Yamaha YZ450FX 2019 Owner'S Service Manual Download Page 234

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CYLINDER AND PISTON

5-35

clip from falling into the crankcase.

•

Make sure that the end of the piston pin clip is
not positioned at the cutout in the piston.

3. Lubricate:

•

Piston

•

Piston ring

•

Cylinder

4. Offset:

•

Piston ring end gap

5. Install:

•

Cylinder gasket

•

Dowel pin

•

Cylinder

TIP

•

While compressing 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 ring rail
d. Oil ring expander
e. Lower oil ring rail

Cylinder bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)

New

Summary of Contents for YZ450FX 2019

Page 1: ... Read this manual carefully before operating this vehicle YZ450FXK OWNER S SERVICE MANUAL YZ450FX 2019 PRINTED IN JAPAN 2018 05 0 3 2 E PRINTED ON RECYCLED PAPER 2019 YZ450FXK B3J 28199 10_2_cover_12mm indd 1 3 2018 09 14 14 16 15 ...

Page 2: ...side out Genuine Yamaha Service Manuals Get the same factory manual for your vehicle that the technicians at your authorized Yamaha dealer use Service manuals are available through your Yamaha dealer or you can order them directly through yamahapubs com Genuine Yamaha products are available only from your Yamaha dealer Find out more at yamaha motor com EAM20161 Read this manual carefully Operating...

Page 3: ... the 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 limits set forth for an uncontrolled environment and meets the FCC radio frequency RF Exposure Guidelines This equipment has very low levels of RF energy that is deemed to comply without maximum p...

Page 4: ...2019 by Yamaha Motor Corporation U S A First edition May 2018 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 32 25 ...

Page 5: ...requested 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 MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU...

Page 6: ... HIGHLY FLAMMABLE Always turn off the engine while refueling Take care to not spill any gasoline on the engine or exhaust system Never refuel in the vicinity of an open flame or while smoking GASOLINE CAN CAUSE INJURY If you should swallow some gasoline inhale excess gasoline vapors or allow any gasoline to get into your eyes contact a doctor immediately If any gasoline spills onto your skin or cl...

Page 7: ...EAM20162 YAMAHA MOTOR CORPORATION U S A YZ MOTORCYCLE LIMITED WARRANTY ...

Page 8: ...ure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a removal or a disassembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction chart 6 accompanies the exploded diagram providing the order of jobs the names of parts the notes ...

Page 9: ...ITION 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 clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent LOCTITE Engine oil Replace the part with a new one G M BF B T R LS M S LT E New ...

Page 10: ......

Page 11: ...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 12: ......

Page 13: ... 6 GASKETS OIL SEALS AND O RINGS 1 7 LOCK WASHERS PLATES AND COTTER PINS 1 7 BEARINGS AND OIL SEALS 1 7 CIRCLIPS 1 7 BASIC SERVICE INFORMATION 1 8 ELECTRICAL SYSTEM 1 8 SPECIAL TOOLS 1 12 CONTROL FUNCTIONS 1 18 WARNING LIGHTS 1 18 ENGINE STOP SWITCH 1 18 START SWITCH 1 18 MODE SWITCH 1 18 CLUTCH LEVER 1 19 SHIFT PEDAL 1 19 THROTTLE GRIP 1 19 FRONT BRAKE LEVER 1 19 REAR BRAKE PEDAL 1 19 SIDESTAND 1...

Page 14: ...BREAK IN PROCEDURES 1 22 ENGINE STARTING PRECAUTION 1 22 MAINTENANCE AFTER BREAK IN 1 23 MAJOR MAINTENANCE 1 23 TORQUE CHECK POINTS 1 24 MOTORCYCLE CARE AND STORAGE 1 26 CARE 1 26 STORAGE 1 27 ...

Page 15: ...gasoline only 3FB 2415E 02 4AA 22259 80 WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open 17D 2812P 00 For use only on a closed course in sanctioned competition This motorcycle does not meet EPA noise and emissions standards and is not for general off road recreational riding ...

Page 16: ...ou have purchased 1 12 13 14 15 16 17 18 19 20 4 5 7 6 8 9 10 11 2 3 1 Clutch lever 2 Engine trouble warning light 3 Fuel level warning light 4 Front brake lever 5 Throttle grip 6 Start switch 7 Radiator cap 8 Fuel tank cap 9 Mode switch 10 Engine stop switch 11 Fuel tank 12 Radiator 13 Coolant drain bolt 14 Rear brake pedal 15 Air filter 16 Drive chain 17 Shift pedal 18 Oil level check window 19 ...

Page 17: ...ositive 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 identification number 1 is stamped into the right side of the frame EAM30003 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the right side of the engine 1 1 1 1 ...

Page 18: ...ine in a closed area The exhaust gas is poisonous Never let flames near the servicing area NOTICE ECA26050 This application is designed for adjusting the settings on a standard vehicle In case the engine specifications muffler com pression ratio etc have been changed the performance may not match to the actu al settings Do not run the engine with the smartphone carried with you Otherwise the smart...

Page 19: ...s 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 another location and perform the operation again 1 Turn on the smartphone 2 For two minutes after the start switch is pressed or while the engine is running the CCU is activated input the CCU serial num ber into...

Page 20: ... for each section 5 Flammable Keep servicing areas away from any source of fire 6 During servicing take special care not to re ceive an injury or a burn on the engine the exhaust pipe the silencer or the like 7 If coolant is left adhered 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 hand...

Page 21: ...AM30013 BEARINGS AND OIL SEALS Install bearings 1 and oil seals 2 with their manufacturer s marks or size symbols facing outward During installation of an oil seal make sure that its main lip faces 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 with compressed air because this will damage t...

Page 22: ...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 battery terminals Reversing the bat tery lead connections could damage the electrical components NOTICE ECA16771 When connecting the battery leads to the battery be sure to connect the positive bat tery...

Page 23: ...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 into the cou pler terminal slots Always insert the probes from the opposite end a of the coupler tak ing care not to loosen or damage the leads NOTICE ECA16640 For waterproof couplers never insert th...

Page 24: ...oth 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 connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up After disassembling or assembling a coupler pull on the leads to make sure that they are in stal...

Page 25: ...If 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 90890 03243 Model 88 Multimeter with tachom eter YU A1927 ...

Page 26: ...and Canada use tool 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 tachometer YU A1927 1 11 5 38 8 57 8 58 8 58 8 58 8 61 8 61 8 63 8 63 8 63 8 64 8 64 8 65 8 65 8 66 8 67 8 67 8 68 8 69 Radiator cap tester 90890 01325 Mityvac cooling system tester kit ...

Page 27: ...l tachometer YU 39951 B 3 16 3 37 8 65 Thickness gauge 90890 03268 Feeler gauge set YU 26900 9 3 17 5 43 Valve lapper ø14 90890 04101 Valve lapping tool 14mm YM A8998 3 17 5 25 Spoke nipple wrench 6 7 90890 01521 Spoke nipple wrench 6 7 YM 01521 3 33 Steering nut wrench 90890 01403 Exhaust flange nut wrench YU A9472 3 34 4 52 Tool name Tool No Illustration Reference pages 90890 04101 YM A8998 ...

Page 28: ...ver 90890 01502 Fork seal driver 48 YM A0948 4 45 4 46 Yamaha bond No 1215 90890 85505 Three bond No 1215 5 18 5 58 5 65 Valve spring compressor 90890 04019 Valve spring compressor YM 04019 5 25 5 30 Valve spring compressor attachment 90890 04108 Valve spring compressor adapter 22 mm YM 04108 5 25 5 30 Valve guide remover installer set ø5 5 90890 04016 Valve guide remover 5 5 mm YM 01122 5 27 Tool...

Page 29: ...amer 5 5 mm 90890 01196 Valve guide reamer 5 5 mm YM 01196 5 27 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 32 Universal clutch holder 90890 04086 Universal clutch holder YM 91042 5 43 5 46 Rotor puller 90890 04151 Rotor puller YM 04151 5 58 Tool name Tool No Illustration Reference pages YU 01304 ...

Page 30: ...shaft installer pot 90890 01274 Installing pot YU 90058 5 69 Crankshaft installer bolt 90890 01275 Bolt YU 90060 5 69 Adapter M12 90890 01278 Adapter 3 YU 90063 5 69 Spacer crankshaft installer 90890 04081 Pot spacer YM 91044 5 69 Tool name Tool No Illustration Reference pages YU 90058 YU 90059 YM 91044 ...

Page 31: ...e adapter YM 03186 7 4 Lithium battery charger 90890 05376 Lithium battery charger DBY ACC51 70 02 8 60 8 60 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 62 Test harness S pressure sensor 3P 90890 03207 Test harness S pressure sensor 3P YU 03207 8 67 Tool name Tool No Illustration Reference pages ...

Page 32: ...it of the warning light can be checked by pushing the start switch The warn ing light should come on for a few seconds and then go off If the warning light does not come on initially when the start switch is pushed or if the warning light remains on have a Yamaha dealer check the electrical circuit EAM30182 ENGINE STOP SWITCH The engine stop switch 1 is located on the left handlebar Continue pushi...

Page 33: ...s it down for N neutral to 1st and kick it up for 2nd to 5th EAM30187 THROTTLE GRIP The throttle grip 1 is located on the right han dlebar The throttle grip accelerates or deceler ates the engine For acceleration turn the grip toward you for deceleration turn it away from you EAM30188 FRONT BRAKE LEVER The front brake lever 1 is located on the right handlebar Pull it toward the handlebar to acti v...

Page 34: ... di rection the starter knob 1 moves in the direc tion b as shown and returns to its original position WARNING EWA20470 While handling the starter knob take care not to burn yourself on exhaust pipes EAM30192 FUEL TANK CAP Fuel tank cap 1 is located under the fuel tank cap 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 p...

Page 35: ...LTER EL EMENT section in the CHAPTER 3 apply the Yamaha foam air filter oil or other quality foam air filter oil to the element Excess oil in the ele ment may adversely affect engine starting 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 operate the throttle ...

Page 36: ...4 Make a pit stop again and thoroughly check mounted areas for looseness 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 NOTICE ECA25821 After a break in or after each race always check the points shown in TORQUE CHECK POINTS for tightening torques and re...

Page 37: ...tor is not being discon nected Silencer Check the main body and stay for cracks Check for leaks Mounting bolts and nuts Check for looseness in mounted areas of parts as well as engine mounting bolts and engine brackets 2 For the chassis Check welds and mounted areas of the frame the swingarm the link the bracket and so on for looseness and cracks Wheel s Check the wheel for runout Check the spoke ...

Page 38: ...e 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 wheel axle Tightening of axle holder Tightening of spoke nipple Rear Tightening of wheel axle Wheel to rear wheel sprocket Tightening of spoke nipple Brake s Front Brake caliper to front fork Brake ...

Page 39: ...ft 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 rear fender Tightening of mud flap Tightening of rear brake disc cover Tightening of rear brake caliper cover ...

Page 40: ...chemical products on plastic parts Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products solvent or thinner fuel gasoline rust re movers or inhibitors brake fluid antifreeze or electrolyte Do not use high pressure washers or steam jet cleaners since they cause water seepage and deterioration in the following areas seals of wheel and swingarm ...

Page 41: ...haust system are cool before covering the mo torcycle NOTICE ECA24250 Storing the motorcycle in a poorly ventilat ed room or covering it with a tarp while it is still wet will allow water and humidity to seep in and cause rust To prevent corrosion avoid damp cellars stables because of the presence of ammo nia and areas where strong chemicals are stored Long term Before storing your motorcycle for ...

Page 42: ...ore the battery in an exces sively cold or warm place less than 0 C 32 F or more than 65 C 149 F For more in formation on storing the battery CHECKING AND CHARGING THE BATTERY on page 8 59 TIP Make any necessary repairs before storing the motorcycle ...

Page 43: ...RICAL SPECIFICATIONS 2 9 TIGHTENING TORQUES 2 10 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 10 ENGINE TIGHTENING TORQUES 2 11 CHASSIS TIGHTENING TORQUES 2 14 LUBRICATION POINTS AND LUBRICANT TYPES 2 17 ENGINE 2 17 CHASSIS 2 18 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 21 LUBRICATION DIAGRAMS 2 21 CABLE ROUTING DIAGRAM 2 31 ...

Page 44: ...odel Model B3J1 Dimensions Overall length 2175 mm 85 6 in Overall width 825 mm 32 5 in Overall height 1270 mm 50 0 in Seat height 955 mm 37 6 in Wheelbase 1480 mm 58 3 in Ground clearance 320 mm 12 60 in Weight Curb weight 116 kg 256 lb Riding capacity 1 person ...

Page 45: ...gine oil quantity Oil change 0 62 L 0 66 US qt 0 55 Imp qt With oil filter removal 0 64 L 0 68 US qt 0 56 Imp qt Quantity disassembled 0 90 L 0 95 US qt 0 79 Imp qt Oil filter Oil filter type Paper Oil pump Inner rotor to outer rotor tip clearance 0 000 0 150 mm 0 0000 0 0059 in Limit 0 23 mm 0 0091 in Outer rotor to oil pump housing clearance 0 13 0 18 mm 0 0051 0 0071 in Limit 0 25 mm 0 0098 in ...

Page 46: ... 0 2152 0 2157 in Limit 5 435 mm 0 2140 in Valve guide inside diameter intake 5 500 5 512 mm 0 2165 0 2170 in Valve guide inside diameter exhaust 5 500 5 512 mm 0 2165 0 2170 in Valve stem to valve guide clearance in take 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clearance ex haust 0 020 0 047 mm 0 0008 0 0019 in Limit 0 100 mm 0 0039 in Valve stem runout 0...

Page 47: ... 0 111 in Plate quantity 6 pcs Friction plate 2 thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 82 mm 0 111 in Plate quantity 2 pcs Clutch plate thickness 1 50 1 70 mm 0 059 0 067 in Plate quantity 7 pcs Warpage limit 0 10 mm 0 004 in Clutch spring free length 48 00 mm 1 89 in Limit 45 60 mm 1 80 in Push rod bending limit 0 10 mm 0 004 in Drivetrain Primary reduction ratio 2 609 60 23 Transmiss...

Page 48: ...ody ID mark BR91 00 Idling condition Engine idling speed 1900 2100 r min Coolant temperature 70 90 C 158 194 F Engine oil temperature 70 80 C 158 176 F Fuel line pressure at idle 300 390 kPa 3 0 3 9 kgf cm 43 5 56 6 psi Throttle grip free play 3 0 6 0 mm 0 12 0 24 in ...

