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Yamaha 2003 YZ450FR Owner's Service Manual

Other manuals for 2003 YZ450FR: Owner's Service Manual

Summary of 2003 YZ450FR

  • Page 1

    Lit-11626-16-38 yz450fr 5ta-28199-10 owner’s service manual.

  • Page 3

    Ec010000 yz450fr owner’s service manual ©2002 by yamaha motor corporation, u.S.A. 1st edition, june 2002 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-11626-16-38.

  • Page 4: Introduction

    Ec020000 introduction congratulations on your purchase of a yamaha yz series. This model is the culmina- tion of yamaha’s vast experience in the pro- duction of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made yamaha a leader. This manual e...

  • Page 6: Important Notice

    Important notice this machine is designed strictly for competition use, only on a closed course. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regula- tions before riding. 1. This machine is ...

  • Page 7

    6. 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 clothing, immediately wash skin areas with soap and water, and change your clothes. 7....

  • Page 8: To The New Owner

    Ec050000 to the new owner this manual will provide you with a good basic understanding of features, operation, and basic maintenance and inspection items of this machine. Please read this manual carefully and completely before operating your new machine. If you have any questions regarding the opera...

  • Page 9: How to Use

    Ec080000 how to use this manual ec081000 particularly important information the safety alert symbol means attention! Become alert! Your safety is involved! Failure to follow warning instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or re...

  • Page 10

    Ec083000 manual format all of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspect...

  • Page 11: Gen

    Illustrated symbols (refer to the illustration) illustrated symbols 1 to 7 are designed as thumb tabs to indicate the chapter’s number and content. 1 general information 2 specifications 3 regular inspection and adjustments 4 engine 5 chassis 6 electrical 7 tuning illustrated symbols 8 to d are used...

  • Page 12: Memo

    Memo.

  • Page 13: Index

    Ec090000 index general information 1 specifications spec 2 regular inspection and adjustments 3 engine eng 4 chassis chas 5 electrical elec 6 tuning tun 7 gen info insp adj – +.

  • Page 14: Contents

    Ec0a0000 contents chapter 1 general information description .......................................... 1-1 machine identification .................... 1-2 important information ................... 1-3 checking of connection ................ 1-6 special tools ...................................... 1-...

  • Page 15: Chapter 4

    Chapter 4 engine seat, fuel tank and side covers ................................. 4-1 exhaust pipe and silencer ............ 4-3 radiator ................................................ 4-5 carburetor ......................................... 4-8 camshafts ............................................

  • Page 16: Chapter 6

    Chapter 6 electrical electrical components and wiring diagram .......................... 6-1 map-controlled cdi unit ................ 6-2 ignition system ................................... 6-3 tps (throttle position sensor) system .................................................... 6-7 chapter 7 t...

  • Page 17: Gen

    Gen info 1 - 1 description ec100000 general information ec110000 description 1 clutch lever 2 hot starter lever 3 front brake lever 4 throttle grip 5 radiator cap 6 fuel tank cap 7 “engine stop” button 8 kick starter 9 fuel tank 0 radiator a coolant drain bolt b rear brake pedal c valve joint d fuel...

  • Page 18: Gen

    1 - 2 gen info machine identification ec120001 machine identification there are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your yamaha dealer for posi- tive identification of the model you own. 2. If your machine is stole...

  • Page 19: Gen

    1 - 3 gen info important information ec130000 important information ec131010 preparation for removal and disassembly 1. Remove all dirt, mud, dust, and foreign material before removal and disassem- bly. When washing the machine with high pressured water, cover the parts as fol- lows. ● silencer exha...

  • Page 20: Gen

    1 - 4 gen info important information ec132000 all replacement parts 1. We recommend to use yamaha genuine parts for all replacements. Use oil and/or grease recommended by yamaha for assembly and adjustment. Ec133000 gaskets, oil seals and o-rings 1. All gaskets, oil seals, and o-rings should be repl...

  • Page 21: Gen

    1 - 5 gen info important information ec136000 circlips 1. All circlips should be inspected carefully before reassembly. Always replace pis- ton pin clips after one use. Replace dis- torted circlips. When installing a circlip 1 , make sure that the sharp-edged cor- ner 2 is positioned opposite to the...

  • Page 22: Gen

    1 - 6 gen info checking of connection ec1c0001 checking of connection dealing with stains, rust, moisture, etc. On the connector. 1. Disconnect: ● connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not...

  • Page 23: Gen

    Gen info 1 - 7 special tools ec140001 special tools the proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the spec...

  • Page 24: Gen

    Gen info 1 - 8 special tools yu-33975, 90890-01403 ring nut wrench this tool is used when tighten the steering ring nut to specification. Yu-33975 90890-01403 ym-1423, 90890-01423 damper rod holder use this tool to remove and install the damper rod. Ym-1423 90890-01423 ym-01442, 90890-01442 fork sea...

  • Page 25: Gen

    Gen info 1 - 9 special tools ym-4117, 90890-04117 ym-4098, 90890-04098 valve guide installer intake exhaust this tool is needed to install the valve guide. Ym-4117 ym-4098 90890-04117 90890-04098 ym-4118, 90890-04118 ym-4099, 90890-04099 valve guide reamer intake 4.5 mm (0.18 in) exhaust 5.0 mm (0.2...

  • Page 26: Gen

    1 - 10 gen info control functions ec150000 control functions ec151000 “engine stop” button the “engine stop” button 1 is located on the left handlebar. Continue pushing the “engine stop” button till the engine comes to a stop. Ec152000 clutch lever the clutch lever 1 is located on the left han- dleb...

  • Page 27: Gen

    1 - 11 gen info control functions ec156000 front brake lever the front brake lever 1 is located on the right handlebar. Pull it toward the handlebar to acti- vate the front brake. Ec157000 rear brake pedal the rear brake pedal 1 is located on the right side of the machine. Press down on the brake pe...

  • Page 28: Gen

    1 - 12 gen info control functions ec15r001 detachable sidestand this sidestand 1 is used to support only the machine when standing or transporting it. Warning ● never apply additional force to the side- stand. ● remove this sidestand before starting out. Ec15f000 valve joint this valve joint 1 preve...

  • Page 29: Gen

    1 - 13 gen info fuel always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race. Caution: use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts such as valves, piston rings, and exhaust system, etc. Note...

  • Page 30: Gen

    1 - 14 gen info starting and break-in starting and break-in warning never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Always operate the machine in a well-ventilated area. Caution: ● the carburetor on...

  • Page 31: Gen

    1 - 15 gen info starting and break-in 6. Return the cold starter knob to its original position and run the engine at 3,000 ~ 5,000 r/min for 1 or 2 minutes. Note: since this model is equipped with an accelera- tor pump, if the engine is raced (the throttle opened and closed), the air/fuel mixture wi...

  • Page 32: Gen

    1 - 16 gen info starting and break-in starting a warm engine do not operate the cold starter knob and throt- tle. Pull the hot starter lever 1 and start the engine by kicking the kick starter forcefully with a firm stroke. As soon as the engine starts, release the hot starter lever to close the air ...

  • Page 33: Gen

    1 - 17 gen info break-in procedures 1. Before starting the engine, fill the fuel tank with the fuel. 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the “engine stop” button. Then, restart the engi...

  • Page 34: Gen

    Gen info 1 - 18 torque-check points torque-check points note: concerning the tightening torque, refer to “maintenance specifications” section in the chapter 2. Frame to rear frame fuel tank to frame silencer to rear frame frame to engine engine bracket to engine engine bracket to frame steering shaf...

  • Page 35: Gen

    1 - 19 gen info cleaning and storage ec1b0000 cleaning and storage ec1b1000 cleaning frequent cleaning of your machine will enhance its appearance, maintain good over- all performance, and extend the life of many components. 1. Before washing the machine, block off the end of the exhaust pipe to pre...

  • Page 36: Gen

    1 - 20 gen info cleaning and storage 8. Automotive wax may be applied to all painted or chromed surfaces. Avoid com- bination cleaner-waxes, as they may con- tain abrasives. 9. After completing the above, start the engine and allow it to idle for several min- utes. Ec1b2001 storage if your machine i...

  • Page 37: Spec

    Spec 2 - 1 general specifications ec200000 specifications ec211000 general specifications model name: yz450fr (usa) yz450f (europe) yz450f(r) (cdn, aus, nz, za) model code number: 5ta1 (usa) 5ta2 (europe) 5ta4 (cdn, aus, nz, za) dimensions: overall length 2,171 mm (85.5 in) overall width 827 mm (32....

  • Page 38: Spec

    Spec 2 - 2 general specifications oil capacity: engine oil periodic oil change 1.0 l (0.88 imp qt, 1.06 us qt) with oil filter replacement 1.1 l (0.97 imp qt, 1.16 us qt) total amount 1.2 l (1.06 imp qt, 1.27 us qt) coolant capacity (including all routes): 1.2 l (1.06 imp qt, 1.27 us qt) air filter:...

  • Page 39: Spec

    Spec 2 - 3 general specifications brake: front brake type single disc brake operation right hand operation rear brake type single disc brake operation right foot operation suspension: front suspension telescopic fork rear suspension swingarm (link type monocross suspension) shock absorber: front sho...

  • Page 40: Spec

    Spec 2 - 4 maintenance specifications maintenance specifications engine item standard limit cylinder head: warp limit ---- 0.05 mm (0.002 in) cylinder: bore size 95.00 ~ 95.01 mm (3.7402 ~ 3.7406 in) ---- out of round limit ---- 0.05 mm (0.002 in) camshaft: drive method chain drive (left) ---- camsh...

  • Page 41: Spec

    Spec 2 - 5 maintenance specifications cam chain: cam chain type/no. Of links 98xrh2010-118m/118 ---- cam chain adjustment method automatic ---- valve, valve seat, valve guide: valve clearance (cold) in 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) ---- ex 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in) ---- valve dimensi...

  • Page 42: Spec

    Spec 2 - 6 maintenance specifications valve spring: free length in 37.03 mm (1.46 in) 35.17 mm (1.38 in) ex 37.68 mm (1.48 in) 35.79 mm (1.41 in) set length (valve closed) in 27.87 mm (1.10 in) ---- ex 27.38 mm (1.08 in) ---- compressed force (installed) in 111.3 ~ 127.9 n at 27.87 mm (11.3 ~ 13.0 k...

  • Page 43: Spec

    Spec 2 - 7 maintenance specifications piston rings: top ring: type barrel ---- dimensions (b × t) 1.2 × 3.5 mm (0.05 × 0.14 in) ---- end gap (installed) 0.20 ~ 0.30 mm (0.008 ~ 0.012 in) 0.55 mm (0.022 in) side clearance (installed) 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in) 0.12 mm (0.005 in) 2nd ring: ...

  • Page 44: Spec

    Spec 2 - 8 maintenance specifications clutch: friction plate thickness 2.92 ~ 3.08 mm (0.115 ~ 0.121 in) 2.8 mm (0.110 in) quantity 9 ---- clutch plate thickness 1.1 ~ 1.3 mm (0.043 ~ 0.051 in) ---- quantity 8 ---- warp limit ---- 0.1 mm (0.004 in) clutch spring free length 50 mm (1.97 in) 49 mm (1....

  • Page 45: Spec

    Spec 2 - 9 maintenance specifications lubrication system: oil filter type wire mesh type ---- oil pump type trochoid type ---- tip clearance “a” 0.12 mm or less (0.0047 in or less) 0.20 mm (0.008 in) tip clearance “b” 0.09 ~ 0.17 mm (0.0035 ~ 0.0067 in) 0.24 mm (0.009 in) side clearance 0.03 ~ 0.10 ...

  • Page 46: Spec

    Spec 2 - 10 maintenance specifications item standard lubrication chart: pressure feed splashed scavenge oil strainer oil pan oil pump rotor 2 oil pump rotor 1 oil tank oil filter check ball cylinder head crank pin piston pin piston drive axle main axle transmission gears camshaft valve lifter.

