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Yamaha 2008 WR450F, Owner'S Service Manual

The Yamaha 2008 WR450F Owner's Service Manual is a comprehensive guide that ensures effortless maintenance for your bike. This manual is a must-have for every Yamaha owner, allowing you to easily download it for free from our website, guaranteeing hassle-free riding and maximum performance.

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2-14

TIGHTENING TORQUES

CHASSIS

△

- marked portion shall be checked for torque tightening after break-in or before each race.

Balancer weight plate

M6 × 1.0

3

10

1.0

7.2

Drive sprocket

M20 × 1.0

1

75

7.5

54

Drive chain sprocket cover

M6 × 1.0

2

8

0.8

5.8

Shift pedal

M6 × 1.0

1

12

1.2

8.7

Shift guide

M6 × 1.0

2

10

1.0

7.2

Stopper lever

M6 × 1.0

1

10

1.0

7.2

Segment

M8 × 1.25

1

30

3.0

22

Part to be tightened

Thread size

Q'ty

Tightening torque

Nm

m•kg

ft•lb

Part to be tightened

Thread size

Q'ty

Tightening torque

Nm

m•kg

ft•lb

△

Upper bracket and outer tube 

M8 × 1.25

4

21

2.1

15

△

Lower bracket and outer tube

M8 × 1.25

4

21

2.1

15

△

Upper bracket and steering stem

M24 × 1.0

1

145

14.5

105

△

Handlebar holder (upper)

M8 × 1.25

4

28

2.8

20

△

Handlebar holder (lower) 

M12 × 1.25

2

34

3.4

24

△

Steering ring nut

M28 × 1.0

1

Refer to NOTE.

Front fork and cap bolt

M51 × 1.5

2

30

3.0

22

Front fork and base valve

M30 × 1.0

2

55

5.5

40

Cap bolt and damper rod (front fork)

M12 × 1.25

2

29

2.9

21

Bleed screw (front fork) and cap bolt

M5 × 0.8

2

1

0.1

0.7

△

Front fork and protector

M6 × 1.0

6

7

0.7

5.1

△

Front fork protector and brake hose holder

M6 × 1.0

2

7

0.7

5.1

Throttle cable cap

M5 × 0.8

2

4

0.4

2.9

Clutch lever holder mounting

M5 × 0.8

2

4

0.4

2.9

Clutch lever mounting

M6 × 1.0

1

4

0.4

2.9

Hot starter lever holder mounting

M5 × 0.8

2

4

0.4

2.9

Hot starter lever mounting

M5 × 0.8

1

2

0.2

1.4

△

Front brake master cylinder and bracket 

M6 × 1.0

2

9

0.9

6.5

Front brake master cylinder cap

M4 × 0.7

2

2

0.2

1.4

Brake lever mounting (bolt)

M6 × 1.0

1

6

0.6

4.3

Brake lever mounting (nut)

M6 × 1.0

1

6

0.6

4.3

Brake lever position locknut

M6 × 1.0

1

5

0.5

3.6

△

Hose guide (front brake hose) and hose guide bracket

M5 × 0.8

1

4

0.4

2.9

△

Hose guide (front brake hose) and under bracket

M6 ×1.0

1

4

0.4

2.9

△

Front brake hose union bolt (master cylinder)

M10 × 1.25

1

30

3.0

22

△

Front brake hose union bolt (caliper) 

M10 × 1.25

1

30

3.0

22

△

Front brake caliper and front fork

M8 × 1.25

2

23

2.3

17

△

Front brake caliper and brake hose holder

M6 × 1.0

1

10

1.0

7.2

△

Brake caliper (front and rear) and pad pin plug 

M10 × 1.0

2

3

0.3

2.2

△

Brake caliper (front and rear) and pad pin

M10 × 1.0

2

18

1.8

13

△

Brake caliper (front and rear) and bleed screw 

M8 × 1.25

2

6

0.6

4.3

△

Front wheel axle and nut

M16 × 1.5

1

90

9.0

65

Summary of Contents for 2008 WR450F

Page 1: ...2008 5TJ 28199 71 WR450F X 2008 5TJ 28199 71 WR450F X WR450F X 2008 OWNER S SERVICE MANUAL MANUEL D ATELIER DU PROPRIETAIRE ...

Page 2: ......

Page 3: ...S SERVICE MANUAL 2007 by Yamaha Motor Co Ltd 1st Edition June 2007 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Page 4: ...Please check local regulations before riding 1 THIS MACHINE IS TO BE OP ERATED BY AN EXPERI ENCED RIDER ONLY Do not attempt to operate this machine at maximum power until you are totally familiar with its characteristics 2 THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OP ERATOR ONLY Do not carry passengers on this machine 3 ALWAYS WEAR PROTEC TIVE APPAREL When operating this ma chine always wear an...

Page 5: ... TO USE THIS MANUAL FINDING THE REQUIRED PAGE 1 This manual consists of seven chapters General Information Specifications Regular inspec tion and adjustments Tuning Engine Chassis and Electri cal 2 The table of contents is at the be ginning of the manual Look over the general layout of the book be fore finding then required chapter and item Bend the book at its edge as shown to find the required f...

Page 6: ...informa tion the step by step format sup plements 5 are given in addition to the exploded diagram and job instruction chart ILLUSTRATED SYMBOLS Refer to the illustration Illustrated symbols 1 to 7 are used to identify the specifications appear ing 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 Elect...

Page 7: ...TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 REGULAR INSPECTION AND ADJUSTMENTS 3 TUNING 4 ENGINE 5 CHASSIS 6 ELECTRICAL 7 ...

Page 8: ... CHAPTER 4 TUNING ENGINE 4 1 CHASSIS 4 5 CHAPTER 5 ENGINE RADIATOR 5 1 CARBURETOR 5 4 AIR INDICTOIN SYSTEM 5 11 CAMSHAFTS 5 13 CYLINDER HEAD 5 18 VALVES AND VALVE SPRINGS 5 21 CYLINDER AND PISTON 5 25 CLUTCH 5 28 OIL FILTER ELEMENT AND WATER PUMP 5 32 BALANCER 5 36 OIL PUMP 5 38 KICK SHAFT AND SHIFT SHAFT 5 41 AC MAGNETO AND STARTER CLUTCH 5 46 ENGINE REMOVAL 5 51 CRANKCASE AND CRANKSHAFT 5 55 TRA...

Page 9: ... Hot starter lever 3 Engine stop switch 4 Multi function display 5 Main switch 6 Start switch 7 Front brake lever 8 Throttle grip 9 Radiator cap 10 Fuel tank cap 11 Taillight 12 Kickstarter crank 13 Fuel tank 14 Headlight 15 Radiator 16 Coolant drain bolt 17 Rear brake pedal 18 Valve joint 19 Fuel cock 20 Cold starter knob 21 Air cleaner 22 Catch tank 23 Drive chain 24 Shift pedal 25 Oil dipstick ...

Page 10: ...PLUG WRENCH This spark plug wrench 1 is used to remove and install the spark plug NIPPLE WRENCH This nipple wrench 1 is used to tighten the spoke JET NEEDLE PULL UP TOOL The jet needle pull up tool 1 is used to pull the jet needle out of the carbu retor IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1 Remove all dirt mud dust and foreign material before removal and disassembly When ...

Page 11: ...tweight lithium base grease to the seal lip s Oil the bearings liberally when installing Do not use compressed air to spin the bearings dry This causes dam age to the bearing surfaces CIRCLIPS 1 All circlips should be inspected carefully before reassembly Al ways replace piston pin clips after one use Replace distorted cir clips When installing a circlip 1 make sure that the sharp edged corner 2 i...

Page 12: ...How to use Illustration Dial gauge and stand YU 3097 90890 01252 Stand YU 1256 These tools are used to check each part for runout or bent Crankshaft installing tool Crankshaft installing pot YU 90050 90890 01274 Crankshaft installing bolt YU 90050 90890 01275 Spacer crankshaft installer YM 91044 90890 04081 Adapter M12 YU 90063 90890 01278 These tools are used to install the crankshaft Piston pin ...

Page 13: ...is tool is used for when loosening or tightening the flywheel magneto securing nut Pocket tester YU 3112 C 90890 03112 Use this tool to inspect the coil resis tance output voltage and amper age Timing light YM 33277 A 90890 03141 This tool is necessary for checking ignition timing Valve spring compressor YM 4019 90890 04019 This tool is needed to remove and install the valve assemblies Tool name P...

Page 14: ...nstaller Intake 4 5 mm 0 18 in Exhaust 5 0 mm 0 20 in YM 4117 90890 04117 YM 4098 90890 04098 This tool is needed to install the valve guide Valve guide reamer Intake 4 5 mm 0 18 in Exhaust 5 0 mm 0 20 in YM 4118 90890 04118 YM 4099 90890 04099 This tool is needed to rebore the new valve guide Rotor puller YM 4142 90890 04142 This tool is used to remove the fly wheel magneto Crankcase separating t...

Page 15: ... Vacuum pressure pump gauge set YB 35956 A 90890 06756 This tool is used to check the air in duction system Digital tachometer YU 39951 B 90890 06760 This tool is needed for observing en gine rpm YAMAHA Bond No 1215 ThreeB ond No 1215 90890 85505 This sealant Bond is used for crankcase mating surface etc Tool name Part number How to use Illustration ...

Page 16: ...ft pedal 1 on the left side of the engine 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 st...

Page 17: ...accu mulated travel distance in timer measurement Change tripmeter digits capable of change to any given ones DESCRIPTION Operation buttons 1 Select button SLCT 1 2 Select button SLCT 2 3 Reset button RST Screen display 4 Tripmeter indicator 5 Tripmeter indicator 6 Timer indicator 7 Clock Timer 8 Speedometer 9 Odometer Tripmeter The operation buttons can be pushed in the following two manners Shor...

Page 18: ... starts either of which can be selected Manual start Starting measurement by the rider himself operating the button A long push on the SLCT2 button will put measurement on standby Auto start Starting timer measurement automat ically on detection of the movement of the machine A long push on the SLCT1 button will put measurement on standby Manual start Initial setting at changeover to RACE MODE wil...

