Yamaha WR450FX Owner'S Service Manual Download

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6-10

FRONT BRAKE AND REAR BRAKE

HANDLING NOTE

Support the machine securely so
there is no danger of it falling over.

DRAINING THE BRAKE FLUID

1. Remove:

•

Brake master cylinder cap "1"

•

Protector (rear brake)

Do not remove the diaphragm.

A. Front
B. Rear

2. Connect the transparent hose "2"

to the bleed screw "1" and place a
suitable container under its end.

A. Front
B. Rear

3. Loosen the bleed screw and drain

the brake fluid while pulling the le-
ver in or pushing down on the
pedal.

•

Do not reuse the drained brake
fluid.

•

Brake fluid may erode painted
surfaces or plastic parts. Always
clean up spilled fluid immediate-
ly.

REMOVING THE BRAKE CALIPER
PISTON

1. Remove:

•

Brake caliper piston
Use compressed air and proceed
carefully.

•

Cover piston with rag and use ex-
treme caution when expelling
piston from cylinder.

•

Never attempt to pry out piston.

Caliper piston removal steps:

a. Insert a piece of rag into the brake

caliper to lock one brake caliper.

b. Carefully force the piston out of

the brake caliper cylinder with
compressed air.

A. Front
B. Rear

REMOVING THE BRAKE CALIPER
PISTON SEAL KIT

1. Remove:

•

Brake caliper piston dust seal "1"

•

Brake caliper piston seal "2"

Remove the brake caliper piston
seals and brake caliper piston dust
seals by pushing them with a finger.

Never attempt to pry out brake cal-
iper piston seals and brake caliper
piston dust seals.

Replace the brake caliper piston
seals and brake caliper piston dust
seals whenever a caliper is disas-
sembled.

A. Front
B. Rear

CHECKING THE BRAKE MASTER
CYLINDER

1. Inspect:

•

Brake master cylinder inner sur-
face "a"
Wear/scratches

→

Replace mas-

ter cylinder assembly.
Stains

→

Clean.

Use only new brake fluid.

A. Front
B. Rear

2. Inspect:

•

Diaphragm "1"
Crack/damage

→

Replace.

A. Front
B. Rear

3. Inspect: (front brake only)

•

Reservoir float "1"
Damage

→

Replace.

4. Inspect:

•

Brake master cylinder piston "1"

•

Brake master cylinder cup "2"
Wear/damage/score marks

→

Re-

place brake master cylinder kit.

ProCarManuals.com

Summary of Contents for WR450FX

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

Page 2: ...ProCarManuals com...

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

Page 4: ...ck local regulations before riding 1 THIS MACHINE IS TO BE OP ERATED BY AN EXPERI ENCED RIDER ONLY Do not attempt to operate this machine at maximum power until you are totally familiar with its chara...

Page 5: ...IS MANUAL FINDING THE REQUIRED PAGE 1 This manual consists of seven chapters General Information Specifications Regular inspec tion and adjustments Tuning Engine Chassis and Electri cal 2 The table of...

Page 6: ...ion the step by step format sup plements 5 are given in addition to the exploded diagram and job instruction chart ILLUSTRATED SYMBOLS Refer to the illustration Illustrated symbols 1 to 7 are used to...

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

Page 8: ...TUNING ENGINE 4 1 CHASSIS 4 5 CHAPTER 5 ENGINE RADIATOR 5 1 CARBURETOR 5 4 AIR INDICTOIN SYSTEM 5 11 CAMSHAFTS 5 13 CYLINDER HEAD 5 18 VALVES AND VALVE SPRINGS 5 21 CYLINDER AND PISTON 5 25 CLUTCH 5...

Page 9: ...er lever 3 Engine stop switch 4 Multi function display 5 Main switch 6 Start switch 7 Front brake lever 8 Throttle grip 9 Radiator cap 10 Fuel tank cap 11 Taillight 12 Kickstarter crank 13 Fuel tank 1...

Page 10: ...H This spark plug wrench 1 is used to remove and install the spark plug NIPPLE WRENCH This nipple wrench 1 is used to tighten the spoke JET NEEDLE PULL UP TOOL The jet needle pull up tool 1 is used to...

Page 11: ...thium base grease to the seal lip s Oil the bearings liberally when installing Do not use compressed air to spin the bearings dry This causes dam age to the bearing surfaces CIRCLIPS 1 All circlips sh...

Page 12: ...Illustration Dial gauge and stand YU 3097 90890 01252 Stand YU 1256 These tools are used to check each part for runout or bent Crankshaft installing tool Crankshaft installing pot YU 90050 90890 0127...

Page 13: ...used for when loosening or tightening the flywheel magneto securing nut Pocket tester YU 3112 C 90890 03112 Use this tool to inspect the coil resis tance output voltage and amper age Timing light YM...

Page 14: ...ntake 4 5 mm 0 18 in Exhaust 5 0 mm 0 20 in YM 4117 90890 04117 YM 4098 90890 04098 This tool is needed to install the valve guide Valve guide reamer Intake 4 5 mm 0 18 in Exhaust 5 0 mm 0 20 in YM 41...

Page 15: ...essure pump gauge set YB 35956 A 90890 06756 This tool is used to check the air in duction system Digital tachometer YU 39951 B 90890 06760 This tool is needed for observing en gine rpm YAMAHA Bond No...

Page 16: ...on the left side of the engine KICKSTARTER CRANK Rotate the kickstarter crank 1 away from the engine Push the starter down lightly with your foot until the gears engage then kick smoothly and forcefu...

