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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 yz450ff yz450f 1sl-28199-81 printed in japan 2014.03—1.0 × 1 ! (e, f, g) printed on recycled paper 2015 yz450f yz450ff 2015 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: Yz450Ff

    Yz450ff yz450ff 2015 2015 yz450f yz450f 1sl-28199-81-e0 1sl-28199-81-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

    Eas1sl5002 yz450f yz450ff owner’s service manual ©2014 by yamaha motor co., ltd. First edition, march 2014 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

    Eas1sl5003 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

    Eas1sl5005 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

    Eas1sl5006 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

    Eas1sl5007 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 adjust- ments chassis engine cooling system fuel system electrical system trouble shooting tuning.

  • Page 13: General Information

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

  • Page 14

    Starting and break-in ..........................................................................1-22 fuel ........................................................................................................1-22 starting a cold engine .................................................................

  • Page 15: Location of Important Labels

    Location of important labels 1-1 eas1sl5008 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 eas1sl5009 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. Coolant drain bolt 2. Front bra...

  • Page 19: Identification

    Identification 1-5 eas1sl5010 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: Features

    Features 1-6 eas20170 features eas1sl5014 outline of the fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture. In the conventional carburet...

  • Page 21: Features

    Features 1-7 eas1sl5015 fi system the fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kpa (3.24 kgf/cm 2 , 47.0 psi). Accordingly, when the energizing signal from the ecu energizes t...

  • Page 22: Included Parts

    Included parts 1-8 eas1sl5016 included parts eas1sl5017 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. Eas1sl5018 spark plug wrench the spar...

  • Page 23: Included Parts

    Included parts 1-9 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 24: Important Information

    Important information 1-10 eas20180 important information eas1sl5023 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 25: Important Information

    Important information 1-11 eas1sl5025 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 prop...

  • Page 26: Basic Service Information

    Basic service information 1-12 eas1sl5029 basic service information eas1sl5030 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 27: Basic Service Information

    Basic service information 1-13 eca16790 notice when disconnecting a connector, do not pull the leads. Hold both sections of the connector, and then disconnect the con- nector. 2. Check: • lead • coupler • connector moisture  dry with compressed air. Rust/stains  connect and disconnect sev- eral ti...

  • Page 28: Basic Service Information

    Basic service information 1-14 5. Check: • no continuity tip • if there is no continuity, clean the terminals. • when checking the wire harness, perform steps (1) to (4). • as a quick remedy, use a contact revitalizer available at most part stores. Pocket tester 90890-03112 analog pocket tester yu-0...

  • Page 29: Special Tools

    Special tools 1-15 eas1sl5031 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 30: Special Tools

    Special tools 1-16 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 31: Special Tools

    Special tools 1-17 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 32: Special Tools

    Special tools 1-18 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 33: Special Tools

    Special tools 1-19 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 34: Control Functions

    Control functions 1-20 eas1sl5032 control functions eas1sl5033 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. Eas1sl5034 clutch lever the clutch lever “1” is located on the left han- dlebar. The...

  • Page 35: Control Functions

    Control functions 1-21 eas1sl5039 rear brake pedal the rear brake pedal “1” is in the right of the chassis. Press down on the brake pedal to ac- tivate the rear brake. Eas1sl5040 starter knob/idle screw starting a cold engine requires a larger amount of intake air, which is supplied by the starter k...

  • Page 36: Starting and Break-In

    Starting and break-in 1-22 eas1sl5042 starting and break-in eas1sl5043 fuel always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race. Jca notice use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts su...

  • Page 37: Starting and Break-In

    Starting and break-in 1-23 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. Eas1sl5045 starting a warm engine when the engine is warm, give a kick with the throttle closed without using the starter knob/ idle sc...

  • Page 38: Maintenance After Break-In

    Maintenance after break-in 1-24 eas1sl5047 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. Eas1sl5048 major maintenance 1. For the engine • leaks around the engine ch...

  • Page 39: Torque-Check Points

    Torque-check points 1-25 eas1sl5049 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 40: Torque-Check Points

    Torque-check points 1-26 tip concerning the tightening torque, refer to “tightening torques” on page 2-13. Tightening of front fender tightening of fork leg protector tightening of air scoop left cover to rear frame tightening of side cover tightening of rear fender tightening of mud flap tightening...

  • Page 41: Cleaning and Storage

    Cleaning and storage 1-27 eas1sl5050 cleaning and storage eas1sl5051 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 42: Cleaning and Storage

    Cleaning and storage 1-28.

  • Page 43: Specifications

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

  • Page 44: General Specifications

    General specifications 2-1 eas1sl5053 general specifications model model 1sl5 (usa) (can) 1sl6 (eur) 1sl7 (jpn) 1sl8 (aus) (nzl) (zaf) dimensions overall length 2175 mm (85.6 in) (usa) (can) 2180 mm (85.8 in) (eur) (jpn) (aus) (nzl) (zaf) overall width 825 mm (32.5 in) overall height 1290 mm (50.8 i...

  • Page 45: Engine Specifications

    Engine specifications 2-2 eas1sl5054 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 46: Engine Specifications

    Engine specifications 2-3 cylinder head 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 in) camshaft-journal...

  • Page 47: Engine Specifications

    Engine specifications 2-4 valve seat width c (intake) 0.90–1.10 mm (0.0354–0.0433 in) valve seat width c (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) valve margin thickness d (intake) 1.20 mm (0.0472 in) valve margin thickness d (exhaust) 0.85 mm (0.0335 in) valve stem diameter (intake) 5.475–5.490 mm ...

  • Page 48: Engine Specifications

    Engine specifications 2-5 winding direction (intake) clockwise winding direction (exhaust) clockwise cylinder bore 97.000–97.010 mm (3.8189–3.8193 in) taper limit 0.050 mm (0.0020 in) out of round limit 0.050 mm (0.0020 in) piston piston-to-cylinder clearance 0.030–0.055 mm (0.0012–0.0022 in) limit ...

  • Page 49: Engine Specifications

    Engine specifications 2-6 oil ring dimensions (b  t) 1.50  2.55 mm (0.06  0.10 in) end gap (installed) 0.20–0.50 mm (0.0079–0.0197 in) crankshaft width a 61.95–62.00 mm (2.439–2.441 in) runout limit c 0.030 mm (0.0012 in) big end side clearance d 0.150–0.450 mm (0.0059–0.0177 in) balancer balance...

  • Page 50: Engine Specifications

    Engine specifications 2-7 shifting mechanism shift mechanism type shift drum and guide bar shift fork guide bar bending limit 0.050 mm (0.0020 in) shift fork thickness 4.85 mm (0.1909 in) decompression device device type auto decomp air filter air filter element wet element air filter oil grade foam...

  • Page 51: Chassis Specifications

    Chassis specifications 2-8 eas1sl5055 chassis specifications chassis frame type semi double cradle caster angle 27.08 ° (usa) (can) 27.50 ° (eur) 27.67 ° (jpn) 27.58 ° (aus) (nzl) (zaf) trail 120 mm (4.7 in) (usa) (can) 122 mm (4.8 in) (eur) 124 mm (4.9 in) (jpn) (aus) (nzl) (zaf) front wheel wheel ...

