Yamaha WR450FN 2022 Owner'S Service Manual Download

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FRONT BRAKE

4-22

4. Check:

•

Brake fluid level
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-23.

5. Check:

•

Brake lever operation
A softy or spongy feeling



Bleed the brake

system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-25.

EAM30030

REMOVING THE FRONT BRAKE CALIPER

TIP

Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.

1. Remove:

•

Union bolt

•

Copper washer

•

Brake hose

TIP

Put the end of the brake hose into a container
and pump out the brake fluid.

EAM30031

DISASSEMBLING THE FRONT BRAKE

CALIPER

1. Remove:

•

Brake caliper piston “1”

•

Brake caliper piston seal kit “2”

a. Blow compressed air into the brake hose

joint opening to force out the piston from
the brake caliper.

WARNING

EWA13550

• Cover the brake caliper piston with a rag.

Be careful not to get injured when the pis-

ton is expelled from the brake caliper.

• Never try to pry out the brake caliper pis-

ton.

b. Remove the brake caliper piston dust seal

and the brake caliper piston seal.

EAM30032

CHECKING THE FRONT BRAKE CALIPER

1. Check:

•

Brake caliper piston “1”
Rust/scratches/wear



Replace the brake

caliper piston.

•

Brake caliper cylinder “2”
Scratches/wear



Replace the brake caliper

assembly.

•

Brake caliper body “3”
Cracks/damage



Replace the brake caliper

assembly.

•

Brake fluid delivery passages
(brake caliper body)
Obstruction



Blow out with compressed air.

WARNING

EWA19220

When the brake caliper is disassembled, re-

place the brake caliper piston seal and the

brake caliper piston dust seal with new ones.

2. Check:

•

Brake caliper bracket
Crack/damage



Replace.

EAM30033

ASSEMBLING THE FRONT BRAKE CALIPER

WARNING

EWA19230

• Before installation, clean and lubricate the

internal parts. Use new brake fluid for

Summary of Contents for WR450FN 2022

Page 1: ...Read this manual carefully before operating this vehicle 2022 OWNER S SERVICE MANUAL WR450F WR450FN LIT 11626 35 44 BDB 2819U 11...

Page 2: ...cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wea...

Page 3: ...ANUAL 2022 by Yamaha Motor Corporation U S A First edition June 2021 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expres...

Page 4: ...manual is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowl edge and skill conce...

Page 5: ...EAM20093 YAMAHA MOTOR CORPORATION U S A WR MOTORCYCLE LIMITED WARRANTY...

Page 6: ...teps 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 removal or a disassemb...

Page 7: ...TION 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 clea...

Page 8: ......

Page 9: ...GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 TUNING 10 EAM10003 TABLE OF CONTENTS...

Page 10: ......

Page 11: ...ECTING OPTIONAL PART 1 7 IMPORTANT INFORMATION 1 8 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 8 REPLACEMENT PARTS 1 8 GASKETS OIL SEALS AND O RINGS 1 8 LOCK WASHERS PLATES AND COTTER PINS 1 9 BEARINGS...

Page 12: ...HANDLING NOTE 1 32 STARTING A COLD ENGINE 1 32 STARTING A WARM ENGINE 1 33 BREAK IN PROCEDURES 1 33 SHIFTING 1 33 MAINTENANCE AFTER BREAK IN 1 35 MAJOR MAINTENANCE 1 35 AIR FILTER MAINTENANCE 1 35 TOR...

Page 13: ...e riding 2 This motorcycle is designed to carry the oper ator only No passengers 3 The failure of motorists to detect and recog nize motorcycles in traffic is the predominat ing cause of automobile mo...

Page 14: ...Many companies with no connection to Yamaha manufacture parts and accessories or offer oth er modifications for Yamaha vehicles Yamaha is not in a position to test the products that these aftermarket...

Page 15: ...e fuel cock if equipped is in the OFF position and that there are no fuel leaks 3 Point the front wheel straight ahead on the trailer or in the truck bed and choke it in a rail to prevent movement 4 S...

Page 16: ...BELS Please read the following important labels carefully before operating this vehicle 2 4 1 3 4AA 22259 80 WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read...

Page 17: ...13 15 16 17 18 19 20 21 22 5 6 8 7 9 10 12 11 3 4 2 1 Clutch lever 2 Multi function display 3 Engine trouble warning light 4 Fuel level warning light 5 Front brake lever 6 Throttle grip 7 Start switch...

Page 18: ...your vehicle EAM30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the frame EAM30003 ENGINE SERIAL NUMBER The engine serial number 1 is stamped...

Page 19: ...other foreign materials from entering the inside when the fuel hose is discon nected EAM30008 COUPLER FOR CONNECTING OPTIONAL PART The coupler 1 is used for connecting the op tional Power Tuner and so...

Page 20: ...ed to the chassis paint and plating will be damaged Therefore rinse it out with water in good time WARNING EWA18970 Coolant is potentially harmful and should be handled with special care If it enters...

Page 21: ...il seal make sure that its main lip faces the oil chamber the target to be sealed Before installation always apply a light coat of grease to the oil seal lip NOTICE ECA13300 Do not spin the bearing wi...

Page 22: ...y dangerous TIP If a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct ba...

Page 23: ...ti function display goes off Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never insert the tester probes...

Page 24: ...th sections of the connec tor securely and then disconnect the con nector 2 Check Lead Coupler Connector Moisture Dry with compressed air Rust stains Connect and disconnect sev eral times 3 Check All...

Page 25: ...f 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 Digital circuit tester CD732...

Page 26: ...ing with YM YU or ACC For others use tool number starting with 90890 Tool name Tool No Illustration Reference pages Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A192...

Page 27: ...3 27 4 57 Spoke nipple wrench 6 7 90890 01521 Spoke nipple wrench 6 7 YM 01521 3 33 Timing light 90890 03141 Timing light YU 03141 3 35 Cap bolt ring wrench 90890 01501 Cap bolt ring wrench YM 01501...

Page 28: ...ing compressor adapter 22 mm YM 04108 5 26 5 30 Valve guide remover installer set 5 5 90890 04016 Valve guide remover 5 5 mm YM 01122 5 28 Valve guide installer 5 5 90890 04015 Valve guide installer 5...

Page 29: ...42 5 49 5 52 Crankcase separating tool 90890 04152 Crankcase separating tool YU A9642 5 68 Crankshaft installer pot 90890 01274 Installing pot YU 90058 5 69 Crankshaft installer bolt 90890 01275 Bolt...

Page 30: ...ooling system tester kit YU 24460 A 6 4 6 4 Radiator cap tester adapter 90890 01352 Pressure tester adapter YU 33984 6 4 6 4 Pressure gauge 90890 03153 Pressure gauge YU 03153 7 8 Fuel pressure adapte...

Page 31: ...0 spark checker YM 34487 8 65 Test harness speed sensor 5TJ 3P 90890 03228 Test harness speed sensor 5TJ 3P YU 03228 8 68 Test harness S pressure sensor 3P 90890 03207 Test harness S pressure sensor 3...

Page 32: ...e The electrical circuit of the warning light can be checked by pushing the start switch The warn ing light should come on for a few seconds and then go off If the warning light does not come on initi...

Page 33: ...nob toward a turns ON the start er resulting in a larger angle of throttle valve TIP When operating the throttle grip in the closing di rection the starter knob 1 moves in the direc tion b as shown an...

Page 34: ...INSTRUMENT AND CONTROL FUNCTIONS 1 22 Install the fuel tank cap cover after placing the bands 3 all the way in under the seat 1 1 2 2 3 3 a a a 2 2...

Page 35: ...button to change the meter dis play The display will change in the following order ODO TRIP A TRIP B Clock Timer Accumulated fuel consumption ODO TIP To reset the digits select the meter involved and...

Page 36: ...o perform a new mea surement long push the A button for 1 second or more to reset the timer Manual start 1 Push the A button and B button simultane ously to start the timer measurement 2 Push the A bu...

Page 37: ...sumption correction Setting the tire di ameter correction Setting the backlight brightness TIP If one of the following situations occurs while performing the setting mode the setting value that is dis...

Page 38: ...IP The digits capable of setting go on flashing 2 Push the A button to set the minute The set ting of the time will then be kept and the dis play of the multifunction meter will shift to the unit disp...

Page 39: ...If the outer diameter of a tire varies with tire wear or tire pressure it can be corrected in the follow ing manner TIP The initial value is preset with approximately 700 mm 27 56 in as 100 If the out...

Page 40: ...MULTI FUNCTION DISPLAY 1 28 TIP When terminating the setting mode long push the engine stop switch to turn off the display and terminate the setting mode...

Page 41: ...MULTI FUNCTION DISPLAY 1 29...

Page 42: ...Measurement starts as the machine moves A button B button Timer in operation Timer not in operation Reset timer A button B button A short push on the button changes the operation in the arrowed direct...

Page 43: ...er 7 Accumulated fuel consumption 8 Speedometer 9 Speed 10 SETTING MODE 11 Setting the backlight brightness 12 Setting the clock time hour 13 Setting the clock time minute 14 Setting the unit 15 Setti...

Page 44: ...The exhaust fumes are poisonous they can cause loss of consciousness and death in a very short time Always operate the ma chine in a well ventilated area NOTICE ECA25910 If the throttle is open the a...

Page 45: ...left idling for 7 minutes If the engine stops push the start switch to restart the engine 2 Make a pit stop and check mounted areas for looseness oil leaks or other problems 3 Then drive it for about...

Page 46: ...ch lever in 5 Shift the transmission into second gear Make sure not to shift the transmission into the neutral position 6 Open the throttle part way and gradually re lease the clutch lever 7 Follow th...

Page 47: ...and nuts Check for looseness in mounted areas of parts as well as engine mounting bolts and engine brackets 2 For the chassis Check welds and mounted areas of the frame the swingarm the link the brac...

