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Yamaha 2009 YZ450F, Owner'S Manual

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Yamaha 2009 YZ450F Owner'S Manual Download Page 35

2-13

TIGHTENING TORQUES

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

△

Cable guide (front brake hose) and under bracket

M6 × 1.0

1

4

0.4

2.9

△

Front brake hose union bolt (brake master cylinder)

M10 × 1.25

1

30

3.0

22

△

Front brake hose union bolt (brake caliper)

M10 × 1.25

1

30

3.0

22

△

Front brake caliper and front fork

M8 × 1.25

2

28

2.8

20

△

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 axle nut

M16 × 1.5

1

105

10.5

75

△

Front wheel axle holder

M8 × 1.25

4

21

2.1

15

△

Front brake disc and wheel hub

M6 × 1.0

6

12

1.2

8.7

△

Rear brake disc and wheel hub

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

△

Rear brake master cylinder and frame

M6 × 1.0

2

10

1.0

7.2

Rear brake master cylinder cap

M4 × 0.7

2

2

0.2

1.4

△

Rear brake hose union bolt (brake caliper)

M10 × 1.25

1

30

3.0

22

△

Rear brake hose union bolt (brake master cylinder)

M10 × 1.25

1

30

3.0

22

△

Rear wheel axle and axle nut

M22 × 1.5

1

135

13.5

98

△

Driven sprocket and wheel hub

M8 × 1.25

6

42

4.2

30

△

Nipple (spoke)

—

72

3

0.3

2.2

△

Disc cover and rear brake caliper

M6 × 1.0

2

10

1.0

7.2

△

Protector and rear brake caliper

M6 × 1.0

2

7

0.7

5.1

Drive chain puller adjust bolt and locknut

M8 × 1.25

2

19

1.9

13

Engine mounting:

△

Upper engine bracket and frame

M10 × 1.25

4

55

5.5

40

△

Lower engine bracket and frame

M8 × 1.25

4

34

3.4

24

△

Engine and engine bracket (front)

M10 × 1.25

1

53

5.3

38

△

Engine and engine bracket (upper)

M10 × 1.25

1

55

5.5

40

△

Engine and frame (lower)

M10 × 1.25

1

53

5.3

38

△

Engine guard

M6 × 1.0

1

10

1.0

7.2

Lower engine guard

M6 × 1.0

3

10

1.0

7.2

CDI unit bracket

M6 × 1.0

2

7

0.7

5.1

Cable guide and CDI unit bracket

M5 × 0.8

2

4

0.4

2.9

Cable guide and frame

M5 × 0.8

1

5

0.5

3.6

△

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 × 1.25

1

38

3.8

27

△

Rear frame and frame (lower)

M8 × 1.25

2

32

3.2

23

Part to be tightened

Thread size

Q'ty

Tightening torque

Nm

m•kg

ft•lb

Summary of Contents for 2009 YZ450F

Page 1: ...e attentivement ce manuel avant la première utilisation du véhicule Read this manual carefully before operating this vehicle Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch bevor Sie das Fahrzeug in Betrieb nehmen ...

Page 2: ...ire attentivement ce manuel avant la première utilisation du véhicule Le manuel doit être remis avec le véhicule en cas de vente de ce dernier Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch bevor Sie das Fahrzeug in Betrieb nehmen Diese Bedienungsanleitung muss wenn das Fahrzeug verkauft wird beim Fahrzeug verbleiben ...

Page 3: ...YZ450F Y 2009 2009 34P 28199 80 E0 34P 28199 80 E0 OWNER S SERVICE MANUAL OWNER S SERVICE MANUAL Read this manual carefully before operating this vehicle Read this manual carefully before operating this vehicle ...

Page 4: ......

Page 5: ... S SERVICE MANUAL 2008 by Yamaha Motor Co Ltd 1st Edition May 2008 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Page 6: ...racter istics THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY Do not carry passengers on this machine ALWAYS WEAR PROTECTIVE APPAREL When operating this machine al ways wear an approved helmet with goggles or a face shield Also wear heavy boots gloves and protective clothing Always wear proper fitting clothing that will not be caught in any of the moving parts or controls of the machine...

Page 7: ...wn to find the required fore edge symbol mark and go to a page for required item and de scription MANUAL FORMAT All of the procedures in this manual are organized in a sequential step by step format The information has been complied to provide the me chanic with an easy to read handy reference that contains comprehen sive explanations of all disassembly repair assembly and inspection op erations I...

Page 8: ...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 9: ...TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE 4 CHASSIS 5 ELECTRICAL 6 TUNING 7 ...

Page 10: ... 3 14 ELECTRICAL 3 24 CHAPTER 4 ENGINE SEAT FUEL TANK AND SIDE COVERS 4 1 EXHAUST PIPE AND SILENCER 4 3 RADIATOR 4 5 CARBURETOR 4 7 CAMSHAFTS 4 14 CYLINDER HEAD 4 19 VALVES AND VALVE SPRINGS 4 22 CYLINDER AND PISTON 4 26 CLUTCH 4 29 OIL FILTER ELEMENT AND WATER PUMP 4 33 BALANCER 4 37 OIL PUMP 4 39 KICK SHAFT AND SHIFT SHAFT 4 42 CDI MAGNETO 4 47 ENGINE REMOVAL 4 49 CRANKCASE AND CRANKSHAFT 4 53 T...

