Yamaha WR450FB 2012 Owner's Service Manual
  1. Manuals
  2. Brands
  3. Yamaha Manuals
  4. Motorcycle
  5. WR450FB 2012
  6. Owner's service manual

Yamaha WR450FB 2012 Owner's Service Manual

Hide thumbs Also See for WR450FB 2012:
1
2
3
4
5
6
7
8
Table Of Contents
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
Table of Contents

Advertisement

Quick Links

2012-2015
q Read this manual carefully before operating this vehicle.
OWNER'S SERVICE MANUAL
WR450FB
LIT-11626-25-58
1DX-28199-10

Advertisement

Table of Contents
loading

Related Manuals for Yamaha WR450FB 2012

Summary of Contents for Yamaha WR450FB 2012

  • Page 1 2012-2015 q Read this manual carefully before operating this vehicle. OWNER’S SERVICE MANUAL WR450FB LIT-11626-25-58 1DX-28199-10...
  • Page 2 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
  • Page 3 EAS1DX3002 WR450FB OWNER’S SERVICE MANUAL ©2012 by Yamaha Motor Corporation, U.S.A. 1st Edition, January 2012 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan P/N. LIT-11626-25-58...
  • Page 4 EAS1DX3003 INTRODUCTION Congratulations on your purchase of a Yamaha WR series. This model is the culmination of Yama- ha'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 5 EAS1DX3005 SAFETY INFORMATION THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding. •...
  • Page 6 EAS1DX3006 YAMAHA MOTOR CORPORATION, U.S.A. WR MOTORCYCLE LIMITED WARRANTY...
  • Page 7 EAS1DX3007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
  • Page 8 EAS1DX3008 SYMBOLS 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 9: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUST- MENTS TUNING CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 11: General Information

    GENERAL INFORMATION LOCATION OF IMPORTANT LABELS............1-1 DESCRIPTION....................1-3 CONSUMER INFORMATION ................1-4 VEHICLE IDENTIFICATION NUMBER ............1-4 ENGINE SERIAL NUMBER................1-4 MODEL LABEL...................1-4 VEHICLE EMISSION CONTROL INFORMATION LABEL......1-4 FEATURES .......................1-5 OUTLINE OF THE FI SYSTEM ..............1-5 FI SYSTEM....................1-6 INCLUDED PARTS...................1-7 VALVE JOINT.....................1-7 SPARK PLUG WRENCH................1-7 NIPPLE WRENCH..................1-7 HANDLEBAR PROTECTOR ..............1-7 HOOK (FUEL TANK) ..................1-7...
  • Page 12 KICKSTARTER CRANK ................1-21 THROTTLE GRIP ..................1-21 FRONT BRAKE LEVER ................1-21 REAR BRAKE PEDAL................1-22 SIDESTAND .....................1-22 STARTER KNOB/IDLE ADJUSTING SCREW .........1-22 MULTI-FUNCTION DISPLAY .................1-22 DESCRIPTION ..................1-22 BASIC MODE ...................1-23 CHANGEOVER TO BASIC MODE/RACE MODE........1-24 RACE MODE ....................1-25 FUNCTION DIAFRAM ................1-29 STARTING AND BREAK-IN................1-30 FUEL......................1-30 HANDLING NOTE ..................1-31 AIR FILTER MAINTENANCE ..............1-31...

  • Page 13: Location Of Important Labels

    LOCATION OF IMPORTANT LABELS EAS1DX3009 LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle. 1,2,3...
  • Page 14 LOCATION OF IMPORTANT LABELS CANADA Essence super sans plomb seulement. 3FB-2415E-12...

  • Page 15: Description

    DESCRIPTION EAS1DX3010 DESCRIPTION 1. Clutch lever 13. Headlight 2. Engine stop switch 14. Radiator 3. Multi-function display 15. Coolant drain bolt 4. Main switch 16. Rear brake pedal 5. Start switch 17. Valve joint 6. Front brake lever 18. Starter knob/idle adjusting screw 7.

  • Page 16: Consumer Information

    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 machine is stolen, the authorities will need the number to search for and identify your machine.

  • Page 17: Features

    FEATURES EAS20170 FEATURES EAS1DX3016 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.

  • Page 18: Fi System

    FEATURES EAS1DX3017 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at a certain level. Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be inject- ed into the intake manifold only during the time the passage remains open.

  • Page 19: Included Parts

    INCLUDED PARTS EAS1DX3018 EAS1DX3022 INCLUDED PARTS HANDLEBAR PROTECTOR Install the handlebar protector "1" so that the notch "a" face backward. EAS1DX3019 VALVE JOINT This valve joint "1" prevents fuel from flowing out and is installed to the fuel tank breather hose.

  • Page 20: Coupler For Connecting Optional Part

    5. Keep all parts away from any source of fire. EAS1DX3027 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but...

  • Page 21: Gaskets, Oil Seals And O-Rings

    IMPORTANT INFORMATION EAS1DX3030 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.
  • Page 22 BASIC SERVICE INFORMATION EAS1DX3032 BASIC SERVICE INFORMATION EAS1DX3033 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. Screw type 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.

  • Page 23: Basic Service Information

    BASIC SERVICE INFORMATION If a battery lead is difficult to disconnect due to rust on the battery terminal, remove the rust us- ing hot water. EAS1DX3034 ELECTRICAL SYSTEM Electrical parts handling ECA16600 ECA16760 NOTICE NOTICE Never disconnect a battery lead while the Be sure to connect the battery leads to the engine is running;...
  • Page 24 BASIC SERVICE INFORMATION ECA16610 NOTICE When resetting the ECU by turning the main Turn the main switch to “OFF” before dis- switch to “OFF”, be sure to wait approximately connecting or connecting an electrical com- 5 seconds before turning the main switch back ponent.
  • Page 25 BASIC SERVICE INFORMATION ECA16640 ECA16790 NOTICE NOTICE For waterproof couplers, never insert the When disconnecting a connector, do not tester probes directly into the coupler. pull the leads. Hold both sections of the When performing any checks using a water- connector securely, and then disconnect proof coupler, use the specified test har- the connector.
  • Page 26 BASIC SERVICE INFORMATION 5. Check: • Continuity (with the pocket tester) 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 27 SPECIAL TOOLS EAS1DX3035 SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised tech- niques. The shape and part number used for the special tool differ by country, so two types are pro- vided.
  • Page 28 SPECIAL TOOLS Reference Tool name/Part number Illustration pages Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984 Steering nut wrench 3-24, 5-59 90890-01403 Exhaust flange nut wrench YU-A9472 Cap bolt wrench 5-48, 5-51 90890-01500 YM-01500 Cap bolt ring wrench 5-47, 5-48 5-51, 5-54 90890-01501 5-56...

  • Page 29: Special Tools

    Test harness S-pressure sensor (3P) 9-76 90890-03207 YU-03207 Test harness-lean angle sensor (6P) 9-73 90890-03209 YU-03209 FI diagnostic tool sub-lead 9-26 90890-03212 Yamaha diagnostic tool 9-26 90890-03215 Test harness-speed sensor 5TJ (3P) 9-74 90890-03228 YU-03228 Valve spring compressor 6-19, 6-24 90890-04019 YM-04019...
  • Page 30 SPECIAL TOOLS Reference Tool name/Part number Illustration pages Spacer (crankshaft installer) 6-69 90890-04081 Pot spacer YM-91044 YM-91044 Universal clutch holder 6-39, 6-41 90890-04086 YM-91042 Valve guide remover (Ø5) 6-21 90890-04097 YM-04097 Valve guide installer (Ø5) 6-21 90890-04098 YM-04098 Valve guide reamer (Ø5) 6-21 90890-04099 YM-04099...
  • Page 31 90890-04118 YM-04118 Rotor puller 6-59 90890-04142 YM-04142 Crankcase separating tool 6-68 90890-04152 Crankcase separator YU-A9642 Ignition checker 9-71 90890-06754 Oppama pet-4000 spark checker YM-34487 Digital tachometer 3-11 90890-06760 YU-39951-B Yamaha bond No. 1215 (Three bond 6-60, 6-66 No.1215®) 90890-85505 1-19...

  • Page 32: Control Functions

    This warning light comes on or flashes if a prob- stalls. lem is detected in the electrical circuit monitor- ing the engine. If this occurs, have a Yamaha All electrical systems are off. dealer check the vehicle. The electrical circuit of the warning light can be...

  • Page 33: Start Switch

    CONTROL FUNCTIONS EAS1DX3040 EAS1DX3043 START SWITCH KICKSTARTER CRANK The start switch "1" is located on the right han- Rotate the kickstarter crank "1" away from the dlebar. Push this switch to crank the engine engine. Push the starter down lightly with your with the starter.

  • Page 34: Rear Brake Pedal

    MULTI-FUNCTION DISPLAY EAS1DX3046 EAS1DX3049 MULTI-FUNCTION DISPLAY REAR BRAKE PEDAL The rear brake pedal "1" is located on the right EWA32D1008 side of the machine. Press down on the brake WARNING pedal to activate the rear brake. Be sure to stop the machine before making any setting changes to the multi-function display.

  • Page 35: Basic Mode

    MULTI-FUNCTION DISPLAY The operation buttons can be pushed in the fol- lowing two manners: Short push: Push the button. ( Long push: Push the button for 2 seconds or more. ( 3. Push the "SLCT1" button (plus) or "SLCT2" button (minus) and change the time. A long push on the button will fast-forward the time.

  • Page 36: Changeover To Basic Mode/Race Mode

    MULTI-FUNCTION DISPLAY 3. Push the "SLCT1" button (plus) or "SLCT2" button (minus) and change the setting. A To reset the digits, select the tripmeter involved long push on the button will fast-forward the and push the "RST" button for 2 seconds or digits.

  • Page 37: Race Mode

    MULTI-FUNCTION DISPLAY Changeover from BASIC MODE to RACE MODE 1. Push the "SLCT1" button and "SLCT2" but- ton for 2 seconds or more at the same time to change over to RACE MODE. Changeover to RACE MODE will put manual start measurement on standby causing , and the average speed display to flash.
  • Page 38 MULTI-FUNCTION DISPLAY 3. When stopping timer measurement, pushing the "SLCT1" button and "SLCT2" button at the same time. If the machine is run while timer measurement is not made, no change will occur to the digit in tripmeter A (TRIP A). 5.
  • Page 39 MULTI-FUNCTION DISPLAY Resetting average speed (AVS) and tripmeter Correcting tripmeter A (TRIP A) A (TRIP A) 1. Change the travel distance display by push- 1. Check that the timer is in operation. If the ing the "SLCT1" button (plus) or "SLCT2" timer is not in operation, start the timer by button (minus).
  • Page 40 MULTI-FUNCTION DISPLAY • Change in the digits of the travel distance will be accompanied by the change in the tire's di- ametric percentage. • Colon (:) in the tire diameter display repre- sents the decimal marker. • If the tire diameter extends beyond the set range (65.0 to 115.0%), the error indicator "E"...

  • Page 41: Function Diafram

    MULTI-FUNCTION DISPLAY EAS1DX3054 FUNCTION DIAFRAM The following diagram illustrates the multi-function display regarding the direction and operation con- dition involved in each of its functions. 1-29...

  • Page 42: Starting And Break-In

    Your Yamaha engine has been designed to use premium unleaded gasoline with a pump oc- tane number [(R+M)/2] of 91 or higher, or a re- search octane number of 95 or higher.

  • Page 43: Handling Note

    2. Shift the transmission into the neutral posi- tion. The neutral indicator light should come on. If not, ask a Yamaha dealer to check the electrical circuit. 3. Turn the starter on and completely close the throttle.

  • Page 44: Break-In Procedures

    STARTING AND BREAK-IN ECA1DX1009 NOTICE • After the break-in or before each race, you must check the entire machine for loose fittings and fasteners as per "TORQUE- CHECK POINTS". Tighten all such fasten- ers as required. • When any of the following parts have been replaced, they must be broken in.

  • Page 45: Torque-Check Points

    TORQUE-CHECK POINTS EAS1DX3062 TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and fuel tank Fuel tank to frame Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Steering stem to handlebar Steering stem to frame Steering stem to upper bracket...

  • Page 46: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE • Do not use any harsh chemical products EAS1DX3063 MOTORCYCLE CARE AND STOR- on plastic parts. Be sure to avoid using cloths or sponges which have been in con- tact with strong or abrasive cleaning prod- ucts, solvent or thinner, fuel (gasoline), EAS1DX3064 CARE...

  • Page 47: Storage

    • Avoid using abrasive polishing com- pounds as they will wear away the paint. • Consult a Yamaha dealer for advice on what products to use. • Washing, rainy weather or humid climates can cause the headlight lens to fog. Turning...
  • Page 48 MOTORCYCLE CARE AND STORAGE e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. WARNING! To pre- vent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over.

  • Page 49: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-8 ELECTRICAL SPECIFICATIONS ..............2-11 TIGHTENING TORQUES ................2-13 GENERAL TIGHTENING TORQUE SPECIFICATIONS ......2-13 ENGINE TIGHTENING TORQUES ............2-14 CHASSIS TIGHTENING TORQUES ............2-17 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 ..................2-29...

  • Page 50: General Specifications

    GENERAL SPECIFICATIONS EAS1DX3066 GENERAL SPECIFICATIONS Model Model 1DX3 (USA) 1DX4 (CANADA) Dimensions Overall length 2160 mm (85.0 in) Overall width 825 mm (32.5 in) Overall height 1275 mm (50.2 in) Seat height 960 mm (37.8 in) Wheelbase 1465 mm (57.7 in) Ground clearance 335 mm (13.19 in) Weight...