Page 49: ... 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 Disc outside diameter thickness 270 0 3 0 mm 10 63 0 12 in Brake disc thickness limit 2 5 mm 0 10 in Brake disc runout limit as measured on wheel 0 15 mm 0 0059 in Brake pad lining thickness limit 1 0 mm 0 04 in Master cylinder inside diameter 9 52 mm 0 37 in Caliper cylinde...

Page 50: ...ping Adjusting system Mechanical adjustable type Unit for adjustment Click Adjustment value from the start position Soft 20 Adjustment value from the start position STD 11 Adjustment value from the start position Hard 0 Rear suspension Type Swingarm link suspension Spring Coil spring Shock absorber Gas hydraulic damper Spring preload Adjusting system Mechanical adjustable type Adjustment value Sof...

Page 51: ...stment value from the start position Soft 20 Adjustment value from the start position STD 12 Adjustment value from the start position Hard 0 Swingarm Swingarm end free play limit radial 1 0 mm 0 04 in Swingarm end free play limit axial 0 2 0 9 mm 0 01 0 04 in Drive chain Size DID520MXV5 Chain type Sealed type Number of links 114 Drive chain slack Maintenance stand 50 0 60 0 mm 1 97 2 36 in 15 link...

Page 52: ...attery Model BR98 Voltage capacity 12 V 2 4 Ah 5 HR Indicator light Fuel level warning light 1 7 W Engine trouble warning light 1 7 W Starter motor Power output 0 85 kW Armature coil resistance 0 008 0 010 Brush overall length 11 0 mm 0 43 in Brush overall length limit 5 5 mm 0 22 in Brush spring force 4 80 7 20 N 489 734 gf 17 28 25 92 oz Commutator diameter 80 6 mm 3 17 in Commutator diameter li...

Page 53: ... To 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 specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques N m kgf m lb ft 10 mm 6 mm 6 0 ...

Page 54: ...alancer 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 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 Coolant drain bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft Radiator hose clamp screw M6 8 1 5 N m 0 15 kgf m 1 1 lb ft Radiator bolt M6 4 10 N m ...

Page 55: ...t 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 8 9 lb ft Plate bolt M6 4 12 N m 1 2 kgf m 8 9 lb ft Starter motor cover bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft Clutch cover bolt M6 7 10 N m 1 0 kgf m 7 4 lb ft Crankcase cover bolt left M6 7 10 N m 1...

Page 56: ...12 N m 1 2 kgf m 8 9 lb ft AC magneto 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 AC magneto lead holder bolt M5 1 8 N m 0 8 kgf m 5 9 lb ft Coolant temperature sensor M10 1 15 N m 1 5 kgf m 11 lb ft Gear position switch bolt M5 2 3 5 N m 0 35 kgf m 2 6 lb ft Rectifier regulator bolt M6 ...

Page 57: ...5 2 1 3 N m 0 13 kgf m 0 95 lb ft Front fork protector bolt M6 6 5 N m 0 5 kgf m 3 7 lb ft Brake hose holder 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 ft Clutch lever position locknut M5 1 4 8 N m 0 48 kgf m 3 5 lb ft Front brake master cylinde...

Page 58: ... Nipple spoke 72 2 5 N m 0 25 kgf m 1 8 lb ft Bolt rear brake disc cover M6 2 10 N m 1 0 kgf m 7 4 lb ft Rear brake caliper protector bolt M6 2 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 5 3 kgf m 39 lb ft Engine bracket bolt upper side M8 4 34...

Page 59: ...lb ft Fuel tank bracket bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Fuel pump bolt M5 5 7 N m 0 7 kgf m 5 2 lb ft Screw fuel inlet pipe M5 2 3 5 N m 0 35 kgf m 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 kgf m 5 2 lb ft Side cover bolt right M6 2 7 N m...

Page 60: ...ace Decompression system moving parts Water pump impeller shaft Oil pump rotors inner and outer Oil passage gasket Oil pump shaft Primary drive gear nut threads and contacting surface Clutch boss nut threads and contacting surface Primary driven gear inner surface and end surface Clutch push rod washer Clutch push rod 1 outer surface Clutch push rod 1 thrust surface Clutch push rod 2 outer surface...

Page 61: ... collar outer surface Swingarm pivot portion oil seal lip Pivot shaft outer surface Relay arm bearing and oil seal lip Relay arm thrust washer surface both sides Relay arm collar outer surface and bolt outer surface Relay arm bolt threads swingarm side Connecting arm bearing and oil seal lip Connecting arm collar outer surface and bolt outer surface Rear shock absorber assembly collar outer surfac...

Page 62: ...iston Front brake caliper piston seal Front brake caliper dust seal Front brake caliper piston outer surface Front brake caliper pin bolt and boot Front brake master cylinder push rod end Front brake master cylinder kit Rear brake caliper piston Rear brake caliper piston seal Rear brake caliper dust seal Rear brake caliper piston outer surface Rear brake caliper pin bolt and boot Rear brake master...

Page 63: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 20 ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 21 EAM20151 LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30331 LUBRICATION DIAGRAMS ...

Page 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 22 1 Intake camshaft 2 Exhaust camshaft 3 Piston 4 Oil filter element 5 Oil nozzle 6 Oil pump 7 Oil strainer 8 Crankshaft 9 Drive axle 10 Main axle ...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 ...

Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 24 1 Exhaust camshaft 2 Intake camshaft 3 Oil filter element 4 Oil pump 5 Drive axle ...

Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 ...

Page 69: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Connecting rod 2 Oil nozzle 3 Crankshaft ...

Page 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 ...

Page 71: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Connecting rod 2 Engine oil check bolt 3 Crankshaft 4 Oil pump ...

Page 72: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 ...

Page 73: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Oil filter element 2 Oil pump 3 Oil strainer ...

Page 74: ...CABLE ROUTING DIAGRAM 2 31 EAM20152 CABLE ROUTING DIAGRAM ...

Page 75: ...ifier regulator coupler to the bracket Attach the coupler cover G Pass the AC magneto lead through rear side of the vehicle No pinch is allowed 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 locking tie to rear side of the vehicle Cut the end of the plastic locking tie I Route the starter m...

Page 76: ...CABLE ROUTING DIAGRAM 2 33 ...

Page 77: ...fter connecting the throttle position sensor coupler attach the cover G Route the radiator breather hose as follows Route it over the boss of the upper side of the radiator toward the rear of the vehicle Route it over the boss on the lower side of the radiator toward the front of the vehicle Route it over the radiator hose toward the front of the vehicle H Route the fuel hose in front of the fuel ...

Page 78: ...CABLE ROUTING DIAGRAM 2 35 ...

Page 79: ...engine stop switch lead and mode switch lead to the handlebar using the plastic locking tie Do not cut the end of the plastic locking tie D 30 50 E Vertical direction of vehicle F Pass the engine stop switch lead and mode switch lead between the frame and the cable guide G Pass the warning light lead through the cable guide H Pass the front brake hose through the front side of the number plate I P...

Page 80: ...CABLE ROUTING DIAGRAM 2 37 ...

Page 81: ...rd 31 Air filter assembly 32 Wire harness 33 Grommet 34 Clamp A Fasten the main harness by 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 not matter It is allowed to run the leads near the radiator cap on the inside B No pinch is allowed the leads between the tank rail and the air filter joint C Insert the pro...

Page 82: ...CABLE ROUTING DIAGRAM 2 39 ...

Page 83: ...y terminal B Install the clamp wire harness to the hole of the battery bracket C After connecting the battery negative coupler position to the right side of the starter relay D The position of the starter motor lead and battery negative lead does not matter E Pass the battery negative lead through lower side of the cross member F After connecting the battery positive lead in the direction shown in...

Page 84: ...CABLE ROUTING DIAGRAM 2 41 ...

Page 85: ...e 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 that the rear brake hose is not excessively twisted F Make sure that the metal part of the rear brake hose contacts the stopper of the rear brake master cylinder G Install the rear brake hose so that the ...

Page 86: ...CABLE ROUTING DIAGRAM 2 43 ...

Page 87: ... SYSTEM 3 12 CHECKING THE FUEL LINE 3 13 CHECKING THE ENGINE OIL LEVEL 3 13 CHANGING THE ENGINE OIL 3 14 ADJUSTING THE ENGINE IDLING SPEED 3 15 ADJUSTING THE VALVE CLEARANCE 3 16 VALVE CLEARANCE SHIM CHART 3 19 CHASSIS 3 21 BLEEDING THE BRAKE SYSTEM 3 21 CHECKING THE BRAKE HOSES 3 22 ADJUSTING THE FRONT BRAKE 3 22 ADJUSTING THE REAR BRAKE 3 23 CHECKING THE FRONT BRAKE PADS 3 23 CHECKING THE REAR B...

Page 88: ...NG HEAD 3 33 LUBRICATING THE LEVERS 3 34 LUBRICATING THE PEDAL 3 34 LUBRICATING THE DRIVE CHAIN 3 34 LUBRICATING THE SIDESTAND 3 34 CHECKING THE CHASSIS FASTENERS 3 35 ELECTRICAL SYSTEM 3 36 CHECKING THE SPARK PLUG 3 36 CHECKING THE IGNITION TIMING 3 36 CHECKING AND CHARGING THE BATTERY 3 37 ...

Page 89: ...e valve faces for wear Replace Valve spring Inspect Check the free length and the tilt Replace Valve lifter Inspect Check for scratches and wear Replace Camshaft Inspect Inspect the camshaft surface Inspect the decompression system Replace Camshaft sprocket Inspect Check for wear on the teeth and for damage Replace Piston Inspect Inspect crack Clean Inspect carbon deposits and eliminate them Repla...

Page 90: ... filter Clean and lubricate Use Yamaha foam air filter oil or other quality foam air filter oil Replace Spark plug Inspect and clean Check the electrodes and the terminals for wear Replace Cooling system Check coolant level and leakage Check radiator cap operation Use the radiator cap tester for a checkup Check radiator cap attached Change the coolant Every two years Inspect hoses Engine guard Rep...

Page 91: ...d Lubricate Lithium soap based grease Steering head Inspect free play and retighten Check for tightening torques Clean and lube After rain ride Replace bearings Tire wheels Inspect air pressure wheel run out tire wear and spoke looseness Retighten sprocket bolt Check the bearing Replace bearings Lubricate Lithium soap based grease Drive chain Clean lubricate slack alignment Use chain oil Replace U...

Page 92: ... and bolts Retighten Refer to TORQUE CHECK POINTS on page 1 24 Battery Inspect Check terminal for looseness and corrosion Item Check or mainte nance job After break in Every race about 2 5 hours Every third about 7 5 hours Every fifth about 12 5 hours As required Remarks ...

Page 93: ... 21 3 22 3 22 3 23 3 23 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 65 4 65 4 66 4 66 4 66 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play 3 32 3 32 3 33 3 33 Steering Check that the handlebar can be turned smoothly and have no excessive play 3 33 Front forks and rear s...

Page 94: ...few minutes until the coolant has settled EAM30211 CHECKING THE COOLING SYSTEM 1 Remove Seat Side cover left right Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Air filter case cover Refer to THROTTLE BODY on page 7 5 2 Check Radiator Radiator hose Crack damage Replace Refer to RADIATOR on page 6 1 3 Install Air filter case cover Refer to THROTTLE BODY on page 7 5 Air scoop left right ...

Page 95: ... Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 6 EAM30213 CHECKING THE RADIATOR CAP 1 Check Seal radiator cap 1 Valve and valve seat 2 Crack damage Replace Exist fur deposits Clean or replace EAM30214 CHECKING THE RADIATOR CAP VALVE OPENING PRESSURE 1 Check Radiator cap valve opening pressure a Install the radiator cap tester adapter 2 and the radiator cap tester 3 to the radiator c...

Page 96: ...eaks Correct or replace Radiator hoses Bulges Replace WARNING EWA19090 When the radiator cap tester is removed coolant will spout therefore cover it with a cloth beforehand EAM30370 ADJUSTING THE CLUTCH LEVER POSITION 1 Adjust Clutch lever position a Loosen the locknut 1 and use the adjuster 2 to adjust the clutch lever position a as desired 2 Tighten Locknut EAM30216 ADJUSTING THE CLUTCH LEVER FR...

Page 97: ...E THROTTLE GRIP FREE PLAY TIP Prior to adjusting throttle grip free play the en gine idling speed should be adjusted 1 Check Throttle grip free play a Out of specification Regulate 2 Adjust Throttle grip free play a Loosen the locknut 1 b Turn the adjuster 2 in direction a or b until the specified throttle grip free play is ob tained Direction a Clutch lever free play is increased Direction b Clut...

Page 98: ...ottle grip moves smoothly If this does not move smoothly correct the installed positions EAM30219 CLEANING THE AIR FILTER ELEMENT 1 Remove Fuel tank cap cover 1 Refer to FUEL TANK CAP on page 1 20 Air filter case cover 2 TIP Loosen the quick fastener screw 3 and re move the air filter case cover Remove the two ribs a located on the left and right sides of the projections b on the air scoop and sli...

Page 99: ...er element Air filter element 3 to the air filter guide Air filter guide 4 TIP Apply lithium soap based grease on the entire seal lips when installing the air filter guide Make sure that the two projections a at the rear side of the vehicle on the air filter guide are securely fitted into the two slots b in the air fil ter case Check that the air filter element is turned up be tween the air filter...

Page 100: ...e 1 Crack damage Replace Loose connection Connect properly NOTICE ECA14920 Make sure the cylinder head breather hose is routed correctly EAM30221 CHECKING THE EXHAUST SYSTEM 1 Remove Exhaust pipe protector 2 Check Exhaust pipe 1 Exhaust pipe 2 Silencer Crack damage Replace Refer to ENGINE REMOVAL on page 5 1 Exhaust gas Leaks Replace the gasket Refer to ENGINE REMOVAL on page 5 1 3 Check Tightenin...

Page 101: ...that the engine oil level is above the minimum level mark a shown for the oil level check window 1 and that the engine oil does not come out by removing the oil check bolt 2 The minimum level mark a or below Add the engine oil until its level exceeds the mini mum level mark a Engine oil coming out of the oil check bolt Drain it until its last drop is out NOTICE ECA24290 Since engine oil also lubri...

