B > é ANU Servi vice ManualYZF-RF SERVICE MANUAL, ©2015 by Yamaha Motor Corporation, U. First edition, January 2015 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. expressly prohibited.IMPORTANT This manual was produced by the Yamaha Motor Corporation, U.S.A. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in ‘one manual. 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 vehicle unsafe and unfit for use. ‘Yamaha Motor Corporation, U.S.A. is continually striving to improve all ofits 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 T1P Designs and specifications are subject to change without notice. IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations, ‘This is the safety alert symbol. Itis used to alert you to potential personal inju- ad ry hazards. Obey all safety messages that follow this symbol to avold possible injury or death. . ‘A WARNING indicates a hazardous situation which, if not avoided, could result PMI fin death or serious injury. ‘ANOTIGE indicates special precautions that must be taken to avoid damage to WoneH the vehicle or other property. TIP ‘ATIP provides key information to make procedures easier or clearer.HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive ‘explanations of al 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 titles "2” appear in smaller print than the section title. + To help identify parts and clarity procedure steps, there are exploded diagrams “3” at the start of each removal and disassembly section, + Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas- sembly step. + Symbols “5” indicate parts to be lubricated or replaced. Refer to “SYMBOLS”. “A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation and assembly procedure, reverse the steps. * Jobs "7 requiing mere Infomation (éuch a8 special tole and tecrical dat) are described sequen- tially. 1 zSYMBOLS The following symbols are used in this manual for easier understanding. TP. The following symbols are not relevant to every vehicle, ‘SYMBOL, DEFINITION ‘SYMBOL, DEFINITION x Serviceable with engine mounted 1 _@ 1 mo) 1 Gear oil a Filing fluid Molybdenum disulfide oi Lubricant Brake fluid Special tool Whee! bearing grease Tightening torque ESI | Lihium-soap-based grease Wear limit, clearance SEH | Motyoconum disuitide grease Engine speed =ESP4 | Silicone grease Electrical data Apply locking agent (LOCTITE®) Engine oil Replace the part with anew one, o> (A[S|YLINIL Silicone fluidTABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING OoooGENERAL INFORMATION IDENTIFICATION 1... es VEHICLE IDENTIFICATION NUMBER... 14 MODEL LABEL.. ennntnnsesee 14 FEATURES... ‘OUTLINE OF THE Fi SYSTEM. FISYSTEM. MULTI-FUNCTION METER UNIT..... IMPORTANT INFORMATION 2.00. PREPARATION FOR REMOVAL AND DISASSEMBLY... REPLACEMENT PARTS, GASKETS, OIL SEALS AND O-RINGS...... LOCK WASHERS/PLATES AND COTTER PINS... BEARINGS AND OIL SEALS... CIRCLIPS. RUBBER PARTS... BASIC SERVICE INFORMATION. QUICK FASTENERS....ccsntnnsestnnseen i ELECTRICAL SYSTEM 112 SPECIAL TOOLS...IDENTIFICATION IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicte identification number“ is stamped into the frame under the passenger seat MODEL LABEL ‘The model label “1” is affixed to the frame under the passenger seat. This information will be needed to order spare parts. 1-1FEATURES FEATURES OUTLINE OF THE FI SYSTEM ‘The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor. Despite the same volume of intake air, the fuel volume requirement varies by the engine operating con- sitions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the {uel through the use of jets have been provided with various auxiliary devices, so that an optimum air- fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the en- ine, A the requirements fr the engine to deliver more performance and cleaner exhaust gases increase, itbecomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accom modate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place ‘of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected by various sensors. ‘The adoption of the Fl system has resulted in a highly precise fuel supply, improved engine response, better fuel economy, and reduced exhaust emissions. 16 151413 12 1110 9 1. Engine trouble warning light 10.1SC (idle speed contro!) unit 2. Ignition coils 11. Throttle body sensor assembly 8. Air induction system solenoid 12.0 sensor 4, Coolant temperature sensor 13,Sidestand switch 5. Fuel pump 14.Crankshaft position sensor 6. Battery 18. Speed sensor 7. ECU (engine control unit) 16. Spark plugs 8. Lean angle sensor 9. Fuel injectors 1-2FEATURES FISYSTEM ‘The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the {uel pressure that is applied to the fuelinjector at a certain level. Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open. Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized (injection duration), the lesser the volume of fuel that is supplied. ‘The injection duration and the injection timing are controlled by the ECU. Signals that are input from the throttle position sensor, coolant temperature sensor, lean angle sensor, crankshaft position sensor, in- take air pressure sensor, intake air temperature sensor, speed sensor and O, sensor enable the ECU to determine the injection duration. The injection timing is determined through the signals from the ‘crankshaft position sensor. Asa result, the volume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions. 1. Fue! pump 18. Intake air temperature sensor 2. Fuslinjector 14. Thvottle position sensor 3. Ignition coil 1. Inlake air pressure sensor ‘4. ECU (engine control unit) 16. Air filter case 6. Lean ange sre A Fuel sje ' B. Air system 7. 1SC (idle speed contol unit - 8. Opsonsor 9. Coolant temperature sensor 10.Crankshatt position sensor 11. Throttle body 12. Throttle body sensor assembly 1-3FEATURES MULTI-FUNCTION METER UNIT 2 678 1. “SEL’ button 2. *RES" button 3. Tachometer 4, Fuel meter 5. Shift timing indicator light 6. Clock 7. Transmission gear display 8. Speedometer 9. Multifunction display 10.Coolant temperature meter PI Be sure to stop the vehicle before making any setting changes to the multi-function meter unit. Changing settings while riding can distract the operator and increase the risk of an accident. ‘The multi-function meter unit is equipped with the following: +a speedometer +a tachometer *aclock + a fuel meter + a coolant temperature meter ‘a transmission gear display +a multi-function display +a shift timing indicator light +a self-diagnosis device 1p Be sure to turn the key to “0.” before using the “SEL” and “RES” buttons, except for setting the shift timing indicator light control mode. Speedometer ‘The speedometer shows the vehicle's traveling speed. 1-4 1. Tachometer 2. Tachometer red zone The tachometer allows the rider to monitor the engine speed and keep it within the ideal power range. When the key is tured to “0”, the tachometer will sweep across the rmin range and then re- tur to zero r/min in order to test the electrical cir- cuit. NOTICE Do not operate the engine in the tachometer red zon Red zone 12500 r/min and above Clock 1. Clock The clock displays when the key is turned to Oo [To set the clock] 4, Turn the key to “ 2. Push the “SEL” button and “RES” button to- gether for at least two seconds. When the hour digits start flashing, push the “RES” button to set the hours. Push the “SEL” button, and the minute digits will start flashing. 5, Push the "RES" button to set the minutes. 3. 4.FEATURES 6. Push the “SEL” button and then release it to start the clock. Fuel meter 1. Fuol meter ‘The fuel meter indicates the amount of fuel in the fuel tank. ‘When the key is turned to“, the display seg- ments of the fuel meter will sweep once across the fuel level range and then return to the current ‘amount in order to test the electrical circuit. The display segments of the fuel meter disap- pear towards “E" (Empty) as the fuel level de- creases. When the last segment starts flashing, refuel as soon as possible. T1P This fuel meter is equipped with a self-diagnosis system. If a problem is detected in the electrical circuit, the following cycle is repeated until the malfunction is corrected: fuel level segments flash eight times, then go off for approximately three seconds. If this occurs, check the electrical circuit. Referto “SIGNALING SYSTEM" on page 821 Coolant temperature meter MW a) f 1. Coolant temperature meter ce ‘The coolant temperature meter indicates the temperature of the coolant. When the key is tured to “0”, the display seg- ments of the digital coolant temperature gauge will sweep once across the temperature range and then retum to °C” in order to test the electri- cal circuit. Ifthe last segment on the right flashes, stop the vehicle, then stop the engine, and let the engine cool. NOTICE Do not continue to operate the engine if itis overheati TP The coolant temperature varies with changes in the weather and engine load. Transmission gear display 1. Neutral indicator ight “N” 2. Transmission gear display This display shows the selected gear. The neu- tral position is indicated by “=" and by the neu- tral indicator light. Multi-function display 1 \ 1. Multi-function display The muitifunction display is equipped with the following + an odometer + two tripmeters + a fuel reserve tripmeter + an instantaneous fuel consumption display + an average fuel consumption display + an oil change tripmeter 1-5FEATURES ‘+ an oll change indicator Push the “SEL” button to switch the display be- tween the odometer mode “ODO", tripmeter modes “TRIP 1” and “TRIP 2", instantaneous fuel consumption mode “km/L", “L/100" or “MPG, average fuel consumption mode "AVE _kmi/L”, “AVE__._L/100 km, of “AVE_ -_MPG" and oil change tripmeter mode “OIL RIP" in the following order: ODO > TRIP 1 > TRIP 2 — kmv/L, L100 km or MPG > AVE__._km/L, AVE__._L/100 km or AVE__._MPG— OIL TRIP > ODO I the left segment of the fuel meter starts flash- ing, the display automatically changes to the fuel reserve tripmeter mode “TRIP F” and starts counting the distance traveled from that point. In that case, push the “SEL" button to switch the display between the various tripmeter, odome- ter, instantaneous fuel consumption and aver- age fuel consumption modes in the following order: TRIP F > km/L, L100 km, or MPG —> AVE__ _km/L, AVE__._U/100 km or AVE__. MPG. OIL TRIP > ODO > TRIP 1 > TRIP 2—> TRIP F To reset a tripmeter, select it by pushing the “SEL” button, and then push the “RES” button {or at least one second, H you do not reset the fuel reserve tripmeter manually, it resets itself automatically and the display returns to the prior mode after refueling and traveling 5 km (3 mi) Instantaneous fuel consumption display A kt) (98 wo 1. Instantaneous fuel consumption display ‘The instantaneous fuel consumption display can bbe set to either *km/L”, "L100 km” or *MPG", ‘+ °knv/L": The distance that can be traveled on 4.0 Lof fuel under the current riding conditions. is shown. *°L/100 km”: The amount of fuel necessary to travel 100 km under the current riding condi- tions is shown. IPG": The distance that can be traveled on 1.0 US Gallon of fuel under the current riding condition is shown To switch between the instantaneous fuel con- ‘sumption displays, push the “SEL” button for ‘one second. pe Iftraveling at speeds under 20 kmvh (12 mith), "_ _._" is displayed, Average fuel consumption display isa ioe 7 1. Average fuel consumption di The average fuel consumption display can be set to either “AVE__._km/L”, “AVE___L/100 km” or “AVE__._M This display shows the average fuel consump- tion since it was last reset. + "AVE__._kmIL”: The average distance that 1n be traveled on 1.0 L of fuel is shown, \VE___ L/100 km”: The average amount of fuel necessary to travel 100 km is shown. + "AVE___MPG": The average distance that ‘can be traveled on 1.0 US Gallon of fuel is shown. To switch between the average fuel consump- tion displays, push the “SEL” button for one sec- ond. To reset the average fuel consumption display, push the "RES" button for at least one second. me ‘ter resetting the average fuel consumption dis play, is shown until the vehicle has trav- led 1 km (0.6 mi), 1-6FEATURES Oil change tripmeter 1. Oil change indicator “OIL” 2. Oil change triometer ‘The oil change tripmeter shows the distance traveled since itwas last reset (ie., since the last oil change). The oil change indicator “OIL” will flash at the ini tial 1000 km (600 mi), then at 5000 km (3000 mi) and every 5000 km (8000 mi) thereafter to indi- cate that the engine oil should be changed After changing the engine oil, reset the oil change tripmeter and the oil change indicator. To reset them both, select the oil change tripme- ter, and then push the "RES" button for one sec- ‘ond. Then, while “OIL” and the oil change {ripmeter are flashing, push the "RES" button for three seconds, The oil change indicator will be reset. It the engine oil is changed before the oil change indicator comes on (.¢., before the periodic oil change interval has been reached), the oil change tripmeter must be reset for the next peri- ‘odie oil change to be indicated at the correct time. ‘Shift timing indicator light 41. Shift timing indicator light 2. Brightness level display ‘The shift timing indicator light has four settings which can be adjusted. + Flashing pattem: this function allows you to choose whether or not the indicator light will come on and whether it should flash or stay on when activated 1-7 + Activation point: this function allows you to se- lect the engine speed at which the indicator light is activated. + Deactivation point: this function allows you to select the engine speed at which the indicator light is deactivated. + Brightness: this function allows you to adjust. the brightness of the indicator light. [To adjust the shift 1. Tum the key to “ 2, Push and hold the “SEL” button, 3. Tum the key to "0", and then release the “SEL” button after five seconds, The shift tim- ing indicator light can now be adjusted. ing indicator light] [To set the flashing pattern] 1, Push the “RES” button to select one of the fol lowing flashing pattern settings: + On: the indicator light stays on when activat- ed. (This setting is selected when the indica- tor light stays on.) ‘+ Flash: the indicator ight flashes when activat- ed. (This setting is selected when the indica- tor light flashes four times per second.) + Off: the indicator light is deactivated; in other words, it does not come on or flash. (This set- ting is selected when the indicator light flash- es once every two seconds.) Push the “SEL button to confirm the selected flashing patter. The shift timing indicator light changes to the activation point setting mode. The tachometer will show the current setting r/min for the activation point and deactivation point setting modes. [To set the shift activation point] a The shift timing indicator light activation point can be set between 7000 r/min and 13000 rimin. From 7000 rfmin to 12000 r/min, the indicator light can be set in increments of 500 r/min. From 12000 rimin to 13000 r/min, the indicator light can be set in increments of 200 r/min 1, Push the “RES" button to select the desired engine speed for activating the indicator light. 2, Push the "SEL" button to confirm the selected engine speed. The control mode changes to the deactivation point setting mode.FEATURES [To set the deactivation point] m1 + The shift timing indicator light deactivation point can be set between 7000 rimin and 18000 rmin. From 7000 rmin to 12000 r/min, the indicator light can be set in increments of 500 r/min. From 12000 r/min to 18000 r/min, the indicator light can be set in inerements of 200 rimin. + Be sure to set the deactivation point toa higher engine speed than for the activation point, oth- erwise the shift timing indicator light will not come on. 1. Push the “RES” button to select the desired engine speed for deactivating the indicator light. 2. Push the “SEL” button to confirm the selected ‘engine speed. The control mode changes to the brightness setting mode. [To adjust the brightness] 1, Push the “RES” button to select the desired shift indicator light brightness level. Push the “SEL” button to confirm the selected brightness level. The display exits the shift timing light control mode and returns to the standard multi-function display mode. 2 Self-diagnosis device 1. Engine trouble warning light "23" 2. Fault code display This model is equipped with a self-diagnosis de- vice for various electrical circuits Ha problem is detected in any of those circuits, the engine trouble waming light will come on and the display will indicate a fault code. Hthe display indicates any fault codes, note the ‘code number, and then check the fuel injection system, Refer to “FUEL INJECTION SYSTEM" on page 8-33, NOTICE It the display indicates a fault code, the vehi- cle should be checked as soon as possible in order to avoid engine damage. 1-8IMPORTANT INFORMATION IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2, Use only the proper tools and cleaning equip- ment. Refer to “SPECIAL TOOLS" on page 1-17. 8. When disassembling, always keep 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. 4, During disassembly, clean all of the parts and place them in trays in the order of disassem- bly. This will speed up assembly and allow for the correct installation of all parts. 5. Keep all parts away from any source of fre. REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha forall lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfac- 8, oil seal lips and O-rings must be cleaned. 2. During reassembly, property ol all mating parts and bearings and lubricate the oil seal lips with grease. _ Ii a, 2 if \—3 1 {i 4 1. o# 2. Up 3. Spring 4. Grease LOCK WASHERSIPLATES AND COTTER PINS Ater removal, replace all lock washers/plates 1" and cotter pins. After the boltor nut has been tightened to specification, bend the lock tabs along a fat ofthe bolt or nutIMPORTANT INFORMATION BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer marks or numbers are visible. ‘When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate. NOTICE Do not spin the bearing with compressed air because this will damage the bearing surfac- es. 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 “", make sure the sharp-edged comer “2” is positioned opposite the thrust “3" that the circlip receives. 1-10 RUBBER PARTS ‘Check rubber parts for deterioration during in- spection. Some of the rubber parts are sensitive to gasoline, flammable oil, grease, etc. Do not al- low any items other than the specified one to contact the parts.BASIC SERVICE INFORMATION BASIC SERVICE INFORMATION ‘QUICK FASTENERS , — Rivet type 1. Remove: * Quick fastener . 1. To remove the quick fastener, pushits pin with a screwdriver, then pull the fastener out. ‘Screw type 1. Remove: * Quick fastener 1p To remove the quick fastener, loosen the screw ~ with a screwdriver, then pull the fastener out. 6 =&. 2. Install: a XO r= qe To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastenerintothe parttobe secured and push > Ingta the pin in with a screwdriver. Make sure that the + Quick fastener pin is flush with the fastener’s head i To install the quick fastener, insert the fastener into the part to be secured and tighten the screw. *¥3 - &)s _ 1-11BASIC SERVICE INFORMATION ELECTRICAL SYSTEM Electrical parts handling NOTICE Never disconnect a battery lead while the en- gine is running; otherwise, the electrical ‘components could be damaged. ;connecting the battery leads from , be sure to disconnect the nega- tive battery lead first, then the positive bat- tery lead. If the positive battery lead is disconnected first and a tool or similar item contacts the vehicle, a spark could be gener- ated, which is extremely dangerous. TP Ha battery lead is difficult to disconnect due to rust on the battery terminal, remove the rust us- ing hot water. NOTICE Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- tery lead connections could damage the electrical components. NOTICE ‘When connecting the battery leads to tt battery, be sure to connect the positive bat- tery lead first, then the negative battery lead. If the negative battery lead is connected first and a tool or similar item contacts the vehi- cle while the positive battery lead is being connected, a spark could be generated, which is extremely dangerous. NOTICE. Turn the main switch to “OFF” before dis- connecting or connecting an electrical com- ponent. 