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2014
q Read this manual carefully before operating this vehicle.
q 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 ( E )
1SL-28199-80

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   Summary of Contents for Yamaha YZ450F(E) 2014

  • Page 1

    2014 q Read this manual carefully before operating this vehicle. q 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...

  • 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

    2014 2014 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(E) YZ450F(E) 1SL-28199-80-E0 1SL-28199-80-E0...

  • Page 5

    EAS1SL1002 YZ450F(E) 2014 OWNER’S SERVICE MANUAL ©2013 by Yamaha Motor Co., Ltd. First edition, April 2013 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 EAS1SL1003 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 EAS1SL1005 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 EAS1SL1006 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 EAS1SL1007 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 GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUST- MENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLE SHOOTING TUNING...

  • Page 13: Table Of Contents

    GENERAL INFORMATION LOCATION OF IMPORTANT LABELS............1-1 DESCRIPTION....................1-4 IDENTIFICATION .....................1-5 VEHICLE IDENTIFICATION NUMBER ............1-5 ENGINE SERIAL NUMBER ...............1-5 MODEL LABEL...................1-5 FEATURES.......................1-6 OUTLINE OF THE FI SYSTEM..............1-6 FI SYSTEM....................1-7 INCLUDED PARTS ..................1-8 SIDESTAND ....................1-8 SPARK PLUG WRENCH ................1-8 NIPPLE WRENCH..................1-8 HANDLEBAR PROTECTOR ..............1-8 FUEL HOSE JOINT COVER ..............1-8 COUPLER FOR CONNECTING OPTIONAL PART........1-8 IMPORTANT INFORMATION ................1-10...

  • Page 14: Table Of Contents

    STARTING AND BREAK-IN ................1-22 FUEL ......................1-22 STARTING A COLD ENGINE ..............1-22 STARTING A WARM ENGINE..............1-23 BREAK-IN PROCEDURES ..............1-23 MAINTENANCE AFTER BREAK-IN ..............1-24 MAJOR MAINTENANCE................1-24 TORQUE-CHECK POINTS ................1-25 CLEANING AND STORAGE................1-27 CLEANING ....................1-27 STORAGE ....................1-27...

  • Page 15: Location Of Important Labels

    LOCATION OF IMPORTANT LABELS LOCATION OF IMPORTANT LABELS EAS1SL1008 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 EAS1SL1009 16 15 14 1. Clutch lever 10. Coolant drain bolt 2. Front brake lever 11. Rear brake pedal 3. Throttle grip 12. Air filter 4. Radiator cap 13. Drive chain 5. Fuel tank cap 14. Shift pedal 6.

  • 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: Features

    FEATURES FEATURES EAS20170 OUTLINE OF THE FI SYSTEM EAS1SL1014 The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.

  • Page 21: Fi System

    FEATURES FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the ² fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kgf/cm , 47.0 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 22: Included Parts

    INCLUDED PARTS HANDLEBAR PROTECTOR INCLUDED PARTS EAS1SL1016 Install the handlebar protector “1” with the mark “a” facing forward. EAS1SL1017 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 23

    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 24: 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 25: Gaskets, Oil Seals And O-rings

    IMPORTANT INFORMATION GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets and O-rings. All gasket surfaces, oil seal lips, and O-rings must be cleaned so that there may be no dust on them. 2. During assembly, always apply proper oil to bearings and proper grease to oil seal lips before installation.

  • Page 26: Basic Service Information

    BASIC SERVICE INFORMATION BASIC SERVICE INFORMATION EAS1SL1029 EAS1SL1030 ELECTRICAL SYSTEM Electrical parts handling ECA16620 NOTICE Handle electrical components with special care, and do not subject them to strong shocks. ECA16640 NOTICE For waterproof couplers, never insert the tester probes directly into the coupler. When performing any checks using a water- proof coupler, use the specified test har- ness or a suitable commercially available...

  • Page 27

    BASIC SERVICE INFORMATION ECA16790 NOTICE When disconnecting a connector, do not pull the leads. Hold both sections of the connector, and then disconnect the con- nector. 4. Connect: • Lead • Coupler • Connector • When connecting a coupler or a connector, 2.

  • Page 28

    BASIC SERVICE INFORMATION 5. Check: • No continuity Pocket tester 90890-03112 Analog pocket tester YU-03112-C • If there is no continuity, clean the terminals. • When checking the wire harness, perform steps (1) to (4). • As a quick remedy, use a contact revitalizer available at most part stores.

  • Page 29: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS EAS1SL1031 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 30

    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 31

    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. Valve guide remover & in- This tool is used to replace staller set (ø5.5) the valve guide.

  • Page 32

    SPECIAL TOOLS Tool name/Part number How to use Illustration Spacer (crankshaft installer) This tool is used to install the 90890-04081 crankshaft. Pot spacer YM-91044 YM-91044 Clutch holder This tool is used to hold the 90890-04086 clutch when removing or in- YM-91042 stalling the clutch boss secur- ing nut.

  • Page 33

    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 34: Control Functions

    CONTROL FUNCTIONS KICKSTARTER LEVER CONTROL FUNCTIONS EAS1SL1032 The kickstarter lever “1” is in the right of the chassis. EAS1SL1033 ENGINE STOP SWITCH To start the engine, pull out and push down the The engine stop switch “1” is located on the left kickstarter lever with your foot.

  • Page 35: Rear Brake Pedal

    CONTROL FUNCTIONS REAR BRAKE PEDAL The rear brake pedal “1” is in the right of the chassis. Press down on the brake pedal to ac- tivate the rear brake. STARTER KNOB/IDLE SCREW EAS1SL1040 Starting a cold engine requires a larger amount of intake air, which is supplied by the starter knob/idle screw “1.”...

  • Page 36: Starting And Break-in

    Do not open the throttle at the moment when you kick the kickstarter lever, be- Your Yamaha engine has been designed to use cause this may kick back premium unleaded gasoline with a pump oc-...

  • Page 37: 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 38: Maintenance After Break-in

    MAINTENANCE AFTER BREAK-IN MAINTENANCE AFTER BREAK-IN • Cable 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 39: Torque-check Points

    TORQUE-CHECK POINTS TORQUE-CHECK POINTS EAS1SL1048 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 40

    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 41: Cleaning And Storage

    CLEANING AND STORAGE 3. Remove the drive chain, clean it thoroughly CLEANING AND STORAGE EAS1SL1049 with solvent, and lubricate it Reinstall the drive chain or store it in a plastic bag tied to EAS1SL1050 CLEANING the frame. Frequent cleaning of your vehicle will enhance 4.

  • Page 42

    CLEANING AND STORAGE 1-28...

  • Page 43

    SPECIFICATIONS GENERAL SPECIFICATIONS .................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-8 ELECTRICAL SPECIFICATIONS ..............2-12 TIGHTENING TORQUES ................2-13 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-13 ENGINE TIGHTENING TORQUES............2-14 CHASSIS TIGHTENING TORQUES............2-18 LUBRICATION POINTS AND LUBRICANT TYPES ........2-21 ENGINE....................2-21 CHASSIS....................2-23 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-25 LUBRICATION DIAGRAMS ..............2-25 CABLE ROUTING DIAGRAM ................2-33...

  • Page 44

    GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS EAS1SL1052 Model Model 1SL1 (USA) (CAN) 1SL2 (EUR) 1SL3 (JPN) 1SL4 (AUS) (NZ) (ZAF) Dimensions Overall length 2175 mm (85.6 in) (USA) (CAN) 2180 mm (85.8 in) (EUR) (JPN) (AUS) (NZL)  (ZAF) Overall width 825 mm (32.5 in) Overall height 1290 mm (50.8 in) (USA) (CAN)...

  • Page 45

    ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS EAS1SL1053 Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 449 cm Cylinder arrangement Single cylinder Bore  stroke 97.0  60.8 mm (3.82  2.39 in) Compression ratio 12.50:1 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 46

    ENGINE SPECIFICATIONS Cylinder head 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 Intake A 37.730–37.830 mm (1.4854–1.4894 in)

  • Page 47

    ENGINE SPECIFICATIONS Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in) Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Valve margin thickness D (intake) 1.20 mm (0.0472 in) Valve margin thickness D (exhaust) 0.85 mm (0.0335 in) Valve stem diameter (intake) 5.475–5.490 mm (0.2156–0.2161 in) Limit 5.445 mm (0.2144 in)

  • Page 48

    ENGINE SPECIFICATIONS Winding direction (intake) Clockwise Winding direction (exhaust) Clockwise Cylinder Bore 97.000–97.010 mm (3.8189–3.8193 in) Taper limit 0.050 mm (0.0020 in) Out of round limit 0.050 mm (0.0020 in) Piston Piston-to-cylinder clearance 0.030–0.055 mm (0.0012–0.0022 in) Limit 0.15 mm (0.006 in) Diameter D 96.955–96.970 mm (3.8171–3.8177 in) Height H...