Page 102: ...r element is also to be replaced perform the following procedure a Remove the oil filter element cover 1 and oil filter element 2 b Replace the new O ring 3 c Install the new oil filter element and the oil fil ter element cover 5 To check the oil strainer perform the follow ing procedure a Remove the oil strainer 1 b Check the oil strainer Damage Replace Clogging due to dirt Wash with kerosene c R...

Page 103: ...ause the air pressure is lower at high alti tudes the air fuel mixture will become richer If the idling speed is low turn the idle screw clockwise to increase the speed before the ad justment Before adjusting the engine idling speed make sure that the air filter element is not clogged the engine compression is proper and the throttle grip free play is proper Adjust the engine idling speed with the...

Page 104: ...ke sure that the valve clearance is checked or adjusted while the engine is cold at room temperature While the valve clearance is checked or adjust ed make sure that the piston is positioned in the top dead center TDC 1 Remove Seat Side cover left right Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 ECU 2 Remove Spark plug Cylinder head cover Ref...

Page 105: ...f the clearance is incorrect 5 Adjust Valve clearance a Remove the camshaft intake and exhaust Refer to CAMSHAFT on page 5 11 b Remove the valve lifter 2 and the adjusting pad 3 with a valve lapper 1 TIP Place a cloth in the timing chain space to pre vent adjusting pads from falling into the crank case Identity each valve lifter and adjusting pad po sition very carefully so that they can be rein s...

Page 106: ... number to replace Example Pad number 148 Rounded value 150 e Install the new adjusting pads 4 and the valve lifters 5 NOTICE ECA24310 Do not twist adjusting pads and valve lifters forcibly during installation TIP Apply the engine oil on the valve lifters Apply molybdenum disulfide oil to the valve stem ends Check that the valve lifters turn smoothly when rotated with your finger Make sure that va...

Page 107: ...180 185 190 195 200 205 210 215 220 225 230 235 240 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 84 185 190 195 200 205 210 215 220 225 230 235 240 0 85 0 89 190 195 200 205 210 215 220 225 230 235 240 0 90 0 94 195 200 205 210 215 220 225 230 235 240 0 95 0 99 200 205 210 215 220 225 230 235 240 1 00 1 04 20...

Page 108: ...215 220 225 230 235 240 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 84 180 185 190 195 200 205 210 215 220 225 230 235 240 0 85 0 89 185 190 195 200 205 210 215 220 225 230 235 240 0 90 0 94 190 195 200 205 210 215 220 225 230 235 240 0 95 0 99 195 200 205 210 215 220 225 230 235 240 1 00 1 04 200 20...

Page 109: ...plastic hose 1 to the bleed screw 2 securely and place a container un der the end of the plastic hose d Slowly apply the brake several times e Fully pull the brake lever or fully press down the brake pedal and hold it in position f Loosen the bleed screw TIP Loosening the bleed screw will release the pres sure in the brake caliper and cause the brake le ver to contact the throttle grip or the brak...

Page 110: ...ocknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified brake lever position is obtained c Tighten the locknut WARNING EWA13050 A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance ...

Page 111: ...he brake sys tem Air in the brake system will cause brak ing performance to be reduced NOTICE ECA13510 After adjusting the brake pedal position make sure there is no brake drag EAM30231 CHECKING THE FRONT BRAKE PADS 1 Measure Brake pad thickness a Out of specification Replace as a set TIP The pads worn up to the indicator b grooves mean that the brake pad thickness limit is reached 2 Replace Brake...

Page 112: ...h their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point i Install the brake caliper 8 and tighten the pad pin 9 j Install the pad pin plug 10 3 Check Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 26 4 Check Brake lever operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE BRAKE SYSTEM Bleed screw 6 N m 0...

Page 113: ...age 4 9 d Remove the pad pin 6 and the brake pads 7 e Connect the plastic hose 8 to the bleed screw 9 and place a container under the end of the plastic hose f Loosen the bleed screw and push the brake caliper piston in WARNING EWA19170 Do not reuse the drained brake fluid g Tighten the bleed screw h Install the brake pad 10 and the pad pin 11 TIP Install the brake pads with their projections a in...

Page 114: ...efer to REAR BRAKE on page 4 23 2 Check Rear brake pad insulator 1 Damage Replace EAM30234 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle upright on a level surface TIP In order to ensure a correct reading of the brake fluid level make sure that the top of the brake fluid reservoir is horizontal 2 Check Brake fluid level The minimum level mark a or below Add WARNING EWA13090 Use only the desig...

Page 115: ...e the rear wheel off the ground WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Shift the transmission into the neutral posi tion 3 Pull the drive chain up above the drive chain guide installation bolt with a force of about 50 N 5 0 kgf 36 lbf 4 Check Drive chain slack a Out of specification Regulate TIP Measure drive chain slack between the drive chai...

Page 116: ...to FRONT FORK on page 4 38 EAM30236 CHECKING THE FRONT FORK PROTECTOR GUIDE 1 Check Protector guide 1 Out of specification Replace TIP The protector guide reaches the limit of its use when it is worn down to the same height a as of the outer tube circumference EAM30237 CLEANING THE FRONT FORK OIL SEAL AND DUST SEAL 1 Remove Protector Dust seal 1 NOTICE ECA24330 Be careful not to damage the dust se...

Page 117: ...n of a or b to make an adjustment Compression damping NOTICE ECA24350 Do not turn the adjuster forcibly beyond its adjusting range 1 Adjust Compression damping a Turn the adjuster 1 in the direction of a or b to make an adjustment Bleed screw 1 3 N m 0 13 kgf m 0 95 lb ft Direction a Rebound damping is increased sus pension is harder Direction b Rebound damping is decreased sus pension is softer T...

Page 118: ...y operates smoothly Unsmooth operation Correct or replace Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 55 EAM30242 ADJUSTING THE REAR SHOCK 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 ECA24360 Do not turn the adjuster forcibly beyond its adjusti...

Page 119: ...damping a Turn the adjuster 1 in the direction of a or b to make an adjustment 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 6 0 mm 0 24 in from its free length Maximum Position in which the spring is turned in 18 0 mm 0 71 in from its free length Locknut 10 N m 1 0 kgf m 7...

Page 120: ...s position Cor rect the tire position EAM30244 CHECKING AND TIGHTENING THE SPOKES 1 Check Spoke Bend damage Replace Loose Tighten Fast compression damping Minimum soft 2 turn s in direction b Standard 1 1 2 turn s in direction b Maximum hard 0 turn s in direction b With the adjusting screw fully turned in di rection a Direction a Compression damping is increased suspension is harder Direction b Co...

Page 121: ...ge 4 6 and CHECKING THE REAR WHEEL on page 4 10 EAM30247 CHECKING AND ADJUSTING THE STEERING HEAD 1 Use a maintenance stand to raise the front wheel off the ground WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Check Steering head Grasp the bottom of the front fork legs and gently rock the front fork Blinding looseness Adjust the steering head 3 Remov...

Page 122: ...l EAM30251 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts If the drive chain is not maintained proper ly it will wear out quickly Therefore the drive chain should be serviced especially when the vehicle is used in dusty areas This vehicle has a drive chain with small rubber O rings between each side plate Steam clean ing high pressure washing certain solvents and th...

Page 123: ...S 3 35 EAM30253 CHECKING THE CHASSIS FASTENERS Make sure that all nuts bolts and screws are properly tightened Refer to CHASSIS TIGHTENING TORQUES on page 2 14 Recommended lubricant Lithium soap based grease ...

Page 124: ...rk plug type Wrong type Replace 4 Check Electrode Damage wear Replace the spark plug Insulator Abnormal color Replace the spark plug Normal color is medium to 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 plug gap 7 Install Spark plug TIP Before installing the spark plug clean the spark plug and gasket surfac...

Page 125: ...ring range b on the rotor Incorrect firing range Check rotor and crankshaft position sensor 5 Install Timing mark accessing screw EAM30256 CHECKING AND CHARGING THE BATTERY Refer to CHECKING AND CHARGING THE BATTERY on page 8 59 Timing light 90890 03141 Timing light YU 03141 Digital tachometer 90890 06760 Digital tachometer YU 39951 B Timing mark accessing screw 6 N m 0 6 kgf m 4 4 lb ft 1 2 2 3 3...

Page 126: ...ELECTRICAL SYSTEM 3 38 ...

Page 127: ... THE FRONT BRAKE CALIPER 4 17 DISASSEMBLING THE FRONT BRAKE CALIPER 4 17 CHECKING THE FRONT BRAKE CALIPER 4 18 ASSEMBLING THE FRONT BRAKE CALIPER 4 18 INSTALLING THE BRAKE CALIPER PISTON 4 18 INSTALLING THE FRONT BRAKE CALIPER 4 19 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 20 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 20 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 20 INSTALLING THE FRONT BRAKE M...

Page 128: ... REAR SHOCK ABSORBER ASSEMBLY 4 55 HANDLING THE REAR SHOCK ABSORBER 4 57 DISPOSING OF A REAR SHOCK ABSORBER 4 57 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 57 REMOVING THE BEARING 4 57 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 58 CHECKING THE CONNECTING ARM AND RELAY ARM 4 58 INSTALLING THE RELAY ARM 4 58 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 59 SWINGARM 4 61 REMOVING THE SWINGARM 4 62 ...

Page 129: ...de 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 Main relay 1 10 Radiator fan motor relay 1 11 CCU Communication Control Unit 1 6 7 9 1 2 22 N m 2 2 kgf m 16 lb ft 7 N m 0 7 kgf m 5 2 lb ft 8 5 3 4 11 22 N m 2 2 kgf m 16 lb ft 10 ...

Page 130: ... to CLEANING THE AIR FILTER ELE MENT on page 3 10 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 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 16 N m 1 6 kgf m 12 lb ft 1 ...

Page 131: ...utch 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 the number plate insert the projection on the number plate into the hole in the upper side of the band EAM30458 INSTALLING THE AIR SCOOP 1 Install Air scoop left 1 right TIP After inserting the proj...

Page 132: ...n 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 right so that the rib is lo cated under the rib of the rear fender a Projection b Slot a Projection b Slot c Rib side cover d Rib rear fender 1 1 1 b b a a a a a 1 1 c c b b d d ...

Page 133: ...ise 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 7 6 5 6 7 6 8 2 1 1 3 4 21 N m 2 1 kgf m 15 lb ft 21 N m 2 1 kgf m 15 lb ft 115 N m 11 5 kgf m 85 lb ft 12 N m 1 2 kgf m 8 9 lb ft ...

Page 134: ... 32 and CHECKING THE WHEELS on page 3 33 3 Check Spoke Bend damage Replace Loose Tighten Tap the spokes with a screwdriver TIP A tight spoke will emit a clear ringing tone a loose spoke will sound flat 4 Tighten Spoke Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 32 TIP After tightening the spokes measure the wheel runout 5 Measure Radial wheel runout a Lateral wheel runout b Out of specif...

Page 135: ...earing right side 3 Oil seal 4 TIP Apply the lithium soap based grease to the bearing and the oil seal lip when installing Left side of bearing shall be installed first Install the oil seal with its manufacture s marks or numbers facing outward NOTICE ECA24420 Install the bearing by pressing its outer race parallel TIP Use a socket 1 that matches the diameter of the bearing outer race and that of ...

Page 136: ...heel axle 1 TIP Apply the lithium soap based grease to the front wheel axle 3 Tighten Front wheel axle nut 1 NOTICE ECA24430 Before tightening the front wheel 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 LT 2 1 1 1 2 Front wheel axle nut 115 N m 11 5 kgf m 85 lb ft Front wheel axle pinch bolt 21 N m 2...

Page 137: ...ground 1 Nut rear wheel axle 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 2 10 Brake disc 1 6 2 5 7 9 LS LS 6 4 6 1 6 3 LS 8 9 10 7 5 LT 3 21 N m 2 1 kgf m 15 lb ft 21 N m 2 1 kgf m 15 lb ft 125 N m 12 5 kgf m 92 lb ft 50 N m 5 0 kgf m 37 lb ft 12 N m 1 2 kgf m 8 9 lb ft ...

Page 138: ... on page 3 33 3 Check Spoke Refer to CHECKING THE FRONT WHEEL on page 4 6 4 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 6 EAM30024 DISASSEMBLING THE REAR WHEEL 1 Remove Oil seal Bearing Refer to DISASSEMBLING THE FRONT WHEEL on page 4 7 EAM30025 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1 Check Rear wheel sprocket More than 1 4 tooth wear a Rep...

Page 139: ...ith its manufacture s marks or numbers facing outward NOTICE ECA24440 Install the bearing by pressing its outer race parallel TIP Use a socket 1 that matches the diameter of the bearing outer race and that of the oil seal 2 Install Brake disc 1 Brake disc bolt 2 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 li...

Page 140: ... from the left side Apply the lithium soap based grease to the rear wheel axle 4 Install Right drive chain puller 1 Washer 2 Rear wheel axle nut 3 TIP Temporarily tighten the nut rear wheel axle at this point 5 Adjust Drive chain slack a Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 27 6 Tighten Rear wheel axle nut 1 Locknut 2 Drive chain slack Maintenance stand 50 0 60 0 mm 1 97 2 36 in Whee...

Page 141: ...EM on page 3 21 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 3 9 1 2 8 4 5 7 6 28 N m 2 8 kgf m 21 lb ft 30 N m 3 0 kgf m 22 lb ft 6 N m 0 6 kgf m 4 4 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 17 N m 1 7 kgf m 13 lb ft ...

Page 142: ...sembling 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 3 4 S S BF BF S 6 N m 0 6 kgf m 4 4 lb ft ...

Page 143: ...olt 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 cylinder holder 1 9 Front brake master cylinder 1 5 6 7 2 3 4 8 9 1 30 N m 3 0 kgf m 22 lb ft 6 N m 0 6 kgf m 4 4 lb ft 6 N m 0 6 kgf m 4 4 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 9 N m 0 9 kgf m 6 6 lb ft ...

Page 144: ...RONT BRAKE 4 16 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Push rod 1 2 Dust boot 1 3 Circlip 1 4 Washer 1 5 Brake master cylinder kit 1 BF 5 4 3 2 1 S New New ...

Page 145: ...ttention EAM30029 CHECKING THE FRONT BRAKE DISC 1 Remove Front wheel Refer to FRONT WHEEL on page 4 5 2 Check Front brake disc Damage galling Replace 3 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace 4 Install Front wheel Refer to FRONT WHEEL on page 4 5 EAM30030 REMOVING THE FRONT BRAKE CALIPER TIP Before disassembling the b...

