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Yamaha 2010 WR450FZ, Owner'S Service Manual

The Yamaha 2010 WR450FZ Owner's Service Manual is a comprehensive guide to maintaining and repairing your off-road motorcycle. This manual, available for free download at manualshive.com, provides step-by-step instructions, diagrams, and valuable tips to ensure your bike performs at its best. Fine-tune your machine with this essential manual.

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5-48

AC MAGNETO AND STARTER CLUTCH

AC MAGNETO AND STARTER CLUTCH

REMOVING THE AC MAGNETO AND STARTER CLUTCH

Order

Part name

Q'ty

Remarks

Drain the engine oil.

Refer to "CHANGING THE ENGINE OIL" 
section in the CHAPTER 3.

Seat and fuel tank

Refer to "REMOVING THE 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 TIP.

11

Rotor

1

Refer to removal section.

Summary of Contents for 2010 WR450FZ

Page 1: ...AI IWATA SHIZUOKA JAPAN PRINTED ON RECYCLED PAPER 2010 WR450F Z 2010 q Read this manual carefully before operating this vehicle q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule q Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch bevor Sie das Fahrzeug in Betrieb nehmen q Lea atentamente este manual antes de utilizar el vehículo 5TJ 9 47 cover 09 7 14...

Page 2: ...anuel doit étre remis avec le véhicule en cas de vente de ce dernier Q 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 Q Lea atentamente este manual antes de utilizar el vehículo Este manual debe acompañar al vehículo si este se vende 5TJ 9 47 cover 09 7 14 10...

Page 3: ...WR450F Z 2010 2010 5TJ 28199 47 E0 5TJ 28199 47 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 2009 by Yamaha Motor Co Ltd 1st Edition July 2009 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: ...achine is designed for off road use only It is illegal for this machine to be operated on any public street road or highway Off road use on public lands may be illegal Please check local regulations before riding Except for Canada THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE ONLY ON A CLOSED COURSE It is illegal for this machine to be operated on any public street road or highway Off road...

Page 7: ... 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 fore edge symbol mark and go to a page for required item and de scriptio...

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 TUNING 4 ENGINE 5 CHASSIS 6 ELECTRICAL 7 ...

Page 10: ...RE OPERATION INSPECTION AND MAINTENANCE 3 7 ENGINE 3 8 CHASSIS 3 19 ELECTRICAL 3 29 CHAPTER 4 TUNING ENGINE Except for Canada 4 1 CHASSIS 4 5 CHAPTER 5 ENGINE RADIATOR 5 1 CARBURETOR 5 4 AIR INDICTOIN SYSTEM 5 13 CAMSHAFTS 5 15 CYLINDER HEAD 5 20 VALVES AND VALVE SPRINGS 5 23 CYLINDER AND PISTON 5 27 CLUTCH 5 30 OIL FILTER ELEMENT AND WATER PUMP 5 34 BALANCER 5 38 OIL PUMP 5 40 KICK SHAFT AND SHIF...

Page 11: ...ON OF IMPORTANT LABELS GENERAL INFORMATION LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle CANADA Essence super sans plomb seulement 3FB 2415E 12 1 ...

Page 12: ...1 2 LOCATION OF IMPORTANT LABELS EUROPE ...

Page 13: ...1 3 LOCATION OF IMPORTANT LABELS AUS NZ ZA ...

Page 14: ...ains high pressure nitrogen gas Mishandling can cause explosion Do not incinerate puncture or open Turn off the main switch after riding to avoid draining the battery Use unleaded gasoline only Measure tire pressure when tires are cold Adjust tire pressure Improper tire pressure can cause loss of control Loss of control can result in severe injury or death ...

Page 15: ...ter 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 26 Front ...

Page 16: ... as required by feder al law state law and Environment Canada A Left B Right INCLUDED PARTS VALVE JOINT This valve 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 wrenc...

Page 17: ...ring s 1 and oil seal s 2 with their manufactur er s marks or numbers facing out ward In other words the stamped 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 CI...

Page 18: ...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 19: ...1521 90980 01521 This tool is used to tighten the spoke Sheave holder YS 1880 A 90890 01701 This 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 Tool name Part number Ho...

Page 20: ...ed to remove and install the valve guide Valve guide installer 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 ...

Page 21: ...s 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 Three Bond No 1215 90890 85505 This sealant Bond is used for crankcase mating surface etc Tool name Part number How to use Illustration ...

