Page 1 Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. q Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen. OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE FAHRER- UND WARTUNGSHANDBUCH YZ450F YZ450FG B11-28199-80...
Page 2 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit être remis avec le véhicule en cas de vente de ce dernier. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
Page 3 2015 2016 Read this manual carefully before operating this vehicle. Read this manual carefully before operating this vehicle. OWNER’S SERVICE MANUAL OWNER’S SERVICE MANUAL YZ450F YZ450F YZ450FG B11-28199-80-E0...
Page 5 EASB111002 YZ450F YZ450FG OWNER’S SERVICE MANUAL ©2015 by Yamaha Motor Co., Ltd. First edition, March 2015 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
Page 6: Important Manual Information
INTRODUCTION EASB111003 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.
Page 7: Safety Information
SAFETY INFORMATION EASB111005 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. •...
Page 8: How To Use This Manual
HOW TO USE THIS MANUAL EASB111006 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 section title “1”...
Page 9 SYMBOLS EASB111007 The following symbols are used in this manual for easier understanding. 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 tool Wheel bearing grease Tightening torque...
Page 11: Table Of Contents
TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING TUNING...
Page 13: General Information
GENERAL INFORMATION LOCATION OF IMPORTANT LABELS............1-1 DESCRIPTION....................1-4 IDENTIFICATION .....................1-5 VEHICLE IDENTIFICATION NUMBER ............1-5 ENGINE SERIAL NUMBER ...............1-5 INCLUDED PARTS ..................1-6 SIDESTAND ....................1-6 SPARK PLUG WRENCH ................1-6 NIPPLE WRENCH..................1-6 HANDLEBAR PROTECTOR ..............1-6 FUEL HOSE JOINT COVER ..............1-6 COUPLER FOR CONNECTING OPTIONAL PART........1-6 IMPORTANT INFORMATION ................1-8 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-8 REPLACEMENT PARTS................1-8...
Page 14 STARTING AND BREAK-IN ................1-21 FUEL ......................1-21 STARTING A COLD ENGINE ..............1-21 STARTING A WARM ENGINE..............1-22 BREAK-IN PROCEDURES ..............1-22 MAINTENANCE AFTER BREAK-IN ..............1-23 MAJOR MAINTENANCE................1-23 TORQUE-CHECK POINTS ................1-24 CLEANING AND STORAGE................1-26 CLEANING ....................1-26 STORAGE ....................1-26...
Page 15: Location Of Important Labels
LOCATION OF IMPORTANT LABELS LOCATION OF IMPORTANT LABELS EASB111008 Please read the following important labels carefully before operating this vehicle. 1,2,3 4,5,6 9,10,11...
Page 16 LOCATION OF IMPORTANT LABELS...
Page 17 LOCATION OF IMPORTANT LABELS AUS, NZL, ZAF...
Page 18: Description
DESCRIPTION DESCRIPTION EASB111009 17 16 15 1. Clutch lever 10. Radiator 2. Front brake lever 11. Coolant drain bolt 3. Throttle grip 12. Rear brake pedal 4. Radiator cap 13. Air filter 5. Fuel tank cap 14. Drive chain 6. Launch control switch 15.
Page 19: 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 need the number to search for and identify your vehicle.
Page 20: Included Parts
INCLUDED PARTS HANDLEBAR PROTECTOR INCLUDED PARTS EASB111013 Install the handlebar protector “1” with the mark “a” facing forward. EASB111014 SIDESTAND The sidestand “1” is used to support only the machine when standing or transporting it. EWA@ WARNING • Never apply additional force to the sides- tand.
Page 21 INCLUDED PARTS Part name Part number GYTR Power Tuner 33D-H59C0-V0-00 (For USA) YZ Power Tuner 33D-859C0-10 (Except for USA) The Power Tuner is an optional part.
Page 22: Important Information
2. Use proper special tools and equipment. used for repair of the vehicle, including periodic See “SPECIAL TOOLS”. replacement parts, are new YAMAHA genuine parts and recommended parts. Do not use any used parts, because these may not be genuine though they have similar ap- pearances or because the quality may be changed by aging.
Page 23: Gaskets, Oil Seals And O-Rings
IMPORTANT INFORMATION GASKETS, OIL SEALS AND O-RINGS BEARINGS AND OIL SEALS EASB111022 EASB111024 1. When overhauling the engine, replace all Install bearings “1” and oil seals “2” with their gaskets and O-rings. All gasket surfaces, oil manufacturer’s marks or size symbols facing seal lips, and O-rings must be cleaned so outward.
Page 24: Basic Service Information
BASIC SERVICE INFORMATION Checking the electrical system BASIC SERVICE INFORMATION EASB111026 ECA14371 NOTICE EASB111027 ELECTRICAL SYSTEM Never insert the tester probes into the cou- pler terminal slots. Always insert the probes Electrical parts handling from the opposite end “a” of the coupler, ECA16620 taking care not to loosen or damage the NOTICE...
Page 25 BASIC SERVICE INFORMATION Checking the connections 2. Check: Check leads, couplers, and connectors for • Lead stains, rust, moisture, etc. • Coupler 1. Disconnect: • Connector Moisture  Dry with compressed air. • Lead Rust/stains  Connect and disconnect sev- •...
Page 26 BASIC SERVICE INFORMATION 4. Connect: 5. Check: • Lead • No continuity • Coupler Pocket tester • Connector 90890-03112 Analog pocket tester YU-03112-C • When connecting a coupler or a connector, make sure that both terminals are connected securely. • Make sure all connections are tight. •...
Page 27: Special Tools
SPECIAL TOOLS SPECIAL TOOLS EASB111028 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 tool differ by country, so two types are provided.
Page 28 SPECIAL TOOLS Tool name/Part number How to use Illustration Radiator cap tester This tool is used to check the 90890-01325 radiator and the radiator cap. Mityvac cooling system tester YU-24460-A Radiator cap tester adapter This tool is used to check the 90890-01352 radiator and the radiator cap.
Page 29 90890-03207 voltage. YU-03207 FI diagnostic tool sub-lead This tool is used to connect 90890-03212 the Yamaha diagnostic tool YU-03212 to a battery. Yamaha diagnostic tool This tool is used to check er- 90890-03231 ror codes or carry out self-di- Yamaha diagnostic tool (US) agnosis.
Page 30 SPECIAL TOOLS Tool name/Part number How to use Illustration Valve spring compressor This tool is used to discon- 90890-04019 nect or connect the valve and YM-04019 the valve spring. YM-04019 Spacer (crankshaft installer) This tool is used to install the 90890-04081 crankshaft.
Page 31 SPECIAL TOOLS Tool name/Part number How to use Illustration Crankcase separating tool This tool is used to remove 90890-04152 the crankshaft. YU-A9642 Ignition checker This tool is used to check the 90890-06754 spark performance of the ig- Oppama pet-4000 spark nition coil.
Page 32: Control Functions
CONTROL FUNCTIONS CONTROL FUNCTIONS EASB111029 When the launch control switch is turned off, in- EASB111030 ENGINE STOP SWITCH dicator will stop flashing. The engine stop switch “1” is located on the left handlebar. Continue pushing the engine stop switch till the engine comes to a stop. CLUTCH LEVER EASB111032 The clutch lever “1”...
Page 33: Kickstarter Lever
CONTROL FUNCTIONS KICKSTARTER LEVER REAR BRAKE PEDAL EASB111034 EASB111037 The kickstarter lever “1” is in the right of the The rear brake pedal “1” is in the right of the chassis. chassis. Press down on the brake pedal to ac- To start the engine, pull out and push down the tivate the rear brake.
Page 34: Fuel Tank Cap
CONTROL FUNCTIONS FUEL TANK CAP EASB111039 Fuel tank cap “1” is located under the fuel tank cap cover “2”. Remove the fuel tank cap cover to open the fuel tank cap. • To remove the fuel tank cap cover, insert fin- gers under part “a”, and then use both hands to lift it up towards the rear of the vehicle.
Page 35: Starting And Break-In
3. Push down the kickstarter lever lightly until resistance is felt. Your Yamaha engine has been designed to use 4. Fully close the throttle, and push down the premium unleaded gasoline with a pump oc- kickstarter lever in a stroke.
Page 36: Starting A Warm Engine
STARTING AND BREAK-IN 7. To stop the engine, push the engine stop NOTICE switch “1”. After a break-in or after each race, always check the points shown in “TORQUE- Continue pushing the engine stop switch till the CHECK POINTS” for tightening torques and engine comes to a full stop.
Page 37: Maintenance After Break-In
MAINTENANCE AFTER BREAK-IN • Cable MAINTENANCE AFTER BREAK-IN EASB111045 Grease and adjust cables. After a break-in, perform careful maintenance • Drive chain to get ready for the next practice or race. Lubricate the drive chain and adjust its ten- Refer to “PRE-OPERATION INSPECTION sion.
Page 38: Torque-Check Points
TORQUE-CHECK POINTS TORQUE-CHECK POINTS EASB111047 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 handlebar Steering stem to frame...
Page 39 TORQUE-CHECK POINTS Plastic cover Tightening of number plate Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake disc cov- Tightening of rear brake caliper cover Concerning the tightening torque, refer to “TIGHTENING TORQUES”...
Page 40: Cleaning And Storage
CLEANING AND STORAGE 3. Remove the drive chain, clean it thoroughly CLEANING AND STORAGE EASB111048 with solvent, and lubricate it Reinstall the drive chain or store it in a plastic bag tied to EASB111049 CLEANING the frame. Frequent cleaning of your vehicle will enhance 4.
Page 41: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS .................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-11 TIGHTENING TORQUES ................2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-12 ENGINE TIGHTENING TORQUES............2-13 CHASSIS TIGHTENING TORQUES............2-17 LUBRICATION POINTS AND LUBRICANT TYPES ........2-20 ENGINE....................2-20 CHASSIS....................2-21 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-23 LUBRICATION DIAGRAMS ..............2-23 CABLE ROUTING DIAGRAM ................2-31...
Page 42: General Specifications
GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS EASB111051 Model Model B111, B115 (USA) (CAN) B112, B116 (EUR) B113 (JPN) B114, B117 (AUS) (NZL) (ZAF) Dimensions Overall length 2180 mm (85.8 in) Overall width 825 mm (32.5 in) Overall height 1280 mm (50.4 in) Seat height 965 mm (38.0 in) Wheelbase...
Page 43: Engine Specifications
ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS EASB111052 Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 450 cm 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 unleaded gasoline only Fuel tank capacity 7.5 L (1.98 US gal, 1.65 Imp.gal) Engine oil...
Page 44 ENGINE SPECIFICATIONS Cylinder head Combustion chamber volume 25.98–26.78 cm (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-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) Camshaft lobe dimensions Lobe height (Intake)
Page 45 ENGINE SPECIFICATIONS Valve spring Free length (intake) 40.76 mm (1.60 in) Limit 38.72 mm (1.52 in) Free length (exhaust) 36.94 mm (1.45 in) Limit 35.09 mm (1.38 in) Installed length (intake) 34.78 mm (1.37 in) Installed length (exhaust) 30.83 mm (1.21 in) Spring rate K1 (intake) 31.90 N/mm (3.25 kgf/mm, 182.15 lbf/in) Spring rate K2 (intake)
Page 46 ENGINE SPECIFICATIONS Crankshaft Crank assembly width 61.95–62.00 mm (2.439–2.441 in) Runout limit 0.030 mm (0.0012 in) Big end side clearance 0.150–0.450 mm (0.0059–0.0177 in) Balancer Balancer drive method Gear Clutch Clutch type Wet, multiple-disc Clutch release method Inner push, cam push Clutch lever free play 7.0–12.0 mm (0.28–0.47 in) Friction plate thickness...
Page 47 ENGINE SPECIFICATIONS Throttle body Type/quantity 30RA-JX1A/1 ID mark 1SL5 10 Fuel line pressure at idling 324.0 kPa (3.24 kgf/cm , 47.0 psi) Throttle position sensor Resistance 6.30 k Output voltage (at idle) 0.48–0.52 V Fuel injection sensor 228–342  Crankshaft position sensor resistance Intake air pressure sensor output voltage 3.57–3.71 V at 101.3 kPa 290–390 ...
Page 48: Chassis Specifications
CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS EASB111053 Chassis Frame type Semi double cradle Caster angle 27.25 ° Trail 118 mm (4.6 in) Front wheel Wheel type Spoke wheel 21  1.60 Rim size Rim material Aluminum Wheel travel 310 mm (12.2 in) Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit...
Page 49 CHASSIS SPECIFICATIONS Front brake Type Single disc brake Operation Right hand operation Front disc brake Disc outside diameter  thickness 270  3.0 mm (10.6  0.12 in) Brake disc thickness limit 2.5 mm (0.10 in) Brake pad lining thickness (inner) 4.4 mm (0.17 in) Limit 1.0 mm (0.04 in)
Page 50 CHASSIS SPECIFICATIONS Rebound damping adjusting positions Minimum 20 clicks out* Standard 11 clicks out* Maximum Fully turned in *With the adjuster fully turned in Compression damping adjusting positions Minimum 20 clicks out* Standard 8 clicks out* (USA) (CAN) 16 clicks out* (EUR) (JPN) (AUS) (NZL) (ZAF) Maximum Fully turned in *With the adjuster fully turned in...
Page 51 CHASSIS SPECIFICATIONS Swingarm Swingarm end free play limit (radial) 1.0 mm (0.04 in) Swingarm end free play limit (axial) 0.2–0.9 mm (0.01–0.04 in) Drive chain Size/manufacturer 520DMA2-SDH/DAIDO Number of links Drive chain slack 50–60 mm (1.97–2.36 in) 15-link length limit 242.9 mm (9.56 in) 2-10...
Page 52: Electrical Specifications
Advancer type Digital Ignition timing (B.T.D.C.) 10.0 ° at 2000 r/min Engine control unit Model/manufacturer B110/YAMAHA (USA) (CAN) B111/YAMAHA (EUR) (JPN) (AUS) (NZL) (ZAF) Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64  Primary coil resistance Secondary coil resistance 8.64–12.96 k...
Page 53: Tightening Torques
TIGHTENING TORQUES TIGHTENING TORQUES EAS20320 EASB111055 GENERAL TIGHTENING TORQUE SPECIFI- CATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a criss- cross pattern and progressive stages until the specified tightening torque is reached.
Page 54: Engine Tightening Torques
TIGHTENING TORQUES ENGINE TIGHTENING TORQUES EASB111056 - marked portion shall be checked for torque tightening after break-in or before each race. Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Cylinder head blind plug 28 Nm (2.8 m·kgf, 20 ft·lbf) Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Page 55 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Air filter joint clamp bolt 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Air filter case bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Air filter bolt 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) Air filter guide holder screw 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) Air filter case cap screw 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Page 56 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Primary drive gear nut 100 Nm (10 m·kgf, 72 ft·lbf) Clutch spring bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Clutch boss nut 75 Nm (7.5 m·kgf, 54 ft·lbf) Use a Drive sprocket nut 75 Nm (7.5 m·kgf, 54 ft·lbf) lock washer.
Page 57 TIGHTENING TORQUES *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 further to reach the specified angle 150°...
Page 58: Chassis Tightening Torques
TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES EASB111057 - marked portion shall be checked for torque tightening after break-in or before each race. Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Outer tube and upper bracket bolt 21 Nm (2.1 m·kgf, 15 ft·lbf) Outer tube and lower bracket bolt 21 Nm (2.1 m·kgf, 15 ft·lbf) Upper bracket and steering stem nut...
Page 59 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Front wheel axle pinch bolt 21 Nm (2.1 m·kgf, 15 ft·lbf) Front brake disc bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Rear brake disc bolt 14 Nm (1.4 m·kgf, 10 ft·lbf) Footrest bracket bolt 55 Nm (5.5 m·kgf, 40 ft·lbf) Rear brake pedal bolt...
Page 60 TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Drive chain tensioner bolt (lower 16 Nm (1.6 m·kgf, 12 ft·lbf) side) Drive chain support bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Drive chain support nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Drive chain guide bolt 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Rear frame and left cover bolt...
Page 61: Lubrication Points And Lubricant Types
LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES EASB111058 EASB111059 ENGINE Lubrication point Lubricant types Oil seal lips Bearing O-ring Camshaft cap bolt threads and contacting surface Cylinder head bolt threads, seats, washers Valve stems Valve stem ends Valve lifter outer surface Camshaft lobe and journal Valve lifter top surface...
Page 62: Chassis
LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Three Bond Cylinder head cover gasket No.1215® Three Bond Crankcase mating surface No.1215® Three Bond Stator assembly lead grommet No.1215® EASB111060 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...
Page 63 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Front brake caliper dust seal Front brake caliper piston outer surface Front brake caliper pin bolt and boot Front brake master cylinder push rod end Front brake master cylinder kit Rear brake caliper piston Rear brake caliper piston seal Rear brake caliper dust seal Rear brake caliper piston outer surface...
Page 64: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION SYSTEM CHART AND DIAGRAMS EASB111061 EASB111062 LUBRICATION DIAGRAMS 2-23...
Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 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 2-24...
Page 66 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25...
Page 67 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Connecting rod 2. Crankshaft 3. Main axle 4. Oil strainer 5. Drive axle 2-26...
Page 68 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
Page 69 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Exhaust camshaft 2. Intake camshaft 3. Oil filter element 4. Oil pump 2-28...
Page 70 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
Page 71 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil pressure check bolt 3. Oil filter element 4. Oil pump 2-30...
Page 72: Cable Routing Diagram
CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM EASB111063 2-31...
Page 73 CABLE ROUTING DIAGRAM Q. After connecting the neutral switch coupler, at- 1. Clutch cable tach the coupler cover. 2. Throttle cable (return) R. After connecting the AC magneto coupler, attach 3. Throttle cable (pull) the coupler cover. 4. Launch control switch lead S.
Page 74 CABLE ROUTING DIAGRAM 2-33...
Page 75 CABLE ROUTING DIAGRAM S. Insert the projection on the plastic locking tie into 1. Bracket the hole in the rear frame. 2. Condenser T. Clamp the painted part on the fuel hose by the 3. Coolant temperature sensor plastic clamp. Make the lock on the plastic clamp 4.
Page 76 CABLE ROUTING DIAGRAM 2-35...
Page 77 CABLE ROUTING DIAGRAM 1. Throttle cable 2. Clutch cable 3. Plastic band 4. Engine stop switch lead 5. Launch control switch lead 6. Front brake hose 7. Brake hose guide 8. Number plate A. Number plate band B. Pass the clutch cable to the rear of the number plate band.
Page 78 CABLE ROUTING DIAGRAM 2-37...
Page 79 CABLE ROUTING DIAGRAM 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.
Page 80 CABLE ROUTING DIAGRAM 2-39...
Page 81 CABLE ROUTING DIAGRAM 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.
Page 82 CABLE ROUTING DIAGRAM 2-41...
Page 83: Periodic Checks And Adjustments
PERIODIC CHECKS AND ADJUSTMENTS MAINTENANCE INTERVALS ................3-1 MAINTENANCE INTERVALS ..............3-1 PRE-OPERATION INSPECTION AND MAINTENANCE.........3-7 GENERAL INSPECTION AND MAINTENANCE........3-7 ENGINE ......................3-8 CHECKING THE COOLANT LEVEL............3-8 CHECKING THE COOLING SYSTEM ............3-8 CHANGING THE COOLANT..............3-8 CHECKING THE RADIATOR CAP ............3-9 CHECKING THE RADIATOR CAP VALVE OPENING PRESSURE ..3-9 CHECKING THE COOLANT CIRCULATORY SYSTEM FOR LEAKS ..3-10 ADJUSTING THE CLUTCH LEVER POSITION ........3-10 ADJUSTING THE CLUTCH LEVER FREE PLAY........3-11...
Page 84 CHECKING THE WHEEL BEARINGS .............3-34 CHECKING AND ADJUSTING THE STEERING HEAD ......3-35 LUBRICATING THE LEVERS ..............3-36 LUBRICATING THE PEDAL ..............3-36 ELECTRICAL SYSTEM..................3-37 CHECKING THE SPARK PLUG ..............3-37 CHECKING THE IGNITION TIMING............3-37...
Page 85: Maintenance Intervals
MAINTENANCE INTERVALS MAINTENANCE INTERVALS EASB111064 EASB111065 MAINTENANCE INTERVALS ECA@ NOTICE • After a break-in or before each race, always check the points shown in “TORQUE-CHECK POINTS” for tightening torques and retighten them. (“TORQUE-CHECK POINTS” on page 1- 24.) • Periodic inspection is essential in making full use of the machine performance. The life of parts varies significantly according to the environment in which the machine runs (e.g., rain, dirt, etc.).
Page 86 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) 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.
Page 87 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) NUT (ROTOR) Retighten Check for tightening torques. EXHAUST PIPE, SI- LENCER, PROTEC- Inspect and re- Check for exhaust leaks, and tighten tightening torques.
Page 88 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) FUEL TANK, FUEL PUMP Inspect FUEL HOSE Inspect Replace Every four years FRONT FORK LEG Clean Dust seal Inspect and adjust Replace oil Replace oil seal...
Page 89 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) BRAKE(S) Adjust lever posi- tion and pedal height Lubricate pivot point Check brake disc surface Check fluid level and leakage Retighten brake Check for tightening torques.
Page 90 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) DRIVE CHAIN Use chain oil. Clean, lubricate, slack, alignment Replace DRIVE CHAIN GUIDE Inspect Inspect wear. DRIVE CHAIN GUIDE AND DRIVE CHAIN SUPPORT Replace...
Page 91: Pre-Operation Inspection And Maintenance
PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE EASB111066 Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. GENERAL INSPECTION AND MAINTENANCE EASB111067 ITEM inspect Page...
Page 92: Engine
ENGINE ENGINE CHECKING THE COOLING SYSTEM EASB111068 EASB111070 1. Remove: EASB111069 CHECKING THE COOLANT LEVEL • Seat • Side cover (left/right) EWA1DX1003 WARNING • Air scoop (left/right) If coolant seems hot, do not remove the ra- Refer to “GENERAL CHASSIS” on page 4- diator cap.
Page 93: Checking The Radiator Cap
ENGINE 5. Install: CHECKING THE RADIATOR CAP EASB111072 • Copper washer 1. Check: • Coolant drain bolt • Seal (radiator cap) “1” • Valve and valve seat “2” Coolant drain bolt Crack/damage  Replace. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Exist fur deposits ...
Page 94: Checking The Coolant Circulatory System For Leaks
ENGINE 4. Check: • Pressure value No stay for 5 to 10 seconds at the test pres- sure value  Correct. • Radiator • Radiator hose connections Coolant leaks  Correct or replace. • Radiator hoses Bulges  Replace EWA@ WARNING ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 95: Adjusting The Clutch Lever Free Play
ENGINE ADJUSTING THE CLUTCH LEVER FREE EASB111076 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Clutch cable side PLAY a. Slide the clutch cable cover. 1. Check: b. Loosen the locknut “1”. • Clutch lever free play “a” Out of specification  Regulate. c. Turn the adjuster “2” in direction “a” or “b” until the specified clutch lever free play is ob- Clutch lever free play tained.
Page 96: Lubricating The Throttle Cable
ENGINE 2. Adjust: • Throttle grip free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. b. Turn the adjuster “2” until the specified free play is obtained. Direction “a” Throttle grip free play is increased. Direction “b” Throttle grip free play is decreased. 3.
Page 97: Checking The Throttle Body Joint
ENGINE 3. Wash: 7. Install: • Air filter element • Air filter case cover “1” WARNING Align the air filter case cover groove “a” with the Do not use gasoline or organic (acid/alka- air filter case edge “b”. line) volatile oil for washing. After washing the element with air filter cleaner or kerosene, squeeze and dry it completely.