Page 146: ...cating 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 EAM30034 INSTALLING THE BRAKE CALIPER PISTON 1 Clean Brake caliper Brake caliper piston seal Brake caliper piston dust seal Brake caliper piston Use brake f...

Page 147: ...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 ...

Page 148: ... 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 Brake master cylinder kit Damage scratches wear Replace 3 Check Brake master cylinder reservoir cap 4 Check Brake hose Cracks damage wear Replace EAM30038 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER WARNING E...

Page 149: ...INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Brake master cylinder 1 TIP Install the front brake master cylinder holder with the UP mark facing up First tighten the upper bolt then the lower 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 During installation bring the brake hose int...

Page 150: ...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 4 Bleed Brake system Refer to BLEEDING THE BRAKE SYSTEM on page 3 2...

Page 151: ...opper 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 caliper assembly 1 2 3 4 11 5 6 7 9 1 8 9 10 S 7 N m 0 7 kgf m 5 2 lb ft 30 N m 3 0 kgf m 22 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 17 N m 1 7 kgf m 13 lb ft 2 5 N m 0 25 kgf m 1 8 l...

Page 152: ...isassembling 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 6 kgf m 4 4 lb ft ...

Page 153: ...3 21 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 cylinder reservoir diaphragm 1 10 Rear brake master cylinder 1 1 2 3 4 7 5 8 6 9 10 30 N m 3 0 kgf m 22 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft ...

Page 154: ...REAR BRAKE 4 26 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Push rod 1 4 Brake master cylinder kit 1 4 3 2 1 BF S New New ...

Page 155: ...AM30041 CHECKING THE REAR BRAKE DISC 1 Remove Rear wheel Refer to REAR WHEEL on page 4 9 2 Check Brake disc Damage galling Replace 3 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISC on page 4 17 4 Measure Brake disc deflection Out of specification Correct the brake disc deflection or repl...

Page 156: ...seal EAM30044 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA19270 When the brake cal...

Page 157: ...e caliper piston 1 TIP Apply the brake fluid on the piston outer surface NOTICE ECA24480 Install the piston with its side a facing the brake caliper Never force to insert EAM30047 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake caliper Rear brake caliper bracket 2 Install Rear wheel Refer to REAR WHEEL on page 4 9 Copper washer Brake hose Union bolt WARNING EWA13531 Proper brake hose routin...

Page 158: ...evel mark a or below Add Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 26 7 Check Brake pedal operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE BRAKE SYSTEM on page 3 21 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 hos...

Page 159: ...auses poor braking performance 3 Install Spring 1 Install to the brake master cylinder piston 2 TIP Install the spring with a smaller inside diameter to the brake master cylinder piston 4 Install Master cylinder kit 1 Push rod 2 Circlip 3 Dust boot 4 TIP Before installation apply brake fluid to the brake master cylinder kit Before installation apply silicone grease to the push rod end Use circlip ...

Page 160: ...mance 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 ECA24510 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE BRAKE SYSTEM on page 3 21 4 Check Brake flui...

Page 161: ...able pull 1 Disconnect 8 Throttle cable return 1 Disconnect 9 Right grip 1 10 Tube guide 1 11 Start switch 1 12 Left grip 1 13 Upper handlebar holder 2 14 Handlebar 1 15 Lower handlebar holder 2 16 Damper 4 12 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 m ...

Page 162: ...over 2 Install Damper 1 Lower handlebar holder 2 temporarily Handlebar 3 Upper handlebar holder 4 TIP Install the lower handlebar holders with them side having the greater distance a from the mounting bolt center facing forward Installing the lower handlebar holders in the re verse direction allow the front to rear offset amount of the handlebar position to be changed The upper handlebar holders s...

Page 163: ...TIP Install the handlebar grip to the handlebar so that the line a between the two arrow marks faces straight upward 5 Install Engine stop switch 1 Clutch lever 2 Clutch lever holder 3 Mode switch 4 Clamp 5 TIP The engine stop switch the clutch lever the clutch lever holder and the mode switch should be installed according to the dimensions shown a 3 4 4 Lower handlebar holder nut 40 N m 4 0 kgf m...

Page 164: ... grip 2 TIP Apply the lithium soap based grease on the throttle grip sliding surface 8 Install Throttle cables 1 TIP Slightly coat the end of throttle cable and inside of throttle grip with lithium soap based grease Then mount the throttle grip onto the handlebar 9 Install Throttle cable housing 1 Screw throttle cable housings 2 WARNING EWA19310 After tightening the throttle cable housing screws c...

Page 165: ...inder assembly to be level First tighten the upper bolt then the lower bolt 12 Install Clutch cable 1 TIP Before installation apply the lithium soap based grease to the clutch cable end 13 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 8 14 Adjust Throttle grip free play Refer to ADJUSTING THE THROTTLE GRIP FREE PLAY on page 3 9 Front brake master cylinder ho...

Page 166: ...r to FRONT WHEEL on page 4 5 Front brake caliper Refer to FRONT BRAKE on page 4 13 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 4 Lower bracket pinch bolt 2 Loosen 5 Front fork leg 1 5 N m 0 5 kgf m 3 7 lb ft 5 N m 0 5 kgf m 3 7 lb ft 9 N m 0 9 kgf m 6 6 lb ft 21 N m 2 1 kgf m 15 lb ft 1 5 4 2 3 3 2 2 3 ...

Page 167: ... 1 5 Inner tube 1 6 Outer tube 1 7 Piston metal 1 8 Protector guide 1 9 Slide metal 1 10 Washer 1 11 Oil seal 1 12 Base valve 1 13 Damper assembly 1 LS 13 2 6 9 8 10 11 4 3 1 5 7 12 New New New New New New New LT 1 3 N m 0 13 kgf m 0 95 lb ft 28 N m 2 8 kgf m 21 lb ft 29 N m 2 9 kgf m 21 lb ft 30 N m 3 0 kgf m 22 lb ft 55 N m 5 5 kgf m 41 lb ft ...

Page 168: ...nt 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 tube and locknut 3 Hold the locknut and remove the adjuster NOTICE ECA24520 Do not remove the locknut as the damper rod may go into the damper assembly and not be taken out 3 Remove Dust seal 1 Oil se...

Page 169: ...bent inner tube as this may dangerously weaken it 2 Check Outer tube Scratches wear damage Replace 3 Measure Fork spring free length a Out of specification Replace 4 Check Damper assembly 1 Bend damage Replace O ring 2 Wear damage Replace NOTICE ECA14200 The front fork leg has a built in damper ad justing rod and a very sophisticated inter nal construction which are particularly sensitive to forei...

Page 170: ...ube bushing Outer tube bushing 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 NOTICE ECA24530 Be sure to use the recommended oil Other oils may have an adverse effect on front fork performance When disassembling and assembling the front fork leg take care not to allow any for eign...

Page 171: ...tion Unless the damping force adjuster is fully loos ened correct damping characteristic cannot be obtained after installation 7 Install Base valve 1 to the damper assembly 2 TIP First bring the damper rod pressure to a maxi mum Then install the base valve while releasing the damper rod pressure 8 Check Damper assembly Not fully stretched Repeat the steps 1 to 7 9 Tighten Base valve 1 Standard oil...

Page 172: ...the damper assem bly 12 Allow the overflowing oil to escape at the hole a in the damper assembly TIP The overflow measures about 10 cm 0 34 US oz 0 35 Imp oz 13 Check Damper assembly smooth movement Tightness binding rough spots Repeat the steps 1 to 12 14 Install Dust seal 1 Oil seal clip 2 Oil seal 3 Washer 4 Outer tube bushing 5 to the inner tube 6 NOTICE ECA24550 Make sure that the numbered si...

Page 173: ...nstall Piston metal 1 TIP Install the piston metal onto the slot on inner tube 16 Install Outer tube 1 to the inner tube 2 17 Install Slide metal 1 Washer 2 to the outer tube TIP Press the slide metal into the outer tube with fork seal driver 3 18 Install Oil seal 1 TIP Using a fork seal driver 2 press the oil seal in until the stopper ring groove fully appears LS New Fork seal driver 90890 01502 ...

Page 174: ...h spots Repeat the steps 14 to 20 22 Measure Distance a Out of specification Turn into the locknut 23 Install Collar 1 Fork spring 2 to the damper assembly 3 TIP Install the collar with its larger dia end a facing the fork spring 24 Install Damper assembly 1 to the inner tube 2 Fork seal driver 90890 01502 Fork seal driver 48 YM A0948 New Distance a 16 mm 0 63 in or more Between the damper assembl...

Page 175: ...ster 3 to the damper assembly 4 TIP While compressing the inner tube 5 set the cap bolt ring wrench 7 between the inner tube and locknut 6 Fully finger tighten the adjuster onto the damp er assembly 27 Measure 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 ...

Page 176: ...ghten the damper assembly 32 Install Protector guide 1 EAM30059 INSTALLING THE FRONT FORK LEGS 1 Install Front fork 1 TIP Temporarily tighten the pinch bolts lower bracket Do not tighten the pinch bolts upper bracket yet 2 Tighten Damper assembly 1 TIP Use the cap bolt ring wrench 2 to tighten the damper assembly Adjuster 55 N m 5 5 kgf m 41 lb ft LOCTITE Recommended oil Yamaha Suspension Oil S1 S...

Page 177: ... 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 finger tight and then turn out to the originally set position Cap bolt ring wrench 90890 01501 Cap bolt ring wrench YM 01501 Front fork top end standard a 5 mm 0 02 in Upper bracket pinch bolt 21 N m 2 1 kgf m 15 lb ft Lower bracket...

Page 178: ...FRONT FORK 4 50 1 ...

Page 179: ...fender 1 2 Steering stem nut 1 3 Front fork leg 2 Refer to FRONT FORK on page 4 38 4 Warning light engine trouble 1 Br Y W 5 Warning light fuel level 1 Br L Y 6 Upper bracket 1 7 Steering ring nut 1 8 Lower bracket 1 9 Bearing race cover 1 10 Upper bearing 1 11 Bearing race 2 12 Bearing lower side 1 2 6 7 9 3 1 8 10 12 11 LS LS LS 21 N m 2 1 kgf m 15 lb ft 21 N m 2 1 kgf m 15 lb ft 9 N m 0 9 kgf m...

Page 180: ...lace 3 Replace Bearing Bearing race a Remove the bearing race from the steering head pipe with a long rod 1 and a hammer b Remove the bearing race from the lower bracket with a chisel 2 and a hammer c Install a new bearing race NOTICE ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged TIP Always replace the bearing and the bearing race as a set 4 Check U...

Page 181: ...steering 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 33 5 Check the steering stem by turning this lock to lock If there is any binding remove the steering stem and check the steering bear ing 6 Install Washer 1 7 Install Front fork 1 Upper bracket 2 TIP Temporarily tighten th...

Page 182: ...steering ring nut little by lit tle 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 WARNING EWA19330 Tighten the lower bracket to specified torque If torqued too much it may cause the front fork to malfunction Steering stem nut 145 N m 14 5 kgf m 107 lb ft Front fork top end standard a 5 mm 0 02 in T R a Upper bracket pinch bolt 21 N m 2 1 kgf m 15 l...

Page 183: ...t 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 assembly 1 4 Locknut 1 5 Adjusting nut 1 6 Lower spring guide 1 7 Upper spring guide 1 8 Spring 1 9 Dust seal 2 10 Collar 2 11 Bushing 1 12 Collar 2 13 Bearing 1 2 13 12 12 4 5 7 6 8 3 9 9 10 10 11 1 M 56 N m 5...

Page 184: ... 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 5 6 6 5 4 3 2 4 6 6 3 4 4 M M M M M M M 80 N m 8 0 kgf m 59 lb ft ...

Page 185: ...of run ning EAM30064 DISPOSING OF A REAR SHOCK ABSORBER Before disposing the rear shock absorber 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 worn out rear shock absorber take the unit to your Yamaha dealer for this disposal procedure EAM30065 REMO...

Page 186: ... Damage wear Replace Bearing Damage wear Replace Bolt Bends damage wear Replace EAM30068 CHECKING THE CONNECTING ARM AND RELAY ARM 1 Check Connecting arm Relay arm Damage wear Replace 2 Check Bearing Spacer Damage pitting scratches Replace the bearings and spacers as a set 3 Check Oil seal Damage pitting Replace EAM30069 INSTALLING THE RELAY ARM 1 Lubricate Oil seal Bearing Spacer Washer Collar 2 ...

Page 187: ... swingarm bolt circumference 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 up the swingarm Install the rear shock absorber assembly upper bolt and connecting arm bolt frame side from the right Install the rear shock absorber assembly lower bolts c...

Page 188: ...REAR SHOCK ABSORBER ASSEMBLY 4 60 Rear shock absorber assembly lower bolt Relay arm bolt swingarm side 70 N m 7 0 kgf m 52 lb ft Rear shock absorber assembly lower bolt 53 N m 5 3 kgf m 39 lb ft T R T R ...

Page 189: ...se the front wheel off the ground Brake hose holder Refer to REAR BRAKE on page 4 23 Rear brake caliper Refer to REAR BRAKE on page 4 23 Bolt brake pedal Drive chain 1 Collar 2 2 Oil seal 2 3 Thrust bearing 2 4 Bushing 2 5 Oil seal 2 6 Bearing 4 1 2 3 6 4 6 4 1 3 6 2 5 4 0 N m 0 40 kgf m 3 0 lb ft 70 N m 7 0 kgf m 52 lb ft ...

Page 190: ...rm vertical movement is not smooth or if there is binding check the spacers the bearings and the collars EAM30072 REMOVING THE BEARING 1 Remove Bearing 1 TIP Remove the bearing by pressing its outer race 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 attempt to straighten a...

Page 191: ...om the right 4 Install Rear wheel Refer to REAR WHEEL on page 4 9 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 27 Recommended lubricant Molybdenum disulfide grease Installed depth a 0 0 5 mm 0 0 02 in Installed depth b 6 5 mm 0 26 in Pivot shaft nut 85 N m 8 5 kgf m 63 lb ft Drive chain slack Maintenance stand 50 0 60 0 mm 1 97 2 36 in New 2 2 2 1 1 a a a b b a New...

Page 192: ...Order Job Parts to remove Q ty Remarks Drive sprocket Refer to ENGINE REMOVAL on page 5 1 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 1 2 3 4 5 6 7 N m 0 7 kgf m 5 2 lb ft 75 N m 7 5 kgf m 55 lb ft ...

