1-9

SPECIAL TOOLS
EAS20012
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
IP
• For U.S.A. and Canada, use part numbers starting

starting with “YM-
“YM-”,
”, “YU-”, or “ACC-”.
“ACC-”.
• For others,
others, use part numbers starting
starting with “90890-”.
“90890-”.
Reference
Tool name/Tool No. Illustration
pages
Pocket tester 1-8, 1-8
1-8, 1-8,, 8-97,
8-97,
90890-03112 8-98,, 8-98,
8-98 8-98, 8-99,
8-99,
Analog pocket tester 8-102,, 8-103,
8-102 8-103,
YU-03112-C 8-103,, 8-103,
8-103 8-103,
8-104,, 8-104,
8-104 8-104,
8-105,, 8-105,
8-105 8-105,
8-106,, 8-107,
8-106 8-107,
8-108,, 8-108
8-108
Tappet adjusting tool 3-7
90890-01311
Six piece tappet set
YM-A5970
YM-A5970
ø8 ø9 ø10
ø3 ø4
Yamaha diagnostic tool USB 3-7, 3-8

3-7, 3-8,, 4-51,
4-51,
90890-03250 4-55, 7-14,
7-14, 7-14,
7-14,
8-28,, 8-69,
8-28 8-69, 8-90
Yamaha diagnostic tool (A/I) 3-7, 3-8

3-7, 3-8,, 4-51,
4-51,
90890-03252 4-55, 7-14,
7-14, 7-14,
7-14,
8-28,, 8-69,
8-28 8-69, 8-90
Steering nut wrench 3-14,, 3-15,

3-14 3-15, 4-69
90890-01403
Exhaust flange nut wrench
YU-A9472
Thickness gauge 4-26

90890-03180
Feeler gauge set
YU-26900-9
1-10

SPECIAL TOOLS
Reference
pages
T-handle 4-63,, 4-64
4-63
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
Fork seal driver weight 4-64,, 4-65

4-64
90890-01367
Replacement hammer
YM-A9409-7
9409-7 /YM-A5142-
YM-A9409-7
YM-A /YM-A5142-4
4
Fork seal driver attachment (ø30) 4-64,, 4-65

4-64
90890-01400
Compression gauge 90890-03081

5-1
90890-03081
Engine compression tester
YU-33223
YU-33223
Extension 5-1
90890-04136
Camshaft wrench 5-13,, 5-17

5-13
90890-04162
Camshaft wrench
YM-04162
Yamaha bond No. 1215 5-16,, 5-55

5-16
90890-85505
(Three bond No.1215®)
1-11

SPECIAL TOOLS
Reference
pages
Slide hammer bolt 5-19
90890-01085
Slide hammer bolt 8 mm
YU-01083-2
Weight 5-19
90890-01084
Weight
YU-01083-3
YU-01083-3
Valve spring compressor 5-23,, 5-28

5-23
90890-04019
Valve spring compressor

YM-04019
Valve spring compressor attachment 5-23,, 5-28

5-23
90890-04108
Valve spring compressor adapter 22 mm
YM-04108
Valve guide remover (ø5) 5-24

90890-04097
Valve guide remover (5.0 mm)
YM-04097
Valve guide installer (ø5) 5-24

90890-04098
Valve guide installer (5.0 mm)
YM-04098
Valve guide reamer (ø5) 5-24

90890-04099
Valve guide reamer (5.0 mm)
YM-04099
1-12

SPECIAL TOOLS
Reference
pages
Piston pin puller set 5-30
90890-01304
Piston pin puller
YU-01304
YU-01304
Rotor holding tool 5-37, 5-42,

5-37, 5-42, 5-44,
5-44,
90890-01235 5-44
Universal magneto and rotor holder
YU-01235
Rotor holding tool 5-37,, 5-41

5-37
90890-01701
Socket wrench (39 mm) 5-37,, 5-41

5-37
90890-01493
Sheave spring compressor 5-37,, 5-40

5-37
90890-04134
Sheave spring compressor
YM-04134
1-13

SPECIAL TOOLS
Reference
pages
Sheave fixed block 5-37,, 5-40
5-37
90890-04135
Sheave fixed bracket
YM-04135
Oil seal guide (37 mm) 5-40

90890-04177
ø37
Flywheel puller 5-44

90890-01189
Flywheel
YM-01189puller
Digital circuit tester 5-51, 8-106,

5-51, 8-106,
90890-03174 8-109
Model 88 Multimeter with tachometer
YU-A1927
Crankcase separating tool 5-53

90890-01135
Crankcase separator
YU-01135-B
1-14

SPECIAL TOOLS
Reference
pages
Crankshaft installer pot 5-54
90890-01274
Installing pot
YU-90058
YU-90058/YU-90059
Crankshaft installer bolt 5-54

90890-01275
Bolt
YU-90060
Adapter (M12) 5-54

90890-01278
Adapter
YU-90063#3
Spacer (crankshaft installer) 5-54

90890-04081
Pot spacer
YM-91044
YM-91044
Radiator cap tester 6-3,, 6-3

6-3
90890-05375
Mechanical seal installer 6-8

90890-04145 ø30
ø10
Middle driven shaft bearing driver 6-8

90890-04058
Middle drive bearing installer 40 & 50 mm
YM-04058
1-15

SPECIAL TOOLS
Reference
pages
Pressure gauge 7-4
90890-03153
Pressure gauge
YU-03153
Fuel pressure adapter 6.3mm 7-4

90890-03227
Ignition checker 8-105

90890-06754
Oppama pet–4000 spark checker
YM-34487
1-16

SPECIAL TOOLS
1-17

SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................2-1
ENGINE SPECIFICATIONS ............................................................................2-2
CHASSIS SPECIFICATIONS ..........................................................................2-6
2
ELECTRICAL SPECIFICATIONS ...................................................................2-8
TIGHTENING TORQUES ..............................................................................2-10

GENERAL TIGHTENING TORQUE SPECIFICATIONS.........................2-10
SPECIFICATIONS .........................2-10
ENGINE TIGHTENING TORQUES.........................................................2-11
TORQUES .........................................................2-11
CHASSIS TIGHTENING TORQUES .......................................................2-13
LUBRICATION POINTS AND LUBRICANT TYPES ....................................2-15

ENGINE...................................................................................................2-15
ENGINE ...................................................................................................2-15
LUBRICATION SYSTEM CHART AND DIAGRAMS....................................2-16

DIAGRAMS....................................2-16
ENGINE OIL LUBRICATION CHART .....................................................2-16
LUBRICATION DIAGRAMS ....................................................................2-17
COOLING SYSTEM DIAGRAMS ..................................................................2-19
CABLE ROUTING .........................................................................................2-20

GENERAL SPECIFICATIONS
EAS20013
GENERAL SPECIFICATIONS
Model
Model B631/B633
Dimensions
O
Ov
ve
erra
allll lw
eindgthth 10
790
90mmmm(2(7
7.85.3ini)n)
Overall height 1125 mm (44.3 in)
Seat height 790 mm (31.1 in)
Wheelbase 1350 mm (53.1 in)
Ground clearance 140 mm (5.50 in)
Minimum turning radius 2.0 m
Weight
Curb weight 116 kg (255 lb) (GDR155)
118 kg (260 lb) (GDR155-A)
Maximum load 154 kg (339 lb) (GDR155)
153 kg (336 lb) (GDR155-A)
2-1

ENGINE SPECIFICATIONS
EAS20014
Engine
Engine type Liquid cooled 4-stroke, SOHC
Displacement 155 cm³
Cylinder arrangement Single cylinder
  
Compr st
Bore s
estrsoiokn
e ratio 58 .0 58.7
10.5 : 1 mm (2.28 2.31 in)
Compression pressure 1374–1769 kPa/1393 r/min
Starting system Electric starter
Fuel
Recommended fuel Regular unleaded gasoline (Gasohol [E10]
acceptable)
Fuel tank capacity 4.6 L (1.2 US gal, 1.1 lmp.gal)
Fuel reserve amount 0.8 L
Engine oil
Lubrication system Wet sump
Recommended brand YAMALUBE
Type SAE 10W-40
Recommended engine oil grade API service SG type or higher, JASO standard
MA or MB
Engine oil quantity
Quantity (disassembled) 1.00 L (1.06 US qt, 0.88 Imp.qt)
Periodic oil change 0.90 L (0.95 US qt, 0.79 Imp.qt)
Final transmission oil

Type Motor oil SAE 10W-30 type SE or higher or Gear
oil SAE 85W GL-3
Quantity (disassembled) 0.16 L (0.17 US qt, 0.14 Imp.qt)
Quantity 0.15 L (0.16 US qt, 0.13 Imp.qt)
Oil filter
Oil filter type Centrifugal
Oil pump
Inner-rotor-to-outer-rotor-tip clearance 0.150 mm (0.0059 in)
Limit 0.23 mm (0.0091 in)
Oute
Ou ter-
r-rrot
otor
or-t
-to-
o-oi
oil-
l-pu
pum
mp-
p-ho
hous
usin
ing
g cle
lear
aran
anc
ce 0.
0.13
13–0
–0.1
.18
8 mm (0
(0.0
.005
051–
1–0.
0.00
0071
71 in)
in)
Limit 0.22 mm (0.0086 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.06–0.11 mm (0.0024–0.0043 in)
Limit 0.18 mm (0.0071 in)
Coolant quantity
Radiator (including all routes) 0.46 L (0.49 US qt, 0.40 Imp.qt)
Coolant
Coolant reser
reservoi
voirr (up to
to the maximu
maximum
m level
level mark)
mark) 0.13 L (0.13
(0.13 US qt,
qt, 0.11 lmp.
lmp.qt)
qt)
2-2

Radiator cap valve opening pressure 78.6–137.4 kPa (0.79–1.37 kgf/cm²,

11.4–19.9 psi)
Thermostat
Valve opening temperature 74.0–78.0 °C (165.20–172.40 °F)
Valve full open temperature 90.0 °C (194.00 °F)
Valve lift (full open) 7.0 mm (0.28 in)
Water pump
Water pump type Single suction centrifugal pump
Spark plug(s)
Manufacturer/model NGK/CPR8EA-9
DENSO/U24EPR-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 lobe dimensions
Lobe height (Intake) 32.211–32.311 mm (1.2681–1.2721 in)
Limit 32.111 mm (1.2642 in)
Lobe height (Intake high speed) 32.587–32.687 mm (1.2830–1.2869 in)
Limit (High speed) 32.487 mm (1.2790 in)
Lobe height (Exhaust) 29.420–29.520 mm (1.1583–1.1622 in)
Limit 29.320 mm (1.1543 in)
Camshaft runout limit 0.030 mm (0.0012 in)
Rocker arm/rocker arm shaft

Rocker arm inside diameter 9.985–10.000 mm (0.3931–0.3937 in)
Limit 10.015 mm (0.3943 in)
Rocker arm shaft outside diameter 9.966–9.976 mm (0.3924–0.3928 in)
Limit 9.935 mm (0.3911 in)
Valve, valve seat, valve guide
Valve
Intakclearance
e (cold) 0.10–0.14 mm (0.0039–0.0055 in)
Exhaust 0.21–0.25 mm (0.0083–0.0098 in)
Valve dimensions
Valve seat contact width (intake) 0.90–1.20 mm (0.0354–0.0472 in)
Limit 1.7 mm (0.068 in)
Valve seat contact wi
width (exhaust) 0.90–1.20 mm
mm (0.0354–0.0472 in)
Limit 1.7 mm (0.068 in)
2-3

Valve stem diameter (intake) 4.975–4.990 mm (0.1959–0.1965 in)

Limit 4.945 mm (0.1946 in)
Valve stem diameter (exhaust) 4.960–4.975 mm (0.1953–0.1959 in)
Limit 4.930 mm (0.1940 in)
Valve guide inside diameter (intake) 5.000–5.012 mm (0.1969–0.1973 in)
Valve guide inside diameter (exhaust) 5.000–5.012 mm (0.1969–0.1973 in)
Valv
Va lve-
e-st
stem
em-t
-to-
o-va
valv
lve-
e-gu
guid
ide
e clea
cleara
ranc
nce
e (int
(intak
ake)
e) 0.
0.01
010–
0–0.
0.03
037
7 mm (0.0
(0.000
004–
4–0.
0.00
0015
15 in)
in)
Limit 0.080 mm (0.0032 in)
Valv
Va lve-s
e-stem
tem-t
-to-
o-val
valve
ve-g
-gui
uide
de cleara
clearanc
nce
e (exhau
(exhaust)
st) 0.025–
0.025–0.
0.052
052 mm (0.0
(0.0010
010–0.
–0.002
0020
0 in)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.010 mm (0.0004 in)
Valve spring
Free length (intake) 33.81 mm (1.33 in)
Limit 32.11 mm (1.26 in)
Free length (exhaust) 33.81 mm (1.33 in)
Limit 32.11 mm (1.26 in)
Spring tilt (intake) 1.7 mm (0.068 in)
Spring tilt (exhaust) 1.7 mm (0.068 in)
Cylinder
Bore 58.000–58.010 mm (2.2835–2.2839 in)
Wear limit 58.060 mm (2.3224 in)
Piston
Diameter 57.962–57.985 mm (2.2820–2.2829 in)
Measuring point (from piston skirt bottom) 6.0 mm (0.24 in)
Piston pin bore inside diameter 14.002–14.013 mm (0.5513–0.5517 in)
Limit 14.043 mm (0.5529 in)
Piston pin outside diameter 13.995–14.000 mm (0.5510–0.5512 in)
Limit 13.975 mm (0.5502 in)
Piston-pin-to-piston-pin-bore cl
clearance 0.002–0.018 mm
mm (0.0001–0.0007 in)
Piston ring
Top ring
Ring type Barrel
End gap (installed) 0.10–0.25 mm (0.0039–0.0098 in)
Limit 0.50 mm (0.0197 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Limit 0.115 mm (0.0045 in)
2nd ring
Ring type Taper
End gap (installed) 0.35–0.50 mm (0.0138–0.0197 in)
Limit 0.85 mm (0.0335 in)
Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in)
Limit 0.115 mm (0.0045 in)
Crankshaft
Crank assembly width 51.45–51.50 mm (2.026–2.028 in)
Runout limit 0.030 mm (0.0012 in)
2-4

Clutch
Clutch type Dry, centrifugal automatic
Automatic centrifugal clutch

Clutch shoe thickness 4.0 mm (0.16 in)
Limit 2.5 mm (0.10 in)
Clutch shoe spring free length 29.5 mm (1.16 in)
Clutch housing inside diameter 125.0 mm (4.92 in)
Limit 125.5 mm (4.94 in)
Compression spring free length 116.4 mm (4.58 in)
Limit 104.8 mm (4.12 in)
Weight outside diameter 20.0 mm (0.79 in)
Limit 19.5 mm (0.77 in)
Clutch-in revolution 2200–2600 r/min
Clutch-stall revolution 5000–5600 r/min
V-belt
V-belt width 24.1 mm (0.95 in)
Limit 21.7 mm (0.85 in)
Transmission
Transmission type V-belt automatic
Primary reduction ratio 1.000
Secondary reduction ratio 10.769 (56/16  40/13)
Final drive Gear
Gear ratio 2.300–0.724 : 1
Air filter
Air filter element Oil-coated paper element
Fuel injector
Resistance 12.2 
Throttle body
ID mark B631 00
Fuel injection sensor

Intak
take ai
air p
prress
essure sen
sens
sor out
utpu
putt v
vol
olttage
age 3.8
.88–
8–4.
4.12
12 V at 101.
101.3
3 kP
kPa (3.
(3.8
88–4.1
–4.12
2 V at
1.01 kgf/cm², 3.88–4.12 V at 14.7 psi)
Intake air temperature sensor resistance 5850.0–6150.0  at 0 °C (5850.0–6150.0  at
32 °F)
Coolant temperature sensor resistance 2512–2777  at 20 °C (2512–2777  at 68 °F)
Coolant temperature sensor resistance 210–221  at 100 °C (210–221  at 212 °F)
Idling condition
Fuel line pressure at idling 220–300 kPa (2.2–3.0 kgf/cm², 31.9–43.5 psi)
Engine idling speed 1500–1700 r/min
CO% (Muffler tail pipe) 0.0–1.0 %
Water temperature 80 °C (175.2 °F)
Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)
2-5

CHASSIS SPECIFICATIONS
EAS20015
Chassis
Frame type Underbone
Caster angle 26.5°
Trail 95 mm (3.7 in)
Front wheel
Wheel type Cast wheel
Rim size 14M/C  MT2.50
Rim material Aluminum
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)
Rear wheel
Wheel type Cast wheel
Rim size 14M/C  MT3.50
Rim material Aluminum
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)
Front tire
Type Tubeless
Size 110/80-14M/C 53P
Manufacturer/model IRC/SCT-005F
Wear limit (front) 1.0 mm (0.04 in)
Rear tire
Type Tubeless
Size 140/70-14M/C 62P
Manufacturer/model IRC/SCT-005R
Wear limit (rear) 1.0 mm (0.04 in)
Tire air pressure (measured on cold tires)

Front (1 person) 200 kPa (2.00 kgf/cm², 29 psi)
Rear (1 person) 225 kPa (2.25 kgf/cm², 33 psi)
Front (2 persons) 200 kPa (2.00 kgf/cm², 29 psi)
Rear (2 persons) 225 kPa (2.25 kgf/cm², 33 psi)
Front brake
Type Hydraulic single disc brake
Front disc brake
Disc outside diameter  t th
hickness 230.0  4.0 mm (9.06  0.16 in)
Brake disc thickness limit 3.5 mm (0.14 in)
Brake
Bra ke disc
disc runout
runout limit
limit (as measu
measured
red on wheel)
wheel) 0.15 mm (0.00
(0.0059
59 in)
Brake pad lining thickness 4.4 mm (0.17 in)
2-6

Master cylinder inside diameter 11.00 mm (0.43 in)

Caliper cylinder inside diameter 33.34 mm (1.31 in)
Specified brake fluid YAMAHA GENUINE BRAKE FLUID: DOT3 or
DOT 4 (GDR155)
YAMAHA GENUINE BRAKE FLUID: DOT
4-Plus (GDR155-A)
Rear brake
Type Drum barke
Rear barke lever free play 10.0–20.0 mm (0.39–0.79 in)
Rear drum brake
Drum brake type Leading, trailing
Brake drum inside diameter 130.0 mm (5.12 in)
Limit 131.0 mm (5.16 in)
Lining thickness 4.5 mm (0.18 in)
Shoe spring length 52.0 mm (2.05 in)
Shoe spring length 2 48.0 mm (1.89 in)
Steering
Steering bearing type Angular bearing
Center to lock angle (left) 47.5°
Center to lock angle (right) 47.5°
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/hydraulic damper
Wheel travel 100.0 mm (3.94 in)
Fork spring free length 282.1 mm (11.10 in)
Limit 276 mm (10.88 in)
Recommended oil Fork oil 10W or equivalent Yamaha Suspension
Oil G10
Quantity 55.0 cm³ (1.86 US oz, 1.93 Imp.oz)
Level 87.0 mm (3.06 in)
Rear suspension
Type Unit swing
Spring/shock absorber type Coil spring/hydraulic damper
Wheel travel 86.0 mm (3.39 in)
2-7

ELECTRICAL SPECIFICATIONS
SPECIFICATIONS
EAS20016
Voltage
System voltage 12 V
Ignition system
Igdnvitaionncesrystyte
A pme TC
D igIital
Ignition timing (B.T.D.C.) 5.0°/1600 r/min
Ignition coil
Primary coil resistance 2.16–2.64 
Secondary coil resistance 8.64–12.96 k
Spark plug cap

Resistance 3.75–6.25 k
AC magneto
Standard output 14.0 V, 705 W at 5000 r/min
Stator coil resistance 0.048–0.072 
Battery
Model GTZ7V
Voltage, capacity 12 V, 6.0 Ah (10HR)
Bulb voltage, wattage  quantity

Headlight LED
Auxiliary light 12 V, 5.0 W  2
Tail/brake light LED
Front turn signal light 12 V, 10.0 W  2
Rear turn signal light 12 V, 10.0 W  2
Meter lighting LED
License plate light 12 V, 5.0 W  1
Indicator light
Turn signal indicator light LED
High beam indicator light LED
Coolant temperature warning light LED
Engine trouble warning light LED
ABS warning light LED (GDR155-A)
Stop and Start System indicator light LED (GDR155-A)
Smart key system indicator light LED (GDR155-A)
Starter generator
Power output 0.29 kW
Fuel sender unit

Sender unit resistance (full) 10–14.0 
Sender unit resistance (empty) 267–273.0 
2-8

SPECIFICATIONS
Fuses
Main fuse 30.0 A
Headlight fuse 7.5 A
Fuel injection system fuse 7.5 A
Signaling system fuse 7.5 A
Ignition fuse 7.5 A
Backup fuse 7.5 A
Terminal fuse 1 2.0 A
ABS motor fuse 10.0 A (GDR155-A)
ABS control unit fuse 2.0 A (GDR155-A)
ABS solenoid fuse 7.5 A (GDR155-A)
Smart key system fuse 2.0 A (GDR155-A)
Spare fuse 10.0 A (GDR155-A)
Spare fuse 30.0 A
Spare fuse 7.5 A
Spare fuse 2.0 A
2-9

TIGHTENING TORQUES
EAS20017
TIGHTENING TORQUES
EAS30015
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. Distan
Distance
ce betwe
between
en flats
flats
B. Outsid
Outside
e thr
thread
ead diame
diameter
ter
General tightening torques

A (n
(nut) B (b
(bolt)
N ·m kgf·m lb·ft
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
2-10

TIGHTENING TORQUES
EAS30016
ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Muffler nut M8 2 20 N·m (2.0 kgf·m, 14 lb·ft)
Muffler bolt M10 3 57 N·m (5.7 kgf·m, 41 lb·ft)
Muffler protector bolt M6 2 8 N·m (0.8 kgf·m, 5.8 lb·ft) LT
Cylinder head bolt M6 2 10 N·m (1.0 kgf·m, 7.2 lb·ft)

Cylinder head nut M8 4 24 N·m (2.4 kgf·m, 17 lb·ft) M
VVA (variable valve actuator) sole-

VVA
M6 2 10 N·m (1.0 kgf·m, 7.2 lb·ft)
noid bolt
Cylinder head cover bolt M6 4 10 N·m (1.0 kgf·m, 7.2 lb·ft)
Engine oil check bolt M6 1 7 N·m (0.7 kgf·m, 5.1 lb·ft)
Camshaft sprocket bolt M8 1 30 N·m (3.0 kgf·m, 22 lb·ft)
Spark plug M10 1 13 N·m (1.3 kgf·m, 9.4 lb·ft)
Valve clearance adjusting
a djusting screw
M5 4 7 N·m (0.7 kgf·m, 5.1 lb·ft)
locknut
Coolant drain bolt (cylinder side) M6 1 10 N·m (1.0 kgf·m, 7.2 lb·ft)
Radiator fan case bolt M6 5 10 N·m (1.0 kgf·m, 7.2 lb·ft)
Radiator fan bolt M6 3 10 N·m (1.0 kgf·m, 7.2 lb·ft)
Radiator bolt M6 4 10 N·m (1.0 kgf·m, 7.2 lb·ft)
Coolant drain bolt (radiator side) M12 1 1.0 N·m (0.10 kgf·m, 0.72 lb·ft)
Radiator cover bolt M6 3 10 N·m (1.0 kgf·m, 7.2 lb·ft)
Fuel injector bolt M6 1 10 N·m (1.0 kgf·m, 7.2 lb·ft)
ISC (Idle Speed Control) unit holder
M6 1 5 N·m (0.5 kgf·m, 3.6 lb·ft)
screw
Air filter case bolt M6 2 10 N·m (1.0 kgf·m, 7.2 lb·ft)
AC magneto rotor nut M12 1 70 N·m (7.0 kgf·m, 51 lb·ft)
Transmission case cover bolt M8 6 20 N·m (2.0 kgf·m, 14 lb·ft)
Final transmission oil drain bolt M8 1 20 N·m (2.0 kgf·m, 14 lb·ft)
V-belt case bolt M6 10 10 N·m (1.0 kgf·m, 7.2 lb·ft)
Engine oil drain bolt M12 1 20 N·m (2.0 kgf·m, 14 lb·ft)
V-belt case air filter element cover
M6 6 7 N·m (0.7 kgf·m, 5.1 lb·ft)
bolt
Primary fixed sheave nut M12 1 49 N·m (4.9 kgf·m, 35 lb·ft)
Clutch housing nut M12 1 45 N·m (4.5 kgf·m, 33 lb·ft)
Secondar y sheave nut M28 1 55 N·m (5.5 kgf·m, 40 lb·ft)
2-11

TIGHTENING TORQUES
Cylinder head tightening sequence:
3 4
1 2
6 5
2-12

TIGHTENING TORQUES
EAS30017
CHASSIS TIGHTENING TORQUES

Thread
size
Engine bracket nut M10 1 54 N·m (5.4 kgf·m, 39 lb·ft)
Engine mounting nut (front side) M10 2 50 N·m (5.0 kgf·m, 36 lb·ft)
Engine mounting nut (rear side) M10 2 54 N·m (5.4 kgf·m, 39 lb·ft)
Grab bar bolt M8 4 11 N·m (1.1 kgf·m, 8.0 lb·ft)
Seat hinge nut M6 2 7 N·m (0.7 kgf·m, 5.1 lb·ft)
Storage box bolt M6 4 9 N·m (0.9 kgf·m, 6.5 lb·ft)
Front brake master cylinder holder
M6 2 10 N·m (1.0 kgf·m, 7.2 lb·ft)
bolt
Brake master cylinder reservoir cap
M4 2 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
screw
Front brake hose union bolt (master
M10 1 29 N·m (2.9 kgf·m, 21 lb·ft)
cylinder side)
Throttle cable holder bolt (handlebar
M5 1 3.5 N·m (0.35 kgf·m, 2.5 lb·ft)
switch side)
Lower ring nut M25 1 See TIP.
Upper ring nut M25 1 See TIP.
Horn bracket bolt M6 1 7 N·m (0.7 kgf·m, 5.1 lb·ft)
Horn bolt M6 1 7 N·m (0.7 kgf·m, 5.1 lb·ft)
Lower bracket pinch bolt M10 4 53 N·m (5.3 kgf·m, 38 lb·ft)
Front fork damper rod bolt M10 2 23 N·m (2.3 kgf·m, 17 lb·ft) LT
Front wheel sensor bolt M6 1 7 N·m (0.7 kgf·m, 5.1 lb·ft)

Front brake caliper bolt M10 2 35 N·m (3.5 kgf·m, 25 lb·ft)
Front brake hose union bolt (brake
M10 1 29 N·m (2.9 kgf·m, 21 lb·ft)
caliper side)
Brake caliper bleed screw M8 1 6 N·m (0.6 kgf·m, 4.3 lb·ft)
Front wheel axle nut M10 1 26 N·m (2.6 kgf·m, 19 lb·ft)
Front brake hose holder bolt M6 1 7 N·m (0.7 kgf·m, 5.1 lb·ft)
LT
Front brake disc bolt M8 3 23 N·m (2.3 kgf·m, 17 lb·ft)
Front wheel sensor rotor bolt M5 3 8 N·m (0.8 kgf·m, 5.8 lb·ft) LT
Camshaft lever bolt M6 1 7 N·m (0.7 kgf·m, 5.1 lb·ft)

Rear wheel axle nut M16 1 95 N·m (9.5 kgf·m, 69 lb·ft)
Hydraulic unit assembly bolt M6 2 7 N·m (0.7 kgf·m, 5.1 lb·ft)
Front brake hose union bolt
M10 2 29 N·m (2.9 kgf·m, 21 lb·ft)
(hydraulic unit assembly side)
Starter generator control unit assem-
M6 2 7 N·m (0.7 kgf·m, 5.1 lb·ft)
bly bolt
Rear shock absorber assembly nut
M8 2 23 N·m (2.3 kgf·m, 17 lb·ft)
(upper)
Rear shock absorber assembly bolt
M8 2 23 N·m (2.3 kgf·m, 17 lb·ft)
(lower)
Swingarm mounting bolt M10 2 57 N·m (5.7 kgf·m, 41 lb·ft)
Fuel tank bolt M6 4 9 N·m (0.9 kgf·m, 6.5 lb·ft)
2-13

TIGHTENING TORQUES
Thread
size
Throttle cable holder bolt (throttle
M6 2 5 N·m (0.5 kgf·m, 3.6 lb·ft)
body side)
Sidestand switch bolt M5 1 7 N·m (0.7 kgf·m, 5.1 lb·ft) LT
Centerstand spring hook bolt M6 1 7 N·m (0.7 kgf·m, 5.1 lb·ft)

Sidestand nut M8 1 32 N·m (3.2 kgf·m, 23 31 lb·ft)
IP
Steering column ring nut
1. Tighten the lowlower
er ring nut 38 N·m (3.8 kgf·m, 27 lb·f
lb·ft)
t) with a torque wrenc
wrenchh and the steering nut
wrench, and then loosen the nut 1/4 turn.
2. Tighten the lowlower
er ring nut 16 N·m (1.6 kgf·m, 12 lb·f
lb·ft)
t) with a torque wrenc
wrenchh and the steering nut
wrench.
3. Install the rubber
rubber washer
washer and the
the center ring nut.
nut.
4. Finger tig
tighten
hten the center ring
ring nut, align the slots of both rin
ring
g nuts, and then install tthe
he lock washer.
washer.
5. Hold the lower a and
nd center ring nuts,
nuts, and then tighten
tighten the upper ring nut 75 N·m (7.5
(7.5 kgf·m,
kgf·m, 54 lb·ft)
with a torque wrench and the steering nut wrench.
2-14

LUBRICATION POINTS AND LUBRICANT TYPES
EAS20018
LUBRICATION POINTS AND LUBRICANT TYPES

EAS30018
ENGINE
Lubrication point Lubricant
Bearings E
O-rings LS
O-rings (cam shaft) M
Oil seals LS
Rocker arm stopper pin M
Cylinder head nut contact face and stud bolt thread M
Camshaft lobes M
Decompression cam M
Rocker arm shafts M
Valve stems and valve guide (intake and exhaust) M
Valve stem seals E
Valve stem ends (intake and exhaust) M
Rocker arm valve inner surface M
Camshaft sprocket M
Connecting rod big end face E
Piston pin outer surface E
Piston, piston ring, and cylinder inner surface E
Crank pin E
Cam chain sprocket inner surface M
Oil pump drive gear inner surface M
Oil pump shaft E
O-ring (fuel injector) E

Starter wheel and bearing E
Starter clutch idle gear inner surface M
Drive axle and bearings LS
Crankshaft threads and conical spring washer outer mating surface LS
Yamaha bond
Timing chain tensioner bolts
No.1215®
Yamaha bond
Crankcase mating surfaces
No.1215®
Yamaha bond
Crankcase bolt
No.1215®
2-15

LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20019

EAS30020
ENGINE OIL LUBRICATION CHART
1. Oil str
strai
aine
nerr
2. Oi
Oill pum
pump p ass
assem
embl
bly
y
3. Cranksh
nksha aft
4. Oil no
nozzle
zle
5. Camshaf haft
2-16

EAS30021
LUBRICATION DIAGRAMS
1. Oil str
strai
aine
nerr
2. Oi
Oill pum
pump
p ass
assem
embl
bly
y
3. Camshafhaft
2-17

1. Oil str
strai
aine
nerr
2. Oi
Oill pum
pump p ass
assem
embl
bly
y
3. Cranksh
nksha aft
4. Roc
Rocker
ker arm/
arm/VValv
alve
e st
stem
em en
end
d
2-18

COOLING SYSTEM DIAGRAMS
EAS20020
COOLING SYSTEM DIAGRAMS

1 2
3
4 6
8
7
7
5
7
6
5
4
1 2 3
1. Radi
adiat
ator
or c
ca
ap 7. Water
ater p
pum
ump
p inle
inlett hose
hose
2. Co
Cool
olant
ant res
reserv
ervoi
oirr hos
hose
e 8. Water
ater p
pum
ump
p asse
assemb mbly
ly
3. Radiator
tor
4. Ra
Radi
diato
atorr iinl
nlet
et hose
hose
5. Ra
Radi
diato
atorr ou
outl tlet
et hos
hose
e
6. Th
Therm
ermosostatatt as
asse
semb
mbly
ly
2-19

CABLE ROUTING
EAS20021
CABLE ROUTING
Handlebar (front view)
10 F
1 2 3 A 4 B
5
6
9
C
8
E
11
D G
I 7
11
2 3
6
2-20

CABLE ROUTING
1. Han
Handledlebar
bar swit
switchch lead
lead ((righ
right)
t)
2. Fr
Front
ont brak
brake e light
light s
swit
witch
ch le
lead
ad
3. Front
ront br
brak
akee hos
hose e
4. Rea
Rearr brbrake
ake liglight
ht swit
switch
ch le
lead
ad
5. Han
Handledlebar
bar swit
switchch lead
lead ((lef
left)
t)
6. Re
Rearar br
brak
akee cabl
cable e
7. Wir ire
e ha
harnes
rness s
8. Thr
Thrott
ottle
le cable
cable (de(decel
celera
erator
tor ca
cable
ble))
9. Thr
Thrott
ottle
le cable
cable (acc
(accele
elerat
rator
or cable)
cable)
10. Proje
Projection
ction mark
11. Han
Handledlebar
bar
A. Cov
Coverer the m meter
eter cocoupler
upler with
with the m meter
eter co
coupler
upler
cover.
B. Route the rea rearr brak
brake e light switch
switch llead
ead abo
above
ve th
the
e
left handlebar switch lead.
C. Route the wir wire e harne
harness ss to the rrear
ear of th
the
e front
brake hose.
D. Secur
Secure e the gr gromme
ommett by ins inserting
erting the ffront
ront br
brake
ake
hose grommet into the hose guide.
E. Secur
Secure e the h holder
older by insinserting
erting tthe
he proj
projection
ection on
the holder into the hole in the steering pipe.
F. 73.5°
G. Route th thee left handlebar
handlebar s switch
witch couplers
couplers to the rrear
ear
of the rear brake cable.
H. Route the thr throttle
ottle ca
cables
bles tthrough
hrough the hol holee of the
handlebar cover.
I. Rou
Route te the rrigh
ightt hand
handleb
lebar
ar sw
switc
itch
h couple
couplers
rs to the
the
rear of the front brake hose.
2-21

CABLE ROUTING
Handlebar (left side view)
2
5
5
1
2-22

CABLE ROUTING
1. Re
Rear
ar br
brak
ake
e cabl
cablee
2. Th
Thro
rott
ttle
le ca
cab
ble
3. Front
ront br
brak
akee hos
hose
e
4. Wir
ire
e ha
harnes
rnesss
5. Handleleb
bar
2-23

CABLE ROUTING
Headlight stay (right side view)
7
6
1
A
5
3
4
C
1
2
2-24

CABLE ROUTING
1. Front
ront br
brak
akee hos
hosee
2. Fr
Front
ont wh
wheel
eel sen
sensor
sor lea
leadd
3. Hydr
Hydrau
aulilic
c uni
unitt
4. Fu
Fuel
el lid
lid cab
cable
le
5. Seat
Seat lock
lock cacab
ble
6. Fr
Front
ont brake
brake pip
pipee (hyd
(hydrauli
raulic
c unit to front
front br
brake
ake
caliper)
7. Fr
Front
ont brake
brake pipe
pipe (fr
(front
ont brake
brake master
master cylinde
cylinderr to
hydraulic unit)
A. 30°
B. GDR155- 55-A
C. GDR155
2-25

CABLE ROUTING
Headlight stay (left side view)
3
A 2
1
3
4 1
1
B 3
3
1
2-26

CABLE ROUTING
1. Fr
Front
ont wh
wheel
eel sen
sensor
sor lea
leadd
2. Fr
Front
ont brake
brake pipe
pipe (fr
(front
ont brake
brake master
master cylinde
cylinderr to
hydraulic unit)
3. Front
ront br
brak
ake e hos
hose
e
4. Fr
Front
ont brake
brake pip
pipe
e (hyd
(hydraul
raulic
ic unit to ffront
ront br
brake
ake
caliper)
5. Head
Headliligh
ghtt sta
stay
A. GD
GDR R155-
55-A
B. GDR155
2-27

CABLE ROUTING
Front fork (rear and right side view)
1 C 7
5
D
4 5
6
3
5 7 1
H G
J
5
2 1 A 5
6 6
E F
6
4
2-28

CABLE ROUTING
1. Horn lead
2. Horn
3. Front
ront wh
wheeeell sen
senso
sorr
4. Front
ront b
bra
rake
ke cal
calipe
iperr
5. Front
ront br
brak
akee hos
hosee
6. Fr
Front
ont wh
wheel
eel sen
sensor
sor lea
leadd
7. Fr
Front
ont bra
brake
ke hos
hose ehhold
older
er
A. Po
Positio
sition
n the hold
holder
er with
within
in the rrange
ange shown
shown inin the
illustration.
B. Route the fr front
ont bbrake
rake hose throug
throughh the guide.
guide.
C. Secur
Secure e the cla
clamp
mp by ho hooking
oking tthe
he horn lealead
d clamp
into the hole of the front brake hose holder.
D. Mak
Make e sure the brak
brake e pipe totouches
uches tthe
he projection
projection
on the brake caliper.
E. Inward
F. Outward
G. Fororw
ward
ard
H. Rearw
earwa ard
I. Align
Align ththee holder
holder w with
ith tthe
he wh
white
ite pain
paintt mark
mark on th the
e
brake hose.
J. Align the g gap
ap in the h holder
older with the w white
hite paint
paint
mark on the brake hose.
2-29

CABLE ROUTING
Front frame (left side view)
E G
E
F
6
J
I
B
3
1 2
8
3
A 2
3
B
2
1
4
3
2
C
6 5
2
3
2-30

CABLE ROUTING
1. Re
Rear
ar br
brak
akee cabl
cablee
2. Thr
Thrott
ottle
le cable
cable (de
(decel
celera
erator
tor ca
cable
ble))
3. Thr
Thrott
ottle
le cable
cable (acc
(accele
elerat
rator
or cable)
cable)
4. Fuel
uel hos
hose
5. Si
Side
dest
stan
andd swit
switch
ch
6. Wir
ire
e ha
harnes
rnesss
7. Buz
Buzzer
zer cou
couple
plerr (G
(GDR
DR155
155-A)
-A)
8. O2 sensor lead
A. White
hite tape
ape
B. Secur
Secure e the g gromme
rommett by ininserting
serting the fue
fuell hose
grommet into the hose guide.
C. Route th the
e sidest
sidestand
and sw
switch
itch lea
leadd throug
through h the cable
cable
guide.
D. Insert ththee proje
projection
ction on the bra
brake
ke cab
cable
le holder
holder
completely into the hole in the frame.
E. Insert tthe
he proj
projection
ection on the wire harness holderholder
completely into the hole in the headlight stay. stay.
F. Instal
Installl the front
front wh
wheel
eel se
sensor
nsor ccoupler
oupler to the
headlight stay.
G. Route tthe he buzz
buzzer
er lead as shshown
own in th
the
e illustr
illustration.
ation.
(GDR155-A)
H. Fasten
Fasten the rrearear brak
brakee cable a and
nd throttle
throttle cables
cables
with the holder.
I. Route the O2 sensor lead between the cylinder cyli nder
head cover and the fuel hose bracket.
J. Fasten
Fasten the tthrottl
hrottle
e cables
cables wwith
ith th
the
e hold
holder
er..
2-31

CABLE ROUTING
Rear frame (left side view)
C D E
9
F
B
10
11 H
18
12
17
16
13
G C
14
15
A
7 8
5
4
6 6 6
2-32

CABLE ROUTING
1. Wir
ire
e ha
harnes
rness s
2. Lice
Licens
nsee light
light lead
lead
3. Rea
Rearr turn sig
signal
nal lligh
ightt lead
lead (left)
(left)
4. Rea
Rearr turn sig
signal
nal lligh
ightt lead
lead (right
(right))
5. Tail
ail/br
/brak
akee lligh
ightt llead
ead
6. Re
Rear
ar br
brak
akee cabl
cable e
7. Yama
amahaha dia
diagno
gnosti stic
c tool coupl
coupler
er
8.
9. ABS
St
Start
artertes
test
er gtener
genco
coupl
upler
erater
or ((GD
ator GDR15
lleadR155-A
ead 5-A))
10. Igniti
Ignition
on coil
11. Crankshaft position senso sensorr lead
12. Engin
Engine e ground
ground
13. Igniti
Ignition
on coi
coill lead
14. Throttle body sensor assemb assemblyly lead
15. ISC unit lead
16. Injector lead
17. O2 sensor lead
18. Fue
Fuell hose
hose
A. Fit the slot in the
the ABS test co
coupler
upler o
onto
nto the batte
battery
ry
case rib. (GDR155-A)
B. Route tthe
he VV
VVAA solen
solenoid
oid lea
leadd under tthe
he fuel h
hose.
ose.
C. Route the stastarter
rter gener
generator
ator lead
lead abo
aboveve the
the wire
harness.
D. holder
Secur
Secure einto
thethe
hol
holder
der
holeby
of iinserting
nserting tthe
the bracket.he wire h
harness
arness
E. Fasten
Fasten ththee spark p
plug
lug lea
lead
d with ththe
e band aand
nd then
secure the holder to the coolant reservoir hose
bracket.
F. Cut ooff
ff the excess
excess end of tthehe ban
bandd to less
less than 5
mm (0.20 in).
G. Cut ooff
ff the excess
excess end of tthehe ban
band.
d.
H. Route tthe
he cran
crankshaft
kshaft p
positio
osition
n sensor lelead
ad abov
abovee
the starter generator lead.
2-33