  • Page 51: Engine Specifications

    ENGINE SPECIFICATIONS EAS1DX3067 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 449 cm³ Cylinder arrangement Forward-inclined single cylinder Bore stroke 95.0 63.4 mm (3.74 2.50 in) Compression ratio 12.30 :1 Starting system Electric starter and kickstarter Fuel Recommended fuel Premium unleaded gasoline only Fuel tank capacity 7.5 L (1.98 US gal, 1.65 Imp.gal)
  • Page 52 ENGINE SPECIFICATIONS Spark plug Manufacturer/model NGK/CR8E Spark plug gap 0.7–0.8 mm (0.028–0.031 in) Cylinder head Volume 22.75–23.55 cm³ (1.39–1.44 cu.in) Warpage limit 0.10 mm (0.0039 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...
  • Page 53 ENGINE SPECIFICATIONS Valve face width B (intake) 2.260 mm (0.0890 in) Valve face width B (exhaust) 2.260 mm (0.0890 in) 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) 1.00 mm (0.0394 in) Valve margin thickness D (exhaust) 1.00 mm (0.0394 in)
  • Page 54 ENGINE SPECIFICATIONS Spring tilt (intake) 2.5 °/1.7 mm (2.5 °/0.07 in) Spring tilt (exhaust) 2.5 °/1.6 mm (2.5 °/0.06 in) Winding direction (intake) Clockwise Winding direction (exhaust) Clockwise Cylinder Bore 95.000–95.010 mm (3.7402–3.7405 in) Taper limit 0.050 mm (0.0020 in) Out of round limit 0.050 mm (0.0020 in) Piston...
  • Page 55 ENGINE SPECIFICATIONS End gap (installed) 0.35–0.50 mm (0.0138–0.0197 in) Limit 0.85 mm (0.0335 in) Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in) Limit 0.115 mm (0.0045 in) Oil ring Dimensions (B 2.00 2.90 mm (0.08 0.11 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)
  • Page 56 ENGINE SPECIFICATIONS Gear ratio 2.417 (29/12) 1.733 (26/15) 1.313 (21/16) 1.050 (21/20) 0.840 (21/25) 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...

  • Page 57: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS1DX3068 CHASSIS SPECIFICATIONS Chassis Frame type Semi double cradle Caster angle 27.00 ° Trail 117.0 mm (4.61 in) Front wheel Wheel type Spoke wheel Rim size 21 x 1.60 Rim material Aluminum Wheel travel 300.0 mm (11.81 in) Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit...
  • Page 58 CHASSIS SPECIFICATIONS Rear brake Type Single disc brake Operation Right foot operation Rear disc brake Disc outside diameter thickness 245.0 4.0 mm (9.65 0.16 in) Brake disc thickness limit 3.5 mm (0.14 in) Brake disc deflection limit 0.15 mm (0.0059 in) Brake pad lining thickness (inner) 6.4 mm (0.25 in) Limit...
  • Page 59 CHASSIS SPECIFICATIONS Spring preload adjusting positions Minimum 238.5 mm Standard 222.0 mm Maximum 222.0 mm Rebound damping adjusting positions *With the adjusting screw fully turned in Minimum 30 click (s) out* Standard 18 click (s) out* Maximum Fully turned in Compression damping adjusting positions (for fast compression damping) *With the adjusting screw fully turned in...

  • Page 60: Electrical Specifications

    12 V Ignition system Ignition system Advancer type Digital Ignition timing (B.T.D.C.) 10.0 °/2000 r/min Engine control unit Model/manufacturer 1DX2/YAMAHA Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) Primary coil resistance 3.57-4.83 Secondary coil resistance 10.71–14.49 k AC magneto Standard output 14.0 V, 160 W@5000 r/min...
  • Page 61 ELECTRICAL SPECIFICATIONS Starter relay Amperage 180.0 A Coil resistance 4.18–4.62 Starting circuit cut-off relay Coil resistance 86.4–105.6 Headlight relay Coil resistance 86.4–105.6 Fuses Main fuse 15.0 A Spare fuse 15.0 A 2-12...

  • Page 62: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 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 63: Engine Tightening Torques

    TIGHTENING TORQUES EAS1DX3070 ENGINE TIGHTENING TORQUES - marked portion shall be checked for torque tightening after break-in. Thread Item Q’ty Tightening torque 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) Cylinder head stud bolt 15 Nm (1.5 m·kgf, 11 ft·lbf) Spark plug...
  • Page 64 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust pipe protector screw 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Spark arrester bolt 9 Nm (0.9 m·kgf, 6.4 ft·lbf) Muffler cap bolt 5 Nm (0.5 m·kgf, 3.6 ft·lbf) Throttle cable (pull) nut 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Throttle cable (return) nut 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
  • Page 65 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Segment 30 Nm (3.0 m·kgf, 22 ft·lbf) Impeller 14 Nm (1.4 m·kgf, 10 ft·lbf) Water pump housing cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Coolant drain bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Clutch cable holder bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Radiator hose clamp screw...

  • Page 66: Chassis Tightening Torques

    TIGHTENING TORQUES EAS1DX3071 CHASSIS TIGHTENING TORQUES - marked portion shall be checked for torque tightening after break-in. Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (upper side) 45 Nm (4.5 m·kgf, 33 ft·lbf) Engine mounting nut (front lower 53 Nm (5.3 m·kgf, 38 ft·lbf) side) Engine mounting nut (rear lower...
  • Page 67 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Air scoop and fuel tank 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Catch tank bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Pivot shaft nut 85 Nm (8.5 m·kgf, 61 ft·lbf) Rear shock absorber assembly —...
  • Page 68 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Start switch screw 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf) Engine stop switch screw 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf) Clutch cable lock 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Clutch lever nut 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Front brake lever pivot bolt 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
  • Page 69 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear brake caliper support bolt 17 Nm (1.7 m·kgf, 12 ft·lbf) Drive chain tensioner bolt (upper, 16 Nm (1.6 m·kgf, 12 ft·lbf) lower) Drive chain adjuster locknut 19 Nm (1.9 m·kgf, 14 ft·lbf) Front fork protector bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Seat bolt...

  • Page 70: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant types Oil seal lips O-rings Bearings Camshaft cap bolt threads Cylinder head bolt threads, seats Camshaft profile, journal Decompression system moving parts Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Valve lifter surface Crank assembly (crankshaft pin surface)
  • Page 71 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant types Shift cam Clutch boss nut threads Three Bond Cylinder head cover gasket No.TB1541C® Yamaha bond Cylinder head semicircular surface No.1215 (Three Bond No.1215®) Yamaha bond Crankcase mating surface No.1215 (Three Bond No.1215®)

  • Page 72: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES EAS1DX3072 CHASSIS Lubrication point Lubricant types Upper bearings and oil seal lip (steering head) Lower bearings and oil seal lip (steering head) Steering shaft and nut thread Handle lower holder threads Front wheel oil seal (left/right) Rear wheel oil seal (left/right) Brake pedal pivoting point and bolt Throttle cable end and throttle grip...
  • Page 73 LUBRICATION POINTS AND LUBRICANT TYPES 2-24...

  • Page 74: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-25...
  • Page 75 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter element 2. Oil pump 3. Drive axle 4. Main axle 5. Crankshaft 6. Connecting rod A. From cylinder B. To oil tank 2-26...
  • Page 76 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
  • Page 77 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft A. To main axle B. From oil pump 2-28...

  • Page 78: Cable Routing

    CABLE ROUTING EAS1DX3073 CABLE ROUTING 2-29...
  • Page 79 CABLE ROUTING 1. Protector 2. Main harness 3. Intake air pressure sensor coupler 4. Throttle position sensor coupler 5. Connecting arm 6. Catch tank breather hose 7. Condenser 8. Starter motor lead 9. Coolant temperature sensor lead 10. Neutral switch lead 11.
  • Page 80 CABLE ROUTING 2-31...
  • Page 81 CABLE ROUTING 1. Main harness 2. Coupler for connecting optional part 3. Taillight coupler 4. Injector coupler 5. Clutch cable 6. Catch tank breather hose 7. Air cleaner joint 8. Starter motor lead 9. Negative lead 10. Throttle position sensor coupler 11.
  • Page 82 CABLE ROUTING 2-33...
  • Page 83 CABLE ROUTING 1. Throttle cable 2. Clutch cable 3. Radiator breather hose 4. Condenser 5. Main harness 6. Right handlebar switch coupler A. Pass the right handlebar switch lead through the upper cable guide. B. Pass the throttle cable and clutch cable through the lower cable guide.
  • Page 84 CABLE ROUTING 2-35...
  • Page 85 CABLE ROUTING V. Connect the neutral switch coupler (1P) to the 1. Lean angle sensor main harness. 2. Right handlebar switch coupler W. Connect the regulator coupler (3P) to the AC 3. Fuel sender coupler magneto lead. 4. Fuel pump coupler X.
  • Page 86 CABLE ROUTING 2-37...
  • Page 87 CABLE ROUTING 1. Clutch cable 2. Hose guide 3. Engine trouble warning light coupler 4. Auxiliary light lead 5. Clutch switch coupler 6. Engine stop switch coupler 7. Main harness 8. Resistor coupler 9. Headlight coupler 10. Brake hose 11. Auxiliary light coupler 12.
  • Page 88 CABLE ROUTING 2-39...
  • Page 89 CABLE ROUTING 1. Brake master cylinder 2. Brake hose holder 3. Brake hose A. Install the brake hose so that its pipe portion di- rects as shown and lightly touches the projection on the brake caliper. B. Pass the brake hose into the brake hose holders. C.
  • Page 90 CABLE ROUTING 2-41...

  • Page 91: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM..................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ......3-1 MAINTENANCE INTERVALS FOR COMPETITION USE......3-3 CHECKING THE FUEL LINE ..............3-6 CHECKING THE SPARK PLUG..............3-6 ADJUSTING THE VALVE CLEARANCE............3-7 CLEANING THE AIR FILTER ELEMENT...........3-9 CHECKING THE BREATHER HOSES ............3-10 ADJUSTING THE ENGINE IDLING SPEED ..........3-11...

  • Page 92: Periodic Maintenance

    • From 4200 mi (7000 km) or 9 months, repeat the maintenance intervals starting from 1800 mi (3000 km) or 3 months. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 93 • Replace if necessary. Rear suspension • Apply molybdenum disulfide grease lightly. link pivots • Apply Yamaha chain and cable lube or engine oil Control cables 10W-30 thoroughly. Throttle grip • Check operation and free play. housing and ca- •...

  • Page 94: Maintenance Intervals For Competition Use

    If you are a doubt as to what intervals to follow in main- taining and lubricating your machine, consult your Yamaha dealer. Every...
  • Page 95 PERIODIC MAINTENANCE Every Every After Every fifth (or As re- ITEM third (or Remarks break-in race 1,000 quired 500 km) Replace bearing SHIFT FORK, SHIFT CAM, Inspect wear. GUIDE BAR Inspect ROTOR NUT Retighten MUFFLER Inspect and retighten Clean Replace CRANK Inspect and clean THROTTLE BODY...
  • Page 96 TIRE, WHEELS Inspect air pressure, wheel run-out, tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate Lithium base grease THROTTLE, CONTROL CA- Check routing and con- Yamaha cable lube or nection Lubricate SAE 10W-30 motor oil...

  • Page 97: Checking The Fuel Line

    PERIODIC MAINTENANCE EAS1DX3079 CHECKING THE FUEL LINE The following procedure applies to all of the fu- el, vacuum and breather hoses. 1. Remove: • Seat • Side cover (left/right) • Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 5- •...

  • Page 98: Adjusting The Valve Clearance

    PERIODIC MAINTENANCE 7. Install: 4. Measure: • Spark plug • Valve clearance Out of specification Adjust. Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf) Valve clearance (cold) Intake 0.10–0.15 mm (0.0039–0.0059 in) Exhaust Before installing the spark plug, clean the spark 0.20–0.25 mm (0.0079–0.0098 in) plug and gasket surface.
  • Page 99 PERIODIC MAINTENANCE c. Select the proper valve pad from the follow- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ing table. 5. Adjust: • Valve clearance Valve pad range Nos. 120–240 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Valve pad thickness 1.20–2.40 mm a. Remove: (0.047–0.094 in) • Cam chain tensioner Available valve pads 25 thicknesses in •...

  • Page 100: Cleaning The Air Filter Element

    PERIODIC MAINTENANCE • Install the valve lifter and the valve pad in the correct place. e. Install the exhaust and intake camshafts, timing chain and the camshaft caps. Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Refer to “CAMSHAFT” on page 6-7 3.

  • Page 101: Checking The Breather Hoses

    PERIODIC MAINTENANCE 6. Check: • Air filter element Damage Replace. 7. Apply the recommended oil to the entire sur- face of the air filter element and squeeze out the excess oil. The air filter element should be wet but not dripping. Recommended oil grade API service SG type or higher, JASO standard MA...

  • Page 102: Adjusting The Engine Idling Speed

    PERIODIC MAINTENANCE 3. Install: Oil temperature • Fuel tank 70–80 °C (158–176 °F) Refer to “FUEL TANK” on page 8-1. • Air scoop (left/right) 3. Install: • Side cover (left/right) • Digital tachometer • Seat (Ignition coil lead) Refer to “GENERAL CHASSIS” on page 5- Digital tachometer 90890-06760 YU-39951-B...

  • Page 103: Checking The Exhaust System

    PERIODIC MAINTENANCE 6. Adjust: 4. Install: • Throttle grip free play • Exhaust pipe protector Refer to “ADJUSTING THE THROTTLE Exhaust pipe protector screw GRIP FREE PLAY” on page 3-29. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® Throttle grip free play 3.0–5.0 mm (0.12–0.20 in) EAS1DX3086 CHECKING THE ENGINE OIL LEVEL...

