Yamaha YZ450FA 2011 Owner'S Service Manual Download Page 51 | Manualshive

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Yamaha YZ450FA 2011 Owner'S Service Manual Download Page 51

2-15

TIGHTENING TORQUES

*1: Tighten the cylinder head bolts to 30 Nm (3.0 m•kg, 22 ft•lb) in the proper tightening sequence,
remove and retighten the cylinder head bolts to 20 Nm (2.0 m•kg, 14 ft•lb) in the proper tightening
sequence, and then tighten the cylinder head bolts further to reach the specified angle 150° in the
proper tightening sequence.

CHASSIS

△

- marked portion shall be checked for torque tightening after break-in or before each race.

Part to be tightened

Thread size

Q'ty

Tightening torque

Nm

m•kg

ft•lb

△

Upper bracket and outer tube

M8 × 1.25

4

21

2.1

15

△

Lower bracket and outer tube

M8 × 1.25

4

21

2.1

15

△

Upper bracket and steering stem

M24 × 1.0

1

145

14.5

105

△

Handlebar upper holder

M8 × 1.25

4

28

2.8

20

△

Handlebar lower holder

M10 × 1.25

2

34

3.4

24

△

Steering ring nut

M28 × 1.0

1

Refer to TIP.

Front fork and damper assembly

M51 × 1.5

2

30

3.0

22

Front fork and adjuster

M22 × 1.25

2

55

5.5

40

Damper assembly and base valve

M42 × 1.5

2

29

2.9

21

Adjuster and damper assembly

M12 × 1.25

2

29

2.9

21

Bleed screw (front fork) and base valve

M5 × 0.8

2

1

0.1

0.7

△

Front fork and front fork protector

M6 × 1.0

6

5

0.5

3.6

△

Front fork protector and brake hose holder

M6 × 1.0

2

8

0.8

5.8

Throttle grip cap

M5 × 0.8

2

4

0.4

2.9

Clutch lever holder

M6 × 1.0

2

5

0.5

3.6

Clutch lever mounting nut

M6 × 1.0

1

4

0.4

2.9

Clutch lever position lock nut

M5 × 0.8

1

5

0.5

3.6

△

Front brake master cylinder and bracket

M6 × 1.0

2

9

0.9

6.5

Front brake master cylinder cap

M4 × 0.7

2

2

0.2

1.4

Brake lever mounting bolt

M6 × 1.0

1

6

0.6

4.3

Brake lever mounting nut

M6 × 1.0

1

6

0.6

4.3

Brake lever position locknut

M6 × 1.0

1

5

0.5

3.6

△

Cable guide (front brake hose) and under bracket

M6 × 1.0

1

4

0.4

2.9

△

Front brake hose union bolt (brake master cylin-
der)

M10 × 1.25

1

30

3.0

22

△

Front brake hose union bolt (brake caliper)

M10 × 1.25

1

30

3.0

22

△

Front brake caliper and front fork

M8 × 1.25

2

28

2.8

20

Brake caliper (front and rear) and pad pin plug

M10 × 1.0

2

2

0.2

1.4

△

Brake caliper (front and rear) and pad pin

M10 × 1.0

2

18

1.8

13

△

Brake caliper (front and rear) and bleed screw

M8 × 1.25

2

6

0.6

4.3

△

Front wheel axle and axle nut

M16 × 1.5

1

105

10.5

75

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Summary of Contents for YZ450FA 2011

Page 1: ...ZUOKA JAPAN PRINTED ON RECYCLED PAPER PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories YZ450FA 2011 OWNER S SERVICE MANUAL YZ450FA 33D 28199 11 LIT 11626 24 22 2011 q Read this manual carefully before operating this vehicle 33D 9 11 cover 2010 5 25 11 08 ページ 1 ...

Page 2: ...Q Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold 33D 9 10 cover 09 7 16 13 11 ページ 2 ...

Page 3: ... by Yamaha Motor Corporation U S A 1st Edition May 2010 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 24 22 ...

Page 4: ...ANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OP ERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWL EDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFETY ENJOY THE CAPABILI TIES AND THE RELIABI...

Page 5: ...MMABLE Always turn off the engine while refueling Take care to not spill any gasoline on the en gine or exhaust system Never refuel in the vi cinity of an open flame or while smoking GASOLINE CAN CAUSE INJURY If you should swallow some gasoline inhale excess gasoline vapors or allow any gasoline to get into your eyes contact a doctor imme diately If any gasoline spills onto your skin or clothing i...

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

Page 7: ...as shown to find the required fore edge symbol mark and go to a page for required item and description MANUAL FORMAT All of the procedures in this manual are organized in a sequential step by step format The informa tion has been complied to provide the mechanic with an easy to read handy reference that contains comprehensive explanations of all disassembly repair assembly and inspection operation...

Page 8: ...iagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy to read way by the use of symbol marks 3 The meanings of the symbol marks are given on the next page 4 A job instruction chart 4 accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc 5 For jobs requiring more information the st...

Page 9: ...c cur rent A Illustrated symbols 8 to 13 in the exploded diagrams indicate grade of lubricant and loca tion of lubrication point 8 Apply engine oil 9 Apply molybdenum disulfide oil 10 Apply brake fluid 11 Apply lightweight lithium soap base grease 12 Apply molybdenum disulfide grease 13 Apply silicone grease Illustrated symbols 14 to 15 in the exploded diagrams indicate where to apply a locking ag...

Page 10: ...MEMO ...

Page 11: ...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 12: ...NFORMATION 1 8 HANDLING THE ELECTRONIC PARTS 1 10 CHECKING OF CONNECTION 1 10 SPECIAL TOOLS 1 12 CONTROL FUNCTIONS 1 17 STARTING AND BREAK IN 1 19 TORQUE CHECK POINTS 1 21 CLEANING AND STORAGE 1 22 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 TIGHTENING TORQUES 2 13 LUBRICATION DIAGRAMS 2 21 CABLE ROUTING DIAGRAM 2 23 ...

Page 13: ... 4 ENGINE SEAT AND SIDE COVERS 4 1 EXHAUST PIPE AND SILENCER 4 3 RADIATOR 4 8 CAMSHAFTS 4 12 CYLINDER HEAD 4 19 VALVES AND VALVE SPRINGS 4 23 CYLINDER AND PISTON 4 30 CLUTCH 4 35 OIL FILTER ELEMENT AND WATER PUMP 4 41 BALANCER 4 47 OIL PUMP 4 51 KICK SHAFT AND SHIFT SHAFT 4 55 AC MAGNETO 4 62 ENGINE REMOVAL 4 65 CRANKCASE AND CRANKSHAFT 4 71 TRANSMISSION SHIFT CAM AND SHIFT FORK 4 79 ...

Page 14: ... 42 SWINGARM 5 47 REAR SHOCK ABSORBER 5 54 CHAPTER 6 FUEL SYSTEM FUEL TANK 6 2 THROTTLE BODY 6 6 CHAPTER 7 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 7 1 IGNITION SYSTEM 7 4 THROTTLE POSITION SENSOR SYSTEM 7 8 FUEL INJECTION SYSTEM 7 11 FUEL PUMP SYSTEM 7 44 ELECTRICAL COMPONENTS 7 45 CHAPTER 8 TUNING CHASSIS 8 1 ...

Page 15: ...asoline 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 1 ...

Page 16: ...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 17: ... machine is stolen the authorities will need the number to search for and identify your machine 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 un der the rider s s...

Page 18: ... a heavy load Carburetors that me ter the fuel through the use of jets have been provided with various auxiliary devices so that an op timum 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 conven tional carburetor system This system can achieve a...

Page 19: ...pplied The injection duration and the injection timing are controlled by the ECU Signals that are input from the throttle position sensor coolant temperature sensor atmospheric pressure sensor lean angle sensor crankshaft position sensor intake air pressure sensor and intake air temperature sensor en able the ECU to determine the injection duration The injection timing is determined through the si...

Page 20: ...lowing out and is installed to the fuel tank breather hose In this installation make sure the arrow fac es the fuel tank and also downward SPARK PLUG WRENCH This spark plug wrench 1 is used to remove and install the spark plug NIPPLE WRENCH This nipple wrench 1 is used to tighten the spoke HANDLEBAR PROTECTOR Install the handlebar protector 1 so that the mark a face forward FUEL TANK HOLDING CABLE...

Page 21: ...nected COUPLER FOR CONNECTING OPTIONAL PART This coupler 1 is used for connection to an op tional Power Tuner and so on When no optional parts etc are connected connect the connection terminal to the orig inal coupler 2 Before removing the coupler thoroughly wipe off any mud or water stuck to it Part name Part number GYTR Power Tuner 33D H59C0 V0 00 The GYTR Power Tuner is optional ...

Page 22: ...rts that have been mated through normal wear Mated parts must be reused as an as sembly or replaced 4 During the machine disassembly clean all parts and place them in trays in the order of disassembly This will speed up assembly time and help assure that all parts are cor rectly reinstalled 5 Keep away from fire ALL REPLACEMENT PARTS 1 We recommend to use Yamaha genuine parts for all replacements ...

Page 23: ...ds the stamped letters must be on the side ex posed to view When installing oil seal s apply a light coating of lightweight lithium base grease to the seal lip s Oil the bear ings liberally when installing Do not use compressed air to spin the bear ings dry This causes damage to the bearing surfaces CIRCLIPS 1 All circlips should be inspected carefully be fore reassembly Always replace piston pin ...

Page 24: ...o not touch and do not make them dirty CHECKING OF CONNECTION Check the leads couplers and connectors for stains rust moisture etc 1 Disconnect Lead Coupler Connector 2 Check Lead Coupler Connector Moisture Dry with an air blower Rust stains Connect and disconnect sev eral times 3 Check All connections Loose connection Connect properly If the pin 1 on the terminal is flattened bend it up If the co...

Page 25: ...u can insert 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 its center pin a back so that it protrudes from the fastener head then insert ...

Page 26: ...se part number starting with 90890 Tool name Part number 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 T...

Page 27: ...is tool is used to loosen or tighten the damper assembly Fork seal driver YM A0948 90890 01502 This 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 resistance output voltage and amperage Timing light YM 33277 A 90890 03141 This tool is necessary for che...

Page 28: ...ssure sensor and the wire harness and is used to measure the voltage Test harness speed sensor 3P YU 03208 90890 03208 This tool is connected be tween 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 diagnostic tool to a bat tery Valve guide remover in staller set 90890 04016 Th...

Page 29: ...015 This tool is needed to install the valve guide Valve guide reamer 5 5 mm 0 22 in YM 01196 This tool is needed to rebore the new valve guide Valve spring compressor at tachment YM 04108 90890 04108 This tool is needed to remove and install the valve assem blies Rotor puller YM 04151 90890 04151 This tool is used to remove the flywheel magneto Crankcase separating tool YU A9642 90890 04152 These...

Page 30: ... necessary for checking the ignition sys tem components Digital tachometer YU 39951 B 90890 06760 This tool is needed for ob serving engine rpm YAMAHA Bond No 1215 ThreeBond No 1215 90890 85505 This sealant Bond is used for crankcase mating surface etc Tool name Part number How to use Illustration ...

Page 31: ...ears can be shifted by using the shift pedal 1 on the left side of the engine KICKSTARTER CRANK Rotate the kickstarter crank 1 away from the engine Push the starter down lightly with your foot until the gears engage then kick smoothly and forcefully to start the engine This model has a primary kickstarter crank so the engine can be started in any gear if the clutch is disen gaged In normal practic...

Page 32: ...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 ...

Page 33: ...ciousness and death in a very short time Always operate the ma chine in a well ventilated area Unlike a two stroke engine this engine cannot be kick started when the throttle is open because the kickstarter may kick back Also if the throttle is open the air fuel mixture may be too lean for the engine to start Before starting the machine perform the checks in the pre operation check list AIR FILTER...

Page 34: ...and the engine stop switch Then restart the engine and check its operation within no more than 5 minutes after it is re started 4 Operate the machine in the lower gears at moderate throttle openings for five to eight minutes 5 Check how the engine runs when the ma chine is ridden with the throttle 1 4 to 1 2 open low to medium speed for about one hour 6 Restart the engine and check the operation o...

Page 35: ...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 36: ... keep the cover pliable and glossy 8 Automotive wax may be applied to all paint ed or chromed surfaces 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 measures must be tak en to avoid deterioration After cleaning the ma ch...

Page 37: ...29 in Wheelbase 1 492 mm 58 74 in 1 487 mm 58 54 in Minimum ground clearance 383 mm 15 08 in 384 mm 15 12 in Weight With oil and fuel 111 kg 245 lb Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Single cylinder Backward inclined 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 s...

Page 38: ... 6 2 L 1 40 Imp gal 1 64 US gal Throttle body Type 30RA Manufacturer KEIHIN Spark plug Type manufacturer CR8E NGK resistance type Gap 0 7 0 8 mm 0 028 0 031 in Clutch type Wet multiple disc Transmission Primary reduction system Gear Primary reduction ratio 61 23 2 652 Secondary reduction system Chain drive Secondary reduction ratio 48 13 3 692 For USA CDN 49 13 3 769 For EUROPE AUS NZ ZA Transmiss...

Page 39: ... kPa 1 0 kgf cm2 15 psi Brake Front brake type Single disc brake Operation Right hand operation Rear brake type Single disc brake Operation Right foot operation Suspension Front suspension Telescopic fork Rear suspension Swingarm link type monocross suspension Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring gas oil damper Wheel travel Front wheel travel 3...

Page 40: ...haft 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 33 540 33 640 mm 1 3205 1 3244 in 33 440 mm 1 3165 in Exha...

Page 41: ...lve clearance cold IN 0 10 0 15 mm 0 0039 0 0059 in EX 0 20 0 25 mm 0 0079 0 0098 in Valve dimensions A head diameter IN 35 9 36 1 mm 1 4134 1 4213 in A head diameter EX 29 9 30 1 mm 1 1772 1 1850 in B face width 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 Item Standar...

Page 42: ... mm 0 003 in Stem to guide clearance EX 0 020 0 047 mm 0 0008 0 0019 in 0 10 mm 0 004 in Stem runout limit 0 01 mm 0 0004 in Valve seat width IN 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Valve seat width EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Valve spring Free 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...

Page 43: ...65 96 980 mm 3 8175 3 8181 in Measuring point H 9 0 mm 0 354 in Piston off set Zero mm Zero in Piston pin bore inside diameter 18 004 18 015 mm 0 7088 0 7093 in 18 045 mm 0 7104 in Piston pin outside diameter 17 991 18 000 mm 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...

Page 44: ...kshaft Crank width A 61 95 62 00 mm 2 439 2 441 in Runout limit C 0 03 mm 0 0012 in 0 05 mm 0 002 in Big end side clearance D 0 15 0 45 mm 0 0059 0 0177 in 0 50 mm 0 02 in Small end free play F 0 4 1 0 mm 0 02 0 04 in 2 0 mm 0 08 in Balancer Balancer drive method Gear Air filter oil grade Foam air filter oil or equivalent oil Clutch Friction plate thickness 2 92 3 08 mm 0 115 0 121 in 2 8 mm 0 110...

Page 45: ...body I D mark 33D1 00 Manufacturer KEIHIN Throttle position sensor Throttle position sensor maximum resistance 5 kΩ Throttle position sensor variable resistance 0 2 kΩ full closed Throttle position sensor input voltage 4 6 V Fuel injection sensor Crankshaft position sensor resistance 248 372 Ω Intake air pressure sensor output voltage 3 57 3 71 V at 101 3kPa 1 013 kg cm2 14 41 psi Atmospheric pres...

Page 46: ...9 25 in Thickness 28 mm 1 10 in Radiator cap opening pressure 108 137 kPa 1 08 1 37 kg cm2 15 4 19 5 psi Radiator capacity total 0 62 L 0 55 Imp qt 0 66 US qt Water pump Type Single suction centrifugal pump Item Standard Limit Item Standard Limit Steering system Steering bearing type Taper roller bearing Front suspension USA CDN EUROPE AUS NZ ZA Front fork travel 310 mm 12 2 in Fork spring free le...

Page 47: ...Wheel Front wheel type Spoke wheel Rear wheel type Spoke wheel Front rim size material 21 1 60 Aluminum Rear rim size material 19 2 15 Aluminum Rim runout limit Radial 2 0 mm 0 08 in Lateral 2 0 mm 0 08 in Drive chain Type manufacturer DID520DMA2 SDH DAIDO Number of links 113 links joint Chain slack 50 60 mm 2 0 2 4 in Chain length 15 links 242 9 mm 9 563 in Front disc brake Disc outside dia Thick...

Page 48: ...m 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 position sensor resistance color 248 372 Ωat 20 C 68 F Gray Black ECU model manufacturer 33D0 USA CDN 33D4 EUROPE 33D6 AUS NZ ...

Page 49: ...ust side M6 1 0 2 10 1 0 7 2 Exhaust pipe nut M6 1 0 3 10 1 0 7 2 Exhaust pipe and frame M8 1 25 1 20 2 0 14 Silencer M8 1 25 2 30 3 0 22 Silencer clamp front M8 1 25 1 12 1 2 8 7 Silencer clamp rear M8 1 25 1 16 1 6 11 Starter knob Idle screw M12 1 0 1 2 0 2 1 4 Throttle body joint M6 1 0 2 10 1 0 7 2 Throttle body joint clamp M5 0 8 1 3 0 3 2 2 Air filter case M6 1 0 3 7 0 7 5 1 Air filter case ...

Page 50: ...nozzle M5 0 8 1 8 0 8 5 8 Crankcase bearing stopper M6 1 0 8 10 1 0 7 2 Crankcase bearing stopper crankshaft M8 1 25 4 22 2 2 16 Drive axle oil seal stopper M6 1 0 2 10 1 0 7 2 Kick shaft ratchet wheel guide M6 1 0 2 12 1 2 8 7 Kickstarter crank M8 1 25 1 33 3 3 24 Screw kickstarter crank M6 1 0 1 7 0 7 5 1 Primary drive gear M20 1 0 1 100 10 0 72 Clutch boss M20 1 0 1 75 7 5 54 Clutch cable lockn...

Page 51: ...juster and damper assembly M12 1 25 2 29 2 9 21 Bleed screw front fork and base valve M5 0 8 2 1 0 1 0 7 Front fork and front fork protector M6 1 0 6 5 0 5 3 6 Front fork protector and brake hose holder M6 1 0 2 8 0 8 5 8 Throttle grip cap M5 0 8 2 4 0 4 2 9 Clutch lever holder M6 1 0 2 5 0 5 3 6 Clutch lever mounting nut M6 1 0 1 4 0 4 2 9 Clutch lever position lock nut M5 0 8 1 5 0 5 3 6 Front b...

Page 52: ...Upper engine bracket and frame M8 1 25 4 45 4 5 32 Front engine bracket and frame M8 1 25 4 34 3 4 24 Engine and engine bracket front M10 1 25 1 53 5 3 38 Engine and engine bracket upper M10 1 25 2 45 4 5 32 Engine and frame lower M10 1 25 1 53 5 3 38 Engine guard M6 1 0 1 10 1 0 7 2 Lower engine guard M6 1 0 3 10 1 0 7 2 Pivot shaft and nut M16 1 5 1 85 8 5 61 Relay arm and swingarm M14 1 5 1 70 ...

Page 53: ... 0 8 6 4 0 4 2 9 Fuel tank side cover M6 1 0 4 7 0 7 5 1 Fuel tank and seat set bracket M6 1 0 1 7 0 7 5 1 Fuel tank and fuel tank bracket M6 1 0 4 7 0 7 5 1 Seat M8 1 25 2 22 2 2 16 Side cover M6 1 0 4 7 0 7 5 1 Heat protector M5 0 8 2 4 0 4 2 9 Air scoop and fuel tank M6 1 0 2 9 0 9 6 5 Air scoop and air duct M6 1 0 2 7 0 7 5 1 Radiator and radiator guard M6 1 0 2 10 1 0 7 2 Air scoop and radiat...

Page 54: ...ctor M5 0 8 2 3 0 3 2 2 Ignition coil M5 0 8 2 4 0 4 2 9 Coolant temperature sensor M10 1 25 1 16 1 6 11 Rectifier regulator M6 1 0 2 7 0 7 5 1 Ignition coil bracket M6 1 0 2 10 1 0 7 2 Intake air pressure sensor M5 0 8 1 5 0 5 3 6 Atmospheric pressure sensor M5 0 8 1 4 0 4 2 9 Atmospheric pressure sensor bracket M6 1 0 1 7 0 7 5 1 Condenser bracket M6 1 0 2 7 0 7 5 1 Ground lead M5 0 8 1 4 0 4 2 ...

Page 55: ...warpage tighten multi fastener assemblies in a crisscross fash ion in progressive stages until full torque is reached Unless otherwise specified torque specifications call for clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter A Nut B Bolt TORQUE SPECIFICA TION 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 ...

Page 56: ...imeter 10 2 meter Length kg kilogram 103 gram Weight N Newton 1 kg m sec2 Force Nm Newton meter N m Torque m kg Meter kilogram m kg Torque Pa Pascal N m2 Pressure N mm Newton per millimeter N mm Spring rate L Liter Volume or capacity cm3 Cubic centimeter Volume or capacity r min Revolution per minute Engine speed ...

Page 57: ......

Page 58: ...2 21 LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS ...

Page 59: ...AGRAMS 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 60: ...2 23 CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM ...

Page 61: ...he hole in the steering stem B Fit the accessory coupler into the connec tor 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 hold er E Route the cylinder head breather hose be tween the frame and radiator hose 3 and to the outside of the AC ma...

Page 62: ...2 25 CABLE ROUTING DIAGRAM F F A B D D C C E F F C C D D B A E 100mm ...

Page 63: ... from the ignition coil side G Fasten the AC magneto lead to the ignition coil bracket with a plastic locking tie mak ing sure to position the tie above the lower mounting portion of the bracket 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 between the condenser and the ignition coil I Fit the clip portion of the clamp ...

Page 64: ...2 27 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 65: ...coil lead to the frame with the plastic band making sure to position the band between the ignition 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 rear ward I Fit the bracket into the hole in the rubber portion of the condenser J Fasten the radiator breather hose to the frame with the plastic band ...

Page 66: ...2 29 CABLE ROUTING DIAGRAM ...

Page 67: ...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 between 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 t...

Page 68: ...2 31 CABLE ROUTING DIAGRAM ...

Page 69: ...n directs as shown and lightly touches the projection on the brake caliper B Pass the brake hose into the brake hose holders C If the brake hose contacts the spring rear shock absorber correct its twist D Install the brake hose so that its pipe por tion directs as shown and lightly touches the projection on the brake master cylinder ...

Page 70: ...2 33 CABLE ROUTING DIAGRAM ...

Page 71: ...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 72: ...fe of the parts varies substantially according to the environment in which the machine runs e g rain dirt etc Therefore earlier inspection is required by reference to the list below Item After 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 th...

Page 73: ...he piston pis ton pin piston pin clip and piston ring all as a set CYLINDER HEAD Inspect carbon deposits and eliminate them Inspect and clean Change gasket CYLINDER Inspect and clean Inspect score marks Replace Inspect wear CLUTCH Inspect and adjust Inspect housing friction plate clutch plate and spring Replace TRANSMISSION Inspect Replace bearing SHIFT FORK SHIFT CAM GUIDE BAR Inspect Inspect wea...

Page 74: ...te 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 hoses OUTSIDE NUTS AND BOLTS Retighten Refer to STARTING AND BREAK IN section in the CHAPTER 1 AIR FILTER Clean and lubricate Use foam air filter oil or equivalent oil Replace OIL FILTER Replace Item After break in Every race...

Page 75: ...ck fluid level and leakage Retighten brake disc bolts caliper 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 Item After break in Every race about 2 5 hours Every third about 7 5 hours ...

Page 76: ...de grease STEERING HEAD Inspect free play and retighten Clean and lube Lithium base grease Replace bearing TIRE WHEELS Inspect air pressure wheel run out tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate Lithium base grease THROTTLE CON TROL CABLE Check routing and connection Yamaha cable lube or SAE 10W 40 motor oil Lubricate Item After break in Eve...

Page 77: ...hain slack and alignment Check that the drive chain is lubricated properly P 3 25 27 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 32 33 Steering Check that the handlebar can be turned smoothly and have no excessive play P 3 33 34 Front forks and rear shock absorber Check that they operate smoothly and there is no oil leakage P 3 27 32 Cabl...

Page 78: ...n a level place and hold it in an upright position 2 Remove Radiator cap 3 Check Coolant level a Coolant level low Add coolant 1 Radiator CHANGING THE COOLANT Do not remove the radiator cap when the en gine is hot Take care so that coolant does not splash on painted surfaces If it splashes wash it away with water 1 Place a container under the engine 2 Remove Coolant drain bolt 1 3 Remove Radiator ...

Page 79: ...to a doctor 7 Install Radiator cap Start the engine and warm it up for a several minutes 8 Check Coolant level Coolant level low Add coolant CHECKING THE RADIATOR CAP 1 Inspect Seal radiator cap 1 Valve and valve seat 2 Crack damage Replace Exist fur deposits 3 Clean or replace CHECKING THE RADIATOR CAP OPENING PRESSURE 1 Attach Radiator cap tester 1 and adapter 2 Apply water on the radiator cap s...

Page 80: ... 1 b Turn the adjusting bolt 2 until the clutch le ver position a is in the desiered position c Tighten the locknuts 2 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH CA BLE FREE PLAY ADJUSTING THE CLUTCH CABLE 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...

Page 81: ...rottle grip free play adjustment steps a Slide the adjuster cover b Loosen the locknut 1 c Turn the adjuster 2 until the specified free play is obtained d Tighten the locknut Before adjusting the throttle cable free play the engine idle speed should be adjusted After adjusting the throttle cable free play start the engine and turn the handlebar to right and left and make sure that the engine idlin...

Page 82: ... 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 bind er 5 Remove Air filter guide Air filter element 1 Do not remove the thin sheet air filter ele ment 2 2 under the air filter element un less it is ...

Page 83: ... following steps Cleaning steps a Remove the air filter element 2 1 b Clean the air filter element 2 with solvent After cleaning remove the remaining solvent by squeezing the element Do not twist the element when squeezing the element c Inspect the air filter element 2 Damage Replace d Install the air filter element 2 10 Install Air filter element 1 Air filter guide 2 Binder 11 Install Mounting bo...

Page 84: ...dow Above the upper limit a Check that no oil comes out when the check bolt 1 for the oil quantity upper limit is removed If any engine oil comes out drain it until its last drop is out Below the level mark b Add sufficient oil and idle run the engine and after stopping the engine recheck through the oil inspec tion window that the oil is at the specified level Check the oil quantity within 5 minu...

Page 85: ... aged replace them with a new one c Install the oil filter element and oil filter ele ment cover 5 Install Gaskets Oil drain bolt oil pan Oil drain bolt oil tank 6 Fill Engine oil Recommended brand YAMALUBE Recommended engine oil type SAE10W 30 SAE 10W 40 SAE10W 50 SAE 15W 40 SAE 20W 40 or SAE 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA Oil filter element cov...

Page 86: ...ing the engine idling speed make sure that the compression pressure is within specification and that the air filter ele ment is not clogged Adjust the engine idling speed with the starter choke knob idling screw pushed in com pletely 1 Start the engine and warm it up until the en gine oil has reached the specified tempera ture 2 Use a temperature probe tester 1 and con tact it to the drain bolt th...

Page 87: ...E COVERS sec tion in the CHAPTER 4 Fuel tank Refer to FUEL TANK section in the CHAP TER 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 counterclockwise with a wrench b Align the alignment mark ...

Page 88: ...original place c Select the proper pad using the pad select ing table The thickness a of each pad is indicated in hundredths of millimeters on the pad upper sur face d Round off the last digit of the installed pad number to the nearest increment EXAMPLE Installed pad number 148 Rounded off value 150 Pads can only be selected in 0 05 mm incre ments e Locate the rounded off value and the mea sured v...

Page 89: ...valve lifters 5 Apply the engine oil on the valve lifters Apply the molybdenum disulfide oil on the valve stem ends Valve lifter must turn smoothly when rotated with a finger Be careful to reinstall valve lifters and pads in their original place g Install the camshafts exhaust and intake Refer to CAMSHAFTS section in the CHAPTER 4 ...

Page 90: ...3 19 ENGINE INTAKE EXHAUST ...

Page 91: ... sever al times f Pull the lever in or push down on the pedal Hold the lever or pedal in position g Loosen the bleed screw and allow the lever or pedal to travel towards its limit h Tighten the bleed screw when the lever or pedal limit has been reached then release the lever or pedal i Repeat steps e to h until of the air bub bles have been removed from the system If bleeding is difficult it may b...

Page 92: ...e pedal height Pedal height adjustment steps a Loosen the locknut 1 b Turn the adjusting nut 2 until the pedal height a is within specified height Adjust the pedal height between the maxi mum A and the minimum B as shown In this adjustment the bolt 3 end b should protrude out of the threaded por tion 4 but not be less than 2 mm 0 08 in c away from the brake pedal 5 After the pedal height adjustmen...

Page 93: ...d brake pads 4 e Connect the transparent hose 5 to the bleed screw 6 and place the suitable con tainer under its end f Loosen the bleed screw and push the brake caliper piston in Do not reuse the drained brake fluid g Tighten the bleed screw h Install the brake pads 7 and pad pin Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at th...

Page 94: ...CING THE REAR BRAKE PADS 1 Inspect Brake pad thickness a Out of specification Replace as a set 2 Replace Brake pad Brake pad replacement steps a Remove the protector 1 and pad pin plug 2 b Loosen the pad pin 3 c Remove the rear wheel 4 and brake caliper 5 Refer to FRONT WHEEL AND REAR WHEEL section in the CHAPTER 5 d Remove the pad pin 6 and brake pads 7 Bolt brake caliper 28 Nm 2 8 m kg 20 ft lb ...

Page 95: ...e caliper 12 and rear wheel 13 Refer to FRONT WHEEL AND REAR WHEEL section in the CHAPTER 5 j Tighten the pad pin 14 k Install the pad pin plug 15 and protector 16 3 Inspect Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL section 4 Check Brake pedal operation A softy or spongy feeling Bleed brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM section CHECKING THE REAR BRAKE PAD INS...

Page 96: ...r when refill ing Clean up spilled fluid immediately to avoid erosion of painted surfaces or plastic parts a Lower level A Front B Rear CHECKING THE SPROCKET 1 Inspect Sprocket teeth a Excessive wear Replace Replace the drive sprocket rear wheel sprock et and drive chain as a set CHECKING THE DRIVE CHAIN 1 Measure Drive chain length 15 links a Out of specification Replace While measuring the drive...

Page 97: ...ip 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 suit able stand under the engine 2 Check Drive chain slack a Above the seal guard installation bolt Out of specification Adjust Before checking and or adjusting rotate the rear wheel through several revolutions and check the slack several times to find th...

Page 98: ...ts A Right B Left Turn the adjuster so that the drive chain is in line with the sprocket as viewed from the rear d Tighten the axle nut while pushing down the drive chain e Tighten the locknuts CHECKING THE FRONT FORK 1 Inspect Front fork smooth action Operate the front brake and stroke the front fork Unsmooth action oil leakage Repair or re place CHECKING THE FRONT FORK PROTECTOR GUIDE 1 Inspect ...

Page 99: ...rom the front fork 3 Install Air bleed screw ADJUSTING THE FRONT FORK REBOUND DAMPING FORCE 1 Adjust Rebound damping force By turning the adjuster 1 STANDARD POSITION This is the position which is back by the spe cific number of clicks from the fully turned in position Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be damaged Always adjust each front f...

Page 100: ...Swingarm smooth action Abnormal noise unsmooth action Grease the pivoting points or repair the pivoting points Damage oil leakage Replace ADJUSTING THE REAR SHOCK ABSORBER SPRING PRELOAD 1 Elevate the rear wheel by placing the suit able stand under the engine 2 Measure Spring fitting length Stiffer a Increase the compression damping force Turn the adjuster 1 in Softer b Decrease the compression da...

Page 101: ... This is the position which is back by the spe cific number of clicks from the fully turned in position Which align the punch mark a on the adjuster with the punch mark b on the bracket Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be damaged Stiffer Increase the spring preload Turn the adjuster 2 in Softer Decrease the spring preload Turn the adjuste...

Page 102: ...SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE 1 Adjust High compression damping force By turning the adjuster 1 Stiffer a Increase the low compression damping force Turn the adjuster 1 in Softer b Decrease the low compres sion damping force Turn the adjuster 1 out Extent of adjustment Maximum Minimum Fully turned in posi tion 20 clicks out from maximum position Standard position About 8 clicks out...

Page 103: ...A tilted tire valve stem indicates that the tire slips off its position on the rim If the tire valve stem is found tilted the tire is considered to be slipping off its position Cor rect the tire position CHECKING AND TIGHTENING THE SPOKES The following procedure applies to all of the spokes 1 Check Spokes Bend damage Replace Loose spoke Retighten Tap the spokes with a screwdriver A tight spoke wil...

Page 104: ...d 3 Check Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering ring nut 4 Adjust Steering ring nut Steering ring nut adjustment steps a Remove the number plate b Remove the handlebar and upper bracket c Loosen the steering ring nut 1 using the steering nut wrench 2 d Tighten the steering ring nut 3 using steer ing nut wrench 4 Apply the lithium soap base grease on...

Page 105: ...handlebar upper holder should be in stalled 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 projection 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 steering stem First tighten the bolts on the front side of th...

Page 106: ...3 35 CHASSIS LUBRICATION ...

Page 107: ...rest pivot 5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding portion 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 lithium soap base grease Wipe off any excess grease and avoid get ting grease on the brake discs ...

Page 108: ...s gauge Out of specification Regap 4 Clean the plug with a spark plug cleaner if necessary 5 Tighten Spark plug Before installing a spark plug clean the gas ket surface and plug surface Finger tighten a the spark plug before torqu ing 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...

Page 109: ...g Visually check the stationary pointer a is within the firing range b on the rotor Incorrect firing range Check rotor and Crankshaft position sensor 5 Install Timing mark accessing screw Timing mark accessing screw 6 Nm 0 6 m kg 4 3 ft lb ...

Page 110: ... procedures provided in this manual contact your Yamaha dealer Engine starting problems engine idling speed problems and medium and high speed perfor mance problems Engine does not start even though the kickstarter is pushed Engine starts but soon stops Engine idling speed problems Engine idling speed fluctuates Engine idling speed is high Engine idling speed is low Medium and high speed performan...

Page 111: ...erly and is not kinked or pinched No good Repair OK Check the spark plug for dirt the spark plug gap and the spark plug cap Refer to CHECKING THE SPARK PLUG section in the CHAPTER 3 No good Clean or adjust OK Check that the air filter element is in stalled correctly and is not clogged Re fer to CLEANING THE AIR FILTER section in the CHAPTER 3 No good Clean or repair OK Checking the sensors injecto...

Page 112: ...d skill concerning servicing are requested not to undertake inspection adjustment disas sembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage 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 remo...

Page 113: ...CHECKING AND REPLACING THE PROTECTOR 1 Inspect Protector 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 cov er wipe stains etc off its surface with a de greasing agent or the like Make sure that the insulators do not protrude past the edges of the side covers Affix the in...

Page 114: ...D SIDE COV ERS section Side cover left and right Refer to SEAT AND SIDE COV ERS section Rear fender Refer to SEAT AND SIDE COV ERS section 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 ...

Page 115: ...4 4 EXHAUST PIPE AND SILENCER 10 Exhaust pipe 1 1 11 Gasket 3 12 Heat protector 1 Order Part name Q ty Remarks ...

Page 116: ...mage to the silencer Remove the inner pipe while holding the silenc er in place with a vise etc 3 Replace Fiber 1 4 Install Inner pipe 1 Bolt 2 Apply heat resistant sealant to the areas a 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 inner pipe Apply locking agent LOCTITE to the threads of the bolts Bolt silencer ...

Page 117: ...ner pipe 1 Rivet front 2 Band 3 Apply heat resistant sealant to the areas a 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 inner pipe Install the band 3 with the mating ends b positioned as shown INSTALLING THE SILENCER AND EXHAUST PIPE 1 Install Gasket Exhaust pipe 1 Nut exhaust pipe 2 First temporarily tighten bo...

Page 118: ...tall and temporarily tighten the silencer so that its joint is positioned as shown with respect to the exhaust pipe 2 4 Install Bolt exhaust pipe 2 Silencer clamp front Silencer clamp rear Tighten while checking that their front and rear joints are inserted in position Bolt silencer 30 Nm 3 0 m kg 22 ft lb 3 7 mm 0 12 0 28 in Bolt exhaust pipe 2 20 Nm 2 0 m kg 14 ft lb Silencer clamp front 12 Nm 1...

Page 119: ...n in the CHAPTER 3 Seat Refer to SEAT AND SIDE COV ERS section Fuel tank Refer to FUEL TANK section in the CHAPTER 6 Exhaust pipe Refer to EXHAUST PIPE AND SI LENCER section 1 Radiator guard 2 2 Radiator hose clamp 8 Only loosening 3 Right radiator 1 4 Radiator hose 2 1 5 Radiator hose 3 1 6 Radiator hose 4 1 7 Pipe 2 O ring 1 1 ...

Page 120: ...4 9 RADIATOR 8 Radiator breather hose 1 9 Left radiator 1 10 Radiator hose 1 1 11 Pipe 1 O ring 1 1 Order Part name Q ty Remarks ...

Page 121: ... while turning counter clockwise and remove it CHECKING THE RADIATOR 1 Inspect Radiator core 1 Obstruction Blow out with compressed air through rear of the radiator Bent 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 in ward 3 Install Radiato...

Page 122: ...to CABLE ROUTING DIAGRAM section in the CHAPTER 2 5 Install Radiator guard 1 First fit the inner hook portion a and then the outer one b onto the radiator 6 Install Bolt radiator guard 1 Right radiator 10 Nm 1 0 m kg 7 2 ft lb Bolt radiator guard 1 10 Nm 1 0 m kg 7 2 ft lb ...

Page 123: ...E COV ERS section Fuel tank Refer to FUEL TANK section in the CHAPTER 6 Cover Refer to THROTTLE BODY section in the CHAPTER 6 Engine upper bracket left 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 124: ...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 125: ...ocket and the alignment mark d on the intake camshaft sprocket are aligned with the edge of the cylinder head 3 Remove Timing chain tensioner cap bolt 1 Timing chain tensioner 2 Gasket 4 Remove Bolt camshaft cap 1 Camshaft cap 2 Clip Remove the bolts camshaft cap in a criss cross pattern working from the outside in The bolts camshaft cap must be removed evenly to prevent damage to the cylinder hea...

Page 126: ...steps a Install the camshaft onto the cylinder head b Position a strip of Plastigauge 1 onto the camshaft Cam lobes length Intake a 37 750 37 850 mm 1 4862 1 4902 in Limit 37 650 mm 1 4823 in Intake b 28 129 28 229 mm 1 1072 1 1114 in Limit 28 029 mm 1 1035 in Exhaust a 33 540 33 640 mm 1 3205 1 3244 in Limit 33 440 mm 1 3165 in Exhaust b 24 769 24 869 mm 0 9752 0 9791 in Limit 24 669 mm 0 9712 in...

Page 127: ... Replace the camshaft as sembly and timing chain as a set CHECKING THE DECOMPRESSION SYSTEM 1 Check Decompression system Checking steps a Check that the decompression mechanism cam 1 moves smoothly b Check that the decompression mechanism cam lever pin 2 projects from the camshaft CHECKING THE TIMING CHAIN TENSIONER 1 Check While pressing the tensioner rod lightly with fingers use a thin screwdriv...

Page 128: ...t mark a on the rotor with the alignment mark b on the crank case cover The alignment mark a on the rotor is there for camshaft installation This alignment mark is stamped 23 ATDC c Fit the timing chain 3 onto both camshaft sprockets and install the camshafts on the cylinder head Make sure that the alignment mark c on the exhaust camshaft sprocket and the alignment mark d on the intake camshaft sp...

Page 129: ... fingers use a thin screwdriver and wind the tensioner rod up fully clockwise b With the rod fully wound and the chain ten sioner UP mark a facing upward install the gasket 1 the timing chain tensioner 2 and the gasket 3 and tighten the bolt 4 to the specified torque c Release the screwdriver check the tension er rod to come out and tighten the gasket 5 and the cap bolt 6 to the specified torque 3...

Page 130: ...section in the CHAPTER 6 Exhaust pipe and silencer Refer to EXHAUST PIPE AND SI LENCER section Radiator Refer to RADIATOR section Throttle body Refer to THROTTLE BODY section in the CHAPTER 6 Camshaft Refer to CAMSHAFTS section 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 ...

Page 131: ...ve and retighten the cylinder head bolts to 20 Nm 2 0 m kg 14 ft lb in the proper tightening se quence and then tighten the cylinder head bolts further to reach the specified angle 150 in the proper tightening sequence 6 Coolant temperature sensor 1 7 Oil check bolt 2 8 Oil passage plug 1 Order Part name Q ty Remarks ...

Page 132: ... head b Use a feeler gauge to measure the warpage c If the warpage is out of specification resur face the cylinder head d Place a 400 600 grit wet sandpaper on the surface plate and resurface the head using a figure eight sanding pattern To ensure an even surface rotate the cylinder head several times INSTALLING THE CYLINDER HEAD 1 Install Timing chain guide intake side 1 Dowel pin 2 Cylinder head...

Page 133: ... the molybdenum disulfide grease on the threads and contact surfaces of the bolts and on both contact surfaces of the plain washers g Retighten the bolts Tighten the bolts to the specified torque in two or three steps in the proper tightening se quence as shown h Put a mark on the corner 1 of the bolt cyl inder head and the cylinder head 2 as shown Tighten the bolts two times at specified angles o...

Page 134: ...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 Intake valve 2 9 Exhaust valve 2 ...

Page 135: ...There should be no leakage at the valve seat 2 3 Remove Valve cotter Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attach ment 2 CHECKING THE VALVE 1 Measure Stem to guide clearance Out of specification Replace the valve guide Valve spring compressor YM 04019 90890 04019 Valve spring compressor attach ment YM 04108 90890...

Page 136: ...3 to obtain proper stem to guide clearance After replacing the valve guide reface the valve seat 3 Inspect Valve face Pitting wear Grind the face Valve stem end Mushroom shape or diameter larger than the body of the stem Replace 4 Measure Margin thickness a Out of specification Replace Valve guide installation height a Intake 15 1 15 5 mm 0 59 0 61 in Exhaust 12 2 12 6 mm 0 48 0 50in Valve guide r...

Page 137: ... made contact blueing will have been removed e If the valve seat is too wide too narrow or the seat is not centered the valve seat must be refaced 9 Lap Valve face Valve seat This model uses titanium intake and ex haust 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 ...

Page 138: ...e Dykem to the valve face g Install the valve into the cylinder head h Press the valve through the valve guide and onto the valve seat to make a clear pattern i Measure the valve seat width again If the valve seat width is out of specification reface and relap the valve seat CHECKING THE VALVE SPRINGS 1 Measure Valve spring free length a Out of specification Replace 2 Measure Compressed spring for...

Page 139: ...pring retainers 5 Install the valve a with the identification 33DI on the intake side and the valve b with the identification 33DE on the exhaust side Install the valve springs with the larger pitch d facing upward e Smaller pitch 3 Install Valve cotters Install the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attach ment 2 Spring...

Page 140: ...ting the valve tip with excessive force could damage the valve 5 Install Adjusting pad 1 Valve lifter 2 Apply the molybdenum disulfide oil on the valve stem end Apply the engine oil on the valve lifters Valve lifter must turn smoothly when rotated with a finger Be careful to reinstall valve lifters and pads in their original place ...

Page 141: ...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 142: ...same time lifting the piston ring over the top of the pis ton crown as shown in the illustration CHECKING THE CYLINDER AND PISTON 1 Inspect Cylinder and piston walls Vertical scratches Replace cylinder and piston 2 Measure Piston to cylinder clearance Measurement steps a Measure the cylinder bore C with a cylin der bore gauge Measure the cylinder bore C in parallel to and at right angles to the cr...

Page 143: ...ing into the cylinder and push it ap proximately 40mm 1 57 in into the cylinder Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore a 40 mm 1 57 in 3 Measure Ring end gap Out of specification Replace You cannot measure the end gap on the ex pander spacer of the oil control ring If the oil control ring rails show excessive gap replace all three rings P...

Page 144: ...stall 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 Offset the piston ring end gaps as shown a Top ring end b 2nd ring end c Oil ring end upper d Oil ring e Oil ring end lower Outside diameter ...

Page 145: ...n pin clip cover the crankcase with a clean rag to prevent the pis ton 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 com pressing the piston rings with the other hand Pass the timing chain 3 through the tim ing chain cavity Be careful not to damage the timing chain guide 4 during installat...

Page 146: ... oil Refer to CHANGING THE ENGINE OIL section in the CHAPTER 3 Brake pedal Refer to ENGINE REMOVAL sec tion 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 ...

Page 147: ...ion plate 8 13 Nut clutch boss 1 Refer to removal section 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 148: ... DRIVEN GEAR 1 Check Circumferential play Free play exists Replace Gear teeth a Wear damage Replace CHECKING THE CLUTCH SPRINGS 1 Measure Clutch spring free length a Out of specification Replace springs as a set CHECKING THE FRICTION PLATES 1 Measure Friction plate thickness Out of specification Replace friction plate as a set Measure at all four points Clutch holding tool YM 91042 90890 04086 Clu...

Page 149: ...HECKING THE PUSH ROD 1 Inspect Push rod 1 1 Bearing 2 Washer 3 Push rod 2 4 Ball 5 Wear damage bend Replace INSTALLING THE PUSH LEVER SHAFT 1 Install Push lever shaft 1 Apply the lithium soap base grease on the oil seal lip Apply the engine oil on the push lever shaft INSTALLING THE CLUTCH 1 Install Primary driven gear 1 Thrust washer 2 Clutch boss 3 Apply the engine oil on the primary driven gear...

Page 150: ...sur face b outward Use the clutch holding tool 3 to hold the clutch boss A For USA and CDN B Except for USA and CDN 3 Install Friction plate 1 Clutch plate 2 Install the clutch plates and friction plates al ternately 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...

Page 151: ...ch spring Bolt clutch spring Tighten the bolts in stage using a crisscross pattern 8 Install O ring clutch cover 1 Apply the lithium soap base grease on the O ring 9 Install Clutch cover 1 Bolt clutch cover Tighten the bolts in stage using a crisscross pattern Bolt clutch spring 10 Nm 1 0 m kg 7 2 ft lb Bolt clutch cover 10 Nm 1 0 m kg 7 2 ft lb ...

Page 152: ... REMOVAL sec tion Drain the engine oil Refer to CHANGING THE ENGINE OIL section in the CHAPTER 3 Drain the coolant Refer to CHANGING THE COOL ANT section Exhaust pipe Refer to EXHAUST PIPE AND SI LENCER section Brake pedal Refer to ENGINE REMOVAL sec tion 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 ...

Page 153: ...8 Gasket 1 9 Dowel pin O ring 3 1 10 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 154: ... with spanners etc and remove the im peller REMOVING THE OIL SEAL It is not necessary to disassemble the water pump unless there is an abnormality such as excessive change in coolant level discolor ation of coolant or milky transmission oil 1 Remove Bearing 1 Oil seal 2 CHECKING THE IMPELLER SHAFT 1 Inspect Impeller shaft 1 Bend wear damage Replace Fur deposits Clean ...

Page 155: ... facing the right crankcase cover 2 2 Install Bearing 1 Install the bearing by pressing its outer race parallel INSTALLING THE IMPELLER SHAFT 1 Install Impeller shaft 1 Washer 2 Impeller 3 Take care so that the oil seal lip is not dam aged or the spring does not slip off its posi tion When installing the impeller shaft apply the engine oil on the oil seal lip bearing and im peller shaft And instal...

Page 156: ...er onto the crankcase be sure that the impeller shaft end 3 aligns with the balancer end slot 4 Tighten the bolts in stage using a crisscross pattern INSTALLING THE KICKSTARTER CRANK 1 Install Kickstarter crank 1 Washer Bolt kickstarter crank Install so that there is a clearance a of 8 mm 0 31 in or more between the kickstarter and frame and that the kickstarter does not contact the crankcase cove...

Page 157: ...iator pipe 2 Apply the lithium soap base grease on the O ring INSTALLING THE OIL FILTER ELEMENT 1 Install Oil filter element 1 O ring 2 Oil filter element cover 3 Bolt oil filter element cover Apply the lithium soap base grease on the O ring Bolt water pump housing 10 Nm 1 0 m kg 7 2 ft lb Coolant drain bolt 10 Nm 1 0 m kg 7 2 ft lb Bolt radiator pipe 10 Nm 1 0 m kg 7 2 ft lb Bolt oil filter eleme...

Page 158: ...TER ELEMENT AND WATER 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 ...

Page 159: ...4 48 BALANCER 11 Balancer shaft driven gear 1 Order Part name Q ty Remarks ...

Page 160: ... gear 5 CHECKING THE PRIMARY DRIVE GEAR BALANCER SHAFT DRIVE GEAR AND BALANCER SHAFT DRIVEN GEAR 1 Inspect Primary drive gear 1 Balancer shaft drive gear 2 Balancer shaft driven gear 3 Wear damage Replace CHECKING THE BALANCER 1 Inspect Balancer Cracks damage Replace INSTALLING THE BALANCER 1 Install Balancer shaft driven gear 1 Install the balancer shaft driven gear and bal ancer shaft with their...

Page 161: ... Straight key 6 Balancer 7 Lock washer 8 Nut balancer 9 Apply molybdenum disulfide grease to the contact surface and threaded portion of the nut primary drive gear Apply molybdenum disulfide grease to the contact surface of the conical spring washer Place an aluminum plate a between the teeth of the balancer shaft drive gear 10 and balancer shaft driven gear 11 Install the conical washer with its ...

Page 162: ...en gear Refer to CLUTCH section Right crankcase cover Refer to OIL FILTER ELEMENT AND WATER 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 ...

Page 163: ...4 52 OIL PUMP 12 Inner rotor 1 1 13 Dowel pin 1 14 Washer 1 15 Oil pump drive shaft 1 16 Rotor housing 1 Order Part name Q ty Remarks ...

Page 164: ...p assembly 3 Check Unsmooth Repeat steps 1 and 2 or re place the defective parts INSTALLING THE OIL PUMP 1 Install Oil pump drive shaft 1 Washer 2 Dowel pin 3 Inner rotor 1 4 Apply the engine oil on the oil pump drive shaft and inner rotor 1 Fit the dowel pin into the groove in the inner rotor 1 2 Install Outer rotor 1 1 Apply the engine oil on the outer rotor 1 Tip clearance a 0 12 mm or less 0 0...

Page 165: ...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 engine oil on the outer rotor 2 5 Install Oil pump drive gear 1 Washer 2 Circlip 3 Apply the engine oil on the oil pump drive gear inner circumference Screw oil pump cover 2 Nm 0 2 m kg 1 4 ft lb Bolt oil pump assembly 10 Nm 1 0 m kg 7 2 ft lb ...

Page 166: ...rder Part name Q ty Remarks Oil pump Refer to OIL PUMP 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 ...

Page 167: ...r to removal section 15 Shift lever assembly 1 Refer to removal section 16 Shift lever 1 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 168: ...THE SEGMENT 1 Remove Bolt segment 1 Segment 2 Turn the segment counterclockwise until it stops and loosen the bolt If the segment gets an impact it may be damaged Take care not to give an impact to the segment when removing the bolt CHECKING THE KICK SHAFT AND RATCHET WHEEL 1 Check Ratchet wheel 1 smooth movement Unsmooth movement Replace Kick shaft 2 Wear damage Replace Spring 3 Broken Replace CH...

Page 169: ...age Replace Torsion spring 2 Broken Replace INSTALLING THE SEGMENT 1 Install Segment 1 Bolt segment Align the notch a on the segment with the pin b on the shift cam If the segment gets an impact it may be damaged Take care not to give an impact to the segment when tightening the bolt INSTALLING THE STOPPER LEVER 1 Install Torsion spring 1 Washer 2 Stopper lever 3 Bolt stopper lever 4 Align the sto...

Page 170: ...hift lever assembly is installed at the same time as the shift guide Apply the engine oil on the bolt segment shaft 4 Install Bolt shift guide 1 INSTALLING THE SHIFT SHAFT 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 ...

Page 171: ...haft 2 Make sure the stopper a of the torsion spring fits into the hole b on the kick shaft 3 Install Spring guide 1 Slide the spring guide into the kick shaft make sure the groove a in the spring guide fits on the stopper of the torsion spring 4 Install Kick shaft assembly 1 Washer 2 Apply the molybdenum disulfide grease on the contacting surfaces of the kick shaft stop per a and kick shaft ratch...

Page 172: ...on 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 the engine oil on the kick idle gear inner circumference Install the kick idle gear with its depressed side a toward you ...

Page 173: ... Seat Refer to SEAT AND SIDE COV ERS section 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 174: ...TO 1 Install Stator 1 Screw stator 2 Crankshaft position sensor 3 Holder 4 Bolt crankshaft position sensor 5 Apply the sealant on the grommet of the AC magneto lead Tighten the screws using the T30 bit Pass the crankshaft position sensor lead a this side of the stator lead b Install the holder so that the projection c on the holder contacts the stopper Rotor puller YM 04151 90890 04151 Screw stato...

Page 175: ...alling 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 DIAGRAM section in the CHAPTER 2 5 Install Dowel pin Gasket left crankcase cover Left crankcase cover 1 Hose guide cylinder head breather hose 2 Bolt left crankcase cover Tighten the bolts in stage using a crisscross pattern Nut rotor 65 Nm 6 5 m kg 4...

Page 176: ...nd under the frame Refer to HANDLING NOTE Seat Refer to SEAT AND SIDE COV ERS section Fuel tank Air filter case 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 177: ...r to SEAT AND SIDE COV ERS section Exhaust pipe and silencer Refer to EXHAUST PIPE AND SI LENCER 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 ...

Page 178: ...ve sprocket 1 Refer to removal section 5 Clip 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 179: ...er into the other side of the swingarm to support it 2 Remove Engine 1 From right side Make sure that the couplers hoses and ca bles are disconnected Turn the engine 90 to the right as shown and then while lifting the crankcase in the direc tion of the arrow shown remove the engine from the right side of the vehicle INSTALLING THE ENGINE 1 Install Engine 1 Install the engine from right side Pivot ...

Page 180: ...on the bolt O rings and brake pedal bracket INSTALLING THE DRIVE SPROCKET 1 Install Drive sprocket 1 Drive chain 2 Install the drive sprocket together with the drive chain 2 Install Lock washer 1 Nut drive sprocket 2 Tighten the nut while applying the rear brake Make sure to tighten to specification other wise it may damage the other part that is fastened together Bolt upper engine bracket 45 Nm 4...

Page 181: ...INE REMOVAL 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 Bolt drive chain sprocket cover 7 Nm 0 7 m kg 5 1 ft lb ...

Page 182: ... section Balancer Refer to BALANCER section Kick shaft assembly Refer to KICK 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 ...

Page 183: ... in 4 Refer to removal section 7 Right crankcase 1 Refer to removal section 8 Left crankcase 1 Refer to removal section 9 Oil strainer 1 10 Balancer shaft 1 Refer to removal section 11 Crankshaft 1 Refer to removal section Order Part name Q ty Remarks ...

Page 184: ...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 10 Refer to removal section ...

Page 185: ...g boss using a soft hammer and leave the crankshaft and transmission with the left crankcase Use soft hammer to tap on the case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If the cases do not separate check for a remaining case bolt or fitting Do not force c Remove the dowel pins and O ring REM...

Page 186: ...pect Timing chain guide Wear damage Replace CHECKING THE CRANKCASE 1 Inspect Contacting surface a Scratches Replace Engine mounting boss b crankcase Cracks damage Replace 2 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace 3 Inspect Oil seal Damage Replace CHECKING THE CRANKSHAFT 1 Measure Runout limit a Small end free play limit b Connecting rod big end side clearance c C...

Page 187: ...screwdriver receiving hole in the screw head INSTALLING THE CRANKSHAFT 1 Install Crankshaft 1 Use the crankshaft installing tool 2 3 4 and 5 Standard Limit Runout lim it 0 03 mm 0 0012 in 0 05 mm 0 002 in Small end free play 0 4 1 0 mm 0 016 0 039 in 2 0 mm 0 08 in Side clear ance 0 15 0 45 mm 0 0059 0 0177 in 0 50 mm 0 02 in Crack width 61 95 62 00 mm 2 439 2 441 in Bolt bearing stopper 10 Nm 1 0...

Page 188: ...e molybdenum disulfide grease to the crankshaft to prevent it from being scratched Do not use a hammer to drive in the crank shaft A For USA and CDN B Except for USA and CDN 2 Check Shifter operation Transmission operation Unsmooth operation Repair 3 Install Oil strainer 1 Bolt oil strainer 2 4 Apply Sealant On the right crankcase Clean the contacting surface of left and right crankcase before app...

Page 189: ...crankcase Tighten the crankcase tightening bolts in stage using a crisscross pattern 7 Install Timing chain Timing chain guide exhaust side Bolt for timing chain guide exhaust 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 operation Unsmooth operation Repair Bolt crankcase 12 Nm ...

Page 190: ...s Engine Refer to ENGINE REMOVAL sec tion Separate the crankcase Refer to CRANKCASE AND CRANKSHAFT 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 191: ... forks Remove the main axle drive axle shift cam and shift fork all together by tapping lightly on the transmission drive axle with a soft ham mer CHECKING THE GEARS 1 Inspect Matching dog a Gear teeth b Shift fork groove c Wear damage Replace 2 Inspect O ring 1 Damage Replace 3 Check Gears movement Unsmooth movement Repair or replace CHECKING THE BEARING 1 Inspect Bearing 1 Rotate inner race with...

Page 192: ...8T 2 Collar 3 4th pinion gear 22T 4 2nd pinion gear 15T 5 To main axle 6 Apply the molybdenum disulfide oil on the inner and end surface of the idler gear and on the in ner surface of the sliding gear then install 2 Install Collar 1 2nd wheel gear 23T 2 4th wheel gear 24T 3 3rd wheel gear 23T 4 5th wheel gear 20T 5 Collar 6 1st wheel gear 27T 7 O ring 8 To drive axle 9 Apply the molybdenum disulfi...

Page 193: ...hen installing the collar into the crankcase pay careful attention to the crankcase oil seal 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 bear ing contact surface and shift fork shaft Mesh the shift fork 1 L with the 4th wheel gear 5 and ...

Page 194: ...ISSION SHIFT CAM AND SHIFT FORK 6 Install Transmission assembly 1 To left crankcase 2 Apply the engine oil on the bearings and guide bars 7 Check Shifter operation Transmission operation Unsmooth operation Repair ...

Page 195: ...icing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowl edge and skill concerning servicing are requested not to undertake inspection adjustment disas sembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage 5 ...

Page 196: ...er Part name Q ty Remarks Hold the machine by placing the suit able stand under the engine Refer to HANDLING NOTE 1 Bolt axle holder 4 Only loosening 2 Nut front wheel axle 1 3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Oil seal 2 7 Bearing 2 Refer to removal section 8 Brake disc 1 ...

Page 197: ...chine by placing the suit able 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 ...

Page 198: ...ING THE WHEEL 1 Measure Wheel runout Out of limit Repair replace 2 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace Replace the bearings oil seal and wheel collar as a set CHECKING THE WHEEL AXLE 1 Measure Wheel axle bends Out of 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 ...

Page 199: ...ing and oil seal lip when installing Use a socket that matches the outside diam eter of the race of the bearing Left side of bearing shall be installed first Install the oil seal with its manufacture s marks or numbers facing outward Do not strike the inner race of the bearing Contact should be made only with the outer race 2 Install Brake disc 1 Bolt brake disc 2 Tighten the bolts in stage using ...

Page 200: ... brake disc 1 between the brake pads 2 correctly 5 Install Wheel axle 1 Apply the lithium soap base grease on the wheel axle 6 Install Nut wheel axle 1 7 Tighten Bolt axle holder 1 Before tightening the bolt fit the wheel axle to the axle holder by stroking the front fork several times with the front brake applied Nut wheel axle 105 Nm 10 5 m kg 75 ft lb Bolt axle holder 21 Nm 2 1 m kg 15 ft lb ...

Page 201: ...l the oil seal with its manufacture s marks or numbers facing outward Do not strike the inner race of the bearing Contact should be made only with the outer race 2 Install Brake disc 1 Bolt brake disc 2 Tighten the bolts in stage using a crisscross pattern 3 Install Rear wheel sprocket 1 Bolt rear wheel sprocket 2 Washer rear wheel sprocket 3 Nut rear wheel sprocket 4 Tighten the nuts in stage usi...

Page 202: ...n 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 CHAIN SLACK section in the CHAPTER 3 10 Tighten Nut wheel axle 1 Locknut 2 Drive chain slack 50 60 mm 2 0 2 4 in Nut wheel ...

Page 203: ...stand 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 caliper 6 Brake caliper 1 7 Brake lever 1 8 Brake master cylinder bracket 1 9 Brake master cylinder 1 ...

Page 204: ...ine 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 caliper 8 Brake caliper 1 ...

Page 205: ...Order 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 206: ...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 207: ...o not reuse the drained brake fluid Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately REMOVING THE BRAKE CALIPER PISTON 1 Remove Brake caliper piston Use compressed air and proceed carefully Cover piston with rag and use extreme caution when expelling piston from cylin der Never attempt to pry out piston Caliper piston removal steps a Insert a piece ...

Page 208: ... dust seals whenever a caliper is disassembled A Front B Rear CHECKING THE BRAKE MASTER CYLINDER 1 Inspect Brake master cylinder inner surface a Wear scratches Replace master cylinder assembly Stains Clean Use only new brake fluid A Front B Rear 2 Inspect Diaphragm 1 Crack damage Replace A Front B Rear 3 Inspect front brake only Reservoir float 1 Damage Replace 4 Inspect Brake master cylinder pist...

Page 209: ...ernal parts should be lubricated with brake fluid when installed Replace the brake caliper piston seals and brake 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 du...

Page 210: ...e brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point 2 Install Brake caliper 1 Bolt brake caliper 2 3 Tighten Pad pin 3 4 Install Pad pin plug 4 INSTALLING THE REAR BRAKE CALIPER 1 Install Pad support 1 Brake pad 2 Pad pin 3 Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad ...

Page 211: ...ith brake fluid 2 Install Brake master cylinder cup primary 1 Brake master cylinder cup secondary 2 To brake master cylinder piston 3 Apply the brake fluid on the brake master cylin der cup After installing cylinder cup should be in stalled as shown direction Wrong installa tion cause improper brake performance 3 Install Spring 1 To brake master cylinder piston 2 Install the spring at the smaller ...

Page 212: ...ONT BRAKE MASTER CYLINDER 1 Install Brake master cylinder 1 Brake master cylinder bracket 2 Bolt brake master cylinder bracket 3 Install the bracket so that the arrow mark a face upward First tighten the bolts on the upper side of the brake master cylinder bracket and then tight en the bolts on the lower side 2 Install Brake lever 1 Bolt brake lever 2 Nut brake lever 3 Apply the silicone grease on...

Page 213: ...linder 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 ADJUSTING THE REAR BRAKE section in the CHAPTER 3 Union bolt 30 Nm 3 0 m kg 22 ft lb Bolt b...

Page 214: ...e holder 1 Bolt brake hose holder 2 Align the top a of the brake hose holder with the paint b of the brake hose 3 Pass the brake hose through the cable guide 1 4 Install Copper washer 1 Brake hose 2 Union bolt 3 Always use new copper washers Install the brake hose so that its pipe por tion a directs as shown and lightly touch es the projection b on the brake master cylinder Union bolt 30 Nm 3 0 m ...

Page 215: ...oes 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 flu id otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Refill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and lead to poor perfor mance Be careful that water does...

Page 216: ...ction 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 le ver in or pushing down on the brake pedal check whether there is any brake fluid leak ing where the union bolts are installed re spectively at the brake master cylinder and brake caliper A Front B Rear 5 Install rear...

Page 217: ...er 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 218: ...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 219: ...rk is disas sembled and reassembled Before removing the base valves or front forks be sure to extract the air from the air chamber completely REMOVING THE DAMPER ASSEMBLY 1 Loosen Damper assembly 1 Before removing the front fork from the ma chine loosen the damper assembly with the cap bolt ring wrench 2 REMOVING THE ADJUSTER 1 Drain the outer tube of its front fork oil at its top 2 Loosen Adjuste...

Page 220: ...o remove the base valve CHECKING THE DAMPER ASSEMBLY 1 Inspect Damper assembly 1 Bend damage Replace O ring 2 Wear damage Replace The front fork with a built in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign mate rial Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and r...

Page 221: ...Use 1 000 grit wet sandpaper Damaged oil lock piece Replace Inner tube bends Out of 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 dangerously weaken the tube CHECKING THE OUTER TUBE 1 Inspect Outer tube 1 Score marks wear damage Replace Fork spring free length 470 mm 18 5 in Lim...

Page 222: ...nter the front fork 4 After filling pump the damper assembly 1 slowly up and down about 200 mm 7 9 in stroke several times to bleed the damper assembly of air Be careful not to excessive full stroke A stroke of 200 mm 7 9 in or more will cause air to en ter In this case repeat the steps 2 to 4 5 Measure Oil level left and right a Out of specification Adjust 6 Tighten Locknut 1 Fully finger tighten...

Page 223: ...fully stretched Repeat the steps 2 to 8 10 Tighten Base valve 1 Hold the damper assembly with 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 assembly 1 slowly up and down more than 10 times to distribute the fork oil 12 While protecting the damper assembly 1 with a rag and compressing fully allow ex cessive ...

Page 224: ...Stopper ring 2 Oil seal 3 Oil seal washer 4 Slide metal 5 To inner tube 6 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 Install the oil seal with its manufacture s marks or number facing the axle holder side 16 Install Piston metal 1 Install the piston metal onto the slot on inner tube 17 Install Outer tube 1 To...

Page 225: ...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 Fork seal driver YM A0948 90890 01502 Fork seal driver YM A0948 90890 01502 ...

Page 226: ...may fall into it damaging the valve inside 26 Loosen Rebound damping adjuster 1 Loosen the rebound damping adjuster finger tight Record the set position of the adjuster the amount of turning out the fully turned in posi tion 27 Install Push rod 1 Copper washer 2 Adjuster 3 To damper assembly 4 While compressing the inner tube 5 set the cap bolt ring wrench 7 between the inner tube and locknut 6 Fu...

Page 227: ...ment between the maximum and minimum amount and always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability Be sure to use recommended fork oil If other oils are used they may have an ex cessively adverse effect on the front fork performance Never allow foreign materials to enter the front fork Gap a between the adjuster and locknut 0 5 1 0 mm ...

Page 228: ... the cap bolt ring wrench 2 to tighten the damper assembly with specified torque 3 Adjust Front fork top end a 4 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 Tighten the lower bracket to specified torque If torqued too much it may cause the front fork to malfunction Damper assembly 30 Nm 3 0 m kg 22 ft lb Cap bolt ring wrench YM 01501 90890 01501 Front fork top end standard a Zero...

Page 229: ...damping force Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 7 Adjust Compression damping force Turn in the damping adjuster 1 finger tight and then turn out to the originally set position Bolt protector 5 Nm 0 5 m kg 3 6 ft lb ...

Page 230: ...older 1 3 Engine stop 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 ...

Page 231: ...5 37 HANDLEBAR 14 Handlebar lower holder 2 15 Cap 1 Order Part name Q ty Remarks ...

Page 232: ...ace Do not attempt to straighten a bent handle bar as this may dangerously weaken the handlebar INSTALLING THE HANDLEBAR 1 Install Handlebar lower holder 1 Washer 2 Nut handlebar lower holder 3 Be sure the side of the handlebar lower holder having the greater distance a from the mounting bolt center faces forward And in stall it in the hole b in the rear of the upper bracket Apply the lithium soap...

Page 233: ...en the bolts on the front side of the handlebar upper holder and then tighten the bolts on the rear side 3 Tighten Nut handlebar lower holder 1 Cap 2 Install the cap 2 onto the handlebar lower holder nut left 4 Install Left grip 1 Apply the adhesive to the handlebar 2 Before applying the adhesive wipe off grease or oil on the handlebar surface a with a lac quer thinner Install the left grip to the...

Page 234: ...wn 6 Install Collar 1 Grip cap cover 2 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...

Page 235: ...Engine stop switch 1 Clutch lever holder 2 Bolt clutch lever holder 3 Clamp 4 The engine stop switch clutch lever holder and clamp should be installed according to the dimensions shown Pass the engine stop switch lead in the middle of the clutch lever holder 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 ...

Page 236: ... 7 Nm 0 7 m kg 5 1 ft lb Hold the machine by placing the suit able stand under the engine Refer to HANDLING NOTE Number plate Refer to SEAT AND SIDE COV ERS 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 ...

Page 237: ...5 43 STEERING 6 Lower bracket 1 7 Bearing race cover 1 8 Upper bearing 1 9 Lower bearing 1 Refer to removal section 10 Bearing race 2 Refer to removal section Order Part name Q ty Remarks ...

Page 238: ...BEARING RACE 1 Remove Bearing race 1 Remove the bearing race using long rod 2 and the hammer CHECKING THE STEERING STEM 1 Inspect Steering stem 1 Bend damage Replace CHECKING THE BEARING AND BEARING RACE 1 Wash the bearings and bearing races with a solvent 2 Inspect Bearing 1 Bearing race Pitting damage Replace bearings and bearing races as a set Install the bearing in the bearing races Spin the b...

Page 239: ...he lithium soap base grease on the bearing the portion a and thread of the steer ing stem 4 Install Steering ring nut 1 Install the steering nut with its stepped side a facing downward Tighten the steering ring nut using the steer ing nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD section in the CHAPTER 3 5 Check the steering stem by turning it lock to lock If there is any binding ...

Page 240: ...check the steering for smooth movement If not adjust the steering by loosening the steering ring nut little by little 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 Tighten the lower bracket to specified torque If torqued too much it may cause the front fork to malfunction Steering stem nut 145 Nm 14 5 m kg 105 ft lb Front fork top end standard a Ze...

Page 241: ...LING 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 242: ...8 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 243: ...st Replace bearing and collar as a set 2 Inspect Oil seal 3 Damage Replace CHECKING THE CONNECTING ROD 1 Inspect Bearing 1 Collar 2 Free play exists unsmooth revolution rust Replace bearing and collar as a set 2 Inspect Oil seal 3 Damage Replace INSTALLING THE BEARING AND OIL SEAL 1 Install Bearing 1 Oil seal 2 To swingarm Apply the molybdenum disulfide grease on the bearing when installing Instal...

Page 244: ...ng the manufacture s marks or numbers Apply the molybdenum disulfide grease on the washer 3 Install Bearing 1 Oil seal 2 To connecting rod Apply the molybdenum disulfide grease on the bearing when installing Install the bearing by pressing it on the side having the manufacture s marks or numbers Installed depth of bearings a Zero mm Zero in Installed depth of bearings a Zero mm Zero in ...

Page 245: ...grease on the collars and oil seal lips 3 Install Collar 1 To connecting rod 2 Apply the molybdenum disulfide grease on the collar and oil seal lips 4 Install Connecting rod 1 Bolt connecting rod 2 Washer 3 Nut connecting rod 4 To relay arm 5 Apply the molybdenum disulfide grease on the bolt 5 Install Relay arm 1 Bolt relay arm 2 Washer 3 Nut relay arm 4 To swingarm Apply the molybdenum disulfide ...

Page 246: ...rease or replace bearings bushings and collars 8 Install Bolt connecting rod 1 Washer 2 Nut connecting rod 3 Apply the molybdenum disulfide grease on the bolt Do not tighten the nut yet 9 Install Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm 2 Apply the molybdenum disulfide grease on the bolt 10 Tighten Nut connecting rod 1 Pivot shaft 85 Nm 8 5 m kg 61 ft lb Nut rear shoc...

Page 247: ...ll Drive chain support 1 Drive chain support cover 2 Bolt drive chain support L 50 mm 1 97 in 3 Nut drive chain support 4 Bolt drive chain support cover L 10 mm 0 39 in 5 Nut relay arm 70 Nm 7 0 m kg 50 ft lb Nut lower chain tensioner 16 Nm 1 6 m kg 11 ft lb Nut drive chain support 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 248: ...ING NOTE Seat Refer to SEAT AND SIDE COV ERS section in the CHAPTER 4 Silencer Refer to EXHAUST PIPE AND SI LENCER 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 ...

Page 249: ...5 55 REAR SHOCK ABSORBER 9 Bearing 2 Refer to removal section Order Part name Q ty Remarks ...

Page 250: ...rt of the gas tank A damaged gas tank will impair the damping performance or cause a malfunction Take care not to scratch the contact sur face of the piston rod with the cylinder or oil could leak out Never attempt to remove the plug at the bottom of the nitrogen gas tank It is very dangerous to remove the plug When scrapping the rear shock absorb er follow the instructions on disposal NOTES ON DI...

Page 251: ...place spring Move spring up and down Spring guide 4 Wear damage Replace spring guide Bearing 5 Free play exists unsmooth revolution rust Replace INSTALLING THE BEARING 1 Install Upper bearing 1 Install the bearing parallel until the stopper ring groove appears by pressing its outer race Do not apply the grease on the bearing out er race because it will wear the rear shock absorber surface on which...

Page 252: ...2 Lower spring guide 3 2 Tighten Adjuster 1 3 Adjust Spring length installed Refer to ADJUSTING THE REAR SHOCK ABSORBER SPRING PRELOAD section in the CHAPTER 3 4 Tighten Locknut 1 INSTALLING THE REAR SHOCK ABSORBER 1 Install Dust seal 1 O ring 2 Collar 3 Apply the molybdenum disulfide grease on the dust seal lips and collars Apply the lithium soap base grease on the O rings Installed depth of the ...

Page 253: ...ll Rear shock absorber 4 Install Bolt rear shock absorber frame 1 Washer 2 Nut rear shock absorber frame 3 Apply the molybdenum disulfide grease on the bolt 5 Install Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm 2 Apply the molybdenum disulfide grease on the bolt Nut rear shock absorber frame 56 Nm 5 6 m kg 40 ft lb Nut rear shock absorber relay arm 53 Nm 5 3 m kg 38 ft l...

Page 254: ...ervicing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowl edge and skill concerning servicing are requested not to undertake inspection adjustment disas sembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage ...

Page 255: ...ction in the chapter 4 Air scoop left right 1 1 Refer to SEAT AND SIDE COV ERS 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 tank 1 Refer to removal section 5 Fuel pump bracket 1 6 Fuel pump assembly 1 Refer to removal section 7 O ring 1 6 ...

Page 256: ...k remove the fuel hose connector holder a and then slide the fuel hose connector cover Slide the fuel hose connector cover 1 in the direction of the arrow mark and press the but tons 2 on both sides of the connector to re move the fuel hose Disconnecting the hose is done by hand There is no need to use tools To prevent sand dust and other foreign ma terial from entering the fuel pump install the i...

Page 257: ...the projection a on the fuel pump with the slot in the fuel pump bracket Align the slot b on the fuel tank damper with the projection a on the fuel pump Tighten the fuel pump bolts in stages in a crisscross pattern INSTALLING THE FUEL TANK 1 Install Fuel hose When installing the fuel hose make sure that it is securely connected and that the fuel hose holders are in the correct posi tion otherwise ...

Page 258: ... 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 259: ...er 4 Air scoop left right Refer to SEAT AND SIDE COV ERS 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 260: ...6 7 THROTTLE BODY DISASSEMBLING THE THROTTLE BODY Order Part name Q ty Remarks 1 Injector 1 2 Gasket 2 ...

Page 261: ...o not directly push the throttle valves to open them Do not loosen the throttle valve stopper screw 1 throttle valve pulley nut 2 or throttle valve screw 3 Otherwise a loss of performance may occur Do not use compressed air to clean the throttle body Otherwise foreign material may adhere to the intake air pressure sen sor passage a and fuel injector b in the throttle body 1 Check Throttle body Cra...

Page 262: ... ward the bottom of the vehicle Align the slot a on the throttle body joint with the projection b on the throttle body 2 Install the water resistant cover 1 onto the throttle body CHECKING AND REPLACING THE PROTECTOR 1 Check Protector 1 Wear damage Replace Affix the protector as shown Throttle body joint clamp screw 3 Nm 0 3 m kg 2 2 ft lb ...

Page 263: ...disas sembly 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 264: ...g 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 Y L L L Y Br W B L B L B L B B L B L Br W1 Br W W2 R R O B L L Y B L Br R P Gy Gy B R B R R W B Y B L W1 W2 W1 R R R B B Y Lg Lg O R B R B Br W P W P W L L Y B L B L B L Br B B W B W B B B L B L P ...

Page 265: ...1 Intake air temperature sensor 12 Intake air pressure sensor 13 Throttle position sensor 14 Atmospheric pressure sensor 15 Coolant temperature sensor 16 Coupler for connecting 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 ...

Page 266: ... 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 connec tion 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 267: ... spark plug c 7 Inspect Installed condition of spark plug and spark plug cap Push in the spark plug cap making sure that it is securely fitted into the hole in the cylin der head cover CHECKING THE COUPLERS AND LEADS CONNECTION 1 Check Couplers and leads connection Rust dust looseness short circuit Repair or replace CHECKING THE ENGINE STOP SWITCH 1 Inspect Engine stop switch conduction Not conduc...

Page 268: ...r coil resistance Out of specification Replace Tester lead Orange lead 1 Tester lead Red lead 2 Primary coil re sistance Tester selector position 3 57 4 83 Ω at 20 C 68 F Ω 1 Tester lead Orange lead 1 Tester lead Spark plug terminal 2 Secondary coil resistance Tester selector position 10 71 14 49 kΩ at 20 C 68 F kΩ 1 Tester lead Gray lead 1 Tester lead Black lead 2 Crankshaft posi tion sensor resi...

Page 269: ...e sure that the ECU is installed correct ly The lean angle sensor is built into the ECU The lean angle sensor stops the engine in case of a turnover To ensure that the lean angle sensor operates correctly do not change the installation posi tion of the sensor 3 Check ECU If no fault is found replace the ECU ...

Page 270: ...n Use the following special tools in this inspection Check entire ignition system for connec tion 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 voltage No good Replace Model 88 Multimeter with tachome ter YU A1927 Digital circuit tester 90890 03174 Test harness speed sensor 3P YU 03208 908...

Page 271: ...k that the resistance in increased as the throttle grip is moved from the full close position to the full open position Out of specification Replace CHANGING AND ADJUSTING THE THROTTLE POSITION SENSOR 1 Remove Throttle position sensor coupler 2 Remove Screw throttle position sensor 1 Throttle position sensor 2 Loosen the screw throttle position sensor us ing the T25 bit Tester lead Blue lead 1 Tes...

Page 272: ... TIC MODE 9 Adjust the position of the throttle position sensor so that the angle displayed on the LCD of the FI diagnostic tool is 12 21 10 After adjusting the throttle position sensor angle tighten the throttle position sensor screw 1 Tighten the screw throttle position sensor us ing the T25 bit CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1 Disconnect the throttle position sensor cou ple...

Page 273: ... ECU reinstatement action Refer to Reinstatement method of table in TROUBLESHOOTING DETAILS 6 Set the switch on the FI diagnostic tool sub wire harness from OFF to ON and then check whether a fault code number is dis played again If other fault code displayed repeat steps 2 to 5 until all fault code number is not displayed 7 Set the switch on the FI diagnostic tool sub wire harness to OFF and then...

Page 274: ...n the FI diagnostic tool sub wire har ness to ON When the switch on the FI diagnostic tool sub wire harness is set to ON make sure that Waiting for connection is displayed on the LCD of the FI diagnostic tool DIAG appears on the LCD of the FI diagnos tic tool 2 Select the diagnostic mode DIAG by pressing the UP button 3 After selecting DIAG press the MODE button 4 Select the diagnostic code number...

Page 275: ...3000 m above sea level Ap prox 70 kPa D03 Intake air pres sure Display Displays the intake air pres sure Check the intake manifold pressure Check that the intake air pressure changes while the engine is being cranked 0 126 kPa While the engine is stopped Displays the atmospheric pressure according to the el evation and weather Example 0 m above sea level Approx 101 kPa 3000 m above sea level Ap pr...

Page 276: ... fuel injector is actuated D36 Injectors Actuation Check that power is sup plied to the fuel injector Check the fuel injector op eration by listening for the operating sound or by con firming the operation visu ally Actuates the injector for five times every second The WARNING LED on the FI diagnostic tool comes on each time the fuel injector is actuated D60 EEPROM fault code display Display Displ...

Page 277: ...ing normally 00 No history 1 15 History exists When this diagnostic code number is selected fault code numbers for previously detected malfunctions are deleted from the history if the corresponding items are cur rently operating normally D64 Setting history display Display Displays whether or not his tory exists for settings that were made using the Power Tuner 00 There is no setting histo ry 01 T...

Page 278: ...eck or maintenance job Checking method 1 Check the connection and locking con dition of the crankshaft position sensor coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Poor connection Properly connect repair or replace Crank the engine and check the fault code display Fault code number is not displayed Service is finished Fault code numbe...

Page 279: ...t code display Fault code number is not displayed Service is finished Fault code number is displayed Re fer to item 5 5 Defective crankshaft position sensor Sensor malfunction Re place Refer to CHECKING THE AC MAGNETO section Crank the engine and check the fault code display Fault code number is not displayed Service is finished Fault code number is displayed Re fer to item 6 6 Malfunction in ECU ...

Page 280: ...e display Fault code number is not displayed Service is finished Fault code number is displayed Re fer to item 2 2 Check the connection and locking con dition 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 connect repair or replace Set the switch on the FI diagnostic tool sub wire harness...

Page 281: ...e No D03 When the engine is stopped displays the at mospheric pressure ac cording to the elevation and weather 0 m above sea level Ap prox 101 kPa 1000 m above sea level Approx 90 kPa 2000 m above sea level Approx 80 kPa 3000 m above sea level Approx 70 kPa Check that the value changes while the engine is being cranked Displayed value is incorrect Replace Set the switch on the FI diagnostic tool s...

Page 282: ...hed or twisted Repair or replace Start the engine and let it idle for approxi mately 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 displayed Re fer to item 2 2 Defective intake air pressure sensor Execute the diagnostic mode diagnostic code No ...

Page 283: ... and then check the fault code display Fault code number is not displayed Service is finished Fault code number is displayed Re fer to item 2 2 Check the connection and locking con dition 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 connect repair or replace Set the switch on the FI dia...

Page 284: ...e is finished Fault code number is displayed Re fer to item 6 Open circuit item Applied volt age Ground wire open circuit 5 V Output wire open circuit 0 V Power sup ply wire open circuit 0 V 6 Defective throttle position sensor Execute the diagnostic mode diagnostic code No D01 When throttle is fully closed A value of 15 19 is indicated When throttle is fully opened A value of 95 101 is indicated ...

Page 285: ...ly and that there are no pinched leads Incorrect installation Re install or repair Incorrect installation posi tion Properly install Set the switch on the FI diagnostic tool sub wire harness 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 displayed Re...

Page 286: ...c tool sub wire harness to ON and then check the fault code display Fault code number is not displayed Service is finished Fault code number is displayed Re fer to item 2 2 Check the connection and locking con dition 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 connect repair or replace...

Page 287: ...e diagnostic code No D06 Cold engine Displayed temperature is close to the ambient temperature Displayed value is incorrect Replace Set the switch on the FI diagnostic tool sub wire harness to ON and then check the fault code display Fault code number is not displayed Service is finished Fault code number is displayed Re fer to item 6 6 Malfunction in ECU Replace the ECU Fault code No 21 Symptom C...

Page 288: ...FI diagnostic tool sub wire harness to ON and then check the fault code display Fault code number is not displayed Service is finished Fault code number is displayed Re fer to item 2 2 Check the connection and locking con dition 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 connect repai...

Page 289: ...o the ambient temperature Displayed value is incorrect Replace Set the switch on the FI diagnostic tool sub wire harness to ON and then check the fault code display Fault code number is not displayed Service is finished Fault code number is displayed Re fer to item 6 6 Malfunction in ECU Replace the ECU Fault code No 22 Symptom Intake air temperature sensor signal is not received properly Fail saf...

Page 290: ...lt code number is not displayed Service is finished Fault code number is displayed Re fer to item 2 2 Check the connection and locking con dition 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 connect repair or replace Set the switch on the FI diagnostic tool sub wire harness to ON and th...

Page 291: ...spheric pressure ac cording to the elevation and weather 0 m above sea level Ap prox 101 kPa 1000 m above sea level Approx 90 kPa 2000 m above sea level Approx 80 kPa 3000 m above sea level Approx 70 kPa Displayed value is incorrect Replace Set the switch on the FI diagnostic tool sub wire harness to ON and then check the fault code display Fault code number is not displayed Service is finished Fa...

Page 292: ...n posi tion is correct Check that the sensor is in stalled securely and that there are no pinched leads Check that the ECU is installed securely and that there are no pinched leads Incorrect installation Re install or repair Incorrect installation posi tion Properly install Set the switch on the FI diagnostic tool sub wire harness to ON and then check the fault code display Fault code number is no...

Page 293: ... broken terminals and locking condition of the pins Poor connection Properly connect repair or replace Start the engine and let it idle for approxi mately 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 displayed Re fer to item 2 2 Check the connection and locking con dition o...

Page 294: ...ed leads Incorrect installation Re install or repair Start the engine and let it idle for approxi mately 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 displayed Re fer to item 5 Fault code No 33 Symptom Ignition system circuit signal is not received properly Fail safe system...

Page 295: ...to item 6 6 Malfunction in ECU Execute the diagnostic mode diagnostic code No D30 No spark Replace the ECU Fault code No 33 Symptom Ignition system circuit signal is not received properly Fail safe system Unable to start Unable to drive Diagnostic code No D30 FI diagnostic tool dis play Actuates the ignition coil for five times every second The WARNING LED on the FI diagnostic tool comes on each t...

Page 296: ...the fuel injector coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Poor connection Properly connect repair or replace Start the engine and let it idle for approxi mately 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...

Page 297: ... coupler Red Red Red Black Red Black Start the engine and let it idle for approxi mately 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 displayed Re fer to item 5 5 Malfunction in ECU Replace the ECU Fault code No 39 Symptom Injection system circuit signal is not received pro...

Page 298: ...rcumstances Able to drive vehicle depending on circumstances Diagnostic code No D60 FI diagnostic tool dis play 00 No fault 01 CO adjustment valve 07 Power Tuner adjustment values 0 8 for fuel injection amount or ignition timing Checking method Item Item components and probable cause Check or maintenance job Checking method 1 Determine the area of the problem Execute the diagnostic mode diagnostic...

Page 299: ...c mode diagnostic code No D65 Set the switch on the FI diagnostic tool sub wire harness to ON and then check the fault code display Fault code number is not displayed Service is finished Fault code number is displayed Re fer to item 1 4 Malfunction in ECU Replace the ECU Fault code No 44 Symptom Error is detected while reading or writing on EEPROM Fail safe system Able to start engine depending on...

Page 300: ... sub wire harness to OFF while the engine is idling and let the en gine continue to idle for 5 seconds or more 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 displayed Re fer to item 2 2 Continuity of harness Open or short circuit Re place Between Rectifier regulator and the ECU Red Re...

Page 301: ...to CHECKING THE AC MAGNETO section Start the engine set the switch on the FI di agnostic tool sub wire harness to OFF while the engine is idling and let the en gine continue to idle for 5 seconds or more 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 displayed Re fer to item 5 5 Malfun...

Page 302: ... signal is not received Fail safe system Able to start unable when ECU is malfunctioning Able to drive vehicle unable when ECU is malfunctioning Diagnostic code No FI diagnostic tool dis play Checking method Item Item components and probable cause Check or maintenance job Checking method 1 Check the connection and locking con dition of the FI diagnostic tool coupler Disconnect the coupler and chec...

Page 303: ...tic tool sub wire harness to ON and then check the fault code display Fault code number is not displayed Service is finished Fault code number is displayed Re fer to item 4 4 FI diagnostic tool malfunction Replace the FI diagnostic tool Set the switch on the FI diagnostic tool sub wire harness to ON and then check the fault code display Fault code number is not displayed Service is finished Fault ...

Page 304: ...er is not displayed Service is finished Fault code number is displayed Re fer to item 2 2 Check the connection and locking con dition 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 connect repair or replace Set the switch on the FI diagnostic tool sub wire harness to ON and then check the...

Page 305: ...umber is not displayed Service is finished Fault code number is displayed Re fer to item 5 5 Malfunction in ECU Replace the ECU Fault code No Er 4 Symptom Registered data cannot be received from the FI diagnostic tool Fail safe system Able to start Able to drive Diagnostic code No FI diagnostic tool dis play Checking method Item Item components and probable cause Check or maintenance job Checking ...

Page 306: ... 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 con nections 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 307: ...owly heat the coolant and then let it cool to the specified temperature indicated in the table Out of specification Replace CHECKING THE INTAKE AIR PRESSURE SENSOR 1 Check Intake air pressure sensor output voltage 2 Connect Test harness S pressure sensor 3P 1 Tester Tester lead Pink White lead wire har ness color Tester lead Black Blue lead wire har ness color 3 Connect the FI diagnostic tool sub ...

Page 308: ...ter lead Black Blue lead wire har ness color 3 Connect the FI diagnostic tool sub wire har ness to a battery and then set the switch on the harness to ON When checking the atmospheric pressure sensor do not start the engine 4 Measure the atmospheric pressure sensor output voltage Out of specification Replace CHECKING THE RECTIFIER REGULATOR 1 Connect Connect the tester to the coupler for con necti...

Page 309: ...CTORS 1 Remove Seat Fuel tank Air filter case 2 Check Injector resistance 3 Connect Tester Tester lead Injector terminal 1 Tester lead Injector terminal 2 Out of specification Replace Injector resistance Tester selector po sition 12 0 Ω 20 C 68 F Ω 10 ...

Page 310: ...d the best balance then determine the second ary reduction ratio If a course has a long straight portion where a machine can run at maximum speed the ma chine is generally set such that it can develop its maximum revolutions toward the end of the straight line with care taken to avoid the en gine over revving Riding technique varies from rider to rider and the performance of a machine also vary fr...

Page 311: ...ses the front fork to produce a noise at full rebound or the rider to feel some pressure on his hands or body Alternatively too large oil amount will cause the air spring characteristics to have a tendency to be stiffer with the consequent deteriorated performance and characteris tics Therefore adjust the front fork within the specified range A Air spring characteristics in relation to oil amount ...

Page 312: ...ing preload Change the set length of the spring Change the spring 2 Setting of damping force Change the rebound damping Change the compression damping CHOOSING SET LENGTH 1 Place a stand or block under the engine to put the rear wheel above the floor and mea sure the length a between the rear wheel axle center and the rear fender holding bolt 2 Remove the stand or block from the engine and with a ...

Page 313: ...with the rebound damping adjuster one or two clicks on the stiffer side and readjust it to suit your preference Adjusting the rebound damping will be followed more or less by a change in the compression damping For correction turn the low compres sion damping adjuster on the softer side When using a rear shock absorber other than currently installed use the one whose overall length a does not exce...

Page 314: ...preload adjustment refer to AD JUSTING THE REAR SHOCK ABSORBER SPRING PRELOAD in the CHAPTER 3 Maximum Minimum Position in which the spring is turned in 18 mm 0 71 in from its free length Position in which the spring is turned in 1 5 mm 0 06 in from its free length ...

Page 315: ...ntire 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 o...

Page 316: ...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...

Page 317: ...Q Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold 33D 9 10 cover 09 7 16 13 11 ページ 2 ...

Page 318: ...ZUOKA JAPAN PRINTED ON RECYCLED PAPER PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories YZ450FA 2011 OWNER S SERVICE MANUAL YZ450FA 33D 28199 11 LIT 11626 24 22 2011 q Read this manual carefully before operating this vehicle 33D 9 11 cover 2010 5 25 11 08 ページ 1 ...

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