1-12BASIC SERVICE INFORMATION NOTICE Handle electrical components with special car and do not subject them to strong Checking the electrical system me Before checking the electrical system, make shocks. sure that the battery voltage is at least 12 V. NOTICE NOTICE Electrical components are very sensitive to and can be damaged by static electricity. Therefore, never touch the terminals and be sure to keep the contacts clean. Never insert the tester probes into the cou- pler terminal slots. Always insert the probes from the opposite end “a” of the coupler, tak- ing care not to loosen or damage the leads. 11 ‘When resetting the ECU by turing the main switch to “OFF”, be sure to wait approximately 5 seconds before turing the main switch back to pred For waterproof couplers, never insert the tester probes directly into the coupler. When performing any checks using a waterproof ‘coupler, use the specified test harness or a suitable commercially available test har- ness. 1-13BASIC SERVICE INFORMATION ‘Checking the connections ‘Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: Lead = Coupler = Connector Nore + When disconnecting a coupler, release the coupler lock, hold both sections of the cou- pler securely, and then disconnect the cou- pler. + There are many types of coupler locks; therefore, be sure to check the type of cou- pler lock before disconnecting the coupler. NOTICE ‘When disconnecting a connector, do not pull the leads. Hold both sections of the conneo- tor securely, and then disconnect the con- nector. 2. Check: ‘Lead Coupler Connector Moisture — Dry with an air blower. Rust/stains > Connect and disconnect sev- eral times. 8. Check: All connections Loose connection -> Connect propery. 1? + Ifthe pin “1” on the terminalis flattened, bend itup. + After disassembling and assembling a coupler, pull on the leads to make sure that they are in- stalled securely. 1-14BASIC SERVICE INFORMATION 4, Connect: Lead + Coupler = Connector TP + When connecting a coupler or connector, push both sections of the coupler or connector to- gether until they are connected securely. + Make sure all connections are tight + As a quick remedy, use a contact revitalizer available at most part stores. 6. Check: + Resistance Ua Pocket tester 90890-03112 Analog pocket tester YU-03112-C TIP °C (68 °F), ‘The resistance values shown were obtained at the standard measuring temperature of 20 °C (68 °F). I the measuring temperature is not 20 |, the specified measuring conditions will be shown. 5. Check: * Continuity (with the pocket tester) Z| Pocket tester 90890-03132 m1 + If there is no continuity, clean the terminals. + When checking the wire hamess, perform steps (1) to (4) ill Coolant temperature sensor re- sistance 210-221 0 at 100 °C (210-221 2 at 212 °F) 1-15BASIC SERVICE INFORMATION 1-16SPECIAL TOOLS 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, TIP + For U.S.A. and Canada, use part number starting with "YM-", “YU-', or “ACC~”, + For others, use part number starting with “90890-”. Tool name/To0! No. tustration Fefrence Pocket tester 1s 90890-08132 Pocket ster Tis, 805,584, 90890-08112 < 8.85, 885, 8-60, Analog pocket tester | 8-90, 8-91, 8-91, yUost 2c 8.02, 899, 8.0, 3 6-00, 895, 6-25, 8.06, 8978.07 8.98 Thickness gauge 35,36 555 20890-03180 Fooler gauge sot vu-2sd0o8 Valve apper or 36 90890-04101 — Vale lapping tot in Yu-aeaes cae soos soo Yamaha diagnostic tool US) 38,744, 774, 90800-05234 2.36 1-17SPECIAL TOOLS Tool namefToo! No. lustration Reference pages Vacuum gauge 30890-03094 Vacuummate Yu-44456 0800-09004 yusssiss, 38 Carburetor angle driver 2 90890-03173 ‘Steering nut wrench 90890-01403 Exhaust flange nut wrench ‘YU-A9472 319, 478 Oilfter wrench 90890-01426 Oilfiter wrench YU-38411 3:22, 675 Damper rod holder 90890-01460 470, 472 Thandie 90890-01326 ‘handle 3/8" drive 60 em long YM-01326 470, 472 Fork seal driver weight 90890-01367 Replacement hammer YM-A9409-7 YMeAR400-77YMAS 142-4 475, 478, 473 1-18SPECIAL TOOLS Tool namefToo! No. lustration Reference pages Fork seal driver attachment (041) 90890-01381 Replacement 41 mm YM-AS142-2 473, 478 Extension 90890-04196 ot ‘Compression gauge 90890-03081 Engine compression tester Yu-33223, yu-ase23 ST Rotor holding too! 90890-01235, Universal magneto and rotor holder YU-01235 516, 618 Valve spring compressor 90890-04019 Valve spring compressor YM-04018 5-29, 5-34 Valve spring compressor attachment 90890-04108 Valve spring compressor adapter 22 mm YM-04108 5:20, 634 Valve guide remover (64.5) 90890-04116 Valve guide remover (4.5 mm) YM-04416 Valve guide installer (04.5) 90890-04117 Valve guide installer (4.5 mm) YM-04117 Sa BtSPECIAL TOOLS Tool namefToo! No. lustration Reference pages Valve guide reamer (e4.5) 90890-04118 Valve guide reamer (4.5 mm) M041 18 Sat Piston pin puller set 90890-01304 Piston pin puller YU-01304 Yuo1s04 537 Rotor holding tool 90890-04166 YM-04166 5d, 5-44, 5-45, 5-46 Flywheel puller ‘90890-01404 Flywheel puller YM-01404 Baa Yamaha bond No. 1215 90890-85505 (Three bond No.1215@) 5-46, 5:76, 5-77 Digital circuit tester 90890-03174 Model 88 Multimeter with tachometer YU-A1927 5-40, 8-04 Universal clutch holder 90890-04086 Universal clutch holder YM-91042 ym.ar082 554, 657 1-20SPECIAL TOOLS Tool namefToo! No. lustration Reference pages Radiator cap tester 90890-01925 Mityvac cooling system tester kit YU-24460-A 90880-01525 Yu-2s46-k 63 Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984 63 Mechanical seal installer 90890-04145 610 Middle driven shaft bearing driver 90890-04058 Middle drive bearing installer 40 & 50 mm. ‘YM-04058 Pressure gauge 90890-03153 Pressure gauge YU-03153) TAB, TAS Fuel injector pressure adapter 90890-03210 Fuel injector pressure adapter YU-08210 TAR Fuel pressure adapter ‘90890-03176 Fuel pressure adapter YM-03176 1-21SPECIAL TOOLS Tool namefToo! No. lustration Reference pages Ignition checker 30890-06754 Oppama pet-4000 spark checker ‘YM-34487 B92 TTest hamess- lean angle sensor (6P) 90890-03209 Test hares lean angle sensor (6P) YU-03209 893 TTest hamess S- pressure sensor (9P) 90890-03207 ‘Test hamess S~ pressure sensor (3P) YU-03207 8-95 1-22SPECIAL TOOLS 1-23SPECIFICATIONS GENERAL SPECIFICATIONS .... ENGINE SPECIFICATIONS CHASSIS SPECIFICATIONS ELECTRICAL SPECIFICATIONS TIGHTENING TORQUES GENERAL TIGHTENING TORQUE SPECIFICATIONS. ENGINE TIGHTENING TORQUES. CHASSIS TIGHTENING TORQUES. LUBRICATION POINTS AND LUBRICANT TYPES, ENGINE. LUBRICATION SYSTEM CHART AND DIAGRAMS... ENGINE OIL LUBRICATION CHART LUBRICATION DIAGRAMS. COOLING SYSTEM DIAGRAMS CABLE ROUTING... 27 2-40 242 242 2.43 2418 2-22 2-22 2:25 2:25 2.27 244 2-43GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Model Dimensions ‘Overall length ‘Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius 2Ms1 2090 mm (82.3 in) 720 mm (28.3 in) 1135 mm (44.7 in) 780 mm (30.7 in) 4380 mm (54.3 in) 160 mm (6.30 in) 2700 mm (106.3 in) Weight ‘Curb weight Maximum load 2-1 167 kg (368 Ib) 160 kg (353 Ib)ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 321 om? Cylinder arrangement Inline 2-oylinder Bore x stroke 68.0 x 44,1 mm (2.68 x 1.74 in) ‘Compression ratio Standard compression pressure (at sea level) Minimum-maximum Starting system 12:4 1440 kP.a/390 rimin (14.4 kgl/em®/390 r/min, 204.8 psi‘390 r/min) 41250-1610 kPa/390 r/min (12.5-16.1 kgt/om#/390 rimin, 177.8-228.0 psi/390 r/min) Electric starter Fuel Recommended fuel Fuel tank capacity Fuel reserve amount Regular unleaded gasoline (Gasohol (E10) acceptable) 14.0 (3.70 US gal, 3.08 Imp.gal) 3.0 L (0.79 US gal, 0.66 Imp.gal) Engine oil Lubrication system Recommended brand Type Recommended engine oll grade Engine oil quantity Quantity (disassembled) Without oil fier cartridge replacement With oil iter cartridge replacement Oil pressure Wet sump YAMALUBE SAE 10W-30, 10W-40, 10W-50, 15W-40, 20W- 40 or 20W-50 API service SG type or higher, JASO standard MA 2.40 L (2.54 US qt, 2.11 Imp.qt) 1.80 L (1.90 US qt, 1.58 Imp.qt) 2.10 L (2.22 US qt. 1.85 Imp.qt) 206.0 kPa/5000 r/min at 130 °C (29.9 psi/5000 timin at 266 °F) Oil filter Oil fiter type Cartridge Oil pump il pump type Trochoid Inner-rotor-to-outer-rotor-tp clearance Limit uter-rotor-to-oll-pump-housing clearance Limit it pump-housing-to-inner-and-outer-rotor clearance Limit Bypass valve opening pressure Relief valve operating pressure (0.060-0.120 mm (0.0024-0.0047 in) 0.20 mm (0.0079 in) 0.09-0.17 mm (0,0035-0.0067 in) 0.24 mm (0.0094 in) 0.05~0.09 mm (0.0020-0.0037 in) 0.170 mm (0.0067 in) £80.0-120.0 kPa (0.80-1.20 kgllem, 11.6-17.4 psi) 650.0-770.0 kPa (6.50-7.70 kgt/om2, 94.3~ 111.7 psi) 2-2ENGINE SPECIFICATIONS Cooling system Radiator (including all routes) Coolant reservoir (up to the maximum level mark) Radiator cap opening pressure Thermostat ‘Valve opening temperature Valve full open temperature Valve lift (ull open) 0.96 L (1.01 US qt, 0.84 Imp.qt) 0.25 L (0.26 US qt, 0.22 Imp.at) 108.0-137.4 kPa (1.08-1.37 kaffem?, 15.7-19.9 psi) 80,5-89.5 °C (176.90-182.80 °F) 95.0 °C (203,00 °F) 3.0 mm (0.12 in) Radiator core Width 145.8 mm (6.74 in) Height 270.0 mm (10.63 in) Depth 24.0 mm (0.94 in) Water pump Water pump type Single suction centrifugal pump Reduction ratio 41/28 (1,783) Spark plug(s) Manufacturer/model NGKICR8E Spark plug gap 0.7-0.8 mm (0.028-0.031 in) Cylinder head ‘Combustion chamber volume 10.80-11.60 om? (0.66-0.71 cu.in) Warpage limit 0.05 mm (0.0020 in) ‘Camshaft Drive system Chain drive (right) ‘Camshaft cap inside diameter Camshaft joumal diameter ‘Camshaft-joural-to-camshaft-cap clearance Camshaft lobe dimensions Lobe height (Intake) Limit Base circle diameter (Intake) Limit Lobe height (Exhaust) Limit Base circle diameter (Exhaust) Limit Camshaft runout limit 22,500-22.521 mm (0.8858-0.8867 in) 22.459-22.472 mm (0.8842-0.8847 in) 0.028-0.062 mm (0.0011-0.0024 in) 32,650-32,750 mm (1.2854—1.2894 in) 32.550 mm (1.2815 in) 24.972-25.072 mm (0,9831-0.9871 in) 24.872 mm (0.9792 in) 30.750-30.850 mm (1.2106-1.2146 in) 30.650 mm (1.2067 in) 25.027-25.127 mm (0,9853-0.9893 in) 24.927 mm (0.9814 in) 0.030 mm (0.0012 in) Valve, valve seat, valve guide Valve clearance (cold) Intake Exhaust Valve dimensions Valve head diameter (intake) Valve head diameter (exhaust) Valve seat contact width (intake) Valve seat contact width (exhaust) Valve stem diameter (intake) Limit 2-3 0.11-0.18 mm (0.0043-0.0071 in) 0.21-0.90 mm (0.0083-0.0118 in) 25,90-26.10 mm (1.0197-1.0276 in) 22.40-22.60 mm (0.8819-0.8898 in) 0.90-1.20 mm (0,0354-0.0472 