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Yamaha YZ450FY 2009 Owner's Service Manual

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Table of Contents

2009
Read this manual carefully before operating this vehicle.
OWNER'S SERVICE MANUAL
YZ450FY
LIT-11626-22-57
34P-28199-10

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Summary of Contents for Yamaha YZ450FY 2009

  • Page 1 2009 Read this manual carefully before operating this vehicle. OWNER’S SERVICE MANUAL YZ450FY LIT-11626-22-57 34P-28199-10...
  • Page 2 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
  • Page 3 YZ450FY OWNER'S SERVICE MANUAL ©2008 by Yamaha Motor Corporation, U.S.A. 1st Edition, May 2008 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan P/N. LIT-11626-22-57...
  • Page 4 INTRODUCTION IMPORTANT MANUAL INFORMATION Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Particularly important information is distin- Yamaha's vast experience in the production of guished in this manual by the following nota- pacesetting racing machines. It represents the tions.
  • Page 5 SAFETY INFORMATION Always turn off the engine if you are going to leave the machine. Do not park the machine THIS MACHINE IS DESIGNED STRICTLY on a slope or soft ground as it may fall over. FOR COMPETITION USE, ONLY ON A •...
  • Page 6 YAMAHA MOTOR CORPORATION, U.S.A. YZ MOTORCYCLE LIMITED WARRANTY...
  • Page 7 F.I.M. MACHINE WEIGHTS Weights of machines without fuel The minimum weights for motocross machines are: for the class 125 cc: minimum 88 kg (194 lb) for the class 250 cc: minimum 98 kg (216 lb) for the class 500 cc: minimum 102 kg (225 lb) In modifying your machine (e.g., for weight re- duction), take note of the above limits of weight.
  • Page 8 HOW TO USE THIS MANUAL FINDING THE REQUIRED PAGE 1. This manual consists of seven chapters; "General Information", "Specifications", "Regular inspec- tion and adjustments", "Engine", "Chassis", "Electrical" and "Tuning" 2. The table of contents is at the beginning of the manual. Look over the general layout of the book before finding then required chapter and item.
  • Page 9 HOW TO READ DESCRIPTIONS To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 1. An easy-to-see exploded diagram "1" is provided for removal and disassembly jobs. 2. Numbers "2" are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step.
  • Page 10 ILLUSTRATED SYMBOLS (Refer Illustrated symbols "1" to "7" are used to identi- to the illustration) fy the specifications appearing in the text. 1. With engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening 6. Specified value, Service limit 7.

  • Page 11: Table Of Contents

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

  • Page 12: General Information

    CONTENTS CHAPTER 1 GENERAL INFORMATION LOCATION OF IMPORTANT LABELS ..1-1 DESCRIPTION ........... 1-2 MACHINE IDENTIFICATION ..... 1-3 INCLUDED PARTS ........1-4 IMPORTANT INFORMATION ....1-5 CHECKING OF CONNECTION ....1-7 SPECIAL TOOLS........1-8 CONTROL FUNCTIONS ......1-12 STARTING AND BREAK-IN ....1-14 TORQUE-CHECK POINTS ......
  • Page 13 CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS . 4-2 EXHAUST PIPE AND SILENCER ..... 4-4 RADIATOR..........4-7 CARBURETOR ........4-11 CAMSHAFTS ........... 4-22 CYLINDER HEAD ........4-29 VALVES AND VALVE SPRINGS .... 4-32 CYLINDER AND PISTON ......4-39 CLUTCH ...........
  • Page 14 CONTENTS CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ..........6-2 IGNITION SYSTEM ........6-4 THROTTLE POSITION SENSOR SYSTEM ............. 6-8 CHAPTER 7 TUNING ENGINE ............7-1 CHASSIS............ 7-8...
  • Page 15 LOCATION OF IMPORTANT LABELS GENERAL INFORMATION LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle.
  • Page 16 DESCRIPTION DESCRIPTION 1. Clutch lever 11. Coolant drain bolt 2. Hot starter lever 12. Rear brake pedal 3. Front brake lever 13. Valve joint 4. Throttle grip 14. Fuel cock 5. Radiator cap 15. Cold starter knob 6. Fuel tank cap 16.
  • Page 17 There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the num- ber to your Yamaha dealer for positive iden- tification of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine.
  • Page 18 INCLUDED PARTS INCLUDED PARTS NIPPLE WRENCH This nipple wrench "1" is used to tighten the DETACHABLE SIDESTAND spoke. This sidestand "1" is used to support only the machine when standing or transporting it. • Never apply additional force to the side- stand.
  • Page 19 5. Keep away from fire. ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for as- sembly and adjustment.
  • Page 20 IMPORTANT INFORMATION CIRCLIPS LOCK WASHERS/PLATES AND COTTER 1. All circlips should be inspected carefully be- PINS fore reassembly. Always replace piston pin 1. All lock washers/plates "1" and cotter pins clips after one use. Replace distorted cir- must be replaced when they are removed. clips.
  • Page 21 CHECKING OF CONNECTION CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: • Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off. 5.
  • Page 22 SPECIAL TOOLS SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised tech- niques. The shape and part number used for the special tool differ by country, so two types are pro- vided.
  • Page 23 SPECIAL TOOLS Tool name/Part number How to use Illustration Rotor puller This tool is used to remove YM-04151, 90890-04151 the flywheel magneto. Steering nut wrench This tool is used when tighten YU-33975, 90890-01403 the steering ring nut to speci- fication. Cap bolt wrench This tool is used to loosen or YM-01500, 90890-01500...
  • Page 24 SPECIAL TOOLS Tool name/Part number How to use Illustration Timing light This tool is necessary for YM-33277-A, 90890-03141 checking ignition timing. Valve spring compressor This tool is needed to remove YM-4019, 90890-04019 and install the valve assem- blies. Clutch holding tool This tool is used to hold the YM-91042, 90890-04086 clutch when removing or in-...
  • Page 25 Ignition checker tem components. 90890-06754 Digital tachometer This tool is needed for ob- YU-39951-B, 90890-06760 serving engine rpm. YAMAHA Bond No. 1215 This sealant (Bond) is used ® (ThreeBond No. 1215) for crankcase mating surface, 90890-85505 etc.
  • Page 26 CONTROL FUNCTIONS CONTROL FUNCTIONS KICKSTARTER CRANK Rotate the kickstarter crank "1" away from the ENGINE STOP SWITCH engine. Push the starter down lightly with your The engine stop switch "1" is located on the left foot until the gears engage, then kick smoothly handlebar.
  • Page 27 CONTROL FUNCTIONS REAR BRAKE PEDAL COLD STARTER KNOB The rear brake pedal "1" is located on the right When cold, the engine requires a richer air-fuel side of the machine. Press down on the brake mixture for starting. A separate starter circuit, pedal to activate the rear brake.
  • Page 28 STARTING AND BREAK-IN STARTING AND BREAK-IN AIR FILTER MAINTENANCE According to "CLEANING THE AIR FILTER FUEL ELEMENT" section in the CHAPTER 3, apply Always use the recommended fuel as stated the foam-air-filter oil or its equivalent to the ele- below. Also, be sure to use new gasoline the ment.
  • Page 29 STARTING AND BREAK-IN STARTING A WARM ENGINE Do not operate the cold starter knob and throt- Observe the following break-in procedures tle. Pull the hot starter lever "1" and start the during initial operation to ensure optimum engine by kicking the kickstarter crank forceful- performance and avoid engine damage.
  • Page 30 TORQUE-CHECK POINTS TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and fuel tank Fuel tank to frame Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Steering stem to handlebar Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar...
  • Page 31 CLEANING AND STORAGE CLEANING AND STORAGE 2. Remove the spark plug, pour a tablespoon of SAE 10W-30 motor oil in the spark plug CLEANING hole, and reinstall the plug. With the engine Frequent cleaning of your machine will en- stop switch pushed in, kick the engine over hance its appearance, maintain good overall several times to coat the cylinder walls with performance, and extend the life of many com-...

