Yamaha NMAX GPD155 A (2022)

Manual Yamaha NMAX Gpd155 A 2022 ini merangkum panduan penggunaan dan perawatan utama kendaraan. Pembahasan utama mencakup Perawatan Berkala, Mengatasi Masalah, Keamanan Berkendara, Petunjuk Pengoperasian, Spesifikasi

Yamaha NMAX GPD155 A 2022 Service Manual

Unduh gratis Service Manual Yamaha NMAX GPD155 A dalam format PDF. Panduan servis, spesifikasi, dan prosedur perawatan.

Download Service Manual Yamaha NMAX GPD155 A | BukuManual Indonesia

# YAMAHA 2022

## SERVICE MANUAL

### NMAX

GPD155-A
BBD-F8197-EK

Page 1

Page 2

EAS20003
IMPORTANT
This manual was produced by the PT Yamaha Indonesia Motor Manufacturing. primarily for use by Ya-
maha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechan-
ic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on 
Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these 
types of vehicles. Please refer to “BASIC INFORMATION” (separate volume, Y0A-28197-E0*) for basic 
instructions that must be observed during servicing. Repair and maintenance work attempted by any-
one without this knowledge is likely to render the vehicle unsafe and unfit for use.
PT Yamaha Indonesia Motor Manufacturing. is continually striving to improve all of its models. Modifi-
cations and significant changes in specifications or procedures will be forwarded to all authorized Ya-
maha dealers and will appear in future editions of this manual where applicable.
TIP

 
• * If the contents of the manual are revised, the last digit of the manual number will be increased by 
one.
• Designs and specifications are subject to change without notice.

 

EAS30001
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 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 
result in death or serious injury.

WARNING

A NOTICE indicates special precautions that must be taken to avoid 
damage to the vehicle or other property.

NOTICE

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

TIP

GPD155-A
SERVICE MANUAL
©2022 by PT Yamaha Indonesia Motor 
Manufacturing
First edition, November 2021
All rights reserved.
Any reproduction or unauthorized use 
without the written permission of 
PT Yamaha Indonesia Motor Manufacturing 
is expressly prohibited.

Page 3

EAS20004
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.
• 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. 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.

CYLINDER AND PISTON

EAS20046
CYLINDER AND PISTON

Removing the cylinder and piston

Order
Q’ty

Job/Parts to remove
Remarks

Cylinder head

Refer to “CYLINDER HEAD” on page 5-10.

1

Timing chain guide (exhaust side)

1

2
1

Cylinder

3

Cylinder gasket

1

4

Dowel pin

2

5

Piston pin clip

2

6

Piston pin

1

7

Piston

1

8

Top ring

1

9

1
2nd ring

10
1

Oil ring

11

1
Coolant drain bolt (cylinder side)

5-30

CYLINDER AND PISTON

EAS30289
REMOVING THE PISTON

1. Remove:
• Piston pin clips “1”
• Piston pin “2”
• Piston “3”

ECA13810

NOTICE

Do not use a hammer to drive the piston pin 
out.

TIP

EAS30291
CHECKING THE CYLINDER AND PISTON

 
• Before removing the piston pin clips, cover the
crankcase opening with a clean rag to prevent
them from falling into the crankcase.
• Before removing the piston pin, deburr the pis-
ton pin clip groove and the piston pin bore ar-
ea. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller set “4”.

1. Check:
• Piston wall
• Cylinder wall
Vertical scratches → Rebore or replace the
cylinder, and replace the piston and piston
rings as a set.

2. Measure:
• Piston-to-cylinder clearance

a. Measure cylinder bore “C” with the cylinder
bore gauge.

Piston pin puller set

90890-01304

TIP

 
Measure cylinder bore “C” by taking side-to-side 
and front-to-back measurements of the cylinder.

Bore
52.000–52.010 mm (2.0472–
2.0476 in)
Wear limit

52.060 mm (2.0496 in)

“C” = maximum of D1 - D2

2. Remove:
• Top ring
• 2nd ring
• Oil ring

b. If out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
c. Measure piston skirt diameter P with the mi-

TIP

 
When removing a piston ring, open the end gap 
with your fingers and lift the other side of the ring 
over the piston crown.

crometer.

5-31

Page 4

EAS20005
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

Serviceable with engine mounted
Gear oil

Filling fluid
Molybdenum disulfide oil

Lubricant
Brake fluid

Special tool
Wheel bearing grease

Tightening torque
Lithium-soap-based grease

T R
.

.

Wear limit, clearance
Molybdenum disulfide grease

Engine speed
Silicone grease

Electrical data
Apply locking agent (LOCTITE®).

E
New

Engine oil
Replace the part with a new one.

G

M

BF

B

LS

M

S

LT

Page 5

Page 6

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND
ADJUSTMENTS

CHASSIS

ENGINE

COOLING SYSTEM

FUEL SYSTEM

ELECTRICAL SYSTEM

SELF DIAGNOSTIC

1

2

3

4

5

6

7

8

9

Page 7

Page 8

# GENERAL INFORMATION

## IDENTIFICATION
*   VEHICLE IDENTIFICATION NUMBER ................................................................ 1-1
*   ENGINE SERIAL NUMBER ............................................................................ 1-1

## FEATURES
*   MULTI-FUNCTION METER UNIT .................................................................... 1-2

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

1

Page 9

EAS20007
IDENTIFICATION

EAS30002
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped 
onto the frame.

1

EAS30004
ENGINE SERIAL NUMBER
The engine serial number “1” is stamped onto 
the crankcase.

1

1-1

IDENTIFICATION

Page 10

EAS20008
FEATURES

EAS30982
MULTI-FUNCTION METER UNIT

Multi-function meter unit

1
3
4
5
7
6
2

8

1.
Fuel meter
2.
Yamaha Motorcycle Connect icon
3.
VVA (variable valve actuation) indicator
4.
Clock
5.
Speedometer
6.
Smartphone battery level meter
7.
Coolant temperature meter 
8.
Multi-function display

EWA12423

WARNING

Be sure to stop the vehicle before making 
any setting changes to the multi-function 
meter unit. Changing settings while riding 
can distract the operator and increase the 
risk of an accident.

 The “MENU” switch is located on the left side of 
handlebar. This switch allows you to control or 
change the settings of multi-function meter unit.

1

1.
“MENU” switch

1-2

FEATURES

The multi-function meter unit is equipped with 
the following:
• a speedometer
• a VVA indicator
• a clock
• a fuel meter
• a Yamaha Motorcycle Connect icon
• a smartphone battery level meter
• a coolant temperature meter
• a multi-function display
TIP

 
Be sure to turn the main switch on before using 
the “MENU” switch.

 

Yamaha Motorcycle Connect icon
This icon comes on when CCU and smartphone 
is connected via Yamaha Motorcycle Connect.

TIP

 
Even if the smartphone is not connected, when 
the vehicle is turned on, this icon should come 
on for a few seconds. Otherwise have a Yamaha 
dealer check the CCU and the electrical circuit.

 

Smartphone battery level meter
This meter indicates the current battery level of 
the connected smartphone. The display seg-
ment of the meter disappears from full to blank 
as the battery level decreases. When approxi-
mately 10% or less of the battery remains, the 
last segment starts flashing.
TIP

 
Even if the smartphone is not connected, when 
the vehicle is turned on, this icon should come 
on for a few seconds. Otherwise have a Yamaha 
dealer check the CCU and the electrical circuit.

 

Switching the display units
The display units can be switched between kilo-
meters and miles.

To switch the display units
1. Turn the vehicle off.
2. While pushing the “MENU” switch, turn the 
vehicle on.
3. Continue to push the “MENU” switch until the 
display unit setting screen comes on (approx-
imately 5 seconds).
4. Push the “MENU” switch once to switch the 
display units.
5. Push the “MENU” switch for 1 second to con-
firm the setting.

Page 11

Speedometer
The speedometer shows the vehicle’s traveling 
speed.

Fuel meter

1
2

1.
Fuel meter

The fuel meter indicates the amount of fuel in the 
fuel tank. The display segments of the fuel meter 
disappear from “F” (full) towards “E” (empty) as 
the fuel level decreases. When approximately 
1.7 L (0.45 US gal, 0.37 Imp.gal) of fuel remains, 
the last segment starts flashing. Refuel as soon 
as possible.
TIP

 
If a problem is detected in the electrical circuit, 
the fuel level segments will flash repeatedly. If 
this occurs, have a Yamaha dealer check the ve-
hicle.

 

Clock

1

1.
Clock

The clock uses a 12-hour time system.

To set the clock
1. Push the “MENU” switch until the hour digits 
start flashing.
2. Use the “MENU” switch to set the hours.
3. Push the “MENU” switch until the minute dig-
its start flashing.
4. Use the “MENU” switch to set the minutes.
5. Push the “MENU” switch until the minute dig-
its stop flashing. The setting is confirmed.

1-3

FEATURES

TIP

 
When CCU and smartphone is connected after 
vehicle power on, the clock is automatically ad-
justed.

 

Coolant temperature meter

1

1.
Coolant temperature meter

This meter shows the temperature of the cool-
ant, and thereby the condition of the engine. The 
segments come on from “C” (cold) to “H” (hot) as 
the engine temperature increases. If the hot seg-
ment flashes, stop the engine as soon as possi-
ble, and let the engine cool.
TIP

 
If a problem is detected in the electrical circuit, all 
segments will flash repeatedly. Have a Yamaha 
dealer check the vehicle.

 

VVA indicator

1

1.
VVA (variable valve actuation) indicator

This model is equipped with variable valve actu-
ation (VVA) for good fuel economy and acceler-
ation in both the low-speed and high-speed 
ranges. The VVA indicator comes on when the 
variable valve actuation system has switched to 
the high-speed range.

Page 12

To turn the VVA indicator on or off
1. Turn the vehicle off.
2. While pushing the “MENU” switch, turn the 
vehicle on.
3. Continue pushing the “MENU” switch. The 
display unit setting screen will come on (after 
5 seconds), and after that (an additional 10 
seconds) all segments other than the VVA in-
dicator will start flashing. Now release the 
“MENU” switch.
4. Push the “MENU” switch once to change the 
on or off setting.
5. Push the “MENU” switch for 1 second to con-
firm the setting.
TIP

 
Turning the VVA indicator off does not turn off 
the variable valve actuation system.

 

Multi-function display

1

1.
Multi-function display

The multi-function display is equipped with the 
following:
• an odometer (ODO)
• two tripmeters (TRIP 1 and TRIP 2)
• a fuel reserve tripmeter (TRIP F)
• an oil change tripmeter (OIL TRIP)
• an oil change indicator
• a V-belt replacement tripmeter (V-BELT TRIP)
• a V-belt replacement indicator
• an instantaneous fuel consumption display 
(F/ECO)
• an average fuel consumption display 
(AVE F/ECO)
• a battery voltage display (BATT)
• a traction control system display (TCS)
Push the “MENU” switch to change the display 
in the following order:

ODO and F/ECO → TRIP 1 and AVE F/ECO → 
TRIP 2 and AVE F/ECO → TRIP F → BATT → 
TCS → OIL TRIP → V-BELT TRIP → ODO and 
F/ECO

1-4

FEATURES

TIP

 
• The fuel reserve tripmeter appears only when 
you are low on fuel.
• The oil change tripmeter and V-belt replace-
ment tripmeter are not displayed while the ve-
hicle is moving.
• There is an average fuel consumption display 
for each tripmeter (TRIP 1 and TRIP 2). When 
a tripmeter is reset, the average fuel consump-
tion display for that tripmeter will also be reset.

 

Odometer

1

1.
Odometer

The odometer shows the total distance traveled 
by the vehicle.
TIP

 
The odometer will lock at 999999 and cannot be 
reset.

 

Tripmeters

1

1.
Tripmeter

The tripmeters show the distance traveled since 
they were last reset.
To reset a tripmeter, set the display to the trip-
meter you want to reset, and then push the 
“MENU” switch until it is reset.

TIP

 
The tripmeters will reset and continue counting 
after 9999.9 is reached.

Page 13

Fuel reserve tripmeter

1

1.
Fuel reserve tripmeter

If the last segment of the fuel meter starts flash-
ing, the display automatically changes to the fuel 
reserve tripmeter “TRIP F” and starts counting 
the distance traveled from that point.
To reset the fuel reserve tripmeter, push the 
“MENU” switch until it is reset.
TIP

 
If you do not reset the fuel reserve tripmeter 
manually, it will reset automatically and disap-
pear from the display after refueling and travel-
ing 5 km (3 mi).

 

Oil change tripmeter

1

2

1.
Oil change indicator “OIL”
2.
Oil change tripmeter

This tripmeter shows the distance traveled since 
the last engine oil change. The oil change indi-
cator “OIL” will flash at the initial 1000 km (600 
mi), the next 5000 km (3100 mi), and then every 
6000 km (3700 mi) thereafter.
To reset the oil change tripmeter and oil change 
indicator, select the oil change tripmeter, and 
then push the “MENU” switch until “OIL” and the 
tripmeter start flashing. While “OIL” and the trip-
meter are flashing, push the “MENU” switch until 
the tripmeter is reset.

1-5

FEATURES

TIP

 
When the engine oil has been changed, the oil 
change tripmeter and the oil change indicator 
must be reset. Otherwise, the oil change indica-
tor will not come on at the correct time.

 

V-belt replacement tripmeter

1

2

1.
V-belt replacement indicator “V-BELT”
2.
V-belt replacement tripmeter

This tripmeter shows the distance traveled since 
the V-belt was last replaced. The V-belt replace-
ment indicator “V-BELT” will flash every 18000 
km (11200 mi) to indicate that the V-belt should 
be replaced.
To reset both the tripmeter and the indicator, se-
lect the V-belt replacement tripmeter, and then 
push the “MENU” switch until “V-BELT” and the 
tripmeter start flashing. While “V-BELT” and the 
tripmeter are flashing, push the “MENU” switch 
until the tripmeter is reset.
TIP

 
When the V-belt is replaced, the tripmeter and 
indicator must be reset. Otherwise, the V-belt re-
placement indicator will not come on at the cor-
rect time.

Page 14

Instantaneous fuel consumption display

1

1.
Instantaneous fuel consumption display

This display shows fuel consumption under cur-
rent riding conditions. It can be set to either “km/
L” or “L/100 km”, or “MPG” when using miles.
• “km/L”: the distance that can be traveled on 1.0 
L of fuel.
• “L/100 km”: the amount of fuel necessary to 
travel 100 km.
• “MPG”: the distance that can be traveled on 
1.0 Imp.gal of fuel.
TIP

 
When traveling under 10 km/h (6 mi/h), “_ _._” is 
displayed.

 

1-6

FEATURES

Average fuel consumption display

1

1.
Average fuel consumption display

This display shows the average fuel consump-
tion since it was last reset. The average fuel con-
sumption display can be set to either “km/L” or 
“L/100 km”, or “MPG” when using miles.
• “km/L”: the average distance that can be trav-
eled on 1.0 L of fuel.
• “L/100 km”: the average amount of fuel neces-
sary to travel 100 km.
• “MPG”: the average distance that can be trav-
eled on 1.0 Imp.gal of fuel.
TIP

 
• To reset the display, push the “MENU” switch 
until it resets.
• After resetting, “_ _._” is shown until the vehicle 
has traveled some distance.