Page 98: Checking The Exhaust System
ENGINE CHECKING THE EXHAUST SYSTEM CHECKING THE FUEL LINE EASB111082 EASB111083 1. Remove: 1. Remove: • Exhaust pipe protector • Seat 2. Check: • Side cover (left/right) • Exhaust pipe 1 • Air scoop (left/right) • Exhaust pipe 2 Refer to “GENERAL CHASSIS” on page 4- •...
Page 99: Changing The Engine Oil
ENGINE ECA33DD018 NOTICE • Since engine oil also lubricates the clutch, the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives. • Do not allow foreign material to enter the crankcase. Recommended brand YAMALUBE 4.
Page 100: Adjusting The Engine Idling Speed
ENGINE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Slightly loosen the oil pressure check bolt “1”. WARNING When the engine is started with the check bolt removed, oil will spout; therefore, al- ways loosen it before the checkup. d. Install the oil strainer. Oil strainer bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 101: Adjusting The Valve Clearance
YU-39951-B • This section is intended for those who have basic knowledge and skill concerning the ser- vicing of Yamaha motorcycles (e.g., Yamaha Get the high tension cord “1” of the ignition coil dealers, service engineers, etc.). Those who pinched in the detector “a” of the digital tachom- have little knowledge and skill concerning ser- eter.
Page 102 ENGINE 3. Remove: • Timing mark accessing screw “1” • Crankshaft end accessing screw “2” • O-ring c. Measure the valve clearance “e” using a thickness gauge “1”. Record the measured reading if the clearance 4. Check: is incorrect. • Valve clearance Out of specification ...
Page 103 ENGINE Valve lapper • There are 25 types of adjusting pads, ranging 90890-04101 from 1.20 mm (0.0472 in) to 2.40 mm (0.0945 Valve lapping tool in), in increments of 0.05 mm (0.0020 in). YM-A8998 • The field where the number on the originally installed adjusting pad and the measured valve clearance intersect shows the adjusting pad number to replace.
Page 104 ENGINE INTAKE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230...
Page 105 ENGINE 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 0.00 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 0.03 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225...
Page 106: Chassis
CHASSIS CHASSIS EASB111088 EASB111089 BLEEDING THE BRAKE SYSTEM EWA13100 WARNING Bleed the brake system whenever: • The system is disassembled. • A brake hose is loosened, disconnected, or replaced. • The brake fluid level is very low. • Brake operation is faulty. A.
Page 107: Checking The Brake Hose
CHASSIS CHECKING THE BRAKE HOSE EASB111090 1. Check: • Brake hose “1” Cracks/damage/wear  Replace. 2. Remove: • Brake lever cover 3. Adjust: • Brake lever position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. b. Turn the adjusting bolt “2” in direction “a” or “b”...
Page 108: Adjusting The Rear Brake
CHASSIS 4. Install: WARNING • Brake lever cover A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake ADJUSTING THE REAR BRAKE EASB111092 system. Before running, bleed the brake 1. Check: system. Air in the brake system will cause •...
Page 109 CHASSIS 2. Replace: f. Loosen the bleed screw and push the brake • Brake pads caliper piston in. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ WARNING a. Remove the pad pin plug “1”. Do not reuse the drained brake fluid. g. Tighten the bleed screw. Bleed screw 6 Nm (0.6 m·kgf, 4.3 ft·lbf) h.
Page 110: Checking The Rear Brake Pads
CHASSIS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the protector “1” and the pad pin plug “2”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Check: • Brake fluid level Refer to “CHECKING THE BRAKE FLUID b. Loosen the pad pin “3”. LEVEL” on page 3-27. c. Remove the rear wheel “4” and the brake 4.
Page 111: Checking The Rear Brake Pad Insulator
CHASSIS f. Loosen the bleed screw and push the brake caliper piston in. WARNING Do not reuse the drained brake fluid. g. Tighten the bleed screw. Bleed screw 6 Nm (0.6 m·kgf, 4.3 ft·lbf) h. Install the brake pad “10” and the pad pin “11”.
Page 112: Adjusting The Drive Chain Slack
CHASSIS 2. Check: 1. Use a suitable stand to raise the rear wheel • Brake fluid level off the ground. The minimum level mark “a” or below  EWA13120 WARNING Add. Securely support the vehicle so that there is Specified brake fluid no danger of it falling over.
Page 113: Checking The Front Fork Legs
CHASSIS CHECKING THE FRONT FORK PROTEC- EASB111099 • To maintain the proper wheel alignment, ad- TOR GUIDE just both sides evenly. 1. Check: • Push the rear wheel forward to make sure that • Protector guide “1” there is no clearance between the swingarm Out of specification ...
Page 114: Air Bleeding From Front Fork
CHASSIS 2. Clean: ADJUSTING THE FRONT FORK LEGS • Dust seal “a” EWA32D1006 WARNING • Oil seal “b” • Always adjust the left and right front forks evenly. If this is not done, the vehicle may • Clean the dust seal and oil seal after every have poor stability.
Page 115: Checking The Swingarm Operation
CHASSIS Compression damping CHECKING THE REAR SUSPENSION 1. Stand the vehicle upright on a level surface. ECA@ NOTICE Do not turn the adjuster forcibly beyond its WARNING Securely support the vehicle so that there is adjusting range. no danger of it falling over. 1.
Page 116 CHASSIS 2. Adjust: • Spring preload ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. b. Loosen the adjuster “2” until there is some clearance between the spring and the ad- juster. c. Measure the spring free length “a”. e. Tighten the locknut. Locknut 30 Nm (3.0 m·kgf, 22 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 117 CHASSIS Compression damping (for slow compres- sion damping) ECA@ NOTICE Do not turn the adjuster forcibly beyond its adjusting range. 1. Adjust: • Compression damping (for slow compres- sion damping) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjuster “1” in the direction of “a” or ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 118: Checking The Tires
CHASSIS 2. Tighten: CHECKING THE TIRES EASB111106 • Spokes 1. Measure: Use a spoke nipple wrench “1” for tighten- • Tire pressure ing. Out of specification  Regulate. Tire air pressure (measured on cold tires) Front 100 kPa (1.00 kgf/cm , 15 psi) Rear 100 kPa (1.00 kgf/cm...
Page 119: Checking And Adjusting The Steering Head
CHASSIS CHECKING AND ADJUSTING THE STEER- EASB111110 ING HEAD 1. Use a suitable stand to raise the front wheel off the ground. WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Check: • Steering head Grasp the bottom of the front fork legs and Steering nut wrench gently rock the front fork.
Page 120: Lubricating The Levers
CHASSIS 5. Install: • Upper bracket Refer to “STEERING HEAD” on page 4-51. • Handlebar Refer to “HANDLEBAR” on page 4-32. LUBRICATING THE LEVERS EASB111111 1. Lubricate the pivoting points and metal-to- metal moving parts of the following parts. • Brake lever Recommended lubricant Silicone grease •...
Page 121: Electrical System
ELECTRICAL SYSTEM 5. Clean: ELECTRICAL SYSTEM EASB111113 • Spark plug (with a spark plug cleaner or a wire brush) EASB111114 CHECKING THE SPARK PLUG 6. Measure: 1. Remove: • Spark plug gap “a” • Seat Out of specification  Adjust the spark plug •...
Page 122 ELECTRICAL SYSTEM 2. Attach: • Timing light “1” • Digital tachometer “2” To the high tension code “3”. Timing light 90890-03141 YU-03141 Digital tachometer 90890-06760 YU-39951-B 3. Adjust: • Engine idling speed Refer to “ADJUSTING THE ENGINE IDLING SPEED” on page 3-16. 4.
Page 123 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE LEFT SIDE COVER............4-2 REMOVING THE SEAT ................4-2 REMOVING THE NUMBER PLATE............4-2 FRONT WHEEL....................4-3 REMOVING THE FRONT WHEEL.............4-4 CHECKING THE FRONT WHEEL .............4-4 DISASSEMBLING THE FRONT WHEEL...........4-5 ASSEMBLING THE FRONT WHEEL............4-5 INSTALLING THE FRONT WHEEL ............4-6 REAR WHEEL ....................4-7 REMOVING THE REAR WHEEL ...............4-8 CHECKING THE REAR WHEEL..............4-8...
Page 124 HANDLEBAR ....................4-32 REMOVING THE HANDLEBAR...............4-34 CHECKING THE HANDLEBAR ...............4-34 INSTALLING THE HANDLEBAR .............4-34 FRONT FORK....................4-38 REMOVING THE FRONT FORK LEGS...........4-40 DISASSEMBLING THE FRONT FORK LEGS .........4-40 CHECKING THE FRONT FORK LEGS ...........4-41 ASSEMBLING THE FRONT FORK LEGS ..........4-42 INSTALLING THE FRONT FORK LEGS ..........4-48 STEERING HEAD...................4-51 REMOVING THE LOWER BRACKET............4-52 CHECKING THE STEERING HEAD ............4-52...
Page 125: General Chassis
This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.
Page 126: Removing The Left Side Cover
GENERAL CHASSIS REMOVING THE LEFT SIDE COVER REMOVING THE NUMBER PLATE EASB111118 EASB111120 1. Remove: 1. Remove: • Bolt (side cover) • Bolt (number plate) • Side cover “1” • Number plate “1” Draw the left side cover “1” backward to re- •...
Page 127: Front Wheel
FRONT WHEEL FRONT WHEEL EASB111121 Removing the front wheel 21 Nm (2.1 m kgf, 15 ft Ibf) • • 21 Nm (2.1 m kgf, 15 ft Ibf) • • 115 Nm (11.5 m kgf, 83 ft lbf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...
Page 128: Removing The Front Wheel
FRONT WHEEL REMOVING THE FRONT WHEEL EASB111122 1. Use a suitable stand to raise the front wheel A tight spoke will emit a clear, ringing tone; a off the ground. loose spoke will sound flat. WARNING 4. Tighten: Securely support the vehicle so that there is •...
Page 129: Disassembling The Front Wheel
FRONT WHEEL DISASSEMBLING THE FRONT WHEEL EASB111124 1. Remove: • Oil seals • Bearings ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside of the front wheel hub. b. Remove the oil seals “1” with a flat-head screwdriver. To prevent damaging the wheel, place a rag “2” between the screwdriver and the wheel sur- face.
Page 130: Installing The Front Wheel
FRONT WHEEL 3. Install: 3. Tighten: • Collar “1” • Front wheel axle nut “1” Front wheel axle nut Apply the lithium-soap-based grease on the oil 115 Nm (11.5 m·kgf, 83 ft·lbf) seal lip. NOTICE Before tightening the front wheel axle nut, push down hard on the handlebar(s) several times and check if the front fork rebounds smoothly.
Page 131: Rear Wheel
REAR WHEEL REAR WHEEL EASB111127 Removing the rear wheel 14 Nm (1.4 m kgf, 10 ft Ibf) • • 135 Nm (13.5 m kgf, 98 ft lbf) • • 21 Nm (2.1 m kgf, 15 ft Ibf) • • 42 Nm (4.2 m kgf, 30 ft Ibf) •...
Page 132: Removing The Rear Wheel
REAR WHEEL 4. Measure: REMOVING THE REAR WHEEL EASB111128 • Radial wheel runout 1. Use a suitable stand to raise the rear wheel • Lateral wheel runout off the ground. Refer to “CHECKING THE FRONT WHEEL” WARNING on page 4-4. Securely support the vehicle so that there is Radial wheel runout limit no danger of it falling over.
Page 133: Assembling The Rear Wheel
REAR WHEEL Tighten the self-locking nuts in stages and in a crisscross pattern. 2. Install: • Brake disc “1” • Brake disc bolt “2” Brake disc bolt ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 14 Nm (1.4 m·kgf, 10 ft·lbf) LOCTITE® ASSEMBLING THE REAR WHEEL EASB111132 1.
Page 134: Installing The Rear Wheel
REAR WHEEL 4. Install: INSTALLING THE REAR WHEEL EASB111133 • Right drive chain puller “1” 1. Install: • Washer “2” • Rear wheel • Rear wheel axle nut “3” Install the brake disc “1” between the brake Temporarily tighten the nut (rear wheel axle) at pads “2”...
Page 135 REAR WHEEL 4-11...
Page 136: Front Brake
FRONT BRAKE FRONT BRAKE EASB111134 Removing the front brake caliper 30 Nm (3.0 m kgf, 22 ft lbf) 28 Nm (2.8 m kgf, 20 ft lbf) 6 Nm (0.6 m kgf, 4.3 ft lbf) 17 Nm (1.7 m kgf, 12 ft lbf) 2.5 Nm (0.25 m kgf, 1.8 ft...
Page 137 FRONT BRAKE Disassembling the front brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) Order Part name Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassemble pro- cedure.