  • Page 32: Specifications

    GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: YZ450FY (USA, CDN, AUS, NZ) YZ450F (EUROPE, ZA) Model code number: 34P1 (USA,CDN) 34P2 (EUROPE) 34P4 (AUS, NZ, ZA) Dimensions: USA, CDN, AUS, NZ, EUROPE Overall length 2,195 mm (86.42 in) 2,196 mm (86.46 in) Overall width 825 mm (32.48 in) ←...
  • Page 33 GENERAL SPECIFICATIONS (Except for USA and CDN) SAE10W-30, SAE10W-40, SAE15W-40, SAE20W-40 or SAE20W-50 API service SG type or higher, JASO standard MA Oil capacity: Engine oil Periodic oil change 0.95 L (0.84 Imp qt, 1.00 US qt) With oil filter replacement 1.0 L (0.88 Imp qt, 1.06 US qt) Total amount 1.2 L (1.06 Imp qt, 1.27 US qt)
  • Page 34 GENERAL SPECIFICATIONS Chassis: USA, CDN, AUS, NZ, EUROPE Frame type Semi double cradle ← Caster angle 26.9° 26.8° Trail 115.7 mm (4.56 in) 114.2 mm (4.50 in) Tire: Type With tube Size (front) 80/100-21 51M Size (rear) 120/80-19 63M (For USA, CDN, ZA, AUS, NZ) 110/90-19 62M (For EUROPE) Tire pressure (front and rear) 100 kPa (1.0 kgf/cm...
  • Page 35 MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.05 mm (0.002 in) Cylinder: Bore size 95.00–95.01 mm (3.7402–3.7406 ---- Out of round limit ---- 0.05 mm (0.002 in) Camshaft: Drive method Chain drive (Left) ---- Camshaft cap inside diameter 22.000–22.021 mm (0.8661–...
  • Page 36 MAINTENANCE SPECIFICATIONS Item Standard Limit Timing chain: Timing chain type/No. of links 98XRH2010-118M/118 ---- Timing chain adjustment method Automatic ---- Valve, valve seat, valve guide: Valve clearance (cold) 0.10–0.15 mm (0.0039–0.0059 in) ---- 0.20–0.25 mm (0.0079–0.0098 in) ---- Valve dimensions: "A"...
  • Page 37 MAINTENANCE SPECIFICATIONS Item Standard Limit Guide inside diameter (IN) 4.500–4.512 mm (0.1772–0.1776 4.550 mm (0.1791 in) Guide inside diameter (EX) 5.000–5.012 mm (0.1969–0.1973 5.050 mm (0.1988 in) Stem-to-guide clearance (IN) 0.010–0.037 mm (0.0004–0.0015 0.08 mm (0.003 in) Stem-to-guide clearance (EX) 0.020–0.047 mm (0.0008–0.0019 0.10 mm (0.004 in)
  • Page 38 MAINTENANCE SPECIFICATIONS Item Standard Limit Piston: Piston to cylinder clearance 0.020–0.045 mm (0.0008–0.0018 0.1 mm (0.004 in) Piston size "D" 94.965–94.980 mm (3.7388– ---- 3.7394 in) Measuring point "H" 8 mm (0.315 in) ---- Piston off-set 1 mm (0.0394 in) ---- Piston pin bore inside diameter 18.004–18.015 mm (0.7088–...
  • Page 39 MAINTENANCE SPECIFICATIONS Item Standard Limit Crankshaft: Crank width "A" 61.95–62.00 mm (2.439–2.441 in) ---- Runout limit "C" 0.03 mm (0.0012 in) 0.05 mm (0.002 in) Big end side clearance "D" 0.15–0.45 mm (0.0059–0.0177 in) 0.50 mm (0.02 in) Small end free play "F" 0.4–1.0 mm (0.02–0.04 in) 2.0 mm (0.08 in)
  • Page 40 MAINTENANCE SPECIFICATIONS Item Standard Limit Carburetor: Type/manufacturer FCR-MX39/KEIHIN ---- I. D. mark 2S2B B0 ---- Main jet (M.J) #160 ---- Main air jet (M.A.J) ø2.0 ---- Jet needle - clip position (J.N) NFLR-3 ---- Cutaway (C.A) ---- Pilot jet (P.J) ---- Pilot air jet (P.A.J) #100...
  • Page 41 MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing ---- Front suspension: EUROPE, AUS, USA, CDN NZ, ZA Front fork travel 300 mm (11.8 in) ---- ← Fork spring free length 454 mm (17.9 in) 449 mm ←...
  • Page 42 MAINTENANCE SPECIFICATIONS Item Standard Limit Rear wheel type Spoke wheel ---- Front rim size/material 21 × 1.60/Aluminum ---- Rear rim size/material 19 × 2.15/Aluminum ---- Rim runout limit: Radial ---- 2.0 mm (0.08 in) Lateral ---- 2.0 mm (0.08 in) Drive chain: Type/manufacturer DID520DMA2 SDH/DAIDO...
  • Page 43 44–66 Ωat 20 °C (68 °F) (Black– ---- Pink) Pickup coil resistance (color) 248–372 Ωat 20 °C (68 °F) ---- (White–Red) CDI unit-model/manufacturer 34P-00/YAMAHA (USA and CDN) ---- 34P-10/YAMAHA (Except for USA ---- and CDN) Ignition coil: Model/manufacturer 5TA-10/DENSO ---- Minimum spark gap 6 mm (0.24 in)
  • Page 44 TIGHTENING TORQUES TIGHTENING TORQUES ENGINE △ - marked portion shall be checked for torque tightening after break-in or before each race. Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Spark plug M10S × 1.0 Camshaft cap M6 × 1.0 Cylinder head blind plug screw M12 ×...
  • Page 45 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Oil pump cover M4 × 0.7 Oil pump M6 × 1.0 Oil pump drive gear shaft M6 × 1.0 Oil filter element drain bolt M6 × 1.0 Oil filter element cover M6 ×...
  • Page 46 TIGHTENING TORQUES *1: Tighten the cylinder head bolts to 30 Nm (3.0 m•kg, 22 ft•lb) in the proper tightening sequence, remove and retighten the cylinder head bolts to 20 Nm (2.0 m•kg, 14 ft•lb) in the proper tightening sequence, and then tighten the cylinder head bolts further to reach the specified angle 180° in the proper tightening sequence.
  • Page 47 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb △ Front wheel axle holder M8 × 1.25 △ Front brake disc and wheel hub M6 × 1.0 △ Rear brake disc and wheel hub M6 × 1.0 △...
  • Page 48 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Drive chain support and swingarm M6 × 1.0 △ Seal guard and swingarm M5 × 0.8 △ Fuel tank mounting boss and frame M10 × 1.25 △ Fuel tank mounting M6 ×...
  • Page 49 TIGHTENING TORQUES GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasten- ers with standard I.S.O. pitch threads. Torque specifications for special components or as- semblies are included in the applicable sec- tions of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fash- ion, in progressive stages, until full torque is reached.
  • Page 50 TIGHTENING TORQUES DEFINITION OF UNITS Unit Read Definition Measure millimeter meter Length centimeter meter Length kilogram gram Weight Newton 1 kg × m/sec Force Newton meter N × m Torque m•kg Meter kilogram m × kg Torque Pascal Pressure N/mm Newton per millimeter N/mm Spring rate...
  • Page 51 MEMO...
  • Page 52 LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 2-20...
  • Page 53 LUBRICATION DIAGRAMS 1. Oil filter element 2. Oil pump 3. Drive axle 4. Main axle 5. Crankshaft 6. Connecting rod A. From cylinder B. To oil tank 2-21...
  • Page 54 LUBRICATION DIAGRAMS 2-22...
  • Page 55 LUBRICATION DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft A. To main axle B. From oil pump 2-23...
  • Page 56 CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM 2-24...
  • Page 57 CABLE ROUTING DIAGRAM 1. Fuel tank breather hose 2. Radiator hose 1 3. Cylinder head breather hose 4. Hose holder 5. Radiator hose 4 6. Clutch cable 7. Connector cover 8. Fuel hose 9. Throttle position sensor lead 10. Hot starter cable 11.
  • Page 58 CABLE ROUTING DIAGRAM 2-26...
  • Page 59 CABLE ROUTING DIAGRAM 1. Hot starter cable L. Locate the clamp ends in the arrowed 2. Clamp range. 3. Throttle position sensor lead M. Fasten the neutral switch lead and CDI 4. Hump (frame) magneto lead to the frame over its hump. 5.
  • Page 60 CABLE ROUTING DIAGRAM 2-28...
  • Page 61 CABLE ROUTING DIAGRAM 1. Throttle cable (pull) 2. Throttle cable (return) 3. Radiator hose 2 4. Ignition coil 5. Rear arm bracket 6. Cylinder head breather hose A. Pass the throttle cables over the radiator hose 2. B. Pass the throttle cables on the outside of the ignition coil.
  • Page 62 CABLE ROUTING DIAGRAM 2-30...
  • Page 63 CABLE ROUTING DIAGRAM 1. Brake master cylinder 2. Brake hose holder 3. Brake hose A. Install the brake hose so that its pipe por- tion directs as shown and lightly touches the projection on the brake caliper. B. Pass the brake hose into the brake hose holders.
  • Page 64 CABLE ROUTING DIAGRAM 2-32...
  • Page 65 CABLE ROUTING DIAGRAM 1. Throttle cable 2. Clamp 3. Hot starter cable 4. Clutch cable 5. Engine stop switch lead 6. Cable guide 7. Brake hose 8. Hose guide A. Fasten the engine stop switch lead to the handlebar. B. Pass the clutch cable and hot starter cable through the cable guide.

  • Page 66: Regular Inspection And Adjustments

    If you are a doubt as to what intervals to follow in main- taining and lubricating your machine, consult your Yamaha dealer. Every...
  • Page 67 MAINTENANCE INTERVALS Every Every After Every As re- third fifth (or Item break Remarks race (or 500 1,000 quired CYLINDER HEAD Inspect carbon deposits and eliminate them. Inspect and clean Change gasket. ● CYLINDER Inspect and clean Inspect score marks. ●...
  • Page 68 MAINTENANCE INTERVALS Every Every After Every As re- third fifth (or Item break Remarks race (or 500 1,000 quired COOLING SYSTEM Check coolant level and ● ● leakage Check radiator cap operation ● Replace coolant Every two years ● Inspect hoses ●...
  • Page 69 ● Inspect bearings ● Replace bearings ● Lubricate Lithium base grease ● THROTTLE, CONTROL CABLE Check routing and con- Yamaha cable lube or SAE ● ● nection 10W-30 motor oil Lubricate ● ● HOT STARTER, CLUTCH LEVER Inspect free play...
  • Page 70 PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. GENERAL INSPECTION AND MAINTENANCE Item Routine Page Check that coolant is filled up to the radiator cap.

