Yamaha YZ450F 2020 Owner's Service Manual
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Yamaha YZ450F 2020 Owner's Service Manual

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OWNER'S SERVICE MANUAL
MANUEL D'ATELIER DU PROPRIÉTAIRE
FAHRER- UND WARTUNGSHANDBUCH
Read this manual carefully before operating this vehicle.
Il convient de lire attentivement ce manuel avant la première utilisation du véhicule.
Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
2020
YZ450F
YZ450F
YZ450FL
B2W-28199-80

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  • Page 1 2020 OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIÉTAIRE FAHRER- UND WARTUNGSHANDBUCH YZ450F Read this manual carefully before operating this vehicle. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen. YZ450F YZ450FL B2W-28199-80...
  • Page 2 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit être remis avec le véhicule en cas de vente de ce dernier. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
  • Page 3 2020 OWNER’S SERVICE MANUAL YZ450F Read this manual carefully before operating this vehicle. YZ450F YZ450FL B2W-28199-80-E0...
  • Page 4 EAM20161 Read this manual carefully Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. This device complies with Industry Canada’s licence-exempt RSSs. Operation is subject to the following two con- ditions: (1) This device may not cause interference;...
  • Page 5 Declaration of Conformity: Hereby, YAMAHA MOTOR CO., LTD declares that the radio equipment type, Communication Control Unit, T722- A00 is in compliance with Directive 2014/53/EU. The full text of the EU declaration of conformity is available at the following internet address: https://global.yamaha-motor.com/eu_doc/...
  • Page 6 EAM20080 YZ450F YZ450FL OWNER’S SERVICE MANUAL ©2020 by Yamaha Motor Co., Ltd. First edition, April 2019 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
  • Page 7 EAM20180 IMPORTANT Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.
  • Page 8 EAM20082 HOW TO USE THIS MANUAL In this manual, descriptions of installation, removal, disassembly, assembly, check, and adjustment procedures are laid out with the individual steps in sequential order. • The manual is divided into chapters and each chapter is divided into sections. The current section title “1”...
  • Page 9 EAM20083 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 11: General Information

    TABLE OF CONTENTS EAM10003 GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING TUNING...

  • Page 13: Table Of Contents

    GENERAL INFORMATION SAFETY INFORMATION..................1-1 FOR SAFETY, BE SURE TO OBEY THE FOLLOWING: ......1-1 LOCATION OF IMPORTANT LABELS ............1-4 DESCRIPTION....................1-7 IDENTIFICATION....................1-8 VEHICLE IDENTIFICATION NUMBER ............1-8 ENGINE SERIAL NUMBER ...............1-8 INCLUDED PARTS...................1-9 SIDESTAND ....................1-9 NIPPLE WRENCH..................1-9 HANDLEBAR PROTECTOR ..............1-9 FUEL HOSE JOINT COVER ..............1-9 POWER TUNER..................1-9 IMPORTANT INFORMATION .................1-11 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-11...
  • Page 14 STARTING A WARM ENGINE..............1-27 BREAK-IN PROCEDURES ..............1-27 ENGINE STARTING PRECAUTION ............1-27 MAINTENANCE AFTER BREAK-IN ..............1-28 MAJOR MAINTENANCE................1-28 AIR FILTER MAINTENANCE ..............1-28 TORQUE-CHECK POINTS................1-29 MOTORCYCLE CARE AND STORAGE ............1-31 CARE......................1-31 STORAGE ....................1-32...

  • Page 15: Safety Information

    Yamaha machine, and take care to maintain it accidents. Many accidents have been properly and operate it safely. caused by an automobile driver who did not see the motorcycle.
  • Page 16 1. Always wear an approved helmet. Yamaha can neither endorse nor recommend 2. Wear a face shield or goggles. Wind in your the use of accessories not sold by Yamaha or unprotected eyes could contribute to an im- modifications not specifically recommended by...
  • Page 17 SAFETY INFORMATION cause a dangerous loss of lights or engine power. Aftermarket Tires and Rims The tires and rims that came with your motorcy- cle were designed to match the performance ca- pabilities and to provide the best combination of handling, braking, and comfort.

  • Page 18: Location Of Important Labels

    LOCATION OF IMPORTANT LABELS EAM20085 LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle. 1,2,3 4,5,6 9,10,11 12,13,14...
  • Page 19 LOCATION OF IMPORTANT LABELS 4AA-22259-40...
  • Page 20 LOCATION OF IMPORTANT LABELS AUS, NZL, ZAF 4AA-22259-40...

  • Page 21: Description

    DESCRIPTION EAM20086 DESCRIPTION 11.Radiator 1. Clutch lever 12.Coolant drain bolt 2. Front brake lever 3. Throttle grip 13.Rear brake pedal 14.Air filter 4. Start switch 15.Drive chain 5. Launch control switch 16.Shift pedal 6. Radiator cap 17.Oil level check window 7.

  • Page 22: Identification

    There are two significant reasons for knowing the serial number of your vehicle: 1. When ordering parts, you can give the num- ber to your Yamaha dealer for positive identi- fication of the model you own. 2. If your vehicle is stolen, the authorities will need the number to search for and identify your vehicle.

  • Page 23: Included Parts

    INCLUDED PARTS vent mud, dust, and other foreign materials from EAM20088 INCLUDED PARTS entering the inside when the fuel hose is discon- nected. EAM30190 SIDESTAND This sidestand “1” is used to support only the machine when standing or transporting it. EWA20260 WARNING •...
  • Page 24 INCLUDED PARTS • There are facilities nearby that are emitting strong radio waves (TV or radio towers, power plants, broadcasting stations, air- ports, etc.) • You are carrying or using communication equipment such as radios or mobile phones in close proximity of the CCU •...

  • Page 25: Important Information

    2. Use proper special tools and equipment. Re- used for repair of the vehicle, including periodic fer to “SPECIAL TOOLS” on page 1-17. replacement parts, are new YAMAHA genuine parts and recommended parts. Do not use any used parts, because these may...

  • Page 26: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION 1. Oil 2. Lip 3. Spring 4. Grease EAM30012 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace lock washers/plates “1” and cotter pins with new ones. After the bolt or nut has been tightened to specification, firmly bend the lock tabs along a flat of the bolt or nut. EAM30014 CIRCLIPS When assembling parts, always use new cir-...

  • Page 27: Basic Service Information

    BASIC SERVICE INFORMATION EAM20120 BASIC SERVICE INFORMATION EAM30181 ELECTRICAL SYSTEM Electrical parts handling ECA16600 NOTICE Never disconnect a battery lead while the en- gine is running; otherwise, the electrical components could be damaged. ECA16760 NOTICE Be sure to connect the battery leads to the correct battery terminals.
  • Page 28 BASIC SERVICE INFORMATION ECA16630 ECA14371 NOTICE NOTICE Electrical components are very sensitive to Never insert the tester probes into the cou- and can be damaged by static electricity. pler terminal slots. Always insert the probes Therefore, never touch the terminals and be from the opposite end “a”...
  • Page 29 BASIC SERVICE INFORMATION ECA16780 NOTICE • When disconnecting a coupler, release the coupler lock, hold both sections of the cou- pler securely, and then disconnect the cou- pler. • There are many types of coupler locks; therefore, be sure to check the type of cou- pler lock before disconnecting the coupler.
  • Page 30 BASIC SERVICE INFORMATION 5. Check: • No continuity Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachom- eter YU-A1927 • If there is no continuity, clean the terminals. • When checking the wire harness, perform steps (1) to (4). •...

  • Page 31: Special Tools

    Feeler gauge set YU-26900-9 Valve lapper (ø14) 3-7, 5-27 90890-04101 90890-04101 Valve lapping tool (14mm) YM-A8998 YM-A8998 Yamaha diagnostic tool USB 3-11, 7-8, 8-17 90890-03267 Yamaha diagnostic tool (A/I) 3-11, 7-8, 8-17 90890-03262 FI diagnostic tool sub–lead 3-11, 7-8, 8-17 90890-03212 FI diagnostic tool sub–lead...
  • Page 32 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages OBD/ GST Leadwire kit 3-11, 7-8, 8-17 90890-03249 Digital tachometer 3-11, 3-35, 8-49 90890-06760 Digital tachometer YU-39951-B Steering nut wrench 3-26, 4-56 90890-01403 Exhaust flange nut wrench YU-A9472 Spoke nipple wrench (6–7) 3-33 90890-01521 Spoke nipple wrench (6–7)
  • Page 33 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Yamaha bond No. 1215 5-20, 5-39, 5-68 90890-85505 (Three bond No.1215®) Valve spring compressor 5-27, 5-31 90890-04019 Valve spring compressor YM-04019 Valve spring compressor attachment 5-27, 5-31 90890-04108 Valve spring compressor adapter 22 mm YM-04108 Valve guide remover &...
  • Page 34 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rotor puller 5-39 90890-04151 Rotor puller YM-04151 Universal clutch holder 5-50, 5-53 90890-04086 Universal clutch holder YM-91042 Crankcase separating tool 5-70 90890-04152 Crankcase separating tool YU-A9642 Crankshaft installer pot 5-71 90890-01274 Installing pot YU-90058 YU-90058/YU-90059 Crankshaft installer bolt...
  • Page 35 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Adapter (M12) 5-71 90890-01278 Adapter #3 YU-90063 Spacer (crankshaft installer) 5-71 90890-04081 Pot spacer YM-91044 YM-91044 Radiator cap tester 6-4, 6-4 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter 6-4, 6-4 90890-01352 Pressure tester adapter...
  • Page 36 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Fuel pressure adapter 90890-03186 Fuel pressure adapter YM-03186 Lithium battery charger 8-44, 8-45 90890-05376 Lithium battery charger DBY-ACC51-70-02 Ignition checker 8-46 90890-06754 Oppama pet–4000 spark checker YM-34487 Test harness S– pressure sensor (3P) 8-50 90890-03207 Test harness S–...

  • Page 37: Instrument And Control Functions

    INSTRUMENT AND CONTROL FUNCTIONS EAM20181 INSTRUMENT AND CONTROL FUNCTIONS EAM30182 ENGINE STOP SWITCH The engine stop switch “1” is located on the left handlebar. Continue pushing the engine stop switch till the engine comes to a stop. How to operate 1.

  • Page 38: Shift Pedal

    INSTRUMENT AND CONTROL FUNCTIONS To change the mode EAM30189 REAR BRAKE PEDAL 1. Shift to neutral. The rear brake pedal “1” is in the right of the 2. Start the engine. chassis. Press down on the brake pedal to acti- 3.

  • Page 39: Fuel Tank Cap

    INSTRUMENT AND CONTROL FUNCTIONS EAM30192 FUEL TANK CAP Fuel tank cap “1” is located under the fuel tank cap cover “2”. Remove the fuel tank cap cover to open the fuel tank cap. • To remove the fuel tank cap cover, insert fin- gers under part “a”, and then use both hands to lift it up towards the rear of the vehicle.

  • Page 40: Starting And Break-In

    4. When the engine starts running, warm this up one or two minutes at a steady speed (of 3000 to 5000 r/min), and then return the start- Your Yamaha engine has been designed to use er knob to its original position. premium unleaded gasoline with a pump octane...

  • Page 41: Starting A Warm Engine

    STARTING AND BREAK-IN check the points shown in “TORQUE- CHECK POINTS” for tightening torques and retighten them. Also when the following parts are replaced, a break-in is required. • Cylinder and Crankshaft: A break-in is re- quired for about an hour. •...

  • Page 42: Maintenance After Break-In

    EMENT” section in the CHAPTER 3, apply the • Generator Yamaha foam air filter oil or other quality foam Check for looseness in mounted areas of the air filter oil to the element. (Excess oil in the ele- generator rotor and the stator coil assembly.

  • Page 43: Torque-Check Points

    TORQUE-CHECK POINTS EAM20125 TORQUE-CHECK POINTS Frame construction Frame to rear frame Frame to engine protector Combined seat and fuel tank Fuel tank to frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Seat Seat to frame Steering Steering stem to handlebar Steering stem to frame...
  • Page 44 TORQUE-CHECK POINTS Shift pedal Shift pedal to shift shaft Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake disc cover Tightening of rear brake caliper cover...

  • Page 45: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE any longer than instructed. Also, thorough- EAM20126 MOTORCYCLE CARE AND STOR- ly rinse the area off with water, immediately dry it, and then apply a corrosion protec- tion spray. • Improper cleaning can damage plastic EAM30200 CARE parts (such as cowlings, panels, wind- While the open design of a motorcycle reveals...

