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Yamaha YZ450FN 2022, Owner'S Service Manual, Page: 134 / 366

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Yamaha YZ450FN 2022 Owner'S Service Manual Download Page 134

FRONT BRAKE

4-20

cleaning and lubricating.

• Never use solvents on internal brake com-

ponents as they will cause the piston seals

to swell and distort.

• When the brake caliper is disassembled, re-

place the brake caliper piston seal and the

brake caliper piston dust seal with new

ones.

EAM30035

INSTALLING THE FRONT BRAKE CALIPER

1. Install:

•

Front brake caliper bracket

•

Front brake caliper
(temporarily)

•

Copper washer 

•

Brake hose

•

Union bolt

WARNING

EWA13531

Proper brake hose routing is essential to in-

sure safe vehicle operation.

NOTICE

ECA24460

Make sure that the pipe portion “a” of the

brake hose touches the projection “b” on the

brake caliper.

2. Install:

•

Front brake caliper

•

Brake pad spring

•

Brake pad

•

Brake pad pin

•

Brake hose holder

Refer to “CHECKING THE FRONT BRAKE
PADS” on page 3-24.

3. Tighten:

•

Brake hose holder bolt “1”

TIP

Make sure that 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.

WARNING

EWA13090

• Use only the designated brake fluid. Other

brake fluids may cause the rubber seals to

deteriorate, causing leakage and poor

brake performance.

• Refill with the same type of brake fluid that

is already in the system. Mixing brake fluids

may result in a harmful chemical reaction,

leading to poor brake performance.

• When refilling, be careful that water does

not enter the brake fluid reservoir. Water

will significantly lower the boiling point of

the brake fluid and could cause vapor lock.

NOTICE

ECA13540

Brake fluid may damage painted surfaces

and plastic parts. Therefore, always clean up

any spilt brake fluid immediately.

5. Bleed:

•

Brake system

Specified brake fluid

DOT 4

Front brake caliper bracket

28 N·m (2.8 kgf·m, 21 lb·ft)

Brake hose union bolt

30 N·m (3.0 kgf·m, 22 lb·ft)

Ne

w

T

R

.

.

a

a

a

b

Brake pad pin

17 N·m (1.7 kgf·m, 13 lb·ft)

Brake hose holder bolt

9 N·m (0.9 kgf·m, 6.6 lb·ft)

Specified brake fluid

DOT 4

T

R

.

.

T

R

.

.

2

1

b

a

Summary of Contents for YZ450FN 2022

Page 1: ...Read this manual carefully before operating this vehicle 2022 OWNER S SERVICE MANUAL YZ450F YZ450FN LIT 11626 35 03 B2W 2819U 12...

Page 2: ...and lead which are known to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessar...

Page 3: ...user s authority to operate the equipment This transmitter must not be co located or operated in conjunction with any other antenna or transmitter This equipment complies with FCC radiation exposure l...

Page 4: ...NUAL 2022 by Yamaha Motor Corporation U S A First edition March 2021 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expres...

Page 5: ...uested not to undertake inspection adjustment disassem bly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage WARNING EWA20270 PLEASE READ THIS MANUA...

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

Page 7: ...teps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a removal or a disassemb...

Page 8: ...TION 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 clea...

Page 9: ...GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 TUNING 10 EAM10003 TABLE OF CONTENTS...

Page 10: ......

Page 11: ...T INFORMATION 1 9 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 9 REPLACEMENT PARTS 1 9 GASKETS OIL SEALS AND O RINGS 1 9 LOCK WASHERS PLATES AND COTTER PINS 1 10 BEARINGS AND OIL SEALS 1 10 CIRCLIPS 1 10...

Page 12: ...25 BREAK IN PROCEDURES 1 25 ENGINE STARTING PRECAUTION 1 25 MAINTENANCE AFTER BREAK IN 1 26 MAJOR MAINTENANCE 1 26 AIR FILTER MAINTENANCE 1 26 TORQUE CHECK POINTS 1 27 MOTORCYCLE CARE AND STORAGE 1 2...

Page 13: ...e riding 2 This motorcycle is designed to carry the oper ator only No passengers 3 The failure of motorists to detect and recog nize motorcycles in traffic is the predominat ing cause of automobile mo...

Page 14: ...Many companies with no connection to Yamaha manufacture parts and accessories or offer oth er modifications for Yamaha vehicles Yamaha is not in a position to test the products that these aftermarket...

Page 15: ...e fuel cock if equipped is in the OFF position and that there are no fuel leaks 3 Point the front wheel straight ahead on the trailer or in the truck bed and choke it in a rail to prevent movement 4 S...

Page 16: ...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 17: ...for the vehicle you have purchased 1 11 12 13 14 15 16 17 18 19 2 3 6 4 5 7 8 9 10 1 Clutch lever 2 Front brake lever 3 Throttle grip 4 Start switch 5 Launch control switch 6 Radiator cap 7 Fuel tank...

Page 18: ...sitive identi fication of the model you own 2 If your vehicle is stolen the authorities will need the number to search for and identify your vehicle EAM30002 VEHICLE IDENTIFICATION NUMBER The vehicle...

Page 19: ...r smartphone and wirelessly connecting to the CCU wireless network you can adjust various vehicle settings WARNING EWA20460 Do not operate the engine in a closed area The exhaust gas is poisonous Neve...

Page 20: ...s radios or mobile phones in close proximity of the CCU The CCU is in contact with or covered by a metallic object Other vehicles equipped with a CCU are nearby In such situations move the CCU to anot...

Page 21: ...ed to the chassis paint and plating will be damaged Therefore rinse it out with water in good time WARNING EWA18970 Coolant is potentially harmful and should be handled with special care If it enters...

Page 22: ...il seal make sure that its main lip faces the oil chamber the target to be sealed Before installation always apply a light coat of grease to the oil seal lip NOTICE ECA13300 Do not spin the bearing wi...

Page 23: ...y dangerous TIP If a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct ba...

Page 24: ...ti function display goes off Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never insert the tester probes...

Page 25: ...th sections of the connec tor securely and then disconnect the con nector 2 Check Lead Coupler Connector Moisture Dry with compressed air Rust stains Connect and disconnect sev eral times 3 Check All...

Page 26: ...f there is no continuity clean the terminals When checking the wire harness perform steps 1 to 4 As a quick remedy use a contact revitalizer available at most part stores Digital circuit tester CD732...

Page 27: ...number starting with YM YU or ACC For others use tool number starting with 90890 Tool name Tool No Illustration Reference pages Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom...

Page 28: ...3 27 4 56 Spoke nipple wrench 6 7 90890 01521 Spoke nipple wrench 6 7 YM 01521 3 33 Timing light 90890 03141 Timing light YU 03141 3 35 Cap bolt ring wrench 90890 01501 Cap bolt ring wrench YM 01501...

Page 29: ...ing compressor adapter 22 mm YM 04108 5 26 5 30 Valve guide remover installer set 5 5 90890 04016 Valve guide remover 5 5 mm YM 01122 5 28 Valve guide installer 5 5 90890 04015 Valve guide installer 5...

Page 30: ...42 5 49 5 52 Crankcase separating tool 90890 04152 Crankcase separating tool YU A9642 5 68 Crankshaft installer pot 90890 01274 Installing pot YU 90058 5 69 Crankshaft installer bolt 90890 01275 Bolt...

Page 31: ...ooling system tester kit YU 24460 A 6 4 6 4 Radiator cap tester adapter 90890 01352 Pressure tester adapter YU 33984 6 4 6 4 Pressure gauge 90890 03153 Pressure gauge YU 03153 7 8 Fuel pressure adapte...

Page 32: ...ium battery charger DBY ACC51 70 02 8 46 8 46 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 48 Test harness S pressure sensor 3P 90890 03207 Test harness S pressure sensor 3P Y...

Page 33: ...man ner on a slippery road surface However the effect may not be adequate de pending on the rider s operations and road sur face conditions How to operate 1 Put the gear into the neutral position 2 St...

Page 34: ...handlebar Pull it toward the handlebar to acti vate the front brake EAM30189 REAR BRAKE PEDAL The rear brake pedal 1 is in the right of the chassis Press down on the brake pedal to acti vate the rear...

Page 35: ...cover 2 Remove the fuel tank cap cover to open the fuel tank cap TIP To remove the fuel tank cap cover insert fin gers under part a and then use both hands to lift it up towards the rear of the vehicl...

Page 36: ...problems EAM30196 STARTING A COLD ENGINE 1 Press the shift pedal to neutral 2 Push the starter knob 1 completely TIP When the ambient temperature is 15 C 59 F or below use the starter knob Do not ope...

Page 37: ...eness oil leaks or other problems Thorough checks and ad justments are required in particular for stretch of cables free play of the brake stretch of the drive chain looseness of the spoke and so on N...