  • Page 71: Engine

    ENGINE ENGINE CHANGING THE COOLANT CHECKING THE COOLANT LEVEL Do not remove the radiator cap when the en- gine is hot. Do not remove the radiator cap "1", drain bolt and hoses when the engine and radia- tor are hot. Scalding hot fluid and steam Take care so that coolant does not splash may be blown out under pressure, which on painted surfaces.
  • Page 72 ENGINE CHECKING THE RADIATOR CAP Recommended coolant: 1. Inspect: High quality ethylene glycol anti- • Seal (radiator cap) "1" freeze containing anti-corrosion • Valve and valve seat "2" for aluminum engine Crack/damage → Replace. Coolant "1" and water (soft water) Exist fur deposits "3"...
  • Page 73 ENGINE CHECKING THE COOLING SYSTEM 1. Inspect: • Coolant level 2. Attach: • Radiator cap tester "1" and adapter "2" Radiator cap tester: YU-24460-01/90890-01325 Radiator cap tester adapter: YU-33984/90890-01352 c. Tighten the locknuts. Locknut: 5 Nm (0.5 m•kg, 3.6 ft•lb) 2.
  • Page 74 ENGINE 2. Adjust: • Throttle grip free play • Before adjustment, expose the adjuster by moving the boot "3" and cap "4" away. • Make minute adjustment on the lever side us- Throttle grip free play adjustment steps: ing the adjuster "5". a.
  • Page 75 ENGINE CLEANING THE AIR FILTER ELEMENT Proper air filter maintenance is the biggest key to preventing premature engine wear and dam- age. Never run the engine without the air filter el- ement in place; this would allow dirt and dust to enter the engine and cause rapid 3.
  • Page 76 ENGINE 5. Install: CHECKING THE ENGINE OIL LEVEL • Air filter guide "1" 1. Stand the machine on a level surface. Align the projection "a" on filter guide with the • When checking the oil level make sure that hole "b" in air filter element. the machine is upright.
  • Page 77 ENGINE (Except for USA and CDN) Recommended oil: SAE10W-30, SAE10W-40, SAE15W-40, SAE20W-40 or SAE20W-50 API service SG type or higher, JASO standard MA • Engine oil also luburicates the clatch and the wrong oil types or additives could cause clatch slippage. Therefore, do not oils with a grade of CD "a"...
  • Page 78 ENGINE 5. Install: • Gaskets • Oil filter drain bolt Oil filter drain bolt: 10 Nm (1.0 m•kg, 7.2 ft•lb) • Drain bolt (right crankcase) Drain bolt (right crankcase): 20 Nm (2.0 m•kg, 14 ft•lb) • Drain bolt (left crankcase) Drain bolt (left crankcase): 20 Nm (2.0 m•kg, 14 ft•lb) 6.
  • Page 79 ENGINE CHECKING THE OIL PRESSURE 1. Check: • Oil pressure Checking steps: a. Slightly loosen the oil pressure check bolt "1". b. Start the engine and keep it idling until oil starts to seep from the oil pressure check bolt. If no oil comes out after one minute, ADJUSTING THE ENGINE IDLING SPEED turn the engine off so it will not seize.
  • Page 80 • This section is intended for those who have Intake valve: basic knowledge and skill concerning the ser- 0.10–0.15 mm (0.0039–0.0059 in) vicing of Yamaha motorcycles (e.g., Yamaha Exhaust valve: dealers, service engineers, etc.) Those who 0.20–0.25 mm (0.0079–0.0098 in)
  • Page 81 ENGINE c. Measure the valve clearance "e" using a feeler gauge "1". Record the measured reading if the clearance is incorrect. c. Select the proper pad using the pad select- ing table. Pad Availability: 25 Pad range increments No. 120– 1.20 mm–...
  • Page 82 ENGINE EXAMPLE: Installed pad number = 148 Rounded off value = 150 Pads can only be selected in 0.05 mm incre- ments. e. Locate the rounded-off value and the mea- sured valve clearance in the chart "PAD SE- LECTION TABLE". The field where these two coordinates intersect shows the new pad number to use.
  • Page 83 ENGINE INTAKE EXHAUST 3-18...

  • Page 84: Chassis

    CHASSIS CHASSIS e. Slowly apply the brake lever or pedal sever- al times. BLEEDING THE HYDRAULIC BRAKE f. Pull the lever in or push down on the pedal. SYSTEM Hold the lever or pedal in position. g. Loosen the bleed screw and allow the lever or pedal to travel towards its limit.
  • Page 85 CHASSIS 2. Remove: b. Turn the adjusting nut "2" until the pedal • Brake lever cover height "a" is within specified height. 3. Adjust: c. Tighten the locknut. • Brake lever position • Adjust the pedal height between the maxi- Brake lever position adjustment steps: mum "A"...
  • Page 86 CHASSIS 2. Replace: f. Loosen the bleed screw and push the brake • Brake pad caliper piston in. Brake pad replacement steps: Do not reuse the drained brake fluid. a. Remove the pad pin plug "1". g. Tighten the bleed screw. Bleed screw: 6 Nm (0.6 m•kg, 4.3 ft•lb) h.
  • Page 87 CHASSIS j. Install the pad pin plug "10". Pad pin plug: 3 Nm (0.3 m•kg, 2.2 ft•lb) b. Loosen the pad pin "3". c. Remove the rear wheel "4" and brake caliper "5". Refer to "FRONT WHEEL AND REAR WHEEL" section in the CHAPTER 5. 3.
  • Page 88 CHASSIS Do not reuse the drained brake fluid. g. Tighten the bleed screw. Bleed screw: 6 Nm (0.6 m•kg, 4.3 ft•lb) h. Install the brake pad "10" and pad pin "11". • Install the brake pads with their projections "a" into the brake caliper recesses "b".
  • Page 89 CHASSIS • While measuring the drive chain length, push • Use only designated quality brake fluid to down on the drive chain to increase its ten- avoid poor brake performance. sion. • Refill with same type and brand of brake •...
  • Page 90 CHASSIS 4. Check: ADJUSTING THE DRIVE CHAIN SLACK • Drive chain stiffness "a" 1. Elevate the rear wheel by placing the suit- Clean and oil the drive chain and hold as il- able stand under the engine. lustrated. 2. Check: Stiff →...
  • Page 91 CHASSIS CLEANING THE FRONT FORK OIL SEAL AND DUST SEAL 1. Remove: • Protector • Dust seal "1" Use a thin screw driver, and be careful not to damage the inner fork tube and dust seal. 2. Clean: • Dust seal "a" A.
  • Page 92 CHASSIS Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability. ADJUSTING THE FRONT FORK COMPRESSION DAMPING FORCE 1. Adjust: • Compression damping force By turning the adjuster "1". ADJUSTING THE FRONT FORK REBOUND Stiffer "a"...
  • Page 93 CHASSIS CHECKING THE REAR SHOCK ABSORBER 1. Inspect: • Swingarm smooth action Abnormal noise/unsmooth action → Grease the pivoting points or repair the pivoting points. Damage/oil leakage → Replace. ADJUSTING THE REAR SHOCK ABSORBER SPRING PRELOAD 1. Elevate the rear wheel by placing the suit- able stand under the engine.
  • Page 94 CHASSIS position. (Which align the punch mark "a" on the adjuster with the punch mark "b" on the • Be sure to remove all dirt and mud from bracket.) around the locknut and adjuster before adjust- ment. Standard position: • The length of the spring (installed) changes About 12 clicks out 1.5 mm (0.06 in) per turn of the adjuster.
  • Page 95 CHASSIS • STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position. (Which align the punch mark "a" on the adjuster with the punch mark "b" on the high compression damping adjuster.) Standard position: About 10 clicks out * About 9 clicks out...
  • Page 96 CHASSIS Spokes: 3 Nm (0.3 m•kg, 2.2 ft•lb) CHECKING THE WHEELS 1. Inspect: • Wheel runout Elevate the wheel and turn it. Abnormal runout → Replace. CHECKING AND TIGHTENING THE SPOKES The following procedure applies to all of the spokes. 1.
  • Page 97 CHASSIS 3. Check: • Steering smooth action Turn the handlebar lock to lock. Unsmooth action → Adjust steering ring nut. e. Loosen the steering ring nut one turn. f. Retighten the steering ring nut using the steering nut wrench. 4. Adjust: Avoid over-tightening.
  • Page 98 CHASSIS 3-33...
  • Page 99 CHASSIS LUBRICATION To ensure smooth operation of all components, A. Use Yamaha cable lube or equivalent on lubricate your machine during setup, after these areas. break-in, and after every race. B. Use SAE 10W-30 motor oil or suitable 1. All control cable chain lubricants.