  • Page 49

    ENGINE SPECIFICATIONS Oil ring Dimensions (B  T) 1.50  2.55 mm (0.06  0.10 in) End gap (installed) 0.20–0.50 mm (0.0079–0.0197 in) Crankshaft Width A 61.95–62.00 mm (2.439–2.441 in) Runout limit C 0.030 mm (0.0012 in) Big end side clearance D 0.150–0.450 mm (0.0059–0.0177 in) Balancer Balancer drive method...

  • Page 50

    ENGINE SPECIFICATIONS Shifting mechanism Shift mechanism type Shift drum and guide bar Shift fork guide bar bending limit 0.050 mm (0.0020 in) Shift fork thickness 4.85 mm (0.1909 in) Decompression device Device type Auto decomp Air filter Air filter element Wet element Air filter oil grade Foam air-filter oil...

  • Page 51

    CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS EAS1SL1054 Chassis Frame type Semi double cradle Caster angle 27.08 ° (USA) (CAN) 27.50 ° (EUR) 27.67 ° (JPN) 27.58 ° (AUS) (NZL) (ZAF) Trail 120 mm (4.7 in) (USA) (CAN) 122 mm (4.8 in) (EUR) 124 mm (4.9 in) (JPN) (AUS) (NZL) (ZAF) Front wheel Wheel type...

  • Page 52

    CHASSIS SPECIFICATIONS Brake disc thickness limit 2.5 mm (0.10 in) Brake pad lining thickness (inner) 4.4 mm (0.17 in) Limit 1.0 mm (0.04 in) Brake pad lining thickness (outer) 4.4 mm (0.17 in) Limit 1.0 mm (0.04 in) Master cylinder inside diameter 9.52 mm (0.37 in) 22.65 mm ...

  • Page 53

    CHASSIS SPECIFICATIONS Compression damping adjusting positions * Position in which the adjuster is turned in finger tight Minimum 20 click (s) out* Standard 9 click (s) out* (USA) (CAN) 8 click (s) out* (EUR) (JPN) (AUS) NZL) (ZAF) Maximum (hard) Fully turned in Rear suspension Type...

  • Page 54

    CHASSIS SPECIFICATIONS Drive chain Type/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) 2-11...

  • Page 55

    Advancer type Digital Ignition timing (B.T.D.C.) 10.0 ° at 2000 r/min Engine control unit Model/manufacturer 1SL0/YAMAHA (USA) (CAN) 1SL1/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 56

    TIGHTENING TORQUES TIGHTENING TORQUES EAS20320 EAS1SL1056 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 57

    TIGHTENING TORQUES ENGINE TIGHTENING TORQUES EAS1SL1057 - 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 58

    TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Air filter bolt 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) Air filter case cover bolt 6 Nm (0.6 m·kgf, 4.3 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) Starter knob/Idle screw...

  • Page 59

    TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size Use a Drive sprocket nut 75 Nm (7.5 m·kgf, 54 ft·lbf) lock washer. Drive axle oil seal stopper bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Segment 30 Nm (3.0 m·kgf, 22 ft·lbf) Shift guide bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Stopper lever bolt...

  • Page 60

    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 61

    TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES - 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 145 Nm (14.5 m·kgf, 105 ft·lbf)

  • Page 62

    TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size 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 26 Nm (2.6 m·kgf, 19 ft·lbf) Rear brake pedal position locknut 6 Nm (0.6 m·kgf, 4.3 ft·lbf) Rear brake master cylinder bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

  • Page 63

    TIGHTENING TORQUES Thread ITEM Q’ty TIGHTENING TORQUES Remarks size 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 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Fuel tank bolt (front side) 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Fuel tank bolt (rear side)

  • Page 64

    LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES EAS1SL1059 EAS1SL1060 ENGINE Lubrication point Lubricant types Oil seal lips Bearing O-ring Cylinder head bolt threads, seats, washers Valve stems Valve stem ends Valve lifter outer surface Camshaft lobe and journal Valve lifter top surface Crankshaft journal Crankshaft big end thrust surfaces...

  • Page 65

    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® EAS1SL1061 2-22...

  • Page 66

    LUBRICATION POINTS AND LUBRICANT TYPES 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 Swingarm pivot portion (collar side surface and thrust bearing) Swingarm pivot portion (collar outer surface) Swingarm pivot portion (oil seal lip)

  • Page 67

    LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Rear brake caliper pin bolt and boot Rear brake master cylinder push rod end Rear brake master cylinder kit 2-24...

  • Page 68

    LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION SYSTEM CHART AND DIAGRAMS EAS1SL1062 EAS1SL1063 LUBRICATION DIAGRAMS 2-25...

  • Page 69

    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 2-26...

  • Page 70

    LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...

  • Page 71

    LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Connecting rod 2. Crankshaft 3. Main axle 4. Oil strainer 5. Drive axle 2-28...

  • Page 72

    LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...

  • Page 73

    LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Exhaust camshaft 2. Intake camshaft 3. Oil filter element 4. Relief valve 5. Oil pump 2-30...

  • Page 74

    LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...

  • Page 75

    LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil pressure check bolt 3. Oil filter element 4. Oil pump 2-32...

  • Page 76

    CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM EAS1SL1064 2-33...

  • Page 77

    CABLE ROUTING DIAGRAM 1. Clutch cable R. Pass the rectifier/regulator lead to the inside of the tension arm (the side of the vehicle). 2. Throttle cable (pull) S. Pass the main harness to the front of the radiator 3. Throttle cable (return) hose (the front of the vehicle), and to the inside of 4.

  • Page 78

    CABLE ROUTING DIAGRAM 2-35...

  • Page 79

    CABLE ROUTING DIAGRAM 1. Bracket T. Clamp the painted part on the fuel hose by the plastic clamp. Make the lock on the plastic clamp 2. Condenser face the bottom of the vehicle, and cut the end. 3. Coolant temperature sensor 4.

  • Page 80

    CABLE ROUTING DIAGRAM 2-37...

  • Page 81

    CABLE ROUTING DIAGRAM 1. Throttle cable 2. Clutch cable 3. Engine stop switch lead 4. Cable guide 5. Head pipe 6. Front brake hose 7. Brake hose guide 8. Number plate A. Number plate band B. Pass the clutch cable to the rear of the number plate band.

  • Page 82

    CABLE ROUTING DIAGRAM 2-39...

  • Page 83

    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 84

    CABLE ROUTING DIAGRAM 2-41...

  • Page 85

    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 86

    CABLE ROUTING DIAGRAM 2-43...

  • Page 87

    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 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........3-10...

  • Page 88

    CHECKING THE WHEEL BEARINGS .............3-33 CHECKING AND ADJUSTING THE STEERING HEAD ......3-33 LUBRICATING THE LEVERS ..............3-34 LUBRICATING THE PEDAL ..............3-34 ELECTRICAL SYSTEM..................3-35 CHECKING THE SPARK PLUG ..............3-35 CHECKING THE IGNITION TIMING............3-35...

  • Page 89

    MAINTENANCE INTERVALS MAINTENANCE INTERVALS EAS1SL1065 EAS1SL1066 MAINTENANCE INTERVALS ECA@ NOTICE • After a break-in or before each race, always check the points shown in “TORQUE-CHECK POINTS” for tightening torques and retighten them. (“TORQUE-CHECK POINTS” on page 1- 25.) • Periodic 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 90

    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 91

    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 92

    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 93

    MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) Replace brake flu- Every one year SWINGARM Inspect, lube and Molybdenum disulfide grease retighten RELAY ARM, CON- NECTING ROD Inspect, lube and Molybdenum disulfide grease retighten...

  • Page 94

    MAINTENANCE INTERVALS Every Every Every After race third fifth As re- ITEM break- (about (about (about Remarks quired 12.5 hours) hours) hours) LEVERS Adjust clutch lever free play KICKSTARTER LE- VER, BRAKE PED- AL, FOOTREST Lubricate OUTSIDE NUTS AND BOLTS Retighten Refer to “TORQUE-CHECK POINTS”...

  • Page 95

    PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE EAS1SL1067 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 EAS1SL1068 ITEM inspect Page...

