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Yamaha YZ450FP 2023, Owner'S Service Manual


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REAR BRAKE

4-36

The minimum level mark or below 

 Add.

Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-24.

7. Check:

•

Brake pedal operation
A softy or spongy feeling 

 Bleed the brake

system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-26.

EAM30048

REMOVING THE REAR BRAKE MASTER 

CYLINDER

TIP

Before removing the rear brake master cylinder,
drain the brake fluid from the entire brake sys-
tem.

1. Remove:

•

Union bolt

•

Copper washer

•

Brake hose

TIP

To drain any remaining brake fluid, place a con-
tainer under the master cylinder and the end of
the brake hose.

EAM30049

CHECKING THE REAR BRAKE MASTER 

CYLINDER

1. Check:

•

Brake master cylinder “1”
Damage/scratches/wear 

 Replace.

•

Brake fluid delivery passages “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 cylinder reservoir diaphragm
Crack/damage 

 Replace.

3. Check:

•

Brake hose
Cracks/damage/wear 

 Replace.

EAM30050

ASSEMBLING THE REAR BRAKE MASTER 

CYLINDER

WARNING

EWA13520

• 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 with brake

fluid.

2. Install:

•

Primary cylinder cup “1”

•

Secondary cylinder cup “2”
(to the brake master cylinder piston “3”)

WARNING

EWA19300

Apply brake fluid to the cylinder cups and in-

stall them as shown. Wrong orientation in in-

stallation causes poor braking performance.

3. Install:

•

Spring “1” 
(to the brake master cylinder piston “2”)

1

2

Specified brake fluid

DOT 4

2

3

1

2

3

1

Summary of Contents for YZ450FP 2023

Page 1: ...BHR 2819U 10 LIT 11626 36 32 Read this manual carefully before operating this vehicle YZ450FP OWNER S SERVICE MANUAL YZ450F 2023...

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: ...ANUAL 2023 by Yamaha Motor Corporation U S A First edition July 2022 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: ...NT INFORMATION 1 9 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 9 REPLACEMENT PARTS 1 9 GASKETS OIL SEALS AND O RINGS 1 9 LOCK WASHERS PLATES AND COTTER PINS 1 10 BEARINGS AND OIL SEALS 1 10 CIRCLIPS 1 1...

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

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: ...3FB 2415E 03 4AA 22259 80 WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open 17D 2812P 00 For...

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

Page 18: ...positive 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 vehicl...

Page 19: ...the illus tration EAM30007 FUEL HOSE JOINT COVER The fuel hose joint covers 1 are used to pre vent mud dust and other foreign materials from entering the inside when the fuel hose is discon nected EAM...

Page 20: ...ong radio waves or other electromagnet ic noise There are facilities nearby that are emitting strong radio waves TV or radio towers power plants broadcasting stations air ports etc You are carrying or...

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: ...ystem TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never insert the tester probes into the cou pler terminal slots Always insert the pr...

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 tacho...

Page 28: ...49 4 51 4 55 4 56 Cap bolt wrench 90890 01911 4 49 4 51 Fork seal driver 90890 01502 Fork seal driver 48 YM A0948 4 53 4 53 Valve spring compressor 90890 04200 Valve spring compressor YM 04019 5 24 5...

Page 29: ...ve guide reamer 5 5 mm YM 01196 5 26 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 31 Rotor puller 90890 04151 Rotor puller YM 04151 5 38 Yamaha bond No 1215 90890 85505 Three bond No...

Page 30: ...haft installer pot 90890 01274 Installing pot YU 90058 5 74 Crankshaft installer bolt 90890 01275 Bolt YU 90060 5 74 Adapter M12 90890 01278 Adapter 3 YU 90063 5 74 Spacer crankshaft installer 90890 0...

Page 31: ...YU 33984 6 4 6 4 Pressure gauge 90890 03153 Pressure gauge YU 03153 7 8 Fuel pressure adapter 90890 03186 Fuel pressure adapter YM 03186 7 8 Lithium battery charger 90890 05376 Lithium battery charge...

Page 32: ...SPECIAL TOOLS 1 20 Test harness S pressure sensor 3P 90890 03207 Test harness S pressure sensor 3P YU 03207 8 53 Tool name Tool No Illustration Reference pages...

Page 33: ...from a stationary position This can be used to starting off in a stable man ner on a slippery road surface However the effect may not be adequate de pending on the rider s operations and road sur fac...

Page 34: ...stop mea suring TIP The indicator light 2 flashes blue while the lap time record mode is on Drive mode cannot be changed while in lap time record mode Measurement results can be received and saved on...

Page 35: ...lied by the starter knob 1 Pushing the knob toward a turns ON the start er resulting in a larger angle of throttle valve TIP When operating the throttle grip in the closing di rection the starter knob...

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

Page 40: ...HTENING TORQUES on page 2 9 Shift pedal Shift pedal to shift shaft Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of shroud Tightening of side cover Tightening of...

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

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 BHR1 BHR5 Dimensions Overall length 2180 mm 85 8 in Overall width 825 mm 32 5 in Overall height 1275 mm 50 2 in Seat height 965 mm 38 0 in Wheelbase 1480 mm 58 3 in Ground clearance 350 mm 13...

Page 47: ...96 L 1 01 US qt 0 84 Imp qt Quantity disassembled 1 20 L 1 27 US qt 1 06 Imp qt Oil filter Oil filter type Cartridge Cooling system Coolant quantity Radiator including all routes 1 03 L 1 09 US qt 0 9...

Page 48: ...inder clearance 0 010 0 045 mm 0 0004 0 0018 in Diameter 96 955 96 970 mm 3 8171 3 8177 in Measuring point from piston skirt bottom 9 0 mm 0 35 in Piston pin bore inside diameter limit 18 045 mm 0 710...

Page 49: ...67 27 Transmission type Constant mesh 5 speed Gear ratio 1st 2 000 28 14 2nd 1 625 26 16 3rd 1 350 27 20 4th 1 136 25 22 5th 1 000 21 21 Main axle runout limit 0 08 mm 0 0032 in Drive axle runout lim...

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: ...e from the start position Soft 20 Adjustment value from the start position STD 10 Adjustment value from the start position Hard 0 Rear suspension Type Swingarm link suspension Spring Coil spring Shock...

Page 52: ...Click Adjustment value from the start position Soft 20 Adjustment value from the start position STD 10 Adjustment value from the start position Hard 0 Drive chain Size 520 Chain type Non sealed type...

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

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: ...chain guide stopper plate exhaust side M6 1 10 N m 1 0 kgf m 7 4 lb ft Timing chain tensioner cap bolt M6 1 6 N m 0 6 kgf m 4 4 lb ft Timing chain tensioner bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Coola...

Page 56: ...f m 7 4 lb ft Timing mark accessing screw M14 1 6 N m 0 6 kgf m 4 4 lb ft Drive sprocket cover bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Crankcase bearing cover plate screw M8 4 30 N m 3 0 kgf m 22 lb ft Be...

Page 57: ...threads and seats as well as to both sides of the plain washers Stopper lever bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft Shift pedal bolt M6 1 12 N m 1 2 kgf m 8 9 lb ft Generator rotor nut M12 1 65 N m 6 5...

Page 58: ...b M4 2 0 6 N m 0 06 kgf m 0 44 lb ft Front fork protector bolt M6 6 7 N m 0 7 kgf m 5 2 lb ft Brake hose holder bolt M6 2 9 N m 0 9 kgf m 6 6 lb ft Screw throttle cable housing M5 2 3 8 N m 0 38 kgf m...

Page 59: ...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 5 3 k...

Page 60: ...Side cover bolt left M6 2 7 N m 0 7 kgf m 5 2 lb ft Side cover bolt right M6 2 7 N m 0 7 kgf m 5 2 lb ft Shroud bolt frame M6 2 7 N m 0 7 kgf m 5 2 lb ft Shroud bolt air filter case M6 2 7 N m 0 7 kgf...

