Page 1 2023 OWNER’S SERVICE MANUAL YZ450F Read this manual carefully before operating this vehicle. YZ450FP LIT-11626-36-32 BHR-2819U-10...
Page 2 EAM20161 Read this manual carefully Operating, servicing and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.
Page 3 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. FCC CAUTION Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment. This transmitter must not be co-located or operated in conjunction with any other antenna or transmitter.
Page 4 EAM20080 YZ450FP OWNER’S SERVICE MANUAL ©2023 by Yamaha Motor Corporation, U.S.A. First edition, July 2022 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. P/N. LIT-11626-36-32...
Page 5 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 6 EAM20162 YAMAHA MOTOR CORPORATION, U.S.A. YZ MOTORCYCLE LIMITED WARRANTY...
Page 7 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 8 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 9: Table Of Contents
TABLE OF CONTENTS EAM10003 GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING TUNING...
Page 11 GENERAL INFORMATION SAFETY INFORMATION ..................1-1 FOR SAFETY, BE SURE TO OBEY THE FOLLOWING:......1-1 LOCATION OF IMPORTANT LABELS.............1-4 DESCRIPTION....................1-5 IDENTIFICATION ....................1-6 VEHICLE IDENTIFICATION NUMBER ............1-6 ENGINE SERIAL NUMBER................1-6 INCLUDED PARTS ...................1-7 SIDESTAND ....................1-7 NIPPLE WRENCH ..................1-7 HANDLEBAR PROTECTOR ..............1-7 FUEL HOSE JOINT COVER ..............1-7 POWER TUNER ..................1-7 IMPORTANT INFORMATION ................1-9 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-9...
Page 12 STARTING A COLD ENGINE ..............1-24 STARTING A WARM ENGINE ..............1-25 BREAK-IN PROCEDURES ..............1-25 ENGINE STARTING PRECAUTION ............1-25 MAINTENANCE AFTER BREAK-IN ..............1-26 MAJOR MAINTENANCE ................1-26 AIR FILTER MAINTENANCE ..............1-26 TORQUE-CHECK POINTS................1-27 MOTORCYCLE CARE AND STORAGE............1-29 CARE ......................1-29 STORAGE ....................1-30...
Page 13: Safety Information
Yamaha ma- accidents. Many accidents have been chine, and take care to maintain it properly and caused by an automobile driver who did not operate it safely.
Page 14 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 15 SAFETY INFORMATION 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. Other tires, rims, sizes, and combinations may not be appropriate. Refer to “CHECKING THE TIRES”...
Page 16: Location Of Important Labels
LOCATION OF IMPORTANT LABELS EAM20085 LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle. 4, 5 Premium unleaded gasoline only. 3FB-2415E-03 WARNING This unit contains high pressure nitrogen gas. Mishandling can cause explosion. Read owner's manual for instructions. 5PA-2118K-01 Do not incinerate, puncture or open.
Page 17: Description
DESCRIPTION EAM20086 DESCRIPTION 1. Clutch lever 10.Radiator 11.Coolant drain bolt 2. Front brake lever 12.Oil level check window 3. Throttle grip 13.Rear brake pedal 4. Start switch 14.Air filter 5. Radiator cap 6. Fuel tank cap 15.Drive chain 16.Shift pedal 7.
Page 18: 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 19: Included Parts
INCLUDED PARTS EAM20088 INCLUDED PARTS EAM30190 SIDESTAND This sidestand “1” is used to support only the machine when standing or transporting it. EWA20260 WARNING • Never apply additional force to the sides- tand. • Remove this sidestand before starting out. EAM30007 FUEL HOSE JOINT COVER EAM30005...
Page 20 INCLUDED PARTS pression ratio, etc.) have been changed, the performance may not match to the actu- al settings. • Do not run the engine with the smartphone COMMUN.CONT.UNIT ASSY. carried with you. Otherwise, the smart- phone could be damaged. P/N: S/N: •...
Page 21: Important Information
2. Use proper special tools and equipment. Re- used for repair of the vehicle, including periodic fer to “SPECIAL TOOLS” on page 1-15. replacement parts, are new YAMAHA genuine parts and recommended parts. Do not use any used parts, because these may...