Page 193: ...th a between pin inner sides length b between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a different location each time 2 Check Drive chain Stiffness Clean lubricate or replace 3 Clean Drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and remove any remain...

Page 194: ...78 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 10 EAM30079 INSTALLING THE DRIVE CHAIN 1 Install Drive chain NOTICE ECA17410 Be sure to put on safety goggles when work ing TIP Install the drive chain joint with the drive chain cut rivet tool Use goods on the market a When press fitting the connecting plate 1 make sure the space a between the en...

Page 195: ...ts this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 27 NOTICE ECA24590 A drive chain that is too 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 Recommended lubrican...

Page 196: ...CHAIN DRIVE 4 68 ...

Page 197: ...COMPRESSION SYSTEM 5 16 INSTALLING THE CAMSHAFTS 5 16 CYLINDER HEAD 5 19 REMOVING THE CYLINDER HEAD 5 21 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 5 21 CHECKING THE CYLINDER HEAD 5 21 INSTALLING THE CYLINDER HEAD 5 22 VALVES AND VALVE SPRINGS 5 24 REMOVING THE VALVES 5 25 CHECKING THE VALVES AND VALVE GUIDES 5 26 CHECKING THE VALVE SEATS 5 27 CHECKING THE VALVE SPRINGS 5 29 CHECKING THE VALVE LI...

Page 198: ...STOPPER LEVER 5 49 INSTALLING THE STOPPER LEVER 5 49 INSTALLING THE SEGMENT 5 50 INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 5 50 INSTALLING THE SHIFT SHAFT 5 51 INSTALLING THE SHIFT PEDAL 5 51 OIL PUMP AND BALANCER GEAR 5 52 REMOVING THE BALANCER 5 54 CHECKING THE PRIMARY DRIVE GEAR BALANCER DRIVE GEAR AND BALANCER WEIGHT GEAR 5 54 CHECKING THE BALANCER 5 54 CHECKING THE OIL PUMP 5 54 ASS...

Page 199: ... BALANCER SHAFT 5 68 REMOVING THE CRANKSHAFT ASSEMBLY 5 68 CHECKING THE CRANKSHAFT ASSEMBLY 5 68 INSTALLING THE CRANKSHAFT ASSEMBLY 5 69 TRANSMISSION 5 70 REMOVING THE TRANSMISSION 5 71 CHECKING THE SHIFT FORKS 5 71 CHECKING THE SHIFT DRUM ASSEMBLY 5 71 CHECKING THE TRANSMISSION 5 72 INSTALLING THE TRANSMISSION 5 72 ...

Page 200: ...Y on page 4 55 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 1 9 5 8 2 6 1 6 6 3 4 7 8 6 New New New LT LT 1st 2nd 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft 30 N m 3 0 kgf m 22 lb ft 30 N m 3 0 kgf m 22 lb ft 30 N m 3 0 kgf m 22 lb ft 20 N m 2 0 kgf m 1...

Page 201: ...k Refer to FUEL TANK on page 7 1 Air filter case cover Refer to CLEANING THE AIR FILTER ELE MENT on page 3 10 Intake air temperature sensor coupler Refer to THROTTLE BODY on page 7 5 ECU Refer to THROTTLE BODY on page 7 5 Ignition coil Refer to THROTTLE BODY on page 7 5 1 Rectifier regulator 1 2 AC magneto coupler 1 Disconnect 3 Crankshaft position sensor coupler 1 Disconnect 4 Coolant temperature...

Page 202: ... 7 5 Throttle body Refer to THROTTLE BODY on page 7 5 Clutch cable Refer to CLUTCH on page 5 40 Shift pedal Drive chain Refer to SHIFT SHAFT on page 5 48 Refer to CHAIN DRIVE on page 4 64 1 Engine guard 1 2 Brake pedal 1 3 Spring 1 4 Cylinder head breather hose 1 5 Drive sprocket cover 1 6 Drive chain guide 1 7 Drive sprocket 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 2...

Page 203: ...emoving the engine Order Job Parts to remove Q ty Remarks 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 75 N m 7 5 kgf m 55 lb ft 34 N m 3 4 kgf m 25 lb ft 53 N m 5 3 kgf m 39 lb ft 55 N m 5 5 kgf m 41 lb ft 26 N m 2 6 kgf m 19 lb ft 34 N m 3 4 kgf m 25 lb ft 45 N m 4 5 kgf m 33 lb ft 1 2 3 4 5 6 7 8 9 11 13 10 11 10 12 ...

Page 204: ...he exhaust pipe 2 into the state as shown by moving this and then remove it EAM30160 REMOVING THE DRIVE SPROCKET 1 Straighten the lock washer tab 2 Remove Nut drive sprocket 1 Lock washer 2 TIP Loosen the nut while applying the rear brake 3 Remove Drive sprocket 1 Drive chain 2 TIP Remove the drive sprocket together with the drive chain EAM30161 REMOVING THE ENGINE 1 Remove Pivot shaft 1 TIP If th...

Page 205: ...and remove this from its low er part toward the right of the chassis EAM30163 CHECKING THE SILENCER AND EXHAUST PIPE 1 Check Gasket 1 Damage Replace EAM30373 CHANGING THE SILENCER FIBER 1 Remove Bolt 1 Silencer body 2 NOTICE ECA25800 Do not hit the silencer stay a as it may do damage to the silencer TIP Remove the inner pipe while holding the silencer in place with a vise etc 2 Remove Rivet 1 Sile...

Page 206: ...Fiber 1 TIP Stuff the fiber into the silencer body by using a flat board 2 6 Install Silencer cap 1 Rivet 2 TIP Apply heat resistant sealant to the areas a shown making sure that there are no gaps in the beads of sealant Take care not to allow the fiber out of place when installing the silencer body 3 Silencer body bolt 8 N m 0 8 kgf m 5 9 lb ft LOCTITE 2 1 1 1 1 T R 2 1 a LT 2 1 1 1 a 2 3 3 ...

Page 207: ...2 O ring 3 Bolt brake pedal 4 Clip 5 TIP Apply the lithium soap based grease on the bolt O rings and brake pedal bracket EAM30166 INSTALLING THE DRIVE SPROCKET 1 Install Drive sprocket 1 Drive chain 2 TIP Install the drive sprocket together with the drive Pivot shaft 85 N m 8 5 kgf m 63 lb ft Engine mounting bolt lower side 53 N m 5 3 kgf m 39 lb ft Engine bracket bolt front side 34 N m 3 4 kgf m ...

Page 208: ... INSTALLING THE EXHAUST PIPE AND MUFFLER 1 Install Gasket Exhaust pipe 1 1 Nut exhaust pipe 1 2 TIP First temporarily tighten all nuts to 7 N m 0 7 kgf m 5 2 lb ft Then retighten them to 10 N m 1 0 kgf m 7 4 lb ft 2 Install Clamp Exhaust pipe 2 1 Bolt exhaust pipe 2 2 TIP Make sure that the exhaust pipe band 1 does not ride on the projection a on the exhaust pipe Nut drive sprocket 75 N m 7 5 kgf ...

Page 209: ...ncer 2 4 Tighten Bolt exhaust pipe 2 Clamp TIP Tighten while checking that their front and rear joints are inserted in position A Exhaust pipe 1 and exhaust pipe 2 B Exhaust pipe 2 and silencer Bolt silencer 30 N m 3 0 kgf m 22 lb ft 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 2 1 a b a b A 3 1 B T R 2 2 2 1 1 T R T R ...

Page 210: ...r left right Refer to GENERAL CHASSIS on page 4 1 Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Ignition coil Refer to ENGINE REMOVAL on page 5 1 1 Cylinder head breather hose 1 2 Spark plug 1 3 Cylinder head cover 1 4 Timing chain guide top side 1 5 Cylinder head cover gasket 1 1 2 3 4 5 10 N m 1 0 kgf m 7 4 lb ft 13 N m 1 3 kgf m 9 6 lb ft ...

Page 211: ...rew 1 3 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 LS 5 8 3 4 1 2 7 6 5 4 4 6 M M E LS E E 6 N m 0 6 kgf m 4 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 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft E 6 N m 0 6 kgf m 4 4 lb ft ...

Page 212: ...t sprocket with the edge of the cylinder head 3 Remove Timing chain tensioner cap bolt 1 Timing chain tensioner 2 Gasket 4 Remove Bolt camshaft cap 1 Camshaft cap 2 Clip 3 TIP Remove the bolts camshaft cap in a criss cross pattern working from the outside in In order to prevent the clip from falling into the crankcase remove the camshaft cap NOTICE ECA24610 The bolts camshaft cap must be removed e...

Page 213: ...e camshaft journal as shown c Install the dowel pins and the camshaft caps TIP Tighten the camshaft cap 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 width of the Plastigauge 1 Camshaft lobe dimensions Lobe height Intake 38 130 38 230 mm 1 5012 1 5051...

Page 214: ... the camshaft and the timing chain as a set EAM30083 CHECKING THE TIMING CHAIN TENSIONERS 1 Check Timing chain tensioner Crack damage Replace a While pressing the tensioner rod lightly with your fingers use a thin screwdriver 1 to wind the tensioner rod up fully clockwise b When releasing the screwdriver by pressing lightly with your fingers make sure that the tensioner rod will come out smoothly ...

Page 215: ... the tops a of the valve lifters b Align the top dead center TDC mark a on the rotor with the alignment mark b on the crankcase cover c Fit the timing chain 3 onto both camshaft sprockets and install the camshafts on the cylinder head TIP Make sure that the alignment mark c on the ex haust camshaft sprocket and the alignment mark d on the intake camshaft sprocket are aligned with the edge of the c...

Page 216: ...ing chain ten sioner 2 and the gasket 3 and tighten the bolt 4 c Release the screwdriver check that the ten sioner rod comes out smoothly and tighten the gasket 5 and the cap bolt 6 3 Turn Crankshaft Counterclockwise several turns 4 Check Top dead center TDC mark on the rotor Align with the crankcase alignment mark Camshaft match marks Align with the cylinder head surface Out of alignment Adjust 5...

Page 217: ...CAMSHAFT 5 18 6 Install Cylinder head breather hose Spark plug Yamaha bond No 1215 90890 85505 Three bond No 1215 Spark plug 13 N m 1 3 kgf m 9 6 lb ft 1 3 4 4 2 a T R ...

Page 218: ...MOVAL on page 5 1 Radiator hose Disconnect Coolant temperature sensor coupler Disconnect Throttle body Refer to THROTTLE BODY on page 7 5 Camshaft Refer to CAMSHAFT on page 5 11 Upper engine bracket Refer to ENGINE REMOVAL on page 5 1 1 Bolt cylinder head 2 2 Bolt cylinder head 3 3 Bolt cylinder head 1 4 Cylinder head 1 5 Cylinder head gasket 1 6 Timing chain guide intake side 1 M 8 7 7 10 N m 1 0...

Page 219: ...sage plug 1 Removing the cylinder head Order Job Parts to remove Q ty Remarks M 8 7 7 10 N m 1 0 kgf m 7 4 lb ft 1st 3rd 4th 2nd 40 N m 4 0 kgf m 30 lb ft 22 N m 2 2 kgf m 16 lb ft 2 60 3 90 90 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 6 ...

Page 220: ...e or scratch the spark plug bore threads 2 Check Cylinder head Damage scratches Replace TIP When replacing the cylinder head replace also the valve Refer to CHECKING THE VALVE SEATS on page 5 27 Cylinder head coolant passages Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge and a thickness gauge across the cylin...

Page 221: ... and contact surfaces of the bolts and to both contact surfaces of the washers 1 c Install the washers and the bolts d Tighten the bolts to the specified torque in two or three steps in the proper tightening se quence as shown e Remove the bolts f Again apply molybdenum disulfide grease to the threads and contact surfaces of the bolts and to both contact surfaces of the washers g Retighten the bol...

Page 222: ...ghten the cylinder head mounting bolts in the proper tightening sequence TIP Tighten the bolts in two steps 90 and 60 to reach the specified angle in the proper tighten ing sequence l Tighten the bolts to the specified torque Bolt 1 4 3rd Specified angle 90 Final Specified angle Bolt 1 2 3 60 149 mm 5 87 in Bolt 4 90 165 mm 6 49 in 90 T R Bolt 5 6 10 N m 1 0 kgf m 7 4 lb ft T R ...

Page 223: ...ves and valve springs Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 19 1 Valve lifter 4 2 Adjusting pad 4 3 Valve cotter 8 4 Valve spring retainer 4 5 Valve spring 4 6 Valve stem seal 4 7 Valve spring seat 4 8 Intake valve 2 9 Exhaust valve 2 ...

Page 224: ...idth Refer to CHECKING THE VALVE SEATS on page 5 27 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 Remove Valve cotter 1 TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attachment 3 4 Remove Valve ...

Page 225: ...an oven a Remove the valve guide with the valve guide remover 1 b Install the new valve guide with the valve guide installer 1 and the valve guide remov er 2 Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clear ance exhaust 0 020 0 ...

Page 226: ... replace the valve guide If the valve is removed or replaced always re place the valve stem seal EAM30092 CHECKING THE VALVE SEATS 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat contact width a Out of specification Replace the cylinder head Valve guide remover installer set ø5 5 90890 04016 Valve guide r...

Page 227: ...s with new ones without them When replacing the valves or the valve guides use new valves to lap the valve seats and then replace them with new valves a Apply a coarse lapping compound a to the valve face NOTICE ECA13790 Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder...

Page 228: ... spring EAM30094 CHECKING THE VALVE LIFTERS 1 Check Valve lifter Damage scratches Replace the valve lift ers and cylinder head EAM30095 INSTALLING THE VALVES 1 Clean Valve stem end 2 Lubricate Valve stem 1 Valve stem seal 2 3 Install Spring seat 1 Valve stem seal 2 Valve 3 Valve spring 4 Valve spring retainer 5 to the cylinder head TIP Make sure each valve is installed in its original place Instal...

Page 229: ...ECA13800 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 when rotated with your finger Make sure that the valve lifter and the adjusting pad are reinstalled in their original positions b Smaller pitch Valve spring compressor 90890 04019 Valve spring compr...

Page 230: ...piston Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 19 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 1 1 2 3 4 4 5 6 7 E E LT 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft ...

Page 231: ...rs and 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 replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure the cylinder bore C with the cylin der bore gauge TIP Measure cylinder bore C by taking side to side an...