Page 22: ...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 23: ...time that has been accumulated since the start of timer measurement Tripmeter which shows the 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 Speedome...

Page 24: ...is not in op eration If the timer is in operation stop the timer by pushing the SLCT1 button and SLCT2 but ton at the same time 2 Push the SLCT1 button and SLCT2 button for 2 seconds or more at the same time to change over to BASIC MODE RACE MODE Putting measurement on standby Starting measurement consists of the following two starts either of which can be selected Manual start Starting measuremen...

Page 25: ... Reset tripmeter A and timer Resetting tripmeter A TRIP A 1 Check that the timer is in opera tion If the timer is not in opera tion start the timer by pushing the SLCT1 button and SLCT2 but ton at the same time 2 Reset tripmeter A TRIP 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 ...

Page 26: ... 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 27: ...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 28: ...ut off system The engine can be started under the following conditions When the transmission is in neutral When the clutch is disengaged with the transmission 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 st...

Page 29: ... minutes 5 Check how the engine runs when the machine is ridden with the throttle 1 4 to 1 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 After the break in or before each ride you must check the entire ma chine for loose fittings an...

Page 30: ...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 31: ...ith 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 be stored for 60 days or more some preventive mea sures must be taken to avoid dete...

Page 32: ...8 kg 270 7 lb 122 7 kg 270 5 lb 122 5 kg 270 1 lb 122 6 kg 270 3 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 Recommended brand YAMALUB...

Page 33: ...mission 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 20 1 050 5th 21 25 0 840 Chassis USA CDN ZA EUROPE AUS NZ Frame type Semi double cra dle Caster angle 27 3 26 8 27 0 Trail 117 mm 4 61 in 115 mm 4 53 in 116 mm 4 57 in Tire Type With tube Size front 80 100 21 51M USA CDN ZA 90 90 21 M C 54M M S EUROPE AUS NZ Size rear ...

Page 34: ...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 Standard Limit Cylinder head Warp limit 0 05 mm 0 002 in Cylinder Bore size 95 00 95 01 mm 3 7402 3 7406 in Out of round limit 0 05 mm 0 002 in Camshaft Drive method Chain drive Left Camshaft cap inside diameter 22 000 22 021 mm 0 8661 0 8670 ...

Page 35: ...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 0 20 0 25 mm 0 0079 0 0098 in Valve dimensions A head diameter IN 26 9 27 1 mm 1 0591 1 0669 in A head diameter EX 27 9 28 1 mm 1 0984 1 1063 in B face width IN 2 26 mm 0 089 in B face width EX 2 26 mm 0 089 in C seat ...

Page 36: ... 010 0 037 mm 0 0004 0 0015 in 0 08 mm 0 003 in Stem to guide clearance EX 0 020 0 047 mm 0 0008 0 0019 in 0 10 mm 0 004 in Stem runout limit 0 01 mm 0 0004 in Valve spring Free length IN 39 46 mm 1 55 in 38 46 mm 1 51 in Free length EX 37 61 mm 1 48 in 36 61 mm 1 44 in Set length valve closed IN 27 87 mm 1 10 in Set length valve closed EX 28 38 mm 1 12 in Compressed force installed IN 130 2 149 8...

Page 37: ...4 in Piston pin outside diameter 17 991 18 000 mm 0 7083 0 7087 in 17 971 mm 0 7075 in Piston rings Top ring Type Barrel Dimensions B T 1 2 3 5 mm 0 05 0 14 in End gap installed 0 20 0 30 mm 0 008 0 012 in 0 55 mm 0 022 in Side clearance installed 0 030 0 065 mm 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...

Page 38: ... 3 08 mm 0 115 0 121 in 2 8 mm 0 110 in Quantity 8 Clutch plate 1 thickness 1 9 2 1 mm 0 075 0 083 in Quantity 4 Warp limit 0 1 mm 0 004 in Clutch plate 2 thickness 1 5 1 7 mm 0 059 0 067 in Quantity 3 Warp limit 0 1 mm 0 004 in Clutch spring free length 50 0 mm 1 97 in 49 0 mm 1 93 in Quantity 6 Clutch housing thrust clearance 0 10 0 35 mm 0 0039 0 0138 in Clutch housing radial clearance 0 010 0 ...