  • Page 104: Changing The Engine Oil

    PERIODIC MAINTENANCE 5. Start the engine and let it warm up for sever- al minutes. ECA1DX1003 NOTICE When the oil tank is empty, never start the engine. 6. Idle the engine more than 10 seconds while keeping the machine upright. Then stop the engine and add the oil to the maximum level.
  • Page 105 PERIODIC MAINTENANCE 6. Fill: • Engine oil Engine oil quantity Without oil filter element replace- ment 0.95 L (1.00 US qt, 0.84 Imp qt) With oil filter element replace- ment 1.00 L (1.06 US qt, 0.88 Imp qt) Quantity (disassembled) 1.20 L (1.27 US qt, 1.06 Imp qt) 4.

  • Page 106: Adjusting The Clutch Lever Free Play

    PERIODIC MAINTENANCE c. Turn the adjusting bolt “2” in direction “a” or EAS1DX3088 ADJUSTING THE CLUTCH LEVER FREE “b” until the specified clutch lever free play is PLAY obtained. 1. Check: • Clutch lever free play “a” Direction “a” Out of specification Adjust.

  • Page 107: Checking The Cooling System

    PERIODIC MAINTENANCE 2. Check: • Radiator • Radiator hose Cracks/damage Replace. Refer to “RADIATOR” on page 7-1. 3. Install: • Fuel tank Refer to “FUEL TANK” on page 8-1. • Air scoop (left/right) • Seat Refer to “GENERAL CHASSIS” on page 5- 3.

  • Page 108: Cleaning The Spark Arrester

    PERIODIC MAINTENANCE 5. Clean: 9. Install: • Cooling system • Radiator cap Thoroughly flush the cooling system with 10.Start the engine, warm it up for several min- clean tap water. utes, and then stop it. 6. Install: 11.Check: • Copper washer •...

  • Page 109: Adjusting The Front Disc Brake

    PERIODIC MAINTENANCE EWA13090 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ WARNING a. Loosen the locknut “1”. • Use only the designated brake fluid. Other b. Turn the adjusting bolt “2” in direction “a” or brake fluids may cause the rubber seals to “b” until the specified brake lever position is deteriorate, causing leakage and poor obtained.

  • Page 110: Adjusting The Rear Disc Brake

    PERIODIC MAINTENANCE c. Tighten the locknut. EWA1DX1001 WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system.

  • Page 111: Bleeding The Hydraulic Brake System

    PERIODIC MAINTENANCE EAS1DX3099 BLEEDING THE HYDRAULIC BRAKE SYS- EWA13100 WARNING Bleed the hydraulic brake system whenev- • the system is disassembled. • a brake hose is loosened, disconnected or replaced. A. Front • the brake fluid level is very low. B.

  • Page 112: Checking The Front Brake Hose

    PERIODIC MAINTENANCE EAS1DX3100 EAS1DX3102 CHECKING THE FRONT BRAKE HOSE CHECKING THE WHEELS 1. Check: The following procedure applies to both of the • Brake hose “1” wheels. Cracks/damage/wear Replace. 1. Check: • Wheel Damage/out-of-round Replace. EWA13260 WARNING Never attempt to make any repairs to the wheel.

  • Page 113: Checking The Tires

    Yamaha dealer, who has the nec- • The tire air pressure must be adjusted in essary professional knowledge and expe- accordance with the weight of the rider, rience.

  • Page 114: Checking The Wheel Bearings

    PERIODIC MAINTENANCE EAS1DX3105 CHECKING THE WHEEL BEARINGS The following procedure applies to all of the wheel bearings. 1. Check: • Wheel bearings Refer to “CHECKING THE FRONT WHEEL” on page 5-6 and “CHECKING THE REAR WHEEL” on page 5-11. EAS1DX3106 CHECKING THE SWINGARM OPERATION 1.

  • Page 115: Lubricating The Drive Chain

    PERIODIC MAINTENANCE e. Tighten the wheel axle nut. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the collar “1” and the washer “2”. Wheel axle nut 125 Nm (12.5 m·kgf, 90 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS1DX3108 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts.

  • Page 116: Lubricating The Levers

    PERIODIC MAINTENANCE e. Check the steering head for looseness or EAS1DX3113 CHECKING THE FRONT FORK binding by turning the front fork all the way in 1. Stand the vehicle on a level surface. both directions. If any binding is felt, remove EWA13120 the lower bracket and check the upper and WARNING...

  • Page 117: Air Bleeding From Front Fork

    PERIODIC MAINTENANCE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Compression damping a. Turn the adjusting screw “1” in direction “a” Maximum (hard) or “b”. Fully turned in Standard Direction “a” 14 click (s) out* Rebound damping is increased (sus- Minimum pension is harder). 20 click (s) out* Direction “b”...

  • Page 118: Checking The Rear Suspension

    PERIODIC MAINTENANCE 1. Remove: • Rear frame Refer to “REAR SHOCK ABSORBER AS- SEMBLY” on page 5-61. 2. Adjust: • Spring preload ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. b. Loosen the adjusting ring “2” until there is some clearance between the spring and ad- 3.
  • Page 119 PERIODIC MAINTENANCE Rebound damping adjusting posi- tions Maximum Fully turned in Standard 18 click (s) out* Minimum 30 click (s) out* * With the adjusting screw fully turned in e. Tighten the locknut. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Locknut Compression damping (for fast compres- 30 Nm (3.0 m·kgf, 22 ft·lbf) sion damping) ECA13590...

  • Page 120: Checking The Connecting Arm And Relay Arm

    PERIODIC MAINTENANCE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping (for slow compres- EAS1DX3118 CHECKING THE CONNECTING ARM AND sion damping) RELAY ARM ECA13590 Refer to “CHECKING THE CONNECTING NOTICE ARM AND RELAY ARM” on page 5-65. Never go beyond the maximum or minimum adjustment positions.

  • Page 121: Checking The Chassis Fasteners

    PERIODIC MAINTENANCE 1. Check: EAS1DX3121 CHECKING THE CHASSIS FASTENERS • Throttle grip free play “a” Make sure that all nuts, bolts, and screws are Out of specification Adjust. properly tightened. Refer to “CHASSIS TIGHTENING TORQUES” on page 2-17. EAS1DX3122 CHECKING AND CHARGING THE BATTERY Refer to “CHECKING AND CHARGING THE BATTERY”...
  • Page 122 PERIODIC MAINTENANCE 3-31...

  • Page 123: Tuning

    TUNING CHASSIS ......................4-1 SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET) 4-1 DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS....4-1 TIRE PRESSURE..................4-1 FRONT FORK SETTING................4-2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL ....4-2 SETTING OF SPRING AFTER REPLACEMENT........4-2 FRONT FORK SETTING PARTS...............4-3 REAR SUSPENSION SETTING..............4-3 CHOOSING SET LENGTH.................4-3 SETTING OF SPRING AFTER REPLACEMENT........4-4...

  • Page 124: Chassis

    CHASSIS EAS1DX3124 EAS1DX3126 CHASSIS DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS Part name Size Part number EAS1DX3125 SELECTION OF THE SECONDARY REDUC- Drive sprocket "1" TION RATIO (SPROCKET) (STD) 13T 9383E-13233 Secondary reduction ratio = Number of rear wheel sprocket teeth/Number of Rear wheel drive sprocket teeth sprocket "2"...

  • Page 125: Front Fork Setting

    CHASSIS • Under a stony or hard road condition, the tire pressure should be higher to prevent a flat tire. Extent of adjustment: 100–120 kPa (1.0–1.2 kgf/ ,15–18 psi) EAS1DX3128 FRONT FORK SETTING The front fork setting should be made depend- ing on the rider's feeling of an actual run and the circuit conditions.

  • Page 126: Front Fork Setting Parts

    CHASSIS Generally a stiff spring gives a stiff riding feel- ing. Rebound damping tends to become weak- er, resulting in lack of a sense of contact with the road surface or in a vibrating handlebar. EAS1DX3131 FRONT FORK SETTING PARTS •...

  • Page 127: Setting Of Spring After Replacement

    CHASSIS 2. Remove the stand or block from the engine EAS1DX3134 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 128: Rear Shock Absorber Setting Parts

    CHASSIS EAS1DX3135 REAR SHOCK ABSORBER SETTING PARTS • Rear shock spring "1" SPRING SPRING PART I.D. TYPE RATE NUMBER MARK [N/mm] (-22212-) Q’TY SOFT 1DX-10(Blue) Yellow 1DX-20(Blue) Pink STIFF 1DX-30(Blue) White • The I.D. mark "a" is marked at the end of the spring.

  • Page 129: Suspension Setting (Front Fork)

    CHASSIS EAS1DX3136 SUSPENSION SETTING (FRONT FORK) • 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 130 CHASSIS Section Medi- Symptom Check Adjust Large Small Jump Compression Turn adjuster clockwise (about damping 2 clicks) to increase damping. Rebound Turn adjuster counterclock- damping wise (about 2 clicks) to de- crease damping. Low front, tend- ing to lower Balance with Set sunken length for 95–100 front posture rear end...

  • Page 131: Suspension Setting (Rear Shock Absorber)

    CHASSIS EAS1DX3137 SUSPENSION SETTING (REAR SHOCK ABSORBER) • If any of the following symptoms is experienced with the standard position as the base, make reset- ting by reference to the adjustment procedure given in the same chart. • Adjust the rebound damping in 2-click increments or decrements. •...
  • Page 132 CHASSIS Section Medi- Symptom Check Adjust Large Small Jump Turn adjuster counterclock- High compres- wise (about 1/6 turn) to de- sion damping crease damping. Stiff travel Spring set Set sunken length for 90–100 length mm (3.5–3.9 in) when one passenger is astride seat. Spring Replace with soft spring.
  • Page 133 CHASSIS GENERAL CHASSIS..................5-1 REMOVING THE SIDE COVER..............5-4 FRONT WHEEL ....................5-5 REMOVING THE FRONT WHEEL.............5-6 CHECKING THE FRONT WHEEL .............5-6 DISASSEMBLING THE FRONT WHEEL ...........5-7 ASSEMBLING THE FRONT WHEEL ............5-7 INSTALLING THE FRONT WHEEL (DISC) ..........5-8 REAR WHEEL ....................5-10 REMOVING THE REAR WHEEL .............5-11 CHECKING THE REAR WHEEL..............5-11 DISASSEMBLING THE REAR WHEEL ...........5-11 CHECKING AND REPLACING THE REAR WHEEL SPROCKET...5-11...
  • Page 134 HANDLEBAR....................5-38 REMOVING THE HANDLEBAR ...............5-39 CHECKING THE HANDLEBAR..............5-39 INSTALLING THE HANDLEBAR..............5-39 FRONT FORK....................5-44 REMOVING THE FRONT FORK LEGS ...........5-47 DISASSEMBLING THE FRONT FORK LEGS .........5-47 CHECKING THE FRONT FORK LEGS............5-48 ASSEMBLING THE FRONT FORK LEGS ..........5-49 INSTALLING THE FRONT FORK LEGS..........5-55 STEERING HEAD...................5-58 REMOVING THE LOWER BRACKET............5-59 CHECKING THE STEERING HEAD ............5-59...
  • Page 135 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 136 GENERAL CHASSIS Removing the headlight assembly, multi-function meter and front fender Order Job/Parts to remove Q’ty Remarks Handlebar Refer to“HANDLEBAR” on page 5-38. Front fork legs Refer to“FRONT FORK” on page 5-44. Headlight body Headlight unit Headlight coupler Disconnect. Auxiliary light coupler Disconnect.
  • Page 137 GENERAL CHASSIS Removing the headlight assembly, multi-function meter and front fender 11 12 Order Job/Parts to remove Q’ty Remarks Clutch switch coupler Disconnect. Engine stop switch coupler Disconnect. Resistor coupler Disconnect. Main harness Multi-function meter bracket Front fender For installation, reverse the removal proce- dure.

  • Page 138: General Chassis

    GENERAL CHASSIS EAS1DX3139 REMOVING THE SIDE COVER 1. Remove: • Bolt (side cover) • Right side cover “1” Draw the side cover backward to remove it be- cause its projection “a” is inserted in the air filter case.
  • Page 139 FRONT WHEEL EAS1DX3140 FRONT WHEEL Removing the front wheel 21 Nm (2.1 m kgf, 15 ft lbf) 21 Nm (2.1 m kgf, 15 ft lbf) 90 Nm (9.0 m kgf, 65 ft lbf) 12 Nm (1.2 m kgf, 8.7 ft lbf) Order Job/Parts to remove Q’ty...

  • Page 140: Front Wheel

    FRONT WHEEL EAS21890 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the front wheel is elevated.

  • Page 141: Disassembling The Front Wheel

    FRONT WHEEL EAS21960 ASSEMBLING THE FRONT WHEEL 1. Install: • Bearing (left side) “1” • Spacer “2” • Bearing (right side) “3” • Oil seal “4” • Apply the lithium soap base grease on the bearing and oil seal lip when installing. •...

  • Page 142: Installing The Front Wheel (Disc)

    FRONT WHEEL 4. Install • Speed sensor “1” Apply the lithium soap base grease on the oil seal lip of speed sensor. Make sure the two projections “a” in the wheel hub are meshed with the two slots “b” in the speed sensor.
  • Page 143 FRONT WHEEL 2. Install: • Wheel axle “1” Apply the lithium soap base grease on the wheel axle. 3. Install: • Wheel axle nut “1” Front wheel axle nut 90 Nm (9.0 m·kgf, 65 ft·lbf) ECA14140 NOTICE Before tightening the wheel axle nut, push down hard on the handlebar(s) several times and check if the front fork rebounds smoothly.
  • Page 144 REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel 14 Nm (1.4 m kgf, 10 ft lbf) 125 Nm (12.5 m kgf, 90 ft lbf) 19 Nm (1.9 m kgf, 13 ft lbf) 50 Nm (5.0 m kgf, 36 ft lbf) 19 Nm (1.9 m kgf, 13 ft lbf) Order Job/Parts to remove...