Page 22: 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 23: 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 24 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 25 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 26 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 27: Special Tools
Feeler gauge set YU-26900-9 Valve lapper (ø14) 3-8, 5-24 90890-04101 90890-04101 Valve lapper (ø14) YM-A8998 YM-A8998 Yamaha diagnostic tool USB (US) 3-12, 7-7, 7-8, 90890-03269 8-17, 8-49 Yamaha diagnostic tool (A/I) 3-12, 7-7, 7-8, 90890-03264 8-17, 8-49 Digital tachometer 3-12, 8-52...
Page 28 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Steering nut wrench 3-28, 4-60 90890-01403 Exhaust flange nut wrench YU-A9472 Spoke nipple wrench (6–7) 3-34 90890-01521 Spoke nipple wrench (6–7) YM-01521 Cap bolt ring wrench 4-48, 4-48, 4-49, 90890-01501 4-51, 4-55, 4-56 Cap bolt ring wrench YM-01501 Cap bolt wrench...
Page 29 YM-01196 Piston pin puller set 5-31 90890-01304 Piston pin puller YU-01304 YU-01304 Rotor puller 5-38 90890-04151 Rotor puller YM-04151 Yamaha bond No. 1215 5-38, 5-70 90890-85505 Three bond No. 1215® Clutch holder 5-48, 5-52 90890-04199 Universal clutch holder YM-91042 1-17...
Page 30 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Crankcase separating tool 5-73 90890-04152 Crankcase separating tool YU-A9642 Crankshaft installer pot 5-74 90890-01274 Installing pot YU-90058 YU-90058/YU-90059 Crankshaft installer bolt 5-74 90890-01275 Bolt YU-90060 Adapter (M12) 5-74 90890-01278 Adapter #3 YU-90063 Spacer (crankshaft installer) 5-74 90890-04081...
Page 31 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages 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 YU-33984 YU-33984 Pressure gauge 90890-03153 Pressure gauge YU-03153 Fuel pressure adapter 90890-03186 Fuel pressure adapter YM-03186...
Page 32 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Test harness S– pressure sensor (3P) 8-53 90890-03207 Test harness S– pressure sensor (3P) YU-03207 1-20...
Page 33: Instrument And Control Functions
INSTRUMENT AND CONTROL FUNCTIONS pending on the rider’s operations and road sur- EAM20181 INSTRUMENT AND CONTROL face conditions. FUNCTIONS How to operate 1. Put the gear into the neutral position. 2. Start the engine. EAM30182 ENGINE STOP SWITCH 3. Push the mode switch “1” for more than one The engine stop switch “1”...
Page 34: Lap Time Record Mode
INSTRUMENT AND CONTROL FUNCTIONS • Measurement results can be received and saved on the app. A. Drive mode 1 B. Drive mode 2 1. Push the mode switch EAM30627 DRIVE MODE 2. Purple Push the mode switch “1” to change between 3.
Page 35: Shift Pedal
INSTRUMENT AND CONTROL FUNCTIONS EAM30185 SHIFT PEDAL When operating the throttle grip in the closing di- The shift pedal “1” has adopted a method of 1 rection, the starter knob “1” moves in the direc- down & 4 ups (press-down & kick-ups). tion “b”...
Page 36: Starting And Break-In
(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. unleaded gasoline with a pump octane number...
Page 37: Starting A Warm Engine
STARTING AND BREAK-IN 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. • Piston, Piston ring, Valve, Camshaft, and Gear: A break-in is required for about 30 minutes at a throttle opening of 1/2 or less.
Page 38: Maintenance After Break-In
Pour the specified amount of the recom- AIR FILTER MAINTENANCE mended oil. Apply the Yamaha foam air filter oil or other qual- • Generator ity foam air filter oil to the element. (Excess oil in Check for looseness in mounted areas of the the element may adversely affect engine start- generator rotor and the stator coil assembly.
Page 39: Torque-Check Points
TORQUE-CHECK POINTS EAM20125 TORQUE-CHECK POINTS Frame construction Fuel tank to frame Frame to rear frame Frame to engine protector Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Seat Seat to rear fender Steering Steering stem to handlebar Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar...
