Yamaha YZ450FF 1SL-28199-11 Owner'S Service Manual Download Page 154

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REAR BRAKE

4-30

EAS1SL5161

ASSEMBLING THE REAR BRAKE MASTER
CYLINDER

EWA13520

WARNING

• Before installation, all internal brake com-

ponents should be cleaned and lubricated
with clean or new brake fluid.

• Never use solvents on internal brake com-

ponents.

1. Wash the brake master cylinder and the

brake master cylinder kit with brake fluid.

2. Install:

• Primary cylinder cup “1”
• Secondary cylinder cup “2”

Install to the brake master cylinder piston
“3”.

EWA13520

WARNING

Apply brake fluid to the cylinder cups and
install them as shown. Wrong orientation in
installation causes poor braking perfor-
mance.

3. Install:

• Spring “1”

Install to the brake master cylinder piston
“2”.

TIP

Install the spring with a smaller inside diameter
to the brake master cylinder piston.

4. Install:

• Master cylinder kit “1”
• Push rod “2”
• Circlip “3”
• Dust boot “4”

TIP

• Before installation, apply brake fluid to the

brake master cylinder kit.

• Before installation, apply silicone grease to

the push rod end.

• Use circlip pliers to install the circlip.

EAS1SL5162

INSTALLING THE REAR BRAKE MASTER
CYLINDER

1. Install:

• Copper washers
• Brake hose
• Union bolt

EWA13530

WARNING

Proper brake hose routing is essential to in-
sure safe vehicle operation.

ECA1DX1008

NOTICE

Make sure that the pipe portion of the brake
hose touches the projection “a” on the
brake caliper.

Recommended brake fluid

DOT 4

Brake hose union bolt

30 Nm (3.0 m·kgf, 22 ft·lbf)

New

Summary of Contents for YZ450FF 1SL-28199-11

Page 1: ...MANUAL YZ450FF 1SL 28199 11 LIT 11626 28 10 YZ450FF 2015 q Read this manual carefully before operating this vehicle PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2014 03 1 0 1 E 1SL 28199 11_cover indd 1...

Page 2: ...lube Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamah...

Page 3: ...2014 by Yamaha Motor Corporation U S A 1st Edition March 2014 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohi...

Page 4: ...IS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTI...

Page 5: ...HIGHLY FLAMMABLE Always turn off the engine while refueling Take care to not spill any gasoline on the engine or ex haust system Never refuel in the vicinity of an open flame or while smoking GASOLIN...

Page 6: ...EAS1SL5006 YAMAHA MOTOR CORPORATION U S A YZ MOTORCYCLE LIMITED WARRANTY...

Page 7: ...he section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in t...

Page 8: ...FINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit...

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

Page 10: ......

Page 11: ...1 6 COUPLER FOR CONNECTING OPTIONAL PART 1 6 IMPORTANT INFORMATION 1 8 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 8 REPLACEMENT PARTS 1 8 GASKETS OIL SEALS AND O RINGS 1 9 LOCK WASHERS PLATES AND COTTE...

Page 12: ...0 FUEL 1 20 STARTING A COLD ENGINE 1 20 STARTING A WARM ENGINE 1 21 BREAK IN PROCEDURES 1 21 MAINTENANCE AFTER BREAK IN 1 22 MAJOR MAINTENANCE 1 22 TORQUE CHECK POINTS 1 23 CLEANING AND STORAGE 1 25 C...

Page 13: ...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...

Page 14: ...erent from those for the vehicle you have pur chased 1 Clutch lever 10 Coolant drain bolt 2 Front brake lever 11 Rear brake pedal 3 Throttle grip 12 Air filter 4 Radiator cap 13 Drive chain 5 Fuel tan...

Page 15: ...is stolen the authorities will need the number to search for and identify your vehicle EAS1SL5012 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of th...

Page 16: ...nd operation under a heavy load The carburetor that mea sures fuel through the use of jets are provided with various auxiliary devices so that the optimum air fuel ratio can be obtained to accommodate...

Page 17: ...the lesser the volume of fuel that is supplied The injection duration and the injection timing are controlled by the ECU Signals input from the throt tle position sensor the coolant temperature senso...

Page 18: ...e spoke EAS1SL5021 HANDLEBAR PROTECTOR Install the handlebar protector 1 with the mark a facing forward EAS1SL5022 FUEL HOSE JOINT COVER The fuel hose joint covers 1 are used to pre vent mud dust and...

Page 19: ...INCLUDED PARTS 1 7 The Power Tuner is an optional part Part name Part number GYTR Power Tuner For USA 33D H59C0 V0 00 YZ Power Tuner Except for USA 33D 859C0 10...

Page 20: ...ach section 5 Flammable Keep servicing areas away from any source of fire 6 During servicing take special care not to re ceive an injury or a burn on the engine the exhaust pipe the silencer or the li...

Page 21: ...1SL5028 BEARINGS AND OIL SEALS Install bearings 1 and oil seals 2 with their manufacturer s marks or size symbols facing outward During installation of an oil seal make sure that its main lip faces th...

Page 22: ...erefore never touch the terminals and be sure to keep the contacts clean Checking the electrical system ECA14371 NOTICE Never insert the tester probes into the cou pler terminal slots Always insert th...

Page 23: ...to check the type of cou pler lock before disconnecting the cou pler ECA16790 NOTICE When disconnecting a connector do not pull the leads Hold both sections of the connector and then disconnect the co...

Page 24: ...h terminals are connected securely Make sure all connections are tight 5 Check No continuity TIP If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 4 As a...

Page 25: ...se tool number starting with YM YU or ACC For others use tool number starting with 90890 Tool name Part number How to use Illustration Dial gauge stand set 90890 01252 Dial gauge set YU 03097 B This t...

Page 26: ...01403 Exhaust flange nut wrench YU A9472 This tool is used to remove or tighten the steering nut Cap bolt wrench 90890 01500 YM 01500 This tool is used to remove or tighten the base valve Cap bolt rin...

Page 27: ...arness S pressure sensor 3P 90890 03207 YU 03207 This tool is used to check the throttle position sensor input voltage FI diagnostic tool sub lead 90890 03212 YU 03212 This tool is used to connect the...

Page 28: ...his tool is used to hold the clutch when removing or in stalling the clutch boss secur ing nut Valve lapper 90890 04101 Valve lapping tool YM A8998 This tool is used to remove the valve lifter or lap...

Page 29: ...4 Oppama pet 4000 spark checker YM 34487 This tool is used to check the spark performance of the ig nition coil Digital tachometer 90890 06760 YU 39951 B This tool is used to measure the engine speed...

Page 30: ...The shift pedal 1 has adopted a method of 1 down 4 ups press down kick ups Press it down for N neutral to 1st and kick it up for 2nd to 5th EAS1SL5037 KICKSTARTER LEVER The kickstarter lever 1 is in...

Page 31: ...in a larger amount of intake air Pushing the knob toward b turns OFF the starter EWA WARNING While handling the starter knob idle screw take care not to burn yourself on exhaust pipes EAS1SL5042 FUEL...

Page 32: ...ing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems EAS1SL5045 STARTING A COLD ENGINE 1 Press the shift pedal to neutral 2 Pull the...

Page 33: ...e a pit stop and check mounted areas for looseness oil leaks or other problems 3 Then drive it for about 40 minutes at a throt tle opening of 3 4 or less 4 Make a pit stop again and thoroughly check m...

Page 34: ...connected Silencer Check the main body and stay for cracks Check for leaks Mounting bolts and nuts Check for looseness in mounted areas of parts as well as engine mounting bolts and engine brackets 2...

Page 35: ...absorber Link to swingarm Mounting of rear shock absorber Rear shock absorber and frame Mounting of swingarm Tightening of pivot shaft Wheel s Mounting of wheel Front Tightening of wheel axle Tighteni...

Page 36: ...TORQUES on page 2 13 Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fender Tightening of mud...

Page 37: ...pliable and glossy 8 Automotive wax may be applied to all paint ed or chromed surfaces Avoid using such wax as contains abrasives because it may scratch surfaces 9 After completing the above start the...

Page 38: ...CLEANING AND STORAGE 1 26...

Page 39: ...FICATIONS 2 12 TIGHTENING TORQUES 2 13 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 13 ENGINE TIGHTENING TORQUES 2 14 CHASSIS TIGHTENING TORQUES 2 18 LUBRICATION POINTS AND LUBRICANT TYPES 2 21 ENGINE 2...

Page 40: ...6 in USA CAN 2180 mm 85 8 in EUR JPN AUS NZL ZAF Overall width 825 mm 32 5 in Overall height 1290 mm 50 8 in USA CAN 1280 mm 50 4 in EUR JPN AUS NZL ZAF Seat height 975 mm 38 4 in USA CAN 965 mm 38 0...

Page 41: ...US qt 0 61 Imp qt Without oil filter element replacement 0 67 L 0 71 US qt 0 59 Imp qt Oil filter Oil filter type Paper Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance Less th...

Page 42: ...B 27 950 28 050 mm 1 1004 1 1043 in Limit 27 850 mm 1 0965 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...

Page 43: ...e 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clearance exhaust 0 020 0 047 mm 0 0008 0 0019 in Limit 0 100 mm 0 0039 in Valve stem runout 0 010 mm 0 0004 in Val...