Page 11: ...ubject to change without notice 1 Clutch lever 2 Hot starter lever 3 Front brake lever 4 Throttle grip 5 Radiator cap 6 Fuel tank cap 7 Engine stop switch 8 Kickstarter crank 9 Fuel tank 10 Radiator 11 Coolant drain bolt 12 Rear brake pedal 13 Valve joint 14 Fuel cock 15 Cold starter knob 16 Drive chain 17 Air cleaner 18 Shift pedal 19 Oil dipstick 20 Front fork 1 ...

Page 12: ...e joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose In this installation make sure the arrow faces the fuel tank and also downward SPARK 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 ne...

Page 13: ...amped letters must be on the side exposed to view When in stalling oil seal s apply a light coating of lightweight 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 afte...

Page 14: ...staller YM 91044 90890 04081 Adapter M12 YU 90063 90890 01278 These tools are used to install the crankshaft Piston pin puller set YU 1304 90890 01304 This tool is used to remove the pis ton pin Radiator cap tester YU 24460 01 90890 01325 Radiator cap tester adapter YU 33984 90890 01352 These tools are used for checking the cooling system Rotor puller YM 04151 90890 04151 This tool is used to remo...

Page 15: ...ed when install the fork oil seal Spoke nipple wrench YM 01521 90890 01521 This tool is used to tighten the spoke 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 t...

Page 16: ...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 Crankcase separating tool YU A9642 90890 04152 These tool is used to remove the crankshaft from either case Dynamic spark tester Y...

Page 17: ...ometer 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 18: ...EAR 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 FUEL COCK The fuel cock supplies fuel from the tank to carburetor and also filters the fuel The fuel cock has the two posi tions OFF With the lever in this position fuel will not flow Always return the lever to this position when the engine is not running ON W...

Page 19: ...he cold starter knob to its original position and run the en gine at 3 000 5 000 r min for 1 or 2 minutes Since this model is equipped with an accelerator pump if the engine is raced the throttle opened and closed the air fuel mixture will be too rich and the engine may stall Also unlike a two stroke engine this model can idle Do not warm up the engine for ex tended periods of time STARTING A WARM...

Page 20: ... 2 open low to me dium speed for about one hour 6 Restart the engine and check the operation of 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 su...

Page 21: ...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 22: ...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 23: ...nder 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 Kickstarter Lubrication system Dry sump Oil type or grade Engine oil For USA and CDN Yamalube 4 SAE10W 40 or SAE20W 50 Yamalube 4 R SAE10W 50 API service SG type or higher JASO standard MA Except for USA and CDN SAE10W 30 SAE10...

Page 24: ...ration Gear ratio 1st 27 14 1 929 2nd 23 15 1 533 3rd 23 18 1 278 4th 24 22 1 091 5th 20 21 0 952 Chassis USA CDN AUS NZ ZA EUROPE Frame type Semi double cradle Caster angle 26 9 26 8 Trail 115 7 mm 4 56 in 114 2 mm 4 50 in Tire Type With tube Size front 80 100 21 51M Size rear 120 80 19 63M For USA CDN ZA AUS NZ 110 90 19 62M For EUROPE Tire pressure front and rear 100 kPa 1 0 kgf cm2 15 psi Brak...

Page 25: ...shaft 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 in 0 08mm 0 003 in Cam dimensions Intake A 31 200 31 300 mm 1 2283 1 2323 in 31 100 mm 1 2244 in Intake B 22 550 22 650 mm 0 8878 0 8917 in 22 450 mm 0 8839 in Exhaust A 30 900 31 000 mm 1 ...

Page 26: ...089 in B face width EX 2 26 mm 0 089 in C seat width IN 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in C seat width EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D margin thickness IN 1 mm 0 0394 in 0 85 mm 0 033 in D margin thickness EX 1 mm 0 0394 in 0 85 mm 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 ...

Page 27: ...4 in Set length valve closed IN 27 87 mm 1 10 in Set length valve closed EX 27 38 mm 1 08 in Compressed force installed IN 111 3 127 9 N at 27 87 mm 11 3 13 0 kg at 27 87 mm 24 91 28 66 lb at 1 10 in Compressed force installed EX 127 4 146 4 N at 27 38 mm 13 0 14 9 kg at 27 38 mm 28 66 32 85 lb at 1 08 in Tilt limit IN 2 5 1 61 mm 2 5 0 063 in Tilt limit EX 2 5 1 65 mm 2 5 0 065 in Direction of wi...

Page 28: ... 0 0012 0 0026 in 0 12 mm 0 005 in 2nd ring Type Taper Dimensions B T 1 00 3 35 mm 0 04 0 13 in End gap installed 0 35 0 50 mm 0 014 0 020 in 0 85mm 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 ...

Page 29: ...ease 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 Kick and ratchet type Carburetor Type manufacturer FCR MX39 KEIHIN I D mark 2S2B B0 Main jet M J 160 Main air jet M A J ø2 0 Jet needle clip position J N NFLR 3 Cutaway C A 1 5 Pilot jet P J 45 Pilot air jet P A J 100 Pilot outlet P O ø0 9 Pilot screw example P S 1 ...