Page 38: ...and nuts Check for looseness in mounted areas of parts as well as engine mounting bolts and engine brackets 2 For the chassis Check welds and mounted areas of the frame the swingarm the link the brac...

Page 39: ...Link to rear shock absorber Link to swingarm Mounting of rear shock absorber Rear shock absorber and frame Mounting of swingarm Tightening of pivot shaft Wheel s Mounting of wheel Front Tightening of...

Page 40: ...t pedal Shift pedal to shift shaft Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rea...

Page 41: ...y rinse the area off with water immediately dry it and then apply a corrosion protec tion spray Improper cleaning can damage plastic parts such as cowlings panels wind shields headlight lenses meter l...

Page 42: ...nd nickel plated sur faces 5 Use spray oil as a universal cleaner to re move any remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry c...

Page 43: ...k plug and then install the spark plug and the spark plug cap WARNING To pre vent damage or injury from sparking make sure to ground the spark plug electrodes while turning the engine over 4 Lubricate...

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

Page 45: ...ATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 5 ELECTRICAL SPECIFICATIONS 2 8 TIGHTENING TORQUES 2 9 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 9 ENGINE TIGHTENING TORQUES 2 10 CHASSIS...

Page 46: ...l Model B2WC B2WG Dimensions Overall length 2185 mm 86 0 in Overall width 825 mm 32 5 in Overall height 1285 mm 50 6 in Seat height 965 mm 38 0 in Wheelbase 1485 mm 58 5 in Ground clearance 330 mm 12...

Page 47: ...lter removal 0 65 L 0 69 US qt 0 57 Imp qt Quantity disassembled 0 90 L 0 95 US qt 0 79 Imp qt Oil filter Oil filter type Cartridge Cooling system Coolant quantity Radiator including all routes 1 03 L...

Page 48: ...Measuring point from piston skirt bottom 9 0 mm 0 35 in Piston pin bore inside diameter limit 18 045 mm 0 7104 in Piston pin outside diameter limit 17 981 mm 0 7079 in Piston pin to piston pin bore c...

Page 49: ...Drive axle runout limit 0 08 mm 0 0032 in Secondary reduction ratio 3 769 49 13 Final drive Chain Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or other qua...

Page 50: ...sure measured on cold tires Front 100 kPa 1 00 kgf cm 15 psi Rear 100 kPa 1 00 kgf cm 15 psi Front brake Type Hydraulic single disc brake Brake disc thickness limit 2 5 mm 0 10 in Brake disc runout li...

Page 51: ...from the start position Soft 20 Adjustment value from the start position STD 9 Adjustment value from the start position Hard 0 Rear suspension Type Swingarm link suspension Spring Coil spring Shock a...

Page 52: ...Click Adjustment value from the start position Soft 20 Adjustment value from the start position STD 6 Adjustment value from the start position Hard 0 Drive chain Size 520 Chain type Non sealed type N...

Page 53: ...ngle phase Regulated voltage DC 14 0 14 8 V Battery Model BR98 Voltage capacity 12 V 2 4 Ah 5 HR Starter motor Brush overall length 11 0 mm 0 43 in Brush overall length limit 5 5 mm 0 22 in Brush spri...

Page 54: ...o avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifi...

Page 55: ...t M14 1 50 N m 5 0 kgf m 37 lb ft Use a lock washer Balancer nut M10 1 45 N m 4 5 kgf m 33 lb ft Use a lock washer Timing chain guide stopper plate exhaust side M6 1 10 N m 1 0 kgf m 7 4 lb ft Timing...

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

Page 57: ...m 8 9 lb ft Generator rotor nut M12 1 65 N m 6 5 kgf m 48 lb ft Stator coil screw M5 3 10 N m 1 0 kgf m 7 4 lb ft Crankshaft position sensor bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Stator coil assembly...

Page 58: ...er bolt M6 2 9 N m 0 9 kgf m 6 6 lb ft Throttle grip cap screw M5 2 3 8 N m 0 38 kgf m 2 8 lb ft Clutch lever holder bolt M6 2 5 N m 0 5 kgf m 3 7 lb ft Clutch lever nut M6 1 4 0 N m 0 40 kgf m 3 0 lb...

Page 59: ...7 N m 0 7 kgf m 5 2 lb ft Engine mounting bolt upper side M10 2 45 N m 4 5 kgf m 33 lb ft Engine mounting bolt front side M10 1 55 N m 5 5 kgf m 41 lb ft Engine mounting bolt lower side M10 1 53 N m...

Page 60: ...2 6 lb ft Bolt fuel tank cap cover M6 2 4 0 N m 0 40 kgf m 3 0 lb ft Seat set bracket screw M6 1 7 N m 0 7 kgf m 5 2 lb ft Seat bolt M8 2 22 N m 2 2 kgf m 16 lb ft Side cover bolt left M6 2 7 N m 0 7...

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

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

Page 63: ...tor Be sure the lead will not be pinched between the radiator and the tension arm H Fasten the starter motor lead to the bracket using the plastic locking tie Position the lock part of the plastic loc...

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

Page 65: ...the vehicle The cylinder head breather hose at the rear of the vehicle The lower radiator boss at the front of the vehicle The radiator hose at the front of the vehicle For routing the remaining lead...

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

Page 67: ...of the number plate band C Secure the engine stop switch lead and mode switch lead to the handlebar using the plastic locking tie Do not cut off the end of the plastic locking tie D Pass the engine st...

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

Page 69: ...on cord A Fasten the main harness and start switch lead using the clamp and insert the clamp projection into the hole in the sheet metal of the radiator The direction of the clamp lock portion does no...

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

Page 71: ...to the battery bracket and fasten it C After connecting the negative battery coupler position to the right side of the starter relay D The position of the starter motor lead and negative battery lead...

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

Page 73: ...brake hose holders C Route the rear brake hose so that it is not bent as shown by the double dash line D Route the rear brake hose and spring so that they do not interfere with each other E Make sure...

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

Page 75: ...KING THE COOLANT LEVEL 3 20 CHECKING THE COOLING SYSTEM 3 21 CHANGING THE COOLANT 3 21 CHASSIS 3 23 ADJUSTING THE FRONT DISC BRAKE 3 23 ADJUSTING THE REAR DISC BRAKE 3 23 CHECKING THE BRAKE FLUID LEVE...

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

Page 77: ...hours Every third race about 7 5 hours Every fifth race about 12 5 hours As required 1 Valve Check the valve clearances Check the valve seats and the valve faces for wear Replace 2 Valve spring Check...

Page 78: ...encer protector Check for exhaust leaks and tightening torques Clean Replace fiver When the exhaust sound becomes louder or when a perfor mance drop is felt 21 Crankshaft Inspect and clean 22 Throttle...

Page 79: ...Inspect lube and retighten 35 Relay arm connect ing rod Inspect lube and retighten 36 Steering head Inspect free play and retighten Check for tightening torques Clean and lube After rain ride Replace...

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

Page 81: ...3 3 23 3 23 3 24 3 24 3 24 3 24 3 25 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 26 4 69 4 69 4 70 4 70 4 70 Wheels Check for excessive wear a...

Page 82: ...eft right Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 ECU Engine Control Unit 2 Remove Spark plug Cylinder head cover Refer to CAMSHAFT on page 5...

Page 83: ...oper valve clearance from the adjusting pad se lection table TIP There are 25 types of adjusting pads ranging from 1 20 mm 0 0472 in to 2 40 mm 0 0945 in in increments of 0 05 mm 0 0020 in The field w...

Page 84: ...ir numbers facing upward f Install the camshafts exhaust and intake Refer to CAMSHAFT on page 5 13 g Measure the valve clearance again h If the valve clearance is out of specifica tion repeat adjustin...

Page 85: ...80 185 190 195 200 205 210 215 220 225 230 235 240 0 70 0 74 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 75 0 79 180 185 190 195 200 205 210 215 220 225 230 235 240 0 80 0 84 185 190 195...

Page 86: ...15 220 225 230 235 240 0 70 0 74 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 75 0 79 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 80 0 84 180 185 190 195 200 205 210 215...

Page 87: ...3 Install Digital tachometer TIP Get the high tension cord 1 of the ignition coil pinched in the detector a of the digital tachom eter 4 Measure Engine idling speed Out of specification Regulate 5 Adj...

Page 88: ...2 as shown 2 Remove Spark plug cap Spark plug Refer to CAMSHAFT on page 5 13 NOTICE ECA24410 In order not to allow the dirt accumulated around the spark plug to drop from the spark plug hole into the...

Page 89: ...ves could cause clutch slippage Therefore do not add any chemical additives Do not allow foreign material to enter the crankcase EAM30225 CHANGING THE ENGINE OIL Stand the vehicle upright on a level s...

Page 90: ...eck Engine oil pressure a Start the engine WARNING EWA19130 Always keep the engine idling speed during the checkup without increasing the engine speed b Look at the oil level check window 1 and then m...