Page 39: ...ay 3 6 mm 0 12 0 24 in Lubrication system Oil filter type Paper type Oil pump type Trochoid type Tip clearance 0 12 mm or less 0 0047 in or less 0 20 mm 0 008 in Side clearance 0 09 0 17 mm 0 0035 0 0067 in 0 24 mm 0 009 in Housing and rotor clearance 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 0067 in Bypass valve setting pressure 40 80 kPa 0 4 0 8 kg cm2 5 69 11 38 psi Cooling Radiator core size Wid...

Page 40: ...out spring 95 150 mm 3 74 5 91 in Oil grade Suspension oil S1 Inner tube outer diameter 48 mm 1 89 in Front fork top end Zero mm Zero in Rear suspension USA CDN AUS NZ ZA EUROPE Shock absorber travel 130 mm 5 12 in Spring free length 260 mm 10 24 in Fitting length 252 5 mm 9 94 in 251 5 mm 9 90 in Preload length Min Max 1 5 22 mm 0 06 0 87 in Spring rate STD K 54 0 N mm 5 50 kg mm 308 0 lb in Opti...

Page 41: ...mm 0 25 in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Caliper cylinder inside dia 25 4 mm 1 000 in 1 Brake fluid type DOT 4 Brake lever and brake pedal Brake lever position 95 mm 3 74 in Brake pedal height vertical height above footrest top 10 mm 0 39 in Clutch lever free play lever end 8 13 mm 0 31 0 51 in Throttle grip free play 3 5 mm 0 12 0 20 in Item Standard Limit Item Standa...

Page 42: ... A Electric starting system Type Constant mesh Starter motor Model manufacturer 5UM20 YAMAHA Operation voltage 12 V Output 0 48 kW Armature coil resistance 0 0117 0 0143 Ω at 20 C 68 F Brush overall length 7 mm 0 28 in 3 5 mm 0 14 in Brush quantity 2 pcs Spring force 3 92 5 88 N 400 600 g 14 1 21 2 oz Commutator diameter 17 6 mm 0 69 in 16 6 mm 0 65 in Mica undercut depth 1 5 mm 0 06 in Starter re...

Page 43: ...p 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 Silencer M8 1 25 2 30 3 0 22 Silencer clamp M8 1 25 1 16 1 6 11 Exhaust pipe protector M6 1 0 3 10 1 0 7 2 Spark arrester M5 0 8 4 7 0 7 5 1 Silencer cap M5 0 8 6 5 0 5 3 6 Air induction pipe M6 1 0 2 10 1 0 7 2 Air cut off valve assembly and brack...

Page 44: ...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 1 10 1 0 7 2 Oil strainer M6 1 0 1 10 1 0 7 2 Crankcase bearing stopper M6 1 0 4 14 1 4 10 Crankcase bearing stopper M6 1 0 8 10 1 0 7 2 Drive axle oil seal stopper M6 1 0 2 10 1 0 7 2 Ratchet wheel guide M6 1 0 2 12 1 2 8 7 Kickstarter crank M8 1 25 1 33 3 3 24 S...

Page 45: ... 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 b...

Page 46: ...8 1 25 2 32 3 2 23 Swingarm and brake hose holder M5 0 8 4 2 0 2 1 4 Swingarm and patch M4 0 7 4 2 0 2 1 4 Drive chain tensioner mounting upper M8 1 25 1 16 1 6 11 Drive chain tensioner mounting lower M8 1 25 1 16 1 6 11 Chain support and swingarm M6 1 0 3 7 0 7 5 1 Seal guard and swingarm M5 0 8 4 6 0 6 4 3 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...

Page 47: ...mp 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 4 55 5 5 40 Sidestand mounting M10 1 25 1 25 2 5 18 Front reflector For CDN M6 1 0 2 4 0 4 2 9 Rear reflector For CDN M5 0 8 3 2 0 2 1 4 Part to be tightened Thread size Q ty Tightening torque Nm m kg ft lb Part to be tightened Thread size Q ty Tightening t...

Page 48: ...nts 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 We...

Page 49: ...2 18 TIGHTENING TORQUES ...

Page 50: ...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 51: ...2 20 LUBRICATION DIAGRAMS 1 Intake camshaft 2 Exhaust camshaft A To main axle B From oil pump ...

Page 52: ...Throttle position sensor lead 6 Wire harness 7 Hump frame 8 Negative battery lead 9 Starter motor lead 10 Neutral 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 17 Hot starter cable protector 18 Rubber cap ...