Page 30: ... pump Type Single suction centrifugal pump Item Standard Limit Item Standard Limit Steering system Steering bearing type Taper roller bearing Front suspension USA CDN EUROPE AUS NZ ZA Front fork travel 300 mm 11 8 in Fork spring free length 454 mm 17 9 in 449 mm 17 7 in Spring rate STD K 4 6 N mm 0 469 kg mm 26 3 lb in Optional spring Yes Oil capacity 541 cm3 19 0 lmp oz 18 3 US oz 531 cm3 18 7 lm...

Page 31: ...2 0 mm 0 08 in Drive chain Type manufacturer DID520DMA2 SDH DAIDO Number of links 113 links joint Chain slack 50 60 mm 2 0 2 4 in Chain length 15 links 242 9 mm 9 563 in Front disc brake Disc outside dia Thickness 250 3 0 mm 9 84 0 12 in 250 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 9 52 mm 0 375 in Caliper cylinder inside dia 22 65 mm 0 892 in 2 Br...

Page 32: ... manufacturer 34P 00 YAMAHA USA and CDN 34P 10 YAMAHA Except for USA and CDN Ignition coil Model manufacturer 5TA 10 DENSO Minimum spark gap 6 mm 0 24 in Primary coil resistance 0 08 0 10 Ωat 20 C 68 F Secondary coil resistance 4 6 6 8 kΩat 20 C 68 F Part to be tightened Thread size Q ty Tightening torque Nm m kg ft lb Spark plug M10S 1 0 1 13 1 3 9 4 Camshaft cap M6 1 0 10 10 1 0 7 2 Cylinder hea...

Page 33: ... 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 drain bolt 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 1 10 1 0 7 2 Oil hose clamp 2 2 0 2 1 4 Crankshaft end accessing screw M27 1 5 1 10 1 0 7 2 Timing mark accessing screw M14 1 5 1 6 0 6 4 3 Clutch cover M6 1 0 7 10 1 0 7 2 Right crank...

Page 34: ...2 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 upper holder M8 1 25 4 28 2 8 20 Handlebar lower holder M10 1 25 2 34 3 4 24 Steering ring nut ...

Page 35: ... master cylinder M10 1 25 1 30 3 0 22 Rear wheel axle and axle nut M22 1 5 1 135 13 5 98 Driven sprocket and wheel hub M8 1 25 6 42 4 2 30 Nipple spoke 72 3 0 3 2 2 Disc cover and rear brake caliper M6 1 0 2 10 1 0 7 2 Protector and rear brake caliper M6 1 0 2 7 0 7 5 1 Drive chain puller adjust bolt and locknut M8 1 25 2 19 1 9 13 Engine mounting Upper engine bracket and frame M10 1 25 4 55 5 5 4...

Page 36: ...ting boss and frame M10 1 25 1 20 2 0 14 Fuel tank mounting M6 1 0 2 9 0 9 6 5 Fuel tank and fuel cock M6 1 0 2 4 0 4 2 9 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 23 2 3 17 Side cover M6 1 0 2 7 0 7 5 1 Air scoop and fuel tank M6 1 0 6 7 0 7 5 1 Air scoop and radiator guard lower M6 1 0 2 7 0 7 5 1 Front fender M6 1 0 4 7 0...

Page 37: ...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 38: ...2 16 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 39: ...2 17 LUBRICATION DIAGRAMS 1 Intake camshaft 2 Exhaust camshaft A To main axle B From oil pump ...

Page 40: ...r lead 10 Hot starter cable 11 Carburetor breather hose 12 Carburetor overflow hose A Insert the end of the fuel tank breather hose into the hole in the steering stem B Pass the cylinder head breather hose on the outside of the radia tor hose 1 and between the radi ator hose 4 and frame C Align the paint on the cylinder head breather hose with the front edge of the hose holder D Pass the clutch ca...

Page 41: ...ss F Install the connector cover so that it does not come in between the radiator hose 1 and radiator G Pass the fuel hose on the out side of throttle position sensor lead H Pass the carburetor breather hoses and overflow hose so that all there hoses do not contact the rear shock absorber ...

Page 42: ...ub wire harness 14 Ground lead 15 CDI unit bracket 16 CDI unit 17 Cable guide 18 Ignition coil lead 19 Throttle cable 20 Hot starter cable protector 21 Rubber cap A Fasten the hot starter cable and throttle cables onto the frame B Fasten the hot starter cable throttle cables throttle position sensor lead and ignition coil lead to the frame C Pass the throttle position sensor lead over the hot star...

Page 43: ...hassis and then between the frame and radiator hose 4 J Fasten the sub wire harness engine stop switch lead and ground lead to the CDI unit bracket at the position taped portion of the sub wire harness and with the clamp ends facing downward K Fasten the ground lead and ca ble guide together to the CDI unit bracket L Locate the clamp ends under the throttle cable and after clamping leave the other...

Page 44: ...r head breather hose A Pass the throttle cables over the radiator hose 2 B Pass the throttle cables on the outside of the ignition coil C Fasten the throttle cables with the clamp so that the cables are not bent and pass them under the rear arm bracket D Pass the cylinder head breather hose so that it does not contact the ignition coil ...

Page 45: ... 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 46: ...e hose 8 Hose guide A Fasten the engine stop switch lead to the handlebar B Pass the clutch cable and hot starter cable through the cable guide C Pass the brake hose in front of the number plate D Pass the throttle cables through the cable guide E Pass the clutch cable and hot starter cable through the cable guide on the number plate ...

Page 47: ...GINE 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 t...