  • Page 46: Storage

    Salt sprayed on roads in the winter may remain well into spring. • Consult a Yamaha dealer for advice on what 1. Clean the motorcycle with cold water and a products to use.
  • Page 47 MOTORCYCLE CARE AND STORAGE stored. Long-term Before storing your motorcycle for several months: 1. Follow all the instructions in the “CARE” sec- tion of this chapter. 2. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating.
  • Page 48 MOTORCYCLE CARE AND STORAGE 1-34...
  • Page 49 SPECIFICATIONS GENERAL SPECIFICATIONS................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-6 ELECTRICAL SPECIFICATIONS ..............2-9 TIGHTENING TORQUES ................2-10 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-10 ENGINE TIGHTENING TORQUES............2-11 CHASSIS TIGHTENING TORQUES............2-14 CABLE ROUTING DIAGRAM ................2-17...

  • Page 50: Specifications

    GENERAL SPECIFICATIONS EAM20127 GENERAL SPECIFICATIONS Model Model B2W1 (CAN) B2W2 (AUT, BEL, CHE, CYP, CZE, DEU, DNK, ESP, FIN, FRA, GBR, GRC, HRV, HUN, IRL, ITA, NLD, NOR, POL, PRT, SVK, SVN, SWE, TUR) B2W4 (AUS, NZL, ZAF) Dimensions Overall length 2185 mm (86.0 in) Overall width 825 mm (32.5 in)

  • Page 51: Engine Specifications

    ENGINE SPECIFICATIONS EAM20128 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train DOHC Displacement 450 cm³ Number of cylinders Single cylinder Bore  stroke 97.0  60.8 mm (3.82  2.39 in) Compression ratio 13.0 : 1 Starting system Electric starter Fuel...
  • Page 52 ENGINE SPECIFICATIONS Camshaft lobe dimensions Lobe height (Intake) 38.130–38.230 mm (1.5012–1.5051 in) Limit 38.030 mm (1.4972 in) Lobe height (Exhaust) 34.270–34.370 mm (1.3492–1.3531 in) Limit 34.170 mm (1.3453 in) Camshaft runout limit 0.030 mm (0.0012 in) Valve, valve seat, valve guide Valve clearance (cold) Intake 0.10–0.17 mm (0.0039–0.0067 in)
  • Page 53 3.769 (49/13) Final drive Chain Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil Fuel pump Pump type Electrical Maximum consumption amperage 2.4 A Fuel injector 12.0 ...
  • Page 54 ENGINE SPECIFICATIONS Idling condition Engine idling speed 1900–2100 r/min 70–80 C (158–176 F) Coolant temperature Fuel line pressure (at idle) 300–390 kPa (3.0–3.9 kgf/cm², 43.5–56.6 psi) Throttle grip free play 3.0–6.0 mm (0.12–0.24 in)

  • Page 55: Chassis Specifications

    CHASSIS SPECIFICATIONS EAM20129 CHASSIS SPECIFICATIONS Chassis Frame type Semi double cradle Caster angle 26 55’ Trail 120 mm (4.7 in) Front wheel Wheel type Spoke wheel Rim size 21x1.6 Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in) Wheel axle bending limit 0.50 mm (0.02 in)
  • Page 56 497.0 mm (19.57 in) Limit 492.0 mm (19.37 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil S1 Quantity (left) 501.0 cm³ (16.94 US oz, 17.67 Imp.oz) Quantity (right) 501.0 cm³ (16.94 US oz, 17.67 Imp.oz) Rebound damping...
  • Page 57 CHASSIS SPECIFICATIONS Shock absorber Gas-hydraulic damper Spring preload Adjusting system Mechanical adjustable type Adjustment value (Soft) 1.5 mm (0.06 in) 4.0 mm (0.16 in) (AUS, CAN, NZL, ZAF)  Adjustment value (STD) 7.0 mm (0.28 in) (AUT, BEL, CHE, CYP, CZE, DEU, DNK, ESP, FIN, FRA, GBR, GRC, HRV, HUN, IRL, ITA, NLD, NOR, POL, PRT, SVK, SVN, SWE, TUR)

  • Page 58: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAM20130 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system 10.0 2000 r/min Ignition timing (B.T.D.C.) Engine control unit Model B2W0 (CAN) B2W1 (AUS, AUT, BEL, CHE, CYP, CZE, DEU, DNK, ESP, FIN, FRA, GBR, GRC, HRV, HUN, IRL, ITA, NLD, NOR, NZL, POL, PRT, SVK, SVN, SWE, TUR, ZAF) Ignition coil...

  • Page 59: Tightening Torques

    TIGHTENING TORQUES EAM20131 TIGHTENING TORQUES EAM30205 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.

  • Page 60: Engine Tightening Torques

    TIGHTENING TORQUES EAM30203 ENGINE TIGHTENING TORQUES - marked portion shall be checked for torque tightening after break-in or before each race. Thread Item Q’ty Tightening torques Remarks size Camshaft cap bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) Cylinder head stud bolt (exhaust 7 N·m (0.7 kgf·m, 5.2 lb·ft) pipe)
  • Page 61 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Clutch cable locknut (clutch cable 4.3 N·m (0.43 kgf·m, 3.2 lb·ft) adjuster) Clutch cable locknut (engine side) 7 N·m (0.7 kgf·m, 5.2 lb·ft) Exhaust pipe nut 10 N·m (1.0 kgf·m, 7.4 lb·ft) Exhaust pipe protector screw 10 N·m (1.0 kgf·m, 7.4 lb·ft) Exhaust pipe bracket bolt...
  • Page 62 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Shift pedal bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft)  Generator rotor nut 65 N·m (6.5 kgf·m, 48 lb·ft) Stator coil screw 10 N·m (1.0 kgf·m, 7.4 lb·ft) Crankshaft position sensor bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Stator coil assembly lead holder bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft)

  • Page 63: Chassis Tightening Torques

    TIGHTENING TORQUES EAM30204 CHASSIS TIGHTENING TORQUES - marked portion shall be checked for torque tightening after break-in or before each race. Thread Item Q’ty Tightening torques Remarks size Upper bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft)  Lower bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) ...
  • Page 64 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Rear brake disc bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) / Footrest bracket bolt 55 N·m (5.5 kgf·m, 41 lb·ft) Rear brake pedal bolt 26 N·m (2.6 kgf·m, 19 lb·ft)  Rear brake pedal adjusting locknut 6 N·m (0.6 kgf·m, 4.4 lb·ft) Rear brake master cylinder bolt...
  • Page 65 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Bolt (drive chain support) 7 N·m (0.7 kgf·m, 5.2 lb·ft) Drive chain support nut 7 N·m (0.7 kgf·m, 5.2 lb·ft) Drive chain guide bolt 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) Bolt (rear frame cover) (left) 7 N·m (0.7 kgf·m, 5.2 lb·ft) ...

  • Page 66: Cable Routing Diagram

    CABLE ROUTING DIAGRAM EAM20152 CABLE ROUTING DIAGRAM Frame and engine (left side view) 2-17...
  • Page 67 U. Pass the cylinder head breather hose engine stop switch lead. between the down tube and radiator, and B. Insert the Yamaha diagnostic tool 3-pin cou- front of the radiator under boss. pler (black) into the connector, and secure it V.
  • Page 68 CABLE ROUTING DIAGRAM Frame and engine (right side view) 2-19...
  • Page 69 CABLE ROUTING DIAGRAM H. Pass the cylinder head breather hose 1. Negative battery lead between the radiator hose and the engine 2. Cross tube bracket. 3. Starter motor lead I. Install the cylinder head breather hose so 4. Coolant temperature sensor coupler (black, that the outlet faces downward.
  • Page 70 CABLE ROUTING DIAGRAM Handlebar (front view) 2-21...
  • Page 71 CABLE ROUTING DIAGRAM 1. Plastic locking tie 2. Number plate band 3. Clutch cable 4. Engine stop switch lead 5. Mode switch lead 6. Front brake hose 7. Cable guide 8. Start switch lead 9. Number plate 10.Launch control switch lead A.
  • Page 72 CABLE ROUTING DIAGRAM Frame and engine (top view) 2-23...
  • Page 73 CABLE ROUTING DIAGRAM L. Insert the clamp into the rib so that it contacts 1. Clamp the rib. 2. Diode 3. Throttle position sensor lead 4. Intake air pressure sensor lead 5. Joint coupler 6. Intake air pressure sensor coupler (dark blue, 3-pin) 7.
  • Page 74 CABLE ROUTING DIAGRAM Frame and battery (top view) 2-25...
  • Page 75 CABLE ROUTING DIAGRAM 1. Positive battery lead 2. CCU (Communication Control Unit) 3. Diode 4. Fuel pump lead 5. Fuel hose 6. Wire harness (to the negative battery cou- pler) 7. Joint connector 8. Main relay 9. Starter relay coupler (black, 4-pin) 10.Starter relay 11.Starter motor lead 12.Negative battery lead...
  • Page 76 CABLE ROUTING DIAGRAM Rear brake (right side view) 2-27...
  • Page 77 CABLE ROUTING DIAGRAM 1. Protector 2. Rear brake caliper 3. Bleed screw 4. Gasket 5. Rear brake hose 6. Brake pedal 7. Rear brake master cylinder assembly 8. Swingarm 9. Spring 10.Frame A. It does not matter whether the spring is installed upward or downward.
  • Page 78 CABLE ROUTING DIAGRAM 2-29...
  • Page 79 PERIODIC CHECKS AND ADJUSTMENTS MAINTENANCE INTERVALS................3-1 MAINTENANCE INTERVALS ..............3-1 PRE-OPERATION INSPECTION AND MAINTENANCE .........3-5 GENERAL INSPECTION AND MAINTENANCE........3-5 ENGINE ......................3-6 ADJUSTING THE VALVE CLEARANCE ...........3-6 VALVE CLEARANCE SHIM CHART............3-9 CHECKING THE ENGINE IDLING SPEED ..........3-11 CHECKING THE THROTTLE GRIP............3-11 CHECKING THE SPARK PLUG ..............3-12 CHECKING THE ENGINE OIL LEVEL.............3-13 CHANGING THE ENGINE OIL ..............3-13 ADJUSTING THE CLUTCH LEVER FREE PLAY........3-15...
  • Page 80 CHECKING THE WHEEL BEARINGS .............3-33 CHECKING THE CHASSIS FASTENERS ..........3-33 CHECKING AND LUBRICATING THE CABLES ........3-33 LUBRICATING THE BRAKE LEVER ............3-33 LUBRICATING THE CLUTCH LEVER.............3-33 LUBRICATING THE PEDAL ..............3-33 ELECTRICAL SYSTEM..................3-35 CHECKING AND CHARGING THE BATTERY........3-35 CHECKING THE FUSES .................3-35 CHECKING THE IGNITION TIMING............3-35...

  • Page 81: Maintenance Intervals

    (e.g., rain, dirt, etc.). Therefore, earlier inspection is required by reference to the list below. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 82 MAINTENANCE INTERVALS Every fifth Every Every race After race third race Item Routine (about break-in (about 2.5 (about 7.5 required 12.5 hours) hours) hours) • Check the coolant passages for corrosion. • Inspect carbon deposits and elim- 11 * Cylinder head ...
  • Page 83 MAINTENANCE INTERVALS Every fifth Every Every race After race third race Item Routine (about break-in (about 2.5 (about 7.5 required 12.5 hours) hours) hours) • Clean.   • Inspect and adjust.   • Replace oil.   30 * Front fork leg(s) •...
  • Page 84 MAINTENANCE INTERVALS Every fifth Every Every race After race third race Item Routine (about break-in (about 2.5 (about 7.5 required 12.5 hours) hours) hours) • Adjust clutch lever free play.  Levers • Lubricate.   Brake pedal, footrest • Retighten. Outside nuts and ...

  • Page 85: Pre-Operation Inspection And Maintenance

    PRE-OPERATION INSPECTION AND MAINTENANCE EAM20134 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating con- dition. Before using this machine, check the following points. EAM30209 GENERAL INSPECTION AND MAINTENANCE Item Inspect Page...

  • Page 86: Engine

    Turn the crankshaft counterclockwise with sic knowledge and skill concerning the servic- a wrench. ing of Yamaha motorcycles (e.g., Yamaha b. Align the top dead center (TDC) mark “a” dealers, service engineers, etc.). Those who on the generator rotor with the alignment have little knowledge and skill concerning ser- mark “b”...
  • Page 87 ENGINE c. Check the number on the originally in- stalled adjusting pad. • The adjusting pad number “a” is indicated on the top of the adjusting pad. • For the number on the originally installed ad- justing pad, convert the last digit of adjusting pad number as per the below table.
  • Page 88 ENGINE ECA24310 NOTICE Do not twist adjusting pads and valve lifters forcibly during installation. • Apply the engine oil on the valve lifters. • Apply molybdenum disulfide oil to the valve stem ends. • Check that the valve lifters turn smoothly when rotated with your finger.

  • Page 89: Valve Clearance Shim Chart

    ENGINE EAM30383 VALVE CLEARANCE SHIM CHART INTAKE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.02 0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230...
  • Page 90 ENGINE EXHAUST 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 0.02 0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225...

