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Yamaha WR450FX Owner's Service Manual
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Yamaha WR450FX Owner's Service Manual

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2008
OWNER'S SERVICE MANUAL
WR450F(X)
5TJ-28199-71

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Summary of Contents for Yamaha WR450FX

  • Page 1 2008 OWNER’S SERVICE MANUAL WR450F(X) 5TJ-28199-71...
  • Page 3 WR450F (X) OWNER'S SERVICE MANUAL ©2007 by Yamaha Motor Co., Ltd. 1st Edition, June 2007 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan...
  • Page 4 Always turn off the engine Congratulations on your purchase of damage to the machine. while refueling. Take care to a Yamaha WR series. This model is not spill any gasoline on the the culmination of Yamaha's vast ex- engine or exhaust system.
  • Page 5 The information has tion or maintenance of your machine, been complied to provide the me- please consult your Yamaha dealer. chanic with an easy to read, handy reference that contains comprehen- This manual should be considered a...
  • Page 6 der of the jobs in the exploded di- 4. A job instruction chart "4" accom- HOW TO READ DESCRIPTIONS agram. A number that is enclosed panies the exploded diagram, To help identify parts and clarify pro- by a circle indicates a disassem- providing the order of jobs, names cedure steps, there are exploded dia- bly step.

  • Page 7: Table Of Contents

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

  • Page 8: General Information

    CONTENTS CHAPTER 1 CHAPTER 3 CRANKCASE AND CRANKSHAFT ....5-55 GENERAL INFOR- REGULAR INSPEC- TRANSMISSION, SHIFT MATION TION AND AD- CAM AND SHIFT FORK....5-61 JUSTMENTS DESCRIPTION ....1-1 CHAPTER 6 MACHINE MAINTENANCE IDENTIFICATION ..... 1-2 CHASSIS INTERVALS...... 3-1 INCLUDED PARTS ..1-2 PRE-OPERATION IMPORTANT INSPECTION AND...
  • Page 9 DESCRIPTION GENERAL INFORMATION DESCRIPTION Clutch lever 14. Headlight Hot starter lever 15. Radiator Engine stop switch 16. Coolant drain bolt Multi-function display 17. Rear brake pedal Main switch 18. Valve joint Start switch 19. Fuel cock Front brake lever 20. Cold starter knob Throttle grip 21.
  • Page 10 There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own. SPARK PLUG WRENCH 2. If your machine is stolen, the au- This spark plug wrench "1"...
  • Page 11 CHECKING OF CONNECTION ALL REPLACEMENT PARTS • If there in no continuity, clean the 1. We recommend to use Yamaha terminals. genuine parts for all replace- • Be sure to perform the steps 1 to 7 ments. Use oil and/or grease rec-...
  • Page 12 SPECIAL TOOLS SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided.
  • Page 13 SPECIAL TOOLS Tool name/Part number How to use Illustration Damper rod holder Use this tool to remove and install YM-01494, 90890-01494 the damper rod. Fork seal driver This tool is used when install the fork YM-A0948, 90890-01502 oil seal. Sheave holder This tool is used for when loosening YS-1880-A, 90890-01701 or tightening the flywheel magneto...
  • Page 14 SPECIAL TOOLS Tool name/Part number How to use Illustration Clutch holding tool This tool is used to hold the clutch YM-91042, 90890-04086 when removing or installing the clutch boss securing nut. Valve guide remover This tool is needed to remove and Intake 4.5 mm (0.18 in) install the valve guide.
  • Page 15 This tool is used to check the air in- YB-35956-A, 90890-06756 duction system. Digital tachometer This tool is needed for observing en- YU-39951-B, 90890-06760 gine rpm. YAMAHA Bond No. 1215 (ThreeB- This sealant (Bond) is used for ® No. 1215) crankcase mating surface, etc. 90890-85505...
  • Page 16 CONTROL FUNCTIONS CONTROL FUNCTIONS CLUTCH LEVER The clutch lever "1" is located on the MAIN SWITCH left handlebar; it disengages or en- Functions of the respective switch po- gages the clutch. Pull the clutch lever sitions are as follows: to the handlebar to disengage the clutch, and release the lever to en- The engine can be started only at this gage the clutch.
  • Page 17 MULTI-FUNCTION DISPLAY MULTI-FUNCTION DISPLAY Be sure to stop the machine before making any setting changes to the multi-function display. The multi-function display is equipped with the following: COLD STARTER KNOB BASIC MODE: Setting the time When cold, the engine requires a •...
  • Page 18 MULTI-FUNCTION DISPLAY Returning to BASIC MODE from RACE MODE When the machine is made ready for a run by manual start, will It is possible to return to BASIC start flashing. MODE with timer measurement at a 2. Start timer measurement by stop.
  • Page 19 MULTI-FUNCTION DISPLAY If the machine is run while timer mea- • Resetting will reset the timer display surement is not made, no change will and travel distance display and put occur to the digit in tripmeter A (TRIP measurement on standby. •...
  • Page 20 MULTI-FUNCTION DISPLAY FUNCTION DIAGRAM A short push on the button changes the operation in the arrowed direction. Meter function A short push on the button changes the operation in both arrowed directions. Function that can be performed whether the time is or is not in operation. A long push on the button changes the operation in the arrowed direction.
  • Page 21 MULTI-FUNCTION DISPLAY The following diagram illustrates the multi-function display regarding the direction and operation condition in- volved in each of its functions. A short push on the button changes the operation in the ar- rowed direction. A short push on the button changes the operation in both arrowed directions.
  • Page 22 STARTING AND BREAK-IN AIR FILTER MAINTENANCE STARTING AND BREAK-IN 7. Return the cold starter knob to its According to "CLEANING THE AIR original position and run the en- FUEL FILTER ELEMENT" section in the gine at 3,000–5,000 r/min for 1 or Always use the recommended fuel as CHAPTER 3, apply the foam-air-filter 2 minutes.
  • Page 23 STARTING AND BREAK-IN The engine fails to start 4. Operate the machine in the lower Pull the hot starter lever all the way gears at moderate throttle open- out and while holding the lever, kick ings for five to eight minutes. the kickstarter crank 10 to 20 times to 5.
  • Page 24 TORQUE-CHECK POINTS TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and fuel tank Fuel tank to frame Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Steering stem to handlebar Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar...
  • Page 25 CLEANING AND STORAGE CLEANING AND STORAGE 1. Drain the fuel tank, fuel lines, and the carburetor float bowl. CLEANING 2. Remove the spark plug, pour a ta- Frequent cleaning of your machine blespoon of SAE 10W-30 motor will enhance its appearance, maintain oil in the spark plug hole, and re- good overall performance, and ex- install the plug.

