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  5. Owner's Service Manual

Yamaha WR450F Owner's Service Manual

Summary of WR450F

  • Page 1

    Owner’s service manual manuel d’atelier du proprietaire wr450f wr450fg 2gc-28199-70 printed on recycled paper 2016 wr450f wr450fg 2016 q read this manual carefully before operating this vehicle. Q il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Printed in japan...

  • Page 2

    Q read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. Q il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit être remis avec le véhicule en cas de vente de ce dernier. 2gc-28199-70_cover.I...

  • Page 3: Wr450Fg

    Wr450fg 2015 2016 wr450f 2gc-28199-70-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

    Eas2gc1002 wr450f wr450fg owner’s service manual ©2015 by yamaha motor co., ltd. First edition, august 2015 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited. Printed in japan..

  • Page 6

    Eas2gc1003 introduction congratulations on your purchase of a yamaha wr series. This model is the culmination of yama- ha's vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made yamaha a leader. This manual e...

  • Page 7

    Eas2gc1005 safety information 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 regulations before riding. • this m...

  • Page 8

    Eas2gc1006 how to use this manual in this manual, descriptions of installation, removal, disassembly, assembly, check, and adjustment procedures are laid out with the individual steps in sequential order. • the manual is divided into chapters and each chapter is divided into sections. The current se...

  • Page 9

    Eas2gc1007 symbols the following symbols are used in this manual for easier understanding. Tip the following symbols are not relevant to every vehicle. Symbol definition symbol definition serviceable with engine mounted gear oil filling fluid molybdenum disulfide oil lubricant brake fluid special to...

  • Page 11: Table of Contens

    1 2 3 4 5 6 7 8 9 10 table of contens general information specifications periodic checks and adjustments tuning chassis engine cooling system fuel system electrical system troubleshooting.

  • Page 13

    1 general information location of important labels ............................................................1-1 description ..................................................................................................1-4 identification ...........................................................

  • Page 14

    Multi-function display .........................................................................1-21 description .........................................................................................1-21 basic mode .....................................................................................

  • Page 15

    Location of important labels 1-1 eas2gc1008 location of important labels please read the following important labels carefully before operating this vehicle. Can 9,10,11 7,8 13 12 1,2,3 4,5,6.

  • Page 16

    Location of important labels 1-2 eur.

  • Page 17

    Location of important labels 1-3 aus, nzl, zaf.

  • Page 18

    Description 1-4 eas2gc1009 description tip designs and specifications of the vehicle are subject to change without notice. Therefore, please note that the descriptions in this manual may be different from those for the vehicle you have pur- chased. 1. Clutch lever 12. Headlight 2. Multi-function dis...

  • Page 19

    Identification 1-5 eas2gc1010 identification there are two significant reasons for knowing the serial number of your vehicle: 1. When ordering parts, you can give the num- ber to your yamaha dealer for positive iden- tification of the model you own. 2. If your vehicle is stolen, the authorities will...

  • Page 20

    Included parts 1-6 eas2gc1014 included parts eas2gc1015 spark plug wrench the spark plug wrench “1” is used to remove or install the spark plug. Eas2gc1016 nipple wrench the nipple wrench “1” is used to tighten the spoke. Eas2gc1017 handlebar protector install the handlebar protector “1” so that the...

  • Page 21

    Important information 1-7 eas20180 important information eas2gc1020 preparation for removal and dis- assembly 1. Before the jobs, completely remove mud, dust, and the like in order to prevent the en- try of them into the inside during the jobs. • before cleaning with high-pressure water of washers, ...

  • Page 22

    Important information 1-8 eas2gc1022 gaskets, oil seals and o-rings 1. When overhauling the engine, replace all gaskets and o-rings. All gasket surfaces, oil seal lips, and o-rings must be cleaned so that there may be no dust on them. 2. During assembly, always apply proper oil to bearings and prope...

  • Page 23

    Basic service information 1-9 eas2gc1026 basic service information eas2gc1027 electrical system electrical parts handling eca notice never disconnect a battery lead while the engine is running; otherwise, the electrical components could be damaged. Eca notice when disconnecting the battery leads fro...

  • Page 24

    Basic service information 1-10 eca notice handle electrical components with special care, and do not subject them to strong shocks. Eca notice electrical components are very sensitive to and can be damaged by static electricity. Therefore, never touch the terminals and be sure to keep the contacts c...

  • Page 25

    Basic service information 1-11 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector eca notice • when disconnecting a coupler, release the coupler lock, hold both sections of the coupler, and then disconnect t...

  • Page 26

    Basic service information 1-12 4. Connect: • lead • coupler • connector tip • when connecting a coupler or connector, make sure that both terminals are connected securely. • make sure all connections are tight. 5. Check: • no continuity tip • if there is no continuity, clean the terminals. • when ch...

  • Page 27

    Special tools 1-13 eas2gc1028 special tools the following special tools are required for accurate and complete adjustment and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and tool number used for the special...

  • Page 28

    Special tools 1-14 radiator cap tester 90890-01325 mityvac cooling system tester kit yu-24460-a this tool is used to check the radiator and the radiator cap. Radiator cap tester adapter 90890-01352 pressure tester adapter yu-33984 this tool is used to check the radiator and the radiator cap. Steerin...

  • Page 29

    Special tools 1-15 pocket tester 90890-03112 analog pocket tester yu-03112-c this tool is used to measure the voltage, current, and re- sistance of electrical compo- nents. Timing light 90890-03141 timing light yu-03141 this tool is used to measure the ignition timing. Pressure gauge 90890-03153 pre...

  • Page 30

    Special tools 1-16 valve guide remover & in- staller set (ø5.5) 90890-04016 valve guide remover (5.5 mm) ym-01122 valve guide installer (5.5 mm) ym-04015 valve guide reamer (5.5 mm) 90890-01196 this tool is used to replace the valve guide. Valve spring compressor 90890-04019 valve spring compressor ...

  • Page 31

    Special tools 1-17 valve spring compressor at- tachment 90890-04108 valve spring compressor adapter 22 mm ym-04108 this tool is used to discon- nect or connect the valve and the valve spring. Rotor puller 90890-04142 rotor puller ym-04142 this tool is used to remove the rotor. Crankcase separating t...

  • Page 32

    Control functions 1-18 eas2gc1029 control functions eas2gc1030 indicator lights and warning lights fuel level warning light “ ” this warning light comes on when the fuel level drops below approximately 1.6 l (0.42 us gal, 0.35 imp.Gal). When this occurs, refuel as soon as possible. The electrical ci...

  • Page 33

    Control functions 1-19 eas2gc1034 shift pedal the shift pedal “1” has adopted a method of 1 down & 4 ups (press-down & kick-ups). Press it down for n (neutral) to 1st, and kick it up for 2nd to 5th. Recommended shift points the recommended shift points during accelera- tion and deceleration are show...

  • Page 34

    Control functions 1-20 eas2gc1039 sidestand this sidestand “1” is used to support only the machine when standing or transporting it. Ewa warning • never apply additional force to the sides- tand. • hold up the sidestand before starting out. Eas2gc1040 starter knob/idle screw starting a cold engine r...

  • Page 35

    Multi-function display 1-21 eas2gc1042 multi-function display ewa warning be sure to stop the machine before making any setting changes to the multi-function display. The multi-function display is equipped with the following: basic mode: • speedometer • clock • two tripmeters (which shows the distan...

  • Page 36

    Multi-function display 1-22 4. To end the setting, push the “rst” button for 2 seconds or more. Tip • in a 30-second absence of button operation, the setting will come to an end with the indi- cated time. • to reset the seconds, push the “slct1” but- ton or “slct2” button. Changing odometer and trip...

  • Page 37

    Multi-function display 1-23 returning to basic mode from race mode tip it is possible to return to basic mode with tim- er measurement at a stop. 1. Check that the timer is not in operation. If the timer is in operation, stop the timer by push- ing the “slct1” button and “slct2” button at the same t...

  • Page 38

    Multi-function display 1-24 3. Run the machine and start timer measure- ment. 4. To stop timer measurement, pushing the “slct1” button and “slct2” button at the same time. Tip if the machine is run while timer measurement is not made, no change will occur to the digit in tripmeter a (trip a). 5. To ...

  • Page 39

    Multi-function display 1-25 correcting tripmeter a (trip a) 1. Change the travel distance display by push- ing the “slct1” button (plus) or “slct2” button (minus). A long push on the button will fast-forward the change. Tip change can be made any time while timer measurement is or is not being made..

  • Page 40

    Multi-function display 1-26 eas2gc1047 function diagram tip the following diagram illustrates the multi-function display regarding the direction and operation con- dition involved in each of its functions. A short push on the button changes the operation in the arrowed direction. A short push on the...

  • Page 41

    Multi-function display 1-27 a. A short push on the button changes the op- eration in the arrowed direction. B. A short push on the button changes the op- eration in both arrowed directions. C. A long push on the button changes the oper- ation in the arrowed direction. D. A long push on the button ch...

  • Page 42

    Starting and break-in 1-28 eas2gc1048 starting and break-in eas2gc1049 fuel always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race. Eca notice use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts su...

  • Page 43

    Starting and break-in 1-29 eca notice if the starter motor will not turn when the start switch is pushed, stop pushing it im- mediately in order to avoid placing extra load on the starter motor, and start the en- gine by using the kickstarter. Tip if the engine fails to start, push the engine stop s...

  • Page 44

    Starting and break-in 1-30 eas2gc1053 starting a warm engine follow the same procedure as for starting a cold engine with the exception that the starter is not required when the engine is warm. Tip if it fails to start, fully open the throttle grip and give 10 to 20 slow kicks to clear the engine of...

  • Page 45

    Maintenance after break-in 1-31 eas2gc1055 maintenance after break-in after a break-in, perform careful maintenance to get ready for the next practice or race. Refer to “pre-operation inspection and maintenance” on page 3-9. Eas2gc1056 major maintenance 1. For the engine • leaks around the engine ch...

  • Page 46

    Torque-check points 1-32 eas2gc1057 torque-check points frame construction frame to rear frame frame to engine protector combined seat and fuel tank fuel tank to frame engine mounting frame to engine engine bracket to engine engine bracket to frame seat seat to frame steering steering stem to handle...

  • Page 47

    Torque-check points 1-33 tip concerning the tightening torque, refer to “tightening torques” on page 2-12. Fuel system fuel pump to fuel tank fuel sender to fuel tank plastic cover tightening of front fender tightening of fork leg protector tightening of air scoop left cover to rear frame tightening...

  • Page 48

    Motorcycle care and storage 1-34 eas2gc1058 motorcycle care and stor- age eas2gc1059 care while the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pip...

  • Page 49

    Motorcycle care and storage 1-35 2. Apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces to prevent corrosion. After cleaning 1. Dry the motorcycle with a chamois or an ab- sorbing cloth. 2. Immediately dry the drive chain and lubri- cate it to prevent it fr...

  • Page 50

    Motorcycle care and storage 1-36 e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. Warning! To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 51

    2 specifications general specifications .........................................................................2-1 engine specifications .............................................................................2-2 chassis specifications ............................................................

  • Page 52

    General specifications 2-1 eas2gc1061 general specifications model model 2gc1 (usa) 2gc2 (can) 2gc3 (eur) 2gc4, 2gc5 (aus) (nzl) (zaf) dimensions overall length 2165 mm (85.2 in) overall width 825 mm (32.5 in) overall height 1280 mm (50.4 in) seat height 965 mm (38.0 in) wheelbase 1465 mm (57.7 in) ...

  • Page 53

    Engine specifications 2-2 eas2gc1062 engine specifications engine engine type liquid cooled 4-stroke, dohc displacement 449 cm 3 number of cylinders single cylinder bore stroke 97.0 60.8 mm (3.82 2.39 in) compression ratio 12.5:1 starting system electric starter and kickstarter fuel recommended fuel...

  • Page 54

    Engine specifications 2-3 cylinder head combustion chamber volume 25.98–26.78 cm 3 (1.59–1.63 cu.In) warpage limit 0.05 mm (0.0020 in) camshaft drive system chain drive (left) camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in) camshaft journal diameter 21.959–21.972 mm (0.8645–0.8650 i...

  • Page 55

    Engine specifications 2-4 valve spring free length (intake) 40.76 mm (1.60 in) limit 38.72 mm (1.52 in) free length (exhaust) 36.94 mm (1.45 in) limit 35.09 mm (1.38 in) installed length (intake) 34.78 mm (1.37 in) installed length (exhaust) 30.83 mm (1.21 in) spring rate k1 (intake) 31.90 n/mm (3.2...

  • Page 56

    Engine specifications 2-5 crankshaft crank assembly width 61.93–62.00 mm (2.438–2.441 in) runout limit 0.030 mm (0.0012 in) big end side clearance 0.150–0.450 mm (0.0059–0.0177 in) balancer balancer drive method gear clutch clutch type wet, multiple-disc clutch release method inner push, cam push cl...

  • Page 57

    Engine specifications 2-6 fuel pump pump type electrical fuel injector model/quantity 1010/1 resistance 12 throttle body type/quantity 30ra-a05u/1 id mark 2gc1 00 fuel line pressure (at idle) 300.0–390.0 kpa (3.00–3.90 kgf/cm 2 , 43.5– 56.6 psi) throttle position sensor resistance 6.30 k output volt...

  • Page 58

    Chassis specifications 2-7 eas2gc1063 chassis specifications chassis frame type semi double cradle caster angle 26.2 ° trail 114 mm (4.5 in) front wheel wheel type spoke wheel rim size 1.6 21 rim material aluminum wheel travel 310 mm (12.2 in) radial wheel runout limit 2.0 mm (0.08 in) lateral wheel...

  • Page 59

    Chassis specifications 2-8 rear brake type hydraulic single disc brake operation right foot operation brake pedal position 5.0 mm (0.20 in) rear disc brake disc outside diameter thickness 245.0 4.0 mm (9.65 0.16 in) brake disc thickness limit 3.5 mm (0.14 in) brake disc runout limit (as measured on ...

  • Page 60

    Chassis specifications 2-9 rear suspension type swingarm (link suspension) spring/shock absorber type coil spring/gas-hydraulic damper rear shock absorber assembly travel 126.0 mm (4.96 in) spring free length 275.0 mm (10.83 in) spring installed length 263.0 mm (10.35 in) spring rate k1 56.00 n/mm (...

  • Page 61

    Electrical specifications 2-10 eas2gc1064 electrical specifications voltage system voltage 12 v ignition system ignition system tci advancer type digital ignition timing (b.T.D.C.) 10.0 ° at 2000 r/min engine control unit model/manufacturer 2gc0/yamaha (usa) (can) 2gc1/yamaha (eur) (aus) (nzl) (zaf)...