  • Page 91: Checking The Engine Idling Speed

    2. Measure the coolant temperature using the 5. Adjust: Yamaha diagnostic tool. • Engine idling speed Yamaha diagnostic tool USB a. Turn the idle screw “1” to make an adjust- 90890-03267 ment. Yamaha diagnostic tool (A/I) 90890-03262 FI diagnostic tool sub–lead...

  • Page 92: Checking The Spark Plug

    ENGINE 2. Adjust: ECA24410 NOTICE • Throttle grip free play In order not to allow the dirt accumulated a. Loosen the locknut “1”. around the spark plug to drop from the spark b. Turn the adjuster “2” until the specified plug hole into the cylinder, clean it before re- throttle grip free play is obtained.

  • Page 93: Checking The Engine Oil Level

    ENGINE • Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1. EAM30224 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle upright on a level surface. 2. Start the engine, warm this up for 2–3 min- utes, and then stop the engine and wait about 1 minute.
  • Page 94 ENGINE Engine oil quantity Oil change 0.63 L (0.67 US qt, 0.55 Imp.qt) With oil filter removal 0.65 L (0.69 US qt, 0.57 Imp.qt) Quantity (disassembled) 0.90 L (0.95 US qt, 0.79 Imp.qt) c. Install the new oil filter element and the oil filter element cover.

  • Page 95: Adjusting The Clutch Lever Free Play

    ENGINE Clutch cable side ECA26740 NOTICE a. Slide the clutch cable cover. If the engine oil level does not decrease after b. Loosen the locknut “1”. the engine has been started, immediately c. Turn the adjuster “2” until the specified turn the engine off.
  • Page 96 2. Turn the plates “1” in direction “a”. • Air filter element Damage  Replace. 6. Apply: Yamaha foam air filter oil or other quality foam air filter oil. Oil application quantify 30 cm³ Squeeze out the excess oil. Element should be wet but not dripping.

  • Page 97: Checking The Throttle Body Joint

    ENGINE 8. Turn the plates “1” to the original position. 10.Install: • Fuel tank cap cover EAM30335 CHECKING THE THROTTLE BODY JOINT 1. Check: • Throttle body joint “1” Crack/damage  Replace. 9. Install: • Air filter case cover “1” •...

  • Page 98: Checking The Cylinder Head Breather Hose

    ENGINE ECA25800 NOTICE Do not hit the silencer stay “a” as it may do damage to the silencer. Remove the inner pipe while holding the silencer in place with a vise etc. 3. Install: • Fuel tank Refer to “FUEL TANK” on page 7-1. •...
  • Page 99 ENGINE “c”. f. Install the silencer body “8” and bolts “9”. Silencer body bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) LOCTITE® Apply heat-resistant sealant to the areas “d” shown, making sure that there are no gaps in the beads of sealant. j.

  • Page 100: Checking The Coolant Level

    ENGINE 6. Check: • Tightening torques Exhaust pipe nut “1” 10 N·m (1.0 kgf·m, 7.4 lb·ft) Exhaust pipe clamp bolt “2” 12 N·m (1.2 kgf·m, 8.9 lb·ft) Exhaust pipe clamp bolt “3” 12 N·m (1.2 kgf·m, 8.9 lb·ft) Silencer bolt (rear) “4” 30 N·m (3.0 kgf·m, 22 lb·ft) 3.

  • Page 101: Changing The Coolant

    ENGINE 2. Check: Recommended coolant • Radiator High quality ethylene glycol • Radiator hose anti-freeze containing anti-cor- Crack/damage  Replace. rosion for aluminum engine Refer to “RADIATOR” on page 6-2. Radiator (including all routes) 3. Install: 1.03 L (1.09 US qt, 0.91 Imp.qt) •...

  • Page 102: Chassis

    CHASSIS EAM20136 ECA13490 CHASSIS NOTICE After adjusting the brake lever position, EAM30479 make sure there is no brake drag. ADJUSTING THE FRONT DISC BRAKE 1. Check: 4. Install: • Brake lever position “a” • Brake lever cover Brake lever position EAM30480 ADJUSTING THE REAR DISC BRAKE 100 mm (3.94 in)

  • Page 103: Checking The Brake Fluid Level

    CHASSIS ing performance to be reduced. EAM30231 CHECKING THE FRONT BRAKE PADS ECA13510 The following procedure applies to all of the NOTICE brake pads. After adjusting the brake pedal position, 1. Operate the brake. make sure there is no brake drag. 2.

  • Page 104: Checking The Rear Brake Hose

    CHASSIS Refer to “FRONT BRAKE” on page 4-13 and “REAR BRAKE” on page 4-24. Drive on the dry road, operate the front and rear brakes separately and check to see if the brakes are operating properly. EAM30477 BLEEDING THE HYDRAULIC BRAKE SYSTEM EWA19140 2.

  • Page 105: Drive Chain Slack

    CHASSIS EAM30481 DRIVE CHAIN SLACK ECA13550 NOTICE A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swing- arm or cause an accident. Therefore, keep the drive chain slack within the specified lim- its.

  • Page 106: Checking And Adjusting The Steering Head

    CHASSIS b. Loosen both locknuts “2”. c. Turn the adjusting bolt “3” until the speci- fied drive chain slack is obtained. b. After loosening the ring nut “2” with a steering nut wrench “3”, tighten it to the specified torque. •...

  • Page 107: Lubricating The Steering Head

    CHASSIS 4. Check: Ring nut (final tightening torque) • Front fork operation 7 N·m (0.7 kgf·m, 5.2 lb·ft) Push down hard on the handlebar several times and check if the front fork rebounds e. Check the steering head for looseness or smoothly.

  • Page 108: Adjusting The Front Fork Legs

    CHASSIS 7. Clean: Rebound damping • Dust seal “a” Minimum (soft) • Oil seal “b” 20 click(s) in direction “b”* Standard • Clean the dust seal and oil seal after every run. 10 click(s) in direction “b”* • Apply lithium-soap-based grease on the inner (AUT, BEL, CHE, CYP, CZE, tube.

  • Page 109: Checking The Rear Shock Absorber Assembly

    CHASSIS Compression damping Bleed screw Minimum (soft) 1.3 N·m (0.13 kgf·m, 0.95 lb·ft) 20 click(s) in direction “b”* Standard 11 click(s) in direction “b”* (AUT, BEL, CHE, CYP, CZE, DEU, DNK, ESP, FIN, FRA, GBR, GRC, HRV, HUN, IRL, ITA, NLD, NOR, POL, PRT, SVK, SVN, SWE, TUR) 9 click(s) in direction “b”* (AUS,...
  • Page 110 CHASSIS off the ground. Spring preload adjusting positions EWA13120 Minimum WARNING Position in which the spring is Securely support the vehicle so that there is turned in 1.5 mm (0.06 in) from no danger of it falling over. its free length. Standard Spring preload Position in which the spring is...
  • Page 111 CHASSIS adjusting range. 1. Adjust: • Rebound damping 1. Adjust: a. Turn the adjuster “1” in the direction of “a” • Compression damping (for fast compression or “b” to make an adjustment. damping) a. Turn the adjuster “1” in the direction of “a” Direction “a”...

  • Page 112: Checking The Swingarm Operation

    CHASSIS page 4-66. Direction “a” Compression damping is increased EAM30501 (suspension is harder). CHECKING THE CONNECTING ARM AND Direction “b” RELAY ARM Compression damping is decreased Refer to “CHECKING THE CONNECTING ARM (suspension is softer). AND RELAY ARM” on page 4-63. EAM30243 Slow compression damping CHECKING THE TIRES...

  • Page 113: Checking The Wheels

    CHASSIS WHEEL” on page 4-10. A tight spoke will emit a clear, ringing tone; a EAM30253 loose spoke will sound flat. CHECKING THE CHASSIS FASTENERS Make sure that all nuts, bolts, and screws are 2. Tighten: properly tightened. • Spoke Refer to “CHASSIS TIGHTENING TORQUES”...
  • Page 114 CHASSIS al moving parts of the pedal. Recommended lubricant Lithium-soap-based grease 3-34...
  • Page 115 ELECTRICAL SYSTEM 4. Check: EAM20137 ELECTRICAL SYSTEM • Ignition timing Check whether the alignment mark “a” on the EAM30256 left crankcase cover is within the firing range CHECKING AND CHARGING THE BATTERY “b” on the generator rotor. Refer to “CHECKING AND CHARGING THE Incorrect firing range ...
  • Page 116 ELECTRICAL SYSTEM 3-36...
  • Page 117 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE SEAT ................4-3 REMOVING THE NUMBER PLATE............4-3 INSTALLING THE AIR SCOOP ..............4-3 REMOVING THE SIDE COVER..............4-4 INSTALLING THE SIDE COVER ...............4-4 FRONT WHEEL....................4-5 REMOVING THE FRONT WHEEL.............4-6 DISASSEMBLING THE FRONT WHEEL...........4-6 CHECKING THE FRONT WHEEL .............4-6 ASSEMBLING THE FRONT WHEEL............4-7 INSTALLING THE FRONT WHEEL (DISC BRAKE) ........4-8 REAR WHEEL ....................4-9...
  • Page 118 INSTALLING THE REAR BRAKE MASTER CYLINDER ......4-33 HANDLEBAR ....................4-35 REMOVING THE HANDLEBAR...............4-37 CHECKING THE HANDLEBAR ...............4-37 INSTALLING THE HANDLEBAR .............4-37 FRONT FORK....................4-42 REMOVING THE FRONT FORK LEGS...........4-44 DISASSEMBLING THE FRONT FORK LEGS .........4-44 CHECKING THE FRONT FORK LEGS ...........4-45 ASSEMBLING THE FRONT FORK LEGS ..........4-46 INSTALLING THE FRONT FORK LEGS ..........4-53 STEERING HEAD...................4-55 REMOVING THE LOWER BRACKET............4-56...

  • Page 119: General Chassis

    GENERAL CHASSIS EAM20094 GENERAL CHASSIS Removing the seat and battery 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 120 GENERAL CHASSIS Removing the side cover 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 1.3 N ・ m (0.13 kgf ・ m, 0.95 lb ・ ft) 7 N ・...

  • Page 121: Removing The Seat

    GENERAL CHASSIS EAM30016 REMOVING THE SEAT The fuel tank cap cover and the seat are coupled with each other with a plastic band. When removing the seat, always remove the fuel tank cap cover beforehand. 1. Remove: • Fuel tank cap cover “1” Refer to “FUEL TANK CAP”...

  • Page 122: Removing The Side Cover

    GENERAL CHASSIS EAM30459 REMOVING THE SIDE COVER 1. Remove: • Side cover (right) “1” Remove the side cover (right) from the vehicle by removing the bolts and sliding it as shown. 1 1 1 a. Projection b. Slot EAM30460 INSTALLING THE SIDE COVER 1.

  • Page 123: Front Wheel

    FRONT WHEEL EAM20095 FRONT WHEEL Removing the front wheel 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 115 N ・ m (11.5 kgf ・ m, 85 lb ・ ft) 12 N ・...

  • Page 124: Removing The Front Wheel

    FRONT WHEEL EAM30017 REMOVING THE FRONT WHEEL 1. Use a maintenance stand to raise the front wheel off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Front wheel EWA13460 EAM30019 DISASSEMBLING THE FRONT WHEEL...

  • Page 125: Assembling The Front Wheel

    FRONT WHEEL 5. Measure: ECA24420 NOTICE • Radial wheel runout “a” Install the bearing by pressing its outer race • Lateral wheel runout “b” parallel. Out of specification  Repair/replace. Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in) 6.

  • Page 126: Installing The Front Wheel (Disc Brake)

    FRONT WHEEL 3. Install: 3. Tighten: • Collar “1” • Front wheel axle nut “1” Front wheel axle nut Apply the lithium-soap-based grease on the oil 115 N·m (11.5 kgf·m, 85 lb·ft) seal lip. ECA24430 NOTICE Before tightening the front wheel axle nut, push down hard on the handlebar(s) several times and check if the front fork rebounds smoothly.

  • Page 127: Rear Wheel

    REAR WHEEL EAM20096 REAR WHEEL Removing the rear wheel 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 135 N ・ m (13.5 kgf ・ m, 100 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 42 N ・...

  • Page 128: Removing The Rear Wheel

    REAR WHEEL Refer to “CHECKING THE TIRES” on page EAM30022 REMOVING THE REAR WHEEL 3-32 and “CHECKING THE WHEELS” on 1. Use a maintenance stand to raise the rear page 3-33. wheel off the ground. 3. Check: EWA13120 • Spoke WARNING Refer to “CHECKING THE FRONT WHEEL”...