Page 40 TORQUE-CHECK POINTS Shift pedal Shift pedal to shift shaft Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of shroud Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake caliper cover Concerning the tightening torque, refer to “TIGHTENING TORQUES”...
Page 41: Motorcycle Care And Storage
MOTORCYCLE CARE AND STORAGE ly rinse the area off with water, immediately EAM20126 MOTORCYCLE CARE AND STOR- dry it, and then apply a corrosion protec- tion spray. • Improper cleaning can damage plastic parts (such as cowlings, panels, wind- EAM30200 CARE shields, headlight lenses, meter lenses, While the open design of a motorcycle reveals...
Page 42: 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 43 MOTORCYCLE CARE AND STORAGE stored. Long-term Before storing your motorcycle for several months: 1. Follow all the instructions in the “CARE” on page 1-29. 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 44 MOTORCYCLE CARE AND STORAGE 1-32...
Page 45: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS ................2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-5 ELECTRICAL SPECIFICATIONS..............2-8 TIGHTENING TORQUES..................2-9 GENERAL TIGHTENING TORQUE SPECIFICATIONS ......2-9 ENGINE TIGHTENING TORQUES ............2-10 CHASSIS TIGHTENING TORQUES ............2-13 CABLE ROUTING DIAGRAM ................2-17...
Page 46: General Specifications
GENERAL SPECIFICATIONS EAM20127 GENERAL SPECIFICATIONS Model Model BHR1 BHR5 Dimensions Overall length 2180 mm (85.8 in) Overall width 825 mm (32.5 in) Overall height 1275 mm (50.2 in) Seat height 965 mm (38.0 in) Wheelbase 1480 mm (58.3 in) Ground clearance 350 mm (13.78 in) Weight Curb weight...
Page 47: 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 48 ENGINE SPECIFICATIONS Exhaust 0.15–0.22 mm (0.0059–0.0087 in) Valve dimensions Valve seat contact width limit (intake) 1.5 mm (0.06 in) Valve seat contact width limit (exhaust) 1.5 mm (0.06 in) Valve stem diameter limit (intake) 5.445 mm (0.2144 in) Valve stem diameter limit (exhaust) 5.435 mm (0.2140 in) Valve guide inside diameter (intake) 5.500–5.512 mm (0.2165–0.2170 in)
Page 49 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 Maximum consumption amperage 2.4 A Fuel injector 12.0  Resistance...
Page 50 CHASSIS SPECIFICATIONS EAM20129 CHASSIS SPECIFICATIONS Chassis 26.9  Caster angle 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) Rear wheel...
Page 51 Fork spring free length 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) 476.0 cm³ (16.09 US oz, 16.79 Imp.oz) Quantity (right) 476.0 cm³ (16.09 US oz, 16.79 Imp.oz)
Page 52: Chassis Specifications
CHASSIS SPECIFICATIONS Adjustment value from the start position (Hard) Slow compression damping Unit for adjustment Click Adjustment value from the start position (Soft) Adjustment value from the start position (STD) Adjustment value from the start position (Hard) Drive chain Size Chain type Non-sealed type Number of links...
Page 53: Electrical Specifications
ELECTRICAL SPECIFICATIONS EAM20130 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system 8.0–12.0 /2000 r/min Ignition timing (B.T.D.C.) Engine control unit Model BHR0 Ignition coil 1.98–2.42  Primary coil resistance Secondary coil resistance 14.64–21.96 k Spark plug cap Resistance 10.00 k...
Page 54: 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 55: 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) Oil passage plug (cylinder head) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Cylinder head bolt...
Page 56 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 57 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Stopper lever bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) 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)
Page 58: 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 59 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Front brake disc bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) / 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) ...
Page 60 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size 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) Fuel tank bolt (front side) 8 N·m (0.8 kgf·m, 5.9 lb·ft) ...
Page 61 TIGHTENING TORQUES 2-16...
Page 62: Cable Routing Diagram
CABLE ROUTING DIAGRAM EAM20152 CABLE ROUTING DIAGRAM Frame and engine (front left side view) 5, A 4, A 17, K 5, A 4, A 20, L 9, C 15, I 14, H 12, G 11, N 12, N 1, M 2-17...