 

Battery voltage display

1

1.
Battery voltage meter

This display shows the current charge state of 
the battery.
• Over 12.8 V = Full charge.
• Under 12.7 V = Charging is required.
TIP

 
If the battery voltage is less than 9.0 V, “_ _._” is 
displayed.

Page 15

EAS20012
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 numbers starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part numbers starting with “90890-”.

 

Tool name/Tool No.
Illustration
Reference
pages

Yamaha diagnostic tool USB
90890-03267
3-4, 3-7, 4-63, 
4-64, 7-15, 
7-16, 9-3, 9-20, 
9-21

Yamaha diagnostic tool (A/I)
90890-03264
3-4, 3-7, 4-63, 
4-64, 7-15, 
7-16, 9-3, 9-20, 
9-21

Tappet adjusting tool
90890-01311
Six piece tappet set
YM-A5970

YM-A5970

Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472

Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9

T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326

1-7

SPECIAL TOOLS

3-7

ø9
ø8
ø10

ø3
ø4

3-16, 3-17, 4-83

4-28

4-77, 4-78

Page 16

SPECIAL TOOLS

| Tool name/Tool No. | Illustration | Reference pages |
| :----------------------------------------------------------- | :----------- | :-------------- |
| Fork seal driver weight 90890-01367 Replacement hammer YM-A9409-7 | | 4-78, 4-79 |
| Fork seal driver attachment (ø30) 90890-01400 | | 4-78, 4-79 |
| Compression gauge 90890-03081 Engine compression tester YU-33223 | | 5-2 |
| Compression gauge extension 122mm 90890-04136 Compression gauge extension 122mm YM-04136 | | 5-2 |
| Camshaft wrench 90890-04162 Camshaft wrench YM-04162 | | 5-14, 5-18 |
| Yamaha bond No. 1215 90890-85505 Three bond No. 1215® | | 5-17, 5-59 |
| Slide hammer bolt (M8) 90890-01085 Slide hammer bolt 8 mm YU-01083-2 | | 5-21 |

1-8

Page 17

## SPECIAL TOOLS

| Tool name/Tool No.                     | Illustration | Reference pages |
| :--------------------------------------- | :----------- | :-------------- |
| Weight                                   |              | 5-21            |
| 90890-01084                              |              |                 |
| Weight                                   |              |                 |
| YU-01083-3                               |              |                 |
| Valve spring compressor                  |              | 5-25, 5-30      |
| 90890-04019                              |              |                 |
| Valve spring compressor                  |              |                 |
| YM-04019                                 |              |                 |
| Valve spring compressor attachment       |              | 5-25, 5-30      |
| 90890-04108                              |              |                 |
| Valve spring compressor adapter 22 mm    |              |                 |
| YM-04108                                 |              |                 |
| Valve guide remover (ø5)                 |              | 5-27            |
| 90890-04097                              |              |                 |
| Valve guide remover (5.0 mm)             |              |                 |
| YM-04097                                 |              |                 |
| Valve guide installer (ø5)               |              | 5-27            |
| 90890-04098                              |              |                 |
| Valve guide installer (5.0 mm)           |              |                 |
| YM-04098                                 |              |                 |
| Valve guide reamer (ø5)                  |              | 5-27            |
| 90890-04099                              |              |                 |
| Valve guide reamer (5.0 mm)              |              |                 |
| YM-04099                                 |              |                 |
| Piston pin puller set                    |              | 5-32            |
| 90890-01304                              |              |                 |
| Piston pin puller                        |              |                 |
| YU-01304                                 |              |                 |

1-9

Page 18

Tool name/Tool No.
Illustration
Reference
pages

Rotor holding tool (including handle and 
3 pins)
90890-04195

Rotor holding tool attachment 7 x 12 mm
90890-04197
5-40, 5-46

Rotor holding tool
90890-04166
Rotor holding tool
YM-04166

Socket wrench (39 mm)
90890-01493
5-40, 5-44

Sheave spring compressor
90890-04134
Sheave spring compressor
YM-04134

Sheave fixed block
90890-04135
Sheave fixed bracket
YM-04135

Oil seal guide (37 mm)
90890-04177
5-43

1-10

SPECIAL TOOLS

5-40, 5-46, 
5-48, 5-48

ø7
12

5-40, 5-40, 
5-44, 5-45

5-41, 5-44

5-41, 5-44

ø37

Page 19

## SPECIAL TOOLS

| Tool name/Tool No.                     | Illustration | Reference pages |
| :------------------------------------- | :----------- | :-------------- |
| Rotor holding tool attachment 7 x 5 mm 90890-04198 |              | 5-48, 5-48      |
| Flywheel puller 90890-01189 Flywheel puller YM-01189 |              | 5-48            |
| Crankcase separating tool 90890-01135 Crankcase separator YU-01135-B |              | 5-57            |
| Crankshaft installer pot 90890-01274 Installing pot YU-90058 |              | 5-59            |
| Crankshaft installer bolt 90890-01275 Bolt YU-90060 |              | 5-59            |
| Adapter (M12) 90890-01278 Adapter #3 YU-90063 |              | 5-59            |

1-11

Page 20

# SPECIAL TOOLS

| Tool name/Tool No.                                   | Illustration                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          | Reference pages |
| :--------------------------------------------------- | :-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- | :-------------- |
| Spacer (crankshaft installer)                        | 90890-04081                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                           | 5-59            |
| 90890-04081                                          | YM-91044                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          |                 |
| Pot spacer                                           |                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     |                 |
| YM-91044                                             |                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     |                 |
| Radiator cap tester                                  | 90890-01325                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                           | 6-4, 6-4        |
| 90890-01325                                          | YU-24460-A                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          |                 |
| Mityvac cooling system tester kit                    |                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     |                 |
| YU-24460-A                                           |                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     |                 |
| Radiator cap tester adapter 31mm                     |                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     | 6-4             |
| 90890-05375                                          |                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     |                 |
| Radiator cap tester adapter 31mm                     |                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     |                 |
| YM-05375                                             |                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     |                 |
| Mechanical seal installer                            |                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     | 6-10            |
| 90890-04145                                          |                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     |                 |
| Middle driven shaft bearing driver                   |                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     | 6-10            |
| 90890-04058                                          |                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     |                 |
| Middle drive bearing installer 40 & 50 mm            |                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     |                 |
| YM-04058                                             |                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     |                 |
| Pressure gauge                                       |                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     | 7-5             |
| 90890-03153                                          |                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     |                 |
| Pressure gauge                                       |                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     |                 |
| YU-03153                                             |                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     |                 |
| Fuel pressure adapter 6.3mm                          |                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     | 7-5             |
| 90890-03227                                          |                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     |                 |

1-12

Page 21

Tool name/Tool No.
Illustration
Reference
pages

Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with tachometer
YU-A1927

Ignition checker
90890-06754
Oppama pet–4000 spark checker
YM-34487

1-13

SPECIAL TOOLS

8-36, 8-38, 
8-39, 8-39, 
8-39, 8-40, 
8-41, 8-41, 
8-42, 8-42, 
8-43, 8-43

8-40

Page 22

## SPECIFICATIONS

GENERAL SPECIFICATIONS ............................................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................................... 2-2
CHASSIS SPECIFICATIONS .............................................................................................. 2-6
ELECTRICAL SPECIFICATIONS .......................................................................................... 2-8
TIGHTENING TORQUES .................................................................................................... 2-10
  ENGINE TIGHTENING TORQUES ................................................................................ 2-10
  CHASSIS TIGHTENING TORQUES ............................................................................. 2-12
CABLE ROUTING .............................................................................................................. 2-15

Page 23

GENERAL SPECIFICATIONS

EAS20013
**GENERAL SPECIFICATIONS**

**Model**
Model                                                                            BBDC

**Dimensions**
Overall length                                                                   1935 mm (76.2 in)
Overall width                                                                    740 mm (29.1 in)
Overall height                                                                   1160 mm (45.7 in)
Wheelbase                                                                        1340 mm (52.8 in)
Ground clearance                                                                 125 mm (4.92 in)
Minimum turning radius                                                           2.0 m (6.56 ft)

**Weight**
Curb weight                                                                      131 kg (289 lb)

**Loading**
Maximum load                                                                     167 kg (368 lb)
Riding capacity                                                                  2 person

2-1

Page 24

EAS20014
ENGINE SPECIFICATIONS

Engine
Combustion cycle
4-stroke
Cooling system
Liquid cooled
Valve train
SOHC
Displacement
155 cm³
Number of cylinders
Single cylinder
Bore × stroke
58.0 × 58.7 mm (2.28 × 2.31 in)
Number of cylinders
Single cylinder
Compression ratio
11.6 : 1
Compression pressure
1783–2296 kPa/1050 r/min (17.8–23.0 kgf/cm²/
1050 r/min, 253.7–326.6 psi/1050 r/min)

Fuel
Recommended fuel
Regular unleaded gasoline (E10 acceptable)
Fuel tank capacity
7.1 L (1.9 US gal, 1.6 Imp.gal)
Fuel reserve amount
1.7 L (0.45 US gal, 0.37 Imp.gal)

Engine oil
Lubrication system
Wet sump
Recommended brand
YAMALUBE
SAE viscosity grades
10W-40
Recommended engine oil grade
API service SG type or higher, JASO standard 
MA or MB
Engine oil quantity
Quantity (disassembled)
1.00 L (1.06 US qt, 0.88 Imp.qt)
Oil change
0.90 L (0.95 US qt, 0.79 Imp.qt)

Final transmission oil
Type
Motor oil SAE 10W-40 type SG or higher
Quantity (disassembled)
0.11 L (0.12 US qt, 0.10 Imp.qt)
Quantity
0.10 L (0.11 US qt, 0.09 Imp.qt)

Oil filter
Oil filter type
Centrifugal

Cooling system
Coolant quantity
Radiator (including all routes)
0.46 L (0.49 US qt, 0.40 Imp.qt)
Coolant reservoir (up to the maximum level 
mark)
0.13 L (0.14 US qt, 0.11 Imp.qt)
Radiator cap valve opening pressure
108.0–137.4 kPa (1.08–1.37 kgf/cm², 15.7–19.9 
psi)
Cooling system leak test pressure
137.4 kPa (1.37 kgf/cm², 19.9 psi)

Thermostat
Valve opening temperature
74.0–78.0 °C (165.20–172.40 °F)
Valve full open temperature
90.0 °C (194.00 °F)

2-2

ENGINE SPECIFICATIONS

Page 25

Spark plug(s)
Manufacturer/model
NGK/CPR8EA-9
Spark plug gap
0.8–0.9 mm (0.031–0.035 in)

Cylinder head
Warpage limit
0.05 mm (0.0020 in)

Camshaft
Camshaft lobe dimensions
Lobe height limit (Intake)
32.111 mm (1.2642 in)
Lobe height limit (Intake high speed)
32.487 mm (1.2790 in)
Lobe height limit (Exhaust)
29.320 mm (1.1543 in)

Rocker arm/rocker arm shaft
Rocker arm inside diameter limit
10.015 mm (0.3943 in)
Rocker arm shaft outside diameter limit
9.935 mm (0.3911 in)

Valve, valve seat, valve guide
Valve clearance (cold)
Intake
0.10–0.14 mm (0.0039–0.0055 in)
Exhaust
0.21–0.25 mm (0.0083–0.0098 in)
Valve dimensions
Valve seat contact width limit (intake)
1.3 mm (0.05 in)
Valve seat contact width limit (exhaust)
1.7 mm (0.07 in)
Valve stem diameter limit (intake)
4.945 mm (0.1947 in)
Valve stem diameter limit (exhaust)
4.930 mm (0.1941 in)
Valve guide inside diameter (intake)
5.000–5.012 mm (0.1969–0.1973 in)
Valve guide inside diameter (exhaust)
5.000–5.012 mm (0.1969–0.1973 in)
Valve-stem-to-valve-guide clearance limit 
(intake)
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance limit 
(exhaust)
0.100 mm (0.0039 in)
Valve stem runout
0.020 mm (0.0008 in)

Valve spring
Free length limit (intake)
32.10 mm (1.26 in)
Free length limit (exhaust)
32.10 mm (1.26 in)

Cylinder
Bore
58.000–58.010 mm (2.2835–2.2839 in)
Wear limit
58.060 mm (2.2858 in)

Piston
Piston-to-cylinder clearance
0.015–0.048 mm (0.0006–0.0019 in)
Diameter
57.962–57.985 mm (2.2820–2.2829 in)
Measuring point (from piston skirt bottom)
6.0 mm (0.24 in)
Piston pin bore inside diameter limit
14.043 mm (0.5529 in)
Piston pin outside diameter limit
13.975 mm (0.5502 in)

2-3

ENGINE SPECIFICATIONS

Page 26

# ENGINE SPECIFICATIONS

---

### Piston ring

*   **Top ring**
    *   End gap limit: 0.50 mm (0.0197 in)
    *   Side clearance limit: 0.115 mm (0.0045 in)
*   **2nd ring**
    *   End gap limit: 0.85 mm (0.0335 in)
    *   Side clearance limit: 0.115 mm (0.0045 in)

---

### Crankshaft

*   Crank assembly width: 51.45–51.50 mm (2.026–2.028 in)
*   Runout limit: 0.030 mm (0.0012 in)

---

### Clutch

*   Clutch type: Dry, centrifugal, shoe

---

### Automatic centrifugal clutch

*   Clutch shoe thickness limit: 2.1 mm (0.08 in)
*   Clutch housing inside diameter limit: 125.5 mm (4.94 in)
*   Compression spring free length limit: 104.7 mm (4.12 in)
*   Weight outside diameter limit: 19.5 mm (0.77 in)
*   Clutch-in revolution: 2200–2600 r/min
*   Clutch-stall revolution: 4700–5300 r/min

---

### V-belt

*   V-belt width limit: 21.6 mm (0.85 in)

---

### Drivetrain

*   Transmission type: V-belt automatic
*   Primary reduction ratio: 1.000
*   Secondary reduction ratio: 10.208 (56/16 x 35/12)
*   Transmission ratio: 2.239–0.706 : 1

---

### Air filter

*   Air filter element: Oil-coated paper element
*   V-belt filter element: Wet element

---

### Fuel injector

*   Resistance: 12.2 Ω

---

### Fuel injection sensor

*   Intake air temperature sensor resistance: 5700–6300 Ω at 0 °C (5700–6300 Ω at 32 °F)
*   Atmospheric pressure sensor output voltage: 3.88–4.12 V at 101.3 kPa (3.88–4.12 V at 1.01 kgf/cm², 3.88–4.12 V at 14.7 psi)
*   Coolant temperature sensor resistance: 2513–2777 Ω at 20 °C (2513–2777 Ω at 68 °F)
*   Coolant temperature sensor resistance: 210–221 Ω at 100 °C (210–221 Ω at 212 °F)