Page 48: ...frame Link to rear shock absorber Link to swingarm Mounting of rear shock absorber Rear shock absorber and frame Mounting of swingarm Tightening of pivot shaft Wheel s Mounting of wheel Front Tighten...

Page 49: ...t pedal Shift pedal to shift shaft Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rea...

Page 50: ...y rinse the area off with water immediately dry it and then apply a corrosion protec tion spray Improper cleaning can damage plastic parts such as cowlings panels wind shields headlight lenses meter l...

Page 51: ...nd nickel plated sur faces 5 Use spray oil as a universal cleaner to re move any remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry c...

Page 52: ...k plug and then install the spark plug and the spark plug cap WARNING To pre vent damage or injury from sparking make sure to ground the spark plug electrodes while turning the engine over 4 Lubricate...

Page 53: ...TIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 5 ELECTRICAL SPECIFICATIONS 2 8 TIGHTENING TORQUES 2 10 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 10 ENGINE TIGHTENING TORQUES 2 11 CHASSI...

Page 54: ...ght 955 mm 37 6 in Wheelbase 1480 mm 58 3 in Ground clearance 320 mm 12 60 in Weight Curb weight 119 kg 262 lb Riding capacity 1 person Shift up points 1st 2nd 20 km h 12 mph 2nd 3rd 30 km h 19 mph 3r...

Page 55: ...y Oil change 0 63 L 0 67 US qt 0 55 Imp qt With oil filter removal 0 65 L 0 69 US qt 0 57 Imp qt Quantity disassembled 0 90 L 0 95 US qt 0 79 Imp qt Oil filter Oil filter type Cartridge Cooling system...

Page 56: ...3 in Wear limit 97 060 mm 3 8213 in Piston Piston to cylinder clearance 0 010 0 045 mm 0 0004 0 0018 in Diameter 96 955 96 970 mm 3 8171 3 8177 in Measuring point from piston skirt bottom 9 0 mm 0 35...

Page 57: ...08 mm 0 0032 in Drive axle runout limit 0 08 mm 0 0032 in Secondary reduction ratio 3 846 50 13 Final drive Chain Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter...

Page 58: ...ressure measured on cold tires Front 100 kPa 1 00 kgf cm 15 psi Rear 100 kPa 1 00 kgf cm 15 psi Front brake Type Hydraulic single disc brake Brake disc thickness limit 2 5 mm 0 10 in Brake disc runout...

Page 59: ...e from the start position Soft 20 Adjustment value from the start position STD 12 Adjustment value from the start position Hard 0 Rear suspension Type Swingarm link suspension Spring Coil spring Shock...

Page 60: ...nt Click Adjustment value from the start position Soft 20 Adjustment value from the start position STD 10 Adjustment value from the start position Hard 0 Drive chain Size 520 Chain type Sealed type Nu...

Page 61: ...HR Headlight Bulb type Halogen bulb Bulb wattage Headlight HS1 35 0 W 35 0 W Brake tail light LED Meter lighting EL Electroluminescent Indicator light Fuel level warning light LED Engine trouble warni...

Page 62: ...ELECTRICAL SPECIFICATIONS 2 9 Radiator fan motor fuse 5 0 A Spare fuse 15 0 A...

Page 63: ...To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specif...

Page 64: ...nut M14 1 50 N m 5 0 kgf m 37 lb ft Use a lock washer Balancer nut M10 1 45 N m 4 5 kgf m 33 lb ft Use a lock washer Timing chain guide stopper plate exhaust side M6 1 10 N m 1 0 kgf m 7 4 lb ft Timin...

Page 65: ...cessing screw M36 1 10 N m 1 0 kgf m 7 4 lb ft Timing mark accessing screw M14 1 6 N m 0 6 kgf m 4 4 lb ft Drive sprocket cover bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Crankcase bearing cover plate screw...

Page 66: ...N m 1 0 kgf m 7 4 lb ft Shift pedal bolt M6 1 12 N m 1 2 kgf m 8 9 lb ft Generator rotor nut M12 1 65 N m 6 5 kgf m 48 lb ft Stator coil screw M5 3 10 N m 1 0 kgf m 7 4 lb ft Crankshaft position senso...

Page 67: ...stop switch screw M3 1 0 5 N m 0 05 kgf m 0 37 lb ft Start switch M3 1 0 5 N m 0 05 kgf m 0 37 lb ft Lower ring nut M28 1 See TIP Damper assembly front fork M51 2 30 N m 3 0 kgf m 22 lb ft Inner tube...

Page 68: ...disc bolt M6 6 12 N m 1 2 kgf m 8 9 lb ft Rear brake disc bolt M6 6 12 N m 1 2 kgf m 8 9 lb ft Footrest bracket bolt M10 4 55 N m 5 5 kgf m 41 lb ft Sidestand bolt M10 1 35 N m 3 5 kgf m 26 lb ft Rear...

Page 69: ...M8 1 16 N m 1 6 kgf m 12 lb ft Drive chain tensioner bolt lower side M8 1 16 N m 1 6 kgf m 12 lb ft Bolt drive chain support M6 1 7 N m 0 7 kgf m 5 2 lb ft Drive chain support nut M6 2 7 N m 0 7 kgf m...

Page 70: ...front side M6 4 7 N m 0 7 kgf m 5 2 lb ft Rear fender bolt rear side M6 2 16 N m 1 6 kgf m 12 lb ft Headlight body and headlight stay bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Multi function meter screw M5...

Page 71: ...TIGHTENING TORQUES 2 18...

Page 72: ...CABLE ROUTING DIAGRAM 2 19 EAM20152 CABLE ROUTING DIAGRAM Frame and engine left side view...

Page 73: ...lock part of the plastic locking tie to rear side of the vehicle Cut the end of the plastic locking tie H Route the starter motor lead along the cylin der body without slack I Route the gear position...

Page 74: ...CABLE ROUTING DIAGRAM 2 21 Frame and engine right side view...

Page 75: ...ead termi nal it can face either way F Route the fuel hose in front of the fuel pump G After connecting the fuel pump coupler attach the cover H Fasten the starter relay lead and the starter motor lea...

Page 76: ...CABLE ROUTING DIAGRAM 2 23 Handlebar front view...

Page 77: ...the end of the plastic locking tie to the right side of the vehi cle The excess should be cut D Connect the headlight lead to the headlight E After fastening the speed sensor lead route it as U lette...

Page 78: ...CABLE ROUTING DIAGRAM 2 25 Frame and engine top view...

Page 79: ...een the fuel tank bracket and tools when tightening the bolts is accepted E Right side of the vehicle F 10 G Install the plug cap so it faces to the right side of the vehicle H Install the collar with...

Page 80: ...CABLE ROUTING DIAGRAM 2 27 Frame and battery top view...

Page 81: ...ative battery lead with their battery sides downward C No slack in this section D No slack to the rear side of the vehicle E Absorb the slack in this section F Connect the positive battery lead and st...

Page 82: ...CABLE ROUTING DIAGRAM 2 29 Rear brake right side view...

Page 83: ...e hose holders C Route the rear brake hose so that it is not bent as shown by the double dash line D Route the rear brake hose and spring so that they do not interfere with each other E Make sure that...

Page 84: ...CABLE ROUTING DIAGRAM 2 31 Front brake front view and right side view...

Page 85: ...speed sensor lead B Clamp securely the speed sensor lead to the hook of the protector C Install the front brake hose with its paint aligning with the upper end of the clamp The circumference direction...

Page 86: ...CABLE ROUTING DIAGRAM 2 33 Taillight top view and right side view...

Page 87: ...CABLE ROUTING DIAGRAM 2 34 1 Taillight lead 2 Clamp 3 Taillight A Pass the taillight lead to the groove of the rear fender B There should be no slack of the taillight lead...

Page 88: ...CABLE ROUTING DIAGRAM 2 35...

Page 89: ...G THE FUEL LINE 3 18 CHECKING THE CYLINDER HEAD BREATHER HOSE 3 18 CHECKING THE EXHAUST SYSTEM 3 19 CHECKING THE COOLANT LEVEL 3 20 CHECKING THE COOLING SYSTEM 3 21 CHANGING THE COOLANT 3 21 CHASSIS 3...

Page 90: ...G THE CHASSIS FASTENERS 3 34 CHECKING AND LUBRICATING THE CABLES 3 34 LUBRICATING THE BRAKE LEVER 3 34 LUBRICATING THE CLUTCH LEVER 3 34 LUBRICATING THE PEDAL 3 34 CHECKING THE SIDESTAND 3 34 LUBRICAT...

Page 91: ...Odometer readings 600 mi 1000 km or 1 month 1800 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...

Page 92: ...chain slack alignment 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...

Page 93: ...ce to the list below Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills No Item Routine After break in Every race Every third...

Page 94: ...nt Every two years Inspect hoses 22 Outside nuts and bolts Retighten 23 Air filter Clean and lubricate Replace 24 Oil filter Replace 25 Engine guard Replace 26 Frame Clean and inspect 27 Fuel tank fue...

Page 95: ...hten 37 Relay arm connect ing rod Inspect lube and retighten 38 Sidestand Lubricate 39 Steering head Inspect free play and retighten Clean and lubricate Replace bearings 40 Tire wheels Inspect air pre...

Page 96: ...23 3 23 3 24 3 24 3 24 3 24 3 25 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 26 4 70 4 70 4 71 4 71 4 71 Wheels Check for excessive wear and...

Page 97: ...eft right Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 ECU Engine Control Unit 2 Remove Spark plug Cylinder head cover Refer to CAMSHAFT on page 5...

Page 98: ...oper valve clearance from the adjusting pad se lection table TIP There are 25 types of adjusting pads ranging from 1 20 mm 0 0472 in to 2 40 mm 0 0945 in in increments of 0 05 mm 0 0020 in The field w...