Page 91: ...ble side Clutch cable side a Slide the clutch cable cover b Loosen the locknut 1 c Turn the adjuster 2 until the specified clutch lever free play is obtained d Tighten the locknut 1 e Return the clutc...

Page 92: ...o the bag b With the element inside the bag rub it thoroughly so that the element is evenly permeated with the oil c Wrap the element in a clean cloth rub the element gently and wipe off any excess oi...

Page 93: ...cat ed on the left and right sides of the air filter case cover with the projections d on the air scoop and then install the air filter case cover 10 Install Fuel tank cap cover EAM30335 CHECKING THE...

Page 94: ...30221 CHECKING THE EXHAUST SYSTEM 1 Remove Exhaust pipe 1 Exhaust pipe 2 Refer to ENGINE REMOVAL on page 5 6 2 Remove Exhaust pipe protector 3 Check Exhaust pipe 1 Exhaust pipe 2 Silencer Crack damage...

Page 95: ...he silencer body by using a flat board 11 h Install the fiber insert 12 to the inner pipe i Install the fiber insert 13 to the inside of the silencer cap 14 j Install the silencer cap 15 and rivet 16...

Page 96: ...ng sound has stopped press down on the radi ator cap and turn it counterclockwise to re move 1 Stand the vehicle upright on a level surface 2 Remove Radiator cap 1 3 Check Coolant level Maximum level...

Page 97: ...hissing sound has stopped press down on the radi ator cap and turn it counterclockwise to re move 1 Place a container under the engine 2 Remove Coolant drain bolt 1 3 Remove Radiator cap Slowly loose...

Page 98: ...used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 7 Install Radiator cap 8 Start the engine warm this up for several m...

Page 99: ...TING THE REAR DISC BRAKE 1 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting bolt 2 until the brake pedal is in the correct position c Tighten the locknut WARNING EWA19150 A soft...

Page 100: ...f the brake pads 1 Operate the brake 2 Check Front brake pad Wear indicator grooves 1 almost touch the brake disc Replace the brake pads as a set Refer to FRONT BRAKE on page 4 13 EAM30232 CHECKING TH...

Page 101: ...er the brake system considerably lengthening the bleeding proce dure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the t...

Page 102: ...e chain guide installation bolt with a force of about 50 N 5 0 kgf 37 lbf 4 Check Drive chain slack a Out of specification Regulate TIP Measure drive chain slack between the drive chain guide and the...

Page 103: ...he right and left a few times and make sure that the steering ro tates smoothly If it does not turn smooth ly remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD on...

Page 104: ...tor guide reaches the limit of its use when it is worn down to the same height a as of the outer tube circumference 6 Remove Protector Dust seal 1 NOTICE ECA24330 Be careful not to damage the dust sea...

Page 105: ...force adjusting mechanism and to modify the specifications as necessary Air bleeding from front fork TIP If the front fork initial movement feels stiff during a run relieve the front fork internal pre...

Page 106: ...the vehicle so that there is no danger of it falling over Spring preload NOTICE ECA24360 Do not turn the adjuster forcibly beyond its adjusting range 1 Adjust Spring preload a Loosen the locknut 1 b...

Page 107: ...g for fast compression damping a Turn the adjuster 1 in the direction of a or b to make an adjustment TIP To obtain a precise adjustment it is advisable to check the actual total number of turns of th...

Page 108: ...lar Refer to INSTALLING THE SWINGARM on page 4 66 EAM30501 CHECKING THE CONNECTING ARM AND RELAY ARM Refer to CHECKING THE CONNECTING ARM AND RELAY ARM on page 4 63 EAM30243 CHECKING THE TIRES 1 Measu...

Page 109: ...0 Never attempt to make any repairs to the wheel EAM30246 CHECKING THE WHEEL BEARINGS 1 Check Wheel bearing Refer to CHECKING THE FRONT WHEEL on page 4 6 and CHECKING THE REAR WHEEL on page 4 10 EAM30...

Page 110: ...to metal moving parts of the following parts Brake lever EAM30503 LUBRICATING THE CLUTCH LEVER 1 Lubricate the pivoting points and metal to metal moving parts of the following parts Clutch lever EAM30...

Page 111: ...e high tension cord 3 3 Adjust Engine idling speed Refer to CHECKING THE ENGINE IDLING SPEED on page 3 11 4 Check Ignition timing Check whether the alignment mark a on the left crankcase cover is with...

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

Page 113: ...ACING THE FRONT BRAKE PADS 4 17 REMOVING THE FRONT BRAKE CALIPER 4 19 DISASSEMBLING THE FRONT BRAKE CALIPER 4 19 CHECKING THE FRONT BRAKE CALIPER 4 19 ASSEMBLING THE FRONT BRAKE CALIPER 4 19 INSTALLIN...

Page 114: ...NG THE STEERING HEAD 4 56 REAR SHOCK ABSORBER ASSEMBLY 4 59 HANDLING THE REAR SHOCK ABSORBER 4 62 DISPOSING OF A REAR SHOCK ABSORBER 4 62 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 62 CHECKING THE RE...

Page 115: ...s 1 Side cover left 1 2 Seat 1 3 Negative battery lead 1 Disconnect 4 Positive battery lead 1 Disconnect 5 Battery band 1 6 Battery 1 7 Cover 1 8 Starter relay 1 9 Main relay 1 10 CCU Communication Co...

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

Page 117: ...tch cable 2 from the cable guide b on the number plate The projection c on the lower bracket is in serted into the number plate Remove the number plate by pulling it off the projection When installing...

Page 118: ...EAM30460 INSTALLING THE SIDE COVER 1 Install Side cover right 1 TIP Install the side cover right by sliding it as shown and secure it with the bolts to fit it to the vehicle Install the side cover ri...

Page 119: ...se the front wheel off the ground 1 Front wheel axle pinch bolt 4 Loosen 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Oil seal 2 7 Bearing 2 8 Brake disc 1 LT LS LS LS 5...

Page 120: ...x le 2 Check Tire Front wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 32 and CHECKING THE WHEELS on page 3 33 3 Check Spoke Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 33 4...

Page 121: ...2 Install Brake disc Brake disc bolt TIP Tighten the bolts in stages and in a crisscross pattern 3 Install Collar 1 TIP Apply the lithium soap based grease on the oil seal lip EAM30617 INSTALLING THE...

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

Page 123: ...the ground 1 Rear wheel axle nut 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 3 10 Brake disc 1 2 5 7 9 4 6 1 6 3 8...

Page 124: ...2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 32 and CHECKING THE WHEELS on page 3 33 3 Check Spoke Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 33 4 Measu...

Page 125: ...the bearing by pressing its outer race parallel TIP Use a socket 6 that matches the diameter of the bearing outer race and that of the oil seal 2 Install Brake disc Brake disc bolt TIP Tighten the bol...

Page 126: ...nstall Drive chain puller right 1 Washer 2 Rear wheel axle nut 3 TIP Temporarily tighten the rear wheel axle nut at this point 5 Adjust Drive chain slack a Refer to DRIVE CHAIN SLACK on page 3 26 6 Ti...

Page 127: ...ge 3 25 1 Union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Brake pad pin plug 1 5 Brake pad pin 1 6 Brake pad 2 7 Brake pad spring 1 8 Front brake caliper assembly 1 9 Front brake caliper bracket...

Page 128: ...ling the front brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 2 2 Brake caliper piston dust seal 2 3 Brake caliper piston seal 2 4 Bleed screw 1 1 2 4 S S S BF BF 3 2 3 S...

Page 129: ...on bolt 1 3 Copper washer 2 4 Front brake hose 1 5 Brake master cylinder reservoir cap 1 6 Brake master cylinder reservoir diaphragm 1 7 Front brake master cylinder float 1 8 Front brake master cylind...

Page 130: ...FRONT BRAKE 4 16 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 BF 1 S New...

Page 131: ...inutes and get im mediate medical attention EAM30029 CHECKING THE FRONT BRAKE DISC 1 Check Front brake disc Damage galling Replace 2 Measure Brake disc thickness Measure the brake disc thickness at a...

Page 132: ...euse the drained brake fluid c Tighten the bleed screw d Install the brake pads 3 and the pad pin TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tigh...

Page 133: ...the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston d...

Page 134: ...ts 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 WARNING EWA13090 Use only the designated brake fluid Other...

Page 135: ...r 1 Damage scratches wear Replace the brake master cylinder assembly Brake fluid delivery passages 2 brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder r...

Page 136: ...tighten the upper bolt then the lower bolt 2 Install Copper washer Brake hose Union bolt WARNING EWA13531 Proper brake hose routing is essential to in sure safe vehicle operation NOTICE ECA24470 Durin...

Page 137: ...Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any s...

