2018-2020 - Yamaha - mt-07 CAP1

Service Manual
Se
EASZOR03
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Please refer to “BASIC INFORMATION” (separate volume, YOA-28197-10*) for basic instructions that
must be observed during servicing. Repair and maintenance work attempted by anyone without this
knowledge is likely to render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-
cle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is in-
tended to provide the customer with the most satisfaction from their vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP
e * If the contents of the manual are revised, the last digit of the manual number will be increased by
one.
e This Service Manual contains information regarding periodic maintenance to the emission control sys-
tem. Please read this material carefully.
e Designs and specifications are subject to change without notice.
Es«S300
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal injury
A\ hazards. Obey all safety messages that follow this symbol to avoid possible in-
jury or death.
A WARNING indicates a hazardous situation which, if not avoided, could result

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

NOTICE the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.
EASe0002
MTO07J/MTO7JC
SERVICE MANUAL
©2018 by Yamaha Motor Corporation, U.S.A.
First edition, February 2018
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-31-60
EASzO004
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive ex-
planations of all installation, removal, disassembly, assembly, repair and check procedures are laid out
with the individual steps in sequential order.
e 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.
e 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.
e Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
e Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
e A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
¢ Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
CLUTCH CLUTCH
inion ines beeen

CLUTCH CHECKING THE FRICTION PLATES CHECKING THE CLUTCH PLATES
=a = ?
The following procedure apalies tall of the frie- The follawing procedure applies to all of the
Removing the clutch cover and pull ewer shaft tion plates. éluteh plates.
1. Check: 1. Chic:
* Friction plaie * Cluich plate
Damage wear —* Replace the frietion plates Damage + Raplace ihe cluich plates aa a
ag 4 gal eel
2. Measure: 2. Meacure:
* Friction plate thickness ‘Clutch pale warpage
Out of specification — Replace the friction (with a surface plate and thickness gauge “17
plales ae a Set. Out of specification + Replace the clutch
TUF plates a9 4 eet
3 Meagure the Trielion plabe al four placed. ;
(4) Thickness gauge
Z # 0891-0310
iy, Friction plate1 thickness Feeler gauge sel oe
“es ) 2.00-0.10 mm (0.714-0.122 inp ¥U-26900-9 P
Wear limit
2.82 mm (0.111 in)
Friction plate2 thickness 5%) Warpage limit
2,993.08 mem (0.145-0.121 in) =~] 0.10 mm (0.004 In}
Wear limit
re 2.60 mim (0.110 iin)
ceanete _
] ] ] CHECKING THE CLUTCH SPRINGS
iB a | onter | a | a |5 — The following procedure applies to all of the
rain ;
Engin“ae
e cil Faage
lnter toez“CHANGING:
THE ENGINE Oil" m
A ets
B aly
Chin Barings.
1. Check:
[Water pump housing | to “WATER: PUMP" on page 610.
| Rater or son eo} = Cluich spring
| Ghutch caine | 1 | Cisconnedt | ' ‘ ‘ 4 oe > Replace the cluich springs a3 &
z | Glatch coil rotor | 4 | t + i| } | 2 Measure:
4 ne lead and ol prosaure avdich 2 c MN a : ‘ + Clutch spring tree length “a”
7 each coe —— Trrc1X5 oT Gut of specification — Replaces the clutch
|“ | | — springs a6 a set
5 Clutch cowar gaskal 1 . Fa a
5 ee ei 5 an Clutch epring free length
‘ a 50.00 min (1.97 in}
Limit
47.50 mm (1.87 in)
6-55 5-60
EASZO005
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
|S)— /)—
serviceable with engine mounted Gear oil
§
Filling fluid Molybdenum disulfide oil

C4
G>—
Lubricant Brake fluid
f
Special tool Wheel bearing grease

:
VTL ated |S
Tightening torque Lithium-soap-based grease

:
Wear limit, clearance Molybdenum disulfide grease

;
Engine speed Silicone grease
Electrical data Apply locking agent (LOCTITE®).

O-—p— |EL
5D
Engine oil S Replace the part with a new one.

Zz
=
Silicone fluid
TABLE OF CONTENTS
GENERAL INFORMATION
ee
SPECIFICATIONS
PERIODIC CHECKS AND

ADJUSTMENTS
CHASSIS
CaS ee ee
ENGINE
COOLING SYSTEM
FUEL SYSTEM
ELECTRICAL SYSTEM
APPENDIX
GENERAL INFORMATION
IDENTIFICATION ......ccccccccecccesceseeeceseeeenseeseneaenaeesseseaeeasessaseaseasessaseaeeusesssssaenanes 1-1

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SPECIAL TOOLS .n.ccccctcssessccccsssesscessccessesecsansecessecscsnccessessascessseessancesessecsancscess 1-7

IDENTIFICATION
EASsOu07
IDENTIFICATION
EAS30002
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the right side of the steering head pipe.
Se
A
at LZ
NG - A | 4
ig (hs =
GSSae,
Dy ROE
EAS30003
MODEL LABEL
The model label “1” is affixed to the frame under
the passenger seat. This information will be
needed to order spare parts.
1-1
FEATURES
EAS20008
FEATURES TIP
e Except when accessing the brightness control
EAS30o82
MULTI-FUNCTION METER UNIT mode or when displaying the clock, the key
must be turned to “ON” before you can use the
left and right set buttons to adjust the multi-
function meter.
* To switch between kilometers and miles, press
the left set button for at least three seconds.
Speedometer
The speedometer shows the vehicle’s traveling
speed.
1. Left set button Tachometer

2. Right set button
4 5
as Ak at nia
AMOR. Fza
(=~ [= /=1 = a a init
“= aia —
pare
r=
T 2
cs = = T =.
1. Tachometer
7 6
2. lachometer red zone
1. Fuel meter
2. Clock The tachometer allows the rider to monitor the
3. Transmission gear display engine speed and keep it within the ideal power
4. Eco indicator “ECO” range.
ECA1S660
5. Speedometer
NOTICE
6. Tachometer
Do not operate the engine in the tachometer
7. Multi-function display
red zone.
The multi-function meter unit is equipped with
the following:
* speedometer Clock
¢ tachometer
¢ clock
e fuel meter
© eco indicator
ib)
¢ transmission gear display

¢ multi-function display FEE: FG —E
EWAIZS423
Be sure to stop the vehicle before making

any setting changes to the multi-function
meter unit. Changing settings while riding 1. a
can distract the operator and increase the The clock uses a 12-hour time system. When
risk of an accident. the main switch is not in the “ON” position, the
clock can be viewed for 10 seconds by pushing
the left set button.
FEATURES
[To set the clock] The eco indicator comes on when the vehicle is
1. Turn the key to “ON”. being operated in an environmentally friendly,
2. Push the left set button and right set button fuel-efficient manner. The indicator goes off
together for two seconds. The hour digits will when the vehicle is stopped.
start flashing. TIP
Use the right set button to set the hours. Consider the following tips to reduce fuel con-
> W
Push the left set button, and the minute digits sumption:
will start flashing. * Avoid high engine speeds during acceleration.
Use the right set button to set the minutes. ¢ Travel at a constant speed.
Oo
Push the left set button and then release it to * Select the transmission gear that is appropri-
start the clock. ate for the vehicle speed.
Fuel meter
Transmission gear display
1 2
Ao) eS .
pes OS SS
1. Fuel meter Se ms
os |
2. Fuel level warning indicator “gs” 1. Transmission gear display

The fuel meter indicates the amount of fuel in the 2. Neutral indicator light “Ny”
fuel tank. The segments of the fuel meter disap- The transmission gear display shows the select-
pear from “F” (full) towards “E” (empty) as the ed gear. The neutral position is indicated by “—”
fuel level decreases. When the last segment of and by the neutral indicator light.
the fuel meter and the fuel level warning indica-
tor start flashing, refuel as soon as possible. Multi-function display
TIP
The fuel meter is equipped with a self-diagnosis
function. If a problem is detected in the fuel me-
ter electrical circuit, the fuel meter and the fuel
Zs
level warning indicator will flash repeatedly. If
this occurs, check the electrical circuit. Refer to
“SIGNALING SYSTEM” on page 8-21. (“ OO,
Eco indicator \\ i000 A
1. Multi-function display
1
AES ZR The multi-function display is equipped with the

following:
mag ~O as * odometer
¢ two tripmeters
¢ fuel reserve tripmeter
* instantaneous fuel consumption
a
* average fuel consumption
a | * coolant temperature
* air temperature
1. Eco indicator “ECO”
¢ self-diagnosis mode
FEATURES
¢ brightness control mode TIP

* Push the right set button to change the display
Navigating the multi-function display in the reverse order.
Push the left set button to change the display be- ¢ You can manually reset the fuel reserve trip-
tween the odometer “ODO”, tripmeters “TRIP 1” meter, or after refueling and traveling 5 km (3
and “TRIP 2”, instantaneous fuel consumption mi) it will reset automatically and disappear
“km/L”, “L/100 km” or “MPG”, average fuel con- from the display.
sumption “AVE__. km/L”, “AVE__._ L/100 km”
or “AVE__._ MPG”, coolant temperature “_ _
°F”, and air temperature “Air_ _ °F” in the follow- Instantaneous fuel consumption
ing order:
ODO -> TRIP 1 > TRIP 2 > km/L, L/100 km or

MPG > AVE__. km/L, AVE__. L/100 km or aa
_ oO
AVE__.. MPG->__°F>Air__ °F > ODO
TIP
e Push the right set button to change the display
in the reverse order.
e The fuel reserve tripmeter and the self-diagno-
sis mode come on automatically, while the
\ MPG
Lf fj —*
brightness control mode is accessed separate- 1. Instantaneous fuel consumption display

ly. This function calculates the fuel consumption
under current riding conditions.
Odometer and tripmeters The instantaneous fuel consumption can be set
The odometer shows the total distance traveled to either “km/L”, “L/100 km” or “MPG”.
by the vehicle. e “km/L”: The distance that can be traveled on
The tripmeters show the distance traveled since 1.0 L of fuel under the current riding conditions
they were last reset. is shown.
To reset a tripmeter, use the left set button to ¢ “L/100 km”: The amount of fuel necessary to
display the tripmeter you want to reset, and then travel 100 km under the current riding condi-
push the right set button for one second. tions is shown.
TIP ¢ “MPG”: The distance that can be traveled on
1.0 US gal of fuel under the current riding con-
e The odometer will lock at 999999.
ditions is shown.
e The tripmeters will lock at 9999.9 but can be
To switch the instantaneous fuel consumption
manually reset.
settings, push and hold the left set button until
the display changes.
Fuel reserve tripmeter TIP
When the fuel level becomes low, the fuel level lf traveling at speeds under 20 km/h (12 mi/h), “_
warning indicator and the last segment of the _._” is displayed.
fuel meter will start flashing. The fuel reserve
tripmeter“TRIP F” will automatically appear and
start counting the distance traveled from that Average fuel consumption
point. In this case, push the left set button to
switch the display in the following order:
TRIP F > km/L, L/100 km or MPG > AVE__._ a

km/L, AVE__._ L/100 km or AVE__._ MPG >
__°F>Air__
+> TRIPF
°F > ODO -> TRIP 1 > TRIP2 CeO
FEATURES
1. Average fuel consumption display Air temperature

This function calculates the average fuel con-
sumption since it was last reset.
a
GQ we
The average fuel consumption can be set to ei-
ther “AVE__. km/L”, “AVE_ _._ L/100 km” or
“AVE__.. MPG”.
e“AVE__. km/L”: The average distance that
can be traveled on 1.0 L of fuel is shown.
e“AVE__. L/100 km”: The average amount of
fuel necessary to travel 100 km is shown.
\\\ 0 7SF
e“AVE__._ MPG”: The average distance that 1. Air temperature display
can be traveled on 1.0 US gal of fuel is shown.
To switch the average fuel consumption set- This shows the air temperature from 14 °F to
tings, push and hold the left set button until the 210 °F in 1 °F increments. The temperature dis-
display changes. played may vary from the ambient temperature.
To reset the average fuel consumption, push TIP
and hold the right set button until the display ¢ When the temperature is below 14 °F, “LO” will
changes. be displayed.
TIP e The accuracy of the temperature reading may
After resetting the average fuel consumption, “_ be affected by engine heat when riding slowly
_._” will be shown until the vehicle has traveled 1 (under 20 km/h [12 mi/h]) or when stopped at
km (0.6 mi). traffic signals, etc.
Coolant temperature Self-diagnosis mode

1
ZS os
Ce We}
\ |—7
AAA
1. Coolant temperature display 1. Error code display

This shows the coolant temperature from 104 °F 2. Engine trouble warning light “=,”
to 242 °F in 1 °F increments. This model is equipped with a self-diagnosis
lf the message “HI” flashes, stop the vehicle, function for various electrical circuits. If a prob-
then stop the engine, and let it cool. lem is detected in any of those circuits, the en-
TIP gine trouble warning light will come on and the
e When the coolant temperature is below 104 °F, display changes to self-diagnosis mode. If the
“LO” will be displayed. display indicates any error codes, note the code
e The coolant temperature varies with changes number, and then check the fuel injection sys-
in the weather and engine load. tem. (Refer to “FUEL INJECTION SYSTEM?” on
page 8-33.)
ECAI1591
NOTICE
If the display indicates an error code, the ve-
hicle should be checked as soon as possible
in order to avoid engine damage.
FEATURES
Brightness control mode
1. Brightness level display
The brightness control mode allows you to ad-

just the brightness level of the multi-function me-
ter unit.
[To adjust the brightness]

1. Turn the key to “OFF”.
2. Push and hold the left set button.
3. Turn the key to “ON” and continue pushing
the left set button until the display switches to
the brightness control mode.
4. Push the right set button to set the brightness
level.
5. Push the left set button to confirm the select-
ed brightness level and exit the brightness
control mode.
SPECIAL TOOLS
EASs2o012
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
TIP
¢ For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
¢ For others, use part number starting with “90890-”.
. Reference
Tool name/Tool No. lllustration pages
Yamaha diagnostic tool USB | 3-4, 3-9, 4-64,

90890-03257 } 4-65, 5-9, 7-13,
YDT « (| |7-13, 7-14,
0 AMAHA DIAGNOSTIC TOOL] &f 7-14, 8-36,
| 8-104, 8-129,
8-133
Yamaha diagnostic tool (A/I) 3-4, 3-9, 4-64,
90890-03262 4-65, 5-9, 7-13,
7-13, 7-14,
7-14, 8-36,
8-104, 8-129,
8-133
Thickness gauge 3-6, 4-22, 4-31,
90890-03180 5-60
Feeler gauge set
YU-26900-9
90890-04101
Valve lapping tool (14mm) 3 o-
YM-A8998
YM-A8998
Vacuum gauge 3-9

90890-03094 90890-03094
Vacuummate
YU-44456
YU-44456
SPECIAL TOOLS
Reference
Tool name/Tool No. Illustration pages
Carburetor angle driver 2 3-10
90890-03173
steering nut wrench 3-20, 4-84

90890-01403 ve
Exhaust flange nut wrench
YU-A9472
Oil filter wrench 3-23

90890-01426
Oil filter wrench
YU-38411
Pressure gauge 3-24, 7-15, 7-16

90890-03153
Pressure gauge
YU-03153
Oil pressure adapter H 3-24

90890-03139
Mi6xP1.5
Damper rod holder (621.2) 4-76, 4-78

90890-01460
T-handle 4-76, 4-78

90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
Fork seal driver weight 4-79, 4-79, 4-79

90890-01367
Replacement hammer
YM-A9409-7
SPECIAL TOOLS
Reference
Tool name/Tool No. Illustration
pages
Fork seal driver attachment (#41) 4-79, 4-79
90890-01381
Replacement 41 mm
YM-A5142-2
Compression gauge extension 122mm

