Yamaha YZ450F(D) Owner'S Service Manual Download Page 219 | Manualshive

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7-35

FUEL PUMP SYSTEM

FUEL PUMP SYSTEM

INSPECTION STEPS

If the fuel pump is not operating normally, perform the following procedures in the order given.

• Remove the following parts before inspection.
1. Seat
2. Side cover (right/left)
3. Fuel tank
• Use the following special tools in this inspection.

Check engine stop switch.

No good

→

Replace.

OK

↓

Checking the couplers and leads connections

No good

→

Repair or replace.

OK

↓

Check the fuel pump.(Checking the fuel pump
body)

No good

→

Replace the fuel pump assembly.

OK

↓

Replace the ECU.

Pocket tester:

YU-03112-C/90890-03112

Test harness S-pressure sensor (3P):

YU-03207/90890-03207

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Summary of Contents for YZ450F(D)

Page 1: ... 1 E F G PRINTED ON RECYCLED PAPER 2013 YZ450F D 2013 q Read this manual carefully before operating this vehicle q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule q Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch bevor Sie das Fahrzeug in Betrieb nehmen 33D 9 83 cover 12 5 1 16 45 ページ 1 ...

Page 2: ...t ce manuel avant la première utilisation du véhicule Le manuel doit être remis avec le véhicule en cas de vente de ce dernier Q Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch bevor Sie das Fahrzeug in Betrieb nehmen Diese Bedienungsanleitung muss wenn das Fahrzeug verkauft wird beim Fahrzeug verbleiben 33D 9 83 cover 12 5 1 16 45 ページ 2 ...

Page 3: ...YZ450F D 2013 2013 33D 28199 83 E0 33D 28199 83 E0 OWNER S SERVICE MANUAL OWNER S SERVICE MANUAL Read this manual carefully before operating this vehicle Read this manual carefully before operating this vehicle ...

Page 4: ......

Page 5: ...S SERVICE MANUAL 2012 by Yamaha Motor Co Ltd 1st Edition April 2012 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Page 6: ...s may also be illegal Please check local regulations before riding THIS MACHINE IS TO BE OPER ATED BY AN EXPERIENCED RID ER ONLY Do not attempt to operate this ma chine at maximum power until you are totally familiar with its character istics THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY Do not carry passengers on this machine ALWAYS WEAR PROTECTIVE APPAREL When operating this machine...

Page 7: ...as shown to find the required fore edge symbol mark and go to a page for required item and de scription MANUAL FORMAT All of the procedures in this manual are organized in a sequential step by step format The information has been complied to provide the me chanic with an easy to read handy reference that contains comprehen sive explanations of all disassembly repair assembly and inspection op erat...

Page 8: ...informa tion the step by step format sup plements 5 are given in addition to the exploded diagram and job instruction chart ILLUSTRATED SYMBOLS Refer to the illustration Illustrated symbols 1 to 7 are used to identify the specifications appear ing in the text 1 With engine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening 6 Specified value Service limit 7 Resistance Ω Voltage V Elect...

Page 9: ...TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE 4 CHASSIS 5 FUEL SYSTEM 6 ELECTRICAL 7 TUNING 8 ...

Page 10: ...14 ELECTRICAL 3 24 CHAPTER 4 ENGINE SEAT AND SIDE COVERS 4 1 EXHAUST PIPE AND SILENCER 4 3 RADIATOR 4 5 CAMSHAFTS 4 8 CYLINDER HEAD 4 13 VALVES AND VALVE SPRINGS 4 17 CYLINDER AND PISTON 4 21 CLUTCH 4 25 OIL FILTER ELEMENT AND WATER PUMP 4 29 BALANCER 4 33 OIL PUMP 4 35 KICK SHAFT AND SHIFT SHAFT 4 38 AC MAGNETO 4 43 ENGINE REMOVAL 4 45 CRANKCASE AND CRANKSHAFT 4 50 TRANSMISSION SHIFT CAM AND SHIF...

Page 11: ...1 1 LOCATION OF IMPORTANT LABELS GENERAL INFORMATION LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle CANADA 1 ...

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

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

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

Page 15: ...ubject to change without notice 1 Clutch lever 2 Front brake lever 3 Throttle grip 4 Radiator cap 5 Fuel tank cap 6 Engine stop switch 7 Kickstarter crank 8 Fuel tank 9 Radiator 10 Coolant drain bolt 11 Rear brake pedal 12 Valve joint 13 Air cleaner 14 Drive chain 15 Shift pedal 16 Oil level check window 17 Starter knob idle screw 18 Front fork ...

Page 16: ...achine is stolen the au thorities will need the number to search for and identify your ma chine VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped on the right of the steering head pipe ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the right side of the engine MODEL LABEL The model label 1 is affixed to the frame under the rider s se...

Page 17: ...der a heavy load Carburetors that meter thefuel through the use of jets have been provided with various auxiliary devices so that an optimum air fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine This model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor sys tem This system can achieve a...

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

Page 19: ...material from entering the fuel pump when the fuel hose is discon nected COUPLER FOR CONNECTING OPTIONAL PART This coupler 1 is used for connec tion to an optional Power Tuner and so on When no optional parts etc are connected connect the connec tion terminal to the original cou pler 2 Before removing the coupler thor oughly wipe off any mud or water stuck to it IMPORTANT INFORMATION PREPARATION F...

Page 20: ...rs must be on the side exposed to view When in stalling oil seal s apply a light coating of lightweight lithium base grease to the seal lip s Oil the bearings liberally when installing Do not use compressed air to spin the bearings dry This causes dam age to the bearing surfaces CIRCLIPS 1 All circlips should be inspected carefully before reassembly Al ways replace piston pin clips after one use R...

Page 21: ...e or elec trical continuity insert the measuring probe from back side as you can in sert from back side 1 Probe 2 Coupler REMOVING THE QUICK FASTENER Do not push the center pin with too much force Otherwise the center pin could be damaged To remove a quick fastener push the center pin in with a screwdriver then pull the fastener out INSTALLING THE QUICK FASTENER To install a quick fastener push it...

Page 22: ...How to use Illustration Dial gauge and stand YU 3097 90890 01252 Stand YU 1256 These tools are used to check each part for runout or bend Crankshaft installing tool Crankshaft installing pot YU 90050 90890 01274 Crankshaft installing bolt YU 90050 90890 01275 Spacer crankshaft installer YM 91044 90890 04081 Adapter M12 YU 90063 90890 01278 These tools are used to install the crankshaft Piston pin ...

Page 23: ...s tool is used when install the fork oil seal Spoke nipple wrench YM 01521 90890 01521 This tool is used to tighten the spoke Pocket tester YU 03112 C 90890 03112 Use this tool to inspect the coil resis tance output voltage and amper age Timing light YM 33277 A 90890 03141 This tool is necessary for checking ignition timing Pressure gauge YU 03153 90890 03153 This tool is used to measure the fuel ...

Page 24: ...0890 03208 This tool is connected between the throttle position sensor and the wire harness and is used to measure the voltage FI diagnostic tool sub lead YU 03212 90890 03212 This tool is used to connect the FI di agnostic tool to a battery Valve guide remover installer set 90890 04016 This tool is needed to remove and install the valve guide Valve spring compressor YM 04019 90890 04019 This tool...

Page 25: ...ve guide Valve spring compressor attach ment YM 04108 90890 04108 This tool is needed to remove and install the valve assemblies Rotor puller YM 04151 90890 04151 This tool is used to remove the fly wheel magneto Crankcase separating tool YU A9642 90890 04152 These tool is used to remove the crankshaft from either case Dynamic spark tester YM 34487 Ignition checker 90890 06754 This instrument is n...

Page 26: ...hometer YU 39951 B 90890 06760 This tool is needed for observing en gine rpm YAMAHA Bond No 1215 Three Bond No 1215 90890 85505 This sealant Bond is used for crankcase mating surface etc Tool name Part number How to use Illustration ...

Page 27: ...side of the machine Press down on the brake pedal to activate the rear brake STARTER KNOB IDLE SCREW The starter knob idle screw 1 is used when starting a cold engine Pull the starter knob idle screw out to open the circuit for starting When the engine has warmed up push it in to close the circuit STARTING AND BREAK IN FUEL Always use the recommended fuel as stated below Also be sure to use new ga...

Page 28: ...m up the engine for ex tended periods of time STARTING A WARM ENGINE To start a warm engine make sure that the starter choke knob idling screw is pushed in and the throttle is closed and then start the engine by pushing the kickstarter crank If the engine fails to start give the kickstarter 10 to 20 slow kicks at full throttle in order to clear the engine of the rich air fuel mixture retained in i...

Page 29: ...lower bracket Rear For link type Assembly of links Link to frame Link to rear shock absorber Link to swingarm Installation of rear shock absorber Rear shock absorber to frame Installation of swingarm Tightening of pivot shaft Wheel Installation of wheel Front Tightening of wheel axle Tightening of axle holder Rear Tightening of wheel axle Wheel to rear wheel sprocket Brake Front Brake caliper to f...

Page 30: ... keep the cover pliable and glossy 8 Automotive wax may be applied to all painted or chromed surfac es Avoid combination cleaner waxes as they may contain abra sives 9 After completing the above start the engine and allow it to idle for several minutes STORAGE If your machine is to be stored for 60 days or more some preventive mea sures must be taken to avoid deterio ration After cleaning the mach...

Page 31: ...t Curb weight 111 kg 245 lb Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Single cylinder Displacement 449 7 cm3 15 8 Imp oz 15 2 US oz Bore stroke 97 0 60 8 mm 3 82 2 39 in Compression ratio 12 5 1 Starting system Kickstarter Lubrication system Dry sump Oil type or grade Engine oil Recommended brand YAMALUBE SAE10W 30 SAE10W 40 SAE10W 50 SAE15W 40 SAE20W 40 or SAE20W 50 API ...

Page 32: ... 1 929 27 14 2nd 1 533 23 15 3rd 1 278 23 18 4th 1 091 24 22 5th 0 952 20 21 Chassis USA CDN EUROPE AUS NZ ZA Frame type Semi double cra dle Caster angle 26 95 26 80 27 00 Trail 118 mm 4 65 in 117 mm 4 61 in 120 mm 4 72 in Tire Type With tube Size front 80 100 21 51M Size rear 120 80 19 63M For USA CDN AUS NZ ZA 110 90 19 62M For EUROPE Tire pressure front and rear 100 kPa 1 0 kgf cm2 15 psi Brake...

Page 33: ... 05 mm 0 002 in Camshaft Drive method Chain drive Left Camshaft cap inside diameter 22 000 22 021 mm 0 8661 0 8670 in Camshaft outside diameter 21 959 21 972 mm 0 8645 0 8650 in Shaft to cap clearance 0 028 0 062 mm 0 0011 0 0024 in 0 08 mm 0 003 in Cam dimensions Intake A 37 750 37 850 mm 1 4862 1 4902 in 37 650 mm 1 4823 in Intake B 28 129 28 229 mm 1 1074 1 1114 in 28 029 mm 1 1035 in Exhaust A...

Page 34: ...h IN 2 26 mm 0 089 in B face width EX 2 26 mm 0 089 in C seat width IN 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in C seat width EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D margin thickness IN 1 3 mm 0 0512 in D margin thickness EX 1 0 mm 0 0394 in Stem outside diameter IN 5 475 5 490 mm 0 2156 0 2161 in 5 445 mm 0 2144 in Stem outside diameter EX 5 465 5 480 mm 0 2152 0 2157 in 5 435 mm 0 2...

Page 35: ... length IN 40 76 mm 1 60 in 39 76 mm 1 57 in Free length EX 37 01mm 1 46 in 36 01 mm 1 42 in Set length valve closed IN 34 78 mm 1 37 in Set length valve closed EX 30 83 mm 1 21 in Compressed force installed IN 178 204 N at 34 78 mm 18 2 20 8 kg at 34 78 mm 40 01 45 86 lb at 1 37 in Compressed force installed EX 124 142 N at 30 83 mm 12 6 14 5 kg at 30 83 mm 27 88 31 92 lb at 1 21 in Tilt limit IN...

Page 36: ...0 7083 0 7087 in 17 971 mm 0 7075 in Piston rings Top ring Type Barrel Dimensions B T 1 00 3 30 mm 0 04 0 13 in End gap installed 0 20 0 30 mm 0 008 0 012 in 0 55 mm 0 022 in Side clearance installed 0 015 0 065 mm 0 0006 0 0026 in 0 120 mm 0 005 in 2nd ring Type Taper Dimensions B T 1 00 3 10 mm 0 04 0 12 in End gap installed 0 35 0 50 mm 0 014 0 020 in 0 85 mm 0 033 in Side clearance 0 020 0 060...

Page 37: ...110 in Quantity 8 Clutch plate thickness 1 5 1 7 mm 0 059 0 067 in Quantity 7 Warp limit 0 1 mm 0 004 in Clutch spring free length 50 0 mm 1 97 in 49 0 mm 1 93 in Quantity 6 Clutch housing thrust clearance 0 10 0 35 mm 0 0039 0 0138 in Clutch housing radial clearance 0 010 0 044 mm 0 0004 0 0017 in Clutch release method Inner push cam push Shifter Shifter type Cam drum and guide bar Guide bar bend...

Page 38: ...C 176 F Idling condition Engine idle speed 1 900 2 100 r min Oil temperature 55 65 C 131 149 F Lubrication system Oil filter type Paper type Oil pump type Trochoid type Tip clearance 0 12 mm or less 0 0047 in or less 0 20 mm 0 008 in Side clearance 0 09 0 17 mm 0 0035 0 0067 in 0 24 mm 0 009 in Housing and rotor clearance 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 0067 in Bypass valve setting pressur...

Page 39: ... 0 mm 5 20 in Spring free length 260 0 mm 10 24 in 254 8 mm 10 03 in Fitting length 250 0 mm 9 84 in 246 0 mm 9 69 in Preload length Min Max 1 5 18 mm 0 06 0 71 in Spring rate STD K 56 0 N mm 5 7 kg mm 319 2 lb in K 54 0 N mm 5 5 kg mm 308 0 lb in Optional spring Yes Enclosed gas pressure 1 000 kPa 10 kg cm2 142 psi Swingarm Swingarm free play limit End 1 0 mm 0 04 in Wheel Front wheel type Spoke ...

Page 40: ...tion 95 mm 3 74 in Brake pedal height vertical height above footrest top 0 mm 0 in Clutch lever free play lever end 7 12 mm 0 28 0 47 in Throttle grip free play 3 5 mm 0 12 0 20 in Item Standard Limit Item Standard Limit Ignition system Advancer type Electrical AC magneto Magneto model stator manufacturer 33D00 YAMAHA Stator coil resistance color 0 60 0 90 Ωat 20 C 68 F White White Crankshaft posi...

Page 41: ...12 Nm 1 2 m kg 8 7 ft lb Silencer clamp rear M8 1 16 Nm 1 6 m kg 11 ft lb Starter knob Idle screw M12 1 2 Nm 0 2 m kg 1 4 ft lb Throttle body joint M6 2 10 Nm 1 0 m kg 7 2 ft lb Throttle body joint clamp M5 1 3 Nm 0 3 m kg 2 2 ft lb Air filter case M6 3 7 Nm 0 7 m kg 5 1 ft lb Air filter joint and air filter case M4 9 1 Nm 0 1 m kg 0 7 ft lb Air filter case cover M5 2 5 Nm 0 5 m kg 3 6 ft lb Air f...

Page 42: ... 10 Nm 1 0 m kg 7 2 ft lb Oil nozzle M5 1 8 Nm 0 8 m kg 5 8 ft lb Crankcase bearing stopper M6 8 10 Nm 1 0 m kg 7 2 ft lb Crankcase bearing stopper crankshaft M8 4 22 Nm 2 2 m kg 16 ft lb Stake Drive axle oil seal stopper M6 2 10 Nm 1 0 m kg 7 2 ft lb Kick shaft ratchet wheel guide M6 2 12 Nm 1 2 m kg 8 7 ft lb Lock washer Kickstarter crank M8 1 33 Nm 3 3 m kg 24 ft lb Screw kickstarter crank M6 1...

Page 43: ...tch lever mounting nut M6 1 4 Nm 0 4 m kg 2 9 ft lb Clutch lever position lock nut M5 1 5 Nm 0 5 m kg 3 6 ft lb Front brake master cylinder and bracket M6 2 9 Nm 0 9 m kg 6 5 ft lb Front brake master cylinder cap M4 2 2 Nm 0 2 m kg 1 4 ft lb Brake lever mounting bolt M6 1 6 Nm 0 6 m kg 4 3 ft lb Brake lever mounting nut M6 1 6 Nm 0 6 m kg 4 3 ft lb Brake lever position locknut M6 1 5 Nm 0 5 m kg 3...

Page 44: ... 1 10 Nm 1 0 m kg 7 2 ft lb Lower engine guard M6 3 10 Nm 1 0 m kg 7 2 ft lb Pivot shaft and nut M16 1 85 Nm 8 5 m kg 61 ft lb Relay arm and swingarm M14 1 70 Nm 7 m kg 50 ft lb Relay arm and connecting rod M14 1 80 Nm 8 0 m kg 58 ft lb Connecting rod and frame M14 1 80 Nm 8 0 m kg 58 ft lb Rear shock absorber and frame M10 1 56 Nm 5 6 m kg 40 ft lb Rear shock absorber and relay arm M10 1 53 Nm 5 ...

Page 45: ...b Number plate M6 1 7 Nm 0 7 m kg 5 1 ft lb Item Thread size Q ty Tightening torque Remarks Item Thread size Q ty Tightening torque Remarks Stator M5 3 8 Nm 0 8 m kg 5 8 ft lb Rotor M12 1 65 Nm 6 5 m kg 47 ft lb Crankshaft position sensor M6 2 10 Nm 1 0 m kg 7 2 ft lb Throttle position sensor M5 1 3 Nm 0 3 m kg 2 2 ft lb Injector M5 2 3 Nm 0 3 m kg 2 2 ft lb Ignition coil M5 2 4 Nm 0 4 m kg 2 9 ft...

Page 46: ...nts should be at room temperature A Distance between flats B Outside thread diameter DEFINITION OF UNITS A Nut B Bolt TORQUE SPECIFI CATION Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 94 Unit Read Definition Measure mm millimeter 10 3 meter Length cm centimeter 10 2 meter Length kg kilogram 103 gram We...

Page 47: ...ICATION DIAGRAMS 1 Oil strainer 2 Oil check bolt 3 Scavenging pump 4 Oil feed pump 5 Oil filter element 6 Crankshaft 7 Oil nozzle 8 Exhaust camshaft 9 Intake camshaft 10 Main axle 11 Drive axle 12 Oil level check window 13 Oil tank ...

Page 48: ...2 18 CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM ...

Page 49: ...he hole in the steering stem B Fit the accessory coupler into the connector to fasten it to the bracket C Point the end of the cylinder head breather hose downward D Pass the cylinder head breather hose through the hose holder making sure that the stopper on the hose contacts the holder E Route the cylinder head breath er hose between the frame and radiator hose 3 and to the out side of the AC mag...

Page 50: ...2 20 CABLE ROUTING DIAGRAM F F A B D D C C E F F C C D D B A E 100mm ...

Page 51: ...neto lead to the ignition coil bracket with a plastic locking tie making sure to position the tie above the low er mounting portion of the brack et Face the buckle of the plastic locking tie forward and then cut off the excess end of the tie H Route the ignition coil lead be tween the condenser and the ig nition coil I Fit the clip portion of the clamp into the ignition coil bracket and fasten the...

Page 52: ...2 22 CABLE ROUTING DIAGRAM B B F G A A C C D D E E B B G F C C D D E E A A ...

Page 53: ...the frame with the plastic band making sure to po sition the band between the igni tion coil bracket and the tension pipe Face the buckle of the plastic band to the right with the end pointing rearward H Point the end of the vacuum hose rearward I Fit the bracket into the hole in the rubber portion of the con denser J Fasten the radiator breather hose to the frame with the plas tic band making sur...

Page 54: ...el hose 9 Fuel pump lead 10 Fuel injector coupler 11 Throttle body 12 High tension code 13 Throttle cable 14 AC magneto lead A Route the fuel pump lead to the outside of the fuel hose and above the cover B Route the spark plug wire be tween the throttle cables and the throttle body When installing the air filter be sure not to pinch the spark plug wire C Route the AC magneto lead to the inside of ...

Page 55: ... directs as shown and lightly touches the projec tion on the brake caliper B Pass the brake hose into the brake hose holders C If the brake hose contacts the spring rear shock absorber correct its twist D Install the brake hose so that its pipe portion directs as shown and lightly touches the projec tion on the brake master cylin der ...

Page 56: ...p switch lead 5 Hose guide 6 Main harness A Route the clutch cable to the rear of the number plate band B Fasten the engine stop switch lead to the handlebar C Route the brake hose to the front of the number plate D Pass the clutch cable through the cable guide on the number plate ...

Page 57: ... break in Every race about 2 5 hours Every third about 7 5 hours Every fifth about 12 5 hours As re quired Remarks ENGINE OIL Replace VALVES Check the valve clearances The engine must be cold Inspect Check the valve seats and valve stems for wear Replace VALVE SPRINGS Inspect Check the free length and the tilt Replace VALVE LIFTERS Inspect Check for scratches and wear Replace CAMSHAFTS Inspect the...

Page 58: ...t and retighten Clean Replace fiver When the exhaust sound becomes louder or when a performance drop is felt CRANK Inspect and clean THROTTLE BODY Inspect SPARK PLUG Inspect and clean Replace DRIVE CHAIN Use chain lube Lubricate slack alignment Chain slack 50 60 mm 2 0 2 4 in Replace COOLING SYSTEM Check coolant level and leakage Check radiator cap operation Replace coolant Every two years Inspect...

Page 59: ...leakage Retighten brake disc bolts cali per bolts master cylinder bolts and union bolts Replace pads Replace brake fluid Every one year FRONT FORKS Inspect and adjust Replace oil Suspension oil S1 Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium base grease PROTECTOR GUIDE Replace REAR SHOCK ABSORBER Inspect and adjust Lube After rain ride Molybdenum disulfide grease Retig...

Page 60: ... Lithium base grease Replace bearing TIRE WHEELS Inspect air pressure wheel run out tire wear and spoke loose ness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate Lithium base grease THROTTLE CONTROL CABLE Check routing and connection Yamaha cable lube or SAE 10W 40 motor oil Lubricate Item After break in Every race about 2 5 hours Every third about 7 5 hours Every fifth about ...

Page 61: ...ain slack and alignment Check that the drive chain is lubricated properly P 3 17 18 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 21 Steering Check that the handlebar can be turned smoothly and have no ex cessive play P 3 21 22 Front forks and rear shock absorber Check that they operate smoothly and there is no oil leakage P 3 18 20 Cables ...

Page 62: ...ove Radiator cap Drain the coolant completely 4 Clean Cooling system Thoroughly flush the cooling sys tem with clean tap water 5 Install Copper washer Coolant drain bolt 6 Fill Radiator Engine To specified level Do not mix more than one type of ethylene glycol antifreeze con taining corrosion inhibitors for aluminum engine Do not use water containing im purities or oil Handling notes of coolant Th...

Page 63: ...tion a is in the desired position c Tighten the locknuts 2 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY ADJUSTING THE CLUTCH LEVER FREE PLAY 1 Check Clutch lever free play a Out of specification Adjust 2 Adjust Clutch lever free play Clutch lever free play adjustment steps a Loosen the locknuts 1 b Turn the adjuster 2 until free play is within the specified limits c ...

Page 64: ...up the flat portion of the lower end a of the drain hose CLEANING THE AIR FILTER ELEMENT 1 Remove Seat 2 Remove the fuel tank bolt front 1 and lift the fuel tank Hold the fuel tank in position by the use of the fuel tank holding cable 2 3 Remove Mounting bolt for air filter case cover 4 Loosen and release the binder 1 and lift the air filter case lid Hold the air filter case lid by the use of the ...

Page 65: ...sure that the machine is upright Place the machine on a suitable stand 2 Start the engine warm it up for 2 3 minutes at engine idling speed and then stop the engine and wait approximately 1 minute 3 Inspect Oil level Make sure that the engine oil level is between the maximum level line a and minimum level line b shown for the oil level check win dow Above the upper limit a Check that no oil comes ...

Page 66: ...ck the oil pressure e Tighten the oil pressure check bolt ADJUSTING THE ENGINE IDLING SPEED Because the air pressure is lower at high altitudes the air fuel mixture will become richer If the engine idling speed is low turn the starter choke knob idling screw a few clicks counterclockwise to increase the idling speed Before adjusting the engine idling speed make sure that the com pression pressure ...

Page 67: ...UEL TANK section in the CHAPTER 6 2 Remove Spark plug Cylinder head cover Refer to CAMSHAFTS section in the CHAPTER 4 3 Remove Timing mark accessing screw 1 Crankshaft end accessing screw 2 O ring 4 Check Valve clearance Out of specification Adjust Checking steps a Turn the crankshaft counterclock wise with a wrench b Align the alignment mark a on the rotor with the alignment mark b on the crankca...

Page 68: ...ed off value 150 Pads can only be selected in 0 05 mm increments e Locate the rounded off value and the measured valve clearance in the chart PAD SELECTION TA BLE The field where these two coordinates intersect shows the new pad number to use Use the new pad number only as a guide when verifying the valve clear ance adjustment f Install the new pads 4 and the valve lifters 5 Apply the engine oil o...

Page 69: ...3 13 ENGINE INTAKE EXHAUST ...

Page 70: ...ours Repeat the bleeding procedure when the tiny bubbles in the system have disap peared j Add brake fluid to the level line on the reservoir Check the operation of the brake after bleeding the brake system 3 Install Protector rear brake Reservoir float front brake Diaphragm Brake master cylinder cap ADJUSTING THE FRONT BRAKE 1 Check Brake lever position a 2 Remove Brake lever cover 3 Adjust Brake...

Page 71: ...rake pads 7 and pad pin Install the brake pads with their pro jections a into the brake caliper re cesses b Temporarily tighten the pad pin at this point i Install the brake caliper 8 and tighten the pad pin 9 j Install the pad pin plug 10 3 Inspect Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL section 4 Check Brake lever operation A softy or spongy feeling Bleed brake system Refer to ...

Page 72: ...spect Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL section 4 Check Brake pedal operation A softy or spongy feeling Bleed brake system Refer to BLEEDING THE HY DRAULIC BRAKE SYSTEM sec tion CHECKING THE REAR BRAKE PAD INSULATOR 1 Remove Brake pad Refer to CHECKING AND RE PLACING THE REAR BRAKE PADS section 2 Inspect Rear brake pad insulator 1 Damage Replace CHECKING THE BRAKE FLUID LEV...

Page 73: ...Drive chain 1 Joint 2 Master link clip 3 Be sure to install the master link clip to the direction as shown a Turning direction 6 Lubricate Drive chain ADJUSTING THE DRIVE CHAIN SLACK 1 Elevate the rear wheel by placing the suitable stand under the en gine 2 Check Drive chain slack a Above the seal guard installation bolt Out of specification Adjust Before checking and or adjusting ro tate the rear...

Page 74: ... 1 Remove Protector Dust seal 1 Use a thin screw driver and be care ful not to damage the inner fork tube and dust seal 2 Clean Dust seal a Oil seal b Clean the dust seal and oil seal af ter every run Apply the lithium soap base grease on the inner tube RELIEVING THE FRONT FORK INTERNAL PRESSURE If the front fork initial movement feels stiff during a run relieve the front fork internal pressure 1 ...

Page 75: ... accord ing to the difference in the produc tion lot 3 Adjust Spring preload Adjustment steps a Loosen the locknut 1 b Loosen the adjuster 2 until there is some clearance between the spring and adjuster c Measure the spring free length a d Turn the adjuster 2 Be sure to remove all dirt and mud from around the locknut and adjust er before adjustment The length of the spring installed changes 1 5 mm...

Page 76: ...the position which is back by the specific number of turns from the fully turned in position Which align the punch mark a on the adjuster with the punch mark b on the adjuster body Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged Stiffer a Increase the re bound damping force Turn the adjuster 1 in Softer b Decrease the re bound damping force Tu...

Page 77: ...t play Replace CHECKING AND ADJUSTING THE STEERING HEAD 1 Place a stand under the engine to raise the front wheel off the ground WARNING Securely support the vehicle so that there is no danger of it falling over 2 Check Steering stem Grasp the bottom of the forks and gently rock the fork assembly back and forth Free play Adjust steering head 3 Check Steering smooth action Turn the handlebar lock t...

Page 78: ... handlebar upper holder should be installed with the punched mark a forward Install the handlebar so that the marks b are in place on both sides Install the handlebar so that the pro jection c of the handlebar upper holder is positioned at the mark on the handlebar as shown Insert the end of the fuel breather hose 11 into the hole in the steer ing stem First tighten the bolts on the front side of ...

Page 79: ... Footrest pivot 5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding por tion 8 Throttle cable end 9 Clutch cable end A Use Yamaha cable lube or equivalent on these areas B Use SAE 10W 40 motor oil or suitable chain lubricants C Lubricate the following areas with high quality lightweight lith ium soap base grease Wipe off any excess grease and avoid getting grease on the brake ...

Page 80: ...park plug clean the gasket surface and plug sur face Finger tighten a the spark plug before torquing to specification b CHECKING THE IGNITION TIMING 1 Remove Timing mark accessing screw 1 2 Attach Timing light Digital tachometer To the ignition coil lead orange lead 1 3 Adjust Engine idling speed Refer to ADJUSTING THE EN GINE IDLING SPEED section 4 Check Ignition timing Visually check the station...

Page 81: ...e order given Check that the fuel tank is filled with fresh gaso line No good Fill the fuel tank OK Check that the fuel tank breather hose is not clogged Refer to INCLUDED PARTS section in the CHAPTER 1 No good Repair or replace OK Adjusting the engine idling speed Refer to AD JUSTING THE ENGINE IDLLING SPEED sec tion in the CHAPTER 3 No good Adjust OK Check that the fuel hose is connected properl...

Page 82: ... skill concerning servicing are request ed not to undertake inspection adjustment disassembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage SEAT AND SIDE COVERS REMOVING THE SEAT AND SIDE COVERS Order Part name Q ty Remarks 1 Seat 1 2 Air scoop left 1 3 Air scoop right 1 4 Side cover left 1 5 Side cover right 1 6 Number plate 1 Refer to remov...

Page 83: ...HECKING AND REPLACING THE PROTECTOR 1 Inspect Protector 1 Wear damage Replace Affix the protector as shown CHECKING AND REPLACING THE INSULATOR 1 Inspect Insulator Damage peeled off Replace Before affixing the insulators to the side cover wipe stains etc off its surface with a degreasing agent or the like Make sure that the insulators do not protrude past the edges of the side covers Affix the ins...

Page 84: ...e cover left and right Refer to SEAT AND SIDE COVERS sec tion Rear fender Refer to SEAT AND SIDE COVERS sec tion 1 Bolt silencer clamp 1 Only loosening 2 Silencer clamp 1 3 Bolt silencer 2 4 Silencer 1 5 Bolt exhaust pipe 1 Only loosening 6 Silencer clamp 1 7 Bolt exhaust pipe 2 1 8 Exhaust pipe 2 1 9 Nut exhaust pipe 3 10 Exhaust pipe 1 1 11 Gasket 3 12 Heat protector 1 ...

Page 85: ...l Gasket Exhaust pipe 1 Nut exhaust pipe 2 First temporarily tighten both nuts to 7 Nm 0 7 m kg 5 1 ft lb Then retight en the same nut to 10 Nm 1 0 m kg 7 2 ft lb 2 Install Silencer clamp front Exhaust pipe 2 1 Bolt exhaust pipe 2 2 Install and temporarily tighten the ex haust pipe 2 with its end positioned as shown with respect to the exhaust pipe 1 3 Install Silencer clamp rear Silencer 1 Bolt s...

Page 86: ... AND SIDE COVERS sec tion Fuel tank Refer to FUEL TANK section in the CHAP TER 6 Air filter case Refer to THROTTLE BODY section in the CHAPTER 6 1 Radiator guard 2 2 Radiator hose clamp 8 Only loosening 3 Right radiator 1 4 Radiator hose 2 1 5 Radiator hose 4 1 6 Radiator hose 3 1 7 Pipe 2 O ring 1 1 8 Radiator breather hose 1 9 Left radiator 1 10 Radiator hose 1 1 ...

Page 87: ...4 6 RADIATOR 11 Pipe 1 O ring 1 1 Order Part name Q ty Remarks ...

Page 88: ...t fin Repair replace INSTALLING THE RADIATOR 1 Install O ring 1 Pipe 1 2 Radiator hose 1 3 O ring 4 Pipe 2 5 Radiator hose 3 6 Radiator hose 4 7 2 Install Grommet 1 Face the smaller portion a of the grommet inward 3 Install Radiator hose 2 1 Left radiator 2 4 Install Radiator breather hose 1 Right radiator 2 Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 5 Install Radiator guard 1 First ...

Page 89: ...SEAT AND SIDE COVERS sec tion Fuel tank Refer to FUEL TANK section in the CHAP TER 6 Cover Refer to THROTTLE BODY section in the CHAPTER 6 1 Spark plug 1 2 Cylinder head breather hose 1 3 Bolt cylinder head cover 3 4 Cylinder head cover 1 5 Cylinder head cover gasket 1 6 Timing chain guide top side 1 ...

Page 90: ...al section 3 Timing chain tensioner cap bolt 1 Refer to removal section 4 Timing chain tensioner 1 Refer to removal section 5 Gasket 1 Refer to removal section 6 Bolt camshaft cap 8 Refer to removal section 7 Camshaft cap 2 Refer to removal section 8 Clip 2 Refer to removal section 9 Exhaust camshaft 1 Refer to removal section 10 Intake camshaft 1 Refer to removal section ...

Page 91: ...sscross pattern working from the outside in The bolts camshaft cap must be removed evenly to prevent dam age to the cylinder head cam shafts or camshaft caps 5 Remove Exhaust camshaft 1 Intake camshaft 2 Attach a wire 3 to the timing chain to prevent it from falling into the crank case CHECKING THE CAMSHAFT 1 Inspect Cam lobe Pitting scratches blue discolor ation Replace 2 Measure Cam lobe length ...

Page 92: ... Check that the decompression mechanism cam lever pin 2 proj ects from the camshaft CHECKING THE TIMING CHAIN TENSIONER 1 Check While pressing the tensioner rod lightly with fingers use a thin screwdriver 1 and wind the ten sioner rod up fully clockwise When releasing the screwdriver by pressing lightly with fingers make sure that the tensioner rod will come out smoothly If not replace the tension...

Page 93: ...be tightened evenly or damage to the cylinder head camshaft caps and camshaft will result 2 Install Timing chain tensioner Installation steps a While pressing the tensioner rod lightly with fingers use a thin screwdriver and wind the tension er rod up fully clockwise b With the rod fully wound and the chain tensioner UP mark a fac ing upward install the gasket 1 the timing chain tensioner 2 and th...

Page 94: ...Refer to SEAT AND SIDE COVERS sec tion Fuel tank Refer to FUEL TANK section in the CHAP TER 6 Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section Radiator Refer to RADIATOR section Throttle body Refer to THROTTLE BODY section in the CHAPTER 6 Camshaft Refer to CAMSHAFTS section ...

Page 95: ...n the proper tightening sequence and then tighten the cylinder head bolts further to reach the specified angle 150 in the proper tightening sequence 1 Bolt cylinder head 2 2 Bolt cylinder head 4 Refer to TIP 3 Cylinder head 1 4 Cylinder head gasket 1 5 Timing chain guide intake side 1 6 Coolant temperature sensor 1 7 Oil check bolt 2 8 Oil passage plug 1 Order Part name Q ty Remarks ...

Page 96: ...all the timing chain guide intake side and cylinder head 2 Install Washer 1 Bolts 2 Installation steps Tighten the cylinder head using the rotation angle procedure to ob tain uniform tightening torque a Wash the threads and contact surfaces of the bolts the contact surfaces of the plain washers the contact surface of the cylinder head and the threads of the crankcase b Apply the molybdenum disulfi...

Page 97: ...o times at speci fied angles of 90 and 60 to reach the specified angle of 150 in the proper tightening sequence as shown 3 Install Bolt cylinder head 1 Bolts cylinder head Final Specified angle 150 Bolt cylinder head 10 Nm 1 0 m kg 7 2 ft lb ...

Page 98: ...me Q ty Remarks Cylinder head Refer to CYLINDER HEAD section 1 Valve lifter 4 Refer to removal section 2 Adjusting pad 4 Refer to removal section 3 Valve cotter 8 Refer to removal section 4 Valve spring retainer 4 5 Valve spring 4 6 Valve stem seal 4 7 Valve spring seat 4 8 Exhaust valve 2 9 Intake valve 2 ...

Page 99: ... installation and to maintain correct fit heat the cylinder head in an over to 100 C 212 F a Remove the valve guide using a valve guide remover 1 b Install the new valve guide using a valve guide remover 1 and valve guide installer 2 c After installing the valve guide bore the valve guide using a valve guide reamer 3 to obtain proper stem to guide clearance After replacing the valve guide reface t...

Page 100: ... uses titanium intake and exhaust valves Titanium valves that have been used to lap the valve seats must not be used Always replace lapped valves with new valves When replacing the cylinder head replace the valves without lapping the valve seats and valve faces When replacing the valves or valve guides use new valves to lap the valve seats and then replace them with new valves Lapping steps a Appl...

Page 101: ...DE on the exhaust side Install the valve springs with the larger pitch c facing upward d Smaller pitch 3 Install Valve cotters Install the valve cotters by compress ing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 4 To secure the valve cotters onto the valve stem lightly tap the valve tip with a piece of wood Hitting the valve tip with excessive ...

Page 102: ...rt name Q ty Remarks Cylinder head Refer to CYLINDER HEAD section 1 Bolt cylinder 1 2 Cylinder 1 3 Gasket 1 4 Dowel pin 2 5 Piston pin clip 2 Refer to removal section 6 Piston pin 1 Refer to removal section 7 Piston 1 Refer to removal section 8 Piston ring set 1 Refer to removal section ...

Page 103: ...eplace the piston and piston rings as set c Measure the piston skirt diameter P with a micrometer a 9 0 mm 0 35 in from the pis ton bottom edge d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with following formula f If out of specification replace the cylinder and replace the piston and piston rings as set CHECKING THE PISTON RIN...

Page 104: ...pin to piston clearance with the following for mula d If out of specification replace the piston INSTALLING THE PISTON RING AND PISTON 1 Install Piston ring Onto the piston Be sure to install the piston rings so that the manufacturer s marks or numbers are located on the upper side of the rings Lubricate the piston and piston rings liberally with engine oil 2 Position Top ring 2nd ring Oil ring Of...

Page 105: ...n pin clip cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase INSTALLING THE CYLINDER 1 Install Dowel pins Cylinder gasket 1 Cylinder 2 Install the cylinder with one hand while compressing the piston rings with the other hand Pass the timing chain 3 through the timing chain cavity Be careful not to damage the tim ing chain guide 4 during instal lati...

Page 106: ...ion in the CHAPTER 3 Brake pedal Refer to ENGINE REMOVAL section Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Gasket 1 3 Clutch spring 6 4 Pressure plate 1 5 Push rod 1 1 6 Circlip 1 7 Washer 1 8 Bearing 1 9 Ball 1 10 Push rod 2 1 11 Clutch plate 7 12 Friction plate 8 13 Nut clutch boss 1 Refer to removal section ...

Page 107: ...4 26 CLUTCH 14 Conical washer 1 Refer to removal section 15 Clutch boss 1 Refer to removal section 16 Thrust washer 1 17 Primary driven gear 1 18 Push lever shaft 1 Order Part name Q ty Remarks ...

Page 108: ...thickness Out of specification Replace friction plate as a set Measure at all four points CHECKING THE CLUTCH PLATES 1 Measure Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thick ness gauge 2 CHECKING THE PUSH LEVER SHAFT 1 Inspect Push lever shaft 1 Wear damage Replace CHECKING THE PUSH ROD 1 Inspect Push rod 1 1 Bearing 2 Washer 3 Push rod 2 4 ...

Page 109: ... 1 Clutch plate 2 Install the clutch plates and friction plates alternately on the clutch boss starting with a friction plate and ending with a friction plate Apply the engine oil on the friction plates and clutch plates 4 Install Bearing 1 Washer 2 Circlip 3 To push rod 1 4 Apply the engine oil on the bearing and washer 5 Install Push rod 2 1 Ball 2 Push rod 1 3 Apply the engine oil on the push r...

Page 110: ...il Refer to CHANGING THE ENGINE OIL section in the CHAPTER 3 Drain the coolant Refer to CHANGING THE COOLANT sec tion Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section Brake pedal Refer to ENGINE REMOVAL section Clutch cover Refer to CLUTCH section 1 Oil filter element cover 1 2 Oil filter element 1 3 Radiator pipe 1 4 Water pump housing 1 5 Dowel pin 2 6 Kickstarter crank 1 7 Right crankcas...

Page 111: ...Impeller 1 Refer to removal section 11 Washer 1 Refer to removal section 12 Impeller shaft 1 Refer to removal section 13 Oil seal 1 1 Refer to removal section 14 Oil seal 2 1 Refer to removal section 15 Bearing 1 Refer to removal section Order Part name Q ty Remarks ...

Page 112: ...Rough spot seizure Replace CHECKING THE OIL SEAL 1 Inspect Oil seal 1 Wear damage Replace INSTALLING THE OIL SEAL 1 Install Oil seal 1 Apply the lithium soap base grease on the oil seal lip Install the oil seal with its manufac ture s marks or numbers facing the right crankcase cover 2 2 Install Bearing 1 Install the bearing by pressing its out er race parallel INSTALLING THE IMPELLER SHAFT 1 Inst...

Page 113: ... the kickstarter and frame and that the kickstarter does not contact the crankcase cover when it is pulled INSTALLING THE WATER PUMP HOUSING 1 Install Dowel pin 1 Gasket 2 2 Install Water pump housing 1 Bolt water pump housing 2 Washer 3 Coolant drain bolt 4 3 Install O ring Coolant pipe 1 Bolt radiator pipe 2 Apply the lithium soap base grease on the O ring INSTALLING THE OIL FILTER ELEMENT 1 Ins...

Page 114: ...A TER PUMP section Stator Refer to AC MAGNETO section 1 Nut balancer 1 Refer to removal section 2 Nut primary drive gear 1 Refer to removal section 3 Nut balancer shaft driven gear 1 Refer to removal section 4 Lock washer 1 5 Balancer 1 6 Straight key 1 7 Conical washer 1 8 Primary drive gear 1 9 Balancer shaft drive gear 1 10 Lock washer 1 11 Balancer shaft driven gear 1 ...

Page 115: ...the punched mark a on the balancer shaft drive gear with the punched mark b on the balancer shaft driven gear Install the balancer shaft driven gear and crankshaft with the lower splines c aligning with each other 3 Install Lock washer 1 Nut balancer shaft driven gear 2 Primary drive gear 3 Conical washer 4 Nut primary drive gear 5 Straight key 6 Balancer 7 Lock washer 8 Nut balancer 9 Apply molyb...

Page 116: ...section Right crankcase cover Refer to OIL FILTER ELEMENT AND WA TER PUMP section 1 Circlip 1 2 Washer 1 3 Oil pump drive gear 1 4 Oil pump assembly 1 5 Dowel pin 2 6 Outer rotor 2 1 7 Circlip 1 8 Inner rotor 2 1 9 Dowel pin 1 10 Oil pump cover 1 11 Outer rotor 1 1 12 Inner rotor 1 1 13 Dowel pin 1 14 Washer 1 ...

Page 117: ...4 36 OIL PUMP 15 Oil pump drive shaft 1 16 Rotor housing 1 Order Part name Q ty Remarks ...

Page 118: ...n the inner rotor 1 2 Install Outer rotor 1 1 Apply the engine oil on the outer rotor 1 3 Install Oil pump cover 1 Screw oil pump cover 2 Dowel pin 3 Inner rotor 2 4 Circlip 5 Apply the engine oil on the oil pump drive shaft end and inner rotor 2 Fit the dowel pin into the groove in the inner rotor 2 4 Install Outer rotor 2 1 Dowel pin 2 Oil pump assembly 3 Bolt oil pump assembly 4 Apply the engin...

Page 119: ...section 1 Kick idle gear 1 2 Kick shaft assembly 1 Refer to removal section 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick shaft 1 8 Washer 1 9 Shift pedal 1 10 Shift shaft 1 11 Collar 1 12 Torsion spring 1 13 Roller 1 14 Shift guide 1 Refer to removal section 15 Shift lever assembly 1 Refer to removal section 16 Shift lever 1 ...

Page 120: ...4 39 KICK SHAFT AND SHIFT SHAFT 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt stopper lever 1 21 Stopper lever 1 22 Torsion spring 1 23 Segment 1 Refer to removal section Order Part name Q ty Remarks ...

Page 121: ... move ment Unsmooth movement Replace Kick shaft 2 Wear damage Replace Spring 3 Broken Replace CHECKING THE KICK GEAR KICK IDLE GEAR AND RATCHET WHEEL 1 Inspect Kick gear 1 Kick idle gear 2 Ratchet wheel 3 Gear teeth a Ratchet teeth b Wear damage Replace CHECKING THE SHIFT SHAFT 1 Inspect Shift shaft 1 Bend damage Replace Spring 2 Broken Replace CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1 I...

Page 122: ...HAFT 1 Install Roller 1 Collar 2 Torsion spring 3 Washer 4 Shift shaft 5 Apply the engine oil on the roller and shift shaft 2 Install Shift pedal 1 Bolt shift pedal 2 Align the punch mark a on the shift shaft with the notch b in the shift pedal INSTALLING THE KICK SHAFT ASSEMBLY 1 Install Kick gear 1 Washer 2 Circlip 3 Ratchet wheel 4 Spring 5 Washer 6 Circlip 7 To kick shaft 8 Apply the molybdenu...

Page 123: ... and kick shaft ratchet wheel guide 3 Apply the engine oil on the kick shaft Slide the kick shaft assembly into the crankcase and make sure the kick shaft stopper a fits into the kick shaft ratchet wheel guide 5 Hook Torsion spring 1 Turn the torsion spring clockwise and hook into the proper hole a in the crankcase INSTALLING THE KICK IDLE GEAR 1 Install Kick idle gear 1 Washer 2 Circlip 3 Apply t...

Page 124: ... Seat Refer to SEAT AND SIDE COVERS sec tion Fuel tank Refer to FUEL TANK section in the CHAPER 6 Disconnect the AC magneto lead 1 Left crankcase cover 1 2 Gasket 1 3 Dowel pin 2 4 Nut rotor 1 Refer to removal section 5 Rotor 1 Refer to removal section 6 Stator 1 7 Woodruff key 1 ...

Page 125: ...opper 2 Install Woodruff key 1 Rotor 2 Degrease the contact surfaces of the tapered portions of the crank shaft and rotor When installing the woodruff key make sure that its flat surface a is in parallel with the crankshaft center line b When installing the rotor align the keyway c of the rotor with the woodruff key 3 Install Washer Nut rotor 1 4 Connect AC magneto lead Refer to CABLE ROUTING DIA ...

Page 126: ...Refer to SEAT AND SIDE COVERS sec tion Fuel tank Refer to FUEL TANK section in the CHAP TER 6 Air filter case Refer to THROTTLE BODY section in the CHAPTER 6 Radiator Refer to RADIATOR section 1 Rectifier regulator 1 2 Ignition coil bracket 1 3 Ignition coil 1 4 Atmospheric pressure sensor 1 5 Condenser 1 6 AC magneto lead 1 Disconnect 7 Coolant temperature sensor coupler 1 Disconnect ...

Page 127: ...pipe and silencer Refer to EXHAUST PIPE AND SILENCER section Clutch cable Disconnect at the engine side Shift pedal Refer to KICK SHAFT AND SHIFT SHAFT section Cylinder head breather hose Refer to CAMSHAFTS section Drain the engine oil Refer to CHANGING THE ENGINE OIL section in the CHAPTER 3 Engine guard Right 1 Drive chain sprocket cover 1 2 Nut drive sprocket 1 Refer to removal section 3 Lock w...

Page 128: ...ip 1 6 Bolt brake pedal 1 7 Brake pedal 1 8 Upper engine bracket 2 9 Lower engine bracket 2 10 Engine mounting bolt 4 11 Pivot shaft 1 Refer to removal section 12 Engine 1 Refer to removal section Order Part name Q ty Remarks ...

Page 129: ...LLING THE ENGINE 1 Install Engine 1 Install the engine from right side Pivot shaft 2 Engine mounting bolt lower 3 Lower engine bracket 4 Bolt lower engine bracket 5 Patch 6 Engine mounting bolt front 7 Upper engine bracket 8 Bolt upper engine bracket 9 Engine mounting bolt upper 10 Apply the molybdenum disulfide grease on the pivot shaft Install the patch with the claw a facing outside the chassis...

Page 130: ...ten to specifica tion otherwise it may damage the other part that is fastened togeth er 3 Bend the lock washer tab to lock the nut 4 Install Drive chain sprocket guide Drive chain sprocket cover 1 Bolt drive chain sprocket cover 2 Nut drive sprocket 75 Nm 7 5 m kg 54 ft lb Bolt drive chain sprock et cover 7 Nm 0 7 m kg 5 1 ft lb ...

Page 131: ...SHAFT AND SHIFT SHAFT section Segment Refer to KICK SHAFT AND SHIFT SHAFT section Stator Refer to AC MAGNETO section 1 Timing chain guide exhaust side 1 2 Timing chain guide stopper plate 1 3 Timing chain 1 4 Bolt L 50 mm 1 97 in 7 Refer to removal section 5 Bolt L 60 mm 2 36 in 2 Refer to removal section 6 Bolt L 70 mm 2 76 in 4 Refer to removal section 7 Right crankcase 1 Refer to removal sectio...

Page 132: ...4 51 CRANKCASE AND CRANKSHAFT 10 Balancer shaft 1 Refer to removal section 11 Crankshaft 1 Refer to removal section Order Part name Q ty Remarks ...

Page 133: ...ASE BEARING Order Part name Q ty Remarks Transmission Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section Shift cam and shift fork Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section 1 Circlip 1 2 Oil seal 3 3 Bearing 11 Refer to removal section ...

Page 134: ... 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 REMOVING THE BALANCER SHAFT 1 Remove Balancer shaft 1 Remove the balancer shaft with its flat side a facing the crankshaft REMOVING THE CRANKSHAFT 1 Remove Crankshaft 1 Use the crankcase separating tool 2 Install the crankcase separating tool as shown Do not use a hammer ...

Page 135: ... at top dead center with one hand while turning the nut of the installing tool with the other Operate the installing tool un til the crankshaft bottoms against the bearing Before installing the crankshaft clean the contacting surface of crankcase Apply the molybdenum disulfide grease to the crankshaft to pre vent it from being scratched Do not use a hammer to drive in the crankshaft A For USA and ...

Page 136: ...t TDC top dead center 6 Tighten Bolt crankcase Tighten the crankcase tightening bolts in stage using a crisscross pat tern 7 Install Timing chain Timing chain guide exhaust side Bolt for timing chain guide ex haust side 8 Remove Sealant Forced out on the cylinder mating surface 9 Apply Engine oil To the crank pin bearing and oil delivery hole 10 Check Crankshaft and transmission op eration Unsmoot...

Page 137: ...s Engine Refer to ENGINE REMOVAL section Separate the crankcase Refer to CRANKCASE AND CRANK SHAFT section 1 Main axle 1 Refer to removal section 2 Drive axle 1 Refer to removal section 3 Shift cam 1 Refer to removal section 4 Shift fork 3 1 Refer to removal section 5 Shift fork 2 1 Refer to removal section 6 Shift fork 1 1 Refer to removal section 7 Collar 1 ...

Page 138: ...HECKING THE SHIFT FORK SHIFT CAM AND SEGMENT 1 Inspect Shift fork 1 Wear damage scratches Re place 2 Inspect Shift cam 1 Segment 2 Wear damage Replace 3 Check Shift fork movement Unsmooth operation Replace shift fork For a malfunctioning shift fork re place not only the shift fork itself but the two gears each adjacent to the shift fork INSTALLING THE TRANSMISSION 1 Install 5th pinion gear 21T 1 3...

Page 139: ...al lip 5 Install Shift fork 1 L 1 Shift fork 2 C 2 Shift fork 3 R 3 Shift cam 4 To main axle and drive axle Apply the molybdenum disulfide oil on the shift fork grooves Apply engine oil to the shift cam groove bearing contact surface and shift fork shaft Mesh the shift fork 1 L with the 4th wheel gear 5 and 3 R with the 5th wheel gear 7 on the drive axle Mesh the shift fork 2 C with the 3rd pinion...

Page 140: ...dertake inspection adjustment disassembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage FRONT WHEEL AND REAR WHEEL REMOVING THE FRONT WHEEL Order Part name Q ty Remarks Hold the machine by placing the suitable stand under the engine Refer to HANDLING NOTE 1 Bolt axle holder 4 Only loosening 2 Nut front wheel axle 1 3 Front wheel axle 1 4 Fron...

Page 141: ...chine by placing the suitable stand under the engine Refer to HANDLING NOTE 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 Refer to removal section 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 3 Refer to removal section 10 Brake disc 1 5 ...

Page 142: ...rake disc deflection only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in good condi tion replace the brake disc 2 Measure Brake disc thickness a Out of limit Replace INSTALLING THE FRONT WHEEL 1 Install Bearing left 1 Spacer 2 Bearing right 3 Oil seal 4 Apply the lithium soap base grease on the bearing and oil seal lip when installing Use a soc...

Page 143: ... axle holder by strok ing the front fork several times with the front brake applied INSTALLING THE REAR WHEEL 1 Install Bearing right 1 Circlip 2 Spacer 3 Bearing left 4 Oil seal 5 Apply the lithium soap base grease on the bearing and oil seal lip when installing Install the bearing with seal facing outward Use a socket that matches the out side diameter of the race of the bearing Right side of be...

Page 144: ...he wheel 2 forward and install the drive chain 7 Install Left drive chain puller 1 Wheel axle 2 Install the left drive chain puller and insert the wheel axle from left side Apply the lithium soap base grease on the wheel axle 8 Install Right drive chain puller 1 Washer 2 Nut wheel axle 3 Temporarily tighten the nut wheel axle at this point 9 Adjust Drive chain slack a Refer to ADJUSTING THE DRIVE ...

Page 145: ...tand under the engine Refer to HANDLING NOTE Drain the brake fluid Refer to removal section 1 Brake hose holder protector 2 2 Union bolt 2 3 Brake hose 1 4 Pad pin plug 1 Remove when loosening the pad pin 5 Pad pin 1 Loosen when disassembling the brake cali per 6 Brake caliper 1 7 Brake lever 1 8 Brake master cylinder bracket 1 9 Brake master cylinder 1 ...

Page 146: ...ne Refer to HANDLING NOTE Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Drain the brake fluid Refer to removal section 1 Brake pedal 1 2 Brake master cylinder 1 3 Brake hose holder 2 4 Union bolt 2 5 Brake hose 1 6 Pad pin plug 1 Remove when loosening the pad pin 7 Pad pin 1 Loosen when disassembling the brake cali per 8 Brake caliper 1 ...

Page 147: ...rder Part name Q ty Remarks A Front B Rear A B 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Brake caliper piston 2 1 Refer to removal section 5 Brake caliper piston dust seal 2 1 Refer to removal section 6 Brake caliper piston seal 2 1 Refer to removal section ...

Page 148: ...LINDER Order Part name Q ty Remarks A Front B Rear 1 Brake master cylinder cap 1 2 Diaphragm 1 3 Reservoir float 1 4 Push rod front 1 5 Brake master cylinder boot 1 6 Circlip 1 Use a long nose circlip pliers 7 Washer 1 8 Push rod rear 1 9 Brake master cylinder kit 1 ...

Page 149: ...tion when expelling piston from cylinder Never attempt to pry out piston Caliper piston removal steps a Insert a piece of rag into the brake caliper to lock one brake caliper b Carefully force the piston out of the brake caliper cylinder with compressed air A Front B Rear REMOVING THE BRAKE CALIPER PISTON SEAL KIT 1 Remove Brake caliper piston dust seal 1 Brake caliper piston seal 2 Remove the bra...

Page 150: ...e caliper piston dust seals whenever a caliper is disassembled INSTALLING THE BRAKE CALIPER PISTON 1 Clean Brake caliper Brake caliper piston seal Brake caliper piston dust seal Brake caliper piston Clean them with brake fluid 2 Install Brake caliper piston seal 1 Brake caliper piston dust seal 2 Always use new brake caliper pis ton seals and brake caliper piston dust seals Apply the brake fluid o...

Page 151: ...nder cup sec ondary 2 To brake master cylinder piston 3 Apply the brake fluid on the brake master cylinder cup After installing cylinder cup should be installed as shown di rection Wrong installation cause improper brake performance 3 Install Spring 1 To brake master cylinder piston 2 Install the spring at the smaller dia side 4 Install Brake master cylinder kit 1 Washer front brake 2 Push rod rea...

Page 152: ... pipe portion a directs as shown and lightly touches the projection b on the brake master cylinder 2 Install Brake master cylinder 1 Bolt brake master cylinder 2 3 Install Spring 1 Brake pedal 2 O ring 3 Bolt brake pedal 4 Clip 5 Apply the lithium soap base grease on the bolt O ring and brake pedal bracket 4 Install Pin 1 Washer 2 Cotter pin 3 After installing check the brake pedal height Refer to...

Page 153: ...hes the projection b on the brake caliper 2 Install Brake hose holder 1 Screw brake hose holder 2 After installing the brake hose holders make sure the brake hose does not contact the spring rear shock absorber If it does correct its twist FILLING THE BRAKE FLUID 1 Fill Brake fluid Until the fluid level reaches LOWER level line a Use only the designated quality brake fluid otherwise the rubber sea...

Page 154: ... section in the CHAPTER 3 4 Install Reservoir float front brake Diaphragm Brake master cylinder cap 1 Screw bolt brake master cylinder cap 2 After installation while pulling the brake lever in or pushing down on the brake pedal check whether there is any brake fluid leaking where the union bolts are installed respectively at the brake master cylinder and brake caliper A Front B Rear 5 Install rear...

Page 155: ...r to FRONT WHEEL AND REAR WHEEL section Front brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Number plate Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 1 Protector 1 2 Pinch bolt upper bracket 2 Only loosening 3 Damper assembly 1 Loosen when disassembling the front fork Refer to removal section 4 Pinch bolt lower bracket 2 Only loosening 5 Front fork 1 ...

Page 156: ...k spring 1 3 Dust seal 1 Refer to removal section 4 Stopper ring 1 Refer to removal section 5 Inner tube 1 Refer to removal section 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Oil seal washer 1 10 Oil seal 1 11 Base valve 1 Drain the fork oil Refer to removal section 12 Damper assembly 1 Drain the fork oil Refer to removal section ...

Page 157: ...ts front fork oil at its top 2 Loosen Adjuster 1 3 Remove Adjuster 1 While compressing the inner tube 2 set the cap bolt ring wrench 4 between the inner tube and locknut 3 Hold the locknut and remove the adjuster Do not remove the locknut as the damper rod may go into the damp er assembly and not be taken out REMOVING THE INNER TUBE 1 Remove Dust seal 1 Stopper ring 2 Using slotted head screwdrive...

Page 158: ...f specification Replace Use the dial gauge 1 The bending value is shown by one half of the dial gauge reading Do not attempt to straighten a bent inner tube as this may dangerous ly weaken the tube CHECKING THE OUTER TUBE 1 Inspect Outer tube 1 Score marks wear damage Re place CHECKING THE ADJUSTER 1 Inspect Adjuster 1 O ring 2 Wear damage Replace ASSEMBLING THE FRONT FORK 1 Wash the all parts in ...

Page 159: ...ith the cap bolt ring wrench 2 and use the cap bolt wrench 3 to tighten the base valve with specified torque 11 After filling pump the damper as sembly 1 slowly up and down more than 10 times to distribute the fork oil 12 While protecting the damper as sembly 1 with a rag and com pressing fully allow excessive oil to overflow on the base valve side Take care not to damage the damp er assembly 13 A...

Page 160: ...into the outer tube with fork seal driver 3 19 Install Oil seal 1 Press the oil seal into the outer tube with fork seal driver 2 20 Install Stopper ring 1 Fit the stopper ring correctly in the groove in the outer tube 21 Install Dust seal 1 Apply the lithium soap base grease on the inner tube 22 Check Inner tube smooth movement Tightness binding rough spots Repeat the steps 15 to 21 23 Measure Dis...

Page 161: ...per damping force can not be obtained 29 Tighten Adjuster locknut 1 Hold the locknut 2 and tighten the adjuster with specified torque 30 Install Adjuster 1 To inner tube 31 Fill Front fork oil 1 From outer tube top Never fail to make the oil amount adjustment between the maximum and minimum amount and always adjust each front fork to the same setting Uneven adjustment can cause poor handling and l...

Page 162: ...i fied torque If torqued too much it may cause the front fork to mal function 5 Install Protector 1 Bolt protector 2 6 Adjust Rebound damping force Turn in the damping adjuster 1 fin ger tight and then turn out to the orig inally set position 7 Adjust Compression damping force Turn in the damping adjuster 1 fin ger tight and then turn out to the orig inally set position Damper assembly 30 Nm 3 0 m...

Page 163: ...top switch 1 4 Brake master cylinder 1 Refer to removal section 5 Throttle cable cap 1 6 Throttle cable 1 pulled 1 Disconnect at the throttle side 7 Throttle cable 2 pushed 1 Disconnect at the throttle side 8 Right grip 1 Refer to removal section 9 Tube guide 1 10 Collar 1 11 Left grip 1 Refer to removal section 12 Handlebar upper holder 2 13 Handlebar 1 14 Handlebar lower holder 2 15 Cap 1 ...

Page 164: ...is tance a from the mounting bolt center faces forward And install it in the hole b in the rear of the up per bracket Apply the lithium soap base grease on the thread of the handlebar low er holder Change in the direction back to front and installing position of the handlebar lower holder allows the front to rear offset amount of the handlebar position to be changed Do not tighten the nut yet A Fo...

Page 165: ... Throttle grip 3 Apply the lithium soap base grease on the throttle grip sliding surface 7 Install Throttle cables 1 To tube guide 2 Apply the lithium soap base grease on the throttle cable end and tube guide cable winding portion 8 Install Throttle cable cap 1 Screw throttle cable cap 2 After tightening the screws check that the throttle grip 3 moves smoothly If it does not retighten the bolts fo...

Page 166: ... in stalled according to the dimensions shown Pass the engine stop switch lead in the middle of the clutch lever hold er 12 Install Clutch cable 1 Apply the lithium soap base grease on the clutch cable end 13 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY section in the CHAPTER 3 Bolt clutch lever holder 5 Nm 0 5 m kg 3 6 ft lb 0 mm 0 mm ...

Page 167: ...ng the suitable stand under the engine Refer to HANDLING NOTE Number plate Refer to SEAT AND SIDE COVERS section in the CHAPTER 4 Handlebar Refer to HANDLEBAR section 1 Front fender 1 2 Steering stem nut 1 3 Front fork 2 Refer to FRONT FORK section 4 Upper bracket 1 5 Steering ring nut 1 Refer to removal section 6 Lower bracket 1 7 Bearing race cover 1 8 Upper bearing 1 9 Lower bearing 1 Refer to ...

Page 168: ...5 29 STEERING 10 Bearing race 2 Refer to removal section Order Part name Q ty Remarks ...

Page 169: ...hand If the bearings hang up or are not smooth in their operation in the bearing races replace bearings and bearing races as a set INSTALLING THE LOWER BRACKET 1 Install Lower bearing 1 Apply the lithium soap base grease on the dust seal lip and bearing inner circumference 2 Install Bearing race Upper bearing 1 Bearing race cover 2 Apply the lithium soap base grease on the bearing and bearing race...

Page 170: ... the nut check the steering for smooth movement If not adjust the steering by loosen ing the 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 Tighten the lower bracket to speci fied torque If torqued too much it may cause the front fork to mal function Steering stem nut 145 Nm 14 5 m kg 105 ft lb Front fork top end ...

Page 171: ...ING NOTE Brake hose holder Refer to FRONT BRAKE AND REAR BRAKE section Rear brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Bolt brake pedal Shift the brake pedal backward Drive chain 1 Drive chain support 1 2 Lower chain tensioner 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt connecting rod 1 5 Pivot shaft 1 6 Swingarm 1 ...

Page 172: ...3 SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q ty Remarks 1 Relay arm 1 2 Connecting rod 1 3 Collar 2 4 Oil seal 2 5 Thrust bearing 2 6 Bushing 2 7 Oil seal 8 8 Bearing 10 Refer to removal section ...

Page 173: ...OIL SEAL 1 Install Bearing 1 Oil seal 2 To swingarm Apply the molybdenum disulfide grease on the bearing when install ing Install the bearing by pressing it on the side having the manufacture s marks or numbers First install the outer and then the inner bearings to a specified depth from inside 2 Install Bearing 1 Washer 2 Oil seal 3 To relay arm Apply the molybdenum disulfide grease on the bearin...

Page 174: ...t relay arm 4 To swingarm Apply the molybdenum disulfide grease on the bolt circumference and threaded portion Do not tighten the nut yet 6 Install Swingarm 1 Pivot shaft 2 Apply the molybdenum disulfide grease on the pivot shaft Insert the pivot shaft from right side 7 Check Swingarm side play a Free play exists Replace thrust bearing Swingarm up and down move ment b Unsmooth movement binding rou...

Page 175: ...e chain support 1 Drive chain support cover 2 Bolt drive chain support L 50 mm 1 97 in 3 Nut drive chain support 4 Bolt drive chain support cover L 10 mm 0 39 in 5 Nut connecting rod 80 Nm 8 0 m kg 58 ft lb Nut relay arm 70 Nm 7 0 m kg 50 ft lb Nut lower chain tension er 16 Nm 1 6 m kg 11 ft lb Nut drive chain sup port 7 Nm 0 7 m kg 5 1 ft lb Bolt drive chain support cover 7 Nm 0 7 m kg 5 1 ft lb ...

Page 176: ...r to SEAT AND SIDE COVERS section in the CHAPTER 4 Silencer Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 4 1 Bolt rear shock absorber relay arm 1 Hold the swingarm 2 Bolt rear shock absorber frame 1 3 Rear shock absorber 1 4 Locknut 1 Only loosening 5 Adjuster 1 Only loosening 6 Lower spring guide 1 7 Upper spring guide 1 8 Spring rear shock absorber 1 9 Bearing 2 Refer to removal sec...

Page 177: ...n disposal NOTES ON DISPOSAL YAMAHA DEALERS ONLY Before disposing the rear shock ab sorber be sure to extract the nitrogen gas from valve 1 Wear eye protec tion to prevent eye damage from es caping gas and or metal chips To dispose of a damaged or worn out rear shock absorber take the unit to your Yamaha dealer for this disposal procedure REMOVING THE BEARING 1 Remove Stopper ring upper bearing 1 ...

Page 178: ... Dust seal 1 O ring 2 Collar 3 Apply the molybdenum disulfide grease on the dust seal lips and col lars Apply the lithium soap base grease on the O rings 2 Install Bushing 1 Collar 2 Dust seal 3 Apply the molybdenum disulfide grease on the bearing and dust seal lips Install the dust seals with their lips facing inward 3 Install Rear shock absorber 4 Install Bolt rear shock absorber frame 1 Washer ...

Page 179: ...r reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage FUEL TANK REMOVING THE FUEL TANK Order Part name Q ty Remarks Seat Refer to SEAT AND SIDE COVERS section in the chapter 4 Air scoop left right 1 1 Refer to SEAT AND SIDE COVERS section in the chapter 4 1 Fuel pump coupler 1 Disconnect 2 Fuel hose 1 Refer to removal section 3 Fuel tank bolt 2 4 Fuel...

Page 180: ...ong shock CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Cracks damage Replace fuel pump assembly CHECKING THE FUEL PUMP OPERATION 1 Check Fuel pump operation Refer to CHECKING THE FUEL PRESSURE section INSTALLING THE FUEL PUMP 1 Install Fuel pump Fuel pump bracket Do not damage the installation surfaces of the fuel tank when in stalling the fuel pump Before installing the fuel pump remove any...

Page 181: ...n pipe 4 Install the fuel tank Refer to INSTALLING THE FUEL TANK section 5 Start the engine 6 Measure the fuel pressure CHECKING AND REPLACING THE DUMPER 1 Inspect Damper 1 1 Damper 2 2 Damper 3 3 Wear damage Replace Affix dampers 1 and 3 so that the arrow on each damper is pointing outward Affix damper 2 so that the edge of the damper contacts the edge a of the frame Pressure gauge YU 03153 90890...

Page 182: ...er 4 Air scoop left right Refer to SEAT AND SIDE COVERS section in the chapter 4 Fuel tank Refer to FUEL TANK section 1 Cover 1 2 Air filter case 1 3 Fuel hose 1 4 Fuel injector coupler 1 Disconnect 5 Intake air pressure sensor coupler 1 Disconnect I D MARK 2 6 Throttle cable cover 1 7 Throttle cable 2 8 Throttle body 1 9 Throttle body joint 1 ...

Page 183: ...6 5 THROTTLE BODY DISASSEMBLING THE THROTTLE BODY Order Part name Q ty Remarks 1 Injector 1 2 Gasket 1 ...

Page 184: ...the throttle body Other wise foreign material may ad here to the intake air pressure sensor passage a and fuel in jector b in the throttle body 1 Check Throttle body Cracks damage Replace the throttle body as a set 2 Check Starter knob idle screw delivery passages a Obstructions Blow out with compressed air ASSEMBLING THE THROTTLE BODY 1 Install O ring 1 Injector 2 Bolt 3 Always use a new O ring I...

Page 185: ... disassembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS 1 Crankshaft position sensor 2 AC magneto 3 Rectifier regulator 4 Condenser 5 Fuel pump 6 Engine stop switch 7 ECU 8 Ignition coil 9 Spark plug 10 Fuel injector 11 Intake air temperature sensor 12 Intake air pressure senso...

Page 186: ...ng optional part COLOR CODE B Black Br Brown Gy Gray L Blue Lg Light green O Orange P Pink R Red W White Y Yellow B L Black Blue B R Black Red B W Black White B Y Black Yellow Br W Brown White P W Pink White R B Red Black R W Red White STOP ON Gy Gy B B L W1 W2 W2 O R B R R R R R R R Lg Lg Lg L P W P Y B R B B B B B B B B B W B W B W Br W Gy B L W1 W1 W2 W2 B Y B Y Br B R R W O O R B R R R L P W P...

Page 187: ...g special tools in this inspection Spark gap test Spark Clean or replace spark plug Check the connection of the spark plug cap to the spark plug No spark Check entire ignition system for connection couplers leads and ignition coil No good Repair or replace OK Check engine stop switch No good Replace OK Check ignition coil primary coil and secondary coil No good Replace OK Check AC magneto cranksha...

Page 188: ...ductive while it is pushed Replace Conductive while it is freed Re place Set the tester selection position to Ω 1 CHECKING THE IGNITION COIL 1 Remove the ignition coil cap 2 Inspect Primary coil resistance Out of specification Replace 3 Inspect Secondary coil resistance Out of specification Replace Disconnect the spark plug cap before measuring the secondary coil resis tance CHECKING THE AC MAGNET...

Page 189: ...ectly The lean angle sensor is built into the ECU The lean angle sensor stops the en gine in case of a turnover To ensure that the lean angle sen sor operates correctly do not change the installation position of the sensor 3 Check ECU If no fault is found replace the ECU Tester lead White lead 1 Tester lead White lead 2 Stator coil resistance Tester se lector posi tion 0 60 0 90 Ω at 20 C 68 F Ω 1...

Page 190: ...on Use the following special tools in this inspection Check entire ignition system for connection No good Repair or replace OK Check throttle position sensor No good Replace OK Check AC magneto No good Replace OK Check ECU Throttle position sensor input volt age No good Replace Model 88 Multimeter with tacometer YU A1927 Digital circuit tester 90890 03174 Test harness speed sensor 3P YU 03208 9089...

Page 191: ...ttle position sensor 2 Align the projection b on the throt tle body with the slot a in the throt tle position sensor Temporarily tighten the screw throttle position sensor 5 Make sure that the throttle grip is in the fully closed position 6 Install Throttle position sensor coupler 7 Connect the FI diagnostic tool Refer to CONNECTING THE FI DIAGNOSTIC TOOL 8 Set the FI diagnostic tool to the di agn...

Page 192: ...arness speed sensor 3P 1 as shown 3 Start the engine 4 Inspect Throttle position sensor input volt age Out of specification Replace the ECU Test harness speed sen sor 3P YU 03208 90890 03208 Tester lead Blue lead wire harness color Tester lead Black Blue lead wire harness color Throttle po sition sen sor input voltage Tester se lector posi tion 4 6 V DCV 20 ...

Page 193: ...ess to OFF and then disconnect the FI diag nostic tool FI diagnostic tool sub wire harness and battery Place the accessory coupler in its origi nal position The malfunction history is stored even if the switch on the FI diagnostic tool sub wire harness is set to OFF Erase the malfunction history in the diagnostic mode Refer to DIAG NOSTIC CODE TABLE Diagnostic code No D62 CONNECTING THE FI DIAGNOS...

Page 194: ...ct the diagnostic code num ber corresponding to the fault code number by pressing the UP and DOWN buttons Select the diagnostic code number corresponding to the fault code number by pressing the UP and DOWN buttons To decrease the selected diagnos tic code number press the DOWN button Press the DOWN button for 1 second or more to automati cally decrease the diagnostic code numbers To increase the ...

Page 195: ...level Approx 101 kPa 3000 m above sea level Approx 70 kPa While the engine is being cranked Displays the intake air pressure D05 Intake air temperature Display Displays the intake air tempera ture Check the temperature in the in take manifold 20 100 C Cold engine Displayed tempera ture is close to the ambient temper ature Warm engine Displayed tempera ture is approximately 20 C higher than the amb...

Page 196: ...epeats the same process 00 No history 12 50 History exists Refer to the fault code number D62 Malfunction history code erasure Actuation and display Displays the total number of mal functions including the current malfunction that have occurred since the history was last erased In addition deletes the fault code numbers from the history if the cor responding items are currently op erating normally...

Page 197: ...ction Properly con nect repair or replace Crank the engine and check the fault code dis play Fault code number is not displayed Service is finished Fault code number is dis played Refer to item 2 2 Check the connection and locking condition of the wire harness ECU coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Poor connection Properly c...

Page 198: ...oupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Poor connection Properly con nect repair or replace Set the switch on the FI di agnostic tool sub wire har ness to ON and then check the fault code dis play Fault code number is not displayed Service is finished Fault code number is dis played Refer to item 2 2 Check the connection and locki...

Page 199: ...d Fault code number is dis played Refer to item 5 5 Defective intake air pressure sensor Execute the diagnostic mode di agnostic code No D03 When the engine is stopped displays the atmospheric pres sure according to the elevation and weather 0 m above sea level Approx 101 kPa 1000 m above sea level Ap prox 90 kPa 2000 m above sea level Ap prox 80 kPa 3000 m above sea level Ap prox 70 kPa Check tha...

Page 200: ...e sensor hose is clogged damaged disconnected kinked pinched or twisted Repair or replace Start the engine and let it idle for approximately 5 seconds with the throttle fully closed After completing the above operation check whether a fault code number is dis played Fault code number is not displayed Service is finished Fault code number is dis played Refer to item 2 2 Defective intake air pressur...

Page 201: ...ition of the pins Poor connection Properly con nect repair or replace Set the switch on the FI di agnostic tool sub wire har ness to ON and then check the fault code dis play Fault code number is not displayed Service is finished Fault code number is dis played Refer to item 3 3 Continuity of harness Open or short circuit Replace Between throttle position sensor coupler and ECU coupler Black Blue ...

Page 202: ... closed A value of 15 19 is indicated When throttle is fully opened A value of 95 101 is indicated Displayed value is out of specifica tion Replace Set the switch on the FI di agnostic tool sub wire har ness to ON and then check the fault code dis play Fault code number is not displayed Service is finished Fault code number is dis played Refer to item 7 7 Malfunction in ECU Replace the ECU Fault c...

Page 203: ...installation Reinstall or repair Incorrect installation position Properly install Set the switch on the FI di agnostic tool sub wire har ness to ON and then operate the throttle After completing the above operation check whether a fault code number is dis played Fault code number is not displayed Service is finished Fault code number is dis played Refer to item 2 2 Defective throttle position sens...

Page 204: ...ck the connection and locking condition of the wire harness ECU coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Poor connection Properly con nect repair or replace Set the switch on the FI di agnostic tool sub wire har ness to ON and then check the fault code dis play Fault code number is not displayed Service is finished Fault code numb...

Page 205: ... higher than the ambient tem perature Checking method Check the temperature in the intake manifold Item Item components and probable cause Check or maintenance job Checking method 1 Check the connection and locking condition of the intake air temperature sensor coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Poor connection Properly con ...

Page 206: ...are no pinched leads Incorrect installation Reinstall or repair Set the switch on the FI di agnostic tool sub wire har ness to ON and then check the fault code dis play Fault code number is not displayed Service is finished Fault code number is dis played Refer to item 5 5 Defective intake temperature sensor Execute the diagnostic mode di agnostic code No D05 Cold engine Displayed temper ature is ...

Page 207: ...nt or broken terminals and locking condition of the pins Poor connection Properly con nect repair or replace Set the switch on the FI di agnostic tool sub wire har ness to ON and then check the fault code dis play Fault code number is not displayed Service is finished Fault code number is dis played Refer to item 3 3 Continuity of harness Open or short circuit Replace Between atmospheric pressure ...

Page 208: ...is incorrect Re place Set the switch on the FI di agnostic tool sub wire har ness to ON and then check the fault code dis play Fault code number is not displayed Service is finished Fault code number is dis played Refer to item 6 6 Malfunction in ECU Replace the ECU Fault code No 23 Symptom Atmospheric pressure sensor signal is not received properly Fail safe system Able to start Able to drive Dia...

Page 209: ...position is cor rect Check that the sensor is installed securely and that there are no pinched leads Check that the ECU is installed securely and that there are no pinched leads Incorrect installation Reinstall or repair Incorrect installation position Properly install Set the switch on the FI di agnostic tool sub wire har ness to ON and then check the fault code dis play Fault code number is not ...

Page 210: ...the above operation check whether a fault code number is dis played Fault code number is not displayed Service is finished Fault code number is dis played Refer to item 2 2 Check the connection and locking condition of the wire harness ECU coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Poor connection Properly con nect repair or replace...

Page 211: ...COIL Start the engine and let it idle for approximately 5 seconds After completing the above operation check whether a fault code number is dis played Fault code number is not displayed Service is finished Fault code number is dis played Refer to item 6 6 Malfunction in ECU Execute the diagnostic mode di agnostic code No D30 No spark Replace the ECU Fault code No 33 Symptom Ignition system circuit...

Page 212: ... After completing the above operation check whether a fault code number is dis played Fault code number is not displayed Service is finished Fault code number is dis played Refer to item 2 2 Faulty injector Defective Replace Refer to CHECKING THE FUEL INJECTORS Start the engine and let it idle for approximately 5 seconds After completing the above operation check whether a fault code number is dis...

Page 213: ...able to drive Diagnostic code No D08 FI diagnostic tool display Lean angle sensor 1 0 V Upright 4 0 V Overturned Checking method Remove the ECU and incline it 45 or more Item Item components and probable cause Check or maintenance job Checking method 1 Malfunction in ECU Replace the ECU Fault code No 39 Symptom Injection system circuit signal is not received properly Fail safe system Unable to sta...

Page 214: ...ult code dis play Fault code number is not displayed Service is finished Fault code number is dis played Repeat item 1 If the fault code number is still displayed refer to item 3 2 EEPROM data error CO adjustment value Change the CO density and write the changed setting on EEPROM Set the switch on the FI di agnostic tool sub wire har ness to ON and then check the fault code dis play Fault code num...

Page 215: ...rvice is finished Fault code number is dis played Refer to item 2 2 Continuity of harness Open or short circuit Replace Between Rectifier regulator and the ECU Red Red White Between Rectifier regulator and the condenser Red Red Start the engine set the switch on the FI diagnostic tool sub wire harness to OFF while the engine is idling and let the engine continue to idle for 5 sec onds or more Afte...

Page 216: ... ECU internal malfunction Fail safe system Unable to start Unable to drive Diagnostic code No FI diagnostic tool display Checking method Item Item components and probable cause Check or maintenance job Checking method 1 Malfunction in ECU Replace the ECU Set the switch on the FI di agnostic tool sub wire har ness to ON and then check the fault code dis play Fault code number is not displayed Servi...

Page 217: ... condition of the wire harness ECU coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Poor connection Properly con nect repair or replace Set the switch on the FI di agnostic tool sub wire har ness to ON and then check the fault code dis play Fault code number is not displayed Service is finished Fault code number is dis played Refer to ite...

Page 218: ... coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Poor connection Properly con nect repair or replace Set the switch on the FI di agnostic tool sub wire har ness to ON and then check the fault code dis play Fault code number is not displayed Service is finished Fault code number is dis played Refer to item 3 3 Continuity of harness Open o...

Page 219: ...t 2 Side cover right left 3 Fuel tank Use the following special tools in this inspection Check engine stop switch No good Replace OK Checking the couplers and leads connections No good Repair or replace OK Check the fuel pump Checking the fuel pump body No good Replace the fuel pump assembly OK Replace the ECU Pocket tester YU 03112 C 90890 03112 Test harness S pressure sensor 3P YU 03207 90890 03...

Page 220: ...a battery and then set the switch on the harness to ON When checking the intake air pres sure sensor do not start the en gine 4 Measure the intake air pressure sensor output voltage Out of specification Replace CHECKING THE INTAKE AIR TEMPERATURE SENSOR 1 Remove Intake air temperature sensor from the air filter case Handle the intake air temperature sensor with special care Never subject the intak...

Page 221: ...d Red lead 1 Tester lead Black White lead 2 2 Start the engine 3 Check Rectifier regulato output voltage Out of specification Replace 4 Stop the engine CHECKING THE FUEL INJECTORS 1 Remove Seat Fuel tank Air filter case 2 Check Injector resistance 3 Connect Tester Tester lead Injector termi nal 1 Tester lead Injector termi nal 2 Out of specification Replace Test harness S pressure sensor 3P YU 032...

Page 222: ...rface Under a stony or hard road condi tion the tire pressure should be higher to prevent a flat tire FRONT FORK SETTING The front fork setting should be made depending on the rider s feeling of an actual run and the circuit conditions The front fork setting includes the fol lowing three factors 1 Setting of air spring characteris tics Change the fork oil amount 2 Setting of spring preload Change ...

Page 223: ...feeling of an actual run and the circuit conditions The rear suspension setting includes the following two factors 1 Setting of spring preload Change the set length of the spring Change the spring 2 Setting of damping force Change the rebound damping Change the compression damp ing CHOOSING SET LENGTH 1 Place a stand or block under the engine to put the rear wheel above the floor and measure the l...

Page 224: ...rently installed use the one whose overall length a does not exceed the standard as it may result in faulty performance Never use one whose overall length is greater than standard REAR SHOCK ABSORBER SETTING PARTS Rear shock spring 1 The I D mark a is marked at the end of the spring Spring specification varies accord ing to the color and quantity of I D marks Extent of adjustment spring pre load F...

Page 225: ...tire range bottoming out Compression damping Turn adjuster clockwise about 2 clicks to in crease damping Oil amount Increase oil amount by about 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Spring Replace with stiff spring Stiff toward stroke end Oil amount Decrease oil amount by about 5 cm3 0 2 Imp oz 0 2 US oz Soft toward stroke end bottoming out Oil amount Increase oil amount by about 5 cm3 0 2 Imp oz...

Page 226: ...eavy and dragging Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Spring Replace with soft spring Poor road gripping Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Low compression damping Turn adjuster clockwise about 1 clicks to in crease damping High compression damping Turn adjuster clockwise about 1 6 turn to in crease dampin...

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Page 228: ...PRINTED IN JAPAN E PRINTED ON RECYCLED PAPER ...

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