in) 0.90-1.20 mm (0,0354~0.0472 in) 4.475~4.490 mm (0.1762-0.1768 in) 4.445 mm (0.1750 in)ENGINE SPECIFICATIONS Valve stem diameter (exhaust) Limit Valve guide inside diameter (Intake) Limit Valve guide inside diameter (exhaust) Limit Valve-stem-to-valve-quide clearance (intake) Limit Valve-stem-to-valve-guide clearance (exhaust) Limit Valve stem runout Valve spring Free length (intake) Limit Free length (exhaust) Limit Installed length (intake) Installed length (exhaust) Spring rate Kt (intake) Spring rate K2 (intake) Spring rate K1 (exhaust) Spring rate K2 (exhaust) Installed compression spring force (intake) Installed compression spring force (exhaust) Spring tl (intake) ‘Spring tit (exhaust) Winding direction (intake) Winding direction (exhaust) 4.460-4.475 mm (0.1756-0.1762 in) 4.430 mm (0.1744 in) 4.500-4.512 mm (0.1772-0.1776 in) 4.550 mm (0.1791 in) 4.500-4.512 mm (0.1772-0.1776 in) 4.550 mm (0.1791 in) 0.010-0.037 mm (0.0004-0.0015 in) 0.080 mm (0.0032 in) 0.025-0.052 mm (0.0010-0.0020 in) 0.100 mm (0.0039 in) 0.010 mm (0.0004 in) 38.21 mm (1.50 in) 36.30 mmn (1.43 in) 38.21 mm (1.50 in) 36.30 mm (1.43 in) 32.00 mm (1.26 in) 32.00 mmn (1.26 in) 27.64 Nimm (2.82 kgf/mm, 157.82 Ibf/in) 98.73 Nimm (3.95 kgf/mm, 221.15 Ibn) 27.64 Nimm (2.82 kgf/mm, 157.82 Ibf/in) 98.73 Nimm (3.95 kgf/mm, 221.15 Ibn) 159.60-183.60 N (16.27-18.72 kgf, 35.88— 41.27 Ibf) 159,60-183,60 N (16.27-18.72 kgf, 35.88— 41.27 Ibf) 4.7 mm (0.07 in) 4.7 mm (0.07 in) Clockwise Clockwise Cylinder Bore Taper limit Out of round limit 68.000-68.010 mm (2.6772-2.6776 in) (0,050 mm (0.0020 in) 0.050 mm (0.0020 in) Piston Piston-to-oylinder clearance Diameter Measuring point (from piston skirt bottom) Offset Oftset direction Piston pin bore inside diameter Limit Piston pin outside diameter Limit Piston-pin-to-piston-pin-bore clearance 0,015-0.048 mm (0,0006-0.0019 in) 67.962-67.985 mm (2.6757-2.6766 in) 7.0 mm (0.28 in) 0.25 mm (0.0098 in) Intake side 15,002-15.013 mm (0.5906-0.5911 in) 1.043 mm (0.5922 in) 414.995-15.000 mm (0.5904~0.5906 in) 14.975 mm (0.5896 in) 0,002-0.018 mm (0.0001-0.0007 in) Piston ring Top ring Ring type End gap (installed) 2-4 Barrel 0.15-0.25 mm (0.0059-0.0098 in)ENGINE SPECIFICATIONS Limit Ring side clearance Limit 2nd ring Ring type End gap (installed) Limit 1g side clearance Limit Oilring End gap (installed) Connecting rod 0.50 mm (0.0197 in) 0,030-0.065 mm (0.0012-0.0026 in) 0.115 mm (0.0045 in) Taper 0.30-0.50 mm (0.0118-0.0197 in) 0.85 mm (0.0835 in) 0,020-0.055 mm (0.0008-0.0022 in) 0.11 mm (0.0045 in) 0,10-0.35 mm (0.0039-0.0138 in) Oil clearance 0.036-0.060 mm (0.0014-0.0024 in) Bearing color code 1, Blue 2. Black 3. Brown 4, Green Crankshaft Runout limit 0.030 mm (0.0012 in) Journal oil clearance 0.021-0.045 mm (0.0008-0.0018 in) Bearing color code 1.Blue 2.Black 3.Brown 4.Green 5.Yellow Balancer Balancer shaft journal to balancer shaft bearing clearance Bearing color code 0.021-0.045 mm (0.0008-0.0018 in) 1. Blue 2. Black 3. Brown 4, Green 5. Yellow Clutch Clutch type Clutch release method Clutch lever free play Friction plate thickness Wear limit Plate quantity Clutch plate thickness Plate quantity Warpage limit Clutch spring free length Limit Spring quantity Wet, muttiple-ise ‘Outer pull, rack and pinion pull 10.0-15.0 mm (0.39-0.59 in) 2.92-3.08 mm (0.115-0.121 in) 2.82 mm (0.111 in) 7 pes 1.50-1.70 mm (0.059-0.067 in) 6 pes 0.10 mm (0.004 in) 49.80 mm (1.96 in) 47.30 mm (1.86 in) 4 pes Transmission Transmission type Primary reduction ratio Final drive ‘Secondary reduction ratio Operation Gear ratio 1st 2nd 3rd ath sth eth 2-5 Constant mesh 6-speed 3.043 (70/23) Chain 3.071 (43/14) Left foot operation 2.500 (35/14) 1.824 (31/17) 1.348 (31/23) 1.087 (25/23) 0.920 (23/25) 0.800 (24/30)ENGINE SPECIFICATIONS Main axle runout limit Drive axle runout limit 0.06 mm (0.0024 in) 0,06 mm (0.0024 in) Shifting mechanism fork quide bar bending limit 0.050 mm (0.0020 in) Shift fork thickness 5.76-5.89 mm (0,2268-0.2319 in) Air filter Air fiter element Oi-coated paper element Fuel pump Pump type Electrical Maximum consumption amperage 1A Fuel injector ModeVquantity 297500-237072 Throttle body Type/quantity S2EHDW-2 1D mark 2MS1 00 Throttle position sensor Output voltage (at idle) 0.63-0.73 V Fuel injection sensor Crankshaft position sensor resistance 192-288 2 Intake air pressure sensor output voltage Intake air temperature sensor resistance Coolant temperature sensor resistance Coolant temperature sensor resistance 3.88-4.12 V at 101.3 kPa (8.88-4.12 V at 1.01 kgtfom®, 3.88-4.12 V at 147 psi) 5700-6300 © at 0 °C (5700-6300 © at 32°F) 2518-2777 Q at 20°C (2513-2777 Qat 68 °F) 210-221 © at 100 °C (210-221 Oat 212 °F) idling condition Fuel line pressure at idling Engine idling speed Intake vacuum Water temperature Throttle grip free play 220-300 kPa (2.2-3.0 kgt/cm?, 31.9-43.5 psi) 4300-1500 r/min 52.0-58.0 kPa (390-435 mmHg, 15.4-17.1 inHg) '95,0-105.0 °C (203,00-221.00 °F) 3.0-5.0 mm (0.12-0.20 in)CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 25.00" Trail 95 mm (3.7 in) Front wheel Wheel type Cast wheel Rim size 47MIC x MT2.75 Rim material Aluminum Wheel travel 130 mm (5.1 in) Radial wheel runout limit 4.0. mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) Rear wheel Wheel type Cast wheel Rim size 47MIC x MT4.00 Rim material Aluminum Wheel travel 125 mm (4.9 in) Radial wheel runout limit Lateral wheel runout limit 4.0 mm (0.04 in) 0.5 mm (0.02 in) Front tire Type Size Manufacturer/model Wear limit (front) Rear tire Type Size Manufacturer/model Wear limit (rear) Tubeless, 110/70-17MIC (54H) MICHELIN/PILOT STREET 1.0 mm (0.04 in) Tubeless 140/70-17M/C (66H) MICHELIN/PILOT STREET 1.0 mm (0.04 in) Tire air pressure (measured on cold tires) Loading condition Front (1 person) Rear (1 person) Loading condition Front (2 persons) Rear (2 persons) Maximum load (0-90 kg (0-198 Ib) 200 kPa (2.00 kgt/om:, 29 psi) 250 kPa (2.50 katiem?, 36 psi) 90-160 kg (198-353 Ib) 200 kPa (2.00 kat/em?, 29 psi) 250 kPa (2.50 kat/om:, 36 psi) 160 kg (353 Ib) Front brake Type Operation Front disc brake Disc outside diameter x thickness Brake disc thickness limit Brake disc runout limit (as measured on wheel) Brake pad lining thickness (inner) 2-7 Single disc brake Right hand operation 298.0 x 4.5 mm (11.73 x 0.18 in) 4.0 mm (0.16 in) 0.15 mm (0.0059 in) 5.3 mm (0.21 in)CHASSIS SPECIFICATIONS Limit Brake pad lining thickness (outer) Limit Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Specified brake fluid Rear brake Type ‘Operation Rear disc brake Disc outside diameter x thickness Brake disc thickness limit Brake disc runout limit (as measured on wheel) Brake pad lining thickness (inner) Limit Brake pad lining thickness (outer) Limit Master cylinder inside diameter Caliper oylinder inside diameter 0.8 mm (0.03 in) 5.3 mm (0.21 in) 0.8 mm (0.03 in) 11.00 mm (0.43 in) 26.99 mm (1.06 in) 26.99 mm (1.06 in) DOT 4 Single disc brake Right foot operation 220.0 x 4.5 mm (8.66 x 0.18 in) 4.0 mm (0.16 in) 0.15 mm (0.0059 in) 7.7 mm (0.30 in) 0.8 mm (0.03 in) 7.7 mm (0.30 in) 0.8 mm (0.03 in) 12.7 mm (0.50 in) 33.34 mm (1.31 in) Specified brake fluid DoT 4 Steering Steering bearing type Angular bearing Center to lock angle (left) 34.0° Center o lock angle (right) 34.0° Front suspension Type Telescopic fork Spring/shock absorber type Coil spring/oil damper Front fork travel Fork spring free length Limit Collar length Spring rate K1 Spring stroke K1 Inner tube outer diameter Inner tube bending limit Recommended oil Quantity Level 130.0 mm (6.12 in) 297.8 mm (11.72 in) 294.4 mm (11.59 in) 229.0 mm (8.02 in) 6.45 Nimm (0.66 kg/mm, 36.83 Ibt/in) 0.0-130.0 mm (0,00-5.12 in) 41.0 mm (1.61 in) 0.2 mm (0.01 in) Fork oil 10W or equivalent 487.0 cm? (16.47 US 02, 17.18 Imp.0z) 421.0 mm (4.76 in) Rear suspension Type Spring/shock absorber type Rear shock absorber assembly travel Spring installed length Spring rate K1 Spring stroke K1 ‘Spring preload adjusting positions Minimum Standard 2-8 ‘Swingarm Coil spring/oil damper 45.0 mm (1.77 in) 157.0 mm (6.18 in) 161.60 N/mm (16.48 kgtimm, $22.74 Ibtfin) 0,045.0 mm (0,00-1.77 in) 1 3CHASSIS SPECIFICATIONS Maximum, 7 Drive chain Size/manufacturer S20VF/DAIDO Number of links. 112 1¢link length limit Drive chain slack 2-9 239.3 mm (9.42 in) 35,0~45.0 mm (1.38-1.77 in)ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Voltage ‘System vottage 12v Ignition system Ignition system Tel Ignition timing (B.T.0.C.) Engine control unit Modelimanufacturer 5.0°/1400 rimin TBDFQS/DENSO Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) Primary coil resistance 2.16-2.64.0 Secondary coil resistance 8.64-12.96 ko Lean angle sensor output voltage Less than 45° O44 More than 45° 37-44 ‘AC magneto Standard output 14.0 V, 298 W at 5000 r/min Stator coil resistance 0.216-0.324 0 (W-W) Rectifier/regulator Regulator type Semi conductor-short circuit Regulated voltage (DC) 141-149 V Rectifier capacity 35.0A Battery Mode! GTzev Voltage, capacity 12V, 7.0Ah Specific gravity 1.350 Manufacturer Gs Ten hour rate charging current 0.70 Headlight Bulb type Halogen bulb Bulb voltage, wattage x quantity Headlight 12 V, 55.0Wx2 ‘Auxiliary light 12V,5.0Wx1 Taiiforake light LeD Front turn signal/position light 12V, 21.0 WI5.0W x2 Rear turn signal light 12V, 21.0Wx2 License plate light 12V,5.0Wx1 Meter lighting LED Indicator light Neutral indicator ight LED Tum signal indicator light LED 2-10ELECTRICAL SPECIFICATIONS Oil pressure warming light LED High beam indicator light LED Engine trouble warning light LED Starter motor Power output 0.40 kW Armature coil resistance Brush overall length Limit Brush spring force Mica undercut (depth) 0.0630-0.0770.9 7.0 mm (0.28 in) 8,00 mm (0.12 in) 6.08-9.12 N (620-930 gf, 21.89-32.83 oz) 1.50 mm (0.06 in) Starter relay ‘Amperage 150.0 Coil resistance 3.06-3.74.2 Horn Hom type Plane Quantity 1 Maximum amperage 35A Turn signal relay Built-in, self-canceling device No Fuel sender ut ‘Sender unit resistance (ful) 100-1400 ‘Sender unit resistance (empty) 267.0-2738.0.2 Fuses Main fuse 30.0 A Headlight fuse 150A Signaling system fuse 15.0 Ignition fuse 150A Radiator fan motor fuse 75A Backup fuse 75A Spare fuse 30.0 Spare fuse 15.0A Spare fuse 75A 2-11TIGHTENING TORQUES TIGHTENING TORQUES 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 multfastener assemblies