  • Page 145: Rear Wheel

    REAR WHEEL 2. Check: EAS22040 REMOVING THE REAR WHEEL • Tire 1. Stand the vehicle on a level surface. • Rear wheel EWA13120 Damage/wear Replace. WARNING Refer to “CHECKING THE TIRES” on page Securely support the vehicle so that there is 3-22 and “CHECKING THE WHEELS”...

  • Page 146: Assembling The Rear Wheel

    REAR WHEEL 2. Replace: • Rear wheel sprocket ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the self-locking nuts and the rear wheel sprocket. b. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the sprocket. c. Install the new rear wheel sprocket. Rear wheel sprocket self-locking 50 Nm (5.0 m·kgf, 36 ft·lbf) Tighten the self-locking nuts in stages and in a...

  • Page 147: Installing The Rear Wheel (Disc)

    REAR WHEEL 4. Install 3. Install: • Collar “1” • Left drive chain puller “1” • Wheel axle “2” Apply the lithium soap base grease on the oil seal lip. • Install the left drive chain puller, and insert the wheel axle from left side.
  • Page 148 REAR WHEEL 5. Adjust: • Drive chain slack “a” Drive chain slack 48.0–58.0 mm (1.89– 2.28 in) Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-23. 6. Tighten: • Wheel axle nut “1” Wheel axle nut 125 Nm (12.5 m·kgf, 90 ft·lbf) •...
  • Page 149 FRONT BRAKE EAS1DX3144 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty Remarks Brake pad pin plug Brake pad pin Front brake caliper assembly Brake pad Brake pad spring For installation, reverse the removal proce- dure. 5-15...
  • Page 150 FRONT BRAKE Removing the front brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) 6 Nm (0.6 m kgf, 4.3 ft Ibf) 6 Nm (0.6 m kgf, 4.3 ft Ibf) 30 Nm (3.0 m kgf, 22 ft Ibf) Order Job/Parts to remove Q’ty...

  • Page 151: Front Brake

    FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Master cylinder kit For assembly, reverse the disassembly pro- cedure. 5-17...
  • Page 152 FRONT BRAKE Removing the front brake caliper Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-20. Union bolt Copper washer Front brake hose Brake pad pin plug Brake pad pin Brake pad Brake pad spring Front brake caliper assembly...
  • Page 153 FRONT BRAKE Disassembling the front brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.

  • Page 154: Introduction

    FRONT BRAKE EAS22220 INTRODUCTION ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Place the vehicle on a suitable stand so that EWA14100 the front wheel is elevated. WARNING b. Before measuring the front brake disc de- Disc brake components rarely require dis- flection, turn the handlebar to the left or right assembly.

  • Page 155: Replacing The Front Brake Pads

    FRONT BRAKE 2. Install: Brake disc bolt • Brake pads 12 Nm (1.2 m·kgf, 8.7 ft·lbf) • Pad support LOCTITE® d. Measure the brake disc deflection. Always install new brake pads, and a pad sup- e. If out of specification, repeat the adjustment port as a set.

  • Page 156: Removing The Front Brake Caliper

    FRONT BRAKE 4. Check: • Brake fluid level Below the minimum level mark “a” the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-17. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Blow compressed air into the brake hose joint opening to force out the pistons from the brake caliper.

  • Page 157: Assembling The Front Brake Caliper

    FRONT BRAKE • Brake caliper cylinders “2” • Union bolt Scratches/wear Replace the brake cali- Front brake caliper bracket per assembly. 23 Nm (2.3 m·kgf, 17 ft·lbf) • Brake caliper body “3” Brake hose union bolt Cracks/damage Replace the brake cali- 30 Nm (3.0 m·kgf, 22 ft·lbf) per assembly.

  • Page 158: Removing The Front Brake Master Cylinder

    FRONT BRAKE • Refill with the same type of brake fluid that EAS22500 CHECKING THE FRONT BRAKE MASTER is already in the system. Mixing brake flu- CYLINDER ids may result in a harmful chemical reac- 1. Check: tion, leading to poor brake performance. •...

  • Page 159: Installing The Front Brake Master Cylinder

    FRONT BRAKE EAS1DX3148 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Brake master cylinder “1” Brake master cylinder holder bolt 9 Nm (0.9 m·kgf, 6.5 ft·lbf) • Install the brake master cylinder holder with 3. Fill: the “UP” mark facing up. •...
  • Page 160 FRONT BRAKE • Brake lever operation Soft or spongy feeling Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-20. 5-26...
  • Page 161 REAR BRAKE EAS1DX3149 REAR BRAKE Removing the rear brake pads 17 Nm (1.7 m kgf, 12 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty...
  • Page 162 REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-20. Union bolt Copper washer 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 163: Rear Brake

    REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Master cylinder kit For assembly, reverse the disassembly pro- cedure. 5-29...
  • Page 164 REAR BRAKE 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 165 REAR BRAKE Disassembling the rear brake calipers 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.

  • Page 166: Introduction

    REAR BRAKE EAS22560 INTRODUCTION EWA14100 Brake disc thickness limit WARNING 3.5 mm (0.14 in) Disc brake components rarely require dis- assembly. Therefore, always follow these 5. Adjust: preventive measures: • Brake disc deflection • Never disassemble brake components un- Refer to “CHECKING THE FRONT BRAKE less absolutely necessary.

  • Page 167: Removing The Rear Brake Caliper

    REAR BRAKE Always install new brake pads, brake pad shims, and a brake pad spring as a set. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. 5.

  • Page 168: Checking The Rear Brake Caliper

    REAR BRAKE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Blow compressed air into the brake hose joint opening to force out the piston from the brake caliper. EWA13550 WARNING • Cover the brake caliper piston with a rag. Be careful not to get injured when the pis- ton is expelled from the brake caliper.

  • Page 169: Removing The Rear Brake Master Cylinder

    REAR BRAKE ECA14170 ECA13540 NOTICE NOTICE Install the brake hose so that its pipe por- Brake fluid may damage painted surfaces tion “a” directs as shown and lightly touch- and plastic parts. Therefore, always clean es the projection “b” on the brake caliper. up any spilt brake fluid immediately.

  • Page 170: Checking The Rear Brake Master Cylinder

    REAR BRAKE 1. Install: EAS22710 CHECKING THE REAR BRAKE MASTER • Cylinder cup CYLINDER • Master cylinder piston 1. Check: 2. Install: • Brake master cylinder “1” • Spring “1” Damage/scratches/wear Replace. • Master cylinder piston “2” • Brake fluid delivery passages “2” •...
  • Page 171 REAR BRAKE 2. Fill: • Brake fluid reservoir Recommended fluid DOT 4 EWA13090 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system.
  • Page 172 HANDLEBAR EAS1DX3154 HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty Remarks Front brake master cylinder holder Front brake master cylinder assembly Throttle cable housing Throttle cable Disconnect. Throttle grip Start switch Clutch cable Disconnect. Clutch switch Disconnect. Clutch lever holder Clutch lever Engine stop switch Handlebar grip...

  • Page 173: Handlebar

    HANDLEBAR EAS1DX3155 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Clutch switch “1” EAS22880 CHECKING THE HANDLEBAR 1. Check: •...
  • Page 174 HANDLEBAR ECA14250 NOTICE • First, tighten the bolts on the front side of the upper handlebar holder, and then on the rear side. • Turn the handlebar all the way to the left and right. If there is any contact with the fuel tank, adjust the handlebar position.
  • Page 175 HANDLEBAR ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: • Engine stop switch “1” • Clutch lever “2” • Clutch lever holder “3” • Clamp “4” Engine stop switch screw 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf) Clutch lever holder bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) 7.
  • Page 176 HANDLEBAR 9. Install: 11.Install: • Throttle cable housings "1" • Start switch "1" • Screw (throttle cable housings) "2" • Front brake master cylinder assembly "2" • Front brake master cylinder holder "3" Screw (throttle cable housings) • Bolt (brake master cylinder holder) "4" 3.8 Nm (0.38 m·kg, 2.8 ft·lb) Front brake master cylinder hold- EWA1DX5001...
  • Page 177 HANDLEBAR 12.Adjust: • Clutch cable free play Refer to “ADJUSTING THE CLUTCH LE- VER FREE PLAY” on page 3-15. Clutch lever free play 8.0–13.0 mm (0.31–0.51 in) 13.Adjust: • Throttle grip free play Refer to “ADJUSTING THE THROTTLE GRIP FREE PLAY” on page 3-29. Throttle grip free play 3.0–5.0 mm (0.12–0.20 in) 5-43...
  • Page 178 FRONT FORK EAS1DX3157 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Front wheel Refer to“FRONT WHEEL” on page 5-5. Front brake caliper Refer to“FRONT BRAKE” on page 5-15. Brake hose holder Front fork protector Upper bracket pinch bolt...
  • Page 179 FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Adjuster Copper washer O-ring Damper adjusting rod Fork spring Collar Dust seal Oil seal clip Inner tube Outer tube Inner tube bushing Front fork protector guide...
  • Page 180 FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks Base valve Base valve bushing O-ring Air bleed screw O-ring Damper assembly O-ring For assembly, reverse the disassembly pro- cedure. 5-46...

  • Page 181: Front Fork

    FRONT FORK 3. Remove: EAS22970 REMOVING THE FRONT FORK LEGS • Front fork leg The following procedure applies to both of the front fork legs. EAS22980 DISASSEMBLING THE FRONT FORK LEGS 1. Stand the vehicle on a level surface. The following procedure applies to both of the EWA13120 WARNING front fork legs.

  • Page 182: Checking The Front Fork Legs

    FRONT FORK 4. Remove: • Inner tube “1” EAS23010 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the front fork leg horizontally. front fork legs. b. Securely clamp the brake caliper bracket in 1.

  • Page 183: Assembling The Front Fork Legs

    FRONT FORK 3. Measure: • Air bleed screw “5” • Fork spring free length “a” Wear/damage Replace. Out of specification Replace. Fork spring free length 454.0 mm (17.87 in) Limit 449.0 mm (17.68 in) 6. Check: • Contacting surface “a” Wear/damage Replace.
  • Page 184 FRONT FORK 4. Measure: • Oil level (left and right) “a” • When assembling the front fork leg, be sure to Out of specification Adjust. replace the following parts: –Inner tube bushing Standard oil level –Outer tube bushing 145–148 mm (5.71–5.83 in) –Oil seal From top of fully stretched damper assembly.
  • Page 185 FRONT FORK 7. Check: 10.While protecting the damper assembly “1” • Damper assembly with a rag and compressing fully, allow ex- Not fully stretched Repeat the steps 1 to cessive oil to overflow on the base valve side. 8. Tighten: ECA32D1010 NOTICE •...
  • Page 186 FRONT FORK 13.Install: 15.Install: • Dust seal “1” • Outer tube “1” • Oil seal clip “2” (to the inner tube “2”) • Oil seal “3” • Washer “4” • Outer tube bushing “5” (to the inner tube “6”) ECA32D1010 NOTICE Make sure the numbered side of the oil seal faces bottom side.
  • Page 187 FRONT FORK 17.Install: 20.Check: • Oil seal “1” • Inner tube smooth movement Tightness/binding/rough spots Repeat the steps 13 to 19. Press the oil seal into the outer tube with fork seal driver “2”. Fork seal driver 90890-01502 Fork seal driver(48) YM-A0948 21.Measure: •...
  • Page 188 FRONT FORK 23.Install: 25.Inspect: • Damper assembly “1” • Gap “a” between the adjuster “1” and lock- (to the inner tube “2”) nut “2”. Out of specification Retighten and read- ECA32D1010 NOTICE just the locknut. Allow the damper assembly to slide slowly Gap “a”...

  • Page 189: Installing The Front Fork Legs

    FRONT FORK 27.Install: • Adjuster “1” Temporarily tighten the damper assembly. (to the inner tube) Adjuster 55 Nm (5.5 m·kgf, 40 ft·lbf) LOCTITE® 30.Install: • Fork protector guide “1” 28.Fill: • Front fork leg (with the specified amount of the recom- mended fork oil) Recommended oil Suspension oil S1...
  • Page 190 FRONT FORK 2. Tighten: • Lower bracket pinch bolt “1” Lower bracket pinch bolt 21 Nm (2.1 m·kgf, 15 ft·lbf) EWA1DX1005 WARNING Tighten the lower bracket pinch bolt to specified torque. If torqued too much, it may cause the front fork to malfunction. 5.
  • Page 191 FRONT FORK 7. Adjust: • Rebound damping • Compression damping Refer to “ADJUSTING THE FRONT FORK LEGS” on page 3-25. 5-57...
  • Page 192 STEERING HEAD EAS1DX3159 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Headlight assembly / multi-function meter / front Refer to“GENERAL CHASSIS” on page 5-1. fender Reflector For Canada Steering stem nut Upper bracket Collar Washer Ring nut Lower bracket Bearing cover Upper bearing...