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

Page 62: ...G DIAGRAM 2 17 EAM20152 CABLE ROUTING DIAGRAM Frame and engine front left side view 1 12 11 18 17 K 1 2 3 J 16 11 N 9 12 N 1 M O 14 H 12 G F 13 E 12 11 7 10 D 9 C 8 B 6 15 I P 1 2 3 6 Q 21 20 L 19 4 A...

Page 63: ...t between the radiator and the gear position switch 3 pin coupler white G Pass the stator coil assembly lead behind the radiator Be sure the lead will not be pinched between the radiator and the tensi...

Page 64: ...CABLE ROUTING DIAGRAM 2 19 Frame rear left side view G 1 2 3 A 4 5 B 6 C 7 8 10 D 11 E 12 F 13 14 10 11 H 2 5 1 9...

Page 65: ...then cut off the end B Route the starter motor lead between the starter relay and the rear fender Adjust any slack between the starter relay and the plas tic locking tie of the rear frame C Route the...

Page 66: ...CABLE ROUTING DIAGRAM 2 21 Frame and engine right side view 1 A B 2 C 3 4 D 5 6 E 7 9 8 13 12 10 1 11...

Page 67: ...n installing the engine ground lead termi nal it can face either way Point the engine ground lead to the upper side of the vehicle and then install it C After connecting the water temperature sen sor...

Page 68: ...CABLE ROUTING DIAGRAM 2 23 Handlebar front view 6 5 D 4 3 2 B 1 A 8 F H I 5 10 G 7 E 8 7 E 2 3 9 C J...

Page 69: ...the start switch lead and handlebar switch lead left to the handlebar using the plastic locking tie Point the lock portion of the plastic locking tie to the upper part of the vehicle while pointing th...

Page 70: ...CABLE ROUTING DIAGRAM 2 25 Frame and engine top view 1 A B 2 3 4 6 C 7 14 9 I D E 10 F 11 12 13 G 14 8 C 8 9 5 H...

Page 71: ...l of the ignition coil and the white cover to the green terminal B Route the coolant temperature sensor lead engine ground lead and high tension cord outside the vehicle past the cylinder head breathe...

Page 72: ...CABLE ROUTING DIAGRAM 2 27 Frame and battery top view 2 1 B 5 4 3 A 7 4 E 6 D 2 3 C...

Page 73: ...positive battery lead under the vehicle s negative battery lead B Point the terminal of the negative battery lead to the inside of the vehicle and install it C After connecting the positive battery l...

Page 74: ...CABLE ROUTING DIAGRAM 2 29 Rear brake right side view 8 C C C D D E E F G B H 4 3 2 1 7 6 5 A A...

Page 75: ...that it is not bent as shown by the double dash line D Route the rear brake hose and spring so that they do not interfere with each other E Make sure that the rear brake hose is not excessively twist...

Page 76: ...CABLE ROUTING DIAGRAM 2 31...

Page 77: ...3 19 CHECKING THE EXHAUST SYSTEM 3 19 CHECKING THE COOLANT LEVEL 3 21 CHECKING THE COOLING SYSTEM 3 22 CHANGING THE COOLANT 3 22 CHASSIS 3 24 ADJUSTING THE FRONT DISC BRAKE 3 24 ADJUSTING THE REAR DI...

Page 78: ...WHEEL BEARINGS 3 34 CHECKING THE CHASSIS FASTENERS 3 34 CHECKING AND LUBRICATING THE CABLES 3 34 LUBRICATING THE BRAKE LEVER 3 35 LUBRICATING THE CLUTCH LEVER 3 35 LUBRICATING THE PEDAL 3 35 ELECTRIC...

Page 79: ...from a Yamaha dealer by stating the identification number of your vehicle Ref No Part No Part name in parts catalog Q ty 1 B2W 25805 00 BRAKE PAD KIT 1 2 94701 00434 PLUG SPARK NGK LMAR8G 1 3 B2W 839...

Page 80: ...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 81: ...ctor Check for exhaust leaks and tightening torques Clean Replace fiver When the exhaust sound becomes louder or when a perfor mance drop is felt 20 Crankshaft Inspect and clean 21 Throttle body Inspe...

Page 82: ...Inspect lube and retighten 34 Relay arm connect ing rod Inspect lube and retighten 35 Steering head Inspect free play and retighten Check for tightening torques Clean and lube After rain ride Replace...

Page 83: ...otrest Lubricate 43 Outside nuts and bolts Retighten 44 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 84: ...4 3 24 3 24 3 25 3 25 3 25 3 26 3 26 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 27 4 75 4 75 4 76 4 76 4 76 Wheels Check for excessive wear a...

Page 85: ...cover left right Shroud left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 2 Remove Spark plug Cylinder head cover Refer to CAMSHAFT on page 5 10 3 Remove Timing...

Page 86: ...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 87: ...ir numbers facing upward f Install the camshafts exhaust and intake Refer to CAMSHAFT on page 5 10 g Measure the valve clearance again h If the valve clearance is out of specifica tion repeat adjustin...

Page 88: ...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 89: ...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 90: ...tachom eter 4 Measure Engine idling speed Out of specification Regulate 5 Adjust Engine idling speed a Turn the idle screw 1 to make an adjust ment EAM30475 CHECKING THE THROTTLE GRIP TIP Prior to adj...

Page 91: ...bnormal color Replace the spark plug Normal color is medium to light tan 5 Clean Spark plug with a spark plug cleaner or a wire brush 6 Measure Spark plug gap a Out of specification Adjust the spark p...

Page 92: ...f 6 Check the engine oil level again TIP Before checking the engine oil level wait a few minutes until the oil has settled EAM30225 CHANGING THE ENGINE OIL 1 Stand the vehicle upright on a level surfa...

Page 93: ...gine oil level does not decrease after the engine has been started immediately turn the engine off Otherwise the engine could seize c If the engine oil level does not decrease at the specified level m...

Page 94: ...juster 2 to adjust the clutch lever position a as desired 2 Tighten Locknut EAM30219 CLEANING THE AIR FILTER ELEMENT 1 Remove Sub seat Refer to FUEL TANK CAP on page 1 23 Air filter case cover 1 TIP T...

Page 95: ...a plastic bag and drip the filter oil into the bag b With the element inside the bag rub it thoroughly so that the element is evenly permeated with the oil c Wrap the element in a clean cloth rub the...

Page 96: ...the fuel tank breather hose end with the protector into the steering shaft hole Fit the other end of the fuel tank breather hose into the projection on the fuel tank cap Route the fuel tank breather h...

Page 97: ...on Connect properly NOTICE ECA14920 Make sure the cylinder head breather hose is routed correctly EAM30221 CHECKING THE EXHAUST SYSTEM 1 Remove Exhaust pipe 1 Exhaust pipe 2 Refer to ENGINE REMOVAL on...

Page 98: ...in the beads of sealant g Install the fiber 10 TIP Stuff the fiber into the silencer body by using a flat board 11 h Install the fiber insert 12 to the inner pipe i Install the fiber insert 13 to the...

Page 99: ...r cap and slowly turn the radiator cap counter clockwise toward the detent to allow any re sidual pressure to escape When the hissing sound has stopped press down on the radi ator cap and turn it coun...

Page 100: ...the en gine is hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the rad...

Page 101: ...ifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is...

Page 102: ...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 103: ...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 16 EAM30232 CHECKING THE REAR BRAKE PADS The following proced...

Page 104: ...servoir diaphragm Reservoir float front brake Protector rear brake TIP Be careful not to spill any brake fluid or allow the reservoir to overflow Make sure that there is enough brake fluid be fore app...

Page 105: ...ts Checking the drive chain slack 1 Use a maintenance stand to raise the rear wheel off the ground WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Shift t...

Page 106: ...ck that it moves smoothly c Turn the front fork to the right and left a few times and make sure that the steering ro tates smoothly If it does not turn smooth ly remove the lower bracket and check the...

