Yamaha WR450F(Y) 2009 Owner's Service Manual
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Yamaha WR450F(Y) 2009 Owner's Service Manual

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2009
Read this manual carefully before operating this vehicle.
Il convient de lire attentivement ce manuel avant la première utilisation du véhicule.
Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
Lea atentamente este manual antes de utilizar el vehículo.
OWNER'S SERVICE MANUAL
MANUEL D'ATELIER DU
PROPRIETAIRE
FAHRER- UND
WARTUNGSHANDBUCH
MANUAL DE SERVICIO
DEL PROPIETARIO
WR450F(Y)
5TJ-28199-46

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Summary of Contents for Yamaha WR450F(Y) 2009

  • Page 1 2009 Read this manual carefully before operating this vehicle. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen. Lea atentamente este manual antes de utilizar el vehículo. OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE...
  • Page 2 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit étre remis avec le véhicule en cas de vente de ce dernier. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
  • Page 3 2009 2009 Read this manual carefully before operating this vehicle. Read this manual carefully before operating this vehicle. OWNER’S SERVICE MANUAL OWNER’S SERVICE MANUAL WR450F(Y) WR450F(Y) 5TJ-28199-46-E0 5TJ-28199-46-E0...
  • Page 5 WR450F(Y) OWNER'S SERVICE MANUAL ©2008 by Yamaha Motor Co., Ltd. 1st Edition, June 2008 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan...

  • Page 6: Safety Information

    When operating this machine, al- Congratulations on your purchase of distinguished in this manual by the ways wear an approved helmet with a Yamaha WR series. This model is following notations. goggles or a face shield. Also wear the culmination of Yamaha's vast ex-...

  • Page 7: General Information

    • PROPERLY SECURE THE MA- MANUAL FORMAT CHINE BEFORE TRANSPORTING All of the procedures in this manual are organized in a sequential, step- When transporting the machine in by-step format. The information has another vehicle, always be sure it is been complied to provide the me- properly secured and in an upright chanic with an easy to read, handy...
  • Page 8 2. Numbers "2" are given in the or- 4. A job instruction chart "4" accom- HOW TO READ DESCRIPTIONS der of the jobs in the exploded di- panies the exploded diagram, To help identify parts and clarify pro- agram. A number that is enclosed providing the order of jobs, names cedure steps, there are exploded dia- by a circle indicates a disassem-...

  • Page 9: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS TUNING ENGINE CHASSIS ELECTRICAL...

  • Page 10: Table Of Contents

    CONTENTS CHAPTER 1 CHAPTER 3 OIL FILTER ELEMENT AND WATER PUMP ..5-34 GENERAL INFOR- REGULAR INSPEC- BALANCER ....5-38 MATION TION AND AD- OIL PUMP .......5-40 KICK SHAFT AND JUSTMENTS SHIFT SHAFT ....5-43 DESCRIPTION ....1-1 AC MAGNETO AND MACHINE STARTER CLUTCH..5-48 PERIODIC MAINTENANCE IDENTIFICATION .....

  • Page 11: Description

    DESCRIPTION GENERAL INFORMATION DESCRIPTION Clutch lever 14. Headlight Hot starter lever 15. Radiator Engine stop switch 16. Coolant drain bolt Multi-function display 17. Rear brake pedal Main switch 18. Valve joint Start switch 19. Fuel cock Front brake lever 20. Cold starter knob Throttle grip 21.

  • Page 12: Identification

    1. Remove all dirt, mud, dust, and 1. When ordering parts, you can foreign material before removal give the number to your Yamaha and disassembly. dealer for positive identification of • When washing the machine with the model you own.

  • Page 13: Checking Of Connection

    "1" and reinsert the termi- ALL REPLACEMENT PARTS nal into the connector. 1. We recommend to use Yamaha genuine parts for all replace- ments. Use oil and/or grease rec- ommended by Yamaha for assembly and adjustment.

  • Page 14: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided.
  • Page 15 SPECIAL TOOLS Tool name/Part number How to use Illustration Damper rod holder Use this tool to remove and install YM-01494, 90890-01494 the damper rod. Fork seal driver This tool is used when install the fork YM-A0948, 90890-01502 oil seal. Spoke nipple wrench This tool is used to tighten the YM-01521, 90980-01521 spoke.
  • Page 16 SPECIAL TOOLS Tool name/Part number How to use Illustration Valve spring compressor This tool is needed to remove and YM-4019, 90890-04019 install the valve assemblies. Clutch holding tool This tool is used to hold the clutch YM-91042, 90890-04086 when removing or installing the clutch boss securing nut.
  • Page 17 This tool is used to check the air in- YB-35956-A, 90890-06756 duction system. Digital tachometer This tool is needed for observing en- YU-39951-B, 90890-06760 gine rpm. YAMAHA Bond No. 1215 (ThreeB- This sealant (Bond) is used for ® No. 1215) crankcase mating surface, etc. 90890-85505...

  • Page 18: Control Functions

    CONTROL FUNCTIONS CONTROL FUNCTIONS CLUTCH LEVER The clutch lever "1" is located on the MAIN SWITCH left handlebar; it disengages or en- Functions of the respective switch po- gages the clutch. Pull the clutch lever sitions are as follows: to the handlebar to disengage the clutch, and release the lever to en- The engine can be started only at this gage the clutch.

  • Page 19: Multi-Function Display

    MULTI-FUNCTION DISPLAY MULTI-FUNCTION DISPLAY BASIC MODE Changing speedometer display (for U.K.) Be sure to stop the machine before 1. Push the "SLCT2" button for 2 making any setting changes to the seconds or more to change the multi-function display. speedometer units. The speed- ometer display will change in the The multi-function display is following order:...
  • Page 20 MULTI-FUNCTION DISPLAY Changing odometer and tripmeter RACE MODE A/B (TRIP A/B) Putting measurement on standby 1. Push the "SLCT2" button to change the tripmeter display. The Starting measurement consists of the display will change in the follow- following two starts, either of which ing order: can be selected.
  • Page 21 MULTI-FUNCTION DISPLAY Auto start Resetting measurement data Correcting tripmeter A (TRIP A) 1. Check that changeover has been 1. Change the travel distance dis- made to RACE MODE. (Refer to play by pushing the "SLCT1" but- Resetting can be made in the follow- "Changeover from BASIC MODE ton (plus) or "SLCT2"...
  • Page 22 MULTI-FUNCTION DISPLAY FUNCTION DIAGRAM A short push on the button changes the operation in the arrowed direction. Meter function A short push on the button changes the operation in both arrowed directions. Function that can be performed whether the time is or is not in operation. A long push on the button changes the operation in the arrowed direction.
  • Page 23 MULTI-FUNCTION DISPLAY BASIC MODE Clock The following diagram illustrates the Trip meter multi-function display regarding the Speedometer (for U.K.) direction and operation condition in- RACE MODE volved in each of its functions. Putting measurement on stand- A short push on the button Manual start changes the operation in the ar- Auto start...

  • Page 24: Starting And Break-In

    10%. Gaso- hol containing methanol is not recom- mended by Yamaha because it can cause damage to the fuel system or vehicle performance problems. HANDLING NOTE Never start or run the engine in a 6.
  • Page 25 STARTING AND BREAK-IN The engine fails to start BREAK-IN PROCEDURES Pull the hot starter lever all the way 1. Before starting the engine, fill the out and while holding the lever, kick fuel tank with the fuel. the kickstarter crank 10 to 20 times to 2.

  • Page 26: Torque-Check Points

    TORQUE-CHECK POINTS TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and fuel tank Fuel tank to frame Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Steering stem to handlebar Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar...

  • Page 27: Cleaning And Storage

    CLEANING AND STORAGE CLEANING AND STORAGE STORAGE If your machine is to be stored for 60 CLEANING days or more, some preventive mea- Frequent cleaning of your machine sures must be taken to avoid deterio- will enhance its appearance, maintain ration.

  • Page 28: General Specifications

    GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: WR450FY (USA, CDN, AUS, NZ) WR450F (EUROPE, ZA) Model code number: 5TJN (USA) 5TJP (CDN) 5TJR (EUROPE) 5TJS (AUS, NZ, ZA) Dimensions: USA, CDN, ZA EUROPE AUS, NZ Overall length 2,175 mm (85.63 2,200 mm (86.61 2,190 mm (86.22 Overall width...