  • Page 129: Assembling The Rear Wheel

    REAR WHEEL Rear wheel sprocket self-locking 42 N·m (4.2 kgf·m, 31 lb·ft) Tighten the self-locking nuts in stages and in a crisscross pattern. 2. Install: • Brake disc “1” • Brake disc bolt “2” Brake disc bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) LOCTITE®...
  • Page 130 REAR WHEEL Install the brake disc “1” between the brake pads Temporarily tighten the nut (rear wheel axle) at “2” correctly. this point. 2. Install: 5. Adjust: • Drive chain “1” • Drive chain slack “a” Drive chain slack (Maintenance Push the rear wheel “2”...

  • Page 131: Front Brake

    FRONT BRAKE EAM20097 FRONT BRAKE Removing the front brake caliper 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 28 N ・ m (2.8 kgf ・ m, 21 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 17 N ・...
  • Page 132 FRONT BRAKE Disassembling the front brake caliper 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw 4-14...
  • Page 133 FRONT BRAKE Removing the front brake master cylinder 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 6 N ・...
  • Page 134 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Push rod Dust boot Circlip Washer Brake master cylinder kit 4-16...

  • Page 135: Introduction

    FRONT BRAKE 3. Measure: EAM30028 INTRODUCTION • Brake disc runout EWA19210 Out of specification  Correct the brake disc WARNING runout or replace the brake disc. If you need to disassemble the disc brake components, observe the following precau- Brake disc runout limit (as mea- tions.

  • Page 136: Replacing The Front Brake Pads

    FRONT BRAKE ment steps until the brake disc runout is 2. Measure: within specification. • Brake pad wear limit “a” Out of specification  Replace the brake g. If the brake disc runout cannot be brought within specification, replace the brake pads as a set.

  • Page 137: Removing The Front Brake Caliper

    FRONT BRAKE EAM30030 REMOVING THE FRONT BRAKE CALIPER Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • Union bolt • Copper washer • Brake hose Put the end of the brake hose into a container e.

  • Page 138: Checking The Front Brake Caliper

    FRONT BRAKE EAM30032 EAM30035 CHECKING THE FRONT BRAKE CALIPER INSTALLING THE FRONT BRAKE CALIPER 1. Check: 1. Install: • Brake caliper piston “1” • Front brake caliper bracket Rust/scratches/wear  Replace the brake • Front brake caliper caliper piston. (temporarily) •...

  • Page 139: Removing The Front Brake Master Cylinder

    FRONT BRAKE stalled with its upper end “a” aligned with the system. paint “b” on the brake hose. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-24. EAM30036 REMOVING THE FRONT BRAKE MASTER CYLINDER Before removing the front brake master cylinder, drain the brake fluid from the entire brake sys- tem.

  • Page 140: Installing The Front Brake Master Cylinder

    FRONT BRAKE ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake com- ponents. Specified brake fluid DOT 4 1. Wash the brake master cylinder and the brake master cylinder kit with brake fluid. 2.
  • Page 141 FRONT BRAKE brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.

  • Page 142: Rear Brake

    REAR BRAKE EAM20098 REAR BRAKE Removing the rear brake caliper 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 13 lb ・ ft) 30 N ・...
  • Page 143 REAR BRAKE Disassembling the rear brake caliper 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw 4-25...
  • Page 144 REAR BRAKE Removing the rear brake master cylinder 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 145 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Push rod Brake master cylinder kit 4-27...

  • Page 146: Introduction

    REAR BRAKE EAM30040 INTRODUCTION Brake disc runout limit (as mea- sured on wheel) EWA19260 0.15 mm (0.0059 in) WARNING If you need to disassemble the disc brake components, observe the following precau- 4. Adjust: • Brake disc runout tions. • Never disassemble the brake components Refer to “CHECKING THE FRONT BRAKE DISC”...
  • Page 147 REAR BRAKE Bleed screw 6 N·m (0.6 kgf·m, 4.4 lb·ft) d. Install the brake pads “3” and the pad pin “4”. • Install the brake pads with their projections “a” into the brake caliper recesses “b”. • Temporarily tighten the pad pin at this point. 2.

  • Page 148: Removing The Rear Brake Caliper

    REAR BRAKE 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 149: Assembling The Rear Brake Caliper

    REAR BRAKE 2. Check: • Brake caliper bracket Crack/damage  Replace. EAM30045 ASSEMBLING THE REAR BRAKE CALIPER EWA19280 WARNING • Before installation, clean and lubricate the internal parts. Use new brake fluid for cleaning and lubricating. • Never use solvents on internal brake com- 3.

  • Page 150: Removing The Rear Brake Master Cylinder

    REAR BRAKE 6. Check: • Brake fluid level The minimum level mark “a” or below  Add. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-23. 2. Check: • Brake master cylinder kit Damage/wear  Replace. 3. Check: • Master cylinder reservoir cap Crack/damage ...

  • Page 151: Installing The Rear Brake Master Cylinder

    REAR BRAKE EAM30051 INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • Copper washer • Brake hose • Union bolt Brake hose union bolt 30 N·m (3.0 kgf·m, 22 lb·ft) EWA13531 3. Install: WARNING • Spring “1” Proper brake hose routing is essential to in- Install to the brake master cylinder piston “2”.
  • Page 152 REAR BRAKE is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. • When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.

  • Page 153: Handlebar

    HANDLEBAR EAM20099 HANDLEBAR Removing the handlebar 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 0.5 N ・ m (0.05 kgf ・ m, 0.37 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 1.3 N ・...
  • Page 154 HANDLEBAR Removing the handlebar 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 0.5 N ・ m (0.05 kgf ・ m, 0.37 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 1.3 N ・...

  • Page 155: Removing The Handlebar

    HANDLEBAR • Installing the lower handlebar holders in the re- EAM30052 REMOVING THE HANDLEBAR verse direction allow the front-to-rear offset 1. Stand the vehicle upright on a level surface. amount of the handlebar position to be EWA13120 changed. WARNING • The upper handlebar holders should be in- Securely support the vehicle so that there is stalled with the punch marks “b”...
  • Page 156 HANDLEBAR 168 mm (6.61 in) 5. Install: • Engine stop switch “1” • Mode switch “2” • Clamp “3” Engine stop switch screw 0.5 N·m (0.05 kgf·m, 0.37 lb·ft) Screw (mode switch) 1.3 N·m (0.13 kgf·m, 0.95 lb·ft) • The engine stop switch “1” and the mode switch “2”...
  • Page 157 HANDLEBAR 7. Install: • Clutch cable “1” Before installation, apply the lithium-soap-based grease to the clutch cable end. 10.Install: • Rubber cover “1” • Throttle grip “2” Apply the lithium-soap-based grease on the throttle grip sliding surface. 8. Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY”...
  • Page 158 HANDLEBAR 12.Install: 14.Install: • Throttle cable housing “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 N·m (0.38 kgf·m, 2.8 lb·ft) •...
  • Page 159 HANDLEBAR 15.Adjust: • Throttle grip free play Refer to “CHECKING THE THROTTLE GRIP” on page 3-11. Throttle grip free play 3.0–6.0 mm (0.12–0.24 in) 4-41...

  • Page 160: Front Fork

    FRONT FORK EAM20100 FRONT FORK Removing the front fork legs 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 5 N ・...
  • Page 161 FRONT FORK Disassembling the front fork leg 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 29 N ・ m (2.9 kgf ・ m, 21 lb ・ ft) 28 N ・ m (2.8 kgf ・ m, 21 lb ・ ft) 55 N ・...

  • Page 162: Removing The Front Fork Legs

    FRONT FORK EAM30055 REMOVING THE FRONT FORK LEGS 1. Use a maintenance stand to raise the front wheel off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Record the adjusting screw setting position be- fore loosening the adjuster and the base valve.

  • Page 163: Checking The Front Fork Legs

    FRONT FORK Cap bolt wrench 90890-01500 Cap bolt wrench YM-01500 Cap bolt ring wrench 90890-01501 Cap bolt ring wrench YM-01501 3. Remove: • Dust seal “1” • Oil seal clip “2” (with a flat-head screwdriver) ECA14180 NOTICE Do not scratch the inner tube. EAM30057 CHECKING THE FRONT FORK LEGS 1.

  • Page 164: Assembling The Front Fork Legs

    FRONT FORK Scratches/wear/damage  Replace. Damage/fatigue  Replace the base valve. 3. Measure: • Air bleed screw “4” Wear/damage  Replace. • Fork spring free length “a” Out of specification  Replace. Fork spring free length 497.0 mm (19.57 in) Limit 492.0 mm (19.37 in) 6.
  • Page 165 1. Stretch the damper assembly fully. 2. Fill: • Damper assembly Recommended oil Yamaha Suspension Oil S1 Standard oil amount 216 cm³ (7.30 US oz, 7.62 Imp.oz) ECA24530 NOTICE • Be sure to use the recommended oil. Other oils may have an adverse effect on front fork performance.
  • Page 166 FRONT FORK 7. Install: 10.After filling, pump the damper assembly “1” • Base valve “1” slowly up and down more than 10 times to (to the damper assembly “2”) distribute the fork oil. First bring the damper rod pressure to a maxi- mum.
  • Page 167 FRONT FORK 13.Check: 15.Install: • Damper assembly smooth movement • Piston metal “1” Tightness/binding/rough spots  Repeat the steps (1) to (12). Install the piston metal onto the slot on inner tube. 14.Install: • Dust seal “1” 16.Install: • Oil seal clip “2” •...
  • Page 168 FRONT FORK 20.Install: • Dust seal “1” Apply lithium-soap-based grease on the inner tube. 18.Install: • Oil seal “1” Using a fork seal driver “2”, press the oil seal in until the stopper ring groove fully appears. 21.Check: Fork seal driver •...
  • Page 169 FRONT FORK • Unless the damping force adjuster is fully loos- ened, correct damping characteristic cannot be obtained after installation. 23.Install: • Collar “1” • Fork spring “2” (to the damper assembly “3”) 26.Install: • Damper adjusting rod “1” Install the collar with its larger dia. end “a” facing •...
  • Page 170 FRONT FORK correct damping force cannot be obtained. Recommended oil Yamaha Suspension Oil S1 Standard oil amount 295 cm³ (9.97 US oz, 10.41 Imp.oz) Extent of adjustment 260–365 cm³ (8.79–12.34 US oz, 9.17–12.87 Imp.oz) ECA24570 NOTICE • Be sure to use the recommended oil. Other oils may have an adverse effect on front 28.Tighten:...

  • Page 171: Installing The Front Fork Legs

    FRONT FORK EAM30059 INSTALLING THE FRONT FORK LEGS 1. Install: • Front fork “1” • Temporarily tighten the pinch bolts (lower bracket). • Do not tighten the pinch bolts (upper bracket) yet. 3. Adjust: • Front fork top end “a” Front fork top end (standard) “a”...
  • Page 172 FRONT FORK 8. Adjust: Lower bracket pinch bolt • Compression damping force 21 N·m (2.1 kgf·m, 15 lb·ft) Turn in the damping adjuster “1” finger-tight and EWA19320 then turn out to the originally set position. WARNING Tighten the lower bracket to specified torque.

  • Page 173: Steering Head

    STEERING HEAD EAM20101 STEERING HEAD Removing the lower bracket 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 145 N ・ m (14.5 kgf ・ m, 107 lb ・ ft) 38 N ・ m (3.8 kgf ・ m, 28 lb ・ ft) 7 N ・...

  • Page 174: Removing The Lower Bracket

    STEERING HEAD EAM30060 ECA14270 REMOVING THE LOWER BRACKET NOTICE 1. Use a maintenance stand to raise the front If the bearing race is not installed properly, wheel off the ground. the steering head pipe could be damaged. EWA13120 WARNING Always replace the bearing and the bearing race Securely support the vehicle so that there is as a set.
  • Page 175 STEERING HEAD 2. Install: • Bearing race • Upper bearing “1” • Bearing race cover “2” Apply the lithium-soap-based grease on the bearing and bearing race cover lip. 5. Check the steering stem by turning this lock to lock. If there is any binding, remove the steering stem and check the steering bear- ing.
  • Page 176 STEERING HEAD 8. Install: 11.Tighten: • Steering stem nut “1” • Pinch bolt (upper bracket) “1” Steering stem nut Upper bracket pinch bolt 145 N·m (14.5 kgf·m, 107 lb·ft) 21 N·m (2.1 kgf·m, 15 lb·ft) • Pinch bolt (lower bracket) “2” Apply the lithium-soap-based grease to the con- Lower bracket pinch bolt tact surface of the steering stem nut when in-...

  • Page 177: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAM20102 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 56 N ・ m (5.6 kgf ・ m, 41 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 53 N ・ m (5.3 kgf ・ m, 39 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 178 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 56 N ・ m (5.6 kgf ・ m, 41 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 53 N ・ m (5.3 kgf ・ m, 39 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 179 REAR SHOCK ABSORBER ASSEMBLY Disassembling the relay arm 80 N ・ m (8.0 kgf ・ m, 59 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Relay arm Connecting arm Collar Oil seal Washer Bearing 4-61...

