Yz 250 Fe

2014
q Read this manual carefully before operating this vehicle.
q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule.
q Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
q Leggere attentamente questo manuale prima di utilizzare questo veicolo.
YZ250F(E)
OWNER’S SERVICE MANUAL
MANUEL D’ATELIER DU
PROPRIETAIRE
FAHRER- UND
WARTUNGSHANDBUCH
MANUALE DI SERVIZIO DEL
PROPRIETARIO
2014
YZ250F(E)
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 1SM-28199-30
2013.08—2.0 × 1 !
(E, F, G, H)
1SM-28199-30_cover.indd 1 2013/07/23 18:31:44

Q Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
Q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit
être remis avec le véhicule en cas de vente de ce dernier.
Q Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
Diese Bedienungsanleitung muss, wenn das Fahrzeug verkauft wird, beim Fahrzeug verbleiben.
Q Leggere attentamente questo manuale prima di utilizzare il veicolo. Questo manuale dovrebbe
accompagnare il veicolo se viene venduto.
1SM-28199-30_cover.indd 2 2013/07/23 18:31:45

2014
Read this manual carefully before operating this vehicle.
YZ250F(E)
1SM-28199-30-E0
EAS1SM1002
YZ250F(E) 2014
©2013 by Yamaha Motor Co., Ltd.
First edition, August 2013
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
INTRODUCTION
EAS1SM1003
Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha’s
vast experience in the production of pacesetting racing machines. It represents the highest grade of
craftsmanship and reliability that have made Yamaha a leader.
This manual explains operation, inspection, basic maintenance and tuning of your machine. If you
have any questions about this manual or your machine, please contact your Yamaha dealer.
TIP
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual
contains the most current product information available at the time of printing, there may be minor
discrepancies between your machine and this manual. If you have any questions concerning this
manual, please consult your Yamaha dealer.
EWA1DX0001
WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS
MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A
SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL
YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPEC-
TIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE
THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.
IMPORTANT MANUAL INFORMATION

EAS1SM1004
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
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could

WARNING result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid

NOTICE damage to the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.

SAFETY INFORMATION
EAS1SM1005
THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED

COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road
use on public lands may also be illegal. Please check local regulations before riding.
• THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY.
Do not attempt to operate this machine at maximum power until you are totally familiar with its char-
acteristics.
• THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY.
Do not carry passengers on this machine.
• ALWAYS WEAR PROTECTIVE APPAREL.
When operating this machine, always wear an approved helmet with goggles or a face shield. Also
wear heavy boots, gloves, and protective clothing. Always wear proper fitting clothing that will not
be caught in any of the moving parts or controls of the machine.
• ALWAYS MAINTAIN YOUR MACHINE IN PROPER WORKING ORDER.
For safety and reliability, the machine must be properly maintained. Always perform the pre-oper-
ation checks indicated in this manual.
Correcting a mechanical problem before you ride may prevent an accident.
• GASOLINE IS HIGHLY FLAMMABLE.
Always turn off the engine while refueling. Take care to not spill any gasoline on the engine or ex-
haust system. Never refuel in the vicinity of an open flame, or while smoking.
• GASOLINE CAN CAUSE INJURY.
If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get
into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, imme-
diately wash skin areas with soap and water, and change your clothes.
• ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILATION.
Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are
poisonous. These fumes contain carbon monoxide, which by itself is odorless and colorless. Car-
bon monoxide is a dangerous gas which can cause unconsciousness or can be lethal.
• PARK THE MACHINE CAREFULLY; TURN OFF THE ENGINE.
Always turn off the engine if you are going to leave the machine. Do not park the machine on a slope
or soft ground as it may fall over.
• THE ENGINE, EXHAUST PIPE AND MUFFLER WILL BE VERY HOT AFTER THE ENGINE HAS
BEEN RUN.
Be careful not to touch them or to allow any clothing item to contact them during inspection or repair.
• PROPERLY SECURE THE MACHINE BEFORE TRANSPORTING IT.
For safety, drain the gasoline from the fuel tank before transporting the vehicle.
HOW TO USE THIS MANUAL
EAS1SM1006
In this manual, descriptions of installation, removal, disassembly, assembly, check, and adjustment
procedures are laid out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section
title “1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of
each removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a re-
moval or a disassembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, the
names of parts, the notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described se-
quentially.
5 1
6
7
SYMBOLS
EAS1SM1007
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil

G
Filling fluid Molybdenum disulfide oil

M
Lubricant Brake fluid

BF
Special tool B Wheel bearing grease
Tightening torque LS Lithium-soap-based grease

T.
R.
Wear limit, clearance M Molybdenum disulfide grease
Engine speed S Silicone grease
Electrical data Locking agent (LOCTITE®)

LT
Engine oil New Replace the part with a new one.

E
TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND ADJUST-
MENTS
3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL SYSTEM 7
ELECTRICAL SYSTEM 8
TROUBLE SHOOTING 9
TUNING 10
GENERAL INFORMATION
LOCATION OF IMPORTANT LABELS............................................................1-1
DESCRIPTION..................................................................................................1-4 1
IDENTIFICATION .............................................................................................1-5
VEHICLE IDENTIFICATION NUMBER ......................................................1-5
ENGINE SERIAL NUMBER .......................................................................1-5
MODEL LABEL...........................................................................................1-5
FEATURES.......................................................................................................1-6
OUTLINE OF THE FI SYSTEM..................................................................1-6
FI SYSTEM.................................................................................................1-7
INCLUDED PARTS ..........................................................................................1-8

SIDESTAND ...............................................................................................1-8
SPARK PLUG WRENCH ...........................................................................1-8
NIPPLE WRENCH......................................................................................1-8
HANDLEBAR PROTECTOR ......................................................................1-8
FUEL HOSE JOINT COVER ......................................................................1-8
COUPLER FOR CONNECTING OPTIONAL PART...................................1-8
IMPORTANT INFORMATION ........................................................................1-10

PREPARATION FOR REMOVAL AND DISASSEMBLY..........................1-10
REPLACEMENT PARTS..........................................................................1-10
GASKETS, OIL SEALS AND O-RINGS ...................................................1-11
LOCK WASHERS/PLATES AND COTTER PINS ....................................1-11
BEARINGS AND OIL SEALS ...................................................................1-11
CIRCLIPS .................................................................................................1-11
BASIC SERVICE INFORMATION..................................................................1-12

ELECTRICAL SYSTEM............................................................................1-12
SPECIAL TOOLS ...........................................................................................1-15
CONTROL FUNCTIONS ................................................................................1-20

ENGINE STOP SWITCH..........................................................................1-20
CLUTCH LEVER ......................................................................................1-20
SHIFT PEDAL ..........................................................................................1-20
KICKSTARTER LEVER............................................................................1-20
THROTTLE GRIP.....................................................................................1-20
FRONT BRAKE LEVER ...........................................................................1-20
REAR BRAKE PEDAL..............................................................................1-21
STARTER KNOB/IDLE SCREW ..............................................................1-21
FUEL TANK CAP .....................................................................................1-21
STARTING AND BREAK-IN ..........................................................................1-22
FUEL ........................................................................................................1-22
STARTING A COLD ENGINE ..................................................................1-22
STARTING A WARM ENGINE.................................................................1-23
BREAK-IN PROCEDURES ......................................................................1-23
MAINTENANCE AFTER BREAK-IN ..............................................................1-24

MAJOR MAINTENANCE..........................................................................1-24
TORQUE-CHECK POINTS ............................................................................1-25
CLEANING AND STORAGE..........................................................................1-27

CLEANING ...............................................................................................1-27
STORAGE ................................................................................................1-27
LOCATION OF IMPORTANT LABELS

EAS1SM1008
Please read the following important labels carefully before operating this vehicle.
1,2,3 4,5,6 7,8 9,10,11
13 12
CAN
1-1
EUR
1-2
AUS, NZL, ZAF
1-3
DESCRIPTION
DESCRIPTION
EAS1SM1009
1 2
6 5 4 3
7 8 9 12
11 10 17 16 15 14 13
1. Clutch lever 10. Coolant drain bolt
2. Front brake lever 11. Rear brake pedal
3. Throttle grip 12. Air filter
4. Radiator cap 13. Drive chain
5. Fuel tank cap 14. Shift pedal
6. Engine stop switch 15. Oil level check window
7. Fuel tank 16. Starter knob/idle screw
8. Kickstarter lever 17. Front fork
9. Radiator
TIP
Designs and specifications of the vehicle are subject to change without notice. Therefore, please
note that the descriptions in this manual may be different from those for the vehicle you have pur-
chased.
1-4
IDENTIFICATION
IDENTIFICATION
EAS1SM1010
There are two significant reasons for knowing

the serial number of your vehicle:
1. When ordering parts, you can give the num-
ber to your Yamaha dealer for positive iden-
tification of the model you own.
2. If your vehicle is stolen, the authorities will
need the number to search for and identify
your vehicle.
VEHICLE IDENTIFICATION NUMBER
EAS1SM1011
The vehicle identification number “1” is

stamped into the right side of the frame.
ENGINE SERIAL NUMBER

EAS1SM1012
The engine serial number “1” is stamped into

the elevated part of the right-side of the engine.
MODEL LABEL
EAS1SM1013
The model label “1” is affixed to the rear frame.

This information will be needed to order spare
parts.
1-5
FEATURES
FEATURES
EAS20170
OUTLINE OF THE FI SYSTEM

EAS1SM1014
The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti-
mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera-
ture. In the conventional carburetor system, the air-fuel ratio of the mixture to be supplied to the
combustion chamber is determined by the amount of intake air and fuel that is measured on the basis
of the jets to be used in the carburetor.
Despite the same amount of intake air, the fuel amount requirement varies with the engine operating
conditions (acceleration, deceleration, and operation under a heavy load). The carburetor that mea-
sures fuel through the use of jets are provided with various auxiliary devices, so that the optimum air
fuel ratio can be obtained to accommodate frequent changes in the operating conditions of the en-
gine. This model has adopted an electronically controlled fuel injection (FI) system, in place of the
conventional carburetor system. This system can obtain the optimum air-fuel ratio required by the
engine at all times by using a microprocessor that regulates the fuel injection amount according to
the engine operating conditions detected by various sensors.
123 4 5 6
10 9 8 7
1. Fuel injector
2. Throttle position sensor
3. Intake air pressure sensor
4. Intake air temperature sensor
5. ECU
6. Fuel pump
7. Condenser
8. Crankshaft position sensor
9. Coolant temperature sensor
10.Ignition coil
EAS1SM1015
1-6
FEATURES
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kgf/cm2, 47.0 psi). 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. There-
fore, 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 input from the throt-
tle position sensor, the coolant temperature sensor, the crankshaft position sensor, the intake air
pressure sensor, and the intake air temperature sensor enable the ECU to determine the injection
duration. The injection timing is determined through the signals from the crankshaft position sensor.
As a result, the volume of fuel that is required by the engine can be supplied at all times in accordance
with the driving conditions.
C
1
3
A 5
2
10
B
9
4
8 7
1. Fuel pump
2. Fuel injector
3. ECU
8. Throttle body
10.Air filter case
A. Fuel system
B. Intake system
C. Control system
1-7
INCLUDED PARTS
INCLUDED PARTS HANDLEBAR PROTECTOR

EAS1SM1016
Install the handlebar protector “1” with the mark

SIDESTAND “a” facing forward.
EAS1SM1017
The sidestand “1” is used to support only the

machine when standing or transporting it.
EWA@
WARNING a
• Never apply additional force to the sides-
tand.
• Remove this sidestand before starting out.
1
FUEL HOSE JOINT COVER

EAS1SM1021
The fuel hose joint covers “1” are used to pre-

vent mud, dust, and other foreign materials
from entering the inside when the fuel hose is
disconnected.
1
SPARK PLUG WRENCH
EAS1SM1018
The spark plug wrench “1” is used to remove or

install the spark plug.
COUPLER FOR CONNECTING OPTIONAL

EAS1SM1022
PART
1 The coupler “1” is used for connecting the op-
tional Power Tuner and so on.
ECA1DX1002
NOTICE
NIPPLE WRENCH
EAS1SM1019
The nipple wrench “1” is used to tighten the When no optional parts, etc. are connected,
spoke. connect the connection terminal to the orig-
inal coupler.
Before disconnecting the coupler, thor-
oughly wipe off any mud or water stuck to it.
EAS1SM1020 1
1-8
INCLUDED PARTS
Part name Part number

GYTR Power Tuner 33D-H59C0-V0-00
(For USA)
YZ Power Tuner 33D-859C0-10
(Except for USA)
The Power Tuner is an optional part.
1-9
IMPORTANT INFORMATION
EAS20180
PREPARATION FOR REMOVAL AND DIS-

EAS1SM1023
ASSEMBLY
1. Before the jobs, completely remove mud,
dust, and the like in order to prevent the en-
try of them into the inside during the jobs.
4. During disassembly, clean each of the parts,

and store them in trays for each section.
5. Flammable. Keep servicing areas away
from any source of fire.
6. During servicing, take special care not to re-
ceive an injury or a burn on the engine, the
exhaust pipe, the silencer, or the like.
• Before cleaning with high-pressure water of 7. If coolant is left adhered to the chassis, paint
washers, cover the following parts. and plating will be damaged. Therefore,
Air duct rinse it out with water in good time.
Silencer exhaust port
EWA
WARNING
Drain hole on the cylinder head (right side)
Coolant is potentially harmful and should
Hole under the water pump housing
be handled with special care.
• If it enters your eyes, wash it away with wa-
ter enough and then get medical attention
• If it splashes on your skin or clothes,
quickly wash it away with water and then
with soapy water.
• If it is swallowed, immediately induce vom-
iting and get medical attention.
REPLACEMENT PARTS
EAS1SM1024
Make sure that the parts and grease or oil to be

2. Use proper special tools and equipment. used for repair of the vehicle, including periodic
See “SPECIAL TOOLS”. replacement parts, are new YAMAHA genuine
parts and recommended parts.
Do not use any used parts, because these may
not be genuine though they have similar ap-
pearances or because the quality may be
changed by aging.
3. During disassembly, check and measure the

required parts, and make a record of them
so that you may refer to the record when in-
stalling them. Moreover, arrange gears, cyl-
inders, pistons, and other parts for each
section so as not to confuse or lose them. EAS1SM1025
1-10
GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all
gaskets and O-rings. All gasket surfaces, oil
seal lips, and O-rings must be cleaned so
that there may be no dust on them.
2. During assembly, always apply proper oil to
bearings and proper grease to oil seal lips
before installation.
1. Oil
2. Lip
3. Spring
4. Grease CIRCLIPS
EAS1SM1028
LOCK WASHERS/PLATES AND COTTER

EAS1SM1026
When assembling parts, always use new cir-
PINS clips. During installation of a circlip, make sure
After removal, replace lock washers/plates “1” that the edge “2” of the circlip “1” is positioned
and cotter pins with new ones. After the bolt or opposite to the force “3” that the circlip re-
nut has been tightened to specification, firmly ceives. Install the circlip with its end aligned
bend the lock tabs along a flat of the bolt or nut. with the center of the spline, without opening
the circlip more than necessary.
BEARINGS AND OIL SEALS

EAS1SM1027
Install bearings “1” and oil seals “2” with their

manufacturer’s marks or size symbols facing
outward. During installation of an oil seal, make
sure that its main lip faces the oil chamber (the
target to be sealed). Before installation, always
apply a light coat of grease to the oil seal lip.
ECA13300
NOTICE
Do not spin a bearing with compressed air
because this will damage the bearing sur-
faces.
1-11
BASIC SERVICE INFORMATION

EAS1SM1029
a
ELECTRICAL SYSTEM
EAS1SM1030
Electrical parts handling

ECA16620
NOTICE
Handle electrical components with special
care, and do not subject them to strong
shocks.
ECA16640
NOTICE
For waterproof couplers, never insert the
tester probes directly into the coupler.
When performing any checks using a water-
proof coupler, use the specified test har-
ness or a suitable commercially available
test harness.
ECA16630
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.
Checking the connections

Check leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• Lead
• Coupler
• Connector
ECA16780
NOTICE
Checking the electrical system
ECA14371
• When disconnecting a coupler, release the
NOTICE coupler lock, hold both sections of the
Never insert the tester probes into the cou- coupler, and then disconnect the coupler.
pler terminal slots. Always insert the probes • There are many types of coupler locks;
from the opposite end “a” of the coupler, therefore, be sure to check the type of cou-
taking care not to loosen or damage the pler lock before disconnecting the cou-
leads. pler.
1-12
1
ECA16790
NOTICE
When disconnecting a connector, do not
pull the leads. Hold both sections of the
connector, and then disconnect the con-
nector.
4. Connect:
• Lead
• Coupler
• Connector
TIP
• When connecting a coupler or a connector,
2. Check:
make sure that both terminals are connected
• Lead
securely.
• Coupler
• Make sure all connections are tight.
• Connector
Moisture  Dry with compressed air.
Rust/stains  Connect and disconnect sev-
eral times.
3. Check:
• All connections
Loose connection  Connect properly.
TIP
• If the pin “1” on the terminal is flattened, bend
it up.
• After disassembling or assembling a coupler,
pull on the leads to make sure that they are in-
stalled securely.
1-13
5. Check:
• No continuity
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
TIP
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (4).
• As a quick remedy, use a contact revitalizer
available at most part stores.
1-14
SPECIAL TOOLS
SPECIAL TOOLS
EAS1SM1031
The following special tools are required for accurate and complete adjustment and assembly. Using
the correct special tool will help prevent damage caused by the use of improper tools or improvised
techniques. The shape and tool number used for the special tool differ by country, so two types are
provided. Refer to the list provided to avoid errors when placing an order.
TIP
• For U.S.A. and Canada, use tool number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use tool number starting with “90890-”.
Tool name/Part number How to use Illustration

Dial gauge & stand set This tool is used to check
90890-01252 parts for runout or bend.
Dial gauge set
YU-03097-B
Crankshaft installer pot This tool is used to install the

90890-01274 crankshaft.
Installing pot
YU-90058
Crankshaft installer bolt This tool is used to install the

Bolts
YU-90060
Adapter (M12) This tool is used to install the

Adapter #3
YU-90063
Piston pin puller set This tool is used to remove

90890-01304 the piston pin.
Piston pin puller
YU-01304
1-15
SPECIAL TOOLS

Radiator cap tester This tool is used to check the
90890-01325 radiator and the radiator cap.
Mityvac cooling system tester
kit
YU-24460-A
Radiator cap tester adapter This tool is used to check the

90890-01352 radiator and the radiator cap.
Pressure tester adapter
YU-33984
Steering nut wrench This tool is used to remove or

90890-01403 tighten the steering nut.
Exhaust flange nut wrench
YU-A9472
Cap bolt wrench This tool is used to remove or

90890-01500 tighten the base valve.
YM-01500
Cap bolt ring wrench This tool is used to loosen or

90890-01501 tighten the damper assem-
YM-01501 bly.
Fork seal driver This tool is used to install the

90890-01502 oil seal of the front fork.
YM-A0948
Spoke nipple wrench (6–7) This tool is used to tighten the

90890-01521 spoke.
YM-01521
1-16
SPECIAL TOOLS

Pocket tester This tool is used to measure
90890-03112 the voltage, current, and re-
Analog pocket tester sistance of electrical compo-
YU-03112-C nents.
Timing light This tool is used to measure

90890-03141 the ignition timing.
YU-03141
Pressure gauge This tool is used to measure

90890-03153 the fuel pressure.
YU-03153
Yamaha diagnostic tool This tool is used to check er-

90890-03215 ror codes or carry out self-di-
agnosis.
Fuel pressure adapter This tool is used to mount the

90890-03186 pressure gauge.
YM-03186
Test harness S-pressure This tool is used to check the

sensor (3P) throttle position sensor input
90890-03207 voltage.
YU-03207
FI diagnostic tool sub-lead This tool is used to connect

90890-03212 the Yamaha diagnostic tool
YU-03212 to a battery.
Spacer (crankshaft installer) This tool is used to install the

Pot spacer
YM-91044
YM-91044
1-17
SPECIAL TOOLS

Clutch holder This tool is used to hold the
90890-04086 clutch when removing or in-
YM-91042 stalling the clutch boss secur-
ing nut.
Valve lapper This tool is used to remove

90890-04101 the valve lifter or lap the
Valve lapping tool valve.
YM-A8998
Valve spring compressor This tool is used to discon-

90890-04019 nect or connect the valve and
YM-04019 the valve spring.
YM-04019
Valve spring compressor This tool is used to discon-

adapter 22 mm nect or connect the valve and
90890-04108 the valve spring.
YM-04108
Valve guide remover (ø5) This tool is used to replace

90890-04097 the valve guide.
Valve guide remover (5.0
mm)
YM-04097
Valve guide installer (ø5) This tool is used to replace

Valve guide installer (5.0
mm)
YM-04098
Valve guide reamer (ø5) This tool is used to replace

Valve guide reamer (5.0 mm)
YM-04099
1-18
SPECIAL TOOLS

Valve guide remover (ø4.5) This tool is used to replace
Valve guide remover (4.5
mm)
YM-04116
Valve guide installer (ø4.5) This tool is used to replace

Valve guide installer (4.5
mm)
YM-04117
Valve guide reamer (ø4.5) This tool is used to replace

Valve guide reamer (4.5 mm)
YM-04118
Rotor puller This tool is used to remove

90890-04151 the rotor.
YM-04151
Crankcase separating tool This tool is used to remove

90890-04152 the crankshaft.
YU-A9642
Ignition checker This tool is used to check the

90890-06754 spark performance of the ig-
Oppama pet-4000 spark nition coil.
checker
YM-34487
Digital tachometer This tool is used to measure

90890-06760 the engine speed.
YU-39951-B
Three bond No.1215® This sealant (Bond) is used

90890-85505 for crankcase mating sur-
face, etc.
1-19
CONTROL FUNCTIONS
CONTROL FUNCTIONS KICKSTARTER LEVER

EAS1SM1032
The kickstarter lever “1” is in the right of the

ENGINE STOP SWITCH chassis.
EAS1SM1033
The engine stop switch “1” is located on the left To start the engine, pull out and push down the
handlebar. Continue pushing the engine stop kickstarter lever with your foot.
switch till the engine comes to a stop.
1
THROTTLE GRIP
EAS1SM1037
CLUTCH LEVER The throttle grip “1” is located on the right han-
EAS1SM1034
The clutch lever “1” is located on the left handlebar. The throttle grip accelerates or deceler-
dlebar. The clutch lever disengages or engag- ates the engine. For acceleration, turn the grip
es the clutch. toward you; for deceleration, turn it away from
Pull the clutch lever toward the handlebar to you.
disengage the clutch, and release the lever to
engage the clutch.
FRONT BRAKE LEVER

EAS1SM1038
The front brake lever “1” is located on the right

SHIFT PEDAL handlebar. Pull it toward the handlebar to acti-
EAS1SM1035
The shift pedal “1” has adopted a method of 1 vate the front brake.
down & 4 ups (press-down & kick-ups).
Press it down for N (neutral) to 1st, and kick it
up for 2nd to 5th. 1
EAS1SM1039
EAS1SM1036
1-20
CONTROL FUNCTIONS
REAR BRAKE PEDAL

The rear brake pedal “1” is in the right of the
chassis. Press down on the brake pedal to ac- 1
tivate the rear brake. 3 2
STARTER KNOB/IDLE SCREW

EAS1SM1040
b
a
1
Starting a cold engine requires a larger amount

of intake air, which is supplied by the starter
knob/idle screw “1”.
Pulling the knob toward “a” turns ON the start-
er, resulting in a larger amount of intake air.
Pushing the knob toward “b” turns OFF the
starter.
EWA@
WARNING
While handling the starter knob/idle screw,
take care not to burn yourself on exhaust
pipes.
FUEL TANK CAP

EAS1SM1040
Fuel tank cap “1” is located under the fuel tank

cap cover “2”.
Remove the fuel tank cap cover to open the fuel
tank cap.
TIP
• To remove the fuel tank cap cover, insert fin-
gers under part “a”, and then use both hands
to lift it up towards the rear of the vehicle.
• Install the fuel tank cap cover after placing the
bands “3” all the way in under the seat.
1-21
STARTING AND BREAK-IN

EAS1SM1041
FUEL
EAS1SM1042
Always use the recommended fuel as stated

below. Also, be sure to use new gasoline the 1
day of a race.
Recommended fuel
Premium unleaded gasoline
Fuel tank capacity
7.5 L (1.98 US gal, 1.65 lmp.gal)
3. Push down the kickstarter lever lightly until
JCA
resistance is felt.
NOTICE
4. Fully close the throttle, and push down the
Use only unleaded gasoline. The use of kickstarter lever in a stroke.
leaded gasoline will cause severe damage 5. Immediately release the kickstarter lever.
to the engine internal parts such as valves, EWA
piston rings, and exhaust system, etc. WARNING

Do not open the throttle at the moment
TIP when you kick the kickstarter lever, be-
Your Yamaha engine has been designed to use cause this may kick back
premium unleaded gasoline with a pump oc-
tane number [(R+M)/2] of 91 or higher, or a re- TIP
search octane number of 95 or higher. If If it fails to start, fully open the throttle grip and
knocking (or pinging) occurs, use a gasoline of give 10 to 20 slow kicks to clear the engine of
a different brand. the rich air-fuel mixture retained in it.
JWA
6. When the engine starts running, warm this

WARNING
up one or two minutes at a steady speed (of
• For refueling, be sure to stop the engine 3000 to 5000 r/min), and then return the
and use enough care not to spill any fuel. starter knob/idle screw to its original posi-
Also be sure to avoid refueling close to a tion.
fire.
• Refuel after the engine, exhaust pipe, etc.
have cooled off.
Gasohol (For USA and Canada)
There are two types of gasohol: gasohol con-
taining ethanol and that containing methanol.
Gasohol containing ethanol can be used if the
ethanol content does not exceed 10%. Gasohol
containing methanol is not recommended by
Yamaha because it can cause damage to the
fuel system or vehicle performance problems.
EWA
WARNING
STARTING A COLD ENGINE Since exhaust gas contains harmful ingre-
EAS1SM1043
1. Press the shift pedal to neutral. dients, do not start or warm it up at an ill-
2. Pull the starter knob/idle screw “1” to its full ventilated place or a closed narrow place.
length.
TIP
When the ambient temperature is 15°C (59°F)
or below, use the starter knob/idle screw.
1-22
7. To stop the engine, push the engine stop NOTICE

switch “1”.
After a break-in or after each race, always
TIP check the points shown in “TORQUE-
Continue pushing the engine stop switch till the CHECK POINTS” for tightening torques and
engine comes to a full stop. retighten them. (Refer to “TORQUE-CHECK
POINTS” on page 1-25.)
Also when the following parts are replaced,
a break-in is required.
• Cylinder and Crankshaft: A break-in is re-
quired for about an hour.
• Piston, Piston ring, Valve, Camshaft, and
Gear: A break-in is required for about 30
minutes at a throttle opening of 1/2 or less.
Observe the condition of the engine careful-
ly during a break-in.
For checkpoints for a break-in, see “MAIN-
STARTING A WARM ENGINE TENANCE AFTER BREAK-IN”. If any prob-
EAS1SM1044
When the engine is warm, give a kick with the lem is found, immediately stop the engine
throttle closed without using the starter knob/ and make a checkup.
idle screw.
TIP
If it fails to start, fully open the throttle grip and
give 10 to 20 slow kicks to clear the engine of
the rich air-fuel mixture retained in it.
BREAK-IN PROCEDURES
EAS1SM1045
A break-in is important so that rotating portion,

sliding surfaces, and mounted areas may fit
one another, and that the rider may become ac-
customed to the machine.
ECA
NOTICE
Before running, do maintenance on the air
filter element.
Refer to “CLEANING THE AIR FILTER ELE-
MENT” on page 3-12.
1. After warming up the engine, drive it for
about 20 minutes at a throttle opening of 1/2
or less.
2. Make a pit stop, and check mounted areas
for looseness, oil leaks, or other problems.
3. Then, drive it for about 40 minutes at a throt-
tle opening of 3/4 or less.
4. Make a pit stop again, and thoroughly check
mounted areas for looseness, oil leaks, or
other problems. Thorough checks and ad-
justments are required in particular for
stretch of cables, free play of the brake,
stretch of the drive chain, looseness of the
spoke, and so on.
ECA
1-23
MAINTENANCE AFTER BREAK-IN
MAINTENANCE AFTER BREAK-IN • Cable

EAS1SM1046
Grease and adjust cables.

After a break-in, perform careful maintenance
• Drive chain
to get ready for the next practice or race.
Lubricate the drive chain and adjust its ten-
Refer to “PRE-OPERATION INSPECTION
sion.
AND MAINTENANCE” on page 3-7.
• Fuel tank
MAJOR MAINTENANCE Clean the inside of the fuel tank. Check for
EAS1SM1047
1. For the engine leaks.

• Leaks around the engine • Suspension
Check for pressure leaks from the cylinder Check for oil leaks in the front fork or the rear
head or the cylinder, oil leaks from the shock absorber. Check that the mounted
crankcase or the case cover, leaks from the conditions are good.
coolant system, and other leaks. • Sprocket
• Check that the valve, the cylinder head, the Check for looseness in the sprocket mount-
cylinder, the piston, and the piston ring fit ed on the rear wheel.
one another, and that contact between the • Mounting bolts and nuts
valve and the cylinder head, and that be- Check mounted areas for looseness.
tween the cylinder and the piston are cor-
JCA1SL1001
NOTICE
rect.
After a break-in or before each race, always
• Engine oil change
check the points shown in “TORQUE-
Drain the oil, and check for dirt and foreign
CHECK POINTS” for tightening torques and
materials such as metal chips. (If any foreign
retighten them. (Refer to “TORQUE-CHECK
material is mixed, disassemble and check
POINTS”.)
the crankcase.)
Pour the specified amount of the recom- • Greasing and oiling
mended oil. Always grease or oil the specified points.
• AC magneto
Check for looseness in mounted areas of
the rotor and the stator.
Check that the connector is not being dis-
connected.
• Silencer
Check the main body and stay for cracks.
Check for leaks.
• Mounting bolts and nuts
Check for looseness in mounted areas of
parts, as well as engine mounting bolts and
engine brackets.
2. For the chassis
• Check welds and mounted areas of the
frame, the swingarm, the link, the bracket,
and so on, for looseness and cracks.
• Wheel (s)
Check the wheel for runout. Check the
spoke for looseness.
• Brake(s)
Check the brake disc mounting bolt for
looseness.
Check that the reservoir contains the speci-
fied amount of brake fluid. Check for leaks.
1-24
TORQUE-CHECK POINTS
TORQUE-CHECK POINTS
EAS1SM1048
Frame construction Frame to rear frame

Frame to engine protector
Combined seat and fuel tank Fuel tank to frame
Engine mounting Frame to engine
Engine bracket to engine
Engine bracket to frame
Seat Seat to frame
Steering Steering stem to handlebar Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Suspension Front Steering stem to front fork Front fork to upper bracket
Front fork to lower bracket
Rear Link Assembly of links
Link to frame
Link to rear shock absorber
Link to swingarm
Mounting of rear shock absorber Rear shock absorber and frame
Mounting of swingarm Tightening of pivot shaft
Wheel (s) Mounting of wheel Front Tightening of wheel axle
Tightening of axle holder
Tightening of spoke nipple
Rear Tightening of wheel axle
Wheel to rear wheel sprocket
Tightening of spoke nipple
Brake(s) Front Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to handle-
bar
Tightening of bleed screw
Tightening of brake hose holder
Rear Brake pedal to frame
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw
Tightening of brake hose holder
Shift pedal Shift pedal to shift shaft
Fuel system Fuel pump to fuel tank
1-25
TORQUE-CHECK POINTS
Plastic cover Tightening of number plate

Tightening of front fender
Tightening of fork leg protector
Tightening of air scoop
Left cover to rear frame
Tightening of side cover
Tightening of rear fender
Tightening of mud flap
Tightening of rear brake disc cov-
er
Tightening of rear brake caliper
cover
TIP
Concerning the tightening torque, refer to “TIGHTENING TORQUES” on page 2-12.
1-26
CLEANING AND STORAGE
CLEANING AND STORAGE 3. Remove the drive chain, clean it thoroughly

EAS1SM1049
with solvent, and lubricate it Reinstall the

CLEANING drive chain or store it in a plastic bag tied to
EAS1SM1050
Frequent cleaning of your vehicle will enhance the frame.

its appearance, maintain performance, and ex- 4. Lubricate all cables.
tend the life of parts. 5. Lift up the frame of the vehicle to keep the
1. Before cleaning, block the silencer outlet to wheels off the ground.
prevent water from entering. A plastic bag 6. Tie a plastic bag over the muffler outlet to
secured with a rubber band may be used for prevent moisture from entering.
this purpose. 7. If the vehicle is to be stored in a place that is
2. If the engine is contaminated with oil, apply humid or exposed to the sea breeze, apply a
some degreaser to it with a brush. Do not light coat of oil to metal surfaces. Do not ap-
apply degreaser to the drive chain, the ply oil to the seat or rubber parts.
sprockets, or the wheel axles. TIP
3. Hose off dirt. Use only enough water pres- Make any necessary repairs before the vehicle
sure to do the job. is stored.
ECA
NOTICE
Do not use high-pressure washers or steam
cleaners. Otherwise, these may cause a fail-
ure because of the entry of water.
4. After hosing off the dirt, wash all surfaces
with a mild detergent and warm water. Use
a toothbrush to clean hard-to-reach places.
5. Rinse the detergent with clean water, and
dry the surfaces with a soft towel or a cloth.
6. Immediately after cleaning, remove any wa-
ter from the drive chain with a paper towel,
and lubricate it to prevent rust.
7. Clean the seat with a vinyl upholstery clean-
er to keep the cover pliable and glossy.
8. Automotive wax may be applied to all paint-
ed or chromed surfaces. Avoid using such
wax as contains abrasives, because it may
scratch surfaces.
9. After completing the above, start the engine
and allow it to warm up for several minutes.
STORAGE
EAS1SM1051
If your vehicle is to be stored for 60 days or

more, some preventive measures must be tak-
en to avoid deterioration. After cleaning the ve-
hicle thoroughly, prepare it for storage as
follows:
1. Fill the fuel tank with gasoline.
2. Remove the spark plug, pour a spoonful of
engine oil (SAE 10W-40) into the spark plug
hole, and reinstall the plug. With the engine
stop switch pushed in, by pushing down the
kickstarter lever, crank the engine to coat
the cylinder walls with oil.
1-27
CLEANING AND STORAGE
1-28
SPECIFICATIONS
GENERAL SPECIFICATIONS .........................................................................2-1
ENGINE SPECIFICATIONS .............................................................................2-2
CHASSIS SPECIFICATIONS ...........................................................................2-8
ELECTRICAL SPECIFICATIONS ..................................................................2-11 2

TIGHTENING TORQUES ...............................................................................2-12
GENERAL TIGHTENING TORQUE SPECIFICATIONS..........................2-12
ENGINE TIGHTENING TORQUES..........................................................2-13
CHASSIS TIGHTENING TORQUES........................................................2-16
LUBRICATION POINTS AND LUBRICANT TYPES .....................................2-19

ENGINE....................................................................................................2-19
CHASSIS..................................................................................................2-21
LUBRICATION SYSTEM CHART AND DIAGRAMS.....................................2-23

LUBRICATION DIAGRAMS .....................................................................2-23
CABLE ROUTING DIAGRAM ........................................................................2-31

GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
EAS1SM1052
Model
Model 1SM1 (USA) (CAN)
1SM2 (EUR)
1SM3 (JPN)
1SM4 (AUS) (NZL) (ZAF)
Dimensions
Overall length 2165 mm (85.2 in) (USA) (CAN) (AUS) (NZL)
(ZAF)
2170 mm (85.4 in) (EUR) (JPN)
Overall width 825 mm (32.5 in)
Overall height 1280 mm (50.4 in) (USA) (CAN) (EUR) (JPN)
1275 mm (50.2 in) (AUS) (NZL) (ZAF)
Seat height 965 mm (38.0 in) (USA) (CAN) (EUR) (JPN)
960 mm (37.8 in) (AUS) (NZL) (ZAF)
Wheelbase 1475 mm (58.1 in)
Ground clearance 325 mm (12.80 in) (USA) (CAN) (AUS) (NZL)
(ZAF)
330 mm (12.99 in) (EUR) (JPN)
Weight
Curb weight 105 kg (231 lb)
2-1
ENGINE SPECIFICATIONS
EAS1SM1053
Engine
Engine type Liquid cooled 4-stroke, DOHC
Displacement 250 cm3
Cylinder arrangement Single cylinder
Bore  stroke 77.0  53.6 mm (3.03  2.11 in)
Compression ratio 13.50:1
Starting system Kickstarter
Fuel
Recommended fuel Premium unleaded gasoline only
Fuel tank capacity 7.5 L (1.98 US gal, 1.65 Imp.gal)
Engine oil
Lubrication system Wet sump
Recommended brand YAMALUBE
Type SAE 10W-30, SAE 10W-40, SAE 10W-50,
SAE 15W-40, SAE 20W-40 or SAE 20W-50
Recommended oil grade API service SG type or higher, JASO standard
MA
Engine oil quantity
Quantity (disassembled) 0.90 L (0.95 US qt, 0.79 Imp.qt)
With oil filter element replacement 0.73 L (0.77 US qt, 0.64 Imp.qt)
Without oil filter element replacement 0.71 L (0.75 US qt, 0.62 Imp.qt)
Oil filter
Oil filter type Paper
Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance Less than 0.150 mm (0.0059 in)
Limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.13–0.18 mm (0.0051–0.0071 in)
Limit 0.24 mm (0.0094 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.06–0.11 mm (0.0024–0.0043 in)
Limit 0.17 mm (0.0067 in)
Cooling system
Radiator capacity (including all routes) 1.00 L (1.06 US qt, 0.88 Imp.qt)
Radiator capacity 0.58 L (0.61 US qt, 0.51 Imp.qt)
Radiator cap opening pressure 108–137 kPa (1.08–1.37 kg/cm2, 15.7–19.9
psi)
Radiator core
Width 112.6 mm (4.43 in)
Height 235.0 mm (9.25 in)
Depth 28.0 mm (1.10 in)
Water pump
Water pump type Single suction centrifugal pump
Spark plug
Manufacturer/model NGK/LMAR8G
Spark plug gap 0.7–0.8 mm (0.028–0.031 in)
2-2
Cylinder head
Volume 12.07–12.87 cm3 (0.74–0.79 cu.in)
Warpage limit 0.05 mm (0.0020 in)
Camshaft
Drive system Chain drive (left)
Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in)
Camshaft journal diameter 21.959–21.972 mm (0.8645–0.8650 in)
Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in)
Camshaft lobe dimensions
Intake A 31.730–31.830 mm (1.2492–1.2531 in)
Limit 31.630 mm (1.2453 in)
Intake B 22.450–22.550 mm (0.8839–0.8878 in)
Limit 22.350 mm (0.8799 in)
Exhaust A 33.370–33.470 mm (1.3138–1.3177 in)
Limit 33.270 mm (1.3098 in)
Exhaust B 25.211–25.311 mm (0.9926–0.9965 in)
Limit 25.111 mm (0.9886 in)
B
Camshaft runout limit 0.030 mm (0.0012 in)
Timing chain
Tensioning system Automatic
Valve, valve seat, valve guide
Valve clearance (cold)
Intake 0.12–0.19 mm (0.0047–0.0075 in)
Exhaust 0.17–0.24 mm (0.0067–0.0094 in)
Valve dimensions
Valve head diameter A (intake) 30.90–31.10 mm (1.2165–1.2244 in)
Valve head diameter A (exhaust) 24.90–25.10 mm (0.9803–0.9882 in)
A
Valve face width B (intake) 1.697 mm (0.0668 in)
Valve face width B (exhaust) 1.909 mm (0.0752 in)
2-3
Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in)

Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)
Valve margin thickness D (intake) 1.20 mm (0.0472 in)

Valve margin thickness D (exhaust) 0.85 mm (0.0335 in)
D
Valve stem diameter (intake) 4.975–4.990 mm (0.1959–0.1965 in)
Limit 4.945 mm (0.1947 in)
Valve stem diameter (exhaust) 4.460–4.475 mm (0.1756–0.1762 in)
Limit 4.430 mm (0.1744 in)
Valve guide inside diameter (intake) 5.000–5.012 mm (0.1969–0.1973 in)
Limit 5.050 mm (0.1988 in)
Valve guide inside diameter (exhaust) 4.500–4.512 mm (0.1772–0.1776 in)
Limit 4.550 mm (0.1791 in)
Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.010 mm (0.0004 in)
Valve spring
Free length (intake) 36.69 mm (1.44 in)
Limit 35.69 mm (1.41 in)
Free length (exhaust) 34.86 mm (1.37 in)
Limit 33.86 mm (1.33 in)
Installed length (intake) 31.40 mm (1.24 in)
Installed length (exhaust) 28.50 mm (1.12 in)
Spring rate K1 (intake) 29.65 N/mm (2.99 kgf/mm, 169.30 lbf/in)
Spring rate K2 (intake) 39.31 N/mm (4.01 kgf/mm, 222.46 lbf/in)
Spring rate K1 (exhaust) 23.11 N/mm (2.36 kgf/mm, 131.96 lbf/in)
Spring rate K2 (exhaust) 30.88 N/mm (3.15 kgf/mm, 176.32 lbf/in)
Installed compression spring force (intake) 146.00–168.00 N (14.89–17.13 kgf,
32.82–37.77 lbf)
Installed compression spring force (exhaust) 137.00–157.00 N (13.97–16.01 kgf,
30.80–35.29 lbf)
2-4
Spring tilt (intake) 2.5 °/1.6 mm (2.5 °/0.06 in)

Spring tilt (exhaust) 2.5 °/1.5 mm (2.5 °/0.06 in)
Winding direction (intake) Clockwise

Winding direction (exhaust) Clockwise
Cylinder
Bore 77.000–77.010 mm (3.0315–3.0319 in)
Taper limit 0.050 mm (0.0020 in)
Out of round limit 0.050 mm (0.0020 in)
Piston
Piston-to-cylinder clearance 0.030–0.055 mm (0.0012–0.0022 in)
Limit 0.15 mm (0.006 in)
Diameter D 76.955–76.970 mm (3.0297–3.0303 in)
Height H 6.0 mm (0.24 in)
H
D
Offset 0.00 mm (0.0000 in)
Piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in)
Limit 16.043 mm (0.6316 in)
Piston pin outside diameter 15.991–16.000 mm (0.6296–0.6299 in)
Limit 15.971 mm (0.6288 in)
Piston ring
Top ring
Ring type Barrel
Dimensions (B  T) 0.90  2.70 mm (0.04  0.11 in)
B
T
End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in)
Limit 0.50 mm (0.0197 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Limit 0.120 mm (0.0047 in)
Oil ring
Dimensions (B  T) 1.50  2.25 mm (0.06  0.89 in)
B
T
End gap (installed) 0.10–0.35 mm (0.0039–0.0138 in)
2-5
Crankshaft
Width A 55.95–56.00 mm (2.203–2.205 in)
Runout limit C 0.030 mm (0.0012 in)
Big end side clearance D 0.150–0.450 mm (0.0059–0.0177 in)
C C
D
A
Balancer
Balancer drive method Gear
Clutch
Clutch type Wet, multiple-disc
Clutch release method Inner push, cam push
Clutch lever free play 7.0–12.0 mm (0.28–0.47 in)
Friction plate thickness 2.90–3.10 mm (0.114–0.122 in)
Wear limit 2.80 mm (0.110 in)
Plate quantity 9 pcs
Clutch plate thickness 1.10–1.30 mm (0.043–0.051 in)
Plate quantity 8 pcs
Warpage limit 0.10 mm (0.0039 in)
Clutch spring free length 45.00 mm (1.77 in)
Limit 44.00 mm (1.73 in)
Spring quantity 5 pcs
Push rod bending limit 0.10 mm (0.0039 in)
Transmission
Transmission type Constant mesh 5-speed
Primary reduction system Spur gear
Primary reduction ratio 3.353 (57/17)
Final drive Chain
Secondary reduction ratio 3.846 (50/13)
Operation Left foot operation
Gear ratio
1st 2.143 (30/14)
2nd 1.750 (28/16)
3rd 1.444 (26/18)
4th 1.222 (22/18)
5th 1.042 (25/24)
Shifting mechanism
Shift mechanism type Shift drum and guide bar
Shift fork guide bar bending limit 0.050 mm (0.0020 in)
Shift fork thickness 4.85 mm (0.1909 in)
Decompression device
Device type Auto decomp
2-6
Air filter
Air filter element Wet element
Air filter oil grade Foam air-filter oil
Fuel pump
Pump type Electrical
Fuel injector
Model/quantity 30NA-FZ31/1
Resistance 12 
Throttle body
Type/quantity 30RA-A13M/1
ID mark 1SM1 00
Fuel pressure 324.0 kPa (3.24 kgf/cm2, 47.0 psi)
Throttle position sensor
Resistance 6.30 k
Output voltage (at idle) 0.5 V
Fuel injection sensor
Crankshaft position sensor resistance 228–342 
Intake air pressure sensor output voltage 3.57–3.71 V at 101.3 kPa
Intake air temperature sensor resistance 290–390  at 80 °C (176 °F)
Coolant temperature sensor resistance 2.51–2.78 k at 20 °C (68 °F)
210–221  at 100 °C (212 °F)
Idling condition
Engine idling speed 1900–2100 r/min
Water temperature 70–80 °C (158–176 °F)
Oil temperature 55–65 °C (131–149 °F)
Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)
2-7
CHASSIS SPECIFICATIONS
EAS1SM1054
Chassis
Frame type Semi double cradle
Caster angle 27.08 ° (USA) (CAN) (AUS) (NZL) (ZAF)
26.83 ° (EUR)
27.00 ° (JPN)
Trail 118 mm (4.6 in) (USA) (CAN) (EUR)
119 mm (4.7 in) (JPN) (AUS) (NZL) (ZAF)
Front wheel
Wheel type Spoke wheel
Rim size 21  1.60
Rim material Aluminum
Wheel travel 310.0 mm (12.20 in)
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Wheel axle bending limit 0.50 mm (0.02 in)
Rear wheel
Wheel type Spoke wheel
Rim size 19  1.85
Rim material Aluminum
Wheel travel 315.0 mm (12.40 in)
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Wheel axle bending limit 0.50 mm (0.02 in)
Front tire
Type With tube
Size 80/100-21 51M
Manufacturer/model BRIDGESTONE/M403A (USA) (CAN) (AUS)
(NZL) (ZAF)
PIRELLI/MID SOFT 32 (EUR)
DUNLOP/MX51FA (JPN)
Rear tire
Type With tube
Size 100/90-19 57M
Manufacturer/model BRIDGESTONE/M404 (USA) (CAN) (AUS)
(NZL) (ZAF)
PIRELLI/MID SOFT 32 (EUR)
DUNLOP/MX51G (JPN)
Tire air pressure (measured on cold tires)
Front 100 kPa (1.00 kgf/cm2, 15 psi)
Rear 100 kPa (1.00 kgf/cm2, 15 psi)
Front brake
Type Single disc brake
Operation Right hand operation
Front disc brake
Disc outside diameter  thickness 250.0  3.0 mm (9.84  0.12 in)
2-8
Brake disc thickness limit 2.5 mm (0.10 in)