  • Page 29: Chassis

    GENERAL SPECIFICATIONS (Except for USA and CDN) SAE10W-30, SAE10W-40, SAE15W-40, SAE20W-40 or SAE20W-50 API service SG type or higher, JASO standard MA Oil capacity: Engine oil Periodic oil change 0.95 L (0.84 Imp qt, 1.00 US qt) With oil filter replacement 1.0 L (0.88 Imp qt, 1.06 US qt) Total amount 1.2 L (1.06 Imp qt, 1.27 US qt)

  • Page 30: Maintenance Specifications

    MAINTENANCE SPECIFICATIONS Tire: Type With tube Size (front) 80/100-21 51M (USA, CDN, ZA) 90/90-21 54R (EUROPE, AUS, NZ) Size (rear) 110/100-18 64M (USA, CDN, ZA) 130/90-18 69R (EUROPE, AUS, NZ) Tire pressure (front and rear) 100 kPa (1.0 kgf/cm , 15 psi) Brake: Front brake type Single disc brake...
  • Page 31 MAINTENANCE SPECIFICATIONS Item Standard Limit Camshaft: Drive method Chain drive (Left) ---- Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in) ---- Camshaft outside diameter 21.959–21.972 mm (0.8645–0.8650 in) ---- Shaft-to-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) 0.08 mm (0.003 Cam dimensions Intake "A"...

  • Page 32: Specifications

    MAINTENANCE SPECIFICATIONS Item Standard Limit "B" face width (IN) 2.26 mm (0.089 in) ---- "B" face width (EX) 2.26 mm (0.089 in) ---- "C" seat width (IN) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 "C" seat width (EX) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 "D"...
  • Page 33 MAINTENANCE SPECIFICATIONS Item Standard Limit Set length (valve closed) (IN) 27.87 mm (1.10 in) ---- Set length (valve closed) (EX) 28.38 mm (1.12 in) ---- Compressed force (installed) (IN) 130.2–149.8 N at 27.87 mm (13.28–15.28 ---- kg at 27.87 mm, 29.27–33.68 lb at 1.10 in) Compressed force (installed) (EX) 123.1–141.7 N at 28.38 mm (12.55–14.45 ----...
  • Page 34 MAINTENANCE SPECIFICATIONS Item Standard Limit Type Taper ---- Dimensions (B × T) 1.00 × 3.35 mm (0.04 × 0.13 in) ---- End gap (installed) 0.35–0.50 mm (0.014–0.020 in) 0.85 mm (0.033 Side clearance 0.020–0.055 mm (0.0008–0.0022 in) 0.12 mm (0.005 Oil ring: Dimensions (B ×...

  • Page 35: Engine

    MAINTENANCE SPECIFICATIONS Item Standard Limit Shifter: Shifter type Cam drum and guide bar ---- Guide bar bending limit ---- 0.05 mm (0.002 Kickstarter: Type Ratchet type ---- Carburetor: USA, CDN, AUS, EUROPE NZ, ZA I. D. mark 5TJE E0 5TJL L0 ---- Main jet (M.J) #162...
  • Page 36 MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing ---- Front suspension: USA, CDN EUROPE, AUS, NZ, ZA Front fork travel 300 mm (11.8 in) ---- ← Fork spring free length 460 mm (18.1 in) 455 mm (17.9 ←...

  • Page 37: Electrical

    MAINTENANCE SPECIFICATIONS Item Standard Limit Drive chain: Type/manufacturer DID520VM/DAIDO ---- Number of links 113 links + joint ---- Chain slack 48–58 mm (1.9–2.3 in) ---- Chain length (15 links) ---- 239.3 mm (9.42 in) Front disc brake: Disc outside dia. × Thickness 250 ×...
  • Page 38 Item Standard Limit Charging system: System type AC magneto ---- Model (stator)/manufacturer 5TJ 50/YAMAHA ---- Normal output 14 V/120 W at 5,000 r/min ---- Charging coil resistance (color) 0.288–0.432 Ω at 20 °C (68 °F) (White–Ground) ---- Lighting coil resistance (color) 0.224–0.336 Ω...

  • Page 39: Tightening Torques

    TIGHTENING TORQUES TIGHTENING TORQUES ENGINE △ - marked portion shall be checked for torque tightening after break-in or before each race. *1: Tighten the cylinder head bolts to 30 Nm (3.0 m•kg, 22 ft•lb) in the proper tightening sequence, remove and retighten the cylinder head bolts to 20 Nm (2.0 m•kg, 14 ft•lb) in the proper tightening sequence, and then tighten the cylinder head bolts further to reach the specified angle 180°...
  • Page 40 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Radiator pipe 1, 2 M10 × 1.0 Impeller M8 × 1.25 Water pump housing cover M6 × 1.0 Coolant drain bolt M6 × 1.0 Oil pump cover M4 ×...
  • Page 41 TIGHTENING TORQUES CHASSIS △ - marked portion shall be checked for torque tightening after break-in or before each race. Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Upper bracket and outer tube M8 × 1.25 △ Lower bracket and outer tube M8 ×...
  • Page 42 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Driven sprocket and wheel hub M8 × 1.25 △ Nipple (spoke) — △ Disc cover and rear brake caliper M6 × 1.0 △ Protector and rear brake caliper M6 ×...
  • Page 43 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Headlight mounting (left and right) M6 × 1.0 △ Taillight mounting — Taillight lead clamp and rear fender — 0.05 0.36 Catch tank (upper) M6 × 1.0 △...
  • Page 44 TIGHTENING TORQUES GENERAL TORQUE TORQUE SPECIFI- SPECIFICATIONS CATION (Bolt This chart specifies torque for stan- (Nut) dard fasteners with standard I.S.O. m•kg ft•lb pitch threads. Torque specifications 6 mm for special components or assem- blies are included in the applicable sections of this book.

  • Page 46: Lubrication Diagrams

    LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS Oil filter element Oil pump Drive axle Main axle Crankshaft Connecting rod From cylinder To oil tank 2-18...
  • Page 47 LUBRICATION DIAGRAMS Intake camshaft Exhaust camshaft To main axle From oil pump 2-19...

  • Page 48: Cable Routing Diagram

    CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM Fuel tank breather hose 10. Neutral switch lead Clamp 11. AC magneto lead Diode 12. Brake hose Hot starter cable 13. Rectifier/regulator lead Throttle position sensor lead 14. Carburetor breather hose Wire harness 15. Carburetor overflow hose Hump (frame) 16.
  • Page 49 CABLE ROUTING DIAGRAM Insert the end of the fuel tank Locate the clamp between the breather hose into the hole in hot starter cable protector and the steering stem. rubber cap. Fasten the throttle cable, hot starter cable and rectifier/regula- tor lead onto the frame.
  • Page 50 CABLE ROUTING DIAGRAM Throttle cable (pull) Cross the pull and push throttle Pass the carburetor breather Throttle cable (return) cables. hose (of the throttle cable cover) Catch tank hose Fasten the catch tank hose and through the hose holder. Ignition coil air induction hose (air cut-off Clamp valve-rear of cylinder head) onto...
  • Page 51 CABLE ROUTING DIAGRAM Brake master cylinder Install the brake hose so that its Install the brake hose so that its Brake hose holder pipe portion directs as shown pipe portion directs as shown Brake hose and lightly touches the projec- and lightly touches the projec- tion on the brake caliper.
  • Page 52 CABLE ROUTING DIAGRAM Clamp Fasten the wire harness to the Fasten the wire harness to the Positive battery lead upper engine bracket (left side). upper engine bracket (left side). Battery Locate the clamp end facing to- Locate the clamp end facing to- Negative battery lead ward the upper side of the frame ward the upper side of the frame...
  • Page 53 CABLE ROUTING DIAGRAM Connect the wire harness to the starter relay. Fasten the catch tank breather hose and catch tank hose to the rear frame. Clamp them close to where they are joined to the frame. Fasten the pipe tightly enough not to crush it.
  • Page 54 CABLE ROUTING DIAGRAM Throttle cable 12. Upper bracket Fasten the start switch lead to Clamp 13. Clutch switch coupler the handlebar with the plastic Brake hose 14. Engine stop switch coupler bands. Clutch cable 15. Multi-function display coupler Fasten the engine stop switch Hose guide 16.
  • Page 55 CABLE ROUTING DIAGRAM Secure the coupler by inserting it into the multi-function display bracket. Pass the throttle cables, clutch cable and hot starter cable be- tween the upper bracket and multi-function display bracket. Fasten the multi-function display leads to the bracket. Cut off the tie end.

  • Page 56: Adjustments

    • From 4,200 mi (7,000 km) or 9 months, repeat the maintenance intervals starting from 1,800 mi (3,000 km) or 3 months. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

  • Page 57: General Maintenance And Lubrication Chart

    GENERAL MAINTENANCE AND LUBRICATION CHART (For Canada) GENERAL MAINTENANCE AND LUBRICATION CHART (For Canada) ODOMETER INITIAL READINGS 600 mi 1,800 mi 3,000 mi ITEM CHECKS AND MAINTENANCE JOBS (1,000 (3,000 (5,000 km) or 1 km) or 3 km) or 6 month months months...