Page 17: ...ed travel distance in timer measurement Change tripmeter digits capable of change to any given ones DESCRIPTION Operation buttons 1 Select button SLCT 1 2 Select button SLCT 2 3 Reset button RST Scree...

Page 18: ...ther of which can be selected Manual start Starting measurement by the rider himself operating the button A long push on the SLCT2 button will put measurement on standby Auto start Starting timer meas...

Page 19: ...ay by pushing the RST button for 2 seconds or more If reset and travel distance dis play will go on flashing for four sec onds Resetting tripmeter A TRIP A and timer 1 Check that the timer is not in o...

Page 20: ...tton changes the operation in both arrowed directions Meter function Function that can be performed whether the time is or is not in operation Extent to which the meter can operate Clock BASIC MODE Tr...

Page 21: ...changes the operation in the ar rowed direction D A long push on the button changes the operation in both arrowed directions E Meter function F Function that can be performed whether the time is or i...

Page 22: ...position However it is recommended to shift into neutral before starting the en gine 1 Inspect the coolant level 2 Turn the fuel cock to ON 3 Push on the main switch to ON 4 Shift the transmission in...

Page 23: ...e through out its entire operating range Re start the machine and operate it for about 10 to 15 more minutes The machine will now be ready to race After the break in or before each race you must check...

Page 24: ...ssembly 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 In...

Page 25: ...paper towel and lubri cate the chain to prevent rust 7 Clean the seat with a vinyl uphol stery cleaner to keep the cover pliable and glossy 8 Automotive wax may be applied to all painted or chromed s...

Page 26: ...in 370 mm 14 57 in Dry weight Without oil and fuel 112 5 kg 248 0 lb Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Single cylinder forward inclined Displacement 449 cm3 15 8 Imp...

Page 27: ...manufacturer CR8E NGK resistance type Gap 0 7 0 8 mm 0 028 0 031 in Clutch type Wet multiple disc Transmission Primary reduction system Gear Primary reduction ratio 61 23 2 652 Secondary reduction sys...

Page 28: ...il damper Rear shock absorber Coil spring gas oil damper Wheel travel Front wheel travel 300 mm 11 8 in Rear wheel travel 305 mm 12 0 in Electrical Ignition system CDI Generator system AC magneto Batt...

Page 29: ...39 0 8878 in 22 350 mm 0 8799 in Exhaust A 30 200 30 300 mm 1 1890 1 1929 in 30 100 mm 1 1850 in Exhaust B 22 450 22 550 mm 0 8839 0 8878 in 22 350 mm 0 8799 in Camshaft runout limit 0 03 mm 0 0012 in...

Page 30: ...tem outside diameter IN 4 475 4 490 mm 0 1762 0 1768 in 4 445 mm 0 1750 in Stem outside diameter EX 4 965 4 980 mm 0 1955 0 1961 in 4 935 mm 0 1943 in Guide inside diameter IN 4 500 4 512 mm 0 1772 0...

Page 31: ...5 kg at 28 38 mm 27 67 31 85 lb at 1 12 in Tilt limit IN 2 5 1 7 mm 2 5 0 067 in Tilt limit EX 2 5 1 6 mm 2 5 0 063 in Direction of winding top view IN Clockwise Direction of winding top view EX Clock...

Page 32: ...in 0 85 mm 0 033 in Side clearance 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in Oil ring Dimensions B T 2 0 2 9 mm 0 08 0 11 in End gap installed 0 2 0 5 mm 0 01 0 02 in Crankshaft Crank width A...

Page 33: ...clearance 0 010 0 044 mm 0 0004 0 0017 in Clutch release method Inner push cam push Shifter Shifter type Cam drum and guide bar Guide bar bending limit 0 05 mm 0 002 in Kickstarter Type Ratchet type C...

Page 34: ...ndard Limit Steering system Steering bearing type Taper roller bearing Front suspension CDN AUS NZ ZA Front fork travel 300 mm 11 8 in Fork spring free length 460 mm 18 1 in 455 mm 17 9 in Spring rate...

Page 35: ...84 0 10 in Pad thickness 4 4 mm 0 17 in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Caliper cylinder inside dia 27 0 mm 1 063 in 2 Brake fluid type DOT 4 Rear disc brake Disc outside d...

Page 36: ...e color 0 224 0 336 at 20 C 68 F Yellow Ground Rectifier regulator Regulator type Semiconductor short circuit Model manufacturer SH770AA SHINDENGEN Regulated voltage AC 12 5 13 5 V Regulated voltage D...

Page 37: ...15 1 5 11 Cylinder head bolt M10 1 25 4 Refer to NOTE 1 Cylinder head bolt M6 1 0 2 10 1 0 7 2 Cylinder head cover M6 1 0 2 10 1 0 7 2 Cylinder M6 1 0 1 10 1 0 7 2 Timing chain tensioner M6 1 0 2 10 1...

Page 38: ...7 10 1 0 7 2 Crankcase cover right M6 1 0 8 10 1 0 7 2 Crankcase cover right M6 1 0 2 12 1 2 8 7 Crankcase cover left M6 1 0 8 10 1 0 7 2 Idle gear cover starter motor M6 1 0 2 10 1 0 7 2 Crankcase M6...

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

Page 40: ...3 38 Engine guard M6 1 0 3 7 0 7 5 1 Regulator mounting M6 1 0 2 7 0 7 5 1 Pivot shaft and nut M16 1 5 1 85 8 5 61 Relay arm and swingarm M14 1 5 1 70 7 0 50 Relay arm and connecting rod M14 1 5 1 80...