Brake pad lining thickness (inner) 4.4 mm (0.17 in)
Limit 1.0 mm (0.04 in)
Brake pad lining thickness (outer) 4.4 mm (0.17 in)
Master cylinder inside diameter 9.52 mm (0.37 in)
Caliper cylinder inside diameter 22.65 mm  2 (0.89 in  2)
Recommended brake fluid DOT 4
Rear brake
Type Single disc brake
Operation Right foot operation
Rear disc brake
Disc outside diameter  thickness 245.0  4.0 mm (9.65  0.16 in)
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc deflection limit 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 6.4 mm (0.25 in)
Brake pad lining thickness (outer) 6.4 mm (0.25 in)
Master cylinder inside diameter 11.0 mm (0.43 in)
Caliper cylinder inside diameter 25.40 mm  1 (1.00 in  1)
Recommended fluid DOT 4
Steering
Steering bearing type Taper roller bearing
Center to lock angle (left) 43.0 °
Center to lock angle (right) 43.0 °
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 310.0 mm (12.20 in)
Fork spring free length 497.0 mm (19.57 in)
Limit 492.0 mm (19.37 in)
Installed length 497.0 mm (19.57 in)
Spring rate K1 4.70 N/mm (0.48 kgf/mm, 26.84 lbf/in) (USA)
(CAN)
4.60 N/mm (0.47 kgf/mm, 26.27 lbf/in) (EUR)
(JPN) (AUS) (NZL) (ZAF)
Spring stroke K1 0.0–310.0 mm (0.00–12.20 in)
Inner tube outer diameter 48.0 mm (1.89 in)
Inner tube bending limit 0.2 mm (0.01 in)
Optional spring available Yes
Recommended oil Suspension oil S1
Standard oil amount 526.0 cm3 (17.78 US oz, 18.55 Imp.oz) (USA)
(CAN)
551.0 cm3 (18.63 US oz, 19.43 Imp.oz) (EUR)
Rebound damping adjusting positions
* Position in which the adjuster is turned in finger tight
Minimum 20 click (s) out*
Standard 9 click (s) out* (USA) (CAN)
8 click (s) out* (EUR) (JPN) (AUS) (NZL) (ZAF)
Maximum (hard) Fully turned in
2-9
Compression damping adjusting positions

Standard 8 click (s) out* (USA) (CAN)
6 click (s) out* (EUR) (JPN) (AUS) (NZL) (ZAF)
Maximum (hard) Fully turned in
Rear suspension
Type Swingarm (link suspension)
Spring/shock absorber type Coil spring/gas-oil damper
Rear shock absorber assembly travel 132.0 mm (5.20 in)
Spring free length 275.0 mm (10.83 in)
Spring rate K1 56.00 N/mm (5.71 kgf/mm, 319.76 lbf/in) (USA)
(CAN)
54.00 N/mm (5.51 kgf/mm, 308.34 lbf/in) (EUR)
Spring stroke K1 0.0–150.0 mm (0.00–5.91 in)
Optional spring available Yes
Enclosed gas/air pressure (STD) 980 kPa (9.8 kgf/cm2, 139.4 psi)
Spring installed length
Minimum Position in which the spring is turned in 1.5 mm
(0.06 in) from its free length.
Standard Position in which the spring is turned in 10 mm
Maximum Position in which the spring is turned in 18 mm
Rebound damping adjusting positions
Standard 14 click (s) out*
Maximum Fully turned in
(for fast compression damping)
Minimum 2 turn (s) out*
Standard 1-1/3 turn (s) out* (USA) (CAN)
1-1/8 turn (s) out* (EUR) (JPN) (AUS) (NZL)
(ZAF)
(for slow compression damping)
Standard 10 click (s) out*
Swingarm
Swingarm end free play limit (radial) 1.0 mm (0.04 in)
Swingarm end free play limit (axial) 0.2–0.9 mm (0.01–0.04 in)
Drive chain
Type/manufacturer 520DMA2-SDH/DAIDO
Number of links 114
Drive chain slack 50–60 mm (1.97–2.36 in)
15-link length limit 242.9 mm (9.56 in)
2-10
ELECTRICAL SPECIFICATIONS
ELECTRICAL SPECIFICATIONS
EAS1SM1055
Voltage
System voltage 12 V
Ignition system
Ignition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 10.0 ° at 2000 r/min
Engine control unit
Model/manufacturer 1SM0/YAMAHA (USA) (CAN)
1SM1/YAMAHA (EUR) (AUS) (NZL) (ZAF)
1SM2/YAMAHA (JPN)
Ignition coil
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 2.16–2.64 
Secondary coil resistance 8.64–12.96 k
AC magneto
Standard output 14.0 V, 95 W at 5000 r/min
Stator coil resistance 0.624–0.936 
Rectifier/regulator
Regulator type Semi conductor-short circuit
No load regulated voltage 14.1–14.9 V
Rectifier capacity (DC) 23.0 A
2-11
TIGHTENING TORQUES
TIGHTENING TORQUES
EAS20320
GENERAL TIGHTENING TORQUE SPECIFI-

EAS1SM1056
CATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread
pitch. Tightening torque specifications for spe-
cial components or assemblies are provided for
each chapter of this manual. To avoid warpage,
tighten multi-fastener assemblies in a criss-
cross pattern and progressive stages until the
specified tightening torque is reached. Unless
otherwise specified, tightening torque specifi-
cations require clean, dry threads. Compo-
nents should be at room temperature.
A. Distance between flats

B. Outside thread diameter
General tightening
B torques
A (nut)
(bolt)
Nm m·kgf ft·lbf
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
2-12
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES

EAS1SM1057
TIP
- marked portion shall be checked for torque tightening after break-in or before each race.
Thread
ITEM Q’ty TIGHTENING TORQUES Remarks
size
Camshaft cap bolt M6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head blind plug M12 1 28 Nm (2.8 m·kgf, 20 ft·lbf) LT
Spark plug M10 1 13 Nm (1.3 m·kgf, 9.4 ft·lbf)

Cylinder head stud bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Cylinder head stud bolt (exhaust
M8 2 15 Nm (1.5 m·kgf, 11 ft·lbf)
pipe)
Cylinder head bolts M9 4 33 Nm (3.3 m·kgf, 24 ft·lbf) M
Cylinder head nuts M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Cylinder head cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pressure check bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Balancer weight plate screw M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Balancer driven gear nut M14 1 50 Nm (5.0 m·kgf, 36 ft·lbf)

Balancer nut M10 1 40 Nm (4.0 m·kgf, 29 ft·lbf)
Timing chain guide stopper plate
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
(exhaust side) LT
Timing chain tensioner cap bolt M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)

Timing chain tensioner bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Coolant drain bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator hose clamp screw M6 8 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Radiator bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator pipe bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator pipe joint bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Water pump housing cover bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pump bolt M5 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf) LT
Oil pump cover screw M4 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)

Oil strainer bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Throttle cable cover bolt M5 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Throttle body joint bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Throttle body joint clamp bolt M5 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Air filter joint clamp bolt M4 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Air filter case bolt M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Air filter bolt M6 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Air filter case cover bolt M6 3 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
2-13
TIGHTENING TORQUES
Thread
size
Air filter guide holder screw M5 8 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Air filter case cap screw M5 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Starter knob/Idle screw M12 1 2.1 Nm (0.21 m·kgf, 1.5 ft·lbf)
Throttle cable nut (pull) M10 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Throttle cable nut (return) M10 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Clutch cable adjuster and locknut M6 1 4.3 Nm (0.43 m·kgf, 3.1 ft·lbf)
Clutch cable locknut (engine side) M8 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Exhaust pipe nut M8 2 See TIP.
Exhaust pipe protector screw M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Exhaust pipe bracket bolt M8 1 20 Nm (2.0 m·kgf, 14 ft·lbf)

Frame and silencer bolt (front) M8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Frame and silencer bolt (rear) M8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Exhaust pipe clamp bolt M8 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Silencer body bolt M5 6 8 Nm (0.8 m·kgf, 5.8 ft·lbf) LT
Oil nozzle bolt M5 1 5 Nm (0.5 m·kgf, 3.6 ft·lbf) LT
Engine oil drain bolt M10 1 20 Nm (2.0 m·kgf, 14 ft·lbf)

Crankcase bolt M6 12 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Clutch cable holder bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Crankshaft end accessing screw M36 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Timing mark accessing screw M14 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Drive chain sprocket cover bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Crankcase bearing cover plate
M6 6 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
screw LT
Crankcase bearing cover plate

M8 4 22 Nm (2.2 m·kgf, 16 ft·lbf)
screw (crankshaft) LT
Oil passage squeeze nozzle M8 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)

Clutch cover bolt M6 7 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Left crankcase cover bolt M6 7 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Right crankcase cover bolt M6 11 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil filter element cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Kick shaft ratchet wheel guide
M6 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
bolt LT
Kick starter lever bolt M8 1 33 Nm (3.3 m·kgf, 24 ft·lbf) LT
Kick starter lever boss screw M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)

Primary drive gear nut M16 1 75 Nm (7.5 m·kgf, 54 ft·lbf)
Clutch spring bolt M6 5 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Use a lock
Clutch boss nut M16 1 75 Nm (7.5 m·kgf, 54 ft·lbf)
washer.
2-14
TIGHTENING TORQUES
Thread
size
Use a lock
Drive sprocket nut M18 1 75 Nm (7.5 m·kgf, 54 ft·lbf)
washer.
Segment M8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Shift guide bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Stopper lever bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Shift pedal bolt M6 1 12 Nm (1.2 m·kgf, 8.7 ft·lbf)

Rotor nut M12 1 65 Nm (6.5 m·kgf, 47 ft·lbf)
Stator screw M5 3 8 Nm (0.8 m·kgf, 5.8 ft·lbf) LT
Crankshaft position sensor bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
AC magneto lead holder bolt M5 1 8 Nm (0.8 m·kgf, 5.8 ft·lbf) LT
Coolant temperature sensor M10 1 16 Nm (1.6 m·kgf, 12 ft·lbf)

Neutral switch bolt M5 2 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) LT
Intake air temperature sensor

M5 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
screw
Rectifier/regulator bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
ECU bolt M5 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Ignition coil bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Throttle position sensor screw M5 2 3.4 Nm (0.34 m·kgf, 2.5 ft·lbf)
Intake air pressure sensor screw M6 1 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
TIP
Exhaust pipe nut
First temporarily tighten nuts to 13 Nm (1.3 m·kgf, 9.4 ft·lbf). Then retighten them to 20 Nm (2.0 m·kgf,
14 ft·lbf).
EAS1SM1058
2-15
TIGHTENING TORQUES
CHASSIS TIGHTENING TORQUES

TIP
- marked portion shall be checked for torque tightening after break-in or before each race.
Thread
size
Outer tube and upper bracket bolt M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
Outer tube and lower bracket bolt M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
Upper bracket and steering stem
M24 1 145 Nm (14.5 m·kgf, 105 ft·lbf)
nut
Upper handlebar holder bolt M8 4 28 Nm (2.8 m·kgf, 20 ft·lbf)
Lower handlebar holder nut M10 2 40 Nm (4.0 m·kgf, 29 ft·lbf)
Engine stop switch screw M3 1 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Lower ring nut M28 1 See TIP.
Outer tube and damper assembly M51 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
Inner tube and adjuster M22 2 55 Nm (5.5 m·kgf, 40 ft·lbf) LT
Damper assembly and base

M42 2 28 Nm (2.8 m·kgf, 20 ft·lbf)
valve
Damper assembly adjuster M12 2 29 Nm (2.9 m·kgf, 21 ft·lbf)
Bleed screw (front fork) and base
M5 2 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
valve
Front fork protector bolt M6 6 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Front fork protector and brake
M6 2 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
hose holder bolt
Throttle grip cap screw M5 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Clutch lever holder bolt M6 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Clutch lever nut M6 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Clutch lever position locknut M5 1 4.8 Nm (0.48 m·kgf, 3.5 ft·lbf)
Front brake master cylinder hold-
M6 2 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
er bolt
Front brake master cylinder res-
M4 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
ervoir cap screw
Front brake lever pivot bolt M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front brake lever pivot nut M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front brake lever position locknut M6 1 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Front brake hose holder and low-
M6 1 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
er bracket bolt
Front brake hose union bolt M10 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
Front brake caliper bolt M8 2 28 Nm (2.8 m·kgf, 20 ft·lbf)
Front brake pad pin M10 1 17 Nm (1.7 m·kgf, 12 ft·lbf)
Front brake pad pin plug M10 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Front brake caliper bleed screw M8 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front wheel axle nut M18 1 115 Nm (11.5 m·kgf, 83 ft·lbf)
2-16
TIGHTENING TORQUES
Thread
size
Front wheel axle pinch bolt M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
Front brake disc bolt M6 6 12 Nm (1.2 m·kgf, 8.7 ft·lbf) LT
Rear brake disc bolt M6 6 14 Nm (1.4 m·kgf, 10 ft·lbf) LT
Footrest bracket bolt M10 4 55 Nm (5.5 m·kgf, 40 ft·lbf) LT
Rear brake pedal bolt M8 1 26 Nm (2.6 m·kgf, 19 ft·lbf)

Rear brake pedal position locknut M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Rear brake master cylinder bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear brake master cylinder reser-
M4 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
voir cap bolt
Rear brake hose union bolt M10 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
Rear brake caliper bleed screw M8 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Rear brake pad pin M10 1 17 Nm (1.7 m·kgf, 12 ft·lbf)
Rear brake pad pin plug M10 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Rear wheel axle nut M22 1 135 Nm (13.5 m·kgf, 98 ft·lbf)
Drive chain puller adjust bolt and
M8 2 21 Nm (2.1 m·kgf, 15 ft·lbf)
locknut
Rear wheel sprocket nut M8 6 42 Nm (4.2 m·kgf, 30 ft·lbf)
Nipple (spoke) — 72 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Rear brake disc cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear brake caliper protector bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Engine mounting bolt (upper side) M10 2 45 Nm (4.5 m·kgf, 33 ft·lbf)
Engine mounting bolt (front side) M10 1 55 Nm (5.5 m·kgf, 40 ft·lbf)
Engine mounting bolt (lower side) M10 1 53 Nm (5.3 m·kgf, 38 ft·lbf)
Engine bracket bolt (upper side) M8 4 34 Nm (3.4 m·kgf, 25 ft·lbf)
Engine bracket bolt (front side) M8 4 34 Nm (3.4 m·kgf, 25 ft·lbf)
Rear frame and frame bolt M8 4 32 Nm (3.2 m·kgf, 23 ft·lbf)
Engine guard bolt (right side) M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Pivot shaft and nut M16 1 85 Nm (8.5 m·kgf, 61 ft·lbf)
Rear shock absorber assembly
M10 1 56 Nm (5.6 m·kgf, 41 ft·lbf)
upper bolt
M10 1 53 Nm (5.3 m·kgf, 38 ft·lbf)
lower bolt
Rear shock absorber locknut M60 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Relay arm bolt (swingarm side) M14 1 70 Nm (7.0 m·kgf, 51 ft·lbf)
Connecting arm bolt (relay arm
M14 1 80 Nm (8.0 m·kgf, 58 ft·lbf)
side)
Connecting arm bolt (frame side) M14 1 80 Nm (8.0 m·kgf, 58 ft·lbf)
Swingarm and brake hose holder
M5 4 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
screw
2-17
TIGHTENING TORQUES
Thread
size
Drive chain tensioner bolt (upper
M8 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
side)
Drive chain tensioner bolt (lower
M8 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
side)
Drive chain support bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Drive chain support nut M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Drive chain guide bolt M5 3 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Rear frame and left cover bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank bolt (front side) M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank bolt (rear side) M6 1 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Fuel tank bracket bolt (front side) M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank bracket bolt (rear side) M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel pump bolt M5 6 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Fuel inlet pipe screw M5 2 3.4 Nm (0.34 m·kgf, 2.5 ft·lbf)
Fuel tank cap cover bolt M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Seat set bracket and fuel tank
M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
screw
Seat bolt M8 2 22 Nm (2.2 m·kgf, 16 ft·lbf)
Left side cover bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Right side cover bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Frame and air scoop bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank and air scoop bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Radiator guard and air scoop bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front fender bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear fender bolt (front side) M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear fender bolt (rear side) M6 2 16 Nm (1.6 m·kgf, 12 ft·lbf)
Mud flap screw — 2 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
Number plate bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
TIP
Lower ring nut
1. First, tighten the lower ring nut approximately 38 Nm (3.8 m·kgf, 27 ft·lbf) by using the steering nut
wrench, then loosen the lower ring nut one turn.
2. Retighten the lower ring nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf).
2-18
LUBRICATION POINTS AND LUBRICANT TYPES

EAS1SM1059
ENGINE
EAS1SM1060
Lubrication point Lubricant types

Oil seal lips LS
Bearing E
O-ring LS
Cylinder head bolt threads, seats, washers M
Valve stems M
Valve stem ends M
Valve lifter outer surface E
Camshaft lobe and journal M
Valve lifter top surface E
Crankshaft journal M
Crankshaft big end thrust surfaces E
Piston outer surface E
Piston pin outer surface E
Balancer shaft journal (left) M
Decompression system moving parts E
Water pump impeller shaft E
Oil pump rotors (inner and outer) E
Oil passage gasket LS
Oil pump shaft E
Kick gear and ratchet wheel M
Kick shaft E
Kick idle gear inner surface E
Ratchet wheel and ratchet wheel guide contacting portion M
Primary drive gear nut threads and contacting surface E
Primary driven gear inner surface and end surface E
Clutch push rod washer E
Clutch push rod 1 outer surface E
Clutch push rod 1 thrust surface E
Clutch push rod 2 outer surface E
Push lever shaft outer surface E
Transmission gear inner surface (wheel and pinion) and collar M
Transmission gears (shift fork groove) E
Shift cam grooves E
Shift fork and shift fork guide outer surface E
Shift shaft E
Shift lever assembly moving parts E
2-19

Three bond
Cylinder head cover gasket
No.1215®
Three bond
Crankcase mating surface
No.1215®
Three bond
Stator assembly lead grommet
No.1215®
EAS1SM1061
2-20
CHASSIS
Upper bearings (steering head) LS
Upper bearings and bearing race cover (steering head) LS
Lower bearings and oil seal lip (steering head) LS
Steering stem threads and nut contacting surface LS
Pivot shaft bearing M
Swingarm pivot portion (collar side surface and thrust bearing) M
Swingarm pivot portion (collar outer surface) M
Swingarm pivot portion (oil seal lip) M
Pivot shaft outer surface M
Relay arm bearing and oil seal lip M
Relay arm thrust washer surface (both sides) M
Relay arm collar outer surface and bolt outer surface M
Relay arm bolt threads (swingarm side) M
Connecting arm bearing and oil seal lip M
Connecting arm collar outer surface and bolt outer surface M
Rear shock absorber assembly collar outer surface and dust seal lip (upper M
side)
Rear shock absorber assembly bearing and dust seal lip (lower side) M
Brake pedal pivot portion (O-ring and bolt outer surface) LS
Front wheel oil seal lip LS
Front wheel axle outer surface LS
Rear wheel oil seal lip LS
Rear wheel axle outer surface LS
Push rod contacting portion (front brake master cylinder) LS
Front brake lever bolt outer surface LS
Clutch lever sliding surface and bolt outer surface LS
Clutch lever position adjuster end LS
Clutch lever adjuster rubber lip LS
Clutch cable end (clutch lever side) LS
Tube guide (throttle grip) inner surface and throttle cable end LS
Front brake caliper piston

Front brake caliper piston seal S
Front brake caliper dust seal

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

Rear brake caliper piston
Rear brake caliper piston seal S
Rear brake caliper dust seal
2-21

Rear brake caliper pin bolt and boot S
Rear brake master cylinder push rod end S
Rear brake master cylinder kit
2-22
LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS1SM1062
LUBRICATION DIAGRAMS
EAS1SM1063
2-23
1. Intake camshaft
2. Exhaust camshaft
3. Piston
4. Oil nozzle
5. Oil filter element
6. Oil pump
7. Oil strainer
8. Crankshaft
9. Drive axle
10. Main axle
2-24
2-25
1. Connecting rod
2. Crankshaft
3. Main axle
4. Oil strainer
5. Drive axle
2-26
2-27
1. Exhaust camshaft
2. Intake camshaft
4. Oil pump
2-28
2-29
1. Camshaft
2. Oil pressure check bolt
4. Oil pump
2-30
CABLE ROUTING DIAGRAM

EAS1SM1064
2-31
1. Clutch cable R. Pass the rectifier/regulator lead to the inside of

2. Throttle cable (pull) the tension arm (the side of the vehicle).
3. Throttle cable (return) S. Pass the main harness to the front of the radiator
4. Cable holder hose (the front of the vehicle), and to the inside of
5. Engine stop switch lead the clutch cable (the side of the vehicle).
6. Frame T. Pass the engine stop switch lead between the
7. Coupler for connecting optional part coupler for connecting optional part and the tank
rail, with the lead on the main harness side facing
8. Bracket the top of the vehicle.
9. Engine stop switch coupler U. Pass the radiator breather hose between the
10. Rectifier/regulator coupler down tubes.
11. Starter knob/idle screw V. Clamp the radiator breather hose, above the en-
12. Neutral switch lead gine bracket (front). Clamp the lock on the plastic
13. Crankcase cover tie with it located outside the vehicle, and face the
14. AC magneto lead end toward the front of the vehicle.
15. Front engine bracket W. Clamp the clutch cable at the front of the lead (the
16. Radiator hose front of the vehicle).
17. Coupler cover X. Make the lock on the plastic locking tie face the
18. Rectifier/regulator lead front of the vehicle, and insert the projection into
19. Tension arm the hole in the frame. Cut the end of the plastic
20. Main harness locking tie.
21. Tank rail
22. Radiator
23. Cylinder head breather hose
24. Radiator breather hose
25. Down tube
26. Crankcase
A. Pass the engine stop switch lead between the
frame and the cable holder.
B. Pass the engine stop switch lead between the
coupler for connecting optional part and the
frame, where the main harness should face the
outside of the vehicle.
C. Insert the coupler for connecting optional part into
the connector, and fix it to the bracket.
D. Insert and fix the engine stop switch coupler to
the bracket.
E. Insert and fix the rectifier/regulator coupler to the
bracket.
F. Pass the AC magneto lead to the front of the ve-
hicle beyond the starter knob/idle screw and to
the rear of the vehicle beyond the radiator. No
pinch is allowed between the radiator and the
tension arm.
G. 70 mm (2.76 in)
H. Bring the neutral switch lead into line with the
crankcase cover with no sag allowed.
I. Bring the AC magneto lead into line with the
clutch cable with no sag allowed.
J. Pass the neutral switch lead to the inside of the
front engine bracket (the side of the vehicle).
K. Clamp the clutch cable and the AC magneto lead
by the plastic locking tie. Regardless of the orien-
tation of the lock on the plastic locking tie, cut the
end.
L. Pass the clutch cable with no downward sag al-
lowed.
M. Bring the grommet of the clutch cable into contact
with the radiator hose, and pass it to the outside
of the neutral switch lead and the AC magneto
lead (the outside of the vehicle).
N. 40 mm (1.57 in)
O. Clamp the clutch cable, the AC magneto lead,
and the neutral switch lead by the plastic locking
tie. Make sure that they are clamped at the posi-
tioning tape in the clutch cable. Make the lock on
the plastic locking tie face the front of the vehicle,
and cut the end.
P. After connecting the neutral switch coupler, at-
tach the coupler cover.
Q. After connecting the AC magneto coupler, attach
the coupler cover.
2-32
2-33
1. Bracket T. Clamp the painted part on the fuel hose by the

2. Condenser plastic clamp. Make the lock on the plastic clamp
3. Coolant temperature sensor face the bottom of the vehicle, and cut the end.
4. Coupler cover
5. Intake air temperature sensor coupler
6. Intake air temperature sensor coupler
7. Radiator hoses
9. Joint coupler
10. Plate
11. Tension arm
12. Throttle position sensor lead
13. Ground lead
14. Throttle position sensor coupler
16. Cylinder head breather hose
17. Engine guard
18. Crankcase
19. Fuel pump coupler
20. Fuel hose
21. Condenser lead
22. Fuel pump lead
23. Condenser coupler
24. Ground lead terminal
25. Fuel tank
26. Damper
27. Rear frame
28. Main harness
A. Insert the condenser into the bracket as far as it
will go.
B. Attach the coupler cover to the coolant tempera-
ture sensor coupler.
C. Pass the radiator breather hose to the inside of
the radiator hose (the side of the vehicle).
D. Insert and fix the joint coupler to the plate. After
fixing it, attach the cover.
E. Pass the throttle position sensor lead to the out-
side of the tension arm (the outside of the vehi-
cle).
F. After connecting the throttle position sensor cou-
pler, attach the cover.
G. Pass the radiator breather hose to the outside of
the tension arm and the throttle position sensor
lead (the outside of the vehicle), and to the inside
of the radiator hose (the side of the vehicle).
H. Pass the protector of the cylinder head breather
hose until it touches the holder.
I. Pass the cylinder head breather hose between
the engine guard and the crankcase.
J. Install the end of the cylinder head breather hose
with it facing downward.
K. After connecting the fuel pump coupler, attach
the coupler cover.
L. 55 mm (2.17 in) (seat load receiver)
M. Clamp the fuel hose and the fuel pump lead by
the holder. Make sure that the painted part on the
fuel hose is clamped, and face the lock on the
clamp toward the rear top of the vehicle.
N. Do not install the plastic locking tie to the seat
load receiver.
O. Make the lock on the plastic locking tie face the
front of the vehicle, and make the end face the
bottom of the vehicle. Do not cut the end.
P. Install the ground lead terminal between the plate
and the bolt.
Q. Detent
R. Fix the ground lead terminal to the detent in the
plate. For the ground lead terminal, either side
will do.
S. Insert the projection on the plastic locking tie into
the hole in the rear frame.
2-34
2-35
1. Throttle cable
2. Clutch cable
3. Engine stop switch lead
4. Cable guide
5. Head pipe
6. Front brake hose
7. Brake hose guide
8. Number plate
A. Number plate band
B. Pass the clutch cable to the rear of the number
plate band.
C. Clamp the engine stop switch lead to the handle-
bar by the plastic band. Do not cut the end of the
plastic band.
D. Pass the engine stop switch lead between the
head pipe and the cable guide.
E. Pass the front brake hose to the front of the num-
ber plate.
F. 40°±10°
G. Vertical direction
H. Pass the engine stop switch lead under the han-
dlebar.
I. Pass the clutch cable to the guide in the number
plate.
2-36
2-37
1. Main harness
2. Radiator
3. Throttle position sensor lead
4. Joint coupler
5. Intake air temperature sensor lead
6. Intake air pressure sensor lead
7. Frame
8. Fuel hose
9. High tension cord
10. Spark plug cap
11. Cylinder head cover
12. Sub-wire harness
13. Injector coupler
14. Injector lead
15. Throttle body
16. Air filter case
17. ECU
18. Sub-wire harness coupler
A. Fix the main harness by the plastic clamp, and in-
sert the projection of the plastic clamp into the
hole in the sheet metal of the radiator.
B. Insert the projection of the main harness into the
hole in the frame.
C. To the sub-wire harness
D. Pass the high tension cord above the fuel hose.
E. ±10°
F. Install the spark plug cap with this facing the right
of the vehicle.
G. Push the spark plug cap home, where there shall
be no gap between it and the cylinder head cover.
H. Pass the injector lead to the top of the vehicle be-
yond the fuel hose.
I. Insert the coupler of the sub-wire harness into the
rib of the air filter case.
J. Pass the sub-wire harness between the ECU and
the air filter case.
2-38
2-39
1. Brake master cylinder

2. Brake hose holder
3. Brake hoses
A. While installing the brake hose, direct a bend in
its pipe portion as shown, and bring it into contact
with the projection on the brake caliper.
B. Pass the brake hose into the brake hose holders.
C. If the brake hose interferes with the rear shock
absorber, correct its twist.
D. While installing the brake hose, direct a bend in
its pipe portion as shown, and bring it into contact
with the projection on the brake master cylinder.
2-40
2-41
PERIODIC CHECKS AND ADJUSTMENTS
MAINTENANCE INTERVALS ..........................................................................3-1

MAINTENANCE INTERVALS ....................................................................3-1
PRE-OPERATION INSPECTION AND MAINTENANCE.................................3-7

GENERAL INSPECTION AND MAINTENANCE........................................3-7
ENGINE ............................................................................................................3-8
CHECKING THE COOLANT LEVEL..........................................................3-8
CHECKING THE COOLING SYSTEM .......................................................3-8
CHANGING THE COOLANT......................................................................3-8
CHECKING THE RADIATOR CAP ............................................................3-9
CHECKING THE RADIATOR CAP OPENING PRESSURE ......................3-9
CHECKING THE COOLANT CIRCULATORY SYSTEM FOR LEAKS ....3-10
3
ADJUSTING THE CLUTCH LEVER POSITION ......................................3-10
ADJUSTING THE CLUTCH LEVER FREE PLAY....................................3-10
ADJUSTING THE THROTTLE GRIP FREE PLAY ..................................3-11
LUBRICATING THE THROTTLE CABLE ................................................3-12
CLEANING THE AIR FILTER ELEMENT.................................................3-12
CHECKING THE THROTTLE BODY JOINT............................................3-13
CHECKING THE BREATHER HOSES ....................................................3-13
CHECKING THE EXHAUST SYSTEM.....................................................3-13
CHECKING THE FUEL LINE ...................................................................3-14
CHECKING THE ENGINE OIL LEVEL.....................................................3-14
CHANGING THE ENGINE OIL ................................................................3-15
ADJUSTING THE ENGINE IDLING SPEED ............................................3-16
ADJUSTING THE VALVE CLEARANCE .................................................3-17
CHASSIS ........................................................................................................3-21
BLEEDING THE BRAKE SYSTEM ..........................................................3-21
CHECKING THE BRAKE HOSE ..............................................................3-22
ADJUSTING THE FRONT BRAKE ..........................................................3-22
ADJUSTING THE REAR BRAKE.............................................................3-23
CHECKING THE FRONT BRAKE PADS .................................................3-23
CHECKING THE REAR BRAKE PADS ...................................................3-25
CHECKING THE REAR BRAKE PAD INSULATOR ................................3-26
CHECKING THE BRAKE FLUID LEVEL..................................................3-26
ADJUSTING THE DRIVE CHAIN SLACK ................................................3-27
CHECKING THE FRONT FORK LEGS ...................................................3-28
CHECKING THE FRONT FORK PROTECTOR GUIDE ..........................3-28
CLEANING THE FRONT FORK OIL SEAL AND DUST SEAL ................3-28
AIR BLEEDING FROM FRONT FORK ....................................................3-28
ADJUSTING THE FRONT FORK LEGS ..................................................3-29
CHECKING THE SWINGARM OPERATION ...........................................3-30
CHECKING THE REAR SUSPENSION...................................................3-30
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY...................3-30
CHECKING THE TIRES...........................................................................3-32
CHECKING AND TIGHTENING THE SPOKES.......................................3-32
CHECKING THE WHEELS ......................................................................3-33
CHECKING THE WHEEL BEARINGS .....................................................3-33
CHECKING AND ADJUSTING THE STEERING HEAD ..........................3-33
LUBRICATING THE LEVERS ..................................................................3-34
LUBRICATING THE PEDAL ....................................................................3-34
ELECTRICAL SYSTEM..................................................................................3-35
CHECKING THE SPARK PLUG ..............................................................3-35
CHECKING THE IGNITION TIMING........................................................3-35
MAINTENANCE INTERVALS
EAS1SM1065
EAS1SM1066
ECA@
NOTICE
• After a break-in or before each race, always check the points shown in “TORQUE-CHECK
POINTS” for tightening torques and retighten them. (“TORQUE-CHECK POINTS” on page 1-
25.)
• Periodic inspection is essential in making full use of the machine performance. The life of
parts varies significantly according to the environment in which the machine runs (e.g., rain,
dirt, etc.). Therefore, earlier inspection is required by reference to the list below.
Every Every Every
After race third fifth
As re-
ITEM break- (about (about (about Remarks
quired
in 2.5 7.5 12.5
hours) hours) hours)
VALVE
Check the valve The engine must be cold.
clearances
Inspect Check the valve seats and the
valve faces for wear.
Replace
VALVE SPRING
Inspect Check the free length and the
tilt.
Replace
VALVE LIFTER
Inspect Check for scratches and wear.
Replace
CAMSHAFT Inspect the camshaft surface.
Inspect Inspect the decompression
system.
Replace
CAMSHAFT
SPROCKET
Inspect Check for wear on the teeth
and for damage.
Replace
PISTON
Inspect Inspect crack.
Clean Inspect carbon deposits and
eliminate them.
Replace Replace the piston, piston pin,
piston pin clip, and piston ring
all as a set.
3-1
Every Every Every

As re-
quired
in 2.5 7.5 12.5
PISTON RING
Inspect Check the end gap of the pis-
ton ring.
all as a set.
PISTON PIN
Inspect
all as a set.
CYLINDER HEAD Check the coolant passages
for corrosion.
Inspect carbon deposits and
eliminate them.
Inspect and clean Check for warpage, and re-
place the gasket.
CYLINDER
Inspect and clean Inspect score marks.
Replace Inspect wear.
ENGINE OIL
Inspect Check the engine oil amount.
Replace
OIL FILTER ELE-
MENT
Replace
OIL STRAINER
Clean
CLUTCH
Inspect and adjust Inspect housing, friction plate,
clutch plate and spring.
Replace
TRANSMISSION
Inspect
Replace bearings
SHIFT FORK, SHIFT
CAM, GUIDE BAR
Inspect Inspect wear.
3-2
Every Every Every

As re-
quired
in 2.5 7.5 12.5
NUT (ROTOR)
Retighten Check for tightening torques.
EXHAUST PIPE, SI-
LENCER, PROTEC-
TOR
Inspect and re- Check for exhaust leaks, and
tighten tightening torques.
Clean
* When the exhaust sound be-
Replace fiver * comes louder or when a per-
formance drop is felt.
CRANKSHAFT
Inspect and clean
THROTTLE BODY
Inspect
AIR FILTER
Clean and lubri- Use foam air-filter oil or equiv-
cate alent oil.
Replace
SPARK PLUG
Inspect and clean Check the electrodes and the
terminals for wear.
Replace
COOLING SYSTEM
Check coolant lev-
el and leakage
Check radiator cap Use the radiator cap tester for
operation a checkup.
Check radiator cap
attached
Change the cool- Every two years
ant
Inspect hoses
ENGINE GUARD
Replace Breakage
FRAME
Clean and inspect
3-3
Every Every Every

As re-
quired
in 2.5 7.5 12.5
FUEL TANK, FUEL
PUMP
Inspect
FUEL HOSE
Inspect
Replace Every four years
FRONT FORK LEG
(S)
Clean Dust seal
Inspect and adjust
Replace oil
Replace oil seal
Clean and grease Lithium soap base grease
oil seals and dust
seals
PROTECTOR
GUIDE
Replace
REAR SHOCK AB-
SORBER
Inspect and adjust
(After
rain Grease pillow balls and bear-
Lubricate ride) ings.
Retighten Check for tightening torques.
BRAKE(S)
Adjust lever posi-
tion and pedal
height
Lubricate pivot
point
Check brake disc
surface
Check fluid level
and leakage
Retighten brake Check for tightening torques.
disc bolts, caliper
bolts, master cylin-
der bolts and union
bolts
Replace pads
3-4
Every Every Every

As re-
quired
in 2.5 7.5 12.5
Replace brake flu- Every one year
id
SWINGARM
Inspect, lube and Molybdenum disulfide grease
retighten
RELAY ARM, CON-
NECTING ROD
Inspect, lube and Molybdenum disulfide grease
retighten
STEERING HEAD
Inspect free play Check for tightening torques.
and retighten
Clean and lube After rain ride
Replace bearings
TIRE, WHEELS
Inspect air pres-
sure, wheel run-
out, tire wear and
spoke looseness
Retighten sprocket
bolt
Check the bearing
Replace bearings
Lubricate Lithium soap base grease
DRIVE CHAIN Use chain oil.
Clean, lubricate,
slack, alignment
Replace
DRIVE CHAIN
GUIDE
Inspect Inspect wear.
DRIVE CHAIN
GUIDE AND DRIVE
CHAIN SUPPORT
Replace
CABLES
Routing (Connec-
tion)
Check and grease
Check and clean Check throttle cables on the
throttle cable throttle body for dirt and wear.
3-5
Every Every Every

As re-
quired
in 2.5 7.5 12.5
LEVERS
Adjust clutch lever
free play
KICKSTARTER LE-
VER, BRAKE PED-
AL, FOOTREST
Lubricate
OUTSIDE NUTS
AND BOLTS
Retighten Refer to “TORQUE-CHECK
POINTS” on page 1-25.
3-6
PRE-OPERATION INSPECTION AND MAINTENANCE
PRE-OPERATION INSPECTION AND MAINTENANCE

EAS1SM1067
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
EAS1SM1068
ITEM inspect Page

Check that coolant is filled up to the radiator cap.
Coolant 3-8 – 10
Check the cooling system for leakage.
Check that a fresh gasoline is filled in the fuel tank.
Fuel 1-22
Check the fuel line for leakage.
Check that the oil level is correct. Check the crank-
Engine oil 3-14 – 16
case and oil line for leakage.
Check that gears can be shifted correctly in order and
Gear shifter and clutch 3-10 – 11
that the clutch operates smoothly.
Check that the throttle grip operation and free play
Throttle grip/Housing are correctly adjusted. Lubricate the throttle grip and 3-11 – 12
housing, if necessary.
Check the play of front brake and effect of front and
Brakes 3-21 – 27
rear brake.
Check drive chain slack and alignment. Check that 3-27
Drive chain
the drive chain is lubricated properly. 4-64 – 65
Check for excessive wear and tire pressure. Check
Wheels 3-33
for loose spokes and have no excessive play.
Check that the handlebar can be turned smoothly and
Steering 3-33 – 34
have no excessive play.
Front forks and rear Check that they operate smoothly and there is no oil
3-28 – 32
shock absorber leakage.
Check that the clutch and throttle cables move
smoothly. Check that they are not caught when the
Cables (wires) —
handlebars are turned or when the front forks travel
up and down.
Check that the exhaust pipe is tightly mounted and
Exhaust pipe 3-13 – 14
has no cracks.
Check that the rear wheel sprocket tightening bolt is
Rear wheel sprocket 4-8 – 9
not loose.
Lubrication Check for smooth operation. Lubricate if necessary. 3-12, 3-34
Check the chassis and engine for loose bolts and
Bolts and nuts 1-25 – 26
nuts.
Check that the AC magneto, ECU and ignition coil are
Lead connectors 1-12 – 14
connected tightly.
Is the machine set suitably for the condition of the rac-
ing course and weather or by taking into account the
Settings 10-1 – 8
results of test runs before racing? Are inspection and
maintenance completely done?
TIP
Perform usual maintenance enough so that, in the race course, a confirmation of that and simple set-
ting adjustments may only be left, in order to get enough time to use effectively.
3-7
ENGINE
ENGINE CHECKING THE COOLING SYSTEM

EAS1SM1069 EAS1SM1071
1. Remove:
CHECKING THE COOLANT LEVEL
EAS1SM1070
• Seat
• Side cover (left/right)
EWA1DX1003
WARNING
• Air scoop (left/right)
If coolant seems hot, do not remove the ra-
Refer to “GENERAL CHASSIS” on page 4-
diator cap.
1.
1. Stand the vehicle upright on a level surface. • Air filter case cover
2. Remove: Refer to “THROTTLE BODY” on page 7-5.
• Radiator cap “1” 2. Check:
• RADIATOR
• Radiator hoses
Crack/damage  Replace.
Refer to “RADIATOR” on page 6-1.
3. Install:
• Air filter case cover
Refer to “THROTTLE BODY” on page 7-5.
• Seat
3. Check: Refer to “GENERAL CHASSIS” on page 4-
• Coolant level 1.
Maximum level “a” or below  Add coolant
CHANGING THE COOLANT
EAS1SM1072
up to the maximum level. EWA1DX1004
WARNING
diator cap.
1. Place a container under the engine.
2. Remove:
• Coolant drain bolt “1”
1. Radiator
1
ECA1DX1004
NOTICE
• Adding water instead of coolant lowers the
antifreeze content. If, therefore, water is
used instead of coolant, check, and if nec-
essary, adjust the antifreeze concentra-
tion. 3. Remove:
• Use only distilled water. However, if dis- • Radiator cap
tilled water is not available, soft water may Slowly loosen the radiator cap to drain cool-
be used. ant.
TIP
4. Start the engine, warm this up for several
minutes, and then stop it. When the radiator cap is loosened, coolant will
5. Check: gush out transversely; therefore, bring the con-
• Coolant level tainer near to the outlet.
TIP 4. Thoroughly flush the cooling system with
Before checking the coolant level, wait a few clean tap water.
minutes until the coolant has settled.
3-8
ENGINE
5. Install: Crack/damage  Replace.

• Copper washers New Exist fur deposits  Clean or replace.
• Coolant drain bolt
Coolant drain bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
6. Pour coolant.
Recommended coolant
High quality ethylene glycol
anti-freeze containing anti-cor-
rosion for aluminum engine
Radiator capacity (including all
routes) CHECKING THE RADIATOR CAP OPENING
EAS1SM1074
1.00 L (1.06 US qt, 0.88 Imp.qt) PRESSURE

Coolant mixing ratio
1:1 (Coolant:Water) 1. Check:
• Radiator cap opening pressure
EWA13040
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
WARNING
a. Install the radiator cap tester adapter “2” and
• If coolant splashes in your eyes, thorough- the radiator cap tester “3” to the radiator cap
ly wash them with water and consult a “1,” and activate the tester to check whether
doctor.
it can stay for 5 to 10 seconds within stan-
• If coolant splashes on your clothes, quick-
dard pressure values.
ly wash it away with water and then with
soap and water. TIP
• If coolant is swallowed, induce vomiting Before attaching the cap to the tester, apply
and get immediate medical attention. water to its sealing surface.
ECA13480
NOTICE Radiator cap opening pressure

• Adding water instead of coolant lowers the 108–137 kPa (1.08–1.37 kg/cm2,
antifreeze content. If, therefore, water is 15.7–19.9 psi)
used instead of coolant, check, and if nec-
essary, adjust the antifreeze concentra- No stay  Replace.
tion. Radiator cap tester
• Use only distilled water. However, if dis- 90890-01325
tilled water is not available, soft water may Mityvac cooling system tester kit
be used. YU-24460-A
• If coolant comes into contact with painted Radiator cap tester adapter
surfaces, immediately wash them with wa- 90890-01352
ter. Pressure tester adapter
• Do not mix different types of coolant. YU-33984
7. Install:
• Radiator cap
8. Start the engine, warm this up for several
minutes, stop it, and then wait for it to cool
down.
9. Check:
• Coolant level
Refer to “CHECKING THE COOLANT LEV-
EL” on page 3-8.
CHECKING THE RADIATOR CAP
EAS1SM1073
1. Check: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Seal (radiator cap) “1”
• Valve and valve seat “2”
3-9
ENGINE
CHECKING THE COOLANT CIRCULATORY ADJUSTING THE CLUTCH LEVER POSI-

SYSTEM FOR LEAKS TION

1. Check: 1. Adjust:
• Coolant level • Clutch lever position “a”
2. Install: Loosen the locknut “1” and use the adjuster
• Radiator cap tester “1” “2” to adjust the clutch lever position “a” as
• Adapter “2” desired.
Radiator cap tester 1
90890-01325 2
Mityvac cooling system tester kit a
YU-24460-A
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984
2. Tighten:
• Locknut
Locknut
4.8 Nm (0.48 m·kgf, 3.5 ft·lbf)
T.
R.
ADJUSTING THE CLUTCH LEVER FREE

EAS1SM1077
PLAY
1. Check:
3. Activate the tester to apply the test pressure. • Clutch lever free play “a”
Out of specification  Regulate.
Test pressure value
196 kPa (1.96 kg/cm2, 27.9 psi) Clutch lever free play
7.0–12.0 mm (0.28–0.47 in)
ECA@
NOTICE
• Do not apply such a high pressure as ex-
ceeds the test pressure.
• Make sure that a checkup after the cylin-
der head gasket is replaced is made after 2
to 3 minutes of warm-up.
• Make sure that coolant is filled up to the
upper level beforehand.
4. Check:
• Pressure value
No stay for 5 to 10 seconds at the test pres- 2. Adjust:
sure value  Correct. • Clutch lever free play
• Radiator ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Radiator hose connections Handlebar side
Coolant leaks  Correct or replace. a. Turn the adjuster “1” in direction “a” or “b”
• Radiator hoses until the specified clutch lever free play is ob-
Bulges  Replace tained.
EWA@
WARNING Direction “a”

When the radiator cap tester is removed, Clutch lever free play is increased.
coolant will spout; therefore, cover it with a Direction “b”
cloth beforehand. Clutch lever free play is decreased.
3-10
ENGINE
ADJUSTING THE THROTTLE GRIP FREE

EAS1SM1078
b PLAY
1
TIP
Prior to adjusting throttle grip free play, the en-
a gine idling speed should be adjusted.
1. Check:
• Throttle grip free play “a”
Throttle grip free play
TIP 3.0–5.0 mm (0.12–0.20 in)
If the clutch lever free play cannot be obtained
on the handlebar side, use the adjuster on the
clutch cable side.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Clutch cable side
a. Slide the clutch cable cover.
b. Loosen the locknut “1”.
c. Turn the adjuster “2” in direction “a” or “b”
until the specified clutch lever free play is ob-
tained. 2. Adjust:
Direction “a” • Throttle grip free play
Clutch lever free play is increased. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Direction “b” a. Loosen the locknut “1”.
Clutch lever free play is decreased. b. Turn the adjuster “2” until the specified free
play is obtained.
d. Tighten the locknut “1”.
Direction “a”
Locknut Throttle grip free play is increased.
4.3 Nm (0.43 m·kgf, 3.1 ft·lbf) Direction “b”
T.
R.
Throttle grip free play is decreased.

e. Return the clutch cable cover to its original
position. c. Tighten the locknut.
EWA33DD008
WARNING
1 a After adjusting the throttle grip free play,
turn the handlebar to the right and to the left
to ensure that this does not cause the en-
gine idling speed to change.
b
2 2 1
b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-11
ENGINE
LUBRICATING THE THROTTLE CABLE

EAS1SM1079
1. Remove: 2
• Cover (throttle cable cap) “1” 1
• Cover (grip cap) “2”
• Throttle grip cap “3”
2. Remove:
• Air filter mounting bolt “1”
• Air filter element “2”
• Air filter guide “3” (from the air filter element)
2. Lubricate: 3 1
• Throttle cable end “a”
Recommended lubricant
Lithium-soap-based grease
3. Wash:
• Air filter element
EWA
WARNING
Do not use gasoline or organic (acid/alka-
line) volatile oil for washing.
TIP
3. Install:
• Throttle grip cap After washing the element with air filter cleaner
• Screw (throttle grip cap) or kerosene, squeeze and dry it completely.
ECA33DD016
Screw (throttle grip cap) NOTICE

3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) Do not twist the element when squeezing
T.
R.
the element.
4. Install:
• Cover (grip cap)
• Cover (throttle cable cap)
EWA
WARNING
Check that the throttle grip moves smooth-
ly. If this does not move smoothly, correct
the installed positions.
CLEANING THE AIR FILTER ELEMENT

EAS1SM1080
1. Remove:
• Fuel tank cap cover “1”
Refer to “FUEL TANK CAP” on page 1-21.
• Air filter case cover “2”
3-12
ENGINE
4. Check: CHECKING THE THROTTLE BODY JOINT

EAS1SM1081
• Air filter element 1. Check:

Damage  Replace. • Throttle body joint “1”
5. Foam-air-filter oil or equivalent oil to the ele- Refer to “CHECKING THE THROTTLE
ment BODY JOINT” on page 7-8.
Oil application quantify CHECKING THE BREATHER HOSES
EAS1SM1082
50 g 1. Check:
• Breather hose “1”
TIP Crack/damage  Replace.
Squeeze out the excess oil. Element should be Loose connection  Connect properly.
wet but not dripping. ECA14920
NOTICE
6. Install: Make sure that the breather hoses are rout-
• Air filter guide “1” (to the air filter element) ed correctly.
• Air filter element “2”
• Air filter mounting bolt “3”
Air filter mounting bolt
2 Nm (0.2 m·kgf, 1.4 ft·lbf)
1
T.
R.
1 3
CHECKING THE EXHAUST SYSTEM

EAS1SM1083
2 1. Remove:
• Exhaust pipe protector
2. Check:
7. Install: • Exhaust pipe 1
• Air filter case cover “1” • Exhaust pipe 2
• Air filter case cover mounting bolt • Silencer
TIP Crack/damage  Replace.
Refer to “ENGINE REMOVAL” on page 5-1.
Align the air filter case cover groove “a” with the
• Exhaust gas
air filter case edge “b”.
Leaks  Replace the gasket.
Refer to “ENGINE REMOVAL” on page 5-1.
Air filter case cover mounting bolt
3. Check:
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
• Tightening torques
T.
R.
Exhaust pipe bolt 1 and nut “1”

20 Nm (2.0 m·kgf, 14 ft·lbf)
1
T.
a Exhaust pipe 1 and exhaust pipe

R.
2 bolt “2”
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
b Exhaust pipe 2 and silencer bolt
“3”
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Silencer and silencer bracket bolt
“4”
30 Nm (3.0 m·kgf, 22 ft·lbf)
8. Install:
• Fuel tank cap cover
3-13
ENGINE
3. Install:
• Fuel tank
Refer to “FUEL TANK” on page 7-1.
2 • Seat
1 Refer to “GENERAL CHASSIS” on page 4-
1.
CHECKING THE ENGINE OIL LEVEL
EAS1SM1085
1. Stand the vehicle upright on a level surface.