Page 63 CABLE ROUTING DIAGRAM L. When fastening the starter motor lead with 1. Clutch cable the clamp, close the clamp while applying 2. Throttle cable (return) tension to the starter motor lead so that the 3. Throttle cable (pull) starter motor lead has no slack. 4.
Page 64 CABLE ROUTING DIAGRAM Frame (rear left side view) 5, B 3, A 6, C 10, D 11, E 12, F 2-19...
Page 65 CABLE ROUTING DIAGRAM 1. Wire harness 2. Rear frame 3. Plastic locking tie 4. Starter relay coupler (black, 4-pin) 5. Starter motor lead 6. Positive battery lead 7. Negative battery lead 8. CCU (Communication Control Unit) 9. Rear fender (projection) 10.Starter relay 11.Starter relay cover 12.CCU coupler...
Page 66 CABLE ROUTING DIAGRAM Frame and engine (right side view) 1, A 2, C 4, D 6, E 2-21...
Page 67 CABLE ROUTING DIAGRAM 1. Fuel pump coupler (black, 5-pin) 2. Coolant temperature sensor coupler (black, 2-pin) 3. Upper radiator boss 4. Throttle position sensor coupler (black, 3-pin) 5. Lower radiator boss 6. Radiator breather hose 7. Radiator hose 8. CCU (Communication Control Unit) 9.
Page 68 CABLE ROUTING DIAGRAM Handlebar (front view) 1, A 2, B 5, D 10, G 7, E 7, E 2-23...
Page 69 CABLE ROUTING DIAGRAM 1. Throttle cable 2. Start switch lead 3. Handlebar switch lead (left) 4. Clutch cable 5. Front brake hose 6. Number plate 7. Plastic locking tie 8. Handlebar protector 9. Upper bracket 10.Protector A. Route the throttle cable on the right side of the number plate mounting bracket.
Page 70 CABLE ROUTING DIAGRAM Frame and engine (top view) 1, A 10, F 2-25...
Page 71 CABLE ROUTING DIAGRAM 1. Ignition coil lead 2. Coolant temperature sensor lead 3. Engine ground lead 4. Cylinder head breather hose 5. Intake air pressure sensor coupler (dark blue, 3-pin) 6. Fuel injector coupler (gray, 2-pin) 7. Intake air temperature sensor coupler (black, 2-pin) 8.
Page 72 CABLE ROUTING DIAGRAM Frame and battery (top view) 6, D 3, C 4, E 3, A 2-27...
Page 73 CABLE ROUTING DIAGRAM 1. ECU lead 2. Battery 3. Positive battery lead 4. Negative battery lead 5. CCU (Communication Control Unit) 6. ECU (Engine Control Unit) 7. Rear frame A. Route the positive battery lead under the vehicle’s negative battery lead. B.
Page 74 CABLE ROUTING DIAGRAM Rear brake (right side view) C C C 2-29...
Page 75 CABLE ROUTING DIAGRAM 1. Protector 2. Rear brake caliper 3. Bleed screw 4. Rear brake hose 5. Brake pedal 6. Rear brake master cylinder assembly 7. Swingarm 8. Rear shock absorber assembly A. It does not matter whether the spring is installed upward or downward.
Page 76 CABLE ROUTING DIAGRAM 2-31...
Page 77: Periodic Checks And Adjustments
PERIODIC CHECKS AND ADJUSTMENTS SERVICING PARTS ..................3-1 MAINTENANCE INTERVALS ................3-2 MAINTENANCE INTERVALS..............3-2 PRE-OPERATION INSPECTION AND MAINTENANCE .........3-6 GENERAL INSPECTION AND MAINTENANCE ........3-6 ENGINE......................3-7 ADJUSTING THE VALVE CLEARANCE............3-7 VALVE CLEARANCE SHIM CHART ............3-10 CHECKING THE ENGINE IDLING SPEED..........3-12 CHECKING THE THROTTLE GRIP ............3-12 CHECKING THE SPARK PLUG...............3-13 CHECKING THE ENGINE OIL LEVEL .............3-13 CHANGING THE ENGINE OIL..............3-14...