  • Page 96

    ENGINE ENGINE CHECKING THE COOLING SYSTEM EAS1SL1069 EAS1SL1071 1. Remove: EAS1SL1070 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 97

    ENGINE Crack/damage  Replace. 5. Install: Exist fur deposits  Clean or replace. • Copper washers • Coolant drain bolt Coolant drain bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 6. Pour coolant. Recommended coolant High quality ethylene glycol anti-freeze containing anti-cor- rosion for aluminum engine Coolant level 1.04 L (1.10 US qt, 0.92 Imp.qt)

  • Page 98

    ENGINE CHECKING THE COOLANT CIRCULATORY ADJUSTING THE CLUTCH LEVER POSI- EAS1SL1076 SYSTEM FOR LEAKS TION 1. Check: 1. Adjust: • Coolant level • Clutch lever position “a”  2. Install: Loosen the locknut “1” and use the adjuster • Radiator cap tester “1” “2”...

  • Page 99

    ENGINE ADJUSTING THE THROTTLE GRIP FREE PLAY Prior to adjusting throttle grip free play, the en- gine idling speed should be adjusted. 1. Check: • Throttle grip free play “a” Out of specification  Regulate. Throttle grip free play 3.0–5.0 mm (0.12–0.20 in) If the clutch lever free play cannot be obtained on the handlebar side, use the adjuster on the clutch cable side.

  • Page 100

    ENGINE LUBRICATING THE THROTTLE CABLE 1. Remove: • Cover (throttle cable cap) “1” • Cover (grip cap) “2” • Throttle grip cap “3” 2. Remove: • Air filter mounting bolt “1” • Air filter element “2” • Air filter guide “3” (from the air filter element) 2.

  • Page 101

    ENGINE 4. Check: CHECKING THE THROTTLE BODY JOINT • Air filter element 1. Check: Damage  Replace. • Throttle body joint “1” 5. Foam-air-filter oil or equivalent oil to the ele- Refer to “CHECKING THE THROTTLE ment BODY JOINT” on page 7-8. Oil application quantify CHECKING THE BREATHER HOSES EAS1SL1082...

  • Page 102

    ENGINE 3. Install: • Fuel tank Refer to “FUEL TANK” on page 7-1. • Air scoop (left/right) • Seat • Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4- EAS1SL1085 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle upright on a level surface. 2.

  • Page 103

    ENGINE c. Install the new oil filter element and the oil fil- CHANGING THE ENGINE OIL EAS1SL1086 ter element cover. Stand the vehicle upright on a level surface. Oil filter element cover bolt 1. Start the engine, warm this up for several 10 Nm (1.0 m·kgf, 7.2 ft·lbf) minutes, and then stop the engine and wait about 5 minutes.

  • Page 104

    ENGINE 7. Pour the specified amount of engine oil into NOTICE the oil filler cap hole. If no engine oil seeps out after one minute, immediately turn the engine off so it will not Engine oil quantity seize. With oil filter element replace- ment b.

  • Page 105

    “b” on the basic knowledge and skill concerning the ser- crankcase cover. vicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowledge and skill concerning ser- vicing are requested not to undertake inspec- tion, adjustment, disassembly, or reassembly only by reference to this manual.

  • Page 106

    ENGINE 5. Adjust: • Valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the camshaft (intake and exhaust). Refer to “CAMSHAFT” on page 5-11. b. Remove the valve lifter “2” and the adjusting pad “3” with a valve lapper “1.” • Place a cloth in the timing chain space to pre- vent adjusting pads from falling into the crank- case.

  • Page 107

    ENGINE d. Select an adjusting pad with a proper valve f. Install the camshafts (exhaust and intake). clearance from the adjusting pad selection Refer to “CAMSHAFT” on page 5-11. table. g. Measure the valve clearance again. h. If the valve clearance is out of specification, repeat adjusting the valve clearance until it •...

  • Page 108

    ENGINE INTAKE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.00 ~ 0.02 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 109

    CHASSIS CHASSIS EAS1SL1089 EAS1SL1090 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 110

    CHASSIS CHECKING THE BRAKE HOSE 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 111

    CHASSIS ADJUSTING THE REAR BRAKE EAS1SL1093 NOTICE 1. Check: After adjusting the brake pedal position, • Brake pedal position “a” make sure that there is no brake drag. (distance from the top of the rider footrest to the top of the brake pedal) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 112

    CHASSIS b. Loosen the pad pin “2.” c. Remove the brake caliper “3” from the front fork. i. Install the brake caliper “8” and tighten the pad pin “9”. Bolt (brake caliper) d. Remove the pad pin and brake pads “4.” 28 Nm (2.8 m·kgf, 20 ft·lbf) Pad pin 17 Nm (1.7 m·kgf, 12 ft·lbf)

  • Page 113

    CHASSIS CHECKING THE REAR BRAKE PADS EAS1SL1095 1. Measure: • Brake pad thickness “a” Out of specification  Replace as a set. The pads worn up to the indicator “b” grooves mean that the brake pad thickness limit is reached. Brake pad lining thickness (inner) d.

  • Page 114

    CHASSIS 4. Check: • Brake pedal operation A softy or spongy feeling  Bleed the brake system. Refer to “BLEEDING THE BRAKE SYS- TEM” on page 3-21. EAS1SL1096 CHECKING THE REAR BRAKE PAD INSU- LATOR 1. Remove: • Brake pads i.

  • Page 115

    CHASSIS WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake flu- ids may result in a harmful chemical reac- tion, leading to poor brake performance.

  • Page 116

    CHASSIS CLEANING THE FRONT FORK OIL SEAL CHECKING THE FRONT FORK LEGS EAS1SL1099 AND DUST SEAL 1. Stand the vehicle upright on a level surface. 1. Remove: EWA13120 WARNING • Protector Securely support the vehicle so that there is • Dust seal “1” no danger of it falling over.

  • Page 117

    CHASSIS 3. Tighten: • Air bleed screw Air bleed screw 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping force ECA13590 NOTICE Do not turn the adjuster forcibly beyond its adjusting range. EAS1SL1103 ADJUSTING THE FRONT FORK LEGS 1. Adjust: EWA32D1006 WARNING •...

  • Page 118

    CHASSIS CHECKING THE SWINGARM OPERATION 1. Remove: 1. Check: • Rear frame • Swingarm smooth action Refer to “REAR SHOCK ABSORBER AS- • Swingarm free play SEMBLY” on page 4-53. Refer to “SWINGARM” on page 4-60. 2. Adjust: • Spring preload CHECKING THE REAR SUSPENSION EAS1SL1105 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 119

    CHASSIS Rebound damping force Maximum Turn it in finger-tight. Turn it out by 14 clicks.* (USA)(CAN) Turn it out by 12 clicks.* (EUR)(JPN)(AUS)(NZL)(ZAF) Minimum Turn it out by 30 clicks.* * With the adjuster fully turned e. Tighten the locknut. Locknut ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 120

    CHASSIS CHECKING THE TIRES 1. Measure: • Tire pressure Out of specification  Regulate. Tire pressure 100 kPa (1.0 kgf/cm ,15 psi) • Check the tire while it is cold. • Loose bead stoppers allow the tire to slip off ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 121

    CHASSIS 2. Tighten: CHECKING AND ADJUSTING THE STEER- • Spokes ING HEAD Use a spoke nipple wrench “1” for tighten- 1. Use a suitable stand to raise the front wheel ing. off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over.

  • Page 122

    CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: • Upper bracket Refer to “STEERING HEAD” on page 4-49. • Handlebar Refer to “HANDLEBAR” on page 4-31. EAS1SL1112 LUBRICATING THE LEVERS 1. Lubricate the pivoting points and metal-to- metal moving parts of the following parts. •...

  • Page 123

    ELECTRICAL SYSTEM 5. Clean: ELECTRICAL SYSTEM EAS1SL1114 • Spark plug (with a spark plug cleaner or a wire brush) EAS1SL1115 CHECKING THE SPARK PLUG 6. Measure: 1. Remove: • Spark plug gap “a” • Seat Out of specification  Adjust the spark plug •...

  • Page 124

    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 125

    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 126

    HANDLEBAR ....................4-31 REMOVING THE HANDLEBAR...............4-33 CHECKING THE HANDLEBAR ...............4-33 INSTALLING THE HANDLEBAR .............4-33 FRONT FORK....................4-37 REMOVING THE FRONT FORK LEGS...........4-39 DISASSEMBLING THE FRONT FORK LEGS .........4-39 CHECKING THE FRONT FORK LEGS ...........4-40 ASSEMBLING THE FRONT FORK LEGS ..........4-41 INSTALLING THE FRONT FORK LEGS ..........4-47 STEERING HEAD...................4-49 REMOVING THE LOWER BRACKET............4-50 CHECKING THE STEERING HEAD ............4-50...