90890-04136
Compression gauge extension 122mm
YM-04136
Compression gauge 5-8

90890-03081
Engine compression tester
YU-33223
YU-33223
Rotor holding tool 5-24, 5-27

90890-01235
Universal magneto and rotor holder
YU-01235
Yamaha bond No. 1215

90890-85505
(Three bond No.1215®)
Valve spring compressor 5-39, 5-44

90890-04019
Valve spring compressor
YM-04019
Valve spring compressor attachment 5-39, 5-44

(926)
90890-01243
Valve spring compressor adapter (26 a26
mm)
YM-01253-1
Valve guide remover (04.5) 5-41
90890-04116
Valve guide remover (4.5 mm)
YM-04116
SPECIAL TOOLS
: Reference
Tool name/Tool No. llustration pages
Valve guide installer (o4.5) 5-41

90890-04117
Valve guide installer (4.5 mm)
YM-04117
Valve guide reamer (04.5) 5-41

90890-04118
Valve guide reamer (4.5 mm)
YM-04118
Rotor holding tool 5-48, 5-48,

90890-04166 5-49, 5-49
Rotor holding tool
YM-04166
Flywheel puller 5-48

90890-01362
Heavy duty puller
YU-33270-B
Digital circuit tester (CD732) 5-53, 8-133,

90890-03243 8-135, 8-136,
Model 88 Multimeter with tachometer 8-137, 8-137,
YU-A1927 8-138, 8-138,
8-139, 8-139,
8-141, 8-141,
8-142, 8-143,
8-143, 8-144,
8-144, 8-145
Universal clutch holder 5-59, 5-62
90890-04086 M8xP1.25 ~
90890-04086
Universal clutch holder
YM-91042
YM-91042
1-10
SPECIAL TOOLS
Reference
Tool name/Tool No. Illustration
pages
Piston pin puller set 90890-01304 5-82
90890-01304
Piston pin puller
YU-01304
Piston ring compressor 5-89

90890-05158
Piston ring compressor
YM-08037
Radiator cap tester 90890-01325 6-4

90890-01325
Mityvac cooling system tester kit
YU-24460-A
YU-24460-A
Radiator cap tester adapter

90890-0
90890-01352
Pressure tester adapter
YU-33984
Mechanical seal installer (#33) 6-13

90890-04132
Water pump seal installer (933)
YM-33221-A
SPECIAL TOOLS
Reference
Tool name/Tool No. Illustration pages
Middle driven shaft bearing driver 6-13
90890-04058
Middle drive bearing installer 40 & 50 mm
YM-04058
Fuel injector pressure adapter 7-15

90890-03210
Fuel injector pressure adapter
YU-03210
Fuel pressure adapter 7-16

90890-03176
Fuel pressure adapter
YM-03176
OBD/ GST Leadwire kit 8-36

90890-03249
Ignition checker 8-138

90890-06754
Oppama pet—4000 spark checker
YM-34487
Test harness— lean angle sensor (6P) 8-139

90890-03209
Test harness— lean angle sensor (6P)
YU-03209
1-12
SPECIAL TOOLS
1-13
SPECIFICATIONS
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GENERAL SPECIFICATIONS
EAS20013
GENERAL SPECIFICATIONS
Model
Model B4C2 (MTO7J)
B4C3 (MTO7JC)
Dimensions
Overall length 2085 mm (82.1 in)
Overall width 745 mm (29.3 in)
Overall height 1090 mm (42.9 in)
Wheelbase 1400 mm (55.1 in)
Ground clearance 140 mm (5.51 in)
Minimum turning radius 2.7 m (8.86 ft)
Weight
Curb weight 183 kg (403 Ib)
Loading
Maximum load 172 kg (379 Ib)
Riding capacity 2 person
2-1
ENGINE SPECIFICATIONS
EaAS20014
Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train DOHC
Displacement 689 cms
Cylinder arrangement Inline
Number of cylinders 2-cylinder
Bore x stroke 80.0 x 68.6 mm (3.15 x 2.70 in)
Compression ratio 11.5: 1
Compression pressure 765-985 kPa/355 r/min (7.7—9.9 kgf/cm?/355
r/min, 108.9—140.2 psi/355 r/min)
Compression pressure (#2 cylinder) 687-884 kPa/355 r/min (6.9-8.8 kgf/cm?/355
r/min, 97.8—125.8 psi/355 r/min)
Starting system Electric starter
Fuel
Recommended fuel Regular unleaded gasoline (Gasohol [E10]
acceptable)
Fuel tank capacity 14 L (3.7 US gal, 3.1 Imp.gal)
Fuel reserve amount 2.7 L (0.71 US gal, 0.59 Imp.gal)
Engine oil
Recommended brand YAMALUBE
SAE viscosity grades 10W-40, 10W-50, 15W-40, 20W-40 or 20W-50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Lubrication system Wet sump
Engine oil quantity
Oil change 2.30 L (2.43 US qt, 2.02 Imp.qt)
With oil filter removal 2.60 L (2.75 US qt, 2.29 Imp.qt)
Quantity (disassembled) 3.00 L (3.17 US qt, 2.64 Imp.qt)
Oil filter
Oil filter type Cartridge
Oil pump
Inner-rotor-to-outer-rotor-tip clearance 0.03-0.08 mm (0.0012-—0.0032 in)
Limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pbump-housing clearance 0.09-0.15 mm (0.0035-0.0059 in)
Limit 0.22 mm (0.0087 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.03-0.08 mm (0.0012-0.0032 in)
Limit 0.15 mm (0.0059 in)
Oil pressure 280.0 kPa/5000 r/min (2.80 kgf/cm?/5000 r/min,
40.6 psi/5000 r/min)
Relief valve operating pressure 720.0 kPa (7.20 kgf/cm?, 104.4 psi)
Cooling system
Coolant quantity
Radiator (including all routes) 1.60 L (1.69 US at, 1.41 Imp.qt)
Coolant reservoir (up to the maximum level
mark) 0.25 L (0.26 US qt, 0.22 Imp.at)
Radiator cap valve opening pressure 108.0-137.4 kPa (1.08-1.37 kgf/cm2, 15.7-19.9
psi)
Thermostat
Valve opening temperature 80.0—84.0 °C (176.00—183.20 °F)
Valve full open temperature 95.0 °C (203.00 °F)
Valve lift (full open) 8.0 mm (0.31 in)
Spark plug(s)
Manufacturer/model NGK/LMAR8A-9
Spark plug gap 0.8-0.9 mm (0.031-0.035 in)
Cylinder head
Warpage limit 0.10 mm (0.0039 in)
Camshaft
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 (0.001 1—-0.0024 in)
Limit 0.080 mm (0.0032 in)
Camshaft lobe dimensions
Lobe height (Intake) 35.610-35.710 mm (1.4020-1.4059 in)
Limit 35.510 mm (1.3980 in)
Lobe height (Exhaust) 35.710-35.810 mm (1.4059—-1.4098 in)
Limit 35.610 mm (1.4020 in)
Valve, valve seat, valve guide
Valve clearance (cold)
Intake 0.11—0.20 mm (0.0043-—0.0079 in)
Exhaust 0.24—0.30 mm (0.0094—0.01 18 in)
Valve dimensions
Valve seat contact width (intake) 0.90—1.10 mm (0.0354—0.0433 in)
Limit 1.6 mm (0.06 in)
Valve seat contact width (exhaust) 0.90—1.10 mm (0.0354—0.0433 in)
Limit 1.6 mm (0.06 in)
Valve stem diameter (intake) 4.475—4.490 mm (0.1762-0.1768 in)
Limit 4.445 mm (0.1750 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) 4.500—4.512 mm (0.1772-0.1776 in)
Valve guide inside diameter (exhaust) 4.500—4.512 mm (0.1772-0.1776 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) 40.30 mm (1.59 in)
Limit 38.29 mm (1.51 in)
Free length (exhaust) 41.39 mm (1.63 in)
Limit 39.32 mm (1.55 in)
Cylinder
Bore 80.000—80.010 mm (3.1496—3.1500 in)
Wear limit 80.060 mm (3.1520 in)
Piston
Diameter 79.970—79.985 mm (3.1484—3.1490 in)
Measuring point (from piston skirt bottom) 8.0 mm (0.31 in)
Piston-to-cylinder clearance 0.015—0.040 mm (0.0006—0.0016 in)
Piston pin bore inside diameter 18.004—18.015 mm (0.7088-—0.7093 in)
Limit 18.045 mm (0.7104 in)
Piston pin outside diameter 17.990—17.995 mm (0.7083—0.7085 in)
Limit 17.970 mm (0.7075 in)
Piston-pin-to-piston-pin-bore clearance 0.009—0.025 mm (0.0004—0.0010 in)
Piston ring
Top ring
End gap limit 0.50 mm (0.0197 in)
Ring side clearance 0.030-0.065 mm (0.0012-0.0026 in)
Side clearance limit 0.115 mm (0.0045 in)
2nd ring
End gap limit 0.80 mm (0.0315 in)
Ring side clearance 0.020-0.055 mm (0.0008-0.0022 in)
Side clearance limit 0.115 mm (0.0045 in)
Connecting rod
Oil clearance 0.027—0.051 mm (0.0011—0.0020 in)
Bearing color code
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
Crankshaft
Runout limit 0.030 mm (0.0012 in)
Journal oil clearance 0.018—0.042 mm (0.0007-—0.0017 in)
Bearing color code
Model identification color Pink
Code -1 Purple
Code 0 White
Code 1 Blue
Code 2 Black
Code 3 Brown
Balancer
Balancer shaft runout limit 0.030 mm (0.0012 in)
Bearing color code
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
Code 5 Yellow
Balancer shaft journal to balancer shaft
bearing clearance 0.020—0.054 mm (0.0008-—0.0021 in)
Clutch
Clutch type Wet, multiple-disc
Clutch lever free play 5.0—10.0 mm (0.20—0.39 in)
Friction plate 1 thickness 2.92—3.08 mm (0.115—0.121 in)
Plate quantity 5 pcs
Friction plate 2 thickness 2.90—3.10 mm (0.114—0.122 in)
Clutch plate thickness 1.90—2.10 mm (0.075—0.083 in)
Warpage limit 0.10 mm (0.004 in)
Clutch spring free length 50.00 mm (1.97 in)
Limit 47.50 mm (1.87 in)
Drivetrain
Primary reduction ratio 1.925 (77/40)
Transmission type Constant mesh 6-speed
Gear ratio
1st 2.846 (37/13)
2nd 2.125 (34/16)
3rd 1.632 (31/19)
4th 1.300 (26/20)
5th 1.091 (24/22)
6th 0.964 (27/28)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Secondary reduction ratio 2.688 (43/16)
Final drive Chain
Shifting mechanism
Installed shift rod length 217.5—219.5 mm (8.56-8.64 in)
Air filter
Air filter element Oil-coated paper element
2-5
Fuel pump
Pump type Electrical
Maximum consumption amperage 3.3 A
Fuel injector
Resistance 12.00
Throttle body
ID mark 1WS1 00 (MTO7J)
1WS1 10 (MTO7JC)
Idling condition
Engine idling speed 1250-1450 r/min
O2 feedback control Active
Coolant temperature 85-105 °C (185-221 °F)
Difference in vacuum pressure between the
cylinders 0 kPa—1.3 kPa (0 mmHg—10 mmHg, 0 inHg—0.4
inHg)
CO% 0.0—2.0 %
Fuel line pressure (at idle) 300-390 kPa (3.0—3.9 kgf/cm?, 43.5—56.6 psi)
Throttle grip free play 3.0—5.0 mm (0.12—0.20 in)
CHASSIS SPECIFICATIONS
EaAS20015
Chassis
Frame type Diamond
Caster angle 24.8 °
Trail 90 mm (3.5 in)
Front wheel
Wheel type Cast wheel
Rim size 17M/C x MT3.50
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Rear wheel
Wheel type Cast wheel
Rim size 17M/C x MT5.50
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Front tire
Type Tubeless
Size 120/70 ZR 17M/C(58W)
Manufacturer/model MICHELIN/PILOT ROAD 4
Manufacturer/model BRIDGESTONE/BT023F F
Rear tire
Type Tubeless
Size 180/55 ZR 17M/C(73W)
Manufacturer/model MICHELIN/PILOT ROAD 4
Manufacturer/model BRIDGESTONE/BT023R M
Tire air pressure (measured on cold tires)

1 person
Front 225 kPa (2.25 kgf/cm, 33 psi)
Rear 250 kPa (2.50 kgf/cm?, 36 psi)
2 persons
Front 225 kPa (2.25 kgf/cm?, 33 psi)
Rear 250 kPa (2.50 kgf/cm?, 36 psi)
Front brake
Type Hydraulic dual disc brake
Disc outside diameter x thickness 282.0 x 4.5 mm (11.10 x 0.18 in)
Brake disc thickness limit 4.0 mm (0.16 in)
Brake disc runout limit (as measured on
wheel) 0.10 mm (0.00339 in)
Brake pad lining thickness limit 0.5 mm (0.02 in)
Master cylinder inside diameter 15.00 mm (0.59 in)
Caliper cylinder inside diameter (Left) 30.23 mm, 27.00 mm (1.19 in, 1.06 in)
Caliper cylinder inside diameter (Right) 30.23 mm, 27.00 mm (1.19 in, 1.06 in)
Specified brake fluid DOT 4
Rear brake
Type Hydraulic single disc brake
Disc outside diameter x thickness 245.0 x 5.0 mm (9.65 x 0.20 in)
Brake disc thickness limit 4.5 mm (0.18 in)
Brake disc runout limit (as measured on
wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness limit 1.0 mm (0.04 in)
Master cylinder inside diameter 12.7 mm (0.50 in)
Caliper cylinder inside diameter 38.18 mm (1.50 in)
Specified brake fluid DOT 4
Front suspension
Type Telescopic fork
Spring Coil spring
Shock absorber Hydraulic damper
Wheel travel 130 mm (5.1 in)
Fork spring free length 345.4 mm (13.60 in)
Limit 338.4 mm (13.33 in)
Recommended oil Yamaha Suspension Oil G10
Quantity (left) 405.0 cm? (13.69 US oz, 14.28 Imp.oz)
Quantity (right) 405.0 cm? (13.69 US oz, 14.28 Imp.oz)
Level (left) 160 mm (6.3 in)
Level (right) 160 mm (6.3 in)
Rear suspension
Type Swingarm (link suspension)
Spring Coil spring
shock absorber Gas-hydraulic damper
Wheel travel 130 mm (5.1 in)
Spring preload
Adjusting system Mechanical adjustable type
Unit for adjustment Cam position
Adjustment value (Soft) 1
Adjustment value (STD) 4
-
Adjustment value (Hard)
Rebound damping
Adjusting system Mechanical adjustable type
Unit for adjustment Turn
Adjustment value from the start position
(Soft) 3
(STD) 1.5
(Hard)
Drive chain
size 525VZ
Chain type Sealed type
Number of links 108
Drive chain slack 51.0—56.0 mm (2.01—2.20 in)
Drive chain slack (Maintenance stand) 56.0—-61.0 mm (2.20—2.40 in)
Limit 58.0 mm (2.28 in)
15-link length limit 239.3 mm (9.42 in)
ELECTRICAL SPECIFICATIONS
EAS20016
Voltage
system voltage 12V
Ignition system
Ignition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 10.0 °/1350 r/min
Engine control unit

Model TBDFN8/DENSO
Ignition coil
Primary coil resistance 1.19-1.61
Secondary coil resistance 8.50—-11.50 kQ
Lean angle sensor output voltage