Page 99: ...ir numbers facing upward f Install the camshafts exhaust and intake Refer to CAMSHAFT on page 5 13 g Measure the valve clearance again h If the valve clearance is out of specifica tion repeat adjustin...

Page 100: ...80 185 190 195 200 205 210 215 220 225 230 235 240 0 70 0 74 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 75 0 79 180 185 190 195 200 205 210 215 220 225 230 235 240 0 80 0 84 185 190 195...

Page 101: ...15 220 225 230 235 240 0 70 0 74 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 75 0 79 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 80 0 84 180 185 190 195 200 205 210 215...

Page 102: ...3 Install Digital tachometer TIP Get the high tension cord 1 of the ignition coil pinched in the detector a of the digital tachom eter 4 Measure Engine idling speed Out of specification Regulate 5 Adj...

Page 103: ...2 as shown 2 Remove Spark plug cap Spark plug Refer to CAMSHAFT on page 5 13 NOTICE ECA24410 In order not to allow the dirt accumulated around the spark plug to drop from the spark plug hole into the...

Page 104: ...cause clutch slippage Therefore do not add any chemical additives Do not allow foreign material to enter the crankcase EAM30225 CHANGING THE ENGINE OIL Stand the vehicle upright on a level surface 1...

Page 105: ...eck Engine oil pressure a Start the engine WARNING EWA19130 Always keep the engine idling speed during the checkup without increasing the engine speed b Look at the oil level check window 1 and then m...

Page 106: ...btained on the handlebar side use the adjuster on the clutch cable side Clutch cable side a Slide the clutch cable cover b Loosen the locknut 1 c Turn the adjuster 2 until the specified clutch lever f...

Page 107: ...hat the element is evenly permeated with the oil c Wrap the element in a clean cloth rub the element gently and wipe off any excess oil TIP The element should be permeated with oil so that it is wet b...

Page 108: ...tank cap cover EAM30335 CHECKING THE THROTTLE BODY JOINT 1 Check Throttle body joint 1 Crack damage Replace EAM30222 CHECKING THE FUEL LINE 1 Remove Seat Side cover left right Air scoop left right Ref...

Page 109: ...the spark arrester bolts 2 c Remove the tail pipe 3 tail pipe gasket 4 and spark arrester 5 TIP Pull the spark arrester out of the muffler d Remove the spark arrester gasket 6 e Clean the spark arres...

Page 110: ...owly turn the radiator cap counter clockwise toward the detent to allow any re sidual pressure to escape When the hissing sound has stopped press down on the radi ator cap and turn it counterclockwise...

Page 111: ...cap when the en gine is hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel ov...

Page 112: ...ifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is...

Page 113: ...TING THE REAR DISC BRAKE 1 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting bolt 2 until the brake pedal is in the correct position c Tighten the locknut WARNING EWA19150 A soft...

Page 114: ...f the brake pads 1 Operate the brake 2 Check Front brake pad Wear indicator grooves 1 almost touch the brake disc Replace the brake pads as a set Refer to FRONT BRAKE on page 4 16 EAM30232 CHECKING TH...

Page 115: ...er the brake system considerably lengthening the bleeding proce dure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the t...

Page 116: ...ve chain guide installation bolt with a force of about 50 N 5 0 kgf 37 lbf 4 Check Drive chain slack a Out of specification Regulate TIP Measure drive chain slack between the drive chain guide and the...

Page 117: ...falling over 2 Check Steering head Grasp the bottom of the front fork legs and gently rock the front fork Blinding looseness Adjust the steering head 3 Remove Handlebar Refer to HANDLEBAR on page 4 37...

Page 118: ...ork leg Oil leaks between inner tube and outer tube 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...

Page 119: ...just Compression damping a Turn the adjuster 1 in the direction of a or b to make an adjustment TIP Although the total number of clicks of a damping force adjusting mechanism may not exactly match the...

Page 120: ...ion Rear suspension link smooth action Sit astride the seat and shake your body up and down several times to check whether the rear shock absorber assembly operates smoothly Unsmooth operation Correct...

Page 121: ...necessary Compression damping for fast compres sion damping NOTICE ECA24370 Do not turn the adjuster forcibly beyond its adjusting range 1 Adjust Compression damping for fast compression damping a Tur...

Page 122: ...clicks of each damping force adjusting mechanism and to modify the specifications as necessary EAM30240 CHECKING THE SWINGARM OPERATION 1 Check Swingarm smooth action Swingarm free play Refer to SWIN...

Page 123: ...ll sound flat 2 Tighten Spoke with a spoke nipple wrench 1 TIP Do not give a half turn 180 or more for one tightening Make sure that tightening after a break in is done until the initial looseness in...

Page 124: ...LUBRICATING THE BRAKE LEVER 1 Lubricate the pivoting points and metal to metal moving parts of the following parts Brake lever EAM30503 LUBRICATING THE CLUTCH LEVER 1 Lubricate the pivoting points and...

Page 125: ...eft crankcase cover is within the firing range b on the generator rotor Incorrect firing range Check generator ro tor and crankshaft position sensor 5 Install Timing mark accessing screw EAM30339 REPL...

Page 126: ...he head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly c...

Page 127: ...ISC 4 20 REPLACING THE FRONT BRAKE PADS 4 20 REMOVING THE FRONT BRAKE CALIPER 4 22 DISASSEMBLING THE FRONT BRAKE CALIPER 4 22 CHECKING THE FRONT BRAKE CALIPER 4 22 ASSEMBLING THE FRONT BRAKE CALIPER 4...

Page 128: ...NG THE STEERING HEAD 4 57 REAR SHOCK ABSORBER ASSEMBLY 4 60 HANDLING THE REAR SHOCK ABSORBER 4 63 DISPOSING OF A REAR SHOCK ABSORBER 4 63 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 63 CHECKING THE RE...

Page 129: ...arks 1 Seat 1 2 Side cover left 1 3 Negative battery lead 1 Disconnect 4 Positive battery lead 1 Disconnect 5 Battery band 1 6 Battery 1 7 Cover 1 8 Starter relay 1 9 Main relay 1 10 Radiator fan moto...

Page 130: ...er case cover 1 Refer to CLEANING THE AIR FILTER ELE MENT on page 3 16 2 Air scoop left 1 3 Air scoop right 1 4 Side cover right 1 5 Rear fender 1 5 4 1 3 2 1 3 N m 0 13 kgf m 0 95 lb ft 7 N m 0 7 kgf...

Page 131: ...ht coupler 1 Disconnect 3 Headlight unit 1 4 Speed sensor coupler 1 Disconnect 5 Multi function meter coupler 1 Disconnect 6 Multi function meter 1 7 Meter bracket 1 4 2 6 7 5 1 3 2 3 8 N m 0 38 kgf m...

Page 132: ...n serting the grooves c into the ribs d of the air filter case and inserting the projection e into the slot f in the air filter case install the air scoop and secure it with the bolts EAM30459 REMOVIN...

Page 133: ...GENERAL CHASSIS 4 5 a Projection b Slot c Rib side cover d Rib rear fender a a a 1 1 c c b b d d...

Page 134: ...ge 4 45 1 Front wheel axle pinch bolt 4 Loosen 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Speed sensor bracket 1 5 Speed sensor 1 6 Front wheel 1 7 Collar 2 8 Oil seal 2 9 Bearing 2 10 Brake disc...

Page 135: ...attempt to disassemble it If faulty replace with a new one Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the speed sensor Do not drop or shock the speed sensor or t...

Page 136: ...P After tightening the spokes measure the wheel runout 5 Measure Radial wheel runout a Lateral wheel runout b Out of specification Repair replace 6 Check Collar Damage wear Replace 7 Check Bearing Fro...

Page 137: ...or numbers facing outward NOTICE ECA24420 Install the bearing by pressing its outer race parallel TIP Use a socket 5 that matches the diameter of the bearing outer race and that of the oil seal 4 Inst...

Page 138: ...eel sensor lead for twists 3 Install Front wheel axle 1 TIP Apply the lithium soap based grease to the front wheel axle 4 Tighten Front wheel axle nut 1 NOTICE ECA24430 Before tightening the front whe...

Page 139: ...If there is any defective part repair or replace the de fective part TIP Measure the distance between the front wheel sensor rotor and front wheel sensor in several places in one rotation of the front...

Page 140: ...the ground 1 Rear wheel axle 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 6 2 5 9 6 4 6 1 6...

Page 141: ...2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 33 and CHECKING THE WHEELS on page 3 33 3 Check Spoke Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 33 4 Measu...

Page 142: ...umbers facing outward NOTICE ECA24440 Install the bearing by pressing its outer race parallel TIP Use a socket 6 that matches the diameter of the bearing outer race and that of the oil seal 2 Install...

Page 143: ...the lithium soap based grease to the rear wheel axle 4 Install Drive chain puller right 1 Washer 2 Rear wheel axle nut 3 TIP Temporarily tighten the rear wheel axle nut at this point 5 Adjust Drive ch...

Page 144: ...ge 3 25 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 1 8 Front brake caliper assembly 1 9 Front brake caliper bracket...

Page 145: ...BRAKE 4 17 Disassembling the front brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston kit 2 2 Brake caliper piston seal kit 2 3 Bleed screw 1 1 2 3 S S 2 5 N m 0 5 kgf m 3 7 l...

Page 146: ...on bolt 1 3 Copper washer 2 4 Front brake hose 1 5 Brake master cylinder reservoir cap 1 6 Brake master cylinder reservoir diaphragm 1 7 Front brake master cylinder float 1 8 Front brake master cylind...

Page 147: ...FRONT BRAKE 4 19 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 BF 1 S New...

Page 148: ...inutes and get im mediate medical attention EAM30029 CHECKING THE FRONT BRAKE DISC 1 Check Front brake disc Damage galling Replace 2 Measure Brake disc thickness Measure the brake disc thickness at a...