  • Page 26: Specifications

    GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: WR450FX (CDN, AUS, NZ) WR450F (ZA) Model code number: 5TJK (CDN) 5TJM (AUS, NZ, ZA) Dimensions: CDN, ZA AUS, NZ Overall length 2,175 mm (85.63 in) 2,190 mm (86.22 in) ← Overall width 825 mm (32.48 in)
  • Page 27 GENERAL SPECIFICATIONS Oil capacity: Engine oil Periodic oil change 0.95 L (0.84 Imp qt, 1.00 US qt) With oil filter replacement 1.0 L (0.88 Imp qt, 1.06 US qt) Total amount 1.2 L (1.06 Imp qt, 1.27 US qt) Coolant capacity (including all routes): 1.0 L (0.88 Imp qt, 1.06 US qt) Air filter: Wet type element...
  • Page 28 MAINTENANCE SPECIFICATIONS Brake: Front brake type Single disc brake Operation Right hand operation Rear brake type Single disc brake Operation Right foot operation Suspension: Front suspension Telescopic fork Rear suspension Swingarm (link type monocross suspension) Shock absorber: Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/gas, oil damper...
  • Page 29 MAINTENANCE SPECIFICATIONS Item Standard Limit Camshaft: Drive method Chain drive (Left) ---- Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in) ---- Camshaft outside diameter 21.959–21.972 mm (0.8645–0.8650 in) ---- Shaft-to-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) 0.08 mm (0.003 Cam dimensions Intake "A"...
  • Page 30 MAINTENANCE SPECIFICATIONS Item Standard Limit "B" face width (IN) 2.26 mm (0.089 in) ---- "B" face width (EX) 2.26 mm (0.089 in) ---- "C" seat width (IN) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 "C" seat width (EX) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 "D"...
  • Page 31 MAINTENANCE SPECIFICATIONS Item Standard Limit Valve spring: Free length (IN) 39.46 mm (1.55 in) 38.46 mm (1.51 Free length (EX) 37.61 mm (1.48 in) 36.61 mm (1.44 Set length (valve closed) (IN) 27.87 mm (1.10 in) ---- Set length (valve closed) (EX) 28.38 mm (1.12 in) ---- Compressed force (installed) (IN)
  • Page 32 MAINTENANCE SPECIFICATIONS Item Standard Limit Piston rings: Top ring: Type Barrel ---- Dimensions (B × T) 1.2 × 3.5 mm (0.05 × 0.14 in) ---- End gap (installed) 0.20–0.30 mm (0.008–0.012 in) 0.55 mm (0.022 Side clearance (installed) 0.030–0.065 mm (0.0012–0.0026 in) 0.12 mm (0.005 2nd ring: Type...
  • Page 33 MAINTENANCE SPECIFICATIONS Item Standard Limit Clutch: Friction plate thickness 2.92–3.08 mm (0.115–0.121 in) 2.8 mm (0.110 Quantity ---- Clutch plate 1 thickness 1.9–2.1 mm (0.075–0.083 in) ---- Quantity ---- Warp limit ---- 0.1 mm (0.004 Clutch plate 2 thickness 1.5–1.7 mm (0.059–0.067 in) ---- Quantity ----...
  • Page 34 MAINTENANCE SPECIFICATIONS Item Standard Limit Lubrication system: Oil filter type Paper type ---- Oil pump type Trochoid type ---- Tip clearance 0.12 mm or less (0.0047 in or less) 0.20 mm (0.008 Side clearance 0.09–0.17 mm (0.0035–0.0067 in) 0.24 mm (0.009 Housing and rotor clearance 0.03–0.10 mm (0.0012–0.0039 in) 0.17 mm...
  • Page 35 MAINTENANCE SPECIFICATIONS Item Standard Limit Swingarm: Swingarm free play limit ---- 1.0 mm (0.04 Wheel: Front wheel type Spoke wheel ---- Rear wheel type Spoke wheel ---- Front rim size/material 21 × 1.60/Aluminum ---- Rear rim size/material 18 × 2.15/Aluminum ---- Rim runout limit: Radial...
  • Page 36 4.6–6.8 k at 20 °C (68 °F) ---- Charging system: System type AC magneto ---- Model (stator)/manufacturer 5TJ 50/YAMAHA ---- Normal output 14 V/120 W at 5,000 r/min ---- Ω Charging coil resistance (color) 0.288–0.432 at 20 °C (68 °F) (White–...
  • Page 37 TIGHTENING TORQUES Item Standard Limit Starting circuit cut-off relay: Model/manufacturer ACM33221 M06/MATSUSHITA ---- Ω Coil winding resistance 75.69–92.51 at 20 °C (68 °F) ---- Fuse (amperage×quantity): Main fuse 10 A × 1 ---- Reserve fuse 10 A × 1 ---- TIGHTENING TORQUES ENGINE △...
  • Page 38 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Throttle cable cover M5 × 0.8 Hot starter plunger M12 × 1.0 Hot starter cable adjust bolt and locknut M6 × 0.75 Air filter element M6 × 1.0 Radiator stay M6 ×...
  • Page 39 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Balancer weight plate M6 × 1.0 Drive sprocket M20 × 1.0 Drive chain sprocket cover M6 × 1.0 Shift pedal M6 × 1.0 Shift guide M6 × 1.0 Stopper lever M6 ×...
  • Page 40 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb △ Front wheel axle holder M8 × 1.25 △ Front brake disc and wheel hub M6 × 1.0 △ Rear brake disc and wheel hub M6 × 1.0 △...
  • Page 41 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb △ Front fender mounting M6 × 1.0 △ Rear fender mounting(front) M6 × 1.0 △ Rear fender mounting (rear) M6 × 1.0 Multi-function display bracket mounting M6 × 1.0 Multi-function display mounting M5 ×...
  • Page 42 TIGHTENING TORQUES GENERAL TORQUE TORQUE SPECIFI- SPECIFICATIONS CATION (Bolt This chart specifies torque for stan- (Nut) dard fasteners with standard I.S.O. m•kg ft•lb pitch threads. Torque specifications 6 mm for special components or assem- blies are included in the applicable sections of this book.
  • Page 43 TIGHTENING TORQUES 2-18...
  • Page 44 LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS Oil filter element Oil pump Drive axle Main axle Crankshaft Connecting rod From cylinder To oil tank 2-19...
  • Page 45 LUBRICATION DIAGRAMS Intake camshaft Exhaust camshaft To main axle From oil pump 2-20...
  • Page 46 CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM Fuel tank breather hose 10. Neutral switch lead Insert the end of the fuel tank Clamp 11. AC magneto lead breather hose into the hole in Diode 12. Brake hose the steering stem. Hot starter cable 13.
  • Page 47 CABLE ROUTING DIAGRAM Fasten the diode (at the mark- ing), throttle cable and hot start- er cable onto the frame. Locate the clamp end facing toward the lower right of the frame and with the tie end facing downward. Fasten the wire harness, throttle position sensor lead and clutch cable onto the frame.
  • Page 48 CABLE ROUTING DIAGRAM Throttle cable (pull) Fasten the catch tank hose and Pass the carburetor breather Throttle cable (return) air induction hose (air cut-off hose (of the throttle cable cover) Catch tank hose valve-rear of cylinder head) onto through the hose holder. Ignition coil the frame.
  • Page 49 CABLE ROUTING DIAGRAM Brake master cylinder If the brake hose contacts the Brake hose holder spring (rear shock absorber), Brake hose correct its twist. Install the brake hose so that its Install the brake hose so that its pipe portion directs as shown pipe portion directs as shown and lightly touches the projec- and lightly touches the projec-...
  • Page 50 CABLE ROUTING DIAGRAM Clamp Fasten the wire harness to the Fasten the wire harness to the Positive battery lead upper engine bracket (left side). upper engine bracket (left side). Battery Locate the clamp end facing to- Locate the clamp end facing to- Negative battery lead ward the upper side of the frame ward the upper side of the frame...
  • Page 51 CABLE ROUTING DIAGRAM Connect the wire harness to the starter relay. Fasten the catch tank breather hose and catch tank hose to the rear frame. Clamp them close to where they are joined to the frame. Fasten the pipe tightly enough not to crush it.
  • Page 52 CABLE ROUTING DIAGRAM Throttle cable 12. Upper bracket Fasten the engine stop switch Clamp 13. Clutch switch coupler lead and clutch switch lead to Brake hose 14. Engine stop switch coupler the handlebar with the plastic Clutch cable 15. Multi-function display coupler bands.
  • Page 53 CABLE ROUTING DIAGRAM Pass the throttle cables, clutch cable and hot starter cable be- tween the upper bracket and multi-function display bracket. Fasten the multi-function display leads to the bracket. Cut off the tie end. Secure the coupler by pushing it into the hole in the multi-function display bracket.