  • Page 127

    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 128: General Chassis

    GENERAL CHASSIS REMOVING THE NUMBER PLATE REMOVING THE LEFT SIDE COVER EAS1SL1119 1. Remove: 1. Remove: • Bolt (number plate) • Bolt (side cover) • Number plate “1” • Side cover “1” • The projection “a” is inserted into the band of Draw the left side cover “1”...

  • Page 129

    FRONT WHEEL FRONT WHEEL EAS1SL1122 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 130: Front Wheel

    FRONT WHEEL REMOVING THE FRONT WHEEL EAS1SL1123 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. EWA13120 WARNING 4. Tighten: Securely support the vehicle so that there is •...

  • Page 131

    FRONT WHEEL DISASSEMBLING THE FRONT WHEEL EAS1SL1125 1. Remove: • Oil seals • Bearing ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside of the front wheel hub. b. Remove the oil seals “1” with a flat-head screwdriver. To prevent damaging the wheel, place a rag “2” between the screwdriver and the wheel sur- face.

  • Page 132

    FRONT WHEEL 3. Install: 3. Tighten: • Collar “1” • Front wheel axle nut “1” Front wheel axle nut Apply the lithium soap base grease on the oil 115 Nm (11.5 m·kgf, 83 ft·lbf) seal lip. ECA14140 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 133

    REAR WHEEL REAR WHEEL EAS1SL1128 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 134

    REAR WHEEL 4. Measure: REMOVING THE REAR WHEEL EAS1SL1129 • 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” EWA13120 WARNING on page 4-4. Securely support the vehicle so that there is Radial wheel runout limit no danger of it falling over.

  • Page 135

    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 EAS1SL1133 1.

  • Page 136

    REAR WHEEL Install the brake disc “1” between the brake Temporarily tighten the nut (rear wheel axle) at pads “2” correctly. this point. 2. Install: 5. Adjust: • Drive chain “1” • Drive chain slack “a” Drive chain slack Push the rear wheel “2” forward and install the 50–60 mm (1.97–2.36 in) drive chain.

  • Page 137

    FRONT BRAKE FRONT BRAKE EAS1SL1135 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 138

    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 139

    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 140

    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. 4-14...

  • Page 141

    FRONT BRAKE INTRODUCTION EAS1SL1136 EWA14100 WARNING If you need to disassemble the disc brake components, observe the following precau- tions. • Never disassemble the brake components unless absolutely necessary. • If there is any problem with connections on the hydraulic brake system, perform the following jobs....

  • Page 142

    FRONT BRAKE a. Blow compressed air into the brake hose WARNING joint opening to force out the piston from the When the brake caliper is disassembled, re- brake caliper. place the brake caliper piston seal and the EWA13550 brake caliper piston dust seal with new WARNING ones.

  • Page 143

    FRONT BRAKE NOTICE Make sure that the pipe portion “a” of the brake hose touches the projection “b” on the brake caliper. 3. Install: • Brake caliper piston “1” Apply the brake fluid on the piston wall. 2. Install: ECA33DD047 NOTICE •...

  • Page 144

    FRONT BRAKE WARNING To drain any remaining brake fluid, place a con- • Use only the designated brake fluid. Other tainer under the master cylinder and the end of brake fluids may cause the rubber seals to the brake hose. deteriorate, causing leakage and poor brake performance.

  • Page 145

    FRONT BRAKE WARNING • Before installation, apply brake fluid to the Apply brake fluid to the cylinder cups and brake master cylinder kit. install them as shown. Wrong orientation in • Before installation, apply silicone grease to installation causes poor braking perfor- the push rod end.

  • Page 146

    FRONT BRAKE 4. Bleed: WARNING • Brake system Proper brake hose routing is essential to in- Refer to “BLEEDING THE BRAKE SYS- sure safe vehicle operation. Refer to“CA- TEM” on page 3-21. BLE ROUTING DIAGRAM” on page 2-33. 5. Check: ECA1DX1007 •...

  • Page 147

    REAR BRAKE REAR BRAKE EAS1SL1148 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 148

    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 149

    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 3-21. Union bolt Copper washers Brake hose Split pin Plain washer Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm plate Brake master cylinder reservoir diaphragm Rear brake master cylinder...

  • Page 150

    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. 4-24...

  • Page 151

    REAR BRAKE INTRODUCTION EAS1SL1149 EWA14300 WARNING If you need to disassemble the disc brake components, observe the following precau- tions. • Never disassemble the brake components unless absolutely necessary. • If there is any problem with connections on the hydraulic brake system, perform the following jobs....

  • Page 152

    REAR BRAKE REMOVING THE REAR BRAKE CALIPER CHECKING THE REAR BRAKE CALIPER EAS1SL1153 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. 1.

  • Page 153

    REAR BRAKE INSTALLING THE BRAKE CALIPER PISTON INSTALLING THE REAR BRAKE CALIPER EAS1SL1156 1. Clean: 1. Install: • Brake caliper • Rear brake caliper • Brake caliper piston seal • Rear brake caliper bracket • Brake caliper piston dust seal 2.

  • Page 154

    REAR BRAKE REMOVING THE REAR BRAKE MASTER WARNING CYLINDER • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to Before removing the rear brake master cylin- deteriorate, causing leakage and poor der, drain the brake fluid from the entire brake brake performance.

  • Page 155

    REAR BRAKE ASSEMBLING THE REAR BRAKE MASTER CYLINDER EWA13520 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. Recommended brake fluid 4. Install: DOT 4 •...

  • Page 156

    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 Recommended brake fluid system. DOT 4 Refer to “BLEEDING THE BRAKE SYS- TEM”...

  • Page 157

    HANDLEBAR HANDLEBAR EAS1SL1161 Removing the handlber Order Part name Q’ty Remarks Number plate Remove the band only. Clutch cable Disconnect. Clutch lever holder Engine stop switch Brake master cylinder Throttle cable cap Throttle cable (pull) Disconnect. Throttle cable (return) Disconnect. Right grip Tube guide Collars...

  • Page 158

    HANDLEBAR Removing the handlber Order Part name Q’ty Remarks For installation, reverse the removal proce- dure. 4-32...

  • Page 159

    HANDLEBAR REMOVING THE HANDLEBAR EAS1SL1162 1. Stand the vehicle upright on a level surface. • Install the lower handlebar holders with them EWA13120 side having the greater distance “a” from the WARNING mounting bolt center facing forward. Securely support the vehicle so that there is •...

  • Page 160

    HANDLEBAR 4. Install: • Handlebar grip “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Slightly coat the handlebar left end with a rubber adhesive. b. Install the handlebar grip on the handlebar by pressing the grip from the left side. c. Wipe off any excess adhesive with a clean cloth.

  • Page 161

    HANDLEBAR 6. Install: 8. Install: • Right grip “1” • Throttle cables “1” • Collar “2” Apply adhesive to the tube guide “3.” Slightly coat the end of throttle cable and inside of throttle grip with lithium-soap-based • Before applying the adhesive, wipe off grease grease.Then, mount the throttle grip onto the or oil on the tube guide surface “a”...

  • Page 162

    HANDLEBAR 12.Install: • Clutch cable “1” Before installation, apply the lithium-soap- based grease to the clutch cable end. 10.Install: • Rubber cover “1” • Cover (throttle cable housings) “2” 13.Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LE- VER FREE PLAY”...

  • Page 163

    FRONT FORK FRONT FORK EAS1SL1165 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 164

    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 165: Front Fork

    FRONT FORK REMOVING THE FRONT FORK LEGS EAS1SL1166 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 EWA13120 tube and locknut “3”. WARNING •...

  • Page 166

    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 167

    FRONT FORK 5. Check: ASSEMBLING THE FRONT FORK LEGS EAS1SL1169 • 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 168

    FRONT FORK 6. Loosen: • Compression damping force adjuster “1” • Before loosening the damping force adjuster, record the setting position. • Unless the damping force adjuster is fully loosened, correct damping characteristic can- not be obtained after installation. 4. Measure: •...

  • Page 169

    FRONT FORK Cap bolt wrench 90890-01500 YM-01500 Cap bolt ring wrench 90890-01501 YM-01501 13.Check: • Damper assembly smooth movement Tightness/binding/rough spots  Repeat the steps 1 to 12. 10.After filling, pump the damper assembly “1” slowly up and down more than 10 times to distribute the fork oil.

  • Page 170

    FRONT FORK 15.Install: • Inner tube bushing “1” Install the inner tube bushing onto the slot on inner tube. 18.Install: • Oil seals “1” Using a fork seal driver “2,” press the oil seal in until the stopper ring groove fully appears. 16.Install: Fork seal driver •...