Page 138 FRONT BRAKE Removing the front brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft lbf) 6 Nm (0.6 m kgf, 4.3 ft lbf) 6 Nm (0.6 m kgf, 4.3 ft lbf) 30 Nm (3.0 m kgf, 22 ft lbf) Order Part name Q’ty...
Page 139 FRONT BRAKE Disassembling the front brake master cylinder Order Part name Q’ty Remarks Push rod Dust boot Circlip Washer Brake master cylinder kit For assembly, reverse the disassemble pro- cedure. 4-15...
Page 140: Introduction
FRONT BRAKE INTRODUCTION EASB111135 Brake disc thickness limit WARNING 2.5 mm (0.10 in) If you need to disassemble the disc brake 4. Install: components, observe the following precau- • Front wheel tions. Refer to “FRONT WHEEL” on page 4-3. • Never disassemble the brake components unless absolutely necessary.
Page 141: Checking The Front Brake Caliper
FRONT BRAKE ASSEMBLING THE FRONT BRAKE CALI- WARNING • Before installation, clean and lubricate the internal parts. Use new brake fluid for cleaning and lubricating. • Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
Page 142: Installing The Front Brake Caliper
FRONT BRAKE 3. Install: 2. Install: • Brake caliper piston “1” • Front brake caliper • Brake pad spring • Brake pad Apply the brake fluid on the piston outer sur- • Brake pad pin face. • Brake hose holder NOTICE Brake pad pin •...
Page 143: Removing The Front Brake Master Cylinder
FRONT BRAKE NOTICE Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Bleed: • Brake system Refer to “BLEEDING THE BRAKE SYS- TEM” on page 3-22. 6. Check: • Brake fluid level 2.
Page 144: Installing The Front Brake Master Cylinder
FRONT BRAKE INSTALLING THE FRONT BRAKE MASTER EASB111146 CYLINDER 1. Install: • Brake master cylinder “1” Brake master cylinder holder bolt 9 Nm (0.9 m·kgf, 6.5 ft·lbf) • Install the front brake master cylinder holder 3. Install: with the “UP” mark facing up. •...
Page 145 FRONT BRAKE Turn the handlebar toward right and left to make sure that the brake hose does not touch other parts (e.g., wire harness, cables, leads). Adjust if necessary. 6. Check: • Brake lever free play Refer to “ADJUSTING THE FRONT BRAKE”...
Page 146: Rear Brake
REAR BRAKE REAR BRAKE EASB111147 Removing the rear brake caliper 10 Nm (1.0 m kgf, 7.2 ft Ibf) 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf)
Page 147 REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) Order Part name Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassemble pro- cedure.
Page 148 REAR BRAKE Removing the rear brake master cylinder Order Part name Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE BRAKE SYSTEM” on page 3-22. Union bolt Copper washers Brake hose Split pin Washer Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm plate Brake master cylinder reservoir diaphragm Rear brake master cylinder For installation, reverse the removal proce-...
Page 149 REAR BRAKE Disassembling the rear brake master cylinder Order Part name Q’ty Remarks Dust boot Circlip Push rod Brake master cylinder kit For assembly, reverse the disassemble pro- cedure. 4-25...
Page 150: Introduction
REAR BRAKE INTRODUCTION EASB111148 WARNING If you need to disassemble the disc brake components, observe the following precau- tions. • Never disassemble the brake components unless absolutely necessary. • If there is any problem with connections on the hydraulic brake system, perform the following jobs.
Page 151: Removing The Rear Brake Caliper
REAR BRAKE REMOVING THE REAR BRAKE CALIPER CHECKING THE REAR BRAKE CALIPER EASB111150 EASB111152 1. Check: • Brake caliper piston “1” Before disassembling the brake caliper, drain Rust/scratches/wear  Replace the brake the brake fluid from the entire brake system. caliper piston.
Page 152: Installing The Brake Caliper Piston
REAR BRAKE INSTALLING THE BRAKE CALIPER PISTON INSTALLING THE REAR BRAKE CALIPER EASB111154 EASB111155 1. Clean: 1. Install: • Brake caliper • Rear brake caliper • Brake caliper piston seal • Rear brake caliper bracket • Brake caliper piston dust seal 2.
Page 153: Removing The Rear Brake Master Cylinder
REAR BRAKE REMOVING THE REAR BRAKE MASTER EASB111156 WARNING CYLINDER • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor Before removing the rear brake master cylin- brake performance. der, drain the brake fluid from the entire brake •...
Page 154: Assembling The Rear Brake Master Cylinder
REAR BRAKE ASSEMBLING THE REAR BRAKE MASTER EASB111158 CYLINDER 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. Specified brake fluid 4.
Page 155 REAR BRAKE 2. Pour brake fluid to the brake fluid reservoir 5. Check: up to the specified level. • Brake pedal operation A softy or spongy feeling  Bleed the brake Specified brake fluid system. DOT 4 Refer to “BLEEDING THE BRAKE SYS- TEM”...
Page 156 HANDLEBAR HANDLEBAR EASB111160 Removing the handlebar Order Part name Q’ty Remarks Number plate Remove the band only. Clutch cable Disconnect. Clutch lever holder Engine stop switch Launch control switch Brake master cylinder Throttle cable cap Throttle cable (pull) Disconnect. Throttle cable (return) Disconnect.
Page 157 HANDLEBAR Removing the handlebar Order Part name Q’ty Remarks Handlebar Handlebar lower holder Damper For installation, reverse the removal proce- dure. 4-33...
Page 158: Handlebar
HANDLEBAR • Installing the lower handlebar holders in the REMOVING THE HANDLEBAR EASB111161 reverse direction allow the front-to-rear offset 1. Stand the vehicle upright on a level surface. amount of the handlebar position to be EWA13120 WARNING changed. Securely support the vehicle so that there is •...
Page 159 HANDLEBAR ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: • Handlebar grip “1” • Handlebar grip “2” • Handlebar grip “3” • Launch control switch “4” • Clamp “5” Engine stop switch screw 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf) Clutch lever holder bolt 5 Nm (0.5 m·kgf, 3.6 ft·lbf) Launch control switch screw 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf) •...
Page 160 HANDLEBAR 9. Install: • Throttle cable housings “1” • Screw (throttle cable housings) “2” Screw (throttle cable housings) 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) EWA1DX5001 WARNING After tightening the throttle cable housing screws, check that the throttle grip “3” moves smoothly. If it does not, retighten the 7.
Page 161 HANDLEBAR 10.Install: • Rubber cover “1” • Cover (throttle cable housings) “2” 13.Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LE- 11.Install: VER FREE PLAY” on page 3-11. • Front brake master cylinder assembly “1” Clutch lever free play •...
Page 162: Front Fork
FRONT FORK FRONT FORK EASB111164 Removing the front fork legs 21 Nm (2.1 m kgf, 15 ft lbf) 9 Nm (0.9 m kgf, 6.5 ft lbf) 5 Nm (0.5 m kgf, 3.6 ft lbf) 5 Nm (0.5 m kgf, 3.6 ft lbf) Order Part name...
Page 163 FRONT FORK Disassembling the front fork leg 30 Nm (3.0 m kgf, 22 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • 55 Nm (5.5 m kgf, 40 ft Ibf) •...
Page 164: Removing The Front Fork Legs
FRONT FORK REMOVING THE FRONT FORK LEGS EASB111165 1. Use a suitable stand to raise the front wheel • While compressing the inner tube “2”, set the off the ground. cap bolt ring wrench “4” between the inner tube and locknut “3”. WARNING •...
Page 165: Checking The Front Fork Legs
FRONT FORK WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Remove: • Base valve “1” (from the damper assembly) 2. Check: • Outer tube Hold the damper assembly with the cap bolt Scratches/wear/damage ...
Page 166: Assembling The Front Fork Legs
FRONT FORK 5. Check: ASSEMBLING THE FRONT FORK LEGS EASB111168 • Base valve “1” EWA13660 Wear/damage  Replace. WARNING Contamination  Clean. • Make sure the oil levels in both front fork • O-rings “2” legs are equal. Wear/damage  Replace. •...
Page 167 FRONT FORK 4. Measure: 6. Loosen: • Oil level (left and right) “a” • Compression damping force adjuster “1” Out of specification  Regulate. • Before loosening the damping force adjuster, Standard oil level record the setting position. 145–148 mm (5.71–5.83 in) •...
Page 168 FRONT FORK 9. Tighten: • Base valve “1” Base valve 28 Nm (2.8 m·kgf, 20 ft·lbf) Hold the damper assembly with the cap bolt ring wrench “2” and use the cap bolt wrench “3” to tighten the base valve. 12.Allow the overflowing oil to escape at the Cap bolt wrench hole “a”...
Page 169 FRONT FORK • Apply the lithium-soap-based grease on the dust seal lip and oil seal lip. • Apply the fork oil on the inner tube. • When installing the oil seal, use vinyl seat “a” with fork oil applied to protect the oil seal lip. 17.Install: •...
Page 170 FRONT FORK 19.Install: 22.Measure: • Oil seal clip “1” • Distance “a” Out of specification  Turn into the locknut. Fit the oil seal clip correctly in the groove in the Distance “a” outer tube. 16 mm (0.63 in) or more Between the damper assembly “1”...
Page 171 FRONT FORK 24.Install: • Damper assembly “1” (to the inner tube “2”) ECA32D1010 NOTICE Allow the damper assembly to slide slowly down the inner tube until it contacts the bot- tom of the inner tube. Be careful not to dam- age the inner tube.
Page 172: Installing The Front Fork Legs
FRONT FORK 29.Install: 31.Install: • Adjuster “1” • Damper assembly “1” (to the inner tube) (to the outer tube) Adjuster Temporarily tighten the damper assembly. 55 Nm (5.5 m·kgf, 40 ft·lbf) LOCTITE® 32.Install: • Protector guide “1” 30.Fill: • Front fork leg Recommended oil Suspension oil S1 Standard oil amount...
Page 173 FRONT FORK 2. Tighten: WARNING • Damper assembly “1” Tighten the lower bracket to specified torque. If torqued too much, it may cause Damper assembly the front fork to malfunction. 30 Nm (3.0 m·kgf, 22 ft·lbf) Use the cap bolt ring wrench “2” to tighten the damper assembly.
Page 174 FRONT FORK 7. Adjust: • Compression damping force Turn in the damping adjuster “1” finger-tight and then turn out to the originally set position. 4-50...
Page 175: Steering Head
STEERING HEAD STEERING HEAD EASB111170 Removing the lower bracket 21 Nm (2.1 m kgf, 15 ft lbf) 145 Nm (14.5 m kgf, 105 ft lbf) 21 Nm (2.1 m kgf, 15 ft lbf) 38 Nm (3.8 m kgf, 27 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft...
Page 176: Removing The Lower Bracket
STEERING HEAD REMOVING THE LOWER BRACKET EASB111171 NOTICE 1. Use a suitable stand to raise the front wheel If the bearing race is not installed properly, off the ground. the steering head pipe could be damaged. WARNING Securely support the vehicle so that there is Always replace the bearing and the bearing no danger of it falling over.
Page 177 STEERING HEAD 2. Install: • Bearing races • Upper bearing “1” • Bearing race cover “2” Apply the lithium-soap-based grease on the bearing and bearing race cover lip. 5. Check the steering stem by turning this lock to lock. If there is any binding, remove the steering stem and check the steering bear- ing.
Page 178 STEERING HEAD 11.Tighten: • Pinch bolt (upper bracket) “1” Upper bracket pinch bolts 21 Nm (2.1 m·kgf, 15 ft·lbf) • Pinch bolt (lower bracket) “2” Lower bracket pinch bolts 21 Nm (2.1 m·kgf, 15 ft·lbf) EWA33DD049 8. Install: WARNING • Steering stem nut “1” Tighten the lower bracket to specified torque.
Page 179: Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY REAR SHOCK ABSORBER ASSEMBLY EASB111174 Removing the rear shock absorber assembly 16 15 14 13 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”...
Page 180 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 16 15 14 13 Order Part name Q’ty Remarks Collars Bushing Collars O-ring Dust seal Stopper ring Bearing For installation, reverse the removal proce- dure. 4-56...
Page 181 REAR SHOCK ABSORBER ASSEMBLY Disassembling the relay arm 80 Nm (8.0 m kgf, 58 ft lbf) Order Part name Q’ty Remarks Relay arm Connecting arm Collars Oil seals Washers Bearing For assembly, reverse the disassemble pro- cedure. 4-57...
Page 182: Handling The Rear Shock Absorber
• To dispose of a damaged or a worn-out rear shock absorber, take the unit to your Yamaha dealer for this disposal proce- 3. Remove: dure. • Rear shock absorber assembly upper bolt •...
Page 183: Removing The Bearing