Page 19: ...P A dis play by pushing the RST button for 2 seconds or more If reset and travel distance dis play will go on flashing for four sec onds Resetting tripmeter A TRIP A and timer 1 Check that the timer is not in op eration If the timer is in operation stop it by pushing the SLCT1 button and SLCT2 button at the same time 2 Reset all measured data by push ing the RST button for 2 sec onds or more Reset...

Page 20: ... on the button changes the operation in both arrowed directions Meter function Function that can be performed whether the time is or is not in operation Extent to which the meter can operate Clock BASIC MODE Tripmeter ODO TRIP A TRIP B ODO Speedometer for U K MPH km h MPH Putting measurement on standby Manual start Auto start RACE MODE Timer in operation Reset TRIP A Correct TRIP A Measurement sta...

Page 21: ...the button changes the operation in the ar rowed direction D A long push on the button changes the operation in both arrowed directions E Meter function F Function that can be performed whether the time is or is not in operation G Extent to which the meter can operate 1 BASIC MODE 2 Clock 3 Trip meter 4 Speedometer for U K 5 RACE MODE 6 Putting measurement on stand by 7 Manual start 8 Auto start 9...

Page 22: ...ion in any position However it is recommended to shift into neutral before starting the en gine 1 Inspect the coolant level 2 Turn the fuel cock to ON 3 Push on the main switch to ON 4 Shift the transmission into neutral 5 Fully open the cold starter knob 1 6 Start the engine by pushing the start switch or by kicking the kick starter crank If the engine fails to start by pushing the start switch r...

Page 23: ...the machine through out its entire operating range Re start the machine and operate it for about 10 to 15 more minutes The machine will now be ready to race After the break in or before each race you must check the entire machine for loose fittings and fasteners as per TORQUE CHECK POINTS Tighten all such fasteners as required When any of the following parts have been replaced they must be broken ...

Page 24: ...ink type Assembly of links Link to frame Link to rear shock absorber Link to swingarm Installation of rear shock absorber Rear shock absorber to frame Installation of swingarm Tightening of pivot shaft Wheel Installation of wheel Front Tightening of wheel axle Tightening of axle holder Rear Tightening of wheel axle Wheel to rear wheel sprocket Brake Front Brake caliper to front fork Brake disc to ...

Page 25: ...ain with a paper towel and lubri cate the chain to prevent rust 7 Clean the seat with a vinyl uphol stery cleaner to keep the cover pliable and glossy 8 Automotive wax may be applied to all painted or chromed surfac es Avoid combination cleaner waxes as they may contain abra sives 9 After completing the above start the engine and allow it to idle for several minutes STORAGE If your machine is to b...

Page 26: ... mm 14 37 in 370 mm 14 57 in Dry weight Without oil and fuel 112 5 kg 248 0 lb Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Single cylinder forward inclined Displacement 449 cm3 15 8 Imp oz 15 2 US oz Bore stroke 95 0 63 4 mm 3 74 2 50 in Compression ratio 12 3 1 Starting system Kick and electric starter Lubrication system Dry sump Oil type or grade Engine oil For CDN Yamalu...

Page 27: ...plug Type manufacturer CR8E NGK resistance type Gap 0 7 0 8 mm 0 028 0 031 in Clutch type Wet multiple disc Transmission Primary reduction system Gear Primary reduction ratio 61 23 2 652 Secondary reduction system Chain drive Secondary reduction ratio 50 13 3 846 Transmission type Constant mesh 5 speed Operation Left foot operation Gear ratio 1st 29 12 2 417 2nd 26 15 1 733 3rd 21 16 1 313 4th 21 ...

Page 28: ...l spring oil damper Rear shock absorber Coil spring gas oil damper Wheel travel Front wheel travel 300 mm 11 8 in Rear wheel travel 305 mm 12 0 in Electrical Ignition system CDI Generator system AC magneto Battery type YTZ7S F Battery voltage capacity 12V 6 AH Specific gravity 1 310 Headlight type Quartz bulb halogen Bulb wattage quantity Headlight 12 V 35 36 5 W 1 Taillight 12 V 1 6 0 3 W 1 Item ...

Page 29: ...50 mm 0 8839 0 8878 in 22 350 mm 0 8799 in Exhaust A 30 200 30 300 mm 1 1890 1 1929 in 30 100 mm 1 1850 in Exhaust B 22 450 22 550 mm 0 8839 0 8878 in 22 350 mm 0 8799 in Camshaft runout limit 0 03 mm 0 0012 in Timing chain Timing chain type No of links 98XRH2010 118M 118 Timing chain adjustment method Automatic Valve valve seat valve guide Valve clearance cold IN 0 10 0 15 mm 0 0039 0 0059 in EX ...

Page 30: ...0 033 in Stem outside diameter IN 4 475 4 490 mm 0 1762 0 1768 in 4 445 mm 0 1750 in Stem outside diameter EX 4 965 4 980 mm 0 1955 0 1961 in 4 935 mm 0 1943 in Guide inside diameter IN 4 500 4 512 mm 0 1772 0 1776 in 4 550 mm 0 1791 in Guide inside diameter EX 5 000 5 012 mm 0 1969 0 1973 in 5 050 mm 0 1988 in Stem to guide clearance IN 0 010 0 037 mm 0 0004 0 0015 in 0 08 mm 0 003 in Stem to gui...

Page 31: ...12 55 14 45 kg at 28 38 mm 27 67 31 85 lb at 1 12 in Tilt limit IN 2 5 1 7 mm 2 5 0 067 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 in 0 1 mm 0 004 in Piston size D 94 965 94 980 mm 3 7388 3 7394 in Measuring point H 8 mm 0 315 in Piston off set 1 mm 0...

Page 32: ... 014 0 020 in 0 85 mm 0 033 in Side clearance 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in Oil ring Dimensions B T 2 0 2 9 mm 0 08 0 11 in End gap installed 0 2 0 5 mm 0 01 0 02 in Crankshaft Crank width A 61 95 62 00 mm 2 439 2 441 in Runout limit C 0 03 mm 0 0012 in 0 05 mm 0 002 in Big end side clearance D 0 15 0 45 mm 0 0059 0 0177 in 0 50 mm 0 02 in Small end free play F 0 4 1 0 mm 0 02 0...

Page 33: ... radial clearance 0 010 0 044 mm 0 0004 0 0017 in Clutch release method Inner push cam push Shifter Shifter type Cam drum and guide bar Guide bar bending limit 0 05 mm 0 002 in Kickstarter Type Ratchet type Carburetor I D mark 5TJE E0 Main jet M J 162 Main air jet M A J ø2 0 Jet needle J N NFNT Cutaway C A 1 5 Pilot jet P J 45 Pilot air jet P A J 70 Pilot outlet P O ø0 9 Bypass B P ø1 0 Valve seat...

Page 34: ...t Item Standard Limit Steering system Steering bearing type Taper roller bearing Front suspension CDN AUS NZ ZA Front fork travel 300 mm 11 8 in Fork spring free length 460 mm 18 1 in 455 mm 17 9 in Spring rate STD K 4 5 N mm 0 459 kg mm 25 7 lb in Optional spring spacer Yes Oil capacity 648 cm3 22 8 lmp oz 21 9 US oz 655 cm3 23 1 lmp oz 22 1 US oz Oil level 132 mm 5 20 in 125 mm 4 92 in Min Max F...

Page 35: ...0 2 5 mm 9 84 0 10 in Pad thickness 4 4 mm 0 17 in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Caliper cylinder inside dia 27 0 mm 1 063 in 2 Brake fluid type DOT 4 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...

Page 36: ...resistance color 0 224 0 336 Ω at 20 C 68 F Yellow Ground Rectifier regulator Regulator type Semiconductor short circuit Model manufacturer SH770AA SHINDENGEN Regulated voltage AC 12 5 13 5 V Regulated voltage DC 14 0 15 0 V Rectifier capacity AC 12 A Rectifier capacity DC 8 A Electric starting system Type Constant mesh Starter motor Model manufacturer 5UM20 YAMAHA Operation voltage 12 V Output 0 ...

Page 37: ... M8 1 25 1 15 1 5 11 Cylinder head bolt M10 1 25 4 Refer to NOTE 1 Cylinder head bolt M6 1 0 2 10 1 0 7 2 Cylinder head cover M6 1 0 2 10 1 0 7 2 Cylinder M6 1 0 1 10 1 0 7 2 Timing chain tensioner M6 1 0 2 10 1 0 7 2 Timing chain tensioner cap bolt M6 1 0 1 7 0 7 5 1 Timing chain guide intake side M6 1 0 2 10 1 0 7 2 Exhaust pipe nut M8 1 25 1 20 2 0 14 Exhaust pipe bolt M8 1 25 1 20 2 0 14 Silen...

Page 38: ...er M6 1 0 7 10 1 0 7 2 Crankcase cover right M6 1 0 8 10 1 0 7 2 Crankcase cover right M6 1 0 2 12 1 2 8 7 Crankcase cover left M6 1 0 8 10 1 0 7 2 Idle gear cover starter motor M6 1 0 2 10 1 0 7 2 Crankcase M6 1 0 12 12 1 2 8 7 Clutch cable holder M6 1 0 1 10 1 0 7 2 Oil drain bolt crankcase right M6 1 25 1 20 2 0 14 Oil drain bolt crankcase left M6 1 0 1 20 2 0 14 Oil check bolt crankcase M6 1 0...

Page 39: ... 7 Front fork and protector M6 1 0 6 7 0 7 5 1 Front fork protector and brake hose holder M6 1 0 2 7 0 7 5 1 Throttle cable cap M5 0 8 2 4 0 4 2 9 Clutch lever holder mounting M5 0 8 2 4 0 4 2 9 Clutch lever mounting M6 1 0 1 4 0 4 2 9 Hot starter lever holder mounting M5 0 8 2 4 0 4 2 9 Hot starter lever mounting M5 0 8 1 2 0 2 1 4 Front brake master cylinder and bracket M6 1 0 2 9 0 9 6 5 Front ...

Page 40: ... 25 1 53 5 3 38 Engine guard M6 1 0 3 7 0 7 5 1 Regulator mounting M6 1 0 2 7 0 7 5 1 Pivot shaft and nut M16 1 5 1 85 8 5 61 Relay arm and swingarm M14 1 5 1 70 7 0 50 Relay arm and connecting rod M14 1 5 1 80 8 0 58 Connecting rod and frame M14 1 5 1 80 8 0 58 Rear shock absorber and frame M10 1 25 1 56 5 6 40 Rear shock absorber and relay arm M10 1 25 1 53 5 3 38 Rear frame and frame upper M8 1...

