Del 1 - Service Manual Exciter t150

B15F8197E0.
book Page 1 Thursday, March 5, 2015 4:37 PM
2015
SERVICE MANUAL
T150
B15-F8197-E0
B15F8197E0.book Page 1 Thursday, March 5, 2015 4:37 PM
EAS20040
T150
SERVICE MANUAL
© 2015 by Yamaha Motor Vietnam Co., Ltd.
First edition, March 2015
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Vietnam Co., Ltd.
is expressly prohibited.
EAS20070
INTRODUCTION
This manual was produced by the Yamaha Motor Vietnam Co., Ltd. primarily for use by Yamaha deal-
ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehi-
cles should have a basic understanding of mechanics and the techniques to repair these types of vehi-
cle. 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 intended to provide the customer with the most satisfaction from his vehicle and to conform to fed-
eral environmental quality objectives.
Yamaha Motor Vietnam Co., Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
TIP
_
• This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
• Designs and specifications are subject to change without notice.
EAS20081
IMPORTANT MANUAL INFORMATION

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

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

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

EAS20090
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
GENERATOR AND STARTER CLUTCH ENG GENERATOR AND STARTER CLUTCH ENG
EAS00346
Removing the generator and starter clutch
REMOVING THE GENERATOR
1. Drain:
• engine oil
(completely from the crankcase)
3
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
2. Remove:
• side cowling (left)
1 Refer to “REMOVING THE SIDE COWL-
3 4 d INGS” in chapter 3.
• shift pedal
1 • drive sprocket cover
Refer to “REMOVING THE DRIVE CHAIN
AND SPROCKETS” in chapter 6.
3. Disconnect:
• AC magneto coupler 1
• crankshaft position sensor coupler 2
4 3 4 3
1
1
5 2
4. Remove:
• crankcase cover (left) 1
• gasket
• dowel pins
6 Order Job/Parts to remove Q’ty Remarks

12 Star ter clutch gear 1
13 Bearing 1 1
14 Washer 1
15 Star ter clutch idle gear shaft 1
5. Remove:
16
17
Washer
Circlip
1
1
1
• generator rotor nut 1
• washer
7
18 Star ter clutch idle gear 1
3 TIP
19 Star ter clutch assembly 1
• While holding the generator rotor 2 with the
For installation, reverse the removal proce-
dure. sheave holder 3, loosen the generator rotor
nut.
• Do not allow the sheave holder to touch the
2 projection on the generator rotor.
Sheave holder
90890-01701
4-39 4-40
1 2 SYMBOLS
The following symbols are not relevant to every
GEN vehicle.
INFO SPEC Symbols 1 to 9 indicate the subject of each
chapter.
3 4
1 General information
CHK 2 Specifications
ADJ ENG 3 Periodic checks and adjustments
4 Engine
5 6 5 Cooling system
6 Fuel injection system
7 Chassis
COOL FI 8
9
Electrical system
Troubleshooting
7 8
Symbols 0 to G indicate the following.
– +
CHAS ELEC 0 Serviceable with engine mounted
A Filling fluid
9 0 B Lubricant
C Special tool
TRBL D Tightening torque
E Wear limit, clearance
SHTG F Engine speed
G Electrical data
A B
Symbols H to O in the exploded diagrams

indicate the types of lubricants and lubrication
points.
C D
H Engine oil
I Gear oil
J Molybdenum-disulfide oil
T.
R.
K Brake fluid
L Wheel-bearing grease
E F G
M Lithium-soap-based grease
N Molybdenum-disulfide grease
O Silicone grease
H I J K Symbols P to Q in the exploded diagrams

indicate the following.
E G M BF P Apply locking agent (LOCTITE®)

Q Replace the part
L M N O
B LS M S
P Q
LT
EASF0003
TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC
2
PERIODIC CHECKS AND
ADJUSTMENTS CHK
ADJ 3
ENGINE ENG
4
COOLING SYSTEM COOL
5
FUEL INJECTION SYSTEM FI
6
CHASSIS CHAS
7
– +
ELECTRICAL SYSTEM ELEC

8
TROUBLESHOOTING TRBL
SHTG 9
GEN
INFO
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1

VEHICLE IDENTIFICATION NUMBER ..................................................... 1-1
ENGINE SERIAL NUMBER ...................................................................... 1-1
FEATURES...................................................................................................... 1-2
OUTLINE OF THE FI SYSTEM ................................................................. 1-2
FI SYSTEM................................................................................................ 1-3
IMPORTANT INFORMATION ......................................................................... 1-4

PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-4
REPLACEMENT PARTS........................................................................... 1-4
GASKETS, OIL SEALS AND O-RINGS .................................................... 1-4
LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-5
BEARINGS AND OIL SEALS .................................................................... 1-5
CIRCLIPS .................................................................................................. 1-5
RUBBER PARTS....................................................................................... 1-5
CHECKING THE CONNECTIONS .................................................................. 1-6
SPECIAL TOOLS ............................................................................................ 1-7

GEN
IDENTIFICATION INFO
EAS20130
GENERAL INFORMATION
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER

1 The vehicle identification number “1” is stamped
into the frame.
EAS20160
ENGINE SERIAL NUMBER

The engine serial number “1” is stamped into the
crankcase.
TIP
Designs and specifications are subject to change
without notice.
1-1
GEN
FEATURES INFO
EAS20170
FEATURES
EAS3C11022
OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel
ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional
carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the
volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating conditions,
such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the fuel through
the use of jets have been provided with various auxiliary devices, so that an optimum airfuel ratio can be
achieved to accommodate the constant changes in the operating conditions of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase, it
becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accommodate
this need, this model has adopted an electronically controlled fuel injection (FI) system, in place of the
conventional carburetor system. This system can achieve an optimum air-fuel ratio required by the engine at
all times by using a microprocessor that regulates the fuel injection volume according to the engine operating
conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response, better
fuel economy, and reduced exhaust emissions.
1 2 3 4 5 6
9
0
B A 8 7
1 ECU (engine control unit)
2 Engine trouble warning light
3 Ignition Coil
4 Fuel Injector
5 Coolant temperature sensor
6 Lean angle sensor
7 Fuel pump
8 Crankshaft position sensor
9 Intake air pressure sensor
0 Throttle position sensor
A Intake air temperature sensor
B Spark plug
1-2
GEN
FEATURES INFO
EAS3C11023
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel
pressure that is applied to the fuel injector at only 220-300 kPa (2.20-3.00 kgf/cm2, 31-43 psi). Accordingly,
when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel
to be injected into the intake manifold only during the time the passage remains open. Therefore, the longer
the length of time the fuel injector is energized (injection duration), the greater the volume of fuel that is
supplied. Conversely, the shorter the length of time the fuel injector is energized (injection duration), the lesser
the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the
throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake air temperature sensor,
lean angle sensor and coolant temperature sensor enable the ECU to determine the injection duration. The
injection timing is determined through the signals from the crankshaft position sensor. As a result, the volume
of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions.
Illustration is for
reference only.
1 Fuel pump È Fuel system

2 Fuel injector É Air system
3 Ignition coil Ê Control system
4 ECU (engine control unit)
5 Catalytic converter
6 Coolant temperature sensor
7 Crankshaft position sensor
8 Intake air pressure sensor
9 Throttle body
0 Intake air temperature sensor
A Air filter case
B Throttle position sensor
C O2 sensor
D Idle adjusting screw
1-3
GEN
IMPORTANT INFORMATION INFO
EAS00200
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all dirt,
mud, dust and foreign material.
2. Use only the proper tools and cleaning equip-

ment.
Refer to the “SPECIAL TOOLS”.
3. When disassembling, always keep mated parts
together. This includes gears, cylinders, pistons
and other parts that have been “mated” through
normal wear. Mated parts must always be
reused or replaced as an assembly.
4. During disassembly, clean all of the parts and
place them in trays in the order of disassembly.
This will speed up assembly and allow for the
correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS00210
REPLACEMENT PARTS
Use only genuine Yamaha parts for all
replacements. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands may
be similar in function and appearance, but inferior in
quality.
EAS00220
GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all gas-
kets, seals and O-rings. All gasket surfaces, oil
seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating parts
and bearings and lubricate the oil seal lips with
grease.
1-4
GEN
IMPORTANT INFORMATION INFO
EAS00230
LOCK WASHERS/PLATES AND COTTER

PINS
After removal, replace all lock washers/plates 1
and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs along
a flat of the bolt or nut.
EAS00240
BEARINGS AND OIL SEALS