Page 149: ...euse the drained brake fluid c Tighten the bleed screw d Install the brake pads 3 and the pad pin TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tigh...

Page 150: ...er piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston dust seal and th...

Page 151: ...aligned with the paint b on the brake hose 4 Pour brake fluid to the brake master cylinder reservoir up to the specified level WARNING EWA13090 Use only the designated brake fluid Other brake fluids...

Page 152: ...r 1 Damage scratches wear Replace the brake master cylinder assembly Brake fluid delivery passages 2 brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder r...

Page 153: ...e master cylinder holder with the UP mark facing up First tighten the upper bolt then the lower bolt 2 Install Copper washer Brake hose Union bolt WARNING EWA13531 Proper brake hose routing is essenti...

Page 154: ...ter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts T...

Page 155: ...6 Brake pad pin 1 7 Rear brake pad assembly 1 8 Brake pad shim left 1 9 Brake pad shim right 1 10 Brake pad shim heat insulator 2 11 Brake pad shim bracket 1 12 Rear brake caliper bracket 1 13 Brake p...

Page 156: ...AR BRAKE 4 28 Disassembling the rear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston kit 1 2 Brake caliper piston seal kit 1 3 Bleed screw 1 3 5 N m 0 5 kgf m 3 7 lb ft 1 2...

Page 157: ...age 3 25 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Split pin 1 5 Washer 1 6 Pin 1 7 Brake master cylinder reservoir cap 1 8 Brake master cylinder reservoir diaphragm plate 1 9 Brake master cyl...

Page 158: ...REAR BRAKE 4 30 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder joint 1 2 Brake master cylinder kit 1 2 1 New S BF...

Page 159: ...ush with water for 15 minutes and get im mediate medical attention EAM30041 CHECKING THE REAR BRAKE DISC 1 Check Brake disc Damage galling Replace 2 Measure Brake disc thickness Measure the brake disc...

Page 160: ...l the brake pads 3 and the pad pin 4 TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point e Install the brake caliper 5 a...

Page 161: ...iper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston dust seal and...

Page 162: ...ate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brak...

Page 163: ...eplace EAM30050 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use s...

Page 164: ...r 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 fluids may result in a harmful chemical reaction l...

Page 165: ...7 Throttle cable pull 1 Disconnect 8 Throttle cable return 1 Disconnect 9 Right grip 1 10 Tube guide 1 11 Start switch 1 12 Left grip 1 13 Upper handlebar holder 2 14 Handlebar 1 15 Lower handlebar ho...

Page 166: ...M30054 INSTALLING THE HANDLEBAR 1 Stand the vehicle upright on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Damper 1 Lower hand...

Page 167: ...position 3 Tighten Lower handlebar holder nut 4 Install Clutch lever holder 1 Clutch lever 2 TIP The clutch lever holder 1 should be installed according to the dimensions shown 5 Install Engine stop s...

Page 168: ...faces straight upward 7 Install Clutch cable 1 TIP Before installation apply the lithium soap based grease to the clutch cable end 8 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER F...

Page 169: ...le grip 3 moves smoothly If it does not retighten the screws for adjustment 13 Install Rubber cover 1 Cover throttle cable housing 2 14 Install Start switch 1 Front brake master cylinder assembly 2 Fr...

Page 170: ...HANDLEBAR 4 42 15 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 12 Throttle grip free play 3 0 6 0 mm 0 12 0 24 in 2 5 1 4 3 4...

Page 171: ...Front brake caliper Refer to FRONT BRAKE on page 4 16 Headlight Refer to GENERAL CHASSIS on page 4 1 1 Protector 2 2 Upper bracket pinch bolt 2 Loosen 3 Damper assembly 1 Loosen 4 Lower bracket pinch...

Page 172: ...1 7 Inner tube 1 8 Outer tube 1 9 Piston metal 1 10 Protector guide 1 11 Slide metal 1 12 Washer 1 13 Oil seal 1 14 Base valve 1 15 Damper assembly 1 16 Upper spring seat 1 LS 15 2 8 10 12 13 5 4 1 7...

Page 173: ...t fork leg EAM30056 DISASSEMBLING THE FRONT FORK LEGS 1 Drain Fork oil 2 Remove Adjuster 1 from the inner tube TIP While compressing the inner tube 2 set the cap bolt ring wrench 4 between the inner t...

Page 174: ...erously weaken it 2 Check Outer tube Scratches wear damage Replace 3 Measure Fork spring free length a Out of specification Replace 4 Check Damper assembly 1 Bend damage Replace O ring 2 Wear damage R...

Page 175: ...er tube bushing Slide metal Oil seal Copper washer Before assembling the front fork leg make sure that all of the components are clean 1 Stretch the damper assembly fully 2 Fill Damper assembly NOTICE...

Page 176: ...ion Unless the damping force adjuster is fully loos ened correct damping characteristic cannot be obtained after installation 7 Install Base valve 1 to the damper assembly 2 TIP First bring the damper...

Page 177: ...e damper assem bly 12 Allow the overflowing oil to escape at the hole a in the damper assembly TIP The overflow measures about 10 cm 0 34 US oz 0 35 Imp oz 13 Check Damper assembly smooth movement Tig...

Page 178: ...ct the oil seal lip 15 Install Piston metal 1 TIP Install the piston metal onto the slot on inner tube 16 Install Outer tube 1 to the inner tube 2 17 Install Slide metal 1 Washer 2 to the outer tube T...

Page 179: ...t the steps 14 to 20 22 Measure Distance a Out of specification Turn the locknut to specification 23 Install Upper spring seat 1 Fork spring 2 to the damper assembly 3 TIP Install the upper spring sea...

Page 180: ...the damper assembly 4 TIP While compressing the inner tube 5 set the cap bolt ring wrench 7 between the inner tube and locknut 6 Fully finger tighten the adjuster onto the damp er assembly 27 Measure...

Page 181: ...ghten the damper assembly 32 Install Protector guide 1 EAM30059 INSTALLING THE FRONT FORK LEGS 1 Install Front fork 1 TIP Temporarily tighten the lower bracket pinch bolts Do not tighten the upper bra...

Page 182: ...fork protector 6 Install Protector 1 Bolt protector 2 7 Adjust Rebound damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position Cap bolt ring wre...

Page 183: ...FRONT FORK 4 55 8 Adjust Compression damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 1 1...

Page 184: ...4 1 Handlebar Refer to HANDLEBAR on page 4 37 1 Front fender 1 2 Steering stem nut 1 3 Front fork leg 2 Refer to FRONT FORK on page 4 43 4 Upper bracket 1 5 Steering ring nut 1 6 Lower bracket 1 7 Be...

Page 185: ...ace 3 Replace Bearing Bearing race a Remove the bearing race from the steer ing head pipe with a long rod 1 and a hammer b Remove the bearing race from the lower bracket with a chisel 2 and a hammer c...

Page 186: ...teering ring nut with its stepped side a facing downward Tighten the steering ring nut with a steering nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 27 5 Check the steering...

Page 187: ...teering ring nut little by lit tle 10 Adjust Front fork top end a 11 Tighten Upper bracket pinch bolt 1 Lower bracket pinch bolt 2 WARNING EWA19330 Tighten the lower bracket to specified torque If tor...

Page 188: ...right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Rear shock absorber assembly lower bolt 1 2 Rear shock absorber assembly upper bolt 1 3 Rear shock absorber assem...

Page 189: ...r shock absorber assembly Order Job Parts to remove Q ty Remarks 13 Collar 2 14 O ring 2 15 Dust seal 2 16 Bushing 1 17 Stopper ring 1 M 56 N m 5 6 kgf m 41 lb ft 53 N m 5 3 kgf m 39 lb ft M M LS New...

Page 190: ...Disassembling the 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 5 3 5 6 1 6 5 4 5 5 4 6 6 5 3 2 4 6 6 3 4 4 M M M M M...

Page 191: ...er be sure to extract the nitrogen gas from valve 1 WARNING EWA19340 Wear protective glasses to prevent your eyes from damage due to possible gas or metal chips scattered To dispose of a damaged or a...

Page 192: ...asher 2 Oil seal 3 into the relay arm 4 Collar 5 3 Install Bearing 1 Oil seal 2 into the connecting arm 3 Collar 4 EAM30070 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate Bearing lower side D...

Page 193: ...IP When installing the rear shock absorber as sembly lift up the swingarm Install the rear shock absorber assembly upper bolt and connecting arm bolt frame side from the right Install the rear shock a...

Page 194: ...heel off the ground Brake hose holder Refer to REAR BRAKE on page 4 27 Rear brake caliper Refer to REAR BRAKE on page 4 27 Brake pedal bolt Drive chain 1 Collar 2 2 Oil seal 2 3 Thrust bearing 2 4 Bus...

Page 195: ...Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash with kerosene Pivot shaft B...

Page 196: ...SWINGARM 4 68 4 Install Rear wheel Refer to REAR WHEEL on page 4 12 5 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 26 Drive chain slack Maintenance Stand 50 0 60 0 mm 1 97 2 36 in...

Page 197: ...rder Job Parts to remove Q ty Remarks Drive sprocket Refer to ENGINE REMOVAL on page 5 6 1 Drive chain 1 2 Drive sprocket cover 1 3 Bracket 1 4 Drive sprocket nut 1 5 Lock washer 1 6 Drive sprocket 1...

Page 198: ...ength 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 different location each time 2 Ch...

Page 199: ...OCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 13 EAM30079 INSTALLING THE DRIVE CHAIN 1 Install Drive chain NOTICE ECA17410 Be sure to put on safety goggles when work ing TIP...

Page 200: ...rockets this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 26 NOTICE ECA24590 A drive chain that is too tight will overload the engin...