  • Page 171

    FRONT FORK 20.Install: 23.Install: • Dust seal “1” • Collar “1” • Fork spring “2” (to the damper assembly “3”) Apply lithium-soap-based grease on the inner tube. Install the collar with its larger dia. end “a” fac- ing the fork spring. 21.Check: •...

  • Page 172

    FRONT FORK 25.Loosen: Gap “a” between the adjuster and • Rebound damping force adjuster “1” the locknut 0.5-1.0 mm (0.02-0.04 in) • Before loosening the damping force adjuster, record the setting position. • Unless the damping force adjuster is fully If it is installed with a gap out of specification, loosened, correct damping characteristic can- correct damping force cannot be obtained.

  • Page 173

    FRONT FORK 30.Fill: • Front fork leg Recommended oil Suspension oil S1 Standard oil amount 335 cm (11.33 US oz, 11.82 lmp 355 cm (12.00 US oz, 12.52 lmp Extent of adjustment 300–365 cm (10.14–12.34 US INSTALLING THE FRONT FORK LEGS EAS1SL1170 oz, 10.58–12.87 lmp oz) 1.

  • Page 174

    FRONT FORK 3. Adjust: • Front fork top end “a” Front fork top end (standard) “a” 0 mm (0 in) 6. Adjust: • Rebound damping force Turn in the damping adjuster “1” finger-tight and then turn out to the originally set position. 4.

  • Page 175

    STEERING HEAD STEERING HEAD EAS1SL1171 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

    STEERING HEAD REMOVING THE LOWER BRACKET EAS1SL1172 NOTICE 1. Use a suitable stand to raise the front wheel • Take care not to damage the steering shaft off the ground. thread. EWA13120 • If the bearing race is not installed properly, WARNING the steering head pipe could be damaged.

  • Page 177

    STEERING HEAD 2. Install: • Bearing races • Upper bearing “1” • Bearing race cover “2” Apply the lithium soap base 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 EAS1SL1175 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 Spring Dust seal Collars Bushing Collars O-ring Dust seal Stopper ring Bearing For installation, reverse the removal proce- dure. 4-54...

  • 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. 4-55...

  • Page 182

    • Rear shock absorber assembly upper bolt • To dispose of a damaged or a worn-out • Rear shock absorber assembly (-ies) rear shock absorber, take the unit to your Yamaha dealer for this disposal proce- REMOVING THE BEARING EAS1SL1179 dure.

  • Page 183

    REAR SHOCK ABSORBER ASSEMBLY 2. Remove: CHECKING THE CONNECTING ARM AND • Upper bearing “1” RELAY ARM 1. Check: • Connecting arm Remove the bearing by pressing its outer race. • Relay arm Damage/wear  Replace 2. Check: • Bearing •...

  • Page 184

    REAR SHOCK ABSORBER ASSEMBLY Install the dust seals with their lips facing in- ward. Installed depth “a” 4.25 mm (0.17 in) INSTALLING THE REAR SHOCK ABSORB- EAS1SL1183 ER ASSEMBLY 1. Lubricate: • Bearing (lower side) • Dust seal • Collars •...

  • Page 185

    REAR SHOCK ABSORBER ASSEMBLY • Connecting arm bolt (relay arm side) Connecting arm bolt (relay arm side) 80 Nm (8.0 m·kgf, 58 ft·lbf) • Relay arm bolt (swingarm side) Relay arm bolt (swingarm side) 70 Nm (7.0 m·kgf, 51 ft·lbf) •...

  • Page 186

    SWINGARM SWINGARM EAS1SL1184 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

    SWINGARM REMOVING THE SWINGARM EAS1SL1185 1. Use a suitable stand to raise the rear wheel off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Measure: • Swingarm side play •...

  • Page 188

    SWINGARM INSTALLING THE SWINGARM 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 EAS1SL1189 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

    CHAIN DRIVE REMOVING THE DRIVE CHAIN EAS1SL1190 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

    CHAIN DRIVE 4. Check: • Drive chain rollers “1” Damage/wear  Replace the drive chain. • Drive chain side plates “2” Damage/wear  Replace the drive chain. 2. Lubricate: • Drive chain 3. Install: • Drive sprocket • Lock washer 5.

  • Page 192

    CHAIN DRIVE 4-66...

  • Page 193

    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 ....................5-11...

  • Page 194

    CLUTCH ......................5-37 REMOVING THE CLUTCH ..............5-40 CHECKING THE FRICTION PLATES............5-40 CHECKING THE CLUTCH PLATES ............5-40 CHECKING THE CLUTCH SPRINGS............5-40 CHECKING THE CLUTCH HOUSING .............5-41 CHECKING THE CLUTCH BOSS............5-41 CHECKING THE PRESSURE PLATE .............5-41 CHECKING THE PUSH LEVER SHAFT..........5-41 CHECKING THE CLUTCH PUSH RODS ..........5-41 CHECKING THE PRIMARY DRIVE GEAR..........5-41 CHECKING THE PRIMARY DRIVEN GEAR ...........5-42 INSTALLING THE OIL SEAL ..............5-42...

  • Page 195

    AC MAGNETO....................5-59 REMOVING THE AC MAGNETO.............5-60 CHECKING THE AC MAGNETO .............5-60 CHECKING THE WOODRUFF KEY ............5-60 INSTALLING THE AC MAGNETO ............5-60 CRANKCASE ....................5-62 DISASSEMBLING THE CRANKCASE.............5-65 REMOVING THE CRANKCASE BEARING ..........5-65 CHECKING THE TIMING CHAIN, TIMING CHAIN GUIDE, OIL STRAINER..................5-65 CHECKING THE CRANKCASE ...............5-65 ASSEMBLING THE CRANKCASE............5-66 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT .......5-67...

  • Page 196

    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 1st 7 Nm (0.7 m kgf, 5.1 ft lbf) • • 2nd 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) •...

  • 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 Upper engine bracket Lower engine bracket Pivot shaft Engine For installation, reverse the removal proce- dure.

  • Page 201

    ENGINE REMOVAL REMOVING THE SILENCER EAS1SL1197 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 EAS1SL1199 1.

  • Page 202

    ENGINE REMOVAL REMOVING THE ENGINE 1. Remove: • Pivot shaft “1” 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. EAS1SL1202 CHANGING THE SILENCER FIBER 1.

  • Page 203

    ENGINE REMOVAL 3. Replace: • Fiber “1” • Apply heat-resistant sealant to the areas “a” shown, making sure that there are no gaps in the beads of sealant. • Take care not to allow the fiber out of place when installing the silencer body “3”. 4.

  • Page 204

    ENGINE REMOVAL 2. Install: • Lock washer “1” • Nut (drive sprocket) “2” Nut (drive sprocket) 75 Nm (7.5 m·kgf, 54 ft·lbf) Tighten the nut while applying the rear brake. ECA33DD040 NOTICE Make sure to tighten to specification; other- INSTALLING THE BRAKE PEDAL EAS1SL1204 wise, it may damage the other part that is 1.

  • Page 205

    ENGINE REMOVAL 3. Install: INSTALLING THE EXHAUST PIPE AND EAS1SL1206 • Clamp MUFFLER • Silencer “1” 1. Install: • Bolt (silencer) “2” • Gasket • Exhaust pipe 1 “1” Bolt (silencer) • Nut (exhaust pipe 1) “2” 30 Nm (3.0 m·kgf, 22 ft·lbf) Nut (exhaust pipe) 10 Nm (1.0 m·kgf, 7.2 ft·lbf) First temporarily tighten nuts to 7 Nm (0.7...

  • Page 206

    CAMSHAFT CAMSHAFT EAS1SL1207 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 207

    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) •...

  • Page 208

    CAMSHAFT REMOVING THE CAMSHAFT EAS1SL1208 1. Remove: • Timing mark accessing screw “1” • Crankshaft end accessing screw “2” 4. Remove: • Bolt (camshaft cap) “1” • Camshaft cap “2” • Clip “3” 2. Align: • Alignment mark • Remove the bolts (camshaft cap) in a criss- cross pattern, working from the outside in.

  • Page 209

    CAMSHAFT 3. Measure: CHECKING THE CAMSHAFT EAS1SL1209 • Camshaft runout 1. Check: Out of specification  Replace. • Camshaft lobes Blue discoloration/pitting/scratches  Re- Camshaft runout limit 0.015 mm (0.0006 in) place the camshaft. 2. Measure: • Camshaft lobe dimensions “A” and “B” Out of specification ...