Page 107: ...n hard on the handlebar several times and check if the front fork rebounds smoothly Unsmooth operation Correct or replace Refer to FRONT FORK on page 4 46 5 Check Protector guide 1 Out of specificatio...

Page 108: ...m may not exactly match the above specifications due to small dif ferences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it woul...

Page 109: ...HOCK ABSORBER ASSEMBLY Use a maintenance stand to raise the rear wheel off the ground WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over Spring preload NOTICE...

Page 110: ...ts adjusting range 1 Adjust Compression damping for fast compression damping a Turn the adjuster 1 in the direction of a or b to make an adjustment TIP To obtain a precise adjustment it is advisable t...

Page 111: ...r Refer to INSTALLING THE SWINGARM on page 4 72 EAM30501 CHECKING THE CONNECTING ARM AND RELAY ARM Refer to CHECKING THE CONNECTING ARM AND RELAY ARM on page 4 67 EAM30243 CHECKING THE TIRES 1 Measure...

Page 112: ...wheel EAM30246 CHECKING THE WHEEL BEARINGS 1 Check Wheel bearing Refer to CHECKING THE FRONT WHEEL on page 4 8 and CHECKING THE REAR WHEEL on page 4 13 EAM30253 CHECKING THE CHASSIS FASTENERS Make su...

Page 113: ...ts Brake lever EAM30503 LUBRICATING THE CLUTCH LEVER 1 Lubricate the pivoting points and metal to metal moving parts of the following parts Clutch lever EAM30250 LUBRICATING THE PEDAL 1 Lubricate the...

Page 114: ...L SYSTEM 3 36 EAM20137 ELECTRICAL SYSTEM EAM30256 CHECKING AND CHARGING THE BATTERY Refer to CHECKING AND CHARGING THE BATTERY on page 8 47 EAM30505 CHECKING THE FUSES Refer to CHECKING THE FUSES on p...

Page 115: ...CING THE FRONT BRAKE PADS 4 20 REMOVING THE FRONT BRAKE CALIPER 4 22 DISASSEMBLING THE FRONT BRAKE CALIPER 4 22 CHECKING THE FRONT BRAKE CALIPER 4 22 ASSEMBLING THE FRONT BRAKE CALIPER 4 22 INSTALLING...

Page 116: ...AD 4 60 REAR SHOCK ABSORBER ASSEMBLY 4 63 HANDLING THE REAR SHOCK ABSORBER 4 66 DISPOSING OF A REAR SHOCK ABSORBER 4 66 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 66 CHECKING THE REAR SHOCK ABSORBER...

Page 117: ...Side cover left 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 CCU Communication Control Unit 1 10 Holder 1 13 N...

Page 118: ...ob Parts to remove Q ty Remarks 1 Side cover right 1 2 Rear fender 1 3 ECU Engine Control Unit 1 4 Holder 1 13 N m 1 3 kgf m 9 6 lb ft 7 N m 0 7 kgf m 5 2 lb ft 16 N m 1 6 kgf m 12 lb ft 7 N m 0 7 kgf...

Page 119: ...move Q ty Remarks 1 Air filter case cover 1 Refer to CLEANING THE AIR FILTER ELE MENT on page 3 16 2 Shroud left 1 3 Shroud right 1 4 Number plate 1 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft...

Page 120: ...mber plate Number plate 1 TIP Remove the brake hose 2 from the upper guide a and the lower guide b on the num ber plate The projection c on the number plate is insert ed into the front fender Remove t...

Page 121: ...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 122: ...ve Q ty Remarks Use a maintenance stand to raise 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 left 1 6 C...

Page 123: ...FRONT WHEEL 4 7 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Bearing 2 3 Brake disc 1 LS LS 12 N m 1 2 kgf m 8 9 lb ft 1 2 3 1 2 6 0 mm 0 in...

Page 124: ...wheel ax le 2 Check Tire Front wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 33 and CHECKING THE WHEELS on page 3 34 3 Check Spoke Refer to CHECKING AND TIGHTENING THE SPOKES on pag...

Page 125: ...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 126: ...el 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 127: ...emarks Use a maintenance stand to raise the rear wheel off the ground 1 Rear wheel axle nut 1 2 Rear wheel axle 1 3 Drive chain puller left 1 4 Drive chain puller right 1 5 Rear wheel 1 6 Collar 2 21...

Page 128: ...the rear wheel Order Job Parts to remove Q ty Remarks 1 Rear wheel sprocket 1 2 Oil seal 2 a Approx 1 0 mm 0 04 in 3 Circlip 1 4 Bearing 3 5 Brake disc 1 12 N m 1 2 kgf m 8 9 lb ft 42 N m 4 2 kgf m 31...

Page 129: ...eck Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 33 and CHECKING THE WHEELS on page 3 34 3 Check Spoke Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 34 4 Measure R...

Page 130: ...ter 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 bolts in stages and in a crisscro...

Page 131: ...l 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 27 6 Tighten...

Page 132: ...1 Union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Brake pad pin plug 1 5 Brake pad pin 1 6 Brake pad 2 7 Brake pad spring 1 8 Front brake caliper assembly 1 9 Front brake caliper bracket 1 10 Br...

Page 133: ...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 S BF S S S BF 5 N m 0 5 kg...

Page 134: ...aster cylinder reservoir cap 1 Adjust the front brake master cylinder so that the top a of the brake master cylinder reservoir cap is horizontal 6 Brake master cylinder reservoir diaphragm 1 7 Front b...

Page 135: ...FRONT BRAKE 4 19 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 New BF S 1...

Page 136: ...ediate 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 few dif ferent loca...

Page 137: ...all the brake pads 3 and the pad pin TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point e Install the brake caliper 4 a...

Page 138: ...areful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston dust seal and the brake caliper piston se...

Page 139: ...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 f...

Page 140: ...ter cylinder assembly Brake fluid delivery passages 2 brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder reservoir cap Damage scratches wear Replace 3 Ch...

Page 141: ...39 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 lowe...

Page 142: ...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...

Page 143: ...REAR WHEEL on page 4 11 1 Protector 1 2 Union bolt 1 3 Copper washer 2 4 Rear brake hose 1 5 Brake pad pin plug 1 6 Brake pad pin 1 7 Rear brake pad assembly 2 8 Rear brake caliper bracket 1 9 Brake...

Page 144: ...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 S BF 5 N m 0 5 kgf m...

Page 145: ...ove Q ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 26 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 FWD FWD 30 N m 3 0 kgf m 22 lb ft 10 N m 1 0 kgf m 7 4 lb f...

Page 146: ...Pin 1 7 Brake master cylinder reservoir cap 1 8 Brake master cylinder reservoir diaphragm plate 1 9 Brake master cylinder reservoir diaphragm 1 10 Rear brake master cylinder 1 FWD FWD 30 N m 3 0 kgf...

Page 147: ...REAR BRAKE 4 31 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 BF S 2 1...

Page 148: ...ush 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 disc...

Page 149: ...brake pads 3 and the pad pin 4 TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point e Install the brake caliper 5 and the...

Page 150: ...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 151: ...g Brake pad Brake pad pin Brake pad pin plug Refer to CHECKING THE REAR BRAKE PADS on page 3 25 4 Pour brake fluid to the brake fluid reservoir up to the specified level WARNING EWA13090 Use only the...

Page 152: ...ster 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 cylinder reservoir...

Page 153: ...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 154: ...REAR BRAKE 4 38 system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 26...

Page 155: ...dlebar switch left 1 5 Brake master cylinder 1 6 Throttle cable housing 1 7 Throttle cable pull 1 Disconnect 8 Throttle cable return 1 Disconnect 9 Handlebar grip right 1 10 Tube guide 1 3 8 N m 0 38...

Page 156: ...line a between the two arrow marks faces straight upward 13 Upper handlebar holder 2 14 Handlebar 1 15 Lower handlebar holder 2 16 Damper 4 3 8 N m 0 38 kgf m 2 8 lb ft 0 5 N m 0 05 kgf m 0 37 lb ft...