Page 41: ...0 4 2 9 Plate 2 and protector 2 0 5 0 05 0 36 Speed sensor lead holder and under bracket M6 1 0 1 13 1 3 9 4 Headlight body and headlight unit 2 1 0 1 0 7 Headlight mounting left and right M6 1 0 2 7 0 7 5 1 Taillight mounting 3 1 0 1 0 7 Taillight lead clamp and rear fender 3 0 5 0 05 0 36 Catch tank upper M6 1 0 1 16 1 6 11 Catch tank lower M6 1 0 1 7 0 7 5 1 Footrest bracket and frame M10 1 25 ...

Page 42: ...ts should be at room temperature A Distance between flats B Outside thread diameter DEFINITION OF UNITS A Nut B Bolt TORQUE SPECIFI CATION Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 94 Unit Read Definition Measure mm millimeter 10 3 meter Length cm centimeter 10 2 meter Length kg kilogram 103 gram Wei...

Page 43: ...2 18 TIGHTENING TORQUES ...

Page 44: ...2 19 LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Oil filter element 2 Oil pump 3 Drive axle 4 Main axle 5 Crankshaft 6 Connecting rod A From cylinder B To oil tank ...

Page 45: ...2 20 LUBRICATION DIAGRAMS 1 Intake camshaft 2 Exhaust camshaft A To main axle B From oil pump ...

Page 46: ...al switch lead 11 AC magneto lead 12 Brake hose 13 Rectifier regulator lead 14 Carburetor breather hose 15 Carburetor overflow hose 16 Catch tank breather hose A Insert the end of the fuel tank breather hose into the hole in the steering stem B Fasten the throttle cable hot starter cable and rectifier regula tor lead onto the frame Locate the clamp end facing the lower side of the hot starter cabl...

Page 47: ...en the connecting rod and cross tube frame G Pass the neutral switch lead on the inside of the engine bracket H Fasten the neutral switch lead and AC magneto lead onto the frame Locate the clamp end facing toward the outside of the frame and tie end facing toward the rear of the frame I Fasten the AC magneto lead and neutral switch lead onto the frame Locate the clamp end facing toward the rear of...

Page 48: ...e A Cross the pull and push throttle cables B Fasten the catch tank hose and air induction hose air cut off valve rear of cylinder head onto the frame Locate the clamp end facing toward the lower side of the frame and cut off the tie end C Fasten the catch tank breather hose and carburetor breather hoses together D Pass the carburetor breather hose of the throttle cable cover through the hose hold...

Page 49: ... directs as shown and lightly touches the projec tion 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 projec tion on the brake master cylin der ...

Page 50: ...et left side Locate the clamp end facing to ward the upper side of the frame with the tie end cut off on the in side of the frame B Fasten the wire harness to the upper engine bracket left side Locate the clamp end facing to ward the upper side of the frame with the tie end cut off on the in side of the frame Clamp the wire harness at the marking C Pass the starter motor lead through the hole in t...

Page 51: ...te the clamp end facing toward the upper side of the frame and the tie end to ward the inside of the frame Clamp the wire harness at the marking K Pass the wire harness starter relay lead starting circuit cut off relay lead and negative battery lead through the hole in the relay holder L Fasten the three CDI unit leads and taillight lead to the rear frame Locate the clamp end facing toward the low...

Page 52: ...ch switch coupler 14 Engine stop switch coupler 15 Multi function display coupler 16 Start switch coupler 17 Speed sensor coupler 18 Speed sensor lead A Fasten the start switch lead to the handlebar with the plastic bands B Fasten the engine stop switch lead and clutch switch lead to the handlebar with the plastic bands C Pass the brake hose through the hose guides D Secure the coupler by insertin...

Page 53: ...he coupler by pushing it into the hole in the multi function display bracket H Secure the wire harness clip by pushing it into the hole in the multi function display bracket on the inside I Fasten the main switch lead wire harness side to the multi function display bracket Locate the clamp end facing toward the lower side of the frame and cut off the tie end J Pass the speed sensor lead through th...

Page 54: ...NGINE OIL Replace VALVES Check the valve clearances The engine must be cold Inspect Check the valve seats and valve stems for wear Replace VALVE SPRINGS Inspect Check the free length and the tilt Replace VALVE LIFTERS Inspect Check for scratches and wear Replace CAMSHAFTS Inspect the camshaft surface Inspect Inspect the decompression system Replace CAMSHAFT SPROCKETS Inspect Check for wear on the ...

Page 55: ...n SPARK PLUG Inspect and clean Replace DRIVE CHAIN Use chain lube Lubricate slack alignment Chain slack 48 58 mm 1 9 2 3 in Replace COOLING SYSTEM Check coolant level and leakage Check radiator cap operation Replace coolant Every two years Inspect hoses OUTSIDE NUTS AND BOLTS Retighten Refer to STARTING AND BREAK IN section in the CHAPTER 1 AIR FILTER Clean and lubricate Use foam air filter oil or...

Page 56: ...K OIL SEAL AND DUST SEAL Clean and lube Lithium base grease PROTECTOR GUIDE Replace REAR SHOCK ABSORBER Inspect and adjust Lube After rain ride Molybdenum disulfide grease Retighten DRIVE CHAIN GUIDE AND ROLLERS Inspect SWINGARM Inspect lube and retighten Molybdenum disulfide grease RELAY ARM CONNECTING ROD Inspect lube and retighten Molybdenum disulfide grease SIDESTAND Lubricate Lithium base gre...

Page 57: ...s Replace bearings Lubricate Lithium base grease THROTTLE CONTROL CABLE Check routing and connection Lubricate Yamaha cable lube or SAE 10W 30 motor oil HOT STARTER CLUTCH LEVER Inspect free play BATTERY Check terminal for looseness and corrosion Item After break in Every race Every third or 500 km Every fifth or 1 000 km As re quired Remarks ...

Page 58: ...in slack and alignment Check that the drive chain is lubricated properly P 3 20 21 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 24 Steering Check that the handlebar can be turned smoothly and have no ex cessive play P 3 24 25 Front forks and rear shock absorber Check that they operate smoothly and there is no oil leakage P 3 21 23 Cables w...

Page 59: ... name Q ty Remarks Turn the fuel cock to OFF Disconnect the fuel hose 1 Seat 1 2 Air scoop left and right 2 3 Bolt fuel tank 2 4 Fuel tank 1 5 Left side cover 1 Open the air filter case cover 6 Right side cover 1 Refer to removal section 7 Headlight coupler 1 8 Headlight 1 ...

Page 60: ...3 7 ENGINE REMOVING THE SIDE COVER 1 Remove Bolt side cover Right side cover 1 Draw the side cover backward to re move it because its claw a is insert ed in the air filter case ...

Page 61: ...Remarks Right side cover Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Bolt silencer clamp 1 Only loosening 2 Bolt silencer front 1 3 Bolt silencer rear 1 4 Collar 1 5 Silencer 1 6 Silencer clamp 1 7 Nut exhaust pipe 1 8 Bolt exhaust pipe 1 9 Exhaust pipe 1 10 Gasket 2 ...

Page 62: ...1 Place the machine on a level place and hold it in an upright po sition 2 Remove Radiator cap 3 Check Coolant level a Coolant level low Add coolant 1 Radiator CHANGING THE COOLANT Do not remove the radiator cap when the engine is hot Take care so that coolant does not splash on painted surfaces If it splashes wash it away with water 1 Place a container under the en gine 2 Remove Seat Left side co...

Page 63: ...ied pressure Do not apply pressure more than specified pressure Radiator should be filled fully 4 Inspect Pressure Impossible to maintain the speci fied pressure for 10 seconds Repair Radiator Radiator hose joint Coolant leakage Repair or re place Radiator hose Swelling Replace ADJUSTING THE CLUTCH CABLE FREE PLAY 1 Check Clutch lever free play a Out of specification Adjust 2 Adjust Clutch lever f...

Page 64: ...r lever free play adjust ment steps a Loosen the locknut 1 b Turn the adjuster 2 until free play a is within the specified lim its c Tighten the locknut After adjustment check proper oper ation of hot starter CLEANING THE AIR FILTER ELEMENT Proper air filter maintenance is the biggest key to preventing premature engine wear and damage Never run the engine without the air filter element in place th...

Page 65: ...t after high speed operation The heated oil could spurt out causing danger Wait until the oil cools down to approximately 70 C 158 F 2 Idle the engine more than 3 min utes while keeping the machine upright Then stop the engine and inspect the oil level 3 Remove Oil tank cap 1 4 Inspect Oil level Check that the engine oil is above the level mark a and that the oil does not come out when the check b...

Page 66: ... 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 5 Install Gaskets Oil filter drain bolt Drain bolt right crankcase Drain bolt left crankcase 6 Fill Engine oil 7 Install Oil filler cap 1 8 Inspect Engine for oil leaks Oil level Refer to CHECKING THE EN GINE OIL LEVEL CHECKING THE OIL PRESSURE...

Page 67: ...fication Adjust Checking steps a Turn the crankshaft counterclock wise with a wrench b Align the T D C mark a on the rotor with the align mark b on the crankcase cover when piston is at T D C on compression stroke In order to be sure that the piston is at Top Dead Center the punch mark c on the exhaust camshaft and the punch mark d on the intake cam shaft must align with the cylinder head surface ...

Page 68: ...enum 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 5 h Install the timing chain tensioner Refer to CAMSHAFTS section in the CHAPTER 5 Turn the crankshaft counterclockwise several turns so that t...

Page 69: ...3 16 ENGINE INTAKE EXHAUST ...

Page 70: ...eding steps a Add proper brake fluid to the res ervoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube 2 tightly to the caliper bleed screw 1 A Front B Rear 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...

Page 71: ...an 2 mm 0 08 in c away from the brake pedal 5 After the pedal height adjust ment make sure that the rear brake does not drag CHECKING AND REPLACING THE FRONT BRAKE PADS 1 Inspect Brake pad thickness a Out of specification Replace as a set 2 Replace Brake pad Brake pad replacement steps a Remove the pad pin plug 1 b Loosen the pad pin 2 c Remove the brake caliper 3 from the front fork d Remove the ...