  • Page 52: Chassis Specifications

    Chassis specifications 2-9 brake disk 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 pad lining thickness (outer) 4.4 mm (0.17 in) limit 1.0 mm (0.04 in) master cylinder inside diameter 9.52 mm (0.37 in) caliper cylinder inside diame...

  • Page 53: Chassis Specifications

    Chassis specifications 2-10 compression damping adjusting positions * position in which the adjuster is turned in finger tight minimum 20 click (s) out* standard 8 click (s) out* maximum (hard) fully turned in rear suspension type swingarm (link suspension) spring/shock absorber type coil spring/gas...

  • Page 54: Chassis Specifications

    Chassis specifications 2-11 drive chain type/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 in).

  • Page 55: Electrical Specifications

    Electrical specifications 2-12 eas1sl5056 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 1sl4/yamaha (usa) (can) 1sl5/yamaha (eur) (jpn) (aus) (nzl)...

  • Page 56: Tightening Torques

    Tightening torques 2-13 eas20320 tightening torques eas1sl5057 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 57: Tightening Torques

    Tightening torques 2-14 eas1sl5058 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 58: Tightening Torques

    Tightening torques 2-15 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 59: Tightening Torques

    Tightening torques 2-16 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 60: Tightening Torques

    Tightening torques 2-17 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 61: Tightening Torques

    Tightening torques 2-18 eas1sl5059 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 62: Tightening Torques

    Tightening torques 2-19 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, 19 ft·lbf) rear brake pedal position locknut m6 1 6 nm (0.6 m·...

  • Page 63: Tightening Torques

    Tightening torques 2-20 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 64: 2-21

    Lubrication points and lubricant types 2-21 eas1sl5060 lubrication points and lubricant types eas1sl5061 engine lubrication point lubricant types oil seal lips bearing o-ring cylinder head bolt threads, seats, washers valve stems valve stem ends valve lifter outer surface camshaft lobe and journal v...

  • Page 65: 2-22

    Lubrication points and lubricant types 2-22 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.

  • Page 66: 2-23

    Lubrication points and lubricant types 2-23 eas1sl5062 chassis lubrication point lubricant types upper bearings (steering head) upper bearings and bearing race cover (steering head) lower bearings and oil seal lip (steering head) steering stem threads and nut contacting surface pivot shaft bearing s...

  • Page 67: 2-24

    Lubrication points and lubricant types 2-24 rear brake caliper dust seal rear brake caliper piston outer surface rear brake caliper pin bolt and boot rear brake master cylinder push rod end rear brake master cylinder kit lubrication point lubricant types s s s.

  • Page 68: 2-25

    Lubrication system chart and diagrams 2-25 eas1sl5063 lubrication system chart and diagrams eas1sl5064 lubrication diagrams.

  • Page 69: 2-26

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

  • Page 70: 2-27

    Lubrication system chart and diagrams 2-27.

  • Page 71: 2-28

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

  • Page 72: 2-29

    Lubrication system chart and diagrams 2-29.

  • Page 73: 2-30

    Lubrication system chart and diagrams 2-30 1. Exhaust camshaft 2. Intake camshaft 3. Oil filter element 4. Relief valve 5. Oil pump.

  • Page 74: 2-31

    Lubrication system chart and diagrams 2-31.

  • Page 75: 2-32

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

  • Page 76: Cable Routing Diagram

    Cable routing diagram 2-33 eas1sl5065 cable routing diagram.

  • Page 77: Cable Routing Diagram

    Cable routing diagram 2-34 1. Clutch cable 2. Throttle cable (pull) 3. Throttle cable (return) 4. Cable holder 5. Engine stop switch lead 6. Frame 7. Coupler for connecting optional part 8. Bracket 9. Engine stop switch coupler 10. Rectifier/regulator coupler 11. Starter knob/idle screw 12. Neutral ...

  • Page 78: Cable Routing Diagram

    Cable routing diagram 2-35.

  • Page 79: Cable Routing Diagram

    Cable routing diagram 2-36 1. Bracket 2. Condenser 3. Coolant temperature sensor 4. Coupler cover 5. Intake air temperature sensor coupler 6. Intake air temperature sensor coupler 7. Radiator hoses 8. Radiator breather hose 9. Joint coupler 10. Plate 11. Tension arm 12. Throttle position sensor lead...

  • Page 80: Cable Routing Diagram

    Cable routing diagram 2-37.

  • Page 81: Cable Routing Diagram

    Cable routing diagram 2-38 1. Throttle cable 2. Clutch cable 3. Engine stop switch lead 4. Cable guide 5. Head pipe 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 switch lead to the ...

  • Page 82: Cable Routing Diagram

    Cable routing diagram 2-39.

  • Page 83: Cable Routing Diagram

    Cable routing diagram 2-40 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. Injector co...

  • Page 84: Cable Routing Diagram

    Cable routing diagram 2-41.

  • Page 85: Cable Routing Diagram

    Cable routing diagram 2-42 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 86: Cable Routing Diagram

    Cable routing diagram 2-43.

  • Page 87

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

  • Page 88

    Checking the wheel bearings .....................................................3-33 checking and adjusting the steering head ..........................3-33 lubricating the levers ..................................................................3-34 lubricating the pedal .............................

  • Page 89: Maintenance Intervals

    Maintenance intervals 3-1 eas1sl5066 maintenance intervals eas1sl5067 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- 25.) • periodic inspecti...

  • Page 90: 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 91: 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 92: 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 base grease protector guide replace rear shock ab- sorber inspec...

  • Page 93: Maintenance Intervals

    Maintenance intervals 3-5 replace brake flu- id every one year swingarm inspect, lube and retighten molybdenum disulfide grease relay arm, con- necting rod inspect, lube and retighten molybdenum disulfide grease steering head inspect free play and retighten check for tightening torques. Clean and lu...

  • Page 94: Maintenance Intervals

    Maintenance intervals 3-6 levers adjust clutch lever free play kickstarter le- ver, brake ped- al, footrest lubricate outside nuts and bolts retighten refer to “torque-check points” on page 1-25. Item after break- in every race (about 2.5 hours) every third (about 7.5 hours) every fifth (about 12.5 ...

  • Page 95: 3-7

    Pre-operation inspection and maintenance 3-7 eas1sl5068 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. Eas1sl5069 general inspection and ma...

  • Page 96: Engine

    Engine 3-8 eas1sl5070 engine eas1sl5071 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 97: Engine

    Engine 3-9 5. Install: • copper washers • 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 coola...

  • Page 98: Engine

    Engine 3-10 eas1sl5076 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 test pressure. • make sure that a...

  • Page 99: Engine

    Engine 3-11 tip if the clutch lever free play cannot be obtained on the handlebar side, use the adjuster on the clutch cable side. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ clutch cable side a. Slide the clutch cable cover. B. Loosen the locknut “1”. C. Turn the adjuster “2” ...

  • Page 100: Engine

    Engine 3-12 eas1sl5080 lubricating the throttle cable 1. Remove: • cover (throttle cable cap) “1” • cover (grip cap) “2” • throttle grip cap “3” 2. Lubricate: • throttle cable end “a” 3. Install: • throttle grip cap • screw (throttle grip cap) 4. Install: • cover (grip cap) • cover (throttle cable c...