Page 48: ...UG Inspect and clean Replace DRIVE CHAIN Use chain lube Lubricate slack alignment Chain slack 50 60 mm 2 0 2 4 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 equivalen...

Page 49: ...FORK 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 Replace spring seat Every one year 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 greas...

Page 50: ...ocket bolt Inspect bearings Replace bearings Lubricate Lithium base grease THROTTLE CONTROL CABLE Check routing and connection Yamaha cable lube or SAE 10W 30 motor oil Lubricate HOT STARTER CLUTCH LEVER Inspect free play Item After break in Every race Every third or 500 km Every fifth or 1 000 km As re quired Remarks ...

Page 51: ... slack and alignment Check that the drive chain is lubricated properly P 3 17 18 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 20 21 Steering Check that the handlebar can be turned smoothly and have no ex cessive play P 3 21 22 Front forks and rear shock absorber Check that they operate smoothly and there is no oil leakage P 3 18 20 Cables ...

Page 52: ...water 5 Install Copper washer Coolant drain bolt Engine guard Bolt engine guard 6 Fill Radiator Engine To specified level Do not mix more than one type of ethylene glycol antifreeze con taining corrosion inhibitors for aluminum engine Do not use water containing im purities or oil Handling notes of coolant The coolant is harmful so it should be handled with special care When coolant splashes to yo...

Page 53: ...k Clutch lever free play a Out of specification Adjust 2 Adjust Clutch lever free play Clutch lever free play adjustment steps a Loosen the locknuts 1 b Turn the adjuster 2 until free play a is within the specified lim its c Tighten the locknuts Before adjustment expose the ad juster by moving the boot 3 and cap 4 away Make minute adjustment on the le ver side using the adjuster 5 After adjustment...

Page 54: ... 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 this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage 1 Remove Seat Fitting bolt 1 Washer 2 Air filter element 3 Air filter guide 4 2 Clean Air filter element Clean them with solvent...

Page 55: ...into the oil tank Insert the gauge lightly Engine oil also luburicates the clatch and the wrong oil types or additives could cause clatch slippage Therefore do not oils with a grade of CD a or higher and do not use oils labeled EN ERGY CONSERVING II b Do not allow foreign material to enter the crankcase For USA and CDN Except for USA and CDN 5 Start the engine and let it warm up for several minute...

Page 56: ...rew has been individually set at the factory Before adjusting the pilot screw turn it in fully and count the number of turns Record this number as the factory set number of turns out a Turn in the pilot screw until it is lightly seated b Turn out the pilot screw by the factory set number of turns ADJUSTING THE ENGINE IDLING SPEED 1 Start the engine and thoroughly warm it up 2 Adjust Engine idling ...

Page 57: ...ecking 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 as shown in the il...

Page 58: ...eld where these two coordinates intersect shows the new pad number to use Use the new pad number only as a guide when verifying the valve clear ance adjustment f Install the new pads 3 and the valve lifters 4 Apply the engine oil on the valve lift ers 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 l...

Page 59: ...3 13 ENGINE INTAKE EXHAUST ...

Page 60: ... bleeding procedure when the tiny bubbles in the system have disap peared j Add brake fluid to the level line on the reservoir Check the operation of the brake after bleeding the brake system 3 Install Protector rear brake Reservoir float front brake Diaphragm Brake master cylinder cap ADJUSTING THE FRONT BRAKE 1 Check Brake lever position a 2 Remove Brake lever cover 3 Adjust Brake lever position...

Page 61: ... pads with their pro jections a into the brake caliper re cesses b Temporarily tighten the pad pin at this point i Install the brake caliper 8 and tighten the pad pin 9 j Install the pad pin plug 10 3 Inspect Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL section 4 Check Brake lever operation A softy or spongy feeling Bleed brake system Refer to BLEEDING THE HY DRAULIC BRAKE SYSTEM sec ...

Page 62: ...efer to CHECKING THE BRAKE FLUID LEVEL section 4 Check Brake pedal operation A softy or spongy feeling Bleed brake system Refer to BLEEDING THE HY DRAULIC BRAKE SYSTEM sec tion CHECKING THE REAR BRAKE PAD INSULATOR 1 Remove Brake pad Refer to CHECKING AND RE PLACING THE REAR BRAKE PADS section 2 Inspect Rear brake pad insulator 1 Damage Replace CHECKING THE BRAKE FLUID LEVEL 1 Place the brake mast...

Page 63: ... by placing the suitable stand under the en gine 2 Check Drive chain slack a Above the seal guard installation bolt Out of specification Adjust Before checking and or adjusting ro tate the rear wheel through several revolutions and check the slack sev eral times to find the tightest point Check and or adjust the drive chain slack with the rear wheel in this tight chain position 3 Adjust Drive chai...

Page 64: ... force By turning the adjuster 1 STANDARD POSITION This is the position which is back by the specific number of clicks from the fully turned in position Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged Always adjust each front fork to the same setting Uneven adjust ment can cause poor handling and loss of stability ADJUSTING THE FRONT FORK COMP...

Page 65: ...pring installed changes 1 5 mm 0 06 in per turn of the adjuster Never attempt to turn the adjuster beyond the maximum or minimum setting e Tighten the locknut 5 Install Rear frame upper Rear frame lower ADJUSTING THE REAR SHOCK ABSORBER REBOUND DAMPING FORCE 1 Adjust Rebound damping force By turning the adjuster 1 Standard position 12 clicks out 10 clicks out Except for USA and CDN Standard fittin...