Page 72: ...nect the transparent hose 8 to the bleed screw 9 and place the suitable container under its end f Loosen the bleed screw and push the brake caliper piston in Do not reuse the drained brake flu id g Tighten the bleed screw h Install the brake pad 10 and pad pin 11 Install the brake pads with their pro jections a into the brake caliper re cesses b Temporarily tighten the pad pin at this point i Inst...

Page 73: ...nspect Sprocket teeth a Excessive wear Replace Replace the drive sprocket rear wheel sprocket and drive chain as a set CHECKING THE DRIVE CHAIN 1 Measure Drive chain length 15 links a Out of specification Replace While measuring the drive chain length push down on the drive chain to increase its tension Measure the length between drive chain roller 1 and 16 as shown Perform this measurement at two...

Page 74: ...e marks a on each side of the drive chain puller alignment Turn the adjuster so that the drive chain is in line with the sprocket as viewed from the rear Too small drive chain slack will overload the engine and other vital parts keep the slack within the specified limits d Tighten the axle nut while pushing down the drive chain e Tighten the locknuts CHECKING THE FRONT FORK 1 Inspect Front fork sm...

Page 75: ...ction Abnormal noise unsmooth action Grease the pivoting points or repair the pivoting points Damage oil leakage Replace ADJUSTING THE REAR SHOCK ABSORBER SPRING PRELOAD 1 Elevate the rear wheel by placing the suitable stand under the en gine 2 Remove Rear frame 3 Loosen Locknut 1 4 Adjust Spring preload By turning the adjuster 2 Be sure to remove all dirt and mud from around the locknut and adjus...

Page 76: ... 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 Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged Rear frame upper 38 Nm 3 8 m kg 27 ft lb Rear frame lower 32 Nm 3 2 m kg 23 ft lb Stiffer a Increase the re...

Page 77: ...ebar lock to lock Unsmooth action Adjust steer ing ring nut 4 Adjust Steering ring nut Steering ring nut adjustment steps a Remove the headlight b Remove the handlebar and upper bracket c Loosen the steering ring nut 1 using the steering nut wrench 2 d Tighten the steering ring nut 3 using steering nut wrench 4 Apply the lithium soap base grease on the thread of the steering stem Set the torque wr...

Page 78: ...d of the fuel breather hose 12 into the hole in the steer ing stem First tighten the bolts on the front side of the handlebar upper holder and then tighten the bolts on the rear side 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 brack et 21 Nm 2 1 m kg 15 ft lb Headlight 7 Nm 0 7 m kg 5 1 ft lb ...

Page 79: ...vot 5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding por tion 8 Throttle cable end 9 Clutch cable end 10 Hot starter cable end A Use Yamaha cable lube or equivalent on these areas B Use SAE 10W 30 motor oil or suitable chain lubricants C Lubricate the following areas with high quality lightweight lith ium soap base grease Wipe off any excess grease and avoid getting grease ...

Page 80: ...sures Wear protective eye gear when handling or working near batter ies Charge batteries in a well venti lated area Keep batteries away from fire sparks or open flames e g welding equipment lighted ciga rettes DO NOT SMOKE when charging or handling batteries KEEP BATTERIES AND ELEC TROLYTE OUT OF REACH OF CHILDREN Avoid bodily contact with elec trolyte as it can cause severe burns or permanent eye...

Page 81: ...use bat tery overheating and battery plate damage If it is impossible to regulate the charging current on the battery charger be careful not to over charge the battery When charging a battery be sure to remove it from the machine If charging has to be done with the battery mounted on the machine disconnect the negative battery lead from the battery terminal To reduce the chance of sparks do not pl...

Page 82: ...3 29 ELECTRICAL Charging method using a variable voltage charger ...

Page 83: ...3 30 ELECTRICAL Charging method using a constant voltage charger ...

Page 84: ...g amperage rating may cause extensive damage to the electrical system cause the starting and ig nition systems to malfunction and could possibly cause a fire 4 Install Fuse cover Seat REPLACING THE HEADLIGHT BULBS 1 Remove Headlight Refer to SEAT FUEL TANK AND SIDE COVERS section 2 Remove Headlight bulb holder cover 1 3 Remove Headlight bulb holder 1 Remove the headlight bulb holder by pushing it ...

Page 85: ...RICAL ADJUSTING THE HEADLIGHT BEAMS 1 Adjust Headlight beam vertically Adjusting steps a Turn the adjusting screw 1 in di rection a or b Direction a Headlight beam is raised Direction b Headlight beam is lowered ...

Page 86: ...ngine is stopped or when riding at no load do not open and close the throttle un necessarily Otherwise too much fuel may be discharged starting may become difficult or the engine may not run well After installing the carburetor check that the throttle operates correctly and opens and closes smoothly ATMOSPHERIC CONDITIONS AND CARBURETOR SETTINGS The air density i e concentration of oxygen in the a...

Page 87: ...e diameter of the straight portion adjusts the air fuel mixture when the throttle is 1 8 to 1 4 open A Idle B Fully open RELATIONSHIP WITH THROTTLE OPENING The flow of the fuel through the car buretor main system is controlled by the main jet and then it is further reg ulated by the area between the main nozzle and the jet needle The fuel flow relates to the diameter of the straight portion of the...

Page 88: ...14948 Rich 55 4MX 09 52 4MX 08 50 4MX 07 48 4MX 06 STD Lean 45 4MX 05 Jet needle Size Part number 14916 Rich GDDUM 5TJ 9M GDDUN 5TJ 9N GDDUP 5TJ 9P GDDUQ 5TJ 91 GDDUR 5TJ 9R GDDUS 5TJ 9S Lean GDDUT 5TJ 9T Rich GDDSM 5TJ AM GDDSN 5TJ AN GDDSP 5TJ AP GDDSQ 5TJ A1 GDDSR 5TJ AR GDDSS 5TJ AS Lean GDDST 5TJ AT Leak jet Size Part number 1494F Rich 35 4JT 01 40 4JT 03 45 4JT 05 50 4JT 07 55 4JT 09 STD 60 ...

Page 89: ...m the top Check that the accelerator pump operates smoothly except for rich mixture symp tom Rich mixture Raise jet needle clip position 1 groove up 1 4 3 4 throttle Hard breathing Lack of speed Lower jet needle clip position 1 groove down 1 4 1 2 throttle Slow speed pick up Poor acceleration Raise jet needle clip position 1 groove up Closed to 1 4 throttle Hard breathing Speed down Use jet needle...

Page 90: ...higher to prevent a flat tire FRONT FORK SETTING The front fork setting should be made depending on the rider s feeling of an actual run and the circuit conditions The front fork setting includes the fol lowing three factors 1 Setting of air spring characteris tics Change the fork oil level 2 Setting of spring preload Change the spring Install the adjustment washer 3 Setting of damping force Chang...

Page 91: ...gaps 2 Use of stiff spring Change the rebound damping Turn in one or two clicks Change the compression damp ing Turn out one or two clicks Generally a stiff spring gives a stiff riding feeling Rebound damping tends to become weaker resulting in lack of a sense of contact with the road surface or in a vibrating handle bar FRONT FORK SETTING PARTS Adjustment washer 1 Front fork spring 2 The I D mark...

Page 92: ...g load Run with the rebound damping adjuster one or two clicks on the softer side and readjust it to suit your preference 2 Use of stiff spring Set the soft spring for more re bound damping to compensate for its greater spring load Run with the rebound damping adjust er one or two clicks on the stiffer side and readjust it to suit your preference Adjusting the rebound damping will be followed more...

Page 93: ...amping Turn adjuster clockwise about 2 clicks to in crease damping Oil level oil amount Increase oil level by about 5 10 mm 0 2 0 4 in Spring Replace with stiff spring Stiff toward stroke end Oil level oil amount Decrease oil level by about 5 mm 0 2 in Soft toward stroke end bottoming out Oil level oil amount Increase oil level by about 5 mm 0 2 in Stiff initial move ment Compression damping Turn ...

Page 94: ...avy and dragging Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Spring Replace with soft spring Poor road gripping Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Low compression damping Turn adjuster clockwise about 1 clicks to in crease damping High compression damping Turn adjuster clockwise about 1 6 clicks to in crease dampi...

Page 95: ...tank and left side cover Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 3 Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 3 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 pipe 4 1 7 Pipe 2 O ring 1 1 8 Catch tank hose 1 9 Left radiator 1 10 Radiator hose 1 1 5 ...

Page 96: ...5 2 RADIATOR 11 Pipe 1 O ring 1 1 12 Catch tank breather hose 1 13 Catch tank 1 Order Part name Q ty Remarks ...

Page 97: ...E RADIATOR 1 Install Pipe 1 1 Radiator hose 1 2 Pipe 2 3 Radiator hose 3 4 Radiator hose 4 5 2 Install Radiator hose 2 1 Left radiator 2 3 Install Catch tank hose 1 Right radiator 2 Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 4 Install Radiator guard 1 First fit the inner hook portion a and then the outer one b onto the radia tor 5 Install Catch tank 1 Bolt catch tank 2 Bolt catch tan...

Page 98: ... 2 Throttle position sensor lead coupler 1 3 Throttle cable cover 1 4 Throttle cable 2 5 Clamp air filter joint 1 Loosen the screw air filter joint 6 Clamp carburetor joint 1 Loosen the screws carburetor joint 7 Hot starter plunger 1 8 Carburetor 1 9 Cylinder head breather pipe 1 10 Cylinder head breather hose 1 1 11 Cylinder head breather hose 2 1 12 Cylinder head breather hose 3 1 13 Bracket cyl...

Page 99: ... cover 1 3 Screw throttle shaft 1 4 Throttle valve 1 5 Needle holder 1 6 Jet needle 1 7 Accelerator pump cover 1 8 Spring 1 9 Diaphragm accelerator pump 1 10 Air cut valve cover 1 11 Spring air cut valve 1 12 Diaphragm air cut valve 1 13 Float chamber 1 14 Leak jet 1 15 Float pin 1 16 Float 1 17 Needle valve 1 18 Main jet 1 ...

Page 100: ...dle jet 1 20 Spacer 1 21 Pilot jet 1 22 Starter jet 1 23 Push rod 1 Pull the push rod 24 Throttle shaft assembly 1 25 Push rod link lever assembly 1 26 Pilot air jet 1 27 Cold starter plunger 1 Order Part name Q ty Remarks ...