---

2-4

Page 27

ENGINE SPECIFICATIONS
___

**Idling condition**
Engine idling speed
O2 feedback control
Coolant temperature
CO%
Fuel line pressure (at idle)
Throttle grip free play
1500–1700 r/min
Active
85 °C (185 °F)
0.0–1.0 %
220–300 kPa (2.2–3.0 kgf/cm², 31.9–43.5 psi)
3.0–5.0 mm (0.12–0.20 in)

2-5

Page 28

# CHASSIS SPECIFICATIONS

EAS20015
## CHASSIS SPECIFICATIONS

### Chassis
*   Caster angle: 26.5 °
*   Trail: 100 mm (3.9 in)

### Front wheel
*   Wheel type: Cast wheel
*   Rim size: J13M/C x MT3.00
*   Radial wheel runout limit: 1.0 mm (0.04 in)
*   Lateral wheel runout limit: 1.0 mm (0.04 in)
*   Wheel axle bending limit: 0.25 mm (0.01 in)

### Rear wheel
*   Wheel type: Cast wheel
*   Rim size: J13M/C x MT3.50
*   Radial wheel runout limit: 1.0 mm (0.04 in)
*   Lateral wheel runout limit: 1.0 mm (0.04 in)
*   Wheel axle bending limit: 0.25 mm (0.01 in)

### Front tire
*   Type: Tubeless
*   Size: 110/70-13M/C 48P
*   Manufacturer/model: DUNLOP/SCOOT SMART L

### Rear tire
*   Type: Tubeless
*   Size: 130/70-13M/C 63P
*   Manufacturer/model: DUNLOP/SCOOT SMART L

### Tire air pressure (measured on cold tires)
*   **1 person**
    *   Front: 150 kPa (1.50 kgf/cm², 22 psi)
    *   Rear: 250 kPa (2.50 kgf/cm², 36 psi)
*   **2 persons**
    *   Front: 150 kPa (1.50 kgf/cm², 22 psi)
    *   Rear: 250 kPa (2.50 kgf/cm², 36 psi)

### Front brake
*   Brake disc thickness limit: 3.5 mm (0.14 in)
*   Brake disc runout limit (as measured on wheel): 0.15 mm (0.0059 in)
*   Brake pad lining thickness limit: 0.8 mm (0.03 in)
*   Master cylinder inside diameter: 11.00 mm (0.43 in)
*   Caliper cylinder inside diameter (Right): 33.34 mm (1.31 in)
*   Specified brake fluid: DOT 4

2-6

Page 29

Rear brake
Brake disc thickness limit
4.0 mm (0.16 in)
Brake disc runout limit (as measured on 
wheel)
0.15 mm (0.0059 in)
Brake pad lining thickness limit
0.8 mm (0.03 in)
Master cylinder inside diameter
12.7 mm (0.50 in)
Caliper cylinder inside diameter
33.34 mm (1.31 in)
Specified brake fluid
DOT 4

Front suspension
Shock absorber
Hydraulic damper
Fork spring free length limit
235.6 mm (9.28 in)
Inner tube bending limit
0.2 mm (0.01 in)
Recommended oil
Yamaha Suspension Oil G10
Quantity (left)
89.0 cm³ (3.01 US oz, 3.14 Imp.oz)
Quantity (right)
89.0 cm³ (3.01 US oz, 3.14 Imp.oz)
Level (left)
77 mm (3.1 in)
Level (right)
77 mm (3.1 in)

Rear suspension
Shock absorber
Hydraulic damper

Spring preload
Unit for adjustment
Cam position
Adjustment value (STD)
1
Adjustment value (Hard)
2

2-7

CHASSIS SPECIFICATIONS

Page 30

EAS20016
ELECTRICAL SPECIFICATIONS

Voltage
System voltage
12 V

Engine control unit
Model
TBDY88

Ignition system
Ignition timing (B.T.D.C.)
3.0–7.0 °/1600 r/min

Ignition coil
Primary coil resistance
2.16–2.64 Ω
Secondary coil resistance
8.64–12.96 kΩ

Spark plug cap
Resistance
3.75–6.25 kΩ

Charging system
Charging system
Starter generator
Standard output
14.0 V, 50.4 A at 5000 r/min
Stator coil resistance
0.048–0.072 Ω

Rectifier/regulator
Regulated voltage (DC)
14.3–14.7 V

Battery
Model
YTZ7V
Voltage, capacity
12 V, 6.0 Ah (10 HR)

Bulb wattage
Headlight
LED
Brake/tail light
LED
Front turn signal light
10.0 W
Rear turn signal light
10.0 W
Auxiliary light
LED
License plate light
5.0 W
Meter lighting
LED
Turn signal indicator light
LED
High beam indicator light
LED
Stop and Start System indicator light
LED
ABS warning light
LED
Smart key system indicator light
LED
Traction control system indicator light
LED
Engine trouble warning light
LED

Fuel sender unit
Sender unit resistance (full)
10.0–14.0 Ω
Sender unit resistance (empty)
267.0–273.0 Ω

2-8

ELECTRICAL SPECIFICATIONS

Page 31

# ELECTRICAL SPECIFICATIONS

## Fuse(s)

| Fuse Type                   | Amperage |
| :-------------------------- | :------- |
| Main fuse                   | 30.0 A   |
| Headlight fuse              | 7.5 A    |
| Signaling system fuse      | 7.5 A    |
| Ignition fuse               | 7.5 A    |
| Fuel injection system fuse  | 7.5 A    |
| Terminal fuse 1             | 5.0 A    |
| Backup fuse                 | 7.5 A    |
| ABS motor fuse              | 30.0 A   |
| ABS solenoid fuse           | 15.0 A   |
| ABS control unit fuse       | 2.0 A    |
| Smart key system fuse       | 2.0 A    |

2-9

Page 32

EAS20017
TIGHTENING TORQUES
EAS30016
ENGINE TIGHTENING TORQUES

| Item                                     | Thread size | Q'ty | Tightening torque                 | Remarks                                     |
| :--------------------------------------- | :---------- | :--- | :-------------------------------- | :------------------------------------------ |
| Muffler nut                              | M8          | 2    | 20 N·m (2.0 kgf·m, 15 lb·ft)      |                                             |
| Muffler bolt                             | M10         | 3    | 53 N·m (5.3 kgf·m, 39 lb·ft)      |                                             |
| Muffler protector bolt                   | M6          | 2    | 8 N·m (0.8 kgf·m, 5.9 lb·ft)      |                                             |
| Cylinder head bolt                       | M6          | 2    | 10 N·m (1.0 kgf·m, 7.4 lb·ft)     |                                             |
| Cylinder head nut                        | M8          | 4    | 24 N·m (2.4 kgf·m, 18 lb·ft)      | M                                           |
| VVA (variable valve actuator) solenoid bolt | M6          | 2    | 10 N·m (1.0 kgf·m, 7.4 lb·ft)     |                                             |
| Cylinder head cover bolt                 | M6          | 4    | 10 N·m (1.0 kgf·m, 7.4 lb·ft)     |                                             |
| Engine oil check bolt                    | M6          | 1    | 7 N·m (0.7 kgf·m, 5.2 lb·ft)      |                                             |
| Cylinder head stud bolt (exhaust pipe)   | M8          | 2    | 15 N·m (1.5 kgf·m, 11 lb·ft)      |                                             |
| Camshaft sprocket bolt                   | M8          | 1    | 30 N·m (3.0 kgf·m, 22 lb·ft)      |                                             |
| Spark plug                               | M10         | 1    | 13 N·m (1.3 kgf·m, 9.6 lb·ft)     |                                             |
| Valve clearance adjusting screw locknut  | M5          | 4    | 7 N·m (0.7 kgf·m, 5.2 lb·ft)      |                                             |
| Timing chain tensioner bolt              | M6          | 2    | 10 N·m (1.0 kgf·m, 7.4 lb·ft)     | Yamaha bond No. 1215                        |
| Coolant temperature sensor               | M10         | 1    | 15 N·m (1.5 kgf·m, 11 lb·ft)      |                                             |
| Coolant drain bolt (cylinder side)       | M6          | 1    | 10 N·m (1.0 kgf·m, 7.4 lb·ft)     |                                             |
| Water pump assembly bolt                 | M6          | 3    | 10 N·m (1.0 kgf·m, 7.4 lb·ft)     |                                             |
| Radiator fan case bolt                   | M6          | 5    | 10 N·m (1.0 kgf·m, 7.4 lb·ft)     |                                             |
| Thermostat assembly bolt                 | M6          | 2    | 9 N·m (0.9 kgf·m, 6.6 lb·ft)      |                                             |
| Radiator fan bolt                        | M6          | 3    | 10 N·m (1.0 kgf·m, 7.4 lb·ft)     |                                             |
| Radiator bolt                            | M6          | 4    | 10 N·m (1.0 kgf·m, 7.4 lb·ft)     |                                             |
| Coolant drain bolt (radiator side)       | M12         | 1    | 1 N·m (0.10 kgf·m, 0.73 lb·ft)    |                                             |
| Oil strainer cover                       | M30         | 1    | 20 N·m (2.0 kgf·m, 15 lb·ft)      |                                             |
| Fuel injector bolt                       | M6          | 1    | 10 N·m (1.0 kgf·m, 7.4 lb·ft)     |                                             |
| Intake manifold bolt                     | M6          | 2    | 10 N·m (1.0 kgf·m, 7.4 lb·ft)     |                                             |
| Air filter case bolt                     | M6          | 2    | 10 N·m (1.0 kgf·m, 7.4 lb·ft)     |                                             |
| Starter generator rotor nut              | M12         | 1    | 70 N·m (7.0 kgf·m, 52 lb·ft)      |                                             |
| Starter generator assembly bolt          | M6          | 3    | 10 N·m (1.0 kgf·m, 7.4 lb·ft)     |                                             |
| Crankcase bolt                           | M6          | 11   | 10 N·m (1.0 kgf·m, 7.4 lb·ft)     |                                             |
| Transmission case cover bolt             | M8          | 6    | 20 N·m (2.0 kgf·m, 15 lb·ft)      |                                             |
| Final transmission oil drain bolt        | M8          | 1    | 20 N·m (2.0 kgf·m, 15 lb·ft)      |                                             |
| V-belt case bolt                         | M6          | 10   | 10 N·m (1.0 kgf·m, 7.4 lb·ft)     |                                             |
| Engine oil drain bolt                    | M12         | 1    | 20 N·m (2.0 kgf·m, 15 lb·ft)      |                                             |

2-10

Page 33

# TIGHTENING TORQUES

| Item                                    | Thread size | Q'ty | Tightening torque                 | Remarks |
| :-------------------------------------- | :---------- | :--- | :-------------------------------- | :------ |
| V-belt case air filter element cover bolt | M6          | 6    | 7 N·m (0.7 kgf·m, 5.2 lb·ft)      |         |
| Primary fixed sheave nut                | M12         | 1    | 76 N·m (7.6 kgf·m, 56 lb·ft)      |         |
| Clutch housing nut                      | M12         | 1    | 45 N·m (4.5 kgf·m, 33 lb·ft)      |         |
| Secondary sheave nut                    | M28         | 1    | 55 N·m (5.5 kgf·m, 41 lb·ft)      |         |

Cylinder head tightening sequence:

![Cylinder head tightening sequence illustration with points 1-6 marked](image_of_cylinder_head_tightening_sequence.png)

2-11

Page 34

# TIGHTENING TORQUES

## EAS30017 CHASSIS TIGHTENING TORQUES

| Item | Thread size | Q'ty | Tightening torque | Remarks |
|---|---|---|---|---|
| Engine bracket nut | M10 | 1 | 52 N·m (5.2 kgf·m, 38 lb·ft) | |
| Engine mounting nut (front side) | M10 | 2 | 50 N·m (5.0 kgf·m, 37 lb·ft) | |
| Engine mounting nut (rear side) | M10 | 2 | 28 N·m (2.8 kgf·m, 21 lb·ft) | |
| Meter assembly panel bolt | M6 | 2 | 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) | |
| Grab bar bolt | M8 | 4 | 17 N·m (1.7 kgf·m, 13 lb·ft) | |
| Seat nut | M6 | 3 | 7 N·m (0.7 kgf·m, 5.2 lb·ft) | |
| Storage box bolt | M6 | 4 | 9 N·m (0.9 kgf·m, 6.6 lb·ft) | |
| Front brake master cylinder holder bolt | M6 | 2 | 16 N·m (1.6 kgf·m, 12 lb·ft) | |
| Front brake hose union bolt (master cylinder side) | M10 | 1 | 29 N·m (2.9 kgf·m, 21 lb·ft) | |
| Rear brake hose union bolt (master cylinder side) | M10 | 1 | 29 N·m (2.9 kgf·m, 21 lb·ft) | |
| Throttle cable holder bolt (handlebar switch side) | M5 | 1 | 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) | |
| Rear brake master cylinder holder bolt | M6 | 2 | 16 N·m (1.6 kgf·m, 12 lb·ft) | |
| Brake light switch screw | M4 | 2 | 1.2 N·m (0.12 kgf·m, 0.88 lb·ft) | |
| Handlebar bracket nut | M10 | 1 | 53 N·m (5.3 kgf·m, 39 lb·ft) | |
| Lower ring nut | M25 | 1 | See TIP. | |
| Upper ring nut | M25 | 1 | See TIP. | |
| Lower bracket pinch bolt | M10 | 4 | 53 N·m (5.3 kgf·m, 39 lb·ft) | |
| Front fork damper rod bolt | M10 | 2 | 23 N·m (2.3 kgf·m, 17 lb·ft) | [circled S symbol] |
| Ignition coil bolt | M6 | 2 | 7 N·m (0.7 kgf·m, 5.2 lb·ft) | |
| Front wheel sensor bolt | M6 | 1 | 7 N·m (0.7 kgf·m, 5.2 lb·ft) | |
| Front brake caliper bolt | M10 | 2 | 35 N·m (3.5 kgf·m, 26 lb·ft) | |
| Front brake hose union bolt (brake caliper side) | M10 | 1 | 29 N·m (2.9 kgf·m, 21 lb·ft) | |
| Brake caliper bleed screw | M8 | 2 | 6 N·m (0.6 kgf·m, 4.4 lb·ft) | |
| Front wheel axle nut | M10 | 1 | 26 N·m (2.6 kgf·m, 19 lb·ft) | |
| Front brake disc bolt | M8 | 3 | 23 N·m (2.3 kgf·m, 17 lb·ft) | [circled S symbol] |
| Front wheel sensor rotor bolt | M5 | 3 | 8 N·m (0.8 kgf·m, 5.9 lb·ft) | [circled S symbol] |
| Rear brake disc bolt | M8 | 3 | 23 N·m (2.3 kgf·m, 17 lb·ft) | [circled S symbol] |
| Rear brake caliper bolt | M10 | 2 | 35 N·m (3.5 kgf·m, 26 lb·ft) | |
| Rear wheel axle nut | M16 | 1 | 125 N·m (12.5 kgf·m, 92 lb·ft) | |
| Rear shock absorber assembly nut | M10 | 2 | 21 N·m (2.1 kgf·m, 15 lb·ft) | |
| Rear shock absorber assembly bolt | M8 | 2 | 21 N·m (2.1 kgf·m, 15 lb·ft) | |
| Swingarm mounting bolt | M10 | 2 | 57 N·m (5.7 kgf·m, 42 lb·ft) | |

2-12

Page 35

Item
Thread 
size
Q’ty
Tightening torque
Remarks

Fuel tank bolt
M6
4
9 N·m (0.9 kgf·m, 6.6 lb·ft)

Coolant reservoir bolt
M6
1
11 N·m (1.1 kgf·m, 8.1 lb·ft)

Sidestand switch bolt
M5
2
7 N·m (0.7 kgf·m, 5.2 lb·ft)

Centerstand spring hook bolt
M6
1
7 N·m (0.7 kgf·m, 5.2 lb·ft)

Sidestand nut
M8
1
32 N·m (3.2 kgf·m, 24 lb·ft)

TIP

 
Steering column ring nut
1. Tighten the lower ring nut 38 N·m (3.8 kgf·m, 28 lb·ft) with a torque wrench and the steering nut 
wrench, and then loosen the nut 1/4 turn.
2. Tighten the lower ring nut 17 N·m (1.7 kgf·m, 13 lb·ft) with a torque wrench and the steering nut 
wrench.
3. Install the rubber washer and the center ring nut.
4. Finger tighten the center ring nut, align the slots of both ring nuts, and then install the lock washer.
5. Hold the lower and center ring nuts, and then tighten the upper ring nut 75 N·m (7.5 kgf·m, 55 lb·ft) 
with a torque wrench and the steering nut wrench.