  • Page 100: Electrical

    ELECTRICAL ELECTRICAL CHECKING THE SPARK PLUG 1. Remove: • Spark plug 2. Inspect: • Electrode "1" Wear/damage → Replace. • Insulator color "2" Normal condition is a medium to light tan color. CHECKING THE IGNITION TIMING Distinctly different color → Check the engine 1.
  • Page 101 ELECTRICAL 4. Check: • Ignition timing Visually check the stationary pointer "a" is within the firing range "b" on the rotor. Incorrect firing range→Check rotor and pick- up assembly. 5. Install: • Timing mark accessing screw 3-36...
  • Page 102 This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.
  • Page 103 SEAT, FUEL TANK AND SIDE COVERS SEAT, FUEL TANK AND SIDE COVERS REMOVING THE SEAT, FUEL TANK AND SIDE COVERS Order Part name Q'ty Remarks Turn the fuel cock to "OFF". Disconnect the fuel hose. Seat Air scoop (left and right) Bolt (fuel tank) Fuel tank Left side cover...
  • Page 104 SEAT, FUEL TANK AND SIDE COVERS REMOVING THE SIDE COVER 1. Remove: • Bolt (side cover) • Left side cover "1" • Right side cover "2" Draw the side cover downward to remove it be- cause its claws "a" are inserted in the air filter case.
  • Page 105 EXHAUST PIPE AND SILENCER EXHAUST PIPE AND SILENCER REMOVING THE EXHAUST PIPE AND SILENCER Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND Right side cover SIDE COVERS" section. Bolt (silencer clamp) Only loosening. Bolt [silencer (front)] Bolt [silencer (rear)] Collar Silencer Silencer clamp...
  • Page 106 EXHAUST PIPE AND SILENCER CHECKING THE SILENCER AND EXHAUST 3. Replace: • Fiber "1" (For USA and CDN) PIPE 1. Inspect: • Gasket "1" Wrap around the inner pipe the fiber as is vinyl Damage → Replace. packaged, then secure it with pieces of tape "2".
  • Page 107 EXHAUST PIPE AND SILENCER 2. Install: • Silencer clamp "1" Silencer clamp: 14 Nm (1.4 m•kg, 10 ft•lb) • Gasket "2" • Silencer "3" • Washer "4" • Bolt (silencer) "5" Bolt (silencer): 30 Nm (3.0 m•kg, 22 ft•lb) • Install the gasket with its meshed area "a" to- ward the exhaust pipe side.
  • Page 108 RADIATOR RADIATOR REMOVING THE RADIATOR Order Part name Q'ty Remarks Refer to "CHANGING THE COOL- Drain the coolant. ANT" section in the CHAPTER 3. Refer to "SEAT, FUEL TANK AND Seat and fuel tank SIDE COVERS" section. Refer to "EXHAUST PIPE AND SI- Exhaust pipe LENCER"...
  • Page 109 RADIATOR Order Part name Q'ty Remarks Radiator hose 1 Pipe 1/O-ring...
  • Page 110 RADIATOR HANDLING NOTE Do not remove the radiator cap when the en- gine and radiator are hot. Scalding hot fluid and steam may be blown out under pres- sure, which could cause serious injury. When the engine has cooled, open the radi- ator cap by the following procedure: Place a thick rag, like a towel, over the radi- ator cap, slowly rotate the cap counter-...
  • Page 111 RADIATOR 4. Install: • Radiator guard "1" First fit the inner hook portion "a" and then the outer one "b" onto the radiator. 4-10...
  • Page 112 CARBURETOR CARBURETOR REMOVING THE CARBURETOR Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND Seat and fuel tank SIDE COVERS" section. Refer to "REAR SHOCK ABSORB- Rear shock absorber ER" section in the CHAPTER 5. Clamp Throttle position sensor lead coupler Throttle cable cover Throttle cable Clamp (air filter joint)
  • Page 113 CARBURETOR DISASSEMBLING THE CARBURETOR Order Part name Q'ty Remarks Carburetor breather hose Valve lever housing cover Screw (throttle shaft) Throttle valve Needle holder Jet needle Accelerator pump cover Spring Diaphragm (accelerator pump) Float chamber Leak jet Pilot screw Refer to removal section. Float pin Float Needle valve...
  • Page 114 CARBURETOR Order Part name Q'ty Remarks Main jet Needle jet Spacer Pilot jet Starter jet Push rod Pull the push rod. Throttle shaft assembly Push rod link lever assembly Pilot air jet Cold starter plunger 4-13...
  • Page 115 CARBURETOR HANDLING NOTE Do not loosen the screw (throttle position sensor) "1" except when changing the throttle position sensor due to failure be- cause it will cause a drop in engine perfor- mance. 2. Inspect: • Main jet "1" • Pilot jet "2" •...
  • Page 116 CARBURETOR CHECKING THE THROTTLE VALVE 1. Check: • Free movement Stick → Repair or replace. Insert the throttle valve "1" into the carburetor body, and check for free movement. Measurement and adjustment steps: a. Hold the carburetor in an upside down posi- tion.
  • Page 117 CARBURETOR 2. Inspect: CHECKING THE FLOAT • Throttle shaft "1" 1. Inspect: • Spring "2" • Float "1" • Lever 1 "3" Damage → Replace. • Spring 1 "4" • Lever 2 "5" • Spring 2 "6" Dirt → Clean. CHECKING THE STARTER PLUNGER 1.
  • Page 118 CARBURETOR 7. Install: • Spring "1" To throttle shaft "2". Install the bigger hook "a" of the spring fits on the stopper "b" of the throttle shaft pulley. 4. Install: • Spring 2 "1" To lever 2 "2". 8. Install: •...
  • Page 119 CARBURETOR 11.Install: • Needle valve "1" • Float "2" • Float pin "3" • After installing the needle valve to the float, in- stall them to the carburetor. • Check the float for smooth movement. 12.Install: • Pilot screw "1" 9.
  • Page 120 CARBURETOR 13.Install: • O-ring • Leak jet "1" • Float chamber "2" • Bolt (float chamber) "3" • Cable holder (throttle stop screw cable) "4" • Hose holder (carburetor breather hose) "5" 16.Install: • Throttle valve assembly "1" • Screw (throttle shaft) "2" Install the valve lever rollers "3"...
  • Page 121 CARBURETOR INSTALLING THE CARBURETOR 1. Install: • Carburetor joint "1" Carburetor joint: 10 Nm (1.0 m•kg, 7.2 ft•lb) ADJUSTING THE ACCELERATOR PUMP TIMING Adjustment steps: In order for the throttle valve height "a" to 2. Install: achieve the specified value, tuck under the •...
  • Page 122 CARBURETOR 4. Tighten: • Bolt (carburetor joint) "1" Bolt (carburetor joint): 3 Nm (0.3 m•kg, 2.2 ft•lb) • Bolt (air filter joint) "2" Bolt (air filter joint): 3 Nm (0.3 m•kg, 2.2 ft•lb) 8. Install: • Throttle position sensor lead coupler "1" •...
  • Page 123 CAMSHAFTS CAMSHAFTS REMOVING THE CYLINDER HEAD COVER Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND Seat and fuel tank SIDE COVERS" section. Hot starter plunger Refer to "CARBURETOR" section. Refer to "ENGINE REMOVAL" sec- Engine upper bracket (right) tion.
  • Page 124 CAMSHAFTS REMOVING THE CAMSHAFTS Order Part name Q'ty Remarks Timing mark accessing screw Refer to removal section. Crankshaft end accessing screw Refer to removal section. Timing chain tensioner cap bolt Refer to removal section. Timing chain tensioner Refer to removal section. Gasket Refer to removal section.
  • Page 125 CAMSHAFTS REMOVING THE CAMSHAFT 3. Remove: 1. Remove: • Timing chain tensioner cap bolt "1" • Timing mark accessing screw "1" • Timing chain tensioner "2" • Crankshaft end accessing screw "2" • Gasket 4. Remove: 2. Align: • Bolt (camshaft cap) "1" •...
  • Page 126 CAMSHAFTS CHECKING THE CAMSHAFT 3. Measure: • Runout (camshaft) 1. Inspect: Out of specification → Replace. • Cam lobe Pitting/scratches/blue discoloration → Re- Runout (camshaft): place. Less than 0.03 mm (0.0012 in) 2. Measure: • Cam lobe length "a" and "b" Out of specification →...
  • Page 127 CAMSHAFTS CHECKING THE DECOMPRESSION SYSTEM 1. Check: • Decompression system Checking steps: a. Check that the decompression mechanism cam "1" moves smoothly. b. Check that the decompression mechanism cam lever pin "2" projects from the camshaft. 5. Measure: • Camshaft outside diameter "a" Out of specification→Replace the camshaft.
  • Page 128 CAMSHAFTS INSTALLING THE CAMSHAFT 1. Install: • Exhaust camshaft "1" • Intake camshaft "2" Do not turn the crankshaft during the cam- shaft installation. Damage or improper valve timing will result. d. Install the clips, camshaft caps "4" and bolts Installation steps: (camshaft cap) "5".
  • Page 129 CAMSHAFTS 2. Install: 3. Turn: • Timing chain tensioner • Crankshaft Counterclockwise several turns. 4. Check: Installation steps: • Rotor T.D.C. mark a. While pressing the tensioner rod lightly with Align with the crankcase align mark. fingers, use a thin screwdriver and wind the •...
  • Page 130 CYLINDER HEAD CYLINDER HEAD REMOVING THE CYLINDER HEAD Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND Seat and fuel tank SIDE COVERS" section. Refer to "EXHAUST PIPE AND SI- Exhaust pipe and silencer LENCER" section. Radiator Refer to "RADIATOR" section Carburetor Refer to "CARBURETOR"...
  • Page 131 CYLINDER HEAD CHECKING THE CYLINDER HEAD 1. Eliminate: • Carbon deposits (from the combustion chambers) Use a rounded scraper. Do not use a sharp instrument to avoid damag- ing or scratching: • Spark plug threads • Valve seats INSTALLING THE CYLINDER HEAD 1.
  • Page 132 CYLINDER HEAD a. Wash the threads and contact surfaces of h. Put a mark on the corner "1" of the bolt (cyl- inder head) and the cylinder head "2" as the bolts, the contact surfaces of the plain shown. washers, the contact surface of the cylinder head, and the threads of the crankcase.
  • Page 133 VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS REMOVING THE VALVES AND VALVE SPRINGS Order Part name Q'ty Remarks Cylinder head Refer to "CYLINDER HEAD" section. Valve lifter Refer to removal section. Adjusting pad Refer to removal section. Valve cotter Refer to removal section.
  • Page 134 VALVES AND VALVE SPRINGS REMOVING THE VALVE LIFTER AND 3. Remove: VALVE COTTER • Valve cotter 1. Remove: • Valve lifter "1" Attach a valve spring compressor "1" between • Pad "2" the valve spring retainer and the cylinder head to remove the valve cotters.
  • Page 135 VALVES AND VALVE SPRINGS 2. Replace: Valve guide remover: • Valve guide Intake:4.5 mm (0.18 in) YM-4116/90890-04116 Replacement steps: Exhaust:5.0 mm (0.20 in) YM-4097/90890-04097 Valve guide installer: To ease guide removal, installation and to Intake: maintain correct fit heat the cylinder head in an YM-4117/90890-04117 over to 100 °C (212 °F).
  • Page 136 VALVES AND VALVE SPRINGS 5. Measure: • Runout (valve stem) Measurement steps: Out of specification → Replace. a. Apply Mechanic's blueing dye (Dykem) "b" to the valve face. Runout limit: 0.01 mm (0.0004 in) • When installing a new valve always replace the guide.