  • Page 47: Spec

    Spec 2 - 11 maintenance specifications part to be tightened thread size q’ty tightening torque nm m·kg ft·lb spark plug m10s × 1.0 1 13 1.3 9.4 camshaft cap m6 × 1.0 10 10 1.0 7.2 cylinder head blind plug screw m12 × 1.0 1 37 3.7 27 cylinder head (stud bolt) m6 × 1.0 2 7 0.7 5.1 m8 × 1.25 1 15 1.5 1...

  • Page 48: Spec

    Spec 2 - 12 maintenance specifications note: - marked portion shall be checked for torque tightening after break-in or before each race. Note: *1: tighten the cylinder head bolts to 30 nm (3.0 m · kg, 22 ft · lb) in the proper tightening sequence, remove and retighten the cylinder head bolts to 20 n...

  • Page 49: Spec

    Spec 2 - 13 maintenance specifications ec212201 chassis item standard limit steering system: steering bearing type taper roller bearing ---- front suspension: front fork travel 300 mm (11.8 in) ---- fork spring free length 460 mm (18.1 in) 455 mm (17.9 in) spring rate, std k = 4.51 n/mm (0.46 kg/mm,...

  • Page 50: Spec

    Spec 2 - 14 maintenance specifications wheel: front wheel type spoke wheel ---- rear wheel type spoke wheel ---- front rim size/material 21 × 1.60/aluminum ---- rear rim size/material 19 × 2.15/aluminum ---- rim runout limit: radial ---- 2.0 mm (0.08 in) lateral ---- 2.0 mm (0.08 in) drive chain: us...

  • Page 51: Spec

    Spec 2 - 15 maintenance specifications note: 1. First, tighten the ring nut approximately 38 nm (3.8 m • kg, 27 ft • lb) by using the ring nut wrench, then loosen the ring nut one turn. 2. Retighten the ring nut 7 nm (0.7 m • kg, 5.1 ft • lb). Part to be tightened thread size q’ty tightening torque ...

  • Page 52: Spec

    Spec 2 - 16 maintenance specifications note: - marked portion shall be checked for torque tightening after break-in or before each race. Part to be tightened thread size q’ty tightening torque nm m·kg ft·lb rear wheel axle and nut m20 × 1.5 1 125 12.5 90 driven sprocket and wheel hub m8 × 1.25 6 42 ...

  • Page 53: Spec

    Spec 2 - 17 maintenance specifications ec212300 electrical item standard limit ignition system: advancer type electrical ---- c.D.I.: magneto-model (stator)/manufacturer 5sf-00/yamaha ---- source coil 1 resistance (color) 720 ~ 1,080 Ω at 20 ˚c (68 ˚f) (green – brown) ---- source coil 2 resistance (...

  • Page 54: Spec

    2 - 18 spec general torque specifications/ definition of units ec220001 general torque specifications this chart specifies torque for standard fasten- ers with standard i.S.O. Pitch threads. Torque specifications for special components or assemblies are included in the applicable sec- tions of this ...

  • Page 55: Spec

    2 - 19 spec lubrication diagrams lubrication diagrams 1 oil delivery pipe 2 intake camshaft 3 exhaust camshaft 4 oil cleaner element 5 oil pump 6 main axle 7 drive axle 7 6 5 4 3 2 1 4 5 a - a d - d g g d d a a.

  • Page 56: Spec

    2 - 20 spec lubrication diagrams 1 camshaft 2 connecting rod 3 oil cleaner element 4 crankshaft 5 main axle 6 drive axle 7 oil delivery pipe 1 2 3 4 5 6 7.

  • Page 57: Spec

    2 - 21 spec cable routing diagram ec240000 cable routing diagram 1 fuel tank breather hose 2 hot starter cable 3 radiator hose 4 4 cylinder head breather hose 5 radiator hose 1 6 oil tank breather hose 7 hose guide 8 brake hose 9 “engine stop” button lead 0 clamp a sub wire harness b tps (throttle p...

  • Page 58: Spec

    2 - 22 spec cable routing diagram Ó pass the sub wire harness between the engine brackets. È make sure that the tps lead coupler does not go outside the chassis. Ô fasten the tps lead to the frame with a plastic band.  fasten the neutral switch lead and oil hose together with a plastic locking tie ...

  • Page 59: Spec

    2 - 23 spec cable routing diagram 1 cable holder 2 cdi unit 3 hot starter cable 4 clutch cable 5 throttle cable (return) 6 throttle cable (pull) 7 ignition coil 8 radiator breather hose 9 radiator hose 4 0 cylinder head breather hose a cdi unit bracket b cdi unit band Å fasten the grommet of the clu...

  • Page 60: Spec

    2 - 24 spec cable routing diagram 1 master cylinder 2 brake hose holder 3 brake hose Å install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the caliper. ı pass the brake hose into the brake hose holders. Ç if the brake hose contacts the spring (rear ...

  • Page 61: Spec

    2 - 25 spec cable routing diagram 1 throttle cable 2 fuel tank breather hose 3 clamp 4 clutch cable 5 hot starter cable 6 “engine stop” button lead 7 brake hose 8 hose guide Å fasten the “engine stop” but- ton lead to the handlebar with the plastic band. ı pass the brake hose in front of the number ...

  • Page 62: Insp

    3 - 1 insp adj maintenance intervals ec300000 regular inspection and adjustments maintenance intervals the following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the ...

  • Page 63: Insp

    3 - 2 insp adj maintenance intervals shift fork, shift cam, guide bar inspect ● inspect wear rotor nut retighten ● ● muffler inspect and retighten clean replace ● ● ● ● * whichever comes first crank inspect and clean ● ● carburetor inspect, adjust and clean ● ● when using a high-pres- sure washer, m...

  • Page 64: Insp

    3 - 3 insp adj maintenance intervals front fork oil seal and dust seal clean and lube ● ● lithium base grease rear shock absorber inspect and adjust lube retighten ● ● ● ● ● (after rain ride) ● molybdenum disulfide grease chain guard and rollers inspect ● ● swingarm inspect, lube and retighten ● ● m...

  • Page 65: Insp

    3 - 4 insp adj pre-operation inspection and maintenance ec320000 pre-operation inspection and maintenance before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. General inspection and main...

  • Page 66: Insp

    3 - 5 insp adj ec350000 engine ec351011 coolant level inspection warning do not remove the radiator cap 1, drain bolt and hoses when the engine and radia- tor are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, place a ...

  • Page 67: Insp

    3 - 6 insp adj coolant replacement ec353011 coolant replacement warning do not remove the radiator cap when the engine is hot. Caution: take care so that coolant does not splash on painted surfaces. If it splashes, wash it away with water. 1. Place a container under the engine. 2. Remove: ● engine g...

  • Page 68: Insp

    3 - 7 insp adj radiator cap inspection caution: ● do not mix more than one type of ethyl- ene glycol antifreeze containing corro- sion inhibitors for aluminum engine. ● do not use water containing impurities or oil. 7. Install: ● radiator cap start the engine and warm it up for a several minutes. 8....

  • Page 69: Insp

    3 - 8 insp adj radiator cap opening pressure inspection/ cooling system inspection ec356001 radiator cap opening pressure inspection 1. Attach: ● radiator cap tester 1 and adapter 2 note: apply water on the radiator cap seal. 3 radiator cap 2. Apply the specified pressure. 3. Inspect: ● pressure imp...

  • Page 70: Insp

    3 - 9 insp adj clutch adjustment note: ● do not apply pressure more than specified pressure. ● radiator should be filled fully. 4. Inspect: ● pressure impossible to maintain the specified pressure for 10 seconds → repair. ● radiator ● radiator hose joint coolant leakage → repair or replace. ● radiat...

  • Page 71: Insp

    3 - 10 insp adj throttle cable adjustment/ throttle lubrication ec35a001 throttle cable adjustment 1. Check: ● throttle grip free play a out of specification → adjust. Throttle grip free play a: 3 ~ 5 mm (0.12 ~ 0.20 in) 2. Adjust: ● throttle grip free play throttle grip free play adjustment steps: ...

  • Page 72: Insp

    3 - 11 insp adj hot starter lever adjustment/ air filter cleaning hot starter lever adjustment 1. Check: ● hot starter lever free play a out of specification → adjust. 2. Adjust: ● hot starter lever free play note: after adjustment, check proper operation of hot starter. Hot starter lever free play ...

  • Page 73: Insp

    3 - 12 insp adj air filter cleaning 2. Clean: ● air filter element clean them with solvent. Note: after cleaning, remove the remaining solvent by squeezing the element. Caution: ● do not twist the element when squeezing the element. ● leaving too much of solvent in the ele- ment may result in poor s...

  • Page 74: Insp

    3 - 13 insp adj 7. Install: ● air filter element 1 ● washer ● fitting bolt note: align the projection a on filter guide with the hole b in air filter case. T r . . 2 nm (0.2 m · kg, 1.4 ft · lb) engine oil level inspection 1. Stand the motorcycle on a level surface. Note: ● when checking the oil lev...

  • Page 75: Insp

    3 - 14 insp adj engine oil level inspection 4. Inspect: ● oil level oil level should be between maximum a and minimum b marks. Oil level low → add oil to proper level. Note: when inspecting the oil level, do not screw the oil level gauge into the oil tank. Insert the gauge lightly. (for usa and cdn)...

  • Page 76: Insp

    3 - 15 insp adj engine oil replacement 5. Start the engine and let it warm up for several minutes. Caution: when the oil tank is empty, never start the engine. 6. Idle the engine more than 10 seconds while keeping the motorcycle upright. Then stop the engine and add the oil to the maximum level. 7. ...

  • Page 77: Insp

    3 - 16 insp adj engine oil replacement 6. If the oil filter is to be replaced during this oil change, remove the following parts and reinstall them. 7. Install: ● plain washer 1 ● oil strainer (frame) 2 ● engine oil hose 3 ● bolt (engine oil hose) 4 ● engine oil hose clamp 5 ● engine skid plate 8. I...

  • Page 78: Insp

    3 - 17 insp adj pilot screw adjustment 12. Check: ● oil pressure checking steps: ● slightly loosen the oil gallery bolt 1. ● start the engine and keep it idling until oil starts to seep from the oil gallery bolt. If no oil comes out after one minute, turn the engine off so it will not seize. ● check...

  • Page 79: Insp

    3 - 18 insp adj idle speed adjustment/ valve clearance adjustment ec35m021 idle speed adjustment 1. Start the engine and thoroughly warm it up. 2. Adjust: ● idle speed adjustment steps: ● adjust the pilot screw. Refer to “pilot screw adjustment” section. ● turn the throttle stop screw 1 until the en...

  • Page 80: Insp

    3 - 19 insp adj valve clearance adjustment 4. Check: ● valve clearance out of specification → adjust. Valve clearance (cold): intake valve: 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) exhaust valve: 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in) checking steps: ● turn the crankshaft counterclockwise with a wrench. ● a...

  • Page 81: Insp

    3 - 20 insp adj valve clearance adjustment 5. Adjust: ● valve clearance adjustment steps: ● loosen the timing chain tensioner cap bolt. ● remove the timing chain tensioner and camshaft caps. Note: remove the camshaft cap bolts in a criss- cross pattern from the outside working inwards. ● remove the ...

  • Page 82: Insp

    3 - 21 insp adj valve clearance adjustment ● round off the last digit of the installed pad number to the nearest increment. Last digit of pad number rounded value 0, 1 or 2 0 4, 5 or 6 5 8 or 9 10 example: installed pad number = 148 rounded off value = 150 note: pads can only be selected in 0.05 mm ...

  • Page 83: Insp

    3 - 22 insp adj 6. Install: ● all removed parts note: install all removed parts in reversed order of their removal. Note the following points. ● install the timing chain tensioner. Refer to “camshafts” section in the chapter 4. Note: turn the crankshaft counterclockwise sev- eral turns so that the i...

  • Page 84: Insp

    3 - 23 insp adj valve clearance adjustment intake measured clearance installed pad number 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.05 ~...

  • Page 85: Insp

    3 - 24 insp adj chassis/brake system air bleeding ec360000 chassis ec361012 brake system air bleeding warning bleed the brake system if: ● the system has been disassembled. ● a brake hose has been loosened or removed. ● the brake fluid is very low. ● the brake operation is faulty. A dangerous loss o...

