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  5. Owner's Service Manual

Yamaha 2010 WR450F Owner's Service Manual

Summary of 2010 WR450F

  • Page 1

    5tj-28199-46 wr450f(y) printed in japan 2008.06-1.7 × 1 cr (e,f,g,s) owner’s service manual manuel d’atelier du proprietaire fahrer- und wartungshandbuch manual de servicio del propietario il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Read this manual careful...

  • Page 2

    Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit étre remis avec le véhicule en cas de vente de ce dernier. Bitte lesen sie diese be...

  • Page 3: Wr450F(Y)

    Wr450f(y) wr450f(y) 2009 2009 5tj-28199-46-e0 5tj-28199-46-e0 owner’s service manual owner’s service manual read this manual carefully before operating this vehicle. Read this manual carefully before operating this vehicle..

  • Page 5

    Wr450f(y) owner's service manual ©2008 by yamaha motor co., ltd. 1st edition, june 2008 all rights reserved. Any reprinting or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited. Printed in japan.

  • Page 6

    Foreword introduction congratulations on your purchase of a yamaha wr series. This model is the culmination of yamaha's vast ex- perience in the production of paceset- ting racing machines. It represents the highest grade of craftsmanship and reliability that have made yama- ha a leader. This manual...

  • Page 7

    • properly secure the ma- chine before transporting it. When transporting the machine in another vehicle, always be sure it is properly secured and in an upright position and that the fuel cock is in the "off" position. Otherwise, fuel may leak out of the carburetor or fuel tank. F.I.M. Machine weig...

  • Page 8

    How to read descriptions to help identify parts and clarify pro- cedure steps, there are exploded dia- grams at the start of each removal and disassembly section. 1. An easy-to-see exploded diagram "1" is provided for removal and disassembly jobs. 2. Numbers "2" are given in the or- der of the jobs ...

  • Page 9

    Table of contents general information 1 specifications 2 regular inspection and adjustments 3 tuning 4 engine 5 chassis 6 electrical 7.

  • Page 10

    Contents chapter 1 general infor- mation description ................. 1-1 machine identification ............. 1-2 included parts .......... 1-2 important information................. 1-2 checking of connection.................. 1-3 special tools ............. 1-4 control functions .. 1-8 multi-fun...

  • Page 11

    1-1 description general information description • the machine you have purchased may differ slightly from those shown in the following. • designs and specifications are subject to change without notice. 1. Clutch lever 2. Hot starter lever 3. Engine stop switch 4. Multi-function display 5. Main swit...

  • Page 12

    1-2 machine identification 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 positive identification of the model you own. 2. If your machine is stolen, the au- thorities w...

  • Page 13

    1-3 checking of connection 4. During the machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled. 5. Keep away from fire. All replacement parts 1. We recommend to use yamaha ge...

  • Page 14

    1-4 special tools 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 special tool differ by c...

  • Page 15

    1-5 special tools damper rod holder ym-01494, 90890-01494 use this tool to remove and install the damper rod. Fork seal driver ym-a0948, 90890-01502 this tool is used when install the fork oil seal. Spoke nipple wrench ym-01521, 90980-01521 this tool is used to tighten the spoke. Sheave holder ys-18...

  • Page 16

    1-6 special tools valve spring compressor ym-4019, 90890-04019 this tool is needed to remove and install the valve assemblies. Clutch holding tool ym-91042, 90890-04086 this tool is used to hold the clutch when removing or installing the clutch boss securing nut. Valve guide remover intake 4.5 mm (0...

  • Page 17

    1-7 special tools dynamic spark tester ym-34487 ignition checker 90890-06754 this instrument is necessary for checking the ignition system compo- nents. Vacuum/pressure pump gauge set yb-35956-a, 90890-06756 this tool is used to check the air in- duction system. Digital tachometer yu-39951-b, 90890-...

  • Page 18

    1-8 control functions control functions main switch functions of the respective switch po- sitions are as follows: on: the engine can be started only at this position. Off: all electrical circuits are switched off. Main switch indicator light the main switch "1" is equipped with an indicator light "...

  • Page 19

    1-9 multi-function display cold starter knob when cold, the engine requires a richer air-fuel mixture for starting. A separate starter circuit, which is con- trolled by the cold starter knob "1", supplies this mixture. Pull the cold starter knob out to open the circuit for starting. When the engine ...

  • Page 20

    1-10 multi-function display changing odometer and tripmeter a/b (trip a/b) 1. Push the "slct2" button to change the tripmeter display. The display will change in the follow- ing order: odometer → trip a → trip b → trip a → odometer. To reset the digits, select the tripme- ter involved and push the "...

  • Page 21

    1-11 multi-function display auto start 1. Check that changeover has been made to race mode. (refer to "changeover from basic mode to race mode".) 2. Make the machine ready for a run by pushing the "slct1" button for 2 seconds or more. When the measurement is made ready for a run by auto start, and w...

  • Page 22

    1-12 multi-function display function diagram a short push on the button changes the operation in the arrowed direction. A short push on the button changes the operation in both arrowed directions. A long push on the button changes the operation in the arrowed direction. A long push on the button cha...

  • Page 23

    1-13 multi-function display the following diagram illustrates the multi-function display regarding the direction and operation condition in- volved in each of its functions. A. A short push on the button changes the operation in the ar- rowed direction. B. A short push on the button changes the oper...

  • Page 24

    1-14 starting and break-in starting and break-in fuel always use the recommended fuel as stated below. Also, be sure to use new gasoline. Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine inter- nal parts such as valves, piston rings, and exhaust system, e...

  • Page 25

    1-15 starting and break-in the engine fails to start pull the hot starter lever all the way out and while holding the lever, kick the kickstarter crank 10 to 20 times to clear the engine. Then, restart the en- gine. Refer to "restarting an engine after a fall". Observe the following break-in procedu...

  • Page 26

    1-16 torque-check points torque-check points concerning the tightening torque, refer to "tightening torques" section in the chapter 2. Frame construction frame to rear frame combined seat and fuel tank fuel tank to frame exhaust system silencer to rear frame engine mounting frame to engine engine br...

  • Page 27

    1-17 cleaning and storage cleaning and storage cleaning frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and ex- tend the life of many components. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from enter- ing. A...

  • Page 28

    2-1 general specifications specifications general specifications model name: wr450fy (usa, cdn, aus, nz) wr450f (europe, za) model code number: 5tjn (usa) 5tjp (cdn) 5tjr (europe) 5tjs (aus, nz, za) dimensions: usa, cdn, za europe aus, nz overall length 2,175 mm (85.63 in) 2,200 mm (86.61 in) 2,190 ...

  • Page 29

    2-2 general specifications (except for usa and cdn) sae10w-30, sae10w-40, sae15w-40, sae20w-40 or sae20w-50 api service sg type or higher, jaso standard ma oil capacity: engine oil periodic oil change 0.95 l (0.84 imp qt, 1.00 us qt) with oil filter replacement 1.0 l (0.88 imp qt, 1.06 us qt) total ...

  • Page 30

    2-3 maintenance specifications maintenance specifications engine tire: type with tube size (front) 80/100-21 51m (usa, cdn, za) 90/90-21 54r (europe, aus, nz) size (rear) 110/100-18 64m (usa, cdn, za) 130/90-18 69r (europe, aus, nz) tire pressure (front and rear) 100 kpa (1.0 kgf/cm 2 , 15 psi) brak...

  • Page 31

    2-4 maintenance specifications camshaft: drive method chain drive (left) ---- camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in) ---- camshaft outside diameter 21.959–21.972 mm (0.8645–0.8650 in) ---- shaft-to-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) 0.08 mm (0.003 in) cam dimen...

  • Page 32

    2-5 maintenance specifications "b" face width (in) 2.26 mm (0.089 in) ---- "b" face width (ex) 2.26 mm (0.089 in) ---- "c" seat width (in) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 in) "c" seat width (ex) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 in) "d" margin thickness (in) 1 mm (0.0394 in) ...

