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Yamaha YZ450F Owner's Service Manual

Summary of YZ450F

  • Page 1

    Owner’s service manual manuel d’atelier du proprietaire fahrer- und wartungshandbuch yz450fg yz450f b11-28199-80 printed in japan 2015.03—1.8 × 1 ! (e, f, g) printed on recycled paper 2016 yz450f yz450fg 2016 q read this manual carefully before operating this vehicle. Q il convient de lire attentive...

  • 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. Q bitte lesen sie di...

  • Page 3: Yz450Fg

    Yz450fg 2015 2016 yz450f yz450f b11-28199-80-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

    Easb111002 yz450f yz450fg owner’s service manual ©2015 by yamaha motor co., ltd. First edition, march 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: Introduction

    Easb111003 introduction congratulations on your purchase of a yamaha yz series. This model is the culmination of yamaha’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 exp...

  • Page 7: Safety Information

    Easb111005 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: How To Use This Manual

    Easb111006 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: Symbols

    Easb111007 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 Contents

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

  • Page 13: General Information

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

  • Page 14

    Starting and break-in ..........................................................................1-21 fuel ........................................................................................................1-21 starting a cold engine .................................................................

  • Page 15: Location of Important Labels

    Location of important labels 1-1 easb111008 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

    Location of important labels 1-2 eur.

  • Page 17: Location of Important Labels

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

  • Page 18: Description

    Description 1-4 easb111009 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 10. Radiator 2. Front brake lever 1...

  • Page 19: Identification

    Identification 1-5 easb111010 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

    Included parts 1-6 easb111013 included parts easb111014 sidestand the sidestand “1” is used to support only the machine when standing or transporting it. Ewa@ warning • never apply additional force to the sides- tand. • remove this sidestand before starting out. Easb111015 spark plug wrench the spar...

  • Page 21: Included Parts

    Included parts 1-7 the power tuner is an optional part. Part name part number gytr power tuner (for usa) 33d-h59c0-v0-00 yz power tuner (except for usa) 33d-859c0-10

  • Page 22: Important Information

    Important information 1-8 eas20180 important information easb111020 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 23: Important Information

    Important information 1-9 easb111022 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 24: Basic Service Information

    Basic service information 1-10 easb111026 basic service information easb111027 electrical system electrical parts handling eca16620 notice handle electrical components with special care, and do not subject them to strong shocks. Eca16630 notice electrical components are very sensitive to and can be ...

  • Page 25: Basic Service Information

    Basic service information 1-11 checking the connections check leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector eca16780 notice • when disconnecting a coupler, release the coupler lock, hold both sections of the coupler, and then disconnect ...

  • Page 26: Basic Service Information

    Basic service information 1-12 4. Connect: • lead • coupler • connector tip • when connecting a coupler or a 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 ...

  • Page 27: Special Tools

    Special tools 1-13 easb111028 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

    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

    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 yu-03141 this tool is used to measure the ignition timing. Pressure gauge 90890-03153 yu-03153 this to...

  • Page 30: Special Tools

    Special tools 1-16 valve spring compressor 90890-04019 ym-04019 this tool is used to discon- nect or connect the valve and the valve spring. Spacer (crankshaft installer) 90890-04081 pot spacer ym-91044 this tool is used to install the crankshaft. Clutch holder 90890-04086 ym-91042 this tool is used...

  • Page 31: Special Tools

    Special tools 1-17 crankcase separating tool 90890-04152 yu-a9642 this tool is used to remove the crankshaft. Ignition checker 90890-06754 oppama pet-4000 spark checker ym-34487 this tool is used to check the spark performance of the ig- nition coil. Digital tachometer 90890-06760 yu-39951-b this to...

  • Page 32: Control Functions

    Control functions 1-18 easb111029 control functions easb111030 engine stop switch the engine stop switch “1” is located on the left handlebar. Continue pushing the engine stop switch till the engine comes to a stop. Easb111031 launch control switch the launch control switch “1” is located on top of ...

  • Page 33: Control Functions

    Control functions 1-19 easb111034 kickstarter lever the kickstarter lever “1” is in the right of the chassis. To start the engine, pull out and push down the kickstarter lever with your foot. Easb111035 throttle grip the throttle grip “1” is located on the right han- dlebar. The throttle grip accele...

  • Page 34: Control Functions

    Control functions 1-20 easb111039 fuel tank cap fuel tank cap “1” is located under the fuel tank cap cover “2”. Remove the fuel tank cap cover to open the fuel tank cap. Tip • to remove the fuel tank cap cover, insert fin- gers under part “a”, and then use both hands to lift it up towards the rear o...

  • Page 35: Starting and Break-In

    Starting and break-in 1-21 easb111040 starting and break-in easb111041 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 36: Starting and Break-In

    Starting and break-in 1-22 7. To stop the engine, push the engine stop switch “1”. Tip continue pushing the engine stop switch till the engine comes to a full stop. Easb111043 starting a warm engine when the engine is warm, give a kick with the throttle closed without using the starter knob/ idle sc...

  • Page 37: Maintenance After Break-In

    Maintenance after break-in 1-23 easb111045 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 3-7. Easb111046 major maintenance 1. For the engine • leaks around the engine ch...

  • Page 38: Torque-Check Points

    Torque-check points 1-24 easb111047 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 39: Torque-Check Points

    Torque-check points 1-25 tip concerning the tightening torque, refer to “tightening torques” on page 2-12. Plastic cover tightening of number plate tightening of front fender tightening of fork leg protector tightening of air scoop left cover to rear frame tightening of side cover tightening of rear...

  • Page 40: Cleaning and Storage

    Cleaning and storage 1-26 easb111048 cleaning and storage easb111049 cleaning frequent cleaning of your vehicle will enhance its appearance, maintain performance, and ex- tend the life of parts. 1. Before cleaning, block the silencer outlet to prevent water from entering. A plastic bag secured with ...

  • Page 41: Specifications

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

  • Page 42: General Specifications

    General specifications 2-1 easb111051 general specifications model model b111, b115 (usa) (can) b112, b116 (eur) b113 (jpn) b114, b117 (aus) (nzl) (zaf) dimensions overall length 2180 mm (85.8 in) overall width 825 mm (32.5 in) overall height 1280 mm (50.4 in) seat height 965 mm (38.0 in) wheelbase ...

  • Page 43: Engine Specifications

    Engine specifications 2-2 easb111052 engine specifications engine engine type liquid cooled 4-stroke, dohc displacement 450 cm 3 cylinder arrangement single cylinder bore  stroke 97.0  60.8 mm (3.8  2.4 in) compression ratio 12.5:1 starting system kickstarter fuel recommended fuel premium unleade...

  • Page 44: Engine Specifications

    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 45: Engine Specifications

    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 46: Engine Specifications

    Engine specifications 2-5 crankshaft crank assembly width 61.95–62.00 mm (2.439–2.441 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 47: Engine Specifications

    Engine specifications 2-6 throttle body type/quantity 30ra-jx1a/1 id mark 1sl5 10 fuel line pressure at idling 324.0 kpa (3.24 kgf/cm 2 , 47.0 psi) throttle position sensor resistance 6.30 k output voltage (at idle) 0.48–0.52 v fuel injection sensor crankshaft position sensor resistance 228–342 inta...

  • Page 48: Chassis Specifications

    Chassis specifications 2-7 easb111053 chassis specifications chassis frame type semi double cradle caster angle 27.25 ° trail 118 mm (4.6 in) front wheel wheel type spoke wheel rim size 21  1.60 rim material aluminum wheel travel 310 mm (12.2 in) radial wheel runout limit 2.0 mm (0.08 in) lateral w...

  • Page 49: Chassis Specifications

    Chassis specifications 2-8 front brake type single disc brake operation right hand operation front disc brake disc outside diameter  thickness 270  3.0 mm (10.6  0.12 in) brake disc thickness limit 2.5 mm (0.10 in) brake pad lining thickness (inner) 4.4 mm (0.17 in) limit 1.0 mm (0.04 in) brake p...

  • Page 50: Chassis Specifications

    Chassis specifications 2-9 rebound damping adjusting positions minimum 20 clicks out* standard 11 clicks out* maximum fully turned in *with the adjuster fully turned in compression damping adjusting positions minimum 20 clicks out* standard 8 clicks out* (usa) (can) 16 clicks out* (eur) (jpn) (aus) ...

  • Page 51: Chassis Specifications

    Chassis specifications 2-10 swingarm swingarm end free play limit (radial) 1.0 mm (0.04 in) swingarm end free play limit (axial) 0.2–0.9 mm (0.01–0.04 in) drive chain size/manufacturer 520dma2-sdh/daido number of links 114 drive chain slack 50–60 mm (1.97–2.36 in) 15-link length limit 242.9 mm (9.56...

  • Page 52: Electrical Specifications

    Electrical specifications 2-11 easb111054 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 b110/yamaha (usa) (can) b111/yamaha (eur) (jpn) (aus) (nzl)...

  • Page 53: Tightening Torques

    Tightening torques 2-12 eas20320 tightening torques easb111055 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 54: Tightening Torques

    Tightening torques 2-13 easb111056 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 55: Tightening Torques

    Tightening torques 2-14 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 2.5 nm (0.25 m·kgf, 1.8 ft·lbf) air filter case cap screw m5 1 2.5 n...