Install bearings and oil seals so that the
manufacturer’s marks or numbers are visible. When
installing oil seals, lubricate the oil seal lips with a
light coat of lithium-soap-based grease. Oil
bearings liberally when installing, if appropriate.
1 Oil seal
NOTICE
_
Do not spin the bearing with compressed air

because this will damage the bearing surfaces.
1 Bearing
EAS00250
CIRCLIPS
Before reassembly, check all circlips carefully and
replace damaged or distorted circlips. Always
replace piston pin clips after one use. When
installing a circlip 1, make sure the sharp-edged
corner 2 is positioned opposite the thrust 3 that
the circlip receives.
4 Shaft
EAS1MC1085
RUBBER PARTS
Check rubber parts for deterioration during
inspection. Some of the rubber parts are sensitive
to gasoline, flammable oil, grease, etc. Do not allow
any items other than the specified one to contact
the parts.
1-5
GEN
CHECKING THE CONNECTIONS INFO
EAS00260
CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
● lead
● coupler
● connector
2. Check:
● lead
● coupler
● connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect
several times.
3. Check:
● all connections
Loose connection → Connect properly.
TIP
If the pin 1 on the terminal is flattened, bend it up.
4. Connect:
● lead
● coupler
● connector
TIP
Make sure all connections are tight.
5. Check:
● continuity
(with the pocket tester)
Pocket tester
YMV-SL054-00
TIP
● If there is no continuity, clean the terminals.
● When checking the wire harness, perform
steps (1) to (3).
● As a quick remedy, use a contact revitalizer
available at most part stores.
1-6
GEN
SPECIAL TOOLS INFO
EAS00027
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.
Tool no. Tool name/Usage Illustration

Slide hammer bolt
90890-01085
These tools are used when removing or
installing the cam shaft.
Ring nut wrench
90890-01268
This tool is used to loosen and tighten the
steering ring nut.
Tappet adjusting tool
90890-01311
This tool is necessary for adjusting valve
clearance.
Radiator cap tester
90890-01325
This tool is used for testing radiator cap.

Radiator cap tester adapter
90890-01326
This tool is necessary for adapter radiator
cap tester.
T-handle 1
Shock absorber rod mounting 2
90890-01326
90890-01294 This tool is used for holding the damper
rod holder when removing or installing the
damper rod holder.
Flywheel puller
90890-01362
This tool is used for removing the AC
magneto rotor.
Fork seal driver weight 1
Fork seal driver attachment 2
90890-01184
90890-01186
This tool is used to install the oil seal.
1-7
GEN
SPECIAL TOOLS INFO
Oil seal guide
90890-01384
This tool is used to install oil seals.

Steering nut wrench
90890-01403
This tool is used to loosen and tighten the
steering ring nut.
Sheave holder
90890-01701
This tool is used for holding the primary
sheave and secondary sheave.
Thickness gauge
90890-03180
This tool is used to measure the valve
clearance.
Compression gauge
90890-03081
These tools are used to measure the
engine compression.
Digital tachometer
90890-06760
This tool is needed for detecting engine
rpm.
Timing light
90890-03141
This tool is used for measuring mark at
AC magneto rotor.
Pocket tester
90890-03112
These instruments are invaluable for
checking the electrical system.
Valve lapper
90890-04101
This tool is used for lapping the valve.
1-8
GEN
SPECIAL TOOLS INFO
Valve spring compressor
Valve spring compressor attachment
90890-04019
90890-04108 (ø19 mm)
These tools are used when removing or
installing the valve and the valve spring.
Valve guide remover (4.5 mm)
90890-04116
This tool is needed to remove and install
the valve guide.
Valve guide installer (4.5 mm)
90890-04117
This tool is needed to install the valve
guide.
Valve guide reamer (4.5 mm)
90890-04118
This tool is needed to rebore the new
valve guide.
Ignition checker
90890-06754
This instrument is necessary for checking
the ignition system components.
Yamaha bond No. 1215
(Three bond No. 1215®)
90890-85505
This sealant (bond) is used for crankcase
mating surface, etc.
Digital circuit tester
90890-03174
This instrument is necessary for checking
the electrical system.
Pressure guage
90890-03153
This tool is needed to measure fuel
pressure.
Crankcase separating tool
90890-01135
This tool is necessary for separating the
crankcase.
1-9
GEN
SPECIAL TOOLS INFO
Crankshaft installer pot
90890-01274
This tool is necessary for installing the
crankshaft.
Crankshaft installer bolt
90890-01275
crankshaft.
Adapter (M12)
90890-01278
crankshaft.
Crankshaft installer spacer
90890-04156
crankshaft.
Cam chain sprocket holder
90843-110A0
This tool is used for removing or installing
the camshaft sprocket.
Bearing puller attachment (ø32 mm)
90843-110A3
This tool is used for joining crankcase
separating tool.
YAMAHA DIAGNOSTIC TOOL
90890-03231
This tool is used for checking fault
diagnostic mode.
Fuel pressure adapter (ø6.3 mm)
90890-03227
This tool is used for measure fuel
pressure.
1-10
SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................ 2-2
CHASSIS SPECIFICATIONS .......................................................................... 2-9
ELECTRICAL SPECIFICATIONS ................................................................. 2-12
CONVERSION TABLE .................................................................................. 2-14
GENERAL TIGHTENING TORQUE SPECIFICATIONS............................... 2-14
ENGINE TIGHTENING TORQUES ...............................................................2-15
CHASSIS TIGHTENING TORQUES .............................................................2-19
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-21

ENGINE ...................................................................................................2-21
CHASSIS................................................................................................. 2-23
LUBRICATION SYSTEM CHART AND DIAGRAMS.................................... 2-24

ENGINE OIL LUBRICATION CHART ..................................................... 2-24
LUBRICATION DIAGRAMS ....................................................................2-26
CABLE ROUTING ......................................................................................... 2-31

GENERAL SPECIFICATIONS SPEC

EAS20280
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model
Model B151
Dimensions
Overall length 1970 mm (77.6 in)
Overall width 670 mm (26.4 in)
Overall height 1080 mm (42.5 in)
Seat height 780 mm (30.7 in)
Wheelbase 1290 mm (50.8 in)
Ground clearance 135 mm (5.3 in)
Minimum turning radius 1990 mm (78.3 in)
Weight
Curb weight 115.0 kg (254 lb)
Maximum load 151.0 kg (333 lb)
2-1
ENGINE SPECIFICATIONS SPEC

EAS20290
ENGINE SPECIFICATIONS
Engine
Engine type Liquid cooled 4-stroke, SOHC
Displacement 149 cm³
Cylinder arrangement Single cylinder
Bore × stroke 57.0 × 58.7 mm (2.24 × 2.31 in)
Compression ratio 10.40 :1
Standard compression pressure (at sea level) 510 kPa (72.5 psi) (5.1 kgf/cm²)
Minimum–maximum 440–580 kPa (62.6–82.5 psi) (4.4–5.8 kgf/cm²)
Starting system Electric starter and kickstarter
Fuel
Recommended fuel Regular unleaded gasoline
(Gasohol (E10 acceptable))
Fuel tank capacity 4.2 L (1.11 US gal, 0.92 Imp.gal)
Engine oil
Lubrication system Wet sump
Recommended brand YAMALUBE
Type SAE20W40 or SAE20W50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Engine oil quantity
Total amount 1.15 L (1.22 US qt) (1.01 Imp.qt)
Without oil filter element replacement 0.95 L (1.00 US qt, 0.84 Imp.qt)
With oil filter element replacement 1.00 L (1.06 US qt, 0.88 Imp.qt)
Oil filter
Oil filter type Paper
Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance 0.00–0.15mm (0.00–0.0059 in)
Limit 0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing clearance 0.13–0.18 mm (0.0051–0.0071 in)
Limit 0.25 mm (0.0098 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.06–0.11 mm (0.0024–0.0043 in)
Limit 0.18 mm (0.0071 in)
Rotor thickness 9.95–9.98 mm (0.3917–0.3929 in)
Relief valve operating pressure 39.2–78.4 kPa (5.7–11.4 psi) (0.39–0.78 kgf/cm²)
Cooling system
Radiator capacity (including all routes) 0.48 L (0.51 US qt) (0.42 Imp qt)
Coolant reservoir capacity (up to the maximum
level mark) 0.28 L (0.30 US qt) (0.25 Imp qt)
Radiator cap opening pressure 93.3–122.7 kPa (13.5–17.8 psi) (0.95–1.25 kgf/cm2)
Thermostat
Model/manufacturer 5YP/NIPPON THERMOSTAT
2-2