  • Page 33

    2-6 maintenance specifications set length (valve closed) (in) 27.87 mm (1.10 in) ---- set length (valve closed) (ex) 28.38 mm (1.12 in) ---- compressed force (installed) (in) 130.2–149.8 n at 27.87 mm (13.28–15.28 kg at 27.87 mm, 29.27–33.68 lb at 1.10 in) ---- compressed force (installed) (ex) 123....

  • Page 34

    2-7 maintenance specifications type taper ---- dimensions (b × t) 1.00 × 3.35 mm (0.04 × 0.13 in) ---- end gap (installed) 0.35–0.50 mm (0.014–0.020 in) 0.85 mm (0.033 in) side clearance 0.020–0.055 mm (0.0008–0.0022 in) 0.12 mm (0.005 in) oil ring: dimensions (b × t) 2.0 × 2.9 mm (0.08 × 0.11 in) -...

  • Page 35

    2-8 maintenance specifications shifter: shifter type cam drum and guide bar ---- guide bar bending limit ---- 0.05 mm (0.002 in) kickstarter: type ratchet type ---- carburetor: usa, cdn, aus, nz, za europe i. D. Mark 5tje e0 5tjl l0 ---- main jet (m.J) #162 #160 ---- main air jet (m.A.J) ø2.0 ← ----...

  • Page 36

    2-9 maintenance specifications chassis item standard limit steering system: steering bearing type taper roller bearing ---- front suspension: usa, cdn europe, aus, nz, za 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 = 4.5 n/...

  • Page 37

    2-10 maintenance specifications electrical drive chain: type/manufacturer did520vm/daido ---- number of links 113 links + joint ---- chain slack 48–58 mm (1.9–2.3 in) ---- chain length (15 links) ---- 239.3 mm (9.42 in) front disc brake: disc outside dia. × thickness 250 × 3.0 mm (9.84 × 0.12 in) 25...

  • Page 38

    2-11 maintenance specifications charging system: system type ac magneto ---- model (stator)/manufacturer 5tj 50/yamaha ---- normal output 14 v/120 w at 5,000 r/min ---- charging coil resistance (color) 0.288–0.432 Ω at 20 °c (68 °f) (white–ground) ---- lighting coil resistance (color) 0.224–0.336 Ω ...

  • Page 39

    2-12 tightening torques tightening torques engine △ - marked portion shall be checked for torque tightening after break-in or before each race. *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 nm (...

  • Page 40

    2-13 tightening torques radiator pipe 1, 2 m10 × 1.0 2 10 1.0 7.2 impeller m8 × 1.25 1 14 1.4 10 water pump housing cover m6 × 1.0 3 10 1.0 7.2 coolant drain bolt m6 × 1.0 1 10 1.0 7.2 oil pump cover m4 × 0.7 1 2 0.2 1.4 oil pump m6 × 1.0 2 10 1.0 7.2 oil pump drive gear shaft m6 × 1.0 1 10 1.0 7.2 ...

  • Page 41

    2-14 tightening torques chassis △ - 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 △ upper bracket and outer tube m8 × 1.25 4 21 2.1 15 △ lower bracket and outer tube m8 × 1.25 4 21 2.1 1...

  • Page 42

    2-15 tightening torques △ driven sprocket and wheel hub m8 × 1.25 6 50 5.0 36 △ nipple (spoke) — 72 3 0.3 2.2 △ disc cover and rear brake caliper m6 × 1.0 2 10 1.0 7.2 △ protector and rear brake caliper m6 × 1.0 2 7 0.7 5.1 chain puller adjust bolt and locknut m8 × 1.25 2 19 1.9 13 engine mounting: ...

  • Page 43

    2-16 tightening torques 1. First, tighten the steering ring nut approximately 38 nm (3.8 m•kg, 27 ft•lb) by using the steering nut wrench, then loosen the steering ring nut one turn. 2. Retighten the steering ring nut 7 nm (0.7 m•kg, 5.1 ft•lb). Electrical tighten the rotor nut to 65 nm (6.5 m•kg, 4...

  • Page 44

    2-17 tightening torques general torque specifications this chart specifies torque for stan- dard fasteners with standard i.S.O. Pitch threads. Torque specifications for special components or assem- blies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener a...

  • Page 46

    2-18 lubrication diagrams lubrication diagrams 1. Oil filter element 2. Oil pump 3. Drive axle 4. Main axle 5. Crankshaft 6. Connecting rod a. From cylinder b. To oil tank.

  • Page 47

    2-19 lubrication diagrams 1. Intake camshaft 2. Exhaust camshaft a. To main axle b. From oil pump.

  • Page 48

    2-20 cable routing diagram cable routing diagram 1. Fuel tank breather hose 2. Clamp 3. Diode 4. Hot starter cable 5. Throttle position sensor lead 6. Wire harness 7. Hump (frame) 8. Negative battery lead 9. Starter motor lead 10. Neutral switch lead 11. Ac magneto lead 12. Brake hose 13. Rectifier/...

  • Page 49

    2-21 cable routing diagram a. Insert the end of the fuel tank breather hose into the hole in the steering stem. B. Fasten the throttle cable, hot starter cable and rectifier/regula- tor lead onto the frame. Locate the clamp ends under the throt- tle cable, and after clamping, leave the other end as ...

  • Page 50

    2-22 cable routing diagram 1. Throttle cable (pull) 2. Throttle cable (return) 3. Catch tank hose 4. Ignition coil 5. Clamp 6. Air induction hose (air cut-off valve - rear of cylinder head) 7. Catch tank breather hose a. Cross the pull and push throttle cables. B. Fasten the catch tank hose and air ...

  • Page 51

    2-23 cable routing diagram 1. Brake master cylinder 2. Brake hose holder 3. Brake hose a. Install the brake hose so that its pipe portion directs as shown and lightly touches the projec- tion on the brake caliper. B. Pass the brake hose into the brake hose holders. C. If the brake hose contacts the ...

  • Page 52

    2-24 cable routing diagram 1. Clamp 2. Positive battery lead 3. Battery 4. Negative battery lead 5. Taillight coupler 6. Cdi unit coupler (6-pin) 7. Cdi unit coupler (3-pin) 8. Cdi unit coupler (6-pin) a. Fasten the wire harness to the upper engine bracket (left side). Locate the clamp end facing to...

  • Page 53

    2-25 cable routing diagram e. Connect the wire harness to the starter relay. F. Fasten the catch tank breather hose and catch tank hose to the rear frame. Clamp them close to where they are joined to the frame. Fasten the pipe tightly enough not to crush it. Locate the clamp end facing toward the re...

  • Page 54

    2-26 cable routing diagram 1. Throttle cable 2. Clamp 3. Brake hose 4. Clutch cable 5. Hose guide 6. Main switch coupler 7. Wire harness 8. Headlight coupler 9. Hot starter cable 10. Multi-function display bracket 11. Main switch 12. Upper bracket 13. Clutch switch coupler 14. Engine stop switch cou...

  • Page 55

    2-27 cable routing diagram d. Secure the coupler by inserting it into the multi-function display bracket. E. Pass the throttle cables, clutch cable and hot starter cable be- tween the upper bracket and multi-function display bracket. F. Fasten the multi-function display leads to the bracket. Cut off...

  • Page 56

    3-1 periodic maintenance chart for the emission control system (for canada) regular inspection and adjustments periodic maintenance chart for the emission control system (for canada) • from 4,200 mi (7,000 km) or 9 months, repeat the maintenance intervals starting from 1,800 mi (3,000 km) or 3 month...

  • Page 57

    3-2 general maintenance and lubrication chart (for canada) general maintenance and lubrication chart (for canada) no. Item checks and maintenance jobs initial odometer readings 600 mi (1,000 km) or 1 month 1,800 mi (3,000 km) or 3 months 3,000 mi (5,000 km) or 6 months 1 clutch check operation. √ √ ...

  • Page 58

    3-3 maintenance intervals for competition use • the air filter needs more frequent service if you are riding in unusually wet or dusty areas. • hydraulic brake service • after disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and f...