  • Page 86: Insp

    3 - 25 insp adj front brake adjustment 3. Install: ● protector (rear brake) ● diaphragm ● master cylinder cap note: if bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disap- pea...

  • Page 87: Insp

    3 - 26 insp adj rear brake adjustment/ front brake pad inspection and replacement ec364002 rear brake adjustment 1. Check: ● brake pedal height a out of specification → adjust. Brake pedal height a: 5 mm (0.20 in) 2. Adjust: ● brake pedal height pedal height adjustment steps: ● loosen the locknut 1....

  • Page 88: Insp

    3 - 27 insp adj front brake pad inspection and replacement ● loosen the pad pin 2. ● remove the brake hose holder 3 and cal- iper 4 from the front fork. ● remove the pad pin and brake pads 5. ● connect the transparent hose 6 to the bleed screw 7 and place the suitable con- tainer under its end. ● lo...

  • Page 89: Insp

    3 - 28 insp adj rear brake pad inspection and replacement 3. Inspect: ● brake fluid level refer to “brake fluid level inspection” section. 4. Check: ● brake lever operation a softy or spongy feeling → bleed brake system. Refer to “brake system air bleeding” section. ● install the pad pin plug b. T r...

  • Page 90: Insp

    3 - 29 insp adj rear brake pad inspection and replacement ● remove the pad pin 6 and brake pads 7. ● connect the transparent hose 8 to the bleed screw 9 and place the suitable con- tainer under its end. ● loosen the bleed screw and push the cali- per piston in. Caution: do not reuse the drained brak...

  • Page 91: Insp

    3 - 30 insp adj rear brake pad insulator inspection/ brake fluid level inspection 3. Inspect: ● brake fluid level refer to “brake fluid level inspection” section. 4. Check: ● brake pedal operation a softy or spongy feeling → bleed brake system. Refer to “brake system air bleeding” section. Ec36b000 ...

  • Page 92: Insp

    3 - 31 insp adj sprockets inspection/drive chain inspection ec368000 sprockets inspection 1. Inspect: ● sprocket teeth a excessive wear → replace. Note: replace the drive, driven sprockets and drive chain as a set. Ec369002 drive chain inspection 1. Remove: ● master link clip ● joint 1 ● drive chain...

  • Page 93: Insp

    3 - 32 insp adj drive chain slack adjustment 5. Install: ● drive chain 1 ● joint 2 ● master link clip 3 caution: be sure to install the master link clip to the direction as shown. A turning direction 6. Lubricate: ● drive chain drive chain lubricant: sae 10w-30 motor oil or suit- able chain lubrican...

  • Page 94: Insp

    3 - 33 insp adj front fork inspection 3. Adjust: ● drive chain slack drive chain slack adjustment steps: ● loosen the axle nut 1 and locknuts 2. ● adjust chain slack by turning the adjusters 3. To tighten → turn adjuster 3 counter- clockwise. To loosen → turn adjuster 3 clockwise and push wheel forw...

  • Page 95: Insp

    3 - 34 insp adj front fork oil seal and dust seal cleaning/ front fork internal pressure relieving/ front fork rebound damping force adjustment ec36d001 front fork oil seal and dust seal cleaning 1. Remove: ● protector ● dust seal 1 note: use a thin screw driver, and be careful not to damage the inn...

  • Page 96: Insp

    3 - 35 insp adj front fork compression damping force adjustment ● standard position: this is the position which is back by the spe- cific number of clicks from the fully turned-in position. Caution: do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damag...

  • Page 97: Insp

    3 - 36 insp adj rear shock absorber inspection ● standard position: this is the position which is back by the spe- cific number of clicks from the fully turned-in position. * for europe caution: do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. ...

  • Page 98: Insp

    3 - 37 insp adj rear shock absorber spring preload adjustment rear shock absorber spring preload adjustment 1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Remove: ● rear frame 3. Loosen: ● locknut 1 4. Adjust: ● spring preload by turning the adjuster 2. * for europe not...

  • Page 99: Insp

    3 - 38 insp adj rear shock absorber rebound damping force adjustment ec36n014 rear shock absorber rebound damping force adjustment 1. Adjust: ● rebound damping force by turning the adjuster 1. Stiffer a → increase the rebound damp- ing force. (turn the adjuster 1 in.) softer b → decrease the rebound...

  • Page 100: Insp

    3 - 39 insp adj rear shock absorber low compression damping force adjustment ec36c000 rear shock absorber low compression damping force adjustment 1. Adjust: ● low compression damping force by turning the adjuster 1. Stiffer a → increase the low compres- sion damping force. (turn the adjuster 1 in.)...

  • Page 101: Insp

    3 - 40 insp adj ec36d000 rear shock absorber high compression damping force adjustment 1. Adjust: ● high compression damping force by turning the adjuster 1. Stiffer a → increase the high compres- sion damping force. (turn the adjuster 1 in.) softer b → decrease the high compres- sion damping force....

  • Page 102: Insp

    3 - 41 insp adj tire pressure check/spokes inspection and tightening/wheel inspection ec36q000 tire pressure check 1. Measure: ● tire pressure out of specification → adjust. Note: ● check the tire while it is cold. ● loose bead stoppers allow the tire to slip off its position on the rim when the tir...

  • Page 103: Insp

    3 - 42 insp adj steering head inspection and adjustment 2. Inspect: ● bearing free play exist play → replace. Steering head inspection and adjustment 1. Elevate the front wheel by placing a suit- able stand under the engine. 2. Check: ● steering shaft grasp the bottom of the forks and gen- tly rock ...

  • Page 104: Insp

    3 - 43 insp adj steering head inspection and adjustment ● tighten the ring nut 3 using ring nut wrench 4. Note: ● apply the lithium soap base grease on the thread of the steering shaft. ● set the torque wrench to the ring nut wrench so that they form a right angle. Ring nut wrench: yu-33975/90890-01...

  • Page 105: Insp

    3 - 44 insp adj lubrication lubrication to ensure smooth operation of all compo- nents, lubricate your machine during setup, after break-in, and after every race. 1 all control cable 2 clutch lever pivot 3 shift pedal pivot 4 footrest pivot 5 throttle-to-handlebar contact 6 drive chain 7 tube guide ...

  • Page 106: Insp

    3 - 45 insp adj electrical/spark plug inspection ec370000 electrical ec371001 spark plug inspection 1. Remove: ● spark plug 2. Inspect: ● electrode 1 wear/damage → replace. ● insulator color 2 normal condition is a medium to light tan color. Distinctly different color → check the engine condition. N...

  • Page 107: Insp

    3 - 46 insp adj ignition timing check ignition timing check 1. Remove: ● timing plug 1 2. Attach: ● timing light ● inductive tachometer to the spark plug lead. 3. Check: ● ignition timing timing light: ym-33277-a/90890-03141 inductive tachometer: yu-8036-b engine tachometer: 90890-03113 checking ste...

  • Page 108: Eng

    4 - 1 eng ec400000 engine ec4r0000 seat, fuel tank and side covers extent of removal: 1 seat removal 2 fuel tank removal 3 side covers removal 4 number plate removal extent of removal order part name q’ty remarks preparation for removal seat, fuel tank and side covers removal turn the fuel cock to “...

  • Page 109: Eng

    4 - 2 eng removal points side cover 1. Remove: ● bolt (side cover) ● side cover (left) 1 ● side cover (right) 2 note: draw the side cover downward to remove it because its claws a are inserted in the air fil- ter case. Seat, fuel tank and side covers 4.

  • Page 110: Eng

    4 - 3 eng exhaust pipe and silencer ec4s0000 exhaust pipe and silencer Å except for usa extent of removal: 1 silencer removal 2 exhaust pipe removal extent of removal order part name q’ty remarks exhaust pipe and silencer removal preparation for removal side cover (right) refer to “seat, fuel tank a...

  • Page 111: Eng

    4 - 4 eng exhaust pipe and silencer inspection exhaust pipe and silencer 1. Inspect: ● gasket 1 damage → replace. 1 assembly and installation exhaust pipe and silencer 1. Install: ● gasket ● exhaust pipe 1 ● nut (exhaust pipe) 2 ● bolt (exhaust pipe) 3 note: first, temporarily tighten the nut (exhau...

  • Page 112: Eng

    4 - 5 eng radiator ec450001 radiator extent of removal: 1 radiator removal extent of removal order part name q’ty remarks radiator removal preparation for removal drain the coolant. Refer to “coolant replacement” section in the chapter 3. Seat and fuel tank refer to “seat, fuel tank and side covers”...

  • Page 113: Eng

    4 - 6 eng radiator ec456000 handling note warning do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radi- ator cap by the following procedure: place...

  • Page 114: Eng

    4 - 7 eng radiator 3. Install: ● radiator breather hose 1 ● radiator (right) 2 refer to “cable routing dia- gram” section in the chapter 2. T r . . 10 nm (1.0 m · kg, 7.2 ft · lb) 4. Install: ● panel 1 ● bolt (radiator panel upper) 2 note: fit the hook a on the inner side first into the radiator. T ...

  • Page 115: Eng

    4 - 8 eng carburetor carburetor 5 1 2 6 6 4 4 3 t r . . 4 nm (0.4 m • kg, 2.9 ft • ib) t r . . 3 nm (0.3 m • kg, 2.2 ft • ib) t r . . 3 nm (0.3 m • kg, 2.2 ft • ib) 9 7 8 t r . . 2 nm (0.2 m • kg, 1.4 ft • ib) extent of removal: 1 carburetor removal extent of removal order part name q’ty remarks car...

  • Page 116: Eng

    4 - 9 eng carburetor carburetor disassembly extent of removal: 1 carburetor disassembly extent of removal order part name q’ty remarks carburetor disassembly 1 breather hose 4 2 valve lever housing cover 1 3 screw (throttle shaft) 1 4 throttle valve 1 5 needle holder 1 6 jet needle 1 7 cover 1 8 spr...

  • Page 117: Eng

    4 - 10 eng carburetor extent of removal order part name q’ty remarks e main jet 1 f needle jet 1 g spacer 1 h pilot jet 1 i starter jet 1 j push rod 1 pull the push rod. K throttle shaft assembly 1 l push rod link lever assembly 1 m pilot air jet 1 n cold starter plunger 1 1.

  • Page 118: Eng

    4 - 11 eng carburetor ec466020 handling note caution: do not loosen the screws {tps (throttle position sensor)} 1 except when changing the tps (throttle position sensor) due to failure because it will cause a drop in engine performance. 1 removal points pilot screw 1. Remove: ● pilot screw 1 note: t...

  • Page 119: Eng

    4 - 12 eng carburetor 2. Inspect: ● main jet 1 ● pilot jet 2 ● needle jet 3 ● starter jet 4 ● pilot air jet 5 damage → replace. Contamination → clean. Note: ● use a petroleum based solvent for cleaning. Blow out all passages and jets with com- pressed air. ● never use a wire. Needle valve 1. Inspect...

  • Page 120: Eng

    4 - 13 eng carburetor ec464511 float height 1. Measure: ● float height a out of specification → adjust. Float height: 8.0 mm (0.31 in) measurement and adjustment steps: ● hold the carburetor in an upside down position. Note: ● slowly tilt the carburetor in the opposite direction, then take the measu...

  • Page 121: Eng

    4 - 14 eng starter plunger 1. Inspect: ● cold starter plunger 1 ● hot starter plunger 2 wear/damage → replace. Accelerator pump 1. Inspect: ● diaphragm (accelerator pump) 1 ● spring 2 ● cover 3 ● o-ring 4 ● push rod 5 tears (diaphragm)/damage → replace. Dirt → clean. 2. Inspect: ● throttle shaft 1 ●...

  • Page 122: Eng

    4 - 15 eng carburetor 3. Install: ● spring 1 1 ● lever 1 2 to lever 2 3. Note: make sure the spring 1 fits on the stopper a of the lever 2. 3 1 2 a 4. Install: ● spring 2 1 to lever 2 2. 1 2 5. Install: ● push rod link lever assembly 1 note: make sure the stopper a of the spring 2 fits into the rece...