  • Page 62

    Electrical specifications 2-11 starter motor power output 0.48 kw armature coil resistance 0.0117–0.0143 brush overall length 7.0 mm (0.28 in) limit 3.50 mm (0.14 in) brush spring force 3.92–5.88 n (400–600 gf, 14.11–21.17 oz) commutator diameter 17.6 mm (0.69 in) limit 16.6 mm (0.65 in) mica underc...

  • Page 63

    Tightening torques 2-12 eas20320 tightening torques eas2gc1065 general tightening torque specifi- cations this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each c...

  • Page 64

    Tightening torques 2-13 eas2gc1066 engine tightening torques tip - marked portion shall be checked for torque tightening after break-in or before each race. Item thread size q’ty tightening torques remarks camshaft cap bolt m6 8 10 nm (1.0 m·kgf, 7.2 ft·lbf) cylinder head blind plug m12 1 28 nm (2.8...

  • Page 65

    Tightening torques 2-14 throttle body joint clamp bolt m5 1 3.0 nm (0.30 m·kgf, 2.2 ft·lbf) air filter joint clamp bolt m4 1 3.5 nm (0.35 m·kgf, 2.5 ft·lbf) air filter case bolt m6 3 7 nm (0.7 m·kgf, 5.1 ft·lbf) air filter bolt m6 1 2.0 nm (0.20 m·kgf, 1.4 ft·lbf) air filter guide holder screw m5 8 ...

  • Page 66

    Tightening torques 2-15 tip *1:cylinder head bolt first, tighten the cylinder head bolts to 30 nm (3.0 m·kgf, 22 ft·lbf) in the proper tightening sequence and remove them. Retighten the cylinder head bolts to 20 nm (2.0 m·kgf, 14 ft·lbf) in the proper tight- ening sequence, and then tighten the cyli...

  • Page 67

    Tightening torques 2-16 tip *2:exhaust pipe nut first temporarily tighten all nuts to 7 nm (0.7 m·kgf, 5.1 ft·lbf). Then retighten them to 10 nm (1.0 m·kgf, 7.2 ft·lbf). 1 4 2 3 x4 fwd.

  • Page 68

    Tightening torques 2-17 eas2gc1067 chassis tightening torques tip - marked portion shall be checked for torque tightening after break-in or before each race. Item thread size q’ty tightening torques remarks outer tube and upper bracket bolt m8 4 21 nm (2.1 m·kgf, 15 ft·lbf) outer tube and lower brac...

  • Page 69

    Tightening torques 2-18 front brake disc bolt m6 6 12 nm (1.2 m·kgf, 8.7 ft·lbf) rear brake disc bolt m6 6 14 nm (1.4 m·kgf, 10 ft·lbf) footrest bracket bolt m10 4 55 nm (5.5 m·kgf, 40 ft·lbf) sidestand bolt m10 1 25 nm (2.5 m·kgf, 18 ft·lbf) rear brake pedal bolt m8 1 26 nm (2.6 m·kgf, 19 ft·lbf) r...

  • Page 70

    Tightening torques 2-19 drive chain tensioner bolt (lower side) m8 1 16 nm (1.6 m·kgf, 12 ft·lbf) drive chain support bolt m6 1 7 nm (0.7 m·kgf, 5.1 ft·lbf) drive chain support nut m6 2 7 nm (0.7 m·kgf, 5.1 ft·lbf) drive chain guide bolt m5 3 4.0 nm (0.40 m·kgf, 2.9 ft·lbf) rear frame and left cover...

  • Page 71

    Tightening torques 2-20 tip lower ring nut 1. First, tighten the lower ring nut approximately 38 nm (3.8 m·kgf, 27 ft·lbf) by using the steering nut wrench, then loosen the lower ring nut one turn. 2. Retighten the lower ring nut 7 nm (0.7 m·kgf, 5.1 ft·lbf). Starter relay and starter motor lead bol...

  • Page 72

    Lubrication points and lubricant types 2-21 eas2gc1068 lubrication points and lubricant types eas2gc1069 engine lubrication point lubricant types oil seal lips bearing o-ring camshaft cap bolt threads and contacting surface cylinder head bolt threads, seats, washers valve stems valve stem ends valve...

  • Page 73

    Lubrication points and lubricant types 2-22 eas2gc1070 chassis starter idle gear inner surface, thrust surfaces starter clutch drive gear inner surface, thrust surfaces cylinder head cover gasket yamaha bond no.1215 (three bond no.1215®) crankcase mating surface yamaha bond no.1215 (three bond no.12...

  • Page 74

    Lubrication points and lubricant types 2-23 clutch lever sliding surface and bolt outer surface clutch lever adjuster rubber lip clutch cable end (clutch lever side) tube guide (throttle grip) inner surface and throttle cable end front brake caliper piston front brake caliper piston seal front brake...

  • Page 75

    Lubrication points and lubricant types 2-24 eas2gc1071.

  • Page 76

    Lubrication system chart and diagrams 2-25 lubrication system chart and diagrams eas2gc1072 lubrication diagrams.

  • Page 77

    Lubrication system chart and diagrams 2-26 1. Intake camshaft 2. Exhaust camshaft 3. Piston 4. Oil nozzle 5. Oil filter element 6. Oil pump 7. Oil strainer 8. Crankshaft 9. Drive axle 10. Main axle.

  • Page 78

    Lubrication system chart and diagrams 2-27.

  • Page 79

    Lubrication system chart and diagrams 2-28 1. Connecting rod 2. Crankshaft 3. Main axle 4. Oil strainer 5. Drive axle.

  • Page 80

    Lubrication system chart and diagrams 2-29.

  • Page 81

    Lubrication system chart and diagrams 2-30 1. Exhaust camshaft 2. Intake camshaft 3. Oil filter element 4. Oil pump.

  • Page 82

    Lubrication system chart and diagrams 2-31.

  • Page 83

    Lubrication system chart and diagrams 2-32 1. Camshaft 2. Oil pressure check bolt 3. Oil filter element 4. Oil pump.

  • Page 84

    Cable routing diagram 2-33 eas2gc1073 cable routing diagram.

  • Page 85

    Cable routing diagram 2-34 1. Clutch cable 2. Throttle cable (return) 3. Throttle cable (pull) 4. Engine stop switch lead 5. Coupler for connecting optional part 6. Engine stop switch coupler 7. Rectifier/regulator coupler 8. Ac magneto lead 9. Starter knob/idle screw 10. Engine ground sub-lead 11. ...

  • Page 86

    Cable routing diagram 2-35.

  • Page 87

    Cable routing diagram 2-36 1. Clamp 2. Throttle position sensor lead 3. Joint coupler 4. Intake air temperature sensor lead 5. Intake air pressure sensor lead 6. Wire harness 7. Injector lead 8. Injector coupler 9. Throttle body 10. Cylinder head breather hose 11. Engine ground sub-lead 12. Plate 13...

  • Page 88

    Cable routing diagram 2-37.

  • Page 89

    Cable routing diagram 2-38 1. Cable guide 2. Speed sensor lead 3. Joint coupler 4. Ground lead 5. Throttle position sensor lead 6. Throttle position sensor coupler 7. Radiator breather hose 8. Radiator hose 9. Fuel hose 10. Coolant temperature sensor coupler 11. Radiator fan motor lead 12. Intake ai...

  • Page 90

    Cable routing diagram 2-39.

  • Page 91

    Cable routing diagram 2-40 1. Battery negative lead 2. Fuel hose 3. Fuel pump coupler 4. Fuel pump lead 5. Resistor 6. Resistor coupler 7. Battery positive lead 8. Lean angle sensor 9. Starter motor lead 10. Radiator fan motor relay (blue tape) 11. Main relay (red tape) 12. Wire harness 13. Ground l...

  • Page 92

    Cable routing diagram 2-41.

  • Page 93

    Cable routing diagram 2-42 1. Clutch switch lead 2. Engine stop switch lead 3. Clutch cable 4. Brake hose guide 5. Headlight lead 6. Speed sensor lead 7. Indicator light coupler 8. Meter assembly optional switch coupler 9. Meter assembly coupler 10. Speed sensor coupler 11. Start switch lead 12. Pla...

  • Page 94

    Cable routing diagram 2-43.

  • Page 95

    Cable routing diagram 2-44 1. Brake master cylinder 2. Brake hose holder 3. Brake hoses a. While installing the brake hose, direct a bend in its pipe portion as shown, and bring it into contact with the projection on the brake caliper. B. Pass the brake hose into the brake hose holders. C. If the br...

  • Page 96

    Cable routing diagram 2-45.

  • Page 97

    3 periodic checks and adjustments periodic maintenance .............................................................................3-1 introduction ........................................................................................3-1 periodic maintenance chart for the emission control system ...

  • Page 98

    Adjusting the rear shock absorber assembly...................3-34 checking the tires...........................................................................3-36 checking and tightening the spokes.......................................3-36 checking the wheels .........................................

  • Page 99

    Periodic maintenance 3-1 eas2gc1074 periodic maintenance eas2gc1075 introduction this chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and ...

  • Page 100

    Periodic maintenance 3-2 eas2gc1077 general maintenance and lubrication chart no. Item checks and maintenance jobs initial odometer read- ings 600 mi (1000 km) or 1 month 1800 mi (3000 km) or 3 months 3000 mi (5000 km) or 6 months 1 clutch • check operation. • adjust or replace cable. 2 * cooling sy...

  • Page 101

    Periodic maintenance 3-3 tip • 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 fill the reservoir...

  • Page 102

    Periodic maintenance 3-4 eas2gc1078 maintenance intervals for competition use tip • 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 re- quired maintena...

  • Page 103

    Periodic maintenance 3-5 piston pin inspect replace cylinder head inspect carbon deposits and eliminate them. Inspect and clean change gasket. Cylinder inspect and clean inspect score marks. Inspect wear. Replace clutch inspect and adjust inspect housing, friction plate, clutch plate and spring. Rep...

  • Page 104

    Periodic maintenance 3-6 cooling system check coolant lev- el and leakage check radiator cap operation replace coolant every two years inspect hoses outside nuts and bolts retighten refer to “starting and break-in” on page 1-28. Air filter clean and lubri- cate use yamaha foam air filter oil or othe...

  • Page 105

    Periodic maintenance 3-7 brakes adjust lever posi- tion and pedal height lubricate pivot point check brake disc surface check fluid level and leakage retighten brake disc bolts, caliper bolts, master cylin- der bolts and union bolts replace pads replace brake flu- id every one year front forks inspe...

  • Page 106

    Periodic maintenance 3-8 swingarm inspect, lube and retighten molybdenum disulfide grease relay arm, con- necting rod inspect, lube and retighten molybdenum disulfide grease sidestand lubricate lithium-soap-based grease steering head inspect free play and retighten clean and lube lithium-soap-based ...

  • Page 107

    Pre-operation inspection and maintenance 3-9 eas2gc1079 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. Eas2gc1080 general inspection and ma...

  • Page 108

    Engine 3-10 eas2gc1081 engine eas2gc1082 checking the coolant level ewa warning if coolant seems hot, do not remove the ra- diator cap. 1. Stand the vehicle upright on a level surface. 2. Remove: • radiator cap “1” 3. Check: • coolant level maximum level “a” or below add coolant up to the maximum le...

  • Page 109

    Engine 3-11 3. Remove: • radiator cap slowly loosen the radiator cap to drain cool- ant. Tip when the radiator cap is loosened, coolant will gush out transversely; therefore, bring the con- tainer near to the outlet. 4. Thoroughly flush the cooling system with clean tap water. 5. Install: • copper w...

  • Page 110

    Engine 3-12 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas2gc1087 checking the coolant circulatory system for leaks 1. Check: • coolant level 2. Install: • radiator cap tester “1” • adapter “2” 3. Activate the tester to apply the test pressure. Eca notice • do not apply such a high pressure as ex- ceeds the t...

  • Page 111

    Engine 3-13 2. Adjust: • clutch lever free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ handlebar side a. Turn the adjuster “1” in direction “a” or “b” until the specified clutch lever free play is ob- tained. Tip if the clutch lever free play cannot be obtained on the handlebar side, use the adjuster on t...

  • Page 112

    Engine 3-14 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas2gc1090 lubricating the throttle cable 1. Remove: • cover (throttle cable cap) “1” • cover (grip cap) “2” • throttle grip cap “3” 2. Lubricate: • throttle cable end “a” 3. Install: • throttle grip cap • screw (throttle grip cap) 4. Install: • cover (gr...

  • Page 113

    Engine 3-15 notice do not twist the element when squeezing the element. 4. Check: • air filter element damage replace. 5. Yamaha foam air filter oil or other quality foam air filter oil. Tip squeeze out the excess oil. Element should be wet but not dripping. 6. Install: • air filter guide “1” (to th...

  • Page 114

    Engine 3-16 3. Check: • tightening torques 4. Install: • exhaust pipe protector eas2gc1095 checking the fuel line 1. Remove: • seat • side cover (left/right) • air scoop (left/right) refer to “general chassis” on page 5- 1. • fuel tank refer to “fuel tank” on page 8-1. 2. Check: • fuel hose “1” crac...

  • Page 115

    Engine 3-17 notice • since engine oil also lubricates the clutch, the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives. • do not allow foreign material to enter the crankcase. Eas2gc1097 changing the engine oil stand the vehicle upright on a leve...

  • Page 116

    Engine 3-18 c. Replace the o-ring “2”. D. Install the oil strainer. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • gasket • drain bolt 7. Pour the specified amount of engine oil into the oil filler cap hole. 8. Install: • oil filler cap 9. Check: • oil level refer to “checking the engine oil level” ...

  • Page 117

    Engine 3-19 eas2gc1098 adjusting the engine idling speed tip • because the air pressure is lower at high alti- tudes, the air-fuel mixture will become richer. If the idling speed is low, turn the starter knob/ idle screw a few clicks counterclockwise to in- crease the speed before the adjustment. • ...

  • Page 118

    Engine 3-20 eas2gc1099 adjusting the valve clearance tip • this section is intended for those who have basic knowledge and skill concerning the ser- vicing of yamaha motorcycles (e.G., yamaha dealers, service engineers, etc.). Those who have little knowledge and skill concerning ser- vicing are requ...

  • Page 119

    Engine 3-21 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Adjust: • valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the camshaft (intake and exhaust). Refer to “camshaft” on page 6-11. B. Remove the valve lifter “2” and the adjusting pad “3” with a valve lapper “1”. Tip • place a cloth in the timin...