  • Page 137 VALVES AND VALVE SPRINGS i. Measure the valve seat width again. If the valve seat width is out of specification, re- face and relap the valve seat. CHECKING THE VALVE SPRINGS 1. Measure: • Valve spring free length "a" Out of specification → Replace. Free length (valve spring): Intake: b.
  • Page 138 VALVES AND VALVE SPRINGS 3. Measure: • Spring tilt "a" Out of specification → Replace. Spring tilt limit: Intake: 2.5°/1.61 mm (0.063 in) Exhaust: 2.5°/1.65 mm (0.065 in) CHECKING THE VALVE LIFTERS 1. Inspect: e. Smaller pitch • Valve lifter 3.
  • Page 139 VALVES AND VALVE SPRINGS 5. Install: • Adjusting pad "1" • Valve lifter "2" • Apply the molybdenum disulfide oil on the valve stem end. • Apply the engine oil on the valve lifters. • Valve lifter must turn smoothly when rotated with a finger.
  • Page 140 CYLINDER AND PISTON CYLINDER AND PISTON REMOVING THE CYLINDER AND PISTON Order Part name Q'ty Remarks Cylinder head Refer to "CYLINDER HEAD" section. Bolt (cylinder) Cylinder Gasket Dowel pin Piston pin clip Refer to removal section. Piston pin Refer to removal section. Piston Refer to removal section.
  • Page 141 CYLINDER AND PISTON REMOVING THE PISTON AND PISTON RING 1. Remove: • Piston pin clip "1" • Piston pin "2" • Piston "3" • Put identification marks on each piston head for reference during reinstallation. • Before removing each piston pin, deburr the clip groove and pin hole area.
  • Page 142 CYLINDER AND PISTON c. Measure the piston skirt diameter "P" with a micrometer. 2. Position: • Piston ring a. 8 mm (0.31 in) from the piston bottom (in cylinder) edge Insert a ring into the cylinder and push it ap- Piston size "P"...
  • Page 143 CYLINDER AND PISTON INSTALLING THE PISTON RING AND CHECKING THE PISTON PIN PISTON 1. Inspect: 1. Install: • Piston pin • Piston ring Blue discoloration/grooves → Replace, then Onto the piston. inspect the lubrication system. 2. Measure: • Piston pin-to-piston clearance •...
  • Page 144 CYLINDER AND PISTON 3. Install: 2. Install: • Piston "1" • Bolt (cylinder) • Piston pin "2" Bolt (cylinder): • Piston pin clip "3" 10 Nm (1.0 m•kg, 7.2 ft•lb) • Apply engine oil onto the piston pin and pis- ton.
  • Page 145 CLUTCH CLUTCH REMOVING THE CLUTCH Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE Drain the engine oil. OIL" section in the CHAPTER 3. Refer to "ENGINE REMOVAL" sec- Brake pedal tion. Clutch cable Disconnect at engine side. Clutch cover Gasket Dowel pin Clutch spring...
  • Page 146 CLUTCH Order Part name Q'ty Remarks Push rod 2 Clutch plate Friction plate Nut (clutch boss) Refer to removal section. Lock washer Refer to removal section. Clutch boss Refer to removal section. Thrust washer Primary driven gear Push lever shaft 4-45...
  • Page 147 CLUTCH REMOVING THE CLUTCH BOSS CHECKING THE PRIMARY DRIVEN GEAR 1. Remove: 1. Check: • Nut "1" • Circumferential play • Lock washer "2" Free play exists → Replace. • Clutch boss "3" • Gear teeth "a" Wear/damage → Replace. Straighten the lock washer tab and use the clutch holding tool "4"...
  • Page 148 CLUTCH CHECKING THE CLUTCH PLATES INSTALLING THE PUSH LEVER SHAFT 1. Measure: 1. Install: • Clutch plate warpage • Push lever shaft "1" Out of specification → Replace clutch plate as a set. • Apply the lithium soap base grease on the oil Use a surface plate "1"...
  • Page 149 CLUTCH • Install the lock washer with its concaves fitted over the convexes of the clutch boss. • Use the clutch holding tool "3" to hold the clutch boss. Clutch holding tool: YM-91042/90890-04086 5. Install: • Bearing "1" • Washer "2" •...
  • Page 150 CLUTCH 7. Install: 10.Install: • Pressure plate "1" • Clutch cover "1" • Bolt (clutch cover) Bolt (clutch cover): 10 Nm (1.0 m•kg, 7.2 ft•lb) Tighten the bolts in stage, using a crisscross pattern. 8. Install: • Clutch spring • Bolt (clutch spring) Bolt (clutch spring): 10 Nm (1.0 m•kg, 7.2 ft•lb) Tighten the bolts in stage, using a crisscross...
  • Page 151 OIL FILTER ELEMENT AND WATER PUMP OIL FILTER ELEMENT AND WATER PUMP REMOVING THE OIL FILTER ELEMENT AND WATER PUMP 10 Nm (1.0 m kg, 7.2 ft lb) 33 Nm (3.3 m kg, 24 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 12 Nm (1.2 m kg, 8.7 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb)
  • Page 152 OIL FILTER ELEMENT AND WATER PUMP 10 Nm (1.0 m kg, 7.2 ft lb) 33 Nm (3.3 m kg, 24 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 12 Nm (1.2 m kg, 8.7 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 14 Nm (1.4 m kg, 10 ft lb)
  • Page 153 OIL FILTER ELEMENT AND WATER PUMP REMOVING THE IMPELLER SHAFT 1. Remove: • Impeller "1" • Washer "2" • Impeller shaft "3" Hold the impeller shaft on its width across the flats "a" with spanners, etc. and remove the im- peller.
  • Page 154 OIL FILTER ELEMENT AND WATER PUMP CHECKING THE OIL SEAL INSTALLING THE IMPELLER SHAFT 1. Inspect: 1. Install: • Oil seal "1" • Impeller shaft "1" Wear/damage → Replace. • Washer "2" • Impeller "3" Impeller: 14 Nm (1.4 m•kg, 10 ft•lb) •...
  • Page 155 OIL FILTER ELEMENT AND WATER PUMP INSTALLING THE RIGHT CRANKCASE COVER 1. Install: • Dowel pin "1" • O-ring "2" • Collar "3" • Gasket "4" Apply the lithium soap base grease on the O- ring. INSTALLING THE KICKSTARTER CRANK 1.
  • Page 156 OIL FILTER ELEMENT AND WATER PUMP INSTALLING THE WATER PUMP HOUSING 1. Install: • Dowel pin "1" • O-ring "2" Apply the lithium soap base grease on the O- ring. INSTALLING THE OIL FILTER ELEMENT 1. Install: • Oil filter element "1" •...
  • Page 157 BALANCER BALANCER REMOVING THE BALANCER Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Refer to "OIL FILTER ELEMENT Right crankcase cover AND WATER PUMP" section. Stator Refer to "CDI MAGNETO" section. Nut (balancer) Refer to removal section. Nut (primary drive gear) Refer to removal section.
  • Page 158 BALANCER REMOVING THE BALANCER 1. Straighten the lock washer tab. 2. Loosen: • Nut (balancer) "1" • Nut (primary drive gear) "2" • Nut (balancer shaft driven gear) "3" Place an aluminum plate "a" between the teeth of the balancer shaft drive gear "4" and driven gear "5".
  • Page 159 BALANCER 3. Install: 4. Bend the lock washer tab. • Lock washer "1" • Nut (balancer shaft driven gear) "2" Nut (balancer shaft driven gear): 50 Nm (5.0 m•kg, 36 ft•lb) • Primary drive gear "3" • Conical washer "4" •...
  • Page 160 OIL PUMP OIL PUMP REMOVING THE OIL PUMP Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Refer to "OIL FILTER ELEMENT Right crankcase cover AND WATER PUMP" section. Circlip Washer Oil pump drive gear Oil pump assembly Dowel pin Outer rotor 2 Circlip...
  • Page 161 OIL PUMP Order Part name Q'ty Remarks Inner rotor 1 Dowel pin Washer Oil pump drive shaft Rotor housing 4-60...
  • Page 162 OIL PUMP CHECKING THE OIL PUMP 1. Inspect: • Oil pump drive gear • Oil pump drive shaft • Rotor housing • Oil pump cover Cracks/wear/damage → Replace. 2. Measure: • Tip clearance "a" (between the inner rotor "1" and outer rotor "2") INSTALLING THE OIL PUMP •...
  • Page 163 OIL PUMP 3. Install: • Oil pump cover "1" • Screw (oil pump cover) "2" Screw (oil pump cover): 2 Nm (0.2 m•kg, 1.4 ft•lb) • Dowel pin "3" • Inner rotor 2 "4" • Circlip "5" • Apply the engine oil on the oil pump drive shaft end and inner rotor 2.
  • Page 164 KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Remarks Oil pump Refer to "OIL PUMP" section. Kick idle gear Kick shaft assembly Refer to removal section. Spring guide Torsion spring Ratchet wheel Kick gear...
  • Page 165 KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Remarks Shift guide Refer to removal section. Shift lever assembly Refer to removal section. Shift lever Pawl Pawl pin Spring Bolt (stopper lever) Stopper lever Torsion spring Segment Refer to removal section. 4-64...
  • Page 166 KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT ASSEMBLY 1. Remove: • Kick shaft assembly "1" Unhook the torsion spring "2" from the hole "a" in the crankcase. CHECKING THE KICK SHAFT AND RATCHET WHEEL 1. Check: • Ratchet wheel "1" smooth movement Unsmooth movement →...
  • Page 167 KICK SHAFT AND SHIFT SHAFT INSTALLING THE SEGMENT CHECKING THE SHIFT SHAFT 1. Install: 1. Inspect: • Segment "1" • Shift shaft "1" • Bolt (segment) Bend/damage → Replace. • Spring "2" Bolt (segment): Broken → Replace. 30 Nm (3.0 m•kg, 22 ft•lb) Align the notch "a"...
  • Page 168 KICK SHAFT AND SHIFT SHAFT 4. Install: INSTALLING THE SHIFT GUIDE AND SHIFT • Bolt (shift guide) "1" LEVER ASSEMBLY 1. Install: Bolt (shift guide): • Spring "1" 10 Nm (1.0 m•kg, 7.2 ft•lb) • Pawl pin "2" • Pawl "3" To shift lever "4".
  • Page 169 KICK SHAFT AND SHIFT SHAFT INSTALLING THE KICK SHAFT ASSEMBLY 3. Install: 1. Install: • Spring guide "1" • Kick gear "1" • Washer "2" Slide the spring guide into the kick shaft, make • Circlip "3" sure the groove "a" in the spring guide fits on •...
  • Page 170 KICK SHAFT AND SHIFT SHAFT 5. Hook: • Torsion spring "1" Turn the torsion spring clockwise and hook into the proper hole "a" in the crankcase. INSTALLING THE KICK IDLE GEAR 1. Install: • Kick idle gear "1" • Washer "2" •...
  • Page 171 CDI MAGNETO CDI MAGNETO REMOVING THE CDI MAGNETO Order Part name Q'ty Remarks Seat and fuel tank Refer to "SEAT, FUEL TANK AND SIDE COVERS" section. Disconnect the CDI magneto lead. Left crankcase cover Gasket Dowel pin Nut (rotor) Refer to removal section. Rotor Refer to removal section.
  • Page 172 Screw (stator): 10 Nm (1.0 m•kg, 7.2ft•lb) • Apply the sealant on the grommet of the CDI magneto lead. • Tighten the screws using the T30 bit. YAMAHA Bond No. 1215 (ThreeB- ® No. 1215): 90890-85505 CHECKING THE CDI MAGNETO 1.
  • Page 173 CDI MAGNETO • Apply the lithium soap base grease on the O- ring. • Tighten the bolts in stage, using a crisscross pattern. 3. Install: • Washer • Nut (rotor) "1" Nut (rotor): 56 Nm (5.6 m•kg, 40 ft•lb) 4. Connect: •...
  • Page 174 ENGINE REMOVAL ENGINE REMOVAL REMOVING THE ENGINE Order Part name Q'ty Remarks Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the frame. Refer to "SEAT, FUEL TANK AND Seat and fuel tank SIDE COVERS" section. Refer to "REAR SHOCK ABSORB- Rear shock absorber ER"...