  • Page 59

    3-4 maintenance intervals for competition use replace ● camshafts inspect the camshaft surface. Inspect ● inspect the decompression system. Replace ● camshaft sprockets inspect ● check for wear on the teeth and for damage. Replace ● piston inspect ● ● inspect crack. Clean ● inspect carbon deposits a...

  • Page 60

    3-5 maintenance intervals for competition use carburetor inspect, adjust and clean ● ● spark plug inspect and clean ● ● replace ● drive chain use chain lube. Lubricate, slack, alignment ● ● chain slack: 48–58 mm (1.9–2.3 in) replace ● cooling system check coolant level and leakage ● ● check radiator...

  • Page 61

    3-6 maintenance intervals for competition use front fork oil seal and dust seal clean and lube ● ● lithium base grease protector guide replace ● rear shock absorber inspect and adjust ● ● lube ● (after rain ride) ● molybdenum disulfide grease retighten ● ● drive chain guide and rollers inspect ● ● s...

  • Page 62

    3-7 pre-operation inspection and maintenance pre-operation inspection and maintenance before riding for break-in operation or practice, make sure the machine is in good operating condition. Before using this machine, check the following points. General inspection and maintenance item routine page co...

  • Page 63

    3-8 engine engine removing the seat, fuel tank and side covers order part name q'ty remarks turn the fuel cock to "off". Disconnect the fuel hose. 1 seat 1 2 air scoop (left and right) 2 3 bolt (fuel tank) 2 4 fuel tank 1 5 left side cover 1 open the air filter case cover. 6 right side cover 1 refer...

  • Page 64

    3-9 engine removing the side cover 1. Remove: • bolt (side cover) • right side cover "1" draw the side cover backward to re- move it because its claw "a" is insert- ed in the air filter case..

  • Page 65

    3-10 engine removing the exhaust pipe and silencer order part name q'ty remarks right side cover refer to "removing the seat, fuel tank and side covers" section. 1 bolt (silencer clamp) 1 only loosening. 2 bolt [silencer (front)] 1 3 bolt [silencer (rear)] 1 4 collar 1 5 silencer 1 6 silencer clamp ...

  • Page 66

    3-11 engine checking the silencer and exhaust pipe 1. Inspect: • gasket "1" damage → replace. Installing the silencer and exhaust pipe 1. Install: • gasket • exhaust pipe "1" • nut (exhaust pipe) "2" • bolt (exhaust pipe) "3" first, temporarily tighten the nut (ex- haust pipe), then tighten the bolt...

  • Page 67

    3-12 engine handling notes of coolant: the coolant is harmful so it should be handled with special care. • when coolant splashes to your eye. Thoroughly wash your eye with water and see your doctor. • when coolant splashes to your clothes. Quickly wash it away with water and then with soap. • when c...

  • Page 68

    3-13 engine 2. Adjust: • throttle grip free play throttle grip free play adjustment steps: a. Slide the adjuster cover. B. Loosen the locknut "1". C. Turn the adjuster "2" until the specified free play is obtained. D. Tighten the locknut. Before adjusting the throttle cable free play, the engine idl...

  • Page 69

    3-14 engine 5. Inspect: • air filter element damage → replace. 6. Apply: • foam-air-filter oil or equivalent oil to the element • squeeze out the excess oil. Ele- ment should be wet but not drip- ping. • wipe off the oil left on the element surface using a clean dry cloth. (ex- cess oil in the eleme...

  • Page 70

    3-15 engine 5. Start the engine and let it warm up for several minutes. When the oil tank is empty, never start the engine. 6. Idle the engine more than 10 sec- onds while keeping the machine upright. Then stop the engine and add the oil to the maximum level. 7. Install: • oil tank cap changing the ...

  • Page 71

    3-16 engine adjusting the pilot screw (for europe) 1. Adjust: • pilot screw "1" adjustment steps: to optimize the fuel flow at a smaller throttle opening, each machine's pilot screw has been individually set at the factory. Before adjusting the pilot screw, turn it in fully and count the number of t...

  • Page 72

    3-17 engine 5. Adjust: • valve clearance adjustment steps: a. Remove the camshaft (intake and exhaust). Refer to "camshafts" section in the chapter 5. B. Remove the valve lifters "1" and the pads "2". • place a rag in the timing chain space to prevent pads from falling into the crankcase. • identity...

  • Page 73

    3-18 engine intake exhaust.

  • Page 74

    3-19 chassis cleaning the spark arrester (for usa) • be sure the exhaust pipe and si- lencer are cool before cleaning the spark arrester. • do not start the engine when cleaning the exhaust system. 1. Remove: • screw (silencer cap) "1" 2. Remove: • bolt (spark arrester) "1" 3. Remove: • tail pipe "1...

  • Page 75

    3-20 chassis 2. Remove: • brake lever cover 3. Adjust: • brake lever position brake lever position adjustment steps: a. Loosen the locknut "1". B. Turn the adjusting bolt "2" until the lever position "a" is within speci- fied position. C. Tighten the locknut. Be sure to tighten the locknut, as it wi...

  • Page 76

    3-21 chassis i. Install the brake caliper "8" and tighten the pad pin "9". J. Install the pad pin plug "10". 3. Inspect: • brake fluid level refer to "checking the brake fluid level" section. 4. Check: • brake lever operation a softy or spongy feeling → bleed brake system. Refer to "bleeding the hy-...

  • Page 77

    3-22 chassis 3. Inspect: • brake fluid level refer to "checking the brake fluid level" section. 4. Check: • brake pedal operation a softy or spongy feeling → bleed brake system. Refer to "bleeding the hy- draulic brake system" sec- tion. Checking the rear brake pad insulator 1. Remove: • brake pad r...

  • Page 78

    3-23 chassis 6. Install: • chain joint "1" • o-ring "2" • drive chain "3" • link plate "4" when installing the drive chain, apply the lithium soap base grease on the chain joint and o-rings. 7. Install: • link plate • press the link plate onto the chain joint using a drive chain riveter "5". • rivet...

  • Page 79

    3-24 chassis relieving the front fork internal pressure if the front fork initial movement feels stiff during a run, relieve the front fork internal pressure. 1. Elevate the front wheel by placing a suitable stand under the engine. 2. Remove the air bleed screw "1" and release the internal pressure ...

  • Page 80

    3-25 chassis 4. Adjust: • spring preload adjustment steps: a. Loosen the locknut "1". B. Loosen the adjuster "2" until there is some clearance between the spring and adjuster. C. Measure the spring free length "a". D. Turn the adjuster "2". • be sure to remove all dirt and mud from around the locknu...

  • Page 81

    3-26 chassis adjusting the rear shock absorber high compression damping force 1. Adjust: • high compression damping force by turning the adjuster "1". • standard position: this is the position which is back by the specific number of turns from the fully turned-in position. (which align the punch mar...

  • Page 82

    3-27 chassis 4. Adjust: • steering ring nut steering ring nut adjustment steps: a. Remove the headlight. B. Remove the handlebar and upper bracket. C. Loosen the steering ring nut "1" using the steering nut wrench "2". D. Tighten the steering ring nut "3" using steering nut wrench "4". • apply the l...

  • Page 83

    3-28 chassis lubrication to ensure smooth operation of all components, lubricate your machine during setup, after break-in, and after every ride. 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 cable wind...

  • Page 84

    3-29 electrical electrical checking the spark plug 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. When the engine runs for many hours at low spe...

  • Page 85

    3-30 electrical 3. Remove: • battery band • battery 4. Measure: • battery charge measurement steps: a. Connect a pocket tester "1" to the battery terminals. • the charge state of an mf battery can be checked by measuring its open-circuit voltage (i.E., the volt- age when the positive terminal is dis...

  • Page 86

    3-31 electrical charging method using a variable voltage charger.

  • Page 87

    3-32 electrical charging method using a constant voltage charger.

  • Page 88

    3-33 electrical 6. Install: • battery • battery band 7. Connect: • battery leads (to the battery terminals) first, connect the positive lead "1", then the negative lead "2". 8. Check: • battery terminals dirt → clean with a wire brush. Loose connection → connect properly. 9. Lubricate: • battery ter...