Page 41: ...ate 2 and protector 2 0 5 0 05 0 36 Speed sensor lead holder and under bracket M6 1 0 1 13 1 3 9 4 Headlight body and headlight unit 2 1 0 1 0 7 Headlight mounting left and right M6 1 0 2 7 0 7 5 1 Ta...

Page 42: ...be at room temperature A Distance between flats B Outside thread diameter DEFINITION OF UNITS A Nut B Bolt TORQUE SPECIFI CATION Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30...

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

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

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

Page 46: ...lead 11 AC magneto lead 12 Brake hose 13 Rectifier regulator lead 14 Carburetor breather hose 15 Carburetor overflow hose 16 Catch tank breather hose A Insert the end of the fuel tank breather hose in...

Page 47: ...necting rod and cross tube frame G Pass the neutral switch lead on the inside of the engine bracket H Fasten the neutral switch lead and AC magneto lead onto the frame Locate the clamp end facing towa...

Page 48: ...the pull and push throttle cables B Fasten the catch tank hose and air induction hose air cut off valve rear of cylinder head onto the frame Locate the clamp end facing toward the lower side of the fr...

Page 49: ...s shown and lightly touches the projec tion on the brake caliper B Pass the brake hose into the brake hose holders C If the brake hose contacts the spring rear shock absorber correct its twist D Insta...

Page 50: ...de Locate the clamp end facing to ward the upper side of the frame with the tie end cut off on the in side of the frame B Fasten the wire harness to the upper engine bracket left side Locate the clamp...

Page 51: ...mp end facing toward the upper side of the frame and the tie end to ward the inside of the frame Clamp the wire harness at the marking K Pass the wire harness starter relay lead starting circuit cut o...

Page 52: ...coupler 14 Engine stop switch coupler 15 Multi function display coupler 16 Start switch coupler 17 Speed sensor coupler 18 Speed sensor lead A Fasten the start switch lead to the handlebar with the pl...

Page 53: ...by pushing it into the hole in the multi function display bracket H Secure the wire harness clip by pushing it into the hole in the multi function display bracket on the inside I Fasten the main swit...

Page 54: ...Replace VALVES Check the valve clearances The engine must be cold Inspect Check the valve seats and valve stems for wear Replace VALVE SPRINGS Inspect Check the free length and the tilt Replace VALVE...

Page 55: ...UG Inspect and clean Replace DRIVE CHAIN Use chain lube Lubricate slack alignment Chain slack 48 58 mm 1 9 2 3 in Replace COOLING SYSTEM Check coolant level and leakage Check radiator cap operation Re...

Page 56: ...AND DUST SEAL Clean and lube Lithium base grease PROTECTOR GUIDE Replace REAR SHOCK ABSORBER Inspect and adjust Lube After rain ride Molybdenum disulfide grease Retighten DRIVE CHAIN GUIDE AND ROLLER...

Page 57: ...bearings Lubricate Lithium base grease THROTTLE CONTROL CABLE Check routing and connection Lubricate Yamaha cable lube or SAE 10W 30 motor oil HOT STARTER CLUTCH LEVER Inspect free play BATTERY Check...

Page 58: ...nd alignment Check that the drive chain is lubricated properly P 3 20 21 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 24 Steering Check that...

Page 59: ...Remarks Turn the fuel cock to OFF Disconnect the fuel hose 1 Seat 1 2 Air scoop left and right 2 3 Bolt fuel tank 2 4 Fuel tank 1 5 Left side cover 1 Open the air filter case cover 6 Right side cover...

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

Page 61: ...ght side cover Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Bolt silencer clamp 1 Only loosening 2 Bolt silencer front 1 3 Bolt silencer rear 1 4 Collar 1 5 Silencer 1 6 Silencer clamp 1 7 Nut ex...

Page 62: ...e machine on a level place and hold it in an upright po sition 2 Remove Radiator cap 3 Check Coolant level a Coolant level low Add coolant 1 Radiator CHANGING THE COOLANT Do not remove the radiator ca...

Page 63: ...re Do not apply pressure more than specified pressure Radiator should be filled fully 4 Inspect Pressure Impossible to maintain the speci fied pressure for 10 seconds Repair Radiator Radiator hose joi...

Page 64: ...ee play adjust ment steps a Loosen the locknut 1 b Turn the adjuster 2 until free play a is within the specified lim its c Tighten the locknut After adjustment check proper oper ation of hot starter C...

Page 65: ...gh speed operation The heated oil could spurt out causing danger Wait until the oil cools down to approximately 70 C 158 F 2 Idle the engine more than 3 min utes while keeping the machine upright Then...

Page 66: ...r element 2 b Check the O rings 3 if cracked or damaged replace them with a new one c Install the oil filter element and oil filter element cover 5 Install Gaskets Oil filter drain bolt Drain bolt rig...

Page 67: ...djust Checking steps a Turn the crankshaft counterclock wise with a wrench b Align the T D C mark a on the rotor with the align mark b on the crankcase cover when piston is at T D C on compression str...

Page 68: ...fide oil on the valve stem ends Valve lifter must turn smoothly when rotated with a finger Be careful to reinstall valve lifters and pads in their original place g Install the camshafts exhaust and in...

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

Page 70: ...s a Add proper brake fluid to the res ervoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube 2 tightly to the caliper blee...

Page 71: ...08 in c away from the brake pedal 5 After the pedal height adjust ment make sure that the rear brake does not drag CHECKING AND REPLACING THE FRONT BRAKE PADS 1 Inspect Brake pad thickness a Out of sp...

Page 72: ...ransparent hose 8 to the bleed screw 9 and place the suitable container under its end f Loosen the bleed screw and push the brake caliper piston in Do not reuse the drained brake flu id g Tighten the...