Page 101: ...Jet needle 1 Bends wear Replace Clip groove Free play exists wear Replace MEASURING AND ADJUSTING THE FLOAT HEIGHT 1 Measure Float height a Out of specification Adjust Measurement and adjustment steps a Hold the carburetor in an upside down position Slowly tilt the carburetor in the op posite direction then take the mea surement when the needle valve aligns with the float arm If the carburetor is ...

Page 102: ...er a of the lever 2 4 Install Spring 2 1 To lever 2 2 5 Install Push rod link lever assembly 1 Make sure the stopper a of the spring 2 fits into the recess b in the carburetor 6 Install Washer 1 Circlip 2 7 Install Spring 1 To throttle shaft 2 Install the bigger hook a of the spring fits on the stopper b of the throttle shaft pulley 8 Install Throttle shaft assembly 1 Washer metal 2 Washer resin 3...

Page 103: ...over 4 Hose holder drain hose 5 Screw accelerator pump cover 6 Install the diaphragm accelerator pump with its mark a facing the spring 15 Install Jet needle 1 Collar 2 Spring 3 Needle holder 4 Throttle valve plate 5 To throttle valve 6 16 Install Throttle valve assembly 1 Screw throttle shaft 2 Install the valve lever rollers 3 into the slits a of the throttle valve 17 Install O ring 1 Valve leve...

Page 104: ... 1 4 Tighten Bolt carburetor joint 1 Bolt air filter joint 2 5 Install Throttle cable pull 1 Throttle cable return 2 6 Adjust Throttle grip free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY section in the CHAPTER 3 7 Install Throttle cable cover 1 Bolt throttle cable cover 2 8 Install Throttle position sensor lead cou pler 1 Clamp 2 Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 ...

Page 105: ...r Part name Q ty Remarks 1 Bracket 1 2 Air cut off valve assembly 1 3 Air induction hose air cut off valve front of cyl inder head 1 4 Air induction pipe 1 5 Gasket 1 6 Air induction hose air cut off valve rear of cylin der head 1 7 Air induction hose air cut off valve air filter case 1 ...

Page 106: ... of the vacuum pressure pump gauge set 1 When using vacuum on the pipe c take care not to exceed the specified value a From air filter b To cylinder head exhaust port c From cylinder head intake port A Check for induction from air filter B Check for prevention of back flow into air filter C Check for prevention of after burn When throttle is closed at sudden deceleration a to b Air passes b to a A...

Page 107: ...TANK AND SIDE COVERS section in the CHAPTER 3 Air cut off valve assembly Refer to AIR INDUCTION SYSTEM section Engine upper bracket right Refer to ENGINE REMOVAL section Engine upper bracket left 1 Spark plug 1 2 Cylinder head breather hose 1 3 Bolt cylinder head cover 2 4 Cylinder head cover 1 5 Cylinder head cover gasket 1 ...

Page 108: ...al 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 10 Refer to removal section 7 Camshaft cap 2 Refer to removal section 8 Clip 2 Refer to removal section 9 Exhaust camshaft 1 Refer to removal section 10 Intake camshaft 1 Refer to removal section ...

Page 109: ...sscross pattern working from the outside in The bolts camshaft cap must be removed evenly to prevent dam age to the cylinder head cam shafts or camshaft caps 5 Remove Exhaust camshaft 1 Intake camshaft 2 Attach a wire 3 to the timing chain to prevent it from falling into the crank case CHECKING THE CAMSHAFT 1 Inspect Cam lobe Pitting scratches blue discolora tion Replace 2 Measure Cam lobe length ...

Page 110: ... pressing the tensioner rod lightly with fingers use a thin screwdriver 1 and wind the ten sioner rod up fully clockwise When releasing the screwdriver by pressing lightly with fingers make sure that the tensioner rod will come out smoothly If not replace the tensioner as sembly INSTALLING THE CAMSHAFT 1 Install Exhaust camshaft 1 Intake camshaft 2 Installation steps a Turn the crankshaft counterc...

Page 111: ...ming chain tensioner Installation steps a While pressing the tensioner rod lightly with fingers use a thin screwdriver and wind the tension er rod up fully clockwise b With the rod fully wound and the chain tensioner UP mark a fac ing upward install the gasket 1 the timing chain tensioner 2 and the gasket 3 and tighten the bolt 4 to the specified torque c Release the screwdriver check the tensione...

Page 112: ...pecified angle 180 in the proper tightening sequence Order Part name Q ty Remarks Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 3 Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 3 Radiator Refer to RADIATOR section Air cut off valve assembly Refer to AIR INDUCTION SYSTEM section Carburetor Refer to CARBURETOR section Camshaft ...

Page 113: ...ead using the rotation angle procedure to ob tain uniform tightening torque 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 con tact surfaces of the bolts and on both contact surfaces of the plain washers c Install the p...

Page 114: ...5 20 CYLINDER HEAD 3 Install Bolt cylinder head 1 Bolt cylinder head 10 Nm 1 0 m kg 7 2 ft lb ...

Page 115: ...me Q ty Remarks Cylinder head Refer to CYLINDER HEAD section 1 Valve lifter 5 Refer to removal section 2 Adjusting pad 5 Refer to removal section 3 Valve cotter 10 Refer to removal section 4 Valve spring retainer 5 5 Valve spring 5 6 Valve stem seal 5 7 Valve spring seat 5 8 Exhaust valve 2 9 Intake valve 3 ...

Page 116: ...r to 100 C 212 F a Remove the valve guide using a valve guide remover 1 b Install the new valve guide using a valve guide remover 1 and valve guide installer 2 c After installing the valve guide bore the valve guide using a valve guide reamer 3 to obtain proper stem to guide clearance After replacing the valve guide reface the valve seat 3 Inspect Valve face Pitting wear Grind the face Valve stem ...

Page 117: ...lve stem and the guide b Apply molybdenum disulfide oil to the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly pol ished then clean off all of the compound For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands e Apply a fine lapping compound to the valve face and repeat th...

Page 118: ...cing upward e Smaller pitch 3 Install Valve cotters While compressing the valve spring with a valve spring compressor 1 in stall the valve cotters 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 s...

Page 119: ...rt name Q ty Remarks Cylinder head 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 ...

Page 120: ...ston bottom edge d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with following formula f If out of specification replace the cylinder and replace the piston and piston rings as set CHECKING THE PISTON RING 1 Measure Ring side clearance Use a feeler gauge 1 Out of specification Replace the piston and rings as a set Clean carbon fr...

Page 121: ...per d Oil ring e Oil ring end lower 3 Install Piston 1 Piston pin 2 Piston pin clip 3 Apply engine oil onto the piston pin and piston Be sure that the arrow mark a on the piston points to the exhaust side of the engine Before installing the piston pin clip cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase Install the piston pin clips with their end...

Page 122: ... ENGINE OIL section in the CHAPTER 3 Brake pedal Refer to ENGINE REMOVAL section Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Gasket 1 3 Dowel pin 2 4 Clutch spring 6 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Washer 1 9 Bearing 1 10 Ball 1 11 Push rod 2 1 12 Clutch plate 7 13 Friction plate 8 ...

Page 123: ...t clutch boss 1 Refer to removal section 15 Lock washer 1 Refer to removal section 16 Clutch boss 1 Refer to removal section 17 Thrust washer 1 18 Primary driven gear 1 19 Push lever shaft 1 Order Part name Q ty Remarks ...

Page 124: ...at all four points CHECKING THE CLUTCH PLATES 1 Measure Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thick ness gauge 2 CHECKING THE PUSH LEVER SHAFT 1 Inspect Push lever shaft 1 Wear damage Replace CHECKING THE PUSH ROD 1 Inspect Push rod 1 1 Bearing 2 Washer 3 Push rod 2 4 Ball 5 Wear damage bend Replace INSTALLING THE PUSH LEVER SHAFT 1 Insta...

Page 125: ...gine oil on the friction plates and clutch plates Check the clutch plate for thickness and install 4 thicker ones a on the engine side and 3 thinner ones b on the outside 5 Install Bearing 1 Washer 2 Circlip 3 To push rod 1 4 Apply the engine oil on the bearing and washer 6 Install Push rod 2 1 Ball 2 Push rod 1 3 Apply the engine oil on the push rod 1 2 and ball 7 Install Pressure plate 1 8 Insta...

Page 126: ...ANT sec tion Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section Brake pedal Refer to ENGINE REMOVAL section Clutch cover Refer to CLUTCH section 1 Oil filter element cover 1 2 Oil filter element 1 3 Coolant pipe 2 1 4 Water pump housing 1 5 Pin 2 6 Oil tank breather hose 1 7 Kickstarter crank 1 8 Right crankcase cover 1 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft l...

Page 127: ...Refer to removal section 14 Oil seal 1 1 Refer to removal section 15 Oil seal 2 1 Refer to removal section 16 Bearing 1 Refer to removal section Order Part name Q ty Remarks 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 33 Nm 3 3 m kg 24 ft lb 14 Nm 1 4 m kg 10 ft lb 12 Nm 1 2 m kg 8 7 ft lb ...

Page 128: ... 1 Wear damage Replace INSTALLING THE OIL SEAL 1 Install Oil seal 1 Apply the lithium soap base grease on the oil seal lip Install the oil seal with its manufac ture s marks or numbers facing the right crankcase cover 2 2 Install Bearing 1 Install the bearing by pressing its out er race parallel INSTALLING THE IMPELLER SHAFT 1 Install Impeller shaft 1 Washer 2 Impeller 3 Take care so that the oil ...

Page 129: ... Clamp 2 INSTALLING THE WATER PUMP HOUSING 1 Install Dowel pin 1 O ring 2 Apply the lithium soap base grease on the O ring 2 Install Water pump housing 1 Bolt water pump housing 2 Washer 3 Coolant drain bolt 4 3 Install O ring 3 Coolant pipe 1 Bolt coolant pipe 2 Apply the lithium soap base grease on the O ring INSTALLING THE OIL FILTER ELEMENT 1 Install Oil filter element 1 O ring 2 Oil filter el...

Page 130: ...A TER PUMP section Stator Refer to CDI 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 4 Lock washer 1 5 Balancer 1 6 Straight key 1 7 Conical washer 1 8 Primary drive gear 1 9 Balancer shaft drive gear 1 10 Lock washer 1 11 Balancer shaft driven gear 1 ...