  • Page 54: Regular Inspection And Adjustments

    The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. Every...
  • Page 55 MAINTENANCE INTERVALS Every Every After third fifth (or Every As re- Item break- Remarks race (or 500 1,000 quired CLUTCH ● ● Inspect and adjust Inspect housing, friction plate, clutch plate and spring. ● Replace TRANSMISSION ● Inspect ● Replace bearing SHIFT FORK, SHIFT CAM, GUIDE BAR ●...
  • Page 56 MAINTENANCE INTERVALS Every Every After third fifth (or Every As re- Item break- Remarks race (or 500 1,000 quired FUEL TANK, COCK ● ● Clean and inspect BRAKES ● ● Adjust lever position and pedal height ● ● Lubricate pivot point ●...
  • Page 57 Lubricate Lithium base grease THROTTLE, CONTROL CABLE ● ● Check routing and connection ● ● Lubricate Yamaha cable lube or SAE 10W-30 motor oil HOT STARTER, CLUTCH LEVER ● Inspect free play BATTERY ● Check terminal for looseness and corrosion...
  • Page 58 PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation or practice, make sure the machine is in good operating condition. Before using this machine, check the following points. GENERAL INSPECTION AND MAINTENANCE Item Routine Page Check that coolant is filled up to the radiator cap. Check the cool- Coolant P.3-9 –...
  • Page 59 ENGINE ENGINE REMOVING THE SEAT, FUEL TANK AND SIDE COVERS Order Part name Q'ty Remarks Turn the fuel cock to "OFF". Disconnect the fuel hose. Seat Air scoop (left and right) Bolt (fuel tank) Fuel tank Left side cover Open the air filter case cover. Right side cover Refer to removal section.
  • Page 60 ENGINE REMOVING THE SIDE COVER 1. Remove: • Bolt (side cover) • Right side cover "1" Draw the side cover backward to re- move it because its claw "a" is insert- ed in the air filter case.
  • Page 61 ENGINE REMOVING THE EXHAUST PIPE AND SILENCER Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND SIDE Right side cover COVERS" section. Bolt (silencer clamp) Only loosening. Bolt [silencer (front)] Bolt [silencer (rear)] Collar Silencer Silencer clamp Nut (exhaust pipe) Bolt (exhaust pipe) Exhaust pipe Gasket...

  • Page 62: Engine

    ENGINE CHECKING THE SILENCER AND EXHAUST PIPE Take care so that coolant does not 1. Inspect: splash on painted surfaces. If it • Gasket "1" splashes, wash it away with water. → Damage Replace. 1. Place a container under the en- gine.
  • Page 63 ENGINE → Coolant leakage Repair or re- place. Apply water on the radiator cap seal. • Radiator hose → Swelling Replace. ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: • Clutch lever free play "a" → Out of specification Adjust. Handling notes of coolant: Clutch lever free play "a"...
  • Page 64 ENGINE Never run the engine without the air filter element in place; this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage. 1. Open the air filter case cover "1" 2. Adjust: 3.
  • Page 65 ENGINE 5. Inspect: CHECKING THE ENGINE OIL • Air filter element LEVEL → Damage Replace. 1. Stand the machine on a level sur- 6. Apply: face. • Foam-air-filter oil or equivalent oil to the element • When checking the oil level make sure that the machine is upright.
  • Page 66 ENGINE • Engine oil Oil quantity: • Do not add any chemical addi- Periodic oil change: tives or use oils with a grade of 0.95 L (0.84 Imp qt, CD "a" or higher. 1.00 US qt) • Do not use oils labeled "ENERGY With oil filter replace- CONSERVING II"...
  • Page 67 ENGINE ADJUSTING THE ENGINE IDLING Refer to "AIR INDUCTION SYS- SPEED TEM" section in the CHAPTER 5. 1. Start the engine and thoroughly • Spark plug warm it up. • Engine upper bracket 2. Adjust: • Cylinder head cover • Engine idling speed Refer to "CAMSHAFTS"...
  • Page 68 ENGINE • Apply the engine oil on the valve lift- ers. • Apply the molybdenum disulfide oil on the valve stem ends. • Valve lifter must turn smoothly when rotated with a finger. • Be careful to reinstall valve lifters c.
  • Page 69 ENGINE INTAKE EXHAUST 3-16...

  • Page 70: Chassis

    CHASSIS CLEANING THE SPARK • Silencer cap ARRESTER (For USA) Silencer cap: 5 Nm (0.5 m•kg, 3.6 ft•lb) • Be sure the exhaust pipe and si- lencer are cool before cleaning the spark arrester. First tighten the two screws "a" locat- •...
  • Page 71 CHASSIS b. Turn the adjusting nut "2" until the pedal height "a" is within specified height. c. Tighten the locknut. • Adjust the pedal height between the maximum "A" and the mini- mum "B" as shown. (In this ad- 2. Remove: b.
  • Page 72 CHASSIS Do not reuse the drained brake flu- g. Tighten the bleed screw. Bleed screw: 6 Nm (0.6 m•kg, 4.3 ft•lb) Install the brake caliper "8" and 2. Replace: tighten the pad pin "9". • Brake pad h. Install the brake pad "10" and pad Bolt (brake caliper): pin "11".
  • Page 73 CHASSIS 3. Inspect: • Brake fluid level Refer to "CHECKING THE BRAKE FLUID LEVEL" section. 4. Check: • Brake pedal operation → A softy or spongy feeling Bleed brake system. Refer to "BLEEDING THE HY- Lower level 3. Clean: DRAULIC BRAKE SYSTEM" sec- A.
  • Page 74 CHASSIS e. Tighten the locknuts. When installing the drive chain, apply Locknut: Before checking and/or adjusting, ro- the lithium soap base grease on the 19 Nm (1.9 m•kg, 13 tate the rear wheel through several chain joint and O-rings. ft•lb) revolutions and check the slack sev- eral times to find the tightest point.
  • Page 75 CHASSIS 1. Elevate the front wheel by placing Abnormal noise/unsmooth action → a suitable stand under the engine. Grease the pivoting points or Always adjust each front fork to 2. Remove the air bleed screw "1" repair the pivoting points. the same setting.
  • Page 76 CHASSIS Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. 5. Tighten: ADJUSTING THE REAR SHOCK • Locknut ABSORBER HIGH COMPRESSION 6. Install: DAMPING FORCE • Rear frame (upper) 1. Adjust: •...
  • Page 77 CHASSIS CHECKING THE TIRE PRESSURE 1. Measure: • Tire pressure → Out of specification Adjust. Standard tire pressure: 100 kPa (1.0 kgf/cm 15 psi) 2. Inspect: d. Tighten the steering ring nut "3" • Bearing free play using steering nut wrench "4". •...
  • Page 78 CHASSIS • Install the handlebar so that the pro- jection "c" of the handlebar upper holder is positioned at the mark on the handlebar as shown. • Insert the end of the fuel breather hose "12" into the hole in the steer- ing stem.
  • Page 79 Footrest pivot avoid getting grease on the brake Throttle-to-handlebar contact discs. Drive chain Tube guide cable winding por- tion Throttle cable end Clutch cable end 10. Hot starter cable end Use Yamaha cable lube or equivalent on these areas. 3-26...

