STARTING AND BREAK-IN
1-30
EAS2GBB048
STARTING AND BREAK-IN
EAS2GBB049FUEL
Always use the recommended fuel as stated
below. Also, be sure to use new gasoline the
day of a race.
ECA
NOTICE
Use only unleaded gasoline. The use of
leaded gasoline will cause severe damage
to the engine internal parts such as valves,
piston rings, and exhaust system, etc.
TIP
Your Yamaha engine has been designed to use
premium unleaded gasoline with a pump oc-
tane number [(R+M)/2] of 91 or higher, or a re-
search octane number of 95 or higher. If
knocking (or pinging) occurs, use a gasoline of
a different brand.
EWA
WARNING
• For refueling, be sure to stop the engine
and use enough care not to spill any fuel.
Also be sure to avoid refueling close to a
fire.
• Refuel after the engine, exhaust pipe, etc.
have cooled off.
Gasohol (For USA and Canada)
There are two types of gasohol: gasohol con-
taining ethanol and that containing methanol.
Gasohol containing ethanol can be used if the
ethanol content does not exceed 10%. Gasohol
containing methanol is not recommended by
Yamaha because it can cause damage to the
fuel system or vehicle performance problems.
EAS2GBB050HANDLING NOTEEWA
WARNING
Never start or run the engine in a closed ar-
ea. The exhaust fumes are poisonous; they
can cause loss of consciousness and death
in a very short time. Always operate the ma-
chine in a well-ventilated area.
ECA
NOTICE
• Unlike a two-stroke engine, this engine
cannot be kick started when the throttle is
open because the kickstarter may kick
back. Also, if the throttle is open the air/
fuel mixture may be too lean for the engine
to start.
• Before starting the machine, perform the
checks in the pre-operation check list.
EAS2GBB051AIR FILTER MAINTENANCE
According to “CLEANING THE AIR FILTER
ELEMENT” section in the CHAPTER 3, apply
the Yamaha foam air filter oil or other quality
foam air filter oil to the element. (Excess oil in
the element may adversely affect engine start-
ing.)
EAS2GBB052STARTING A COLD ENGINEECA
NOTICE
For maximum engine life, never accelerate
hard when the engine is cold!
In order for the ignition circuit cut-off system to
enable starting, one of the following conditions
must be met:
• The transmission is in the neutral position.
• The transmission is in gear with the clutch le-
ver pulled.
1. Pull the starter knob/idle screw “1” to its full
length.
TIP
When the ambient temperature is 15°C (59°F)
or below, use the starter knob/idle screw.
2. Completely close the throttle. Recommended fuel
Premium unleaded gasoline
only
Fuel tank capacity
7.5 L (2.0 US gal, 1.7 lmp.gal)
Fuel reserve amount
2.1 L (0.55 US gal, 0.46 lmp.gal)
1
ENGINE SPECIFICATIONS
2-2
EAS2GBB062
ENGINE SPECIFICATIONS
Engine
Engine type Liquid cooled 4-stroke, DOHC
Displacement 250 cm
3
Number of cylinders Single cylinder
Bore stroke 77.0 53.6 mm (3.03 2.11 in)
Compression ratio 13.5:1
Starting system Electric starter and kickstarter
Fuel
Recommended fuel Premium unleaded gasoline only
Fuel tank capacity 7.5 L (2.0 US gal, 1.7 Imp.gal)
Fuel reserve amount 2.1 L (0.55 US gal, 0.46 lmp.gal)
Engine oil
Lubrication system Wet sump
Recommended brand YAMALUBE
Type SAE 10W-40, SAE 10W-50, SAE 15W-40,
SAE 20W-40 or SAE 20W-50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Engine oil quantity
Quantity (disassembled) 1.10 L (1.16 US qt, 0.97 Imp.qt)
Oil change 0.83 L (0.88 US qt, 0.73 Imp.qt)
With oil filter removal 0.85 L (0.90 US qt, 0.75 Imp.qt)
Oil filter
Oil filter type Paper
Bypass valve opening pressure 40.0–80.0 kPa (0.40–0.80 kgf/cm
2,
5.8–11.6 psi)
Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance 0.000–0.150 mm (0.0000–0.0059 in)
Limit 0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing clearance 0.13–0.18 mm (0.0051–0.0071 in)
Limit 0.25 mm (0.0098 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.06–0.11 mm (0.0024–0.0043 in)
Limit 0.18 mm (0.0071 in)
Cooling system
Radiator (including all routes) 1.00 L (1.06 US qt, 0.88 Imp.qt)
Radiator capacity 0.56 L (0.59 US qt, 0.49 Imp.qt)
Radiator cap valve opening pressure 107.9–137.3 kPa (1.08–1.37 kg/cm