Valve opening temperature 80.5–83.5 °C (176.90–182.30 °F)
Valve full open temperature 95.0 °C (203.00 °F)
Valve lift (full open) 3.0 mm (0.12 in)
Radiator core
Width 185.0 mm (7.28 in)
Height 107.4 mm (4.23 in)
Depth 22.0 mm (0.87 in)
Water pump
Water pump type Single suction centrifugal pump
Reduction ratio 1/2 (0.500)
Spark plug(s)
Manufacturer/model NGK/CR8E
Spark plug gap 0.7–0.8 mm (0.028–0.031 in)
Cylinder head
Volume 9.90–10.50 cm³ (0.60–0.64 cu.in)
Warpage limit 0.03 mm (0.0012 in)
Camshaft
Drive system Chain drive (left)
Camshaft lobe dimensions
Intake A 30.225–30.325 mm (1.1899–1.1938 in)
Limit 30.125 mm (1.1860 in)
Intake B 25.101–25.201 mm (0.9882–0.9922 in)
Limit 25.001 mm (0.9843 in)
Exhaust A 30.087–30.187 mm (1.1845–1.1885 in)
Limit 29.987 mm (1.1806 in)
Exhaust B 25.037–25.137 mm (0.9858–0.9896 in)
Limit 24.937 mm (0.9818 in)
Camshaft runout limit 0.03 mm (0.0012 in)
2-3
Rocker arm/rocker arm shaft

Rocker arm inside diameter 9.985–10.000 mm (0.3931–0.3937 in)
Limit 10.015 mm (0.3943 in)
Rocker arm shaft outside diameter 9.966–9.976 mm (0.3924–0.3928 in)
Limit 9.935 mm (0.3911 in)
Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.034 mm (0.0004–0.0013 in)
Limit 0.08 mm (0.0031 in)
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.10–0.14 mm (0.0039–0.0055 in)
Exhaust 0.20–0.24 mm (0.0079–0.0094 in)
Valve dimensions
Valve head diameter A (intake) 19.40–19.60 mm (0.7638–0.7717 in)
Valve head diameter A (exhaust) 16.90–17.10 mm (0.6654–0.6732 in)
A
Valve face width B (intake) 1.200–2.500 mm (0.0472–0.0984 in)
Valve face width B (exhaust) 1.200–2.500 mm (0.0472–0.0984 in)
Valve seat width C (intake) 0.09–1.20 mm (0.0354–0.0472 in)

Valve seat width C (exhaust) 0.09–1.20 mm (0.0354–0.0472 in)
Valve margin thickness D (intake) 0.50–0.90 mm (0.0197–0.0354 in)

Valve margin thickness D (exhaust) 0.50–0.90 mm (0.0197–0.0354 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)
2-4

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) 37.84 mm (1.49 in)
Limit 35.95 mm (1.42 in)
Free length (exhaust) 37.84 mm (1.49 in)
Limit 35.95 mm (1.42 in)
Installed length (intake) 32.30 mm (1.27 in)
Installed length (exhaust) 32.30 mm (1.27 in)
Spring rate K1 (intake) 27.28 N/mm (155.77 lb/in) (2.78 kgf/mm)
Spring rate K2 (intake) 36.58 N/mm (208.87 lb/in) (3.73 kgf/mm)
Spring rate K1 (exhaust) 27.28 N/mm (155.77 lb/in) (2.78 kgf/mm)
Spring rate K2 (exhaust) 36.58 N/mm (208.87 lb/in) (3.73 kgf/mm)
Installed compression spring force (intake) 140–162 N (31.47–36.42 lbf) (14.28–16.52 kgf)
Installed compression spring force (exhaust) 140–162 N (31.47–36.42 lbf) (14.28–16.52 kgf)
Spring tilt (intake) 2.5°/1.7 mm (2.5°/0.067 in)
Spring tilt (exhaust) 2.5°/1.7 mm (2.5°/0.067 in)
Winding direction (intake) Clockwise

Winding direction (exhaust) Clockwise
Cylinder
Bore 56.985–57.010 mm (2.2435–2.2445 in)
Taper limit 0.05 mm (0.0020 in)
Out of round limit 0.05 mm (0.0020 in)
Piston
Piston-to-cylinder clearance 0.015–0.025 mm (0.0006–0.00098 in)
Diameter D 56.965–56.990 mm (2.2427–2.2437 in)
2-5

Height H 5.0 mm (0.20 in)
H
D
Offset 0.25 mm (0.0098 in)

Offset direction Intake side
Piston pin bore inside diameter 14.002–14.013 mm (0.5513–0.5517 in)
Limit 14.043 mm (0.5529 in)
Piston pin outside diameter 13.995–14.000 mm (0.5510–0.5512 in)
Limit 13.975 mm (0.5502 in)
Piston-pin-to-piston-pin-bore clearance 0.002–0.018 mm (0.0001–0.0007 in)
Limit 0.068 mm (0.0027 in)
Piston ring
Top ring
Ring type Barrel
Dimensions (B × T) 0.80 × 2.10 mm (0.0315 × 0.0827 in)
B
T
End gap (installed) 0.10–0.25 mm (0.0039–0.0098 in)

Limit 0.50 mm (0.0197 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Limit 0.115 mm (0.0045 in)
2nd ring
Ring type Taper
B
T

Limit 0.60 mm (0.0236 in)
Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in)
Limit 0.115 mm (0.0045 in)
Oil ring
B
T
2-6
Connecting rod
Small end inside diameter 14.015–14.028 mm (0.5518–0.5523 in)
Crankshaft
Width A 47.95–48.00 mm (1.888–1.890 in)
Runout limit C 0.030 mm (0.0012 in)
Big end side clearance D 0.110–0.410 mm (0.0043–0.0161 in)
Big end radial clearance E 0.004 - 0.015 mm (0.0002 - 0.0006 in)
C C
E
D
Balancer
Balancer drive method Gear
Clutch
Clutch type Wet, multiple-disc
Clutch release method Inner push, cam push
Clutch lever free play 8.0–12.0 mm (0.31–0.47 in)
Friction plate thickness 2.90–3.10 mm (0.114–0.122 in)
Wear limit 2.80 mm (0.110 in)
Plate quantity 4 pcs
Clutch plate thickness 1.90–2.10 mm (0.075–0.083 in)
Plate quantity 3 pcs
Warpage limit 0.10 mm (0.0039 in)
Clutch spring free length 40.94 mm (1.61 in)
Minimum length 36.80 mm (1.45 in)
Spring quantity 4 pcs
Push rod bending limit 0.500 mm (0.0197 in)
Transmission
Transmission type Constant mesh 5-speed
Primary reduction system Helical gear
Primary reduction ratio 73/24 (3.042)
Secondary reduction system Chain drive
Secondary reduction ratio 42/14 (3.000)
Operation Left foot operation
Gear ratio
1st 34/12 (2.833)
2-7

2nd 30/16 (1.875)
3rd 30/21 (1.429)
4th 24/21 (1.143)
5th 22/23 (0.957)
Main axle runout limit 0.08 mm (0.0031 in)
Drive axle runout limit 0.08 mm (0.0031 in)
Shifting mechanism
Shift mechanism type Shift drum and guide bar
Shift fork-L thickness 5.76–5.89 mm (0.2268–0.2319 in)
Shift fork-C, -R thickness 4.76–4.89 mm (0.1874–0.1925 in)
Decompression device
Device type Auto decompresion
Air filter
Air filter element Dry element
Fuel injector
Model/quantity 5D78 00
Throttle body
Type/quantity AC28-14D01/1
Manufacturer MIKUNI
ID mark 2ND1 00
Fuel injection sensor

Crankshaft position sensor resistance 228–342 Ω
Intake air pressure sensor output voltage 3.88–4.12 V at 101.32 kPa
Intake air temperature sensor resistance 5.7–6.3 kΩ at 0 °C (32 °F)
Coolant temperature sensor resistance 210–221 Ω at 100 °C (212 °F)
2.51 - 2.78 kΩ at 20 °C (68 °F)
Idling condition
Engine idling speed 1300–1500 r/min
Coolant temperature 100 °C (212.00 °F)
Throttle grip free play 3.0–7.0 mm (0.12–0.28 in)
Fuel pressure at idling 220–300 kPa (2.2–3.0 kgf/cm2, 31 - 43 psi)
2-8
CHASSIS SPECIFICATIONS SPEC

EAS20300
CHASSIS SPECIFICATIONS
Chassis
Frame type Backbone
Caster angle 26.00°
Trail 81 mm (3.189 in)
Front wheel
Wheel type Cast wheel
Rim size 17 M/C × MT 1.85
Rim material Aluminum
Wheel travel 100 mm (3.94 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)
Rear wheel
Wheel type Cast wheel
Rim size 17 M/C × MT 3.50
Rim material Aluminum
Wheel travel 91 mm (3.58 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)
Front tire
Type Tubeless
Size 70/90–17M/C 38P
Manufacturer/model IRC/NF67
Wear limit (front) 1.0 mm (0.04 in)
Rear tire
Type Tubeless
Size 120/70–17M/C 58P
Manufacturer/model IRC/NF67
Wear limit (rear) 1.0 mm (0.04 in)
Tire air pressure (measured on cold tires)

