ENGINE

ADJUSTING THE VALVE CLEARANCE

  • This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowledge and skill concerning servicing are requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage.

  • Make sure that the valve clearance is checked or adjusted while the engine is cold (at room temperature).

  • While the valve clearance is checked or adjusted, make sure that the piston is positioned in the top dead center (TDC).

1.Remove:

2.Remove:

  • Spark plug

  • Cylinder head cover

    Refer to CAMSHAFT.

3.Remove:

  • Timing mark accessing screw “1”

  • Crankshaft end accessing screw “2”

  • O-ring

4.Check:

  • Valve clearance

    Out of specification → Regulate.

Valve clearance (cold)

  • Intake

    0.10–0.17 mm (0.0039–0.0067 in)

  • Exhaust

    0.15–0.22 mm (0.0059–0.0087 in)

a.Turn the crankshaft counterclockwise with a wrench.

b.Align the top dead center (TDC) mark “a” on the generator rotor with the alignment mark “b” on the crankcase cover.

Check that the alignment marks “c” on the camshaft sprockets are aligned with the edge of the camshaft cap surfaces “d”.

c.Measure the valve clearance using a thickness gauge “1”.

  • Thickness gauge

    90890-03268

  • Feeler gauge set

    YU-26900-9

Record the measured reading if the clearance is incorrect.

5.Adjust:

  • Valve clearance

a.Remove the camshaft (intake and exhaust).

Refer to CAMSHAFT.

b.Remove the valve lifter “2” and the adjusting pad “3” with a valve lapper “1”.

  • Place a cloth in the timing chain space to prevent adjusting pads from falling into the crankcase.

  • Identity each valve lifter and adjusting pad position very carefully so that they can be reinstalled in their original place.

  • Valve lapper (ø14)

    90890-04101

  • Valve lapper (ø14)

    YM-A8998

c.Check the number on the originally installed adjusting pad.

  • The adjusting pad number “a” is indicated on the top of the adjusting pad.

  • For the number on the originally installed adjusting pad, convert the last digit of adjusting pad number as per the below table.

d.Select an adjusting pad with a proper valve clearance from the adjusting pad selection table.

  • There are 25 types of adjusting pads, ranging from 1.20 mm (0.0472 in) to 2.40 mm (0.0945 in), in increments of 0.05 mm (0.0020 in).

  • The field where the number on the originally installed adjusting pad and the measured valve clearance intersect shows the adjusting pad number to replace.

Last digit of pad number

Rounded value

0, 1 or 2

0

4, 5 or 6

5

8 or 9

10

Example:

Pad number = 148

Rounded value = 150

e.Install the new adjusting pads “4” and the valve lifters “5”.

Do not twist adjusting pads and valve lifters forcibly during installation.

  • Apply the engine oil on the valve lifters.

  • Apply molybdenum disulfide oil to the valve stem ends.

  • Check that the valve lifters turn smoothly when rotated with your finger.

  • Make sure that valve lifters and adjusting pads are installed in place.

  • Make sure that adjusting pads are installed with their numbers facing upward.

f.Install the camshafts (exhaust and intake).

Refer to CAMSHAFT.

g.Measure the valve clearance again.

h.If the valve clearance is out of specification, repeat adjusting the valve clearance until it is within specification.

VALVE CLEARANCE SHIM CHART

INTAKE

A.

Measured clearance

B.

Installed pad number

C.

Standard clearance

Example:

Valve clearance (cold) 0.10–0.17 mm (0.0039–0.0067 in)

Installed is 175.

Measured clearance 0.25 mm (0.0098 in)

Replace 175 pad with 185 pad.

Pad No. 175 = 1.75 mm (0.0689 in)

Pad No. 185 = 1.85 mm (0.0728 in)

EXHAUST

A.

Measured clearance

B.

Installed pad number

C.

Standard clearance

Example:

Valve clearance (cold) 0.15–0.22 mm (0.0059–0.0087 in)

Installed is 175.

Measured clearance 0.30 mm (0.0118 in)

Replace 175 pad with 185 pad.