  • Page 120

    Engine 3-22 e. Install the new adjusting pads “4” and the valve lifters “5”. Eca notice do not twist adjusting pads and valve lifters forcibly during installation. Tip • apply the engine oil on the valve lifters. • apply molybdenum disulfide oil to the valve stem ends. • check that the valve lifters...

  • Page 121

    Engine 3-23 intake example: valve clearance (cold) 0.13–0.20 mm (0.0051–0.0079 in) installed is 175 measured clearance 0.27 mm (0.0106 in) replace 175 pad with 185 pad pad no.175 = 1.75 mm (0.0689 in) pad no.185 = 1.85 mm (0.0728 in) 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 20...

  • Page 122

    Engine 3-24 exhaust example: valve clearance (cold) 0.18–0.25 mm (0.0071–0.0098 in) installed is 175 measured clearance 0.32 mm (0.0126 in) replace 175 pad with 185 pad pad no.175 = 1.75 mm (0.0689 in) pad no.185 = 1.85 mm (0.0728 in) eas2gc1100 cleaning the spark arrester refer to “cleaning the spa...

  • Page 123

    Chassis 3-25 eas2gc1101 chassis eas2gc1102 bleeding the brake system ewa warning bleed the brake system whenever: • the system is disassembled. • a brake hose is loosened, disconnected, or replaced. • the brake fluid level is very low. • brake operation is faulty. 1. Remove: • brake master cylinder ...

  • Page 124

    Chassis 3-26 eas2gc1103 checking the brake hose 1. Check: • brake hose “1” cracks/damage/wear replace. 2. Check: • brake hose clamp loose connection tighten the clamp bolt. 3. Stand the vehicle upright and apply the front brake and the rear brake several times. 4. Check: • brake hoses brake fluid le...

  • Page 125

    Chassis 3-27 eas2gc1105 adjusting the rear brake 1. Check: • brake pedal position “a” (distance from the top of the rider footrest to the top of the brake pedal) out of specification regulate. 2. Adjust: • brake pedal position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. B. Turn the a...

  • Page 126

    Chassis 3-28 c. Remove the brake caliper “3” from the front fork. D. Remove the pad pin and brake pads “4”. E. Connect the plastic hose “5” to the bleed screw “6” and place a container under the end of the plastic hose. F. Loosen the bleed screw and push the brake caliper piston in. Ewa warning do n...

  • Page 127

    Chassis 3-29 eas2gc1107 checking the rear brake pads 1. Measure: • brake pad thickness “a” out of specification replace as a set. Tip the pads worn up to the indicator “b” grooves mean that the brake pad thickness limit is reached. 2. Replace: • brake pads ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove ...

  • Page 128

    Chassis 3-30 i. Install the brake caliper “12” and the rear wheel “13”. Refer to “rear wheel” on page 5-9. J. Tighten the pad pin “14”. K. Install the pad pin plug “15” and the protector “16”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Check: • brake fluid level refer to “checking the brake fluid level” on...

  • Page 129

    Chassis 3-31 • when refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. Eca notice brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt br...

  • Page 130

    Chassis 3-32 3. Hold the vehicle upright and apply the front brake. 4. Check: • front fork operation push down hard on the handlebar several times and check if the front fork rebounds smoothly. Unsmooth operation correct or replace. Refer to “front fork” on page 5-40. Eas2gc1112 checking the front f...

  • Page 131

    Chassis 3-33 3. Tighten: • air bleed screw eas2gc1115 adjusting the front fork legs ewa warning • always adjust the left and right front forks evenly. If this is not done, the vehicle may have poor stability. • securely support the vehicle so that there is no danger of it falling over. Rebound dampi...

  • Page 132

    Chassis 3-34 eas2gc1116 checking the swingarm operation 1. Check: • swingarm smooth action • swingarm free play refer to “swingarm” on page 5-65. Eas2gc1117 checking the rear suspension 1. Stand the vehicle upright on a level surface. Ewa warning securely support the vehicle so that there is no dang...

  • Page 133

    Chassis 3-35 tip • be sure to remove all dirt and mud from around the locknut and adjusting ring before adjustment. • the length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjusting ring. E. Tighten the locknut. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • rear frame refer ...

  • Page 134

    Chassis 3-36 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ compression damping (for slow compres- sion damping) eca notice do not turn the adjuster forcibly beyond its adjusting range. 1. Adjust: • compression damping (for slow compres- sion damping) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjuster “1” in t...

  • Page 135

    Chassis 3-37 2. Tighten: • spokes use a spoke nipple wrench “1” for tighten- ing. Tip • do not give a half turn (180 °) or more for one tightening. • make sure that tightening after a break-in is done until the initial looseness in nipples dis- appears. • make sure that tightening is done in stages,...

  • Page 136

    Chassis 3-38 c. Turn the front fork to the right and left a few times, and make sure that the steering ro- tates smoothly. If it does not turn smoothly, remove the lower bracket and check the up- per and lower bearings. Refer to “steering head” on page 5-53. D. Loosen the ring nut fully turn and the...

  • Page 137

    Chassis 3-39 eas2gc1127 lubricating the drive chain the drive chain consists of many interacting parts. If the drive chain is not maintained prop- erly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas. This vehicle has a dri...

  • Page 138

    Electrical system 3-40 eas2gc1130 electrical system eas2gc1131 checking the spark plug 1. Remove: • seat • air scoop (left/right) refer to “general chassis” on page 5- 1. • fuel tank “1” refer to “fuel tank” on page 8-1. Eca notice do not use too much force to pull the hose. Tip remove the fuel tank...

  • Page 139

    Electrical system 3-41 2. Attach: • timing light “1” • digital tachometer “2” to the high tension code “3”. 3. Adjust: • engine idling speed refer to “adjusting the engine idling speed” on page 3-19. 4. Check: • ignition timing check whether the alignment mark “a” on the left crankcase cover is with...

  • Page 140

    Electrical system 3-42 4. Install: • headlight bulb fasten the new headlight bulb with the headlight bulb holder. Eca notice avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adv...

  • Page 141

    4 tuning chassis ..........................................................................................................4-1 selection of the secondary reduction ratio (sprocket) ............................................................................................4-1 drive and rear wheel sp...

  • Page 142

    Chassis 4-1 eas2gc1136 chassis eas2gc1137 selection of the secondary reduc- tion ratio (sprocket) reduction ratio> • it is generally said that the secondary gear ra- tio should be reduced for a longer straight por- tion of a speed course and should be increased for a course with many corners. Ac- tu...

  • Page 143

    Chassis 4-2 • under a stony or a hard road condition, the tire pressure should be higher to prevent a flat tire. Eas2gc1140 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 fol...

  • Page 144

    Chassis 4-3 tip generally a stiff spring gives a stiff riding feel- ing. Rebound damping tends to become weak- er, resulting in lack of a sense of contact with the road surface or in a vibrating handlebar. Eas2gc1143 front fork setting parts • front fork spring “1” tip the i.D. Mark (slits) “a” is p...

  • Page 145

    Chassis 4-4 tip • 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 reevalua- tion. • if the standard figure cannot be achieved by adjusting the adjuster and changing the set le...

  • Page 146

    Chassis 4-5 • spring preload adjusting positions tip for the spring preload adjustment, refer to “ad- justing the rear shock absorber assembly” on page 3-34. Spring preload adjusting positions minimum position in which the spring is turned in 1.5 mm (0.06 in) from its free length. Standard position ...

  • Page 147

    Chassis 4-6 eas2gc1148 suspension setting (front fork) tip • if any of the following symptoms is experienced with the standard position as the base, make reset- ting by reference to the adjustment procedure given in the same chart. • before any change, set the rear shock absorber sunken length to th...

  • Page 148

    Chassis 4-7 eas2gc1149 suspension setting (rear shock absorber) tip • if any of the following symptoms is experienced with the standard position as the base, make reset- ting by reference to the adjustment procedure given in the same chart. • adjust the rebound damping in 2-click increments or decre...

  • Page 149

    Chassis 4-8 heavy and dragging rebound damping force turn adjuster counterclock- wise (about 2 clicks) to de- crease damping. Spring replace with soft spring. Poor road grip- ping rebound damping force turn adjuster counterclock- wise (about 2 clicks) to de- crease damping. Low compres- sion damping...

  • Page 150

    Chassis 4-9.

  • Page 151

    5 chassis general chassis ........................................................................................5-1 removing the left side cover.......................................................5-3 removing the seat ................................................................................

  • Page 152

    Handlebar .................................................................................................5-33 removing the handlebar...............................................................5-35 checking the handlebar ...............................................................5-35 install...

  • Page 153

    General chassis 5-1 eas2gc1150 tip 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 knowl- edge and skill concerning servicing are requested not to undertake ins...

  • Page 154

    General chassis 5-2 removing the headlight assembly and multi-function meter order job/parts to remove q’ty remarks 1 headlight body 1 2 headlight coupler 1 disconnect. 3 headlight unit 1 4 speed sensor coupler 1 disconnect. 5 multi-function meter coupler 2 disconnect. 6 multi-function meter optiona...

  • Page 155

    General chassis 5-3 eas2gc1152 removing the left side cover 1. Remove: • bolt (side cover) • side cover “1” tip draw the left side cover “1” backward to re- move it because its projection “a” is inserted in the rear frame. Eas2gc1153 removing the seat tip the fuel tank cap cover and the seat are cou...

  • Page 156

    Front wheel 5-4 eas2gc1154 front wheel removing the front wheel order part name q’ty remarks use a suitable stand to raise the front wheel off the ground. 1 front wheel axle pinch bolt 4 loosen. 2 front wheel axle nut 1 3 front wheel axle 1 4 front wheel 1 5 speed sensor 1 6 collar 1 7 oil seal 1 8 ...

  • Page 157

    Front wheel 5-5 eas2gc1155 removing the front wheel 1. Use a suitable stand to raise the front wheel off the ground. Ewa warning securely support the vehicle so that there is no danger of it falling over. 2. Remove: • front wheel eas2gc1156 checking the front wheel 1. Check: • front wheel axle roll ...

  • Page 158

    Front wheel 5-6 eas2gc1157 disassembling the front wheel 1. Remove: • oil seals • bearings ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside of the front wheel hub. B. Remove the oil seals “1” with a flat-head screwdriver. Tip to prevent damaging the wheel, place a rag “2” between the screwdrive...

  • Page 159

    Front wheel 5-7 3. Install: • collar “1” tip apply the lithium-soap-based grease on the oil seal lip. 4. Install: • speed sensor “1” tip apply the lithium-soap-based grease on the oil seal lip of speed sensor. Make sure the two projections “a” in the wheel hub are meshed with the two slots “b” in th...

  • Page 160

    Front wheel 5-8 1 1.

  • Page 161

    Rear wheel 5-9 eas2gc1160 rear wheel removing the rear wheel order part name q’ty remarks use a suitable stand to raise the rear wheel off the ground. 1 nut (rear wheel axle) 1 2 rear wheel axle 1 3 drive chain puller 2 4 rear wheel 1 5 collars 2 6 rear wheel sprocket 1 7 oil seals 2 8 circlip 1 9 b...

  • Page 162

    Rear wheel 5-10 eas2gc1161 removing the rear wheel 1. Use a suitable stand to raise the rear wheel off the ground. Ewa warning securely support the vehicle so that there is no danger of it falling over. 2. Remove: • rear wheel axle nut “1” 3. Loosen: • locknut “2” 4. Tighten: • adjusting bolt “3” 5....

  • Page 163

    Rear wheel 5-11 tip tighten the self-locking nuts in stages and in a crisscross pattern. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas2gc1165 assembling the rear wheel 1. Install: • bearing (right side) “1” • circlip “2” • spacer “3” • bearing (left side) “4” • oil seals “5” tip • apply the lithium-soap-base...

  • Page 164

    Rear wheel 5-12 tip install the brake disc “1” between the brake pads “2” correctly. 2. Install: • drive chain “1” tip push the rear wheel “2” forward and install the drive chain. 3. Install: • left drive chain puller “1” • rear wheel axle “2” tip • install the left drive chain puller, and insert th...

  • Page 165

    Front brake 5-13 eas2gc1167 front brake removing the front brake caliper order part name q’ty remarks brake fluid drain. Refer to “bleeding the brake system” on page 3-25. 1 union bolt 1 2 copper washers 2 3 front brake hose 1 4 brake pad pin plug 1 5 brake pad pin 1 6 brake pads 2 7 brake pad sprin...

  • Page 166

    Front brake 5-14 disassembling the front brake caliper order part name q’ty remarks 1 brake caliper piston 2 2 brake caliper piston dust seal 2 3 brake caliper piston seal 2 4 bleed screw 1 for assembly, reverse the disassemble pro- cedure. 1 2 3 4 s s bf bf t r . . S 6 nm (0.6 m kgf, 4.3 ft ibf).

  • Page 167

    Front brake 5-15 removing the front brake master cylinder order part name q’ty remarks brake fluid drain. Refer to “bleeding the brake system” on page 3-25. 1 brake lever 1 2 union bolt 1 3 copper washers 2 4 front brake hose 1 5 brake master cylinder reservoir cap 1 6 brake master cylinder reservoi...

  • Page 168

    Front brake 5-16 disassembling the front brake master cylinder order part name q’ty remarks 1 push rod 1 2 dust boot 1 3 circlip 1 4 washer 1 5 brake master cylinder kit 1 for assembly, reverse the disassemble pro- cedure. Bf 5 4 3 2 1 s new new.

  • Page 169

    Front brake 5-17 eas2gc1168 introduction ewa warning if you need to disassemble the disc brake components, observe the following precau- tions. • never disassemble the brake components unless absolutely necessary. • if there is any problem with connections on the hydraulic brake system, perform the ...

  • Page 170

    Front brake 5-18 b. Remove the brake caliper piston dust seal and the brake caliper piston seal. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas2gc1172 checking the front brake caliper 1. Check: • brake caliper piston “1” rust/scratches/wear replace the brake caliper piston. • brake caliper cylinder “2” scratc...

  • Page 171

    Front brake 5-19 3. Install: • brake caliper piston “1” tip apply the brake fluid on the piston outer sur- face. Eca notice • install the piston with its side “a” facing the brake caliper. • never force to insert. Eas2gc1175 installing the front brake caliper 1. Install: • front brake caliper bracke...

  • Page 172

    Front brake 5-20 notice brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Bleed: • brake system refer to “bleeding the brake sys- tem” on page 3-25. 6. Check: • brake fluid level the minimum level mark or below add. Refer to “...