2. Start the engine, warm this up for 2–3 min-
utes, and then stop the engine and wait
about 5 minute.
4 3. Check:
3 • Oil level
The engine oil level should be between the
minimum level mark “a” and maximum level
mark “b”.
Below the minimum level mark  Add the
recommended engine oil to the proper level.
4. Install:
• Exhaust pipe protector
Exhaust pipe protector screw
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
LOCTITE®
R.
CHECKING THE FUEL LINE

EAS1SM1084
1. Remove: b
• Seat
• Side cover (left/right) a
• Air scoop (left/right) ECA33DD018
NOTICE
Refer to “GENERAL CHASSIS” on page 4-
1. • Since engine oil also lubricates the clutch,
• Fuel tank the wrong oil types or additives could
Refer to “FUEL TANK” on page 7-1. cause clutch slippage. Therefore, do not
2. Check: add any chemical additives.
• Fuel hose “1” • Do not allow foreign material to enter the
Crack/damage  Replace. crankcase.
Loose connection  Connect properly.
Recommended brand
YAMALUBE
Recommended engine oil type
SAE10W-30, SAE10W-40,
1 SAE10W-50, SAE15W-40,
SAE20W-40 or SAE20W-50
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
3-14
ENGINE
1
3 New 2
c. Install the new oil filter element and the oil fil-
CHANGING THE ENGINE OIL
EAS1SM1086
ter element cover.

Stand the vehicle upright on a level surface.
1. Start the engine, warm this up for several Oil filter element cover bolt
minutes, and then stop the engine and wait 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
about 5 minutes.
2. Place an oil pan under the drain bolt. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Remove: 5. To check the oil strainer, perform the follow-
• Oil filler cap “1” ing procedure.
• Drain bolt (with gasket) “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the oil strainer “1”.
b. Check the oil strainer.
Damage  Replace.
Clogging due to dirt  Wash with kerosene.
c. Replace the O-rings “2”.
2 New 2
d. Install the oil strainer.
Oil strainer bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. If the oil filter element is also to be replaced,
6. Install:
perform the following procedure.
• Gaskets New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Drain bolt
a. Remove the oil filter element cover “1” and
oil filter element “2”. Drain bolt
b. Replace the O-rings “3”. 20 Nm (2.0 m·kgf, 14 ft·lbf)
T.
R.
3-15
ENGINE
7. Pour the specified amount of engine oil into WARNING

the oil filler cap hole. Always keep the engine idling speed during
Engine oil quantity the checkup without increasing the engine
Without oil filter element replace- speed.
ment ECA
0.71 L (0.75 US qt, 0.62 Imp.qt) NOTICE

With oil filter element replace- If no engine oil seeps out after one minute,
ment immediately turn the engine off so it will not
0.73 L (0.77 US qt, 0.64 Imp.qt) seize.
Quantity (disassembled)
0.90 L (0.95 US qt, 0.79 Imp.qt) b. If no engine oil seeps out, check the engine
oil for leaks, and the engine oil passage and
the oil pump for damage.
c. Check the oil pressure again.
d. Tighten the oil pressure check bolt.
Oil pressure check bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ADJUSTING THE ENGINE IDLING SPEED

EAS1SM1087
TIP
8. Install:
• Because the air pressure is lower at high alti-
• Oil filler cap
tudes, the air-fuel mixture will become richer.
9. Check:
If the idling speed is low, turn the starter knob/
• Oil level
idle screw a few clicks counterclockwise to in-
Refer to “CHECKING THE ENGINE OIL
crease the speed before the adjustment.
LEVEL” on page 3-14.
• Before adjusting the engine idling speed,
10.Check:
make sure that the air filter element is not
• Engine oil pressure
clogged, the engine compression is proper,
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ and the throttle grip free play is proper.
a. Slightly loosen the oil pressure check bolt • Adjust the engine idling speed with the starter
“1”. knob/idle screw pushed in completely.
EWA
WARNING 1. Start the engine, and warm this up until the

When the engine is started with the check oil has reached the specified temperature.
bolt removed, oil will spout; therefore, al- 2. Attach the pocket tester with temperature
ways loosen it before the checkup. probe “1” to the oil drain bolt.
1 1
Start the engine and keep it idling until oil

starts to seep from the oil pressure check Oil temperature
55–65 °C (131–149 °F)
bolt.
EWA
3-16
ENGINE
3. Install: ADJUSTING THE VALVE CLEARANCE

• Digital tachometer TIP
Digital tachometer • This section is intended for those who have
90890-06760 basic knowledge and skill concerning the ser-
YU-39951-B vicing of Yamaha motorcycles (e.g., Yamaha
dealers, service engineers, etc.). Those who
TIP have little knowledge and skill concerning ser-
Get the high tension cord “1” of the ignition coil vicing are requested not to undertake inspec-
pinched in the detector “a” of the digital tachom- tion, adjustment, disassembly, or reassembly
eter. only by reference to this manual. It may lead
to servicing trouble and mechanical damage.
• Make sure that the valve clearance is
1 checked or adjusted while the engine is cold
(at room temperature).
a • While the valve clearance is checked or ad-
1 justed, make sure that the piston is positioned
in the top dead center (TDC).
1. Remove:
• Seat
a • Side cover (left/right)
4. Measure: • Air scoop (left/right)
• Engine idling speed Refer to “GENERAL CHASSIS” on page 4-
Out of specification  Regulate. 1.
• Fuel tank
Engine idling speed Refer to “FUEL TANK” on page 7-1.
1900–2100 r/min • ECU
2. Remove:
5. Adjust:
• Spark plug
• Engine idling speed
• Cylinder head cover
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Refer to “CAMSHAFT” on page 5-11.
a. Turn the starter knob/idle screw “1” in the di- 3. Remove:
rection of “a” or “b” to make an adjustment. • Timing mark accessing screw “1”
• Crankshaft end accessing screw “2”
• O-ring
b 1
a
Direction “a” Engine idling speed  De- 1 2

creases.
Direction “b” Engine idling speed  In- 4. Check:
creases. • Valve clearance
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1SM1088
Valve clearance (cold)
Intake
0.12–0.19 mm (0.0047–0.0075 in)
Exhaust
0.17–0.24 mm (0.0067–0.0094 in)
3-17
ENGINE
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
a. Turn the crankshaft counterclockwise with a
wrench.
b. Align the top dead center (TDC) mark “a” on
the rotor with the alignment mark “b” on the
crankcase cover.
a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Adjust:
• Valve clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the camshaft (intake and exhaust).
Refer to “CAMSHAFT” on page 5-11.
TIP b. Remove the valve lifter “2” and the adjusting
Check that the alignment mark “c” on the cam- pad “3” with a valve lapper “1”.
shaft sprocket and the alignment mark “d” on TIP
the intake camshaft sprocket are aligned with • Place a cloth in the timing chain space to pre-
the edge of the cylinder head. vent adjusting pads from falling into the crank-
case.
• Identity each valve lifter and adjusting pad po-
d c sition very carefully so that they can be rein-
stalled in their original place.
Valve lapper
90890-04101
Valve lapping tool
YM-A8998
c. Measure the valve clearance “e” using a 1

2
thickness gauge “1”.
3
TIP
Record the measured reading if the clearance
is incorrect.
e e
3-18
ENGINE
c. Check the number on the originally installed TIP

adjusting pad. • Apply the engine oil on the valve lifters.
TIP • Apply molybdenum disulfide oil to the valve
• The adjusting pad number “a” is indicated on stem ends.
the top of the adjusting pad. • Check that the valve lifters turn smoothly
• For the number on the originally installed ad- when rotated with your finger.
justing pad, convert the last digit of adjusting • Make sure that valve lifters and adjusting
pad number as per the below table. pads are installed in place.
• Make sure that adjusting pads are installed
with their numbers facing upward.
5
4
d. Select an adjusting pad with a proper valve

clearance from the adjusting pad selection
table. f. Install the camshafts (exhaust and intake).
TIP Refer to “CAMSHAFT” on page 5-11.
• There are 25 types of adjusting pads, ranging g. Measure the valve clearance again.
from 1.20 mm (0.0472 in) to 2.40 mm (0.0945 h. If the valve clearance is out of specification,
in), in increments of 0.05 mm (0.0020 in). repeat adjusting the valve clearance until it
• The field where the number on the originally is within specification.
installed adjusting pad and the measured ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
valve clearance intersect shows the adjusting
pad number to replace.
Last digit of pad

Rounded valve
number
0, 1 or 2 0
4, 5 or 6 5
8 or 9 10
Example:
Pad number = 148
Rounded value = 150
e. Install the new adjusting pads “4” and the
valve lifters “5”.
ECA@
NOTICE
Do not twist adjusting pads and valve lifters
forcibly during installation.
3-19
ENGINE
INTAKE
120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.02 0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.07 0.11 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.12 0.19
0.20 0.24 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.25 0.29 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.30 0.34 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.35 0.39 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.40 0.44 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.45 0.49 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.50 0.54 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.55 0.59 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.60 0.64 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.65 0.69 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.70 0.74 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.75 0.79 180 185 190 195 200 205 210 215 220 225 230 235 240
0.80 0.84 185 190 195 200 205 210 215 220 225 230 235 240
0.85 0.89 190 195 200 205 210 215 220 225 230 235 240
0.90 0.94 195 200 205 210 215 220 225 230 235 240
0.95 0.99 200 205 210 215 220 225 230 235 240 0.12 0.19
1.00 1.04 205 210 215 220 225 230 235 240
1.05 1.09 210 215 220 225 230 235 240
1.10 1.14 215 220 225 230 235 240
1.15 1.19 220 225 230 235 240
1.20 1.24 225 230 235 240
1.25 1.29 230 235 240
1.30 1.34 235 240
1.35 1.39 240
EXHAUST
120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.02 0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.07 0.11 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.12 0.16 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.17 0.24
0.25 0.29 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.30 0.34 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.35 0.39 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.40 0.44 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.45 0.49 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.50 0.54 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.55 0.59 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.60 0.64 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.65 0.69 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.70 0.74 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.75 0.79 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.80 0.84 180 185 190 195 200 205 210 215 220 225 230 235 240
0.85 0.89 185 190 195 200 205 210 215 220 225 230 235 240
0.90 0.94 190 195 200 205 210 215 220 225 230 235 240
0.95 0.99 195 200 205 210 215 220 225 230 235 240
1.00 1.04 200 205 210 215 220 225 230 235 240
0.17 0.24
1.05 1.09 205 210 215 220 225 230 235 240
1.10 1.14 210 215 220 225 230 235 240
1.15 1.19 215 220 225 230 235 240
1.20 1.24 220 225 230 235 240
1.25 1.29 225 230 235 240
1.30 1.34 230 235 240
1.35 1.39 235 240
1.40 1.44 240
3-20
CHASSIS
CHASSIS
EAS1SM1089
B
2
BLEEDING THE BRAKE SYSTEM
EAS1SM1090
EWA13100
WARNING
Bleed the brake system whenever: 1
• The system is disassembled.
• A brake hose is loosened, disconnected,
or replaced.
• The brake fluid level is very low.
• Brake operation is faulty.
A. Front
1. Remove: B. Rear
• Brake master cylinder cap d. Slowly apply the brake several times.
• Reservoir diaphragm e. Fully pull the brake lever or fully press down
• Reservoir float (front brake) the brake pedal and hold it in position.
• Protector (rear brake) f. Loosen the bleed screw.
TIP TIP
• Be careful not to spill any brake fluid or allow Loosening the bleed screw will release the
the reservoir to overflow. pressure in the brake caliper and cause the
• Make sure that there is enough brake fluid be- brake lever to contact the throttle grip or the
fore applying the brake. Ignoring this precau- brake pedal to fully extend.
tion could allow air to enter the brake system,
considerably lengthening the bleeding proce- g. Tighten the bleed screw and then release
dure. the brake lever or brake pedal.
• If bleeding is difficult, it may be necessary to h. Repeat steps (d) to (g) until all of the air bub-
let the brake fluid settle for a few hours. Re- bles have disappeared from the brake fluid
peat the bleeding procedure when the tiny in the plastic hose.
bubbles in the hose have disappeared. TIP
2. Bleed the brake system. During the procedure, keep adding brake fluid
to the reservoir.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the reservoir to the proper level with the
ECA
NOTICE
recommended brake fluid.
Brake fluid may erode painted surfaces or
b. Install the reservoir diaphragm.
plastic parts. Always clean up spilled fluid
c. Connect the plastic hose “1” to the bleed
immediately.
screw “2” securely, and place a container
under the end of the plastic hose. i. Tighten the bleed screw.
A Bleed screw
2 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
T.
R.
1 j. Pour brake fluid to the reservoir up to the

specified level.
Refer to “CHECKING THE BRAKE FLUID
EWA13110
WARNING
After bleeding, check the brake operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-21
CHASSIS
CHECKING THE BRAKE HOSE

EAS1SM1091
1. Check:
• Brake hose “1”
Cracks/damage/wear  Replace.
2. Remove:
• Brake lever cover
3. Adjust:
• Brake lever position
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1”.
b. Turn the adjusting bolt “2” in direction “a” or
“b” until the specified brake lever position is
obtained.
Direction “a”
1 Brake lever position is increased.
Direction “b”
Brake lever position is decreased.
A. Front
B. Rear
2. Check: a
• Brake hose clamp
Loose Connection  Tighten the clamp bolt.
3. Stand the vehicle upright and apply the front b
brake and the rear brake several times.
4. Check:
• Brake hoses
Brake fluid leaks  Replace the damaged
brake hose. c. Tighten the locknut.
Refer to “FRONT BRAKE” on page 4-11. Locknut
Refer to “REAR BRAKE” on page 4-21. 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
T.
R.
ADJUSTING THE FRONT BRAKE

EAS1SM1092
EWA13050
1. Check: WARNING
• Brake lever position “a” A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake
Brake lever position
95 mm (3.74 in) system. Before running, bleed the brake
Extent of adjustment system. Air in the brake system will cause
86–105 mm (3.39–4.13 in) braking performance to be reduced.
ECA13490
NOTICE
After adjusting the brake lever position,
make sure that there is no brake drag.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• Brake lever cover
3-22
CHASSIS
ADJUSTING THE REAR BRAKE

EAS1SM1093 ECA13510
NOTICE
1. Check:
After adjusting the brake pedal position,
• Brake pedal position “a”
make sure that there is no brake drag.
(distance from the top of the rider footrest to
the top of the brake pedal) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE FRONT BRAKE PADS
EAS1SM1094
Brake pedal position 1. Measure:

0.0 mm (0.00 in) • Brake pad thickness “a”
Out of specification  Replace as a set.
TIP
The pads worn up to the indicator “b” grooves
mean that the brake pad thickness limit is
reached.
Brake pad lining thickness (inner)

4.4 mm (0.17 in)
Limit
1.0 mm (0.04 in)
Brake pad lining thickness (outer)
2. Adjust: 4.4 mm (0.17 in)
• Brake pedal position Limit
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1.0 mm (0.04 in)
a. Loosen the locknut “1”.
b. Turn the adjusting bolt “2” in direction “a” or
“b” until the specified brake pedal position is b
obtained.
Direction “a”
Brake pedal is raised.
Direction “b”
Brake pedal is lowered.
a
a
a 2. Replace:
b • Brake pads
2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the pad pin plug “1”.
1
c. Tighten the locknut.

Locknut
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
1
T.
R.
EWA1DX1001
WARNING
A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
system. Before running, bleed the brake
system. Air in the brake system will cause
braking performance to be reduced.
3-23
CHASSIS
b. Loosen the pad pin “2”.

c. Remove the brake caliper “3” from the front 7
fork.
b a
2 i. Install the brake caliper “8” and tighten the

pad pin “9”.
Bolt (brake caliper)
d. Remove the pad pin and brake pads “4”.
28 Nm (2.8 m·kgf, 20 ft·lbf)
T.
Pad pin
R.
4
17 Nm (1.7 m·kgf, 12 ft·lbf)
e. Connect the plastic hose “5” to the bleed 9

screw “6” and place a container under the
end of the plastic hose.
j. Install the pad pin plug “10”.
6
Pad pin plug
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
T.
R.
f. Loosen the bleed screw and push the brake

caliper piston in.
EWA@ 10
WARNING
Do not reuse the drained brake fluid.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
g. Tighten the bleed screw.
3. Check:
Bleed screw • Brake fluid level
6 Nm (0.6 m·kgf, 4.3 ft·lbf) Refer to “CHECKING THE BRAKE FLUID
T.
R.

h. Install the brake pads “7” and the pad pin. 4. Check:
TIP • Brake lever operation
• Install the brake pads with their projections “a” A softy or spongy feeling  Bleed the brake
into the brake caliper recesses “b”. system.
• Temporarily tighten the pad pin at this point. Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-21.
3-24
CHASSIS
CHECKING THE REAR BRAKE PADS

EAS1SM1095
4
1. Measure:
• Brake pad thickness “a” 3
Out of specification  Replace as a set.
TIP
The pads worn up to the indicator “b” grooves
mean that the brake pad thickness limit is
reached. 5
Brake pad lining thickness (inner)

6.4 mm (0.25 in) d. Remove the pad pin “6” and the brake pads
Limit “7”.
1.0 mm (0.04 in) 6 7
Brake pad lining thickness (outer)
6.4 mm (0.25 in)
Limit
1.0 mm (0.04 in)
a
a
e. Connect the plastic hose “8” to the bleed

screw “9” and place a container under the
b end of the plastic hose.
2. Replace:
• Brake pads
9
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the protector “1” and the pad pin 8
plug “2”.
2 f. Loosen the bleed screw and push the brake

caliper piston in.
EWA@
WARNING
Do not reuse the drained brake fluid.
1 g. Tighten the bleed screw.
Bleed screw
b. Loosen the pad pin “3”. 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
T.
R.
c. Remove the rear wheel “4” and the brake

h. Install the brake pad “10” and the pad pin
caliper “5”.
“11”.
Refer to “REAR WHEEL” on page 4-7.
TIP
• Install the brake pads with their projections “a”
into the brake caliper recesses “b”.
• Temporarily tighten the pad pin at this point.
3-25
CHASSIS
4. Check:
11 10 • Brake pedal operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
a
CHECKING THE REAR BRAKE PAD INSU-
EAS1SM1096
b
LATOR
1. Remove:
• Brake pads
i. Install the brake caliper “12” and the rear
Refer to “REAR BRAKE” on page 4-21.
wheel “13”.
2. Check:
• Rear brake pad insulator “1”
j. Tighten the pad pin “14”.
Damage  Replace.
Pad pin
17 Nm (1.7 m·kgf, 12 ft·lbf)
T.
R.
13
14
12
CHECKING THE BRAKE FLUID LEVEL
EAS1SM1097

k. Install the pad pin plug “15” and the protector TIP
“16”. In order to ensure a correct reading of the brake
Pad pin plug fluid level, make sure that the top of the brake
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) fluid reservoir is horizontal.
T.
Bolt (protector)
R.
2. Check:
7 Nm (0.7 m·kgf, 5.1 ft·lbf) • Brake fluid level
The minimum level mark “a” or below 
Add.
15 Recommended brake fluid
DOT 4
16
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• Brake fluid level
A. Front brake
B. Rear brake
3-26
CHASSIS
EWA13090
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to a
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
• When pouring the brake fluid, be careful
that water does not enter the reservoir. Drive chain slack
Water will significantly lower the boiling 50–60 mm (1.97–2.36 in)
point of the brake fluid and could cause
vapor lock. 5. Adjust:
ECA13540 • Drive chain slack
NOTICE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Immediately wipe off the spilled brake fluid a. Loosen the wheel axle nut “1”.
to avoid damage to painted surfaces or b. Loosen both locknuts “2”.
plastic parts. c. Turn the drive chain puller “3” in direction “a”
or “b” until the specified drive chain slack is
ADJUSTING THE DRIVE CHAIN SLACK obtained.
EAS1SM1098
ECA13550
NOTICE Direction “a”

A drive chain that is too tight will overload The drive chain slack decreases.
the engine and other vital parts, and one Direction “b”
that is too loose can skip and damage the The drive chain slack increases.
swingarm or cause an accident. Therefore,
keep the drive chain slack within the speci-
fied limits.
1. Use a suitable stand to raise the rear wheel a
off the ground.
EWA13120
WARNING b
Securely support the vehicle so that there is 1
no danger of it falling over. 2
3
2. Shift the transmission into the neutral posi-
tion.
TIP
3. Pull the drive chain up above the drive chain
guide installation bolt with a force of about • To maintain the proper wheel alignment, ad-
50 N (5.0 kgf, 36 lbf). just both sides evenly.
4. Check: • Push the rear wheel forward to make sure that
• Drive chain slack “a” there is no clearance between the swingarm
Out of specification  Regulate. end plates and the ends of the swingarm.
TIP d. Tighten the locknut.
Measure drive chain slack between the drive Locknut
chain guide and the bottom of the chain as 21 Nm (2.1 m·kgf, 15 ft·lbf)
shown.
T.
R.
e. Tighten the wheel axle nut.

Wheel axle nut
135 Nm (13.5 m·kgf, 98 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-27
CHASSIS
CHECKING THE FRONT FORK LEGS CLEANING THE FRONT FORK OIL SEAL
1. Stand the vehicle upright on a level surface. AND DUST SEAL

1. Remove:
EWA13120
WARNING
• Protector
Securely support the vehicle so that there is
• Dust seal “1”
no danger of it falling over. ECA?
NOTICE
2. Check:
• Inner tube Be careful not to damage the dust seal and
Damage/scratches  Replace. the inner tube by a driver.
• Front fork leg (s)
Oil leaks between inner tube and outer tube
 Replace the oil seal.
3. Hold the vehicle upright and apply the front
brake.
4. Check:
• Front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds 1
smoothly.
Unsmooth operation  Correct or replace. 2. Clean:
Refer to “FRONT FORK” on page 4-37. • Dust seal “a”
• Oil seal “b”
TIP
• Clean the dust seal and oil seal after every
run.
• Apply lithium-soap-based grease on the inner
tube.
CHECKING THE FRONT FORK PROTEC-

EAS1SM1100
a
TOR GUIDE
1. Check: b
• Protector guide “1”
LS
Out of specification  Replace.
TIP
The protector guide reaches the limit of its use
AIR BLEEDING FROM FRONT FORK
EAS1SM1102
when it is worn down to the same height “a” as

of the outer tube circumference. TIP
If the front fork initial movement feels stiff dur-
ing a run, relieve the front fork internal pres-
sure.
1. Use a suitable stand to raise the front wheel
1
off the ground.
EWA@
WARNING
no danger of it falling over.
a
2. Remove the air bleed screw “1” and release
the internal pressure from the front fork.
3-28
CHASSIS
3. Tighten:
• Air bleed screw
Air bleed screw
1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
T.
R.
1
a b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Compression damping force

ECA13590
NOTICE
Do not turn the adjuster forcibly beyond its
ADJUSTING THE FRONT FORK LEGS
EAS1SM1103
adjusting range.
1. Adjust:
EWA32D1006
WARNING
• Compression damping force
• Always adjust the left and right front forks
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
evenly. If this is not done, the vehicle may
a. Turn the adjuster “1” in the direction of “a” or
have poor stability.
“b” to make an adjustment.
• Securely support the vehicle so that there
is no danger of it falling over. Direction “a”
Compression damping force is in-
Rebound damping force creased (suspension is harder).
ECA13590 Direction “b”
NOTICE Compression damping force is de-
Do not turn the adjuster forcibly beyond its creased (suspension is softer).
adjusting range.
1. Adjust: Compression damping force
Maximum
• Rebound damping force
Turn it in finger-tight.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ STD
a. Turn the adjuster “1” in the direction of “a” or Turn it out by 8 clicks.*
“b” to make an adjustment. (USA) (CAN)
Turn it out by 6 clicks.*
Direction “a”
(EUR) (JPN) (AUS) (NZL) (ZAF)
Rebound damping force is increased
Minimum
(suspension is harder).
Direction “b”
Rebound damping force is decreased * With the adjuster fully turned in
(suspension is softer).
Rebound damping force b a

Maximum
STD 1
(USA) (CAN)
(EUR) (JPN) (AUS) (NZL) (ZAF)
Minimum
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
* With the adjuster fully turned in
3-29
CHASSIS
CHECKING THE SWINGARM OPERATION 1. Remove:

EAS1SM1104
1. Check: • Rear frame

• Swingarm smooth action Refer to “REAR SHOCK ABSORBER AS-
• Swingarm free play SEMBLY” on page 4-53.
Refer to “SWINGARM” on page 4-60. 2. Adjust:
• Spring preload
CHECKING THE REAR SUSPENSION
EAS1SM1105
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1. Stand the vehicle upright on a level surface. a. Loosen the locknut “1”.
EWA@
WARNING b. Loosen the adjuster “2” until there is some

Securely support the vehicle so that there is clearance between the spring and the ad-
no danger of it falling over. juster.
c. Measure the spring free length “a”.
2. Check:
• Rear shock absorber assembly
Gas leaks/oil leaks  Replace the rear
shock absorber assembly.
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-53.
3. Check:
• Rear shock absorber assembly smooth ac-
tion
• Rear suspension link smooth action
Sit astride the seat and shake your body up
d. Turn the adjuster in the direction of “b” or “c”
and down several times to check whether
to make an adjustment.
the rear shock absorber assembly operates
smoothly. Direction “b”
Unsmooth operation  Correct or replace. Spring preload is increased (suspen-
Refer to “REAR SHOCK ABSORBER AS- sion is harder).
SEMBLY” on page 4-53. Direction “c”
Spring preload is decreased (suspen-
sion is softer).
Spring installed length “d”

Minimum
Position in which the spring is
turned in 1.5 mm (0.06 in) from
its free length.
STD
Position in which the spring is
turned in 10 mm (0.39 in) from its
free length.
ADJUSTING THE REAR SHOCK ABSORB-
EAS1SM1106
Maximum
ER ASSEMBLY Position in which the spring is
Use a suitable stand to raise the rear wheel off turned in 18 mm (0.71 in) from its
the ground. free length.
EWA13120
WARNING
TIP
no danger of it falling over. • Be sure to remove all dirt and mud from
around the locknut and adjusting ring before
adjustment.
Spring preload
ECA13590 • The length of the spring (installed) changes
NOTICE 1.5 mm (0.06 in) per turn of the adjusting ring.
adjusting range.
3-30
CHASSIS
Rebound damping force

Maximum
STD
c Minimum
b Turn it out by 30 clicks.*
* With the adjuster fully turned
b
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
e. Tighten the locknut.
High compression damping
Locknut ECA13590
30 Nm (3.0 m·kgf, 22 ft·lbf) NOTICE

T.

R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ adjusting range.

3. Install: 1. Adjust:
• Rear frame • High compression damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
SEMBLY” on page 4-53.
Rebound damping force
Direction “a”
ECA13590
NOTICE
High compression damping force is in-
Do not turn the adjuster forcibly beyond its creased (suspension is harder).
adjusting range. Direction “b”
1. Adjust: High compression damping force is de-
• Rebound damping force creased (suspension is softer).
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjuster “1” in the direction of “a” or High compression damping
“b” to make an adjustment. Maximum
Direction “a” STD
Rebound damping force is increased Turn it out by 1 1/3 turns.*
(suspension is harder). (USA)(CAN)
Direction “b” Turn it out by 1 1/8 turns.*
Rebound damping force is decreased (EUR)(JPN)(AUS)(NZL)(ZAF)
(suspension is softer). Minimum
Turn it out by two turns.*
* With the adjuster fully turned
3-31
CHASSIS
CHECKING THE TIRES

EAS1SM1107
1. Measure:
• Tire pressure
b Out of specification  Regulate.
1 a Tire pressure
100 kPa (1.0 kgf/cm2,15 psi)
TIP
• Check the tire while it is cold.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Loose bead stoppers allow the tire to slip off
its position on the rim when the tire pressure
Low compression damping is low.
ECA13590
• If the tire valve stem is found tilted, the tire is
NOTICE considered to be slipping off its position. Cor-
Do not turn the adjuster forcibly beyond its rect the tire position.
adjusting range.
1. Adjust:
• Low compression damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Direction “a”
Low compression damping force is in-
creased (suspension is harder).
Direction “b”
Low compression damping force is de-
CHECKING AND TIGHTENING THE
EAS1SM1108
creased (suspension is softer).

SPOKES
Low compression damping 1. Check:
Maximum • Spokes
Turn it in finger-tight. Bend/damage  Replace.
STD Loose  Tighten.
Minimum
* With the adjuster fully turned in
b
1 a TIP
A tight spoke will emit a clear, ringing tone; a
loose spoke will sound flat.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-32
CHASSIS
2. Tighten: CHECKING AND ADJUSTING THE STEER-

EAS1SM1111
• Spokes ING HEAD

Use a spoke nipple wrench “1” for tighten- 1. Use a suitable stand to raise the front wheel
ing. off the ground.
EWA13120
WARNING
1 Securely support the vehicle so that there is
2. Check:
• Steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Blinding/looseness  Adjust the steering
head.
3. Remove:
Spoke nipple wrench (6–7) • Handlebar
90890-01521
Refer to “HANDLEBAR” on page 4-31.
YM-01521
• Upper bracket
Refer to “STEERING HEAD” on page 4-49.
Spokes 4. Adjust:
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
• Steering head
T.
R.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
TIP
a. Remove the washer “1”.
• Do not give a half turn (180 °) or more for one
tightening.
• Make sure that tightening after a break-in is 1
done until the initial looseness in nipples dis-
appears.
• Make sure that tightening is done in stages,
not at a time.
CHECKING THE WHEELS

EAS1SM1109
1. Check:
• Wheel (s) b. After loosening the ring nut “2” with a steer-
Damage/out-of-round  Replace. ing nut wrench “3”, tighten it to the specified
EWA13260
WARNING torque.
Never attempt to make any repairs to the TIP
wheel. • Set the torque wrench at a right angle to the
TIP steering nut wrench.
• Move the steering to the left and right a couple
After replacing a tire or a wheel, always bal-
of times to check that it moves smoothly.
ance the wheel.
CHECKING THE WHEEL BEARINGS

EAS1SM1110
1. Check:
• Wheel bearings
“CHECKING THE FRONT WHEEL” on page
4-4and “CHECKING THE REAR WHEEL”
on page 4-8.
3-33
CHASSIS
5. Install:
• Upper bracket
3 • Handlebar
Refer to “HANDLEBAR” on page 4-31.
LUBRICATING THE LEVERS
EAS1SM1112
1. Lubricate the pivoting points and metal-to-

2 metal moving parts of the following parts.
• Brake lever
Steering nut wrench Recommended lubricant

90890-01403 Silicone grease
YU-A9472 • Clutch lever
Ring nut (initial tightening torque) Lithium-soap-based grease
38 Nm (3.8 m·kgf, 27 ft·lbf)
T.
R.
LUBRICATING THE PEDAL

EAS1SM1113
c. Turn the front fork to the right and left a few 1. Lubricate the pivoting point and metal-to-
times, and make sure that the steering ro- metal moving parts of the pedal.
tates smoothly. If it does not turn smoothly,
remove the lower bracket and check the up- Recommended lubricant
per and lower bearings. Lithium-soap-based grease
d. Loosen the ring nut fully turn and then tight-
en it to specification with a steering nut
wrench.
EWA13140
WARNING
Do not overtighten the ring nut beyond the
specified torque. Otherwise, the steering
may malfunction.
Ring nut (final tightening torque)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.
e. Check the steering head for looseness or

binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and check the upper and
lower bearings.
f. Install the washer “1”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-34
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM 5. Clean:

EAS1SM1114
• Spark plug
CHECKING THE SPARK PLUG (with a spark plug cleaner or a wire brush)
EAS1SM1115
1. Remove: 6. Measure:
• Seat • Spark plug gap “a”
• Air scoop (left/right) Out of specification  Adjust the spark plug
Refer to “GENERAL CHASSIS” on page 4- gap.
1.
Spark plug gap
• Fuel tank “1” 0.7–0.8 mm (0.028–0.031 in)
Refer to “FUEL TANK” on page 7-1.
ECA1DX1001
NOTICE
Do not use too much force to pull the hose.
TIP
Remove the fuel tank, turn this 180 ° clockwise,
and put it in the frame “2” as shown.
1
1
7. Install:
• Spark plug
Spark plug
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
T.
R.
2
TIP
2. Remove: Before installing the spark plug, clean the spark
• Spark plug cap plug and gasket surface.
• Spark plug
Refer to “CAMSHAFT” on page 5-11. 8. Install:
ECA13330
• Spark plug cap
NOTICE • Fuel tank
In order not to allow the dirt accumulated • Air scoop (left/right)
around the spark plug to drop from the • Seat
spark plug hole into the cylinder, clean it be- • Side cover (left/right)
fore removing the spark plug. Refer to “GENERAL CHASSIS” on page 4-
3. Check: 1.
• Spark plug type CHECKING THE IGNITION TIMING
EAS1SM1116
Wrong type  Replace. 1. Remove:

Manufacturer/model • Timing mark accessing screw “1”
NGK/LMAR8G
4. Check:
• Electrode
Damage/wear  Replace the spark plug.
• Insulator
Abnormal color  Replace the spark plug.
Normal color is medium-to-light tan.
1
3-35
ELECTRICAL SYSTEM
2. Attach:
• Timing light “1”
• Digital tachometer “2”
To the high tension code “3”.
Timing light
90890-03141
YU-03141
Digital tachometer
90890-06760
YU-39951-B
2 3
3. Adjust:
• Engine idling speed
Refer to “ADJUSTING THE ENGINE
IDLING SPEED” on page 3-16.
4. Check:
• Ignition timing
Check whether the alignment mark “a” on
the left crankcase cover is within the firing
range “b” on the rotor.
Incorrect firing range  Check rotor and
Crankshaft position sensor.
b a
5. Install:
• Timing mark accessing screw
Timing mark accessing screw
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
T.
R.
3-36
CHASSIS
GENERAL CHASSIS........................................................................................4-1
REMOVING THE LEFT SIDE COVER.......................................................4-2
REMOVING THE SEAT .............................................................................4-2
REMOVING THE NUMBER PLATE...........................................................4-2
FRONT WHEEL................................................................................................4-3
REMOVING THE FRONT WHEEL.............................................................4-4
CHECKING THE FRONT WHEEL .............................................................4-4
DISASSEMBLING THE FRONT WHEEL...................................................4-5
ASSEMBLING THE FRONT WHEEL.........................................................4-5
INSTALLING THE FRONT WHEEL ...........................................................4-6
REAR WHEEL ..................................................................................................4-7

REMOVING THE REAR WHEEL ...............................................................4-8
CHECKING THE REAR WHEEL................................................................4-8
DISASSEMBLING THE REAR WHEEL .....................................................4-8
CHECKING AND REPLACING THE REAR WHEEL SPROCKET ............4-8
ASSEMBLING THE REAR WHEEL ...........................................................4-9
4
INSTALLING THE REAR WHEEL..............................................................4-9
FRONT BRAKE ..............................................................................................4-11

INTRODUCTION ......................................................................................4-15
CHECKING THE FRONT BRAKE DISC ..................................................4-15
REMOVING THE FRONT BRAKE CALIPER...........................................4-15
DISASSEMBLING THE FRONT BRAKE CALIPER .................................4-15
CHECKING THE FRONT BRAKE CALIPER ...........................................4-16
ASSEMBLING THE FRONT BRAKE CALIPER .......................................4-16
INSTALLING THE BRAKE CALIPER PISTON ........................................4-16
INSTALLING THE FRONT BRAKE CALIPER .........................................4-17
REMOVING THE FRONT BRAKE MASTER CYLINDER ........................4-18
CHECKING THE FRONT BRAKE MASTER CYLINDER.........................4-18
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ....................4-18
INSTALLING THE FRONT BRAKE MASTER CYLINDER.......................4-19
REAR BRAKE ................................................................................................4-21

INTRODUCTION ......................................................................................4-25
CHECKING THE REAR BRAKE DISC.....................................................4-25
REMOVING THE REAR BRAKE CALIPER .............................................4-26
DISASSEMBLING THE REAR BRAKE CALIPER ...................................4-26
CHECKING THE REAR BRAKE CALIPER..............................................4-26
ASSEMBLING THE REAR BRAKE CALIPER .........................................4-26
INSTALLING THE BRAKE CALIPER PISTON ........................................4-27
INSTALLING THE REAR BRAKE CALIPER............................................4-27
REMOVING THE REAR BRAKE MASTER CYLINDER ..........................4-28
CHECKING THE REAR BRAKE MASTER CYLINDER ...........................4-28
ASSEMBLING THE REAR BRAKE MASTER CYLINDER.......................4-29
INSTALLING THE REAR BRAKE MASTER CYLINDER .........................4-29
HANDLEBAR .................................................................................................4-31
REMOVING THE HANDLEBAR...............................................................4-33
CHECKING THE HANDLEBAR ...............................................................4-33
INSTALLING THE HANDLEBAR .............................................................4-33
FRONT FORK.................................................................................................4-37
REMOVING THE FRONT FORK LEGS...................................................4-39
DISASSEMBLING THE FRONT FORK LEGS .........................................4-39
CHECKING THE FRONT FORK LEGS ...................................................4-40
ASSEMBLING THE FRONT FORK LEGS ...............................................4-41
INSTALLING THE FRONT FORK LEGS .................................................4-47
STEERING HEAD...........................................................................................4-49
REMOVING THE LOWER BRACKET......................................................4-50
CHECKING THE STEERING HEAD ........................................................4-50
INSTALLING THE STEERING HEAD ......................................................4-50
REAR SHOCK ABSORBER ASSEMBLY .....................................................4-53

HANDLING THE REAR SHOCK ABSORBER .........................................4-56
DISPOSING OF A REAR SHOCK ABSORBER ......................................4-56
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY....................4-56
REMOVING THE BEARING.....................................................................4-56
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....................4-57
CHECKING THE CONNECTING ARM AND RELAY ARM......................4-57
INSTALLING THE RELAY ARM...............................................................4-57
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ..................4-58
SWINGARM....................................................................................................4-60
REMOVING THE SWINGARM.................................................................4-61
REMOVING THE BEARING.....................................................................4-61
CHECKING THE SWINGARM .................................................................4-61
INSTALLING THE SWINGARM ...............................................................4-62
CHAIN DRIVE.................................................................................................4-63
REMOVING THE DRIVE CHAIN..............................................................4-64
CHECKING THE DRIVE CHAIN ..............................................................4-64
CHECKING THE DRIVE SPROCKET......................................................4-65
CHECKING THE REAR WHEEL SPROCKET.........................................4-65
INSTALLING THE DRIVE CHAIN ............................................................4-65
GENERAL CHASSIS
EAS1SM1117
TIP
This section is intended for those who have basic knowledge and skill concerning the servicing of
Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl-
edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas-
sembly, or reassembly only by reference to this manual. It may lead to servicing trouble and
mechanical damage.
GENERAL CHASSIS
EAS1SM1118
Removing the seat and side cover

1.3 Nm (0.13 m•kgf, 0.94 ft•Ibf)
T.R
.
16 Nm (1.6 m•kgf, 12 ft•Ibf)
T .R
.
5 7
1
3
7 Nm (0.7 m•kgf, 5.1 ft •Ibf)
T .R
.
(2)
4
6
22 Nm (2.2 m•kgf, 16 ft •Ibf)
T .R
.
7 Nm (0.7 m•kgf, 5.1 ft •Ibf)

T .R
.
7 Nm (0.7 m•kgf, 5.1 ft •Ibf) 7 Nm (0.7 m•kgf, 5.1 ft •Ibf)

T .R
T .R
.
Order Part name Q’ty Remarks

1 Seat 1
2 Air scoop (left) 1
3 Air scoop (right) 1
4 Side cover (left) 1
5 Side cover (right) 1

6 Number plate 1
7 Rear fender 1
For installation, reverse the removal proce-
dure.
4-1
GENERAL CHASSIS
REMOVING THE LEFT SIDE COVER REMOVING THE NUMBER PLATE

1. Remove: 1. Remove:
• Bolt (side cover) • Bolt (number plate)
• Side cover “1” • Number plate “1”
TIP TIP
Draw the left side cover “1” backward to re- • The projection “a” is inserted into the band of
move it because its projection “a” is inserted in the number plate. Pull the band off the projec-
the rear frame. tion before removal.
• Remove the clutch cable “2” from the cable
1 guide “b” on the number plate.
• The projection “c” on the lower bracket is in-
serted into the number plate. Remove the
number plate by pulling it off the projection.
a
REMOVING THE SEAT

EAS1SM1120
TIP
The fuel tank cap cover and the seat are cou-
pled with each other with a plastic band.
When removing the seat, always remove the
fuel tank cap cover beforehand.
1. Remove:
• Fuel tank cap cover “1”
Refer to “FUEL TANK CAP” on page 1-21.
2. Remove:
• Seat “1”
4-2
FRONT WHEEL
FRONT WHEEL
EAS1SM1122
Removing the front wheel
LS 21 Nm (2.1 m•kgf, 15 ft •Ibf)
T .R
.
3
21 Nm (2.1 m•kgf, 15 ft •Ibf)
T .R
.
1
5 6 New 2
7 1
115 Nm (11.5 m•kgf, 83 ft•lbf)
T.R
.
LS 8
LS
New
(6)
4 7
6 5
LT 12 Nm (1.2 m•kgf, 8.7 ft •Ibf)
T .R
.

