33D-9-11_cover 2010.5.25 11:08 ページ 1 PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories 2011 q Read this manual carefully before operating this vehicle. YZ450FA OWNER’S SERVICE MANUAL 2011 YZ450FA PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN JAPAN 2010.05—0.
33D-9-10_cover 09.7.16 13:11 ページ 2 Q Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
YZ450FA OWNER'S SERVICE MANUAL ©2010 by Yamaha Motor Corporation, U.S.A. 1st Edition, May 2010 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan P/N.
INTRODUCTION Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha's vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader. This manual explains operation, inspection, basic maintenance and tuning of your machine. If you have any questions about this manual or your machine, please contact your Yamaha dealer.
SAFETY INFORMATION THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding. • THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY. Do not attempt to operate this machine at maximum power until you are totally familiar with its characteristics.
YAMAHA MOTOR CORPORATION, U.S.A.
HOW TO USE THIS MANUAL FINDING THE REQUIRED PAGE 1. This manual consists of eight chapters; "General Information", "Specifications", "Regular inspection and adjustments", "Engine", "Chassis", "Fuel system", "Electrical" and "Tuning". 2. The table of contents is at the beginning of the manual. Look over the general layout of the book before finding then required chapter and item.
HOW TO READ DESCRIPTIONS To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 1. An easy-to-see exploded diagram "1" is provided for removal and disassembly jobs. 2. Numbers "2" are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step. 3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks "3".
ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols "1" to "7" are used to identify the specifications appearing in the text. 1. With engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening 6. Specified value, Service limit 7. Resistance (Ω), Voltage (V), Electric current (A) Illustrated symbols "8" to "13" in the exploded diagrams indicate grade of lubricant and location of lubrication point. 8. Apply engine oil 9. Apply molybdenum disulfide oil 10. Apply brake fluid 11.
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TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE 4 CHASSIS 5 FUEL SYSTEM 6 ELECTRICAL 7 TUNING 8
CONTENTS CHAPTER 1 GENERAL INFORMATION LOCATION OF IMPORTANT LABELS ..... 1-1 DESCRIPTION ........................................... 1-2 CONSUMER INFORMATION .................... 1-3 FEATURES ................................................ 1-4 INCLUDED PARTS .................................... 1-6 IMPORTANT INFORMATION .................... 1-8 HANDLING THE ELECTRONIC PARTS ..................................................... 1-10 CHECKING OF CONNECTION ............... 1-10 SPECIAL TOOLS.................
CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS.................... 3-1 PRE-OPERATION INSPECTION AND MAINTENANCE ......................................... 3-6 ENGINE ...................................................... 3-7 CHASSIS.................................................. 3-20 ELECTRICAL ........................................... 3-37 TROUBLESHOOTING ............................. 3-39 CHAPTER 4 ENGINE SEAT AND SIDE COVERS........................ 4-1 EXHAUST PIPE AND SILENCER .
CHAPTER 5 CHASSIS FRONT WHEEL AND REAR WHEEL ....... 5-2 FRONT BRAKE AND REAR BRAKE........ 5-9 FRONT FORK .......................................... 5-23 HANDLEBAR ........................................... 5-36 STEERING ............................................... 5-42 SWINGARM ............................................. 5-47 REAR SHOCK ABSORBER .................... 5-54 CHAPTER 6 FUEL SYSTEM FUEL TANK ............................................... 6-2 THROTTLE BODY ...............................
LOCATION OF IMPORTANT LABELS GENERAL INFORMATION LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle. 1 For use only on a closed course in sanctioned competition. This motorcycle does not meet EPA noise and emissions standards and is not for general off-road recreational riding. Premium unleaded gasoline only. 3FB-2415E-02 17D-2812P-00 WARNING This unit contains high pressure nitrogen gas. Mishandling can cause explosion.
DESCRIPTION DESCRIPTION 1. 2. 3. 4. 5. 6. 7. 8. 9. Clutch lever Front brake lever Throttle grip Radiator cap Fuel tank cap Engine stop switch Kickstarter crank Fuel tank Radiator 10. 11. 12. 13. 14. 15. 16. 17. 18. Coolant drain bolt Rear brake pedal Valve joint Air cleaner Drive chain Shift pedal Oil level check window Starter knob/idle screw Front fork • The machine you have purchased may differ slightly from those shown in the following.
CONSUMER INFORMATION CONSUMER INFORMATION There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine. VEHICLE IDENTIFICATION NUMBER The vehicle identification number "1" is stamped on the right of the steering head pipe.
FEATURES FEATURES OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature.Inthe conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustionchamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
FEATURES FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kgf/cm ² , 47.0 psi). Accordingly,when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
INCLUDED PARTS INCLUDED PARTS NIPPLE WRENCH This nipple wrench "1" is used to tighten the spoke. DETACHABLE SIDESTAND This sidestand "1" is used to support only the machine when standing or transporting it. • Never apply additional force to the sidestand. • Remove this sidestand before starting out. HANDLEBAR PROTECTOR Install the handlebar protector "1" so that the mark "a" face forward. VALVE JOINT This valve joint "1" prevents fuel from flowing out and is installed to the fuel tank breather hose.
INCLUDED PARTS FUEL HOSE JOINT COVER The fuel hose joint covers "1" are used to prevent mud, dust, and other foreign material from entering the fuel pump when the fuel hose is disconnected. COUPLER FOR CONNECTING OPTIONAL PART This coupler "1" is used for connection to an optional Power Tuner and so on. When no optional parts, etc. are connected, connect the connection terminal to the original coupler "2". Before removing the coupler, thoroughly wipe off any mud or water stuck to it.
IMPORTANT INFORMATION IMPORTANT INFORMATION 3. When disassembling the machine, keep mated parts together. They include gears, cylinders, pistons, and other mated parts that have been "mated" through normal wear. Mated parts must be reused as an assembly or replaced. PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. • When washing the machine with high pressured water, cover the parts follows.
IMPORTANT INFORMATION LOCK WASHERS/PLATES AND COTTER PINS 1. All lock washers/plates "1" and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened. CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips.
HANDLING THE ELECTRONIC PARTS HANDLING THE ELECTRONIC PARTS Electronic parts are very sensitive. Handle with care and do not give impact. 3. Check: • All connections Loose connection → Connect properly. If the pin "1" on the terminal is flattened, bend it up. • Mankind has static electricity. It`s voltage is very high and electronic parts are very sensitive. • It is possible that inner small components of electronic parts are destroyed by static electricity. • Do not touch and do not make them dirty.
CHECKING OF CONNECTION REMOVING THE QUICK FASTENER 5. Check: • Continuity (with the pocket tester) Do not push the center pin with too much force. Otherwise, the center pin could be damaged. Pocket tester: 90890-03112 Analog pocket tester: YU-03112-C To remove a quick fastener, push the center pin in with a screwdriver, then pull the fastener out. • If there is no continuity, clean the terminals. • When checking the wire harness, perform steps (1) to (5).
SPECIAL TOOLS SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order. • For U.S.A. and Canada, use part number starting with "YM-", "YU-" or "ACC-".
SPECIAL TOOLS Tool name/Part number How to use Steering nut wrench YU-33975, 90890-01403 This tool is used when tighten the steering ring nut to specification. Cap bolt wrench YM-01500, 90890-01500 This tool is used to loosen or tighten the base valve. Cap bolt ring wrench YM-01501, 90890-01501 This tool is used to loosen or tighten the damper assembly. Fork seal driver YM-A0948, 90890-01502 This tool is used when install the fork oil seal.
SPECIAL TOOLS Tool name/Part number How to use Pressure gauge. YU-03153, 90890-03153 This tool is used to measure the fuel pressure. FI diagnostic tool YU-03182, 90890-03182 This tool is used to check the fault codes and diagnose any problems. Fuel pressure adapter YM-03186, 90890-03186 This tool is used to attach the pressure gauge.
SPECIAL TOOLS Tool name/Part number How to use Clutch holding tool YM-91042, 90890-04086 This tool is used to hold the clutch when removing or installing the clutch boss securing nut. Valve guide remover 5.5 mm (0.22 in) YM-01122 This tool is needed to remove and install the valve guide. Valve guide installer 5.5 mm (0.22 in) YM-04015 This tool is needed to install the valve guide. Valve guide reamer 5.5 mm (0.22 in) YM-01196 This tool is needed to rebore the new valve guide.
SPECIAL TOOLS Tool name/Part number How to use Dynamic spark tester YM-34487 Ignition checker 90890-06754 This instrument is necessary for checking the ignition system components. Digital tachometer YU-39951-B, 90890-06760 This tool is needed for observing engine rpm. YAMAHA Bond No. 1215 (ThreeBond® No. 1215) 90890-85505 This sealant (Bond) is used for crankcase mating surface, etc.
CONTROL FUNCTIONS CONTROL FUNCTIONS KICKSTARTER CRANK Rotate the kickstarter crank "1" away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine. This model has a primary kickstarter crank so the engine can be started in any gear if the clutch is disengaged. In normal practices, however, shift to neutral before starting. ENGINE STOP SWITCH The engine stop switch "1" is located on the left handlebar.
CONTROL FUNCTIONS REAR BRAKE PEDAL The rear brake pedal "1" is located on the right side of the machine. Press down on the brake pedal to activate the rear brake. STARTER KNOB/IDLE SCREW The starter knob/idle screw "1" is used when starting a cold engine. Pull the starter knob/idle screw out to open the circuit for starting. When the engine has warmed up, push it in to close the circuit.
STARTING AND BREAK-IN STARTING AND BREAK-IN FUEL Always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race. • 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.
STARTING AND BREAK-IN 6. When the engine starts running, warm it up one or two minutes at a steady speed (of 3,000 to 5,000 r/min), and then return the starter knob/ idle screw to its original position. BREAK-IN PROCEDURES 1. Before starting the engine, fill the fuel tank with the fuel. 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the engine stop switch.
TORQUE-CHECK POINTS TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and fuel tank Fuel tank to frame Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Steering stem to handlebar Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar Suspension Front Steering stem to front fork Front fork to upper bracket Front fork to lower bracket Rear For link type Assembly of link
CLEANING AND STORAGE CLEANING AND STORAGE STORAGE If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as follows: 1. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating. 2. Remove the spark plug, pour a tablespoon of SAE 10W-40 motor oil in the spark plug hole, and reinstall the plug.
GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: YZ450FA (USA, CDN, AUS) YZ450F (EUROPE, NZ, ZA) Model code number: 33D5 (USA,CDN) 33D6 (EUROPE) 33D8 (AUS, NZ, ZA) Dimensions: USA, CDN EUROPE 2,191 mm (86.26 in) AUS, NZ, ZA Overall length 2,193 mm (86.34 in) Overall width 825 mm (32.48 ← in) ← Overall height 1,311 mm (51.61 in) ← Seat height 999 mm (39.33 ← in) 998 mm (39.29 in) Wheelbase 1,492 mm (58.74 in) ← Minimum ground clearance 383 mm (15.
GENERAL SPECIFICATIONS Oil capacity: Engine oil Periodic oil change 0.95 L (0.84 Imp qt, 1.00 US qt) With oil filter replacement 1.0 L (0.88 Imp qt, 1.06 US qt) Total amount 1.2 L (1.06 Imp qt, 1.27 US qt) Coolant capacity (including all routes): 1.13 L (0.99 Imp qt, 1.19 US qt) Air filter: Wet type element Fuel: Type Premium unleaded gasoline only. Tank capacity 6.2 L (1.40 Imp gal, 1.
GENERAL SPECIFICATIONS Chassis: USA, CDN EUROPE AUS, NZ, ZA Frame type Semi double cradle ← ← Caster angle 26.9° 26.8° 26.9° Trail 118.6 mm (4.67 in) 117.5 mm (4.63 in) 119.0 mm (4.69 in) Tire: Type With tube Size (front) 80/100-21 51M Size (rear) 120/80-19 63M (For USA, CDN, AUS, NZ, ZA) 110/90-19 62M (For EUROPE) Tire pressure (front and rear) 100 kPa (1.
MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.05 mm (0.002 in) Cylinder: Bore size 97.00–97.01 mm (3.8189–3.8193 ---in) Out of round limit ---- 0.05 mm (0.002 in) Drive method Chain drive (Left) ---- Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in) ---- Camshaft outside diameter 21.959–21.972 mm (0.8645–0.8650 in) ---- Shaft-to-cap clearance 0.028–0.062 mm (0.0011–0.0024 0.08 mm in) (0.
MAINTENANCE SPECIFICATIONS Item Camshaft runout limit Standard Limit ---- 0.03 mm (0.0012 in) Timing chain type/No. of links 98XRH2010-122M/122 ---- Timing chain adjustment method Automatic ---- Timing chain: Valve, valve seat, valve guide: Valve clearance (cold) IN 0.10–0.15 mm (0.0039–0.0059 in) ---- EX 0.20–0.25 mm (0.0079–0.0098 in) ---- Valve dimensions: "A" head diameter (IN) 35.9–36.1 mm (1.4134–1.4213 in) ---- "A" head diameter (EX) 29.9–30.1 mm (1.1772–1.
MAINTENANCE SPECIFICATIONS Item Standard Limit "D" margin thickness (IN) 1.3 mm (0.0512 in) ---- "D" margin thickness (EX) 1.0 mm (0.0394 in) ---- Stem outside diameter (IN) 5.475–5.490 mm (0.2156–0.2161 5.445 mm in) (0.2144 in) Stem outside diameter (EX) 5.465–5.480 mm (0.2152–0.2157 5.435 mm in) (0.2140 in) Guide inside diameter (IN) 5.500–5.512 mm (0.2165–0.2170 5.550 mm in) (0.2185 in) Guide inside diameter (EX) 5.500–5.512 mm (0.2165–0.2170 5.550 mm in) (0.
MAINTENANCE SPECIFICATIONS Item Standard Limit Tilt limit* (IN) ---- 2.5°/1.8 mm (2.5°/0.071 in) Tilt limit* (EX) ---- 2.5°/1.6 mm (2.5°/0.063 in) Direction of winding (top view) (IN) Clockwise ---- Direction of winding (top view) (EX) Clockwise ---- Piston: Piston to cylinder clearance 0.020–0.045 mm (0.0008–0.0018 0.1 mm in) (0.004 in) Piston size "D" 96.965–96.980 mm (3.8175–3.8181 in) ---- Measuring point "H" 9.0 mm (0.
MAINTENANCE SPECIFICATIONS Item Standard Limit 2nd ring: Type Taper ---- Dimensions (B × T) 1.00 × 3.10 mm (0.04 × 0.12 in) ---- End gap (installed) 0.35–0.50 mm (0.014–0.020 in) 0.85 mm (0.033 in) Side clearance 0.020–0.060 mm (0.0008–0.0024 0.120 mm in) (0.0047 in) Oil ring: Dimensions (B × T) 1.5 × 2.55 mm (0.06 × 0.10 in) ---- End gap (installed) 0.20–0.50 mm (0.008–0.020 in) ---- Crankshaft: Crank width "A" 61.95–62.00 mm (2.439–2.441 in) ---- Runout limit "C" 0.03 mm (0.
MAINTENANCE SPECIFICATIONS Item Clutch spring free length Quantity Standard Limit 50.0 mm (1.97 in) 49.0 mm (1.93 in) 6 ---- Clutch housing thrust clearance 0.10–0.35 mm (0.0039–0.0138 in) ---- Clutch housing radial clearance 0.010–0.044 mm (0.0004–0.0017 ---in) Clutch release method Inner push, cam push ---- Shifter type Cam drum and guide bar ---- Guide bar bending limit ---- 0.05 mm (0.002 in) Kick and ratchet type ---- 324 kPa (3.24 kg/cm2, 46.
MAINTENANCE SPECIFICATIONS Item Standard Limit Lubrication system: Oil filter type Paper type ---- Oil pump type Trochoid type ---- Tip clearance 0.12 mm or less (0.0047 in or less) 0.20 mm (0.008 in) Side clearance 0.09–0.17 mm (0.0035–0.0067 in) 0.24 mm (0.009 in) Housing and rotor clearance 0.03–0.10 mm (0.0012–0.0039 in) 0.17 mm (0.007 in) Bypass valve setting pressure 40–80 kPa (0.4–0.8 kg/cm2, 5.69–11.38 psi) ---- Width 121.4 mm (4.78 in) ---- Height 235 mm (9.