Page 138: ...3 Copper washer 2 4 Rear brake hose 1 5 Brake pad pin plug 1 6 Brake pad pin 1 7 Rear brake pad assembly 2 8 Rear brake caliper bracket 1 9 Brake pad spring 2 10 Rear brake disc cover 1 11 Rear brake...

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

Page 140: ...age 3 25 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Split pin 1 5 Washer 1 6 Pin 1 7 Brake master cylinder reservoir cap 1 8 Brake master cylinder reservoir diaphragm plate 1 9 Brake master cyl...

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

Page 142: ...lush with water for 15 minutes and get im mediate medical attention EAM30041 CHECKING THE REAR BRAKE DISC 1 Check Brake disc Damage galling Replace 2 Measure Brake disc thickness Measure the brake dis...

Page 143: ...stall the brake pads 3 and the pad pin 4 TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point e Install the brake caliper...

Page 144: ...ake hose joint opening to force out the piston from the brake caliper WARNING EWA13550 Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the bra...

Page 145: ...ake pad spring Brake pad Brake pad pin Brake pad pin plug Refer to CHECKING THE REAR BRAKE PADS on page 3 24 4 Pour brake fluid to the brake fluid reservoir up to the specified level WARNING EWA13090...

Page 146: ...es 2 brake master cylinder body Obstruction Blow out with compressed air 2 Check Master cylinder reservoir cap Crack damage Replace Brake master cylinder reservoir diaphragm holder Brake master cylind...

Page 147: ...Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in...

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

Page 149: ...ll 1 Disconnect 8 Throttle cable return 1 Disconnect 9 Right grip 1 10 Tube guide 1 11 Start switch 1 12 Launch control switch 1 13 Left grip 1 14 Upper handlebar holder 2 15 Handlebar 1 13 3 8 N m 0...

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

Page 151: ...Damper 1 Lower handlebar holder 2 temporarily Handlebar 3 Upper handlebar holder 4 TIP Install the lower handlebar holders with the side having the longer distance a from the mounting bolt center fac...

Page 152: ...ould be installed according to the dimensions shown Pass the engine stop switch lead through the middle of the clutch lever holder a 3 4 4 b 1 2 1 2 1 2 1 2 c 1 2 1 2 d Lower handlebar holder nut 40 N...

Page 153: ...ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 15 9 Install Right grip 1 Collar 2 Apply adhesive to the tube guide 3 TIP Before applying the adhesive wipe off grease or oil on the tube guide surface a...

Page 154: ...brake master cylinder holder bolt 4 Launch control switch 5 Clamp 6 TIP Install the brake master cylinder holder with the UP mark facing up Install in order for the top of the front brake master cyli...

Page 155: ...HANDLEBAR 4 41 15 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 11 Throttle grip free play 3 0 6 0 mm 0 12 0 24 in...

Page 156: ...aliper Refer to FRONT BRAKE on page 4 13 Number plate Refer to GENERAL CHASSIS on page 4 1 Lower handlebar holder Refer to HANDLEBAR on page 4 35 with the handlebar holder 1 Protector 1 2 Upper bracke...

Page 157: ...6 Inner tube 1 7 Outer tube 1 8 Piston metal 1 9 Protector guide 1 10 Slide metal 1 11 Washer 1 12 Oil seal 1 13 Base valve 1 14 Damper assembly 1 15 Upper spring seat 1 LS 14 2 7 9 11 12 5 4 1 6 13 N...

Page 158: ...ork leg from the ve hicle loosen the damper assembly 1 with the cap bolt ring wrench 2 It is allowed to remove the lower handlebar holder with the handlebar installed as shown When doing so make sure...

Page 159: ...THE FRONT FORK LEGS 1 Check Inner tube surface Scratches Repair or replace Use 1000 grit wet sandpaper Damaged oil lock piece Replace Inner tube bends Out of specification Replace Use the dial gauge...

Page 160: ...ace Contamination Clean O ring 2 Wear damage Replace Base valve bushing Wear damage Replace Fork spring 3 Damage fatigue Replace the base valve Bleed screw 4 Wear damage Replace 6 Check Upper spring s...

Page 161: ...the damper as sembly of air TIP Avoid excessive full stroke A stroke of 200 mm 7 9 in or more will cause air to enter In this case repeat the steps 1 to 3 4 Measure Oil level left and right a Out of...

Page 162: ...filling pump the damper assembly 1 slowly up and down more than 10 times to distribute the fork oil 11 While protecting the damper assembly 1 with a cloth and compressing fully allow ex cessive oil to...

Page 163: ...ased grease on the dust seal lip and oil seal lip Apply the fork oil on the inner tube When installing the oil seal use vinyl seat a with fork oil applied to protect the oil seal lip 15 Install Piston...

Page 164: ...outer tube 20 Install Dust seal 1 TIP Apply lithium soap based grease on the inner tube 21 Check Inner tube smooth movement Tightness binding rough spots Repeat the steps 14 to 20 22 Measure Distance...

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

Page 166: ...rformance When disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 31 Install Damper assembly 1 to the outer tube TIP Temporarily tighten the dam...

Page 167: ...y 3 Adjust Front fork top end a 4 Install Lower handlebar holder with the handlebar 5 Tighten Upper bracket pinch bolt 1 Lower bracket pinch bolt 2 Damper assembly 30 N m 3 0 kgf m 22 lb ft Cap bolt r...

Page 168: ...ll Protector 1 Bolt protector 2 7 Adjust Rebound damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 8 Adjust Compression damping force TIP T...

Page 169: ...bar Refer to HANDLEBAR on page 4 35 1 Front fender 1 2 Steering stem nut 1 3 Front fork leg 2 Refer to FRONT FORK on page 4 42 4 Upper bracket 1 5 Steering ring nut 1 6 Lower bracket 1 7 Bearing race...

Page 170: ...ace 3 Replace Bearing Bearing race a Remove the bearing race from the steer ing head pipe with a long rod 1 and a hammer b Remove the bearing race from the lower bracket with a chisel 2 and a hammer c...

Page 171: ...teering ring nut with its stepped side a facing downward Tighten the steering ring nut with a steering nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 27 5 Check the steering...

Page 172: ...teering ring nut little by lit tle 10 Adjust Front fork top end a 11 Tighten Upper bracket pinch bolt 1 Lower bracket pinch bolt 2 WARNING EWA19330 Tighten the lower bracket to specified torque If tor...

Page 173: ...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 assembly upper bolt 1 3 Rear shock absorber assem...

Page 174: ...r shock absorber assembly Order Job Parts to remove Q ty Remarks 13 Collar 2 14 O ring 2 15 Dust seal 2 16 Bushing 1 17 Stopper ring 1 M 56 N m 5 6 kgf m 41 lb ft 53 N m 5 3 kgf m 39 lb ft M M M LS M...

Page 175: ...Disassembling the relay arm Order Job Parts to remove Q ty Remarks 1 Relay arm 1 2 Connecting arm 1 3 Collar 3 4 Oil seal 6 5 Washer 8 6 Bearing 6 5 3 5 6 1 6 5 4 5 5 4 6 6 5 3 2 4 6 6 3 4 4 M M M M M...

Page 176: ...er be sure to extract the nitrogen gas from valve 1 WARNING EWA19340 Wear protective glasses to prevent your eyes from damage due to possible gas or metal chips scattered To dispose of a damaged or a...

Page 177: ...ring outer race because it will wear the rear shock ab sorber surface on which the bearing is press fitted 2 Lubricate O ring 3 Install Bushing Stopper ring into the rear shock absorber assembly up pe...

Page 178: ...sorber assembly lower bolts connecting arm bolt relay arm side and relay arm bolt swingarm side from the left 7 Tighten Rear shock absorber assembly upper nut Connecting arm nut frame side Connecting...

Page 179: ...heel off the ground Brake hose holder Refer to REAR BRAKE on page 4 24 Rear brake caliper Refer to REAR BRAKE on page 4 24 Bolt brake pedal Drive chain 1 Collar 2 2 Oil seal 2 3 Thrust bearing 2 4 Bus...

Page 180: ...arm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash with kerosene Pivot sha...

Page 181: ...SWINGARM 4 67 4 Install Rear wheel Refer to REAR WHEEL on page 4 9 5 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 26 Drive chain slack Maintenance stand 50 0 60 0 mm 1 97 2 36 in...

Page 182: ...rder Job Parts to remove Q ty Remarks Drive sprocket Refer to ENGINE REMOVAL on page 5 6 1 Drive chain 1 2 Drive sprocket cover 1 3 Bracket 1 4 Drive sprocket nut 1 5 Lock washer 1 6 Drive sprocket 1...

Page 183: ...e length c of the 15 link sec tion of the drive chain using the following formula Drive chain 15 link section length c length a between pin inner sides length b between pin outer sides 2 TIP When meas...

Page 184: ...n the figure 2 Lubricate Drive chain 3 Install Drive sprocket Lock washer Drive sprocket nut Refer to ENGINE REMOVAL on page 5 6 NOTICE ECA14300 Never install a new drive chain onto worn drive chain s...