  • Page 180: Handling The Rear Shock Absorber

    • To dispose of a damaged or a worn-out rear shock absorber, take the unit to your EAM30067 CHECKING THE REAR SHOCK ABSORBER Yamaha dealer for this disposal procedure. ASSEMBLY 1. Check: • Rear shock absorber rod Bends/damage  Replace the rear shock absorber assembly.

  • Page 181: Checking The Connecting Arm And Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY EAM30068 CHECKING THE CONNECTING ARM AND RELAY ARM 1. Check: • Connecting arm • Relay arm Damage/wear  Replace. 2. Check: • Bearing • Collar Damage/pitting/scratches  Replace the bearings and collars as a set. EAM30070 INSTALLING THE REAR SHOCK 3.
  • Page 182 REAR SHOCK ABSORBER ASSEMBLY Installed depth “a” Relay arm nut (swingarm side) 4.25 mm (0.17 in) 70 N·m (7.0 kgf·m, 52 lb·ft) • Rear shock absorber assembly lower nut Rear shock absorber assembly lower nut 53 N·m (5.3 kgf·m, 39 lb·ft) 5.

  • Page 183: Swingarm

    SWINGARM EAM20103 SWINGARM Removing the swingarm 85 N ・ m (8.5 kgf ・ m, 63 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 4.0 N ・ m (0.40 kgf ・ m, 3.0 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 184: Removing The Swingarm

    SWINGARM shaft. EAM30071 REMOVING THE SWINGARM 1. Use a maintenance stand to raise the rear wheel off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Measure: • Swingarm side play •...
  • Page 185 SWINGARM 3. Install: • Swingarm Pivot shaft nut 85 N·m (8.5 kgf·m, 63 lb·ft) Install the pivot shaft from the right. 4. Install: • Rear wheel Refer to “REAR WHEEL” on page 4-9. 5. Adjust: • Drive chain slack Refer to “DRIVE CHAIN SLACK” on page 3-25.

  • Page 186: Chain Drive

    CHAIN DRIVE EAM20104 CHAIN DRIVE Removing the drive chain 90 N ・ m (9.0 kgf ・ m, 66 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Drive sprocket Refer to “ENGINE REMOVAL”...

  • Page 187: Removing The Drive Chain

    CHAIN DRIVE EAM30075 REMOVING THE DRIVE CHAIN 1. Use a maintenance stand to raise the rear wheel off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Chain joint clip •...

  • Page 188: Checking The Drive Sprocket

    CHAIN DRIVE 5. Lubricate: 2. Lubricate: • Drive chain • Drive chain 3. Install: EAM30077 • Drive sprocket CHECKING THE DRIVE SPROCKET • Lock washer 1. Check: • Drive sprocket nut • Drive sprocket Refer to “ENGINE REMOVAL” on page 5-6. More than 1/4 tooth wear “a”...
  • Page 189 ENGINE LUBRICATION SYSTEM CHART AND DIAGRAMS ........5-1 ENGINE OIL LUBRICATION CHART ............5-1 LUBRICATION DIAGRAMS ...............5-2 ENGINE REMOVAL..................5-6 REMOVING THE ENGINE ...............5-10 INSTALLING THE ENGINE..............5-10 INSTALLING THE EXHAUST PIPE AND MUFFLER.......5-11 CAMSHAFT ....................5-13 REMOVING THE CAMSHAFT ..............5-15 CHECKING THE CAMSHAFT..............5-16 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET ..5-17 CHECKING THE TIMING CHAIN TENSIONERS ........5-17 CHECKING THE DECOMPRESSION SYSTEM........5-17 INSTALLING THE CAMSHAFTS .............5-18...
  • Page 190 ELECTRIC STARTER..................5-43 CHECKING THE STARTER MOTOR ............5-45 ASSEMBLING THE STARTER MOTOR..........5-45 CLUTCH ......................5-47 REMOVING THE CLUTCH ..............5-50 CHECKING THE FRICTION PLATES............5-50 CHECKING THE CLUTCH PLATES ............5-50 CHECKING THE CLUTCH SPRINGS............5-50 CHECKING THE CLUTCH HOUSING .............5-51 CHECKING THE CLUTCH BOSS............5-51 CHECKING THE PRESSURE PLATE .............5-51 CHECKING THE PUSH LEVER SHAFT..........5-51 CHECKING THE PUSH RODS ..............5-51 CHECKING THE PRIMARY DRIVE GEAR..........5-51...

  • Page 191: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAM20185 LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30526 ENGINE OIL LUBRICATION CHART 1. Intake camshaft 2. Exhaust camshaft 3. Piston 4. Oil filter element 5. Oil nozzle 6. Oil pump 7. Oil strainer 8. Crankshaft 9. Drive axle 10.Main axle...

  • Page 192: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30507 LUBRICATION DIAGRAMS 1. Camshaft 2. Drive axle 3. Main axle...
  • Page 193 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Connecting rod 2. Oil nozzle 3. Crankshaft...
  • Page 194 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Exhaust camshaft 2. Intake camshaft 3. Oil filter element 4. Oil pump...
  • Page 195 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter element 2. Oil pump 3. Oil strainer...

  • Page 196: Engine Removal

    ENGINE REMOVAL EAM20105 ENGINE REMOVAL Removing the exhaust pipe 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 20 N ・...
  • Page 197 ENGINE REMOVAL Removing the electronic parts 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Use a maintenance stand to raise the front wheel off the ground.
  • Page 198 ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 85 N ・ m (8.5 kgf ・ m, 63 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 7 N ・...
  • Page 199 ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 85 N ・ m (8.5 kgf ・ m, 63 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 7 N ・...

  • Page 200: Removing The Engine

    ENGINE REMOVAL EAM30161 REMOVING THE ENGINE 1. Remove: • Exhaust pipe 2 Put the exhaust pipe 2 into the state as shown by moving this, and then remove it. 2. Remove: • Pivot shaft “1” If the pivot shaft is pulled all the way out, the EAM30164 INSTALLING THE ENGINE swingarm will come loose.

  • Page 201: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL Engine mounting bolt (upper side) 45 N·m (4.5 kgf·m, 33 lb·ft) • Apply molybdenum disulfide grease to the piv- ot shaft. • Place the projection of the shims to the outside of the vehicle. 2. Install: • Clamp •...
  • Page 202 ENGINE REMOVAL 4. Tighten: • Bolt (exhaust pipe 2) Bolt (exhaust pipe 2) 20 N·m (2.0 kgf·m, 15 lb·ft) • Clamp Clamp 12 N·m (1.2 kgf·m, 8.9 lb·ft) Tighten while checking that their front and rear joints are inserted in position. 5-12...

  • Page 203: Camshaft

    Refer to “ENGINE REMOVAL” on page 5-6. Cylinder head breather hose Spark plug Cylinder head cover Cylinder head cover breather plate Gasket Timing chain guide (top side) Cylinder head cover gasket Gasket * Yamaha bond No. 1215 (Three bond No.1215®) 5-13...
  • Page 204 CAMSHAFT Removing the camshaft 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 10 N ・...

  • Page 205: Removing The Camshaft

    CAMSHAFT EAM30080 REMOVING THE CAMSHAFT 1. Remove: • Timing mark accessing screw “1” • Crankshaft end accessing screw “2” 4. Remove: • Bolt (camshaft cap) “1” • Camshaft cap “2” • Clip “3” 2. Align: • Remove the bolts (camshaft cap) in a criss- •...

  • Page 206: Checking The Camshaft

    CAMSHAFT 4. Measure: EAM30081 CHECKING THE CAMSHAFT • Camshaft-journal-to-camshaft-cap clearance 1. Check: Out of specification  Measure the camshaft • Camshaft lobe journal diameter. Blue discoloration/pitting/scratches  Re- Camshaft-journal-to-camshaft- place the camshaft. cap clearance 2. Measure: 0.028–0.062 mm (0.0011–0.0024 • Camshaft lobe dimensions “A” Out of specification ...

  • Page 207: Checking The Timing Chain And Camshaft Sprocket

    CAMSHAFT a. 1/4 tooth 5. Measure: b. Correct • Camshaft journal diameter “a” Out of specification  Replace the camshaft. 1. Timing chain roller Within specification  Replace the cylinder 2. Camshaft sprocket head and the camshaft caps as a set. EAM30083 CHECKING THE TIMING CHAIN Camshaft journal diameter...

  • Page 208: Installing The Camshafts

    CAMSHAFT a. Check that the decompressor cam “1” cylinder head. moves smoothly. b. Check that the decompressor lever pin “2” • Check that the alignment marks “c” on the projects from the camshaft. camshaft sprockets are aligned with the edge of the camshaft cap surfaces “d”.
  • Page 209 CAMSHAFT Bolt (camshaft cap) 10 N·m (1.0 kgf·m, 7.4 lb·ft) • Before installing the clips, cover the cylinder head with a clean cloth to prevent the clips from coming off into the cylinder head cavity. • Apply the engine oil to the threads and contact surfaces.
  • Page 210 CAMSHAFT Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 6. Install: • Cylinder head breather hose • Spark plug Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) 5-20...
  • Page 211 CYLINDER HEAD EAM20107 CYLINDER HEAD Removing the cylinder head 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 90˚ 60˚ 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 7 N ・...

  • Page 212: Cylinder Head

    CYLINDER HEAD Removing the cylinder head 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 90˚ 60˚ 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 7 N ・...

  • Page 213: Removing The Cylinder Head

    CYLINDER HEAD EAM30086 REMOVING THE CYLINDER HEAD 1. Remove: • Cylinder head bolt • Loosen the bolts in the proper sequence as shown. • Loosen each bolt 1/2 of a turn at a time. After fully loosening all the bolts, remove them. •...

  • Page 214: Installing The Cylinder Head

    CYLINDER HEAD two or three steps in the proper tightening EAM30089 INSTALLING THE CYLINDER HEAD sequence as shown. 1. Install: • Timing chain guide (intake side) “1” Tighten the bolts to the specified torque in two or • Dowel pin “2” three steps in the proper tightening sequence as •...
  • Page 215 CYLINDER HEAD j. Retighten the cylinder head mounting bolt Final in the proper tightening sequence. Specified angle 60 n. Tighten the bolts to the specified torque. Bolt [5], [6] 10 N·m (1.0 kgf·m, 7.4 lb·ft) 90˚ Bolt [1] Specified angle 90...
  • Page 216 VALVES AND VALVE SPRINGS EAM20108 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 5-21. Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Intake valve...

  • Page 217: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAM30090 REMOVING THE VALVES Check that there are no kerosene leaks from the valve seat “1”. Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure that the valves are properly sealed. 1.

  • Page 218: Checking The Valves And Valve Guides

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

  • Page 219: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 2. Check: • Valve seat After replacing the valve guide, reface the valve Pitting/wear  Replace the cylinder head. seat. 3. Measure: • Valve seat contact width “a” Valve guide remover & installer Out of specification  Replace the cylinder set (ø5.5) 90890-04016 head.

  • Page 220: Checking The Valve Springs

    VALVES AND VALVE SPRINGS valve seat. e. Apply a fine lapping compound to the valve face, and repeat the above steps. f. After every lapping step, be sure to clean off all of the lapping compound from the valve face and the valve seat. g.

  • Page 221: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 3. Install: EAM30094 CHECKING THE VALVE LIFTERS • Spring seat “1” 1. Check: • Valve stem seal “2” • Valve lifter • Valve “3” Damage/scratches  Replace the valve lift- • Valve spring “4” ers and cylinder head. •...
  • Page 222 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: • Adjusting pad “1” •...

  • Page 223: Cylinder And Piston

    CYLINDER AND PISTON EAM20109 CYLINDER AND PISTON Removing the cylinder and piston 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Cylinder head...

  • Page 224: Removing The Piston

    CYLINDER AND PISTON the piston ring over the piston crown. EAM30096 REMOVING THE PISTON 1. Remove: • Piston pin clip “1” • Piston pin “2” • Piston “3” ECA13810 NOTICE Do not use a hammer to drive the piston pin out.

  • Page 225: Checking The Piston Rings

    CYLINDER AND PISTON Diameter Top ring 96.955–96.970 mm (3.8171– Ring side clearance 3.8177 in) 0.015–0.065 mm (0.0006–0.0026 Measuring point (from piston skirt bottom) Side clearance limit 9.0 mm (0.35 in) 0.120 mm (0.0047 in) 2nd ring Ring side clearance 0.020–0.060 mm (0.0008–0.0024 Side clearance limit 0.100 mm (0.0039 in) d.