MAINTENANCE SPECIFICATIONS Item Rear suspension: Shock absorber travel Spring free length Fitting length Preload length Spring rate, STD Optional spring Enclosed gas pressure Swingarm: Swingarm free play limit End Wheel: Front wheel type Rear wheel type Front rim size/material Rear rim size/material Rim runout limit: Radial Lateral Standard EUROPE, AUS, NZ, ZA 132.0 mm (5.20 in) ← 260 mm (10.24 in) ← Limit USA, CDN 252 mm (9.92 in) 253 mm (9.96 in) 1.5–18 mm (0.06–0.71 in) K = 56.
MAINTENANCE SPECIFICATIONS Item Standard Limit Rear disc brake: Disc outside dia.×Thickness 245 × 4.0 mm (9.65 × 0.16 in) 245 × 3.5 mm (9.65 × 0.14 in) Deflection limit ---- 0.15 mm (0.006 in) Pad thickness 6.4 mm (0.25 in) 1.0 mm (0.04 in) Master cylinder inside dia. 11.0 mm (0.433 in) ---- Caliper cylinder inside dia. 25.4 mm (1.000 in) × 1 ---- Brake fluid type DOT #4 ---- 95 mm (3.
TIGHTENING TORQUES TIGHTENING TORQUES ENGINE △ - marked portion shall be checked for torque tightening after break-in or before each race. Part to be tightened Thread size Q'ty M10S × 1.0 Camshaft cap Tightening torque Nm m•kg ft•lb 1 13 1.3 9.4 M6 × 1.0 8 10 1.0 7.2 Cylinder head blind plug screw M12 × 1.0 2 28 2.8 20 Oil passage plug M8 × 1.25 1 15 1.5 11 Cylinder head (stud bolt) M6 × 1.0 3 7 0.7 Spark plug Cylinder head (bolt) M10 × 1.
TIGHTENING TORQUES Part to be tightened Thread size Q'ty Coolant drain bolt M6 × 1.0 Oil pump cover Tightening torque Nm m•kg ft•lb 1 10 1.0 7.2 M4 × 0.7 1 2 0.2 1.4 Oil pump M6 × 1.0 2 10 1.0 7.2 Oil pump drive gear shaft M6 × 1.0 1 10 1.0 7.2 Oil filter element cover M6 × 1.0 2 10 1.0 7.2 Oil pressure check bolt M6 × 1.0 2 10 1.0 7.2 Crankshaft end accessing screw M36 × 1.5 1 10 1.0 7.2 Timing mark accessing screw M14 × 1.5 1 6 0.6 4.
TIGHTENING TORQUES *1: Tighten the cylinder head bolts to 30 Nm (3.0 m•kg, 22 ft•lb) in the proper tightening sequence, remove and retighten the cylinder head bolts to 20 Nm (2.0 m•kg, 14 ft•lb) in the proper tightening sequence, and then tighten the cylinder head bolts further to reach the specified angle 150° in the proper tightening sequence. CHASSIS △ - marked portion shall be checked for torque tightening after break-in or before each race.
TIGHTENING TORQUES Part to be tightened Thread size Q'ty △ Front wheel axle holder M8 × 1.25 △ Front brake disc and wheel hub △ Rear brake disc and wheel hub Tightening torque Nm m•kg ft•lb 4 21 2.1 15 M6 × 1.0 6 12 1.2 8.7 M6 × 1.0 6 14 1.4 10 △ Footrest bracket and frame M10 × 1.25 4 55 5.5 40 △ Brake pedal mounting M8 × 1.25 1 26 2.6 19 M6 × 1.0 1 6 0.6 4.3 M6 × 1.0 2 10 1.0 7.2 M4 × 0.7 2 2 0.2 1.4 △ Rear brake hose union bolt (brake caliper) M10 × 1.
TIGHTENING TORQUES Part to be tightened Thread size Q'ty M10 × 1.25 Tightening torque Nm m•kg ft•lb 1 20 2.0 14 M6 × 1.0 2 9 0.9 6.5 M6 × 1.0 4 7 0.7 5.1 M6 × 1.0 2 9 0.9 6.5 M6 × 1.0 2 7 0.7 5.1 M5 × 0.8 6 4 0.4 2.9 Fuel tank side cover M6 × 1.0 4 7 0.7 5.1 Fuel tank and seat set bracket M6 × 1.0 1 7 0.7 5.1 Fuel tank and fuel tank bracket M6 × 1.0 4 7 0.7 5.1 Seat M8 × 1.25 2 22 2.2 16 M6 × 1.0 4 7 0.7 5.1 M5 × 0.8 2 4 0.4 2.
TIGHTENING TORQUES ELECTRICAL Part to be tightened Thread size Q'ty Stator M5 × 0.8 Rotor Tightening torque Nm m•kg ft•lb 3 8 0.8 5.8 M12 × 1.25 1 65 6.5 47 Crankshaft position sensor M6 × 1.0 2 10 1.0 7.2 Throttle position sensor M5 × 0.8 1 3 0.3 2.2 Injector M5 × 0.8 2 3 0.3 2.2 Ignition coil M5 × 0.8 2 4 0.4 2.9 M10 × 1.25 1 16 1.6 11 Rectifier/regulator M6 × 1.0 2 7 0.7 5.1 Ignition coil bracket M6 × 1.0 2 10 1.0 7.
TIGHTENING TORQUES GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature. A.
TIGHTENING TORQUES DEFINITION OF UNITS Unit mm cm Read millimeter centimeter kg kilogram Definition 10-3 meter Measure Length -2 10 meter Length 3 10 gram Weight 2 N Newton 1 kg × m/sec Nm Newton meter N×m Torque m•kg Meter kilogram m × kg Torque 2 Force Pa Pascal N/m Pressure N/mm Newton per millimeter N/mm Spring rate L Liter — Volume or capacity Cubic centimeter — Volume or capacity Revolution per minute — Engine speed cm 3 r/min 2-20
LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 2-21
LUBRICATION DIAGRAMS 1. Oil strainer 2. Oil check bolt 3. Scavenging pump 4. Oil feed pump 5. Oil filter element 6. Crankshaft 7. Oil nozzle 8. Exhaust camshaft 9. Intake camshaft 10. Main axle 11. Drive axle 12. Oil level check window 13.
CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM 2-23
CABLE ROUTING DIAGRAM 1. 2. 3. 4. 5. Fuel tank breather hose Coupler for connecting optional part Cylinder head breather hose Hose holder Radiator hose 3 A. Insert the end of the fuel tank breather hose into the hole in the steering stem. B. Fit the accessory coupler into the connector to fasten it to the bracket. C. Point the end of the cylinder head breather hose downward. D. Pass the cylinder head breather hose through the hose holder, making sure that the stopper on the hose contacts the holder. E.
CABLE ROUTING DIAGRAM F-F F A A F B E D D C 100mm C E D-D C-C 2-25 B
CABLE ROUTING DIAGRAM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. A. Pass the clutch cable, throttle cables, and engine stop switch lead through the cable holder. Pass the clutch cable through the lower guide only. B. Route the engine stop switch lead to the inside of the clip. C. Fasten the rectifier/regulator lead and engine stop switch lead (wire harness end). D. Insert the projection on the engine stop switch coupler into the hole in the bracket. E.
CABLE ROUTING DIAGRAM G G A-A B-B A A B B F F C-C C C D D E D-D E E-E 2-27
CABLE ROUTING DIAGRAM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. A. B. C. D. E. F. G. H. I.
CABLE ROUTING DIAGRAM 2-29
CABLE ROUTING DIAGRAM 1. 2. 3. 4. 5. 6. 7. 8 9. 10. 11. 12. 13. 14. Ignition coil coupler Coolant temperature sensor lead Atmospheric pressure sensor coupler Intake air temperature sensor lead Clamp Intake air pressure sensor coupler Cover Fuel hose Fuel pump lead Fuel injector coupler Throttle body High tension code Throttle cable AC magneto lead A. Route the fuel pump lead to the outside of the fuel hose and above the cover. B. Route the spark plug wire between the throttle cables and the throttle body.
CABLE ROUTING DIAGRAM 2-31
CABLE ROUTING DIAGRAM 1. Brake master cylinder 2. Brake hose holder 3. Brake hose A. Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the brake caliper. B. Pass the brake hose into the brake hose holders. C. If the brake hose contacts the spring (rear shock absorber), correct its twist. D. Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the brake master cylinder.
CABLE ROUTING DIAGRAM 2-33
CABLE ROUTING DIAGRAM 1. 2. 3. 4. 5. 6. A. Route the clutch cable to the rear of the number plate band. B. Fasten the engine stop switch lead to the handlebar. C. Route the brake hose to the front of the number plate. D. Pass the clutch cable through the cable guide on the number plate.
MAINTENANCE INTERVALS REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS •The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.
MAINTENANCE INTERVALS Item After break-in Every race (about 2.5 hours) Every third (about 7.5 hours) Every fifth (about 12.5 hours) As required Remarks PISTON Inspect ● Inspect crack. Clean ● Inspect carbon deposits and eliminate them. ● Replace the piston, piston pin, piston pin clip, and piston ring all as a set. ● Check ring end gap. ● Replace the piston, piston pin, piston pin clip, and piston ring all as a set.
MAINTENANCE INTERVALS Item After break-in Every race (about 2.5 hours) ● ● Every third (about 7.5 hours) Every fifth (about 12.5 hours) As required Remarks EXHAUST PIPE, SILENCER, PROTECTOR Inspect and retighten Clean ● Replace fiver ●* ● * When the exhaust sound becomes louder or when a performance drop is felt. CRANK Inspect and clean ● ● THROTTLE BODY Inspect ● SPARK PLUG Inspect and clean ● ● Replace ● DRIVE CHAIN Lubricate, slack, alignment Use chain lube.
MAINTENANCE INTERVALS Item After break-in Every race (about 2.5 hours) Every third (about 7.5 hours) Every fifth (about 12.
MAINTENANCE INTERVALS Item After break-in Every race (about 2.5 hours) ● ● Every third (about 7.5 hours) Every fifth (about 12.
PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. GENERAL INSPECTION AND MAINTENANCE Item Routine Page Coolant Check that coolant is filled up to the radiator cap. Check the cooling system for leakage. Fuel Check that a fresh gasoline is filled in the fuel tank. Check the fuel line for leakage. P.
ENGINE ENGINE CHANGING THE COOLANT CHECKING THE COOLANT LEVEL Do not remove the radiator cap when the engine is hot. Do not remove the radiator cap "1", drain bolt and hoses when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, place a thick towel over the radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape.
ENGINE CHECKING THE RADIATOR CAP 1. Inspect: • Seal (radiator cap) "1" • Valve and valve seat "2" Crack/damage → Replace. Exist fur deposits "3" → Clean or replace. • Do not mix more than one type of ethylene glycol antifreeze containing corrosion inhibitors for aluminum engine. • Do not use water containing impurities or oil. CHECKING THE RADIATOR CAP OPENING PRESSURE 1.
ENGINE CHECKING THE COOLING SYSTEM 1. Inspect: • Coolant level 2. Attach: • Radiator cap tester "1" and adapter "2" Radiator cap tester: YU-24460-01/90890-01325 Radiator cap tester adapter: YU-33984/90890-01352 c. Tighten the locknuts. Locknut: 5 Nm (0.5 m•kg, 3.6 ft•lb) 2. Adjust: • Clutch cable free play Refer to "ADJUSTING THE CLUTCH CABLE FREE PLAY". ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: • Clutch lever free play "a" Out of specification → Adjust. 3. Apply the specified pressure.
ENGINE 2. Adjust: • Throttle grip free play • Before adjustment, expose the adjuster by moving the boot "3" and cap "4" away. • Make minute adjustment on the lever side using the adjuster "5". • After adjustment, check proper operation of clutch lever. Throttle grip free play adjustment steps: a. Slide the adjuster cover. b. Loosen the locknut "1". c. Turn the adjuster "2" until the specified free play is obtained. d. Tighten the locknut.
ENGINE 2. Apply: • Lithium soap base grease On the throttle cable end "a". 3. Remove: • Mounting bolt for air filter case cover 4. Loosen and release the binder "1" and lift the air filter case lid. 3. Install: • Throttle grip cap • Screw (throttle grip cap) Hold the air filter case lid by the use of the binder. Screw (throttle grip cap): 4 Nm (0.4 m•kg, 2.
ENGINE b. Clean the air filter element 2 with solvent. 6. Clean: • Air filter element Clean them with solvent. After cleaning, remove the remaining solvent by squeezing the element. After cleaning, remove the remaining solvent by squeezing the element. Do not twist the element when squeezing the element. • Do not twist the element when squeezing the element. • Leaving too much of solvent in the element may result in poor starting. c. Inspect the air filter element 2. Damage → Replace. d.
ENGINE 3. Inspect: • Oil level Make sure that the engine oil level is between the maximum level line "a" and minimum level line "b" shown for the oil level check window. Above the upper limit "a" → Check that no oil comes out when the check bolt "1" for the oil quantity upper limit is removed. If any engine oil comes out, drain it until its last drop is out.
ENGINE Recommended brand: YAMALUBE Recommended engine oil type SAE10W-30, SAE 10W-40, SAE10W-50, SAE 15W-40, SAE 20W-40 or SAE 20W-50 Recommended engine oil grade API service SG type or higher, JASO standard MA Replacement steps: a. Remove the oil filter element cover "1" and oil filter element "2". b. Check the O-rings "3", if cracked or damaged, replace them with a new one. c. Install the oil filter element and oil filter element cover. Oil filter element cover: 10 Nm (1.0 m•kg, 7.
ENGINE 7. Install: • Oil filler cap 8. Inspect: • Engine (for oil leaks) • Oil level CHECKING THE OIL PRESSURE 1. Check: • Oil pressure 2. Use a temperature probe tester "1" and contact it to the drain bolt thread. Oil temperature: 55.0–65.0 °C (131–149°F) Checking steps: a. Slightly loosen the oil pressure check bolt "1". b. Start the engine and keep it idling until oil starts to seep from the oil pressure check bolt. If no oil comes out after one minute, turn the engine off so it will not seize. c.
ENGINE 4. Check: • Valve clearance Out of specification → Adjust. Valve clearance (cold): Intake valve: 0.10–0.15 mm (0.0039–0.0059 in) Exhaust valve: 0.20–0.25 mm (0.0079–0.0098 in) Checking steps: a. Turn the crankshaft counterclockwise with a wrench. b. Align the alignment mark "a" on the rotor with the alignment mark "b" on the crankcase cover. ADJUSTING THE VALVE CLEARANCE • This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g.
ENGINE c. Measure the valve clearance "e" using a feeler gauge "1". Record the measured reading if the clearance is incorrect. c. Select the proper pad using the pad selecting table. Pad range No. 120–No. 240 Pad Availability: 25 increments 1.20 Pads are available in mm–2.40 0.05 mm increments mm The thickness "a" of each pad is indicated in hundredths of millimeters on the pad upper surface. 5. Adjust: • Valve clearance Adjustment steps: a. Remove the camshaft (intake and exhaust).
ENGINE Use the new pad number only as a guide when verifying the valve clearance adjustment. f. Install the new pads "4" and the valve lifters "5". • Apply the engine oil on the valve lifters. • Apply the molybdenum disulfide oil on the valve stem ends. • Valve lifter must turn smoothly when rotated with a finger. • Be careful to reinstall valve lifters and pads in their original place. g. Install the camshafts (exhaust and intake). Refer to "CAMSHAFTS" section in the CHAPTER 4.
ENGINE INTAKE EXHAUST 3-19
CHASSIS CHASSIS d. Place the other end of the tube into a container. e. Slowly apply the brake lever or pedal several times. f. Pull the lever in or push down on the pedal. Hold the lever or pedal in position. g. Loosen the bleed screw and allow the lever or pedal to travel towards its limit. h. Tighten the bleed screw when the lever or pedal limit has been reached; then release the lever or pedal. BLEEDING THE HYDRAULIC BRAKE SYSTEM Bleed the brake system if: • The system has been disassembled.