Page 44: ...6 in Diameter D 96 955 96 970 mm 3 8171 3 8177 in Height H 9 0 mm 0 35 in Offset 0 00 mm 0 0000 in Piston pin bore inside diameter 18 004 18 015 mm 0 7088 0 7093 in Limit 18 045 mm 0 7104 in Piston pi...

Page 45: ...ever free play 7 0 12 0 mm 0 28 0 47 in Friction plate thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 85 mm 0 112 in Plate quantity 8 pcs Clutch plate thickness 1 10 1 30 mm 0 043 0 051 in Plate q...

Page 46: ...0 Fuel pressure 324 0 kPa 3 24 kgf cm2 47 0 psi Throttle position sensor Resistance 6 30 k Output voltage at idle 0 48 0 52 V Fuel injection sensor Crankshaft position sensor resistance 248 372 Intake...

Page 47: ...l type Spoke wheel Rim size 19 2 15 Rim material Aluminum Wheel travel 315 mm 12 4 in Radial wheel runout limit 2 0 mm 0 08 in Lateral wheel runout limit 2 0 mm 0 08 in Wheel axle bending limit 0 50 m...

Page 48: ...0 04 in Brake pad lining thickness outer 6 4 mm 0 25 in Limit 1 0 mm 0 04 in Master cylinder inside diameter 11 0 mm 0 43 in Caliper cylinder inside diameter 25 40 mm 1 1 00 in 1 Recommended fluid DO...

Page 49: ...lbf in EUR JPN AUS NZL ZAF Spring stroke K1 0 0 150 0 mm 0 00 5 91 in Optional spring available Yes Enclosed gas air pressure STD 980 kPa 9 8 kgf cm2 139 4 psi Spring installed length Minimum Positio...

Page 50: ...lick s out Standard 12 click s out USA CAN 10 click s out EUR JPN AUS NZL ZAF Maximum Fully turned in Swingarm Swingarm end free play limit radial 1 0 mm 0 04 in Swingarm end free play limit axial 0 2...

Page 51: ...odel manufacturer 1SL4 YAMAHA USA CAN 1SL5 YAMAHA EUR JPN AUS NZL ZAF Ignition coil Minimum ignition spark gap 6 0 mm 0 24 in Primary coil resistance 2 16 2 64 Secondary coil resistance 8 64 12 96 k A...

Page 52: ...To avoid warpage tighten multi fastener assemblies in a criss cross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specif...

Page 53: ...36 ft lbf Use a lock washer Balancer nut M10 1 45 Nm 4 5 m kgf 33 ft lbf Use a lock washer Timing chain guide stopper plate exhaust side M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Timing chain tensioner cap bol...

Page 54: ...0 8 m kgf 5 8 ft lbf Oil nozzle bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Engine oil drain bolt M10 1 20 Nm 2 0 m kgf 14 ft lbf Crankcase bolt M6 12 12 Nm 1 2 m kgf 8 7 ft lbf Clutch cable holder bolt M6...

Page 55: ...m 6 5 m kgf 47 ft lbf Stator screw M5 3 8 Nm 0 8 m kgf 5 8 ft lbf Crankshaft position sensor bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf AC magneto lead holder bolt M5 1 8 Nm 0 8 m kgf 5 8 ft lbf Coolant tem...

Page 56: ...m Retighten the cylinder head bolts to 20 Nm 2 0 m kgf 14 ft lbf in the prop er tightening sequence and then tighten the cylinder head bolts further to reach the specified angle 150 in the proper tigh...

Page 57: ...Nm 0 5 m kgf 3 6 ft lbf Front fork protector and brake hose holder bolt M6 2 9 Nm 0 9 m kgf 6 5 ft lbf Throttle grip cap screw M5 2 3 8 Nm 0 38 m kgf 2 8 ft lbf Clutch lever holder bolt M6 2 5 Nm 0 5...

Page 58: ...2 ft lbf Rear brake caliper protector bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Engine mounting bolt upper side M10 2 45 Nm 4 5 m kgf 33 ft lbf Engine mounting bolt front side M10 1 55 Nm 5 5 m kgf 40 ft l...

Page 59: ...acket bolt rear side M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Fuel pump bolt M5 6 4 0 Nm 0 40 m kgf 2 9 ft lbf Fuel inlet pipe screw M5 2 3 4 Nm 0 34 m kgf 2 5 ft lbf Fuel tank cap cover bolt M6 2 4 0 Nm 0 40 m...

Page 60: ...sket Oil pump shaft Kick gear and ratchet wheel Kick shaft Kick idle gear inner surface Ratchet wheel and ratchet wheel guide contacting portion Primary drive gear nut threads and contacting surface C...

Page 61: ...ION POINTS AND LUBRICANT TYPES 2 22 Cylinder head cover gasket Three Bond No 1215 Crankcase mating surface Three Bond No 1215 Stator assembly lead grommet Three Bond No 1215 Lubrication point Lubrican...

Page 62: ...outer surface and dust seal lip upper side Rear shock absorber assembly bearing and dust seal lip lower side Brake pedal pivot portion O ring and bolt outer surface Front wheel oil seal lip Front whee...

Page 63: ...NT TYPES 2 24 Rear brake caliper dust seal Rear brake caliper piston outer surface Rear brake caliper pin bolt and boot Rear brake master cylinder push rod end Rear brake master cylinder kit Lubricati...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EAS1SL5064 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS1SL5065 LUBRICATION DIAGRAMS...

Page 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Intake camshaft 2 Exhaust camshaft 3 Piston 4 Oil nozzle 5 Oil filter element 6 Oil pump 7 Oil strainer 8 Crankshaft 9 Drive axle 10 Main axle...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27...

Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Connecting rod 2 Crankshaft 3 Main axle 4 Oil strainer 5 Drive axle...

Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29...

Page 69: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Exhaust camshaft 2 Intake camshaft 3 Oil filter element 4 Relief valve 5 Oil pump...

Page 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31...

Page 71: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Camshaft 2 Oil pressure check bolt 3 Oil filter element 4 Oil pump...

Page 72: ...CABLE ROUTING DIAGRAM 2 33 EAS1SL5066 CABLE ROUTING DIAGRAM...

Page 73: ...lamp the clutch cable and the AC magneto lead by the plastic locking tie Regardless of the orien tation of the lock on the plastic locking tie cut the end L Pass the clutch cable with no downward sag...

Page 74: ...CABLE ROUTING DIAGRAM 2 35...

Page 75: ...e to the outside of the tension arm and the throttle position sensor lead the outside of the vehicle and to the inside of the radiator hose the side of the vehicle H Pass the protector of the cylinder...

Page 76: ...CABLE ROUTING DIAGRAM 2 37...

Page 77: ...of the number plate band C Clamp the engine stop switch lead to the handle bar by the plastic band Do not cut the end of the plastic band D Pass the engine stop switch lead between the head pipe and...

Page 78: ...CABLE ROUTING DIAGRAM 2 39...

Page 79: ...sert the projection of the plastic clamp into the hole in the sheet metal of the radiator B Insert the projection of the main harness into the hole in the frame C To the sub wire harness D Pass the hi...

Page 80: ...CABLE ROUTING DIAGRAM 2 41...

Page 81: ...s shown and bring it into contact with the projection on the brake caliper B Pass the brake hose into the brake hose holders C If the brake hose interferes with the rear shock absorber correct its twi...

Page 82: ...CABLE ROUTING DIAGRAM 2 43...

Page 83: ...3 14 CHECKING THE FUEL LINE 3 14 CHECKING THE ENGINE OIL LEVEL 3 14 CHANGING THE ENGINE OIL 3 15 ADJUSTING THE ENGINE IDLING SPEED 3 16 ADJUSTING THE VALVE CLEARANCE 3 17 CHASSIS 3 21 BLEEDING THE BR...

Page 84: ...HE WHEEL BEARINGS 3 33 CHECKING AND ADJUSTING THE STEERING HEAD 3 34 LUBRICATING THE LEVERS 3 35 LUBRICATING THE PEDAL 3 35 ELECTRICAL SYSTEM 3 36 CHECKING THE SPARK PLUG 3 36 CHECKING THE IGNITION TI...

Page 85: ...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 VALVE Check the valve clearances The engine must be cold...

Page 86: ...d eliminate them Inspect and clean Check for warpage and re place the gasket CYLINDER Inspect and clean Inspect score marks Replace Inspect wear ENGINE OIL Inspect Check the engine oil amount Replace...

Page 87: ...R Clean and lubri cate Use foam air filter oil or equiv alent oil Replace SPARK PLUG Inspect and clean Check the electrodes and the terminals for wear Replace COOLING SYSTEM Check coolant lev el and l...

Page 88: ...ce oil seal Clean and grease oil seals and dust seals Lithium soap base grease PROTECTOR GUIDE Replace REAR SHOCK AB SORBER Inspect and adjust Lubricate After rain ride Grease pillow balls and bear in...

Page 89: ...etighten Molybdenum disulfide grease RELAY ARM CON NECTING ROD Inspect lube and retighten Molybdenum disulfide grease STEERING HEAD Inspect free play and retighten Check for tightening torques Clean a...

Page 90: ...tion Check and grease Check and clean throttle cable Check throttle cables on the throttle body for dirt and wear LEVERS Adjust clutch lever free play KICKSTARTER LE VER BRAKE PED AL FOOTREST Lubrica...

Page 91: ...es Check the play of front brake and effect of front and rear brake 3 21 27 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 27 28 4 66 67 Wheels C...