Pad No. 175 = 1.75 mm (0.0689 in)

Pad No. 185 = 1.85 mm (0.0728 in)

CHECKING THE ENGINE IDLING SPEED

  • Because the air pressure is lower at high altitudes, the air-fuel mixture will become richer. If the idling speed is low, turn the idle screw clockwise to increase the speed before the adjustment.

  • Before adjusting the engine idling speed, make sure that the air filter element is not clogged, the engine compression is proper, and the throttle grip free play is proper.

  • Adjust the engine idling speed with the starter knob pulled in completely.

1.Start the engine, and warm this up until the oil has reached the specified temperature.

2.Measure the coolant temperature using the Yamaha diagnostic tool.

  • Yamaha diagnostic tool USB (US)

    90890-03269

  • Yamaha diagnostic tool (A/I)

    90890-03264

  • Coolant temperature

    70–80 °C (158–176 °F)

3.Install:

  • Digital tachometer

  • Digital tachometer

    90890-06760

  • Digital tachometer

    YU-39951-B

Get the high tension cord “1” of the ignition coil pinched in the detector “a” of the digital tachometer.

4.Measure:

  • Engine idling speed

    Out of specification → Regulate.

  • Engine idling speed

    1900–2100 r/min

5.Adjust:

  • Engine idling speed

a.Turn the idle screw “1” to make an adjustment.

CHECKING THE THROTTLE GRIP

Prior to adjusting throttle grip free play, the engine idling speed should be adjusted.

1.Check:

  • Throttle grip free play “a”

    Out of specification → Regulate.

  • Throttle grip free play

    3.0–6.0 mm (0.12–0.24 in)

2.Adjust:

  • Throttle grip free play

a.Loosen the locknut “1”.

b.Turn the adjuster “2” until the specified throttle grip free play is obtained.

c.Tighten the locknut.

After adjusting the throttle grip free play, start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change.

CHECKING THE SPARK PLUG

1.Remove:

Do not use too much force to pull the hose.

Remove the fuel tank, turn this 180° clockwise, and put it in the frame “2” as shown.

2.Remove:

  • Spark plug cap

  • Spark plug

    Refer to CAMSHAFT.

In order not to allow the dirt accumulated around the spark plug to drop from the spark plug hole into the cylinder, clean it before removing the spark plug.

3.Check:

  • Spark plug type

    Wrong type → Replace.

  • Manufacturer/model

    NGK/LMAR8G

4.Check:

  • Electrode

    Damage/wear → Replace the spark plug.

  • Insulator

    Abnormal color → Replace the spark plug.

    Normal color is medium-to-light tan.

5.Clean:

  • Spark plug

    (with a spark plug cleaner or a wire brush)

6.Measure:

  • Spark plug gap “a”

    Out of specification → Adjust the spark plug gap.

  • Spark plug gap

    0.7–0.8 mm (0.028–0.031 in)

7.Install:

  • Spark plug

  • Spark plug

    13 N·m (1.3 kgf·m, 9.6 lb·ft)

Before installing the spark plug, clean the spark plug and gasket surface.

8.Install:

  • Spark plug cap

  • Fuel tank

  • Shroud (left/right)

  • Side cover (left/right)

  • Seat

    Refer to GENERAL CHASSIS.

CHECKING THE ENGINE OIL LEVEL

1.Start the engine and warm it up for ten minutes until the engine oil has reached a normal temperature of 60 °C (140 °F), and then turn the engine off.

2.Stand the vehicle upright on a level surface.

3.Start the engine, wait for ten seconds, turn the engine off, and then wait a few minutes.

4.Check:

  • Engine oil level

    The engine oil level should be between the minimum level (lower edge of the oil check window “1”) and the maximum level mark “a”.

    Below the minimum level → Add the recommended engine oil to the proper level.

Before checking the engine oil level, wait a few minutes until the oil has settled.

  • 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

  • Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of “CD” or higher and do not use oils labeled “ENERGY CONSERVING II”.