Page 131: ...other 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 Primary drive gear 3 Conical washer 4 Nut primary drive gear 5 Straight key 6 ...

Page 132: ...section Right crankcase cover Refer to OIL FILTER ELEMENT AND WA TER PUMP section 1 Circlip 1 2 Washer 1 3 Oil pump drive gear 1 4 Oil pump assembly 1 5 Dowel pin 2 6 Outer rotor 2 1 7 Circlip 1 8 Inner rotor 2 1 9 Dowel pin 1 10 Oil pump cover 1 11 Outer rotor 1 1 12 Inner rotor 1 1 13 Dowel pin 1 14 Washer 1 ...

Page 133: ...5 39 OIL PUMP 15 Oil pump drive shaft 1 16 Rotor housing 1 Order Part name Q ty Remarks ...

Page 134: ...n the inner rotor 1 2 Install Outer rotor 1 1 Apply the engine oil on the outer rotor 1 3 Install Oil pump cover 1 Screw oil pump cover 2 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 Install Outer rotor 2 1 Dowel pin 2 Oil pump assembly 3 Bolt oil pump assembly 4 Apply the engin...

Page 135: ...section 1 Kick idle gear 1 2 Kick shaft assembly 1 Refer to removal section 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 14 Shift guide 1 Refer to removal section 15 Shift lever assembly 1 Refer to removal section 16 Shift lever 1 ...

Page 136: ...5 42 KICK SHAFT AND SHIFT SHAFT 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 Refer to removal section Order Part name Q ty Remarks ...

Page 137: ...G THE KICK GEAR KICK IDLE GEAR AND RATCHET WHEEL 1 Inspect Kick gear 1 Kick idle gear 2 Ratchet wheel 3 Gear teeth a Ratchet teeth b Wear damage Replace CHECKING THE SHIFT SHAFT 1 Inspect Shift shaft 1 Bend damage Replace Spring 2 Broken Replace CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1 Inspect Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear damage Replace CHECKING THE STOPPE...

Page 138: ...7 To kick shaft 8 Apply the molybdenum disulfide oil on the inner circumferences of the kick gear and ratchet wheel Align the punch mark a on the ratchet wheel with the punch mark b on the kick shaft 2 Install Torsion spring 1 To kick shaft 2 Make sure the stopper a of the tor sion spring fits into the hole b on the kick shaft 3 Install Spring guide 1 Slide the spring guide into the kick shaft mak...

Page 139: ...ND SHIFT SHAFT 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 de pressed side a toward you ...

Page 140: ...IL section in the CHAPTER 3 Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 3 Disconnect the AC magneto lead 1 Shift pedal 1 2 Cover torque limiter 1 3 Torque limiter 1 Do not disassemble 4 Crankcase cover left 1 5 Gasket 1 6 Dowel pin 2 7 Idle gear 1 8 Bearing 1 9 Shaft 1 10 Nut rotor 1 Refer to NOTE 11 Rotor 1 Refer to removal section 12 Woodruff key 1 ...

Page 141: ...47 ft lb loosen and retighten the rotor nut to 65 Nm 6 5 m kg 47 ft lb 13 Starter clutch assembly cover 1 Refer to removal section 14 Starter clutch 1 Refer to removal section 15 Starter clutch drive gear 1 16 Holder 1 17 Pickup coil 1 18 Stator 1 Order Part name Q ty Remarks ...

Page 142: ...ive parts 3 Check Starter clutch operation a Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch b When turning the starter clutch drive gear counterclockwise B the starter clutch and the starter clutch drive gear should engage If the starter clutch drive gear and starter clutch do not engage the starter clutch is faulty and must be replaced c When turning...

Page 143: ...t 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 6 Install Washer rotor Nut rotor 1 Use the sheave holder 2 Tighten the rotor nut to 65 Nm 6 5 m kg 47 ft lb loosen and retighten the rotor nut to 65 Nm 6 5 m kg 47 ft lb 7 Install Shaft 1 Bearing 2 Idle gear 2 3 Apply the engine oil on the shaft bearing and i...

Page 144: ... ROUTING DIA GRAM section in the CHAPTER 2 12 Install Shift pedal 1 Bolt shift pedal When installing the shift pedal onto the shift shaft be sure that the center of the shift pedal is about 5 1 mm 0 2 in a above the top of the footrest Bolt shift pedal 12 Nm 1 2 m kg 8 7 ft lb ...

Page 145: ... 3 Radiator Refer to RADIATOR section Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 3 Air cut off valve assembly Refer to AIR INDUCTION SYSTEM section Clutch cable and guide Disconnect at the engine side Shift pedal Refer to AC MAGNETO AND STARTER CLUTCH section Rear shock absorber Refer to REAR SHOCK ABSORBER sec tion in the CHAPTER 6 Carburetor Refer to CARB...

Page 146: ...uard 1 2 Neutral switch 1 3 Drive chain sprocket cover 1 4 Nut drive sprocket 1 Refer to removal section 5 Lock washer 1 Refer to removal section 6 Drive sprocket 1 Refer to removal section 7 Clip 1 8 Bolt brake pedal 1 9 Brake pedal 1 10 Upper engine bracket 2 11 Lower engine bracket 2 12 Engine mounting bolt 3 13 Pivot shaft 1 Refer to removal section 14 Engine 1 Refer to removal section Order P...

Page 147: ...nting bolt lower 3 Lower engine bracket 4 Bolt lower engine bracket 5 Patch 6 Engine mounting bolt front 7 Upper engine bracket 8 Bolt upper engine bracket 9 Engine mounting bolt upper 10 Apply the molybdenum disulfide grease on the pivot shaft Install the patch with the claw a facing outside the chassis INSTALLING THE BRAKE PEDAL 1 Install Spring 1 Brake pedal 2 O ring 3 Bolt brake pedal 4 Clip 5...

Page 148: ...ab to lock the nut 4 Install Drive chain sprocket guide Drive chain sprocket cover 1 Screw drive chain sprocket cov er 2 INSTALLING THE NEUTRAL SWITCH 1 Install Spring 1 Pin 2 O ring 3 Neutral switch 4 Screw neutral switch 5 Apply the lithium soap base grease on the O ring Nut drive sprocket 75 Nm 7 5 m kg 54 ft lb Screw drive chain sprocket cover 8 Nm 0 8 m kg 5 8 ft lb Screw neutral switch 4 Nm ...

Page 149: ... AND SHIFT SHAFT section Segment Refer to KICK SHAFT AND SHIFT SHAFT section Stator Refer to AC MAGNETO AND STARTER CLUTCH section 1 Timing chain guide intake side 1 2 Timing chain 1 3 Bolt L 50 mm 1 97 in 7 Refer to removal section 4 Bolt L 60 mm 2 36 in 2 Refer to removal section 5 Bolt L 80 mm 3 15 in 3 Refer to removal section 6 Hose guide 1 Refer to removal section 7 Clutch cable holder 1 Ref...

Page 150: ...56 CRANKCASE AND CRANKSHAFT 9 Left crankcase 1 Refer to removal section 10 Oil strainer 1 11 Balancer shaft 1 Refer to removal section 12 Crankshaft 1 Refer to removal section Order Part name Q ty Remarks ...

Page 151: ...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 Oil seal 3 2 Bearing 10 Refer to removal section ...

Page 152: ...ing Do not force 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 REMOVING THE CRANKSHAFT 1 Remove Crankshaft 1 Use the crankcase separating tool 2 Install the crankcase separating tool as shown Do not use a hammer to drive out the crankshaft REMOVING THE CRANKCASE BEARING 1 Remove Bearing ...

Page 153: ...e bearing Before installing the crankshaft clean the contacting surface of crankcase Do not use a hammer to drive in the crankshaft A For USA and CDN B Except for USA and CDN 2 Check Shifter operation Transmission operation Unsmooth operation Repair 3 Install Oil strainer 1 Bolt oil strainer 2 4 Apply Sealant On the right crankcase Clean the contacting surface of left and right crankcase before ap...

Page 154: ...lutch cable holder 2 Bolt clutch cable holder Bolt crankcase Tighten the crankcase tightening bolts in stage using a crisscross pat tern 7 Install Timing chain Timing chain guide intake side Bolt timing chain guide 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 op eration Unsmooth ope...

Page 155: ...s Engine Refer to ENGINE REMOVAL section Separate the crankcase Refer to CRANKCASE AND CRANK SHAFT 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 6 Shift fork 1 1 Refer to removal section 7 Collar 1 ...

Page 156: ...FT FORK SHIFT CAM AND SEGMENT 1 Inspect Shift fork 1 Wear damage scratches Re place 2 Inspect Shift cam 1 Segment 2 Wear damage Replace 3 Check Shift fork movement Unsmooth operation Replace shift fork For a malfunctioning shift fork re place not only the shift fork itself but the two gears each adjacent to the shift fork INSTALLING THE TRANSMISSION 1 Install 5th pinion gear 25T 1 3rd pinion gear ...

Page 157: ...l Shift fork 1 L 1 Shift fork 2 C 2 Shift fork 3 R 3 Shift cam 4 To main axle and drive axle Apply the molybdenum disulfide oil on the shift fork grooves Apply engine oil to the shift cam groove bearing contact surface and shift fork shaft Mesh the shift fork 1 L with the 4th wheel gear 5 and 3 R with the 5th wheel gear 7 on the drive axle Mesh the shift fork 2 C with the 3rd pinion gear 6 on the ...

Page 158: ...g the suitable stand under the engine Refer to HANDLING NOTE 1 Bolt axle holder 4 Only loosening 2 Nut front wheel axle 1 3 Front wheel axle 1 4 Front wheel 1 5 Speed sensor 1 6 Collar 1 7 Oil seal 1 8 Bearing 2 Refer to removal section 9 Brake disc 1 21 Nm 2 1 m kg 15 ft lb 21 Nm 2 1 m kg 15 ft lb 12 Nm 1 2 m kg 8 7 ft lb 90 Nm 9 0 m kg 65 ft lb ...

Page 159: ... HANDLING NOTE 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 Refer to removal section 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 Refer to removal section 10 Brake disc 1 125 Nm 12 5 m kg 90 ft lb 14 Nm 1 4 m kg 10 ft lb 19 Nm 1 9 m kg 13 ft lb 19 Nm 1 9 m kg 13 ft lb 50 Nm 5 0 m kg 36 ft lb 6 ...