 

2-13

TIGHTENING TORQUES

LT

Page 36

Page 37

2-15
CABLE ROUTING
EAS20021
CABLE ROUTING
Handlebar (front view)
A
A
B
C
1
1
1
7
2
2
2
3
4
5
5
4
6

Page 38

1.
Front brake hose
2.
Rear brake hose
3.
Rear brake light switch lead
4.
Throttle cable (decelerator cable)
5.
Throttle cable (accelerator cable)
6.
Front brake light switch lead
7.
Accessories coupler

A. 15° – 25°
B. Insert the projection on the wire harness 
holder into the hole in the lower handlebar 
cover.
C. Route the throttle cables through the hole 
in the lower handlebar cover.

2-16

CABLE ROUTING

Page 39

Handlebar (side view)

5

1

5

2

1

3

4

2

3

4

B

1

A

2-17

CABLE ROUTING

2

3

4

Page 40

1.
Rear brake hose
2.
Throttle cable (decelerator cable)
3.
Throttle cable (accelerator cable)
4.
Wire harness
5.
Front brake hose

A. Route the throttle cable (accelerator cable) 
to the outside of the throttle cable (deceler-
ator cable).
B. Insert the projection on the wire harness 
holder into the hole in the bracket.

2-18

CABLE ROUTING

Page 41

2-19
CABLE ROUTING
Front frame (front and left side view)
10
18 20
3
3
1
2
3
4
5
6
7
9
8
A
B
B
11
12
C
9
11 12
9
10
3
4
13
3
4
14
10
6
15
E
F
16
G
20
22
23
7
24
5
D
7
6
26
21
18
20
H
6
26
25
27
25
26
8
7
6
25
13
28
I
J
29
13
17
18
19

Page 42

1.
Front side cowling (right)
2.
Meter assembly lead
3.
Headlight lead
4.
Buzzer lead
5.
Fuse box
6.
Front wheel sensor lead
7.
Front brake hose (hydraulic unit to front 
brake caliper)
8.
Hydraulic unit assembly
9.
SGCU (Starter Generator Control Unit)
10. Front turn signal light lead (front right turn 
signal light)
11. Starter charger relay
12. Main relay
13. Front turn signal light lead (front left turn 
signal light)
14. Meter assembly
15. Auxiliary DC jack lead
16. Auxiliary DC jack
17. Main switch
18. Seat lock cable
19. Fuel tank cap lid lock cable
20. Frame ground lead
21. Main switch steering lock assy
22. Throttle cable (accelerator)
23. Throttle cable (decelerator)
24. Frame
25. Rear brake hose (rear brake master cylin-
der to hydraulic unit)
26. Front brake hose (front brake master cylin-
der to hydraulic unit)
27. Wire harness
28. Headlight unit
29. Front turn signal light

A. Insert the projection of clamp wire harness 
into the hole of front side cowling (right).
B. Insert the projection of clamp wire harness 
into the hole of stay.
C. Make sure the white connector of wire har-
ness shall be connected to relay with white 
paint.
D. Make sure the protrusion of wire harness 
shall be assembled to the stay.
E. Make sure the auxiliary DC jack coupler 
shall be assembled to protrusion of the 
front side cowling (left).
F.
Insert the projection of clamp wire harness 
into the hole of frame.
G. Make sure the stopper of seat lock cable 
and fuel tank cap lid lock cable shall be 
assembled to the main switch.
H. Insert the projection of clamp front wheel 
sensor into the hole of stay.

2-20

CABLE ROUTING

I.
Route the headlight lead through the head-
light lead guide (two places).
J.
Route the front turn signal light lead (front 
left turn signal light) through the guide of 
front side panel (left).

Page 43

2-21
CABLE ROUTING
Front fork (rear and right side view)
A
B
C
D
E
F
G
H
1
2
2
2
3
3
4
4
B
C
2
4
4
4
2
2
4
5
5
6

Page 44

1.
Front wheel sensor
2.
Front wheel sensor lead
3.
Front brake caliper
4.
Front brake hose
5.
Horn
6.
Front brake hose holder

A. Route the front brake hose through the 
guide.
B. Backward
C. Frontward
D. Install the horn fit to the frame.
E. Install the guide fit to the lower bracket.
F.
The front brake hose and front wheel sen-
sor lead should be passed through the 
vehicle rear side of the guide.
G. Inward
H. Outward

2-22

CABLE ROUTING

Page 45

# CABLE ROUTING

## Frame (left side view)

### Key Labels and Components

* **Boxed Letter Labels:** A, B, C, D, E, F, G, H, I, J, K
* **Circled Number Labels:** ①, ②, ③, ④, ⑤, ⑥, ⑦, ⑧, ⑨, ⑩, ⑪, ⑫, ⑬

---

### Inset Details

#### Top Inset (E)
* Labels: **E**, ①, ②

#### Top Inset (F, G, H)
* Labels: **F**, **G**, **H**, ③, ④, ⑧

#### Upper Right Inset (I)
* Labels: **I**, ⑧

#### Middle Right Inset (B)
* Labels: ①, ②, ③, ④, ⑨, ⑩

#### Left Inset (K - Horn Assembly)
* Labels: **K**, ⑫, ⑬

#### Middle Left Inset (D, C)
* Labels: **D**, **C**, ①, ②, ⑥, ⑦, ⑫

#### Lower Left Inset
* Labels: ①, ②, ⑥, ⑦, ⑫

#### Lower Right Inset (J)
* Labels: **J**, ①, ②, ⑥, ⑪

#### Bottom Center Inset
* Labels: ⑥

#### Bottom Right Inset
* Labels: ①, ②, ⑫

---

**2-23**

Page 46

1.
Throttle cable (decelerator cable)
2.
Throttle cable (accelerator cable)
3.
Fuel tank cap lid lock cable
4.
Seat lock cable
5.
Fuel tank overflow tray
6.
Sidestand switch lead
7.
Fuel tank overflow hose
8.
Main switch cover
9.
Wire harness
10. Frame ground lead
11. Fuel hose
12. Frame
13. Horn

A. Insert the projection on the seat lock cable 
clamp into the hole in the inner panel.
B. Clamp in the fuel tank cap lid lock cable 
shall be assembled into the inner panel. 
And the fuel tank cap lid lock cable with 
white tape is fixed on the front side of the 
vehicle. Do not cross the fuel tank cap lid 
lock cable and seat lock cable.
C. Install the fuel tank overflow hose so that 
this part of the fuel tank overflow hose 
comes to the bottom than clamp.
D. Insert the projection on the wire harness 
into the hole in the frame.
E. Install the throttle cable grommet into 
guide of frame.
F.
Pass the wire seat lock and fuel tank lid 
lock cable in upper the main switch cover.
G. Push the coupler to forward of vehicle.
H. Tighten the bolt while pressing the terminal 
against the projection of the frame.
I.
Insert the projection on the wire harness 
clamp into the hole in the main switch 
cover.
J.
Install the fuel hose grommet into guide of 
frame.
K. Install the horn leads in any direction.

2-24

CABLE ROUTING

Page 47

# CABLE ROUTING

## Frame (left side view)

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)

A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P

2-25

Page 48

1.
Seat lock cable
2.
Smart key unit lead
3.
Fuel hose
4.
Throttle cable (accelerator cable) 
5.
Throttle cable (decelerator cable)
6.
Starter generator lead
7.
O2 sensor lead
8.
Throttle body sensor assembly
9.
Engine ground lead
10. Injector lead 
11. Positive battery lead
12. Yamaha diagnostic tool coupler lead
13. Negative battery lead
14. Wire harness
15. Rear brake hose
16. Rear wheel sensor lead
17. Frame

A. Insert the projection on the seat lock cable 
clamp into the hole in the storage box.
B. Insert the projection on the seat lock cable 
clamp into the hole in the frame.
C. Pass the seat lock cable in groove of the 
rear fender.
D. Insert the throttle cable into the clamp.
E. Insert the wire harness clamp into the 
plate.
F.
Insert the O2 sensor connector into the 
holder.
G. Insert the projection on the seat lock cable 
clamp into the hole in the bracket.
H. Pass the wire harness inside of frame.
I.
Insert the projection on the wire.
J.
Insert the projection of clamp wire harness 
into the hole of the battery stay.
K. Pass the wire harness in the inside of 
frame.
L.
Insert the projection of clamp wire harness 
into the hole of the ignition coil stay.
M. Pass the coolant reservoir hose in upper 
side of the holder.
N. Insert the projection of clamp wire harness 
into the hole of the guide.
O. Pass the wire harness in the inside of pillar 
guide.
P. Insert the projection of clamp wire harness 
into the hole of the frame.

2-26

CABLE ROUTING

Page 49

2-27
CABLE ROUTING
Frame (right side view)
A
A
A
B
1
2
3
4
5
7
7
8
9
9
10
10
10
10
1
1
14
6
11
3
2
A

Page 50

1.
CCU (Communication Control Unit)
2.
Positive battery lead
3.
Ignition coil
4.
Joint
5.
Frame ground lead
6.
Hydraulic unit assembly
7.
Wire harness
8.
Footrest board
9.
Coolant reservoir breather hose
10. Frame
11. Fuel pump lead
12. Starter generator lead
13. Wire harness (to battery)
14. Wire harness (to engine)

A. Insert the projection on the wire harness 
into the hole in the frame.
B. White paint portion of the coolant reservoir 
breather hose and clamp location should 
be combined.

2-28

CABLE ROUTING

Page 51

Frame (right side view)

1

A

7

5
C
6

2-29

CABLE ROUTING

4
4

B

B

1

2

3

Page 52

1.
Frame ground lead
2.
Wire harness 
3.
Coolant temperature sensor lead
4.
Frame
5.
Rear fender
6.
License light lead
7.
O2 sensor lead

A. Pass the wire harness in groove of the rear 
fender.
B. Insert the projection on the wire harness 
clamp into the hole in the frame.
C. Pass the license light lead before assem-
bled the rear fender.

2-30

CABLE ROUTING

Page 53

Hydraulic unit (top and right side view)

5

3
4

5

1

7

6

2-31

CABLE ROUTING

1

2

A

2

3

4

Page 54

1.
Hydraulic unit assembly
2.
Rear brake hose (hydraulic unit to rear 
brake caliper)
3.
Rear brake hose (rear brake master cylin-
der to hydraulic unit)
4.
Front brake hose (front brake master cylin-
der to hydraulic unit)
5.
Front brake hose (hydraulic unit to front 
brake caliper)
6.
Main switch lead
7.
Hydraulic unit assembly lead

A. Insert the projection of claim wire harness 
into the hole of stay.

2-32

CABLE ROUTING

Page 55

CABLE ROUTING

Rear brake (right side view)

D
E
F

C
A B ⑤
ROTATION

⑤
③
②

⑧
③
⑦

② G

2-33

Page 56

1.
Rear brake caliper
2.
Rear brake hose
3.
Rear wheel sensor lead
4.
Radiator
5.
Coolant reservoir hose
6.
Swingarm 
7.
Radiator fan cover
8.
Rear brake hose bracket
9.
Rear brake hose holder

A. Turn the clip to the left side of the vehicle. 
The clip shall not be on the spool.
B. Turn the white paint mark to upper side of 
the vehicle and insert the hose until the 
radiator assy.
C. Connect the coolant reservoir hose to the 
radiator, and then fasten the hose by 
inserting the projection on the holder into 
the hole in the rear brake hose bracket.
D. Position the clamp within the range shown 
in the illustration.
E. Upward
F.
Downward
G. The rear brake hose should be passed 
through the guide.

2-34

CABLE ROUTING

Page 57

Fuel tank (top and bottom view)

A
4
3
2

D

1

8

E

5

6

2-35

CABLE ROUTING

1

7

C

4

B

Page 58

1.
Rear brake hose
2.
Coolant reservoir cap
3.
Coolant reservoir breather hose
4.
Rear wheel sensor lead
5.
Coolant reservoir hose
6.
Fuel hose
7.
Clamp 1
8.
Clamp 2

A. Install the coolant reservoir cap as shown 
in the illustration.
B. Rear wheel sensor lead between the 
clamp 1 and clamp 2 is gotten rid of the 
slack by sliding the clamp 2 toward the 
arrow mark.
After adjustment, the rear wheel sensor 
lead shall be placed between the upper 
limit line and lower limit line.
C. Slide direction
D. Upper limit line
E. Lower limit line

2-36

CABLE ROUTING

Page 59

# CABLE ROUTING

## Fuel tank (right side view)

### Main Diagram

*   1
*   2
*   3
*   4
*   5
*   6
*   7
*   8
*   A
*   B
*   C
*   D

### Detailed Views

*   **Fuel Tank Top Section:**
    *   9
    *   E
    *   7
    *   8
    *   10

*   **Top Middle Clamp Detail:**
    *   H
    *   5
    *   I

*   **Top Right Clamp Details:**
    *   F
    *   4
    *   G
    *   3
    *   F
    *   G
    *   4
    *   3

*   **Bottom Left Bracket Detail:**
    *   1
    *   4
    *   3

*   **Bottom Middle Routing Detail:**
    *   K
    *   5
    *   12
    *   7
    *   J

*   **Bottom Right Component Detail:**
    *   6
    *   11

2-37

Page 60

1.
Ignition coil
2.
Ignition coil cord
3.
Rear brake hose
4.
Rear wheel sensor lead
5.
Coolant reservoir breather hose
6.
Inner fender
7.
Coolant reservoir hose
8.
Fuel hose
9.
Frame
10. Engine
11. Fuel tank overflow hose
12. Coolant reservoir

A. Install the coolant reservoir breather hose 
on the frontward of vehicle.
B. Install the fuel hose grommet into guide of 
frame.
C. Install the coolant reservoir hose so that 
the hose protector is back of the guide 
wire.
D. Insert the projection on the ignition coil 
clamp into the hole in the frame.
E. Install the curved part of the coolant reser-
voir hose as close to the outside of the 
vehicle.
F.
Upward
G. Downward
H. Face the white paint mark on the recovery 
tank upward.
I.
Install the knob of coolant reservoir cap as 
shown in illustration.
J.
Face the white paint mark on the hose 
upward.
K. Install the coolant reservoir hose fit to the 
coolant reservoir.