  • Page 89

    3-34 electrical adjusting the headlight beams 1. Adjust: • headlight beam (vertically) adjusting steps: a. Turn the adjusting screw "1" in di- rection "a" or "b". Direction "a" headlight beam is raised. Direction "b" headlight beam is lowered..

  • Page 90

    4-1 engine (except for canada) tuning engine (except for canada) carburetor setting • the air/fuel mixture will vary de- pending on atmospheric conditions. Therefore, it is necessary to take into consideration the air pressure, ambient temperature, humidity, etc., when adjusting the carburetor. • pe...

  • Page 91

    4-2 engine (except for canada) adjusting the pilot jet the richness of the air-fuel mixture with the throttle open 1/4 or less can be set by adjusting the pilot jet "1". Effects of adjusting the pilot jet (reference) a. Idle b. Fully open 1. #48 2. #42 3. #45 adjusting the jet needle groove position...

  • Page 92

    4-3 engine (except for canada) carburetor setting parts main jet size part number (-14943-) rich #185 4mx-44 #182 4mx-94 #180 4mx-43 #178 4mx-93 #175 4mx-42 #172 4mx-92 #170 4mx-41 #168 4mx-91 #165 4mx-40 (std) #162 4mx-90 *(std) lean #160 4mx-39 pilot jet size part number (-14948-) rich #55 4mx-09 ...

  • Page 93

    4-4 engine (except for canada) 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 ...

  • Page 94

    4-5 chassis chassis selection of the secondary reduction ratio (sprocket) ondary gear reduction ratio> • it is generally said that the second- ary gear ratio should be reduced for a longer straight portion of a speed course and should be increased for a course with many corners. Actual- ly, however,...

  • Page 95

    4-6 chassis a. Air spring characteristics in relation to oil level change b. Load c. Stroke 1. Max. Oil level 2. Standard oil level 3. Min. Oil level adjusting the spring preload the spring preload is adjusted by in- stalling the adjustment washer "1" be- tween the fork spring "2" and damper rod "3"...

  • Page 96

    4-7 chassis choosing set length 1. Place a stand or block under the engine to put the rear wheel above the floor, and measure the length "a" between the rear wheel axle center and the rear fender holding bolt. 2. Remove the stand or block from the engine and with a rider astride the seat, measure th...

  • Page 97

    4-8 chassis suspension setting (front fork) • 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 length to the standard figure...

  • Page 98

    4-9 chassis suspension setting (rear shock absorber) • 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 t...

  • Page 99

    5-1 radiator engine this section is intended for those who have basic knowledge and skill concerning the servicing of yamaha motorcycles (e.G., yamaha dealers, service engineers, etc.) those who have little knowledge and skill concerning servicing are request- ed not to undertake inspection, adjustm...

  • Page 100

    5-2 radiator 6 radiator hose 4 1 7 pipe 2/o-ring 1/1 8 catch tank hose 1 9 left radiator 1 10 radiator hose 1 1 11 pipe 1/o-ring 1/1 12 catch tank breather hose 1 13 catch tank 1 order part name q'ty remarks.

  • Page 101

    5-3 radiator handling note 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 radiator cap by the following procedure: place a thick rag, like a towe...

  • Page 102

    5-4 carburetor carburetor removing the carburetor order part name q'ty remarks seat and fuel tank refer to "removing the seat, fuel tank and side covers" section in the chapter 3. Rear shock absorber refer to "rear shock absorber" sec- tion in the chapter 6. 1 clamp 2 2 throttle position sensor lead...

  • Page 103

    5-5 carburetor 13 bracket (cylinder head breather pipe) 1 14 carburetor joint 1 order part name q'ty remarks.

  • Page 104

    5-6 carburetor disassembling the carburetor order part name q'ty remarks 1 carburetor 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 accelerator pump cover 1 8 spring 1 9 diaphragm (accelerator pump) 1 10 air cut valve c...

  • Page 105

    5-7 carburetor 19 main jet 1 20 needle jet 1 21 spacer 1 22 pilot jet 1 23 starter jet 1 24 push rod 1 pull the push rod. 25 throttle shaft assembly 1 26 push rod link lever assembly 1 27 pilot air jet 1 28 cold starter plunger 1 order part name q'ty remarks.

  • Page 106

    5-8 carburetor handling note do not loosen the screw (throttle position sensor) "1" except when changing the throttle position sen- sor due to failure because it will cause a drop in engine perfor- mance. Removing the pilot screw (for europe) 1. Remove: • pilot screw "1" to optimize the fuel flow at...

  • Page 107

    5-9 carburetor e. If both are fine, adjust the float height by bending the float tab "b" on the float. F. Recheck the float height. Checking the float 1. Inspect: • float "1" damage → replace. Checking the starter plunger 1. Inspect: • cold starter plunger "1" • hot starter plunger "2" wear/damage →...

  • Page 108

    5-10 carburetor • apply the fluorochemical grease on the bearings. • fit the projection "a" on the throttle shaft assembly into the slot "b" in the throttle position sensor. • make sure the stopper "c" of the spring fits into the recess in the car- buretor. • turn the throttle shaft assembly left wh...

  • Page 109

    5-11 carburetor 16. Install: • jet needle "1" • collar "2" • spring "3" • needle holder "4" • throttle valve plate "5" to throttle valve "6". 17. Install: • throttle valve assembly "1" • screw (throttle shaft) "2" install the valve lever rollers "3" into the slits "a" of the throttle valve. 18. Inst...

  • Page 110

    5-12 carburetor 5. Install: • throttle cable (pull) "1" • throttle cable (return) "2" 6. Adjust: • throttle grip free play refer to "adjusting the throttle cable free play" section in the chapter 3. 7. Install: • throttle cable cover "1" • bolt (throttle cable cover) "2" 8. Install: • throttle posit...

  • Page 111

    5-13 air indictoin system air indictoin system removing the air induction system order part name q'ty remarks 1 bracket 1 2 air cut-off valve assembly 1 3 air induction hose (air cut-off valve - front of cyl- inder head) 1 4 air induction pipe 1 5 gasket 1 6 air induction hose (air cut-off valve - r...

  • Page 112

    5-14 air indictoin system checking the air induction system 1. Inspect: • air induction hose crack/damage → replace. • air induction pipe crack/damage → replace. 2. Check: • operation of air cut valve pass air through the pipe and check the air cut valve for opera- tion. Does not meet the following ...

  • Page 113

    5-15 camshafts camshafts removing the cylinder head cover order part name q'ty remarks seat and fuel tank refer to "removing the seat, fuel tank and side covers" section in the chapter 3. Air cut-off valve assembly refer to "air induction system" section. Engine upper bracket (right) refer to "engin...

  • Page 114

    5-16 camshafts removing the camshafts order part name q'ty remarks 1 timing mark accessing screw 1 refer to removal section. 2 crankshaft end accessing screw 1 refer to removal section. 3 timing chain tensioner cap bolt 1 refer to removal section. 4 timing chain tensioner 1 refer to removal section....

  • Page 115

    5-17 camshafts removing the camshaft 1. Remove: • timing mark accessing screw "1" • crankshaft end accessing screw "2" 2. Align: • t.D.C. Mark with align mark. Checking steps: a. Turn the crankshaft counterclock- wise with a wrench. B. Align the t.D.C. Mark "a" on the rotor with the align mark "b" o...

  • Page 116

    5-18 camshafts 3. Measure: • runout (camshaft) out of specification → replace. 4. Measure: • camshaft-to-cap clearance out of specification → measure camshaft outside diameter. Measurement steps: a. Install the camshaft onto the cylin- der head. B. Position a strip of plastigauge ® "1" onto the cams...

  • Page 117

    5-19 camshafts installing the camshaft 1. Install: • exhaust camshaft "1" • intake camshaft "2" installation steps: a. Turn the crankshaft counterclock- wise with a wrench. • apply the molybdenum disulfide oil on the camshafts. • apply the engine oil on the decom- pression system. B. Align the t.D.C...