  • Page 193: Steering Head

    STEERING HEAD EAS23110 ECA14270 REMOVING THE LOWER BRACKET NOTICE 1. Stand the vehicle on a level surface. • Take care not to damage the steering shaft EWA13120 thread. WARNING • If the bearing race is not installed properly, Securely support the vehicle so that there is the steering head pipe could be damaged.
  • Page 194 STEERING HEAD • Install the ring nut with its stepped side “a” fac- ing downward. • Apply lithium-soap-based grease on the por- tion “b” and thread of the steering stem. 6. Install: • Speed sensor lead holder “1” • Speed sensor lead clamp “2” Speed sensor lead holder bolt 13 Nm (1.3 m·kgf, 9.4 ft·lbf) Speed sensor lead clamp bolt...
  • Page 195 REAR SHOCK ABSORBER ASSEMBLY EAS1DX3161 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Seat/Side cover Refer to“GENERAL CHASSIS” on page 5-1. Silencer Refer to“ENGINE REMOVAL” on page 6-1. Fuel tank bracket pin Refer to“FUEL TANK”...
  • Page 196 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Spring Dust seal Collar Bushing Collar O-ring Dust seal Stopper ring Bearing For installation, reverse the removal proce- dure. 5-62...
  • Page 197 REAR SHOCK ABSORBER ASSEMBLY Disassembling the relay arm 80 Nm (8.0 m kgf, 58 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Relay arm Connecting arm Collar Oil seal Washer Bearing For assembly, reverse the disassembly pro- cedure. 5-63...

  • Page 198: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23180 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that the EWA13740 WARNING rear wheel is elevated. This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling • Rear frame upper bolt the rear shock absorber, read and make 3.

  • Page 199: Checking The Connecting Arm And Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY • Rear shock absorber Gas leaks/oil leaks Replace the rear shock absorber assembly. • Spring Damage/wear Replace. • Spring guide Damage/wear Replace. • Bearings Damage/wear Replace. • Bolts Bends/damage/wear Replace. EAS23260 CHECKING THE CONNECTING ARM AND RELAY ARM 1.
  • Page 200 REAR SHOCK ABSORBER ASSEMBLY • Rear shock absorber assembly lower bolt ECA1DX1012 NOTICE Recommended lubricant Do not apply the grease on the bearing out- Lithium-soap-based grease er race because it will wear the rear shock absorber surface on which the bearing is 6.

  • Page 201: Swingarm

    SWINGARM EAS1DX3162 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to“REAR WHEEL” on page 5-10. Brake hose holder Brake pedal bolt Brake pedal Drive chain support cover Drive chain support Pivot shaft nut Pivot shaft Swingarm Drive chain guide Collar...
  • Page 202 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Oil seal Bearing For installation, reverse the removal proce- dure. 5-68...

  • Page 203: Removing The Swingarm

    SWINGARM EAS23350 REMOVING THE SWINGARM 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated. 2.

  • Page 204: Installing The Swingarm

    SWINGARM EAS1DX3163 INSTALLING THE SWINGARM 1. Lubricate: • Bearings • Collars • Spacers • Oil seals • Pivot shaft Recommended lubricant Lithium-soap-based grease 5. Install: 2. Install: • Rear wheel • Bearings “1” Refer to “REAR WHEEL” on page 5-10 •...

  • Page 205: Chain Drive

    CHAIN DRIVE EAS1DX3164 CHAIN DRIVE Removing the drive chain Order Job/Parts to remove Q’ty Remarks Drive sprocket Refer to“ENGINE REMOVAL” on page 6-1. Drive chain For installation, reverse the removal proce- dure. 5-71...

  • Page 206: Removing The Drive Chain

    CHAIN DRIVE EAS23420 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated.

  • Page 207: Checking The Drive Sprocket

    CHAIN DRIVE • Do not soak the drive chain in kerosene for EAS23460 CHECKING THE DRIVE SPROCKET more than ten minutes, otherwise the O- 1. Check: rings can be damaged. • Drive sprocket More than 1/4 tooth “a” wear Replace the drive chain sprockets as a set.
  • Page 208 CHAIN DRIVE b. After riveting, make sure the diameter be- 4. Adjust: tween the edges “b” of the connecting pin “2” • Drive chain slack is 5.5–5.8 mm (0.22–0.23 in). Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-23. Drive chain slack 48.0–58.0 mm (1.89–...

  • Page 209: Engine

    ENGINE ENGINE REMOVAL..................6-1 REMOVING THE ENGINE .................6-4 CLEANING THE SPARK ARRESTER ............6-4 INSTALLING THE ENGINE................6-5 INSTALLING THE EXHAUST PIPE AND MUFFLER .........6-5 INSTALLING THE SHIFT PEDAL ..............6-6 CAMSHAFT ......................6-7 REMOVING THE CAMSHAFT ..............6-9 CHECKING THE CAMSHAFT..............6-9 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET...6-11 CHECKING THE TIMING CHAIN TENSIONERS ........6-11 CHECKING THE DECOMPRESSION SYSTEM ........6-12 INSTALLING THE CAMSHAFTS .............6-12...
  • Page 210 CHECKING THE CLUTCH HOUSING .............6-40 CHECKING THE CLUTCH BOSS ............6-40 CHECKING THE PRESSURE PLATE .............6-40 CHECKING THE CLUTCH PUSH RODS..........6-40 CHECKING THE PRIMARY DRIVE GEAR ..........6-41 CHECKING THE PRIMARY DRIVEN GEAR ...........6-41 INSTALLING THE CLUTCH ..............6-41 KICKSTATER ....................6-44 REMOVING THE KICK SHAFT ASSEMBLY ...........6-45 CHECKING THE KICK SHAFT AND RATCHET WHEEL ......6-45 CHECKING THE KICK GEAR, KICK IDLE GEAR AND RATCHET WHEEL ..
  • Page 211 TRANSMISSION.....................6-70 CHECKING THE SHIFT FORKS..............6-71 CHECKING THE SHIFT DRUM ASSEMBLY ...........6-71 CHECKING THE TRANSMISSION ............6-71 INSTALLING THE TRANSMISSION ............6-72...
  • Page 212 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 213: Engine Removal

    ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Hold the machine by placing the suitable stand under the frame. Refer to“CHANGING THE ENGINE OIL” on Drain the engine oil. page 3-13. Seat Refer to“GENERAL CHASSIS” on page 5-1. Fuel tank Refer to“FUEL TANK”...
  • Page 214 ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Engine guard Neutral switch Drive chain sprocket cover Nut (drive sprocket) Lock washer Drive sprocket Clip Bolt (brake pedal) Brake pedal Upper engine bracket Lower engine bracket Front engine bracket Engine mounting bolt Pivot shaft Engine...

  • Page 215: Removing The Engine

    ENGINE REMOVAL EAS1DX3167 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.

  • Page 216: Installing The Engine

    ENGINE REMOVAL 6. Install: • muffler cap Apply the lithium-soap based grease on the piv- ot shaft. Muffler cap screw 5 Nm (0.5 m·kgf, 3.6 ft·lbf) First tighten the two screws “a” located horizon- tally apart, and then tighten the others. EAS23720 INSTALLING THE ENGINE 1.

  • Page 217: Installing The Shift Pedal

    ENGINE REMOVAL 2. Install: • Muffler clamp “1” Muffler clamp 16 Nm (1.6 m·kgf, 12 ft·lbf) • Gasket “2” • Muffler “3” • Washer “4” • Muffler bolt “5” Muffler bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) EAS32D1009 INSTALLING THE SHIFT PEDAL 1.

  • Page 218: Camshaft

    CAMSHAFT EAS23730 CAMSHAFT 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 Job/Parts to remove Q’ty Remarks Seat Refer to“GENERAL CHASSIS” on page 5-1 Fuel tank Refer to“FUEL TANK”...

  • Page 219: Removing The Camshaft

    CAMSHAFT REMOVING THE CAMSHAFT 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) •...

  • Page 220: Checking The Camshaft

    CAMSHAFT 4. Remove: EAS23800 REMOVING THE CAMSHAFT • Timing chain tensioner assembly 1. Remove: • Gasket • Timing mark accessing screw “1” 5. Remove: • Crankshaft end cover “2” • Camshaft cap bolts “1” • Camshaft cap “2” • Clip Remove the bolts (camshaft cap) in a criss- cross pattern, working from the outside in.
  • Page 221 CAMSHAFT 2. Measure: • Camshaft lobe dimensions “a” and “b” Out of specification Replace the cam- shaft. Camshaft lobe dimensions Intake A 30.100–30.200 mm (1.1850– 1.1890 in) Limit 30.000 mm (1.1811 in) Intake B 4. Measure: 22.450–22.550 mm (0.8839– • Camshaft-journal-to-camshaft-cap clear- 0.8878 in) ance Limit...

  • Page 222: Checking The Timing Chain And Camshaft Sprocket

    CAMSHAFT a. 1/4 tooth ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Correct 5. Measure: • Camshaft journal diameter “a” 1. Timing chain roller Out of specification Replace the cam- 2. Camshaft sprocket shaft. EAS23960 Within specification Replace the cylinder CHECKING THE TIMING CHAIN TENSION- head and the camshaft caps as a set. The following procedure applies to both of the Camshaft journal diameter timing chain tensioners.

  • Page 223: Checking The Decompression System

    CAMSHAFT EAS32D1001 CHECKING THE DECOMPRESSION SYS- 1. Check: • Decompression system ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check that the decompressor lever pin “1” projects from the camshaft. b. Check that the decompressor cam “2” moves smoothly. c. Fit the timing chain “3” onto both camshaft sprockets and install the camshafts on the cylinder head.
  • Page 224 CAMSHAFT c. Release the screwdriver, check the tension- er rod to come out and tighten the gasket “5” • Before installing the clips, cover the cylinder and the cap bolt “6” to the specified torque. head with a clean rag to prevent the clips from into the cylinder head cavity.

  • Page 225: Cylinder Head

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Seat Refer to“GENERAL CHASSIS” on page 5-1. Fuel tank Refer to“FUEL TANK” on page 8-1. Exhaust pipe and silencer Refer to“ENGINE REMOVAL” on page 6-1. Radiator Refer to“RADIATOR”...

  • Page 226: Removing The Cylinder Head

    CYLINDER HEAD EAS1DX3171 REMOVING THE CYLINDER HEAD 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 all of the bolts are fully loosened, remove them.

  • Page 227: Installing The Cylinder Head

    CYLINDER HEAD d. Tighten the bolts to the specified torque in EAS24230 INSTALLING THE CYLINDER HEAD two or three steps in the proper tightening 1. Install: sequence as shown. • Timing chain guide (exhaust side) “1” • Dowel pin “2” Bolts “1”...
  • Page 228 CYLINDER HEAD Tighten the bolts 90° in each of the two steps to reach the specified angle of 180° in the proper tightening sequence as shown. Bolts “1” – “4” Final Specified angle 180° g. Tighten the bolts to the specified torque. Bolt “5”, “6”...
  • Page 229 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to“CYLINDER HEAD” on page 6-14. Valve lifter Valve pad Valve cotter Valve spring retainer Valve spring Exhaust valve Intake valve Valve stem seal...

  • Page 230: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.

  • Page 231: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS EAS24290 CHECKING THE VALVES AND VALVE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve guide with the valve guide GUIDES remover “1”. The following procedure applies to all of the valves and valve guides. 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification Replace the valve guide.

  • Page 232: Checking The Valve Seats

    VALVES AND VALVE SPRINGS After replacing the valve guide, reface the valve seat. Intake Valve guide remover (ø4.5) 90890-04116 YM-04116 Valve guide installer (ø4.5) 90890-04117 YM-04117 6. Measure: Valve guide reamer (ø4.5) • Valve stem runout 90890-04118 Out of specification Replace the valve.
  • Page 233 VALVES AND VALVE SPRINGS ECA1DX1018 NOTICE This model uses titanium intake valves. Titanium valves that have been used to lap the valve seats must not be used.Always re- place lapped valves with new valves. • When replacing the cylinder head, replace the valves without lapping the valve seats and valve faces.

  • Page 234: Checking The Valve Springs

    VALVES AND VALVE SPRINGS h. Install the valve into the cylinder head. 2. Measure: i. Press the valve through the valve guide and • Compressed valve spring force “a” onto the valve seat to make a clear impres- Out of specification Replace the valve sion.

  • Page 235: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 3. Install: • Spring seat “1” EAS24320 CHECKING THE VALVE LIFTERS • Valve stem seal “2” The following procedure applies to all of the • Valve “3” valve lifters. • Valve spring “4” 1. Check: • Valve spring retainer “5” •...
  • Page 236 VALVES AND VALVE SPRINGS 5. To fasten the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. ECA13800 NOTICE Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Valve pad “1” •...

  • Page 237: Cylinder And Piston

    CYLINDER AND PISTON EAS24350 CYLINDER AND PISTON Removing the cylinder and piston Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to“CYLINDER HEAD” on page 6-14. Cylinder Dowel pin Cylinder gasket Piston pin clip Piston pin Piston Piston ring set For installation, reverse the removal proce- dure.

  • Page 238: Removing The Piston

    CYLINDER AND PISTON EAS24380 REMOVING THE PISTON 1. Remove: • Piston pin clips “1” • Piston pin “2” • Piston “3” ECA13810 NOTICE Do not use a hammer to drive the piston pin out. • Before removing the piston pin clip, cover the EAS24390 CHECKING THE CYLINDER AND PISTON crankcase opening with a clean rag to prevent...

  • Page 239: Checking The Piston Rings

    CYLINDER AND PISTON b. If out of specification, rebore or replace the cylinder, and replace the piston and piston Before measuring the piston ring side clear- rings as a set. ance, eliminate any carbon deposits from the c. Measure piston skirt diameter “P” with the piston ring grooves and piston rings.