  • Page 58: Intervals For Competition Use

    The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. Every...
  • Page 59 MAINTENANCE INTERVALS FOR COMPETITION USE Every Every After third fifth (or Every As re- Item break- Remarks race (or 500 1,000 quired Replace ● CAMSHAFTS Inspect the camshaft surface. Inspect Inspect the decompression system. ● Replace ● CAMSHAFT SPROCKETS Inspect Check for wear on the teeth and for ●...
  • Page 60 MAINTENANCE INTERVALS FOR COMPETITION USE Every Every After third fifth (or Every As re- Item break- Remarks race (or 500 1,000 quired CARBURETOR Inspect, adjust and clean ● ● SPARK PLUG Inspect and clean ● ● Replace ● DRIVE CHAIN Use chain lube.
  • Page 61 ● Inspect bearings ● Replace bearings ● Lubricate Lithium base grease ● THROTTLE, CONTROL CABLE Check routing and connection ● ● Lubricate Yamaha cable lube or SAE 10W-30 ● ● motor oil HOT STARTER, CLUTCH LEVER Inspect free play ●...

  • Page 62: Inspection And Maintenance

    PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation or practice, make sure the machine is in good operating condition. Before using this machine, check the following points. GENERAL INSPECTION AND MAINTENANCE Item Routine Page Check that coolant is filled up to the radiator cap. Check the cool- Coolant P.3-11 –...
  • Page 63 ENGINE ENGINE REMOVING THE SEAT, FUEL TANK AND SIDE COVERS Order Part name Q'ty Remarks Turn the fuel cock to "OFF". Disconnect the fuel hose. Seat Air scoop (left and right) Bolt (fuel tank) Fuel tank Left side cover Open the air filter case cover. Right side cover Refer to removal section.
  • Page 64 ENGINE REMOVING THE SIDE COVER 1. Remove: • Bolt (side cover) • Right side cover "1" Draw the side cover backward to re- move it because its claw "a" is insert- ed in the air filter case.
  • Page 65 ENGINE REMOVING THE EXHAUST PIPE AND SILENCER Order Part name Q'ty Remarks Refer to "REMOVING THE SEAT, FUEL Right side cover TANK AND SIDE COVERS" section. Bolt (silencer clamp) Only loosening. Bolt [silencer (front)] Bolt [silencer (rear)] Collar Silencer Silencer clamp Nut (exhaust pipe) Bolt (exhaust pipe) Exhaust pipe...
  • Page 66 ENGINE CHECKING THE SILENCER AND EXHAUST PIPE Take care so that coolant does not 1. Inspect: splash on painted surfaces. If it • Gasket "1" splashes, wash it away with water. Damage → Replace. 1. Place a container under the en- gine.
  • Page 67 ENGINE • Radiator hose joint Coolant leakage → Repair or re- Apply water on the radiator cap seal. place. • Radiator hose Swelling → Replace. ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: • Clutch lever free play "a" Out of specification → Adjust. Handling notes of coolant: The coolant is harmful so it should be Clutch lever free play "a"...
  • Page 68 ENGINE Never run the engine without the air filter element in place; this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage. 1. Open the air filter case cover "1" 2. Adjust: 3.
  • Page 69 ENGINE 5. Inspect: CHECKING THE ENGINE OIL • Air filter element LEVEL Damage → Replace. 1. Stand the machine on a level sur- 6. Apply: face. • Foam-air-filter oil or equivalent oil to the element • When checking the oil level make sure that the machine is upright.
  • Page 70 ENGINE 4. If the oil filter is to be replaced dur- 7. Install: ing this oil change, remove the fol- • Oil filler cap "1" lowing parts and reinstall them. Replacement steps: a. Remove the oil filter element cov- er "1" and oil filter element "2". b.
  • Page 71 Yama- b. Align the T.D.C. mark "a" on the ha motorcycles (e.g., Yamaha deal- rotor with the align mark "b" on the ers, service engineers, etc.) Those crankcase cover when piston is at who have little knowledge and skill T.D.C.
  • Page 72 ENGINE g. Install the camshafts (exhaust and intake). The thickness "a" of each pad is indi- Refer to "CAMSHAFTS" section cated in hundredths of millimeters on in the CHAPTER 5. the pad upper surface. Bolt (camshaft cap): 10 Nm (1.0 m•kg, 7.2 ft•lb) h.
  • Page 73 ENGINE INTAKE EXHAUST 3-18...
  • Page 74 CHASSIS CLEANING THE SPARK 6. Install: ARRESTER (For USA) • Silencer cap Silencer cap: 5 Nm (0.5 m•kg, 3.6 • Be sure the exhaust pipe and si- ft•lb) lencer are cool before cleaning the spark arrester. • Do not start the engine when First tighten the two screws "a"...
  • Page 75 CHASSIS Pedal height adjustment steps: a. Loosen the locknut "1". b. Turn the adjusting nut "2" until the pedal height "a" is within specified height. c. Tighten the locknut. 2. Remove: b. Loosen the pad pin "2". • Brake lever cover c.
  • Page 76 CHASSIS Do not reuse the drained brake flu- g. Tighten the bleed screw. Bleed screw: 6 Nm (0.6 m•kg, 4.3 ft•lb) Install the brake caliper "8" and 2. Replace: tighten the pad pin "9". • Brake pad h. Install the brake pad "10" and pad pin "11".
  • Page 77 CHASSIS 3. Inspect: • Brake fluid level Refer to "CHECKING THE BRAKE FLUID LEVEL" section. 4. Check: • Brake pedal operation A softy or spongy feeling → Bleed brake system. Refer to "BLEEDING THE HY- Lower level 3. Clean: DRAULIC BRAKE SYSTEM" sec- A.
  • Page 78 CHASSIS 6. Install: Out of specification → Adjust. d. Tighten the axle nut while pushing • Chain joint "1" down the drive chain. Drive chain slack: • O-ring "2" 48–58 mm (1.9–2.3 in) Axle nut: • Drive chain "3" 125 Nm (12.5 m•kg, 90 •...
  • Page 79 CHASSIS RELIEVING THE FRONT FORK 3. Install: INTERNAL PRESSURE • Rubber cap Do not force the adjuster past the CHECKING THE REAR SHOCK minimum or maximum extent of If the front fork initial movement feels ABSORBER adjustment. The adjuster may be 1.
  • Page 80 CHASSIS 4. Adjust: • Rear frame (lower) ADJUSTING THE REAR SHOCK • Spring preload ABSORBER LOW COMPRESSION Rear frame (lower): DAMPING FORCE 32 Nm (3.2 m•kg, 23 1. Adjust: Adjustment steps: ft•lb) • Low compression damping force a. Loosen the locknut "1". ADJUSTING THE REAR SHOCK By turning the adjuster "1".
  • Page 81 CHASSIS ADJUSTING THE REAR SHOCK Spokes: ABSORBER HIGH COMPRESSION • Check the tire while it is cold. 3 Nm (0.3 m•kg, 2.2 DAMPING FORCE • Loose bead stoppers allow the tire ft•lb) 1. Adjust: to slip off its position on the rim CHECKING THE WHEELS •...
  • Page 82 CHASSIS 4. Adjust: g. Check the steering stem by turn- • Steering ring nut ing it lock to lock. If there is any binding, remove the steering stem assembly and inspect the steer- Steering ring nut adjustment ing bearings. steps: h.
  • Page 83 CHASSIS LUBRICATION To ensure smooth operation of all Use Yamaha cable lube or components, lubricate your machine equivalent on these areas. during setup, after break-in, and after Use SAE 10W-30 motor oil or every ride. suitable chain lubricants. All control cable...
  • Page 84 ELECTRICAL ELECTRICAL CHECKING THE IGNITION TIMING • Charge batteries in a well-venti- 1. Remove: lated area. CHECKING THE SPARK PLUG • Timing mark accessing screw "1" • Keep batteries away from fire, 1. Remove: sparks or open flames (e.g., • Spark plug welding equipment, lighted ciga- 2.
  • Page 85 ELECTRICAL • To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery. • Before removing the battery charger lead clips from the bat- tery terminals, be sure to turn off the battery charger.
  • Page 86 ELECTRICAL Charging method using a variable voltage charger 3-31...
  • Page 87 ELECTRICAL Charging method using a constant voltage charger 3-32...
  • Page 88 ELECTRICAL 6. Install: 2. Remove: • Battery • Headlight bulb holder cover "1" • Battery band 7. Connect: • Battery leads (to the battery terminals) First, connect the positive lead "1", Reserve fuse then the negative lead "2". c. If the pocket tester indicates " ∞ ", replace the fuse.
  • Page 89 ELECTRICAL ADJUSTING THE HEADLIGHT BEAMS 1. Adjust: • Headlight beam (vertically) Adjusting steps: a. Turn the adjusting screw "1" in di- rection "a" or "b". Direction "a" Headlight beam is raised. Direction "b" Headlight beam is lowered. 3-34...