  • Do not allow foreign materials to enter the crankcase.

5.Start the engine, warm it up for several minutes, and then turn it off.

6.Check the engine oil level again.

Before checking the engine oil level, wait a few minutes until the oil has settled.

CHANGING THE ENGINE OIL

1.Stand the vehicle upright on a level surface.

2.Start the engine, warm it up for several minutes, and then turn it off.

3.Place a container under the engine oil drain bolts.

4.Remove:

  • Oil filler cap

    (along with the O-ring)

5.Remove:

  • Engine oil drain bolt (crankcase) “1”

    (along with the gasket “2”)

  • Engine oil drain bolt (oil tank) “3”

    (along with the gasket “4”)

6.Drain:

  • Engine oil

    (completely from the oil tank and crankcase)

7.If the oil filter element is also to be replaced, perform the following procedure.

a.Remove the oil filter element cover “1”, oil filter element “2”.

b.Replace the new O-ring “3”.

c.Install the new oil filter element and the oil filter element cover.

  • Oil filter element cover bolt

    10 N·m (1.0 kgf·m, 7.4 lb·ft)

8.Install:

  • Engine oil drain bolt (oil tank)

    (along with the gasket )

  • Engine oil drain bolt (crankcase)

    (along with the gasket )

  • Engine oil drain bolt (oil tank)

    10 N·m (1.0 kgf·m, 7.4 lb·ft)

  • Engine oil drain bolt (crankcase)

    20 N·m (2.0 kgf·m, 15 lb·ft)

9.Fill:

  • Crankcase

    (with the specified amount of the recommended engine oil)

Engine oil quantity

  • Oil change

    0.94 L (0.99 US qt, 0.83 Imp.qt)

  • With oil filter removal

    0.96 L (1.01 US qt, 0.84 Imp.qt)

  • Quantity (disassembled)

    1.20 L (1.27 US qt, 1.06 Imp.qt)

10.Install:

  • Engine oil filler cap

    (along with the O-ring )

11.Check:

12.Check:

  • Engine oil pressure

a.Start the engine.

Always keep the engine idling speed during the checkup without increasing the engine speed.

b.Look at the oil level check window “1”, and then make sure that the engine oil flows and that the engine oil level decreases.

Check the engine oil level while the engine is at idling speed.

a.

Maximum level mark

If the engine oil level does not decrease after the engine has been started, immediately turn the engine off. Otherwise, the engine could seize.

c.If the engine oil level does not decrease at the specified level mark, check the engine oil system for leaks, and the engine oil passages and oil pump for damage.

d.Check the oil pressure again.

ADJUSTING THE CLUTCH LEVER FREE PLAY

1.Check:

  • Clutch lever free play “a”

    Out of specification → Regulate.

  • Clutch lever free play

    7.0–12.0 mm (0.28–0.47 in)

2.Adjust:

  • Clutch lever free play

Handlebar side

a.Turn the adjuster “1” until the specified clutch lever free play is obtained.

If the clutch lever free play cannot be obtained on the handlebar side, use the adjuster on the clutch cable side.

Clutch cable side

a.Slide the clutch cable cover.

b.Loosen the locknut “1”.

c.Turn the adjuster “2” until the specified clutch lever free play is obtained.

d.Tighten the locknut “1”.

  • Clutch cable locknut

    4.3 N·m (0.43 kgf·m, 3.2 lb·ft)

e.Return the clutch cable cover to its original position.

ADJUSTING THE CLUTCH LEVER POSITION

1.Adjust:

  • Clutch lever position “a”

Loosen the locknut “1” and use the adjuster “2” to adjust the clutch lever position “a” as desired.

2.Tighten:

  • Locknut

  • Locknut (clutch lever position)

    4.8 N·m (0.48 kgf·m, 3.5 lb·ft)

CLEANING THE AIR FILTER ELEMENT

1.Remove:

To remove the air filter case cover:

  • Raise the air filter case cover rear side while pushing the side “a” of the air intake duct from inside to unhook the ribs “b” on both sides of the air filter case cover from the air filter case “2”.