Page 92: ...a few minutes until the coolant has settled EAS1SL5073 CHECKING THE COOLING SYSTEM 1 Remove Seat Side cover left right Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Air filter case cover...

Page 93: ...heck Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 8 EAS1SL5075 CHECKING THE RADIATOR CAP 1 Check Seal radiator cap 1 Valve and valve seat 2 Crack damage Replace Exist fur deposits Clea...

Page 94: ...at the test pres sure value Correct Radiator Radiator hose connections Coolant leaks Correct or replace Radiator hoses Bulges Replace EWA WARNING When the radiator cap tester is removed coolant will...

Page 95: ...a or b until the specified clutch lever free play is ob tained d Tighten the locknut 1 e Return the clutch cable cover to its original position EAS1SL5080 ADJUSTING THE THROTTLE GRIP FREE PLAY TIP Pri...

Page 96: ...ottle grip cap 4 Install Cover grip cap Cover throttle cable cap EWA WARNING Check that the throttle grip moves smooth ly If this does not move smoothly correct the installed positions EAS1SL5082 CLEA...

Page 97: ...Air filter guide 1 to the air filter element Air filter element 2 Air filter mounting bolt 3 7 Install Air filter case cover 1 TIP Align the air filter case cover groove a with the air filter case ed...

Page 98: ...AS1SL5087 CHECKING THE ENGINE OIL LEVEL 1 Stand the vehicle upright on a level surface 2 Start the engine warm this up for 2 3 min utes and then stop the engine and wait about 1 minute 3 Check Oil lev...

Page 99: ...f the oil filter element is also to be replaced perform the following procedure a Remove the oil filter element cover 1 and oil filter element 2 b Replace the O rings 3 c Install the new oil filter el...

Page 100: ...the engine oil for leaks and the engine oil passage and the oil pump for damage c Check the oil pressure again d Tighten the oil pressure check bolt EAS1SL5089 ADJUSTING THE ENGINE IDLING SPEED TIP B...

Page 101: ...rs etc Those who have little knowledge and skill concerning ser vicing are requested not to undertake inspec tion adjustment disassembly or reassembly only by reference to this manual It may lead to s...

Page 102: ...cylinder head c Measure the valve clearance e using a thickness gauge 1 TIP Record the measured reading if the clearance is incorrect 5 Adjust Valve clearance a Remove the camshaft intake and exhaust...

Page 103: ...Pad number 148 Rounded value 150 e Install the new adjusting pads 4 and the valve lifters 5 ECA NOTICE Do not twist adjusting pads and valve lifters forcibly during installation TIP Apply the engine o...

Page 104: ...230 235 240 1 26 1 30 230 235 240 1 31 1 35 235 240 1 36 1 40 240 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 04 120 125 130 135 140 145...

Page 105: ...reservoir diaphragm c Connect the plastic hose 1 to the bleed screw 2 securely and place a container under the end of the plastic hose d Slowly apply the brake several times e Fully pull the brake le...

Page 106: ...locknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified brake lever position is obtained c Tighten the locknut EWA13050 WARNING A soft or spongy feeling in the brake lever can in...

Page 107: ...efore running bleed the brake system Air in the brake system will cause braking performance to be reduced ECA13510 NOTICE After adjusting the brake pedal position make sure that there is no brake drag...

Page 108: ...on in EWA WARNING Do not reuse the drained brake fluid g Tighten the bleed screw h Install the brake pads 7 and the pad pin TIP Install the brake pads with their projections a into the brake caliper r...

Page 109: ...ndicator b grooves mean that the brake pad thickness limit is reached 2 Replace Brake pads a Remove the protector 1 and the pad pin plug 2 b Loosen the pad pin 3 c Remove the rear wheel 4 and the brak...

Page 110: ...G THE BRAKE FLUID LEVEL on page 3 26 4 Check Brake pedal operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE BRAKE SYS TEM on page 3 21 EAS1SL5098 CHECKING THE REAR BRAKE...

Page 111: ...engine and other vital parts and one that is too loose can skip and damage the swingarm or cause an accident Therefore keep the drive chain slack within the speci fied limits 1 Use a suitable stand t...

Page 112: ...l seal 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Unsmooth operation...

Page 113: ...D1006 WARNING Always adjust the left and right front forks evenly If this is not done the vehicle may have poor stability Securely support the vehicle so that there is no danger of it falling over Reb...

Page 114: ...spension link smooth action Sit astride the seat and shake your body up and down several times to check whether the rear shock absorber assembly operates smoothly Unsmooth operation Correct or replace...

Page 115: ...ECA13590 NOTICE Do not turn the adjuster forcibly beyond its adjusting range 1 Adjust Rebound damping force a Turn the adjuster 1 in the direction of a or b to make an adjustment Direction b Spring pr...

Page 116: ...y 30 clicks With the adjuster fully turned Direction a High compression damping force is in creased suspension is harder Direction b High compression damping force is de creased suspension is softer H...

Page 117: ...Spokes Use a spoke nipple wrench 1 for tighten ing TIP Do not give a half turn 180 or more for one tightening Make sure that tightening after a break in is done until the initial looseness in nipples...

Page 118: ...d right a couple of times to check that it moves smoothly c Turn the front fork to the right and left a few times and make sure that the steering ro tates smoothly If it does not turn smoothly remove...

Page 119: ...ubricate the pivoting points and metal to metal moving parts of the following parts Brake lever Clutch lever EAS1SL5115 LUBRICATING THE PEDAL 1 Lubricate the pivoting point and metal to metal moving p...

Page 120: ...ore removing the spark plug 3 Check Spark plug type Wrong type Replace 4 Check Electrode Damage wear Replace the spark plug Insulator Abnormal color Replace the spark plug Normal color is medium to li...

Page 121: ...6 4 Check Ignition timing Check whether the alignment mark a on the left crankcase cover is within the firing range b on the rotor Incorrect firing range Check rotor and Crankshaft position sensor 5 I...

Page 122: ...ELECTRICAL SYSTEM 3 38...

Page 123: ...PER 4 16 CHECKING THE FRONT BRAKE CALIPER 4 17 ASSEMBLING THE FRONT BRAKE CALIPER 4 17 INSTALLING THE BRAKE CALIPER PISTON 4 17 INSTALLING THE FRONT BRAKE CALIPER 4 18 REMOVING THE FRONT BRAKE MASTER...

Page 124: ...MBLY 4 55 HANDLING THE REAR SHOCK ABSORBER 4 58 DISPOSING OF A REAR SHOCK ABSORBER 4 58 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 58 REMOVING THE BEARING 4 59 CHECKING THE REAR SHOCK ABSORBER ASSEMB...

Page 125: ...this manual It may lead to servicing trouble and mechanical damage EAS1SL5120 GENERAL CHASSIS Removing the seat and side cover Order Part name Q ty Remarks 1 Seat 1 2 Air scoop left 1 3 Air scoop rig...

Page 126: ...e seat always remove the fuel tank cap cover beforehand 1 Remove Fuel tank cap cover 1 Refer to FUEL TANK CAP on page 1 19 2 Remove Seat 1 EAS1SL5123 REMOVING THE NUMBER PLATE 1 Remove Bolt number pla...

Page 127: ...wheel axle pinch bolt 4 Loosen 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Front wheel 1 5 Collars 2 6 Oil seals 2 7 Bearing 2 8 Brake disc 1 For installation reverse the removal proce dure 12 Nm...

Page 128: ...3 and CHECKING THE WHEELS on page 3 33 3 Check Spokes Bend damage Replace Loose Tighten Tap the spokes with a screwdriver TIP A tight spoke will emit a clear ringing tone a loose spoke will sound flat...

Page 129: ...earing right side 3 Oil seals 4 TIP Apply the lithium soap base grease to the bearing and the oil seal lip when installing Left side of bearing shall be installed first Install the oil seal with its m...

Page 130: ...ront wheel axle 1 TIP Apply the lithium soap base grease to the front wheel axle 3 Tighten Front wheel axle nut 1 ECA14140 NOTICE Before tightening the front wheel axle nut push down hard on the handl...

Page 131: ...el axle 1 3 Drive chain puller 2 4 Rear wheel 1 5 Collars 2 6 Rear wheel sprocket 1 7 Oil seals 2 8 Circlip 1 9 Bearing 3 10 Brake disc 1 For installation reverse the removal proce dure 6 21 Nm 2 1 m...

Page 132: ...o CHECKING THE FRONT WHEEL on page 4 4 4 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 4 EAS1SL5133 DISASSEMBLING THE REAR WHEEL 1 Remove Oil seals Beari...

Page 133: ...de of bearing shall be installed first Install the oil seal with its manufacture s marks or numbers facing outward ECA1DX1006 NOTICE Install the bearing by pressing its outer race parallel TIP Use a s...

Page 134: ...puller and insert the rear wheel axle from the left side Apply the lithium soap base grease to the rear wheel axle 4 Install Right drive chain puller 1 Washer 2 Rear wheel axle nut 3 TIP Temporarily...

Page 135: ...REAR WHEEL 4 11 1 2...

Page 136: ...washers 2 3 Front brake hose 1 4 Brake pad pin plug 1 5 Brake pad pin 1 6 Brake pads 2 7 Brake pad spring 1 8 Front brake caliper assembly 1 9 Front brake caliper bracket 1 For installation reverse th...