2,
15.6–19.9 psi)
Radiator core
Width 112.6 mm (4.43 in)
Height 235.0 mm (9.25 in)
Depth 28.0 mm (1.10 in)
Water pump
Water pump type Single suction centrifugal pump
Spark plug(s)
Manufacturer/model NGK/LMAR8G
Spark plug gap 0.7–0.8 mm (0.028–0.031 in)
ENGINE SPECIFICATIONS
2-5
Clutch
Clutch type Wet, multiple-disc
Clutch release method Inner push, cam push
Clutch lever free play 7.0–12.0 mm (0.28–0.47 in)
Friction plate 1 thickness 2.90–3.10 mm (0.114–0.122 in)
Wear limit 2.85 mm (0.112 in)
Plate quantity 4 pcs
Friction plate 2 thickness 2.90–3.10 mm (0.114–0.122 in)
Wear limit 2.85 mm (0.112 in)
Plate quantity 5 pcs
Clutch plate thickness 1.10–1.30 mm (0.043–0.051 in)
Plate quantity 8 pcs
Warpage limit 0.10 mm (0.004 in)
Clutch spring free length 47.80 mm (1.88 in)
Limit 45.41 mm (1.79 in)
Spring quantity 5 pcs
Push rod bending limit 0.30 mm (0.012 in)
Transmission
Transmission type Constant mesh 6-speed
Primary reduction system Spur gear
Primary reduction ratio 3.353 (57/17)
Final drive Chain
Secondary reduction ratio 3.846 (50/13)
Operation Left foot operation
Gear ratio
1st 2.385 (31/13)
2nd 1.813 (29/16)
3rd 1.444 (26/18)
4th 1.143 (24/21)
5th 0.957 (22/23)
6th 0.815 (22/27)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Shifting mechanism
Shift mechanism type Shift drum and guide bar
Shift fork guide bar bending limit 0.050 mm (0.0020 in)
Shift fork thickness 4.85 mm (0.1909 in)
Decompression device
Device type Auto decomp
Air filter
Air filter element Wet element
Air filter oil grade Yamaha foam air filter oil or other quality foam
air filter oil
Fuel pump
Pump type Electrical
Fuel injector
Model/quantity 30NA-FZ31/1
Resistance 12.0
ENGINE SPECIFICATIONS
2-6
Throttle body
Type/quantity 30RA-A95R/1
ID mark 2GB1 00
Fuel line pressure (at idle) 300.0–390.0 kPa (3.00–3.90 kgf/cm
2,
43.5–56.6 psi)
Throttle position sensor
Resistance 6.30 k
Output voltage (at idle) 0.48–0.52 V
Fuel injection sensor
Crankshaft position sensor resistance 228–342
Intake air pressure sensor output voltage 3.61–3.67 V at 101.3 kPa (3.61–3.67 V at
1.01 kgf/cm
2, 3.61–3.67 V at 14.7 psi)
Intake air temperature sensor resistance 5400.0–6600.0 at 0 °C (5400.0–6600.0
at 32 °F)
289–391 at 80 °C (289–391 at 176 °F)
Coolant temperature sensor resistance 2512–2777 at 20 °C (2512–2777 at 68 °F)
210–220 at 100 °C (210–220 at 212 °F)
Idling condition
Engine idling speed 1900–2100 r/min
CO% 3.0–4.0 % (USA) (CAN)
Intake vacuum 27.3 kPa (205 mmHg, 8.1 inHg) (USA) (CAN)
Water temperature 70–90 °C (158–194 °F)
Oil temperature 70–80 °C (158–176 °F)
Throttle grip free play 3.0–6.0 mm (0.12–0.24 in)
ELECTRICAL SPECIFICATIONS
2-10
EAS2GBB064
ELECTRICAL SPECIFICATIONS
Voltage
System voltage 12 V
Ignition system
Ignition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 10.0 ° at 2000 r/min
Engine control unit
Model/manufacturer 2GB0/YAMAHA (USA) (CAN)
2GB1/YAMAHA (EUR) (AUS) (NZL) (ZAF)
Ignition coil
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 2.16–2.64
Secondary coil resistance 8.64–12.96 k
Spark plug cap
Resistance 7.50–12.50 k
Lean angle sensor output voltage
Operating angle 45 °
Output voltage up to operating angle 0.4–1.4 V
Output voltage over operating angle 3.7–4.4 V
AC magneto
Standard output 14.0 V, 160 W at 5000 r/min
Stator coil resistance 0.528–0.792 (W–W)
Rectifier/regulator
Regulator type Three-phase
Regulated voltage (DC) 14.1–14.9 V
Rectifier capacity (DC) 35.0 A
Battery
Model YTZ7S (F)
Voltage, capacity 12 V, 6.0 Ah (10 HR)
Specific gravity 1.31
Manufacturer GS YUASA
Ten hour rate charging current 0.60 A
Headlight
Bulb type Halogen bulb
Bulb voltage, wattage quantity
Headlight HS1, 35.0 W/35.0 W 1
Tail/brake light LED
Meter lighting EL (Electroluminescent)
Indicator light
Fuel level warning light 12 V, 1.7 W 1
Engine trouble warning light 12 V, 1.7 W 1
Electric starting system
System type Constant mesh
ELECTRICAL SYSTEM
3-40
EAS2GBB130
ELECTRICAL SYSTEM
EAS2GBB131CHECKING THE SPARK PLUG
1. Remove:
• Seat
• Air scoop (left/right)
Refer to “GENERAL CHASSIS” on page 5-
1.