CABLE ROUTING
Front frame (left side view)
C
J
I
2
F 6
G
A 3
B
6 K
7
R 6
4 L
M
E D C
11
P
10
11
G O
C
6 Q
N
2-34
2 34
CABLE ROUTING
1. Main
Main swi
switctch
h cou
coupl pler
er
2. Hydrau
Hydraulic lic un
unit
it lea
leadd (GDR155
(GDR155-A) -A)
3. Fuel
Fuel lid
lid ccab
able
le
4. SGCU
SGCU le lead
ad
5. Fuel
Fuel pu
pump mp lead
lead
6. Seat
Seat lo
lockck cabl
cablee
7. Frame
8. Fuel
Fuel ttank
ank overfl
overflowow hose
hose
9. In
Inne
nerr ffen
ende
derr
10.Frame ground lead
11.Sidestand switch lead
A. Route the wire wire harness to the inside
inside of the
the
cross tube.
B. Insert the projection
projection on the fuel lid cable
cable
holder into the hole in the cover.cover.
C. Insert the
the projection
projection on the wire harness
harness
holder into the hole in the frame.
D. Route thethe coolant reservoir
reservoir hose through
through the
the
guide of the frame.
E. Route the wire wire harness above
above the engine
engine
bracket.
F. Route the seatseat lock
lock cable
cable to the
the outside
outside of the
the
holder.
G. Insert the projection
projection on the wirewire harness
holder into the hole in the footrest board.
H. Fasten
Fasten the cocoolant
olant reservoir
reservoir hose
hose at the white
white
paint mark with the holder. Position the hose
end facing forward.
I. Route
Route the seat
seat lock
lock cable
cable throug
through h the br
brack
acket
et
hole and route the cable between the wire
harness and the frame.
J. Fit the
the slot in the turn signal
signal relay
relay onto
onto the leg
shield rib.
K. Route the seat lock cable
cable between
between the wirewire
harness holder and the frame.
L. Route the seat
seat lock cable
cable to the inside of the
footrest board.
M. Insert the end of the fuefuell tank overflo
overfloww hose
into the inner fender. Make sure that the end
of the hose protector on the fuel tank overflow
hose contacts the edge of the hole in the
inner fender.
N. Install
Install the frame
frame ground
ground lead
lead terminal
terminal as
shown in the illustration.
O. Install
Install the frame
frame ground lead terminal
terminal so that
that
the crimped section of the terminal that
secures the lead is facing upward.
P. Route the coolant
coolant reservoir
reservoir hose
hose to the
the inside
of the sidestand switch lead.
Q. Route the
the seat lock
lock cable
cable between
between the
sidestand switch lead and the footrest board.
R. Do not route
route this SGCU lead lead above
above the other
other
SGCU leads.
2 35
CABLE ROUTING
Rear frame (right side view)
2
2
5 D
1
F
7
2 36
CABLE ROUTING
1. Seat
Seat lock
lock cacabble
2. Wir
ire
e ha
harnes
rness s
3. Co
Cool
olant
ant res
reserv
ervoioirr hos
hosee
4. Coo
Coolan
lantt temper
temperatuaturere senso
sensorr lead
5. Spar
Sparkkpplu
lug
g llea
ead
d
6. VV
VVA
As sol
olen
enoi
oidd
7. Radi
Radiat
ator
or hose
hose
A. paint
Fasten
Fasten th
the
marke with
coola
coolantnt rese
the reservoir
rvoir hose
holder. hose at the w
white
hite
B. Insert tthe
he proj
projection
ection on the wire harness holder
holder
into the hole in the crankcase bracket.
C. Insert th
the
e proje
projection
ction on the wir
wire
e harnes
harnesss holde
holderr
into the hole in the rear side cover.
D. Route the spa
spark
rk plug le
lead
ad betw
between
een the V
VVVA
solenoid and the radiator hose.
E. Route the wiwire
re harn
harness
ess thr
through
ough tthe
he gu
guide
ide of the
frame.
F. Route the seseat
at lock
lock cable
cable through
through th
the
e hole of the
rear frame.
2 37
CABLE ROUTING
Frame (top view)
N 2
14 M
3
4
1
A
L B
V 6
J 5
P
13 8
6
13
16 15
5
5
C
11 10
8 7 Q
9
5
U 5 15
R 11 5
10
12 E
10 11 Q
12
G
10
11
F
I
H
Q
Q
11
T F
10
12 R
S Q
2 38
CABLE ROUTING
1. Aux
uxililia
iary
ry DC jack
jack llea
ead
d
2. Bu
Buzz
zzerer ((GD
GDR1R15555-A
-A))
3. Turn sign
signal
al rrel
elay
ay
4. Ma
Mainin switc
witchh
5. Wir
ire
e haharnes
rness s
6. Fuse b boox
7. Ma
Mainin rela
elay
8. St
Start
arter
er cha
chargrgee re
relalay
y
9. Fu
Fuse
se box
box 2 (GD(GDR1R155 55-A-A))
10. Rear tuturn
rn signal lig light
ht lead
11. Licen
Licensese light lead
lead
12. Tail/brake light lead
13. Smart key unit lead (G (GDR155-A)
DR155-A)
14. Hor
Horn n lea
lead
d
15. Seat lock c cable
able
16. Smart key uni unitt (GDR15
(GDR155-A) 5-A)
A. Fasten
Fasten ththee sides
sidestandtand s switch
witch lead wi with
th the ban
band. d.
Point the end of the band rearward.
B. Route the sidesidestand
stand s switch
witch lead bet
betwee
weenn the wirwire e
harness and the coolant reservoir hose.
C. Route the A ABS
BS test coupl
coupler er lead abo
aboveve the rela
relayy.
(GDR155-A)
D. 30–
30–4040 mmmm (1.18–
(1.18–1.5 1.577 in)
E. 10 mm (0.3(0.39 9 in)
in)
F. Fasten
Fasten ththee licen
licensese light lead, re rear
ar turn signal
signal lig
light
ht
lead, and tail/brake light lead with the plastic
locking tie to the hole of the frame.
G. Route the seat lock c cable
able ou outside
tside o
off the wir
wiree
harness.
H. Po
Position
sition th
thee plastic lo locking
cking ttie
ie to the rear o off the rib
on the grab bar.
I. Be susure
re not
not to pi pinch
nch tthe
he leleads
ads w when
hen iinst
nstall
alling
ing the
the
grab bar.
J. Route the si sidesta
destand nd sswitch
witch llead
ead un
under
der the throttle
throttle
cable and the fuel hose.
K. Route th the
e sidest
sidestandand sw switch
itch lead o over
ver th
the
e frame
frame..
L. Fasten
Fasten the si sidesta
destand nd swi
switch
tch lead wi
with
th the hold
holderer..
M. Insert the pr project
ojection
ion on the wir wiree harness ho holder
lder
into the hole in the front brake hose holder.
N. Insert the projec
projectiontion on thethe wire haharness
rness holder
holder
into the hole in the main switch bracket.
O. illustration.
Instal
Installl the fuse to thethe fuse bo
boxx as show
shown n in the
P. Fit the s slot
lot in the
the rela
relayy onto th
the
e rib on the battery
box.
Q. 5 mm (0 (0.2
.200 in
in))
R. Insert the projec
projection
tion on the
the wire haharness
rness holder
holder
into the hole in the rear fender.
S. Fasten
Fasten the lilicense
cense lilight
ght lead, rear
rear turn sig
signal
nal light
light
lead, and tail/brake light lead with the plastic
locking tie to the guide.
T. Position
Position th the
e buck
bucklele of the plas
plastic
tic lock
locking
ing tie to the
outside of the guide.
U. Insert the projprojectio
ection
n on the tail/br
tail/brake
ake ligh
lightt coupler
into the hole in the rear fender.
V. Insert the projec
projection
tion on the
the wire haharness
rness holder
holder
into the hole in the frame.
2-39
CABLE ROUTING
Headlight
A 1 2 B 3
H 2
C
3
2 I
4
3 6
5 G
1 J 2
K
1
2-40
CABLE ROUTING
1. Head
Headli ligh
ghtt lead
lead
2. Front turn s sign
ignalal light
light lead
lead
3. Auxil
Auxiliaiary
ry li
light
ght llea
eadd
4. Au
Auxil
xiliary
iary DC jack jack llead
ead
5. Front whewheel el sens
sensoror lead
lead
6. Buzze
Buzzerr leadlead (GDR15
(GDR155-A 5-A))
A. Insert the ffrontront turn signal
signal light
light le
lead
ad into the
the
groove in the headlight unit. Be sure to fasten
the front turn signal light lead before the split
in the lead.
B. Insert the coupler
coupler into the the groove
groove in the
headlight unit.
C. Route the the front turn signal
signal light
light lead above
above
the headlight lead and the auxiliary light lead.
D. Route the the front turnturn signal light
light lead
lead under the the
headlight lead and the auxiliary light lead.
E. Route the front front turn signal
signal light
light lead trough
trough
the hole of the front side panel.
F. Insert thethe auxiliary
auxiliary DC DC jack
jack coupler
coupler into
into the
slot in the leg shield.
G. Route the the front wheel
wheel sensor
sensor lead above
above the
auxiliary DC jack lead.
H. Fasten
Fasten the ffront ront turn signal
signal light
light lead and
and the
auxiliary light lead with the clamp, making
sure to align the clamp with the white tape on
the front turn signal light lead. Point the ends
of the clamp forward.
I. Be sure
sure notnot to pinch
pinch thethe fr
front
ont turn
turn signal
signal ligh
lightt
lead when installing the front side panel.
J. Insert thethe headlight
headlight lead
lead into the groovgroove e in th
the
e
headlight unit.
K. Route the headlight
headlight leadlead through
through thethe hole of
the headlight unit.
2-41
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE ............................................................................3-1

INTRODUCTION .......................................................................................3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM ................................................................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART .......................3-1
CHECKING THE FUEL LINE ....................................................................3-4
CHECKING THE FUEL FILTER ................................................................3-4
CHECKING THE SPARK PLUG ...............................................................3-4
ADJUSTING THE VALVE CLEARANCE ..................................................3-5
CHECKING THE ENGINE IDLING SPEED ..............................................3-7
CHECKING THE EXHAUST SYSTEM......................................................3-7
SYSTEM ......................................................3-7
ADJUSTING THE EXHAUST GAS VOLUME ...........................................3-8
REPLACING THE AIR FILTER ELEMENT AND CLEANING
THE CHECK HOSE..................................................................................3-8
HOSE ..................................................................................3-8
CHECKING THE BREATHER HOSES .....................................................3-8
CLEANING THE V-BELT CASE AIR FILTER ELEMENT
3
AND CLEANING THE CHECK HOSE ......................................................3-9
CHECKING AND CHARGING THE BATTERY .......................................3-10
CHECKING THE BRAKE OPERATION ..................................................3-10
CHECKING THE FRONT BRAKE PADS ................................................3-10
CHECKING THE REAR BRAKE SHOES................................................3-10
SHOES ................................................3-10
CHECKING THE BRAKE FLUID LEVEL.................................................3-10
LEVEL .................................................3-10
CHECKING THE FRONT BRAKE HOSES .............................................3-11
BLEEDING THE HYDRAULIC BRAKE SYSTEM ...................................3-11
CHECKING THE WHEELS .....................................................................3-12
CHECKING THE TIRES ..........................................................................3-12
CHECKING THE WHEEL BEARINGS ....................................................3-14
CHECKING AND ADJUSTING THE STEERING HEAD .........................3-14
LUBRICATING THE STEERING HEAD ..................................................3-15
CHECKING THE CHASSIS FASTENERS ..............................................3-15
LUBRICATING THE LEVERS .................................................................3-15
CHECKING THE SIDESTAND................................................................3-15
SIDESTAND ................................................................3-15
LUBRICATING THE SIDESTAND...........................................................3-15
SIDESTAND ...........................................................3-15
CHECKING THE CENTERSTAND .........................................................3-15
LUBRICATING THE CENTERSTAND ....................................................3-16
CHECKING THE SIDESTAND SWITCH.................................................3-16
SWITCH .................................................3-16
CHECKING THE FRONT FORK .............................................................3-16
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................3-16
ASSEMBLIES ................3-16
CHECKING THE ENGINE OIL LEVEL....................................................3-16
LEVEL ....................................................3-16
CHANGING THE ENGINE OIL ...............................................................3-17
CHECKING THE COOLANT LEVEL .......................................................3-18
CHECKING THE COOLING SYSTEM ....................................................3-19
CHANGING THE COOLANT...................................................................3-19
COOLANT...................................................................3-19
CHANGING THE FINAL TRANSMISSION OIL.......................................3-21
OIL .......................................3-21
REPLACING THE V-BELT ......................................................................3-22

LUBRICATING THE SECONDARY SHEAVE .........................................3-22

CHECKING THE BRAKE LIGHT SWITCHES.........................................3-22
SWITCHES .........................................3-22
CHECKING AND LUBRICATING THE CABLES ....................................3-22
CHECKING THE THROTTLE GRIP OPERATION .................................3-23
CHECKING THE SWITCHES, LIGHTS AND SIGNALS .........................3-24
ADJUSTING THE HEADLIGHT BEAM ...................................................3-24

PERIODIC MAINTENANCE
EAS20022
EAS30022
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAU46932
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

IP
• The annual checks must be performed every year, except if a kilometer-based maintenance is
performed instead.
• From 16000 km, repeat the maintenance
maintenance intervals
intervals starting
starting from 4000 km.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
ODOMETER READING (whichever comes first)

CHECK OR MAINTENANCE ANNUAL
NO. ITEM 1000 km 4000 km 7000 km 10000 km 13000 km
JOB CHECK
or or or or or
1 month 4 months 7 months 10 months 13 months
• Check
Check fuel hoses
hoses for
for crack
cracks
s or
1 * Fuel line
damage.
    
• Check
Check c
cond
onditio
ition.
n.
2 * Fuel filter Every 12000 km (7500 mi)
• Replace
Replace if neces
necessary
sary..
• Check
Check c
cond
onditio
ition.
n.
• Clean
Clean a
and
nd rega
regap.p.    
3 Spark plug
• Replace. Ever y 10000 km (6000 mi)
• Check
Check valve
valve clearance
clearance..
4 * Valves
• Adjust
Adjust if necess
necessary
ary..
 
5 * Fuel injection • Check
Check engine
engine iidle
dle s
speed
peed..     
• Check
Check for
for lea
leakag
kage.
e.
• Tighten
Tighten if neces
necessary
sary..
6 * Exhaust system
• Replace
Replace ga
gasket(
sket(s)
s) if neces-
neces-     
sary.
EAUN0284
GENERAL MAINTENANCE AND LUBRICATION CHART

IP
• The annual checks must be performed every year, except if a kilometer-based maintenance is
performed instead.
• From 16000 km, repeat the maintenance
maintenance intervals
intervals starting
starting from 4000 km.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.

CHECK OR MAINTENANCE 1000 km 4000 km 7000 km 10000 km 13000 km ANNUAL
NO. ITEM
JOB or or or or or CHECK
• Per
Perform
form d
dynami
ynamicc inspe
inspection
ction
Diagnostic sys- using Yamaha
Yamaha diagnostic tool.
1 *      
tem check • Check
Check the error codes
codes..
Air filter element
2 • Re
Repl
plac
ace.
e. Every 16000 km (10000 mi)
Air filter check
3 • Clea
Cleann.     
hose
3-1

NO. ITEM
V-belt case air fil- • Clea
Clean
n.
4 * ter element • Replace
Replace if neces
necessary
sary..    
• Check
Check vol
voltag
tage.
e.
5 * Battery • Charge
Charge iiff necessa
necessary
ry..      
• and
Check
Checvehicle
k operation,
operafor
tion, ffluid
fluid luid le
level
vel
leakage.      
6 * Front brake
• Replac
Replace
e bra
brake
ke pad
pads.
s. Whenever worn to the limit
• Check
Check operation
operation and a adjust
djust
brake lever free play.      
7 * Rear brake
• Replac
Replace
e brak
brake
e shoe
shoes.
s. Whenever worn to the limit
• Check
Check for crac
cracks
ks or da
damage
mage..
• Check
Check for correct
correct ro
routing
uting a
and
nd     
8 * Brake hoses clamping.
• Re
Repl
plac
ace.
e. Every 4 years
9 * Brake fluid • Ch
Chan
ange
ge.. Every 2 years
• Check
Check runout
runout an and d fo
forr dam
dam--
10 * Wheels age.    
• Check
Check tread depth and ffor or
damage.
11 * Tires • Replace
Replace if neces
necessary
sary..     
• Check
Check aiairr pres
pressur
sure.
e.
• Correct
Correct ifif necessa
necessary ry..
• Check
Check bearings
bearings for loose-
12 * Wheel bearings ness or damage.    
• Check
Check bearing
bearing pla playy and steer-
steer-
ing for roughness.     
13 * Steering bearings
• Lubricate
Lubricate w with
ith lithiu
lithium-soap-
m-soap-
based grease. Every 12000 km (7500 mi)
• Make sure
sure that
that all nuts
nuts,, bolts
14 * Chassis fasteners and screws are properly tight-     
ened.
Front brake lever • Lubricate
Lubricate with silicone
15 pivot shaft grease.     
Rear brake lever • Lubricate
Lubricate with silicone
16 pivot shaft grease.     
• Check
Check op
opera
eratio
tion.
n.
Sidestand, center-
17 • Lubricate
Lubricate wwith
ith lithiu
lithium-soap-
m-soap-     
stand
based grease.
18 * Sidestand switch • Check
Check op
opera
eratio
tion.
n.      
• Check
Check operation
operation and ffor
or oil
leakage.    
19 * Front fork
• Change
Change the front fork oil. Every 20000 km (12000 mi)
Shock absorber • Check
Check operation
operation and shshock
ock
20 * assemblies absorbers for oil leakage.    
• Ch
Chanange
ge..
21 Engine oil • Check
Check oil level
level an
and
d veh
vehicle
icle ffor
or  Every 3000 km (1800 mi)
oil leakage.
22 * Engine oil strainer • Clea
Clean
n.  
• Check
Check coolant
coolant lev
level
el and vehi-
vehi-
cle for coolant leakage.     
23 * Cooling system
• Change
Change with Y Yamaha
amaha ge genuine
nuine
coolant. Every 3 years
Final transmis- • Check

Check vehicle
vehicle for oil leaka
leakage.
ge.     
24 sion oil • Ch
Chan
ange
ge..  Every 10000 km (6000 mi)
• Check
Check for damage
damage an
and
d wea
wear.
r.    
25 * V-belt
• Re
Repl
plac
ace.
e. Every 25000 km (15500 mi)
V-belt secondary
26 * sheave • Lu
Lubri
brica
cate
te.. Every 12000 km (7500 mi)
Front and rear
27 * • Check
Check op
opera
eratio
tion.
n.      
brake switches
Moving parts and
28 • Lu
Lubri
brica
cate
te..     
cables
3-2

NO. ITEM
• Check
Check op
opera
eratio
tion.
n.
• Check
Check throttle
throttle grip free p
play
lay,,
29 * Throttle grip and adjust if necessar y.     
• Lubricate
Lubricate ca
cable
ble and grip
housing.
Lights, signals • Check
Check op
opera
eratio
tion.
n.
30 * and switches • Adjust headlight
headlight beam.      
EAU62401
IP
• Air
Air filt
filter
er
• This model’s air filter is equipped with a disposable
disposable oil-coated paper element, which must not be
cleaned with compressed air to avoid damaging it.
• The air filter element
element needs to be replaced more frequently
frequently when riding in unusually wet or dusty
areas.
• V-belt case airair filter
filter
• The air filter needs more frequent
frequent service if you are riding in unusually
unusually wet or dusty areas.
• Hydraulic
Hydraulic brake service
service
• Regularly check and, if necessary, correct the brake fluid level. After dissembling the brake master
cylinders and calipers, always change the brake fluid.
• Every two years replace
replace the internal com
components
ponents of the brake master cylinder
cylinder and caliper,
caliper, and
change the brake fluid.
• Replace the brake
brake hose every four years
years and if cracked
cracked or damaged.
3-3
EAS30619
CHECKING THE FUEL LINE

1. Rem
Remove:
ove:
• Front side
side cover assembly
assembly (left)
Refer to “GENERAL CHASSIS (2)” on page
4-3..
4-3
• Footres
Footrestt board (left)
(left) 1

4-16..
4-16
2. Che
Check:
• Fuel hose “1”
3. In
Inst
stal
all:
l:
Cracks/damage  Replace.
• Fuel
Fuel filte
filterr
Loose connections  Connect properly.
Refer to “FUEL TANK” on page 7-1. 7-1.
• Footres
(left)
4-16..
4-16
• Front side
side cover assembly
assembly (left)
4-3..
4-3
EAS30620
CHECKING THE SPARK PLUG

1
1. Remo
Remove ve::
3. Inst
Instal
all:
l: • Front side
side cover assembly
assembly (right)
(right)
• Footres
(left) Refer to “GENERAL CHASSIS (2)” on page
Refer to “GENERAL CHASSIS (6)” on page 4-3..
4-3
4-16..
4-16 • Footres
Footrestt board
board (ri
(right)
ght)
• Front side
side cover assembly
assembly (left) Refer to “GENERAL CHASSIS (6)” on page
Refer to “GENERAL CHASSIS (2)” on page 4-16..
4-16
4-3..
4-3 2. Remo
Remove ve::
• Spark
Spark plug
plug cap
cap
EAS31178
• Spark
Spark plug
plug
CHECKING THE FUEL FILTER ECA13330
1. Rem
Remove:
ove: NOTICE
• Front side
side cover assembly
assembly (left) Before removing the spark plug, blow away
Refer to “GENERAL CHASSIS (2)” on page any dirt accumulated in the spark plug well
4-3..
4-3
• Footres
(left) with compressed
into the cylinder. air to prevent it from falling
4-16..
4-16 3. Che
Check:
• Fuel
Fuel filt
filter
er • Spark
Spark plug
plug type
type
Refer to “FUEL TANK” on page 7-1. 7-1. Incorrect  Change.
2. Che
Check:
Manufacturer/model
• Fuel fil
filter
ter “1”
NGK/CPR8EA-9
Damage/contaminants  Replace.
DENSO/U24EPR-9
IP
Replace the fuel filter every 12000 km (7500 mi) 4. Che
Check:
of operation. • Electr
Electrode
ode “1”
Damage/wear  Replace the spark plug.
• Insulat
Insulator
or “2”
Abnormal color  Replace the spark plug.
Normal color is medium-to-light tan.
3-4
b
a 2
5. Cl
Cle
ean:
an: 8. In
Inst
stal
all:
l:
• Spar
Sparkk plug
plug • Footrest
Footrest board assembly
assembly (right)
(right)
(with a spark plug cleaner or wire brush) Refer to “GENERAL CHASSIS (6)” on page
6. Meas
Measurure:
e: 4-16..
4-16
• Spark
Spark plug
plug gap “a”
“a” • Front side cover
cover (right)
(right)
(with a wire thickness gauge) Refer to “GENERAL CHASSIS (2)” on page
Out of specification  Regap. 4-3..
4-3
Spark plug gap EAS30622
0.8–0.9 mm (0.031–0.035 in) ADJUSTING THE VALVE CLEARANCE

The following procedure applies to all of the
valves.
IP
• Valve clearance
clearance adjustment
adjustment should
should be made
on a cold engine, at room temperature.
• When the valve
valve clearance
clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1. Remo
Remove ve::
• Front side
side covers
covers (left and
and right)
7. Inst
Instal
all:
l:
4-3..
4-3
• Spark
Spark plug “1”
• Footrest
Footrest boards (left and
and right)
• Spark
Spark plug
plug cap
Spark plug 4-16..
4-16
T
.
R
.
13 N·m (1.3 kg lbf·m, 9.4 lb·ft) • Radiator cover

cover and radiator
radiator fan 6-1.
case

Refer to “RADIATOR” on page 6-1.
IP 2. Move:
• Before installi
installing
ng the spark plug,
plug, clean the • Radiator
Radiator “1”
spark plug and gasket surface. • Radiator
Radiator fan
fan case “2”
“2”
• When tightening
tightening the spark
spark plug, make
make sure IP
that the inside “a” of the spark plug wrench “2” Move the rear of the radiator outward.
does not the contact the portion “b” of the spark
plug.
• To route the
the spark plug
plug lead, refer
refer to “CON-
NECTING THE LEADS” on page 5-8. 5-8 .
3-5
a b
2 1
3. Move: d. Measure the

the valve clearanc
clearance
e with a thicknes
thickness
s
• Cylinder
Cylinder head
head cover
cover “1”
“1” gauge “1”.
Out of specification  Adjust.
1
4. Meas
Measur
ure:
e: 1
• Valve
Valve cleara
clearance
nce
Out of specification  Adjust. 5. Adj
Adjus
ust:
t:
• Valve
Valve clear
clearance
ance
Valve clearance (cold) a. Loosen
Loosen the
the lockn
locknut
ut “1”.
“1”.
Intake
b. Insert a thickness
thickness gau
gauge
ge “2” between
between the
the end

0.10–0.14 mm (0.0039–0.0055 in)
of the adjusting screw and the valve tip.
Exhaust
0.21–0.25 mm (0.0083–0.0098 in)
a. Tur
Turnn the cranksha
crankshaftft clockw
clockwise
ise..
b. When tthe
he piston
piston is at the Top Dead
Dead Center
Center
(TDC) on the compression stroke, align the
“I” mark “a” on the camshaft sprocket with the
match mark “b” on the camshaft stopper
plate. 2
c. Align the “I” mark “c”
“c” on the
the A.C. magneto
magneto ro-
ro-
1
tor with the stationary pointer “d” on the
crankcase.
c. Turn the adjusting
adjusting screw
screw “3” in
in direction
direction “a” or
d “b” with the tappet adjusting tool “4” until the
c specified valve clearance is obtained.
Direction “a”
Valve clearance is incr
increased.
eased.
Direction “b”
Valve clearance is dec
decreased.
reased.
3-6
“02”  Clean the ISC (idle speed control) unit

Tappet adjusting tool and throttle body.
90890-0131m, 1 Refer to “CLEANING THE ISC (IDLE SPEED

Six piece tappet set CONTROL) UNIT AND THROTTLE BODY”
YM-A5970
on page 7-12.
7-12.
a. Connect the Yamaha
Yamaha diagnostic
diagnostic tool.
Use the diagnostic code number “67”.
Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE” on page
3
9-5..
9-5
(b)
Yamaha diagnostic tool USB
4 90890-03250
(a)
Yamaha diagnostic tool (A/I)
90890-03252
d. Hold the adjusting

adjusting screw
screw to prevent
prevent itit from EAS30625
moving and tighten the locknut to specifica- CHECKING THE EXHAUST SYSTEM
tion. 1. Che
Check:
• Muffl
Muffler
er “1
“1””
Valve clearance adjusting screw

T
.
R
.
locknut
7 N·m (0.7 kgf·m, 5.1 lb·ft)

• Gaske
Gaskett “2”
Exhaust “2” leaks  Replace.
gas
e. Measur
Measure e the valve clearance
clearance again.
again. 2. Che
Check:
f. If the valve
valve clear
clearance
ance is
is still
still out of
of specifi
specifica-
ca- Tightening torque
tion, repeat all of the valve clearance adjust- • Muffler
Muffler nuts “3”
ment steps until the specified clearance is • Muffler
Muffler bolts
bolts “4”
“4”
obtained.
Muffler nut
6. Inst
Instal
alll:
T
.
R
.
20 N·m (2.0 kgf·m, 14 lb·ft)
• All remov
removeded parts
parts
Muffler bolt
IP 57 N·m (5.7 kgf·m, 41 lb·ft)
For installation, reverse the removal procedure.
EAS31017
CHECKING THE ENGINE IDLING SPEED

IP
Prior to checking the engine idling speed, the
t he air
filter element should be clean, and the engine
should have adequate compression.
1. Start tthe
he engine and
and let it warm
warm up for several
several
minutes.
2. Che
Check:
• Engine
Engine idlin
idling
g speed
speed
Out of specification  Go to next step. 4 1
4 2
Engine idling speed
1500–1700 r/min

3
3. Che
Check:
• ISC (idle
(idle speed control)
control) learning
learning value
“00” or “01”  Check the intake system.
3-7
EAS30799
ADJUSTING THE EXHAUST GAS VOLUME

IP 2
• Be sure to set
set the CO density level to standard,
standard,
and then adjust the exhaust gas volume.
• To adjust the
the exhaust gas volume,
volume, use the COCO
adjustment mode of the Yamaha diagnostic
tool. For more information, refer to the opera-
tion manual of the Yamaha diagnostic tool.
1. Connect the Yamaha
Yamaha diagnosti
diagnosticc tool to the
connector. For information about connecting 2. Che
Check:
the Yamaha diagnostic tool, refer to “YAMA- • Air filte
filterr elem
element
ent
HA DIAGNOSTIC TOOL” on page 8-46. 8-46 . Damage  Replace.
IP
• Replace thethe air filter
filter element every
every 16000 km
90890-03250

Yamaha diagnostic tool (A/I) (1000 mi) of operation.
90890-03252 • The air filter
filter needs more frequent
frequent service
service if you
are riding in unusually wet or dusty areas.
EAS31130
3. In
Inst
stal
all:l:
REPLACING THE AIR FILTER ELEMENT
• Air filte
filterr elem
element
ent
AND CLEANING THE CHECK HOSE
IP • Air filte
filterr case cov
cover
er
Check the air filter check hose “1” that is located Air filter case cover screw
on the rear side of the air filter case. If dust or
T
.
R
.
1.2 N·m (0.12 kgf·m, 0.87 lb·ft)
water or both collects in the hose, clean the hose

ECA20480
and replace the air filter element. NOTICE
Never operate the engine without the air filter

element installed. Unfiltered air will cause
rapid wear of engine parts and may damage
the engine. Operating the engine without the
air filter element will also affect throttle body
tuning, leading to poor engine performance
1 and possible overheating.
IP
When installing the air filter element into the air
1. Rem
Remove:ove: filter case, make sure that the sealing surfaces
• Air filter
filter case
case cover
cover “1” are aligned to prevent any air leaks.
• Air filter element “2”
EAS31179
CHECKING THE BREATHER HOSES

1
1. Remo
Removeve::
• Front side
side cover assembly
assembly (left)
4-3..
4-3
2. Che
Check:
• Cylinder
Cylinder head breather
breather hose
hose “1”
• Transmissio
Transmissionn case breather
breather hose “2”
Loose connections  Connect properly.
3-8
ECA21600
1. Remo
Removeve::
NOTICE
• V-belt case
case air filter
filter element
element cover “1”
Make sure the cylinder head breather hose • V-belt case
case air filter
filter element
element “2”
and transmission case breather hose are
routed correctly.
1
2. Clea
Clean:
n:
• V-belt case
case air filter
filter element
element
3. Inst
Instal
alll: (with solvent)
EWA17971
• Front side
side cover assembly
assembly (left) WARNING
Never use low flash point solvents, such as
4-3..
4-3
gasoline, to clean the V-belt case air filter el-
EAS31704 ement. Such solvents may cause a fire or an
CLEANING THE V-BELT CASE AIR FILTER explosion.
ELEMENT AND CLEANING THE CHECK
HOSE IP
IP • The air filter
filter needs more frequent
frequent service
service if you
are riding in unusually wet or dusty areas.
Check the V-belt
that is located case
on the airside
rear filterofcheck hosecase.
t he V-belt
the “1” • After cleaning,
cleaning, gently
gently squeeze the V-belt
V-belt case
If dust or water or both collects
co llects in the hose, clean air filter element to remove the excess solvent.
the hose and replace the V-belt case air filter el- ECA21590
ement. NOTICE
Do not twist the V-belt case air filter element

when squeezing it.
1
3-9
3. Che
Check:
• V-belt case
case air filter
filter element
element
Damage  Replace.
4. Apply the recommended
recommended oil to the entire
entire sur-
face of the V-belt case air filter element and
squeeze out the excess oil. The V-belt case
a
air filter element should be wet but not drip- a
ping.
Recommended oil
Engine oil EAS00126
CHECKING THE REAR BRAKE SHOES

5. Inst
Instal
alll: 1. Opera
Operate
te the
the brake.
brake.
• V-belt case
case air filter
filter element
element 2. Che
Check:
• V-belt case
case air filter
filter element
element cover • Wear indic
indicator
ator “1”
“1”
V-belt case air filter element cov- Reaches the wear limit line “2”  Replace the

T
.
R er bolt brake shoes as a set.

Refer to “REAR WHEEL AND BRAKE” in
.

7 N·m (0.7 kgf·m, 5.1 lb·ft)
chapter 4.
EAS30816
CHECKING AND CHARGING THE BATTERY

Refer to “CHECKING AND CHARGING THE
BATTERY” on page 8-124.
8-124.
EAS30801
2
CHECKING THE BRAKE OPERATION 1
1. Che
Check:
• Brake
Brake opera
operatio
tion
n
Brake not working properly  Check the
brake system.
Refer to “FRONT BRAKE” on page 4-30 and
4-30 and EAS30632
“REAR BRAKE” on page 4-43.

4-43. CHECKING THE BRAKE FLUID LEVEL
1. Stand the
the vehicle
vehicle on a level
level surface.
surface.
IP
IP
Drive on the road, operate the front and rear
brakes separately and check to see if the brakes • Place the vehicle
vehicle on the centerstan
centerstand.
d.
are operating properly. • Make sure
sure the vehicle
vehicle is upright.
upright.
• In order
brake to
to level,
fluid ensure a correct
correct
make reading
reading
sure the top of of
thethe
thbrake
e
EAS30633
CHECKING THE FRONT BRAKE PADS fluid reservoir is horizontal.

The following procedure applies to all of the 2. Che
Check:
brake pads. • Brake
Brake fluid
fluid level
level
1. Ope
Operarate
te the
the brake
brake.. Below the minimum level mark “1”  Add the
2. Che
Check: specified brake fluid to the proper level.
• Front
Front brake
brake pad
Wear indicator grooves “a” almost disap- Specified brake fluid
peared  Replace the brake pads as a set. YAMAHA GENUINE BRAKE FLUID
Refer to “FRONT BRAKE” on page 4-30. 4-30.
(DOT 3 or DOT 4)-GDR155
YAMAHA GENUINE BRAKE
FLUID (DOT 4-plus)-GDR155-A
3-10
3. Hold the vehicle

vehicle upright
upright and apply
apply the front
front
brake several times.
4. Che
Check:
• Br
Brak
ake
e hoses
hoses
1 Brake fluid leakage  Replace the damaged
hose.
Refer to “FRONT BRAKE” on page 4-30 and
4-30 and
“ABS (ANTI-LOCK BRAKE SYSTEM)
(GDR155-A)” on page 4-47.
4-47.
EAS30893
EWA13540
WARNING BLEEDING THE HYDRAULIC BRAKE

SYSTEM
• Use only the designated
designated brake
brake fluid.
fluid. Other EWA14000
brake fluids may cause the rubber seals to WARNING

deteriorate, causing leakage and poor Always bleed the brake system when the
brake performance. brake related parts are removed.
• Refill with
with the same type
type of brake fluid
fluid that
ECA22780
is already in the system. Mixing brake fluids NOTICE
may result in a harmful chemical reaction,
• Bleed the brake
brake system in the
the following
following or-
leading to poor brake performance.
der.
• When refilling,
refilling, be careful that
that water does
does
• Front
Front brake
brake caliper
caliper
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil- EWA16530
ing point of the brake fluid and could cause WARNING

vapor lock. Bleed the ABS whenever:
ECA13540
• the system is disassembled
disassembled..
NOTICE • a brake hose is loosened
loosened,, disconnected
disconnected or
replaced.
Brake fluid may damage painted surfaces
• the brake
brake fluid level is very low.
and plastic parts. Therefore, always clean up
• brake operatio
operationn is faulty.
any spilt brake fluid immediately.
IP
EAS30635
• Be careful
careful not to spill any
any brake fluid
fluid or allow
CHECKING THE FRONT BRAKE HOSES
the brake master cylinder reservoir to overflow.
1. Che
Check:
• When bleeding
bleeding the ABS, make
make sure that there
there
• Brake
Brake hoses
hoses “1”
is always enough brake fluid before applying
the brake. Ignoring this precaution could allow
air to enter the ABS, considerably lengthening
the bleeding procedure.
• If bleeding is difficu
difficult,
lt, it may be necess
necessary
ary to let
1 the brake fluid settle for a few hours.
• Repeat the bleeding
bleeding procedure
procedure when the tiny
tiny
bubbles in the hose have disappeared.
1. Ble
Bleed:
ed:
• ABS
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2. Che
Check: a. Fill the brake master
master cylinder
cylinder reservoi
reservoirr to the
• Brake
Brake hose
hose holder
holder proper level with the specified brake fluid.
• Brake
Brake hose
hose guid
guide
e b. Install the brake
brake master
master cylinder
cylinder diaphrag
diaphragm. m.
Loose  Tighten the holder and guide bolt. c. Connect a clear plastic
plastic hose “1” tightly to the
bleed screw “2”.
3-11
EAS30638
CHECKING THE WHEELS

wheels.
1. Che
Check:
1 • Whee
Wheell
Damage/out-of-round  Replace.
EWA13260
WARNING
Never attempt to make any repairs to the
2 wheel.
d. Place the other end of the
the hose into
into a con-
con- IP
tainer.
After a tire or wheel has been changed or re-
e. Slowl
Slowlyy apply
apply the brake several
several times.
times.
placed, always balance the wheel.
f. Fully
Fully squeez
squeeze e the brake
brake lever
lever and hold
hold it in
position. 2. Meas
Measur
ure:
e:
g. Loos
Loosenen the
the bleed
bleed scre
screw.
w. • Radial
Radial wheel
wheel runout
runout
IP • Lateral
Lateral wheel
wheel runout
runout
Loosening the bleed screw will release the pres- Refer to “CHECKING THE FRONT WHEEL”
sure and cause the brake lever to contact the on page 4-22 and
4-22 and “CHECKING THE REAR
throttle grip or handlebar grip. WHEEL” on page 4-29.
4-29.
EAS30640
h. Tighten the bleed
bleed screw and then release
release the
the
CHECKING THE TIRES
brake lever.
i. Repeat
Repeat steps
steps (e)
(e) to (h)
(h) until
until all
all of the
the air bub-
bub-
tires.
bles have disappeared from the brake fluid in
1. Che
Check:
the plastic hose.
• Tire
Tire pressu
pressure
re
j. Check the
the operation
operation of the hydraulic
hydraulic unit.
unit.
Out of specification  Regulate.
Refer to “HYDRAULIC UNIT OPERATION
TESTS” on page 4-51.
4-51.
ECA18060
NOTICE
Make sure that the main switch is turned to

“OFF” before checking the operation of the
hydraulic unit.
k. After operating
operating the ABS, repeat steps (e) (e) to
(i), and then fill the brake master cylinder res-
ervoir to the proper level with the specified
brake fluid. EWA13181
l. Tighten
Tighten the
the bleed
bleed scre
screw
w to speci
specific
ficatio
ation.
n. WARNING
• The tire pressure
pressure should
should only
only be checked
checked
Brake caliper bleed screw and regulated when the tire temperature

T
.
R .
6 N·m (0.6 kgf·m, 4.3 lb·ft) equals the ambient air temperature.

• The tire pressure

pressure and the suspension
suspension must
must
m. Fill the brake master cylinder reservoir to the
be adjusted according to the total weight
proper level with the specified brake fluid.
(including cargo, rider, passenger and ac-
Refer to “CHECKING THE BRAKE FLUID
cessories) and the anticipated riding
LEVEL” on page 3-10.
3-10.
EWA13110
speed.
WARNING • Operation
Operation of an overloaded
overloaded vehicle could
could
After bleeding the hydraulic brake system, cause tire damage, an accident or an injury.
check the brake operation. NEVER OVERLOAD THE VEHICLE.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-12
• To avoid pinching
pinching the
the tube, make sure
sure the
Tire air pressure (measured on wheel rim band and tube are centered in the
cold tires) wheel groove.