Page 232: ... 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 measured If the oil ring rail s gap is exces sive replace all three piston rings Diameter 96 955 96 970 mm 3 8171 3 8177 in Measuring point from piston skirt bottom 9 0 mm 0 35 in Piston to cylinder ...

Page 233: ...rail 2 Upper oil ring rail 3 2nd ring 4 Top ring 5 TIP Be sure to install the piston rings so that the manufacturer s marks or numbers face up 2 Install Piston 1 Piston pin 2 Piston pin clip 3 TIP Apply molybdenum disulfide oil to the piston pin Install the piston with the mark a on it pointing to its exhaust rear side Before installing the piston pin clip cover the crankcase opening with a cloth ...

Page 234: ...ring end gap 5 Install Cylinder gasket Dowel pin Cylinder TIP While compressing 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 ring rail d Oil ring expander e Lower oil ring rail Cylinder bolt 10 N m 1 0 kgf m 7 4 lb ft 1 3 2 a 3 a c e b d 15 15 15 15...

Page 235: ...ic locking tie 1 2 Starter motor cover upper 1 3 Starter motor cover lower 1 4 Starter motor 1 5 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 side firmly in place using a spanner 5 1 2 4 FWD FWD 10 N m 1 0 kgf m 7 4 lb ft 6 N m 0 6 kgf m 4 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 3 ...

Page 236: ...Q 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 4 5 6 6 7 1 FWD FWD 9 8 4 5 N m 0 45 kgf m 3 3 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft ...

Page 237: ...pecification Replace the starter motor a Measure the armature assembly resistances 1 with the digital circuit tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brush set 6 Measure Brush spring force Out of specification Replace the brush set 7 Check Gear teeth Damage wear Replace the starter motor Commutator diam...

Page 238: ... of the starter motor yoke 3 Install Circlip Plain washer O ring Washer starter motor front 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 grease on the O ring 5 Install Starter motor Starter motor cover upper lower Starter motor bolt Starter motor ...

Page 239: ...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 2 13 Clutch plate 7 14 Friction plate 2 6 Identification color purple 15 Clutch boss 1 E E 2 3 4 5 7 8 9 6 10 11 13 12 12 18 14 13 13 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 4 lb ft 75 N m 7 5 kgf m ...

Page 240: ...ver shaft 1 Removing the clutch Order Job Parts to remove Q ty Remarks E E 2 3 4 5 7 8 9 6 10 11 13 12 12 18 14 13 13 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 4 lb ft 75 N m 7 5 kgf m 55 lb ft 1 E E E E E E E E E FWD FWD ...

Page 241: ... 3 14 Coolant Drain Refer to CHANGING THE COOLANT on page 3 6 Brake pedal Refer to ENGINE REMOVAL on page 5 1 Clutch cover Refer to CLUTCH on page 5 40 1 Oil filter element cover 1 2 Oil filter element 1 3 Radiator pipe 2 1 4 Right crankcase cover 1 5 Gasket 1 6 Dowel pin 2 7 Collar 1 LS 5 6 2 4 1 6 7 3 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 m 1 0 kgf m 7 4 lb ft ...

Page 242: ...ck Clutch plate Damage Replace the clutch plates as a set 2 Measure Clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clutch plates as a set EAM30111 CHECKING THE CLUTCH 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 Universal clutch ...

Page 243: ...SSURE PLATE 1 Check Pressure plate Crack damage Replace EAM30115 CHECKING THE PUSH LEVER SHAFT 1 Check Push lever shaft Wear damage Replace EAM30116 CHECKING THE CLUTCH PUSH RODS 1 Check Push rod 1 1 Bearing 2 Washer 3 Push rod 2 4 Ball 5 Cracks damage wear Replace 2 Measure Push rod 2 bending limit Out of specification Replace EAM30117 CHECKING THE PRIMARY DRIVE GEAR 1 Check Primary drive gear Da...

Page 244: ...ith its manufac ture s marks or numbers facing inward EAM30120 INSTALLING THE RIGHT CRANKCASE COVER 1 Install Dowel pin 1 O ring 2 Collar 3 Gasket 4 TIP Apply the lithium soap based grease on the O ring 2 Install Right crankcase cover 1 Right crankcase cover bolt 2 TIP Apply the engine oil on the impeller shaft end When installing the crankcase cover onto the crankcase make sure that the impeller ...

Page 245: ...universal clutch holder 3 to hold the clutch boss 4 Bend the lock washer 1 tab 5 Install Friction plate 1 1 Clutch plate 2 Friction plate 2 3 TIP Install the clutch plates and 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 1 friction plate 2 identificatio...

Page 246: ...te 1 9 Install Clutch spring Clutch spring bolt TIP Tighten the bolts in stages and in a crisscross pattern 10 Install O ring 1 TIP Apply the lithium soap based grease to the O ring 11 Install Clutch cover 1 Clutch cover bolt TIP Tighten the bolts in stages and in a crisscross pattern New E E 1 2 3 1 1 1 Clutch spring bolt 10 N m 1 0 kgf m 7 4 lb ft Clutch cover bolt 10 N m 1 0 kgf m 7 4 lb ft T R...

Page 247: ...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 lever spring 1 15 Segment 1 LS 1 3 13 15 14 LT 6 10 11 12 11 8 12 10 4 2 5 7 LT E E 30 N m 3 0 kgf m 22 lb ft 12 N m 1 2 kgf m 8 9 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft ...

Page 248: ...ts an impact the stopper le ver may be damaged Take care not to give an impact to it when removing the bolt EAM30125 CHECKING THE SHIFT SHAFT 1 Check Shift shaft 1 Bends damage wear Replace Shift shaft spring 2 Damage wear Replace EAM30126 CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1 Check Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear damage Replace EAM30127 CHECKING THE STOPP...

Page 249: ...UIDE AND SHIFT LEVER ASSEMBLY 1 Install Spring 1 Pawl pin 2 Pawl 3 to the shift lever TIP Apply the engine oil on the spring pawl pin and pawl 2 Install Shift lever assembly to the shift guide 3 Install Shift lever assembly 1 Shift guide 2 TIP The shift lever assembly is installed at the same time as the shift guide Apply the engine oil on the segment bolt shaft 4 Tighten Shift guide bolt 1 Bolt s...

Page 250: ...ift shaft 4 TIP Apply the engine oil on the roller and shift shaft 2 Install Oil seal EAM30132 INSTALLING THE SHIFT PEDAL 1 Install Shift pedal 1 Shift pedal bolt 2 TIP Align the punch mark a on the shift shaft with the punch mark b in the shift pedal Shift pedal bolt 12 N m 1 2 kgf m 8 9 lb ft E E 1 1 2 2 3 3 4 4 New T R 1 1 2 2 a b ...

Page 251: ... ty Remarks Primary driven gear Refer to CLUTCH on page 5 40 Right crankcase cover Refer to CLUTCH on page 5 40 1 Oil pump assembly 1 2 Oil pump cover 1 3 Outer rotor 1 4 Dowel pin 1 5 Inner rotor 1 6 Oil pump drive shaft 1 7 Oil pump housing 1 LT E 3 2 1 4 5 7 6 5 N m 0 5 kgf m 3 7 lb ft 2 0 N m 0 20 kgf m 1 5 lb ft ...

Page 252: ...tor Refer to AC MAGNETO on page 5 57 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 Balancer drive gear 1 10 Lock washer 1 11 Balancer weight gear 1 10 N m 1 0 kgf m 7 4 lb ft 50 N m 5 0 kgf m 37 lb ft 6 2 7 8 9 11 10 3 5 4 1 E LT 45 N m 4 5 kgf m 33 lb ft 80 N m 8 0 kgf m 59 lb ft ...

Page 253: ...Replace EAM30135 CHECKING THE BALANCER 1 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 defec tive part s 2 Measure Inner rotor to outer rotor tip clearance a Outer rotor to oil pump housing clearance b Oil pump housing to inner rotor and outer rotor clearance c Out of specification Repl...

Page 254: ...e groove in the inner ro tor 2 Install Outer rotor 1 TIP Apply the engine oil on the outer rotor 3 Install Oil pump cover 1 Oil pump cover screw 2 EAM30138 INSTALLING THE OIL PUMP AND BALANCER GEAR 1 Install Oil pump assembly 1 Oil pump assembly bolt 2 NOTICE ECA13890 After tightening the bolts make sure the oil 1 Inner rotor 2 Outer rotor 3 Oil pump housing b a 1 2 3 c 2 1 3 Oil pump cover screw ...

Page 255: ...her 4 Primary drive gear nut 5 Straight key 6 Balancer 7 Lock washer 8 Balancer nut 9 TIP Apply engine oil to the contact surface and threaded portion of the primary drive gear nut Apply engine 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 face b ...

Page 256: ...ENERAL CHASSIS on page 4 1 1 AC magneto 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 assembly 1 9 Rotor 1 10 Woodruff key 1 1 10 2 4 7 5 8 3 9 6 LT 6 10 N m 1 0 kgf m 7 4 lb ft 8 N m 0 8 kgf m 5 9 lb ft 12 N m 1 2 kgf m 8 9 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 65 N...

Page 257: ...STALLING THE AC MAGNETO 1 Install Stator 1 Screw stator 2 Crankshaft position sensor 3 Bolt crankshaft position sensor 4 Holder Bolt holder TIP Apply the sealant to the grommet of the AC magneto lead Tighten the stator coil screws using the T25 bit Pass the AC magneto lead through the crank case cover side Rotor puller 90890 04151 Rotor puller YM 04151 1 1 2 1 a 2 b Screw stator 10 N m 1 0 kgf m 7...

Page 258: ...lign the keyway c of the rotor with the woodruff key 3 Install Washer Nut rotor 1 4 Install Dowel pin 1 Gasket left crankcase cover 2 Crankcase cover left 3 Lead holder 4 Bolt left crankcase cover 5 TIP Tighten the bolts in stages and in a crisscross pattern 5 Connect AC magneto lead Refer to CABLE ROUTING DIAGRAM on page 2 31 Nut rotor 65 N m 6 5 kgf m 48 lb ft 2 4 3 4 1 LT b 1 a c 1 2 T R 1 New ...

Page 259: ...e starter clutch Order Job Parts to remove Q ty Remarks Engine oil Refer to CHANGING THE ENGINE OIL on page 3 14 Clutch Refer to CLUTCH on page 5 40 1 Holder 1 2 Washer 1 3 Damper assembly 1 4 Starter clutch assembly 1 1 2 4 3 12 N m 1 2 kgf m 8 9 lb ft LT ...

Page 260: ...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 turn freely otherwise the starter clutch is faulty and must be replaced c When turning the starter clutch drive gear clockwise B the starter clutch and the start er clutch drive gear should engage ot...

Page 261: ...e 5 48 Stator Refer to AC MAGNETO on page 5 57 1 Timing chain guide exhaust side 1 2 Timing chain guide stopper plate 1 3 Timing chain 1 4 Bolt L 45 mm 1 77 in 5 5 Bolt L 60 mm 2 36 in 4 6 Bolt L 75 mm 2 95 in 3 7 Right crankcase 1 8 Left crankcase 1 9 Dowel pin 2 10 Crankshaft 1 11 Oil nozzle 1 3 1 5 2 6 4 10 5 5 5 4 4 4 6 9 7 8 11 9 LT LT 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 12 ...

Page 262: ...n Refer to TRANSMISSION on page 5 70 Shift cam and shift fork Refer to TRANSMISSION on page 5 70 1 Circlip 1 2 Oil seal 3 3 Bearing 11 E 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 lb ft 10 N m 1 0 kgf m 7 4 lb ft 12 N m 1 2 kgf m 8 9 lb ft 22 N m 2 2 kgf m 16 lb ft LT E LT E E LT ...

Page 263: ...er to tap on the case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If the cases do not separate check for a remaining case bolt or fitting Do not force c Remove the dowel pins and O ring EAM30148 REMOVING THE CRANKCASE BEARING 1 Remove Bearing 1 TIP Remove the bearing from the crankcase by press...

Page 264: ... TIP Apply the lithium soap based grease on the O ring 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 center TDC Tighten the bolts in a crisscross pattern in two stages with 1 4 turn each Installed depth a 0 0 0 5 mm 0 00 0 02 in Bearing cover plate 12 N m 1 2 kgf m 8 9 lb ft...

Page 265: ...CRANKCASE 5 66 4 45 mm 1 77 in 5 60 mm 2 36 in 6 75 mm 2 95 in 5 6 4 5 5 4 4 4 6 2 3 1 2 LT 5 6 ...

Page 266: ... ASSEMBLY 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 62 Transmission Refer to TRANSMISSION on page 5 70 1 Balancer shaft 1 2 Crankshaft assembly 1 1 2 ...

Page 267: ... the crankcase separating tool 2 EAM30145 CHECKING THE CRANKSHAFT ASSEMBLY 1 Measure Crankshaft runout Out of specification Replace the crank shaft bearing or both TIP Turn the crankshaft slowly 2 Measure Crank assembly width a Out of specification Replace the crank shaft 3 Check Crankshaft sprocket 1 Damage Replace the crankshaft Crankcase separating tool 90890 04152 Crankcase separating tool YU ...

Page 268: ...ion procedure lubricate the oil seal lips with lithium soap based grease In order to prevent the crankshaft seizure apply molybdenum disulfide grease TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft as sembly bottoms against the bearing Crankshaft installer ...

Page 269: ...emarks Engine Refer to ENGINE REMOVAL on page 5 1 Crankcase Separate Refer to CRANKCASE on page 5 62 1 Main axle 1 2 Drive axle 1 3 Long shift fork guide bar 1 4 Short shift fork guide bar 1 5 Spring 4 6 Shift cam 1 7 Shift fork 3 R 1 8 Shift fork 2 C 1 9 Shift fork 1 L 1 10 Collar 1 2 10 1 5 3 4 5 7 8 6 9 M M M M M E E E E LS FWD FWD ...

Page 270: ...le 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 the shift fork guide bar on a flat surface Bends Replace WARNING EWA12840 Do not attempt to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide bar Rough movem...

Page 271: ...nion gear 16T 2 Collar 3 4th pinion gear 20T 4 2nd pinion gear 15T 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 the sliding gear then install 2 Install Collar 1 2nd wheel gear 26T 2 4th wheel gear 21T 3 3rd wheel gear 21T 4 5th wheel gear 21T 5 Collar 6 1st wheel gear 29T 7 O ring 8 to the dri...