  • Page 123: Eng

    4 - 16 eng carburetor 8. Install: ● throttle shaft assembly 1 ● plain washer (metal) 2 ● plain washer (resin) 3 ● valve lever 4 note: ● apply the fluorochemical grease on the bear- ings. ● fit the projection a on the throttle shaft assembly into the slot b in the tps (throttle position sensor). ● ma...

  • Page 124: Eng

    4 - 17 eng carburetor 11. Install: ● needle valve 1 ● float 2 ● float pin 3 note: ● after installing the needle valve to the float, install them to the carburetor. ● check the float for smooth movement. 12. Install: ● pilot screw 1 ● spring 2 ● washer 3 ● o-ring 4 note the following installation poi...

  • Page 125: Eng

    4 - 18 eng carburetor 15. Install: ● jet needle 1 ● collar 2 ● spring 3 ● needle holder 4 ● throttle valve plate 5 to throttle valve 6. 5 6 1 2 3 4 16. Install: ● throttle valve assembly 1 ● screw (throttle shaft) 2 note: install the valve lever rollers 3 into the slits a of the throttle valve. 17. ...

  • Page 126: Eng

    4 - 19 eng carburetor accelerator pump timing adjustment adjustment steps: note: in order for the throttle valve height a to achieve the specified value, tuck under the throttle valve plate 1 the rod 2 etc. With the same outer diameter as the specified value. Throttle valve height: 3.40 mm (0.134 in...

  • Page 127: Eng

    4 - 20 eng 4. Tighten: ● screw (air cleaner joint) 1 ● screw (carburetor joint) 2 t r . . 3 nm (0.3 m · kg, 2.2 ft · lb) t r . . 3 nm (0.3 m · kg, 2.2 ft · lb) 5. Install: ● throttle cable 1 6. Adjust: ● throttle grip free play refer to “throttle cable adjust- ment” section in the chapter 3. 1 7. In...

  • Page 128: Eng

    4 - 21 eng camshafts camshafts cylinder head cover extent of removal: 1 cylinder head cover removal extent of removal order part name q’ty remarks cylinder head cover removal preparation for removal seat and fuel tank refer to “seat, fuel tank and side covers” section. Carburetor refer to “carbureto...

  • Page 129: Eng

    4 - 22 eng camshafts camshafts extent of removal: 1 camshaft removal extent of removal order part name q’ty remarks camshafts removal 1 timing plug 1 refer to “removal points”. 2 straight plug 1 3 tensioner cap bolt 1 4 timing chain tensioner 1 5 gasket 1 6 bolt (camshaft cap) 10 7 camshaft cap 2 8 ...

  • Page 130: Eng

    4 - 23 eng camshafts removal points camshaft 1. Remove: ● timing plug 1 ● straight plug 2 2. Align: ● “i” mark with stationary pointer. Checking steps: ● turn the crankshaft counterclockwise with a wrench. ● align the “i” mark a on the rotor with the stationary pointer b on the crankcase cover. When...

  • Page 131: Eng

    4 - 24 eng camshafts 6. Remove: ● clips ● exhaust camshaft 1 ● intake camshaft 2 note: attach a wire 3 to the timing chain to prevent it from falling into the crankcase. 1 2 3 inspection camshaft 1. Inspect: ● cam lobes pitting/scratches/blue discoloration → replace. 2. Measure: ● cam lobes length a...

  • Page 132: Eng

    4 - 25 eng camshafts 4. Measure: ● camshaft-to-cap clearance out of specification → measure cam- shaft journal diameter. Camshaft-to-cap clearance: 0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) : 0.08 mm (0.003 in) measurement steps: ● install the camshaft onto the cylinder head. ● position a strip of plast...

  • Page 133: Eng

    4 - 26 eng camshafts decompression system 1. Check: ● decompression system checking steps: ● check that the decompressor cam 1 moves smoothly. ● check that the decompressor lever pin 2 projects from the camshaft. Timing chain tensioner 1. Check: ● while pressing the tensioner rod lightly with finger...

  • Page 134: Eng

    4 - 27 eng camshafts ● fit the timing chain 3 onto both camshaft sprockets and install the camshafts on the cylinder head. Note: the camshafts should be installed onto the cylinder head so that the exhaust cam sprocket punch mark c and the intake cam sprocket punch mark d align with the sur- face of...

  • Page 135: Eng

    4 - 28 eng ● with the rod fully wound and the chain tensioner up mark a facing upward, install the gasket 1 and the chain ten- sioner 2, and tighten the bolt 3 to the specified torque. T r . . Bolt (timing chain tensioner): 10 nm (1.0 m • kg, 7.2 ft • lb) ● release the screwdriver, check the ten- si...

  • Page 136: Eng

    4 - 29 eng cylinder head cylinder head cylinder head extent of removal: 1 cylinder head removal note: tighten the cylinder head bolts to 30 nm (3.0 m · kg, 22 ft · lb) in the proper tightening sequence, remove and retighten the cylinder head bolts to 20 nm (2.0 m · kg, 14 ft · lb) in the proper tigh...

  • Page 137: Eng

    4 - 30 eng cylinder head inspection cylinder head 1. Eliminate: ● carbon deposits (from the combustion chambers) use a rounded scraper. Note: do not use a sharp instrument to avoid dam- aging or scratching: ● spark plug threads ● valve seats 2. Inspect: ● cylinder head scratches/damage → replace. 3....

  • Page 138: Eng

    4 - 31 eng cylinder head assembly and installation 1. Install: ● timing chain guide (front) 1 ● dowel pin 2 ● cylinder head gasket 3 ● cylinder head 4 note: while pulling up the timing chain, install the timing chain guide (front) and cylinder head. New 2. Install: ● plain washer 1 ● bolt [l=160 mm ...

  • Page 139: Eng

    4 - 32 eng ● remove the bolts. ● again apply the molybdenum disulfide grease on the threads and contact sur- faces of the bolts and on both contact sur- faces of the plain washers. ● retighten the bolts. Note: tighten the bolts to the specified torque in two or three steps in the proper tightening s...

  • Page 140: Eng

    4 - 33 eng valves and valve springs valves and valve springs valves and valve springs extent of removal: 1 valve removal extent of removal order part name q’ty remarks valves and valve springs removal preparation for removal cylinder head refer to “cylinder head” section. 1 valve lifter 5 use specia...

  • Page 141: Eng

    4 - 34 eng valves and valve springs removal points 1. Remove: ● valve lifters 1 ● pads 2 note: identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place. 2. Check: ● valve sealing leakage at the valve seat → inspect the valve face, valve seat an...

  • Page 142: Eng

    4 - 35 eng valves and valve springs inspection valve 1. Measure: ● stem-to-guide clearance out of specification → replace the valve guide. Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b clearance (stem to guide): intake: 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) : 0.08 m...

  • Page 143: Eng

    4 - 36 eng valves and valve springs valve guide remover: intake: 4.5 mm (0.18 in) ym-4116/90890-04116 exhaust: 5.0 mm (0.20 in) ym-4097/90890-04097 valve guide installer: intake: ym-4117/90890-04117 exhaust: ym-4098/90890-04098 valve guide reamer: intake: 4.5 mm (0.18 in) ym-4118/90890-04118 exhaust...

  • Page 144: Eng

    4 - 37 eng valves and valve springs 5. Measure: ● runout (valve stem) out of specification → replace. Note: ● when installing a new valve always replace the guide. ● if the valve is removed or replaced always replace the oil seal. 6. Eliminate: ● carbon deposits (from the valve face and valve seat) ...

  • Page 145: Eng

    4 - 38 eng valves and valve springs 9. Lap: ● valve face ● valve seat note: after refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. Lapping steps: ● apply a coarse lapping compound to the valve face. Caution: do not let the compound enter...

  • Page 146: Eng

    4 - 39 eng valves and valve springs valve spring 1. Measure: ● valve spring free length a out of specification → replace. 2. Measure: ● compressed spring force a out of specification → replace. B installed length free length (valve spring): intake: 37.03 mm (1.46 in) : 35.17 mm (1.38 in) exhaust: 37...

  • Page 147: Eng

    4 - 40 eng valves and valve springs combination of cylinder head and valve lifter 1. Combination: for this combination, match the paint color on the cylinder head with that on the valve lifter according to the chart below. Note: when you purchase a cylinder head, you can- not designate its size. Cho...

  • Page 148: Eng

    4 - 41 eng valves and valve springs 3. Install: ● valve cotters note: while compressing the valve spring with a valve spring compressor 1 install the valve cotters. 4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood. Caution: hitting the valve tip with...

  • Page 149: Eng

    4 - 42 eng cylinder and piston cylinder and piston cylinder and piston extent of removal: 1 cylinder removal 2 piston removal extent of removal order part name q’ty remarks cylinder and piston removal preparation for removal cylinder head refer to “cylinder head” section. 1 bolt (cylinder) 1 2 cylin...

  • Page 150: Eng

    4 - 43 eng cylinder and piston removal points piston 1. Remove: ● piston pin clips 1 ● piston pin 2 ● piston 3 note: ● put identification marks on each piston head for reference during reinstallation. ● before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groo...

  • Page 151: Eng

    4 - 44 eng cylinder and piston cylinder bore “c” 95.00 ~ 95.01 mm (3.7402 ~ 3.7406 in) taper limit “t” 0.05 mm (0.002 in) out of round “r” 0.05 mm (0.002 in) “c” = maximum d “t” = (maximum d 1 or d 2 ) – (maximum d 5 or d 6 ) “r” = (maximum d 1 , d 3 or d 5 ) – (minimum d 2 , d 4 or d 6 ) ● if out o...

  • Page 152: Eng

    4 - 45 eng cylinder and piston piston ring 1. Measure: ● ring side clearance use a feeler gauge 1. Out of specification → replace the pis- ton and rings as a set. Note: clean carbon from the piston ring grooves and rings before measuring the side clearance. 2. Position: ● piston ring (in cylinder) n...

  • Page 153: Eng

    4 - 46 eng cylinder and piston piston pin 1. Inspect: ● piston pin blue discoloration/grooves → replace, then inspect the lubrication system. 2. Measure: ● piston pin-to-piston clearance assembly and installation piston 1. Install: ● piston rings onto the piston. Note: ● be sure to install the pisto...

  • Page 154: Eng

    4 - 47 eng cylinder and piston 2. Position: ● top ring ● 2nd ring ● oil ring offset the piston ring end gaps as shown. A top ring end b 2nd ring end c oil ring end (upper) d oil ring e oil ring end (lower) 3. Install: ● piston 1 ● piston pin 2 ● piston pin clips 3 note: ● apply engine oil onto the p...

  • Page 155: Eng

    4 - 48 eng clutch clutch clutch extent of removal: 1 push rod and push lever removal 2 push pod 1 disassembly 3 friction plate and clutch plate removal 4 clutch housing removal extent of removal order part name q’ty remarks clutch removal preparation for removal drain the engine oil. Refer to “engin...

  • Page 156: Eng

    4 - 49 eng clutch extent of removal order part name q’ty remarks 12 clutch plate 8 13 friction plate 9 14 nut 1 use special tool. Refer to “removal points”. 15 look washer 1 16 clutch boss 1 17 thrust washer 1 18 clutch housing 1 19 push lever 1 4 1 3.

  • Page 157: Eng

    4 - 50 eng clutch ec493000 removal points ec483211 clutch boss 1. Remove: ● nut 1 ● lock washer 2 ● clutch boss 3 note: straighten the lock washer tab and use the clutch holding tool 4 to hold the clutch boss. Å for usa and cdn ı except for usa and cdn clutch holding tool: ym-91042/90890-04086 Å ı e...

  • Page 158: Eng

    4 - 51 eng clutch ec484500 friction plate 1. Measure: ● friction plate thickness out of specification → replace friction plate as a set. Measure at all four points. Ec484600 clutch plate 1. Measure: ● clutch plate warpage out of specification → replace clutch plate as a set. Use a surface plate 1 an...