  • Page 226: Checking The Piston Pin

    CYLINDER AND PISTON b. Upper of cylinder EAM30100 INSTALLING THE PISTON AND CYLINDER EAM30099 1. Install: CHECKING THE PISTON PIN • Oil ring expander “1” 1. Check: • Lower oil ring rail “2” • Piston pin • Upper oil ring rail “3” Blue discoloration/grooves ...
  • Page 227 CYLINDER AND PISTON clip from falling into the crankcase. • Make sure that the end of the piston pin clip is • While compressing the piston rings with one not positioned at the cutout in the piston. hand, install the cylinder with the other hand. •...

  • Page 228: Generator

    GENERATOR EAM20183 GENERATOR Removing the stator coil assembly 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 8 N ・...

  • Page 229: Removing The Generator

    T25 bit. • Stator coil assembly “2” outer surface “b” • Pass the stator coil assembly lead through the Damage  Inspect the crankshaft runout and crankcase cover side. crankshaft bearing. Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 5-39...
  • Page 230 GENERATOR • Crankcase cover (left) “3” • Lead holder “4” • Bolt (left crankcase cover) “5” Bolt (left crankcase cover) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Tighten the bolts in stages and in a crisscross pattern. 2. Install: • Woodruff key “1” •...

  • Page 231: Starter Clutch

    STARTER CLUTCH EAM20175 STARTER CLUTCH Removing the starter clutch 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Refer to “CHANGING THE ENGINE OIL” on Engine oil page 3-13. Clutch Refer to “CLUTCH” on page 5-47. Holder Washer Damper assembly...

  • Page 232: Checking The Starter Clutch

    STARTER CLUTCH EAM30140 CHECKING THE STARTER CLUTCH 1. Check: • Starter clutch assembly • Starter clutch drive gear Burrs/chips/roughness/wear  Replace the starter clutch. 2. Check: • Starter clutch assembly gear Damage/pitting/wear  Replace the starter clutch assembly. 3. Check: •...
  • Page 233 ELECTRIC STARTER EAM20110 ELECTRIC STARTER Removing the starter motor 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Exhaust pipe Refer to “ENGINE REMOVAL”...
  • Page 234 ELECTRIC STARTER Disassembling the starter motor 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 4.5 N ・ m (0.45 kgf ・ m, 3.3 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Starter motor assembly O-ring Starter motor front cover Starter motor yoke Armature assembly...

  • Page 235: Electric Starter

    ELECTRIC STARTER 4. Measure: EAM30106 CHECKING THE STARTER MOTOR • Brush length “a” 1. Check: Out of specification  Replace the brush set. • Commutator Dirt  Clean with 600 grit sandpaper. Brush overall length limit 5.5 mm (0.22 in) 2.
  • Page 236 ELECTRIC STARTER • Starter motor yoke “2” Install the starter motor rear cover with its projec- tion “a” facing the groove “b” of the starter motor yoke. 3. Install: • Circlip • Plain washer • O-ring • Washer (starter motor front cover) •...

  • Page 237: Clutch

    CLUTCH EAM20111 CLUTCH Removing the clutch 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 75 N ・...
  • Page 238 CLUTCH Removing the clutch 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 75 N ・...
  • Page 239 CLUTCH Removing the right crankcase cover 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 240: Removing The Clutch

    CLUTCH EAM30108 REMOVING THE CLUTCH 1. Remove: • Clutch boss nut “1” • Lock washer “2” • Clutch boss “3” • Straighten the lock washer tab. • While holding the clutch boss with the univer- sal clutch holder “4”, loosen the clutch boss nut.

  • Page 241: Checking The Clutch Housing

    CLUTCH EAM30114 Clutch spring free length CHECKING THE PRESSURE PLATE 48.00 mm (1.89 in) 1. Check: Limit • Pressure plate 45.60 mm (1.80 in) Crack/damage  Replace. EAM30115 CHECKING THE PUSH LEVER SHAFT 1. Check: • Push lever shaft Wear/damage  Replace. EAM30112 CHECKING THE CLUTCH HOUSING 1.

  • Page 242: Checking The Primary Driven Gear

    CLUTCH the primary drive and primary driven gears as a set. 2. Check: • Primary-drive-gear-to-primary-driven-gear free play Free play exists  Replace the primary drive and primary driven gears as a set. EAM30118 CHECKING THE PRIMARY DRIVEN GEAR 1. Check: •...
  • Page 243 CLUTCH 1 1 1 2 2 2 3 3 3 5. Install: 7. Bend the lock washer “1” tab. • Primary driven gear “1” • Thrust washer “2” • Clutch boss “3” Apply the engine oil on the primary driven gear inner circumference.
  • Page 244 CLUTCH To push rod 1 “4”. Tighten the bolts in stages and in a crisscross Apply the engine oil on the bearing and washer. pattern. 4 4 4 10.Install: 13.Install: • Push rod 2 “1” • O-ring “1” • Ball “2” •...
  • Page 245 SHIFT SHAFT EAM20113 SHIFT SHAFT Removing the shift shaft and stopper lever 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 10 N ・...

  • Page 246: Shift Shaft

    SHIFT SHAFT EAM30124 REMOVING THE SEGMENT 1. Remove: • Bolt (segment) “1” • Segment “2” Turn the segment counterclockwise until it stops and loosen the bolt. ECA24670 NOTICE If the segment gets an impact, the stopper le- EAM30127 ver may be damaged. Take care not to give CHECKING THE STOPPER LEVER an impact to it when removing the bolt.
  • Page 247 SHIFT SHAFT • Apply the engine oil on the segment bolt shaft. Segment bolt 30 N·m (3.0 kgf·m, 22 lb·ft) • Align the notch “a” on the segment with the pin “b” on the shift cam. • With the stopper lever pushed down, install the segment.
  • Page 248 SHIFT SHAFT Shift pedal bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) Align the punch mark “a” on the shift shaft with the punch mark “b” in the shift pedal. 5-58...
  • Page 249 OIL PUMP EAM20182 OIL PUMP Removing the oil pump 2.0 N ・ m (0.20 kgf ・ m, 1.5 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Primary driven gear Refer to “CLUTCH”...

  • Page 250: Oil Pump

    OIL PUMP Removing the balancer 80 N ・ m (8.0 kgf ・ m, 59 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 45 N ・ m (4.5 kgf ・ m, 33 lb ・ ft) 50 N ・...

  • Page 251: Removing The Oil Pump

    OIL PUMP EAM30485 REMOVING THE OIL PUMP 1 1 1 1. Straighten the lock washer tab. 2. Loosen: • Balancer nut “1” • Primary drive gear nut “2” • Balancer weight gear nut “3” Place an aluminum plate “a” between the teeth of the balancer drive gear “4”...

  • Page 252: Assembling The Oil Pump

    OIL PUMP Inner-rotor-to-outer-rotor-tip • Apply the engine oil on the oil pump drive shaft clearance and inner rotor. 0.000–0.150 mm (0.0000–0.0059 • Fit the dowel pin into the groove in the inner ro- tor. Limit 0.230 mm (0.0091 in) Outer-rotor-to-oil-pump-housing clearance 0.130–0.180 mm (0.0051–0.0071 Limit...
  • Page 253 OIL PUMP Oil pump assembly bolt 5 N·m (0.5 kgf·m, 3.7 lb·ft) LOCTITE® 4. Install: • Lock washer “1” 1 1 1 • Balancer weight gear nut “2” Balancer weight gear nut 50 N·m (5.0 kgf·m, 37 lb·ft) ECA13890 NOTICE After tightening the bolts, make sure the oil •...
  • Page 254 OIL PUMP 5. Bend the lock washer tab. 5-64...

  • Page 255: Crankcase

    CRANKCASE EAM20116 CRANKCASE Separating the crankcase 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 12 N ・...
  • Page 256 CRANKCASE Removing the bearing and oil seal 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 12 N ・...

  • Page 257: Disassembling The Crankcase

    CRANKCASE EAM30147 DISASSEMBLING THE CRANKCASE 1. Separate: • Right crankcase • Left crankcase a. Remove the crankcase bolts. c. Remove the dowel pins and O-ring. 2. Remove: • Bearing “1” • Remove the bearing from the crankcase by pressing its inner race. •...

  • Page 258: Assembling The Crankcase

    Install the bearing by pressing its outer race par- allel. 3. Apply: • Sealant (to the crankcase mating surface) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 4. 45 mm (1.77 in) 5. 60 mm (2.36 in) 6. 75 mm (2.95 in) 4.

  • Page 259: Crankshaft And Balancer Shaft

    CRANKSHAFT AND BALANCER SHAFT EAM20184 CRANKSHAFT 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 5-65. Transmission Refer to “TRANSMISSION” on page 5-72. Balancer shaft Crankshaft assembly 5-69...

  • Page 260: Removing The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT Out of specification  Replace the crank- EAM30491 REMOVING THE CRANKSHAFT shaft, bearing or both. 1. Remove: • Balancer shaft “1” Turn the crankshaft slowly. Remove the balancer shaft with its flat side “a” Runout limit facing the crankshaft.

  • Page 261: Installing The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT EAM30493 INSTALLING THE CRANKSHAFT 1. Install: • Crankshaft assembly Install the crankshaft assembly with the crank- shaft installer pot “1”, crankshaft installer bolt “2”, adapter (M12) “3” and spacer “4”. Crankshaft installer pot 90890-01274 Installing pot YU-90058 Crankshaft installer bolt 90890-01275...

  • Page 262: Transmission

    TRANSMISSION EAM20118 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-6. Separate. Crankcase Refer to “CRANKCASE” on page 5-65. Main axle Drive axle Long shift fork guide bar Short shift fork guide bar Spring Shift cam...

  • Page 263: Removing The Transmission

    TRANSMISSION EAM30153 REMOVING THE TRANSMISSION 1. Remove: • Long shift fork guide bar “1” • Short shift fork guide bar “2” • Shift cam “3” • Shift fork 3 “4” • Shift fork 2 “5” • Shift fork 1 “6” •...

  • Page 264: Checking The Transmission

    TRANSMISSION sembly. EAM30157 INSTALLING THE TRANSMISSION 1. Install: EAM30156 CHECKING THE TRANSMISSION • 5th pinion gear (21T) “1” 1. Measure: • 3rd pinion gear (20T) “2” • Main axle runout • Collar “3” (with a centering device and dial gauge “1”) •...
  • Page 265 TRANSMISSION • Drive axle “2” 3. Install: • Washer “1” • Circlip “2” • Install to the left crankcase simultaneously. • Apply engine oil to the main axle and the drive • Be sure the circlip sharp-edged corner “a” is axle bearing.
  • Page 266 TRANSMISSION 7. Install: • Long shift fork guide bar “1” • Short shift fork guide bar “2” • Spring “3” • Screw the spring into the shift fork guide bar lightly beforehand. • Apply the engine oil on the shift fork guide bars. 8.
  • Page 267 COOLING SYSTEM COOLING SYSTEM DIAGRAMS ..............6-1 RADIATOR......................6-2 CHECKING THE RADIATOR..............6-4 INSTALLING THE RADIATOR..............6-4 WATER PUMP ....................6-6 DISASSEMBLING THE WATER PUMP.............6-7 CHECKING THE WATER PUMP ...............6-7 ASSEMBLING THE WATER PUMP............6-7...

  • Page 268: Cooling System

    COOLING SYSTEM DIAGRAMS EAM20186 COOLING SYSTEM DIAGRAMS 1. Radiator hose 1 2. Radiator (right) 3. Radiator hose 4 4. Water pump 5. Radiator hose 3 6. Radiator (left)

  • Page 269: Radiator

    RADIATOR EAM20138 RADIATOR Removing the radiator 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・...
  • Page 270 RADIATOR Removing the radiator 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・...

  • Page 271: Checking The Radiator

    RADIATOR EAM30341 CHECKING THE RADIATOR 1. Check: • Radiator fins “1” Obstructions  Clean. Apply compressed air to the rear of the radia- tor. Damage  Repair or replace. Correct any flattened fins with a thin, flat-head screwdriver. EAM30506 INSTALLING THE RADIATOR 1.
  • Page 272 RADIATOR head gasket is replaced is made after 3 min- utes of warm-up. • Make sure that coolant is filled up to the up- per level beforehand. 5. Check: • Pressure value No stay for 5 to 10 seconds at the test pres- sure value ...
  • Page 273 WATER PUMP EAM20139 WATER PUMP Removing the water pump 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT”...

  • Page 274: Water Pump

    WATER PUMP EAM30494 DISASSEMBLING THE WATER PUMP • Remove the oil seal when the coolant level changes frequently more than usual, coolant has discolored, or engine oil has become milky. • Do not use the removed oil seal. 1. Remove: •...
  • Page 275 WATER PUMP 1 1 1 5. Install: • Water pump housing “1” • Water pump housing bolt “2” Water pump housing bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) • Washer “3” • Coolant drain bolt “4” Coolant drain bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft)
  • Page 276 WATER PUMP...
  • Page 277 FUEL SYSTEM FUEL TANK ......................7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP ..............7-2 CHECKING THE FUEL PUMP BODY............7-2 CHECKING THE FUEL PUMP OPERATION..........7-2 INSTALLING THE FUEL PUMP..............7-2 INSTALLING THE FUEL TANK..............7-3 THROTTLE BODY ....................7-4 CHECKING THE INJECTOR ..............7-7 CHECKING THE THROTTLE BODY ............7-7 CHECKING THE FUEL PRESSURE ............7-7 ADJUSTING THE THROTTLE POSITION SENSOR.........7-8...