Page 272: ...stall Main axle 1 Drive axle 2 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 and the drive axle TIP Apply engine oil to the shift fork grooves Apply engine oil to the shift cam groove and the bearing contact surface Mesh the shift fork 1 L with t...

Page 273: ...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 Transmission operation Unsmooth operation Repair 6 7 5 2 4 3 1 E E E 2 1 3 E 2 ...

Page 274: ...TRANSMISSION 5 75 ...

Page 275: ...COOLING SYSTEM RADIATOR 6 1 HANDLING NOTE 6 3 CHECKING THE RADIATOR 6 3 WATER PUMP 6 4 REMOVING THE OIL SEAL 6 5 CHECKING THE WATER PUMP 6 5 CHECKING THE BEARING 6 5 INSTALLING THE OIL SEAL 6 5 ASSEMBLING THE WATER PUMP 6 5 ...

Page 276: ...FUEL TANK on page 7 1 Air filter case Refer to THROTTLE BODY on page 7 5 1 Radiator guard 2 2 Radiator hose clamp 8 Loosen 3 Radiator fan 1 For JPN 4 Radiator right 1 5 Radiator hose 2 1 6 Radiator hose 4 1 7 Radiator hose 3 1 8 Radiator pipe 2 1 9 Radiator breather hose 1 1 2 3 4 5 6 7 8 9 10 11 12 13 2 2 2 2 2 2 2 1 New New New 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...

Page 277: ...ving the radiator Order Job Parts to remove Q ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 2 2 2 2 2 2 2 1 New New New 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 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 15 N m 1 5 kgf m 11 lb ft 8 N m 0 8 kgf m 5 9 lb ft ...

Page 278: ...the radi ator cap EAM30341 CHECKING THE RADIATOR 1 Check Radiator fins 1 Obstructions Clean Apply compressed air to the rear of the radia tor Damage Repair or replace TIP Correct any flattened fins with a thin flat head screwdriver 2 Check Radiator hoses Radiator pipes Crack damage Replace ...

Page 279: ... on page 3 6 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 14 Right crankcase cover Refer to CLUTCH on page 5 40 1 Water pump housing 1 2 Dowel pin 2 3 Gasket 1 4 Collar 1 5 Pin 1 6 Impeller shaft assembly 1 7 Oil seal 1 8 Bearing 1 9 Oil seal 1 LS LS 7 6 2 2 3 1 8 5 4 E 9 E 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft ...

Page 280: ...AM30261 INSTALLING THE OIL SEAL 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 crankcase cover 2 Install Bearing 1 TIP Install the bearing by pressing its outer race par allel EAM30262 ASSEMBLING THE WATER PUMP 1 Install Impeller shaft assembly 1 Pin 2 Collar 3 Circlip 4 TIP Take care so...

Page 281: ... 3 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 2 T R New T R 1 4 2 2 3 ...

Page 282: ...WATER PUMP 6 7 ...

Page 283: ...2 CHECKING THE FUEL PUMP BODY 7 2 INSTALLING THE FUEL PUMP 7 2 INSTALLING THE FUEL TANK 7 3 CHECKING THE FUEL PRESSURE 7 3 CHECKING THE DAMPER 7 4 THROTTLE BODY 7 5 CHECKING THE INJECTOR 7 8 CHECKING THE THROTTLE BODY 7 8 CHECKING THE THROTTLE BODY JOINT 7 8 ADJUSTING THE THROTTLE POSITION SENSOR 7 9 ...

Page 284: ... 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 filter 1 6 Thermistor cover 1 7 Fuel pump gasket 1 8 Rubber damper 4 3 5 2 2 4 7 2 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 9 N m 0 9 kgf m 6 6 lb ft 7 N m 0 7 kgf m 5 2 lb ft 1 8 8 8 1 7 N m 0 7 kgf m 5 2 lb ft 6 5 ...

Page 285: ...el hose connector cover 1 on the end of the hose in 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 To prevent sand dust and other foreign mate rials from entering the fuel pump install the in cluded fuel hose joint cover 1 3 and the fuel hose joint...

Page 286: ... the fuel hose connector cover 1 at the hose end in the direction of the arrow Install the fuel hose connector holder a Check that the fuel hose and the fuel pump lead are routed through the guide on the cover 3 Connect Fuel pump coupler 4 Install Air scoop left right Seat Side cover left right Refer to GENERAL CHASSIS on page 4 1 EAM30268 CHECKING THE FUEL PRESSURE 1 Check Fuel pressure a Remove ...

Page 287: ...Damper 3 3 Wear damage Replace TIP Affix dampers 1 and 3 with the arrow on each damper pointing outward Affix the damper 2 with its projection a facing the rear of the vehicle Pressure gauge 90890 03153 Pressure gauge YU 03153 Fuel pressure adapter 90890 03186 Fuel pressure adapter YM 03186 Fuel line pressure at idle 300 390 kPa 3 0 3 9 kgf cm 43 5 56 6 psi 1 2 1 2 a 2 1 84 mm 84 mm 3 31 in 3 31 i...

Page 288: ...ntake air temperature sensor coupler 1 Disconnect 4 Breather hose 1 5 Air filter case 1 6 Fuel injector coupler 1 Disconnect 7 Intake air pressure sensor coupler 1 Disconnect 8 Throttle position sensor coupler 1 Disconnect 9 Cover 1 10 Throttle cable cover 1 3 2 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 8 N m 0 8 kgf m 5 9 lb ft 2 2 2 11 11 11 11 10 13 15 1...

Page 289: ...dy 1 14 Exhaust pipe bracket 1 15 Throttle body joint 1 Removing the throttle body Order Job Parts to remove Q ty Remarks 3 2 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 8 N m 0 8 kgf m 5 9 lb ft 2 2 2 11 11 11 11 10 13 15 14 6 8 10 N m 1 0 kgf m 7 4 lb ft 3 0 N m 0 30 kgf m 2 2 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 3 0 N m 0 30 kgf m 2 2 lb ft 3 5 N m 0 35 kgf ...

Page 290: ...g 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 5 N m 0 35 kgf m 2 6 lb ft ...

Page 291: ...gn material from falling into the engine If the throttle body is subject to strong shocks or dropped during cleaning re place it Do not use any caustic carburetor cleaning solution Do not directly push the throttle valves to open them Do not loosen the throttle valve stopper screw 1 throttle valve pulley nut 2 throttle valve screw 3 or starter knob nut 4 A loss of performance may occur Do not use ...

Page 292: ...ghten the throttle position sen sor c Check that the throttle grip is fully closed d Connect the throttle position sensor to the wire harness e Set the Yamaha diagnostic tool to diagnostic mode f Choose the diagnostic code No 01 g Adjust the throttle position sensor mounted angle until 11 14 appears on the Yamaha diagnostic tool h After adjusting the throttle position sensor mounted angle tighten ...

Page 293: ...OTING METHOD 8 24 YAMAHA DIAGNOSTIC TOOL 8 25 FEATURES OF THE YAMAHA DIAGNOSTIC TOOL 8 26 FUNCTIONS OF THE YAMAHA DIAGNOSTIC TOOL 8 26 CONNECTING THE YAMAHA DIAGNOSTIC TOOL 8 26 TROUBLESHOOTING DETAILS FAULT CODE 8 28 FUEL PUMP SYSTEM 8 47 CIRCUIT DIAGRAM 8 47 TROUBLESHOOTING 8 49 ELECTRICAL COMPONENTS 8 51 CHECKING THE SWITCHES 8 55 CHECKING THE BULBS AND BULB SOCKETS 8 58 CHECKING THE FUSES 8 58...

Page 294: ...ING THE FUEL SENDER 8 65 CHECKING THE RESISTOR 8 65 CHECKING THE RADIATOR FAN MOTOR For JPN 8 66 CHECKING THE COOLANT TEMPERATURE SENSOR 8 66 CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 8 67 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 8 67 CHECKING THE GEAR POSITION SWITCH 8 68 CHECKING THE FUEL INJECTOR 8 68 ...

Page 295: ......

Page 296: ...IGNITION SYSTEM 8 1 EAM20142 IGNITION SYSTEM EAM30277 CIRCUIT DIAGRAM ...

Page 297: ...7 Battery 8 Frame ground 9 Main fuse 10 Starter relay 11 Starter motor 12 Diode 1 13 Diode 2 14 CCU Communication Control Unit 21 ECU Engine Control Unit 22 Ignition coil 23 Spark plug 33 Engine stop switch 34 Gear position switch 35 Mode switch A Battery sub lead B Wire harness C Ignition coil sub lead D CCU sub lead ...

Page 298: ... page 8 59 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 36 NG Correct or replace the spark plug OK 5 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 62 OK The ignition system circuit is OK NG 6 Check the ignition coil Refer to CHECKING THE IGNI TION COIL on page 8 63 NG Replace t...

Page 299: ...0 Check the ignition system wire har ness Refer to CIRCUIT DIAGRAM on page 8 1 NG Repair or replace the wire harness OK Replace the ECU 1 Check the mode switch coupler connections NG Reconnect OK 2 Check the mode switch Refer to CHECKING THE SWITCHES on page 8 55 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 wi...

Page 300: ...ELECTRIC STARTING SYSTEM 8 5 EAM20143 ELECTRIC STARTING SYSTEM EAM30279 CIRCUIT DIAGRAM ...

Page 301: ...ain relay 6 Engine ground 7 Battery 8 Frame ground 9 Main fuse 10 Starter relay 11 Starter motor 12 Diode 1 13 Diode 2 21 ECU Engine Control Unit 33 Engine stop switch 34 Gear position switch 36 Start switch 37 Diode 3 A Battery sub lead B Wire harness ...

Page 302: ...KING THE RE LAYS on page 8 61 NG Replace the main relay OK 4 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 64 OK Starter motor is OK Perform the electric starting system troubleshooting starting with step 6 NG 5 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 38 NG Repair or replace the starter motor OK 6 Check the diodes Diode 1 ...

Page 303: ...rt switch Refer to CHECKING THE SWITCHES on page 8 55 NG Replace the start switch OK 10 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 5 NG Properly connect or repair the starting sys tem s wiring OK Replace the ECU ...

Page 304: ...CHARGING SYSTEM 8 9 EAM20144 CHARGING SYSTEM EAM30282 CIRCUIT DIAGRAM ...

Page 305: ...CHARGING SYSTEM 8 10 2 AC magneto 3 Rectifier regulator 6 Engine ground 7 Battery 8 Frame ground 9 Main fuse A Battery sub lead B Wire harness ...

Page 306: ...Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 59 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 65 NG Replace the rectifier regulator OK 5 Check the stator coil Refer to CHECKING THE STA TOR COIL on page 8 64 NG Replace the stator coil OK 6 Check the charging system wire...

Page 307: ...CHARGING SYSTEM 8 12 ...

Page 308: ...SIGNALING SYSTEM 8 13 EAM20154 SIGNALING SYSTEM EAM30348 CIRCUIT DIAGRAM ...

Page 309: ...SYSTEM 8 14 4 Joint connector 5 Main relay 7 Battery 8 Frame ground 9 Main fuse 15 Warning light 16 Fuel level warning light 18 Resistor 19 Fuel sender 21 ECU Engine Control Unit A Battery sub lead B Wire harness ...

Page 310: ...nals Recharge or replace the battery OK 3 Check the main relay Refer to CHECKING THE RE LAYS on page 8 61 NG Replace the main relay OK 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 13 NG Properly connect or repair the signaling system s wiring OK This circuit is OK 1 Check the fuel level warning light bulb and socket Refer to CHECKING THE BULBS AND BULB SOCKETS on...

Page 311: ...SIGNALING SYSTEM 8 16 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 13 NG Properly connect or repair the signaling system s wiring OK Replace the ECU ...

Page 312: ...COOLING SYSTEM For JPN 8 17 EAM20155 COOLING SYSTEM For JPN EAM30350 CIRCUIT DIAGRAM ...

Page 313: ... For JPN 8 18 4 Joint connector 5 Main relay 7 Battery 8 Frame ground 9 Main fuse 21 ECU Engine Control Unit 26 Radiator fan motor fuse 27 Radiator fan motor 28 Radiator fan motor relay 30 Coolant temperature sensor ...

Page 314: ...main relay Refer to CHECKING THE RE LAYS on page 8 61 NG Replace the main relay OK 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR For JPN on page 8 66 NG Replace the radiator fan motor OK 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 61 NG Replace the radiator fan motor relay OK 6 Check the coolant temperature sen sor Refer to CHECKING THE C...

Page 315: ...COOLING SYSTEM For JPN 8 20 ...

Page 316: ...FUEL INJECTION SYSTEM 8 21 EAM20145 FUEL INJECTION SYSTEM EAM30284 CIRCUIT DIAGRAM ...

Page 317: ... warning light 20 Yamaha diagnostic tool coupler 21 ECU Engine Control Unit 22 Ignition coil 23 Spark plug 24 Fuel injector 25 Fuel pump 26 Radiator fan motor fuse 27 Radiator fan motor For JPN 28 Radiator fan motor relay 29 Intake air temperature sensor 30 Coolant temperature sensor 31 Throttle position sensor 32 Intake air pressure sensor 33 Engine stop switch 34 Gear position switch A Battery s...

Page 318: ...cation and fuel injection system operation The engine trouble warning light flashes when any one of the following conditions is present and the start switch is pushed Checking the engine trouble warning light The engine trouble warning light comes on for around 2 seconds when pushing the start switch to turn on the engine trouble warning light comes on while the start switch is being pushed Warnin...

Page 319: ...fuel injection system Refer to Confirmation of service com pletion in the appropriate table in TROUBLESHOOTING DETAILS FAULT CODE on page 8 28 4 After pushing the engine stop switch push the start switch to check whether the fault code number is displayed TIP If another fault code number is displayed repeat steps 1 to 4 until no fault code number is displayed 5 Erase the malfunction history in the...

Page 320: ...2 OBD GST Leadwire kit 90890 03249 Diagnosis of malfunction Fault codes recorded on the ECU are read and the contents are dis played The freeze frame data FFD is the operation data when a malfunction was detected This data can be used to identify when the malfunction occurred and check the engine conditions and running conditions when it occurred Diagnosis of function Check the operation of the ou...

Page 321: ...lead 3 Connect the FI 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 fire and the battery could be damaged Fault diagnosis mode Fault codes recorded on the ECU are read and the contents are displayed Function diagnostic mode Check the operation of the ...