  • Page 159: Eng

    4 - 52 eng clutch ec4a5000 assembly and installation push lever 1. Install: ● push lever 1 ● bolt (push lever) note: ● apply the lithium soap base grease on the oil seal lip. ● apply the engine oil on the push lever. ● fit the seat plate 2 in the groove a of the push lever and tighten the bolt (seat...

  • Page 160: Eng

    4 - 53 eng clutch 3. Bend the lock washer 1 tab. 4. Install: ● friction plate 1 ● clutch plate 2 note: ● install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate. ● apply the engine oil on the friction plates and cl...

  • Page 161: Eng

    4 - 54 eng clutch 7. Install: ● pressure plate 1 8. Install: ● clutch spring ● bolt (clutch spring) note: tighten the bolts in stage, using a crisscross pattern. T r . . 8 nm (0.8 m · kg, 5.8 ft · lb) 9. Install: ● gasket (clutch cover) 1 ● dowel pin 2 new 10. Install: ● clutch cover 1 ● bolt (clutc...

  • Page 162: Eng

    4 - 55 eng oil filter, water pump and crankcase cover (right) oil filter, water pump and crankcase cover (right) oil filter, water pump and crankcase cover (right) extent of removal: 1 oil filter removal 2 water pump removal 3 crankcase cover (right) removal extent of removal order part name q’ty re...

  • Page 163: Eng

    4 - 56 eng oil filter, water pump and crankcase cover (right) extent of removal order part name q’ty remarks 7 oil hose 1 8 kick starter 1 9 crankcase cover (right) 1 10 gasket 1 11 dowel pin/o-ring 4/2 12 impeller 1 refer to “removal points”. 13 plain washer 1 14 impeller shaft 1 15 oil seal 1 1 16...

  • Page 164: Eng

    4 - 57 eng oil filter, water pump and crankcase cover (right) removal points ec4g3110 impeller shaft 1. Remove: ● impeller 1 ● plain washer 2 ● impeller shaft 3 note: hold the impeller shaft on its width across the flats a with spanners, etc. And remove the impeller. Ec4g3210 oil seal note: it is no...

  • Page 165: Eng

    4 - 58 eng oil filter, water pump and crankcase cover (right) ec4h4600 bearing 1. Inspect: ● bearing rotate inner race with a finger. Rough spot/seizure → replace. Ec444400 oil seal 1. Inspect: ● oil seal wear/damage → replace. Assembly and installation ec4g5110 oil seal 1. Install: ● oil seal 1 not...

  • Page 166: Eng

    4 - 59 eng oil filter, water pump and crankcase cover (right) ec4g5220 impeller shaft 1. Install: ● impeller shaft 1 ● plain washer 2 ● impeller 3 note: ● take care so that the oil seal lip is not dam- aged or the spring does not slip off its posi- tion. ● when installing the impeller shaft, apply t...

  • Page 167: Eng

    4 - 60 eng oil filter, water pump and crankcase cover (right) kick crank 1. Install: ● kick starter 1 ● plain washer ● bolt (kick starter) note: install the kick starter so that the kick starter is as vertical as possible with the distance a between the kick starter and the frame being 5 mm (0.20 in...

  • Page 168: Eng

    4 - 61 eng oil filter, water pump and crankcase cover (right) 2. Install: ● water pump housing 1 ● bolt (water pump housing) 2 ● plain washer 3 ● coolant drain bolt 4 t r . . 10 nm (1.0 m · kg, 7.2 ft · lb) new t r . . 10 nm (1.0 m · kg, 7.2 ft · lb) 3. Install: ● o-ring ● coolant pipe 1 ● bolt (coo...

  • Page 169: Eng

    4 - 62 eng balancer balancer balancer extent of removal: 1 balancer drive gear 2 balancer extent of removal order part name q’ty remarks balancer removal preparation for removal clutch housing refer to “clutch” section. Crankcase cover (right) refer to “oil filter, water pump and crankcase cover (ri...

  • Page 170: Eng

    4 - 63 eng balancer removal points balancer drive gear and balancer driven gear 1. Straighten the lock washer tab. 2. Loosen: ● nut (primary drive gear) 1 ● nut (balancer) 2 note: place an aluminum plate a between the teeth of the balancer drive gear 3 and driven gear 4. Balancer 1. Remove: ● balanc...

  • Page 171: Eng

    4 - 64 eng balancer assembly and installation balancer, balancer drive gear and balancer driven gear 1. Install: ● balancer 1 note: when installing the balancer shaft, align the center of the balancer shaft weight a along the line connecting the centers of the crank- shaft and balancer shaft. 2. Ins...

  • Page 172: Eng

    4 - 65 eng oil pump oil pump oil pump extent of removal: 1 oil pump removal 2 oil pump disassembly extent of removal order part name q’ty remarks oil pump removal and dis- assembly preparation for removal clutch housing refer to “clutch” section. Crankcase cover (right) refer to “oil filter, water p...

  • Page 173: Eng

    4 - 66 eng oil pump extent of removal order part name q’ty remarks 13 pin 1 14 washer 1 15 oil pump drive shaft 1 16 rotor housing 1 2.

  • Page 174: Eng

    4 - 67 eng oil pump inspection oil pump 1. Inspect: ● oil pump drive gear ● oil pump driven gear ● rotor housing ● oil pump cover cracks/wear/damage → replace. 2. Measure: ● tip clearance a between the inner rotor 1 and the outer rotor 2. ● tip clearance b between the outer rotor 2 and the rotor hou...

  • Page 175: Eng

    4 - 68 eng oil pump 2. Install: ● outer rotor 1 1 note: apply the engine oil on the outer rotor 1. 3. Install: ● oil pump cover 1 ● screw (oil pump cover) 2 ● pin 3 ● inner rotor 2 4 ● circlip 5 note: ● apply the engine oil on the oil pump drive shaft end and inner rotor 2. ● fit the pin into the gr...

  • Page 176: Eng

    4 - 69 eng kick axle and shift shaft kick axle and shift shaft kick axle and shift shaft extent of removal: 1 kick axle removal 2 kick axle disassembly 3 shift shaft removal 4 segment removal extent of removal order part name q’ty remarks kick axle and shift shaft removal preparation for removal oil...

  • Page 177: Eng

    4 - 70 eng kick axle and shift shaft extent of removal order part name q’ty remarks 13 roller 1 14 shift guide 1 refer to “removal points”. 15 shift lever assembly 1 16 shift lever 1 17 pawl 2 18 pawl pin 2 19 spring 2 20 bolt (stopper lever) 1 21 stopper lever 1 22 torsion spring 1 23 segment 1 ref...

  • Page 178: Eng

    4 - 71 eng kick axle and shift shaft removal points ec4b3101 kick axle assembly 1. Remove: ● kick axle assembly 1 note: unhook the torsion spring 2 from the hole a in the crankcase. Ec4c3101 shift guide and shift lever assembly 1. Remove: ● bolt (shift guide) ● shift guide 1 ● shift lever assembly 2...

  • Page 179: Eng

    4 - 72 eng kick axle and shift shaft ec4b4400 shift shaft 1. Inspect: ● shift shaft 1 bend/damage → replace. ● spring 2 broken → replace. Ec4c4100 shift guide and shift lever assembly 1. Inspect: ● shift guide 1 ● shift lever 2 ● pawl 3 ● pawl pin 4 ● spring 5 wear/damage → replace. Ec4b4500 stopper...

  • Page 180: Eng

    4 - 73 eng kick axle and shift shaft ec4b5111 stopper lever 1. Install: ● torsion spring 1 ● stopper lever 2 ● bolt (stopper lever) 3 note: align the stopper lever roller with the slot on segment. Shift guide and shift lever assembly 1. Install: ● spring 1 ● pawl pin 2 ● pawl 3 to shift lever 4. Not...

  • Page 181: Eng

    4 - 74 eng kick axle and shift shaft ec4c5301 shift shaft 1. Install: ● roller 1 ● collar 2 ● torsion spring 3 ● shift shaft 4 note: apply the engine oil on the roller and shift shaft. 2. Install: ● shift pedal 1 ● bolt (shift pedal) note: when installing the shift pedal onto the shift shaft, be sur...

  • Page 182: Eng

    4 - 75 eng kick axle and shift shaft 3. Install: ● spring guide 1 note: slide the spring guide into the kick axle, make sure the groove a in the spring guide fits on the stopper of the torsion spring. 4. Install: ● kick axle assembly 1 ● plain washer 2 note: ● apply the molybdenum disulfide grease o...

  • Page 183: Eng

    4 - 76 eng cdi magneto ec4l0000 cdi magneto extent of removal: 1 cdi magneto removal extent of removal order part name q’ty remarks cdi magneto removal preparation for removal seat and fuel tank refer to “saet, fuel tank and side covers” section. Bolt [radiator (left)] disconnect the cdi magneto lea...

  • Page 184: Eng

    4 - 77 eng cdi magneto ec4l3000 removal points ec4l3101 rotor 1. Remove: ● nut (rotor) 1 ● plain washer use the rotor holding tool 2. 2. Remove: ● rotor 1 use the flywheel puller 2. Note: when installing the flywheel puller, turn it counterclockwise. Rotor holding tool: yu-1235/90890-01235 flywheel ...

  • Page 185: Eng

    4 - 78 eng cdi magneto ec4l5000 assembly and installation cdi magneto 1. Install: ● stator 1 ● screw (stator) 2 note: ● apply the sealant to the grommet of the cdi magneto lead. ● tighten the screws using the t30 bit. Quick gasket ® : acc-quick-gs-kt yamaha bond no. 1215: 90890-85505 t r . . 10 nm (...

  • Page 186: Eng

    4 - 79 eng cdi magneto 4. Connect: ● cdi magneto lead refer to “cable routing dia- gram” section in the chapter 2. 5. Install: ● gasket [crankcase cover (left)] ● crankcase cover (left) 1 ● hose holder (cylinder head breather hose) 2 ● bolt [crankcase cover (left)] note: tighten the bolts in stage, ...

  • Page 187: Eng

    4 - 80 eng engine removal ec4m0000 engine removal extent of removal order part name q’ty remarks engine removal preparation for removal hold the machine by placing the suitable stand under the frame. Warning support the machine securely so there is no danger of it falling over. Seat and fuel tank re...

  • Page 188: Eng

    4 - 81 eng engine removal extent of removal: 1 engine removal extent of removal order part name q’ty remarks 1 engine skid plate (front) 1 2 neutral switch 1 3 oil hose 2 4 chain cover 1 5 nut (drive sprocket) 1 refer to “removal points”. 6 lock washer 1 7 drive sprocket 1 8 clip 1 9 bolt (brake ped...

  • Page 189: Eng

    4 - 82 eng engine removal ec4m3000 removal points ec4f3100 drive sprocket 1. Remove: ● nut (drive sprocket) 1 ● lock washer 2 note: ● straighten the lock washer tab. ● loosen the nut while applying the rear brake. 2. Remove: ● drive sprocket 1 ● drive chain 2 note: remove the drive sprocket together...

  • Page 190: Eng

    4 - 83 eng engine removal ec4m5000 assembly and installation engine installation 1. Install: ● engine 1 install the engine from right side. ● pivot shaft 2 ● engine mounting bolt (lower) 3 ● engine lower bracket 4 ● bolt (engine bracket) 5 ● engine mounting bolt (front) 6 ● engine upper bracket (rig...

  • Page 191: Eng

    4 - 84 eng engine removal 2. Install: ● lock washer 1 ● nut (drive sprocket) 2 note: tighten the nut while applying the rear brake. New t r . . 75 nm (7.5 m · kg, 54 ft · lb) 3. Bend the lock washer tab to lock the nut. 4. Install: ● chain guide ● chain cover 1 ● screw (chain cover) 2 2 1 t r . . 8 ...

  • Page 192: Eng

    4 - 85 eng crankcase and crankshaft crankcase and crankshaft crankcase and crankshaft extent of removal: 1 crankcase separation 2 crankshaft removal extent of removal order part name q’ty remarks crankcase separation preparation for removal engine refer to “engine removal” section. Piston refer to “...