Page 157: ...onger distance a from the mounting bolt center facing towards the front side of the vehicle Installing the lower handlebar holders in the re verse direction allow the front to rear offset amount of th...

Page 158: ...own 2 1 a 3 4 4 b 1 2 1 2 1 2 1 2 c A Routing when installing the damper and lower handlebar in the rear holes B Routing when installing the damper and lower handlebar in the front holes Lower handleb...

Page 159: ...a between the two arrow marks faces straight upward 7 Install Clutch cable 1 TIP Before installation apply the lithium soap based grease to the clutch cable end 8 Adjust Clutch lever free play Refer t...

Page 160: ...n the screws for adjustment 13 Install Rubber cover 1 Cover throttle cable housings 2 14 Install Start switch 1 Front brake master cylinder assembly 2 Front brake master cylinder holder 3 Front brake...

Page 161: ...HANDLEBAR 4 45 15 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 12 Throttle grip free play 3 0 6 0 mm 0 12 0 24 in 0 mm 0 in 2 1 5 3 4 3 mm 0 12 in 2 mm 0 08 in...

Page 162: ...WHEEL on page 4 6 Front brake caliper Refer to FRONT BRAKE on page 4 16 Number plate Refer to GENERAL CHASSIS on page 4 1 1 Protector 1 2 Upper bracket pinch bolt 2 Loosen 3 Damper assembly 1 Loosen...

Page 163: ...1 8 Piston metal 1 9 Protector guide 1 10 Slide metal 1 11 Washer 1 12 Oil seal 1 13 Adjuster knob 1 14 Base valve 1 15 Damper assembly 1 16 Upper spring seat 1 New New New New New New New LS LT New 3...

Page 164: ...t fork leg EAM30056 DISASSEMBLING THE FRONT FORK LEGS 1 Drain Fork oil 2 Remove Adjuster 1 from the inner tube TIP While compressing the inner tube 2 set the cap bolt ring wrench 4 between the inner t...

Page 165: ...ding value is shown by one half of the dial gauge reading WARNING EWA13650 Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Check Outer tube Scratches wear damage Rep...

Page 166: ...Inner tube bushing Slide metal Oil seal Copper washer 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 NOT...

Page 167: ...r rod pressure 7 Check Damper assembly Not fully stretched Repeat the steps 1 to 7 8 Tighten Base valve 1 Screw adjuster knob TIP Hold the damper assembly with the cap bolt ring wrench 2 and use the c...

Page 168: ...er assembly TIP The overflow measures about 10 cm 0 34 US oz 0 35 Imp oz 12 Check Damper assembly smooth movement Tightness binding rough spots Repeat the steps 1 to 12 13 Install Dust seal 1 Stopper...

Page 169: ...ss the slide metal into the outer tube with fork seal driver 3 17 Install Oil seal 1 TIP Using a fork seal driver 2 press the oil seal in until the stopper ring groove fully appears 18 Install Stopper...

Page 170: ...TIP Install the upper spring seat with its larger dia end a facing the fork spring 23 Install Damper assembly 1 to the inner tube 2 NOTICE ECA24560 Allow the damper assembly to slide slowly down the i...

Page 171: ...ure Gap a between the adjuster 1 and the locknut 2 Out of specification Retighten and readjust the locknut TIP If it is installed with a gap out of specification correct damping force cannot be obtain...

Page 172: ...otector guide 1 EAM30059 INSTALLING THE FRONT FORK LEGS 1 Install Front fork 1 TIP Temporarily tighten the lower bracket pinch bolts Do not tighten the upper bracket pinch bolts yet 2 Tighten Damper a...

Page 173: ...6 Adjust Rebound damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 7 Adjust Compression damping force TIP Turn in the damping adjuster 1 fi...

Page 174: ...the front wheel off the ground Number plate Refer to GENERAL CHASSIS on page 4 1 Handlebar Refer to HANDLEBAR on page 4 39 1 Front fender 1 2 Steering stem nut 1 3 Front fork leg 2 Refer to FRONT FOR...

Page 175: ...t 1 6 Lower bracket 1 a Approx 20 0 mm 0 79 in 7 Bearing race cover 1 8 Upper bearing 1 9 Bearing race 2 10 Lower bearing 1 LS LS 21 N m 2 1 kgf m 15 lb ft 145 N m 14 5 kgf m 107 lb ft 1st 2nd 38 N m...

Page 176: ...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 177: ...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 28 5 Check the steering...

Page 178: ...ering 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 torqu...

Page 179: ...r left right Refer to GENERAL CHASSIS on page 4 1 Shroud 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 sho...

Page 180: ...uide 1 7 Upper spring guide 1 8 Spring 1 9 Dust seal 2 10 Collar 2 a 0 3 mm 0 01 in or more 11 Bushing 1 12 Bearing 1 13 Collar 2 14 O ring 2 15 Dust seal 2 16 Bushing 1 17 Stopper ring 1 M M M New M...

Page 181: ...ts to remove Q ty Remarks 1 Relay arm 1 2 Connecting arm 1 3 Collar 1 4 Oil seal 2 5 Bearing 2 6 Washer 4 7 Oil seal 4 8 Collar 2 9 Washer 4 10 Bearing 4 M M M M M M 80 N m 8 0 kgf m 59 lb ft 6 1 10 9...

Page 182: ...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 183: ...seal Damage pitting Replace EAM30069 INSTALLING THE RELAY ARM 1 Lubricate Oil seal Bearing Washer Collar 2 Install Bearing 1 Washer 2 Oil seal 3 into the relay arm 4 Collar 5 EAM30625 INSTALLING THE C...

Page 184: ...and threaded portion Rear shock absorber assembly upper bolt Rear shock absorber assembly lower bolt 6 Install Rear shock absorber assembly TIP When installing the rear shock absorber as sembly lift...

Page 185: ...REAR SHOCK ABSORBER ASSEMBLY 4 69 Rear shock absorber assembly lower nut Rear shock absorber assembly lower nut 53 N m 5 3 kgf m 39 lb ft T R...

Page 186: ...AR BRAKE on page 4 27 Rear brake caliper Refer to REAR BRAKE on page 4 27 Bolt brake pedal Refer to ENGINE REMOVAL on page 5 2 Drive chain Refer to CHAIN DRIVE on page 4 74 4 0 N m 0 40 kgf m 3 0 lb f...

Page 187: ...g 2 5 Oil seal 2 6 Bearing 4 7 Drive chain support 1 8 Drive chain support cover 1 4 0 N m 0 40 kgf m 3 0 lb ft 70 N m 7 0 kgf m 52 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 1 2 3 6 6...

Page 188: ...arings and the collars EAM30073 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not atte...

Page 189: ...then install Align the slit c in the drive chain support with swingarm stay as shown and then install the drive chain support 5 Install Rear wheel Refer to REAR WHEEL on page 4 11 6 Adjust Drive chain...

Page 190: ...DRIVE Removing the drive chain Order Job Parts to remove Q ty Remarks 1 Drive chain 1 2 Drive sprocket cover 1 3 Drive sprocket nut 1 4 Lock washer 1 5 Drive sprocket 1 7 N m 0 7 kgf m 5 2 lb ft 90 N...

Page 191: ...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 192: ...k clip 3 WARNING EWA20250 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 NOTICE ECA1430...

Page 193: ...tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its...

Page 194: ...CHAIN DRIVE 4 78...

Page 195: ...HAIN GUIDE INTAKE SIDE 5 19 CHECKING THE CYLINDER HEAD 5 19 INSTALLING THE CYLINDER HEAD 5 19 VALVES AND VALVE SPRINGS 5 22 REMOVING THE VALVES 5 24 CHECKING THE VALVES AND VALVE GUIDES 5 25 CHECKING...

Page 196: ...LLING THE SHIFT SHAFT 5 56 STARTER CLUTCH 5 59 REMOVING THE BALANCER GEAR 5 61 CHECKING THE STARTER CLUTCH 5 61 INSTALLING THE BALANCER GEAR 5 61 OIL PUMP 5 63 CHECKING THE OIL PUMP 5 64 ASSEMBLING TH...