in a crisscross pat- tem and progressive stages unti the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications re- ‘quire clean, dry threads. Components should be at room temperature. A. Distance between flats B. Outside thread diameter General tightening torques, A (out) | B (bolt) Nm | mkgf | ftlbt 1omm | 6mm | 6 06 | 43 2mm | @mm | 18 | 18 | if 4mm | 10mm | 30 | 30 | 22 7mm | 2mm | 88 | 58 | 40 Tomm | témm| 88 | 85 | ot amm | temm | 130 | 180 | 94 2412TIGHTENING TORQUES ENGINE TIGHTENING TORQUES tem Thread | gy Tightening torque Remarks Air fiter case joint lamp serew us | 2 25 Nm (0.28 mkgf, 18 Wibt) Tirfiter case bot me [2 TN (0-7 mag, 5.1 FIBA, Air fiter case side cover screw (eh) | MB |S 2S Nm (0.35 m-kgf, 1.8 fbf) Airfiter case side cover sorew (ight)| MB | 8 | 1.9Nm/(0.13 mkgf, 0.94 Rb) Spark plug mio | 2 131Nm (1.3 mgt 84 PBA) Op sensor m2 | 4 25 Nm (2.5 maf, 18 ful) Muffler protector (outer) me ft Nm (0.8 mgt, 68 Rib) a Muffler protector (inner) we | 2 Nm (08 mkgl, 5.8 Tbh) =a Exhaust pipe protector bracket bot | MB | 2 TO Nm (1.0 mvkgf, 7.2 fbf) “a Exhaust pipe nut wef 4 45Nm (1.5 mkgh, 17 FbH) Exhaust pipe bolt Me [1 20 Nim (2.0 mk, 14 fbi) Muffler assembly bolt weft 20 Nim (2.0 m kof, 14 fb") Exhaust pipe joint bolt me [1 20 Nim (2.0 m kgf, 14 bi) Exhaust pipe protector bolt ue | 3 Nm (0.8 mgt, 68 Rib) a Engine ground lead bot uefa TONey (1.0 mekgh, 72 Rb) ‘Camshaft cap bolt me | 12 TO Nm (1.0 mgt, 7.2 Roh) —@ ‘Camshaft sprocket bolt wf 4 2O Nim (2.0 mk, 14 Wi) Timing chain tensioner bolt ue | 2 TO Nm (1.0 mkgh, 72 iby) Timing chain tensioner cap bolt ue [ 1 7 Nim (0.7 kg, 5.1 RBA) Timing mark accessing bolt weft TO Nev (1.0 mgt, 7.2 bt) Grankshaft end cover wae [ 1 2.0 Nm (0.20 mkgh, 14 Febf) Gylinder head cover bolt wef 4 TO Nm (1.0 mgt, 72 Roh) Coolant temperature sensor mio [1 17 Nm (1.7 mkof 12 fbf) Timing han bo (gH OTA | ys | akin (berks PN) Engine oil check bolt wef 4 78 Nm (1.8 mkgf, 17 fib Cylinder head bolt mio | 6 See TIP om Gylinderhead bat wef 2 See TIP Cylinder head biind plug m2 | 2 28 Nm (2.8 m kgf, 20 bi) “a ‘Starter olutch bolt M6 3 14.Nm (1.4 m-kgf, 10 ftlbf) -a Generator rotor bolt mio | 1 {60 Nm (6.0 m kgf, 43 fbi) <4 Generator cover bolt wef 9 TON (1.0 moh, 72 Roh) ‘Stator col bolt ue | 3 TO Nm (1.0 mkgh, 7.2 Rb) -a Crankshaft position sensor bot Me | 2 7 Nm (0.7 mg, 6.1 FDA) -a Siarier moior lead sorew ws ft 3.5 Nm (0:35 mkgh, 25 fbi) Siarter motor bolt me | 2 TONm (1.0 mvkof, 7.2 fbf) Starter motor front cover bolt maf 2 3.5 Nm (0:95 mkgf, 2.5 fbf) Brush holder sorew maf 2 7.5 Nm (0.18 mkgf, 1.4 Wit) 2413TIGHTENING TORQUES Item Thread | ay Tightening torque Remarks size ‘Clutch boss nut me | 1 400 Nm (10 m-kgf, 72 feb) =—@ Clutch spring bolt Me | 4 10 Nm (1.0 m-kgf, 7.2 Reh) ‘Clutch cover Bott Me [7 TONm (1.0 m-kgf, 7.2 RBA) Clutch cable holder bolt Me | 2 10 Nm (1.0 mkgf, 7.2 elbt) ~d ‘Shift shat spring stopper we | t 22. Nm (22 maf, 16 fib) -d Cilpump cover screw Ma | t 2.0 Nem (0.20 mvkaf, 1.4 tlb§) Oil pump bolt Me | 4 TO Nm (1.0 m-kgf, 7.2 febA) Oilpan bolt Me] 1 TO Ne (1.0 mikgf, 7.2 RIA) Engine oll dain Bot m2 | 7 BO Nm (2.0 mmkgf, 14 RBA) Grankcase bolt wa | 6 See TIP. =a Grankease bolt we | 2 See TIP, =e Grankease bolt Me | 14 See TIP. =a Banya chain guide bok (intake side | yg 7 10.Nm (1.0 mgt, 7.2 fot) “a Bayne chain guide bok (ewerside | yg | 2 1ONm (1.0 mgt, 7.2 feb) - Primary drive gear bot mo | 1 {60 Nm (6.0 mkgf, 43 fbf) <0 Oil pressure switch pri | 1 15Nm (1.5 mkgf, 11 Fibs) -d Cillpressure switch lead bot waft 18 Nm (0.18 mkgh, 13 feo ‘Gear position switch screw Ms | 2 3.5 Nm (0.35 m-kaf, 25 ftlbt) -d Oil iter cartridge mzo_| 1 T7 Nim (1.7 maf, 12 bh Giifiter cartridge union bolt 20 | 1 70 Nm (7.0 mg, 61 Felt) =—@ ‘Grankcase breather cover bolt Me | 8 TONm (1.0 mkgf, 7.2 RBA, ‘Speed sensor bolt Me | t TONm (1.0 m-kgf, 7.2 RBA) Connecting rod nut Me | 4 See TIP, —@ Balancer driven gear bolt we] t 35 Nm (3.5 maf, 25 fbf) —@ ‘Shift fork guide bar retainer bot Me | 2 TONm (7.0 m-Kgf, 7.2 fbf) -d ‘Shift drum segment sorew Me | ot 12 Nm (1.2 m-kgh, 8:7 FebA) - Radiator bolt Me | 2 TO Nin (1.0 mvkgf, 7.2 Pb) Radiator fan cover bolt Me | 8 ONm (0.8 mgt, 65 RIB Coolant reservoir cover Balt MS | 2 TE Nim (0.15 mkgf, 1.1 Ploy) Radiator outlot hose clamp screw | MS | 1 2.0 Nm (0.20 mvkgf, 1.4 Flbth Radiator inlet hose clamp screw Me [ot 2.0 Nm (0.20 m-kgf, 1.4 lof) Thermostat cover bolt Me | 2 TO Nm (1.0 m-kgf, 7.2 Reh) Water pump housing bolt Me | 8 TO Nm (1.0 m-kgf, 7.2 Reh) Coolant drain batt Me | t TONm (1.0 m-kgf, 7.2 RBA) Impeller shaft retaining plate bolt Me | 2 1 Nm (1.0 mkgf, 7.2 elt) ~d Throttle body joint bolt we [3 TO Nm (1.0 m-kgh, 7.2 Reb) TSC (le speed contro) unitate | yg | 4 Nm (0.5 mkgt, 2.6 ft) 2-14TIGHTENING TORQUES tem Thread | oty Tightening torque omarks Fala [EBS Rin OS IL EE TBH Thee body ni amp sew | MS | 2 | 28 Nm (025 mgt) Throttie cable bracket bolt M5 2 5.Nm (0.5 mkgf, 3.6 fbf) Reed valve cover bolt M6 2 10 Nm (1.0 m-kgf, 7.2 ft-lbf) 1p Cylinder head bolt Tighten the oylinder head bolts “1"-"8" in the proper tightening sequence as follows: 1. Lubricate the cylinder head bolts “1"-"6” threads and mating surface with molybdenum disulfide ease. 2, Tighten the cylinder head bolts “t""6" to 10 Nm (1.0 maf, 72th) 3, Tighten the oylinder head bolts “1""6" to 30 Nm (3.0 m-kgf, 22 fbf). 4. Loosen and retighten each cylinder head bott “1"-"6" with the following steps (after loosening a bot, retighten it before loosening the next bolt) + Loosen the oylinder head bott. + Tighten the cylinder head bolt to 12 Nm (1.2 m-kgf, 8.7 ftibf). + Tighten the cylinder head bolt to reach the specified angle 115-125". 5, Tighten the cylinder head bolts “7” and “8” to 10 Nm (1.0 m-kgf, 7.2 ftibf) 1 Crankcase bolt Tighten the crankcase bolts “t’—"21" in the proper tightening sequence as follows: 1. Lubricate the crankcase bolts “1”="15" and "17'-"21” threads, mating surfaces with the engine oll 2. Lubricate the mating surface of the bolt "16" with engine oil and apply Yamaha bond No. 1215 to the bolt threads. 8. Tighten the crankcase bolts “1"-"6” to 20 Nm (2.0 m-kgf, 14 ft). 4, Loosen and retighten the crankcase bolts “1"-"6" to 24 Nm (2.4 m-kgf, 17 ftibf) in the proper tight- ening sequence (after loosening a bolt, retighten it before loosening the next bolt). 5, Tighten the crankcase bolts "7’-"8" to 20 Nm (2.0 m-kgf, 14 tb}. 2-15TIGHTENING TORQUES 6. Loosen and retighten the crankcase bolts “7"-"8" to 26 Nm (2.6 m-kgf, 19 ftbf) in the proper tight- ‘ening sequence (after loosening a bolt, retighten it before loosening the next bolt). 7. Tighten the crankcase bolts “9'-"21" to 10 Nm (1.0 m-kgf, 7.2 ftibf) in the proper tightening se- 7 x6 || x2 2-16TIGHTENING TORQUES A. Lower crankcase B. Upper crankcase T1P Connecting rod bolt 1. Lubricate the connecting rod bolts threads and connecting rod nuts mating surface with molybde- num disulfide oil 2, Tighten the connecting rodbolts to 15 Nm (1.5 m-kgf, 11 ftbf), and then tighten them further to reach the specified angle 145-155". 217TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES tem Thread | oy Tightening torque Remarks Engine mounting ut ear upper | ig | 4 | G8 Nm (6@ msg, 49m) Seca eat WO |_| GN BS mg, a8 BH Engine mounting nut (rear lower Engr wo [1 | €8Nm(6.8mbgt, 49: Engine mounting bolt (right front Engr mio | + | Genm 6.8 mkat, 49 1) Engine mounting BOK (ei Wont side) | WHO | 1 | 68 Nim (68 mk 49 RTE Engine bracket Bo (ah WO | 2 | 68 Nm (68 mig, 40 Eb Engine bracket Bo (eh) WHO| | eB Nm 6S mgt AORN Engre mounting bar eRURP= T yig | 1 | G8 Nm 6.@maat 40.) Engine ‘mounting bolt (leit upper mo | 4 68 Nm (6.8 mig, 49 tb) Rider seat bolt MG 2 7. Nm (0.7 m-kgf, 5.1 ftlbf) Center cover screw MS | 2 7.8 Nm (0.18 m-kgf, 1.3 felbf) Passenger sat brackatiak wef 4 Rim (0.7 mh 6.16) Passenger sat band nut we 2 Fim (07 mag 8 TT Side panel bot WE [ TE Nn OE mgt TRH petal S| 2 | TB Nm O18 migh 13 RI Rear upper side cowling bolt M6 2 7. Nm (0.7 m-kgt, 5.1 ftlbf) ‘Seat lock nut M5 2 7 Nm (0.7 m-kgf, 5.1 ft-lbf) Rear lower side cowling screw ‘M5. 5 1.8 Nm (0.18 m-kgf, 1.3 ft-lbf) ‘Seat lock key cylinder screw MS | 2 7.8 Nm (0.18 mkgf, 1.3 felbt) Lean angle sensor screw Ma | 2 7.0 Nm (0.10 maf, 0.72 fbi) Rectierreguator bot wef 2 TR (07 kgf 8.1 RTE Front panel bo WE [| TEN OEM Igh TTT Fuel ak cover Bol (ear Side) | WB | 4 | BN OS kg, 8 RBH Fool ank cover bof (Font side) | ~W6[ 7m (027 mk 8.4 Fuel tank cover screw M5. 6 1.8 Nm (0.18 m-kgf, 1.3 ftlbf) Bottom cowling screw M5, 4 1.8 Nm (0.18 m-kgf, 1.3 ftlbf) Front botom cowing Bok (UB x12 i ms | 4 1.8 Nm (0.18 m-kgf, 1.3 flbf) Frat Potom cowiing bol(MEx22 | yg) 2 7 Nm (0.7 mf, 6.1 fbf) Front Boom cowtng racket bot | WE | THR 07 GEE RTE Front ede cowfng sew WE_[ 2 [TSN OE migh TST Front side cowing imer panel screw | MS | 2 | _1.8Nm (0.18 mk, 1.9 7D) Front upper cowing ut (efsde) | WB | 1 Nm (0.7 mG 8.1 FH) Front upper cowling screw M5. 4 1.8 Nm (0.18 m-kgf, 1.3 ft-Ibf) Front upper cowing Bo we | 2 7 (07 mG 8.1 RIGA Front Tower cowing screw M5 [2 [FB Nm (OTB mk 13 RIB 2-18TIGHTENING TORQUES tem Thread | gy Tightening torque Remarks vise aan nina asa] Tn OT Frnt coving assembly Bat a} 2] aa in gt 2a Meter assembly bracket bolt M6 2 7. Nm (0.7 mkgf, 5.1 ftbf), Meter assembly screw M5 3 1.3 Nm (0.13 m-kgf, 0.94 ft-lbf) Windshield assembly screw M5 2 0.4 Nm (0.04 m-kgf, 0.29 ft-lbf) Front cowling screw M5 4 7.8 Nm (0.18 m-kgf, 1.3 ftlbf) Font cong mer panel serew | S| 6] 18 im (18 mal 1.3) Headlight assembly sew ws —|4 | TB Nin (18 magl 73H Fon aks Fase hoe a wie | | TNO gh Font rake calipr bot aie] aE Sg Font wheel ena wie [1 | SER 2 migh 38) | ea Fronts dse bot we [ 5 | Bain mig TRH “a Rear brake caliper bolt MB 1 23 Nm (2.3 m-kgf, 17 ftlbfy Drive chain puller locknut MB 2 16 Nm (1.6 m-kgf, 12 ft-lbf) Drive chain puller adjusting nut MB 2 1.5. Nm (0.15 m-kgf, 1.1 ft-lpf) Rear wheel axle nut mis | 1 57 Nm (5.7 m-kgf, 41 f-lbf) < Rear brake caliper bolt M12 1 31. Nm (3.1 m-kgf, 22 ft-lb) Rear wheel sprocket nut M10, 6 68 Nm (6.8 m-kgf, 49 ft-Ibf) Fear whoa spocktoudbat™ | wio| 6 | 27 Hm (27 maa 20m a Rear brake disc bolt we) 3 23 Nm (2.3 m-kgh, 17 felbi) “a Brake caliper bleed screw M7 2 6 Nm (0.6 m-kgf, 4.3 fbf) Fonbrakerastr nGereeeNT | yg |g | 15 nm OAS magl 11 RID Font ars Te BOTT Wea ST Font rake ave pot a et] oR Oo AT Front brake light switch screw wa | Tat Nem (0.11 rm gf, 0.80 felbt) “qd Frag foes union BOBBITT aq | | gon @8magl 21 HD) Fron rag hase union BENE yiq | | gon @9magl 21 HH Lor lores master cyliraler ticker: M6 2 10. Nm (1.0 m-kgf, 7.2 ftslbf) Rear brake fluid reservoir holder bolt | M6 1 7. Nm (0.7 m-kgf, 5.1 ftlbf) Rea Batefooe non Dok master I yiq | | gem @9magl 21 Rib Rearbrakeroso wen DORaIS yap | | gonm @amagl 21m) Tanaka gh baat bat | WE | ETN Ta gh TR Foote assonbiybot a —| a | ain Rear brake master cylinder bolt MB 2 23 Nm (2.3 m-kgf, 17 ft-lbf) Rear brake pedal bott mio | 1 ‘30 Nm (3.0 mAgh, 22 ftibi) -a Fear brake hose guia bal weft TO 2-19TIGHTENING TORQUES tem Thread | ty Tightening torque Remarks Fear brake pedal using o&nak [WB |B [ A Win oT GH TERT ip end bok We [2 [TN (07 mk 5.1 Handlebar switch screw (right) M5. 