  • Page 240: Checking The Piston Pin

    CYLINDER AND PISTON 3. Measure: • Piston pin bore diameter “b” The oil ring expander spacer’s end gap cannot Out of specification Replace the piston. be measured. If the oil ring rail’s gap is exces- sive, replace all three piston rings. Piston pin bore inside diameter 18.004–18.015 mm (0.7088–...
  • Page 241 CYLINDER AND PISTON a. Top ring end b. 2nd ring end c. Upper oil ring end d. Oil ring e. Lower oil ring end 5. Install: • Cylinder gasket • Dowel pin • Cylinder Cylinder bolt 2. Install: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) •...

  • Page 242: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Exhaust pipe Refer to“ENGINE REMOVAL” on page 6-1. Starter motor For assembly, reverse the disassemble pro- cedure. 6-31...
  • Page 243 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks Starter motor front cover Starter motor yoke Armature assembly Starter motor rear cover Brush set For assembly, reverse the disassembly pro- cedure. 6-32...

  • Page 244: Checking The Starter Motor

    ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure the armature assembly resistanc- 1. Check: es with the pocket tester. • Commutator Dirt Clean with 600 grit sandpaper. Pocket tester 2. Measure: 90890-03112 • Commutator diameter “a” Analog pocket tester YU-03112-C Out of specification Replace the starter...

  • Page 245: Assembling The Starter Motor

    ELECTRIC STARTER 7. Check: • Gear teeth Damage/wear Replace the starter motor. 8. Check: • Oil seal Damage/wear Replace the defective part (s). EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: 4. Install: • Brush spring “1” • O-ring “1” • Brush “2” •...
  • Page 246 CLUTCH EAS1DX3173 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Clutch cover Gasket Dowel pin Clutch spring Pressure plate Push rod 1 Circlip Washer Bearing Ball Push rod 2 Clutch plate Friction plate Clutch boss nut Conical washer 6-35...
  • Page 247 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Clutch boss Thrust washer Primary driven gear Push lever shaft For installation, reverse the removal proce- dure. 6-36...
  • Page 248 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Engine guard Refer to“ENGINE REMOVAL” on page 6-1. Refer to “CHANGING THE ENGINE OIL” on Drain the engine oil. page 3-13. Refer to “CHANGING THE COOLANT” on Drain the coolant. page 3-16.

  • Page 249: Clutch

    CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Gasket Dowel pin/O-ring For installation, reverse the removal proce- dure. 6-38...

  • Page 250: Removing The Clutch

    CLUTCH EAS25070 REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Remove: • Clutch boss nut “1” • Conical washer “2” • Clutch boss “3” While holding the clutch boss with the universal clutch holder “4”, loosen the clutch boss nut. Universal clutch holder EAS25110 CHECKING THE CLUTCH PLATES...

  • Page 251: Checking The Clutch Housing

    CLUTCH 2. Measure: • Clutch spring free length Out of specification Replace the clutch springs as a set. Clutch spring free length 50.00 mm (1.97 in) Limit 49.00 mm (1.93 in) 2. Check: • Primary driven gear Damage/wear Replace the primary drive and clutch housing as a set.

  • Page 252: Checking The Primary Drive Gear

    CLUTCH EAS25200 CHECKING THE PRIMARY DRIVE GEAR 1. Check: • Primary drive gear Damage/wear Replace the primary drive and primary driven gears as a set. Excessive noise during operation place the primary drive and primary driven gears as a set. 2.
  • Page 253 CLUTCH 4. Install: 6. Install: • Friction plate “1” • Push rod 2 “1” • Clutch plate 1 [t=2.0 mm (0.079 in)] “2” • Ball “2” • Clutch plate 2 [t=1.6 mm (0.063 in)] “3” • Push rod 1 “3” •...
  • Page 254 CLUTCH 9. Install: • Clutch cover gasket “1” • Dowel pin “2” 10.Install: • Clutch cover “1” • Clutch cover bolt Clutch cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tighten the bolts in stage, using a crisscross pattern. 6-43...
  • Page 255 KICKSTATER EAS1DX3174 KICKSTATER Removing the kick shaft Order Job/Parts to remove Q’ty Remarks Kick idle gear Kick shaft assembly Spring guide Torsion spring Ratchet wheel Kick gear Kick shaft Washer For assembly, reverse the disassembly pro- cedure. 6-44...

  • Page 256: Kickstater

    KICKSTATER EAS1DX3175 REMOVING THE KICK SHAFT ASSEMBLY 1. Remove: • Kick shaft assembly “1” Unhook the torsion spring “2” from the hole “a” in the crankcase. EAS1DX3178 INSTALLING THE KICK SHAFT ASSEMBLY 1. Install: • Kick gear “1” • Washer “2” •...

  • Page 257: Installing The Kick Idle Gear

    KICKSTATER 5. Hook: • 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 258: Shift Shaft

    SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever 12 Nm (1.2 m kgf, 8.7 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft lbf) 30 Nm (3.0 m kgf, 22 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft lbf) Order Job/Parts to remove Q’ty...
  • Page 259 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Washer Stopper lever spring Segment For installation, reverse the removal proce- dure. 6-48...

  • Page 260: Removing The Segment

    SHIFT SHAFT EAS1DX3180 REMOVING THE SEGMENT 1. Remove: • Bolt (segment) “1” • Segment “2” Turn the segment counterclockwise until it stops and loosen the bolt. ECA1DX1021 NOTICE If the segment gets an impact, it may be EAS1DX3181 damaged. Take care not to give an impact to INSTALLING THE SEGMENT the segment when removing the bolt.

  • Page 261: Installing The Shift Guide And Shift Lever Assembly

    SHIFT SHAFT 4. Install: • Shift guide bolt “1” EAS1DX3183 INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY Shift guide bolt 1. Install: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Spring “1” • Pawl pin “2” • Pawl “3” To shift lever “4”. Apply the engine oil on the spring, pawl pin and pawl.

  • Page 262: Oil Pump And Balancer Gear

    OIL PUMP AND BALANCER GEAR EAS1DX3184 OIL PUMP AND BALANCER GEAR Removing the oil pump and balancer 45 Nm (4.5 m kgf, 33 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft lbf) 110 Nm (11.0 m kgf, 80 ft lbf) 50 Nm (5.0 m kgf, 36 ft lbf) Order Job/Parts to remove...
  • Page 263 OIL PUMP AND BALANCER GEAR Removing the oil pump and balancer 45 Nm (4.5 m kgf, 33 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft lbf) 110 Nm (11.0 m kgf, 80 ft lbf) 50 Nm (5.0 m kgf, 36 ft lbf) Order Job/Parts to remove Q’ty...
  • Page 264 OIL PUMP AND BALANCER GEAR Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil pump cover Outer rotor 1 Inner rotor 1 Dowel pin Washer Oil pump drive shaft Rotor housing For assembly, reverse the disassembly pro- cedure. 6-53...

  • Page 265: Removing The Balancer

    OIL PUMP AND BALANCER GEAR 2. Measure: EAS1DX3185 REMOVING THE BALANCER • Inner-rotor-to-outer-rotor-tip clearance “a” 1. Straighten the lock washer tab. • Outer-rotor-to-oil-pump-housing clearance 2. Loosen: “b” • Balancer nut “1” • Oil-pump-housing-to-inner-rotor-and-outer- • Primary drive gear nut “2” rotor clearance “c” •...

  • Page 266: Assembling The Oil Pump

    OIL PUMP AND BALANCER GEAR EAS1DX3187 ASSEMBLING THE OIL PUMP 1. Install: • Oil pump drive shaft “1” • Washer “2” • Dowel pin “3” • Inner rotor 1 “4” • Apply the engine oil on the oil pump drive shaft and inner rotor 1.
  • Page 267 OIL PUMP AND BALANCER GEAR • Primary drive gear “3” • Conical washer “4” • Primary drive gear nut “5” Primary drive gear nut 110 Nm (11.0 m·kgf, 80 ft·lbf) • Straight key “6” • Balancer “7” • Lock washer “8” •...

  • Page 268: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS1DX3189 GENERATOR AND STARTER CLUTCH Removing the generator 11 9 Order Job/Parts to remove Q’ty Remarks Refer to “CHANGING THE ENGINE OIL” on Drain the engine oil. page 3-13. Refer to “GENERAL CHASSIS” on page 5-1 Seat and fuel tank and “FUEL TANK”...
  • Page 269 GENERATOR AND STARTER CLUTCH Removing the generator Order Job/Parts to remove Q’ty Remarks Starter clutch drive gear Crankshaft position sensor Stator For installation, reverse the removal proce- dure. 6-58...

  • Page 270: Removing The Generator

    GENERATOR AND STARTER CLUTCH 2. Check: EAS1DX3190 REMOVING THE GENERATOR • Starter clutch idle gear 1. Remove: • Starter clutch gear • Generator rotor nut “1” Burrs/chips/roughness/wear Replace the • Washer defective part (s). 3. Check: • Starter clutch gear Damage/pitting/wear Replace the starter clutch gear.

  • Page 271: Installing The Starter Clutch

    • Tighten the stator bolt using the T25 bit. • Apply the sealant to the grommet of the AC magneto lead. Starter clutch bolt 16 Nm (1.6 m·kgf, 12 ft·lbf) YAMAHA Bond No. 1215 (Three- LOCTITE® Bond No. 1215®) 90890-85505 EAS1DX3193 INSTALLING THE GENERATOR 1.
  • Page 272 GENERATOR AND STARTER CLUTCH 2. Install: • Washer • Generator rotor nut “1” Generator rotor nut 65 Nm (6.5 m·kgf, 47 ft·lbf) Tighten the generator rotor nut to 65 Nm (6.5 m·kgf, 47 ft·lbf), loosen and retighten the gener- ator rotor nut to 65 Nm (6.5 m·kgf, 47 ft·lbf). 5.
  • Page 273 CRANKCASE EAS25540 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 6-1. Refer to “CYLINDER AND PISTON” on page Piston 6-26. Refer to “OIL PUMP AND BALANCER Balancer GEAR” on page 6-51. Kick shaft assembly Refer to “KICKSTATER”...

  • Page 274: Crankcase

    CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure. 6-63...
  • Page 275 CRANKCASE Removing the bearing and oil seal Order Job/Parts to remove Q’ty Remarks Refer to“CRANKSHAFT ASSEMBLY AND Crankshaft assembly BALANCER SHAFT” on page 6-67. Transmission assembly Refer to“TRANSMISSION” on page 6-70. Oil seal Bearing For installation, reverse the removal proce- dure.

  • Page 276: Disassembling The Crankcase

    CRANKCASE EAS25570 DISASSEMBLING THE CRANKCASE 1. Separate: • Right crankcase • Left crankcase ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the crankcase bolts, hose guide and clutch cable holder. c. Remove the dowel pins and O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Remove: • Balancer shaft “1” Remove the balancer shaft with its flat side “a” facing the crankshaft.

  • Page 277: Assembling The Crankcase

    2. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 3. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 (Three Bond No.1215®) 90890-85505 3. M6 80 mm 4. M6 60 mm 5.

  • Page 278: Crankshaft Assembly And Balancer Shaft

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EAS25970 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT Removing the crankshaft assembly and balancer shaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to“CRANKCASE” on page 6-62. Balancer shaft Crankshaft assembly For installation, reverse the removal proce- dure.

  • Page 279: Removing The Balancer Shaft

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EAS1DX3195 EAS26060 REMOVING THE BALANCER SHAFT CHECKING THE CRANKSHAFT ASSEMBLY 1. Remove: 1. Measure: • Balancer shaft “1” • Crankshaft runout Out of specification Replace the crank- shaft, bearing or both. Remove the balancer shaft with its flat side “a” facing the crankshaft.

  • Page 280: Installing The Crankshaft Assembly

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT ECA13970 NOTICE To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil. Hold the connecting rod at top dead center (TDC) with one hand while turning the nut of the crankshaft installer bolt with the other.
  • Page 281 TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to“CRANKCASE” on page 6-62. Main axle assembly Drive axle assembly Shift drum Shift fork-R Shift fork-C Shift fork-L Collar For installation, reverse the removal proce- dure.
  • Page 282 TRANSMISSION EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: • Shift fork cam follower “1” • Shift fork pawl “2” Bends/damage/scoring/wear Replace the shift fork. EAS1DX3196 CHECKING THE TRANSMISSION 1. Measure: •...
  • Page 283 TRANSMISSION • Transmission gear dogs Cracks/damage/rounded edges Replace • Apply the molybdenum disulfide oil on the in- the defective gear (s). ner and end surface of the idler gear and on 4. Check: the inner surface of the sliding gear, then in- •...
  • Page 284 TRANSMISSION 4. Install: • Collar “1” • Apply the lithium soap base grease on the oil seal lip. • When installing the collar into the crankcase, pay careful attention to the crankcase oil seal lip. 6. Install: • Transmission assembly “1” To left crankcase “2”.
  • Page 285 COOLING SYSTEM RADIATOR .......................7-1 HANDLING NOTE ..................7-3 CHECKING THE RADIATOR ..............7-3 INSTALLING THE RADIATOR ..............7-3 WATER PUMP....................7-5 CHECKING THE WATER PUMP ...............7-6 ASSEMBLING THE WATER PUMP............7-6...
  • Page 286 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 287 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Radiator hose 4 Pipe 2/O-ring Catch tank hose Left radiator Radiator hose 1 Pipe 1/O-ring Catch tank breather hose Catch tank For installation, reverse the removal proce- dure.