  • Page 56: Tightening Torques

    Tightening torques 2-15 primary drive gear nut m20 1 100 nm (10 m·kgf, 72 ft·lbf) clutch spring bolt m6 6 10 nm (1.0 m·kgf, 7.2 ft·lbf) clutch boss nut m20 1 75 nm (7.5 m·kgf, 54 ft·lbf) drive sprocket nut m20 1 75 nm (7.5 m·kgf, 54 ft·lbf) use a lock washer. Drive axle oil seal stopper bolt m6 2 10...

  • Page 57: Tightening Torques

    Tightening torques 2-16 tip *1: first, tighten the cylinder head bolts to 30 nm (3.0 m·kgf, 22 ft·lbf) in the proper tightening se- quence and remove them. Retighten the cylinder head bolts to 20 nm (2.0 m·kgf, 14 ft·lbf) in the prop- er tightening sequence, and then tighten the cylinder head bolts ...

  • Page 58: Tightening Torques

    Tightening torques 2-17 easb111057 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 59: Tightening Torques

    Tightening torques 2-18 front wheel axle pinch bolt m8 4 21 nm (2.1 m·kgf, 15 ft·lbf) 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) rear brake pedal bolt m8 1 26 nm (2.6 m·kgf, ...

  • Page 60: Tightening Torques

    Tightening torques 2-19 tip 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). Drive chain tensioner bolt (lower side) m8 1 16 nm (1.6...

  • Page 61: 2-20

    Lubrication points and lubricant types 2-20 easb111058 lubrication points and lubricant types easb111059 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 62: 2-21

    Lubrication points and lubricant types 2-21 easb111060 chassis cylinder head cover gasket three bond no.1215® crankcase mating surface three bond no.1215® stator assembly lead grommet three bond no.1215® lubrication point lubricant types upper bearings (steering head) upper bearings and bearing race...

  • Page 63: 2-22

    Lubrication points and lubricant types 2-22 front brake caliper dust seal front brake caliper piston outer surface front brake caliper pin bolt and boot front brake master cylinder push rod end front brake master cylinder kit rear brake caliper piston rear brake caliper piston seal rear brake calipe...

  • Page 64: 2-23

    Lubrication system chart and diagrams 2-23 easb111061 lubrication system chart and diagrams easb111062 lubrication diagrams.

  • Page 65: 2-24

    Lubrication system chart and diagrams 2-24 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 66: 2-25

    Lubrication system chart and diagrams 2-25.

  • Page 67: 2-26

    Lubrication system chart and diagrams 2-26 1. Connecting rod 2. Crankshaft 3. Main axle 4. Oil strainer 5. Drive axle.

  • Page 68: 2-27

    Lubrication system chart and diagrams 2-27.

  • Page 69: 2-28

    Lubrication system chart and diagrams 2-28 1. Exhaust camshaft 2. Intake camshaft 3. Oil filter element 4. Oil pump.

  • Page 70: 2-29

    Lubrication system chart and diagrams 2-29.

  • Page 71: 2-30

    Lubrication system chart and diagrams 2-30 1. Camshaft 2. Oil pressure check bolt 3. Oil filter element 4. Oil pump.

  • Page 72: Cable Routing Diagram

    Cable routing diagram 2-31 easb111063 cable routing diagram.

  • Page 73: Cable Routing Diagram

    Cable routing diagram 2-32 1. Clutch cable 2. Throttle cable (return) 3. Throttle cable (pull) 4. Launch control switch lead 5. Engine stop switch lead 6. Cable holder 7. Coupler for connecting optional part 8. Engine stop switch coupler 9. Launch control switch coupler 10. Rectifier/regulator coupl...

  • Page 74: Cable Routing Diagram

    Cable routing diagram 2-33.

  • Page 75: Cable Routing Diagram

    Cable routing diagram 2-34 1. Bracket 2. Condenser 3. Coolant temperature sensor 4. Coupler cover 5. Intake air pressure sensor coupler 6. Intake air temperature sensor coupler 7. Radiator hose 8. Radiator breather hose 9. Joint coupler 10. Plate 11. Tension arm 12. Throttle position sensor lead 13....

  • Page 76: Cable Routing Diagram

    Cable routing diagram 2-35.

  • Page 77: Cable Routing Diagram

    Cable routing diagram 2-36 1. Throttle cable 2. Clutch cable 3. Plastic band 4. Engine stop switch lead 5. Launch control switch lead 6. Front brake hose 7. Brake hose guide 8. Number plate a. Number plate band b. Pass the clutch cable to the rear of the number plate band. C. Clamp the engine stop s...

  • Page 78: Cable Routing Diagram

    Cable routing diagram 2-37.

  • Page 79: Cable Routing Diagram

    Cable routing diagram 2-38 1. Main harness 2. Radiator 3. Throttle position sensor lead 4. Joint coupler 5. Intake air temperature sensor lead 6. Intake air pressure sensor lead 7. Frame 8. Fuel hose 9. High tension cord 10. Spark plug cap 11. Cylinder head cover 12. Sub-wire harness 13. Sub-wire ha...

  • Page 80: Cable Routing Diagram

    Cable routing diagram 2-39.

  • Page 81: Cable Routing Diagram

    Cable routing diagram 2-40 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 82: Cable Routing Diagram

    Cable routing diagram 2-41.

  • Page 83

    3 periodic checks and adjustments maintenance intervals ..........................................................................3-1 maintenance intervals ....................................................................3-1 pre-operation inspection and maintenance...................................

  • Page 84

    Checking the wheel bearings .....................................................3-34 checking and adjusting the steering head ..........................3-35 lubricating the levers ..................................................................3-36 lubricating the pedal .............................

  • Page 85: Maintenance Intervals

    Maintenance intervals 3-1 easb111064 maintenance intervals easb111065 maintenance intervals eca@ notice • after a break-in or before each race, always check the points shown in “torque-check points” for tightening torques and retighten them. (“torque-check points” on page 1- 24.) • periodic inspecti...

  • Page 86: Maintenance Intervals

    Maintenance intervals 3-2 piston ring inspect check the end gap of the pis- ton ring. Replace replace the piston, piston pin, piston pin clip, and piston ring all as a set. Piston pin inspect replace replace the piston, piston pin, piston pin clip, and piston ring all as a set. Cylinder head check t...

  • Page 87: Maintenance Intervals

    Maintenance intervals 3-3 nut (rotor) retighten check for tightening torques. Exhaust pipe, si- lencer, protec- tor inspect and re- tighten check for exhaust leaks, and tightening torques. Clean replace fiver * * when the exhaust sound be- comes louder or when a per- formance drop is felt. Crankshaf...

  • Page 88: Maintenance Intervals

    Maintenance intervals 3-4 fuel tank, fuel pump inspect fuel hose inspect replace every four years front fork leg (s) clean dust seal inspect and adjust replace oil replace oil seal clean and grease oil seals and dust seals lithium-soap-based grease protector guide replace rear shock ab- sorber inspe...

  • Page 89: Maintenance Intervals

    Maintenance intervals 3-5 brake(s) 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 check for tightening torques. Replace pads replace brake flu- id...

  • Page 90: Maintenance Intervals

    Maintenance intervals 3-6 drive chain use chain oil. Clean, lubricate, slack, alignment replace drive chain guide inspect inspect wear. Drive chain guide and drive chain support replace cables routing (connec- tion) check and grease check and clean throttle cable check throttle cables on the throttl...

  • Page 91: 3-7

    Pre-operation inspection and maintenance 3-7 easb111066 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. Easb111067 general inspection and ma...

  • Page 92: Engine

    Engine 3-8 easb111068 engine easb111069 checking the coolant level ewa1dx1003 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 ma...

  • Page 93: Engine

    Engine 3-9 5. Install: • copper washer • coolant drain bolt 6. Pour coolant. Ewa13040 warning • if coolant splashes in your eyes, thorough- ly wash them with water and consult a doctor. • if coolant splashes on your clothes, quick- ly wash it away with water and then with soap and water. • if coolan...

  • Page 94: Engine

    Engine 3-10 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ easb111074 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 ...

  • Page 95: Engine

    Engine 3-11 easb111076 adjusting the clutch lever free play 1. Check: • clutch lever free play “a” out of specification  regulate. 2. Adjust: • clutch lever free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ handlebar side a. Turn the adjuster “1” in direction “a” or “b” until the specified clutch lever fr...

  • Page 96: Engine

    Engine 3-12 2. Adjust: • throttle grip free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. B. Turn the adjuster “2” until the specified free play is obtained. C. Tighten the locknut. Ewa warning after adjusting the throttle grip free play, turn the handlebar to the right and to the...

  • Page 97: Engine

    Engine 3-13 3. Wash: • air filter element ewa warning do not use gasoline or organic (acid/alka- line) volatile oil for washing. Tip after washing the element with air filter cleaner or kerosene, squeeze and dry it completely. Eca notice do not twist the element when squeezing the element. 4. Check:...