2 1.5 Nm (0.15 m-kgf, 1.1 ft-Ibf) TEyotigcablegude screw Mande: ys | | as nm (0.28migh 181) Handlebar pinch ba [ee Handlebar bolt M6 2 13 Nm (1.3 m-kgf, 9.4 ftlbf) Handlebar switch screw (lefty MS | 2 75 Nm (0.18 mkgf, 1.1 felbf) hich Tver pot a WE [ LT 0 gh TRI Chih cable Tock WB [ [TNO 5.1 Cc ever nls pinch bok We | [TN (0-7 mig 5.1 ‘Clutch switch sorew ms | 1 (0.6 Nm (0.06 m-kgf, 0.43 fbf) -a Front fender bolt (front) M6 2 7 Nm (0.7 mkof, 5.1 fbf) Front fender bolt (rear) Me | 7Nm (0.7 mkgf, 6.1 fbt) Tower bracket ch bo TWO | 2] 80 i OMG BRB Upper bracket ch Bot WE |B] BT im Et STB Front fork cap bolt M38 | 2 23 Nm (2.3 m-kgf, 17 ftlbf) Front fork damper rod bolt mo | 2 230 Nm (3.0 mf, 22 ftlbt) -a Hern We | | T6Nim (1.8 mk 2H Fai baka hose Ba WE [LR 7 8TH Horn bracket bo WE [2 [ TN 07 mh STR Cable guide Eo (oA ME] 1] TN (07 KGS Cable guide bolt (right) M6 1 7 Nm (0.7 m-kgf, 5.1 ft-lbf) Steering stem bolt M14 1 95 Nm (9.5 m-kof, 69 ftlbfy Lower tog ru OETERONG yay | | son eamiat a5 tie) Lowering mutraltonening yay | 4 | de Nm (.8magt 1989 dguarT BoE WEE a i OT GL TS TBH Rear shook absorber asemBvEOR Tyra | | ae nm .0magt, 42mB) Rear shook abeoborassombiyrat [ yyo | 4 | aa nm (.8migl, 42m) Drive chain guard bolt M6 2 10 Nm (1.0 m-kgf, 7.2 ftlbf) Pivot shaft nut mie | 1 15 Nm (17.5 m-kgl, 83 febA) Drive sprocket cover bolt Me | 2 10 Nm (1.0 mkgf, 7.2 felbf) Drive sprocket a WoO [ 1 | 78 Nim OS mh SHIEH a Shift arm pinch bolt M6 1 14. Nm (1.4 m-kgf, 10 ftlbf) ‘Shift rod locknut (shift arm side) M6 1 7 Nm (0.7 m-kgf, 5.1 ftlbf) Shitodocknut (eit pedal ido) | MB | 1 | 7Nm@7mag6.1 nb | Ueland Shilipdal bok Wao | 1 [80 Nin BOmmIGK ae 2-20TIGHTENING TORQUES tem Thread | oty Tightening torque omarks Foes ae Fo FiBL TON OGL TERT Fuel pump bok S| 6 | 0 Nim (040 magh 29 toy Rear fuel tank bracket bolt (fuel tank) | M6 2 10 Nm (1.0 m-kgf, 7.2 ft-lbf) Rear fuel tank bracket bolt (frame) MB 2 12.Nm (1.2 m-kgf, 8.7 ft-lbf) ean, fuel tank bracket bolt (uel M6 2 10 Nm (1.0 m-kgf, 7.2 ft-lbf) Front fuel tank bracket bolt (frame) M6 2 12.Nm (1.2 mkgf, 8.7 ftlbf) Too able guide bo vig [2] BN OS migh 68H) Sesion nat LL Passenger boTaSTaSSEmEW BaI | WE | | 28 im (BE igh 20TH Fea lender bot we [4 | BNO mg 6 by Taillight unit assembly bolt M6 2 3.3 Nm (0.33 m-kgf, 2.4 ftlbf) ‘Sidestand switch bolt M5 2 4.0 Nm (0.40 m-kof, 2.9 ftlbf) Canister bracket bolt (Engine) M6 2 7 Nm (0.7 m-kgf, 5.1 ft-lbf) ‘Canister bracket bolt (Frame) MB 1 16 Nm (1.6 m-kgf, 12 ftlbf) 2-21LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Bearings (O-rings: Oil seal lips Cylinder head bolt seats, cylinder head bolt threads and washers ‘Crankshaft big ends Connecting rod bolts| ‘Generator rotor bolt thread and washer ‘Crankshaft journals, Balancer gear and damper Balancer shaft journals, Cylinder inner surface, piston, ring grooves, and piston rings, Piston pins ‘Camshaft lobes ‘Camshaft journals Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Valve lifter surfaces Valve stem seals, Timing chain tensioner outer surface il pump rotors (inner and outer) (ll pump shaft Gil fiter cartridge union bolt Oil strainer seal AAeeee SebebsessASDeantOat tte Oil pump idle gear shaft (il pump idle gear inner and thrust surfaces ‘Starter clutch ile gear thrust surfaces ‘Starter clutch rollers and starter elutch gear boss ‘Starter clutch idle gear shaft Primary drive gear bolt threads and washer Primary driven gear inner surface ‘Grankease cover and clutch pull rod <4 Oil pump drive gear inner surface and washer =e ‘Clutch boss nut and conical washer ol ‘Clutch housing thrust washer —@ 2-22LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant ‘Transmission gears (wheel and pinion) and collar ‘Transmission gears inner surface (shift fork contact parts) Shift fork and transmission gear contact surface ‘Shift drum assembly Shift forks and shift fork guide bars ‘Shift shaft moving surface Shift shaft washer addaadla 2-23LUBRICATION POINTS AND LUBRICANT TYPES 2-24LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION SYSTEM CHART AND DIAGRAMS ENGINE OIL LUBRICATION CHART (JOO 00] 4 16 2-25LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Olt strainer 2. Ollpump 3. Relief valve 4. Olititer cartdge 5. Sub gallery 6. Oil pressure switch 7. Main gallery 8. Crankshaft 9. Oilnozzie 40. Balancer shaft assembly 11, Timing chain tensioner 12. Intake camshatt 19. Exhaust camshatt 14. Main axle 16, Transmission shower 16. Drive axle 2-26LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION DIAGRAMS rankcase, cylinder, and cylinder head (right side view) 2-27LUBRICATION SYSTEM CHART AND DIAGRAMS “Trming chaln tensioner Intake camshatt Exhaust camshaft Crankshaft Balancer shaft assem il fiter cartridge i strainer i! pump ‘Transmission shower Ny 2-28LUBRICATION SYSTEM CHART AND DIAGRAMS Crankcase and cylinder (left side view) 2-29LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft Balancer shaft assembly ‘Connecting rod i rain bot il fiter cartridge il pressure switch 2-30LUBRICATION SYSTEM CHART AND DIAGRAMS ll pump (right side view) 2-31LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Ol pump 2. Relief valve 2-32LUBRICATION SYSTEM CHART AND DIAGRAMS il strainer (bottom view) 2-33LUBRICATION SYSTEM CHART AND DIAGRAMS Main gallery il fiter cartidge Sub gallery 1 strainer 2-34LUBRICATION SYSTEM CHART AND DIAGRAMS J OF — O's Camshaft (top view) rLUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshatt 2. Exhaust camshaft 38. Cylinder head 2-36LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft (rear view) aa) SI =) | aap | SY eS fo £ (LUBRICATION SYSTEM CHART AND DIAGRAMS Grankshatt il nozzle Piston Main gallery ‘Sub gallery 2-38LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft and transmission (top view)LUBRICATION SYSTEM CHART AND DIAGRAMS Grankshatt Balancer shaft assembly Main axle Drive axle 2-40COOLING SYSTEM DIAGRAMS COOLING SYSTEM DIAGRAMS 2-41COOLING SYSTEM DIAGRAMS Radator Radiator outlet hose Water pump ‘Thermostat Radiator init hose 2-42CABLE ROUTING CABLE ROUTING Handlebar (ront view) 2-43CABLE ROUTING ‘Throttle cable (accelerator cable) ‘Throtle cable (decelerator cable) Front brake light switch lead Handlebar suitcn lead (right handlebar switch) Clutch cable ‘Clutch switch fead Handlebar suit lead (left handlebar switch) Hom ‘Main switch lead Hom lead Front brake hose Upper bracket ‘Main switen Guide FRoute the thottie cables through the guide Route the horn lead through the guid. Route the clutch cable to the trot ofthe trata cables and letthandlebar switch lead. Route the left handlebar switch lead so that the horn lead that branches off om the lett handlebar sitch lead is routed forward, Fasten the hom lead at the white tape tothe front brake hose with the plastic band. Pesition the horn lead to the ront ofthe front orake hose. ‘The main switch lead, left handlobar switch lea, ‘and right handlebar sultch lead may be routed in any otder. Route the horn lead to the outside of the tront brake hose. Foute the main switch, left handlebar switch, and right handlebar switch ieads according to instructions “',"K', ", and “M"in the order listed, Formard Route the main switch lead between the cable {guide and the main switch Route the main switch lead through the cable {guide as shown in the ilustration, making sure to ft {the lead In between the bends in the guide Flute the main switch lead back through the cable ‘guide so that it is looped around the guide as shown inthe ilstration. Route the left handlebar switch lead and right handlebar switc lead through the guide as shown in the tlustation, 2-44CABLE ROUTING Engine (right side view) 2-45CABLE ROUTING Negative battery sub-wire hamess coupler Engine bracket (right) Fuel tank overtiow hose Ignition col lead Headlight lead (ight) Front turn signal ight lead (right turn signal ight) Coolant reservoir nose Air cutoff valve Speed sensor coupler (0p sensor ‘Coolant temperature sensor coupler ‘Starier motor lead Nogative battory sub-wire harness (0, sensor lead ‘Speed sensor lead Stator coll lead ‘Spark plug aad Electrical components tray Radiator fan motor relay Haadlight relay Dust seal Lower crankcase Fasten the fuel tank overflow hose between the hose clamps, Route the tue tank evertiow hose tothe front and under the engine braoket (igh), ‘Connect the ignition col lead with the white tape to the right ignition col ‘The main switch lead, eft handlebar switch lead, ‘and right handlebar suit lead may be routed in any order. Fasten the O, sensor lead withthe holders. Fasten the stator coll ead, coolant temperature ‘sensor lead, oll pressure switch lead, gear position ‘switch lead, Op Sensor lead, negative battery sub- wire harness, and starter motor lead with the holder. The leads may be fastened in any order, Fasten the speed sensor lead, O, sensorlead, and negative battery sub-wire hamess with the holder. ‘The leads may be fastened in any order. Install re raciator fan motor relay and headlight relay completely onto the tabs on the electrical ‘components tray. ‘Adjust the main switch lead, left handlebar switch lead, and right handlebar switch lead so thatthe upper edge ofthe white tape on each lead is positioned below the upper edge of the dust seal ‘Att adjusting the leads in instruction “G’, fasten the main switch lead, let handlebar switch lead, land right handlebar switch lead with the plastic band. Align the plastic band with the white tape on the right handlebar switch lead. Insert the projection on the holder into the