Page 322: ...Yamaha diagnostic tool refer to YAMAHA DIAGNO STIC TOOL OPERATION MANUAL 1 2 3 4 5 5 5 6 7 8 9 1 ECU Engine Control Unit 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 cable included with the Yamaha diagnostic tool 9 Yamaha diagnostic tool ...

Page 323: ...rankshaft 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 display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of crankshaft posi tion sensor coupler Check the locking condition of the coupl...

Page 324: ...ered 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 Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on page 8 63 Crank 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 7 and finish the service Condit...

Page 325: ...ON and then check the condi tion of the fault 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 4 4 Mounted condition of intake air pressure sensor Check for looseness or pinch ing Check the mounted position for correctness Improperly mounted sensor Remount or replace the sensor Start switch to ...

Page 326: ...twisted or bent Repair or replace the sensor 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 Condition is Recovered Go to item 3 and finish the service Condition is Detected Go to item 2 2 Defective intake air pressure sensor Execute the diagnostic mode Co...

Page 327: ...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 of the pins Improperly connected Con nect the coupler securely or repair replace the wire harness Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Condit...

Page 328: ...sconnect the starter relay lead to the starter motor and then push the starter switch Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 7 7 Faulty ECU Replace the ECU Service is finished 8 Delete the fault code Confirm t...

Page 329: ...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 code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No 21 Item Coolant temperature sensor open or short circuit detected Fail safe system Able to start engine Able to drive vehicle D...

Page 330: ...tem 4 4 Mounted 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 relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is De...

Page 331: ...e 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 of the pins Improperly connected Con nect the coupler securely or repair replace the wire harness Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Cond...

Page 332: ...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 more Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 The vehicle has overturned Raise the vehicle upright Start switch to ON main relay ON wait 10 seconds then check the condition of the fau...

Page 333: ...tion 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 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 of the fault code using the malfunction...

Page 334: ...ion 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 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 8 and finish the service Condition is Detected Go...

Page 335: ... Check the injector Refer to CHECKING THE FUEL INJECTOR on page 8 68 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 diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 3 Connection of wire harness ECU coupler Check the locking condition of the coupl...

Page 336: ...supplied to the main relay 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 the start switch Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of main relay cou pler Check the locking cond...

Page 337: ... the 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 Recovered Go to item 6 and finish the service Condition is Detected Go to item 4 4 Defective main relay No operating sound Replace the main relay Execute the diagnostic mode Code No 09 Fuel system voltag...

Page 338: ...n and rewrite in EEPROM After this adjustment push the engine stop switch and then Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 5 and finish the service Condition is Detected Repeat item 1 If the same number is indicated go to item 3 3 07 is indicated in diagnostic mode Co...

Page 339: ... and 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 of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 3 Wire harness continuity Ope...

Page 340: ... of service com pletion 1 Faulty ECU Replace the ECU Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Check that the fault code num ber is not displayed Fault code No 70 Item Engine forcibly stops when the vehicle is left idling for a long period of time Fail safe system Unable to drive vehicle Diagnostic code...

Page 341: ...FUEL INJECTION SYSTEM 8 46 ...

Page 342: ...FUEL PUMP SYSTEM 8 47 EAM20146 FUEL PUMP SYSTEM EAM30287 CIRCUIT DIAGRAM ...

Page 343: ...YSTEM 8 48 2 AC magneto 3 Rectifier regulator 4 Joint connector 6 Engine ground 7 Battery 8 Frame ground 9 Main fuse 21 ECU Engine Control Unit 25 Fuel pump 33 Engine stop switch A Battery sub lead B Wire harness ...

Page 344: ... on page 8 58 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 59 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 55 NG Replace the engine stop switch OK 5 Check fuel pressure Refer to CHECKING THE FUEL PRESSURE on page 7 3 NG Replace the fuel pump OK 6 Check t...

Page 345: ...FUEL PUMP SYSTEM 8 50 ...

Page 346: ...ELECTRICAL COMPONENTS 8 51 EAM20147 ELECTRICAL COMPONENTS 1 2 3 4 6 7 8 9 5 ...

Page 347: ...PONENTS 8 52 1 Rectifier regulator 2 Mode switch 3 Intake air temperature sensor 4 Coolant temperature sensor 5 Resistor 6 Radiator fan motor fuse 7 Radiator fan motor relay 8 Main relay 9 Radiator fan motor For JPN ...

Page 348: ...ELECTRICAL COMPONENTS 8 53 1 2 3 4 5 11 10 6 7 8 9 ...

Page 349: ... 8 54 1 Intake air pressure sensor 2 Throttle position sensor 3 Injector 4 Ignition coil 5 ECU Engine Control Unit 6 CCU Communication Control Unit 7 Starter relay 8 Main fuse 9 Battery 10 Gear position switch 11 Fuel pump ...

Page 350: ...ELECTRICAL COMPONENTS 8 55 EAM30289 CHECKING THE SWITCHES Y W P Sb 3 1 4 2 P Sb B W R L B R Y W B ...

Page 351: ...ELECTRICAL COMPONENTS 8 56 1 Engine stop switch 2 Mode switch 3 Gear position switch 4 Engine start switch ...

Page 352: ...hecking 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 shown in the far left column and the switch lead colors are shown in the top row in the switch illustration TIP indicates continuity between switch terminals i e a closed circuit at each switch positio...

Page 353: ...s described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the digital circuit tester probes to the respective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb socket EAM30290 CHECKING THE FUSES The following procedure applies to all of the fus es 1 Remove Seat Refer t...

Page 354: ... switch for a long time Wait for more than 10 seconds before attempting to start again Charge the bat tery again as soon as possible A long state of discharge below 10 V will damage the battery Do not use the specified battery charger to charge a battery other than the lithium ion battery Otherwise the battery or charger could be damaged Be careful not to drop the battery or subject it to strong i...

Page 355: ...sed after check ing the battery it should be replaced When replacing the battery be sure to use a Yamaha genuine lithium ion battery TIP Do not check the battery at high temperature of 65 C 149 F or more or low temperatures be low 10 C 50 F Otherwise the control feature preventing battery charging and discharging will temporarily intervene 1 Check Battery a If the battery is hot wait until the bat...

Page 356: ...y 12 V to the relay terminal as shown Check the relay operation Out of specification Replace Starter relay Main relay Radiator fan motor relay EAM30293 CHECKING THE DIODE 1 Check Diode Out of specification Replace Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester p...

Page 357: ... d Crank the engine and gradually increase the spark gap until a misfire 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 No continuity Tester positive lead Blue Green 1 Tester negative lead Blue 2 Continuity Tester positive lead Blue 2 Tester negative lead Blue Green 1 No continuity Tester p...

Page 358: ...on coil b Measure the secondary coil resistance EAM30297 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Primary coil resistance 2 16 2 64 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ...

Page 359: ...l 1 and starter motor lead 2 with a jumper lead 3 WARNING EWA13810 A wire that 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 fluid is in the vicinity b Check the starter motor operation EAM30300 CHECKING THE STATOR COIL 1 Disconnect Stator coil coup...

Page 360: ...t Out of specification Replace the fuel pump EAM30360 CHECKING THE RESISTOR 1 Disconnect Resistor coupler from the wire harness 2 Check Resistor resistance Out of specification Replace the resistor a Connect the digital circuit tester to the re sistor as shown Regulated voltage DC 14 0 14 8 V Digital tachometer 90890 06760 Digital tachometer YU 39951 B Digital circuit tester CD732 90890 03243 Mode...

Page 361: ...ace a Connect the digital circuit tester to the coolant temperature sensor b Immerse the coolant temperature sensor in a container 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 temperature indicated in the ta ble e Check the coolant temperature sensor fo...

Page 362: ...he intake air temperature 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 circuit tester to the in take air temperature sensor terminal Throttle position sensor input voltage 4 6 V Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A19...

Page 363: ...43 Model 88 Multimeter with tachom eter YU A1927 1 2 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 Positive tester probe Pink 2 Negative tester probe Sensor terminal c Continuity Positive tester probe Yellow White 3 Negative tester probe Sensor terminal d Continuity Posi...

Page 364: ...tal circuit tester to the fuel injector coupler c Measure the fuel injector resistance Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Positive tester probe Injector terminal 1 Negative tester probe Injector terminal 2 1 2 ...

Page 365: ...HIFTING IS DIFFICULT 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 CLUTCH SLIPS 9 2 CLUTCH DRAGS 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FRONT FORK OIL LEAKING 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 LIST OF SELF DIAGNOSTIC AND FAIL SAFE ACTIONS 9 4 LIST OF DIAGNOSTIC CODES 9 4 SENSOR OPERATION TABLE 9 5 ACTUATOR OPERATION TABLE 9 6 ...

Page 366: ...ed or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery Short main relay 2 Fuse Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 4 Ignition coil Cracked or broken ignition coil body Broken or shorted primary...

Page 367: ...Improperly returned stopper lever 2 Shift forks Worn shift fork 3 Shift drum Incorrect axial play Worn shift drum groove 4 Transmission Worn gear dog EAM30316 CLUTCH SLIPS Engine 1 Clutch Improperly assembled clutch Loose or fatigued clutch spring Worn friction plate Worn clutch plate 2 Engine oil Incorrect oil level Incorrect oil viscosity low Deteriorated oil EAM30317 CLUTCH DRAGS Engine 1 Clutc...

Page 368: ...embly bolt Damaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring EAM30321 FAULTY FRONT FORK LEGS Chassis 1 Front fork Bent or damaged inner tube Bent or damaged outer tube Broken fork spring Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAM30322 UNSTABLE HANDLING Chassis 1 Handlebar Bent or improperly installed handlebar 2 Steering head componen...

Page 369: ...is detected 8 33 21 Coolant temperature sensor open or short circuit detected 8 34 22 Intake air temperature sensor open or short circuit detected 8 36 30 The vehicle has overturned 8 37 33 Ignition coil open or short circuit detected in the primary lead of the ignition coil 8 38 39 Injector open or short circuit detected 8 40 41 ECU built in lean angle sensor malfunction 8 41 43 Fuel system volta...

Page 370: ...lant temperature Displays the coolant tempera ture Compare the actually mea sured coolant temperature with the Yamaha diagnostic tool display value 08 Lean angle sensor Displays the output voltage Remove the ECU and incline it 45 or more Upright Overturn 0 4 1 4 V 3 7 4 4 V 09 Monitor voltage Displays the voltage of the external battery connected to the Yamaha diagnostic tool Approximately 12 0 V ...

Page 371: ...ere is no setting There is some setting 00 01 70 Program version number Displays a program version No Diag nostic code No Item Actuation Procedure 30 Ignition coil Actuates the ignition coil five times at one second intervals WARNING on the Yamaha diagnostic 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 Injecto...

Page 372: ...LIST OF SELF DIAGNOSTIC AND FAIL SAFE ACTIONS 9 7 ...

Page 373: ...0 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 10 3 SETTING OF SPRING AFTER REPLACEMENT 10 4 REAR SHOCK ABSORBER SETTING PARTS 10 4 SUSPENSION SETTING FRONT FORK 10 6 SUSPENSION SETTING REAR SHOCK ABSORBER 10 7 ...

Page 374: ...eed the ma chine is generally set such that it can develop its maximum revolutions toward the end of the straight line with care taken to avoid the en gine over revving TIP Riding technique varies from rider to rider and the performance of a machine also vary from machine to machine Therefore do not imitate other rider s settings from the beginning but choose your own setting according to the leve...

Page 375: ...ount will cause the 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 SETTING OF SPRING AFTER REPLACEMENT As the front fork setting can be easily affected by the rear suspension take care so that the front and the rear are balanced in position etc when se...

Page 376: ...r a block under the engine to put the rear wheel above the floor and mea sure the length a between the rear wheel axle center and the rear fender holding bolt 2 Remove the stand or block from the engine and with a rider astride the seat measure the sunken length b between the rear wheel axle center and the rear fender holding bolt 3 Loosen the locknut 1 and make adjustment by turning the adjuster ...

Page 377: ...bound damping force will be fol lowed more or less by a change in the compres sion damping 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 exceed the stan dard as it may result in faulty performance Never use one whose overall length is great er than standa...

Page 378: ...RBER 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 6 0 mm 0 24 in from its free length Maximum Position in which the spring is turned in 18 0 mm 0 71 in from its free length 1 a ...

Page 379: ...oticeable 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 specified torque Poor initial move ment Rebound damp ing force Turn adjuster counterclockwise about 2 clicks to decrease damping Oil seals Apply grease in oil seal wall Soft over entire range bottomin...

Page 380: ...ount 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 Balance with rear end Set sunken length for 90 95 mm 3 5 3 7 in when one passenger is astride seat upper rear pos ture Spring Replace with soft spring Oil amount Decrease oil amount by about 5 10 cm 0 ...

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 mm 3 5 3 9 in when one pas senger is astride seat Spring Replace with stiff spring Bouncing Rebound damp ing force Turn adjuster clockwise about 2 clicks to increase damping Spring Replace with soft...

Page 382: ...CHASSIS 10 9 ...

Page 383: ...tor relay 29 Intake air temperature sensor 30 Coolant temperature sensor 31 Throttle position sensor 32 Intake air pressure sensor 33 Engine stop switch 34 Gear position switch 35 Mode switch 36 Start switch 37 Diode 3 A Battery sub lead B Wire harness C Ignition coil sub lead D CCU sub lead EAM30323 COLOR CODE B Black Br Brown Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W Whit...

Page 384: ......

Page 385: ...side out Genuine Yamaha Service Manuals Get the same factory manual for your vehicle that the technicians at your authorized Yamaha dealer use Service manuals are available through your Yamaha dealer or you can order them directly through yamahapubs com Genuine Yamaha products are available only from your Yamaha dealer Find out more at yamaha motor com EAM20161 Read this manual carefully Operating...

Page 386: ... Read this manual carefully before operating this vehicle YZ450FXK OWNER S SERVICE MANUAL YZ450FX 2019 PRINTED IN JAPAN 2018 05 0 3 2 E PRINTED ON RECYCLED PAPER 2019 YZ450FXK B3J 28199 10_2_cover_12mm indd 1 3 2018 09 14 14 16 15 ...

Page 387: ...YZ450FXK 2019 WIRING DIAGRAM B3J 28199 10_W D indd 1 2018 04 18 11 44 57 ...

Page 388: ...YZ450FXK 2019 WIRING DIAGRAM B3J 28199 10_W D indd 2 2018 04 18 11 44 57 ...

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