• Fuel tank “1”
Refer to “FUEL TANK” on page 8-1.
ECA
NOTICE
Do not use too much force to pull the hose.
TIP
Remove the fuel tank, turn this 180 ° clockwise,
and put it in the frame “2” as shown.
2. Remove:
• Spark plug cap
• Spark plug
Refer to “CAMSHAFT” on page 6-12.
ECA
NOTICE
In order not to allow the dirt accumulated
around the spark plug to drop from the
spark plug hole into the cylinder, clean it be-
fore removing the spark plug.
3. Check:
• Spark plug type
Wrong type Replace.
4. Check:
• Electrode
Damage/wear Replace the spark plug.
• Insulator
Abnormal color Replace the spark plug.
Normal color is medium-to-light tan.
5. Clean:
• Spark plug
(with a spark plug cleaner or a wire brush)6. Measure:
• Spark plug gap “a”
Out of specification Adjust the spark plug
gap.
7. Install:
• Spark plug
TIP
Before installing the spark plug, clean the spark
plug and gasket surface.
8. Install:
• Spark plug cap
• Fuel tank
• Air scoop (left/right)
• Seat
• Side cover (left/right)
Refer to “GENERAL CHASSIS” on page 5-
1.
EAS2GBB132CHECKING THE IGNITION TIMING
1. Remove:
• Timing mark accessing screw “1”
2. Attach:
• Timing light “1”
• Digital tachometer “2”
To the high tension code “3”. Manufacturer/model
NGK/LMAR8G
1
1
2
Spark plug gap
0.7–0.8 mm (0.028–0.031 in)
Spark plug
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
T R..
1
FUEL INJECTION SYSTEM
9-31
ECU detects an abnormal signal from a sensor
If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu-
minates the engine trouble warning light and provides the engine with alternate operating instructions
that are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue operating or stop operating, depending on the conditions.
EAS2GBB375TROUBLESHOOTING METHOD
The engine operation is not normal and the engine trouble warning light comes on.
1. Check:
• Fault code number
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a. Connect the Yamaha diagnostic tool. Refer to “YAMAHA DIAGNOSTIC TOOL” on page 9-32.
b. Check the fault code number displayed on the Yamaha diagnostic tool.
c. Identify the faulty system with the fault code number.
d. Identify the probable cause of the malfunction.
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2. Check and repair the probable cause of the malfunction.
3. Perform the reinstatement action for the fuel injection system. Refer to “Confirmation of service
completion” in the appropriate table in “TROUBLESHOOTING DETAILS” on page 9-35.
4. After pushing the engine stop switch, push the start switch to check whether the fault code number
is displayed.
TIP
If another fault code number is displayed, repeat steps (1) to (4) until no fault code number is dis-
played.
5. Erase the malfunction history in the diagnostic mode. Refer to “SENSOR OPERATION TABLE”
(Diagnostic code No.62).
TIP
Turning off the meter light will not erase the malfunction history.
The engine operation is not normal, but the engine trouble warning light does not come on.
1. Check the operation of the following sensors and actuators in the diagnostic mode. Refer to
“TROUBLESHOOTING DETAILS” on page 9-35.
If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors and actuators, check and repair the inner parts of the
engine.Fault code No. No fault code No.
Check and repair. Refer to “TROUBLESHOOT-
ING DETAILS” on page 9-35.
Monitor the operation of the sensors and actua-
tors in the diagnostic mode. Refer to “TROU-
BLESHOOTING DETAILS” on page 9-35 and
“LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE
ACTIONS” on page 10-5.Check and repair.
01: Throttle position sensor signal (throttle angle)
30: Ignition coil
36: Injector
FUEL INJECTION SYSTEM
9-34
Operation of the Yamaha diagnostic tool (Malfunction mode)
Malfunction results are displayed in the top part of the window area.
1. Recovered
The item list of the malfunction detected in the past (already recovered) are displayed.
2. Detected
The item list of the malfunction currently occurred are displayed.
3. Code
The following icons and the fault code numbers for the detected malfunctions are displayed.
4. ECU
The types of the control units are displayed.
5. Item
The item names of the detected malfunction are displayed.
A. Detected malfunction
B. Recovered malfunction
23
1
456789101112
AB