Page 73: ...ocket teeth a Excessive wear Replace Replace the drive sprocket rear wheel sprocket and drive chain as a set CHECKING THE DRIVE CHAIN 1 Measure Drive chain length 15 links a Out of specification Repla...

Page 74: ...on each side of the drive chain puller alignment Turn the adjuster so that the drive chain is in line with the sprocket as viewed from the rear Too small drive chain slack will overload the engine and...

Page 75: ...rmal noise unsmooth action Grease the pivoting points or repair the pivoting points Damage oil leakage Replace ADJUSTING THE REAR SHOCK ABSORBER SPRING PRELOAD 1 Elevate the rear wheel by placing the...

Page 76: ...he position which is back by the specific number of turns from the fully turned in position Which align the punch mark a on the adjuster with the punch mark b on the adjuster body Do not force the adj...

Page 77: ...to lock Unsmooth action Adjust steer ing ring nut 4 Adjust Steering ring nut Steering ring nut adjustment steps a Remove the headlight b Remove the handlebar and upper bracket c Loosen the steering ri...

Page 78: ...uel breather hose 12 into the hole in the steer ing stem First tighten the bolts on the front side of the handlebar upper holder and then tighten the bolts on the rear side Steering stem nut 145 Nm 14...

Page 79: ...ttle to handlebar contact 6 Drive chain 7 Tube guide cable winding por tion 8 Throttle cable end 9 Clutch cable end 10 Hot starter cable end A Use Yamaha cable lube or equivalent on these areas B Use...

Page 80: ...protective eye gear when handling or working near batter ies Charge batteries in a well venti lated area Keep batteries away from fire sparks or open flames e g welding equipment lighted ciga rettes...

Page 81: ...ry overheating and battery plate damage If it is impossible to regulate the charging current on the battery charger be careful not to over charge the battery When charging a battery be sure to remove...

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

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

Page 84: ...rating may cause extensive damage to the electrical system cause the starting and ig nition systems to malfunction and could possibly cause a fire 4 Install Fuse cover Seat REPLACING THE HEADLIGHT BUL...

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

Page 86: ...topped or when riding at no load do not open and close the throttle un necessarily Otherwise too much fuel may be discharged starting may become difficult or the engine may not run well After installi...

Page 87: ...of the straight portion adjusts the air fuel mixture when the throttle is 1 8 to 1 4 open A Idle B Fully open RELATIONSHIP WITH THROTTLE OPENING The flow of the fuel through the car buretor main syst...

Page 88: ...55 4MX 09 52 4MX 08 50 4MX 07 48 4MX 06 STD Lean 45 4MX 05 Jet needle Size Part number 14916 Rich GDDUM 5TJ 9M GDDUN 5TJ 9N GDDUP 5TJ 9P GDDUQ 5TJ 91 GDDUR 5TJ 9R GDDUS 5TJ 9S Lean GDDUT 5TJ 9T Rich...

Page 89: ...Check that the accelerator pump operates smoothly except for rich mixture symp tom Rich mixture Raise jet needle clip position 1 groove up 1 4 3 4 throttle Hard breathing Lack of speed Lower jet needl...

Page 90: ...prevent a flat tire FRONT FORK SETTING The front fork setting should be made depending on the rider s feeling of an actual run and the circuit conditions The front fork setting includes the fol lowing...

Page 91: ...of stiff spring Change the rebound damping Turn in one or two clicks Change the compression damp ing Turn out one or two clicks Generally a stiff spring gives a stiff riding feeling Rebound damping t...

Page 92: ...with the rebound damping adjuster one or two clicks on the softer side and readjust it to suit your preference 2 Use of stiff spring Set the soft spring for more re bound damping to compensate for it...

Page 93: ...n adjuster clockwise about 2 clicks to in crease damping Oil level oil amount Increase oil level by about 5 10 mm 0 2 0 4 in Spring Replace with stiff spring Stiff toward stroke end Oil level oil amou...

Page 94: ...agging Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Spring Replace with soft spring Poor road gripping Rebound damping Turn adjuster counterclockwise about 2 click...

Page 95: ...eft side cover Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 3 Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 3 1 Radiator guard 2 2 Radiator hose clamp 8 3 Ri...

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

Page 97: ...1 Install Pipe 1 1 Radiator hose 1 2 Pipe 2 3 Radiator hose 3 4 Radiator hose 4 5 2 Install Radiator hose 2 1 Left radiator 2 3 Install Catch tank hose 1 Right radiator 2 Refer to CABLE ROUTING DIA G...

Page 98: ...e position sensor lead coupler 1 3 Throttle cable cover 1 4 Throttle cable 2 5 Clamp air filter joint 1 Loosen the screw air filter joint 6 Clamp carburetor joint 1 Loosen the screws carburetor joint...

Page 99: ...Screw throttle shaft 1 4 Throttle valve 1 5 Needle holder 1 6 Jet needle 1 7 Accelerator pump cover 1 8 Spring 1 9 Diaphragm accelerator pump 1 10 Air cut valve cover 1 11 Spring air cut valve 1 12 D...

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

Page 101: ...1 Bends wear Replace Clip groove Free play exists wear Replace MEASURING AND ADJUSTING THE FLOAT HEIGHT 1 Measure Float height a Out of specification Adjust Measurement and adjustment steps a Hold th...

Page 102: ...e lever 2 4 Install Spring 2 1 To lever 2 2 5 Install Push rod link lever assembly 1 Make sure the stopper a of the spring 2 fits into the recess b in the carburetor 6 Install Washer 1 Circlip 2 7 Ins...