  • Page 118

    5-20 cylinder head cylinder head removing the cylinder head 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 tightening sequence, and then tighten the cylinder hea...

  • Page 119

    5-21 cylinder head checking the cylinder head 1. Eliminate: • carbon deposits (from the com- bustion chambers) use a rounded scraper. Do not use a sharp instrument to avoid damaging or scratching: • spark plug threads • valve seats 2. Inspect: • cylinder head scratches/damage → replace. 3. Measure: ...

  • Page 120

    5-22 cylinder head 3. Install: • bolt (cylinder head) "1" bolt (cylinder head): 10 nm (1.0 m•kg, 7.2 ft•lb).

  • Page 121

    5-23 valves and valve springs valves and valve springs removing the valves and valve springs order part name q'ty remarks cylinder head refer to "cylinder head" section. 1 valve lifter 5 refer to removal section. 2 adjusting pad 5 refer to removal section. 3 valve cotter 10 refer to removal section....

  • Page 122

    5-24 valves and valve springs removing the valve lifter and valve cotter 1. Remove: • valve lifter "1" • pad "2" identify each lifter "1" and pad "2" po- sition very carefully so that they can be reinstalled in their original place. 2. Check: • valve sealing leakage at the valve seat → in- spect the...

  • Page 123

    5-25 valves and valve springs 3. Inspect: • valve face pitting/wear → grind the face. • valve stem end mushroom shape or diameter larger than the body of the stem → replace. 4. Measure: • margin thickness "a" out of specification → replace. 5. Measure: • runout (valve stem) out of specification → re...

  • Page 124

    5-26 valves and valve springs checking the valve springs 1. Measure: • valve spring free length "a" out of specification → replace. 2. Measure: • compressed spring force "a" out of specification → replace. B. Installed length 3. Measure: • spring tilt "a" out of specification → replace. Checking the...

  • Page 125

    5-27 cylinder and piston cylinder and piston removing the cylinder and piston order part name q'ty remarks cylinder head refer to "cylinder head" section. 1 bolt (cylinder) 1 2 cylinder 1 3 gasket 1 4 dowel pin 2 5 piston pin clip 2 refer to removal section. 6 piston pin 1 refer to removal section. ...

  • Page 126

    5-28 cylinder and piston removing the piston and piston ring 1. Remove: • piston pin clip "1" • piston pin "2" • piston "3" • put identification marks on each piston head for reference during re- installation. • before removing each piston pin, deburr the clip groove and pin hole area. If the piston...

  • Page 127

    5-29 cylinder and piston you cannot measure the end gap on the expander spacer of the oil control ring. If the oil control ring rails show excessive gap, replace all three rings. Checking the piston pin 1. Inspect: • piston pin blue discoloration/grooves → re- place, then inspect the lubrication sys...

  • Page 128

    5-30 clutch clutch removing the clutch order part name q'ty remarks drain the engine oil. Refer to "changing the engine oil" section in the chapter 3. Brake pedal refer to "engine removal" section. Clutch cable disconnect at engine side. 1 clutch cover 1 2 gasket 1 3 dowel pin 2 4 clutch spring 6 5 ...

  • Page 129

    5-31 clutch 14 nut (clutch boss) 1 refer to removal section. 15 lock washer 1 refer to removal section. 16 clutch boss 1 refer to removal section. 17 thrust washer 1 18 primary driven gear 1 19 push lever shaft 1 order part name q'ty remarks.

  • Page 130

    5-32 clutch removing the clutch boss 1. Remove: • nut "1" • lock washer "2" • clutch boss "3" straighten the lock washer tab and use the clutch holding tool "4" to hold the clutch boss. A. For usa and cdn b. Except for usa and cdn checking the clutch housing and boss 1. Inspect: • clutch housing "1"...

  • Page 131

    5-33 clutch 2. Install: • lock washer "1" • nut (clutch boss) "2" make sure to tighten to specifica- tion; otherwise, it may damage the other part that is fastened togeth- er. • install the lock washer with its con- caves fitted over the convexes of the clutch boss. • use the clutch holding tool "3"...

  • Page 132

    5-34 oil filter element and water pump oil filter element and water pump removing the oil filter element and water pump order part name q'ty remarks right engine guard refer to "engine removal" section. Drain the engine oil. Refer to "changing the engine oil" section in the chapter 3. Drain the cool...

  • Page 133

    5-35 oil filter element and water pump 9 gasket 1 10 dowel pin/o-ring 3/1 11 impeller 1 refer to removal section. 12 washer 1 refer to removal section. 13 impeller shaft 1 refer to removal section. 14 oil seal 1 1 refer to removal section. 15 oil seal 2 1 refer to removal section. 16 bearing 1 refer...

  • Page 134

    5-36 oil filter element and water pump removing the impeller shaft 1. Remove: • impeller "1" • washer "2" • impeller shaft "3" hold the impeller shaft on its width across the flats "a" with spanners, etc. And remove the impeller. Removing the oil seal it is not necessary to disassemble the water pum...

  • Page 135

    5-37 oil filter element and water pump 2. Install: • right crankcase cover "1" • bolt "2" • bolt • apply the engine oil on the impeller shaft end. • when installing the crankcase cov- er onto the crankcase, be sure that the impeller shaft end "2" aligns with the balancer end slot "3". • tighten the ...

  • Page 136

    5-38 balancer balancer removing the balancer order part name q'ty remarks primary driven gear refer to "clutch" section. Right crankcase cover refer to "oil filter element and wa- ter pump" section. Stator refer to "cdi magneto" section. 1 nut (balancer) 1 refer to removal section. 2 nut (primary dr...

  • Page 137

    5-39 balancer removing the balancer 1. Straighten the lock washer tab. 2. Loosen: • nut (balancer) "1" • nut (primary drive gear) "2" • nut (balancer shaft driven gear) "3" place an aluminum plate "a" between the teeth of the balancer shaft drive gear "4" and driven gear "5". Checking the primary dr...

  • Page 138

    5-40 oil pump oil pump removing the oil pump order part name q'ty remarks primary driven gear refer to "clutch" section. Right crankcase cover refer to "oil filter element and wa- ter pump" section. 1 circlip 1 2 washer 1 3 oil pump drive gear 1 4 oil pump assembly 1 5 dowel pin 2 6 outer rotor 2 1 ...

  • Page 139

    5-41 oil pump 15 oil pump drive shaft 1 16 rotor housing 1 order part name q'ty remarks.

  • Page 140

    5-42 oil pump checking the oil pump 1. Inspect: • oil pump drive gear • oil pump drive shaft • rotor housing • oil pump cover cracks/wear/damage → replace. 2. Measure: • tip clearance "a" (between the inner rotor "1" and outer rotor "2") • side clearance "b" (between the outer rotor "2" and rotor ho...

  • Page 141

    5-43 kick shaft and shift shaft kick shaft and shift shaft removing the kick shaft and shift shaft order part name q'ty remarks oil pump refer to "oil pump" section. 1 kick idle gear 1 2 kick shaft assembly 1 refer to removal section. 3 spring guide 1 4 torsion spring 1 5 ratchet wheel 1 6 kick gear...

  • Page 142

    5-44 kick shaft and shift shaft 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 refer to removal section. Order part name q'ty remarks.

  • Page 143

    5-45 kick shaft and shift shaft removing the kick shaft assembly 1. Remove: • kick shaft assembly "1" unhook the torsion spring "2" from the hole "a" in the crankcase. Removing the shift guide and shift lever assembly 1. Remove: • bolt (shift guide) • shift guide "1" • shift lever assembly "2" the s...

  • Page 144

    5-46 kick shaft and shift shaft installing the shift guide and shift lever assembly 1. Install: • spring "1" • pawl pin "2" • pawl "3" to shift lever "4". Apply the engine oil on the spring, pawl pin and pawl. 2. Install: • shift lever assembly "1" to shift guide "2". 3. Install: • shift lever assem...

  • Page 145

    5-47 kick shaft and shift shaft • kick idle gear "1" • washer "2" • circlip "3" • apply the engine oil on the kick idle gear inner circumference. • install the kick idle gear with its de- pressed side "a" toward you..