  • Page 278: Fuel Tank

    FUEL TANK EAM20140 FUEL TANK Removing the fuel tank 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 4.0 N ・...

  • Page 279: Removing The Fuel Tank

    FUEL TANK EAM30263 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 EWA19370 WARNING Cover the fuel hose connection with a cloth when disconnecting it. This is because re- sidual pressure in the fuel hose could cause fuel to spurt out when the hose is removed.

  • Page 280: Installing The Fuel Tank

    FUEL TANK • Take care not to damage the installation sur- faces of the fuel tank. • Always use a new fuel pump gasket. • Install the lip on the fuel pump gasket upward. • Install the fuel pump as shown in the figure. •...

  • Page 281: Throttle Body

    THROTTLE BODY EAM20141 THROTTLE BODY Removing the throttle body 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 4.0 N ・...
  • Page 282 THROTTLE BODY Removing the throttle body 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 4.0 N ・...
  • Page 283 THROTTLE BODY Removing the injector 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel inlet pipe Injector Gasket Throttle position sensor Intake air pressure sensor...

  • Page 284: Checking The Injector

    THROTTLE BODY EAM30271 CHECKING THE INJECTOR 1. Check: • Injector Obstruction  Replace, and check the fuel pump and the fuel injection system. Refer to “FUEL INJECTION SYSTEM” on page 8-15. Deposits  Replace. Damage  Replace. 2. Check: • Injector resistance Refer to “CHECKING THE INJECTOR”...

  • Page 285: Adjusting The Throttle Position Sensor

    Check that the throttle grip is fully closed. d. Connect the throttle position sensor to the wire harness. e. Set the Yamaha diagnostic tool to “diag- nostic mode”. f. Choose the diagnostic code No. “01”. g. Adjust the throttle position sensor mount- ed angle until “11”–“14”...
  • Page 286 THROTTLE BODY...
  • Page 287 CHARGING SYSTEM..................8-11 CIRCUIT DIAGRAM .................8-11 TROUBLESHOOTING ................8-13 FUEL INJECTION SYSTEM................8-15 CIRCUIT DIAGRAM .................8-15 YAMAHA DIAGNOSTIC TOOL ..............8-17 CONNECTING THE YAMAHA DIAGNOSTIC TOOL.......8-17 TROUBLESHOOTING DETAILS (FAULT CODE) ........8-19 FUEL PUMP SYSTEM..................8-37 CIRCUIT DIAGRAM .................8-37 TROUBLESHOOTING ................8-39 ELECTRICAL COMPONENTS...............8-40 CHECKING THE SWITCHES ..............8-41 CHECKING THE FUSES .................8-43...

  • Page 288: Ignition System

    IGNITION SYSTEM EAM20142 IGNITION SYSTEM EAM30277 CIRCUIT DIAGRAM...
  • Page 289 IGNITION SYSTEM 1. Crankshaft position sensor 2. AC magneto 3. Rectifier/regulator 4. Joint connector 6. Battery 7. Engine ground 8. Frame ground 9. Fuse 10.Starter relay 11.Starter motor 12.Diode 1 13.Diode 2 14.CCU (Communication Control Unit) 16.ECU (Engine Control Unit) 17.Ignition coil 18.Spark plug 25.Engine stop switch...

  • Page 290: Troubleshooting

    IGNITION SYSTEM EAM30278 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). Before troubleshooting, remove the following part(s): 1. Side cover (left/right) 2. Seat 3. Fuel tank 4. Air scoop (left/right) 5. Air filter case cover 1. Check the ignition system wire har- Reconnect.
  • Page 291 IGNITION SYSTEM 9. Check the stator coil assembly. Refer to “CHECKING THE STA- Replace the stator coil assembly. NG TOR COIL” on page 8-48. OK 10.Check the ignition system wire har- ness. Repair or replace the wire harness. Refer to “CIRCUIT DIAGRAM” on NG...
  • Page 292 IGNITION SYSTEM The mode switch to blink. Before troubleshooting, remove the following part(s): 1. Seat 2. Air scoop (left) 1. Check the mode switch coupler Reconnect. connections. NG OK 2. Check the mode switch. Refer to “CHECKING THE Replace the mode switch. NG...
  • Page 293 IGNITION SYSTEM...

  • Page 294: Electric Starting System

    ELECTRIC STARTING SYSTEM EAM20143 ELECTRIC STARTING SYSTEM EAM30279 CIRCUIT DIAGRAM...
  • Page 295 ELECTRIC STARTING SYSTEM 4. Joint connector 5. Main relay 6. Battery 7. Frame ground 8. Engine ground 9. Fuse 10.Starter relay 11.Starter motor 12.Diode 1 13.Diode 2 16.ECU (Engine Control Unit) 25.Engine stop switch 27.Gear position switch 29.Start switch 30.Diode 3 A.

  • Page 296: Troubleshooting

    ELECTRIC STARTING SYSTEM EAM30281 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 5. Air filter case cover 1. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse(s).
  • Page 297 ELECTRIC STARTING SYSTEM 9. Check the start switch. Refer to “CHECKING THE Replace the start switch. NG SWITCHES” on page 8-41. OK 10.Check the entire starting system’s wiring. Properly connect or repair the starting sys- Refer to “CIRCUIT DIAGRAM” on tem’s wiring.

  • Page 298: Charging System

    CHARGING SYSTEM EAM20144 CHARGING SYSTEM EAM30282 CIRCUIT DIAGRAM 8-11...
  • Page 299 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 6. Battery 7. Frame ground 8. Engine ground 9. Fuse A. Battery sub-lead B. Wire harness 8-12...

  • Page 300: Troubleshooting

    CHARGING SYSTEM EAM30283 TROUBLESHOOTING The battery is not being charged. Before troubleshooting, remove the following part(s): 1. Seat 2. Air scoop (left) 1. Check the entire charging system’s Reconnect. wiring. NG OK 2. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse(s).
  • Page 301 CHARGING SYSTEM 8-14...

  • Page 302: Fuel Injection System

    FUEL INJECTION SYSTEM EAM20145 FUEL INJECTION SYSTEM EAM30284 CIRCUIT DIAGRAM 8-15...
  • Page 303 3. Rectifier/regulator 4. Joint connector 6. Battery 7. Frame ground 8. Engine ground 9. Fuse 14.CCU (Communication Control Unit) 15.Yamaha diagnostic tool coupler 16.ECU (Engine Control Unit) 17.Ignition coil 18.Spark plug 19.Fuel injector 20.Fuel pump 21.Intake air temperature sensor 22.Coolant temperature sensor 23.Throttle position sensor...

  • Page 304: Yamaha Diagnostic Tool

    • Prepare the fully charged 12 V lead battery for yourself. • Replace the vehicle battery with a lead battery (12 V). • For information on how to connect and use the Yamaha diagnostic tool, refer to “YAMAHA DIGNO- STIC TOOL OPERATION MANUAL”.
  • Page 305 2. Lead battery (12 V) 3. Vehicle battery 4. Vehicle 5. Coupler for connecting optional part 6. FI diagnostic tool sub-lead 7. Sub-harness (included with the Yamaha diag- nostic tool) 8. Vehicle communication cable (included with the Yamaha diagnostic tool) 9. Yamaha diagnostic tool...

  • Page 306: Troubleshooting Details (Fault Code)

    Yamaha diagnostic tool according to the reinstatement method. Fault code No.: Fault code number displayed on the Yamaha diagnostic tool when the engine failed to work normally. Diagnostic code No.: Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC CODE: SENSOR OPERATION TABLE”...
  • Page 307 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air pressure. Procedure The atmospheric pressure is displayed on the Yamaha diagnostic tool. Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check...
  • Page 308 Replace the intake air pressure sensor. Faulty ECU. Replace the ECU. Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-21...
  • Page 309 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air pressure. Procedure The atmospheric pressure is displayed on the Yamaha diagnostic tool. Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check...
  • Page 310 Disconnect the coupler, and Yamaha diagnostic tool. Condition is “Recovered”  Go check the pins (for bent or bro- ken terminals and locking condi- to item 8 and finish the service.
  • Page 311 Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. Fault code No. 16 • If fault code numbers 15 and 16 are both displayed, perform checkup and repair jobs for fault code number 15 first.
  • Page 312 Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the coolant temperature. Compare the actually measured coolant temperature with the Yamaha Procedure diagnostic tool display value. Probable cause of malfunc- Confirmation of service com- Item...
  • Page 313 Refer to “RADIATOR” on page 6-2. item 6. Faulty ECU. Replace the ECU. Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-26...
  • Page 314 Fail-safe system Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air temperature. Compare the actually measured intake air temperature with the Yamaha Procedure diagnostic tool display value. Probable cause of malfunc- Confirmation of service com-...
  • Page 315 Start switch to ON (main relay ON), wait 10 seconds, then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 4 and finish the service. Condition is “Detected”  Go to item 2.
  • Page 316 Unable to drive vehicle Diagnostic code No. Actuates the ignition coil five times at one-second intervals. Actuation “WARNING” on the Yamaha diagnostic tool blinks five times when the ignition coil is actuated. Check that a spark is generated five times. Procedure •...
  • Page 317 Check the condition of the fault the coupler. ness. code using the malfunction Disconnect the coupler, and mode of the Yamaha diagnostic check the pins (for bent or bro- tool. Condition is “Recovered”  Go ken terminals and locking condi- tion of the pins).
  • Page 318 Unable to drive vehicle Diagnostic code No. Actuates injector five times at one-second intervals. Actuation “WARNING” on the Yamaha diagnostic tool blinks five times when the injector is actuated. Check that injector is actuated five times by listening for the operating Procedure sound.
  • Page 319 Check the condition of the fault check the pins (bent or broken code using the malfunction terminals and locking condition mode of the Yamaha diagnostic of the pins). tool. Condition is “Recovered”  Go to item 6 and finish the service.
  • Page 320 Check the condition of the fault check the pins (bent or broken code using the malfunction terminals and locking condition mode of the Yamaha diagnostic of the pins). tool. Condition is “Recovered”  Go to item 6 and finish the service.
  • Page 321 If the same number is indicated, go to item 4. Faulty ECU. Replace the ECU. Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-34...
  • Page 322 Check the condition of the fault the coupler. code using the malfunction Disconnect the coupler and mode of the Yamaha diagnostic check the pins (bent or broken tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
  • Page 323 Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check pletion Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-36...

  • Page 324: Fuel Pump System

    FUEL PUMP SYSTEM EAM20146 FUEL PUMP SYSTEM EAM30287 CIRCUIT DIAGRAM 8-37...
  • Page 325 FUEL PUMP SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Joint connector 6. Battery 7. Frame ground 8. Engine ground 9. Fuse 16.ECU (Engine Control Unit) 20.Fuel pump 25.Engine stop switch A. Battery sub-lead B. Wire harness C. Ignition coil sub-lead D.

  • Page 326: Troubleshooting

    FUEL PUMP SYSTEM EAM30288 TROUBLESHOOTING The fuel pump fails to operate. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 5. Air filter case cover 1. Check the fuel pump system wire Reconnect.

  • Page 327: Electrical Components

    ELECTRICAL COMPONENTS EAM20147 ELECTRICAL COMPONENTS 1. Rectifier/regulator 2. Intake air pressure sensor 3. Throttle position sensor 4. Injector 5. Launch control switch 6. Mode switch 7. Intake air temperature sensor 8. ECU (Engine Control Unit) 9. Ignition coil 10.CCU (Communication Control Unit) 11.Starter relay 12.Fuse 13.Battery...

  • Page 328: Checking The Switches

    ELECTRICAL COMPONENTS EAM30289 CHECKING THE SWITCHES Y/W P 1. Engine stop switch 2. Mode switch 3. Launch control switch 4. Gear position switch 5. Engine start switch 8-41...
  • Page 329 ELECTRICAL COMPONENTS Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14371 NOTICE Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end “a”...

  • Page 330: Checking The Fuses

    ELECTRICAL COMPONENTS cause a fire. EAM30290 CHECKING THE FUSES 4. Install: The following procedure applies to all of the fus- • Seat Refer to “GENERAL CHASSIS” on page 4-1. 1. Remove: • Seat EAM30291 Refer to “GENERAL CHASSIS” on page 4-1. CHECKING AND CHARGING THE BATTERY 2.
  • Page 331 4. Connect the battery charger (special tool) to ing the battery, it should be replaced. When the battery. replacing the battery, be sure to use a Lithium battery charger Yamaha genuine lithium-ion battery. 90890-05376 Lithium battery charger Do not check the battery at high temperature of DBY-ACC51-70-02 65 C (149 F) or more or low temperatures be-...