Page 160: ...eflection only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in good condi tion replace the brake disc 2 Measure Brake disc thickness a Out of limit Replace INSTALLING THE FRONT WHEEL 1 Install Bearing left 1 Spacer 2 Bearing right 3 Oil seal 4 Apply the lithium soap base grease on the bearing and oil seal lip when installing Use a socket that ma...

Page 161: ...ll Nut wheel axle 1 8 Tighten Bolt axle holder 1 Before tightening the bolt fit the wheel axle to the axle holder by strok ing the front fork several times with the front brake applied 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 facin...

Page 162: ...forward and install the drive chain 7 Install Left drive chain puller 1 Wheel axle 2 Install the left drive chain puller and insert the wheel axle from left side Apply the lithium soap base grease on the wheel axle 8 Install Right drive chain puller 1 Washer 2 Nut wheel axle 3 Temporarily tighten the nut wheel axle at this point 9 Adjust Drive chain slack a Refer to ADJUSTING THE DRIVE CHAIN SLACK...

Page 163: ...ine Refer to HANDLING NOTE Drain the brake fluid Refer to removal section 1 Brake hose holder protector 2 2 Brake hose holder brake caliper 1 3 Union bolt 2 4 Brake hose 1 5 Pad pin plug 1 Remove when loosening the pad pin 6 Pad pin 1 Loosen when disassembling the brake cali per 7 Brake caliper 1 8 Brake lever 1 9 Brake master cylinder bracket 1 10 Brake master cylinder 1 ...

Page 164: ...ne 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 7 Pad pin 1 Loosen when disassembling the brake cali per 8 Brake caliper 1 ...

Page 165: ...rder 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 ...

Page 166: ...KE 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 Brake master cylinder boot 1 5 Circlip 1 Use a long nose circlip pliers 6 Washer 1 7 Push rod 1 8 Brake master cylinder kit 1 ...

Page 167: ...l steps a Insert a piece of rag into the brake caliper to lock one brake caliper b Carefully force the piston out of the brake caliper cylinder with compressed air A Front B Rear REMOVING THE BRAKE CALIPER PISTON SEAL KIT 1 Remove Brake caliper piston dust seal 1 Brake caliper piston seal 2 Remove the brake caliper piston seals and brake caliper piston dust seals by pushing them with a finger Neve...

Page 168: ...ston dust seal Brake caliper piston Clean them with brake fluid 2 Install Brake caliper piston seal 1 Brake caliper piston dust seal 2 Always use new brake caliper pis ton seals and brake caliper piston dust seals Apply the brake fluid on the brake caliper piston seal Apply the silicone grease on the brake caliper piston dust seal Fit the brake caliper piston seals and brake caliper piston dust se...

Page 169: ... cause improper brake performance A Front B Rear 3 Install Spring 1 To brake master cylinder piston 2 Install the spring at the smaller dia side A Front B Rear 4 Install Brake master cylinder kit 1 Washer front brake 2 Push rod rear brake 2 Circlip 3 Brake master cylinder boot 4 To brake master cylinder Apply the brake fluid on the brake master cylinder kit Apply the silicone grease on the tip of ...

Page 170: ...um soap base grease on the bolt O ring and brake pedal bracket 4 Install Pin 1 Washer 2 Cotter pin 3 After installing check the brake pedal height Refer to ADJUSTING THE REAR BRAKE section in the CHAP TER 3 INSTALLING THE FRONT BRAKE HOSE 1 Install Copper washer 1 Brake hose 2 Union bolt 3 Always use new copper washers Install the brake hose so that its pipe portion a directs as shown and lightly ...

Page 171: ...he spring rear shock absorber If it does correct its twist FILLING THE BRAKE FLUID 1 Fill Brake fluid Until the fluid level reaches LOWER level line a Use only the designated quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and lead to poor perfo...

Page 172: ...w bolt brake master cylin der cap 2 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 5 Install rear brake only Protector 1 Bolt protector 2 Screw bolt brake mas ter cylinder cap 2 Nm 0 2 m kg 1 4 ft lb Bo...

Page 173: ...o HANDLING NOTE Front wheel Refer to FRONT WHEEL AND REAR WHEEL section Front brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Headlight Handlebar Refer to HANDLEBAR section 1 Protector 1 2 Pinch bolt upper bracket 2 Only loosening 3 Cap bolt 1 Loosen when disassembling the front fork 4 Pinch bolt lower bracket 2 Only loosening 5 Front fork 1 ...

Page 174: ... spring 1 Drain the fork oil 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 Spring guide 1 12 Base valve 1 Refer to removal section 13 Damper rod 1 Refer to removal section ...

Page 175: ...o scratch the inner tube 2 Remove Inner tube 1 Oil seal removal steps a Push in slowly a the inner tube just before it bottoms out and then pull it back quickly b b Repeat this step until the inner tube can be pulled out from the outer tube REMOVING THE DAMPER ROD 1 Remove Base valve 1 Damper rod 2 Use a damper rod holder 3 to lock the damper rod CHECKING THE DAMPER ROD 1 Inspect Damper rod 1 Bend...

Page 176: ... 4 4 Tighten Base valve 1 Use a damper rod holder 2 to lock the damper rod 3 Apply the LOCTITE on the base valve thread 5 Install Spring guide 1 Locknut 2 To damper rod 3 Install the spring guide with its smaller dia end a facing down ward With its thread b facing upward fully finger tighten the locknut onto the damper rod 6 Install Dust seal 1 Stopper ring 2 Oil seal 3 Oil seal washer 4 Slide met...

Page 177: ...tube top surface with recom mended fork oil once more 18 After filling pump the outer tube 1 slowly up and down about 200 mm 7 9 in stroke to distrib ute the fork oil once more Be careful not to excessive full stroke A stroke of 200 mm 7 9 in or more will cause air to enter In this case re peat the steps 15 to 18 19 Wait ten minutes until the air bub bles have been removed from the front fork and ...

Page 178: ...d end so that it will not go down 24 Install Spring seat 1 Front fork cap bolt 2 Fully finger tighten the front fork cap bolt onto the damper rod 25 Tighten Front fork cap bolt locknut 1 Hold the locknut 2 and tighten the front fork cap bolt with specified torque 26 Install Front fork cap bolt 1 To outer tube Temporarily tighten the cap bolt 27 Install Protector guide 1 Install the protector guide...

Page 179: ...m b of the plate 1 with the same paint 6 Install Speed sensor lead 1 Plate 2 2 Screw plate 2 3 To right protector 4 Install the plate 2 in the direction as shown 7 Install Protector 1 Bolt protector 2 8 Adjust Rebound damping force Turn in the damping adjuster 1 fin ger tight and then turn out to the orig inally set position Pinch bolt upper brack et 21 Nm 2 1 m kg 15 ft lb Pinch bolt lower brack ...

Page 180: ... Engine stop switch 1 Disconnect the engine stop switch lead 6 Brake master cylinder 1 Refer to removal section 7 Start switch 1 Disconnect the start switch lead 8 Throttle cable cap 1 9 Throttle cable 1 pulled 1 Disconnect at the throttle side 10 Throttle cable 2 pushed 1 Disconnect at the throttle side 11 Right grip 1 Refer to removal section 12 Tube guide 1 13 Left grip 1 Refer to removal secti...

Page 181: ...g the handlebar lower hold er in the reverse direction allows the front to rear offset amount of the handlebar position to be changed Do not tighten the nut yet 2 Install Handlebar 1 Handlebar upper holder 2 Bolt handlebar upper holder 3 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 ha...

Page 182: ...itch 1 Brake master cylinder 2 Brake master cylinder bracket 3 Bolt brake master cylinder brack et 4 Clamp 5 The start switch and brake master cylinder bracket should be installed according to the dimensions shown 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 11 Ins...

Page 183: ...the clutch cable end and hot start er cable end 13 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY section in the CHAPTER 3 Hot starter lever free play Refer to ADJUSTING THE HOT STARTER LEVER FREE PLAY section in the CHAPTER 3 ...

Page 184: ... placing the suitable stand under the engine Refer to HANDLING NOTE Headlight Handlebar Refer to HANDLEBAR section Front brake hose guide Front fender 1 Multi function display 1 2 Multi function display bracket 1 3 Main switch 1 Disconnect the main switch lead 4 Steering stem nut 1 5 Front fork 2 Refer to FRONT FORK section 6 Upper bracket 1 7 Steering ring nut 1 Refer to removal section 8 Lower b...

Page 185: ...6 28 STEERING 9 Bearing race cover 1 10 Upper bearing 1 11 Lower bearing 1 Refer to removal section 12 Bearing race 2 Refer to removal section Order Part name Q ty Remarks ...

Page 186: ...s Spin the bearings by hand If the bearings hang up or are not smooth in their operation in the bearing races replace bearings and bearing races as a set INSTALLING THE LOWER BRACKET 1 Install Lower bearing 1 Apply the lithium soap base grease on the dust seal lip and bearing inner circumference 2 Install Bearing race Upper bearing 1 Bearing race cover 2 Apply the lithium soap base grease on the b...

Page 187: ...r bracket to speci fied torque If torqued too much it may cause the front fork to mal function 13 Install Multi function display bracket 1 Multi function display 2 Pass the throttle cables 3 clutch ca ble 4 and hot starter cable 5 be tween the multi function display bracket and upper bracket 14 Install Holder 1 Clamp 2 Install so that the marking a on the speed sensor lead aligns with the holder e...

Page 188: ...ING 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 Drive chain 1 Drive chain support 1 2 Lower chain tensioner 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt connecting rod 1 5 Pivot shaft 1 6 Swingarm 1 ...

Page 189: ...EMBLING THE SWINGARM Order Part name Q ty Remarks 1 Cap 2 Refer to removal section 2 Relay arm 1 3 Connecting rod 1 4 Collar 2 5 Oil seal 2 6 Thrust bearing 2 7 Bushing 2 8 Oil seal 8 9 Bearing 10 Refer to removal section ...

Page 190: ...l seal 3 Damage Replace INSTALLING THE BEARING AND OIL SEAL 1 Install Bearing 1 Oil seal 2 To swingarm Apply the molybdenum disulfide grease on the bearing when install ing Install the bearing by pressing it on the side having the manufacture s marks or numbers First install the outer and then the inner bearings to a specified depth from inside 2 Install Bearing 1 Washer 2 Oil seal 3 To relay arm ...