Page 53: ...etween the connecting rod and cross tube frame F Pass the neutral switch lead on the inside of the engine bracket G 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 H Fasten the AC magneto lead and neutral switch lead onto the frame Locate the clamp end facing toward the rea...

Page 54: ...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 55: ... 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 56: ...2 25 CABLE ROUTING DIAGRAM 1 Clamp 2 Positive battery lead 3 Battery 4 Negative battery lead 5 Taillight coupler 6 CDI unit coupler 6 pin 7 CDI unit coupler 3 pin 8 CDI unit coupler 6 pin ...

Page 57: ...p end facing toward the upper side of the frame and cut off the tie end H Connect the negative battery lead to the battery negative ter minal I Connect the negative battery lead to the wire harness J Fasten the wire harness to the rear frame Locate 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 th...

Page 58: ...ain switch coupler 7 Wire harness 8 Headlight coupler 9 Hot starter cable 10 Multi function display bracket 11 Main switch 12 Upper bracket 13 Clutch switch coupler 14 Engine stop switch coupler 15 Multi function display coupler 16 Start switch coupler 17 Speed sensor coupler 18 Speed sensor lead ...

Page 59: ... tween the upper bracket and multi function display bracket F Fasten the multi function display leads to the bracket Cut off the tie end G Secure the 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 func...

Page 60: ... months 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plug Check condition Adjust gap and clean 3 Valve clearance Check and adjust valve clearance when en gine is cold 4 Air filter element Clean with solvent and apply foam air filter oil or equivalent oil Replace if necessary 5 Breather system Check ventilation hose for cracks or damage and drain any deposits Repla...

Page 61: ...r Every 1 year 6 Brake hoses Check for cracks or damage Replace Every 4 years 7 Wheels Check runout spoke tightness and for dam age Tighten spokes if necessary 8 Tires Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary 9 Wheel bearings Check bearings for smooth operation Replace if necessary 10 Swingarm pivot bearings Check bearing assemblies for loosenes...

Page 62: ...t in which the machine runs e g rain dirt etc Therefore earlier inspection is required by reference to the list below 15 Sidestand pivot Check operation Apply lithium soap based grease all purpose grease lightly 16 Front fork Check operation and for oil leakage Replace if necessary 17 Shock absorber assembly Check operation and for oil leakage Replace if necessary 18 Rear suspension link pivots Ap...

Page 63: ...are also replaced at the same time PISTON RING Inspect Check ring end gap Replace PISTON PIN Inspect Replace CYLINDER HEAD Inspect carbon deposits and eliminate them Inspect and clean Change gasket CYLINDER Inspect and clean Inspect score marks Replace Inspect wear CLUTCH Inspect and adjust Inspect housing friction plate clutch plate and spring Replace TRANSMISSION Inspect Replace bearing SHIFT FO...

Page 64: ...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 equivalent oil Replace OIL FILTER Replace ENGINE GUARD Replace Breakage FRAME Clean and inspect FUEL TANK COCK Clean and inspect BRAKES Adjust lever position and pedal height Lubricate pivot point Check brake disc surface Check fluid level and leakage Retighten brak...

Page 65: ...ct lube and retighten Molybdenum disulfide grease SIDESTAND Lubricate Lithium base grease STEERING HEAD Inspect free play and retighten Clean and lube Lithium base grease Replace bearing TIRE WHEELS Inspect air pressure wheel run out tire wear and spoke loose ness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate Lithium base grease THROTTLE CONTROL CABLE Check routing and connec...

Page 66: ...chain slack and alignment Check that the drive chain is lubricated properly P 3 22 23 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 26 Steering Check that the handlebar can be turned smoothly and have no ex cessive play P 3 26 27 Front forks and rear shock absorber Check that they operate smoothly and there is no oil leakage P 3 23 26 Cable...

Page 67: ... 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 68: ...3 9 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 69: ...s Right side cover Refer to REMOVING THE 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 70: ... 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 c...

Page 71: ...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 72: ...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 73: ...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 bolt 1 is removed Below the level mark a Add oil through the filler cap hole until it is above the level mark a Oil comes out at the check bolt Drain the oil until it stops ...

Page 74: ...ne minute turn the engine off so it will not seize c Check oil passages and oil pump for damage or leakage d Start the engine after solving the problem s and recheck the oil pressure e Tighten the oil pressure check bolt ADJUSTING THE PILOT SCREW For EUROPE 1 Adjust Pilot screw 1 Adjustment steps To optimize the fuel flow at a smaller throttle opening each machine s pilot screw has been individual...