  • Page 101: Engine

    Engine 3-13 4. Check: • air filter element damage  replace. 5. Foam-air-filter oil or equivalent oil to the ele- ment tip squeeze out the excess oil. Element should be wet but not dripping. 6. Install: • air filter guide “1” (to the air filter element) • air filter element “2” • air filter mounting...

  • Page 102: Engine

    Engine 3-14 4. Install: • exhaust pipe protector eas1sl5085 checking the fuel line 1. Remove: • seat • side cover (left/right) • air scoop (left/right) refer to “general chassis” on page 4- 1. • fuel tank refer to “fuel tank” on page 7-1. 2. Check: • fuel hose “1” crack/damage  replace. Loose conne...

  • Page 103: Engine

    Engine 3-15 eas1sl5087 changing the engine oil stand the vehicle upright on a level surface. 1. Start the engine, warm this up for several minutes, and then stop the engine and wait about 5 minutes. 2. Place an oil pan under the drain bolt. 3. Remove: • oil filler cap “1” • drain bolt (with gasket) ...

  • Page 104: Engine

    Engine 3-16 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. 10.Check: • engine oil pressure ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Slightly loosen the oil pressure check bo...

  • Page 105: Engine

    Engine 3-17 tip get the high tension cord “1” of the ignition coil pinched in the detector “a” of the digital tachom- eter. 4. Measure: • engine idling speed out of specification  regulate. 5. Adjust: • engine idling speed ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the starter knob/idle screw “1” in ...

  • Page 106: Engine

    Engine 3-18 tip check that the alignment mark “c” on the cam- shaft sprocket and the alignment mark “d” on the intake camshaft sprocket are aligned with the edge of the cylinder head. C. Measure the valve clearance “e” using a thickness gauge “1”. Tip record the measured reading if the clearance is ...

  • Page 107: Engine

    Engine 3-19 d. Select an adjusting pad with a proper valve clearance from the adjusting pad selection table. Tip • there are 25 types of adjusting pads, ranging from 1.20 mm (0.0472 in) to 2.40 mm (0.0945 in), in increments of 0.05 mm (0.0020 in). • the field where the number on the originally insta...

  • Page 108: Engine

    Engine 3-20 intake exhaust 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.03 ~ 0.07 0.00 ~ 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 120 125 130 135 140 145 150 155 160 165 170 175 180 185 1...

  • Page 109: Chassis

    Chassis 3-21 eas1sl5090 chassis eas1sl5091 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 110: Chassis

    Chassis 3-22 eas1sl5092 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 111: Chassis

    Chassis 3-23 eas1sl5094 adjusting the rear brake 1. Check: • brake pedal position “a” (distance from the top of the rider footrest to the top of the brake pedal) out of specification  regulate. 2. Adjust: • brake pedal position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. B. Turn the...

  • Page 112: Chassis

    Chassis 3-24 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 container under the end of the plastic hose. F. Loosen the bleed screw and push the brake caliper ...

  • Page 113: Chassis

    Chassis 3-25 eas1sl5096 checking the rear brake pads 1. Measure: • brake pad thickness “a” out of specification  replace as a set. Tip the pads worn up to the indicator “b” grooves mean that the brake pad thickness limit is reached. 2. Replace: • brake pads ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remov...

  • Page 114: Chassis

    Chassis 3-26 i. Install the brake caliper “12” and the rear wheel “13”. Refer to “rear wheel” on page 4-7. J. Tighten the pad pin “14”. K. Install the pad pin plug “15” and the protector “16”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Check: • brake fluid level refer to “checking the brake fluid level” on...

  • Page 115: Chassis

    Chassis 3-27 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 reac-...

  • Page 116: Chassis

    Chassis 3-28 eas1sl5100 checking the front fork legs 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. Check: • inner tube damage/scratches  replace. • front fork leg (s) oil leaks between inner tube and ...

  • Page 117: Chassis

    Chassis 3-29 3. Tighten: • air bleed screw eas1sl5104 adjusting the front fork legs ewa32d1006 warning • always adjust the left and right front forks evenly. If this is not done, the vehicle may have poor stability. • securely support the vehicle so that there is no danger of it falling over. Reboun...

  • Page 118: Chassis

    Chassis 3-30 eas1sl5105 checking the swingarm operation 1. Check: • swingarm smooth action • swingarm free play refer to “swingarm” on page 4-60. Eas1sl5106 checking the rear suspension 1. Stand the vehicle upright on a level surface. Ewa@ warning securely support the vehicle so that there is no dan...

  • Page 119: Chassis

    Chassis 3-31 e. Tighten the locknut. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • rear frame refer to “rear shock absorber as- sembly” on page 4-53. Rebound damping force eca@ notice do not turn the adjuster forcibly beyond its adjusting range. 1. Adjust: • rebound damping force ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 120: Chassis

    Chassis 3-32 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ low compression damping eca@ notice do not turn the adjuster forcibly beyond its adjusting range. 1. Adjust: • low compression damping ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjuster “1” in the direction of “a” or “b” to make an adjustment. ▲▲▲▲▲▲▲...

  • Page 121: Chassis

    Chassis 3-33 2. Tighten: • spokes use a spoke nipple wrench “1” for tighten- ing. Tip • do not give a half turn (180 °) or more for one tightening. • make sure that tightening after a break-in is done until the initial looseness in nipples dis- appears. • make sure that tightening is done in stages,...

  • Page 122: Chassis

    Chassis 3-34 c. Turn the front fork to the right and left a few times, and make sure that the steering ro- tates smoothly. If it does not turn smoothly, remove the lower bracket and check the up- per and lower bearings. Refer to “steering head” on page 4-49. D. Loosen the ring nut fully turn and the...

  • Page 123: Electrical System

    Electrical system 3-35 eas1sl5115 electrical system eas1sl5116 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. Eca1dx1001 notice do not use too much force to pull the hose. Tip remove the fu...

  • Page 124: Electrical System

    Electrical system 3-36 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 125: Chassis

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

  • Page 126

    Handlebar .................................................................................................4-31 removing the handlebar...............................................................4-33 checking the handlebar ...............................................................4-33 install...

  • Page 127: General Chassis

    General chassis 4-1 eas1sl5118 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 128: General Chassis

    General chassis 4-2 eas1sl5120 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. Eas1sl5121 removing the seat tip the fuel tank cap cover and the seat are cou...

  • Page 129: Front Wheel

    Front wheel 4-3 eas1sl5123 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 130: Front Wheel

    Front wheel 4-4 eas1sl5124 removing the front wheel 1. Use a suitable stand to raise the front wheel off the ground. Ewa13120 warning securely support the vehicle so that there is no danger of it falling over. 2. Remove: • front wheel eas1sl5125 checking the front wheel 1. Check: • front wheel axle ...

  • Page 131: Front Wheel

    Front wheel 4-5 eas1sl5126 disassembling the front wheel 1. Remove: • oil seals • bearing ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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 screwdriver...

  • Page 132: Front Wheel

    Front wheel 4-6 3. Install: • collar “1” tip apply the lithium soap base grease on the oil seal lip. Eas1sl5128 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 base...