Front (1 person) • Patching
Patching a punctured
punctured tube
tube is not recom-
recom-
200 kPa (2.00 kgf/cm², 29 psi)
mended. If it is absolutely necessary to do
Rear (1 person)
225 kPa (2.25 kgf/cm², 33 psi) so, use great care and replace the tube as
soon as possible with a good quality re-
Front (2 persons)
200 kPa (2.00 kgf/cm², 29 psi) placement.
Rear (2 persons)
225 kPa (2.25 kgf/cm², 33 psi) A B
Maximum load
154 kg (339 lb) (GDR155)
153 kg (336 lb) (GDR155-A)
* Total weight of rider
rider,, passenger, cargo
cargo
and accessories
EWA13190
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit, re- A. Tire
place the tire immediately. B. Wheel
2. Che
Check: Tube wheel Tube tire only
• Tire
Tire surf
surfaces
aces Tubeless wheel Tube or tubeless tire
Damage/wear  Replace the tire.
EWA14090
WARNING
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer
and of the same design. No guarantee con-
cerning handling characteristics can be giv-
en if a tire combination other than one
approved by Yamaha is used on this vehicle.
1. Tire
Tire tread
tread depth
depth
2. Sid
ide
e wall Front
Size tire
3. Wear
ear indi
indica
cato
torr

110/80–14M/C 53P
Manufacturer/model
Wear limit (front)
IRC/SCT-005F
1.0 mm (0.04 in)

Wear limit (rear)
1.0 mm (0.04 in) Rear tire
EWA14080
Size

140/70–14M/C 62P
WARNING
Manufacturer/model
• Do not use
use a tubeless
tubeless tire on a wheel de- IRC/SCT-005R
signed only for tube tires to avoid tire fail-
ure and personal injury from sudden
deflation.
• When using a tube
tube tire, be sure to install
install the
correct tube.
• Always replace
replace a new tube
tube tire and
and a new
tube as a set.
3-13
EWA13210
3. Remo
Remove ve::
WARNING • Front
Front cover assemb
assembly
ly
New tires have a relatively low grip on the • Front cowling assembly
assembly
road surface until they have been slightly Refer to “GENERAL CHASSIS (4)” on page
worn. Therefore, approximately 100 km 4-9..
4-9
should be traveled at normal speed before • Handl
Handleb
ebarar
any high-speed riding is done. Refer to “HANDLEBAR” on page 4-55.
4-55.
4. Adj
Adjus
ust:
t:
IP
• Steerin
Steering g head
head
For tires with a direction of rotation mark “1”: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Install the
the tire with the
the mark pointing
pointing in the di- a. Remove the upper ring nut “1”, lock
lock washer
washer
rection of wheel rotation. “2”, center ring nut “3” and rubber washer
wa sher “4”.
• Align the mark “2”“2” with the valve installati
installation
on
point.
2
1
1
3
b. Loosen the lower ring

ring nut “5”
“5” and then
then tighten
tighten
it to specification with a steering nut wrench
EAS30641
“6”.
CHECKING THE WHEEL BEARINGS IP
The following procedure applies to all of the Set the torque wrench at a right angle to the
wheel bearings. steering nut wrench.
1. Che
Check:
• Wheel
Wheel bear
bearings
ings Steering nut wrench
Refer to “CHECKING THE FRONT WHEEL” 90890-01403
on page 4-22.
4-22.
EAS30645
YU-A9472
CHECKING AND ADJUSTING THE
STEERING HEAD
Lower ring nut (initial tightening
1. Stand tthe
EWA13120
he vehicle
vehicle on a level
level surface.
surface.
T
.
R
.
torque)

38 N·m (3.8 kgf·m, 27 lb·ft)
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
IP
Place the vehicle on a suitable stand so that the
front wheel elevated.
2. Che
Check:
• Steeri
Steering
ng head 6
Grasp the handlebar and gently rock the han-
5
dlebar.
Binding/looseness  Adjust the steering c. Loosen the
the lower
lower ring
ring nut 1/4 of a turn, and
head. then tighten it to specification with a steering

nut wrench.
3-14
EWA13140
5. In
Inst
stal
all:
l:
WARNING • Handl
Handleb ebar
ar
Do not overtighten the lower ring nut. Refer to “HANDLEBAR” on page 4-55.
4-55.
• Front cowling assembly
assembly
Lower ring nut (final tightening • Front
Front cover assemb
assembly
ly

T
.
R
.
torque) Refer to “GENERAL CHASSIS (4)” on page

16 N·m (1.6 kgf·m, 12 lb·ft) 4-9..
4-9
d. Check the steering

steering head for
for looseness
looseness or EAS30646
LUBRICATING THE STEERING HEAD

binding by turning the front fork
for k all the way in
1. Lu
Lubr
bric
icat
ate:
e:
both directions. If any binding is felt, remove
the lower bracket and check the upper and • Upper
Upper bearing
bearing
• Lower
Lower bearing
bearing
lower bearings.
Refer to “STEERING HEAD” on page 4-67. 4-67. • Lower bearing
bearing dust seal
e. Ins
Install
tall the rubbe
rubberr washer.
washer. Recommended lubricant
f. Instal
Installl the
the cente
centerr ring
ring nut.
nut. Lithium-soap-based grease
g. Finger tighten the center
center ring
ring nut, then
then align
align
the slots of both ring nuts. If necessary, hold EAS31186
the lower ring nut and tighten the center ring CHECKING THE CHASSIS FASTENERS
nut until their slots are aligned. Make sure that all nuts, bolts, and screws are
h. Inst
Install
all the
the lock
lock washer
washer “2”.
“2”. properly tightened.
IP Refer to “CHASSIS TIGHTENING TORQUES”
Make sure the lock washer tabs “a” sit correctly on page 2-13.
2-13.
in the ring nut slots “b”. EAS30648
LUBRICATING THE LEVERS

Lubricate the pivoting point and metal-to-metal
moving parts of the levers.
2
Recommended lubricant
a
Silicone grease

EAS30650
b CHECKING THE SIDESTAND
1. Che
Check:
• Sidest
Sidestand
and operat
operation
ion
i. Hold the lower
lower and cente
centerr ring
ring nuts
nuts with
with a Check that the sidestand moves smoothly.
steering nut wrench and tighten the upper Rough movement  Repair or replace.
ring nut with a another steering nut wrench. EAS30651
LUBRICATING THE SIDESTAND

Steering nut wrench
Lubricate the pivoting point, metal-to-metal mov-
90890-01403
ing parts, and spring contact point of the side-

YU-A9472 stand.
Upper ring nut Lithium-soap-based grease
75 N·m (7.5 kgf·m, 54 lb·ft)

T
.
R
.

EAS30856
CHECKING THE CENTERSTAND

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1. Che
Check:
• Centerstand
Centerstand operation
operation
Check that the centerstand moves smoothly.
Rough movement  Repair or replace.
3-15
EAS30857
2. Che
Check:
LUBRICATING THE CENTERSTAND
• Rear shock
shock absorber
absorber assembly
assembly
Lubricate the pivoting point, metal-to-metal
metal-to -metal mov-
Oil leaks  Replace the rear shock absorber
ing parts, and spring contact points of the
th e center-
assembly.
stand.
Refer to “CHECKING THE REAR SHOCK
Recommended lubricant ABSORBER ASSEMBLY” on page 4-81. 4-81.
3. Che
Check:
Lithium-soap-based grease • Rear shock absorber
absorber assembly
assembly operation
operation
EAS30652 Push down seat on the vehicle several times
CHECKING THE SIDESTAND SWITCH and check if the rear shock absorber assem-
Refer to “CHECKING THE SWITCHES” on bly rebounds smoothly.
page 8-120.
8-120. Rough movement  Replace.
EAS30653
Refer to “REAR SHOCK ABSORBER AS-
CHECKING THE FRONT FORK SEMBLIES AND SWINGARM” on page
1. Stand tthe
he vehicle
vehicle on a level
level surface.
surface. 4-79..
4-79
EWA13120
EAS30656
WARNING
CHECKING THE ENGINE OIL LEVEL
Securely support the vehicle so that there is 1. Stand the
the vehicle
vehicle on a level
level surface.
surface.
no danger of it falling over. IP
2. Che
Check: • Place the vehicle
centerstand.
d.
• Inner
Inner tube
tube
Damage/scratches  Replace. • Make sure
sure the vehicle
vehicle is upright.
upright.
• Oi
Oill s
sea
eall 2. Start the
the engine,
engine, warm it up for
for several
several min-
min-
Oil leakage  Replace. utes, and then turn it off.
3. Hold ththee vehicle
vehicle upright
upright and apply
apply the
the front 3. Remo
Remove ve::
brake. • Dipstic
Dipstickk “1”
4. Che
Check: 4. Che
Check:
• Front
Front fork
fork operation
operation • Engine
Engine oil
oil level
level
Push down hard on the handlebar several The engine oil level should be between the
times and check if the front fork rebounds minimum level mark “a” and maximum level
smoothly. mark “b”.
Rough movement  Repair. Below the minimum level mark  Add the
Refer to “FRONT FORK” on page 4-60. 4-60. recommended engine oil to the proper level.
IP
• Before checking
checking the
the engine oil level,
level, wait a few
minutes until the oil has settled.
• Do not screw the
the dipstick
dipstick in when inspecting
inspecting
the oil level.
EAS30808
CHECKING THE REAR SHOCK ABSORBER

ASSEMBLIES
The following procedure applies to both of the
rear shock absorber assemblies.
1. Stand tthe
he vehicle
vehicle on a level
level surface.
surface.
EWA13120
WARNING
3-16
1
b
a
1 1
Recommended brand
YAMALUBE

Type
SAE 10W-40 3
Recommended engine oil grade
API service SG type or higher, 2
JASO standard MA or MB
4. Dr
Dra ain:
• Engin
Engine e oil
oil
(completely from the crankcase)
5. If the oil
oil strainer
strainer is also to be cleaned,
cleaned, per-
form the following procedure.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
–20 –10 0 10 a. Remove the oil strainer
strainer ccover
over “1”,
“1”, spring “2”,
and oil strainer “3”.
ECA13370 b. Install
Install a new O-rin
O-ring g “4”.
“4”.
NOTICE
IP
Do not allow foreign materials to enter the Lubricate the O-ring with lithium-soap-based
crankcase. grease.
5. Start tthe
he engine,
for several
several min-
min-
utes, and then turn it off.
6. Chec
Check k the engine
engine oil level
level again
again..
IP
Before checking the engine oil level, wait a few 3
minutes until the oil has settled. 2
4 New
EAS30657 1
CHANGING THE ENGINE OIL
1. Start tthe
he engine,
for several
several min-
min-
utes, and then turn it off. c. Clean the
the engine oil strainer
strainer with solvent,
solvent, and
2. Place a container
container under
under the engine
engine oil
oil drain then check it for damage and replace it if nec-
bolt. essary.
3. Rem
Remove:
ove: d. Install the oil strainer
strainer,, spring,
spring, and oil strainer
strainer
• Dipsti
Dipstick
ck “1” cover.
• Engine oil drain
drain bolt
bolt “2”
(along with the gasket “3”) Oil strainer cover
T
.

R
.
32 N·m (3.2 kgf·m, 23 lb·ft)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-17
6. Inst
Instal
alll: d. Start the
the engine after solvin
solvingg the problem(s
problem(s))
• Engine
Engine oiloil drain
drain bolt and check the engine oil pressure again.
(along with the gasket New ) e. Tighten the
the oil check bolt
bolt to specifi
specification.
cation.
Engine oil drain bolt Engine oil check bolt

T
.
20 N·m (2.0 kgf·m, 14 lb·ft)
T
.
R
.
7 N·m (0.7 kgf·m, 5.1 lb·ft)
R
.
7. Fill: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

• Crank
Crankcacase
se
EAS30811
(with the specified amount of the recom-
CHECKING THE COOLANT LEVEL
mended engine oil)
1. Stand the
the vehicle
vehicle on a level
level surface.
surface.
Engine oil quantity IP
Quantity (disassembled) • Place the vehicle
centerstand.
d.

1.00 L (1.06 US qt, 0.88 Imp.qt) • Make sure
sure the vehicle
vehicle is upright.
upright.
Periodic oil change
0.90 L (0.95 US qt, 0.79 Imp.qt) 2. Che
Check:
• Coolant
Coolant level
level
8. Inst
Instal
all:
l: The coolant level should be between the min-
• Dips
Dipstitick
ck imum level mark “a” and maximum level mark
9. Start the
the engine,
for several
several min-
min- “b”.
utes, and then turn it off. Below the minimum level mark  Add the
10.Check: recommended coolant to the proper level.
• Engi
Enginene
(for engine oil leaks)
11.Check:
• Engine
Engine oil oil llevel
evel
Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-16. 3-16.
12.Remove: b
• Front side
side cover assembly
assembly (right)
(right) a
4-3..
4-3
ECA13470
13.Check:
NOTICE
• Engine
Engine oil oil pressure
pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Adding water
water instead of coolant
coolant lowers
lowers the
a. Sligh
Slightly
tly loosen
loosen the oil check
check bolt
bolt “1”. antifreeze content
used instead of the check,
of coolant coolant. If water
and is
if nec-
essary, correct the antifreeze concentra-
1 tion of the coolant.
• Use only distilled
distilled water. However,
However, if dis-
tilled water is not available, soft water may
be used.
3. Start the
the engine,
for several
several min-
min-
4. Che
Check:
• Coolant
Coolant level
level
b. Start tthe
he engine and
and keep it idling
idling until
until engine
engine
IP
oil starts to seep from the oil check bolt. If no
engine oil comes out after one minute, turn Before checking the coolant level, wait a few
the engine off so that it will not seize. minutes until the coolant has settled.
c. Check the engine
engine oil passages and the oil
pump for damage or leakage. Refer to “OIL
PUMP” on page 5-45.5-45.
3-18
EAS30812
3. Disc
Disconn
onnect
ect::
CHECKING THE COOLING SYSTEM
• Coolant reservoir
reservoir hose “1”
“1”
1. Rem
Remove:
ove:
• Radiato
Radiatorr c
cover
over
6-1.
2. Che
Check:
• Radiat
Radiator
or “1”
“1”
reservoir hose “2”
“2”
• Radiator
Radiator inlet
inlet hose
hose “3”
• Radiator
Radiator outlet
outlet hose
hose “4”
• Thermostat
Thermostat assembl
assembly y “5”
• Water pump inlet
inlet hose
hose “6” 1
Cracks/tears  Replace.
4. Dr
Draain:
Refer to “RADIATOR” on page 6-1 and6-1 and
• Cool
Coolan
antt
“THERMOSTAT” on page 6-4. 6-4.
(from the coolant reservoir)
5. Rem
Remov ove:
e:
3 • Radiator
Radiator cover
cover “1”
“1”
2
5
4 6
3. Inst
Instal
all:
l:
• Radiato
Radiatorr c
cover
over 1
6-1.
6. Rem
Remov
ove:
e:
EAS30813 • Radiator
Radiator cap “1”
CHANGING THE COOLANT
1. Rem
Remove:
ove:
• Front side
side cover assembly
assembly (right)
(right)
4-3..
4-3
• Footrest
Footrest board
board (right)
(right)
4-16..
4-16 1
2. Rem
Remove:
ove:
reservoir cap
cap “1”
EWA13030
WARNING
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in-
jury. When the engine has cooled, open the
radiator cap as follows:
1 Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap counter-
counter -
clockwise toward the detent to allow any re-
sidual pressure to escape. When the hissing
3-19
sound has stopped, press down on the radi-

ator cap and turn it counterclockwise to re- Recommended antifreeze
move. YAMAHA GENUINE COOLANT

Mixing ratio
7. Rem
Remove:
ove: 1:1 (antifreeze: water)
• Coolant drain
drain bolt (radiator
(radiator side)
side) “1” Radiator (including all routes)
(along with the O-ring) 0.46 L (0.49 US qt, 0.40 Imp.qt)
• Coolant drain
drain bolt (cylinder
(cylinder side)
side) “2” Coolant
maximum reservoir (up to the
level mark)
(along with the copper washer)
0.13 L (0.13 US qt, 0.11 Imp.qt)
Handling notes for coolant

Coolant is potentially harmful and should be
handled with special care.
EWA13040
WARNING
• If coolant splashes in your
your eyes, thoroughly
thoroughly
wash them with water and consult a doctor.
• If coolant splashes
splashes on your
your clothes, quickly
quickly
1
wash it away with water and then with soap
and water.
• If coolant is
is swallowed, induce
induce vomiting
vomiting
and get immediate medical attention.
ECA13481
NOTICE
• Adding water
water instead of coolant
coolant lowers
lowers the
antifreeze content of the coolant. If water is
used instead of coolant, check, and if nec-
2 essary, correct the antifreeze concentra-
tion of the coolant.
8. Dr
Draain: • Use only distilled
distilled water. However,
However, if dis-
• Cool
Coolan
antt tilled water is not available, soft water may
(from the engine and radiator) be used.
9. Inst
Instal
all:
l: • If coolant comes
comes into contact
contact with
with painted
• Coolant drain
drain bolt (cylinde
(cylinderr side) surfaces, immediately wash them with wa-
(along with the copper washer New ) ter.
• Coolant drain
drain bolt
bolt (radiator
(radiator side)
side) • Do not mix different
different types
types of antifreeze.
antifreeze.
(along with the O-ring New ) 12.Install:
• Radiator
Radiator cap
Coolant drain bolt (cylinder side) 13.Fill:

T
10 N·m (1.0 kgf·m, 7.2 lb·ft)
• Coolant
Coolant reserv
reservoir
oir
.
R
.

Coolant drain bolt (radiator side)
1.0 N·m (0.10 kgf·m, 0.72 lb·ft) (with the recommended coolant to the maxi-
mum level mark “a”)
10.Connect:
reservoir hose
11.Fill:
• Cooling
Cooling system
system
mended coolant)
a
3-20
14.Install: • Final transmis

transmission
sion oil drain
drain bolt “3”
reservoir cap
cap “1” (along with the copper washer “4”)
IP Completely drain the final transmission oil.
Point the tab “a” on the coolant
coo lant reservoir cap for-
ward.
1
W D
FW
1 a
15.Start the engine, warm it up for several min-

16.Check:
• Coolant
Coolant level
level
Refer to “CHECKING THE COOLANT LEV-
EL” on page 3-18.
3-18. 3 4
IP
Before checking the coolant level, wait a few 5. In
Inst
stal
all:
l:
minutes until the coolant has settled. • Final transmis
transmission
sion oil drain
drain bolt
17.Install: (along with the copper washer New )
• Radiato
Radiatorr c
cover
over Final transmission oil drain bolt

T 20 N·m (2.0 kgf·m, 14 lb·ft)
Radiator cover bolt
.
R
.

T
10 N·m (1.0 kgf·m, 7.2 lb·ft)
6. Fill:
.
R
.
18.Install: • Final transmissio

transmissionn oil
• Footrest
Footrest board
board (right)
(right) (with the specified amount of the recom-
Refer to “GENERAL CHASSIS (6)” on page mended final transmission oil)
4-16..
4-16 Final transmission oil
• Front side
side cover assembly
assembly (right)
(right) Type
Motor oil SAE 10W-30 type SE
4-3..
4-3 or higher or Gear oil SAE 85W
EAS31187
GL-3
CHANGING THE FINAL TRANSMISSION OIL Quantity
1. Stand tthe
he vehicle
vehicle on a level
level surface.
surface. 0.15 L (0.16 US qt, 0.13 Imp.qt)
IP 7. In
Inst
stal
all:
l:
• Place the
the vehicle
vehicle on the centersta
centerstand.
nd. • Final transmis
transmission
sion oil filler
filler cap
• Make sure
sure the vehicle
vehicle is upright.
upright. (along with the O-ring New )
2. Start tthe
he engine,
engine, warm it up for for several
several min-
min- IP
utes, and then turn it off. Lubricate the O-ring with lithium-soap-based
3. Place a container
container under
under the final
final transmis
transmis-- grease.
sion.
8. Start the
the engine,
for several
several min-
min-
4. Rem
Remove:
ove:
• Final transmis
transmission
sion oil filler
filler cap “1”
“1” utes, and then turn it off.
9. Che
Check:
(along with the O-ring “2”)
• Final transmi
transmission
ssion oil
oil leakage
leakage
3-21
EAS31188
REPLACING THE V-BELT

1. Rem
Remove:ove: 1
• Air fil
filter
ter case
case
Refer to “AIR FILTER CASE” on page 7-7.
7-7 .
• V-bel
V-beltt case
case
Refer to “V-BELT AUTOMATIC TRANSMIS- 5
2. SION”
Check:on page 5-34.
Che 5-34.
• V-
V-be
belt
lt
Damage/wear  Replace. 4
Grease/oil  Clean the primary and second- 3
ary pulleys.
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
5-34. 3
IP 2
Replace the V-belt every 25000 km (15500 mi)

of operation.
3. Inst
Instal
alll:
• V-bel
V-beltt case
case
5-34. 4. Asse
Assemb mblele::
• Air fil
filter
ter case
case • Secondary
Secondary sheavesheave assembly
assembly
7-7 . Refer to “V-BELT AUTOMATIC TRANSMIS-
EAS31705
SION” on page 5-34.5-34.
LUBRICATING THE SECONDARY SHEAVE 5. In
Inst
stal
all:l:
1. Rem
Remove:ove: • Secondary
Secondary sheavesheave assembly
assembly
• Air fil
filter
ter case
case Refer to “V-BELT AUTOMATIC TRANSMIS-
7-7 . SION” on page 5-34.5-34.
• Secondary
Secondary sheave
sheave assembl
assembly
y • Air fil
filter
ter c
case
ase
Refer to “V-BELT AUTOMATIC TRANSMIS- Refer to “AIR FILTER CASE” on page 7-7.
7-7 .
5-34. EAS30658
2. Disa
Disassssem
embl
ble:
e: CHECKING THE BRAKE LIGHT SWITCHES
• Secondary
Secondary sheave
sheave assembly
assembly 1. Che
Check:
Refer to “V-BELT AUTOMATIC TRANSMIS- • Front brake
brake light switch operation
5-34. • Rear brake
brake light switch
switch operation
operation
3. Lu
Lubr
bric
icat
ate:
e: When operating the brake levers, confirm
• Spring
Spring seat“1”
seat“1” that the brake light comes on.
• O-
O-ri
rings
ngs “2”
“2” Faulty  Refer to “CHECKING THE
• Oil seals
seals ““3”
3” SWITCHES” on page 8-120.8-120.
• Secondary
Secondary sliding
sliding sheave“4”
sheave“4”
EAS30660
• Secondary
Secondary fixed
fixed sheave“5”
sheave“5” CHECKING AND LUBRICATING THE
Recommended lubricant CABLES
Shell dolium grease R® The following procedure applies to all of the in-
ner and outer cables.
EWA13270
WARNING
Damaged outer cable may cause the cable to
corrode and interfere with its movement. Re-
place damaged
as soon outer cable and inner cables
as possible.
3-22
1. Che
Check:
• Outer
Outer cabl
cable
e
Damage  Replace.
2. Che
Check:
• Cable
Cable operati
operation
on
Rough movement  Lubricate. A
a
A
Engine oil or a suitable cable lu-

bricant
4. Adj
Adjus
ust:
t:
IP
• Throttle
Throttle grip free play
play
Hold the cable end upright and pour a few drops ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
of lubricant into the cable sheath or use a suit- a. Slide
Slide back the
the rubber
rubber cover
cover “1”.
able lubricating device. b. Loosen
Loosen the
the lockn
locknut
ut “3”.
“3”.
c. Turn the adjusting
adjusting nut
nut “2” in direction
direction “a” or “b”
EAS30861 until the specified throttle grip free play is ob-
CHECKING THE THROTTLE GRIP tained.
OPERATION
1. Che
Check: Direction “a”
• Throttl
Throttle
e cables
cables Throttle grip free play is increased.
 Direction “b”
Damage/deterioration
• Throttle
Throttle cable installation Replace.
installation Throttle grip free play is decreased.
Incorrect  Reinstall the throttle cables.
Refer to “HANDLEBAR” on page 4-55. 4-55.
2. Che
Check:
• Throttle
Throttle grip
grip movement
movement
Rough movement  Lubricate or replace the
defective part(s).
Recommended lubricant b
Suitable cable lubricant

a 1 2 3
IP
With the engine stopped, turn the throttle grip d. Tighten
Tighten the locknut
locknut..
slowly and release it. Make sure that the throttle
grip turns smoothly and returns properly when Throttle cable adjusting locknut
released.
T
.
R
.
3.8 N·m (0.38 kgf·m, 2.8 lb·ft)

Repeat this check with the handlebar turned all

e. Slide the
the rubber
rubber cover its original
original position.
position.
the way to the left and right.
IP
3. Che
Check: Make sure that the adjusting nut is covered com-
• Throttle
Throttle grip free
free play
play “a” pletely by the rubber cover.
EWA17990
Throttle grip free play WARNING

3.0–5.0 mm (0.12–0.20 in) After adjusting the throttle grip free play,

start the engine and turn the handlebars to
the right and to the left to ensure that this
does not cause the engine idling speed to
change.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-23
EAS30663
CHECKING THE SWITCHES, LIGHTS AND

SIGNALS
1. Check tthat
hat all switches
switches operate
operate and that
that all
lights come on.
Refer to “INSTRUMENT AND CONTROL
FUNCTIONS” in Owner’s manual.
Faulty  Refer to “CHECKING THE
SWITCHES” on page 8-120 and
8-120 and “CHECK-
ING THE BULBS AND BULB SOCKETS” on
page 8-123.
8-123.
EAS30664
ADJUSTING THE HEADLIGHT BEAM

1. Adj
djus
ust:
t:
• Headlight
Headlight beam (vertically)
(vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the ad
adjusting
justing bolt “1” in direction
direction “a” or
“b”.
Direction “a”
Headlight beam is raised.
Direction “b”
Headlight beam is lowered.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-24
3-25
CHASSIS
GENERAL CHASSIS (1) .................................................................................4-1

REMOVING THE BATTERY COVER .......................................................4-2
INSTALLING THE BATTERY COVER ......................................................4-2
GENERAL CHASSIS (2) .................................................................................4-3

REMOVING THE TAIL/BRAKE LIGHT OUTER COVER ..........................4-4
INSTALLING THE TAIL/BRAKE LIGHT OUTER COVER.........................4-4
COVER .........................4-4
REMOVING THE FRONT SIDE COVER ASSEMBLY ..............................4-4
INSTALLING THE FRONT SIDE COVER ASSEMBLY ............................4-5
REMOVING THE MOLE SIDE COVER ....................................................4-5
INSTALLING THE MOLE SIDE COVER ...................................................4-5
GENERAL CHASSIS (3) .................................................................................4-6

REMOVING THE REAR SIDE COVER ASSEMBLY ................................4-8
INSTALLING THE REAR SIDE COVER ASSEMBLY...............................4-8
ASSEMBLY ...............................4-8
4
GENERAL CHASSIS
REMOVING (4) .................................................................................4-9
THE FRONT UPPER COWLING ASSEMBLY ...................4-10
INSTALLING THE FRONT UPPER COWLING ASSEMBLY ..................4-10
DISASSEMBLING THE FRONT UPPER COWLING ASSEMBLY..........4-10 ASSEMBLY ..........4-10
ASSEMBLING THE FRONT UPPER COWLING ASSEMBLY................4-10
ASSEMBLY ................4-10
GENERAL CHASSIS (5) ...............................................................................4-12

REMOVING THE FRONT COWLING ASSEMBLY.................................4-13
ASSEMBLY .................................4-13
INSTALLING THE FRONT COWLING ASSEMBLY ...............................4-13
REMOVING THE FRONT SIDE COWLING ............................................4-13
INSTALLING THE FRONT SIDE COWLING ..........................................4-14
REMOVING THE FRONT BODY COWLING ..........................................4-14
INSTALLING THE FRONT BODY COWLING.........................................4-14
COWLING .........................................4-14
INSTALLING THE FRONT TURN SIGNAL LIGHT .................................4-15
GENERAL CHASSIS (6) ...............................................................................4-16

INSTALLING THE FOOTREST BOARD .................................................4-17
INSTALLING THE LOWER MOLE COVER ............................................4-17
GENERAL CHASSIS (7) ...............................................................................4-18

INSTALLING THE CENTER LOWER COVER........................................4-19
COVER ........................................4-19
FRONT WHEEL.............................................................................................4-20
WHEEL .............................................................................................4-20
REMOVING THE FRONT WHEEL..........................................................4-22
WHEEL ..........................................................4-22
DISASSEMBLING THE FRONT WHEEL................................................4-22
WHEEL ................................................4-22
CHECKING THE FRONT WHEEL ..........................................................4-22

MAINTENANCE OF THE FRONT WHEEL SENSOR

AND SENSOR ROTOR ..........................................................................4-23
ASSEMBLING THE FRONT WHEEL ......................................................4-23
ADJUSTING THE FRONT WHEEL STATIC BALANCE .........................4-24
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC)..................4-25
DISC) ..................4-25
REAR WHEEL ...............................................................................................4-28

CHECKING THE REAR WHEEL.............................................................4-29
WHEEL .............................................................4-29
ADJUSTING THE REAR WHEEL STATIC BALANCE............................4-29
BALANCE ............................4-29
FRONT BRAKE .............................................................................................4-30

INTRODUCTION .....................................................................................4-36
CHECKING THE FRONT BRAKE DISC .................................................4-36
REPLACING THE FRONT BRAKE PADS ..............................................4-37
REMOVING THE FRONT BRAKE CALIPER ..........................................4-38
DISASSEMBLING THE FRONT BRAKE CALIPER ................................4-38
CHECKING THE FRONT BRAKE CALIPER ..........................................4-39
ASSEMBLING THE FRONT BRAKE CALIPER ......................................4-39
INSTALLING THE FRONT BRAKE CALIPER ........................................4-39
REMOVING THE FRONT BRAKE MASTER CYLINDER .......................4-40
CHECKING THE FRONT BRAKE MASTER CYLINDER........................4-41
CYLINDER ........................4-41
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ...................4-41
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................4-41
CYLINDER ......................4-41
REAR BRAKE ...............................................................................................4-43

REMOVING THE REAR BRAKE.............................................................4-44
BRAKE .............................................................4-44
CHECKING THE REAR BRAKE SHOES................................................4-44
SHOES ................................................4-44
ASSEMBLING THE REAR BRAKE SHOE PLATE .................................4-45
CHECKING THE REAR BRAKE DRUM WEAR LIMIT ...........................4-46
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)......................................4-47

(GDR155-A)......................................4-47
REMOVING THE HYDRAULIC UNIT ASSEMBLY .................................4-49
CHECKING THE HYDRAULIC UNIT ASSEMBLY ..................................4-49
INSTALLING THE HYDRAULIC UNIT ASSEMBLY ................................4-49
HYDRAULIC UNIT OPERATION TESTS................................................4-51
TESTS ................................................4-51
CHECKING THE ABS WARNING LIGHT ...............................................4-54
HANDLEBAR ................................................................................................4-55
REMOVING THE FRONT HANDLEBAR COVER ASSEMBLY ..............4-57
DISASSEMBLING THE FRONT HANDLEBAR COVER ASSEMBLY ....4-57
REMOVING THE HANDLEBAR..............................................................4-57
HANDLEBAR ..............................................................4-57
CHECKING THE HANDLEBAR ..............................................................4-57
INSTALLING THE HANDLEBAR ............................................................4-57
ASSEMBLING THE FRONT HANDLEBAR COVER ASSEMBLY ..........4-59
INSTALLING THE FRONT HANDLEBAR COVER ASSEMBLY .............4-59

FRONT FORK................................................................................................4-60
FORK................................................................................................4-60
REMOVING THE FRONT FORK LEGS ..................................................4-62
DISASSEMBLING THE FRONT FORK LEGS ........................................4-62
CHECKING THE FRONT FORK LEGS ..................................................4-63
ASSEMBLING THE FRONT FORK LEGS ..............................................4-63
INSTALLING THE FRONT FORK LEGS ................................................4-66
STEERING HEAD..........................................................................................4-67
HEAD..........................................................................................4-67
REMOVING THE LOWER BRACKET.....................................................4-69
BRACKET.....................................................4-69
CHECKING THE STEERING HEAD .......................................................4-69
INSTALLING THE STEERING HEAD .....................................................4-69
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM ...................4-71

REMOVING THE SWINGARM................................................................4-73
SWINGARM ................................................................4-73
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ...................4-73
CHECKING THE SWINGARM ................................................................4-73
INSTALLING THE SWINGARM ..............................................................4-73

GENERAL CHASSIS (1)
EAS20026
GENERAL CHASSIS (1)

Removing the battery and battery cover
Order Job/Parts to remove Q’t y Remarks

Seat Open.
1 Batter y cover 1
2 Negative batter y lead 1 Disconnect.
3 Positive battery lead 1 Disconnect.
4 Battery 1
4-1
GENERAL CHASSIS (1)
EAS31677
REMOVING THE BATTERY COVER 1

1. Rem
Remove:
ove: a
• Battery
Battery cover
cover “1”
a
b. Install the battery
battery cover
cover screws,
screws, and then
tighten the screws to specification.
Battery cover screw

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
T
.
R 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

a. Open
Open the
the sea
seat.
t.
.
b. Rem
Remove
ove the batter
battery
y cover
cover screws.
screws. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. Slide the battery
battery cover
cover rearward
rearward to remove
remove
the projections “a” on the battery cover from
the holes “b” in the storage box.
1
a
a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31678
INSTALLING THE BATTERY COVER

1. Inst
Instal
alll:
• Battery
Battery cover
cover “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit th
the
e projections
projections “a”
“a” on the
the battery
battery cover
cover
into the holes “b” in the storage box, and then
slide the cover forward.
4-2
GENERAL CHASSIS (2)
EAS20155
GENERAL CHASSIS (2)

Removing the front side cover assembly and tail/brake light outer cover
1
2
1 Tail/brake light outer cover 1

2 Front side cover (right) 1
3 Mole side cover (right) 1
4 Front side cover (left) 1
5 Mole side cover (left) 1
4-3
GENERAL CHASSIS (2)
EAS31681
REMOVING THE TAIL/BRAKE LIGHT OUTER 1

COVER
1. Rem
Remove:
ove:
• Tail/brake
Tail/brake light
light outer cover
cover “1”
“1” b
a
b. Install the tail/brake

tail/brake light
light outer cover
cover screws,
screws,
and then tighten the screws to specification.
Tail/brake light outer cover screw

T
.
R
.
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the tail/brake

tail/brake light outer cover
cover ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
screws.
EAS31683
b. Slide tthe
he tail/brake
tail/brake light
light outer
outer cover rearward REMOVING THE FRONT SIDE COVER
to remove the projection “a” on the cover from ASSEMBLY
the hole “b” in the tail/brake light. The following procedure applies to both of the
1 front side cover assembly.
1. Remo
Removeve::
• Front side
side cover assembly
assembly “1”
b
a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31682
INSTALLING THE TAIL/BRAKE LIGHT

OUTER COVER ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1. Inst
Instal
alll: a. Remove the front
front side
side cover
cover assembly
assembly
• Tail/brake
Tail/brake light
light outer cover
cover “1”
“1” screws.
b. Pull the
the front s
side
ide cover
cover assembly
assembly outward
outward to
remove the projections “a” from the grom-
mets “b”.
b
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slide tthe
he tail/brake
tail/brake light
light outer cover
cover forward,
forward,
fit the projection “a” on the cover
co ver into the hole
“b” in the tail/brake light. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4-4
GENERAL CHASSIS (2)
EAS31684
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
INSTALLING THE FRONT SIDE COVER a. Remove the mole
mole side
side cov
cover
er screws.
screws.
ASSEMBLY b. Pull the
the mole side cover
cover outward
outward to remove
remove
The following procedure applies to both of the the projections “a” from the grommets “b”.
front side cover assembly.
1. Inst
Instal
alll:
• Front side
side cover assembly
assembly “1”
a
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
INSTALLING THE MOLE SIDE COVER

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1. In
Inst
stal
all:
l:
a. Fit th
the
e projections
projections “a”
“a” on the
the front side
side cover
cover • Mole
Mole side cover
cover “1”
assembly into the grommets “b”.
b
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b. Install the front side cover
cover assembly
assembly screws
screws,, a. Fit the projections
projections “a”
“a” on the mole
mole side
side cover
and then tighten the screw to specification. into the grommets “b”.
Front side cover screw

T
.
R
.
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a 1
REMOVING THE MOLE SIDE COVER
1. Rem
Remove:
ove: b
• Mole
Mole side cover
cover “1”
“1”
b. Install the mole

mole side cover
cover screws
screws and then
tighten the screws to specitification.
Front side cover screw

T
.
R
.
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-5
GENERAL CHASSIS (3)
EAS20157
GENERAL CHASSIS (3)

Removing the rear side covers and storage box
T
.
R
.
9 N m (0.9kg
• (0.9kgff m, 6.5lb.f
• 6.5lb.ft)
t)
T
.
R
.
9 N m (0.9kg
• (0.9kgff m, 6.5lb.f
6.5lb.ft)
t)
2
3
5

Battery
4-1.
4-1.
Front side cover
4-3..
4-3
1 Rear side cover (left) 1
2 Rear side cover (right) 1
3 Storage box 1
4 Pin (seat) 1
5 Hinge (seat) 1
4-6
GENERAL CHASSIS (3)
Removing the rear fender

T
.
R
.
9 N m (0.9kgf
(0.9kgf m, 6.5lb.ft
• 6.5lb.ft))
•
T
.
R
.
11 N m (1.1kgf
• (1.1kgf m, 8.0lb.ft)
• 8.0lb.ft) T
.
R
.
4 N m (0.4kgf
• (0.4kgf m, 2.9lb.ft)
• 2.9lb.ft)
4
2
T
.
R
.
9 N m (0.9kgf
(0.9kgf m, 6.5lb.ft
• 6.5lb.ft))
•
T
.
R
.
11 N m (1.1kgf
• (1.1kgf m, 8.0lb.ft)
• 8.0lb.ft)

1 Grab bar (left) 1
2 Grab bar (right) 1
3 Tail cover 1
4 Rear fender 1 1
5 Rear fender 2 1
4-7
GENERAL CHASSIS (3)
EAS31687
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
REMOVING THE REAR SIDE COVER a. Fit the projectio
projections
ns “a” on the rear side
side cover
ASSEMBLY assembly into the holes “b” in the storage
The following procedure applies to both of the box.
rear side cover assembly.
1. Rem
Remove:
ove: b
• Rear side
side cover
cover assembly
assembly “1”
“1” a
a
b. Install the screws,

screws, and then tighten the
screws to specification.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Rear side cover assembly screw
a. Rem
Remove
ove the
the scre
screws
ws..
T
.
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
R
b. Remove the projections
projections “a” on the
the rear side
.
cover assembly from the holes “b” in the stor- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

age box.
b
a
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31688
INSTALLING THE REAR SIDE COVER
ASSEMBLY
rear side cover assembly.
1. Inst
Instal
alll:
• Rear side
side cover
cover assembly
assembly “1”
“1”
4-8
GENERAL CHASSIS (4)
EAS20159
GENERAL CHASSIS (4)

Removing the front upper cowling assembly

1 Front upper cowling assembly 1
2 Front upper cowling 1 1
3 Front upper cowling 2 1
4-9
GENERAL CHASSIS (4)
EAS31692
REMOVING THE FRONT UPPER COWLING a b

ASSEMBLY
1. Rem
Remove:
ove:
• Front upper
upper cowling
cowling assembly
assembly “1”
b. Install the front

front upper cowling
cowling assembly
assembly
screw, and then tighten the screw to specifi-
cation.
Front upper cowling assembly

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

T
screw
a. Remove the front
front upper
upper cowling
cowling assembly
assembly
.
R .