Page 75: ...rk accessing screw 1 Crankshaft end accessing screw 2 O ring 4 Check Valve clearance Out of specification 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...

Page 76: ...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 77: ... 240 1 31 1 35 240 0 00 0 04 0 05 0 09 0 10 0 14 0 15 0 19 0 20 0 25 0 26 0 30 0 31 0 35 0 36 0 40 0 41 0 45 0 46 0 50 0 51 0 55 0 56 0 60 0 61 0 65 0 66 0 70 0 71 0 75 0 76 0 80 0 81 0 85 0 86 0 90 0 91 0 95 0 96 1 00 1 01 1 05 1 06 1 10 1 11 1 15 1 16 1 20 1 21 1 25 1 26 1 30 1 31 1 35 1 36 1 40 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 120 125 1...

Page 78: ...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 79: ...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 80: ...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 81: ...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 82: ...ent There are marks a on each side of the drive chain puller alignment NOTICE Im proper drive chain slack will overload the engine as well as other vital parts of the motorcy cle and can lead to chain slip page or breakage To prevent this from occurring keep the drive chain slack within the specified limits Turn the adjuster so that the drive chain is in line with the sprocket as viewed from the r...

Page 83: ...he adjuster may be damaged Always adjust each front fork to the same setting Uneven adjust ment can cause poor handling and loss of stability 3 Install Rubber cap CHECKING THE REAR SHOCK ABSORBER 1 Inspect Swingarm smooth action Abnormal noise unsmooth action Grease the pivoting points or repair the pivoting points Damage oil leakage Replace ADJUSTING THE REAR SHOCK ABSORBER SPRING PRELOAD 1 Eleva...

Page 84: ...s from the fully turned in position Which align the punch mark a on the adjuster with the punch mark b on the high compression damping adjuster Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged Stiffer Increase the spring pre load Turn the adjuster 2 in Softer Decrease the spring pre load Turn the adjuster 2 out Extent of adjustment Maximum Mini...

Page 85: ...with a screw driver A tight spoke will emit a clear ringing tone a loose spoke will sound flat 2 Tighten Spokes with a spoke nipple wrench 1 Be sure to retighten these spokes be fore and after break in CHECKING THE WHEELS 1 Inspect Wheel runout Elevate the wheel and turn it Abnormal runout Replace 2 Inspect Bearing free play Exist play Replace CHECKING AND ADJUSTING THE STEERING HEAD 1 Place a sta...

Page 86: ...sher 7 steering stem nut 8 handlebar 9 han dlebar upper holder 10 and headlight 11 The handlebar upper holder should be installed with the punched mark a forward Install the handlebar so that the marks b are in place on both sides Install the handlebar so that the pro jection c of the handlebar upper holder is positioned at the mark on the handlebar as shown Insert the end of the fuel breather hos...

Page 87: ...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 40 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 88: ...ures 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 89: ...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 90: ...3 31 ELECTRICAL Charging method using a variable voltage charger ...

Page 91: ...3 32 ELECTRICAL Charging method using a constant voltage charger ...

Page 92: ...ing 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 REMOVING THE SEAT FUEL TANK AND SIDE COV ERS section 2 Remove Headlight bulb holder cover 1 3 Remove Headlight bulb holder 1 Remove the headlight bulb holder by pushing it ...

Page 93: ...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 94: ...When the engine 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 oxyge...

Page 95: ...he 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 jet needle with the throttle 1 8 to 1 4 open and relates to the clip ...

Page 96: ...t number 14948 Rich 55 4MX 09 52 4MX 08 50 4MX 07 STD 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 4...

Page 97: ...bered 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 Poor acceleration Raise jet needle clip position 1 groove up Closed to 1 4 throttle Hard breathing Speed down Use j...

Page 98: ... 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 level 2 Setting of spring preload Change the spring Install the adjus...

Page 99: ... 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 slits a is proved on the end of the spring When using a spring with a spring rate of 0 469 kg mm do n...

Page 100: ...less re bound damping to compensate for its less spring 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 preferen...

Page 101: ...n the CHAPTER 3 SPRING PART NUM BER 22212 Maximum Minimum 5UN 00 5UN 10 5UN 20 5UN 30 Position in which the spring is turned in 20 mm 0 79 in from its free length Position in which the spring is turned in 1 5 mm 0 06 in from its free length 5UN 40 5UN 50 5UN 60 5UN 70 Position in which the spring is turned in 22 mm 0 87 in from its free length ...