Page 66: ...djustment The adjuster may be damaged CHECKING THE TIRE PRESSURE 1 Measure Tire pressure Out of specification Adjust Check the tire while it is cold Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low A tilted tire valve stem indicates that the tire slips off its position on the rim If the tire valve stem is found tilted the tire is considered to be...

Page 67: ... the thread of the steering stem Set the torque wrench to the steer ing nut wrench so that they form a right angle e Loosen the steering ring nut one turn f Retighten the steering ring nut us ing the steering nut wrench Avoid over tightening g Check the steering stem by turn ing it lock to lock If there is any binding remove the steering stem assembly and inspect the steer ing bearings h Install t...

Page 68: ...3 22 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 brack et 21 Nm 2 1 m kg 15 ft lb Number plate 7 Nm 0 7 m kg 5 1 ft lb ...

Page 69: ...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 70: ...er if necessary 5 Tighten Spark plug Before installing a spark plug clean the gasket surface and plug sur face Finger tighten a the spark plug before torquing to specification b CHECKING THE IGNITION TIMING 1 Remove Timing mark accessing screw 1 2 Attach Timing light Digital tachometer To the ignition coil lead orange lead 1 3 Adjust Engine idling speed Refer to ADJUSTING THE EN GINE IDLING SPEED ...

Page 71: ...inspection adjustment disassembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage SEAT FUEL TANK AND SIDE COVERS REMOVING THE SEAT FUEL TANK AND SIDE COVERS Order Part 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 Refer to removal s...

Page 72: ...n a is inserted into the band of the number plate Pull the band off the projection before removal Remove the hot starter cable 2 and clutch cable 3 from the cable guide b on the number plate The projection c on the lower bracket is inserted into the number plate Remove the number plate by pulling it off the projection INSTALLING THE AIR SCOOP 1 Install Air scoop 1 Bolt air scoop Put the portion a ...

Page 73: ... Order Part name Q ty 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 74: ... as shown Take care not to allow the fiber out of place when installing the inner pipe Install the band 3 with the mating ends c positioned as shown INSTALLING THE SILENCER AND EXHAUST PIPE 1 Install Gasket Exhaust pipe 1 Nut exhaust pipe 2 Bolt exhaust pipe 3 First temporarily tighten the nut ex haust pipe then tighten the bolt ex haust pipe 13 Nm 1 3 m kg 9 4 ft lb After that retighten the nut e...

Page 75: ...fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section 1 Radiator guard 2 2 Radiator hose clamp 8 Only loosening 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 8 Radiator breather hose 1 9 Left radiator 1 10 Radiator hose 1 1 11 Pipe 1 O ring 1 1 ...

Page 76: ... core 1 Obstruction Blow out with com pressed air through rear of the ra diator Bent fin Repair replace INSTALLING THE 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 Radiator breather hose 1 Right radiator 2 Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 4 Install Radiator guard 1 First fit ...

Page 77: ...ock absorber Refer to REAR SHOCK ABSORBER sec tion in the CHAPTER 5 1 Clamp 1 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 assembly 1 9 Carburetor joint 1 ...

Page 78: ...using 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 Float chamber 1 11 Leak jet 1 12 Pilot screw 1 Refer to removal section 13 Float pin 1 14 Float 1 15 Needle valve 1 16 Main jet 1 17 Needle jet 1 18 Spacer 1 ...

Page 79: ...BURETOR 19 Pilot jet 1 20 Starter jet 1 21 Push rod 1 Pull the push rod 22 Throttle shaft assembly 1 23 Push rod link lever assembly 1 24 Pilot air jet 1 25 Cold starter plunger 1 Order Part name Q ty Remarks ...

Page 80: ... b Clean Filter c Clogged Clean CHECKING THE THROTTLE VALVE 1 Check Free movement Stick Repair or replace Insert the throttle valve 1 into the carburetor body and check for free movement CHECKING THE JET NEEDLE 1 Inspect Jet needle 1 Bends wear Replace Clip groove Free play exists wear Replace Clip position MEASURING AND ADJUSTING THE FLOAT HEIGHT 1 Measure Float height a Out of specification Adju...

Page 81: ...1 fits on the stopper 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 met...

Page 82: ...ng Leak jet 1 Float chamber 2 Bolt float chamber 3 Cable holder throttle stop screw cable 4 Hose holder carburetor breather hose 5 14 Install Diaphragm accelerator pump 1 Spring 2 O ring 3 Accelerator pump cover 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...

Page 83: ... joint slots 3 Install Hot starter plunger 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 ...

Page 84: ... TANK AND SIDE COVERS section Hot starter plunger Refer to CARBURETOR 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 6 Timing chain guide top side 1 ...

Page 85: ...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 86: ...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 87: ... 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 88: ...iming 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 tension...

Page 89: ...ten the cylinder head bolts further to reach the specified 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 Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section Radiator Refer to RADIATOR section Carburetor Refer to CARBURETOR section Camshaft Refer to CAMSHAFTS section 1 Bolt 2 2 Bolt 4 Refe...

Page 90: ...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 91: ...4 21 CYLINDER HEAD 3 Install Bolt cylinder head 1 Bolt cylinder head 10 Nm 1 0 m kg 7 2 ft lb ...

Page 92: ...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 93: ... head in an over 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 f...