2-38

CABLE ROUTING

Page 61

2-39
CABLE ROUTING
Canister
1
2
A
B
D
1
2
4
5
3
6
2
1
7
8
C
3
2
3
1
L
2
14
9
10
E
4
M
F
4
B
O
N
10
11
12
G
13
5
5
2
6
C
A
I
H
K
15

Page 62

1.
Fuel tank breather hose (fuel tank to roll-
over valve)
2.
Fuel tank breather hose (rollover valve to 
canister)
3.
Rollover valve
4.
Canister breather hose
5.
Canister purge hose
6.
Frame
7.
Main switch lead
8.
Frame ground lead
9.
Fuel hose
10. Canister
11. Throttle body assembly
12. Canister purge hose guide
13. Main switch cover
14. Fuel pump lead
15. Coolant reserver breather hose

A. Face the white paint mark on the hose to 
the right. Install the hose completely onto 
the hose fitting.
B. Point the ends of the hose clamp to the 
right of the vehicle.
C. Face the yellow paint mark on the hose to 
the rear of the vehicle. Install the hose 
completely onto the hose fitting.
D. Route the fuel tank breather hose (rollover 
valve to canister) grommet fit in the notch 
of portion of the flange of fuel tank.
E. Face the white paint mark on the hose to 
the upper. Install the hose completely onto 
the hose fitting.
F.
Insert the projection of clamp the canister 
breather hose in to the hole of frame.
G. Face the white paint mark on the hose to 
the rear and shall be located on this range.
H. Upward
I.
Downward
J.
Put the rollover valve through the clamp to 
the main switch cover at rivet.
K. Insert the canister breather hose to the 
hole of frame.
L.
Pass the roll over valve to the clamp and 
fasten it with rivet to the main switch cover.
M. Direction of the clamp insertion should be 
aligned with white paint mark of the canis-
ter breather hose.
N. Face the white paint mark to the right.
O. Face the hose clip to the lower direction.

2-40

CABLE ROUTING

Page 63

2-41
CABLE ROUTING
Radiator (top and right side view)
A
A
A
A
A
B
D
E
D
E
D
F
D
E
G
F
D
F
M
L
D
F
M
L
J
K
1
1
2
2
2
3
3
4
4
5
5
6
6
7
7
H
I
I
C
C

Page 64

1.
Water pump
2.
Water pump inlet hose 
3.
Thermostat assembly
4.
Radiator outlet hose
5.
Radiator
6.
Coolant reservoir hose
7.
Radiator inlet hose

A. Install the hose completely onto the hose 
fitting.
B. Face the white paint mark on the hose to 
the left.
C. 45°
D. Upward
E. Downward
F.
Frontward
G. Backward
H. To coolant reservoir
I.
Face the yellow paint mark on the hose to 
the right.
J.
Align the yellow paint mark on the hose 
with the center of the thermostat assembly.
K. Face the white paint mark on the hose 
downward.
L.
Outward
M. Inward

2-42

CABLE ROUTING

Page 65

Air filter case (top and left side view)

A

3

3

2
2

B

C

A

B

C

F

1

E

A
C

2-43

CABLE ROUTING

1

2

C

D

3

A

Page 66

1.
V-belt case breather hose
2.
Air filter case
3.
Cylinder head breather hose

A. Point the ends of the hose clamp outward.
B. Face the yellow paint mark on the hose 
outward.
C. Install the hose completely onto the hose 
fitting.
D. Face the white paint mark on the hose out-
ward.
E. 5–6 mm (0.20–0.24 in)
F.
1–5 mm (0.04–0.20 in)

2-44

CABLE ROUTING

Page 67

Page 68

PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE ............................................................................3-1
INTRODUCTION.......................................................................................3-1
PERIODIC MAINTENANCE CHART 
FOR THE EMISSION CONTROL SYSTEM.............................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART .......................3-1
CHECKING THE VEHICLE 
USING THE YAMAHA DIAGNOSTIC TOOL............................................3-4
CHECKING THE FUEL LINE ....................................................................3-4
CHECKING THE SPARK PLUG ...............................................................3-5
ADJUSTING THE VALVE CLEARANCE ..................................................3-6
CHECKING THE ENGINE IDLING SPEED ..............................................3-7
CHECKING THE EXHAUST SYSTEM......................................................3-8
CHECKING THE CANISTER ....................................................................3-8
REPLACING THE AIR FILTER ELEMENT 
AND CLEANING THE CHECK HOSE......................................................3-8
CHECKING THE BREATHER HOSES .....................................................3-9
CLEANING THE V-BELT CASE AIR FILTER ELEMENT 
AND CLEANING THE CHECK HOSE....................................................3-10
CHECKING THE BRAKE OPERATION..................................................3-11
CHECKING THE FRONT BRAKE PADS................................................3-11
CHECKING THE REAR BRAKE PADS ..................................................3-11
CHECKING THE BRAKE FLUID LEVEL.................................................3-11
CHECKING THE FRONT BRAKE HOSES .............................................3-12
CHECKING THE REAR BRAKE HOSES................................................3-12
BLEEDING THE HYDRAULIC BRAKE SYSTEM ...................................3-12
CHECKING THE WHEELS .....................................................................3-14
CHECKING THE TIRES..........................................................................3-14
CHECKING THE WHEEL BEARINGS....................................................3-15
CHECKING AND ADJUSTING THE STEERING HEAD .........................3-16
LUBRICATING THE STEERING HEAD..................................................3-17
CHECKING THE CHASSIS FASTENERS..............................................3-17
LUBRICATING THE LEVERS.................................................................3-17
CHECKING THE SIDESTAND................................................................3-17
LUBRICATING THE SIDESTAND...........................................................3-17
CHECKING THE CENTERSTAND .........................................................3-17
LUBRICATING THE CENTERSTAND ....................................................3-17
CHECKING THE SIDESTAND SWITCH.................................................3-17
CHECKING THE FRONT FORK.............................................................3-18
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................3-18
CHECKING THE ENGINE OIL LEVEL....................................................3-18
CHANGING THE ENGINE OIL ...............................................................3-19
CHECKING THE COOLANT LEVEL.......................................................3-20
CHECKING THE COOLING SYSTEM....................................................3-21
CHANGING THE COOLANT...................................................................3-21
CHANGING THE FINAL TRANSMISSION OIL.......................................3-24
REPLACING THE V-BELT......................................................................3-24
CHECKING THE BRAKE LIGHT SWITCHES.........................................3-25
CHECKING AND LUBRICATING THE CABLES ...................................3-25
CHECKING THE THROTTLE GRIP OPERATION .................................3-25
CHECKING THE SWITCHES, LIGHTS AND SIGNALS .........................3-26

3

Page 69

ADJUSTING THE HEADLIGHT BEAM ...................................................3-26

Page 70

EAS20022
PERIODIC MAINTENANCE

EAS30022
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.

TIP

 
• The annual checks must be performed every year, except if a distance-based maintenance is 
performed instead.
• From 30000 km (17500 mi), repeat the maintenance intervals starting from 6000 km (3500 mi).
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, 
data and technical skills.

 

EAS30614
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

ODOMETER READING
ANNUAL 
CHECK
1000 km 
(600 mi)
6000 km 
(3500 mi)
12000 km 
(7000 mi)
18000 km 
10500 mi)
24000 km 
(14000 mi)

No.
ITEM
CHECK OR MAINTENANCE 
JOB

1
*
Fuel line
• Check fuel hoses for cracks or 
damage.
• Replace if necessary.
√
√
√
√
√

2
Spark plug
• Check condition.
• Adjust gap and clean.
√
√

• Replace.
√
√

3
*
Valve clearance
• Check and adjust.
√
√
√
√

4
*
Fuel injection
• Check engine idle speed.
√
√
√
√
√
√

5
*
Exhaust system
• Check for leakage.
• Tighten if necessary.
• Replace gasket if necessary.
√
√
√
√
√

6
*
Evaporative emis-
sion control sys-
tem

• Check control system for 
damage.
• Replace if necessary.
√
√

EAS30615
GENERAL MAINTENANCE AND LUBRICATION CHART

ODOMETER READING
ANNUAL 
CHECK
1000 km 
(600 mi)
6000 km 
(3500 mi)
12000 km 
(7000 mi)
18000 km 
(10500 mi)
24000 km 
(14000 mi)

No.
ITEM
CHECK OR MAINTENANCE 
JOB

• Perform dynamic inspection 
using Yamaha diagnostic tool.
• Check the error codes.
√
√
√
√
√
√

1
*
Diagnostic sys-
tem check

2
*
Air filter element
• Replace.
Every 18000 km (10500 mi)

3
Air filter case 
check hose
• Clean.
√
√
√
√
√

4
*
V-belt case air fil-
ter element
• Clean.
• Replace if necessary.
√
√
√
√
√

5
*
Battery
• Check voltage.
• Charge if necessary.
√
√
√
√
√
√

• Check operation, fluid level, 
and for fluid leakage.
• Replace brake pads if neces-
sary.

6
*
Front brake

√
√
√
√
√
√

3-1

PERIODIC MAINTENANCE

Page 71

ODOMETER READING
ANNUAL 
CHECK
1000 km 
(600 mi)
6000 km 
(3500 mi)
12000 km 
(7000 mi)
18000 km 
(10500 mi)
24000 km 
(14000 mi)

No.
ITEM
CHECK OR MAINTENANCE 
JOB

• Check operation, fluid level, 
and for fluid leakage.
• Replace brake pads if neces-
sary.

7
*
Rear brake

√
√
√
√
√
√

8
*
Brake hose
• Check for cracks or damage.
√
√
√
√
√

• Replace.
Every 4 years

9
*
Brake fluid
• Change.
Every 2 years

10 *
Wheels
• Check runout and for damage.
• Replace if necessary.
√
√
√
√

• Check tread depth and for 
damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.

11 *
Tires

12 *
Wheel bearings
• Check bearing for looseness 
or damage.
√
√
√
√

• Check bearing assemblies for 
looseness.
√
√
√
√

13 *
Steering bearings

• Moderately repack with lithi-
um-soap-based grease.
√

14 *
Chassis fasteners
• Make sure that all nuts, bolts 
and screws are properly tight-
ened.
√
√
√
√
√

15
Front and rear 
brake lever pivot 
shaft
• Lubricate with silicone grease.
√
√
√
√
√

• Check operation.
• Lubricate with lithium-soap-
based grease.
√
√
√
√
√

16
Sidestand, center-
stand

17 *
Sidestand switch
• Check operation and replace 
if necessary.
√
√
√
√
√
√

18 *
Front fork
• Check operation and for oil 
leakage.
• Replace if necessary.
√
√
√
√

• Check operation and for oil 
leakage.
• Replace if necessary.
√
√
√
√

19 *
Shock absorber 
assemblies

• Change (warm engine before 
draining).
• Check oil level and vehicle for 
oil leakage.

At the initial interval and when the oil change indicator flash-
es or comes on.
√

20
Engine oil

21 *
Engine oil strainer
• Clean.
√

22 *
Final transmis-
sion oil
• Check vehicle for oil leakage.
√
√
√
√
√

• Change.
√
√
√

23 *
Cooling system
• Check coolant level and vehi-
cle for coolant leakage.
√
√
√
√
√

• Change.
Every 3 years

24 *
V-belt
• Replace.
When the V-belt replacement indicator flashes or comes on.

25 *
Front and rear 
brake switches
• Check operation.
√
√
√
√
√
√

26 *
Moving parts and 
cables
• Lubricate.
√
√
√
√
√

• Check operation and free 
play. 
• Adjust the throttle cable free 
play if necessary.
• Lubricate the throttle grip 
housing and cable.

27 *
Throttle grip 
housing and cable

28 *
Lights, signals 
and switches
• Check operation.
• Adjust headlight beam.
√
√
√
√
√
√

3-2

PERIODIC MAINTENANCE

√
√
√
√
√

√
√
√
√
√

Page 72

TIP

 
• Engine air filter and V-belt air filter
• This model’s engine air filter is equipped with a disposable oil-coated paper element, which must not 
be cleaned with compressed air to avoid damaging it.
• The engine air filter element needs to be replaced and the V-belt air filter element needs to be ser-
viced more frequently when riding in unusually wet or dusty areas.
• Hydraulic brake service
• After disassembling the brake master cylinders and calipers, always change the fluid. Regularly 
check the brake fluid levels and fill the reservoirs as required.
• 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 and if cracked or damaged.

 

3-3

PERIODIC MAINTENANCE

Page 73

EAS32024
CHECKING THE VEHICLE USING THE 
YAMAHA DIAGNOSTIC TOOL
Use the Yamaha diagnostic tool and check the 
vehicle according to the following procedure.
1. Remove:
• Battery cover
Refer to “GENERAL CHASSIS (1)” on 
page 4-1.
2. Disconnect the Yamaha diagnostic tool cou-
pler from the CCU (Communication Control 
Unit) “1”, and then connect the Yamaha diag-
nostic tool to the coupler.

Yamaha diagnostic tool USB
90890-03267
Yamaha diagnostic tool (A/I)
90890-03264

1

3. Check:
• Fault code
TIP

 
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 “ FUNCTION 
AND DIAGNOSTIC CODE TABLE” on 
page 9-37.
4. Perform:
• Dynamic inspection
TIP

 
Use the “Dynamic inspection” function of the Ya-
maha diagnostic tool version 3.0 and after to 
perform the dynamic inspection. For information 
about using the Yamaha diagnostic tool, refer to 
the operation manual that is included with the 
tool.

 

3-4

PERIODIC MAINTENANCE

5. Install:
• Battery cover
Refer to “GENERAL CHASSIS (1)” on 
page 4-1.

EAS30619
CHECKING THE FUEL LINE
1. Remove:
• Front side cover (left)
Refer to “GENERAL CHASSIS (2)” on 
page 4-3.
• Footrest board assembly (left)
Refer to “GENERAL CHASSIS (5)” on 
page 4-12.
2. Check:
• Fuel hose “1”
Cracks/damage → Replace.
Loose connections → Connect properly.

