Yamaha YZ450F 2021 Owner'S Service Manual Download Page 46

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GENERAL SPECIFICATIONS

2-1

EAM20127

GENERAL SPECIFICATIONS

Model

Model

B2W5

Dimensions

Overall length

2185 mm (86.0 in)

Overall width

825 mm (32.5 in)

Overall height

1285 mm (50.6 in)

Seat height

965 mm (38.0 in)

Wheelbase

1485 mm (58.5 in)

Ground clearance

330 mm (12.99 in)

Weight

Curb weight

111 kg (245 lb)

Riding capacity

1 person

Summary of Contents for YZ450F 2021

Page 1: ...Read this manual carefully before operating this vehicle 2021 OWNER S SERVICE MANUAL YZ450F YZ450FM LIT 11626 34 12 B2W 2819U 11 ...

Page 2: ...s and lead which are known to the State of California to 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 wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehicle ...

Page 3: ... user s authority to operate the equipment This transmitter must not be co located or operated in conjunction with any other antenna or transmitter This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment and meets the FCC radio frequency RF Exposure Guidelines This equipment has very low levels of RF energy that is deemed to comply without maximum permi...

Page 4: ...ANUAL 2021 by Yamaha Motor Corporation U S A First edition April 2020 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited P N LIT 11626 34 12 ...

Page 5: ...quested not to undertake inspection adjustment disassem bly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage WARNING EWA20270 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU H...

Page 6: ...EAM20162 YAMAHA MOTOR CORPORATION U S A YZ MOTORCYCLE LIMITED WARRANTY ...

Page 7: ...ure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a removal or a disassembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction chart 6 accompanies the exploded diagram providing the order of jobs the names of parts the notes ...

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

Page 9: ...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: ...NT INFORMATION 1 9 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 9 REPLACEMENT PARTS 1 9 GASKETS OIL SEALS AND O RINGS 1 9 LOCK WASHERS PLATES AND COTTER PINS 1 10 BEARINGS AND OIL SEALS 1 10 CIRCLIPS 1 10 BASIC SERVICE INFORMATION 1 11 ELECTRICAL SYSTEM 1 11 SPECIAL TOOLS 1 15 INSTRUMENT AND CONTROL FUNCTIONS 1 21 ENGINE STOP SWITCH 1 21 START SWITCH 1 21 LAUNCH CONTROL SWITCH 1 21 MODE SWITCH 1 21 S...

Page 12: ...1 25 BREAK IN PROCEDURES 1 25 ENGINE STARTING PRECAUTION 1 25 MAINTENANCE AFTER BREAK IN 1 26 MAJOR MAINTENANCE 1 26 AIR FILTER MAINTENANCE 1 26 TORQUE CHECK POINTS 1 27 MOTORCYCLE CARE AND STORAGE 1 29 CARE 1 29 STORAGE 1 30 ...

Page 13: ...re 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 motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspic uous appears to be very effective in reducing the chance of this type...

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 companies produce Therefore Yamaha can neither endorse nor recommend the use of accessories not sold by Yamaha or modifications not specifically recommended by Yamaha even if sold and installed by a ...

Page 15: ...he 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 Shift the transmission in gear for models with a manual transmission 5 Secure the motorcycle with tie downs or suit able straps that are attached to solid parts of the motorcycle such as the frame or ...

Page 16: ...gasoline only 3FB 2415E 02 4AA 22259 80 WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open 17D 2812P 00 For use only on a closed course in sanctioned competition This motorcycle does not meet EPA noise and emissions standards and is not for general off road recreational riding ...

Page 17: ...e for the vehicle you have purchased 1 11 12 13 14 15 16 17 18 19 2 3 6 4 5 7 8 9 10 1 Clutch lever 2 Front brake lever 3 Throttle grip 4 Start switch 5 Launch control switch 6 Radiator cap 7 Fuel tank cap 8 Mode switch 9 Engine stop switch 10 Fuel tank 11 Radiator 12 Coolant drain bolt 13 Rear brake pedal 14 Air filter 15 Drive chain 16 Shift pedal 17 Oil level check window 18 Starter knob 19 Fro...

Page 18: ...ositive identi fication of the model you own 2 If your vehicle is stolen the authorities will need the number to search for and identify 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 into the elevated part of the right side of the engine 1 1 1 1 ...

Page 19: ...ur smartphone and wirelessly connecting to the CCU wireless network you can adjust various vehicle settings WARNING EWA20460 Do not operate the engine in a closed area The exhaust gas is poisonous Never let flames near the servicing area NOTICE ECA26050 This application is designed for adjusting the settings on a standard vehicle In case the engine specifications muffler com pression ratio etc hav...

Page 20: ...as radios or mobile phones in close proximity of the CCU The CCU is in contact with or covered by a metallic object Other vehicles equipped with a CCU are nearby In such situations move the CCU to another location and perform the operation again 1 Turn on the smartphone 2 For two minutes after the start switch is pressed or while the engine is running the CCU is activated input the CCU serial num ...

Page 21: ...red 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 your eyes wash it away with wa ter enough and then get medical attention If it splashes on your skin or clothes quick ly wash it away with water and then with soapy water If it is swallowed immediate...

Page 22: ...oil 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 with compressed air because this will damage the bearing surfac es EAM30014 CIRCLIPS When assembling parts always use new cir clips During installation of a circlip make sure that the edge 2 of the cir...

Page 23: ...ly 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 battery terminals Reversing the bat tery lead connections could damage the electrical components NOTICE ECA16771 When connecting the battery leads to the battery be sure to connect the positive bat ter...

Page 24: ...lti 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 into the cou pler terminal slots Always insert the probes from the opposite end a of the coupler tak ing care not to loosen or damage the leads NOTICE ECA16640 For waterproof couplers never insert t...

Page 25: ...oth 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 connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up After disassembling or assembling a coupler pull on the leads to make sure that they are in stal...

Page 26: ...If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 4 As a quick remedy use a contact revitalizer available at most part stores Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 ...

Page 27: ...ber starting 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 A1927 1 14 5 45 8 44 8 45 8 47 8 47 8 48 8 49 8 49 8 49 8 50 8 51 8 51 8 52 8 52 8 53 8 53 Thickness gauge 90890 03268 Feeler gauge set YU 26900 9 3 6 5 50 Valve lapper ø14 90890 04101 Valve lapp...

Page 28: ...2 3 27 4 56 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 4 44 4 44 4 45 4 48 4 51 4 53 Cap bolt wrench 90890 01500 Cap bolt wrench YM 01500 4 45 4 48 Fork seal driver 90890 01502 Fork seal driver 48 YM A0948 4 49 4 50 Tool name Tool No Illustration Referen...

Page 29: ...ing compressor adapter 22 mm YM 04108 5 27 5 31 Valve guide remover installer set ø5 5 90890 04016 Valve guide remover 5 5 mm YM 01122 5 29 Valve guide installer ø5 5 90890 04015 Valve guide installer 5 5 mm YM 04015 5 29 Valve guide reamer 5 5 mm 90890 01196 Valve guide reamer 5 5 mm YM 01196 5 29 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 34 Tool name Tool No Illustration Ref...

Page 30: ...Universal clutch holder YM 91042 5 50 5 53 Crankcase separating tool 90890 04152 Crankcase separating tool YU A9642 5 69 Crankshaft installer pot 90890 01274 Installing pot YU 90058 5 70 Crankshaft installer bolt 90890 01275 Bolt YU 90060 5 70 Tool name Tool No Illustration Reference pages YU 90058 YU 90059 ...

Page 31: ...acer YM 91044 5 70 Radiator cap tester 90890 01325 Mityvac cooling 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 Tool name Tool No Illustration Reference pages YM 91044 YU 24460 A YU 33984 ...

Page 32: ...um battery charger 90890 05376 Lithium battery charger DBY ACC51 70 02 8 46 8 46 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 48 Test harness S pressure sensor 3P 90890 03207 Test harness S pressure sensor 3P YU 03207 8 52 Tool name Tool No Illustration Reference pages ...

Page 33: ... man ner on a slippery road surface However the effect may not be adequate de pending on the rider s operations and road sur face conditions How to operate 1 Put the gear into the neutral position 2 Start the engine 3 Push the launch control switch for more than one second to turn on the launch control switch TIP When the launch control switch is turned on but ton 1 will flash 4 Put the gear into ...

Page 34: ...t handlebar Pull it toward the handlebar to acti vate the front brake EAM30189 REAR BRAKE PEDAL The rear brake pedal 1 is in the right of the chassis Press down on the brake pedal to acti vate the rear brake EAM30444 STARTER KNOB Starting a cold engine requires a larger amount of intake air which is supplied by the starter knob 1 Pushing the knob toward a turns ON the start er resulting in a large...

Page 35: ... cover 2 Remove the fuel tank cap cover to open the fuel tank cap TIP To remove the fuel tank cap cover insert fin gers under part a and then use both hands to lift it up towards the rear of the vehicle 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 36: ...ehicle performance problems EAM30196 STARTING A COLD ENGINE 1 Press the shift pedal to neutral 2 Push the starter knob 1 completely TIP When the ambient temperature is 15 C 59 F or below use the starter knob Do not operate the throttle grip when operating the starter knob 3 Start the engine by pushing the start switch If the engine fails to start when using the start switch release it wait a few s...

Page 37: ...seness oil leaks or other problems Thorough checks and ad justments are required in particular for stretch of cables free play of the brake stretch of the drive chain looseness of the spoke and so on NOTICE ECA25821 After a break in or after each race always check the points shown in TORQUE CHECK POINTS for tightening torques and retighten them Also when the following parts are replaced a break in...

Page 38: ...s 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 bracket and so on for looseness and cracks Wheel s Check the wheel for runout Check the spoke for looseness Brake s Check the brake disc mounting bolt for loose ness Check that the reservoir contains the...

Page 39: ...e 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 Tightening of wheel axle Tightening of axle holder Tightening of spoke nipple Rear Tightening of wheel axle Wheel to rear wheel sprocket Tightening of spoke nipple Brake s Front Brake caliper to front fork Brake ...

Page 40: ...ft 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 rear fender Tightening of mud flap Tightening of rear brake disc cover Tightening of rear brake caliper cover ...

Page 41: ...ly 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 lenses etc and the mufflers Use only a soft clean cloth or sponge with water to clean plastic However if the plastic parts cannot be thor oughly cleaned with water diluted mild de tergent with water m...

Page 42: ...and 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 completely before storing or covering it WARNING EWA19050 Contaminants on the brakes or tires can cause loss of control Make sure that there is no oil or wax on the brakes or tires If necessary clean ...

Page 43: ...rk 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 all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so tha...

Page 44: ...MOTORCYCLE CARE AND STORAGE 1 32 ...

Page 45: ...CATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 5 ELECTRICAL SPECIFICATIONS 2 8 TIGHTENING TORQUES 2 9 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 9 ENGINE TIGHTENING TORQUES 2 10 CHASSIS TIGHTENING TORQUES 2 13 CABLE ROUTING DIAGRAM 2 17 ...

Page 46: ...odel Model B2W5 Dimensions Overall length 2185 mm 86 0 in Overall width 825 mm 32 5 in Overall height 1285 mm 50 6 in Seat height 965 mm 38 0 in Wheelbase 1485 mm 58 5 in Ground clearance 330 mm 12 99 in Weight Curb weight 111 kg 245 lb Riding capacity 1 person ...

Page 47: ...S 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 Coolant quantity Radiator including all routes 1 03 L 1 09 US qt 0 91 Imp qt Radiator cap valve opening pressure 107 9 137 3 kPa 1 08 1 37 kgf cm 15 6 19 9 psi Spark plug s Manufacturer model NGK LMAR8G Spark plug gap 0 7 0 8 mm 0 028 0 031 in Cylinder head Warpage limit 0 05 mm...

Page 48: ...n Measuring point from piston skirt bottom 9 0 mm 0 35 in Piston pin bore inside diameter limit 18 045 mm 0 7104 in Piston pin outside diameter limit 17 981 mm 0 7079 in Piston pin to piston pin bore clearance 0 004 0 024 mm 0 0002 0 0009 in Piston ring Top ring End gap limit 0 55 mm 0 0217 in Ring side clearance 0 015 0 065 mm 0 0006 0 0026 in Side clearance limit 0 120 mm 0 0047 in 2nd ring End ...

Page 49: ...e runout limit 0 08 mm 0 0032 in Secondary reduction ratio 3 769 49 13 Final drive Chain Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil Fuel pump Pump type Electrical Maximum consumption amperage 2 4 A Fuel injector Resistance 12 0 Throttle body ID mark BR91 Idling condition Engine idling speed 1900 2100 r min Coolant ...

Page 50: ...l DUNLOP MX33 Tire air pressure 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 limit as measured on wheel 0 15 mm 0 0059 in Brake pad lining thickness limit 1 0 mm 0 04 in Master cylinder inside diameter 9 52 mm 0 37 in Caliper cylinder inside diameter L...