  • Page 90: Tuning

    ENGINE (Except for Canada) TUNING • After installing the carburetor, CONSTRUCTION OF check that the throttle operates CARBURETOR AND SETTING ENGINE (Except for Canada) correctly and opens and closes PARTS CARBURETOR SETTING smoothly. The FLATCR carburetor has a prima- • The air/fuel mixture will vary de- ry main jet.
  • Page 91 ENGINE (Except for Canada) ADJUSTING THE PILOT JET Effects of changing the jet needle ADJUSTING THE LEAK JET The richness of the air-fuel mixture groove position (reference) (ADJUSTING THE ACCELERATOR with the throttle open 1/4 or less can PUMP) be set by adjusting the pilot jet "1". The leak jet "1"...
  • Page 92 ENGINE (Except for Canada) CARBURETOR SETTING PARTS Part Leak jet Size number Part (-1494F-) Main jet Size number Rich 4JT-01 (-14943-) 4JT-03 Rich #185 4MX-44 4JT-05 #182 4MX-94 4JT-07 #180 4MX-43 4JT-09 #178 4MX-93 (STD) 4JT-11 #175 4MX-42 Lean 4JT-13 #172 4MX-92 * For EUROPE...
  • Page 93 ENGINE (Except for Canada) EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM Symptom Setting Checking At full throttle Increase main jet calibration no. (Gradual- Discoloration of spark plug → If tan color, it Hard breathing is in good condition. Shearing noise If cannot be corrected: Whitish spark plug Clogged float valve seat...
  • Page 94 CHASSIS CHASSIS DRIVE AND REAR WHEEL TIRE PRESSURE SPROCKETS SETTING PARTS Tire pressure should be adjust to suit SELECTION OF THE SECONDARY the road surface condition of the cir- REDUCTION RATIO (SPROCKET) Part cuit. Size Part number name Secondary reduction ratio = Standard tire pressure: Number of rear wheel sprocket Drive...
  • Page 95 CHASSIS FRONT FORK SETTING PARTS Standard oil level: Standard washer quanti- • Adjustment washer "1" 132 mm (5.20 in) TYPE (thick- *125 mm (4.92 in) Zero adjustment wash- PART NUMBER ness) Extent of adjustment: 95–150 mm (3.74–5.91 Extent of adjustment: T = 2.3 mm (0.09 5XE-23364-00 Zero–2 adjustment...
  • Page 96 CHASSIS CHOOSING SET LENGTH SETTING OF SPRING AFTER REAR SHOCK ABSORBER 1. Place a stand or block under the REPLACEMENT SETTING PARTS engine to put the rear wheel After replacement, be sure to adjust • Rear shock spring "1" above the floor, and measure the the spring to the set length [sunken SPRING SPRI...
  • Page 97 CHASSIS SUSPENSION SETTING (FRONT FORK) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in). Section Medi- Symptom...
  • Page 98 CHASSIS SUSPENSION SETTING (REAR SHOCK ABSORBER) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Adjust the rebound damping in 2-click increments or decrements. •...

  • Page 99: Radiator

    RADIATOR ENGINE This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are request- ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage.
  • Page 100 RADIATOR Order Part name Q'ty Remarks Radiator hose 4 Pipe 2/O-ring Catch tank hose Left radiator Radiator hose 1 Pipe 1/O-ring Catch tank breather hose Catch tank...
  • Page 101 RADIATOR HANDLING NOTE 5. Install: • Catch tank "1" • Bolt (catch tank) "2" Do not remove the radiator cap Bolt (catch tank): when the engine and radiator are 7 Nm (0.7 m•kg, 5.1 hot. Scalding hot fluid and steam ft•lb) may be blown out under pressure, which could cause serious injury.

  • Page 102: Carburetor

    CARBURETOR CARBURETOR REMOVING THE CARBURETOR Order Part name Q'ty Remarks Refer to "REMOVING THE SEAT, FUEL Seat and fuel tank TANK AND SIDE COVERS" section in the CHAPTER 3. Refer to "REAR SHOCK ABSORBER" sec- Rear shock absorber tion in the CHAPTER 6. Clamp Throttle position sensor lead coupler Throttle cable cover...
  • Page 103 CARBURETOR Order Part name Q'ty Remarks Bracket (cylinder head breather pipe) Carburetor joint...
  • Page 104 CARBURETOR DISASSEMBLING THE CARBURETOR Order Part name Q'ty Remarks Carburetor breather hose Valve lever housing cover Screw (throttle shaft) Throttle valve Needle holder Jet needle Accelerator pump cover Spring Diaphragm (accelerator pump) Air cut valve cover Spring (air cut valve) Diaphragm (air cut valve) Float chamber Leak jet...
  • Page 105 CARBURETOR Order Part name Q'ty Remarks Main jet Needle jet Spacer Pilot jet Starter jet Push rod Pull the push rod. Throttle shaft assembly Push rod link lever assembly Pilot air jet Cold starter plunger...
  • Page 106 CARBURETOR HANDLING NOTE 2. Inspect: CHECKING THE JET NEEDLE • Main jet "1" 1. Inspect: • Pilot jet "2" • Jet needle "1" Do not loosen the screw (throttle • Needle jet "3" Bends/wear → Replace. position sensor) "1" except when •...
  • Page 107 CARBURETOR e. If both are fine, adjust the float 2. Inspect: 4. Install: height by bending the float tab "b" • Throttle shaft "1" • Spring 2 "1" on the float. • Spring "2" To lever 2 "2". • Lever 1 "3" •...
  • Page 108 CARBURETOR 10. Install: 13. Install: • Starter jet "1" • O-ring • Apply the fluorochemical grease on • Pilot jet "2" • Leak jet "1" the bearings. • Spacer "3" • Float chamber "2" • Fit the projection "a" on the throttle •...
  • Page 109 CARBURETOR 16. Install: ADJUSTING THE ACCELERATOR 2. Install: • Jet needle "1" PUMP TIMING • Carburetor "1" • Collar "2" • Spring "3" Install the projection "a" between the Adjustment steps: • Needle holder "4" carburetor joint slots. • Throttle valve plate "5" In order for the throttle valve height To throttle valve "6".
  • Page 110 CARBURETOR 5. Install: 9. Install: • Throttle cable (pull) "1" • Clamp "1" Refer to "CABLE ROUTING DIA- Throttle cable (pull): GRAM" section in the CHAPTER 4 Nm (0.4 m•kg, 2.9 ft•lb) • Throttle cable (return) "2" Throttle cable (return): 11 Nm (1.1 m•kg, 8.0 ft•lb) 6.

  • Page 111: Air Indictoin System

    AIR INDICTOIN SYSTEM AIR INDICTOIN SYSTEM REMOVING THE AIR INDUCTION SYSTEM Order Part name Q'ty Remarks Bracket Air cut-off valve assembly Air induction hose (air cut-off valve - front of cyl- inder head) Air induction pipe Gasket Air induction hose (air cut-off valve - rear of cylin- der head) Air induction hose (air cut-off valve - air filter case)
  • Page 112 AIR INDICTOIN SYSTEM CHECKING THE AIR INDUCTION SYSTEM 1. Inspect: • Air induction hose Crack/damage → Replace. • Air induction pipe Crack/damage → Replace. 2. Check: • Operation of air cut valve From air filter Pass air through the pipe and To cylinder head (exhaust check the air cut valve for opera- port)