  • Page 80: Electrical

    ELECTRICAL • Keep batteries away from fire, ELECTRICAL sparks or open flames (e.g., CHECKING THE SPARK PLUG welding equipment, lighted ciga- 1. Remove: rettes). • Spark plug • DO NOT SMOKE when charging 2. Inspect: or handling batteries. • Electrode "1" •...
  • Page 81 ELECTRICAL • To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery. • Before removing the battery charger lead clips from the bat- tery terminals, be sure to turn off the battery charger.
  • Page 82 ELECTRICAL Charging method using a variable voltage charger 3-29...
  • Page 83 ELECTRICAL Charging method using a constant voltage charger 3-30...
  • Page 84 ELECTRICAL 6. Install: • Battery • Battery band 7. Connect: • Battery leads (to the battery terminals) First, connect the positive lead "1", Reserve fuse 3. Remove: then the negative lead "2". ∞ c. If the pocket tester indicates " ", •...
  • Page 85 ELECTRICAL ADJUSTING THE HEADLIGHT BEAMS 1. Adjust: • Headlight beam (vertically) Adjusting steps: a. Turn the adjusting screw "1" in di- rection "a" or "b". Direction "a" Headlight beam is raised. Direction "b" Headlight beam is lowered. 3-32...
  • Page 86 ENGINE TUNING • After installing the carburetor, CONSTRUCTION OF check that the throttle operates CARBURETOR AND SETTING ENGINE correctly and opens and closes PARTS CARBURETOR SETTING smoothly. The FLATCR carburetor has a prima- • The air/fuel mixture will vary de- ry main jet.
  • Page 87 ENGINE ADJUSTING THE PILOT JET ADJUSTING THE LEAK JET Effects of changing the jet needle The richness of the air-fuel mixture (ADJUSTING THE ACCELERATOR groove position (reference) with the throttle open 1/4 or less can PUMP) be set by adjusting the pilot jet "1". The leak jet "1"...
  • Page 88 ENGINE CARBURETOR SETTING PARTS Part Main jet Size number (-14943-) Rich #185 4MX-44 #182 4MX-94 #180 4MX-43 #178 4MX-93 #175 4MX-42 #172 4MX-92 #170 4MX-41 #168 4MX-91 #165 4MX-40 (STD) Lean #162 4MX-90 Part Pilot jet Size number (-14948-) Rich 4MX-09 4MX-08 4MX-07...
  • Page 89 ENGINE EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM Symptom Setting Checking → At full throttle Increase main jet calibration no. (Gradual- Discoloration of spark plug If tan color, it Hard breathing is in good condition. Shearing noise If cannot be corrected: Whitish spark plug Clogged float valve seat ↓...
  • Page 90 CHASSIS CHASSIS 1. Setting of air spring characteris- Part name Size Part number tics SELECTION OF THE SECONDARY Rear wheel • Change the fork oil level. REDUCTION RATIO (SPROCKET) sprocket 2. Setting of spring preload "2" • Change the spring. Secondary reduction ratio = 48T 5GS-25448-50 •...
  • Page 91 CHASSIS • Front fork spring "2" SPRING SPRI I.D. PART TYPE MARK NUMBER RATE (slits) (-23141-) 0.408 5TJ-00 0.418 5TJ-10 A. Load SOFT 0.428 5TJ-20 B. Fork stroke 0.438 5TJ-30 |||| Without adjustment washer (standard) 0.449 5TJ-40 ||||| 1 adjustment washer 0.459 5TJ-L0 —...
  • Page 92 CHASSIS CHOOSING SET LENGTH SETTING OF SPRING AFTER REAR SHOCK ABSORBER 1. Place a stand or block under the REPLACEMENT SETTING PARTS engine to put the rear wheel After replacement, be sure to adjust • Rear shock spring "1" above the floor, and measure the the spring to the set length [sunken SPRIN SPRI...
  • Page 93 CHASSIS SUSPENSION SETTING (FRONT FORK) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in). Section Medi- Symptom...
  • Page 94 CHASSIS SUSPENSION SETTING (REAR SHOCK ABSORBER) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Adjust the rebound damping in 2-click increments or decrements. •...
  • Page 95 RADIATOR ENGINE RADIATOR REMOVING THE RADIATOR Order Part name Q'ty Remarks Refer to "CHANGING THE COOLANT" sec- Drain the coolant. tion in the CHAPTER 3. Refer to "SEAT, FUEL TANK AND SIDE Seat, fuel tank and left side cover COVERS" section in the CHAPTER 3. Refer to "EXHAUST PIPE AND SILENCER"...
  • Page 96 RADIATOR Order Part name Q'ty Remarks Pipe 1/O-ring Catch tank breather hose Catch tank...
  • Page 97 RADIATOR HANDLING NOTE • Bolt (catch tank) "2" Bolt (catch tank): 7 Nm (0.7 m•kg, 5.1 Do not remove the radiator cap ft•lb) when the engine and radiator are hot. Scalding hot fluid and steam • Bolt (catch tank) "3" may be blown out under pressure, Bolt (catch tank): which could cause serious injury.
  • Page 98 CARBURETOR CARBURETOR REMOVING THE CARBURETOR Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS" section in the CHAPTER 3. Refer to "REAR SHOCK ABSORBER" sec- Rear shock absorber tion in the CHAPTER 6. Clamp Throttle position sensor lead coupler Throttle cable cover...
  • Page 99 CARBURETOR DISASSEMBLING THE CARBURETOR Order Part name Q'ty Remarks Carburetor breather hose Valve lever housing cover Screw (throttle shaft) Throttle valve Needle holder Jet needle Accelerator pump cover Spring Diaphragm (accelerator pump) Air cut valve cover Spring (air cut valve) Diaphragm (air cut valve) Float chamber Leak jet...
  • Page 100 CARBURETOR Order Part name Q'ty Remarks Needle jet Spacer Pilot jet Starter jet Push rod Pull the push rod. Throttle shaft assembly Push rod link lever assembly Pilot air jet Cold starter plunger...
  • Page 101 CARBURETOR → HANDLING NOTE Dust "b" Clean. • Filter "c" Measurement and adjustment → Clogged Clean. steps: Do not loosen the screw (throttle a. Hold the carburetor in an upside position sensor) "1" except when down position. changing the throttle position sen- sor due to failure because it will cause a drop in engine perfor- •...
  • Page 102 CARBURETOR CHECKING THE ACCELERATOR 2. Install: 7. Install: PUMP • Pilot air jet "1" • Spring "1" 1. Inspect: To throttle shaft "2". • Diaphragm (accelerator pump) "1" Install the bigger hook "a" of the • Spring (accelerator pump) "2" spring fits on the stopper "b"...
  • Page 103 CARBURETOR • Hose holder (carburetor breather 16. Install: hose) "5" • Throttle valve assembly "1" • Screw (throttle shaft) "2" Install the valve lever rollers "3" into the slits "a" of the throttle valve. 9. Install: • Push rod "1" 13.
  • Page 104 CARBURETOR • Hot starter plunger "1" Hot starter plunger: 2 Nm (0.2 m•kg, 1.4 ft•lb) a. Fully turn in the accelerator pump 8. Install: adjusting screw "3". • Throttle position sensor lead cou- b. Check that the link lever "4" has pler "1"...
  • Page 105 AIR INDICTOIN SYSTEM AIR INDICTOIN SYSTEM REMOVING THE AIR INDUCTION SYSTEM Order Part name Q'ty Remarks Bracket Air cut-off valve assembly Air induction hose (air cut-off valve - front of cyl- inder head) Air induction pipe Gasket Air induction hose (air cut-off valve - rear of cylin- der head) Air induction hose (air cut-off valve - air filter case)
  • Page 106 AIR INDICTOIN SYSTEM CHECKING THE AIR INDUCTION SYSTEM 1. Inspect: • Air induction hose → Crack/damage Replace. • Air induction pipe → Crack/damage Replace. 2. Check: • Operation of air cut valve From air filter Pass air through the pipe and To cylinder head (exhaust check the air cut valve for opera- port)
  • Page 107 CAMSHAFTS CAMSHAFTS REMOVING THE CYLINDER HEAD COVER Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS" section in the CHAPTER 3. Air cut-off valve assembly Refer to "AIR INDUCTION SYSTEM" section. Engine upper bracket (right) Refer to "ENGINE REMOVAL"...