Page 137: ...ke caliper Order Part name Q ty Remarks 1 Brake caliper piston 2 2 Brake caliper piston dust seal 2 3 Brake caliper piston seal 2 4 Bleed screw 1 For assembly reverse the disassemble pro cedure 1 2 3...

Page 138: ...Front brake hose 1 5 Brake master cylinder reservoir cap 1 6 Brake master cylinder reservoir diaphragm 1 7 Front brake master cylinder float 1 8 Front brake master cylinder holder 1 9 Front brake mas...

Page 139: ...ssembling the front brake master cylinder Order Part name Q ty Remarks 1 Push rod 1 2 Dust boot 1 3 Circlip 1 4 Washer 1 5 Brake master cylinder kit 1 For assembly reverse the disassemble pro cedure B...

Page 140: ...ion EAS1SL5139 CHECKING THE FRONT BRAKE DISC 1 Remove Front wheel Refer to FRONT WHEEL on page 4 3 2 Check Front brake disc Damage galling Replace 3 Measure Brake disc thickness Measure the brake disc...

Page 141: ...n clean and lubricate the internal parts Use new brake fluid for cleaning and lubricating Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort When...

Page 142: ...hat the brake hose holder 2 is in stalled with its upper end a aligned with the paint b on the brake hose 4 Pour brake fluid to the brake master cylinder reservoir up to the specified level EWA13090 W...

Page 143: ...der and the end of the brake hose EAS1SL5147 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder 1 Damage scratches wear Replace Brake fluid delivery passages 2 brake master cylinde...

Page 144: ...9 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Brake master cylinder 1 TIP Install the front brake master cylinder holder with the UP mark facing up First tighten the upper bolt then the lower...

Page 145: ...poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause va...

Page 146: ...pad pin plug 1 6 Brake pad pin 1 7 Rear brake pad assembly 2 8 Rear brake caliper bracket 1 9 Brake pad springs 2 10 Rear brake disc cover 1 11 Rear brake caliper assembly 1 For installation reverse...

Page 147: ...brake caliper Order Part name Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 For assembly reverse the disassemble pro cedure 1 2...

Page 148: ...age 3 21 1 Union bolt 1 2 Copper washers 2 3 Brake hose 1 4 Split pin 1 5 Washer 1 6 Pin 1 7 Brake master cylinder reservoir cap 1 8 Brake master cylinder reservoir diaphragm plate 1 9 Brake master cy...

Page 149: ...5 Disassembling the rear brake master cylinder Order Part name Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Push rod 1 4 Brake master cylinder kit 1 For assembly reverse the disassemble pro cedure 4 3 2 1...

Page 150: ...ention EAS1SL5152 CHECKING THE REAR BRAKE DISC 1 Remove Rear wheel Refer to REAR WHEEL on page 4 7 2 Check Brake disc Damage galling Replace 3 Measure Brake disc thickness Measure the brake disc thick...

Page 151: ...CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scratches wear Replace the brake cali per assembly Brake c...

Page 152: ...th its side a facing the brake caliper Never force to insert EAS1SL5158 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake caliper Rear brake caliper bracket 2 Install Rear wheel Refer to REAR WHE...

Page 153: ...to CHECKING THE BRAKE FLUID LEVEL on page 3 26 7 Check Brake pedal operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE BRAKE SYS TEM on page 3 21 EAS1SL5159 REMOVING THE R...

Page 154: ...stall to the brake master cylinder piston 2 TIP Install the spring with a smaller inside diameter to the brake master cylinder piston 4 Install Master cylinder kit 1 Push rod 2 Circlip 3 Dust boot 4 T...

Page 155: ...reful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 NOTICE Brake fluid may damage painted...

Page 156: ...h cable 1 Disconnect 2 Clutch lever holder 1 3 Engine stop switch 1 4 Brake master cylinder 1 5 Throttle cable cap 1 6 Throttle cable pull 1 Disconnect 7 Throttle cable return 1 Disconnect 8 Right gri...

Page 157: ...HANDLEBAR 4 33 For installation reverse the removal proce dure Removing the handlebar Order Part name Q ty Remarks...

Page 158: ...ebar 3 Upper handlebar holders 4 TIP Install the lower handlebar holders with them side having the greater distance a from the mounting bolt center facing forward Installing the lower handlebar holder...

Page 159: ...itch 1 Clutch lever 2 Clutch lever holder 3 Clamp 4 TIP The engine stop switch the clutch lever and the clutch lever holder should be installed ac cording to the dimensions shown Pass the engine stop...

Page 160: ...and inside of throttle grip with lithium soap based grease Then mount the throttle grip onto the handle bar 9 Install Throttle cable housings 1 Screw throttle cable housings 2 EWA1DX5001 WARNING After...

Page 161: ...embly to be level First tighten the upper bolt then the lower bolt 12 Install Clutch cable 1 TIP Before installation apply the lithium soap based grease to the clutch cable end 13 Adjust Clutch lever...

Page 162: ...rake caliper Refer to FRONT BRAKE on page 4 12 Number plate Refer to GENERAL CHASSIS on page 4 1 1 Protector 1 2 Upper bracket pinch bolts 2 Loosen 3 Damper assembly 1 Loosen 4 Lower bracket pinch bol...

Page 163: ...n metal 1 8 Protector guide 1 9 Slide metal 1 10 Washer 1 11 Oil seals 1 12 Base valve 1 13 Damper assembly 1 For assembly reverse the disassemble pro cedure LS 13 2 6 9 8 10 11 4 3 1 5 7 12 New New N...

Page 164: ...mbly 1 with the cap bolt ring wrench 2 3 Remove Front fork leg s EAS1SL5169 DISASSEMBLING THE FRONT FORK LEGS 1 Drain Fork oil 2 Remove Adjuster 1 from the inner tube TIP While compressing the inner t...

Page 165: ...bent inner tube as this may dangerously weaken it 2 Check Outer tube Scratches wear damage Replace 3 Measure Fork spring free length a Out of specification Replace 4 Check Damper assembly 1 Bend dama...

Page 166: ...Outer tube bushing Oil seals Copper washers Before assembling the front fork leg make sure that all of the components are clean 1 Stretch the damper assembly fully 2 Fill Damper assembly ECA14210 NOT...

Page 167: ...tting position Unless the damping force adjuster is fully loosened correct damping characteristic can not be obtained after installation 7 Install Base valve 1 to the damper assembly 2 TIP First bring...

Page 168: ...ICE Take care not to damage the damper assem bly 12 Allow the overflowing oil to escape at the hole a in the damper assembly TIP The overflow measures about 8 cm3 0 27 US oz 0 28 lmp oz 13 Check Dampe...

Page 169: ...g 1 TIP Install the inner tube bushing onto the slot on inner tube 16 Install Outer tube 1 to the inner tube 2 17 Install Inner tube bushing 1 Washer 2 to the outer tube TIP Press the inner tube bushi...

Page 170: ...eck Inner tube smooth movement Tightness binding rough spots Repeat the steps 14 to 20 22 Measure Distance a Out of specification Turn into the locknut 23 Install Collar 1 Fork spring 2 to the damper...

Page 171: ...djusting rod 1 Copper washer 2 Adjuster 3 to the damper assembly 4 TIP While compressing the inner tube 5 set the cap bolt ring wrench 7 between the inner tube and locknut 6 Fully finger tighten the a...

Page 172: ...1 to the outer tube TIP Temporarily tighten the damper assembly 32 Install Protector guide 1 EAS1SL5172 INSTALLING THE FRONT FORK LEGS 1 Install Front fork 1 TIP Temporarily tighten the pinch bolts lo...

Page 173: ...e the front fork to malfunction 5 Install Protector 1 Bolt protector 2 6 Adjust Rebound damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position D...

Page 174: ...FRONT FORK 4 50 7 Adjust Compression damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 1...

Page 175: ...3 Front fork leg s 2 Refer to FRONT FORK on page 4 38 4 Upper bracket 1 5 Steering ring nut 1 6 Lower bracket 1 7 Bearing race cover 1 8 Upper bearing 1 9 Bearing lower side 1 10 Bearing races 2 For...

Page 176: ...lace 3 Replace Bearing Bearing races a Remove the bearing race from the steering head pipe with a long rod 1 and a hammer b Remove the bearing race from the lower bracket with a chisel 2 and a hammer...

Page 177: ...steering nut with its stepped side a facing downward Tighten the steering ring nut with a steering nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 34 5 Check the steering ste...

Page 178: ...eering ring nut little by little 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 EWA33DD049 WARNING Tighten the lower bracket to specified torque If tor...

Page 179: ...fer to GENERAL CHASSIS on page 4 1 Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Rear shock absorber assembly lower bolt 1 2 Rear shock absorber...

Page 180: ...der Part name Q ty Remarks 8 Spring 1 9 Dust seal 2 10 Collars 2 11 Bushing 1 12 Collars 2 13 O ring 2 14 Dust seal 2 15 Stopper ring 1 16 Bearing 1 For installation reverse the removal proce dure 2 1...

Page 181: ...arm Order Part name Q ty Remarks 1 Relay arm 1 2 Connecting arm 1 3 Collars 3 4 Oil seals 6 5 Washers 8 6 Bearing 6 For assembly reverse the disassemble pro cedure 5 3 5 6 1 6 5 4 5 5 4 5 6 6 5 4 3 2...