  • Page 173

    Front brake 5-21 3. Install: • spring “1” install to the brake master cylinder piston “2”. Tip install the spring with a smaller inside diameter to the brake master cylinder piston. 4. Install: • brake master cylinder kit “1” • washer “2” • circlip “3” • dust boot “4” • push rod “5” tip • before ins...

  • Page 174

    Front brake 5-22 tip turn the handlebar toward right and left to make sure that the brake hose does not touch other parts (e.G., wire harness, cables, leads). Adjust if necessary. 3. Pour brake fluid to the brake master cylinder reservoir up to the specified level. Ewa warning • use only the designa...

  • Page 175

    Rear brake 5-23 eas2gc1180 rear brake removing the rear brake caliper order part name q’ty remarks brake fluid drain. Refer to “bleeding the brake system” on page 3-25. 1 protector 1 2 union bolt 1 3 copper washers 2 4 rear brake hose 1 5 brake pad pin plug 1 6 brake pad pin 1 7 rear brake pad assem...

  • Page 176

    Rear brake 5-24 disassembling the rear brake caliper order part name q’ty remarks 1 brake caliper piston 1 2 brake caliper piston dust seal 1 3 brake caliper piston seal 1 4 bleed screw 1 for assembly, reverse the disassemble pro- cedure. 1 2 3 4 s bf t r . . 6 nm (0.6 m kgf, 4.3 ft ibf).

  • Page 177

    Rear brake 5-25 removing the rear brake master cylinder order part name q’ty remarks brake fluid drain. Refer to “bleeding the brake system” on page 3-25. 1 union bolt 1 2 copper washers 2 3 brake hose 1 4 split pin 1 5 washer 1 6 pin 1 7 brake master cylinder reservoir cap 1 8 brake master cylinder...

  • Page 178

    Rear brake 5-26 disassembling the rear brake master cylinder order part name q’ty remarks 1 dust boot 1 2 circlip 1 3 push rod 1 4 brake master cylinder kit 1 for assembly, reverse the disassemble pro- cedure. 4 3 2 1 bf s new new.

  • Page 179

    Rear brake 5-27 eas2gc1181 introduction ewa warning if you need to disassemble the disc brake components, observe the following precau- tions. • never disassemble the brake components unless absolutely necessary. • if there is any problem with connections on the hydraulic brake system, perform the f...

  • Page 180

    Rear brake 5-28 eas2gc1183 removing the rear brake caliper tip before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt • copper washers • brake hose tip put the end of the brake hose into a container and pump out the brake fluid. Eas2gc1184...

  • Page 181

    Rear brake 5-29 eas2gc1187 installing the brake caliper piston 1. Clean: • brake caliper • brake caliper piston seal • brake caliper piston dust seal • brake caliper piston use brake fluid for cleaning. 2. Install: • brake caliper piston seals “1” • brake caliper piston dust seal “2” ewa warning alw...

  • Page 182

    Rear brake 5-30 warning • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type of brake fluid that is already in the system. Mixing brake flu- ids may result in a harmful chemical re...

  • Page 183

    Rear brake 5-31 1. Wash the brake master cylinder and the brake master cylinder kit with brake fluid. 2. Install: • primary cylinder cup “1” • secondary cylinder cup “2” install to the brake master cylinder piston “3”. Ewa warning apply brake fluid to the cylinder cups and install them as shown. Wro...

  • Page 184

    Rear brake 5-32 2. Pour brake fluid to the brake fluid reservoir up to the specified level. Ewa warning • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type of brake fluid that is ...

  • Page 185

    Handlebar 5-33 eas2gc1193 handlebar removing the handlebar order part name q’ty remarks 1 clutch cable 1 disconnect. 2 clutch switch 1 3 clutch lever holder 1 4 engine stop switch 1 5 brake master cylinder 1 6 throttle cable cap 1 7 throttle cable (pull) 1 disconnect. 8 throttle cable (return) 1 dis...

  • Page 186

    Handlebar 5-34 15 handlebar lower holder 2 16 damper 4 for installation, reverse the removal proce- dure. Removing the handlebar order part name q’ty remarks.

  • Page 187

    Handlebar 5-35 eas2gc1194 removing the handlebar 1. Stand the vehicle on a level surface. Ewa warning securely support the vehicle so that there is no danger of it falling over. 2. Remove: • clutch switch “1” tip press the projection, and remove it from the clutch lever assembly. 3. Remove: • handle...

  • Page 188

    Handlebar 5-36 notice • first, tighten the bolts on the front side of the upper handlebar holder, and then on the rear side. • turn the handlebar all the way to the left and right. If there is any contact with the fuel tank, adjust the handlebar position. 3. Tighten: • lower handlebar holder nut 4. ...

  • Page 189

    Handlebar 5-37 5. Install: • engine stop switch “1” • clutch lever “2” • clutch lever holder “3” • clamp “4” tip • the engine stop switch, the clutch lever, and the clutch lever holder should be installed ac- cording to the dimensions shown. • pass the engine stop switch lead through the middle of t...

  • Page 190

    Handlebar 5-38 warning after tightening the throttle cable housing screws, check that the throttle grip “3” moves smoothly. If it does not, retighten the screws for adjustment. 10.Install: • rubber cover “1” • cover (throttle cable housings) “2” 11.Install: • start switch “1” • front brake master cy...

  • Page 191

    Handlebar 5-39 14.Adjust: • throttle grip free play refer to “adjusting the throttle grip free play” on page 3-13. Throttle grip free play 3.0–6.0 mm (0.12–0.24 in).

  • Page 192

    Front fork 5-40 eas2gc1197 front fork removing the front fork legs order part name q’ty remarks use a suitable stand to raise the front wheel off the ground. Front wheel refer to “front wheel” on page 5-4. Front brake caliper refer to “front brake” on page 5-13. 1 brake hose holder 2 2 protector 1 3...

  • Page 193

    Front fork 5-41 disassembling the front fork leg order part name q’ty remarks 1 adjuster 1 2 fork spring 1 3 dust seal 1 4 stopper ring 1 5 inner tube 1 6 outer tube 1 7 piston metal 1 8 protector guide 1 9 slide metal 1 10 washer 1 11 oil seals 1 12 base valve 1 13 damper assembly 1 for assembly, r...

  • Page 194

    Front fork 5-42 eas2gc1198 removing the front fork legs 1. Use a suitable stand to raise the front wheel off the ground. Ewa warning securely support the vehicle so that there is no danger of it falling over. Tip record the adjusting screw setting position be- fore loosening the adjuster and the bas...

  • Page 195

    Front fork 5-43 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Remove: • base valve “1” (from the damper assembly) tip hold the damper assembly with the cap bolt ring wrench “2” and use the cap bolt wrench “3” to remove the base valve. Eas2gc1200 checking the front fork legs 1. Check: • inner tube surface “a” ...

  • Page 196

    Front fork 5-44 5. Check: • base valve “1” wear/damage replace. Contamination clean. • o-rings “2” wear/damage replace. • base valve bushing “3” wear/damage replace. • spring “4” damage/fatigue replace the base valve. • air bleed screw “5” wear/damage replace. 6. Check: • contacting surface “a” wear...

  • Page 197

    Front fork 5-45 4. Measure: • oil level (left and right) “a” out of specification regulate. 5. Tighten: • locknut “1” tip fully finger tighten the locknut onto the damper assembly. 6. Loosen: • compression damping force adjuster “1” tip • before loosening the damping force adjuster, record the setti...

  • Page 198

    Front fork 5-46 9. Tighten: • base valve “1” tip hold the damper assembly with the cap bolt ring wrench “2” and use the cap bolt wrench “3” to tighten the base valve. 10.After filling, pump the damper assembly “1” slowly up and down more than 10 times to distribute the fork oil. 11.While protecting ...

  • Page 199

    Front fork 5-47 tip • apply the lithium-soap-based grease on the dust seal lip and oil seal lip. • apply the fork oil on the inner tube. • when installing the oil seal, use vinyl seat “a” with fork oil applied to protect the oil seal lip. 15.Install: • inner tube bushing “1” tip install the inner tu...

  • Page 200

    Front fork 5-48 19.Install: • oil seal clip “1” tip fit the oil seal clip correctly in the groove in the outer tube. 20.Install: • dust seal “1” tip apply lithium-soap-based grease on the inner tube. 21.Check: • inner tube smooth movement tightness/binding/rough spots repeat the steps 14 to 20. 22.M...

  • Page 201

    Front fork 5-49 24.Install: • damper assembly “1” (to the inner tube “2”) eca notice allow the damper assembly to slide slowly down the inner tube until it contacts the bot- tom of the inner tube. Be careful not to dam- age the inner tube. 25.Loosen: • rebound damping force adjuster “1” tip • before...

  • Page 202

    Front fork 5-50 29.Install: • adjuster “1” (to the inner tube) 30.Fill: • front fork leg eca notice • be sure to use the recommended oil. Other oils may have an adverse effect on front fork performance. • when disassembling and assembling the front fork leg, do not allow any foreign ma- terial to en...

  • Page 203

    Front fork 5-51 2. Tighten: • damper assembly “1” tip use the cap bolt ring wrench “2” to tighten the damper assembly. 3. Adjust: • front fork top end “a” 4. Tighten: • pinch bolt (upper bracket) “1” • pinch bolt (lower bracket) “2” ewa warning tighten the lower bracket to specified torque. If torqu...

  • Page 204

    Front fork 5-52 6. Install: • speed sensor lead “1” • plate 2 “2” (to the right front fork protector) tip install the plate 2 in the direction as shown. 7. Install: • protector “1” • bolt (protector) “2” 8. Adjust: • rebound damping force tip turn in the damping adjuster “1” finger-tight and then tu...

  • Page 205

    Steering head 5-53 eas2gc1203 steering head removing the lower bracket order part name q’ty remarks refer to “checking and adjusting the steering head” on page 3-37. Use a suitable stand to raise the front wheel off the ground. Headlight assembly/multi-function meter/front fender refer to “general c...

  • Page 206

    Steering head 5-54 for installation, reverse the removal proce- dure. Removing the lower bracket order part name q’ty remarks 2 4 5 7 3 (2) (2) (2) (2) (2) 1 6 8 9 10 ls ls t.R. 21 nm (2.1 m lbf) kgf, 15 ft t.R. 21 nm (2.1 m lbf) kgf, 15 ft t.R. 21 nm (2.1 m lbf) kgf, 15 ft t.R. 21 nm (2.1 m lbf) kg...

  • Page 207

    Steering head 5-55 eas2gc1204 removing the lower bracket 1. Use a suitable stand to raise the front wheel off the ground. Ewa warning securely support the vehicle so that there is no danger of it falling over. 2. Remove: • rng nut “1” tip remove the ring nut with the steering nut wrench “2”. Ewa war...

  • Page 208

    Steering head 5-56 tip apply the lithium-soap-based grease on the bearing and bearing race cover lip. 3. Install: • lower bracket “1” tip apply the lithium-soap-based grease on the bearing, the portion “a” and thread of the steer- ing stem. 4. Install: • steering ring nut “1” tip install the steerin...

  • Page 209

    Steering head 5-57 tip apply the lithium-soap-based grease to the contact surface of the steering stem nut when installing. 9. After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the steering ring nut little by little. 10.Adjust: • front fork to...

  • Page 210

    Rear shock absorber assembly 5-58 eas2gc1207 rear shock absorber assembly removing the rear shock absorber assembly order part name q’ty remarks seat refer to “general chassis” on page 5-1. Side cover (left / right) refer to “general chassis” on page 5-1. Air scoop (left / right) refer to “general c...

  • Page 211

    Rear shock absorber assembly 5-59 12 collars 2 13 o-ring 2 14 dust seal 2 15 stopper ring 1 16 bearing 1 for installation, reverse the removal proce- dure. Removing the rear shock absorber assembly order part name q’ty remarks 2 12 16 15 14 13 12 14 4 5 7 6 8 3 9 9 10 10 11 1 new new 13 new ls ls m ...

  • Page 212

    Rear shock absorber assembly 5-60 disassembling the relay arm order part name q’ty remarks 1 relay arm 1 2 connecting arm 1 3 collars 3 4 oil seals 6 5 washers 8 6 bearing 6 for assembly, reverse the disassemble pro- cedure. 5 3 5 6 1 6 5 4 5 5 4 5 6 6 5 4 3 2 4 6 6 3 4 4 t.R. 80 nm (8.0 m lbf) kgf,...

  • Page 213

    Rear shock absorber assembly 5-61 eas2gc1208 handling the rear shock absorber ewa warning this rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure that you understand the following in- formation. The manufacturer cannot be held res...

  • Page 214

    Rear shock absorber assembly 5-62 2. Remove: • upper bearing “1” tip remove the bearing by pressing its outer race. 3. Remove: • lower bearing “1” tip remove the bearing by pressing its outer race. Eas2gc1212 checking the rear shock absorber assembly 1. Check: • rear shock absorber rod bends/damage ...

  • Page 215

    Rear shock absorber assembly 5-63 3. Install: • bearing “1” • oil seals “2” (to connecting arm “3”) eas2gc1215 installing the rear shock absorb- er assembly 1. Lubricate: • bearing (lower side) • dust seal • collars • bushing eca notice do not apply the grease to the bearing outer race because it wi...

  • Page 216

    Rear shock absorber assembly 5-64 7. Tighten: • rear shock absorber assembly upper bolt • connecting arm bolt (frame side) • connecting arm bolt (relay arm side) • relay arm bolt (swingarm side) • rear shock absorber assembly lower bolt rear shock absorber assembly upper bolt 56 nm (5.6 m·kgf, 41 ft...

  • Page 217

    Swingarm 5-65 eas2gc1216 swingarm removing the swingarm order part name q’ty remarks use a suitable stand to raise the front wheel off the ground. Brake hose holder refer to “rear brake” on page 5-23. Rear brake caliper refer to “rear brake” on page 5-23. Bolt (brake pedal) drive chain 1 collars 2 2...

  • Page 218

    Swingarm 5-66 eas2gc1217 removing the swingarm 1. Use a suitable stand to raise the rear wheel off the ground. Ewa warning securely support the vehicle so that there is no danger of it falling over. 2. Measure: • swingarm side play • swingarm vertical movement ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Mea...

  • Page 219

    Swingarm 5-67 eas2gc1220 installing the swingarm 1. Lubricate: • bearing • collars • spacers • oil seal • pivot shaft 2. Install: • bearing “1” • oil seals “2” (to the swingarm) tip first install the outer and then the inner bear- ings to a specified depth from inside. 3. Install: • swingarm tip ins...