  • Slide the air filter case cover to the rear of the vehicle to remove the projection “c” from the hole “d” in the air filter case.

2.Remove:

  • Air filter element guide “1”

  • Air filter element “2”

    (from the air filter element guide)

  • Seal “3”

    (from the air filter element)

To remove the air filter element:

  • Release the band “a” from the projection “b”, and then move the air filter case assembly bracket “4” in the direction of the arrow to release the projection “c”.

  • Remove the air filter element and the air filter element guide as a set.

3.Wash:

  • Air filter element

a.After washing the element with air filter cleaner or kerosene, squeeze and dry it completely.

Do not use gasoline or organic (acid/alkaline) volatile oil for washing.

Do not twist the element when squeezing the element.

4.Check:

  • Air filter element

    Damage → Replace.

5.Apply:

  • Yamaha foam air filter oil or other quality foam air filter oil

a.Put the air filter element into a plastic bag and drip the filter oil into the bag.

b.With the element inside the bag, rub it thoroughly so that the element is evenly permeated with the oil.

c.Wrap the element in a clean cloth, rub the element gently, and wipe off any excess oil.

  • The element should be permeated with oil so that it is wet but not dripping.

  • When replacing the element, permeate the element in oil by using the same procedure as when cleaning.

6.Install:

  • Air filter case assembly bracket

    (if removed)

    Refer to THROTTLE BODY.

  • Seal “1”

    (to the air filter element)

  • Air filter element “2”

    (to the air filter element guide)

  • Air filter element guide “3”

  • Apply lithium-soap-based grease on the entire seal lips when installing the air filter element guide.

  • To install the air filter element:

    • Move the air filter case assembly bracket “4” to the rear of the vehicle.

    • Set the projection “a” on the air filter element guide to the air filter case assembly bracket and insert the projection “b” on the air filter element guide to the band “c”.

7.Install:

  • Air filter case cover “1”

  • Fuel tank breather hose “2”

    (to the air filter case cover)

  • To install the air filter case cover:

    • Insert the projection “a” on air filter case cover to the hole “b” in the air filter case “3”.

    • Push the rear side of the air filter case cover to hook the ribs “c” to the air filter case.

  • Insert the fuel tank breather hose end with the protector into the steering shaft hole.

  • Fit the other end of the fuel tank breather hose into the projection on the fuel tank cap.

  • Route the fuel tank breather hose through the guide “d”, and then fit it into the groove “e” in the air filter case cover.

8.Install:

  • Sub-seat

CHECKING THE THROTTLE BODY JOINT

1.Check:

  • Throttle body joint “1”

    Crack/damage → Replace.

CHECKING THE FUEL LINE

1.Remove:

2.Check:

  • Fuel hose “1”

    Crack/damage → Replace.

    Loose connection → Connect properly.

3.Install:

CHECKING THE CYLINDER HEAD BREATHER HOSE

1.Check:

  • Breather hose “1”

    Crack/damage → Replace.

    Loose connection → Connect properly.

Make sure the cylinder head breather hose is routed correctly.

CHECKING THE EXHAUST SYSTEM

1.Remove:

2.Remove:

  • Exhaust pipe protector

3.Check:

  • Exhaust pipe 1

  • Exhaust pipe 2

  • Silencer

    Crack/damage → Replace.

4.Check:

  • Silencer fiber

    Damage → Replace.

5.Replace:

  • Silencer fiber

a.Remove the bolts “1” and silencer body “2”.

Do not hit the silencer stay “a” as it may do damage to the silencer.

Remove the inner pipe while holding the silencer in place with a vise etc.

b.Remove the rivets “3” and silencer cap “4”.

c.Replace the fiber inserts “5”.

d.Install the fiber insert “6” to the part “b”.

e.Twist the fiber insert “7” onto the inner pipe “c”.

f.Install the silencer body “8” and bolts “9”.