REAR SHOCK ABSORBER ASSEMBLY CHECKING THE REAR SHOCK ABSORBER REMOVING THE BEARING EASB111178 ASSEMBLY 1. Remove: 1. Check: • Stopper ring (upper bearing) “1” • Rear shock absorber rod Bends/damage  Replace the rear shock Press in the bearing while pressing its outer absorber assembly.
Page 184: Installing The Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY 3. Install: • Bearing • Stopper ring (to rear shock absorber assembly (upper side)) • Install the bearing parallel until the stopper ring groove appears by pressing its outer race. • After installing the stopper ring, push back the 3.
Page 185 REAR SHOCK ABSORBER ASSEMBLY 6. Install: • Rear shock absorber assembly • When installing the rear shock absorber as- sembly, lift up the swingarm. • Install the rear shock absorber assembly up- per bolt, and connecting arm bolt (frame side) from the right.
Page 186: Swingarm
SWINGARM SWINGARM EASB111183 Removing the swingarm 70 Nm (7.0 m kgf, 51 ft lbf) 4.0 Nm (0.40 m kgf, 2.9 ft lbf) 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”...
Page 187: Removing The Swingarm
SWINGARM REMOVING THE SWINGARM EASB111184 1. Use a suitable stand to raise the rear wheel off the ground. WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Measure: • Swingarm side play • Swingarm vertical movement ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 188: Installing The Swingarm
SWINGARM INSTALLING THE SWINGARM EASB111187 1. Lubricate: • Bearing • Collars • Spacers • Oil seal • Pivot shaft Recommended lubricant Molybdenum disulfide grease 2. Install: • Bearing “1” • Oil seals “2” (to the swingarm) Installed depth “a” 0–0.5 mm (0–0.02 in) Installed depth “b”...
Page 189: Chain Drive
CHAIN DRIVE CHAIN DRIVE EASB111188 Removing the drive chain 75 Nm (7.5 m kgf, 54 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft lbf) Job Order Part name Q’ty Servicing Information Drive sprocket Refer to “ENGINE REMOVAL” on page 5-1. Drive chain For installation, reverse the removal proce- dure.
Page 190: Removing The Drive Chain
CHAIN DRIVE REMOVING THE DRIVE CHAIN EASB111189 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 •...
Page 191: Checking The Drive Sprocket
CHAIN DRIVE 4. Check: INSTALLING THE DRIVE CHAIN • Drive chain rollers “1” 1. Install: Damage/wear  Replace the drive chain. • Drive chain “1” • Drive chain side plates “2” • Drive chain joint “2” Damage/wear  Replace the drive chain. •...
Page 192 CHAIN DRIVE 4-68...
Page 193: Engine
ENGINE ENGINE REMOVAL ..................5-1 REMOVING THE SILENCER..............5-6 REMOVING THE EXHAUST PIPE 2............5-6 REMOVING THE DRIVE SPROCKET ............5-6 REMOVING THE ENGINE .................5-7 CHECKING THE SILENCER AND EXHAUST PIPE........5-7 CHANGING THE SILENCER FIBER ............5-7 INSTALLING THE ENGINE................5-8 INSTALLING THE BRAKE PEDAL ............5-9 INSTALLING THE DRIVE SPROCKET............5-9 INSTALLING THE EXHAUST PIPE AND MUFFLER.......5-10 CAMSHAFT ....................5-12...
Page 194 CLUTCH ......................5-38 REMOVING THE CLUTCH ..............5-41 CHECKING THE FRICTION PLATES............5-41 CHECKING THE CLUTCH PLATES ............5-41 CHECKING THE CLUTCH SPRINGS............5-41 CHECKING THE CLUTCH HOUSING .............5-42 CHECKING THE CLUTCH BOSS............5-42 CHECKING THE PRESSURE PLATE .............5-42 CHECKING THE PUSH LEVER SHAFT..........5-42 CHECKING THE CLUTCH PUSH RODS ..........5-42 CHECKING THE PRIMARY DRIVE GEAR..........5-42 CHECKING THE PRIMARY DRIVEN GEAR ...........5-43 INSTALLING THE OIL SEAL ..............5-43...
Page 195 AC MAGNETO....................5-61 REMOVING THE AC MAGNETO.............5-62 CHECKING THE AC MAGNETO .............5-62 CHECKING THE WOODRUFF KEY ............5-62 INSTALLING THE AC MAGNETO ............5-62 CRANKCASE ....................5-64 DISASSEMBLING THE CRANKCASE.............5-67 REMOVING THE CRANKCASE BEARING ..........5-67 CHECKING THE TIMING CHAIN, TIMING CHAIN GUIDE, OIL STRAINER ....................5-67 CHECKING THE CRANKCASE ...............5-68 ASSEMBLING THE CRANKCASE............5-68 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT .......5-69...
Page 196: Engine Removal
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, adjustment, disas- sembly, or reassembly only by reference to this manual.
Page 197 ENGINE REMOVAL Removing the exhaust pipe 7 Nm (0.7 m kgf, 5.1 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 8 Nm (0.8 m kgf, 5.8 ft Ibf) 30 Nm (3.0 m kgf, 22 ft Ibf) 30 Nm (3.0 m kgf, 22 ft Ibf) 20 Nm (2.0 m kgf, 14 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf)
Page 198 ENGINE REMOVAL 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 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”...
Page 200 ENGINE REMOVAL Removing the engine Order Part name Q’ty Remarks Drive sprocket cover Drive chain guide Drive sprocket Upper engine bracket Patch Lower engine bracket Pivot shaft Engine For installation, reverse the removal proce- dure.
Page 201: Removing The Silencer
ENGINE REMOVAL REMOVING THE SILENCER EASB111196 1. Remove: • Rear shock absorber assembly lower bolt “1” • Connecting arm bolt (frame side) “2” • Silencer “3” Move the rear shock absorber to the left side of the chassis, and remove the silencer. REMOVING THE DRIVE SPROCKET EASB111198 1.
Page 202: Removing The Engine
ENGINE REMOVAL CHECKING THE SILENCER AND EXHAUST REMOVING THE ENGINE EASB111199 PIPE 1. Remove: 1. Check: • Pivot shaft “1” • Gasket “1” Damage  Replace. 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.
Page 203: Installing The Engine
ENGINE REMOVAL 2. Remove: 5. Replace: • Rivet “1” • Fiber “1” • Silencer cap “2” Stuff the fiber into the silencer body by using a flat board “2”. 3. Replace: • Fiber “1” 6. Install: • Silencer cap “1” •...
Page 204: Installing The Brake Pedal
ENGINE REMOVAL • Front engine bracket “4” INSTALLING THE BRAKE PEDAL • Engine bracket bolt (front side) “5” 1. Install: • Spring “1” Engine bracket bolt (front side) • Brake pedal “2” 34 Nm (3.4 m·kgf, 25 ft·lbf) • O-rings “3” •...
Page 205: Installing The Exhaust Pipe And Muffler
ENGINE REMOVAL Tighten the nut while applying the rear brake. NOTICE Make sure to tighten to specification; other- wise, it may damage the other part that is fastened together. 2. Install: • Clamp • Exhaust pipe 2 “1” • Bolt (exhaust pipe 2) “2” 3.
Page 206 ENGINE REMOVAL Install and temporarily tighten the silencer so that its joint is positioned as shown with respect to the exhaust pipe 2. 2mm (0.08in) 4. Tighten: • Bolt (exhaust pipe 2) Bolt (exhaust pipe 2) 20 Nm (2.0 m·kgf, 14 ft·lbf) •...
Page 207: Camshaft
CAMSHAFT CAMSHAFT EASB111206 Removing the cylinder head cover 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Part name Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 4-1. Side cover (left/right) Refer to “GENERAL CHASSIS”...
Page 208 CAMSHAFT Removing the camshaft 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 6 Nm (0.6 m kgf, 4.3 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 6 Nm (0.6 m kgf, 4.3 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name...
Page 209: Removing The Camshaft
CAMSHAFT 3. Remove: REMOVING THE CAMSHAFT EASB111207 • Timing chain tensioner cap bolt “1” 1. Remove: • Timing chain tensioner “2” • Timing mark accessing screw “1” • Gaskets • Crankshaft end accessing screw “2” 4. Remove: 2. Align: • Bolt (camshaft cap) “1” •...
Page 210: Checking The Camshaft
CAMSHAFT 5. Remove: • Exhaust camshaft “1” • Intake camshaft “2” Attach a wire “3” to the timing chain to prevent it from falling into the crankcase. EASB111208 CHECKING THE CAMSHAFT 1. Check: • Camshaft lobes 3. Measure: Blue discoloration/pitting/scratches  Re- •...
Page 211: Checking The Timing Chain And Camshaft Sprocket
CAMSHAFT ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the camshaft into the cylinder head. b. Position a strip of Plastigauge® “1” onto the camshaft journal as shown. CHECKING THE TIMING CHAIN AND CAM- EASB111209 SHAFT SPROCKET 1. Check: • Timing chain “1” c. Install the dowel pins and the camshaft Damage/stiffness ...
Page 212: Checking The Decompression System
CAMSHAFT c. If not, replace the tensioner assembly. INSTALLING THE CAMSHAFTS 1. Install: • Exhaust camshaft “1” • Intake camshaft “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise with a wrench. • Apply molybdenum disulfide oil to the cam- shafts. • Apply the engine oil on the decompression ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 213 CAMSHAFT 2. Install: • Timing chain tensioner Make sure that the alignment mark “c” on the exhaust camshaft sprocket and the alignment ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. While pressing the tensioner rod lightly with mark “d” on the intake camshaft sprocket are your fingers, use a thin screwdriver to wind aligned with the edge of the cylinder head.
Page 214 CAMSHAFT 3. Turn: • Crankshaft Counterclockwise several turns. 4. Check: • Top dead center (TDC) mark on the rotor Align with the crankcase alignment mark. • Camshaft match marks Align with the cylinder head surface. Out of alignment  Adjust. 5.
Page 215: Cylinder Head
CYLINDER HEAD CYLINDER HEAD EASB111213 Removing the cylinder head 30 Nm (3.0 m kgf, 22 ft Ibf) 20 Nm (2.0 m kgf, 14 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 15 Nm (1.5 m kgf, 11 ft Ibf) Order Part name...
Page 216 CYLINDER HEAD Removing the cylinder head 30 Nm (3.0 m kgf, 22 ft Ibf) 20 Nm (2.0 m kgf, 14 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 15 Nm (1.5 m kgf, 11 ft Ibf) Order Part name Q’ty...
Page 217: Removing The Cylinder Head
CYLINDER HEAD REMOVING THE CYLINDER HEAD EASB111214 1. Remove: • Cylinder head bolts • 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. •...
Page 218: Installing The Cylinder Head
CYLINDER HEAD INSTALLING THE CYLINDER HEAD EASB111217 Bolts “1”–“4” 1. Install: • Timing chain guide (intake side) “1” 30 Nm (3.0 m·kgf, 22 ft·lbf) • Dowel pins • Cylinder head gasket • Dowel pins While pulling up the timing chain, install the tim- ing chain guide (intake side) and the cylinder head.
Page 219 CYLINDER HEAD i. Retighten the cylinder head mounting bolts 150° in the proper tightening sequence. Tighten the bolts in two steps (90° and 60°) to reach the specified angle in the proper tighten- ing sequence. Bolts “1”–“4” Final Specified angle 150° j.
Page 220 VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS EASB111218 Removing the valves and valve springs Order Part name Q’ty Remarks Refer to “CYLINDER HEAD” on page 5-20. Cylinder head Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Intake valve...
Page 221: Valves And Valve Springs
VALVES AND VALVE SPRINGS 2. Check: REMOVING THE VALVES EASB111219 • Valve sealing Leakage at the valve seat  Check the Before removing the internal parts of the cylin- valve face, the valve seat, and the valve seat der head (e.g., valves, valve springs, valve contact width.
Page 222: Checking The Valves And Valve Guides
VALVES AND VALVE SPRINGS 4. Remove: • Valve spring retainer “1” • Valve spring “2” • Valve “3” • Valve stem seat “4” • Valve spring seat “5” Identify the position of each part very carefully so that it can be reinstalled in its original place. 2.
Page 223: Checking The Valve Seats
VALVES AND VALVE SPRINGS c. After installing the valve guide, expand the hole in the valve guide with the valve guide reamer “3” to obtain the proper valve-stem- to-valve-guide clearance. 6. Measure: • Valve stem runout Out of specification  Replace the valve. •...
Page 224 VALVES AND VALVE SPRINGS 4. Lap: • Valve face • Valve seat NOTICE This model uses titanium intake and ex- haust valves. Do not use the valves used for lapping the valve seat. Always replace the valves used for lapping with new ones. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 225: Checking The Valve Springs
VALVES AND VALVE SPRINGS e. Apply a fine lapping compound to the valve face, and repeat the above steps. f. After every lapping step, be sure to clean off all of the lapping compound from the valve face and the valve seat. g.
Page 226: Checking The Valve Lifters