  • Page 332: Checking The Relays

    ELECTRICAL COMPONENTS Out of specification  Replace. a. If the battery is hot, wait until the battery has cooled down to the ambient tempera- Starter relay ture. b. Measure the voltage between the battery terminals. 13.25 V or more  The battery is normal. Checking is finished.

  • Page 333: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS EAM30294 CHECKING THE IGNITION SPARK GAP The digital circuit tester and the multimeter with 1. Check: tachometer readings are shown in the following • Ignition spark gap table. Out of specification  Perform the ignition system troubleshooting, starting with step (5). No continuity Refer to “TROUBLESHOOTING”...

  • Page 334: Checking The Ignition Coil

    ELECTRICAL COMPONENTS b. Measure the primary coil resistance. Digital circuit tester (CD732) 3. Check: 90890-03243 • Secondary coil resistance Model 88 Multimeter with tachom- Out of specification  Replace. eter YU-A1927 Secondary coil resistance 8.64–12.96 k a. Connect the digital circuit tester () to the ignition coil.

  • Page 335: Checking The Lean Angle Sensor

    ELECTRICAL COMPONENTS • Positive tester probe  Gray “1” • Negative tester probe  Black “2” b. Check the starter motor operation. EAM30300 CHECKING THE STATOR COIL 1. Disconnect: • Stator coil assembly coupler b. Measure the crankshaft position sensor (from the wire harness) resistance.

  • Page 336: Checking The Coolant Temperature Sensor

    ELECTRICAL COMPONENTS Regulated voltage (DC) Coolant temperature sensor re- 14.0–14.8 V sistance 2513–2777  at 20 C (2513– 2777  at 68 F) a. Set the digital tachometer to the ignition Coolant temperature sensor re- coil. sistance Digital tachometer 210–221  at 100 C (210–221  90890-06760 at 212 F) Digital tachometer...

  • Page 337: Checking The Throttle Position Sensor Input Voltage

    ELECTRICAL COMPONENTS d. Measure the throttle position sensor input voltage. EAM30307 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 1. Remove: • Intake air temperature sensor (from the air filter case) EWA14110 WARNING • Handle the intake air temperature sensor EAM30305 CHECKING THE THROTTLE POSITION with special care.

  • Page 338: Checking The Gear Position Switch

    ELECTRICAL COMPONENTS EAM30467 EAM30496 CHECKING THE GEAR POSITION SWITCH CHECKING THE INJECTOR 1. Remove: 1. Remove: • Gear position switch • Fuel injector 2. Check: Refer to “THROTTLE BODY” on page 7-4. • Gear position switch 2. Check: Out of specification  Replace. •...
  • Page 339 TROUBLESHOOTING TROUBLESHOOTING..................9-1 GENERAL INFORMATION ................9-1 TROUBLESHOOTING OF ENGINE (fault code not detected)....9-1 TROUBLESHOOTING OF CLUTCH............9-4 TROUBLESHOOTING OF TRANSMISSION ..........9-6 TROUBLESHOOTING OF COOLING SYSTEM ........9-7 TROUBLESHOOTING OF BRAKE ............9-8 TROUBLESHOOTING OF SUSPENSION..........9-8 TROUBLESHOOTING OF STEERING/HANDLING ........9-10 TROUBLESHOOTING OF CHARGING SYSTEM ........9-11 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE ...9-12 SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION ...

  • Page 340: Troubleshooting

    TROUBLESHOOTING EAM20148 TROUBLESHOOTING EAM30309 GENERAL INFORMATION Troubleshooting information provided here does not cover all the trouble symptoms, possible causes, and remedial actions. Some items may not apply depending on the model. Use this information as a guide and quick reference matrix when performing basic troubleshooting. Refer to the each chapter for detailed information on checking, adjustment, and replacement.
  • Page 341 TROUBLESHOOTING Symptom Possible cause Actions Water or foreign material in fuel, Change fuel. degraded fuel Tighten the spark plug to the spec- Loose spark plug ified torque. Tighten bolts or nuts on cylinder Loose cylinder head or cylinder head and cylinder to the specified torque.
  • Page 342 TROUBLESHOOTING Symptom Possible cause Actions Worn camshaft lobe Replace the camshaft. Water or foreign material in fuel, Change fuel. degraded fuel Contaminated throttle body or Clean the throttle body. clogged internal passage Incorrectly adjusted throttle cable Adjust the throttle grip free play. Incorrectly adjusted idling speed Adjust the idle screw.

  • Page 343: Troubleshooting Of Clutch

    TROUBLESHOOTING Symptom Possible cause Actions Replace the piston and piston Worn or damaged piston ring rings as a set. Replace the piston and piston Worn or damaged piston rings as a set. Replace the piston and piston pin Worn piston (piston pin hole) as a set.
  • Page 344 TROUBLESHOOTING Symptom Possible cause Actions Replace the clutch springs as a Faulty clutch spring set. Warped pressure plate Replace the pressure plate. Replace the friction plates as a Swollen friction plate set. Warped clutch plate Replace the clutch plates as a set. Bent pull rod (outer pull type) Replace the pull rod.

  • Page 345: Troubleshooting Of Transmission

    TROUBLESHOOTING EAM30511 TROUBLESHOOTING OF TRANSMISSION Symptom Possible cause Actions Clutch drags Refer to “Clutch drags”. Adjust the shift rod installation Improperly adjusted shift rod length. Bent shift shaft Replace the shift shaft. Foreign object in a shift drum Remove foreign object from shift groove drum groove.

  • Page 346: Troubleshooting Of Cooling System

    TROUBLESHOOTING EAM30512 TROUBLESHOOTING OF COOLING SYSTEM Symptom Possible cause Actions Carbon buildup in piston head and Clean the piston head and com- combustion chamber bustion chamber. Clogged engine cooling water Check and clean the engine cool- passages ing water passages. Adjust the oil level to the specified Incorrect oil level level.

  • Page 347: Troubleshooting Of Brake

    TROUBLESHOOTING EAM30513 TROUBLESHOOTING OF BRAKE Symptom Possible cause Actions Worn brake pad Replace the brake pads as a set. Worn or deflected brake disc Replace the brake disc. Air in hydraulic brake system Bleed the hydraulic brake system. Check the hydraulic brake system Brake fluid leakage and repair or replace faulty parts as necessary.
  • Page 348 TROUBLESHOOTING Symptom Possible cause Actions Fatigued or broken fork spring Replace the fork spring. Incorrect oil viscosity (low) Change to recommended fork oil. Incorrect oil level (low) Adjust to the specified oil level. Improperly adjusted spring pre- Adjust the spring preload. Front fork is soft load (soft) Improperly adjusted rebound...

  • Page 349: Troubleshooting Of Steering/Handling

    TROUBLESHOOTING Symptom Possible cause Actions Oil leaking from rear shock Replace the rear shock absorber. absorber Gas leaking from rear shock Replace the rear shock absorber. absorber Fatigued or damaged rear shock Replace the rear shock absorber. absorber spring Rear suspension is soft Improperly adjusted rear shock Adjust the spring preload.

  • Page 350: Troubleshooting Of Charging System

    TROUBLESHOOTING Symptom Possible cause Actions Incorrect wheel balance Adjust the wheel balance. Tighten the spoke and adjust the Loose spoke runout. Damaged or worn wheel bearing Replace the wheel bearing. Worn, deformed, or incorrect tire Replace the tire. Front wheel vibration Loose wheel axle or wheel axle Tighten the wheel axle or wheel axle nut to the specified torque.

  • Page 351: Self-Diagnostic Function And Diagnostic Code Table

    Pressure of suction pipe Displays the intake air pressure. The atmospheric pressure is • Check the change of the displayed on the Yamaha intake pressure valve when diagnostic tool. the starter switch is pushed. Intake air temperature Displays the intake air tempera- Compare the actually mea- ture.
  • Page 352 Coolant temperature Displays the coolant tempera- Compare the actually mea- ture. sured coolant temperature with the Yamaha diagnostic tool display value. Lean angle sensor Displays the output voltage. Remove the ECU, and incline it 45 or more. • Upright •...

  • Page 353: Diagnostic Code: Actuator Operation Table

    Actuates the ignition coil five Check that a spark is gener- times at one-second intervals. ated five times. • Connect an ignition checker. “WARNING” on the Yamaha diagnostic tool blinks five times when the ignition coil is actu- ated. TIP: Before performing this...
  • Page 354 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9-15...
  • Page 355 TUNING CHASSIS ......................10-1 SELECTION OF THE SECONDARY REDUCTION RATIO  (SPROCKET) ..................10-1 DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS ....10-1 TIRE PRESSURE..................10-1 FRONT FORK SETTING................10-2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL..10-2 SETTING OF SPRING AFTER REPLACEMENT ........10-2 FRONT FORK SETTING PARTS.............10-3 REAR SUSPENSION SETTING ..............10-3 CHOOSING SET LENGTH ..............10-3 SETTING OF SPRING AFTER REPLACEMENT ........10-4...

  • Page 356: Chassis

    CHASSIS EAM20119 Part name Type Part number CHASSIS Rear wheel 17D-25447-50 EAM30168 sprocket “2” SELECTION OF THE SECONDARY 17D-25448-50 REDUCTION RATIO (SPROCKET) (STD) 17D-25449-50 Secondary reduction ratio = Number of 17D-25450-50 rear wheel sprocket teeth/Number of 17D-25451-50 drive sprocket teeth 17D-25452-50 Secondary reduction ratio 3.769 (49/13)

  • Page 357: Front Fork Setting

    (in position etc.) when Recommended oil setting the front fork. Yamaha Suspension Oil S1 1. Use of soft spring Standard oil amount • Change the rebound damping force.

  • Page 358: Front Fork Setting Parts

    CHASSIS and the circuit conditions. The rear suspension setting includes the follow- Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, re- ing two factors: 1. Setting of spring preload sulting in lack of a sense of contact with the road •...

  • Page 359: Setting Of Spring After Replacement

    CHASSIS • If the standard figure cannot be achieved by adjusting the adjuster and changing the set length, replace the spring with an optional one and make readjustment. EAM30178 REAR SHOCK ABSORBER SETTING PARTS • Rear shock spring “1” STD Spring rate N/mm EAM30177 SETTING OF SPRING AFTER...
  • Page 360 CHASSIS • Spring preload adjusting positions Spring preload adjusting positions Minimum Position in which the spring is turned in 1.5 mm (0.06 in) from its free length. Standard Position in which the spring is turned in 4.0 mm (0.16 in) from its free length.

  • Page 361: Suspension Setting (Front Fork)

    CHASSIS EAM30179 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).

  • Page 362: Suspension Setting (Rear Shock Absorber)

    CHASSIS Section Symptom Check Adjust Large Medium Small Jump Compression Turn adjuster clockwise (about 2 damping force clicks) to increase damping. Turn adjuster counterclockwise Rebound damp- (about 2 clicks) to decrease ing force damping. Low front, tend-   ing to lower front Set sunken length for 95–100 posture Balance with rear...
  • Page 363 CHASSIS Section Symptom Check Adjust Large Medium Small Jump Turn adjuster counterclockwise Rebound damp- (about 2 clicks) to decrease Heavy and drag- ing force   damping. ging Spring Replace with soft spring. Turn adjuster counterclockwise Rebound damp- (about 2 clicks) to decrease ing force damping.
  • Page 364 CHASSIS 10-9...
  • Page 365 11. Starter motor Black/Blue 12. Diode 1 Black/Orange 13. Diode 2 Black/Red 14. CCU (Communication Control Black/White Unit) Black/Yellow 15. Yamaha diagnostic tool cou- Br/W Brown/White pler Green/White 16. ECU (Engine Control Unit) Green/Yellow 17. Ignition coil Blue/Black 18. Spark plug Blue/Green 19.
  • Page 366 PRINTED IN JAPAN...
  • Page 368 Original instructions Notice originale Originalbetriebsanleitung PRINTED IN JAPAN 2019.05-1.3×2 ! (E, F, G)
  • Page 369 YZ450F/YZ450FL 2020 YZ450F/YZ450FL 2020 YZ450F/YZ450FL 2020 SCHÉMA DE CÂBLAGE WIRING DIAGRAM SCHALTPLAN R/L R/L R/L (Gy) B/L Gy B/L B/L B/L B/L B/L B/L R R/B (Gy) R,R/W Br/W Br/W L/R W/B Gy B/Y G/Y Y/G G/W B/L R/B B/W B/O Br/W P Y/R W/B Lg R/L...
  • Page 370 YZ450F/YZ450FL 2020 YZ450F/YZ450FL 2020 YZ450F/YZ450FL 2020 SCHÉMA DE CÂBLAGE WIRING DIAGRAM SCHALTPLAN...

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