Page 197: ...ND DIAGRAMS EAM30526 ENGINE OIL LUBRICATION CHART 1 Intake camshaft 2 Exhaust camshaft 3 Piston 4 Oil nozzle 5 Oil filter element 6 Relief valve 7 Oil feed pump 8 Scavenging pump 9 Oil strainer 10 Oil...

Page 198: ...Exhaust pipe 2 1 5 Exhaust pipe 1 1 6 Gasket 1 7 Exhaust pipe 1 protector 1 8 Gasket 1 9 Gasket 1 10 Silencer body 1 11 Silencer cap 1 FWD FWD New LT LT New New 1st 2nd 7 N m 0 7 kgf m 5 2 lb ft 10 N...

Page 199: ...arks Use a maintenance stand to raise the front wheel off the ground Seat Refer to GENERAL CHASSIS on page 4 1 Side cover left Refer to GENERAL CHASSIS on page 4 1 Shroud left Refer to GENERAL CHASSIS...

Page 200: ...tator coil assembly coupler 1 Disconnect 3 Crankshaft position sensor coupler 1 Disconnect 4 Coolant temperature sensor coupler 1 5 Gear position switch 1 6 Starter motor lead 1 Disconnect 7 Engine gr...

Page 201: ...TANK on page 7 1 Exhaust pipe Silencer Refer to ENGINE REMOVAL on page 5 2 Air filter case Refer to THROTTLE BODY on page 7 4 Throttle body Refer to THROTTLE BODY on page 7 4 Clutch cable Refer to CL...

Page 202: ...to RADIATOR on page 6 2 1 Engine guard 1 2 Brake pedal 1 3 Spring 1 4 Cylinder head breather hose 1 5 Upper engine bracket right 1 6 Upper engine bracket left 1 7 Lower engine bracket 4 8 Pivot shaft...

Page 203: ...he engine 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 Low...

Page 204: ...all Exhaust pipe 2 clamp Exhaust pipe 2 1 Exhaust pipe bracket bolt 2 TIP Make sure that the clamp 3 does not ride on the projection a on the exhaust pipe 4 or si lencer 5 Be sure to insert the projec...

Page 205: ...Tighten while checking that their front and rear joints are inserted in position Exhaust pipe bracket bolt 20 N m 2 0 kgf m 15 lb ft Exhaust pipe clamp bolt exhaust pipe 2 clamp 12 N m 1 2 kgf m 8 9...

Page 206: ...page 4 1 Shroud left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Cylinder head breather hose 1 2 Spark plug 1 3 Cylinder head cover 1 4 Cylinder head cover br...

Page 207: ...ng screw 1 3 Timing chain tensioner cap bolt 1 4 Timing chain tensioner 1 5 Camshaft cap 2 6 Intake camshaft 1 7 Exhaust camshaft 1 8 Oil nozzle 1 10 N m 1 0 kgf m 7 4 lb ft 6 N m 0 6 kgf m 4 4 lb ft...

Page 208: ...3 Remove Timing chain tensioner cap bolt 1 Timing chain tensioner 2 Gasket 4 Remove Camshaft cap bolt 1 Camshaft cap 2 TIP Remove the camshaft cap bolts in a crisscross pattern working from the outsi...

Page 209: ...camshaft caps and then mea sure the width of the Plastigauge 1 4 Measure Camshaft journal diameter a Out of specification Replace the camshaft Within specification Replace the cylinder head and the ca...

Page 210: ...E DECOMPRESSION SYSTEM 1 Check Decompression system a Check that the decompressor cam 1 moves smoothly b Check that the decompressor lever pin 2 projects from the camshaft EAM30085 INSTALLING THE CAMS...

Page 211: ...linder head cam shaft caps and camshaft will result 2 Install Timing chain tensioner a While pressing the tensioner rod lightly with your fingers use a thin screwdriver to wind the tensioner rod up fu...

Page 212: ...p 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 Three bond No 1541C to the cylinder head cover gasket...

Page 213: ...K on page 7 1 Exhaust pipe Silencer Refer to ENGINE REMOVAL on page 5 2 Radiator hose Disconnect Coolant temperature sensor coupler Disconnect Throttle body Refer to THROTTLE BODY on page 7 4 Camshaft...

Page 214: ...chain guide intake side 1 5 Cylinder head gasket 1 6 Oil passage plug 2 7 Cylinder head stud bolt 3 Tighten until they contact the bottom x4 M M 1st 3rd 4th 2nd 36 N m 3 6 kgf m 27 lb ft 18 N m 1 8 kg...

Page 215: ...ING THE VALVE SEATS on page 5 26 Cylinder head coolant passages Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge...

Page 216: ...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 Remove the bolt 1 TIP Remove t...

Page 217: ...loosen any other bolt until one bolt is completely tightened l Retighten the bolt cylinder head in the proper tightening sequence m Tighten the bolts to the specified torque Bolt 1 3rd Specified angl...

Page 218: ...valve springs Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 17 1 Valve lifter 4 2 Adjusting pad 4 3 Valve cotter 8 4 Valve spring retainer 4 5 Valve spring 4 5...

Page 219: ...ve springs Order Job Parts to remove Q ty Remarks 6 Valve stem seal 4 7 Valve spring seat 4 8 Intake valve 2 9 Exhaust valve 2 10 Intake valve guide 2 11 Exhaust valve guide 2 8 9 9 9 10 6 7 7 7 7 12...

Page 220: ...THE VALVE SEATS on page 5 26 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...

Page 221: ...ve 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 c...

Page 222: ...Measure Valve seat contact width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cylinder head c Press the valve through t...

Page 223: ...ad 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...

Page 224: ...the valve springs with the larger pitch a facing up 4 Install Valve cotter 1 TIP Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring comp...

Page 225: ...bricate Adjusting pad 1 Valve lifter 2 7 Install Adjusting pad Valve lifter TIP Check that the valve lifter turns smoothly when rotated with your finger Make sure that the valve lifter and the adjusti...

Page 226: ...cylinder and piston Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 17 1 Cylinder body 1 2 Gasket 1 3 Dowel pin 2 4 Piston pin clip 2 5 Piston pin 1 6 Piston 1 7...

Page 227: ...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 228: ...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 229: ...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 piston...

Page 230: ...g the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide exhaust side through the timing chain cavity a Top ring b 2nd ring c Upper oil ri...

Page 231: ...rts to remove Q ty Remarks Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 14 Seat Refer to GENERAL CHASSIS on page 4 1 Shroud left Refer to GENERAL CHASSIS on page 4 1 10 N m 1 0 kgf m 7...

Page 232: ...sembly coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Shift pedal 1 When installing align the punch marks on the shift pedal and the shift shaft 4 Clamp 1 2 5 Clamp 2 1 10 N...

Page 233: ...to remove Q ty Remarks 6 Crankcase cover left 1 7 Gasket 1 8 Dowel pin 2 9 Clamp 3 1 10 Stator coil assembly 1 11 Generator rotor 1 12 Woodruff key 1 10 N m 1 0 kgf m 7 4 lb ft 12 N m 1 2 kgf m 8 9 lb...

Page 234: ...LING THE GENERATOR 1 Install Stator coil assembly 1 Screw stator coil assembly 2 Crankshaft position sensor 3 Bolt crankshaft position sensor 4 TIP Apply the sealant to the grommet of the stator coil...

Page 235: ...uff key 3 Install Washer Nut generator rotor 1 4 Install Dowel pin 1 Gasket crankcase cover left 2 Crankcase cover left 3 Lead holder 4 Crankcase cover bolt left 5 Washer Engine oil drain bolt oil tan...

Page 236: ...st pipe Refer to ENGINE REMOVAL on page 5 2 1 Clamp 1 2 Starter motor lead 1 When removing or installing the installation nut of the starter motor lead be sure to hold the nut on the starter motor sid...