VALVES AND VALVE SPRINGS 3. Install: CHECKING THE VALVE LIFTERS EASB111223 • Spring seat “1” 1. Check: • Valve stem seal “2” • Valve lifter • Valve “3” Damage/scratches  Replace the valve lift- • Valve spring “4” ers and cylinder head. •...
Page 227 VALVES AND VALVE SPRINGS 5. To fasten the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. NOTICE Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Adjusting pad “1” •...
Page 228 CYLINDER AND PISTON CYLINDER AND PISTON EASB111225 Removing the cylinder and piston 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks Refer to “CYLINDER HEAD” on page 5-20. Cylinder head Cylinder body Gaskets...
Page 229: Cylinder And Piston
CYLINDER AND PISTON REMOVING THE PISTON EASB111226 1. Remove: • Piston pin clips “1” • Piston pin “2” • Piston “3” ECA13810 NOTICE Do not use a hammer to drive the piston pin out. • Before removing the piston pin clip, cover the CHECKING THE CYLINDER AND PISTON EASB111227 crankcase opening with a cloth to prevent the...
Page 230: Checking The Piston Rings
CYLINDER AND PISTON CHECKING THE PISTON RINGS 1. Measure: • Piston ring side clearance Out of specification  Replace the piston and piston rings as a set. Before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring grooves and piston rings.
Page 231: Checking The Piston Pin
CYLINDER AND PISTON 3. Measure: • Piston pin bore inside diameter “b” The oil ring expander’s end gap cannot be Out of specification  Replace the piston. measured. If the oil ring rail’s gap is excessive, replace all three oil rings. Piston pin bore inside diameter 18.004–18.015 mm (0.7088–...
Page 232 CYLINDER AND PISTON 2. Install: 5. Install: • Piston “1” • Cylinder gasket • Piston pin “2” • Dowel pin • Piston pin clips “3” • Cylinder Cylinder bolt • Apply molybdenum disulfide oil to the piston 10 Nm (1.0 m·kgf, 7.2 ft·lbf) pin.
Page 233 CLUTCH CLUTCH EASB111231 Removing the clutch Order Part name Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-15. Brake pedal Refer to “ENGINE REMOVAL” on page 5-1. Clutch cable Disconnect. Clutch cover O-ring Clutch spring Pressure plate Push rod 1 Circlip...
Page 234: Clutch
CLUTCH Removing the clutch Order Part name Q’ty Remarks Friction plate 2 Identification color (purple) Clutch boss Thrust washer Primary driven gear Push lever shaft For installation, reverse the removal proce- dure. 5-39...
Page 235 CLUTCH Removing the right crankcase cover Order Part name Q’ty Remarks Right engine guard Refer to “ENGINE REMOVAL” on page 5-1. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-15. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-8.
Page 236: Removing The Clutch
CLUTCH REMOVING THE CLUTCH CHECKING THE CLUTCH PLATES EASB111232 EASB111234 1. Remove: 1. Check: • Clutch boss nut “1” • Clutch plate Damage  Replace the clutch plates as a • Conical washer “2” • Clutch boss “3” set. 2. Measure: •...
Page 237: Checking The Clutch Housing
CLUTCH CHECKING THE PUSH LEVER SHAFT CHECKING THE CLUTCH HOUSING EASB111236 1. Check: 1. Check: • Push lever shaft • Clutch housing dogs “a” Wear/damage  Replace. Damage/pitting/wear  Deburr the clutch housing dogs or replace the clutch housing. Pitting on the clutch housing dogs will cause er- ratic clutch operation.
Page 238: Checking The Primary Driven Gear
CLUTCH 2. Check: • Primary-drive-gear-to-primary-driven-gear free play Free play exists  Replace the primary drive and primary driven gears as a set. CHECKING THE PRIMARY DRIVEN GEAR EASB111242 1. Check: • Primary driven gear Damage/wear  Replace the primary drive and primary driven gears as a set.
Page 239: Installing The Clutch
CLUTCH INSTALLING THE CLUTCH EASB111245 NOTICE 1. Install: Make sure to tighten to specification; other- • Push lever shaft “1” wise, it may damage the other part that is fastened together. • Apply the lithium-soap-based grease on the oil seal lip. •...
Page 240 CLUTCH 7. Install: • Pressure plate “1” a. Identification color 5. Install: 8. Install: • Bearing “1” • Clutch spring • Washer “2” • Clutch spring bolt • Circlip “3” To push rod 1 “4”. Clutch spring bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Apply the engine oil on the bearing and washer.
Page 241: Installing The Kickstarter Lever
CLUTCH 10.Install: • Clutch cover “1” • Clutch cover bolt Clutch cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tighten the bolts in stages and in a crisscross pattern. INSTALLING THE KICKSTARTER LEVER EASB111246 1. Install: • Kickstarter lever “1” •...
Page 242 KICKSTATER KICKSTATER EASB111247 Removing the kick shaft Order Part name Q’ty Remarks Primary driven gear Refer to “CLUTCH” on page 5-38. Kick idle gear Kick shaft assembly Spring guide Torsion spring Ratchet wheel Kick gear Kick shaft For installation, reverse the removal proce- dure.
Page 243: Kickstater
KICKSTATER REMOVING THE KICK SHAFT ASSEMBLY EASB111248 1. Remove: • Kick shaft assembly “1” Unhook the torsion spring “2” from the hole “a” in the crankcase. INSTALLING THE KICK SHAFT ASSEMBLY EASB111251 1. Install: • Kick gear “1” • Washer “2” •...
Page 244: Installing The Kick Idle Gear
KICKSTATER 5. Install: • Torsion spring “1” Turn the torsion spring clockwise and hook into the proper hole “a” in the crankcase. 3. Install: • Transmission 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.
Page 245: Shift Shaft
SHIFT SHAFT SHIFT SHAFT EASB111253 Removing the shift shaft and stopper lever 10 Nm (1.0 m kgf, 7.2 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 30 Nm (3.0 m kgf, 22 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty...
Page 246 SHIFT SHAFT Removing the shift shaft and stopper lever 10 Nm (1.0 m kgf, 7.2 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 30 Nm (3.0 m kgf, 22 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty...
Page 247: Removing The Shift Guide And Shift Lever Assembly
SHIFT SHAFT REMOVING THE SHIFT GUIDE AND SHIFT EASB111254 LEVER ASSEMBLY 1. Remove: • Bolt (shift guide) • Shift guide “1” • Shift lever assembly “2” Make sure that the shift lever assembly is re- moved together with the shift guide. CHECKING THE SHIFT GUIDE AND SHIFT EASB111257 LEVER ASSEMBLY...
Page 248: Installing The Stopper Lever
SHIFT SHAFT INSTALLING THE STOPPER LEVER INSTALLING THE SHIFT GUIDE AND SHIFT EASB111259 EASB111261 1. Install: LEVER ASSEMBLY • Torsion spring “1” 1. Install: • Collar “2” • Spring “1” • Stopper lever “3” • Pawl pin “2” • Bolt (stopper lever) “4” •...
Page 249: Installing The Shift Shaft
SHIFT SHAFT 4. Tighten: • Shift guide bolt “1” Shift guide bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® EASB111262 INSTALLING THE SHIFT SHAFT 1. Install: • Roller “1” • Stopper lever “2” (to shift shaft) • Collar “3” (to shift shaft) •...
Page 250 OIL PUMP AND BALANCER GEAR OIL PUMP AND BALANCER GEAR EASB111264 Removing the oil pump 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • Order Part name Q’ty Remarks Primary driven gear Refer to “CLUTCH”...
Page 251: Oil Pump And Balancer Gear
OIL PUMP AND BALANCER GEAR Removing the balancer 45 Nm (4.5 m kgf, 33 ft Ibf) • • 100 Nm (10 m kgf, 72 ft lbf) • • 50 Nm (5.0 m kgf, 36 ft Ibf) • • Order Part name Q’ty Remarks Primary driven gear...
Page 252: Removing The Balancer
OIL PUMP AND BALANCER GEAR REMOVING THE BALANCER EASB111265 1. Straighten the lock washer tab. 2. Loosen: • Balancer nut “1” • Primary drive gear nut “2” • Balancer weight gear nut “3” Place an aluminum plate “a” between the teeth of the balancer drive gear “4”...
Page 253: Assembling The Oil Pump
OIL PUMP AND BALANCER GEAR ASSEMBLING THE OIL PUMP Inner-rotor-to-outer-rotor-tip 1. Install: clearance • Oil pump drive shaft “1” Less than 0.150 mm (0.0059 in) • Inner rotor “2” Limit • Dowel pin “3” 0.20 mm (0.0079 in) Outer-rotor-to-oil-pump-housing clearance •...
Page 254: Installing The Oil Pump And Balancer Gear
OIL PUMP AND BALANCER GEAR INSTALLING THE OIL PUMP AND BALANC- EASB111270 ER GEAR 1. Install: • Oil pump assembly “1” • Oil pump assembly bolt “2” Oil pump assembly bolt 5 Nm (0.5 m·kgf, 3.6 ft·lbf) LOCTITE® 4. Install: •...
Page 255 OIL PUMP AND BALANCER GEAR 5. Bend the lock washer tab. 5-60...
Page 256: Ac Magneto
AC MAGNETO AC MAGNETO EASB111271 Removing the AC magneto 8 Nm (0.8 m kgf, 5.8 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 8 Nm (0.8 m kgf, 5.8 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 65 Nm (6.5 m kgf, 47 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order...
Page 257: Removing The Ac Magneto
AC MAGNETO CHECKING THE WOODRUFF KEY REMOVING THE AC MAGNETO EASB111272 1. Check: 1. Remove: • Woodruff key “1” • Nut (rotor) “1” Damage  Replace. • Washers 2. Remove: EASB111275 INSTALLING THE AC MAGNETO • Rotor “1” 1. Install: Use the rotor puller “2”...
Page 258 AC MAGNETO 4. Install: • Dowel pin “1” • Gasket (left crankcase cover) “2” • Left crankcase cover “3” • Lead holder “4” • Bolt (left crankcase cover) “5” Bolt (left crankcase cover) 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 2. Install: Tighten the bolts in stages and in a crisscross •...
Page 259: Crankcase
CRANKCASE CRANKCASE EASB111276 Separating the crankcase 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 260 CRANKCASE Separating the crankcase 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 261 CRANKCASE Removing the bearing and oil seal Order Part name Q’ty Remarks Transmission Refer to “TRANSMISSION” on page 5-72. Shift cam and shift fork Refer to “TRANSMISSION” on page 5-72. Circlip Oil seals Bearing For installation, reverse the removal proce- dure.
Page 262: Disassembling The Crankcase
CRANKCASE DISASSEMBLING THE CRANKCASE EASB111277 1. Separate: • Right crankcase • Left crankcase ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the crankcase bolts. c. Remove the dowel pins and O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ REMOVING THE CRANKCASE BEARING EASB111278 1. Remove: • Bearing “1” • Remove the bearing from the crankcase by Loosen each bolt 1/4 of a turn at a time and af- pressing its inner race.
Page 263: Checking The Crankcase
CRANKCASE CHECKING THE CRANKCASE EASB111280 1. Wash: • Crankcase • Wash the crankcase in a mild solvent. • Remove any remaining gasket from the crankcase mating surface. 2. Check: • Crankcase Crack/damage  Replace. 3. Install: • Oil delivery passages •...
Page 264: Crankshaft Assembly And Balancer Shaft
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EASB111282 Removing the crankshaft assembly and balancer shaft Order Part name Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-64. Transmission Refer to “TRANSMISSION” on page 5-72. Balancer shaft Crankshaft assembly For installation, reverse the removal proce- dure.
Page 265: Removing The Balancer Shaft
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT CHECKING THE CRANKSHAFT ASSEMBLY REMOVING THE BALANCER SHAFT EASB111283 1. Measure: 1. Remove: • Crankshaft runout • Balancer shaft “1” Out of specification  Replace the crank- shaft, bearing or both. Remove the balancer shaft with its flat side “a” facing the crankshaft.
Page 266: Installing The Crankshaft Assembly
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT NOTICE • To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease. • In order to prevent the crankshaft seizure, apply molybdenum disulfide grease. Hold the connecting rod at top dead center 4.
Page 267: Transmission
TRANSMISSION TRANSMISSION EASB111287 Removing the transmission, shift drum assembly, and shift forks Order Part name Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Separate. Crankcase Refer to “CRANKCASE” on page 5-64. Main axle Drive axle Long shift fork guide bar Short shift fork guide bar Spring Shift cam...
Page 268: Removing The Transmission
TRANSMISSION CHECKING THE SHIFT FORKS REMOVING THE TRANSMISSION EASB111288 1. Check: 1. Remove: • Shift fork cam follower “1” • Long shift fork guide bar “1” • Shift fork pawl “2” • Short shift fork guide bar “2” Bends/damage/scoring/wear  Replace the •...
Page 269: Checking The Shift Drum Assembly
TRANSMISSION CHECKING THE SHIFT DRUM ASSEMBLY EASB111290 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. 3. Check: • Transmission gears Blue discoloration/pitting/wear  Replace the defective gear (s).