Page 94: ...ed Lapping steps a Apply a coarse lapping compound to the valve face Do not let the compound enter the gap between the valve 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 w...

Page 95: ... 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 stem end Apply...

Page 96: ...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 97: ...he piston 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 carb...

Page 98: ...nd upper 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 thei...

Page 99: ... 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 100: ...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 101: ...et Measure 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 SH...

Page 102: ...and ending with a friction plate Apply the engine oil on the friction plates and clutch plates 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 Install Clutch spring Bolt clutch spring Tighten the bolts in stage using a criss...

Page 103: ...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 104: ...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 105: ... 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 106: ...1 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 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 ele...

Page 107: ...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 108: ...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 109: ...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 110: ...4 40 OIL PUMP 15 Oil pump drive shaft 1 16 Rotor housing 1 Order Part name Q ty Remarks ...

Page 111: ...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 112: ...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 113: ...4 43 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 114: ...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 115: ...AFT ASSEMBLY 1 Install Kick gear 1 Washer 2 Circlip 3 Ratchet wheel 4 Spring 5 Washer 6 Circlip 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 ...

Page 116: ...on 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 de pressed side a toward you ...

Page 117: ...ame Q ty Remarks Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Disconnect the CDI 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 6 Stator 1 7 Woodruff key 1 ...

Page 118: ...ons of the crank shaft 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 3 Install Washer Nut rotor 1 4 Connect CDI magneto lead Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 5 Install Dowel pin O ring Gasket left crankcase cover Lef...

Page 119: ...REAR SHOCK ABSORBER sec tion in the CHAPTER 5 Carburetor Refer to CARBURETOR section Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section Clutch cable Disconnect at the engine side Radiator Refer to RADIATOR section Shift pedal Refer to KICK SHAFT AND SHIFT SHAFT section Cylinder head breather hose Refer to CAMSHAFTS section Drain the engine oil Refer to CHANGING THE ENGINE OIL sec...

Page 120: ... section 4 Lock washer 1 Refer to removal section 5 Drive sprocket 1 Refer to removal section 6 Clip 1 7 Bolt brake pedal 1 8 Brake pedal 1 9 Upper engine bracket 2 10 Lower engine bracket 2 11 Engine mounting bolt 3 12 Pivot shaft 1 Refer to removal section 13 Engine 1 Refer to removal section Order Part name Q ty Remarks ...

Page 121: ...2 Engine mounting 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 pe...

Page 122: ...ock washer tab 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 ...

Page 123: ...AFT AND SHIFT SHAFT section Segment Refer to KICK SHAFT AND SHIFT SHAFT section Stator Refer to CDI MAGNETO 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 Right crankcase 1 Refer to removal secti...

Page 124: ...4 54 CRANKCASE AND CRANKSHAFT 10 Balancer shaft 1 Refer to removal section 11 Crankshaft 1 Refer to removal section Order Part name Q ty Remarks ...

Page 125: ...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 126: ...ting 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 127: ...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 128: ...t TDC top dead center 6 Tighten Bolt hose guide 1 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...

Page 129: ...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 130: ...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 21T 1 3rd pinion gear ...

Page 131: ...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 132: ...dertake 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 REMOVING THE FRONT WHEEL Order Part name Q ty Remarks Hold the machine by placing 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 Fron...

Page 133: ...chine 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 Refer to removal section 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 3 Refer to removal section 10 Brake disc 1 5 ...

Page 134: ...rake disc deflection 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 soc...

Page 135: ...eal 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 out side diameter of the race of the bearing Right side of bearing shall be in stalled first Install the oil seal with its manufac ture s marks or numbers facing out ward Do not strike the inner race of the bearing Contact should be mad...

Page 136: ...el 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 section in the CHAPTER 3 10 Tighten Nut wheel axle 1 Locknut 2 Drive chain...

Page 137: ...tand 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 cali per 6 Brake caliper 1 7 Brake lever 1 8 Brake master cylinder bracket 1 9 Brake master cylinder 1 ...

Page 138: ...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 139: ...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 140: ...LINDER 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 Use a long nose circlip pliers 7 Washer 1 8 Push rod Rear 1 9 Brake master cylinder kit 1 ...

Page 141: ...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 142: ...on 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 seals onto the slot on brake calipe...

Page 143: ...ng installation cause improper brake performance 3 Install Spring 1 To brake master cylinder piston 2 Install the spring at the smaller dia side 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 Apply the brake fluid on the brake master cylinder kit Apply the silicone grease on the...

Page 144: ... 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 touches the projection b on the brake caliper 2 Install Brake ho...

Page 145: ... fluid mixing fluids may result in a harmful chemical reaction and lead to poor performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the flu id and may result in vapor lock Brake fluid may erode painted sur faces or plastic parts Always clean up spilled fluid immediately A Front B Rear 2 Air bleed Brake system Refer...

Page 146: ...5 15 FRONT BRAKE AND REAR BRAKE A Front B Rear 5 Install rear brake only Protector 1 Bolt protector 2 Bolt protector 7 Nm 0 7 m kg 5 1 ft lb ...

Page 147: ...r 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 3 Damper assembly 1 Loosen when disassembling the front fork Refer to removal section 4 Pinch bolt lower bracket 2 Only loosening 5 Front fork 1 ...