  • Page 108 CAMSHAFTS REMOVING THE CAMSHAFTS Order Part name Q'ty Remarks Timing mark accessing screw Refer to removal section. Crankshaft end accessing screw Refer to removal section. Timing chain tensioner cap bolt Refer to removal section. Timing chain tensioner Refer to removal section. Gasket Refer to removal section.
  • Page 109 CAMSHAFTS → REMOVING THE CAMSHAFT Out of specification Replace. 1. Remove: Cam lobes length: • Timing mark accessing screw "1" Intake "a": • Crankshaft end accessing screw 30.100–30.200 mm "2" (1.1850–1.1890 in) <Limit>: 30.000 mm (1.1811 in) Intake "b": 4. Remove: 22.450–22.550 mm •...
  • Page 110 CAMSHAFTS Camshaft-to-cap clear- ance: 0.028–0.062 mm (0.0011–0.0024 in) <Limit>:0.08 mm (0.003 CHECKING THE CAMSHAFT Measurement steps: SPROCKET a. Install the camshaft onto the cylin- 1. Inspect: der head. • Camshaft sprocket "1" ® b. Position a strip of Plastigauge → Wear/damage Replace the "1"...
  • Page 111 CAMSHAFTS b. With the rod fully wound and the chain tensioner UP mark "a" fac- Do not turn the crankshaft during ing upward, install the gasket "1", the camshaft installation. Damage the timing chain tensioner "2", and or improper valve timing will re- the gasket "3", and tighten the bolt sult.
  • Page 112 CYLINDER HEAD CYLINDER HEAD REMOVING THE CYLINDER HEAD Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS" section in the CHAPTER 3. Refer to "EXHAUST PIPE AND SILENCER" Exhaust pipe and silencer section in the CHAPTER 3.
  • Page 113 CYLINDER HEAD CHECKING THE CYLINDER HEAD • Cylinder head "4" e. Remove the bolts. 1. Eliminate: f. Again apply the molybdenum dis- • Carbon deposits (from the com- ulfide grease on the threads and While pulling up the timing chain, in- bustion chambers) contact surfaces of the bolts and stall the timing chain guide (exhaust...
  • Page 114 CYLINDER HEAD 3. Install: • Bolt (cylinder head) "1" Bolt (cylinder head): 10 Nm (1.0 m•kg, 7.2 ft•lb) 5-20...
  • Page 115 VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS REMOVING THE VALVES AND VALVE SPRINGS Order Part name Q'ty Remarks Cylinder head Refer to "CYLINDER HEAD" section. Valve lifter Refer to removal section. Adjusting pad Refer to removal section. Valve cotter Refer to removal section.
  • Page 116 VALVES AND VALVE SPRINGS REMOVING THE VALVE LIFTER AND VALVE COTTER 1. Remove: • Valve lifter "1" • Pad "2" Identify each lifter "1" and pad "2" po- sition very carefully so that they can CHECKING THE VALVE b. Install the new valve guide using a be reinstalled in their original place.
  • Page 117 VALVES AND VALVE SPRINGS → Out of specification Replace. Margin thickness: Intake: 1.0 mm (0.039 in) <Limit>:0.85 mm (0.033 in) Exhaust: 1.0 mm (0.039 in) c. Install the valve into the cylinder <Limit>:0.85 mm head. Measurement steps: (0.033 in) d. Turn the valve until the valve face a.
  • Page 118 VALVES AND VALVE SPRINGS INSTALLING THE VALVES 1. Apply: Hitting the valve tip with excessive • Molybdenum disulfide oil force could damage the valve. Onto the valve stem and valve stem seal. 2. Install: • Valves "1" • Valve spring seats "2" 2.
  • Page 119 CYLINDER AND PISTON CYLINDER AND PISTON REMOVING THE CYLINDER AND PISTON Order Part name Q'ty Remarks Cylinder head Refer to "CYLINDER HEAD" section. Bolt (cylinder) Cylinder Gasket Dowel pin Piston pin clip Refer to removal section. Piston pin Refer to removal section. Piston Refer to removal section.
  • Page 120 CYLINDER AND PISTON REMOVING THE PISTON AND • Piston-to-cylinder clearance Piston-to-cylinder clear- PISTON RING ance: 1. Remove: 0.020–0.045 mm Measurement steps: • Piston pin clip "1" (0.0008–0.0018 in) a. Measure the cylinder bore "C" • Piston pin "2" <Limit>:0.1 mm (0.004 with a cylinder bore gauge.
  • Page 121 CYLINDER AND PISTON • Ring end gap c. Calculate the piston pin-to-piston → Out of specification Replace. clearance with the following for- • Apply engine oil onto the piston pin mula. and piston. You cannot measure the end gap on •...
  • Page 122 CLUTCH CLUTCH REMOVING THE CLUTCH Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Brake pedal Refer to "ENGINE REMOVAL" section. Clutch cable Disconnect at engine side. Clutch cover Gasket Dowel pin Clutch spring...
  • Page 123 CLUTCH Order Part name Q'ty Remarks Nut (clutch boss) Refer to removal section. Lock washer Refer to removal section. Clutch boss Refer to removal section. Thrust washer Primary driven gear Push lever shaft 5-29...
  • Page 124 CLUTCH → REMOVING THE CLUTCH BOSS CHECKING THE CLUTCH Wear/damage Replace. 1. Remove: SPRINGS • Nut "1" 1. Measure: • Lock washer "2" • Clutch spring free length "a" → • Clutch boss "3" Out of specification Replace springs as a set. Straighten the lock washer tab and Clutch spring free use the clutch holding tool "4"...
  • Page 125 CLUTCH • Nut (clutch boss) "2" • Check the clutch plate for thickness 8. Install: and install 4 thicker ones "a" on the • Clutch spring Nut (clutch boss): engine side and 3 thinner ones "b" • Bolt (clutch spring) 75 Nm (7.5 m•kg, 54 on the outside.
  • Page 126 OIL FILTER ELEMENT AND WATER PUMP OIL FILTER ELEMENT AND WATER PUMP REMOVING THE OIL FILTER ELEMENT AND WATER PUMP 10 Nm (1.0 m kg, 7.2 ft lb) 33 Nm (3.3 m kg, 24 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 12 Nm (1.2 m kg, 8.7 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb)
  • Page 127 OIL FILTER ELEMENT AND WATER PUMP 10 Nm (1.0 m kg, 7.2 ft lb) 33 Nm (3.3 m kg, 24 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 12 Nm (1.2 m kg, 8.7 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 14 Nm (1.4 m kg, 10 ft lb)
  • Page 128 OIL FILTER ELEMENT AND WATER PUMP REMOVING THE IMPELLER SHAFT 1. Remove: • Impeller "1" • Washer "2" • Impeller shaft "3" Hold the impeller shaft on its width CHECKING THE BEARING INSTALLING THE IMPELLER across the flats "a" with spanners, 1.
  • Page 129 OIL FILTER ELEMENT AND WATER PUMP • O-ring "3" • Coolant pipe "1" • Bolt (coolant pipe) "2" Bolt (coolant pipe): 10 Nm (1.0 m•kg, 7.2 ft•lb) 2. Install: 2. Install: Apply the lithium soap base grease • Right crankcase cover "1" •...
  • Page 130 BALANCER BALANCER REMOVING THE BALANCER Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Refer to "OIL FILTER ELEMENT AND WA- Right crankcase cover TER PUMP" section. Stator Refer to "CDI MAGNETO" section. Nut (balancer) Refer to removal section. Nut (primary drive gear) Refer to removal section.
  • Page 131 BALANCER REMOVING THE BALANCER • Nut (balancer) "9" 1. Straighten the lock washer tab. Nut (balancer): 2. Loosen: 45 Nm (4.5 m•kg, 33 • Nut (balancer) "1" ft•lb) • Nut (primary drive gear) "2" • Nut (balancer shaft driven gear) "3"...
  • Page 132 OIL PUMP OIL PUMP REMOVING THE OIL PUMP Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Refer to "OIL FILTER ELEMENT AND WA- Right crankcase cover TER PUMP" section. Circlip Washer Oil pump drive gear Oil pump assembly Dowel pin Outer rotor 2 Circlip...
  • Page 133 OIL PUMP Order Part name Q'ty Remarks Oil pump drive shaft Rotor housing 5-39...
  • Page 134 OIL PUMP CHECKING THE OIL PUMP INSTALLING THE OIL PUMP • Bolt (oil pump assembly) "4" 1. Inspect: 1. Install: Bolt (oil pump assem- • Oil pump drive gear • Oil pump drive shaft "1" bly): • Oil pump drive shaft •...