CHASSIS 2. Remove: • Brake lever cover 3. Adjust: • Brake lever position 2. Adjust: • Brake pedal height Pedal height adjustment steps: a. Loosen the locknut "1". b. Turn the adjusting nut "2" until the pedal height "a" is within specified height. Brake lever position adjustment steps: a. Loosen the locknut "1". b. Turn the adjusting bolt "2" until the lever position "a" is within specified position. • Adjust the pedal height between the maximum "A" and the minimum "B" as shown.
CHASSIS CHECKING AND REPLACING THE FRONT BRAKE PADS 1. Inspect: • Brake pad thickness "a" Out of specification → Replace as a set. d. Remove the pad pin and brake pads "4". Brake pad thickness: 4.4 mm (0.17 in) : 1.0 mm (0.04 in) e. Connect the transparent hose "5" to the bleed screw "6" and place the suitable container under its end. 2. Replace: • Brake pad Brake pad replacement steps: a. Remove the pad pin plug "1". f. Loosen the bleed screw and push the brake caliper piston in.
CHASSIS i. Install the brake caliper "8" and tighten the pad pin "9". Bolt (brake caliper): 28 Nm (2.8 m•kg, 20 ft•lb) Pad pin: 18 Nm (1.8 m•kg, 13 ft•lb) 2. Replace: • Brake pad Brake pad replacement steps: a. Remove the protector "1" and pad pin plug "2". j. Install the pad pin plug "10". Pad pin plug: 2 Nm (0.2 m•kg, 1.4 ft•lb) b. Loosen the pad pin "3". c. Remove the rear wheel "4" and brake caliper "5". Refer to "FRONT WHEEL AND REAR WHEEL" section in the CHAPTER 5. 3.
CHASSIS e. Connect the transparent hose "8" to the bleed screw "9" and place the suitable container under its end. k. Install the pad pin plug "15" and protector "16". Pad pin plug: 2 Nm (0.2 m•kg, 1.4 ft•lb) Bolt (protector): 7 Nm (0.7 m•kg, 5.1 ft•lb) f. Loosen the bleed screw and push the brake caliper piston in. Do not reuse the drained brake fluid. g. Tighten the bleed screw. Bleed screw: 6 Nm (0.6 m•kg, 4.3 ft•lb) h. Install the brake pad "10" and pad pin "11".
CHASSIS 2. Inspect: • Rear brake pad insulator "1" Damage → Replace. CHECKING THE SPROCKET 1. Inspect: • Sprocket teeth "a" Excessive wear → Replace. Replace the drive sprocket, rear wheel sprocket and drive chain as a set. CHECKING THE BRAKE FLUID LEVEL 1. Place the brake master cylinder so that its top is in a horizontal position. 2. Inspect: • Brake fluid level Fluid at lower level → Fill up. CHECKING THE DRIVE CHAIN 1. Measure: • Drive chain length (15 links) "a" Out of specification → Replace.
CHASSIS 2. Remove: • Master link clip • Joint "1" • Drive chain "2" Be sure to install the master link clip to the direction as shown. 3. Clean: • Drive chain Place it in kerosene, and brush off as much dirt as possible. Then remove the drive chain from the kerosene and dry the drive chain. a. Turning direction 6. Lubricate: • Drive chain Drive chain lubricant: SAE 10W-40 motor oil or suitable chain lubricants 4. Check: • Drive chain stiffness "a" Clean and oil the drive chain and hold as illustrated.
CHASSIS A. Right B. Left Turn the adjuster so that the drive chain is in line with the sprocket, as viewed from the rear. d. Tighten the axle nut while pushing down the drive chain. Axle nut: 135 Nm (13.5 m•kg, 98 ft•lb) 3. Adjust: • Drive chain slack e. Tighten the locknuts. Locknut: 21 Nm (2.1 m•kg, 15 ft•lb) Drive chain slack adjustment steps: a. Loosen the axle nut "1" and locknuts "2". b. Adjust the drive chain slack by turning the adjusters "3". CHECKING THE FRONT FORK 1.
CHASSIS CLEANING THE FRONT FORK OIL SEAL AND DUST SEAL 1. Remove: • Protector • Dust seal "1" Use a thin screw driver, and be careful not to damage the inner fork tube and dust seal. ADJUSTING THE FRONT FORK REBOUND DAMPING FORCE 1. Adjust: • Rebound damping force By turning the adjuster "1". Stiffer "a" → Increase the rebound damping force. (Turn the adjuster "1" in.) Softer "b" → Decrease the rebound damping force. (Turn the adjuster "1" out.) 2.
CHASSIS ADJUSTING THE FRONT FORK COMPRESSION DAMPING FORCE 1. Adjust: • Compression damping force By turning the adjuster "1". CHECKING THE REAR SHOCK ABSORBER 1. Inspect: • Swingarm smooth action Abnormal noise/unsmooth action → Grease the pivoting points or repair the pivoting points. Damage/oil leakage → Replace. Stiffer "a" → Increase the compression damping force. (Turn the adjuster "1" in.) Softer "b" → Decrease the compression damping force. (Turn the adjuster "1" out.
CHASSIS e. Tighten the locknut. • The I.D. mark "a" is marked at the end of the spring. • Spring specification varies according to the difference in the production lot. Locknut: 30 Nm (3.0 m•kg, 22 ft•lb) ADJUSTING THE REAR SHOCK ABSORBER REBOUND DAMPING FORCE 1. Adjust: • Rebound damping force By turning the adjuster "1". 3. Adjust: • Spring preload Adjustment steps: a. Loosen the locknut "1". b. Loosen the adjuster "2" until there is some clearance between the spring and adjuster. c.
CHASSIS Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. ADJUSTING THE REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE 1. Adjust: • Low compression damping force By turning the adjuster "1". ADJUSTING THE REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE 1. Adjust: • High compression damping force By turning the adjuster "1". Stiffer "a" →Increase the low compression damping force. (Turn the adjuster "1" in.
CHASSIS • STANDARD POSITION: This is the position which is back by the specific number of turns from the fully turned-in position. (Which align the punch mark "a" on the adjuster with the punch mark "b" on the adjuster body.) Standard position: About 1-1/4 turns out * About 1-1/2 turns out * Except for USA and CDN CHECKING AND TIGHTENING THE SPOKES The following procedure applies to all of the spokes. 1. Check: • Spokes Bend/damage → Replace. Loose spoke → Retighten. Tap the spokes with a screwdriver.
CHASSIS 3. Check: • Steering smooth action Turn the handlebar lock to lock. Unsmooth action → Adjust steering ring nut. Spokes: 3 Nm (0.3 m•kg, 2.2 ft•lb) CHECKING THE WHEELS 1. Inspect: • Wheel runout Elevate the wheel and turn it. Abnormal runout → Replace. 4. Adjust: • Steering ring nut Steering ring nut adjustment steps: a. Remove the number plate. b. Remove the handlebar and upper bracket. c. Loosen the steering ring nut "1" using the steering nut wrench "2". 2.
CHASSIS Steering stem nut: 145 Nm (14.5 m•kg, 105 ft•lb) Handlebar upper holder: 28 Nm (2.8 m•kg, 20 ft•lb) Pinch bolt (upper bracket): 21 Nm (2.1 m•kg, 15 ft•lb) Number plate: 7 Nm (0.7 m•kg, 5.1 ft•lb) e. Loosen the steering ring nut one turn. f. Retighten the steering ring nut using the steering nut wrench. Avoid over-tightening. Steering ring nut (final tightening): 7 Nm (0.7 m•kg, 5.1 ft•lb) g. Check the steering stem by turning it lock to lock.
CHASSIS LUBRICATION 3-35
CHASSIS To ensure smooth operation of all components, lubricate your machine during setup, after break-in, and after every race. 1. All control cable 2. Clutch lever pivot 3. Shift pedal pivot 4. Footrest pivot 5. Throttle-to-handlebar contact 6. Drive chain 7. Tube guide cable winding portion 8. Throttle cable end 9. Clutch cable end A. Use Yamaha cable lube or equivalent on these areas. B. Use SAE 10W-40 motor oil or suitable chain lubricants. C.
ELECTRICAL ELECTRICAL CHECKING THE SPARK PLUG 1. Remove: • Spark plug 2. Inspect: • Electrode "1" Wear/damage → Replace. • Insulator color "2" Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition. CHECKING THE IGNITION TIMING 1. Remove: • Timing mark accessing screw "1" An extended run at low speeds causes the insulator to be colored black even if the air-fuel mixture is normal. 2.
ELECTRICAL 4. Check: • Ignition timing Visually check the stationary pointer "a" is within the firing range "b" on the rotor. Incorrect firing range → Check rotor and Crankshaft position sensor. 5. Install: • Timing mark accessing screw Timing mark accessing screw: 6 Nm (0.6 m•kg, 4.
TROUBLESHOOTING TROUBLESHOOTING The following guide for troubleshooting does not cover all the possible causes of problems. If the following problems occur, perform the specified checks or maintenance jobs. If a problem occurs that is not listed in this manual or if the problem cannot be corrected by the procedures provided in this manual, contact your Yamaha dealer.
TROUBLESHOOTING INSPECTION STEPS If the aforementioned problems have occurred, perform the following inspection steps in the order given. Check that the fuel tank is filled with fresh gasoline. No good Fill the fuel tank. → OK ↓ Check that the fuel tank breather hose is not clogged. (Refer to "INCLUDED PARTS" section in the CHAPTER 1.) No good → Repair or replace. OK ↓ Adjusting the engine idling speed(Refer to "ADJUSTING THE ENGINE IDLLING SPEED" section in the CHAPTER 3.) No good → Adjust.
SEAT AND SIDE COVERS ENGINE This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage.
SEAT AND SIDE COVERS • Affix the insulators in the following order with the portion "a" overlapping one on another. REMOVING THE NUMBER PLATE 1. Remove: • Bolt (number plate) • Number plate "1" • Insulator 1 "1" • Insulator 2 "2" • Insulator 3 "3" • Insulator 4 "4" • Insulator 5 "5" • Insulator 6 "6" • The projection "a" is inserted into the band of the number plate. Pull the band off the projection before removal. • Remove the clutch cable "2" from the cable guide "b" on the number plate.
EXHAUST PIPE AND SILENCER EXHAUST PIPE AND SILENCER REMOVING THE EXHAUST PIPE AND SILENCER Order Part name Q'ty Seat Remarks Refer to "SEAT AND SIDE COVERS" section. Side cover (left and right) Refer to "SEAT AND SIDE COVERS" section. Rear fender Refer to "SEAT AND SIDE COVERS" section.
EXHAUST PIPE AND SILENCER Order Part name Q'ty 10 Exhaust pipe 1 1 11 Gasket 3 12 Heat protector 1 4-4 Remarks
EXHAUST PIPE AND SILENCER CHECKING THE SILENCER AND EXHAUST PIPE 1. Inspect: • Gasket "1" Damage → Replace. 3. Replace: • Fiber "1" 4. Install: • Inner pipe "1" • Bolt "2" CHANGING THE SILENCER FIBER For USA and CDN 2. Remove: • Bolt "1" • Inner pipe "2" Bolt (silencer): 8 Nm (0.8 m•kg, 5.8 ft•lb) • Apply heat-resistant sealant to the areas "a" shown, making sure that there are no gaps in the beads of sealant. • Take care not to allow the fiber out of place when installing the inner pipe.
EXHAUST PIPE AND SILENCER Except for USA and CDN 1. Remove: • Rivet (front) "1" • Inner pipe "2" • Apply heat-resistant sealant to the areas "a" shown, making sure that there are no gaps in the beads of sealant. • Take care not to allow the fiber out of place when installing the inner pipe. • Install the band "3" with the mating ends "b" positioned as shown. • Take care not to damage the rivet fitting holes (ø4.9 mm) "a" in removal. • Do not hit the silencer stay "b" as it may do damage to the silencer.
EXHAUST PIPE AND SILENCER 2. Install: • Silencer clamp (front) • Eexhaust pipe 2 "1" • Bolt (exhaust pipe 2) "2" 1 - 9 mm (0.04 - 0.35 in) 4. Install: •Bolt (exhaust pipe 2): Bolt (exhaust pipe 2): 20 Nm (2.0 m•kg, 14 ft•lb) •Silencer clamp (front): Install and temporarily tighten the exhaust pipe 2 with its end positioned as shown with respect to the exhaust pipe 1. Silencer clamp (front): 12 Nm (1.2 m•kg, 8.7 ft•lb) •Silencer clamp (rear): 3 - 7 mm (0.12 - 0.28 in) Silencer clamp (rear): 16 Nm (1.
RADIATOR RADIATOR REMOVING THE RADIATOR Order Part name Q'ty Remarks Drain the coolant. Refer to "CHANGING THE COOLANT" section in the CHAPTER 3. Seat Refer to "SEAT AND SIDE COVERS" section. Fuel tank Refer to "FUEL TANK" section in the CHAPTER 6. Refer to "EXHAUST PIPE AND SILENCER" section. Exhaust pipe 1 Radiator guard 2 2 Radiator hose clamp 8 3 Right radiator 1 4 Radiator hose 2 1 5 Radiator hose 3 1 6 Radiator hose 4 1 7 Pipe 2/O-ring 1/1 4-8 Only loosening.
RADIATOR Order Part name Q'ty 8 Radiator breather hose 1 9 Left radiator 1 10 Radiator hose 1 1 11 Pipe 1/O-ring 1/1 4-9 Remarks
RADIATOR • Radiator hose 4 "7" HANDLING NOTE Radiator hose 4: 2 Nm (0.2 m•kg, 1.4 ft•lb) Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radiator cap by the following procedure: Place a thick rag, like a towel, over the radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape.
RADIATOR 4. Install: • Radiator breather hose "1" • Right radiator "2" Right radiator: 10 Nm (1.0 m•kg, 7.2 ft•lb) Refer to "CABLE ROUTING DIAGRAM" section in the CHAPTER 2. 5. Install: • Radiator guard "1" First fit the inner hook portion "a" and then the outer one "b" onto the radiator. 6. Install: • Bolt (radiator guard) "1" Bolt (radiator guard) "1": 10 Nm (1.0 m•kg, 7.
CAMSHAFTS CAMSHAFTS REMOVING THE CYLINDER HEAD COVER Order Part name Q'ty Remarks Seat Refer to "SEAT AND SIDE COVERS" section. Fuel tank Refer to "FUEL TANK" section in the CHAPTER 6. Cover Refer to "THROTTLE BODY" section in the CHAPTER 6.
CAMSHAFTS REMOVING THE CAMSHAFTS Order Part name Q'ty Remarks 1 Timing mark accessing screw 1 Refer to removal section. 2 Crankshaft end accessing screw 1 Refer to removal section. 3 Timing chain tensioner cap bolt 1 Refer to removal section. 4 Timing chain tensioner 1 Refer to removal section. 5 Gasket 1 Refer to removal section. 6 Bolt (camshaft cap) 8 Refer to removal section. 7 Camshaft cap 2 Refer to removal section. 8 Clip 2 Refer to removal section.
CAMSHAFTS REMOVING THE CAMSHAFT 1. Remove: • Timing mark accessing screw "1" • Crankshaft end accessing screw "2" 3. Remove: • Timing chain tensioner cap bolt "1" • Timing chain tensioner "2" • Gasket 2. Align: • Alignmen mark 4. Remove: • Bolt (camshaft cap) "1" • Camshaft cap "2" • Clip Checking steps: a. Turn the crankshaft counterclockwise with a wrench. b. Align the alignment mark "a" on the rotor with the alignment mark "b" on the crankcase cover.
CAMSHAFTS CHECKING THE CAMSHAFT 1. Inspect: • Cam lobe Pitting/scratches/blue discoloration → Replace. 2. Measure: • Cam lobe length "a" and "b" Out of specification → Replace. 3. Measure: • Runout (camshaft) Out of specification → Replace. Runout (camshaft): Less than 0.03 mm (0.0012 in) Cam lobes length: Intake "a": 37.750–37.850 mm (1.4862–1.4902 in) : 37.650 mm (1.4823 in) Intake "b": 28.129–28.229 mm (1.1072–1.1114 in) : 28.029 mm (1.1035 in) Exhaust "a": 33.540–33.640 mm (1.3205–1.