Page 51: ... type Unit for compression damping adjustment Click Adjustment value from the start position Soft 20 Adjustment value from the start position STD 9 Adjustment value from the start position Hard 0 Rear suspension Type Swingarm link suspension Spring Coil spring Shock absorber Gas hydraulic damper Spring preload Adjusting system Mechanical adjustable type Adjustment value Soft 1 5 mm 0 06 in Adjustm...

Page 52: ...mping Unit for adjustment Click Adjustment value from the start position Soft 20 Adjustment value from the start position STD 9 Adjustment value from the start position Hard 0 Drive chain Size 520 Chain type Non sealed type Number of links 114 Drive chain slack Maintenance stand 50 0 60 0 mm 1 97 2 36 in 15 link length limit 242 9 mm 9 56 in ...

Page 53: ...ingle phase Regulated voltage DC 14 0 14 8 V Battery Model BR98 Voltage capacity 12 V 2 4 Ah 5 HR Starter motor Brush overall length 11 0 mm 0 43 in Brush overall length limit 5 5 mm 0 22 in Brush spring force 4 80 7 20 N 489 734 gf 17 28 25 92 oz Mica undercut depth 2 40 mm 0 09 in Fuel injection sensor Crankshaft position sensor resistance 228 342 Intake air temperature sensor resistance 5400 66...

Page 54: ...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 specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques N m kgf m lb ft 10 mm 6 mm 6 0 6...

Page 55: ... 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 Timing chain tensioner cap bolt M6 1 6 N m 0 6 kgf m 4 4 lb ft Timing chain tensioner bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Coolant drain bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft Radiator hose clamp screw M6 8 1 5 N m 0 15 kgf m 1 1 lb ...

Page 56: ...t Drive sprocket cover bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Crankcase bearing cover plate screw M8 4 22 N m 2 2 kgf m 16 lb ft Bearing plate cover bolt left side of the drive axle M6 2 12 N m 1 2 kgf m 8 9 lb ft Plate bolt M6 4 12 N m 1 2 kgf m 8 9 lb ft Starter motor cover bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft Clutch cover bolt M6 7 10 N m 1 0 kgf m 7 4 lb ft Crankcase cover bolt left M6 7 10 N m 1...

Page 57: ...f 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 sensor bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Stator coil assembly lead holder bolt M5 1 8 N m 0 8 kgf m 5 9 lb ft Coolant temperature sensor M10 1 15 N m 1 5 kgf m 11 lb ft Gear position switch bolt M5 2 3 5 N m 0 35 kgf m 2 6 lb ft Rectifier regulator bolt M6 2 7 ...

Page 58: ...der bolt M6 2 9 N m 0 9 kgf m 6 6 lb ft Throttle grip cap screw M5 2 3 8 N m 0 38 kgf m 2 8 lb ft Clutch lever holder bolt M6 2 5 N m 0 5 kgf m 3 7 lb ft Clutch lever nut M6 1 4 0 N m 0 40 kgf m 3 0 lb ft Clutch lever position locknut M5 1 4 8 N m 0 48 kgf m 3 5 lb ft Front brake master cylinder holder bolt M6 2 9 N m 0 9 kgf m 6 6 lb ft Front brake master cylinder reservoir cap screw M4 2 1 5 N m...

Page 59: ... 0 7 kgf m 5 2 lb ft Engine mounting bolt upper side M10 2 45 N m 4 5 kgf m 33 lb ft Engine mounting bolt front side M10 1 55 N m 5 5 kgf m 41 lb ft Engine mounting bolt lower side M10 1 53 N m 5 3 kgf m 39 lb ft Engine bracket bolt upper side M8 4 34 N m 3 4 kgf m 25 lb ft Engine bracket bolt front side M8 4 34 N m 3 4 kgf m 25 lb ft Rear frame bolt M8 4 38 N m 3 8 kgf m 28 lb ft Engine guard bol...

Page 60: ... m 3 0 lb ft Screw fuel inlet pipe M5 2 3 5 N m 0 35 kgf m 2 6 lb ft Bolt fuel tank cap cover M6 2 4 0 N m 0 40 kgf m 3 0 lb ft Seat set bracket screw M6 1 7 N m 0 7 kgf m 5 2 lb ft Seat bolt M8 2 22 N m 2 2 kgf m 16 lb ft Side cover bolt left M6 2 7 N m 0 7 kgf m 5 2 lb ft Side cover bolt right M6 2 7 N m 0 7 kgf m 5 2 lb ft Air scoop bolt frame M6 2 7 N m 0 7 kgf m 5 2 lb ft Air scoop bolt fuel ...

Page 61: ...TIGHTENING TORQUES 2 16 ...

Page 62: ...CABLE ROUTING DIAGRAM 2 17 EAM20152 CABLE ROUTING DIAGRAM Frame and engine left side view ...

Page 63: ...e radiator Be sure the lead will not be pinched between the radiator and the tension arm H Fasten the starter motor lead to the bracket using the plastic locking tie Position the lock part of the plastic locking tie to rear side of the vehicle Cut the end of the plastic locking tie I Route the starter motor lead along the cylin der body without slack J Route the gear position sensor along the cran...

Page 64: ...CABLE ROUTING DIAGRAM 2 19 Frame and engine right side view ...

Page 65: ...ar of the vehicle The cylinder head breather hose at the rear of the vehicle The lower radiator boss at the front of the vehicle The radiator hose at the front of the vehicle For routing the remaining leads refer to the diagram Z under Frame and engine left side view H Pass the cylinder head breather hose between the radiator hose and the engine bracket I Install the cylinder head breather hose so...

Page 66: ...CABLE ROUTING DIAGRAM 2 21 Handlebar front view ...

Page 67: ... of the number plate band C Secure the engine stop switch lead and mode switch lead to the handlebar using the plastic locking tie Do not cut off the end of the plastic locking tie D Pass the engine stop switch lead and mode switch lead between the frame and the cable guide E Pass the front brake hose through the front side of the number plate F Pass the start switch lead between the frame and the...

Page 68: ...CABLE ROUTING DIAGRAM 2 23 Frame and engine top view ...

Page 69: ... A Fasten the main harness and start switch lead using the clamp and insert the clamp projection into the hole in the sheet metal of the radiator The direction of the clamp lock portion does not matter When assembling it is allowed to run the leads near the radiator cap on the inside B No pinch is allowed the leads between the tank rail and the air filter joint C Insert the projection of the main ...

Page 70: ...CABLE ROUTING DIAGRAM 2 25 Frame and battery top view ...

Page 71: ...nto the battery bracket and fasten it C After connecting the negative battery coupler position to the right side of the starter relay D The position of the starter motor lead and negative battery lead does not matter E Pass the negative battery lead through lower side of the cross member F The position of the negative battery lead in relation to the battery side and coupler side and the correspond...

Page 72: ...CABLE ROUTING DIAGRAM 2 27 Rear brake right side view ...

Page 73: ... brake 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 the rear brake hose is not excessively twisted F Make sure that the metal part of the rear brake hose contacts the stopper of the rear brake master cylinder G Install the rear brake hose so that...

Page 74: ...CABLE ROUTING DIAGRAM 2 29 ...

Page 75: ...CKING THE COOLANT LEVEL 3 20 CHECKING THE COOLING SYSTEM 3 21 CHANGING THE COOLANT 3 21 CHASSIS 3 23 ADJUSTING THE FRONT DISC BRAKE 3 23 ADJUSTING THE REAR DISC BRAKE 3 23 CHECKING THE BRAKE FLUID LEVEL 3 24 CHECKING THE FRONT BRAKE PADS 3 24 CHECKING THE REAR BRAKE PADS 3 24 CHECKING THE FRONT BRAKE HOSE 3 24 CHECKING THE REAR BRAKE HOSE 3 25 CHECKING THE BRAKE OPERATION 3 25 BLEEDING THE HYDRAUL...

Page 76: ...RS 3 33 CHECKING AND LUBRICATING THE CABLES 3 33 LUBRICATING THE BRAKE LEVER 3 34 LUBRICATING THE CLUTCH LEVER 3 34 LUBRICATING THE PEDAL 3 34 ELECTRICAL SYSTEM 3 35 CHECKING AND CHARGING THE BATTERY 3 35 CHECKING THE FUSES 3 35 CHECKING THE IGNITION TIMING 3 35 ...

Page 77: ... hours Every third race about 7 5 hours Every fifth race about 12 5 hours As required 1 Valve Check the valve clearances Check the valve seats and the valve faces for wear Replace 2 Valve spring Check the free length Replace 3 Valve lifter Check for scratches and wear Replace 4 Camshaft Inspect the camshaft surface Inspect the decompression sys tem Replace 5 Timing chain Check for damage and stick...

Page 78: ...lencer protector Check for exhaust leaks and tightening torques Clean Replace fiver When the exhaust sound becomes louder or when a perfor mance drop is felt 21 Crankshaft Inspect and clean 22 Throttle body Inspect 23 Air filter Clean and lubricate Replace 24 Spark plug Check the electrodes and the ter minals for wear Replace 25 Cooling system Check coolant level and leakage Check radiator cap ope...

Page 79: ...Inspect lube and retighten 35 Relay arm connect ing rod Inspect lube and retighten 36 Steering head Inspect free play and retighten Check for tightening torques Clean and lube After rain ride Replace bearings 37 Tire wheels Inspect air pressure wheel run out tire wear and spoke loose ness Retighten sprocket bolt Check the bearing Replace bearings Lubricate 38 Drive chain Clean lubricate slack alig...

Page 80: ...ootrest Lubricate 44 Outside nuts and bolts Retighten 45 Battery Check terminal for looseness and corrosion No Item Routine After break in Every race about 2 5 hours Every third race about 7 5 hours Every fifth race about 12 5 hours As required ...

Page 81: ...23 3 23 3 24 3 24 3 24 3 24 3 25 3 25 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 26 4 69 4 69 4 70 4 70 4 70 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play 3 32 3 33 3 33 3 33 Steering Check that the handlebar can be turned smoothly and have no excessive play 3 27 Front forks and rear sh...

Page 82: ... cover left right Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 ECU 2 Remove Spark plug Cylinder head cover Refer to CAMSHAFT on page 5 13 3 Remove Timing mark accessing screw 1 Crankshaft end accessing screw 2 O ring 4 Check Valve clearance Out of specification Regulate a Turn the crankshaft counterclockwise with a wrench b Align the top dead c...

Page 83: ...r 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 where the number on the originally in stalled adjusting pad and the measured valve clearance intersect shows the adjusting pad number to replace Example Pad number 148 Rounded value 150 e Install the new ...

Page 84: ...eir 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 adjusting the valve clearance until it is within specification M E 4 5 ...

Page 85: ...180 185 190 195 200 205 210 215 220 225 230 235 240 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 84 185 190 195 200 205 210 215 220 225 230 235 240 0 85 0 89 190 195 200 205 210 215 220 225 230 235 240 0 90 0 94 195 200 205 210 215 220 225 230 235 240 0 95 0 99 200 205 210 215 220 225 230 235 240 1 00 1 04 20...

Page 86: ...215 220 225 230 235 240 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 84 180 185 190 195 200 205 210 215 220 225 230 235 240 0 85 0 89 185 190 195 200 205 210 215 220 225 230 235 240 0 90 0 94 190 195 200 205 210 215 220 225 230 235 240 0 95 0 99 195 200 205 210 215 220 225 230 235 240 1 00 1 04 200 20...

Page 87: ... 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 Adjust Engine idling speed a Turn the idle screw 1 to make an adjust ment EAM30475 CHECKING THE THROTTLE GRIP TIP Prior to adjusting throttle grip free play the en gine idling speed should be adjusted 1...

Page 88: ... 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 cylinder clean it before re moving the spark plug 3 Check Spark plug type Wrong type Replace 4 Check Electrode Damage wear Replace the spark plug Insulator Abnormal color Replace the spark plug Norma...

Page 89: ...ives could 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 Start the engine warm this up for several minutes and then stop the engine and wait about 5 minutes TIP This model is equipped with an engine auto stop system The engine stops automatically ...

Page 90: ...heck 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 make sure that the engine oil flows and that the engine oil level decreases TIP Check the engine oil level while the engine is at idling speed Oil filter element cover bolt 10 N m 1 0 kgf m 7 4 lb ft ...

Page 91: ...ndlebar 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 free play is obtained d Tighten the locknut 1 e Return the clutch cable cover to its original position EAM30370 ADJUSTING THE CLUTCH LEVER POSITION 1 Adjust Clutch lever position a Loosen the locknut 1 and use the adju...

Page 92: ...into a plastic bag and drip the filter oil into the bag b With the element inside the bag rub it thoroughly so that 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 but not dripping When replacing the element permeate the el ement in oil by using the sam...

Page 93: ...ocat ed on the left and right sides of the air filter case cover with the projections d on the air scoop and then install the air filter case cover 10 Install Fuel 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 Refer to GENERAL CHASSIS on page 4 1 Fu...