hole in the engine bracket (ight), 2-46CABLE ROUTING Rear fender (right side view) 2-47B>geernemrene Fuse box Rear fender Fuse box lead Raat brake light switch coupler Rear brake light switch lead Fuel tank overtiow hose Down tube Stay Engine stay Frame Install the fuse box onto the tab on the rear fender. Pass a plastic locking tie through the ricer seat bracket and through the nole Inthe stay. Face the Ducks ofthe plastic locking tle outward wth the ‘end pointing downward, Cutoff the excess end of the plastic locking tie to 3 mm (0,12 in) or less, Position the plastic locking te atthe location ‘shown in the ilustration, Route the rear brake light switch lead tothe front of the frame cross mame. Route the fuel tank overtiow hose between the stay land the engine stay Fasten the rear brake ight switch lead atthe white tape to the down tube with a plastc locking tie. Face the buckle ofthe plastic locking tle outward vith the end pointing upward. Cut off the excess. ‘end ofthe plastic locking tle to 3 mm (0.12 in) or less, 2-48 CABLE ROUTINGCABLE ROUTING Engine (left side view) 2-49CABLE ROUTING 18, ‘Auxiliary light lead Fuel tank breather hose Guide Coolant reservoir hose (Oz sensor lead (©, sensor coupler Sidestand switch connector ‘Stator col lead Gear position switch lead Fuel tank overtiow hose ‘Sidestand switch il pressure switch lead ‘Coolant temperature sensor coupler Front turn signal light load (left turn signal light) Front coming assembly bracket ‘Meter assembly lead Bracket Wire harness Frame Drive sprocket cover Coolant reservoir cover Coolant reservoir Cylinder head ‘Sidestand switch lead wire ‘Chain case cover Route the auxiliary light lead as shown in the ilustation Fasten the fuel tank breather hose, oll pressure ‘switch load, gear position Staten lead and sidastand sich lead atthe location shown in the illustration wath a plastic locking te. The leads may be routed in any order. Cutoff the excess end of the plastic locking tle to 3 mm (0.12 in) or less. Fasten the oll pressure switch lead and gear positon switch lead at the location shown in the itustration vath a plastic locking ie. The leads may be routed In any ardor. Route the fuel tank breather hose through the ‘guide on the sidestand bracket, Point the end ofthe plastic locking tle downwara, Position the white paint mark on the fuel tank broather hose at the location shown in the ilustation Insert the projection on the wire hamess holder into the hole inthe front couling assembly Bracket. Fasten the meter assembly lead to the bracket with a plastic locking i. Face the buckle of the plastic locking te outward with the end pointing ‘downward. Cut olf the excess end of the plastic locking te to 3 mm (0.12 in) ar less, Fasten the main switch ead, let handlebar switch lead, and right handlebar switch lead atthe white tape on each lead witha plastic locking te Fasten the main switch lead, left handlebar switch lead, and night handlebar switch lead with a plastic locking te as shown in the illustration. Fit ie end ‘of the plastic locking tie into the electrical ‘components tray. ‘The main switch lead, left handlebar switch lead, ‘and right handlebar switch lead may be routed in any otder 2-50 The gear position switch lead, negative battery sub-wire harness, and starter motor aad may be routed in any order. Insert the projection on the wire harness holder Into the note in the frame. L. Face the paint mark on the fuel tank breather hose forwars, Fooute the fuel tank breather hose under the stator col load, Roule the ol pressure switch lead, gear position ‘itch lead, and fuel tank breather hose to the Dulside ofthe nib on the drive sprocket cover. ‘when instaling the drive chain cover, be sure not topinch the leads Route the oll pressure switch lead, uel tank breather hose, gear positon switch lead ang sidestand switch lead may be routed in any order Fooute the fuel tank breather hose to tha outside of the coolant resorvor. Route the fuel tank breather hose through the guide. Hold lead wires thoroughiy with clamp. ACM, water temperature sensor, pressure sensor, neutral Sith, Op sensor, minus lead wir, starter lead Wite, and sidestand switch in any order. Pass breather hose and sidestand switch lead wire to guide of chain case cover. Pass sidestand switch load wir to clamp.CABLE ROUTING Rear fender (left side view) 2-51CABLE ROUTING 24. Coolant reservoir breather hose Gear positon switch coupler Starting circuit cutoff relay ‘Starter motor lead terminal ‘Starter relay coupler ‘Yamaha diagnostic tool coupler ‘Tallbrake light lead Lean angle sensor lead Rctiferregulator coupler License plate light connector ‘Talibrake light coupler ‘Stator col lead Negative battery lead Wire harness Frame Starter relay Rear tender ‘Mudguard Rear turn signal light lead (left turn signal ight) License plate light lead Far turn signal light lead (right turn signal light) ECU (engine control unit) Battery Nogativ battory sub-wire harness Positive battery lead Fasten the starter motor lead, negative battery sub-nire harness, stator coil lead, and gear position switch ead to the wire harness with a Dlasic locking te. Do not install the plastic locking tie on the section ofthe stator col lead that isnot ‘covered by the protective sleeve Insert the end of the coolant reservoir breather hose into the frame pipe. Make sure thal the end of the hose protector onthe coolant reservoir breather hose contacts the edge ofthe le inthe Install the stating circuit cut-off relay onto the tab ‘on the rear fender. Instal tho startor motor lead and positive battory lead terminals so that the crimped section ofthe terminal that secures the lead is facing upward, Fasten the starter motor lead and negative battery ‘sulbvre harnass tothe wire harass wth a plastic lacking te at the lacation shown in the ilustration, ‘Make sure that there is no slack in the starter motor lead and negative ballery sub-wire harness. between the plastic locking ties. ‘The stator coll lead and gear position switch lead may be routed in any order. Fasten the starer motor lead, negative battery ‘subwire harness, stator col lead, and gear position switch lead to the wire harness with a Dlasic locking tie as shown in the illustration, Face {he buckle of te plastic locking te outward withthe ‘end pointing upward. Cutoff the excess end of the plastic locking te to 3 mm (0,12 in) or les. ‘The negative battery sub-wire hamess and starter motor lead may be routed in any order. ‘The wire hamess and tallbrake light lead may be routed in any order. 2-52 Fasten the wire hamess and talbrake light lad to the frame witha plastic locking teas shown in the llustton, Point the end af the plastic eking te ‘utara, Cutoff the excess end ofthe plastic locking be to 3 mm (0.12 in) oF lass. LInstall the starter relay completly onto the tabs on the rear fender. Route the rear left turn signal light lead, rea right tur signal ight lead, and license plate light lead under the starter relay, The leads may be routed in any order. NN. Route the rear lft turn signal light lead, rear right tur signal light lead, and license plate light lead through the guides on the mudguard. Insert the projection on the wite harness holder Ito the hole inthe rear fonder. P. Fasten the starter motor lead and negative battery Sub-wire harness tothe wire hamess with aplastic locking te as snown in tha ilustration. Face the buckle of the plastic locking te outward with the fend pointing upward. Cut otf the excess end of the plastic locking ie to 3 mm (0.12 in) or lass,CABLE ROUTING Engine (top view) 2-53CABLE ROUTING eo @ CCluteh cable Handlebar suitch lead (elt handlebar switch) Front turn signal light lead (left tur signal light) Headlight lead (et) ‘Auxiliary light lead ‘Meter assembly ‘Meter assembly lead ‘Throtle cable (accelerator cable) Throttle cable (decelerator cable) Hom lead Headlight lead (right) Front turn signal ight lead (right turn signal ight) Front brake hose Handlebar suitch coupler (right handlebar switch) Coolant reservoir hose Fuel tank overtiow hose Frame Fuel tank breather hose Electrical components tray Handlebar switch coupler (left handlebar switch) ‘Main switch coupler Front side cowiing inner panel (lft) Front side cowiing inner panel (right) Fuel injector lead Fuel rail ‘Spark plug lead Place the let handlebar switch coupler, right handlebar switch coupler, and main switch coupler in the electrical components tray go thatthe leads to the switches are routed upward. Insert the projection on the wire harness holder into the hole inthe frame. TT fuel pump Route the headlight lead through the guides on the front side cowting inner panel. Insert the projection on the plastic locking te nto the Note in the electrical components tray. ‘The main switch lead, eft handlebar switch lead, ‘and right handlebar switch lead may be routed in any otder. Fasten the main switch lead, left hanslebar switch lead, and right handlebar switch lead atthe white tape on each lead withthe plastic locking te. Point ‘tho end ofthe plastic locking te outward. Cut off the excess end ofthe plastic locking tie to 3 mm (0.12 in) or less. Fasten the fue injector lead atthe white tape to the ‘uel al with aplastic locking te. Face the buckle of the plastic lacking te rearward with he ang pointing downward. Cutoff the excoss and of the plastic locking te to 3 mm (0.12 In) or lass. Gross the throttle cables above the plastic locking tie Wite tape Faston the throtle cable (accelerator cable) and throtle cable (decelerator cable) with the plastic locking te. Be sure to route the throttle cable (accelerator cable) above the throtle cable (decelerator cable). Cut off the excess end of the plastic locking te to 3 mm (0.12 In) or less. Route the spark plug ead tothe front ofthe projection on the electical components tray 2-54CABLE ROUTING Rear fender (top view) 2-55CABLE ROUTING @ Fuel tank overtiow hose (©z sensor lead Negative battery sub-wire hamess. Frame Raat brake light switch lead Fuse box lead “Tur signal relay Fuse box ECU (engine control unit) Rocifierregulator ‘Yamaha diagnostic tool coupler ‘Yamaha diagnostic tool coupler lead Rear turn signal light lead (right turn signal light) License plate light lead Roar turn signal light lead (Jett urn signal ight) Lean angle sensor ‘Tallbrake light lead Froar fender Starter relay Reciierreguiator