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
screw.
b. Remove tthe
he projections
projections “a”
“a” on the front upper
upper
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
cowling assembly from the holes “b” in the leg
EAS31694
shield and remove the projections “c” from DISASSEMBLING THE FRONT UPPER
the holes “d” in the headlight unit.
COWLING ASSEMBLY
a b 1. Disas
Disassem
sembl
ble:
e:
• Front
Front upper cowlin
cowling
g “1”
• Front
Front upper
upper panel
panel “2”
IP
Remove the projections “a” on the front upper
1
cowling from the holes “b” in the front upper pan-
el, slide the panel in the direction shown in the il-
c
lustration, and remove the projections “c” on the
d panel from the holes “d” in the cowling.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31693
INSTALLING THE FRONT UPPER COWLING 2

ASSEMBLY
1. Inst
Instal
alll:
• Front upper
upper cowling
cowling assembly
assembly “1”
1
EAS31695
ASSEMBLING THE FRONT UPPER

COWLING ASSEMBLY
1. Asse
Assemb
mble
le::
• Front
Front upper
upper panel
panel “1”
• Front
Front upper cowlin
cowling
g “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the projections
projections “a”
“a” on the front
front upper
upper cowl-
cowl- Front upper panel screw
T
.
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
ing assembly into the holes “b” in the head-
R
.
light unit and fit the projections “c” into the

holes “d” in the leg shield.
4-10
GENERAL CHASSIS (4)
IP
Slide the front upper panel in the direction
shown in the illustration, fit the projections “a” on
the panel into the holes “b” in the front upper
cowling, and fit the projections “c” on the cowling
into the holes “d” in the panel.
1
4-11
GENERAL CHASSIS (5)
EAS20193
GENERAL CHASSIS (5)

Removing the front cowling assembly
8
7
2
3 1
T
.
R
.
9 N m (0.9kgf
• (0.9kgf m, 6.5lb.ft
• 6.5lb.ft))

4-9..
4-9
1 Front turn signal light (left) 1 Disconnect
2 Front turn signal light (right) 1 Disconnect
3 Headlight unit assembly 1 Disconnect
4 Front side cowling (left) 1
5 Front body cowling (left) 1
6 Front lower cowling 1
7 Front side cowling (right) 1
8 Front body cowling (right) 1
4-12
GENERAL CHASSIS (5)
EAS31278
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
REMOVING THE FRONT COWLING a. Fit the projectio
projections
ns “a” on the
the leg shield
shield into
into
ASSEMBLY the holes “b” in the front cowling assembly.
1. Rem
Remove:
ove:
• Front cowling
cowling assembly
assembly “1” b
a
• Disconnect
Disconnect turn signal
signal light coupler
coupler
• Disconnect
Disconnect head light coupler
coupler
• Disconnect
Disconnect auxiliar
auxiliary
y coupler
coupler
b. Install the front

front cowling
cowling assembly
assembly screws,
screws,
and then tighten the screws to specification.
Front cowling assembly screw

T
.
R
.
(M5  6)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
a. Remove the front
front cowling
cowling assembly
assembly screws.
screws. Front cowling assembly bolt
b. Pull tthe
he front cowling
cowling assembly
assembly forward
forward to re-
re- 10 N·m (1.0 kgf·m, 7.2 lb·ft)
move theholes
from the projections “a”front
“b” in the on the leg shield
cowling a ssem-
assem- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31696
bly.
REMOVING THE FRONT SIDE COWLING
b The following procedure applies to both of the
a
front side cowling.
1. Remo
Removeve::
• Front side cowling
cowling “1”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31279
INSTALLING THE FRONT COWLING

ASSEMBLY
1. Inst
Instal
alll: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Disconnect
Disconnect turn signal
signal light coupler
coupler a. Removing
Removing the front side
side cowling
cowling screws.
screws.
• Disconnect
Disconnect head light coupler
coupler b. Remove the projections
projections “a” on the front side
• Disconnect
Disconnect auxiliar
auxiliary
y coupler
coupler cowling from the holes “b” in the front lower
• Front cowling
cowling assembly
assembly “1” cowling.
1
a
b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-13
GENERAL CHASSIS (5)
EAS31697
REMOVING THE FRONT BODY COWLING
INSTALLING THE FRONT SIDE COWLING
1. Remo
Removeve::
• Front
Front body cowling
cowling “1”
front side cowling.
1. Inst
Instal
alll:
• Front side cowling
cowling “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the front
front body
body cowling
cowling screws.
screws.
b. Pull the
the front body cowling
cowling forward
forward to
to remove
remove
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
the projections “a” on the front cowling as-
a. Fit th
the
e projections
projections “a”
“a” on the
the front side cowl-
cowl-
sembly from the holes “b” in the front body
ing into the holes “b” in the front lower cowl-
cowling.
ing.
1 1
a
b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Install the front side cowling
cowling screws,
screws, and then
tighten the screws to specification. INSTALLING THE FRONT BODY COWLING
1. In
Inst
stal
all:
l:
Front side cowling screw • Front
Front body cowlin
cowling
g “1”

T
.
R
.
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the projections
projections “a” on the front
front body
body cowl-
ing into the holes “b” in the front cowling as-
sembly.
4-14
GENERAL CHASSIS (5)
b. Install the front body cowling

cowling screws
screws and then
tighten the screws to specitification.
Front body cowling screw

T
.
R
.
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31698
INSTALLING THE FRONT TURN SIGNAL

LIGHT
front turn signal light.
1. Inst
Instal
alll:
• Turn
Turn signal
signal light
light “1”
Turn signal light screw

T
.
R
.
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

IP
Tighten the turn signal light screw in the proper
tightening sequence as shown.
1
4-15
GENERAL CHASSIS (6)
EAS20158
GENERAL CHASSIS (6)

Removing the footrest board assembly
T
.
R
.
7 N m (0.7kgf
• (0.7kgf m, 5.1lb.ft
• 5.1lb.ft))
• •
4 N m (0.4kgf
(0.4kgf m, 2.9lb.ft
2.9lb.ft))
T R
T R
.
.
2
4
1
6
8
7
T
.
R
.
7 N m (0.7kgf
• (0.7kgf m, 5.1lb.ft
• 5.1lb.ft))
T
.
R
.
4 N m (0.4kgf
• (0.4kgf m, 2.9lb.ft
• 2.9lb.ft))

4-9.
4-9.
Front cowling assembly
4-12..
4-12
1 Footrest board assembly (right) 1
2 Front lower cover (right) 1
3 Footrest board mat (right) 1
4 Footrest board (right) 1
5 Footrest board assembly (left) 1
6 Footrest board mat (left) 1
7 Front lower cover (left) 1
8 Footrest board (left) 1
4-16
GENERAL CHASSIS (6)
EAS31690
INSTALLING THE FOOTREST BOARD

1. Inst
Instal
alll:
• Footres
Footrestt board
board “1”
a
1
b
Footrest board assembly bolt

T
.
R
.
10 N·m (1.0 kgf·m, 7.2 lb·ft)

IP
Make sure that the projection “a” on the frame
fits into the hole “b” in the footrest board assem-
bly.
EAS31691
INSTALLING THE LOWER MOLE COVER

1. Inst
Instal
alll:
• Lower mole cover “1”
IP
Make sure that the projections “a” on the center
lower cover fit into the holes “b” in the bottom
cover.
4-17
GENERAL CHASSIS (7)
EAS20194
GENERAL CHASSIS (7)

Removing the leg shield
T
.
R
.
9 N m (0.9kg
• (0.9kgff m, 6.5lb.ft
6.5lb.ft))
•
T
.
R
.
7 N m (0.7kg
• 5.1lb.ft))
4
3
7 5 6
2
T
.
R
.
9 N m (0.9kg
6.5lb.ft))
•

Battery
4-1.
4-1.
Front side covers
4-3..
4-3
Seat assembly 4-6..
4-6
Storage box
4-6..
4-6
4-12..
4-12
1 Center lower cover 1
2 Side cover (left) 1
3 Side cover (right) 1
4 Center cover assembly 1
5 Fuel tank cover 1
6 Center cover 1
7 Leg shield 1
4-18
GENERAL CHASSIS (7)
EAS31689
INSTALLING THE CENTER LOWER COVER

1. Inst
Instal
alll:
• Center lower cover “1”
IP
• Fit the end of the fuel tank
tank overfl
overflow
ow hose “2”
into the hole “a” in the center lower cover.
• Fit the hole “b”
“b” in the center lower
lower cover
cover over
the hook “c” on the frame.
d
e
b
c
1 2 a
4-19
FRONT WHEEL
EAS20028
FRONT WHEEL
Removing the front wheel and brake disc

d 26 N•m (2.6 k gf•m, 19 lb•ft

ft))
e
35 N•m (3.5 k gf•m, 25 lb•ft
ft))
a
1
a
1
7 N•m (0.7 k gf•m, 5.1 lb•ft

ft))
1 2
8 N•m (0.8 k gf•m, 5.8 l

lb
b•ft
ft)) 23 N•m (2.3 k gf•m, 17 lb•ft
ft))
c
bb
1 Front brake hose guide 1
2 Front brake caliper 1
3 Front wheel sensor 1
4 Front wheel axle nut 1
5 Front wheel axle 1
6 Collar 2
7 Front wheel 1
8 Front wheel sensor rotor 1
9 Front brake disc 1
4-20
FRONT WHEEL
Disassembling the front wheel

1 Oil seal 2
2 Wheel bearing 2
3 Spacer 1
4-21
FRONT WHEEL
EAS30145
REMOVING THE FRONT WHEEL

ECA20981
NOTICE
• Keep any type

type of magnets
magnets (including
(including mag-
mag-
netic pick-up tools, magnetic screwdrivers,
etc.) away from the front wheel sensor or 2
front wheel sensor rotor; otherwise, the
sensor or rotor may be damaged, resulting 1
in improper performance of the ABS sys-
tem.
• Do not drop the
the front wheel
wheel sensor rotor
rotor or c. Remove the wheel
wheel bearings
bearings “3”
“3” with
with a gener-
gener-
subject it to shocks. al bearing puller.
• If any solvent
solvent gets on the front
front wheel sen-
sen-
sor rotor, wipe it off immediately.
1. Stand tthe
he vehicle
vehicle on a level
level surface.
surface.
EWA13120
WARNING
2. Rem
Remove:
ove:
• Front
Front brake
brake caliper
caliper
ECA21830
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
NOTICE
EAS30147
Do not apply the brake lever when removing CHECKING THE FRONT WHEEL
the brake caliper. 1. Che
Check:
3. Elev
levate:
ate: • Wheel
Wheel axl
axle
e
• Fr
Front
ont wheel
wheel Roll the wheel axle on a flat surface.
Bends  Replace.
IP EWA13460
Place the vehicle on a suitable stand so that the WARNING

front wheel is elevated. Do not attempt to straighten a bent wheel
axle.
EAS30146
DISASSEMBLING THE FRONT WHEEL

1. Rem
Remove:
ove:
• Oi
Oill seal
seals
s
• Wheel
Wheel bear
bearings
ings
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the surface
surface of
of the front wheel hub.
hub.
b. Remove the oil seals “1” with
with a flat-head
flat-head
screwdriver.
IP
To prevent damaging the wheel, place a rag “2”
between the screwdriver and the wheel surface. 2. Che
Check:
• Tire
• Fr
Front
ont wheel
wheel
Damage/wear  Replace.
Refer to “CHECKING THE TIRES” on page
3-12 and
3-12 and “CHECKING THE WHEELS” on
page 3-12.
3-12.
3. Meas
Measur
ure:
e:
• Radial wheel runout “1”
4-22
FRONT WHEEL
• Lateral
Lateral wheel
wheel runout
runout “2” 1. Che
Check:
Over the specified limits  Replace. • Front
Front wheel senso
sensorr “1”
Cracks/bends/distortion  Replace.
Radial wheel runout limit Iron powder/dust  Clean.
1.0 mm (0.04 in)

Lateral wheel runout limit
1.0 mm (0.04 in)
2
1
2. Che
Check:
• Front wheel
wheel sensor
sensor rotor
rotor “1”
Cracks/damage/scratches  Replace the
4. Che
Check: front wheel sensor rotor.
• Wheel
Wheel bear
bearings
ings Iron powder/dust/solvent  Clean.
Front wheel turns roughly or is loose  Re- IP
• place
Oi the
Oill seals wheel bearings.
seals When cleaning
ful not to damagethe wheel
the sensor
surface rotor,
of the be care-
sensor rotor.
EAS30151
EAS30155
ASSEMBLING THE FRONT WHEEL
MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR 1.• Oil
Lu
Lubr
bric
icat
ate:
seal e:
lip
lips
s
ECA21070
NOTICE
• Handle the
the ABS components
components with
with care Lithium-soap-based grease
since they have been accurately adjusted.
Keep them away from dirt and do not sub- 2. In

Inst
stal
all:
l:
ject them to shocks. New
• Wheel
Wheel bearin
bearings
gs
• The front
front wheel sensor
sensor cannot be disas-
• Oi
Oill seal
seals
s New
sembled. Do not attempt to disassemble it.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
If faulty, replace with a new one.
a. Install the new wheel
wheel bearing
bearing (right
(right side).
side).
• Keep any typetype of magnets
magnets (including
(including mag-
mag- ECA18110
netic pick-up tools, magnetic screwdrivers, NOTICE

etc.) away from the front wheel sensor or Do not contact the wheel bearing inner race
front wheel sensor rotor. “1” or balls “2”. Contact should be made
• Do not drop
drop or shock
shock the wheel sensor
sensor or only with the outer race “3”.
the wheel sensor rotor.
4-23
FRONT WHEEL
IP b. When the
the front
front wheel stops
stops,, put an “X1” mark
Use a socket “4” that matches the diameter of at the bottom of the wheel.
the wheel bearing outer race.
c. Turn the
the front
front wheel
wheel 90° so
so that the
the “X1” mark
is positioned as shown.
b. Inst
Install
all the spacer
spacer..
d. Release
Release the
the front
front wheel
wheel..
c. Install the new wheel bearing (left side).
side).
e. When the wheel
wheel stops
stops,, put an “X2” mark at
IP
the bottom of the wheel.
Place a suitable washer “1” between the socket
“2” and the bearing so that both the inner race
“3” and outer race “4” are pressed at the same
time, and then press the bearing until the inner
race makes contact with the spacer “5”.
f. Repeat
Repeat steps
steps (c
(c)) through
through (e)
(e) sever
several
al times
times
until all the marks come to rest at the same
spot.
g. The spot where all all the marks
marks come
come to rest
rest is
the front wheel’s heavy spot “X”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30152 3. Adj
Adjus
ust:
t:
ADJUSTING
BALANCE THE FRONT WHEEL STATIC • Front wheel static
static balance
IP
IP • Install the
the balancing
balancing weights on the
the rim of the
• After replacing
replacing the tire,
tire, wheel or both,
both, the front brake disc side of the wheel.
wheel static balance should be adjusted. • Install up
up to four balancing
balancing weights
weights on the rim.
• Adjust the
the front wheel static
static balance
balance with the
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
brake disc installed. a. Install a balancing
balancing weight
weight “1” onto the rim
rim ex-
1. Rem
Remove:
ove: actly opposite the heavy spot “X”.
• Balanci
Balancing
ng weight(
weight(s)
s) IP
2. Find: Start with the lightest weight.
• Front wheel’s heavy spot
spot
IP
Place the front wheel on a suitable balancing
stand.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Spi
Spin
n the
the front
front wheel.
wheel.
4-24
FRONT WHEEL
Front wheel sensor rotor bolt

T
.
R .
8 N·m (0.8 kgf·m, 5.8 lb·ft)

Front brake disc bolt
23 N·m (2.3 kgf·m, 17 lb·ft)
ECA21011
NOTICE
• Do not drop
drop the wheel
wheel sensor rotor
rotor or sub-
sub-
ject it to shocks.
• If any solvent
solvent gets
gets on the wheel
wheel sensor ro-
ro-
b. Turn the front
front wheel 90° so that the
the heavy tor, wipe it off immediately.
spot is positioned as shown. • Replace thethe brake disc
disc bolts and
and wheel
sensor rotor bolts with new ones.
IP
• Install the
the brake disc with
with its chamfered side
side
“a” facing inward.
• Install the
the front wheel sensor
sensor rotor with
with the
stamped mark “b” facing away from the wheel.
• Tighten the bolts
bolts in stages.
stages.
c. If the heavy spot does

does not stay in that posi- 1
tion, install a heavier weight. 1
d. Repeat s steps
teps (b) and (c) until the
the front wheel
wheel
is balanced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Che
Check:
• Front wheel static balance a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the ffront
ront wheel and make
make sure it stays at
each position shown.
b
2. Che
Check:
b. If the fr
front
ont wheel does not remain stationary
stationary
• Front
Front brake
brake disc
disc
at all of the positions, rebalance it.
Refer to “CHECKING THE FRONT BRAKE
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
DISC” on page 4-36.
4-36.
EAS30154
3. Lu
Lubr
bric
icat
ate:
e:
INSTALLING THE FRONT WHEEL (FRONT
• Wheel
Wheel axl
axle
e
BRAKE DISC)
1. Inst
Instal
alll: Recommended lubricant
•• Front
Front
Front brake
brake disc
wheel
wheel discsor
“1”
“1” rotor
sensor
sen rotor “2”
Lithium-soap-based grease
4-25
FRONT WHEEL
4. Inst
Instal
alll: Out of specification  Check the wheel bear-
• Fr
Front
ont wheel
wheel ing for looseness, and the front wheel sensor
• Coll
Collar
arss and sensor rotor installation conditions (war-
• Front
Front wheel
wheel axle
axle page caused by overtorque, wrong installa-
IP tion direction, rotor decentering, LOCTITE®
Install the front wheel with the mark “a” on the on the mounting surface of the rotor, defor-
front tire pointing in the direction of wheel rota- mation caused
and caught by an
foreign impact during
materials). service
If there is any
tion.
defective part, repair or replace the defective
part.
a Distance “a” (between the front

wheel sensor rotor and front

wheel sensor)
0.81–1.57 mm (0.032–0.062 in)
IP
Measure the distance between the front wheel
sensor rotor and front wheel sensor in several
5. Tigh
Tighte
ten:
n: places in one rotation of the front wheel. Do not
• Front
Front wheel
wheel axle
axle nut turn the front wheel while the thickness gauge is
installed. This may damage the front wheel sen-
Front wheel axle nut sor rotor and the front wheel sensor.

T
R
.
.
26 N·m (2.6 kgf·m, 19 lb·ft)

ECA14140 Thickness gauge

NOTICE 90890-03180

Feeler gauge set
Before tightening the wheel axle nut, push
YU-26900-9
down hard on the handlebar(s) several times
and check if the front fork rebounds
re bounds smooth-
ly. a
6. Inst
Instal
alll:
• Front
Front wheel
wheel sensor
sensor
2
Front wheel sensor bolt 1

T
.
R .
7 N·m (0.7 kgf·m, 5.1 lb·ft)

ECA21020
NOTICE
Make sure there are no foreign materials in

8. In
Inst
stal
all:
l:
the front wheel sensor rotor and front wheel
• Front
Front brake
brake caliper
caliper
sensor. Foreign materials cause damage to
• Front brake hose guide
guide “1”
“1”
the front wheel sensor rotor and front wheel
sensor. Front brake caliper bolt
IP
T
.
R
.
35 N·m (3.5 kgf·m, 25 lb·ft)

Front brake hose guide bolt
• When installing
installing the front wheel sensor,
sensor, check 7 N·m (0.7 kgf·m, 5.1 lb·ft)
the wheel sensor lead for twists.
• To route the front
front wheel sensor
sensor lead, refer
refer to EWA13500
“CABLE ROUTING” on page 2-20. 2-20. WARNING

Make sure the brake hose is routed properly.
7. Meas
Measur
ure:
e:
• Distan
Distance
ce “a”
(between the front wheel sensor rotor “1” and
front wheel sensor “2”)
4-26
FRONT WHEEL
IP
While holding the front brake hose guide and
front wheel sensor lead holder so that the por-
tions “a” of the guide and holder contact the front
f ront
fork outer tube, tighten the bolts to specification.
a
1
4-27
REAR WHEEL
EAS22020
REAR WHEEL
Removing the rear wheel
2
3
. R
. R
.
95 N•m (9.5 k gf•m, 69 lb•ft)

Place the vehicle on the centerstand so that
the rear wheel is elevated
el evated..
Muffler Refer to “ENGINE REREMOV
MOVAL AL”” on page 5-
5-33.
1 Rear arm 1
2 Rear wheel 1
3 Rear brake shoe assembly 1
4-28
REAR WHEEL
EAS22090
CHECKING THE REAR WHEEL

1. Che
Check:
• Tire
• Rear
Rear whee
wheell
Refer to “CHECKING THE TIRES” on page
3-12 and
3-12 and “CHECKING THE WHEELS” on
page 3-12.
3-12.
2. Meas
Measurure:
e:
• Radial
Radial wheel
wheel runout
runout
• Lateral
Lateral wheel
wheel runou
runoutt
Refer to “CHECKING THE FRONT WHEEL”
on page 4-22.
4-22.
EAS22150
ADJUSTING THE REAR WHEEL STATIC

BALANCE
IP
After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted.
1. Adj
djus
ust:
t:
• Rear wheel
wheel static
static balance
Refer to “ADJUSTING THE FRONT WHEEL
STATIC BALANCE” on page 4-24.
4-24.
4-29
FRONT BRAKE
EAS20030
FRONT BRAKE
Removing the front brake pads
6 N•m (0.6 k gf•m, 4.3 lb•ft)
7
1
6
2 . R
R
.
35 N•m (3.5 k gf•m, 25 lb•ft)
4
5

2 Brake pad clip 2
3 Brake pad pin 1
4 Brake pad (inner) 1
5 Brake pad (outer) 1
6 Brake pad spring 1
7 Brake caliper bleed screw 1
4-30
FRONT BRAKE
Removing the front brake master cylinder
10 N•m (1.0 k gf•m, 7.2 lb•ft

ft))
1.5 N•m (0.15 k gf•m, 1.1 lb•ft
ft))
29 N•m (2.9 k gf•m, 21 lb•ft

ft))
6 N•m (0.6 k gf•m, 4.3 l
lb
b•ft
ft))
6 N•m (0.6 k gf•m, 4.3 l

lb
b•ft
ft)) 1.1 N•m (0.11 k gf•m, 0.80 lb•ft
ft))
Upper handlebar cover assembly Refer to “HANDLEBAR” on page 4-55

4-55..
Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-11.
3-11 .
1 Brake master cylinder reser voir cap 1
Brake master cylinder reservoir diaphragm hold-
2 1
er
3 Brake master cylinder reser voir diaphragm 1
4 Front brake light switch connector 2 Disconnect.
5 Front brake light switch 1
6 Front brake lever pivot bolt/nut 1/1
7 Front brake lever 1
Front brake
brake hose union bolt (master cylinder
8 1
side)
9 Brake hose gasket 2
4-31
FRONT BRAKE
Removing the front brake master cylinder
• • •
1.5 N•m (0.15 k gf•m, 1.1 lb•ft
ft)) 10 N m (1.0 k gf m, 7.2 lb ft
ft))
11
12 29 N•m (2.9 k gf•m, 21 lb•ft

ft))
6 N•m (0.6 k gf•m, 4.3 l
lb
b•ft
ft))
10
6 N•m (0.6 k gf•m, 4.3 l

lb
b•ft
ft)) 1.1 N•m (0.11 k gf•m, 0.80 lb•ft
ft))
Front brake
brake hose (front brake master cylinder to
10 1 Disconnect.
hydraulic unit)
11 Front brake master cylinder holder 1
12 Front brake master cylinder assembly 1
4-32
FRONT BRAKE
Disassembling the front brake master cylinder
BF
S
BF
2
1 New
1 Brake master cylinder kit 1

2 Brake master cylinder body 1
4-33
FRONT BRAKE
Removing the front brake caliper
1 3
2
4
29 N•m (2.9 k gf•m, 21 lb•ft)

35 N•m (3.5 k gf•m, 25 lb•ft)
Drain.
3-11 .
1 Front brake hose union bolt (brake caliper side) 1

Front brake hose (hydraulic unit to front brake
3 1 Disconnect.
caliper)
4-34
FRONT BRAKE
Disassembling the front brake caliper
6
T
. R
R
.
6 N•m (0.6 k gf•m, 4.3
4.3 lb•ft)
7
11 New 8
New 9
10
2 5
BF
S 3
4
1
1 Brake pad clip 2

2 Brake pad pin 1
3 Brake pad (inner) 1

4 Brake pad (outer) 1
5 Brake pad spring 1
6 Front brake caliper bracket 1
7 Brake caliper piston 1
8 Brake caliper piston dust seal 1
9 Brake caliper piston seal 1
10 Brake caliper bleed screw 1
11 Brake caliper body 1
4-35
FRONT BRAKE
EAS30168
e. Measure the runout
runout 1.5 mm
mm (0.06
(0.06 in) below
below
INTRODUCTION
EWA14101
the edge of the brake disc.
WARNING
Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
• Never disassemble
disassemble brake
brake components
components un- un-
less absolutely necessary.
• If any connection
connection on the
the hydraulic brake
brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
sembly.
• Never use solvents
solvents on internal brake com- 4. Meas
Measurure:
e:
ponents. • Brake
Brake disc thickn
thickness
ess
• Use only clean
clean or new brake
brake fluid for
for clean-
clean- Measure the brake disc thickness at a few dif-
ing brake components. ferent locations.
• Brake fluid
fluid may damage
damage painted surfaces Out of specification  Replace.
and plastic parts. Therefore, always clean
Brake disc thickness limit
up any spilt brake fluid immediately.
3.5 mm (0.14 in)
• Avoid brake
brake fluid coming
coming into contact
contact with
the eyes as it can cause serious injury.

FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with
with water for 15 minutes
minutes and get
get im-
mediate medical attention.
EAS30169
CHECKING THE FRONT BRAKE DISC

1. Rem
Remove:
ove:
• Fr
Front
ont wheel
wheel
Refer to “FRONT WHEEL” on page 4-20. 4-20.
2. Che
Check: 5. Adj
Adjus
ust:
t:
• Brake
Brake di
disc
sc • Brake
Brake disc
disc runout
runout
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Damage/galling  Replace.
3. Meas
Measurure:
e: a.
b. Remove
Remo
Rotateve the
the
the
the brak
brake
ee
brake
brak disc.
dicsc.
disc
dis by one bolt
bolt hole.
• Brake
Brake disc
disc runout
runout c. Install
Install the brake
brake disc.
disc.
Out of specification  Correct the brake disc
runout or replace the brake disc. Front brake disc bolt

T
.
R 23 N·m (2.3 kgf·m, 17 lb·ft)

Brake disc runout limit (as mea-
.

LOCTITE®
sured on wheel)

0.15 mm (0.0059 in) ECA19150
NOTICE
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Replace the brake disc bolts with new ones.
a. Place the vehicle
vehicle on a suitable
suitable stand
stand so that
that
the front wheel is elevated. IP
b. Before mmeasuri
easuring
ng the front brake disc
disc runout,
runout, • Install the
the brake disc “1” with
with its chamfered
chamfered
turn the handlebar to the left
le ft or right to ensure side “a” facing inward.
that the front wheel is stationary. • Tighten the
the brake disc bolts
bolts in stages.
stages.
c. Remove
Remove the
the brake
brake cali
caliper.
per.
d. Hold th
the
e dial gauge at a right angle against
against
the brake disc surface.
4-36
FRONT BRAKE
B
1
1
A. Inner
d. Meas
Measureure the
the brake disc
disc runout
runout..
B. Outer
e. If out of specification,
specification, repeat the
the adjustment
adjustment
steps until the brake disc runout is within 2. In
Inst
stal
all:
l:
specification. • Brake
Brake pad spri
spring
ng “1”
f. If the
the brake
brake disc
disc runout
runout canno
cannott be brough
broughtt • Br
Brak
ake
e pads
pads
within specification, replace the brake disc. IP
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Always install new brake pads, and new brake
6. Inst
Instal
alll: pad spring, as a set.
• Fr
Front
ont wheel
wheel
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Refer to “FRONT WHEEL” on page 4-20.

4-20. a. Connect a clear plastic
plastic hose “1” tightly to the
EAS30170 bleed screw “2”. Put the other end of the hose
REPLACING THE FRONT BRAKE PADS into an open container.
IP b. Loosen the
the bleed
bleed screw
screw and push thethe brake
brake
When replacing the brake pads, it is not neces- caliper piston into the brake caliper with your
sary to disconnect the brake hose or disassem- finger.
ble the brake caliper.
1
1. Meas
Measur
ure:
e:
• Brake pad wear limit
limit “a”
Out of specification  Replace the brake
pads as a set. 2
Brake pad lining thickness (in-

ner)
4.4 mm (0.17 in)

Limit
0.8 mm (0.03 in) c. Tighten
Tighten the bleed
bleed screw
screw..
Brake pad lining thickness (out-
er) Brake caliper bleed screw
4.4 mm (0.17 in)
T
R
.
.
6 N·m (0.6 kgf·m, 4.3 lb·ft)
Limit

0.8 mm (0.03 in) d. Install new brake

brake pad spring
spring and new
new brake
pads.
IP
A
The longer tangs “a” of the brake pad spring
must point in the direction of the brake caliper
a piston.
4-37
FRONT BRAKE
EAS31328
REMOVING THE FRONT BRAKE CALIPER

a
IP
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remo
Removeve::
1 • Brake hose union
union bolt “1”
• Brake
Brake hose gasket
gaskets
s “2”
• Front
Front brake
brake hose “3”
“3”
IP
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Put the end of the brake hose into a container
3. Inst
Instal
alll:
and pump out the brake fluid carefully.
• Brake
Brake pad pin
• Brake
Brake pad pad clips
clips
• Front
Front brake
brake caliper
caliper
• Front brake hose guide
guide “1”
“1”
• Front brake caliper bolts
3
Front brake caliper bolt

T
.
R 35 N·m (3.5 kgf·m, 25 lb·ft) 1

2
.
1
EAS30172
DISASSEMBLING THE FRONT BRAKE

CALIPER
1. Remo
Remove
ve::
• Brake caliper piston “1”
• Brake caliper
caliper piston
piston dust
dust seal “2”
“2”
• Brake caliper
caliper piston
piston seal
seal “3”
4. Che
Check:
• Brake
Brake fluid
fluid level
level
Below the minimum level mark “a”  Add the
specified brake fluid to the proper level. 3
2
Refer to “CHECKING THE BRAKE FLUID 1
3-10.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a a. Blow compress
compressed ed air into
into the brake hose
hose joint
opening “a” to force out the piston from the
brake caliper “1”.
EWA13550
WARNING
• Cover the
the brake caliper
caliper piston with a rag.
5. Che
Check: Be careful not to get injured when the pis-
• Brake lever operation
operation ton is expelled from the brake caliper.
Soft or spongy feeling  Bleed the brake sys- • Never try to
to pry out the brake caliper
caliper pis-
pis-
tem. ton.
Refer to “BLEEDING THE HYDRAULIC
3-11 .
4-38
FRONT BRAKE
a
2 3
1
b. Remove the brake

brake caliper
caliper piston
piston dust
dust seal 2. Che
Check:
and brake caliper piston seal. • Brake caliper bracket
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Cracks/damage  Replace.
EAS30173
EAS30174
CHECKING THE FRONT BRAKE CALIPER ASSEMBLING THE FRONT BRAKE CALIPER
EWA13621
Recommended brake component replacement
schedule WARNING
• Before installatio
installation,
n, all internal
internal brake com-
Brake pads If necessary
ponents should be cleaned and lubricated
Piston seal Every two years with clean or new brake fluid.
Piston dust seal Every two years • ponents

Never use
Brake hose Every four years assolvents
sthey
olvents on
on internal
intern
will cause thealbrake
brake com-
com-
caliper
Every two years and
piston dust seals and brake caliper piston
Brake fluid whenever the brake is seals to swell and distort.
disassembled • Whenever a brake
brake caliper
caliper is disassembled,
disassembled,
replace the brake caliper piston dust seals
1. Che
Check: and brake caliper piston seals.
• Brake caliper piston “1”
Rust/scratches/wear  Replace the brake
Specified brake fluid
caliper piston. YAMAHA GENUINE BRAKE
• Brake caliper cylinder
cylinder “2”
FLUID : DOT 3 or Dot 4
Scratches/wear  Replace the brake caliper (GDR155)
assembly. YAMAHA GENUINE BRAKE
• Brake caliper body “3”
“3” FLUID : Dot 4-Plus (GDR155-A)
Cracks/damage  Replace the brake caliper
EAS30934
assembly.
• Brake fluid delivery
delivery passages
passages INSTALLING THE FRONT BRAKE CALIPER
(brake caliper body) 1. In
Inst
stal
all:
l:
Obstruction  Blow out with compressed air. • Front brake caliper
caliper “1”
EWA17070 (temporarily)
WARNING
gaskets “2” New
• Brake hose gaskets
Whenever a brake caliper is disassembled, • Front
Front brake
brake hose “3”
“3”
replace the brake caliper piston dust seal • Brake hose union
union bolt “4”
and brake caliper piston seal.
Front brake hose union bolt

T
.
R
.
(brake caliper side)

29 N·m (2.9 kgf·m, 21 lb·ft)
EWA13531
WARNING
Proper brake hose routing is essential to in-

sure safe vehicle operation.
4-39
FRONT BRAKE
ECA19080
• When refilling,
refilling, be careful
careful that
that water does
does
NOTICE
When installing the brake hose onto the voir. Water will significantly lower the boil-
brake caliper “1”, make sure the brake pipe ing point of the brake fluid and could cause
“a” passes between the projections “b” on vapor lock.
the brake caliper. ECA13540
NOTICE
b
3
4 5. Ble
Bleed:
ed:
a • Brake
Brake sys
system
tem
1 2 Refer to “BLEEDING THE HYDRAULIC
New
BRAKE SYSTEM” on page 3-11. 3-11.
6. Che
Check:
• Brake
Brake fluid
fluid level
level
2. Rem
Remove:
ove: Below the minimum level mark “a”  Add the
• Front
Front brake
brake caliper
caliper specified brake fluid to the proper level.
3. Inst
Instal
alll: Refer to “BLEEDING THE HYDRAULIC
• Brake
Brake pad pad sprin
spring
g BRAKE SYSTEM” on page 3-11. 3-11.
• Brak
Brake
e pads
pads
• Brake
Brake pad pin
• Brake
Brake pad
pad clips
clips
• Front
Front brake
brake caliper
caliper
• Front wheel
wheel sensor
sensor lead
lead holder a
• Front brake caliper bolts
Front brake caliper bolt

T
.
R
.
35 N·m (3.5 kgf·m, 25 lb·ft)

Refer to “REPLACING THE FRONT BRAKE

PADS” on page 4-37.
4-37. 7. Che
Check:
4. Fill: • Brake lever operation
operation
• Brake master
master cylinder
cylinder reservoir
reservoir Soft or spongy feeling  Bleed the brake sys-
(with the specified amount of the specified tem.
brake fluid) Refer to “BLEEDING THE HYDRAULIC
3-11.
YAMAHA GENUINE BRAKE FLU- EAS30179
REMOVING THE FRONT BRAKE MASTER

ID: DOT 3 or DOT 4 (GDR155)
CYLINDER
YAMAHA GENUINE BRAKE FLU-
IP
ID: DOT 4-Plus (GDR155-A)
Before removing the front brake master cylinder,
EWA13540 drain the brake fluid from the entire brake sys-
WARNING tem.
designated brake
brake fluid.
fluid. Other
1. Remo
Removeve::
brake fluids may cause the rubber seals to
• Brake hose union
union bolt “1”
deteriorate, causing leakage and poor
• Brake
Brake hose gasket
gaskets
s “2”
brake performance.
• Front
Front brake
brake hose “3”
“3”
• Refill with
with the same type
type of brake fluid
fluid that
is already in the system. Mixing brake fluids IP
may result in a harmful chemical reaction, To collect any remaining brake fluid, place a
container under the master cylinder and the end
leading to poor brake performance. container under the master cylinder and the end
of the brake hose.
4-40
FRONT BRAKE


FLUID: DOT 3 or DOT 4 (GDR155)
FLUID: DOT 4-Plus (GDR155-A)
2 1 EAS30182
3
INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1. In
Inst
stal
all:
l:
EAS30725 • Brake master cylinder
cylinder
CHECKING THE FRONT BRAKE MASTER • Brake master
master cylinder
cylinder holder “1”
“1”
CYLINDER
1. Che
Check: Front brake master cylinder hold-
• Brake master cylinder
cylinder
T
.
R
.
er bolt
Damage/scratches/wear  Replace.
10 N·m (1.0 kgf·m, 7.2 lb·ft)
• Brake fluid delivery
delivery passages
passages
(brake master cylinder body) IP
Obstruction  Blow out with compressed air. • Install the
the brake master cylinder
cylinder holder
holder with the
2. Che
Check: “UP” mark “a” facing up.
• Brake master cylinder
cylinder kit • First,
First, tighten the upper
upper bolt, then the lower
lower bolt.
Damage/scratches/wear  Replace.
3. Che
Check:
1
• Brake master
master cylinder
cylinder reservoir
reservoir “1”
“1”
• Brake master
master cylinder
cylinder reservoir
reservoir cap “2”
• Brake master
master cylinder reservoir
reservoir diaphragm
diaphragm
up
holder “3”
• Brake master
master cylinder reservoir
reservoir diaphragm
diaphragm
“4”
Damage/wear  Replace. a
2
1 2. In
Inst
stal
all:
l:
• Brake hose gaskets
gaskets “1” New
3 • Front
Front brake
brake hose “2”
“2”
• Brake hose union
union bolt “3”
4 Front brake hose union bolt

T
.
R
.
(master cylinder side)

29 N·m (2.9 kgf·m, 21 lb·ft)
4. Che
Check: EWA13531
• Front
Front brake
brake hose WARNING
Cracks/damage/wear  Replace. Proper brake hose routing is essential to in-
EAS30181
sure safe vehicle operation.
ASSEMBLING THE FRONT BRAKE MASTER
IP
CYLINDER
EWA13520 • Make sure
sure that the distance
distance “a” between
between the
WARNING brake hose and the handlebar “4” is 40–44 mm
• Before installation
installation,, all internal
internal brake com- (1.57–1.73 in) as shown in the illustration.
ponents should be cleaned and lubricated • sure

Turn the
the brake
handlebar
handlebar
hoseto the left
does left and
not right
touch to make
other make
parts
with clean or new brake fluid.
(e.g., wire harness, cables, leads). Correct if
Never use solvents
solvents on internal brake com
ponents. necessary.
4-41
FRONT BRAKE
a
4
1 New a
3
2
3. Fill: 6. Che
Check:
• Brake master
master cylinder
cylinder reservoir
reservoir • Brake lever operation
operation
(with the specified amount of the specified Soft or spongy feeling  Bleed the brake sys-
brake fluid) tem.
Specified brake fluid BRAKE SYSTEM” on page 3-11. 3-11.
YAMAHA GENUINE
GE NUINE BRAKE

FLUID: DOT 3 or DOT 4 (GDR155)
YAMAHA GENUINE
GE NUINE BRAKE
FLUID: DOT 4-Plus (GDR155-A)
EWA13540
WARNING
designated brake
brake fluid.
fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with
with the same type
type of brake fluid
fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling,
refilling, be careful that
that water does
does
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
ECA13540
NOTICE

4. Bleed
eed:
• Brake
Brake sys
system
tem
BRAKE SYSTEM” on page 3-11. 3-11 .
5. Che
Check:
• Brake
Brake fluid
fluid level
level
Below the minimum level mark “a”  Add the
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
3-10.
4-42
REAR BRAKE
EAS5P03037
REAR BRAKE
Disassembling the brake shoe
T
.
R
.
7 N m (0.7kgf
• (0.7kgf m, 5.1lb.ft
• 5.1lb.ft))
3
6
7
4
8
5 9
10
T
.
R
.
95 N m (9.5kgf
• (9.5kgf m, 69 lb ft)
• ft) • 2

Rear wheel Refer to “REAR WHEEL” on page 4-28.
4-28.
1 Brake shoe 2
2 Brake shoe spring 2
3 Rear brake cable adjusting nut 1
4 Compression spring 1
5 Rear brake cable assembly 1
6 Pin 1
7 Brake camshaft lever 1
8 Washer 1
9 Brake shoe wear indicator 1
10 Brake camshaft 1
4-43
REAR BRAKE
EAS5P03038
4. Remo
Removeve::
REMOVING THE REAR BRAKE
• Brake
Brake camshaf
camshaftt “1”
1. Rem
Remove:
ove:
• Brake
Brake shoes
shoes “1”
• Brake
Brake shoe
shoe spring
spring “2”
1 EAS5P03039
CHECKING THE REAR BRAKE SHOES

1. Che
Check:
2. Rem
Remove:
ove: • Brake
Brake shoe
shoe lining
lining
• Adjust
Adjusting
ing n
nut
ut “1”
“1” Glazed areas  Repair.
• Rear brak
brake e cable
cable “2” Sand the glazed areas with coarse sandpa-
• Pin “3
“3”” per.
• Brake camshaft
camshaft lever
lever bolt “4”
“4”
IP
• Brake camshaft
camshaft lever
lever “5”
After sanding the glazed areas, clean the brake
shoe with a cloth.
1
2
3
3. Rem
Remove:
ove:
• Wave
Wave washer
washer “1”
• Brake shoe wear indicator
indicator “2”
2. Meas
Measur
ure:
e:
• Brake shoe
shoe lining
lining thickness
thickness “a”
Out of specification  Replace.
Lining thickness
4.0 mm (0.16 in)
2
Limit
2.0 mm (0.08 in)
1
a
4-44
REAR BRAKE
EWA3C11004
c. Check
Check that the
the brake
brake shoes are
are properly
properly
WARNING positioned.
Do not allow oil or grease on the brake
shoes. b
IP 1
Replace the brake shoes as a set, if either is
worn to the wear limit.
3. Meas
Measur
ure:
e:
• Brake drum
drum inside
inside diameter
diameter “a” 2
Out of specification  Replace the wheel. a
Brake drum inside diameter

130.0 mm (5.12 in) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

Limit EWA5P03004
131.0 mm (5.16 in) WARNING

After installing the brake camshaft, remove
any excess grease.
a
2. In
Inst
stal
all:
l:
• Brake camshaft
camshaft lever
lever “1”
Brake camshaft lever pinch bolt

T
.
R
.
7 N·m (0.7 kgf·m, 5.2 lb·ft)