Page 94: ...ed correctly EAM30221 CHECKING THE EXHAUST SYSTEM 1 Remove Exhaust pipe 1 Exhaust pipe 2 Refer to ENGINE REMOVAL on page 5 6 2 Remove Exhaust pipe protector 3 Check Exhaust pipe 1 Exhaust pipe 2 4 Check Silencer Crack damage Replace 5 Replace Silencer fiber a Remove the bolts 1 and silencer body 2 NOTICE ECA25800 Do not hit the silencer stay a as it may do damage to the silencer TIP Remove the inn...

Page 95: ...nto the silencer body by using a flat board 11 h Install the fiber insert 12 to the inner pipe i Install the fiber insert 13 to the inside of the silencer cap 14 j Install the silencer cap 15 and rivet 16 TIP Apply heat resistant sealant to the areas e shown making sure that there are no gaps in the beads of sealant Take care not to allow the fiber out of place when installing the silencer body 17...

Page 96: ...ing sound has stopped press down on the radi ator cap and turn it counterclockwise to re move 1 Stand the vehicle upright on a level surface 2 Remove Radiator cap 1 3 Check Coolant level Maximum level a or below Add coolant up to the maximum level NOTICE ECA24260 Adding water instead of coolant lowers the antifreeze content If therefore water is used instead of coolant check and if nec essary adju...

Page 97: ... 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 to re move 1 Place a container under the engine 2 Remove Coolant drain bolt 1 3 Remove Radiator cap Slowly loosen the radiator cap to drain cool ant TIP When the radiator cap is loosened coolant will gush out transversely therefore bring the con tainer n...

Page 98: ... used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 7 Install Radiator cap 8 Start the engine warm this up for several minutes stop it and then wait for it to cool down 9 Check Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 20 ...

Page 99: ... will consid erably reduce braking performance NOTICE ECA13490 After adjusting the brake lever position make sure there is no brake drag 4 Install Brake lever cover EAM30480 ADJUSTING THE REAR DISC BRAKE 1 Check Brake pedal position a distance from the top of the rider footrest to the top of the brake pedal Out of specification Regulate 2 Adjust Brake pedal position a Loosen the locknut 1 b Turn t...

Page 100: ...hen refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately EAM30231 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pad...

Page 101: ...master cylinder cap Reservoir diaphragm Reservoir float front brake Protector rear brake TIP Be careful not to spill any brake fluid or allow the reservoir to overflow Make sure that there is enough brake fluid be fore applying the brake Ignoring this precau tion could allow air to enter the brake system considerably lengthening the bleeding proce dure If bleeding is difficult it may be necessary ...

Page 102: ...off the ground WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Shift the transmission into the neutral posi tion 3 Pull the drive chain up above the drive 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 b...

Page 103: ...o check that it moves smoothly c Turn the front fork to the right and left a few times and make sure that the steering ro tates smoothly If it does not turn smooth ly remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD on page 4 55 d Loosen the ring nut fully turn and then tighten it to specification with a steering nut wrench WARNING EWA13140 Do not overtighten ...

Page 104: ...wn hard on the handlebar several times and check if the front fork rebounds smoothly Unsmooth operation Correct or replace Refer to FRONT FORK on page 4 42 5 Check Protector guide 1 Out of specification Replace TIP The protector guide reaches the limit of its use when it is worn down to the same height a as of the outer tube circumference 6 Remove Protector Dust seal 1 NOTICE ECA24330 Be careful n...

Page 105: ...ting mechanism may not exactly match the above specifications due to small dif ferences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary Air bleeding from front fork TIP If the front fork ini...

Page 106: ...ING THE REAR SHOCK ABSORBER ASSEMBLY Use a maintenance stand to raise the rear wheel off the ground WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over Spring preload NOTICE ECA24360 Do not turn the adjuster forcibly beyond its adjusting range 1 Adjust Spring preload a Loosen the locknut 1 b Loosen the adjuster 2 until there is some clearance between the spr...

Page 107: ...d its adjusting range 1 Adjust Compression damping for fast compression damping a Turn the adjuster 1 in the direction of a or b to make an adjustment TIP To obtain a precise adjustment it is advisable to check the actual total number of turns of the damping force adjusting mechanism This ad justment range may not exactly match the spec ifications listed due to small differences in production Dire...

Page 108: ...llars Refer to INSTALLING THE SWINGARM on page 4 66 EAM30501 CHECKING THE CONNECTING ARM AND RELAY ARM Refer to CHECKING THE CONNECTING ARM AND RELAY ARM on page 4 63 EAM30243 CHECKING THE TIRES 1 Measure Tire pressure Out of specification Regulate TIP Check the tire while it is cold Because if the bead stopper tightening nut is loose when the tire pressure is low the tire could slip off the rim t...

Page 109: ... replacing a tire or a wheel always balance the wheel EAM30246 CHECKING THE WHEEL BEARINGS 1 Check Wheel bearing Refer to CHECKING THE FRONT WHEEL on page 4 6 and CHECKING THE REAR WHEEL on page 4 10 EAM30253 CHECKING THE CHASSIS FASTENERS Make sure that all nuts bolts and screws are properly tightened Refer to CHASSIS TIGHTENING TORQUES on page 2 13 EAM30248 CHECKING AND LUBRICATING THE CABLES Th...

Page 110: ...parts of the following parts Brake lever EAM30503 LUBRICATING THE CLUTCH LEVER 1 Lubricate the pivoting points and metal to metal moving parts of the following parts Clutch lever EAM30250 LUBRICATING THE PEDAL 1 Lubricate the pivoting point and metal to met al moving parts of the pedal Recommended lubricant Engine oil or a suitable cable lu bricant Recommended lubricant Silicone grease Recommended...

Page 111: ...he high tension cord 3 3 Adjust Engine idling speed Refer to CHECKING THE ENGINE IDLING SPEED on page 3 11 4 Check Ignition timing Check whether the alignment mark a on the left 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 Timing light 90890 03141 Timing light Y...

Page 112: ...ELECTRICAL SYSTEM 3 36 ...

Page 113: ...LACING THE FRONT BRAKE PADS 4 17 REMOVING THE FRONT BRAKE CALIPER 4 19 DISASSEMBLING THE FRONT BRAKE CALIPER 4 19 CHECKING THE FRONT BRAKE CALIPER 4 19 ASSEMBLING THE FRONT BRAKE CALIPER 4 20 INSTALLING THE FRONT BRAKE CALIPER 4 20 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 21 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 21 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 21 INSTALLING THE FRONT BRAKE M...

Page 114: ...ING THE STEERING HEAD 4 56 REAR SHOCK ABSORBER ASSEMBLY 4 59 HANDLING THE REAR SHOCK ABSORBER 4 62 DISPOSING OF A REAR SHOCK ABSORBER 4 62 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 62 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 62 CHECKING THE CONNECTING ARM AND RELAY ARM 4 63 INSTALLING THE RELAY ARM 4 63 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 63 SWINGARM 4 65 REMOVING THE SWINGARM 4 66 ...

Page 115: ...ks 1 Side cover left 1 2 Seat 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 CCU Communication Control Unit 1 6 7 9 2 1 22 N m 2 2 kgf m 16 lb ft 7 N m 0 7 kgf m 5 2 lb ft 8 5 3 4 10 22 N m 2 2 kgf m 16 lb ft ...

Page 116: ... to CLEANING THE AIR FILTER ELE MENT on page 3 15 2 Air scoop right 1 3 Air scoop left 1 4 Side cover right 1 5 Number plate 1 6 Rear fender 1 6 4 1 3 5 2 1 3 N m 0 13 kgf m 0 95 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 16 N m 1 6 kgf m 12 lb ft 1 ...

Page 117: ...utch cable 2 from the cable guide b on the number plate The projection c on the lower bracket is in serted into the number plate Remove the number plate by pulling it off the projection When installing the number plate insert the projection on the number plate into the hole in the upper side of the band EAM30458 INSTALLING THE AIR SCOOP 1 Install Air scoop left 1 right TIP After inserting the proj...

Page 118: ...n EAM30460 INSTALLING THE SIDE COVER 1 Install Side cover right 1 TIP Install the side cover right by sliding it as shown and secure it with the bolts to fit it to the vehicle Install the side cover right so that the rib is lo cated under the rib of the rear fender a Projection b Slot a Projection b Slot c Rib side cover d Rib rear fender 1 1 1 b b a a a a a 1 1 c c b b d d ...

Page 119: ...ise the front wheel off the ground 1 Front wheel axle pinch bolt 4 Loosen 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Oil seal 2 7 Bearing 2 8 Brake disc 1 LT LS LS LS 5 7 6 5 6 7 6 8 2 1 1 3 4 21 N m 2 1 kgf m 15 lb ft 21 N m 2 1 kgf m 15 lb ft 115 N m 11 5 kgf m 85 lb ft 12 N m 1 2 kgf m 8 9 lb ft ...

Page 120: ...oll the front wheel axle on a flat surface Bends Replace WARNING EWA13460 Do not attempt to straighten a bent wheel ax le 2 Check Tire Front wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 32 and CHECKING THE WHEELS on page 3 33 3 Check Spoke Bend damage Replace Loose Tighten Tap the spokes with a screwdriver TIP A tight spoke will emit a clear ringing tone a loose spoke will sound...

Page 121: ...th its manufacture s marks or numbers facing outward NOTICE ECA24420 Install the bearing by pressing its outer race parallel TIP Use a socket 1 that matches the diameter of the bearing outer race and that of the oil seal 2 Install Brake disc Brake disc bolt TIP Tighten the bolts in stages and in a crisscross pattern 3 Install Collar 1 TIP Apply the lithium soap based grease on the oil seal lip EAM...

Page 122: ...l axle nut 1 NOTICE ECA24430 Before tightening the front wheel axle nut push down hard on the handlebar s several times and check if the front fork rebounds smoothly 4 Tighten Front wheel axle pinch bolt 1 Front wheel axle nut 115 N m 11 5 kgf m 85 lb ft 1 2 1 T R 1 1 Front wheel axle pinch bolt 21 N m 2 1 kgf m 15 lb ft T R 1 1 ...

Page 123: ... the ground 1 Nut rear wheel axle 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 3 10 Brake disc 1 2 5 7 9 4 6 1 6 3 8 9 10 7 5 3 21 N m 2 1 kgf m 15 lb ft 21 N m 2 1 kgf m 15 lb ft 135 N m 13 5 kgf m 100 lb ft 42 N m 4 2 kgf m 31 lb ft 12 N m 1 2 kgf m 8 9 lb ft 6 6 ...

Page 124: ...ge 4 6 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 32 and CHECKING THE WHEELS on page 3 33 3 Check Spoke Refer to CHECKING THE FRONT WHEEL on page 4 6 4 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 6 EAM30025 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1 Check Rear wheel sprocket More than 1 4 tooth wear a Rep...

Page 125: ...tall the bearing by pressing its outer race parallel TIP Use a socket 1 that matches the diameter of the bearing outer race and that of the oil seal 2 Install Brake disc Brake disc bolt TIP Tighten the bolts in stages and in a crisscross pattern 3 Install Collar 1 TIP Apply the lithium soap based grease on the oil seal lip EAM30027 INSTALLING THE REAR WHEEL 1 Install Rear wheel TIP Install the bra...

Page 126: ...Install Right drive chain puller 1 Washer 2 Rear wheel axle nut 3 TIP Temporarily tighten the nut rear wheel axle at this point 5 Adjust Drive chain slack a Refer to DRIVE CHAIN SLACK on page 3 26 6 Tighten Rear wheel axle nut 1 Locknut 2 Drive chain slack Maintenance stand 50 0 60 0 mm 1 97 2 36 in 1 1 2 LS 1 1 2 3 1 2 3 Wheel axle nut 135 N m 13 5 kgf m 100 lb ft Locknut 21 N m 2 1 kgf m 15 lb f...

Page 127: ...age 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 1 10 Brake pad spring 1 3 9 1 2 8 4 5 7 6 28 N m 2 8 kgf m 21 lb ft 30 N m 3 0 kgf m 22 lb ft 6 N m 0 6 kgf m 4 4 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 17 N m 1 7 kgf m 13 lb ft 10 ...

Page 128: ...bling the front brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 2 2 Brake caliper piston dust seal 2 3 Brake caliper piston seal 2 4 Bleed screw 1 1 2 4 S S S BF BF 3 2 3 S 6 N m 0 6 kgf m 4 4 lb ft ...

Page 129: ...ion 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 cylinder holder 1 9 Front brake master cylinder 1 5 6 7 2 3 4 8 9 1 30 N m 3 0 kgf m 22 lb ft 6 N m 0 6 kgf m 4 4 lb ft 6 N m 0 6 kgf m 4 4 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 9 N m 0 9 kgf m 6 6 lb ft ...

Page 130: ...RONT BRAKE 4 16 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Push rod 1 2 Dust boot 1 3 Circlip 1 4 Washer 1 5 Brake master cylinder kit 1 BF 5 4 3 2 1 S New New ...