CAMSHAFTS CHECKING THE CAMSHAFT SPROCKET 1. Inspect: • Camshaft sprocket "1" Wear/damage → Replace the camshaft assembly and timing chain as a set. c. Install the clip, dowel pins and camshaft caps. Bolt (camshaft cap): 10 Nm (1.0 m•kg, 7.2 ft•lb) • Tighten the bolts (camshaft cap) in a crisscross pattern from innermost to outer caps. • Do not turn the camshaft when measuring clearance with the Plastigauge®. d. Remove the camshaft caps and measure the width of the Plastigauge® "1".
CAMSHAFTS The alignment mark "a" on the rotor is there for camshaft installation. This alignment mark is stamped 23° ATDC. c. Fit the timing chain "3" onto both camshaft sprockets and install the camshafts on the cylinder head. Make sure that the alignment mark "c" on the exhaust camshaft sprocket and the alignment mark "d" on the intake camshaft sprocket are aligned with the edge of the cylinder head. INSTALLING THE CAMSHAFT 1.
CAMSHAFTS b. With the rod fully wound and the chain tensioner UP mark "a" facing upward, install the gasket "1", the timing chain tensioner "2", and the gasket "3", and tighten the bolt "4" to the specified torque. d. Install the clips, camshaft caps "4" and bolts (camshaft cap) "5". Bolt (camshaft cap): 10 Nm (1.0 m•kg, 7.2 ft•lb) Bolt (timing chain tensioner): 10 Nm (1.0 m•kg, 7.
CYLINDER HEAD CYLINDER HEAD REMOVING THE CYLINDER HEAD Order Part name Q'ty Remarks Refer to "SEAT AND SIDE COVERS" section. Seat Fuel tank Refer to "FUEL TANK" section in the CHAPTER 6. Exhaust pipe and silencer Refer to "EXHAUST PIPE AND SILENCER" section. Radiator Refer to "RADIATOR" section Throttle body Refer to "THROTTLE BODY" section in the CHAPTER 6. Camshaft Refer to "CAMSHAFTS" section.
CYLINDER HEAD Order Part name Q'ty 6 Coolant temperature sensor 1 7 Oil check bolt 2 8 Oil passage plug 1 Remarks Tighten the cylinder head bolts to 30 Nm (3.0 m•kg, 22 ft•b) in the proper tightening sequence, remove and retighten the cylinder head bolts to 20 Nm (2.0 m•kg, 14 ft•lb) in the proper tightening sequence, and then tighten the cylinder head bolts further to reach the specified angle 150° in the proper tightening sequence.
CYLINDER HEAD CHECKING THE CYLINDER HEAD 1. Eliminate: • Carbon deposits (from the combustion chambers) Use a rounded scraper. Do not use a sharp instrument to avoid damaging or scratching: • Spark plug threads • Valve seats INSTALLING THE CYLINDER HEAD 1. Install: • Timing chain guide (intake side) "1" • Dowel pin "2" • Cylinder head gasket "3" • Cylinder head "4" While pulling up the timing chain, install the timing chain guide (intake side) and cylinder head. 2.
CYLINDER HEAD a. Wash the threads and contact surfaces of the bolts, the contact surfaces of the plain washers, the contact surface of the cylinder head, and the threads of the crankcase. b. Apply the molybdenum disulfide grease on the threads and contact surfaces of the bolts and on both contact surfaces of the plain washers. c. Install the plain washers and bolts. d. Tighten the bolts to the specified torque in two or three steps in the proper tightening sequence as shown. h.
VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS REMOVING THE VALVES AND VALVE SPRINGS Order Part name Q'ty Cylinder head Remarks Refer to "CYLINDER HEAD" section. 1 Valve lifter 4 Refer to removal section. 2 Adjusting pad 4 Refer to removal section. 3 Valve cotter 8 Refer to removal section.
VALVES AND VALVE SPRINGS REMOVING THE VALVE LIFTER AND VALVE COTTER 1. Remove: • Valve lifter "1" • Pad "2" 3. Remove: • Valve cotter Remove the valve cotters by compressing the valve spring with the valve spring compressor "1" and the valve spring compressor attachment "2". Identify each lifter "1" and pad "2" position very carefully so that they can be reinstalled in their original place. Valve spring compressor: YM-04019/90890-04019 Valve spring compressor attachment: YM-04108/90890-04108 2.
VALVES AND VALVE SPRINGS 2. Replace: • Valve guide Valve guide remover & installer set (ø5.5): 90890-04016 Valve guide remover (5.5 mm): YM-01122 Valve guide installer (5.5 mm): YM-04015 Valve guide reamer (5.5 mm): YM-01196 Replacement steps: To ease guide removal, installation and to maintain correct fit heat the cylinder head in an over to 100 °C (212 °F). a. Remove the valve guide using a valve guide remover "1". After replacing the valve guide reface the valve seat. 3.
VALVES AND VALVE SPRINGS 5. Measure: • Runout (valve stem) Out of specification → Replace. Measurement steps: a. Apply Mechanic's blueing dye (Dykem) "b" to the valve face. Runout limit: 0.01 mm (0.0004 in) • When installing a new valve always replace the guide. • If the valve is removed or replaced always replace the oil seal. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear pattern. d. Measure the valve seat width.
VALVES AND VALVE SPRINGS h. Press the valve through the valve guide and onto the valve seat to make a clear pattern. i. Measure the valve seat width again. If the valve seat width is out of specification, reface and relap the valve seat. CHECKING THE VALVE SPRINGS 1. Measure: • Valve spring free length "a" Out of specification → Replace. b. Apply molybdenum disulfide oil to the valve stem. Free length (valve spring): Intake: 40.76 mm (1.60 in) : 39.76 mm (1.57 in) Exhaust: 37.01 mm (1.
VALVES AND VALVE SPRINGS 3. Measure: • Spring tilt "a" Out of specification → Replace. Spring tilt limit: Intake: 2.5°/1.8 mm (0.070 in) Exhaust: 2.5°/1.6 mm (0.062 in) CHECKING THE VALVE LIFTERS 1. Inspect: • Valve lifter Scratches/damage → Replace both lifters and cylinder head. e. Smaller pitch 3. Install: • Valve cotters Install the valve cotters by compressing the valve spring with the valve spring compressor "1" and the valve spring compressor attachment "2".
VALVES AND VALVE SPRINGS 4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood. Hitting the valve tip with excessive force could damage the valve. 5. Install: • Adjusting pad "1" • Valve lifter "2" • Apply the molybdenum disulfide oil on the valve stem end. • Apply the engine oil on the valve lifters. • Valve lifter must turn smoothly when rotated with a finger. • Be careful to reinstall valve lifters and pads in their original place.
CYLINDER AND PISTON CYLINDER AND PISTON REMOVING THE CYLINDER AND PISTON Order Part name Q'ty Cylinder head Remarks Refer to "CYLINDER HEAD" section. 1 Bolt (cylinder) 1 2 Cylinder 1 3 Gasket 1 4 Dowel pin 2 5 Piston pin clip 2 Refer to removal section. 6 Piston pin 1 Refer to removal section. 7 Piston 1 Refer to removal section. 8 Piston ring set 1 Refer to removal section.
CYLINDER AND PISTON REMOVING THE PISTON AND PISTON RING 1. Remove: • Piston pin clip "1" • Piston pin "2" • Piston "3" • Put identification marks on each piston head for reference during reinstallation. • Before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller set "4". CHECKING THE CYLINDER AND PISTON 1.
CYLINDER AND PISTON b. If out of specification, replace the cylinder, and replace the piston and piston rings as set. c. Measure the piston skirt diameter "P" with a micrometer. 2. Position: • Piston ring (in cylinder) Insert a ring into the cylinder and push it approximately 40mm (1.57 in) into the cylinder. Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore. a. 9 mm (0.35 in) from the piston bottom edge Piston size "P" Standard 96.965–96.980 mm (3.8175–3.
CYLINDER AND PISTON CHECKING THE PISTON PIN 1. Inspect: • Piston pin Blue discoloration/grooves → Replace, then inspect the lubrication system. 2. Measure: • Piston pin-to-piston clearance d. If out of specification, replace the piston. Piston pin-to-piston clearance: 0.004–0.024 mm (0.00016–0.00094 in) :0.07 mm (0.003 in) INSTALLING THE PISTON RING AND PISTON 1. Install: • Piston ring Onto the piston. Measurement steps: a. Measure the outside diameter (piston pin) "a".
CYLINDER AND PISTON 3. Install: • Piston "1" • Piston pin "2" • Piston pin clip "3" • Apply engine oil onto the piston. • Apply molybdenum disulfide oil onto the piston pin. • Install the piston with the F mark "a" on it pointing to its intake (front) side. • Before installing the piston pin clip, cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase. 2. Install: • Bolt (cylinder) Bolt (cylinder): 10 Nm (1.0 m•kg, 7.2 ft•lb) INSTALLING THE CYLINDER 1.
CLUTCH CLUTCH REMOVING THE CLUTCH Order Part name Q'ty Remarks Drain the engine oil. Refer to "CHANGING THE ENGINE OIL" section in the CHAPTER 3. Brake pedal Refer to "ENGINE REMOVAL" section. Clutch cable Disconnect at engine side.
CLUTCH Order Part name Q'ty Remarks 11 Clutch plate 7 12 Friction plate 8 13 Nut (clutch boss) 1 Refer to removal section. 14 Conical washer 1 Refer to removal section. 15 Clutch boss 1 Refer to removal section.
CLUTCH CHECKING THE PRIMARY DRIVEN GEAR 1. Check: • Circumferential play Free play exists → Replace. • Gear teeth "a" Wear/damage → Replace. REMOVING THE CLUTCH BOSS 1. Remove: • Nut "1" • Conical washer "2" • Clutch boss "3" Use the clutch holding tool "4" to hold the clutch boss. Clutch holding tool: YM-91042/90890-04086 CHECKING THE CLUTCH SPRINGS 1. Measure: • Clutch spring free length "a" Out of specification → Replace springs as a set. Clutch spring free length: 50.0 mm (1.97 in) : 49.
CLUTCH CHECKING THE PUSH ROD 1. Inspect: • Push rod 1 "1" • Bearing "2" • Washer "3" • Push rod 2 "4" • Ball "5" Wear/damage/bend → Replace. CHECKING THE CLUTCH PLATES 1. Measure: • Clutch plate warpage Out of specification → Replace clutch plate as a set. Use a surface plate "1" and thickness gauge "2". Warp limit: 0.1 mm (0.004 in) INSTALLING THE PUSH LEVER SHAFT 1. Install: • Push lever shaft "1" • Apply the lithium soap base grease on the oil seal lip. • Apply the engine oil on the push lever shaft.
CLUTCH 2. Install: • Conical washer "1" • Nut (clutch boss) "2" A. For USA and CDN B. Except for USA and CDN 3. Install: • Friction plate "1" • Clutch plate "2" Nut (clutch boss): 75 Nm (7.5 m•kg, 54 ft•lb) • Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate. • Apply the engine oil on the friction plates and clutch plates.
CLUTCH 5. Install: • Push rod 2 "1" • Ball "2" • Push rod 1 "3" 8. Install: • O-ring (clutch cover) "1" Apply the lithium soap base grease on the Oring Apply the engine oil on the push rod 1, 2 and ball. 9. Install: • Clutch cover "1" • Bolt (clutch cover) 6. Install: • Pressure plate "1" Bolt (clutch cover): 10 Nm (1.0 m•kg, 7.2 ft•lb) Tighten the bolts in stage, using a crisscross pattern. 7. Install: • Clutch spring • Bolt (clutch spring) Bolt (clutch spring): 10 Nm (1.0 m•kg, 7.
OIL FILTER ELEMENT AND WATER PUMP OIL FILTER ELEMENT AND WATER PUMP REMOVING THE OIL FILTER ELEMENT AND WATER PUMP Order Part name Q'ty Remarks Right engine guard Refer to "ENGINE REMOVAL" section. Drain the engine oil. Refer to "CHANGING THE ENGINE OIL" section in the CHAPTER 3. Drain the coolant. Refer to "CHANGING THE COOLANT" section. Exhaust pipe Refer to "EXHAUST PIPE AND SILENCER" section. Brake pedal Refer to "ENGINE REMOVAL" section. Clutch cover Refer to "CLUTCH" section.
OIL FILTER ELEMENT AND WATER PUMP Order Part name Q'ty Remarks 5 Dowel pin 2 6 Kickstarter crank 1 7 Right crankcase cover 1 8 Gasket 1 9 Dowel pin/O-ring 10 Impeller 1 Refer to removal section. 11 Washer 1 Refer to removal section. 12 Impeller shaft 1 Refer to removal section. 13 Oil seal 1 1 Refer to removal section. 14 Oil seal 2 1 Refer to removal section. 15 Bearing 1 Refer to removal section.
OIL FILTER ELEMENT AND WATER PUMP REMOVING THE IMPELLER SHAFT 1. Remove: • Impeller "1" • Washer "2" • Impeller shaft "3" 1. Remove: • Bearing "1" • Oil seal "2" Hold the impeller shaft on its width across the flats "a" with spanners, etc. and remove the impeller. CHECKING THE IMPELLER SHAFT 1. Inspect: • Impeller shaft "1" Bend/wear/damage → Replace. Fur deposits → Clean.
OIL FILTER ELEMENT AND WATER PUMP CHECKING THE BEARING 1. Inspect: • Bearing Rotate inner race with a finger. Rough spot/seizure → Replace. 2. Install: • Bearing "1" Install the bearing by pressing its outer race parallel. CHECKING THE OIL SEAL 1. Inspect: • Oil seal "1" Wear/damage → Replace. INSTALLING THE IMPELLER SHAFT 1. Install: • Impeller shaft "1" • Washer "2" • Impeller "3" Impeller: 14 Nm (1.
OIL FILTER ELEMENT AND WATER PUMP INSTALLING THE RIGHT CRANKCASE COVER 1. Install: • Dowel pin "1" • O-ring "2" • Collar "3" • Gasket "4" Apply the lithium soap base grease on the Oring. INSTALLING THE KICKSTARTER CRANK 1. Install: • Kickstarter crank "1" • Washer • Bolt (kickstarter crank) Bolt (kickstarter crank): 33 Nm (3.3 m•kg, 24 ft•lb) Install so that there is a clearance "a" of 8 mm (0.
OIL FILTER ELEMENT AND WATER PUMP INSTALLING THE WATER PUMP HOUSING 1. Install: • Dowel pin "1" • Gasket "2" INSTALLING THE OIL FILTER ELEMENT 1. Install: • Oil filter element "1" • O-ring "2" • Oil filter element cover "3" • Bolt (oil filter element cover) 2. Install: • Water pump housing "1" • Bolt (water pump housing) "2" Bolt (oil filter element cover): 10 Nm (1.0 m•kg, 7.2 ft•lb) Bolt (water pump housing): 10 Nm (1.0 m•kg, 7.
BALANCER BALANCER REMOVING THE BALANCER Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Right crankcase cover Refer to "OIL FILTER ELEMENT AND WATER PUMP" section. Stator Refer to "AC MAGNETO" section. 1 Nut (balancer) 1 Refer to removal section. 2 Nut (primary drive gear) 1 Refer to removal section. 3 Nut (balancer shaft driven gear) 1 Refer to removal section.
BALANCER Order 11 Part name Q'ty Balancer shaft driven gear 1 4-48 Remarks
BALANCER REMOVING THE BALANCER 1. Straighten the lock washer tab. 2. Loosen: • Nut (balancer) "1" • Nut (primary drive gear) "2" • Nut (balancer shaft driven gear) "3" CHECKING THE PRIMARY DRIVE GEAR, BALANCER SHAFT DRIVE GEAR AND BALANCER SHAFT DRIVEN GEAR 1. Inspect: • Primary drive gear "1" • Balancer shaft drive gear "2" • Balancer shaft driven gear "3" Wear/damage → Replace. Place an aluminum plate "a" between the teeth of the balancer shaft drive gear "4" and driven gear "5".
BALANCER 2. Install: • Balancer shaft driven gear "1" • Align the punched mark "a" on the balancer shaft drive gear with the punched mark "b" on the balancer shaft driven gear. • Install the balancer shaft driven gear and crankshaft with the lower splines "c" aligning with each other. 3. Install: • Lock washer "1" • Nut (balancer shaft driven gear) "2" 4. Bend the lock washer tab. Nut (balancer shaft driven gear): 50 Nm (5.
OIL PUMP OIL PUMP REMOVING THE OIL PUMP Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Right crankcase cover Refer to "OIL FILTER ELEMENT AND WATER PUMP" section.