  • Page 133: Rear Wheel

    Rear wheel 4-7 eas1sl5129 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 134: Rear Wheel

    Rear wheel 4-8 eas1sl5130 removing the rear wheel 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: • rear wheel axle nut “1” 3. Loosen: • locknut “2” 4. Tighten: • adjusting bolt “3...

  • Page 135: Rear Wheel

    Rear wheel 4-9 tip tighten the self-locking nuts in stages and in a crisscross pattern. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas1sl5134 assembling the rear wheel 1. Install: • bearing (right side) “1” • circlip “2” • spacer “3” • bearing (left side) “4” • oil seals “5” tip • apply the lithium soap base ...

  • Page 136: Rear Wheel

    Rear wheel 4-10 tip install the brake disc “1” between the brake pads “2” correctly. 2. Install: • drive chain “1” tip push the rear wheel “2” forward and install the drive chain. 3. Install: • left drive chain puller “1” • rear wheel axle “2” tip • install the left drive chain puller, and insert th...

  • Page 137: Front Brake

    Front brake 4-11 eas1sl5136 front brake removing the front brake caliper order part name q’ty remarks brake fluid drain. Refer to “bleeding the brake system” on page 3-21. 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 138: Front Brake

    Front brake 4-12 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 139: Front Brake

    Front brake 4-13 removing the front brake master cylinder order part name q’ty remarks brake fluid drain. Refer to “bleeding the brake system” on page 3-21. 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 140: Front Brake

    Front brake 4-14 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 141: Front Brake

    Front brake 4-15 eas1sl5137 introduction ewa14100 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...

  • Page 142: Front Brake

    Front brake 4-16 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Blow compressed air into the brake hose joint opening to force out the piston from the brake caliper. Ewa13550 warning • cover the brake caliper piston with a rag. Be careful not to get injured when the pis- ton is expelled from the brake caliper....

  • Page 143: Front Brake

    Front brake 4-17 3. Install: • brake caliper piston “1” tip apply the brake fluid on the piston outer sur- face. Eca33dd047 notice • install the piston with its side “a” facing the brake caliper. • never force to insert. Eas1sl5144 installing the front brake caliper 1. Install: • front brake caliper...

  • Page 144: Front Brake

    Front brake 4-18 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 r...

  • Page 145: Front Brake

    Front brake 4-19 warning apply brake fluid to the cylinder cups and install them as shown. Wrong orientation in installation causes poor braking perfor- mance. 3. Install: • spring “1” install to the brake master cylinder piston “2”. Tip install the spring with a smaller inside diameter to the brake...

  • Page 146: Front Brake

    Front brake 4-20 warning proper brake hose routing is essential to in- sure safe vehicle operation. Eca1dx1007 notice during installation, bring the brake hose into contact with the brake master cylinder projection “a” and make its bent portion “b” face downward. Tip turn the handlebar toward right ...

  • Page 147: Rear Brake

    Rear brake 4-21 eas1sl5149 rear brake removing the rear brake caliper order part name q’ty remarks brake fluid drain. Refer to “bleeding the brake system” on page 3-21. 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 148: Rear Brake

    Rear brake 4-22 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 149: Rear Brake

    Rear brake 4-23 removing the rear brake master cylinder order part name q’ty remarks brake fluid drain. Refer to “bleeding the brake system” on page 3-21. 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 150: Rear Brake

    Rear brake 4-24 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 151: Rear Brake

    Rear brake 4-25 eas1sl5150 introduction ewa14300 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 ...

  • Page 152: Rear Brake

    Rear brake 4-26 eas1sl5152 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. Eas1sl5153...

  • Page 153: Rear Brake

    Rear brake 4-27 eas1sl5156 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” ewa33dd033 warn...

  • Page 154: Rear Brake

    Rear brake 4-28 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 155: Rear Brake

    Rear brake 4-29 eas1sl5160 assembling the rear brake master cylinder ewa13520 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 ...

  • Page 156: Rear Brake

    Rear brake 4-30 2. Pour brake fluid to the brake fluid reservoir up to the specified level. Ewa13090 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 tha...

  • Page 157: Handlebar

    Handlebar 4-31 eas1sl5162 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 brake master cylinder 1 5 throttle cable cap 1 6 throttle cable (pull) 1 disconnect. 7 throttle cab...

  • Page 158: Handlebar

    Handlebar 4-32 for installation, reverse the removal proce- dure. Removing the handlebar order part name q’ty remarks.

  • Page 159: Handlebar

    Handlebar 4-33 eas1sl5163 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 160: Handlebar

    Handlebar 4-34 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 161: Handlebar

    Handlebar 4-35 6. Install: • right grip “1” • collar “2” apply adhesive to the tube guide “3”. Tip • before applying the adhesive, wipe off grease or oil on the tube guide surface “a” with a lac- quer thinner. • install the grip to the tube guide so that the grip match mark “b” and tube guide slot “...

  • Page 162: Handlebar

    Handlebar 4-36 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 163: Front Fork

    Front fork 4-37 eas1sl5166 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 4-11. Number plate refer to “general chassi...

  • Page 164: Front Fork

    Front fork 4-38 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 165: Front Fork

    Front fork 4-39 eas1sl5167 removing the front fork legs 1. Use a suitable stand to raise the front wheel off the ground. Ewa13120 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 th...

  • Page 166: Front Fork

    Front fork 4-40 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. Eas1sl5169 checking the front fork legs 1. Check: • inner tube surface “a” scratches  repair or replace. Us...

  • Page 167: Front Fork

    Front fork 4-41 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 168: Front Fork

    Front fork 4-42 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 169: Front Fork

    Front fork 4-43 10.After filling, pump the damper assembly “1” slowly up and down more than 10 times to distribute the fork oil. 11.While protecting the damper assembly “1” with a cloth and compressing fully, allow ex- cessive oil to overflow on the base valve side. Eca32d1010 notice take care not t...

  • Page 170: Front Fork

    Front fork 4-44 15.Install: • inner tube bushing “1” tip install the inner tube bushing onto the slot on inner tube. 16.Install: • outer tube “1” (to the inner tube “2”) 17.Install: • inner tube bushing “1” • washer “2” (to the outer tube) tip press the inner tube bushing into the outer tube with fo...

  • Page 171: Front Fork

    Front fork 4-45 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.Measure: • distance “a” out of specification  turn into the locknut. 23.Install: • collar “1” • for...

  • Page 172: Front Fork

    Front fork 4-46 25.Loosen: • rebound damping force adjuster “1” tip • before loosening the damping force adjuster, record the setting position. • unless the damping force adjuster is fully loosened, correct damping characteristic can- not be obtained after installation. 26.Install: • damper adjustin...

  • Page 173: Front Fork

    Front fork 4-47 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 to enter the front fork. 31.Install: • damper a...

  • Page 174: Front Fork

    Front fork 4-48 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. If torqued too much, it may cause the front fork to malfunction. 5. Install: • protector “1” • bolt (pro...

  • Page 175: Steering Head

    Steering head 4-49 eas1sl5172 steering head removing the lower bracket order part name q’ty remarks 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 “handlebar” on page 4-31. 1 front fender 1 2 steering stem nut 1 3...