lead ‘Starting rout cut-off rotay ECU (engine control unit) lead Wire harness Nagative battery sub-wire hamess coupler Battery Gear position switch coupler Crankshaft position sensor coupler ‘Stator coi coupler Negative battery sub-wire harness. Positive battery lead Insert the projection on the holder at the waite tape ‘on the wire harnass into the frame hole shown the illustration Insert the projection on the wire harness holder into the hole inthe frame. Fit the turn signal relay into the Hole in the ECU. bana, Route the negative battery sub-wire harness undor the ECU (engne contsol uni). Route the rear turn signa light leads, license plate light lead, and Yamaha diagnostic tool coupler lead tough the guide on the rear fender. Fasten the wire harness to the trame with a plastic locking te. Position the plastic locking te to the front of where the leads branch off from the wire hamess. Route the rear turn signal light leads between the {um signal relay lead and the negative battery sub- wire harness, Fit the negative battary sub-wire hamess coupler into the hole inthe ECU band, ‘The rear tur signal light leads may be routed in any order. Fasten the wire harness to the trame with a plastic locking tie as shown in ine lustraion. Face the buckle ofthe plastic locking ie outward with the ‘end pointing downward, Cutoff the excess end of the plastic locking tie to 3 mm (0,12 in) or less, 2-56 K. The starter motor lead, negative battery sub-wire harness, taorake light lead, and wire harness ‘may be routed in any orcer.CABLE ROUTING Front brake (right side view)CABLE ROUTING Brene Front brake hose Front brake caliper Guide Flute the front brake hose aver the guide. ‘When installing the brake hose onto the brake ‘caliper, make sure that the brake pipe touches the projection on the brake caliper. 2-58CABLE ROUTING Rear brake (right side view) 2-59CABLE ROUTING pas Rear brake callper Brake hose (rear brake master cylinder to rear brake caliper) Brake fuid reservoir hose Roar brake master cylindar ‘When installing the brake hose (rear brake master cylinder to rear brake caliper) on the rear brake master cylinder, make sure that the brake pipe touches the projection on the master cylinder. ‘Connect the end ofthe brake hose (rear brake master eylinder to rear brake calipet) that is Identiied by the white paint mark tothe rear brake master eylinde. ‘When instling the brake hose onto the brake ccaliper, make sure that the brake pipe touches the projection on the brake caliper 2-60CABLE ROUTING Fuel tank (left side view) 2-61CABLE ROUTING OD >exepeenn Fuel tank Fuel hase (uel tank to fuel rai) Fuel pump Fuel tank breather hose (fuel tank to hose joint) Fuel tank breather hose Hose joint Fuel tank evertiow hose Fuel tank overtiow hose (vel tank to hose joint) ‘Connect the orange connector ofthe fuel Nose (fuel tank to tue al) to the fuel pump. Fommard Face the white paint mark on the fuel tank overflow hose (ue! tank to hose joint) forwara, Face the white paint mark on the fuel tank breather hose (ue! tank to hose joint) forward. Install the fuel tank breather hose (Iuel tank to hose joint) so thatit contacts the tapered portion of the Nose ting on the fuel tank and it contacts the ‘stopper on the hose joint ‘Align the yellow paint mark on the fuel tank breather hose with the yellow paint mark on the fuel tank breather hose (tue tank to hose joint). ‘Align the yellow paint mark on the fuel tank ‘overiow hose withthe yellow paint mark on the ‘uel tank overflow hose (fuel tank to hose joint) Install the fuel tank overfiow hose (fuel tank to hose joint) so that it contacts the tapered portion of the hose tting on the fuel tank and iteantacts the stopper on the hose joint. 2-62CABLE ROUTING ‘Throttle bodies (left and right view) 2-63CABLE ROUTING zee xp MDM @ >ZePNeRAeNe ze ‘Throtia bodies: Fuel hase (uel tank to fuel rail) Crankcase breather hose Air fter case assembly Clip CCrankcase breather cover Pipe balance (canister purge hose) ISC (idle speed contro) unit inlet hose Way (joint pipe) Clamp Direction of yellow paint shall be let side of vehieie Part should install yellow paint being part side and let ot vehicle. Prt should insert incicate rear end of pipe. Patt should not get on pipe spool Front Direction of clip shall be back side of vehicle, and ‘one side ear is parallel to a vehicle crecton, and the other ear is parallel to a vehicle direction, and the other ear tuming tothe body inside. ‘Artach black side ta throttle body assy. Part should install yellow paint being part side and right of vehicie. Direction of clip shal be lower sie of vehicle Direction of clip shall be back side of vehicte. Direction of clip shall be right slant lower direction of vehicle. Direction of white paint shall be right side of vehicte Direction of clip shal be right side of vehicle, Direction of clip shal be front side of vehicle, 2-64CABLE ROUTING Air induction system (top view) 2-65CABLE ROUTING Raed valve cover Air induction system hose (air cut-off valve to reed valve cover) Air cutoff valve ‘Air induction system hase (air iter case to ar cut- off valve) Air fiter case assembly Point tne ends of the hase clamp upward. Face the yellow paint mark on the air induction system hose (air fiter case to air cutof valve) upward, Face the white paint mark on the alr induction system hose (ar fiter case to alr cut-off valve) upward, Point ta ends of the hose clamp downwar Install te hose completely onto the hose fting Point tha ands of the hase clamp to the forward, angled downward. 2-66CABLE ROUTING Radiator (top view) HH a SnCABLE ROUTING Bresogsene Radator Radiator outlet hose Coolant reservoir nose Coolant reservoir cap Coolant reservoir breather hase Coolant reservoir Radator init hose Coolant hose ce Face the white paint mark on the coolant reservotr hose upward 40° 31mm (0.12 in) or more. Make sure not to install the hose clamp on the ralsed portion of the hose ‘ting. Downware Install te coolant reservoir hose untl the end ot the hose contacts the raised portion of the hose fiting.. 401mm (0.99 in) or more 5mm (0.20 in) Install the pipe up tothe groove in the coolant reservoir cap. Install te coolant reservoir breather hose ‘completely onto the hose fting of te coolant reservoir Lott side Install the coolant hose so that the end ofthe hose Is positioned as shown inthe lustration 2-68CABLE ROUTING Radiator (left side view) 2-69CABLE ROUTING peenogeenn oc - za omm Coolant reservoir hose Electrical components tray Coolant reservoir cap Coolant reservoir areather hose Frame Coolant reservoir ‘Thermostat cover Radiator init hose Radator Insert the end of the coolant reservoir breathor hose into the frame pipe. Make sure thatthe end of the hose protector on the coolant reservoir breather hose contacts the edge ofthe hole in the trame. Face the white paint mark on the coolant reservoir breather hose outward, Install the radiator inlet hose completely onto the hose fiting of the thermostat cover. Connect the end of he radiator inlet hose that is identifies by the white paint mar tothe raciatr. White paint mark Install the racator inlet hose up to the projection ‘on the hose fting 3. Outwaret Insert the projection on the holder into the hole in the electrical components tray ‘The fastener of the screw clamp should be facing downward with the screw head facing outward, Downward 2-70CABLE ROUTING Radiator (right side view) 271CABLE ROUTING moO @ paeNe Coolant reservoir hose Radator Radiator outlet hose Water pump housing Connect the end of the radiator out hose that is. Identified by the white paint mark tothe radiator. Install he radiator outiet hose completely onto the hose fiting ofthe water pump housing. ‘Outwarc ite paint mark Install te raciator outlet hose up to the projection ‘on the hose fing. “The fastener ofthe screw clamp should be facing forward with the screw head facing outwars. 2-72CABLE ROUTING Canister >e ie 2-73CABLE ROUTING 1. Fuel tank compartment 2. Fuelhose 3, Throttle wire assy 4. Canister assy 5. Canister purge hose 6. Rollover valve assy 7. Radator hose 8. Frame 9. Fuel tank breather hose 40. Staner lead wire 11, Way (jint pipe) 12. Clamp ‘A. Tum clip to front side of vehicle B. Fox clamp on canister purge hose at closest clip. ‘Should not be clamp way (joint pipe). C. Clamp canister purge nose and starter lead wire Fix smaller ole of clamo to starter lead wire. Open side of clamp should be on back side of vehicle, 2-74CABLE ROUTING 2-75PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE... INTRODUCTION. PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL, SYSTEM.. GENERAL MAINTENANCE AND LUBRICATION CHART CHECKING THE FUEL LINE....... CHECKING THE SPARK PLUGS. ADJUSTING THE VALVE CLEARANCE .... CHECKING THE ENGINE IDLING SPEED SYNCHRONIZING THE THROTTLE BODIES. CHECKING THE THROTTLE BODY JOINT. 3-10 CHECKING THE CANISTER .. neces 340 CHECKING THE EXHAUST SYSTEM....... 3-10 CHECKING THE GRANKCASE BREATHER HOSE «00... Sot CHECKING THE AIR INDUCTION SYSTEM. att REPLACING THE AIR FILTER ELEMENT AND CLEANING THE CHECK HOSE att ADJUSTING THE CLUTCH LEVER FREE PLAY... B12 CHECKING THE BRAKE OPERATION.... 343 CHECKING THE FRONT BRAKE PADS. 313 CHECKING THE REAR BRAKE PADS 3-13 CHECKING THE FRONT BRAKE HOSES... CHECKING THE REAR BRAKE HOSE... BLEEDING THE HYDRAULIC BRAKE SYSTEM... i CHECKING THE BRAKE FLUID LEVEL. 315 CHECKING THE WHEELS. 3-15 CHECKING THE TIRES ..rnorn 3-15 CHECKING THE WHEEL BEARINGS... 3417 CHECKING THE SWINGARM OPERATION... : 3-17 LUBRICATING THE SWINGARM PIVOT 3-47 ADJUSTING THE DRIVE CHAIN SLACK. 3417 LUBRICATING THE DRIVE CHAIN 348 CHECKING AND ADJUSTING THE STEERING HEAD ......0necennnn 348 LUBRICATING THE STEERING HEAD... oe 319 CHECKING THE CHASSIS FASTENERS... enenennneesene AQ LUBRICATING THE BRAKE LEVER, 349 LUBRICATING THE PEDAL ...s:rrsnnnnniesnnnnnnnnennsnnniennnns S20 LUBRICATING THE CLUTCH LEVER... 3:20 CHECKING THE SIDESTAND.... 3-20 LUBRICATING THE SIDESTAND.. CHECKING THE SIDESTAND SWITCH... CHECKING THE FRONT FORK... . . CHECKING THE REAR SHOCK ABSORBER ASSEMBLY..... ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY... CHECKING THE ENGINE OIL LEVEL. 3.21 CHANGING THE ENGINE OIL 3.22 CHECKING THE COOLANT LEVEL..... 3-23, CHECKING THE COOLING SYSTEM 3-23 CHANGING THE COOLANT. sono: sonnei 22M CHECKING THE BRAKE LIGHT SWITCHES. 3.25 3-20 3-20