Page 148: ...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 Refer to removal section 30 Nm 3 0 m kg 22 ft lb 29 Nm 2 9 m kg 21 ft lb 29 Nm 2 9 m kg 21 ft lb 1 Nm 0 1 m kg 0 7 ft lb 55 Nm 5 5 m kg 40 ft lb ...

Page 149: ...n the inner tube and locknut 3 Hold the locknut and remove the adjuster Do not remove the locknut as the damper rod may go into the damp er assembly and not be taken out REMOVING THE INNER TUBE 1 Remove Dust seal 1 Stopper ring 2 Using slotted head screwdriver Take care not to scratch the inner tube 2 Remove Inner tube 1 Oil seal removal steps a Push in slowly a the inner tube just before it botto...

Page 150: ...r damage Re place CHECKING THE ADJUSTER 1 Inspect Adjuster 1 O ring 2 Wear damage Replace ASSEMBLING THE FRONT FORK 1 Wash the all parts in a clean sol vent 2 Stretch the damper assembly ful ly 3 Fill Front fork oil 1 To damper assembly Be sure to use recommended fork oil If other oils are used they may have an excessively ad verse effect on the front fork per formance Never allow foreign material...

Page 151: ...y up and down more than 10 times to distribute the fork oil 12 While protecting the damper as sembly 1 with a rag and com pressing fully allow excessive oil to overflow on the base valve side Take care not to damage the damp er assembly 13 Allow the overflowing oil to es cape at the hole a in the damper assembly 14 Check Damper assembly smooth move ment Tightness binding rough spots Repeat the ste...

Page 152: ... dia end a facing the fork spring 25 Install Damper assembly 1 To inner tube 2 To install the damper assembly into the inner tube hold the inner tube aslant If the inner tube is held vertically the damper assembly may fall into it damaging the valve inside 26 Loosen Rebound damping adjuster 1 Loosen the rebound damping ad juster finger tight Record the set position of the ad juster the amount of t...

Page 153: ...nce Never allow foreign materials to enter the front fork 32 Install Damper assembly 1 To outer tube Temporarily tighten the damper as sembly 33 Install Protector guide 1 INSTALLING THE FRONT FORK 1 Install Front fork 1 Temporarily tighten the pinch bolts lower bracket Do not tighten the pinch bolts up per bracket yet 2 Tighten Damper assembly 1 Use the cap bolt ring wrench 2 to tighten the damper...

Page 154: ...1 Bolt protector 2 6 Adjust Rebound damping force Turn in the damping adjuster 1 fin ger tight and then turn out to the orig inally set position 7 Adjust Compression 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 et 21 Nm 2 1 m kg 15 ft lb Bolt protector 5 Nm 0 5 m...

Page 155: ...ver side 4 Clutch lever holder 1 5 Engine stop switch 1 6 Brake master cylinder 1 Refer to removal section 7 Throttle cable cap 1 8 Throttle cable 1 pulled 1 Disconnect at the throttle side 9 Throttle cable 2 pushed 1 Disconnect at the throttle side 10 Right grip 1 Refer to removal section 11 Tube guide 1 12 Collar 1 13 Left grip 1 Refer to removal section 14 Handlebar upper holder 2 15 Handlebar ...

Page 156: ...bar low er holder Change in the direction back to front and installing position of the handlebar lower holder allows the front to rear offset amount of the handlebar position to be changed Do not tighten the nut yet A Forward 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 handle...

Page 157: ...etighten the bolts for adjustment 9 Install Grip cap cover 1 Cover throttle cable cap 2 10 Install Brake master cylinder 1 Brake master cylinder bracket 2 Bolt brake master cylinder brack et 3 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 Install Engine stop swit...

Page 158: ...um soap base grease on 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 159: ...der the engine Refer to HANDLING NOTE Number plate Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Handlebar Refer to HANDLEBAR section Front fender 1 Steering stem nut 1 2 Front fork 2 Refer to FRONT FORK section 3 Upper bracket 1 4 Steering ring nut 1 Refer to removal section 5 Lower bracket 1 6 Bearing race cover 1 7 Upper bearing 1 8 Lower bearing 1 Refer to removal section 9 ...

Page 160: ...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 161: ...djust the steering by loosen ing the steering ring nut little by lit tle 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 Tighten the lower bracket to speci fied torque If torqued too much it may cause the front fork to mal function Steering stem nut 145 Nm 14 5 m kg 105 ft lb Front fork top end stan dard a 5 mm 0 20 in Pinch bolt upper brack et 21 Nm...

Page 162: ...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 163: ...2 SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q ty Remarks 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 Refer to removal section ...

Page 164: ...stall 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 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 Apply the molybd...

Page 165: ...bdenum 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 bushings and collars 8 Install Bolt connecting rod 1 Washer 2 Nut connecting rod 3 Apply the molybdenum disulfide grease on the bolt Do not tighten the...

Page 166: ...nstall 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 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 167: ... in the CHAPTER 4 Silencer Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 4 1 Clamp air filter joint 1 Only loosening 2 Rear frame 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt rear shock absorber frame 1 5 Rear shock absorber 1 6 Locknut 1 Only loosening 7 Adjuster 1 Only loosening 8 Spring seat 2 9 Lower spring guide 1 10 Upper spring guide 1 11 Spring rear shock a...

Page 168: ... 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 stopper ring 2 Re...

Page 169: ...disulfide grease on the dust seal lips and col lars Apply the lithium soap base grease on the O rings 2 Install Bushing 1 Collar 2 Dust 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 molybde...