IP
Align the punch mark on the brake camshaft with
the mark on the brake camshaft lever positioned
positione d
4. Che
Check: as shown “a”.
• Brake drum inner
inner surface
surface
Oil deposits  Clean.
Remove the oil with a rag soaked in lacquer
thinner or solvent.
Scratches  Repair.
Lightly and evenly polish the scratches with a
an emery cloth.
5. Che
Check:
1
• Brake
Brake cams
camshaft
haft
EAS5P03040
3. In
Inst
stal
all:
l:
ASSEMBLING THE REAR BRAKE SHOE
• Brake shoe springs
springs “1” New
PLATE
• Br
Brak
ake
e shoes
shoes
1. Inst
Instal
alll:
• Brake
Brake camsh
camshaft
aft “1”
“1” IP
• Brake shoe wear indicator
indicator “2” • Lubricate
Lubricate the pivot pin
pin with a thin coat of sili-
sili-
• Wave
Wave was washer
her cone grease.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Do not to damage the springs
springs during
during installa-
installa-
a. Install the brake
brake camshaft
camshaft so its punch
punch mark
mark tion.
“a” is positioned as shown. • Install the
the brake shoe springs
springs as shown.
shown.
b. Align the projection
projection “b” on the brake
brake shoe
wear indicator with the notch in the brake
camshaft.
4-45
REAR BRAKE
EWA3C11005
2. Che
Check:
WARNING • Brake
Brake pedal
pedal free play
play
Do not apply grease to the brake shoe lin- If the free play is out of specification.
ings. Refer to “ADJUSTING THE REAR DRUM
BRAKE” on page 3-10.
3. While pressing
pressing the brake
brake pedal
pedal all the way
down, push the brake camshaft lever fully in
the arrow indicated direction and check that
the brake shoe wear indicator does not reach
the brake drum wear indicator.
Not reaching  Still usable.
Reaching  Replace the wheel.
EAS5P03041
CHECKING THE REAR BRAKE DRUM WEAR

LIMIT
IP
After the new brake shoes are installed, the
brake drum inside diameter can be checked as
to whether it is within the wear
we ar limit “a” by means
of the brake drum wear indicator on the brake
shoe plate.
1. Che
Check:
• Position
Position at which to install
install the brake camsha
camshaft
ft
lever
Reinstall the brake camshaft lever if its
installed position is out of specification.
4-46
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
EAS20032

Removing the hydraulic unit assembly
T
.
R
.
29 N m (2.5kgf
• (2.5kgf m, 21lb.ft
• 21lb.ft))
2
2
3
3
NEW
NEW
3 3
T
.
R
.
7 N m (0.7kgf
• (0.7kgf m, 5.1lb
• 5.1lb.ft
.ft))

Drain.
3-11 .
4-15.
4-9..
4-9
1 ABS ECU coupler 1 Disconnect.
Front brake
brake hose union bolt (hydraulic unit as-
2 2
sembly side)
4-47
Removing the hydraulic unit assembly
T
.
R
.
29 N m (2.5kgf
• (2.5kgf m, 21lb.ft
• 21lb.ft))
NEW
NEW
4
5
NEW
NEW
T
.
R
.
7 N m (0.7kgf
• (0.7kgf m, 5.1lb
• 5.1lb.ft
.ft))
Front brake
brake hose (front brake master cylinder to
4 1 Disconnect.
hydraulic unit)
Front brake hose (hydraulic unit to front brake
5 caliper) 1 Disconnect.
6 Hydraulic unit assembly 1
4-48
EAS30197
IP
REMOVING THE HYDRAULIC UNIT
ASSEMBLY Do not operate the brake levers while removing
ECA21091 the brake hoses.
NOTICE
ECA14530
Unless necessary, avoid removing and in- NOTICE

stalling the brake hoses of the hydraulic unit
assembly. When removing
area around the brake unit
the hydraulic hoses, cover any
to catch the
EWA13930 spilt brake fluid. Do not allow the brake fluid
WARNING to contact other parts.
Refill with the same type of brake fluid that is 3. Remo
Remove
ve::
already in the system. Mixing fluids may re- • Hydraulic
Hydraulic unit
unit assembly
assembly “1”
“1”
sult in a harmful chemical reaction, leading
IP
to poor braking performance.
ECA18241
• To avoid brake
brake fluid leakage
leakage and to prevent
prevent for-
NOTICE
eign materials from entering the hydraulic unit
assembly, insert a rubber plug “a” or a bolt
• Handle the
the ABS components
components with
with care
(M10  1.25) into each brake hose union bolt
since they have been accurately adjusted.
hole.
Keep them away from dirt and do not sub-
• When using a bolt,
bolt, do not tighten the bolt
bolt until
ject them to shocks.
the bolt head touches the hydraulic unit. Other-
• Do not turn
removing turn the
the main
main switch
hydraulic to “ON” when
unit assembly. wise, the brake hose union bolt seating surface
could be deformed.
• Do not clean with
with compressed
compressed air.air.
• Do not reuse thethe brake fluid.
• Brake fluid
fluid may damage
damage painted surfaces
a 1
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
• Do not allow
allow any brake fluid toto contact the
the
couplers. Brake fluid may damage the cou-
plers and cause bad contacts.
• If the union bolts for the
the hydraulic unitunit as-
sembly have been removed, be sure to
tighten them to the specified torque and
bleed the brake system. EAS30198
CHECKING THE HYDRAULIC UNIT

1.• ABS
Disc
Discon
onne
nect
ECU
ECUct:
: pler “1”
coupler
cou “1” ASSEMBLY
1. Che
Check:
• Hydraulic
Hydraulic unit
unit assembly
assembly
Cracks/damage  Replace the hydraulic unit
assembly and the brake hoses that are con-
nected to the assembly as a set.
EAS30200
1 INSTALLING THE HYDRAULIC UNIT

ASSEMBLY
1. In
Inst
stal
all:
l:
• Hydraulic
Hydraulic unit
unit assembly
assembly
Hydraulic unit assembly bolt

T
.
R
.
7 N·m (0.7 kgf·m, 5.1 lb·ft)

2. Rem
Remove:
ove:
• Brak
Brake
e hoses
hoses
4-49
ECA21110
IP
NOTICE
• Connect the ABS ECU coupler
coupler 1.
Do not remove the rubber plugs or bolts
• Make sure
sure that the ABS ECU
ECU coupler is
is con-
(M10  1.25) installed in the brake hose union
nected in the correct position.
bolt holes before installing the hydraulic unit
assembly.
IP
Do not allow any foreign materials to enter the 1
hydraulic unit assembly or the brake hoses
when installing the hydraulic unit assembly.
2. Rem
Remove:
ove:
• Rubber plugs (M10  1.25)
plugs or bolts (M10
3. Inst
Instal
alll:
• Front brake
brake hose (front brake
brake master cylinde
cylinderr
to hydraulic unit) “1” 5. Fill:
• Front brake hose
hose (hydraulic
(hydraulic unit to front brake
brake • Brake master
master cylinder
cylinder reservoir
reservoir
caliper) “2” • Brake fluid reservoir
reservoir
(with the specified amount of the specified
Front brake hose union bolt brake fluid)
T
.
R .
(hydraulic unit assembly side)
29 N·m (2.9 kgf·m, 21 lb·ft) Specified brake fluid
ECA21121

FLUID: DOT
DOT 3 or DOT 4 (GDR155)
(GDR155)
NOTICE
If the brake hose union bolt does not turn FLUID: DOT 4-Plus (GDR155-A)
(GDR155-A)
easily, replace the hydraulic unit assembly,
brake hoses, and related parts as a set. EWA13090
WARNING
IP
• Use only the designate
designatedd brake fluid.
fluid. Other
Position the pipe sections of the brake hoses at brake fluids may cause the rubber seals to
a 30° angle from the line “a” as shown in the il- deteriorate, causing leakage and poor
lustration, and then tighten the brake hose union brake performance.
bolts to specification. • Refill with
with the same type
type of brake fluid
fluid that
is already in the system. Mixing brake fluids
2 may result
leading in a harmful
to poor chemical reaction,
brake performance.
• When refilling,
refilling, be careful
careful that
that water does
does
not enter the brake fluid reservoir. Water
a
will significantly lower the boiling point of
a the brake fluid and could cause vapor lock.
ECA13540
NOTICE
1
4. Conn
Connec
ect:
t: and plastic parts. Therefore, always clean up
• ABS ECU
ECU coupler
coupler “1”
“1” any spilt brake fluid immediately.
6. Ble
Bleed:
ed:
• Brake
Brake sys
system
tem
3-11.
4-50
7. Check tthe
he operation
operation of the
the hydraulic
hydraulic unit
unit ac-
cording to the brake levers response. (Refer Battery voltage
to “HYDRAULIC UNIT OPERATION TESTS” Higher than 12.8 V

on page 4-51.)
4-51.)
ECA14550 IP
NOTICE If the battery voltage is lower than 12.8 V, charge
Always check the operation of the hydraulic the battery, and then perform brake line routing
unit according to the brake lever response. confirmation.
8. Del
Delete
ete the fault
fault codes.
codes. (Refe
(Referr to “[B-3] DE-
LETING THE FAULT CODES” on page
8-102.)
8-102 .)
9. Per
Perfor
form
m a trial
trial run.
run. (Refer
(Refer to “CHECKING
THE ABS WARNING LIGHT” on page 4-54.) 4-54 .)
EAS30201
HYDRAULIC UNIT OPERATION TESTS

The reaction-force pulsating action generated in
the brake levers when the ABS is activated can
be tested when the vehicle is stopped.
The hydraulic unit operation can be tested
teste d using 6. Removing
Removing the protecti
protective
ve cap
cap “1”, and then
the following two methods. connect the Yamaha diagnostic tool to the
• Brake line
line routing confirmatio
confirmation:
n: this test Yamaha diagnostic tool coupler (4P).
checks the function of the ABS after the sys-
tem was disassembled, adjusted, or serviced.
90890-03250
• ABS reaction-forc
reaction-forcee confirmation:
confirmation: this test gen-
erates the same reaction-force pulsating action 90890-03252
that is generated in the front brake lever when
the ABS is front activated.
Brake line routing confirmation

EWA13120
WARNING
1
IP
• For the brake line
line routing
routing confirmation,
confirmation, use the
the
diagnosis mode of the Yamaha diagnostic tool.
• Before performing
performing the brake
brake line routing confir-
confir- 7. Start the
the Yamaha
Yamaha diagnostic
diagnostic tool and
and display
display
mation, make sure that no malfunctions have the diagnosis mode screen.
been detected in the ABS ECU and that the 8. Select code No. 2, “Brake
“Brake line
line routing
routing confir-
confir-
wheels are not rotating. mation”.
9. Click “Acti
“Action”
on” “1”,
“1”, and then operate the
the front
1. Place the vehicle
vehicle on a center
center stand. brake lever “2” simultaneously.
2. Tur
Turnn the main
main switch
switch to “OFF
“OFF”.
”. IP
3. Open
Open the
the sea
seat.
t.
• The hydraulic
hydraulic unit operates
operates 1 second after
after the
4. Rem
Remove:
ove:
front brake lever operated and continues for
• Batter
Batteryy cover
cover
approximately 1 second.
• The operation
hydraulic unit can be con-
con-
4-1..
4-1
firmed using the indicator.
5. Che
Check:
• Battery
Battery voltage
voltage On: The hydraulic unit is operating.
Lower than 12.8 V  Charge or replace the
battery.
4-51
Flashing: The conditions for operating the hy- 11.If the operation of the hydraulic unit is normal,
draulic unit have not been met. delete all of the fault codes.
Off: The front brake lever is not being
operated. ABS reaction-force confirmation
EWA13120
WARNING

IP
1 • For the ABS reaction-fo
reaction-force
rce confirmation,
confirmation, use
use
the diagnosis mode of the Yamaha diagnostic
tool. For more information, refer to the opera-
tion manual of the Yamaha diagnostic tool.
• Before performin
performing
g the ABS reaction-force
reaction-force con-
firmation, make sure that no malfunctions have
been detected in the ABS ECU and that the
wheels are not rotating.
vehicle on a center stand.
2. Turn the
the main
main switch
switch to “OFF”
“OFF”..
3.
4. Open
Ope
Remo
Removen ve:
tthe
he: seat.
seat.
• Battery
Battery cover
cover
2
4-1..
4-1
10.Check: 5. Che
Check:
• Hydraulic
Hydraulic unit
unit operation
operation • Battery
Battery volt
voltage
age
Click “Action”, a single pulse will be generat- Lower than 12.8 V  Charge or replace the
ed in the front brake lever “1”, operate only battery.
once.
Battery voltage
Higher than 12.8 V

IP
If the battery voltage is lower than 12.8 V, charge
the battery, and then perform ABS reaction-
force confirmation.
IP
“ON” and “OFF” on the tool screen indicate
when the brakes are being applied and released
respectively.
ECA22080
NOTICE
• Check that the

the pulse is felt in
in the front
brake lever.
4-52
6. Removi
Removing
ng the protective
protective cap
cap “1”,
“1”, and then
then
connect the Yamaha diagnostic tool to the
Yamaha diagnostic tool coupler (4P).

90890-03250

90890-03252
2
10.A reaction-force pulsating action is generated

in the front brake lever “1” and continues for a
few seconds.
1 IP
• The reaction-force
reaction-force pulsating
pulsating action
action consists
consists of
quick pulses.
• Be sure to continue
continue operating
operating the front brake
brake
lever even after the pulsating action has
7. Start the Yamaha
Yamaha diagnostic
diagnostic tool and display
display stopped.
the diagnosis mode screen. • “ON” and “OFF”
“OFF” on the tool screen
screen indicate
indicate
8. Select code No.
No. 1, “ABS
“ABS reaction-f
reaction-force
orce con-
con- when the brakes are being applied and re-
firmation”. leased respectively.
9. Click “Action”
“Action” “1”,
“1”, and then operate the front
brake lever “2” simultaneously.
IP
• The hydraulic
hydraulic unit operates
operates 1 second after
after the
front brake lever operated and continues for
approximately 1 second.
• The operation
hydraulic unit
unit can be con-
firmed using the indicator.
On: The hydraulic unit is operating.
1
Flashing: The conditions for operating the hy-
draulic unit have not been met. ECA22080
Off: The front brake lever is not being operated.

ope rated. NOTICE
• Check that the

the pulse is felt
felt in the front
brake lever.
• If the pulse is hardly
hardly felt in either
either the front
front
brake lever, check that the brake hoses and
brake pipes are connected correctly to the
hydraulic unit assembly.
4-53
11.Turn the main switch to “OFF”.

12.Remove the Yamaha diagnostic tool from the
Yamaha diagnostic tool coupler, and then in-
stall the protective cap.
13.Turn the main switch to “ON”.
14.Check for brake fluid leakage around the hy-
draulic unit.
Brake fluid leakage  Replace the hydraulic
unit, brake hoses, and related parts as a set.
15.If the operation of the hydraulic unit is normal,
delete all of the fault codes.
EAS30202
CHECKING THE ABS WARNING LIGHT

After all checks and servicing are completed, en-
sure that the ABS warning light goes off by walk-
ing the vehicle at a speed of faster
f aster than 10 km/h
(6 mph) or performing a trial run.
4-54
HANDLEBAR
EAS20033
HANDLEBAR
Removing the rear view mirror and handlebar cover
6 1
8
10 1
5
7
9
8

1 Rear view mirror (left and right) 2
2 Front handlebar cover 1 1
3 Front handlebar cover 2 1
4 Rear handlebar cover 1
5 Left handlebar switch 1 Disconnect.
6 Right handlebar switch 1 Disconnect.
7 Meter assembly 1
8 Grip end (left and right) 2
9 Left handlebar grip 1
10 Throttle grip 1
4-55
HANDLEBAR
Removing the rear view mirror and handlebar cover
11
17
16
12
14 15
13
11 Throttle cable housing 1

12 Throttle cable 1 Disconnect.
13 Front brake switch 1

14 Front brake lever 1
15 Brake hose 1
16 Front brake master cylinder holder 1
17 Handlebar 1
4-56
HANDLEBAR
EAS31622
3. Remo
Remove
ve::
REMOVING THE FRONT HANDLEBAR
• Handlebar
Handlebar grip
grip “1”
“1”
COVER ASSEMBLY
IP
1. Rem
Remove:
ove:
• Front handlebar
handlebar cover
cover assembly
assembly “1”
“1” Blow compressed air between the handlebar
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ and the handlebar grip, and gradually push the
a. Remove the quick
quick fastener
fastener and front
front handle-
handle- grip off the handlebar.
bar cover assembly screws.
b. Unhook tthe
he projections
projections “a” on the
the front han-
dlebar cover assembly from the slots “b” in
the lower handlebar cover.
1
a
b
EAS30204
CHECKING THE HANDLEBAR

1. Che
Check:
• Handl
Handleb
ebar
ar
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Bends/cracks/damage  Replace.
EWA13690
EAS31701
DISASSEMBLING THE FRONT HANDLEBAR WARNING

COVER ASSEMBLY Do not attempt to straighten a bent handle-
1. Disa
Disass
ssem
embl
ble:
e: bar as this may dangerously weaken it.
• Front handlebar cover “1”
• Front handlebar cover “2” EAS30205
INSTALLING THE HANDLEBAR

IP
1. Stand the
the vehicle
vehicle on a level
level surface.
surface.
Unhook the projections “a” on the front handle- EWA13120
bar cover from the slots “b” in the front handlebar WARNING
cover. Securely support the vehicle so that there is
b 1 2. In
Inst
stal
all:
l:
2 a • Handleba
Handlebarr “1”
Handlebar bolt
a
T
.
R
.
53 N·m (5.3 kgf·m, 38 lb·ft)

ECA18300
NOTICE
b First, tighten the bolts on the front side of the
handlebar holder, and then on the rear side.
EAS30203
REMOVING THE HANDLEBAR IP

1. Stand tthe
he vehicle
vehicle on a level
level surface.
surface. • Make sure
sure that the projection
projection “a”
“a” of the handle-
EWA13120
WARNING bar contacts the lower handlebar holder.

• The front handlebar
handlebar holders
holders should be installed
installed
with the punch mark “b” facing forward.
2. Rem
Remove:
ove:
• Gr
Grip
ip en
end
d
4-57
HANDLEBAR
c. Wipe off
off any excess rubber adhesive
adhesive with a
1 clean rag.
EWA13700
WARNING
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried.
d. Install
Install the
the left
left grip
grip end.
end.
IP
There should be 1.0–3.0 mm (0.04–0.12 in) of
clearance “c” between the handlebar grip and
3. Inst
Instal
alll:
the grip end.
• Handlebar
Handlebar switch
switch (left)
(left) “1”
IP
1
Align the projection “a” on the left handlebar
switch with the hole “b” in the rear handlebar 2
cover.
1
b 2
1 a
a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. In
Inst
stal
all:
l:
• Handlebar switch (right) “1”
• Throttl
Throttlee cables
cables “2”
• Throttl
Throttlee grip
grip “3”
4. Inst
Instal
alll:
• Grip
Grip end (right)
(right) “4”
“4”
• Handleba
Handlebarr grip
grip “1”
• Grip
Grip end (left
(left)) “2” Throttle cable holder bolt (han-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
T
.
dlebar switch side)
R
a. Apply a thin coat of a rubber adhesive
adhesive to the
the
.
3.5 N·m (0.35 kgf·m, 2.5 lb·ft)

left end of the handlebar.
b. Slide the handlebar
handlebar grip
grip over the left
left end of IP
the handlebar.
IP • Lubricate
Lubric
inside ate thethrottle
of the end of grip
the throttle
throt
withtle cables
a thin and
anof
coat d the
lith-
Make sure that the distance “a” between the end
e nd ium-soap-based grease.
of the left handlebar switch and the end of the • Align the
the projection
projection “a” on the right
right handlebar
handlebar grip is 0 mm (0 in). switch with the hole “b” in the rear handlebar
cover.
• There should
should be 1.0–3.0 mm (0.04–0.12
(0.04–0.12 inin)) of
1 a clearance “c” between the throttle grip and the
grip end.
4-58
HANDLEBAR
IP
Fit the projections “a” on the front handlebar
2 3 4 cover into the slots “b” in the front handlebar
b LS
cover.
c
3 1 b 1
a a
2
a
6. Inst
Instal
alll:
• Front brake
brake master
master cylinder
cylinder
• Front brake
brake master cylinder
cylinder holder
holder “1”
b
Front brake master cylinder

T
.
R
.
holder bolt EAS31623

10 N·m (1.0 kgf·m, 7.2 lb·ft) INSTALLING THE FRONT HANDLEBAR
COVER ASSEMBLY
IP 1. In
Inst
stal
all:
l:
• Install the
the brake master cylinder
cylinder holder
holder with the • Front handlebar
handlebar cover
cover assembly
assembly “1”
“1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• “UP”
Align mark “a”efacing
the edge
edg up. brake master
“b” of the master cylinder
cylinder a. Fit the projections
projections “a” on the front
front handlebar
handlebar
cover into the slots “b” in the lower handlebar
holder with the edge “c” of the stay on the han-
cover.
dlebar as shown in the illustration.
• First, tighten
tighten the upper bolt, then the lower
lower bolt.
1
a
b
b. Install the front handlebar cover assembl

assembly
y
screws and quick fasteners, and then tighten
7. Adj
djus
ust:
t:
the screws to specification.
• Throttle
Throttle grip
grip free play
Refer to “CHECKING THE THROTTLE GRIP Upper handlebar cover assembly
OPERATION” on page 3-23.3-23.
T
.
R screw
.

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Throttle grip free play
3.0–5.0 mm (0.12–0.20 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS31702
ASSEMBLING THE FRONT HANDLEBAR

COVER ASSEMBLY
1. Asse
Assemb
mblele::
4-59
FRONT FORK
EAS20034
FRONT FORK
Removing the front fork legs
53 N•m (5.3
(5.3 k gf•m, 3.8 lb•ft)
2
3
8 N•m (0.8
(0.8 k gf•m, 5.8
5.8 lb•ft)
8 N•m (0.8
(0.8 k gf•m, 5.8
5.8 lb•ft)

The following procedure applies to both of
the front fork legs.
Front wheel Refer to “FRONT WHEEL” on page 4-20
4-20..
1 Front fender 1
2 Lower bracket pinch bolt 2
3 Front fork leg 1
4-60
FRONT FORK
Disassembling the front fork legs
10
13
15
1
11
2
16
3
12
14
9
5
8
6
23 N•m (2.3
(2.3 k gf•m, 17 lb•ft)

The following procedure applies to both of
the front fork legs.
1 Front fork cap clip 1
2 Front fork cap 1
3 O-ring 1
4 Fork spring 1
5 Tip guard 1
6 Dust seal 1
7 Oil seal clip 1
8 Front fork damper rod bolt 1
9 Copper washer 1
10 Oil flow stopper 1
11 Damper rod 1
12 Rebound spring 1
13 Damper rod ring 1
14 Inner tube 1
15 Oil seal 1
16 Outer tube 1
16 Outer tube 1
4-61
FRONT FORK
EAS30206
REMOVING THE FRONT FORK LEGS

front fork legs. 1
1. Stand tthe
he vehicle
vehicle on a level
level surface.
surface.
EWA13120
2
WARNING
IP
Place the vehicle on a suitable stand so that the 2. Dr
Drai
ain
n:
front wheels are elevated. • Fork
Fork oi
oill
IP
2. Lo
Loos
osen
en::
• Lower bracket
bracket pinch
pinch bolts
bolts “1” Stroke the outer tube several times while drain-
EWA18000 ing the fork oil.
WARNING
Before loosening the lower bracket pinch
bolts, support the front fork leg.
1 3. Remo
Remove ve::
• Dust seal
seal “1”
“1”
• Oil seal
seal clip
clip “2”
(with a flathead screwdriver)
EAS30207 ECA14180
DISASSEMBLING THE FRONT FORK LEGS NOTICE

The following procedure applies to both of the Do not scratch the inner tube.
front fork legs.
ECA19110
NOTICE 1
• The front fork
fork leg has a very sophisticat
sophisticated
ed
internal construction, which are particular-
ly sensitive to foreign material. 2
• When disassembling
disassembling and
and assembling
assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
1. Rem
Remove:
ove:
• Front fork cap clip
clip “1”
4. Remo
Removeve::
• Front
Front fork
fork cap
cap “2”
• Front fork
fork damper rod bolt
bolt “1”
IP • Copper
Copper washer
washer
Push the front fork cap in the direction of the ar- IP
row shown in the illustration to remove the front
While holding the damper rod with the hexagon
fork cap clip.
bit socket (14 mm) “2” and T-handle “3”, loosen
the front fork damper rod bolt.
4-62
FRONT FORK
EAS30209
T-handle ASSEMBLING THE FRONT FORK LEGS

90890-01326 The following procedure applies to both of the

T-handle 3/8" drive 60 cm long front fork legs.
YM-01326 EWA13660
WARNING
• Make sure the oil
oil levels in both
both front fork
legs are equal.
• Uneven oil
oil levels can
can result in poor han-
1 2 3 dling and a loss of stability.
IP
• When assembling
assembling the front
front fork leg, be sure to
replace the following parts:
–Front fork cap clip
–Oil seal
EAS30208
–Oil seal clip
CHECKING THE FRONT FORK LEGS –Dust seal
The following procedure applies to both of the –Copper washer
front fork legs. –O-ring
1. Che
Check: • Before assembli
assemblingng the front fork
fork leg, make
• Inner
Inner tube
tube sure all of the components are clean.
• Outer
Outer tube
tube 1. In
Inst
stal
all:
l:
Bends/damage/scratches  Replace. • Damper
Damper rod ring ring “1”
“1”
EWA13650
WARNING • Damper
Damper rod rod “2”
“2”
• Rebound
Rebound sprinspringg “3”
Do not attempt to straighten a bent inner
(in the inner tube “4”)
tube as this may dangerously weaken it.
• Oil flow
flow st
stoppe
opperr “5”
2. Meas
Measur
ure:
e: ECA22740
NOTICE
• Fork spring
spring free
free length
length “a”
Out of specification  Replace. Allow the damper rod to slide slowly down
the inner tube until it protrudes from the bot-
Fork spring free length tom of the inner tube. Be careful not to dam-
282.1 mm (11.10 in) age the inner tube.

Limit
276.0 mm (10.88 in) IP
Fit the damper rod ring into the damper rod
groove so that the side of the ring with the pro-
jections
jections is ffacing
acing in
in the direction
direction shown in the il-
lustration.
a
2
1
3. Che
Check:
• Damper
Damper rod
rod
Obstruction  Blow out all of the oil passag-
es with compressed air.
• Oil flow stopper
stopper
Damage  Replace.
4-63
FRONT FORK
3. Lu
Lubr
bric
icat
ate:
e:
• Inner tube’s
tube’s outer surface
surface
Recommended oil
Fork oil 10W or equivalent

4.• Inner
In
Inst
stal
Inn all:
er l:tube
tube
5 4 3 1 2 (in the outer tube)
5. In
Inst
stal
all:
l:
2. Inst
Instal
alll: • Copper washerr New
Copper washe
• Front fork
fork damper rod bolt
bolt “1”
• Oil seal “1” New
(with the fork seal driver attachment “2” and Front fork damper rod bolt
fork seal driver weight “3”)
T
.
R
.
23 N·m (2.3 kgf·m, 17 lb·ft)
ECA14220
LOCTITE®
NOTICE
Make sure the numbered side of the oil seal IP

faces up. While holding the damper rod assembly with the
IP hexagon bit socket (14 mm) “2” and T-handle
“3”, tighten the front fork damper rod bolt.
• Lubricate
Lubricate the outer surface
surface of the inner
inner tube
with fork oil.
• Before installi
installing
ng the oil seal,
seal, cover the top of T-handle
the front fork leg with a plastic bag to protect 90890-01326

T-handle 3/8" drive 60 cm long
the oil seal during installation.
YM-01326
Fork seal driver weight

90890-01367

Replacement hammer
YM-A9409-7 1 2 3
Fork seal driver attachment (ø30)
90890-01400
6. In
Inst
stal
all:
l:
• Oil seal
seal clip
clip “1”
“1” New
IP
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
2
1 New
1 New
4-64
FRONT FORK
7. Inst
Instal
alll:
• Dust
Dust seal “1” New
seal “1”
(with the fork seal driver attachment “2” and
fork seal driver weight “3”) 1
Fork seal driver weight

90890-01367

Replacement hammer
YM-A9409-7
Fork seal driver attachment (ø30)
90890-01400 10.Before measuring the fork oil level, wait ten
minutes until the oil has settled and the air
bubbles have dispersed.
IP
3 Be sure to bleed the front fork leg of any residual
air.
2 11.Measure:
• Front fork
fork leg oil
oil level
level “a”
1 New (from the top of the inner tube, with the inner
tube fully compressed and without the fork

spring)
8. Fill: Out of specification  Correct.
• Front
Front fork
fork leg
(with the specified amount of the recom- Level
mended fork oil) 78.0 mm (3.07 in)

Recommended oil IP
Fork oil 10W or equivalent
• While filling
filling the front for
fork
k leg, keep it upright.
upright.

Quantity
• After filling,
filling, slowly
slowly pump
pump the front fork leg
leg up
86.0 cm³ (2.91 US oz, 3.03
Imp.oz) and down to distribute the fork oil.
ECA14230
NOTICE
• Be sure to use the recommended

recommended fork oil.
oil.
Other oils may have an adverse effect on
front fork performance.
• When disassembling
disassembling and
and assembling
assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
9. After fi
filling
lling the
the front fork
fork leg, slowly
slowly stroke
stroke the
inner tube “1” up and down (at least ten
12.Install:
times) to distribute the fork oil. • Fork spring
spring “1”
“1”
IP
• O-ring New
O-ring
Be sure to stroke the inner tube slowly because
• Front
Front fork
fork cap
cap
the fork oil may spurt out.
• Front
Front fork cap
cap clip
clip New
IP
Install the fork spring with its smaller pitch down-
down -
ward.
4-65
FRONT FORK
EAS30210
INSTALLING THE FRONT FORK LEGS

front fork legs.
1. Rem
Remove:
ove:
• Front
Front side
side cover
cover
• Refe
Referr to “GENERAL CHASSIS (2)” on page
4-3..
4-3
2. Inst
Instal
alll:
• Front
Front fork
fork leg
leg “1”
Temporarily
bolts. tighten the lower bracket pinch
IP
Make sure the inner tube end is flush with the top
of the lower bracket.
3. Tigh
Tighte
ten:
n:
• Lower bracket
bracket pinch
pinch bolts
bolts “1”
Lower bracket pinch bolt

T
.
R
.
53 N·m (5.3 kgf·m, 38 lb·ft)

IP
Tighten the lower bracket pinch bolts to specifi-
cation twice. Tighten the upper and lower bolts
alternately, starting with the upper bolts.
4-66
STEERING HEAD
EAS20035
STEERING HEAD
Removing the lower bracket
38 N
38 N•m (3
(3.8 k gf•m, 27 lb•ft)
75 N•m (7.5 k gf•m, 54 lb•ft)
16 N•m (1.6 k gf•m, 12 lb•ft)
19
1
16
6
17
8
18 7
13 9
12 10
20 11
7 N•m (0.7 k gf•m, 5.1 lb•ft) 14
5 15
4
2
3
7 N•m (0.7 k gf•m, 5.1 lb•ft)

53 N•m (5.3
(5.3 k gf•m, 38
38 lb
lb•ft)
* Loosen the lower ring nut 1/4 of a turn, and then tighten it to specification.

Front side covers
4-3..
4-3
Center lower cover
4-16..
4-16
Front upper cowling assembly Refer to “GENERAL CHASSIS (4)” on page

4-9..
4-9
Front wheel Refer to “FRONT WHEEL” on page 4-20
4-20..
Handlebar Refer to “HANDLEBAR” on page 4-55.
4-55.
Front fork legs Refer to “FRONT FORK” on page 4-60.
4-60.
1 Handlebar bracket 1
2 Hor n connector 2 Disconnect.
3 Hor n 1
4 Hor n bracket 1
5 Front brake hose holder 1
4-67
STEERING HEAD
Removing the lower bracket
38 N•m (3
38 N (3.8 k gf•m, 27 lb•ft)
75 N•m (7.5 k gf•m, 54 lb•ft)
16 N•m (1.6 k gf•m, 12 lb•ft)
19
1
16
6
17
8
18 7
13 9
12 10
20 11
7 N•m (0.7 k gf•m, 5.1 lb•ft) 14
5 15
4
2
3
7 N•m (0.7 k gf•m, 5.1 lb•ft)

53 N•m (5.3
(5.3 k gf•m, 38
38 lb
lb•ft)
* Loosen the lower ring nut 1/4 of a turn, and then tighten it to specification.
6 Ring nut cover 1

7 Upper ring nut 1
8 Lock washer 1
9 Center ring nut 1
10 Rubber washer 1
11 Lower ring nut 1
12 Lower bracket 1
13 Bearing cover 1
14 Upper bearing inner race 1
15 Upper bear ing 1
16 Lower bearing 1
17 Lower bearing inner race 1
18 Dust seal 1
19 Lower bearing outer race 1

20 Upper bearing outer race 1
4-68
STEERING HEAD
EAS30213
3. Repl
Replac
ace:
e:
REMOVING THE LOWER BRACKET
• Beari
Bearing
ngs
s
1. Stand tthe
he vehicle
vehicle on a level
level surface.
surface.
EWA13120
• Bearing
Bearing races
races
WARNING ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bearing
bearing races from thethe steering
steering
Securely support the vehicle so that there is head pipe “1” with a long rod “2” and hammer.
no danger of it falling over. b. Remove the the bearing
bearing race “3”
“3” from the lower
lower
2. Rem
Remove:
ove: bracket with a floor chisel “4” and hammer.
• Ring
Ring nut
nut cover
cover c. Install a new dust seal
seal and new bearing
bearing rac-
rac-
• Upper
Upper ring
ring nut
nut “1” es.
ECA14270
• Lock
Lock washe
washerr
NOTICE
• Center
Center ring
ring nut
• Rubber
Rubber washer
washer If the bearing race is not installed properly,
• Lower
Lower rring
ing nut the steering head pipe could be damaged.
• Lower
Lower brac
bracket
ket IP
EWA13730
WARNING • Always
Always replace the bearings
bearings and bearing
bearing races
Securely support the lower bracket so that as a set.
there is no danger of it falling. • Whenever the
the steering head is disassembl
disassembled,
ed,
replace the dust seal.
IP
Remove the upper ring nut and lower ring nut
with the steering nut wrench “2”.
Steering nut wrench

90890-01403

YU-A9472
EAS30214
CHECKING THE STEERING HEAD

1. Wash: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Bear
Bearin
ings
gs 4. Che
Check:
• Bearin
Bearing
g race
races
s • Lower
Lower bracket
bracket
(along with the steering stem)
Recommended cleaning solvent Bends/cracks/damage  Replace.
Kerosene

EAS30216
2. Che
Check: INSTALLING THE STEERING HEAD
• Bear
Bearin
ings
gs 1. In
Inst
stal
all:
l:
• Bearin
Bearing
g race
races
s •• Lower
Upper
Upperr bearing
bearing
bearing
ing “1”
“1”
Damage/pitting  Replace the bearings and Lowe bear
bearing races as a set. • Lower bearing
bearing dust seal
4-69
STEERING HEAD
IP 4. In
Inst
stal
all:
l:
• Apply lithium-
lithium-soap-bas
soap-based ed grease to each part. • Horn bracke
brackett “1”
• Be sure to install
install the upper bearing
bearing so that
that the • Horn
Horn “2“2””
marks “a” on the bearing are facing upward.
Horn bracket bolt

T
.
R
.
7 N·m (0.7 kgf·m, 5.1 lb·ft)
a
Horn bolt
7 N·m (0.7 kgf·m, 5.1 lb·ft)
IP
1 While holding the horn so that the horn contacts
the portion “a” of the horn bracket, tighten the
bolt to specification.
2. Inst
Instal
alll:
• Lower
Lower ringring nut
nut “1”
• Rubber
Rubber washer
washer “2”
• Center
Center ringring nut “3”
“3”
1
• Lock
Lock washer
washer “4”
• Refer
Upper
Upperto
ring
ring nut
nut “5”
“CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-14.
3-14.
5 2
4
3
1
1
3. Inst
Instal
alll:
• Front brake hose holder
holder “1”
“1” 5. In
Inst
stal
all:
l:
• Handlebar
Handlebar bracke
brackett “1”
Front brake hose holder bolt

T
.
7 N·m (0.7 kgf·m, 5.1 lb·ft) Handlebar bracket nut
R

.