Page 102: ...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 103: ...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 104: ...only by reference to this manual It may lead to servicing trouble and mechanical damage RADIATOR REMOVING THE RADIATOR Order Part name Q ty Remarks Drain the coolant Refer to CHANGING THE COOLANT sec tion in the CHAPTER 3 Seat fuel tank and left side cover Refer to REMOVING THE SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 3 Exhaust pipe Refer to REMOVING THE EXHAUST PIPE AND SILENCER sect...

Page 105: ...RADIATOR 6 Radiator hose 4 1 7 Pipe 2 O ring 1 1 8 Catch tank hose 1 9 Left radiator 1 10 Radiator hose 1 1 11 Pipe 1 O ring 1 1 12 Catch tank breather hose 1 13 Catch tank 1 Order Part name Q ty Remarks 5 ...

Page 106: ...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 107: ...ER sec tion in the CHAPTER 6 1 Clamp 2 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...

Page 108: ...5 5 CARBURETOR 13 Bracket cylinder head breather pipe 1 14 Carburetor joint 1 Order Part name Q ty Remarks ...

Page 109: ...ottle 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 Pilot screw For EUROPE 1 Refer to removal section 16 Float pin 1 17 Float 1 18 Needle valve 1 ...

Page 110: ... 20 Needle jet 1 21 Spacer 1 22 Pilot jet 1 23 Starter jet 1 24 Push rod 1 Pull the push rod 25 Throttle shaft assembly 1 26 Push rod link lever assembly 1 27 Pilot air jet 1 28 Cold starter plunger 1 Order Part name Q ty Remarks ...

Page 111: ...VALVE 1 Inspect Needle valve 1 Valve seat 2 Grooved wear a Replace Dust 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 MEASURING AND ADJUSTING THE FLOAT ...

Page 112: ... Dirt Clean CHECKING THE AIR CUT VALVE 1 Inspect Diaphragm air cut valve 1 Spring air cut valve 2 Air cut valve cover 3 O ring 4 Tears diaphragm damage Re place ASSEMBLING THE CARBURETOR 1 Install Cold starter plunger 2 Install Pilot air jet 1 3 Install Spring 1 1 Lever 1 2 To lever 2 3 Make sure the spring 1 fits on the stopper a of the lever 2 4 Install Spring 2 1 To lever 2 2 5 Install Push rod...

Page 113: ...ve to the float install them to the carbure tor Check the float for smooth move ment 12 Install For EUROPE Pilot screw 1 Spring 2 Washer 3 O ring 4 Note the following installation points a Turn in the pilot screw until it is lightly seated b Turn out the pilot screw by the number of turns recorded before removing 13 Install O ring Leak jet 1 Float chamber 2 Bolt float chamber 3 Cable holder thrott...

Page 114: ...meter as the specified value a Fully turn in the accelerator pump adjusting screw 3 b Check that the link lever 4 has free play b by pushing lightly on it c Gradually turn out the adjusting screw while moving the link lever until it has no more free play INSTALLING THE CARBURETOR 1 Install Carburetor joint 1 Bracket cylinder head breather pipe 2 Bolt carburetor joint 3 Cylinder head breather pipe ...

Page 115: ...ll 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 9 Install Clamp 1 Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 Throttle cable pull 4 Nm 0 4 m kg 2 9 ft lb Throttle cable return 11 Nm 1 1 m kg 8 0 ft lb Bolt throttle cable cov er 4 Nm 0 4 m kg 2 9 ft lb ...

Page 116: ...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 117: ... 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 118: ...T FUEL 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 119: ...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 120: ... Gasket 4 Remove Bolt camshaft cap 1 Camshaft cap 2 Clip Remove the bolts camshaft cap in a crisscross 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 CAMSH...

Page 121: ...CKING THE CAMSHAFT SPROCKET 1 Inspect Camshaft sprocket 1 Wear damage Replace the camshaft assembly and timing chain as a set CHECKING THE DECOMPRESSION SYSTEM 1 Check Decompression system Checking steps a Check that the decompression mechanism cam 1 moves smoothly b Check that the decompression mechanism cam lever pin 2 proj ects from the camshaft CHECKING THE TIMING CHAIN TENSIONER 1 Check While...

Page 122: ...s from into the cylin der head cavity Apply the molybdenum disulfide oil on the thread of the bolts camshaft cap Tighten the bolts to the specified torque in two or three steps in the proper tightening sequence as shown The bolts camshaft cap must be tightened evenly or damage to the cylinder head camshaft caps and camshaft will result 2 Install Timing chain tensioner Installation steps a While pr...

Page 123: ...le 180 in the proper tightening sequence Order Part name Q ty Remarks Seat and fuel tank Refer to REMOVING THE SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 3 Exhaust pipe and silencer Refer to REMOVING THE 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 sec...

Page 124: ...stallation steps Tighten the cylinder head 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 surfac...

Page 125: ...5 22 CYLINDER HEAD 3 Install Bolt cylinder head 1 Bolt cylinder head 10 Nm 1 0 m kg 7 2 ft lb ...

Page 126: ...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 127: ... 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 128: ... valves with new valves When replacing the cylinder head replace the valves without lapping the valve seats and valve faces When replacing the valves or valve guides use new valves to lap the valve seats and then replace them with new valves 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 molybdenu...

Page 129: ...ke right left b gray Exhaust c brown Install the valve springs with the larger pitch d facing 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...

Page 130: ...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 131: ...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 132: ...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 133: ... 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 134: ...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 135: ...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 136: ...Apply the engine 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 pla...

Page 137: ...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 138: ...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 139: ... 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 140: ...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 141: ...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 142: ...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 143: ...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 144: ...5 41 OIL PUMP 15 Oil pump drive shaft 1 16 Rotor housing 1 Order Part name Q ty Remarks ...

Page 145: ...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 146: ...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 147: ...5 44 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 148: ...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 149: ...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 150: ...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 151: ...E OIL section in the CHAPTER 3 Seat and fuel tank Refer to REMOVING THE 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 TIP 11 Rotor 1 Refer to removal section ...

Page 152: ...loosen and retighten the rotor nut to 65 Nm 6 5 m kg 47 ft lb 12 Woodruff key 1 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 153: ...heck Idle gear Idle gear shaft Starter clutch drive gear Pitting burrs chips roughness wear Replace the defective 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 clutc...

Page 154: ...r 5 Install Woodruff key 1 Rotor 2 Degrease the contact surfaces of the tapered portions 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 6 Install Washer rotor Nut rotor 1 Use the sheave holder 2 Tighten the rotor nut to 65...

Page 155: ...ct AC magneto lead Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 12 Install Shift pedal 1 Bolt shift pedal 2 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 10 Nm 1 0 m kg 7 2 ft lb Bolt shift pedal 12 Nm 1 2 m kg 8 7 ft lb ...

Page 156: ... 3 Radiator Refer to RADIATOR section Exhaust pipe and silencer Refer to REMOVING THE 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 ...

Page 157: ...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 158: ...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 159: ...tab to lock the nut 4 Install Drive chain sprocket guide Drive chain sprocket cover 1 Bolt drive chain sprocket cover 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 Bolt drive chain sprock et cover 7 Nm 0 7 m kg 5 1 ft lb Screw neutral switch 4 Nm 0...

Page 160: ... 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 161: ...58 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 162: ...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 163: ...es do not separate check for a remaining case bolt or fitting 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 c...

Page 164: ...ter with one hand while turning the nut of the installing tool with the other Operate the installing tool un til the crankshaft bottoms against the 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 In...

Page 165: ... dead center 6 Tighten Hose guide 1 Clutch 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...

Page 166: ...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 167: ...HECKING THE SHIFT 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 3...

Page 168: ...al lip 5 Install Shift fork 1 L 1 Shift fork 2 C 2 Shift fork 3 R 3 Shift cam 4 To main axle and drive axle 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...

Page 169: ...ly 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 Front wheel 1 5 Speed sensor 1 6 Collar 1 7 Oil seal 1 8 Beari...

Page 170: ...o 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 ...

Page 171: ...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 172: ... the wheel axle 7 Install 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 ...

Page 173: ...he wheel 2 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 ...

Page 174: ...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 175: ...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 176: ...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 177: ...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 178: ...tion when expelling piston from cylinder Never attempt to pry out piston Caliper piston removal 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 bra...

Page 179: ...nd brake caliper piston dust seals whenever a caliper is disassembled INSTALLING THE BRAKE CALIPER PISTON 1 Clean Brake caliper Brake caliper piston seal Brake caliper piston 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 ...

Page 180: ... cup sec ondary 2 To brake master cylinder piston 3 Apply the brake fluid on the brake master cylinder cup After installing cylinder cup should be installed as shown di rection Wrong installation 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 ...

Page 181: ... touches the projection b on the brake master cylinder 2 Install Brake master cylinder 1 Bolt brake master cylinder 2 3 Install Spring 1 Brake pedal 2 O ring 3 Bolt brake pedal 4 Clip 5 Apply the lithium 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 CHA...

Page 182: ...stalling the brake hose holders make sure the brake hose does not contact the 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 mix...

Page 183: ...t front brake Diaphragm Brake master cylinder cap 1 Screw 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 bo...

Page 184: ...fer to 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 185: ... 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 186: ...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 187: ...lve 3 To inner tube 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...

Page 188: ...e front fork 16 After filling pump the damper rod 1 slowly up and down more than 10 times to distribute the fork oil 17 Fill Front fork oil Until outer 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 mo...

Page 189: ...g with the damper rod 3 pulled up After installing the fork spring hold the damper rod 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 Temp...

Page 190: ...or lead so that its paint a directs as shown and align the bottom 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 Front for...

Page 191: ... 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 192: ...holder Installing 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 side...

Page 193: ...hrottle cable cap 2 10 Install Start switch 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 ti...

Page 194: ...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 195: ...the machine by 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 sec...

Page 196: ...6 28 STEERING 8 Lower bracket 1 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 197: ...ring races 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...

Page 198: ...er bracket 2 Tighten the lower 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 ...

Page 199: ...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 200: ...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 201: ...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 202: ...t relay arm 4 To swingarm Apply the molybdenum 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 rou...

Page 203: ...r 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 connecting rod 80 Nm 8 0 m kg 58 ft lb 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 sup...

Page 204: ...section in the CHAPTER 3 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 CHA...

Page 205: ...ear frame 1 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 206: ...n disposal NOTES ON DISPOSAL YAMAHA DEALERS ONLY Before disposing 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 ...

Page 207: ...eal 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 inward 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 bol...

Page 208: ...6 40 REAR SHOCK ABSORBER 7 Tighten Screw air filter joint 1 8 Install Plastic band Taillight coupler Locking tie Screw air filter joint 3 Nm 0 3 m kg 2 2 ft lb ...

Page 209: ...y or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS 1 Headlight 2 Multi function 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...

Page 210: ...t 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 1 For USA CDN and EUROPE 2 For AUS NZ and ZA 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 Re...

Page 211: ...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 212: ... it is freed Re place Set the tester selection position to Ω 1 2 Inspect Rubber part a Tears damage Replace 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 ...

Page 213: ...sed 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 the starting cir cuit cut off relay is ...

Page 214: ...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 215: ...attery is connected Replace Conductive while the battery is not connected Replace Set the tester selection position to Ω 1 CHECKING THE CLUTCH 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 pocke...

Page 216: ... conduction Not conductive while it is pushed Replace Conductive while it is freed Re place Set the tester selection position to Ω 1 2 Inspect Rubber part a Tears damage Replace Tester lead Black lead 1 Tester lead Black lead 2 Result Conductive while the start switch is pushed ...

Page 217: ...7 9 ELECTRIC STARTING SYSTEM REMOVING THE STARTER MOTOR Order Part name Q ty Remarks Exhaust pipe Refer to REMOVING THE EXHAUST PIPE AND SILENCER section in the CHAPTER 3 1 Starter motor 1 ...

Page 218: ...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 219: ...easure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs 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 ...

Page 220: ...over 3 Starter motor front cover 4 For installation align the projec tions on the washer with the slots in the front cover Align the match mark a on the starter motor yoke with the match mark b on the starter motor front cover 5 Install Bolt 1 O ring 2 Apply the lithium soap base grease on the O ring ...

Page 221: ...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 222: ...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 223: ...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 224: ...tion sensor using the T25 bit 3 Replace Throttle position sensor 4 Install Throttle position sensor 1 Screw throttle position sensor 2 Align the slot 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...

Page 225: ...11 Stop the engine 12 Remove the carburetor 13 Tighten Screw throttle position sensor 1 Tighten the screw throttle position sensor using the T25 bit 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 ...

Page 226: ...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 227: ...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 228: ...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 229: ...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 230: ...PRINTED IN JAPAN E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

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