  • Page 98: Engine

    Engine 3-14 easb111082 checking the exhaust system 1. Remove: • exhaust pipe protector 2. Check: • exhaust pipe 1 • exhaust pipe 2 • silencer crack/damage  replace. Refer to “engine removal” on page 5-1. • exhaust gas leaks  replace the gasket. Refer to “engine removal” on page 5-1. 3. Check: • ti...

  • Page 99: Engine

    Engine 3-15 eca33dd018 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. Easb111085 changing the engine oil stand the vehicle uprigh...

  • Page 100: Engine

    Engine 3-16 d. Install the oil strainer. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • engine oil drain bolt • 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” on page 3-14...

  • Page 101: Engine

    Engine 3-17 1. Start the engine, and warm this up until the oil has reached the specified temperature. 2. Attach the pocket tester with temperature probe “1” to the oil drain bolt. 3. Install: • digital tachometer tip get the high tension cord “1” of the ignition coil pinched in the detector “a” of ...

  • Page 102: Engine

    Engine 3-18 3. Remove: • timing mark accessing screw “1” • crankshaft end accessing screw “2” • o-ring 4. Check: • valve clearance out of specification  regulate. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise with a wrench. B. Align the top dead center (tdc) mark “a” on t...

  • Page 103: Engine

    Engine 3-19 c. Check the number on the originally installed adjusting pad. Tip • the adjusting pad number “a” is indicated on the top of the adjusting pad. • for the number on the originally installed ad- justing pad, convert the last digit of adjusting pad number as per the below table. D. Select a...

  • Page 104: Engine

    Engine 3-20 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 105: Engine

    Engine 3-21 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) 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 2...

  • Page 106: Chassis

    Chassis 3-22 easb111088 chassis easb111089 bleeding the brake system ewa13100 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 cyli...

  • Page 107: Chassis

    Chassis 3-23 easb111090 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 flui...

  • Page 108: Chassis

    Chassis 3-24 4. Install: • brake lever cover easb111092 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. Loo...

  • Page 109: Chassis

    Chassis 3-25 2. Replace: • brake pads ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the pad pin plug “1”. B. Loosen the pad pin “2”. 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 containe...

  • Page 110: Chassis

    Chassis 3-26 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Check: • brake fluid level refer to “checking the brake fluid level” on page 3-27. 4. Check: • brake lever operation a softy or spongy feeling  bleed the brake system. Refer to “bleeding the brake sys- tem” on page 3-22. Easb111094 checking the rear ...

  • Page 111: Chassis

    Chassis 3-27 f. Loosen the bleed screw and push the brake caliper piston in. Ewa warning do not reuse the drained brake fluid. G. Tighten the bleed screw. H. Install the brake pad “10” and the pad pin “11”. Tip • install the brake pads with their projections “a” into the brake caliper recesses “b”. ...

  • Page 112: Chassis

    Chassis 3-28 2. Check: • brake fluid level the minimum level mark “a” or below add. 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 already ...

  • Page 113: Chassis

    Chassis 3-29 tip • to maintain the proper wheel alignment, ad- just both sides evenly. • push the rear wheel forward to make sure that there is no clearance between the swingarm end plates and the ends of the swingarm. D. Tighten the locknut. E. Tighten the wheel axle nut. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 114: Chassis

    Chassis 3-30 2. Clean: • dust seal “a” • oil seal “b” tip • clean the dust seal and oil seal after every run. • apply lithium-soap-based grease on the inner tube. Easb111101 air bleeding from front fork tip if the front fork initial movement feels stiff dur- ing a run, relieve the front fork interna...

  • Page 115: Chassis

    Chassis 3-31 compression damping eca@ notice do not turn the adjuster forcibly beyond its adjusting range. 1. Adjust: • compression damping ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjuster “1” in the direction of “a” or “b” to make an adjustment. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ easb111103 chec...

  • Page 116: Chassis

    Chassis 3-32 2. Adjust: • spring preload ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. B. Loosen the adjuster “2” until there is some clearance between the spring and the ad- juster. C. Measure the spring free length “a”. D. Turn the adjuster in the direction of “b” or “c” to make an a...

  • Page 117: Chassis

    Chassis 3-33 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ compression damping (for fast compres- sion damping) eca@ notice do not turn the adjuster forcibly beyond its adjusting range. 1. Adjust: • compression damping (for fast compression damping) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjuster “1” in th...

  • Page 118: Chassis

    Chassis 3-34 easb111106 checking the tires 1. Measure: • tire pressure out of specification  regulate. Tip • check the tire while it is cold. • loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low. • if the tire valve stem is found tilted, the tire is...

  • Page 119: Chassis

    Chassis 3-35 easb111110 checking and adjusting the steer- ing head 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. Check: • steering head grasp the bottom of the front fork legs and gently roc...

  • Page 120: Chassis

    Chassis 3-36 5. Install: • upper bracket refer to “steering head” on page 4-51. • handlebar refer to “handlebar” on page 4-32. Easb111111 lubricating the levers 1. Lubricate the pivoting points and metal-to- metal moving parts of the following parts. • brake lever • clutch lever easb111112 lubricati...

  • Page 121: Electrical System

    Electrical system 3-37 easb111113 electrical system easb111114 checking the spark plug 1. Remove: • seat • air scoop (left/right) refer to “general chassis” on page 4- 1. • fuel tank “1” refer to “fuel tank” on page 7-1. Eca notice do not use too much force to pull the hose. Tip remove the fuel tank...

  • Page 122: Electrical System

    Electrical system 3-38 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 3-16. 4. Check: • ignition timing check whether the alignment mark “a” on the left crankcase cover is with...

  • Page 123: Chassis

    4 chassis general chassis........................................................................................4-1 removing the left side cover.......................................................4-2 removing the seat .............................................................................4...

  • Page 124

    Handlebar .................................................................................................4-32 removing the handlebar...............................................................4-34 checking the handlebar ...............................................................4-34 install...

  • Page 125: General Chassis

    General chassis 4-1 easb111116 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 126: General Chassis

    General chassis 4-2 easb111118 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. Easb111119 removing the seat tip the fuel tank cap cover and the seat are cou...

  • Page 127: Front Wheel

    Front wheel 4-3 easb111121 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 collars 2 6 oil seals 2 7 bearing 2 8 bra...

  • Page 128: Front Wheel

    Front wheel 4-4 easb111122 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 easb111123 checking the front wheel 1. Check: • front wheel axle roll ...

  • Page 129: Front Wheel

    Front wheel 4-5 easb111124 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 130: Front Wheel

    Front wheel 4-6 3. Install: • collar “1” tip apply the lithium-soap-based grease on the oil seal lip. Easb111126 installing the front wheel 1. Install: • front wheel tip install the brake disc “1” between the brake pads “2” correctly. 2. Install: • front wheel axle “1” tip apply the lithium-soap-bas...

  • Page 131: Rear Wheel

    Rear wheel 4-7 easb111127 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 132: Rear Wheel

    Rear wheel 4-8 easb111128 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 133: Rear Wheel

    Rear wheel 4-9 tip tighten the self-locking nuts in stages and in a crisscross pattern. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ easb111132 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-based...

  • Page 134: Rear Wheel

    Rear wheel 4-10 easb111133 installing the rear wheel 1. Install: • rear wheel 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 axl...

  • Page 135: Rear Wheel

    Rear wheel 4-11 1 2.

  • Page 136: Front Brake

    Front brake 4-12 easb111134 front brake removing the front brake caliper order part name q’ty remarks brake fluid drain. Refer to “bleeding the brake system” on page 3-22. 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 137: Front Brake

    Front brake 4-13 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 138: Front Brake

    Front brake 4-14 removing the front brake master cylinder order part name q’ty remarks brake fluid drain. Refer to “bleeding the brake system” on page 3-22. 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 139: Front Brake

    Front brake 4-15 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 140: Front Brake

    Front brake 4-16 easb111135 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 141: Front Brake

    Front brake 4-17 b. Remove the brake caliper piston dust seal and the brake caliper piston seal. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ easb111139 checking the front brake caliper 1. Check: • brake caliper piston “1” rust/scratches/wear  replace the brake caliper piston. • brake caliper cylinder “2” scra...

  • Page 142: Front Brake

    Front brake 4-18 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. Easb111142 installing the front brake caliper 1. Install: • front brake caliper bracke...

  • Page 143: Front Brake

    Front brake 4-19 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 3-22. 6. Check: • brake fluid level the minimum level mark or below  add. Refer to...

  • Page 144: Front Brake

    Front brake 4-20 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 145: Front Brake

    Front brake 4-21 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. Ewa13540 warning • use only the de...

  • Page 146: Rear Brake

    Rear brake 4-22 easb111147 rear brake removing the rear brake caliper order part name q’ty remarks brake fluid drain. Refer to “bleeding the brake system” on page 3-22. 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 147: Rear Brake

    Rear brake 4-23 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 148: Rear Brake

    Rear brake 4-24 removing the rear brake master cylinder order part name q’ty remarks brake fluid drain. Refer to “bleeding the brake system” on page 3-22. 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 149: Rear Brake

    Rear brake 4-25 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 150: Rear Brake

    Rear brake 4-26 easb111148 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 151: Rear Brake

    Rear brake 4-27 easb111150 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. Easb111151...