Use a suitable stand to raise the front wheel
off the ground.
1 Front wheel axle pinch bolt 4 Loosen.
2 Front wheel axle nut 1
3 Front wheel axle 1
4 Front wheel 1
5 Collars 2
6 Oil seals 2
7 Bearing 2
8 Brake disc 1
dure.
4-3
FRONT WHEEL
REMOVING THE FRONT WHEEL

EAS1SM1123
TIP
1. Use a suitable stand to raise the front wheel A tight spoke will emit a clear, ringing tone; a
off the ground. loose spoke will sound flat.
EWA13120
WARNING 4. Tighten:
Securely support the vehicle so that there is • Spokes
no danger of it falling over. Refer to “CHECKING AND TIGHTENING
2. Remove: THE SPOKES” on page 3-32.
• Front wheel Spokes
CHECKING THE FRONT WHEEL
EAS1SM1124
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
T.
R.
1. Check:
• Front wheel axle TIP
Roll the front wheel axle on a flat surface. After tightening the spokes, measure the wheel
Bends  Replace. runout.
5. Measure:
• Wheel radial runout “a”
• Wheel lateral runout “b”
Out of specification  Repair/replace.
b
a
EWA13460
WARNING
Do not use a bent front wheel axle even after
correcting this.
2. Check:
• Tire (s) Radial wheel runout limit
• Front wheel 2.0 mm (0.08 in)
Damage/wear  Replace. Lateral wheel runout limit
Refer to “CHECKING THE TIRES” on page 2.0 mm (0.08 in)
3-32 and “CHECKING THE WHEELS” on
6. Check:
page 3-33.
• Collars
3. Check:
Damage/wear  Replace.
• Spokes
7. Check:
Bend/damage  Replace.
• Bearing
Loose  Tighten.
Front wheel turns roughly or is loose  Re-
Tap the spokes with a screwdriver.
place the wheel bearings.
• Oil seals
4-4
FRONT WHEEL
DISASSEMBLING THE FRONT WHEEL

EAS1SM1125
1. Remove:
• Oil seals
• Bearing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 4 New
a. Clean the outside of the front wheel hub. 3
b. Remove the oil seals “1” with a flat-head
screwdriver. 2
TIP
To prevent damaging the wheel, place a rag “2”
between the screwdriver and the wheel sur-
face.
2
1
4 New
TIP
1
Use a socket “1” that matches the diameter of
c. Remove the bearings with a bearing puller. the bearing outer race and that of the oil seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
ASSEMBLING THE FRONT WHEEL • Brake disc “1”
EAS1SM1126
1. Install: • Brake disc bolt “2”

• Bearing (left side) “1”
Brake disc bolt
• Spacer “2”
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
• Bearing (right side) “3”
T.
LOCTITE®
R.
• Oil seals “4” New

TIP TIP
• Apply the lithium soap base grease to the Tighten the bolts in stages and in a crisscross
bearing and the oil seal lip when installing. pattern.
• Left side of bearing shall be installed first.
• Install the oil seal with its manufacture’s
marks or numbers facing outward.
ECA1DX1005
NOTICE
Install the bearing by pressing its outer race
parallel.
4-5
FRONT WHEEL
3. Install: 3. Tighten:
• Collar “1” • Front wheel axle nut “1”
TIP Front wheel axle nut
Apply the lithium soap base grease on the oil 115 Nm (11.5 m·kgf, 83 ft·lbf)
T.
seal lip.
R.
ECA14140
NOTICE
1 Before tightening the front wheel axle nut,
push down hard on the handlebar(s) several
times and check if the front fork rebounds
smoothly.
LS
INSTALLING THE FRONT WHEEL

EAS1SM1127
1
1. Install:
• Front wheel
TIP
Install the brake disc “1” between the brake
4. Tighten:
pads “2” correctly.
• Front wheel axle pinch bolt “1”
Front wheel axle pinch bolt
21 Nm (2.1 m·kgf, 15 ft·lbf)
T.
R.
2. Install:
• Front wheel axle “1” 1 1
TIP
Apply the lithium soap base grease to the front
wheel axle.
4-6
REAR WHEEL
REAR WHEEL
EAS1SM1128
Removing the rear wheel
1 3 14 Nm (1.4 m•kgf, 10 ft •Ibf)
T .R
.
135 Nm (13.5 m•kgf, 98 ft•lbf)
(6)
T.R
LT
.
10
5
7
8
21 Nm (2.1 m•kgf, 15 ft •Ibf) 9
T .R
.
LS
(6)
42 Nm (4.2 m•kgf, 30 ft•Ibf)
T .R
.
6
(6) LS
5
3
9
7
2
LS
4
21 Nm (2.1 m•kgf, 15 ft•Ibf)

T .R
.

Use a suitable stand to raise the rear wheel
off the ground.
1 Nut (rear wheel axle) 1
2 Rear wheel axle 1
3 Drive chain puller 2

4 Rear wheel 1
5 Collars 2
6 Rear wheel sprocket 1
7 Oil seals 2
8 Circlip 1
9 Bearing 3
10 Brake disc 1

dure.
4-7
REAR WHEEL
REMOVING THE REAR WHEEL 4. Measure:

EAS1SM1129
1. Use a suitable stand to raise the rear wheel • Radial wheel runout
off the ground. • Lateral wheel runout
EWA13120
Refer to “CHECKING THE FRONT WHEEL”

WARNING
on page 4-4.
no danger of it falling over. Radial wheel runout limit
2.0 mm (0.08 in)
2. Remove: Lateral wheel runout limit
• Rear wheel axle nut “1” 2.0 mm (0.08 in)
3. Loosen:
• Locknut “2” DISASSEMBLING THE REAR WHEEL
EAS1SM1131
4. Tighten: 1. Remove:
• Adjusting bolt “3” • Oil seals
• Bearing
Refer to “DISASSEMBLING THE FRONT
WHEEL” on page 4-5.
2 CHECKING AND REPLACING THE REAR
EAS1SM1132
WHEEL SPROCKET
1. Check:
• Rear wheel sprocket
3
More than 1/4 tooth wear “a”  Replace the
1
rear wheel sprocket and the drive sprocket
5. Remove: as a set.
• Rear wheel axle Bent tooth  Replace the rear wheel
• Rear wheel sprocket and the drive sprocket as a set.
TIP
• Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
• Do not depress the brake pedal with the rear
wheel removed.
CHECKING THE REAR WHEEL

EAS1SM1130
1. Check:
• Rear wheel axle
• Rear wheel
• Bearing b. Correct
• Oil seals 1. Drive chain roller
Refer to “CHECKING THE FRONT WHEEL” 2. Rear wheel sprocket
on page 4-4. 2. Replace:
2. Check: • Rear wheel sprocket
• Tire (s) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Rear wheel a. Remove the self-locking nuts and the rear
Damage/wear  Replace. wheel sprocket.
Refer to “CHECKING THE TIRES” on page b. Clean the rear wheel drive hub with a clean
3-32 and “CHECKING THE WHEELS” on cloth, especially the surfaces that contact
page 3-33. the sprocket.
3. Check: c. Install the new rear wheel sprocket.
• Spokes
Refer to “CHECKING THE FRONT WHEEL” Rear wheel sprocket self-locking
nut
on page 4-4.
T.
42 Nm (4.2 m·kgf, 30 ft·lbf)

R.
4-8
REAR WHEEL
TIP
Tighten the self-locking nuts in stages and in a
crisscross pattern. 1
2. Install:
• Brake disc “1”
• Brake disc bolt “2”
Brake disc bolt
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
14 Nm (1.4 m·kgf, 10 ft·lbf)
T.
LOCTITE®
R.
ASSEMBLING THE REAR WHEEL
EAS1SM1133
1. Install:
• Bearing (right side) “1” TIP
• Circlip “2” New Tighten the bolts in stages and in a crisscross
• Spacer “3” pattern.
• Bearing (left side) “4”
TIP
• Apply the lithium soap base grease to the
bearing and the oil seal lip when installing.
• Install the bearing with seal facing outward.
• Right side of bearing shall be installed first.
marks or numbers facing outward.
ECA1DX1006
NOTICE 3. Install:
Install the bearing by pressing its outer race • Collar “1”
parallel. TIP
Apply the lithium soap base grease on the oil
5 2
seal lip.
1
LS LS
3 5
4
LS
TIP
Use a socket “1” that matches the diameter of
the bearing outer race and that of the oil seal.
INSTALLING THE REAR WHEEL
EAS1SM1134
1. Install:
• Rear wheel
4-9
REAR WHEEL
TIP TIP
Install the brake disc “1” between the brake Temporarily tighten the nut (rear wheel axle) at
pads “2” correctly. this point.
3 1
2. Install: 5. Adjust:
• Drive chain “1” • Drive chain slack “a”
TIP Drive chain slack
Push the rear wheel “2” forward and install the 50–60 mm (1.97–2.36 in)
drive chain.
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” on page 3-27.
3. Install:
• Left drive chain puller “1”
6. Tighten:
• Rear wheel axle “2”
• Rear wheel axle nut “1”
TIP
• Install the left drive chain puller, and insert the Wheel axle nut
rear wheel axle from the left side. 135 Nm (13.5 m·kgf, 98 ft·lbf)
T.
R.
• Apply the lithium soap base grease to the rear

• Locknut “2”
wheel axle.
Locknut
21 Nm (2.1 m·kgf, 15 ft·lbf)
T.
R.
2
1
1
2
LS
4. Install:
• Right drive chain puller “1”
• Washer “2”
• Rear wheel axle nut “3”
4-10
FRONT BRAKE
FRONT BRAKE
EAS1SM1135
Removing the front brake caliper
30 Nm (3.0 m kgf, 22 ft lbf)
T .R
.
28 Nm (2.8 m kgf, 20 ft lbf)
T .R
.
6 Nm (0.6 m kgf, 4.3 ft lbf)
T .R
.
3
9
2
8
7
5 4
17 Nm (1.7 m kgf, 12 ft lbf)

T .R
.
6 2.5 Nm (0.25 m kgf, 1.8 ft lbf)

T.R
.

Drain.
Brake fluid Refer to “BLEEDING THE BRAKE SYSTEM”
on page 3-21.
1 Union bolt 1
2 Copper washers 2
3 Front brake hose 1
4 Brake pad pin plug 1
5 Brake pad pin 1

6 Brake pads 2
7 Brake pad spring 1
8 Front brake caliper assembly 1
9 Front brake caliper bracket 1

dure.
4-11
FRONT BRAKE
Disassembling the front brake caliper
6 Nm (0.6 m • kgf, 4.3 ft • Ibf)
T.
R.
1 2 S 4
BF
BF

1 Brake caliper piston 2
2 Brake caliper piston dust seal 2
3 Brake caliper piston seal 2

4 Bleed screw 1
For assembly, reverse the disassemble pro-
cedure.
4-12
FRONT BRAKE
Removing the front brake master cylinder
1.5 Nm (0.15 m kgf, 1.1 ft lbf)
T.R
.
8
5
6
6 Nm (0.6 m kgf, 4.3 ft lbf)
T .R
.
7
6 Nm (0.6 m kgf, 4.3 ft lbf)
T .R
.
9
1
2
30 Nm (3.0 m kgf, 22 ft lbf)
T .R
.

Drain.
on page 3-21.
1 Brake lever 1
2 Union bolt 1
3 Copper washers 2
4 Front brake hose 1
5 Brake master cylinder reservoir cap 1
6 Brake master cylinder reservoir diaphragm 1
7 Front brake master cylinder float 1
8 Front brake master cylinder holder 1

9 Front brake master cylinder 1
dure.
4-13
FRONT BRAKE
Disassembling the front brake master cylinder
1
S
2
3 New
4
5 New
BF

1 Push rod 1
2 Dust boot 1
3 Circlip 1
4 Washer 1
5 Brake master cylinder kit 1

cedure.
4-14
FRONT BRAKE
INTRODUCTION
EAS1SM1136
EWA14100
Brake disc thickness limit
WARNING 2.5 mm (0.10 in)
If you need to disassemble the disc brake
components, observe the following precau- 4. Install:
tions. • Front wheel
• Never disassemble the brake components Refer to “FRONT WHEEL” on page 4-3.
unless absolutely necessary.
REMOVING THE FRONT BRAKE CALIPER
EAS1SM1138
• If there is any problem with connections

on the hydraulic brake system, perform TIP
the following jobs. Before disassembling the brake caliper, drain
Disassemble the brake system, drain the the brake fluid from the entire brake system.
brake fluid, and clean it. After that, add a 1. Remove:
suitable amount of brake fluid. Then, bleed • Union bolt
it after reassembly. • Copper washers
• Use only brake fluid for washing brake • Brake hose
components.
TIP
• Use new brake fluid for cleaning the brake
components. Put the end of the brake hose into a container
• Immediately wipe off the spilled brake fluid and pump out the brake fluid.
to avoid damage to painted surfaces or
DISASSEMBLING THE FRONT BRAKE CAL-
EAS1SM1139
plastic parts.
• Handle brake fluid with special care not to IPER
let it enter your eyes so that you may not 1. Remove:
lost your eyesight. • Brake caliper piston “1”
• FIRST AID FOR BRAKE FLUID ENTERING • Brake caliper piston dust seal “2”
THE EYES: • Brake caliper piston seals “3”
• Flush with water for 15 minutes and get
1
immediate medical attention. 3
CHECKING THE FRONT BRAKE DISC
EAS1SM1137
1. Remove:
• Front wheel
Refer to “FRONT WHEEL” on page 4-3.
2. Check:
• Front brake disc 2
Damage/galling  Replace.
3. Measure: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Brake disc thickness a. Blow compressed air into the brake hose
Measure the brake disc thickness at a few joint opening to force out the piston from the
different locations. brake caliper.
EWA13550
WARNING
• Cover the brake caliper piston with a cloth.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Do not use a screwdriver etc. for removing
the brake caliper piston.
4-15
FRONT BRAKE
ASSEMBLING THE FRONT BRAKE CALI-

PER
EWA13620
WARNING
• Before installation, clean and lubricate the
internal parts. Use new brake fluid for
cleaning and lubricating.
• Never use solvents on internal brake com-
ponents as they will cause the piston seals
to swell and distort.
• When the brake caliper is disassembled,
b. Remove the brake caliper piston dust seal
replace the brake caliper piston seal and
and the brake caliper piston seal.
the brake caliper piston dust seal with new
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ones.
CHECKING THE FRONT BRAKE CALIPER
EAS1SM1140
1. Check: Recommended brake fluid

• Brake caliper piston “1” DOT 4
Rust/scratches/wear  Replace the brake
INSTALLING THE BRAKE CALIPER PISTON
EAS1SM1142
caliper piston.
• Brake caliper cylinder “2” 1. Clean:
Scratches/wear  Replace the brake cali- • Brake caliper
per assembly. • Brake caliper piston seal
• Brake caliper body “3” • Brake caliper piston dust seal
Cracks/damage  Replace the brake cali- • Brake caliper piston
per assembly. Use brake fluid for cleaning.
• Brake fluid delivery passages 2. Install:
(brake caliper body) • Brake caliper piston seals “1” New
Obstruction  Blow out with compressed • Brake caliper piston dust seal “2” New
EWA33DD033
air. WARNING
Always use new brake caliper piston seal
2 3 and brake caliper piston dust seal.
TIP
• Apply the brake fluid on the brake caliper pis-
ton seal.
• Apply the silicone grease on the brake caliper
piston dust seal.
• Fit the brake caliper piston seal and the brake
1 1 caliper piston dust seal into the grooves in the
brake caliper correctly.
EWA13600
WARNING
When the brake caliper is disassembled, re- 1
place the brake caliper piston seal and the
brake caliper piston dust seal with new
ones. 1
2. Check:
• Brake caliper bracket
Crack/damage  Replace. 2
EAS1SM1141
4-16
FRONT BRAKE
3. Install: 2. Install:
• Brake caliper piston “1” • Front brake caliper
TIP • Brake pad spring
Apply the brake fluid on the piston wall. • Brake pad
ECA33DD047
• Brake pad pin
NOTICE • Brake hose holder
• Install the piston with its side “a” facing Brake pad pin
the brake caliper. 17 Nm (1.7 m·kgf, 12 ft·lbf)
T.
• Never force to insert.
R.
Refer to “CHECKING THE FRONT BRAKE
1 PADS” on page 3-23.
3. Tighten:
• Brake hose holder mounting bolt “1”
Brake hose holder mounting bolt
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
T.
R.
a TIP
1
Make sure that the brake hose holder “2” is in-
stalled with its upper end “a” aligned with the
INSTALLING THE FRONT BRAKE CALIPER
EAS1SM1143
paint “b” on the brake hose.
1. Install:
• Front brake caliper bracket 2
• Front brake caliper
(temporarily)
• Copper washers New b
• Brake hose
• Union bolt
a
Front brake caliper bracket
28 Nm (2.8 m·kgf, 20 ft·lbf) 1
T.
Brake hose union bolt

R.
30 Nm (3.0 m·kgf, 22 ft·lbf) 4. Pour brake fluid to the brake master cylinder
reservoir up to the specified level.
EWA13530
WARNING Recommended brake fluid

Proper brake hose routing is essential to in- DOT 4
sure safe vehicle operation. Refer to “CA-
BLE ROUTING DIAGRAM” on page 2-31.
EWA13090
WARNING
ECA14170
NOTICE
brake fluids may cause the rubber seals to
Make sure that the pipe portion “a” of the
brake hose touches the projection “b” on
brake performance.
the brake caliper.
that water does not enter the reservoir.
Water will significantly lower the boiling
a point of the brake fluid and could cause
b vapor lock.
4-17
FRONT BRAKE
ECA13540
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean 1
up any spilt brake fluid immediately.
5. Bleed:
• Brake system
TEM” on page 3-21. 2
6. Check:
• Brake fluid level 2. Check:
The minimum level mark or below  Add. • Brake master cylinder kit
Refer to “CHECKING THE BRAKE FLUID Damage/scratches/wear  Replace.
LEVEL” on page 3-26. 3. Check:
7. Check: • Brake master cylinder reservoir cap
• Brake lever free play 4. Check:
Refer to “ADJUSTING THE FRONT • Brake hoses
BRAKE” on page 3-22. Cracks/damage/wear  Replace.
• Brake lever operation
ASSEMBLING THE FRONT BRAKE MAS-
EAS1SM1146

TER CYLINDER
system. EWA13520
Refer to “BLEEDING THE BRAKE SYS- WARNING

TEM” on page 3-21. • Before installation, clean and lubricate the
internal parts. Use new brake fluid for
REMOVING THE FRONT BRAKE MASTER
EAS1SM1144

CYLINDER
TIP ponents.
Before removing the front brake master cylin-
der, drain the brake fluid from the entire brake Recommended brake fluid
system. DOT 4
1. Remove: 1. Wash the brake master cylinder and the
• Union bolt brake master cylinder kit with brake fluid.
• Copper washers 2. Install:
• Brake hoses • Primary cylinder cup “1” New
TIP • Secondary cylinder cup “2” New
To drain any remaining brake fluid, place a con- Install to the brake master cylinder piston
tainer under the master cylinder and the end of “3”.
the brake hose.
EWA13520
WARNING
Apply brake fluid to the cylinder cups and
CHECKING THE FRONT BRAKE MASTER
EAS1SM1145
install them as shown. Wrong orientation in

CYLINDER
installation causes poor braking perfor-
1. Check:
mance.
• Brake master cylinder “1”
Damage/scratches/wear  Replace.
• Brake fluid delivery passages “2”
(brake master cylinder body) 1 2
Obstruction  Blow out with compressed
air.
4-18
FRONT BRAKE
INSTALLING THE FRONT BRAKE MASTER

EAS1SM1147
CYLINDER
1 2 1. Install:
Brake master cylinder holder bolt
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
T.
R.
3 TIP
• Install the front brake master cylinder holder
3. Install: with the “UP” mark facing up.
• Spring “1” • First, tighten the upper bolt, then the lower
Install to the brake master cylinder piston bolt.
“2”.
TIP
Install the spring with a smaller inside diameter
to the brake master cylinder piston.
2. Install:
• Copper washers New
• Brake hose
• Union bolt
4. Install: Brake hose union bolt
• Brake master cylinder kit “1” New 30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.
• Washer “2” EWA13530
• Circlip “3” New WARNING

• Dust boot “4” Proper brake hose routing is essential to in-
• Push rod “5” sure safe vehicle operation. Refer to“CA-
TIP BLE ROUTING DIAGRAM” on page 2-31.
• Before installation, apply brake fluid to the ECA1DX1007
brake master cylinder kit. NOTICE

• Before installation, apply silicone grease to During installation, bring the brake hose
the push rod end. into contact with the brake master cylinder
• Use circlip pliers to install the circlip. projection “a” and make its bent portion “b”
face downward.
TIP
Turn the handlebar toward right and left to
make sure that the brake hose does not touch
other parts (e.g., wire harness, cables, leads).
Adjust if necessary.
4-19
FRONT BRAKE
3. Pour brake fluid to the brake master cylinder 6. Check:

reservoir up to the specified level. • Brake lever free play
Refer to “ADJUSTING THE FRONT
Recommended brake fluid
BRAKE” on page 3-22.
DOT 4
• Brake lever operation
EWA13540
WARNING system.
• Use only the designated brake fluid. Other Refer to “BLEEDING THE BRAKE SYS-
brake fluids may cause the rubber seals to TEM” on page 3-21.
brake performance.
vapor lock.
ECA13540
NOTICE
Immediately wipe off the spilled brake fluid
to avoid damage to painted surfaces or
plastic parts.
4. Bleed:
• Brake system
5. Check:
Add.
4-20
REAR BRAKE
REAR BRAKE
EAS1SM1148
Removing the rear brake caliper

10 Nm (1.0 m•kgf, 7.2 ft •Ibf) 2.5 Nm (0.25 m•kgf, 1.8 ft •Ibf)
T .R
.
T.R
.
17 Nm (1.7 m•kgf, 12 ft •Ibf)
T .R
.
30 Nm (3.0 m•kgf, 22 ft •Ibf)
T .R
.
10 9 S
2
New 3
11 4
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)

9 5
T .R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T .R
.

Drain.
on page 3-21.
1 Protector 1
2 Union bolt 1
3 Copper washers 2
4 Rear brake hose 1
5 Brake pad pin plug 1
6 Brake pad pin 1
7 Rear brake pad assembly 2
8 Rear brake caliper bracket 1

9 Brake pad springs 2
10 Rear brake disc cover 1
11 Rear brake caliper assembly 1

dure.
4-21
REAR BRAKE
Disassembling the rear brake caliper
2
3
BF
6 Nm (0.6 m • kgf, 4.3 ft • Ibf)

T.
R.

1 Brake caliper piston 1
2 Brake caliper piston dust seal 1
3 Brake caliper piston seal 1
4 Bleed screw 1
cedure.
4-22
REAR BRAKE
Removing the rear brake master cylinder
T.
R.
T.
R.
T.
R.
7
1
8
9 2
10
5
4
Drain.
on page 3-21.
1 Union bolt 1
2 Copper washers 2
3 Brake hose 1
4 Split pin 1
5 Plain washer 1
6 Pin 1
7 Brake master cylinder reservoir cap 1
8 Brake master cylinder reservoir diaphragm plate 1

9 Brake master cylinder reservoir diaphragm 1
10 Rear brake master cylinder 1

dure.
4-23
REAR BRAKE
Disassembling the rear brake master cylinder
BF
4 New
S 3
2 New

1 Dust boot 1
2 Circlip 1
3 Push rod 1
4 Brake master cylinder kit 1
cedure.
4-24
REAR BRAKE
INTRODUCTION
EAS1SM1149
EWA14300
WARNING
If you need to disassemble the disc brake
components, observe the following precau-
tions.
• Never disassemble the brake components
unless absolutely necessary.
• If there is any problem with connections
on the hydraulic brake system, perform
the following jobs.
Disassemble the brake system, drain the Brake disc deflection limit
brake fluid, and clean it. After that, add a 0.15 mm (0.0059 in)
suitable amount of brake fluid. Then, bleed
it after reassembly. 5. Adjust:
• Use only brake fluid for washing internal • Brake disc deflection
brake components. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Use new brake fluid for cleaning the brake a. Remove the brake disc.
components. b. Turn the mounted position of the brake disc
• Immediately wipe off the spilled brake fluid by one bolt hole.
to avoid damage to painted surfaces or c. Install the brake disc.
plastic parts. TIP
• Handle brake fluid with special care not to Tighten the brake disc bolts in stages and in a
let it enter your eyes so that you may not crisscross pattern.
lost your eyesight.
• FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.
CHECKING THE REAR BRAKE DISC

EAS1SM1150
1. Remove:
• Rear wheel
2. Check:
• Brake disc Brake disc bolt
Damage/galling  Replace. 14 Nm (1.4 m·kgf, 10 ft·lbf)
T.
3. Measure: LOCTITE®
R.
• Brake disc thickness

Measure the brake disc thickness at a few d. Measure the brake disc deflection.
different locations. e. If out of specification, repeat the adjustment
Out of specification  Replace. steps until the brake disc deflection is within
Refer to “CHECKING THE FRONT BRAKE specification.
DISC” on page 4-15. f. If the brake disc deflection cannot be
brought within specification, replace the
Brake disc thickness limit brake disc.
3.5 mm (0.14 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
4. Measure:
• Rear wheel
• Brake disc deflection
Out of specification  Correct the brake disc
deflection or replace the brake disc.
4-25
REAR BRAKE
REMOVING THE REAR BRAKE CALIPER CHECKING THE REAR BRAKE CALIPER
TIP 1. Check:
Before disassembling the brake caliper, drain • Brake caliper piston “1”
the brake fluid from the entire brake system. Rust/scratches/wear  Replace the brake
caliper piston.
1. Remove: • Brake caliper cylinder “2”
• Union bolt Scratches/wear  Replace the brake cali-
• Copper washers per assembly.
• Brake hose • Brake caliper body “3”
TIP Cracks/damage  Replace the brake cali-
Put the end of the brake hose into a container per assembly.
and pump out the brake fluid. • Brake fluid delivery passages
(brake caliper body)
DISASSEMBLING THE REAR BRAKE CALI-
EAS1SM1152

PER air.
1. Remove:
• Brake caliper piston “1” 2
• Brake caliper piston dust seal “2”
• Brake caliper piston seal “3” 1
1 3
2 3 EWA13610
WARNING
When the brake caliper is disassembled, re-
place the brake caliper piston seal and the
brake caliper piston dust seal with new
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ones.
a. Blow compressed air into the brake hose
2. Check:
joint opening to force out the piston from the
• Brake caliper bracket
brake caliper.
EWA13550 Crack/damage  Replace.
WARNING
ASSEMBLING THE REAR BRAKE CALIPER
EAS1SM1154
• Cover the brake caliper piston with a cloth. EWA13620
Be careful not to get injured when the pis- WARNING

ton is expelled from the brake caliper. • Before installation, clean and lubricate the
• Do not use a screwdriver etc. for removing internal parts. Use new brake fluid for
the brake caliper piston. cleaning and lubricating.
ponents as they will cause the piston seals
to swell and distort.
• When the brake caliper is disassembled,
replace the brake caliper piston seal and
the brake caliper piston dust seal with new
ones.

DOT 4
b. Remove the brake caliper piston dust seal
and the brake caliper piston seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-26
REAR BRAKE
INSTALLING THE BRAKE CALIPER PISTON INSTALLING THE REAR BRAKE CALIPER
1. Clean: 1. Install:
• Brake caliper • Rear brake caliper
• Brake caliper piston seal • Rear brake caliper bracket
• Brake caliper piston dust seal 2. Install:
• Brake caliper piston • Rear wheel
Use brake fluid for cleaning. Refer to “REAR WHEEL” on page 4-7.
2. Install: • Copper washers New
• Brake caliper piston seals “1” New • Brake hose
• Brake caliper piston dust seal “2” New • Union bolt
EWA33DD033
WARNING Brake hose union bolt

Always use new brake caliper piston seal 30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.
and brake caliper piston dust seal. EWA13530
TIP WARNING
• Apply the brake fluid on the brake caliper pis- Proper brake hose routing is essential to in-
ton seal. sure safe vehicle operation. Refer to “CA-
• Apply the silicone grease on the brake caliper BLE ROUTING DIAGRAM” on page 2-31.
piston dust seal.
ECA14170
NOTICE
• Fit the brake caliper piston seals and brake
Make sure that a bend in its pipe portion “a”
caliper piston dust seals onto the slot on
is directed as shown and the brake hose
brake caliper correctly.
touches the projection “b” on the brake cal-
iper.
2 b
3. Install: b a
• Brake caliper piston “1”
3. Install:
TIP • Brake pad springs
Apply the brake fluid on the piston wall. • Brake pads
ECA33DD047
• Brake pad pin
NOTICE • Brake pad pin plug
• Install the piston with its side “a” facing
the brake caliper. Brake pad pin
17 Nm (1.7 m·kgf, 12 ft·lbf)
• Never force to insert.
T.
Brake pad pin plug

R.
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)

1
Refer to “CHECKING THE REAR BRAKE
PADS” on page 3-25.
4. Pour brake fluid to the brake fluid reservoir
up to the specified level.
a 1 DOT 4
4-27
REAR BRAKE
REMOVING THE REAR BRAKE MASTER

EWA13090
WARNING
CYLINDER
TIP
deteriorate, causing leakage and poor Before removing the rear brake master cylin-
brake performance. der, drain the brake fluid from the entire brake
• Refill with the same type of brake fluid that system.
is already in the system. Mixing brake flu- 1. Remove:
ids may result in a harmful chemical reac- • Union bolt
tion, leading to poor brake performance. • Copper washers
• When pouring the brake fluid, be careful • Brake hose
TIP
point of the brake fluid and could cause To drain any remaining brake fluid, place a con-
vapor lock. tainer under the master cylinder and the end of
ECA13540
the brake hose.
NOTICE
CHECKING THE REAR BRAKE MASTER
EAS1SM1158

and plastic parts. Therefore, always clean CYLINDER
up any spilt brake fluid immediately. 1. Check:
5. Bleed: Damage/scratches/wear  Replace.
• Brake system • Brake fluid delivery passages “2”
(brake master cylinder body)
6. Check: air.
Add.
1 2
2. Check:
• Brake master cylinder kit
a 3. Check:
• Master cylinder reservoir cap
7. Check:
• Brake pedal operation • Brake master cylinder reservoir diaphragm
A softy or spongy feeling  Bleed the brake holder
system.
• Brake master cylinder reservoir diaphragm
Refer to “BLEEDING THE BRAKE SYS- Crack/damage  Replace.
TEM” on page 3-21. 4. Check:
• Brake hoses
EAS1SM1157
EAS1SM1159
4-28
REAR BRAKE
ASSEMBLING THE REAR BRAKE MASTER

CYLINDER
EWA13520
WARNING
• Before installation, clean and lubricate the
internal parts. Use new brake fluid for 2
1
ponents.

DOT 4 4. Install:
• Master cylinder kit “1” New
1. Wash the brake master cylinder and the • Push rod “2”
brake master cylinder kit with brake fluid. • Circlip “3” New
2. Install: • Dust boot “4”
• Primary cylinder cup “1” New TIP
• Secondary cylinder cup “2” New • Before installation, apply brake fluid to the
Install to the brake master cylinder piston brake master cylinder kit.
“3”. • Before installation, apply silicone grease to
EWA13520
WARNING the push rod end.

Apply brake fluid to the cylinder cups and • Use circlip pliers to install the circlip.
install them as shown. Wrong orientation in
installation causes poor braking perfor-
mance.
1 New 3 New
2 4
1
2
INSTALLING THE REAR BRAKE MASTER

EAS1SM1160
3
CYLINDER
1. Install:
• Copper washers New
2 • Brake hose
• Union bolt
1 Brake hose union bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.
3
EWA13530
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CA-
3. Install: BLE ROUTING DIAGRAM” on page 2-31.
• Spring “1” ECA1DX1008
Install to the brake master cylinder piston NOTICE

“2”. Make sure that the pipe portion of the brake
TIP hose touches the projection “a” on the
Install the spring with a smaller inside diameter brake caliper.
to the brake master cylinder piston.
4-29
REAR BRAKE
a
2. Pour brake fluid to the brake fluid reservoir 5. Check:
up to the specified level. • Brake pedal operation
system.
DOT 4
EWA13090
WARNING
brake performance.
vapor lock.
ECA13540
NOTICE
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
3. Bleed:
• Brake system
4. Check:
Add.
4-30
HANDLEBAR
HANDLEBAR
EAS1SM1161
Removing the handlebar

Number plate Remove the band only.
1 Clutch cable 1 Disconnect.
2 Clutch lever holder 1
3 Engine stop switch 1

4 Brake master cylinder 1
5 Throttle cable cap 1

6 Throttle cable (pull) 1 Disconnect.
7 Throttle cable (return) 1 Disconnect.
8 Right grip 1
9 Tube guide 1
10 Collars 1
11 Left grip 1
12 Handlebar upper holder 2
13 Handlebar 1
4-31
HANDLEBAR
Removing the handlebar

14 Handlebar lower holder 2
15 Damper 4
dure.
4-32
HANDLEBAR
REMOVING THE HANDLEBAR

EAS1SM1162
TIP
1. Stand the vehicle upright on a level surface. • Install the lower handlebar holders with them
EWA13120
WARNING side having the greater distance “a” from the

Securely support the vehicle so that there is mounting bolt center facing forward.
no danger of it falling over. • Installing the lower handlebar holders in the
reverse direction allow the front-to-rear offset
2. Remove: amount of the handlebar position to be
• Grip “1” changed.
TIP • The upper handlebar holders should be in-
Blow in compressed air between the handlebar stalled with the punch marks “b” facing for-
or tube guide and the grip. Then remove the ward.
grip which has become loose. • When installing the handlebar, make sure that
right and left marks “c” are in place identically
on both sides.
• Install the handlebar so that the projection “d”
of the upper handlebar holders is positioned
at the mark on the handlebar as shown.
ECA14250
NOTICE
• First, tighten the bolts on the front side of
the upper handlebar holder, and then on
the rear side.
• Turn the handlebar all the way to the left
CHECKING THE HANDLEBAR and right. If there is any contact with the
EAS1SM1163
1. Check: fuel tank, adjust the handlebar position.

• Handlebar
Bends/cracks/damage  Replace. 2
EWA13690
WARNING
Do not attempt to straighten a bent handle- 1
bar as this may dangerously weaken it.
INSTALLING THE HANDLEBAR

EAS1SM1164
1
EWA13120
WARNING
no danger of it falling over. a
2. Install:
• Damper “1”
• Lower handlebar holders “2” (temporarily)
• Handlebar “3”
• Upper handlebar holders “4”
Upper handlebar holder bolt
28 Nm (2.8 m·kgf, 20 ft·lbf)
T.
R.
4-33
HANDLEBAR
4. Install:
• Handlebar grip “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3 a. Slightly coat the handlebar left end with a
rubber adhesive.
4 b. Install the handlebar grip on the handlebar
by pressing the grip from the left side.
c. Wipe off any excess adhesive with a clean
cloth.
EWA13120
WARNING
Do not touch and move the handlebar grip
until its adhesive dries completely.
TIP
Install the handlebar grip to the handlebar so
that the line “a” between the two arrow marks
faces straight upward.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• Engine stop switch “1”
• Clutch lever “2”
• Clutch lever holder “3”
• Clamp “4”
Engine stop switch screw
0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
T.
Clutch lever holder bolt

R.
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
TIP
3. Tighten: • The engine stop switch, the clutch lever, and
• Lower handlebar holder nut the clutch lever holder should be installed ac-
Lower handlebar holder nut cording to the dimensions shown.
40 Nm (4.0 m·kgf, 29 ft·lbf) • Pass the engine stop switch lead through the
middle of the clutch lever holder.
T.
R.
4-34
HANDLEBAR
• Right grip “1” • Throttle cables “1”
• Collar “2” TIP
Apply adhesive to the tube guide “3”. Slightly coat the end of throttle cable and inside
TIP of throttle grip with lithium-soap-based grease.
• Before applying the adhesive, wipe off grease Then, mount the throttle grip onto the handle-
or oil on the tube guide surface “a” with a lac- bar.
quer thinner.
• Install the grip to the tube guide so that the
grip match mark “b” and tube guide slot “c”
form the angle as shown.
9. Install:
• Throttle cable housings “1”
• Screw (throttle cable housings) “2”
Screw (throttle cable housings)
3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
T.
R.
b EWA1DX5001
WARNING
After tightening the throttle cable housing
1
screws, check that the throttle grip “3”
moves smoothly. If it does not, retighten the
c screws for adjustment.
3
7. Install:
• Collar “1”
• Rubber cover “2”
• Throttle grip “3”
TIP
Apply the lithium soap base grease on the
throttle grip sliding surface.
4-35
HANDLEBAR
12.Install:
• Clutch cable “1”
TIP
Before installation, apply the lithium-soap-
based grease to the clutch cable end.
LS 1
10.Install:
• Rubber cover “1”
• Cover (throttle cable housings) “2”
13.Adjust:
• Clutch lever free play
Refer to “ADJUSTING THE CLUTCH LE-
VER FREE PLAY” on page 3-10.
Clutch lever free play
7.0–12.0 mm (0.28–0.47 in)
11.Install: 14.Adjust:
• Front brake master cylinder assembly “1” • Throttle grip free play
• Front brake master cylinder holder “2” Refer to “ADJUSTING THE THROTTLE
• Bolt (brake master cylinder holder) “3” GRIP FREE PLAY” on page 3-11.
Front brake master cylinder hold- Throttle grip free play
er bolt 3.0–5.0 mm (0.12–0.20 in)
T.
9 Nm (0.9 m·kgf, 6.5 ft·lbf)

R.
TIP
• Install the brake master cylinder holder with
the “UP” mark facing up.
• Install in order for the top of the front brake
master cylinder assembly to be level.
• First, tighten the upper bolt, then the lower
bolt.
4-36
FRONT FORK
FRONT FORK
EAS1SM1165
Removing the front fork legs
21 Nm (2.1 m kgf, 15 ft lbf)
T .R
.
4
9 Nm (0.9 m kgf, 6.5 ft lbf)

T .R
.
5 Nm (0.5 m kgf, 3.6 ft lbf)

T .R
.
5 Nm (0.5 m kgf, 3.6 ft lbf)

T .R
.

off the ground.
Front wheel Refer to “FRONT WHEEL” on page 4-3.
Front brake caliper Refer to “FRONT BRAKE” on page 4-11.
Number plate Refer to “GENERAL CHASSIS” on page 4-1.

1 Protector 1
2 Upper bracket pinch bolts 2 Loosen.
3 Damper assembly 1 Loosen.
4 Lower bracket pinch bolts 2 Loosen.
5 Front fork leg 1
dure.
4-37
FRONT FORK
Disassembling the front fork leg

30 Nm (3.0 m•kgf, 22 ft•Ibf)
T .R
.
29 Nm (2.9 m•kgf, 21 ft •Ibf)
T .R
.
New
7 13
New New
6
2
New 12
8
9
11 New
10
LT
4 New
1 New
28 Nm (2.8 m•kgf, 20 ft•Ibf)
T .R
LS
.
55 Nm (5.5 m•kgf, 40 ft •Ibf) 3 1.3 Nm (0.13 m•kgf, 0.94 ft•Ibf)

T .R
.
T.R
.

1 Adjuster 1
2 Fork spring 1
3 Dust seal 1
4 Stopper ring 1
5 Inner tube 1
6 Outer tube 1
7 Piston metal 1
8 Protector guide 1
9 Slide metal 1
10 Oil seal washer 1
11 Oil seals 1
12 Base valve 1
13 Damper assembly 1
cedure.
4-38
FRONT FORK
REMOVING THE FRONT FORK LEGS

EAS1SM1166
TIP
1. Use a suitable stand to raise the front wheel • While compressing the inner tube “2”, set the
off the ground. cap bolt ring wrench “4” between the inner
EWA13120
WARNING tube and locknut “3”.

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

90890-01501 • Dust seal “1”
YM-01501 • Oil seal clip “2”
(with a flat-head screwdriver)
ECA14180
2 NOTICE
1
Do not scratch the inner tube.
3. Remove: 2
• Front fork leg (s)
DISASSEMBLING THE FRONT FORK LEGS
EAS1SM1167
4. Remove:
1. Drain:
• Inner tube “1”
• Fork oil
2. Remove: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Adjuster “1” a. Push in slowly “a” the inner tube just before
(from the inner tube) it bottoms out and then pull it back quickly
“b”.
b. Repeat this step until the inner tube can be
pulled out from the outer tube.
4-39
FRONT FORK
EWA13650
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Remove:
• Base valve “1”
(from the damper assembly)
TIP 2. Check:
• Outer tube
Hold the damper assembly with the cap bolt
Scratches/wear/damage  Replace.
ring wrench “2” and use the cap bolt wrench “3”
3. Measure:
to remove the base valve.
• Fork spring free length “a”
Cap bolt wrench
90890-01500 Fork spring free length
YM-01500 497.0 mm (19.57 in)
Cap bolt ring wrench Limit
90890-01501 492.0 mm (19.37 in)
YM-01501
3
2
1
4. Check:
• Damper assembly “1”
CHECKING THE FRONT FORK LEGS
EAS1SM1168
Bend/damage  Replace.
1. Check:
• O-ring “2”
• Inner tube surface “a”
Wear/damage  Replace.
Scratches  Repair or replace. ECA1DX1010
Use #1000 grit wet sandpaper. NOTICE

Damaged oil lock piece  Replace. • The front fork leg has a built-in damper ad-
• Inner tube bends justing rod and a very sophisticated inter-
Out of specification  Replace. nal construction, which are particularly
Use the dial gauge “1”. sensitive to foreign material.
Inner tube bending limit • When disassembling and assembling the
0.2 mm (0.01 in) front fork leg, do not allow any foreign ma-
terial to enter the front fork.
TIP
The bending value is shown by one half of the
dial gauge reading.
4-40
FRONT FORK
1
1
2 2 New
5. Check:
ASSEMBLING THE FRONT FORK LEGS
EAS1SM1169
• Base valve “1” EWA13660
Wear/damage  Replace. WARNING

Contamination  Clean. • Make sure the oil levels in both front fork
• O-rings “2” New legs are equal.
Wear/damage  Replace. • Uneven oil levels can result in poor han-
• Base valve bushing “3” dling and a loss of stability.
• Spring “4” TIP
Damage/fatigue  Replace the base valve. • When assembling the front fork leg, be sure to
• Air bleed screw “5” replace the following parts:
Wear/damage  Replace. • Inner tube bushing
• Outer tube bushing
3
• Oil seals
• Copper washers
• Before assembling the front fork leg, make
sure that all of the components are clean.
New 2 1. Stretch the damper assembly fully.
4 2. Fill:
• Damper assembly
5
1 Recommended oil
New 2
6. Check: Suspension oil S1
• Contacting surface “a” Standard oil amount
Wear/damage  Replace. 196 cm3 (6.63 US oz, 6.91
Imp.oz)
a ECA14210
NOTICE
• Be sure to use the recommended oil. Other
oils may have an adverse effect on front
fork performance.
• When disassembling and assembling the
front fork leg, take care not to allow any
foreign material to enter the front fork.
3. After filling, pump the damper assembly “1”
7. Check: slowly up and down (about 200 mm (7.9 in)
• Adjuster “1” stroke) several times to bleed the damper
• O-rings “2” New assembly of air.
Wear/damage  Replace. TIP
Avoid excessive full stroke. A stroke of 200 mm
(7.9 in) or more will cause air to enter. In this
case, repeat the steps 1 to 3.
4-41
FRONT FORK
6. Loosen:
• Compression damping force adjuster “1”
TIP
• Before loosening the damping force adjuster,
record the setting position.
1 • Unless the damping force adjuster is fully
loosened, correct damping characteristic can-
not be obtained after installation.
4. Measure:
• Oil level (left and right) “a”
Out of specification  Regulate. 1
Standard oil level

145–148 mm (5.71–5.83 in)
From top of fully stretched
damper assembly.
7. Install:
a (to the damper assembly “2”)
TIP
First bring the damper rod pressure to a maxi-
mum. Then install the base valve while releas-
ing the damper rod pressure.
8. Check:
5. Tighten: • Damper assembly
• Locknut “1” Not fully stretched  Repeat the steps 1 to
TIP 7.
9. Tighten:
Fully finger tighten the locknut onto the damper
assembly.
Base valve
28 Nm (2.8 m·kgf, 20 ft·lbf)
T.
R.
TIP
Hold the damper assembly with the cap bolt
ring wrench “2” and use the cap bolt wrench “3”
to tighten the base valve.
4-42
FRONT FORK
Cap bolt wrench a

90890-01500
YM-01500
90890-01501
YM-01501
3
2
13.Check:
1 • Damper assembly smooth movement
Tightness/binding/rough spots  Repeat
the steps 1 to 12.
10.After filling, pump the damper assembly “1”

slowly up and down more than 10 times to
distribute the fork oil.
14.Install:
• Dust seal “1” New
1 • Oil seal clip “2”
• Washer “4”
• Outer tube bushing “5” New
11.While protecting the damper assembly “1” (to the inner tube “6”)
with a cloth and compressing fully, allow ex- ECA32D1010
cessive oil to overflow on the base valve NOTICE

side. Make sure that the numbered side of the oil
ECA32D1010
seal faces bottom side.

NOTICE
Take care not to damage the damper assem- TIP
bly. • Apply the lithium soap base grease on the
dust seal lip and oil seal lip.
• Apply the fork oil on the inner tube.
• When installing the oil seal, use vinyl seat “a”
with fork oil applied to protect the oil seal lip.
12.Allow the overflowing oil to escape at the

hole “a” in the damper assembly.
TIP LS
The overflow measures about 8 cm3 (0.27 US
oz, 0.28 lmp.oz).
4-43
FRONT FORK
15.Install:
• Inner tube bushing “1” New
TIP
Install the inner tube bushing onto the slot on
inner tube.
18.Install:
TIP
Using a fork seal driver “2”, press the oil seal in
until the stopper ring groove fully appears.
16.Install:
Fork seal driver
• Outer tube “1”
90890-01502
(to the inner tube “2”) YM-A0948
17.Install:
• Inner tube bushing “1” 19.Install:
• Washer “2” • Oil seal clip “1”
(to the outer tube) TIP
TIP Fit the oil seal clip correctly in the groove in the
Press the inner tube bushing into the outer tube outer tube.
with fork seal driver “3”.
Fork seal driver

90890-01502
YM-A0948
4-44
FRONT FORK
2
1 a
20.Install: 23.Install:
• Dust seal “1” New • Collar “1”
TIP • Fork spring “2”
Apply lithium-soap-based grease on the inner (to the damper assembly “3”)
tube. TIP
Install the collar with its larger dia. end “a” fac-
ing the fork spring.
1 2
3 a
21.Check:
• Inner tube smooth movement
Tightness/binding/rough spots  Repeat 24.Install:
the steps 14 to 20. • Damper assembly “1”
(to the inner tube “2”)
ECA32D1010
NOTICE
Allow the damper assembly to slide slowly
down the inner tube until it contacts the bot-
tom of the inner tube. Be careful not to dam-
age the inner tube.
22.Measure:
• Distance “a”
1
Out of specification  Turn into the locknut.
Distance “a”
16 mm (0.63 in) or more
Between the damper assembly 2
“1” bottom and locknut “2” bot-
tom.
4-45
FRONT FORK
25.Loosen:
• Rebound damping force adjuster “1” Gap “a” between the adjuster and
TIP
the locknut
0.5–1.0 mm (0.02–0.04 in)
• Before loosening the damping force adjuster,
record the setting position. TIP
• Unless the damping force adjuster is fully If it is installed with a gap out of specification,
loosened, correct damping characteristic can- correct damping force cannot be obtained.
not be obtained after installation.
1
1
28.Tighten:
26.Install: • Adjuster (locknut) “1”
• Damper adjusting rod “1”
• Copper washer “2” New Adjuster (locknut)
• Adjuster “3” 29 Nm (2.9 m·kgf, 21 ft·lbf)
T.
R.
(to the damper assembly “4”)

TIP
TIP
Hold the locknut “2” and tighten the adjuster.
• While compressing the inner tube “5”, set the
cap bolt ring wrench “7” between the inner
tube and locknut “6”.
• Fully finger tighten the adjuster onto the
damper assembly.