Page 191: ...olybdenum disulfide grease on the bolt circumference and threaded portion Do not tighten the nut yet 6 Install Swingarm 1 Pivot shaft 2 Apply the molybdenum disulfide grease on the pivot shaft Insert the pivot shaft from right side 7 Check Swingarm side play a Free play exists Replace thrust bearing Swingarm up and down move ment b Unsmooth movement binding rough spots Grease or replace bearings b...

Page 192: ...t lower chain tensioner 5 14 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 Bolt drive chain support cover L 10 mm 0 39 in 5 Nut relay arm 70 Nm 7 0 m kg 50 ft lb Nut lower chain tension er 16 Nm 1 6 m kg 11 ft lb Nut drive chain sup port 7 Nm 0 7 m kg 5 1 ft lb Bolt drive chain support cover 7 Nm 0 7 m kg 5 1 ft lb ...

Page 193: ... Drain the coolant Refer to CHANGING THE COOLANT sec tion in the CHAPTER 3 Catch tank breather hose Disconnect at the catch tank side Catch tank hose Disconnect at the catch tank side Air induction hose air cut off valve air filter case Disconnect at the air filter case side Cylinder head breather hose Disconnect at the air filter case side Battery Refer to CHECKING AND CHARGING THE BATTERY sectio...

Page 194: ... 7 Bolt rear shock absorber relay arm 1 Hold the swingarm 8 Bolt rear shock absorber frame 1 9 Rear shock absorber 1 10 Locknut 1 Only loosening 11 Adjuster 1 Only loosening 12 Lower spring guide 1 13 Upper spring guide 1 14 Spring rear shock absorber 1 15 Bearing 2 Refer to removal section Order Part name Q ty Remarks ...

Page 195: ... the rear shock ab sorber be sure to extract the nitrogen gas from valve 1 Wear eye protec tion to prevent eye damage from es caping gas and or metal chips To dispose of a damaged or worn out rear shock absorber take the unit to your Yamaha dealer for this disposal procedure REMOVING THE BEARING 1 Remove Stopper ring upper bearing 1 Press in the bearing while pressing its outer race and remove the...

Page 196: ...seal 3 Apply the molybdenum disulfide grease on the bearing and dust seal lips Install the dust seals with their lips facing outward 3 Install Rear shock absorber 4 Install Bolt rear shock absorber frame 1 Washer 2 Nut rear shock absorber frame 3 Apply the molybdenum disulfide grease on the bolt 5 Install Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm 2 Apply the molybdenum...

Page 197: ...6 40 REAR SHOCK ABSORBER 8 Install Plastic band Taillight coupler Locking tie ...

Page 198: ...on display 3 Engine stop switch 4 Clutch switch 5 Diode 6 Starter relay diode 7 Throttle position sensor 8 Starter relay 9 Fuse 10 Starting circuit cut off relay 11 CDI unit 12 Taillight 13 Neutral switch 14 Starter motor 15 AC magneto 16 Rectifier regulator 17 Ignition coil 18 Spark plug 19 Start switch 20 Main switch 21 Speed sensor 22 Battery ...

Page 199: ... off relay 11 CDI unit 12 Taillight 13 Neutral switch 14 Starter motor 15 AC magneto 16 Rectifier regulator 17 Ignition coil 18 Spark plug 19 Start switch 20 Main switch 21 Speed sensor 22 Battery COLOR CODE B Black Br Brown Ch Chocolate Dg Dark green G Green Gy Gray L Blue O Orange R Red Sb Sky blue W White Y Yellow B L Black Blue B W Black White L B Blue Black L R Blue Red L Y Blue Yellow L W Bl...

Page 200: ...Use the following special tools in this inspection 1 Check fuse No good Replace fuse and check wire harness OK 2 Check battery No good Recharge or replace OK Spark gap test Spark 3 Clean or replace spark plug No spark Check entire ignition system for connection couplers leads and ignition coil No good Repair or replace OK Check engine stop switch No good Replace OK Check main switch No good Replac...

Page 201: ...ace CHECKING THE MAIN SWITCH 1 Inspect Main switch conduction Not conductive while the main switch is moved to ON Replace Conductive while the main switch is moved to OFF Replace Set the tester selection position to Ω 1 2 Inspect Main switch indicator light Use 12 V battery Indicator light does not come on Replace 3 Inspect Rubber part a Tears damage Replace CHECKING THE IGNITION COIL 1 Remove the...

Page 202: ...is in neutral the neutral switch is closed The clutch lever is pulled to the han dlebar the clutch switch is closed The starting circuit cut off relay pre vents the starter motor from operating when neither of these conditions has been met In this instance the start ing circuit cut off relay is open so cur rent cannot reach the starter motor When at least one of the above con ditions has been met ...

Page 203: ...12 V battery in this inspection Use the following special tools in this inspection 1 Check fuse No good Replace fuse and check wire harness OK 2 Check battery No good Recharge or replace OK Check each coupler and wire connection No good Repair or replace OK 3 Check main switch No good Replace OK Check starter motor operation No good Repair or replace OK Check starting circuit cut off relay No good...

Page 204: ...CH SWITCH 1 Inspect Clutch switch conduction Not conductive while it is pulled Re place Conductive while it is freed Re place Set the tester selection position to Ω 1 CHECKING THE DIODE 1 Remove the diode from wire har ness 2 Inspect Diode continuity Use pocket tester tester selec tion position Ω 1 Incorrect continuity Replace CHECKING THE START SWITCH 1 Inspect Start switch conduction Not conduct...

Page 205: ...7 8 ELECTRIC STARTING SYSTEM 2 Inspect Rubber part a Tears damage Replace ...

Page 206: ...7 9 ELECTRIC STARTING SYSTEM REMOVING THE STARTER MOTOR Order Part name Q ty Remarks Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 3 1 Starter motor 1 ...

Page 207: ...E STARTER MOTOR Order Part name Q ty Remarks 1 Starter motor front cover 1 2 Washer starter motor front cover 1 3 Washer 1 4 Circlip 1 5 O ring 1 6 Starter motor yoke 1 7 Armature assembly 1 8 Starter motor rear cover 1 9 Brush 2 10 Brush spring 2 ...

Page 208: ...as a set ASSEMBLING THE STARTER MOTOR 1 Install Brush spring 1 Brush 2 2 Install Armature assembly 1 Install while holding down the brush using a thin screw driver Be careful not to damage the brush during installation 3 Install O ring 1 Starter motor yoke 2 Align the match mark a on the starter motor yoke with the match mark b on the starter motor rear cover Install the starter motor yoke with it...

Page 209: ...7 12 ELECTRIC STARTING SYSTEM 5 Install Bolt 1 O ring 2 Apply the lithium soap base grease on the O ring ...

Page 210: ...emove the following parts before inspection 1 Seat 2 Fuel tank Use the following special tools in this inspection 1 Check fuse No good Replace fuse and check wire harness OK 2 Check battery No good Recharge or replace OK Check each coupler and wire connection No good Repair or replace OK Check charging voltage OK Charging system is good No good Check AC magneto Charging coil No good Replace OK Rep...

Page 211: ...t of specification If no failure is found in checking the source coil resistance replace the rectifi er regulator 3 Inspect Charging coil resistance Out of specification Replace Tester lead Red lead 1 Tester lead Black lead 2 Charging voltage Tester se lector posi tion 14 0 15 0 V at 5 000 r min DCV 20 Tester lead White lead 1 Tester lead Ground 2 Charging coil resis tance Tester se lector posi ti...

Page 212: ...the following inspection steps Use the following special tools in this inspection Check entire ignition system for connection No good Repair or replace OK Check throttle position sensor Throttle position sensor coil No good Replace OK Check CDI unit Throttle position sensor input voltage No good Replace Pocket tester YU 3112 C 90890 03112 ...

Page 213: ...lot a in the throttle posi tion sensor with the projection b on the carburetor Temporarily tighten the screw throttle position sensor 5 Install Carburetor Throttle position sensor coupler 6 Adjust Engine idling speed Refer to ADJUSTING THE EN GINE IDLING SPEED section in the CHAPTER 3 7 Insert the thin electric conductors 2 lead into the throttle position sensor coupler 1 as shown and connect the ...

Page 214: ...it 14 Install the carburetor CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1 Disconnect the throttle position sensor coupler 2 Start the engine 3 Inspect Throttle position sensor input volt age Out of specification Replace the CDI unit Throttle po sition sen sor output voltage Tester se lector posi tion 0 58 0 78 V DCV Tester lead Blue lead 1 Tester lead Black Blue lead 2 Throttle po sition ...

Page 215: ...following special tools in this inspection Check the bulb and bulb socket No good Replace the bulb and or bulb socket OK Check the taillight LEDs No good Replace the taillight assembly OK Check the AC magneto Lighting coil No good Replace OK Check the entire lighting system proper for con nections Improperly connected Repair or replace OK Check the rectifier regulator Out put voltage No good Repla...

Page 216: ...ble gas or fluid is in the vicinity CHECKING THE AC MAGNETO 1 Inspect Lighting coil resistance Out of specification Replace CHECKING THE RECTIFIER REGULATOR 1 Connect the battery leads 2 Start the engine 3 Turn on the headlight and taillight by turning on the light switch 4 Inspect Out put voltage Out of specification Replace rectifier regulator Battery terminal Blue lead 2 Battery terminal Black ...

Page 217: ...ts before inspection 1 Headlight Use the following special tools in this inspection 1 Check battery No good Recharge or replace OK Check each coupler and wire connection No good Repair or replace OK Check multi function display Input voltage No good Replace wire harness OK Check multi function display Output voltage No good Replace multi function display OK Check speed sensor No good Replace Pocke...

Page 218: ...D SENSOR OUTPUT VOLTAGE 1 Insert the thin electric conductors 1 lead into the speed sensor coupler 2 as shown and con nect the tester to them Do not insert the electric conduc tors more than required because it may reduce the waterproof function of the coupler Make sure that a short circuit does not develop between the terminals because it may cause damage to electrical compo nents 2 Set the main ...

Page 219: ......

Page 220: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2007 07 0 9 1 CR E OSM Cover4_CDN_E fm Page 1 Friday June 29 2007 5 35 PM ...

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