OIL PUMP Order Part name Q'ty 12 Inner rotor 1 1 13 Dowel pin 1 14 Washer 1 15 Oil pump drive shaft 1 16 Rotor housing 1 4-52 Remarks
OIL PUMP 3. Check: • Unsmooth → Repeat steps #1 and #2 or replace the defective parts. CHECKING THE OIL PUMP 1. Inspect: • Oil pump drive gear • Oil pump drive shaft • Rotor housing • Oil pump cover Cracks/wear/damage → Replace. 2.
OIL PUMP 3. Install: • Oil pump cover "1" • Screw (oil pump cover) "2" 5. Install: • Oil pump drive gear "1" • Washer "2" • Circlip"3" Screw (oil pump cover): 2 Nm (0.2 m•kg, 1.4 ft•lb) Apply the engine oil on the oil pump drive gear inner circumference. • Dowel pin "3" • Inner rotor 2 "4" • Circlip "5" • Apply the engine oil on the oil pump drive shaft end and inner rotor 2. • Fit the dowel pin into the groove in the inner rotor 2. 4.
KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Oil pump Remarks Refer to "OIL PUMP" section. 1 Kick idle gear 1 2 Kick shaft assembly 1 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick shaft 1 8 Washer 1 9 Shift pedal 1 10 Shift shaft 1 11 Collar 1 12 Torsion spring 1 13 Roller 1 4-55 Refer to removal section.
KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Remarks 14 Shift guide 1 Refer to removal section. 15 Shift lever assembly 1 Refer to removal section. 16 Shift lever 1 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt (stopper lever) 1 21 Stopper lever 1 22 Torsion spring 1 23 Segment 1 4-56 Refer to removal section.
KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT ASSEMBLY 1. Remove: • Kick shaft assembly "1" Unhook the torsion spring "2" from the hole "a" in the crankcase. CHECKING THE KICK SHAFT AND RATCHET WHEEL 1. Check: • Ratchet wheel "1" smooth movement Unsmooth movement → Replace. • Kick shaft "2" Wear/damage → Replace. • Spring "3" Broken → Replace. REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1.
KICK SHAFT AND SHIFT SHAFT INSTALLING THE SEGMENT 1. Install: • Segment "1" • Bolt (segment) CHECKING THE SHIFT SHAFT 1. Inspect: • Shift shaft "1" Bend/damage → Replace. • Spring "2" Broken → Replace. Bolt (segment): 30 Nm (3.0 m•kg, 22 ft•lb) Align the notch "a" on the segment with the pin "b" on the shift cam. If the segment gets an impact, it may be damaged. Take care not to give an impact to the segment when tightening the bolt. CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1.
KICK SHAFT AND SHIFT SHAFT INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1. Install: • Spring "1" • Pawl pin "2" • Pawl "3" To shift lever "4". 4. Install: • Bolt (shift guide) "1" Bolt (shift guide): 10 Nm (1.0 m•kg, 7.2 ft•lb) Apply the engine oil on the spring, pawl pin and pawl. INSTALLING THE SHIFT SHAFT 1. Install: • Roller "1" • Collar "2" • Torsion spring "3" • Washer "4" • Shift shaft "5" 2. Install: • Shift lever assembly "1" To shift guide "2".
KICK SHAFT AND SHIFT SHAFT INSTALLING THE KICK SHAFT ASSEMBLY 1. Install: • Kick gear "1" • Washer "2" • Circlip "3" • Ratchet wheel "4" • Spring "5" • Washer "6" • Circlip "7" To kick shaft "8". 3. Install: • Spring guide "1" Slide the spring guide into the kick shaft, make sure the groove "a" in the spring guide fits on the stopper of the torsion spring. • Apply the molybdenum disulfide oil on the inner circumferences of the kick gear and ratchet wheel.
KICK SHAFT AND SHIFT SHAFT 5. Hook: • Torsion spring "1" Turn the torsion spring clockwise and hook into the proper hole "a" in the crankcase. INSTALLING THE KICK IDLE GEAR 1. Install: • Kick idle gear "1" • Washer "2" • Circlip "3" • Apply the engine oil on the kick idle gear inner circumference. • Install the kick idle gear with its depressed side "a" toward you.
AC MAGNETO AC MAGNETO REMOVING THE AC MAGNETO Order Part name Q'ty Remarks Seat Refer to "SEAT AND SIDE COVERS" section. Fuel tank Refer to "FUEL TANK" section in the CHAPER 6. Disconnect the AC magneto lead 1 Left crankcase cover 1 2 Gasket 1 3 Dowel pin 2 4 Nut (rotor) 1 Refer to removal section. 5 Rotor 1 Refer to removal section.
AC MAGNETO REMOVING THE ROTOR 1. Remove: • Nut (rotor) "1" • Washer CHECKING THE WOODRUFF KEY 1. Inspect: • Woodruff key "1" Damage → Replace. 2. Remove: • Rotor "1" Use the rotor puller 2. INSTALLING THE AC MAGNETO 1. Install: • Stator "1" • Screw (stator) "2" Rotor puller: YM-04151/90890-04151 Screw (stator): 8 Nm (0.8 m•kg, 5.8ft•lb) • Crankshaft position sensor "3" • Holder "4" • Bolt (crankshaft position sensor) "5" Bolt (crankshaft position sensor): 10 Nm (1.0 m•kg, 7.
AC MAGNETO 2. Install: • Woodruff key "1" • Rotor "2" 5. Install: • Dowel pin • Gasket (left crankcase cover) • Left crankcase cover "1" • Hose guide (cylinder head breather hose) "2" • Bolt (left crankcase cover) • Degrease the contact surfaces of the tapered portions of the crankshaft and rotor. • When installing the woodruff key, make sure that its flat surface "a" is in parallel with the crankshaft center line "b". • When installing the rotor, align the keyway "c" of the rotor with the woodruff key.
ENGINE REMOVAL ENGINE REMOVAL REMOVING THE ELECTRONIC PARTS Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the frame. Refer to "HANDLING NOTE". Seat Refer to "SEAT AND SIDE COVERS" section. Fuel tank Air filter case Radiator Refer to "RADIATOR" section. 1 Rectifier/regulator 1 2 Ignition coil bracket 1 3 Ignition coil 1 4 Atmospheric pressure sensor 1 5 Condenser 1 6 AC magneto lead 1 Disconnect.
ENGINE REMOVAL REMOVING THE ENGINE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the frame. Refer to "HANDLING NOTE". Throttle body Refer to "THROTTLE BODY" section in the CHAPRE 6. Rear fender Refer to "SEAT AND SIDE COVERS" section. Exhaust pipe and silencer Refer to "EXHAUST PIPE AND SILENCER" section. Clutch cable Disconnect at the engine side. Shift pedal Refer to "KICK SHAFT AND SHIFT SHAFT" section.
ENGINE REMOVAL Order Part name Q'ty Remarks 3 Lock washer 1 Refer to removal section. 4 Drive sprocket 1 Refer to removal section. 5 Clip 1 6 Bolt (brake pedal) 1 7 Brake pedal 1 8 Upper engine bracket 2 9 Lower engine bracket 2 10 Engine mounting bolt 4 11 Pivot shaft 1 Refer to removal section. 12 Engine 1 Refer to removal section.
ENGINE REMOVAL HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE DRIVE SPROCKET 1. Remove: • Nut (drive sprocket) "1" • Lock washer "2" 2. Remove: • Engine "1" From right side. • Straighten the lock washer tab. • Loosen the nut while applying the rear brake. • Make sure that the couplers, hoses and cables are disconnected.
ENGINE REMOVAL • Upper engine bracket "8" • Bolt (upper engine bracket) "9" Bolt (upper engine bracket): 45 Nm (4.5 m•kg, 32 ft•lb) • Engine mounting bolt (upper) "10" Engine mounting bolt (upper): 45 Nm (4.5 m•kg, 32 ft•lb) • Apply the molybdenum disulfide grease on the pivot shaft. • Install the patch with the claw "a" facing outside the chassis. INSTALLING THE DRIVE SPROCKET 1. Install: • Drive sprocket "1" • Drive chain "2" Install the drive sprocket together with the drive chain. 2.
ENGINE REMOVAL 3. Bend the lock washer tab to lock the nut. 4. Install: • Drive chain sprocket guide • Drive chain sprocket cover "1" • Bolt(drive chain sprocket cover) "2" Bolt (drive chain sprocket cover): 7 Nm (0.7 m•kg, 5.
CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT REMOVING THE CRANKSHAFT Order Part name Q'ty Remarks Engine Refer to "ENGINE REMOVAL" section. Piston Refer to "CYLINDER AND PISTON" section. Balancer Refer to "BALANCER" section. Kick shaft assembly Refer to "KICK SHAFT AND SHIFT SHAFT" section. Segment Refer to "KICK SHAFT AND SHIFT SHAFT" section. Stator Refer to "AC MAGNETO" section.
CRANKCASE AND CRANKSHAFT Order Part name Q'ty Remarks 6 Bolt [L = 70 mm (2.76 in)] 4 Refer to removal section. 7 Right crankcase 1 Refer to removal section. 8 Left crankcase 1 Refer to removal section. 9 Oil strainer 1 10 Balancer shaft 1 Refer to removal section. 11 Crankshaft 1 Refer to removal section.
CRANKCASE AND CRANKSHAFT REMOVING THE CRANKCASE BEARING Order Part name Q'ty Remarks Transmission Refer to "TRANSMISSION, SHIFT CAM AND SHIFT FORK" section. Shift cam and shift fork Refer to "TRANSMISSION, SHIFT CAM AND SHIFT FORK" section. 1 Circlip 1 2 Oil seal 3 3 Bearing 10 4-73 Refer to removal section.
CRANKCASE AND CRANKSHAFT DISASSEMBLING THE CRANKCASE 1. Separate: • Right crankcase • Left crankcase Separation steps: a. Remove the crankcase bolts, hose guide and clutch cable holder. c. Remove the dowel pins and O-ring. REMOVING THE BALANCER SHAFT 1. Remove: • Balancer shaft "1" Remove the balancer shaft with its flat side "a" facing the crankshaft. Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them. b. Remove the right crankcase "1".
CRANKCASE AND CRANKSHAFT CHECKING THE CRANKCASE 1. Inspect: • Contacting surface "a" Scratches → Replace. • Engine mounting boss "b", crankcase Cracks/damage → Replace. REMOVING THE CRANKCASE BEARING 1. Remove: • Bearing "1" • Remove the bearing from the crankcase by pressing its inner race. • Do not use the removed bearing. 2. Inspect: • Bearing Rotate inner race with a finger. Rough spot/seizure → Replace. CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1.
CRANKCASE AND CRANKSHAFT Standard INSTALLING THE CRANKCASE BEARING 1. Install: • Bearing • Bearing stopper • Bolt (bearing stopper) 0.05 mm Runout lim0.03 mm (0.0012 in) (0.002 in) it: Small end free play: Side clearance: Crack width: 0.4–1.0 mm (0.016–0.039 in) 2.0 mm (0.08 in) Bolt (bearing stopper): 10 Nm (1.0 m•kg, 7.2 ft•lb) 0.15–0.45 mm 0.50 mm (0.0059–0.0177 in) (0.02 in) 61.95–62.00 mm (2.439–2.441 in) • Screw (bearing stopper) Screw (bearing stopper): 10 Nm (1.0 m•kg, 7.
CRANKCASE AND CRANKSHAFT 2. Check: • Shifter operation • Transmission operation Unsmooth operation → Repair. • Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms against the bearing. • Before installing the crankshaft, clean the contacting surface of crankcase. • Apply the molybdenum disulfide grease to the crankshaft to prevent it from being scratched.
CRANKCASE AND CRANKSHAFT 8. Remove: • Sealant Forced out on the cylinder mating surface. 9. Apply: • Engine oil To the crank pin, bearing and oil delivery hole. 10.Check: • Crankshaft and transmission operation. Unsmooth operation → Repair. 5. Install: • Dowel pin "1" • Right crankcase To left crankcase. • Fit the right crankcase onto the left crankcase. Tap lightly on the case with soft hammer. • When installing the crankcase, the connecting rod should be positioned at TDC (top dead center). 6.
TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION, SHIFT CAM AND SHIFT FORK Order Part name Q'ty Remarks Engine Refer to "ENGINE REMOVAL" section. Separate the crankcase. Refer to "CRANKCASE AND CRANKSHAFT" section. 1 Main axle 1 Refer to removal section. 2 Drive axle 1 Refer to removal section. 3 Shift cam 1 Refer to removal section. 4 Shift fork 3 1 Refer to removal section. 5 Shift fork 2 1 Refer to removal section.
TRANSMISSION, SHIFT CAM AND SHIFT FORK 2. Inspect: • O-ring "1" Damage → Replace. REMOVING THE TRANSMISSION 1. Remove: • Main axle "1" • Drive axle "2" • Shift cam • Shift fork 3 • Shift fork 2 • Shift fork 1 • Remove assembly with the collar "3" installed to the crankcase. • Remove assembly carefully. Note the position of each part. Pay particular attention to the location and direction of shift forks.
TRANSMISSION, SHIFT CAM AND SHIFT FORK 2. Inspect: • Shift cam "1" • Segment "2" Wear/damage → Replace. 3. Check: • Shift fork movement Unsmooth operation → Replace shift fork. 2. Install: • Collar "1" • 2nd wheel gear (23T) "2" • 4th wheel gear (24T) "3" • 3rd wheel gear (23T) "4" • 5th wheel gear (20T) "5" • Collar "6" • 1st wheel gear (27T) "7" • O-ring "8" To drive axle "9". For a malfunctioning shift fork, replace not only the shift fork itself but the two gears each adjacent to the shift fork.
TRANSMISSION, SHIFT CAM AND SHIFT FORK 4. Install: • Collar "1" • Apply the lithium soap base grease on the oil seal lip. • When installing the collar into the crankcase, pay careful attention to the crankcase oil seal lip. 5. Install: • Shift fork 1 (L) "1" • Shift fork 2 (C) "2" • Shift fork 3 (R) "3" • Shift cam "4" To main axle and drive axle. 3. Install: • Washer "1" • Circlip "2" • Be sure the circlip sharp-edged corner "a" is positioned opposite side to the washer and gear "b".
TRANSMISSION, SHIFT CAM AND SHIFT FORK 6. Install: • Transmission assembly "1" To left crankcase "2". Apply the engine oil on the bearings and guide bars. 7. Check: • Shifter operation • Transmission operation Unsmooth operation → Repair.
CHASSIS This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage.
FRONT WHEEL AND REAR WHEEL FRONT WHEEL AND REAR WHEEL REMOVING THE FRONT WHEEL Order Part name Q'ty Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". 1 Bolt (axle holder) 4 2 Nut (front wheel axle) 1 3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Oil seal 2 7 Bearing 2 8 Brake disc 1 5-2 Remarks Only loosening. Refer to removal section.
FRONT WHEEL AND REAR WHEEL REMOVING THE REAR WHEEL Order Part name Q'ty Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". 1 Nut (rear wheel axle) 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 3 10 Brake disc 1 5-3 Remarks Refer to removal section. Refer to removal section.
FRONT WHEEL AND REAR WHEEL HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE REAR WHEEL 1. Remove: • Wheel "1" Push the wheel forward and remove the drive chain "2". 2. Inspect: • Bearing Rotate inner race with a finger. Rough spot/seizure → Replace. Replace the bearings, oil seal and wheel collar as a set. REMOVING THE WHEEL BEARING 1. Remove: • Bearing "1" Remove the bearing using a general bearing puller "2". CHECKING THE WHEEL AXLE 1.
FRONT WHEEL AND REAR WHEEL CHECKING THE BRAKE DISC 1. Measure: • Brake disc deflection (only rear brake disc) Use the dial gauge "1". Out of specification → Inspect wheel runout. If wheel runout is in good condition, replace the brake disc. • Use a socket that matches the outside diameter of the race of the bearing. • Left side of bearing shall be installed first. • Install the oil seal with its manufacture's marks or numbers facing outward. Brake disc deflection limit: Rear: : 0.15 mm (0.