Loading condition 1 person
Front 200 kPa (28 psi) (2.00 kgf/cm²
Rear 225 kPa (33 psi) (2.25 kgf/cm²)
Loading condition 2 person
Front 200 kPa (28 psi) (2.20 kgf/cm²)
Rear 225 kPa (33 psi) (2.25 kgf/cm²)
Front brake
Type Single disc brake
Operation Right hand operation
Front disc brake
Disc outside diameter × thickness 245.0 × 4.0 mm (9.65 × 0.16 in)
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc deflection limit 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 4.4 mm (1.17 in)
Limit 0.8 mm (0.031 in)
2-9

Brake pad lining thickness (outer) 4.4 mm (1.17 in)
Limit 0.8 mm (0.031 in)
Master cylinder inside diameter 11.00 mm (0.43 in)
Caliper cylinder inside diameter 33.34 mm (1.31 in)
Recommended fluid DOT 3 or 4
Rear brake
Type Single disc brake
Operation Right foot operation
Rear disc brake
Disc outside diameter × thickness 203.0 × 4.0 mm (7.99 × 0.16 in)
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc deflection limit 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 7.0 mm (0.26 in)
Limit 1.5 mm (0.06 in)
Brake pad lining thickness (outer) 7.0 mm (0.26 in)
Limit 1.5 mm (0.06 in)
Master cylinder inside diameter 14.0 mm (0.55 in)
Caliper cylinder inside diameter 32.00 mm (1.26 in)
Recommended fluid DOT 3 or 4
Steering
Steering bearing type Ball and race bearing
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 100.0 mm (3.94 in)
Fork spring free length 288.6 mm (11.36 in)
Limit 282.8 mm (11.13 in)
Collar length 100.0 mm (3.94 in)
Installed length 281.6 mm (11.09 in)
Spring rate K1 3.60 N/mm (20.56 lb/in) (0.37 kgf/mm)
Spring stroke K1 0.0–65.0 mm (0.00–2.56 in)
Spring stroke K2 65.0–100.0 mm (2.56–3.94 in)
Inner tube outer diameter 26.0 mm (1.02 in)
Optional spring available No
Recommended oil Fork oil 10W or equivalent
Quantity 66 cm³ (2.23 US oz) (2.32 Imp.oz)
Level 78.0 mm (3.07 in)
2-10
Rear suspension
Type Swingarm (link suspension)
Spring/shock absorber type Coil spring/oil damper
Rear shock absorber assembly travel 32 mm (1.26 in)
Spring free length 123 mm (4.84 in)
Installed length 120 mm (4.72 in)
Spring stroke K1 0.0–32 mm (0.00–1.26 in)
Optional spring available No
Swingarm
Swingarm end free play limit (axial) 0 mm (0 in)
Drive chain
Type/manufacturer 428SB/RK
Link quantity 122
Drive chain slack 20–30 mm (0.79–1.18 in)
15-link length limit 194.3 mm (7.65 in)
2-11
ELECTRICAL SPECIFICATIONS SPEC

EAS20310
ELECTRICAL SPECIFICATIONS
Voltage
System voltage 12 V
Ignition system
Ignition system Transistorized coil ignition (digital)
Advancer type Digital
Ignition timing (B.T.D.C.) 5.0°/1300 r/min
Engine control unit

Model/manufacturer 2ND0/YAMAHA MOTOR ELECTRONICS .CO., LTD.
Ignition coil
Model/manufacturer 1FC-0/YAMAHA MOTOR ELECTRONICS .CO., LTD.
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 2.16–2.64 Ω
Secondary coil resistance 8.64–12.96 kΩ
Spark plug cap

Material Resin
Resistance 3.75-6.25 kΩ
AC magneto
Standard output 14.0 V 175 W@5000 r/min
Stator coil resistance 0.36–0.54 Ω
Rectifier/regulator
Regulator type Semi conductor-open circuit
Model/manufacturer SH852AA. SHINDENGEN
Regulated voltage (DC) 14.0–14.8 V
Rectifier capacity 16.0 A
Battery
Model GTZ4V
Voltage, capacity 12 V, 3.0 Ah
Manufacturer GS Battery Vietnam Co., Ltd.
Ten hour rate amperage 0.30 A
Headlight
Bulb type Halogen bulb
Bulb voltage, wattage × quantity

Headlight 12 V, 35.0 W/35.0 W × 1
Auxiliary light LED
Tail/brake light LED
Front turn signal light 12 V, 10.0 W × 2
Rear turn signal light 12 V, 10.0 W × 2
License light 12V, 5W × 1
2-12
ELECTRICAL SPECIFICATIONS SPEC
Indicator light
Neutral indicator light LED
Turn signal indicator light LED
High beam indicator light LED
Coolant temperature warning light LED
Engine trouble warning light LED
Electric starting system

System type Constant mesh
Starter motor
Power output 0.30 kW
Armature coil resistance 0.0279–0.0341 Ω
Brush overall length 7.0 mm (0.28 in)
Limit 3.50 mm (0.14 in)
Brush spring force 3.92–5.88 N (14.11–21.17 oz) (400–600 gf)
Commutator diameter 17.6 mm (0.69 in)
Limit 16.6 mm (0.65 in)
Mica undercut (depth) 1.35 mm (0.05 in)
Starter relay
Model/manufacturer 3S4/MITSUBA
Amperage 50.0 A
Horn
Horn type Plane
Quantity 1 pc
Model/manufacturer HF-12/NIKKO
Maximum amperage 3.0 A
Coil resistance 1.07 - 1.11 Ω at 20 °C
Turn signal relay

Relay type Condenser
Model/manufacturer FR22-100/MITSUBA
Built-in, self-canceling device No
Turn signal blinking frequency 75.0–95.0 cycles/min
Wattage 10 W × 2+LED
Fuel sender
Sender unit resistance (full) 10–14 Ω
Sender unit resistance (empty) 267–273 Ω
Fan motor relay

Model/manufacturer 3C1-00/OMRON
Coil resistance 54.0–66.0 Ω
Fuse
Main Fuse 15.0 A
Sub Fuse 7.5 A
2-13
CONVERSION TABLE/
GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC
EAS00028 EAS00030
CONVERSION TABLE GENERAL TIGHTENING TORQUE

All specification data in this manual are listed in SI SPECIFICATIONS
and METRIC UNITS.
This chart specifies tightening torques for standard
Use this table to convert METRIC unit data to
fasteners with a standard ISO thread pitch.
IMPERIAL unit data.
Tightening torque specifications for special
components or assemblies are provided for each
Ex.
chapter of this manual. To avoid warpage, tighten
METRIC MULTIPLIER IMPERIAL
multi-fastener assemblies in a crisscross pattern
** mm × 0.03937 = ** in
and progressive stages until the specified
2 mm × 0.03937 = 0.08 in
tightening torque is reached. Unless otherwise
CONVERSION TABLE specified, tightening torque specifications require
clean, dry threads. Components should be at room
METRIC TO IMPERIAL
temperature.
Metric unit Multiplier Imperial unit
m·kg 7.233 ft·lb
Tighten- m·kg 86.794 in·lb
ing torque cm·kg 0.0723 ft·lb
cm·kg 0.8679 in·lb
kg 2.205 lb
Weight
g 0.03527 oz
Speed km/hr 0.6214 mph
km 0.6214 mi
m 3.281 ft
A: Distance between flats
Distance m 1.094 yd
B: Outside thread diameter
cm 0.3937 in
mm 0.03937 in A B General tightening torques
cc (cm3) 0.03527 oz (lMP liq.) nut bolt
(mm) (mm) Nm m·kg ft·lb
Volume/ cc (cm3) 0.06102 cu.in
Capacity lt (liter) 0.8799 qt (IMP liq.) 10 6 6 0.6 4.3
lt (liter) 0.2199 gal (lMP liq.)
12 8 15 1.5 11
kg/mm 55.997 lb/in
kgf/cm2 14.2234 psi (lb/in2) 14 10 30 3.0 22
Misc.
Centigrade 9/5+32 Fahrenheit
(°C) (°F) 17 12 55 5.5 40
19 14 85 8.5 61
22 16 130 13.0 94
2-14
ENGINE TIGHTENING TORQUES SPEC