Page 185: ...HEAD 5 22 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 5 22 CHECKING THE CYLINDER HEAD 5 22 INSTALLING THE CYLINDER HEAD 5 22 VALVES AND VALVE SPRINGS 5 25 REMOVING THE VALVES 5 26 CHECKING THE VALVES...

Page 186: ...MOVING THE SEGMENT 5 55 CHECKING THE SHIFT SHAFT 5 55 CHECKING THE STOPPER LEVER 5 55 INSTALLING THE SHIFT SHAFT 5 55 OIL PUMP 5 58 REMOVING THE BALANCER 5 60 CHECKING THE OIL PUMP 5 60 ASSEMBLING THE...

Page 187: ...S 5 1 EAM20185 LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30526 ENGINE OIL LUBRICATION CHART 1 Intake camshaft 2 Exhaust camshaft 3 Piston 4 Oil filter element 5 Oil nozzle 6 Oil pump 7 Oil strainer 8 C...

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

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

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

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

Page 192: ...MBLY on page 4 59 1 Silencer clamp 1 Loosen 2 Silencer 1 3 Exhaust pipe 2 clamp 1 Loosen 4 Exhaust pipe 2 1 5 Exhaust pipe 1 1 6 Gasket 3 7 Exhaust pipe 1 protector 1 8 Silencer body 1 9 Silencer cap...

Page 193: ...EL TANK on page 7 1 Air filter case cover Refer to CLEANING THE AIR FILTER ELE MENT on page 3 15 Intake air temperature sensor coupler Refer to THROTTLE BODY on page 7 4 ECU Engine Control Unit Refer...

Page 194: ...ROTTLE BODY on page 7 4 Throttle body Refer to THROTTLE BODY on page 7 4 Clutch cable Refer to CLUTCH on page 5 46 Shift pedal Drive chain Refer to SHIFT SHAFT on page 5 54 Refer to CHAIN DRIVE on pag...

Page 195: ...engine bracket 2 11 Shim 4 12 Pivot shaft 1 13 Engine 1 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 34 N m 3 4 kgf m 25 lb ft 85 N m 8 5 kgf m 63 lb ft 90 N m 9 0 kgf m 66 lb ft 34 N m 3 4 kg...

Page 196: ...ngine and remove this from its low er part toward the right of the chassis EAM30164 INSTALLING THE ENGINE 1 Install Engine 1 from the right side Pivot shaft 2 Engine mounting bolt lower side 3 Lower e...

Page 197: ...Exhaust pipe 2 1 Bolt exhaust pipe 2 2 TIP Make sure that the exhaust pipe band 3 does not ride on the projection a on the exhaust pipe 4 or silencer 5 Be sure to insert the projection b into the slo...

Page 198: ...4 Tighten Bolt exhaust pipe 2 Clamp TIP Tighten while checking that their front and rear joints are inserted in position Bolt exhaust pipe 2 20 N m 2 0 kgf m 15 lb ft Clamp 12 N m 1 2 kgf m 8 9 lb ft...

Page 199: ...Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Ignition coil Refer to ENGINE REMOVAL on page 5 6 1 Cylinder head breather hose 1 2 Spark plug 1 3 Cy...

Page 200: ...Timing chain tensioner cap bolt 1 4 Timing chain tensioner 1 5 Camshaft cap 2 6 Clip 2 7 Intake camshaft 1 8 Exhaust camshaft 1 9 Oil nozzle 1 M LS 5 8 3 4 1 2 7 6 4 3 6 E LS E 6 N m 0 6 kgf m 4 4 lb...

Page 201: ...cap surfaces d 3 Remove Timing chain tensioner cap bolt 1 Timing chain tensioner 2 Gasket 4 Remove Bolt camshaft cap 1 Camshaft cap 2 Clip 3 TIP Remove the bolts camshaft cap in a criss cross pattern...

Page 202: ...p bolts in a crisscross pattern from innermost to outer caps Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance d Remove the camshaft caps and then mea sure the wid...

Page 203: ...h your fingers use a thin screwdriver 1 to wind the tensioner rod up fully clock wise b When releasing the screwdriver by press ing lightly with your fingers make sure that the tensioner rod will come...

Page 204: ...TIP Before installing the clips cover the cylinder head with a clean cloth to prevent the clips from coming off into the cylinder head cavity Apply the engine oil to the threads and contact surfaces T...

Page 205: ...chain guide top side 1 Cylinder head cover gasket 2 Gasket spark plug hole 3 Cylinder head cover 4 Bolt cylinder head cover 5 TIP Before installation apply the sealant to the cylin der head cover gas...

Page 206: ...to ENGINE REMOVAL on page 5 6 Radiator hose Disconnect Coolant temperature sensor coupler Disconnect Throttle body Refer to THROTTLE BODY on page 7 4 Camshaft Refer to CAMSHAFT on page 5 13 Upper engi...

Page 207: ...linder head Order Job Parts to remove Q ty Remarks 6 Oil passage plug 2 M 7 N m 0 7 kgf m 5 2 lb ft 1st 3rd 4th 2nd 40 N m 4 0 kgf m 30 lb ft 23 N m 2 3 kgf m 17 lb ft 60 90 10 N m 1 0 kgf m 7 4 lb ft...

Page 208: ...CKING THE VALVE SEATS on page 5 28 Cylinder head coolant passages Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedg...

Page 209: ...lt and washer are lightly seated against the cylinder head e Tighten the bolts to the specified torque in two or three steps in the proper tightening sequence as shown f Loosen the bolt 1 TIP Loosen t...

Page 210: ...olt is completely tightened l Put a mark on the corner of the bolt cylin der head and the cylinder head m Retighten the bolt cylinder head in the proper tightening sequence n Tighten the bolts to the...

Page 211: ...er Job Parts to remove 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...

Page 212: ...THE VALVE SEATS on page 5 28 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves are properly sealed TIP Check that there are no kerosene leaks from the valve seat 1 3 R...

Page 213: ...lve guide installer 1 and the valve guide re mover 2 c After installing the valve guide expand the hole in the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide...

Page 214: ...3 Measure Valve seat contact width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cylinder head c Press the valve throug...

Page 215: ...d Turn the valve until the valve face and the valve seat are evenly polished then clean off all of the lapping compound TIP While turning the valve lapper tap and lap the valve seat e Apply a fine lap...

Page 216: ...the cylinder head TIP Make sure each valve is installed in its original place Install the valve springs with the larger pitch a facing up 4 Install Valve cotter 1 TIP Install the valve cotters by com...

Page 217: ...800 Hitting the valve tip with excessive force could damage the valve 6 Lubricate Adjusting pad 1 Valve lifter 2 7 Install Adjusting pad Valve lifter TIP Check that the valve lifter turns smoothly whe...

Page 218: ...ston Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 20 1 Cylinder body 1 2 Gasket 1 3 Dowel pin 2 4 Piston pin clip 2 5 Piston pin 1 6 Piston 1 7 Piston ring set...

Page 219: ...nd lift the opposite end gap of the piston ring over the piston crown EAM30097 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Sidewall Cylinder wall Vertical scratches Replace the cylinder and r...

Page 220: ...the piston ring near bottom of cylinder a where cylinder wear is lowest 3 Measure Piston ring end gap Out of specification Replace the piston ring TIP The oil ring expander spacer s end gap cannot be...

Page 221: ...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 2 Install Piston 1 Piston pin 2 Piston pin clip 3 TIP Apply the engine oil to the p...

Page 222: ...mpressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide exhaust side through the timing chain cavity a Top ring b 2nd ring c Uppe...

Page 223: ...SSIS on page 4 1 1 Stator coil assembly coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Shift pedal 1 4 Crankcase cover left 1 5 Gasket 1 6 Dowel pin 2 7 Holder 1 8 Stator coi...

Page 224: ...stall Stator coil assembly 1 Screw stator coil assembly 2 Crankshaft position sensor 3 Bolt crankshaft position sensor 4 Holder Bolt holder TIP Apply the sealant to the grommet of the stator coil asse...

Page 225: ...e keyway c of the generator rotor with the woodruff key 3 Install Washer Nut generator rotor 1 4 Install Dowel pin 1 Gasket left crankcase cover 2 Crankcase cover left 3 Lead holder 4 Bolt left crankc...

Page 226: ...arter clutch Order Job Parts to remove Q ty Remarks Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 13 Clutch Refer to CLUTCH on page 5 46 1 Holder 1 2 Washer 1 3 Damper assembly 1 4 Start...

Page 227: ...3 Check Starter clutch operation a Install the starter clutch drive gear 1 onto the starter clutch and hold the starter clutch b When turning the starter clutch drive gear counterclockwise A it should...