Operating angle 65°
Output voltage up to operating angle 0.4-1.4V
Output voltage over operating angle 3.74.4 V
Charging system
Charging system AC magneto
standard output 14.0 V, 29.3 A at 5000 r/min
Stator coil resistance 0.128-0.192 QO
Rectifier/regulator
Regulator type Three-phase
Regulated voltage (DC) 14.3-14.7 V
Rectifier capacity (DC) 50.0 A
Battery
Model YTZ10S
Voltage, capacity 12 V, 8.6 Ah (10 HR)
Headlight
Bulb type Halogen bulb
Bulb wattage
Headlight H4, 60.0 W/55.0 W
Brake/tail light LED
Front turn signal/position light 21.0 W/5.0 W
Rear turn signal light 21.0 W
Auxiliary light 5.0 W
License plate light 5.0 W
Meter lighting LED
Indicator light
Neutral indicator light LED
Oil pressure warning light LED
2-10
High beam indicator light LED

Turn signal indicator light LED
Coolant temperature warning light LED
Engine trouble warning light LED
ABS warning light LED
Starter motor
Power output 0.50 kW
Armature coil resistance 0.016—0.024 9
Brush overall length limit 6.5 mm (0.26 in)
Mica undercut (depth) 0.70 mm (0.03 in)
Fuel sender unit

sender unit resistance (full) 9.0-11.0
Sender unit resistance (empty) 213.0—219.0
Fuel injection sensor

Crankshaft position sensor resistance 228-342 O
Intake air temperature sensor resistance 5400-6600 Q at 0 °C (5400-6600 © at 32 °F)
Intake air temperature sensor resistance 290-390 Q at 80 °C (290-390 © at 176 °F)
Coolant temperature sensor resistance 2513-2777 Q at 20 °C (2513-2777 Q at 68 °F)
Coolant temperature sensor resistance 210-221 Q at 100 °C (210-221 © at 212 °F)
Fuse(s)
Main fuse 30.0 A
Headlight fuse 15.0A
signaling system fuse 10.0A
Ignition fuse 10.0A
Parking lighting fuse 10.0A
Radiator fan motor fuse 10.0A
ABS control unit fuse 7.5A
ABS motor fuse 30.0 A
ABS solenoid fuse 20.0A
Auxiliary fuse 2.0A
Backup 1 fuse 7.5A
Backup 2 fuse 10.0A
2-11
TIGHTENING TORQUES
EAS2oO017
TIGHTENING TORQUES
EAS30016
ENGINE TIGHTENING TORQUES
ltem Lng Q’ty Tightening torque Remarks
Exhaust pipe nut M8 4 20 N-m (2.0 kgf-m, 15 Ib-ft)

Muffler bracket bolt M6 4 10 N-m (1.0 kgf-m, 7.4 Ib-ft)
Muffler bracket bolt M8 2 20 N-m (2.0 kgf-m, 15 Ib-ft)
Muffler cover bolt M6 3 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Spark plug M10 2 13 N-m (1.3 kgf-m, 9.6 lb-ft)
Cylinder head cover bolt M6 a 10 N-m (1.0 kgf-m, 7.4 Ib-ft)
Generator rotor bolt M12 1 70 N-m (7.0 kgf-m, 52 Ib-ft) —iG)
Generator cover bolt M6 2 12 N-m (1.2 kgf-m, 8.9 Ib-ft) -C
Generator cover bolt M6 8 12 N-m (1.2 kgf-m, 8.9 Ib-ft)
Clutch boss nut M20 1 95 N-m (9.5 kgf-m, 70 Ib-ft) Stake.
— iC)
Clutch spring bolt M6 6 8 N-m (0.8 kgf-m, 5.9 Ib-ft)
Clutch cover bolt M6 10 12 N-m (1.2 kgf-m, 8.9 Ib-ft)
Clutch cover bolt M6 2 12 N-m (1.2 kgf-m, 8.9 Ib-ft) -C
Oil filter cartridge M20 1 17 N-m (1.7 kgf-m, 13 lb-ft)
Oil filter cartridge union bolt M20 1 40 N-m (4.0 kgf-m, 30 Ib-ft) —i©)
Coolant drain bolt M6 1 7 N-m (0.7 kgf-m, 5.2 Ib-ft)
Engine oil drain bolt M14 1 43 N-m (4.3 kgf-m, 32 Ib-ft)
CHASSIS TIGHTENING TORQUES
Item ie Q’ty Tightening torque Remarks
Front wheel axle M16 1 65 N-m (6.5 kgf-m, 48 Ib-ft)

Front wheel axle pinch bolt M8 1 23 N-m (2.3 kgf-m, 17 lb-ft)
Rear wheel sprocket nut M10 6 80 N-m (8.0 kgf-m, 59 Ib-ft)
Wheel axle nut M18 1 105 N-m (10.5 kgf-m, 77 Ib-ft)
Rear brake caliper bolt M8 1 22 N-m (2.2 kgf-m, 16 lb-ft) -C
Brake caliper bleed screw Mg 3 5 N-m (0.5 kof-m, 3.7 lb-ft)
Front brake caliper bolt M10 2 40 N-m (4.0 kgf-m, 30 Ib-ft)
Upper handlebar holder bolt M8 a 28 N-m (2.8 kgf-m, 21 I|b-ft)
Lower handlebar holder nut M10 2 32 N-m (3.2 kgf-m, 24 Ib-ft)
Clutch cable locknut M8 1 7 N-m (0.7 kgf-m, 5.2 Ib-ft)
Lower bracket pinch bolt M8 4 23 N-m (2.3 kgf-m, 17 Ib-ft)
Upper bracket pinch bolt (leftand | Msg 2 26 N-m (2.6 kgf-m, 19 lb-ft)
right)
Upper bracket pinch bolt (center) | M10 1 21 N-m (2.1 kgf-m, 15 lb-ft)
2-12
TIGHTENING TORQUES
item ane Q’ty Tightening torque Remarks
Cap nut M25 1 See TIP.

Drive sprocket nut M22 1 95 N-m (9.5 kgf-m, 70 lb-ft) Stake
—=©
TIP
Cap nut
1. First, tighten the cap nut to approximately 52 N-m (5.2 kgf-m, 38 Ib-ft) with a torque wrench, then
loosen the cap nut completely.
2. Retighten the cap nut to 18 N-m (1.8 kgf-m, 13 lb-ft) with a torque wrench.
2-13
TIGHTENING TORQUES
2-14
CABLE ROUTING
EAS20021
CABLE ROUTING
Handlebar (front view)
2-15
CABLE ROUTING
Throttle cable (accelerator cable) T. Route the brake hose (front brake master
ONOoahrahn= cylinder to hydraulic unit) to the rear of the
Throttle cable (decelerator cable)
bracket.
Clutch cable
Connect the headlight coupler.
<C
Clutch switch lead
Clamp the handlebar switch lead (right) at
Handlebar switch lead (left) the end of the master cylinder.
Handlebar switch coupler (left) . Place the handlebar switch lead (right) on
=
Front wheel sensor lead the rear side of the vehicle.
Headlight coupler Face the fastening portion of the plastic
x
Handlebar switch coupler (right) band toward the vehicle top and point the
end of plastic band toward the vehicle
worno—_— oO"
. Wire harness end cap

front.
ee ee
. Front brake light switch connector

a
. Main switch lead

. Brake hose
Clamp the handlebar switch lead (left) and

>
clutch cable at the position shown in the

illustration.
Connect the clutch switch.
W
Connect the auxiliary light coupler.

OO
Route the throttle cables through the guide

on the frame. Route the throttle cable
(decelerator cable) over the throttle cable
(accelerator cable).
Make sure that the front wheel sensor lead
does not contact the headlight coupler.
Route the headlight lead below the other
leads.
. The leads that branch off from the wire har-
ness (except for the headlight lead) may be
routed in any order. Route the headlight
lead downward of the leads that branch off
from the wire harness.
Connect the front brake switch connector.
To meter
Route the brake hose (front brake master
cylinder to hydraulic unit) as shown in the
illustration.
Connect the coupler, and then place the
coupler in the coupler cover.
The couplers may be positioned in any
order.
. Route the main switch lead to the front of
the clutch cable and to the rear of the han-
dlebar switch lead (left handlebar switch).
Fasten the main switch lead along with the
cable guide at the tape using the plastic
band. Point the clamp tip toward the inside
of the vehicle and insert it between the
main switch and the connector cover.
Route the wire harness closer to the inside
O
of the vehicle than to the clutch cable.

Route the wire harness closer to the inside
of the vehicle than to the throttle cable.
DO
. Route the wire harness closer to the inside

of the vehicle than to the brake hose.
Insert the projection on the wire harness
holder into the hole in the cable guide.
Route the handlebar switch lead (right han-
o
dlebar switch) to the inside of the throttle

cables.
2-16
CABLE ROUTING
Frame and engine (right side view)
A Se eee > \\
: ao
KO \ a £
fh | ELNV Ly) i” 3s “er
SX
UL ony
" \ Ty) y ol Gp, Ne”

We Ps
2-17
CABLE ROUTING
Fuel tank breather hose (blue paint mark) Less than 10 mm (0.39 in). Fasten the
OaNogarah= hose protector of each hose with the
Fuel tank overflow hose (white paint mark)
holder.
Headlight coupler
To fuel tank
Front turn signal/position light lead
O70
When fastening the fuel tank breather hose
Clutch cable with the holder, make sure that the paint
Oil pressure switch lead mark on the hose is positioned 0-10 mm
Oil pressure switch from the holder.
O. sensor When installing the hoses, silicone water
or soapy water may be applied to the
O, sensor lead
inside of the hoses.
. Rear brake light switch lead
O°
Point the end of hose clamp upward.

amntk
. O, sensor coupler
<cHo
Point the end of hose clamp inward.
mks
. Rear brake light switch coupler Point the end of hose clamp downward.
why
. Oil pressure switch connector

Place the wire sub-lead coupler closer to
. Rear wheel sensor coupler the vehicle inside than to the bracket.
. Meter coupler . For California only
Ss
. Cylinder head breather hose
. Hose air 3
Ont
. Hose air 1
19. Wire sub lead
. Canister purge hose (hose joint to canis-
ter)
. Fuel tank breather hose
Route the front turn signal/position light

lead in the clamp.
To headlight
To meter
To front turn signal/position light
Route the clutch cable through the guide
as shown in the illustration.
Route the oil pressure switch lead through
the guide, and then secure the lead by
bending the guide around the lead.
. Route the oil pressure switch lead to the
inside of the O. sensor lead, and then
secure the leads by bending the guides
around the leads.
Do not pinch the O. sensor lead between
the pivot shaft protector and the engine.
Fasten the rear brake light switch lead and
O, sensor lead with the holder.
Connect the O, sensor coupler, and then
insert the projection on the coupler into the
hole in the bracket.
Make sure that the wire harness is not
pinched between the pivot shaft protector
(right) and the frame.
holder into the hole in the frame from the
inside of the frame.
. After connecting the meter coupler, install
the coupler cover completely until it con-
tacts the meter assembly.
Make sure that there is no slack in the fuel
tank breather hose or fuel tank overflow
hose.
2-18
CABLE ROUTING
Frame and engine (left front side view)
a EAM bes 5s
. 7 ) AO) Sy ‘oz gia)
S0 TL
GEELTUT, MTN ey
2-19
CABLE ROUTING
Main switch lead J. Fasten the stator coil lead, horn lead, and
ONOoarah= coolant reservoir hose with the holder at
Fuel pump coupler
the location shown in the illustration. Make
Throttle cable (decelerator cable) sure that there is no slack in the stator coll
Throttle cable (accelerator cable) lead, horn lead, and coolant reservoir
Throttle body assembly hose.
Oil cooler inlet hose K. Route the stator coil lead to the inside of
the radiator inlet hose, and then connect
Coolant reservoir hose
the stator coil coupler to the rectifier/regu-
Horn lead lator.
Stator coil lead L. Clamp the front turn signal/position light
. Radiator inlet hose lead at 5 mm (0.20 in) from the left end of
ts
oho"
. Front turn signal/position light lead the coupler. The clamp can be moved
within the range of 0-15 mm (0.59 in) from
sees
. Clutch cable the left end of front turn signal/position light

. Stator coil coupler lead coupler.
. Rectifier/regulator coupler M. Route the clutch cable through the hole in
the cover.
ont
. Joint coupler
ie
. Auxiliary DC outlet coupler N. Slack in the main switch lead must be posi-
tioned closer to the inside of the vehicle
. Rectifier/regulator bracket than to the wire harness.
nr
. Crankshaft position sensor coupler Connect the crankshaft position sensor
O
mm
OoOnm- ooo
. Radiator fan motor coupler lead to the coupler.

. Ignition coil #1 coupler Connect the coupler, and then insert the
-U
POOP
. Ignition coil #2 coupler projection on the coupler into the hole in

the rectifier/regulator bracket.
. Frame
RD PO
. Connect the stator coil coupler to the recti-

. Center line
D OC
fier/regulator.
Route the main switch lead under the lower Connect the rectifier/regulator coupler to
>
handlebar holder. the rectifier/regulator.

Fasten the main switch lead at the tape Secure the joint coupler to the cover.
S$<CHH
with a plastic locking tie. Face the buckle of Onward

the plastic locking tie forward with the end Front side
pointing downward.
Face the catch of the holder inward.
To the front turn signal/position light lead
. Cut the end of plastic band. The cut length
Make sure that the throttle cables do not must be less than 3 mm (0.12 in).
twist between the throttle body assembly
and the cable guide of the frame. Place the fastening portion of the plastic
x
band below the center line shown in the

5-10 mm (0.20-0.39 in) illustration.
Fasten the stator coil lead to the oil cooler
aL
inlet hose with a plastic locking tie. Make

sure to route the stator coil lead to the out-
side of the oil cooler inlet hose. Align the
plastic locking tie with the blue tape on the
stator coil lead. Face the buckle of the
plastic locking tie rearward, and then cut
off the excess end of the tie to 2 mm (0.08
in) or less.
. Fasten the stator coil lead and coolant res-
ervoir hose with the holder at the location
shown in the illustration. Make sure that
there is no slack in the stator coil lead.
Secure the holder by inserting the projec-
tion on the holder into the hole in the radia-
tor fan motor bracket, and then fasten the
stator coil lead, horn lead, and coolant res-
ervoir hose with the holder. Make sure that
the coolant reservoir hose and leads do
not cross between the oil cooler inlet hose
and this holder.
Fasten the stator coil lead, horn lead, and
coolant reservoir hose with the holder.
2-20
CABLE ROUTING
Frame and engine (left rear side view)
= ie oe -
=e He
HM oy Ne?
Be eros 4
eo >8
all
2-21
CABLE ROUTING
Starter motor lead The gear position switch lead and coolant
ONoOahrah= temperature sensor lead may be posi-
Tail/brake light coupler
tioned and routed in any order. Make sure
License plate light coupler that the leads is not twisted.
Yamaha diagnostic tool coupler Route the coolant temperature sensor lead
Rear turn signal light coupler (left) to the front of the gear position switch lead.
Rear turn signal light coupler (right) . Insert the projection on the coupler into the
=
Engine ground lead hole in the bracket.
Sidestand switch lead For California only
vOZ
Sidestand switch coupler Point the ends of the hose clamp inward.
Do not pinch the sidestand switch lead
oc"
. Terminal cover
4
between the engine ground lead and the

-coo
. Injector #1 coupler
frame.
Ss
+
. [SC (Idle Speed Control) unit coupler Insert the projection on the holder into the
es
On ontrhaht
O
. Injector #2 coupler hole in the frame from the bottom of the
oe
. Throttle position sensor coupler frame. The catch of the holder may be fac-
ing in any direction.
ee
. Throttle position sensor