ENGINE TIGHTENING TORQUES
Thread Tightening torque
Part to be tightened Part name Q’ty Remarks
size Nm m·kg ft·lb
Cylinder head Bolt M8 4 24 2.4 17
Cylinder head (timing chain side) Bolt M6 2 10 1.0 7.2
Cylinder head (oil check) Bolt M6 1 7 0.7 5.1
Spark plug — M10 1 13 1.3 9.4
Cylinder head cover Bolt M6 5 10 1.0 7.2
Water pump assembly Bolt M6 3 10 1.0 7.2
Stud bolt (cylinder head) Bolt M8 2 15 1.5 11
Cylinder (coolant water drain) Bolt M6 1 10 1.0 7.2
Balancer driven gear Nut M10 1 50 5.0 36
Generator rotor Nut M12 1 70 7.0 51
Timing chain guide (intake side) Bolt M6 1 10 1.0 7.2
Valve adjusting screw locknut (intake Nut M5 4 7 0.7 5.1
and exhaust side)
Camshaft sprocket Bolt M8 1 30 3.0 22
Camshaft retainer Bolt M6 2 7 0.7 5.1
Timing chain tensioner assembly Bolt M6 2 10 1.0 7.2
Thermostat cover Bolt M6 2 10 1.0 7.2
Oil pump assembly Screw M5 2 4 0.4 2.9
Oil filter cover Bolt M6 3 10 1.0 7.2
Engine oil drain bolt Bolt M35 1 32 3.2 23
Oil pump cover plate Bolt M6 2 10 1.0 7.2
Intake manifold (engine side) Bolt M6 2 10 1.0 7.2
Throttle body assembly Bolt M4 3 2 0.2 1.4
Fuel injector Bolt M6 1 12 1.2 8.7
Exhaust pipe Nut M8 2 15 1.5 11
Muffler and passenger footrest Bolt M8 1 20 2.0 14
Air filter assembly Bolt M6 4 4 0.4 2.9
Crankcase Bolt M6 13 10 1.0 7.2
Generator cover Bolt M6 7 10 1.0 7.2
Drive sprocket cover Bolt M6 2 10 1.0 7.2
Clutch cover Bolt M6 10 10 1.0 7.2
Timing check plug — M14 1 3 0.3 2.2
Starter clutch Bolt M6 3 14 1.4 10
Primary drive gear Nut M12 1 60 6.0 43
Clutch pressure plate Bolt M6 4 12 1.2 8.7
Clutch boss Nut M14 1 70 7.0 51
Drive sprocket Bolt M6 1 10 1.0 7.2
Main axle bearing retainer Screw M6 2 7 0.7 5.1
Clutch release adjusting locknut Nut M6 1 8 0.8 5.8
Shift pedal Bolt M8 1 23 2.8 17
2-15
Thread Tightening torque

Part to be tightened Part name Q’ty Remarks
size Nm m·kg ft·lb
Shift drum segment Bolt M6 1 12 1.2 8.7
Shift drum stopper lever Bolt M6 1 10 1.0 7.2
Crankshaft position sensor Bolt M6 2 10 1.0 7.2
Stator coil Bolt M6 3 10 1.0 7.2
Gear position switch Screw M5 2 4 0.4 2.9
Starter motor Bolt M6 2 10 1.0 7.2
Coolant temperature sensor — M10 1 15 1.5 11
O2 sensor — M12 1 25 2.5 18
Speed sensor Bolt M6 1 10 1.0 7.2
Kickstarter lever Nut M12 1 50 5.0 36
Guide ratchet wheel Bolt M6 2 12 1.2 8.7
2-16

Cylinder head tightening sequence:
1 3
5
4 2
Generator cover tightening sequence:

7
1,6
8
5
9
4
3,11 2,10
Clutch cover tightening sequence:

6
1,7
5
9
10
3,13 2,12
11
2-17

Crankcase tightening sequence:
A B
14
1,6 7
8 15
5 9
2,12
4
10
3,13 11
A. Left crankcase
B. Right crankcase
2-18
CHASSIS TIGHTENING TORQUES SPEC

CHASSIS TIGHTENING TORQUES
Tightening torque
Part to be tightened Thread size Q’ty Remarks
Nm m·kg ft·lb
Handlebar bracket and lower bracket M10 1 53 5.3 38
Brake hose and brake master cylinder M10 1 26 2.6 19
Brake hose and brake caliper M10 1 26 2.6 19
Brake master cylinder and holder M6 2 11 1.1 8.0
Brake master cylinder and brake lever M6 1 7 0.7 5.1
Throltle grip holder M5 2 2 0.2 1.4
Throltle cable holder M5 2 4.8 0.48 3.5
Rear view mirror upper (left and right) M10 2 22 2.2 16
Rear view mirror lower (left and right) M10 2 22 2.2 16
Front wheel axle nut M10 1 40 4.0 29
Brake hose holder M6 1 7 0.7 5.1
Front fork and brake caliper M10 2 35 3.5 25
Bleed screw M8 1 6 0.6 4.3
Lower bracket pinch bolt M10 4 53 5.3 38
Damper rod bolt M8 2 23 2.3 17
Upper ring nut M25 1 75 7.5 54 See NOTE
Lower ring nut M25 1 30 3.0 22 See NOTE
Front fender M6 4 10 1.0 7.2
Brake disc and wheel hub M8 5 23 2.3 17
Driven sprocket and rear wheel drive hub M8 6 43 4.3 31
Rear wheel axle nut M14 1 90 9.0 65
Rear shock absorber and frame M10 1 46 4.6 33
Rear shock absorber and swingarm M10 1 46 4.6 33
Swingarm pivot nut M12 1 46 4.6 33
Engine mounting nut (rear) M10 2 45 4.5 33
Engine mounting nut (front) M10 1 53 5.3 38
Swingarm and drive chain case M6 3 3.8 0.38 2.8
Drive chain adjuster locknut M6 2 7 0.7 5.1
Swingarm and caliper M10 1 39 3.9 28
Reserver tank (screw) M6 1 7 0.7 5.1
Master cylinder bracket and frame M8 2 32 3.2 23
Master cylinder and bracket M8 2 32 3.2 23
Coolant reservior tank and reservior tank bracket M6 1 7 0.7 5.1
Recovery tank bracket and bracket M6 3 7 0.7 5.1
Radiator and radiator bracket M6 1 7 0.7 5.1
Radiator bracket and recovery tank M6 1 7 0.7 5.1
Fan and radiator M6 2 7 0.7 5.1
Rider footrest and crankcase M8 4 23 2.3 17
2-19
CHASSIS TIGHTENING TORQUES SPEC

Tightening torque
Part to be tightened Thread size Q’ty Remarks
Nm m·kg ft·lb
Passenger footrest bracket and frame M8 4 34 3.4 25
Sidestand and rider footrest (bolt) M8 1 26 2.6 19
Sidestand and rider footrest (nut) M8 1 16 1.6 12
Side panel bracket and crankcase cover M6 4 10 1.0 7.2
(left and right)
Main switch and frame M6 2 10 1.0 7.2
Ignition coil and frame M6 2 7 0.7 5.1
Fuel tank and frame M6 6 7 0.7 5.1
Fuel pump and fuel tank M5 4 4 0.4 2.9
Rectifier Regulator and bracket (nut) M6 2 7 0.7 5.1
Seat lock bracket and frame M6 2 7 0.7 5.1
Seat lock and seat lock braket M6 2 7 0.7 5.1
Tail light unit M6 2 3.5 0.35 2.5
Seat handle M6 4 10 1.0 7.2
Battery stay M6 2 7 0.7 5.1
Rear fender and frame (bolt) M6 2 7 0.7 5.1
Rear fender and frame (nut) M6 2 7 0.7 5.1
Stay and mud guard M6 4 8 0.8 5.8
TIP
1. First tighten the lower ring nut 30 Nm (3.0 m·kg, 22 ft·lb) by using a torque wrench, then loosen
the ring nut 1/4 turn.
2. Then, hold the lower ring nut and tighten the upper ring nut 75 Nm (7.5 m·kg, 54 ft·lb) by using a
torque wrench.
2-20
LUBRICATION POINTS AND LUBRICANT TYPES SPEC

EAS20360
LUBRICATION POINTS AND LUBRICANT TYPES

EAS20370
ENGINE
Lubrication point Lubricant
Oil seal lips LS
Bearings E
Cylinder head bolts and washers M
Connecting rod bearing inner surface E
Connecting rod big end thrust surface E
Crank pin E
Piston pin E
Piston out side surface and ring groove E
Balancer driven gear inner surface E
Camshaft lobes M
Decompression cam E
Valve stem and valve end M
Valve stem seal E
Rocker arm shaft M
Rocker arm inner surfaces M
Decompression lever pin M
Water pump case O-ring LS
Oil seal (clutch cover) E
Oil pump rotors (inner and outer) E
Oil pump shaft E
Oil strainer plug O-ring LS
Oil filter element cover O-ring LS
Intake manifold O-ring LS
Injector O-ring E
Timing mark accessing screw O-ring LS
Crankshaft end accessing screw O ring LS
Oil level gauge O-ring E
Crankshaft end oil seal (right side) E
Starter motor O-ring LS
Starter clutch idle gear thrust surface E
Starter clutch idle gear shaft E
2-21

Starter clutch gear inner surface and thrust surface E
Starter clutch rollers E
Clutch push lever E
Primary driven gear inner surface E
Clutch push rod (short and long) and ball E
Clutch boss nut and lock washer contact surface E
Transmission gears (wheel and pinion) and collar M
Shift forks and shift fork guide bar E
Shift drum E
Shift shaft E
Gear position switch O-ring LS
Speed sensor O-ring LS
Yamaha bond No.