Page 131: ...cation Replace 3 Measure Brake disc runout Out of specification Correct the brake disc runout or replace the brake disc a Place the vehicle on a maintenance stand so that the front wheel is elevated b Remove the brake caliper c Hold the dial gauge at a right angle against the brake disc surface d Measure the runout 1 5 mm 0 06 in above the brake disc edge 4 Adjust Brake disc runout a Remove the fr...

Page 132: ... bleed screw and push the brake caliper piston in WARNING EWA19160 Do not reuse 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 tighten the pad pin at this point e Install the brake caliper 4 and tighten the pad pin 5 Brake pad lining thickness limit 1 0 mm...

Page 133: ...Brake caliper piston 1 Brake caliper piston dust seal 2 Brake caliper piston seal 3 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 calipe...

Page 134: ...E FRONT BRAKE CALIPER 1 Install Front brake caliper bracket Front brake caliper temporarily Copper washer Brake hose Union bolt WARNING EWA13531 Proper brake hose routing is essential to in sure safe vehicle operation NOTICE ECA24460 Make sure that the pipe portion a of the brake hose touches the projection b on the brake caliper 2 Install Front brake caliper Brake pad spring Brake pad Brake pad p...

Page 135: ...M30036 REMOVING THE FRONT BRAKE MASTER CYLINDER TIP Before removing the front brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Union bolt Copper washer Brake hose TIP To drain any remaining brake fluid place a con tainer under the master cylinder and the end of the brake hose EAM30037 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder 1 Damage ...

Page 136: ...clip pliers to install the circlip EAM30039 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Brake master cylinder 1 TIP Install the front brake 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 essential to in sure safe vehicle operation NOTICE ECA24470 ...

Page 137: ...ul chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING...

Page 138: ...1 3 Copper washer 2 4 Rear brake hose 1 5 Brake pad pin plug 1 6 Brake pad pin 1 7 Rear brake pad assembly 2 8 Rear brake caliper bracket 1 9 Brake pad spring 2 10 Rear brake disc cover 1 11 Rear brake caliper assembly 1 2 3 4 11 6 7 9 1 8 9 10 S 7 N m 0 7 kgf m 5 2 lb ft 30 N m 3 0 kgf m 22 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 17 N m 1 7 kgf m 13 lb ft 2 5 N m 0 25 kgf m 1 ...

Page 139: ...isassembling the rear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 1 2 3 4 S BF 6 N m 0 6 kgf m 4 4 lb ft ...

Page 140: ...page 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 cylinder reservoir diaphragm 1 10 Rear brake master cylinder 1 1 2 3 4 7 5 8 6 9 10 30 N m 3 0 kgf m 22 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft ...

Page 141: ...REAR BRAKE 4 27 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Push rod 1 4 Brake master cylinder kit 1 4 3 2 1 BF S New New ...

Page 142: ...e medical attention EAM30041 CHECKING THE REAR BRAKE DISC 1 Check Brake disc Damage galling Replace 2 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISC on page 4 17 3 Measure Brake disc runout Out of specification Correct the brake disc runout or replace the brake disc Refer to CHECKING TH...

Page 143: ...Install 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 and the rear wheel 6 Refer to REAR WHEEL on page 4 9 f Tighten the pad pin 7 g Install the pad pin plug 8 and the protector 9 Brake pad lining thickness limit 1 0 mm 0 04 in 7 6 a 2 1 Bleed screw...

Page 144: ...rake 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 EAM30044 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper ...

Page 145: ...rake pad spring Brake pad Brake pad pin Brake pad pin plug Refer to CHECKING THE REAR BRAKE PADS on page 3 24 4 Pour brake fluid to the brake fluid reservoir up to the specified level WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in...

Page 146: ...ylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage wear Replace 3 Check Master cylinder reservoir cap Crack damage Replace Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm Crack damage Replace 4 Check Brake hose Cracks damage wear Replace EAM30050 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING EWA13520 Before ...

Page 147: ... EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water...

Page 148: ...REAR BRAKE 4 34 system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 ...

Page 149: ...ull 1 Disconnect 8 Throttle cable return 1 Disconnect 9 Right grip 1 10 Tube guide 1 11 Start switch 1 12 Launch control switch 1 13 Left grip 1 14 Upper handlebar holder 2 15 Handlebar 1 13 3 8 N m 0 38 kgf m 2 8 lb ft 1 3 N m 0 13 kgf m 0 95 lb ft 5 N m 0 5 kgf m 3 7 lb ft 0 5 N m 0 05 kgf m 0 37 lb ft 0 5 N m 0 05 kgf m 0 37 lb ft 28 N m 2 8 kgf m 21 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 40 N m 4 ...

Page 150: ...2 17 Damper 4 3 8 N m 0 38 kgf m 2 8 lb ft 1 3 N m 0 13 kgf m 0 95 lb ft 5 N m 0 5 kgf m 3 7 lb ft 0 5 N m 0 05 kgf m 0 37 lb ft 0 5 N m 0 05 kgf m 0 37 lb ft 28 N m 2 8 kgf m 21 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 40 N m 4 0 kgf m 30 lb ft 9 N m 0 9 kgf m 6 6 lb ft 1 3 N m 0 13 kgf m 0 95 lb ft 16 17 17 ...

Page 151: ...er handlebar holder 4 TIP Install the lower handlebar holders with the side having the longer distance a from the mounting bolt center facing towards the rear side of the vehicle Installing the lower handlebar holders in the re verse direction allow the front to rear offset amount of the handlebar position to be changed The upper handlebar holders should be in stalled with the punch marks b facing...

Page 152: ...clutch lever holder 6 Install Handlebar grip 1 a Slightly coat the handlebar left end with a rubber adhesive b Install the handlebar grip on the handlebar by pressing the grip from the left side c Wipe off any excess adhesive with a clean cloth Lower handlebar holder nut 40 N m 4 0 kgf m 30 lb ft 3 4 4 b 1 2 1 2 1 2 1 2 c 1 2 1 2 d T R Clutch lever holder bolt 5 N m 0 5 kgf m 3 7 lb ft Clutch leve...

Page 153: ...de 3 TIP Before applying the adhesive wipe off grease or oil on the tube guide surface a with a lac quer thinner Install the grip to the tube guide so that the grip match mark b and tube guide slot c form the angle as shown 10 Install Rubber cover 1 Throttle grip 2 TIP Apply the lithium soap based grease on the throttle grip sliding surface 11 Install Throttle cables 1 TIP Slightly coat the end of...

Page 154: ...3 Bolt brake master cylinder holder 4 Launch control switch 5 Clamp 6 TIP Install the brake master cylinder holder with the UP mark facing up Install in order for the top of the front brake master cylinder assembly to be level First tighten the upper bolt then the lower bolt Align the installation portion a of the clamp with the line c on the painted portion b of the handlebar and then install the...

Page 155: ...HANDLEBAR 4 41 15 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 11 Throttle grip free play 3 0 5 0 mm 0 12 0 20 in ...

Page 156: ...caliper Refer to FRONT BRAKE on page 4 13 Number plate Refer to GENERAL CHASSIS on page 4 1 Lower handlebar holder Refer to HANDLEBAR on page 4 35 with the handlebar holder 1 Protector 1 2 Upper bracket pinch bolt 2 Loosen 3 Damper assembly 1 Loosen 4 Lower bracket pinch bolt 2 Loosen 5 Front fork leg 1 5 N m 0 5 kgf m 3 7 lb ft 5 N m 0 5 kgf m 3 7 lb ft 9 N m 0 9 kgf m 6 6 lb ft 21 N m 2 1 kgf m ...

Page 157: ... 6 Inner tube 1 7 Outer tube 1 8 Piston metal 1 9 Protector guide 1 10 Slide metal 1 11 Washer 1 12 Oil seal 1 13 Base valve 1 14 Damper assembly 1 15 Upper spring seat 1 LS 14 2 7 9 11 12 5 4 1 6 13 New New 10 New New New New New LT 3 8 1 3 N m 0 13 kgf m 0 95 lb ft 28 N m 2 8 kgf m 21 lb ft 29 N m 2 9 kgf m 21 lb ft 30 N m 3 0 kgf m 22 lb ft 55 N m 5 5 kgf m 41 lb ft 15 ...

Page 158: ...fork leg from the ve hicle loosen the damper assembly 1 with the cap bolt ring wrench 2 It is allowed to remove the handlebar lower holder with the handlebar installed as shown When doing so make sure that the handlebar is secured so that it does not move 4 Remove Front fork leg EAM30056 DISASSEMBLING THE FRONT FORK LEGS 1 Drain Fork oil 2 Remove Adjuster 1 from the inner tube TIP While compressin...

Page 159: ...G THE FRONT FORK LEGS 1 Check Inner tube surface Scratches Repair or replace Use 1000 grit wet sandpaper Damaged oil lock piece Replace Inner tube bends Out of specification Replace Use the dial gauge TIP The bending value is shown by one half of the dial gauge reading WARNING EWA13650 Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Check Outer tube Scratches wea...

Page 160: ...ce Contamination Clean O ring 2 Wear damage Replace Base valve bushing Wear damage Replace Fork spring 3 Damage fatigue Replace the base valve Air bleed screw 4 Wear damage Replace 6 Check Upper spring seat 1 Contacting surface a Wear damage Replace 7 Check Adjuster 1 O ring 2 Wear damage Replace EAM30058 ASSEMBLING THE FRONT FORK LEGS WARNING EWA13660 Make sure the oil levels in both front fork l...

Page 161: ...d the damper as sembly of air TIP Avoid excessive full stroke A stroke of 200 mm 7 9 in or more will cause air to enter In this case repeat the steps 1 to 3 4 Measure Oil level left and right a Out of specification Regulate 5 Tighten Locknut 1 TIP Fully finger tighten the locknut onto the damper assembly 6 Loosen Compression damping force adjuster 1 TIP Before loosening the damping force adjuster ...

Page 162: ... filling pump the damper assembly 1 slowly up and down more than 10 times to distribute the fork oil 11 While protecting the damper assembly 1 with a cloth and compressing fully allow ex cessive oil to overflow on the base valve side NOTICE ECA24540 Take care not to damage the damper assem bly 12 Allow the overflowing oil to escape at the hole a in the damper assembly TIP The overflow measures abo...

Page 163: ...based grease on the dust seal lip and oil seal lip Apply the fork oil on the inner tube When installing the oil seal use vinyl seat a with fork oil applied to protect 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 TIP Press the slide metal into the ou...

Page 164: ... in the outer tube 20 Install Dust seal 1 TIP Apply lithium soap based grease on the inner tube 21 Check Inner tube smooth movement Tightness binding rough spots Repeat the steps 14 to 20 22 Measure Distance a Out of specification Turn into the locknut Fork seal driver 90890 01502 Fork seal driver 48 YM A0948 New Distance a 16 mm 0 63 in or more Between the damper assembly 1 bottom and locknut 2 b...

Page 165: ...ion Unless the damping force adjuster is fully loos ened correct damping characteristic cannot be obtained after installation 26 Install Damper adjusting rod 1 Copper washer 2 Adjuster 3 to 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 Gap a betw...

Page 166: ...erformance When disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 31 Install Damper assembly 1 to the outer tube TIP Temporarily tighten the damper assembly 32 Install Protector guide 1 Adjuster damper assembly 29 N m 2 9 kgf m 21 lb ft Adjuster 55 N m 5 5 kgf m 41 lb ft LOCTITE 1 2 a T R T R 1 Recommended oil Yamaha Suspension Oil S1 Standa...

Page 167: ...ly 3 Adjust Front fork top end a 4 Install Lower handlebar holder with the handlebar 5 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 Damper assembly 30 N m 3 0 kgf m 22 lb ft Cap bolt ring wrench 90890 01501 Cap bolt ring wrench YM 01501 1 T R Front fork top end standard a 5 mm 0 20 in Lower handlebar holder nut 40 N m 4 0 kgf m 30 lb ft Upper bracket pinch bolt 21 N m 2 1 kgf m 15...

Page 168: ...all 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 8 Adjust Compression damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position Bolt protector 5 N m 0 5 kgf m 3 7 lb ft 1 2 T R 1 2 1 1 ...

Page 169: ...ebar Refer to HANDLEBAR on page 4 35 1 Front fender 1 2 Steering stem nut 1 3 Front fork leg 2 Refer to FRONT FORK on page 4 42 4 Upper bracket 1 5 Steering ring nut 1 6 Lower bracket 1 7 Bearing race cover 1 8 Upper bearing 1 9 Bearing race 2 10 Lower bearing 1 2 4 5 7 3 1 6 8 10 9 LS LS LS 21 N m 2 1 kgf m 15 lb ft 21 N m 2 1 kgf m 15 lb ft 9 N m 0 9 kgf m 6 6 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1s...

Page 170: ...lace 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 Install a new bearing race NOTICE ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged TIP Always replace the bearing and the bearing race as a set 4 Check ...

Page 171: ...steering 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 stem by turning this lock to lock If there is any binding remove the steering stem and check the steering bear ing 6 Install Washer 1 7 Install Front fork 1 Upper bracket 2 TIP Temporarily tighten th...