  • Page 152: Rear Brake

    Rear brake 4-28 easb111154 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 153: Rear Brake

    Rear brake 4-29 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 154: Rear Brake

    Rear brake 4-30 easb111158 assembling the rear brake master cylinder ewa warning • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • never use solvents on internal brake com- ponents. 1. Wash the brake master cylinder and the brake...

  • Page 155: Rear Brake

    Rear brake 4-31 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 156: Handlebar

    Handlebar 4-32 easb111160 handlebar removing the handlebar order part name q’ty remarks number plate remove the band only. 1 clutch cable 1 disconnect. 2 clutch lever holder 1 3 engine stop switch 1 4 launch control switch 1 5 brake master cylinder 1 6 throttle cable cap 1 7 throttle cable (pull) 1 ...

  • Page 157: Handlebar

    Handlebar 4-33 14 handlebar 1 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 158: Handlebar

    Handlebar 4-34 easb111161 removing the handlebar 1. Stand the vehicle upright on a level surface. Ewa13120 warning securely support the vehicle so that there is no danger of it falling over. 2. Remove: • grip “1” tip blow in compressed air between the handlebar or tube guide and the grip. Then remov...

  • Page 159: Handlebar

    Handlebar 4-35 3. Tighten: • lower handlebar holder nut 4. Install: • handlebar grip “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Slightly coat the handlebar left end with a rubber adhesive. B. Install the handlebar grip on the handlebar by pressing the grip from the left side. C. Wipe off any excess adh...

  • Page 160: Handlebar

    Handlebar 4-36 7. Install: • collar “1” • rubber cover “2” • throttle grip “3” tip apply the lithium-soap-based grease on the throttle grip sliding surface. 8. Install: • throttle cables “1” tip slightly coat the end of throttle cable and inside of throttle grip with lithium-soap-based grease. Then,...

  • Page 161: Handlebar

    Handlebar 4-37 10.Install: • rubber cover “1” • cover (throttle cable housings) “2” 11.Install: • front brake master cylinder assembly “1” • front brake master cylinder holder “2” • bolt (brake master cylinder holder) “3” tip • install the brake master cylinder holder with the “up” mark facing up. •...

  • Page 162: Front Fork

    Front fork 4-38 easb111164 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 4-3. Front brake caliper refer to “front brake” on page 4-12. Number plate refer to “general chassi...

  • Page 163: Front Fork

    Front fork 4-39 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 164: Front Fork

    Front fork 4-40 easb111165 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 165: Front Fork

    Front fork 4-41 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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. Easb111167 checking the front fork legs 1. Check: • inner tube scratches  ...

  • Page 166: Front Fork

    Front fork 4-42 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 surf...

  • Page 167: Front Fork

    Front fork 4-43 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 set...

  • Page 168: Front Fork

    Front fork 4-44 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 169: Front Fork

    Front fork 4-45 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 170: Front Fork

    Front fork 4-46 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...

  • Page 171: Front Fork

    Front fork 4-47 24.Install: • damper assembly “1” (to the inner tube “2”) eca32d1010 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 •...

  • Page 172: Front Fork

    Front fork 4-48 29.Install: • adjuster “1” (to the inner tube) 30.Fill: • front fork leg eca14210 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 ...

  • Page 173: Front Fork

    Front fork 4-49 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” ewa33dd044 warning tighten the lower bracket to specified torque. I...

  • Page 174: Front Fork

    Front fork 4-50 7. Adjust: • compression damping force tip turn in the damping adjuster “1” finger-tight and then turn out to the originally set position. 1.

  • Page 175: Steering Head

    Steering head 4-51 easb111170 steering head removing the lower bracket order part name q’ty remarks refer to “checking and adjusting the steering head” on page 3-35. Use a suitable stand to raise the front wheel off the ground. Number plate refer to “general chassis” on page 4-1. Handlebar refer to ...

  • Page 176: Steering Head

    Steering head 4-52 easb111171 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 177: Steering Head

    Steering head 4-53 2. Install: • bearing races • upper bearing “1” • bearing race cover “2” 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 ste...

  • Page 178: Steering Head

    Steering head 4-54 8. Install: • steering stem nut “1” 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 b...

  • Page 179: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-55 easb111174 rear shock absorber assembly removing the rear shock absorber assembly order part name q’ty remarks seat refer to “general chassis” on page 4-1. Side cover (left / right) refer to “general chassis” on page 4-1. Air scoop (left / right) refer to “general c...

  • Page 180: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-56 10 collars 2 11 bushing 1 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...

  • Page 181: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-57 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 182: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-58 easb111175 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 183: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-59 easb111178 removing the bearing 1. Remove: • stopper ring (upper bearing) “1” tip press in the bearing while pressing its outer race and remove the stopper ring. 2. Remove: • upper bearing “1” tip remove the bearing by pressing its outer race. 3. Remove: • lower bea...

  • Page 184: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-60 3. Install: • bearing “1” • oil seals “2” (to connecting arm “3”) easb111182 installing the rear shock absorb- er assembly 1. Lubricate: • bearing (lower side) • dust seal • collars • bushing eca1dx1012 notice do not apply the grease to the bearing outer race becaus...

  • Page 185: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-61 6. Install: • rear shock absorber assembly tip • when installing the rear shock absorber as- sembly, lift up the swingarm. • install the rear shock absorber assembly up- per bolt, and connecting arm bolt (frame side) from the right. • install the rear shock absorber...

  • Page 186: Swingarm

    Swingarm 4-62 easb111183 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 4-22. Rear brake caliper refer to “rear brake” on page 4-22. Bolt (brake pedal) drive chain 1 collars 2 2...

  • Page 187: Swingarm

    Swingarm 4-63 easb111184 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 188: Swingarm

    Swingarm 4-64 easb111187 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 189: Chain Drive

    Chain drive 4-65 easb111188 chain drive removing the drive chain job order part name q’ty servicing information drive sprocket refer to “engine removal” on page 5-1. 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 190: Chain Drive

    Chain drive 4-66 easb111189 removing the drive chain 1. Use a suitable stand to raise the rear wheel off the ground. Ewa13120 warning securely support the vehicle so that there is no danger of it falling over. 2. Remove: • joint clip • drive chain joint “1” • drive chain “2” easb111190 checking the ...

  • Page 191: Chain Drive

    Chain drive 4-67 4. Check: • drive chain rollers “1” damage/wear  replace the drive chain. • drive chain side plates “2” damage/wear  replace the drive chain. 5. Lubricate: • drive chain easb111191 checking the drive sprocket 1. Check: • drive sprocket more than 1/4 tooth wear “a”  replace the dr...

  • Page 192: Chain Drive

    Chain drive 4-68.

  • Page 193: Engine

    5 engine engine removal .........................................................................................5-1 removing the silencer.....................................................................5-6 removing the exhaust pipe 2..........................................................5-6 ...

  • Page 194

    Clutch .........................................................................................................5-38 removing the clutch ......................................................................5-41 checking the friction plates......................................................5-41 c...

  • Page 195

    Ac magneto................................................................................................5-61 removing the ac magneto.............................................................5-62 checking the ac magneto .............................................................5-62 checking t...

  • Page 196: Engine Removal

    Engine removal 5-1 easb111194 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 197: Engine Removal

    Engine removal 5-2 5 exhaust pipe 1 1 6 gaskets 3 7 exhaust pipe 1 protector 1 8 exhaust pipe 2 protector 1 9 silencer body 1 10 silencer cap 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 (8) (6) 30 nm (3.0 m kgf,...

  • Page 198: Engine Removal

    Engine removal 5-3 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 4-1. Side cover (left/right) refer to “general chassis” on page 4-1. Air scoop (left / right) refer to “general chassis”...

  • Page 199: Engine Removal

    Engine removal 5-4 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 4-1. Side cover (left/right) refer to “general chassis” on page 4-1. Air scoop (left / right) refer to “general chassis” on page 4...

  • Page 200: Engine Removal

    Engine removal 5-5 5 drive sprocket cover 1 6 drive chain guide 1 7 drive sprocket 1 8 upper engine bracket 2 9 patch 2 10 lower engine bracket 2 11 pivot shaft 1 12 engine 1 for installation, reverse the removal proce- dure. Removing the engine order part name q’ty remarks.

  • Page 201: Engine Removal

    Engine removal 5-6 easb111196 removing the silencer 1. Remove: • rear shock absorber assembly lower bolt “1” • connecting arm bolt (frame side) “2” • silencer “3” tip move the rear shock absorber to the left side of the chassis, and remove the silencer. Easb111197 removing the exhaust pipe 2 1. Remo...

  • Page 202: Engine Removal

    Engine removal 5-7 easb111199 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 203: Engine Removal

    Engine removal 5-8 2. Remove: • rivet “1” • silencer cap “2” 3. Replace: • fiber “1” 4. Install: • silencer body “1” • bolt “2” tip apply heat-resistant sealant to the areas “a” shown, making sure that there are no gaps in the beads of sealant. 5. Replace: • fiber “1” tip stuff the fiber into the si...