90890-01501
YM-01501
29.Install:
• Adjuster “1”
(to the inner tube)
Adjuster
55 Nm (5.5 m·kgf, 40 ft·lbf)
T.
LOCTITE®
R.
27.Measure:
• Gap “a” between the adjuster “1” and the 1
LT
locknut “2”
Out of specification  Retighten and read-
just the locknut.
4-46
FRONT FORK
30.Fill:
• Front fork leg
Recommended oil
Suspension oil S1
1
Standard oil amount
330 cm3 (11.16 US oz, 11.64
lmp.oz) (USA) (CAN)
355 cm3 (12.00 US oz, 12.52
lmp.oz) (EUR) (JPN) (AUS) (NZL)
(ZAF)
Extent of adjustment
300–365 cm3 (10.14–12.34 US INSTALLING THE FRONT FORK LEGS
EAS1SM1170
oz, 10.58–12.87 lmp.oz) 1. Install:

ECA14210
• Front fork “1”
NOTICE TIP
• Be sure to use the recommended oil. Other • Temporarily tighten the pinch bolts (lower
oils may have an adverse effect on front bracket).
fork performance. • Do not tighten the pinch bolts (upper bracket)
• When disassembling and assembling the yet.
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
2. Tighten:
31.Install:
Damper assembly
30 Nm (3.0 m·kgf, 22 ft·lbf)
(to the outer tube)
T.
R.
TIP TIP
Temporarily tighten the damper assembly. Use the cap bolt ring wrench “2” to tighten the
damper assembly.

90890-01501
YM-01501
32.Install:
• Protector guide “1” 2
4-47
FRONT FORK
3. Adjust:
• Front fork top end “a” 1
Front fork top end (standard) “a”
5 mm (0.20 in)
2
6. Adjust:
• Rebound damping force
TIP
Turn in the damping adjuster “1” finger-tight
and then turn out to the originally set position.
4. Tighten:
• Pinch bolt (upper bracket) “1”
Upper bracket pinch bolts
21 Nm (2.1 m·kgf, 15 ft·lbf)
1
T.
R.
• Pinch bolt (lower bracket) “2”

Lower bracket pinch bolts
21 Nm (2.1 m·kgf, 15 ft·lbf)
T.
R.
EWA33DD044
WARNING
7. Adjust:
Tighten the lower bracket to specified • Compression damping force
torque. If torqued too much, it may cause
TIP
the front fork to malfunction.
Turn in the damping adjuster “1” finger-tight
and then turn out to the originally set position.
1
2 1
5. Install:
• Protector “1”
• Bolt (protector) “2”
Bolt (protector)
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
T.
R.
4-48
STEERING HEAD
STEERING HEAD
EAS1SM1171
Removing the lower bracket

21 Nm (2.1 m kgf, 15 ft lbf)
T .R
.
145 Nm (14.5 m kgf, 105 ft lbf)
T .R
.
21 Nm (2.1 m kgf, 15 ft lbf) LS
T .R
2
.
LS 4
6
5
7
8
1
10
9 LS
1st 38 Nm (3.8 m kgf, 27 ft lbf)

2nd 7 Nm (0.7 m kgf, 5.1 ft lbf)
T .R
.
9 Nm (0.9 m kgf, 6.5 ft lbf)

T .R
.
10 Nm (1.0 m kgf, 7.2 ft lbf)

T .R
.

off the ground.
Number plate Refer to “GENERAL CHASSIS” on page 4-1.
Handlebar Refer to “HANDLEBAR” on page 4-31.
1 Front fender 1
2 Steering stem nut 1
3 Front fork leg (s) 2 Refer to “FRONT FORK” on page 4-37.
4 Upper bracket 1
5 Steering ring nut 1
6 Lower bracket 1
7 Bearing race cover 1
8 Upper bearing 1
9 Bearing (lower side) 1
10 Bearing races 2
dure.
4-49
STEERING HEAD
REMOVING THE LOWER BRACKET

EAS1SM1172
NOTICE
1. Use a suitable stand to raise the front wheel • Take care not to damage the steering shaft
off the ground. thread.
EWA13120
WARNING • If the bearing race is not installed properly,

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

90890-01403
YU-A9472
EWA13730
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Upper bracket
CHECKING THE STEERING HEAD
EAS1SM1173
• Lower bracket
1. Wash with kerosene: (along with the steering stem)
• Bearing Bends/cracks/damage  Replace.
• Bearing races
INSTALLING THE STEERING HEAD
EAS1SM1174
2. Check:
• Bearing 1. Install:
• Bearing races • Lower bearing “1”
Damage/pitting  Replace. TIP
3. Replace: Apply the lithium soap base grease on the dust
• Bearing seal lip and bearing inner circumference.
• Bearing races
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bearing race from the steering
head pipe with a long rod “1” and a hammer.
b. Remove the bearing race from the lower
bracket with a chisel “2” and a hammer.
c. Install a new bearing race.
ECA14270
4-50
STEERING HEAD
2. Install:
• Bearing races
• Upper bearing “1”
• Bearing race cover “2”
TIP
bearing and bearing race cover lip.
5. Check the steering stem by turning this lock

to lock. If there is any binding, remove the
steering stem and check the steering bear-
ing.
3. Install:
• Lower bracket “1”
TIP
bearing, the portion “a” and thread of the steer-
ing stem.
6. Install:
• Washer “1”
LS
a
LS
4. Install:
• Steering ring nut “1”
7. Install:
Steering ring nut • Front fork “1”
7 Nm (0.7 m·kgf, 5.1 ft·lbf) • Upper bracket “2”
T.
R.
TIP
TIP • Temporarily tighten the pinch bolts (lower
Install the steering nut with its stepped side “a” bracket).
facing downward. • Do not tighten the pinch bolts (upper bracket)
Tighten the steering ring nut with a steering yet.
nut wrench “2”.
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-33.
4-51
STEERING HEAD
11.Tighten:
• Pinch bolt (upper bracket) “1”
Upper bracket pinch bolts
21 Nm (2.1 m·kgf, 15 ft·lbf)
T.
R.
• Pinch bolt (lower bracket) “2”
Lower bracket pinch bolts
21 Nm (2.1 m·kgf, 15 ft·lbf)
T.
R.
EWA33DD049
8. Install: WARNING
• Steering stem nut “1” Tighten the lower bracket to specified
Steering stem nut torque. If torqued too much, it may cause
145 Nm (14.5 m·kgf, 105 ft·lbf) the front fork to malfunction.
T.
R.
TIP 1
Apply the lithium soap base grease to the con-
tact surface of the steering stem nut when in-
stalling.
2
9. After tightening the nut, check the steering

for smooth movement. If not, adjust the
steering by loosening the steering ring nut
little by little.
10.Adjust:
• Front fork top end “a”
Front fork top end (standard) “a”
5 mm (0.20 in)
4-52
REAR SHOCK ABSORBER ASSEMBLY

EAS1SM1175
Removing the rear shock absorber assembly

2 M
3
12 13 New
14
16 15 New
LS
14 13 New
M 12
LS
9 6
4 10
11
5 10
9
M 1

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

Air scoop (left / right) Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
1 Rear shock absorber assembly lower bolt 1
2 Rear shock absorber assembly upper bolt 1
3 Rear shock absorber assembly (-ies) 1
4 Locknut 1
5 Adjusting nut 1
6 Lower spring guide 1
7 Upper spring guide 1
4-53
Removing the rear shock absorber assembly

2 M
3
12 13 New
14
16 15 New
LS
14 13 New
M 12
LS
9 6
4 10
11
5 10
9
M 1

8 Spring 1
9 Dust seal 2
10 Collars 2
11 Bushing 1
12 Collars 2
13 O-ring 2
14 Dust seal 2
15 Stopper ring 1
16 Bearing 1
dure.
4-54
Disassembling the relay arm
4
5
4 5
6
1
5 6 4
5
80 Nm (8.0 m kgf, 58 ft lbf) 5 5 3

T .R
.
6
3
6 6
4 5
4 2
4 3

1 Relay arm 1
2 Connecting arm 1
3 Collars 3
4 Oil seals 6
5 Washers 8
6 Bearing 6
cedure.
4-55
HANDLING THE REAR SHOCK ABSORBER

EAS1SM1176 EWA13120
EWA13740
WARNING
WARNING Securely support the vehicle so that there is
This rear shock absorber contains highly no danger of it falling over.
compressed nitrogen gas. Before handling 2. Remove:
the rear shock absorber, read and make • Rear shock absorber assembly lower bolt
sure that you understand the following in- “1”
formation. The manufacturer cannot be held TIP
responsible for property damage or person-
While removing the rear shock absorber as-
al injury that may result from improper han-
sembly lower bolt, hold the swingarm so that it
dling of the rear shock absorber.
does not drop down.
• Do not tamper or attempt to open the rear
shock absorber.
• Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion
due to excessive gas pressure.
• Do not deform or damage the rear shock
absorber in any way. Rear shock absorber
damage will result in poor damping perfor-
mance.
TIP
A break-in is required up to about 50 km of run-
ning.
DISPOSING OF A REAR SHOCK ABSORB-

EAS1SM1177
ER
Before disposing the rear shock absorber, be
sure to extract the nitrogen gas from valve “1”.
EWA33DD052
WARNING
• Wear protective glasses to prevent your 1
eyes from damage due to possible gas or
metal chips scattered. 3. Remove:
• To dispose of a damaged or a worn-out • Rear shock absorber assembly upper bolt
rear shock absorber, take the unit to your • Rear shock absorber assembly (-ies)
Yamaha dealer for this disposal proce- REMOVING THE BEARING
EAS1SM1179
dure. 1. Remove:
• Stopper ring (upper bearing) “1”
TIP
Press in the bearing while pressing its outer
race and remove the stopper ring.
REMOVING THE REAR SHOCK ABSORBER

EAS1SM1178
ASSEMBLY
1. Use a suitable stand to raise the rear wheel
off the ground.
4-56
2. Remove: CHECKING THE CONNECTING ARM AND

• Upper bearing “1” RELAY ARM
TIP 1. Check:
Remove the bearing by pressing its outer race. • Connecting arm
• Relay arm
2. Check:
• Bearing
• Spacers
Damage/pitting/scratches  Replace the
bearings and spacers as a set.
3. Check:
• Oil seals
Damage/pitting  Replace.
INSTALLING THE RELAY ARM
EAS1SM1182
3. Remove:
• Lower bearing “1” 1. Lubricate:
TIP
• Oil seals
• Bearing
Remove the bearing by pressing its outer race. • Spacers
• Washers
• Collars
2. Install:
• Bearing “1”
• Washer “2”
1 • Oil seals “3” New
(to relay arm “4”)
CHECKING THE REAR SHOCK ABSORBER
EAS1SM1180
Installed depth “a”

ASSEMBLY 0 mm (0 in)
1. Check:
• Rear shock absorber rod
Bends/damage  Replace the rear shock 3 3
a
absorber assembly. 2 4
• Rear shock absorber
2
Gas leaks/oil leaks  Replace the rear 1
shock absorber assembly. 1 1
• Spring 2
Damage/wear  Replace. 2
• Spring guide 3
• Bearing 3. Install:
Damage/wear  Replace. • Bearing “1”
• Bolts • Oil seals “2” New
Bends/damage/wear  Replace. (to connecting arm “3”)
EAS1SM1181
0 mm (0 in)
4-57
TIP
2 3
Install the dust seals with their lips facing in-
1 ward.
a
4.25 mm (0.17 in)
a
1
2
INSTALLING THE REAR SHOCK ABSORB-
EAS1SM1183
ER ASSEMBLY
1. Lubricate:
• Bearing (lower side)
• Dust seal
• Collars
• Bushing
5. Lubricate:
Recommended lubricant • Connecting arm and frame bolt
Lithium-soap-based grease • Relay arm and connecting arm bolt
ECA1DX1012
• Relay arm and swingarm bolt
NOTICE (circumference and threaded portion)
Do not apply the grease to the bearing outer • Rear shock absorber assembly upper bolt
race because it will wear the rear shock ab- • Rear shock absorber assembly lower bolt
sorber surface on which the bearing is Recommended lubricant
press fitted. Lithium-soap-based grease
2. Lubricate:
• O-ring 6. Install:
• Rear shock absorber assembly
Recommended lubricant TIP
• When installing the rear shock absorber as-
3. Install: sembly, lift up the swingarm.
• Bearing • Install the rear shock absorber assembly up-
• Stopper ring New per bolt, and connecting arm bolt (frame side)
(to rear shock absorber assembly (upper from the right.
side)) • Install the rear shock absorber assembly low-
er bolts, connecting arm bolt (relay arm side),
TIP
and relay arm bolt (swingarm side) from the
• Install the bearing parallel until the stopper left.
ring groove appears by pressing its outer
race. 7. Tighten:
• After installing the stopper ring, push back the • Rear shock absorber assembly upper bolt
bearing unit it contacts the stopper ring. Rear shock absorber assembly
4. Install: upper bolt
T.
56 Nm (5.6 m·kgf, 41 ft·lbf)

R.
• Bearing “1”
• Bushing “2” • Connecting arm bolt (frame side)
• Collar “3”
• Dust seal “4” Connecting arm bolt (frame side)
(to rear shock absorber assembly (lower 80 Nm (8.0 m·kgf, 58 ft·lbf)
T.
R.
side))
4-58
• Connecting arm bolt (relay arm side)

Connecting arm bolt (relay arm
side)
T.
80 Nm (8.0 m·kgf, 58 ft·lbf)

R.
• Relay arm bolt (swingarm side)

Relay arm bolt (swingarm side)
70 Nm (7.0 m·kgf, 51 ft·lbf)
T.
R.
• Rear shock absorber assembly lower bolt

lower bolt
T.
53 Nm (5.3 m·kgf, 38 ft·lbf)

R.
4-59
SWINGARM
SWINGARM
EAS1SM1184
Removing the swingarm
70 Nm (7.0 m kgf, 51 ft lbf)

T .R
.
2
1 3
6
4.0 Nm (0.40 m kgf, 2.9 ft lbf)
T.R
.
6 6
4 3
2
4

off the ground.
Brake hose holder Refer to “REAR BRAKE” on page 4-21.
Rear brake caliper Refer to “REAR BRAKE” on page 4-21.
Bolt (brake pedal)
Drive chain
1 Collars 2
2 Oil seals 2
3 Thrust bearing 2
4 Bushing 2
5 Oil seals 2
6 Bearing 4

dure.
4-60
SWINGARM
REMOVING THE SWINGARM

EAS1SM1185

off the ground.
EWA13120
WARNING
2. Measure:
• Swingarm side play
• Swingarm vertical movement
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING THE SWINGARM
EAS1SM1187
a. Measure the tightening torque of the pivot

1. Check:
shaft nut.
• Swingarm
Pivot shaft nut Bends/cracks/damage  Replace.
85 Nm (8.5 m·kgf, 61 ft·lbf) 2. Check:
T.
R.
• Pivot shaft
b. Measure the swingarm side play “a” by mov- Roll the pivot shaft on a flat surface.
ing the swingarm from side to side. Bends  Replace.
c. If the swingarm side play is out of specifica- EWA13770
tion, check the spacers, the bearings, and WARNING

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

• Pivot shaft
• Spacers
• Collars
• Bearing
4. Check:
• Oil seals
Damage  Replace.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Bearing
• Spacers
REMOVING THE BEARING
EAS1SM1186
Free play exists/unsmooth revolution/rust 

1. Remove: Replace bearing and bushing as a set.
• Bearing “1” EAS1SM1188
TIP
Remove the bearing by pressing its outer race.
4-61
SWINGARM
INSTALLING THE SWINGARM

1. Lubricate:
• Bearing
• Collars
• Spacers
• Oil seal New
• Pivot shaft
Molybdenum disulfide grease
2. Install:
• Bearing “1”
(to the swingarm)
0–0.5 mm (0–0.02 in)
Installed depth “b”
6.5 mm (0.26 in)
TIP
First install the outer and then the inner bear-
ings to a specified depth from inside.
a a a a
2 New 2 New 2 New
1 1
b b
3. Install:
• Swingarm
Pivot shaft nut
85 Nm (8.5 m·kgf, 61 ft·lbf)
T.
R.
TIP
Install the pivot shaft from the right.
4. Install:
• Rear wheel
5. Adjust:
• Drive chain slack
Drive chain slack
50–60 mm (1.97–2.36 in)
4-62
CHAIN DRIVE
CHAIN DRIVE
EAS1SM1189
Removing the drive chain
75 Nm (7.5 m kgf, 54 ft lbf)

T .R
.
7 Nm (0.7 m kgf, 5.1 ft lbf)

T .R
.
Job Order Part name Q’ty Servicing Information

Drive sprocket Refer to “ENGINE REMOVAL” on page 5-1.
1 Drive chain 1
dure.
4-63
CHAIN DRIVE
REMOVING THE DRIVE CHAIN

EAS1SM1190

off the ground.
EWA13120
WARNING
2. Remove:
• Joint clip
• Drive chain joint “1”
• Drive chain “2” TIP
• When measuring a 15-link section of the drive
chain, make sure that the drive chain is taut.
• Perform this procedure 2–3 times, at a differ-
ent location each time.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Drive chain
Stiffness  Clean, lubricate, or replace.
CHECKING THE DRIVE CHAIN

EAS1SM1191
1. Measure:
• 15-link section “a” of the drive chain
Out of specification  Replace the drive
chain.
15-link length limit
242.9 mm (9.56 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 3. Clean:
a. Measure the length “a” between the inner • Drive chain
sides of the pins and the length “b” between ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
the outer sides of the pins on a 15-link sec- a. Wipe the drive chain with a clean cloth.
tion of the drive chain as shown in the illus- b. Put the drive chain in kerosene and remove
tration. any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
b. Calculate the length “c” of the 15-link section

of the drive chain using the following formu-
la. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Drive chain 15-link section length “c” =
(length “a” between pin inner sides + length
“b” between pin outer sides)/2
4-64
CHAIN DRIVE
4. Check:
• Drive chain rollers “1”
Damage/wear  Replace the drive chain.
• Drive chain side plates “2”
Damage/wear  Replace the drive chain.
2. Lubricate:
• Drive chain
3. Install:
• Drive sprocket
• Lock washer New
5. Lubricate: • Drive sprocket nut
• Drive chain Refer to “ENGINE REMOVAL” on page 5-1.
CHECKING THE DRIVE SPROCKET Drive sprocket nut
EAS1SM1192
1. Check: T.
75 Nm (7.5 m·kgf, 54 ft·lbf)
R.
• Drive sprocket ECA1DX1014
More than 1/4 tooth wear “a”  Replace the NOTICE

drive sprocket and the rear wheel sprocket Never install a new drive chain onto worn
as a set. drive sprockets; this will dramatically short-
Bent tooth  Replace the drive sprocket en the drive chain’s life.
and the rear wheel sprocket as a set.
4. Adjust:
• Drive chain slack
Drive chain slack
50–60 mm (1.97–2.36 in)
ECA13550
NOTICE
A drive chain that is too tight will overload
the engine and other vital parts, and one
b. Correct
that is too loose can skip and damage the
1. Drive chain roller swingarm or cause an accident. Therefore,
2. Drive sprocket keep the drive chain slack within the speci-
CHECKING THE REAR WHEEL SPROCKET
EAS1SM1193
fied limits.
Refer to “CHECKING AND REPLACING THE
REAR WHEEL SPROCKET” on page 4-8.
INSTALLING THE DRIVE CHAIN
EAS1SM1194
1. Install:
• Drive chain “1”
• Drive chain joint “2”
• Joint clip “3” New
EWA
WARNING
When installing the joint clip, always keep
the direction as shown in the figure.
4-65
CHAIN DRIVE
4-66
ENGINE
ENGINE REMOVAL .........................................................................................5-1

REMOVING THE SILENCER.....................................................................5-6
REMOVING THE EXHAUST PIPE 2..........................................................5-6
REMOVING THE DRIVE SPROCKET .......................................................5-6
REMOVING THE ENGINE .........................................................................5-7
CHECKING THE SILENCER AND EXHAUST PIPE..................................5-7
CHANGING THE SILENCER FIBER .........................................................5-7
INSTALLING THE ENGINE........................................................................5-8
INSTALLING THE BRAKE PEDAL ............................................................5-9
INSTALLING THE DRIVE SPROCKET......................................................5-9
INSTALLING THE EXHAUST PIPE AND MUFFLER...............................5-10
CAMSHAFT ....................................................................................................5-11
REMOVING THE CAMSHAFT .................................................................5-13
CHECKING THE CAMSHAFT..................................................................5-14
CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET ..........5-15
CHECKING THE TIMING CHAIN TENSIONERS ....................................5-15
CHECKING THE DECOMPRESSION SYSTEM......................................5-16
INSTALLING THE CAMSHAFTS .............................................................5-16
CYLINDER HEAD...........................................................................................5-18
REMOVING THE CYLINDER HEAD........................................................5-20
CHECKING THE TIMING CHAIN GUIDE (INTAKE SIDE) ......................5-20
5
CHECKING THE CYLINDER HEAD ........................................................5-20
INSTALLING THE CYLINDER HEAD ......................................................5-21
VALVES AND VALVE SPRINGS...................................................................5-22

REMOVING THE VALVES.......................................................................5-23
CHECKING THE VALVES AND VALVE GUIDES ...................................5-24
CHECKING THE VALVE SEATS .............................................................5-25
CHECKING THE VALVE SPRINGS.........................................................5-27
CHECKING THE VALVE LIFTERS ..........................................................5-27
INSTALLING THE VALVES .....................................................................5-28
CYLINDER AND PISTON...............................................................................5-30

REMOVING THE PISTON .......................................................................5-31
CHECKING THE CYLINDER AND PISTON ............................................5-31
CHECKING THE PISTON RINGS............................................................5-32
CHECKING THE PISTON PIN .................................................................5-33
INSTALLING THE PISTON AND CYLINDER ..........................................5-33
CLUTCH .........................................................................................................5-35
REMOVING THE CLUTCH ......................................................................5-38
CHECKING THE FRICTION PLATES......................................................5-38
CHECKING THE CLUTCH PLATES ........................................................5-38
CHECKING THE CLUTCH SPRINGS......................................................5-38
CHECKING THE CLUTCH HOUSING .....................................................5-39
CHECKING THE CLUTCH BOSS............................................................5-39
CHECKING THE PRESSURE PLATE .....................................................5-39
CHECKING THE PUSH LEVER SHAFT..................................................5-39
CHECKING THE CLUTCH PUSH RODS ................................................5-39
CHECKING THE PRIMARY DRIVE GEAR..............................................5-39
CHECKING THE PRIMARY DRIVEN GEAR ...........................................5-40
INSTALLING THE OIL SEAL ...................................................................5-40
INSTALLING THE RIGHT CRANKCASE COVER ...................................5-40
INSTALLING THE CLUTCH.....................................................................5-41
INSTALLING THE KICKSTARTER LEVER .............................................5-43
KICKSTATER .................................................................................................5-44
REMOVING THE KICK SHAFT ASSEMBLY ...........................................5-45
CHECKING THE KICK SHAFT AND RATCHET WHEEL........................5-45
CHECKING THE KICK GEAR, KICK IDLE GEAR,
AND RATCHET WHEEL .........................................................................5-47
INSTALLING THE KICK SHAFT ASSEMBLY..........................................5-45
INSTALLING THE KICK IDLE GEAR.......................................................5-46
SHIFT SHAFT.................................................................................................5-47
REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY.........5-49
REMOVING THE SEGMENT ...................................................................5-49
CHECKING THE SHIFT SHAFT ..............................................................5-49
CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY .........5-49
CHECKING THE STOPPER LEVER .......................................................5-49
INSTALLING THE STOPPER LEVER .....................................................5-50
INSTALLING THE SEGMENT..................................................................5-50
INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY .......5-50
INSTALLING THE SHIFT SHAFT ............................................................5-51
INSTALLING THE SHIFT PEDAL ............................................................5-51
OIL PUMP AND BALANCER GEAR .............................................................5-52

REMOVING THE BALANCER .................................................................5-54
CHECKING THE PRIMARY DRIVE GEAR, BALANCER SHAFT
DRIVE GEAR, AND BALANCER WEIGHT GEAR ..................................5-56
CHECKING THE BALANCER ..................................................................5-54
CHECKING THE OIL PUMP ....................................................................5-54
ASSEMBLING THE OIL PUMP................................................................5-55
INSTALLING THE OIL PUMP AND BALANCER GEAR ..........................5-55
AC MAGNETO................................................................................................5-58
REMOVING THE AC MAGNETO.............................................................5-59
CHECKING THE AC MAGNETO .............................................................5-59
CHECKING THE WOODRUFF KEY ........................................................5-59
INSTALLING THE AC MAGNETO ...........................................................5-59
CRANKCASE .................................................................................................5-61
DISASSEMBLING THE CRANKCASE.....................................................5-64
REMOVING THE CRANKCASE BEARING .............................................5-64
CHECKING THE TIMING CHAIN, TIMING CHAIN GUIDE,
OIL STRAINER........................................................................................5-66
CHECKING THE CRANKCASE ...............................................................5-64
INSTALLING THE OIL SEAL ...................................................................5-65
ASSEMBLING THE CRANKCASE...........................................................5-65
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT ...............................5-66

REMOVING THE CRANKSHAFT ASSEMBLY ........................................5-67
CHECKING THE CRANKSHAFT ASSEMBLY.........................................5-67
INSTALLING THE CRANKSHAFT ASSEMBLY.......................................5-68
INSTALLING THE BALANCER SHAFT ...................................................5-68
TRANSMISSION.............................................................................................5-69
REMOVING THE TRANSMISSION .........................................................5-70
CHECKING THE SHIFT FORKS..............................................................5-70
CHECKING THE SHIFT DRUM ASSEMBLY...........................................5-71
CHECKING THE TRANSMISSION ..........................................................5-71
INSTALLING THE TRANSMISSION ........................................................5-71
ENGINE REMOVAL
EAS1SM1195
TIP
mechanical damage.
ENGINE REMOVAL
EAS1SM1196
Removing the exhaust pipe
1st 13 Nm (1.3 m•kg , 9.4 ft •lbf)

T .R
2nd 20 Nm (2.0 m•kgf, 14 ft •lbf)

.
10 10 Nm (1.0 m•kgf, 7.2 ft •Ibf)

T .R
.
(8)
LT
9
LT 6 New
(6)
New 6
8 Nm (0.8 m•kgf, 5.8 ft •Ibf)
T .R
.
30 Nm (3.0 m•kgf, 22 ft •Ibf)

T .R
2
.
3
30 Nm (3.0 m•kgf, 22 ft •Ibf) 20 Nm (2.0 m•kgf, 14 ft •Ibf)
T .R
T .R
.
1
12 Nm (1.2 m•kgf, 8.7 ft •Ibf) New 6 12 Nm (1.2 m•kgf, 8.7 ft •Ibf)
T .R
.
T .R
.
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)

4
T .R
.
LT 8

Side cover (right) Refer to “GENERAL CHASSIS” on page 4-1.
Rear shock absorber assembly lower bolt SEMBLY” on page 4-53.
Connecting arm bolt (frame side) SEMBLY” on page 4-53.
1 Silencer clamp 1 Loosen.
2 Silencer 1
3 Exhaust pipe 2 clamp 1 Loosen.
4 Exhaust pipe 2 1
5 Exhaust pipe 1 1
6 Gaskets 3
5-1
ENGINE REMOVAL
Removing the exhaust pipe
1st 13 Nm (1.3 m•kg , 9.4 ft •lbf)
T .R
2nd 20 Nm (2.0 m•kgf, 14 ft •lbf)
.
10 10 Nm (1.0 m•kgf, 7.2 ft •Ibf)
T .R
.
(8)
LT
9
LT 6 New
(6)
New 6
8 Nm (0.8 m•kgf, 5.8 ft •Ibf)
T .R
.
30 Nm (3.0 m•kgf, 22 ft •Ibf)

T .R
2
.
3
30 Nm (3.0 m•kgf, 22 ft •Ibf) 20 Nm (2.0 m•kgf, 14 ft •Ibf)
T .R
T .R
.
.
1
12 Nm (1.2 m•kgf, 8.7 ft •Ibf) New 6 12 Nm (1.2 m•kgf, 8.7 ft •Ibf)
T .R
.
T .R
.
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)

4
T .R
.
LT 8

7 Exhaust pipe 1 protector 1
8 Exhaust pipe 2 protector 1
9 Silencer body 1
10 Silencer cap 1
dure.
5-2
ENGINE REMOVAL
Removing the electronic parts
T .R
.
T.R
.
4
8
7
6
New
5
1
LS
LT
T.R
T .R
.
.

off the ground.
Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1.
Air filter case cover
1 Rectifier/regulator 1
2 ECU 1
3 Ignition coil 1
4 Condenser 1
5 Neutral switch 1
6 AC magneto lead 1 Disconnect.
7 Crankshaft position sensor coupler 1 Disconnect.
8 Coolant temperature sensor coupler 1 Disconnect.
dure.
5-3
ENGINE REMOVAL
Removing the engine
M
12
1 8
New
LS
3
New
9
2 8
10
11
7
New
55 Nm (5.5 m•kgf, 40 ft•Ibf) 6 5
T .R
.
13

off the ground.
Exhaust pipe and silencer Refer to “ENGINE REMOVAL” on page 5-1.
Air filter case Refer to “THROTTLE BODY” on page 7-5.
Throttle body Refer to “THROTTLE BODY” on page 7-5.
Clutch cable Refer to “CLUTCH” on page 5-35.
Shift pedal Refer to “SHIFT SHAFT” on page 5-47.
1 Engine guard 1
2 Brake pedal 1
3 Spring 1
4 Cylinder head breather hose 1
5 Drive sprocket cover 1
5-4
ENGINE REMOVAL
Removing the engine
M
12
1 8
New
LS
3
New
9
2 8
10
11
7
New
55 Nm (5.5 m•kgf, 40 ft•Ibf) 6 5
T .R
.
13

6 Drive chain guide 1
7 Drive sprocket 1
8 Upper engine bracket 2

9 Washer 1 Thickness:2.3 mm (0.09 in)
10 Washer 1 Thickness:1.0 mm (0.04 in)
11 Lower engine bracket 2
12 Pivot shaft 1
13 Engine 1
dure.
5-5
ENGINE REMOVAL
REMOVING THE SILENCER

EAS1SM1197
1. Remove:
• Rear shock absorber assembly lower bolt
“1”
• Connecting arm bolt (frame side) “2”
• Silencer “3”
TIP
Move the rear shock absorber to the left side of
the chassis, and remove the silencer.
REMOVING THE DRIVE SPROCKET

EAS1SM1199
1. Straighten the lock washer tab.

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

EAS1SM1198
1. Remove:
• Exhaust pipe 2
TIP
EAS1SM1200
Put the Exhaust pipe 2 into the state as shown

by moving this, and then remove it.
5-6
ENGINE REMOVAL
REMOVING THE ENGINE

1. Remove:
• Pivot shaft “1”
TIP 1
If the pivot shaft is pulled all the way out, the
swingarm will come loose. If possible, insert a
shaft of similar diameter into the other side of
the swingarm to support it.
1
CHANGING THE SILENCER FIBER
EAS1SM1202
1. Remove:
• Bolt “1”
• Silencer body “2”
ECA33DD026
NOTICE
Do not hit the silencer stay “a” as it may do
damage to the silencer.
TIP
2. Remove:
• Engine “1” Remove the inner pipe while holding the silenc-
From the right side. er in place with a vise etc.
TIP
a
• Make sure that the couplers, the hoses, and
the cables are disconnected.
• Lift up the engine, and remove this from its 1
lower part toward the right of the chassis.
2. Remove:
CHECKING THE SILENCER AND EXHAUST
EAS1SM1201
• Rivet “1”
PIPE
• Silencer cap “2”
1. Check:
• Gasket “1”
Damage  Replace.
5-7
ENGINE REMOVAL
3. Replace: TIP
• Fiber “1” • Apply heat-resistant sealant to the areas “a”
shown, making sure that there are no gaps in
the beads of sealant.
• Take care not to allow the fiber out of place
when installing the silencer body “3”.
3 1 2 3
a
1
4. Install:
• Silencer body “1” 1
• Bolt “2”
Silencer body bolt
8 Nm (0.8 m·kgf, 5.8 ft·lbf)
INSTALLING THE ENGINE
EAS1SM1203
T.
LOCTITE®
R.
1. Install:
TIP • Engine “1”
Install the engine from the right side.
Apply heat-resistant sealant to the areas “a”
• Pivot shaft “2”
shown, making sure that there are no gaps in
the beads of sealant. Pivot shaft
85 Nm (8.5 m·kgf, 61 ft·lbf)
T.
R.
2
a • Engine mounting bolt (lower side) “3”
LT
Engine mounting bolt (lower side)
53 Nm (5.3 m·kgf, 38 ft·lbf)
T.
R.
• Front engine bracket “4”

1 • Engine bracket bolt (front side) “5”
Engine bracket bolt (front side)
34 Nm (3.4 m·kgf, 25 ft·lbf)
T.
5. Replace:
R.
• Fiber “1” • Engine mounting bolt (front side) “6”

TIP Engine mounting bolt (front side)
Stuff the fiber into the silencer body by using a 55 Nm (5.5 m·kgf, 40 ft·lbf)
T.
flat board “2”.

R.
• Upper engine bracket “7”

• Engine bracket bolt (upper side) “8”
Engine bracket bolt (upper side)
34 Nm (3.4 m·kgf, 25 ft·lbf)
T.
R.
• Engine mounting bolt (upper side) “9”

2 Engine mounting bolt (upper
1 side)
T.
45 Nm (4.5 m·kgf, 33 ft·lbf)

R.
6. Install: TIP
• Silencer cap “1” Apply molybdenum disulfide grease to the pivot
• Rivet “2” shaft.
5-8
ENGINE REMOVAL
M
8
2
8
7
9
7 3 2. Install:
• Lock washer “1” New
5 9 • Nut (drive sprocket) “2”
4
Nut (drive sprocket)
75 Nm (7.5 m·kgf, 54 ft·lbf)
T.
R.
1 TIP
Tighten the nut while applying the rear brake.
4 6
ECA33DD040
5 NOTICE
INSTALLING THE BRAKE PEDAL

EAS1SM1204
Make sure to tighten to specification; other-
1. Install: wise, it may damage the other part that is
• Spring “1” fastened together.
• Brake pedal “2”
• O-rings “3” New
• Bolt (brake pedal) “4”
Bolt (brake pedal)
26 Nm (2.6 m·kgf, 19 ft·lbf)
T.
R.
• Clip “5”
TIP
Apply the lithium soap base grease on the bolt,
O-rings and brake pedal bracket. 3. Bend the lock washer tab to lock the nut.
4. Install:
2 • Drive sprocket guide
1 5
• Drive sprocket cover “1”
• Bolt (drive sprocket cover) “2”
3 Bolt (drive sprocket cover)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.
4 LS
1
INSTALLING THE DRIVE SPROCKET
EAS1SM1205
1. Install: 2
• Drive sprocket “1”
TIP
Install the drive sprocket together with the drive
chain.
5-9
ENGINE REMOVAL
INSTALLING THE EXHAUST PIPE AND 3. Install:

EAS1SM1206
MUFFLER • Clamp
1. Install: • Silencer “1”
• Gasket New • Bolt (silencer) “2”
• Exhaust pipe 1 “1” Bolt (silencer)
• Nut (exhaust pipe 1) “2” 30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.
Nut (exhaust pipe)
20 Nm (2.0 m·kgf, 14 ft·lbf) 2
T.
R.
TIP
First temporarily tighten nuts to 13 Nm (1.3
m·kgf, 9.4 ft·lbf). Then retighten them to 20 Nm
(2.0 m·kgf, 14 ft·lbf).
1 2
2
1 TIP
2 Install and temporarily tighten the silencer so
that its joint is positioned as shown with respect
to the exhaust pipe 2.
2mm (0.08in)
2. Install:
• Clamp
• Exhaust pipe 2 “1”
• Bolt (exhaust pipe 2) “2”
1 4. Tighten:
2 • Bolt (exhaust pipe 2)
Bolt (exhaust pipe 2)
20 Nm (2.0 m·kgf, 14 ft·lbf)
T.
R.
• Clamp
TIP
Clamp
Install and temporarily tighten the exhaust pipe 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
2 with its end positioned as shown with respect
T.
R.
to the exhaust pipe 1. TIP

2mm (0.08in) Tighten while checking that their front and rear
joints are inserted in position.
5-10
CAMSHAFT
CAMSHAFT
EAS1SM1207
Removing the cylinder head cover
13 Nm (1.3 m•kgf, 9.4 ft •Ibf)

1
T .R
.
3
7
3 6
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)

T .R
.

1 Spark plug 1
2 Cylinder head breather hose 1

3 Bolt (cylinder head cover) 3
4 Cylinder head cover 1
5 Cylinder head cover gasket 1
6 Timing chain guide (top side) 1
7 Cylinder head cover gasket 1

dure.
5-11
CAMSHAFT
Removing the camshaft

(4)
T .R
T .R
.
.
5
(4)
6 E
8
5
6 6 Nm (0.6 m•kgf, 4.3 ft •Ibf)
T .R
.
M
New
7 4
New
M
3
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)
T .R
.
E
6 Nm (0.6 m•kgf, 4.3 ft •Ibf)
T .R
. 1 E
New
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)
T .R
.

1 Timing mark accessing screw 1
2 Crankshaft end accessing screw 1
3 Timing chain tensioner cap bolt 1
4 Timing chain tensioner 1
5 Gasket 1
6 Camshaft cap bolt 8
7 Camshaft cap 2
8 Clip 2
9 Exhaust camshaft 1
10 Intake camshaft 1
dure.
5-12
CAMSHAFT
REMOVING THE CAMSHAFT

EAS1SM1208
1. Remove:
• Timing mark accessing screw “1” 2
• Crankshaft end accessing screw “2”
4. Remove:
• Bolt (camshaft cap) “1”
• Camshaft cap “2”
1 2
• Clip “3”
2. Align: TIP
• Alignment mark • Remove the bolts (camshaft cap) in a criss-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ cross pattern, working from the outside in.
a. Turn the crankshaft counterclockwise with a • In order to prevent the clip from falling into the
wrench. crankcase, remove the camshaft cap.
b. Align the top dead center (TDC) mark “a” on ECA33DD027
the rotor with the alignment mark “b” on the NOTICE

crankcase cover. The bolts (camshaft cap) must be removed
TIP evenly to prevent damage to the cylinder
Align the alignment mark “c” on the exhaust head, camshafts or camshaft caps.
camshaft sprocket and the alignment mark “d”
on the intake camshaft sprocket with the edge 1
of the cylinder head.
d c
5. Remove:
• Exhaust camshaft “1”
• Intake camshaft “2”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ TIP
3. Remove: Attach a wire “3” to the timing chain to prevent
• Timing chain tensioner cap bolt “1” it from falling into the crankcase.
• Timing chain tensioner “2”
• Gaskets
5-13
CAMSHAFT
2 1
3
3. Measure:
CHECKING THE CAMSHAFT
EAS1SM1209
• Camshaft runout
1. Check:
• Camshaft lobes
Blue discoloration/pitting/scratches  Re- Camshaft runout limit
place the camshaft. 0.030 mm (0.0012 in)
2. Measure:
• Camshaft lobe dimensions “A” and “B”
Out of specification  Replace the cam-
shaft.
Camshaft lobe dimensions
Intake A
31.730–31.830 mm (1.2492–
1.2531 in)
Limit
31.630 mm (1.2453 in)
Intake B
22.450–22.550 mm (0.8839– 4. Measure:
0.8878 in) • Camshaft-journal-to-camshaft-cap clear-
Limit ance
22.350 mm (0.8799 in) Out of specification  Measure the cam-
Exhaust A shaft journal diameter.
33.370–33.470 mm (1.3138–
1.3177 in) Camshaft-journal-to-camshaft-
Limit cap clearance
33.270 mm (1.3098 in) 0.028–0.062 mm (0.0011–0.0024
Exhaust B in)
25.211–25.311 mm (0.9926–
0.9965 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Limit a. Install the camshaft into the cylinder head.
25.111 mm (0.9886 in) b. Position a strip of Plastigauge® “1” onto the
camshaft journal as shown.
5-14
CAMSHAFT
c. Install the dowel pins and the camshaft 2. Check:

caps. • Camshaft sprocket
TIP More than 1/4 tooth wear “a”  Replace the
camshaft sprocket and the timing chain as a
• Tighten the camshaft cap bolts in a crisscross
set.
pattern from innermost to outer caps.
• Do not turn the camshaft when measuring the
camshaft journal-to-camshaft cap clearance.
a 1
Camshaft cap bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf) b 2
T.
R.
d. Remove the camshaft caps and then mea-

sure the width of the Plastigauge® “1”.
a. 1/4 tooth
b. Correct
1. Timing chain roller
1 2. Camshaft sprocket
CHECKING THE TIMING CHAIN TENSION-
EAS1SM1211
ERS
1. Check:
• Timing chain tensioner
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Crack/damage  Replace.
5. Measure: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Camshaft journal diameter “a” a. While pressing the tensioner rod lightly with
Out of specification  Replace the cam- your fingers, use a thin screwdriver “1” to
shaft. wind the tensioner rod up fully clockwise.
Within specification  Replace the cylinder b. When releasing the screwdriver by pressing
head and the camshaft caps as a set. lightly with your fingers, make sure that the
tensioner rod will come out smoothly.
Camshaft journal diameter
21.959–21.972 mm (0.8645– c. If not, replace the tensioner assembly.
0.8650 in)
CHECKING THE TIMING CHAIN AND CAM-

EAS1SM1210
SHAFT SPROCKET
1. Check:
• Timing chain “1”
Damage/stiffness  Replace the timing
chain and camshaft and camshaft sprocket
as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-15
CAMSHAFT
CHECKING THE DECOMPRESSION SYS-

EAS1SM1212
TEM b
1. Check:
• Decompression system
a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check that the decompressor cam “1”
moves smoothly.
b. Check that the decompressor lever pin “2”
projects from the camshaft.
c. Fit the timing chain “3” onto both camshaft

sprockets and install the camshafts on the
cylinder head.
TIP
Make sure that the alignment mark “c” on the
exhaust camshaft sprocket and the alignment
mark “d” on the intake camshaft sprocket are
aligned with the edge of the cylinder head.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3
INSTALLING THE CAMSHAFTS
EAS1SM1213
d c
1. Install:
• Exhaust camshaft “1”
• Intake camshaft “2”
2 1
ECA33DD029
NOTICE
Do not turn the crankshaft during the cam-
shaft installation. Damage or improper
valve timing will result.
d. Install the clips, the camshaft caps and the
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ bolts (camshaft cap).
a. Turn the crankshaft counterclockwise with a
Bolt (camshaft cap)
wrench. 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
TIP
• Apply molybdenum disulfide oil to the cam- TIP
shafts. • Before installing the clips, cover the cylinder
• Apply the engine oil on the decompression head with a clean cloth to prevent the clips
system. from coming off into the cylinder head cavity.
b. Align the top dead center (TDC) mark “a” on • Tighten the bolts to the specified torque in two
the rotor with the alignment mark “b” on the or three steps in the proper tightening se-
crankcase cover. quence as shown.
ECA33DD030
NOTICE
The bolts (camshaft cap) must be tightened
evenly, or damage to the cylinder head,
camshaft caps, and camshaft will result.
5-16
CAMSHAFT
3 4 8 7
2 6
1 5
5
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install: 3. Turn:
• Timing chain tensioner • Crankshaft
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Counterclockwise several turns.
a. While pressing the tensioner rod lightly with 4. Check:
your fingers, use a thin screwdriver to wind • Top dead center (TDC) mark on the rotor
the tensioner rod up fully clockwise. Align with the crankcase alignment mark.
• Camshaft match marks
Align with the cylinder head surface.
Out of alignment  Adjust.
5. Install:
• Timing chain guide (top side) “1”
• Cylinder head cover gasket “2”
• Cylinder head cover “3”
• Bolt (cylinder head cover) “4”
Bolt (cylinder head cover)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
b. With the tensioner rod fully wound and the
T.
R.
chain tensioner UP mark “a” facing upward, TIP

install the gasket “1”, the timing chain ten-
sioner “2”, and the gasket “3”, and tighten Before installation, apply the sealant to the cyl-
the bolt “4”. inder head cover gasket.
Bolt (timing chain tensioner) Three Bond No.1215®

10 Nm (1.0 m·kgf, 7.2 ft·lbf) 90890-85505
T.
R.
4
3
1
c. Release the screwdriver, check that the ten- 6. Install:

sioner rod comes out smoothly, and tighten • Cylinder head breather hose
the gasket “5” and the cap bolt “6”. • Spark plug
Tensioner cap bolt Spark plug
6 Nm (0.6 m·kgf, 4.3 ft·lbf) 13 Nm (1.3m·kgf, 9.4 ft·lbf)
T.
T.
R.
R.
5-17
CYLINDER HEAD
CYLINDER HEAD
EAS1SM1214
Removing the cylinder head
33 Nm (3.3 m•kgf, 24 ft •Ibf)
T .R
.
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)
T .R
.
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)

T .R
.

Exhaust pipe and silencer Refer to “ENGINE REMOVAL” on page 5-1.
Radiator hose Disconnect.