Page 201: ...HEAD 5 22 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 5 22 CHECKING THE CYLINDER HEAD 5 22 INSTALLING THE CYLINDER HEAD 5 22 VALVES AND VALVE SPRINGS 5 25 REMOVING THE VALVES 5 26 CHECKING THE VALVES...

Page 202: ...MOVING THE SEGMENT 5 55 CHECKING THE SHIFT SHAFT 5 55 CHECKING THE STOPPER LEVER 5 55 INSTALLING THE SHIFT SHAFT 5 55 OIL PUMP 5 58 REMOVING THE BALANCER 5 60 CHECKING THE OIL PUMP 5 60 ASSEMBLING THE...

Page 203: ...S 5 1 EAM20185 LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30526 ENGINE OIL LUBRICATION CHART 1 Intake camshaft 2 Exhaust camshaft 3 Piston 4 Oil filter element 5 Oil nozzle 6 Oil pump 7 Oil strainer 8 C...

Page 204: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 2 EAM30507 LUBRICATION DIAGRAMS 1 Camshaft 2 Drive axle 3 Main axle...

Page 205: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 3 1 Connecting rod 2 Oil nozzle 3 Crankshaft...

Page 206: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 4 1 Exhaust camshaft 2 Intake camshaft 3 Oil filter element 4 Oil pump...

Page 207: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 5 1 Oil filter element 2 Oil pump 3 Oil strainer...

Page 208: ...clamp 1 Loosen 4 Exhaust pipe 2 1 5 Exhaust pipe 1 1 6 Gasket 3 7 Exhaust pipe 1 protector 1 8 Silencer cap 1 9 Spark arrester 1 9 5 8 2 6 1 6 6 3 4 7 4 6 New New New 20 N m 2 0 kgf m 15 lb ft 10 N m...

Page 209: ...EL TANK on page 7 1 Air filter case cover Refer to CLEANING THE AIR FILTER ELE MENT on page 3 16 Intake air temperature sensor coupler Refer to THROTTLE BODY on page 7 4 ECU Engine Control Unit Refer...

Page 210: ...on page 7 4 Throttle body Refer to THROTTLE BODY on page 7 4 Clutch cable Refer to CLUTCH on page 5 46 Shift pedal Drive chain Refer to SHIFT SHAFT on page 5 54 Refer to CHAIN DRIVE on page 4 69 1 En...

Page 211: ...2 11 Lower engine bracket inside 2 12 Pivot shaft 1 13 Engine 1 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 34 N m 3 4 kgf m 25 lb ft 85 N m 8 5 kgf m 63 lb ft 90 N m 9 0 kgf m 66 lb ft 34 N m...

Page 212: ...ve this from its low er part toward the right of the chassis EAM30164 INSTALLING THE ENGINE 1 Install Engine 1 from the right side Pivot shaft 2 Engine mounting bolt lower side 3 Lower engine bracket...

Page 213: ...re that the exhaust pipe band 3 does not ride on the projection a on the exhaust pipe 4 or silencer 5 Be sure to insert the projection b into the slot in the exhaust pipe or silencer 3 Install Clamp S...

Page 214: ...ENGINE REMOVAL 5 12 Clamp TIP Tighten while checking that their front and rear joints are inserted in position Bolt exhaust pipe 2 20 N m 2 0 kgf m 15 lb ft Clamp 12 N m 1 2 kgf m 8 9 lb ft T R T R...

Page 215: ...Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Ignition coil Refer to ENGINE REMOVAL on page 5 6 1 Cylinder head breather hose 1 2 Cylinder head cov...

Page 216: ...Timing chain tensioner cap bolt 1 4 Timing chain tensioner 1 5 Camshaft cap 2 6 Clip 2 7 Intake camshaft 1 8 Exhaust camshaft 1 9 Oil nozzle 1 M LS 5 8 3 4 1 2 7 6 4 3 6 E LS E 6 N m 0 6 kgf m 4 4 lb...

Page 217: ...cap surfaces d 3 Remove Timing chain tensioner cap bolt 1 Timing chain tensioner 2 Gasket 4 Remove Bolt camshaft cap 1 Camshaft cap 2 Clip 3 TIP Remove the bolts camshaft cap in a criss cross pattern...

Page 218: ...p bolts in a crisscross 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 wid...

Page 219: ...h your fingers use a thin screwdriver 1 to wind the tensioner rod up fully clock wise b When releasing the screwdriver by press ing lightly with your fingers make sure that the tensioner rod will come...

Page 220: ...Before installing the clips cover the cylinder head with a clean cloth to prevent the clips from coming off into the cylinder head cavity Apply the engine oil to the threads and contact surfaces Tigh...

Page 221: ...chain guide top side 1 Cylinder head cover gasket 2 Gasket spark plug hole 3 Cylinder head cover 4 Cylinder head cover bolt 5 TIP Before installation apply the sealant to the cylin der head cover gas...

Page 222: ...to ENGINE REMOVAL on page 5 6 Radiator hose Disconnect Coolant temperature sensor coupler Disconnect Throttle body Refer to THROTTLE BODY on page 7 4 Camshaft Refer to CAMSHAFT on page 5 13 Upper engi...

Page 223: ...linder head Order Job Parts to remove Q ty Remarks 6 Oil passage plug 2 M 7 N m 0 7 kgf m 5 2 lb ft 1st 3rd 4th 2nd 40 N m 4 0 kgf m 30 lb ft 23 N m 2 3 kgf m 17 lb ft 60 90 10 N m 1 0 kgf m 7 4 lb ft...

Page 224: ...CKING THE VALVE SEATS on page 5 28 Cylinder head coolant passages Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedg...

Page 225: ...d washer are lightly seated against the cylinder head e Tighten the bolts to the specified torque in two or three steps in the proper tightening sequence as shown f Loosen the bolt 1 TIP Loosen the bo...

Page 226: ...s completely tightened l Put a mark on the corner of the bolt cylin der head and the cylinder head m Retighten the cylinder head mounting bolts in the proper tightening sequence n Tighten the bolts to...

Page 227: ...er Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 20 1 Valve lifter 4 2 Adjusting pad 4 3 Valve cotter 8 4 Valve spring retainer 4 5 Valve spring 4 6 Valve stem seal 4...

Page 228: ...THE VALVE SEATS on page 5 28 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves are properly sealed TIP Check that there are no kerosene leaks from the valve seat 1 3 R...

Page 229: ...lve guide installer 1 and the valve guide re mover 2 c After installing the valve guide expand the hole in the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide...

Page 230: ...3 Measure Valve seat contact width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cylinder head c Press the valve throug...

Page 231: ...d Turn the valve until the valve face and the valve seat are evenly polished then clean off all of the lapping compound TIP While turning the valve lapper tap and lap the valve seat e Apply a fine lap...

Page 232: ...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 cotter 1 TIP Install the valve cotters by com...

Page 233: ...800 Hitting the valve tip with excessive force could damage the valve 6 Lubricate Adjusting pad 1 Valve lifter 2 7 Install Adjusting pad Valve lifter TIP Check that the valve lifter turns smoothly whe...

Page 234: ...ston Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 20 1 Cylinder body 1 2 Gasket 1 3 Dowel pin 2 4 Piston pin clip 2 5 Piston pin 1 6 Piston 1 7 Piston ring set...

Page 235: ...nd lift the opposite end gap of the piston ring over the piston crown EAM30097 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Sidewall Cylinder wall Vertical scratches Replace the cylinder and r...

Page 236: ...the piston ring near bottom of cylinder a where cylinder wear is lowest 3 Measure Piston ring end gap Out of specification Replace the piston ring TIP The oil ring expander spacer s end gap cannot be...

Page 237: ...il 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 2 Install Piston 1 Piston pin 2 Piston pin clip 3 TIP Apply engine oil to the pis...

Page 238: ...mpressing 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 Top ring b 2nd ring c Uppe...

Page 239: ...SSIS on page 4 1 1 Stator coil assembly coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Shift pedal 1 4 Crankcase cover left 1 5 Gasket 1 6 Dowel pin 2 7 Holder 1 8 Stator coi...

Page 240: ...stall Stator coil assembly 1 Screw stator coil assembly 2 Crankshaft position sensor 3 Bolt crankshaft position sensor 4 Holder Bolt holder TIP Apply the sealant to the grommet of the stator coil asse...

Page 241: ...e keyway c of the generator rotor with the woodruff key 3 Install Washer Nut generator rotor 1 4 Install Dowel pin 1 Gasket left crankcase cover 2 Crankcase cover left 3 Lead holder 4 Bolt left crankc...

Page 242: ...starter clutch Order Job Parts to remove Q ty Remarks Engine oil Refer to CHANGING THE ENGINE OIL on page 3 14 Clutch Refer to CLUTCH on page 5 46 1 Holder 1 2 Washer 1 3 Damper assembly 1 4 Starter...

Page 243: ...3 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 counterclockwise A it should...

Page 244: ...5 6 1 Plastic locking tie 1 2 Starter motor cover upper 1 3 Starter motor 1 4 Starter motor cover lower 1 5 Starter motor lead 1 When removing or installing the installation nut of the starter motor...

Page 245: ...ty Remarks 1 Starter motor assembly 1 2 O ring 1 3 Starter motor front cover 1 4 Starter motor yoke 1 5 Armature assembly 1 6 Gasket 2 7 Brush set 1 8 Brush holder 1 9 Starter motor rear cover 1 2 3...

Page 246: ...asure Brush length a Out of specification Replace the brush set 5 Measure Brush spring force Out of specification Replace the brush set 6 Check Gear teeth Damage wear Replace the starter motor 7 Check...

Page 247: ...he match mark a on the starter motor yoke with the match mark b on the starter mo tor front cover 4 Install Bolt O ring TIP Apply the lithium soap based grease on the O ring 5 Install Starter motor St...