  • Page 220

    Chain drive 5-68 eas2gc1221 chain drive removing the drive chain job order part name q’ty servicing information drive sprocket refer to “engine removal” on page 6-1. 1 drive chain 1 for installation, reverse the removal proce- dure. 1 t.R. 75 nm (7.5 m lbf) kgf, 54 ft t.R. 7 nm (0.7 m lbf) kgf, 5.1 ...

  • Page 221

    Chain drive 5-69 eas23420 removing the drive chain 1. Stand the vehicle on a level surface. Ewa warning securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • drive chain tip cut the drive...

  • Page 222

    Chain drive 5-70 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • o-rings “1” damage replace the drive chain. • drive chain rollers “2” damage/wear replace the drive chain. • drive chain side plates “3” damage/wear replace the drive chain. 5. Lubricate: • drive chain eas2gc1222 checking the drive sprock...

  • Page 223

    Chain drive 5-71 c. After riveting, make sure the space “c”, which is inside of the connecting link “3” and inside of the connecting plate “1”, is 14.1– 14.3 mm (0.56–0.65 in). ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Lubricate: • drive chain 3. Install: • drive sprocket • lock washer • drive sprocket nu...

  • Page 224

    Chain drive 5-72.

  • Page 225

    6 engine engine removal .........................................................................................6-1 removing the silencer.....................................................................6-6 removing the exhaust pipe 2..........................................................6-6 ...

  • Page 226

    Clutch .........................................................................................................6-41 removing the clutch ......................................................................6-44 checking the friction plates......................................................6-44 c...

  • Page 227

    Generator and starter clutch .......................................................6-63 removing the generator ..............................................................6-65 checking the starter clutch .....................................................6-65 installing the starter clutch ........

  • Page 228

    Engine removal 6-1 eas2gc1225 tip 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 knowl- edge and skill concerning servicing are requested not to undertake insp...

  • Page 229

    Engine removal 6-2 4 exhaust pipe 2 1 5 exhaust pipe 1 1 6 gaskets 3 7 exhaust pipe 1 protector 1 8 exhaust pipe 2 protector 1 9 silencer cap 1 10 spark arrester 1 for installation, reverse the removal proce- dure. Removing the exhaust pipe order part name q’ty remarks 10 5 9 2 6 1 6 6 3 8 4 7 (4) (...

  • Page 230

    Engine removal 6-3 removing the electronic parts order part name q’ty remarks use a suitable stand to raise the front wheel off the ground. Seat refer to “general chassis” on page 5-1. Side cover (left/right) refer to “general chassis” on page 5-1. Air scoop (left / right) refer to “general chassis”...

  • Page 231

    Engine removal 6-4 removing the engine order part name q’ty remarks use a suitable stand to raise the front wheel off the ground. Seat refer to “general chassis” on page 5-1. Side cover (left/right) refer to “general chassis” on page 5-1. Air scoop (left / right) refer to “general chassis” on page 5...

  • Page 232

    Engine removal 6-5 5 drive sprocket cover 1 6 drive chain guide 1 7 drive sprocket 1 8 upper engine bracket 2 9 lower engine bracket 2 10 pivot shaft 1 11 engine 1 for installation, reverse the removal proce- dure. Removing the engine order part name q’ty remarks new new ls m 8 8 7 6 11 4 5 new 1 10...

  • Page 233

    Engine removal 6-6 eas2gc1227 removing the silencer 1. Remove: • rear shock absorber assembly lower bolt “1” • connecting arm bolt (relay arm side) “2” • silencer “3” tip move the rear shock absorber to the left side of the chassis, and remove the silencer. Eas2gc1228 removing the exhaust pipe 2 1. ...

  • Page 234

    Engine removal 6-7 eas2gc1230 removing the engine 1. Remove: • pivot shaft “1” tip if the pivot shaft is pulled all the way out, the swingarm will come loose. If possible, insert a shaft of similar diameter into the other side of the swingarm to support it. 2. Remove: • engine “1” from the right sid...

  • Page 235

    Engine removal 6-8 5. Install: • spark arrester gasket • spark arrester insert the spark arrester into the muffler and align the bolt holes. • tail pipe gasket • spark arrester bolts 6. Install: • muffler cap tip first tighten the two screws “a” located horizon- tally apart, and then tighten the oth...

  • Page 236

    Engine removal 6-9 eas2gc1234 installing the brake pedal 1. Install: • spring “1” • brake pedal “2” • o-rings “3” • bolt (brake pedal) “4” • clip “5” tip apply the lithium-soap-based grease on the bolt, o-rings and brake pedal bracket. Eas2gc1235 installing the drive sprocket 1. Install: • drive spr...

  • Page 237

    Engine removal 6-10 2. Install: • clamp • exhaust pipe 2 “1” • bolt (exhaust pipe 2) “2” tip install and temporarily tighten the exhaust pipe 2 with its end positioned as shown with respect to the exhaust pipe 1. 3. Install: • clamp • silencer “1” • bolt (silencer) “2” tip install and temporarily ti...

  • Page 238

    Camshaft 6-11 eas2gc1237 camshaft removing the cylinder head cover order part name q’ty remarks seat refer to “general chassis” on page 5-1. Side cover (left/right) refer to “general chassis” on page 5-1. Air scoop (left / right) refer to “general chassis” on page 5-1. Fuel tank refer to “fuel tank”...

  • Page 239

    Camshaft 6-12 removing the camshaft order part name q’ty remarks 1 timing mark accessing screw 1 2 crankshaft end accessing screw 1 3 timing chain tensioner cap bolt 1 4 timing chain tensioner 1 5 camshaft cap 2 6 clip 2 7 intake camshaft 1 8 exhaust camshaft 1 for installation, reverse the removal ...

  • Page 240

    Camshaft 6-13 eas2gc1238 removing the camshaft 1. Remove: • timing mark accessing screw “1” • crankshaft end accessing screw “2” 2. Align: • alignment mark ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise with a wrench. B. Align the top dead center (tdc) mark “a” on the rotor...

  • Page 241

    Camshaft 6-14 eas2gc1239 checking the camshaft 1. Check: • camshaft lobes blue discoloration/pitting/scratches re- place the camshaft. 2. Measure: • camshaft lobe dimensions “a” and “b” out of specification replace the cam- shaft. 3. Measure: • camshaft runout out of specification replace. 4. Measur...

  • Page 242

    Camshaft 6-15 c. Install the dowel pins and the camshaft caps. Tip • tighten the camshaft cap bolts in a crisscross pattern from innermost to outer caps. • do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance. D. Remove the camshaft caps and then mea- sure the width...

  • Page 243

    Camshaft 6-16 eas2gc1242 checking the decompression sys- tem 1. Check: • decompression system ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check that the decompressor cam “1” moves smoothly. B. Check that the decompressor lever pin “2” projects from the camshaft. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas2gc1243 i...

  • Page 244

    Camshaft 6-17 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install: • timing chain tensioner ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. While pressing the tensioner rod lightly with your fingers, use a thin screwdriver to wind the tensioner rod up fully clockwise. B. With the tensioner rod fully wound and the chain...

  • Page 245

    Cylinder head 6-18 eas2gc1244 cylinder head removing the cylinder head order part name q’ty remarks refer to “installing the cylinder head” on page 6-21. Seat refer to “general chassis” on page 5-1. Side cover (left/right) refer to “general chassis” on page 5-1. Air scoop (left / right) refer to “ge...

  • Page 246

    Cylinder head 6-19 5 cylinder head gasket 1 6 timing chain guide (intake side) 1 7 oil check bolt 2 8 oil passage plug 1 for installation, reverse the removal proce- dure. Removing the cylinder head order part name q’ty remarks 8 6 7 7 10 nm (1.0 m kgf, 7.2 ft ibf) t.R. 10 nm (1.0 m kgf, 7.2 ft ibf)...

  • Page 247

    Cylinder head 6-20 eas2gc1245 removing the cylinder head 1. Remove: • cylinder head bolts tip • loosen the bolts in the proper sequence as shown. • loosen each bolt 1/2 of a turn at a time. After fully loosening all the bolts, remove them. • m6 35 mm (1.38 in): “1” – “2” • m10 149 mm (5.87 in): “3” ...

  • Page 248

    Cylinder head 6-21 eas2gc1248 installing the cylinder head 1. Install: • timing chain guide (intake side) “1” • dowel pins “2” • cylinder head gasket • dowel head “4” tip while pulling up the timing chain, install the tim- ing chain guide (intake side) and the cylinder head. 2. Install: • washer “1”...

  • Page 249

    Cylinder head 6-22 i. Retighten the cylinder head mounting bolts 150° in the proper tightening sequence. Tip tighten the bolts in two steps (90° and 60°) to reach the specified angle in the proper tighten- ing sequence. J. Tighten the bolts to the specified torque. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b...

  • Page 250

    Valves and valve springs 6-23 eas2gc1249 valves and valve springs removing the valves and valve springs order part name q’ty remarks cylinder head refer to “cylinder head” on page 6-18. 1 valve lifter 4 2 adjusting pad 4 3 valve cotter 8 4 valve spring retainer 4 5 valve spring 4 6 valve stem seal 4...

  • Page 251

    Valves and valve springs 6-24 eas2gc1250 removing the valves tip before removing the internal parts of the cylin- der head (e.G., valves, valve springs, valve seats), make sure that the valves are properly sealed. 1. Remove: • valve lifter “1” • adjusting pad “2” tip • place a cloth in the timing ch...

  • Page 252

    Valves and valve springs 6-25 4. Remove: • valve spring retainer “1” • valve spring “2” • valve “3” • valve stem seal “4” • valve spring seat “5” tip identify the position of each part very carefully so that it can be reinstalled in its original place. Eas2gc1251 checking the valves and valve guides...

  • Page 253

    Valves and valve springs 6-26 c. After installing the valve guide, expand the hole in the valve guide with the valve guide reamer “3” to obtain the proper valve-stem- to-valve-guide clearance. Tip after replacing the valve guide, reface the valve seat. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Eliminate: ...

  • Page 254

    Valves and valve springs 6-27 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply mechanic’s blueing dye (dykem) “b” onto the valve face. B. Install the valve into the cylinder head. C. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion. D. Measure the valve seat cont...

  • Page 255

    Valves and valve springs 6-28 g. Apply mechanic’s blueing dye (dykem) “b” onto the valve face. H. Install the valve into the cylinder head. I. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion. J. Measure the valve seat contact width “c” again. If the valve...

  • Page 256

    Valves and valve springs 6-29 eas2gc1254 checking the valve lifters 1. Check: • valve lifter damage/scratches replace the valve lift- ers and cylinder head. Eas2gc1255 installing the valves 1. Clean: • valve stem end 2. Lubricate: • valve stem “1” • valve stem seal “2” 3. Install: • spring seat “1” ...

  • Page 257

    Valves and valve springs 6-30 5. To fasten the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. Eca notice hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • adjusting pad “1” • valve lifter “2” 7. Install: • adjusting pad • valve ...

  • Page 258

    Cylinder and piston 6-31 eas2gc1256 cylinder and piston removing the cylinder and piston order part name q’ty remarks cylinder head refer to “cylinder head” on page 6-18. 1 cylinder body 1 2 gaskets 1 3 dowel pin 2 4 piston pin clip 2 5 piston pin 1 6 piston 1 7 piston ring set 1 for installation, r...

  • Page 259

    Cylinder and piston 6-32 eas2gc1257 removing the piston 1. Remove: • piston pin clips “1” • piston pin “2” • piston “3” eca13810 notice do not use a hammer to drive the piston pin out. Tip • before removing the piston pin clip, cover the crankcase opening with a cloth to prevent the piston pin clip ...

  • Page 260

    Cylinder and piston 6-33 b. If out of specification, rebore or replace the cylinder, and replace the piston and the pis- ton rings as a set. C. Measure the piston outside diameter “a” at the measuring point (from piston skirt bot- tom) “b” with the micrometer. D. If out of specification, replace the...

  • Page 261

    Cylinder and piston 6-34 3. Measure: • piston ring end gap out of specification replace the piston ring. Tip the oil ring expander’s end gap cannot be measured. If the oil ring rail’s gap is excessive, replace all three oil rings. Eas2gc1260 checking the piston pin 1. Check: • piston pin blue discol...

  • Page 262

    Cylinder and piston 6-35 2. Install: • piston “1” • piston pin “2” • piston pin clips “3” tip • apply molybdenum disulfide oil to the piston pin. • install the piston with the f mark “a” on it pointing to its intake (front) side. • before installing the piston pin clip, cover the crankcase opening w...

  • Page 263

    Electric starter 6-36 eas2gc1262 electric starter removing the starter motor order job/parts to remove q’ty remarks exhaust pipe refer to “engine removal” on page 6-1. 1 starter motor cover 1 2 starter motor lead 1 3 starter motor 1 for assembly, reverse the disassemble pro- cedure. 1 12 nm (1.2 m k...

  • Page 264

    Electric starter 6-37 disassembling the starter motor order job/parts to remove q’ty remarks 1 starter motor front cover 1 2 starter motor yoke 1 3 armature assembly 1 4 starter motor rear cover 1 5 brush set 2 for assembly, reverse the disassembly pro- cedure..

  • Page 265

    Electric starter 6-38 eas2gc1263 checking the starter motor 1. Check: • commutator dirt clean with 600 grit sandpaper. 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 proper measurement ...

  • Page 266

    Electric starter 6-39 7. Check: • gear teeth damage/wear replace the starter motor. 8. Check: • oil seal damage/wear replace the defective part (s). Eas2gc1264 assembling the starter motor 1. Install: • brush spring “1” • brush “2” tip align the corner of brush terminal “a” with groove “b” and fit t...

  • Page 267

    Electric starter 6-40 6. Install: • starter motor “1” • starter motor cover “2” • starter motor bolt “3” • starter motor cover bolt “4” tip pass the ac magneto lead “5” and the starter motor laed “6” under the left crankcase cover “a” as shown. Starter motor bolt 12 nm (1.2 m·kgf, 8.7 ft·lbf) starte...

  • Page 268

    Clutch 6-41 eas2gc1265 clutch removing the clutch order part name q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-17. Brake pedal refer to “engine removal” on page 6-1. 1 clutch cable 1 disconnect. 2 clutch cover 1 3 o-ring 1 4 clutch spring 6 5 pressure plate 1 6 push ro...

  • Page 269

    Clutch 6-42 14 friction plate 2 5 identification color (purple) 15 clutch plate 2 3 thickness:1.6 mm (0.063 in) 16 cushion spring 1 17 clutch boss 1 18 thrust washer 1 19 primary driven gear 1 20 push lever shaft 1 for installation, reverse the removal proce- dure. Removing the clutch order part nam...