1

3. Install:
• Footrest board assembly (left)
Refer to “GENERAL CHASSIS (5)” on 
page 4-12.
• Front side cover (left)
Refer to “GENERAL CHASSIS (2)” on 
page 4-3.

Page 74

EAS30620
CHECKING THE SPARK PLUG
1. Remove:
• Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on 
page 4-3.
• Footrest board assembly (right)
Refer to “GENERAL CHASSIS (5)” on 
page 4-12.
2. Remove:
• Spark plug cap
• Spark plug

ECA13330

NOTICE

Before removing the spark plug, blow away 
any dirt accumulated in the spark plug well 
with compressed air to prevent it from falling 
into the cylinder.

 3. Check:
• Spark plug type
Incorrect → Change.

Manufacturer/model
NGK/CPR8EA-9

4. Check:
• Electrode “1”
Damage/wear → Replace the spark plug.
• Insulator “2”
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.

5. Clean:
• Spark plug
(with a spark plug cleaner or wire brush)

3-5

PERIODIC MAINTENANCE

6. Measure:
• Spark plug gap “a”
(with a wire thickness gauge)
Out of specification → Regap.

Spark plug gap
0.8–0.9 mm (0.031–0.035 in)

7. Install:
• Spark plug “1”
• Spark plug cap

Spark plug
13 N·m (1.3 kgf·m, 9.6 lb·ft)

T R
.

.

TIP

 
• Before installing the spark plug, clean the 
spark plug and gasket surface.
• When tightening the spark plug, make sure 
that the inside “a” of the spark plug wrench “2” 
does not contact the portion “b” of the spark 
plug.

 

a
b
2

1

8. Install:
• Footrest board assembly (right)
Refer to “GENERAL CHASSIS (5)” on 
page 4-12.
• Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on 
page 4-3.

Page 75

EAS30622
ADJUSTING THE VALVE CLEARANCE
The following  procedures are applied to all of 
the valves.

TIP

 
• Valve clearance adjustment should be made 
on a cold engine, at room temperature.
• When the valve clearance is to be measured or 
adjusted, the piston must be at top dead center 
(TDC) on the compression stroke.

 1. Remove:
• Battery
Refer to “GENERAL CHASSIS (1)” on 
page 4-1.
• Front side cover
Refer to “GENERAL CHASSIS (3)” on 
page 4-6.
• Fuel tank cover
Refer to “GENERAL CHASSIS (3)” on 
page 4-6.
• Center lower cover
Refer to “GENERAL CHASSIS (5)” on 
page 4-12.
• Fuel tank
Refer to “FUEL TANK” on page 7-1.
• Cylinder head cover
Refer to “CYLINDER HEAD” on page 5-9.
• Radiator cover
Refer to “RADIATOR” on page 6-2.
2. Move:
• Radiator “1”
TIP

 
Move the rear of the radiator outward.

 

1

3. Move:
• Water pump assembly “1”

TIP

 
Move the water pump assembly in the direction 
shown in the illustration.

 

3-6

PERIODIC MAINTENANCE

1

4. Measure:
• Valve clearance
Out of specification → Adjust.

Valve clearance (cold)
Intake
0.10–0.14 mm (0.0039–0.0055 
in)
Exhaust
0.21–0.25 mm (0.0083–0.0098 
in)

 
a. Turn the crankshaft clockwise.

b. When the piston is at the Top Dead Center 
(TDC) on the compression stroke, align the 
mark “a” on the camshaft sprocket with the 
match mark “b” on the camshaft stopper 
plate.

a
b

Page 76

c. Measure the valve clearance with a thick-
ness gauge “1”.
Out of specification → Adjust.

1

 
5. 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.

1

2

c. Turn the adjusting screw “3” with the tappet 
adjusting tool “4” until the specified valve 
clearance is obtained.

Tappet adjusting tool
90890-01311
Six piece tappet set
YM-A5970

3

4

3-7

PERIODIC MAINTENANCE

d. Hold the adjusting screw to prevent it from 
moving and tighten the locknut to specifica-
tion.

Valve clearance adjusting screw 
locknut
7 N·m (0.7 kgf·m, 5.2 lb·ft)

T R
.

.

e. Measure the valve clearance again.
f. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance ad-
justment steps until the specified clearance 
is obtained.

 
6. Install:
• All removed parts
TIP

 
For installation, reverse the removal procedure.

 

EAS31017
CHECKING THE ENGINE IDLING SPEED
TIP

 
Prior to checking the engine idling speed, the air 
filter element should be clean, and the engine 
should have adequate compression.

 1. Start the engine and let it warm up for several 
minutes.
2. Check:
• Engine idling speed
Out of specification → Go to next step.

Engine idling speed
1500–1700 r/min

3. Check:
• ISC (idle speed control) learning value
“00” or “01” → Check the intake system.
“02” → Clean the ISC (idle speed control) unit 
and throttle body.
Refer to “CLEANING THE ISC (IDLE SPEED 
CONTROL) UNIT AND THROTTLE BODY” 
on page 7-13.

 
a. Connect the Yamaha diagnostic tool.
Use the diagnostic code number “67”.
Refer to “ FUNCTION 
AND DIAGNOSTIC CODE TABLE” on 
page 9-37.

Yamaha diagnostic tool USB
90890-03267
Yamaha diagnostic tool (A/I)
90890-03264

Page 77

EAS30625
CHECKING THE EXHAUST SYSTEM
1. Check:
• Muffler “1”
Cracks/damage → Replace.
• Gasket “2”
Exhaust gas leaks → Replace.
2. Check:
Tightening torque
• Muffler nut “3”
• Muffler bolt “4”

Muffler nut
20 N·m (2.0 kgf·m, 15 lb·ft)
Muffler bolt
53 N·m (5.3 kgf·m, 39 lb·ft)

T R
.

.

4

1
2

4

4

3

EAS31922
CHECKING THE CANISTER
1. Remove:
• Front side cover
Refer to “GENERAL CHASSIS (2)” on 
page 4-3.
• Fuel tank cover
Refer to “GENERAL CHASSIS (3)” on 
page 4-6.
• Center lower cover
Refer to “GENERAL CHASSIS (5)” on 
page 4-12.
2. Check:
• Fuel tank breather hose (rollover valve to 
canister)
• Canister purge hose
• Canister breather hose
• Canister
Damage → Replace.

3-8

PERIODIC MAINTENANCE

3. Install:
• Center lower cover
Refer to “GENERAL CHASSIS (5)” on 
page 4-12.
• Fuel tank cover
Refer to “GENERAL CHASSIS (3)” on 
page 4-6.
• Front side cover
Refer to “GENERAL CHASSIS (2)” on 
page 4-3.

EAS31130
REPLACING THE AIR FILTER ELEMENT 
AND CLEANING THE CHECK HOSE
TIP

 
Check the air filter check hose “1” that is located 
on the rear side of the air filter case. If dust or 
water or both collects in the hose, clean the hose 
and replace the air filter element.

 

1

1. Remove:
• Air filter case cover “1”
• Air filter element “2”

1

2

Page 78

2. Check:
• Air filter element 
Damage → Replace.

TIP

 
• Replace the air filter element every 18000 km 
(10500 mi) of operation.
• The air filter needs more frequent service if you 
are riding in unusually wet or dusty areas.

 3. Install:
• Air filter element
• Air filter case cover

Air filter case cover screw
1.2 N·m (0.12 kgf·m, 0.88 lb·ft)

T R
.

.

ECA20480

NOTICE

Never operate the engine without the air filter 
element installed. Unfiltered air will cause 
rapid wear of engine parts and may damage 
the engine. Operating the engine without the 
air filter element will also affect throttle body 
tuning, leading to poor engine performance 
and possible overheating.

 
TIP

 
When installing the air filter element into the air 
filter case, make sure that the sealing surfaces 
are aligned to prevent any air leaks.

 

EAS31179
CHECKING THE BREATHER HOSES
1. Remove:
• Battery
Refer to “GENERAL CHASSIS (1)” on 
page 4-1.
• Front side cover
Refer to “GENERAL CHASSIS (2)” on 
page 4-3.
• Fuel tank cover
Refer to “GENERAL CHASSIS (3)” on 
page 4-6.
• Storage box
Refer to “GENERAL CHASSIS (4)” on 
page 4-9.
2. Check:
• Cylinder head breather hose “1”
• Transmission case breather hose “2”
Cracks/damage → Replace.
Loose connections → Connect properly.

3-9

PERIODIC MAINTENANCE

ECA21600

NOTICE

Make sure the cylinder head breather hose 
and transmission case breather hose are 
routed correctly.

 

1

2

3. Install:
• Storage box
Refer to “GENERAL CHASSIS (4)” on 
page 4-9.
• Fuel tank cover
Refer to “GENERAL CHASSIS (3)” on 
page 4-6.
• Front side cover
Refer to “GENERAL CHASSIS (2)” on 
page 4-3.
• Battery
Refer to “GENERAL CHASSIS (1)” on 
page 4-1.

Page 79

EAS31704
CLEANING THE V-BELT CASE AIR FILTER 
ELEMENT AND CLEANING THE CHECK 
HOSE

TIP

 
Check the V-belt case air filter check hose “1” 
that is located on the rear side of the V-belt case. 
If dust or water or both collects in the hose, clean 
the hose and replace the V-belt case air filter el-
ement.

 

1

1. Remove:
• V-belt case air filter element cover “1”
• V-belt case air filter element “2”

1

2

2. Clean:
• V-belt case air filter element
(with solvent)

EWA17971

WARNING

Never use low flash point solvents, such as 
gasoline, to clean the V-belt case air filter el-
ement. Such solvents may cause a fire or an 
explosion.

 

3-10

PERIODIC MAINTENANCE

TIP

 
• The air filter needs more frequent service if you 
are riding in unusually wet or dusty areas.
• After cleaning, gently squeeze the V-belt case 
air filter element to remove the excess solvent.

 

ECA21590

NOTICE

Do not twist the V-belt case air filter element 
when squeezing it.

 

3. Check:
• V-belt case air filter element
Damage → Replace.
4. Apply the recommended oil to the entire sur-
face of the V-belt case air filter element and 
squeeze out the excess oil. The V-belt case 
air filter element should be wet but not drip-
ping.

Recommended oil
Engine oil

5. Install:
• V-belt case air filter element
• V-belt case air filter element cover

V-belt case air filter element cov-
er bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft)

T R
.

.

Page 80

EAS30801
CHECKING THE BRAKE OPERATION
1. Check:
• Brake operation
Brake not working properly → Check the 
brake system.
Refer to “FRONT BRAKE” on page 4-32 and 
“REAR BRAKE” on page 4-46.
TIP

 
Drive on the road, operate the front and rear 
brakes separately and check to see if the brakes 
are operating properly.

 

EAS30633
CHECKING THE FRONT BRAKE PADS
The following  procedures are applied to all of 
the brake pads.
1. Operate the brake.
2. Check:
• Front brake pad
Wear indicator grooves “a” almost disap-
peared → Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-32.

a

EAS30634
CHECKING THE REAR BRAKE PADS
The following  procedures are applied to all of 
the brake pads.
1. Operate the brake.
2. Check:
• Rear brake pad
Wear indicators “a” almost touch the brake 
disc → Replace the brake pads as a set.
Refer to “REAR BRAKE” on page 4-46.

a

3-11

PERIODIC MAINTENANCE

EAS30632
CHECKING THE BRAKE FLUID LEVEL
1. Stand the vehicle on a level surface.

TIP

 
• Place the vehicle on the centerstand.
• Make sure the vehicle is upright.
• In order to ensure a correct reading of the 
brake fluid level, make sure the top of the brake 
fluid reservoir is horizontal.

 2. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the 
specified brake fluid to the proper level.

Specified brake fluid
DOT 4

a
A

B

a

A. Front brake
B. Rear brake

Page 81

EWA13540

WARNING

• Use only the designated brake fluid. Other 
brake fluids may cause the rubber seals to 
deteriorate, causing leakage and poor 
brake performance.
• Refill with the same type of brake fluid that 
is already in the system. Mixing brake fluids 
may result in a harmful chemical reaction, 
leading to poor brake performance.
• When refilling, be careful that water does 
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause 
vapor lock.

 

ECA13540

NOTICE

Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean up 
any spilt brake fluid immediately.

 

EAS30635
CHECKING THE FRONT BRAKE HOSES
1. Check:
• Brake hose “1”
Cracks/damage → Replace.

1

1

2. Check:
• Brake hose holder
• Brake hose guide
Loose → Tighten the holder and guide bolt.
3. Hold the vehicle upright and apply the front 
brake several times.
4. Check:
• Brake hose
Brake fluid leakage → Replace the damaged 
hose.
Refer to “FRONT BRAKE” on page 4-32.

3-12

PERIODIC MAINTENANCE

EAS30636
CHECKING THE REAR BRAKE HOSES
1. Check:
• Brake hose “1”
Cracks/damage/wear → Replace.

1

1

2. Check:
• Brake hose holder
Loose → Tighten the holder bolt.
3. Hold the vehicle upright and apply the rear 
brake several times.
4. Check:
• Brake hose
Brake fluid leakage → Replace the brake 
hose.
Refer to “REAR BRAKE” on page 4-46.

EAS30893
BLEEDING THE HYDRAULIC BRAKE 
SYSTEM

EWA14000

WARNING

Always bleed the brake system when the 
brake related parts are removed.

 

ECA22780

NOTICE

• Bleed the brake system in the following or-
der.
• 1st step: Front brake caliper
• 2nd step: Rear brake caliper

 

EWA16530

WARNING

Bleed the ABS whenever:
• the system is disassembled.
• a brake hose is loosened, disconnected or 
replaced.
• the brake fluid level is very low.
• brake operation is faulty.

Page 82

TIP

 
• Be careful not to spill any brake fluid or allow 
the brake master cylinder reservoir to overflow.
• When bleeding the ABS, make sure that there 
is always enough brake fluid before applying 
the brake. Ignoring this precaution could allow 
air to enter the ABS, considerably lengthening 
the bleeding procedure.
• If bleeding is difficult, it may be necessary to let 
the brake fluid settle for a few hours.
• Repeat the bleeding procedure when the tiny 
bubbles in the hose have disappeared.

 1. Bleed:
• ABS

 
a. Fill the brake master cylinder reservoir to 
the proper level with the specified brake flu-
id.
b. Install the brake master cylinder dia-
phragm.
c. Connect a clear plastic hose “1” tightly to 
the bleed screw “2”.

A

2

1

B

1

2

A. Front brake caliper
B. Rear brake caliper

d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever and hold it in 
position.

3-13

PERIODIC MAINTENANCE

g. Loosen the bleed screw.
TIP

 
Loosening the bleed screw will release the pres-
sure and cause the brake lever to contact the 
throttle grip or handlebar grip.

 h. Tighten the bleed screw and then release 
the brake lever.
i.
Repeat steps (e) to (h) until all of the air 
bubbles have disappeared from the brake 
fluid in the plastic hose.
j.
Check the operation of the hydraulic unit. 
Refer to “HYDRAULIC UNIT OPERATION 
TESTS” on page 4-62.