Page 248: ...over 1 3 O ring 1 4 Clutch spring 6 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Bearing 1 9 Ball 1 10 Push rod 2 1 11 Friction plate 1 2 Identification color black 12 Clutch plate 7 13 Friction pl...

Page 249: ...rts to remove Q ty Remarks 15 Thrust washer 1 16 Primary driven gear 1 17 Push lever shaft 1 E E T R LT 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 75 N m 7 5 kgf...

Page 250: ...14 Coolant Drain Refer to CHANGING THE COOLANT on page 3 21 Brake pedal Refer to ENGINE REMOVAL on page 5 6 Clutch cover Refer to CLUTCH on page 5 46 1 Oil filter element cover 1 2 Oil filter element...

Page 251: ...CH SPRINGS 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure Clutch spring free length Out of specification Replace the clutch springs as a set EAM30112 CHECKING THE CLUTCH HO...

Page 252: ...gears as a set Excessive noise during operation Replace the primary drive and primary driven gears as a set 2 Check Primary drive gear to primary driven gear free play Free play exists Replace the pri...

Page 253: ...igns with the balancer end slot 4 Tighten the crankcase cover bolts right in stages and in a crisscross pattern 4 Install Push lever shaft 1 TIP Apply the lithium soap based grease on the oil seal lip...

Page 254: ...nd friction plates alter nately on the clutch boss starting with a friction plate and ending with a friction plate From the clutch boss side install the friction plates in order friction plate 1 ident...

Page 255: ...spring bolt TIP Tighten the bolts in stages and in a crisscross pattern 13 Install O ring 1 TIP Apply the lithium soap based grease to the O ring 14 Install Clutch cover Clutch cover bolt TIP Tighten...

Page 256: ...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 Stopper lever 1 14 Stopper le...

Page 257: ...heck Shift shaft 1 Bends damage wear Replace Shift shaft spring 2 Damage wear Replace 2 Check Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear damage Replace EAM30127 CHECKING THE STOPPER L...

Page 258: ...t lever assembly to the shift guide 5 Install Shift lever assembly 1 Shift guide 2 TIP The shift lever assembly is installed at the same time as the shift guide 6 Tighten Shift guide bolt 1 7 Install...

Page 259: ...SHIFT SHAFT 5 57 TIP Align the punch mark a on the shift shaft with the punch mark b in the shift pedal 1 1 2 2 a b...

Page 260: ...driven gear Refer to CLUTCH on page 5 46 Right crankcase cover Refer to CLUTCH on page 5 46 1 Oil pump assembly 1 2 Oil pump cover 1 3 Outer rotor 1 4 Dowel pin 1 5 Inner rotor 1 6 Oil pump drive sha...

Page 261: ...Refer to GENERATOR on page 5 37 1 Nut balancer 1 2 Nut primary drive gear 1 3 Nut balancer weight gear 1 4 Lock washer 1 5 Balancer 1 6 Straight key 1 7 Conical washer 1 8 Primary drive gear 1 9 Bala...

Page 262: ...eplace 4 Check Balancer Crack damage Replace EAM30136 CHECKING THE OIL PUMP 1 Check Oil pump cover Oil pump drive shaft Oil pump housing Cracks damage wear Replace the oil pump assembly 2 Check Oil pu...

Page 263: ...eight gear Install the balancer drive gear and crankshaft with the lower splines c aligning with each other 3 Install Lock washer 1 Balancer weight gear nut 2 Primary drive gear 3 Conical washer 4 Pri...

Page 264: ...nstall the conical washer with its convex sur face b outward 4 Bend the lock washer tab 5 Install Oil pump assembly 1 Oil pump assembly bolt 2 NOTICE ECA13890 After tightening the bolts make sure the...

Page 265: ...l assembly Refer to GENERATOR on page 5 37 1 Timing chain guide exhaust side 1 2 Timing chain guide stopper plate 1 3 Timing chain 1 4 Bolt 5 L 45 mm 1 77 in 5 Bolt 4 L 60 mm 2 36 in 6 Bolt 3 L 75 mm...

Page 266: ...ransmission Refer to TRANSMISSION on page 5 70 Shift cam Shift fork Refer to TRANSMISSION on page 5 70 1 Circlip 1 2 Oil seal 2 3 Bearing 12 4 Collar 1 1 2 2 3 3 3 3 3 3 3 3 3 3 3 12 N m 1 2 kgf m 8 9...

Page 267: ...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...

Page 268: ...t hammer When installing the crankcase the connecting rod should be positioned at top dead center TDC Tighten the bolts in a crisscross pattern in two stages with 1 4 turn each Installed depth a 0 0 0...

Page 269: ...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 5 63 Transmission Refer to TRANSMISSION on p...

Page 270: ...KSHAFT 1 Measure Crankshaft runout a Out of specification Replace the crank shaft TIP Turn the crankshaft slowly 2 Measure Crank assembly width a Out of specification Replace the crank shaft 3 Check C...

Page 271: ...hium soap based grease In order to prevent the crankshaft seizure apply molybdenum disulfide grease TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the cranks...

Page 272: ...emarks Engine Refer to ENGINE REMOVAL on page 5 6 Crankcase Separate Refer to CRANKCASE on page 5 63 1 Main axle 1 2 Drive axle 1 3 Long shift fork guide bar 1 4 Short shift fork guide bar 1 5 Spring...

Page 273: ...1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WARNING EWA12840 Do not attempt to stra...

Page 274: ...oil to the inner and end surface of the idler gear and to the inner 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...

Page 275: ...kcase simultaneously Apply engine oil to the main axle and the drive axle bearing 6 Install Shift fork 1 L 1 Shift fork 2 C 2 Shift fork 3 R 3 Shift cam 4 to the main axle and the drive axle TIP Apply...

Page 276: ...t fork guide bar 2 Spring 3 TIP Screw the spring into the shift fork guide bar lightly beforehand Apply the engine oil on the shift fork guide bars 8 Check Operation of shift cam and shift fork Transm...

Page 277: ...10 COOLING SYSTEM COOLING SYSTEM DIAGRAMS 6 1 RADIATOR 6 2 CHECKING THE RADIATOR 6 4 INSTALLING THE RADIATOR 6 4 WATER PUMP 6 6 DISASSEMBLING THE WATER PUMP 6 7 CHECKING THE WATER PUMP 6 7 ASSEMBLING...

Page 278: ...COOLING SYSTEM DIAGRAMS 6 1 EAM20186 COOLING SYSTEM DIAGRAMS 1 Radiator hose 1 2 Radiator right 3 Radiator fan 4 Radiator hose 4 5 Water pump 6 Radiator hose 3 7 Radiator left...

Page 279: ...uel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to THROTTLE BODY on page 7 4 1 Radiator guard 2 2 Radiator hose clamp 8 Loosen 3 Radiator fan 1 4 Radiator right 1 5 Radiator hose 2 1 6 R...

Page 280: ...left 1 11 Radiator hose 1 1 12 Radiator pipe 1 1 13 Coolant temperature sensor 1 10 11 12 13 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 5 N m 0 15 kgf m 1 1 lb...

Page 281: ...e 3 Check Radiator cap valve opening pressure a Install the radiator cap tester adapter 2 and the radiator cap tester 3 to the radi ator cap 1 and activate the tester to check whether it can stay for...

Page 282: ...s of warm up Make sure that coolant is filled up to the up per level beforehand 5 Check Pressure value No stay for 5 to 10 seconds at the test pres sure value Correct Radiator Radiator hose connection...

Page 283: ...n page 3 21 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 14 Right crankcase cover Refer to CLUTCH on page 5 46 1 Water pump housing 1 2 Dowel pin 2 3 Gasket 1 4 Collar 1 5 Pin 1 6 Impel...

Page 284: ...ce EAM30262 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 TIP Apply the lithium soap based grease on the oil seal lip Install the oil seal with its manufacture s marks or numbers facing the crankcase...

Page 285: ...5 Install Water pump housing 1 Water pump housing bolt 2 Washer 3 Coolant drain bolt 4 Water pump housing bolt 10 N m 1 0 kgf m 7 4 lb ft Coolant drain bolt 10 N m 1 0 kgf m 7 4 lb ft 1 1 1 1 2 T R Ne...

Page 286: ...WATER PUMP 6 9...

Page 287: ...UEL PUMP 7 2 CHECKING THE FUEL PUMP BODY 7 2 CHECKING THE FUEL PUMP OPERATION 7 2 INSTALLING THE FUEL PUMP 7 3 INSTALLING THE FUEL TANK 7 3 THROTTLE BODY 7 4 CHECKING THE INJECTOR 7 7 CHECKING THE THR...

Page 288: ...left right 1 Fuel pump coupler Fuel hose 1 1 Disconnect 2 Fuel tank 1 3 Fuel pump bracket 1 4 Fuel pump 1 5 Fuel filter 1 6 Thermistor cover 1 7 Fuel pump gasket 1 8 Rubber damper 4 3 5 2 2 4 7 2 7 N...

Page 289: ...or cover 1 on the end of the hose in the direction of the arrow shown press the two buttons 2 on the sides of the connector and then remove the hose Before removing the hose place a few cloths in the...

Page 290: ...nstall Fuel tank 2 Connect Fuel hose NOTICE ECA24740 Connect the fuel hose securely and check that the orientation of the installed fuel hose holder is correct Take care not to kink or pinch the fuel...

Page 291: ...2 Ignition coil 1 3 Intake air temperature sensor coupler 1 Disconnect 4 Breather hose 1 5 Air filter case 1 6 Fuel injector coupler 1 Disconnect 7 Intake air pressure sensor coupler 1 Disconnect 8 Th...

Page 292: ...ide of the vehicle and then install the cover 12 Fuel hose 1 13 Throttle body 1 14 Exhaust pipe bracket 1 15 Throttle body joint 1 7 N m 0 7 kgf m 5 2 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 7 N m 0 7 kgf...