Page 228: ...5 6 1 Plastic locking tie 1 2 Starter motor cover upper 1 3 Starter motor 1 4 Starter motor cover lower 1 5 Starter motor lead 1 When removing or installing the installation nut of the starter motor...

Page 229: ...ty Remarks 1 Starter motor assembly 1 2 O ring 1 3 Starter motor front cover 1 4 Starter motor yoke 1 5 Armature assembly 1 6 Gasket 2 7 Brush set 1 8 Brush holder 1 9 Starter motor rear cover 1 2 3...

Page 230: ...asure Brush length a Out of specification Replace the brush set 5 Measure Brush spring force Out of specification Replace the brush set 6 Check Gear teeth Damage wear Replace the starter motor 7 Check...

Page 231: ...he match mark a on the starter motor yoke with the match mark b on the starter mo tor front cover 4 Install Bolt O ring TIP Apply the lithium soap based grease on the O ring 5 Install Starter motor St...

Page 232: ...utch cover 1 3 O ring 1 4 Clutch spring 6 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Washer 1 9 Bearing 1 10 Ball 1 11 Push rod 2 1 12 Friction plate 1 5 Identification color black 13 Clutch plat...

Page 233: ...remove Q ty Remarks 15 Clutch boss 1 16 Thrust washer 1 17 Primary driven gear 1 18 Push lever shaft 1 E E 18 17 16 15 T R LT 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7...

Page 234: ...e 3 13 Coolant Drain Refer to CHANGING THE COOLANT on page 3 21 Brake pedal Refer to ENGINE REMOVAL on page 5 6 Clutch cover Refer to CLUTCH on page 5 46 1 Oil filter element cover 1 2 Oil filter elem...

Page 235: ...CH SPRINGS 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure Clutch spring free length Out of specification Replace the clutch springs as a set EAM30112 CHECKING THE CLUTCH HO...

Page 236: ...gears as a set Excessive noise during operation Replace the primary drive and primary driven gears as a set 2 Check Primary drive gear to primary driven gear free play Free play exists Replace the pri...

Page 237: ...igns with the balancer end slot 4 Tighten the right crankcase cover bolts in stag es and in a crisscross pattern 4 Install Push lever shaft 1 TIP Apply the lithium soap based grease on the oil seal li...

Page 238: ...nd friction plates alter nately on the clutch boss starting with a friction plate and ending with a friction plate From the clutch boss side install the friction plates in order friction plate 1 ident...

Page 239: ...spring bolt TIP Tighten the bolts in stages and in a crisscross pattern 13 Install O ring 1 TIP Apply the lithium soap based grease to the O ring 14 Install Clutch cover Clutch cover bolt TIP Tighten...

Page 240: ...2 Shift shaft 1 3 Oil seal 1 4 Collar 1 5 Shift shaft spring 1 6 Roller 1 7 Shift guide 1 8 Shift lever assembly 1 9 Shift lever 1 10 Pawl 2 11 Pawl pin 2 12 Spring 2 13 Stopper lever 1 14 Stopper le...

Page 241: ...heck Shift shaft 1 Bends damage wear Replace Shift shaft spring 2 Damage wear Replace 2 Check Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear damage Replace EAM30127 CHECKING THE STOPPER L...

Page 242: ...ever assembly to the shift guide 5 Install Shift lever assembly 1 Shift guide 2 TIP The shift lever assembly is installed at the same time as the shift guide 6 Tighten Shift guide bolt 1 7 Install Rol...

Page 243: ...SHIFT SHAFT 5 57 TIP Align the punch mark a on the shift shaft with the punch mark b in the shift pedal 1 1 2 2 a b...

Page 244: ...driven gear Refer to CLUTCH on page 5 46 Right crankcase cover Refer to CLUTCH on page 5 46 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 sha...

Page 245: ...Refer to GENERATOR on page 5 37 1 Nut balancer 1 2 Nut primary drive gear 1 3 Nut balancer weight gear 1 4 Lock washer 1 5 Balancer 1 6 Straight key 1 7 Conical washer 1 8 Primary drive gear 1 9 Bala...

Page 246: ...eplace 4 Check Balancer Crack damage Replace EAM30136 CHECKING THE OIL PUMP 1 Check Oil pump cover Oil pump drive shaft Oil pump housing Cracks damage wear Replace the oil pump assembly 2 Check Oil pu...

Page 247: ...gear 1 TIP Install the balancer weight gear and balancer shaft with their lower splines a aligning with each other 3 Install Balancer drive gear 1 TIP Align the punched mark a on the balancer drive g...

Page 248: ...oil to the contact surfaces of the conical washer Place an aluminum plate a between the teeth of the balancer drive gear 10 and balancer weight gear 11 Install the conical washer with its convex sur f...

Page 249: ...l assembly Refer to GENERATOR on page 5 37 1 Timing chain guide exhaust side 1 2 Timing chain guide stopper plate 1 3 Timing chain 1 4 Bolt 5 L 45 mm 1 77 in 5 Bolt 4 L 60 mm 2 36 in 6 Bolt 3 L 75 mm...

Page 250: ...er to TRANSMISSION on page 5 70 Shift cam Shift fork Refer to TRANSMISSION on page 5 70 1 Circlip 1 2 Oil seal 2 3 Bearing 12 4 Collar 1 E E E E LT LT 1 2 2 3 3 3 3 3 3 3 3 3 3 3 12 N m 1 2 kgf m 8 9...

Page 251: ...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...

Page 252: ...t hammer When installing the crankcase the connecting rod should be positioned at top dead center TDC Tighten the bolts in a crisscross pattern in two stages with 1 4 turn each Installed depth a 0 0 0...

Page 253: ...AND BALANCER SHAFT Removing the crankshaft assembly and balancer shaft Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 63 Transmission Refer to TRANSMISSION on p...

Page 254: ...KSHAFT 1 Measure Crankshaft runout a Out of specification Replace the crank shaft TIP Turn the crankshaft slowly 2 Measure Crank assembly width a Out of specification Replace the crank shaft 3 Check C...

Page 255: ...hium soap based grease In order to prevent the crankshaft seizure apply molybdenum disulfide grease TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the cranks...

Page 256: ...ty Remarks Engine Refer to ENGINE REMOVAL on page 5 6 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 Spr...

Page 257: ...1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WARNING EWA12840 Do not attempt to stra...

Page 258: ...oil to the inner and end surface of the idler gear and to the inner surface of the sliding gear then install 2 Install Collar 1 2nd wheel gear 23T 2 4th wheel gear 24T 3 3rd wheel gear 26T 4 5th wheel...

Page 259: ...kcase simultaneously Apply engine oil to the main axle and the drive axle bearing 6 Install Shift fork 1 L 1 Shift fork 2 C 2 Shift fork 3 R 3 Shift cam 4 to the main axle and the drive axle TIP Apply...

Page 260: ...rk guide bar 2 Spring 3 TIP Screw the spring into the shift fork guide bar lightly beforehand Apply the engine oil on the shift fork guide bars 8 Check Operation of shift cam and shift fork Transmissi...

Page 261: ...10 COOLING SYSTEM COOLING SYSTEM DIAGRAMS 6 1 RADIATOR 6 2 CHECKING THE RADIATOR 6 4 INSTALLING THE RADIATOR 6 4 WATER PUMP 6 6 DISASSEMBLING THE WATER PUMP 6 7 CHECKING THE WATER PUMP 6 7 ASSEMBLING...

Page 262: ...COOLING SYSTEM DIAGRAMS 6 1 EAM20186 COOLING SYSTEM DIAGRAMS 1 Radiator hose 1 2 Radiator right 3 Radiator hose 4 4 Water pump 5 Radiator hose 3 6 Radiator left...

Page 263: ...HASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to THROTTLE BODY on page 7 4 1 Radiator guard 2 2 Radiator hose clamp 8 Loosen 3 Radiator right 1 4 Radiator hose 2 1...

Page 264: ...9 Radiator left 1 10 Radiator hose 1 1 11 Radiator pipe 1 1 12 Coolant temperature sensor 1 11 12 LS LS 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 5 N m 0 15 kg...

Page 265: ...e 3 Check Radiator cap valve opening pressure a Install the radiator cap tester adapter 2 and the radiator cap tester 3 to the radi ator cap 1 and activate the tester to check whether it can stay for...

Page 266: ...s of warm up Make sure that coolant is filled up to the up per level beforehand 5 Check Pressure value No stay for 5 to 10 seconds at the test pres sure value Correct Radiator Radiator hose connection...

Page 267: ...n page 3 21 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 13 Right crankcase cover Refer to CLUTCH on page 5 46 1 Water pump housing 1 2 Dowel pin 2 3 Gasket 1 4 Collar 1 5 Pin 1 6 Impel...

Page 268: ...ce EAM30262 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 TIP Apply the lithium soap based grease on the oil seal lip Install the oil seal with its manufacture s marks or numbers facing the right cra...