Page 172: ...steering ring nut little by lit tle 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 WARNING EWA19330 Tighten the lower bracket to specified torque If torqued too much it may cause the front fork to malfunction Steering stem nut 145 N m 14 5 kgf m 107 lb ft Front fork top end standard a 5 mm 0 20 in T R a Upper bracket pinch bolt 21 N m 2 1 kgf m 15 l...

Page 173: ...fer 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 assembly 1 4 Locknut 1 5 Adjusting nut 1 6 Lower spring guide 1 7 Upper spring guide 1 8 Spring 1 9 Dust seal 2 10 Collar 2 11 Bearing 1 12 Bushing 1 New 2 4 5 7 6 8 3 9 9 10 10 11 1 M 56 N m 5 6 kgf m 41 lb ft 53 ...

Page 174: ...bsorber 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 10 N m 1 0 kgf m 7 4 lb ft M M M LS M LS New 13 16 15 14 15 New 14 New New 13 17 ...

Page 175: ... 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 M M 80 N m 8 0 kgf m 59 lb ft 4 5 ...

Page 176: ...ber 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 worn out rear shock absorber take the unit to your Yamaha dealer for this disposal procedure EAM30065 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Use a maintenance stand to raise the rear wheel off t...

Page 177: ...earing outer race because it will wear the rear shock ab sorber surface on which the bearing is press fitted 2 Lubricate O ring 3 Install Bushing Stopper ring to rear shock absorber assembly upper side TIP Install the bushing parallel until the stopper ring groove appears by pressing its outer race After installing the stopper ring push back the bushing until it contacts the stopper ring 4 Install...

Page 178: ...bsorber assembly lower bolts connecting arm bolt relay arm side and relay arm bolt swingarm side from the left 7 Tighten Rear shock absorber assembly upper nut Connecting arm nut frame side Connecting arm nut relay arm side Relay arm nut swingarm side Rear shock absorber assembly lower nut Installed depth a 4 25 mm 0 17 in Recommended lubricant Molybdenum disulfide grease Rear shock absorber assem...

Page 179: ...wheel off the ground Brake hose holder Refer to REAR BRAKE on page 4 24 Rear brake caliper Refer to REAR BRAKE on page 4 24 Bolt brake pedal Drive chain 1 Collar 2 2 Oil seal 2 3 Thrust bearing 2 4 Bushing 2 5 Oil seal 2 6 Bearing 4 1 2 3 6 4 6 4 1 3 6 2 5 4 0 N m 0 40 kgf m 3 0 lb ft 70 N m 7 0 kgf m 52 lb ft 7 N m 0 7 kgf m 5 2 lb ft ...

Page 180: ...ingarm 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 Bushing Collar Bearing 4 Check Oil seal Damage Replace Bearing Bushing Free play exists unsmooth revolution rust Replace bearing and bushing as a set EAM30074 INSTALLING THE SWINGARM 1 Lubricate...

Page 181: ...SWINGARM 4 67 4 Install Rear wheel Refer to REAR WHEEL on page 4 9 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 182: ...Order 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 1 2 3 4 5 6 7 N m 0 7 kgf m 5 2 lb ft 90 N m 9 0 kgf m 66 lb ft ...

Page 183: ...b Calculate the length c of the 15 link sec tion of the drive chain using the following formula Drive chain 15 link section length c length a between pin inner sides length b between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a different location each time 2 Check Drive chain Stiffness Clean l...

Page 184: ...in the figure 2 Lubricate Drive chain 3 Install Drive sprocket Lock washer Drive sprocket nut Refer to ENGINE REMOVAL on page 5 6 NOTICE ECA14300 Never install a new drive chain onto worn drive chain sprockets this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 26 NOTICE ECA24590 A drive chain that is too tight will overload the eng...

Page 185: ...R HEAD 5 23 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 5 23 CHECKING THE CYLINDER HEAD 5 23 INSTALLING THE CYLINDER HEAD 5 23 VALVES AND VALVE SPRINGS 5 26 REMOVING THE VALVES 5 27 CHECKING THE VALVES AND VALVE GUIDES 5 28 CHECKING THE VALVE SEATS 5 29 CHECKING THE VALVE SPRINGS 5 30 CHECKING THE VALVE LIFTERS 5 31 INSTALLING THE VALVES 5 31 CYLINDER AND PISTON 5 33 REMOVING THE PISTON 5 34 CHECK...

Page 186: ...5 REMOVING THE SEGMENT 5 56 CHECKING THE SHIFT SHAFT 5 56 CHECKING THE STOPPER LEVER 5 56 INSTALLING THE SHIFT 5 56 OIL PUMP 5 59 REMOVING THE OIL PUMP 5 61 CHECKING THE OIL PUMP 5 61 ASSEMBLING THE OIL PUMP 5 61 INSTALLING THE OIL PUMP 5 62 CRANKCASE 5 64 DISASSEMBLING THE CRANKCASE 5 66 CHECKING THE TIMING CHAIN GUIDE EXHAUST SIDE 5 66 CHECKING THE CRANKCASE 5 66 ASSEMBLING THE CRANKCASE 5 67 CR...

Page 187: ...MS 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 Crankshaft 9 Drive axle 10 Main axle ...

Page 188: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 2 EAM30507 LUBRICATION DIAGRAMS 1 Camshaft 2 Drive axle 3 Main axle ...

Page 189: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 3 1 Connecting rod 2 Oil nozzle 3 Crankshaft ...

Page 190: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 4 1 Exhaust camshaft 2 Intake camshaft 3 Oil filter element 4 Oil pump ...

Page 191: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 5 1 Oil filter element 2 Oil pump 3 Oil strainer ...

Page 192: ...EMBLY on page 4 59 1 Silencer clamp 1 Loosen 2 Silencer 1 3 Exhaust pipe 2 clamp 1 Loosen 4 Exhaust pipe 2 1 5 Exhaust pipe 1 1 6 Gasket 3 7 Exhaust pipe 1 protector 1 8 Silencer body 1 9 Silencer cap 1 9 5 8 2 6 1 6 6 3 4 7 8 6 New New New LT LT 1st 2nd 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft 30 N m 3 0 kgf m 22 lb ft 30 N m 3 0 kgf m 22 lb ft 30 N m 3 0 kgf m 22 lb ft 20 N m 2 0 kgf...

Page 193: ...Refer to FUEL TANK on page 7 1 Air filter case cover Refer to CLEANING THE AIR FILTER ELE MENT on page 3 15 Intake air temperature sensor coupler Refer to THROTTLE BODY on page 7 4 ECU Refer to THROTTLE BODY on page 7 4 Ignition coil Refer to THROTTLE BODY on page 7 4 1 Rectifier regulator 1 2 Stator coil assembly coupler 1 Disconnect 3 Crankshaft position sensor coupler 1 Disconnect 4 Coolant tem...

Page 194: ... THROTTLE BODY on page 7 4 Throttle body Refer to THROTTLE BODY on page 7 4 Clutch cable Refer to CLUTCH on page 5 47 Shift pedal Drive chain Refer to SHIFT SHAFT on page 5 55 Refer to CHAIN DRIVE on page 4 68 1 Engine guard 1 2 Brake pedal 1 3 Spring 1 4 Cylinder head breather hose 1 5 Drive sprocket cover 1 6 Drive chain guide 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 ...

Page 195: ...r engine bracket 2 11 Shim 4 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 3 4 kgf m 25 lb ft 53 N m 5 3 kgf m 39 lb ft 55 N m 5 5 kgf m 41 lb ft 26 N m 2 6 kgf m 19 lb ft 34 N m 3 4 kgf m 25 lb ft 45 N m 4 5 kgf m 33 lb ft 11 13 12 10 11 10 7 9 8 ...

Page 196: ...d remove this from its low er part toward the right of the chassis EAM30164 INSTALLING THE ENGINE 1 Install Engine 1 Install the engine from the right side Pivot shaft 2 Engine mounting bolt lower side 3 Front engine bracket 4 Shim 5 Engine bracket bolt front side 6 Engine mounting bolt front side 7 Upper engine bracket 8 Engine bracket bolt upper side 9 Engine mounting bolt upper side 10 1 1 1 Pi...

Page 197: ...p Exhaust pipe 2 1 Bolt exhaust pipe 2 2 TIP Make sure that the exhaust pipe band 1 does not ride on the projection a on the exhaust pipe 2 or silencer 3 Be sure to insert the projection b into the slot in the exhaust pipe or silencer 3 Install Clamp Silencer 1 Bolt silencer 2 Engine mounting bolt upper side 45 N m 4 5 kgf m 33 lb ft Nut exhaust pipe 1 10 N m 1 0 kgf m 7 4 lb ft T R 9 2 6 4 3 1 4 ...

Page 198: ...2 4 Tighten Bolt exhaust pipe 2 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 2 2 2 1 1 T R T R ...

Page 199: ... 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 Spark plug 1 3 Cylinder head cover 1 4 Cylinder head cover breather plate 1 5 Gasket 1 6 Timing chain guide top side 1 7 Cylinder head cover gasket 1 8 Gasket 1 1 2 3 6 7 10 N m 1 0 kgf m 7 4 lb ft 13 N m 1 3 kgf m 9...

Page 200: ... 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 ft 6 N m 0 6 kgf m 4 4 lb ft 3 0 N m 0 30 kgf m 2 2 lb ft 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 M E 9 ...

Page 201: ...p 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 working from the outside in In order to prevent the clip from falling into the crankcase remove the camshaft cap NOTICE ECA24610 The bolts camshaft cap must be removed evenly to prevent damage to the cy...

Page 202: ...shaft caps TIP Tighten the camshaft cap 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 width of the Plastigauge 1 5 Measure Camshaft journal diameter a Out of specification Replace the camshaft Within specification Replace the cylinder head and the cam...

Page 203: ...ewdriver 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 out smoothly c If not replace the tensioner assembly EAM30084 CHECKING THE DECOMPRESSION SYSTEM 1 Check Decompression system a Check that the decompressor cam 1 moves smoothly b Check that the decompressor lever pin 2 projects f...

Page 204: ...is at the center of the link f of the timing chain Do not install it at the position where the position e on the camshaft sprock et is at the joint position of the link f of the tim ing chain NOTICE ECA24620 Do not turn the crankshaft during the cam shaft installation Damage or improper valve timing will result d Install the clips the camshaft caps and the bolts camshaft cap TIP Before installing ...

Page 205: ...he gasket 5 and the cap bolt 6 3 Turn Crankshaft Counterclockwise several turns 4 Check Top dead center TDC mark on the genera tor rotor Align with the crankcase alignment mark Camshaft match marks Align with the cylinder head surface Out of alignment Adjust 5 Install Timing chain guide top side 1 Cylinder head cover gasket 2 Gasket spark plug hole 3 Cylinder head cover 4 Bolt cylinder head cover ...

Page 206: ...CAMSHAFT 5 20 6 Install Cylinder head breather hose Spark plug Spark plug 13 N m 1 3 kgf m 9 6 lb ft T R ...

Page 207: ...er 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 engine bracket Refer to ENGINE REMOVAL on page 5 6 1 Bolt cylinder head 2 2 Bolt cylinder head 4 3 Cylinder head 1 4 Timing chain guide intake side 1 5 Cylinder head gasket 1 M 3 5 4 7 N m 0 7 kgf m 5 ...

Page 208: ...ylinder 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 10 N m 1 0 kgf m 7 4 lb ft LT 6 6 ...

Page 209: ...lace also the valve Refer to CHECKING THE VALVE SEATS on page 5 29 Cylinder head coolant passages Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge and a thickness gauge across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet san...

Page 210: ... e Tighten the bolts to the specified torque in two or three steps in the proper tightening sequence as shown TIP 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 bolt 1 only without loosening any other bolt g Again apply molybdenum disulfide grease to the thread and contact surface of the bolts and to bot...

Page 211: ...is 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 the specified torque Bolt 1 3rd Specified angle 90 Bolt 2 4 2nd 23 N m 2 3 kgf m 17 lb ft 3rd Specified angle 90 Final Specified angle 60 Bolt 5 6 10 N m 1 0 kgf m 7 4 lb ft 90 T R T R T R T R ...

Page 212: ...der Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 21 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 7 Valve spring seat 4 8 Intake valve 2 9 Exhaust valve 2 8 7 7 5 3 3 3 3 9 9 7 6 5 4 3 1 2 7 6 4 3 1 2 5 ...

Page 213: ...VALVE SEATS on page 5 29 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 Remove Valve cotter 1 TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attachment 3 4 Remove Valve spring retainer 1 Valve spr...

Page 214: ...alve 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 clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance limit ...

Page 215: ... 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 through the valve guide and onto the valve seat to make a clear impression d Measure the valve seat contact width c TIP Where the valve seat and the valve face are in contact with each other the blueing wil...

Page 216: ... 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 lapping compound to the valve face and repeat the above steps f After every lapping step be sure to clean off all of the lapping compound from the valve face and the valve seat g Apply blue layout fluid...