  • Page 210

    CAMSHAFT c. Install the dowel pins and the camshaft 2. Check: caps. • Camshaft sprocket More than 1/4 tooth wear “a”  Replace the camshaft sprocket and the timing chain as a • Tighten the camshaft cap bolts in a crisscross set.

  • Page 211

    CAMSHAFT CHECKING THE DECOMPRESSION SYS- EAS1SL1212 1. Check: • Decompression system ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check that the decompressor cam “1” moves smoothly. b. Check that the decompressor lever pin “2” projects from the camshaft. b. Align the top dead center (TDC) mark “a” on the rotor with the alignment mark “b”...

  • Page 212

    CAMSHAFT • Before installing the clips, cover the cylinder head with a clean cloth to prevent the clips from coming off into the cylinder head cavity. • Tighten the bolts to the specified torque in two or three steps in the proper tightening se- quence as shown.

  • Page 213

    CAMSHAFT 6. Install: • Cylinder head breather hose • Spark plug Spark plug 13 Nm (1.3m·kgf, 9.4 ft·lbf) 5-18...

  • Page 214

    CYLINDER HEAD CYLINDER HEAD EAS1SL1214 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) • • Final 10 Nm (1.0 m kgf, 7.2 ft Ibf)

  • Page 215

    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) • • Final 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 216

    CYLINDER HEAD REMOVING THE CYLINDER HEAD EAS1SL1215 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 217

    CYLINDER HEAD INSTALLING THE CYLINDER HEAD EAS1SL1218 Bolts “1”–“4” 1. Install: • Timing chain guide (intake side) “1” 30 Nm (3.0 m·kgf, 22 ft·lbf) • Dowel pin “2” • Cylinder head gasket “3” • Cylinder head “4” While pulling up the timing chain, install the tim- ing chain guide (intake side) and the cylinder head.

  • Page 218

    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 219

    VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS EAS1SL1219 Removing the valves and valve springs Order Part name Q’ty Remarks Refer to “CYLINDER HEAD” on page 5-19. Cylinder head Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Intake valve...

  • Page 220

    VALVES AND VALVE SPRINGS b. Check that the valves are properly sealed. REMOVING THE VALVES EAS1SL1220 Check that there are no kerosene leaks from Before removing the internal parts of the cylin- the valve seat “1.” der head (e.g., valves, valve springs, valve seats), make sure that the valves are properly sealed.

  • Page 221

    VALVES AND VALVE SPRINGS 2. Replace: • Valve guide To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100°C (212°F) in an oven. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve guide with the valve guide remover “1.”...

  • Page 222

    VALVES AND VALVE SPRINGS After replacing the valve guide, reface the valve • When installing a new valve, always replace seat. the valve guide. • If the valve is removed or replaced, always re- Valve guide remover & installer place the oil seal. set (ø5.5) 90890-04016 Valve stem runout...

  • Page 223

    VALVES AND VALVE SPRINGS NOTICE Do not let the lapping compound enter the gap between the valve stem and the valve guide. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion.

  • Page 224

    VALVES AND VALVE SPRINGS Installed compression spring force (intake) 178.00–204.00 N (18.15–20.80 kgf, 40.01–45.86 lbf) Installed compression spring force (exhaust) 124.00–142.00 N (12.64–14.48 kgf, 27.88–31.92 lbf) Installed length (intake) 34.78 mm (1.37 in) Installed length (exhaust) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 30.83 mm (1.21 in) EAS1SL1223 CHECKING THE VALVE SPRINGS 3.

  • Page 225

    VALVES AND VALVE SPRINGS INSTALLING THE VALVES 4. Install: 1. Clean: • Valve cotter “1” • Valve stem end Install the valve cotters by compressing the valve spring with the valve spring compressor “2” and the valve spring compressor adapter “3.”...

  • Page 226

    VALVES AND VALVE SPRINGS 6. Lubricate: • Adjusting pad “1” • Valve lifter “2” 7. Install: • Adjusting pad • Valve lifter • Check that the valve lifter turns smoothly when rotated with your finger. • Make sure that the valve lifter and the adjust- ing pad are reinstalled in their original posi- tions.

  • Page 227

    CYLINDER AND PISTON CYLINDER AND PISTON EAS1SL1226 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 5-19. Cylinder head Cylinder body Gaskets...

  • Page 228: Cylinder And Piston

    CYLINDER AND PISTON REMOVING THE PISTON EAS1SL1227 1. Remove: • Piston pin clip “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 EAS1SL1228 crankcase opening with a cloth to prevent the...

  • Page 229

    CYLINDER AND PISTON b. If out of specification, rebore or replace the Ring side clearance cylinder, and replace the piston and the pis- 0.015–0.065 mm (0.0006–0.0026 ton rings as a set. c. Measure the piston outside diameter D “a” at Limit the measurement position H “b”...

  • Page 230

    CYLINDER AND PISTON Piston ring end gap Top ring End gap (installed) 0.20–0.30 mm (0.0079–0.0118 in) Limit 0.55 mm (0.0217 in) End gap (installed) 0.35–0.50 mm (0.0138–0.0197 in) Limit 0.85 mm (0.0335 in) Oil ring INSTALLING THE PISTON AND CYLINDER EAS1SL1231 End gap (installed) 1.

  • Page 231

    CYLINDER AND PISTON • While compressing the piston rings with one hand, install the cylinder with the other hand. • Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity. 3. Lubricate: • Piston • Piston rings •...

  • Page 232

    CLUTCH CLUTCH EAS1SL1232 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 233

    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. 5-38...

  • Page 234

    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 235

    CLUTCH CHECKING THE CLUTCH PLATES REMOVING THE CLUTCH EAS1SL1233 1. Check: 1. Remove: • Clutch plate • Clutch boss nut “1” Damage  Replace the clutch plates as a • Conical washer “2” set. • Clutch boss “3” 2. Measure: •...

  • Page 236

    CLUTCH CHECKING THE CLUTCH HOUSING CHECKING THE PUSH LEVER SHAFT 1. Check: 1. Check: • Clutch housing dogs “a” • Push lever shaft Damage/pitting/wear  Deburr the clutch Wear/damage  Replace. housing dogs or replace the clutch housing. Pitting on the clutch housing dogs will cause er- ratic clutch operation.

  • Page 237

    CLUTCH CHECKING THE PRIMARY DRIVEN GEAR 2. Install: 1. Check: • Right crankcase cover “1” • Primary driven gear • Right crankcase cover bolt “2” Damage/wear  Replace the primary drive Right crankcase cover bolt and primary driven gears as a set. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Excessive noise during operation ...

  • Page 238

    CLUTCH 2. Install: 4. Install: • Primary driven gear “1” • Friction plate 1 “1” • Thrust washer “2” • Clutch plate “2” • Clutch boss “3” • Friction plate 2 “3” Apply the engine oil on the primary driven gear •...

  • Page 239

    CLUTCH 6. Install: 9. Install: • Push rod 2 “1” • O-ring “1” • Ball “2” • Push rod 1 “3” Apply the lithium-soap-based grease to the O- ring. Apply the engine oil on the push rod 1, 2 and ball.

  • Page 240

    CLUTCH INSTALLING THE KICKSTARTER LEVER 1. Install: • Kickstarter lever “1” • Washers • Bolt (kickstarter lever) Bolt (kickstarter lever) 33 Nm (3.3 m·kgf, 24 ft·lbf) Install so that there is a clearance “a” of 5 mm (0.2 in) or more between the kickstarter lever and the frame and that the kickstarter lever does not contact the right crankcase cover when it is pulled.

  • Page 241

    KICKSTATER KICKSTATER EAS1SL1248 Removing the kick shaft Order Part name Q’ty Remarks Primary driven gear Refer to “CLUTCH” on page 5-37. Kick idle gear Kick shaft assembly Spring guide Torsion spring Ratchet wheel Kick gear Kick shaft For installation, reverse the removal proce- dure.

  • Page 242

    KICKSTATER REMOVING THE KICK SHAFT ASSEMBLY EAS1SL1249 1. Remove: • Kick shaft assembly “1” Unhook the torsion spring “2” from the hole “a” in the crankcase. INSTALLING THE KICK SHAFT ASSEMBLY EAS1SL1252 1. Install: • Kick gear “1” • Washer “2” •...

  • Page 243

    KICKSTATER 5. Install: • Torsion spring “1” Turn the torsion spring clockwise and hook into the proper hole “a” in the crankcase. 3. Install: • Spring guide “1” 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 244

    SHIFT SHAFT SHIFT SHAFT EAS1SL1254 Removing the shift shaft and stopper lever 10 Nm (1.0 m kgf, 7.2 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft lbf) Order Part name Q’ty...