Fit the starter motor lead between the bot-
Oohonwm-
. Coolant temperature sensor lead

eae
tom of the battery box and the rib on the

. Gear position switch lead battery box.
ae
. Gear position switch coupler

=a
. Fuel tank breather hose (blue paint mark)

|]
. Fuel tank overflow hose (white paint mark)

hp
. Coolant temperature sensor coupler

. Battery box
fh
. Battery
rmnprh
. Frame
. Canister breather hose
Insert the projection on the engine ground

>
lead holder into the hole in the frame from

the inside of the frame.
Fasten the engine ground lead and starter
motor lead to the frame with plastic locking
ties. Point the end of each plastic locking
tie rearward, and then cut off the excess
end of the tie to 2 mm (0.08 in) or less.
Fasten the starter motor lead and engine
ground lead with the holder. Align the white
tape on the starter motor lead with the
holder.
Blue paint mark
Ommo
White paint mark

0-10 mm (0-0.39 in)
Make sure that there is no twist in the
starter motor lead and sidestand switch
lead.
Fasten the starter motor lead, gear posi-
tion switch lead, and sidestand switch cou-
pler with the plastic band. Face the buckle
of the plastic band downward with the end
pointing inward.
Cover the engine ground terminal with the
terminal cover.
Route the coolant temperature sensor lead
and gear position switch lead between the
throttle position sensor and the cylinder
head.
2-22
CABLE ROUTING
As ey CL 5hn,
‘ soi oo
Aue ij i
des ee
~
~
SV Ea 0 O | V6
r=
yh4
é
“| “he : =>. 5
—— 5
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Pe Oey ‘hh |
phe ne i ee ee
MEH FA apres oper a =
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"ha
2-23
Frame (top view)
CABLE ROUTING
Rectifier/regulator . After connecting the main switch coupler,

ONOoarah= place the slack in the main switch lead to
Headlight relay
the rear of the plastic band. Make sure that
Turn signal/hazard relay there is no slack in the lead in the area
Radiator fan motor relay shown in the illustration.
Throttle cable Insert the projection on the main switch
Relay unit lead holder into the upper hole in the
frame.
Main switch coupler
Intake air temperature sensor coupler
holder into the lower hole in the frame.
ABS ECU coupler
Route the headlight relay lead and turn sig-
HSH HSH eee eH HS =H OO
oo"
. Hydraulic unit assembly nal/hazard relay lead through the rear hole
omanrtooanmnhbhuwonv=e-
MONMOMONYNYNYON
. ECU (Engine Control Unit) in the rectifier/regulator bracket.

. ECU coupler Position the main switch couplers under
OTA aN
. Cable lead cover the frame.

. Negative battery lead Face the buckle of the plastic band down-
ward with the end pointing inward.
. Fuse box 1
. Fuse box 2 holder into the hole in the frame from the
. Lean angle sensor bottom of the frame.
. Positive battery lead Cut off the excess end of the plastic lock-
ODA
Hh HSH
. Fuel pump coupler ing tie to 10 mm (0.39 in) or less.

. Intake air pressure sensor coupler Route the wire harness and the positive
battery lead as shown in the illustration.
. Frame They should not interfere with the seat.
Hh
. Wire harness Position the buckle of the plastic locking tie

. Seat bracket below the frame welding point.
. Battery Welding point
. Seat lock cable win the side edge of the battery band
. Battery box with the end of the positive battery lead
cover as shown in the illustration.
. Starter motor lead
7 Push the slack in the positive battery lead
. Positive battery lead cover
downward.
. Battery band
Z. The leads may be routed in any order.
To front turn signal/position light (right) AA. Place the positive battery lead coupler
>
lead under the fuse box.

Pass the front turn signal/position light
oO
(right) lead through the clamp.

Pass the front turn signal/position light lead
along with the ECU lead and sub-wire har-
ness through the cable guide.
Insert the projection on the sub-wire har-
ness coupler (13 pins) into the hole in the
bracket.
Route the ECU lead and sub-wire harness
through the cable guide.
Connect the sub-wire harness coupler (7
pins), and then insert the projection on the
coupler into the hole in the bracket.
. Fasten the wire harness with the battery
band. Do not route the wire harness
through the hole in the battery band.
Route the positive battery lead through the
i
hole in the battery band.

To positive battery lead
To starter motor
Ao
. Clamp the wire harness at the white tape.

Insert the projection on each wire harness
~
holder into the hole in the frame.
2-24
CABLE ROUTING
Rear fender (top view)
2-25
CABLE ROUTING
Battery band
ONOoahrahn=
Wire harness
Positive battery lead
Negative battery lead
Fuse box 1
Fuse box 2
Lean angle sensor
Rear turn signal light lead (left turn signal
light)
Rear turn signal light lead (right turn signal
co
light)
10. License plate light lead
11. Tail/brake light assembly lead
12. Battery
13. Battery box
14. Seat lock cable
Route the rear left turn signal light lead,

rear right turn signal light lead, and license
plate light lead through the hole in the
frame.
Install fuse box 1 completely onto the tab
®D
on the battery box.

Route the seat lock cable through the
oO
guide on the battery box.

Install fuse box 2 completely onto the tab
oO
on the battery box.

Route the tail/brake light assembly lead,
rear turn signal light leads, and license
plate light lead through the hole in the bat-
tery box. The leads may be routed in any
order.
Fasten the tail/orake light assembly lead,
plate light lead with the holder. The leads
may be fastened in any order.
2-26
CABLE ROUTING
Rear fender (left side view)
2-27
CABLE ROUTING
Seat lock cable

License plate light lead
oN
Rear turn signal light lead (right turn signal
light)
Tail/brake light assembly lead
oS
Tail/brake light assembly

Rear turn signal light lead (left turn signal
light)
Seat lock key cylinder bracket
Frame
Seat lock assembly
10. Mudguard
11. License plate light
12. Rear turn signal light (left)
13. Plate
Insert the seat lock cable completely into

the hole in the seat lock key cylinder
bracket.
Fasten the tail/brake light assembly lead,
plate light lead with a plastic locking tie.
The leads may be fastened in any order.
Cut off the excess end of the plastic lock-
ing tie so that it does not contact the seat
lock assembly.
Insert the seat lock cable completely into
the hole in the seat lock assembly.
The leads may be routed in any order.
mo
Route the rear turn signal light leads and

license plate light lead between the muda-
guard and the plate.
2-28
CABLE ROUTING
Rear brake hose (right side view)
2-29
CABLE ROUTING
Rear wheel sensor lead

Rear brake fluid reservoir hose
oN
Brake hose (rear brake master cylinder to
hydraulic unit)
Brake hose (hydraulic unit to rear brake
>
caliper)
Oil pressure switch lead
NOM
O, sensor lead
Rear brake light switch lead
Route the rear wheel sensor lead to the

>
outside of the brake hose (hydraulic unit to

rear brake caliper). Make sure that the rear
wheel sensor lead is not twisted.
Align the holder with the pipe section of the
brake hose (hydraulic unit to rear brake
caliper).
Position the holder halfway between the
guide and the end of the protective sleeve
on the rear wheel sensor lead as shown in
the illustration.
Route the brake hoses to the inside of the
frame.
To O, sensor
Fasten the grommets on the rear wheel
a
sensor lead and the brake hose (hydraulic

unit to rear brake caliper) with the holder.
Fasten the rear wheel sensor lead and
caliper) with the holder. Route the rear
wheel sensor lead over the brake hose
(hydraulic unit to rear brake caliper). Align
the holder with the pipe section of the
caliper), making sure that the white tape on
the rear wheel sensor lead is positioned to
the front of the holder.
White tape
To oil pressure switch
Route the rear brake light switch lead, O,
sensor lead and oil pressure switch lead to
the inside of the rear wheel sensor lead.
Route the brake hoses on top of the frame.
rn A
Point the end of the clamp rearward, and

then cut off the excess end of the tie to 5
mm (0.20 in) or less.
. Route the rear wheel sensor lead and
caliper) through the guide.
2-30
CABLE ROUTING
Front brake hose (left and right side view)
2-31
CABLE ROUTING
Brake hose (hydraulic unit to left front

brake caliper)
Front wheel sensor lead
oh
Brake hose (left front brake caliper to right

front brake caliper)
Brake hose (front brake master cylinder to
hydraulic unit)
Make sure that there is no slack in the front

wheel sensor lead and that the lead is not
pinched between the headlight unit side
cover (right) and the brake hose (hydraulic
unit to left front brake caliper) in the area
shown in the illustration.
Fasten the front wheel sensor lead and
brake hose (hydraulic unit to left front brake
caliper) with the holder as shown in the
illustration. Position the holder 80—100 mm
(3.15—3.94 in) from the grommet on the
hose and route the lead over the hose.
Face the catch of the holder forward, and
then close the holder until three clicks or
more are heard.
Make sure that the holder contacts the end
of the hose protector on the brake hose.
illustration. Position the holder 30—50 mm
(1.18—1.97 in) from the grommet on the
hose and route the lead to the rear of the
hose.
To front brake master cylinder
Igo
. To hydraulic unit
illustration. Position the holder 15 mm
(0.59 in) or less from the grommet on the
hose and route the lead to the outside of
the hose. Face the catch of the holder
inward, and then close the holder until two
clicks or more are heard.
2-32
CABLE ROUTING
Hydraulic unit assembly (top and right side view)
4
i
ey
>—
—
2-33
CABLE ROUTING
Brake hose (rear brake master cylinder to

hydraulic unit)
Brake hose (front brake master cylinder to
hydraulic unit)
Brake hose (hydraulic unit to left front
brake caliper)
Brake hose (hydraulic unit to rear brake
caliper)
Make sure that the pipe section of the

brake hose (rear brake master cylinder to
hydraulic unit) does not contact the hydrau-
lic unit.
2-34
CABLE ROUTING
Fuel tank (left side view)
2-35
CABLE ROUTING
Fuel tank
FON Fuel hose
Fuel tank breather hose
Fuel tank overflow hose
Face the blue paint mark on the fuel tank

Pp
breather hose to the right. Install the hose

up to the wide portion of the pipe.
Align the ends of the hose clamp with the
paint mark on the hose. Make sure not to
install the hose clamp on the raised portion
of the hose fitting. Make sure that the hose
clamp does not contact the bottom of the
fuel tank.
Face the white paint mark on the fuel tank
overflow hose to the right. Install the hose
up to the wide portion of the pipe.
2-36
CABLE ROUTING
Throttle bodies (top view)
2-37
CABLE ROUTING
Air filter case

WN=
Fuel hose
Cylinder head breather hose
Face the yellow paint mark on the cylinder

FP
head breather hose to the left.

Position the hose clamp 1—4 mm (0.04—
oO
0.16 in) from the end of the hose. Point the

ends of the hose clamp to the left.
Position the hose clamp 1—4 mm (0.04—
©
0.16 in) from the end of the hose.
2-38
CABLE ROUTING
Air filter case (left and right side view)
2-39
CABLE ROUTING
Throttle cable (accelerator cable)

=
hah
Throttle cable (decelerator cable)
Intake air pressure sensor
Intake air pressure sensor hose
Fuel hose
ONOa
Air filter case

Throttle body assembly
Cylinder head breather hose
Install the intake air pressure sensor hose

FP
up to the bend in the hose fitting of the

intake air pressure sensor.
Make sure that the hose is not twisted.
Install the intake air pressure sensor hose
©)
onto the throttle body assembly, making

sure that the hose contacts the throttle
body assembly.
Forward
©
90°
am
Position the ends of the hose clamp within

the range shown in the illustration.
. Face the blue paint mark on the cylinder
head breather hose upward. Install the cyl-
inder head breather hose onto the air filter
case, making sure that the hose contacts
the case.
2-40
CABLE ROUTING
Radiator (front view)
2-41
CABLE ROUTING
Radiator
Oakhanh= Radiator cap
Radiator inlet hose
Coolant reservoir
Radiator outlet hose
Connect the end of the coolant reservoir

>
hose that is identified by the white paint

mark to the radiator.
Point the ends of the hose clamp toward
the frame.
2-42
CABLE ROUTING
Radiator (left side view)
2-43
CABLE ROUTING

P= = 2 OMNONRWN> Radiator inlet hose
Thermostat housing
Oil cooler inlet hose
Coolant reservoir breather hose
Coolant reservoir
Coolant reservoir cap
Radiator
Radiator cap
. Stator coil lead
. Horn lead
Fasten the coolant reservoir hose to the

radiator inlet hose with the plastic locking
tie. Position the coolant reservoir hose
directly under the radiator inlet hose. Face
the buckle of the plastic locking tie inward
with the end pointing downward.
Align the white paint mark on the radiator
inlet hose with the projection on the ther-
mostat housing. Install the radiator inlet
hose onto the thermostat housing, making
sure that the hose contacts the projection
on the housing.
Point the ends of the hose clamp outward.
Install the coolant reservoir hose onto the
coolant reservoir cap, making sure that the
hose contacts the cap.
Face the catch of the holder forward.
Position the clamp screw within the range
a
shown in the illustration.

. 90°
-IrQ
Outward
Route the coolant reservoir breather hose
to the outside of the oil cooler inlet hose.
2-44
CABLE ROUTING
Radiator (right side view)
2-45
CABLE ROUTING
Radiator inlet hose

ONOahrah=
Radiator cap
Radiator
Coolant reservoir
Coolant reservoir breather hose
Radiator outlet hose
Oil cooler inlet hose
Align the plastic locking tie with the white

FP
paint marks on the radiator inlet hose and

coolant reservoir hose.
Point the ends of the hose clamp in the
direction shown in the illustration. Make
sure that the ends of the hose clamp do
not contact the coolant reservoir hose.
Align the yellow paint mark on the radiator
inlet hose with the projection on the radia-
tor pipe. Install the radiator inlet hose onto
the radiator pipe, making sure that the
hose contacts the projection on the pipe.
2-46
CABLE ROUTING
2-47
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE ..........ccccccescsseneeseescaseneeeeessneeaseeeessaeeaeessessaeeaeeseeseas 3-1

INTRODUCTION .. 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL.
SYSTEM.. seseeeeeeeeeeeeeeeeeOU
GENERAL MAINTENANCE AND LUBRICATION CHART. stesteseees Or
CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC
CHECKING THE FUEL LINE... fethiuhd cies iodsneegindsectdepdvsntaaesduanedeasigechicn wee