Page 78 CHECKING AND TIGHTENING THE SPOKES ........3-34 CHECKING THE WHEELS ..............3-34 CHECKING THE WHEEL BEARINGS .............3-34 CHECKING THE CHASSIS FASTENERS ..........3-34 CHECKING AND LUBRICATING THE CABLES........3-34 LUBRICATING THE BRAKE LEVER ............3-35 LUBRICATING THE CLUTCH LEVER .............3-35 LUBRICATING THE PEDAL..............3-35 ELECTRICAL SYSTEM..................3-36 CHECKING AND CHARGING THE BATTERY ........3-36 CHECKING THE FUSES................3-36...
Page 79 ELEMENT, AIR CLEANER 5D3-13440-02 ELEMENT ASSY, OIL CLEANER BHR-27200-00 PEDAL, BRAKE 1C3-W0046-50 BRAKE PAD KIT 2 The part number is subject to change. In that case, order the part from a Yamaha dealer by stating the identification number of your vehicle.
Page 80: 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 81 MAINTENANCE INTERVALS Every Every Every After race third race fifth race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours) • Check the coolant passages for corrosion. • Inspect carbon deposits and elim-  11 * Cylinder head inate them.
Page 82 MAINTENANCE INTERVALS Every Every Every After race third race fifth race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours) • Clean.   • Inspect and adjust.     • Replace oil. 29 * Front fork leg(s) •...
Page 83 MAINTENANCE INTERVALS Every Every Every After race third race fifth race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours) Brake pedal, footrest • Lubricate.   • Retighten. Outside nuts and   43 * bolts •...
Page 84: 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 85: 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 86 ENGINE • 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. 5.
Page 87 ENGINE • Make sure that adjusting pads are installed with their numbers facing upward. f. Install the camshafts (exhaust and intake). Refer to “CAMSHAFT” on page 5-10. g. Measure the valve clearance again. h. If the valve clearance is out of specifica- tion, repeat adjusting the valve clearance until it is within specification.
Page 88: 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 89 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 90: Checking The Engine Idling Speed
2. Measure the coolant temperature using the Yamaha diagnostic tool. EAM30475 CHECKING THE THROTTLE GRIP Yamaha diagnostic tool USB (US) 90890-03269 Prior to adjusting throttle grip free play, the en- Yamaha diagnostic tool (A/I) gine idling speed should be adjusted.
Page 91: Checking The Spark Plug
ENGINE 4. Check: • Electrode Damage/wear  Replace the spark plug. • Insulator Abnormal color  Replace the spark plug. Normal color is medium-to-light tan. 5. Clean: • Spark plug (with a spark plug cleaner or a wire brush) 6. Measure: •...
Page 92: Changing The Engine Oil
ENGINE 4. Check: • Engine oil level Before checking the engine oil level, wait a few The engine oil level should be between the minutes until the oil has settled. minimum level (lower edge of the oil check window “1”) and the maximum level mark “a”. EAM30225 CHANGING THE ENGINE OIL Below the minimum level ...
Page 93: Adjusting The Clutch Lever Free Play
ENGINE b. Look at the oil level check window “1”, and then make sure that the engine oil flows and that the engine oil level decreases. Check the engine oil level while the engine is at idling speed. c. Install the new oil filter element and the oil filter element cover.
Page 94: Adjusting The Clutch Lever Position
ENGINE clutch lever free play is obtained. 2. Tighten: • Locknut Locknut (clutch lever position) 4.8 N·m (0.48 kgf·m, 3.5 lb·ft) EAM30219 CLEANING THE AIR FILTER ELEMENT 1. Remove: • Sub-seat Refer to “FUEL TANK CAP” on page 1-23. • Air filter case cover “1” If the clutch lever free play cannot be obtained To remove the air filter case cover: on the handlebar side, use the adjuster on the...
Page 95 “b” on the air filter el- NOTICE ement guide to the band “c”. Do not twist the element when squeezing the element. 4. Check: • Air filter element Damage  Replace. 5. Apply: • Yamaha foam air filter oil or other quality 3-17...