  • Page 176: Steering Head

    Steering head 4-50 eas1sl5173 removing the lower bracket 1. Use a suitable stand to raise the front wheel off the ground. Ewa13120 warning securely support the vehicle so that there is no danger of it falling over. 2. Remove: • ring nut “1” tip remove the ring nut with the steering nut wrench “2”. E...

  • Page 177: Steering Head

    Steering head 4-51 2. Install: • bearing races • upper bearing “1” • bearing race cover “2” tip apply the lithium soap base grease on the bearing and bearing race cover lip. 3. Install: • lower bracket “1” tip apply the lithium soap base grease on the bearing, the portion “a” and thread of the steer...

  • Page 178: Steering Head

    Steering head 4-52 8. Install: • steering stem nut “1” tip apply the lithium soap base grease to the con- tact surface of the steering stem nut when in- stalling. 9. After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the steering ring nut littl...

  • Page 179: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-53 eas1sl5176 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 4-54 removing the rear shock absorber assembly order part name q’ty remarks 8 spring 1 9 dust seal 2 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. 2 12 16 15 14 13 12 14...

  • Page 181: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-55 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 4-56 eas1sl5177 handling the rear shock absorber ewa13740 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 hel...

  • Page 183: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-57 2. Remove: • upper bearing “1” tip remove the bearing by pressing its outer race. 3. Remove: • lower bearing “1” tip remove the bearing by pressing its outer race. Eas1sl5181 checking the rear shock absorber assembly 1. Check: • rear shock absorber rod bends/damage ...

  • Page 184: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-58 eas1sl5184 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 because it will wear the rear shock ab- sorber surface on which the bear...

  • Page 185: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-59 • connecting arm bolt (relay arm side) • relay arm bolt (swingarm side) • rear shock absorber assembly lower bolt connecting arm bolt (relay arm side) 80 nm (8.0 m·kgf, 58 ft·lbf) relay arm bolt (swingarm side) 70 nm (7.0 m·kgf, 51 ft·lbf) rear shock absorber assemb...

  • Page 186: Swingarm

    Swingarm 4-60 eas1sl5185 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 4-21. Rear brake caliper refer to “rear brake” on page 4-21. Bolt (brake pedal) drive chain 1 collars 2 2...

  • Page 187: Swingarm

    Swingarm 4-61 eas1sl5186 removing the swingarm 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. Measure: • swingarm side play • swingarm vertical movement ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a...

  • Page 188: Swingarm

    Swingarm 4-62 eas1sl5189 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 4-63 eas1sl5190 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 4-64 eas1sl5191 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” eas1sl5192 checking the ...

  • Page 191: Chain Drive

    Chain drive 4-65 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 eas1sl5193 checking the drive sprocket 1. Check: • drive sprocket more than 1/4 tooth wear “a”  replace the dr...

  • Page 192: Chain Drive

    Chain drive 4-66.

  • Page 193: Engine

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

  • Page 194

    Clutch .........................................................................................................5-37 removing the clutch ......................................................................5-40 checking the friction plates......................................................5-40 c...

  • Page 195

    Ac magneto................................................................................................5-59 removing the ac magneto.............................................................5-60 checking the ac magneto .............................................................5-60 checking t...

  • Page 196: Engine Removal

    Engine removal 5-1 eas1sl5196 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 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, 22 ft • ibf) t .R . 30 nm (3...

  • 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 7 drive sprocket 1 8 upper engine bracket 2 9 lower engine bracket 2 10 pivot shaft 1 11 engine 1 for installation, reverse the removal proce- dure. Removing the engine order part name q’ty remarks new new ls m 8 8 7 6 11 4 5 new 1 10 3 2.

  • Page 201: Engine Removal

    Engine removal 5-6 eas1sl5198 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. Eas1sl5199 removing the exhaust pipe 2 1. Remo...

  • Page 202: Engine Removal

    Engine removal 5-7 eas1sl5201 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 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 silencer body by using a flat board “2”. 6. ...

  • Page 204: Engine Removal

    Engine removal 5-9 eas1sl5205 installing the brake pedal 1. Install: • spring “1” • brake pedal “2” • o-rings “3” • bolt (brake pedal) “4” • clip “5” tip apply the lithium soap base grease on the bolt, o-rings and brake pedal bracket. Eas1sl5206 installing the drive sprocket 1. Install: • drive spro...

  • Page 205: Engine Removal

    Engine removal 5-10 eas1sl5207 installing the exhaust pipe and muffler 1. Install: • gasket • exhaust pipe 1 “1” • nut (exhaust pipe 1) “2” tip first temporarily tighten nuts to 7 nm (0.7 m·kgf, 5.1 ft·lbf). Then retighten them to 10 nm (1.0 m·kgf, 7.2 ft·lbf). 2. Install: • clamp • exhaust pipe 2 “...

  • Page 206: Camshaft

    Camshaft 5-11 eas1sl5208 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 207: Camshaft

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

  • Page 208: Camshaft

    Camshaft 5-13 eas1sl5209 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 209: Camshaft

    Camshaft 5-14 eas1sl5210 checking the camshaft 1. Check: • camshaft lobes blue discoloration/pitting/scratches  re- place the camshaft. 2. Measure: • camshaft lobe dimensions “a” and “b” out of specification  replace the cam- shaft. 3. Measure: • camshaft runout out of specification  replace. 4. ...

  • Page 210: Camshaft

    Camshaft 5-15 c. Install the dowel pins and the camshaft caps. Tip • tighten the camshaft cap bolts in a crisscross pattern from innermost to outer caps. • do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance. D. Remove the camshaft caps and then mea- sure the width...

  • Page 211: Camshaft

    Camshaft 5-16 eas1sl5213 checking the decompression sys- tem 1. Check: • decompression system ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check that the decompressor cam “1” moves smoothly. B. Check that the decompressor lever pin “2” projects from the camshaft. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas1sl5214 i...

  • Page 212: Camshaft

    Camshaft 5-17 tip • before installing the clips, cover the cylinder head with a clean cloth to prevent the clips from coming off into the cylinder head cavity. • tighten the bolts to the specified torque in two or three steps in the proper tightening se- quence as shown. Eca33dd030 notice the bolts ...

  • Page 213: Camshaft

    Camshaft 5-18 6. Install: • cylinder head breather hose • spark plug spark plug 13 nm (1.3m·kgf, 9.4 ft·lbf) 4 4 4 3 2 1 t r . ..

  • Page 214: Cylinder Head

    Cylinder head 5-19 eas1sl5215 cylinder head removing the cylinder head 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 t...

  • Page 215: Cylinder Head

    Cylinder head 5-20 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 1st 2nd final 20 nm (2.0 m • kgf, 14 ft • ibf) t.R . 30 nm (3.0 m • kgf, 22 ft • ibf) 10 nm (1.0 m • kgf, 7.2 ft • ibf) t .R. 10 nm (1.0 m • kgf, 7...