Page 170: ...5 39 REAR SHOCK ABSORBER Bolt rear frame lower 3 7 Tighten Bolt air filter joint 1 Bolt rear frame lower 32 Nm 3 2 m kg 23 ft lb Bolt air filter joint 3 Nm 0 3 m kg 2 2 ft lb ...

Page 171: ...rvicing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowledge and skill concerning servicing are request ed not to undertake inspection adjustment disassembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage 6 ...

Page 172: ...ition sensor 3 Neutral switch 4 CDI magneto 5 Ignition coil 6 Spark plug 7 CDI unit COLOR CODE B Black Br Brown G Green L Blue O Orange P Pink R Red Sb Sky blue W White Y Yellow B L Black Blue B W Black White B Y Black Yellow G B Green Black L W Blue White R W Red White B W B W B L B Y Sb Sb G B L Y L Y P B B B B G O W R P G W R P B Br W W B Y G Br G R R O B Sb Sb Y Y W Y W G G B P P Br Br R R O L...

Page 173: ...e following special tools in this inspection Spark gap test Spark 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 ignition coil primary coil and secondary coil No good Replace OK Check CDI magneto pickup coil and charging coil No good Replace OK Check neu...

Page 174: ...emove the ignition coil cap 2 Inspect Primary coil resistance Out of specification Replace 3 Inspect Secondary coil resistance Out of specification Replace 4 Inspect Sealed portion of ignition coil a Spark plug terminal pin b Threaded portion of spark plug c Wear Replace CHECKING THE CDI MAGNETO 1 Inspect Pickup coil resistance Out of specification Replace 2 Inspect Charging coil 1 resistance Out ...

Page 175: ... engaged Re place Set the tester selection position to Ω 1 CHECKING THE CDI UNIT Check all electrical components If no fault is found replace the CDI unit Then check the electrical compo nents again Tester lead Pink lead 1 Tester lead Black lead 2 Charging coil 2 resis tance Tester se lector posi tion 44 66 Ω at 20 C 68 F Ω 10 Tester lead Sky blue lead 1 Tester lead Ground 2 Result Conductive whil...

Page 176: ... IGNITION SYSTEM section 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 magneto Charging coil No good Replace OK Check CDI unit Throttle position sensor input voltage No good Replace Pocket tester YU 3112 C 90890 03112 ...

Page 177: ...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 178: ...t 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 s...

Page 179: ...essarily 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 air determines the rich ness or leanness of the air fuel mix ture Higher temperature ...

Page 180: ...The engine breathes hard and will not pick up speed quickly Step down the jet needle clip by one groove and move up the nee dle to enrich the mixture Effects of changing the jet needle groove position reference A Idle B Fully open 1 No 4 groove 2 No 2 groove 3 No 3 groove ADJUSTING THE JET NEEDLE The jet needle is adjusted by chang ing it The jet needle setting parts having the same taper angle ar...

Page 181: ...han standard to lean out the mixture Example 55 50 CARBURETOR SETTING PARTS Standard leak jet 55 Main jet Size Part number Rich 172 4MX 14943 92 170 4MX 14943 41 168 4MX 14943 91 165 4MX 14943 40 162 4MX 14943 90 STD 160 4MX 14943 39 158 4MX 14943 89 155 4MX 14943 38 152 4MX 14943 88 150 4MX 14943 37 Lean 148 4MX 14943 87 Pilot jet Size Part number Rich 52 4MX 14948 08 50 4MX 14948 07 48 4MX 14948...

Page 182: ...tion 1 groove down The clip position is the jet needle groove on which the clip is installed The positions are numbered from 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 P...

Page 183: ...7 5 ENGINE This should be taken simply for an example It is necessary to set the carburetor while checking the operating conditions of the engine ...

Page 184: ...rface Under a stony or hard road condi tion the tire pressure should be 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 amount 2 Setting of spring preload Change ...

Page 185: ... put the rear wheel above the floor and measure the length a between the rear wheel axle center and the rear fender holding bolt 2 Remove the stand or block from the engine and with a rider astride the seat measure the sunken length b between the rear wheel axle center and the rear fender holding bolt 3 Loosen the locknut 1 and make adjustment by turning the spring adjuster 2 to achieve the stan d...

Page 186: ...t of adjustment spring pre load For the spring preload adjustment refer to ADJUSTING THE REAR SHOCK ABSORBER SPRING PRELOAD in the CHAPTER 3 Preload adjusting extent is the same for the titanium and steel springs Length a of standard shock 490 mm 19 29 in TYPE SPRI NG RAT E SPRING PART NUMBER 22212 I D MARK SOFT Green 1 4 5 1C3 00 Green 2 Green 3 Red 1 4 7 1C3 10 Red 2 Red 3 Black 1 4 9 1C3 20 Bla...

Page 187: ...tire range bottoming out Compression damping Turn adjuster clockwise about 2 clicks to in crease damping Oil amount Increase oil amount by about 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Spring Replace with stiff spring Stiff toward stroke end Oil amount Decrease oil amount by about 5 cm3 0 2 Imp oz 0 2 US oz Soft toward stroke end bottoming out Oil amount Increase oil amount by about 5 cm3 0 2 Imp oz...

Page 188: ...eavy 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 turn to in crease dampin...

Page 189: ......

Page 190: ...PRINTED IN JAPAN E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

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