Page 96: Checking The Throttle Body Joint
ENGINE a a a b b b c c c c c c 3 3 3 7. Install: • Air filter case cover “1” • Fuel tank breather hose “2” (to the air filter case cover) • To install the air filter case cover: •...
Page 97: Checking The Cylinder Head Breather Hose
ENGINE • Shroud (left/right) 2. Remove: • Exhaust pipe protector Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank 3. Check: • Exhaust pipe 1 Refer to “FUEL TANK” on page 7-1. • Exhaust pipe 2 2. Check: • Fuel hose “1” •...
Page 98 ENGINE c. Replace the fiber inserts “5”. g. Install the fiber “10”. Stuff the fiber into the silencer body by using a flat board “11”. d. Install the fiber insert “6” to the part “b”. e. Twist the fiber insert “7” onto the inner pipe “c”.
Page 99: Checking The Coolant Level
ENGINE the beads of sealant. • Take care not to allow the fiber out of place 5 5 5 when installing the silencer body “17”. 8. Install: • Exhaust pipe protector Exhaust pipe protector screw 10 N·m (1.0 kgf·m, 7.4 lb·ft) 6.
Page 100: Checking The Cooling System
ENGINE be blown out, which could cause serious in- jury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter- clockwise toward the detent to allow any re- sidual pressure to escape.
Page 101 ENGINE EWA13040 WARNING • If coolant splashes in your eyes, thorough- ly wash them with water and consult a doc- tor. • If coolant splashes on your clothes, quickly wash it away with water and then with soap and water. •...
Page 102: Chassis
CHASSIS system. Air in the brake system will consid- EAM20136 CHASSIS erably reduce braking performance. ECA13490 EAM30479 ADJUSTING THE FRONT DISC BRAKE NOTICE After adjusting the brake lever position, There should be no free play at the brake lever make sure there is no brake drag. end.
Page 103: Checking The Front Brake Pads
CHASSIS Specified brake fluid DOT 4 a a a EAM30232 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads. A. Front brake 1. Operate the brake. B. Rear brake 2. Check: • Rear brake pad EWA13090 Wear indicator grooves “1”...
Page 104: Checking The Rear Brake Hose
CHASSIS • Protector (rear brake) • Be careful not to spill any brake fluid or allow the reservoir to overflow. • Make sure that there is enough brake fluid be- fore applying the brake. Ignoring this precau- a a a tion could allow air to enter the brake system, considerably lengthening the bleeding proce- dure.
Page 105: Drive Chain Slack
CHASSIS to fully extend. 4. Check: • Drive chain slack “a” g. Tighten the bleed screw and then release Out of specification  Regulate. the brake lever or brake pedal. h. Repeat steps (d) to (g) until all of the air Measure drive chain slack between the drive bubbles have disappeared from the brake chain guide and the bottom of the chain as...
Page 106: Checking And Adjusting The Steering Head
CHASSIS Wheel axle nut 135 N·m (13.5 kgf·m, 100 lb·ft) e. Tighten the drive chain puller locknut. Drive chain puller locknut 21 N·m (2.1 kgf·m, 15 lb·ft) EAM30247 CHECKING AND ADJUSTING THE STEERING HEAD 1. Use a maintenance stand to raise the front Steering nut wrench wheel off the ground.
Page 107: Lubricating The Steering Head
CHASSIS of the outer tube circumference. 5. Install: • Upper bracket 6. Remove: Refer to “STEERING HEAD” on page 4-58. • Protector • Handlebar • Dust seal “1” Refer to “HANDLEBAR” on page 4-39. ECA24330 NOTICE EAM30502 Be careful not to damage the dust seal and LUBRICATING THE STEERING HEAD the inner tube by a driver.
Page 108 CHASSIS have poor stability. Compression damping • Securely support the vehicle so that there ECA24350 NOTICE is no danger of it falling over. Do not turn the adjuster forcibly beyond its Rebound damping adjusting range. ECA24340 NOTICE 1. Adjust: Do not turn the adjuster forcibly beyond its •...