Crankshaft position sensor/stator assembly lead grommet 1215 (Three Bond
No.1215®)
Yamaha bond No.
Crankcase mating surface 1215 (Three Bond
No.1215®)
Yamaha bond No.
Timing chain tensioner bolts 1215 (Three Bond
No.1215®)
2-22

EAS20380
CHASSIS
Front wheel oil seal lip LS
Front wheel shaft LS
Rear wheel drive hub mating surface LS
Rear wheel oil seal lip LS
Rear wheel shaft LS
Brake pedal pivoting point LS
Brake caliper bracket boots inner surface S
Throttle grip tube guide inner surface and throttle cable end LS
Clutch cable end at the clutch lever LS
Brake lever pivot bolt outer surface S
Clutch lever pivot bolt outer surface LS
Steering head bearings and upper/lower bearing cover lip LS
Steering head dust seal LS
Pivot shaft and nut threads LS
Pivot shaft outer surface LS
Centerstand pivot shaft LS
Sidestand pivoting point and metal-to-metal moving point LS
Sidestand spring pin LS
Passenger footrest pivoting point LS
Engine mounting bolts and nuts LS
2-23
LUBRICATION SYSTEM CHART AND DIAGRAMS SPEC

EAS20390
LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS20400
ENGINE OIL LUBRICATION CHART
4
3
5 6
7
8
2-24

1. Camshaft
2. Drive axle
3. Main axle
4. Clutch assy
5. Oil pump
6. Oil cleaner
7. Strainer
8. Oil pan
2-25

EAS20410
LUBRICATION DIAGRAMS
2-26

1. Clutch push lever
2. Main axle
3. Drive axle
4. Camshaft
5. Crankshaft
2-27
2-28
COOLING SYSTEM DIAGRAMS SPEC

1 Radiator inlet hose È Align the position white paint mark of pipe with
2 Radiator cap projection mark of thermostat.
3 Hose clamp É Band the end of the cover, before install the pro-
4 Coolant reservoir hose jection of the reservoir tank.
5 Frame cross pipe Ê Install the hook of the cover end into the slit of
6 Radiator
the bracket.
7 Radiator outlet hose
Ë Pass the cover around the pipe and insert cover
8 Over flow hose
9 Coolant reservoir tank hook into its hole.
0 Water pump inlet hose Ì Align the position white paint mark of pipe with
projection mark of water pump.
2
A
1
D
4
D
0
5 7
2
N
4
3
8
C N
E
8
B 9
D
K-K K
E
K
E-E
E
2-29
CABLE ROUTING SPEC

EAS00350 0 Right handlebar switch lead
CABLE ROUTING A Front brake switch lead
1 Meter assembly B Throttle cable return side
2 Meter assembly connector C Throttle cable pull side
3 Dimmer switch coupler
4 Clutch cable È Insert the strap of wire harness pass above han-
5 Left handlebar switch lead dlebar.
6 Rear brake switch coupler É Set the lead of headlight into store above han-
7 Headlight lead dlebar center after connecting.
8 Wire harness
9 Brake hose
1 A 2
3
5 4
C 6
@
B A
B
9
8
C 8
B C
9 B
9
4
4
2-30
CABLE ROUTING SPEC

1 Rectifier/Regulator B Throttle cable (return side)
2 ECU (Engine Control Unit) C Guide wire
3 Horn lead D Frame complete
4 O2 sensor lead
5 Fan relay assembly È Set the ECU house inside cover after connecting
6 A.C magneto lead coupler.
7 Gear position switch lead É Insert the ECU cover on bracket.
8 Wire minus lead Ê Pass the horn lead between head pipe and
9 Speed sensor lead guide wire.
0 Clutch cable Ë Pass the flasher lead and O2 sensor lead
A Throttle cable (pull side) through into the guide wire.
1
2
C
4
:
A B C
A D
D =
5 C
6 H-H
B
4 7 G-G
G
E
G
H
I H
9 8 H
2-31
CABLE ROUTING SPEC

Ì Pass the drain hose front of tube cross.
Í Pass the drain hose front of pipe cross.
Î Pass the drain hose into guide.
Ï Pass the wire minus lead between positioning
pin and bolt.
Ð Insert the clamp of horn lead into hole of stay.
1
2
C
4
:
A B C
A D
D =
5 C
6 H-H
B
4 7 G-G
G
E
G
H
I H
9 8 H
2-32
CABLE ROUTING SPEC

1 License light and main harness coupler B Flasher relay lead
2 Wire minus lead C Starter motor lead
3 Sensor module lead D Seat lock cable
4 Injector lead E Tail light/Brake light
5 Coolant temperature sensor lead F License light lead
6 Radiator fan lead G Wire harness
7 High tension cord lead H Lean angle sensor lead
8 Main switch I Clamp
9 Speed sensor lead J Frame complete
0 Main harness and wire minus coupler
A Rear brake switch lead
1 8 B C
7
4 6
C 2 3 5
A
A
C A
E D B
C B E D
F
B
E
A
2
9
G F E 0
G
I E I J J
G
D D
F 2 2 A K
G
H J D
G C A-A
J I
I
H J E-E
C-C B-B
2-33
CABLE ROUTING SPEC

È Pass the seat lock cable inside of wire harness. Ï Insert the clamp into the hole frame complete.
É Locate the main switch coupler to dowside. Ð Insert the clamp into the hole frame complete.
Ê Pass the main switch lead to bottom of seat lock Ñ Insert the clamp into the hole frame complete.
cable and wire harness. Ò Insert the clamp wire harness into the hole of
Ë Pass the wire harness into holder. frame complete.
Ì Pass the license light lead through the hole of
rear fender.
Í Insert the clamp of white license light lead into
the hole rear fender.
Î Pass the license light lead through clamp of
guard mud.
1 8 B C
7
4 6
C 2 3 5
A
A
C A
E D B
C B E D
F
B
E
A
2
9
G F E 0
G
I E I J J
G
D D
F 2 2 A K
G
H J D
G C A-A
J I
I
H J E-E
C-C B-B
2-34
CABLE ROUTING SPEC

1 Main fuse box B Clamp
2 Sub fuse box C Gear position switch lead
3 Front flasher coupler (left side) D Frame complete
4 Auxiliary light coupler È Pass the rear flasher lead through between rib of
5 Front flasher couple (right side) rear fender.
6 Lean angle sensor lead É Pass the license light lead through between fib
7 Service tool coupler of rear fender.
8 Rear fender Ê Insert the battery positive lead and fuses box
9 Battery lead under battery.
0 Seat lock cable Ë Insert the flasher coupler into the hole of side panel.
A Wire harness Ì Insert the clamp into frame complete.
C E
A
D
?
D
A
1 2
3
4
B 5
9 7
6
C
D-D
2-35
CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION.............................................................................................. 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION

CONTROL SYSTEM....................................................................................... 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART............................ 3-1
COVERS AND COWLINGS ............................................................................ 3-3
ENGINE ........................................................................................................... 3-7

ADJUSTING THE VALVE CLEARANCE .................................................. 3-7
ADJUSTING THE ENGINE IDLING SPEED ........................................... 3-11
CHECKING THE THROTTLE GRIP OPERATION ................................. 3-12
CHECKING THE SPARK PLUG .............................................................3-14
MEASURING THE COMPRESSION PRESSURE .................................. 3-15
CHECKING THE ENGINE OIL LEVEL....................................................3-17
CHANGING THE ENGINE OIL ...............................................................3-19
CHECKING THE ENGINE OIL PRESSURE ........................................... 3-20
CHECKING THE OIL FILTER ................................................................. 3-21
CHECKING THE EXHAUST SYSTEM....................................................3-21
ADJUSTING THE EXHAUST GAS VOLUME .........................................3-21
CLEANING THE AIR FILTER ELEMENT................................................3-22
ADJUSTING THE CLUTCH LEVER FREE PLAY ...................................3-23
CHECKING THE THROTLLE BODY JOINT AND
INTAKE MANIFOLD ...............................................................................3-24
CHECKING THE FUEL HOSES.............................................................. 3-24
CHECKING THE CRANKCASE BREATHER PIPE ................................ 3-25
CHECKING THE COOLANT LEVEL....................................................... 3-25
CHECKING THE COOLING SYSTEM ....................................................3-26
CHANGING THE COOLANT................................................................... 3-27
CHASSIS .......................................................................................................3-30
CHECKING THE FRONT BRAKE PADS ................................................3-30
CHECKING THE REAR BRAKE PADS ..................................................3-30
ADJUSTING THE REAR BRAKE LIGHT SWITCH ................................. 3-30
CHECKING THE FRONT AND REAR BRAKE HOSE ............................3-31
BLEEDING THE HYDRAULIC BRAKE SYSTEM ...................................3-32
ADJUSTING THE DRIVE CHAIN SLACK ............................................... 3-33
LUBRICATING THE DRIVE CHAIN ........................................................ 3-35
CHECKING THE BRAKE FLUID LEVEL................................................. 3-35
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-36
CHECKING THE FRONT FORK .............................................................3-38
CHECKING THE TIRES .......................................................................... 3-39
CHECKING AND LUBRICATING THE CABLES .................................... 3-42
LUBRICATING THE LEVER AND PEDALS............................................ 3-42
LUBRICATING THE SIDESTAND...........................................................3-42
LUBRICATING THE CENTERSTAND ....................................................3-42
CHK
ADJ
ELECTRICAL SYSTEM.................................................................................3-43
CHECKING AND CHARGING THE BATTERY .......................................3-43
CHECKING THE FUSE........................................................................... 3-49
REPLACING THE HEADLIGHT BULBS ................................................. 3-50
ADJUSTING THE HEADLIGHT BEAM ................................................... 3-51
INTRODUCTION/PERIODIC MAINTENANCE CHART CHK