FRONT WHEEL AND REAR WHEEL 3. Install: • Collar "1" 6. Install: • Nut (wheel axle) "1" Nut (wheel axle): 105 Nm (10.5 m•kg, 75 ft•lb) • Apply the lithium soap base grease on the oil seal lip. • Install the collars with their projections "a" facing the wheel. 7. Tighten: • Bolt (axle holder) "1" Bolt (axle holder): 21 Nm (2.1 m•kg, 15 ft•lb) 4. Install: • Wheel Before tightening the bolt, fit the wheel axle to the axle holder by stroking the front fork several times with the front brake applied.
FRONT WHEEL AND REAR WHEEL INSTALLING THE REAR WHEEL 1. Install: • Bearing (right) "1" • Circlip "2" • Spacer "3" • Bearing (left) "4" • Oil seal "5" • Apply the lithium soap base grease on the bearing and oil seal lip when installing. • Install the bearing with seal facing outward. • Use a socket that matches the outside diameter of the race of the bearing. • Right side of bearing shall be installed first. • Install the oil seal with its manufacture's marks or numbers facing outward. 3.
FRONT WHEEL AND REAR WHEEL 5. Install: • Wheel 8. Install: • Right drive chain puller "1" • Washer "2" • Nut (wheel axle) "3" Install the brake disc "1" between the brake pads "2" correctly. Temporarily tighten the nut (wheel axle) at this point. 6. Install: • Drive chain "1" 9. Adjust: • Drive chain slack "a" Push the wheel "2" forward and install the drive chain. Drive chain slack: 50–60 mm (2.0–2.4 in) Refer to "ADJUSTING THE DRIVE CHAIN SLACK" section in the CHAPTER 3. 7.
FRONT BRAKE AND REAR BRAKE FRONT BRAKE AND REAR BRAKE REMOVING THE FRONT BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Drain the brake fluid. Refer to removal section. 1 Brake hose holder (protector) 2 2 Union bolt 2 3 Brake hose 1 4 Pad pin plug 1 Remove when loosening the pad pin. 5 Pad pin 1 Loosen when disassembling the brake caliper.
FRONT BRAKE AND REAR BRAKE REMOVING THE REAR BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Rear wheel Refer to "FRONT WHEEL AND REAR WHEEL" section. Drain the brake fluid. Refer to removal section. 1 Brake pedal 1 2 Brake master cylinder 1 3 Brake hose holder 2 4 Union bolt 2 5 Brake hose 1 6 Pad pin plug 1 Remove when loosening the pad pin.
FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE CALIPER Order Part name Q'ty Remarks A. Front B. Rear A B 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Brake caliper piston 2 1 Refer to removal section. 5 Brake caliper piston dust seal 2 1 Refer to removal section. 6 Brake caliper piston seal 2 1 Refer to removal section.
FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE MASTER CYLINDER Order Part name Q'ty Remarks A. Front B. Rear 1 Brake master cylinder cap 1 2 Diaphragm 1 3 Reservoir float 1 4 Push rod (front) 1 5 Brake master cylinder boot 1 6 Circlip 1 7 Washer 1 8 Push rod (rear) 1 9 Brake master cylinder kit 1 5-12 Use a long nose circlip pliers.
FRONT BRAKE AND REAR BRAKE HANDLING NOTE • Do not reuse the drained brake fluid. • Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately. Support the machine securely so there is no danger of it falling over. DRAINING THE BRAKE FLUID 1. Remove: • Brake master cylinder cap "1" • Protector (rear brake) REMOVING THE BRAKE CALIPER PISTON 1. Remove: • Brake caliper piston Use compressed air and proceed carefully. Do not remove the diaphragm.
FRONT BRAKE AND REAR BRAKE Remove the brake caliper piston seals and brake caliper piston dust seals by pushing them with a finger. Never attempt to pry out brake caliper piston seals and brake caliper piston dust seals. A. Front B. Rear 2. Inspect: • Diaphragm "1" Crack/damage → Replace. Replace the brake caliper piston seals and brake caliper piston dust seals whenever a caliper is disassembled. A. Front B. Rear 3. Inspect: (front brake only) • Reservoir float "1" Damage → Replace. A. Front B.
FRONT BRAKE AND REAR BRAKE HANDLING NOTE CHECKING THE BRAKE CALIPER 1. Inspect: • Brake caliper cylinder inner surface "a" Wear/score marks → Replace brake caliper assembly. • All internal parts should be cleaned in new brake fluid only. • Internal parts should be lubricated with brake fluid when installed. • Replace the brake caliper piston seals and brake caliper piston dust seals whenever a caliper is disassembled. INSTALLING THE BRAKE CALIPER PISTON 1.
FRONT BRAKE AND REAR BRAKE • Install the brake pads with their projections "a" into the brake caliper recesses "b". • Temporarily tighten the pad pin at this point. A. Front B. Rear 3. Install: • Brake caliper piston "1" 2. Install: • Brake caliper "1" • Bolt (brake caliper) "2" Apply the brake fluid on the piston wall. Bolt (brake caliper): 28 Nm (2.8 m•kg, 20 ft•lb) • Install the piston with its shallow depressed side "a" facing the brake caliper. • Never force to insert. 3.
FRONT BRAKE AND REAR BRAKE INSTALLING THE BRAKE MASTER CYLINDER KIT 1. Clean: • Brake master cylinder • Brake master cylinder kit Clean them with brake fluid. 2. Install: • Brake master cylinder cup (primary) "1" • Brake master cylinder cup (secondary) "2" To brake master cylinder piston "3". 2. Install: • Brake disc cover "1" • Bolt (brake disc cover) "2" Apply the brake fluid on the brake master cylinder cup. Bolt (brake disc cover): 10 Nm (1.0 m•kg, 7.
FRONT BRAKE AND REAR BRAKE INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Brake master cylinder "1" • Brake master cylinder bracket "2" • Bolt (brake master cylinder bracket) "3" Bolt (brake master cylinder bracket): 9 Nm (0.9 m•kg, 6.5 ft•lb) 4. Install: • Brake master cylinder kit "1" • Washer (front brake) "2" • Push rod (rear brake) "2" • Circlip "3" • Brake master cylinder boot "4" • Push rod (front brake) "5" To brake master cylinder.
FRONT BRAKE AND REAR BRAKE INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • Copper washer "1" • Brake hose "2" • Union bolt "3" Union bolt: 30 Nm (3.0 m•kg, 22 ft•lb) 3. Install: • Spring "1" • Brake pedal "2" • O-ring "3" • Bolt (brake pedal) "4" Always use new copper washers. Bolt (brake pedal): 26 Nm (2.6 m•kg, 19 ft•lb) • Clip "5" Apply the lithium soap base grease on the bolt, O-ring and brake pedal bracket.
FRONT BRAKE AND REAR BRAKE INSTALLING THE FRONT BRAKE HOSE 1. Install: • Copper washer "1" • Brake hose "2" • Union bolt "3" Union bolt: 30 Nm (3.0 m•kg, 22 ft•lb) Always use new copper washers. 3. Pass the brake hose through the cable guide "1". 4. Install: • Copper washer "1" • Brake hose "2" • Union bolt "3" Install the brake hose so that its pipe portion "a" directs as shown and lightly touches the projection "b" on the brake caliper. Union bolt: 30 Nm (3.
FRONT BRAKE AND REAR BRAKE After installing the brake hose holders, make sure the brake hose does not contact the spring (rear shock absorber). If it does, correct its twist. INSTALLING THE REAR BRAKE HOSE 1. Install: • Copper washer "1" • Brake hose "2" • Union bolt "3" Union bolt: 30 Nm (3.0 m•kg, 22 ft•lb) Always use new copper washers. FILLING THE BRAKE FLUID 1. Fill: • Brake fluid Until the fluid level reaches "LOWER" level line "a".
FRONT BRAKE AND REAR BRAKE Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately. After installation, while pulling the brake lever in or pushing down on the brake pedal, check whether there is any brake fluid leaking where the union bolts are installed respectively at the brake master cylinder and brake caliper. A. Front B. Rear 2. Air bleed: • Brake system Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" section in the CHAPTER 3. 3.
FRONT FORK FRONT FORK REMOVING THE FRONT FORK Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Front wheel Refer to "FRONT WHEEL AND REAR WHEEL" section. Front brake caliper Refer to "FRONT BRAKE AND REAR BRAKE" section. Number plate Refer to "SEAT, FUEL TANK AND SIDE COVERS" section in the CHAPTER 4. 1 Protector 1 2 Pinch bolt (upper bracket) 2 Only loosening.
FRONT FORK DISASSEMBLING THE FRONT FORK Order Part name Q'ty Remarks Drain the fork oil. Refer to removal section. 1 Adjuster 1 2 Fork spring 1 3 Dust seal 1 Refer to removal section. 4 Stopper ring 1 Refer to removal section. 5 Inner tube 1 Refer to removal section. 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Oil seal washer 1 10 Oil seal 1 11 Base valve 1 Drain the fork oil. Refer to removal section. 12 Damper assembly 1 Drain the fork oil.
FRONT FORK HANDLING NOTE REMOVING THE ADJUSTER 1. Drain the outer tube of its front fork oil at its top. 2. Loosen: • Adjuster "1" Support the machine securely so there is no danger of it falling over. The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers.
FRONT FORK REMOVING THE INNER TUBE 1. Remove: • Dust seal "1" • Stopper ring "2" Using slotted-head screwdriver. Take care not to scratch the inner tube. CHECKING THE DAMPER ASSEMBLY 1. Inspect: • Damper assembly "1" Bend/damage → Replace. • O-ring "2" Wear/damage → Replace. The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material.
FRONT FORK CHECKING THE INNER TUBE 1. Inspect: • Inner tube surface "a" Score marks → Repair or replace. Use #1,000 grit wet sandpaper. Damaged oil lock piece → Replace. • Inner tube bends Out of specification → Replace. Use the dial gauge "1". Inner tube bending limit: 0.2 mm (0.008 in) CHECKING THE COLLAR 1. Inspect: • Piston metal "1" Wear/damage → Replace. The bending value is shown by one half of the dial gauge reading.
FRONT FORK CHECKING THE ADJUSTER 1. Inspect: • Adjuster "1" • O-ring "2" Wear/damage → Replace. 5. Measure: • Oil level (left and right) "a" Out of specification → Adjust. Standard oil level: 145–148 mm (5.71–5.83 in) From top of fully stretched damper assembly. ASSEMBLING THE FRONT FORK 1. Wash the all parts in a clean solvent. 2. Stretch the damper assembly fully. 3. Fill: • Front fork oil "1" To damper assembly. Recommended oil: Suspension oil "S1" Oil capacity: 197 cm3 (6.93 Imp oz, 6.
FRONT FORK 9. Check: • Damper assembly Not fully stretched → Repeat the steps 2 to 8. 10.Tighten: • Base valve "1" Base valve: 29 Nm (2.9 m•kg, 21 ft• lb) Hold the damper assembly with the cap bolt ring wrench "2" and use the cap bolt wrench "3" to tighten the base valve with specified torque. 7. Loosen: • Compression damping adjuster "1" • Loosen the compression damping adjuster finger tight. • Record the set position of the adjuster (the amount of turning out the fully turned in position).
FRONT FORK 13.Allow the overflowing oil to escape at the hole "a" in the damper assembly. 16.Install: • Piston metal "1" 14.Check: • Damper assembly smooth movement Tightness/binding/rough spots → Repeat the steps 2 to 13. Install the piston metal onto the slot on inner tube. 17.Install: • Outer tube "1" To inner tube "2". 15.Install: • Dust seal "1" • Stopper ring "2" • Oil seal "3" • Oil seal washer "4" • Slide metal "5" To inner tube "6". • Apply the fork oil on the inner tube.
FRONT FORK 18.Install: • Slide metal "1" • Oil seal washer "2" To outer tube slot. 20.Install: • Stopper ring "1" Fit the stopper ring correctly in the groove in the outer tube. Press the slide metal into the outer tube with fork seal driver "3". Fork seal driver: YM-A0948/90890-01502 21.Install: • Dust seal "1" Apply the lithium soap base grease on the inner tube. 19.Install: • Oil seal "1" 22.Check: • Inner tube smooth movement Tightness/binding/rough spots → Repeat the steps 15 to 21.
FRONT FORK 23.Measure: • Distance "a" Out of specification → Turn into the locknut. Distance "a": 16 mm (0.63 in) or more Between the damper assembly "1" bottom and locknut "2" bottom. 26.Loosen: • Rebound damping adjuster "1" • Loosen the rebound damping adjuster finger tight. • Record the set position of the adjuster (the amount of turning out the fully turned in position). 24.Install: • Collar "1" • Fork spring "2" To damper assembly "3". Install the collar with its larger dia.
FRONT FORK 30.Install: • Adjuster "1" Adjuster: 55 Nm (5.5 m•kg, 40 ft•lb) To inner tube. 28.Inspect: • Gap "a" between the adjuster "1" and locknut "2". Out of specification → Retighten and readjust the locknut. Gap "a" between the adjuster and locknut: 0.5–1.0 mm (0.02–0.04 in) 31.Fill: • Front fork oil "1" From outer tube top. Recommended oil: Suspension oil "S1" Standard oil amount: 355 cm3 (12.5 Imp oz, 12.0 US oz) Extent of adjustment: 300–365 cm3 (10.6–12.8 Imp oz,10.1–12.
FRONT FORK 32.Install: • Damper assembly "1" To outer tube. 2. Tighten: • Damper assembly "1" Damper assembly: 30 Nm (3.0 m•kg, 22 ft•lb) Temporarily tighten the damper assembly. Use the cap bolt ring wrench "2" to tighten the damper assembly with specified torque. Cap bolt ring wrench: YM-01501/90890-01501 33.Install: • Protector guide "1" 3. Adjust: • Front fork top end "a" Front fork top end (standard) "a": Zero mm (Zero in) INSTALLING THE FRONT FORK 1.
FRONT FORK 5. Install: • Protector "1" • Bolt (protector) "2" Bolt (protector): 5 Nm (0.5 m•kg, 3.6 ft•lb) 6. Adjust: • Rebound damping force Turn in the damping adjuster "1" finger-tight and then turn out to the originally set position. 7. Adjust: • Compression damping force Turn in the damping adjuster "1" finger-tight and then turn out to the originally set position.
HANDLEBAR HANDLEBAR REMOVING THE HANDLEBAR Order Part name Q'ty Number plate Remarks Remove the band only. 1 Clutch cable 1 2 Clutch lever holder 1 3 Engine stop switch 1 4 Brake master cylinder 1 5 Throttle cable cap 1 6 Throttle cable #1 (pulled) 1 Disconnect at the throttle side. 7 Throttle cable #2 (pushed) 1 Disconnect at the throttle side. 8 Right grip 1 Refer to removal section.
HANDLEBAR Order Part name Q'ty 14 Handlebar lower holder 2 15 Cap 1 5-37 Remarks
HANDLEBAR REMOVING THE BRAKE MASTER CYLINDER 1. Remove: • Brake master cylinder bracket "1" • Brake master cylinder "2" • Do not let the brake master cylinder hang on the brake hose. • Keep the brake master cylinder cap side horizontal to prevent air from coming in. INSTALLING THE HANDLEBAR 1. Install: • Handlebar lower holder "1" • Washer "2" • Nut (handlebar lower holder) "3" • Be sure the side of the handlebar lower holder having the greater distance "a" from the mounting bolt center faces forward.
HANDLEBAR 2. Install: • Handlebar "1" • Handlebar upper holder "2" • Bolt (handlebar upper holder) "3" Bolt (handlebar upper holder): 28 Nm (2.8 m•kg, 20 ft•lb) • The handlebar upper holder should be installed with the punched mark "a" forward. • Install the handlebar so that the marks "b" are in place on both sides. • Install the handlebar so that the projection "c" of the handlebar upper holder is positioned at the mark on the handlebar as shown.
HANDLEBAR 5. Install: • Right grip "1" • Collar "2" Apply the adhesive on the tube guide "3". 7. Install: • Throttle cables "1" To tube guide "2". Apply the lithium soap base grease on the throttle cable end and tube guide cable winding portion. • Before applying the adhesive, wipe off grease or oil on the tube guide surface "a" with a lacquer thinner. • Install the grip to the tube guide so that the grip match mark "b" and tube guide slot "c" form the angle as shown. 8.