  • Page 204: Engine Removal

    Engine removal 5-9 • front engine bracket “4” • engine bracket bolt (front side) “5” • engine mounting bolt (front side) “6” • patch “7” • upper engine bracket “8” • engine bracket bolt (upper side) “9” • engine mounting bolt (upper side) “10” tip • apply molybdenum disulfide grease to the pivot sha...

  • Page 205: Engine Removal

    Engine removal 5-10 tip tighten the nut while applying the rear brake. Eca notice make sure to tighten to specification; other- wise, it may damage the other part that is fastened together. 3. Bend the lock washer tab to lock the nut. 4. Install: • drive sprocket guide • drive sprocket cover “1” • b...

  • Page 206: Engine Removal

    Engine removal 5-11 tip install and temporarily tighten the silencer so that its joint is positioned as shown with respect to the exhaust pipe 2. 4. Tighten: • bolt (exhaust pipe 2) • clamp tip tighten while checking that their front and rear joints are inserted in position. Bolt (exhaust pipe 2) 20...

  • Page 207: Camshaft

    Camshaft 5-12 easb111206 camshaft removing the cylinder head cover order part name q’ty remarks seat refer to “general chassis” on page 4-1. Side cover (left/right) refer to “general chassis” on page 4-1. Air scoop (left / right) refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank”...

  • Page 208: Camshaft

    Camshaft 5-13 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 209: Camshaft

    Camshaft 5-14 easb111207 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 210: Camshaft

    Camshaft 5-15 5. Remove: • exhaust camshaft “1” • intake camshaft “2” tip attach a wire “3” to the timing chain to prevent it from falling into the crankcase. Easb111208 checking the camshaft 1. Check: • camshaft lobes blue discoloration/pitting/scratches  re- place the camshaft. 2. Measure: • cams...

  • Page 211: Camshaft

    Camshaft 5-16 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the camshaft into the cylinder head. B. Position a strip of plastigauge® “1” onto the camshaft journal as shown. C. Install the dowel pins and the camshaft caps. Tip • tighten the camshaft cap bolts in a crisscross pattern from innermost to o...

  • Page 212: Camshaft

    Camshaft 5-17 c. If not, replace the tensioner assembly. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ easb111211 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 “...

  • Page 213: Camshaft

    Camshaft 5-18 tip make sure that the alignment mark “c” on the exhaust camshaft sprocket and the alignment mark “d” on the intake camshaft sprocket are aligned with the edge of the cylinder head. Eca33dd029 notice do not turn the crankshaft during the cam- shaft installation. Damage or improper valv...

  • Page 214: Camshaft

    Camshaft 5-19 3. Turn: • crankshaft counterclockwise several turns. 4. Check: • top dead center (tdc) mark on the rotor align with the crankcase alignment mark. • camshaft match marks align with the cylinder head surface. Out of alignment  adjust. 5. Install: • timing chain guide (top side) “1” • c...

  • Page 215: Cylinder Head

    Cylinder head 5-20 easb111213 cylinder head removing the cylinder head order part name q’ty remarks refer to “installing the cylinder head” on page 5-23. Seat refer to “general chassis” on page 4-1. Side cover (left/right) refer to “general chassis” on page 4-1. Air scoop (left / right) refer to “ge...

  • Page 216: Cylinder Head

    Cylinder head 5-21 5 timing chain guide (intake side) 1 6 oil check bolt 2 7 oil passage plug 1 for installation, reverse the removal proce- dure. Removing the cylinder head order part name q’ty remarks 7 6 6 10 nm (1.0 m kgf, 7.2 ft ibf) t.R. 10 nm (1.0 m kgf, 7.2 ft ibf) t.R. 15 nm (1.5 m kgf, 11 ...

  • Page 217: Cylinder Head

    Cylinder head 5-22 easb111214 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): ...

  • Page 218: Cylinder Head

    Cylinder head 5-23 easb111217 installing the cylinder head 1. Install: • timing chain guide (intake side) “1” • dowel pins • cylinder head gasket • dowel pins tip while pulling up the timing chain, install the tim- ing chain guide (intake side) and the cylinder head. 2. Install: • cylinder head • cy...

  • Page 219: Cylinder Head

    Cylinder head 5-24 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 220: Valves and Valve Springs

    Valves and valve springs 5-25 easb111218 valves and valve springs removing the valves and valve springs order part name q’ty remarks cylinder head refer to “cylinder head” on page 5-20. 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 221: Valves and Valve Springs

    Valves and valve springs 5-26 easb111219 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 222: Valves and Valve Springs

    Valves and valve springs 5-27 4. Remove: • valve spring retainer “1” • valve spring “2” • valve “3” • valve stem seat “4” • valve spring seat “5” tip identify the position of each part very carefully so that it can be reinstalled in its original place. Easb111220 checking the valves and valve guides...

  • Page 223: Valves and Valve Springs

    Valves and valve springs 5-28 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 224: Valves and Valve Springs

    Valves and valve springs 5-29 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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 225: Valves and Valve Springs

    Valves and valve springs 5-30 e. Apply a fine lapping compound to the valve face, and repeat the above steps. F. After every lapping step, be sure to clean off all of the lapping compound from the valve face and the valve seat. G. Apply mechanic’s blueing dye (dykem) “b” onto the valve face. H. Inst...

  • Page 226: Valves and Valve Springs

    Valves and valve springs 5-31 easb111223 checking the valve lifters 1. Check: • valve lifter damage/scratches  replace the valve lift- ers and cylinder head. Easb111224 installing the valves 1. Clean: • valve stem end 2. Lubricate: • valve stem “1” • valve stem seal “2” 3. Install: • spring seat “1...

  • Page 227: Valves and Valve Springs

    Valves and valve springs 5-32 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 228: Cylinder and Piston

    Cylinder and piston 5-33 easb111225 cylinder and piston removing the cylinder and piston order part name q’ty remarks cylinder head refer to “cylinder head” on page 5-20. 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 229: Cylinder and Piston

    Cylinder and piston 5-34 easb111226 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 230: Cylinder and Piston

    Cylinder and piston 5-35 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 231: Cylinder and Piston

    Cylinder and piston 5-36 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. Easb111229 checking the piston pin 1. Check: • piston pin blue discoloration/grooves  replace the piston pin and then check the lubrication system. ...

  • Page 232: Cylinder and Piston

    Cylinder and piston 5-37 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 233: Clutch

    Clutch 5-38 easb111231 clutch removing the clutch order part name q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-15. Brake pedal refer to “engine removal” on page 5-1. 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 234: Clutch

    Clutch 5-39 14 friction plate 2 3 identification color (purple) 15 clutch boss 1 16 thrust washer 1 17 primary driven gear 1 18 push lever shaft 1 for installation, reverse the removal proce- dure. Removing the clutch order part name q’ty remarks ls new new new 2 3 4 5 7 8 9 6 10 11 13 12 12 18 1 14...

  • Page 235: Clutch

    Clutch 5-40 removing the right crankcase cover order part name q’ty remarks right engine guard refer to “engine removal” on page 5-1. Engine oil drain. Refer to “changing the engine oil” on page 3-15. Coolant drain. Refer to “changing the coolant” on page 3-8. Brake pedal refer to “engine removal” o...

  • Page 236: Clutch

    Clutch 5-41 easb111232 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. Easb111233 checking the friction plates 1. Check: • friction plate damage/wear  replace the fr...

  • Page 237: Clutch

    Clutch 5-42 easb111236 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. Easb111237 checking the clutch boss 1. Check: • clu...

  • Page 238: Clutch

    Clutch 5-43 2. Check: • primary-drive-gear-to-primary-driven-gear free play free play exists  replace the primary drive and primary driven gears as a set. Easb111242 checking the primary driven gear 1. Check: • primary driven gear damage/wear  replace the primary drive and primary driven gears as ...

  • Page 239: Clutch

    Clutch 5-44 easb111245 installing the clutch 1. Install: • push lever shaft “1” tip • apply the lithium-soap-based grease on the oil seal lip. • before installation, apply the engine oil to the push lever shaft sliding surface. 2. Install: • primary driven gear “1” • thrust washer “2” • clutch boss ...

  • Page 240: Clutch

    Clutch 5-45 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 241: Clutch

    Clutch 5-46 10.Install: • clutch cover “1” • clutch cover bolt tip tighten the bolts in stages and in a crisscross pattern. Easb111246 installing the kickstarter lever 1. Install: • kickstarter lever “1” • washers • bolt (kickstarter lever) tip install so that there is a clearance “a” of 5 mm (0.2 i...

  • Page 242: Kickstater

    Kickstater 5-47 easb111247 kickstater removing the kick shaft order part name q’ty remarks primary driven gear refer to “clutch” on page 5-38. 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 243: Kickstater

    Kickstater 5-48 easb111248 removing the kick shaft assembly 1. Remove: • kick shaft assembly “1” tip unhook the torsion spring “2” from the hole “a” in the crankcase. Easb111249 checking the kick shaft and ratch- et wheel 1. Check: • ratchet wheel “1” smooth movement unsmooth movement  replace. • k...

  • Page 244: Kickstater

    Kickstater 5-49 3. Install: • transmission 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 contacting su...