  • Page 193: Eng

    4 - 86 eng crankcase and crankshaft extent of removal order part name q’ty remarks 10 oil strainer 1 11 oil delivery pipe 2 1 12 crankshaft 1 use special tool. Refer to “removal points”. 2.

  • Page 194: Eng

    4 - 87 eng crankcase and crankshaft crankcase bearing extent of removal: 1 crankcase bearing removal extent of removal order part name q’ty remarks crankcase bearing removal preparation for removal transmission shift cam and shift fork refer to “transmission, shift cam and shift fork” section. 1 oil...

  • Page 195: Eng

    4 - 88 eng crankcase and crankshaft removal points crankcase 1. Separate: ● crankcase (right) ● crankcase (left) separation steps: ● remove the crankcase bolts, hose guide and clutch cable holder. Note: loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them. ● rem...

  • Page 196: Eng

    4 - 89 eng crankcase and crankshaft crankshaft 1. Remove: ● crankshaft 1 use the crankcase separating tool 2. Caution: do not use a hammer to drive out the crankshaft. Crankshaft bearing 1. Remove: ● bearing 1 note: ● remove the bearing from the crankcase by pressing its inner race. ● do not use the...

  • Page 197: Eng

    4 - 90 eng crankcase and crankshaft ec4n4201 crankshaft 1. Measure: ● runout limit a ● small end free play limit b ● connecting rod big end side clearance c ● crank width d out of specification → replace. Use the dial gauge and a thickness gauge. Dial gauge and stand: yu-3097/90890-01252 standard ru...

  • Page 198: Eng

    4 - 91 eng crankcase and crankshaft ec4n5000 assembly and installation crankshaft bearing 1. Install: ● bearing ● bearing stopper ● bolt (bearing stopper) ● screw (bearing stopper) ● screw [bearing stopper (crankshaft)] 1 to crankcase (left and right). Note: ● install the bearing by pressing its out...

  • Page 199: Eng

    4 - 92 eng crankcase and crankshaft note: ● hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms against the bearing. ● before installing the crankshaft, clean the contacting sur...

  • Page 200: Eng

    4 - 93 eng crankcase and crankshaft 5. Install: ● dowel pin 1 ● o-ring 2 ● crankcase (right) to crankcase (left). Note: ● fit the crankcase (right) onto the crankcase (left). Tap lightly on the case with soft ham- mer. ● when installing the crankcase, the connect- ing rod should be positioned at tdc...

  • Page 201: Eng

    4 - 94 eng transmission, shift cam and shift fork transmission, shift cam and shift fork transmission, shift cam and shift fork extent of removal: 1 shift fork, shift cam, main axle and drive axle removal extent of removal order part name q’ty remarks transmission, shift cam and shift fork removal p...

  • Page 202: Eng

    4 - 95 eng transmission, shift cam and shift fork ec4h3000 removal points shift fork, shaft cam and transmission 1. Remove: ● shift forks ● shift cam ● main axle ● drive axle note: ● tap lightly on the transmission drive axle and shift cam with a soft hammer to remove. ● remove assembly carefully. N...

  • Page 203: Eng

    4 - 96 eng transmission, shift cam and shift fork ec4h4801 shift fork, shift cam and segment 1. Inspect: ● shift fork 1 wear/damage/scratches → replace. 2. Inspect: ● shift cam 1 ● segment 2 bend/wear/damage → replace. 3. Check: ● shift fork movement unsmooth operation → replace shift fork. Note: fo...

  • Page 204: Eng

    4 - 97 eng transmission, shift cam and shift fork 2. Install: ● 2nd wheel gear (25t) 1 ● 3rd wheel gear (23t) 2 ● 4th wheel gear (21t) 3 ● 1st wheel gear (27t) 4 ● o-ring 5 to drive axle 6. Note: ● apply the molybdenum disulfide oil on the 1st, 2nd and 3rd wheel gears inner circum- ference and on th...

  • Page 205: Eng

    4 - 98 eng transmission, shift cam and shift fork 5. Install: ● shift fork 1 (l) 1 ● shift fork 2 (r) 2 ● shift cam 3 to main axle and drive axle. Note: ● apply the molybdenum disulfide oil on the shift fork grooves. ● mesh the shift fork #1 (l) with the 3rd pinion gear 4 on the main axle. ● mesh th...

  • Page 206: Chas

    5 - 1 chas ec500000 chassis ec590000 front wheel and rear wheel ec598000 front wheel front wheel and rear wheel extent of removal: 1 front wheel removal 2 wheel bearing removal 3 brake disc removal extent of removal order part name q’ty remarks preparation for removal front wheel removal hold the ma...

  • Page 207: Chas

    5 - 2 chas ec598100 rear wheel extent of removal: 1 rear wheel removal 2 wheel bearing removal 3 brake disc removal extent of removal order part name q’ty remarks preparation for removal rear wheel removal hold the machine by placing the suitable stand under the engine. Warning support the machine s...

  • Page 208: Chas

    5 - 3 chas front wheel and rear wheel ec593000 removal points ec523101 rear wheel 1. Remove: ● wheel 1 note: push the wheel forward and remove the drive chain 2 . Ec513201 wheel bearing (if necessary) 1. Remove: ● bearing 1 note: remove the bearing using a general bearing puller 2 . Ec594000 inspect...

  • Page 209: Chas

    5 - 4 chas front wheel and rear wheel ec514200 wheel axle 1. Measure: ● wheel axle bends out of specification → replace. Use the dial gauge 1 . Note: the bending value is shown by one half of the dial gauge reading. Warning do not attempt to straighten a bent axle. Wheel axle bending limit: 0.5 mm (...

  • Page 210: Chas

    5 - 5 chas front wheel and rear wheel ec595000 assembly and installation front wheel 1. Install: ● bearing (left) 1 ● spacer 2 ● bearing (right) 3 ● oil seal 4 note: ● apply the lithium soap base grease on the bearing and oil seal lip when installing. ● use a socket that matches the outside diam- et...

  • Page 211: Chas

    5 - 6 chas front wheel and rear wheel 5. Install: ● wheel axle 1 note: apply the lithium soap base grease on the wheel axle. 6. Install: ● nut (wheel axle) 1 t r . . 105 nm (10.5 m · kg, 75 ft · lb) 7. Tighten: ● bolt (axle holder) 1 note: before tightening the bolt, fit the wheel axle to the axle h...

  • Page 212: Chas

    5 - 7 chas front wheel and rear wheel 9. Install: ● hose cover 1 ● plain washer 2 ● bolt [hose cover (m8)] 3 ● bolt [hose cover (m6)] 4 t r . . 16 nm (1.6 m · kg, 11 ft · lb) t r . . 7 nm (0.7 m · kg, 5.1 ft · lb) rear wheel 1. Install: ● bearing (right) 1 ● circlip 2 ● spacer 3 ● bearing (left) 4 ●...

  • Page 213: Chas

    5 - 8 chas 3. Install: ● driven sprocket 1 ● bolt (driven sprocket) 2 ● plain washer (driven sprocket) 3 ● nut (driven sprocket) 4 note: tighten the nuts in stage, using a crisscross pattern. T r . . 42 nm (4.2 m · kg, 30 ft · lb) front wheel and rear wheel 4. Install: ● collar 1 note: apply the lit...

  • Page 214: Chas

    5 - 9 chas front wheel and rear wheel 8. Install: ● chain puller (right) 1 ● plain washer 2 ● nut (wheel axle) 3 note: temporarily tighten the nut (wheel axle) at this point. 9. Adjust: ● drive chain slack a refer to “drive chain slack adjustment” section in the chap- ter 3. Drive chain slack: 40 ~ ...

  • Page 215: Chas

    5 - 10 chas front brake and rear brake ec5a0000 front brake and rear brake ec5a8000 front brake extent of removal: 1 brake hose removal 2 caliper removal 3 master cylinder removal extent of removal order part name q’ty remarks preparation for removal front brake removal hold the machine by placing t...

  • Page 216: Chas

    5 - 11 chas ec5a8100 rear brake extent of removal: 1 master cylinder removal 2 brake hose removal 3 caliper removal extent of removal order part name q’ty remarks preparation for removal rear brake removal hold the machine by placing the suitable stand under the engine. Warning support the machine s...

  • Page 217: Chas

    5 - 12 chas ec5a8200 caliper disassembly Å front ı rear extent of removal: 1 front caliper disassembly 2 rear caliper disassembly extent of removal order part name q’ty remarks caliper disassembly a b 1 pad pin 1 1 2 brake pad 2 2 3 pad support 1 1 4 caliper piston 2 1 refer to “removal points”. 5 d...

  • Page 218: Chas

    5 - 13 chas front brake and rear brake ec5a8300 master cylinder disassembly Å front ı rear extent of removal: 1 front master cylinder disassembly 2 rear master cylinder disassembly extent of removal order part name q’ty remarks master cylinder disas- sembly 1 master cylinder cap 1 2 diaphragm 1 3 ma...

  • Page 219: Chas

    5 - 14 chas front brake and rear brake ec5a3000 removal points brake fluid 1. Remove: [front] ● master cylinder cap 1 [rear] ● master cylinder cap 1 ● protector note: do not remove the diaphragm. Å front ı rear 2. Connect the transparent hose 2 to the bleed screw 1 and place a suitable con- tainer u...

  • Page 220: Chas

    5 - 15 chas front brake and rear brake ec533402 piston seal kit 1. Remove: ● dust seal 1 ● piston seal 2 note: remove the piston seals and dust seals by pushing them with a finger. Achtung: caution: never attempt to pry out piston seals and dust seals. Warning replace the piston seals and dust seals...

  • Page 221: Chas

    5 - 16 chas ec534214 caliper 1. Inspect: ● caliper cylinder inner surface a wear/score marks → replace caliper assembly. Å front ı rear ı Å 2. Inspect: ● caliper piston 1 wear/score marks → replace caliper piston assembly. Warning replace the piston seals and dust seals 2 whenever a caliper is disas...

  • Page 222: Chas

    5 - 17 chas 2. Install: ● piston seal 1 ● dust seal 2 warning always use new piston seals and dust seals. Note: fit the piston seals and dust seals onto the slot on caliper correctly. Å front ı rear Å new new ı 3. Install: ● caliper piston 1 note: apply the brake fluid on the piston wall. Achtung: c...

  • Page 223: Chas

    5 - 18 chas front brake and rear brake 2. Install: ● copper washer 1 ● union bolt 2 warning always use new copper washers. Achtung: caution: install the brake hose so that its pipe por- tion a directs as shown and lightly touches the projection b on the caliper. New t r . . 30 nm (3.0 m · kg, 22 ft ...

  • Page 224: Chas

    5 - 19 chas front brake and rear brake 2. Install: ● disc cover 1 ● bolt (disc cover) 2 t r . . 7 nm (0.7 m · kg, 5.1 ft · lb) 3. Install: ● caliper 1 ● rear wheel 2 refer to “front wheel and rear wheel” section. 4. Tighten: ● pad pin 3 5. Install: ● pad pin plug 4 master cylinder kit 1. Clean: ● ma...

  • Page 225: Chas

    5 - 20 chas front brake and rear brake 3. Install: ● spring 1 to master cylinder piston 2. Note: install the spring at the smaller dia. Side. Å front ı rear Å ı 4. Install: [front] ● master cylinder kit 1 ● plain washer 2 ● circlip 3 ● master cylinder boot 4 to master cylinder 5. [rear] ● master cyl...

  • Page 226: Chas

    5 - 21 chas front brake and rear brake 2. Install: ● brake lever 1 ● bolt (brake lever) 2 ● nut (brake lever) 3 note: apply the lithium soap base grease on the brake lever sliding surface, bolt and contacting surface of the master cylinder piston. Rear master cylinder 1. Install: ● copper washer 1 ●...

  • Page 227: Chas

    5 - 22 chas front brake and rear brake 4. Install: ● pin 1 ● plain washer 2 ● cotter pin 3 note: after installing, check the brake pedal height. Refer to “rear brake adjustment” sec- tion in the chapter 3. New front brake hose 1. Install: ● brake hose 1 to brake hose holder 2. Note: before tightenin...