  • Page 288: Cooling System

    RADIATOR EAS1DX3198 HANDLING NOTE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the radiator cap tester “1” and radiator EWA1DX1007 cap tester adapter “2” to the radiator cap “3”. WARNING Do not remove the radiator cap when the en- Radiator cap tester gine and radiator are hot. Scalding hot fluid 90890-01325 and steam may be blown out under pres- Mityvac cooling system tester kit...
  • Page 289 RADIATOR b. Apply the 137.3 kPa (1.37 kg/cm ) (19.9 psi) pressure. c. Measure the indicated pressure with the gauge. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Measure: • Radiator cap opening pressure Below the specified pressure Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 7-3.

  • Page 290: Water Pump

    WATER PUMP EAS1DX3200 WATER PUMP Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft lbf) 12 Nm (1.2 m kgf, 8.7 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft lbf) 14 Nm (1.4 m kgf, 10 ft lbf) Order...

  • Page 291: Checking The Water Pump

    WATER PUMP 2. Install: EAS26530 CHECKING THE WATER PUMP • Dowel pin “1” 1. Check: • O-ring “2” • Water pump housing cover • Impeller shaft Apply the lithium-soap-based grease on the O- Cracks/damage/wear Replace. ring. EAS26560 ASSEMBLING THE WATER PUMP 1.
  • Page 292 WATER PUMP...

  • Page 293: Fuel System

    FUEL SYSTEM FUEL TANK ......................8-1 REMOVING THE FUEL TANK ..............8-3 REMOVING THE FUEL PUMP ..............8-3 CHECKING THE FUEL PUMP BODY............8-3 INSTALLING THE FUEL PUMP ..............8-3 REMOVING THE FUEL SENDER..............8-4 CHECKING THE FUEL SENDER ..............8-4 INSTALLING THE FUEL SENDER ............8-4 INSTALLING THE FUEL TANK..............8-5 CHECKING THE FUEL PRESSURE............8-5 THROTTLE BODY....................8-6 REMOVING THE THROTTLE BODY............8-8...

  • Page 294: Fuel Tank

    This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.
  • Page 295 FUEL TANK Removing the fuel tank 9 Nm (0.9 m kgf, 6.5 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 4 Nm (0.4 m kgf, 2.9 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 4 Nm (0.4 m kgf, 2.9 ft Ibf) Order...

  • Page 296: Removing The Fuel Tank

    FUEL TANK EAS26630 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose coupler EWA23P1001 WARNING Cover fuel hose connections with a cloth when disconnecting them. Residual pres- sure in the fuel lines could cause fuel to spurt out when removing the hose.

  • Page 297: Removing The Fuel Sender

    FUEL TANK (from the fuel tank) 4. Connect: • Do not damage the installation surfaces of the • Fuel sender coupler fuel tank when installing the fuel pump. 5. Push the main switch to “ON”. • Always use a new fuel pump gasket. 6.

  • Page 298: Installing The Fuel Tank

    FUEL TANK d. Connect the pressure gauge “1” and fuel EAS1DX3205 INSTALLING THE FUEL TANK pressure adapter “2” to the fuel hose. 1. Install: • Fuel hose Pressure gauge 90890-03153 ECA1DX1024 NOTICE YU-03153 Fuel pressure adapter When installing the fuel hose, make sure 90890-03186 that it is securely connected, and that the YM-03186...

  • Page 299: Throttle Body

    THROTTLE BODY EAS26970 THROTTLE BODY Removing the throttle body Order Job/Parts to remove Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 5-1. Side cover (left/right) Air scoop (left/right) Fuel tank Refer to “FUEL TANK” on page 8-1. Throttle cable cover Throttle cable Ignition coil lead Rear frame...
  • Page 300 THROTTLE BODY Disassembling the throttle body Order Job/Parts to remove Q’ty Remarks Delivery pipe Injector Gasket Throttle position sensor For assembly, reverse the disassembly pro- cedure.

  • Page 301: Removing The Throttle Body

    THROTTLE BODY EAS1DX3207 ECA1DX1027 REMOVING THE THROTTLE BODY NOTICE The following procedure applies to both of the • Before removing the throttle body, clean throttle body. the area around the throttle body to pre- 1. Remove: vent dirt and other foreign material from •...

  • Page 302: Checking The Throttle Body Joint

    SITION SENSOR” on page 9-76. 2. Adjust: • Throttle position sensor angle ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the diagnostic tool. Refer to “YAMAHA DIAGNOSTIC TOOL” on page 9-26. b. Temporary tighten the throttle position sen- sor. c. Check that the throttle grip is fully closed.

  • Page 303: Electrical System

    TROUBLESHOOTING................9-18 SIGNALING SYSTEM..................9-20 CIRCUIT DIAGRAM .................9-20 TROUBLESHOOTING................9-22 FUEL INJECTION SYSTEM ................9-24 CIRCUIT DIAGRAM .................9-24 YAMAHA DIAGNOSTIC TOOL ..............9-26 ECU SELF-DIAGNOSTIC FUNCTION .............9-27 TROUBLESHOOTING METHOD .............9-29 LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS ......9-30 LIST OF DIAGNOSTIC CODES ...............9-31 TROUBLESHOOTING DETAILS..............9-33 FUEL PUMP SYSTEM..................9-52 CIRCUIT DIAGRAM .................9-52...
  • Page 304 CHECKING THE IGNITION COIL ............9-71 CHECKING THE CRANKSHAFT POSITION SENSOR......9-72 CHECKING THE LEAN ANGLE SENSOR..........9-72 CHECKING THE STARTER MOTOR OPERATION ........9-73 CHECKING THE STATOR COIL..............9-73 CHECKING THE RECTIFIER/REGULATOR ...........9-74 CHECKING THE SPEED SENSOR ............9-74 CHECKING THE FUEL SENDER ............9-74 CHECKING THE COOLANT TEMPERATURE SENSOR ......9-75 CHECKING THE THROTTLE POSITION SENSOR ........9-76 CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE ..9-76 CHECKING THE INTAKE AIR PRESSURE SENSOR......9-77...
  • Page 305 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 306: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS1DX3209 CIRCUIT DIAGRAM...
  • Page 307 IGNITION SYSTEM 1. AC magneto 4. Battery 5. Main fuse 6. Starter relay 16.Main switch 17.Joint connector 22.ECU (electronic control unit) 23.Ignition coil 24.Spark plug 29.Lean angle sensor 32.Joint connector...

  • Page 308: Troubleshooting

    IGNITION SYSTEM EAS1DX3210 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 1. Check the fuse. Refer to “CHECKING THE FUSE” Replace the fuse.
  • Page 309 8. Check the engine stop switch. Refer to “CHECKING THE Replace the engine stop switch. SWITCHES” on page 9-60. 9. Check the neutral switch. Replace the neutral switch. Refer to “CHECKING THE SWITCHES” on page 9-60. 10.Check the relay unit (Starting circuit cut-off relay).

  • Page 310: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS1DX3211 CIRCUIT DIAGRAM...
  • Page 311 ELECTRIC STARTING SYSTEM 4. Battery 5. Main fuse 6. Starter relay 7. Starter motor 8. Starter relay diode 10.Connector 11.Connector 12.Connector 14.Starting circuit cut-off relay 15.Start switch 16.Main switch 17.Joint connector 18.Clutch switch 19.Diode 26.Neutral switch 32.Joint connector 40.Joint connector 42.Connector...

  • Page 312: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAS1DX3212 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to "ON", the starter motor can only operate if at least one of the following conditions is met:” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
  • Page 313 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Starting circuit cut-off relay 5. Start switch 6. Diode 7. Clutch switch 8.

  • Page 314: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS1DX3213 TROUBLESHOOTING The starter motor fails to turn. Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 1. Check the fuse. Refer to “CHECKING THE FUSE” Replace the fuse.
  • Page 315 ELECTRIC STARTING SYSTEM 8. Check the main switch. Replace the main switch. Refer to “CHECKING THE SWITCHES” on page 9-60. 9. Check the engine stop switch. Refer to “CHECKING THE Replace the start switch. SWITCHES” on page 9-60. 10.Check the neutral switch. Replace the neutral switch.

  • Page 316: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS1DX3214 CIRCUIT DIAGRAM 9-12...
  • Page 317 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 3. Connector 4. Battery 5. Main fuse 6. Starter relay 32.Joint connector 9-13...

  • Page 318: Troubleshooting

    CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged. Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 1. Check the fuse. Replace the fuse. Refer to “CHECKING THE FUSE” on page 9-65. 2. Check the battery. Refer to “CHECKING AND •...
  • Page 319 CHARGING SYSTEM 9-15...

  • Page 320: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS1DX3215 CIRCUIT DIAGRAM 9-16...
  • Page 321 LIGHTING SYSTEM 4. Battery 5. Main fuse 6. Starter relay 9. Headlight relay 10.Connector 11.Connector 12.Connector 16.Main switch 17.Joint connector 22.ECU (electronic control unit) 32.Joint connector 40.Joint connector 41.Joint connector 42.Connector 43.Headlight 44.Taillight 9-17...

  • Page 322: Troubleshooting

    LIGHTING SYSTEM EAS1DX3216 TROUBLESHOOTING Any of the following fail to light: headlight or meter light. Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left) 3. Air scoop (left/right) 4. Fuel tank 1. Check the each bulbs and bulb sockets condition.
  • Page 323 LIGHTING SYSTEM 9-19...

  • Page 324: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS1DX3217 CIRCUIT DIAGRAM 9-20...
  • Page 325 SIGNALING SYSTEM 4. Battery 5. Main fuse 6. Starter relay 16.Main switch 17.Joint connector 22.ECU (electronic control unit) 32.Joint connector 34.Speed sensor 35.Multi-function display 36.Fuel sender 37.Resistor 40.Joint connector 41.Joint connector 42.Connector 9-21...

  • Page 326: Troubleshooting

    SIGNALING SYSTEM EAS1DX3218 TROUBLESHOOTING • The speedometer does not operate normally. • The fuel indicator light does not come on. Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 1.
  • Page 327 SIGNALING SYSTEM The fuel level warning light fails to come on. 1. Check the fuel sender. Replace the fuel sender assembly. Refer to “CHECKING THE FUEL SENDER” on page 9-74. 2. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM”...

  • Page 328: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS1DX3219 CIRCUIT DIAGRAM 9-24...
  • Page 329 FUEL INJECTION SYSTEM 1. AC magneto 4. Battery 5. Main fuse 6. Starter relay 10.Connector 11.Connector 12.Connector 14.Starting circuit cut-off relay 15.Start switch 16.Main switch 17.Joint connector 19.Diode 22.ECU (electronic control unit) 25.Injector 26.Neutral switch 27.Throttle position sensor 28.Intake air pressure sensor 29.Lean angle sensor 30.Coolant temperature sensor 31.Intake air temperature sensor...

  • Page 330: Yamaha Diagnostic Tool

    FUEL INJECTION SYSTEM EAS1DX3220 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 331: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM When the Yamaha diagnostic tool is connected to the vehicle, the operation of the meter and indica- tors will be different from the normal operation. EAS1DX3221 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally.
  • Page 332 FUEL INJECTION SYSTEM Checking the engine trouble warning light The engine trouble warning light comes on for around 2 seconds after the main switch has been set to “ON” and it comes on while the start switch is being pushed. If the warning light does not come on under these conditions, the warning light bulb may be defective.

  • Page 333: Troubleshooting Method

    FUEL INJECTION SYSTEM The engine operation is not normal, but the EAS27400 TROUBLESHOOTING METHOD engine trouble warning light does not come The engine operation is not normal and the 1. Check the operation of the following sensors engine trouble warning light comes on. and actuators in the diagnostic mode.

  • Page 334: List Of Self-Diagnostic And Fail-Safe Actions

    FUEL INJECTION SYSTEM EAS1DX3222 LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS Able/unable to start: Indicates whether the engine can be started when the malfunction for the appli- cable item has occurred. Able/unable to drive: Indicates whether the vehicle can continue to be driven (the engine can contin- ue to operate) when the malfunction for the applicable item has occurred while the vehicle is being driven (the engine is operating).

  • Page 335: List Of Diagnostic Codes

    FUEL INJECTION SYSTEM EAS1DX3223 LIST OF DIAGNOSTIC CODES Diag- nostic Standard values of the meter dis- Item Details code play or description of operation d:01 Throttle angle Displays the throttle angle. Display when the throttle is fully • Check with throttle fully closed: 9–16 closed.
  • Page 336 FUEL INJECTION SYSTEM Diag- nostic Standard values of the meter dis- Item Details code play or description of operation d:30 Ignition coil Check that power is sup- Actuates the ignition coil five times at plied to the ignition coil. 1-second intervals. •...