  • Page 135 KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Remarks Oil pump Refer to "OIL PUMP" section. Kick idle gear Kick shaft assembly Refer to removal section. Spring guide Torsion spring Ratchet wheel Kick gear...
  • Page 136 KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Remarks Pawl Pawl pin Spring Bolt (stopper lever) Stopper lever Torsion spring Segment Refer to removal section. 5-42...
  • Page 137 KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT • Kick shaft "2" CHECKING THE STOPPER LEVER → ASSEMBLY Wear/damage Replace. 1. Inspect: 1. Remove: • Spring "3" • Stopper lever "1" → • Kick shaft assembly "1" Broken Replace. →...
  • Page 138 KICK SHAFT AND SHIFT SHAFT INSTALLING THE SHIFT GUIDE INSTALLING THE SHIFT SHAFT AND SHIFT LEVER ASSEMBLY 1. Install: 1. Install: • Roller "1" • Spring "1" • Collar "2" • Pawl pin "2" • Torsion spring "3" • Pawl "3" •...
  • Page 139 KICK SHAFT AND SHIFT SHAFT INSTALLING THE KICK IDLE GEAR 1. Install: • Kick idle gear "1" • Washer "2" • Circlip "3" • Apply the engine oil on the kick idle gear inner circumference. • Install the kick idle gear with its de- pressed side "a"...
  • Page 140 AC MAGNETO AND STARTER CLUTCH AC MAGNETO AND STARTER CLUTCH REMOVING THE AC MAGNETO AND STARTER CLUTCH Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS"...
  • Page 141 AC MAGNETO AND STARTER CLUTCH Order Part name Q'ty Remarks Starter clutch assembly cover Refer to removal section. Starter clutch Refer to removal section. Starter clutch drive gear Holder Pickup coil Stator Tighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb), loosen and retighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb). 5-47...
  • Page 142 AC MAGNETO AND STARTER CLUTCH REMOVING THE ROTOR b. When turning the starter clutch 1. Remove: drive gear counterclockwise "B", • Nut (rotor) "1" the starter clutch and the starter • Washer clutch drive gear should engage. Use the sheave holder "2". If the starter clutch drive gear and starter clutch do not engage, the Sheave holder:...
  • Page 143 AC MAGNETO AND STARTER CLUTCH • Apply the sealant to the grommet of the AC magneto lead. Apply the engine oil on the shaft, bearing and idle gear inner circumfer- YAMAHA Bond No. 1215 ence. ® (ThreeBond No. 1215): 90890-85505 5.
  • Page 144 AC MAGNETO AND STARTER CLUTCH 11. Connect: • AC magneto lead Refer to "CABLE ROUTING DIA- GRAM" section in the CHAPTER 12. Install: • Shift pedal "1" • Bolt (shift pedal) Bolt (shift pedal): 12 Nm (1.2 m•kg, 8.7 ft•lb) When installing the shift pedal onto the shift shaft, be sure that the center of the shift pedal is about 5.1 mm (0.2...
  • Page 145 ENGINE REMOVAL ENGINE REMOVAL REMOVING THE ENGINE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the frame. Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS"...
  • Page 146 ENGINE REMOVAL Order Part name Q'ty Remarks Ignition coil Disconnect the AC magneto lead. Refer to "ELECTRIC STARTING SYSTEM" Disconnect the starter motor lead. section in the CHAPTER 7. Negative battery lead Disconnect at the engine side. Engine guard Neutral switch Drive chain sprocket cover Nut (drive sprocket) Refer to removal section.
  • Page 147 ENGINE REMOVAL HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE DRIVE SPROCKET 1. Remove: INSTALLING THE ENGINE • Nut (drive sprocket) "1" 1. Install: • Lock washer "2" • Engine "1" Install the engine from right side.
  • Page 148 ENGINE REMOVAL • Nut (drive sprocket) "2" Nut (drive sprocket): 75 Nm (7.5 m•kg, 54 ft•lb) Tighten the nut while applying the rear brake. Make sure to tighten to specifica- tion; otherwise, it may damage the other part that is fastened togeth- 3.
  • Page 149 CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT REMOVING THE CRANKSHAFT Order Part name Q'ty Remarks Engine Refer to "ENGINE REMOVAL" section. Piston Refer to "CYLINDER AND PISTON" section. Balancer Refer to "BALANCER" section. Refer to "KICK SHAFT AND SHIFT SHAFT" Kick shaft assembly section.
  • Page 150 CRANKCASE AND CRANKSHAFT Order Part name Q'ty Remarks Left crankcase Refer to removal section. Oil strainer Balancer shaft Refer to removal section. Crankshaft Refer to removal section. 5-56...
  • Page 151 CRANKCASE AND CRANKSHAFT REMOVING THE CRANKCASE BEARING Order Part name Q'ty Remarks Refer to "TRANSMISSION, SHIFT CAM AND Transmission SHIFT FORK" section. Refer to "TRANSMISSION, SHIFT CAM AND Shift cam and shift fork SHIFT FORK" section. Oil seal Bearing Refer to removal section. 5-57...
  • Page 152 CRANKCASE AND CRANKSHAFT DISASSEMBLING THE c. Remove the dowel pins and O- CRANKCASE ring. 1. Separate: • Right crankcase REMOVING THE BALANCER • Left crankcase SHAFT 1. Remove: Separation steps: • Balancer shaft "1" a. Remove the crankcase bolts, CHECKING THE TIMING CHAIN hose guide and clutch cable hold- Remove the balancer shaft with its AND TIMING CHAIN GUIDE...
  • Page 153 On the right crankcase. INSTALLING THE CRANKCASE the nut of the installing tool with the BEARING other. Operate the installing tool un- YAMAHA Bond No. 1215 1. Install: ® til the crankshaft bottoms against (ThreeBond No.1215): •...
  • Page 154 CRANKCASE AND CRANKSHAFT • Bolt (timing chain guide) Bolt (timing chain guide): 10 Nm (1.0 m•kg, 7.2 ft•lb) 8. Remove: • Sealant Forced out on the cylinder mating surface. 5. Install: 9. Apply: • Dowel pin "1" • Engine oil •...
  • Page 155 TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION, SHIFT CAM AND SHIFT FORK Order Part name Q'ty Remarks Engine Refer to "ENGINE REMOVAL" section. Refer to "CRANKCASE AND CRANK- Separate the crankcase. SHAFT" section. Main axle Refer to removal section.
  • Page 156 TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION 1. Remove: Apply the molybdenum disulfide oil • Main axle "1" on the inner and end surface of the • Drive axle "2" idler gear and on the inner surface of •...
  • Page 157 TRANSMISSION, SHIFT CAM AND SHIFT FORK • Be sure the circlip sharp-edged cor- ner "a" is positioned opposite side to the washer and gear "b". • Install the circlip with its ends "c" settled evenly on the spline crests. 6. Install: •...
  • Page 158 FRONT WHEEL AND REAR WHEEL CHASSIS FRONT WHEEL AND REAR WHEEL REMOVING THE FRONT WHEEL 21 Nm (2.1 m kg, 15 ft lb) 21 Nm (2.1 m kg, 15 ft lb) 90 Nm (9.0 m kg, 65 ft lb) 12 Nm (1.2 m kg, 8.7 ft lb) Order Part name Q'ty...
  • Page 159 FRONT WHEEL AND REAR WHEEL REMOVING THE REAR WHEEL 14 Nm (1.4 m kg, 10 ft lb) 125 Nm (12.5 m kg, 90 ft lb) 19 Nm (1.9 m kg, 13 ft lb) 50 Nm (5.0 m kg, 36 ft lb) 19 Nm (1.9 m kg, 13 ft lb) Order Part name...
  • Page 160 FRONT WHEEL AND REAR WHEEL HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE REAR WHEEL 1. Remove: • Wheel "1" CHECKING THE WHEEL AXLE 1. Measure: Push the wheel forward and remove •...
  • Page 161 FRONT WHEEL AND REAR WHEEL • Bolt (brake disc) "2" Bolt (brake disc): 12 Nm (1.2 m•kg, 8.7 ft•lb) Tighten the bolts in stage, using a crisscross pattern. 6. Install: INSTALLING THE REAR WHEEL 3. Install: • Wheel axle "1" 1.
  • Page 162 FRONT WHEEL AND REAR WHEEL • Bolt (brake disc) "2" Bolt (brake disc): 14 Nm (1.4 m•kg, 10 ft•lb) Tighten the bolts in stage, using a crisscross pattern. 6. Install: 10. Tighten: • Drive chain "1" • Nut (wheel axle) "1" Nut (wheel axle): Push the wheel "2"...