Page 109: Checking The Rear Shock Absorber Assembly
CHASSIS EWA13120 EWA13120 WARNING WARNING Securely support the vehicle so that there is Securely support the vehicle so that there is no danger of it falling over. no danger of it falling over. 2. Remove the bleed screw “1” and release the Spring preload internal pressure from the front fork.
Page 110 CHASSIS • The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjusting ring. Compression damping (for fast compres- sion damping) e. Tighten the locknut. ECA24370 NOTICE Rebound damping Do not turn the adjuster forcibly beyond its ECA24370 adjusting range.
Page 111: Checking The Swingarm Operation
CHASSIS 1 1 1 1 1 1 Compression damping (for slow compres- EAM30240 CHECKING THE SWINGARM OPERATION sion damping) 1. Check: ECA24390 • Swingarm smooth action NOTICE • Swingarm free play Do not turn the adjuster forcibly beyond its adjusting range. Refer to “SWINGARM”...
Page 112: Checking And Tightening The Spokes
CHASSIS rect the tire position. Spoke 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) • Do not give a half turn (180) or more for one tightening. • Make sure that tightening after a break-in is done until the initial looseness in nipples disap- pears.
Page 113: Lubricating The Brake Lever
CHASSIS Recommended lubricant Engine oil or a suitable cable lu- bricant Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit- able lubricating device. EAM30483 LUBRICATING THE BRAKE LEVER 1. Lubricate the pivoting points and metal-to- metal moving parts of the following parts.
Page 114: Electrical System
ELECTRICAL SYSTEM EAM20137 ELECTRICAL SYSTEM EAM30256 CHECKING AND CHARGING THE BATTERY Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-47. EAM30505 CHECKING THE FUSES Refer to “CHECKING THE FUSES” on page 8-47. 3-36...
Page 115 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE SEAT................4-4 REMOVING THE NUMBER PLATE ............4-4 INSTALLING THE SHROUD ..............4-4 REMOVING THE SIDE COVER ..............4-5 INSTALLING THE SIDE COVER ...............4-5 FRONT WHEEL ....................4-6 REMOVING THE FRONT WHEEL .............4-8 DISASSEMBLING THE FRONT WHEEL ...........4-8 CHECKING THE FRONT WHEEL .............4-8 ASSEMBLING THE FRONT WHEEL ............4-8 INSTALLING THE FRONT WHEEL ............4-9 REAR WHEEL ....................4-11...
Page 116 INSTALLING THE REAR BRAKE MASTER CYLINDER ......4-37 HANDLEBAR....................4-39 REMOVING THE HANDLEBAR ...............4-41 CHECKING THE HANDLEBAR..............4-41 INSTALLING THE HANDLEBAR..............4-41 FRONT FORK....................4-46 REMOVING THE FRONT FORK LEGS ...........4-48 DISASSEMBLING THE FRONT FORK LEGS .........4-48 CHECKING THE FRONT FORK LEGS............4-49 ASSEMBLING THE FRONT FORK LEGS ..........4-50 INSTALLING THE FRONT FORK LEGS..........4-56 STEERING HEAD...................4-58 REMOVING THE LOWER BRACKET ............4-60...
Page 117 GENERAL CHASSIS EAM20094 GENERAL CHASSIS Removing the seat and battery 13 N ・ m (1.3 kgf ・ m, 9.6 lb ・ ft) 13 N ・ m (1.3 kgf ・ m, 9.6 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 7 N ・...
Page 118 GENERAL CHASSIS Removing the side cover 13 N ・ m (1.3 kgf ・ m, 9.6 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 16 N ・...
Page 119 GENERAL CHASSIS Removing the shroud 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・...
Page 120: General Chassis
GENERAL CHASSIS EAM30016 REMOVING THE SEAT 2 2 2 The sub-seat and the seat are coupled with each other with a plastic band. When removing the seat, always remove the sub-seat beforehand. 1. Remove: a a a • Sub-seat “1” Refer to “FUEL TANK CAP”...
Page 121: 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 122: Front Wheel
FRONT WHEEL EAM20095 FRONT WHEEL Removing the front wheel 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 115 N ・ m (11.5 kgf ・ m, 85 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Use a maintenance stand to raise the front wheel off the ground.
Page 123 FRONT WHEEL Disassembling the front wheel 0 mm (0 in) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Oil seal Bearing Brake disc...