  • Page 245

    SHIFT SHAFT Removing the shift shaft and stopper lever 10 Nm (1.0 m kgf, 7.2 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft lbf) Order Part name Q’ty...

  • Page 246

    SHIFT SHAFT CHECKING THE SHIFT SHAFT REMOVING THE SHIFT GUIDE AND SHIFT EAS1SL1255 1. Check: LEVER ASSEMBLY • Shift shaft “1” 1. Remove: Bends/damage/wear  Replace. • Bolt (shift guide) • Shift shaft spring “2” • Shift guide “1” Damage/wear  Replace •...

  • Page 247

    SHIFT SHAFT INSTALLING THE SHIFT GUIDE AND SHIFT INSTALLING THE STOPPER LEVER EAS1SL1260 LEVER ASSEMBLY 1. Install: 1. Install: • Torsion spring “1” • Spring “1” • Collar “2” • Pawl pin “2” • Stopper lever “3” • Pawl “3” •...

  • Page 248

    SHIFT SHAFT 4. Tighten: INSTALLING THE SHIFT PEDAL • Shift guide bolt “1” 1. Install: • Shift pedal “1” Shift guide bolt • Shift pedal bolt “2” 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® Shift pedal bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Align the punch mark “a”...

  • Page 249

    OIL PUMP AND BALANCER GEAR OIL PUMP AND BALANCER GEAR EAS1SL1265 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 250

    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 251

    OIL PUMP AND BALANCER GEAR REMOVING THE BALANCER EAS1SL1266 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 252

    OIL PUMP AND BALANCER GEAR 2. Install: • Outer rotor “1” Apply the engine oil on the outer rotor. 3. Install: • Oil pump cover “1” • Oil pump cover screw “2” Oil pump cover screw 2 Nm (0.2 m·kgf, 1.4 ft·lbf) 1.

  • Page 253

    OIL PUMP AND BALANCER GEAR • Straight key “6” NOTICE • Balancer “7” After tightening the bolts, make sure that • Lock washer “8” the oil pump turns smoothly. • Balancer nut “9” 2. Install: Balancer nut • Balancer weight gear “1” 45 Nm (4.5 m·kgf, 33 ft·lbf) Install the balancer weight gear and balancer shaft with their lower splines “a”...

  • Page 254

    AC MAGNETO AC MAGNETO EAS1SL1272 Removing the AC magneto 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 255

    AC MAGNETO CHECKING THE WOODRUFF KEY REMOVING THE AC MAGNETO EAS1SL1273 1. Check: 1. Remove: • Woodruff key “1” • Nut (rotor) “1” Damage  Replace. • Washers 2. Remove: EAS1SL1276 INSTALLING THE AC MAGNETO • Rotor “1” 1. Install: Use the rotor puller “2”...

  • Page 256

    AC MAGNETO 2. Install: • Woodruff key “1” • Rotor “2” • Clean the contact surfaces of the tapered por- tions of the crankshaft and rotor. • When installing the woodruff key, make sure that its flat surface “a” is in parallel with the crankshaft center line “b”.

  • Page 257

    CRANKCASE CRANKCASE EAS1SL1277 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 258

    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 259

    CRANKCASE Removing the bearing and oil seal Order Part name Q’ty Remarks Transmission Refer to “TRANSMISSION” on page 5-70. Shift cam and shift fork Refer to “TRANSMISSION” on page 5-70. Circlip Oil seals Bearing For installation, reverse the removal proce- dure.

  • Page 260

    CRANKCASE DISASSEMBLING THE CRANKCASE EAS1SL1278 1. Separate: • Right crankcase • Left crankcase ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the crankcase bolts. c. Remove the dowel pins and O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ REMOVING THE CRANKCASE BEARING EAS1SL1279 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 261

    CRANKCASE 2. Check: 3. Install: • Crankcase • Dowel pin “1” Crack/damage  Replace. • Crankcase (to the left crankcase) • Oil delivery passages Crankcase bolt Obstruction  Blow out with compressed 12 Nm (1.2 m·kgf, 8.7 ft·lbf) air. EAS1SL1282 ASSEMBLING THE CRANKCASE 1.

  • Page 262

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EAS1SL1283 Removing the crankshaft assembly and balancer shaft Order Part name Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-62. Transmission Refer to “TRANSMISSION” on page 5-70. Balancer shaft Crankshaft assembly For installation, reverse the removal proce- dure.

  • Page 263

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT CHECKING THE CRANKSHAFT ASSEMBLY REMOVING THE BALANCER SHAFT EAS1SL1284 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 264

    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 265

    TRANSMISSION TRANSMISSION EAS1SL1288 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 5-62. Main axle Drive axle Long shift fork guide bar Short shift fork guide bar Spring Shift cam...

  • Page 266

    TRANSMISSION CHECKING THE SHIFT FORKS REMOVING THE TRANSMISSION EAS1SL1289 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 267

    TRANSMISSION CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: • Shift drum groove Damage/scratches/wear  Replace the shift drum assembly. • Shift drum segment “1” Damage/wear  Replace the shift drum as- sembly. 3. Check: • Transmission gears Blue discoloration/pitting/wear  Replace the defective gear (s).

  • Page 268

    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 269

    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 270

    TRANSMISSION 5-75...

  • Page 271

    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 272

    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 273

    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 274

    RADIATOR HANDLING NOTE EAS1SL1296 EWA1DX1007 WARNING If coolant seems hot, do not remove the ra- diator cap. CHECKING THE RADIATOR EAS1SL1297 1. Check: • Radiator fins “1” Obstructions  Clean. Apply compressed air to the rear of the radi- ator. Damage ...

  • Page 275

    WATER PUMP WATER PUMP EAS1SL1298 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.

  • Page 276: Water Pump

    WATER PUMP REMOVING THE OIL SEAL EAS1SL1299 • 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 277

    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 278

    WATER PUMP...

  • Page 279

    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 280

    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 281: Fuel Tank

    FUEL TANK REMOVING THE FUEL TANK EAS1SL1306 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose coupler EWA23P1001 WARNING Cover the fuel hose connection with a cloth when disconnecting it. This is because re- sidual pressure in the fuel hose could cause fuel to spurt out when the hose is removed.

  • Page 282

    FUEL TANK 3. Connect: • Fuel pump coupler 4. Install: • Air scoop (left/right) • Seat • Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4- EAS1SL1311 CHECKING THE FUEL PRESSURE 1. Check: • Fuel pressure INSTALLING THE FUEL TANK EAS1SL1310 1.

  • Page 283

    FUEL TANK CHECKING AND REPLACING THE PRO- TECTOR 1. Check: • Protector “1” Wear/damage  Replace. Affix the protector as shown. e. Start the engine. f. Measure the fuel pressure. Out of specification  Replace the fuel pump. Fuel pressure 0 mm 324.0 kPa (3.24 kgf/cm , 47.0...

  • Page 284

    THROTTLE BODY THROTTLE BODY EAS1SL1314 Removing the throttle body 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) •...

  • Page 285

    THROTTLE BODY Removing the throttle body 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) •...

  • Page 286

    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 287

    THROTTLE BODY CHECKING THE INJECTOR EAS1SL1315 1. Check: • Injector Obstruction  Replace, and check the fuel pump and the fuel injection system. Refer to “FUEL INJECTION SYSTEM” on page 8-10. Deposits  Replace. Damage  Replace. 2. Check: • Injector resistance Refer to “CHECKING THE FUEL INJEC- TOR”...

  • Page 288

    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 289

    CIRCUIT DIAGRAM ...................8-2 TROUBLESHOOTING ................8-4 CHARGING SYSTEM..................8-6 CIRCUIT DIAGRAM ...................8-6 TROUBLE SHOOTING ................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...

  • Page 291

    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 292: Ignition System

    IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM EAS1SL1321...

  • Page 293

    IGNITION SYSTEM 1. Crankshaft position sensor 2. AC magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser 7. Engine stop switch 9. ECU 10.Ignition coil 11.Spark plug EAS1SL1322...

  • Page 294

    IGNITION SYSTEM TROUBLESHOOTING 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 295

    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.

  • Page 296: Charging System

    CHARGING SYSTEM CHARGING SYSTEM EAS27200 EAS1SL1323 CIRCUIT DIAGRAM...

  • Page 297

    CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser EAS1SL1324...

  • Page 298

    CHARGING SYSTEM TROUBLE SHOOTING 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 299

    CHARGING SYSTEM...