Page 182: ...lt in poor damping perfor mance TIP A break in is required up to about 50 km of run ning EAS1SL5179 DISPOSING OF A REAR SHOCK ABSORB ER Before disposing the rear shock absorber be sure to extract the...

Page 183: ...bly Rear shock absorber Gas leaks oil leaks Replace the rear shock absorber assembly Spring Damage wear Replace Spring guide Damage wear Replace Bearing Damage wear Replace Bolts Bends damage wear Rep...

Page 184: ...its outer race After installing the stopper ring push back the bearing unit it contacts the stopper ring 4 Install Bearing 1 Bushing 2 Collar 3 Dust seal 4 to rear shock absorber assembly lower side T...

Page 185: ...y arm bolt swingarm side from the left 7 Tighten Rear shock absorber assembly upper bolt Connecting arm bolt frame side Connecting arm bolt relay arm side Relay arm bolt swingarm side Rear shock absor...

Page 186: ...ake hose holder Refer to REAR BRAKE on page 4 22 Rear brake caliper Refer to REAR BRAKE on page 4 22 Bolt brake pedal Drive chain 1 Collars 2 2 Oil seals 2 3 Thrust bearing 2 4 Bushing 2 5 Oil seals 2...

Page 187: ...the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacers the bearings and the collars EAS1SL5188 REMOVING THE BEARING 1 Remove Bearing 1 TIP Remov...

Page 188: ...3 Install Swingarm TIP Install the pivot shaft from the right 4 Install Rear wheel Refer to REAR WHEEL on page 4 7 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 27 Reco...

Page 189: ...ving the drive chain Job Order Part name Q ty Servicing Information Drive sprocket Refer to ENGINE REMOVAL on page 5 1 1 Drive chain 1 For installation reverse the removal proce dure 1 T R 75 Nm 7 5 m...

Page 190: ...k sec tion of the drive chain as shown in the illus tration b Calculate the length c of the 15 link section of the drive chain using the following formu la Drive chain 15 link section length c length...

Page 191: ...WA WARNING When installing the joint clip always keep the direction as shown in the figure 2 Lubricate Drive chain 3 Install Drive sprocket Lock washer Drive sprocket nut Refer to ENGINE REMOVAL on pa...

Page 192: ...CHAIN DRIVE 4 68...

Page 193: ...TEM 5 17 INSTALLING THE CAMSHAFTS 5 17 CYLINDER HEAD 5 20 REMOVING THE CYLINDER HEAD 5 22 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 5 22 CHECKING THE CYLINDER HEAD 5 22 INSTALLING THE CYLINDER HEAD...

Page 194: ...9 SHIFT SHAFT 5 50 REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 5 52 REMOVING THE SEGMENT 5 52 CHECKING THE SHIFT SHAFT 5 52 CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 5 52 CHECKING THE ST...

Page 195: ...CRANKCASE 5 67 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 5 68 REMOVING THE BALANCER SHAFT 5 69 REMOVING THE CRANKSHAFT ASSEMBLY 5 69 CHECKING THE CRANKSHAFT ASSEMBLY 5 69 INSTALLING THE CRANKSHAFT ASSEM...

Page 196: ...de cover right Refer to GENERAL CHASSIS on page 4 1 Rear shock absorber assembly lower bolt Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 55 Connecting arm bolt frame side Refer to REAR SHOCK ABSOR...

Page 197: ...Order Part name Q ty Remarks 10 5 9 2 6 1 6 6 3 8 4 7 8 6 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R New New 10 Nm 1 0 m k...

Page 198: ...page 4 1 Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case cover 1 Rectifier regulator 1 2 ECU 1 3 Ignition coil 1 4 Condenser 1 5 Neu...

Page 199: ...SIS on page 4 1 Rear fender Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Exhaust pipe and silencer Refer to ENGINE REMOVAL on page 5 1 Air filter case Refer to THROTTL...

Page 200: ...chain guide 1 7 Drive sprocket 1 8 Upper engine bracket 2 9 Lower engine bracket 2 10 Pivot shaft 1 11 Engine 1 For installation reverse the removal proce dure Removing the engine Order Part name Q t...

Page 201: ...silencer EAS1SL5200 REMOVING THE EXHAUST PIPE 2 1 Remove Exhaust pipe 2 TIP Put the Exhaust pipe 2 into the state as shown by moving this and then remove it EAS1SL5201 REMOVING THE DRIVE SPROCKET 1 St...

Page 202: ...P Make sure that the couplers the hoses and the cables are disconnected Lift up the engine and remove this from its lower part toward the right of the chassis EAS1SL5203 CHECKING THE SILENCER AND EXHA...

Page 203: ...t 2 TIP 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 silencer body 3 E...

Page 204: ...O rings and brake pedal bracket EAS1SL5207 INSTALLING THE DRIVE SPROCKET 1 Install Drive sprocket 1 Drive chain 2 TIP Install the drive sprocket together with the drive chain 2 Install Lock washer 1...

Page 205: ...1 Install Gasket Exhaust pipe 1 1 Nut exhaust pipe 1 2 TIP First temporarily tighten nuts to 7 Nm 0 7 m kgf 5 1 ft lbf Then retighten them to 10 Nm 1 0 m kgf 7 2 ft lbf 2 Install Clamp Exhaust pipe 2...

Page 206: ...t is positioned as shown with respect to the exhaust pipe 2 4 Tighten Bolt exhaust pipe 2 Clamp TIP Tighten while checking that their front and rear joints are inserted in position Bolt exhaust pipe 2...

Page 207: ...4 1 Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Spark plug 1 2 Cylinder head breather hose 1 3 Bolt cylinder head cover 3 4 Cylinder head cove...

Page 208: ...iming chain tensioner 1 5 Camshaft cap 2 6 Clip 2 7 Intake camshaft 1 8 Exhaust camshaft 1 For installation reverse the removal proce dure LS 6 Nm 0 6 m kgf 4 3 ft Ibf T R 5 8 3 4 1 2 7 6 5 4 4 6 M M...

Page 209: ...sprocket and the alignment mark d on the intake camshaft sprocket with the edge of the cylinder head 3 Remove Timing chain tensioner cap bolt 1 Timing chain tensioner 2 Gaskets 4 Remove Bolt camshaft...

Page 210: ...ut Out of specification Replace 4 Measure Camshaft journal to camshaft cap clear ance Out of specification Measure the cam shaft journal diameter Camshaft lobe dimensions Intake A 37 730 37 830 mm 1 4...

Page 211: ...1SL5212 CHECKING THE TIMING CHAIN AND CAM SHAFT SPROCKET 1 Check Timing chain 1 Damage stiffness Replace the timing chain and camshaft as a set 2 Check Camshaft sprocket More than 1 4 tooth wear a Rep...

Page 212: ...tall Exhaust camshaft 1 Intake camshaft 2 a Turn the crankshaft counterclockwise with a wrench TIP Apply molybdenum disulfide oil to the cam shafts Apply the engine oil on the decompression system Fil...

Page 213: ...htening se quence as shown ECA33DD030 NOTICE The bolts camshaft cap must be tightened evenly or damage to the cylinder head camshaft caps and camshaft will result 2 Install Timing chain tensioner a Wh...

Page 214: ...Out of alignment Adjust 5 Install Timing chain guide top side 1 Cylinder head cover gasket 2 Cylinder head cover 3 Bolt cylinder head cover 4 TIP Before installation apply the sealant to the cyl inder...

Page 215: ...ilencer Refer to ENGINE REMOVAL on page 5 1 Radiator hose Disconnect Coolant temperature sensor coupler Disconnect Throttle body Refer to THROTTLE BODY on page 7 5 Camshaft Refer to CAMSHAFT on page 5...

Page 216: ...age plug 1 For installation reverse the removal proce dure Removing the cylinder head Order Part name Q ty Remarks 7 6 6 1st 2nd Final 20 Nm 2 0 m kgf 14 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf 10 Nm 1 0...

Page 217: ...mage or scratch the spark plug bore threads 2 Check Cylinder head Damage scratches Replace TIP When replacing the cylinder head replace also the valve CHECKING THE VALVE SEATS on page 5 28 Cylinder he...

Page 218: ...e threads and contact surfaces of the bolts and to both contact surfaces of the washers 1 c Install the washers and the bolts d Tighten the bolts to the specified torque in two or three steps in the p...

Page 219: ...in the proper tightening sequence TIP Tighten the bolts in two steps 90 and 60 to reach the specified angle in the proper tighten ing sequence j Tighten the bolts to the specified torque Bolts 1 4 Fi...

Page 220: ...gs Order Part name Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 20 1 Valve lifter 4 2 Adjusting pad 4 3 Valve cotter 8 4 Valve spring retainer 4 5 Valve spring 4 6 Valve stem seal 4 7 V...

Page 221: ...iginal places 2 Check Valve sealing Leakage at the valve seat Check the valve face the valve seat and the valve seat width CHECKING THE VALVE SEATS on page 5 28 a Pour a clean solvent a into the intak...

Page 222: ...on and to maintain the correct fit heat the cylinder head to 100 C 212 F in an oven a Remove the valve guide with the valve guide remover 1 b Install the new valve guide with the valve guide installer...

Page 223: ...the valve TIP When installing a new valve always replace the valve guide If the valve is removed or replaced always re place the valve stem seal EAS1SL5224 CHECKING THE VALVE SEATS 1 Eliminate Carbon...