  • Page 113: Camshafts

    CAMSHAFTS CAMSHAFTS REMOVING THE CYLINDER HEAD COVER Order Part name Q'ty Remarks Refer to "REMOVING THE SEAT, FUEL Seat and fuel tank TANK AND SIDE COVERS" section in the CHAPTER 3. Air cut-off valve assembly Refer to "AIR INDUCTION SYSTEM" section. Engine upper bracket (right) Refer to "ENGINE REMOVAL"...
  • Page 114 CAMSHAFTS REMOVING THE CAMSHAFTS Order Part name Q'ty Remarks Timing mark accessing screw Refer to removal section. Crankshaft end accessing screw Refer to removal section. Timing chain tensioner cap bolt Refer to removal section. Timing chain tensioner Refer to removal section. Gasket Refer to removal section.
  • Page 115 CAMSHAFTS REMOVING THE CAMSHAFT 3. Remove: CHECKING THE CAMSHAFT 1. Remove: • Timing chain tensioner cap bolt 1. Inspect: • Timing mark accessing screw "1" "1" • Cam lobe • Crankshaft end accessing screw • Timing chain tensioner "2" Pitting/scratches/blue discolora- "2"...
  • Page 116 CAMSHAFTS 3. Measure: d. Remove the camshaft caps and CHECKING THE • Runout (camshaft) measure the width of the Plasti- DECOMPRESSION SYSTEM ® Out of specification → Replace. gauge "1". 1. Check: • Decompression system Runout (camshaft): Less than 0.03 mm Checking steps: (0.0012 in) a.
  • Page 117 CAMSHAFTS INSTALLING THE CAMSHAFT d. Install the clips, camshaft caps "4" 1. Install: and bolts (camshaft cap) "5". • Exhaust camshaft "1" Bolt (camshaft cap): • Intake camshaft "2" 10 Nm (1.0 m•kg, 7.2 ft•lb) c. Release the screwdriver, check the tensioner rod to come out and tighten the gasket "5"...

  • Page 118: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD REMOVING THE CYLINDER HEAD Order Part name Q'ty Remarks Refer to "REMOVING THE SEAT, FUEL Seat and fuel tank TANK AND SIDE COVERS" section in the CHAPTER 3. Refer to "REMOVING THE EXHAUST PIPE Exhaust pipe and silencer AND SILENCER"...
  • Page 119 CYLINDER HEAD CHECKING THE CYLINDER HEAD INSTALLING THE CYLINDER d. Tighten the bolts to the specified 1. Eliminate: HEAD torque in two or three steps in the • Carbon deposits (from the com- 1. Install: proper tightening sequence as bustion chambers) •...
  • Page 120 CYLINDER HEAD 3. Install: • Bolt (cylinder head) "1" Bolt (cylinder head): 10 Nm (1.0 m•kg, 7.2 ft•lb) 5-22...

  • Page 121: Valves And Valve Springs

    VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS REMOVING THE VALVES AND VALVE SPRINGS Order Part name Q'ty Remarks Cylinder head Refer to "CYLINDER HEAD" section. Valve lifter Refer to removal section. Adjusting pad Refer to removal section. Valve cotter Refer to removal section.
  • Page 122 VALVES AND VALVE SPRINGS REMOVING THE VALVE LIFTER a. Remove the valve guide using a AND VALVE COTTER valve guide remover "1". 1. Remove: • Valve lifter "1" • Pad "2" Identify each lifter "1" and pad "2" po- sition very carefully so that they can CHECKING THE VALVE be reinstalled in their original place.
  • Page 123 VALVES AND VALVE SPRINGS 3. Inspect: Valve seat width: • Valve face Do not let the compound enter the Intake: Pitting/wear → Grind the face. gap between the valve stem and 0.9–1.1 mm (0.0354– • Valve stem end the guide. 0.0433 in) Mushroom shape or diameter <Limit>:1.6 mm...
  • Page 124 VALVES AND VALVE SPRINGS CHECKING THE VALVE SPRINGS 3. Install: 1. Measure: • Valve cotters • Valve spring free length "a" Out of specification → Replace. While compressing the valve spring with a valve spring compressor "1" in- Free length (valve stall the valve cotters.

  • Page 125: Cylinder And Piston

    CYLINDER AND PISTON CYLINDER AND PISTON REMOVING THE CYLINDER AND PISTON Order Part name Q'ty Remarks Cylinder head Refer to "CYLINDER HEAD" section. Bolt (cylinder) Cylinder Gasket Dowel pin Piston pin clip Refer to removal section. Piston pin Refer to removal section. Piston Refer to removal section.
  • Page 126 CYLINDER AND PISTON REMOVING THE PISTON AND 2. Measure: Piston-to-cylinder clear- PISTON RING • Piston-to-cylinder clearance ance: 1. Remove: 0.020–0.045 mm • Piston pin clip "1" (0.0008–0.0018 in) Measurement steps: • Piston pin "2" <Limit>:0.1 mm (0.004 a. Measure the cylinder bore "C" •...
  • Page 127 CYLINDER AND PISTON mula. and piston. • Be sure that the arrow mark "a" on You cannot measure the end gap on Piston pin-to-piston clearance = the piston points to the exhaust side the expander spacer of the oil control Inside diameter (piston) "b"...

  • Page 128: Clutch

    CLUTCH CLUTCH REMOVING THE CLUTCH Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Brake pedal Refer to "ENGINE REMOVAL" section. Clutch cable Disconnect at engine side. Clutch cover Gasket Dowel pin Clutch spring...
  • Page 129 CLUTCH Order Part name Q'ty Remarks Nut (clutch boss) Refer to removal section. Lock washer Refer to removal section. Clutch boss Refer to removal section. Thrust washer Primary driven gear Push lever shaft 5-31...
  • Page 130 CLUTCH REMOVING THE CLUTCH BOSS CHECKING THE CLUTCH CHECKING THE PUSH LEVER 1. Remove: SPRINGS SHAFT • Nut "1" 1. Measure: 1. Inspect: • Lock washer "2" • Clutch spring free length "a" • Push lever shaft "1" • Clutch boss "3" Out of specification →...
  • Page 131 CLUTCH • Clutch plate 2 [t=1.6 mm (0.063 7. Install: in)] "3" • Pressure plate "1" • Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate. •...

  • Page 132: Oil Filter Element And Water Pump

    OIL FILTER ELEMENT AND WATER PUMP OIL FILTER ELEMENT AND WATER PUMP REMOVING THE OIL FILTER ELEMENT AND WATER PUMP 10 Nm (1.0 m kg, 7.2 ft lb) 33 Nm (3.3 m kg, 24 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 12 Nm (1.2 m kg, 8.7 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb)
  • Page 133 OIL FILTER ELEMENT AND WATER PUMP 10 Nm (1.0 m kg, 7.2 ft lb) 33 Nm (3.3 m kg, 24 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 12 Nm (1.2 m kg, 8.7 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 14 Nm (1.4 m kg, 10 ft lb)
  • Page 134 OIL FILTER ELEMENT AND WATER PUMP REMOVING THE IMPELLER CHECKING THE IMPELLER SHAFT SHAFT 1. Inspect: 1. Remove: • Impeller shaft "1" • Impeller "1" Bend/wear/damage → Replace. • Washer "2" Fur deposits → Clean. • Impeller shaft "3" Hold the impeller shaft on its width INSTALLING THE IMPELLER across the flats "a"...
  • Page 135 OIL FILTER ELEMENT AND WATER PUMP 3. Install: • O-ring • Coolant pipe "1" • Bolt (coolant pipe) "2" Bolt (coolant pipe): 10 Nm (1.0 m•kg, 7.2 ft•lb) 2. Install: 2. Install: • Right crankcase cover "1" • Oil tank breather hose "1" Apply the lithium soap base grease •...

  • Page 136: Balancer

    BALANCER BALANCER REMOVING THE BALANCER Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Refer to "OIL FILTER ELEMENT AND WA- Right crankcase cover TER PUMP" section. Stator Refer to "CDI MAGNETO" section. Nut (balancer) Refer to removal section. Nut (primary drive gear) Refer to removal section.
  • Page 137 BALANCER REMOVING THE BALANCER CHECKING THE BALANCER • Straight key "6" 1. Straighten the lock washer tab. 1. Inspect: • Balancer "7" 2. Loosen: • Balancer • Lock washer "8" • Nut (balancer) "1" Cracks/damage → Replace. • Nut (balancer) "9" •...

  • Page 138: Oil Pump

    OIL PUMP OIL PUMP REMOVING THE OIL PUMP Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Refer to "OIL FILTER ELEMENT AND WA- Right crankcase cover TER PUMP" section. Circlip Washer Oil pump drive gear Oil pump assembly Dowel pin Outer rotor 2 Circlip...
  • Page 139 OIL PUMP Order Part name Q'ty Remarks Oil pump drive shaft Rotor housing 5-41...
  • Page 140 OIL PUMP CHECKING THE OIL PUMP 3. Check: 1. Inspect: • Unsmooth→Repeat steps #1 and • Oil pump drive gear #2 or replace the defective parts. • Oil pump drive shaft • Rotor housing • Oil pump cover Cracks/wear/damage → Replace. 2.