  • Page 245: Shift Shaft

    Shift shaft 5-50 easb111253 shift shaft removing the shift shaft and stopper lever order part name q’ty remarks primary driven gear refer to “clutch” on page 5-38. 1 shift pedal 1 2 shift shaft 1 3 oil seals 1 4 collars 1 5 shift shaft spring 1 6 roller 1 7 shift guide 1 8 shift lever assembly 1 9 s...

  • Page 246: Shift Shaft

    Shift shaft 5-51 removing the shift shaft and stopper lever order part name q’ty remarks 14 stopper lever spring 1 15 segment 1 for installation, reverse the removal proce- dure. Ls 1 3 13 15 14 lt 6 10 11 12 11 8 12 10 4 2 5 lt 7 lt e 12 nm (1.2 m kgf, 8.7 ft ibf) t.R. 30 nm (3.0 m kgf, 22 ft t.R. ...

  • Page 247: Shift Shaft

    Shift shaft 5-52 easb111254 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. Easb111255 removing the segment 1. Remove: • bolt (segmen...

  • Page 248: Shift Shaft

    Shift shaft 5-53 easb111259 installing the stopper lever 1. Install: • torsion spring “1” • collar “2” • stopper lever “3” • bolt (stopper lever) “4” easb111260 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 249: Shift Shaft

    Shift shaft 5-54 4. Tighten: • shift guide bolt “1” easb111262 installing the shift shaft 1. Install: • roller “1” • stopper lever “2” (to shift shaft) • collar “3” (to shift shaft) • shift shaft “4” tip apply the engine oil on the roller and shift shaft. 2. Install: • oil seal easb111263 installing...

  • Page 250: Oil Pump and Balancer Gear

    Oil pump and balancer gear 5-55 easb111264 oil pump and balancer gear removing the oil pump order part name q’ty remarks primary driven gear refer to “clutch” on page 5-38. Right crankcase cover refer to “clutch” on page 5-38. 1 oil pump assembly 1 2 oil pump cover 1 3 outer rotor 1 4 dowel pin 1 5 ...

  • Page 251: Oil Pump and Balancer Gear

    Oil pump and balancer gear 5-56 removing the balancer order part name q’ty remarks primary driven gear refer to “clutch” on page 5-38. Right crankcase cover refer to “clutch” on page 5-38. Stator refer to “ac magneto” on page 5-61. 1 nut (balancer) 1 2 nut (primary drive gear) 1 3 nut (balancer shaf...

  • Page 252: Oil Pump and Balancer Gear

    Oil pump and balancer gear 5-57 easb111265 removing the balancer 1. Straighten the lock washer tab. 2. 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”....

  • Page 253: Oil Pump and Balancer Gear

    Oil pump and balancer gear 5-58 3. Check: • oil pump operation rough movement  repeat steps (1) and (2) or replace the defective part(s). Easb111269 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 shaf...

  • Page 254: Oil Pump and Balancer Gear

    Oil pump and balancer gear 5-59 easb111270 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 255: Oil Pump and Balancer Gear

    Oil pump and balancer gear 5-60 5. Bend the lock washer tab. 3 4 5 10 11 a b 3.

  • Page 256: Ac Magneto

    Ac magneto 5-61 easb111271 ac magneto removing the ac magneto order part name q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-15. Seat refer to “general chassis” on page 4-1. Air scoop (left) refer to “general chassis” on page 4-1. 1 ac magneto coupler 1 disconnect. 2 cra...

  • Page 257: Ac Magneto

    Ac magneto 5-62 easb111272 removing the ac magneto 1. Remove: • nut (rotor) “1” • washers 2. Remove: • rotor “1” use the rotor puller “2” to remove the rotor. • woodruff key easb111273 checking the ac magneto 1. Check: • rotor inner surface “a” • stator outer surface “b” damage  inspect the cranksh...

  • Page 258: Ac Magneto

    Ac magneto 5-63 2. Install: • woodruff key “1” • rotor “2” tip • clean the contact surfaces of the tapered por- tions of the crankshaft and rotor. • when installing the woodruff key, make sure that its flat surface “a” is in parallel with the crankshaft center line “b”. • when installing the rotor, ...

  • Page 259: Crankcase

    Crankcase 5-64 easb111276 crankcase separating the crankcase order part name q’ty remarks engine refer to “engine removal” on page 5-1. Piston refer to “cylinder and piston” on page 5-33. Balancer refer to “oil pump and balancer gear” on page 5-55. Kick shaft assembly refer to “kickstater” on page 5...

  • Page 260: Crankcase

    Crankcase 5-65 10 crankshaft 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. 12 nm (1.2 m • kgf, 8.7 ft • ibf) t.R. 12 nm (1.2 m • kgf, 8.7 ft • ibf) t.R. 3 1 5 2 ...

  • Page 261: Crankcase

    Crankcase 5-66 removing the bearing and oil seal order part name q’ty remarks transmission refer to “transmission” on page 5-72. Shift cam and shift fork refer to “transmission” on page 5-72. 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 262: Crankcase

    Crankcase 5-67 easb111277 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 263: Crankcase

    Crankcase 5-68 easb111280 checking the crankcase 1. Wash: • crankcase tip • wash the crankcase in a mild solvent. • remove any remaining gasket from the crankcase mating surface. 2. Check: • crankcase crack/damage  replace. • oil delivery passages obstruction  blow out with compressed air. Easb111...

  • Page 264: 5-69

    Crankshaft assembly and balancer shaft 5-69 easb111282 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 5-64. Transmission refer to “transmission” on page 5-72. 1 balancer shaft 1 ...

  • Page 265: 5-70

    Crankshaft assembly and balancer shaft 5-70 easb111283 removing the balancer shaft 1. Remove: • balancer shaft “1” tip remove the balancer shaft with its flat side “a” facing the crankshaft. Easb111284 removing the crankshaft assembly 1. Remove: • crankshaft assembly “1” tip remove the crankshaft as...

  • Page 266: 5-71

    Crankshaft assembly and balancer shaft 5-71 4. Check: • crankshaft sprocket “1” damage  replace the crankshaft. 5. Check: • crankshaft journal oil passage obstruction  blow out with compressed air. Easb111286 installing the crankshaft assem- bly 1. Install: • crankshaft assembly tip install the cr...

  • Page 267: Transmission

    Transmission 5-72 easb111287 transmission removing the transmission, shift drum assembly, and shift forks order part name q’ty remarks engine refer to “engine removal” on page 5-1. Crankcase separate. Refer to “crankcase” on page 5-64. 1 main axle 1 2 drive axle 1 3 long shift fork guide bar 1 4 sho...

  • Page 268: Transmission

    Transmission 5-73 easb111288 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 269: Transmission

    Transmission 5-74 easb111290 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. Easb111291 checking the transmission 1. Measure: • main axle runout (with a c...

  • Page 270: Transmission

    Transmission 5-75 2. Install: • collar “1” • 2nd wheel gear (23t) “2” • 4th wheel gear (24t) “3” • 3rd wheel gear (26t) “4” • 5th wheel gear (20t) “5” • collar “6” • 1st wheel gear (27t) “7” • o-rings “8” (to the drive axle “9”) tip • before installation, apply molybdenum disul- fide oil to the inne...

  • Page 271: Transmission

    Transmission 5-76 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 272: Transmission

    Transmission 5-77.

  • Page 273: Cooling System

    6 cooling system radiator .......................................................................................................6-1 handling note ......................................................................................6-3 checking the radiator.............................................

  • Page 274: Radiator

    Radiator 6-1 easb111293 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 275: Radiator

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

  • Page 276: Radiator

    Radiator 6-3 easb111295 handling note ewa warning if coolant seems hot, do not remove the ra- diator cap. Easb111296 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 fin...

  • Page 277: Water Pump

    Water pump 6-4 easb111297 water pump removing the water pump order part name q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-8. Engine oil drain. Refer to “changing the engine oil” on page 3-15. Right crankcase cover refer to “clutch” on page 5-38. 1 water pump housing 1 2 dowe...

  • Page 278: Water Pump

    Water pump 6-5 easb111298 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” easb111299 checking the water pump 1. Check: • wa...

  • Page 279: Water Pump

    Water pump 6-6 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 280: Water Pump

    Water pump 6-7.

  • Page 281: Fuel System

    7 fuel system fuel tank......................................................................................................7-1 removing the fuel tank ...................................................................7-2 removing the fuel pump .........................................................

  • Page 282: Fuel Tank

    Fuel tank 7-1 easb111303 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 283: Fuel Tank

    Fuel tank 7-2 easb111305 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 284: Fuel Tank

    Fuel tank 7-3 tip • take care not to damage the installation sur- faces of the fuel tank. • always use a new fuel pump gasket. • install the lip on the fuel pump gasket upward. • install the fuel pump as shown in the figure. • align the projection “a” on the fuel pump with the slot “b” in the fuel p...

  • Page 285: Fuel Tank

    Fuel tank 7-4 notice make sure that the fuel hose is disconnect- ed by hand. Do not forcibly disconnect the hose with tools. D. Connect the pressure gauge “1” and the fuel pressure adapter “2” to the fuel hose. E. Start the engine. F. Measure the fuel pressure. Out of specification  replace the fue...