  • Page 228: Chas

    5 - 23 chas front brake and rear brake 4. Install: ● copper washer 1 ● brake hose 2 ● union bolt 3 warning always use new copper washers. Achtung: caution: install the brake hose so that its pipe por- tion a directs as shown and lightly touches the projection b on the master cylinder. New t r . . 30...

  • Page 229: Chas

    5 - 24 chas front brake and rear brake 2. Install: ● brake hose holder 1 ● screw (brake hose holder) 2 achtung: caution: after installing the brake hose holders, make sure the brake hose does not contact the spring (rear shock absorber). If it does, correct its twist. T r . . 1 nm (0.1 m · kg, 0.7 f...

  • Page 230: Chas

    5 - 25 chas front brake and rear brake 2. Air bleed: ● brake system refer to “brake system air bleeding” section in the chapter 3. 3. Inspect: ● brake fluid level fluid at lower level → fill up. Refer to “brake fluid level inspection” section in the chap- ter 3. 4. Install: [front] ● diaphragm ● mas...

  • Page 231: Chas

    5 - 26 chas front fork ec550000 front fork extent of removal: 1 front fork removal extent of removal order part name q’ty remarks preparation for removal front fork removal hold the machine by placing the suitable stand under the engine. Warning support the machine securely so there is no danger of ...

  • Page 232: Chas

    5 - 27 chas front fork ec558000 front fork disassembly extent of removal: 1 oil seal removal 2 damper rod removal extent of removal order part name q’ty remarks front fork disassembly 1 cap bolt 1 refer to “removal points”. 2 fork spring 1 drain the fork oil. 3 dust seal 1 refer to “removal points”....

  • Page 233: Chas

    5 - 28 chas front fork ec556000 handling note note: the front fork requires careful attention. So it is recommended that the front fork be main- tained at the dealers. Achtung: caution: to prevent an accidental explosion of air, the following instructions should be observed: ● the front fork with a ...

  • Page 234: Chas

    5 - 29 chas ec553201 inner tube 1. Remove: ● dust seal 1 ● stopper ring 2 using slotted-head screwdriver. Achtung: caution: take care not to scratch the inner tube. 2. Remove: ● inner tube 1 oil seal removal steps: ● push in slowly a the inner tube just before it bottoms out and then pull it back qu...

  • Page 235: Chas

    5 - 30 chas ec554200 base valve 1. Inspect: ● valve assembly 1 wear/damage → replace. ● o-ring 2 damage → replace. Ec554400 fork spring 1. Measure: ● fork spring free length a out of specification → replace. Ec554502 inner tube 1. Inspect: ● inner tube surface a score marks → repair or replace. Use ...

  • Page 236: Chas

    5 - 31 chas ec554700 cap bolt 1. Inspect: ● cap bolt 1 ● o-ring 2 ● air bleed screw 3 wear/damage → replace. Front fork ec555000 assembly and installation front fork assembly 1. Wash the all parts in a clean solvent. 2. Install: ● damper rod 1 to inner tube 2. Achtung: caution: to install the damper...

  • Page 237: Chas

    5 - 32 chas front fork 5. Install: ● spring guide 1 ● locknut 2 to damper rod 3. Note: ● install the spring guide with its cut a facing upward. ● with its thread b facing upward, fully finger tighten the locknut onto the damper rod. 6. Install: ● dust seal 1 ● stopper ring 2 ● oil seal 3 ● plain was...

  • Page 238: Chas

    5 - 33 chas front fork 9. Install: ● slide metal 1 ● plain washer 2 to outer tube slot. Note: press the slide metal into the outer tube with fork seal driver 3. Fork seal driver: ym-01442/90890-01442 10. Install: ● oil seal 1 note: press the oil seal into the outer tube with fork seal driver 2. Fork...

  • Page 239: Chas

    5 - 34 chas front fork 13. Check: ● inner tube smooth movement tightness/binding/rough spots → repeat the steps 2 to 12. 14. Compress the front fork fully. 15. Fill: ● front fork oil until outer tube top surface with recom- mended fork oil 1. Achtung: caution: ● be sure to use recommended fork oil. ...

  • Page 240: Chas

    5 - 35 chas front fork 19. Wait ten minutes until the air bubbles have been removed from the front fork, and the oil has dispense evenly in system before setting recommended oil level. Note: fill with the fork oil up to the top end of the outer tube, or the fork oil will not spread over to every par...

  • Page 241: Chas

    5 - 36 chas front fork 21. Measure: ● distance a out of specification → turn into the locknut. Distance a: 20 mm (0.79 in) or more between damper rod 1 top and locknut 2 top. 22. Loosen: ● rebound damping adjuster 1 note: ● loosen the rebound damping adjuster finger tight. ● record the set position ...

  • Page 242: Chas

    5 - 37 chas front fork 26. Tighten: ● cap bolt (locknut) 1 note: ● while compressing the fork spring, set the thin type spanners 2 between the spacer 3 and spring guide 4. ● hold the locknut 5 and tighten the cap bolt with specified torque. 27. Install: ● cap bolt 1 to outer tube. Note: temporarily ...

  • Page 243: Chas

    5 - 38 chas front fork 4. Tighten: ● pinch bolt (handle crown) 1 ● pinch bolt (under bracket) 2 achtung: caution: tighten the under bracket to specified torque. If torqued too much, it may cause the front fork to malfunction. 5. Install: ● brake hose holder 1 ● caliper 2 ● bolt (caliper) 3 note: fit...

  • Page 244: Chas

    5 - 39 chas ec5b0000 handlebar extent of removal: 1 handlebar removal extent of removal order part name q’ty remarks preparation for removal handlebar removal number plate remove the clamp portion only. 1 hot starter cable 1 disconnect at the lever side. 2 hot starter lever holder 1 3 clutch cable 1...

  • Page 245: Chas

    5 - 40 chas ec5b3000 removal points ec5b3100 master cylinder 1. Remove: ● master cylinder bracket 1 ● master cylinder 2 achtung: caution: ● do not let the master cylinder hang on the brake hose. ● keep the master cylinder cap side hori- zontal to prevent air from coming in. Ec5b3200 grip 1. Remove: ...

  • Page 246: Chas

    5 - 41 chas handlebar ec5b5000 assembly and installation handlebar 1. Install: ● handlebar 1 ● handlebar holder 2 ● bolt (handlebar holder) 3 note: ● the upper handlebar holder should be installed with the punched mark a forward. ● first tighten the bolts on the front side of the handlebar holder, a...

  • Page 247: Chas

    5 - 42 chas handlebar 4. Install: ● collar 1 ● cover (grip cap) 2 ● throttle grip 3 note: apply the lithium soap base grease on the throttle grip sliding surface. 5. Install: ● throttle cables 1 to tube guide 2. Note: apply the lithium soap base grease on the throttle cable end and tube guide cable ...

  • Page 248: Chas

    5 - 43 chas handlebar 8. Install: ● master cylinder 1 ● master cylinder bracket 2 ● bolt (master cylinder bracket) 3 note: ● install the bracket so that the arrow mark a faces upward. ● first tighten the bolt on the upper side of the master cylinder bracket, and then tighten the bolt on the lower si...

  • Page 249: Chas

    5 - 44 chas handlebar 12. Clamp the clamp portion a of the num- ber plate to the handlebar. 13. Insert the end of the fuel breather hose 1 into the hole of the number plate..

  • Page 250: Chas

    5 - 45 chas ec560000 steering extent of removal: 1 under bracket removal 2 bearing removal extent of removal order part name q’ty remarks steering removal warning support the machine securely so there is no danger of it falling over. Refer to “handlebar” section. Preparation for removal hold the mac...

  • Page 251: Chas

    5 - 46 chas ec563000 removal points ec563202 ring nut 1. Remove: ● ring nut 1 use the ring nut wrench 2. Warning support the steering shaft so that it may not fall down. Ring nut wrench: yu-33975/90890-01403 ec563300 bearing (lower) 1. Remove: ● bearing (lower) 1 use the floor chisel 2. Achtung: cau...

  • Page 252: Chas

    5 - 47 chas steering ec564101 bearing and ball race 1. Wash the bearings and ball races with a solvent. 2. Inspect: ● bearing 1 ● ball race pitting/damage → replace bearings and ball races as a set. Install the bearing in the ball races. Spin the bearings by hand. If the bear- ings hang up or are no...

  • Page 253: Chas

    5 - 48 chas 4. Install: ● ring nut 1 tighten the ring nut using the ring nut wrench 2. Refer to “steering head inspec- tion and adjustment” section in the chapter 3. T r . . 7 nm (0.7 m · kg, 5.1 ft · lb) 5. Check the steering shaft by turning it lock to lock. If there is any binding, remove the ste...

  • Page 254: Chas

    5 - 49 chas steering 10. Tighten: ● pinch bolt (handle crown) 1 ● pinch bolt (under bracket) 2 achtung: caution: tighten the under bracket to specified torque. If torqued too much, it may cause the front fork to malfunction. T r . . 23 nm (2.3 m · kg, 17 ft · lb) t r . . 20 nm (2.0 m · kg, 14 ft · l...

  • Page 255: Chas

    5 - 50 chas swingarm ec570000 swingarm extent of removal: 1 swingarm removal extent of removal order part name q’ty remarks swingarm removal warning support the machine securely so there is no danger of it falling over. Preparation for removal hold the machine by placing the suitable stand under the...

  • Page 256: Chas

    5 - 51 chas swingarm ec578000 swingarm disassembly extent of removal: 1 swingarm disassembly 2 connecting rod removal and disassembly 3 relay arm removal and disassembly extent of removal order part name q’ty remarks swingarm disassembly 1 cap 2 2 relay arm 1 3 connecting rod 1 4 collar 2 5 oil seal...

  • Page 257: Chas

    5 - 52 chas swingarm ec573000 removal points ec573200 bearing 1. Remove: ● bearing 1 note: install the bearing by pressing its outer race. Ec574010 inspection wash the bearings, bushes, collars, and cov- ers in a solvent. Ec574111 swingarm 1. Inspect: ● bearing 1 ● bush 2 free play exists/unsmooth r...

  • Page 258: Chas

    5 - 53 chas swingarm ec574310 connecting rod 1. Inspect: ● bearing (polylube bearing) 1 ● collar 2 free play exists/unsmooth revolution/rust → replace bearing and collar as a set. 2. Inspect: ● bearing (polylube bearing) 1 loss of solid lubrication → replace. ● oil seal 3 damage → replace. Note: pol...

  • Page 259: Chas

    5 - 54 chas swingarm 2. Install: ● bearing 1 ● oil seal 2 to relay arm. Note: ● apply the molybdenum disulfide grease on the bearing when installing. ● install the bearing by pressing it on the side having the manufacture’s marks or numbers. 3. Install: ● bearing 1 ● oil seal 2 to connecting rod. No...

  • Page 260: Chas

    5 - 55 chas swingarm 3. Install: ● collar 1 to connecting rod 2. Note: apply the molybdenum disulfide grease on the collar and oil seal lips. 4. Install: ● connecting rod 1 ● bolt (connecting rod) 2 ● plain washer 3 ● nut (connecting rod) 4 to relay arm 5. Note: apply the molybdenum disulfide grease...

  • Page 261: Chas

    5 - 56 chas swingarm 8. Install: ● bolt (connecting rod) 1 ● plain washer 2 ● nut (connecting rod) 3 note: ● apply the molybdenum disulfide grease on the bolt. ● do not tighten the nut yet. 9. Install: ● bolt (rear shock absorber-relay arm) 1 ● nut (rear shock absorber-relay arm) 2 note: apply the m...

  • Page 262: Chas

    5 - 57 chas 13. Install: ● bolt [chain tensioner (lower)] 1 ● plain washer 2 ● collar 3 ● chain tensioner 4 ● nut [chain tensioner (lower)] 5 t r . . 20 nm (2.0 m · kg, 14 ft · lb) 14. Install: ● chain support 1 ● support cover 2 ● bolt {chain support [ r= 50 mm (1.97 in)]} 3 ● nut (chain support) 4...