HANDLEBAR 9. Install: • Grip cap cover "1" • Cover (throttle cable cap) "2" 0 mm 10.Install: • Brake master cylinder "1" • Brake master cylinder bracket "2" • Bolt (brake master cylinder bracket) "3" 0 mm Bolt (brake master cylinder bracket): 9 Nm (0.9 m•kg, 6.5 ft•lb) 12.Install: • Clutch cable "1" • Install the bracket so that the arrow mark "a" faces upward. • First tighten the bolt on the upper side of the brake master cylinder bracket, and then tighten the bolt on the lower side.
STEERING STEERING REMOVING THE STEERING Order Part name Q'ty Remarks TIGHTENING STEPS: • Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb) • Loosen it one turn. • Retighten it. 7 Nm (0.7 m•kg, 5.1 ft•lb) Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Number plate Refer to "SEAT AND SIDE COVERS" section in the CHAPTER 4. Handlebar Refer to "HANDLEBAR" section.
STEERING Order Part name Q'ty Remarks 6 Lower bracket 1 7 Bearing race cover 1 8 Upper bearing 1 9 Lower bearing 1 Refer to removal section. 10 Bearing race 2 Refer to removal section.
STEERING HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE STEERING RING NUT 1. Remove: • Steering ring nut "1" Use the steering nut wrench "2". Steering nut wrench: YU-33975/90890-01403 CHECKING THE STEERING STEM 1. Inspect: • Steering stem "1" Bend/damage → Replace. Support the steering stem so that it may not fall down. CHECKING THE BEARING AND BEARING RACE 1. Wash the bearings and bearing races with a solvent. 2.
STEERING INSTALLING THE LOWER BRACKET 1. Install: • Lower bearing "1" 4. Install: • Steering ring nut "1" Steering ring nut: 7 Nm (0.7 m•kg, 5.1 ft•lb) Apply the lithium soap base grease on the dust seal lip and bearing inner circumference. Install the steering nut with its stepped side "a" facing downward. Tighten the steering ring nut using the steering nut wrench "2". Refer to "CHECKING AND ADJUSTING THE STEERING HEAD" section in the CHAPTER 3. 2.
STEERING 7. Install: • Front fork "1" • Upper bracket "2" • Temporarily tighten the pinch bolts (lower bracket). • Do not tighten the pinch bolts (upper bracket) yet. 11.Tighten: • Pinch bolt (upper bracket) "1" Pinch bolt (upper bracket): 21 Nm (2.1 m•kg, 15 ft•lb) • Pinch bolt (lower bracket) "2" Pinch bolt (lower bracket): 21 Nm (2.1 m•kg, 15 ft•lb) 8. Install: • Steering stem nut "1" Tighten the lower bracket to specified torque. If torqued too much, it may cause the front fork to malfunction.
SWINGARM SWINGARM REMOVING THE SWINGARM Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Brake hose holder Refer to "FRONT BRAKE AND REAR BRAKE" section. Rear brake caliper Refer to "FRONT BRAKE AND REAR BRAKE" section. Bolt (brake pedal) Shift the brake pedal backward.
SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q'ty 1 Relay arm 1 2 Connecting rod 1 3 Collar 2 4 Oil seal 2 5 Thrust bearing 2 6 Bushing 2 7 Oil seal 8 8 Bearing 10 5-48 Remarks Refer to removal section.
SWINGARM 2. Inspect: • Oil seal "3" Damage → Replace. HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE BEARING 1. Remove: • Bearing "1" Remove the bearing by pressing its outer race. CHECKING THE CONNECTING ROD 1. Inspect: • Bearing "1" • Collar "2" Free play exists/unsmooth revolution/rust → Replace bearing and collar as a set. 2. Inspect: • Oil seal "3" Damage → Replace. CHECKING THE SWINGARM 1.
SWINGARM 2. Install: • Bearing "1" • Washer "2" • Oil seal "3" To relay arm. 3. Install: • Bearing "1" • Oil seal "2" To connecting rod. • Apply the molybdenum disulfide grease on the bearing when installing. • Install the bearing by pressing it on the side having the manufacture's marks or numbers. • Apply the molybdenum disulfide grease on the bearing when installing. • Install the bearing by pressing it on the side having the manufacture's marks or numbers.
SWINGARM INSTALLING THE SWINGARM 1. Install: • Bushing "1" • Thrust bearing "2" • Oil seal "3" • Collar "4" To swingarm "5". Apply the molybdenum disulfide grease on the bushings, thrust bearings, oil seal lips and contact surfaces of the collar and thrust bearing. 4. Install: • Connecting rod "1" • Bolt (connecting rod) "2" • Washer "3" • Nut (connecting rod) "4" Nut (connecting rod): 80 Nm (8.0 m•kg, 58 ft•lb) To relay arm "5". Apply the molybdenum disulfide grease on the bolt. 2.
SWINGARM 8. Install: • Bolt (connecting rod) "1" • Washer "2" • Nut (connecting rod) "3" • Apply the molybdenum disulfide grease on the bolt. • Do not tighten the nut yet. 6. Install: • Swingarm "1" • Pivot shaft "2" Pivot shaft: 85 Nm (8.5 m•kg, 61 ft•lb) • Apply the molybdenum disulfide grease on the pivot shaft. • Insert the pivot shaft from right side. 9. Install: • Bolt (rear shock absorber-relay arm) "1" • Nut (rear shock absorber-relay arm) "2" Nut (rear shock absorber-relay arm): 53 Nm (5.
SWINGARM 13.Install: • Drive chain support "1" • Drive chain support cover "2" • Bolt {drive chain support [L = 50 mm (1.97 in)]} "3" • Nut (drive chain support) "4" Nut (drive chain support): 7 Nm (0.7 m•kg, 5.1 ft•lb) • Bolt {drive chain support cover [L = 10 mm (0.39 in)]} "5" 11.Tighten: • Nut (relay arm) "1" Bolt (drive chain support cover): 7 Nm (0.7 m•kg, 5.1 ft•lb) Nut (relay arm): 70 Nm (7.0 m•kg, 50 ft•lb) 12.
REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Seat Refer to "SEAT AND SIDE COVERS" section in the CHAPTER 4. Silencer Refer to "EXHAUST PIPE AND SILENCER" section in the CHAPTER 4. 1 Bolt (rear shock absorber-relay arm) 1 2 Bolt (rear shock absorber-frame) 1 3 Rear shock absorber 1 4 Locknut 1 Only loosening.
REAR SHOCK ABSORBER Order 9 Part name Q'ty Bearing 2 5-55 Remarks Refer to removal section.
REAR SHOCK ABSORBER HANDLING NOTE • Support the machine securely so there is no danger of it falling over. • This rear shock absorber is provided with a separate type tank filled with high-pressure nitrogen gas. To prevent the danger of explosion, read and understand the following information before handling the shock absorber. The manufacturer can not be held responsible for property damage or personal injury that may result from improper handling.
REAR SHOCK ABSORBER 3. Remove: • Lower bearing "1" Remove the bearing by pressing its outer race. INSTALLING THE BEARING 1. Install: • Upper bearing "1" Install the bearing parallel until the stopper ring groove appears by pressing its outer race. CHECKING THE REAR SHOCK ABSORBER 1. Inspect: • Damper rod "1" Bends/damage → Replace rear shock absorber assembly. • Shock absorber "2" Oil leaks → Replace rear shock absorber assembly. Gas leaks → Replace rear shock absorber assembly.
REAR SHOCK ABSORBER 3. Adjust: • Spring length (installed) Refer to "ADJUSTING THE REAR SHOCK ABSORBER SPRING PRELOAD" section in the CHAPTER 3. 4. Tighten: • Locknut "1" 3. Install: • Lower bearing "1" Install the bearing by pressing it on the side having the manufacture's marks or numbers. Installed depth of the bearing "a": 4 mm (0.16 in) INSTALLING THE REAR SHOCK ABSORBER 1. Install: • Dust seal "1" • O-ring "2" • Collar "3" INSTALLING THE SPRING (REAR SHOCK ABSORBER) 1.
REAR SHOCK ABSORBER 2. Install: • Bushing "1" • Collar "2" • Dust seal "3" 5. Install: • Bolt (rear shock absorber-relay arm) "1" • Nut (rear shock absorber-relay arm) "2" Nut (rear shock absorber-relay arm): 53 Nm (5.3 m•kg, 38 ft•lb) • Apply the molybdenum disulfide grease on the bearing and dust seal lips. • Install the dust seals with their lips facing inward. Apply the molybdenum disulfide grease on the bolt. 3. Install: • Rear shock absorber 4.
FUEL SYSTEM This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage.
FUEL TANK FUEL TANK REMOVING THE FUEL TANK Order Part name Q'ty Remarks Refer to "SEAT AND SIDE COVERS" section in the chapter 4. Seat Refer to "SEAT AND SIDE COVERS" section in the chapter 4. Air scoop (left/right) 1/1 1 Fuel pump coupler 1 Disconnect. 2 Fuel hose 1 Refer to removal section. 3 Fuel tank bolt 2 4 Fuel tank 1 5 Fuel pump bracket 1 6 Fuel pump assembly 1 7 O-ring 1 6-2 Refer to removal section. Refer to removal section.
FUEL TANK REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. Be careful not to damage the fuel pump. 2. Remove: • Fuel pump coupler Although the fuel has been removed from the fuel tank be careful when removing the fuel hoses, since there may be fuel remaining in it. • Before disconnecting the fuel hose, clean the area around the fuel hose connector. • Before removing the fuel hose, place a few rags in the area under where it will be removed.
FUEL TANK CHECKING THE FUEL PUMP BODY 1. Check: • Fuel pump body Cracks/damage → Replace fuel pump assembly. CHECKING THE FUEL PUMP OPERATION 1. Check: • Fuel pump operation Refer to "CHECKING THE FUEL PRESSURE" section. INSTALLING THE FUEL PUMP 1. Install: • Fuel pump • Fuel pump bracket INSTALLING THE FUEL TANK 1.
FUEL TANK 2. Install: • Fuel pump coupler • Air scoop (left/right) • Seat Refer to "SEAT AND SIDE COVERS" in the chapter 4. CHECKING THE FUEL PRESSURE 1. Check: • Pressure regulator operation 2. Remove the fuel tank. Refer to "REMOVEING THE FUEL TANK" section. 3. Connect the pressure gauge "1" and adapter "2" to the fuel injection pipe. 20mm 35mm 35mm 20mm Pressure gauge YU-03153/90890-03153 Fuel pressure adapter YM-03186/90890-03186 4. Install the fuel tank. Refer to "INSTALLING THE FUEL TANK" section.
THROTTLE BODY THROTTLE BODY REMOVING THE THROTTLE BODY Order Part name Q'ty Remarks Seat Refer to "SEAT AND SIDE COVERS" section in the chapter 4. Air scoop (left/right) Refer to "SEAT AND SIDE COVERS" section in the chapter 4. Fuel tank Refer to "FUEL TANK" section. 1 Cover 1 2 Air filter case 1 3 Fuel hose 1 4 Fuel injector coupler 1 Disconnect. 5 Intake air pressure sensor coupler 1 Disconnect.(I.D.
THROTTLE BODY DISASSEMBLING THE THROTTLE BODY Order Part name Q'ty 1 Injector 1 2 Gasket 2 6-7 Remarks
THROTTLE BODY CHECKING THE INJECTOR Replace the fuel injector with a new one if you have dropped or impacted it. 1. Check: • Injectors Damage → Replace. CHECKING THE THROTTLE BODY 1. Check: • Throttle body Cracks/damage → Replace the throttle body as a set. 2. Check: • Starter knob/ idle screw delivery passages "a" Obstructions → Blow out with compressed air. • Before removing the throttle body, clean the area around the throttle body to prevent dirt and other foreign material from falling into the engine.
THROTTLE BODY CHECKING AND REPLACING THE PROTECTOR 1. Check: • Protector "1" Wear/damage → Replace. INSTALLING THE THROTTLE BODY 1. Install: • Throttle body joint "1" • Throttle body "2" • Face the slot "a" in the throttle body joint toward the bottom of the vehicle. • Align the slot “a” on the throttle body joint with the projection “b” on the throttle body. Affix the protector as shown. Throttle body joint clamp screw 3 Nm (0.3 m•kg, 2.2 ft•lb) 2.
ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage.
ELECTRICAL COMPONENTS AND WIRING DIAGRAM WIRING DIAGRAM B/L Gy Gy B B/L Gy W1 W2 W2 W1 W1 W2 R R/W L Y O R/B Lg P/W B/L Gy B/Y Br Br/W B/R B B/W P B/R R R O R O Gy B/R R/B B/R Br/W B/L R R/B B/Y Br/W Br/W B/Y B/L R ON STOP W2 W1 W1 W2 B R R B B B/Y B R R B B P/W P/W B/L L L Y B/L L Y B/L P P B/L L B B/L P/W L B B R R R R/B R/W W1 W2 O O R B/W Lg B R Lg Lg R L Y Y B L B/L B/L P L Lg B/W Br B/W Br B/L Br B/L B B 7-2 B/W
ELECTRICAL COMPONENTS AND WIRING DIAGRAM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
IGNITION SYSTEM IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. Spark → Spark gap test • *Clean or replace spark plug. • Check the connection of the spark plug cap to the spark plug. No spark ↓ Check entire ignition system for connec- No good → Repair or replace. tion. (couplers, leads and ignition coil) OK ↓ Check engine stop switch.
IGNITION SYSTEM SPARK GAP TEST 1. Disconnect the spark plug cap from spark plug. 2. Connect the dynamic spark tester "1" (ignition checker "2") as shown. • Spark plug cap "3" • Spark plug "4" 7. Inspect: • Installed condition of spark plug and spark plug cap Push in the spark plug cap, making sure that it is securely fitted into the hole in the cylinder head cover. CHECKING THE COUPLERS AND LEADS CONNECTION 1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace.
IGNITION SYSTEM CHECKING THE IGNITION COIL 1. Remove the ignition coil cap. 2. Inspect: • Primary coil resistance Out of specification → Replace. CHECKING THE AC MAGNETO 1. Inspect: • Crankshaft position sensor resistance Out of specification → Replace. Tester (+) lead → Gray lead "1" Tester (-) lead → Black lead "2" Tester (+) lead → Orange lead "1" Tester (-) lead → Red lead "2" Primary coil resistance Tester selector position 3.57–4.
IGNITION SYSTEM CHECKING THE ECU 1. Check: • All electrical components. 2. Check: • ECU installation status Make sure that the ECU is installed correctly. • The lean angle sensor is built into the ECU. • The lean angle sensor stops the engine in case of a turnover. • To ensure that the lean angle sensor operates correctly, do not change the installation position of the sensor. 3. Check: • ECU If no fault is found, replace the ECU.
THROTTLE POSITION SENSOR SYSTEM THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position sensor will not operate, use the following inspection steps. Check entire ignition system for connec- No good → Repair or replace. tion. OK ↓ Check throttle position sensor. No good → Replace. OK ↓ *Check AC magneto. No good → Replace. OK ↓ Check ECU. (Throttle position sensor input voltage) No good → *marked: Refer to "IGNITION SYSTEM" section. Use the following special tools in this inspection.
THROTTLE POSITION SENSOR SYSTEM 2. Inspect: • Throttle position sensor variable resistance Check that the resistance in increased as the throttle grip is moved from the full close position to the full open position. Out of specification → Replace. HANDLING NOTE Do not loosen the screw (throttle position sensor) "1" except when changing the throttle position sensor due to failure because it will cause a drop in engine performance.
THROTTLE POSITION SENSOR SYSTEM 3. Replace: • Throttle position sensor 4. Install: • Throttle position sensor "1" • Screw (throttle position sensor) "2" • Align the projection "b" on the throttle body with the slot "a" in the throttle position sensor. • Temporarily tighten the screw (throttle position sensor). CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1. Disconnect the throttle position sensor coupler. 2. Connect the test harness-speed sensor (3P) "1" as shown.
FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 7. Set the switch on the FI diagnostic tool subwire harness to "OFF", and then disconnect the FI diagnostic tool, FI diagnostic tool subwire harness, and battery. Place the accessory coupler in its original position. TROUBLESHOOTING METHOD Engine starting problems, engine idling speed problems, and medium and high-speed performance problems 1. CHECK: • Refer to "TROUBLESHOOTING" section in the chapter 3. 2. Connect the FI diagnostic tool.