  • Page 146

    5-48 ac magneto and starter clutch ac magneto and starter clutch removing the ac magneto and starter clutch order part name q'ty remarks drain the engine oil. Refer to "changing the engine oil" section in the chapter 3. Seat and fuel tank refer to "removing the seat, fuel tank and side covers" secti...

  • Page 147

    5-49 ac magneto and starter clutch tighten the rotor nut to 65 nm (6.5 m•kg, 47 ft•lb), loosen and retighten the rotor nut to 65 nm (6.5 m•kg, 47 ft•lb). 12 woodruff key 1 13 starter clutch assembly cover 1 refer to removal section. 14 starter clutch 1 refer to removal section. 15 starter clutch dri...

  • Page 148

    5-50 ac magneto and starter clutch removing the rotor 1. Remove: • nut (rotor) "1" • washer use the sheave holder "2". 2. Remove: • rotor "1" use the rotor puller "2". Removing the starter clutch 1. Remove: • starter clutch assembly cover "1" insert a thin screwdriver or the like under the convexity...

  • Page 149

    5-51 ac magneto and starter clutch • pass the ac magneto lead "5" un- der the pickup coil. • pass the ac magneto lead "4" un- der the holder as shown. • take care not to catch the ac mag- neto lead between crankcase cover ribs. • tighten the bolt (stator) using the t25 bit. • apply the sealant to th...

  • Page 150

    5-52 ac magneto and starter clutch 10. Install: • cover (idle gear 1) "1" • bolt "2" install the cover (idle gear 1) with its mark "a" facing upward. 11. Connect: • ac magneto lead refer to "cable routing dia- gram" section in the chapter 2. 12. Install: • shift pedal "1" • bolt (shift pedal) "2" wh...

  • Page 151

    5-53 engine removal engine removal removing the engine order part name q'ty remarks hold the machine by placing the suitable stand under the frame. Refer to "handling note". Drain the engine oil. Refer to "changing the engine oil" section in the chapter 3. Seat and fuel tank refer to "removing the s...

  • Page 152

    5-54 engine removal ignition coil disconnect the ac magneto lead. Disconnect the starter motor lead. Refer to "electric starting system" section in the chapter 7. Negative battery lead disconnect at the engine side. 1 engine guard 1 2 neutral switch 1 3 drive chain sprocket cover 1 4 nut (drive spro...

  • Page 153

    5-55 engine removal handling note support the machine securely so there is no danger of it falling over. Removing the drive sprocket 1. Remove: • nut (drive sprocket) "1" • lock washer "2" • straighten the lock washer tab. • loosen the nut while applying the rear brake. 2. Remove: • drive sprocket "...

  • Page 154

    5-56 engine removal 2. Install: • lock washer "1" • nut (drive sprocket) "2" tighten the nut while applying the rear brake. Make sure to tighten to specifica- tion; otherwise, it may damage the other part that is fastened togeth- er. 3. Bend the lock washer tab to lock the nut. 4. Install: • drive c...

  • Page 155

    5-57 crankcase and crankshaft crankcase and crankshaft removing the crankshaft order part name q'ty remarks engine refer to "engine removal" section. Piston refer to "cylinder and piston" section. Balancer refer to "balancer" section. Kick shaft assembly refer to "kick shaft and shift shaft" section...

  • Page 156

    5-58 crankcase and crankshaft 9 left crankcase 1 refer to removal section. 10 oil strainer 1 11 balancer shaft 1 refer to removal section. 12 crankshaft 1 refer to removal section. Order part name q'ty remarks.

  • Page 157

    5-59 crankcase and crankshaft removing the crankcase bearing order part name q'ty remarks transmission refer to "transmission, shift cam and shift fork" section. Shift cam and shift fork refer to "transmission, shift cam and shift fork" section. 1 oil seal 3 2 bearing 10 refer to removal section..

  • Page 158

    5-60 crankcase and crankshaft disassembling the crankcase 1. Separate: • right crankcase • left crankcase separation steps: a. Remove the crankcase bolts, hose guide and clutch cable hold- er. Loosen each bolt 1/4 of a turn at a time and after all the bolts are loos- ened, remove them. B. Remove the...

  • Page 159

    5-61 crankcase and crankshaft checking the 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 thick- ness gauge. Checking the oil strainer 1. Inspect: • oil s...

  • Page 160

    5-62 crankcase and crankshaft 4. Apply: • sealant on the right crankcase. Clean the contacting surface of left and right crankcase before applying the sealant. 5. Install: • dowel pin "1" • o-ring "2" • right crankcase to left crankcase. • apply the lithium soap base grease on the o-ring. • fit the ...

  • Page 161

    5-63 transmission, shift cam and shift fork transmission, shift cam and shift fork removing the transmission, shift cam and shift fork order part name q'ty remarks engine refer to "engine removal" section. Separate the crankcase. Refer to "crankcase and crank- shaft" section. 1 main axle 1 refer to ...

  • Page 162

    5-64 transmission, shift cam and shift fork removing the transmission 1. Remove: • main axle "1" • drive axle "2" • shift cam • shift fork 3 • shift fork 2 • shift fork 1 • remove assembly with the collar "3" installed to the crankcase. • remove assembly carefully. Note the position of each part. Pa...

  • Page 163

    5-65 transmission, shift cam and shift fork 3. Install: • washer "1" • circlip "2" • be sure the circlip sharp-edged cor- ner "a" is positioned opposite side to the washer and gear "b". • install the circlip with its ends "c" settled evenly on the spline crests. 4. Install: • collar "1" • apply the ...

  • Page 164

    6-1 front wheel and rear wheel chassis this section is intended for those who have basic knowledge and skill concerning the servicing of yamaha motorcycles (e.G., yamaha dealers, service engineers, etc.) those who have little knowledge and skill concerning servicing are request- ed not to undertake ...

  • Page 165

    6-2 front wheel and rear wheel removing the rear wheel order part name q'ty remarks hold the machine by placing the suitable stand under the engine. Refer to "handling note". 1 nut (rear wheel axle) 1 2 rear wheel axle 1 3 drive chain puller 2 4 rear wheel 1 refer to removal section. 5 collar 2 6 re...

  • Page 166

    6-3 front wheel and rear wheel handling note support the machine securely so there is no danger of it falling over. Removing the rear wheel 1. Remove: • wheel "1" push the wheel forward and remove the drive chain "2". Removing the wheel bearing 1. Remove: • bearing "1" remove the bearing using a gen...

  • Page 167

    6-4 front wheel and rear wheel 2. Install: • brake disc "1" • bolt (brake disc) "2" tighten the bolts in stage, using a crisscross pattern. 3. Install: • collar "1" apply the lithium soap base grease on the oil seal lip. 4. Install: • speed sensor "1" • apply the lithium soap base grease on the oil ...

  • Page 168

    6-5 front wheel and rear wheel 2. Install: • brake disc "1" • bolt (brake disc) "2" tighten the bolts in stage, using a crisscross pattern. 3. Install: • rear wheel sprocket "1" • bolt (rear wheel sprocket) "2" • washer (rear wheel sprocket) "3" • nut (rear wheel sprocket) "4" tighten the nuts in st...

  • Page 169

    6-6 front brake and rear brake front brake and rear brake removing the front brake order part name q'ty remarks hold the machine by placing the suitable stand under the engine. Refer to "handling note". Drain the brake fluid. Refer to removal section. 1 brake hose holder (protector) 2 2 brake hose h...

  • Page 170

    6-7 front brake and rear brake removing the rear brake order part name q'ty remarks hold the machine by placing the suitable stand under the engine. Refer to "handling note". Rear wheel refer to "front wheel and rear wheel" section. Drain the brake fluid. Refer to removal section. 1 brake pedal 1 2 ...

  • Page 171

    6-8 front brake and rear brake disassembling the brake caliper order part name q'ty remarks a. Front b. Rear a b 1 pad pin 1 1 2 brake pad 2 2 3 pad support 1 1 4 brake caliper piston 2 1 refer to removal section. 5 brake caliper piston dust seal 2 1 refer to removal section. 6 brake caliper piston ...