Page 237: ...ks 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 4 5 N m 0 45...

Page 238: ...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 239: ...nt cover Starter motor front cover 1 TIP Align the match mark a on the starter motor yoke with the match mark b on the starter mo tor front cover 4 Install Bolt O ring TIP Apply the lithium soap based...

Page 240: ...L on page 3 14 1 Clutch cable 1 Disconnect 2 Clutch cover 1 3 Gasket 1 4 Pressure plate 1 1 5 Clutch spring 1 6 Spring retainer 1 7 Pressure plate 2 1 8 Circlip 1 9 Bearing 1 10 Push rod 1 1 11 Ball 1...

Page 241: ...the pawls 14 Clutch plate 1 7 Thickness 1 4 mm 0 06 in 15 Friction plate 1 4 16 Collar 6 17 Washer 1 18 Sleeve 1 19 Absorber 6 20 Clutch boss 1 21 Washer 1 22 Primary driven gear 1 23 Collar 1 24 Idl...

Page 242: ...GINE OIL on page 3 14 Coolant Drain Refer to CHANGING THE COOLANT on page 3 22 Brake pedal Refer to ENGINE REMOVAL on page 5 2 Clutch cover Refer to CLUTCH on page 5 44 1 Oil filter element cover 1 2...

Page 243: ...to remove Q ty Remarks Drive sprocket cover Refer to CHAIN DRIVE on page 4 74 1 Push lever shaft 1 2 Clutch release 1 3 Oil seal 1 4 Bearing 2 5 Push rod 2 1 6 Oil seal 1 3 5 6 4 1 2 10 N m 1 0 kgf m...

Page 244: ...lutch plate warpage with a surface plate and thickness gauge Out of specification Replace the clutch plates as a set EAM30111 CHECKING THE CLUTCH SPRING 1 Check Pressure plate Damage Replace 2 Check S...

Page 245: ...R 1 Check Primary drive gear Damage wear Replace the primary drive and primary driven gears as a set Excessive noise during operation Replace the primary drive and primary driven gears as a set 2 Chec...

Page 246: ...asher 2 O ring 3 Clutch release 4 TIP Apply lithium soap based grease on the O ring and the seal lip EAM30121 INSTALLING THE CLUTCH 1 Install Oil seal 1 Circlip 2 Check ball seat 3 TIP Apply the lithi...

Page 247: ...pply the lithium soap based grease on the oil seal lip Before installation apply the engine oil to the bearings upper side and lower side 5 Install Washer 1 Idle gear 2 Collar 3 Primary driven gear 4...

Page 248: ...on the out er circumference of the pawls Install the clutch plates and friction plates alter nately on the sleeve starting with a clutch plate and ending with a clutch plate From the clutch boss side...

Page 249: ...temporarily tighten all bolts to 4 0 N m 0 40 kgf m 3 0 lb ft in a crisscross pattern Then retighten them to 10 N m 1 0 kgf m 7 4 lb ft in a crisscross pattern 12 Install Gasket 1 Clutch cover 2 Clutc...

Page 250: ...to remove Q ty Remarks Idle gear Refer to CLUTCH on page 5 44 1 Shift pedal 1 2 Shift shaft 1 3 Oil seal 1 4 Collar 1 5 Shift shaft spring 1 6 Roller 1 7 Shift guide 1 FWD FWD E E E 30 N m 3 0 kgf m...

Page 251: ...y Remarks 8 Shift lever assembly 1 9 Shift lever 1 10 Pawl 2 11 Pawl pin 2 12 Spring 2 13 Stopper lever 1 14 Stopper lever spring 1 15 Segment 1 FWD FWD E E E 30 N m 3 0 kgf m 22 lb ft 12 N m 1 2 kgf...

Page 252: ...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 253: ...er 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 Dowel...

Page 254: ...SHIFT SHAFT 5 58 TIP Align the punch mark a on the shift shaft with the punch mark b in the shift pedal 1 1 1 2 2 a b...

Page 255: ...on page 5 44 1 Primary drive gear nut 1 2 Balancer driven gear nut 1 3 Washer 1 4 Primary drive gear 1 5 Collar 1 6 Starter reduction gear 1 7 Circlip 1 8 Starter clutch assembly 1 a Manufacturer s m...

Page 256: ...amper assembly Order Job Parts to remove Q ty Remarks Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 14 Clutch Refer to CLUTCH on page 5 44 1 Holder 1 2 Damper assembly 1 3 Washer 1 FWD F...

Page 257: ...place the starter clutch assembly 3 Check Starter clutch operation a Install the starter clutch onto the balancer drive gear 1 and then install onto the starter reduction gear 2 b When turning the bal...

Page 258: ...utch assembly Install the starter clutch assembly with its man ufacturer s mark facing outward Apply engine oil to the inner surface and the contact surfaces of the starter reduction gear Apply engine...

Page 259: ...ER CLUTCH on page 5 59 1 Oil pump assembly 1 2 Outer rotor 1 1 3 Inner rotor 1 1 4 Dowel pin 1 5 Oil pump cover 1 6 Outer rotor 2 1 7 Inner rotor 2 1 8 Dowel pin 1 9 Oil pump drive shaft 1 10 Oil pump...

Page 260: ...and outer rotor 2 Fit the dowel pin into the slit in the inner rotor 2 2 Install Oil pump cover 1 Oil pump cover bolt 2 3 Install Washer Dowel pin 1 Inner rotor 1 2 Outer rotor 1 3 Circlip 4 TIP Apply...

Page 261: ...OIL PUMP on page 5 63 Segment Refer to SHIFT SHAFT on page 5 54 Stator coil assembly Refer to GENERATOR on page 5 35 Clutch release Push rod 2 Refer to CLUTCH on page 5 44 1 Timing chain guide exhaust...

Page 262: ...3 L 60 mm 2 36 in 7 Crankcase left 1 8 Crankcase right 1 9 Dowel pin 2 10 Crankshaft 1 11 Gasket 1 12 Oil strainer 1 13 Oil nozzle 1 1 14 Oil nozzle 2 1 LT LT LT 12 N m 1 2 kgf m 8 9 lb ft 10 N m 1 0...

Page 263: ...Transmission Refer to TRANSMISSION on page 5 75 Shift cam Shift fork Refer to TRANSMISSION on page 5 75 1 Bearing 5 2 Collar 1 3 Oil seal 1 LT LT LT E E E E 12 N m 1 2 kgf m 8 9 lb ft 30 N m 3 0 kgf m...

Page 264: ...aring and oil seal right Order Job Parts to remove Q ty Remarks 1 Bearing 5 LT LT E E E LT 12 N m 1 2 kgf m 8 9 lb ft 30 N m 3 0 kgf m 22 lb ft 12 N m 1 2 kgf m 8 9 lb ft 1 1 1 1 1 0 mm 0 in 0 mm 0 in...

Page 265: ...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 266: ...5 to the left crankcase TIP Fit the right crankcase onto the left crankcase Tap lightly on the case with soft hammer When installing the crankcase the connecting rod should be positioned at top dead c...

Page 267: ...CRANKCASE 5 71 6 45 mm 1 77 in 7 60 mm 2 36 in 8 75 mm 2 95 in 1 2 3 3 4 5 6 6 6 8 8 8 7 7 7 LT...

Page 268: ...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 65 Transmission Refer to TRANSMISSION on p...

Page 269: ...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 270: ...thium 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 crank...

Page 271: ...SMISSION Removing the transmission shift drum assembly and shift forks Order Job Parts to remove Q ty Remarks Engine Refer to ENGINE REMOVAL on page 5 2 Crankcase Separate Refer to CRANKCASE on page 5...

Page 272: ...transmission shift drum assembly and shift forks Order Job Parts to remove Q ty Remarks 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 E M M M LS...

Page 273: ...moving the transmission shift drum assembly and shift forks Order Job Parts to remove Q ty Remarks 6 Shift cam 1 7 Shift fork 3 R 1 8 Shift fork 2 C 1 9 Shift fork 1 L 1 10 Collar 1 E M M M LS E E E M...