FOR THE EMISSION CONTROL SYSTEM ADJ
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS

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
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAU46932
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL

SYSTEM
ODOMETER READING (whichever comes first)
1000 km 4000 km 7000 km 10000 km 13000 km ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
or or or or or CHECK
1 month 4 months 7 months 10 months 13 months
• Check fuel hose for cracks or
1 * Fuel line
damage.
• Check condition.
2 * Fuel filter Every 12000 km (7500 mi)
• Replace if necessary.
• Check condition.
3 Spark plug • Clean and regap.
• Replace. Every 10000 km (6200 mi)
• Check valve clearance.
4 * Valves
• Adjust.
• Check engine idle speed.
5 * Fuel injection • Clean, check fuel injection vol-
Every 10000 km (6200 mi)
ume and angle of injector.
• Check for leakage.
6 * Exhaust system • Tighten if necessary.
• Replace gasket(s) if necessary.
EAUU1324
GENERAL MAINTENANCE AND LUBRICATION CHART

ODOMETER READING (km)
ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB 1000 or 4000 or 7000 or 10000 or 13000 or CHECK
Air filter ele- • Clean.
1
ment • Replace. Every 10000 km (6200 mi)
Air filter check
2 • Clean.
hose
• Check voltage.
3 * Battery
• Charge if necessary.
• Check operation.
4 Clutch
• Adjust.
• Check operation, fluid level and
5 * Front brake vehicle for fluid leakage.
• Replace brake pads. Whenever worn to the limit
• Check operation, fluid level and
6 * Rear brake vehicle for fluid leakage.
• Replace brake pads. Whenever worn to the limit
• Check for cracks or damage.
• Check for correct routing and
7 * Brake hose clamping.
• Replace. Every 4 years
8 * Brake fluid • Replace. Every 2 years
• Check runout and for damage.
9 * Wheels
• Replace if necessary.
• Check tread depth and for dam-
age.
10 * Tires • Replace if necessary.
• Check air pressure.
• Correct if necessary.
3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CHK

CONTROL SYSTEM ADJ
ODOMETER READING (km)
ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB 1000 or 4000 or 7000 or 10000 or 13000 or CHECK
• Check bearings for looseness or
11 * Wheel bearings
damage.
• Check operation and for exces-
sive play.
12 * Swingarm
• Lubricate with lithium-soap-
Every 12000 km (7500 mi)
based grease.
• Check chain slack, alignment
and condition.
Every 1000 km (620 mi) and after washing the motorcycle, riding in the
13 Drive chain • Adjust and lubricate chain with a
rain or riding in wet areas
special O-ring chain lubricant
thoroughly.
• Check bearing play and steering
Steering bear- for roughness.
14 *
ings • Lubricate with lithium-soap-
Every 10000 km (6200 mi)
based grease.
• Make sure that all nuts, bolts
Chassis
15 * and screws are properly tight-
fasteners
ened.
Brake lever
16 • Lubricate with silicone grease.
pivot shaft
Brake pedal • Lubricate with lithium-soap-
17
pivot shaft based grease.
Clutch lever • Lubricate with lithium-soap-
18
pivot shaft based grease.
Sidestand,
19 • Lubricate with lithium-soap-
centerstand
based grease.
• Check operation and for oil
20 * Front fork leakage.
• Change the front fork oil. Every 20000 km (12000 mi)
Shock
• Check operation and shock
21 * absorber
absorber for oil leakage.
assembly
• Change.
22 Engine oil • Check oil level and vehicle for Every 3000 km (1800 mi)
oil leakage.
Engine oil filter
23 • Replace. Every 10000 km (6200 mi)
element
• Check coolant level and vehicle
for coolant leakage.
24 * Cooling system
• Change with Yamaha genuine
Every 3 years
coolant.
Front and rear
25 * • Check operation.
brake switches
Moving parts
26 • Lubricate.
and cables
• Check throttle grip free play,
27 * Throttle grip
and adjust if necessary.
• Lubricate cable and grip housing.
Lights, signals • Check operation.
28 *
and switches • Adjust headlight beam.
EAU18662
TIP
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder and caliper, and change the brake
fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-2
CHK
COVERS AND COWLINGS ADJ
COVERS AND COWLINGS
SEAT AND STORAGE BOX
6 5 7
Order Job name/Parts name Q’ty Remarks
Seat and storage box removal Remove the parts in the order below.
1 Center panel (upper) 1
2 Pin 1
3 Double seat 1
4 Tool and storage box cap 1
5 Tool kit 1
6 Helmet lock cable 1
7 Storage box 1
Refer to “COVERS AND COWLINGS”.
For installation, reverse the removal
procedure.
3-3
CHK
LEFT AND RIGHT SIDE COVER ASSEMBLY
5 7
4
2
4 Nm (0.4 m • kg, 2.9 ft • Ib)

.R
.
Left and right side covers removal Remove the parts in the order below.
Seat/Storage box/Center panel (upper) Refer to “SEAT AND STORAGE BOX”.
1 Rear panel 1
2 Side cover assembly (left) 1
3 Lower side cover (left) 1
4 Side cover (left) 1
5 Side cover assembly (right) 1
6 Lower side cover (right) 1
7 Side cover (right) 1
procedure.
3-4
CHK
FRONT COWLING AND LEG SHIELD
12
5
4 Nm (0.4 m • kg, 2.9 ft • Ib)

.R
.
6
14 13
8
4 Nm (0.4 m • kg, 2.9 ft • Ib) 11

.R
.
10
1
3
4
9
2
4 Nm (0.4 m • kg, 2.9 ft • Ib)
.R
.
Front cowling and bottom cowling Remove the parts in the order below.
removal
1 Side panel assembly (left) 1 Disconnect.
2 Lover side panel (left) 1 Disconnect.
3 Side panel (left) 1
4 Air guide (left) 1 Disconnect.
5 Side panel assembly (right) 1
6 Lower side panel (right) 1
7 Side panel (right) 1
8 Air guide (right) 1
9 Front cowing 1
10 Front inner cowling 1
11 Front panel 1
12 Center panel (upper) 1
13 Center panel cover 1
14 Leg shield 1
procedure.
3-5
CHK
HANDLEBAR COVER (front) AND (rear)
2.5 Nm (0.25 m •kg, 1.8 ft • Ib)

.R
.
Handlebar cover (front) and (rear) removal Remove the parts in the order below.
Before remove handlebar cover 1 and
headlight assembly, need disconnect
headlight coupler.
Before remove handlebar cover 2, need
disconnect start and light switch coupler,
Turn signal and horn switch coupler,
dimmer switch coupler, meter coupler.
1 Meter panel 1
2 Headlight unit 1
3 Handlebar cover (front) 1
4 Rear view mirror (left and right) 2
5 Meter assembly 1
6 Start switch 1
7 Dimmer switch 1
8 Turn signal switch and horn switch 1
assembly
9 Handlebar cover (rear) 1
procedure.
3-6
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
EAS00049
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
TIP
• Valve clearance adjustment should be
made on a cold engine, at room tempera-
ture.
• When the valve clearance is to be mea-
sured or adjusted, the piston must be at top
dead center (TDC) on the compression
stroke.
1. Remove:
• side panel assemly (left and right)
2. Drain:
• cooling system
Refer to “CHANGING THE COOLANT”.
3. Disconnect:
• radiator inlet hose
• radiator outlet hose
• water pump inlet hose
• spark plug cap
• O2 sensor coupler
• radiator fan coupler
• clutch cable
4. Remove:
• spark plug
• bracket
3-7
CHK
5. Move:
• radiator assembly
Refer to “RADIATOR SYSTEM” in chapter
5.
6. Remove:
• water pump assembly 1
1 • O-rings
7. Remove:
• cylinder head cover 1
(with O-ring)
8. Remove:
• timing check plug 1
(with O-ring)
1 9. Measure:
• valve clearance
Out of specification - Adjust.
Valve clearance (cold)
Intake valve
0.10-0.14 mm (0.0039-0.0055 in)
Exhaust valve
0.20–0.24 mm (0.0079–0.0094 in)
b
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the rear wheel.
a b. When the piston is at TDC on the compres-
sion stroke, align the “I” mark a on the
camshaft sprocket with the stationary
pointer b on the cylinder head.
3-8
CHK
c. Align the TDC mark c on the generator
rotor with the stationary pointer d on the
crankcase cover.
d. Measure the valve clearance with a thick-

ness gauge 1
Out of specification → Adjust.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
10.Adjust:
• valve clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut 1.
b. Insert a thickness gauge 2 between the
end of the adjusting screw and the valve tip.
c. Turn the adjusting screw 3 in direction a
or b until the specified valve clearance is
obtained.
Valve clearance is
Direction a
increased.
Valve clearance is
Direction b
decreased.
Tappet adjusting tool 4