Page 217: ...o 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 compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attachment 3 Recommended lubricant Molybdenum disulfide oil b Smaller pitch Valve spring compressor 90890 ...

Page 218: ...3800 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 when rotated with your finger Make sure that the valve lifter and the adjusting pad are reinstalled in their original positions 2 2 1 1 3 3 E 1 2 ...

Page 219: ...iston Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 21 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 1 1 2 3 4 4 5 6 7 E E LT 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft E ...

Page 220: ...and 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 replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure the cylinder bore C with the cyl inder bore gauge TIP Measure the cylinder bore C by taking side to side a...

Page 221: ... 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 measured If the oil ring rail s gap is exces sive replace all three piston rings Diameter 96 955 96 970 mm 3 8171 3 8177 in Measuring point from piston skirt bottom 9 0 mm 0 35 in Piston to cylinder ...

Page 222: ...nd 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 molybdenum disulfide oil to the piston pin Install the piston with the mark a on it pointing to its exhaust rear side Before installing the piston pin clip cover the crankcase opening with a cloth to prevent the clip from falli...

Page 223: ...ompressing 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 Upper oil ring rail d Oil ring expander e Lower oil ring rail Cylinder bolt 10 N m 1 0 kgf m 7 4 lb ft 1 3 2 a 3 a c e b d 15 15 15 15 15 New T R ...

Page 224: ...ASSIS 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 coil assembly 1 9 Generator rotor 1 10 Woodruff key 1 1 10 2 4 7 5 8 3 9 6 LT 6 10 N m 1 0 kgf m 7 4 lb ft 8 N m 0 8 kgf m 5 9 lb ft 12 N m 1 2 kgf m 8 9 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf ...

Page 225: ... THE GENERATOR 1 Install 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 assembly lead Tighten the stator coil assembly screws using the T25 bit Pass the stator coil assembly lead through the crankcase cover side Rotor puller 90890 04151 Rotor puller YM 0415...

Page 226: ...he 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 crankcase cover 5 TIP Tighten the bolts in stages and in a crisscross pattern 5 Connect Stator coil assembly lead Refer to CABLE ROUTING DIAGRAM on page 2 17 Nut generator rotor 65 N m 6 5 kgf m 48 lb ft 2...

Page 227: ...e starter clutch Order Job Parts to remove Q ty Remarks Engine oil Refer to CHANGING THE ENGINE OIL on page 3 13 Clutch Refer to CLUTCH on page 5 47 1 Holder 1 2 Washer 1 3 Damper assembly 1 4 Starter clutch assembly 1 1 2 4 3 12 N m 1 2 kgf m 8 9 lb ft LT ...

Page 228: ... 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 turn freely otherwise the starter clutch is faulty and must be replaced c When turning the starter clutch drive gear clockwise B the starter clutch and the starter clutch drive gear should engage ot...

Page 229: ...e 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 lead be sure to hold the nut on the starter motor side firmly in place using a spanner 5 1 2 3 FWD FWD 10 N m 1 0 kgf m 7 4 lb ft 6 N m 0 6 kgf m 4 4 lb ft 4 ...

Page 230: ...Q 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 4 5 6 6 7 1 FWD FWD 9 8 4 5 N m 0 45 kgf m 3 3 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft ...

Page 231: ...er motor 4 Measure 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 Oil seal Damage wear Replace the defective part s EAM30107 ASSEMBLING THE STARTER MOTOR 1 Install Brush spring 1 Brush 2 TIP Install the brush holder using the screws a 2 Install Starter...

Page 232: ... Starter motor front cover 1 TIP Align the 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 Starter motor cover Starter motor bolt Starter motor cover bolt Starter motor bolt 10 N m 1 0 kgf m 7 4 lb ft Starter motor cover bolt 10 N m 1 0 kgf m 7 4 lb ft ...

Page 233: ...Disconnect 2 Clutch cover 1 3 O ring 1 4 Clutch spring 6 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Washer 1 9 Bearing 1 10 Ball 1 11 Push rod 2 1 12 Friction plate 1 5 13 Clutch plate 7 14 Friction plate 2 3 Identification color purple E E 2 3 4 5 7 8 9 6 10 11 13 12 12 14 13 13 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 m 55 lb ft ...

Page 234: ...o remove Q ty Remarks 15 Clutch boss 1 16 Thrust washer 1 17 Primary driven gear 1 18 Push lever shaft 1 E E 18 17 16 15 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 m 55 lb ft E E E E E E E E ...

Page 235: ...ge 3 13 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 47 1 Oil filter element cover 1 2 Oil filter element 1 3 Radiator pipe 2 1 4 Right crankcase cover 1 5 Gasket 1 6 Dowel pin 2 7 Collar 1 LS 5 6 2 4 1 6 7 3 LS LS LS 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 ...

Page 236: ...he clutch plates as a set EAM30111 CHECKING THE CLUTCH 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 HOUSING 1 Check Clutch housing dogs 1 Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing TIP Pitting on the clutch housi...

Page 237: ...age wear Replace the primary drive and primary driven 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 primary drive and primary driven gears as a set EAM30118 CHECKING THE PRIMARY DRIVEN GEAR 1 Check Primary driven gear Damage wear Replace the primary...

Page 238: ...ligns with the balancer end slot 4 Tighten the right crankcase cover bolts in stag es and in a crisscross pattern 4 Install Push lever shaft 1 TIP Apply the lithium soap based grease on the oil seal lip Before installation apply the engine oil to the bearings upper side and lower side 5 Install Primary driven gear 1 Thrust washer 2 Clutch boss 3 TIP Apply the engine oil on the primary driven gear ...

Page 239: ...IP Install the clutch plates and 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 3 friction plate 2 identification color purple 3 and friction plate 1 2 Apply the engine oil on the friction plates and clutch plates 9 Install Bearing 1 Washer 2 Circlip 3 to...

Page 240: ...h 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 the bolts in stages and in a crisscross pattern Clutch spring bolt 10 N m 1 0 kgf m 7 4 lb ft E E E 1 2 3 1 1 1 T R Clutch cover bolt 10 N m 1 0 kgf m 7 4 lb ft New T R ...

Page 241: ...1 2 Shift shaft 1 3 Oil seal 1 4 Collar 1 5 Shift shaft spring 1 6 Roller 1 7 Shift guide 1 8 Shift lever assembly 1 9 Shift lever 1 10 Pawl 2 11 Pawl pin 2 12 Spring 2 13 Stopper lever 1 14 Stopper lever spring 1 15 Segment 1 1 3 13 15 14 6 10 11 12 11 8 9 12 10 4 2 5 7 E 30 N m 3 0 kgf m 22 lb ft 12 N m 1 2 kgf m 8 9 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft E E ...

Page 242: ... 1 Check 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 LEVER 1 Check Stopper lever 1 Wear damage Replace Stopper lever spring 2 Broken Replace EAM30528 INSTALLING THE SHIFT 1 Install Stopper lever spring 1 Collar 2 Stopper lever 3 Bolt stopper lever 4 ...

Page 243: ...hift 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 Apply the engine oil on the segment bolt shaft 6 Tighten Shift guide bolt 1 7 Install Roller 1 Shift shaft spring 2 to shift shaft Collar 3 to shift shaft Shift shaft 4 TIP Apply the engine oil on the shift shaft 8 Install Oil seal 9 In...

Page 244: ...SHIFT SHAFT 5 58 TIP Align the punch mark a on the shift shaft with the punch mark b in the shift pedal Shift pedal bolt 12 N m 1 2 kgf m 8 9 lb ft T R 1 1 2 2 a b ...

Page 245: ...y driven gear Refer to CLUTCH on page 5 47 Right crankcase cover Refer to CLUTCH on page 5 47 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 shaft 1 7 Oil pump housing 1 LT E 3 2 1 4 5 7 6 5 N m 0 5 kgf m 3 7 lb ft 2 0 N m 0 20 kgf m 1 5 lb ft ...

Page 246: ...y Refer to GENERATOR on page 5 38 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 Balancer drive gear 1 10 Lock washer 1 11 Balancer weight gear 1 10 N m 1 0 kgf m 7 4 lb ft 50 N m 5 0 kgf m 37 lb ft 6 2 7 8 9 11 10 3 5 4 1 E LT 45 N m 4 5 kgf m 33 lb ft 80 N m 8 0 kgf m 59 lb ft ...

Page 247: ...place 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 defec tive part s 2 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAM30137 ASSEMBLING THE OIL PUMP 1 Install Oil pump drive shaft 1 Inner rotor 2 Dowel pin 3 TIP Apply the engine oil on ...

Page 248: ...eight gear 1 TIP Install the balancer weight gear and balancer shaft with their lower splines a aligning with each other 3 Install Balancer drive gear 1 TIP Align the punched mark a on the balancer drive gear with the punched mark b on the balancer weight gear Install the balancer drive gear and crankshaft with the lower splines c aligning with each other Oil pump cover screw 2 0 N m 0 20 kgf m 1 ...

Page 249: ... oil to the contact surfaces of the conical washer Place an aluminum plate a between the teeth of the balancer drive gear 10 and balancer weight gear 11 Install the conical washer with its convex sur face b outward 5 Bend the lock washer tab Balancer weight gear nut 50 N m 5 0 kgf m 37 lb ft Primary drive gear nut 80 N m 8 0 kgf m 59 lb ft Balancer nut 45 N m 4 5 kgf m 33 lb ft New T R New T R New...

Page 250: ...il assembly Refer to GENERATOR on page 5 38 1 Timing chain guide exhaust side 1 2 Timing chain guide stopper plate 1 3 Timing chain 1 4 Bolt L 45 mm 1 77 in 5 5 Bolt L 60 mm 2 36 in 4 6 Bolt L 75 mm 2 95 in 3 7 Right crankcase 1 8 Left crankcase 1 9 Dowel pin 2 10 Crankshaft 1 11 Oil nozzle 1 3 1 5 2 6 4 10 5 5 5 4 4 4 6 9 7 8 11 9 LT LT 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 12 N m...

Page 251: ...r to TRANSMISSION on page 5 71 Shift cam and shift fork Refer to TRANSMISSION on page 5 71 1 Circlip 1 2 Oil seal 2 3 Bearing 12 4 Collar 1 E E E E E LT LT 1 2 2 3 3 3 3 3 3 3 3 3 3 3 12 N m 1 2 kgf m 8 9 lb ft 10 N m 1 0 kgf m 7 4 lb ft 12 N m 1 2 kgf m 8 9 lb ft 22 N m 2 2 kgf m 16 lb ft LT E LT E E 4 E ...

Page 252: ...f Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If the cases do not separate check for a remaining case bolt or fitting Do not force c Remove the dowel pins and O ring 2 Remove Bearing 1 TIP Remove the bearing from the crankcase by pressing its inner race Do not use the removed bearing EAM30490 CHECKI...

Page 253: ...ightly on the case with soft 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 2 stages with 1 4 turn each Installed depth a 0 0 0 5 mm 0 00 0 02 in Bearing cover plate 12 N m 1 2 kgf m 8 9 lb ft LOCTITE Bearing cover plate crankshaft 22 N m 2 2 kgf m 16 lb ft Yamaha bond No 1215 90890 85505 Three bo...

Page 254: ... 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 64 Transmission Refer to TRANSMISSION on page 5 71 1 Balancer shaft 1 2 Crankshaft assembly 1 1 2 ...

Page 255: ...ng tool 2 EAM30492 CHECKING THE CRANKSHAFT 1 Measure Crankshaft runout Out of specification Replace the crank shaft bearing or both TIP Turn the crankshaft slowly 2 Measure Crank assembly width a Out of specification Replace the crank shaft 3 Check Crankshaft sprocket 1 Damage Replace the crankshaft Crankcase separating tool 90890 04152 Crankcase separating tool YU A9642 1 a 2 1 Runout limit 0 030...

Page 256: ...dure lubricate the oil seal lips with lithium 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 crankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft as sembly bottoms against the bearing Crankshaft installer pot 90890...

Page 257: ... ty Remarks Engine Refer to ENGINE REMOVAL on page 5 6 Crankcase Separate Refer to CRANKCASE on page 5 64 1 Main axle 1 2 Drive axle 1 3 Long shift fork guide bar 1 4 Short shift fork guide bar 1 5 Spring 4 6 Shift cam 1 7 Shift fork 3 R 1 8 Shift fork 2 C 1 9 Shift fork 1 L 1 10 Collar 1 2 10 1 5 3 4 5 7 8 6 9 M M M M M E E E LS ...

Page 258: ...r 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 straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a set EAM30155 CHECKING THE SHIFT DRUM...

Page 259: ...e 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 23T 2 4th wheel gear 24T 3 3rd wheel gear 26T 4 5th wheel gear 20T 5 Collar 6 1st wheel gear 27T 7 O ring 8 to the drive axle 9 TIP Before installation apply molybdenum disul fide oil to the inner and end surface of the idler gear and the collar and to th...

Page 260: ...ft crankcase 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 engine oil to the shift fork grooves Apply engine oil to the shift cam groove and the bearing contact surface Mesh the shift fork 1 L with the 4th wheel gear 5 and 3 R with the 5th wheel gear ...

Page 261: ...ork 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 Transmission operation Unsmooth operation Repair 6 7 5 2 4 1 3 E E E E 2 1 3 E 2 ...

Page 262: ...TRANSMISSION 5 76 ...

Page 263: ... 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 THE WATER PUMP 6 7 ...

Page 264: ...COOLING SYSTEM DIAGRAMS 6 1 EAM20186 COOLING SYSTEM DIAGRAMS 1 Radiator hose 1 2 Radiator right 3 Radiator hose 4 4 Water pump 5 Radiator hose 3 6 Radiator left ...

Page 265: ...CHASSIS on page 4 1 Fuel 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 right 1 4 Radiator hose 2 1 5 Radiator hose 4 1 6 Radiator hose 3 1 7 Radiator pipe 2 1 8 Radiator breather hose 1 LS LS 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 266: ... 9 Radiator left 1 10 Radiator hose 1 1 11 Radiator pipe 1 1 12 Coolant temperature sensor 1 11 12 LS LS 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 ft 1 5 N m 0 15 kgf m 1 1 lb ft 15 N m 1 5 kgf m 11 lb ft 10 9 ...

Page 267: ...lace 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 5 to 10 sec onds within standard pressure values TIP Before attaching the cap to the tester apply wa ter to its sealing surface No stay Replace EAM30506 INSTALLING THE RADIATOR 1 Fill Cooling syste...

Page 268: ...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 connections Coolant leaks Correct or replace Radiator hoses Bulges Replace WARNING EWA19090 When the radiator cap tester is removed coolant will spout therefore cover it with a cloth beforehand Test pressure va...

Page 269: ...on page 3 21 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 13 Right crankcase cover Refer to CLUTCH on page 5 47 1 Water pump housing 1 2 Dowel pin 2 3 Gasket 1 4 Collar 1 5 Pin 1 6 Impeller shaft assembly 1 7 Oil seal 1 8 Bearing 1 9 Oil seal 1 LS LS 7 6 2 2 3 1 8 5 4 E 9 E 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft ...

Page 270: ...ace 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 right crankcase cover 2 Install Bearing 1 TIP Install the bearing by pressing its outer race par allel 3 Install Impeller shaft assembly 1 Pin 2 Collar 3 Circlip 4 TIP Take care so that the oil seal lip is no...

Page 271: ... 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 1 2 2 T R New T R 1 4 2 2 3 ...

Page 272: ...WATER PUMP 6 9 ...

Page 273: ...FUEL PUMP 7 2 CHECKING THE FUEL PUMP BODY 7 2 CHECKING THE FUEL PUMP OPERATION 7 2 INSTALLING THE FUEL PUMP 7 2 INSTALLING THE FUEL TANK 7 3 THROTTLE BODY 7 4 CHECKING THE INJECTOR 7 7 CHECKING THE THROTTLE BODY 7 7 CHECKING THE FUEL PRESSURE 7 7 ADJUSTING THE THROTTLE POSITION SENSOR 7 8 ...

Page 274: ...eft right Air scoop 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 pump gasket 1 6 Rubber damper 4 3 6 2 2 4 5 2 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 9 N m 0 9 kgf m 6 6 lb ft 7 N m 0 7 kgf m 5 2 lb ft 1 6 6 6 1 ...

Page 275: ...Before removing the hose place a few cloths in the area under where it will be removed To prevent sand dust and other foreign mate rials from entering the fuel pump install the in cluded fuel hose joint cover 1 3 and the fuel hose joint cover 2 4 onto the disconnected fuel hose and the fuel pump 3 Remove Side cover left right Seat Air scoop left right Fuel tank TIP Do not set the fuel tank down on...

Page 276: ... 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 hose TIP Insert the fuel hose into the fuel pipe securely until you hear a click Slide the fuel hose connector cover 1 at the hose end in the direction of the arrow Install the fuel hose connector holder a Check that the fuel ...

Page 277: ...coil 1 3 Intake air temperature sensor coupler 1 Disconnect 4 Air filter case 1 5 Fuel injector coupler 1 Disconnect 6 Intake air pressure sensor coupler 1 Disconnect 7 Throttle position sensor coupler 1 Disconnect 8 Cover 1 9 Throttle cable cover 1 3 2 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 m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 8 N m 0 8 kgf m 5 9 lb ft 2 2 2 9 5 7...

Page 278: ...hicle and then install the cover 11 Fuel hose 1 12 Throttle body 1 13 Exhaust pipe bracket 1 14 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 m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 8 N m 0 8 kgf m 5 9 lb ft 2 2 2 10 10 10 10 10 12 14 13 10 N m 1 0 kgf m 7 4 lb ft 3 0 N m 0 30 kgf m 2 2 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 3 0 N m 0 30 kgf m 2 2 lb ft 3 5 N...

Page 279: ...g 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 5 N m 0 35 kgf m 2 6 lb ft ...

Page 280: ...If 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 loosen the throttle valve stopper screw 1 throttle valve pulley nut 2 throttle valve screw 3 or starter knob nut 4 A loss of performance may occur Do not use compressed air to clean the throttle body...

Page 281: ...nsor Refer to CHECKING THE THROTTLE PO SITION SENSOR INPUT VOLTAGE on page 8 52 2 Adjust Throttle position sensor angle a Connect the Yamaha diagnostic tool Refer to YAMAHA DIAGNOSTIC TOOL on page 8 17 b Temporary tighten the throttle position sensor c Check that the throttle grip is fully closed d Connect the throttle position sensor to the wire harness e Set the Yamaha diagnostic tool to diag no...

Page 282: ...THROTTLE BODY 7 9 ...

Page 283: ...ONENTS 8 42 CHECKING THE SWITCHES 8 43 CHECKING THE FUSES 8 45 CHECKING AND CHARGING THE BATTERY 8 45 CHECKING THE RELAYS 8 47 CHECKING THE RELAY UNIT DIODE 8 47 CHECKING THE IGNITION SPARK GAP 8 48 CHECKING THE SPARK PLUG CAP 8 48 CHECKING THE IGNITION COIL 8 49 CHECKING THE CRANKSHAFT POSITION SENSOR 8 49 CHECKING THE LEAN ANGLE SENSOR 8 50 CHECKING THE STARTER MOTOR OPERATION 8 50 CHECKING THE ...

Page 284: ... Y Y G G W B L R B Sb Lg Br W L B R L P Y R B R Y B B W B O P B Sb P Y B Sb P Y W L L G L G Br Br W L W W Br G Y W B B B W B R R L Y R Y G B R L B Lg W G R B B B O B B B Gy ON OFF ON OFF ON OFF B B B B B Lg W G R B L Gy W W B R R Br Br R W R B B B B B B B R Y R W Br W Br Br W L L G L W L B B R L R L B W B R Y R Y G Y R Y G B B O B R B W L B Sb P Y B Sb P Y B Br W B W B W W Br Br Gy R W B W B G Y G...

Page 285: ...8 Frame ground 9 Fuse 10 Starter relay 11 Starter motor 12 Diode 1 13 Diode 2 14 CCU Communication Control Unit 16 ECU Engine Control Unit 17 Ignition coil 18 Spark plug 25 Engine stop switch 26 Mode switch 27 Gear position switch 28 Launch control switch A Battery sub lead B Wire harness C Ignition coil sub lead D CCU sub lead ...

Page 286: ... page 3 35 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 12 NG Correct or replace the spark plug OK 5 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 48 OK The ignition system circuit is OK NG 6 Check the ignition coil Refer to CHECKING THE IGNI TION COIL on page 8 49 NG Replace t...

Page 287: ...lace the wire harness OK Replace the ECU 1 Check the launch control switch coupler connections NG Reconnect OK 2 Check the gear position switch cou pler connections NG Reconnect OK 3 Check the launch control switch Refer to CHECKING THE SWITCHES on page 8 43 NG Replace the launch control switch OK 4 Check the gear position switch Refer to CHECKING THE GEAR POSITION SWITCH on page 8 53 NG Replace t...

Page 288: ... Air scoop left 1 Check the mode switch coupler connections NG Reconnect OK 2 Check the mode switch Refer to CHECKING THE SWITCHES on page 8 43 NG Replace the mode switch OK 3 Check the ignition system wire har ness Refer to CIRCUIT DIAGRAM on page 8 1 NG Repair or replace the wire harness OK Replace the ECU ...

Page 289: ...IGNITION SYSTEM 8 6 ...

Page 290: ...ELECTRIC STARTING SYSTEM 8 7 EAM20143 ELECTRIC STARTING SYSTEM EAM30279 CIRCUIT DIAGRAM ...

Page 291: ... Main relay 6 Battery 7 Engine ground 8 Frame ground 9 Fuse 10 Starter relay 11 Starter motor 12 Diode 1 13 Diode 2 16 ECU Engine Control Unit 25 Engine stop switch 27 Gear position switch 29 Start switch 30 Diode 3 A Battery sub lead B Wire harness ...

Page 292: ...HE RE LAYS on page 8 47 NG Replace the main relay OK 4 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 50 OK Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 NG 5 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 45 NG Repair or replace the starter motor OK 6 Check the diodes Diode 1 diode ...

Page 293: ...art switch Refer to CHECKING THE SWITCHES on page 8 43 NG Replace the start switch OK 10 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 7 NG Properly connect or repair the starting sys tem s wiring OK Replace the ECU ...

Page 294: ...CHARGING SYSTEM 8 11 EAM20144 CHARGING SYSTEM EAM30282 CIRCUIT DIAGRAM ...

Page 295: ...CHARGING SYSTEM 8 12 2 AC magneto 3 Rectifier regulator 6 Battery 7 Engine ground 8 Frame ground 9 Fuse A Battery sub lead B Wire harness ...

Page 296: ...battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 45 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 50 NG Replace the rectifier regulator OK 5 Check the stator coil assembly Refer to CHECKING THE STA TOR COIL on page 8 50 NG Replace the stator coil assembly OK 6 Check the charging sys...

Page 297: ...CHARGING SYSTEM 8 14 ...

Page 298: ...FUEL INJECTION SYSTEM 8 15 EAM20145 FUEL INJECTION SYSTEM EAM30284 CIRCUIT DIAGRAM ...

Page 299: ...n Control Unit 15 Yamaha diagnostic tool coupler 16 ECU Engine Control Unit 17 Ignition coil 18 Spark plug 19 Fuel injector 20 Fuel pump 21 Intake air temperature sensor 22 Coolant temperature sensor 23 Throttle position sensor 24 Intake air pressure sensor 25 Engine stop switch 27 Gear position switch A Battery sub lead B Wire harness C Ignition coil sub lead D CCU sub lead ...

Page 300: ...FI diagnostic tool sub lead to the Yamaha diagnostic tool WARNING EWA20450 Never connect the sub 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 Prepare the fully charged 12 V lead battery for yourself Replace the vehicle battery with a lead battery 12 V For information on how to connect and use the Yama...

Page 301: ...nit 2 Lead battery 12 V 3 Vehicle battery 4 Vehicle 5 Coupler for connecting optional part 6 FI diagnostic tool sub lead 7 Sub harness included with the Yamaha diag nostic tool 8 Vehicle communication cable included with the Yamaha diagnostic tool 9 Yamaha diagnostic tool ...

Page 302: ...2 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 display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of crankshaft posi tion sensor coupler Check the locking condition of t...

Page 303: ... 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 Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on page 8 49 Crank the engine and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Rec...

Page 304: ...de using 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 Check for looseness or pinch ing Check the mounted position for correctness Improperly mounted sensor Remount or replace the sensor Start switch to ON main relay ON and then check the condi tion o...

Page 305: ...sensor 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 Condition is Recovered Go to item 3 and finish the service Condition is Detected Go to item 2 2 Defective intake air pressure sensor Execute the diagnostic mode Code No 03 Atmospheric pressure at the c...

Page 306: ...er 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 or repair replace the wire harness Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered ...

Page 307: ...ened 86 92 displays Incorrect display range Replace the throttle position sensor Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 7 7 Faulty ECU Replace the ECU Service is finished 8 Delete the fault code Confirm that t...

Page 308: ...ostic 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 fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No 21 Item Coolant temperature sensor open or short circuit detected Fail safe system Able...

Page 309: ... 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 Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to it...

Page 310: ...etected 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 the pins Improperly connected Con nect the coupler securely or repair replace the wire harness Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction...

Page 311: ...Unable 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 more Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 The vehicle has overturned Raise the vehicle upright Start switch to ON main relay ON wait 10 ...

Page 312: ...tion 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 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 of the fault code using the malfunction...

Page 313: ... 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 approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to...

Page 314: ...the injector Refer to CHECKING THE INJECTOR on page 8 53 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 diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 3 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnec...

Page 315: ...y and CCU 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 the start switch Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of main relay cou pler Check the locking condition of the coupler Disc...