CHECKING THE SPARK PLUGS occcccccccccsccsvsssesessssesesesssesssssessssssssseeseeeee 45
ADJUSTING THE VALVE CLEARANCE ....... occ ccc cee eeeceteeeeeeeeeeneeeeeeees OO
CHECKING THE ENGINE IDLING SPEED .......0000 eee OB
SYNCHRONIZING THE THROTTLE BODIES. .......... ee cee eee eeeeeeee OY
CHECKING THE THROTTLE BODY JOINTS .. ccecsssssssssssssnssasisiseneee 3° 11
CHECKING THE CANISTER (for California only)... seaeeeeeeeeeeeneee 7d
REPLACING THE AIR FILTER ELEMENT AND CLEANING
THE CHECK HOSE... cee eeeeeeeaasaeeeeeeesaseeeeee OUD I
ADJUSTING THE CLUTCH LEVER FREE PLAY... secudseeeeeeeuve eee seese Le
CHECKING THE BRAKE OPERATION -cssssssssssesessssssssessesssesssssssssssssesesne 3°13
ADJUSTING THE FRONT DISC BRAKE .....00.0... cee GIS
CHECKING THE FRONT BRAKE PADS ........ ccc ee eeeeeeeeeeeeeeeeeeeee BUT
ADJUSTING THE REAR DISC BRAKE ............ 2. ee teeter OIA
CHECKING THE REAR BRAKE PADS ....... cece eect cee eee eeeeeeteeeeeeaeeee OIA
CHECKING THE BRAKE HOSES... vb riesdeneecucpeae seen 1
BLEEDING THE HYDRAULIC BRAKE SYSTEM H (ABS). beseateeeeeesaeeeeees OTL
CHECKING THE BRAKE FLUID LEVEL... scessssssstsssssisissssseesseeeeee 3°16
CHECKING THE WHEELS.. sscssssssssssssssssssssssisssssuvssssssssssssssssesessessins 316
CHECKING THE TIRES... pew sneiedneey seschaddvas deemnanssteedceeddedeees tl" LO
CHECKING THE WHEEL BEARINGS.. peetwauenk stn cues ceweieW aa ceshe ooecaws So 1
CHECKING THE SWINGARM OPERATION... beeen ees eesaaeeeeeseesaaeeeeeseeeteseeees OIG
LUBRICATING THE SWINGARM PIVOT ..... 0c eect eeeee eee OIG
DRIVE CHAIN SLACK... seeeeideas ide: atacesesisparcudelvesaertecpesesssecevent
LUBRICATING THE DRIVE CHAIN. eee eeeeeeeeeeeeeeeeees OIG
CHECKING AND ADJUSTING THE STEERING HEAD... byivie bectewestucaage Le
LUBRICATING THE STEERING HEAD osssecsccsccssccsssssssssssssssvesssvseeseeeeeee 3-20
CHECKING THE FASTENERS ....0 00... ce ccc ceee eee e cee eeee eee eaesueeeeeeeaeaaees DLO
LUBRICATING THE BRAKE LEVER2.000... e cece cee ee eee eee saa eeeeeeee es OT2O
LUBRICATING THE PEDAL .. be ceeeeeeeeeeaeaeaaeeceseeaeeeeseeseseeeeeeeees O72O
LUBRICATING THE CLUTCH LEVER... peu eais eeu deids a dad ese stew saves
CHECKING THE SIDESTAND .ccscscssssssscccsescsscssecsesssssssssssssssssseveesesesseseeee 3-20
LUBRICATING THE SIDESTAND........ cece cece ee eeeee eee eaa ee eeeeee es OOO
CHECKING THE SIDESTAND SWITCH... occ eeeee teers eee BO
CHECKING THE FRONT FORK.. beste eeeeeeesaeeee O7LO
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY . beeeeeeeeeeeeeeee OPE
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ..................3-21
CHECKING THE CONNECTING ARM AND RELAY ARM......................3-22
CHECKING THE ENGINE OIL LEVEL .......00. eee cece eceeeeeeeeeeeeees OUD
CHANGING THE ENGINE OIL.. vasa eeeeeeecaeaeeaeseeeaeueaeeeseeaes QUOD
MEASURING THE ENGINE OIL PRESSURE .. pase ededeyetdeeee see vecwest se
CHECKING THE COOLANT LEVEL ............ 2. ceeeee cece eee ee ea eeeeee eee eeeeees 3-25
CHECKING THE COOLING SYSTEM... cece ceca eaten ener a eae 3-25
CHANGING THE COOLANT...
CHECKING THE FRONT BRAKE LIGHT SWITCH Pesce dats Souseaaen sven eatewaat 3-27
ADJUSTING THE REAR BRAKE LIGHT SWITCH ..........0.00 eee 3-27
CHECKING AND LUBRICATING THE CABLES ..........0 ee 3-28
CHECKING THE THROTTLE GRIP OPERATION .............cceeceeee seen 3-28
CHECKING AND CHARGING THE BATTERY ................ eee 3-29
CHECKING THE FUSES... wanna O29
REPLACING THE HEADLIGHT BULB...
ADJUSTING THE HEADLIGHT BEAM .......... ccc ccc eeeeeeeeeeeeeeeeeeeeeeees 3-30
PERIODIC MAINTENANCE
EASso0e7
EAS3002e2
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS30614
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

TIP
¢ From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi
(13000 km) or 12 months.
e Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer
perform the service.
INITIAL ODOMETER READINGS

. | 8000 mi | 12000 mi | 16000 mi | 20000 mi
No. ITEM ROUTINE (1000 km) (7000 Km) | (13000 | (19000 | (25000 | (31000
km) km) km) km)
or or
1 month | 6 months or or or or
12 months |18 months |24 months /|30 months
* Check fuel hoses for cracks or

1| *| Fuel line damage. v v Vv v V
* Replace if necessary.
*« Check condition. J J J
2|*| Spark plugs * Adjust gap and clean.
* Replace. 1 1
3|*| Valveclearance | * heck and adjust
ance when engine valve
is cold.clear- Every 26600 mi (42000 km)
« Check breather hose for
4|* ee breath- | cracks or damage. V V V V V
y * Replace if necessary.
5| "| Fuel injection « Adjust synchronization. 4 a} 4 4 4
Evaporative emis-
« Check control system for
g | *| Sion control sys- damage. V V
tem (for California
only) * Replace if necessary.
EAS30615
GENERAL MAINTENANCE AND LUBRICATION CHART

TIP
¢ From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi
(13000 km) or 12 months.
e Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer
perform the service.

. . | 8000 mi | 12000 mi | 16000 mi | 20000 mi
No. ITEM ROUTINE 600 mikm) || (7000
(1000 4000 km)
mi | (43000 | (19000 | (25000 | (31000
or or kim) km) km) km)
or or or or
1 month | 6 months | 49 months|18 months|24 months |30 months
. . _ *« Perform dynamic inspection
1| * Piagnostic sys using Yamaha diagnostic tool. v V v v v v
« Check the error codes.
2|"| Airfilterelement | * Replace. Every 24000 mi (37000 km)
. - | 8000 mi | 12000 mi | 16000 mi | 20000 mi

No. ITEM ROUTINE (1000 km) (7000 Km) | (13000 | (19000 | (25000 | (31000
or or km) km) km) km)
or or or or
1 month | 6 months 12 months | 18 months|24 months |30 months
3) | titer check | « Clean. \ v \ , \ v

« Check operation.
4 Clutch « Adjust or replace cable. \ V V V N V
« Check operation, fluid level,
and for fluid leakage.
5 Front brake * Replace brake pads if neces- N V V V V V
sary.
« Check operation, fluid level,
and for fluid leakage.
6 Rear brake * Replace brake pads if neces- N V V V N V
sary.
e Check for cracks or damage.
¢ Check for correct routing and V y Vv y v
7 Brake hoses clamping.
* Replace. Every 4 years
8 Brake fluid ¢ Change. Every 2 years
* Check runout and for damage.
3 wheels * Replace if necessary. V \ V y V
« Check tread depth and for
damage.
10) * | Tires * Replace if necessary. V 1 Vv y V
« Check air pressure.
¢ Correct if necessary.
e Check bearings for smooth
11| *| Wheel bearings operation. v y v V v
. Check operation and for ex- nl nT J J 1
12 Swingarm pivot cessive play.
bearings ° Moderately repack with lithi-
um-soap-based grease.
|
Every 32000 mi (50000 km)
¢ Check chain slack, alignment
13} | Drive chain * and

Adjustcondition.
and lubricate chain with | Every EY@ry 500
500 mi mi ( (800 km)
m) and
and a after ding ir washingIG) the The PGR,
motorcycle, MCIridingTag iFTn Eri
the rairetin
a special O-ring chain lubri- or riding in wet areas
cant thoroughly.
¢ Check bearing assemblies for nT J \ J yy J
looseness.
14| * | Steering bearings uaa : Dah Ih
* Moderately repack with lithi-
um-scap-based grease. Every 12000 mi (19000 km)
¢ Check all chassis fitting and
15| *| Chassis fasteners | fasteners. v y v v v
* Correct if necessary.
16 cee lever pivot |, Apply silicone grease lightly. v y v V v

Brake pedal pivot | « Apply lithium-soap-based
7 shaft grease lightly. v \ V N V
Clutch lever pivot | * Apply lithium-soap-based
18 shaft grease lightly. V V V N V
Shift pedal pivot * Apply lithium-soap-based
19 shaft grease lightly. V V V N V
¢ Check operation.
20| | Sidestand pivot ¢ Apply lithium-soap-based v y v V v
grease lightly.
, , « Check operation and replace
21| * | Sidestand switch if necessary. v v V V y V
¢ Check operation and for oil
22| * | Front fork leakage. v y v V v
“ - | 8000 mi | 12000 mi | 16000 mi | 20000 mi

No. ITEM ROUTINE (1000 km) (7000 km) | (13000 | (19000 | (25000 | (31000
or or pth, pl, pis, oy
1 month | 6 months | 15 months|18 months|24 months |30 months
Gheck operation and for oil
23) * aan leakage. v 4 Vv Y v
Replace if necessary.
» | Rear suspension Apply lithium-soap-based
24) * | link pivots grease lightly. Every 12000 mi (19000 km)
25| | Engine oil, Change

draining). (warm engine before v V ¥ v y v
26 canta: filter Replace. Y y Y

Check hoses for cracks or
damage. Vv v Vv v Vv
27| * | Cooling system Replace if necessary.
Change coolant. y
28) * ee ee Check operation. Y v 1 Vv v v
Apply Yamaha cable lubricant
29| * | Control cables or other suitable cable lubri- V v 4 Vv v v
cant thoroughly.
« Check operation.
« Check throttle grip free play,
30| * | Throttle grip and adjust if necessary. v V v v v
Lubricate cable and grip hous-
ing.
, | Lights, signals * Check operation.
31 and switches « Adjust headlight beam. V V V V \ V
TIP
¢ Air filter
¢ This model uses a disposable oil-coated paper element. This element cannot be cleaned with com-
pressed air, doing so will only damage it.
* Replace the air filter more frequently if you often ride in the rain or dusty conditions.
e Hydraulic brake service
¢ Regularly check the brake fluid levels. Replenish as necessary
¢ Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
* Replace the brake hoses every four years or sooner if cracked or damaged.
EAsae0e4
5. Install:
CHECKING THE VEHICLE USING THE
e Storage compartment cover
YAMAHA DIAGNOSTIC TOOL
¢« Passenger seat
Use the Yamaha diagnostic tool and check the
Refer to “GENERAL CHASSIS (1)” on
vehicle according to the following procedure.
page 4-1.
1. Remove:
* Passenger seat FAS S0619
e Storage compartment cover CHECKING THE FUEL LINE

Refer to “GENERAL CHASSIS (1)” on The following procedure applies to all of the fuel,
page 4-1. vacuum and breather hoses.
Remove the protective cap “1”, and then con- 1. Remove:
nect the Yamaha diagnostic tool to the cou- e Passenger seat
pler “2”. e Rider seat
Yamaha diagnostic tool USB page 4-1.
90890-03257 e Air scoop (left)
Yamaha diagnostic tool (A/I) ¢ Air scoop (right)
90890-03262 ¢ Fuel tank center cover (fuel tank side covers)
page 4-9.
e Rear fuel tank bracket bolt “1”
TIP
After removing the rear fuel tank bracket bolts,
lift up the rear of the fuel tank.
ECAZ0070
NOTICE
When lifting up the fuel tank, be careful not
to pull the fuel tank overflow hose and fuel
3. Check: tank breather hose.
* Fault codes
2
TIP eat
Use the “Diagnosis of malfunction” function of

the Yamaha diagnostic tool to check the fault
codes. For information about using the Yamaha
diagnostic tool, refer to the operation manual
that is included with the tool.
Fault code number is displayed — Check and
repair the probable cause of the malfunction.
Refer to “TROUBLESHOOTING DETAILS |
2. Check:
(FAULT CODE)” on page 8-37.
4 . Perform: ¢ Fuel hose “1”
¢ Fuel tank overflow hose “2”
¢ Dynamic inspection
¢ Fuel tank breather hose “3”
TIP
Cracks/damage —> Replace.
Use the “Dynamic inspection” function of the Loose connection — Connect properly.
Yamaha diagnostic tool version 3.0 and after to
perform the dynamic inspection. For information NOTICE
about using the Yamaha diagnostic tool, refer to Make sure the fuel tank breather/overflow
the operation manual that is included with the hose is routed correctly.
tool.
3. Check:
¢ Spark plug type
Incorrect + Change.
Manufacturer/model
NGK/LMAR8A-9
4. Check:
e Electrode “1”
Damage/wear — Replace the spark plug.
3. Install: e Insulator “2”
e Rear fuel tank bracket bolt Abnormal color > Replace the spark plug.
Normal color is medium-to-light tan.
X Rear fuel tank bracket bolt 5. Clean:
% 10 N-m (1.0 kgf-m, 7.4 Ib-ft) e Spark plug
(with a spark plug cleaner or wire brush)
4. Install: 6. Measure:
¢ Fuel tank center cover (fuel tank side covers) e Spark plug gap “a”
e Air scoop (right) (with a wire thickness gauge)
* Air scoop (left) Out of specification > Regap.
page 4-9. Spark plug gap
¢ Rider seat 0.8—0.9 mm (0.031—0.035 in)
* Passenger seat
page 4-1.
EASSa0620
CHECKING THE SPARK PLUGS

The following procedure applies to all of the
spark plugs.
1. Remove:
¢ Passenger seat
e Rider seat
page 4-1. 7. Install:
¢ Air scoop (left) e Spark plug
\
¢ Air scoop (right) ¢ Ignition coil
¢ Fuel tank center cover (fuel tank side covers)
Refer to “GENERAL CHASSIS (4)” on XY Spark plug
13 N-m (1.3 kgf-m, 9.6 lb-ft)
page 4-9.
¢ Fuel tank
TIP
Refer to “FUEL TANK” on page 7-1.
2. Remove: Before installing the spark plug, clean the spark
* Ignition coil plug and gasket surface.
¢ Spark plug 8. Install:
ECA133920
NOTICE e Fuel tank

Before removing the spark plugs, blow away
any dirt accumulated in the spark plug wells
e Air scoop (right)
with compressed air to prevent it from falling
e Air scoop (left)
into the cylinders.
page 4-9.
e Rider seat
* Passenger seat
Refer to “GENERAL CHASSIS (1)” on Valve clearance (cold)
page 4-1. Intake
0.11—0.20 mm (0.0043-0.0079
in)
EASSa0622
ADJUSTING THE VALVE CLEARANCE

Exhaust
0.24—0.30 mm (0.0094-0.0118
valves. in)
TIP
e Valve clearance adjustment should be made . Turn the crankshaft counterclockwise.
on acold engine, at room temperature. . When piston #1 is at TDC on the compres-
oOo
e When the valve clearance is to be measured or sion stroke, align the TDC mark “a” on the
adjusted, the piston must be at top dead center generator rotor with the slot “b” in the gen-
(TDC) on the compression stroke. erator rotor cover.
1. Drain:
¢ Coolant
Refer to “CHANGING THE COOLANT” on
page 3-25.
2. Remove:
¢ Passenger seat
¢ Rider seat
¢ Air scoop (left)
¢ Air scoop (right)
¢ Fuel tank center cover (fuel tank side covers) c. Measure the valve clearance with a thick-
Refer to “GENERAL CHASSIS (4)” on ness gauge “1”.
page 4-9.
¢ Radiator Thickness gauge
¢ Radiator inlet hose 90890-03180
Refer to “RADIATOR” on page 6-2. Feeler gauge set
¢ Clutch cable guide YU-26900-9
Refer to “ENGINE REMOVAL’ on page 5-11.
3. Remove:
* Ignition coil
¢ Spark plug
¢ Cylinder head cover
¢ Cylinder head cover gasket
Refer to “CAMSHAFTS” on page 5-20.
4. Remove:
¢ Timing mark accessing bolt “1”
¢ Crankshaft end cover “2”
TIP
¢ If the valve clearance is incorrect, record the
measured reading.
¢ Measure the valve clearance in the following
sequence.
Valve clearance measuring sequence

Cylinder #1 — #2
5. Measure:
° Valve clearance
Out of specification — Adjust.
Ve Valve lapper (014)