  • Page 141: Kick Shaft And Shift Shaft

    KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Remarks Oil pump Refer to "OIL PUMP" section. Kick idle gear Kick shaft assembly Refer to removal section. Spring guide Torsion spring Ratchet wheel Kick gear...
  • Page 142 KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Remarks Pawl Pawl pin Spring Bolt (stopper lever) Stopper lever Torsion spring Segment Refer to removal section. 5-44...
  • Page 143 KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT • Kick shaft "2" CHECKING THE STOPPER LEVER ASSEMBLY Wear/damage → Replace. 1. Inspect: 1. Remove: • Spring "3" • Stopper lever "1" • Kick shaft assembly "1" Broken → Replace. Wear/damage →...
  • Page 144 KICK SHAFT AND SHIFT SHAFT INSTALLING THE SHIFT GUIDE INSTALLING THE SHIFT SHAFT AND SHIFT LEVER ASSEMBLY 1. Install: 1. Install: • Roller "1" • Spring "1" • Collar "2" • Pawl pin "2" • Torsion spring "3" • Pawl "3" •...
  • Page 145 KICK SHAFT AND SHIFT SHAFT • Kick idle gear "1" • Washer "2" • Circlip "3" • Apply the engine oil on the kick idle gear inner circumference. • Install the kick idle gear with its de- pressed side "a" toward you. 5-47...

  • Page 146: Ac Magneto And Starter Clutch

    AC MAGNETO AND STARTER CLUTCH AC MAGNETO AND STARTER CLUTCH REMOVING THE AC MAGNETO AND STARTER CLUTCH Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Refer to "REMOVING THE SEAT, FUEL Seat and fuel tank TANK AND SIDE COVERS"...
  • Page 147 AC MAGNETO AND STARTER CLUTCH Order Part name Q'ty Remarks Woodruff key Starter clutch assembly cover Refer to removal section. Starter clutch Refer to removal section. Starter clutch drive gear Holder Pickup coil Stator Tighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb), loosen and retighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb). 5-49...
  • Page 148 AC MAGNETO AND STARTER CLUTCH REMOVING THE ROTOR 3. Check: 1. Remove: • Starter clutch operation • Nut (rotor) "1" • Washer a. Install the starter clutch drive gear Use the sheave holder "2". "1" onto the starter clutch "2" and hold the starter clutch.
  • Page 149 • Bearing "2" • Apply the sealant to the grommet of • Idle gear 2 "3" the AC magneto lead. Apply the engine oil on the shaft, YAMAHA Bond No. 1215 bearing and idle gear inner circumfer- ® (ThreeBond No. 1215): ence.
  • Page 150 AC MAGNETO AND STARTER CLUTCH 10. Install: • Cover (idle gear 1) "1" • Bolt "2" Bolt: 10 Nm (1.0 m•kg, 7.2 ft•lb) Install the cover (idle gear 1) with its mark "a" facing upward. 11. Connect: • AC magneto lead Refer to "CABLE ROUTING DIA- GRAM"...

  • Page 151: Engine Removal

    ENGINE REMOVAL ENGINE REMOVAL REMOVING THE ENGINE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the frame. Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Refer to "REMOVING THE SEAT, FUEL Seat and fuel tank TANK AND SIDE COVERS"...
  • Page 152 ENGINE REMOVAL Order Part name Q'ty Remarks Ignition coil Disconnect the AC magneto lead. Refer to "ELECTRIC STARTING SYSTEM" Disconnect the starter motor lead. section in the CHAPTER 7. Negative battery lead Disconnect at the engine side. Engine guard Neutral switch Drive chain sprocket cover Nut (drive sprocket) Refer to removal section.
  • Page 153 ENGINE REMOVAL HANDLING NOTE 2. Remove: • Engine "1" From right side. Support the machine securely so there is no danger of it falling over. Make sure that the couplers, hoses and cables are disconnected. REMOVING THE DRIVE SPROCKET 1. Remove: •...
  • Page 154 ENGINE REMOVAL 2. Install: • Lock washer "1" • Nut (drive sprocket) "2" Nut (drive sprocket): 75 Nm (7.5 m•kg, 54 ft•lb) Tighten the nut while applying the rear brake. Make sure to tighten to specifica- tion; otherwise, it may damage the other part that is fastened togeth- 3.

  • Page 155: Crankcase And Crankshaft

    CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT REMOVING THE CRANKSHAFT Order Part name Q'ty Remarks Engine Refer to "ENGINE REMOVAL" section. Piston Refer to "CYLINDER AND PISTON" section. Balancer Refer to "BALANCER" section. Refer to "KICK SHAFT AND SHIFT SHAFT" Kick shaft assembly section.
  • Page 156 CRANKCASE AND CRANKSHAFT Order Part name Q'ty Remarks Left crankcase Refer to removal section. Oil strainer Balancer shaft Refer to removal section. Crankshaft Refer to removal section. 5-58...
  • Page 157 CRANKCASE AND CRANKSHAFT REMOVING THE CRANKCASE BEARING Order Part name Q'ty Remarks Refer to "TRANSMISSION, SHIFT CAM AND Transmission SHIFT FORK" section. Refer to "TRANSMISSION, SHIFT CAM AND Shift cam and shift fork SHIFT FORK" section. Oil seal Bearing Refer to removal section. 5-59...
  • Page 158 CRANKCASE AND CRANKSHAFT DISASSEMBLING THE c. Remove the dowel pins and O- CRANKCASE ring. 1. Separate: • Right crankcase REMOVING THE BALANCER • Left crankcase SHAFT 1. Remove: Separation steps: • Balancer shaft "1" a. Remove the crankcase bolts, CHECKING THE TIMING CHAIN hose guide and clutch cable hold- Remove the balancer shaft with its AND TIMING CHAIN GUIDE...
  • Page 159 CRANKCASE AND CRANKSHAFT CHECKING THE CRANKSHAFT INSTALLING THE CRANKCASE 1. Measure: BEARING • Hold the connecting rod at top dead • Runout limit "a" 1. Install: center with one hand while turning • Small end free play limit "b" • Bearing the nut of the installing tool with the •...
  • Page 160 CRANKCASE AND CRANKSHAFT 4. Apply: • Sealant Tighten the crankcase tightening On the right crankcase. bolts in stage, using a crisscross pat- tern. YAMAHA Bond No. 1215 ® (ThreeBond No.1215): 90890-85505 Clean the contacting surface of left and right crankcase before applying the sealant.

  • Page 161: Transmission, Shift Cam And Shift Fork

    TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION, SHIFT CAM AND SHIFT FORK Order Part name Q'ty Remarks Engine Refer to "ENGINE REMOVAL" section. Refer to "CRANKCASE AND CRANK- Separate the crankcase. SHAFT" section. Main axle Refer to removal section.
  • Page 162 TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION CHECKING THE BEARING INSTALLING THE TRANSMISSION 1. Remove: 1. Inspect: 1. Install: • Main axle "1" • Bearing "1" • 5th pinion gear (25T) "1" • Drive axle "2" Rotate inner race with a finger. •...
  • Page 163 TRANSMISSION, SHIFT CAM AND SHIFT FORK 5. Install: • Shift fork 1 (L) "1" • Shift fork 2 (C) "2" • Shift fork 3 (R) "3" • Shift cam "4" To main axle and drive axle. • Apply the molybdenum disulfide oil on the shift fork grooves.

  • Page 164: Front Wheel And Rear Wheel

    FRONT WHEEL AND REAR WHEEL CHASSIS This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are request- ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual.
  • Page 165 FRONT WHEEL AND REAR WHEEL REMOVING THE REAR WHEEL 14 Nm (1.4 m kg, 10 ft lb) 125 Nm (12.5 m kg, 90 ft lb) 19 Nm (1.9 m kg, 13 ft lb) 50 Nm (5.0 m kg, 36 ft lb) 19 Nm (1.9 m kg, 13 ft lb) Order Part name...
  • Page 166 FRONT WHEEL AND REAR WHEEL HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE REAR WHEEL 1. Remove: • Wheel "1" CHECKING THE WHEEL AXLE 1. Measure: Push the wheel forward and remove •...
  • Page 167 FRONT WHEEL AND REAR WHEEL 2. Install: • Brake disc "1" • Bolt (brake disc) "2" Bolt (brake disc): 12 Nm (1.2 m•kg, 8.7 ft•lb) Tighten the bolts in stage, using a crisscross pattern. 6. Install: INSTALLING THE REAR WHEEL •...
  • Page 168 FRONT WHEEL AND REAR WHEEL 2. Install: 5. Install: 9. Adjust: • Brake disc "1" • Wheel • Drive chain slack "a" • Bolt (brake disc) "2" Drive chain slack: Install the brake disc "1" between the Bolt (brake disc): 48–58 mm (1.9–2.3 in) brake pads "2"...