Page 270 TRANSMISSION 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”) 4.
Page 271 TRANSMISSION 6. Install: 7. Install: • Shift fork 1 (L) “1” • Long shift fork guide bar “1” • Shift fork 2 (C) “2” • Short shift fork guide bar “2” • Shift fork 3 (R) “3” • Spring “3” •...
Page 272 TRANSMISSION 5-77...
Page 273: Cooling System
COOLING SYSTEM RADIATOR .......................6-1 HANDLING NOTE ..................6-3 CHECKING THE RADIATOR..............6-3 WATER PUMP....................6-4 REMOVING THE OIL SEAL...............6-5 CHECKING THE WATER PUMP ...............6-5 CHECKING THE BEARING ...............6-5 INSTALLING THE OIL SEAL ..............6-5 ASSEMBLING THE WATER PUMP............6-5...
Page 274 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, adjustment, disas- sembly, or reassembly only by reference to this manual.
Page 275 RADIATOR Removing the radiator Order Part name Q’ty Remarks Radiator hose 2 Radiator hose 3 Radiator hose 4 Radiator pipe 2 Radiator breather hose Left radiator Radiator hose 1 Radiator pipe 1 Coolant temperature sensor For installation, reverse the removal proce- dure.
Page 276 RADIATOR HANDLING NOTE EASB111295 WARNING If coolant seems hot, do not remove the ra- diator cap. CHECKING THE RADIATOR EASB111296 1. Check: • Radiator fins “1” Obstructions  Clean. Apply compressed air to the rear of the radi- ator. Damage  Repair or replace. Correct any flattened fins with a thin, flat-head screwdriver.
Page 277 WATER PUMP WATER PUMP EASB111297 Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Part name Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-8. Drain.
Page 278 WATER PUMP REMOVING THE OIL SEAL EASB111298 • 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: •...
Page 279 WATER PUMP 2. Install: • Dowel pin “1” • Gasket “2” 3. Install: • Water pump housing “1” • Water pump housing bolt “2” Water pump housing bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Washer “3” • Coolant drain bolt “4” Coolant drain bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Page 280 WATER PUMP...
Page 281: Fuel System
FUEL SYSTEM FUEL TANK......................7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP ..............7-2 CHECKING THE FUEL PUMP BODY............7-2 INSTALLING THE FUEL PUMP..............7-2 INSTALLING THE FUEL TANK..............7-3 CHECKING THE FUEL PRESSURE ............7-3 CHECKING THE DAMPER ................7-4 CHECKING AND REPLACING THE PROTECTOR ........7-4 THROTTLE BODY....................7-5 CHECKING THE INJECTOR ..............7-8 CHECKING THE THROTTLE BODY ............7-8...
Page 282: Fuel Tank
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, adjustment, disas- sembly, or reassembly only by reference to this manual.
Page 283: Removing The Fuel Tank
FUEL TANK REMOVING THE FUEL TANK EASB111305 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose coupler WARNING Cover the fuel hose connection with a cloth when disconnecting it. This is because re- sidual pressure in the fuel hose could cause fuel to spurt out when the hose is removed.
Page 284: Installing The Fuel Tank
FUEL TANK • 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. •...
Page 285: Checking The Damper
FUEL TANK NOTICE 84 mm 115 mm (3.31 in) (4.53 in) Make sure that the fuel hose is disconnect- ed by hand. Do not forcibly disconnect the hose with tools. d. Connect the pressure gauge “1” and the fuel pressure adapter “2” to the fuel hose. Pressure gauge 84 mm 115 mm 90890-03153...
Page 286 THROTTLE BODY THROTTLE BODY EASB111313 Removing the throttle body 7 Nm (0.7 m kgf, 5.1 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft lbf) 3.5 Nm (0.35 m kgf, 2.5 ft lbf) 3.5 Nm (0.35 m kgf, 2.5 ft lbf) 3.0 Nm (0.30 m kgf, 2.2 ft lbf) Order Part name...
Page 287 THROTTLE BODY Removing the throttle body 7 Nm (0.7 m kgf, 5.1 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft lbf) 3.5 Nm (0.35 m kgf, 2.5 ft lbf) 3.5 Nm (0.35 m kgf, 2.5 ft lbf) 3.0 Nm (0.30 m kgf, 2.2 ft lbf) Order Part name Q’ty...
Page 288: Throttle Body
THROTTLE BODY Removing the injector 3.4 Nm (0.34 m kgf, 2.5 ft lbf) 5 Nm (0.5 m kgf, 3.6 ft lbf) 3.4 Nm (0.34 m kgf, 2.5 ft lbf) Order Part name Q’ty Remarks Fuel inlet pipe Injector Gaskets Throttle position sensor Intake air pressure sensor For installation, reverse the removal proce- dure.
Page 289: Checking The Injector
THROTTLE BODY CHECKING THE INJECTOR EASB111314 1. Check: • Injectors Obstruction  Replace, and check the fuel pump and the fuel injection system. Refer to “FUEL INJECTION SYSTEM” on page 8-10. Deposits  Replace. Damage  Replace. 2. Check: • Injector resistance Refer to “CHECKING THE FUEL INJEC- TOR”...
Page 290: Adjusting The Throttle Position Sensor
Check that the throttle grip is fully closed. d. Connect the throttle position sensor to the wire harness. e. Set the Yamaha diagnostic tool to “diagnos- tic mode”. f. Choose the diagnostic code No. “01”. g. Adjust the throttle position sensor mounted angle until “11”–“14”...
Page 291: Electrical System
CIRCUIT DIAGRAM ...................8-2 TROUBLESHOOTING ................8-4 CHARGING SYSTEM..................8-6 CIRCUIT DIAGRAM ...................8-6 TROUBLESHOOTING ................8-8 FUEL INJECTION SYSTEM................8-10 CIRCUIT DIAGRAM .................8-10 YAMAHA DIAGNOSTIC TOOL ..............8-12 TROUBLESHOOTING DETAILS .............8-13 FUEL PUMP SYSTEM..................8-32 CIRCUIT DIAGRAM .................8-32 TROUBLESHOOTING ................8-34 ELECTRICAL COMPONENTS...............8-36 CHECKING THE SWITCHES ..............8-38 CHECKING THE IGNITION SPARK GAP..........8-41 CHECKING THE SPARK PLUG CAP ............8-41...
Page 293 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, adjustment, disas- sembly, or reassembly only by reference to this manual.
Page 294: Ignition System
IGNITION SYSTEM IGNITION SYSTEM EASB111319 EASB111320 CIRCUIT DIAGRAM...
Page 295 IGNITION SYSTEM 1. Crankshaft position sensor 2. AC magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser 7. Engine stop switch 8. Neutral switch 9. Launch control switch 10.ECU 11.Ignition coil 12.Spark plug 19.Ignition coil sub-lead...
Page 296: Troubleshooting
IGNITION SYSTEM TROUBLESHOOTING EASB111321 The ignition system fails to operate (no spark or intermittent spark). 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 NG  1.
Page 297 IGNITION SYSTEM NG  8. Check the ignition system wire har- ness. Repair or replace the wire harness. Refer to “CIRCUIT DIAGRAM” on page 8-2. OK  Replace the ECU. The launch control indicator light fail to blink. Before troubleshooting, remove the following part(s): 1.
Page 298: Charging System
CHARGING SYSTEM CHARGING SYSTEM EAS27200 EASB111322 CIRCUIT DIAGRAM...
Page 299 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser...
Page 300: Troubleshooting
CHARGING SYSTEM TROUBLESHOOTING EASB111323 The condenser is not being charged. Before troubleshooting, remove the following part (s): 1. Seat 2. Air scoop (left) NG  1. Check the entire charging system’s Reconnect. wiring. OK  NG  2. Check the rectifier/regulator. Replace the rectifier/regulator.
Page 301 CHARGING SYSTEM...
Page 302: Fuel Injection System
FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM EASB111324 EASB111325 CIRCUIT DIAGRAM 8-10...
Page 303 FUEL INJECTION SYSTEM 1. Crankshaft position sensor 2. AC magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser 7. Engine stop switch 8. Neutral switch 10.ECU 13.Fuel injector 14.Fuel pump 15.Intake air temperature sensor 16.Coolant temperature sensor 17.Throttle position sensor 18.Intake air temperature sensor 8-11...
Page 304: Yamaha Diagnostic Tool
FUEL INJECTION SYSTEM YAMAHA DIAGNOSTIC TOOL EASB111326 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. Yamaha diagnostic tool 90890-03231...
Page 305: Troubleshooting Details
After the check and service of the malfunctioning part have been completed, reset the Yamaha diag- nostic tool display according to the “Reinstatement method”. Fault code No.: To be displayed on the Yamaha diagnostic tool when the engine fails to work nor- mally Diagnostic code No.: To be used when the diagnostic mode is active...
Page 306 FUEL INJECTION SYSTEM Fault code Crankshaft position sensor: no normal signals are received Symptom from the crankshaft position sensor. Fail-safe system Unable to start engine Unable to drive vehicle Diagnostic code No. — Diagnostic tool display — Procedure — Probable cause of malfunc- Maintenance job Reinstatement method tion and check...
Page 307 Able to start engine Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air pressure. Procedure The atmospheric pressure is displayed on the Yamaha diagnostic tool. Probable cause of malfunc- Maintenance job Reinstatement method tion and check Improperly connected ...
Page 308 Able to start engine Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air pressure. Procedure The atmospheric pressure is displayed on the Yamaha diagnostic tool. Probable cause of malfunc- Maintenance job Reinstatement method tion and check...
Page 309 FUEL INJECTION SYSTEM Fault code Intake air pressure sensor: hose system malfunction (clogged Symptom or detached hose) Defective intake air pressure Execute the diagnostic mode. sensor. (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:...
Page 310 FUEL INJECTION SYSTEM Fault code Symptom Throttle position sensor: open or short circuit detected. Improperly connected  Connection of sub wire har- Turn “ON” the switch on the ness coupler. Connect the coupler secure- FI diagnostic tool sub-lead. Check the locking condition ly, or repair/replace the sub- Fault code No.
Page 311 FUEL INJECTION SYSTEM Fault code Throttle position sensor: stuck throttle position sensor is de- Symptom tected. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the throttle angle. • 11–14 (throttle in fully closed position) •...
Page 312 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the coolant temperature. Procedure Compare the actually measured coolant temperature with the Yamaha diagnostic tool display value. Probable cause of malfunc- Maintenance job Reinstatement method tion and check Improperly connected ...
Page 313 Diagnostic code No. Diagnostic tool display Displays the intake air temperature. Procedure Compare the actually measured intake air temperature with the Yamaha diagnostic tool display value. Probable cause of malfunc- Maintenance job Reinstatement method tion and check Improperly connected ...
Page 314 FUEL INJECTION SYSTEM Fault code Symptom Intake air temperature sensor: open or short circuit detected. Defective intake air tempera- Execute the diagnostic mode. Turn “ON” the switch on the ture sensor. (Code No. 05) FI diagnostic tool sub-lead. When the machine is cold, Fault code No.
Page 315 Unable to drive vehicle Diagnostic code No. Actuation Actuates the ignition coil five times at one-second intervals. “WARNING” on the Yamaha diagnostic tool blinks five times when- ever the ignition coil is actuated. Procedure Check that a spark is generated five times.
Page 316 Unable to drive vehicle Diagnostic code No. Actuation Actuates injector five times at one-second intervals. “WARNING” on the Yamaha diagnostic tool blinks five times when the injector is actuated. Procedure Check that injector is actuated five times by listening for the oper- ating sound.
Page 317 FUEL INJECTION SYSTEM Fault code Symptom Injector: open or short circuit detected. Improperly connected  Connection of sub wire har- After starting the engine, idle ness coupler. Connect the coupler secure- this and wait about 5 sec- Check the locking condition ly, or repair/replace the sub- onds.
Page 318 FUEL INJECTION SYSTEM Fault code EEPROM fault code No.: an error is detected while reading or Symptom writing on EEPROM. Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No. Diagnostic tool display Displays the location of the abnormal portion of the EEPROM data. •...