Page 224: ...ve seat Always replace the valves used for lapping with new ones TIP When replacing the cylinder head replace also the valves with new ones without them When replacing the valves or the valve guides u...

Page 225: ...G THE VALVE SPRINGS 1 Measure Valve spring free length a Out of specification Replace the valve spring 2 Measure Compressed valve spring force a Out of specification Replace the valve spring 3 Measure...

Page 226: ...pring 4 Valve spring retainer 5 to the cylinder head TIP Make sure each valve is installed in its original place Install the valve springs with the larger pitch a facing up 4 Install Valve cotter 1 TI...

Page 227: ...0 NOTICE Hitting the valve tip with excessive force could damage the valve 6 Lubricate Adjusting pad 1 Valve lifter 2 7 Install Adjusting pad Valve lifter TIP Check that the valve lifter turns smoothl...

Page 228: ...marks Cylinder head Refer to CYLINDER HEAD on page 5 20 1 Cylinder body 1 2 Gaskets 1 3 Dowel pin 2 4 Piston pin clip 2 5 Piston pin 1 6 Piston 1 7 Piston ring set 1 For installation reverse the remov...

Page 229: ...h your fingers and lift the opposite end gap of the piston ring over the piston crown EAS1SL5230 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Sidewall Cylinder wall Vertical scratches Replace...

Page 230: ...as a set TIP Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston rings TIP Level the piston ring into the cyl...

Page 231: ...Oil ring expander 1 Lower oil ring rail 2 Upper oil ring rail 3 2nd ring 4 Top ring 5 TIP Be sure to install the piston rings so that the manufacturer s marks or numbers face up Piston ring end gap T...

Page 232: ...falling into the crankcase 3 Lubricate Piston Piston rings Cylinder 4 Offset Piston ring end gap 5 Install Cylinder gasket Dowel pin Cylinder TIP While compressing the piston rings with one hand insta...

Page 233: ...ake pedal Refer to ENGINE REMOVAL on page 5 1 1 Clutch cable 1 Disconnect 2 Clutch cover 1 3 O ring 1 4 Clutch spring 6 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Washers 1 9 Bearing 1 10 Ball 1...

Page 234: ...Clutch boss 1 16 Thrust washer 1 17 Primary driven gear 1 18 Push lever shaft 1 For installation reverse the removal proce dure Removing the clutch Order Part name Q ty Remarks LS New New New 2 3 4 5...

Page 235: ...n Refer to CHANGING THE COOLANT on page 3 8 Brake pedal Refer to ENGINE REMOVAL on page 5 1 Clutch cover Refer to CLUTCH on page 5 38 1 Oil filter element cover 1 2 Oil filter element 1 3 Radiator pip...

Page 236: ...237 CHECKING THE CLUTCH PLATES 1 Check Clutch plate Damage Replace the clutch plates as a set 2 Measure Clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the...

Page 237: ...1 CHECKING THE PRESSURE PLATE 1 Check Pressure plate Crack damage Replace EAS1SL5242 CHECKING THE PUSH LEVER SHAFT 1 Check Push lever shaft Wear damage Replace EAS1SL5243 CHECKING THE CLUTCH PUSH RODS...

Page 238: ...ease on the oil seal lip Install the oil seal in parallel with its manufac ture s marks or numbers facing inward EAS1SL5247 INSTALLING THE RIGHT CRANKCASE COVER 1 Install Dowel pin 1 O rings 2 Collar...

Page 239: ...with its convex sur face a outward Apply engine oil to the threads and contact surface of the clutch boss nut Apply engine oil to the contact surfaces of the conical washer Use the clutch holding tool...

Page 240: ...1 3 TIP Apply the engine oil on the push rod 1 2 and ball 7 Install Pressure plate 1 8 Install Clutch spring Clutch spring bolt TIP Tighten the bolts in stages and in a crisscross pattern 9 Install O...

Page 241: ...tall Kickstarter lever 1 Washers Bolt kickstarter lever TIP Install so that there is a clearance a of 5 mm 0 2 in or more between the kickstarter lever and the frame and that the kickstarter lever doe...

Page 242: ...haft Order Part name Q ty Remarks Primary driven gear Refer to CLUTCH on page 5 38 1 Kick idle gear 1 2 Kick shaft assembly 1 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick...

Page 243: ...Kick gear 1 Wear damage Replace the kick shaft as sembly Kick idle gear 2 Ratchet wheel 3 Gear teeth a Ratchet teeth b Wear damage Replace EAS1SL5254 INSTALLING THE KICK SHAFT ASSEMBLY 1 Install Kick...

Page 244: ...kick shaft stopper a Apply the engine oil on the kick shaft Slide the kick shaft assembly into the crank case and make sure the kick shaft stopper a fits into the kick shaft ratchet wheel guide 5 Ins...

Page 245: ...al 1 2 Shift shaft 1 3 Oil seals 1 4 Collars 1 5 Shift shaft spring 1 6 Roller 1 7 Shift guide 1 8 Shift lever assembly 1 9 Shift lever 1 10 Pawl 2 11 Pawl pin 2 12 Spring 2 13 Stopper lever 1 LS 1 3...

Page 246: ...ty Remarks 14 Stopper lever spring 1 15 Segment 1 For installation reverse the removal proce dure LS 1 3 13 15 14 LT 6 10 11 12 11 8 12 10 4 2 5 LT 7 LT E 12 Nm 1 2 m kgf 8 7 ft Ibf T R 30 Nm 3 0 m kg...

Page 247: ...osen the bolt ECA1DX1021 NOTICE If the segment gets an impact the stopper lever may be damaged Take care not to give an impact to it when removing the bolt EAS1SL5259 CHECKING THE SHIFT SHAFT 1 Check...

Page 248: ...damaged Take care not to give an impact to it when tightening the bolt EAS1SL5264 INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1 Install Spring 1 Pawl pin 2 Pawl 3 to the shift lever 4 TIP Appl...

Page 249: ...TIP Apply the engine oil on the roller and shift shaft 2 Install Oil seal EAS1SL5266 INSTALLING THE SHIFT PEDAL 1 Install Shift pedal 1 Shift pedal bolt 2 TIP Align the punch mark a on the shift shaft...

Page 250: ...Refer to CLUTCH on page 5 38 Right crankcase cover Refer to CLUTCH on page 5 38 1 Oil pump assembly 1 2 Oil pump cover 1 3 Outer rotor 1 4 Dowel pin 1 5 Inner rotor 1 6 Oil pump drive shaft 1 7 Rotor...

Page 251: ...MAGNETO on page 5 60 1 Nut balancer 1 2 Nut primary drive gear 1 3 Nut balancer shaft driven gear 1 4 Lock washer 1 5 Balancer 1 6 Straight key 1 7 Conical washer 1 8 Primary drive gear 1 9 Balancer s...

Page 252: ...L5270 CHECKING THE BALANCER 1 Check Balancer Crack damage Replace EAS1SL5271 CHECKING THE OIL PUMP 1 Check Oil pump drive gear Oil pump driven gear Oil pump housing Oil pump housing cover Cracks damag...

Page 253: ...r Fit the dowel pin into the groove in the inner rotor 2 Install Outer rotor 1 TIP Apply the engine oil on the outer rotor 3 Install Oil pump cover 1 Oil pump cover screw 2 EAS1SL5273 INSTALLING THE O...

Page 254: ...ck washer 1 Balancer weight gear nut 2 Primary drive gear 3 Conical washer 4 Primary drive gear nut 5 Straight key 6 Balancer 7 Lock washer 8 Balancer nut 9 TIP Apply engine oil to the contact surface...

Page 255: ...coupler Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Shift pedal 1 4 Left crankcase cover 1 5 Gaskets 1 6 Dowel pin 2 7 Holder 1 8 Stator assembly 1 9 Rotor 1 10 Woodruff key 1 For i...

Page 256: ...ge Replace EAS1SL5278 INSTALLING THE AC MAGNETO 1 Install Stator 1 Screw stator 2 Crankshaft position sensor 3 Bolt crankshaft position sensor 4 Holder 5 Bolt holder 6 TIP Apply the sealant to the gro...

Page 257: ...he keyway c of the rotor with the woodruff key 3 Install Washers Nut rotor 1 4 Install Dowel pin 1 Gasket left crankcase cover 2 Left crankcase cover 3 Lead holder 4 Bolt left crankcase cover 5 TIP Ti...

Page 258: ...R on page 5 47 Segment Refer to SHIFT SHAFT on page 5 50 Stator Refer to AC MAGNETO on page 5 60 1 Timing chain guide exhaust side 1 2 Timing chain guide stopper plate 1 3 Timing chain 1 4 Bolt L 45 m...

Page 259: ...rse the disassemble pro cedure Separating the crankcase Order Part name Q ty Remarks 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft...

Page 260: ...me Q ty Remarks Transmission Refer to TRANSMISSION on page 5 71 Shift cam and shift fork Refer to TRANSMISSION on page 5 71 1 Circlip 1 2 Oil seals 3 3 Bearing 11 For installation reverse the removal...

Page 261: ...and the transmission with the left crankcase ECA33DD041 NOTICE 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 caref...

Page 262: ...e care not to damage the screwdriver receiving hole in the screw 2 Apply Sealant to the crankcase mating surface 3 Install Dowel pin 1 Crankcase 2 to the left crankcase TIP Apply the lithium soap base...