  • Page 300

    FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM EAS1SL1325 EAS1SL1326 CIRCUIT DIAGRAM 8-10...

  • Page 301

    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 9. ECU 12.Fuel injector 14.Intake air temperature sensor 15.Coolant temperature sensor 16.Throttle position sensor 17.Intake air pressure sensor EAS1SL1327 8-11...

  • Page 302: Fuel Injection System

    FUEL INJECTION SYSTEM YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool 90890-03215 FEATURES OF THE YAMAHA DIAGNOSTIC TOOL A diagnosis can be made more quickly than traditional methods with the Yamaha diagnostic tool.

  • Page 303

    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 304

    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 305

    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 306

    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 307

    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 308

    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 309

    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 310

    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 311

    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 312

    FUEL INJECTION SYSTEM Fault code Symptom The vehicle has overturned. Fail-safe system Able to start engine Unable to drive vehicle Diagnostic code No. Diagnostic tool display Displays the lean angle sensor output voltage. • 1.0 V (upright) • 4.0 V (overturned) Procedure Remove the ECU, and incline it 45°...

  • Page 313

    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 314

    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 315

    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 316

    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 317

    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 318

    — 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 319

    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 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 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 322: Fuel Pump System

    FUEL PUMP SYSTEM FUEL PUMP SYSTEM EAS1SL1329 EAS1SL1330 CIRCUIT DIAGRAM 8-32...

  • Page 323

    FUEL PUMP SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser 7. Engine stop switch 9. ECU 13.Fuel pump EAS1SL1331 8-33...

  • Page 324

    FUEL PUMP SYSTEM TROUBLESHOOTING 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 325

    FUEL PUMP SYSTEM 8-35...

  • Page 326: Electrical Components

    ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS EAS1SL1332 EAS1SL1333 8-36...

  • Page 327

    ELECTRICAL COMPONENTS 1. Rectifier/regulator 2. Intake air pressure sensor 3. Throttle position sensor 4. Injector 5. Intake air temperature sensor 6. ECU 7. Ignition coil 8. Condenser 9. Neutral switch 10.Coolant temperature sensor EAS1SL1334 8-37...

  • Page 328

    ELECTRICAL COMPONENTS CHECKING THE SWITCHES B/Y P 8-38...

  • Page 329

    ELECTRICAL COMPONENTS 1. Engine stop switch 2. Neutral switch 8-39...

  • Page 330

    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 331

    ELECTRICAL COMPONENTS CHECKING THE IGNITION SPARK GAP EAS1SL1335 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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” on page 8- Analog pocket tester YU-03112-C Minimum ignition spark gap...

  • Page 332

    ELECTRICAL COMPONENTS CHECKING THE CRANKSHAFT POSITION SENSOR 1. Disconnect: • Crankshaft position sensor coupler (from the wire harness) 2. Check: • Crankshaft position sensor resistance Out of specification  Replace. Crankshaft position sensor resis- tance b. Measure the primary coil resistance. 228–342 ...

  • Page 333

    ELECTRICAL COMPONENTS CHECKING THE ECU CHECKING THE RECTIFIER/REGULATOR 1. Check: 1. Check: • Mounted condition of ECU. • Rectifier/regulator output voltage Improperly mounted  Remount. Out of specification  Replace. Output voltage • The lean angle sensor is built into the ECU. 14 V or more at 5000 r/min •...

  • Page 334

    ELECTRICAL COMPONENTS CHECKING THE COOLANT TEMPERATURE c. Place a thermometer in the coolant. SENSOR d. Slowly heat the coolant, and then let it cool 1. Remove: to the specified temperature indicated in the • Coolant temperature sensor table. e. Check the coolant temperature sensor for EWA14130 WARNING continuity at the temperatures indicated in...

  • Page 335

    ELECTRICAL COMPONENTS 2. Check: CHECKING THE THROTTLE POSITION • Throttle position sensor maximum resis- SENSOR INPUT VOLTAGE tance 1. Check: Out of specification  Replace. • Throttle position sensor input voltage Out of specification  Replace the ECU. Resistance 6.30 k Throttle position sensor input voltage 4–6 V...

  • Page 336

    ELECTRICAL COMPONENTS CHECKING THE INTAKE AIR PRESSURE 2. Check: SENSOR • Intake air temperature sensor resistance Out of specification  Replace. 1. Check: • Intake air pressure sensor output voltage Intake air temperature sensor re- Out of specification  Replace. sistance 290–390 ...

  • Page 337

    ELECTRICAL COMPONENTS Continuity Positive tester probe  Sky blue “1” Negative tester probe  Sensor terminal “a” Continuity Positive tester probe  Black/Yellow “2” Negative tester probe  Sensor terminal “b” Continuity c. Measure the fuel injector resistance. Positive tester probe  ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 338

    ELECTRICAL COMPONENTS 8-48...

  • Page 339: General Information

    TROUBLE SHOOTING TROUBLE SHOOTING..................9-1 GENERAL INFORMATION ................9-1 STARTING FAILURES................9-1 INCORRECT ENGINE IDLING SPEED .............9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING.................9-2 SHIFT PEDAL DOES NOT MOVE .............9-2 JUMPS OUT OF GEAR................9-2 FAULTY CLUTCH ..................9-2 OVERHEATING ..................9-2 OVERCOOLING..................9-3 POOR BRAKING PERFORMANCE............9-3 FAULTY FRONT FORK LEGS..............9-3 UNSTABLE HANDLING ................9-3 LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS......9-4...

  • Page 340

    TROUBLE SHOOTING Electrical system TROUBLE SHOOTING EAS1SL1349 1. Spark plug • Incorrect spark plug gap EAS1SL1350 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 341

    TROUBLE SHOOTING 3. Ignition system FAULTY CLUTCH EAS1SL1357 • Faulty ECU • Faulty crankshaft position sensor Clutch slips • Broken generator rotor woodruff key 1. Clutch • Improperly assembled clutch EAS1SL1353 POOR MEDIUM-AND-HIGH-SPEED PER- • Loose or fatigued clutch spring FORMANCE •...

  • Page 342

    TROUBLE SHOOTING Fuel system Malfunction 1. Throttle body • Bent or damaged inner tube • Damaged or loose throttle body joint • Bent or damaged outer tube 2. Air filter • Broken fork spring • Clogged air filter element • Bent or damaged damper rod •...

  • Page 343

    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 344

    • 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 345

    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 346

    LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS...

  • Page 347

    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 348

    CHASSIS DRIVE AND REAR WHEEL SPROCKETS CHASSIS EAS1SL1365 SETTING PARTS EAS1SL1366 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 349

    CHASSIS TIRE PRESSURE 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 (1.0 kgf/cm...

  • Page 350

    CHASSIS SETTING OF SPRING AFTER REPLACE- MENT As the front fork setting can be easily affected by the rear suspension, take care so that the front and the rear are balanced (in position etc.) when setting the front fork. 1. Use of soft spring •...

  • Page 351

    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 352: Specifications

    CHASSIS REAR SHOCK ABSORBER SETTING PARTS • Rear shock spring “1” Spring I.D. Type rate Part number Mark N/mm 1SL-22212-40 (Blue) Yellow 1SL-22212-50 (Red) SOFT 1SL-22212-60 (Blue) Pink 1SL-22212-70 (Red) 1SL-22212-20 (Blue) STD* White 1SL-22212-30 (Red) 1SL-22212-00 • Extent of adjustment (spring preload) (Blue) Silver Maximum...

  • Page 353

    CHASSIS SUSPENSION SETTING (FRONT FORK) EAS1SL1377 • 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 354

    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 355

    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 356: Engine

    WIRING DIAGRAM EAS1SL1380 YZ450F 2014 1. Crankshaft position sensor 2. AC magneto 3. Rectifier/regulator 4. Joint connector 5. Condenser 6. Coupler for connecting option- al part 7. Engine stop switch 8. Neutral switch 9. ECU 10. Ignition coil 11. Spark plug 12.

  • Page 358

    PRINTED ON RECYCLED PAPER PRINTED IN JAPAN...

  • Page 359

    SCHÉMA DE CÂBLAGE WIRING DIAGRAM SCHALTPLAN YZ450F (E) 2014 YZ450F (E) 2014 YZ450F (E) 2014 B B B B R R R R R R R B/L B/L B/L B/L B/L B/L P P P L L L R R R R R R R B B B B B/LB/LB/LB/LB/L (BLACK)

  • Page 360

    SCHÉMA DE CÂBLAGE WIRING DIAGRAM SCHALTPLAN YZ450F (E) 2014 YZ450F (E) 2014 YZ450F (E) 2014 (BLACK) (BLACK)

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