  • Page 216: Cylinder Head

    Cylinder head 5-21 eas1sl5216 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 217: Cylinder Head

    Cylinder head 5-22 eas1sl5219 installing the cylinder head 1. Install: • timing chain guide (intake side) “1” • dowel pin “2” • cylinder head gasket “3” • cylinder head “4” tip while pulling up the timing chain, install the tim- ing chain guide (intake side) and the cylinder head. 2. Install: • wash...

  • Page 218: Cylinder Head

    Cylinder head 5-23 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 219: Valves and Valve Springs

    Valves and valve springs 5-24 eas1sl5220 valves and valve springs removing the valves and valve springs order part name q’ty remarks cylinder head refer to “cylinder head” on page 5-19. 1 valve lifter 4 2 adjusting pad 4 3 valve cotter 8 4 valve spring retainer 4 5 valve spring 4 6 valve stem seal 4...

  • Page 220: Valves and Valve Springs

    Valves and valve springs 5-25 eas1sl5221 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 221: Valves and Valve Springs

    Valves and valve springs 5-26 eas1sl5222 checking the valves and valve guides 1. Measure: • valve-stem-to-valve-guide clearance out of specification  replace the valve guide. 2. Replace: • valve guide tip to ease valve guide removal and installation, and to maintain the correct fit, heat the cylind...

  • Page 222: Valves and Valve Springs

    Valves and valve springs 5-27 tip after replacing the valve guide, reface the valve seat. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Check: • valve face pitting/wear  grind the valve face. • valve stem end mushroom shape or diameter larg...

  • Page 223: Valves and Valve Springs

    Valves and valve springs 5-28 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 width “c”. Tip where the valve seat and the valve face are in contact with each other, the blueing wil...

  • Page 224: Valves and Valve Springs

    Valves and valve springs 5-29 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas1sl5224 checking the valve springs 1. Measure: • valve spring free length “a” out of specification  replace the valve spring. 2. Measure: • compressed valve spring force “a” out of specification  replace the valve spring. 3. Measure...

  • Page 225: Valves and Valve Springs

    Valves and valve springs 5-30 eas1sl5226 installing the valves 1. Clean: • valve stem end 2. Lubricate: • valve stem “1” • valve stem seal “2” 3. Install: • spring seat “1” • valve stem seal “2” • valve “3” • valve spring “4” • valve spring retainer “5” (to the cylinder head) tip • make sure each va...

  • Page 226: Valves and Valve Springs

    Valves and valve springs 5-31 6. Lubricate: • adjusting pad “1” • valve lifter “2” 7. Install: • adjusting pad • valve lifter tip • check that the valve lifter turns smoothly when rotated with your finger. • make sure that the valve lifter and the adjust- ing pad are reinstalled in their original po...

  • Page 227: Cylinder and Piston

    Cylinder and piston 5-32 eas1sl5227 cylinder and piston removing the cylinder and piston order part name q’ty remarks cylinder head refer to “cylinder head” on page 5-19. 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 228: Cylinder and Piston

    Cylinder and piston 5-33 eas1sl5228 removing the piston 1. Remove: • piston pin clip “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 f...

  • Page 229: Cylinder and Piston

    Cylinder and piston 5-34 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 d “a” at the measurement position h “b” with the mi- crometer. D. If out of specification, replace the cylinder, the pis...

  • Page 230: Cylinder and Piston

    Cylinder and piston 5-35 eas1sl5231 checking the piston pin 1. Check: • piston pin blue discoloration/grooves  replace the piston pin and then check the lubrication system. 2. Measure: • piston pin outside diameter “a” out of specification  replace the piston pin. 3. Measure: • piston pin bore ins...

  • Page 231: Cylinder and Piston

    Cylinder and piston 5-36 3. Lubricate: • piston • piston rings • cylinder 4. Offset: • piston ring end gap 5. Install: • cylinder gasket • dowel pin • cylinder tip • while compressing the piston rings with one hand, install the cylinder with the other hand. • pass the timing chain and timing chain g...

  • Page 232: Clutch

    Clutch 5-37 eas1sl5233 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 233: Clutch

    Clutch 5-38 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 234: Clutch

    Clutch 5-39 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 235: Clutch

    Clutch 5-40 eas1sl5234 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. Eas1sl5235 checking the friction plates 1. Check: • friction plate damage/wear  replace the fr...

  • Page 236: Clutch

    Clutch 5-41 eas1sl5238 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. Eas1sl5239 checking the clutch boss 1. Check: • clu...

  • Page 237: Clutch

    Clutch 5-42 eas1sl5244 checking the primary driven gear 1. Check: • primary driven gear damage/wear  replace the primary drive and primary driven gears as a set. Excessive noise during operation  re- place the primary drive and primary driven gears as a set. Eas1sl5245 installing the oil seal 1. I...

  • Page 238: Clutch

    Clutch 5-43 2. Install: • primary driven gear “1” • thrust washer “2” • clutch boss “3” tip apply the engine oil on the primary driven gear inner circumference. 3. Install: • conical washer “1” • clutch boss nut “2” eca1dx1020 notice make sure to tighten to specification; other- wise, it may damage ...

  • Page 239: Clutch

    Clutch 5-44 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: • clutch spring • clutch spring bolt tip tighten the bolts in stages and in a crisscross pattern. 9. Install: • o-ring “1” tip app...

  • Page 240: Clutch

    Clutch 5-45 eas1sl5248 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 in) or more between the kickstarter lever and the frame and that the kickstarter lever does not contact the right...

  • Page 241: Kickstater

    Kickstater 5-46 eas1sl5249 kickstater removing the kick shaft order part name q’ty remarks primary driven gear refer to “clutch” on page 5-37. 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 242: Kickstater

    Kickstater 5-47 eas1sl5250 removing the kick shaft assembly 1. Remove: • kick shaft assembly “1” tip unhook the torsion spring “2” from the hole “a” in the crankcase. Eas1sl5251 checking the kick shaft and ratch- et wheel 1. Check: • ratchet wheel “1” smooth movement unsmooth movement  replace. • k...

  • Page 243: Kickstater

    Kickstater 5-48 3. Install: • spring guide “1” tip slide the spring guide into the kick shaft, make sure the groove “a” in the spring guide fits on the stopper of the torsion spring. 4. Install: • kick shaft assembly “1” tip • before installation, apply molybdenum disul- fide grease to the contactin...

  • Page 244: Shift Shaft

    Shift shaft 5-49 eas1sl5255 shift shaft removing the shift shaft and stopper lever order part name q’ty remarks primary driven gear refer to “clutch” on page 5-37. 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 245: Shift Shaft

    Shift shaft 5-50 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 246: Shift Shaft

    Shift shaft 5-51 eas1sl5256 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. Eas1sl5257 removing the segment 1. Remove: • bolt (segmen...

  • Page 247: Shift Shaft

    Shift shaft 5-52 eas1sl5261 installing the stopper lever 1. Install: • torsion spring “1” • collar “2” • stopper lever “3” • bolt (stopper lever) “4” eas1sl5262 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 248: Shift Shaft

    Shift shaft 5-53 4. Tighten: • shift guide bolt “1” eas1sl5264 installing the shift shaft 1. Install: • roller “1” • shift shaft spring “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 eas1sl5265 insta...