  • Page 169: Front Brake And Rear Brake

    FRONT BRAKE AND REAR BRAKE FRONT BRAKE AND REAR BRAKE REMOVING THE FRONT BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Drain the brake fluid. Refer to removal section. Brake hose holder (protector) Brake hose holder (brake caliper) Union bolt...
  • Page 170 FRONT BRAKE AND REAR BRAKE REMOVING THE REAR BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT WHEEL AND REAR Rear wheel WHEEL" section. Drain the brake fluid. Refer to removal section.
  • Page 171 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE CALIPER Order Part name Q'ty Remarks Front Rear Pad pin Brake pad Pad support Brake caliper piston Refer to removal section. Brake caliper piston dust seal Refer to removal section. Brake caliper piston seal Refer to removal section.
  • Page 172 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE MASTER CYLINDER Order Part name Q'ty Remarks Front Rear Brake master cylinder cap Diaphragm Reservoir float Brake master cylinder boot Circlip Use a long nose circlip pliers. Washer Push rod Brake master cylinder kit...
  • Page 173 FRONT BRAKE AND REAR BRAKE HANDLING NOTE REMOVING THE BRAKE CALIPER PISTON 1. Remove: Support the machine securely so • Brake caliper piston there is no danger of it falling over. Use compressed air and proceed carefully. DRAINING THE BRAKE FLUID 1.
  • Page 174 FRONT BRAKE AND REAR BRAKE 3. Inspect: (front brake only) CHECKING THE BRAKE HOSE • Reservoir float "1" 1. Inspect: Damage → Replace. • Brake hose "1" Crack/damage → Replace. A. Front B. Rear 3. Install: 4. Inspect: • Brake caliper piston "1" •...
  • Page 175 FRONT BRAKE AND REAR BRAKE 2. Install: 3. Install: • Brake caliper "1" • Brake caliper "1" • Bolt (brake caliper) "2" • Rear wheel "2" Refer to "FRONT WHEEL AND Bolt (brake caliper): REAR WHEEL" section. 23 Nm (2.3 m•kg, 17 4.
  • Page 176 FRONT BRAKE AND REAR BRAKE INSTALLING THE FRONT BRAKE INSTALLING THE REAR BRAKE MASTER CYLINDER MASTER CYLINDER Apply the lithium soap base grease 1. Install: 1. Install: on the bolt, O-ring and brake pedal • Brake master cylinder "1" • Copper washer "1" bracket.
  • Page 177 FRONT BRAKE AND REAR BRAKE 2. Install: • Brake hose holder "1" Always use new copper washers. • Screw (brake hose holder) "2" Screw (brake hose hold- er): 2 Nm (0.2 m•kg, 1.4 ft•lb) 2. Install: • Brake hose holder "1" After installing the brake hose •...
  • Page 178 FRONT BRAKE AND REAR BRAKE A. Front B. Rear 5. Install: (rear brake only) • Protector "1" • Bolt (protector) "2" Bolt (protector): 7 Nm (0.7 m•kg, 5.1 ft•lb) A. Front B. Rear 2. Air bleed: • Brake system Refer to "BLEEDING THE HY- DRAULIC BRAKE SYSTEM"...

  • Page 179: Front Fork

    FRONT FORK FRONT FORK REMOVING THE FRONT FORK Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT WHEEL AND REAR Front wheel WHEEL" section. Refer to "FRONT BRAKE AND REAR Front brake caliper BRAKE"...
  • Page 180 FRONT FORK DISASSEMBLING THE FRONT FORK Order Part name Q'ty Remarks Front fork cap bolt Refer to removal section. Fork spring Drain the fork oil. Dust seal Refer to removal section. Stopper ring Refer to removal section. Inner tube Refer to removal section. Outer tube Piston metal Slide metal...
  • Page 181 FRONT FORK HANDLING NOTE REMOVING THE INNER TUBE 1. Remove: The front fork with a built-in piston • Dust seal "1" Support the machine securely so rod has a very sophisticated inter- • Stopper ring "2" there is no danger of it falling over. nal construction and is particularly Using slotted-head screwdriver.
  • Page 182 FRONT FORK The bending value is shown by one half of the dial gauge reading. Do not attempt to straighten a bent inner tube as this may dangerous- ly weaken the tube. 3. Install: 6. Install: • Copper washer "1" •...
  • Page 183 FRONT FORK 8. Install: 11. Install: • Outer tube "1" • Stopper ring "1" To inner tube "2". Fit the stopper ring correctly in the groove in the outer tube. 16. After filling, pump the damper rod "1" slowly up and down more than 10 times to distribute the fork oil.
  • Page 184 FRONT FORK 20. Measure: 25. Tighten: • Oil level (left and right) "a" • Front fork cap bolt (locknut) "1" Out of specification → Adjust. Front fork cap bolt (lock- Standard oil level: nut): 132 mm (5.20 in) 29 Nm (2.9 m•kg, 21 *125 mm (4.92 in) ft•lb) Extent of adjustment:...
  • Page 185 FRONT FORK INSTALLING THE FRONT FORK 1. Install: • Front fork "1" • Temporarily tighten the pinch bolts (lower bracket). • Do not tighten the pinch bolts (up- per bracket) yet. 5. Install: 8. Adjust: • Speed sensor lead "1" •...

  • Page 186: Handlebar

    HANDLEBAR HANDLEBAR REMOVING THE HANDLEBAR Order Part name Q'ty Remarks Headlight Hot starter cable Disconnect at the lever side. Hot starter lever holder Clutch cable Disconnect at the lever side. Clutch lever holder Disconnect the clutch switch lead. Engine stop switch Disconnect the engine stop switch lead.
  • Page 187 HANDLEBAR REMOVING THE BRAKE MASTER CYLINDER • Install the handlebar lower holder 1. Remove: with its side having the greater dis- • Brake master cylinder bracket "1" tance "a" from the mounting bolt • Brake master cylinder "2" center facing forward. •...
  • Page 188 HANDLEBAR 5. Install: 8. Install: • First tighten the bolt on the upper • Right grip "1" • Throttle cable cap "1" side of the brake master cylinder • Collar "2" • Screw (throttle cable cap) "2" bracket, and then tighten the bolt on Apply the adhesive on the tube the lower side.
  • Page 189 HANDLEBAR 12. Install: • Clutch cable "1" • Hot starter cable "2" Apply the lithium soap base grease on the clutch cable end and hot start- er cable end. 13. Adjust: • Clutch lever free play Refer to "ADJUSTING THE CLUTCH CABLE FREE PLAY"...

  • Page 190: Steering

    STEERING STEERING REMOVING THE STEERING Order Part name Q'ty Remarks TIGHTENING STEPS: • Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb) • Loosen it one turn. • Retighten it. 7 Nm (0.7 m•kg, 5.1 ft•lb) Hold the machine by placing the suitable stand Refer to "HANDLING NOTE".
  • Page 191 STEERING Order Part name Q'ty Remarks Bearing race cover Upper bearing Lower bearing Refer to removal section. Bearing race Refer to removal section. 6-28...
  • Page 192 STEERING HANDLING NOTE CHECKING THE STEERING STEM 1. Inspect: • Steering stem "1" Support the machine securely so Bend/damage → Replace. there is no danger of it falling over. REMOVING THE STEERING RING 1. Remove: 3. Install: • Steering ring nut "1" •...
  • Page 193 STEERING 6. Install: 10. After tightening the nut, check the • Washer "1" steering for smooth movement. If Pass the throttle cables "3", clutch ca- not, adjust the steering by loosen- ble "4" and hot starter cable "5" be- ing the steering ring nut little by lit- tween the multi-function display tle.

  • Page 194: Swingarm

    SWINGARM SWINGARM REMOVING THE SWINGARM Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT BRAKE AND REAR Brake hose holder BRAKE" section. Refer to "FRONT BRAKE AND REAR Rear brake caliper BRAKE"...
  • Page 195 SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q'ty Remarks Refer to removal section. Relay arm Connecting rod Collar Oil seal Thrust bearing Bushing Oil seal Bearing Refer to removal section. 6-32...
  • Page 196 SWINGARM HANDLING NOTE 2. Inspect: • Oil seal "3" Damage → Replace. Support the machine securely so there is no danger of it falling over. REMOVING THE CAP 1. Remove: • Left cap "1" 2. Install: • Bearing "1" Remove with a slotted-head screw- •...
  • Page 197 SWINGARM 4. Install: 7. Check: • Connecting rod "1" • Swingarm side play "a" • Bolt (connecting rod) "2" Free play exists → Replace thrust • Washer "3" bearing. • Nut (connecting rod) "4" • Swingarm up and down move- ment "b"...
  • Page 198 SWINGARM 10. Tighten: 14. Install: • Nut (connecting rod) "1" • Drive chain support "1" • Drive chain support cover "2" Nut (connecting rod): • Bolt {drive chain support [L = 50 80 Nm (8.0 m•kg, 58 mm (1.97 in)]} "3" ft•lb) •...