Page 293: ...the injector Order Job Parts to remove Q ty Remarks 1 Fuel inlet pipe 1 2 Injector 1 3 Gasket 1 4 Throttle position sensor 1 5 Intake air pressure sensor 1 1 2 2 5 4 3 3 5 N m 0 35 kgf m 2 6 lb ft 3...

Page 294: ...f the throttle body is subject to strong shocks or dropped during cleaning re place it Do not use any caustic carburetor cleaning solution Do not directly push the throttle valves to open them Do not...

Page 295: ...sor Refer to CHECKING THE THROTTLE PO SITION SENSOR INPUT VOLTAGE on page 8 70 2 Adjust Throttle position sensor angle a Connect the Yamaha diagnostic tool Refer to YAMAHA DIAGNOSTIC TOOL on page 8 31...

Page 296: ...THROTTLE BODY 7 9...

Page 297: ...8 23 CIRCUIT DIAGRAM 8 23 TROUBLESHOOTING 8 25 FUEL INJECTION SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 ECU SELF DIAGNOSTIC FUNCTION 8 29 TROUBLESHOOTING METHOD 8 30 YAMAHA DIAGNOSTIC TOOL 8 31 CONNECTING THE...

Page 298: ...67 CHECKING THE RECTIFIER REGULATOR 8 67 CHECKING THE SPEED SENSOR 8 68 CHECKING THE FUEL SENDER 8 68 CHECKING THE RESISTOR 8 68 CHECKING THE RADIATOR FAN MOTOR 8 69 CHECKING THE COOLANT TEMPERATURE S...

Page 299: ......

Page 300: ...IGNITION SYSTEM 8 1 EAM20142 IGNITION SYSTEM EAM30277 CIRCUIT DIAGRAM...

Page 301: ...egulator 4 Joint connector 7 Engine ground 8 Battery 9 Frame ground 10 Main fuse 11 Starter relay 12 Starter motor 13 Diode 3 14 Diode 5 19 ECU Engine Control Unit 20 Ignition coil 21 Spark plug 33 En...

Page 302: ...page 8 60 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 13 NG Correct or replace the spark plug OK 5 Check the ign...

Page 303: ...coil assembly Refer to CHECKING THE STA TOR COIL on page 8 67 NG Replace the stator coil assembly OK 10 Check the ignition system wire har ness Refer to CIRCUIT DIAGRAM on page 8 1 NG Repair or repla...

Page 304: ...ELECTRIC STARTING SYSTEM 8 5 EAM20143 ELECTRIC STARTING SYSTEM EAM30279 CIRCUIT DIAGRAM...

Page 305: ...ry 9 Frame ground 10 Main fuse 11 Starter relay 12 Starter motor 13 Diode 3 14 Diode 5 19 ECU Engine Control Unit 33 Engine stop switch 34 Gear position switch 35 Diode 1 36 Starting circuit cut off r...

Page 306: ...ch 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 condi tions has...

Page 307: ...SSION IS IN NEU TRAL b WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main relay 4 Diode 3 5 Starting circuit cut off relay 6 Start switch 7 Diode 1 8 Clutch switch 9 Gear po...

Page 308: ...THE RE LAYS on page 8 62 NG Replace the main relay OK 4 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 67 OK Starter motor is OK Perform the electric start...

Page 309: ...rt switch Refer to CHECKING THE SWITCHES on page 8 57 NG Replace the start switch OK 10 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 5 NG Properly connect or repair the...

Page 310: ...CHARGING SYSTEM 8 11 EAM20144 CHARGING SYSTEM EAM30282 CIRCUIT DIAGRAM...

Page 311: ...CHARGING SYSTEM 8 12 2 AC magneto 3 Rectifier regulator 7 Engine ground 8 Battery 9 Frame ground 10 Main fuse A Battery sub lead B Wire harness...

Page 312: ...attery Refer to CHECKING AND CHARGING THE BATTERY on page 8 60 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULA...

Page 313: ...CHARGING SYSTEM 8 14...

Page 314: ...SIGNALING SYSTEM 8 15 EAM20154 SIGNALING SYSTEM EAM30348 CIRCUIT DIAGRAM...

Page 315: ...Main relay 7 Engine ground 8 Battery 9 Frame ground 10 Main fuse 16 Resistor 17 Diode 2 18 Yamaha diagnostic tool coupler 19 ECU Engine Control Unit 23 Fuel sender 32 Speed sensor 41 Multi function d...

Page 316: ...RGING THE BATTERY on page 8 60 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main relay Refer to CHECKING THE RE LAYS on page 8 62 NG Replace the main relay OK 4 Check...

Page 317: ...UEL SENDER on page 8 68 NG Replace the fuel pump assembly OK 2 Check the resistor Refer to CHECKING THE RESIS TOR on page 8 68 NG Replace the resistor OK 3 Check the entire signaling system s wiring R...

Page 318: ...LIGHTING SYSTEM 8 19 EAM20153 LIGHTING SYSTEM EAM30346 CIRCUIT DIAGRAM...

Page 319: ...20 4 Joint connector 5 Headlight relay 6 Main relay 7 Engine ground 8 Battery 9 Frame ground 10 Main fuse 19 ECU Engine Control Unit 40 Taillight 41 Multi function display 42 Headlight A Battery sub l...

Page 320: ...FUSES on page 8 59 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 60 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the m...

Page 321: ...LIGHTING SYSTEM 8 22...

Page 322: ...COOLING SYSTEM 8 23 EAM20155 COOLING SYSTEM EAM30350 CIRCUIT DIAGRAM...

Page 323: ...r 6 Main relay 7 Engine ground 8 Battery 9 Frame ground 10 Main fuse 19 ECU Engine Control Unit 25 Radiator fan motor 26 Radiator fan motor fuse 27 Radiator fan motor relay 29 Coolant temperature sens...

Page 324: ...ain relay Refer to CHECKING THE RE LAYS on page 8 62 NG Replace the main relay OK 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 69 NG Replace the radiator fan moto...

Page 325: ...COOLING SYSTEM 8 26...

Page 326: ...FUEL INJECTION SYSTEM 8 27 EAM20145 FUEL INJECTION SYSTEM EAM30284 CIRCUIT DIAGRAM...

Page 327: ...diagnostic tool coupler 19 ECU Engine Control Unit 20 Ignition coil 21 Spark plug 22 Fuel injector 24 Fuel pump 28 Intake air temperature sensor 29 Coolant temperature sensor 30 Throttle position sens...

Page 328: ...rning light Engine trouble warning light indication and fuel injection system operation The engine trouble warning light flashes when any one of the following conditions is present and the start switc...

Page 329: ...system Refer to Confirmation of service com pletion in the appropriate table in TROUBLESHOOTING DETAILS FAULT CODE on page 8 33 4 After pushing the engine stop switch push the start switch to check w...

Page 330: ...o be used to identify malfunctions EAM30356 CONNECTING THE YAMAHA DIAGNOSTIC TOOL Yamaha diagnostic tool USB US 90890 03269 Yamaha diagnostic tool A I 90890 03264 OBD GST Leadwire kit 90890 03249 1 3...

Page 331: ...b lead special tool to the battery Otherwise because of excessive cur rent flow the sub lead can catch fire and the battery could be damaged TIP For information on how to connect and use the Yamaha di...

Page 332: ...Item Crankshaft position sensor no normal signals are received from the crankshaft position sensor Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No Diagnostic tool d...

Page 333: ...of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Defective crankshaft position sensor Check the crankshaft position sensor...

Page 334: ...ng the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 4 4 Mounted condition of intake air pressure sensor Ch...

Page 335: ...ensor hose Start the engine and let it idle for approximately 5 seconds fully close the throttle valve Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Co...

Page 336: ...Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or bro ken terminals and locking condi tion of the pins Improperly connected Con nect the coupler securely...

Page 337: ...ned 86 92 displays Incorrect display range Replace the throttle position sensor Push the start switch main relay ON and then check the condition of the fault code using the malfunction mode of the Yam...

Page 338: ...nostic tool Condition is Recovered Go to item 4 and finish the service Condition is Detected Go to item 3 3 Faulty ECU Replace the ECU Service is finished 4 Delete the fault code Confirm that the faul...

Page 339: ...condition of coolant temperature sensor Check for looseness or pinch ing Check the mounted position for correctness Improperly mounted sensor Remount or replace the sensor Push the start switch main r...

Page 340: ...cted Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or bro ken terminals and locking condi tion of...

Page 341: ...ble to drive vehicle Diagnostic code No 08 Diagnostic tool display Displays the lean angle sensor output voltage 0 4 1 4 V upright 3 7 4 4 V overturned Procedure Remove the ECU and incline it 45 or mo...

Page 342: ...ion 1 Connection of ignition coil cou pler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or bro ken terminals and locking condi tion of the pins Imprope...

Page 343: ...on of ignition coil Check for looseness or pinch ing Check the mounted condition for correctness Improperly mounted sensor Remount or replace the ignition coil Start the engine and let it idle for app...

Page 344: ...jector Refer to CHECKING THE INJECTOR on page 8 71 Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnosti...

Page 345: ...relay Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 09 Diagnostic tool display Fuel system voltage Approximately 12 0 V Procedure Disconnect the main relay and push th...

Page 346: ...d the engine stop switch alternately to switch the power supply main relay from ON OFF ON Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Re...

Page 347: ...n Change the CO concentration and rewrite in EEPROM After this adjustment push the engine stop switch and then push the start switch Push the start switch main relay ON and then check the condition of...

Page 348: ...nd locking condition of the pins Improperly connected Con nect the coupler securely or repair replace the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition...

Page 349: ...e No Diagnostic tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Faulty ECU Replace the ECU Push the start switch main relay O...

Page 350: ...he fault code Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No 70 Item Engine forcibly stops when the vehicle is l...