  • Page 175 ENGINE REMOVAL Order Part name Q'ty Remarks Ignition coil Disconnect the CDI magneto lead. Engine guard Neutral switch Drive chain sprocket cover Nut (drive sprocket) Refer to removal section. Lock washer Refer to removal section. Drive sprocket Refer to removal section. Clip Bolt (brake pedal) Brake pedal...
  • Page 176 ENGINE REMOVAL HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE DRIVE SPROCKET 1. Remove: • Nut (drive sprocket) "1" • Lock washer "2" 2. Remove: • Straighten the lock washer tab. •...
  • Page 177 ENGINE REMOVAL • Engine mounting bolt (upper) "10" Engine mounting bolt (upper): 55 Nm (5.5 m•kg, 40 ft•lb) • Apply the molybdenum disulfide grease on the pivot shaft. • Install the patch with the claw "a" facing out- side the chassis. INSTALLING THE DRIVE SPROCKET 1.
  • Page 178 ENGINE REMOVAL 3. Bend the lock washer tab to lock the nut. 4. Install: • Drive chain sprocket guide • Drive chain sprocket cover "1" • Screw (drive chain sprocket cover) "2" Screw (drive chain sprocket cover): 8 Nm (0.8 m•kg, 5.8 ft•lb) INSTALLING THE NEUTRAL SWITCH 1.
  • Page 179 CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT REMOVING THE CRANKSHAFT Order Part name Q'ty Remarks Refer to "ENGINE REMOVAL" sec- Engine tion. Refer to "CYLINDER AND PISTON" Piston section. Balancer Refer to "BALANCER" section. Refer to "KICK SHAFT AND SHIFT Kick shaft assembly SHAFT"...
  • Page 180 CRANKCASE AND CRANKSHAFT Order Part name Q'ty Remarks Hose guide Refer to removal section. Right crankcase Refer to removal section. Left crankcase Refer to removal section. Oil strainer Balancer shaft Refer to removal section. Crankshaft Refer to removal section. 4-79...
  • Page 181 CRANKCASE AND CRANKSHAFT REMOVING THE CRANKCASE BEARING Order Part name Q'ty Remarks Refer to "TRANSMISSION, SHIFT Transmission CAM AND SHIFT FORK" section. Refer to "TRANSMISSION, SHIFT Shift cam and shift fork CAM AND SHIFT FORK" section. Oil seal Bearing Refer to removal section. 4-80...
  • Page 182 CRANKCASE AND CRANKSHAFT DISASSEMBLING THE CRANKCASE 1. Separate: • Right crankcase • Left crankcase Separation steps: a. Remove the crankcase bolts, hose guide and clutch cable holder. c. Remove the dowel pins and O-ring. REMOVING THE BALANCER SHAFT 1. Remove: •...
  • Page 183 CRANKCASE AND CRANKSHAFT REMOVING THE CRANKCASE BEARING 2. Inspect: 1. Remove: • Bearing • Bearing "1" Rotate inner race with a finger. Rough spot/seizure → Replace. • Remove the bearing from the crankcase by pressing its inner race. • Do not use the removed bearing. 3.
  • Page 184 CRANKCASE AND CRANKSHAFT • Install the bearing by pressing its outer race parallel. • To prevent the screw [bearing stopper (crank- shaft)] from becoming loose, crush the screw head periphery "a" into the concave "b" using a punch etc. In so doing, take care not to dam- age the screwdriver receiving hole in the screw head.
  • Page 185 CRANKCASE AND CRANKSHAFT 4. Apply: • Sealant On the right crankcase. YAMAHA Bond No. 1215 (ThreeB- ® No.1215): 90890-85505 Clean the contacting surface of left and right crankcase before applying the sealant. A. For USA and CDN 5. Install: B. Except for USA and CDN •...
  • Page 186 CRANKCASE AND CRANKSHAFT 6. Tighten: • Bolt (hose guide) "1" • Bolt (crankcase) Bolt (crankcase): 12 Nm (1.2 m•kg, 8.7 ft•lb) Tighten the crankcase tightening bolts in stage, using a crisscross pattern. 7. Install: • Timing chain • Timing chain guide (intake side) •...
  • Page 187 TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION, SHIFT CAM AND SHIFT FORK Order Part name Q'ty Remarks Refer to "ENGINE REMOVAL" sec- Engine tion. Refer to "CRANKCASE AND Separate the crankcase. CRANKSHAFT" section. Main axle Refer to removal section.
  • Page 188 TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION 2. Inspect: • O-ring "1" 1. Remove: Damage → Replace. • Main axle "1" • Drive axle "2" • Shift cam • Shift fork 3 • Shift fork 2 • Shift fork 1 •...
  • Page 189 TRANSMISSION, SHIFT CAM AND SHIFT FORK 2. Inspect: • Shift cam "1" • Segment "2" Wear/damage → Replace. 3. Check: • Shift fork movement Unsmooth operation → Replace shift fork. 2. Install: • Collar "1" • 2nd wheel gear (23T) "2" •...
  • Page 190 TRANSMISSION, SHIFT CAM AND SHIFT FORK 4. Install: • Collar "1" • Apply the lithium soap base grease on the oil seal lip. • When installing the collar into the crankcase, pay careful attention to the crankcase oil seal lip. 5.
  • Page 191 TRANSMISSION, SHIFT CAM AND SHIFT FORK 6. Install: • Transmission assembly "1" To left crankcase "2". Apply the engine oil on the bearings and guide bars. 7. Check: • Shifter operation • Transmission operation Unsmooth operation → Repair. 4-90...
  • Page 192 This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.
  • Page 193 FRONT WHEEL AND REAR WHEEL FRONT WHEEL AND REAR WHEEL REMOVING THE FRONT WHEEL Order Part name Q'ty Remarks Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the engine. Bolt (axle holder) Only loosening. Nut (front wheel axle) Front wheel axle Front wheel...
  • Page 194 FRONT WHEEL AND REAR WHEEL REMOVING THE REAR WHEEL Order Part name Q'ty Remarks Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the engine. Nut (rear wheel axle) Rear wheel axle Drive chain puller Rear wheel Refer to removal section.
  • Page 195 FRONT WHEEL AND REAR WHEEL HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE REAR WHEEL 1. Remove: • Wheel "1" Push the wheel forward and remove the drive 2. Inspect: chain "2". •...
  • Page 196 FRONT WHEEL AND REAR WHEEL CHECKING THE BRAKE DISC 1. Measure: • Apply the lithium soap base grease on the • Brake disc deflection (only rear brake disc) bearing and oil seal lip when installing. Use the dial gauge "1". •...
  • Page 197 FRONT WHEEL AND REAR WHEEL 3. Install: 6. Install: • Nut (wheel axle) "1" • Collar "1" Nut (wheel axle): • Apply the lithium soap base grease on the oil 105 Nm (10.5 m•kg, 75 ft•lb) seal lip. • Install the collars with their projections "a" fac- ing the wheel.
  • Page 198 FRONT WHEEL AND REAR WHEEL INSTALLING THE REAR WHEEL 1. Install: • Bearing (right) "1" • Circlip "2" • Spacer "3" • Bearing (left) "4" • Oil seal "5" • Apply the lithium soap base grease on the bearing and oil seal lip when installing. 3.
  • Page 199 FRONT WHEEL AND REAR WHEEL 5. Install: 8. Install: • Wheel • Right drive chain puller "1" • Washer "2" • Nut (wheel axle) "3" Install the brake disc "1" between the brake pads "2" correctly. Temporarily tighten the nut (wheel axle) at this point.
  • Page 200 FRONT BRAKE AND REAR BRAKE FRONT BRAKE AND REAR BRAKE REMOVING THE FRONT BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the engine. Drain the brake fluid. Refer to removal section. Brake hose holder (protector) Union bolt Brake hose...
  • Page 201 FRONT BRAKE AND REAR BRAKE REMOVING THE REAR BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the engine. Refer to "FRONT WHEEL AND Rear wheel REAR WHEEL" section. Drain the brake fluid.
  • Page 202 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE CALIPER Order Part name Q'ty Remarks A. Front B. Rear Pad pin Brake pad Pad support Brake caliper piston 1 Refer to removal section. Brake caliper piston dust seal 1 Refer to removal section. Brake caliper piston seal 1 Refer to removal section.
  • Page 203 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE MASTER CYLINDER Order Part name Q'ty Remarks A. Front B. Rear Brake master cylinder cap Diaphragm Reservoir float Push rod (Front) Brake master cylinder boot Circlip Use a long nose circlip pliers. Washer Push rod (Rear) Brake master cylinder kit...
  • Page 204 FRONT BRAKE AND REAR BRAKE HANDLING NOTE • Do not reuse the drained brake fluid. Support the machine securely so there is no • Brake fluid may erode painted surfaces or danger of it falling over. plastic parts. Always clean up spilled fluid immediately.
  • Page 205 FRONT BRAKE AND REAR BRAKE Remove the brake caliper piston seals and brake caliper piston dust seals by pushing them with a finger. Never attempt to pry out brake caliper pis- ton seals and brake caliper piston dust seals. A. Front B.
  • Page 206 FRONT BRAKE AND REAR BRAKE CHECKING THE BRAKE CALIPER HANDLING NOTE 1. Inspect: • Brake caliper cylinder inner surface "a" • All internal parts should be cleaned in new Wear/score marks → Replace brake caliper brake fluid only. assembly. • Internal parts should be lubricated with brake fluid when installed.
  • Page 207 FRONT BRAKE AND REAR BRAKE • Install the brake pads with their projections "a" into the brake caliper recesses "b". • Temporarily tighten the pad pin at this point. A. Front B. Rear 3. Install: • Brake caliper piston "1" 2.
  • Page 208 FRONT BRAKE AND REAR BRAKE INSTALLING THE BRAKE MASTER CYLINDER KIT 1. Clean: • Brake master cylinder • Brake master cylinder kit Clean them with brake fluid. 2. Install: • Brake master cylinder cup (primary) "1" • Brake master cylinder cup (secondary) "2" To brake master cylinder piston "3".
  • Page 209 FRONT BRAKE AND REAR BRAKE • Bolt (brake master cylinder bracket) "3" Bolt (brake master cylinder brack- et): 9 Nm (0.9 m•kg, 6.5 ft•lb) • Install the bracket so that the arrow mark "a" face upward. • First tighten the bolts on the upper side of the brake master cylinder bracket, and then tight- en the bolts on the lower side.
  • Page 210 FRONT BRAKE AND REAR BRAKE • Union bolt "3" 3. Install: • Spring "1" Union bolt: • Brake pedal "2" 30 Nm (3.0 m•kg, 22 ft•lb) • O-ring "3" • Bolt (brake pedal) "4" Bolt (brake pedal): Always use new copper washers. 26 Nm (2.6 m•kg, 19 ft•lb) •...
  • Page 211 FRONT BRAKE AND REAR BRAKE 4. Install: • Copper washer "1" Install the brake hose so that its pipe por- • Brake hose "2" tion "a" directs as shown and lightly touch- • Union bolt "3" es the projection "b" on the brake caliper. Union bolt: 30 Nm (3.0 m•kg, 22 ft•lb) Always use new copper washers.
  • Page 212 FRONT BRAKE AND REAR BRAKE Union bolt: 30 Nm (3.0 m•kg, 22 ft•lb) Always use new copper washers. Install the brake hose so that its pipe por- tion "a" directs as shown and lightly touch- es the projection "b" on the brake caliper. FILLING THE BRAKE FLUID 1.