  • Page 172

    6-9 front brake and rear brake disassembling the brake master cylinder order part name q'ty remarks a. Front b. Rear 1 brake master cylinder cap 1 2 diaphragm 1 3 reservoir float 1 4 brake master cylinder boot 1 5 circlip 1 use a long nose circlip pliers. 6 washer 1 7 push rod 1 8 brake master cylin...

  • Page 173

    6-10 front brake and rear brake handling note support the machine securely so there is no danger of it falling over. Draining the brake fluid 1. Remove: • brake master cylinder cap "1" • protector (rear brake) do not remove the diaphragm. A. Front b. Rear 2. Connect the transparent hose "2" to the b...

  • Page 174

    6-11 front brake and rear brake 3. Inspect: (front brake only) • reservoir float "1" damage → replace. 4. Inspect: • brake master cylinder piston "1" • brake master cylinder cup "2" wear/damage/score marks → re- place brake master cylinder kit. A. Front b. Rear checking the brake caliper 1. Inspect:...

  • Page 175

    6-12 front brake and rear brake 2. Install: • brake caliper "1" • bolt (brake caliper) "2" 3. Tighten: • pad pin "3" 4. Install: • pad pin plug "4" installing the rear brake caliper 1. Install: • pad support "1" • brake pad "2" • pad pin "3" • install the brake pads with their pro- jections "a" into...

  • Page 176

    6-13 front brake and rear brake installing the front brake master cylinder 1. Install: • brake master cylinder "1" • brake master cylinder bracket "2" • bolt (brake master cylinder brack- et) "3" • install the bracket so that the arrow mark "a" face upward. • first tighten the bolts on the upper sid...

  • Page 177

    6-14 front brake and rear brake 2. Install: • brake hose holder "1" • bolt (brake hose holder) "2" 3. Install: • brake hose holder "1" • nut (brake hose holder) "2" align the top "a" of the brake hose holder with the paint "b" of the brake hose. 4. Pass the brake hose through the front brake hose gu...

  • Page 178

    6-15 front brake and rear brake a. Front b. Rear 2. Air bleed: • brake system refer to "bleeding the hy- draulic brake system" sec- tion in the chapter 3. 3. Inspect: • brake fluid level fluid at lower level → fill up. Refer to "checking the brake fluid level" section in the chapter 3. 4. Install: •...

  • Page 179

    6-16 front fork front fork removing the front fork order part name q'ty remarks hold the machine by placing the suitable stand under the engine. Refer to "handling note". Front wheel refer to "front wheel and rear wheel" section. Front brake caliper refer to "front brake and rear brake" section. Hea...

  • Page 180

    6-17 front fork disassembling the front fork order part name q'ty remarks 1 front fork cap bolt 1 refer to removal section. 2 fork spring 1 drain the fork oil. 3 dust seal 1 refer to removal section. 4 stopper ring 1 refer to removal section. 5 inner tube 1 refer to removal section. 6 outer tube 1 7...

  • Page 181

    6-18 front fork handling note support the machine securely so there is no danger of it falling over. The front fork requires careful atten- tion. So it is recommended that the front fork be maintained at the deal- ers. To prevent an accidental explosion of air, the following instructions should be o...

  • Page 182

    6-19 front fork the bending value is shown by one half of the dial gauge reading. Do not attempt to straighten a bent inner tube as this may dangerous- ly weaken the tube. Checking the outer tube 1. Inspect: • outer tube "1" score marks/wear/damage → re- place. Checking the front fork cap bolt 1. In...

  • Page 183

    6-20 front fork 8. Install: • outer tube "1" to inner tube "2". 9. Install: • slide metal "1" • oil seal washer "2" to outer tube slot. Press the slide metal into the outer tube with fork seal driver "3". 10. Install: • oil seal "1" press the oil seal into the outer tube with fork seal driver "2". 1...

  • Page 184

    6-21 front fork 20. Measure: • oil level (left and right) "a" out of specification → adjust. Be sure to install the spring guide "2" when checking the oil level. Never fail to make the oil level ad- justment between the maximum and minimum level and always ad- just each front fork to the same settin...

  • Page 185

    6-22 front fork installing the front fork 1. Install: • front fork "1" • temporarily tighten the pinch bolts (lower bracket). • do not tighten the pinch bolts (up- per bracket) yet. 2. Tighten: • front fork cap bolt 3. Adjust: • front fork top end "a" 4. Tighten: • pinch bolt (upper bracket) "1" • p...

  • Page 186

    6-23 handlebar handlebar removing the handlebar order part name q'ty remarks headlight 1 hot starter cable 1 disconnect at the lever side. 2 hot starter lever holder 1 3 clutch cable 1 disconnect at the lever side. 4 clutch lever holder 1 disconnect the clutch switch lead. 5 engine stop switch 1 dis...

  • Page 187

    6-24 handlebar removing the brake master cylinder 1. Remove: • brake master cylinder bracket "1" • brake master cylinder "2" • do not let the brake master cylin- der hang on the brake hose. • keep the brake master cylinder cap side horizontal to prevent air from coming in. Removing the grip 1. Remov...

  • Page 188

    6-25 handlebar 5. Install: • right grip "1" • collar "2" apply the adhesive on the tube guide "3". • before applying the adhesive, wipe off grease or oil on the tube guide surface "a" with a lacquer thinner. • install the grip to the tube guide so that the grip match mark "b" and tube guide slot "c"...

  • Page 189

    6-26 handlebar 12. Install: • clutch cable "1" • hot starter cable "2" apply the lithium soap base grease on the clutch cable end and hot start- er cable end. 13. Adjust: • clutch lever free play refer to "adjusting the clutch cable free play" section in the chapter 3. • hot starter lever free play ...

  • Page 190

    6-27 steering steering removing the steering order part name q'ty remarks tightening steps: • tighten ring nut. 38 nm (3.8 m•kg, 27 ft•lb) • loosen it one turn. • retighten it. 7 nm (0.7 m•kg, 5.1 ft•lb) hold the machine by placing the suitable stand under the engine. Refer to "handling note". Headl...

  • Page 191

    6-28 steering 9 bearing race cover 1 10 upper bearing 1 11 lower bearing 1 refer to removal section. 12 bearing race 2 refer to removal section. Order part name q'ty remarks.

  • Page 192

    6-29 steering handling note support the machine securely so there is no danger of it falling over. Removing the steering ring nut 1. Remove: • steering ring nut "1" use the steering nut wrench "2". Support the steering stem so that it may not fall down. Removing the lower bearing 1. Remove: • lower ...

  • Page 193

    6-30 steering 6. Install: • washer "1" 7. Install: • front fork "1" • upper bracket "2" • main switch "3" • front brake hose guide bracket "4" • temporarily tighten the pinch bolts (lower bracket). • do not tighten the pinch bolts (up- per bracket) yet. 8. Install: • guide (speed sensor lead) "1" af...

  • Page 194

    6-31 swingarm swingarm removing the swingarm order part name q'ty remarks hold the machine by placing the suitable stand under the engine. Refer to "handling note". Brake hose holder refer to "front brake and rear brake" section. Rear brake caliper refer to "front brake and rear brake" section. Bolt...

  • Page 195

    6-32 swingarm disassembling the swingarm order part name q'ty remarks 1 cap 2 refer to removal section. 2 relay arm 1 3 connecting rod 1 4 collar 2 5 oil seal 2 6 thrust bearing 2 7 bushing 2 8 oil seal 8 9 bearing 10 refer to removal section..

  • Page 196

    6-33 swingarm handling note support the machine securely so there is no danger of it falling over. Removing the cap 1. Remove: • left cap "1" remove with a slotted-head screw- driver inserted under the mark "a" on the left cap. Removing the bearing 1. Remove: • bearing "1" remove the bearing by pres...

  • Page 197

    6-34 swingarm installing the swingarm 1. Install: • bushing "1" • thrust bearing "2" • oil seal "3" • collar "4" to swingarm "5" apply the molybdenum disulfide grease on the bushings, thrust bear- ings, oil seal lips and contact surfaces of the collar and thrust bearing. 2. Install: • collar "1" • w...