  • Page 163 FRONT BRAKE AND REAR BRAKE FRONT BRAKE AND REAR BRAKE REMOVING THE FRONT BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Drain the brake fluid. Refer to removal section. Brake hose holder (protector) Brake hose holder (brake caliper) Union bolt...
  • Page 164 FRONT BRAKE AND REAR BRAKE REMOVING THE REAR BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT WHEEL AND REAR Rear wheel WHEEL" section. Drain the brake fluid. Refer to removal section.
  • Page 165 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE CALIPER Order Part name Q'ty Remarks Front Rear Pad pin Brake pad Pad support Brake caliper piston Refer to removal section. Brake caliper piston dust seal Refer to removal section. Brake caliper piston seal Refer to removal section.
  • Page 166 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE MASTER CYLINDER Order Part name Q'ty Remarks Front Rear Brake master cylinder cap Diaphragm Reservoir float Brake master cylinder boot Circlip Use a long nose circlip pliers. Washer Push rod Brake master cylinder kit...
  • Page 167 FRONT BRAKE AND REAR BRAKE HANDLING NOTE • Cover piston with rag and use ex- Support the machine securely so treme caution when expelling there is no danger of it falling over. piston from cylinder. • Never attempt to pry out piston. DRAINING THE BRAKE FLUID 1.
  • Page 168 FRONT BRAKE AND REAR BRAKE • Internal parts should be lubricat- ed with brake fluid when in- • Install the piston with its shallow stalled. depressed side "a" facing the • Replace the brake caliper piston brake caliper. seals and brake caliper piston •...
  • Page 169 FRONT BRAKE AND REAR BRAKE • Pad pin plug "4" • Pad pin plug "4" Pad pin plug: Pad pin plug: 3 Nm (0.3 m•kg, 2.2 3 Nm (0.3 m•kg, 2.2 ft•lb) ft•lb) A. Front B. Rear 4. Install: • Brake master cylinder kit "1" •...
  • Page 170 FRONT BRAKE AND REAR BRAKE 2. Install: 2. Install: INSTALLING THE FRONT BRAKE • Brake lever "1" • Brake master cylinder "1" HOSE • Bolt (brake lever) "2" • Bolt (brake master cylinder) "2" 1. Install: • Copper washer "1" Bolt (brake lever): Bolt (brake master cylin- •...
  • Page 171 FRONT BRAKE AND REAR BRAKE • Nut (brake hose holder) "2" INSTALLING THE REAR BRAKE HOSE Nut (brake hose holder): 1. Install: 7 Nm (0.7 m•kg, 5.1 ft • Copper washer "1" •lb) • Brake hose "2" • Union bolt "3" Align the top "a"...
  • Page 172 FRONT BRAKE AND REAR BRAKE 3. Inspect: • Brake fluid level → Fluid at lower level Fill up. Refer to "CHECKING THE BRAKE FLUID LEVEL" section in the CHAPTER 3. 4. Install: • Reservoir float (front brake) • Diaphragm • Brake master cylinder cap "1" •...
  • Page 173 FRONT FORK FRONT FORK REMOVING THE FRONT FORK Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT WHEEL AND REAR Front wheel WHEEL" section. Refer to "FRONT BRAKE AND REAR Front brake caliper BRAKE"...
  • Page 174 FRONT FORK DISASSEMBLING THE FRONT FORK Order Part name Q'ty Remarks Front fork cap bolt Refer to removal section. Fork spring Drain the fork oil. Dust seal Refer to removal section. Stopper ring Refer to removal section. Inner tube Refer to removal section. Outer tube Piston metal Slide metal...
  • Page 175 FRONT FORK HANDLING NOTE REMOVING THE INNER TUBE 1. Remove: The front fork with a built-in piston • Dust seal "1" Support the machine securely so rod has a very sophisticated inter- • Stopper ring "2" there is no danger of it falling over. nal construction and is particularly Using slotted-head screwdriver.
  • Page 176 FRONT FORK The bending value is shown by one half of the dial gauge reading. Do not attempt to straighten a bent inner tube as this may dangerous- ly weaken the tube. 3. Install: 6. Install: • Copper washer "1" •...
  • Page 177 FRONT FORK 9. Install: 12. Install: 17. Fill: • Slide metal "1" • Dust seal "1" • Front fork oil • Oil seal washer "2" Until outer tube top surface with To outer tube slot. recom-mended fork oil once Apply the lithium soap base grease more.
  • Page 178 FRONT FORK To outer tube. Be sure to install the spring guide "2" when checking the oil level. Temporarily tighten the cap bolt. Never fail to make the oil level ad- justment between the maximum and minimum level and always ad- 23.
  • Page 179 FRONT FORK • Pinch bolt (upper bracket) "1" Pinch bolt (upper brack- et): 21 Nm (2.1 m•kg, 15 ft•lb) • Pinch bolt (lower bracket) "2" Pinch bolt (lower brack- 7. Install: et): • Protector "1" 21 Nm (2.1 m•kg, 15 •...
  • Page 180 HANDLEBAR HANDLEBAR REMOVING THE HANDLEBAR Order Part name Q'ty Remarks Headlight Hot starter cable Disconnect at the lever side. Hot starter lever holder Clutch cable Disconnect at the lever side. Clutch lever holder Disconnect the clutch switch lead. Engine stop switch Disconnect the engine stop switch lead.
  • Page 181 HANDLEBAR REMOVING THE BRAKE MASTER CYLINDER • Install the handlebar lower holder 1. Remove: with its side having the greater dis- • Brake master cylinder bracket "1" tance "a" from the mounting bolt • Brake master cylinder "2" center facing forward. •...
  • Page 182 HANDLEBAR Apply the adhesive on the tube • Screw (throttle cable cap) "2" guide "3". Screw (throttle cable cap): • Before applying the adhesive, wipe 4 Nm (0.4 m•kg, 2.9 off grease or oil on the tube guide ft•lb) surface "a" with a lacquer thinner. •...
  • Page 183 HANDLEBAR Apply the lithium soap base grease on the clutch cable end and hot start- er cable end. 13. Adjust: • Clutch lever free play Refer to "ADJUSTING THE CLUTCH CABLE FREE PLAY" section in the CHAPTER 3. • Hot starter lever free play Refer to "ADJUSTING THE HOT STARTER LEVER FREE PLAY"...
  • Page 184 STEERING STEERING REMOVING THE STEERING Order Part name Q'ty Remarks TIGHTENING STEPS: • Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb) • Loosen it one turn. • Retighten it. 7 Nm (0.7 m•kg, 5.1 ft•lb) Hold the machine by placing the suitable stand Refer to "HANDLING NOTE".
  • Page 185 STEERING Order Part name Q'ty Remarks Bearing race cover Upper bearing Lower bearing Refer to removal section. Bearing race Refer to removal section. 6-28...
  • Page 186 STEERING HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE STEERING RING 1. Remove: CHECKING THE BEARING AND 3. Install: • Steering ring nut "1" BEARING RACE • Lower bracket "1" Use the steering nut wrench "2". 1.
  • Page 187 STEERING 11. Adjust: • Front fork top end "a" Front fork top end (stan- dard) "a": Zero mm (Zero in) 7. Install: 14. Install: • Front fork "1" • Holder "1" • Upper bracket "2" Holder: • Main switch "3" 13 Nm (1.3 m•kg, 9.4 •...
  • Page 188 SWINGARM SWINGARM REMOVING THE SWINGARM Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT BRAKE AND REAR Brake hose holder BRAKE" section. Refer to "FRONT BRAKE AND REAR Rear brake caliper BRAKE"...
  • Page 189 SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q'ty Remarks Refer to removal section. Relay arm Connecting rod Collar Oil seal Thrust bearing Bushing Oil seal Bearing Refer to removal section. 6-32...
  • Page 190 SWINGARM → HANDLING NOTE Damage Replace. Support the machine securely so there is no danger of it falling over. REMOVING THE CAP 1. Remove: • Left cap "1" 2. Install: CHECKING THE CONNECTING • Bearing "1" Remove with a slotted-head screw- •...