Coolant temperature sensor coupler Disconnect.
Throttle body Refer to “THROTTLE BODY” on page 7-5.
Camshaft Refer to “CAMSHAFT” on page 5-11.
Upper engine bracket Refer to “ENGINE REMOVAL” on page 5-1.
1 Bolt (cylinder head) 2
2 Bolt (cylinder head) 4
3 Cylinder head 1
4 Cylinder head gasket 1
5-18
CYLINDER HEAD
Removing the cylinder head
33 Nm (3.3 m•kgf, 24 ft •Ibf)
T .R
.
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)
T .R
.
T .R
.
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)

5 Timing chain guide (intake side) 1
6 Oil check bolt 1

dure.
5-19
CYLINDER HEAD
REMOVING THE CYLINDER HEAD

EAS1SM1215
1. Remove:
• Intake camshaft
• Exhaust camshaft
Refer to “REMOVING THE CAMSHAFT” on
page 5-13.
2. Remove:
• Cylinder head nuts
• Cylinder head bolts
TIP
2. Check:
• Loosen the bolts in the proper sequence as
• Cylinder head
shown.
Damage/scratches  Replace.
• Loosen each bolt 1/2 of a turn at a time. After
fully loosening all the bolts, remove them. TIP
When replacing the cylinder head, replace also
the valve.
“CHECKING THE VALVE SEATS” on page
5-25.
• Cylinder head coolant passages
Mineral deposits/rust  Eliminate.
3. Measure:
FWD • Cylinder head warpage
Out of specification  Resurface the cylin-
x2 x4 der head.
Warpage limit
0.05 mm (0.0020 in)
6 4
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge and a thickness gauge
2 across the cylinder head.
3 5 b. Measure the warpage.
c. If the limit is exceeded, resurface the cylin-
der head as follows.
d. Place a 400–600 grit wet sandpaper on a
surface plate, and resurface the cylinder
CHECKING THE TIMING CHAIN GUIDE (IN- head using a figure-eight sanding pattern.
EAS1SM1216
TAKE SIDE) TIP

1. Check: To ensure an even surface, turn the cylinder
• Timing chain guide (intake side) head several times.
CHECKING THE CYLINDER HEAD
EAS1SM1217
1. Eliminate:
• Combustion chamber carbon deposits
TIP
Use a rounded scraper, not a sharp instrument,
in order not to damage or scratch the spark
plug bore threads.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-20
CYLINDER HEAD
INSTALLING THE CYLINDER HEAD

EAS1SM1218
TIP
1. Install: • Apply molybdenum disulfide grease to the
• Timing chain guide (intake side) “1” threads and contact surfaces of the bolts and
• Dowel pin “2” to both contact surfaces of the washers.
• Cylinder head gasket “3” New • Tighten the bolts and nuts to the specified
• Cylinder head “4” torque in two or three steps in the proper tight-
TIP ening sequence as shown.
• Install the cylinder head gasket with its char-
acter stamp “a” rearward of the vehicle as
shown.
• While pulling up the timing chain, install the
timing chain guide (intake side) and the cylin-
der head.
a
FWD
2 4
3 x2 x4
1
1 3
5
2
6
2. Install: 4 2
• Washer “1”
• Cylinder head bolt “2”
• Cylinder head nut “3”
2 2
1
3
3. Tighten:
• Cylinder head bolt “1” – “4”
• Cylinder head nut “5”, “6”
Cylinder head bolt “1” – “4”
33 Nm (3.3 m·kgf, 24 ft·lbf)
T.
Cylinder head nut “5”, “6”

R.
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
5-21
VALVES AND VALVE SPRINGS

EAS1SM1219
Removing the valves and valve springs

Cylinder head Refer to “CYLINDER HEAD” on page 5-18.
1 Valve lifter 4
2 Adjusting pad 4
3 Valve cotter 8
4 Valve spring retainer 4
5 Valve spring 4
6 Valve stem seal 4
7 Valve spring seat 4
8 Intake valve 2
9 Exhaust valve 2
dure.
5-22
REMOVING THE VALVES b. Check that the valves are properly sealed.
EAS1SM1220
TIP TIP
Before removing the internal parts of the cylin- Check that there are no kerosene leaks from
der head (e.g., valves, valve springs, valve the valve seat “1”.
seats), make sure that the valves are properly
sealed.
1. Remove:
• Valve lifter “1”
• Adjusting pad “2”
1
TIP a
• Place a cloth in the timing chain space to pre- a
vent adjusting pads from falling into the crank-
case.
• Make a note of the positions of valve lifters
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
and adjusting pads so that they can be rein-
stalled in their original places. 3. Remove:
• Valve cotter “1”
Valve lapper TIP
90890-04101 Remove the valve cotters by compressing the
Valve lapping tool valve spring with the valve spring compressor
YM-A8998 “2” and the valve spring compressor adapter
“3”.
1 Valve spring compressor

2 90890-04019
YM-04019
Valve spring compressor adapter
22 mm
90890-04108
YM-04108
4. Remove:
2. Check: • Valve spring retainer “1”
• Valve sealing • Valve spring “2”
Leakage at the valve seat  Check the • Valve “3”
valve face, the valve seat, and the valve seat • Valve stem seal “4”
width. • Valve spring seat “5”
“CHECKING THE VALVE SEATS” on page TIP
5-25. Identify the position of each part very carefully
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ so that it can be reinstalled in its original place.
a. Pour a clean solvent “a” into the intake and
exhaust ports.
5-23
2. Replace:
• Valve guide
2 1 TIP
4 To ease valve guide removal and installation,

and to maintain the correct fit, heat the cylinder
5 head to 100 °C (212 °F) in an oven.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3 a. Remove the valve guide with the valve guide
remover “1”.
CHECKING THE VALVES AND VALVE
EAS1SM1221
GUIDES
1. Measure:
• Valve-stem-to-valve-guide clearance
Out of specification  Replace the valve
guide.
Valve-stem-to-valve-guide clearance = 1
Valve guide inside diameter “a” -
Valve stem diameter “b”
b. Install the new valve guide with the valve
Valve-stem-to-valve-guide clear- guide installer “2” and the valve guide re-
ance (intake) mover “1”.
0.010–0.037 mm (0.0004–0.0015
in) Valve guide installation height “a”
Limit Intake
0.080 mm (0.0032 in) 10.8–11.2 mm (0.43–0.44 in)
Valve-stem-to-valve-guide clear- Exhaust
ance (exhaust) 11.2–11.6 mm (0.44–0.46 in)
0.025–0.052 mm (0.0010–0.0020
in)
Limit
0.100 mm (0.0039 in)
c. After installing the valve guide, expand the

hole in the valve guide with the valve guide
reamer “3” to obtain the proper valve-stem-
to-valve-guide clearance.
5-24
TIP 6. Measure:
After replacing the valve guide, reface the valve • Valve stem runout
seat. Out of specification  Replace the valve.
TIP
Intake • When installing a new valve, always replace
Valve guide remover (ø5.0) the valve guide.
90890-04097 • If the valve is removed or replaced, always re-
YM-04097 place the oil seal.
Valve guide installer (ø5.0)
90890-04098
Valve stem runout
YM-04098
0.010 mm (0.0004 in)
Valve guide reamer (ø5.0)
90890-04099
YM-04099
Exhaust
Valve guide remover (ø4.5)
90890-04116
YM-04116
Valve guide installer (ø4.5)
90890-04117
YM-04117
Valve guide reamer (ø4.5)
90890-04118
YM-04118
CHECKING THE VALVE SEATS
EAS1SM1222
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1. Eliminate:
3. Eliminate: • Carbon deposits
• Carbon deposits (from the valve face and valve seat)
(from the valve face and valve seat) 2. Check:
4. Check: • Valve seat
• Valve face Pitting/wear  Replace the cylinder head.
Pitting/wear  Grind the valve face. 3. Measure:
• Valve stem end • Valve seat width C “a”
Mushroom shape or diameter larger than Out of specification  Replace the cylinder
the body of the valve stem  Replace the head.
valve.
5. Measure: Valve seat width C (intake)
• Valve margin thickness D “a” 0.90–1.10 mm (0.0354–0.0433 in)
Valve seat width C (exhaust)
Out of specification  Replace the valve.
0.90–1.10 mm (0.0354–0.0433 in)
Valve margin thickness D (intake)
1.20 mm (0.0472 in)
Valve margin thickness D (ex-
haust)
0.85 mm (0.0335 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply Mechanic’s blueing dye (Dykem) “b”
onto the valve face.
5-25
NOTICE
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
b. Install the valve into the cylinder head.

c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat width “c”.
TIP
b. Apply molybdenum disulfide oil onto the
valve stem.
Where the valve seat and the valve face are in c. Install the valve into the cylinder head.
contact with each other, the blueing will have d. Turn the valve until the valve face and the
been removed. valve seat are evenly polished, then clean
off all of the lapping compound.
TIP
c While turning the valve lapper, tap and lap the
valve seat.
e. Apply a fine lapping compound to the valve
face, and repeat the above steps.
f. After every lapping step, be sure to clean off
all of the lapping compound from the valve
face and the valve seat.
g. Apply Mechanic’s blueing dye (Dykem) “b”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Lap: onto the valve face.
• Valve face
• Valve seat
ECA1DX1018
NOTICE
This model uses titanium intake and ex-
haust valves.
Do not use the valves used for lapping the
valve seat. Always replace the valves used
for lapping with new ones.
TIP
h. Install the valve into the cylinder head.
• When replacing the cylinder head, replace i. Press the valve through the valve guide and
also the valves with new ones without them. onto the valve seat to make a clear impres-
• When replacing the valves or the valve sion.
guides, use new valves to lap the valve seats, j. Measure the valve seat width “c” again. If the
and then replace them with new valves. valve seat width is out of specification,
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ reface and lap the valve seat.
a. Apply a coarse lapping compound “a” to the
valve face.
ECA13790
5-26
Installed compression spring

force (intake)
146.00–168.00 N (14.89–17.13
kgf, 32.82–37.77 lbf)
Installed compression spring
force (exhaust)
137.00–157.00 N (13.97–16.01
kgf, 30.80–35.29 lbf)
Installed length (intake)
31.40 mm (1.24 in)
Installed length (exhaust)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
28.50 mm (1.12 in)
CHECKING THE VALVE SPRINGS
EAS1SM1223
1. Measure: 3. Measure:
• Valve spring free length “a” • Valve spring tilt “a”
Out of specification  Replace the valve Out of specification  Replace the valve
spring. spring.
Free length (intake) Spring tilt (intake)

36.69 mm (1.44 in) 2.5 °/1.6 mm (2.5 °/0.06 in)
Limit Spring tilt (exhaust)
35.69 mm (1.41 in) 2.5 °/1.5 mm (2.5 °/0.06 in)
Free length (exhaust)
34.86 mm (1.37 in)
Limit
33.86 mm (1.33 in)
CHECKING THE VALVE LIFTERS

EAS1SM1224
1. Check:
• Valve lifter
Damage/scratches  Replace the valve lift-
2. Measure:
ers and cylinder head.
• Compressed valve spring force “a”
Out of specification  Replace the valve
spring.
EAS1SM1225
b. Installed length
5-27
INSTALLING THE VALVES 4. Install:

1. Clean: • Valve cotter “1”
• Valve stem end TIP
Install the valve cotters by compressing the
valve spring with the valve spring compressor
“2” and the valve spring compressor adapter
“3”.
Valve spring compressor

90890-04019
YM-04019
Valve spring compressor adapter
22 mm
2. Lubricate: 90890-04108
• Valve stem “1” YM-04108
• Valve stem seal “2”
Molybdenum disulfide oil
5. To fasten the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
ECA13800
3. Install: NOTICE
• Spring seat “1” Hitting the valve tip with excessive force
• Valve stem seal “2” New could damage the valve.
• Valve “3”
• Valve spring “4”
• Valve spring retainer “5”
(to the cylinder head)
TIP
• Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch
“a” facing up.
b. Smaller pitch
5-28
6. Lubricate:
• Adjusting pad “1”
• Valve lifter “2”
7. Install:
• Adjusting pad
• Valve lifter
TIP
• Check that the valve lifter turns smoothly
when rotated with your finger.
• Make sure that the valve lifter and the adjust-
ing pad are reinstalled in their original posi-
tions.
5-29
CYLINDER AND PISTON
CYLINDER AND PISTON

EAS1SM1226
Removing the cylinder and piston
1 10 Nm (1.0 m•kgf, 7.2 ft •Ibf)
T .R
.
New
E
7
New 4
6
3 5 M
E
4
New
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)

T .R
.
LT

Cylinder head Refer to “CYLINDER HEAD” on page 5-18.
1 Cylinder body 1
2 Gaskets 1
3 Dowel pin 2
4 Piston pin clip 2
5 Piston pin 1
6 Piston 1
7 Piston ring set 1

dure.
5-30
CYLINDER AND PISTON
REMOVING THE PISTON

EAS1SM1227
1. Remove:
• Piston pin clip “1”
• Piston pin “2”
• Piston “3”
ECA13810
NOTICE
Do not use a hammer to drive the piston pin
out.
TIP
• Before removing the piston pin clip, cover the CHECKING THE CYLINDER AND PISTON
EAS1SM1228
crankcase opening with a cloth to prevent the 1. Check:

piston pin clip from falling into the crankcase. • Piston wall (Sidewall)
• Before removing the piston pin, deburr the • Cylinder wall
piston pin clip’s groove and the piston pin’s Vertical scratches  Replace the cylinder,
bore area. If the piston pin groove is deburred and replace the piston and piston rings as a
and the piston pin is still difficult to remove, set.
use the piston pin puller set “4”. 2. Measure:
• Piston-to-cylinder clearance
Piston pin puller set ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
90890-01304 a. Measure the cylinder bore with the cylinder
Piston pin puller bore gauge.
YU-01304
TIP
Measure cylinder bore by taking side-to-side
and front-to-back measurements of the cylin-
der. Then, find the average of the measure-
ments.
Bore
77.000–77.010 mm (3.0315–
3.0319 in)
Taper limit
1 0.050 mm (0.0020 in)
Out of round limit
0.050 mm (0.0020 in)
Cylinder bore = maximum of D1–D6

Taper limit = (maximum of D1or D2) - (maxi-
mum of D5 or D6)
Out of round limit = maximum of D1, D3 or D5
- minimum of D2, D4 or D6
2. Remove:
• Top ring
• Oil ring
TIP
When removing a piston ring, open the end gap
with your fingers and lift the opposite end gap
of the piston ring over the piston crown.
5-31
CYLINDER AND PISTON
b. If out of specification, rebore or replace the

cylinder, and replace the piston and the pis- Ring side clearance
ton rings as a set. 0.030–0.065 mm (0.0012–0.0026
c. Measure the piston outside diameter D “a” at in)
the measurement position H “b” with the mi- Limit
0.120 mm (0.0047 in)
crometer.
Diameter D
76.955–76.970 mm (3.0297–
3.0303 in)
Measurement position H
9.0 mm (0.35 in)
a
b
2. Install:
• Piston rings
TIP
Level the piston ring into the cylinder with the
piston.
d. If out of specification, replace the cylinder,
the piston, and the piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore - Piston diameter
Piston-to-cylinder clearance
0.030–0.055 mm (0.0012–0.0022
in)
Limit a. 10 mm (0.39 in)
0.15 mm (0.006 in)
3. Measure:
f. If out of specification, replace the cylinder, • Piston ring end gap
the piston, and the piston rings as a set. Out of specification  Replace the piston
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ring.
TIP
CHECKING THE PISTON RINGS
EAS1SM1229
1. Measure: The oil ring expander’s end gap cannot be

• Piston ring side clearance measured. If the oil ring rail’s gap is excessive,
Out of specification  Replace the piston replace all three oil rings.
and piston rings as a set.
Piston ring end gap
TIP
Top ring
Before measuring the piston ring side clear- End gap (installed)
ance, eliminate any carbon deposits from the 0.15–0.25 mm (0.0059–0.0098 in)
piston ring grooves and piston rings. Limit
0.50 mm (0.0197 in)
Oil ring
End gap (installed)
0.10–0.35 mm (0.0039–0.0138 in)
EAS1SM1230
5-32
CYLINDER AND PISTON
CHECKING THE PISTON PIN INSTALLING THE PISTON AND CYLINDER

1. Check: 1. Install:
• Piston pin • Oil ring expander “1”
Blue discoloration/grooves  Replace the • Lower oil ring rail “2”
piston pin and then check the lubrication • Upper oil ring rail “3”
system. • Top ring “4”
2. Measure: TIP
• Piston pin outside diameter “a” Be sure to install the piston ring so that the
Out of specification  Replace the piston manufacturer’s marks or numbers face up.
pin.
Piston pin outside diameter
15.991–16.000 mm (0.6296–
0.6299 in) 4
Limit
15.971 mm (0.6288 in)
3. Measure:
• Piston pin bore inside diameter “b”
Out of specification  Replace the piston.
Piston pin bore inside diameter 2. Install:
16.002–16.013 mm (0.6300– • Piston “1”
0.6304 in)
• Piston pin “2”
Limit
16.043 mm (0.6316 in) • Piston pin clip “3” New
TIP
• Apply the engine oil to the piston pin.
• Install the piston with the F mark “a” on it
pointing to its intake (front) side.
• Before installing the piston pin clip, cover the
crankcase opening with a cloth to prevent the
clip from falling into the crankcase.
• Install the piston pin clips, so that the clip ends
are 3 mm (0.12 in) “c” or more from the cutout
b in the piston.
EAS1SM1231
5-33
CYLINDER AND PISTON
a 1
3. Lubricate:
• Piston
• Piston rings
• Cylinder
4. Offset:
• Piston ring end gap
a
15
15 15
d c b
a. Top ring end
b. Upper oil ring end
c. Oil ring end
d. Lower oil ring end
5. Install:
• Cylinder gasket New
• Dowel pin
• Cylinder
Cylinder bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
TIP
• While compressing the piston rings with one
hand, install the cylinder with the other hand.
• Pass the timing chain and timing chain guide
(exhaust side) through the timing chain cavity.
5-34
CLUTCH
CLUTCH
EAS1SM1232
Removing the clutch
LS
11
5
T .R
.
10
4 9
T .R
.
8
7
2 6
T .R
.
New
(5)
12
3 New 21
1
12
(6)
13 LT
14
13
17
16
15
New 20
19
18
T .R
.

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-15.
Brake pedal Refer to “ENGINE REMOVAL” on page 5-1.
1 Clutch cable 1 Disconnect.
2 Clutch cover 1
3 Gasket 1
4 Clutch spring 5
5 Pressure plate 1
6 Push rod 1 1
7 Circlip 1
8 Washer 1
9 Bearing 1
10 Ball 1
11 Push rod 2 1
5-35
CLUTCH
Removing the clutch
LS
11
5
T .R
.
10
4 9
T .R
.
8
7
2 6
T .R
.
New
(5)
12
3 New 21
1
12
(6)
13 LT
14
13
17
16
15
New 20
19
18
T .R
.

12 Friction plate 9
13 Clutch plate 8
14 Cushion spring 1
15 Clutch boss 1
16 Thrust washer 1
17 Primary driven gear 1
18 Spacer 1
19 Bearing 1
20 Washer 1
21 Push lever shaft 1

dure.
5-36
CLUTCH
Removing the right crankcase cover
T .R
.
4
6 New 7
LT
5
E 8
New
New
New
LS
7
New
E
2 3
New
1
LS
New
LS

Right engine guard Refer to “ENGINE REMOVAL” on page 5-1.
Drain.
page 3-15.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-8.
Brake pedal Refer to “ENGINE REMOVAL” on page 5-1.
Clutch cover Refer to “CLUTCH” on page 5-35.
1 Oil filter element cover 1
2 Oil filter element 1
3 Radiator pipe 2 1
4 Kickstarter lever 1
5 Right crankcase cover 1
6 Gaskets 1
7 Dowel pin 2
8 Collar 1
dure.
5-37
CLUTCH
REMOVING THE CLUTCH CHECKING THE CLUTCH PLATES

EAS1SM1233
1. Remove: 1. Check:
• Clutch boss nut “1” • Clutch plate
• Lock washer “2” Damage  Replace the clutch plates as a
• Clutch boss “3” set.
TIP 2. Measure:
• Clutch plate warpage
• Straighten the lock washer tab.
(with a surface plate and thickness gauge
• While holding the clutch boss with the clutch
“1”)
holder “4”, loosen the clutch boss nut.
Out of specification  Replace the clutch
plates as a set.
Clutch holder
90890-04086 Warpage limit
YM-91042 0.10 mm (0.0039 in)
2 1
CHECKING THE FRICTION PLATES

EAS1SM1234
CHECKING THE CLUTCH SPRINGS

EAS1SM1236
1. Check: 1. Check:
• Friction plate • Clutch spring
Damage/wear  Replace the friction plates Damage  Replace the clutch springs as a
as a set. set.
2. Measure: 2. Measure:
• Friction plate thickness • Clutch spring free length
Out of specification  Replace the friction Out of specification  Replace the clutch
plates as a set. springs as a set.
TIP
Clutch spring free length
Measure it at four points on the friction plate. 45.00 mm (1.77 in)
Limit
Friction plate thickness 44.00 mm (1.73 in)
2.90–3.10 mm (0.114–0.122 in)
Wear limit
2.80 mm (0.110 in)
EAS1SM1237
EAS1SM1235
5-38
CLUTCH
CHECKING THE CLUTCH HOUSING CHECKING THE PUSH LEVER SHAFT

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

EAS1SM1241
1. Check:
• Push rod 1 “1”
a • Bearing “2”
• Washer “3”
CHECKING THE CLUTCH BOSS
EAS1SM1238

1. Check: • Ball “5”
• Clutch boss splines Cracks/damage/wear  Replace.
Damage/pitting/wear  Replace the clutch
boss.
TIP
Pitting on the clutch boss splines will cause er-
ratic clutch operation.
2. Measure:
• Push rod 2 bending limit
Push rod bending limit
0.10 mm (0.0039 in)
CHECKING THE PRESSURE PLATE
EAS1SM1239
CHECKING THE PRIMARY DRIVE GEAR

EAS1SM1242
1. Check: 1. Check:
• Pressure plate • Primary drive gear
Crack/damage  Replace. Damage/wear  Replace the primary drive
and primary driven gears as a set.
EAS1SM1240
Excessive noise during operation  Re-

place the primary drive and primary driven
gears as a set.
2. Check:
• Primary-drive-gear-to-primary-driven-gear
free play
Free play exists  Replace the primary
drive and primary driven gears as a set.
EAS1SM1243
5-39
CLUTCH
CHECKING THE PRIMARY DRIVEN GEAR 2. Install:

1. Check: • Right crankcase cover “1”
• Primary driven gear • Right crankcase cover bolt “2”
Damage/wear  Replace the primary drive
Right crankcase cover bolt
and primary driven gears as a set.
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Excessive noise during operation  Re-
T.
R.
place the primary drive and primary driven
TIP
gears as a set.
• Apply the engine oil on the impeller shaft end.
INSTALLING THE OIL SEAL
EAS1SM1244
• Mesh the impeller shaft gear “3” with primary

1. Install: drive gear “4”.
• Oil seal “1” New • Tighten the right crankcase cover bolts in
• Washer “2” stages and in a crisscross pattern.
• Circlip “3” New
TIP
4
• Apply is lithium-soap-based grease on the oil
seal lip.
• Install the oil seal in parallel with its manufac-
ture's marks or numbers facing inward.
LS
3
2
1
E
INSTALLING THE RIGHT CRANKCASE

EAS1SM1245
COVER
1. Install: 1
• Dowel pin “1”
• Collar “3”
• Gasket “4” New
TIP
Apply the lithium-soap-based grease on the O- 2
ring.
4 New LS
1
1 2 New
EAS1SM1246
5-40
CLUTCH
INSTALLING THE CLUTCH

1. Install: Clutch holder
• Push lever shaft “1” 90890-04086
YM-91042
TIP
• Apply the lithium soap base grease on the oil
seal lip. 3
• Before installation, apply the engine oil to the
push lever shaft sliding surface.
1
1
2
4. Bend the lock washer “1” tab.
2. Install: 1
• Primary driven gear “1”
• Thrust washer “2”
• Clutch boss “3”
TIP
Apply the engine oil on the primary driven gear
inner circumference. 5. Install:
• Friction plate “1”
• Clutch plate “2”
• Cushion spring “3”
TIP
• Install the clutch plates and friction plates al-
ternately on the clutch boss, starting with a
friction plate and ending with a friction plate.
• Install the cushion spring “3” in the position as
shown.
• Apply the engine oil on the friction plates and
3. Install: clutch plates.
• Lock washer “1” New
• Clutch boss nut “2” 1 2
Clutch boss nut 2 3
75 Nm (7.5 m·kgf, 54 ft·lbf)
2
T.
R.
ECA1DX1020
1
NOTICE
1
Make sure to tighten to specification; other-
wise, it may damage the other part that is 2
fastened together.
TIP
Use the clutch holding tool “3” to hold the clutch
boss.
5-41
CLUTCH
• Bearing “1” • Clutch spring
• Washer “2” • Clutch spring bolt
Clutch spring bolt
To push rod 1 “4”.
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
TIP
R.
Apply the engine oil on the bearing and washer. TIP
Tighten the bolts in stages and in a crisscross
pattern.
3
1
5
4
7. Install: 2
• Ball “2” 10.Install:
• Push rod 1 “3” • Gasket “1” New
TIP
Apply the engine oil on the push rod 1, 2 and
ball.
11.Install:
• Clutch cover “1”
• Clutch cover bolt
8. Install: Clutch cover bolt
• Pressure plate “1” 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
TIP
pattern.
5-42
CLUTCH
INSTALLING THE KICKSTARTER LEVER

EAS1SM1247
1. Install:
• Kickstarter lever “1”
• Washers
• Bolt (kickstarter lever)
Bolt (kickstarter lever)
33 Nm (3.3 m·kgf, 24 ft·lbf)
T.
R.
TIP
Install so that there is a clearance “a” of 5 mm
(0.2 in) or more between the kickstarter lever
and the frame and that the kickstarter lever
does not contact the right crankcase cover
when it is pulled.
a
1
5-43
KICKSTATER
KICKSTATER
EAS1SM1248
Removing the kick shaft

Primary driven gear Refer to “CLUTCH” on page 5-35.
1 Kick idle gear 1
2 Kick shaft assembly 1
3 Spring guide 1
4 Torsion spring 1
5 Ratchet wheel 1
6 Kick gear 1
7 Kick shaft 1
dure.
5-44
KICKSTATER
REMOVING THE KICK SHAFT ASSEMBLY

EAS1SM1249
1. Remove: a
• Kick shaft assembly “1”
TIP
Unhook the torsion spring “2” from the hole “a”
in the crankcase.
b
1 3 2
INSTALLING THE KICK SHAFT ASSEMBLY

EAS1SM1252
1. Install:
• Kick gear “1”
• Washer “2”
• Ratchet wheel “4”
• Spring “5”
CHECKING THE KICK SHAFT AND RATCH-
EAS1SM1250
• Washer “6”
ET WHEEL • Circlip “7” New
1. Check: (to the kick shaft “8”)
• Ratchet wheel “1” smooth movement TIP
Unsmooth movement  Replace. • Apply molybdenum disulfide oil to the inner
• Kick shaft “2” circumferences of the kick gear and ratchet
Wear/damage  Replace the kick shaft as- wheel.
sembly. • Align the punch mark “a” on the ratchet wheel
• Spring “3” with the punch mark “b” on the kick shaft.
Broken  Replace.
1
2
3
2. Install:
CHECKING THE KICK GEAR, KICK IDLE
EAS1SM1251
• Torsion spring “1”

GEAR, AND RATCHET WHEEL (to the kick shaft “2”)
1. Check:
TIP
• Kick gear “1”
Wear/damage  Replace the kick shaft as- Make sure the stopper “a” of the torsion spring
sembly. fits into the hole “b” on the kick shaft.
• Kick idle gear “2”
• Ratchet wheel “3”
• Gear teeth “a”
• Ratchet teeth “b”
5-45
KICKSTATER
5. Install:
b • Torsion spring “1”
TIP
Turn the torsion spring clockwise and hook into
a
the proper hole “a” in the crankcase.
2
3. Install:
• Spring guide “1”
TIP
Slide the spring guide into the kick shaft, make
sure the groove “a” in the spring guide fits on
the stopper of the torsion spring.
INSTALLING THE KICK IDLE GEAR
EAS1SM1253
1. Install:
• Kick idle gear “1”
• Washer “2”
TIP
• Apply the engine oil on the kick idle gear inner
circumference.
• Install the kick idle gear with its depressed
side “a” toward you.
4. Install:
• Kick shaft assembly “1”
TIP
• Before installation, apply molybdenum disul-
fide grease to the contacting surfaces of the
kick shaft ratchet wheel guide “2” and the kick
shaft stopper “a”.
• Apply the engine oil on the kick shaft.
• Slide the kick shaft assembly into the crank-
case and make sure the kick shaft stopper “a”
fits into the kick shaft ratchet wheel guide.
5-46
SHIFT SHAFT
SHIFT SHAFT
EAS1SM1254
Removing the shift shaft and stopper lever
10 Nm (1.0 m kgf, 7.2 ft lbf)

14 3
13 LS
LT
4
5
2
12 Nm (1.2 m•kgf, 8.7 ft •Ibf)
T .R
.
E
LT
8
E 7
10 15
11
12
12 30 Nm (3.0 m kgf, 22 ft lbf)

11
LT
10
6
10 Nm (1.0 m kgf, 7.2 ft lbf)

1 Shift pedal 1
2 Shift shaft 1
3 Oil seals 1
4 Collars 1
5 Shift shaft spring 1
6 Roller 1
7 Shift guide 1
8 Shift lever assembly 1
9 Shift lever 1
10 Pawl 2
11 Pawl pin 2
12 Spring 2
13 Stopper lever 1
5-47
SHIFT SHAFT
Removing the shift shaft and stopper lever
10 Nm (1.0 m kgf, 7.2 ft lbf)

14 3
13 LS
LT
4
5
2
12 Nm (1.2 m•kgf, 8.7 ft •Ibf)
T .R
.
E
LT
8
E 7
10 15
11
12
12 30 Nm (3.0 m kgf, 22 ft lbf)

11
LT
10
6
10 Nm (1.0 m kgf, 7.2 ft lbf)

14 Stopper lever spring 1
15 Segment 1
dure.
5-48
SHIFT SHAFT
REMOVING THE SHIFT GUIDE AND SHIFT CHECKING THE SHIFT SHAFT
EAS1SM1255
LEVER ASSEMBLY 1. Check:

1. Remove: • Shift shaft “1”
• Bolt (shift guide) Bends/damage/wear  Replace.
• Shift guide “1” • Shift shaft spring “2”
• Shift lever assembly “2” Damage/wear  Replace.
TIP
Make sure that the shift lever assembly is re- 1
moved together with the shift guide.
CHECKING THE SHIFT GUIDE AND SHIFT

EAS1SM1258
LEVER ASSEMBLY
1. Check:
• Shift guide “1”
REMOVING THE SEGMENT
EAS1SM1256
• Shift lever “2”

1. Remove: • Pawl “3”
• Bolt (segment) “1” • Pawl pin “4”
• Segment “2” • Spring “5”
TIP Wear/damage  Replace.
Turn the segment counterclockwise until it 1
stops and loosen the bolt.
ECA1DX1021
NOTICE
2 3
If the segment gets an impact, it may be
damaged. Take care not to give an impact to
it when removing the bolt. 4
5
CHECKING THE STOPPER LEVER
EAS1SM1259
1. Check:
• Stopper lever “1”
• Torsion spring “2”
Broken  Replace.
EAS1SM1257
EAS1SM1260
5-49
SHIFT SHAFT
INSTALLING THE STOPPER LEVER INSTALLING THE SHIFT GUIDE AND SHIFT
1. Install: LEVER ASSEMBLY
• Torsion spring “1” 1. Install:
• Collar “2” • Spring “1”
• Stopper lever “3” • Pawl pin “2”
• Bolt (stopper lever) “4” • Pawl “3”
(to the shift lever “4”)
Bolt (stopper lever)
10 Nm (1.0 m·kgf, 7.2 ft·lbf) TIP
T.
LOCTITE® Apply the engine oil on the spring, pawl pin and
R.
pawl.
LT
3
4 2 1
INSTALLING THE SEGMENT

EAS1SM1261
2. Install:
1. Install: • Shift lever assembly “1”
• Segment “1” (to the shift guide “2”)
• Segment bolt
2
Segment bolt
30 Nm (3.0 m·kgf, 22 ft·lbf) 1
T.
R.
TIP
• Align the notch “a” on the segment with the
pin “b” on the shift cam.
• With the stopper lever pushed down, install
the segment.
3. Install:
ECA1DX1022
NOTICE
• Shift lever assembly “1”
If the segment gets an impact, it may be
• Shift guide “2”
damaged. Take care not to give an impact to
it when tightening the bolt. TIP
• The shift lever assembly is installed at the
same time as the shift guide.
• Apply the engine oil on the segment bolt shaft.
EAS1SM1262
2
1
5-50
SHIFT SHAFT
4. Tighten: INSTALLING THE SHIFT PEDAL

• Shift guide bolt “1” 1. Install:
• Shift pedal “1”
Shift guide bolt
• Shift pedal bolt “2”
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
LOCTITE®
R.
Shift pedal bolt

12 Nm (1.2 m·kgf, 8.7 ft·lbf)
T.
R.
1 TIP
1 Align the punch mark “a” on the shift shaft with
the punch mark “b” in the shift pedal.
b
LT a
INSTALLING THE SHIFT SHAFT

EAS1SM1263
1. Install: 1 2
• Roller “1”
• Shift shaft spring “2” (to shift shaft)
• Collar “3” (to shift shaft)
• Shift shaft “4”
TIP
Apply the engine oil on the roller, collar and
shift shaft.
1
E
3
2
E
4
2. Install:
• Oil seal New
EAS1SM1264
5-51
OIL PUMP AND BALANCER GEAR

EAS1SM1265
Removing the oil pump
2.0 Nm (0.20 m•kgf, 1.4 ft •Ibf)
T.R
.
2
1
LT 3
4
5
5 Nm (0.5 m•kgf, 3.6 ft •Ibf) 7
T .R
.

Right crankcase cover Refer to “CLUTCH” on page 5-35.
1 Oil pump assembly 1
2 Oil pump cover 1
3 Outer rotor 1
4 Dowel pin 1
5 Inner rotor 1
6 Oil pump drive shaft 1
7 Rotor housing 1
dure.
5-52
Removing the balancer
40 Nm (4.0 m•kgf, 29 ft •Ibf)
T .R
.
New
75 Nm (7.5 m •kgf, 54 ft •lbf)

T .R
.
8
7
6
12
11
50 Nm (5.0 m•kgf, 36 ft •Ibf)

T .R
.

Stator Refer to “AC MAGNETO” on page 5-58.
1 Nut (balancer) 1
2 Nut (primary drive gear) 1
3 Nut (balancer shaft driven gear) 1
4 Conical washer 1
5 Balancer 1
6 Conical washer 1
7 Primary drive gear 1
8 Collar 1
9 Balancer shaft drive gear 1
10 Conical washer 1
11 Balancer weight gear 1
12 Collar 1
dure.
5-53
REMOVING THE BALANCER

EAS1SM1266
1. Loosen:
• Balancer nut “1”
• Primary drive gear nut “2”
• Balancer weight gear nut “3”
TIP
Place an aluminum plate “a” between the teeth
of the balancer drive gear “4” and balancer
weight gear “5”.
CHECKING THE BALANCER

EAS1SM1268
1. Check:
• Balancer
1 Crack/damage  Replace.
2
CHECKING THE OIL PUMP
EAS1SM1269
1. Check:
5 • Oil pump drive gear
a • Oil pump driven gear
• Oil pump housing
• Oil pump housing cover
4 a 3 Cracks/damage/wear  Replace the defec-
tive part(s).
2. Measure:
• Inner-rotor-to-outer-rotor-tip clearance “a”
• Outer-rotor-to-oil-pump-housing clearance
“b”
5 • Oil-pump-housing-to-inner-rotor-and-outer-
rotor clearance “c”
Out of specification  Replace the oil pump.
CHECKING THE PRIMARY DRIVE GEAR, Inner-rotor-to-outer-rotor-tip
EAS1SM1267
BALANCER SHAFT DRIVE GEAR, AND clearance

BALANCER WEIGHT GEAR Less than
1. Check: 0.150 mm (0.0059 in)
• Primary drive gear “1” Outer-rotor-to-oil-pump-housing
• Balancer shaft drive gear “2” clearance
0.13–0.18 mm (0.0051–0.0071 in)
• Balancer weight gear “3”
Oil-pump-housing-to-inner-and-
Wear/damage  Replace. outer-rotor
clearance
0.06–0.11 mm (0.0024–0.0043 in)
5-54
b 2. Install:
• Outer rotor “1”
TIP
1 Apply the engine oil on the outer rotor.
a
2
3 3. Install:
c • Oil pump cover “1”
• Oil pump cover screw “2”
Oil pump cover screw
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
T.
R.
1. Inner rotor
2. Outer rotor 2
3. Oil pump housing 1
3. Check:
• Oil pump operation
Rough movement  Repeat steps (1) and
(2) or replace the defective part(s).
ASSEMBLING THE OIL PUMP
EAS1SM1270
1. Install:
• Oil pump drive shaft “1”
• Inner rotor “2” INSTALLING THE OIL PUMP AND BALANC-
EAS1SM1271
• Dowel pin “3” ER GEAR

TIP 1. Install:
• Apply the engine oil on the oil pump drive • Oil pump assembly “1”
shaft and inner rotor. • Oil pump assembly bolt “2”
• Fit the dowel pin into the groove in the inner
Oil pump assembly bolt
rotor. 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
T.
LOCTITE®
R.
1
2
3
LT
2
1
ECA1DX1023
5-55
NOTICE 4. Install:
• Conical washer “1” New
After tightening the bolts, make sure that
• Balancer weight gear nut “2”
the oil pump turns smoothly.
2. Install: Balancer weight gear nut
• Collar “1” 50 Nm (5.0 m·kgf, 36 ft·lbf)
T.
R.
• Balancer weight gear “2”
• Primary drive gear “3”
TIP • Conical washer “4” New
Install the balancer weight gear and balancer • Primary drive gear nut “5”
shaft with their lower splines “a” aligning with
each other. Primary drive gear nut
75 Nm (7.5 m·kgf, 54 ft·lbf)
T.
R.
• Balancer “6”
• Conical washer “7” New
• Balancer nut “8”
1 Balancer nut
2 40 Nm (4.0 m·kgf, 29 ft·lbf)
T.
R.
TIP
• Apply engine oil to the contact surface and
3. Install: threaded portion of the primary drive gear nut.
• Balancer drive gear “1” • Place an aluminum plate “a” between the
• Collar “2” teeth of the balancer drive gear “9” and bal-
ancer weight gear “10”.
TIP
• Install the conical washer with its convex sur-
• Align the punched mark “a” on the balancer face “b” outward.
drive gear with the punched mark “b” on the • Align the balancer flat portion “c” with the flat
balancer weight gear. portion “d”.
• Install the balancer drive gear and crankshaft
with the lower splines “c” aligning with each
other. 1 10
9 2
b 2
a
9 a
4 5 10
3
1
3 b 5
5-56
c
d
6
8
7
6 b 8
5-57
AC MAGNETO
AC MAGNETO
EAS1SM1272
Removing the AC magneto
1
10
2
8 Nm (0.8 m•kgf, 5.8 ft •Ibf)
T .R
.
12 Nm (1.2 m•kgf, 8.7 ft•Ibf)
T .R
.
6
3 8 Nm (0.8 m•kgf, 5.8 ft •Ibf)
T .R
.
LT
8
LT
6
5 New
7
LT
9
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)
T .R
.
65 Nm (6.5 m•kgf, 47 ft •Ibf) 10 Nm (1.0 m•kgf, 7.2 ft •Ibf)

T .R
T .R
.

Drain.
page 3-15.
Air scoop (left) Refer to “GENERAL CHASSIS” on page 4-1.
1 AC magneto lead Disconnect.

2 Crankshaft position sensor lead 1 Disconnect.
3 Shift pedal 1
4 Left crankcase cover 1
5 Gaskets 1
6 Dowel pin 2
7 Holder 1
8 Stator assembly 1
9 Rotor 1
10 Woodruff key 1
dure.
5-58
AC MAGNETO
REMOVING THE AC MAGNETO CHECKING THE WOODRUFF KEY

EAS1SM1273
• Nut (rotor) “1” • Woodruff key “1”
• Washers Damage  Replace.
1
2. Remove: INSTALLING THE AC MAGNETO
EAS1SM1276
• Rotor “1” 1. Install:

Use the rotor puller “2” to remove the rotor. • Stator “1”
• Woodruff key • Screw (stator) “2”
Rotor puller Screw (stator)
90890-04151 8 Nm (0.8 m·kgf, 5.8ft·lbf)
T.
YM-04151 LOCTITE®
R.
• Crankshaft position sensor “3”

• Bolt (crankshaft position sensor) “4”
• Holder “5”
• Bolt (holder) “6”
Bolt (crankshaft position sensor)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
LOCTITE®
R.
Holder
8 Nm (0.8 m·kgf, 5.8 ft·lbf)
LOCTITE®
CHECKING THE AC MAGNETO
EAS1SM1274
1. Check: TIP
• Rotor inner surface “a” • Apply the sealant to the grommet of the AC
• Stator outer surface “b” magneto lead.
Damage  Inspect the crankshaft runout • Tighten the stator screws using the T25 bit.
and crankshaft bearing. • Pass the AC magneto lead “a” through the
crankcase cover side.
b
Three Bond No.1215®
90890-85505
6
LT 5
a 2 LT
EAS1SM1275
a
1
4
4 3
5-59
AC MAGNETO
2. Install:
1 3
• Woodruff key “1”
• Rotor “2” 5
TIP
• Clean the contact surfaces of the tapered por-
tions of the crankshaft and rotor.
• When installing the woodruff key, make sure 4
that its flat surface “a” is in parallel with the 5
crankshaft center line “b”. 2 5
4
1 5 5
• When installing the rotor, align the keyway “c”
of the rotor with the woodruff key. 5. Connect:
• AC magneto lead
Refer to “CABLE ROUTING DIAGRAM” on
1 page 2-31.
b 1 a
2
3. Install:
• Washers
• Nut (rotor) “1”
Nut (rotor)
65 Nm (6.5 m·kgf, 47 ft·lbf)
T.
R.
1
4. Install:
• Gasket (left crankcase cover) “2” New
• Left crankcase cover “3”
• Lead holder “4”
• Bolt (left crankcase cover) “5”
Bolt (left crankcase cover)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
TIP
pattern.
5-60
CRANKCASE
CRANKCASE
EAS1SM1277
Separating the crankcase

6 4
6
7
4 4
4 10 9 11
12 Nm (1.2 m•kgf, 8.7 ft •Ibf)

T .R
.
3
1
9
6 8
4
12 Nm (1.2 m•kgf, 8.7 ft •Ibf)
T .R
.
LT

T .R
T .R
.
.

Engine Refer to “ENGINE REMOVAL” on page 5-1.
Refer to “CYLINDER AND PISTON” on page
Piston 5-30.
Refer to “OIL PUMP AND BALANCER
Balancer GEAR” on page 5-52.
Kick shaft assembly Refer to “KICKSTATER” on page 5-44.
Segment Refer to “SHIFT SHAFT” on page 5-47.
Stator Refer to “AC MAGNETO” on page 5-58.
1 Timing chain guide (exhaust side) 1

2 Timing chain guide stopper plate 1
3 Timing chain 1
4 Bolt [L = 45 mm (1.77 in)] 7
5 Bolt [L = 60 mm (2.36 in)] 2
6 Bolt [L = 75 mm (2.95 in)] 3
7 Right crankcase 1
5-61
CRANKCASE
Separating the crankcase

6 4
6
7
4 4
4 10 9 11
12 Nm (1.2 m•kgf, 8.7 ft •Ibf)

T .R
.
3
1
9
6 8
4
12 Nm (1.2 m•kgf, 8.7 ft •Ibf)
T .R
.
LT

T .R
T .R
.
.

8 Left crankcase 1
9 Dowel pin 2
10 Crankshaft 1
11 Oil passage squeeze nozzle 1

cedure.
5-62
CRANKCASE
Removing the bearing and oil seal

New 1
1
2 New
LT 3
New 2
3
3
3
3
3
LT
22 Nm (2.2 m•kgf, 16 ft •Ibf)

T .R
.
3
3
LT
LT

Transmission Refer to “TRANSMISSION” on page 5-69.
Shift cam and shift fork Refer to “TRANSMISSION” on page 5-69.
1 Circlip 2
2 Oil seals 3
3 Bearing 11
dure.
5-63
CRANKCASE
DISASSEMBLING THE CRANKCASE

EAS1SM1278
1. Separate:
• Right crankcase
• Left crankcase
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the crankcase bolts.
a
c. Remove the dowel pins and O-ring.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
REMOVING THE CRANKCASE BEARING
EAS1SM1279
1. Remove:
• Bearing “1”
TIP
TIP • Remove the bearing from the crankcase by
Loosen each bolt 1/4 of a turn at a time and af- pressing its inner race.
ter all the bolts are loosened, remove them. • Do not use the removed bearing.
b. Remove the right crankcase “1”.