T
.
R
.
53 N·m (5.3 kgf·m, 38 lb·ft)

IP
IP
While holding the front brake hose holder so that
the holder contacts the projection “a” on the low- Align the slots “a” in the lower bracket with the
er bracket, tighten the bolt to specification. pin “b” on the handlebar bracket.
1
a
b
a
1
4-70
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM
EAS20189

Removing the rear shock absorber assemblies and swingarm
. R
.
57 N• m (5.7 kgf • m, 41 lb • ft)
LS New
. R
.
23 N• m (2.3 kgf • m, 17 lb • ft)
1
New
LS
2 2
3
. R
. R
.
95 N • m (9.5 kgf • m, 69 lb • ft)
. R
R
.
23 N • m (2.3 kgf • m, 17 lb • ft)
. R
.
23 N m (2.3 kgf • m, 17 lb•ft )
Order Job/Parts to remove Q’ty Remarks

Muffler Refer to “ENGINE REMOVAL
REMOVAL”” on page 5-3
5 -3..
Radiator cover Refer to “RADIATOR” on page 6-1.
6-1.
1 Rear wheel axle nut 1
2 Rear shock absorber assembly 2
3 Swingarm assembly 1
4-71
Removing the rear shock absorber assemblies and swingarm
. R
.
57 N• m (5.7 kgf • m, 41 lb • ft)
8
10
5
9
LS New
. R
23 N• m (2.3 kgf • m, 17 lb • ft)

4
.
6
7
5
New
LS
2
. R
. R
.
95 N • m (9.5 kgf • m, 69 lb • ft)
. R
. R
.
23 N • m (2.3 kgf • m, 17 lb • ft)
. R
.
23 N• m (2.3 kgf • m, 17 lb • ft)
Order Job/Parts to remove Q’ty Remarks

4 Spacer 1
5 Oil seal 1
6 Circlip 1
7 Bearing 1
8 Bush rear shock absorber 1
9 Swingarm 1
10 Collar 1
4-72
EAS31228
2. Ch
Chececk k:
REMOVING THE SWINGARM
• Sp
Spacacerer
1. Stand tthe
he veh
vehicle
icle on a llevel
evel s
surface.
urface.
EWA13120
• Co
Collllar
ar
WARNING • Oi
Oill se
sealal
Securely support the vehicle so that there is • Ci
Circ
rclilip
p
• Be
Beararin
ingg
no danger of it falling over. Damage/wear  Replace.
IP EAS31231
Place the vehicle on the centerstand so that the INSTALLING THE SWINGARM
rear wheel is elevated. 1. Lubr
Lubric
icat
ate:
e:
• Oil seal lip
lips
s
2. Re
Rem move:
ove:
• Rear w wheel
heel a
axle
xle n
nut
ut “1” Recommended lubricant
• Rear shoc
shockk absorber aassembl
ssemblyy lower bol
boltt Lithium-soap-based grease
(right side)

• Swingar
Swingarm m mounti
mounting
ng bolt (low
(lower
er side) ““3”
3” 2. As
Asse
semb
mble
le::
• Swingar
Swingarm m mounti
mounting
ng bolt (uppe
(upperr side) “4
“4”” • Bea
Beari
ring
ng “1
“1””
• Circ
Circlip
lip “2” New
• Oil seals
seals “3 “3”” New
• Col
Colla
larr “4
“4””
2 • Spa
Spacecerr “5
“5””
(to the swingarm “6”)
4
IP
• Install tthe
he oil seal unt
untilil it is fl
flush
ush with the sur-
sur-
face “a” of the swingarm.
1 3
• Install tthe
he oil seal unt
untilil it is fl
flush
ush with the sur-
sur-
face “b” of the swingarm.
3. Re
Rem
move:
ove:
• Sw
Swin
ingar
garm
m 6
EAS31229
CHECKING THE REAR SHOCK ABSORBER 1 2 3

3
ASSEMBLY 4
1. Ch
Che
eck: 5
• Rear shock absorbe

absorberr rod

Bends/damage
absorber Replace the rear shock
assembly.
• Rear s shock
hock abs
absorber
orber a
assembl
ssemblyy
Oil leaks  Replace the rear shock absorber
assembly.
• Sp
Spri
ring
ng
Damage/wear  Replace the rear shock ab-
sorber assembly.
• Bu
Bush
shin
ings
gs
Damage/wear  Replace the rear shock ab-
sorber assembly.
• Bolt
olts
Bends/damage/wear  Replace.
EAS31230
CHECKING THE SWINGARM

1. Ch
Che
eck:
• Sw
Swin
ingar
garm
m
Bends/cracks/damage  Replace.
4-73
3. Inst
Instal
alll:
• Swingarm
Swingarm assembl
assembly y “1”
“1”
• Rear wheel
wheel axle
axle nut
nut “2”
(temporarily tighten)
• Swingarm
Swingarm mounting
mounting bolt (upper
(upper side) “3”
“3”
• Swingarm
Swingarm mounting
mounting bolt (lower
(lower side) “4”
“4”
4. Tigh
Tighte
ten:n:
• Rear wheel
wheel axle
axle nut
nut “2”
• Swingarm
Swingarm mounting
mounting bolt (upper
(upper side) “3”
“3”
• Swingarm
Swingarm mounting
mounting bolt (lower
(lower side) “4”
“4”
Rear wheel axle nut

T
.
R
.
95 N·m (9.5 kgf·m, 69 lb·ft)

Swingarm mounting bolt
57 N·m (5.7 kgf·m, 41 lb·ft)
IP
Tighten the rear wheel axle nut “2”, then the
swingarm mounting bolts “3”, “4”.
2 4
5. Inst
Instal
alll:
• Rear shock
shock absorber assembli
assemblies
es “5”
Rear shock absorber assembly

T
.
R
.
nut

23 N·m (2.3 kgf·m, 41 lb·ft)
Rear shock absorber assembly
bolt
23 N·m (2.3 kgf·m, 41 lb·ft)
IP
Tighten the rear shock absorber assembly nuts
and bolts temporarily, and then tighten them to
specification.
4-74

4-75
ENGINE
ENGINE INSPECTION ....................................................................................5-1

MEASURING THE COMPRESSION PRESSURE ....................................5-1
ENGINE REMOVAL ........................................................................................5-3

INSTALLING THE ENGINE.......................................................................5-7
ENGINE .......................................................................5-7
CONNECTING THE LEADS .....................................................................5-8
INSTALLING THE MUFFLER ...................................................................5-8
CYLINDER HEAD............................................................................................5-9
REMOVING THE CYLINDER HEAD.......................................................5-13
HEAD .......................................................5-13
CHECKING THE CYLINDER HEAD .......................................................5-13
CHECKING THE CAMSHAFT SPROCKET ............................................5-14
CHECKING THE TIMING CHAIN TENSIONER......................................5-14
TENSIONER ......................................5-14
CHECKING THE DECOMPRESSION SYSTEM.....................................5-15
SYSTEM .....................................5-15
CHECKING THE VVA SOLENOID..........................................................5-15
SOLENOID ..........................................................5-15
INSTALLING THE CYLINDER HEAD .....................................................5-15
CAMSHAFT ...................................................................................................5-18
REMOVING THE CAMSHAFT ................................................................5-19
CHECKING THE CAMSHAFT.................................................................5-19
CAMSHAFT .................................................................5-19
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........5-20
INSTALLING THE CAMSHAFT AND ROCKER ARMS ..........................5-20
VALVES AND VALVE SPRINGS ..................................................................5-22

5
REMOVING THE VALVES ......................................................................5-23
CHECKING THE VALVES AND VALVE GUIDES ..................................5-23
CHECKING THE VALVE SEATS ............................................................5-25
CHECKING THE VALVE SPRINGS........................................................5-26
SPRINGS ........................................................5-26
INSTALLING THE VALVES ....................................................................5-27
CYLINDER AND PISTON..............................................................................5-29

REMOVING THE PISTON ......................................................................5-30
CHECKING THE CYLINDER AND PISTON ...........................................5-30
CHECKING THE PISTON RINGS...........................................................5-31
RINGS ...........................................................5-31
CHECKING THE PISTON PIN ................................................................5-32
CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE) .................5-32
INSTALLING THE PISTON AND CYLINDER .........................................5-32

V-BELT AUTOMATIC TRANSMISSION .......................................................5-34

REMOVING THE PRIMARY SHEAVE....................................................5-37
SHEAVE ....................................................5-37
REMOVING THE SECONDARY SHEAVE .............................................5-37
DISASSEMBLING THE SECONDARY SHEAVE....................................5-37
SHEAVE ....................................5-37
CHECKING THE CLUTCH HOUSING ....................................................5-38
CHECKING THE CLUTCH SHOES ........................................................5-38
CHECKING THE V-BELT........................................................................5-38
V-BELT ........................................................................5-38
CHECKING THE PRIMARY SHEAVE ....................................................5-38
CHECKING THE PRIMARY SHEAVE WEIGHTS...................................5-39
WEIGHTS ...................................5-39
CHECKING THE PRIMARY SHEAVE SLIDERS ....................................5-39
CHECKING THE SECONDARY SHEAVE ..............................................5-39
ASSEMBLING THE PRIMARY SHEAVE ................................................5-39
ASSEMBLING THE SECONDARY SHEAVE..........................................5-39
SHEAVE..........................................5-39
INSTALLING THE PRIMARY SHEAVE,
V-BELT AND SECONDARY SHEAVE ...................................................5-40
STARTER GENERATOR ..............................................................................5-43

REMOVING THE STARTER GENERATOR ...........................................5-44
INSTALLING THE STARTER GENERATOR ..........................................5-44
OIL PUMP ......................................................................................................5-45

CHECKING THE OIL STRAINER ...........................................................5-47
CHECKING THE OIL PUMP ...................................................................5-47
ASSEMBLING THE OIL PUMP ...............................................................5-47
TRANSMISSION............................................................................................5-48
CHECKING THE TRANSMISSION .........................................................5-50
INSTALLING THE TRANSMISSION .......................................................5-50
CRANKSHAFT ..............................................................................................5-51
DISASSEMBLING THE CRANKCASE....................................................5-53
CRANKCASE ....................................................5-53
REMOVING THE CRANKSHAFT ASSEMBLY .......................................5-53
CHECKING THE CRANKSHAFT ASSEMBLY........................................5-53
ASSEMBLY........................................5-53
CHECKING THE CRANKCASE ..............................................................5-54
CHECKING THE BEARING ....................................................................5-54
CHECKING THE OIL PUMP DRIVE GEAR ............................................5-54
INSTALLING THE CRANKSHAFT ..........................................................5-54
ASSEMBLING THE CRANKCASE..........................................................5-55
CRANKCASE ..........................................................5-55
INSTALLING THE CENTERSTAND .......................................................5-55

ENGINE INSPECTION
EAS20041
7. Meas
Measur
ure:
e:
ENGINE INSPECTION • Compression
Compression pressure
pressure
EAS30249
Out of specification  Refer to steps (c) and
MEASURING THE COMPRESSION (d).
PRESSURE
Standard compression pressure
IP (at sea level)
Insufficient compression pressure will result in a
1800 kPa/860 r/min (18.0
loss of performance. kgf/cm²/860 r/min, 256.0 psi/
860 r/min)
1. Meas
Measur ure:
e:
Minimum–Maximum
• Valve
Valve cleara
clearance
nce 1570–2020 kPa/860 r/min
Out of specification  Adjust. (15.7–20.2 kgf/cm²/860 r/min,
Refer to “ADJUSTING THE VALVE CLEAR- 223.3–287.3 psi/860 r/min)
ANCE” on page 3-5.3-5.
2. Start tthe
he engine,
for several
several min-
min- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
utes, and then turn it off. a. Turn the

the main
main switch
switch to “ON”.
“ON”.
3. Rem
Remove:
ove: b. With the throttle
throttle wide open,
open, crank the engine
engine
• Front side
side cover assembly
assembly (right)
(right) until the reading on the compression gauge
Refer to “GENERAL CHASSIS (2)” on page stabilizes.
EWA12960
4-3..
4-3
WARNING
• Footrest
Footrest board
board (right)
(right) To prevent sparking, ground the spark plug
4-16..
4-16 lead before cranking the engine.
4. Disc
Disconn
onnecect:
t: c. If the compression
compression pressure
pressure is above the
the
• Spark
Spark plug
plug cap maximum specification, check the cylinder
5. Rem
Remove:
ove: head, valve surfaces and piston crown for
• Spar
Sparkk plug
plug carbon deposits.
Carbon deposits  Eliminate.
ECA20470
NOTICE
d. If the compressi
compressionon pressure
pressure is below the
the min-
Before removing the spark plug, use com- imum specification, pour a teaspoonful of en-
pressed air to blow away any dirt accumulat- gine oil into the spark plug bore and measure
ed in the spark plug well to prevent it from again.
falling into the cylinder. Refer to the following table.
6. Inst
Instal
alll: Compression pressure (with oil applied into the
• Compre
Compressi
ssion
on gauge “1” cylinder)
• Extensi
Extension
on “2”
“2” Reading Diagnosis
Piston ring(s) wear or
Compression gauge Higher than without oil
damage  Repair.
90890-03081

Engine compression tester Piston, valves, cylinder
YU-33223 head gasket or piston
Same as without oil
ring(s) possibly defec-
Extension
tive  Repair.
90890-04136
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. In
Inst
stal
all:
l:
• Spark
Spark plug
plug “1”
“1”
Spark plug
.
T
R .
13 N·m (1.3 kgf·m, 9.4 lb·ft)

2
5-1
ENGINE INSPECTION
IP
When tightening the spark plug, make sure that
the inside “a” of the spark plug wrench “2” does
not contact the portion “b” of the spark plug.
b
a 2
9. Conn
Connec
ect:
t:
• Spark
Spark plug
plug cap
IP
To route the spark plug lead, refer to “CON-
NECTING THE LEADS” on page 5-8. 5-8 .
10.Install:
• Footrest
Footrest board
board (right)
(right)
4-16..
4-16
• Front side
side cover assembly
assembly (right)
(right)
4-3..
4-3
5-2
ENGINE REMOVAL
EAS20042
ENGINE REMOVAL
Removing the muffler
1 3
1 Muffler protector 1
2 Muffler 1
3 Exhaust gasket 1
5-3
ENGINE REMOVAL
Disconnecting the leads
6
7
5
4
3 8
9
2
10
1
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-17.
3-17.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-19.
3-19.
Battery
4-1..
4-1
Front side covers
4-3..
4-3
Rear side cover assembly 4-6.
Storage box
4-6..
4-6
Air filter case Refer to “AIR FILTER CASE” on page 7-7
7-7..
V-belt case air duct
5-34.
Fuel injector Refer to “FUEL INJECTOR”
INJECTOR” on page 7-5
7-5..
Throttle body Refer to THROTTLE BODY on page 7-10.
7-10.
Rear brake caple Refer to “REAR BRAKE” on page 4-43.
4-43 .
5-4
ENGINE REMOVAL
Disconnecting the leads
6
7
5
4
3 8
9
2
10
1
Muffler Refer to “ENGINE REMOVAL” on page 5-3

5-3..
Rear wheel Refer to “REAR WHEEL” on page 4-28
1 Coolant temperature sensor coupler 1 Disconnect.
2 Crankshaft position sensor coupler 1 Disconnect.
3 Star ter generator lead coupler 1 Disconnect.
4 Ignition coil coupler 1 Disconnect.
5 Engine ground lead 1 Disconnect.
6 Module sensor coupler 1 Disconnect.
7 ISC unit couler 1 Disconnect.
8 VVA (variable valve actuator) solenoid coupler 1 Disconnect.
9 O2 sensor coupler 1 Disconnect.
10 Injector coupler 1 Disconnect.
5-5
ENGINE REMOVAL
Removing the engine
8
6
7
3
2
4
1 Rear shock absorber assembly 2

2 Engine bracket bolt 1
3 Damper
Da 2
4 Spacer 1
5 Engine bracket 1
6 Collar 2
7 Pin 2
8 Engine 1
5-6
ENGINE REMOVAL
EAS23720
INSTALLING THE ENGINE 1

1. Inst
Instal
alll: 2
• Stopp
Stopper er “1”
“1” 8
• Colla
Collars
rs “2”
“2”
• Engine
Engine brack
bracket
et “3”
• Engine bracket
bracket bolt/nut
bolt/nut (center)
(center) “4”
• Engine bracket
bracket bolt/nut
bolt/nut (rear)
(rear) “5”
• Engine bracket
bracket bolt/nut
bolt/nut (front)
(front) “6”
5 7
b. Temporarily
Temporarily instal
installl the engine bracket
bracket
bolt/nut (center) “4” and route the ø4 pin “10”
through the hole of the engine bracket bolt
(rear) and the hole of the inner collar.
10
8
6
3 4
6 4 5 1 4
3
10
1
B 2
c. Tighten the engine
engine bracket
bracket nut
nut (center)
(center) from
from
the right side first, then the left side.
1
Engine bracket nut (center)
4 5 2
T
.
R
.
54 N·m (5.4 kgf·m, 39 lb·ft)
A-A
d. Remove the ø4 pin, insert

insert the
the engine
engine bracket
bracket
7. Engi
Engine
ne as
asse
semb
mbly
ly bolt (rear) “5”, and then tighten the nut “5”.
8. Fra
rame
me comp
comple
lete
te
B. Front
ront
Engine bracket nut (rear)

T R
.
.
27 N·m (2.7 kgf·m, 20 lb·ft)

IP

Follow the installation procedure below to prop-

5
erly function the engine mount.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Tempora
Temporarily
rily put
put the stopper
stopper “1” and
and collar “2”
on the engine assembly “8”.
e. Temporarily
Temporarily instal
installl the engine bracket
bracket
bolt/nut (front) “6”.
5-7
ENGINE REMOVAL
IP
Make sure that the engine ground lead terminal
“a” contacts the stopper “b” on the crankcase.
6 a
1
f. Tighten
Tighten the the rear shock
shock absorbe
absorberr lower
lower bolt
bolt
“7”, lift the rear tire up using the centerstand,
and then tighten the engine bracket nut (front)
“6”.
2. Conn
Connec
ect:
t:
Rear shock absorber lower bolt • Spark
Spark plug
plug cap “1”
“1”

T
.
R
.
23 N·m (2.3 kgf·m, 17 lb·ft) IP

Route the spark plug lead between the VVA

Engine bracket nut (front) (variable valve actuator) solenoid “2” and the

T
.
R
.
50 N·m (5.0 kgf·m, 36 lb·ft) water pump inlet hose “3”. Make sure that the

spark plug lead does not contact the VVA (vari-

able valve actuator) solenoid or water pump inlet
hose.
g. Remove the centerstand

centerstand and then make suresure 3
1
that the stopper “1” is not touching the engine
EAS31588
assembly “8”. INSTALLING THE MUFFLER

1. In
Inst
stal
all:
l:
• Exhaust
Exhaust gaskets “1” New
gaskets “1”
(to the cylinder head)
IP
1 Install the exhaust gasket with its projections “a”
facing toward the cylinder head.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31717
a
CONNECTING THE LEADS
1.• Conn
Connec
ect:
Engine
Engine t: ound lead
ground
gr lead “1”
Engine ground lead bolt a 1 New

T
.
R
.
7 N·m (0.7 kgf·m, 5.1 lb·ft)

5-8
CYLINDER HEAD
EAS20044
CYLINDER HEAD
Removing the cylinder head
4.0 N•m (0.40 k gf•m, 2.9 lb•ft)

10 N•m (1.0 k gf•m, 7.2 lb•ft) 10 N•m (1.0 k gf•m, 7.2 lb•ft)
7 N•m (0.7 k gf•m, 5.1 lb•ft)
7 N•m (0.7 k gf•m, 5.1 lb•ft)
10 N•m (1.0 k gf•m, 7.2 lb•ft)

24 N•m (2.4 k gf•m, 17 lb•ft)
13 N•m (1.3
(1.3 k gf•m, 9.4 lb•ft)
10 N•m (1.0 k gf•m, 7.2 lb•ft)

30 N•m (3
(3.0 k gf•m, 22 lb•ft)
15 N•m (1.5 k gf•m, 11 lb•ft) 25 N•m (2.5 k gf•m, 18
18 lb•ft)
* Apply Yamaha bond No.1215 (90890-85505).

Battery
4-1..
4-1
Front side covers
4-3..
4-3
Fuel tank cover
4-18..
4-18
Storage box
4-6..
4-6
Center lower cover
4-16..
4-16
Drain.
page 3-19.
3-19.
Muffler Refer to “ENGINE RE
REMOV
MOVAL
AL”” on page 5-
5-33.
Radiator Refer to “RADIATOR” on page 6-1
6-1..
Ther mostat assembly Refer to “THERMOSTAT” on page 6-4.
6-4.
Water pump Refer to “WATER PUMP” on page 6-6.
6-6.
Fuel tank Refer to “FUEL TANK” on page 7-1
7-1..
5-9
CYLINDER HEAD
4.0 N•m (0.40 k gf•m, 2.9 lb•ft)

10 N•m (1.0 k gf•m, 7.2 lb•ft)
10 N•m (1.0 k gf•m, 7.2 lb•ft)
7 N•m (0.7 k gf•m, 5.1 lb•ft)
7 N•m (0.7 k gf•m, 5.1 lb•ft)

10 N•m (1.0 k gf•m, 7.2 lb•ft)
24 N•m (2.4 k gf•m, 17 lb•ft)
1
2
13 N•m (1.3
(1.3 k gf•m, 9.4 lb•ft)
3
10 N•m (1.0 k gf•m, 7.2 lb•ft) 5 30 N•m (3
(3.0 k gf•m, 22 lb•ft)
15 N•m (1.5 k gf•m, 11 lb•ft) 4 25 N•m (2.5 k gf•m, 18
18 lb•ft)

7-7..
7-5..
Intake manifold Refer to “THROTTLE BODY” on page 7-10.
7-10.
1 Spark plug cap 1 Disconnect.
2 Spark plug 1
3 O2 sensor coupler 1 Disconnect.
TIP
4 O2 sensor 1 Remove the O2 sensor only when neces-
sary.
5 Coolant temperature sensor coupler 1 Disconnect.

5-10
CYLINDER HEAD
4.0 N•m (0.40 k gf•m, 2.9 lb•ft)

10 N•m (1.0 k gf•m, 7.2 lb•ft)
12 10 N•m (1.0 k gf•m, 7.2 lb•ft)
8
7 9
14
10
7 N•m (0.7 k gf•m, 5.1 lb•ft)
11 13 15
7 N•m (0.7 k gf•m, 5.1 lb•ft)
10 N•m (1.0 k gf•m, 7.2 lb•ft)
24 N•m (2.4 k gf•m, 17 lb•ft)
13 N•m (1.3
(1.3 k gf•m, 9.4 lb•ft)
15
6
10 N•m (1.0 k gf•m, 7.2 lb•ft)

30 N•m (3
(3.0 k gf•m, 22 lb•ft)
18 lb•ft)
6 Coolant temperature sensor 1

7 VVA (variable valve actuator) solenoid coupler 1 Disconnect.
8 VVA (variable valve actuator) solenoid 1
9 VVA (variable valve actuator) solenoid gasket 1
10 VVA (variable valve actuator) solenoid rod 1
11 Fuel hose holder 1
12 Cylinder head breather hose 1
13 Cylinder head cover 1
14 Cylinder head cover gasket 1
15 Dowel pin 2
5-11
CYLINDER HEAD
4.0 N•m (0.40 k gf•m, 2.9 lb•ft)

10 N•m (1.0 k gf•m, 7.2 lb•ft)
19 10 N•m (1.0 k gf•m, 7.2 lb•ft)
20
16
18 17
21
7 N•m (0.7 k gf•m, 5.1 lb•ft)

28
27
26
7 N•m (0.7 k gf•m, 5.1 lb•ft)
10 N•m (1.0 k gf•m, 7.2 lb•ft)
24 N•m (2.4 k gf•m, 17 lb•ft)
27
13 N•m (1.3
(1.3 k gf•m, 9.4 lb•ft) 25 24
23
22
10 N•m (1.0 k gf•m, 7.2 lb•ft)
30 N•m (3
(3.0 k gf•m, 22 lb•ft)
18 lb•ft)
16 Cylinder head cover breather plate 1

17 Cylinder head cover breather plate gasket 1
18 Oil seal 1
19 Timing chain tensioner plug 1
20 Timing chain tensioner 1
21 Timing chain tensioner gasket 1
22 Camshaft sprocket bolt 1
23 Camshaft sprocket 1
24 Decompression cam 1
25 Cylinder head 1
26 Cylinder head gasket 1
27 Dowel pin 2
28 Engine oil check bolt 1
5-12
CYLINDER HEAD
EAS30276
3. Remo
Removeve::
REMOVING THE CYLINDER HEAD
• Cylind
Cylinder
er head
1. Align:
gn:
IP
• “I” mark
mark “a” on the
the AC magneto
magneto rotor
(with the match mark “b” on the right crank- • Loosen the bolts
bolts and nuts
nuts in the proper se-
se-
case) quence as shown.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Loosen each
each bolt and nuts
nuts 1/2 of a turn
turn at a
a. Tur
Turn
n the cranksha
crankshaft
ft clockw
clockwise
ise.. time. After all of the bolts and nuts are fully
loosened, remove them.
×
4 3 4
b
a
×
2
6 5
1 2
b. When the piston isis at TDC on the compres-
compres-
sion stroke, align the “I” mark “c” on the cam-
EAS30277
shaft sprocket with the match mark “d” on the
camshaft stopper plate. CHECKING THE CYLINDER HEAD
1. Elim
Elimin
inat
ate:
e:
• Combustion
Combustion chamber
chamber carbon
carbon deposits
deposits
c
(with a rounded scraper)
d
IP
Do not use a sharp instrument to avoid damag-
ing or scratching:
• Spark
Spark plug bore
bore threads
threads
• Valv
Valve
e seats
seats
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Lo
Loos
osen
en::
• Camshaft
Camshaft sprocket
sprocket bolt “1”
“1”
IP
Use the camshaft wrench “2” and loosen the
camshaft sprocket bolt.
Camshaft wrench
2. Che
Check:
90890-04162
• Cylind
Cylinder
er head

Camshaft wrench
YM-04162 Damage/scratches  Replace.
• Cylinder
Cylinder head water jacket
jacket
Mineral deposits/rust  Eliminate.
3. Meas
Measur
ure:
e:
1
• Cylind
Cylinder
er head warpage
warpage
2 Out of specification  Resurface the cylinder
head.
Warpage limit
0.05 mm (0.0020 in)

5-13
CYLINDER HEAD
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge
straightedge “1”
“1” and a thickness
thickness
gauge “2” across the cylinder head.
a. 1/4 toot
ooth
b. Corr
orrect
1. Ti
Timi
ming
ng cha
chainin rol
rolle
lerr
2. Cams
Camshahaft
ft spro
sprock
cket
et
1 2
EAS30279
CHECKING THE TIMING CHAIN TENSIONER

1. Che
Check:
• Timing chain tensioner
tensioner
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the timing
timing chain
chain tensioner
tensioner plug.
b. While lightly
lightly pressing
pressing the timing
timing chain ten-
ten-
sioner rod by hand, turn the tensioner rod ful-
b. Mea
Measursure e tthe
he warpage
warpage.. ly clockwise with a thin screwdriver “1”.
c. If the llimit
imit is
is exceeded,
exceeded, resurface
resurface the
the cylinder
cylinder
head as follows.
d. Place 400–600 grit grit wet sandpaper
sandpaper on the
the sur-
face plate and resurface the cylinder head
using a figure-eight sanding pattern.
IP
To ensure an even surface, rotate the cylinder
head several times.
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31232
CHECKING THE CAMSHAFT SPROCKET c. While holding the timing
timing chain
chain tensioner
tensioner rod
in place with your hand, turn the screwdriver
1. Che
Check: counterclockwise, remove the screwdriver,
• Camshaf
Camshaftt sprocket
sprocket and slowly release the timing chain tensioner
More than 1/4 tooth wear “a”  Replace the rod.
camshaft sprocket, timing chain and crank-
shaft as a set.
d. Make sure
sure that the timing
timing chain
chain tensioner
tensioner rod
rod
comes out of the timing chain tensioner hous-
ing smoothly. If there is rough movement, re-
place the timing chain tensioner.
5-14
CYLINDER HEAD
e. Instal
Installl the timing
timing chain
chain tensioner
tensioner plug.
plug. • Tighten the
the cylinder
cylinder head nuts and
and bolts in the
the
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ proper tightening sequence as shown and
EAS30280
torque them in two stages.
CHECKING THE DECOMPRESSION SYSTEM
1. Che
Check:
×
3 4
• Decompression
Decompression system 4
IP
1 1 ×
• Check that the
the decompression
decompression lever
lever moves
moves
2
smoothly.
• Check that
that the operating
operating range “a” of the de- 2 1 2 2
compression lever is the same as the range
shown in the illustration. 6 5
a 2. In
Inst
stal
all:
l:
• Decompressio
Decompression n cam “1”
• Camshaft sprocket
sprocket “2”
“2”
• Timing
Timing chain
chain
• Camshaft sprocket
sprocket bolt
bolt
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the
the crankshaf
crankshaftt clockwi
clockwise.
se.
b. Align the
the “I” mark
mark “a”
“a” on the AC
AC magneto
magneto rotor
with the match mark “b” on the right crank-
case.
a. 20.88°
EAS31624
CHECKING THE VVA SOLENOID

1. Che
Check: b
• VVA (variable
(variable valve
valve actuator) solenoid
solenoid “1” a
c. Install
Install the
the decompre
decompressi
ssion
on cam
cam..
d. Install the timing
timing chain
chain onto the camshaft
camshaft
sprocket, then the camshaft sprocket onto
the camshaft, and then finger tighten the
camshaft sprocket bolt.
ECA20600
NOTICE
EAS30282
INSTALLING THE CYLINDER HEAD Do not turn the crankshaft when installing
1. Tigh
Tighte
ten:
n: the camshaft sprocket to avoid damage or
• Cylinder
Cylinder head
head nuts
nuts “1”
“1” improper valve timing.
• Cylinder
Cylinder head
head bolts
bolts “2”
“2”
IP
Cylinder head nut • Fit the pin
pin on the decompressi
decompression
on cam into the
the

T
.
R
.
24 N·m (2.4 kgf·m, 17 lb·ft) slot “c” in the decompression lever on the cam-

Cylinder head bolt shaft sprocket.
10 N·m (1.0 kgf·m, 7.2 lb·ft) • Align the “I” mark
mark “d” on the camshaft
camshaft sprocket
sprocket
with the match mark “e” on the camshaft stop-
IP per plate.
• Lubricate
Lubricate the cylinder
cylinder head nuts and
and washers
with molybdenum disulfide grease.
5-15
CYLINDER HEAD
Timing chain tensioner bolt

2
T
10 N·m (1.0 kgf·m, 7.2 lb·ft)
e
.
R
.
1
a
d
a
e. While ho
holding
lding the
the camshaft,
camshaft, temporaril
temporarily
y tight- 2
en the camshaft sprocket bolt.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Inst
Instal
alll: d. Turn the timing
timing chain tensioner
tensioner rod counter-
counter-
• Timing
Timing chain tensioner
tensioner gasket
gasket New clockwise with a thin screwdriver “1”, make
• Timing
Timing chain
chain tensioner
tensioner sure it releases, and then install the timing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ chain tensioner plug.
a. Remove the timing
tensioner plug.
plug.
b. While lightly
lightly pressing
pressing the
the timing
timing chain ten- 1
sioner rod by hand, turn the tensioner rod ful-
ly clockwise with a thin screwdriver “1”.
IP
Make sure that the tensioner rod has been fully
turned clockwise.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Turn:
• Crank
Crankshshaft
aft
(several turns clockwise)
5. Che
Check:
1 • “I” mark
mark “a”
“a”
Make sure the “I” mark “a” on the AC magne-
c. Install the gasket
gasket and
and the timing
timing chain ten- to rotor is aligned with the match
ma tch mark “b” on
sioner “2” onto the cylinder. the right crankcase.
EWA17620 • “I” mark
mark “c”
“c”
WARNING Make sure the “I” mark “c” on the camshaft
Always use a new gasket. sprocket is aligned with the match mark “d”
on the camshaft stopper plate.
IP Out of alignment  Correct.
• Install the timing
tensioner gasket
gasket so that Refer to the installation steps above.
the tabs “a” on the gasket are protruding in the
directions shown in the illustration.
• Apply Yamaha
Yamaha bond No. 12151215 to the threads
threads of
the timing chain tensioner bolts.
b
a
Yamaha bond No. 1215
90890-85505

5-16
CYLINDER HEAD
IP
Install the oil seal so that it is facing in the direc-
c d tion shown in the illustration. Press the oil seal
into the cylinder head cover using a suitable di-
ameter socket “3”.
3 2
6. Tigh
Tighte
ten:
n: 1
• Camshaft
Camshaft sprocket
sprocket bolt “1”
“1”
Camshaft sprocket bolt

T
.
R .
30 N·m (3.0 kgf·m, 22 lb·ft)

9. In
Inst
stal
all:
l:
Camshaft wrench • VVA (variable
(variable valve
valve actuator) solenoid
solenoid “1”
90890-04162

Camshaft wrench VVA
VVA (variable valve actuator)
YM-04162 T
.

R
.
solenoid boltkgf·m, 7.2 lb·ft)

10 N·m (1.0
ECA20610
NOTICE
IP
Be sure to tighten the camshaft sprocket bolt
While holding the VVA (variable valve actuator)
to the specified torque to avoid the possibil-
solenoid so that it is contacting the cylinder head
ity of the bolt coming loose and damaging
cover “2”, tighten the bolts to specification.
the engine.
IP
Tighten the camshaft sprocket bolt with the cam-
shaft wrench “2”. 1
2
1
2
7. Meas
Measur ure:
e:
• Valve
Valve cleara
clearance
nce
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-5. 3-5.
8. Inst
Instal
alll:
• Oi
Oill seal
seal “1”
“1”
(into the cylinder head cover “2”)
5-17
CAMSHAFT
EAS20043
CAMSHAFT
Removing the rocker arms and camshaft
T
. R
R
.
8 N•m (0.8 k gf•m, 5.8 lb•ft)
T
. R
.
7 N•m (0.7 k gf•m, 5.1 lb•ft)
2
New M
11 14
14
12 10
13 4 New
9
M
M 3
M
E
8
6 7
E
E 5
2 M
7 E
M
2 M 5
M
T
. . R
R
.
7 N•m (0.7 k gf•m, 5.1 lb•ft)
Cylinder head Refer to “CYLINDER HEAD” on page 5-9.

5-9.
1 Camshaft stopper plate 1
2 Locknut 4
3 Camshaft assembly 1
4 Bearing 1
5 Rocker arm shaft 2
6 Exhaust rocker arm 1
7 Adjusting screw (exhaust side) 2
8 Plate 1
9 Spring 1
10 Intake rocker arm 1 1
11 Intake rocker arm stopper pin 1
12 S
Sppring 1
13 Intake rocker arm 2 1
14 Adjusting screw (intake side) 2
5-18
CAMSHAFT
EAS30256
2. Meas
Measur
ure:
e:
REMOVING THE CAMSHAFT
• Camshaft lobe dimensions
dimensions “a” and “b”
“b”
1. Lo
Loos
osen
en::
Out of specification  Replace the camshaft.
• Adjusting
Adjusting screws
screws (intake/exhaust
(intake/exhaust))
2. Rem
Remove:
ove: Camshaft lobe dimensions
• Camshaft
Camshaft assembly
assembly “1” Lobe height (Intake)

32.211–32.311 mm (1.2681–
Slide hammer bolt 1.2721 in)
90890-01085 Limit

Slide hammer bolt 8 mm 32.111 mm (1.2642 in)
YU-01083-2 Lobe height (Intake high speed)
Weight 32.587–32.687 mm (1.2830–
90890-01084 1.2869 in)
Weight Limit (High speed)
YU-01083-3 32.487 mm (1.2790 in)
Lobe height (Exhaust)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
29.420–29.520 mm (1.1583–
a. Align tthe
he holes “a”
“a” in intake
intake rocker
rocker arm 1 “2”
“2” 1.1622 in)
and intake rocker arm 2 “3”, and then push Limit
the intake rocker arm stopper pin “4” in the di- 29.320 mm (1.1543 in)
rection of the arrow shown in the illustration.
4
a
b. While pushing intake

intake rocker
rocker arm
arm 1 “2” and in-
take rocker arm 2 “3” in the direction of the ar-
a r-
row shown in the illustration, remove the
camshaft assembly using a slide hammer
bolt “5” and weight “6”.
3
1
5 3. Meas
Measur
ure:
e:
• Camshaf
Camshaftt runout
runout
6 Out of specification  Replace the camshaft.
Camshaft runout limit

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 0.030 mm (0.0012 in)

EAS30257
CHECKING THE CAMSHAFT

1. Che
Check:
• Camshaf
Camshaftt lobes
lobes
Blue discoloration/pitting/scratches  Re-
place the camshaft.
5-19
CAMSHAFT
4. Che
Check: 4. Meas
Measur
ure:
e:
• Camshaf
Camshaftt oil passage
passage • Rocker arm
arm shaft outside
outside diameter
diameter “a”
Obstruction  Blow out with compressed air. Out of specification  Replace.
EAS30259
Rocker arm shaft outside diame-
CHECKING THE ROCKER ARMS AND ter
ROCKER ARM SHAFTS
9.966–9.976 mm (0.3924–0.3928
The following procedure applies to all of the in)
rocker arms and rocker arm shafts. Limit
1. Che
Check: 9.935 mm (0.3911 in)
• Rocke
Rockerr arm
arm
• Rocker
Rocker arm
arm roller
roller “1”
1 1 5. Calc
Calcul
ulat
ate:
e:
• Rocker-arm-to-
Rocker-arm-to-rocker
rocker-arm-
-arm-shaft
shaft clearance
clearance
2. Che
Check: IP
• Rocker
Rocker arm
arm shaft
shaft Calculate the clearance by subtracting the rock-
Blue discoloration/excessive wear/pit- er arm shaft outside diameter from the rocker
ting/scratches  Replace or check the lubri- arm inside diameter.
cation system.
3. Meas
Measurure:
e: Out of specification  Replace the defective
• Rocker arm inside
inside diameter
diameter “a” part(s).
Rocker-arm-to-rocker-arm-shaft
Rocker arm inside diameter clearance
9.985–10.000 mm (0.3931–

0.009–0.034 mm (0.0004–0.0013

0.3937 in) in)
Limit Limit
10.015 mm (0.3943 in) 0.080 mm (0.0032 in)
EAS30270
INSTALLING THE CAMSHAFT AND ROCKER

ARMS
ARMS
1. Lu
Lubr
bric
icat
ate:
e:
• Camshaft
Camshaft assem
assembly
bly
5-20
CAMSHAFT
b. While pushing
pushing intake
intake rocker
rocker arm
arm 1 “2” and in-
Recommended lubricant take rocker arm 2 “3” in the direction of the ar-
Camshaft row shown in the illustration, install the

Molybdenum disulfide oil camshaft assembly.
Camshaft bearing
Engine oil IP
Install the camshaft with the punch mark “a” fac-

2. Lu
Lubr
bric
icat
ate:
e: ing upward.
• Rocke
Rockerr arms
arms
• Rocker
Rocker arm
arm shafts
shafts
• Spri
Spring
ng 2
• Intake rocker
rocker arm
arm stopper
stopper pin
pin
3
Rocker arm shaft

Intake rocker arm stopper pin
Molybdenum disulfide oil
Spring a
Rocker arm roller
Engine oil ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. In
Inst
stal
all:
l:
3.• Spri
Inst
Instal
Sp all
l: “1”
ring
ng “1” • Camshaft stopper plate
IP Camshaft stopper plate bolt
Install the spring so that the ends “a” of the
T
.
R
.
(M516)
spring are positioned at the locations shown in
8 N·m (0.8 kgf·m, 5.8 lb·ft)
the illustration. Camshaft stopper plate bolt
(M614)
a 1
8 N·m (0.8 kgf·m, 5.8 lb·ft)
IP
Before installing the camshaft stopper plate,
make sure that the slots “a” in the rocker arm
shafts “2” are parallel with the edge “b” of the cyl-
inder head and that the camshaft stopper plate
bolt holes in the cylinder head and rocker arm
shafts are aligned.
4. Inst
Instal
alll:
b
• Camshaft
Camshaft assembly
assembly “1” 2
a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Align tthe
he holes “a”
“a” in intake
intake rocker
rocker arm 1 “2”
“2”
and intake rocker arm 2 “3”, and then push a
the intake rocker arm stopper pin “4” in the di-
rection of the arrow shown in the illustration.
4
a
3
2
5-21
VALVES AND VALVE SPRINGS
EAS20045

Removing the valves and valve springs
2 8 New
1 3
6 New
8 New
4
7
E
7
M
M
6 New
1
E

5-9.
Camshaft/Rocker arms Refer to “CAMSHAFT” on page 5-18.
5-18.
1 Valve cotter 8
2 Valve spring retainer 4
3 Valve spring 4
4 Intake valve 2
5 Exhaust valve 2
6 Valve stem seal 4
7 Valve spring seat 4
8 Valve guide 4
5-22
EAS30283
REMOVING THE VALVES 2

valves and related components.
IP
Before removing the internal parts
part s of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal.
1. Che
Check: 1
• Valve
Valve seal
sealing
ing
Leakage at the valve seat  Check the valve 3. Remo
Removeve::
face, valve seat, and valve seat width. • Valve spring retainer
retainer “1”
Refer to “CHECKING THE VALVE SEATS” • Valve
Valve sprin
spring
g “2”
on page 5-25.
5-25. • Valve
Valve “3”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Valve
Valve stem
stem seal
seal “4”
a. Pour a clean solvent
solvent “a” into
into the intake
intake and • Valve
Valve spring
spring seat
seat “5”
exhaust ports. IP
b. Check that the
the valves
valves properly
properly seal. Identify the position of each
e ach part very carefully so
IP that it can be reinstalled in its original place.
There should be no leakage at the

th e valve seat “1”.
1
5
EAS30284
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE VALVES AND VALVE
2. Rem
Remove:
ove: GUIDES
• Valve
Valve cotter
cotters
s “1” The following procedure applies to all of the
IP valves
1. Measand
Measur
ure:valve guides.
e:
Remove the valve cotters by compressing the • Valve-stem-t
Valve-stem-to-valv
o-valve-guide
e-guide clearance
clearance
valve spring with the valve spring compressor Out of specification  Replace the valve
and the valve spring compressor attachment “2”. guide.
Valve-stem-to-valve-guide
alve-stem-to-valve-guide clearance =
Valve spring compressor Valve guide inside diameter “a” -
90890-04019 Valve stem diameter “b”

YM-04019
Valve spring compressor attach-
ment
90890-04108
Valve spring compressor adapt-
er 22 mm
YM 04108
5-23
b. Install the new valve guide

guide with
with the valve
valve
Valve-stem-to-valve-guide clear-
Valve-stem-to-valve-guide guide installer “2” and valve guide remover
ance (intake) “1”.

0.010–0.037 mm (0.0004–0.0015
in) Valve guide position
Limit 9.9–10.3 mm (0.39–0.41 in)
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide
Valve-stem-to-valve-guide clear-
ance (exhaust)
0.025–0.052 mm (0.0010–0.0020
in)
Limit
0.110 mm (0.0043 in)
a. Valve
alve guid
guide
e posi
positio
tion
n
c. After install
installing
ing the valve guide, bore
bore the valve
valve
guide with the valve guide reamer “3” to ob-
tain the proper valve-stem-to-valve-guide
clearance.
IP
2. Repl
Replac
ace:
e: After replacing the valve guide, reface the valve
seat.
• Valve
Valve guid
guide
e New
IP
Valve guide remover (ø5)
To ease valve guide removal and installation, 90890-04097
and to maintain the correct fit, heat the cylinder
Valve guide remover (5.0 mm)
head to 100 °C (212 °F) in an oven. YM-04097
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Valve guide installer (ø5)
a. Remove the valve
valve guide with the valve guide 90890-04098
remover “1”. Valve guide installer (5.0 mm)
YM-04098
Valve guide reamer (ø5)
90890-04099
Valve guide reamer (5.0 mm)
YM-04099
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Elim
Elimin
inat
ate:
e:
• Carbon
Carbon deposi
deposits
ts
(from the valve face and valve seat)
5-24
4. Che
Check:
• Valv
Valve e face
face
Pitting/wear  Grind the valve face.
• Valve
Valve stem
stem end
end
Mushroom shape or diameter larger than the

body
5. Meas
Me of
asur the valve stem Replace the valve.
ure:
e:
• Valve
Valve stem
stem runout
runout
Out of specification  Replace the valve.
IP
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• When installing
installing a new valve,
valve, always
always replace
replace
a. Apply Blue
Blue layout
layout fluid
fluid “b” onto
onto the valve
valve face.
face.
the valve guide.
• If the valve is
is removed or replaced
replaced,, always re-
re-
place the valve stem seal.
Valve stem runout

0.010 mm (0.0004 in)

b. Install the valve

valve into
into the cylinder
cylinder head.
c. Press the valve
valve through
through the
the valve
valve guide
guide and
onto the valve seat to make a clear impres-
sion.
d. Measure
Measure thethe valve
valve seat
seat width.
width.
IP
EAS30285
Where the valve seat and valve face contacted
CHECKING THE VALVE SEATS one another, the blue layout
layou t fluid will have been
The following procedure applies to all of the removed.
valves and valve seats.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1. El
Elim
imin
inat
ate:
e:
4. Lap:
• Carbon
Carbon depos
deposits
its
(from the valve face and valve seat) •• Valve
Valve
Valve
Valve seat
fac
face
s e
eat
2. Che
Check:
• Valv
Valve e seat
seat IP
Pitting/wear  Replace the cylinder head. After replacing the cylinder head or replacing the
3. Meas
Measur ure:
e: valve and valve guide, the valve seat and valve
• Valve
Valve seat
seat width
width “a” face should be lapped.
Out of specification  Replace the cylinder ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
head. a. Apply a coarse
coarse lapping
lapping compound
compound “a” to the
valve face.
Valve seat contact width (intake) ECA13790
0.90–1.20 mm (0.0354–0.0472 in) NOTICE

Limit Do not let the lapping compound enter the
1.7 mm (0.068 in)
gap between the valve stem and the valve
Valve seat contact width (ex-
guide.
haust)
0.90–1.20 mm (0.0354–0.0472 in)
Limit
1.7 mm (0.068 in)
5-25
j. Measure the valve

valve seat width again.
again. If the
valve seat width is out of specification, reface
and lap the valve seat.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30286
CHECKING
The followingTHE VALVEapplies
procedure SPRINGS
to all of the
valve springs.
1. Meas
Measurure:
e:
• Valve spring free
free length
length “a”
b. Apply molybdenum
molybdenum disulfid
disulfide
e oil onto the
the Out of specification  Replace the valve
valve stem. spring.
c. Install the valve
valve into
into the cylinder
cylinder head.
head.
d. Turn ththe
e valve until the
the valve
valve face and
and valve
valve Free length (intake)
seat are evenly polished, and then clean off 33.81 mm (1.33 in)
all of the lapping compound.