  • Page 337: Troubleshooting Details

    FUEL INJECTION SYSTEM Diag- nostic Standard values of the meter dis- Item Details code play or description of operation d:64 Setting history Display setting history 00:There is no setting history. 01:There is setting history. 02:Whether or not setting history data exists cannot be determined (damage to history data) d:65...
  • Page 338 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received Item 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- Confirmation of service Maintenance job...
  • Page 339 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. d:03 Diagnostic tool display Displays the intake air pressure. Procedure Operate the throttle while pushing the start switch.(If the display value changes, the performance is OK.) Probable cause of malfunc- Confirmation of service...
  • Page 340 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Defective intake air pressure Execute the diagnostic mode. Set the main switch to “ON”. sensor. (Code No. d:03) Fault code number is not dis- When engine is stopped: played Service is finished.
  • Page 341 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged Item or detached hose). Defective intake air pressure Execute the diagnostic mode. sensor. (Code No. d:03) When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is indicated.
  • Page 342 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Connection of wire harness Improperly connected Set the main switch to “ON”. ECU coupler. Connect the coupler securely Fault code number is not dis- Check the locking condition or repair/replace the wire har- played Service is finished.
  • Page 343 FUEL INJECTION SYSTEM If fault code Nos. 15 and 16 are both displayed, perform the checks and maintenance jobs for fault code No. 15 first. Fault code No. Throttle position sensor: stuck throttle position sensor is de- Item tected. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No.
  • Page 344 FUEL INJECTION SYSTEM Fault code No. Item Coolant temperature sensor: open or short circuit detected. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. d:06 Diagnostic tool display Displays the coolant temperature. Procedure Compare the actually measured coolant temperature with the diag- nostic tool display value.
  • Page 345 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. d:05 Diagnostic tool display Displays the intake air temperature. Procedure Compare the actually measured intake air temperature with the di- agnostic tool display value.
  • Page 346 FUEL INJECTION SYSTEM Fault code No. Item Turnover of vehicle. Fail-safe system Unable to start engine Unable to drive vehicle Diagnostic code No. d:08 Diagnostic tool display Lean angle sensor output voltage • 0.4–1.4 (upright) • 3.7–4.4 (overturned) Procedure Remove the lean angle sensor and incline it more than 45 degrees. Probable cause of malfunc- Confirmation of service Maintenance job...
  • Page 347 FUEL INJECTION SYSTEM Fault code No. Ignition coil: open or short circuit detected in the primary lead Item of the ignition coil. Fail-safe system Unable to start engine Unable to drive vehicle Diagnostic code No. d:30 Actuation Actuates the ignition coil five times at one-second intervals. The engine trouble warning light and the “WARNING”...
  • Page 348 FUEL INJECTION SYSTEM Disconnect the fuel pump coupler when this diagnostic tool is used. Fault code No. Item Injector: open or short circuit detected. Fail-safe system Unable to start engine Unable to drive vehicle Diagnostic code No. d:36 Actuation Actuates injector five times at one-second intervals. The engine trouble warning light and the “WARNING”...
  • Page 349 FUEL INJECTION SYSTEM Fault code No. Item Injector: open or short circuit detected. Wire harness continuity. Open or short circuit Check for the operating place the wire harness. sound of the injector in the di- Between injector coupler and agnostic mode (Code No. ECU coupler.
  • Page 350 FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Wire harness continuity. Open or short circuit Set the main switch to “ON”. place the wire harness. Fault code number is not dis- Between lean angle sensor played Service is finished.
  • Page 351 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed Item sensor. Wire harness continuity. Open or short circuit Execute the diagnostic mode. place the wire harness. (Code No. d:07) Between rear wheel sensor Rotate the front wheel by coupler and ECU coupler.
  • Page 352 FUEL INJECTION SYSTEM Fault code No. EEPROM fault code number: an error is detected while read- Item ing or writing on EEPROM. “01” is indicated in Diagnostic Change the CO concentra- Set the main switch to “ON”. mode (Code No. d:60) EEP- tion, and rewrite in EEPROM.
  • Page 353 FUEL INJECTION SYSTEM Fault code No. Faulty ECU memory. (When this malfunction is detected in the Item ECU, the fault code number might not appear on the meter.) Procedure — Probable cause of malfunc- Confirmation of service Maintenance job tion and check completion Malfunction in ECU.
  • Page 354 FUEL INJECTION SYSTEM Fault code No. waiting for connection Item No communication signal is received from the ECU. Malfunction in ECU. Replace the ECU. Fault code No. Er-4 Item Registered data cannot be received from the diagnostic tool. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No.
  • Page 355 FUEL INJECTION SYSTEM 9-51...

  • Page 356: Fuel Pump System

    FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS1DX3225 CIRCUIT DIAGRAM 9-52...
  • Page 357 FUEL PUMP SYSTEM 4. Battery 5. Main fuse 6. Starter relay 10.Connector 11.Connector 12.Connector 16.Main switch 17.Joint connector 20.Fuel pump 22.ECU (electronic control unit) 32.Joint connector 33.Engine stop switch 40.Joint connector 41.Joint connector 42.Connector 9-53...

  • Page 358: Trouble Shooting

    FUEL PUMP SYSTEM EAS1DX3226 TROUBLE SHOOTING 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 1. Check the fuse. Refer to “CHECKING THE FUSE” Replace the fuse.
  • Page 359 FUEL PUMP SYSTEM 9-55...

  • Page 360: Electrical Components

    ELECTRICAL COMPONENTS EAS27971 ELECTRICAL COMPONENTS EAS1DX3227 9-56...
  • Page 361 ELECTRICAL COMPONENTS 1. Main switch 2. Clutch switch 3. Fuel sender 4. Fuel pump 5. Intake air pressure sensor 6. Throttle position sensor 7. Injector 8. Intake air temperature sensor 9. Coupler for connecting optional part 10.Ignition coil 9-57...
  • Page 362 ELECTRICAL COMPONENTS 9-58...
  • Page 363 ELECTRICAL COMPONENTS 1. Rectifier/regulator 2. Lean angle sensor 3. Coolant temperature sensor 4. Head light relay 5. Starting circuit cut-off relay 6. Starter relay 7. Main fuse 8. Battery 9. ECU(engine control unit) 10.Condenser 11.Neutral switch 9-59...

  • Page 364: Checking The Switches

    ELECTRICAL COMPONENTS EAS1DX3228 CHECKING THE SWITCHES 9-60...
  • Page 365 ELECTRICAL COMPONENTS 1. Engine stop switch 2. Clutch switch 3. Neutral switch 4. Main switch 5. Start switch 9-61...
  • Page 366 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 367 ELECTRICAL COMPONENTS The example illustration below shows that: There is continuity between red and brown when the switch is set to “ON”. 9-63...

  • Page 368: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS EAS27990 EWA13320 CHECKING THE BULBS AND BULB SOCK- WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands Do not check any of the lights that use LEDs. away from the bulb until it has cooled down. Check each bulb and bulb socket for damage ECA14380 NOTICE...

  • Page 369: Replacing The Headlight Bulb

    ELECTRICAL COMPONENTS Checking the condition of the bulb sockets The following procedure applies to all of the bulb sockets. 1. Check: • Bulb socket (for continuity) (with the pocket tester) No continuity Replace. Pocket tester 90890-03112 Analog pocket tester 3. Remove: YU-03112-C •...

  • Page 370: Checking And Charging The Battery

    ELECTRICAL COMPONENTS 1. Remove: EWA13310 WARNING • Side cover (left/right) Never use a fuse with an amperage rating • Seat other than that specified. Improvising or us- Refer to “GENERAL CHASSIS” on page 5- ing a fuse with the wrong amperage rating may cause extensive damage to the electri- 2.
  • Page 371 ELECTRICAL COMPONENTS ECA13660 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTICE a. Connect a pocket tester to the battery termi- • This is a VRLA (Valve Regulated Lead Ac- nals. id) battery. Never remove the sealing caps • Positive tester probe because the balance between cells will not positive battery terminal be maintained and battery performance •...
  • Page 372 ELECTRICAL COMPONENTS 5. Charge: • Battery (refer to the appropriate charging method) EWA13300 WARNING Do not quick charge a battery. ECA13670 NOTICE • Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause bat- A.

  • Page 373: Checking The Relays

    ELECTRICAL COMPONENTS f. If charging requires more than 5 hours, it is ECA1DX1028 NOTICE advisable to check the charging current after First, connect the positive battery lead “1”, a lapse of 5 hours. If there is any change in and then the negative battery lead “2”. the amperage, readjust the voltage to obtain the standard charging current.

  • Page 374: Checking The Diode

    ELECTRICAL COMPONENTS Starter relay Result Continuity (between “3” to “4”) EAS1DX3232 CHECKING THE DIODE 1. Check: • Diode Out of specification Replace. Pocket tester 90890-03112 1. Positive battery terminal Analog pocket tester 2. Negative battery terminal YU-03112-C 3. Positive tester probe 4.

  • Page 375: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS EAS1DX3233 CHECKING THE SPARK PLUG CAP 1. Remove: • Spark plug cap (from the spark plug lead) 2. Check: • Spark plug cap resistance Out of specification Replace. Spark plug cap resistance 10 kW ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( 1k) to the EAS28930 CHECKING THE IGNITION SPARK GAP...

  • Page 376: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS (from the wire harness) • Positive tester probe 2. Check: Orange “1” • Crankshaft position sensor resistance • Negative tester probe Out of specification Replace the crank- Red/Blue “2” shaft position sensor. Crankshaft position sensor resis- tance 248–372 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 377: Checking The Starter Motor Operation

    ELECTRICAL COMPONENTS b. Connect the pocket tester (DC 20 V) to the lean angle sensor coupler as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Test harness-lean angle sensor (6P) 90890-03209 YU-03209 b. Check the starter motor operation. • Positive tester probe ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 378: Checking The Rectifier/Regulator

    ELECTRICAL COMPONENTS EAS28240 CHECKING THE SPEED SENSOR 1. Check: • Speed sensor output voltage Out of specification Replace. Output voltage reading cycle 0.6V to 4.8V to 0.6V to 4.8V ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the test harness-speed sensor (3P) to the speed sensor coupler and wire har- b.

  • Page 379: Checking The Coolant Temperature Sensor

    ELECTRICAL COMPONENTS 2. Remove: Out of specification Replace. • Fuel sender Coolant temperature sensor re- (from the fuel tank) sistance 3. Check: 2.51–2.78 k at 20°C (68°F) • Fuel sender resistance 210-221 at 100°C (212°F) Out of specification Replace the fuel pump.

  • Page 380: Checking The Throttle Position Sensor

    ELECTRICAL COMPONENTS • Positive tester probe Yellow “1” • Negative tester probe Black/Blue “2” b. Check the throttle position sensor maximum resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • Throttle position sensor When installing the throttle position sensor, ad- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ just its angle properly. Refer to “ADJUSTING EAS28300 THE THROTTLE POSITION SENSOR”...

  • Page 381: Checking The Intake Air Pressure Sensor

    ELECTRICAL COMPONENTS • Positive tester probe Blue ”1” • Negative tester probe Black/Blue ”2” b. Set the main switch to “ON”. c. Measure the intake air pressure sensor out- put voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ c. Start the engine. EAS1DX3241 d. Measure the throttle position sensor input CHECKING THE INTAKE AIR TEMPERA- voltage.

  • Page 382: Checking The Fuel Injector

    ELECTRICAL COMPONENTS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS1DX3242 CHECKING THE FUEL INJECTOR The following procedure applies to all of the fuel injector. 1. Remove: • Fuel injector Refer to “THROTTLE BODY” on page 8-6 2. Check: • Fuel injector resistance Out of specification Replace the fuel in- jector.

  • Page 383: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING..................10-1 GENERAL INFORMATION ..............10-1 STARTING FAILURES ................10-1 INCORRECT ENGINE IDLING SPEED ...........10-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......10-2 FAULTY GEAR SHIFTING ...............10-2 SHIFT PEDAL DOES NOT MOVE ............10-2 JUMPS OUT OF GEAR................10-2 FAULTY CLUTCH ..................10-2 OVERHEATING..................10-3 OVERCOOLING ..................10-3 POOR BRAKING PERFORMANCE ............10-3 FAULTY FRONT FORK LEGS ..............10-3 UNSTABLE HANDLING ................10-3 FAULTY LIGHTING SYSTEM ..............10-4...

  • Page 384: Troubleshooting

    TROUBLESHOOTING Electrical system EAS28450 TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse • Blown, damaged or incorrect fuse The following guide for troubleshooting does • Improperly installed fuse not cover all the possible causes of trouble. It 3.

  • Page 385: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING Electrical system Transmission 1. Battery • Seized transmission gear • Discharged battery • Foreign object between transmission gears • Faulty battery • Improperly assembled transmission 2. Spark plug • Incorrect spark plug gap EAS28550 JUMPS OUT OF GEAR • Incorrect spark plug heat range •...

  • Page 386: Overheating

    TROUBLESHOOTING EAS28590 EAS28620 OVERHEATING POOR BRAKING PERFORMANCE • Worn brake pad Engine • Worn brake disc 1. Cylinder head and piston • Air in hydraulic brake system • Heavy carbon buildup • Leaking brake fluid • Clogged coolant passages • Defective master cylinder kit 2.

  • Page 387: Faulty Lighting System

    TROUBLESHOOTING 4. Swingarm • Worn bearing or bushing • Bent or damaged swingarm 5. Rear shock absorber assembly (-ies) • Faulty rear shock absorber spring • Leaking oil or gas 6. Tire (s) • Uneven tire pressures (front and rear) •...
  • Page 388 Yellow EAS1DX3247 WIRING DIAGRAM Black/Green Black/Blue WR450FB 2012 Black/White 1. AC magneto Black/Yellow 2. Rectifier/regulator Br/L Brown/Blue 3. Connector Br/W Brown/White 4. Battery Green/Black Green/White 5. Main fuse Green/Yellow 6. Starter relay Gy/B Gray/Black 7. Starter motor Blue/Black 8. Starter relay diode Blue/Green 9.
  • Page 389 For your best ownership experience, think Genuine Yamaha! Genuine Yamaha Parts – Genuine Yamaha replacement parts are the exact same parts as the ones originally equipped on your vehicle, providing you with the performance and durability you have come to expect.
  • Page 390 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2012.01––1.4 × 1 !
  • Page 391 WR450FB 2012 WIRING DIAGRAM B/L Gy/B Gy/B O Y/B L Gy/B Y/G R/B L/Y B/Y Y/W Lg G/W W B/G Br/W G/Y L/G Br W W W W W W Br/L Gy/B Br/L Br/L Br/L START Br Br Br Br...
  • Page 392 WR450FB 2012 WIRING DIAGRAM START...

This manual is also suitable for:

Wr450fb 2015

Table of Contents