  • Page 270

    Clutch 6-43 removing the right crankcase cover order part name q’ty remarks engine guard refer to “engine removal” on page 6-1. Engine oil drain. Refer to “changing the engine oil” on page 3-17. Coolant drain. Refer to “changing the coolant” on page 3-10. Brake pedal refer to “engine removal” on pag...

  • Page 271

    Clutch 6-44 eas2gc1266 removing the clutch 1. Remove: • clutch boss nut “1” • conical washer “2” • clutch boss “3” tip while holding the clutch boss with the clutch holder “4”, loosen the clutch boss nut. Eas2gc1267 checking the friction plates 1. Check: • friction plate damage/wear replace the fric...

  • Page 272

    Clutch 6-45 eas2gc1270 checking the clutch housing 1. Check: • clutch housing dogs “a” damage/pitting/wear deburr the clutch housing dogs or replace the clutch housing. Tip pitting on the clutch housing dogs will cause er- ratic clutch operation. Eas2gc1271 checking the clutch boss 1. Check: • clutc...

  • Page 273

    Clutch 6-46 eas2gc1276 checking the primary driven gear 1. Check: • primary driven gear damage/wear replace the primary drive and primary driven gears as a set. Excessive noise during operation re- place the primary drive and primary driven gears as a set. Eas2gc1277 installing the oil seal 1. Insta...

  • Page 274

    Clutch 6-47 2. Install: • primary driven gear “1” • thrust washer “2” • clutch boss “3” tip apply the engine oil on the primary driven gear inner circumference. 3. Install: • conical washer “1” • clutch boss nut “2” eca1dx1020 notice make sure to tighten to specification; other- wise, it may damage ...

  • Page 275

    Clutch 6-48 5. Install: • bearing “1” • washer “2” • circlip “3” to push rod 1 “4”. Tip apply the engine oil on the bearing and washer. 6. Install: • push rod 2 “1” • ball “2” • push rod 1 “3” tip apply the engine oil on the push rod 1, 2 and ball. 7. Install: • pressure plate “1” 8. Install: • clut...

  • Page 276

    Clutch 6-49 eas2gc1280 installing the kickstarter lever 1. Install: • kickstarter lever “1” • washer • bolt (kickstarter lever) tip install so that there is a clearance “a” of 5 mm (0.2 in) or more between the kickstarter lever and the frame and that the kickstarter lever does not contact the right ...

  • Page 277

    Kickstater 6-50 eas2gc1281 kickstater removing the kick shaft order part name q’ty remarks primary driven gear refer to “clutch” on page 6-41. 1 kick idle gear 1 2 kick shaft assembly 1 3 spring guide 1 4 torsion spring 1 5 ratchet wheel 1 6 kick gear 1 7 kick shaft 1 for installation, reverse the r...

  • Page 278

    Kickstater 6-51 eas2gc1282 removing the kick shaft assembly 1. Remove: • kick shaft assembly “1” tip unhook the torsion spring “2” from the hole “a” in the crankcase. Eas2gc1283 checking the kick shaft and ratch- et wheel 1. Check: • ratchet wheel “1” smooth movement unsmooth movement replace. • kic...

  • Page 279

    Kickstater 6-52 3. Install: • spring guide “1” tip slide the spring guide into the kick shaft, make sure the groove “a” in the spring guide fits on the stopper of the torsion spring. 4. Install: • kick shaft assembly “1” tip • before installation, apply molybdenum disul- fide grease to the contactin...

  • Page 280

    Shift shaft 6-53 eas2gc1287 shift shaft removing the shift shaft and stopper lever order part name q’ty remarks primary driven gear refer to “clutch” on page 6-41. 1 shift pedal 1 2 shift shaft 1 3 oil seal 1 4 collar 1 5 shift shaft spring 1 6 roller 1 7 shift guide 1 8 shift lever assembly 1 9 shi...

  • Page 281

    Shift shaft 6-54 eas2gc1288 removing the shift guide and shift lever assembly 1. Remove: • bolt (shift guide) • shift guide “1” • shift lever assembly “2” tip make sure that the shift lever assembly is re- moved together with the shift guide. Eas2gc1289 removing the segment 1. Remove: • bolt (segmen...

  • Page 282

    Shift shaft 6-55 eas2gc1293 installing the stopper lever 1. Install: • torsion spring “1” • collar “2” • stopper lever “3” • bolt (stopper lever) “4” eas2gc1294 installing the segment 1. Install: • segment “1” • segment bolt tip • align the notch “a” on the segment with the pin “b” on the shift cam....

  • Page 283

    Shift shaft 6-56 4. Tighten: • shift guide bolt “1” eas2gc1296 installing the shift shaft 1. Install: • roller “1” • shift haft spring “2” (to shift shaft) • collar “3” (to shift shaft) • shift shaft “4” tip apply the engine oil on the roller, collar and shift shaft. 2. Install: • oil seal eas2gc129...

  • Page 284

    Oil pump and balancer gear 6-57 eas2gc1298 oil pump and balancer gear removing the oil pump order part name q’ty remarks primary driven gear refer to “clutch” on page 6-41. Right crankcase cover refer to “clutch” on page 6-41. 1 oil pump assembly 1 2 oil pump cover 1 3 outer rotor 1 4 dowel pin 1 5 ...

  • Page 285

    Oil pump and balancer gear 6-58 removing the balancer order part name q’ty remarks primary driven gear refer to “clutch” on page 6-41. Right crankcase cover refer to “clutch” on page 6-41. Generator rotor refer to “generator and starter clutch” on page 6-63. 1 nut (balancer) 1 2 nut (primary drive g...

  • Page 286

    Oil pump and balancer gear 6-59 eas2gc1299 removing the balancer 1. Loosen: • balancer nut “1” • primary drive gear nut “2” • balancer weight gear nut “3” tip place an aluminum plate “a” between the teeth of the balancer drive gear “4” and balancer weight gear “5”. Eas2gc1300 checking the primary dr...

  • Page 287

    Oil pump and balancer gear 6-60 3. Check: • oil pump operation rough movement repeat steps (1) and (2) or replace the defective part(s). Eas2gc1303 assembling the oil pump 1. Install: • oil pump drive shaft “1” • inner rotor “2” • dowel pin “3” tip • apply the engine oil on the oil pump drive shaft ...

  • Page 288

    Oil pump and balancer gear 6-61 eas2gc1304 installing the oil pump and balanc- er gear 1. Install: • oil pump assembly “1” • oil pump assembly bolt “2” eca1dx1023 notice after tightening the bolts, make sure that the oil pump turns smoothly. 2. Install: • balancer weight gear “1” tip install the bal...

  • Page 289

    Oil pump and balancer gear 6-62 5. Bend the lock washer tab. 1 2 11 10 a 3 4 5 10 11 a b 3.

  • Page 290

    Generator and starter clutch 6-63 eas2gc1305 generator and starter clutch removing the generator order job/parts to remove q’ty remarks drain the engine oil. Refer to “changing the engine oil” on page 3-17. Seat and fuel tank refer to “general chassis” on page 5-1 and “fuel tank” on page 8-1. Discon...

  • Page 291

    Generator and starter clutch 6-64 11 starter clutch 1 12 starter clutch drive gear 1 13 crankshaft position sensor 1 14 stator 1 for installation, reverse the removal proce- dure. Removing the generator order job/parts to remove q’ty remarks t r . . T r . . T r . . 5 5 10 8 7 6 2 1 13 3 4 11 9 12 t ...

  • Page 292

    Generator and starter clutch 6-65 eas2gc1306 removing the generator 1. Remove: • generator rotor nut “1” • washer 2. Remove: • generator rotor “1” (with the rotor puller “2”) • woodruff key eas2gc1307 checking the starter clutch 1. Check: • starter clutch rollers damage/wear replace. 2. Check: • sta...

  • Page 293

    Generator and starter clutch 6-66 eas2gc1308 installing the starter clutch 1. Install: • stator “1” • stator bolt “2” • crankshaft position sensor “3” • holder “4” • crankshaft position sensor bolt “5” tip • pass the stator coil lead between ribs “a”, and put it in part “b” so that there is no slack...

  • Page 294

    Generator and starter clutch 6-67 3. Install: • starter clutch “1” to generator rotor “2”. Eas2gc1309 installing the generator 1. Install: • woodruff key “1” • generator rotor “2” tip • clean the contact surfaces of the tapered por- tions of the crankshaft and generator rotor. • when installing the ...

  • Page 295

    Generator and starter clutch 6-68 5. Install: • washer “1” • damper assembly “2” • washer “3” tip apply the engine oil to the shaft and washers. 6. Install: • cover (damper assembly) “1” • bracket “2” • bolt “3” tip install the cover (damper assembly) with its mark “a” facing upward. Bolt 10 nm (1.0...

  • Page 296

    Crankcase 6-69 eas2gc1310 crankcase separating the crankcase order part name q’ty remarks engine refer to “engine removal” on page 6-1. Piston refer to “cylinder and piston” on page 6-31. Balancer refer to “oil pump and balancer gear” on page 6-57. Kick shaft assembly refer to “kickstater” on page 6...

  • Page 297

    Crankcase 6-70 10 crankshaft 1 11 oil nozzle 1 for assembly, reverse the disassemble pro- cedure. Separating the crankcase order part name q’ty remarks 10 nm (1.0 m kgf, 7.2 ft ibf) t.R. 12 nm (1.2 m kgf, 8.7 ft ibf) t.R. 3 1 5 2 6 4 10 5 5 4 4 4 4 6 9 7 8 11 9 lt 10 nm (1.0 m kgf, 7.2 ft ibf) t.R. ...

  • Page 298

    Crankcase 6-71 removing the bearing and oil seal order part name q’ty remarks transmission refer to “transmission” on page 6-77. Shift cam and shift fork refer to “transmission” on page 6-77. 1 circlip 1 2 oil seals 3 3 bearing 11 for installation, reverse the removal proce- dure. Lt lt lt lt lt 1 2...

  • Page 299

    Crankcase 6-72 eas2gc1311 disassembling the crankcase 1. Separate: • right crankcase • left crankcase ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the crankcase bolts. Tip loosen each bolt 1/4 of a turn at a time and af- ter all the bolts are loosened, remove them. B. Remove the right crankcase “1”. T...

  • Page 300

    Crankcase 6-73 • oil delivery passages obstruction blow out with compressed air. Eas2gc1315 installing the oil seal 1. Install: • oil seal “1” (to left crankcase) eas2gc1316 assembling the crankcase 1. Install: • bearing cover plate tip • install the bearing by pressing its outer race parallel. • to...

  • Page 301

    Crankshaft assembly and balancer shaft 6-74 eas2gc1317 crankshaft assembly and balancer shaft removing the crankshaft assembly and balancer shaft order part name q’ty remarks crankcase separate. Refer to “crankcase” on page 6-69. Transmission refer to “transmission” on page 6-77. 1 balancer shaft 1 ...

  • Page 302

    Crankshaft assembly and balancer shaft 6-75 eas2gc1318 removing the balancer shaft 1. Remove: • balancer shaft “1” tip remove the balancer shaft with its flat side “a” facing the crankshaft. Eas2gc1319 removing the crankshaft assembly 1. Remove: • crankshaft assembly “1” tip remove the crankshaft as...

  • Page 303

    Crankshaft assembly and balancer shaft 6-76 4. Check: • crankshaft sprocket “1” damage replace the crankshaft. 5. Check: • crankshaft journal oil passage obstruction blow out with compressed air. Eas2gc1321 installing the crankshaft assem- bly 1. Install: • crankshaft assembly tip install the cranks...

  • Page 304

    Transmission 6-77 eas2gc1322 transmission removing the transmission, shift drum assembly, and shift forks order part name q’ty remarks engine refer to “engine removal” on page 6-1. Crankcase separate. Refer to “crankcase” on page 6-69. 1 main axle 1 2 drive axle 1 3 long shift fork guide bar 1 4 sho...

  • Page 305

    Transmission 6-78 eas2gc1323 removing the transmission 1. Remove: • long shift fork guide bar “1” • short shift fork guide bar “2” • shift cam “3” • shift fork 3 “4” • shift fork 2 “5” • shift fork 1 “6” • main axle “7” • drive axle “8” • collar “9” tip • remove assembly with the collar “9” installe...

  • Page 306

    Transmission 6-79 eas2gc1325 checking the shift drum assembly 1. Check: • shift drum groove damage/scratches/wear replace the shift drum assembly. • shift drum segment “1” damage/wear replace the shift drum as- sembly. Eas2gc1326 checking the transmission 1. Measure: • main axle runout (with a cente...

  • Page 307

    Transmission 6-80 2. Install: • collar “1” • 2nd wheel gear (26t) “2” • 4th wheel gear (21t) “3” • 3rd wheel gear (21t) “4” • 5th wheel gear (21t) “5” • collar “6” • 1st wheel gear (29t) “7” • o-rings “8” (to the drive axle “9”) tip • before installation, apply molybdenum disul- fide oil to the inne...

  • Page 308

    Transmission 6-81 6. Install: • shift fork 1 (l) “1” • shift fork 2 (c) “2” • shift fork 3 (r) “3” • shift cam “4” (to the main axle and the drive axle) tip • apply engine oil to the shift fork grooves. • apply engine oil to the shift cam groove and the bearing contact surface. • mesh the shift fork...

  • Page 309

    7 cooling system radiator .......................................................................................................7-1 handling note ......................................................................................7-3 checking the radiator.............................................

  • Page 310

    Radiator 7-1 eas2gc1328 tip 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 knowl- edge and skill concerning servicing are requested not to undertake inspection...

  • Page 311

    Radiator 7-2 4 right radiator 1 5 radiator hose 2 1 6 radiator hose 3 1 7 radiator hose 4 1 8 radiator pipe 2 1 9 radiator breather hose 1 10 left radiator 1 11 radiator hose 1 1 12 radiator pipe 1 1 13 coolant temperature sensor 1 for installation, reverse the removal proce- dure. Removing the radi...

  • Page 312

    Radiator 7-3 eas2gc1330 handling note ewa warning if coolant seems hot, do not remove the ra- diator cap. Eas2gc1331 checking the radiator 1. Check: • radiator fins “1” obstructions clean. Apply compressed air to the rear of the radi- ator. Damage repair or replace. Tip correct any flattened fins wi...

  • Page 313

    Water pump 7-4 eas2gc1332 water pump removing the water pump order part name q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-10. Engine oil drain. Refer to “changing the engine oil” on page 3-17. Right crankcase cover refer to “clutch” on page 6-41. 1 water pump housing 1 2 dow...