  • Page 213 FRONT BRAKE AND REAR BRAKE A. Front A. Front B. Rear B. Rear 2. Air bleed: 5. Install: (rear brake only) • Brake system • Protector "1" Refer to "BLEEDING THE HYDRAULIC • Bolt (protector) "2" BRAKE SYSTEM" section in the CHAPTER Bolt (protector): 7 Nm (0.7 m•kg, 5.1 ft•lb) 3.
  • Page 214 FRONT FORK FRONT FORK REMOVING THE FRONT FORK Order Part name Q'ty Remarks Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the engine. Refer to "FRONT WHEEL AND Front wheel REAR WHEEL" section. Refer to "FRONT BRAKE AND Front brake caliper REAR BRAKE"...
  • Page 215 FRONT FORK DISASSEMBLING THE FRONT FORK 30 Nm (3.0 m kg, 22 ft lb) 29 Nm (2.9 m kg, 21 ft lb) 1 Nm (0.1 m kg, 0.7 ft lb) 29 Nm (2.9 m kg, 21 ft lb) 55 Nm (5.5 m kg, 40 ft lb) Order Part name Q'ty...
  • Page 216 FRONT FORK HANDLING NOTE REMOVING THE ADJUSTER 1. Drain the outer tube of its front fork oil at its top. Support the machine securely so there is no 2. Loosen: danger of it falling over. • Adjuster "1" The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers.
  • Page 217 FRONT FORK 2. Remove: CHECKING THE DAMPER ASSEMBLY • Inner tube "1" 1. Inspect: • Damper assembly "1" Bend/damage → Replace. Oil seal removal steps: • O-ring "2" a. Push in slowly "a" the inner tube just before Wear/damage → Replace. it bottoms out and then pull it back quickly "b".
  • Page 218 FRONT FORK Inner tube bending limit: 0.2 mm (0.008 in) The bending value is shown by one half of the dial gauge reading. Do not attempt to straighten a bent inner tube as this may dangerously weaken the CHECKING THE COLLAR tube.
  • Page 219 FRONT FORK 5. Measure: ASSEMBLING THE FRONT FORK • Oil level (left and right) "a" 1. Wash the all parts in a clean solvent. Out of specification → Adjust. 2. Stretch the damper assembly fully. 3. Fill: Standard oil level: •...
  • Page 220 FRONT FORK 8. Install: 11.After filling, pump the damper assembly "1" • Base valve "1" slowly up and down more than 10 times to To damper assembly "2". distribute the fork oil. First bring the damper rod pressure to a maxi- mum.
  • Page 221 FRONT FORK 14.Check: 16.Install: • Piston metal "1" • Damper assembly smooth movement Tightness/binding/rough spots → Repeat the steps 2 to 13. Install the piston metal onto the slot on inner tube. 15.Install: • Dust seal "1" 17.Install: • Stopper ring "2" •...
  • Page 222 FRONT FORK 19.Install: 22.Check: • Oil seal "1" • Inner tube smooth movement Tightness/binding/rough spots → Repeat the steps 15 to 21. Press the oil seal into the outer tube with fork seal driver "2". Fork seal driver: YM-A0948/90890-01502 23.Measure: •...
  • Page 223 FRONT FORK 27.Install: • Push rod "1" • Copper washer "2" • Adjuster "3" To damper assembly "4". • While compressing the inner tube "5", set the cap bolt ring wrench "7" between the inner tube and locknut "6". • Fully finger tighten the adjuster onto the damper assembly.
  • Page 224 FRONT FORK 29.Tighten: • Adjuster (locknut) "1" • Be sure to use recommended fork oil. If Adjuster (locknut): other oils are used, they may have an ex- 29 Nm (2.9 m•kg, 21 ft•lb) cessively adverse effect on the front fork performance.
  • Page 225 FRONT FORK 4. Tighten: INSTALLING THE FRONT FORK • Pinch bolt (upper bracket) "1" 1. Install: • Front fork "1" Pinch bolt (upper bracket): 21 Nm (2.1 m•kg, 15 ft•lb) • Temporarily tighten the pinch bolts (lower • Pinch bolt (lower bracket) "2" bracket).
  • Page 226 FRONT FORK 7. Adjust: • Compression damping force Turn in the damping adjuster "1" finger-tight and then turn out to the originally set position. 5-35...
  • Page 227 HANDLEBAR HANDLEBAR REMOVING THE HANDLEBAR Order Part name Q'ty Remarks Number plate Remove the band only. Hot starter cable Disconnect at the lever side. Hot starter lever holder Clutch cable Disconnect at the lever side. Clutch lever holder Engine stop switch Brake master cylinder Refer to removal section.
  • Page 228 HANDLEBAR Order Part name Q'ty Remarks Handlebar upper holder Handlebar Handlebar lower holder 5-37...
  • Page 229 HANDLEBAR REMOVING THE BRAKE MASTER CYLINDER 1. Remove: • Brake master cylinder bracket "1" • Brake master cylinder "2" • Do not let the brake master cylinder hang on the brake hose. • Keep the brake master cylinder cap side horizontal to prevent air from coming in.
  • Page 230 HANDLEBAR 2. Install: • Handlebar "1" • Handlebar upper holder "2" • Bolt (handlebar upper holder) "3" Bolt (handlebar upper holder): 28 Nm (2.8 m•kg, 20 ft•lb) • The handlebar upper holder should be in- stalled with the punched mark "a" forward. •...
  • Page 231 HANDLEBAR 5. Install: 7. Install: • Right grip "1" • Throttle cables "1" • Collar "2" To tube guide "2". Apply the adhesive on the tube guide "3". Apply the lithium soap base grease on the • Before applying the adhesive, wipe off grease throttle cable end and tube guide cable winding or oil on the tube guide surface "a"...
  • Page 232 HANDLEBAR 9. Install: • Grip cap cover "1" • The engine stop switch, clutch lever holder • Cover (throttle cable cap) "2" and clamp should be installed according to the dimensions shown. • Pass the engine stop switch lead in the middle of the clutch lever holder.
  • Page 233 STEERING STEERING REMOVING THE STEERING Order Part name Q'ty Remarks TIGHTENING STEPS: • Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb) • Loosen it one turn. • Retighten it. 7 Nm (0.7 m•kg, 5.1 ft•lb) Hold the machine by placing the suit- Refer to "HANDLING NOTE".
  • Page 234 STEERING Order Part name Q'ty Remarks Steering ring nut Refer to removal section. Lower bracket Bearing race cover Upper bearing Lower bearing Refer to removal section. Bearing race Refer to removal section. 5-43...
  • Page 235 STEERING HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE STEERING RING NUT 1. Remove: • Steering ring nut "1" Use the steering nut wrench "2". Steering nut wrench: CHECKING THE STEERING STEM YU-33975/90890-01403 1.
  • Page 236 STEERING 4. Install: INSTALLING THE LOWER BRACKET • Steering ring nut "1" 1. Install: • Lower bearing "1" Steering ring nut: 7 Nm (0.7 m•kg, 5.1 ft•lb) Apply the lithium soap base grease on the dust Tighten the steering ring nut using the steer- seal lip and bearing inner circumference.
  • Page 237 STEERING 7. Install: 11.Tighten: • Front fork "1" • Pinch bolt (upper bracket) "1" • Upper bracket "2" Pinch bolt (upper bracket): 21 Nm (2.1 m•kg, 15 ft•lb) • Temporarily tighten the pinch bolts (lower • Pinch bolt (lower bracket) "2" bracket).
  • Page 238 SWINGARM SWINGARM REMOVING THE SWINGARM Order Part name Q'ty Remarks Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the engine. Refer to "FRONT BRAKE AND Brake hose holder REAR BRAKE" section. Refer to "FRONT BRAKE AND Rear brake caliper REAR BRAKE"...
  • Page 239 SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q'ty Remarks Relay arm Connecting rod Collar Oil seal Thrust bearing Bushing Oil seal Bearing Refer to removal section. 5-48...
  • Page 240 SWINGARM HANDLING NOTE CHECKING THE RELAY ARM 1. 5294Inspect: • Bearing "1" Support the machine securely so there is no • Collar "2" danger of it falling over. Free play exists/unsmooth revolution/rust → Replace bearing and collar as a set. REMOVING THE BEARING 2.
  • Page 241 SWINGARM INSTALLING THE BEARING AND OIL SEAL 1. Install: • Bearing "1" • Oil seal "2" To swingarm. • Apply the molybdenum disulfide grease on the bearing when installing. • Install the bearing by pressing it on the side having the manufacture's marks or numbers. •...
  • Page 242 SWINGARM INSTALLING THE SWINGARM 1. Install: • Bushing "1" • Thrust bearing "2" • Oil seal "3" • Collar "4" To swingarm "5". Apply the molybdenum disulfide grease on the bushings, thrust bearings, oil seal lips and con- 4. Install: tact surfaces of the collar and thrust bearing.
  • Page 243 SWINGARM 6. Install: • Swingarm "1" • Pivot shaft "2" Pivot shaft: 85 Nm (8.5 m•kg, 61 ft•lb) • Apply the molybdenum disulfide grease on the pivot shaft. • Insert the pivot shaft from right side. 9. Install: • Bolt (rear shock absorber-relay arm) "1" •...
  • Page 244 SWINGARM 11.Tighten: • Nut (relay arm) "1" Nut (relay arm): 70 Nm (7.0 m•kg, 50 ft•lb) 12.Install: • Bolt (lower chain tensioner) "1" • Washer "2" • Collar "3" • Lower chain tensioner "4" • Nut (lower chain tensioner) "5" Nut (lower chain tensioner): 16 Nm (1.6 m•kg, 11 ft•lb) 13.Install:...
  • Page 245 REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER Order Part name Q'ty Remarks Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the engine. Refer to "SEAT, FUEL TANK AND Seat SIDE COVERS" section in the CHAPTER 4.
  • Page 246 REAR SHOCK ABSORBER Order Part name Q'ty Remarks Spring seat Lower spring guide Upper spring guide Spring (rear shock absorber) Bearing Refer to removal section. 5-55...
  • Page 247 To dispose of a damaged or worn-out rear 3. Remove: shock absorber, take the unit to your • Lower bearing "1" Yamaha dealer for this disposal procedure. Remove the bearing by pressing its outer race. 5-56...
  • Page 248 REAR SHOCK ABSORBER INSTALLING THE BEARING 1. Install: • Upper bearing "1" Install the bearing parallel until the stopper ring groove appears by pressing its outer race. Do not apply the grease on the bearing out- er race because it will wear the rear shock CHECKING THE REAR SHOCK ABSORBER absorber surface on which the bearing is 1.
  • Page 249 REAR SHOCK ABSORBER INSTALLING THE SPRING (REAR SHOCK 4. Adjust: ABSORBER) • Spring length (installed) 1. Install: Refer to "ADJUSTING THE REAR SHOCK • Spring "1" ABSORBER SPRING PRELOAD" section in • Upper spring guide "2" the CHAPTER 3. • Lower spring guide "3" 5.
  • Page 250 REAR SHOCK ABSORBER • Apply the molybdenum disulfide grease on the bearing and dust seal lips. • Install the dust seals with their lips facing out- ward. 6. Install: • Rear frame "1" • Bolt [rear frame (upper)] "2" Bolt [rear frame (upper)]: 38 Nm (3.8 m•kg, 27 ft•lb) 3.
  • Page 251 This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.