Page 103: ...e holder drain hose 5 Screw accelerator pump cover 6 Install the diaphragm accelerator pump with its mark a facing the spring 15 Install Jet needle 1 Collar 2 Spring 3 Needle holder 4 Throttle valve p...

Page 104: ...en Bolt carburetor joint 1 Bolt air filter joint 2 5 Install Throttle cable pull 1 Throttle cable return 2 6 Adjust Throttle grip free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY section in t...

Page 105: ...e Q ty Remarks 1 Bracket 1 2 Air cut off valve assembly 1 3 Air induction hose air cut off valve front of cyl inder head 1 4 Air induction pipe 1 5 Gasket 1 6 Air induction hose air cut off valve rear...

Page 106: ...cuum pressure pump gauge set 1 When using vacuum on the pipe c take care not to exceed the specified value a From air filter b To cylinder head exhaust port c From cylinder head intake port A Check fo...

Page 107: ...IDE COVERS section in the CHAPTER 3 Air cut off valve assembly Refer to AIR INDUCTION SYSTEM section Engine upper bracket right Refer to ENGINE REMOVAL section Engine upper bracket left 1 Spark plug 1...

Page 108: ...3 Timing chain tensioner cap bolt 1 Refer to removal section 4 Timing chain tensioner 1 Refer to removal section 5 Gasket 1 Refer to removal section 6 Bolt camshaft cap 10 Refer to removal section 7...

Page 109: ...ttern working from the outside in The bolts camshaft cap must be removed evenly to prevent dam age to the cylinder head cam shafts or camshaft caps 5 Remove Exhaust camshaft 1 Intake camshaft 2 Attach...

Page 110: ...the tensioner rod lightly with fingers use a thin screwdriver 1 and wind the ten sioner rod up fully clockwise When releasing the screwdriver by pressing lightly with fingers make sure that the tensio...

Page 111: ...tensioner Installation steps a While pressing the tensioner rod lightly with fingers use a thin screwdriver and wind the tension er rod up fully clockwise b With the rod fully wound and the chain ten...

Page 112: ...ngle 180 in the proper tightening sequence Order Part name Q ty Remarks Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 3 Exhaust pipe and silencer Refer to EXHAUST P...

Page 113: ...the rotation angle procedure to ob tain uniform tightening torque a Wash the threads and contact surfaces of the bolts the contact surfaces of the plain washers the contact surface of the cylinder hea...

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

Page 115: ...marks Cylinder head Refer to CYLINDER HEAD section 1 Valve lifter 5 Refer to removal section 2 Adjusting pad 5 Refer to removal section 3 Valve cotter 10 Refer to removal section 4 Valve spring retain...

Page 116: ...212 F a Remove the valve guide using a valve guide remover 1 b Install the new valve guide using a valve guide remover 1 and valve guide installer 2 c After installing the valve guide bore the valve...

Page 117: ...nd the guide b Apply molybdenum disulfide oil to the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly pol ished then clean off all...

Page 118: ...d e Smaller pitch 3 Install Valve cotters While compressing the valve spring with a valve spring compressor 1 in stall the valve cotters 4 To secure the valve cotters onto the valve stem lightly tap t...

Page 119: ...ty Remarks Cylinder head Refer to CYLINDER HEAD section 1 Bolt cylinder 1 2 Cylinder 1 3 Gasket 1 4 Dowel pin 2 5 Piston pin clip 2 Refer to removal section 6 Piston pin 1 Refer to removal section 7 P...

Page 120: ...m edge d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with following formula f If out of specification replace the cylinder and rep...

Page 121: ...ring e Oil ring end lower 3 Install Piston 1 Piston pin 2 Piston pin clip 3 Apply engine oil onto the piston pin and piston Be sure that the arrow mark a on the piston points to the exhaust side of th...

Page 122: ...L section in the CHAPTER 3 Brake pedal Refer to ENGINE REMOVAL section Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Gasket 1 3 Dowel pin 2 4 Clutch spring 6 5 Pressure plate 1 6 Push rod...

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

Page 124: ...r points CHECKING THE CLUTCH PLATES 1 Measure Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thick ness gauge 2 CHECKING THE PUSH LEVER SHAFT 1 Inspe...

Page 125: ...n the friction plates and clutch plates Check the clutch plate for thickness and install 4 thicker ones a on the engine side and 3 thinner ones b on the outside 5 Install Bearing 1 Washer 2 Circlip 3...

Page 126: ...on Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section Brake pedal Refer to ENGINE REMOVAL section Clutch cover Refer to CLUTCH section 1 Oil filter element cover 1 2 Oil filter element 1 3 Coolan...

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

Page 128: ...mage Replace INSTALLING THE OIL SEAL 1 Install Oil seal 1 Apply the lithium soap base grease on the oil seal lip Install the oil seal with its manufac ture s marks or numbers facing the right crankcas...

Page 129: ...NSTALLING THE WATER PUMP HOUSING 1 Install Dowel pin 1 O ring 2 Apply the lithium soap base grease on the O ring 2 Install Water pump housing 1 Bolt water pump housing 2 Washer 3 Coolant drain bolt 4...

Page 130: ...section Stator Refer to CDI MAGNETO section 1 Nut balancer 1 Refer to removal section 2 Nut primary drive gear 1 Refer to removal section 3 Nut balancer shaft driven gear 1 Refer to removal section 4...

Page 131: ...stall Balancer shaft driven gear 1 Align the punched mark a on the balancer shaft drive gear with the punched mark b on the balancer shaft driven gear Install the balancer shaft driven gear and cranks...