  • Page 249: Oil Pump and Balancer Gear

    Oil pump and balancer gear 5-54 eas1sl5266 oil pump and balancer gear removing the oil pump order part name q’ty remarks primary driven gear refer to “clutch” on page 5-37. Right crankcase cover refer to “clutch” on page 5-37. 1 oil pump assembly 1 2 oil pump cover 1 3 outer rotor 1 4 dowel pin 1 5 ...

  • Page 250: Oil Pump and Balancer Gear

    Oil pump and balancer gear 5-55 removing the balancer order part name q’ty remarks primary driven gear refer to “clutch” on page 5-37. Right crankcase cover refer to “clutch” on page 5-37. Stator refer to “ac magneto” on page 5-59. 1 nut (balancer) 1 2 nut (primary drive gear) 1 3 nut (balancer shaf...

  • Page 251: Oil Pump and Balancer Gear

    Oil pump and balancer gear 5-56 eas1sl5267 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 252: Oil Pump and Balancer Gear

    Oil pump and balancer gear 5-57 3. Check: • oil pump operation rough movement  repeat steps (1) and (2) or replace the defective part(s). Eas1sl5271 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 253: Oil Pump and Balancer Gear

    Oil pump and balancer gear 5-58 notice after tightening the bolts, make sure that the oil pump turns smoothly. 2. Install: • balancer weight gear “1” tip install the balancer weight gear and balancer shaft with their lower splines “a” aligning with each other. 3. Install: • balancer drive gear “1” t...

  • Page 254: Ac Magneto

    Ac magneto 5-59 eas1sl5273 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 disconnect. 2 crank...

  • Page 255: Ac Magneto

    Ac magneto 5-60 eas1sl5274 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 eas1sl5275 checking the ac magneto 1. Check: • rotor inner surface “a” • stator outer surface “b” damage  inspect the cranksh...

  • Page 256: Ac Magneto

    Ac magneto 5-61 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 257: Crankcase

    Crankcase 5-62 eas1sl5278 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 5-32. Balancer refer to “oil pump and balancer gear” on page 5-54. Kick shaft assembly refer to “kickstater” on page 5...

  • Page 258: Crankcase

    Crankcase 5-63 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 259: Crankcase

    Crankcase 5-64 removing the bearing and oil seal order part name q’ty remarks transmission refer to “transmission” on page 5-70. Shift cam and shift fork refer to “transmission” on page 5-70. 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 260: Crankcase

    Crankcase 5-65 eas1sl5279 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 261: Crankcase

    Crankcase 5-66 2. Check: • crankcase crack/damage  replace. • oil delivery passages obstruction  blow out with compressed air. Eas1sl5283 assembling the crankcase 1. Install: • bearing cover plate tip • install the bearing by pressing its outer race parallel. • to prevent the bearing cover plate s...

  • Page 262: 5-67

    Crankshaft assembly and balancer shaft 5-67 eas1sl5284 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 5-62. Transmission refer to “transmission” on page 5-70. 1 balancer shaft 1 ...

  • Page 263: 5-68

    Crankshaft assembly and balancer shaft 5-68 eas1sl5285 removing the balancer shaft 1. Remove: • balancer shaft “1” tip remove the balancer shaft with its flat side “a” facing the crankshaft. Eas1sl5286 removing the crankshaft assembly 1. Remove: • crankshaft assembly “1” tip remove the crankshaft as...

  • Page 264: 5-69

    Crankshaft assembly and balancer shaft 5-69 4. Check: • crankshaft sprocket “1” damage  replace the crankshaft. 5. Check: • crankshaft journal oil passage obstruction  blow out with compressed air. Eas1sl5288 installing the crankshaft assem- bly 1. Install: • crankshaft assembly tip install the cr...

  • Page 265: Transmission

    Transmission 5-70 eas1sl5289 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 5-62. 1 main axle 1 2 drive axle 1 3 long shift fork guide bar 1 4 sho...

  • Page 266: Transmission

    Transmission 5-71 eas1sl5290 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 267: Transmission

    Transmission 5-72 eas1sl5292 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. Eas1sl5293 checking the transmission 1. Measure: • main axle runout (with a c...

  • Page 268: Transmission

    Transmission 5-73 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 269: Transmission

    Transmission 5-74 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 270: Transmission

    Transmission 5-75.

  • Page 271: Cooling System

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

  • Page 272: Radiator

    Radiator 6-1 eas1sl5295 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 273: 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 274: Radiator

    Radiator 6-3 eas1sl5297 handling note ewa1dx1007 warning if coolant seems hot, do not remove the ra- diator cap. Eas1sl5298 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 flatte...

  • Page 275: Water Pump

    Water pump 6-4 eas1sl5299 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 5-37. 1 water pump housing 1 2 dowe...

  • Page 276: Water Pump

    Water pump 6-5 eas1sl5300 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” eas1sl5301 checking the water pump 1. Check: • wa...

  • Page 277: 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 278: Water Pump

    Water pump 6-7.

  • Page 279: Fuel System

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

  • Page 280: Fuel Tank

    Fuel tank 7-1 eas1sl5305 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 281: Fuel Tank

    Fuel tank 7-2 eas1sl5307 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 ewa23p1001 warning cover the fuel hose connection with a cloth when disconnecting it. This is because re- sidual pressure in the fuel hose could ...

  • Page 282: 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 283: Fuel Tank

    Fuel tank 7-4 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 fuel pump. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas1sl5313 checking the damper 1. Check: • damper 1 “1” • damper 2 “2”...

  • Page 284: Throttle Body

    Throttle body 7-5 eas1sl5315 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 285: Throttle Body

    Throttle body 7-6 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 3.5 nm (0.35 m • kgf, 2.5 ft • ibf) t.R . 3.5 nm (0.35 m • kgf, 2.5 ft • ibf) t.R. 7 nm (0.7 m • kgf, 5.1 f...

  • Page 286: 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 287: Throttle Body

    Throttle body 7-8 eas1sl5316 checking the injector 1. Check: • injector 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 injec...

  • Page 288: Throttle Body

    Throttle body 7-9 eas1sl5319 adjusting the throttle position sensor ewa32d1011 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 ...

  • Page 289: Electrical System

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

  • Page 291: 8-1

    8-1 eas1sl5320 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 292: Ignition System

    Ignition system 8-2 eas1sl5321 ignition system eas1sl5322 circuit diagram b/l gy b r a a a a b rr r r r r r b b b r r r lg lg b/w b/y b/y b b b p p p sb b/l p/b p/b y l y l l g/w br/w g/w br/w b/l b/l b/l b/l b/r b/r r/b r/b o o r o r o r r r sb b gy r b/w p l b/l b/l gy b/l b/l b/l b/l b/l ll pp bb...

  • Page 293: 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 9. Ecu 10.Ignition coil 11.Spark plug.

  • Page 294: Ignition System

    Ignition system 8-4 eas1sl5323 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 295: Ignition System

    Ignition system 8-5 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 296: Charging System

    Charging system 8-6 eas27200 charging system eas1sl5324 circuit diagram b/l gy b r a a a a b rr r r r r r b b b r r r lg lg b/w b/y b/y b b b p p p sb b/l p/b p/b y l y l l g/w br/w g/w br/w b/l b/l b/l b/l b/r b/r r/b r/b o o r o r o r r r sb b gy r b/w p l b/l b/l gy b/l b/l b/l b/l b/l ll pp bb b...