Limit
32.11 mm (1.26 in)
IP Free length (exhaust)
For the best lapping results, lightly tap the valve 33.81 mm (1.33 in)
seat while rotating the valve back and forth be- Limit
32.11 mm (1.26 in)
tween your hands.
e. Apply a fine lapping

lapping compound
compound to the valve
valve 2. Meas
Measur
ure:
e:
face and repeat the above steps. • Compressed
Compressed valve
valve spring
spring force “a”
“a”
f. After
After every
every lappi
lapping
ng proced
procedure,
ure, be sure
sure to Out of specification  Replace the valve
clean
valve off
facealland
of the lapping
valve seat.compound from the
th e spring.
g. Apply blue layout
layout fluid
fluid “b” onto the valve
valve face. Installed compression spring
force (intake)

139.50–160.50 N (14.22–
16.37 kgf, 31.36–36.08
31.36–36.08 lbf)
lbf)
Installed compression spring
force (exhaust)
139.50–160.50 N (14.22–
16.37 kgf, 31.36–36.08
31.36–36.08 lbf)
lbf)
Installed length (intake)
28.90 mm (1.14 in)
Installed length (exhaust)
28.90 mm (1.14 in)
h. Install the valve
valve into
into the cylinder
cylinder head.
i. Press
Press the valv
valve
e through
through the
the valve
valve guide
guide and
and
i. Press
Press the valv
valve
e through
through the
the valve
valve guide
guide and
and
onto the valve seat to make a clear impres-
sion.
5-26
• Valve
Valve stem
stem seal
seal “2”
(with the recommended lubricant)
Engine oil

E
b. Ins
Insta
tall
lled
ed llen
engt
gth
h
3. Meas
Measurure:
e:
• Valve spring tilt “a”
Out of specification  Replace the valve
spring.
5. In
Inst
stal
all:
l:
Spring tilt (intake) • Valve
Valve spring
spring seat
seat “1”
1.7 mm (0.068 in)
• Valve
Valve stem
stem seal “2”
“2” New

Spring tilt (exhaust)
1.7 mm (0.068 in) • Valve
Valve “3”
• Valve
Valve sprin
spring
g “4”
• Valve spring retainer
retainer “5”
(into the cylinder head)
IP
• Make sure each valve
valve is installed
installed in its original
original
place.
• Install the valve springs
springs with the larger
larger pitch “a”
facing up.
5
1
EAS30288
INSTALLING THE VALVES 4

valves and related components. 3
• Valve
Valve stem
stem end
end
(with an oil stone) 2 New
4. Lu
Lubr
bric
icat
ate:
e:
• Valve
Valve stem
stem 1
b. Sm
Smal
alle
lerr pi
pitc
tch
h
Molybdenum disulfide oil 6. In
Inst
stal
all:
l:

• Valve
Valve cotters
cotters “1”
5-27
IP
Install the valve cotters by compressing the
valve spring with the valve spring compressor
and the valve spring compressor attachment “2”.

90890-04019

YM-04019
Valve spring compressor attach-
ment
90890-04108
Valve spring compressor adapt-
er 22 mm
YM-04108
7. To secur
securee the valve
valve cotters
cotters onto the valve
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.
5-28
CYLINDER AND PISTON
EAS20046
CYLINDER AND PISTON

Removing the cylinder and piston
10 N•m (1.0 k gf•m, 7.2 lb•ft)

5-9.
1 Timing chain guide (exhaust side) 1
2 Cylinder 1
3 Cylinder gasket 1
4 Dowel pin 2
5 Piston pin clip 2
6 Piston pin 1
7 Piston 1
8 Top ring 1
9 2nd ring 1
10 Oil ring 1
11 Coolant drain bolt (cylinder side) 1
5-29
CYLINDER AND PISTON
EAS30289
IP
REMOVING THE PISTON
1. Rem
Remove:
ove: When removing a piston ring, open the end gap
• Piston
Piston pin clips “1” with your fingers and lift the other side of the ring
• Piston
Piston pin “2” over the piston crown.
• Pist
Piston
on “3”
“3”
ECA13810
NOTICE
Do not use a hammer to drive the piston pin

out.
IP
• Before removing
removing the pistonpiston pin clips, cover
cover the
crankcase opening with a clean rag to prevent
them from falling into the crankcase.
• Before removing
removing the pistonpiston pin, deburr the pis-
pis-
ton pin clip groove and the piston pin bore ar- EAS30291
CHECKING THE CYLINDER AND PISTON

ea. If both areas are deburred and the piston
1. Che
Check:
pin is still difficult to remove, remove it with the
• Pist
Piston
on wa
wallll
piston pin puller set “4”.
• Cylind
Cylinder
er wall
wall
Piston pin puller set Vertical scratches  Rebore or replace the

cylinder, and replace the piston and piston
90890-01304
rings as a set.

Piston pin puller
2. Meas
Measurure:
e:
YU-01304
• Piston-to-cy
Piston-to-cylinder
linder clearanc
clearance
e
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder
cylinder bore
bore “C” with
with the cylinder
cylinder
bore gauge.
IP
2 1 Measure cylinder bore “C” by taking side-to-side
and front-to-back measurements of the cylinder.
Then, find the average of the measurements.
Bore
3
58.000–58.010 mm

(2.2835–2.2839 in)
Taper limit
0.050 mm (0.0020 in)
Out of round limit
0.050 mm (0.0020 in)
“C” = maximum of D1 - D2

“T” = maximum of D1 or D2 - maximum of D5 or
D6
“R” = maximum of D1, D3 or D5 - minimum of D2,
2. Rem
Remove:
ove: D4 or D6
• Top
Top rin
ring
g
• 2n
2nd
d rin
ring
g
• Oi
Oill ri
ring
ng
5-30
CYLINDER AND PISTON
EAS30292
CHECKING THE PISTON RINGS

1. Meas
Measur
ure:
e:
• Piston ring side
side clearance
clearance
Out of specification  Replace the piston
and piston rings as a set.
IP
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
ring grooves and piston rings.
b. If out of specification,
specification, rebore or replace
replace the
cylinder, and replace the piston and piston Piston ring
rings as a set. Top ring
c. Measur
Measure e piston
piston skirt
skirt diameter
diameter D “a”
“a” with the
Ring side clearance
micrometer. 0.030–0.065 mm
(0.0012–0.0026 in)
Limit
0.115 mm (0.0045 in)
2nd ring
Ring side clearance
0.020–0.055 mmin)
(0.0008–0.0022
Limit
0.115 mm (0.0045 in)
b. 6.0 mm (0.24 in)

in) from the bottom
bottom edge
edge of the
piston
Piston
Diameter

57.962–57.985 mm
(2.2820–2.2829 in)
d. If out of specification,
specification, replace the piston
piston and
piston
e. Calcul rings
Calculate
ate theaspiston-to-cy
a set.to-cylinder
piston- linder clearance
clearance 2. In
Inst
stal
all:
l:
• Pist
Piston
on riring
ng
with the following formula. (into the cylinder)
Piston-to-cylinder clearance = IP
Cylinder bore “C” -
Piston skirt diameter “D”
Use the piston crown to level the position ring
near the bottom of the cylinder where the cylin-
der wear is lowest.
Piston-to-cylinder clearance
0.015–0.048 mm 3. Meas
Measurure:
e:

(0.0006–0.0019 in) • Piston
Piston ring
ring end
end gap
Out of specification  Replace the piston
f. If out of speci
specific
ficati
ation,
on, rebor
rebore
e or replac
replace
e the ring.
cylinder, and replace the piston and piston IP
rings as a set. The oil ring expander spacer end gap cannot be
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
measured. If the
place all three oil ring
piston rail gap is excessive, re-
rings.
5-31
CYLINDER AND PISTON
Piston ring
Top ring

End gap (installed)
0.10–0.25 mm
(0.0039–0.0098 in)
Limit
0.50 mm (0.0197 in)
2nd ring
End gap (installed)
0.35–0.50 mm
(0.0138–0.0197 in) 3. Meas
Measur
ure:
e:
Limit • Piston pin bore
bore diameter
diameter “b”
0.85 mm (0.0335 in) Out of specification  Replace the piston.
Piston pin bore inside diameter

14.002–14.013 mm
a
(0.5513–0.5517 in)
Limit
14.043 mm (0.5529 in)
a. Bott
Bottom
om of cyl
cylin
inder
der
b. Uppe
Upperr o
off c
cyl
ylin
inde
derr
EAS30293
CHECKING THE PISTON PIN

1. Che
Check:
• Pist
Piston
on pin
pin 4. Calc
Calcul
ulat
ate:
e:
Blue discoloration/grooves  Replace the • Piston-pin-to
Piston-pin-to-piston
-piston-pin-b
-pin-bore
ore clearance
clearance
piston pin, and then check the lubrication sys- Out of specification  Replace the piston pin
tem. and piston as a set.
2. Meas
Measurure:
e: Piston-pin-to-piston-pin-bore clearance =
• Piston
Piston pin outside
outside diameter
diameter “a” Piston pin bore diameter “b” -
Out of specification  Replace the piston pin. Piston pin outside diameter “a”
Piston pin outside diameter

13.995–14.000 mm Piston-pin-to-piston-pin-bore

(0.5510–0.5512 in) clearance
Limit
0.002–0.018 mm
13.975 mm (0.5502 in) (0.0001–0.0007 in)
EAS30290
CHECKING THE TIMING CHAIN GUIDE

(EXHAUST SIDE)
1. Che
Check:
• Timing chain guide
guide (exhaust
(exhaust side)
EAS30294
INSTALLING THE PISTON AND CYLINDER

1. In
Inst
stal
all:
l:
• Lower oil oil ring
ring rail
rail “1”
• Oil ring
ring expa
expander
nder “2”
“2”
5-32
CYLINDER AND PISTON
• Upper oil
oil ring
ring rail
rail “3” 3. Lu
Lubr
bric
icat
ate:
e:
• 2nd ring
ring “4”
“4” • Pist
Piston
on
• Top
Top ring
ring “5”
“5” • Piston
Piston rin
rings
gs
IP • Cyli
Cylinde
nderr
Be sure to install the piston rings so that the (with the recommended lubricant)
manufacturer marks face up. Recommended lubricant

Engine oil
5

4. Offs
Offset
et::
• Piston
Piston ring
ring end
end gaps
4 c
3
2
b a
1
135˚
45˚ 45˚
2. Inst
Instal
alll:
• Pist
Piston
on “1”“1” e d
45˚ 45˚
• Piston
Piston pin “2”
• Piston
Piston pin clips “3” New A
a. Top riring
ng
IP
b. 2nd rriing
• Apply engine
engine oil to the piston
piston pin.
c. Uppe
Upperr o oilil ring
ring rai
raill
• Make sure
sure the punch mark “a” “a” on the piston
d. Oi
Oill ri
ring
ng expand
xpanderer
points towards the exhaust side of the cylinder.
e. Lo
Lowe
werr oi
oill ring
ring rai
raill
• Before installing
installing the piston
piston pin clips, cover
cover the
A. Exha
Exhaus ustt si
side
de
crankcase opening with a clean rag to prevent
the clips from falling into the crankcase. 5. In
Inst
stal
all:
l:
• When installing
installing a piston
piston pin clip,
clip, make sure
sure • Dowel
Dowel pins
pins
that the clip ends “b” are positioned away from • Cylind
Cylinder
er gasket
gasket New
the cutout “c” in the piston as shown in the illus- • Cylind
Cylinder
er “1”
tration.
IP
• While holding
holding the piston
piston “2” with
with one hand, in-
New 3 stall the cylinder with the other hand.
2
• Pass the timing
timing chain
chain and timing chain
chain guide
(intake side) through the timing chain cavity.
1 2

3 New 2
1
b
c
5-33
V-BELT AUTOMATIC TRANSMISSI

TRANSMISSION
ON
EAS20050
V-BELT AUTOMATIC TRANSMISSION

Removing the V-belt case
5
NEW
4
6
(2)
NEW
3
T
.
R
.
10 N m (1.0kgf
• (1.0kgf m, 7.2lb.ft)
•7.2lb.ft) NEW
1
2
T
.
R
.
7 N m (0.7kgf
• (0.7kgf m, 5.1lb.ft)
• 5.1lb.ft)

7-7..
1 V-belt case air filter element cover 1
2 V-belt case air filter element 1
3 V-belt case air filter element suppor t 1
4 V-belt case 1
5 Gasket 1
6 Dowel pin 2
5-34

TRANSMISSION
ON
Removing the V-belt, primary sheave and secondary sheave
45 N•m (4.5 k gf•m, 33

33 lb
lb•ft)
49 N•m (4.9 k gf•m, 35 lb•ft)

1 Primar y fixed sheave nut 1
2 Conical spring washer 1
3 Washer
Wa 1
4 Primar y fixed sheave 1
5 V-belt 1
6 Collar 1
7 Primar y sliding sheave 1
8 Primar y sheave weight 6
9 Cam 1
10 S
Sllider 3
11 Clutch housing nut 1
12 Clutch housing 1
13 Secondar y sheave assembly 1
5-35

TRANSMISSION
ON
Disassembling the secondary sheave
* T
. . R
R
.
55 N•m (5.5 k gf•m, 40 lb•ft)
4
3
2
10
11 New 13
12
5 1
6
9 New 7
9 New
* 8 New
* Apply Shell dolium grease R ® .
1 Secondar y sheave nut 1

2 Clutch carrier assembly 1
3 Compression spring 1
4 Spring seat 1
5 Guide pin 3
6 Collar 3
7 Secondar y sliding sheave 1
8 O-ring 2
9 Oil seal 2
10 Bearing 1
11 Circlip 1
12 Bearing 1
13 Secondar y fixed sheave 1
5-36

TRANSMISSION
ON
EAS30310 ECA21820
REMOVING THE PRIMARY SHEAVE NOTICE

1. Rem
Remove:
ove: Do not remove the secondary sheave nut at
• Primary
Primary fixed
fixed sheave
sheave nut “1”
“1” this stage.
• Conical spring washer
• Wash
Washer
er IP
• Primary
Primary fixed
fixed sheave
sheave “2”
“2” While holding the secondary sheave with the ro-
IP tor holding tool “2”, loosen the secondary
While holding the primary fixed sheave with the sheave nut one full turn with the socket wrench
rotor holding tool “3”, loosen the primary fixed “3”.
sheave nut.
Rotor holding tool
Rotor holding tool 90890-01701
90890-01235

Socket wrench (39 mm)

Universal magneto and rotor 90890-01493
holder
YU-01235
1 3
3
1 2
2 EAS30312
DISASSEMBLING THE SECONDARY

EAS30311 SHEAVE
REMOVING THE SECONDARY SHEAVE 1. Remo
Remove
ve::
1. Rem
Remove:
ove: • Secondary
Secondary sheave
sheave nut
nut “1”
“1”
• Clutch housing nut “1”
“1” IP
• Clutch
Clutch housi
housing
ng “2” Install the sheave spring compressor “2” and
IP sheave fixed block “3” onto the secondary
While holding the clutch housing with the rotor sheave as shown. Then, compress the spring,
holding tool “3”, loosen the clutch housing nut. and remove the secondary sheave nut.
Rotor holding tool Sheave spring compressor

90890-01701 90890-04134

YM-04134
Sheave fixed block
90890-04135
3 YM-04135
2
1
2. Lo
Loos
osen
en::
• Secondary
Secondary sheave
sheave nut “1”
“1”
5-37

TRANSMISSION
ON
2 Clutch shoe thickness

4.0 mm (0.16 in)
1
Limit
2.5 mm (0.10 in)
a a
a
3
a
EAS30313
CHECKING THE CLUTCH HOUSING

1. Che
Check:
• Clutch
Clutch housing
housing
Damage/wear  Replace. a a
2. Meas
Measur
ure:
e:
EAS30315
• Clutch housing
housing inside
inside diameter
diameter “a”
“a”
CHECKING THE V-BELT
Out of specification  Replace the clutch
1. Che
Check:
housing.
• V-
V-bel
beltt “1”
“1”
Clutch housing inside diameter Cracks/damage/wear primary
Replace.
125.0 mm (4.92 in) Grease/oil  Clean the and second-

Limit ary sheave.
125.5 mm (4.94 in) 2. Meas
Measurure:
e:
• V-belt
V-belt width
width “a”
V-belt width
24.1 mm (0.95 in)
a
Limit
21.7 mm (0.85 in)
EAS30314
CHECKING THE CLUTCH SHOES

clutch shoes.
1. Che
Check:
• Clut
Clutch
ch shoe
shoe
Damage/wear  Replace the clutch shoes
EAS30316
and springs as a set.
CHECKING THE PRIMARY SHEAVE
Glazed areas  Sand with coarse sandpa-
1. Che
Check:
per.
• Primary
Primary sliding
sliding sheave
IP • Primary
Primary fixed
fixed sheave
After sanding the glazed areas, clean the clutch • Coll
Collar
ar
with a cloth. Cracks/damage/wear  Replace the primary
sliding sheave, primary fixed sheave, and
2.• Meas
Measur
ure:
Clutch e: thicknes
shoe thickness
s “a” collar as a set.
Out of specification  Replace the clutch
shoes and springs as a set.
5-38

TRANSMISSION
ON
EAS30317

WEIGHTS 1
The following procedure applies to all of the pri-
mary sheave weights.
1. Che
Check:
• Primary
Primary sheave weight
Cracks/damage/wear  Replace. a
2. Meas
Measurure:
e:
• Primary
Primary sheave weight
weight outside diameter
diameter “a”
4. Che
Check:
Weight outside diameter • Spring
Spring free
free length
length
20.0 mm (0.79 in) Out of specification  Replace the spring.

Limit
19.5 mm (0.77 in) Compression spring free length
116.4 mm (4.58 in)

Limit
104.8 mm (4.12 in)
EAS31233

SLIDERS
EAS30320
1. Che
Check:
ASSEMBLING THE PRIMARY SHEAVE
• Primary
Primary sheave
sheave slider
1. Clea
Clean:
n:
Cracks/damage/wear  Replace.
• Primary
Primary fixed
fixed sheave
EAS30319 • Primary
Primary sliding
sliding sheave
CHECKING THE SECONDARY SHEAVE • Primary
Primary sheave
sheave weights
weights
1. Che
Check: • Cam
• Secondary
Secondary fixed sheave
EAS30321
• Secondary
Secondary slidin
sliding
g sheave
sheave
ASSEMBLING THE SECONDARY SHEAVE
Cracks/damage/wear  Replace the sec-
1. Lu
Lubr
bric
icat
ate:
e:
ondary fixed and sliding sheaves as a set.
• Secondary
Secondary sliding
sliding sheave inner sur
surface
face
2. Che
Check:
• Oil seal
seals
s “1”
“1”
• Torque
Torque cam groov
groovee “a”
(with the recommended lubricant)
Damage/wear  Replace the secondary
fixed and sliding sheaves as a set. Recommended lubricant
3. Che
Check: Shell dolium grease R®
• Guide
Guide pin
pin “1”
Damage/wear  Replace the secondary IP

fixed and sliding sheaves as a set. Do not apply grease to the inner surface “a” of
the secondary fixed sheave 2 . If any grease
gets on the inner surface of the secondary fixed
sheave, be sure to wipe it off thoroughly.
5-39

TRANSMISSION
ON
• Compres
Compressio
sionn spring
2 * • Clutch carrier
carrier assembly
assembly
1 • Secondary
Secondary sheave
sheave nut
nut “1”
“1”
IP
• Install the
the sheave spring compress
compressor
or “2” and
* sheave fixed block “3” onto the secondary
sheave as shown. Then, compress the spring,
a 1
and install the secondary sheave nut.
• Install the
the secondary sheave
sheave nut “1” with
with its ta-
pered side facing the clutch carrier.
2. Inst
Instal
alll:
• Oi
Oill seals New
seals Sheave spring compressor
• Secondary
Secondary sliding
sliding sheave
sheave “1” 90890-04134
IP
Install the secondary sliding sheave onto the YM-04134
Sheave fixed block
secondary fixed sheave “2” with the oil seal
90890-04135
guide “3”.
YM-04135
Oil seal guide (37 mm)
90890-04177

2
1
1
2
3
EAS31234
INSTALLING THE PRIMARY SHEAVE,

3. Inst
Instal
alll: V-BELT AND SECONDARY SHEAVE
• Guide
Guide pinspins “1” 1. In
Inst
stal
all:
l:
4.• Guide
Lu
Lubr
bric
Gui icat
de ate:
e: groove
pin grooves
s “a” • Secondary
Secondary sheave
sheave assembly
assembly
IP
• O-ring
O-ringss “2” New Before installing the secondary sheave assem-
(with the recommended lubricant) bly, check that there is no grease on
o n the splines
“a” of the primary drive gear. If there is any
Recommended lubricant grease on the splines, be sure to wipe it off thor-
Shell dolium grease R®

oughly.
1
New 2
a
a
5. Inst
Instal
alll: 2. Tigh
Tighte
ten:
n:
• Spri
Spring
ng seat
seat • Secondary
Secondary sheave
sheave nut “1”
5-40

TRANSMISSION
ON
IP
Secondary sheave nut

T
.
55 N·m (5.5 kgf·m, 40 lb·ft) When installing the primary sliding sheave as-
R
sembly, hold the cam to prevent the primary
.
IP
sheave weights from falling out of the primary
sliding sheave.
While holding
tor holding toolthe
“2”,secondary sheave
tighten the with the ro-
secondary
sheave nut with the socket wrench “3”.
Rotor holding tool

90890-01701

Socket wrench (39 mm) 1
90890-01493
1 2 5. In
Inst
stal
all:
l:
• V-
V-bel
beltt “1”
“1”
ECA21720
NOTICE
3 Do not allow grease to come in contact with

the V-belt.
IP
• Install the
the V-belt with
with the printed arrow
arrow mark on
3. Inst
Instal
alll:
the V-belt facing in the direction shown in the il-
• Clutch
Clutch housi
housing
ng “1”
lustration.
• Clutch housing nut “2”“2”
• Install the
the V-belt onto the primary
primary sheave side.
side.
Clutch housing nut

T
.
R
.
45 N·m (4.5 kgf·m, 33 lb·ft)

IP
While holding the clutch housing with the rotor
holding tool “3”, tighten the clutch housing nut.
1
Rotor holding tool
90890-01701

6. In
Inst
stal
all:
l:
• Primary
Primary fixed
fixed shea
sheave
ve “1”
• Wash
Washer er
3
• Conical spring washer “2”
• Primary
Primary fixed
fixed shea
sheave
ve nut
ECA21730
NOTICE
Do not allow grease to contact the primary

1 sheave assembly.
2
IP
4.• Primary
Inst
Instal
Primall
l: sliding
ary sliding sheave assembly
assembly “1” • Apply lithium-
lithium-soap-ba
soap-based
sed grease to the prima-
prima-
ry fixed sheave nut side of the conical spring
washer and to the threaded portion of the
crankshaft.
5-41

TRANSMISSION
ON
• Install the
the conical spring
spring washer with
with the mark
“a” facing outward.
• Install the
the V-belt in
in the primary
primary sheave (when
(when
the pulley is at its widest position) and in the
secondary sheave (when the pulley is at its
narrowest position), and make sure the V-belt
is tight.
2
7. Tigh
Tighte
ten:
n:
• Primary
Primary fixed
fixed sheave
sheave nut “1”
“1”
Primary fixed sheave nut

T
.
R
.
49 N·m (4.9 kgf·m, 35 lb·ft)

IP
While holding the primary fixed sheave with the
rotor holding tool “2”, tighten the primary fixed
sheave nut.
Rotor holding tool

90890-01701

Universal magneto and rotor
holder
YU-01235
1
5-42
STARTER GENERATOR
EAS20190
STARTER GENERATOR
Removing the starter generator assembly
4 LT
T
. . R
R
.
10 N•m (1.0 kgf•m, 7.2 lb•ft)
5 2
LT
T
. . R
R
.
70 N•m (7.0 kgf•m, 51 lb•ft)
Drain.
page 3-19.
3-19.
Battery
4-1..
4-1
Front side cover (right)
4-3..
4-3
Radiator fan Refer to “RADIATOR” on page 6-1
Crankshaft position sensor coupler
1 1/1 Disconnect.
/Starter generator coupler
2 Star ter generator rotor nut 1
3 Star ter generator rotor 1
4 Woodruff key 1
Starter generator/
5 1
Crankshaft position sensor
5-43
STARTER GENERATOR
EAS31239 EAS31240
REMOVING THE STARTER GENERATOR INSTALLING THE STARTER GENERATOR

1. Rem
Remove:
ove: 1. In
Inst
stal
all:
l:
• Starter generator rotor nut “1” • Woodr
Woodruff uff key
key
• Wash
Washerer • Starter generator rotor
IP • Wash
Washer er
While holding the starter generator rotor “2” with • Starter generator rotor nut
the rotor holding tool “3”, loosen the starter gen- IP
erator rotor nut. • Clean the tapered
tapered portion
portion of the crankshaft
crankshaft and
the starter generator rotor hub.
Rotor holding tool • When installing
installing the starter
starter generator rotor,
rotor,
90890-01235 make sure the woodruff key is properly seated

Universal magneto and rotor in the keyway of the crankshaft.
holder
2. Tigh
Tighte
ten:
n:
YU-01235
• Starter generator rotor nut
nut “1”
Starter generator rotor nut

T
.
R .
70 N·m (7.0 kgf·m, 51 lb·ft)

IP
3 While holding the starter generator rotor “2” with
2
the rotor holding tool “3”, tighten the starter gen-
erator rotor nut.
1
Rotor holding tool
2. Rem
Remove:
ove: 90890-01235
• Starter generator rotor “1”

Universal magneto and rotor
holder
(with the flywheel puller “2”)
YU-01235
• Woodruf
Woodrufff key
ECA21740
NOTICE
To protect the end of the crankshaft, place

plac e an
appropriate sized socket between the fly-
wheel puller center bolt and the crankshaft. 3

2
Flywheel puller
90890-01189

Flywheel puller
YM-01189 1
1
2
5-44
OIL PUMP
EAS20054
OIL PUMP
Removing the oil pump
T 4 N m (0.4kgf
• (0.4kgf m, 2.9lb.ft)
• 2.9lb.ft)
5
.
R
.
LS
1 NEW
* Apply Yamaha bond No. 1215 (90890-85505).

V-Belt automatic transmission
5-34.
1 Oil seal 1
2 Oil pump cover 1
3 Gasket 1
4 Dowel pin 2
5 Oil pump assembly 1
5-45
OIL PUMP
Disassembling the oil pump
T
. . R
R
.
1.0 N•m (0.10 k gf•m, 0.72 lb•ft)
7
5
3
6

1 Oil pump housing cover 1
2 Pin 1
3 Oil pump driven gear 1
4 Oil pump rotor assembly 1
5 Oil pump inner rotor 1
6 Oil pump outer rotor 1
7 Oil pump housing 1
5-46
OIL PUMP
EAS30340
CHECKING THE OIL STRAINER

1. Che
Check:
• Oil str
strain
ainer
er
Damage  Replace.
Contaminants  Clean with solvent.
EAS30337
CHECKING THE OIL PUMP

1. Che
Check:
• Oil pump
pump drive
drive gear
gear
• Oil pump
pump drive
driven
n gear EAS30342
• Oil pump
pump housing
housing ASSEMBLING THE OIL PUMP
• Oil pump housing cover 1. Lu
Lubr
bric
icat
ate:
e:
Cracks/damage/wear  Replace the oil • Inner
Inner roto
rotorr
pump. • Outer
Outer roto
rotorr
2. Meas
Measurure:
e: • Oil pum
pump p shaft
shaft
• Inner-rotor-to-
Inner-rotor-to-outer-r
outer-rotor-ti
otor-tip
p clearance
clearance “a”
• Outer-rotor-t
Outer-rotor-to-oil
o-oil-pump-ho
-pump-housing
using clearance
clearance Recommended lubricant
“b” Engine oil
Out of specification  Replace the oil pump.

2. In
Inst
stal
all:
l:
• Oil pump housing “1”
• Oil pump
pump out
outer
er rotor
rotor “2”
• Oil pump
pump in
inner
ner rotor
rotor “3”
“3”
• Oil pump
pump dr
driven
iven gear “4”
“4”
• Pin
Pin “5
“5””
• Oil pump
pump hou
housing
sing cover
cover
Oil pump housing cover screw

T
.
R
.
1.0 N·m (0.10 kgf·m, 0.72 lb·ft)

1. Inn
nnerer ro
roto
torr IP
2. Oute
Outerr rrot
otor
or When installing the inner rotor, align the pin in
3. Oi
Oill p
pum
ump p hou
housi
sing
ng the oil pump driven gear with the groove “a” in
the inner rotor.
Inner-rotor-to-outer-rotor-tip
clearance
4

0.150 mm (0.0059 in) 3
5
Limit
0.23 mm (0.0091 in) 2
Outer-rotor-to-oil-pump-housing
clearance
0.13–0.18 mm (0.0051–0.0071 in)
Limit 1
a
0.22 mm (0.0086 in)
3. Che
Check:
3. Che
Check:
• Oil pump
pump operat
operation
ion
• Oil pump
pump operati
operation
on
Rough movement  Repeat steps (1) and
Refer to “CHECKING THE OIL PUMP” on
(2) or replace the oil pump.
page 5-47.
5-47.
5-47
TRANSMISSION
EAS20062
TRANSMISSION
Removing the transmission
New
New 4 E
E
E
E
E New
LS
New
LS
1
New 3

Muffler Refer to “ENGINE REMOVAL” on page 5-3
5-3..
Radiator cover Refer to “RADIATOR” on page 6-1.
6-1.
Secondary sheave assembly SION” on page 5-34.
5-34.
Swingar m Refer to “REAR WHEEL” on page 4-28
4-28..
Rear wheel Refer to “REAR WHEEL” on page 4-28.
4-28.
1 Final transmission oil filler cap 1
2 Final transmission oil drain bolt 1
3 Transmission case cover 1
4 Transmission case cover gasket 1
5 Dowel pin 2
5-48
TRANSMISSION
Removing the transmission
New
14 12
6 14
8 7
New 10 14 E
E
14 11
E
E
9
13
E New 14
LS
New
New
LS
New

6 Main axle assembly 1
7 Primar y driven gear 1

8 Main axle 1
9 Drive axle 1
10 1st wheel gear 1
11 Circlip 1
12 Primar y drive gear 1
13 Oil seal 2
14 Bearing 6
5-49
TRANSMISSION
EAS30433
CHECKING THE TRANSMISSION

1. Che
Check:
• Transm
Transmissission
ion gears 2
1
Blue discoloration/pitting/wear  Replace New
the defective gear(s).
• Transmissi
Transmission on gear
gear dogs 1 New
Cracks/damage/rounded edges  Replace
the defective gear(s).
2
2. Che
Check:
• Transmissi
Transmission on gear engagement 3. In
Inst
stal
all:
l:
(each pinion gear to its respective wheel • Primary
Primary driven
driven gear
gear “1”
gear) (to the main axle “2”)
Incorrect  Reassemble the transmission
Primary driven gear installed
axle assemblies. depth “a”
3. Che
Check: 0.5–0.9 mm (0.020–0.035 in)
• Transmissi
Transmission on gear movement
movement
Rough movement  Replace the defective a
part(s).
EAS30438 2
INSTALLING THE TRANSMISSION
1. Inst
Instal
alll:
(to the transmission case cover “2”) 1

(to the right crankcase “4”) 4. In
Inst
stal
all:
l:
• Transmission
Transmission case cover
cover “1”
Installed depth “a”
21.7–21.8 mm (0.85–0.86 in) Transmission case cover bolt

Installed depth “b”
T
.
R 20 N·m (2.0 kgf·m, 14 lb·ft)

0.25–0.75 mm (0.01–0.03 in)
.
IP
1
Tighten the transmission case cover bolts in the
2 proper tightening sequence as shown.
3 1
b 1
4
2. Inst
Instal
alll:
• Circli
Circlip “1” New
p “1”
(to the drive axle “2”)
IP
Install the circlip with its chamfered side facing 4
2
as shown. 5
3 8 6
7
5-50
CRANKSHAFT
EAS20061
CRANKSHAFT
Removing the crankshaft
1
E
New
LS
(9)
LS
LS
New
3
LS 2

Engine Refer to “ENGINE REMOVAL” on page 5-3
5-3..
5-9.
Refer to “CYLINDER AND PISTON” on page
Piston 5-29..
5-29
Secondary sheave assembly
5-34.
Oil pump Refer to “OIL PUMP” on page 5-45
5-45..
1 Dipstick 1
2 Centerstand spring 1
3 Centerstand shaft 1
5-51
CRANKSHAFT
Removing the crankshaft
E
New
LS
6 8
4
(9)
LS
LS 7
New
5
LS

4 Dowel pin 2
5 Crankcase (left) 1
6 Crankcase (right) 1
7 Centerstand 1
8 Crankshaft assembly 1
5-52
CRANKSHAFT
EAS31241 ECA20630
DISASSEMBLING THE CRANKCASE NOTICE

1. Rem
Remove:
ove: • To protect
protect the end of the
the crankshaft,
crankshaft, place
• Crankca
Crankcase
se bolts
bolts an appropriate sized socket between the
IP crankcase separating tool bolt and the
Loosen each bolt 1/4 ofpattern.
a turn at a time, crankshaft.
es and in a crisscross After all ofinthe
stag-
• Do not tap on the crankshaft.
crankshaft.
bolts are fully loosened, remove them.
Crankcase separating tool
90890-01135

Crankcase separator
YU-01135-B
2. Rem
Remove:
ove:
• Crankca
Crankcase
ECA13900
se (left)
(left) “1”
NOTICE
Tap on one side of the crankcase with a soft-

EAS31242
face hammer. Tap only on reinforced por- CHECKING THE CRANKSHAFT ASSEMBLY
tions of the crankcase, not on the crankcase 1. Meas
Measurure:
e:
mating surfaces. Work slowly and carefully • Cranksha
Crankshaft ft runout
runout
and make sure the crankcase halves sepa- Out of specification  Replace the crank-
rate evenly. shaft assembly.
IP
Turn the crankshaft slowly.
Runout limit
0.030 mm (0.0012 in)

EAS30414
REMOVING THE CRANKSHAFT ASSEMBLY

1. Rem
Remove:
ove:
• Crankshaft
Crankshaft assembl
assembly
y “1”
“1”
IP
• Remove the cranksh
crankshaft
aft assembly
assembly with the
crankcase separating tool “2” and M6 bolts “3”. 2. Meas
Measur
ure:
e:
• Make sure
sure that the crankcase
crankcase separating
separating tool • Big end
end side clearance
clearance
is centered over the crankshaft assembly. Out of specification  Replace the crank-
shaft assembly.
Big end side clearance
0.150–0.450 mm

(0.0059–0.0177 in)
5-53
CRANKSHAFT
EAS31244
CHECKING THE BEARING

1. Che
Check:
• Bear
Bearin
ing
g
Clean and lubricate the bearings, and then
rotate the inner race with your finger.
Rough movement  Replace.
EAS31245
CHECKING THE OIL PUMP DRIVE GEAR

1. Che
Check:
3. Meas
Measurure:
e: • Oil pump
pump drive
drive gear
gear
• Cranksh
Crankshaft
aft width
width Damage/wear  Replace.
Out of specification  Replace the crank- EAS30791
shaft assembly. INSTALLING THE CRANKSHAFT
1. In
Inst
stal
all:
l:
Crank assembly width
• Crankshaft
Crankshaft assembly
assembly “1”
51.45–51.50 mm (2.026–2.028 in)

IP
• Install the
the crankshaft
crankshaft assembly
assembly with the crank-
shaft installer pot “2”, crankshaft installer bolt
“3”, adapter “4”, and crankshaft installer spacer
“5”.
• Hold the connectin
connectingg rod at top dead
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
assembly bottoms against the bearing.
4. Che
Check: Crankshaft installer pot
• Crankshaft
Crankshaft sprocket
sprocket “1”
“1” 90890-01274
Damage/wear  Replace the crankshaft as-
Installing pot
sembly. YU-90058
• Bear
Bearin
ing
g “2” Crankshaft installer bolt
Cracks/damage/wear  Replace the crank- 90890-01275
Bolt
shaft assembly. YU-90060
Adapter (M12)
90890-01278
2 Adapter #3
YU-90063
1 Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044
EAS31243
CHECKING THE CRANKCASE

1. Thorough
Thoroughly
ly wash the crankcase
crankcase halves in a
mild solvent.
2. Thorough
Thoroughlyly clean
clean all the gasket
gasket surfaces
surfaces and
crankcase mating surfaces.
3. Che
Check:
• Crank
Crankca
case
se
5-54
CRANKSHAFT
EAS31246
ASSEMBLING THE CRANKCASE

1. Thorough
Thoroughlyly clean
clean all the gasket
gasket mating
mating sur-
sur-
faces and crankcase mating surfaces.
2. Appl
pply:
• Seal
Sealan
antt a
(onto the crankcase mating surfaces)
Yamaha bond No. 1215 1

90890-85505 2 b

IP
Do not allow any sealant to come into contact
with the oil gallery.
3. Inst
Instal
alll:
• Crankca
Crankcase se (right)
(right)
(onto the crankcase (left))
• Crankca
Crankcase se bolts
bolts
Crankcase bolt

T
.
R
.
10 N·m (1.0 kgf·m, 7.2 lb·ft)

IP
• Thoroughly
Thoroughly wipe off any sealant
sealant that protrudes
protrudes
from between the left crankcase and the right
crankcase.
• Tighten the
the crankcase
crankcase bolts in
in stages and in
in a
crisscross pattern.
EAS31247
INSTALLING THE CENTERSTAND

1. Inst
Instal
alll:
• Centers
Centerstandtand “1”
• Spri
Spring
ng “2”“2”
IP
• Make sure
sure that the hooked end
end “a” of the spr
spring
ing
is positioned to the outside.
• Make sure
sure that the hooked end
end “b” of the spr
spring
ing
is positioned to the outside.
5-55
COOLING SYSTEM
RADIATOR ......................................................................................................6-1
CHECKING THE RADIATOR....................................................................6-3
RADIATOR ....................................................................6-3
INSTALLING THE RADIATOR..................................................................6-3
RADIATOR ..................................................................6-3
THERMOSTAT ................................................................................................6-4
CHECKING THE THERMOSTAT ASSEMBLY .........................................6-5
INSTALLING THE THERMOSTAT ASSEMBLY .......................................6-5
WATER PUMP.................................................................................................6-6
DISASSEMBLING THE WATER PUMP....................................................6-8
PUMP ....................................................6-8
CHECKING THE WATER PUMP ..............................................................6-8
ASSEMBLING THE WATER PUMP..........................................................6-8
PUMP ..........................................................6-8
INSTALLING THE WATER PUMP ............................................................6-8
6

RADIATOR
EAS20063
RADIATOR
Removing the radiator
4
5
3
2
(5)
(4)
New
1

Drain.
page 3-19.
3-19.
4-3..
4-3
Footrest board assembly (right)/Bottom cover
4-16..
4-16
1 Radiator cover 1
2 Coolant reser voir breather hose 1
3 Coolant reser voir hose 1
4 Rear brake hose bracket 1
5 Rear brake hose holder (front side) 1
6-1
RADIATOR
Removing the radiator
12
11
9
(5)
7
10
8 6
(4)
New

6 Coolant reser voir 1
7 Radiator inlet hose 1

8 Radiator outlet hose 1
9 Radiator cap 1
10 Radiator 1
11 Radiator fan case 1
12 Radiator fan 1
6-2
RADIATOR
EAS30439
b. Apply the
the specified
specified pressure
pressure for ten seconds
seconds
CHECKING THE RADIATOR
and make sure there is no drop in pressure.
1. Che
Check:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Radiato
Radiatorr fins
fins
Obstruction  Clean. 4. Che
Check:
Apply compressed air to the rear of the radia- • Radiator
Radiator fan
tor. Damage  Replace.
Damage  Repair or replace. EAS30440
IP INSTALLING THE RADIATOR

Straighten any flattened fins with a thin, flathead 1. Fill:
screwdriver. • Cooling
Cooling system
system
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-19.
3-19.
2. Che
Check:
• Cooling
Cooling system
system
Leaks  Repair or replace any faulty part.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Attach the
the radiator
radiator cap tester
tester “1” to the radia-
radia-
tor.
Radiator cap tester
2. Che
Check: 90890-05375
• Radiator
Radiator hoses
hoses
reservoir hose
3. Meas
Measurure:
e:
• Radiator
Radiator cap valve
valve opening
opening pressure
pressure
Below the specified pressure  Replace the 1
radiator cap.
Radiator cap valve opening pres-

sure

108.0–137.4 kPa (1.08–1.37
kgf/cm², 15.7–19.9 psi)
b. Apply 196 kPa (1.96 kg/cm²,
kg/cm², 27.87
27.87 psi)
psi) of
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
pressure.
a. Install the radiator
radiator cap
cap tester “1” and radiator c. Measure the pressure
pressure to check its maintain
maintain--
cap tester adapter “2” to the radiator cap “3”. ing applied pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Radiator cap tester
3. Meas
Measurure:
e:
90890-05375

• Radiator cap opening
opening pressure
pressure
Below the specified pressure  Replace the
1 radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-3.
6-3.
2
3
6-3
THERMOSTAT
EAS20065
THERMOSTAT
Removing the thermostat assembly
9 N•m (0.9 k gf•m, 6.5 lb•ft)

Drain.
page 3-19.
3-19.
4-3..
4-3
Footrest board (right)
4-16..
4-16
1 Radiator inlet hose 1 Disconnect.
2 Radiator outlet hose 1 Disconnect.
3 Water pump inlet hose 1 Disconnect.
4 Ther mostat assembly 1
6-4
THERMOSTAT
EAS31248
CHECKING THE THERMOSTAT ASSEMBLY

B
1. Che
Check:
• Thermos
Thermostat
tat “1”
“1”
Does not open at 74–78°C (165–172°F)  0.5 mm
(0.02 in) 7 mm
Replace.
(0.28 in)
A
74 – 78˚C 90˚C
(165 – 172˚F) (194˚F)
1
A. Fu
Full
lly
y cl
clos
osed
ed
B. Full
Fully
y ope
openn
IP
If the accuracy of the thermostat is in doubt, re-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
place it. A faulty thermostat could cause serious
a. Suspend tthehe thermostat
thermostat “1”
“1” in a containe
containerr “2” overheating or overcooling.
filled with water.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Slo
Slowly
wly heat the water
water..
EAS30445
c. Place a thermomete
thermometerr “3”
“3” in the water.
water. INSTALLING THE THERMOSTAT
d. While stirring
stirring the water “4”,
“4”, observe
observe the ther- ASSEMBLY
mostat and thermometer’s indicated temper-
1. Fill:
ature. • Cooling
Cooling system
system
mended coolant)
3
page 3-19.
3-19.
2. Che
Check:
4 • Cooling
Cooling system
system
1
2 Refer to “INSTALLING THE RADIATOR” on
page 6-3.
6-3.
3. Meas
Measurure:
e:
e. Same
Checklevel
tthe
he thermostat
therm ostat
for the element
elementelement
thermostat position
positionupper
“5”. • Radiator cap opening
opening pressure
pressure
end and the hole lower line “a” at 90 °C (194 radiator cap.
°F). Refer to “CHECKING THE RADIATOR” on
page 6-3.
6-3.
5
6-5
WATER PUMP
EAS20066
WATER PUMP
Removing the water pump
10 N•m (1.0 k gf•m, 7.2 lb•ft)

Drain.
page 3-19.
3-19.
Front side cover (left)
4-3..
4-3
Footrest board (left)
4-6..
4-6
1 Water pump inlet hose 1 Disconnect.
2 Water pump assembly 1
3 Dowel pin 2
6-6
WATER PUMP
Disassembling the water pump
7
3 New
6
5 New
10 N•m (1.0 k gf•m, 7.2 lb•ft)

4
T
. R
R
.
2 New
New
LS
T .
R
.
10 N•m (1.0 k gf•m, 7.2 lb•ft)
1 Water pump housing cover 1

2 Water pump housing gasket 1
3 Circlip 1
4 Impeller shaft 1
5 Water pump seal 1
6 Bearing 1
7 Water pump housing 1
6-7
WATER PUMP
EAS30446
DISASSEMBLING THE WATER PUMP A

1. Rem
Remove:
ove:
• Water
Water pump
pump seal
seal “1”
“1” 4
IP
3
Remove the water pump seal from the inside of
the water pump housing “2”. 2
1 New
1
A. Push
Push do
dowwn
2
3. Mec
Mechan
hanica
icall seal iinst
nstall
aller
er
4. Middl
Middle
e driven
driven shaft
shaft bearing driver
driver
1
a
EAS30447
CHECKING THE WATER PUMP 2
1. Che
Check:
• Water
Water pump housin
housing
g cover
• Water
Water pump
pump housing
housing
• Impell
Impeller
er shaft
shaft
Cracks/damage/wear  Replace.
a. Instal
Installed
led depth
depth of wate
waterr pump seal
seal
EAS30448
ASSEMBLING THE WATER PUMP 2. Lu

Lubr
bric
icat
ate:
e:
1. Inst
Instal
alll: • Water
Water pump
pump seal
• Water
Water pump “1” New
pump seal “1” Recommended lubricant
(into the water pump housing “2”) Lithium-soap-based grease
IP
Install the water pump seal with the special tools 3. In

Inst
stal
all:
l:
to the specified depth as shown in the illustra- • Impelle
Impellerr shaft
shaft “1”
tion. New
• Circ
IP
Circlilip
p
Installed depth of water pump After installation, check that the impeller shaft ro-
seal tates smoothly.