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

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

Page 134: ...r rotor 1 2 Install Outer rotor 1 1 Apply the engine oil on the outer rotor 1 3 Install Oil pump cover 1 Screw oil pump cover 2 Dowel pin 3 Inner rotor 2 4 Circlip 5 Apply the engine oil on the oil pu...

Page 135: ...Kick idle gear 1 2 Kick shaft assembly 1 Refer to removal section 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick shaft 1 8 Washer 1 9 Shift pedal 1 10 Shift shaft 1 11 Coll...

Page 136: ...K SHAFT AND SHIFT SHAFT 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt stopper lever 1 21 Stopper lever 1 22 Torsion spring 1 23 Segment 1 Refer to removal section Order Part name Q ty Remarks ProCarManu...

Page 137: ...GEAR KICK IDLE GEAR AND RATCHET WHEEL 1 Inspect Kick gear 1 Kick idle gear 2 Ratchet wheel 3 Gear teeth a Ratchet teeth b Wear damage Replace CHECKING THE SHIFT SHAFT 1 Inspect Shift shaft 1 Bend dam...

Page 138: ...shaft 8 Apply the molybdenum disulfide oil on the inner circumferences of the kick gear and ratchet wheel Align the punch mark a on the ratchet wheel with the punch mark b on the kick shaft 2 Install...

Page 139: ...HAFT INSTALLING THE KICK IDLE GEAR 1 Install Kick idle gear 1 Washer 2 Circlip 3 Apply the engine oil on the kick idle gear inner circumference Install the kick idle gear with its de pressed side a to...

Page 140: ...in the CHAPTER 3 Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 3 Disconnect the AC magneto lead 1 Shift pedal 1 2 Cover torque limiter 1 3 Torque limiter 1 Do not...

Page 141: ...oosen and retighten the rotor nut to 65 Nm 6 5 m kg 47 ft lb 13 Starter clutch assembly cover 1 Refer to removal section 14 Starter clutch 1 Refer to removal section 15 Starter clutch drive gear 1 16...

Page 142: ...3 Check Starter clutch operation a Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch b When turning the starter clutch drive gear counterclockwise B the sta...

Page 143: ...a is in parallel with the crankshaft center line b When installing the rotor align the keyway c of the rotor with the woodruff key 6 Install Washer rotor Nut rotor 1 Use the sheave holder 2 Tighten th...

Page 144: ...IA GRAM section in the CHAPTER 2 12 Install Shift pedal 1 Bolt shift pedal When installing the shift pedal onto the shift shaft be sure that the center of the shift pedal is about 5 1 mm 0 2 in a abov...

Page 145: ...r Refer to RADIATOR section Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 3 Air cut off valve assembly Refer to AIR INDUCTION SYSTEM section Clutch cable and guid...

Page 146: ...eutral switch 1 3 Drive chain sprocket cover 1 4 Nut drive sprocket 1 Refer to removal section 5 Lock washer 1 Refer to removal section 6 Drive sprocket 1 Refer to removal section 7 Clip 1 8 Bolt brak...

Page 147: ...lower 3 Lower engine bracket 4 Bolt lower engine bracket 5 Patch 6 Engine mounting bolt front 7 Upper engine bracket 8 Bolt upper engine bracket 9 Engine mounting bolt upper 10 Apply the molybdenum d...

Page 148: ...the nut 4 Install Drive chain sprocket guide Drive chain sprocket cover 1 Screw drive chain sprocket cov er 2 INSTALLING THE NEUTRAL SWITCH 1 Install Spring 1 Pin 2 O ring 3 Neutral switch 4 Screw ne...

Page 149: ...SHAFT section Segment Refer to KICK SHAFT AND SHIFT SHAFT section Stator Refer to AC MAGNETO AND STARTER CLUTCH section 1 Timing chain guide intake side 1 2 Timing chain 1 3 Bolt L 50 mm 1 97 in 7 Re...

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

Page 151: ...BEARING Order Part name Q ty Remarks Transmission Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section Shift cam and shift fork Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section 1 Oil seal 3 2...

Page 152: ...force c Remove the dowel pins and O ring REMOVING THE BALANCER SHAFT 1 Remove Balancer shaft 1 Remove the balancer shaft with its flat side a facing the crankshaft REMOVING THE CRANKSHAFT 1 Remove Cr...

Page 153: ...Before installing the crankshaft clean the contacting surface of crankcase Do not use a hammer to drive in the crankshaft A For USA and CDN B Except for USA and CDN 2 Check Shifter operation Transmiss...

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

Page 155: ...efer to ENGINE REMOVAL section Separate the crankcase Refer to CRANKCASE AND CRANK SHAFT section 1 Main axle 1 Refer to removal section 2 Drive axle 1 Refer to removal section 3 Shift cam 1 Refer to r...

Page 156: ...IFT CAM AND SEGMENT 1 Inspect Shift fork 1 Wear damage scratches Re place 2 Inspect Shift cam 1 Segment 2 Wear damage Replace 3 Check Shift fork movement Unsmooth operation Replace shift fork For a ma...

Page 157: ...rk 1 L 1 Shift fork 2 C 2 Shift fork 3 R 3 Shift cam 4 To main axle and drive axle Apply the molybdenum disulfide oil on the shift fork grooves Apply engine oil to the shift cam groove bearing contact...

Page 158: ...able stand under the engine Refer to HANDLING NOTE 1 Bolt axle holder 4 Only loosening 2 Nut front wheel axle 1 3 Front wheel axle 1 4 Front wheel 1 5 Speed sensor 1 6 Collar 1 7 Oil seal 1 8 Bearing...

Page 159: ...NOTE 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 Refer to removal section 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 Refer to removal...