FUEL INJECTION SYSTEM CHECKING THE FAULT CODES 1. Set the switch on the FI diagnostic tool subwire harness to "ON". 1. While pressing the "MODE" button, set the switch on the FI diagnostic tool sub-wire harness to "ON". When the switch on the FI diagnostic tool subwire harness is set to "ON", make sure that "Waiting for connection" is displayed on the LCD of the FI diagnostic tool.
FUEL INJECTION SYSTEM SENSOR OPERATION TABLE Diagnostic code No. D01 D02 Item Throttle angle Atmosphere Actuation or display Display Checking method Actuation or LCD standard display values Displays the throttle angle. 0–125° Check with throttle fully closed. When throttle is fully closed:15–19° Check with throttle fully open. When throttle is fully opened:95–101° Displays the atmospheric pressure. • Measure the atmospheric pressure.
FUEL INJECTION SYSTEM Diagnostic code No. D06 D08 D30 D36 D60 Item Actuation or display Coolant temperaDisplay ture Checking method Displays the coolant temperature. • Check the coolant temperature. Actuation or LCD standard display values -20–150°C Cold engine: Displayed temperature is close to the ambient temperature. Warm engine: Displayed temperature is the current coolant temperature. Displays the lean angle sen- 0–5.0 V sor output voltage. 1.0V: Upright Remove the ECU and in4.
FUEL INJECTION SYSTEM Diagnostic code No. Item Actuation or display Checking method Displays the fault code num- 00: No history bers that are stored in the 12–50: History exists malfunction history. • Refer to the fault code If code numbers more than number. one are detected, the display alternates every two seconds to show all the detected code numbers. When all code numbers are shown, the display repeats the same process. D61 Malfunction histoDisplay ry code display.
FUEL INJECTION SYSTEM TROUBLESHOOTING DETAILS This section describes the countermeasures per fault code number displayed on the FI diagnostic tool. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part have been completed, reset the FI diagnostic tool display according to the "Reinstatement method". Fault code No.
FUEL INJECTION SYSTEM Fault code No. 12 Symptom No normal signals are received from the crankshaft position sensor. Fail-safe system Able to start Able to drive Diagnostic code No. — FI diagnostic tool display — Checking method — Item Item/components and probable cause Check or maintenance job Checking method 4 Installed condition of sensor. Check that the gap between the crankshaft position sensor and the rotor is 0.85 mm.
FUEL INJECTION SYSTEM Fault code No. 13 Symptom Intake air pressure sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. D03 FI diagnostic tool display Intake air pressure Checking method Crank the engine. (If the display value changes, the performance is OK.
FUEL INJECTION SYSTEM Fault code No. 13 Symptom Intake air pressure sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. D03 FI diagnostic tool display Intake air pressure Checking method Crank the engine. (If the display value changes, the performance is OK.) Item Item/components and probable cause Check or maintenance job Checking method 4 Installed condition of sensor.
FUEL INJECTION SYSTEM Fault code No. 14 Symptom Intake air pressure sensor system malfunction detected. (clogged hole or disconnected sensor) Fail-safe system Able to start Able to drive Diagnostic code No. D03 FI diagnostic tool display Intake air pressure Checking method Crank the engine. (If the display value changes, the performance is OK.
FUEL INJECTION SYSTEM Fault code No. 15 Symptom Throttle position sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. D01 FI diagnostic tool display • 15–19° (Fully closed position) • 95–101° (Fully opened position) Checking method • Check with throttle valves fully closed. • Check with throttle valves fully open.
FUEL INJECTION SYSTEM Fault code No. 15 Symptom Throttle position sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. D01 FI diagnostic tool display • 15–19° (Fully closed position) • 95–101° (Fully opened position) Checking method • Check with throttle valves fully closed. • Check with throttle valves fully open.
FUEL INJECTION SYSTEM Fault code No. 16 Symptom Signal from throttle position sensor does not change. Fail-safe system Able to start Able to drive Diagnostic code No. D01 FI diagnostic tool display • 15 – 19° (Fully closed position) • 95 – 101° (Fully opened position) Checking method • Check with throttle valves fully closed. • Check with throttle valves fully open. Item Item/components and probable cause Check or maintenance job Checking method 1 Installed condition of sensor.
FUEL INJECTION SYSTEM Fault code No. 21 Symptom Coolant temperature sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. D06 FI diagnostic tool display -20–150°C Cold engine: Displayed temperature is close to the ambient temperature. Warm engine: Displayed temperature is the current coolant temperature. Checking method Check the coolant temperature.
FUEL INJECTION SYSTEM Fault code No. 21 Symptom Coolant temperature sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. D06 FI diagnostic tool display -20–150°C Cold engine: Displayed temperature is close to the ambient temperature. Warm engine: Displayed temperature is the current coolant temperature. Checking method Check the coolant temperature.
FUEL INJECTION SYSTEM Fault code No. 22 Symptom Intake air temperature sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. D05 FI diagnostic tool display -20–100°C Cold engine: Displayed temperature is close to the ambient temperature. Warm engine: Displayed temperature is approximately 20 °C higher than the ambient temperature. Checking method Check the temperature in the intake manifold.
FUEL INJECTION SYSTEM Fault code No. 22 Symptom Intake air temperature sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. D05 FI diagnostic tool display -20–100°C Cold engine: Displayed temperature is close to the ambient temperature. Warm engine: Displayed temperature is approximately 20 °C higher than the ambient temperature. Checking method Check the temperature in the intake manifold.
FUEL INJECTION SYSTEM Fault code No. 23 Symptom Atmospheric pressure sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. D02 FI diagnostic tool display Atmosphere Checking method Measure the atmospheric pressure. Item Item/components and probable cause Check or maintenance job Checking method 1 Check the connection and locking con- Poor connection → Properly dition of the atmospheric pressure sen- connect, repair, or replace. sor coupler.
FUEL INJECTION SYSTEM Fault code No. 23 Symptom Atmospheric pressure sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. D02 FI diagnostic tool display Atmosphere Checking method Measure the atmospheric pressure. Item Item/components and probable cause Check or maintenance job Checking method 4 Installed condition of sensor. Check that the sensor is installed securely and that there are no pinched leads.
FUEL INJECTION SYSTEM Fault code No. 30 Symptom Turnover of vehicle Fail-safe system Able to start Unable to drive Diagnostic code No. D08 FI diagnostic tool display Lean angle sensor • 1.0 V (Upright) • 4.0 V (Overturned) Checking method Remove the ECU and incline it 45° or more. Item Item/components and probable cause Check or maintenance job Checking method 1 The vehicle has overturned. Raise the vehicle upright.
FUEL INJECTION SYSTEM Fault code No. 33 Symptom Ignition system circuit signal is not received properly. Fail-safe system Unable to start Unable to drive Diagnostic code No. D30 FI diagnostic tool display Actuates the ignition coil for five times every second. The "WARNING" LED on the FI diagnostic tool comes on each time the ignition coil is actuated. Checking method Check the spark five times. • Connect an ignition checker.
FUEL INJECTION SYSTEM Fault code No. 33 Symptom Ignition system circuit signal is not received properly. Fail-safe system Unable to start Unable to drive Diagnostic code No. D30 FI diagnostic tool display Actuates the ignition coil for five times every second. The "WARNING" LED on the FI diagnostic tool comes on each time the ignition coil is actuated. Checking method Check the spark five times. • Connect an ignition checker.
FUEL INJECTION SYSTEM Fault code No. 33 Symptom Ignition system circuit signal is not received properly. Fail-safe system Unable to start Unable to drive Diagnostic code No. D30 FI diagnostic tool display Actuates the ignition coil for five times every second. The "WARNING" LED on the FI diagnostic tool comes on each time the ignition coil is actuated. Checking method Check the spark five times. • Connect an ignition checker.
FUEL INJECTION SYSTEM Fault code No. 39 Symptom Injection system circuit signal is not received properly. Fail-safe system Unable to start Unable to drive Diagnostic code No. D36 FI diagnostic tool display Actuates the injector for five times every second. The "WARNING" LED on the FI diagnostic tool comes on each time the fuel injector is actuated. Checking method Check the operating sound of the injector five times.
FUEL INJECTION SYSTEM Fault code No. 39 Symptom Injection system circuit signal is not received properly. Fail-safe system Unable to start Unable to drive Diagnostic code No. D36 FI diagnostic tool display Actuates the injector for five times every second. The "WARNING" LED on the FI diagnostic tool comes on each time the fuel injector is actuated. Checking method Check the operating sound of the injector five times.
FUEL INJECTION SYSTEM Fault code No. 41 Symptom Lean angle sensor malfunction. (the sensor is built into the ECU) Fail-safe system Unable to start Unable to drive Diagnostic code No. D08 FI diagnostic tool display Lean angle sensor • 1.0 V (Upright) • 4.0 V (Overturned) Checking method Remove the ECU and incline it 45° or more. Item Item/components and probable cause 1 Malfunction in ECU. Check or maintenance job Checking method Replace the ECU. Fault code No.
FUEL INJECTION SYSTEM Fault code No. 44 Symptom Error is detected while reading or writing on EEPROM. Fail-safe system Able to start engine (depending on circumstances) Able to drive vehicle (depending on circumstances) Diagnostic code No.
FUEL INJECTION SYSTEM Fault code No. 46 Symptom Power supply to the ECU is not normal. Fail-safe system Able to start (depending on circumstances) Able to drive vehicle (depending on circumstances) Diagnostic code No. — FI diagnostic tool display — Checking method — Item Item/components and probable cause Check or maintenance job Checking method 1 Check the connection and locking con- Poor connection → Properly dition of the ECU coupler. connect, repair, or replace.
FUEL INJECTION SYSTEM Fault code No. 46 Symptom Power supply to the ECU is not normal. Fail-safe system Able to start (depending on circumstances) Able to drive vehicle (depending on circumstances) Diagnostic code No. — FI diagnostic tool display — Checking method — Item Item/components and probable cause Check or maintenance job Checking method 3 Malfunction of the rectifier/regulator. Defective → Replace. Refer to "CHECKING THE RECTIFIER/REGULATOR" section.
FUEL INJECTION SYSTEM Fault code No. 50 Symptom ECU internal malfunction Fail-safe system Unable to start Unable to drive Diagnostic code No. — FI diagnostic tool display — Checking method — Item Item/components and probable cause 1 Check or maintenance job Malfunction in ECU. Replace the ECU. Fault code No. waiting for connection Symptom Communication signal is not received.
FUEL INJECTION SYSTEM Fault code No. waiting for connection Symptom Communication signal is not received. Fail-safe system Able to start (unable when ECU is malfunctioning) Able to drive vehicle (unable when ECU is malfunctioning) Diagnostic code No. — FI diagnostic tool display — Checking method — Item Item/components and probable cause Check or maintenance job Checking method 2 Check the connection and locking con- Poor connection → Properly dition of the wire harness ECU coupler.
FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom Registered data cannot be received from the FI diagnostic tool. Fail-safe system Able to start Able to drive Diagnostic code No. — FI diagnostic tool display — Checking method — Item Item/components and probable cause Check or maintenance job Checking method 1 Check the connection and locking con- Poor connection → Properly dition of the FI diagnostic tool coupler. connect, repair, or replace. Disconnect the coupler and check the pins.
FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom Registered data cannot be received from the FI diagnostic tool. Fail-safe system Able to start Able to drive Diagnostic code No. — FI diagnostic tool display — Checking method — Item Item/components and probable cause Check or maintenance job 4 FI diagnostic tool malfunction Replace the FI diagnostic tool. 5 Malfunction in ECU. Replace the ECU.
FUEL PUMP SYSTEM FUEL PUMP SYSTEM INSPECTION STEPS If the fuel pump is not operating normally, perform the following procedures in the order given. Check engine stop switch. No good Replace. → OK ↓ Checking the couplers and leads connections No good Repair or replace. → OK ↓ Check the fuel pump.(Checking the fuel pump body) No good Replace the fuel pump assembly. → OK ↓ Replace the ECU. • Remove the following parts before inspection. 1. Seat 2. Side cover (right/left) 3.
ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS Coolant temperaTester selector poture sensor resissition tance CHECKING THE COOLANT TEMPERATURE SENSOR 1. Remove: • Coolant temperature sensor Refer to "REMOVING THE CYLINDER HEAD" section in the CHAPTER 4. Ω×100 2.51 — 2.78 kΩ (20 °C, 68°F) kΩ×1 Out of specification → Replace. CHECKING THE INTAKE AIR PRESSURE SENSOR 1. Check: • Intake air pressure sensor output voltage 2.
ELECTRICAL COMPONENTS CHECKING THE INTAKE AIR TEMPERATURE SENSOR 1. Remove: • Intake air temperature sensor (from the air filter case.) • Handle the intake air temperature sensor with special care. • Never subject the intake air temperature sensor to strong shocks. If the intake air temperature sensor is dropped, replace it. 3. Connect the FI diagnostic tool sub-wire harness to a battery, and then set the switch on the harness to "ON". 2. Check: • Intake air temperature sensor resistance 3.
ELECTRICAL COMPONENTS CHECKING THE FUEL INJECTORS 1. Remove: • Seat • Fuel tank • Air filter case 2. Check: • Injector resistance 3. Connect: • Tester Tester (+) lead → Injector terminal "1" Tester (-) lead → Injector terminal "2" Injector resistance Tester selector position 12.0 Ω (20 °C, 68°F) Ω×10 Out of specification → Replace.
CHASSIS TUNING DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS CHASSIS Part name SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET) Part number Drive sprocket "1" (STD) Secondary reduction ratio = Number of rear wheel sprocket teeth/Number of drive sprocket teeth Standard secondary reduction ratio Size 13T 9383E-13233 47T 17D-25447-50 (STD) 48T 17D-25448-50 * (STD) 49T 17D-25449-50 50T 17D-25450-50 51T 17D-25451-50 52T 17D-25452-50 Rear wheel sprocket "2" 48/13 (3.692) * 49/13 (3.
CHASSIS TIRE PRESSURE Tire pressure should be adjust to suit the road surface condition of the circuit. Standard oil amount: 355 cm3 (12.5 Imp oz, 12.0 US oz) Extent of adjustment: 300–365 cm3 (10.6–12.8 Imp oz, 10.1–12.3 US oz) Standard tire pressure: 100 kPa (1.0 kgf/cm2, 15 psi) • Under a rainy, muddy, sandy, or slippery condition, the tire pressure should be lower for a larger area of contact with the road surface. Extent of adjustment: 60–80 kPa (0.6–0.8 kgf/cm2, 9.
CHASSIS 2. Use of stiff spring • Change the rebound damping. Turn in one or two clicks. • Change the compression damping. Turn out one or two clicks. REAR SUSPENSION SETTING The rear suspension setting should be made depending on the rider's feeling of an actual run and the circuit conditions. The rear suspension setting includes the following two factors: 1. Setting of spring preload • Change the set length of the spring. • Change the spring. 2. Setting of damping force • Change the rebound damping.
CHASSIS Length "a" of standard shock: 459 mm (18.07 in) • If the machine is new and after it is broken in, the same set length of the spring may change because of the initial fatigue, etc. of the spring. Therefore, be sure to make reevaluation. • If the standard figure cannot be achieved by adjusting the spring adjuster and changing the spring set length, replace the spring with an optional one and make readjustment.
CHASSIS • Extent of adjustment (spring preload) Maximum Minimum Position in which Position in which the spring is turned the spring is turned in 18 mm (0.71 in) in 1.5 mm (0.06 in) from its free length. from its free length. For the spring preload adjustment, refer to "ADJUSTING THE REAR SHOCK ABSORBER SPRING PRELOAD" in the CHAPTER 3.
CHASSIS SUSPENSION SETTING (FRONT FORK) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in).
CHASSIS SUSPENSION SETTING (REAR SHOCK ABSORBER) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Adjust the rebound damping in 2-click increments or decrements. • Adjust the low compression damping in 1-click increments or decrements. • Adjust the high compression damping in 1/6 turn increments or decrements.
33D-9-10_cover 09.7.16 13:11 ページ 2 Q Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
33D-9-11_cover 2010.5.25 11:08 ページ 1 PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories 2011 q Read this manual carefully before operating this vehicle. YZ450FA OWNER’S SERVICE MANUAL 2011 YZ450FA PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN JAPAN 2010.05—0.