  • Page 191 SWINGARM • Washer "3" • Swingarm up and down move- • Nut (connecting rod) "4" ment "b" Unsmooth movement/binding/ Nut (connecting rod): → rough spots Grease or replace 80 Nm (8.0 m•kg, 58 bearings, bushings and collars. ft•lb) To relay arm "5". INSTALLING THE SWINGARM Apply the molybdenum disulfide 1.
  • Page 192 SWINGARM • Nut (drive chain support) "4" Nut (drive chain sup- port): 7 Nm (0.7 m•kg, 5.1 ft•lb) • Bolt {drive chain support cover[L = 10 mm (0.39 in)]} "5" 11. Tighten: Bolt (drive chain support • Nut (relay arm) "1" cover): 7 Nm (0.7 m•kg, 5.1 Nut (relay arm):...
  • Page 193 REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "SEAT, FUEL TANK AND SIDE Seat and side cover COVERS"...
  • Page 194 REAR SHOCK ABSORBER Order Part name Q'ty Remarks CDI unit coupler Plastic band Clamp (air filter joint) Only loosening. Rear frame Bolt (rear shock absorber-relay arm) Hold the swingarm. Bolt (rear shock absorber-frame) Rear shock absorber Locknut Only loosening. Adjuster Only loosening.
  • Page 195 To dispose of a damaged or worn- ABSORBER out rear shock absorber, take the After installing the stopper ring, push 1. Inspect: unit to your Yamaha dealer for this back the bearing until it contacts the • Damper rod "1" disposal procedure. stopper ring.
  • Page 196 REAR SHOCK ABSORBER Apply the molybdenum disulfide grease on the bolt. 3. Install: INSTALLING THE REAR SHOCK • Lower bearing "1" ABSORBER 1. Install: • Dust seal "1" Install the bearing by pressing it on • O-ring "2" 5. Install: the side having the manufacture's •...
  • Page 197 REAR SHOCK ABSORBER 8. Install: • Plastic band • Taillight coupler • Locking tie 6-40...
  • Page 198 ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS Headlight Fuse 17. Ignition coil Multi-function display 10. Starting circuit cut-off relay 18. Spark plug Engine stop switch 11. CDI unit 19. Start switch Clutch switch 12. Taillight 20.
  • Page 199 ELECTRICAL COMPONENTS AND WIRING DIAGRAM WIRING DIAGRAM Headlight COLOR CODE Multi-function display Black Engine stop switch Brown Clutch switch Chocolate Diode Dark green Starter relay diode Green Throttle position sensor Gray Starter relay Blue Fuse Orange 10. Starting circuit cut-off relay 11.
  • Page 200 IGNITION SYSTEM IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. → *1 Check fuse. No good Replace fuse and check wire harness.
  • Page 201 IGNITION SYSTEM SPARK GAP TEST Use 12 V battery. Result 1. Disconnect the ignition coil from Conductive (while the → Battery (+) lead Red/Black lead spark plug. engine stop switch is "1" 2. Remove the ignition coil cap. pushed) → Battery (-) lead Black lead "2"...
  • Page 202 ELECTRIC STARTING SYSTEM 4. Inspect: CHECKING THE CDI UNIT • Sealed portion of ignition coil "a" Check all electrical components. If no • Spark plug terminal pin "b" fault is found, replace the CDI unit. • Threaded portion of spark plug "c" Then check the electrical compo- →...
  • Page 203 ELECTRIC STARTING SYSTEM INSPECTION STEPS If the starter motor will not operate, use the following inspection steps. → *1 Check fuse. No good Replace fuse and check wire harness. ↓ → *2 Check battery. No good Recharge or replace. ↓ →...
  • Page 204 ELECTRIC STARTING SYSTEM CHECKING THE COUPLERS AND LEADS CONNECTION 1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. CHECKING THE STARTER MOTOR OPERATION CHECKING THE STARTER RELAY CHECKING THE DIODE 1. Connect the positive battery ter- 1. Remove: 1.
  • Page 205 ELECTRIC STARTING SYSTEM 2. Inspect: • Rubber part "a" → Tears/damage Replace.
  • Page 206 ELECTRIC STARTING SYSTEM REMOVING THE STARTER MOTOR Order Part name Q'ty Remarks Refer to "EXHAUST PIPE AND SILENCER" Exhaust pipe section in the CHAPTER 3. Starter motor...
  • Page 207 ELECTRIC STARTING SYSTEM DISASSEMBLING THE STARTER MOTOR Order Part name Q'ty Remarks Starter motor front cover Washer (starter motor front cover) Washer Circlip O-ring Starter motor yoke Armature assembly Starter motor rear cover Brush Brush spring 7-10...
  • Page 208 ELECTRIC STARTING SYSTEM CHECKING AND REPAIRING THE Armature assembly: STARTER MOTOR Commutator resis- 1. Check: tance "1": • Commutator Ω 0.0117–0.0143 → Dirt Clean with 600 grit sandpa- 20 °C (68 °F) per. Insulation resistance 2. Measure: "2": • Commutator diameter "a" Ω...
  • Page 209 ELECTRIC STARTING SYSTEM 5. Install: • Bolt "1" • O-ring "2" Apply the lithium soap base grease on the O-ring. 7-12...
  • Page 210 CHARGING SYSTEM CHARGING SYSTEM INSPECTION STEPS If the battery is not charged, use the following inspection steps. → *1 Check fuse. No good Replace fuse and check wire harness. ↓ → *2 Check battery. No good Recharge or replace. ↓ →...
  • Page 211 CHARGING SYSTEM CHECKING THE COUPLERS AND LEADS CONNECTION 1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. CHECKING THE CHARGING VOLTAGE 1. Start the engine. 2. Inspect: • Charging voltage → Out of specification If no failure is found in checking the source coil resistance, replace the rectifi- er/regulator.
  • Page 212 THROTTLE POSITION SENSOR SYSTEM THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position sensor will not operate, use the following inspection steps. → Check entire ignition system for connection. No good Repair or replace. ↓ → Check throttle position sensor.(Throttle position No good Replace.
  • Page 213 THROTTLE POSITION SENSOR SYSTEM HANDLING NOTE • Throttle position sensor coil vari- able resistance Check that the resistance in in- Do not loosen the screw (throttle creased as the throttle grip is position sensor) "1" except when moved from the full close position changing the throttle position sen- to the full open position.
  • Page 214 THROTTLE POSITION SENSOR SYSTEM Throttle po- Throttle po- Tester se- Tester se- sition sen- sition sen- lector posi- lector posi- sor input sor output tion tion voltage voltage 4–6 V DCV-20 0.58–0.78 V 10. Put the aligning marks "a" on the throttle position sensor and car- buretor.
  • Page 215 LIGHTING SYSTEM LIGHTING SYSTEM INSPECTION STEPS Refer to the following flow chart when inspecting the lighting system for possible problems. → Check the bulb and bulb socket. No good Replace the bulb and/or bulb socket. ↓ → Check the taillight (LEDs). No good Replace the taillight assembly.
  • Page 216 LIGHTING SYSTEM CHECKING THE TAILLIGHT 3. Turn on the headlight and taillight (LEDs) by turning on the light switch. 1. Disconnect the taillight coupler. 4. Inspect: 2. Connect two jumper leads "1" • Out-put voltage → from the battery terminals to the Out of specification Replace respective coupler terminal as...
  • Page 217 SIGNALING SYSTEM SIGNALING SYSTEM INSPECTION STEPS If the speedometer will not operate, use the following inspection steps. → *1 Check battery. No good Recharge or replace. ↓ → Check each coupler and wire connection. No good Repair or replace. ↓ →...
  • Page 218 SIGNALING SYSTEM CHECKING THE COUPLERS AND LEADS CONNECTION Make sure that a short-circuit does 1. Check: not develop between the terminals • Couplers and leads connection because it may cause damage to Rust/dust/looseness/short-circuit electrical components. → Repair or replace. CHECKING THE MULTI-FUNCTION DISPLAY INPUT VOLTAGE 1.
  • Page 220 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN YAMAHA MOTOR CO., LTD. 2007.07-0.9×1 CR 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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