ECA18060

NOTICE

Make sure that the main switch is turned to 
“OFF” before checking the operation of the 
hydraulic unit.

 k. After operating the ABS, repeat steps (e) to 
(i), and then fill the brake master cylinder 
reservoir to the proper level with the speci-
fied brake fluid.
l.
Tighten the bleed screw to specification.

Brake caliper bleed screw
6 N·m (0.6 kgf·m, 4.4 lb·ft)

T R
.

.

m. Fill the brake master cylinder reservoir to 
the proper level with the specified brake flu-
id.
Refer to “CHECKING THE BRAKE FLUID 
LEVEL” on page 3-11.

EWA13110

WARNING

After bleeding the hydraulic brake system, 
check the brake operation.

Page 83

EAS31428
CHECKING THE WHEELS
The following  procedures are applied to all of 
the wheels.
1. Check:
• Wheel
Damage/out-of-round → Replace.

EWA13260

WARNING

Never attempt to make any repairs to the 
wheel.

 
TIP

 
After a tire or wheel has been changed or re-
placed, always balance the wheel.

 2. Measure:
• Radial wheel runout
• Lateral wheel runout
Refer to “FRONT WHEEL” on page 4-22 and 
“REAR WHEEL” on page 4-29.

EAS31429
CHECKING THE TIRES
The following procedures are applied to all of the 
tires.
1. Check:
• Tire pressure
Out of specification → Regulate.

EWA13181

WARNING

• The tire pressure should only be checked 
and regulated when the tire temperature 
equals the ambient air temperature.
• The tire pressure and the suspension must 
be adjusted according to the total weight 
(including cargo, rider, passenger and ac-
cessories) and the anticipated riding 
speed.
• Operation of an overloaded vehicle could 
cause tire damage, an accident or an injury.
NEVER OVERLOAD THE VEHICLE.

 

3-14

PERIODIC MAINTENANCE

Tire air pressure (measured on 
cold tires)
1 person
Front
150 kPa (1.50 kgf/cm², 22 psi)
Rear
250 kPa (2.50 kgf/cm², 36 psi)
2 persons
Front
150 kPa (1.50 kgf/cm², 22 psi)
Rear
250 kPa (2.50 kgf/cm², 36 psi)
* Total weight of rider, passenger, cargo 
and accessories

EWA13190

WARNING

It is dangerous to ride with a worn-out tire. 
When the tire tread reaches the wear limit, re-
place the tire immediately.

 2. Check:
• Tire surfaces
Damage/wear → Replace the tire.

1.
Tire tread depth
2.
Side wall
3.
Wear indicator

Wear limit (front)
1.0 mm (0.04 in)
Wear limit (rear)
1.0 mm (0.04 in)

Page 84

EWA14080

WARNING

• Do not use a tubeless tire on a wheel de-
signed only for tube tires to avoid tire fail-
ure and personal injury from sudden 
deflation.
• When using a tube tire, be sure to install the 
correct tube.
• Always replace a new tube tire and a new 
tube as a set.
• To avoid pinching the tube, make sure the 
wheel rim band and tube are centered in the 
wheel groove.
• Patching a punctured tube is not recom-
mended. If it is absolutely necessary to do 
so, use great care and replace the tube as 
soon as possible with a good quality re-
placement.

 

A
B

A. Tire
B. Wheel

Tube wheel
Tube tire only

Tubeless wheel
Tube or tubeless tire

EWA14090

WARNING

After extensive tests, the tires listed below 
have been approved by Yamaha Motor Co., 
Ltd. for this model. The front and rear tires 
should always be by the same manufacturer 
and of the same design. No guarantee con-
cerning handling characteristics can be giv-
en if a tire combination other than one 
approved by Yamaha is used on this vehicle.

 

Front tire
Size
110/70-13M/C 48P
Manufacturer/model
DUNLOP/SCOOT SMART L

3-15

PERIODIC MAINTENANCE

Rear tire
Size
130/70-13M/C 63P
Manufacturer/model
DUNLOP/SCOOT SMART L

EWA13210

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.

 
TIP

 
For tires with a direction of rotation mark “1”:
• Install the tire with the mark pointing in the di-
rection of wheel rotation.
• Align the mark “2” with the valve installation 
point.

 

1
2

EAS30641
CHECKING THE WHEEL BEARINGS
The following procedures are applied to all of the 
wheel bearings.
1. Check:
• Wheel bearings
Refer to “CHECKING THE FRONT WHEEL” 
on page 4-25.

Page 85

EAS30645
CHECKING AND ADJUSTING THE 
STEERING HEAD
1. Stand the vehicle on a level surface.

EWA13120

WARNING

Securely support the vehicle so that there is 
no danger of it falling over.

 
TIP

 
Place the vehicle on a suitable stand so that the 
front wheel is off ground.

 2. Check:
• Steering head
Grasp the handlebar and gently rock the han-
dlebar.
Binding/looseness → Adjust the steering 
head.
3. Remove:
• Front side covers
Refer to “GENERAL CHASSIS (2)” on 
page 4-3.
• Center lower cover
Refer to “GENERAL CHASSIS (5)” on 
page 4-12.
• Front upper cowling assembly
Refer to “GENERAL CHASSIS (6)” on 
page 4-15.
• Handlebar
Refer to “HANDLEBAR” on page 4-67.
4. Adjust:
• Steering head

 
a. Remove the upper ring nut “1”, lock washer 
“2”, center ring nut “3” and rubber washer 
“4”.

1

3

4

2

b. Loosen the lower ring nut “5” and then tight-
en it to specification with a steering nut 
wrench “6”.

TIP

 
Set the torque wrench at a right angle to the 
steering nut wrench.

 

3-16

PERIODIC MAINTENANCE

Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472

Lower ring nut (initial tightening 
torque)
38 N·m (3.8 kgf·m, 28 lb·ft)

T R
.

.

6

5

c. Loosen the lower ring nut 1/4 of a turn, and 
then tighten it to specification with a steer-
ing nut wrench.

EWA13140

WARNING

Do not overtighten the lower ring nut.

 

Lower ring nut (final tightening 
torque)
17 N·m (1.7 kgf·m, 13 lb·ft)

T R
.

.

d. Check the steering head for looseness or 
binding by turning the front fork all the way 
in both directions. If any binding is felt, re-
move the lower bracket and check the up-
per and lower bearings.
Refer to “STEERING HEAD” on page 4-81.
e. Install the rubber washer.
f. Install the center ring nut.
g. Finger tighten the center ring nut, then align 
the slots of both ring nuts. If necessary, hold 
the lower ring nut and tighten the center ring 
nut until their slots are aligned.

Page 86

h. Install the lock washer “2”.

TIP

 
Make sure the lock washer tabs “a” sit correctly 
in the ring nut slots “b”.

 

2

a

b

i. Hold the lower and center ring nuts with a 
steering nut wrench and tighten the upper 
ring nut with another steering nut wrench.

Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472

Upper ring nut
75 N·m (7.5 kgf·m, 55 lb·ft)

T R
.

.

 
5. Install:
• Handlebar
Refer to “HANDLEBAR” on page 4-67.
• Front upper cowling assembly
Refer to “GENERAL CHASSIS (6)” on 
page 4-15.
• Center lower cover
Refer to “GENERAL CHASSIS (5)” on 
page 4-12.
• Front side cover
Refer to “GENERAL CHASSIS (2)” on 
page 4-3.

EAS30646
LUBRICATING THE STEERING HEAD
1. Lubricate:
• Upper bearing
• Lower bearing
• Lower bearing dust seal

Recommended lubricant
Lithium-soap-based grease

3-17

PERIODIC MAINTENANCE

EAS31186
CHECKING THE CHASSIS FASTENERS
Make sure that all nuts, bolts, and screws are 
properly tightened.
Refer to “TIGHTENING TORQUES” on page 2-
10.

EAS30648
LUBRICATING THE LEVERS
Lubricate the pivoting point and metal-to-metal 
moving parts of the levers.

Recommended lubricant
Silicone grease

EAS30650
CHECKING THE SIDESTAND
1. Check:
• Sidestand operation
Check that the sidestand moves smoothly.
Rough movement → Repair or replace.

EAS30651
LUBRICATING THE SIDESTAND
Lubricate the pivoting point, metal-to-metal mov-
ing parts and spring contact point of the side-
stand.

Recommended lubricant
Lithium-soap-based grease

EAS30856
CHECKING THE CENTERSTAND
1. Check:
• Centerstand operation
Check that the centerstand moves smoothly.
Rough movement → Repair or replace.

EAS30857
LUBRICATING THE CENTERSTAND
Lubricate the pivoting point, metal-to-metal mov-
ing parts, and spring contact points of the center-
stand.

Recommended lubricant
Lithium-soap-based grease

EAS30652
CHECKING THE SIDESTAND SWITCH
Refer to “CHECKING THE SWITCHES” on 
page 8-35.

Page 87

EAS30653
CHECKING THE FRONT FORK
1. Stand the vehicle on a level surface.

EWA13120

WARNING

Securely support the vehicle so that there is 
no danger of it falling over.

 2. Check:
• Inner tube
Damage/scratches → Replace.
• Oil seal
Oil leakage → Replace.
3. Hold the vehicle upright and apply the front 
brake.
4. Check:
• Front fork operation
Push down hard on the handlebar several 
times and check if the front fork rebounds 
smoothly.
Rough movement → Repair.
Refer to “FRONT FORK” on page 4-74.

EAS30808
CHECKING THE REAR SHOCK ABSORBER 
ASSEMBLIES
The following procedures are applied to both of 
the rear shock absorber assemblies.
1. Stand the vehicle on a level surface.

EWA13120

WARNING

Securely support the vehicle so that there is 
no danger of it falling over.

 2. Check:
• Rear shock absorber assembly
Oil leaks → Replace the rear shock absorber 
assembly.
Refer to “CHECKING THE REAR SHOCK 
ABSORBER ASSEMBLY” on page 4-87.

3-18

PERIODIC MAINTENANCE

3. Check:
• Rear shock absorber assembly operation
Push down seat on the vehicle several times 
and check if the rear shock absorber assem-
bly rebounds smoothly.
Rough movement → Replace.
Refer to “REAR SHOCK ABSORBER AS-
SEMBLIES AND SWINGARM” on page 4-
85.

EAS30656
CHECKING THE ENGINE OIL LEVEL
1. Stand the vehicle on a level surface.
TIP

 
• Place the vehicle on the centerstand.
• Make sure the vehicle is upright.

 2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Remove:
• Dipstick “1”
4. Check:
• Engine oil level
The engine oil level should be between the 
minimum level mark “a” and maximum level 
mark “b”.
Below the minimum level mark → Add the 
recommended engine oil to the proper level.
TIP

 
• Before checking the engine oil level, wait a few 
minutes until the oil has settled.
• Do not screw the dipstick in when inspecting 
the oil level.

 

1

1

b

a

Recommended brand
YAMALUBE
SAE viscosity grades
10W-40
Recommended engine oil grade
API service SG type or higher, 
JASO standard MA or MB

Page 88

ECA13370

NOTICE

Do not allow foreign materials to enter the 
crankcase.

 5. Start the engine, warm it up for several min-
utes, and then turn it off.
6. Check the engine oil level again.

TIP

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

 

EAS30657
CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several min-
utes, and then turn it off.
2. Place a container under the engine oil drain 
bolt.
3. Remove:
• Dipstick “1”
• Engine oil drain bolt “2”
(along with the gasket “3”)

1

3

2

4. Drain:
• Engine oil
(completely from the crankcase)
5. If the oil strainer is also to be cleaned, per-
form the following procedure.

 
a. Remove the oil strainer cover “1”, spring 
“3”, and oil strainer “2”.
b. Install a new O-ring “4”.
TIP

 
Lubricate the O-ring with lithium-soap-based 
grease.

 

3-19

PERIODIC MAINTENANCE

2

3
4

1

c. Clean the engine oil strainer with solvent, 
and then check it for damage and replace it 
if necessary.
d. Install the oil strainer, spring, and oil strain-
er cover.

Oil strainer cover
20 N·m (2.0 kgf·m, 15 lb·ft)

T R
.

.

 
6. Install:
• Engine oil drain bolt
(along with the gasket 
)

New

Engine oil drain bolt
20 N·m (2.0 kgf·m, 15 lb·ft)

T R
.

.

7. Fill:
• Crankcase
(with the specified amount of the recom-
mended engine oil)

Engine oil quantity
Quantity (disassembled)
1.00 L (1.06 US qt, 0.88 Imp.qt)
Oil change
0.90 L (0.95 US qt, 0.79 Imp.qt)

8. Install:
• Dipstick
9. Start the engine, warm it up for several min-
utes, and then turn it off.
10.Check:
• Engine
(for engine oil leaks)
11.Check:
• Engine oil level
Refer to “CHECKING THE ENGINE OIL 
LEVEL” on page 3-18.

Page 89

12.Remove:
• Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on 
page 4-3.
• Footrest board assembly (right)
Refer to “GENERAL CHASSIS (5)” on 
page 4-12.
13.Check:
• Engine oil pressure

 
a. Slightly loosen the oil check bolt “1”.

1

b. Start the engine and keep it idling until en-
gine oil starts to seep from the oil check 
bolt. If no engine oil comes out after one 
minute, turn the engine off so that it will not 
seize.
c. Check the engine oil passages and the oil 
pump for damage or leakage. Refer to “OIL 
PUMP” on page 5-49.
d. Start the engine after solving the prob-
lem(s) and check the engine oil pressure 
again.
e. Tighten the oil check bolt to specification.

Engine oil check bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft)

T R
.

.

 
14.Reset:
• Oil change indicator
Refer to “MULTI-FUNCTION METER UNIT” 
on page 1-2.

3-20

PERIODIC MAINTENANCE

EAS30811
CHECKING THE COOLANT LEVEL
1. Stand the vehicle on a level surface.

TIP

 
• Place the vehicle on the centerstand.
• Make sure the vehicle is upright.

 2. Check:
• Coolant level
The coolant level should be between the min-
imum level mark “a” and maximum level mark 
“b”.
Below the minimum level mark → Add the 
recommended coolant to the proper level.

b
a

ECA13470

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

 3. Start the engine, warm it up for several min-
utes, and then turn it off.
4. Check:
• Coolant level
TIP

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

Page 90

EAS30812
CHECKING THE COOLING SYSTEM
1. Remove:
• Radiator cover
Refer to “RADIATOR” on page 6-2.
2. Check:
• Radiator “1”
• Coolant reservoir hose “2”
• Radiator inlet hose “3”
• Radiator outlet hose “4”
• Thermostat assembly “5”
• Water pump inlet hose “6”
Cracks/tears → Replace.
Refer to “RADIATOR” on page 6-2 and 
“THERMOSTAT” on page 6-6.