  • Page 199: Absorber

    REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "REMOVING THE SEAT, FUEL Seat and side cover TANK AND SIDE COVERS"...

  • Page 200: Rear Shock Absorber

    REAR SHOCK ABSORBER Order Part name Q'ty Remarks Taillight coupler CDI unit coupler Plastic band Clamp (air filter joint) Only loosening. Rear frame Bolt (rear shock absorber-relay arm) Hold the swingarm. Bolt (rear shock absorber-frame) Rear shock absorber Locknut Only loosening. Adjuster Only loosening.
  • Page 201 To dispose of a damaged or worn- out rear shock absorber, take the unit to your Yamaha dealer for this disposal procedure. 6-38...
  • Page 202 REAR SHOCK ABSORBER 2. Install: 3. Adjust: 3. Install: • Stopper ring (upper bearing) "1" • Spring length (installed) • Rear shock absorber Refer to "ADJUSTING THE 4. Install: REAR SHOCK ABSORBER • Bolt (rear shock absorber-frame) SPRING PRELOAD" section in "1"...
  • Page 203 REAR SHOCK ABSORBER 7. Tighten: • Screw (air filter joint) "1" Screw (air filter joint): 3 Nm (0.3 m•kg, 2.2 ft•lb) 8. Install: • Plastic band • Taillight coupler • Locking tie 6-40...
  • Page 204 ELECTRICAL This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are request- ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to...

  • Page 205: Components And Wiring Diagram

    ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS Headlight Fuse 17. Ignition coil Multi-function display 10. Starting circuit cut-off relay 18. Spark plug Engine stop switch 11. CDI unit 19. Start switch Clutch switch 12. Taillight 20.

  • Page 206: Electrical Components And Wiring Diagram

    ELECTRICAL COMPONENTS AND WIRING DIAGRAM WIRING DIAGRAM Headlight COLOR CODE Multi-function display Black Engine stop switch Brown Clutch switch Chocolate Diode Dark green Starter relay diode Green Throttle position sensor Gray Starter relay Blue Fuse Orange 10. Starting circuit cut-off relay 11.

  • Page 207: Ignition System

    IGNITION SYSTEM IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. *1 Check fuse. No good → Replace fuse and check wire harness.
  • Page 208 IGNITION SYSTEM SPARK GAP TEST CHECKING THE ENGINE STOP 1. Disconnect the ignition coil from SWITCH spark plug. 1. Inspect: 2. Remove the ignition coil cap. • Engine stop switch conduction 3. Connect the dynamic spark tester Tester (+) lead → Black lead "1" "1"...

  • Page 209: Electric Starting System

    ELECTRIC STARTING SYSTEM 3. Inspect: CHECKING THE NEUTRAL • Secondary coil resistance SWITCH Out of specification → Replace. 1. Inspect: • Neutral switch conduction Tester (+) lead → Orange lead "1" Tester (-) lead → Spark plug termi- Tester (+) lead→Sky blue lead "1" nal "2"...
  • Page 210 ELECTRIC STARTING SYSTEM INSPECTION STEPS If the starter motor will not operate, use the following inspection steps. *1 Check fuse. No good → Replace fuse and check wire harness. OK ↓ *2 Check battery. No good → Recharge or replace. OK ↓...
  • Page 211 ELECTRIC STARTING SYSTEM CHECKING THE COUPLERS AND CHECKING THE CLUTCH SWITCH LEADS CONNECTION 1. Inspect: 1. Check: • Clutch switch conduction • Couplers and leads connection Tester (+) lead → Black lead "1" Rust/dust/looseness/short-circuit Tester (-) lead → Black lead "2" →...
  • Page 212 ELECTRIC STARTING SYSTEM CHECKING THE START SWITCH 1. Inspect: • Start switch conduction Tester (+) lead → Black lead "1" Tester (-) lead → Black lead "2" Result Conductive (while the start switch is pushed) Not conductive while it is pushed → Replace.
  • Page 213 ELECTRIC STARTING SYSTEM REMOVING THE STARTER MOTOR Order Part name Q'ty Remarks Refer to "REMOVING THE EXHAUST PIPE Exhaust pipe AND SILENCER" section in the CHAPTER 3. Starter motor 7-10...
  • Page 214 ELECTRIC STARTING SYSTEM DISASSEMBLING THE STARTER MOTOR Order Part name Q'ty Remarks Starter motor front cover Washer (starter motor front cover) Washer Circlip O-ring Starter motor yoke Armature assembly Starter motor rear cover Brush Brush spring 7-11...
  • Page 215 ELECTRIC STARTING SYSTEM CHECKING AND REPAIRING THE ASSEMBLING THE STARTER Armature assembly: STARTER MOTOR MOTOR Commutator resis- 1. Check: 1. Install: tance "1": • Commutator • Brush spring "1" 0.0117–0.0143 Ω at 20 Dirt → Clean with 600 grit sandpa- •...
  • Page 216 ELECTRIC STARTING SYSTEM 4. Install: • O-ring "1" • Circlip • Plain washer "2" • Washer (starter motor front cover) "3" • Starter motor front cover "4" • For installation, align the projec- tions on the washer with the slots in the front cover.

  • Page 217: Charging System

    CHARGING SYSTEM CHARGING SYSTEM INSPECTION STEPS If the battery is not charged, use the following inspection steps. *1 Check fuse. No good → Replace fuse and check wire harness. OK ↓ *2 Check battery. No good → Recharge or replace. OK ↓...
  • Page 218 CHARGING SYSTEM CHECKING THE COUPLERS AND LEADS CONNECTION 1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. CHECKING THE CHARGING VOLTAGE 1. Start the engine. 2. Inspect: • Charging voltage Out of specification → If no failure is found in checking the source coil resistance, replace the rectifi- er/regulator.

  • Page 219: Throttle Position Sensor System

    THROTTLE POSITION SENSOR SYSTEM THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position sensor will not operate, use the following inspection steps. Check entire ignition system for connection. No good → Repair or replace. OK ↓ Check throttle position sensor.(Throttle position No good →...
  • Page 220 THROTTLE POSITION SENSOR SYSTEM HANDLING NOTE 3. Inspect: 4. Install: • Throttle position sensor coil vari- • Throttle position sensor "1" able resistance • Screw (throttle position sensor) Do not loosen the screw (throttle Check that the resistance in in- "2"...
  • Page 221 THROTTLE POSITION SENSOR SYSTEM 9. Adjust: CHECKING THE THROTTLE • Throttle position sensor output POSITION SENSOR INPUT voltage VOLTAGE 1. Disconnect the throttle position sensor coupler. Adjustment steps: 2. Start the engine. a. Adjust the installation angle of the 3. Inspect: throttle position sensor "1"...

  • Page 222: Lighting System

    LIGHTING SYSTEM LIGHTING SYSTEM INSPECTION STEPS Refer to the following flow chart when inspecting the lighting system for possible problems. Check the bulb and bulb socket. No good → Replace the bulb and/or bulb socket. OK ↓ Check the taillight (LEDs). No good →...
  • Page 223 LIGHTING SYSTEM CHECKING THE TAILLIGHT CHECKING THE RECTIFIER/ (LEDs) REGULATOR 1. Disconnect the taillight coupler. 1. Connect the battery leads. 2. Connect two jumper leads "1" 2. Start the engine. from the battery terminals to the 3. Turn on the headlight and taillight respective coupler terminal as by turning on the light switch.

  • Page 224: Signaling System

    SIGNALING SYSTEM SIGNALING SYSTEM INSPECTION STEPS If the speedometer will not operate, use the following inspection steps. *1 Check battery. No good → Recharge or replace. OK ↓ Check each coupler and wire connection. No good → Repair or replace. OK ↓...
  • Page 225 SIGNALING SYSTEM CHECKING THE COUPLERS AND LEADS CONNECTION Make sure that a short-circuit does 1. Check: not develop between the terminals • Couplers and leads connection because it may cause damage to Rust/dust/looseness/short-circuit electrical components. → Repair or replace. CHECKING THE MULTI-FUNCTION DISPLAY INPUT VOLTAGE 1.
  • Page 226 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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