  • Page 286: Throttle Body

    Throttle body 7-5 easb111313 throttle body removing the throttle body order part name q’ty remarks seat refer to “general chassis” on page 4-1. Side cover (left/right) refer to “general chassis” on page 4-1. Air scoop (left/right) refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank...

  • Page 287: Throttle Body

    Throttle body 7-6 9 exhaust pipe bracket 1 10 throttle body 1 11 throttle body joint 1 for installation, reverse the removal proce- dure. Removing the throttle body order part name q’ty remarks 2 1 6 10 11 9 8 3 7 5 4 10 nm (1.0 m kgf, 7.2 ft lbf) 7 nm (0.7 m kgf, 5.1 ft lbf) 3.5 nm (0.35 m kgf, 2.5...

  • Page 288: Throttle Body

    Throttle body 7-7 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 289: Throttle Body

    Throttle body 7-8 easb111314 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 8-10. Deposits  replace. Damage  replace. 2. Check: • injector resistance refer to “checking the fuel inje...

  • Page 290: Throttle Body

    Throttle body 7-9 easb111317 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 t...

  • Page 291: Electrical System

    8 electrical system ignition system ..........................................................................................8-2 circuit diagram ...................................................................................8-2 troubleshooting ......................................................

  • Page 293: 8-1

    8-1 easb111318 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 294: Ignition System

    Ignition system 8-2 easb111319 ignition system easb111320 circuit diagram on off on off b r r r r r r r r r b b b b b b l l l b/l b/l b/l b/l b/l b/l b/l gy w w w w r r b b b b r y/r y/g y/g y/b y/b y/w y/w b/y l/w b/r b/y b/y b/w r/b r/b b/r b/r g/w p/b p/b b/l b/l b/l g/w br/w br/w b/l b/l b/w y/r...

  • Page 295: Ignition System

    Ignition system 8-3 1. Crankshaft position sensor 2. Ac magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser 7. Engine stop switch 8. Neutral switch 9. Launch control switch 10.Ecu 11.Ignition coil 12.Spark plug 19.Ignition coil sub-lead.

  • Page 296: Ignition System

    Ignition system 8-4 easb111321 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Tip before troubleshooting, remove the following part(s): 1. Side cover (left/right) 2. Seat 3. Fuel tank 4. Air scoop (left/right) 5. Air filter case cover 1. Check the ignition sys...

  • Page 297: Ignition System

    Ignition system 8-5 the launch control indicator light fail to blink. Tip before troubleshooting, remove the following part(s): 1. Seat 2. Air scoop (left) 8. Check the ignition system wire har- ness. Refer to “circuit diagram” on page 8-2. Ng repair or replace the wire harness. Ok replace the ecu. ...

  • Page 298: Charging System

    Charging system 8-6 eas27200 charging system easb111322 circuit diagram on off on off b r r r r r r r r r b b b b b b l l l b/l b/l b/l b/l b/l b/l b/l gy w w w w r r b b b b r y/r y/g y/g y/b y/b y/w y/w b/y l/w b/r b/y b/y b/w r/b r/b b/r b/r g/w p/b p/b b/l b/l b/l g/w br/w br/w b/l b/l b/w y/r s...

  • Page 299: Charging System

    Charging system 8-7 2. Ac magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser.

  • Page 300: Charging System

    Charging system 8-8 easb111323 troubleshooting the condenser is not being charged. Tip before troubleshooting, remove the following part (s): 1. Seat 2. Air scoop (left) 1. Check the entire charging system’s wiring. Ng reconnect. Ok 2. Check the rectifier/regulator. Refer to “checking the recti- fie...

  • Page 301: Charging System

    Charging system 8-9.

  • Page 302: Fuel Injection System

    Fuel injection system 8-10 easb111324 fuel injection system easb111325 circuit diagram on off on off b r r r r r r r r r b b b b b b l l l b/l b/l b/l b/l b/l b/l b/l gy w w w w r r b b b b r y/r y/g y/g y/b y/b y/w y/w b/y l/w b/r b/y b/y b/w r/b r/b b/r b/r g/w p/b p/b b/l b/l b/l g/w br/w br/w b/...

  • Page 303: Fuel Injection System

    Fuel injection system 8-11 1. Crankshaft position sensor 2. Ac magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser 7. Engine stop switch 8. Neutral switch 10.Ecu 13.Fuel injector 14.Fuel pump 15.Intake air temperature sensor 16.Coolant temperature sensor 17.Throttle position sensor 18.Int...

  • Page 304: Fuel Injection System

    Fuel injection system 8-12 easb111326 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 305: Fuel Injection System

    Fuel injection system 8-13 connecting the yamaha diagnostic tool 1. Remove the coupler for connecting setting tool. 2. Connect the fi diagnostic tool sub-lead. 3. Connect the fi diagnostic tool sub-lead to the battery. Tip • prepare the fully charged 12 v battery for yourself. • for information on h...

  • Page 306: Fuel Injection System

    Fuel injection system 8-14 fault code 12 symptom crankshaft position sensor: no normal signals are received from the crankshaft position sensor. Fail-safe system unable to start engine unable to drive vehicle diagnostic code no. — diagnostic tool display — procedure — or- der probable cause of malfu...

  • Page 307: Fuel Injection System

    Fuel injection system 8-15 tip if fault code nos. 13 and 14 are both displayed, perform checkup and repair jobs for fault code no. 13 first. Fault code 13 symptom intake air pressure sensor: open or short circuit detected. Fail-safe system able to start engine able to drive vehicle diagnostic code n...

  • Page 308: Fuel Injection System

    Fuel injection system 8-16 tip if fault code nos. 13 and 14 are both displayed, perform checkup and repair jobs for fault code no. 13 first. 6 defective intake air pressure sensor. Execute the diagnostic mode. (code no.03) atmospheric pressure at the current altitude and weather conditions is indica...

  • Page 309: Fuel Injection System

    Fuel injection system 8-17 2 defective intake air pressure sensor. Execute the diagnostic mode. (code no. 03) atmospheric pressure at the current altitude and weather conditions is indicated. 0 m above sea level: about 101 kpa 1000 m above sea level: about 90 kpa 2000 m above sea level: about 80 kpa...

  • Page 310: Fuel Injection System

    Fuel injection system 8-18 3 connection of sub wire har- ness coupler. Check the locking condition of the coupler. Disconnect the coupler, and check the pins (for bent or broken terminals and locking condition of the pins). Improperly connected connect the coupler secure- ly, or repair/replace the s...

  • Page 311: Fuel Injection System

    Fuel injection system 8-19 fault code 16 symptom throttle position sensor: stuck throttle position sensor is de- tected. Fail-safe system able to start engine able to drive vehicle diagnostic code no. 01 diagnostic tool display displays the throttle angle. • 11–14 (throttle in fully closed position)...

  • Page 312: Fuel Injection System

    Fuel injection system 8-20 tip make sure that the machine is completely cold before checking the coolant temperature sensor. Fault code 21 symptom coolant temperature sensor: open or short circuit detected. Fail-safe system able to start engine able to drive vehicle diagnostic code no. 06 diagnostic...

  • Page 313: Fuel Injection System

    Fuel injection system 8-21 tip make sure that the machine is completely cold before checking the intake air temperature sensor. 6 faulty ecu replace the ecu. Fault code 22 symptom intake air temperature sensor: open or short circuit detected. Fail-safe system able to start engine able to drive vehic...

  • Page 314: Fuel Injection System

    Fuel injection system 8-22 5 defective intake air tempera- ture sensor. Execute the diagnostic mode. (code no. 05) when the machine is cold, displayed temperature is close to the ambient temper- ature. Improper display  replace the intake air temperature sensor. Turn “on” the switch on the fi diagn...

  • Page 315: Fuel Injection System

    Fuel injection system 8-23 fault code 33 symptom ignition coil: open or short circuit detected in the primary lead of the ignition coil. Fail-safe system unable to start engine unable to drive vehicle diagnostic code no. 30 actuation actuates the ignition coil five times at one-second intervals. “wa...

  • Page 316: Fuel Injection System

    Fuel injection system 8-24 tip disconnect the fuel pump coupler when this diagnostic tool is used. 6 faulty ecu execute the diagnostic mode. (code no. 30) no spark  replace the ecu. Fault code 39 symptom injector: open or short circuit detected. Fail-safe system unable to start engine unable to dri...

  • Page 317: Fuel Injection System

    Fuel injection system 8-25 4 connection of sub wire har- ness coupler. Check the locking condition of the coupler. Disconnect the coupler, and check the pins (for bent or broken terminals and locking condition of the pins). Improperly connected connect the coupler secure- ly, or repair/replace the s...

  • Page 318: Fuel Injection System

    Fuel injection system 8-26 fault code 44 symptom eeprom fault code no.: an error is detected while reading or writing on eeprom. Fail-safe system able/unable to start engine able/unable to drive vehicle diagnostic code no. 60 diagnostic tool display displays the location of the abnormal portion of t...