  • Page 263: Chas

    5 - 58 chas rear shock absorber ec580000 rear shock absorber extent of removal: 1 rear shock absorber removal 2 rear shock absorber disassembly extent of removal order part name q’ty remarks preparation for removal rear shock absorber removal hold the machine by placing the suitable stand under the ...

  • Page 264: Chas

    5 - 59 chas rear shock absorber extent of removal order part name q’ty remarks 9 spring guide (upper) 1 10 spring (rear shock absorber) 1 11 bearing 2 refer to “removal points”. 2.

  • Page 265: Chas

    5 - 60 chas ec586000 handling note warning this shock absorber is provided with a separate type tank filled with high-pressure nitrogen gas. To prevent the danger of explosion, read and understand the follow- ing information before handling the shock absorber. The manufacturer can not be held respon...

  • Page 266: Chas

    5 - 61 chas ec583000 removal points ec583320 bearing 1. Remove: ● stopper ring (upper bearing) 1 note: press in the bearing while pressing its outer race and remove the stopper ring. 2. Remove: ● upper bearing 1 note: remove the bearing by pressing its outer race. 3. Remove: ● lower bearing 1 note: ...

  • Page 267: Chas

    5 - 62 chas rear shock absorber ec585000 assembly and installation ec585300 bearing 1. Install: ● upper bearing 1 note: install the bearing parallel until the stopper ring groove appears by pressing its outer race. Achtung: caution: do not apply the grease on the bearing outer race because it will w...

  • Page 268: Chas

    5 - 63 chas rear shock absorber 2. Tighten: ● adjuster 1 3. Adjust: ● spring length (installed) a * for europe note: the length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjuster. Achtung: caution: never attempt to turn the adjuster beyond the maximum or minimum setting. 4. ...

  • Page 269: Chas

    5 - 64 chas rear shock absorber 2. Install: ● bush 1 ● collar 2 ● dust seal 3 note: ● apply the molybdenum disulfide grease on the bearing. ● apply the lithium soap base grease on the bush, collars and dust seals. ● install the dust seals with their lips facing outward. 3. Install: ● rear shock abso...

  • Page 270: Elec

    6 - 1 – + elec electrical components and wiring diagram ec600000 electrical ec610000 electrical components and wiring diagram ec611000 electrical components 1 “engine stop” button 2 tps (throttle position sensor) 3 neutral switch 4 cdi magneto 5 ignition coil 6 spark plug 7 cdi unit color code b.......

  • Page 271: Elec

    – + elec 6 - 2 map-controlled cdi unit map-controlled cdi unit a map-controlled, cdi ignition system is used in the yz450f. The microcomputer in the cdi unit detects the engine speed and throttle position, thus determining the optimum ignition timing through the entire operating range. In this way, ...

  • Page 272: Elec

    – + elec 6 - 3 ignition system ec620000 ignition system inspection steps use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. *marked: only when the ignition checker is us...

  • Page 273: Elec

    6 - 4 – + elec ignition system spark gap test 1. Disconnect the ignition coil from spark plug. 2. Remove the ignition coil cap. 3. Connect the dynamic spark tester 1 (ignition checker 2 ) as shown. ● ignition coil 3 ● spark plug 4 Å for usa and cdn ı except for usa and cdn 4. Kick the kick starter. ...

  • Page 274: Elec

    6 - 5 – + elec ignition system ec626002 ignition coil inspection 1. Remove the ignition coil cap. 2. Inspect: ● primary coil resistance out of specification → replace. Tester (+) lead → orange lead 1 tester (–) lead → black lead 2 primary coil resistance tester selector position 0.08 ~ 0.10 Ω at 20 ...

  • Page 275: Elec

    6 - 6 – + elec ignition system 2. Inspect: ● source coil 1 resistance out of specification → replace. 3. Inspect: ● source coil 2 resistance out of specification → replace. Tester (+) lead → brown lead 1 tester (–) lead → green lead 2 source coil 1 resistance tester selector position 720 ~ 1,080 Ω a...

  • Page 276: Elec

    – + elec 6 - 7 tps (throttle position sensor) system ec690000 tps (throttle position sensor) system inspection steps if the tps will not operate, use the following inspection steps. *marked: refer to “ignition system” section. Note: use the following special tools in this inspection. Pocket tester: ...

  • Page 277: Elec

    6 - 8 – + elec tps (throttle position sensor) system handling note caution: do not loosen the screws {tps (throttle position sensor)} 1 except when changing the tps (throttle position sensor) due to failure because it will cause a drop in engine performance. 1 ec624000 couplers and leads connection ...

  • Page 278: Elec

    6 - 9 – + elec tps (throttle position sensor) system 3. Inspect: ● tps coil variable resistance check that the resistance in increased as the throttle grip is moved from the full close position to the full open posi- tion. Out of specification → replace. Tester (+) lead → yellow lead 1 tester (–) le...

  • Page 279: Elec

    6 - 10 – + elec tps (throttle position sensor) system 4. Adjust: ● idle speed 5. Insert the thin electric conductors 2 (lead) into the tps coupler 1, as shown, and connect the tester to them. Caution: ● do not insert the electric conductors more than required because it may reduce the waterproof fun...

  • Page 280: Elec

    6 - 11 – + elec tps (throttle position sensor) system 8. Tighten: ● screw (tps) 1 9. Stop the engine. 1 ec694000 tps input voltage inspection 1. Disconnect the tps coupler. 2. Start the engine. 3. Inspect: ● tps input voltage out of specification → replace the cdi unit. Tester (+) lead → blue lead 1...

  • Page 281: T U N

    7 - 1 t u n ec700000 tuning ec710000 engine carburetor setting ● the air/fuel mixture will vary depending on atmospheric conditions. Therefore, it is nec- essary to take into consideration the air pres- sure, ambient temperature, humidity, etc., when adjusting the carburetor. ● perform a test run to...

  • Page 282: T U N

    7 - 2 t u n caution: ● the carburetor is extremely sensitive to foreign matter (dirt, sand, water, etc.). During installation, do not allow foreign matter to get into the carburetor. ● always handle the carburetor and its components carefully. Even slight scratches, bends or damage to carbure- tor p...

  • Page 283: T U N

    7 - 3 t u n setting effects of the setting parts on the throttle valve opening 1 pilot screw/pilot jet 2 throttle valve cutaway 3 jet needle 4 main jet Å closed ı fully open 1/2 3/4 1/4 1/8 1 2 3 4 Å ı main system the flatcr carburetor has a primary main jet. This type of main jet is perfect for rac...

  • Page 284: T U N

    7 - 4 t u n setting pilot system the flatcr carburetor is manufactured with a pilot screw. The pilot screw adjustment ranges from fully closed throttle to 1/4 open throttle. Main jet adjustment the richness of the air-fuel mixture at full throt- tle can be set by changing the main jet 1 . If the air...

  • Page 285: T U N

    7 - 5 t u n setting pilot screw adjustment the richness of the air-fuel mixture with the throttle fully closed to 1/4 open can be set by turning the pilot screw 1 . Turning in the pilot screw will make the mixture lean at low speeds, and turning it out will enrich it. Note: ● if the idling speed flu...

  • Page 286: T U N

    7 - 6 t u n setting pilot jet adjustment the richness of the air-fuel mixture with the throttle open 1/4 or less can be set by adjust- ing the pilot jet 1 . Effects of adjusting the pilot jet (reference) Å idle ı fully open jet needle groove position adjustment adjusting the jet needle 1 position af...

  • Page 287: T U N

    7 - 7 t u n jet needle adjustment the jet needle is adjusted by changing it. The tapered sections of all jet needles have the same starting positions, but the needles are available with different straight-portion diameters. Standard jet needle ncvq ncvq - 4 clip position diameter a of straight porti...

  • Page 288: T U N

    7 - 8 t u n setting carburetor setting parts part name size part number main jet rich (std) lean #178 #175 #172 #170 #168 #165 #162 #160 #158 #155 #152 4mx-14943-93 4mx-14943-42 4mx-14943-92 4mx-14943-41 4mx-14943-91 4mx-14943-40 4mx-14943-90 4mx-14943-39 4mx-14943-89 4mx-14943-38 4mx-14943-88 pilot...

  • Page 289: T U N

    7 - 9 t u n examples of carburetor setting depending on symptom this should be taken simply for an example. It is necessary to set the carburetor while checking the operating conditions of the engine. Symptom setting checking at full throttle hard breathing shearing noise whitish spark plug lean mix...

  • Page 290: T U N

    7 - 10 t u n ec720000 chassis ec71p002 selection of the secondary reduction ratio (sprocket) secondary reduction = ratio * for europe reduction ratio> ● it is generally said that the secondary gear ratio should be reduced for a longer straight portion of a speed course and should be increased for a ...

  • Page 291: T U N

    7 - 11 t u n setting ec72n000 drive and driven sprockets setting parts * for europe part name size part number drive sprocket 1 (std) 14t 9383e-14215 drive sprocket 2 *(std) (std) 46t 47t 48t 49t 50t 51t 52t 5ta-25446-00 5et-25447-00 5ny-25448-00 5ny-25449-00 5ny-25450-00 5ny-25451-00 5ny-25452-00 e...

  • Page 292: T U N

    7 - 12 t u n setting ec722011 front fork setting the front fork setting should be made depend- ing on the rider’s feeling of an actual run and the circuit conditions. The front fork setting includes the following three factors: 1. Setting of air spring characteristics ● change the fork oil level. 2....

  • Page 293: T U N

    7 - 13 t u n setting ec727020 spring preload adjustment the spring preload is adjusted by installing the adjustment washer 1 between the fork spring 2 and damper rod 3. Caution: do not install three or more adjustment washers for each front fork. Warning always adjust each front fork to the same set...

  • Page 294: T U N

    7 - 14 t u n 2. Use of stiff spring generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, resulting in lack of a sense of contact with the road surface or in a vibrating handlebar. To set a stiff spring: ● change the rebound damping. Turn in one or two clicks...

  • Page 295: T U N

    7 - 15 t u n ec72p000 front fork setting parts ● adjustment washer 1 ● front fork spring 2 [equal pitch spring] [unequal pitch spring] note: ● the unequal pitch spring is softer in initial characteristic than the equal pitch spring and is difficult to bottom out under full compres- sion. ● the i.D. ...

  • Page 296: T U N

    7 - 16 t u n ec72b000 rear suspension setting the rear suspension setting should be made depending on the rider’s feeling of an actual run and the circuit conditions. The rear suspension setting includes the fol- lowing two factors: 1. Setting of spring preload ● change the set length of the spring....

  • Page 297: T U N

    7 - 17 t u n setting note: ● if the machine is new and after it is broken in, the same set length of the spring may change because of the initial fatigue, etc. Of the spring. Therefore, be sure to make re- evaluation. ● if the standard figure cannot be achieved by adjusting the spring adjuster and c...

  • Page 298: T U N

    7 - 18 t u n caution: when using a rear cushion other than cur- rently installed, use the one whose overall length a does not exceed the standard as it may result in faulty performance. Never use one whose overall length is greater than standard. Å coverage of spring by weight ı rider weight 1 soft ...

  • Page 299: T U N

    7 - 19 t u n setting ec72q000 rear shock absorber setting parts ● rear shock spring 1 [equal pitch spring] [unequal pitch spring] *for europe note: ● the unequal pitch spring is softer in initial characteristic than the equal pitch spring and is difficult to bottom out under full compres- sion. ● th...

  • Page 300: T U N

    7 - 20 t u n setting ec72h002 suspension setting ● front fork note: ● if any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. ● before any change, set the rear shock absorber sunken lengt...

  • Page 301: T U N

    7 - 21 t u n setting ● rear shock absorber note: ● if any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. ● adjust the rebound damping in 2-click increments or decrements. ● adjust the l...

  • Page 302

    Printed in japan 2002.06-2.9 ×1 cr (e) printed on recycled paper yamaha motor co., ltd. 2500 shingai iwata shizuoka japan.