Page 274: ...axle lightly with a soft hammer EAM30154 CHECKING THE SHIFT FORKS 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll...

Page 275: ...llar 3 5th pinion gear 21T 4 2nd pinion gear 16T 5 to the main axle 6 TIP Before installation apply molybdenum disulfide oil to the inner and end surface of the idler gear and to the inner surface of...

Page 276: ...TIP Install to the left crankcase simultaneously Apply engine oil to the main axle and the drive axle bearing 6 Install Shift fork 1 L 1 Shift fork 2 C 2 Shift fork 3 R 3 Shift cam 4 to the main axle...

Page 277: ...t fork 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 Transm...

Page 278: ...TRANSMISSION 5 82...

Page 279: ...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 8 CHECKING THE WATER PUMP 6 8 ASSEMBLING...

Page 280: ...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 281: ...d left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to THROTTLE BODY on page 7 4 1 Radiator guard 2 2 Radiator hose clamp 8 Loosen 3 Radiat...

Page 282: ...diator breather hose 1 9 Radiator left 1 10 Radiator hose 1 1 11 Clip 1 12 Radiator pipe 1 1 13 Coolant temperature sensor 1 FWD FWD LS LS LS 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N...

Page 283: ...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 284: ...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 Cool...

Page 285: ...Drain Refer to CHANGING THE COOLANT on page 3 22 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 14 Crankcase cover right Refer to CLUTCH on page 5 44 1 Water pump housing cover 1 2 O rin...

Page 286: ...6 Circlip 1 7 Impeller 1 1 8 Impeller 2 1 9 Impeller shaft 1 10 Water pump housing 1 11 O ring 1 12 Oil seal 1 Make sure the projections a on the oil seal point to the outside and then install the oil...

Page 287: ...ner race with your finger Rough spot seizure Replace EAM30262 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 TIP Apply the lithium soap based grease on the oil seal lip Make sure the projections a on...

Page 288: ...Install Water pump housing cover 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 2 2 T R...

Page 289: ...FUEL PUMP BODY 7 2 CHECKING THE FUEL PUMP OPERATION 7 2 INSTALLING THE FUEL PUMP 7 2 INSTALLING THE FUEL TANK 7 3 THROTTLE BODY 7 4 CHECKING THE INJECTOR 7 7 CHECKING THE THROTTLE BODY 7 7 CHECKING TH...

Page 290: ...page 4 1 Shroud left right Refer to GENERAL CHASSIS on page 4 1 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 7...

Page 291: ...the direction of the arrow shown press the two buttons 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...

Page 292: ...ose NOTICE ECA24740 Connect the fuel hose securely and check that the orientation of the installed fuel hose holder is correct Take care not to kink or pinch the fuel hose TIP Insert the fuel hose int...

Page 293: ...r filter case cover 1 2 Intake air temperature sensor coupler 1 Disconnect 3 Cylinder head breather hose 1 4 Air filter case 1 5 Air filter case assembly bracket 1 6 Intake air temperature sensor 1 7...

Page 294: ...ion coil bracket 1 15 Ignition coil 1 16 Air filter case bracket right 1 17 Air filter case bracket left 1 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 7 N m 0 7 kg...

Page 295: ...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 3 5 N m 0 35 kgf m 2 6 lb ft 3 5 N m 0 35 k...

Page 296: ...rottle body is subject to strong shocks or dropped during cleaning re place it Do not use any caustic carburetor cleaning solution Do not directly push the throttle valves to open them Do not loosen t...

Page 297: ...subject the throttle position sensor to strong shocks If the throttle position sensor is dropped replace it 1 Check Throttle position sensor Refer to CHECKING THE THROTTLE PO SITION SENSOR INPUT VOLTA...

Page 298: ...ATION TABLE on page 9 12 EAM30631 INSTALLING THE AIR FILTER CASE ASSEMBLY BRACKET 1 Install Air filter case assembly bracket 1 TIP Align the projections a on the air filter case as sembly bracket with...

Page 299: ...CHECKING THE FUSES 8 47 CHECKING AND CHARGING THE BATTERY 8 47 REPLACING THE ECU Engine Control Unit 8 49 CHECKING THE RELAYS 8 49 CHECKING THE RELAY UNIT DIODE 8 49 CHECKING THE IGNITION SPARK GAP 8...

Page 300: ...IGNITION SYSTEM 8 1 EAM20142 IGNITION SYSTEM EAM30277 CIRCUIT DIAGRAM...

Page 301: ...ry 7 Fuse 8 Starter relay 9 Starter motor 10 Diode 1 11 CCU Communication Control Unit 12 ECU Engine Control Unit 13 Ignition coil 14 Spark plug 21 Gear position switch 22 Handlebar switch left 23 Ind...

Page 302: ...e 8 47 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 13 NG Correct or replace the spark plug OK 5 Check the igniti...

Page 303: ...re har ness Refer to CIRCUIT DIAGRAM on page 8 1 NG Repair or replace the wire harness OK Replace the ECU 1 Check the handlebar switch coupler left connections NG Reconnect OK 2 Check the gear positio...

Page 304: ...s NG Reconnect OK 2 Check the handlebar switch left Refer to CHECKING THE SWITCHES on page 8 45 NG Replace the handlebar switch left OK 3 Check the ignition system wire har ness Refer to CIRCUIT DIAGR...

Page 305: ...IGNITION SYSTEM 8 6...

Page 306: ...ELECTRIC STARTING SYSTEM 8 7 EAM20143 ELECTRIC STARTING SYSTEM EAM30279 CIRCUIT DIAGRAM...

Page 307: ...EM 8 8 5 Frame ground 6 Battery 7 Fuse 8 Starter relay 9 Starter motor 10 Diode 1 12 ECU Engine Control Unit 21 Gear position switch 22 Handlebar switch left 25 Engine stop switch 26 Handlebar switch...

Page 308: ...efer to CHECKING THE START ER MOTOR OPERATION on page 8 51 OK Starter motor is OK Perform the electric starting system troubleshooting starting with step 6 NG 4 Check the starter motor Refer to CHECKI...

Page 309: ...ELECTRIC STARTING SYSTEM 8 10 9 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 7 NG Properly connect or repair the starting sys tem s wiring OK Replace the ECU...

Page 310: ...CHARGING SYSTEM 8 11 EAM20144 CHARGING SYSTEM EAM30282 CIRCUIT DIAGRAM...

Page 311: ...CHARGING SYSTEM 8 12 2 AC magneto 3 Rectifier regulator 4 Engine ground 5 Frame ground 6 Battery 7 Fuse...

Page 312: ...ck the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 47 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIE...

Page 313: ...CHARGING SYSTEM 8 14...

Page 314: ...FUEL INJECTION SYSTEM 8 15 EAM20145 FUEL INJECTION SYSTEM EAM30284 CIRCUIT DIAGRAM B...

Page 315: ...nication Control Unit 12 ECU Engine Control Unit 13 Ignition coil 14 Spark plug 15 Fuel injector 16 Fuel pump 17 Intake air temperature sensor 18 Coolant temperature sensor 19 Throttle position sensor...

Page 316: ...EAM30356 CONNECTING THE YAMAHA DIAGNOSTIC TOOL 1 Disconnect the CCU sub lead coupler 1 2 Connect the Yamaha diagnostic tool TIP Prepare the fully charged 12 V lead battery for yourself Replace the veh...

Page 317: ...1 ECU Engine Control Unit 2 Lead battery 12 V 3 Vehicle battery 4 Vehicle 5 CCU sub lead coupler 6 Sub harness included with the Yamaha diag nostic tool 7 Vehicle communication cable included with the...

Page 318: ...ure sensor Fuel injector Coolant temperature sensor Ignition coil Intake air temperature sensor Throttle position sensor Fault code No 8 Item Gear position switch open or short circuit detected Fail s...