  • Page 319: Fuel Injection System

    Fuel injection system 8-27 fault code 46 symptom vehicle system power supply: normal voltage is not supplied to the ecu. Fail-safe system able/unable to start engine able/unable to drive vehicle diagnostic code no. — diagnostic tool display — procedure — or- der probable cause of malfunc- tion and c...

  • Page 320: Fuel Injection System

    Fuel injection system 8-28 fault code 50 symptom ecu: faulty ecu memory fail-safe system unable to start engine unable to drive vehicle diagnostic code no. — diagnostic tool display — procedure — or- der probable cause of malfunc- tion and check maintenance job reinstatement method 1 faulty ecu repl...

  • Page 321: Fuel Injection System

    Fuel injection system 8-29 4 yamaha diagnostic tool mal- function replace the yamaha diag- nostic tool. Turn “on” the switch on the fi diagnostic tool sub-lead. Fault code no. Is not dis- played  repair is finished. Fault code no. Is displayed go to next order. 5 faulty ecu replace the ecu. Fault c...

  • Page 322: Fuel Injection System

    Fuel injection system 8-30 fault code er-3 symptom data from the ecu cannot be received correctly. Fail-safe system able to start engine able to drive vehicle diagnostic code no. — diagnostic tool display — procedure — or- der probable cause of malfunc- tion and check maintenance job reinstatement m...

  • Page 323: Fuel Injection System

    Fuel injection system 8-31 fault code er-4 symptom 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 tool display — procedure — or- der probable cause of malfunc- tion and check maintenan...

  • Page 324: Fuel Pump System

    Fuel pump system 8-32 easb111328 fuel pump system easb111329 circuit diagram on off on off b r r r r r r r r r b b b b b b l l l b/l b/l b/l b/l b/l b/l b/l gy w w w w r r b b b b r y/r y/g y/g y/b y/b y/w y/w b/y l/w b/r b/y b/y b/w r/b r/b b/r b/r g/w p/b p/b b/l b/l b/l g/w br/w br/w b/l b/l b/w ...

  • Page 325: Fuel Pump System

    Fuel pump system 8-33 2. Ac magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser 7. Engine stop switch 9. Ecu 14.Fuel pump.

  • Page 326: Fuel Pump System

    Fuel pump system 8-34 easb111330 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 5. Air filter case cover 1. Check the fuel pump system wire harness connections. Ng rec...

  • Page 327: Fuel Pump System

    Fuel pump system 8-35.

  • Page 328: Electrical Components

    Electrical components 8-36 easb111331 electrical components easb111332 11 1 2 3 4 7 8 5 6 9 10

  • Page 329: Electrical Components

    Electrical components 8-37 1. Rectifier/regulator 2. Intake air pressure sensor 3. Throttle position sensor 4. Injector 5. Launch control switch 6. Intake air temperature sensor 7. Ecu 8. Ignition coil 9. Condenser 10.Neutral switch 11.Coolant temperature sensor.

  • Page 330: Electrical Components

    Electrical components 8-38 easb111333 checking the switches y/w p sb b b/w w r/y 3 1 2 p sb b/w b w r/y y/w.

  • Page 331: Electrical Components

    Electrical components 8-39 1. Engine stop switch 2. Launch control switch 3. Neutral switch.

  • Page 332: Electrical Components

    Electrical components 8-40 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. Eca14370 notice never insert the tester probes into the coupler terminal slots “1”. Always insert the probes ...

  • Page 333: Electrical Components

    Electrical components 8-41 easb111334 checking the ignition spark gap 1. Check: • ignition spark gap out of specification  perform the ignition system troubleshooting. Refer to “troubleshooting” on page 8- 4. Tip if the ignition spark gap is within specification, the ignition system circuit is oper...

  • Page 334: Electrical Components

    Electrical components 8-42 b. Measure the primary coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Check: • secondary coil resistance out of specification  replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (   1k) to the ig- nition coil. B. Measure the secondary coil resi...

  • Page 335: Electrical Components

    Electrical components 8-43 2. Check: • stator coil resistance out of specification  replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (   1) to the sta- tor coil coupler. B. Measure the stator coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ easb111340 checking the rectifier...

  • Page 336: Electrical Components

    Electrical components 8-44 b. Immerse the coolant temperature sensor in a container filled with coolant. Tip make sure the coolant temperature sensor ter- minals do not get wet. C. Place a thermometer in the coolant. D. Slowly heat the coolant, and then let it cool to the specified temperature indic...

  • Page 337: Electrical Components

    Electrical components 8-45 easb111343 checking the throttle position sensor input voltage 1. Check: • throttle position sensor input voltage out of specification  replace the ecu. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the test harness s-pressure sensor (3p) to the throttle position sensor cou...

  • Page 338: Electrical Components

    Electrical components 8-46 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (   1k/100) to the intake air temperature sensor terminal. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ easb111346 checking the neutral switch 1. Remove: • neutral switch 2. Check: • neutral switch out of specification  ...

  • Page 339: Electrical Components

    Electrical components 8-47 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the fuel injector coupler from the fuel injector. B. Connect the pocket tester (   10) to the fuel injector coupler. C. Measure the fuel injector resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ pocket tester 90890-03112 analog ...

  • Page 340: Electrical Components

    Electrical components 8-48.

  • Page 341: Troubleshooting

    9 troubleshooting troubleshooting......................................................................................9-1 general information ........................................................................9-1 starting failures...................................................................

  • Page 342: Troubleshooting

    Troubleshooting 9-1 easb111348 troubleshooting easb111349 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 343: Troubleshooting

    Troubleshooting 9-2 3. Ignition system • faulty ecu • faulty crankshaft position sensor • broken generator rotor woodruff key easb111352 poor medium-and-high-speed per- formance refer to “starting failures” on page 9-1. Engine 1. Air filter • clogged air filter element fuel system 1. Fuel pump • fau...

  • Page 344: Troubleshooting

    Troubleshooting 9-3 fuel system 1. Throttle body • damaged or loose throttle body joint 2. Air filter • clogged air filter element chassis 1. Brake(s) • dragging brake electrical system 1. Spark plug • incorrect spark plug gap • incorrect spark plug heat range 2. Ignition system • faulty ecu • fault...

  • Page 345: 9-4

    List of self-diagnostic and fail-safe actions 9-4 easb111364 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 346: 9-5

    List of self-diagnostic and fail-safe actions 9-5 sensor operation table diag- nostic code no. Item display procedure 01 throttle angle • fully closed position • fully opened position displays the throttle angle. • 11–14 • 109–116 • check with throttle fully closed. • check with throttle fully opene...

  • Page 347: 9-6

    List of self-diagnostic and fail-safe actions 9-6 * 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 operating...

  • Page 348: 9-7

    List of self-diagnostic and fail-safe actions 9-7.

  • Page 349: Tuning

    10 tuning chassis ........................................................................................................10-1 selection of the secondary reduction ratio (sprocket) ..........................................................................................10-1 drive and rear wheel spr...

  • Page 350: Chassis

    Chassis 10-1 easb111366 chassis easb111367 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- t...

  • Page 351: Chassis

    Chassis 10-2 easb111369 tire pressure tire pressure should be adjusted to suit the road surface condition of the circuit. • under a rainy, a muddy, a sandy, or a slippery condition, the tire pressure should be lower for a larger area of contact with the road sur- face. • under a stony or a hard road...

  • Page 352: Chassis

    Chassis 10-3 easb111372 setting of spring after replace- ment as the front fork setting can be easily affected by the rear suspension, take care so that the front and the rear are balanced (in position etc.) when setting the front fork. 1. Use of soft spring • change the rebound damping force. Turn ...

  • Page 353: Chassis

    Chassis 10-4 2. Remove the stand or block from the engine and, with a rider astride the seat, measure the sunken length “b” between the rear wheel axle center and the rear fender hold- ing bolt. 3. Loosen the locknut “1” and make adjustment by turning the adjuster “2” to achieve the standard figure ...

  • Page 354: Chassis

    Chassis 10-5 easb111377 rear shock absorber setting parts • rear shock spring “1” tip • the i.D. Mark “a” is marked at the end of the spring. • spring specification varies according to the color of i.D. Marks. • spring preload adjusting positions tip for the spring preload adjustment, refer to “ad- ...

  • Page 355: Chassis

    Chassis 10-6 easb111378 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 t...

  • Page 356: Chassis

    Chassis 10-7 easb111379 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 decr...

  • Page 357: Chassis

    Chassis 10-8 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 dampin...

  • Page 358: Wiring Diagram

    Easb111381 wiring diagram yz450f/yz450fg 2016 1. Crankshaft position sensor 2. Ac magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser 6. Coupler for connecting option- al part 7. Engine stop switch 8. Neutral switch 9. Launch control switch 10.Ecu 11.Ignition coil 12.Spark plug 13.Fuel in...

  • Page 360

    Printed in japan (e) printed on recycled paper.

  • Page 361

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

  • Page 362

    On off on off yz450f/yz450fg 2016 wiring diagram yz450f/yz450fg 2016 schÉma de cblage yz450f/yz450fg 2016 schaltplan b11-28199-80_w.D.Indd 2 2015/03/26 11:01:39.