TIP
• Place the crankcase with its left side down-
ward and split it by inserting a screwdriver tip
into the splitting slit “a” in the crankcase.
• Lift the right crankcase horizontally while light-
ly patting the crankcase splitting slit and the
engine mounting boss using a soft hammer,
and leave the crankshaft and the transmission
with the left crankcase.
CHECKING THE TIMING CHAIN, TIMING
EAS1SM1280
CHAIN GUIDE, OIL STRAINER

ECA33DD041
NOTICE
1. Check:
Use soft hammer to tap on the case half.
• Timing chain
Tap only on reinforced portions of case. Do Stiffness  Replace the camshaft sprocket,
not tap on gasket mating surface. Work timing chain and crankshaft sprocket as a
slowly and carefully. Make sure the case set.
halves separate evenly. If the cases do not 2. Check:
separate, check for a remaining case bolt or • Timing chain guide
fitting. Do not force. Damage/wear  Replace
CHECKING THE CRANKCASE
EAS1SM1281
1. Wash:
• Crankcase
TIP
1 • Wash the crankcase in a mild solvent.
• Remove any remaining gasket from the
crankcase mating surface.
2. Check:
• Crankcase
• Oil delivery passages
air.
5-64
CRANKCASE

EAS1SM1282
1. Install: Crankcase bolt

• Oil seal “1” New 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
T.
R.
(to left crankcase)
TIP
Installed depth “a” • Apply the lithium-soap-based grease on the
4.5–5.0 mm (0.18–0.20 in) O-ring.
• Fit the right crankcase onto the left crankcase.
Tap lightly on the case with soft hammer.
1
• When installing the crankcase, the connecting
rod should be positioned at top dead center
(TDC).
• Tighten the bolts in a crisscross pattern in two
(2) stages, with 1/4 turn each.
ASSEMBLING THE CRANKCASE

EAS1SM1283
1. Install:
• Bearing cover plate screw 4
Bearing cover plate screw

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
LOCTITE® 3
R.
Bearing cover plate screw (crank-

shaft) 5
22 Nm (2.2 m·kgf, 16 ft·lbf)
LOCTITE®
TIP
parallel.
2. Apply: a b
• Sealant
(to the crankcase mating surface)
5 3 5
Three Bond No.1215® 4
90890-85505
3 3 3
3. 45 mm (1.77 in)
4. 60 mm (2.36 in)
5. 75 mm (2.95 in)
3. Install: a. Hexagon socket head bolt without flange
• Dowel pin “1” b. Hexagon socket head bolt with flange
• Crankcase (to the left crankcase)
5-65
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT

EAS1SM1284
Removing the crankshaft assembly and balancer shaft
1
M

Separate.
Crankcase Refer to “CRANKCASE” on page 5-61.
Transmission Refer to “TRANSMISSION” on page 5-69.
1 Balancer shaft 1
2 Crankshaft assembly 1
dure.
5-66
REMOVING THE CRANKSHAFT ASSEMBLY 2. Measure:

EAS1SM1285
1. Remove: • Big end side clearance D “a”

• Crankshaft assembly “1” Out of specification  Replace the big end
TIP bearing, crankshaft pin, or connecting rod.
Remove the crankshaft assembly by using the Big end side clearance D
crankcase separating tool “2”. 0.150–0.450 mm (0.0059–0.0177
in)
Crankcase separating tool
90890-04152
YU-A9642
1
3. Measure:
• Crankshaft width A “a”
Out of specification  Replace the crank-
shaft.
Width A
55.95–56.00 mm (2.203–2.205 in)
CHECKING THE CRANKSHAFT ASSEMBLY

EAS1SM1286
1. Measure:
• Crankshaft runout
Out of specification  Replace the crank-
shaft, bearing or both. 4. Check:
TIP • Crankshaft sprocket “1”
Damage  Replace the crankshaft.
Turn the crankshaft slowly.
Runout limit C
0.030 mm (0.0012 in)
5. Check:
• Crankshaft journal oil passage
air.
5-67
INSTALLING THE CRANKSHAFT ASSEM-

EAS1SM1287
BLY
1. Install:
• Crankshaft assembly
TIP
Install the crankshaft assembly with the crank-
shaft installer pot “1”, crankshaft installer bolt
“2”, adapter (M12) “3” and spacer “4”.
Crankshaft installer pot

90890-01274 INSTALLING THE BALANCER SHAFT
EAS1SM1288
Installing pot 1. Install:

YU-90058 • Balancer shaft “1”
Crankshaft installer bolt
TIP
90890-01275
Bolts Apply the molybdenum grease to the part “a”
YU-90060 where the balancer shaft fit into the bearing.
Adapter (M12) ECA13970
90890-01278 NOTICE
Adapter #3 Do not apply the molybdenum grease to the
YU-90063 balancer shaft thread.
Spacer (crankshaft installer)
90890-04081 1
Pot spacer M
YM-91044
ECA13970
NOTICE
a
• To avoid scratching the crankshaft and to
ease the installation procedure, lubricate
the oil seal lips with lithium-soap-based
grease.
• In order to prevent the crankshaft seizure,
apply molybdenum disulfide grease.
TIP
Hold the connecting rod at top dead center
(TDC) with one hand while turning the nut of the
crankshaft installer bolt with the other. Turn the
crankshaft installer bolt until the crankshaft as-
sembly bottoms against the bearing.
5-68
TRANSMISSION
TRANSMISSION
EAS1SM1289
Removing the transmission, shift drum assembly, and shift forks

LS
M
2
New
M
10
M
M 9
8
7
1 M
5
3 E
4
5 E 6
E E

Engine Refer to “ENGINE REMOVAL” on page 5-1.
Separate.
Crankcase Refer to “CRANKCASE” on page 5-61.
1 Main axle 1
2 Drive axle 1
3 Long shift fork guide bar 1
4 Short shift fork guide bar 1
5 Spring 4
6 Shift cam 1
7 Shift fork 3 (R) 1
8 Shift fork 2 (C) 1
9 Shift fork 1 (L) 1
10 Collars 1
dure.
5-69
TRANSMISSION
REMOVING THE TRANSMISSION CHECKING THE SHIFT FORKS

EAS1SM1290
• Long shift fork guide bar “1” • Shift fork cam follower “1”
• Short shift fork guide bar “2” • Shift fork pawl “2”
• Shift cam “3” Bends/damage/scoring/wear  Replace the
• Shift fork 3 “4” shift fork.
• Shift fork 2 “5”
• Shift fork 1 “6”
• Main axle “7”
• Drive axle “8”
• Collar “9”
TIP
• Remove assembly with the collar “9” installed
to the crankcase.
• Make a note of the position of each part. Pay
particular attention to the location and direc-
2. Check:
tion of shift forks.
• Shift fork guide bar
• Remove the main axle and the drive axle all
Roll the shift fork guide bar on a flat surface.
together by tapping the drive axle lightly with
Bends  Replace.
a soft hammer. EWA12840
WARNING
Do not attempt to straighten a bent shift fork
2 guide bar.
1
4 3
6
8 3. Check:
• Shift fork movement
(along the shift fork guide bar)
Rough movement  Replace the shift forks
and shift fork guide bar as a set.
7
EAS1SM1291
EAS1SM1292
5-70
TRANSMISSION
CHECKING THE SHIFT DRUM ASSEMBLY

1. Check:
• Shift drum groove
Damage/scratches/wear  Replace the
shift drum assembly.
• Shift drum segment “1”
Damage/wear  Replace the shift drum as-
sembly.
3. Check:
• Transmission gears
Blue discoloration/pitting/wear  Replace
the defective gear (s).
• Transmission gear dogs
Cracks/damage/rounded edges  Replace
the defective gear (s).
4. Check:
• Transmission gear movement
CHECKING THE TRANSMISSION
EAS1SM1293
Rough movement  Replace the defective

1. Measure:
gear (s).
• Main axle runout
(with a centering device and dial gauge “1”) INSTALLING THE TRANSMISSION
EAS1SM1294
Out of specification  Replace the main ax- 1. Install:

le. • 5th pinion gear (24T) “1”
• 3rd pinion gear (18T) “2”
Main axle runout limit
• Collar “3”
0.08 mm (0.0032 in)
• 4th pinion gear (18T) “4”
• 2nd pinion gear (16T) “5”
(to the main axle “6”)
TIP
Before installation, apply molybdenum disulfide
oil to the inner and end surface of the idler gear
and to the inner surface of the sliding gear, then
install.
5
4
3
2. Measure: 2
1
• Drive axle runout
(with a centering device and dial gauge “1”) 6
Out of specification  Replace the drive ax-
le.
Drive axle runout limit M
0.08 mm (0.0032 in)
5-71
TRANSMISSION
2. Install:
• 2nd wheel gear (28T) “1”
• 4th wheel gear (22T) “2” c c
• 3rd wheel gear (26T) “3”
• 5th wheel gear (25T) “4”
• Collar “5”
• 1st wheel gear (30T) “6”
(to the drive axle “8”)
TIP
• Before installation, apply molybdenum disul- 4. Install:
fide oil to the inner and end surface of the idler • Collar “1”
gear and to the inner surface of the sliding TIP
gear, then install. • Apply the lithium soap base grease on the oil
• Apply the lithium-soap-based grease on the seal lip.
O-ring. • When installing the collar into the crankcase,
pay careful attention to the crankcase oil seal
LS 7 lip.
8
1
2
4 3
65 New
3. Install:
• Washer “1”
• Circlip “2” New 5. Install:
TIP • Main axle “1”
• Be sure the circlip sharp-edged corner “a” is • Drive axle “2”
positioned opposite side to the washer and TIP
gear “b”. • Install to the left crankcase simultaneously.
• Install the circlip with its ends “c” settled even- • Apply engine oil to the main axle and the drive
ly on the spline crests. axle bearing.
1 b
1
2
2 2
a
5-72
TRANSMISSION
• Shift fork 1 (L) “1” • Long shift fork guide bar “1”
• Shift fork 2 (C) “2” • Short shift fork guide bar “2”
• Shift fork 3 (R) “3” • Spring “3”
• Shift cam “4” TIP
(to the main axle and the drive axle) • Screw the spring into the shift fork guide bar
TIP lightly beforehand.
• Apply molybdenum disulfide oil to the shift • Apply the engine oil on the shift fork guide
fork grooves. bars.
• Apply engine oil to the shift cam groove and
the bearing contact surface. 3
• Mesh the shift fork 1 (L) with the 4th wheel
gear “5” and 3 (R) with the 5th wheel gear “7” E
on the drive axle.

• Mesh the shift fork 2 (C) with the 3rd pinion
gear “6” on the main axle. 1
2
8. Check:
3 • Operation of shift cam and shift fork
• Transmission operation
Unsmooth operation  Repair.
2
1
7
3
M
1
M
2
E 4
5-73
COOLING SYSTEM
RADIATOR .......................................................................................................6-1
HANDLING NOTE ......................................................................................6-3
CHECKING THE RADIATOR.....................................................................6-3
WATER PUMP..................................................................................................6-4
REMOVING THE OIL SEAL.......................................................................6-6
CHECKING THE WATER PUMP ...............................................................6-6
CHECKING THE BEARING .......................................................................6-6
INSTALLING THE OIL SEAL .....................................................................6-6
ASSEMBLING THE WATER PUMP...........................................................6-6
6
RADIATOR
EAS1SM1295
TIP
mechanical damage.
RADIATOR
EAS1SM1296
Removing the radiator
12
New
LS
New
11
LS New

Drain.
page 3-8.
Air filter case Refer to “THROTTLE BODY” on page 7-5.

1 Radiator guard 2
2 Radiator hose clamp 8 Loosen.
6-1
RADIATOR
Removing the radiator
12
New
LS
New
11
LS New

3 Right radiator 1
4 Radiator hose 2 1
5 Radiator hose 3 1
6 Radiator hose 4 1
7 Radiator pipe 2 1
8 Radiator breather hose 1
9 Left radiator 1
10 Radiator hose 1 1
11 Radiator pipe 1 1
12 Coolant temperature sensor 1

dure.
6-2
RADIATOR
HANDLING NOTE
EAS1SM1297
EWA1DX1007
WARNING
diator cap.
CHECKING THE RADIATOR

EAS1SM1298
1. Check:
• Radiator fins “1”
Obstructions  Clean.
Apply compressed air to the rear of the radi-
ator.
Damage  Repair or replace.
TIP
Correct any flattened fins with a thin, flat-head
screwdriver.
2. Check:
• Radiator hoses
• Radiator pipes
6-3
WATER PUMP
WATER PUMP
EAS1SM1299
Removing the water pump
New
6 4
5
New
7
3 10 4
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)

T .R
.
1
11
E
2
2
8
9 New
New
E
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)
T .R
.

Drain.
page 3-8.
Drain.
page 3-15.
1 Water pump housing 1
2 Dowel pin 2
3 Gasket 1
4 Washer 2
5 Collar 1
6 Gear 1
7 Pin 1
8 Impeller shaft assembly 1
9 Oil seal 1
6-4
WATER PUMP
Removing the water pump
New
6 4
5
New
7
3 10 4
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)

T .R
.
1
11
E
2
2
8
9 New
New
E
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)
T .R
.

10 Bearing 1
11 Oil seal 1
dure.
6-5
WATER PUMP
REMOVING THE OIL SEAL

EAS1SM1300
TIP 1 New
• Remove the oil seal when the coolant level
changes frequently more than usual, coolant
has discolored, or engine oil has become
milky.
• Do not use the removed oil seal. 1 New
LS
1. Remove:
• Oil seals “1” LS
2. Install:
• Bearing “1”
1
TIP
parallel.
1
CHECKING THE WATER PUMP

EAS1SM1301
1. Check:
• Water pump housing cover
• Impeller shaft
CHECKING THE BEARING
EAS1SM1302
ASSEMBLING THE WATER PUMP

EAS1SM1304
1. Check:
1. Install:
• Bearing
• Impeller shaft assembly “1”
Rotate the inner race with your finger.
• Washer “2”
Rough spot/seizure  Replace.
• Pin “3”
• Gear “4”
• Collar “5”
TIP
• Take care so that the oil seal lip is not dam-
aged or the spring does not slip off its posi-
tion.
• When installing the impeller shaft, apply the
engine oil to the oil seal lip, the bearing, and
the impeller shaft.
EAS1SM1303
1. Install: 6
• Oil seals “1” New 4 5 2
2 3
TIP
• Apply the lithium soap base grease on the oil New
seal lip.
marks or numbers facing the right crankcase 1
cover “2”.
E
6-6
WATER PUMP
2. Install:
• Gasket “2” New
1 1
2 New
3. Install:
• Water pump housing “1”
• Water pump housing bolt “2”
Water pump housing bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
• Washer “3” New

• Coolant drain bolt “4”
Coolant drain bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
1
2
2
4 3 New
6-7
FUEL SYSTEM
FUEL TANK......................................................................................................7-1
REMOVING THE FUEL TANK ...................................................................7-2
REMOVING THE FUEL PUMP ..................................................................7-2
CHECKING THE FUEL PUMP BODY........................................................7-2
INSTALLING THE FUEL PUMP.................................................................7-2
INSTALLING THE FUEL TANK..................................................................7-3
CHECKING THE FUEL PRESSURE .........................................................7-3
CHECKING THE DAMPER ........................................................................7-4
CHECKING AND REPLACING THE PROTECTOR ..................................7-4
THROTTLE BODY............................................................................................7-5
CHECKING THE INJECTOR .....................................................................7-8
CHECKING THE THROTTLE BODY .........................................................7-8
CHECKING THE THROTTLE BODY JOINT..............................................7-8
ADJUSTING THE THROTTLE POSITION SENSOR.................................7-9
7
FUEL TANK
EAS1SM1305
TIP
mechanical damage.
FUEL TANK
EAS1SM1306
Removing the fuel tank

T .R
T .R
.
.
7 Nm (0.7 m•kgf, 5.1 ft •Ibf)
T .R
.
4.0 Nm (0.40 m•kgf, 2.9 ft •Ibf)
T.R
.
4.0 Nm (0.40 m•kgf, 2.9 ft •Ibf)
T.R
.
(2)
(2)
6 New
3
5
(6)
4 2
(2)
(2) 1
7 Nm (0.7 m•kgf, 5.1 ft •Ibf)

T .R
.

Side cover (left/right)
Air scoop (left/right)
1 Fuel pump coupler 1 Disconnect.
2 Fuel hose 1 Disconnect.
3 Fuel tank 1
4 Fuel pump bracket 1
5 Fuel pump 1
6 Fuel pump gasket 1
dure.
7-1
FUEL TANK
REMOVING THE FUEL TANK

EAS1SM1307
1. Extract the fuel in the fuel tank through the

fuel tank cap with a pump. 4
2. Remove:
• Fuel hose coupler 3
EWA23P1001
WARNING
Cover the fuel hose connection with a cloth
when disconnecting it. This is because re-
sidual pressure in the fuel hose could cause
fuel to spurt out when the hose is removed. 3. Remove:
ECA23P1090
NOTICE
• Seat
Make sure that the fuel hose is disconnect- • Air scoop (left/right)
ed by hand. Do not forcefully disconnect the • Fuel tank
hose with tools.
TIP
TIP Do not set the fuel tank down on the installation
• To disconnect the fuel hose from the fuel tank, surface of the fuel pump. Be sure to lean the
remove the fuel hose connector holder “a”, fuel tank against a wall or the like.
and then slide the fuel hose connector cover.
• To remove the fuel hose from the fuel rail, REMOVING THE FUEL PUMP
EAS1SM1308
slide the fuel hose connector cover “1” on the 1. Remove:

end of the hose in the direction of the arrow • Fuel pump
shown, press the two buttons “2” on the sides
ECA14720
NOTICE
of the connector, and then remove the hose.
Do not drop the fuel pump or give it a strong
• Before removing the hose, place a few cloths
shock.
in the area under where it will be removed.
• To prevent sand, dust, and other foreign ma- CHECKING THE FUEL PUMP BODY
EAS1SM1309
terials from entering the fuel pump, install the 1. Check:

included fuel hose joint cover 1 “3” and the • Fuel pump body
fuel hose joint cover 2 “4” onto the disconnect- Obstructions  Clean.
ed fuel hose and the fuel pump. Cracks/damage  Replace the fuel pump
assembly.
INSTALLING THE FUEL PUMP
EAS1SM1310
1. Install:
• Fuel pump gasket New
• Fuel pump
a • Fuel pump bracket
Fuel pump bolts
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
T.
R.
TIP
• Take care not to damage the installation sur-
2 faces of the fuel tank.
1 • Always use a new fuel pump gasket.
• Install the lip on the fuel pump gasket upward.
• Install the fuel pump as shown in the figure.
• Align the projection “a” on the fuel pump with
the slot “b” in the fuel pump bracket.
• Tighten the fuel pump bolts in the proper tight-
ening sequence as shown.
7-2
FUEL TANK
b a
3. Connect:
3 • Fuel pump coupler
5 4. Install:
1 • Air scoop (left/right)
• Seat
2 Refer to “GENERAL CHASSIS” on page 4-
4 1.
CHECKING THE FUEL PRESSURE
EAS1SM1312
6
1. Check:
INSTALLING THE FUEL TANK • Fuel pressure
EAS1SM1311
1. Install: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Fuel tank a. Remove the side cover (left/right), the seat
2. Connect: and the air scoop (left/right).
• Fuel hose Refer to “GENERAL CHASSIS” on page 4-
1.
ECA33DD069
NOTICE
b. Remove the fuel tank bolt and lift the fuel
• Connect the fuel hose securely, and check
tank.
that the orientation of the installed fuel
c. Disconnect the fuel hose from the fuel
hose holder is correct.
pump.
• Take care not to kink or pinch the fuel
Refer to “REMOVING THE FUEL TANK” on
hose.
page 7-2.
EWA1DX1008
TIP WARNING
• Insert the fuel hose into the fuel pipe securely Cover the fuel hose connection with a cloth
until you hear a “click”. when disconnecting it. This is because re-
• Slide the fuel hose connector cover “1” at the sidual pressure in the fuel hose could cause
hose end in the direction of the arrow. fuel to spurt out when the hose is removed.
• Install the fuel hose connector holder “a”. ECA1DX1025
• Check that the fuel hose and the fuel pump NOTICE
lead are routed through the guide on the cov- Make sure that the fuel hose is disconnect-
er. ed by hand. Do not forcibly disconnect the
hose with tools.
d. Connect the pressure gauge “1” and the fuel
pressure adapter “2” to the fuel hose.
1
Pressure gauge
90890-03153
YU-03153
Fuel pressure adapter
90890-03186
YM-03186
7-3
FUEL TANK
CHECKING AND REPLACING THE PRO-

1 TECTOR
1. Check:
• Protector “1”
2 TIP
Affix the protector as shown.
A
1
e. Start the engine.
f. Measure the fuel pressure.
Out of specification  Replace the fuel
pump.
Fuel pressure
324.0 kPa (3.24 kgf/cm2, 47.0 0 mm
(0 in)
psi)
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ B
1
CHECKING THE DAMPER
EAS1SM1313
1. Check:
• Damper 1 “1”
15 mm
TIP (0.59 in)
• Affix dampers 1 and 3 with the arrow on each 1
damper pointing outward. A. Left
• Affix the damper 2 with its projection “a” facing B. Right
the rear of the vehicle.
84 mm 115 mm
1 (3.31 in) (4.53 in) 3
a
2
1 84 mm 115 mm 3
(3.31 in) (4.53 in)
EAS1SM1314
7-4
THROTTLE BODY
THROTTLE BODY
EAS1SM1315
Removing the throttle body
7 Nm (0.7 m•kgf, 5.1 ft •Ibf)
T .R
2
.
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)
T .R
.
3.5 Nm (0.35 m•kgf, 2.5 ft •Ibf)
T.R
.
4
5
3
7 1 9
3.5 Nm (0.35 m•kgf, 2.5 ft •Ibf)

T.R
.
10
6
8 11
3.0 Nm (0.30 m•kgf, 2.2 ft •Ibf)

T.R
.


Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 4-1.
ECU Refer to “ENGINE REMOVAL” on page 5-1.
Ignition coil Refer to “ENGINE REMOVAL” on page 5-1.

1 Intake air temperature sensor coupler 1 Disconnect.
2 Air filter case 1
3 Fuel injector coupler 1 Disconnect.
4 Intake air pressure sensor coupler 1 Disconnect.
5 Throttle position sensor coupler 1 Disconnect.
6 Throttle cable cover 1
7 Throttle cable 2
8 Fuel hose 1
9 Exhaust pipe bracket 1
7-5
THROTTLE BODY
Removing the throttle body
7 Nm (0.7 m•kgf, 5.1 ft •Ibf)
T .R
2
.
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)
T .R
.
3.5 Nm (0.35 m•kgf, 2.5 ft •Ibf)
T.R
.
4
5
3
7 1 9
3.5 Nm (0.35 m•kgf, 2.5 ft •Ibf)

T.R
.
10
6
8 11
3.0 Nm (0.30 m•kgf, 2.2 ft •Ibf)

T.R
.

10 Throttle body 1
11 Throttle body joint 1
dure.
7-6
THROTTLE BODY
Removing the injector
3.4 Nm (0.34 m kgf, 2.5 ft lbf) 1
T.R
.
(2)
5 Nm (0.5 m kgf, 3.6 ft lbf)

T .R
.
2
5
3.4 Nm (0.34 m kgf, 2.5 ft lbf)

T.R
.
(2)
3

1 Fuel inlet pipe 1
2 Injector 1
3 Gaskets 1
4 Throttle position sensor 1
5 Intake air pressure sensor 1

dure.
7-7
THROTTLE BODY
CHECKING THE INJECTOR

EAS1SM1316
1. Check:
• Injector
Obstruction  Replace, and check the fuel
pump and the fuel injection system.
Refer to “FUEL INJECTION SYSTEM” on
page 8-10.
Deposits  Replace.
Damage  Replace.
2. Check: 3
• Injector resistance
Refer to “CHECKING THE FUEL INJEC- b
a
TOR” on page 8-47.
CHECKING THE THROTTLE BODY
EAS1SM1317
1. Check:
• Throttle body
Cracks/damage  Replace.
2. Check:
• Fuel passages
Obstructions  Clean.
ECA1DX1027 3. Check:
NOTICE • Starter knob/idle screw passage “c”
• Before removing the throttle body, clean Obstruction  Blow out with compressed
the area around the throttle body to pre- air.
vent dirt and other foreign material from
falling into the engine.
• If the throttle body is subject to strong
shocks or dropped during cleaning, re-
place it.
• Do not use any caustic carburetor clean-
ing solution.
• Do not directly push the throttle valves to c
open them.
• Do not loosen the throttle valve stopper
screw “1”, throttle valve pulley nut “2”, or CHECKING THE THROTTLE BODY JOINT
EAS1SM1318
throttle valve screw “3”. A loss of perfor- 1. Check:

mance may occur. • Throttle body joint “1”
• Do not use compressed air to clean the Crack/damage  Replace.
throttle body. Foreign materials may ad-
here to the intake air pressure sensor pas-
sage “a” and fuel injector “b” in the
throttle body.
1
2 EAS1SM1319
7-8
THROTTLE BODY
ADJUSTING THE THROTTLE POSITION

SENSOR
EWA32D1011
WARNING
• Handle the throttle position sensor with
special care.
• Never subject the throttle position sensor
to strong shocks. If the throttle position
sensor is dropped, replace it.
1. Check:
• Throttle position sensor
Refer to “CHECKING THE THROTTLE PO-
SITION SENSOR” on page 8-44.
2. Adjust:
• Throttle position sensor angle
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the Yamaha diagnostic tool.
Refer to “YAMAHA DIAGNOSTIC TOOL” on
page 8-12.
Yamaha diagnostic tool
90890-03215
b. Temporary tighten the throttle position sen-

sor.
c. Check that the throttle grip is fully closed.
d. Connect the throttle position sensor to the
wire harness.
e. Set the Yamaha diagnostic tool to “diagnos-
tic mode”.
f. Choose the diagnostic code No. “01”.
g. Adjust the throttle position sensor mounted
angle until “11–14” appears on the Yamaha
diagnostic tool.
h. After adjusting the throttle position sensor
mounted angle, tighten the throttle position
sensor screws “1”.
Throttle position sensor screw
3.4 Nm (0.34 m·kgf, 2.5 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-9
ELECTRICAL SYSTEM
IGNITION SYSTEM ..........................................................................................8-2

CIRCUIT DIAGRAM ...................................................................................8-2
TROUBLESHOOTING ...............................................................................8-4
CHARGING SYSTEM.......................................................................................8-6
CIRCUIT DIAGRAM ...................................................................................8-6
TROUBLE SHOOTING ..............................................................................8-8
FUEL INJECTION SYSTEM...........................................................................8-10

CIRCUIT DIAGRAM .................................................................................8-10
YAMAHA DIAGNOSTIC TOOL ................................................................8-12
TROUBLESHOOTING DETAILS .............................................................8-13
FUEL PUMP SYSTEM....................................................................................8-32

CIRCUIT DIAGRAM .................................................................................8-32
TROUBLESHOOTING .............................................................................8-34
ELECTRICAL COMPONENTS.......................................................................8-36
..................................................................................................................8-36
CHECKING THE SWITCHES ..................................................................8-38
CHECKING THE IGNITION SPARK GAP................................................8-41
CHECKING THE SPARK PLUG CAP ......................................................8-41
CHECKING THE IGNITION COIL ............................................................8-41
CHECKING THE CRANKSHAFT POSITION SENSOR...........................8-42
CHECKING THE ECU..............................................................................8-43
CHECKING THE STATOR COIL .............................................................8-43
CHECKING THE RECTIFIER/REGULATOR ...........................................8-43
CHECKING THE COOLANT TEMPERATURE SENSOR........................8-44
CHECKING THE THROTTLE POSITION SENSOR ................................8-44
CHECKING THE THROTTLE POSITION SENSOR
INPUT VOLTAGE ....................................................................................8-45
CHECKING THE INTAKE AIR PRESSURE SENSOR ............................8-46
8
CHECKING THE INTAKE AIR TEMPERATURE SENSOR .....................8-46
CHECKING THE NEUTRAL SWITCH .....................................................8-46
CHECKING THE FUEL INJECTOR .........................................................8-47
EAS1SM1320
TIP
mechanical damage.
8-1
EAS1SM1322
EAS1SM1321
A
B B B B B R R R R R R R
4 B/L B/L B/L B/L B/L B/L P P P L L L
O R R O
R R R R R R R B B B B B P P P L L L B/L B/LB/LB/LB/LB/L (BLACK) (BLACK)
A B
CIRCUIT DIAGRAM
B/L Gy B/L Gy
R B
IGNITION SYSTEM
R R A R 10
Gy B/L B R
1
Gy
O O A O
6 B/W Lg R
R
2 3 R R
11
R Lg Lg O
B R R B B/W
5
B
12
R/B R/B R
B/W
R R/B
B
B/Y
B/Y 13
B B B B/Y B B/R B/R R
7
B/R R
8-2
B
14
Br/W Br/W B/L
B Br/W B/L
15
G/W G/W B/L
G/W B/L
L
16
B
L
8 P P
P Y Y L Y B/L
Sb Sb
B/Y P P P B/L
Sb Sb
P/B
17
B/L L
B/L
P/B
B/L P/B L
B Gy R B/W B/L L Y P/B G/W B/R

R/B Lg Br/W P
O B/Y Sb
IGNITION SYSTEM
IGNITION SYSTEM

2. AC magneto
3. Rectifier/regulator
4. Joint connector
5. Condenser
7. Engine stop switch
9. ECU
10.Ignition coil
11.Spark plug
EAS1SM1323
8-3
IGNITION SYSTEM
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
Before troubleshooting, remove the following part(s):
1. Side cover (left/right)
2. Seat
3. Fuel tank
4. Air scoop (left/right)
5. Air filter case cover
1. Check the ignition system wire har- NG 

Reconnect.
ness connections.
OK 
2. Check the spark plug. NG 

Refer to “CHECKING THE SPARK Correct or replace the spark plug.
PLUG” on page 3-35.
OK 
3. Check the ignition spark gap. OK 

Refer to “CHECKING THE IGNI- The ignition system circuit is OK.
TION SPARK GAP” on page 8-41.
NG 
4. Check the ignition coil. NG 

Refer to “CHECKING THE IGNI- Replace the ignition coil.
TION COIL” on page 8-41.
OK 
5. Check the engine stop switch. NG 

Refer to “CHECKING THE Replace the engine stop switch.
SWITCHES” on page 8-38.
OK 
6. Check the crankshaft position sen- NG 

sor.
Refer to “CHECKING THE CRANK- Replace the crankshaft position sensor.
SHAFT POSITION SENSOR” on
page 8-42.
OK 
7. Check the stator coil. NG 

Refer to “CHECKING THE STA- Replace the stator coil.
TOR COIL” on page 8-43.
OK 
8-4
IGNITION SYSTEM
8. Check the ignition system wire har- NG 

ness.
Repair or replace the wire harness.
Refer to “CIRCUIT DIAGRAM” on
page 8-2.
OK 
Replace the ECU.
8-5
EAS27200
EAS1SM1324
A
O R R O
A B
CIRCUIT DIAGRAM
B/L Gy B/L Gy
R B
R R A R 10
Gy B/L B R
1
CHARGING SYSTEM
Gy
O O A O
6 B/W Lg R
R
2 3 R R
11
R Lg Lg O
B R R B B/W
5
B
12
R/B R/B R
B/W
R R/B
B
B/Y
B/Y 13
7
B/R R
8-6
B
14
Br/W Br/W B/L
B Br/W B/L
15
G/W G/W B/L
G/W B/L
L
16
B
L
8 P P
P Y Y L Y B/L
Sb Sb
B/Y P P P B/L
Sb Sb
P/B
17
B/L L
B/L
P/B
B/L P/B L

R/B Lg Br/W P
O B/Y Sb
CHARGING SYSTEM
CHARGING SYSTEM
2. AC magneto
4. Joint connector
5. Condenser
EAS1SM1325
8-7
CHARGING SYSTEM
TROUBLE SHOOTING
The condenser is not being charged.
TIP
Before troubleshooting, remove the following part (s):
1. Seat
2. Air scoop (left)
1. Check the entire charging system’s NG 

Reconnect.
wiring.
OK 
2. Check the rectifier/regulator. NG 

Refer to “CHECKING THE RECTI- Replace the rectifier/regulator.
FIER/REGULATOR” on page 8-43.
OK 
3. Check the stator coil. NG 

Refer to “CHECKING THE STA- Replace the stator coil.
TOR COIL” on page 8-43.
OK 
4. Check the charging system wire NG 

harness.
page 8-6.
OK 
Replace the condenser.
8-8
CHARGING SYSTEM
EAS1SM1326
8-9
EAS1SM1327
A
O R R O
A B
CIRCUIT DIAGRAM
B/L Gy B/L Gy
R B
R R A R 10
Gy B/L B R
1
Gy
O O A O
6 B/W Lg R
R
2 3 R R
11
R Lg Lg O
B R R B B/W
5
FUEL INJECTION SYSTEM
B
12
R/B R/B R
B/W
R R/B
B
B/Y
B/Y 13
7
B/R R
8-10
B
14
Br/W Br/W B/L
B Br/W B/L
15
G/W G/W B/L
G/W B/L
L
16
B
L
8 P P
P Y Y L Y B/L
Sb Sb
B/Y P P P B/L
Sb Sb
P/B
17
B/L L
B/L
P/B
B/L P/B L

R/B Lg Br/W P
O B/Y Sb

2. AC magneto
4. Joint connector
5. Condenser
8. Neutral switch
9. ECU
12.Fuel injector
14.Intake air temperature sensor
15.Coolant temperature sensor
16.Throttle position sensor
17.Intake air pressure sensor
EAS1SM1328
8-11
YAMAHA DIAGNOSTIC TOOL

This model uses the Yamaha diagnostic tool to identify malfunctions.
For information about using the Yamaha diagnostic tool, refer to the operation manual that is included
with the tool.
Yamaha diagnostic tool
90890-03215
FEATURES OF THE YAMAHA DIAGNOSTIC TOOL

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

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

1. Remove the coupler for connecting setting tool.
8-12
2. Connect the FI diagnostic tool sub-lead.

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

TIP
• Prepare the fully charged 12 V battery for yourself.
• For information on how to connect and use the Yamaha diagnostic tool, refer to “YAMAHA DIGNO-
STIC TOOL OPERATION MANUAL”.
1
6
2 3 4 5
2
1. Vehicle
2. Coupler for connecting optional part
3. FI diagnostic tool sub-lead
4. Sub-harness (included with the Yamaha di-
agnostic tool)
5. Vehicle communication cable (included with
the Yamaha diagnostic tool)
6. Yamaha diagnostic tool
7. Battery (12 V)
TROUBLESHOOTING DETAILS
EAS1SM1329
This section describes the measures per fault code No. displayed on the Yamaha diagnostic tool.
Check and service the items or components that are the probable cause of the malfunction following
the order given in the troubleshooting chart.
After the check and service of the malfunctioning part have been completed, reset the Yamaha diag-
nostic tool display according to the “Reinstatement method”.
Fault code No.: To be displayed on the Yamaha diagnostic tool when the engine fails to work nor-
mally
Diagnostic code No.: To be used when the diagnostic mode is active
8-13
Fault code 12
Crankshaft position sensor: no normal signals are received
Symptom
from the crankshaft position sensor.
Fail-safe system Unable to start engine
Unable to drive vehicle
Diagnostic code No. —
Diagnostic tool display —
Procedure —
Or- Probable cause of malfunc-
Maintenance job Reinstatement method
der tion and check
1 Connection of crankshaft po- Improperly connected  Crank the engine.
sition sensor coupler. Connect the coupler secure- Fault code No. is not dis-
Check the locking condition ly, or repair/replace the wire played  Repair is finished.
of the coupler. harness. Fault code No. is displayed 
Disconnect the coupler, and Go to next order.
check the pins (for bent or
broken terminals and locking
condition of the pins).
2 Connection of wire harness Improperly connected  Crank the engine.
ECU coupler. Connect the coupler secure- Fault code No. is not dis-
Check the locking condition ly, or repair/replace the wire played  Repair is finished.
of the coupler. harness. Fault code No. is displayed 
Disconnect the coupler, and Go to next order.
check the pins (for bent or
3 Wire harness continuity. Open or short circuit  Re- Crank the engine.
place the wire harness. Fault code No. is not dis-
Between the crankshaft posi- played  Repair is finished.
tion sensor coupler and ECU Fault code No. is displayed 
coupler. Go to next order.
gray–gray
black/blue–black/blue
4 Mounted condition of crank- Improperly mounted sensor Crank the engine.
shaft position sensor.  Remount or replace the Fault code No. is not dis-
Check for looseness or sensor. “AC MAGNETO” on played  Repair is finished.
pinching. page 5-58. Fault code No. is displayed 
Check the gap between the Go to next order.
crankshaft position sensor
and the pickup rotor.
5 Defective crankshaft position Check the crankshaft position Crank the engine.
sensor. sensor. Fault code No. is not dis-
“CHECKING THE CRANK- played  Repair is finished.
SHAFT POSITION SEN- Fault code No. is displayed 
SOR” on page 8-42. Go to next order.
6 Faulty ECU Replace the ECU.
8-14
TIP
If fault code Nos. 13 and 14 are both displayed, perform checkup and repair jobs for fault code No.
13 first.
Fault code 13
Symptom Intake air pressure sensor: open or short circuit detected.
Fail-safe system Able to start engine
Able to drive vehicle
Diagnostic code No. 03
Diagnostic tool display Displays the intake air pressure.
Procedure The atmospheric pressure is displayed on the Yamaha diagnostic
tool.
der tion and check
1 Connection of intake air pres- Improperly connected  Turn “ON” the switch on the
sure sensor coupler. Connect the coupler secure- FI diagnostic tool sub-lead.
Check the locking condition ly, or repair/replace the wire Fault code No. is not dis-
of the coupler. harness. played  Repair is finished.
Disconnect the coupler, and Fault code No. is displayed 
check the pins (for bent or Go to next order.
2 Connection of wire harness Improperly connected  Turn “ON” the switch on the
ECU coupler. Connect the coupler secure- FI diagnostic tool sub-lead.
3 Connection of sub wire har- Improperly connected  Turn “ON” the switch on the
ness coupler. Connect the coupler secure- FI diagnostic tool sub-lead.
Check the locking condition ly, or repair/replace the sub- Fault code No. is not dis-
of the coupler. wire harness. played  Repair is finished.
4 Wire harness continuity. Open or short circuit  Re- Turn “ON” the switch on the
place the wire harness. FI diagnostic tool sub-lead.
Between intake air pressure Fault code No. is not dis-
sensor coupler and ECU cou- played  Repair is finished.
pler. Fault code No. is displayed 
pink/black–pink/black Go to next order.
blue–blue
5 Mounted condition of intake Improperly mounted sensor Turn “ON” the switch on the
air pressure sensor.  Remount or replace the FI diagnostic tool sub-lead.
Check for looseness or sensor. Fault code No. is not dis-
pinching. played  Repair is finished.
Check the mounted position Fault code No. is displayed 
for correctness. Go to next order.
8-15
Fault code 13
Symptom Intake air pressure sensor: open or short circuit detected.
6 Defective intake air pressure Execute the diagnostic mode. Turn “ON” the switch on the
sensor. (Code No.03) FI diagnostic tool sub-lead.
Atmospheric pressure at the Fault code No. is not dis-
current altitude and weather played  Repair is finished.
conditions is indicated. Fault code No. is displayed 
0 m above sea level: About Go to next order.
101 kPa
1000 m above sea level:
About 90 kPa
About 80 kPa
About 70 kPa
TIP
If fault code Nos. 13 and 14 are both displayed, perform checkup and repair jobs for fault code No.
13 first.
Fault code 14
Intake air pressure sensor: hose system malfunction (clogged
Symptom
or detached hose)
Diagnostic tool display Displays the intake air pressure.
Procedure The atmospheric pressure is displayed on the Yamaha diagnostic
tool.
der tion and check
1 The intake air pressure sen- Repair or replace the sensor After starting the engine, idle
sor hose is damaged, discon- hose. this and wait about 5 sec-
nected, clogged, twisted or onds.
bent. Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
8-16
Fault code 14
Intake air pressure sensor: hose system malfunction (clogged
Symptom
or detached hose)
2 Defective intake air pressure Execute the diagnostic mode.
sensor. (Code No. 03)
Atmospheric pressure at the
current altitude and weather
conditions is indicated.
0 m above sea level: About
101 kPa
About 90 kPa
About 80 kPa
About 70 kPa
Fault code 15
Symptom Throttle position sensor: open or short circuit detected.
Diagnostic tool display Displays the throttle angle.
• 11–14 (throttle in fully closed position)
• 109–116 (throttle in fully opened position)
Procedure Check with throttle valves fully closed.
Check with throttle valves fully opened.
der tion and check
1 Connection of throttle posi- Improperly connected  Turn “ON” the switch on the
tion sensor coupler. Connect the coupler secure- FI diagnostic tool sub-lead.
8-17
Fault code 15
Symptom Throttle position sensor: open or short circuit detected.
3 Connection of sub wire har- Improperly connected  Turn “ON” the switch on the
ness coupler. Connect the coupler secure- FI diagnostic tool sub-lead.
Check the locking condition ly, or repair/replace the sub- Fault code No. is not dis-
of the coupler. wire harness. played  Repair is finished.
Between throttle position Fault code No. is not dis-
yellow–yellow Go to next order.
blue–blue
5 Mounted condition of throttle Improperly mounted sensor Turn “ON” the switch on the
position sensor.  Remount or replace the FI diagnostic tool sub-lead.
pinching. Refer to “ADJUSTING THE played  Repair is finished.
Check the mounted condition THROTTLE POSITION SEN- Fault code No. is displayed 
for correctness. SOR” on page 7-9. Go to next order.
6 Applied voltage of throttle po- Check the applied voltage. Turn “ON” the switch on the
sition sensor lead. (black/blue–blue) FI diagnostic tool sub-lead.
Refer to “CHECKING THE Fault code No. is not dis-
THROTTLE POSITION SEN- played  Repair is finished.
SOR” on page 8-44. Fault code No. is displayed 
Location of discon- Output Go to next order.
nected lead voltage
Disconnected 5V
ground lead
Disconnected out- 0 V
put lead
Disconnected 0V
power supply lead
7 Defective throttle position Execute the diagnostic mode. Turn “ON” the switch on the
sensor. (Code No. 1) FI diagnostic tool sub-lead.
When the throttle is fully Fault code No. is not dis-
closed, 11–14 displays. played  Repair is finished.
When the throttle is fully Fault code No. is displayed 
opened, 109–116 displays. Go to next order.
Incorrect display range 
Replace the throttle position
sensor.
8-18
Fault code 16
Throttle position sensor: stuck throttle position sensor is de-
Symptom
tected.
Diagnostic tool display Displays the throttle angle.
• 11–14 (throttle in fully closed position)
• 109–116 (throttle in fully opened position)
Procedure Check with throttle valves fully closed.
Check with throttle valves fully opened.
der tion and check
1 Mounted condition of throttle Improperly mounted sensor Turn “ON” the switch on the
position sensor.  Remount or replace the FI diagnostic tool sub-lead.
pinching. Refer to “ADJUSTING THE played  Repair is finished.
Check the mounted condition THROTTLE POSITION SEN- Fault code No. is displayed 
for correctness. SOR” on page 7-9. Go to next order.
2 Defective throttle position Execute the diagnostic mode. Turn “ON” the switch on the
sensor. (Code No. d:01) FI diagnostic tool sub-lead.
When the throttle is fully Fault code No. is not dis-
closed, 11–14 displays. played  Repair is finished.
When the throttle is fully Fault code No. is displayed 
opened, 109–116 displays. Go to next order.
Incorrect display range 
Replace the throttle position
sensor.
8-19
TIP
Make sure that the machine is completely cold before checking the coolant temperature sensor.
Fault code 21
Symptom Coolant temperature sensor: open or short circuit detected.
Diagnostic tool display Displays the coolant temperature.
Procedure Compare the actually measured coolant temperature with the
Yamaha diagnostic tool display value.
der tion and check
1 Connection of coolant tem- Improperly connected  Turn “ON” the switch on the
perature sensor coupler. Connect the coupler secure- FI diagnostic tool sub-lead.
Between coolant temperature Fault code No. is not dis-
green/white–green/white Go to next order.
4 Mounted condition of coolant Improperly mounted sensor Turn “ON” the switch on the
temperature sensor.  Remount or replace the FI diagnostic tool sub-lead.
Check the mounted condition Fault code No. is displayed 
5 Defective coolant tempera- Execute the diagnostic mode. Turn “ON” the switch on the
ture sensor. (Code No. 06) FI diagnostic tool sub-lead.
When the machine is cold, Fault code No. is not dis-
displayed temperature is played  Repair is finished.
close to the ambient temper- Fault code No. is displayed 
ature. Go to next order.
Improper display  Replace
the coolant temperature sen-
sor.
8-20
TIP
Make sure that the machine is completely cold before checking the intake air temperature sensor.
Fault code 22
Symptom Intake air temperature sensor: open or short circuit detected.
Diagnostic tool display Displays the intake air temperature.
Procedure Compare the actually measured intake air temperature with the
Yamaha diagnostic tool display value.
der tion and check
1 Connection of intake air tem- Improperly connected  Turn “ON” the switch on the
perature sensor coupler. Connect the coupler secure- FI diagnostic tool sub-lead.
Between intake air tempera- Fault code No. is not dis-
ture sensor coupler and ECU played  Repair is finished.
coupler. Fault code No. is displayed 
brown/white–brown/white Go to next order.
4 Mounted condition of intake Improperly mounted sensor Turn “ON” the switch on the
air temperature sensor.  Remount or replace the FI diagnostic tool sub-lead.
Check the mounted condition Fault code No. is displayed 
5 Defective intake air tempera- Execute the diagnostic mode. Turn “ON” the switch on the
ture sensor. (Code No. 05) FI diagnostic tool sub-lead.
When the machine is cold, Fault code No. is not dis-
displayed temperature is played  Repair is finished.
close to the ambient temper- Fault code No. is displayed 
ature. Go to next order.
the intake air temperature
sensor.
8-21
Fault code 30
Symptom The vehicle has overturned.
Diagnostic tool display Displays the lean angle sensor output voltage.
• 1.0 V (upright)
• 4.0 V (overturned)
Procedure Remove the ECU, and incline it 45 ° or more.
der tion and check
1 The vehicle has overturned. Raise the vehicle upright. Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Fault code No. is not dis-
Go to next order.
2 Mounted condition of ECU. Improperly mounted ECU  Turn “ON” the switch on the
Check for looseness or Remount the ECU. FI diagnostic tool sub-lead.
pinching. Fault code No. is not dis-
Check the mounted condition played  Repair is finished.
for correctness. Fault code No. is displayed 
Go to next order.
3 Faulty ECU Execute the diagnostic mode.
(Code No. 08)
When the vehicle is upright:
1.0 V
When the vehicle is over-
turned: 4.0 V
the ECU.
8-22
Fault code 33
Ignition coil: open or short circuit detected in the primary lead
Symptom
of the ignition coil.
Actuation Actuates the ignition coil five times at one-second intervals.
“WARNING” on the Yamaha diagnostic tool blinks five times when-
ever the ignition coil is actuated.
Procedure Check that a spark is generated five times.
• Connect an ignition checker.
der tion and check
1 Connection of ignition coil Improperly connected  After starting the engine, idle
coupler. Connect the coupler secure- this and wait about 5 sec-
Check the locking condition ly, or repair/replace the wire onds.
of the coupler. harness. Fault code No. is not dis-
Disconnect the coupler, and played  Repair is finished.
check the pins (for bent or Fault code No. is displayed 
broken terminals and locking Go to next order.
2 Connection of wire harness Improperly connected  After starting the engine, idle
ECU coupler. Connect the coupler secure- this and wait about 5 sec-
3 Wire harness continuity. Open or short circuit  Re- After starting the engine, idle
place the wire harness. this and wait about 5 sec-
Between ignition coil coupler onds.
and ECU coupler. Fault code No. is not dis-
orange–orange played  Repair is finished.
Go to next order.
4 Mounted condition of ignition Improperly mounted ignition After starting the engine, idle
coil. coil  Remount or replace this and wait about 5 sec-
Check for looseness or the ignition coil. onds.
pinching. Fault code No. is not dis-
Check the mounted condition played  Repair is finished.
for correctness. Fault code No. is displayed 
Go to next order.
5 Defective ignition coil (test Check the primary resistance After starting the engine, idle
the primary coils for continu- of the ignition coil. this and wait about 5 sec-
ity). “CHECKING THE IGNITION onds.
COIL” on page 8-41. Fault code No. is not dis-
Go to next order.
8-23
Fault code 33
Ignition coil: open or short circuit detected in the primary lead
Symptom
of the ignition coil.
6 Faulty ECU Execute the diagnostic mode.
(Code No. 30)
No spark  Replace the
ECU.
TIP
Disconnect the fuel pump coupler when this diagnostic tool is used.
Fault code 39
Symptom Injector: open or short circuit detected.
Actuation Actuates injector five times at one-second intervals.
“WARNING” on the Yamaha diagnostic tool blinks five times when
the injector is actuated.
Procedure Check that injector is actuated five times by listening for the oper-
ating sound.
der tion and check
1 Connection of injector cou- Improperly connected  After starting the engine, idle
pler. Connect the coupler secure- this and wait about 5 sec-
2 Defective injector. Check the injector. After starting the engine, idle
“CHECKING THE FUEL IN- this and wait about 5 sec-
JECTOR” on page 8-47. onds.
Go to next order.
ECU coupler. Connect the coupler secure- this and wait about 5 sec-
8-24
Fault code 39
Symptom Injector: open or short circuit detected.
4 Connection of sub wire har- Improperly connected  After starting the engine, idle
ness coupler. Connect the coupler secure- this and wait about 5 sec-
Check the locking condition ly, or repair/replace the sub- onds.
of the coupler. wire harness. Fault code No. is not dis-
place the wire harness. this and wait about 5 sec-
Between injector coupler and onds.
ECU coupler. Fault code No. is not dis-
red/black–red/black played  Repair is finished.
Between injector coupler and Fault code No. is displayed 
rectifier/regulator coupler Go to next order.
red/red
Fault code 41
Symptom ECU: built-in lean angle sensor malfunction
Diagnostic tool display Displays the lean angle sensor output voltage.
• 1.0 V (upright)
• 4.0 V (overturned)
Procedure Remove the ECU, and incline it 45° or more.
der tion and check
8-25
Fault code 44
EEPROM fault code No.: an error is detected while reading or
Symptom
writing on EEPROM.
Fail-safe system Able/Unable to start engine
Able/Unable to drive vehicle
Diagnostic tool display Displays the location of the abnormal portion of the EEPROM data.
• 00: No fault
• 01: CO adjustment valve
• 07: Power Tuner injection correction setting 0–8, or Power Tuner
ignition timing correction setting 0–8
Procedure —
der tion and check
1 Identification of malfunction- Execute the diagnostic mode.
ing point. (Code No. 60)
00: Perform a checkup in or-
der 4.
der 2.
der 3.
2 “01” is indicated in Diagnostic Change the CO concentra- Turn “ON” the switch on the
mode (Code No. 60). EEP- tion, and rewrite in EEPROM. FI diagnostic tool sub-lead.
ROM data error for adjust- After this adjustment, turn Fault code No. is not dis-
ment of CO concentration. OFF the switch on the FI di- played  Repair is finished.
agnostic tool sub-lead, and Fault code number is dis-
turn it ON again. played  Repeat the proce-
Memory not recovered  Re- dure in order 1. If the same
place the ECU. number is indicated, perform
the procedure in order 3.
3 “07” is indicated in Diagnostic Erase the setting map in the Turn “ON” the switch on the
mode (Code No. 60). EE- diagnostic mode. FI diagnostic tool sub-lead.
PROM data error for setting (Code No. 65) Fault code No. is not dis-
tool adjustment values for played  Repair is finished.
fuel injection amount or igni- Fault code number is dis-
tion timing. played  Repeat the proce-
dure in order 1. If the same
number is indicated, perform
the procedure in order 4.
8-26
Fault code 46
Vehicle system power supply: normal voltage is not supplied
Symptom to the ECU.
Fail-safe system Able/Unable to start engine