Page 316: ...he 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 Recovered Go to item 6 and finish the service Condition is Detected Go to item 4 4 Defective main relay No operating sound Replace the main relay Or execute the diagnostic mode Code No 09 Fuel system volta...

Page 317: ...tion Change the CO concentration and rewrite in EEPROM After this adjustment push the engine stop switch and then push the start switch Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 5 and finish the service Condition is Detected Repeat item 1 If the same number is indicated...

Page 318: ...and 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 of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 3 Wire harness continuity Open...

Page 319: ...ode 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 Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Check that the fault code num ber is not displayed Fault code No 70 Item Engine forcibly stops...

Page 320: ...the 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 left idling for a long period of time ...

Page 321: ...FUEL INJECTION SYSTEM 8 38 ...

Page 322: ...FUEL PUMP SYSTEM 8 39 EAM20146 FUEL PUMP SYSTEM EAM30287 CIRCUIT DIAGRAM ...

Page 323: ...agneto 3 Rectifier regulator 4 Joint connector 6 Battery 7 Engine ground 8 Frame ground 9 Fuse 16 ECU Engine Control Unit 20 Fuel pump 25 Engine stop switch A Battery sub lead B Wire harness C Ignition coil sub lead D CCU sub lead ...

Page 324: ... on page 8 45 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 45 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 43 NG Replace the engine stop switch OK 5 Check fuel pressure Refer to CHECKING THE FUEL PRESSURE on page 7 7 NG Replace the fuel pump OK 6 Check t...

Page 325: ...sure sensor 3 Throttle position sensor 4 Injector 5 Launch control switch 6 Mode switch 7 Intake air temperature sensor 8 ECU Engine Control Unit 9 Ignition coil 10 CCU Communication Control Unit 11 Starter relay 12 Fuse 13 Battery 14 Gear position switch 15 Fuel pump 16 Coolant temperature sensor ...

Page 326: ... 43 EAM30289 CHECKING THE SWITCHES Y W P Sb B Lg W G R ON OFF ON OFF B Lg W G R 4 1 2 5 3 P Sb Lg B W G R Y W B W G Lg R 1 Engine stop switch 2 Mode switch 3 Launch control switch 4 Gear position switch 5 Engine start switch ...

Page 327: ...hecking 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 shown in the far left column and the switch lead colors are shown in the top row in the switch illustration TIP indicates continuity between switch terminals i e a closed circuit at each switch positio...

Page 328: ... visibly damaged Do not disassemble or modify the battery or short across its terminals NOTICE ECA26041 To prevent damage to the battery and battery malfunction Be sure to charge the battery using only the specified battery charger Do not use a charger designed for lead acid batteries Otherwise the battery could be damaged such as from a long period of excessive current or voltage exceeding 16 V A...

Page 329: ...nnect the positive battery lead and then the negative battery lead 8 Check Battery terminals Dirt Clean with a wire brush Loose connection Connect properly 9 Lubricate Battery terminals 10 Install Seat Side cover left right Refer to GENERAL CHASSIS on page 4 1 Checking the battery NOTICE ECA26080 The battery has a limited service life If the battery cannot be charged or it is determined that the b...

Page 330: ...nect the relay from the wire harness 2 Connect the digital circuit tester and bat tery 12 V to the relay terminal as shown Check the relay operation Out of specification Replace Starter relay Main relay EAM30495 CHECKING THE RELAY UNIT DIODE 1 Check Diode Out of specification Replace TIP The digital circuit tester and the multimeter with tachometer readings are shown in the following table Digital...

Page 331: ...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 spark plug cap No continuity Tester positive lead Blue Green 1 Tester negative lead Blue 2 Continuity Tester positive lead Blue 2 Tester negative lead Blue Green 1 No continuity Tester positive lead Brown White Brown 3 Tester negative lead Blue Green Bl...

Page 332: ...coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace a Connect the digital circuit tester to the crankshaft position sensor coupler Primary coil resistance 2 16 2 64 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Positive tester probe Ignition coil terminal 1 1 Negative tester probe Ignition coil terminal 2...

Page 333: ... 3 WARNING EWA13810 A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce 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 wire harness 2 Check Stat...

Page 334: ...ontainer filled with coolant TIP Make sure the coolant temperature sensor ter minals do not get wet c Place a thermometer in the coolant d Slowly heat the coolant and then let it cool to the specified temperature indicated in the table e Check the coolant temperature sensor for continuity at the temperatures indicated in the table Regulated voltage DC 14 0 14 8 V Digital tachometer 90890 06760 Dig...

Page 335: ...temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification Replace a Connect the digital circuit tester to the intake air temperature sensor terminal Throttle position sensor input voltage 4 6 V Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Test harness...

Page 336: ...tachom 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 Positive tester probe Pink 2 Negative tester probe Sensor terminal c Continuity Positive tester probe Yellow White 3 Negative tester probe Sensor terminal d Continuity Positive tester probe Yellow White 3...

Page 337: ...N 9 6 TROUBLESHOOTING OF COOLING SYSTEM 9 7 TROUBLESHOOTING OF BRAKE 9 8 TROUBLESHOOTING OF SUSPENSION 9 8 TROUBLESHOOTING OF STEERING HANDLING 9 10 TROUBLESHOOTING OF CHARGING SYSTEM 9 11 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 12 SELF DIAGNOSTIC FUNCTION TABLE FOR FUEL INJECTION SYSTEM 9 12 DIAGNOSTIC CODE SENSOR OPERATION TABLE 9 12 DIAGNOSTIC CODE ACTUATOR OPERATION TABLE 9 14 ...

Page 338: ...STEM on page 8 7 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 Stuck piston or seized crankshaft Disassemble and check the engine Replace defective parts Symptom Possible cause Actions Spark plug does not produce a spark Refer to TROUBLESHOOTING under IGNITION SY...

Page 339: ...lace 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 Symptom Possible cause Actions Spark plug does not produce a spark Incorrect spark plug gap Adjust the spark plug gap Worn or damaged spark plug Replace the spark plug Defective spark plug cap Replace the...

Page 340: ...pecified 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 around cylinder head Incorrect valve clearance too wide Adjust the valve clearance Fatigued or broken valve spring Replace the valve spring Worn or damaged camshaft lobe Replace the camshaft Worn or ...

Page 341: ...ive 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 journal bearing Worn or damaged balancer shaft journal bearing Replace the balancer shaft journal bearing Symptom Possible cause Actions Clutch slippage Improperly assembled clutch Reassemble the clutch I...

Page 342: ... 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 Incorrect oil viscosity high Change to recommended engine oil Deteriorated oil Change to recommended engine oil Clutch noise Damaged or worn primary driven gear Replace the primary drive gear or cranksh...

Page 343: ...transmis 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 axle assembly Jumps out of gear Incorrect shift pedal position Adjust the shift pedal position Improperly returned stopper lever Replace the stopper lever spring Bent or worn shift fork Replace the s...

Page 344: ...Repair the radiator fin or replace the radiator Damaged or faulty water pump Replace the water pump Damaged hoses or pipes Replace the hose or pipe Improperly connected hoses or pipes Connect the hoses and pipes properly Damaged throttle body joint Replace the throttle body joint Loose throttle body joint Tighten the throttle body joint bolts to the specified torque Clogged air filter element Clea...

Page 345: ... 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 pedal pivot Lubricate the brake lever or brake pedal pivot Symptom Possible cause Actions Front fork is hard Bent or damaged inner tube Replace the inner tube Bent or damaged outer tube Replace the o...

Page 346: ...per 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 cap bolt O ring Replace the cap bolt O ring Rear suspension is hard Bent or damaged rear shock absorber rod Replace the rear shock absorber Bent swingarm pivot shaft Replace the swingarm pivot shaft D...

Page 347: ...d rear shock absorber rod Replace the rear shock absorber Damaged oil seal lip Replace the rear shock absorber Symptom Possible cause Actions Handlebar wobble Loose lower ring nut Tighten the lower ring nut to the specified 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 whe...

Page 348: ...Adjust to the specified front fork oil level Rear wheel vibration Incorrect wheel balance Adjust the wheel balance Loose spoke Tighten the spoke and adjust the runout Damaged or worn wheel bearing Replace the wheel bearing Worn deformed or incorrect tire Replace the tire Loose wheel axle nut Tighten the wheel axle nut to the specified torque Loose swingarm pivot shaft Tighten the swingarm pivot sh...

Page 349: ...lead of the ignition coil 8 29 39 Injector open or short circuit detected 8 31 41 ECU built in lean angle sensor malfunction 8 32 43 Fuel system voltage incorrect voltage supplied to the main relay and CCU 8 32 44 EEPROM fault code number an error is detected while reading or writing on EEPROM 8 34 46 Vehicle system power supply normal voltage is not supplied to the ECU 8 35 50 ECU faulty ECU memo...

Page 350: ...Operate the shift pedal Gear in 1st or 2nd ON Gear in other than 1st or 2nd OFF 60 EEPROM fault code display No fault 00 CO adjustment valve 01 Power Tuner injection cor rection setting 0 8 or Power Tuner ignition timing correc tion setting 0 8 07 61 Malfunction history code display 1 There is no history 00 There is some history Other Displays the fault code of 62 Malfunction history code erasure ...

Page 351: ...ber Displays a program version No 79 Gear position switch 2 Operate the shift pedal Gear in 3 5th ON Gear in other than 3 5th OFF Diag nostic code No Item Actuation Procedure 30 Ignition coil Actuates the ignition coil five times at one second 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...

Page 352: ...SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 15 ...

Page 353: ...0 1 FRONT FORK SETTING 10 2 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 10 3 SETTING OF SPRING AFTER REPLACEMENT 10 4 REAR SHOCK ABSORBER SETTING PARTS 10 4 SUSPENSION SETTING FRONT FORK 10 6 SUSPENSION SETTING REAR SHOCK ABSORBER 10 7 ...

Page 354: ...he end of the straight line with care taken to avoid the en gine over revving TIP Riding technique varies from rider to rider and the performance of a machine also vary from machine to machine Therefore do not imitate other rider s settings from the beginning but choose your own setting according to the level of your riding technique EAM30169 DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS EAM30170 T...

Page 355: ...e air spring characteristics to have a 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 front fork setting can be easily affected by the rear suspension take care so that the front and the rear are balanced in position etc when setting the front fo...

Page 356: ... block under the engine to put the rear wheel above the floor and mea sure the length a between the rear wheel axle center and the rear fender holding bolt 2 Remove the stand or block from the engine and with a rider astride the seat measure the sunken length b between the rear wheel axle center and the rear fender holding bolt 3 Loosen the locknut 1 and make adjustment by turning the adjuster 2 t...

Page 357: ...usting the rebound damping force will be fol lowed more or less by a change in the compres sion damping force For correction adjust to decrease compression damping 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 use one whose overall length is great e...

Page 358: ...RBER 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 7 0 mm 0 28 in from its free length Maximum Position in which the spring is turned in 18 0 mm 0 71 in from its free length 1 a ...

Page 359: ...oticeable 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 specified torque Poor initial move ment Rebound damp ing force Turn adjuster counterclockwise about 2 clicks to decrease damping Oil seals Apply grease in oil seal wall Soft over entire range bottomin...

Page 360: ...ount 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 Balance with rear end Set sunken length for 90 95 mm 3 5 3 7 in when one passenger is astride seat upper rear pos ture Spring Replace with soft spring Oil amount Decrease oil amount by about 5 10 cm 0 ...

Page 361: ... 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 mm 3 5 3 9 in when one pas senger is astride seat Spring Replace with stiff spring Bouncing Rebound damp ing force Turn adjuster clockwise about 2 clicks to increase damping Spring Replace with soft...

Page 362: ...CHASSIS 10 9 ...

Page 363: ...take air pressure sensor 25 Engine stop switch 26 Mode switch 27 Gear position switch 28 Launch control switch 29 Start switch 30 Diode 3 A Battery sub lead B Wire harness C Ignition coil sub lead D CCU sub lead EAM30323 COLOR CODE B Black Br Brown DL Dark blue Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y Yellow B L Black Blue B O Black Orange B R Black Red B W Black W...

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Page 365: ...ance 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 products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha from the inside out Genuine Yamaha Service Manuals Get the same factory man...

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Page 367: ... B B W B R R L Y R Y G B R L B Lg W G R B B B B O B B B Gy B B B DL ON OFF ON OFF ON OFF ON OFF B B Gy B B B Lg W G R B L Gy W W B R R Br L R B r L R R W R L R B B B B B B B R Y R W Br W Br Br W L L G L W L B L R L B L B L B B R L R L B W B B R Y R Y G Y R Y G B B O B R B W L B Sb P Y B Sb P Y B Br W B L R W B W B W B Lg Lg R L W W Br Br Gy R W B W B G Y G Y R B R B B Y B Y R R O O R R R R R R R B...

Page 368: ...YZ450FM 2021 WIRING DIAGRAM B2W 2819U 11_W D indd 2 2020 02 05 10 21 39 ...

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