  • Page 297: Charging System

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

  • Page 298: Charging System

    Charging system 8-8 eas1sl5325 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 299: Charging System

    Charging system 8-9.

  • Page 300: Fuel Injection System

    Fuel injection system 8-10 eas1sl5326 fuel injection system eas1sl5327 circuit diagram b/l gy b r a a a a b rr r r r r r b b b r r r lg lg b/w b/y b/y b b b p p p sb b/l p/b p/b y l y l l g/w br/w g/w br/w b/l b/l b/l b/l b/r b/r r/b r/b o o r o r o r r r sb b gy r b/w p l b/l b/l gy b/l b/l b/l b/l...

  • Page 301: 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 9. Ecu 12.Fuel injector 13.Fuel pump 14.Intake air temperature sensor 15.Coolant temperature sensor 16.Throttle position sensor 17.Int...

  • Page 302: Fuel Injection System

    Fuel injection system 8-12 eas1sl5328 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 303: Fuel Injection System

    Fuel injection system 8-13 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 how to connect and use the yamaha diagnostic tool, refer to “yamaha digno- stic tool opera...

  • Page 304: 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 305: 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 306: 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 307: 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 308: 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 309: 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 310: 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 311: Fuel Injection System

    Fuel injection system 8-21 tip make sure that the machine is completely cold before checking the intake air temperature sensor. Fault code 22 symptom intake air temperature sensor: open or short circuit detected. Fail-safe system able to start engine able to drive vehicle diagnostic code no. 05 diag...

  • Page 312: Fuel Injection System

    Fuel injection system 8-22 fault code 30 symptom the vehicle has overturned. Fail-safe system able to start engine unable to drive vehicle diagnostic code no. 08 diagnostic tool display displays the lean angle sensor output voltage. • 1.0 v (upright) • 4.0 v (overturned) procedure remove the ecu, an...

  • Page 313: 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 314: 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 315: 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 316: 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 317: 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 318: 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 319: 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 320: 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 321: 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 322: Fuel Pump System

    Fuel pump system 8-32 eas1sl5330 fuel pump system eas1sl5331 circuit diagram b/l gy b r a a a a b rr r r r r r b b b r r r lg lg b/w b/y b/y b b b p p p sb b/l p/b p/b y l y l l g/w br/w g/w br/w b/l b/l b/l b/l b/r b/r r/b r/b o o r o r o r r r sb b gy r b/w p l b/l b/l gy b/l b/l b/l b/l b/l ll pp...

  • Page 323: 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 13.Fuel pump.

  • Page 324: Fuel Pump System

    Fuel pump system 8-34 eas1sl5332 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 325: Fuel Pump System

    Fuel pump system 8-35.

  • Page 326: Electrical Components

    Electrical components 8-36 eas1sl5333 electrical components eas1sl5334 9 10 1 2 3 4 5 6 7 8.

  • Page 327: Electrical Components

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

  • Page 328: Electrical Components

    Electrical components 8-38 eas1sl5335 checking the switches b/y p sb 2 1.

  • Page 329: Electrical Components

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

  • Page 330: 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 331: Electrical Components

    Electrical components 8-41 eas1sl5336 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 332: 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 333: Electrical Components

    Electrical components 8-43 eas1sl5340 checking the ecu 1. Check: • mounted condition of ecu. Improperly mounted  remount. Tip • the lean angle sensor is built into the ecu. • the lean angle sensor stops the engine in case of a turnover. • to ensure that the lean angle sensor operates correctly, do ...

  • Page 334: Electrical Components

    Electrical components 8-44 eas1sl5343 checking the coolant temperature sensor 1. Remove: • coolant temperature sensor ewa14130 warning • handle the coolant temperature sensor with special care. • never subject the coolant temperature sensor to strong shocks. If the coolant temperature sensor is drop...

  • Page 335: Electrical Components

    Electrical components 8-45 2. Check: • throttle position sensor maximum resis- tance out of specification  replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (   1k) to the throttle position sensor. B. Check the throttle position sensor maximum resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 336: Electrical Components

    Electrical components 8-46 eas1sl5346 checking the intake air pressure sensor 1. Check: • intake air pressure sensor output voltage out of specification  replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (20 vdc) to the intake air pressure sensor coupler (wire har- ness side). ...

  • Page 337: Electrical Components

    Electrical components 8-47 eas1sl5349 checking the fuel injector 1. Remove: • fuel injector refer to “throttle body” on page 7-5. 2. Check: • fuel injector resistance out of specification  replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the fuel injector coupler from the fuel injector. B. C...

  • Page 338: Electrical Components

    Electrical components 8-48.

  • Page 339: Troubleshooting

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

  • Page 340: Troubleshooting

    Troubleshooting 9-1 eas1sl5350 troubleshooting eas1sl5351 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 341: Troubleshooting

    Troubleshooting 9-2 3. Ignition system • faulty ecu • faulty crankshaft position sensor • broken generator rotor woodruff key eas1sl5354 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 342: 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 343: 9-4

    List of self-diagnostic and fail-safe actions 9-4 eas1sl5364 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 344: 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 345: 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 346: 9-7

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

  • Page 347: Tuning

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

  • Page 348: Chassis

    Chassis 10-1 eas1sl5366 chassis eas1sl5367 selection of the secondary reduc- tion ratio (sprocket) *for eur and jpn 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 ma...

  • Page 349: Chassis

    Chassis 10-2 eas1sl5369 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 350: Chassis

    Chassis 10-3 eas1sl5372 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 351: 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 352: Chassis

    Chassis 10-5 eas1sl5377 rear shock absorber setting parts • rear shock spring “1” *except for usa and can 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. • extent of adjustment (spring preload) tip for the spring preload...

  • Page 353: Chassis

    Chassis 10-6 eas1sl5378 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 354: Chassis

    Chassis 10-7 eas1sl5379 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 355: 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 356: Wiring Diagram

    Eas1sl5381 wiring diagram yz450f/yz450ff 2015 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. Ecu 10.Ignition coil 11.Spark plug 12.Injector 13.Fuel pump 14.Intake ...

  • Page 358

    Printed in japan (e) printed on recycled paper.

  • Page 359

    A a a a b r r r r r r r b b b r r r lg lg b/w b/y b/y b b b p p p sb b/l p/b p/b y l y l l g/w br/w g/w br/w b/l b/l b/l b/l b/r b/r r/b r/b o o r o r o r r r sb b gy r b/w p l b/l b/l gy b/lb/lb/lb/lb/l l l p p b b b b 4 1 3 2 5 6 7 8 10 9 12 11 13 14 15 16 17 p p sb r b b/r r r b b/l gy b r b/y p ...

  • Page 360

    A a a a b (black) (black) 4 1 3 2 5 6 7 8 10 9 12 11 13 14 15 16 17 wiring diagram yz450f/yz450ff 2015 schÉma de cblage yz450f/yz450ff 2015 schaltplan yz450f/yz450ff 2015 1sl-28199-81_w.D.Indd 2 2014/03/07 10:18:57.