  • Silencer body bolt

    8 N·m (0.8 kgf·m, 5.9 lb·ft)

    LOCTITE®

Apply heat-resistant sealant to the areas “d” shown, making sure that there are no gaps in the beads of sealant.

g.Install the fiber “10”.

Stuff the fiber into the silencer body by using a flat board “11”.

h.Install the fiber insert “12” to the inner pipe.

i.Install the fiber insert “13” to the inside of the silencer cap “14”.

j.Install the silencer cap “15” and rivet “16”.

  • Apply heat-resistant sealant to the areas “e” shown, making sure that there are no gaps in the beads of sealant.

  • Take care not to allow the fiber out of place when installing the silencer body “17”.

6.Check:

  • Gasket “1”

    Damage → Replace.

7.Check:

  • Tightening torques

  • Exhaust pipe nut “1”

    10 N·m (1.0 kgf·m, 7.4 lb·ft)

  • Exhaust pipe clamp bolt “2”

    12 N·m (1.2 kgf·m, 8.9 lb·ft)

  • Exhaust pipe bracket bolt “3”

    20 N·m (2.0 kgf·m, 15 lb·ft)

  • Exhaust pipe clamp bolt “4”

    12 N·m (1.2 kgf·m, 8.9 lb·ft)

  • Silencer bolt “5”

    30 N·m (3.0 kgf·m, 22 lb·ft)

8.Install:

  • Exhaust pipe protector

  • Exhaust pipe protector screw

    10 N·m (1.0 kgf·m, 7.4 lb·ft)

    LOCTITE®

CHECKING THE COOLANT LEVEL

A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows:

Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the radiator cap and turn it counterclockwise to remove.

1.Stand the vehicle upright on a level surface.

2.Remove:

  • Radiator cap “1”

3.Check:

  • Coolant level

    Maximum level “a” or below → Add coolant up to the maximum level.

    1.

    Radiator

  • Adding water instead of coolant lowers the antifreeze content. If, therefore, water is used instead of coolant, check, and if necessary, adjust the antifreeze concentration.

  • Use only distilled water. However, if distilled water is not available, soft water may be used.

4.Start the engine, warm this up for several minutes, and then stop it.

5.Check:

  • Coolant level

Before checking the coolant level, wait a few minutes until the coolant has settled.

CHECKING THE COOLING SYSTEM

1.Remove:

  • Seat

  • Side cover (left/right)

  • Shroud (left/right)

    Refer to GENERAL CHASSIS.

2.Check:

  • Radiator

  • Radiator hose

    Crack/damage → Replace.

    Refer to RADIATOR.

3.Install:

  • Shroud (left/right)

  • Side cover (left/right)

  • Seat

    Refer to GENERAL CHASSIS.

CHANGING THE COOLANT

A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows:

Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the radiator cap and turn it counterclockwise to remove.

1.Place a container under the engine.

2.Remove:

  • Coolant drain bolt “1”

  • Copper washer

3.Remove:

  • Radiator cap

    Slowly loosen the radiator cap to drain coolant.

    When the radiator cap is loosened, coolant will gush out transversely; therefore, bring the container near to the outlet.

4.Thoroughly flush the cooling system with clean tap water.

5.Install:

  • Copper washer

  • Coolant drain bolt

  • Coolant drain bolt

    10 N·m (1.0 kgf·m, 7.4 lb·ft)

6.Pour coolant.

  • Recommended coolant

    High quality ethylene glycol anti-freeze containing anti-corrosion for aluminum engine

  • Radiator (including all routes)

    1.03 L (1.09 US qt, 0.91 Imp.qt)

  • Coolant mixing ratio

    1:1 (Coolant:Water)

  • If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor.

  • 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.

  • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if necessary, correct the antifreeze concentration of the coolant.

  • Use only distilled water. However, if distilled water is not available, soft water may be used.

  • If coolant comes into contact with painted surfaces, immediately wash them with water.

  • Do not mix different types of antifreeze.

7.Install:

  • Radiator cap

8.Start the engine, warm this up for several minutes, stop it, and then wait for it to cool down.

9.Check: