Yamaha WR450FB 2012 Owner'S Service Manual Download Page 158

Page: 158 / 392

FRONT BRAKE

5-24

• Refill with the same type of brake fluid that

is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.

• When refilling, be careful that water does

not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.

ECA13540

NOTICE

Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.

4. Bleed:

• Brake system

Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-20.

5. Check:

• Brake fluid level

Below the minimum level mark

Add the

recommended brake fluid to the proper lev-
el.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-17.

6. Check:

• Brake lever free play

Refer to “ADJUSTING THE FRONT DISC
BRAKE” on page 3-18.

• Brake lever operation

Soft or spongy feeling

Bleed the brake

system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-20.

EAS22490

REMOVING THE FRONT BRAKE MASTER
CYLINDER

TIP

Before removing the front brake master cylin-
der, drain the brake fluid from the entire brake
system.
1. Remove:

• Union bolt
• Copper washers
• Brake hose

TIP

To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.

EAS22500

CHECKING THE FRONT BRAKE MASTER
CYLINDER

1. Check:

• Brake master cylinder “1”

Damage/scratches/wear

Replace.

• Brake fluid delivery passages “2”

(brake master cylinder body)
Obstruction

Blow out with compressed

air.

2. Check:

• Brake master cylinder kit

Damage/scratches/wear

Replace.

3. Check:

• Brake master cylinder reservoir cap

4. Check:

• Brake master cylinder reservoir diaphragm

holder

• Brake master cylinder reservoir diaphragm

holder
Cracks/damage/wear

Replace.

5. Check:

• Brake hoses

Cracks/damage/wear

Replace.

EAS22520

ASSEMBLING THE FRONT BRAKE MAS-
TER CYLINDER

EWA13520

WARNING

• Before installation, all internal brake com-

ponents should be cleaned and lubricated
with clean or new brake fluid.

• Never use solvents on internal brake com-

ponents.

Recommended fluid

DOT 4

Summary of Contents for WR450FB 2012

Page 1: ...CE MANUAL WR450FB 1DX 28199 10 LIT 11626 25 58 WR450FB 2012 q Read this manual carefully before operating this vehicle PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2012 01 1 4 1 E 1DX 28199 10_Hyoshi indd 1 2012 01 19 16 15 01 ...

Page 2: ...Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha from the inside out Genuine Yamaha Service Manuals Get the same factory manual for your vehicle that the technicians at your authorized Yamaha dealer use Service manuals are available through your Yamaha...

Page 3: ...2012 by Yamaha Motor Corporation U S A 1st Edition January 2012 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 25 58 ...

Page 4: ...ion available at the time of printing there may be minor discrepancies between your machine and this manual If you have any questions concerning this manual please consult your Yamaha dealer EWA1DX0001 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPE...

Page 5: ...LY FLAMMABLE Always turn off the engine while refueling Take care to not spill any gasoline on the engine or ex haust system Never refuel in the vicinity of an open flame or while smoking GASOLINE CAN CAUSE INJURY If you should swallow some gasoline inhale excess gasoline vapors or allow any gasoline to get into your eyes contact a doctor immediately If any gasoline spills onto your skin or clothi...

Page 6: ... SPECIRC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A CUSTOMER SERVICE Post Office Box 6555 Cypress California 90630 0 What costs are my responsibility during the warranty period A The customer s responsibility includes all costs of normal maintenance services non war ranty repairs accident and collision damage and oil oil filters ai...

Page 7: ...Sub section titles 2 appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a dis assembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction c...

Page 8: ...NITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent LOCTITE Engine oil Replace the part with a new one G M BF B T R LS M S LT E New ...

Page 9: ...7 8 9 10 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUST MENTS TUNING CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING toc1 fm 1 ページ２０１２年１月１８日水曜日午前１１時８分 ...

Page 10: ......

Page 11: ...PROTECTOR 1 7 HOOK FUEL TANK 1 7 FUEL HOSE JOINT COVER 1 7 COUPLER FOR CONNECTING OPTIONAL PART 1 8 IMPORTANT INFORMATION 1 8 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 8 REPLACEMENT PARTS 1 8 GASKETS OIL SEALS AND O RINGS 1 9 LOCK WASHERS PLATES AND COTTER PINS 1 9 BEARINGS AND OIL SEALS 1 9 CIRCLIPS 1 9 BASIC SERVICE INFORMATION 1 10 QUICK FASTENERS 1 10 ELECTRICAL SYSTEM 1 11 SPECIAL TOOLS 1 15 ...

Page 12: ...AY 1 22 DESCRIPTION 1 22 BASIC MODE 1 23 CHANGEOVER TO BASIC MODE RACE MODE 1 24 RACE MODE 1 25 FUNCTION DIAFRAM 1 29 STARTING AND BREAK IN 1 30 FUEL 1 30 HANDLING NOTE 1 31 AIR FILTER MAINTENANCE 1 31 STARTING A COLD ENGINE 1 31 STARTING A WARM ENGINE 1 31 BREAK IN PROCEDURES 1 32 TORQUE CHECK POINTS 1 33 MOTORCYCLE CARE AND STORAGE 1 34 CARE 1 34 STORAGE 1 35 ...

Page 13: ...LOCATION OF IMPORTANT LABELS 1 1 EAS1DX3009 LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle USA 7 8 1 2 3 4 5 9 10 6 ...

Page 14: ...LOCATION OF IMPORTANT LABELS 1 2 CANADA Essence super sans plomb seulement 3FB 2415E 12 ...

Page 15: ...p switch 14 Radiator 3 Multi function display 15 Coolant drain bolt 4 Main switch 16 Rear brake pedal 5 Start switch 17 Valve joint 6 Front brake lever 18 Starter knob idle adjusting screw 7 Throttle grip 19 Air cleaner 8 Fuel tank cap 20 Catch tank 9 Taillight 21 Drive chain 10 Kickstarter crank 22 Shift pedal 11 Fuel tank 23 Oil dipstick 12 Radiator cap 24 Front fork 18 20 19 21 22 23 24 9 10 12...

Page 16: ... number 1 is stamped into the right side of the frame EAS1DX3013 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the right side of the engine EAS1DX3014 MODEL LABEL The model label 1 is affixed to the frame un der the seat This information will be needed to order spare parts EAS1DX3015 VEHICLE EMISSION CONTROL INFORMA TION LABEL The Vehicle Emission Control Inf...

Page 17: ...changes in the operating conditions of the engine As the requirements for the engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To ac commodate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This syst...

Page 18: ...supplied The injection duration and the injection timing are controlled by the ECU Signals that are input from the throttle position sensor coolant temperature sensor atmospheric pressure sensor lean angle sensor crankshaft position sensor intake air pressure sensor and intake air temperature sensor en able the ECU to determine the injection duration The injection timing is determined through the ...

Page 19: ...nch 1 is used to remove and install the spark plug EAS1DX3021 NIPPLE WRENCH This nipple wrench 1 is used to tighten the spoke EAS1DX3022 HANDLEBAR PROTECTOR Install the handlebar protector 1 so that the notch a face backward EAS1DX3023 HOOK FUEL TANK The hook tank 1 is used to support the fuel tank during maintenance EAS1DX3024 FUEL HOSE JOINT COVER The fuel hose joint covers 1 are used to pre ven...

Page 20: ...leaning equipment Refer to SPECIAL TOOLS on page 1 15 3 When disassembling always keep mated parts together This includes gears cylin ders pistons and other parts that have been mated through normal wear Mated parts must always be reused or replaced as an as sembly 4 During disassembly clean all of the parts and place them in trays in the order of disas sembly This will speed up assembly and al lo...

Page 21: ...the bolt or nut EAS1DX3030 BEARINGS AND OIL SEALS Install bearings 1 and oil seals 2 so that the manufacturer marks or numbers are visible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appropriate ECA13300 NOTICE Do not spin the bearing with compressed air because this will damage the bearing sur faces...

Page 22: ...fastener push its pin so that it protrudes from the fastener head then insert the fastener into the part to be secured and push the pin in with a screwdriver Make sure that the pin is flush with the fastener s head Screw type 1 Remove Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out 2 Install Quick fastener TIP To install the quick fast...

Page 23: ...be gen erated which is extremely dangerous TIP If a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water ECA16760 NOTICE Be sure to connect the battery leads to the correct battery terminals Reversing the battery lead connections could damage the electrical components ECA16771 NOTICE When connecting the battery leads to the battery be sure to...

Page 24: ... Therefore never touch the terminals and be sure to keep the contacts clean TIP When resetting the ECU by turning the main switch to OFF be sure to wait approximately 5 seconds before turning the main switch back to ON Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V ECA14371 NOTICE Never insert the tester probes into the ...

Page 25: ...tions of the coupler securely and then disconnect the coupler There are many types of coupler locks therefore be sure to check the type of cou pler lock before disconnecting the cou pler ECA16790 NOTICE When disconnecting a connector do not pull the leads Hold both sections of the connector securely and then disconnect the connector 2 Check Lead Coupler Connector Moisture o Dry with an air blower ...

Page 26: ...together until they are connected securely Make sure all connections are tight 5 Check Continuity with the pocket tester TIP If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 4 As a quick remedy use a contact revitalizer available at most part stores 1 Pocket tester 90890 03112 Analog pocket tester YU 03112 C ...

Page 27: ...o the list provided to avoid errors when placing an order TIP For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Part number Illustration Reference pages Crankshaft installer pot 90890 01274 Installing pot YU 90058 6 69 Crankshaft installer bolt 90890 01275 Bolt YU 90060 6 69 Adapter M12 90890 01278 Adapter 3 YU 90063 6 69 Pisto...

Page 28: ...8 5 51 Cap bolt ring wrench 90890 01501 YM 01501 5 47 5 48 5 51 5 54 5 56 Fork seal driver 90890 01502 Fork seal driver 48 YM A0948 5 52 5 53 Spoke nipple wrench 6 7 90890 01521 YM 01521 3 22 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 14 6 33 9 62 9 64 9 65 9 66 9 69 9 70 9 71 9 72 9 73 9 74 9 75 9 76 9 78 Pressure gauge 90890 03153 YU 03153 8 5 Tool name Part number Illustration ...

Page 29: ...90 03186 YM 03186 8 5 Test harness S pressure sensor 3P 90890 03207 YU 03207 9 76 Test harness lean angle sensor 6P 90890 03209 YU 03209 9 73 FI diagnostic tool sub lead 90890 03212 9 26 Yamaha diagnostic tool 90890 03215 9 26 Test harness speed sensor 5TJ 3P 90890 03228 YU 03228 9 74 Valve spring compressor 90890 04019 YM 04019 6 19 6 24 Tool name Part number Illustration Reference pages ...

Page 30: ...42 6 39 6 41 Valve guide remover Ø5 90890 04097 YM 04097 6 21 Valve guide installer Ø5 90890 04098 YM 04098 6 21 Valve guide reamer Ø5 90890 04099 YM 04099 6 21 Valve lapper 90890 04101 Valve lapping tool YM A8998 3 8 Valve guide remover Ø4 5 90890 04116 YM 04116 6 21 Tool name Part number Illustration Reference pages YM 91044 ...

Page 31: ...ler 90890 04142 YM 04142 6 59 Crankcase separating tool 90890 04152 Crankcase separator YU A9642 6 68 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 9 71 Digital tachometer 90890 06760 YU 39951 B 3 11 Yamaha bond No 1215 Three bond No 1215 90890 85505 6 60 6 66 Tool name Part number Illustration Reference pages ...

Page 32: ... level warning light This warning light comes on when the fuel level drops below approximately 3 0 L 0 79 US gal 0 66 Imp gal When this occurs refuel as soon as possible The electrical circuit of the warning light can be checked by pushing the main switch to ON The warning light should come on for a few sec onds and then go off If the warning light does not come on initially when the main switch i...

Page 33: ...sing the shift pedal 1 on the left side of the engine EAS1DX3043 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 disen gaged I normal practices however shi...

Page 34: ...ollowing BASIC MODE Speedometer which shows current speed Clock Two tripmeters which shows the distance that has been traveled since it was last set to zero Tire diameter which shows the difference from initial setting in percentage RACE MODE Timer which shows the time that has been accumulated since the start of timer measure ment Tripmeter which shows the accumulated travel distance in timer mea...

Page 35: ... RST button to change the display for time indication The display will change in the following order HouroMinuteoSecondoHour TIP The digits capable of setting go on flashing 3 Push the SLCT1 button plus or SLCT2 button minus and change the time A long push on the button will fast forward the time 4 To end the setting push the RST button for 2 seconds or more TIP In a 30 second absence of button op...

Page 36: ...0 101 3 Range capable of setting 65 0 115 0 2 Push the SLCT1 button and RST button for 2 seconds or more at the same time to enter tire diameter setting mode 3 Push the SLCT1 button plus or SLCT2 button minus and change the setting A long push on the button will fast forward the digits TIP Colon for the displayed tire diameter repre sents the decimal marker 4 Push the SLCT1 button and RST button f...

Page 37: ... ton for 2 seconds or more at the same time to change over to BASIC MODE EAS1DX3053 RACE MODE Putting measurement on standby TIP Starting measurement consists of the following two starts either of which can be selected Manual start Starting measurement by the rider himself op erating the button A long push on the SLCT2 button will put measurement on standby Auto start Starting timer measurement au...

Page 38: ...er measure ment 4 To stop timer measurement pushing the SLCT1 button and SLCT2 button at the same time TIP If the machine is run while timer measurement is not made no change will occur to the digit in tripmeter A TRIP A 5 To resume the measurement again pushing the SLCT1 button and SLCT2 button at the same time Resetting measurement data TIP Resetting can be made in the following three manners Re...

Page 39: ... the travel distance display by push ing the SLCT1 button plus or SLCT2 button minus A long push on the button will fast forward the change TIP Change can be made any time while timer measurement is or is not being made Change in the travel distance display will be accompanied by the change in the average speed display Correcting tire diameter TIP Correction can be made any time while timer measur...

Page 40: ...lon in the tire diameter display repre sents the decimal marker If the tire diameter extends beyond the set range 65 0 to 115 0 the error indicator E lights up for two seconds After E goes off the minimum 65 or maximum 115 will be automatically set 3 Push the SLCT1 button and RST button for 2 seconds or more at the same time will finish the setting ...

Page 41: ...oth arrowed directions A long push on the button changes the operation in the arrowed direction A long push on the button changes the operation in both arrowed directions BASIC MODE Tripmeter TRIP A TRIP B TRIP A Putting measurement on standby SLCT1 SLCT2 Meter function C C Function that can be performed whether the time is or is not in operation Extent to which the meter can operate current speed...

Page 42: ...y mouth If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor immediately If gasoline spills on your skin wash with soap and water If gasoline spills on your cloth ing change your clothes ECA1DX1004 NOTICE Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and p...

Page 43: ...ectrical circuit 2 Shift the transmission into the neutral posi tion The neutral indicator light should come on If not ask a Yamaha dealer to check the electrical circuit 3 Turn the starter on and completely close the throttle 4 Start the engine by pushing the start switch or by pushing the kickstarter lever down ECA1DX1007 NOTICE If the starter motor will not turn when push ing the start switch s...

Page 44: ... how the engine runs when the ma chine is ridden with the throttle 1 4 to 1 2 open low to medium speed for about one hour 6 Restart the engine and check the operation of the machine throughout its entire operat ing range Restart the machine and operate it for about 10 to 15 more minutes The ma chine will now be ready to race ECA1DX1009 NOTICE After the break in or before each race you must check t...

Page 45: ...link 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 46: ...ater may be used Be sure to rinse off any detergent residue using plenty of water as it is harmful to plastic parts Do not use any harsh chemical products on plastic parts Be sure to avoid using cloths or sponges which have been in con tact with strong or abrasive cleaning prod ucts solvent or thinner fuel gasoline rust removers or inhibitors brake fluid antifreeze or electrolyte Do not use high p...

Page 47: ...t treat them with a suitable care product Avoid using abrasive polishing com pounds as they will wear away the paint TIP Consult a Yamaha dealer for advice on what products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of time will help remove the moisture from the lens EAS1DX3065 STORAGE Short term Always store your ...

Page 48: ...the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alter natively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 6 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 7 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not...

Page 49: ...ECIFICATIONS 2 11 TIGHTENING TORQUES 2 13 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 13 ENGINE TIGHTENING TORQUES 2 14 CHASSIS TIGHTENING TORQUES 2 17 LUBRICATION POINTS AND LUBRICANT TYPES 2 21 ENGINE 2 21 CHASSIS 2 23 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 LUBRICATION DIAGRAMS 2 25 CABLE ROUTING 2 29 2 ...

Page 50: ...IONS Model Model 1DX3 USA 1DX4 CANADA Dimensions Overall length 2160 mm 85 0 in Overall width 825 mm 32 5 in Overall height 1275 mm 50 2 in Seat height 960 mm 37 8 in Wheelbase 1465 mm 57 7 in Ground clearance 335 mm 13 19 in Weight Curb weight 124 kg 273 lb ...

Page 51: ...1 27 US qt 1 06 Imp qt Without oil filter element replacement 0 95 L 1 00 US qt 0 84 Imp qt With oil filter element replacement 1 00 L 1 06 US qt 0 88 Imp qt Oil filter Oil filter type Paper Bypass valve opening pressure 40 0 80 0 kPa 0 40 0 80 kgf cm 5 8 11 6 psi Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance Less than 0 120 mm 0 0047 in Limit 0 20 mm 0 0079 in Outer rot...

Page 52: ... dimensions Intake A 30 100 30 200 mm 1 1850 1 1890 in Limit 30 000 mm 1 1811 in Intake B 22 450 22 550 mm 0 8839 0 8878 in Limit 22 350 mm 0 8799 in Exhaust A 30 200 30 300 mm 1 1890 1 1929 in Limit 30 100 mm 1 1850 in Exhaust B 22 450 22 550 mm 0 8839 0 8878 in Limit 22 350 mm 0 8799 in Camshaft runout limit 0 015 mm 0 0006 in Timing chain Tensioning system Automatic Valve valve seat valve guide...

Page 53: ... 1988 in Valve stem to valve guide clearance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clearance exhaust 0 020 0 047 mm 0 0008 0 0019 in Limit 0 100 mm 0 0039 in Valve stem runout 0 010 mm 0 0004 in Valve spring Free length intake 39 46 mm 1 55 in Limit 38 46 mm 1 51 in Free length exhaust 37 61 mm 1 48 in Limit 36 61mm 1 44 in Installed length intak...

Page 54: ... H 8 0 mm 0 31 in Offset 1 00 mm 0 0394 in Offset direction Intake side Piston pin bore inside diameter 18 004 18 015 mm 0 7088 0 7093 in Limit 18 045 mm 0 7104 in Piston pin outside diameter 17 991 18 000 mm 0 7083 0 7087 in Limit 17 971 mm 0 7075 in Piston pin to piston pin bore clearance 0 004 0 024 mm 0 00016 0 00094 in Piston ring Top ring Ring type Barrel Dimensions B u T 1 20 u 3 50 mm 0 05...

Page 55: ... push Clutch lever free play 8 0 13 0 mm 0 31 0 51 in Friction plate thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 82 mm 0 1110 in Plate quantity 8 pcs Clutch plate 1 thickness 1 90 2 10 mm 0 075 0 083 in Plate quantity 4 pcs Warpage limit 0 10 mm 0 0039 in Clutch plate 2 thickness 1 50 1 17 mm 0 059 0 067 in Plate quantity 3 pcs Warpage limit 0 10 mm 0 0039 in Clutch spring free length 50 00...

Page 56: ...DX3 10 Fuel line pressure at idle 300 0 390 0 kPa 3 00 3 90 kgf cm 43 5 56 6 psi Throttle position sensor Throttle position sensor resistance 5 0 k Throttle position sensor output voltage 0 48 0 52 V Fuel injection sensor Crankshaft position sensor resistance 248 372 Intake air pressure sensor output voltage 3 75 4 25 V Intake air temperature sensor resistance 5 40 6 60 k at 0 C 32 F 290 390 at 80...

Page 57: ...le bending limit 0 50 mm 0 02 in Front tire Type With tube Size 80 100 21 51M Manufacturer model DUNLOP GEOMAX MX51FG Rear tire Type With tube Size 120 90 18 65M Manufacturer model DUNLOP GEOMAX MX51 Standard tire air pressure Front and Rear 100 kPa 1 00 kgf cm 15 psi Front brake Type Single disc brake Operation Right hand operation Front disc brake Disc outside diameter u thickness 250 0 u 3 0 mm...

Page 58: ...9 0 mm 17 68 in Installed length 454 0 mm 17 87 in Spring rate K1 4 50 N mm 0 46 kgf mm 25 70 lb in Spring stroke K1 0 0 300 0 mm 0 00 11 81 in Inner tube outer diameter 48 0 mm 1 89 in Inner tube bending limit 0 2 mm 0 01 in Optional spring available Yes Recommended oil Suspension oil S1 Standard oil amount 528 cm 17 85 Imp oz 18 62 US oz Rebound damping With the adjusting screw fully turned in M...

Page 59: ...djusting screw fully turned in Minimum 2 turn s out Standard 7 8 turn s out Maximum Fully turned in Compression damping adjusting positions for slow compression damping With the adjusting screw fully turned in Minimum 20 click s out Standard 10 click s out Maximum Fully turned in Swingarm Swingarm end free play limit radial 1 0 mm 0 04 in Swingarm end free play limit axial 0 2 0 9 mm 0 01 0 04 in ...

Page 60: ...V Rectifier capacity DC 35 0 A Battery Model YTZ7S F Voltage capacity 12 V 6 0 Ah Specific gravity 1 310 Manufacturer GS YUASA Ten hour rate amperage 0 60 A Headlight Bulb type Halogen bulb Bulb voltage wattage u quantity Headlight 12 V 35 W 35 W u 1 Auxiliary light 12 V 3 0 W u 1 Tail brake light LED Meter lighting EL Electroluminescent Indicator light Fuel level warning light LED Engine trouble ...

Page 61: ...CIFICATIONS 2 12 Starter relay Amperage 180 0 A Coil resistance 4 18 4 62 Starting circuit cut off relay Coil resistance 86 4 105 6 Headlight relay Coil resistance 86 4 105 6 Fuses Main fuse 15 0 A Spare fuse 15 0 A ...

Page 62: ... To avoid warpage tighten multi fastener assemblies in a criss cross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifi cations require clean dry threads Compo nents should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kgf ft lbf 10 mm 6 mm 6 0 ...

Page 63: ... m kgf 7 2 ft lbf Timing chain tensioner cap bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Timing chain guide bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Oil filter cover bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Oil pump bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Oil pump cover bolt M4 1 2 0 Nm 0 20 m kgf 1 4 ft lbf Oil pump drive gear shaft screw M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Engine oil drain bolt oil filter M6 1 10 Nm ...

Page 64: ...lbf Oil drain bolt crankcase M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Crankcase bearing stopper screw M6 4 14 Nm 1 4 m kgf 10 ft lbf Crankcase bearing stopper screw M6 8 10 Nm 1 0 m kgf 7 2 ft lbf Drive axle oil seal stopper bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Ratchet wheel guide bolt M6 2 12 Nm 1 2 m kgf 8 7 ft lbf Kick starter crank bolt M8 1 33 Nm 3 3 m kgf 24 ft lbf Kick starter crank boss screw M6 1 ...

Page 65: ...fied angle of 180 Segment M8 1 30 Nm 3 0 m kgf 22 ft lbf Impeller M8 1 14 Nm 1 4 m kgf 10 ft lbf Water pump housing cover bolt M6 3 10 Nm 1 0 m kgf 7 2 ft lbf Coolant drain bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Clutch cable holder bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Radiator hose clamp screw M6 8 2 0 Nm 0 20 m kgf 1 4 ft lbf Radiator bolt M6 6 10 Nm 1 0 m kgf 7 2 ft lbf Radiator pipe 1 2 M6 2 10 N...

Page 66: ... 7 2 ft lbf Throttle cable housing screw M5 2 3 8 Nm 0 38 m kgf 2 8 ft lbf Throttle cable and throttle body nut M6 2 4 3 Nm 0 43 m kgf 3 1 ft lbf Air temperature sensor screw M5 1 3 8 Nm 0 38 m kgf 2 8 ft lbf Starter relay and positive battery lead bolt M6 1 3 5 Nm 0 35 m kgf 2 5 ft lbf Starter relay and starter motor lead bolt M6 1 3 5 Nm 0 35 m kgf 2 5 ft lbf Footrest bolt M10 4 55 Nm 5 5 m kgf ...

Page 67: ...lbf Lower bracket pinch bolt M8 4 21 Nm 2 1 m kgf 15 ft lbf Fuel tank bracket and fuel tank bolt front side M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank bracket and fuel tank bolt rear side M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank bolt M6 1 9 Nm 0 9 m kgf 6 5 ft lbf Seat set bracket and fuel tank screw M6 3 7 Nm 0 7 m kgf 5 1 ft lbf Fuel pump bolt M5 6 4 0 Nm 0 40 m kgf 2 9 ft lbf Fuel tank bracket an...

Page 68: ...m kgf 21 ft lbf Air bleed screw and base valve M5 2 1 3 Nm 0 13 m kgf 0 94 ft lbf Front fork and reflector bracket bolt For Canada M8 4 21 Nm 2 1 m kgf 15 ft lbf Front fork cap bolt M51 2 30 Nm 3 0 m kgf 22 ft lbf Front fork base valve M22 2 55 Nm 5 5 m kgf 40 ft lbf Front fork axle nut M16 1 90 Nm 9 0 m kgf 65 ft lbf Front wheel axle pinch bolt M8 4 21 Nm 2 1 m kgf 15 ft lbf Front brake disc bolt...

Page 69: ...nder cap screw M4 2 1 5 Nm 0 15 m kgf 1 1 ft lbf Rear brake caliper pin plug M10 1 2 5 Nm 0 25 m kgf 1 8 ft lbf Rear brake master cylinder bolt M6 10 10 Nm 1 0 m kgf 7 2 ft lbf Brake pedal bolt M8 1 26 Nm 2 6 m kgf 19 ft lbf Rear brake master cylinder cap bolt M4 2 1 5 Nm 0 15 m kgf 1 1 ft lbf Rear brake hose union bolt M10 2 30 Nm 3 0 m kgf 22 ft lbf Rear brake caliper bleed screw M8 1 6 Nm 0 6 m...

Page 70: ...n surface Nozzle 3 Cylinder body inner surface Water pump impeller shaft Oil pump rotors inner and outer Oil pump assembly shaft Idle gear inner surface idle gear shaft Kick gear and ratchet wheel Kick shaft Sprocket idle gear Idle gear 2 inner surface thrust surfaces Damper assembly shaft thrust surfaces Gear 3 thrust surfaces Long clutch push rod Short clutch push rod Primary drive gear nut thre...

Page 71: ...er head cover gasket Three Bond No TB1541C Cylinder head semicircular surface Yamaha bond No 1215 Three Bond No 1215 Crankcase mating surface Yamaha bond No 1215 Three Bond No 1215 Stator assembly lead grommet Yamaha bond No 1215 Three Bond No 1215 Lubrication point Lubricant types E E ...

Page 72: ...unt groove Brake caliper piston seal Brake caliper dust seal Brake caliper support bolt Brake pad support bolt Clutch cable end Clutch lever bolt Clutch lever Pivot shaft Swing arm bearing collar spacer and oil seal Relay arm bearing collar washer and oil seal Relay arm bolt thread swing arm side Rear shock absorber assembly bearing collar and oil seal Connecting rod bearing collar and oil seal Co...

Page 73: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ...

Page 74: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 1 2 3 4 5 6 1 ...

Page 75: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 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 76: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 1 2 ...

Page 77: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Intake camshaft 2 Exhaust camshaft A To main axle B From oil pump ...

Page 78: ...CABLE ROUTING 2 29 EAS1DX3073 CABLE ROUTING c m 0 67 0 12 in ...

Page 79: ...tween the cross tube on the frame and the connecting arm I Insert the condenser in the bracket before fixing it J Degrease the condenser on its surface having no lead coming out before affixing the insulation to it When affixing the insulation align its notch with the projection on the condenser When the insu lation materials overlap affix them so that the lon ger one is directed toward the rear o...

Page 80: ...CABLE ROUTING 2 31 ...

Page 81: ... the ECU band Locate the clamp pawl in any di rection F Pass the ECU lead and taillight lead through the rubber band hook while laying out the ECU lead outside of the vehicle beyond the taillight lead G Pass the catch tank breather hose behind the throttle body H After connecting the coolant temperature sensor coupler 2P put a cover over it I After connecting the condenser coupler 2P in sert and f...

Page 82: ...CABLE ROUTING 2 33 ...

Page 83: ... F Lay the radiator breather hose so it is located to the right of the vehicle G Pass the condenser lead between the condenser and the catch tank breather hose and connect it to the main harness at the back of the condenser H Pass the clutch cable grommet through the cable guide I Align the painted positions on the two breather hoses with the hole in the rear frame J Pass the two breather hoses be...

Page 84: ...CABLE ROUTING 2 35 ...

Page 85: ... chassis and direct the remainder downward J Clamp the catch tank breather hose and taillight lead to the rear frame Tighten them to the extent that the breather hose is not crushed Direct the allowed portion from the locking downward K Fasten to the rear frame the radiator breather hose catch tank breather hose and main har ness Clamp the main harness with its branch brought up to the portion whe...

Page 86: ...CABLE ROUTING 2 37 LJ ...

Page 87: ... lead 22 Meter assembly 23 Main switch A Pass the brake hose through the guide B After putting the resistor rubber band projection in the meter bracket firmly secure the resistor by sliding it downward C Make sure to securely fix the main harness clip while pushing it in the round hole in the meter bracket on the inside of the vehicle D Fix the auxiliary light coupler while inserting it in the hol...

Page 88: ...CABLE ROUTING 2 39 A I 0 ...

Page 89: ...rects as shown and lightly touches the projection on the brake caliper B Pass the brake hose into the brake hose holders C If the brake hose contacts the spring rear shock absorber correct its twist D Install the brake hose so that its pipe portion di rects as shown and lightly touches the projection on the brake master cylinder ...

Page 90: ...CABLE ROUTING 2 41 ...

Page 91: ...BRAKE PADS 3 18 ADJUSTING THE REAR DISC BRAKE 3 19 CHECKING THE REAR BRAKE PADS 3 19 CHECKING THE REAR BRAKE PAD INSULATOR 3 19 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 20 CHECKING THE FRONT BRAKE HOSE 3 21 CHECKING THE REAR BRAKE HOSE 3 21 CHECKING THE WHEELS 3 21 CHECKING AND TIGHTENING THE SPOKES 3 21 CHECKING THE TIRES 3 22 CHECKING THE WHEEL BEARINGS 3 23 CHECKING THE SWINGARM OPERATION 3 23 ADJ...

Page 92: ...mi 3000 km or 3 months 3000 mi 5000 km or 6 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 engine 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 cra...

Page 93: ...nment and condition Adjust and lubricate chain with a special O ring chain lubricant thoroughly Every ride 12 Steering bearings Check bearing assemblies for looseness Moderately repack with lithium soap based grease every 1200 mi 2000 km or 12 months whichever comes first 13 Brake and clutch lever pivot shafts Apply lithium soap based grease all purpose grease lightly 14 Brake pedal pivot shafts A...

Page 94: ...he valve clearanc es Check the valve seats and valve stems for wear Inspect Replace VALVE SPRINGS Check the free length and the tilt Inspect Replace VALVE LIFTERS Check for scratches and wear Inspect Replace CAMSHAFTS Inspect the camshaft surface Inspect Inspect the decompression system Replace CAMSHAFT SPROCKETS Check for wear on the teeth and for dam age Inspect Replace PISTON Inspect crack Insp...

Page 95: ...level and leakage Check radiator cap opera tion Replace coolant Every two years Inspect hoses OUTSIDE NUTS AND BOLTS Refer to STARTING AND BREAK IN on page 1 30 Retighten AIR FILTER Use foam air filter oil or equivalent oil Clean and lubricate Replace OIL FILTER Replace FRAME Clean and inspect FUEL TANK FUEL PUMP Clean and inspect FUEL HOSE Inspect Replace Every four years BRAKES Adjust lever posi...

Page 96: ...HAIN STOPPER Inspect SWINGARM Inspect lube and retight en Molybdenum disulfide grease RELAY ARM CONNECTING ROD Inspect lube and retight en Molybdenum disulfide grease SIDESTAND Lubricate Lithium base grease STEERING HEAD Inspect free play and re tighten Clean and lube Lithium base grease Replace bearing TIRE WHEELS Inspect air pressure wheel run out tire wear and spoke looseness Retighten sprocket...

Page 97: ...haft installing the fuel tank in its rear Then support the fuel tank using the sup plied hook 1 as illustrated After that reinstall the removed shaft ECA1DX1001 NOTICE Do not use too much force to pull the hose when holding up the fuel tank 2 Remove Spark plug cap Spark plug Refer to CAMSHAFT on page 6 7 ECA13330 NOTICE Before removing the spark plug blow away any dirt accumulated in the spark plu...

Page 98: ...L TANK on page 8 1 2 Remove Spark plug Cylinder head cover Refer to CAMSHAFT on page 6 7 3 Remove Timing mark accessing screw 1 Crankshaft end cover 2 O ring 4 Measure Valve clearance Out of specification o Adjust a Turn the crankshaft counterclockwise b Align TDC mark a of the generator rotor with mark b of the generator rotor cover TIP In order to be sure that the piston is at Top Dead Center th...

Page 99: ...marked in hundredths of millimeters on the side that touches the valve lifter Since valve pads of various sizes are original ly installed the valve pad number must be rounded in order to reach the closest equiva lent to the original Remember that the replacement valve pad number is a rough value Repeat the above procedure until you have the standard valve clearance d Install the new valve pad 1 an...

Page 100: ...te the following points EAS1DX3082 CLEANING THE AIR FILTER ELEMENT 1 Remove Air filter check hose TIP On the bottom of the air filter case is a check hose If dust or water or both collects in this hose replace the air filter element clean the air filter case and air filter check hose 2 Open the air filter case cover 1 TIP Loosen the quick fastener screw 2 and pull on it to open the air filter case...

Page 101: ...ay damage the engine Operating the engine without the air filter element will also lead ing to poor engine performance and possi ble overheating 9 Install Air filter element 1 TIP Align the projection a on filter guide with the hole b in air filter case 10 Hook Binder 1 TIP Hook the binder 1 so that it contacts the filter guide projections a 11 Install Air filter case cover Air filter check hose E...

Page 102: ...peed make sure that the compression pressure is within specification and that the air filter ele ment is not clogged Adjust the engine idling speed with the starter knob idling adjusting screw pushed in com pletely 1 Start the engine and let it warm up until it reaches the specified temperature 2 Use a temperature probe tester 1 and con tact it to the drain bolt thread 3 Install Digital tachometer...

Page 103: ...urt out causing danger Wait until the oil cools down to approximately 70 C 158 F 2 Idle the engine more than 3 minutes 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 o Add oil thr...

Page 104: ...A1DX1003 NOTICE When the oil tank is empty never start the engine 6 Idle the engine more than 10 seconds while keeping the machine upright Then stop the engine and add the oil to the maximum level 7 Install Oil tank cap EAS1DX3087 CHANGING THE ENGINE OIL 1 Start the engine and let it warm up for sever al minutes 2 Stop the engine and place an oil pan under the drain bolt 3 Remove Engine guard 1 Oi...

Page 105: ...til oil starts to seep from the oil pressure check bolt If no oil comes out after one minute turn the engine off so it will not seize c Check oil passages and oil pump for dam age or leakage d Start the engine after solving the problem s and recheck the oil pressure e Tighten the oil pressure check bolt 10 Install Engine guard Oil filter element cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf Oil filter dra...

Page 106: ... LEVEL EWA1DX1003 WARNING A hot radiator is under pressure Therefore do not remove the radiator cap when the en gine is hot Scalding hot fluid and steam may be blown out which could cause seri ous injury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap coun terclockwise toward the detent to allow any res...

Page 107: ...se Cracks damage o Replace Refer to RADIATOR on page 7 1 3 Install Fuel tank Refer to FUEL TANK on page 8 1 Air scoop left right Seat Refer to GENERAL CHASSIS on page 5 1 EAS1DX3091 CHANGING THE COOLANT EWA1DX1004 WARNING A hot radiator is under pressure Therefore do not remove the radiator cap when the en gine is hot Scalding hot fluid and steam may be blown out which could cause seri ous injury ...

Page 108: ... wash them with wa ter Do not mix different types of antifreeze 9 Install Radiator cap 10 Start the engine warm it up for several min utes and then stop it 11 Check Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 15 TIP Before checking the coolant level wait a few minutes until the coolant has settled 12 Install Left side cover Seat Refer to GENERAL CHASSIS on page 5 1 EAS1DX3092 CLEA...

Page 109: ... a Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified brake lever position is obtained c Tighten the locknut 1 EWA13050 WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce bra...

Page 110: ...r must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance ECA13510 NOTICE After adjusting the brake pedal position make sure there is no brake drag EAS1DX3097 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Rear brake pad Wear indicators 1 almost touch the brake disc o Repla...

Page 111: ...he proper lev el with the recommended brake fluid b Install the diaphragm brake master cylinder reservoir or brake fluid reservoir c Connect a clear plastic hose 1 tightly to the bleed screw 2 and place an oil pan under the vinyl hose end on one side d Place the other end of the hose into a con tainer e Slowly apply the brake several times f Fully pull the brake lever or fully press down the brake...

Page 112: ...and apply the rear brake several times 4 Check Brake hose Brake fluid leakage o Replace the dam aged hose Refer to REAR BRAKE on page 5 27 EAS1DX3102 CHECKING THE WHEELS The following procedure applies to both of the wheels 1 Check Wheel Damage out of round o Replace EWA13260 WARNING Never attempt to make any repairs to the wheel TIP After a tire or wheel has been changed or re placed always balan...

Page 113: ...tioned straight A tilted valve stem indicates that the tire has slipped from its original posi tion on the rim Rotate the tire so that the valve stem is positioned straight Tire information This motorcycle is equipped with spoke wheels and tube tires After extensive tests only the tires listed below have been approved for this model by Yamaha Motor Co Ltd EWA1DX3002 WARNING Have a Yamaha dealer re...

Page 114: ...no danger of it falling over TIP When checking and adjusting the drive chain slack there should be no weight on the motor cycle 2 Shift the transmission into the neutral posi tion 3 Pull the drive chain up above the drive chain guard installation bolt with a force of 50N 5 0 kgf 36 lbf 4 Check Drive chain slack a Out of specification o Adjust TIP Measure drive chain slack between the drive chain g...

Page 115: ...so that the front wheel is elevated 2 Check Steering head Grasp the bottom of the front fork legs and gently rock the front fork Blinding looseness o Adjust the steering head 3 Remove Handlebar Refer to HANDLEBAR on page 5 38 Upper bracket Refer to STEERING HEAD on page 5 58 4 Adjust Steering head a Remove the collar 1 and the washer 2 b Tighten the ring nut 3 with a steering nut wrench 4 TIP Set ...

Page 116: ...e on a level surface EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over 2 Check Inner tube Damage scratches o Replace Front fork leg Oil leaks between inner tube and outer tube o Replace the oil seal 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork reb...

Page 117: ... using an appropri ate stand and bleed the air from the front fork 2 Bleed the air from the front fork Bleed the air from the front fork by removing bleed screw 1 ECA32D1001 NOTICE Always bleed the left and right front fork evenly If this is not done the vehicle will have poor stability Direction a Rebound damping is increased sus pension is harder Direction b Rebound damping is decreased sus pens...

Page 118: ...90 NOTICE Never go beyond the maximum or minimum adjustment positions 1 Remove Rear frame Refer to REAR SHOCK ABSORBER AS SEMBLY on page 5 61 2 Adjust Spring preload a Loosen the locknut 1 b Loosen the adjusting ring 2 until there is some clearance between the spring and ad justing ring c Measure the spring free length a d Turn the adjusting ring in direction b or c TIP Be sure to remove all dirt ...

Page 119: ...ction a or b Locknut 30 Nm 3 0 m kgf 22 ft lbf Direction a Rebound damping is increased sus pension is harder Direction b Rebound damping is decreased sus pension is softer c b d T R Rebound damping adjusting posi tions Maximum Fully turned in Standard 18 click s out Minimum 30 click s out With the adjusting screw fully turned in Direction a Compression damping for fast com pression damping is inc...

Page 120: ...les as soon as possible 1 Check Outer cable Damage o Replace 2 Check Cable operation Rough movement o Lubricate TIP Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device EAS1DX3120 ADJUSTING THE THROTTLE GRIP FREE PLAY TIP Prior to adjusting the throttle grip free play the engine idling speed should be adjusted proper ly Direction a...

Page 121: ...djusting the throttle grip free play start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change EAS1DX3121 CHECKING THE CHASSIS FASTENERS Make sure that all nuts bolts and screws are properly tightened Refer to CHASSIS TIGHTENING TORQUES on page 2 17 EAS1DX3122 CHECKING AND CHARGING THE BATTERY Refer to CHECKING AND CH...

Page 122: ...PERIODIC MAINTENANCE 3 31 ...

Page 123: ...NT FORK SETTING 4 2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL 4 2 SETTING OF SPRING AFTER REPLACEMENT 4 2 FRONT FORK SETTING PARTS 4 3 REAR SUSPENSION SETTING 4 3 CHOOSING SET LENGTH 4 3 SETTING OF SPRING AFTER REPLACEMENT 4 4 REAR SHOCK ABSORBER SETTING PARTS 4 5 SUSPENSION SETTING FRONT FORK 4 6 SUSPENSION SETTING REAR SHOCK ABSORBER 4 8 ...

Page 124: ...ine can run at maximum speed the ma chine is generally set such that it can develop its maximum revolutions toward the end of the straight line with care taken to avoid the en gine over revving TIP Riding technique varies from rider to rider and the performance of a machine also vary from machine to machine Therefore do not imitate other rider s settings from the beginning but choose your own sett...

Page 125: ...natively too large oil amount will cause the air spring characteristics to have a tendency to be stiffer with the consequent deteriorated performance and characteris tics Therefore adjust the front fork within the specified range EAS1DX3130 SETTING OF SPRING AFTER REPLACE MENT As the front fork setting can be easily affected by rear suspension take care so that the ma chine front and rear are bala...

Page 126: ...ludes the fol lowing two factors 1 Setting of spring preload Change the set length of the spring Change the spring 2 Setting of damping force Change the rebound damping Change the compression damping EAS1DX3133 CHOOSING SET LENGTH 1 Place a stand or block under the engine to put the rear wheel above the floor and mea sure the length a between the rear wheel axle center and the rear fender holding ...

Page 127: ... set length sunken length 90 100 mm 3 5 3 9 in and set it 1 Use of soft spring Set the soft spring for less rebound 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 rebound damp ing to compensate for its greater spring load Run with the...

Page 128: ... spring preload TIP For the spring preload adjustment refer to AD JUSTING THE REAR SHOCK ABSORBER ASSEMBLY on page 3 27 TYPE SPRING RATE N mm SPRING PART NUMBER 22212 I D MARK Q TY SOFT 52 1DX 10 Blue Yellow STD 54 1DX 20 Blue Pink STIFF 56 1DX 30 Blue White Maximum Minimum Position in which the spring is turned in 18 mm 0 71 in from its free length Position in which the spring is turned in 1 5 mm...

Page 129: ... other noticeable scars etc If any replace affected parts Slide metal Replace with a new one for ex tended use Piston metal Replace with a new one for ex tended use Under bracket tightening torque Retighten to specified torque Poor initial movement Rebound damping Turn adjuster counterclock wise about 2 clicks to de crease damping Oil seal Apply grease in oil seal wall Soft over entire range botto...

Page 130: ... low er rear posture Oil amount Increase oil amount by about 5 cm3 0 2 Imp oz 0 2 US oz Obtrusive front tending to upper front pos ture Compression damping Turn adjuster counterclock wise about 2 clicks to de crease damping Balance with rear end Set sunken length for 90 95 mm 3 5 3 7 in when one passenger is astride seat up per rear posture Spring Replace with soft spring Oil amount Decrease oil a...

Page 131: ...e damping Low compres sion damping Turn adjuster clockwise about 1 click to increase damping Spring Replace with stiff spring Heavy and dragging Rebound damping Turn adjuster counterclock wise about 2 clicks to de crease damping Spring Replace with soft spring Poor road grip ping Rebound damping Turn adjuster clockwise about 2 clicks to increase damping Low compres sion damping Turn adjuster clock...

Page 132: ... adjuster counterclock wise about 1 6 turn to de crease damping Spring set length Set sunken length for 90 100 mm 3 5 3 9 in when one passenger is astride seat Spring Replace with soft spring Symptom Section Check Adjust Jump Large gap Medi um gap Small gap ...

Page 133: ...G THE FRONT BRAKE CALIPER 5 22 CHECKING THE FRONT BRAKE CALIPER 5 22 ASSEMBLING THE FRONT BRAKE CALIPER 5 23 INSTALLING THE FRONT BRAKE CALIPER 5 23 REMOVING THE FRONT BRAKE MASTER CYLINDER 5 24 CHECKING THE FRONT BRAKE MASTER CYLINDER 5 24 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 5 24 INSTALLING THE FRONT BRAKE MASTER CYLINDER 5 25 REAR BRAKE 5 27 INTRODUCTION 5 32 CHECKING THE REAR BRAKE DISC ...

Page 134: ...59 REAR SHOCK ABSORBER ASSEMBLY 5 61 HANDLING THE REAR SHOCK ABSORBER 5 64 DISPOSING OF A REAR SHOCK ABSORBER 5 64 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 5 64 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 5 64 CHECKING THE CONNECTING ARM AND RELAY ARM 5 65 INSTALLING THE RELAY ARM 5 65 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 5 65 SWINGARM 5 67 REMOVING THE SWINGARM 5 69 CHECKING THE SWINGARM 5 ...

Page 135: ...e requested not to undertake inspection adjustment disas sembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage EAS1DX3138 GENERAL CHASSIS Removing the cowling Order Job Parts to remove Q ty Remarks 1 Seat 1 2 Left side cover 1 3 Right side cover 1 4 Left air panel 1 5 Left air scoop 1 6 Right air panel 1 7 Right air scoop 1 For installation re...

Page 136: ...o FRONT FORK on page 5 44 1 Headlight body 1 2 Headlight unit 1 3 Headlight coupler 1 Disconnect 4 Auxiliary light coupler 1 Disconnect 5 Multi function meter coupler 2 Disconnect 6 Multi function meter 1 7 Main switch coupler 1 Disconnect 8 Main switch 1 9 Engine trouble warning light coupler 1 Disconnect 10 Speed sensor coupler 1 Disconnect T R 9 8 10 1 2 3 4 5 5 6 T R T R T R T R T R T R 7 ...

Page 137: ...rts to remove Q ty Remarks 11 Clutch switch coupler 1 Disconnect 12 Engine stop switch coupler 1 Disconnect 13 Resistor coupler 1 Disconnect 14 Main harness 1 15 Multi function meter bracket 1 16 Front fender 1 For installation reverse the removal proce dure T R T R T R T R T R T R T R 15 13 11 12 14 16 ...

Page 138: ...RAL CHASSIS 5 4 EAS1DX3139 REMOVING THE SIDE COVER 1 Remove Bolt side cover Right side cover 1 TIP Draw the side cover backward to remove it be cause its projection a is inserted in the air filter case 1 a ...

Page 139: ...und 1 Front wheel axle pinch bolt 4 Loosen 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Front wheel 1 5 Speed sensor 1 6 Collar 1 7 Oil seal 1 8 Bearing 2 9 Brake disc 1 For installation reverse the removal proce dure 21 Nm 2 1 m kgf 15 ft lbf 21 Nm 2 1 m kgf 15 ft lbf 12 Nm 1 2 m kgf 8 7 ft lbf 90 Nm 9 0 m kgf 65 ft lbf LS LS LS LT 1 1 2 3 4 5 6 7 8 9 6 8 ...

Page 140: ...e Refer to CHECKING THE TIRES on page 3 22 and CHECKING THE WHEELS on page 3 21 3 Check Spokes Bends damage o Replace Loose o Tighten Tap the spokes with a screwdriver TIP A tight spoke will emit a clear ringing tone a loose spoke will sound flat 4 Tighten Spokes Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 21 TIP After tightening the spokes measure the front wheel runout 5 Measure Front ...

Page 141: ... WHEEL 1 Install Bearing left side 1 Spacer 2 Bearing right side 3 Oil seal 4 TIP Apply the lithium soap base grease on the bearing and oil seal lip when installing Use a socket that matches the outside diam eter of the race of the bearing Left side of bearing shall be installed first Install the oil seal with its manufacture s marks or numbers facing outward ECA1DX1005 NOTICE Do not strike the in...

Page 142: ...p base grease on the oil seal lip of speed sensor Make sure the two projections a in the wheel hub are meshed with the two slots b in the speed sensor EAS1DX3142 INSTALLING THE FRONT WHEEL DISC 1 Install Wheel TIP Install the brake disc 1 between the brake pads 2 correctly Make sure that the projections a in the speed sensor fits over the stopper b on the front fork inner tube Brake disc bolt 12 N...

Page 143: ... axle nut 1 ECA14140 NOTICE Before tightening the wheel axle nut push down hard on the handlebar s several times and check if the front fork rebounds smoothly 4 Tighten Front wheel axle pinch bolt 1 Front wheel axle nut 90 Nm 9 0 m kgf 65 ft lbf Front wheel axle pinch bolt 21 Nm 2 1 m kgf 15 ft lbf T R 1 T R 1 1 ...

Page 144: ...nut 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 10 Brake disc 1 For installation reverse the removal proce dure 125 Nm 12 5 m kgf 90 ft lbf 14 Nm 1 4 m kgf 10 ft lbf 19 Nm 1 9 m kgf 13 ft lbf 19 Nm 1 9 m kgf 13 ft lbf 50 Nm 5 0 m kgf 36 ft lbf LT LS LS LS 6 1 2 3 4 5 6 7 8 9 10 6 7 5 9 6 3 ...

Page 145: ...ngs Oil seals Refer to CHECKING THE FRONT WHEEL on page 5 6 2 Check Tire Rear wheel Damage wear o Replace Refer to CHECKING THE TIRES on page 3 22 and CHECKING THE WHEELS on page 3 21 3 Check Spokes Refer to CHECKING THE FRONT WHEEL on page 5 6 4 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 5 6 EAS22080 DISASSEMBLING THE REAR WHEEL 1 Remove Oil seals W...

Page 146: ...ling Install the bearing with seal facing outward Use a socket that matches the outside diam eter of the race of the bearing Right side of bearing shall be installed first Install the oil seal with its manufacture s marks or numbers facing outward ECA1DX1006 NOTICE Do not strike the inner race of the bearing Contact should be made only with the outer race 2 Install Brake disc 1 Brake disc bolt 2 T...

Page 147: ... correctly 2 Install Drive chain 1 TIP Push the wheel 2 forward and install the drive chain 3 Install Left drive chain puller 1 Wheel axle 2 TIP Install the left drive chain puller and insert the wheel axle from left side Apply the lithium soap base grease on the wheel axle 4 Install Right drive chain puller 1 Washer 2 Wheel axle nut 3 TIP Temporarily tighten the nut wheel axle at this point 1 LS ...

Page 148: ...ain slack a Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 23 6 Tighten Wheel axle nut 1 Locknut 2 Drive chain slack 48 0 58 0 mm 1 89 2 28 in Wheel axle nut 125 Nm 12 5 m kgf 90 ft lbf Locknut 19 Nm 1 9 m kgf 14 ft lbf T R T R 1 2 ...

Page 149: ...ving the front brake pads Order Job Parts to remove Q ty Remarks 1 Brake pad pin plug 1 2 Brake pad pin 1 3 Front brake caliper assembly 1 4 Brake pad 2 5 Brake pad spring 2 For installation reverse the removal proce dure 1 2 3 4 5 T R T R T R S ...

Page 150: ...ake hose 1 5 Brake master cylinder reservoir cap 1 6 Brake master cylinder reservoir diaphragm hold er 1 7 Brake master cylinder reservoir diaphragm 1 8 Front brake master cylinder float 1 9 Front brake master cylinder holder 1 10 Front brake master cylinder 1 For installation reverse the removal proce dure S 1 2 3 4 5 6 7 9 10 S 8 T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R...

Page 151: ...FRONT BRAKE 5 17 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Master cylinder kit 1 For assembly reverse the disassembly pro cedure 1 ...

Page 152: ...G THE HYDRAULIC BRAKE SYSTEM on page 3 20 1 Union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Brake pad pin plug 1 5 Brake pad pin 1 6 Brake pad 2 7 Brake pad spring 2 8 Front brake caliper assembly 1 9 Front brake caliper bracket 1 For installation reverse the removal proce dure S 4 5 8 6 7 9 3 1 2 T R T R T R T R T R ...

Page 153: ...ake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 2 2 Brake caliper dust seal 2 3 Brake caliper piston seal 2 4 Bleed screw 1 For assembly reverse the disassembly pro cedure 1 2 3 4 S S BF BF T R 6 Nm 0 6 m kgf 4 3 ft Ibf ...

Page 154: ...NT BRAKE DISC 1 Remove Front wheel Refer to FRONT WHEEL on page 5 5 2 Check Front brake disc Damage galling o Replace 3 Measure Brake disc deflection Out of specification o Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc de flection turn the handlebar to the left or right...

Page 155: ... set 2 Install Brake pads Pad support TIP Always install new brake pads and a pad sup port as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install new brake pads and a new brake pad spring 3 Insta...

Page 156: ...e brake fluid carefully EAS22320 DISASSEMBLING THE FRONT BRAKE CAL IPER 1 Remove Brake caliper pistons 1 Brake caliper dust seals 2 Brake caliper piston seals 3 a Blow compressed air into the brake hose joint opening to force out the pistons from the brake caliper EWA13550 WARNING Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake ca...

Page 157: ...RAKE CALIPER 1 Install Front brake caliper bracket Front brake caliper temporarily Copper washers Brake hose Union bolt EWA13530 WARNING Proper brake hose routing is essential to in sure safe vehicle operation Refer to CA BLE ROUTING on page 2 29 ECA14170 NOTICE When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection b on the brake caliper 2 Instal...

Page 158: ...ULIC BRAKE SYSTEM on page 3 20 EAS22490 REMOVING THE FRONT BRAKE MASTER CYLINDER TIP Before removing the front brake master cylin der drain the brake fluid from the entire brake system 1 Remove Union bolt Copper washers Brake hose TIP To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS22500 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Ch...

Page 159: ...ake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake flu ids may result in a harmful chemical reac tion leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing po...

Page 160: ...FRONT BRAKE 5 26 Brake lever operation Soft or spongy feeling o Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 20 ...

Page 161: ...EL on page 5 10 1 Protector 1 2 Brake pad pin plug 1 3 Brake pad pin 1 4 Rear brake pad 2 5 Pad shim 2 6 Insulator 2 7 Rear brake pad spring 1 8 Rear brake caliper assembly 1 For installation reverse the removal proce dure 1 2 3 4 5 5 6 6 7 8 T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 ft Ibf ...

Page 162: ...STEM on page 3 20 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Split pin 1 5 Plain washer 1 6 Pin 1 7 Brake master cylinder reservoir cap 1 8 Brake master cylinder reservoir diaphragm plate 1 9 Brake master cylinder reservoir diaphragm 1 10 Rear brake master cylinder 1 For installation reverse the removal proce dure 1 2 3 4 7 5 8 6 9 T R T R 10 T R ...

Page 163: ...REAR BRAKE 5 29 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Master cylinder kit 1 For assembly reverse the disassembly pro cedure S 1 T R ...

Page 164: ...ke hose 1 4 Brake pad pin plug 1 5 Brake pad pin 1 6 Rear brake pad assembly 2 7 Rear brake caliper bracket 1 8 Brake pad spring 2 9 Rear brake disc cover 1 10 Rear brake caliper assembly 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 8 10 9 S T R 30 Nm 3 0 m kgf 22 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 5 Nm 0 25...

Page 165: ...rake calipers Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 For assembly reverse the disassembly pro cedure 1 2 3 4 S BF T R 6 Nm 0 6 m kgf 4 3 ft Ibf ...

Page 166: ...ake disc Damage galling o Replace 3 Measure Brake disc deflection Out of specification o Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISC on page 5 20 4 Measure Brake disc thickness Measure the brake disc thickness at a few different locations Out of specification o Replace Refer to CHECKING THE FRONT BRAKE DISC on page 5 20 5 Adjust Brake disc def...

Page 167: ...o the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 17 5 Check Brake pedal operation Soft or spongy feeling o Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 20 EAS22590 REMOVING THE REAR BRAKE CALIPER TIP Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Union bolt Copper washers Brake hose TIP Put the...

Page 168: ...he brake caliper piston seals 2 Check Brake caliper bracket Cracks damage o Replace EAS22650 ASSEMBLING THE REAR BRAKE CALIPER EWA13620 WARNING Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort Whenever a brake caliper is disassem...

Page 169: ... significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 NOTICE Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 20 6 Check Brake fluid level Below the minimum level mark a o Add the recommended brake fluid to the prop...

Page 170: ... WARNING Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents 1 Install Cylinder cup Master cylinder piston 2 Install Spring 1 Master cylinder piston 2 Adjusting rod 3 Circlip 4 Dust boot 5 EAS1DX3153 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install Copper washers Brake hose Union bolt ...

Page 171: ...eservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 NOTICE Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 20 4 Check Brake fluid level Below the minimum level mark a o Add the recommended brak...

Page 172: ...using 1 4 Throttle cable 1 Disconnect 5 Throttle grip 1 6 Start switch 1 7 Clutch cable 1 Disconnect 8 Clutch switch 1 Disconnect 9 Clutch lever holder 1 10 Clutch lever 1 11 Engine stop switch 1 12 Handlebar grip 1 13 Upper handlebar holder 2 14 Handlebar 1 15 Lower handlebar holder 2 For installation reverse the removal proce dure T R T R T R 4 14 11 6 1 9 8 7 2 10 12 3 5 13 T R T R 15 T R T R ...

Page 173: ...156 INSTALLING THE HANDLEBAR 1 Stand the vehicle on a level surface EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over 2 Install Lower handlebar holders 1 temporarily Handlebar 2 Upper handlebar holders 3 TIP Install the lower handlebar holders with them side having the greater distance a from the mounting bolt center facing forward Apply lithium soap based...

Page 174: ...stall Handlebar grip 1 a Slightly coat the handlebar left end with a rubber adhesive b Install the handlebar grip on the handlebar by pressing the grip from the left side c Wipe off any excess rubber adhesive with a clean rag EWA13120 WARNING Do not touch and move the handlebar grip until its adhesive dries completely TIP Install the handlebar grip to the handlebar so that the line a between the t...

Page 175: ...grease or oil on the tube guide surface a with a lac quer thinner Install the grip to the tube guide so that the grip match mark b and tube guide slot c form the angle as shown 7 Install Rubber cover 1 Throttle grip 2 TIP Apply the lithium soap base grease on the throttle grip sliding surface 8 Install Throttle cables 1 TIP Slightly coat the end of throttle cable and in side of throttle grip with ...

Page 176: ...er cylinder assembly 2 Front brake master cylinder holder 3 Bolt brake master cylinder holder 4 Clamp 5 TIP Install the brake master cylinder holder with the UP mark facing up Install in order for the top of the front brake master cylinder assembly to be level First tighten the upper bolt then the lower bolt The start switch and front brake master cylin der assembly should be installed according t...

Page 177: ...Refer to ADJUSTING THE CLUTCH LE VER FREE PLAY on page 3 15 13 Adjust Throttle grip free play Refer to ADJUSTING THE THROTTLE GRIP FREE PLAY on page 3 29 Clutch lever free play 8 0 13 0 mm 0 31 0 51 in Throttle grip free play 3 0 5 0 mm 0 12 0 20 in ...

Page 178: ...nt fork legs Front wheel Refer to FRONT WHEEL on page 5 5 Front brake caliper Refer to FRONT BRAKE on page 5 15 1 Brake hose holder 2 2 Front fork protector 1 3 Upper bracket pinch bolt 2 Loosen 4 Damper assembly 1 Loosen 5 Lower bracket pinch bolt 2 Loosen 6 Front fork leg 1 7 Reflector Stay Nut 1 For Canada For installation reverse the removal proce dure ...

Page 179: ...h of the front fork legs 1 Adjuster 1 2 Copper washer 1 3 O ring 1 4 Damper adjusting rod 1 5 Fork spring 1 6 Collar 1 7 Dust seal 1 8 Oil seal clip 1 9 Inner tube 1 10 Outer tube 1 11 Inner tube bushing 1 12 Front fork protector guide 1 13 Outer tube bushing 1 14 Washer 1 15 Oil seal 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 LS LT ...

Page 180: ...fork legs Order Job Parts to remove Q ty Remarks 16 Base valve 1 17 Base valve bushing 2 18 O ring 5 19 Air bleed screw 1 20 O ring 1 21 Damper assembly 1 22 O ring 1 For assembly reverse the disassembly pro cedure 16 17 18 19 20 21 22 LS LT ...

Page 181: ...acket pinch bolts EWA13120 WARNING Before loosening the upper and lower bracket pinch bolts support the front fork leg TIP Before removing the front fork leg from the ve hicle loosen the damper assembly 1 with the cap bolt ring wrench 2 3 Remove Front fork leg EAS22980 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Drain Fork oil 2 Remove Adjuste...

Page 182: ...NG THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check Inner tube surface a Scratches o Repair or replace Use 1 000 grit wet sandpaper Damaged oil lock piece o Replace Inner tube bends Out of specification o Replace Use the dial gauge 1 TIP The bending value is shown by one half of the dial gauge reading EWA13650 WARNING Do not attempt to straighten a bent in...

Page 183: ...ase valve 1 Wear damage o Replace Contamination o Clean O ring 2 Wear damage o Replace Base valve bushing 3 Wear damage o Replace Spring 4 Damage fatigue o Replace base valve Air bleed screw 5 Wear damage o Replace 6 Check Contacting surface a Wear damage o Replace 7 Check Adjuster 1 O ring 2 Wear damage o Replace EAS23020 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of t...

Page 184: ... fork 3 After filling pump the damper assembly 1 slowly up and down about 200 mm 7 9 in stroke several times to bleed the damper assembly of air TIP Be careful not to excessive full stroke A stroke of 200 mm 7 9 in or more will cause air to en ter In this case repeat the steps 1 to 3 4 Measure Oil level left and right a Out of specification o Adjust 5 Tighten Locknut 1 TIP Fully finger tighten the...

Page 185: ...While protecting the damper assembly 1 with a rag and compressing fully allow ex cessive oil to overflow on the base valve side ECA32D1010 NOTICE Take care not to damage the damper assem bly 11 Allow the overflowing oil to escape at the hole a in the damper assembly TIP The overflow measures about 8 cm3 0 28 lmp oz 0 27 US oz 12 Check Damper assembly smooth movement Tightness binding rough spots o...

Page 186: ...n installing the oil seal use vinyl seat a with fork oil applied to protect the oil seal lip 14 Install Inner tube bushing 1 TIP Install the inner tube bushing onto the slot on inner tube 15 Install Outer tube 1 to the inner tube 2 16 Install Inner tube bushing 1 Washer 2 to the outer tube TIP Press the inner tube bushing into the outer tube with fork seal driver 3 New New New New Fork seal driver...

Page 187: ...the inner tube 20 Check Inner tube smooth movement Tightness binding rough spots o Repeat the steps 13 to 19 21 Measure Distance a Out of specification o Turn into the locknut 22 Install Collar 1 Fork spring 2 to the damper assembly 3 TIP Install the collar with its larger dia end a fac ing the fork spring Fork seal driver 90890 01502 Fork seal driver 48 YM A0948 Distance a 16 mm 0 63 in or more B...

Page 188: ...ench 7 between the inner tube and locknut 6 Fully finger tighten the adjuster onto the damper assembly 25 Inspect Gap a between the adjuster 1 and lock nut 2 Out of specification o Retighten and read just the locknut TIP If the adjuster is installed out of specification proper damping force cannot be obtained 26 Tighten Adjuster locknut 1 TIP Hold the locknut 2 and tighten the adjuster with specif...

Page 189: ...rily tighten the damper assembly 30 Install Fork protector guide 1 EAS1DX3158 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts TIP Install the front fork leg so that difference a between the outer tube top face and upper bracket top face becomes 5 mm 0 2 in and tighten ...

Page 190: ...sensor lead 1 Plate 1 2 to the right front fork protector TIP Install the speed sensor 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 to the right front fork protector TIP Install the plate 2 in the direction as shown Lower bracket pinch bolt 21 Nm 2 1 m kgf 15 ft lbf Damper assembly 30 Nm 3 0 m kgf 22 ft ...

Page 191: ...FRONT FORK 5 57 7 Adjust Rebound damping Compression damping Refer to ADJUSTING THE FRONT FORK LEGS on page 3 25 ...

Page 192: ...ht assembly multi function meter front fender Refer to GENERAL CHASSIS on page 5 1 Reflector 2 For Canada 1 Steering stem nut 1 2 Upper bracket 1 3 Collar 1 4 Washer 1 5 Ring nut 1 6 Lower bracket 1 7 Bearing cover 1 8 Upper bearing 1 9 Lower bearing 1 10 Bearing races 2 For installation reverse the removal proce dure ...

Page 193: ...d hammer b Remove the bearing race from the lower bracket with a floor chisel 2 and hammer c Install a new bearing races ECA14270 NOTICE Take care not to damage the steering shaft thread If the bearing race is not installed properly the steering head pipe could be damaged TIP Always replace the bearings and bearing races as a set 4 Check Upper bracket Lower bracket along with the steering stem Ben...

Page 194: ...h bolts 5 Tighten Steering stem nut 1 TIP Apply lithium soap based grease on the con tact surface of the steering stem nut when in stalling 6 Install Speed sensor lead holder 1 Speed sensor lead clamp 2 TIP Insert the end of the speed sensor lead holder in the hole in the lower bracket b Install so that the marking a on the speed sensor lead aligns with the speed sensor lead holder edge Install th...

Page 195: ...ket pin Refer to FUEL TANK on page 8 1 Battery Refer to CHECKING AND CHARGING THE BATTERY on page 3 30 Throttle body joint Refer to THROTTLE BODY on page 8 6 1 Plastic band 2 2 Rear frame upper bolt 2 3 Rear frame lower bolt 2 Loosen 4 Rear shock absorber assembly lower bolt 1 5 Rear shock absorber assembly upper bolt 1 6 Rear shock absorber assembly 1 7 Locknut 1 8 Adjusting nut 1 9 Lower spring ...

Page 196: ...embly Order Job Parts to remove Q ty Remarks 11 Spring 1 12 Dust seal 2 13 Collar 2 14 Bushing 1 15 Collar 2 16 O ring 2 17 Dust seal 2 18 Stopper ring 1 19 Bearing 2 For installation reverse the removal proce dure 19 11 12 12 13 13 14 15 16 16 17 17 18 19 T R T R T R T R ...

Page 197: ...relay arm Order Job Parts to remove Q ty Remarks 1 Relay arm 1 2 Connecting arm 1 3 Collar 3 4 Oil seal 6 5 Washer 8 6 Bearing 6 For assembly reverse the disassembly pro cedure 1 2 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 3 3 5 T R 80 Nm 8 0 m kgf 58 ft Ibf ...

Page 198: ...rear shock absorber To release the gas pressure drill a 2 3 mm 0 08 0 12 in hole through the rear shock absorber at a point 30 35 mm from its end as shown EWA13760 WARNING Wear eye protection to prevent eye damage from released gas or metal chips EAS23230 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface EWA13120 WARNING Securely support the vehicle so that there is ...

Page 199: ...atches o Replace the bearings and spacers as a set 3 Check Oil seals Damage pitting o Replace EAS23270 INSTALLING THE RELAY ARM 1 Lubricate Oil seals Bearings Spacers Washers Collars 2 Install Bearings 1 Washers 2 Oil seals 3 to relay arm 4 3 Install Bearings 1 Oil seals 2 to connecting arm 3 EAS23310 INSTALLING THE REAR SHOCK ABSORB ER ASSEMBLY 1 Lubricate Bearing lower side Dust seal Collars Bus...

Page 200: ...shock absorber assembly lower bolt 6 Install Rear shock absorber assembly TIP When installing the rear shock absorber as sembly lift up the swingarm Install the rear shock absorber assembly up per bolt and connecting arm and frame bolt from the right Install the rear shock absorber assembly low er bolts relay arm and connecting arm bolt and relay arm and swingarm bolt from the left 7 Tighten Rear ...

Page 201: ...HEEL on page 5 10 1 Brake hose holder 2 2 Brake pedal bolt 1 3 Brake pedal 1 4 Drive chain support cover 1 5 Drive chain support 1 6 Pivot shaft nut 1 7 Pivot shaft 1 8 Swingarm 1 9 Drive chain guide 1 10 Collar 2 11 Oil seal 2 12 Thrust bearing 2 13 Spacer 2 8 2 3 1 1 6 5 10 7 13 12 T R T R T R T R T R T R T R 11 9 4 13 ...

Page 202: ...SWINGARM 5 68 Removing the swingarm Order Job Parts to remove Q ty Remarks 14 Oil seal 2 15 Bearing 4 For installation reverse the removal proce dure 14 15 15 15 15 T R T R T R T R T R T R T R ...

Page 203: ...ut of specifica tion check the spacers bearings and col lars d Check the swingarm vertical movement b by moving the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacers bearings and collars EAS23360 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage o Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends o Replace EWA1...

Page 204: ...ngarm TIP Install the pivot shaft from the right 4 Install Cap 1 TIP Install the right cap with its mark a facing for ward 5 Install Rear wheel Refer to REAR WHEEL on page 5 10 6 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 23 Recommended lubricant Lithium soap based grease Installed depth a 0 mm 0 in Installed depth b 6 5 mm 0 26 in Pivot shaft nut 85 Nm 8 5 m kgf 6...

Page 205: ... 71 EAS1DX3164 CHAIN DRIVE Removing the drive chain Order Job Parts to remove Q ty Remarks Drive sprocket Refer to ENGINE REMOVAL on page 6 1 1 Drive chain 1 For installation reverse the removal proce dure 1 T R T R ...

Page 206: ...section length c length a between pin inner sides length b between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a differ ent location each time 2 Check Drive chain Stiffness o Clean lubricate or replace 3 Clean Drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerose...

Page 207: ... teeth o Replace the drive chain sprockets as a set EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 5 11 EAS1DX3165 INSTALLING THE DRIVE CHAIN 1 Install Drive chain ECA1DX1013 NOTICE Be sure to put on safety goggles when working TIP Install the drive chain joint with the drive chain cut rivet tool Use goods on the market a When press fittin...

Page 208: ...TICE Never install a new drive chain onto worn drive chain sprockets this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 23 ECA13550 NOTICE A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swingarm or cause an accident Therefore keep the dr...

Page 209: ... SIDE 6 15 CHECKING THE CYLINDER HEAD 6 15 INSTALLING THE CYLINDER HEAD 6 16 VALVES AND VALVE SPRINGS 6 18 REMOVING THE VALVES 6 19 CHECKING THE VALVES AND VALVE GUIDES 6 20 CHECKING THE VALVE SEATS 6 21 CHECKING THE VALVE SPRINGS 6 23 CHECKING THE VALVE LIFTERS 6 24 INSTALLING THE VALVES 6 24 CYLINDER AND PISTON 6 26 REMOVING THE PISTON 6 27 CHECKING THE CYLINDER AND PISTON 6 27 CHECKING THE PIST...

Page 210: ...NSTALLING THE STOPPER LEVER 6 49 INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 6 50 INSTALLING THE SHIFT SHAFT 6 50 OIL PUMP AND BALANCER GEAR 6 51 REMOVING THE BALANCER 6 54 CHECKING THE OIL PUMP 6 54 ASSEMBLING THE OIL PUMP 6 55 INSTALLING THE OIL PUMP AND BALANCER GEAR 6 55 GENERATOR AND STARTER CLUTCH 6 57 REMOVING THE GENERATOR 6 59 CHECKING THE STARTER CLUTCH 6 59 INSTALLING THE STARTE...

Page 211: ...TRANSMISSION 6 70 CHECKING THE SHIFT FORKS 6 71 CHECKING THE SHIFT DRUM ASSEMBLY 6 71 CHECKING THE TRANSMISSION 6 71 INSTALLING THE TRANSMISSION 6 72 ...

Page 212: ...tion adjustment disas sembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage EAS1DX3166 ENGINE REMOVAL Removing the exhaust pipe Order Job Parts to remove Q ty Remarks Side cover right Refer to GENERAL CHASSIS on page 5 1 1 Muffler 1 2 Muffler gasket 1 3 Collar 1 4 Damper 1 5 Muffler clamp 1 6 Exhaust pipe 1 7 Exhaust pipe gasket 1 For installa...

Page 213: ...o RADIATOR on page 7 1 Clutch cable and guide Disconnect at the engine side Condenser Shift pedal Refer to SHIFT SHAFT on page 6 47 Throttle body Refer to THROTTLE BODY on page 8 6 Cylinder head breather hose Refer to CAMSHAFT on page 6 7 Ignition coil Disconnect the AC magneto lead Coolant temperature sensor Disconnect the starter motor lead Refer to ELECTRIC STARTER on page 6 31 Negative battery...

Page 214: ... drive sprocket 1 5 Lock washer 1 6 Drive sprocket 1 7 Clip 1 8 Bolt brake pedal 1 9 Brake pedal 1 10 Upper engine bracket 2 11 Lower engine bracket 1 12 Front engine bracket 2 13 Engine mounting bolt 4 14 Pivot shaft 1 15 Engine 1 For installation reverse the removal proce dure New New LT T R T R New T R T R T R T R T R LS T R T R T R T R T R T R LS ...

Page 215: ...st pipe and muffler are cool before cleaning the spark arrester Do not start the engine when cleaning the exhaust system 1 Remove Muffler cap screws 1 2 Remove Spark arrester bolts 1 3 Remove Tail pipe 1 Tail pipe gasket 2 Spark arrester 3 Pull the spark arrester out of the muffler Spark arrester gasket 4 4 Clean Spark arrester Tap the spark arrester lightly then use a wire brush to remove any car...

Page 216: ...sket Exhaust pipe 1 Exhaust pipe nut 2 Exhaust pipe bolt 3 TIP First temporarily tighten the exhaust pipe nut then tighten the exhaust pipe bolt 13 Nm 1 3 m kgf 9 4 ft lbf After that retighten the ex haust pipe nut 20 Nm 2 0 m kgf 14 ft lbf and then the exhaust pipe bolt 20 Nm 2 0 m kgf 14 ft lbf Muffler cap screw 5 Nm 0 5 m kgf 3 6 ft lbf Pivot shaft 85 Nm 8 5 m kgf 61 ft lbf Lower engine bracket...

Page 217: ...STALLING THE SHIFT PEDAL 1 Install Shift pedal 1 Shift pedal bolt 2 TIP Align the punch mark a on the shift shaft with the notch b in the shift pedal Muffler clamp 16 Nm 1 6 m kgf 12 ft lbf Muffler bolt 30 Nm 3 0 m kgf 22 ft lbf Shift pedal bolt 12 Nm 1 2 m kgf 8 7 ft lbf 1 3 2 T R New T R 3 1 5 4 T R ...

Page 218: ...e 5 1 Fuel tank Refer to FUEL TANK on page 8 1 Engine upper bracket right Refer to ENGINE REMOVAL on page 6 1 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 For installation reverse the removal proce dure T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf ...

Page 219: ...ensioner cap bolt 1 4 Timing chain tensioner 1 5 Gasket 1 6 Bolt camshaft cap 10 7 Camshaft cap 2 8 Clip 2 9 Exhaust camshaft 1 10 Intake camshaft 1 For installation reverse the removal proce dure T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf ...

Page 220: ...haft must align with the cylinder head surface as shown in the illustration 3 Loosen Camshaft sprocket bolt 4 Remove Timing chain tensioner assembly Gasket 5 Remove Camshaft cap bolts 1 Camshaft cap 2 Clip TIP Remove the bolts camshaft cap in a criss cross pattern working from the outside in ECA1DX1015 NOTICE The bolts camshaft cap must be removed evenly to prevent damage to the cylinder head cams...

Page 221: ...risscross pattern from innermost to outer caps Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 Camshaft lobe dimensions Intake A 30 100 30 200 mm 1 1850 1 1890 in Limit 30 000 mm 1 1811 in Intake B 22 450 22 550 mm 0 8839 0 8878 in Limit 22 350 mm 0 8799 in Exhaust A 30 200 30 300 mm ...

Page 222: ...ket and the timing chain as a set EAS23960 CHECKING THE TIMING CHAIN TENSION ERS The following procedure applies to both of the timing chain tensioners 1 Check Timing chain tensioner Cracks damage o Replace a While pressing the tensioner rod lightly with fingers use a thin screwdriver 1 and wind the tensioner rod up fully clockwise b When releasing the screwdriver by pressing lightly with fingers ...

Page 223: ...mark a on the rotor with the align mark b on the crankcase cover when piston is at TDC on compression stroke c Fit the timing chain 3 onto both camshaft sprockets and install the camshafts on the cylinder head TIP The camshafts should be installed onto the cyl inder head so that the punch mark c on the exhaust camshaft and the punch mark d on the intake camshaft must align with the cylinder head s...

Page 224: ...and wind the tensioner rod up fully clockwise b With the rod fully wound and the chain ten sioner UP mark a facing upward install the gasket 1 the timing chain tensioner 2 and the gasket 3 and tighten the bolt 4 to the specified torque c Release the screwdriver check the tension er rod to come out and tighten the gasket 5 and the cap bolt 6 to the specified torque 3 Turn Crankshaft Counterclockwis...

Page 225: ...k Refer to FUEL TANK on page 8 1 Exhaust pipe and silencer Refer to ENGINE REMOVAL on page 6 1 Radiator Refer to RADIATOR on page 7 1 Throttle body Refer to THROTTLE BODY on page 8 6 Camshaft Refer to CAMSHAFT on page 6 7 1 Bolt 2 2 Bolt 4 3 Cylinder head 1 4 Gasket 1 5 Timing chain guide exhaust side 1 For installation reverse the removal proce dure T R T R ...

Page 226: ...scratching Spark plug bore threads Valve seats 2 Check Cylinder head Damage scratches o Replace TIP Replace the titanium valves with the cylinder head Refer to CHECKING THE VALVE SEATS on page 6 21 Cylinder head water jacket Mineral deposits rust o Eliminate 3 Measure Cylinder head warpage Out of specification o Resurface the cylin der head a Place a straightedge and a thickness gauge across the c...

Page 227: ...he threads and contact surfaces of the bolts and on both contact surfaces of the plain 1 4 washers c Install the plain washers and bolts d Tighten the bolts to the specified torque in two or three steps in the proper tightening sequence as shown e Remove the bolts f Again apply the molybdenum disulfide grease on the threads and contact surfaces of the bolts and on both contact surfaces of the plai...

Page 228: ...lts 90 in each of the two steps to reach the specified angle of 180 in the proper tightening sequence as shown Bolts 1 4 Final Specified angle 180 g Tighten the bolts to the specified torque Bolt 5 6 10 Nm 1 0 m kgf 7 2 ft lbf 1 2 T R T R ...

Page 229: ...rder Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 6 14 1 Valve lifter 5 2 Valve pad 5 3 Valve cotter 10 4 Valve spring retainer 5 5 Valve spring 5 6 Exhaust valve 2 7 Intake valve 3 8 Valve stem seal 5 9 Valve spring seat 5 For installation reverse the removal proce dure ...

Page 230: ...age at the valve seat o Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS on page 6 21 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal TIP There should be no leakage at the valve seat 1 3 Remove Valve cotters 1 TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 4 Remov...

Page 231: ...e remover 1 b Install the new valve guide with the valve guide installer 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide clearance Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 ...

Page 232: ... The following procedure applies to all of the valves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear o Replace the cylinder head 3 Measure Valve seat width a Out of specification o Replace the cylinder head Intake Valve guide remover ø4 5 90890 04116 YM 04116 Valve guide installer ø4 5 90890 04117 YM 04117 Valve guide reamer ø4 5 9089...

Page 233: ...eplace the valves without lapping the valve seats and valve faces When replacing the valves or valves guides use new valves to lap the valve seats and then replace them with new valves a Apply a coarse lapping compound a to the valve face ECA13790 NOTICE Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c I...

Page 234: ...essed valve spring force a Out of specification o Replace the valve spring 3 Measure Valve spring tilt a Out of specification o Replace the valve spring Valve spring free length Free length intake 39 46 mm 1 55 in Limit 38 46 mm 1 51 in Free length exhaust 37 61 mm 1 48 in Limit 36 61 mm 1 44 in b Installed length Installed compression spring force intake 130 20 149 80 N 13 28 15 28 kgf 29 27 33 6...

Page 235: ...te Valve stem 1 Valve stem seal 2 with the recommended lubricant 3 Install Spring seat 1 Valve stem seal 2 Valve 3 Valve spring 4 Valve spring retainer 5 onto the cylinder head TIP Make sure each valve is installed in its original place Install the valve springs with the larger pitch a facing up 4 Install Valve cotters 1 TIP Install the valve cotters by compressing the valve spring with the valve ...

Page 236: ...800 NOTICE Hitting the valve tip with excessive force could damage the valve 6 Lubricate Valve pad 1 Valve lifter 2 7 Install Valve pad Valve lifter TIP The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in its original position Recommended lubricant Engine oil 1 2 E 1 2 ...

Page 237: ...cylinder and piston Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 6 14 1 Cylinder 1 2 Dowel pin 2 3 Cylinder gasket 1 4 Piston pin clip 2 5 Piston pin 1 6 Piston 1 7 Piston ring set 1 For installation reverse the removal proce dure ...

Page 238: ...ston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS24390 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Sidewall Cylinder wall Vertical scratches o Replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure cylinder bore C with the cylinder bore gauge TIP Measure cylinder bore C...

Page 239: ...IP Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder TIP Level the piston ring into the cylinder with the piston crown 3 Measure Piston ring end gap Out of specification o Replace the piston ring Diameter D 94 965 94 980 mm 3 7388 3 7394 in a 9 mm 0 35 in from the bottom edge of the p...

Page 240: ...LING THE PISTON AND CYLINDER 1 Install Oil ring expander 1 Lower oil ring rail 2 Upper oil ring rail 3 2nd ring 4 Top ring 5 TIP Be sure to install the piston rings so that the manufacturer s marks or numbers face up Piston ring Top ring End gap installed 0 20 0 30 mm 0 0079 0 0118 in Limit 0 55 mm 0 0217 in 2nd ring End gap installed 0 35 0 50 mm 0 0138 0 0197 in Limit 0 85 mm 0 0335 in Oil ring ...

Page 241: ...Piston Piston rings Cylinder with the recommended lubricant 4 Offset Piston ring end gaps 5 Install Cylinder gasket Dowel pin Cylinder TIP While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide exhaust side through the timing chain cavity A Exhaust side Recommended lubricant Engine oil New a Top ring end b 2nd ring end...

Page 242: ...TER 6 31 EAS24780 ELECTRIC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks Exhaust pipe Refer to ENGINE REMOVAL on page 6 1 1 Starter motor 1 For assembly reverse the disassemble pro cedure ...

Page 243: ...embling the starter motor Order Job Parts to remove Q ty Remarks 1 Starter motor front cover 1 2 Starter motor yoke 1 3 Armature assembly 1 4 Starter motor rear cover 1 5 Brush set 2 For assembly reverse the disassembly pro cedure ...

Page 244: ...re assembly resistances commuta tor and insulation Out of specification o Replace the starter motor a Measure the armature assembly resistanc es with the pocket tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification o Replace the brush set 6 Measure Brush spring force Out of specification o Replace the brush set Limit 16 6 mm 0 6...

Page 245: ...ter motor yoke 2 TIP Align the match mark a on the starter motor yoke with the match mark b on the starter motor rear cover Install the starter motor yoke with its groove c facing rear cover 4 Install O ring 1 Circlip Plain washer 2 Washer starter motor front cover 3 Starter motor front cover 4 TIP For installation align the projections on the washer with the slots in the front cover Align the mat...

Page 246: ...Parts to remove Q ty Remarks 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 14 Clutch boss nut 1 15 Conical washer 1 ...

Page 247: ...CLUTCH 6 36 Removing the clutch Order Job Parts to remove Q ty Remarks 16 Clutch boss 1 17 Thrust washer 1 18 Primary driven gear 1 19 Push lever shaft 1 For installation reverse the removal proce dure ...

Page 248: ...OIL on page 3 13 Drain the coolant Refer to CHANGING THE COOLANT on page 3 16 Exhaust pipe Refer to ENGINE REMOVAL on page 6 1 Brake pedal Refer to ENGINE REMOVAL on page 6 1 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 LS LS LS LS LT 8 LS ...

Page 249: ...CLUTCH 6 38 Removing the clutch Order Job Parts to remove Q ty Remarks 9 Gasket 1 10 Dowel pin O ring 3 1 For installation reverse the removal proce dure LS LS LS LS LT LS ...

Page 250: ...n plates as a set TIP Measure the friction plate at four places EAS25110 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check Clutch plate Damage o Replace the clutch plates as a set 2 Measure Clutch plate warpage with a surface plate and thickness gauge 1 Out of specification o Replace the clutch plates as a set EAS25140 CHECKING THE CLUTCH SPRINGS The fo...

Page 251: ... the clutch boss splines will cause er ratic clutch operation 2 Check Primary driven gear Damage wear o Replace the primary drive and clutch housing as a set Excessive noise during operation o Re place the primary drive and clutch housing as a set EAS25170 CHECKING THE PRESSURE PLATE 1 Check Pressure plate Cracks damage o Replace EAS25190 CHECKING THE CLUTCH PUSH RODS 1 Check Push rod 1 1 Bearing ...

Page 252: ... driven gears as a set EAS25260 INSTALLING THE CLUTCH 1 Install Push lever shaft 1 TIP Apply the lithium soap base grease on the oil seal lip 2 Install Primary driven gear 1 Thrust washer 2 Clutch boss 3 TIP Apply the engine oil on the primary driven gear inner circumference 3 Install Conical washer 1 Clutch boss nut 2 ECA1DX1020 NOTICE Make sure to tighten to specification other wise it may damag...

Page 253: ...tes Check the clutch plate for thickness and in stall 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 TIP Apply the engine oil on the bearing and washer 6 Install Push rod 2 1 Ball 2 Push rod 1 3 TIP Apply the engine oil on the push rod 1 2 and ball 7 Install Pressure plate 1 8 Install Clutch spring Clutch spring bolt T...

Page 254: ...CH 6 43 9 Install Clutch cover gasket 1 Dowel pin 2 10 Install Clutch cover 1 Clutch cover bolt TIP Tighten the bolts in stage using a crisscross pattern Clutch cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf New T R ...

Page 255: ...ing the kick shaft Order Job Parts to remove Q ty Remarks 1 Kick idle gear 1 2 Kick shaft assembly 1 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick shaft 1 8 Washer 1 For assembly reverse the disassembly pro cedure M ...

Page 256: ...pect Kick gear 1 Wear damage o Replace the kick shaft as sembly Kick idle gear 2 Ratchet wheel 3 Gear teeth a Ratchet teeth b Wear damage o Replace EAS1DX3178 INSTALLING THE KICK SHAFT ASSEMBLY 1 Install Kick gear 1 Washer 2 Circlip 3 Ratchet wheel 4 Spring 5 Washer 6 Circlip 7 To kick shaft 8 TIP Apply the molybdenum disulfide oil on the in ner circumferences of the kick gear and ratch et wheel A...

Page 257: ...chet wheel guide 3 Apply the engine oil on the kick shaft Slide the kick shaft assembly into the crank case and make sure the kick shaft stopper a fits into the kick shaft ratchet wheel guide 5 Hook Torsion spring 1 TIP Turn the torsion spring clockwise and hook into the proper hole a in the crankcase EAS1DX3179 INSTALLING THE KICK IDLE GEAR 1 Install Kick idle gear 1 Washer 2 Circlip 3 TIP Apply ...

Page 258: ...Shift pedal 1 2 Shift shaft 1 3 Oil seal 1 4 Collar 1 5 Shift shaft spring 1 6 Roller 1 7 Shift guide 1 8 Shift lever assembly 1 9 Shift lever 1 10 Pawl 2 11 Pawl pin 2 12 Spring 2 13 Bolt stopper lever 1 14 Stopper lever 1 10 Nm 1 0 m kgf 7 2 ft lbf 12 Nm 1 2 m kgf 8 7 ft lbf 10 Nm 1 0 m kgf 7 2 ft lbf 30 Nm 3 0 m kgf 22 ft lbf LT LS 1 3 5 13 14 6 10 11 11 8 7 12 12 10 2 4 LT LT ...

Page 259: ...AFT 6 48 Removing the shift shaft and stopper lever Order Job Parts to remove Q ty Remarks 15 Washer 1 16 Stopper lever spring 1 17 Segment 1 For installation reverse the removal proce dure 17 LT LS 16 15 LT LT ...

Page 260: ...opper lever Bends damage o Replace Roller turns roughly o Replace the stopper lever Stopper lever spring Damage wear o Replace EAS1DX3181 INSTALLING THE SEGMENT 1 Install Segment 1 Segment bolt TIP Align the notch a on the segment with the pin b on the shift cam ECA1DX1022 NOTICE If the segment gets an impact it may be damaged Take care not to give an impact to the segment when tightening the bolt...

Page 261: ... Shift lever assembly 1 Shift guide 2 TIP The shift lever assembly is installed at the same time as the shift guide Apply the engine oil on the segment bolt shaft 4 Install Shift guide bolt 1 EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Roller 1 Collar 2 Shift shaft spring 3 Washer 4 Shift shaft 5 TIP Apply the engine oil on the roller and shift shaft 2 Install Oil seal Shift pedal 1 2 3 4 LT 2 1...

Page 262: ... gear Refer to CLUTCH on page 6 35 Left crankcase cover Refer to CLUTCH on page 6 35 Generator rotor Refer to GENERATOR AND STARTER CLUTCH on page 6 57 1 Balancer nut 1 2 Primary drive gear nut 1 3 Balancer weight gear nut 1 4 Lock washer 1 5 Balancer 1 6 Straight key 1 7 Conical washer 1 8 Primary drive gear 1 9 Balancer drive gear 1 10 Lock washer 1 10 Nm 1 0 m kgf 7 2 ft lbf 45 Nm 4 5 m kgf 33 ...

Page 263: ... Circlip 1 13 Washer 1 14 Oil pump drive gear 1 15 Oil pump assembly 1 16 Dowel pin 2 17 Outer rotor 2 1 18 Circlip 1 19 Inner rotor 2 1 20 Dowel pin 1 For installation reverse the removal proce dure 10 Nm 1 0 m kgf 7 2 ft lbf 45 Nm 4 5 m kgf 33 ft lbf 14 16 16 17 13 12 18 20 19 15 110 Nm 11 0 m kgf 80 ft lbf 50 Nm 5 0 m kgf 36 ft lbf ...

Page 264: ...isassembling the oil pump Order Job Parts to remove Q ty Remarks 1 Oil pump cover 1 2 Outer rotor 1 1 3 Inner rotor 1 1 4 Dowel pin 1 5 Washer 1 6 Oil pump drive shaft 1 7 Rotor housing 1 For assembly reverse the disassembly pro cedure ...

Page 265: ...asure Inner rotor to outer rotor tip clearance a Outer rotor to oil pump housing clearance b Oil pump housing to inner rotor and outer rotor clearance c Out of specification o Replace the oil pump 3 Check Oil pump operation Rough movement o Repeat steps 1 and 2 or replace the defective part s 1 5 4 2 a 4 3 a 5 Inner rotor to outer rotor tip clearance Less than 0 120 mm 0 0047 in Limit 0 20 mm 0 00...

Page 266: ...mp drive shaft end and inner rotor 2 Fit the dowel pin into the groove in the inner rotor 2 4 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 6 54 EAS1DX3188 INSTALLING THE OIL PUMP AND BALANC ER GEAR 1 Install Outer rotor 2 1 Dowel pin 2 Oil pump assembly 3 Oil pump assembly bolt 4 TIP Apply the engine oil on the outer rotor 2 ECA1DX1023 NOTICE After tightening the bolts make sure...

Page 267: ...her 1 Balancer weight gear nut 2 Primary drive gear 3 Conical washer 4 Primary drive gear nut 5 Straight key 6 Balancer 7 Lock washer 8 Balancer nut 9 TIP Apply engine oil to the contact surface and threaded portion of the primary drive gear nut Place an aluminum plate a between the teeth of the balancer drive gear 10 and bal ancer weight gear 11 Install the conical washer with its convex sur face...

Page 268: ...at and fuel tank Refer to GENERAL CHASSIS on page 5 1 and FUEL TANK on page 8 1 Disconnect the AC magneto lead 1 Shift pedal 1 2 Cover Damper assembly 1 3 Damper assembly 1 4 Left crankcase cover 1 5 Gasket 1 6 Dowel pin 2 7 Starter idle gear 1 8 Bearing 1 9 Starter idle gear shaft 1 10 Generator rotor 1 11 Woodruff key 1 12 Starter clutch 1 T R T R 1 6 6 11 9 8 7 3 2 4 5 12 10 T R T R T R LT LS T...

Page 269: ... 58 Removing the generator Order Job Parts to remove Q ty Remarks 13 Starter clutch drive gear 1 14 Crankshaft position sensor 1 15 Stator 1 For installation reverse the removal proce dure T R T R 15 14 13 T R T R T R LT LS T R T R ...

Page 270: ...ter clutch gear 4 Check Damper assembly Damage pitting wear o Replace the damp er assembly Check the gear of the starter motor arma ture 5 Check Starter clutch operation a Install the starter clutch drive gear 1 onto the starter clutch and hold the starter clutch b When turning the starter clutch drive gear clockwise A the starter clutch and the starter clutch drive gear should engage oth erwise t...

Page 271: ...the starter clutch drive gear inner circumference 3 Install Starter clutch 1 To generator rotor 2 EAS1DX3193 INSTALLING THE GENERATOR 1 Install Woodruff key 1 Generator rotor 2 TIP Degrease the contact surfaces of the tapered portions of the crankshaft and generator rotor When installing the woodruff key make sure that its flat surface a is in parallel with the crankshaft center line b When instal...

Page 272: ...and idle gear inner circumfer ence 4 Install Dowel pin Crankcase cover gasket Left crankcase cover 1 Crankcase cover bolt TIP Tighten the bolts in stage using a crisscross pattern 5 Install Washer 1 Damper assembly 2 Washer 3 TIP Apply the engine oil to the shaft and washers 6 Install Cover damper assembly 1 Bolt 2 TIP Install the cover damper assembly with its mark a facing upward Generator rotor...

Page 273: ...ge 6 26 Balancer Refer to OIL PUMP AND BALANCER GEAR on page 6 51 Kick shaft assembly Refer to KICKSTATER on page 6 44 Segment Refer to SHIFT SHAFT on page 6 47 Stator Refer to GENERATOR AND STARTER CLUTCH on page 6 57 1 Timing chain guide intake side 1 2 Timing chain 1 3 Clutch cable holder 1 4 Right crankcase 1 5 Left crankcase 1 6 Oil strainer 1 7 Balancer shaft 1 8 Crankshaft 1 ...

Page 274: ...CRANKCASE 6 63 For installation reverse the removal proce dure Separating the crankcase Order Job Parts to remove Q ty Remarks ...

Page 275: ...Order Job Parts to remove Q ty Remarks Crankshaft assembly Refer to CRANKSHAFT ASSEMBLY AND BALANCER SHAFT on page 6 67 Transmission assembly Refer to TRANSMISSION on page 6 70 1 Oil seal 3 2 Bearing 11 For installation reverse the removal proce dure ...

Page 276: ... the case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If the cases do not separate check for a remaining case bolt or fitting Do not force c Remove the dowel pins and O ring 2 Remove Balancer shaft 1 TIP Remove the balancer shaft with its flat side a facing the crankshaft EAS1DX3194 CHECKING TH...

Page 277: ... mating surfaces 3 Apply Sealant onto the crankcase mating surfaces 4 Install Dowel pins 1 O ring 2 Crankcase to the left crankcase TIP Apply the lithium soap base grease on the O ring Fit the right crankcase onto the left crankcase Tap lightly on the case with soft hammer When installing the crankcase the connecting rod should be positioned at TDC top dead center Tighten the bolts in a crisscross...

Page 278: ... ASSEMBLY AND BALANCER SHAFT Removing the crankshaft assembly and balancer shaft Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 6 62 1 Balancer shaft 1 2 Crankshaft assembly 1 For installation reverse the removal proce dure 1 2 ...

Page 279: ...KING THE CRANKSHAFT ASSEMBLY 1 Measure Crankshaft runout Out of specification o Replace the crank shaft bearing or both TIP Turn the crankshaft slowly 2 Measure Big end side clearance Out of specification o Replace the big end bearing crankshaft pin or connecting rod 3 Measure Crankshaft width Out of specification o Replace the crank shaft Crankcase separating tool 90890 04152 Crankcase separator ...

Page 280: ...id scratching the crankshaft and to ease the installation procedure lubricate the oil seal lips with lithium soap based grease and each bearing with engine oil TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft as sembly bottoms against the bearing Crankshaft ...

Page 281: ...bly and shift forks Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 6 62 1 Main axle assembly 1 2 Drive axle assembly 1 3 Shift drum 1 4 Shift fork R 1 5 Shift fork C 1 6 Shift fork L 1 7 Collar 1 For installation reverse the removal proce dure LS ...

Page 282: ...ECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum groove Damage scratches wear o Replace the shift drum assembly Shift drum segment 1 Damage wear o Replace the shift drum as sembly EAS1DX3196 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a centering device and dial gauge 1 Out of specification o Replace the main ax le 2 Measure Drive axle runout with a centering device and dial gauge 1...

Page 283: ...nd on the in ner surface of the sliding gear then install 2 Install Collar 1 2nd wheel gear 26T 2 4th wheel gear 21T 3 3rd wheel gear 21T 4 5th wheel gear 21T 5 Collar 6 1st wheel gear 29T 7 O ring 8 To drive axle 9 TIP Apply the molybdenum disulfide oil on the in ner and end surface of the idler gear and on the inner surface of the sliding gear then in stall Apply the lithium soap base grease on ...

Page 284: ...y the molybdenum disulfide oil on the shift fork grooves Apply engine oil to the shift cam groove bear ing 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 main axle 6 Install Transmission assembly 1 To left crankcase 2 TIP Apply the engine oil on the ...

Page 285: ...7 COOLING SYSTEM RADIATOR 7 1 HANDLING NOTE 7 3 CHECKING THE RADIATOR 7 3 INSTALLING THE RADIATOR 7 3 WATER PUMP 7 5 CHECKING THE WATER PUMP 7 6 ASSEMBLING THE WATER PUMP 7 6 ...

Page 286: ...mbly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage EAS1DX3197 RADIATOR Removing the radiator Order Job Parts to remove Q ty Remarks Seat Air scoop left right Refer to GENERAL CHASSIS on page 5 1 Fuel tank Refer to FUEL TANK on page 8 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 16 1 Air panel 2 2 Radiator hose clamp 8 3 Right radia...

Page 287: ...rks 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 For installation reverse the removal proce dure New LS T R T R T R T R T R T R 12 13 LS 6 7 8 10 11 9 ...

Page 288: ...iver 2 Check Radiator hoses Radiator pipes Cracks damage o Replace 3 Measure Radiator cap opening pressure Below the specified pressure o Replace the radiator cap a Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap 3 b Apply the specified pressure for ten seconds and make sure there is no drop in pressure EAS1DX3199 INSTALLING THE RADIATOR 1 Fill Cooling syste...

Page 289: ...137 3 kPa 1 37 kg cm2 19 9 psi pressure c Measure the indicated pressure with the gauge 3 Measure Radiator cap opening pressure Below the specified pressure o Replace the radiator cap Refer to CHECKING THE RADIATOR on page 7 3 ...

Page 290: ... on page 3 13 Crankcase cover right Refer to CLUTCH on page 6 35 1 Coolant pipe 2 1 2 Water pump housing 1 3 Pin 2 4 Impeller 1 5 Washer 1 6 Impeller shaft 1 7 Oil seal 1 1 8 Oil seal 2 1 9 Bearing 1 For installation reverse the removal proce dure 10 Nm 1 0 m kgf 7 2 ft lbf 10 Nm 1 0 m kgf 7 2 ft lbf 10 Nm 1 0 m kgf 7 2 ft lbf 10 Nm 1 0 m kgf 7 2 ft lbf 14 Nm 1 4 m kgf 10 ft lbf 12 Nm 1 2 m kgf 8 ...

Page 291: ...install the shaft while turning it Hold the impeller shaft on its width across the flats a with spanners etc and install the im peller 2 Install Dowel pin 1 O ring 2 TIP Apply the lithium soap based grease on the O ring 3 Install Water pump housing 1 Water pump housing bolt 2 Washer 3 Coolant drain bolt 4 4 Install O ring Coolant pipe 1 Coolant pipe bolt 2 TIP Apply the lithium soap based grease o...

Page 292: ...WATER PUMP 7 7 ...

Page 293: ... 8 3 REMOVING THE FUEL SENDER 8 4 CHECKING THE FUEL SENDER 8 4 INSTALLING THE FUEL SENDER 8 4 INSTALLING THE FUEL TANK 8 5 CHECKING THE FUEL PRESSURE 8 5 THROTTLE BODY 8 6 REMOVING THE THROTTLE BODY 8 8 CHECKING THE INJECTOR 8 8 CHECKING THE THROTTLE BODY 8 8 CHECKING THE THROTTLE BODY JOINT 8 9 ADJUSTING THE THROTTLE POSITION SENSOR 8 9 ...

Page 294: ...le and mechanical damage EAS26620 FUEL TANK Removing the fuel tank Order Job Parts to remove Q ty Remarks Seat Refer to GENERAL CHASSIS on page 5 1 Side cover left right Air scoop left right 1 Fuel tank bolt 1 2 Fuel tank bracket pin 1 3 Fuel sender coupler 1 Disconnect 4 Fuel pump coupler 1 Disconnect 5 Fuel hose 1 6 Fuel tank 1 7 Fuel pump bracket 1 2 6 1 7 4 5 3 New New T R 9 Nm 0 9 m kgf 6 5 f...

Page 295: ... Fuel sender 1 11 Fuel sender gasket 1 For installation reverse the removal proce dure 10 11 9 8 New New T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 4 Nm 0 4 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 4 Nm 0 4 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf ...

Page 296: ...e two buttons 2 on the sides of the connector and then remove the hose Remove the fuel hose manually without using any tools Before removing the hose place a few rags in the area under where it will be removed To prevent sand dust and other foreign ma terial from entering the fuel pump install the included fuel hose joint cover 1 3 and fuel hose joint cover 2 4 onto the fuel pump and disconnected ...

Page 297: ...SENDER 1 Disconnect Fuel pump coupler Fuel sender coupler from the wire harness 2 Remove Fuel tank 3 Remove Fuel sender from the fuel tank 4 Connect Fuel sender coupler 5 Push the main switch to ON 6 Check Fuel level warning light Out of specification o Replace the fuel sender EAS1DX3204 INSTALLING THE FUEL SENDER 1 Install Fuel sender gasket Fuel sender TIP Do not damage the installation surfaces...

Page 298: ...age 5 1 b Remove the fuel tank bolt and hold up the fuel tank c Disconnect the fuel hose from the fuel pump Refer to REMOVING THE FUEL TANK on page 8 3 EWA1DX1008 WARNING Cover fuel hose connection with a cloth when disconnecting them Residual pres sure in the fuel lines could cause fuel to spurt out when removing the hose ECA1DX1025 NOTICE Be sure to disconnect the fuel hose by hand Do not forcef...

Page 299: ...5 1 Side cover left right Air scoop left right Fuel tank Refer to FUEL TANK on page 8 1 Throttle cable cover Throttle cable Ignition coil lead Rear frame Loosen Ignition coil lead Loosen 1 Injector coupler 1 Disconnect 2 Throttle body assembly 1 3 Bracket 1 4 Fuel hose 1 5 Clamp 1 For installation reverse the removal proce dure 1 4 5 2 3 T R T R ...

Page 300: ...Y 8 7 Disassembling the throttle body Order Job Parts to remove Q ty Remarks 1 Delivery pipe 1 2 Injector 1 3 Gasket 1 4 Throttle position sensor 1 For assembly reverse the disassembly pro cedure New New 2 3 1 T R ...

Page 301: ...age o Replace 2 Check Injector resistance Refer to CHECKING THE FUEL INJEC TOR on page 9 78 EAS26990 CHECKING THE THROTTLE BODY 1 Check Throttle body Cracks damage o Replace the throttle body as a set 2 Check Fuel passages Obstructions o Clean ECA1DX1027 NOTICE Before removing the throttle body clean the area around the throttle body to pre vent dirt and other foreign material from falling into th...

Page 302: ...t Throttle position sensor angle a Connect the diagnostic tool Refer to YAMAHA DIAGNOSTIC TOOL on page 9 26 b Temporary tighten the throttle position sen sor c Check that the throttle grip is fully closed d Connect the throttle position sensor to the wire harness e Set the main switch to OFF f Set the diagnostic tool to diagnostic mode g Diagnostic code number d 01 is selected h Adjust the positio...

Page 303: ...M 9 24 CIRCUIT DIAGRAM 9 24 YAMAHA DIAGNOSTIC TOOL 9 26 ECU SELF DIAGNOSTIC FUNCTION 9 27 TROUBLESHOOTING METHOD 9 29 LIST OF SELF DIAGNOSTIC AND FAIL SAFE ACTIONS 9 30 LIST OF DIAGNOSTIC CODES 9 31 TROUBLESHOOTING DETAILS 9 33 FUEL PUMP SYSTEM 9 52 CIRCUIT DIAGRAM 9 52 TROUBLE SHOOTING 9 54 ELECTRICAL COMPONENTS 9 56 9 56 CHECKING THE SWITCHES 9 60 CHECKING THE BULBS AND BULB SOCKETS 9 64 REPLACI...

Page 304: ...OIL 9 73 CHECKING THE RECTIFIER REGULATOR 9 74 CHECKING THE SPEED SENSOR 9 74 CHECKING THE FUEL SENDER 9 74 CHECKING THE COOLANT TEMPERATURE SENSOR 9 75 CHECKING THE THROTTLE POSITION SENSOR 9 76 CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 9 76 CHECKING THE INTAKE AIR PRESSURE SENSOR 9 77 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 9 77 CHECKING THE FUEL INJECTOR 9 78 ...

Page 305: ...cing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowl edge and skill concerning servicing are requested not to undertake inspection adjustment disas sembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage ...

Page 306: ... R R B L Y B Y Y W Lg G W W B G Br W G Y R L B Y Br B B B Y W B B B B B B Br R L Y B B B W W W W W W B R B R B R B L Gy B R R L G Br L B R Br Y W R Br Br L Br L Br Br Br G B B B G G B L B L B L B L B L B L ON OFF Y G L B L Y G OFF START Br L W R L B 15A Br B Br B Br L G Br B B R B R B R B Sb Sb G Y G Y Br W Br W B L B L G G L L L L R R R R R R R B L B L B L B L B L B L B L B G Br L B W R R R Br Br...

Page 307: ...NITION SYSTEM 9 3 1 AC magneto 4 Battery 5 Main fuse 6 Starter relay 16 Main switch 17 Joint connector 22 ECU electronic control unit 23 Ignition coil 24 Spark plug 29 Lean angle sensor 32 Joint connector ...

Page 308: ... Recharge or replace the battery OK p 3 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 6 NG o Re gap or replace the spark plug OK p 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 9 71 OK o The ignition system is normal NG p 5 Check the ignition coil Refer to CHECKING THE IGNI TION COIL on page 9 71 NG o Replace the ignition coil OK p 6 Check the c...

Page 309: ...l switch OK p 10 Check the relay unit Starting circuit cut off relay Refer to CHECKING THE RE LAYS on page 9 69 NG o Replace the relay unit OK p 11 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 9 72 NG o Replace the lean angle sensor OK p 12 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 9 2 NG o Properly connect or repair the ignition sys ...

Page 310: ...Br Br R L R R B L Y B Y Y W Lg G W W B G Br W G Y R L B Y Br B B B Y W B B B B B B Br R L Y B B B W W W W W W B R B R B R B L Gy B R R L G Br L B R Br Y W R Br Br L Br L Br Br Br G B B B G G B L B L B L B L B L B L ON OFF Y G L B L Y G OFF START Br L W R L B 15A Br B Br B Br L G Br B B R B R B R B Sb Sb G Y G Y Br W Br W B L B L G G L L L L R R R R R R R B L B L B L B L B L B L B L B G Br L B W R ...

Page 311: ... relay 7 Starter motor 8 Starter relay diode 10 Connector 11 Connector 12 Connector 14 Starting circuit cut off relay 15 Start switch 16 Main switch 17 Joint connector 18 Clutch switch 19 Diode 26 Neutral switch 32 Joint connector 40 Joint connector 42 Connector ...

Page 312: ...ditions is met The transmission is in neutral the neutral switch is closed The clutch lever is pulled to the handlebar the clutch switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these con ditions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the ab...

Page 313: ...HE TRANSMISSION IS IN NEU TRAL b WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Starting circuit cut off relay 5 Start switch 6 Diode 7 Clutch switch 8 Neutral switch 9 Starter relay 10 Starter motor ...

Page 314: ... Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 9 73 OK o Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 NG p 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 6 33 NG o Repair or replace the starter motor OK p 5 Check the relay unit Starting circuit cut off relay Refer to CHECKING THE RE ...

Page 315: ... to CHECKING THE SWITCHES on page 9 60 NG o Replace the neutral switch OK p 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 9 60 NG o Replace the clutch switch OK p 12 Check the start switch Refer to CHECKING THE SWITCHES on page 9 60 NG o Replace the engine stop switch OK p 13 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 9 6 NG o Properly connect or...

Page 316: ... R R B L Y B Y Y W Lg G W W B G Br W G Y R L B Y Br B B B Y W B B B B B B Br R L Y B B B W W W W W W B R B R B R B L Gy B R R L G Br L B R Br Y W R Br Br L Br L Br Br Br G B B B G G B L B L B L B L B L B L ON OFF Y G L B L Y G OFF START Br L W R L B 15A Br B Br B Br L G Br B B R B R B R B Sb Sb G Y G Y Br W Br W B L B L G G L L L L R R R R R R R B L B L B L B L B L B L B L B G Br L B W R R R Br Br...

Page 317: ...CHARGING SYSTEM 9 13 1 AC magneto 2 Rectifier regulator 3 Connector 4 Battery 5 Main fuse 6 Starter relay 32 Joint connector ...

Page 318: ...THE BATTERY on page 9 66 NG o Clean the battery terminals Recharge or replace the battery OK p 3 Check the stator coil Refer to CHECKING THE STA TOR COIL on page 9 73 NG o Replace the stator assembly OK p 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 9 74 NG o Replace the rectifier regulator OK p 5 Check the entire charging system s wiring Refer to CIRCUIT DIAG...

Page 319: ...CHARGING SYSTEM 9 15 ...

Page 320: ... R R B L Y B Y Y W Lg G W W B G Br W G Y R L B Y Br B B B Y W B B B B B B Br R L Y B B B W W W W W W B R B R B R B L Gy B R R L G Br L B R Br Y W R Br Br L Br L Br Br Br G B B B G G B L B L B L B L B L B L ON OFF Y G L B L Y G OFF START Br L W R L B 15A Br B Br B Br L G Br B B R B R B R B Sb Sb G Y G Y Br W Br W B L B L G G L L L L R R R R R R R B L B L B L B L B L B L B L B G Br L B W R R R Br Br...

Page 321: ... fuse 6 Starter relay 9 Headlight relay 10 Connector 11 Connector 12 Connector 16 Main switch 17 Joint connector 22 ECU electronic control unit 32 Joint connector 40 Joint connector 41 Joint connector 42 Connector 43 Headlight 44 Taillight ...

Page 322: ...use Refer to CHECKING THE FUSE on page 9 65 NG o Replace the fuse OK p 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 9 66 NG o Clean the battery terminals Recharge or replace the battery OK p 4 Check the main switch Refer to CHECKING THE SWITCHES on page 9 60 NG o Replace the main switch OK p 5 Check the headlight relay Refer to CHECKING THE RE LAYS on page 9 69 NG o Repla...

Page 323: ...LIGHTING SYSTEM 9 19 ...

Page 324: ...L R R B L Y B Y Y W Lg G W W B G Br W G Y R L B Y Br B B B Y W B B B B B B Br R L Y B B B W W W W W W B R B R B R B L Gy B R R L G Br L B R Br Y W R Br Br L Br L Br Br Br G B B B G G B L B L B L B L B L B L ON OFF Y G L B L Y G OFF START Br L W R L B 15A Br B Br B Br L G Br B B R B R B R B Sb Sb G Y G Y Br W Br W B L B L G G L L L L R R R R R R R B L B L B L B L B L B L B L B G Br L B W R R R Br B...

Page 325: ... 5 Main fuse 6 Starter relay 16 Main switch 17 Joint connector 22 ECU electronic control unit 32 Joint connector 34 Speed sensor 35 Multi function display 36 Fuel sender 37 Resistor 40 Joint connector 41 Joint connector 42 Connector ...

Page 326: ...THE BATTERY on page 9 66 NG o Clean the battery terminals Recharge or replace the battery OK p 3 Check the main switch Refer to CHECKING THE SWITCHES on page 9 60 NG o Replace the main switch OK p 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 9 20 NG o Properly connect or repair the signaling system s wiring OK p This circuit is OK 1 Check the speed sensor Refer to ...

Page 327: ...he fuel sender Refer to CHECKING THE FUEL SENDER on page 9 74 NG o Replace the fuel sender assembly OK p 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 9 20 NG o Properly connect or repair the signaling system s wiring OK p Replace the main switch ...

Page 328: ...Br R L R R B L Y B Y Y W Lg G W W B G Br W G Y R L B Y Br B B B Y W B B B B B B Br R L Y B B B W W W W W W B R B R B R B L Gy B R R L G Br L B R Br Y W R Br Br L Br L Br Br Br G B B B G G B L B L B L B L B L B L ON OFF Y G L B L Y G OFF START Br L W R L B 15A Br B Br B Br L G Br B B R B R B R B Sb Sb G Y G Y Br W Br W B L B L G G L L L L R R R R R R R B L B L B L B L B L B L B L B G Br L B W R R R...

Page 329: ...ff relay 15 Start switch 16 Main switch 17 Joint connector 19 Diode 22 ECU electronic control unit 25 Injector 26 Neutral switch 27 Throttle position sensor 28 Intake air pressure sensor 29 Lean angle sensor 30 Coolant temperature sensor 31 Intake air temperature sensor 32 Joint connector 33 Engine stop switch 40 Joint connector 42 Connector ...

Page 330: ...ng the Yamaha diagnostic tool 1 Remove the side cover left right and seat 2 Open the air filter case cover 3 Disconnect the coupler for connecting optional part 4 Connect the sub lead for diagnostic tool to the coupler for connecting optional part and the diag nostic tool 5 Connect the sub lead for diagnostic tool to the battery Yamaha diagnostic tool 90890 03215 Fault diagnosis mode Error codes r...

Page 331: ...ovides an ap propriate substitute characteristic operation and alerts the rider of the detected malfunction by illu minating the engine trouble warning light After the engine has been stopped the lowest fault code number appears on the clock LCD Once a fault code has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injec...

Page 332: ... abnormal signal from a sensor while the vehicle is being driven the ECU illu minates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction When an abnormal signal is received from a sensor the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate...

Page 333: ...the malfunction history in the diagnos tic mode Refer to LIST OF DIAGNOSTIC CODES Diagnostic code No d 62 TIP Setting the main switch to OFF will not erase the malfunction history The engine operation is not normal but the engine trouble warning light does not come on 1 Check the operation of the following sensors and actuators in the diagnostic mode Refer to TROUBLESHOOTING DETAILS on page 9 33 I...

Page 334: ...34 13 Intake air pressure sensor open or short circuit 9 35 14 Intake air pressure sensor clogged or detached hose 9 36 15 Throttle position sensor open or short circuit 9 37 16 Throttle position sensor stuck 9 39 21 Coolant temperature sensor open or short circuit 9 40 22 Intake air temperature sensor open or short circuit 9 41 30 Overturn detected 9 42 33 Ignition system 9 43 39 Fuel injector op...

Page 335: ...re When the engine is warm Displayed temperature is the ambient tempera ture approx 20 C offset for the ra diant heat d 06 Coolant tempera ture Displays the coolant tem perature Check the coolant temper ature 30 to 120 C 22 to 248 F When the engine is cold Displayed temperature is close to the ambient temperature When the engine is warm Displayed temperature is the current coolant temperature d 07...

Page 336: ...al portion of the EE PROM data that has been detected as fault code num ber 44 If there is more than one lo cation the display alter nates every 2 seconds 00 No fault If fault code number 44 is displayed the ECU is malfunctioning 01 CO adjustment value d 61 Malfunctionhistory code number display 1 Displays the fault code numbers that were previ ously recorded in the mal function history If more th...

Page 337: ... according to the reinstatement method Fault code No Fault code number displayed on the diagnostic tool when the engine failed to work normally Diagnostic code No Diagnostic code number to be used when the diagnostic mode is operated d 64 Setting history Display setting history 00 There is no setting history 01 There is setting history 02 Whether or not setting history data exists cannot be determ...

Page 338: ...bro ken terminals and locking condition of the pins Improperly connected o Connect the coupler securely or repair replace the wire har ness Crank the engine Fault code number is not dis played o Service is finished Fault code number is dis played o Go to next order 3 Wire harness continuity Open or short circuit o Re place the wire harness Between the crankshaft posi tion sensor coupler and ECU co...

Page 339: ...dition of the pins Improperly connected o Connect the coupler securely or repair replace the wire har ness Set the main switch to ON Fault code number is not dis played o Service is finished Fault code number is dis played o Go to next order 3 Connection of sub wire har ness coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and l...

Page 340: ...ault code number is dis played o Go to next order 7 Malfunction in ECU Replace the ECU Fault code No 14 Item Intake air pressure sensor hose system malfunction clogged or detached hose Fail safe system Able to start engine Able to drive vehicle Diagnostic code No d 03 Diagnostic tool display Displays the intake air pressure Procedure Operate the throttle while pushing the start switch If the displ...

Page 341: ...n sensor open or short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No d 01 Diagnostic tool display Throttle position sensor signal 9 16 fully closed position Procedure Check with throttle valves fully closed Or der Probable cause of malfunc tion and check Maintenance job Confirmation of service completion 1 Connection of throttle posi tion sensor co...

Page 342: ...in switch to ON Fault code number is not dis played o Service is finished Fault code number is dis played o Go to next order 5 Installed condition of throttle position sensor Check for looseness or pinching Improperly installed sensor o Reinstall or replace the sensor Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 8 9 Set the main switch to ON Fault code number is not dis played o Servic...

Page 343: ... valves fully closed Or der Probable cause of malfunc tion and check Maintenance job Confirmation of service completion 1 Installed condition of throttle position sensor Check for looseness or pinching Improperly installed sensor o Reinstall or replace the sensor Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 8 9 Set the main switch to ON Fault code number is not dis played o Service is ...

Page 344: ...ng condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected o Connect the coupler securely or repair replace the wire har ness Set the main switch to ON Fault code number is not dis played o Service is finished Fault code number is dis played o Go to next order 3 Wire harness continuity Open or short circuit...

Page 345: ...er and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected o Connect the coupler securely or repair replace the wire har ness Set the main switch to ON Fault code number is not dis played o Service is finished Fault code number is dis played o Go to next order 3 Wire harness continuity Open or short circuit o Re place the wire harness Between intake air ...

Page 346: ... code number is not dis played o Service is finished Fault code number is dis played o Go to next order 2 Installed condition of lean an gle sensor Check for a loose mounting pinched mounting or sensor mounting direction up or down Make sure that the mounting position is correct Set the main switch to ON then to OFF and then back to ON Fault code number is not dis played o Service is finished Faul...

Page 347: ...and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected o Connect the coupler securely or repair replace the wire har ness Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played o Service is finished Fault code number is dis played o Go to next order 3 Wire harness continuity Open or short circuit o Re place the ...

Page 348: ...rder 7 Operating sound unheard o Go to the order 2 2 Defective injector Measure the injector resis tance If the resistance is not 12 replace the injector Check for the operating sound of the injector in the di agnostic mode Code No d 36 Operating sound heard o Go to the order 7 Operating sound unheard o Go to the order 3 3 Connection of wire harness ECU coupler Check the locking condition of the c...

Page 349: ...ngle sensor and incline it more than 45 degrees Or der Probable cause of malfunc tion and check Maintenance job Confirmation of service completion 1 Connection of lean angle sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected o Connect the coupler securely or repair repl...

Page 350: ...each time the wheel is stopped Or der Probable cause of malfunc tion and check Maintenance job Confirmation of service completion 1 Connection of speed sensor meter coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected o Connect the coupler securely or repair replace the wire har...

Page 351: ...ult code number is not dis played o Service is finished Fault code number is dis played o Go to next order 5 Malfunction in ECU Replace the ECU Fault code No 44 Item EEPROM fault code number an error is detected while read ing or writing on EEPROM Fail safe system Able Unable to start engine Able Unable to drive vehicle Diagnostic code No d 60 Diagnostic tool display EEPROM fault code display 00 N...

Page 352: ...perform the procedure in order 4 4 Malfunction in ECU Replace the ECU Fault code No 46 Item Charging voltage is abnormal Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Diagnostic tool display Procedure Or der Probable cause of malfunc tion and check Maintenance job Confirmation of service completion 1 Malfunction in charging sys tem Check the charging system Refer t...

Page 353: ... number is not dis played o Service is finished Fault code number is dis played o Go to next order 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected o Connect the coupler securely or repair replace the wire har ness Set the switch on the diag ...

Page 354: ...coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected o Connect the coupler securely or repair replace the wire har ness Set the switch on the diag nostic tool sub wire harness to ON Fault code number is not dis played o Service is finished Fault code number is dis played o Go to...

Page 355: ...FUEL INJECTION SYSTEM 9 51 ...

Page 356: ...L R R B L Y B Y Y W Lg G W W B G Br W G Y R L B Y Br B B B Y W B B B B B B Br R L Y B B B W W W W W W B R B R B R B L Gy B R R L G Br L B R Br Y W R Br Br L Br L Br Br Br G B B B G G B L B L B L B L B L B L ON OFF Y G L B L Y G OFF START Br L W R L B 15A Br B Br B Br L G Br B B R B R B R B Sb Sb G Y G Y Br W Br W B L B L G G L L L L R R R R R R R B L B L B L B L B L B L B L B G Br L B W R R R Br B...

Page 357: ... Main fuse 6 Starter relay 10 Connector 11 Connector 12 Connector 16 Main switch 17 Joint connector 20 Fuel pump 22 ECU electronic control unit 32 Joint connector 33 Engine stop switch 40 Joint connector 41 Joint connector 42 Connector ...

Page 358: ...NG o Clean the battery terminals Recharge or replace the battery OK p 3 Check the main switch Refer to CHECKING THE SWITCHES on page 9 60 NG o Replace the main switch OK p 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 9 60 NG o Replace the engine stop switch OK p 5 Check fuel pressure Refer to CHECKING THE FUEL PRESSURE on page 8 5 NG o Replace the fuel pump OK p 6 Check th...

Page 359: ...FUEL PUMP SYSTEM 9 55 ...

Page 360: ...ELECTRICAL COMPONENTS 9 56 EAS27971 ELECTRICAL COMPONENTS EAS1DX3227 7 6 10 8 5 4 3 9 1 2 ...

Page 361: ...NTS 9 57 1 Main switch 2 Clutch switch 3 Fuel sender 4 Fuel pump 5 Intake air pressure sensor 6 Throttle position sensor 7 Injector 8 Intake air temperature sensor 9 Coupler for connecting optional part 10 Ignition coil ...

Page 362: ...ELECTRICAL COMPONENTS 9 58 9 8 7 10 11 3 2 1 4 5 6 ...

Page 363: ... 9 59 1 Rectifier regulator 2 Lean angle sensor 3 Coolant temperature sensor 4 Head light relay 5 Starting circuit cut off relay 6 Starter relay 7 Main fuse 8 Battery 9 ECU engine control unit 10 Condenser 11 Neutral switch ...

Page 364: ...ELECTRICAL COMPONENTS 9 60 EAS1DX3228 CHECKING THE SWITCHES 4 2 3 5 1 ...

Page 365: ...ELECTRICAL COMPONENTS 9 61 1 Engine stop switch 2 Clutch switch 3 Neutral switch 4 Main switch 5 Start switch ...

Page 366: ...or continuity set the pocket tester to 0 and to the u 1 range When checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illus tration similar to the one on below The switch positions a are shown in the far left column and the switch lead colors are shown in the top row in the ...

Page 367: ...ELECTRICAL COMPONENTS 9 63 The example illustration below shows that There is continuity between red and brown when the switch is set to ON a ...

Page 368: ...s 1 Remove Bulb EWA13320 WARNING Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down ECA14380 NOTICE Be sure to hold the socket firmly when re moving the bulb Never pull the lead oth erwise it may be pulled out of the terminal in the coupler Avoid touching the glass part of the head light bulb to keep it free from oil other...

Page 369: ...unit bolt 1 TIP After you have removed the headlight unit bolts lift and remove the headlight unit from front fender grommet 2 Remove Headlight coupler 1 Bulb cover 2 3 Remove Headlight bulb 1 4 Install Headlight bulb Fasten the new headlight bulb with the headlight bulb holder ECA13690 NOTICE Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency ...

Page 370: ... CHASSIS on page 5 1 EAS28030 CHECKING AND CHARGING THE BATTERY EWA13290 WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid Therefore always follow these preventive measures Wear protective eye gear when handling or working near batteries Charge batteries in a well ventilated area Keep batteries away from fire spark...

Page 371: ...NERAL CHASSIS on page 5 1 2 Disconnect Battery leads from the battery terminals ECA13640 NOTICE First disconnect the negative battery lead 1 and then positive battery lead 2 3 Remove Battery 4 Check Battery charge a Connect a pocket tester to the battery termi nals TIP The charge state of a VRLA Valve Regulated Lead Acid battery can be checked by mea suring its open circuit voltage i e the voltage...

Page 372: ...d let the battery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of a VRLA Valve Reg ulated Lead Acid battery stabilizes about 30 minutes after charging has been com pleted Therefore wait 30 minutes after charging is completed before measuring the open circuit voltage Charging method using a variable cur rent voltage charger a ...

Page 373: ...15 V TIP Set the charging time at 20 hours maximum e Measure the battery open circuit voltage af ter leaving the battery unused for more than 30 minutes 6 Install Battery 7 Connect Battery leads to the battery terminals ECA1DX1028 NOTICE First connect the positive battery lead 1 and then the negative battery lead 2 8 Check Battery terminals Dirt o Clean with a wire brush Loose connection o Connect...

Page 374: ...ative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 to 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 2 1 3 4 1 2 3 4 1 2 3 4 Result Continuity between 3 to 4 Pocket tester 90890 03112 Analog pocket tester YU 03112 C Continuity Tester positive lead o Blue Red 1 Tester negative lead o Green Bla...

Page 375: ...E SPARK PLUG CAP 1 Remove Spark plug cap from the spark plug lead 2 Check Spark plug cap resistance Out of specification o Replace a Connect the pocket tester u 1k to the spark plug cap as shown b Measure the spark plug cap resistance EAS1DX3234 CHECKING THE IGNITION COIL 1 Disconnect Ignition coil coupler from the wire harness Spark plug cap from the ignition coil 2 Check Primary coil resistance ...

Page 376: ...asure the crankshaft position sensor re sistance EAS28130 CHECKING THE LEAN ANGLE SENSOR 1 Remove Lean angle sensor from the bracket 2 Check Lean angle sensor out put voltage Out of specificationo Replace a Connect the lean angle sensor coupler to the wire harness Positive tester probe Orange 1 Negative tester probe Red Blue 2 Secondary coil resistance 10 71 14 49 k Pocket tester 90890 03112 Analo...

Page 377: ...s check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification o Replace the stator coil a Connect the pocket tester u 1 to the sta tor coil coupler as shown Pocket tester 90890 03112 A...

Page 378: ...s as shown b Connect the pocket tester DC20V to the test harness speed sensor 3P c Set the main switch to ON d Elevate the front wheel and slowly turn it e Measure the voltage DC 5 V of white and black white With the front wheel slowly ro tating voltage alternates between 0 V and 5 V EAS1DX3238 CHECKING THE FUEL SENDER Drain the gasoline 1 Disconnect Fuel sender coupler from the fuel sender Chargi...

Page 379: ...ster u 1k 100 to the coolant temperature sensor as shown b Immerse the coolant temperature sensor in a container filled with coolant TIP Make sure the coolant temperature sensor ter minals do not get wet c Place a thermometer in the coolant d Slowly heat the coolant and then let it cool to the specified temperature indicated in the table e Check the coolant temperature sensor for continuity at the...

Page 380: ...hen installing the throttle position sensor ad just its angle properly Refer to ADJUSTING THE THROTTLE POSITION SENSOR on page 8 9 EAS1DX3240 CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1 Check Throttle position sensor input voltage Out of specification o Replace the ECU a Connect the test harness S pressure sensor 3P to the throttle position sensor coupler and wire harness as shown b Conn...

Page 381: ...are Never subject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification o Replace a Connect the pocket tester u 1k u 100 to the intake air temperature sensor terminal as shown Positive tester probeo Blue 1 Negative tester probeo Black Blue 2 Intake air pressure sensor outpu...

Page 382: ...r resistance Out of specification o Replace the fuel in jector a Disconnect the fuel injector coupler from the fuel injector b Connect the pocket tester u 10 to the fuel injector coupler as shown c Measure the fuel injector resistance Resistance 12 0 Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe o Injector terminal 1 Negative tester probe o Injector terminal 2 1 2...

Page 383: ...E IDLING SPEED 10 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 10 2 FAULTY GEAR SHIFTING 10 2 SHIFT PEDAL DOES NOT MOVE 10 2 JUMPS OUT OF GEAR 10 2 FAULTY CLUTCH 10 2 OVERHEATING 10 3 OVERCOOLING 10 3 POOR BRAKING PERFORMANCE 10 3 FAULTY FRONT FORK LEGS 10 3 UNSTABLE HANDLING 10 3 FAULTY LIGHTING SYSTEM 10 4 ...

Page 384: ...gged or damaged fuel hose 2 Fuel pump Faulty fuel pump 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 4 Ignition coi...

Page 385: ...DOES NOT MOVE Shift shaft Bent shift shaft Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Sh...

Page 386: ...em Leaking brake fluid Defective master cylinder kit Faulty brake caliper kit Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS28660 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect o...

Page 387: ...nt frame Damaged steering head pipe Improperly installed bearing race EAS1DX3245 FAULTY LIGHTING SYSTEM Headlight does not come on Fuse open circuit Wrong headlight bulb Too many electrical accessories Hard charging Incorrect connection Improperly grounded circuit Poor contacts main switch Burnt out headlight bulb Headlight bulb burnt out Wrong headlight bulb Faulty battery Faulty rectifier regula...

Page 388: ...ant temperature sensor 31 Intake air temperature sensor 32 Joint connector 33 Engine stop switch 34 Speed sensor 35 Multi function display 36 Fuel sender 37 Resistor 38 Coupler for connecting option al part 39 Diode 40 Joint connector 41 Joint connector 42 Connector 43 Headlight 44 Taillight EAS1DX3248 COLOR CODE B Black Br Brown Ch Chocolate Dg Dark green G Green L Blue Lg Light green O Orange P ...

Page 389: ...Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha from the inside out Genuine Yamaha Service Manuals Get the same factory manual for your vehicle that the technicians at your authorized Yamaha dealer use Service manuals are available through your Yamaha...

Page 390: ... MANUAL WR450FB 1DX 28199 10 LIT 11626 25 58 WR450FB 2012 q Read this manual carefully before operating this vehicle PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2012 01 1 4 1 E 1DX 28199 10_Hyoshi indd 1 2012 01 19 16 15 01 ...

Page 391: ...r B B B Y W B B B B B B Br R L Y B B B W W W W W W B R B R B R B L Gy B R R L G Br L B R Br Y W R Br Br L Br L Br Br Br G B B B G G B L B L B L B L B L B L ON OFF Y G L B L Y G OFF START Br L W R L B 15A Br B Br B Br L G Br B B R B R B R B Sb Sb G Y G Y Br W Br W B L B L G G L L L L R R R R R R R B L B L B L B L B L B L B L B G Br L B W R R R Br Br Br B B B B B L B L Br Br B L R L R Sb O O O R L S...

Page 392: ...WR450FB 2012 WIRING DIAGRAM OFF START ON OFF 15A ON OFF ...

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