  • Page 198

    6-35 swingarm 10. Tighten: • nut (connecting rod) "1" 11. Tighten: • nut (relay arm) "1" 12. Install: • cap "1" install the right cap with its mark "a" facing forward. 13. Install: • bolt (lower chain tensioner) "1" • washer "2" • collar "3" • lower chain tensioner "4" • nut (lower chain tensioner) ...

  • Page 199

    6-36 rear shock absorber rear shock absorber removing the rear shock absorber order part name q'ty remarks hold the machine by placing the suitable stand under the engine. Refer to "handling note". Seat and side cover refer to "removing the seat, fuel tank and side covers" section in the chapter 3. ...

  • Page 200

    6-37 rear shock absorber 2 taillight coupler 1 3 cdi unit coupler 3 4 plastic band 1 5 clamp (air filter joint) 1 only loosening. 6 rear frame 1 7 bolt (rear shock absorber-relay arm) 1 hold the swingarm. 8 bolt (rear shock absorber-frame) 1 9 rear shock absorber 1 10 locknut 1 only loosening. 11 ad...

  • Page 201

    6-38 rear shock absorber handling note • support the machine securely so there is no danger of it falling over. • this rear shock absorber is pro- vided with a separate type tank filled with high-pressure nitro- gen gas. To prevent the danger of explosion, read and under- stand the following informa...

  • Page 202

    6-39 rear shock absorber 2. Install: • stopper ring (upper bearing) "1" after installing the stopper ring, push back the bearing until it contacts the stopper ring. 3. Install: • lower bearing "1" install the bearing by pressing it on the side having the manufacture's marks or numbers. Installing th...

  • Page 203

    6-40 rear shock absorber 7. Tighten: • screw (air filter joint) "1" 8. Install: • plastic band • taillight coupler • locking tie screw (air filter joint): 3 nm (0.3 m•kg, 2.2 ft•lb).

  • Page 204

    7-1 electrical this section is intended for those who have basic knowledge and skill concerning the servicing of yamaha motorcycles (e.G., yamaha dealers, service engineers, etc.) those who have little knowledge and skill concerning servicing are request- ed not to undertake inspection, adjustment, ...

  • Page 205

    7-2 electrical components and wiring diagram electrical components and wiring diagram electrical components 1. Headlight 2. Multi-function display 3. Engine stop switch 4. Clutch switch 5. Diode 6. Starter relay diode 7. Throttle position sensor 8. Starter relay 9. Fuse 10. Starting circuit cut-off ...

  • Page 206

    7-3 electrical components and wiring diagram wiring diagram 1. Headlight 2. Multi-function display 3. Engine stop switch 4. Clutch switch 5. Diode 6. Starter relay diode 7. Throttle position sensor 8. Starter relay 9. Fuse 10. Starting circuit cut-off relay 11. Cdi unit 12. Taillight 13. Neutral swi...

  • Page 207

    7-4 ignition system 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. *1 marked: refer to "checking the fuse" section in the chapter 3....

  • Page 208

    7-5 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" a. For usa and cdn b. Except for usa and cdn 4. Kick the kickstarter cran...

  • Page 209

    7-6 electric starting system 3. Inspect: • secondary coil resistance out of specification → replace. 4. Inspect: • sealed portion of ignition coil "a" • spark plug terminal pin "b" • threaded portion of spark plug "c" wear → replace. Checking the ac magneto 1. Inspect: • pickup coil resistance out o...

  • Page 210

    7-7 electric starting system inspection steps if the starter motor will not operate, use the following inspection steps. *1 marked: refer to "checking the fuse" section in the chapter 3. *2 marked: refer to "checking and charging the battery" section in the chapter 3. *3 marked: refer to "checking t...

  • Page 211

    7-8 electric starting system checking the couplers and leads connection 1. Check: • couplers and leads connection rust/dust/looseness/short-circuit → repair or replace. Checking the starter motor operation 1. Connect the positive battery ter- minal "1" and starter motor lead "2" with a jumper lead "...

  • Page 212

    7-9 electric starting system checking the start switch 1. Inspect: • start switch conduction not conductive while it is pushed → replace. Conductive while it is freed → re- place. Set the tester selection position to " Ω × 1". 2. Inspect: • rubber part "a" tears/damage → replace. Tester (+) lead → b...

  • Page 213

    7-10 electric starting system removing the starter motor order part name q'ty remarks exhaust pipe refer to "removing the exhaust pipe and silencer" section in the chapter 3. 1 starter motor 1.

  • Page 214

    7-11 electric starting system disassembling the starter motor order part name q'ty remarks 1 starter motor front cover 1 2 washer (starter motor front cover) 1 3 washer 1 4 circlip 1 5 o-ring 1 6 starter motor yoke 1 7 armature assembly 1 8 starter motor rear cover 1 9 brush 2 10 brush spring 2.

  • Page 215

    7-12 electric starting system checking and repairing the starter motor 1. Check: • commutator dirt → clean with 600 grit sandpa- per. 2. Measure: • commutator diameter "a" out of specification → replace the starter motor. 3. Measure: • mica undercut "a" out of specification → scrape the mica to the ...

  • Page 216

    7-13 electric starting system 4. Install: • o-ring "1" • circlip • plain washer "2" • washer (starter motor front cover) "3" • starter motor front cover "4" • for installation, align the projec- tions on the washer with the slots in the front cover. • align the match mark "a" on the starter motor yo...

  • Page 217

    7-14 charging system charging system inspection steps if the battery is not charged, use the following inspection steps. *1 marked: refer to "checking the fuse" section in the chapter 3. *2 marked: refer to "checking and charging the battery" section in the chapter 3. • remove the following parts be...

  • Page 218

    7-15 charging system checking the couplers and leads connection 1. Check: • couplers and leads connection rust/dust/looseness/short-circuit → repair or replace. Checking the charging voltage 1. Start the engine. 2. Inspect: • charging voltage out of specification → if no failure is found in checking...

  • Page 219

    7-16 throttle position sensor system throttle position sensor system inspection steps if the throttle position sensor will not operate, use the following inspection steps. Use the following special tools in this inspection. Check entire ignition system for connection. No good → repair or replace. Ok...

  • Page 220

    7-17 throttle position sensor system handling note do not loosen the screw (throttle position sensor) "1" except when changing the throttle position sen- sor due to failure because it will cause a drop in engine perfor- mance. Checking the couplers and leads connection 1. Check: • couplers and leads...

  • Page 221

    7-18 throttle position sensor system 9. Adjust: • throttle position sensor output voltage adjustment steps: a. Adjust the installation angle of the throttle position sensor "1" to ob- tain the specified output voltage. Measure the output voltage accurate- ly with a digital electronic voltmeter that ...

  • Page 222

    7-19 lighting system lighting system inspection steps refer to the following flow chart when inspecting the lighting system for possible problems. • remove the following parts before inspection. 1. Seat 2. Fuel tank 3. Left side cover • use the following special tools in this inspection. Check the b...

  • Page 223

    7-20 lighting system checking the taillight (leds) 1. Disconnect the taillight coupler. 2. Connect two jumper leads "1" from the battery terminals to the respective coupler terminal as shown. 3. Check: • led (for proper operation) does not light → replace the tail- light assembly. • a wire that is u...

  • Page 224

    7-21 signaling system signaling system inspection steps if the speedometer will not operate, use the following inspection steps. *1 marked: refer to "checking and charging the battery" section in the chapter 3. • remove the following parts before inspection. 1. Headlight • use the following special ...

  • Page 225

    7-22 signaling system checking the couplers and leads connection 1. Check: • couplers and leads connection rust/dust/looseness/short-circuit → repair or replace. Checking the multi-function display input voltage 1. Disconnect the multi-function dis- play coupler. 2. Set the main switch to "on". 3. M...

  • Page 226

    Printed in japan (e) printed on recycled paper yamaha motor co., ltd. 2500 shingai iwata shizuoka japan.