0–0.5 mm (0–0.02 in)
Mechanical seal installer

90890-04145

Middle driven shaft bearing driv-
er
90890-04058
Middle drive bearing installer 40
& 50 mm
YM-04058 1
EAS30449
INSTALLING THE WATER PUMP

1. In
Inst
stal
all:
l:
• O-ring
O-rings “1” New
s “1”
• Water pump
pump assembly
assembly “2”
6-8
WATER PUMP
Water pump assembly bolt

T
.
R
.
10 N·m (1.0 kgf·m, 7.2 lb·ft)

IP
• Align the projecti

projection
on “a” on the impeller
impeller shaft
shaft
with the slit “b” on the camshaft sprocket bolt.
• Lubricate
Lubricate the O-ring
O-ring with a thin coat of
of lithium-
lithium-
soap-based grease.
a b
New 1
LS
2. Fill:
• Cooling
Cooling system
system
mended coolant)
page 3-19.
3-19.
3. Che
Check:
• Cooling
Cooling system
system
Refer to “INSTALLING THE RADIATOR” on
page 6-3.
6-3.
4. Meas
Measurure:
e:
• Radiator
Radiator cap opening pressure
pressure
radiator
Refer to cap.
“CHECKING THE RADIATOR” on
page 6-3.
6-3.
6-9
FUEL SYSTEM
FUEL TANK .....................................................................................................7-1

REMOVING THE FUEL TANK ..................................................................7-2
REMOVING THE FUEL PUMP .................................................................7-2
REMOVING THE FUEL FILTER ...............................................................7-2
CHECKING THE FUEL PUMP BODY.......................................................7-2
BODY .......................................................7-2
CHECKING THE FUEL FILTER................................................................7-2
FILTER ................................................................7-2
INSTALLING THE FUEL FILTER..............................................................7-2
FILTER ..............................................................7-2
INSTALLING THE FUEL PUMP ................................................................7-3
INSTALLING THE FUEL TANK.................................................................7-3
TANK .................................................................7-3
CHECKING THE FUEL PRESSURE ........................................................7-3
FUEL INJECTOR.............................................................................................7-5
REMOVING THE FUEL HOSE .................................................................7-6
CHECKING THE FUEL INJECTOR ..........................................................7-6
INSTALLING THE FUEL INJECTOR ........................................................7-6
INSTALLING THE FUEL HOSE ................................................................7-6
AIR FILTER CASE ..........................................................................................7-7

INSTALLING THE AIR FILTER CASE ......................................................7-9
THROTTLE BODY.........................................................................................7-10
REMOVING THE THROTTLE BODY......................................................7-12
BODY ......................................................7-12
CHECKING THE THROTTLE BODY ......................................................7-12
CLEANING THE ISC (IDLE SPEED CONTROL)
UNIT AND THROTTLE BODY ...............................................................7-12
REPLACING THE THROTTLE BODY ....................................................7-14
INSTALLING THE THROTTLE BODY ....................................................7-15
7

FUEL TANK
EAS20067
FUEL TANK
Removing the fuel tank
5 4
2
7
3
6
11
10
9
8

Front side covers
4-3..
4-3
Fuel tank cover
4-18..
4-18
1 Fuel tank cap 1
2 Fuel tank overflow tray 1
3 Fuel tank overflow hose 1
4 Fuel sender coupler 1 Disconnect.
5 Fuel pump coupler 1 Disconnect.
6 Fuel hose 1 Disconnect.
7 Fuel tank 1
8 Fuel pump bracket 1
9 Fuel pump 1
10 Fuel pump gasket 1
11 Fuel filter 1
7-1
FUEL TANK
EAS30450 EAS31376
REMOVING THE FUEL TANK REMOVING THE FUEL FILTER

1. Extrac
Extractt the fuel in the fuel tank
tank through
through the 1. Remo
Remove ve::
fuel tank cap with a pump. • Fuel filter
filter “1”
2. Disc
Discon
onne
nect
ct:: IP
•• Fuel
Fuel sende
sender
Fuel pump
pum p rcouple
coupler
coup
cou ler
plerr Remove the projections “a” on the fuel pump
from the holes “b” in the fuel filter and slide the
• Fuel
Fuel hose
hose fuel filter in the direction of the arrow shown to
EWA18020
WARNING remove it.

Cover the fuel hose connection with a cloth
when disconnecting it. Residual pressure in a 1
the fuel lines could cause fuel to spurt out
when removing the hose.
ECA20020 a
NOTICE b
Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hose, since there may be fuel remaining
remai ning
in it.
EAS30454
IP CHECKING THE FUEL PUMP BODY

• To remove thethe fuel hose from
from the fuel pump, 1. Che
Check:
slide the fuel hose connector cover “1” on the • Fuel pump
pump body
body
end of the hose in the direction of the arrow Obstruction  Clean.
shown, and then remove the hose. Cracks/damage  Replace fuel pump as-
• Before removing
removing the hose, place
place a few rags in
in sembly.
the area under where it will be removed. EAS31249
CHECKING THE FUEL FILTER

1. Che
Check:
• Fuel
Fuel filte
filterr
Damage  Replace.
Contaminants  Clean with solvent.
1
EAS31377
INSTALLING THE FUEL FILTER

1. In
Inst
stal
all:
l:
• Fuel filter
filter “1”
IP
3. Rem
Remove:
ove: Fit the projections “a” on the fuel pump into the
• Fuel
Fuel tan
tank
k holes “b” in the fuel filter and slide the fuel filter
EAS30451 in the direction of the arrow shown to install it.
REMOVING THE FUEL PUMP
1. Rem
Remove:
ove: 1
• Fuel
Fuel pump
pump a
ECA14721
NOTICE
a
• Do not drop
drop the fuel
fuel pump or give it a
strong shock. b
• Do not touch
touch the base section
section of the fuel
sender.
7-2
FUEL TANK
EAS30456
b. Install the fuel tank overflow
overflow tray
tray and fuel tank
INSTALLING THE FUEL PUMP
cover “3”. To install the fuel tank cover, refer
1. Inst
Instal
alll:
to “GENERAL CHASSIS (3)” on page 4-6. 4-6.
• Fuel pump
pump gasket
gasket “1”
“1” New c. Tighten the fuel
fuel tank bolts to specificat
specification.
ion.
• Fuel
Fuel pump
pump
• Fuel pump bracket
bracket
T
.
Fuel tank
9 N·m bolt
(0.9 kgf·m, 6.5 lb·ft)
R
.
Fuel pump bracket bolt

T
.
R
.
4.0 N·m (0.40 kgf·m, 2.9 lb·ft)

3
IP
• Do not damage the installat
installation
ion surfaces
surfaces of the
fuel tank when installing the fuel pump. 2
• Always use a new fuel pump gasket. gasket.
• The gasket liplip “a” shall
shall face toward
toward the fuel 2
pump.
• Align the projections
projections “b” (two
(two locations)
locations) on the 1
fuel pump gasket with the slots “c” in the fuel
pump. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Align the projectio

projection n “d” on the fuel pump
pump with 2. In
Inst
stal
all:
l:
the slot in the fuel pump bracket. • Fuel
Fuel hose
hose
• Tighten the fuel
fuel pump bolts
bolts in the proper tight-
tight- ECA17500
NOTICE
ening sequence as shown.
When installing the fuel hose, make sure that
it is securely connected, and that the fuel
hose connector cover on the fuel hose is in
the correct position, otherwise the fuel hose
will not be properly installed.
a IP
c
• Install the
the fuel hose securely
securely onto
onto the fuel
1 New
pump until a distinct “click” is heard.
b
• To install
install the fuel hose,
hose, slide
slide the fuel hose con-
con-
nector cover “1” on each end of the hose in the
1 direction of the arrow shown.

d
3
1
EAS30457
INSTALLING THE FUEL TANK

EAS30703
1. Inst
Instal
alll: CHECKING THE FUEL PRESSURE
• Fuel
Fuel tank
tank “1”
“1”
1. Remo
Remove
ve::
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Tempora
Temporarily
rily install
install the fuel tank. • Refer
Front side
si
tode cover assembly
“GENERALassembly (left)(2)” on page
CHASSIS
IP
4-3..
4-3
Make sure that the flanges of the fuel tank bolts
“2” do not contact the fuel tank.
7-3
FUEL TANK
• Footrest
Footrest board
board (right)
(right) Refer to “INSTALLING THE FUEL TANK” on
Refer to “GENERAL CHASSIS (6)” on page page 7-3.
7-3.
4-16..
4-16 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Che
Check: 3. In
Inst
stal
all:
l:
• Pressure
Pressure regulator
regulator operation
operation • Footres
(left)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Refer to “GENERAL CHASSIS (6)” on page
a. Discon
Disconnect
nect the
the fuel hose from
from the fuel pump.
pump.
EWA18020
4-16..
4-16
WARNING • Front side
side cover assembly
assembly (left)
Cover the fuel hose connection with a cloth Refer to “GENERAL CHASSIS (2)” on page
when disconnecting it. Residual pressure in 4-3..
4-3
the fuel lines could cause fuel to spurt out
when removing the hose.
ECA20020
NOTICE
Although the fuel has been removed from

the fuel tank, be careful when removing the
remai ning
in it.
IP
Before removing the hose, place a few rags in
the area under where it will be removed.
b. Connect the pressure
pressure gauge “1”“1” and fuel
pressure adapter “2” to the fuel hose “3”.
Pressure gauge
90890-03153

Pressure gauge
YU-03153
Fuel pressure adapter 6.3mm
90890-03227
1
Y A M
MA

A H
H
2
3
c. Star
Startt the
the engi
engine
ne..
d. Meas
Measureure the
the fuel
fuel pressu
pressure.
re.
Fuel line pressure at idling

220–300 kPa (2.2–3.0 kgf/cm²,

31.9–43.5 psi)
Faulty  Replace the fuel pump.

e. Conn
Connect
ect the fuel hose.
hose.
7-4
FUEL INJECTOR
EAS20191
FUEL INJECTOR
Removing the fuel injector
10 N•m (1.0 k gf•m, 7.2 lb•ft)

Battery
4-1..
4-1
Front side covers
4-18..
4-18
Fuel tank cover Refer to “GENERAL CHASSIS (3)” on page

4-6..
4-6
Storage box
4-6..
4-6
Center lower cover
4-16..
4-16
1 Fuel hose 1
2 Fuel injector coupler 1 Disconnect.
3 Fuel injector 1
4 Fuel injector adaptor 1
7-5
FUEL INJECTOR
EAS31250
REMOVING THE FUEL HOSE Fuel injector bolt

1. Disc
Discon
onne
nect
ct::
T
.
R .
10 N·m (1.0 kgf·m, 7.2 lb·ft)
• Fuel
Fuel hose
hose
EWA17610
IP
WARNING
Cover fuel hose connections with a cloth • Lubricate
Lubricate the O-ring
O-ring with engine
engine oil.
• Align the
the projection
projection “a” on the fuel injector
injector
when disconnecting them. Residual pres-
adapter with the hole “b” in the intake manifold.
sure in the fuel lines could cause fuel to
• Align the projection
projection “c” on the fuel injector
injector with
with
spurt out when removing the hoses.
the hole “d” in the fuel injector adapter.
ECA20020
NOTICE
Although the fuel has been removed from 3
the fuel tank, be careful when removing the New 2

remai ning c
a
in it.
b 1
IP
• To remove the fuel
fuel hose from the
the fuel injector,
injector, d
slide the fuel hose connector cover “1” on the
end of the hose in the direction of the arrow
shown, and then remove the hose. EAS31253
• Before removing
removing the hose, place
place a few rags in
in INSTALLING THE FUEL HOSE
the area under where it will be removed. 1. In
Inst
stal
all:
l:
• Fuel
Fuel hose
hose
ECA17500
NOTICE
When installing the fuel hose, make sure that

it is securely connected, and that the fuel
hose connector cover on the fuel hose is in
1
the correct position, otherwise the fuel hose
will not be properly installed.
IP
• Install the
the fuel hose securely
securely onto
onto the fuel in-
EAS31251 jector until a distinct
distinct “cl
“click”
ick” is heard.
heard.
CHECKING THE FUEL INJECTOR • To install
install the fuel hose onto
onto the fuel injector,
injector,
1. Che
Check: slide the fuel hose connector cover “1” on the
• Inj
Injec
ector
tor end of the hose in the direction of the arrow
Obstruction  Replace and check the fuel shown.
pump/fuel supply system.
Deposit  Replace.
Damage  Replace.
2. Che
Check:
• Injecto
Injectorr resist
resistanc
ance
e
Refer to “CHECKING THE FUEL INJEC- 1
TOR” on page 7-6.7-6.
EAS31617
INSTALLING THE FUEL INJECTOR

1. Inst
Instal
alll:
• Fuel injector
injector adaptor
adaptor “1”
• O-
O-ri
ring “2” New
ng “2”
(to the fuel injector)
• Fuel inj
inject
ector
or “3”
7-6
AIR FILTER CASE
EAS20068
AIR FILTER CASE

Removing the air filter case
3
2

Battery
4-1..
4-1
Front side covers
4-3..
4-3

4-18..
4-18
Storage box
4-6..
4-6
1 Air filter case cover 1
2 Air filter case duct cover 1
3 Air filter case duct 1
4 Air filter element 1
5 Transmission case breather hose 1
7-7
AIR FILTER CASE
Removing the air filter case
9 8
6
10 11
6 Cylinder head breather hose 1 Disconnect.
7 Air filter case joint clamp screw 1 Loosen.

8 Air filter case 1
9 Air filter check hose 1
10 Air filter case joint 1
11 Hose 1
7-8
AIR FILTER CASE
EAS31618
INSTALLING THE AIR FILTER CASE

1. Inst
Instal
alll:
• Hose
Hose “1” “1” 1 2
(to the air filter case joint “2”)
• Clam
Clamp
p “3”
“3”
IP
• Apply Three
Three bond 1521
1521 “4” onto
onto the mating
mating a
b
surfaces of the hose and air filter case joint.
• Align the slot “a”
“a” on the air filter case
case joint with
the projection “b” in the hose. 4. In
Inst
stal
all:l:
• Air filter
filter case
case duc
ductt “1”
2 IP
b Fit the projection “a” on the air filter case duct be-
tween the projections “b” on the air filter case
a
cover “2”.
1
3
b
2. Inst
Instal
alll:
• Air filter
filter case
case joint
joint “1”
(to the air filter case “2”)
IP
2 1 a
• Apply Three
Three Bond 1521 “3” ontoonto the mating
mating
surfaces of the air filter case joint and air filter
case.
• Fit the projection
projection “a” on the air filter case
case joint
between the projections “b” on the air filter
case.
4
2
b
3
3. Inst
Instal
alll:
• Air filter
filter case
case joint clamp
clamp “1”
“1”
(to the air filter case joint “2”)
Air filter case joint clamp screw

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

IP
Align the projection “a” on the air filter case joint
with the slot “b” in the air filter case joint clamp.
7-9
THROTTLE BODY
EAS20070
THROTTLE BODY
Removing the throttle body
T
.
R
.
7 N m (0.7kgf
• (0.7kgf m, 5.1lb.ft
• 5.1lb.ft))
NEW T
.
R
.
10 N m (1.0kgf
• (1.0kgf m, 7.2lb.ft)
7.2lb.ft)

1
2
T
.
R
.
10 N m (1.0kgf m, 7.2lb.ft)
• • 7.2lb.ft)
M
LS
NEW
NEW
T
.
R
.
7 N m (0.7kgf
• (0.7kgf m, 5.1lb.ft
5.1lb.ft))
•

Battery
4-1..
4-1
Front side covers
4-3..
4-3

4-18..
4-18
Storage box
4-6..
4-6
Center lower cover
4-16..
4-16
Air filter case joint Refer to “AIR FILTER CASE” on page 7-7.
7-7 .
7-5..
1 ISC (Idle Speed Control) unit coupler 1 Disconnect.
2 Throttle body sensor assembly coupler 1 Disconnect.
7-10
THROTTLE BODY
Removing the throttle body
T
.
R
.
7 N m (0.7kgf
• (0.7kgf m, 5.1lb.ft
• 5.1lb.ft))
NEW T
10 N m (1.0kgf
• (1.0kgf m, 7.2lb.ft)
 7.2lb.ft)
7
.
R
.
8
9
5
T
.
R
.
10 N m (1.0kgf m, 7.2lb.ft)
• • 7.2lb.ft)
6
M
LS
NEW
NEW 4
3 T
.
R
.
7 N m (0.7kgf
• (0.7kgf m, 5.1lb.ft)
5.1lb.ft)
•
Order Job/Parts to remove Q’ t y Remarks
3 Throttle cable 2 Disconnect.

4 Throttle cable holder 1
5 Throttle body 1 Loosen.
6 Intake manifold 1
7 ISC (Idle Speed Control) unit holder 1
8 ISC (Idle Speed Control) unit 1
9 Spring 1
7-11
THROTTLE BODY
EAS30979
2. Remo
Removeve::
REMOVING THE THROTTLE BODY
• Screw
Screw “1
“1””
1. Rem
Remove:
ove:
• ISC (Idle Speed
Speed Control)
Control) unit holder
holder “2”
• Throttl
Throttle
e body
ECA20500
• ISC (Idle
(Idle Speed Control)
Control) unit
unit “3”
ECA21780
NOTICE
Do not remove the throttle body sensor as- NOTICE

Because the force of the spring may push
sembly from the throttle body.
out the ISC unit unexpectedly, be sure to
EAS30479
hold the ISC unit when removing the compo-
CHECKING THE THROTTLE BODY nents.
IP
Before checking the throttle body, check the fol- 2
lowing items: 3
1
• Valve
Valve cleara
clearance
nce
• Spark
Spark plug
plug
• Air filt
filter
er element
element
• Intake
Intake manif
manifold
old
• Fuel
Fuel hose
hose
• Exhaust
Exhaust system
system
• Cylinder
Cylinder head breather hose
EWA18030
3. Remo
Removeve::
WARNING • Spring
Spring “1”
• O-
O-ri
ring
ng “2”
“2”
If the throttle body is subjected to strong
shocks or dropped during, replace it.
1. Che
Check:
1
• Throttl
Throttlee body
2
Cracks/damage  Replace the throttle body.
2. Che
Check:
• Butterf
Butterfly
ly valve
valve
Damage/scratches/wear  Replace the
throttle body.
ECA21770
NOTICE
Do not adjust the stop screw “1”. 4.• Che

Chec(Idle
ISC k: e Speed Control)
(Idl Control) unit
Plunger “1” does not rotate smoothly/plunger
rotates together with the motor shaft “2” 
Replace.
1
1
EAS31254 2
CLEANING THE ISC (IDLE SPEED
CONTROL) UNIT AND THROTTLE BODY
1. Remove the throttle
throttle body
body from the vehicle.
vehicle. 5. Che
Check:
IP • Spri
Spring
ng
Damage/bent  Replace.
Before removing the throttle body, disconnect
6. Clea
Clean:
n:
the throttle cables and couplers.
• Area “a”
“a” of the ISC
ISC unit
7-12
THROTTLE BODY
• Areas “b”
“b” and “c” of the throttle
throttle body • Do not allow
allow the removed
removed deposits
deposits or for-
for-
Clogs or foreign materials cannot be re- eign materials to adhere to the sealing sur-
moved  Replace. faces of the O-ring.
• Do not scratch
scratch or deform
deform the
the ISC valve or
or
air passage; otherwise, poor starting per-
a formance, an unstable engine idling speed,
or uncontrollable engine speed could re-
sult.
• Do not clean
clean any areas other
other than the areas
areas
“a”, “b”, and “c”. If the cleaning agent en-
ters the ISC unit or throttle body, thorough-
ly wipe it off.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Adjust the ISC unit plunger

plunger to the specified
specified
distance “a” from the motor assembly body.
Distance “a”
0.0–3.0 mm (0.0–0.12 in)

8. In
Inst
stal
all:
l:
• Spri
Spring
ng
c • O-
O-ri
ring “1” New
ng “1”
• ISC (Idle
(Idle Speed Control)
Control) unit
unit “2”
ECA21800
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Use a rag soaked
soaked in the recommend
recommended ed clean-
clean- NOTICE
ing agent to wipe off any deposits
dep osits and foreign • Do not use
use the ISC unit
unit if it was dropped.
dropped.
materials. • Do not allow
allow water to enter the
the ISC unit and
and
do not allow foreign materials to adhere to
Recommended cleaning agent the assembly.
Yamaha oil & brake cleaner

• Do not touch
touch the terminals
terminals of the coupler
coupler
ECA21790 directly.
NOTICE • Because thethe force of the spring
spring may push
push
• Be sure to use the recommended
recommended cleaning out the ISC unit unexpectedly, be sure to
agent. hold the motor assembly when installing
• Do not spray the
the cleaning agent
agent directly
directly the components.
onto the ISC unit or throttle body and do IP
not immerse them in the cleaning agent.
• Install the
the new O-ring until it contacts
contacts the raised
raised
• not
To prevent scratchi
scratching
use a brush, ng the
metal file,components,
comp onents,
or other abra-do
do portion of the ISC unit body.
• When installin
installing
g the ISC unit, be sure
sure to align
sive tool.
the oval portion “a” of the ISC unit
un it with the oval
• Do not clean with
with compressed
compressed air.air.
hole “b” in the throttle body.
7-13
THROTTLE BODY

90890-03250
2 1 New
90890-03252
12.Place the vehicle on the centerstand so that

the rear wheel is elevated.
13.Check:
• Engine
Engine idling
idling speed
speed
Start the engine, warm it up, and then mea-
sure the engine idling speed. Within specifi-
cation  Service is finished.
Out of specification  Replace the throttle
body.
Refer to “REPLACING THE THROTTLE
b BODY” on page 7-14.
7-14.
Engine idling speed

a
1500–1700 r/min

EAS31160
9. Inst
Instal
alll:
REPLACING THE THROTTLE BODY
• ISC (Idle Speed
Speed Control)
Control) unit holder
holder “1”
1. Remove the throttle
throttle body
body from the vehicle.
vehicle.
• Screw
crew
2. Install a new throttle
throttle body
body to the
the vehicle.
vehicle.
ISC (Idle Speed Control)
C ontrol) unit 3. Res
Reset:

T
.
R holder screw • ISC learni

learning
ng valves
valves
.

5 N·m (0.5 kgf·m, 3.6 lb·ft)
IP AND DIAGNOSTIC CODE TABLE” on page
Align the slot “a” in the ISC unit holder with the 9-5..
9-5
projection “b” on the ISC unit “2”. • ISC valve
valve positi
position
on
Use the diagnostic code number “54”
1
2 9-5..
9-5
90890-03250
a
90890-03252
b
vehicle on the centerstand
centerstand so that
the rear wheel is elevated.
10.Install the throttle body to the vehicle.
5. Che
Check:
11.Reset:
• Engine
Engine idling
idling speed
speed
• ISC learni
learning
ng valves
valves
Use the diagnostic code number “67”. Start the engine, warm it up, and then mea-
sure the engine idling speed.
Refer to SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE” on page Engine idling speed
• 9-5.
9-5
ISC. valve
valve posit
position
ion
1500–1700 r/min
9-5..
9-5
7-14
THROTTLE BODY
EAS30980
INSTALLING THE THROTTLE BODY

1. Inst
Instal
alll:
• Throttl
Throttle e body
Throttle body bolt

T
.
R
.
10 N·m (1.0 kgf·m, 7.2 lb·ft)

IP
Align the projection “a” on the O-ring with the slot
“b” in the throttle body.
b a
7-15
ELECTRICAL SYSTEM
IGNITION SYSTEM .........................................................................................8-1

CIRCUIT DIAGRAM (GDR155).................................................................8-1
(GDR155) .................................................................8-1
CIRCUIT DIAGRAM (GDR155-A) .............................................................8-3
TROUBLESHOOTING ..............................................................................8-5
ELECTRIC STARTING SYSTEM ....................................................................8-7

CIRCUIT DIAGRAM (GDR155).................................................................8-7
(GDR155) .................................................................8-7
CIRCUIT DIAGRAM (GDR155-A) .............................................................8-9
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ........................8-11
TROUBLESHOOTING ............................................................................8-12
STOP AND START SYSTEM (GDR155-A)...................................................8-15

(GDR155-A)...................................................8-15
CIRCUIT DIAGRAM ................................................................................8-15
STOP AND START SYSTEM OPERATION ...........................................8-17
CHARGING SYSTEM....................................................................................8-21
SYSTEM ....................................................................................8-21
CIRCUIT DIAGRAM (GDR155)...............................................................8-21
(GDR155) ...............................................................8-21
CIRCUIT DIAGRAM (GDR155-A) ...........................................................8-23
LIGHTING SYSTEM ......................................................................................8-27

(GDR155) ...............................................................8-27
SIGNALING SYSTEM ...................................................................................8-33

(GDR155) ...............................................................8-33
FUEL INJECTION SYSTEM..........................................................................8-41

SYSTEM ..........................................................................8-41
(GDR155) ...............................................................8-41
SGCU SELF-DIAGNOSTIC FUNCTION .................................................8-45
TROUBLESHOOTING METHOD............................................................8-45
METHOD ............................................................8-45
YAMAHA DIAGNOSTIC TOOL ...............................................................8-46
TROUBLESHOOTING DETAILS ............................................................8-47 8
FUEL PUMP SYSTEM...................................................................................8-73
SYSTEM...................................................................................8-73
(GDR155) ...............................................................8-73
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)......................................8-79

(GDR155-A)......................................8-79
CIRCUIT DIAGRAM ................................................................................8-79
ABS COUPLER LOCATION CHART ......................................................8-81
MAINTENANCE OF THE ABS ECU .......................................................8-83
ABS TROUBLESHOOTING OUTLINE....................................................8-83
OUTLINE ....................................................8-83
BASIC INSTRUCTIONS FOR TROUBLESHOOTING ............................8-84
BASIC PROCESS FOR TROUBLESHOOTING .....................................8-85
[A] CHECKING THE ABS WARNING LIGHT ..........................................8-86
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON.............8-86 ON .............8-86
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON ..............................8-86
[A-3] THE ABS WARNING LIGHT COMES ON ......................................8-86
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE
(The select unit screen does not appear.) ..............................................8-87
[A-5] ABS ECU AND SGCU FAIL TO COMMUNICATE
(Cannot connect due to a tool error.)......................................................8-87
error.) ......................................................8-87
[B-1] MALFUNCTION ARE CURRENTLY DETECTED ..........................8-87
[B-2] DIAGNOSIS USING THE FAULT CODES .....................................8-87
[B-3] DELETING THE FAULT CODES..................................................8-102
CODES ..................................................8-102
[C-1] FINAL CHECK ..............................................................................8-102
SMART KEY SYSTEM (GDR155-A) ...........................................................8-105

CIRCUIT DIAGRAM ..............................................................................8-105
TROUBLESHOOTING ..........................................................................8-107
SMART KEY SYSTEM SELF-DIAGNOSIS ...........................................8-111
SMART KEY SYSTEM EMERGENCY MODE ......................................8-112
REGISTERING A SMART KEY.............................................................8-114
KEY .............................................................8-114
DISABLING A SMART KEY ..................................................................8-115
DISABLING THE POWER-ON ALARM.................................................8-117
ALARM .................................................8-117
REPLACEMENT PARTS LIST ..............................................................8-117
ELECTRICAL COMPONENTS....................................................................8-119
COMPONENTS....................................................................8-119
CHECKING THE SWITCHES ...............................................................8-120
CHECKING THE
CHECKING THE BULBS
FUSES AND BULB SOCKETS .................................8-123
......................................................................8-124
REPLACING THE SGCU (starter generator control unit)......................8-124
unit) ......................8-124
CHECKING AND CHARGING THE BATTERY .....................................8-124
CHECKING THE RELAYS ....................................................................8-128
CHECKING THE TURN SIGNAL RELAY .............................................8-128
CHECKING THE DIODE (GDR155-A) ..................................................8-129
CHECKING THE IGNITION SPARK GAP.............................................8-129
GAP .............................................8-129
CHECKING THE SPARK PLUG CAP ...................................................8-130
CHECKING THE IGNITION COIL .........................................................8-130
CHECKING THE STARTER GENERATOR ..........................................8-131
CHECKING THE FUEL SENDER .........................................................8-131
CHECKING THE COOLANT TEMPERATURE SENSOR.....................8-132
SENSOR .....................8-132
CHECKING THE FUEL INJECTOR ......................................................8-132
CHECKING THE VVA SOLENOID........................................................8-133
SOLENOID ........................................................8-133
CHECKING THE SMART KEY BATTERY (GDR155-A) .......................8-133
CHECKING THE BUZZER (GDR155-A) ...............................................8-133
CHECKING THE MAIN SWITCH SOLENOID (GDR155-A)..................8-134
(GDR155-A) ..................8-134

IGNITION SYSTEM
EAS20072
IGNITION SYSTEM
EAS30490
CIRCUIT DIAGRAM (GDR155)
R W
/
B
7 8
2 2
R ) 1 2 G )
y
B
Y (
/
B
3 3
W G
(
/
B
r Y
B O
/
B G
L B Y
r )
/
)
/ /
B B W h

R L B B
( C y
G
/ / /
W W W r G (

r B L
B )
/
Y
R L B B
( L
B
3
/
/ / /
) Y
W W W
0 3
/
B O
B Y
G B
r L (
3 4
3
/
/
y R L
6 G /
W Y
2 b
9
/
B
S ) B
G h R
L
W
B
2
/ /
O C Y

B
/
Y
/
(
G
Y
L
/
G P
Y
y
b
L B
R Y
B L P /
S
G G
/
r B
/
/ /
/ /
W
W W
W
B
R 5
3
/
B
B
B W W 5
3
/
R
O R
/ /
B
B W B B
r P
/
/

/ /
B L B
R Y
B L Y
y B Y L B R Y Y R
Y B B
L /
W
W W
W
r B
/
/
B
/ /
/ /
O P b
/
S
G G
/
O
/
B
h
G C /
Y
/
R Y
/
B B
/
B W
/
B
/
B W
r
R Y B
/
/
W
L
B B
/
/
O R
y /
G
R
W L B
/
L
B B /
/
/
W
Y ) 5
G Y B
B
( 2
L
/
/
W
h L
R
/ W
C
L
/
W y L /
B L
P G R W B R
L W W L Y R
W
R R r B Y L
/
G W y R

/
R L G

/
/
B
/
/
L
/ / / / /
G P B G

Y b R
S Y
/
G
L R
G W
/
R L
y
/
W /
R
R L W W L G
Y L
W
/
G
/
B r B Y L /

/ /
/ / P B

R R B W
/
G B R

B L
B
W B
3
/ /
Y R
R R
2 4 W
7 8 2 W
/
Y
1 1 0

2
W
/
R B B

)
L L 1
2 (
) 2
/
R /
B
B
Y
/
R
R
/
G
( 2
R )
y
/
B
(
9 G
G 1 W
r
/
B
W
W /
P )
R L B
( G W
Y g B
/
L D L
h Y
/
/
B C )

y
B G
(
Y
R B
r Y
/
B B /
Y
5
4
Y
4
g
4
D
Y 3
h
4
C
2
Y
/
B
4
Y
/
B
1
4
0
Y
4
/
B
Y
/
B
Y
/ W
B /
B
G L 9
r Y 3
/
B
R B
B r 8

6
B )
Y B
(
3
B
3
/
B
r Y
B B B /
B
r
B B
7
3
r
B B Y 2
B
5 L B
/
B
r
B L B
6
1 5
Y B B
L
5
/
) r L

B B L B B
( Y
Y )
L B
/
L
(
Y r
B )
4
3 5 L
B
Y
B B
(
r
B
5
R R )
Y R B
r
/ /
B
(
B g W h )
L
2 r r
D B C ( g
/ /
R B D

1 L
/
W
r
B
g g g
B
B
r D D D
/
B B
B g W h ) g
6
/
R L
r
D B C (
/
R D
r 6 5
R
r
/
B B
r
B
B 4
g
D h
R L
/
r r W W C
r B B r r
/ /
B B
/
Y r h h h h

B B C C C C B
H h
r
1 S C 7
r B
B r W 1 R
r /
5 L UP R 5
B
1 B
/
R W
7
r r 4
/
B
B B B B g
R R R
R r r r r P D
P
/ / /
r
B B B B
8
B B
,
W
0 S E
H E 5 B
U R
5 P
/
B
R B
r
R
/ F h
r C
B
,
W 9 B h g )
R
/
P B P B 5 D B

C (
B h g )

B
Y Y Y C D (
B Y B
L
/ /
B L L

/
Y
r W 9 I O
B L
/ B 4 H L Y
B
G /
B
) G Y Y
W B
L L
/ /
8 Y B

L
/
R
(
Y
B
/
B 4
H E Y
5 S E
U R )
N K
1 P F L Y L R
( B B
/
Y
E F C r
N P F O B L G G G G
O O O L r r R
r
B B Y
/
0
R r B F 6
0 Y B
Y
4 O
N F
1 O
/
R
1
/
R
W )
/ W / L R /
R 3 L Y R
G r
1 (
/
B G
R R
r ) 1 r
R
R
G B R
( r
B 6 B B
r
R r B B
B
r
B
r r r r r

R
/
W 9 B

r
B B
RR R R B
B B
B B R
R
/
W
R
/
W B
2 3 4 5 6 7 8
B B
B B
B B
B
B B B
R R
r R W 2
B r
6
/ /
B G
B B B
B B B
B B
B
B
B 3
6
R
1 B
R B
8-1
IGNITION SYSTEM
1. Battery
ery
2. Ma
Main
in fu
fuse
se
5. Ig
Igni
niti
tion
on fuse
fuse
10.Main switch
16.Sidestand switch
25.SGCU (starter generator control unit)
26.Crankshaft position sensor
27.Ignition coil
28.Spark plug
35.Engine ground 2
62.Frame ground
63.Engine ground 1

Yamaha Aerox155 Service Manual

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Yamaha Aerox155 Service Manual

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Available Formats

IMPORTANT MANUAL INFORMATION

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

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

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 par t with a new one.

BASIC SERVICE INFORMATION ...................................................................1-4

SPECIAL TOOLS ..........................................................................................1-10

VEHICLE IDENTIFICATION NUMBER

ENGINE SERIAL NUMBER

PREPARATION FOR REMOVAL AND

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS RUBBER PARTS

Do not spin the bearing with compressed air

BASIC SERVICE INFORMATION

BASIC SERVICE INFORMATION

BASIC SERVICE INFORMATION

When connecting the battery leads to the

Turn the main switch to “OFF” before dis-

BASIC SERVICE INFORMATION

NOTICE Checking the electrical system

BASIC SERVICE INFORMATION

When disconnecting a connector, do not pull

BASIC SERVICE INFORMATION

Coolant temperature sensor re-

BASIC SERVICE INFORMATION

• For U.S.A. and Canada, use part numbers starting

Yamaha diagnostic tool USB 3-7, 3-8

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

Steering nut wrench 3-14,, 3-15,

Thickness gauge 4-26

Fork seal driver weight 4-64,, 4-65

Fork seal driver attachment (ø30) 4-64,, 4-65

Compression gauge 90890-03081

Camshaft wrench 5-13,, 5-17

Yamaha bond No. 1215 5-16,, 5-55

Valve spring compressor 5-23,, 5-28

Valve spring compressor

Valve spring compressor attachment 5-23,, 5-28

Valve guide remover (ø5) 5-24

Valve guide installer (ø5) 5-24

Valve guide reamer (ø5) 5-24

Rotor holding tool 5-37, 5-42,

Rotor holding tool 5-37,, 5-41

Socket wrench (39 mm) 5-37,, 5-41

Sheave spring compressor 5-37,, 5-40

Oil seal guide (37 mm) 5-40

Flywheel puller 5-44

Digital circuit tester 5-51, 8-106,

Crankcase separating tool 5-53

Crankshaft installer bolt 5-54

Adapter (M12) 5-54

Spacer (crankshaft installer) 5-54

Radiator cap tester 6-3,, 6-3

Mechanical seal installer 6-8