Page 269: ...Install Water pump housing 1 Water pump housing bolt 2 Washer 3 Coolant drain bolt 4 Water pump housing bolt 10 N m 1 0 kgf m 7 4 lb ft Coolant drain bolt 10 N m 1 0 kgf m 7 4 lb ft 1 1 1 1 1 2 2 T R...

Page 270: ...WATER PUMP 6 9...

Page 271: ...UEL PUMP 7 2 CHECKING THE FUEL PUMP BODY 7 2 CHECKING THE FUEL PUMP OPERATION 7 2 INSTALLING THE FUEL PUMP 7 2 INSTALLING THE FUEL TANK 7 3 THROTTLE BODY 7 4 CHECKING THE INJECTOR 7 7 CHECKING THE THR...

Page 272: ...ft right Air scoop left right 1 Fuel pump coupler Fuel hose 1 1 Disconnect 2 Fuel tank 1 3 Fuel pump bracket 1 4 Fuel pump 1 5 Fuel pump gasket 1 6 Rubber damper 4 3 6 2 2 4 5 2 7 N m 0 7 kgf m 5 2 lb...

Page 273: ...efore removing the hose place a few cloths in the area under where it will be removed To prevent sand dust and other foreign mate rials from entering the fuel pump install the in cluded fuel hose join...

Page 274: ...Fuel hose NOTICE ECA24740 Connect the fuel hose securely and check that the orientation of the installed fuel hose holder is correct Take care not to kink or pinch the fuel hose TIP Insert the fuel ho...

Page 275: ...Ignition coil 1 3 Intake air temperature sensor coupler 1 Disconnect 4 Air filter case 1 5 Fuel injector coupler 1 Disconnect 6 Intake air pressure sensor coupler 1 Disconnect 7 Throttle position sens...

Page 276: ...icle and then install the cover 11 Fuel hose 1 12 Throttle body 1 13 Exhaust pipe bracket 1 14 Throttle body joint 1 7 N m 0 7 kgf m 5 2 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7...

Page 277: ...the injector Order Job Parts to remove Q ty Remarks 1 Fuel inlet pipe 1 2 Injector 1 3 Gasket 1 4 Throttle position sensor 1 5 Intake air pressure sensor 1 1 2 2 5 4 3 3 5 N m 0 35 kgf m 2 6 lb ft 3...

Page 278: ...f the throttle body is subject to strong shocks or dropped during cleaning re place it Do not use any caustic carburetor cleaning solution Do not directly push the throttle valves to open them Do not...

Page 279: ...sor Refer to CHECKING THE THROTTLE PO SITION SENSOR INPUT VOLTAGE on page 8 52 2 Adjust Throttle position sensor angle a Connect the Yamaha diagnostic tool Refer to YAMAHA DIAGNOSTIC TOOL on page 8 17...

Page 280: ...THROTTLE BODY 7 9...

Page 281: ...NENTS 8 42 CHECKING THE SWITCHES 8 43 CHECKING THE FUSES 8 45 CHECKING AND CHARGING THE BATTERY 8 45 CHECKING THE RELAYS 8 47 CHECKING THE RELAY UNIT DIODE 8 47 CHECKING THE IGNITION SPARK GAP 8 48 CH...

Page 282: ...Sb Lg Br W L B R L P Y R B R Y B B W B O P B Sb P Y B Sb P Y W L L G L G Br Br W L W W Br G Y W B B B W B R R L Y R Y G B R L B Lg W G R B B B O B B B Gy ON OFF ON OFF ON OFF B B B B B Lg W G R B L Gy...

Page 283: ...Frame ground 9 Fuse 10 Starter relay 11 Starter motor 12 Diode 1 13 Diode 2 14 CCU Communication Control Unit 16 ECU Engine Control Unit 17 Ignition coil 18 Spark plug 25 Engine stop switch 26 Mode s...

Page 284: ...page 8 45 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 12 NG Correct or replace the spark plug OK 5 Check the ign...

Page 285: ...8 1 NG Repair or replace the wire harness OK Replace the ECU 1 Check the launch control switch coupler connections NG Reconnect OK 2 Check the gear position switch cou pler connections NG Reconnect O...

Page 286: ...the mode switch Refer to CHECKING THE SWITCHES on page 8 43 NG Replace the mode switch OK 3 Check the ignition system wire har ness Refer to CIRCUIT DIAGRAM on page 8 1 NG Repair or replace the wire...

Page 287: ...IGNITION SYSTEM 8 6...

Page 288: ...ELECTRIC STARTING SYSTEM 8 7 EAM20143 ELECTRIC STARTING SYSTEM EAM30279 CIRCUIT DIAGRAM...

Page 289: ...Main relay 6 Battery 7 Engine ground 8 Frame ground 9 Fuse 10 Starter relay 11 Starter motor 12 Diode 1 13 Diode 2 16 ECU Engine Control Unit 25 Engine stop switch 27 Gear position switch 29 Start swi...

Page 290: ...E RE LAYS on page 8 47 NG Replace the main relay OK 4 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 50 OK Starter motor is OK Perform the electric starting...

Page 291: ...rt switch Refer to CHECKING THE SWITCHES on page 8 43 NG Replace the start switch OK 10 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 7 NG Properly connect or repair the...

Page 292: ...CHARGING SYSTEM 8 11 EAM20144 CHARGING SYSTEM EAM30282 CIRCUIT DIAGRAM...

Page 293: ...CHARGING SYSTEM 8 12 2 AC magneto 3 Rectifier regulator 6 Battery 7 Engine ground 8 Frame ground 9 Fuse A Battery sub lead B Wire harness...

Page 294: ...attery Refer to CHECKING AND CHARGING THE BATTERY on page 8 45 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULA...

Page 295: ...CHARGING SYSTEM 8 14...

Page 296: ...FUEL INJECTION SYSTEM 8 15 EAM20145 FUEL INJECTION SYSTEM EAM30284 CIRCUIT DIAGRAM Sb P Y W...

Page 297: ...Control Unit 15 Yamaha diagnostic tool coupler 16 ECU Engine Control Unit 17 Ignition coil 18 Spark plug 19 Fuel injector 20 Fuel pump 21 Intake air temperature sensor 22 Coolant temperature sensor 2...

Page 298: ...I diagnostic tool sub lead to the Yamaha diagnostic tool WARNING EWA20450 Never connect the sub lead special tool to the battery Otherwise because of excessive cur rent flow the sub lead can catch fir...

Page 299: ...it 2 Lead battery 12 V 3 Vehicle battery 4 Vehicle 5 Coupler for connecting optional part 6 FI diagnostic tool sub lead 7 Sub harness included with the Yamaha diag nostic tool 8 Vehicle communication...

Page 300: ...Item Crankshaft position sensor no normal signals are received from the crankshaft position sensor Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No Diagnostic tool d...

Page 301: ...of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Defective crankshaft position sensor Check the crankshaft position sensor...

Page 302: ...e using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 4 4 Mounted condition of intake air pressure sens...

Page 303: ...ensor hose Start the engine and let it idle for approximately 5 seconds fully close the throttle valve Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Co...

Page 304: ...r Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or bro ken terminals and locking condi tion of the pins Improperly connected Con nect the coupler secure...

Page 305: ...ned 86 92 displays Incorrect display range Replace the throttle position sensor Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamah...

Page 306: ...stic tool Condition is Recovered Go to item 4 and finish the service Condition is Detected Go to item 3 3 Faulty ECU Replace the ECU Service is finished 4 Delete the fault code Confirm that the fault...

Page 307: ...condition of coolant temperature sensor Check for looseness or pinch ing Check the mounted position for correctness Improperly mounted sensor Remount or replace the sensor Start switch to ON main rela...

Page 308: ...tected Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or bro ken terminals and locking condi tion o...

Page 309: ...nable to drive vehicle Diagnostic code No 08 Diagnostic tool display Displays the lean angle sensor output voltage 0 4 1 4 V upright 3 7 4 4 V overturned Procedure Remove the ECU and incline it 45 or...

Page 310: ...ion 1 Connection of ignition coil cou pler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or bro ken terminals and locking condi tion of the pins Imprope...

Page 311: ...of ignition coil Check for looseness or pinch ing Check the mounted condition for correctness Improperly mounted sensor Remount or replace the ignition coil Start the engine and let it idle for approx...

Page 312: ...he injector Refer to CHECKING THE INJECTOR on page 8 53 Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diag...

Page 313: ...and CCU Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 09 Diagnostic tool display Fuel system voltage Approximately 12 0 V Procedure Disconnect the main relay and push...

Page 314: ...e engine stop switch alternately to switch the power supply main relay from ON OFF ON Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recove...

Page 315: ...ion Change the CO concentration and rewrite in EEPROM After this adjustment push the engine stop switch and then push the start switch Start switch to ON main relay ON and then check the condi tion of...

Page 316: ...nd locking condition of the pins Improperly connected Con nect the coupler securely or repair replace the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition...