Page 351: ...FUEL INJECTION SYSTEM 8 52...

Page 352: ...FUEL PUMP SYSTEM 8 53 EAM20146 FUEL PUMP SYSTEM EAM30287 CIRCUIT DIAGRAM...

Page 353: ...STEM 8 54 2 AC magneto 3 Rectifier regulator 4 Joint connector 7 Engine ground 8 Battery 9 Frame ground 10 Main fuse 19 ECU Engine Control Unit 24 Fuel pump 33 Engine stop switch A Battery sub lead B...

Page 354: ...on page 8 59 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 60 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the engine s...

Page 355: ...Injector 4 Rectifier regulator 5 Intake air temperature sensor 6 ECU Engine Control Unit 7 Ignition coil 8 Coolant temperature sensor 9 Resistor 10 Starter relay 11 Main fuse 12 Battery 13 Radiator f...

Page 356: ...ELECTRICAL COMPONENTS 8 57 EAM30289 CHECKING THE SWITCHES Y W P Sb 2 1 3 P Sb Y W 4 1 Engine stop switch 2 Gear position switch 3 Engine start switch 4 Clutch switch...

Page 357: ...ecking for continuity switch back and forth between the switch positions a few times Terminal connections of the switch are shown in the terminal connection diagram below The switch positions a are sh...

Page 358: ...1 Remove Seat Refer to GENERAL CHASSIS on page 4 1 2 Check Main fuse 1 Radiator fan motor fuse 2 a Connect the digital circuit tester to the fuse and check the continuity TIP Set the digital circuit t...

Page 359: ...lated Lead Acid battery are different from those of conventional batteries The VRLA Valve Regulated Lead Acid battery should be charged according to the appropriate charging method If the battery is o...

Page 360: ...comes hot to the touch at any time during the charging process dis connect the battery charger and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the following illu...

Page 361: ...ve Regu lated Lead Acid battery A variable voltage charger is recommended d Charge the battery until the battery s charging voltage is 15 V TIP Set the charging time at 20 hours maximum e Measure the...

Page 362: ...egative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 to 4 2 1 3 4 R W Br W R Y L 1 2 3 4 L R Br R R R W 1 Positive battery terminal 2 Negative battery t...

Page 363: ...L R L R W Br R W No continuity Positive tester probe Sky blue 1 Negative tester probe Green Black 2 Continuity Positive tester probe Green Black 2 Negative tester probe Sky blue 1 No continuity Posit...

Page 364: ...curs EAM30295 CHECKING THE SPARK PLUG CAP 1 Remove Spark plug cap from the spark plug lead 2 Check Spark plug cap resistance Out of specification Replace a Connect the digital circuit tester to the sp...

Page 365: ...igital circuit tester to the crankshaft position sensor coupler b Measure the crankshaft position sensor resistance Primary coil resistance 2 16 2 64 Digital circuit tester CD732 90890 03243 Model 88...

Page 366: ...oduce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAM30300 CHECKING THE STATOR COIL 1 Disconnect Stator coil assembly coupler from the w...

Page 367: ...ter motor lead from the starter relay 2 Connect Fuel pump coupler 3 Push the start switch 4 Check Fuel level warning light Out of specification Replace the fuel pump EAM30360 CHECKING THE RESISTOR 1 D...

Page 368: ...sor resistance Out of specification Replace a Connect the digital circuit tester to the coolant temperature sensor b Immerse the coolant temperature sensor in a container filled with coolant TIP Make...

Page 369: ...G EWA14110 Handle the intake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 2 Chec...

Page 370: ...hom eter YU A1927 Continuity Positive tester probe Sky blue 1 Negative tester probe Sensor terminal a Continuity Positive tester probe Pink 2 Negative tester probe Sensor terminal b Continuity Positiv...

Page 371: ...7 TROUBLESHOOTING OF BRAKE 9 8 TROUBLESHOOTING OF SUSPENSION 9 8 TROUBLESHOOTING OF STEERING HANDLING 9 10 TROUBLESHOOTING OF CHARGING SYSTEM 9 11 TROUBLESHOOTING OF LIGHTING SYSTEM 9 11 TROUBLESHOOT...

Page 372: ...TEM on page 8 5 Starter motor operates but the engine does not crank Starter clutch malfunction Replace the starter clutch Improper oil grade starter clutch slipping Change to recommended engine oil S...

Page 373: ...ace the piston and piston rings as a set Seized or damaged piston Replace the piston and piston rings as a set Worn or damaged cylinder bore Replace the cylinder piston and piston rings as a set Sympt...

Page 374: ...ecified torque Clogged air filter element Clean or replace the air filter ele ment Incorrect oil level high Adjust the oil level to the specified level Symptom Possible cause Actions Noise heard from...

Page 375: ...ve gear Replace the balancer drive gear and balancer shaft as a set Worn or damaged big end bearing Replace the big end bearing Worn or damaged crankshaft jour nal bearing Replace the crankshaft journ...

Page 376: ...bushing Replace the clutch housing Improperly installed pull lever Align the match mark on the pull lever before installation Incorrect oil level Adjust the engine oil level to the specified level Inc...

Page 377: ...ransmis sion gears Remove foreign object from trans mission gears Seized transmission gear Replace the seized gear and the axle as a set Improperly assembled transmis sion Reassemble the transmission...

Page 378: ...tor Faulty radiator fan motor Refer to TROUBLESHOOTING under COOLING SYSTEM on page 8 23 Damaged or faulty water pump Replace the water pump Damaged hoses or pipes Replace the hose or pipe Improperly...

Page 379: ...Damaged brake hose and brake pipe Replace the brake hose and brake pipe Oil or grease on the brake disc or brake pad Clean the brake disc or brake pad Insufficient lubrication of brake lever or brake...

Page 380: ...er rod assembly bolt Tighten the damper rod assembly bolt to the specified torque Damaged damper rod assembly bolt copper washer Replace the damper rod assembly bolt copper washer Cracked or damaged c...

Page 381: ...ed torque Worn bearing or bearing race Replace the bearing and bearing race as a set Warped front fork Repair or replace the front fork Bent front wheel axle Replace the front wheel axle Incorrect tir...

Page 382: ...or worn swingarm bear ing or bushing Replace the swingarm bearing or bushing Symptom Possible cause Actions Battery is not charged Refer to TROUBLESHOOTING under CHARGING SYSTEM on page 8 11 Symptom P...

Page 383: ...ry lead of the ignition coil 8 43 39 Injector open or short circuit detected 8 45 41 ECU built in lean angle sensor malfunction 8 46 43 Fuel system voltage incorrect voltage supplied to the main relay...

Page 384: ...Displays the fuel system volt age Approximately 12 0 V 21 Neutral switch Operate the shift pedal Gear in neutral ON Gear not in neutral OFF 25 Gear position switch Operate the shift pedal Gear in 1st...

Page 385: ...nd intervals WARNING on the Yamaha diagnostic tool blinks five times when the ignition coil is actu ated Check that a spark is gener ated five times Connect an ignition checker 36 Injector Actuates th...

Page 386: ...SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 15...

Page 387: ...1 FRONT FORK SETTING 10 1 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL 10 2 SETTING OF SPRING AFTER REPLACEMENT 10 2 FRONT FORK SETTING PARTS 10 3 REAR SUSPENSION SETTING 10 3 CHOOSING SET LENGTH...

Page 388: ...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 othe...

Page 389: ...ten dency to be stiffer with the consequent dete riorated performance and characteristics Therefore adjust the front fork within the specified range EAM30173 SETTING OF SPRING AFTER REPLACEMENT As the...

Page 390: ...the rear fender holding bolt 2 Remove the stand or block from the engine and with a rider astride the seat measure the sunken length b between the rear wheel axle center and the rear fender holding bo...

Page 391: ...force WARNING EWA19200 When using a rear shock absorber other than currently installed use the one whose overall length a does not exceed the stan dard as it may result in faulty performance Never us...

Page 392: ...BER AS SEMBLY on page 3 30 Spring preload adjusting positions Minimum Position in which the spring is turned in 1 5 mm 0 06 in from its free length Standard Position in which the spring is turned in 1...

Page 393: ...ticeable scars etc If any replace affected parts Slide metal Replace with a new one for extended use Piston metal Replace with a new one for extended use Lower bracket tightening torque Retighten to s...

Page 394: ...unt Increase oil amount by about 5 cm 0 2 US oz 0 2 Imp oz Obtrusive front tending to upper front posture Compression damping force Turn adjuster counterclockwise about 2 clicks to decrease damping Ba...

Page 395: ...senger is astride seat Spring Replace with soft spring Bottoming out High compres sion damping Turn adjuster clockwise about 1 6 turn to increase damping Spring set length Set sunken length for 90 100...

Page 396: ...CHASSIS 10 9...

Page 397: ...sor 31 Intake air pressure sensor 32 Speed sensor 33 Engine stop switch 34 Gear position switch 35 Diode 1 36 Starting circuit cut off relay 37 Clutch switch 38 Start switch 39 Diode 4 40 Taillight 41...

Page 398: ......

Page 399: ...nce Buy with confidence knowing your Genuine Yamaha Accessories will fit right and perform right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care...

Page 400: ......

Page 401: ...B R Y B B W R L B Br W Sb B P L Br Lg L W L P B Y G P Y B O R L R L R L R L R L P L R L R W R W Br R W Br R L R L R L R L B L B L B L B L B L B L B L B L B L B L B L R L B L B L B B B L B B R L Br B L...

Page 402: ...WR450FN 2022 WIRING DIAGRAM 35W 35W 1 2 4 3 5 5A 15A B B B B B B Dl Gy B B B Gy B ON OFF ON OFF B B BDB 2819U 11_W D indd 2 2021 05 26 17 55 58...

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Yamaha WR450FN 2022, Owner'S Service Manual

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