Page 319 FUEL INJECTION SYSTEM Fault code Vehicle system power supply: normal voltage is not supplied Symptom to the ECU. Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No. — Diagnostic tool display — Procedure — Probable cause of malfunc- Maintenance job Reinstatement method tion and check...
Page 320 — Probable cause of malfunc- Maintenance job Reinstatement method tion and check Improperly connected  Connection of Yamaha diag- Turn “ON” the switch on the nostic tool coupler. Connect the coupler secure- FI diagnostic tool sub-lead. Check the locking condition ly, or repair/replace the wire Fault code No.
Page 321 FUEL INJECTION SYSTEM Fault code Waiting for connection Symptom No communication signal is received from the ECU. Yamaha diagnostic tool mal- Replace the Yamaha diag- Turn “ON” the switch on the function nostic tool. FI diagnostic tool sub-lead. Fault code No. is not dis- played ...
Page 322 — Probable cause of malfunc- Maintenance job Reinstatement method tion and check Improperly connected  Connection of Yamaha diag- Turn “ON” the switch on the nostic tool coupler. Connect the coupler secure- FI diagnostic tool sub-lead. Check the locking condition ly, or repair/replace the wire Fault code No.
Page 323 FUEL INJECTION SYSTEM Fault code Er-4 Registered data cannot be received from the Yamaha diagnos- Symptom tic tool. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. — Diagnostic tool display — Procedure — Probable cause of malfunc-...
Page 324: Fuel Pump System
FUEL PUMP SYSTEM FUEL PUMP SYSTEM EASB111328 EASB111329 CIRCUIT DIAGRAM 8-32...
Page 325 FUEL PUMP SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser 7. Engine stop switch 9. ECU 14.Fuel pump 8-33...
Page 326: Troubleshooting
FUEL PUMP SYSTEM TROUBLESHOOTING EASB111330 The fuel pump fails to operate. 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 NG  1. Check the fuel pump system wire Reconnect.
Page 327 FUEL PUMP SYSTEM 8-35...
Page 328: Electrical Components
ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS EASB111331 EASB111332 8-36...
Page 329 ELECTRICAL COMPONENTS 1. Rectifier/regulator 2. Intake air pressure sensor 3. Throttle position sensor 4. Injector 5. Launch control switch 6. Intake air temperature sensor 7. ECU 8. Ignition coil 9. Condenser 10.Neutral switch 11.Coolant temperature sensor 8-37...
Page 330: Checking The Switches
ELECTRICAL COMPONENTS CHECKING THE SWITCHES EASB111333 Y/W P 8-38...
Page 331 ELECTRICAL COMPONENTS 1. Engine stop switch 2. Launch control switch 3. Neutral switch 8-39...
Page 332 ELECTRICAL COMPONENTS 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 from the opposite end of the coupler, taking care not to loosen or damage the leads.
Page 333: Checking The Ignition Spark Gap
ELECTRICAL COMPONENTS CHECKING THE IGNITION SPARK GAP EASB111334 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (  1k) to the 1. Check: spark plug cap. • Ignition spark gap Out of specification  Perform the ignition Pocket tester system troubleshooting. 90890-03112 Refer to “TROUBLESHOOTING”...
Page 334: Checking The Crankshaft Position Sensor
ELECTRICAL COMPONENTS 2. Check: • Crankshaft position sensor resistance Out of specification  Replace. Crankshaft position sensor resis- tance 228–342  ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (  100) to the crankshaft position sensor coupler. b. Measure the primary coil resistance. Pocket tester ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 335: Checking The Rectifier/Regulator
ELECTRICAL COMPONENTS 2. Check: • Positive tester probe  • Stator coil resistance Red “1” Out of specification  Replace. • Negative tester probe  Black “2” Stator coil resistance 0.624–0.936  ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (  1) to the sta- tor coil coupler.
Page 336: Checking The Throttle Position Sensor
ELECTRICAL COMPONENTS 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. 2. Check: • Throttle position sensor maximum resis- tance Out of specification ...
Page 337: Checking The Throttle Position Sensor Input Voltage
ELECTRICAL COMPONENTS CHECKING THE THROTTLE POSITION EASB111343 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (20 VDC) to the SENSOR INPUT VOLTAGE intake air pressure sensor coupler (wire har- 1. Check: ness side). • Throttle position sensor input voltage Out of specification  Replace the ECU. Pocket tester 90890-03112 Throttle position sensor input...
Page 338: Checking The Neutral Switch
ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Continuity a. Connect the pocket tester (  1k/100) to Positive tester probe  the intake air temperature sensor terminal. Sky blue “1” Negative tester probe  Pocket tester Sensor terminal “a” 90890-03112 Continuity Analog pocket tester Positive tester probe ...
Page 339 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the fuel injector coupler from the fuel injector. b. Connect the pocket tester (  10) to the fuel injector coupler. Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe  Injector terminal “1” •...
Page 340 ELECTRICAL COMPONENTS 8-48...
Page 341: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING..................9-1 GENERAL INFORMATION ................9-1 STARTING FAILURES................9-1 INCORRECT ENGINE IDLING SPEED .............9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 SHIFTING IS DIFFICULT ................9-2 SHIFT PEDAL DOES NOT MOVE .............9-2 JUMPS OUT OF GEAR................9-2 CLUTCH SLIPS..................9-2 CLUTCH DRAGS ..................9-2 OVERHEATING ..................9-2 OVERCOOLING..................9-3 POOR BRAKING PERFORMANCE............9-3 FRONT FORK OIL LEAKING..............9-3 FAULTY FRONT FORK LEGS..............9-3 UNSTABLE HANDLING ................9-3...
Page 342: Troubleshooting
TROUBLESHOOTING Electrical system TROUBLESHOOTING EASB111348 1. Spark plug • Incorrect spark plug gap EASB111349 GENERAL INFORMATION • Incorrect spark plug heat range • Fouled spark plug The following guide for troubleshooting does • Worn or damaged electrode not cover all the possible causes of trouble. It •...
Page 343: Poor Medium-And-High-Speed Performance
TROUBLESHOOTING 3. Ignition system CLUTCH SLIPS • Faulty ECU Engine • Faulty crankshaft position sensor 1. Clutch • Broken generator rotor woodruff key • Improperly assembled clutch EASB111352 POOR MEDIUM-AND-HIGH-SPEED PER- • Loose or fatigued clutch spring FORMANCE • Worn friction plate Refer to “STARTING FAILURES”...
Page 344: Overcooling
TROUBLESHOOTING Fuel system FAULTY FRONT FORK LEGS EASB111362 1. Throttle body • Damaged or loose throttle body joint Chassis 2. Air filter 1. Front fork • Clogged air filter element • Bent or damaged inner tube • Bent or damaged outer tube Chassis •...
Page 345: List Of Self-Diagnostic And Fail-Safe Actions
8-28 nection Er-2 Signals from the ECU cannot be received within the specified period 8-29 of time. Er-3 Data from the ECU cannot be received correctly. 8-30 Er-4 Registered data cannot be received from the Yamaha diagnostic tool. 8-31...
Page 346 • Check with throttle fully opened. Pressure of suction pipe Displays the intake air pres- The atmospheric pressure sure. is displayed on the Yamaha diagnostic tool. Intake air temperature Displays the intake air tem- Compare the actually mea- perature. sured intake air tempera-...
Page 347 Actuates the ignition coil five Check that a spark is gener- times at one-second inter- ated five times. vals. • Connect an ignition “WARNING” on the Yamaha checker. diagnostic tool blinks five times when the ignition coil is actuated. Injector...
Page 348 LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS...
Page 349: Tuning
TUNING CHASSIS ......................10-1 SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET) ..................10-1 DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS ....10-1 TIRE PRESSURE..................10-2 FRONT FORK SETTING................10-2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL..10-2 SETTING OF SPRING AFTER REPLACEMENT ........10-3 FRONT FORK SETTING PARTS.............10-3 REAR SUSPENSION SETTING ..............10-3 CHOOSING SET LENGTH ..............10-3 SETTING OF SPRING AFTER REPLACEMENT ........10-4...
Page 350: Chassis
CHASSIS DRIVE AND REAR WHEEL SPROCKETS CHASSIS EASB111366 SETTING PARTS EASB111367 SELECTION OF THE SECONDARY REDUC- Part name Type Part number TION RATIO (SPROCKET) Drive sprocket “1” Secondary reduction ratio = Number of (STD) 13T 9383E-13233 rear wheel sprocket teeth/Number of Rear wheel drive sprocket teeth sprocket “2”...
Page 351: Tire Pressure
CHASSIS TIRE PRESSURE EASB111369 WARNING Tire pressure should be adjusted to suit the Adjust the oil amount in 5 cm (0.2 US oz, road surface condition of the circuit. 0.2 Imp.oz) increments or decrements. Too small oil amount causes the front fork to Standard tire pressure produce a noise at full rebound or the rider 100 kPa (1.00 kgf/cm...
Page 352: Setting Of Spring After Replacement
CHASSIS SETTING OF SPRING AFTER REPLACE- EASB111372 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.
Page 353: Setting Of Spring After Replacement
CHASSIS 2. Remove the stand or block from the engine SETTING OF SPRING AFTER REPLACE- and, with a rider astride the seat, measure MENT the sunken length “b” between the rear After replacement, be sure to adjust the spring wheel axle center and the rear fender hold- to the set length [sunken length 90–100 mm ing bolt.
Page 354: Rear Shock Absorber Setting Parts
CHASSIS REAR SHOCK ABSORBER SETTING EASB111377 PARTS • Rear shock spring “1” Spring I.D. Type rate N/ Part number Mark 1SL-22212-40 (Blue) Yellow B11-22212-00 (Yellow) SOFT 1SL-22212-60 (Blue) Pink B11-22212-10 (Yellow) 1SL-22212-20 (Blue) White B11-22212-20 (Yellow) 1SL-22212-00 • Spring preload adjusting positions (Blue) Silver B11-22212-30...
Page 355: Suspension Setting (Front Fork)
CHASSIS SUSPENSION SETTING (FRONT FORK) EASB111378 • 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 the standard figure 90–100 mm (3.5–3.9 in).
Page 356: Suspension Setting (Rear Shock Absorber)
CHASSIS Section Medi- Symptom Check Adjust Large Small Jump Compression Turn adjuster clockwise (about damping force 2 clicks) to increase damping. Rebound Turn adjuster counterclock- damping force wise (about 2 clicks) to de- crease damping. Low front, tend- ing to lower Balance with Set sunken length for 95–100 front posture...
Page 357 CHASSIS Section Medi- Symptom Check Adjust Large Small Jump Rebound Turn adjuster counterclock- damping force wise (about 2 clicks) to de- Heavy and crease damping. dragging Spring Replace with soft spring. Rebound Turn adjuster counterclock- damping force wise (about 2 clicks) to de- crease damping.
Page 358: Wiring Diagram
WIRING DIAGRAM EASB111381 YZ450F/YZ450FG 2016 1. Crankshaft position sensor 2. AC magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser 6. Coupler for connecting option- al part 7. Engine stop switch 8. Neutral switch 9. Launch control switch 10. ECU 11. Ignition coil 12.
Page 360 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN...
Page 361 YZ450F/YZ450FG 2016 YZ450F/YZ450FG 2016 YZ450F/YZ450FG 2016 SCHÉMA DE CÂBLAGE WIRING DIAGRAM SCHALTPLAN L L L R R R R R R R R B B B B B B B/L B/L B/L B/L B/L B/L R R R R R R R R...
Page 362 YZ450F/YZ450FG 2016 YZ450F/YZ450FG 2016 YZ450F/YZ450FG 2016 SCHÉMA DE CÂBLAGE WIRING DIAGRAM SCHALTPLAN...

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Yamaha YZ450F Owner's Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Maintenance Intervals

Pre-Operation Inspection and Maintenance

Engine

Chassis

Electrical System

Chassis

General Chassis

Front Wheel

Rear Wheel

Front Brake

Rear Brake

Handlebar

Front Fork

Steering Head

Rear Shock Absorber Assembly

Swingarm

Chain Drive

Engine

Engine Removal

Camshaft

Cylinder Head

Valves and Valve Springs

Cylinder and Piston

Clutch

Kickstater

Shift Shaft

Oil Pump and Balancer Gear

Ac Magneto

Crankcase

Crankshaft Assembly and Balancer Shaft

Transmission

Fuel System

Fuel Tank

Throttle Body

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha YZ450F