Page 263: ...CER SHAFT Removing the crankshaft assembly and balancer shaft Order Part name Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 63 Transmission Refer to TRANSMISSION on page 5 71 1 Balancer...

Page 264: ...L5288 CHECKING THE CRANKSHAFT ASSEMBLY 1 Measure Crankshaft runout Out of specification Replace the crank shaft bearing or both TIP Turn the crankshaft slowly 2 Measure Big end side clearance D a Out...

Page 265: ...ankshaft and to ease the installation procedure lubricate the oil seal lips with lithium soap based grease In order to prevent the crankshaft seizure apply molybdenum disulfide grease TIP Hold the con...

Page 266: ...E REMOVAL on page 5 1 Crankcase Separate Refer to CRANKCASE on page 5 63 1 Main axle 1 2 Drive axle 1 3 Long shift fork guide bar 1 4 Short shift fork guide bar 1 5 Spring 4 6 Shift cam 1 7 Shift fork...

Page 267: ...of shift forks Remove the main axle and the drive axle all together by tapping the drive axle lightly with a soft hammer EAS1SL5292 CHECKING THE SHIFT FORKS 1 Check Shift fork cam follower 1 Shift fo...

Page 268: ...3 Check Transmission gears Blue discoloration pitting wear Replace the defective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check Transmission gear movem...

Page 269: ...O ring 3 Install Washer 1 Circlip 2 TIP Be sure the circlip sharp edged corner a is positioned opposite side to the washer and gear b Install the circlip with its ends c settled even ly on the spline...

Page 270: ...rk 1 L with the 4th wheel gear 5 and 3 R with the 5th wheel gear 7 on the drive axle Mesh the shift fork 2 C with the 3rd pinion gear 6 on the main axle 7 Install Long shift fork guide bar 1 Short shi...

Page 271: ...TEM RADIATOR 6 1 HANDLING NOTE 6 3 CHECKING THE RADIATOR 6 3 WATER PUMP 6 4 REMOVING THE OIL SEAL 6 5 CHECKING THE WATER PUMP 6 5 CHECKING THE BEARING 6 5 INSTALLING THE OIL SEAL 6 5 ASSEMBLING THE WA...

Page 272: ...nce to this manual It may lead to servicing trouble and mechanical damage EAS1SL5297 RADIATOR Removing the radiator Order Part name Q ty Remarks Coolant Drain Refer to CHANGING THE COOLANT on page 3 8...

Page 273: ...e 4 1 7 Radiator pipe 2 1 8 Radiator breather hose 1 9 Left radiator 1 10 Radiator hose 1 1 11 Radiator pipe 1 1 12 Coolant temperature sensor 1 For installation reverse the removal proce dure Removin...

Page 274: ...the ra diator cap EAS1SL5299 CHECKING THE RADIATOR 1 Check Radiator fins 1 Obstructions Clean Apply compressed air to the rear of the radi ator Damage Repair or replace TIP Correct any flattened fins...

Page 275: ...ANGING THE ENGINE OIL on page 3 15 Right crankcase cover Refer to CLUTCH on page 5 38 1 Water pump housing 1 2 Dowel pin 2 3 Gasket 1 4 Collar 1 5 Pin 1 6 Impeller shaft assembly 1 7 Oil seal 1 8 Bear...

Page 276: ...Replace EAS1SL5304 INSTALLING THE OIL SEAL 1 Install Oil seals 1 TIP Apply the lithium soap base grease on the oil seal lip Install the oil seal with its manufacture s marks or numbers facing the righ...

Page 277: ...1 Gasket 2 3 Install Water pump housing 1 Water pump housing bolt 2 Washer 3 Coolant drain bolt 4 Water pump housing bolt 10 Nm 1 0 m kgf 7 2 ft lbf Coolant drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf New 2...

Page 278: ...WATER PUMP 6 7...

Page 279: ...2 INSTALLING THE FUEL PUMP 7 2 INSTALLING THE FUEL TANK 7 3 CHECKING THE FUEL PRESSURE 7 3 CHECKING THE DAMPER 7 4 CHECKING AND REPLACING THE PROTECTOR 7 4 THROTTLE BODY 7 5 CHECKING THE INJECTOR 7 8...

Page 280: ...icing trouble and mechanical damage EAS1SL5307 FUEL TANK Removing the fuel tank Order Part name Q ty Remarks Seat Refer to GENERAL CHASSIS on page 4 1 Side cover left right Air scoop left right 1 Fuel...

Page 281: ...2 on the sides of the connector and then remove the hose Before removing the hose place a few cloths in the area under where it will be removed To prevent sand dust and other foreign ma terials from...

Page 282: ...click Slide the fuel hose connector cover 1 at the hose end in the direction of the arrow Install the fuel hose connector holder a Check that the fuel hose and the fuel pump lead are routed through t...

Page 283: ...2 Damper 3 3 Wear damage Replace TIP Affix dampers 1 and 3 with the arrow on each damper pointing outward Affix the damper 2 with its projection a facing the rear of the vehicle EAS1SL5315 CHECKING A...

Page 284: ...REMOVAL on page 5 1 Ignition coil Refer to ENGINE REMOVAL on page 5 1 1 Intake air temperature sensor coupler 1 Disconnect 2 Air filter case 1 3 Fuel injector coupler 1 Disconnect 4 Intake air pressur...

Page 285: ...For installation reverse the removal proce dure Removing the throttle body Order Part name Q ty Remarks 2 1 6 10 11 9 8 3 7 5 4 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 7 Nm 0...

Page 286: ...ks 1 Fuel inlet pipe 1 2 Injector 1 3 Gaskets 1 4 Throttle position sensor 1 5 Intake air pressure sensor 1 For installation reverse the removal proce dure 1 2 2 2 5 4 3 T R 3 4 Nm 0 34 m lbf kgf 2 5...

Page 287: ...foreign material from falling into the engine If the throttle body is subject to strong shocks or dropped during cleaning re place it Do not use any caustic carburetor clean ing solution Do not direct...

Page 288: ...to YAMAHA DIAGNOSTIC TOOL on page 8 12 b Temporary tighten the throttle position sen sor c Check that the throttle grip is fully closed d Connect the throttle position sensor to the wire harness e Set...

Page 289: ...ITCHES 8 38 CHECKING THE IGNITION SPARK GAP 8 41 CHECKING THE SPARK PLUG CAP 8 41 CHECKING THE IGNITION COIL 8 41 CHECKING THE CRANKSHAFT POSITION SENSOR 8 42 CHECKING THE ECU 8 42 CHECKING THE STATOR...

Page 290: ......

Page 291: ...servicing 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 semb...

Page 292: ...W B L B L B L B L B R B R R B R B O O R O R O R R R Sb B Gy R B W P L B L B L Gy B LB LB LB LB L L L P P B B B B P P Sb R B B R R R B B Y P Sb B B R R B L Y B L B W R Lg B L Br W B L P B L B L G W B...

Page 293: ...IGNITION SYSTEM 8 3 1 Crankshaft position sensor 2 AC magneto 3 Rectifier regulator 4 Joint connector 5 Condenser 7 Engine stop switch 9 ECU 10 Ignition coil 11 Spark plug...

Page 294: ...ace the spark plug OK 3 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 41 OK The ignition system circuit is OK NG 4 Check the ignition coil Refer to CHECKING THE IGNI...

Page 295: ...IGNITION SYSTEM 8 5 8 Check the ignition system wire har ness Refer to CIRCUIT DIAGRAM on page 8 2 NG Repair or replace the wire harness OK Replace the ECU...

Page 296: ...W B L B L B L B L B R B R R B R B O O R O R O R R R Sb B Gy R B W P L B L B L Gy B LB LB LB LB L L L P P B B B B P P Sb R B B R R R B B Y P Sb B B R R B L Y B L B W R Lg B L Br W B L P B L B L G W B B...

Page 297: ...CHARGING SYSTEM 8 7 2 AC magneto 3 Rectifier regulator 4 Joint connector 5 Condenser...

Page 298: ...s wiring NG Reconnect OK 2 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 43 NG Replace the rectifier regulator OK 3 Check the stator coil Refer to CHECKING THE ST...

Page 299: ...CHARGING SYSTEM 8 9...

Page 300: ...G W Br W B L B L B L B L B R B R R B R B O O R O R O R R R Sb B Gy R B W P L B L B L Gy B LB LB LB LB L L L P P B B B B P P Sb R B B R R R B B Y P Sb B B R R B L Y B L B W R Lg B L Br W B L P B L B L...

Page 301: ...AC magneto 3 Rectifier regulator 4 Joint connector 5 Condenser 7 Engine stop switch 8 Neutral switch 9 ECU 12 Fuel injector 13 Fuel pump 14 Intake air temperature sensor 15 Coolant temperature sensor...

Page 302: ...ONS OF THE YAMAHA DIAGNOSTIC TOOL However the diagnostic tool cannot be used to freely change the basic vehicle functions such as adjusting the ignition timing Yamaha diagnostic tool 90890 03231 Yamah...

Page 303: ...r components that are the probable cause of the malfunction following the order given in the troubleshooting chart After the check and service of the malfunctioning part have been completed reset the...

Page 304: ...ion of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Crank the engine Fault code No is not dis played Repair is finished Fault code No is displayed Go...

Page 305: ...pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Turn ON the switch on the FI diagnostic tool sub lead Fault code No is not dis played Repair is finished Fau...