4. Drain:
• Coolant
(from the coolant reservoir)
5. Remove:
• Radiator cover “1”
2

3

5

1

6
4

3. Install:
• Radiator cover
Refer to “RADIATOR” on page 6-2.

EAS30813
CHANGING THE COOLANT
1. Remove:
• Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on 
page 4-3.
• Bottom cover
• Footrest board assembly (right)
Refer to “GENERAL CHASSIS (5)” on 
page 4-12.
2. Disconnect:
• Coolant reservoir hose “1”
• Coolant reservoir breather hose “2”

2

1

3-21

PERIODIC MAINTENANCE

3. Remove:
• Coolant reservoir cap “2”
• Coolant reservoir “1”

1

2

1

Page 91

6. Remove:
• Radiator cap “1”

1

EWA13030

WARNING

A hot radiator is under pressure. Therefore, 
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may 
be blown out, which could cause serious in-
jury. 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 counter-
clockwise toward the detent to allow any re-
sidual pressure to escape. When the hissing 
sound has stopped, press down on the radi-
ator cap and turn it counterclockwise to re-
move.

 7. Remove:
• Coolant drain bolt (radiator side) “1” 
(along with the O-ring)
• Coolant drain bolt (cylinder side) “2”
(along with the copper washer)

1

2

3-22

PERIODIC MAINTENANCE

8. Drain:
• Coolant
(from the engine and radiator)
9. Install:
• Coolant drain bolt (cylinder side)
(along with the copper washer 
)
• Coolant drain bolt (radiator side)
(along with the O-ring 
)

New

New

Coolant drain bolt (cylinder side)
10 N·m (1.0 kgf·m, 7.4 lb·ft)
Coolant drain bolt (radiator side)
1.0 N·m (0.10 kgf·m, 0.73 lb·ft)

T R
.

.

10.Connect:
• Coolant reservoir breather hose
• Coolant reservoir hose
11.Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)

Recommended antifreeze
High-quality ethylene glycol an-
tifreeze containing corrosion 
inhibitors for aluminum en-
gines
Mixing ratio
1:1 (antifreeze: water)
Radiator (including all routes)
0.46 L (0.49 US qt, 0.40 Imp.qt)
Coolant reservoir (up to the 
maximum level mark)
0.13 L (0.14 US qt, 0.11 Imp.qt)

TIP

 
• Fill the coolant into the radiator, and then re-
move the air bleed bolt “1” until coolant comes 
out.
• Tighten the air bleed bolt to specification.

 

Air bleed bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)

T R
.

.

1

Page 92

Handling notes for coolant
Coolant is potentially harmful and should be 
handled with special care.

EWA13040

WARNING

• If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
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.

 

ECA13481

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.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may 
be used.
• If coolant comes into contact with painted 
surfaces, immediately wash them with wa-
ter.
• Do not mix different types of antifreeze.

 12.Install:
• Radiator cap
• Coolant reservoir

Coolant reservoir bolt
11 N·m (1.1 kgf·m, 8.1 lb·ft)

T R
.

.

13.Fill:
• Coolant reservoir
(with the recommended coolant to the maxi-
mum level mark “a”)

a

3-23

PERIODIC MAINTENANCE

14.Install:
• Coolant reservoir cap “1”
TIP

 
Point the tab “a” on the coolant reservoir cap for-
ward.

 

1

a

15.Start the engine, warm it up for several min-
utes, and then turn it off.
16.Check:
• Coolant level
Refer to “CHECKING THE COOLANT LEV-
EL” on page 3-20.

TIP

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

 17.Install:
• Radiator cover

Radiator cover bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)

T R
.

.

18.Install:
• Footrest board assembly (right)
Refer to “GENERAL CHASSIS (5)” on 
page 4-12.
• Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on 
page 4-3.

Page 93

EAS31187
CHANGING THE FINAL TRANSMISSION OIL
1. Stand the vehicle on a level surface.

TIP

 
• Place the vehicle on the centerstand.
• Make sure the vehicle is upright.

 2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Place a container under the final transmis-
sion.
4. Remove:
• Final transmission oil filler cap “1”
(along with the O-ring “2”)
• Final transmission oil drain bolt “3”
(along with the copper washer “4”)
Completely drain the final transmission oil.

1

2

3
4

5. Install:
• Final transmission oil drain bolt
(along with the copper washer 
)

New

Final transmission oil drain bolt
20 N·m (2.0 kgf·m, 15 lb·ft)

T R
.

.

3-24

PERIODIC MAINTENANCE

6. Fill:
• Final transmission oil
(with the specified amount of the recom-
mended final transmission oil)

Final transmission oil
Type
Motor oil SAE 10W-40 type SG 
or higher
Quantity
0.10 L (0.11 US qt, 0.09 Imp.qt)

7. Install:
• Final transmission oil filler cap
(along with the O-ring 
)

New

TIP

 
Lubricate the O-ring with lithium-soap-based 
grease.

 8. Start the engine, warm it up for several min-
utes, and then turn it off.
9. Check:
• Final transmission oil leakage

EAS31188
REPLACING THE V-BELT
1. Remove:
• Air filter case
Refer to “AIR FILTER CASE” on page 7-8.
• V-belt case
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-37.
2. Check:
• V-belt
Damage/wear → Replace.
Grease/oil → Clean the primary and second-
ary pulleys.
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-37.
TIP

 
Replace the V-belt every 25000 km (15500 mi) 
of operation.

 3. Install:
• V-belt case
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-37.
• Air filter case
Refer to “AIR FILTER CASE” on page 7-8.

Page 94

EAS30658
CHECKING THE BRAKE LIGHT SWITCHES
1. Check:
• Front brake light switch operation
• Rear brake light switch operation
When operating the brake levers, confirm 
that the brake light comes on.
Faulty → Refer to “CHECKING THE 
SWITCHES” on page 8-35.

EAS31147
CHECKING AND LUBRICATING THE 
CABLES 
The following procedures are applied to all of the 
inner and outer cables.

EWA13270

WARNING

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:
• Cable operation
Rough movement → Lubricate.

 3. Check:
• Throttle grip free play “a”
Out of specification → Adjust.
Recommended lubricant
Engine oil or a suitable cable lu-
bricant

TIP

 
Hold the cable end upright and pour a few drops 
of lubricant into the cable sheath or use a suit-
able lubricating device.

 

3-25

PERIODIC MAINTENANCE

EAS30861
CHECKING THE THROTTLE GRIP 
OPERATION
1. Check:
• Throttle cable
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).

Recommended lubricant
Suitable cable lubricant

TIP

 
With the engine stopped, turn the throttle grip 
slowly and release it. Make sure that the throttle 
grip turns smoothly and returns properly when 
released. 
Repeat this check with the handlebar turned all 
the way to the left and right.

Throttle grip free play
3.0–5.0 mm (0.12–0.20 in)

a

Page 95

4. Adjust:
• Throttle grip free play

 
a. Slide back the rubber cover “1”.
b. Loosen the locknut “2”.
c. Turn the adjusting nut “3” until the specified 
throttle grip free play is obtained.

EAS30664
ADJUSTING THE HEADLIGHT BEAM
1. Adjust:
• Headlight beam (vertically)
Turn the adjusting bolts “1” in direction left or 
right.
• Headlight beam (horizontally)
Turn the adjusting bolts “2” in direction left or 
right.
Throttle cable adjusting locknut
3.8 N·m (0.38 kgf·m, 2.8 lb·ft)

1
2
3

d. Tighten the locknut.

T R
.

.

e. Slide the rubber cover to its original posi-
tion.

TIP

 
Make sure that the adjusting nut is covered com-
pletely by the rubber cover.

 

EWA17990

WARNING

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

 
 

3-26

PERIODIC MAINTENANCE

EAS30663
CHECKING THE SWITCHES, LIGHTS AND 
SIGNALS
1. Check that all switches operate and that all 
lights come on.
Refer to “Instrument and control functions” in 
OWNER’S MANUAL.
Faulty → Refer to “CHECKING THE 
SWITCHES” on page 8-35.

1
2

Page 96

CHASSIS

GENERAL CHASSIS (1) .................................................................................4-1
REMOVING THE BATTERY COVER .......................................................4-2

GENERAL CHASSIS (2) .................................................................................4-3
REMOVING THE TAIL/BRAKE LIGHT OUTER COVER..........................4-4
INSTALLING THE TAIL/BRAKE LIGHT OUTER COVER.........................4-4
REMOVING THE FRONT SIDE COVER ..................................................4-5
INSTALLING THE FRONT SIDE COVER.................................................4-5

GENERAL CHASSIS (3) .................................................................................4-6
REMOVING THE FUEL TANK COVER ....................................................4-7
INSTALLING THE FUEL TANK COVER...................................................4-7
REMOVING THE FUEL TANK CAP LID COVER .....................................4-8
INSTALLING THE FUEL TANK CAP LID COVER....................................4-8

GENERAL CHASSIS (4) .................................................................................4-9
REMOVING THE REAR SIDE COVER ASSEMBLY ..............................4-11
INSTALLING THE REAR SIDE COVER ASSEMBLY.............................4-11

GENERAL CHASSIS (5) ...............................................................................4-12
INSTALLING THE CENTER LOWER COVER........................................4-14
INSTALLING THE FOOTREST BOARD ASSEMBLY.............................4-14
INSTALLING THE BOTTOM COVER .....................................................4-14

GENERAL CHASSIS (6) ...............................................................................4-15
REMOVING THE FRONT UPPER PANEL .............................................4-16
INSTALLING THE FRONT UPPER PANEL............................................4-16
REMOVING THE FRONT COWLING ASSEMBLY.................................4-17
INSTALLING THE FRONT COWLING ASSEMBLY ...............................4-17
REMOVING THE FRONT SIDE COWLING............................................4-18
INSTALLING THE FRONT SIDE COWLING ..........................................4-18

GENERAL CHASSIS (7) ...............................................................................4-19
REMOVING THE UPPER CENTER COVER..........................................4-21
INSTALLING THE UPPER CENTER COVER ........................................4-21

FRONT WHEEL.............................................................................................4-22
REMOVING THE FRONT WHEEL..........................................................4-24
DISASSEMBLING THE FRONT WHEEL................................................4-24
CHECKING THE FRONT WHEEL ..........................................................4-25
MAINTENANCE OF THE FRONT WHEEL SENSOR 
AND SENSOR ROTOR..........................................................................4-25
ASSEMBLING THE FRONT WHEEL......................................................4-26
ADJUSTING THE FRONT WHEEL STATIC BALANCE .........................4-26
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC)..................4-27

4

Page 97

REAR WHEEL...............................................................................................4-29
REMOVING THE REAR WHEEL (DISC)................................................4-30
CHECKING THE REAR WHEEL.............................................................4-30
MAINTENANCE OF THE REAR WHEEL SENSOR ROTOR .................4-30
ADJUSTING THE REAR WHEEL STATIC BALANCE............................4-30
INSTALLING THE REAR WHEEL (REAR BRAKE DISC) ......................4-31

FRONT BRAKE.............................................................................................4-32
INTRODUCTION.....................................................................................4-38
CHECKING THE FRONT BRAKE DISC .................................................4-38
REPLACING THE FRONT BRAKE PADS ..............................................4-39
REMOVING THE FRONT BRAKE CALIPER..........................................4-41
DISASSEMBLING THE FRONT BRAKE CALIPER ................................4-41
CHECKING THE FRONT BRAKE CALIPER ..........................................4-42
ASSEMBLING THE FRONT BRAKE CALIPER......................................4-42
INSTALLING THE FRONT BRAKE CALIPER ........................................4-42
REMOVING THE FRONT BRAKE MASTER CYLINDER .......................4-43
CHECKING THE FRONT BRAKE MASTER CYLINDER........................4-44
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ...................4-44
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................4-44

REAR BRAKE ...............................................................................................4-46
INTRODUCTION.....................................................................................4-51
CHECKING THE REAR BRAKE DISC....................................................4-51
REPLACING THE REAR BRAKE PADS.................................................4-52
REMOVING THE REAR BRAKE CALIPER ............................................4-53
DISASSEMBLING THE REAR BRAKE CALIPER ..................................4-53
CHECKING THE REAR BRAKE CALIPER.............................................4-54
ASSEMBLING THE REAR BRAKE CALIPER ........................................4-54
INSTALLING THE REAR BRAKE CALIPER...........................................4-54
REMOVING THE REAR BRAKE MASTER CYLINDER .........................4-55
CHECKING THE REAR BRAKE MASTER CYLINDER..........................4-56
ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................4-56
INSTALLING THE REAR BRAKE MASTER CYLINDER........................4-56

ABS (Anti-lock Brake System)....................................................................4-58
REMOVING THE HYDRAULIC UNIT ASSEMBLY .................................4-60
CHECKING THE HYDRAULIC UNIT ASSEMBLY..................................4-60
INSTALLING THE HYDRAULIC UNIT ASSEMBLY................................4-61
HYDRAULIC UNIT OPERATION TESTS................................................4-62
CHECKING THE ABS WARNING LIGHT ...............................................4-66

HANDLEBAR ................................................................................................4-67
REMOVING THE UPPER HANDLEBAR COVER ASSEMBLY ..............4-70
DISASSEMBLING THE UPPER HANDLEBAR COVER ASSEMBLY ....4-70
REMOVING THE HANDLEBAR..............................................................4-70
CHECKING THE HANDLEBAR ..............................................................4-70
INSTALLING THE HANDLEBAR ............................................................4-71
ASSEMBLING THE UPPER HANDLEBAR COVER ASSEMBLY ..........4-72
INSTALLING THE UPPER HANDLEBAR COVER ASSEMBLY.............4-73

Page 98

FRONT FORK................................................................................................4-74
REMOVING THE FRONT FORK LEGS..................................................4-76
DISASSEMBLING THE FRONT FORK LEGS........................................4-76
CHECKING THE FRONT FORK LEGS ..................................................4-77
ASSEMBLING THE FRONT FORK LEGS..............................................4-77
INSTALLING THE FRONT FORK LEGS ................................................4-80

STEERING HEAD..........................................................................................4-81
REMOVING THE LOWER BRACKET.....................................................4-83
CHECKING THE STEERING HEAD.......................................................4-83
INSTALLING THE STEERING HEAD.....................................................4-84

REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM...................4-85
REMOVING THE SWINGARM................................................................4-87
MAINTENANCE OF THE REAR WHEEL SENSOR ...............................4-87
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ...................4-87
CHECKING THE SWINGARM ................................................................4-88
INSTALLING THE SWINGARM ..............................................................4-88

Page 99

EAS20026
GENERAL CHASSIS (1)

Removing the battery

3

1
2

4

6

5

Order
Job/Parts to remove
Q’ty
Remarks

Seat
Open.

1
Battery cover
1

2
Negative battery lead
1
Disconnect.

3
Positive battery lead
1
Disconnect.

4
Battery
1

5
CCU (Communication Control Unit)
1

6
Smart key unit
1

4-1

GENERAL CHASSIS (1)

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

Service Manual Yamaha NMAX GPD155 A

Manual Terkait Lainnya