90890-04101
OO
Valve lapping tool (14mm)
YM-A8998
4 A
TIP
¢ Cover the timing chain opening with a rag to
prevent the valve pad from falling into the
crankcase.
A. Front ¢ Make a note of the position of each valve lifter
“1” and valve pad “2” so that they can be in-
d. To measure the valve clearances of cylin-
stalled in the correct place.
der #2 turn the crankshaft 270° counter-
clockwise.
B 0° 180° 360° 540° 720 '1 | 2

——— |1 |
r tT 4 1 | EX © OO O
270°
C
1 D N @ ©8 |
©
de
#2 D / \
2 1
b. Calculate the difference between the spec-

B. Degrees that the crankshaft is turned coun- ified valve clearance and the measured
terclockwise valve clearance.
C. Cylinder Example:
D. Combustion cycle Specified valve clearance = 0.11—0.20 mm
(0.0043—0.0079 in)
6. Remove: Measured valve clearance = 0.25 mm
¢ Camshaft
(0.0098 in)
TIP 0.25 mm (0.0098 in)—0.20 mm (0.0079 in) =
¢ Refer to “CHANGING THE COOLANT” on 0.05 mm (0.0020 in)
page 3-25. c. Check the thickness of the current valve
e When removing the timing chain and cam- pad.
shafts, fasten the timing chain with a wire to re- TIP
trieve it if it falls into the crankcase. The thickness “a” of each valve pad is marked in
7. Adjust: hundredths of millimeters on the side that touch-
* Valve clearance es the valve lifter.
a. Remove the valve lifter “1” and the valve Example:
pad “2” with a valve lapper “3”. lf the valve pad is marked “158”, the pad
thickness is 1.58 mm (0.0622 in).
458
d. Calculate the sum of the values obtained in

steps (b) and (c) to determine the required
valve pad thickness and the valve pad num-
ber.
Example:
1.58 mm (0.0622 in) + 0.05 mm (0.0020 in)
= 1.63 mm (0.0641 in)
The valve pad number is 163.
. Round off the valve pad number according
to the following table, and then select the
suitable valve pad. g. Install the exhaust and intake camshafts,
Last digit Rounded value timing chain and camshaft caps.
0,1,2 0
Exhaust camshaft cap bolt
3,4, 5,6 5 10 N-m (1.0 kgf-m, 7.4 Ib-ft)
7,8,9 10 Intake camshaft cap bolt
10 N-m (1.0 kgf-m, 7.4 lb-ft)
TIP TIP
Refer to the following table for the available * Refer to “CAMSHAFTS’” on page 5-20.
valve pads. ¢ Lubricate the camshaft lobes and camshaft
journals with molybdenum disulfide oil.
Valve pad range No. 150-240 ¢ First, install the exhaust camshaft.
Valve pad thickness 1.50-2.40 mm ¢ Align the camshafts sprocket marks with the
(0.0590-0.0944 in) cylinder head edge.
Available valve pads 25 thicknesses in ¢ Turn the crankshaft counterclockwise several
0.05 mm (0.0020 in) full turns to seat the parts.
increments
h. Measure the valve clearance again.
i. Ifthe valve clearance is still out of specifica-
Example:
tion, repeat all of the valve clearance ad-
Valve pad number = 163
justment steps until the specified clearance
Rounded value = 165
is obtained.
New valve pad number = 165
f. Install the new valve pad “1” and the valve 8. Install:
lifter “2”. e All removed parts
TIP TIP
e Lubricate the valve pad with molybdenum di- For installation, reverse the removal procedure.
sulfide oil.
¢ Lubricate the valve lifter with engine oil. EASSIO1?
e Install the valve lifter and the valve pad in the CHECKING THE ENGINE IDLING SPEED
correct place. TIP
¢ The valve lifter must turn smoothly when rotat- Prior to checking the engine idling speed, the
ed by hand. throttle body synchronization should be adjusted
properly, the air filter element should be clean,
and the engine should have adequate compres-
sion.
1. Start the engine and let it warm up for several
minutes.
2. Check:
¢ Engine idling speed
Out of specification + Go to next step.
e Fuel tank
(-} Engine idling speed

1250-1450 r/min
3. Disconnect:
e Intake air pressure sensor hose
3. Check: Refer to “THROTTLE BODIES” on page 7-8.
¢ ISC (idle speed control) learning value 4. Install:
“00” or “01” — Check the intake system. e Hose “1” (Parts No.: 5JW-24311-00)
“02” —+ Clean the ISC (idle speed control) ° 3-way joint “2” (Parts No.: 90413-05014)
valve. e Vacuum gauge hose #1 “3”
Refer to “CLEANING THE ISC (IDLE SPEED e Vacuum gauge hose #2 “4”
CONTROL) VALVE” on page 7-11. ¢ Intake air pressure sensor hose “5”
a. Connect the Yamaha diagnostic tool. e Vacuum gauge “6”
Use the diagnostic code number “67”.
Refer to “SELF-DIAGNOSTIC FUNCTION Vacuum gauge
AND DIAGNOSTIC CODE TABLE?” on 90890-03094
page 9-1. Vacuummate
x
YU-44456
Yamaha diagnostic tool USB
90890-03257
Yamaha diagnostic tool (A/I)
90890-03262
b. Check the ISC (idle speed control) leaning

value.
EASsoTo?
SYNCHRONIZING THE THROTTLE BODIES

TIP
Before synchronizing the throttle bodies, check
the following items:
e Valve clearance
e Spark plug
e Air filter element
e Throttle body joint
e Fuel hose
e Exhaust system
e Cylinder head breather hose
e Vacuum hose
Checking the throttle body synchronization A. Throttle body #1

1. Stand the vehicle on a level surface. B. Throttle body #2
TIP 5. Install:
Place the vehicle on a suitable stand. e Fuel tank
2. Remove:
6. Check:
*« Passenger seat
e Throttle body synchronization
¢ Rider seat
Refer to “GENERAL CHASSIS (1)” on a. Start the engine, warm it up for several min-
page 4-1. utes, and then let it run at the specified en-
¢ Air scoop (left) gine idling speed.
e Air scoop (right)
* Fuel tank center cover (fuel tank side covers) (x Engine idling speed
1250-1450 r/min
page 4-9.
b. Check the vacuum pressure.
The difference in vacuum pres-

sure between the throttle bodies
| should not exceed 1.33 kPa (10
mmHg).
lf out of specification — Adjust the throttle

body synchronization.
Adjusting the throttle body synchronization

1. Adjust:
¢ Throttle body synchronization
a. Start the engine, warm it up for several min-
utes, and then let it run at the specified en-
gine idling speed.
(-) Engine idling speed

1250-1450 r/min
|
b. With throttle body #1 as standard, adjust

throttle body #2 using the air screw “1”.
A. Throttle body #1
TIP
B. Throttle body #2
¢ Turn the bypass air screw using the carburetor
angle driver. 2. Stop the engine and remove the measuring
e After each step, rev the engine two or three equipment.
times, each time for less than a second, and 3. Connect:
check the synchronization again. e Intake air pressure sensor hose
¢ lf a bypass air screw was removed, turn the Refer to “THROTTLE BODIES” on page 7-8.
screw in fully and be sure to synchronize the 4. Install:
throttle bodies. ¢ Fuel tank
e If the throttle body synchronization can not be Refer to “FUEL TANK” on page 7-1.
adjusted using the bypass air screw, clean or ¢ Fuel tank center cover (fuel tank side covers)
replace the throttle bodies. e Air scoop (right)
e The difference in vacuum pressure between ¢ Air scoop (left)
the throttle bodies should not exceed 1.33 kPa Refer to “GENERAL CHASSIS (4)” on
(10 mmHg). page 4-9.
e Rider seat
¢« Passenger seat
Carburetor angle driver 2 |
90890-03173 Refer to “GENERAL CHASSIS (1)” on
page 4-1.
5. Adjust:
e Throttle grip free play
Refer to “CHECKING THE THROTTLE GRIP
OPERATION” on page 3-28.
Throttle grip free play

3.0—5.0 mm (0.12-0.20 in)
3-10
EASao79a
CHECKING THE THROTTLE BODY JOINTS
1. Remove:
page 4-9.
e Passenger seat
e Fuel tank
¢ Rider seat
2. Check:
page 4-1.
e Canister
¢ Air scoop (left)
e Canister purge hose
e Fuel tank breather hose
e Canister breather hose
Cracks/damage-— Replace.
page 4-9.
3. Install:
e Fuel tank
e Fuel tank
2. Disconnect:
e Fuel tank center cover (fuel tank side covers)
¢ Intake air pressure sensor hose
e Air scoop (right)
¢ Canister purge hose (for California only)
e Air scoop (left)
Refer to “THROTTLE BODIES” on page 7-8.
3. Remove:
page 4-9.
¢ Throttle body
e Rider seat
Refer to “THROTTLE BODIES” on page 7-8.
e Passenger seat
4. Check:
¢ Throttle body joint
page 4-1.
Cracks/damage —> Replace.
5. Install: EAS31130
* Throttle body REPLACING THE AIR FILTER ELEMENT

Refer to “THROTTLE BODIES’ on page 7-8. AND CLEANING THE CHECK HOSE
6. Connect: TIP
¢ Intake air pressure sensor hose There is an air filter check hose “1” at the bottom
¢ Canister purge hose (for California only) of the air filter case. If dust and/or water collects
Refer to “THROTTLE BODIES” on page 7-8. in this hose, clean the air filter check hose and
7. Install: replace the air filter element.
¢ Fuel tank
e Air scoop (right)
e Air scoop (left)
page 4-9.
¢ Rider seat
¢ Passenger seat
page 4-1. -)
1. Remove:
EASSO626
e Passenger seat
CHECKING THE CANISTER (for California
e Rider seat
only)
1. Remove:
page 4-1.
e Passenger seat
e Air scoop (left)
¢ Rider seat
e Air scoop (right)
page 4-1.
¢ Air scoop (left)
page 4-9.
3-11
¢ Fuel tank EC AI4401
Refer to“FUEL TANK” on page 7-1. NOTICE

2. Remove: Never operate the engine without the air filter
e Air duct bracket “1” element installed. Unfiltered air will cause
Refer to “AIR FILTER” on page 7-7. rapid wear of engine parts and may damage
the engine. Operating the engine without the
air filter element will also affect carburetor
synchronization, leading to poor engine per-
formance and possible overheating.
6. Install:
e Fuel tank
e Air scoop (right)
e Air scoop (left)
3. Remove: Refer to “GENERAL CHASSIS (4)” on
page 4-9.
e Rider seat
¢« Passenger seat
page 4-1.
FASS0629
ADJUSTING THE CLUTCH LEVER FREE

PLAY
1. Check:
¢ Clutch lever free play “a”
Out of specification — Adjust.
4. Check:
¢ Air filter element Clutch lever free play
Damage — Replace. 5.0—10.0 mm (0.20—0.39 in)
TIP
¢ Replace the air filter element every 40000 km
(24000 mi) of operation.
e The air filter needs more frequent service if you
are riding in unusually wet or dusty areas.
5. Install:
© Air filter element
© Air duct bracket
Air filter element screw

2. Adjust:
ES 1.6 N-m (0.16 kgf-m, 1.2 Ib-ft)
Air duct bracket screw ¢ Clutch lever free play
1.6 N-m (0.16 kgf-m, 1.2 lb-ft) Handlebar side
a. Turn the adjusting bolt “1” until the specified
clutch lever free play is obtained.
3-12
TIP
* While pushing the brake lever forward, turn the
adjusting dial “1” until the brake lever is in the
desired position.
* Be sure to align the setting on the adjusting dial
with the arrow mark “2” on the brake lever hold-
(|
er.
Position #1
TIP Distance “a” is the largest.
lf the specified clutch lever free play cannot be Position #5
obtained on the handlebar side of the cable, use Distance “a” is the smallest.
the adjusting nut on the engine side.
Engine side
a. Loosen the locknut “1”.
b. Turn the adjusting nut “2” until the specified
clutch lever free play is obtained.
c. Tighten the locknut “1”.
Clutch cable locknut

7 N-m (0.7 kgf-m, 5.2 Ib-ft)
EWA17O50
¢ After adjusting the brake lever position,

make sure the pin on the brake lever holder
is firmly inserted in the hole in the adjusting
dial.
¢ A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will consid-
EAS30801
erably reduce brake performance resulting
CHECKING THE BRAKE OPERATION in loss of control and possibly cause an ac-
1. Check: cident. Therefore, check and if necessary,
¢ Brake operation bleed the brake system.
Brake not working properly — Check the EC AI3490
brake system. NOTICE

Refer to “FRONT BRAKE?” on page 4-32 and After adjusting the brake lever position,
“REAR BRAKE” on page 4-46. make sure there is no brake drag.
TIP
Drive on the dry road, operate the front and rear EFAS 30633
brakes separately and check to see if the brakes CHECKING THE FRONT BRAKE PADS
are operating properly. The following procedure applies to all of the
brake pads.
EASS30630 1. Operate the brake.
ADJUSTING THE FRONT DISC BRAKE 2. Check:
1. Adjust: e Front brake pad
¢ Brake lever position Wear indicators “a” almost touch the brake
(distance “a” from the throttle grip to the brake disc — Replace the brake pads as a set.
lever) Refer to “FRONT BRAKE” on page 4-32.
3-13
Refer to “ADJUSTING THE REAR BRAKE

LIGHT SWITCH?” on page 3-27.
OOOO SAAS
FAS 30634
CHECKING THE REAR BRAKE PADS

brake pads.
1. Operate the brake.
2. Check:
e Rear brake pad
Wear indicators “1” almost touch the brake
EAS30631
disc + Replace the brake pads as a set.
ADJUSTING THE REAR DISC BRAKE
1. Adjust:
¢ Brake pedal position
O00).
a. Loosen the locknut “1”.
b. Turn the adjusting bolt “2” until the specified
brake pedal position is obtained.
Lan
OOS
EWATSB830
After adjusting the brake pedal position,

check that the end of the adjusting bolt “a” is
visible through the hole “b”.
c. Tighten the locknut “1” to specification. FAS S0894
CHECKING THE BRAKE HOSES

Rear brake pedal adjusting lock- The following procedure applies to all of the
nut brake hoses and brake hose holders.
18 N-m (1.8 kgf-m, 13 Ib-ft) 1. Check:
e Brake hose
EWA17030
Cracks/damage/wear —> Replace.
2. Check:
A soft or spongy feeling in the brake pedal e Brake hose holder
can indicate the presence of air in the brake Loose —> Tighten the holder bolts.
system. Before the vehicle is operated, the 3. Hold the vehicle upright and apply the brake
air must be removed by bleeding the brake several times.
system. Air in the brake system will consid- 4. Check:
erably reduce braking performance. ¢ Brake hose
ECA13510 Brake fluid leakage — Replace the damaged
NOTICE hose.
After adjusting the brake pedal position, Refer to “FRONT BRAKE” on page 4-32,
make sure there is no brake drag. “REAR BRAKE” on page 4-46 and “ABS
(ANTI-LOCK BRAKE SYSTEM)” on page 4-
EN
7 \\
59.
FASS0893
— BLEEDING THE HYDRAULIC BRAKE
SYSTEM (ABS)
EWAT4000
Always bleed the brake system when the

brake related parts are removed.
2. Adjust:
¢ Rear brake light switch
3-14
ECA18050
NOTICE
¢ Bleed the brake system in the following or-
der.
¢ Ist step: Front brake calipers
e 2nd step: Rear brake caliper
EWA16530
Bleed the ABS whenever:

¢ the system is disassembled.
¢ a brake hose is loosened, disconnected or Front brake caliper
replaced. Rear brake caliper
¢ the brake fluid level is very low. . Place the other end of the hose into a con-
¢ brake operation is faulty. tainer.
. Slowly apply the brake several times.
TIP Fully squeeze the brake lever or fully de-
¢ Be careful not to spill any brake fluid or allow press the brake pedal and hold it in position.
the brake master cylinder reservoir or brake g. Loosen the bleed screw.
fluid reservoir to overflow.
TIP
¢ When bleeding the ABS, make sure that there
Loosening the bleed screw will release the pres-
is always enough brake fluid before applying
sure and cause the brake lever to contact the
the brake. Ignoring this precaution could allow
throttle grip or the brake pedal to fully extend.
air to enter the ABS, considerably lengthening
the bleeding procedure. h. Tighten the bleed screw and then release
¢ If bleeding is difficult, it may be necessary to let the brake lever or brake pedal.
the brake fluid settle for a few hours. Repeat steps (e) to (h) until all of the air
¢ Repeat the bleeding procedure when the tiny bubbles have disappeared from the brake
bubbles in the hose have disappeared. fluid in the plastic hose.
Check the operation of the hydraulic unit.
1. Bleed:
Refer to “HYDRAULIC UNIT OPERATION
° ABS
TESTS” on page 4-63.
a. Fill the brake master cylinder reservoir or EC AI&060
brake fluid reservoir to the proper level with NOTICE

the specified brake fluid. Make sure that the main switch is turned to
b. Install the diaphragm (brake master cylin- “OFF” before checking the operation of the
der reservoir or brake fluid reservoir). hydraulic unit.
c. Connect a clear plastic hose “1” tightly to
the bleed screw “2”. k. After operating the ABS, repeat steps (e) to
(i), and then fill the brake master cylinder
reservoir or brake fluid reservoir to the prop-
er level with the specified brake fluid.
|. Tighten the bleed screw to specification.
%\ Brake caliper bleed screw

5 N-m (0.5 kgf-m, 3.7 lb-ft)
m. Fill the brake master cylinder reservoir or

brake fluid reservoir to the proper level with
the specified brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-16.
3-15
EWAI3110 EWA13090
After bleeding the hydraulic brake system, ¢ Use only the designated brake fluid. Other
check the brake operation. brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
EASSa06432 brake performance.
CHECKING THE BRAKE FLUID LEVEL * Refill with the same type of brake fluid that
1. Stand the vehicle on a level surface. is already in the system. Mixing brake fluids
TIP may result in a harmful chemical reaction,
e Place the vehicle on a suitable stand. leading to poor brake performance.
¢ Make sure the vehicle is upright. ¢ When refilling, be careful that water does
not enter the brake fluid reservoir. Water
2. Check: will significantly lower the boiling point of
e Brake fluid level the brake fluid and could cause vapor lock.
Below the minimum level mark “a” — Add the
specified brake fluid to the proper level.
NOTICE
VY Specified brake fluid

DOT 4
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
TIP
In order to ensure a correct reading of the brake
fluid level, make sure the top of the brake fluid
reservoir is horizontal.
EAS30638
CHECKING THE WHEELS

The following procedure applies to both of the
wheels.
1. Check:
¢ Wheel
Damage/out-of-round > Replace.
EWA1S260
Never attempt to make any repairs to the

wheel.
TIP
After a tire or wheel has been changed or re-
A. Front brake placed, always balance the wheel.
B. Rear brake
EAS 30640
CHECKING THE TIRES

The following procedure applies to both of the
tires.
1. Check:
e Tire air pressure
Out of specification + Regulate.
3-16
EWA1S181
1. Tire tread depth
ITN Ne 2. Side wall
¢ The tire pressure should only be checked 3. Wear indicator
and regulated when the tire temperature
equals the ambient air temperature.
¢ The tire pressure and the suspension must Wear limit (front)
be adjusted according to the total weight 1.0 mm (0.04 in)
(including cargo, rider, passenger and ac- Wear limit (rear)
1.0 mm (0.04 in)
cessories) and the anticipated riding
speed. EW A14090
¢ Operation of an overloaded vehicle could PIMA NIN Te

cause tire damage, an accident or an injury. After extensive tests, the tires listed below
NEVER OVERLOAD THE VEHICLE. have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer
Tire air pressure (measured on
and of the same design. No guarantee con-
cold tires)
1 person cerning handling characteristics can be giv-
Front en if a tire combination other than one
225 kPa (2.25 kgf/cm2, 33 psi) approved by Yamaha is used on this vehicle.
Rear
250 kPa (2.50 kgf/cm?2, 36 psi)
Front tire
2 persons
Size
Front
120/70 ZR 17M/C(58W)
225 kPa (2.25 kgf/cm?2, 33 psi)
Manufacturer/model
Rear
MICHELIN/PILOT ROAD 4
250 kPa (2.50 kgf/cm2, 36 psi)
Manufacturer/model
Maximum load
BRIDGESTONE/BT023F F
172 kg (379 Ib)
* Total weight of rider, passenger, cargo
and accessories Rear tire
Size
2. Check: 180/55 ZR 17M/C(73W)
¢ Tire surface Manufacturer/model
Damage/wear — Replace the tire. MICHELIN/PILOT ROAD 4
Manufacturer/model
BRIDGESTONE/BT023R M
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit, re-
EWA13210
place the tire immediately.

AX WARNING
New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed before
any high-speed riding is done.
3-17
FAS31923
TIP
DRIVE CHAIN SLACK
For tires with a direction of rotation mark “1”:
¢ Install the tire with the mark pointing in the di- Checking the drive chain slack
rection of wheel rotation. EWAI3120
e Align the mark “2” with the valve installation

point. Securely support the vehicle so that there is
no danger of it falling over.
EC A13550
NOTICE
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep
the drive chain slack within the specified lim-
its.
1. Shift the transmission into the neutral posi-
EAS30641 tion.
CHECKING THE WHEEL BEARINGS 2. Check:
The following procedure applies to all of the Drive chain slack “a”
wheel bearings. Out of specification — Adjust.
1. Check:
¢ Wheel bearing Drive chain slack (Maintenance
Refer to “CHECKING THE FRONT WHEEL” stand)
on page 4-18 and “CHECKING THE REAR 56.0—61.0 mm (2.20—2.40 in)
WHEEL” on page 4-27. Drive chain slack (Sidestand)
51.0—56.0 mm (2.01-2.20 in)
EAS3On02
CHECKING THE SWINGARM OPERATION

Limit
58.0 mm (2.28 in)
1. Check:
¢ Swingarm operation
Swingarm not working properly + Check the
swingarm.
+/ oY)
WV
LZ £0
=
Lom
Refer to “SWINGARM” on page 4-90.

2. Check:
¢ Swingarm excessive play
Refer to “SWINGARM” on page 4-90.
EASS0643
LUBRICATING THE SWINGARM PIVOT

1. Lubricate:
* Bearing Adjusting the drive chain slack
* Spacer EWAIS120
Recommended lubricant Securely support the vehicle so that there is

A Lithium-soap-based grease no danger of it falling over.
Refer to “INSTALLING THE SWINGARM” on 1. Loosen:
page 4-94. e Wheel axle nut “1”
3-18
and the use of a coarse brush can damage

—= 4 S these O-rings. Therefore, use only kerosene to
<a —— clean the drive chain. Wipe the drive chain dry
and thoroughly lubricate it with engine oil or
chain lubricant that is suitable for O-ring chains.
Do not use any other lubricants on the drive
chain since they may contain solvents that could
damage the O-rings.
Recommended lubricant
2. rs Chain lubricant suitable for O-
e Drive chain slack ring chains
a. Loosen both of the drive chain puller lock-
nuts “1”.
FAS S0645
CHECKING AND ADJUSTING THE

b. Turn both of the drive chain puller adjusting STEERING HEAD
nuts “2” in direction until the specified drive
1. Stand the vehicle on a level surface.
chain slack is obtained. EWAIS120
TIP
¢ To maintain the proper wheel alignment, adjust securely support the vehicle so that there is
both sides evenly. no danger of it falling over.
e There should be no clearance between the
swingarm end plate and the adjusting nuts. TIP
Place the vehicle on a suitable stand so that the
front wheel is elevated.
2. Check:
= O (—— e Steering head
( a L \Y
Grasp the bottom of the front fork legs and
(©)
a,
gently rock the front fork.
Blinding/looseness — Adjust the steering
head.
3. Remove:
¢ Upper bracket
c. Tighten the wheel axle nut to specification. Refer to “FRONT FORK” on page 4-72.
4. Adjust:
Wheel axle nut e Steering head
Az 105 N-m (10.5 kgf-m, 77 lb-ft) a. Loosen the cap nut “1”, and then tighten it to
d. Tighten the drive chain puller locknuts to specification with a steering nut wrench “2”.
specification. TIP
* Set the torque wrench at a right angle to the
Drive chain puller locknut steering nut wrench.
16 N-m (1.6 kgf-m, 12 lb-ft) * Move the steering to the left and right a couple
of times to check that it moves smoothly.
EASSa0803
LUBRICATING THE DRIVE CHAIN

The drive chain consists of many interacting
parts. If the drive chain is not maintained proper-
ly, it will wear out quickly. Therefore, the drive
chain should be serviced, especially when the
vehicle is used in dusty areas.
This vehicle has a drive chain with small rubber
O-rings between each side plate. Steam clean-
ing, high-pressure washing, certain solvents,
3-19
FAS S0649
LUBRICATING THE PEDAL

Steering nut wrench
90890-01403 Lubricate the pivoting point and metal-to-metal
Exhaust flange nut wrench moving parts of the pedal.
=
YU-A9472
Lithium-soap-based grease
Cap nut (initial tightening torque)
52 N-m (5.2 kgf-m, 38 Ib-ft) FASS0805
LUBRICATING THE CLUTCH LEVER

b. Loosen the cap nut completely, then tighten Lubricate the pivoting point and metal-to-metal
it to specification. moving parts of the lever.
=
EWAIT?F?O
4X WARNING Recommended lubricant

Do not overtighten the cap nut. Lithium-soap-based grease
EAS 30650
CHECKING THE SIDESTAND

1. Check:
¢ Sidestand operation
c. Check the steering head for looseness or
Check that the sidestand moves smoothly.
binding by turning the front fork all the way
Rough movement —> Repair or replace.
in both directions. If any binding is felt, re-
move the lower bracket and check the up- EFASS0651
per and lower bearings. LUBRICATING THE SIDESTAND

Refer to “STEERING HEAD” on page 4-82. Lubricate the pivoting point, metal-to-metal mov-
ing parts and spring contact point of the side-
5. Install: stand.
=
* Upper bracket
Refer to “FRONT FORK” on page 4-72. Recommended lubricant
EASS0646
LUBRICATING THE STEERING HEAD
1. Lubricate: EFAS S0652
* Upper bearing
CHECKING THE SIDESTAND SWITCH
* Lower bearing
Refer to “CHECKING THE SWITCHES? on
* Bearing cover
page 8-132.
¢ Lower bearing dust seal FAS 30653
=
CHECKING THE FRONT FORK
Recommended lubricant 1. Stand the vehicle on a level surface.
EWAIS120
A WARNING
EASS0647 Securely support the vehicle so that there is
CHECKING THE FASTENERS no danger of it falling over.
Make sure that all nuts, bolts, and screws are
properly tightened. 2. Check:
e Inner tube
EASSoORn04
Damage/scratches —> Replace.
LUBRICATING THE BRAKE LEVER
¢ Front fork leg
Lubricate the pivoting point and metal-to-metal
Oil leaks between inner tube and outer tube
moving parts of the lever.
— Replace the oil seal.
3. Hold the vehicle upright and apply the front
brake.
: Silicone grease
4. Check:
e Front fork operation
3-20
Push down hard on the handlebar several

times and check if the front fork rebounds Unit for adjustment
smoothly. Cam position
Rough movement —> Repair. Adjustment value (Soft)
Refer to “FRONT FORK” on page 4-72. 1
Adjustment value (STD)
4
Adjustment value (Hard)
EASS0n08
CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY
Refer to “CHECKING THE REAR SHOCK AB-
SORBER ASSEMBLY” on page 4-88.
Rebound damping
EASS0655
ECA13590
ADJUSTING THE REAR SHOCK ABSORBER NOTICE
ASSEMBLY
EWA13120
Never go beyond the maximum or minimum
4&4 WARNING adjustment positions.
Securely support the vehicle so that there is 1. Adjust:
no danger of it falling over. ¢e Rebound damping
a. Turn the adjusting screw “1” in direction “a”
Spring preload
or “hy”
ECA13590
NOTICE Direction “a”

Never go beyond the maximum or minimum Rebound damping is increased (sus-
adjustment positions. pension is harder).
Direction “b”
1. Adjust: Rebound damping is decreased (sus-
¢ Spring preload pension is softer).
a. Adjust the spring preload with the special
wrench “1” and extension bar “2” included
Rebound damping
in the owner's tool kit.
Minimum (soft)
. Turn the adjusting ring “3” in direction “a” or
3 turn(s) in direction “b”*
"Er:
Standard
Align the desired position on the adjusting
1.5 turn(s) in direction “b’”*
ring with the stopper “4”. Maximum (hard)
0 turn(s) in direction “b’*
Direction “a”
* With the adjusting screw fully turned in
Spring preload is increased (suspen-
direction “a”
sion is harder).
Direction “b”
Spring preload is decreased (suspen-
sion is softer).
3-21
TIP
To obtain a precise adjustment, it is advisable to
check the actual total number of turns of the
damping force adjusting mechanism. This ad-
justment range may not exactly match the spec-
ifications listed due to small differences in
production.
Recommended brand
YAMALUBE
SAE viscosity grades
10W-40, 10W-50, 15W-40,
20W-40 or 20W-50
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
EASS0809
ECA13361
CHECKING THE CONNECTING ARM AND
NOTICE
RELAY ARM
¢ Engine oil also lubricates the clutch and the
Refer to “CHECKING THE RELAY ARM” on
wrong oil types or additives could cause
page 4-88 and “CHECKING THE CONNECT-
clutch slippage. Therefore, do not add any
ING ARM” on page 4-93.
chemical additives or use engine oils with a
EASSOB56 grade of “CD” or higher and do not use oils
CHECKING THE ENGINE OIL LEVEL labeled “ENERGY CONSERVING II’.
1. Stand the vehicle on a level surface. ¢ Do not allow foreign materials to enter the
TIP crankcase.
e Place the vehicle on a suitable stand.
4. Start the engine, warm it up for several min-
e Make sure the vehicle is upright.
utes, and then turn it off.
2. Start the engine, warm it up for several min- 5. Check the engine oil level again.
utes, and then turn it off. TIP
3. Check: Before checking the engine oil level, wait a few
* Engine oil level minutes until the oil has settled.
The engine oil level should be between the
minimum level mark “a” and maximum level EAS S065?
mark “b”. CHANGING THE ENGINE OIL

Below the minimum level mark — Add the 1. Start the engine, warm it up for several min-
recommended engine oil to the proper level. utes, and then turn it off.
TIP 2. Place a container under the engine oil drain
Before checking the engine oil level, wait a few bolt.
minutes until the oil has settled. 3. Remove:
e Engine oil filler cap “1”
e Engine oil drain bolt “2”
(along with the gasket “S3”)
3-22
c. Tighten the new oil filter cartridge to specifi-

cation with an oil filter wrench.
Oil filter cartridge

CX] 17 Nem (1.7 kgf-m, 13 lb-ft)
2
6. Install:
e Engine oil drain bolt
(along with the gasket [XTAW9)
+ Enaine oll Engine oil drain bolt