Page 306: ...7 Faulty ECU Replace the ECU Fault code 14 Symptom Intake air pressure sensor hose system malfunction clogged or detached hose Fail safe system Able to start engine Able to drive vehicle Diagnostic co...

Page 307: ...Reinstatement method 1 Connection of throttle posi tion sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or broken terminals and locking con...

Page 308: ...e sensor Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 7 9 Turn ON the switch on the FI diagnostic tool sub lead Fault code No is not dis played Repair is finished Fault code No is displaye...

Page 309: ...heck for looseness or pinching Check the mounted condition for correctness Improperly mounted sensor Remount or replace the sensor Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 7 9 Turn ON...

Page 310: ...ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Turn ON the switch on the FI diagnostic tool sub lead Fault code N...

Page 311: ...ayed Go to next order 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or broken terminals and locking condition o...

Page 312: ...cedure Remove the ECU and incline it 45 or more Or der Probable cause of malfunc tion and check Maintenance job Reinstatement method 1 The vehicle has overturned Raise the vehicle upright Turn ON the...

Page 313: ...the coupler and check the pins for bent or broken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness After starting the e...

Page 314: ...pins Improperly connected Connect the coupler secure ly or repair replace the wire harness After starting the engine idle this and wait about 5 sec onds Fault code No is not dis played Repair is finis...

Page 315: ...and ECU coupler red black red black Between injector coupler and rectifier regulator coupler red red After starting the engine idle this and wait about 5 sec onds Fault code No is not dis played Repai...

Page 316: ...e Code No 60 EEP ROM data error for adjust ment of CO concentration Change the CO concentra tion and rewrite in EEPROM After this adjustment turn OFF the switch on the FI di agnostic tool sub lead and...

Page 317: ...diagnostic tool sub lead and wait about 5 sec onds or more Fault code No is not dis played Repair is finished Fault code No is displayed Go to next order 2 Wire harness continuity Open or short circu...

Page 318: ...dition of the coupler Disconnect the coupler and check the pins for bent or broken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the...

Page 319: ...d Fault code No is not dis played Repair is finished Fault code No is displayed Go to next order 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coup...

Page 320: ...r 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or broken terminals and locking condition of the pins Improperl...

Page 321: ...o next order 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or broken terminals and locking condition of the pin...

Page 322: ...Br W B L B L B L B L B R B R R B R B O O R O R O R R R Sb B Gy R B W P L B L B L Gy B LB LB LB LB L L L P P B B B B P P Sb R B B R R R B B Y P Sb B B R R B L Y B L B W R Lg B L Br W B L P B L B L G W...

Page 323: ...FUEL PUMP SYSTEM 8 33 2 AC magneto 3 Rectifier regulator 4 Joint connector 5 Condenser 7 Engine stop switch 9 ECU 13 Fuel pump...

Page 324: ...ver 1 Check the fuel pump system wire harness connections NG Reconnect OK 2 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 38 NG Replace the engine stop switch OK 3 Check fuel p...

Page 325: ...FUEL PUMP SYSTEM 8 35...

Page 326: ...ELECTRICAL COMPONENTS 8 36 EAS1SL5334 ELECTRICAL COMPONENTS EAS1SL5335 9 10 1 2 3 4 5 6 7 8...

Page 327: ...PONENTS 8 37 1 Rectifier regulator 2 Intake air pressure sensor 3 Throttle position sensor 4 Injector 5 Intake air temperature sensor 6 ECU 7 Ignition coil 8 Condenser 9 Neutral switch 10 Coolant temp...

Page 328: ...ELECTRICAL COMPONENTS 8 38 EAS1SL5336 CHECKING THE SWITCHES B Y P Sb 2 1...

Page 329: ...ELECTRICAL COMPONENTS 8 39 1 Engine stop switch 2 Neutral switch...

Page 330: ...cket tester range to 1 to make a 0 adjustment When checking for continuity switch back and forth between the switch positions a few times Terminal connections of the switch are shown in the terminal c...

Page 331: ...heck Spark plug cap resistance Out of specification Replace a Connect the pocket tester 1k to the spark plug cap b Measure the spark plug cap resistance EAS1SL5339 CHECKING THE IGNITION COIL 1 Disconn...

Page 332: ...SL5341 CHECKING THE ECU 1 Check Mounted condition of ECU Improperly mounted Remount TIP The lean angle sensor is built into the ECU The lean angle sensor stops the engine in case of a turnover To ensu...

Page 333: ...l care Never subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace...

Page 334: ...DX1009 WARNING Handle the throttle position sensor with special care Never subject the throttle position sensor to strong shocks If the throttle position sensor is dropped replace it 2 Check Throttle...

Page 335: ...or out put voltage EAS1SL5348 CHECKING THE INTAKE AIR TEMPERA TURE SENSOR 1 Remove Intake air temperature sensor from the air filter case EWA1DX1010 WARNING Handle the intake air temperature sensor wi...

Page 336: ...tor coupler c Measure the fuel injector resistance Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Brown White 1 Negative tester probe Black Blue 2 Pocket tester 90890...

Page 337: ...SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORM...

Page 338: ...aminated fuel Clogged or damaged fuel hose 2 Fuel pump Faulty fuel pump 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Spark plug Incorrect spark plug gap Incorrec...

Page 339: ...ft forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS1SL5359 FAULTY CLUTCH Clutch slips 1 Clutch Improperly assembled clutch Loose or fatigued...

Page 340: ...amaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring Malfunction Bent or damaged inner tube Bent or damaged outer tube Broken fork spring Bent or damaged damper rod Incorre...

Page 341: ...ort circuit detected 8 20 22 Intake air temperature sensor open or short circuit detected 8 21 30 The vehicle has overturned 8 22 33 Ignition coil open or short circuit detected in the primary lead of...

Page 342: ...emper ature Compare the actually mea sured coolant temperature with the Yamaha diagnostic tool display value 08 Lean angle sensor Upright Overturn Displays the output voltage 1 0 V 4 0 V Remove the EC...

Page 343: ...ting map erasure There is no setting There is some setting Displays the presence or ab sence of the setting history by Power Tuner 00 01 Erase all setting maps by the operation start process ing 70 Pr...

Page 344: ...LIST OF SELF DIAGNOSTIC AND FAIL SAFE ACTIONS 9 7...

Page 345: ...FORK SETTING 10 2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL 10 2 SETTING OF SPRING AFTER REPLACEMENT 10 3 FRONT FORK SETTING PARTS 10 3 REAR SUSPENSION SETTING 10 3 CHOOSING SET LENGTH 10 3 SET...

Page 346: ...ng notes of lap times to find 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...

Page 347: ...OUNT AND CHARACTERIS TICS OF FORK OIL Damping characteristic near the final stroke can be changed by changing the fork oil amount EWA1DX4001 WARNING Adjust the oil amount in 5 cm3 0 2 US oz 0 2 Imp oz...

Page 348: ...with the road surface or in a vibrating handlebar EAS1SL5374 FRONT FORK SETTING PARTS Front fork spring 1 Except for USA and CAN TIP The I D mark slits a is proved on the end of the spring EAS1SL5375...

Page 349: ...e set length sunken length 90 100 mm 3 5 3 9 in and set it 1 Use of soft spring Adjust to decrease rebound damping force to compensate for less spring load Run with the rebound damping force adjuster...

Page 350: ...USTING THE REAR SHOCK ABSORBER ASSEMBLY on page 3 30 Type Spring rate N mm Part number I D Mark SOFT 52 1SL 22212 40 Blue Yellow 1SL 22212 50 Red 54 1SL 22212 60 Blue Pink 1SL 22212 70 Red STD 56 1SL...

Page 351: ...ticeable scars etc If any replace affected parts Slide metal Replace with a new one for ex tended use Piston metal Replace with a new one for ex tended use Lower bracket tightening torque Retighten to...

Page 352: ...nt Increase oil amount by about 5 cm3 0 2 US oz 0 2 Imp oz Obtrusive front tending to upper front pos ture Compression damping force Turn adjuster counterclock wise about 2 clicks to de crease damping...

Page 353: ...senger is astride seat Spring Replace with soft spring Bottoming out High compres sion damping Turn adjuster clockwise about 1 6 turn to increase damping Spring set length Set sunken length for 90 100...

Page 354: ...tch 9 ECU 10 Ignition coil 11 Spark plug 12 Injector 13 Fuel pump 14 Intake air temperature sensor 15 Coolant temperature sensor 16 Throttle position sensor 17 Intake air pressure sensor EAS1SL5383 CO...

Page 355: ...lube Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamah...

Page 356: ...MANUAL YZ450FF 1SL 28199 11 LIT 11626 28 10 YZ450FF 2015 q Read this manual carefully before operating this vehicle PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2014 03 1 0 1 E 1SL 28199 11_cover indd 1...

Page 357: ...LB LB LB LB L L L P P B B B B 4 1 3 2 5 6 7 8 10 9 12 11 13 14 15 16 17 P P Sb R B B R R R B B L Gy B R B Y P Sb B B R R B L Y B L B W R Lg B L Br W B L P B L B L G W B B Y B B L B L B L B L B L B L B...

Page 358: ...A A A A B BLACK BLACK 4 1 3 2 5 6 7 8 10 9 12 11 13 14 15 16 17 WIRING DIAGRAM YZ450FF 2015 1SL 28199 11_W D indd 2 2014 03 07 10 16 56...

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