Able/Unable to drive vehicle
Procedure —
der tion and check
ECU coupler. Connect the coupler secure- this, turn “OFF” the switch on
Check the locking condition ly, or repair/replace the wire the FI diagnostic tool sub-
of the coupler. harness. lead, and wait about 5 sec-
Disconnect the coupler, and onds or more.
check the pins (for bent or Fault code No. is not dis-
broken terminals and locking played  Repair is finished.
condition of the pins). Fault code No. is displayed 
Go to next order.
place the wire harness. this, turn “OFF” the switch on
Between rectifier/regulator the FI diagnostic tool sub-
and ECU coupler lead, and wait about 5 sec-
red–red onds or more.
Between condenser and Fault code No. is not dis-
ECU coupler played  Repair is finished.
red–red Fault code No. is displayed 
Go to next order.
3 Faulty AC magneto Check the AC magneto. After starting the engine, idle
“CHECKING THE AC MAG- this, turn “OFF” the switch on
NETO” on page 5-59. the FI diagnostic tool sub-
lead, and wait about 5 sec-
onds or more.
Go to next order.
8-27
Fault code 50
Symptom ECU: faulty ECU memory
Procedure —
der tion and check
1 Faulty ECU Replace the ECU. Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Check that the fault code
number is not displayed.
Fault code Waiting for connection

Symptom No communication signal is received from the ECU.
Fail-safe system Able to start engine (Unable when ECU is malfunctioning)
Able to drive vehicle (Unable when ECU is malfunctioning)
Procedure —
der tion and check
1 Connection of Yamaha diag- Improperly connected  Turn “ON” the switch on the
nostic tool coupler. Connect the coupler secure- FI diagnostic tool sub-lead.
light green–light green Fault code No. is not dis-
Go to next order.
8-28
Fault code Waiting for connection

Symptom No communication signal is received from the ECU.
4 Yamaha diagnostic tool mal- Replace the Yamaha diag- Turn “ON” the switch on the
function nostic tool. FI diagnostic tool sub-lead.
Go to next order.
Fault code Er-2

Signals from the ECU cannot be received within the specified
Symptom
period of time.
Procedure —
der tion and check
Go to next order.
Go to next order.
8-29
Fault code Er-3

Symptom Data from the ECU cannot be received correctly.
Procedure —
der tion and check
Go to next order.
Go to next order.
8-30
Fault code Er-4

Registered data cannot be received from the Yamaha diagnos-
Symptom
tic tool.
Procedure —
der tion and check
Go to next order.
Go to next order.
8-31
EAS1SM1331
EAS1SM1330
A
O R R O
A B
CIRCUIT DIAGRAM
B/L Gy B/L Gy
R B
R R A R 10
Gy B/L B R
1
Gy
O O A O
FUEL PUMP SYSTEM
6 B/W Lg R
R
2 3 R R
11
R Lg Lg O
B R R B B/W
5
B
12
R/B R/B R
B/W
R R/B
B
B/Y
B/Y 13
7
B/R R
8-32
B
14
Br/W Br/W B/L
B Br/W B/L
15
G/W G/W B/L
G/W B/L
L
16
B
L
8 P P
P Y Y L Y B/L
Sb Sb
B/Y P P P B/L
Sb Sb
P/B
17
B/L L
B/L
P/B
B/L P/B L

R/B Lg Br/W P
O B/Y Sb
FUEL PUMP SYSTEM
FUEL PUMP SYSTEM
2. AC magneto
4. Joint connector
5. Condenser
9. ECU
13.Fuel pump
EAS1SM1332
8-33
FUEL PUMP SYSTEM
TROUBLESHOOTING
The fuel pump fails to operate.
TIP
Before troubleshooting, remove the following part(s):
1. Seat
2. Side cover (left/right)
3. Air scoop (left/right)
4. Fuel tank
5. Air filter case cover
1. Check the fuel pump system wire NG 

Reconnect.
harness connections.
OK 
2. Check the engine stop switch. NG 

Refer to “CHECKING THE Replace the engine stop switch.
SWITCHES” on page 8-38.
OK 
3. Check fuel pressure. NG 

Refer to “CHECKING THE FUEL Replace the fuel pump.
PRESSURE” on page 7-3.
OK 
4. Check the fuel pump system wire NG 

harness.
page 8-32.
OK 
Replace the ECU.
8-34
FUEL PUMP SYSTEM
EAS1SM1333
8-35
ELECTRICAL COMPONENTS
EAS1SM1334
4
7
10
8-36
4. Injector
6. ECU
7. Ignition coil
8. Condenser
9. Neutral switch
10.Coolant temperature sensor
EAS1SM1335
8-37
CHECKING THE SWITCHES
2
B/Y P
Sb
8-38

2. Neutral switch
8-39
Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check
the wiring connections and if necessary, replace the switch.
ECA14370
NOTICE
Never insert the tester probes into the coupler terminal slots “1”. Always insert the probes
from the opposite end of the coupler, taking care not to loosen or damage the leads.
Pocket tester
90890-03112
YU-03112-C
TIP
• Before checking for continuity, set the pocket tester range to “  1” to make a “0” adjustment.
• When checking for continuity, switch back and forth between the switch positions a few times.
Terminal connections of the switch are shown in the terminal connection diagram below.
The switch positions “a” are shown in the far left column and the switch lead colors are shown in the
top row in the switch illustration.
TIP
“ ” indicates continuity between switch terminals (i.e., a closed circuit at each switch posi-
tion).
The example illustration below shows that:
There is continuity between red and brown when the switch is “ON”.
8-40
CHECKING THE IGNITION SPARK GAP

EAS1SM1336
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1. Check: a. Connect the pocket tester (  1k) to the
• Ignition spark gap spark plug cap.
Out of specification  Perform the ignition
Pocket tester
system troubleshooting. 90890-03112
Refer to “TROUBLESHOOTING” on page 8- Analog pocket tester
4. YU-03112-C
Minimum ignition spark gap
6.0 mm (0.24 in)
TIP
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the spark plug cap from the spark
plug.
b. Connect the ignition checker “1”.
b. Measure the spark plug cap resistance.
Ignition checker
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
90890-06754
CHECKING THE IGNITION COIL
EAS1SM1338
Oppama pet-4000 spark checker

YM-34487 1. Disconnect:
• Ignition coil terminal
c. Crank the engine, and measure the ignition (from the sub wire harness)
spark gap “a”. • Spark plug cap
(from the ignition coil)
2. Check:
• Primary coil resistance
Primary coil resistance
2.16–2.64 
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (  1) to the igni-
tion coil.
2. Spark plug cap
d. Crank the engine, and gradually increase Pocket tester
the spark gap until a misfire occurs. 90890-03112
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
YU-03112-C
CHECKING THE SPARK PLUG CAP
EAS1SM1337
1. Remove: • Positive tester probe 

• Spark plug cap Ignition coil terminal 1 “1”
(from the spark plug lead) • Negative tester probe 
2. Check: Ignition coil terminal 2 “2”
• Spark plug cap resistance
Spark plug cap resistance
10 k
8-41
CHECKING THE CRANKSHAFT POSITION

SENSOR
1. Disconnect:
• Crankshaft position sensor coupler
(from the wire harness)
2. Check:
• Crankshaft position sensor resistance
Crankshaft position sensor resis-
tance
b. Measure the primary coil resistance. 228–342 
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Secondary coil resistance a. Connect the pocket tester (  100) to the
Out of specification  Replace. crankshaft position sensor coupler.
Secondary coil resistance Pocket tester
8.64–12.96 k 90890-03112
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ YU-03112-C
a. Connect the pocket tester (  1k) to the ig-
nition coil. • Positive tester probe 
Gray “1”
Pocket tester • Negative tester probe 
90890-03112 Black “2”
YU-03112-C
• Positive tester probe  1 2

Ignition coil terminal 1 “1”
• Negative tester probe 
Spark plug lead “2”
Gy B
b. Measure the crankshaft position sensor re-

sistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1SM1340
b. Measure the secondary coil resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1SM1339
8-42
CHECKING THE ECU CHECKING THE RECTIFIER/REGULATOR

1. Check: 1. Check:
• Mounted condition of ECU. • Rectifier/regulator output voltage
Improperly mounted  Remount. Out of specification  Replace.
TIP Output voltage
• The lean angle sensor is built into the ECU. 14 V or more at 5000 r/min
• The lean angle sensor stops the engine in
case of a turnover. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• To ensure that the lean angle sensor operates a. Set the digital tachometer to the ignition coil.
correctly, do not change the installed condi-
Digital tachometer
tion of the ECU.
90890-06760
YU-39951-B
CHECKING THE STATOR COIL
EAS1SM1341
1. Disconnect: b. Connect the pocket tester (20 VDC) to the

• Stator coil coupler rectifier/regulator coupler.
(from the wire harness)
2. Check: Pocket tester
• Stator coil resistance 90890-03112
Out of specification  Replace. Analog pocket tester
YU-03112-C
Stator coil resistance
0.624–0.936  • Positive tester probe 
Red “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Negative tester probe 
a. Connect the pocket tester (  1) to the sta- Black “2”
tor coil coupler.
Pocket tester
90890-03112
YU-03112-C
• Positive tester probe 

White “1” W W B R
White “2” 2 1
c. Start the engine and let it run at about 5000
r/min.
d. Measure the output voltage.
1 2 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1SM1343
b. Measure the stator coil resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1SM1342
8-43
CHECKING THE COOLANT TEMPERATURE c. Place a thermometer in the coolant.

SENSOR d. Slowly heat the coolant, and then let it cool
1. Remove: to the specified temperature indicated in the
• Coolant temperature sensor table.
e. Check the coolant temperature sensor for
EWA14130
WARNING
continuity at the temperatures indicated in
• Handle the coolant temperature sensor
the table.
with special care.
• Never subject the coolant temperature
sensor to strong shocks. If the coolant
temperature sensor is dropped, replace it.
2. Check:
• Coolant temperature sensor resistance
Coolant temperature sensor re-
sistance
2.51–2.78 k at 20 °C (68 °F)
210–221  at 100 °C (212 °F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (  1k/100) to
the coolant temperature sensor.
Pocket tester
90890-03112
YU-03112-C

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Green/White “1”
• Negative tester probe  CHECKING THE THROTTLE POSITION
EAS1SM1344
Black/Blue “2” SENSOR

1. Remove:
(from the throttle body)
G/W B/L EWA1DX1009
WARNING
• Handle the throttle position sensor with
special care.
G/W B/L
• Never subject the throttle position sensor
to strong shocks. If the throttle position
1 2 sensor is dropped, replace it.
b. Immerse the coolant temperature sensor in

a container filled with coolant.
TIP
Make sure the coolant temperature sensor ter-
minals do not get wet.
8-44
2. Check: CHECKING THE THROTTLE POSITION

• Throttle position sensor maximum resis- SENSOR INPUT VOLTAGE
tance 1. Check:
Out of specification  Replace. • Throttle position sensor input voltage
Out of specification  Replace the ECU.
Resistance
6.30 k Throttle position sensor input
voltage
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 4–6 V
a. Connect the pocket tester (  1k) to the
throttle position sensor. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the test harness S-pressure sensor
Pocket tester (3P) to the throttle position sensor coupler
90890-03112 and the wire harness.
Analog pocket tester b. Connect the pocket tester (20 VDC) to the
YU-03112-C
test harness S-pressure sensor (3P).
• Positive tester probe  Pocket tester
Blue “1” 90890-03112
• Negative tester probe  Analog pocket tester
Black/Blue “2” YU-03112-C
Test harness S-pressure sensor
(3P)
90890-03207
YU-03207

Blue “1”
Black/Blue “2”
1 2
b. Check the throttle position sensor maximum
resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
TIP
When mounting the throttle position sensor, ad-
just its angle properly. Refer to “ADJUSTING 1 2
THE THROTTLE POSITION SENSOR” on
page 7-9. c. Start the engine.
d. Measure the throttle position sensor input
EAS1SM1345
voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1SM1346
8-45
CHECKING THE INTAKE AIR PRESSURE 2. Check:

SENSOR • Intake air temperature sensor resistance
1. Check: Out of specification  Replace.
• Intake air pressure sensor output voltage
Intake air temperature sensor re-
sistance
Intake air pressure sensor output 290–390  at 80 °C (176 °F)
voltage
3.57–3.71 V at 101.3 kPa ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (  1k/100) to
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ the intake air temperature sensor terminal.
a. Connect the pocket tester (20 VDC) to the
Pocket tester
intake air pressure sensor coupler (wire har-
90890-03112
ness side). Analog pocket tester
Pocket tester YU-03112-C
90890-03112
Analog pocket tester • Positive tester probe 
YU-03112-C Brown/White “1”
• Positive tester probe  Black/Blue “2”
Pink/Black “1”
Black/Blue “2”
P/B
1 2
P/B
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE NEUTRAL SWITCH

EAS1SM1348
2 1
1. Remove:
b. Start the engine. • Neutral switch
c. Measure the intake air pressure sensor out- 2. Check:
put voltage. • Neutral switch
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE INTAKE AIR TEMPERA-

EAS1SM1347
Pocket tester
90890-03112
TURE SENSOR
1. Remove: YU-03112-C
• Intake air temperature sensor
(from the air filter case)
EWA1DX1010
WARNING
• Handle the intake air temperature sensor
with special care.
• Never subject the intake air temperature
sensor to strong shocks. If the intake air
temperature sensor is dropped, replace it.
8-46
Continuity
Positive tester probe 
Sky blue “1” 1 2
Negative tester probe 
Sensor terminal “a”
Continuity
Black/Yellow “2”
Sensor terminal “b”
Continuity c. Measure the fuel injector resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Pink “3”
Sensor terminal “b”
2 3
B/Y P
Sb
1
c a b
CHECKING THE FUEL INJECTOR

EAS1SM1349
1. Remove:
• Fuel injector
Refer to “THROTTLE BODY” on page 7-5.
2. Check:
• Fuel injector resistance
Fuel injector resistance
12.0 
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the fuel injector coupler from the
fuel injector.
b. Connect the pocket tester (  10) to the
fuel injector coupler.
Pocket tester
90890-03112
YU-03112-C

Injector terminal “1”
Injector terminal “2”
8-47
8-48
TROUBLE SHOOTING
TROUBLE SHOOTING.....................................................................................9-1
GENERAL INFORMATION ........................................................................9-1
STARTING FAILURES...............................................................................9-1
INCORRECT ENGINE IDLING SPEED .....................................................9-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ............................9-2
FAULTY GEAR SHIFTING.........................................................................9-2
SHIFT PEDAL DOES NOT MOVE .............................................................9-2
JUMPS OUT OF GEAR..............................................................................9-2
FAULTY CLUTCH ......................................................................................9-2
OVERHEATING .........................................................................................9-2
OVERCOOLING.........................................................................................9-3
POOR BRAKING PERFORMANCE...........................................................9-3
FAULTY FRONT FORK LEGS...................................................................9-3
UNSTABLE HANDLING .............................................................................9-3
LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS.............................9-4
9
TROUBLE SHOOTING
TROUBLE SHOOTING Electrical system

EAS1SM1350
1. Spark plug
GENERAL INFORMATION
EAS1SM1351
• Incorrect spark plug gap

TIP • Incorrect spark plug heat range
The following guide for troubleshooting does • Fouled spark plug
not cover all the possible causes of trouble. It • Worn or damaged electrode
should be helpful, however, as a guide to basic • Worn or damaged insulator
troubleshooting. Refer to the relative procedure 2. Ignition coil
in this manual for checks, adjustments, and re- • Cracked or broken ignition coil body
placement of parts. • Broken or shorted primary or secondary
coils
STARTING FAILURES
EAS1SM1352
3. Ignition system
• Faulty ECU
Engine • Faulty crankshaft position sensor
1. Cylinder and cylinder head • Broken generator rotor woodruff key
• Loose spark plug 4. Switches and wiring
• Loose cylinder head or cylinder • Faulty ECU
• Damaged cylinder head gasket • Faulty engine stop switch
• Damaged cylinder gasket • Broken or shorted wiring
• Worn or damaged cylinder • Faulty neutral switch
• Incorrect valve clearance • Improperly grounded circuit
• Improperly sealed valve • Loose connections
• Incorrect valve-to-valve-seat contact INCORRECT ENGINE IDLING SPEED
EAS1SM1353
• Incorrect valve timing

• Faulty valve spring Engine
• Seized valve 1. Cylinder and cylinder head
2. Piston and piston ring(s) • Incorrect valve clearance
• Improperly installed piston ring • Damaged valve train components
• Damaged, worn or fatigued piston ring 2. Air filter
• Seized piston ring • Clogged air filter element
• Seized or damaged piston
3. Air filter Fuel system
• Improperly installed air filter 1. Throttle body
• Clogged air filter element • Damaged or loose throttle body joint
4. Crankcase and crankshaft • Improperly synchronized throttle bodies
• Improperly assembled crankcase • Improper throttle cable free play
• Seized crankshaft • Flooded throttle body
Fuel system Electrical system

1. Fuel tank 1. Spark plug
• Empty fuel tank • Incorrect spark plug gap
• Clogged fuel tank breather hose • Incorrect spark plug heat range
• Deteriorated or contaminated fuel • Fouled spark plug
• Clogged or damaged fuel hose • Worn or damaged electrode
2. Fuel pump • Worn or damaged insulator
• Faulty fuel pump • Faulty spark plug cap
3. Throttle body 2. Ignition coil
• Deteriorated or contaminated fuel • Broken or shorted primary or secondary
• Sucked-in air coils
• Cracked or broken ignition coil
9-1
TROUBLE SHOOTING
3. Ignition system FAULTY CLUTCH

EAS1SM1358
• Faulty ECU
• Faulty crankshaft position sensor Clutch slips
• Broken generator rotor woodruff key 1. Clutch
POOR MEDIUM-AND-HIGH-SPEED PER-
EAS1SM1354
• Improperly assembled clutch
FORMANCE • Loose or fatigued clutch spring
Refer to “STARTING FAILURES” on page 9-1. • Worn friction plate
• Worn clutch plate
Engine 2. Engine oil
1. Air filter • Incorrect oil level
• Clogged air filter element • Incorrect oil viscosity (low)
• Deteriorated oil
Fuel system
1. Fuel pump Clutch drags
• Faulty fuel pump 1. Clutch
2. Throttle body • Unevenly tensioned clutch springs
• Defective throttle body • Warped pressure plate
3. ECU • Bent clutch plate
• Faulty ECU • Swollen friction plate
• Bent clutch push rod
FAULTY GEAR SHIFTING
EAS1SM1355
• Damaged clutch boss

• Burnt primary driven gear bushing
Shifting is difficult 2. Engine oil
Refer to “CLUTCH” on page 5-35. • Incorrect oil level
SHIFT PEDAL DOES NOT MOVE • Incorrect oil viscosity (high)
EAS1SM1356
• Deteriorated oil
Shift shaft OVERHEATING
EAS1SM1359
• Bent shift shaft

Engine
Shift drum and shift forks 1. Cylinder head and piston
• Foreign object in a shift drum groove • Heavy carbon buildup
• Seized shift fork • Clogged coolant passages
• Bent shift fork guide bar 2. Engine oil
• Incorrect oil level
Transmission
• Incorrect oil viscosity
• Seized transmission gear
• Inferior oil quality
• Foreign object between transmission gears
• Improperly assembled transmission Cooling system
JUMPS OUT OF GEAR 1. Coolant
EAS1SM1357
• Low coolant level

Shift shaft 2. Radiator
• Incorrect shift pedal position • Damaged or leaking radiator
• Improperly returned stopper lever • Faulty radiator cap
• Bent or damaged radiator fin
Shift forks 3. Water pump
• Worn shift fork • Damaged or faulty water pump
• Damaged hose
Shift drum • Improperly connected hose
• Incorrect axial play • Damaged pipe
• Worn shift drum groove • Improperly connected pipe
Transmission
• Worn gear dog
9-2
TROUBLE SHOOTING
Fuel system Malfunction

1. Throttle body • Bent or damaged inner tube
• Damaged or loose throttle body joint • Bent or damaged outer tube
2. Air filter • Broken fork spring
• Clogged air filter element • Bent or damaged damper rod
• Incorrect oil viscosity
Chassis • Incorrect oil level
1. Brake(s)
UNSTABLE HANDLING
EAS1SM1363
• Dragging brake
1. Handlebar
Electrical system • Bent or improperly installed handlebar
1. Spark plug 2. Steering head components
• Incorrect spark plug gap • Improperly installed upper bracket
• Incorrect spark plug heat range • Improperly installed lower bracket
2. Ignition system (improperly tightened ring nut)
• Faulty ECU • Bent steering stem
• Faulty coolant temperature sensor • Damaged ball bearing or bearing race
3. Front fork leg (s)
OVERCOOLING
EAS1SM1360
• Uneven oil levels (both front fork legs)

• Unevenly tensioned fork spring (both front
Cooling system fork legs)
• Faulty coolant temperature sensor • Broken fork spring
POOR BRAKING PERFORMANCE
EAS1SM1361
• Bent or damaged inner tube

• Worn brake pad • Bent or damaged outer tube
• Worn brake disc 4. Swingarm
• Air in hydraulic brake system • Worn bearing or bushing
• Leaking brake fluid • Bent or damaged swingarm
• Defective master cylinder kit 5. Rear shock absorber assembly (-ies)
• Faulty brake caliper kit • Faulty rear shock absorber spring
• Faulty brake caliper seal • Leaking oil or gas
• Loose union bolt 6. Tire (s)
• Damaged brake hose • Uneven tire pressures (front and rear)
• Oil or grease on the brake disc • Incorrect tire pressure
• Oil or grease on the brake pad • Uneven tire wear
• Incorrect brake fluid level 7. Wheel (s)
• Incorrect wheel balance
FAULTY FRONT FORK LEGS
EAS1SM1362
• Broken or loose spoke

• Damaged wheel bearing
Leaking oil • Bent or loose wheel axle
• Bent, damaged, or rusty inner tube • Excessive wheel runout
• Cracked or damaged outer tube 8. Frame
• Improperly installed oil seal • Bent frame
• Damaged oil seal lip • Damaged steering head pipe
• Incorrect oil level (high) • Improperly installed bearing race
• Loose damper rod assembly bolt
• Damaged damper rod assembly bolt copper
washer
• Cracked or damaged cap bolt O-ring
9-3
LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS

EAS1SM1364
LIST OF DIAGNOSTIC CODES

Fault
ITEM Page
code
12 Crankshaft position sensor: no normal signals are received from the
8-14
crankshaft position sensor.
13 Intake air pressure sensor: open or short circuit detected. 8-15
14 Intake air pressure sensor: hose system malfunction (clogged or de-
8-16
tached hose)
15 Throttle position sensor: open or short circuit detected. 8-17
16 Throttle position sensor: stuck throttle position sensor is detected. 8-19
21 Coolant temperature sensor: open or short circuit detected. 8-20
22 Intake air temperature sensor: open or short circuit detected. 8-21
30 The vehicle has overturned. 8-22
33 Ignition coil: open or short circuit detected in the primary lead of the
8-23
ignition coil.
39 Injector: open or short circuit detected. 8-24
41 ECU: built-in lean angle sensor malfunction 8-25
44 EEPROM fault code No.: an error is detected while reading or writing
8-26
on EEPROM.
46 Vehicle system power supply: normal voltage is not supplied to the
8-27
ECU.
50 ECU: faulty ECU memory 8-28
COMMUNICATION ERROR WITH YAMAHA DIAGNOSTIC TOOL

Fault
ITEM Page
code
Waiting No communication signal is received from the ECU.
for con- 8-29
nection
Er-2 Signals from the ECU cannot be received within the specified period
8-29
of time.
Er-3 Data from the ECU cannot be received correctly. 8-30
Er-4 Registered data cannot be received from the Yamaha diagnostic tool. 8-31
9-4
SENSOR OPERATION TABLE

Diag-
nostic
ITEM Display Procedure
code
No.
01 Throttle angle Displays the throttle angle.
• Fully closed position • 11–14 • Check with throttle fully
• Fully opened position • 109–116 closed.
• Check with throttle fully
opened.
03 Pressure of suction pipe Displays the intake air pres- The atmospheric pressure
sure. is displayed on the Yamaha
diagnostic tool.
05 Intake air temperature Displays the intake air tem- Compare the actually mea-
perature. sured intake air tempera-
ture with the Yamaha
diagnostic tool display val-
ue.
06 Coolant temperature Displays the coolant temper- Compare the actually mea-
ature. sured coolant temperature
with the Yamaha diagnostic
tool display value.
08 Lean angle sensor Displays the output voltage. Remove the ECU, and in-
• Upright • 1.0 (V) cline it 45 ° or more.
• Overturn • 4.0 (V)
09 Monitor voltage Displays the voltage of the —
external battery connected to
the Yamaha diagnostic tool.
• Approximately 12.0 (V)
21 Neutral switch Operate the shift pedal.
• Gear in neutral • ON
• Gear not in neutral • OFF
25 Gear position sensor Operate the shift pedal.
• Gear in 1st or 2nd • ON
• Gear not in 1st or 2nd • OFF
60 EEPROM fault code No. —
display
• No fault • 00
• CO adjustment valve • 01
• Power Tuner injection cor- • 07
rection setting 0–8, or
Power Tuner ignition tim-
ing correction setting 0–8
61 Malfunction history ( ) —
code No. display *1
• There is no history. • 00
• There is some history. • Other: Displays the fault
code of ( ).
9-5
Diag-
nostic
ITEM Display Procedure
code
No.
62 Malfunction history ( ) Replace all ( ) with ( )
code No. erasure *1 by the operation start pro-
• There is no history. • 00 cessing.
• There is some history. • Other: Displays the total
number of ( ) and ( ).
64 Setting history display Displays the presence or ab- —
sence of the setting history by
Power Tuner.
• There is no history. • 00
• There is some history. • 01
• History is unknown (Histo- • 02
ry data is damaged).
65 Setting map erasure Displays the presence or ab- Erase all setting maps by
sence of the setting history by the operation start process-
• There is no setting. Power Tuner. ing.
• There is some setting. • 00
• 01
70 Program version number Displays a program version —
No.
*1: Symbols used in the explanations of the malfunction history
: Normal
: There is currently a malfunction or abnormal condition.
: A malfunction or abnormal condition occurred previously, but the affected system or component
is currently operating normally.
ACTUATOR OPERATION TABLE

Diag-
nostic
ITEM Actuation Procedure
code
No.
30 Ignition coil Actuates the ignition coil five Check that a spark is gener-
times at one-second inter- ated five times.
vals. • Connect an ignition
“WARNING” on the Yamaha checker.
diagnostic tool blinks five
times when the ignition coil is
actuated.
36 Injector Actuates the injector five TIP: Before performing
times at one-second inter- this operation, be sure to
vals. disconnect the fuel pump
“WARNING” on the Yamaha coupler.
diagnostic tool blinks five Check that injector is actu-
times when the injector is ac- ated five times by listening
tuated. for the operating sound.
9-6
9-7
TUNING
CHASSIS ........................................................................................................10-1
SELECTION OF THE SECONDARY REDUCTION
RATIO (SPROCKET) ..............................................................................10-1
DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS ................10-1
TIRE PRESSURE.....................................................................................10-2
FRONT FORK SETTING..........................................................................10-2
CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL..........10-2
SETTING OF SPRING AFTER REPLACEMENT ....................................10-3
FRONT FORK SETTING PARTS.............................................................10-3
REAR SUSPENSION SETTING ..............................................................10-3
CHOOSING SET LENGTH ......................................................................10-3
SETTING OF SPRING AFTER REPLACEMENT ....................................10-4
REAR SHOCK ABSORBER SETTING PARTS .......................................10-5
SUSPENSION SETTING (FRONT FORK)...............................................10-6
SUSPENSION SETTING (REAR SHOCK ABSORBER) .........................10-7
10
CHASSIS
CHASSIS DRIVE AND REAR WHEEL SPROCKETS

EAS1SM1366
SETTING PARTS
SELECTION OF THE SECONDARY REDUC-
EAS1SM1367
Part name Type Part number

TION RATIO (SPROCKET)
Drive sprocket “1”
Secondary reduction ratio = Number of
rear wheel sprocket teeth/Number of (STD) 13T 9383B-13218
drive sprocket teeth Rear wheel
sprocket “2”
Secondary reduction ratio
3.846 (50/13) 47T 17D-25447-50
48T 17D-25448-50
<Requirement for selection of secondary gear
reduction ratio> 49T 17D-25449-50
• It is generally said that the secondary gear ra- (STD) 50T 17D-25450-80
tio should be reduced for a longer straight por- 51T 17D-25451-50
tion of a speed course and should be
increased for a course with many corners. Ac- 52T 17D-25452-80
tually, however, as the speed depends on the
ground condition of the day of the race, be
sure to run through the circuit to set the ma-
chine suitable for the entire course.
• In actuality, it is very difficult to achieve set-
tings suitable for the entire course and some
settings may be sacrificed. Thus, the settings
should be matched to the portion of the
course that has the greatest effect on the race
result. In such a case, run through the entire
course while making notes of lap times to find
the best balance; then, determine the second-
ary reduction ratio.
• If a course has a long straight portion where a
machine can run at maximum speed, the ma-
chine is generally set such that it can develop
its maximum revolutions toward the end of the
straight line, with care taken to avoid the en-
gine over-revving.
TIP
Riding technique varies from rider to rider and
the performance of a machine also vary from EAS1SM1369
machine to machine. Therefore, do not imitate

other rider’s settings from the beginning but
choose your own setting according to the level
of your riding technique.
EAS1SM1368
10-1
CHASSIS
TIRE PRESSURE WARNING

Tire pressure should be adjusted to suit the Adjust the oil amount in 5 cm3 (0.2 US oz,
road surface condition of the circuit. 0.2 Imp.oz) increments or decrements. Too
Standard tire pressure small oil amount causes the front fork to
100 kPa (1.0 kgf/cm2,15 psi) produce a noise at full rebound or the rider
to feel some pressure on his hands or body.
• Under a rainy, a muddy, a sandy, or a slippery Alternatively, too large oil amount will
condition, the tire pressure should be lower cause the air spring characteristics to have
for a larger area of contact with the road sur- a tendency to be stiffer with the consequent
face. deteriorated performance and characteris-
tics. Therefore, adjust the front fork within
Extent of adjustment
60–80 kPa (0.6–0.8 kgf/cm2, 9.0– the specified range.
12 psi)
Standard oil amount
• Under a stony or a hard road condition, the 330 cm3 (11.16 US oz, 11.64
tire pressure should be higher to prevent a flat lmp.oz) (USA) (CAN)
tire. 355 cm3 (12.00 US oz, 12.52
lmp.oz) (EUR) (JPN) (AUS) (NZL)
Extent of adjustment (ZAF)
100–120 kPa (1.0–1.2 kgf/cm2, Extent of adjustment
15–18 psi) 300–365 cm3 (10.14–12.34 US
oz, 10.58–12.87 Imp.oz)
FRONT FORK SETTING
EAS1SM1370
The front fork setting should be made depend-

ing on the rider’s feeling of an actual run and
the circuit conditions.
The front fork setting includes the following
three factors:
1. Setting of air spring characteristics
• Change the fork oil amount.
2. Setting of spring preload
• Change the spring.
3. Setting of damping force
• Change the compression damping force.
• Change the rebound damping force.
The spring acts on the load and the damping
force acts on the cushion travel speed.
CHANGE IN AMOUNT AND CHARACTERIS-
EAS1SM1371
TICS OF FORK OIL

Damping characteristic near the final stroke
can be changed by changing the fork oil
amount.
EWA1DX4001
A. Air spring characteristics in relation to oil

amount change
B. Load
C. Stroke
1. Max. oil amount
2. Standard oil amount
3. Min. oil amount
EAS1SM1372
10-2
CHASSIS
SETTING OF SPRING AFTER REPLACE-

MENT a
As the front fork setting can be easily affected
by the rear suspension, take care so that the
front and the rear are balanced (in position etc.)
when setting the front fork.
1. Use of soft spring
• Change the rebound damping force.
Turn out one or two clicks.
Turn in one or two clicks.
TIP
Generally a soft spring gives a soft riding feel-
ing. Rebound damping tends to become stron-
ger and the front fork may sink deeply over a
series of gaps.
2. Use of stiff spring
• Change the rebound damping force. 1
Turn in one or two clicks.
Turn out one or two clicks. REAR SUSPENSION SETTING
EAS1SM1374
TIP The rear shock absorber setting should be

Generally a stiff spring gives a stiff riding feel- made depending on the rider’s feeling of an ac-
ing. Rebound damping tends to become weak- tual run and the circuit conditions.
er, resulting in lack of a sense of contact with The rear suspension setting includes the fol-
the road surface or in a vibrating handlebar. lowing two factors:
1. Setting of spring preload
FRONT FORK SETTING PARTS
EAS1SM1373
• Change the set length of the spring.

• Front fork spring “1” • Change the spring.
Spring I.D. 2. Setting of damping force
Type rate N/ Part number Mark • Change the rebound damping force.
mm (slits) • Change the compression damping force.
SOFT 4.5 1SL-23141-20 |-|| CHOOSING SET LENGTH
EAS1SM1375
1SM-23141-00 — 1. Place a stand or a block under the engine to

STD* 4.6 put the rear wheel above the floor, and mea-
1SL-23141-30 |-|||
sure the length “a” between the rear wheel
1SL-23141-10 — axle center and the rear fender holding bolt.
STD 4.7
1SL-23141-40 |-||||
4.8 1SL-23141-50 |-|||||
4.9 1SL-23141-60 ||-||
STIFF 5.0 1SL-23141-70 ||-|||
*Except for USA and CAN
TIP
The I.D. mark (slits) “a” is proved on the end of
the spring.
10-3
CHASSIS
2. Remove the stand or block from the engine SETTING OF SPRING AFTER REPLACE-
and, with a rider astride the seat, measure MENT
the sunken length “b” between the rear After replacement, be sure to adjust the spring
wheel axle center and the rear fender hold- to the set length [sunken length 90–100 mm
ing bolt. (3.5–3.9 in)] and set it.
1. Use of soft spring
• Adjust to decrease rebound damping force
to compensate for less spring load. Run with
the rebound damping force adjuster one or
two clicks turned out, and readjust it to suit
your preference.
2. Use of stiff spring
• Adjust to increase rebound damping force to
compensate for greater spring load. Run
with the rebound damping force adjuster
3. Loosen the locknut “1” and make adjustment one or two clicks turned in, and readjust it to
by turning the adjuster “2” to achieve the suit your preference.
standard figure from the subtraction of the TIP
length “b” from the length “a”. Adjusting the rebound damping force will be fol-
Standard figure lowed more or less by a change in the com-
90–100 mm (3.5–3.9 in) pression damping force. For correction, adjust
to decrease compression damping force.
TIP EWA1DX4002
WARNING
• If the machine is new and after it is broken in,
the same set length of the spring may change When using a rear shock absorber other
because of the initial fatigue, etc. of the than currently installed, use the one whose
spring. Therefore, be sure to make reevalua- overall length “a” does not exceed the stan-
tion. dard as it may result in faulty performance.
• If the standard figure cannot be achieved by Never use one whose overall length is
adjusting the adjuster and changing the set greater than standard.
length, replace the spring with an optional one
Length “a” of standard shock
and make readjustment. 458.5 mm (18.05 in)
EAS1SM1376
EAS1SM1377
10-4
CHASSIS
REAR SHOCK ABSORBER SETTING

PARTS
• Rear shock spring “1”
Spring
I.D.
Type rate N/ Part number
Mark
mm
1SL-22212-40
(Blue)
SOFT 52 Yellow
1SL-22212-50
(Red)
1SL-22212-60
(Blue)
STD* 54 Pink
1SL-22212-70
(Red)
1SL-22212-20
(Blue)
STD 56 White
1SL-22212-30
(Red)
1SL-22212-00
(Blue) • Extent of adjustment (spring preload)
58 Silver
1SL-22212-10 Maximum Minimum
(Red) Position in which Position in which
1SL-22212-80 the spring is turned the spring is turned
(Blue) in 18 mm (0.71 in) in 1.5 mm (0.06 in)
STIFF 60 Brown from its free length. from its free length.
1SL-22212-90
(Red) TIP
*Except for USA and CAN For the spring preload adjustment, refer to “AD-
TIP JUSTING THE REAR SHOCK ABSORBER
• The I.D. mark “a” is marked at the end of the ASSEMBLY” on page 3-30.
spring.
• Spring specification varies according to the
color of I.D. marks.
10-5
CHASSIS
SUSPENSION SETTING (FRONT FORK)

EAS1SM1378
TIP
• If any of the following symptoms is experienced with the standard position as the base, make reset-
ting by reference to the adjustment procedure given in the same chart.
• Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm
(3.5–3.9 in).
Section
Symptom Medi- Check Adjust
Large Small
Jump um
gap gap
gap
Compression Turn adjuster counterclock-
damping force wise (about 2 clicks) to de-
crease damping.
Stiff over entire
Oil amount Decrease oil amount by about
range
5–10 cm3 (0.2–0.3 US oz, 0.2–
0.4 Imp.oz).
Spring Replace with soft spring.
Outer tube Check for any bends, dents,
Inner tube other noticeable scars, etc. If
any, replace affected parts.
Slide metal Replace with a new one for ex-
Unsmooth tended use.
movement over
entire range Piston metal Replace with a new one for ex-
tended use.
Lower bracket Retighten to specified torque.
tightening
torque
Rebound Turn adjuster counterclock-
Poor initial damping force wise (about 2 clicks) to de-
movement crease damping.
Oil seals Apply grease in oil seal wall.
Compression Turn adjuster clockwise (about
damping force 2 clicks) to increase damping.
Soft over entire
Oil amount Increase oil amount by about
range, bottom-
5–10 cm3 (0.2–0.3 US oz, 0.2–
ing out
0.4 Imp.oz).
Spring Replace with stiff spring.
Stiff toward Decrease oil amount by about
Oil amount
stroke end 5 cm3 (0.2 US oz, 0.2 Imp.oz).
Soft toward Increase oil amount by about 5
stroke end, bot- Oil amount cm3 (0.2 US oz, 0.2 Imp.oz).
toming out
Stiff initial Turn adjuster counterclock-
Compression
movement wise (about 2 clicks) to de-
damping force
crease damping.
10-6
CHASSIS
Section
Large Small
Jump um
gap gap
gap
Compression Turn adjuster clockwise (about
Low front, tend- crease damping.
ing to lower Balance with Set sunken length for 95–100
front posture rear end mm (3.7–3.9 in) when one
passenger is astride seat (low-
er rear posture).
Oil amount Increase oil amount by about 5
cm3 (0.2 US oz, 0.2 Imp.oz).
Compression Turn adjuster counterclock-
crease damping.
Balance with Set sunken length for 90–95
“Obtrusive” rear end mm (3.5–3.7 in) when one
front, tending to passenger is astride seat (up-
upper front pos- per rear posture).
ture
Oil amount Decrease oil amount by about
5–10 cm3 (0.2–0.3 US oz, 0.2–
0.4 Imp.oz).
SUSPENSION SETTING (REAR SHOCK ABSORBER)
EAS1SM1379
TIP
• If any of the following symptoms is experienced with the standard position as the base, make reset-
ting by reference to the adjustment procedure given in the same chart.
• Adjust the rebound damping in 2-click increments or decrements.
• Adjust the low compression damping in 1-click increments or decrements.
• Adjust the high compression damping in 1/6 turn increments or decrements.
Section
Large Small
Jump um
gap gap
gap
Stiff, tending to crease damping.
sink Spring set Set sunken length for 90–100
length mm (3.5–3.9 in) when one
passenger is astride seat.
Rebound Turn adjuster clockwise (about
Spongy and un-
Low compres- Turn adjuster clockwise (about
stable
sion damping 1 click) to increase damping.
10-7
CHASSIS
Section
Large Small
Jump um
gap gap
gap
Heavy and damping force wise (about 2 clicks) to de-
dragging crease damping.
crease damping.
Low compres- Turn adjuster clockwise (about
sion damping 1 click) to increase damping.
Poor road grip-
High compres- Turn adjuster clockwise (about
ping
sion damping 1/6 turn) to increase damping.
Spring set Set sunken length for 90–100
High compres- Turn adjuster clockwise (about
sion damping 1/6 turn) to increase damping.
Spring set Set sunken length for 90–100
Bottoming out
Rebound Turn adjuster clockwise (about
Bouncing damping force 2 clicks) to increase damping.
Turn adjuster counterclock-
High compres-
wise (about 1/6 turn) to de-
sion damping
crease damping.
Stiff travel Spring set Set sunken length for 90–100
10-8
WIRING DIAGRAM
EAS1SM1381
YZ250F 2014
2. AC magneto
4. Joint connector
5. Condenser
6. Coupler for connecting option-
al part
8. Neutral switch
9. ECU
10. Ignition coil
11. Spark plug
12. Injector
13. Fuel pump
COLOR CODE
EAS1SM1382
B Black
Gy Gray
L Blue
Lg Light green
O Orange
P Pink
R Red
Sb Sky blue
Y Yellow
B/L Black/Blue
B/R Black/Red
B/W Black/White
B/Y Black/Yellow
Br/W Brown/White
G/W Green/White
P/B Pink/Black
R/B Red/Black
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
(E)
WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO
YZ250F (E) 2014 YZ250F (E) 2014 YZ250F (E) 2014 YZ250F (E) 2014
A
4 B B B B B R R R R R R R
B/L B/L B/L B/L B/L B/L P P P L L L
O R R O
A B
B/L Gy B/L Gy
R B
R R A R 10
1 Gy B/L B R
Gy
O O A O
6 B/W Lg R
R
2 3 R R
11
R Lg Lg O
5 B R R B B/W
B
12
R/B R/B R
B/W
R R/B
B
B/Y
B/Y 13
7 B B B B/Y B B/R B/R R
B/R R
9
B
14
Br/W Br/W B/L
B Br/W B/L
15
G/W G/W B/L
G/W B/L
L
B
16
L
8 P P
P Y Y L Y B/L
Sb Sb
B/Y P P P B/L
Sb Sb
P/B
17
B/L
L
B/L
P/B
B/L P/B L

R/B Lg Br/W P
O B/Y Sb
1SM-28199-30_W.D.indd 1 2013/09/03 11:24:21

WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO
YZ250F (E) 2014 YZ250F (E) 2014 YZ250F (E) 2014 YZ250F (E) 2014
A
4
(BLACK) (BLACK)
A B
A 10
1
A
6
2 3 11
12
13
7
14
15
16
8
17
1SM-28199-30_W.D.indd 2 2013/09/03 11:24:21

Yz 250 Fe

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2014

q Read this manual carefully before operating this vehicle.

q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule.

q Leggere attentamente questo manuale prima di utilizzare questo veicolo.

1SM-28199-30_cover.indd 1 2013/07/23 18:31:44

1SM-28199-30_cover.indd 2 2013/07/23 18:31:45

OWNER’S SERVICE MANUAL

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.

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

A NOTICE indicates special precautions that must be taken to avoid

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

THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED

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 Locking agent (LOCTITE®)

Engine oil New Replace the part with a new one.

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

INCLUDED PARTS ..........................................................................................1-8

IMPORTANT INFORMATION ........................................................................1-10

BASIC SERVICE INFORMATION..................................................................1-12

SPECIAL TOOLS ...........................................................................................1-15

CONTROL FUNCTIONS ................................................................................1-20

MAINTENANCE AFTER BREAK-IN ..............................................................1-24

TORQUE-CHECK POINTS ............................................................................1-25

CLEANING AND STORAGE..........................................................................1-27

LOCATION OF IMPORTANT LABELS

1,2,3 4,5,6 7,8 9,10,11

AUS, NZL, ZAF

There are two significant reasons for knowing

The vehicle identification number “1” is

ENGINE SERIAL NUMBER

The engine serial number “1” is stamped into

The model label “1” is affixed to the rear frame.

OUTLINE OF THE FI SYSTEM

INCLUDED PARTS HANDLEBAR PROTECTOR

Install the handlebar protector “1” with the mark

The sidestand “1” is used to support only the

FUEL HOSE JOINT COVER

The fuel hose joint covers “1” are used to pre-

The spark plug wrench “1” is used to remove or

COUPLER FOR CONNECTING OPTIONAL

Part name Part number

PREPARATION FOR REMOVAL AND DIS-

4. During disassembly, clean each of the parts,

Make sure that the parts and grease or oil to be

3. During disassembly, check and measure the

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS

Install bearings “1” and oil seals “2” with their

BASIC SERVICE INFORMATION

Electrical parts handling