  • Page 314

    Water pump 7-5 eas2gc1333 removing the oil seal tip • remove the oil seal when the coolant level changes frequently more than usual, coolant has discolored, or engine oil has become milky. • do not use the removed oil seal. 1. Remove: • oil seals “1” eas2gc1334 checking the water pump 1. Check: • wa...

  • Page 315

    Water pump 7-6 2. Install: • dowel pin “1” • gasket “2” 3. Install: • water pump housing “1” • water pump housing bolt “2” • washer “3” • coolant drain bolt “4” water pump housing bolt 10 nm (1.0 m·kgf, 7.2 ft·lbf) coolant drain bolt 10 nm (1.0 m·kgf, 7.2 ft·lbf) new 2 1 1 new t r . . New t r . . 2 ...

  • Page 316

    Water pump 7-7.

  • Page 317

    8 fuel system fuel tank ......................................................................................................8-1 removing the fuel tank ...................................................................8-3 removing the fuel pump ........................................................

  • Page 318

    Fuel tank 8-1 eas2gc1338 tip 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 knowl- edge and skill concerning servicing are requested not to undertake inspectio...

  • Page 319

    Fuel tank 8-2 for installation, reverse the removal proce- dure. Removing the fuel tank order part name q’ty remarks 4 (6) (2) (2) (2) (2) 2 5 6 3 1 new 4.0 nm (0.40 m kgf, 2.9 ft ibf) t.R. 7 nm (0.7 m kgf, 5.1 ft ibf) t.R. 7 nm (0.7 m kgf, 5.1 ft ibf) t.R. 7 nm (0.7 m kgf, 5.1 ft ibf) t.R. 9 nm (0....

  • Page 320

    Fuel tank 8-3 eas2gc1340 removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel hose coupler ewa warning cover the fuel hose connection with a cloth when disconnecting it. This is because re- sidual pressure in the fuel hose could cause f...

  • Page 321

    Fuel tank 8-4 eas2gc1344 removing the fuel sender 1. Remove: • fuel sender eca notice do not drop the fuel sender or give it a strong shock. Eas2gc1345 checking the fuel sender 1. Disconnect: • fuel pump coupler • fuel sender coupler (from the wire harness) 2. Disconnect: • starter motor lead (from ...

  • Page 322

    Fuel tank 8-5 tip • insert the fuel hose into the fuel pipe securely until you hear a “click”. • slide the fuel hose connector cover “1” at the hose end in the direction of the arrow. • install the fuel hose connector holder “a”. • check that the fuel hose and the fuel pump lead are routed through t...

  • Page 323

    Fuel tank 8-6 eas2gc1350 checking and replacing the pro- tector 1. Check: • protector “1” wear/damage replace. Tip affix the protector as shown. A. Left b. Right (3.31 in) (4.53 in) 84 mm 115 mm 3 1 1 3 a 2 (3.31 in) (4.53 in) 84 mm 115 mm 1 1 a 0 mm (0 in) b 1 1 15 mm (0.59 in).

  • Page 324

    Throttle body 8-7 eas2gc1351 throttle body removing the throttle body order part name q’ty remarks seat refer to “general chassis” on page 5-1. Side cover (left/right) refer to “general chassis” on page 5-1. Air scoop (left/right) refer to “general chassis” on page 5-1. Fuel tank refer to “fuel tank...

  • Page 325

    Throttle body 8-8 9 fuel hose 1 10 exhaust pipe bracket 1 11 throttle body 1 12 throttle body joint 1 for installation, reverse the removal proce- dure. Removing the throttle body order part name q’ty remarks 3 1 2 7 11 12 10 9 4 8 6 5 3.5 nm (0.35 m kgf, 2.5 ft ibf) t.R. 3.5 nm (0.35 m kgf, 2.5 ft ...

  • Page 326

    Throttle body 8-9 removing the injector order part name q’ty remarks 1 fuel inlet pipe 1 2 injector 1 3 gaskets 1 4 throttle position sensor 1 5 intake air pressure sensor 1 for installation, reverse the removal proce- dure. 1 2 (2) (2) 5 4 3 t.R. 3.4 nm (0.34 m lbf) kgf, 2.5 ft t.R. 5 nm (0.5 m lbf...

  • Page 327

    Throttle body 8-10 eas2gc1352 checking the injector 1. Check: • injectors obstruction replace, and check the fuel pump and the fuel injection system. Refer to “fuel injection system” on page 9-28. Deposits replace. Damage replace. 2. Check: • injector resistance refer to “checking the fuel injec- to...

  • Page 328

    Throttle body 8-11 eas2gc1355 adjusting the throttle position sensor ewa warning • handle the throttle position sensor with special care. • never subject the throttle position sensor to strong shocks. If the throttle position sensor is dropped, replace it. 1. Check: • throttle position sensor refer ...

  • Page 329

    9 electrical system ignition system ..........................................................................................9-2 circuit diagram ...................................................................................9-2 troubleshooting ......................................................

  • Page 330

    Electrical components .......................................................................9-60 checking the switches ..................................................................9-64 checking the bulbs and bulb sockets ....................................9-67 checking the fuses ................

  • Page 331

    9-1 eas2gc1357 tip 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 knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustm...

  • Page 332

    Ignition system 9-2 eas2gc1358 ignition system eas2gc1359 circuit diagram on off on off bbb bbb rr r rr r/l br br br br br (gy) (gy) b/l gy ww w b gy b r ww w br r,r/y g r y/b r,r/w br r l/r (b) r/y r/w br/w l/g br/w ,br l/w (b) (b) br br l/y y/r g/y br bb br br l/y y/w (b) (b) b b g g/y r r/l r lg ...

  • Page 333

    Ignition system 9-3 1. Joint connector 2. Joint connector 4. Ac magneto 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 22.Ecu (engine control unit) 23.Ignition coil 24.Spark plug 30.Joint connector 35.Lean angle sensor 36.Engine stop switch 48.Frame ground 49.Ignition coil sub-lead 50.Nega...

  • Page 334

    Ignition system 9-4 eas2gc1360 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Tip before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 5. Air filter case cover 1. Check the fuse. Refer...

  • Page 335

    Ignition system 9-5 8. Check the lean angle sensor. Refer to “checking the lean angle sensor” on page 9-75. Ng replace the lean angle sensor. Ok 9. Check the entire ignition system’s wiring. Refer to “circuit diagram” on page 9-2. Ng properly connect or repair the ignition sys- tem’s wiring. Ok repl...

  • Page 336

    Electric starting system 9-6 eas27160 electric starting system eas2gc1361 circuit diagram on off on off bbb bbb rr r rr r/l br br br br br (gy) (gy) b/l gy ww w b gy b r ww w br r,r/y g r y/b r,r/w br r l/r (b) r/y r/w br/w l/g br/w ,br l/w (b) (b) br br l/y y/r g/y br bb br br l/y y/w (b) (b) b b g...

  • Page 337

    Electric starting system 9-7 1. Joint connector 2. Joint connector 3. Joint connector 7. Main relay 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 13.Starter motor 14.Starter relay diode 22.Ecu (engine control unit) 30.Joint connector 36.Engine stop switch 37.Neutral switch 38.Diode 39.Sta...

  • Page 338

    Electric starting system 9-8 eas2gc1362 starting circuit cut-off system operation if the meter light comes on, the starter motor can only operate if at least one of the following condi- tions is met: • the transmission is in neutral (the neutral switch is closed). • the clutch lever is pulled to the...

  • Page 339

    Electric starting system 9-9 a. When the transmission is in neu- tral b. When the clutch lever is pulled to the handlebar 1. Battery 2. Main fuse 3. Main relay 4. Starting circuit cut-off relay 5. Start switch 6. Diode 7. Clutch switch 8. Neutral switch 9. Starter relay 10.Starter motor.

  • Page 340

    Electric starting system 9-10 eas2gc1363 troubleshooting the starter motor fails to turn. Tip before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 5. Air filter case cover 1. Check the fuse. Refer to “checking the fuses” on ...

  • Page 341

    Electric starting system 9-11 8. Check the main relay. Refer to “checking the re- lays” on page 9-72. Ng replace the main relay. Ok 9. Check the neutral switch. Refer to “checking the switches” on page 9-64. Ng replace the neutral switch. Ok 10.Check the clutch switch. Refer to “checking the switche...

  • Page 342

    Charging system 9-12 eas27200 charging system eas2gc1364 circuit diagram on off on off bbb bbb rr r rr r/l br br br br br (gy) (gy) b/l gy ww w b gy b r ww w br r,r/y g r y/b r,r/w br r l/r (b) r/y r/w br/w l/g br/w ,br l/w (b) (b) br br l/y y/r g/y br bb br br l/y y/w (b) (b) b b g g/y r r/l r lg w...

  • Page 343

    Charging system 9-13 4. Ac magneto 5. Rectifier/regulator 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 50.Negative battery lead.

  • Page 344

    Charging system 9-14 eas2gc1365 troubleshooting the battery is not being charged. Tip before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 1. Check the fuse. Refer to “checking the fuses” on page 9-68. Ng replace the fuse(s). Ok 2. Check the battery. Refer to “ch...

  • Page 345

    Charging system 9-15 eas27240

  • Page 346

    Lighting system 9-16 lighting system eas2gc1366 circuit diagram on off on off bbb bbb rr r rr r/l br br br br br (gy) (gy) b/l gy ww w b gy b r ww w br r,r/y g r y/b r,r/w br r l/r (b) r/y r/w br/w l/g br/w ,br l/w (b) (b) br br l/y y/r g/y br bb br br l/y y/w (b) (b) b b g g/y r r/l r lg w/b (b) bg...

  • Page 347

    Lighting system 9-17 1. Joint connector 2. Joint connector 6. Headlight relay 7. Main relay 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 22.Ecu (engine control unit) 30.Joint connector 42.Joint connector 43.Taillight 44.Headlight 47.Multi-function display 48.Frame ground 50.Negative batt...

  • Page 348

    Lighting system 9-18 eas2gc1367 troubleshooting any of the following fail to light: headlight or meter light. Tip before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left) 3. Air scoop (left/right) 4. Fuel tank 1. Check the each bulbs condition. Refer to “checking the bulbs...

  • Page 349

    Lighting system 9-19 eas27270

  • Page 350

    Signaling system 9-20 signaling system eas2gc1368 circuit diagram on off on off bbb bbb rr r rr r/l br br br br br (gy) (gy) b/l gy ww w b gy b r ww w br r,r/y g r y/b r,r/w br r l/r (b) r/y r/w br/w l/g br/w ,br l/w (b) (b) br br l/y y/r g/y br bb br br l/y y/w (b) (b) b b g g/y r r/l r lg w/b (b) ...

  • Page 351

    Signaling system 9-21 1. Joint connector 2. Joint connector 3. Joint connector 7. Main relay 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 15.Indicator light 17.Fuel level warning light 18.Resistor 19.Fuel sender 22.Ecu (engine control unit) 30.Joint connector 42.Joint connector 46.Speed ...

  • Page 352

    Signaling system 9-22 eas2gc1369 troubleshooting • the speedometer does not operate normally. • the fuel indicator light does not come on. Tip before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank check the signaling system t...

  • Page 353

    Signaling system 9-23 the fuel level warning light fails to come on. 1. Check the fuel sender. Refer to “checking the fuel sender” on page 9-77. Ng replace the fuel sender assembly. Ok 2. Check the resistor. Refer to “checking the resist- er” on page 9-77. Ng replace the resistor. Ok 3. Check the en...

  • Page 354

    Cooling system 9-24 eas2gc1370 cooling system eas2gc1371 circuit diagram on off on off bbb bbb rr r rr r/l br br br br br (gy) (gy) b/l gy ww w b gy b r ww w br r,r/y g r y/b r,r/w br r l/r (b) r/y r/w br/w l/g br/w ,br l/w (b) (b) br br l/y y/r g/y br bb br br l/y y/w (b) (b) b b g g/y r r/l r lg w...

  • Page 355

    Cooling system 9-25 1. Joint connector 2. Joint connector 3. Joint connector 7. Main relay 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 22.Ecu (engine control unit) 27.Radiator fan motor relay 28.Radiator fan motor fuse 29.Radiator fan motor 30.Joint connector 32.Coolant temperature sens...

  • Page 356

    Cooling system 9-26 eas2gc1372 troubleshooting the radiator fan motor fails to turn. Tip before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left) 3. Air scoop (left/right) 4. Fuel tank 1. Check the fuse. Refer to “checking the fuses” on page 9-68. Ng replace the fuse(s). Ok...

  • Page 357

    Cooling system 9-27 eas2gc1373.

  • Page 358

    Fuel injection system 9-28 fuel injection system eas2gc1374 circuit diagram on off on off bbb bbb rr r rr r/l br br br br br (gy) (gy) b/l gy ww w b gy b r ww w br r,r/y g r y/b r,r/w br r l/r (b) r/y r/w br/w l/g br/w ,br l/w (b) (b) br br l/y y/r g/y br bb br br l/y y/w (b) (b) b b g g/y r r/l r l...

  • Page 359

    Fuel injection system 9-29 1. Joint connector 2. Joint connector 3. Joint connector 4. Ac magneto 7. Main relay 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 15.Indicator light 16.Engine trouble warning light 22.Ecu (engine control unit) 25.Injector 30.Joint connector 31.Intake air temper...

  • Page 360

    Fuel injection system 9-30 eas2gc1375 ecu self-diagnostic function the ecu is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute ch...

  • Page 361

    Fuel injection system 9-31 ecu detects an abnormal signal from a sensor if the ecu detects an abnormal signal from a sensor while the vehicle is being driven, the ecu illu- minates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for...

  • Page 362

    Fuel injection system 9-32 eas2gc1377 yamaha diagnostic tool this model uses the yamaha diagnostic tool to identify malfunctions. For information about using the yamaha diagnostic tool, refer to the operation manual that is included with the tool. Features of the yamaha diagnostic tool a diagnosis c...

  • Page 363

    Fuel injection system 9-33 2. Connect the fi diagnostic tool sub-lead. Eca notice in order to avoid short circuit, insulate the battery connection terminals of the fi diagnostic tool sub-lead. Tip for information on how to connect and use the yamaha diagnostic tool, refer to “yamaha digno- stic tool...

  • Page 364

    Fuel injection system 9-34 operation of the yamaha diagnostic tool (malfunction mode) malfunction results are displayed in the top part of the window area. 1. Recovered the item list of the malfunction detected in the past (already recovered) are displayed. 2. Detected the item list of the malfuncti...

  • Page 365

    Fuel injection system 9-35 6. Condition the current conditions are displayed. (detected/recovered) 7. Symptom the symptoms of the detected malfunction are displayed. 8. Diagnosis code the diagnosis codes related to the detected malfunction are displayed. 9. Ffd (only for models that can display free...