(completely from the oil pan) | 48. Nem (4.3 kgt-m, 32 Ib-ft)
5. If the oil filter cartridge is also to be replaced, 7. Fill:
perform the following procedure. ° Oil pan
a. Remove the oil filter cartridge “1” with an oil (with the specified amount of the recom-
filter wrench “2”. mended engine oil)
Oil filter wrench Engine oil quantity

90890-01426 Quantity (disassembled)
Oil filter wrench 3.00 L (3.17 US qt, 2.64 Imp.qt)
YU-38411 Oil change
2.30 L (2.43 US qt, 2.02 Imp.qt)
( LE With oil filter removal
\ ® S On; \ 2.60 L (2.75 US qt, 2.29 Imp.at)
WS
a
? )J Iw 8. Install:
a Hl og ¢ Engine oil filler cap
\ ee ae UU (along with the O-ring INEM) |
JA | ———} 9. Start the engine, warm it up for several min-
| | utes, and then tum it off.
2
21 /| 10.Check:
:
. oo og e Engine
b. Lubricate the O-ring 3” of the new oll filter (for engine oil leaks)
cartridge with a thin coat of engine oil. 11.Check:
GHEE e Engine oil level
Refer to “CHECKING THE ENGINE OIL
Make sure the O-ring “S” is positioned cor- LEVEL’ on page 3-22.
rectly in the groove of the oil filter cartridge.
3-23
EAS30810
MEASURING THE ENGINE OIL PRESSURE

Pressure gauge
90890-03153
TIP Pressure gauge
e Place the vehicle on the suitable stand. YU-03153
e Make sure that the vehicle is upright. Oil pressure adapter H
90890-03139
2. Check:
* Engine oil level
eH
Below the minimum level mark “a” — Add the
recommended engine oil to the proper level.
: \ OY ||
MN Gamo
6. Measure:
e Engine oil pressure
(at the following conditions)
3. Start the engine, warm it up for several min-
utes, and then turn it off. Oil pressure
ECA1IA410
280.0 kPa/5000 r/min (2.80 kgf/
NOTICE cm2/5000 r/min, 40.6 psi/5000 r/
When the engine is cold, the engine oil will min)
have a higher viscosity, causing the engine
oil pressure to increase. Therefore, be sure Out of specification + Check.
to measure the engine oil pressure after Engine oil pressure | Possible causes
warming up the engine.
Below specification e Faulty oil pump
4. Remove: ¢ Clogged oil filter
¢ Main gallery bolt “1” e Leaking oil passage
EWAT2980 ¢ Broken or damaged
oil seal
The engine, muffler and engine oil are ex- Above specification | * Leaking oil passage
tremely hot. ¢ Faulty oil filter
¢ Oil viscosity too high
7. Install:
¢ Main gallery bolt
- O-ring TEM
Main gallery bolt
8 N-m (0.8 kgf-m, 5.9 Ib-ft)
TIP
5. Install: Lubricate the O-ring with a thin coat of lithium-
¢ Oil pressure gauge “1” soap-based grease.
¢ Adapter “2”
3-24
Es4S30811
e Thermostat cover “9”
CHECKING THE COOLANT LEVEL
e Thermostat “10”
e Water pump inlet pipe “11”
TIP e Water pump outlet pipe “12”
e Place the vehicle on a suitable stand. Cracks/damage — Replace.
e Make sure the vehicle is upright. Refer to “RADIATOR?” on page 6-2, “OIL
2. Check: COOLER’ on page 6-5, “THERMOSTAT” on
¢ Coolant level page 6-8 and “WATER PUMP?” on page 6-10.
The coolant level should be between the
maximum level mark “a” and minimum level
mark “b”.
Below the minimum level mark —> Add the
recommended coolant to the proper level.
ECAIB470
NOTICE
¢ Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant. FASS0813
¢ Use only distilled water. However, if dis- CHANGING THE COOLANT

tilled water is not available, soft water may 1. Remove:
be used. e Air scoop (right)
3. Start the engine, warm it up for several min- page 4-9.
utes, and then turn it off. 2. Remove:
4. Check: e Radiator cap bolt “1”
* Coolant level e Radiator cap “2”
TIP EWA13030
Before checking the coolant level, wait a few

minutes until it settles. A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en-
EASa0812
gine is hot. Scalding hot fluid and steam may
CHECKING THE COOLING SYSTEM be blown out, which could cause serious in-
1. Check: jury. When the engine has cooled, open the
e Radiator “1” radiator cap as follows:
e Radiator inlet hose “2” Place a thick rag or a towel over the radiator
e Radiator outlet hose “3” cap and slowly turn the radiator cap counter-
e Oil cooler “4” clockwise toward the detent to allow any re-
e Oil cooler inlet hose “5” sidual pressure to escape. When the hissing
¢ Oil cooler outlet hose “6” sound has stopped, press down on the radi-
¢ Water jacket joint “7” ator cap and turn it counterclockwise to re-
¢ Water jacket joint inlet hose “8” move.
3-25
7. Drain:
¢ Coolant
(from the engine and radiator)
8. Install:
¢ Coolant drain bolt
¢ Copper washer KEY]
Coolant drain bolt

ay 7 Nm (0.7 kof-m, 5.2 lb-ft)
3. Remove: 9. Install:
¢ Coolant reservoir cap “1” e Collar
¢ Coolant reservoir
¢« Coolant reservoir cover
¢ Coolant reservoir quick fastener
e Coolant reservoir bolt
Coolant reservoir bolt

& 5 N-m (0.5 kgf-m, 3.7 lb-ft)
10.Fill:
¢ Cooling system
(with the specified amount of the recom-
4. Remove:
mended coolant)
¢ Coolant reservoir bolt “1”
N
¢ Coolant reservoir quick fastener “2”
Recommended antifreeze
¢ Coolant reservoir cover “3”
High-quality ethylene glycol anti-
¢ Coolant reservoir “4”
freeze containing corrosion
¢ Collar “5”
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze: water)
Radiator (including all routes)
1.60 L (1.69 US qt, 1.41 Imp.qt)
Coolant reservoir (up to the max-
imum level mark)
0.25 L (0.26 US qt, 0.22 Imp.qt)
Handling notes for coolant

Coolant is potentially harmful and should be
5. Drain: handled with special care.
¢ Coolant oe
(from the coolant reservoir)
6. Remove: * If coolant splashes in your eyes, thorough-
© Coolant drain bolt “1” ly wash them with water and consult a doc-
¢ Copper washer “2” tor.
¢ If coolant splashes on your clothes, quickly
wash it away with water and then with soap
and water.
* If coolant is swallowed, induce vomiting
and get immediate medical attention.
3-26
ECA1I481
15.Check:
NOTICE e Coolant level
¢ Adding water instead of coolant lowers the Refer to “CHECKING THE COOLANT LEV-
antifreeze content of the coolant. If water is EL” on page 3-25.
used instead of coolant, check, and if nec- TIP
essary, correct the antifreeze concentra-
Before checking the coolant level, wait a few
tion of the coolant.
minutes until the coolant has settled.
¢ Use only distilled water. However, if dis-
tilled water is not available, soft water may 16.Install:
be used. e Air scoop (right)
¢ If coolant comes into contact with painted Refer to “GENERAL CHASSIS (4)” on
surfaces, immediately wash them with wa- page 4-9.
ter.
FAS31145
¢ Do not mix different types of antifreeze. CHECKING THE FRONT BRAKE LIGHT
11.Install: SWITCH
e Radiator cap “1” Refer to “CHECKING THE SWITCHES” on
¢ Radiator cap bolt “2” page 8-132.
TIP FAS 30659
Align the hole “a” in the radiator cap with the hole ADJUSTING THE REAR BRAKE LIGHT
“b” in the radiator. SWITCH
SUB Ses
TIP
The rear brake light switch is operated by move-
ment of the brake pedal. The rear brake light
switch is properly adjusted when the brake light
Sx
comes on just before the braking effect starts.
1. Check:
e Rear brake light operation timing
Incorrect — Adjust.
2. Adjust:
e Rear brake light operation timing
a. Hold the main body “1” of the rear brake
Radiator cap bolt light switch so that it does not rotate and
AR. 1.0 N-m (0.10 kgf-m, 0.73 Ib-ft) turn the adjusting nut “2” until the rear brake
light comes on at the proper time.
12.Fill:
¢ Coolant reservoir
(with the recommended coolant to the maxi-
mum level mark “a”)
13.Install:
¢ Coolant reservoir cap
14.Start the engine, warm it up for several min-
utes, and then turn it off.
3-27
EASS0660
Out of specification + Adjust.
CHECKING AND LUBRICATING THE
A
CABLES
Throttle grip free play
The following procedure applies to all of the in- 3.0—5.0 mm (0.12—0.20 in)
ner and outer cables.
EWAIS270
Damaged outer cable may cause the cable to

corrode and interfere with its movement. Re-
place damaged outer cable and inner cables
as soon as possible.
1. Check:
¢ Outer cable
Damage — Replace.
2. Check:
4. Adjust:
¢ Cable operation
e Throttle grip free play
Rough movement —> Lubricate.
=
TIP
Recommended lubricant Prior to adjusting the throttle grip free play, throt-
Engine oil or a suitable cable lu- tle body synchronization should be adjusted
bricant properly.
TIP Throttle body side

Hold the cable end upright and pour a few drops a. Loosen the locknut “1” on the accelerator
of lubricant into the cable sheath or use a suit- cable.
able lubricating device. b. Turn the adjusting nut “2” until the specified
throttle grip free play is obtained.
EASSO861
c. Tighten the locknut.
CHECKING THE THROTTLE GRIP
OPERATION Throttle cable locknut (throttle
1. Check: body side)
¢ Throttle cable 4.5 N-m (0.45 kgf-m, 3.3 Ib-ft)
Damage/deterioration > Replace.
¢ Throttle cable installation
Incorrect — Reinstall the throttle cables.
Refer to “HANDLEBAR” on page 4-67.
2. Check:
¢ Throttle grip movement
Rough movement -—> Lubricate or replace the
defective part(s).
=
TIP
Suitable cable lubricant
|
TIP
lf the specified throttle grip free play cannot be
obtained on the throttle body side of the cable,
With the engine stopped, turn the throttle grip
use the adjusting nut on the handlebar side.
slowly and release it. Make sure that the throttle
grip turns smoothly and returns properly when
released. Handlebar side
Repeat this check with the handlebar turned all a. Slide back the rubber cover “1”.
the way to the left and right. b. Loosen the locknut “2”.
c. Turn the adjusting nut “3” until the specified
3. Check: throttle grip free play is obtained.
¢ Throttle grip free play “a”
3-28
2. Disconnect:
Throttle cable locknut (handlebar ep readiignicoupin”

side)
4.3 N-m (0.43 kgf-m, 3.2 lb-ft)
eo
e. Slide the rubber cover to its original posi-
tion.
TIP Sas
Make sure that the adjusting nut is covered com- CO TAC RS <
pletely by the rubber cover. Sa
i
ee, 3. Remove:
CHECKING AND CHARGING THE BATTERY
¢ Headlight bulb cover “1”
Refer to “CHECKING AND CHARGING THE
BATTERY” on page 8-134.
CHECKING THE FUSES QQ

Refer to “CHECKING THE FUSES” on page 8-
133.
EASS0665
REPLACING THE HEADLIGHT BULB

1. Remove:
* Headlight assembly bolt “1”
TIP 4. Unhook:
Lift up the headlight unit “2”, and then remove it ¢ Headlight bulb holder “1”
from the headlight bracket “3”. ©. Remove:
¢ Headlight bulb “2”
3-29
%
EWAIS320
YY Headlight assembly bolt

Since the headlight bulb gets extremely hot, 7 N-m (0.7 kgf-m, 5.2 lb-ft)
keep flammable products and your hands
away from the bulb until it has cooled down. TIP
When the headlight assembly bolts are tight-
6. Install:
ened to specification, there may be gaps “a” be-
¢ Headlight bulb [XTANa tween the washers and the grommets as shown
Secure the new headlight bulb with the head- in the illustration.
light bulb holder.
ECA13690
NOTICE
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
7. Hook:
* Headlight bulb holder EAS 30664
8. Install: ADJUSTING THE HEADLIGHT BEAM

* Headlight bulb cover 1. Adjust:
9. Connect: ¢ Headlight beam (vertically)
¢ Headlight coupler “1” TIP
To adjust the headlight beam (vertically), inserta
crosshead screwdriver into the slit “a” in the
headlight assembly, and than turn the adjusting
screw.
10.Install:
¢ Headlight assembly “1”
TIP
Fit the projections “a” on the headlight bracket
into the holes “b” in the headlight assembly. a. Turn the adjusting screw “1”.
Pos
a
5) _ ip
es
. Ay L au |
yaa Ga) a
_
11.Install: 2. Adjust:
* Headlight assembly bolt “1” ¢ Headlight beam (horizontally)
3-30
TIP
To adjust the headlight beam (horizontally), in-
sert a crosshead screwdriver into the hole “a” in
the headlight assembly, and then turn the ad-
justing screw.
a. Turn the adjusting screw “1”.

ay
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3-31
3-32

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Service Manual

IMPORTANT MANUAL INFORMATION

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

A NOTICE indicates special precautions that must be taken to avoid damage to

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

HOW TO USE THIS MANUAL

inion ines beeen

SYMBOL DEFINITION SYMBOL DEFINITION

Filling fluid Molybdenum disulfide oil

Special tool Wheel bearing grease

Tightening torque Lithium-soap-based grease

Wear limit, clearance Molybdenum disulfide grease

Engine speed Silicone grease

Electrical data Apply locking agent (LOCTITE®).

Engine oil S Replace the part with a new one.

PERIODIC CHECKS AND

IDENTIFICATION ......ccccccccecccesceseeeceseeeenseeseneaenaeesseseaeeasessaseaseasessaseaeeusesssssaenanes 1-1

SPECIAL TOOLS .n.ccccctcssessccccsssesscessccessesecsansecessecscsnccessessascessseessancesessecsancscess 1-7

VEHICLE IDENTIFICATION NUMBER

1. Left set button Tachometer

¢ transmission gear display

Be sure to stop the vehicle before making

2. Fuel level warning indicator “gs” 1. Transmission gear display

AES ZR The multi-function display is equipped with the

¢ brightness control mode TIP

ODO -> TRIP 1 > TRIP 2 > km/L, L/100 km or

brightness control mode is accessed separate- 1. Instantaneous fuel consumption display

TRIP F > km/L, L/100 km or MPG > AVE__._ a

1. Average fuel consumption display Air temperature

Coolant temperature Self-diagnosis mode

1. Coolant temperature display 1. Error code display

Brightness control mode

1. Brightness level display

The brightness control mode allows you to ad-

[To adjust the brightness]

Yamaha diagnostic tool USB | 3-4, 3-9, 4-64,

Vacuum gauge 3-9

steering nut wrench 3-20, 4-84

Oil filter wrench 3-23

Pressure gauge 3-24, 7-15, 7-16

Oil pressure adapter H 3-24

Damper rod holder (621.2) 4-76, 4-78

T-handle 4-76, 4-78

Fork seal driver weight 4-79, 4-79, 4-79

Compression gauge extension 122mm

Compression gauge 5-8

Rotor holding tool 5-24, 5-27

Yamaha bond No. 1215

Valve spring compressor 5-39, 5-44

Valve spring compressor attachment 5-39, 5-44

Valve guide installer (o4.5) 5-41

Valve guide reamer (04.5) 5-41

Rotor holding tool 5-48, 5-48,

Flywheel puller 5-48

Digital circuit tester (CD732) 5-53, 8-133,

Piston ring compressor 5-89

Radiator cap tester 90890-01325 6-4

Radiator cap tester adapter

Mechanical seal installer (#33) 6-13

Fuel injector pressure adapter 7-15

Fuel pressure adapter 7-16

OBD/ GST Leadwire kit 8-36

Ignition checker 8-138