90890-01311
• Hold the adjusting screw to prevent it from

moving and tighten the locknut to specifica-
tion.
Locknut
7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
d. Measure the valve clearance again.

e. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance
adjustment steps until the specified clear-
ance is obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-9
CHK
11.Install:
• O-ring New
• timing check plug
(with O-ring)
3 Nm (0.3 m·kg, 2.2 ft·lb)
T.
R.
12.Install:
• O-ring New
• cylinder head cover
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
13.Install:
• O-ring New
• water pump assembly
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
14.Install:
• radiator assembly
To push the radiator assembly toward the
right side.
15.Install:
• bracket
• spark plug
13 Nm (1.3 m·kg, 9.4 ft·lb)
T.
R.
16.Connect:
• water pump inlet hose
• radiator outlet cover
• radiator inlet hose
• spark plug cap
• O2 sensor coupler
• radiator fan coupler
• clutch cable
17.Fill:
• cooling system
18.Install:
• side panel assembly (left and right)
3-10
CHK
ADJUSTING THE ENGINE IDLING SPEED ADJ
EAS00054
ADJUSTING THE ENGINE IDLING SPEED

TIP
Prior to adjusting the engine idling speed, the
air filter element should be clean, and the
engine should have adequate compression.
1. Remove:
• side panel assembly (left)
2. Start the engine and let it warm up for sev-
eral minutes.
3. Connect:
• engine tachometer
(onto the spark plug lead)
4. Check:
• engine idling speed
Engine idling speed

1,300–1,500 r/min
5. Adjust:
• engine idling speed
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Turn the idle adjusting screw 1 in direction
a or b until the specified engine idling
speed is obtained.
Engine idling speed is
Direction a
increased.
Direction b
decreased.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-11
ADJUSTING THE ENGINE IDLING SPEED/ CHK

CHECKING THE THROTTLE GRIP OPERATION ADJ
6. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play (at the
flange of the throttle grip)
3–7 mm (0.12–0.28 in)
7. Install:
• side panel assemly (left)
Refer to “COVER AND COWLINGS”.
EAS00058
CHECKING THE THROTTLE GRIP OPERATION

1. Check:
• Throttle cables
Damage/deterioration → Replace.
• Throttle cable installation
Incorrect → Reinstall the throttle cables.
Refer to “HANDLEBARS”
2. Check:
• Throttle grip movement
Rough movement → Lubricate or replaced
the defective part(s).
Recommended lubricant
Suitable cable lubricant
TIP
With the engine stopped, turn the throttle grip
slowly and release it. Make sure that the throt-
tle trip turns smoothly and returns properly
when released.
Repeat this check with the handlebar turned all
the way to the left and right.
3. Check:
• throttle cable free play a
Throttle cable free play (at the
a
flange of the throttle grip)
3–7 mm (0.12–0.28 in)
3-12
CHK
CHECKING THE THROTTLE GRIP OPERATION ADJ
4. Adjust:
• throttle cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pull back the adjusting nut cover.
(a) b. Loosen the locknut 1.
c. Turn the adjusting nut 2 in direction a or
b until the specified throttle cable free play
1
2 is obtained.
(b) Engine idling speed is
Direction a
increased.
Direction b
decreased.
d. Tighten the locknut.
e. Side the adjusting nut cover to its original
position.
WARNING
After adjusting the throttle cable free play,
start the engine and turn the handlebar to
the right or left to ensure that this does not
cause the engine idling speed to change.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-13
CHK
CHECKING THE SPARK PLUG ADJ
EAS00060
CHECKING THE SPARK PLUG

1. Remove:
• side panel assembly (right)
2. Disconnect:
• spark plug cap
3. Remove:
• spark plug
NOTICE
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from fall-
ing into the cylinder.
4. Check:
• spark plug type
• Incorrect → Change.
Spark plug type (manufacturer)

CR8E (NGK)
5. Check:
• electrode 1
Damage/wear → Replace the spark plug.
• insulator 2
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:
• spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
• spark plug gap a
(with a wire thickness gauge)
Out of specification → Regap.
Spark plug gap

0.7-0.8 mm (0.027-0.031 in)
3-14
CHECKING THE SPARK PLUG/ CHK

MEASURING THE COMPRESSION PRESSURE ADJ
8. Install:
• spark plug
13 Nm (1.3 m·kg, 9.4 ft·lb)
T.
R.
TIP
Before installing the spark plug, clean the
spark plug and gasket surface.
9. Connect:
• spark plug cap
10.Install:
EAS00067
MEASURING THE COMPRESSION

PRESSURE
TIP
Insufficient compression pressure will result in
a loss of performance.
1. Remove:
2. Measure:
• valve clearance
Refer to “ADJUSTING THE VALVE
CLEARANCE”.
3. Start the engine, warm it up for several min-
utes, and then turn it off.
4. Disconnect:
• spark plug cap
5. Remove:
• spark plug
NOTICE
Before removing the spark plug, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug well to prevent it
from falling into the cylinder.
3-15

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B15F8197E0.

book Page 1 Thursday, March 5, 2015 4:37 PM

IMPORTANT MANUAL INFORMATION

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

A NOTICE indicates special precautions that must be taken to avoid

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

HOW TO USE THIS MANUAL

6 Order Job/Parts to remove Q’ty Remarks

Symbols H to O in the exploded diagrams

H I J K Symbols P to Q in the exploded diagrams

E G M BF P Apply locking agent (LOCTITE®)

ELECTRICAL SYSTEM ELEC

IDENTIFICATION ............................................................................................ 1-1

IMPORTANT INFORMATION ......................................................................... 1-4

CHECKING THE CONNECTIONS .................................................................. 1-6

SPECIAL TOOLS ............................................................................................ 1-7

VEHICLE IDENTIFICATION NUMBER

ENGINE SERIAL NUMBER

OUTLINE OF THE FI SYSTEM

1 Fuel pump È Fuel system

2. Use only the proper tools and cleaning equip-

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS

Do not spin the bearing with compressed air

CHECKING THE CONNECTIONS

Tool no. Tool name/Usage Illustration

This tool is used for testing radiator cap.

This tool is used to install oil seals.

This tool is used for lapping the valve.

Crankcase separating tool

GENERAL SPECIFICATIONS ........................................................................ 2-1

ENGINE SPECIFICATIONS ............................................................................ 2-2

CHASSIS SPECIFICATIONS .......................................................................... 2-9

ELECTRICAL SPECIFICATIONS ................................................................. 2-12

CONVERSION TABLE .................................................................................. 2-14

GENERAL TIGHTENING TORQUE SPECIFICATIONS............................... 2-14

ENGINE TIGHTENING TORQUES ...............................................................2-15

CHASSIS TIGHTENING TORQUES .............................................................2-19

LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-21

LUBRICATION SYSTEM CHART AND DIAGRAMS.................................... 2-24

CABLE ROUTING ......................................................................................... 2-31

GENERAL SPECIFICATIONS SPEC

ENGINE SPECIFICATIONS SPEC

ENGINE SPECIFICATIONS SPEC

Camshaft runout limit 0.03 mm (0.0012 in)

ENGINE SPECIFICATIONS SPEC

Rocker arm/rocker arm shaft

Valve, valve seat, valve guide

Valve seat width C (intake) 0.09–1.20 mm (0.0354–0.0472 in)

Valve margin thickness D (intake) 0.50–0.90 mm (0.0197–0.0354 in)

Valve stem diameter (intake) 4.475–4.490 mm (0.1762–0.1768 in)

ENGINE SPECIFICATIONS SPEC

Winding direction (intake) Clockwise

ENGINE SPECIFICATIONS SPEC

Offset 0.25 mm (0.0098 in)

End gap (installed) 0.10–0.25 mm (0.0039–0.0098 in)

End gap (installed) 0.10–0.25 mm (0.0039–0.0098 in)

End gap (installed) 0.20–0.70 mm (0.0079–0.0276 in)

ENGINE SPECIFICATIONS SPEC