Page 317: ...de No Diagnostic tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Faulty ECU Replace the ECU Start switch to ON main relay ON...

Page 318: ...he fault code Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No 70 Item Engine forcibly stops when the vehicle is l...

Page 319: ...FUEL INJECTION SYSTEM 8 38...

Page 320: ...FUEL PUMP SYSTEM 8 39 EAM20146 FUEL PUMP SYSTEM EAM30287 CIRCUIT DIAGRAM...

Page 321: ...gneto 3 Rectifier regulator 4 Joint connector 6 Battery 7 Engine ground 8 Frame ground 9 Fuse 16 ECU Engine Control Unit 20 Fuel pump 25 Engine stop switch A Battery sub lead B Wire harness C Ignition...

Page 322: ...on page 8 45 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 45 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the engine s...

Page 323: ...ure sensor 3 Throttle position sensor 4 Injector 5 Launch control switch 6 Mode switch 7 Intake air temperature sensor 8 ECU Engine Control Unit 9 Ignition coil 10 CCU Communication Control Unit 11 St...

Page 324: ...43 EAM30289 CHECKING THE SWITCHES Y W P Sb B Lg W G R ON OFF ON OFF B Lg W G R 4 1 2 5 3 P Sb Lg B W G R Y W B W G Lg R 1 Engine stop switch 2 Mode switch 3 Launch control switch 4 Gear position switc...

Page 325: ...ecking for continuity switch back and forth between the switch positions a few times Terminal connections of the switch are shown in the terminal connection diagram below The switch positions a are sh...

Page 326: ...visibly damaged Do not disassemble or modify the battery or short across its terminals NOTICE ECA26041 To prevent damage to the battery and battery malfunction Be sure to charge the battery using only...

Page 327: ...nect the positive battery lead and then the negative battery lead 8 Check Battery terminal Dirt Clean with a wire brush Loose connection Connect properly 9 Lubricate Battery terminal 10 Install Seat S...

Page 328: ...the relay from the wire harness 2 Connect the digital circuit tester and bat tery 12 V to the relay terminal as shown Check the relay operation Out of specification Replace Starter relay Main relay EA...

Page 329: ...CHECKING THE SPARK PLUG CAP 1 Remove Spark plug cap from the spark plug lead 2 Check Spark plug cap resistance Out of specification Replace a Connect the digital circuit tester to the spark plug cap...

Page 330: ...e wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace a Connect the digital circuit tester to the crankshaft position sensor coupler Digital circuit tester CD732 90...

Page 331: ...t is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or f...

Page 332: ...ntainer filled with coolant TIP Make sure the coolant temperature sensor ter minals do not get wet c Place a thermometer in the coolant d Slowly heat the coolant and then let it cool to the specified...

Page 333: ...emperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification Replace a Connect the digital circui...

Page 334: ...achom eter YU A1927 Continuity Positive tester probe Sky blue 1 Negative tester probe Sensor terminal a Continuity Positive tester probe Pink 2 Negative tester probe Sensor terminal b Continuity Posit...

Page 335: ...9 6 TROUBLESHOOTING OF COOLING SYSTEM 9 7 TROUBLESHOOTING OF BRAKE 9 8 TROUBLESHOOTING OF SUSPENSION 9 8 TROUBLESHOOTING OF STEERING HANDLING 9 10 TROUBLESHOOTING OF CHARGING SYSTEM 9 11 SELF DIAGNOS...

Page 336: ...TEM on page 8 7 Starter motor operates but the engine does not crank Starter clutch malfunction Replace the starter clutch Improper oil grade starter clutch slipping Change to recommended engine oil S...

Page 337: ...ace the piston and piston rings as a set Seized or damaged piston Replace the piston and piston rings as a set Worn or damaged cylinder bore Replace the cylinder piston and piston rings as a set Sympt...

Page 338: ...ecified torque Clogged air filter element Clean or replace the air filter ele ment Incorrect oil level high Adjust the oil level to the specified level Symptom Possible cause Actions Noise heard from...

Page 339: ...ve gear Replace the balancer drive gear and balancer shaft as a set Worn or damaged big end bearing Replace the big end bearing Worn or damaged crankshaft jour nal bearing Replace the crankshaft journ...

Page 340: ...bushing Replace the clutch housing Improperly installed pull lever Align the match mark on the pull lever before installation Incorrect oil level Adjust the engine oil level to the specified level Inc...

Page 341: ...ransmis sion gears Remove foreign object from trans mission gears Seized transmission gear Replace the seized gear and the axle as a set Improperly assembled transmis sion Reassemble the transmission...

Page 342: ...epair the radiator fin or replace the radiator Damaged or faulty water pump Replace the water pump Damaged hoses or pipes Replace the hose or pipe Improperly connected hoses or pipes Connect the hoses...

Page 343: ...Damaged brake hose and brake pipe Replace the brake hose and brake pipe Oil or grease on the brake disc or brake pad Clean the brake disc or brake pad Insufficient lubrication of brake lever or brake...

Page 344: ...er rod assembly bolt Tighten the damper rod assembly bolt to the specified torque Damaged damper rod assembly bolt copper washer Replace the damper rod assembly bolt copper washer Cracked or damaged c...

Page 345: ...ed torque Worn bearing or bearing race Replace the bearing and bearing race as a set Warped front fork Repair or replace the front fork Bent front wheel axle Replace the front wheel axle Incorrect tir...

Page 346: ...e Loose wheel axle nut Tighten the wheel axle nut to the specified torque Loose swingarm pivot shaft Tighten the swingarm pivot shaft to the specified torque Bent or damaged swingarm Replace the swing...

Page 347: ...ead of the ignition coil 8 29 39 Injector open or short circuit detected 8 31 41 ECU built in lean angle sensor malfunction 8 32 43 Fuel system voltage incorrect voltage supplied to the main relay and...

Page 348: ...perate the shift pedal Gear in 1st or 2nd ON Gear in other than 1st or 2nd OFF 60 EEPROM fault code display No fault 00 CO adjustment valve 01 Power Tuner injection cor rection setting 0 8 or Power Tu...

Page 349: ...er Displays a program version No 79 Gear position switch 2 Operate the shift pedal Gear in 3 5th ON Gear in other than 3 5th OFF Diag nostic code No Item Actuation Procedure 30 Ignition coil Actuates...

Page 350: ...SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 15...

Page 351: ...1 FRONT FORK SETTING 10 2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL 10 2 SETTING OF SPRING AFTER REPLACEMENT 10 2 FRONT FORK SETTING PARTS 10 3 REAR SUSPENSION SETTING 10 3 CHOOSING SET LENGTH...

Page 352: ...e end of the straight line with care taken to avoid the en gine over revving TIP Riding technique varies from rider to rider and the performance of a machine also vary from machine to machine Therefor...

Page 353: ...air spring characteristics to have a ten dency to be stiffer with the consequent dete riorated performance and characteristics Therefore adjust the front fork within the specified range EAM30173 SETT...

Page 354: ...h a between the rear wheel axle center and the rear fender holding bolt 2 Remove the stand or block from the engine and with a rider astride the seat measure the sunken length b between the rear wheel...

Page 355: ...compression damping force WARNING EWA19200 When using a rear shock absorber other than currently installed use the one whose overall length a does not exceed the stan dard as it may result in faulty p...

Page 356: ...ORBER AS SEMBLY on page 3 30 Spring preload adjusting positions Minimum Position in which the spring is turned in 1 5 mm 0 06 in from its free length Standard Position in which the spring is turned in...

Page 357: ...ticeable scars etc If any replace affected parts Slide metal Replace with a new one for extended use Piston metal Replace with a new one for extended use Lower bracket tightening torque Retighten to s...

Page 358: ...unt Increase oil amount by about 5 cm 0 2 US oz 0 2 Imp oz Obtrusive front tending to upper front posture Compression damping force Turn adjuster counterclockwise about 2 clicks to decrease damping Ba...

Page 359: ...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 360: ...CHASSIS 10 9...

Page 361: ...air pressure sensor 25 Engine stop switch 26 Mode switch 27 Gear position switch 28 Launch control switch 29 Start switch 30 Diode 3 A Battery sub lead B Wire harness C Ignition coil sub lead D CCU su...

Page 362: ......

Page 363: ...nce Buy with confidence knowing your Genuine Yamaha Accessories will fit right and perform right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care...

Page 364: ......

Page 365: ...Y G B R L B Lg W G R B B B B O B B B Gy B B B DL ON OFF ON OFF ON OFF ON OFF B B Gy B B B Lg W G R B L Gy W W B R R Br L R B r L R R W R L R B B B B B B B R Y R W Br W Br Br W L L G L W L B L R L B L...

Page 366: ...YZ450FN 2022 WIRING DIAGRAM B2W 2819U 12_W D indd 2 2021 01 26 11 09 29...

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