Page 160: ...only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in good condi tion replace the brake disc 2 Measure Brake disc thickness a Out of limit Replace I...

Page 161: ...el axle 1 8 Tighten Bolt axle holder 1 Before tightening the bolt fit the wheel axle to the axle holder by strok ing the front fork several times with the front brake applied INSTALLING THE REAR WHEEL...

Page 162: ...d install the drive chain 7 Install Left drive chain puller 1 Wheel axle 2 Install the left drive chain puller and insert the wheel axle from left side Apply the lithium soap base grease on the wheel...

Page 163: ...to HANDLING NOTE Drain the brake fluid Refer to removal section 1 Brake hose holder protector 2 2 Brake hose holder brake caliper 1 3 Union bolt 2 4 Brake hose 1 5 Pad pin plug 1 Remove when loosening...

Page 164: ...o HANDLING NOTE Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Drain the brake fluid Refer to removal section 1 Brake pedal 1 2 Brake master cylinder 1 3 Brake hose holder 2 4 Union bolt 2 5 B...

Page 165: ...name Q ty Remarks A Front B Rear A B 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Brake caliper piston 2 1 Refer to removal section 5 Brake caliper piston dust seal 2 1 Refer to removal section 6...

Page 166: ...CYLINDER Order Part name Q ty Remarks A Front B Rear 1 Brake master cylinder cap 1 2 Diaphragm 1 3 Reservoir float 1 4 Brake master cylinder boot 1 5 Circlip 1 Use a long nose circlip pliers 6 Washer...

Page 167: ...Insert a piece of rag into the brake caliper to lock one brake caliper b Carefully force the piston out of the brake caliper cylinder with compressed air A Front B Rear REMOVING THE BRAKE CALIPER PIST...

Page 168: ...seal Brake caliper piston Clean them with brake fluid 2 Install Brake caliper piston seal 1 Brake caliper piston dust seal 2 Always use new brake caliper pis ton seals and brake caliper piston dust se...

Page 169: ...roper brake performance A Front B Rear 3 Install Spring 1 To brake master cylinder piston 2 Install the spring at the smaller dia side A Front B Rear 4 Install Brake master cylinder kit 1 Washer front...

Page 170: ...se grease on the bolt O ring and brake pedal bracket 4 Install Pin 1 Washer 2 Cotter pin 3 After installing check the brake pedal height Refer to ADJUSTING THE REAR BRAKE section in the CHAP TER 3 INS...

Page 171: ...rear shock absorber If it does correct its twist FILLING THE BRAKE FLUID 1 Fill Brake fluid Until the fluid level reaches LOWER level line a Use only the designated quality brake fluid otherwise the r...

Page 172: ...ke master cylin der cap 2 After installation while pulling the brake lever in or pushing down on the brake pedal check whether there is any brake fluid leaking where the union bolts are installed resp...

Page 173: ...NOTE Front wheel Refer to FRONT WHEEL AND REAR WHEEL section Front brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Headlight Handlebar Refer to HANDLEBAR section 1 Protector 1 2 Pinch bolt...

Page 174: ...Drain the fork oil 3 Dust seal 1 Refer to removal section 4 Stopper ring 1 Refer to removal section 5 Inner tube 1 Refer to removal section 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Oil seal w...

Page 175: ...the inner tube 2 Remove Inner tube 1 Oil seal removal steps a Push in slowly a the inner tube just before it bottoms out and then pull it back quickly b b Repeat this step until the inner tube can be...

Page 176: ...en Base valve 1 Use a damper rod holder 2 to lock the damper rod 3 Apply the LOCTITE on the base valve thread 5 Install Spring guide 1 Locknut 2 To damper rod 3 Install the spring guide with its small...

Page 177: ...urface with recom mended fork oil once more 18 After filling pump the outer tube 1 slowly up and down about 200 mm 7 9 in stroke to distrib ute the fork oil once more Be careful not to excessive full...

Page 178: ...hat it will not go down 24 Install Spring seat 1 Front fork cap bolt 2 Fully finger tighten the front fork cap bolt onto the damper rod 25 Tighten Front fork cap bolt locknut 1 Hold the locknut 2 and...

Page 179: ...plate 1 with the same paint 6 Install Speed sensor lead 1 Plate 2 2 Screw plate 2 3 To right protector 4 Install the plate 2 in the direction as shown 7 Install Protector 1 Bolt protector 2 8 Adjust...

Page 180: ...op switch 1 Disconnect the engine stop switch lead 6 Brake master cylinder 1 Refer to removal section 7 Start switch 1 Disconnect the start switch lead 8 Throttle cable cap 1 9 Throttle cable 1 pulled...

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

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

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

Page 184: ...he suitable stand under the engine Refer to HANDLING NOTE Headlight Handlebar Refer to HANDLEBAR section Front brake hose guide Front fender 1 Multi function display 1 2 Multi function display bracket...

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

Page 186: ...bearings by hand If the bearings hang up or are not smooth in their operation in the bearing races replace bearings and bearing races as a set INSTALLING THE LOWER BRACKET 1 Install Lower bearing 1 A...

Page 187: ...to speci fied torque If torqued too much it may cause the front fork to mal function 13 Install Multi function display bracket 1 Multi function display 2 Pass the throttle cables 3 clutch ca ble 4 and...

Page 188: ...rake hose holder Refer to FRONT BRAKE AND REAR BRAKE section Rear brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Bolt brake pedal Shift the brake pedal backward Drive chain 1 Drive chain su...