  • Page 366

    Fuel injection system 9-36 2 connection of wire harness ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected connect the coupler securely or repair/replace the wire har-...

  • Page 367

    Fuel injection system 9-37 tip • if fault code nos. 13 and 14 are both displayed, perform the checks and maintenance jobs for fault code no. 13 first. • before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code no. 13 item intake air pressure sensor: open or short ...

  • Page 368

    Fuel injection system 9-38 tip • if fault code nos. 13 and 14 are both displayed, perform the checks and maintenance jobs for fault code no. 13 first. • before troubleshooting, disconnect the starter motor lead from the starter relay. 5 defective intake air pressure sensor. Execute the diagnostic mo...

  • Page 369

    Fuel injection system 9-39 tip before troubleshooting, disconnect the starter motor lead from the starter relay. 2 defective intake air pressure sensor. Execute the diagnostic mode. (code no. 03) when engine is stopped: atmospheric pressure at the current altitude and weather conditions is indicated...

  • Page 370

    Fuel injection system 9-40 2 connection of wire harness ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or bro- ken terminals and locking condition of the pins). Improperly connected connect the coupler securely or repair/replace the wire har-...

  • Page 371

    Fuel injection system 9-41 tip before troubleshooting, disconnect the starter motor lead from the starter relay. 7 malfunction in ecu. Replace the ecu. Fault code no. 16 item throttle position sensor: stuck throttle position sensor is de- tected. Fail-safe system able to start engine able to drive v...

  • Page 372

    Fuel injection system 9-42 tip • make sure that the engine is completely cool before checking the coolant temperature sensor. • before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code no. 21 item coolant temperature sensor: open or short circuit detected. Fail-sa...

  • Page 373

    Fuel injection system 9-43 tip • make sure that the engine is completely cool before checking the intake air temperature sensor. • before troubleshooting, disconnect the starter motor lead from the starter relay. 5 defective coolant tempera- ture sensor. Execute the diagnostic mode. (code no. 06) wh...

  • Page 374

    Fuel injection system 9-44 tip before troubleshooting, disconnect the starter motor lead from the starter relay. 3 wire harness continuity. Open or short circuit re- place the wire harness. Between intake air tempera- ture sensor coupler and ecu coupler. Black/blue–black/blue brown/white–brown/white...

  • Page 375

    Fuel injection system 9-45 2 installed condition of lean an- gle sensor. Check the installed direction and condition of the sensor. Push the start switch. Fault code number is not dis- played service is finished. Fault code number is dis- played go to item 3. 3 defective lean angle sensor. Execute t...

  • Page 376

    Fuel injection system 9-46 3 connection of sub wire har- ness coupler.Check the lock- ing condition of the coupler.Disconnect the cou- pler and check the pins (bent or broken terminals and lock- ing condition of the pins). Improperly connected connect the coupler secure- lyor repair/replace the sub ...

  • Page 377

    Fuel injection system 9-47 tip disconnect the fuel pump coupler when this diagnostic tool is used. Fault code no. 39 item injector: open or short circuit detected. Fail-safe system unable to start engine unable to drive vehicle diagnostic code no. 36 actuation actuates injector five times at one-sec...

  • Page 378

    Fuel injection system 9-48 tip before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code no. 41 item lean angle sensor: open or short circuit detected. Fail-safe system unable to start engine able to drive vehicle diagnostic code no. 08 diagnostic tool display lean...

  • Page 379

    Fuel injection system 9-49 fault code no. 43 item fuel system voltage: incorrect voltage supplied to the fuel in- jector and fuel pump. Fail-safe system able to start engine able to drive vehicle diagnostic code no. 09 diagnostic tool display fuel system voltage approximately 12.0 (v) procedure disc...

  • Page 380

    Fuel injection system 9-50 tip before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code no. 44 item eeprom fault code number: an error is detected while read- ing or writing on eeprom. Fail-safe system able/unable to start engine able/unable to drive vehicle diagn...

  • Page 381

    Fuel injection system 9-51 fault code no. 46 item charging voltage is abnormal. Fail-safe system able/unable to start engine able/unable to drive vehicle diagnostic code no. — diagnostic tool display — procedure — item probable cause of malfunc- tion and check maintenance job confirmation of service...

  • Page 382

    Fuel injection system 9-52 tip before troubleshooting, disconnect the starter motor lead from the starter relay. Tip before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code no. 50 item faulty ecu memory. (when this malfunction is detected in the ecu, the fault co...

  • Page 383

    Fuel injection system 9-53 tip before troubleshooting, disconnect the starter motor lead from the starter motor. 3 wire harness continuity. Open or short circuit re- place the wire harness. Light green–light green push the start switch. Fault code number is not dis- played service is finished. Fault...

  • Page 384

    Fuel injection system 9-54 tip before troubleshooting, disconnect the starter motor lead from the starter motor. 4 yamaha diagnostic tool mal- function. Replace the yamaha diag- nostic tool. Push the start switch. Fault code number is not dis- played service is finished. Fault code number is dis- pl...

  • Page 385

    Fuel injection system 9-55 tip before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code no. Er-4 item registered data cannot be received from the yamaha diagnos- tic tool. Fail-safe system able to start engine able to drive vehicle diagnostic code no. — diagnostic...

  • Page 386

    Fuel pump system 9-56 eas2gc1379 fuel pump system eas2gc1380 circuit diagram on off on off bbb bbb rr r rr r/l br br br br br (gy) (gy) b/l gy ww w b gy b r ww w br r,r/y g r y/b r,r/w br r l/r (b) r/y r/w br/w l/g br/w ,br l/w (b) (b) br br l/y y/r g/y br bb br br l/y y/w (b) (b) b b g g/y r r/l r ...

  • Page 387

    Fuel pump system 9-57 1. Joint connector 2. Joint connector 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 22.Ecu (engine control unit) 26.Fuel pump 30.Joint connector 36.Engine stop switch 48.Frame ground 50.Negative battery lead.

  • Page 388

    Fuel pump system 9-58 eas2gc1381 troubleshooting the fuel pump fails to operate. Tip before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 1. Check the fuse. Refer to “checking the fuses” on page 9-68. Ng replace the fuse(s). ...

  • Page 389

    Fuel pump system 9-59 eas2gc1382.

  • Page 390

    Electrical components 9-60 electrical components eas2gc1383 9 10 11 1 3 2 4 5 6 7 8.

  • Page 391

    Electrical components 9-61 1. Rectifier/regulator 2. Clutch switch 3. Ignition coil 4. Ecu (engine control unit) 5. Fuel sender 6. Fuel pump 7. Battery 8. Resistor 9. Neutral switch 10.Radiator fan motor 11.Injector.

  • Page 392

    Electrical components 9-62 12 11 10 2 3 1 6 7 4 5 8 9.

  • Page 393

    Electrical components 9-63 1. Intake air temperature sensor 2. Intake air pressure sensor 3. Throttle position sensor 4. Starter relay 5. Main fuse 6. Headlight relay 7. Starting circuit cut-off relay 8. Lean angle sensor 9. Radiator fan motor fuse 10.Radiator fan motor relay 11.Main relay 12.Coolan...

  • Page 394

    Electrical components 9-64 eas2gc1384 checking the switches 4 1 3 2 b b sb b b b b b b b b.

  • Page 395

    Electrical components 9-65 1. Engine stop switch 2. Neutral switch 3. Clutch switch 4. Start switch.

  • Page 396

    Electrical components 9-66 check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Eca notice never insert the tester probes into the coupler terminal slots “1”. Always insert the probes from ...

  • Page 397

    Electrical components 9-67 eas27990 checking the bulbs and bulb sock- ets tip do not check any of the lights that use leds. Check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear repair or replace the bulb, bulb socket or ...

  • Page 398

    Electrical components 9-68 checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) no continuity replace. Tip check each bulb socket for continuity in the same manner as described in the ...

  • Page 399

    Electrical components 9-69 4. Install: • seat • side cover (left/right) refer to “general chassis” on page 5- 1. Eas2gc1386 checking and charging the battery ewa warning batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. The...

  • Page 400

    Electrical components 9-70 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Charge: • battery (refer to the appropriate charging method) ewa warning do not quick charge a battery. Eca notice • do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause ba...

  • Page 401

    Electrical components 9-71 b. Connect a charger and ammeter to the bat- tery and start charging. Tip set the charging voltage to 16–17 v. If the set- ting is lower, charging will be insufficient. If too high, the battery will be over-charged. C. Make sure that the current is higher than the standard...

  • Page 402

    Electrical components 9-72 eas2gc1387 checking the relays check each switch for continuity with the pock- et tester. If the continuity reading is incorrect, replace the relay. 1. Disconnect the relay from the wire harness. 2. Connect the pocket tester ( 1) and bat- tery (12 v) to the relay terminal ...

  • Page 403

    Electrical components 9-73 eas2gc1388 checking the diode 1. Check: • diode out of specification replace. Tip the pocket tester and the analog pocket tester readings are shown in the following table. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the diode from the wire harness. B. Connect the pocket...

  • Page 404

    Electrical components 9-74 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( 1k) to the spark plug cap. B. Measure the spark plug cap resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas2gc1391 checking the ignition coil 1. Disconnect: • ignition coil terminal (from the sub wire harness) •...

  • Page 405

    Electrical components 9-75 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( 100) to the crankshaft position sensor coupler. B. Measure the crankshaft position sensor re- sistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas2gc1393 checking the lean angle sensor 1. Remove: • lean angle sensor...

  • Page 406

    Electrical components 9-76 b. Check the starter motor operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28150 checking the stator coil 1. Disconnect: • stator coil coupler (from the wire harness) 2. Check: • stator coil resistance out of specification replace the stator coil. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 407

    Electrical components 9-77 eas2gc1396 checking the speed sensor 1. Check: • speed sensor output voltage out of specification replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the test harness-speed sensor (3p) to the speed sensor coupler and wire har- ness. B. Connect the pocket tester (dc20v) to...

  • Page 408

    Electrical components 9-78 b. Measure the resistance of the resister. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas2gc1399 checking the radiator fan motor 1. Check: • radiator fan motor faulty/rough movement replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the radiator fan motor coupler from the wire ...

  • Page 409

    Electrical components 9-79 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas2gc1401 checking the throttle position sensor 1. Remove: • throttle position sensor (from the throttle body) ewa warning • handle the throttle position sensor with special care. • never subject the throttle position sensor to strong shoc...

  • Page 410

    Electrical components 9-80 c. Start the engine. D. Measure the throttle position sensor input voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas2gc1403 checking the intake air pressure sensor 1. Check: • intake air pressure sensor output voltage out of specification replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 411

    Electrical components 9-81 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas2gc1405 checking the fuel injector 1. Remove: • fuel injector refer to “throttle body” on page 8-7. 2. Check: • fuel injector resistance out of specification replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the fuel injector coupl...

  • Page 412

    Electrical components 9-82.

  • Page 413

    10 troubleshooting troubleshooting ....................................................................................10-1 general information ......................................................................10-1 starting failures...................................................................

  • Page 414

    Troubleshooting 10-1 eas2gc1406 troubleshooting eas2gc1407 general information tip the following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks,...

  • Page 415

    Troubleshooting 10-2 electrical system 1. Battery • discharged battery • faulty battery 2. Spark plug • incorrect spark plug gap • incorrect spark plug heat range • fouled spark plug • worn or damaged electrode • worn or damaged insulator • faulty spark plug cap 3. Ignition coil • broken or shorted ...

  • Page 416

    Troubleshooting 10-3 cooling system 1. Coolant • low coolant level 2. Radiator • damaged or leaking radiator • faulty radiator cap • bent or damaged radiator fin 3. Water pump • damaged or faulty water pump • damaged hose • improperly connected hose • damaged pipe • improperly connected pipe fuel sy...

  • Page 417

    Troubleshooting 10-4 7. Wheel (s) • incorrect wheel balance • broken or loose spoke • damaged wheel bearing • bent or loose wheel axle • excessive wheel runout 8. Frame • bent frame • damaged steering head pipe • improperly installed bearing race eas2gc1422 headlight does not come on electrical syst...

  • Page 418

    List of self-diagnostic and fail-safe actions 10-5 eas2gc1425 list of self-diagnostic and fail-safe actions list of diagnostic codes communication error with yamaha diagnostic tool fault code item page 12 crankshaft position sensor: no normal signals are received from the crankshaft position sensor....

  • Page 419

    List of self-diagnostic and fail-safe actions 10-6 sensor operation table diag- nostic code no. Item display procedure 01 throttle position sensor sig- nal • fully closed position • fully opened position • 11–14 • 109–116 • check with throttle valve fully closed. • check with throttle valve fully op...

  • Page 420

    List of self-diagnostic and fail-safe actions 10-7 * 1: symbols used in the explanations of the malfunction history : normal : there is currently a malfunction or abnormal condition. : a malfunction or abnormal condition occurred previously, but the affected system or component is currently operatin...

  • Page 421

    List of self-diagnostic and fail-safe actions 10-8 actuator operation table diag- nostic code no. Item actuation procedure 30 ignition coil actuates the ignition coil five times at one-second inter- vals. “warning” on the yamaha diagnostic tool blinks five times when the ignition coil is actuated. C...

  • Page 422

    Eas2gc1427 wiring diagram wr450f/wr450fg 2016 1. Joint connector 2. Joint connector 3. Joint connector 4. Ac magneto 5. Rectifier/regulator 6. Headlight relay 7. Main relay 8. Engine ground 9. Battery 10.Frame ground 11.Starter relay 12.Main fuse 13.Starter motor 14.Starter relay diode 15.Indicator ...

  • Page 424

    Printed in japan (e) printed on recycled paper.

  • Page 425

    On off on off b b b b b b r r r r r r/l br br br br br br br br br br br r/l r/l r/l r/l r/l b l l l p p l y y r r br r/l r/l r/l p/l p/l r/l r/l r/l r/b r/b l/r l/y l/y y/r y/r g/y g/y g/y g/y b/y b/y r/l b/l b/l b/l b/l b/l y/g y/g b/l b/o l/b y/b w/b w/b g/b l/b w/b w/b l/b l/b l/g l/w l/w l/r br...

  • Page 426

    On off on off (gy) (gy) (b) (b) (b) (b) (b) (b) (gy) (b) (b) (b) (l) (l) (b) (b) (b) (b) (b) (b) (b) (b) (b) (b) , , , , , wr450f/wr450fg 2016 wiring diagram wr450f/wr450fg 2016 schÉma de cblage 2gc-28199-70_w.D.Indd 2 2015/07/08 10:14:33.