Page 319: ...d finish the service Condition is Detected Go to item 4 4 Mounted condition of gear posi tion switch Check for looseness or pinch ing Improperly mounted switch Remount or replace the switch Refer to E...

Page 320: ...o item 7 and finish the service Condition is Detected 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 ben...

Page 321: ...e Condition is Detected Go to item 6 6 Faulty ECU Replace the ECU Service is finished 7 Delete the fault code Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool...

Page 322: ...pinch ing Check the mounted position for correctness Improperly mounted sensor Remount or replace the sensor Start switch to ON no need to start the engine and then check the condition of the fault c...

Page 323: ...ult code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 3 and finish the service Condition is Detected Go to item 2 2 Defective intake air pressure sensor E...

Page 324: ...d check the pins for bent or bro ken terminals and locking condi tion of the pins Improperly connected Con nect the coupler securely or repair replace the wire harness Start switch to ON no need to st...

Page 325: ...he throttle position sensor and then reset the ECU using the diagnostic code num ber 87 Refer to DIAGNOSTIC CODE SENSOR OPERATION TABLE on page 9 12 Start switch to ON no need to start the engine and...

Page 326: ...lay range Replace the throttle position sensor and then reset the ECU using the diagnostic code num ber 87 Refer to DIAGNOSTIC CODE SENSOR OPERATION TABLE on page 9 12 Start switch to ON no need to st...

Page 327: ...n joint connector and ECU coupler black blue black blue Start switch to ON no need to start the engine and then check the condition of the fault code using the malfunction mode of the Yamaha diagnosti...

Page 328: ...code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 2 2 Connection of wire harness ECU coupler Ch...

Page 329: ...erature is close to the ambient temperature Improper display Replace the intake air temperature sensor Start switch to ON no need to start the engine and then check the condition of the fault code usi...

Page 330: ...the service Condition is Detected Go to item 3 3 Faulty ECU Execute the diagnostic mode Code No 08 Proper display When the vehicle is upright 0 4 1 4 V When the vehicle is overturned 3 7 4 4 V Imprope...

Page 331: ...hite Between ignition coil coupler and joint connector red red Between joint connector and ECU coupler red red Start the engine and let it idle for approximately 5 seconds Check the condition of the f...

Page 332: ...art the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish...

Page 333: ...en delete the fault code Fault code No 41 Item ECU built in lean angle sensor malfunction Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 08 Diagnostic tool display Disp...

Page 334: ...k the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 4 and finish the service Condition is Detected Go to item 3 3 Malfunction i...

Page 335: ...o 65 Start switch to ON no need to start the engine and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and fini...

Page 336: ...coupler securely or repair replace the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnos...

Page 337: ...iagnostic 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 no need to start the...

Page 338: ...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 339: ...FUEL INJECTION SYSTEM 8 40...

Page 340: ...FUEL PUMP SYSTEM 8 41 EAM20146 FUEL PUMP SYSTEM EAM30287 CIRCUIT DIAGRAM...

Page 341: ...FUEL PUMP SYSTEM 8 42 2 AC magneto 3 Rectifier regulator 4 Engine ground 5 Frame ground 6 Battery 7 Fuse 12 ECU Engine Control Unit 16 Fuel pump 22 Handlebar switch left 25 Engine stop switch...

Page 342: ...page 8 47 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 47 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the engine stop...

Page 343: ...or 2 Mode switch 3 Engine stop switch 4 Intake air temperature sensor 5 Ignition coil 6 Battery 7 Starter relay 8 Fuse 9 ECU Engine Control Unit 10 CCU Communication Control Unit 11 Fuel pump 12 Gear...

Page 344: ...ELECTRICAL COMPONENTS 8 45 EAM30289 CHECKING THE SWITCHES Y W P Sb 5 1 2 3 4 P Sb Y W 1 Handlebar switch left 2 Mode switch 3 Engine stop switch 4 Start switch 5 Gear position switch...

Page 345: ...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 346: ...use battery if it has been dropped subject to impact or visibly damaged Do not disassemble or modify the battery or short across its terminals NOTICE ECA28440 To prevent damage to the battery and batt...

Page 347: ...ect Battery lead to the battery terminals NOTICE ECA26980 First connect the positive battery lead and then the negative battery lead 8 Check Battery terminal Dirt Clean with a wire brush Loose connect...

Page 348: ...Check each switch for continuity with the digital circuit tester If the continuity reading is incor rect replace the relay 1 Disconnect the relay from the wire harness 2 Connect the digital circuit t...

Page 349: ...occurs EAM30295 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...

Page 350: ...nsor is built into the ECU The lean angle sensor stops the engine in case of a turnover To ensure that the lean angle sensor operates correctly do not change the installed condition of the ECU EAM3029...

Page 351: ...al circuit tester to the stator coil assembly coupler b Measure the stator coil assembly resis tance EAM30301 CHECKING THE RECTIFIER REGULATOR 1 Check Rectifier regulator output voltage Out of specifi...

Page 352: ...for continuity at the temperatures indicated in the table EAM30305 CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1 Check Throttle position sensor input voltage Out of specification Replace the...

Page 353: ...mperature sensor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification Replace a Connect the digital circuit tester to the intake air temperature sensor terminal...

Page 354: ...uity Positive tester probe Pink 2 Negative tester probe Sensor terminal b Continuity Positive tester probe Pink 2 Negative tester probe Sensor terminal c Continuity Positive tester probe Yellow White...

Page 355: ...ion coil failure Replace the ignition coil Injector failure Replace the injector Vehicle has overturned Raise the vehicle upright ECU failure Replace the ECU Fail safe system Possible cause Actions Ab...

Page 356: ...ELECTRICAL COMPONENTS 8 57...

Page 357: ...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 358: ...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 359: ...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 360: ...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 361: ...drive 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 j...

Page 362: ...Replace the primary driven gear 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 Incor...

Page 363: ...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 364: ...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 365: ...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 366: ...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 367: ...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 368: ...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 369: ...in the primary lead of the ignition coil 8 31 39 Injector open or short circuit detected 8 33 41 ECU built in lean angle sensor malfunction 8 34 43 Fuel system voltage incorrect voltage supplied to th...

Page 370: ...fault code display No fault 00 CO adjustment value 01 Power Tuner injection cor rection setting 0 8 or Power Tuner ignition timing correc tion setting 0 8 07 Fully closed throttle angle 12 64 Setting...

Page 371: ...nostic tool blinks five times when the ignition coil is actu ated Check that a spark is gener ated five times Connect an ignition checker 36 Injector Actuates the injector five times at one second int...

Page 372: ...SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 15...

Page 373: ...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 374: ...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 375: ...e air spring characteristics to have a ten dency to be stiffer with the consequent dete riorated performance and characteristics Therefore adjust the front fork within the specified range EAM30173 SET...

Page 376: ...the length a between the rear wheel axle center and mark of rear fender 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 377: ...amping force For correction adjust to decrease compression damping force WARNING EWA19200 When using a rear shock absorber other than currently installed use the one whose overall length a does not ex...

Page 378: ...n page 3 31 Spring preload adjusting positions Minimum Position in which the spring is turned in 1 5 mm 0 06 in from its free length Standard Position in which the spring is turned in 7 0 mm 0 28 in f...

Page 379: ...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 380: ...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 381: ...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 382: ...CHASSIS 10 9...

Page 383: ...r 20 Intake air pressure sensor 21 Gear position switch 22 Handlebar switch left 23 Indicator light 24 Mode switch 25 Engine stop switch 26 Handlebar switch right 27 Start switch A Wire harness B CCU...

Page 384: ......

Page 385: ...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 386: ......

Page 387: ...B YZ450FP 2023 WIRING DIAGRAM BHR 2819U 10_W D indd 1 2022 08 09 13 16 06...

Page 388: ...ON OFF PUSH FREE PUSH FREE B YZ450FP 2023 WIRING DIAGRAM BHR 2819U 10_W D indd 2 2022 08 09 13 16 06...

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