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

Page 190: ...amage Replace INSTALLING THE BEARING AND OIL SEAL 1 Install Bearing 1 Oil seal 2 To swingarm Apply the molybdenum disulfide grease on the bearing when install ing Install the bearing by pressing it on...

Page 191: ...disulfide grease on the bolt circumference and threaded portion Do not tighten the nut yet 6 Install Swingarm 1 Pivot shaft 2 Apply the molybdenum disulfide grease on the pivot shaft Insert the pivot...

Page 192: ...ain tensioner 5 14 Install Drive chain support 1 Drive chain support cover 2 Bolt drive chain support L 50 mm 1 97 in 3 Nut drive chain support 4 Bolt drive chain support cover L 10 mm 0 39 in 5 Nut r...

Page 193: ...coolant Refer to CHANGING THE COOLANT sec tion in the CHAPTER 3 Catch tank breather hose Disconnect at the catch tank side Catch tank hose Disconnect at the catch tank side Air induction hose air cut...

Page 194: ...ar shock absorber relay arm 1 Hold the swingarm 8 Bolt rear shock absorber frame 1 9 Rear shock absorber 1 10 Locknut 1 Only loosening 11 Adjuster 1 Only loosening 12 Lower spring guide 1 13 Upper spr...

Page 195: ...shock ab sorber be sure to extract the nitrogen gas from valve 1 Wear eye protec tion to prevent eye damage from es caping gas and or metal chips To dispose of a damaged or worn out rear shock absorbe...

Page 196: ...ly the molybdenum disulfide grease on the bearing and dust seal lips Install the dust seals with their lips facing outward 3 Install Rear shock absorber 4 Install Bolt rear shock absorber frame 1 Wash...

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

Page 198: ...3 Engine stop switch 4 Clutch switch 5 Diode 6 Starter relay diode 7 Throttle position sensor 8 Starter relay 9 Fuse 10 Starting circuit cut off relay 11 CDI unit 12 Taillight 13 Neutral switch 14 St...

Page 199: ...11 CDI unit 12 Taillight 13 Neutral switch 14 Starter motor 15 AC magneto 16 Rectifier regulator 17 Ignition coil 18 Spark plug 19 Start switch 20 Main switch 21 Speed sensor 22 Battery COLOR CODE B...

Page 200: ...llowing special tools in this inspection 1 Check fuse No good Replace fuse and check wire harness OK 2 Check battery No good Recharge or replace OK Spark gap test Spark 3 Clean or replace spark plug N...

Page 201: ...KING THE MAIN SWITCH 1 Inspect Main switch conduction Not conductive while the main switch is moved to ON Replace Conductive while the main switch is moved to OFF Replace Set the tester selection posi...

Page 202: ...tral the neutral switch is closed The clutch lever is pulled to the han dlebar the clutch switch is closed The starting circuit cut off relay pre vents the starter motor from operating when neither of...

Page 203: ...ry in this inspection Use the following special tools in this inspection 1 Check fuse No good Replace fuse and check wire harness OK 2 Check battery No good Recharge or replace OK Check each coupler a...

Page 204: ...1 Inspect Clutch switch conduction Not conductive while it is pulled Re place Conductive while it is freed Re place Set the tester selection position to 1 CHECKING THE DIODE 1 Remove the diode from w...

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

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

Page 207: ...MOTOR Order Part name Q ty Remarks 1 Starter motor front cover 1 2 Washer starter motor front cover 1 3 Washer 1 4 Circlip 1 5 O ring 1 6 Starter motor yoke 1 7 Armature assembly 1 8 Starter motor rea...

Page 208: ...ASSEMBLING THE STARTER MOTOR 1 Install Brush spring 1 Brush 2 2 Install Armature assembly 1 Install while holding down the brush using a thin screw driver Be careful not to damage the brush during ins...

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

Page 210: ...following parts before inspection 1 Seat 2 Fuel tank Use the following special tools in this inspection 1 Check fuse No good Replace fuse and check wire harness OK 2 Check battery No good Recharge or...

Page 211: ...cification If no failure is found in checking the source coil resistance replace the rectifi er regulator 3 Inspect Charging coil resistance Out of specification Replace Tester lead Red lead 1 Tester...

Page 212: ...ing inspection steps Use the following special tools in this inspection Check entire ignition system for connection No good Repair or replace OK Check throttle position sensor Throttle position sensor...

Page 213: ...the throttle posi tion sensor with the projection b on the carburetor Temporarily tighten the screw throttle position sensor 5 Install Carburetor Throttle position sensor coupler 6 Adjust Engine idli...

Page 214: ...all the carburetor CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1 Disconnect the throttle position sensor coupler 2 Start the engine 3 Inspect Throttle position sensor input volt age Out of spe...

Page 215: ...special tools in this inspection Check the bulb and bulb socket No good Replace the bulb and or bulb socket OK Check the taillight LEDs No good Replace the taillight assembly OK Check the AC magneto L...

Page 216: ...or fluid is in the vicinity CHECKING THE AC MAGNETO 1 Inspect Lighting coil resistance Out of specification Replace CHECKING THE RECTIFIER REGULATOR 1 Connect the battery leads 2 Start the engine 3 Tu...

Page 217: ...inspection 1 Headlight Use the following special tools in this inspection 1 Check battery No good Recharge or replace OK Check each coupler and wire connection No good Repair or replace OK Check multi...

Page 218: ...UTPUT VOLTAGE 1 Insert the thin electric conductors 1 lead into the speed sensor coupler 2 as shown and con nect the tester to them Do not insert the electric conduc tors more than required because it...

Page 219: ...ProCarManuals com...

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

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Yamaha WR450FX, Owner'S Service Manual

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