  • Page 252: Electrical Components And Wiring Diagram

    ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS 1. Engine stop switch 5. Ignition coil 2. Throttle position sensor 6. Spark plug 3. Neutral switch 7. CDI unit 4. CDI magneto...
  • Page 253 ELECTRICAL COMPONENTS AND WIRING DIAGRAM WIRING DIAGRAM 1. Engine stop switch COLOR CODE 2. Throttle position sensor Black 3. Neutral switch Brown 4. CDI magneto Green 5. Ignition coil Blue 6. Spark plug Orange 7. CDI unit Pink Sky blue White Yellow Black/Blue...

  • Page 254: Ignition System

    IGNITION SYSTEM IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. Spark gap test Spark → *Clean or replace spark plug. No spark ↓...
  • Page 255 IGNITION SYSTEM SPARK GAP TEST 1. Disconnect the ignition coil from spark plug. 2. Remove the ignition coil cap. 3. Connect the dynamic spark tester "1" (igni- tion checker "2") as shown. • Ignition coil "3" • Spark plug "4" CHECKING THE ENGINE STOP SWITCH 1.
  • Page 256 IGNITION SYSTEM Pickup coil resis- Tester selector tance position 248-372 Ω at 20 Ω × 100 °C (68 °F) 3. Inspect: • Secondary coil resistance Out of specification → Replace. Tester (+) lead → Orange lead "1" Tester (-) lead → Spark plug terminal "2" 2.
  • Page 257 IGNITION SYSTEM CHECKING THE NEUTRAL SWITCH 1. Inspect: • Neutral switch conduction Tester (+) lead → Sky blue lead "1" Tester (-) lead → Ground "2" Result Conductive (while gear is in neu- tral) Not conductive while it is in neutral → Replace. Conductive while it is engaged →...

  • Page 258: Throttle Position Sensor System

    THROTTLE POSITION SENSOR SYSTEM THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position sensor will not operate, use the following inspection steps. Check entire ignition system for connec- No good → Repair or replace. tion. OK ↓ Check throttle position sensor. (Throttle No good →...
  • Page 259 THROTTLE POSITION SENSOR SYSTEM HANDLING NOTE 2. Loosen: • Throttle stop screw "1" Do not loosen the screw (throttle position Turn out the throttle stop screw until the throttle sensor) "1" except when changing the shaft is in the full close position. throttle position sensor due to failure be- cause it will cause a drop in engine perfor- mance.
  • Page 260 THROTTLE POSITION SENSOR SYSTEM CHANGING AND ADJUSTING THE Tester (+) lead → Yellow lead "3" THROTTLE POSITION SENSOR Tester (-) lead → Black lead "4" 1. Remove: • Throttle position sensor coupler • Carburetor • Do not insert the electric conductors more 2.
  • Page 261 THROTTLE POSITION SENSOR SYSTEM 10.Put the aligning marks "a" on the throttle po- sition sensor and carburetor. 11.Stop the engine. 12.Remove the carburetor. 13.Tighten: • Screw (throttle position sensor) "1" Tighten the screw (throttle position sensor) us- ing the T25 bit. 14.Install the carburetor.

  • Page 262: Tuning

    ENGINE TUNING ATMOSPHERIC CONDITIONS AND CARBURETOR SETTINGS ENGINE CARBURETOR SETTING pres- • The air/fuel mixture will vary depending on at- Humidi- sure Mixture Setting mospheric conditions. Therefore, it is neces- temp. (alti- sary to take into consideration the air tude) pressure, ambient temperature, humidity, etc., when adjusting the carburetor.
  • Page 263 ENGINE CONSTRUCTION OF CARBURETOR AND SETTING PARTS The FLATCR carburetor has a primary main jet. This type of main jet is perfect for racing ma- chines since it supplies an even flow of fuel, even at full load. Use the main jet and the jet needle to set the carburetor.
  • Page 264 ENGINE Effects of adjusting the pilot screw (refer- 2. Too lean at intermediate speeds • The engine breathes hard and will not pick ence) up speed quickly. Step down the jet needle clip by one groove and move up the needle to enrich the mix- ture.
  • Page 265 ENGINE 2. Rough engine operation is felt in quick throt- tle opening, select a leak jet having higher calibrating No. than standard to lean out the mixture. <Example> #55 → #60 Standard leak jet Changing from NFLR-3 to NFPR-3 has the same effect as a rising of 0.5 clip position.
  • Page 266 ENGINE CARBURETOR SETTING PARTS Part name Size Part number Main jet Rich #172 4MX-14943-92 #170 4MX-14943-41 #168 4MX-14943-91 #165 4MX-14943-40 #162 4MX-14943-90 (STD) #160 4MX-14943-39 #158 4MX-14943-89 #155 4MX-14943-38 #152 4MX-14943-88 #150 4MX-14943-37 Lean #148 4MX-14943-87 Pilot jet Rich 4MX-14948-08 4MX-14948-07 4MX-14948-06 (STD)
  • Page 267 ENGINE SPECIFICATIONS OF JET NEEDLE Diameter of straight portion Rich Lean Rich 1 richer NFLN-4 NFLP-4 NFLQ-4 NFLR-4 NFLS-4 NFLT-4 NFLU-4 0.5 richer NFPN-3 NFPP-3 NFPQ-3 NFPR-3 NFPS-3 NFPT-3 NFPU-3 NFLN-3 NFLP-3 NFLQ-3 NFLR-3 NFLS-3 NFLT-3 NFLU-3 0.5 leaner NFPN-2 NFPP-2 NFPQ-2 NFPR-2...
  • Page 268 ENGINE Symptom Setting Checking Closed to 1/4 throttle Use jet needle with a larger diame- Poor acceleration ter. Raise jet needle clip position. (1 groove up) Poor response in the low Raise jet needle clip position. to intermediate speeds If this has no effect, lower the jet needle clip position.
  • Page 269 CHASSIS CHASSIS DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET) Part name Size Part number Drive sprocket "1" Secondary reduction ratio = Number of rear wheel sprocket teeth/Number of (STD) 9383E-13233 drive sprocket teeth Rear wheel sprocket "2"...
  • Page 270 CHASSIS TIRE PRESSURE Standard oil amount: Tire pressure should be adjust to suit the road 350 cm (12.3 Imp oz, 11.8 US oz) surface condition of the circuit. * 340 cm (12.0 Imp oz, 11.5 US oz) Standard tire pressure: Extent of adjustment: 100 kPa (1.0 kgf/cm , 15 psi)
  • Page 271 CHASSIS SETTING OF SPRING AFTER REPLACEMENT As the front fork setting can be easily affected by rear suspension, take care so that the ma- chine front and rear are balanced (in position, etc.) when setting the front fork. 1. Use of soft spring •...

  • Page 272: Chassis

    CHASSIS 2. Remove the stand or block from the engine SETTING OF SPRING AFTER and with a rider astride the seat, measure REPLACEMENT the sunken length "b" between the rear After replacement, be sure to adjust the spring wheel axle center and the rear fender hold- to the set length [sunken length 90–100 mm ing bolt.
  • Page 273 CHASSIS [Unequal-pitch steel spring] REAR SHOCK ABSORBER SETTING PARTS SPRING SPRING I.D. • Rear shock spring "1" PART TYPE RATE (ap- MARK/ [Equal-pitch titanium spring] NUMBER prox.) Q'TY (-22212-) SPRING SPRING PART I.D. SOFT Green/ TYPE 5UN-A0 RATE NUMBER MARK (-22212-) 5UN-B0 Red/2...
  • Page 274 CHASSIS • Extent of adjustment (spring preload) Maximum Minimum Position in which Position in which the spring is turned the spring is turned in 13 mm (0.51 in) in 1.5 mm (0.06 in) from its free length. from its free length. •...
  • Page 275 CHASSIS SUSPENSION SETTING (FRONT FORK) • If any of the following symptoms is experienced with the standard position as the base, make reset- ting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in).
  • Page 276 CHASSIS SUSPENSION SETTING (REAR SHOCK ABSORBER) • If any of the following symptoms is experienced with the standard position as the base, make reset- ting by reference to the adjustment procedure given in the same chart. • Adjust the rebound damping in 2-click increments or decrements. •...
  • Page 278 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2008.05-3.8×1 CR 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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