Page 124: Removing The Front Wheel
FRONT WHEEL 3. Check: EAM30017 REMOVING THE FRONT WHEEL • Spoke 1. Use a maintenance stand to raise the front Refer to “CHECKING AND TIGHTENING wheel off the ground. THE SPOKES” on page 3-34. EWA13120 4. Tighten: WARNING • Spoke Securely support the vehicle so that there is Refer to “CHECKING AND TIGHTENING no danger of it falling over.
Page 125: Installing The Front Wheel
FRONT WHEEL • Left side of bearing shall be installed first. 3. Install: • Install the oil seal with its manufacture’s marks • Collar “1” or numbers facing outward. Apply the lithium-soap-based grease on the oil ECA24420 seal lip. NOTICE Install the bearing by pressing its outer race parallel.
Page 126 FRONT WHEEL Front wheel axle nut 115 N·m (11.5 kgf·m, 85 lb·ft) 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. 4. Tighten: • Front wheel axle pinch bolt “1” Front wheel axle pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) 4-10...
Page 127 REAR WHEEL EAM20096 REAR WHEEL Removing the rear wheel 135 N ・ m (13.5 kgf ・ m, 100 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 128 REAR WHEEL Disassembling the rear wheel 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 42 N ・ m (4.2 kgf ・ m, 31 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Rear wheel sprocket Oil seal [“a”...
Page 129: Rear Wheel
REAR WHEEL Refer to “CHECKING THE TIRES” on page EAM30022 REMOVING THE REAR WHEEL 3-33 and “CHECKING THE WHEELS” on 1. Use a maintenance stand to raise the rear page 3-34. wheel off the ground. 3. Check: EWA13120 • Spoke WARNING Refer to “CHECKING AND TIGHTENING Securely support the vehicle so that there is...
Page 130: Assembling The Rear Wheel
REAR WHEEL • Brake disc bolt Rear wheel sprocket self-locking Brake disc bolt 42 N·m (4.2 kgf·m, 31 lb·ft) 12 N·m (1.2 kgf·m, 8.9 lb·ft) LOCTITE® Tighten the self-locking nuts in stages and in a crisscross pattern. Tighten the bolts in stages and in a crisscross pattern.
Page 131 REAR WHEEL Refer to “DRIVE CHAIN SLACK” on page 3-27. 3. Install: • Drive chain puller (left) “1” • Rear wheel axle “2” 6. Tighten: • Rear wheel axle nut “1” • Install the drive chain puller (left), and insert the Rear wheel axle nut rear wheel axle from the left side.
Page 132 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) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 1.0 mm (0.04 in) 17 N ・...
Page 133: Front Brake
FRONT BRAKE Disassembling the front brake caliper 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw 4-17...
Page 134 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) 30 N ・...
Page 135 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit 4-19...
Page 136: Introduction
FRONT BRAKE b. Remove the brake caliper. EAM30028 INTRODUCTION c. Hold the dial gauge at a right angle against EWA19210 the brake disc surface. WARNING d. Measure the runout 1.5 mm (0.06 in) If you need to disassemble the disc brake above the brake disc edge.
Page 137 FRONT BRAKE d. Install the brake pads “3” and the pad pin. • Install the brake pads with their projections “a” into the brake caliper recesses “b”. • Temporarily tighten the pad pin at this point. 2. Measure: • Brake pad wear limit “a” Out of specification ...
Page 138: Removing The Front Brake Caliper
FRONT BRAKE 5. Check: • Brake lever operation A softy or spongy feeling  Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-26. EAM30030 REMOVING THE FRONT BRAKE CALIPER Before disassembling the brake caliper, drain the brake fluid from the entire brake system.
Page 139: Installing The Front Brake Caliper
FRONT BRAKE cleaning and lubricating. Brake pad pin • Never use solvents on internal brake com- 17 N·m (1.7 kgf·m, 13 lb·ft) ponents as they will cause the piston seals Brake pad pin plug to swell and distort. 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) •...
Page 140: Removing The Front Brake Master Cylinder
FRONT BRAKE 5. Bleed: 2. Check: • Brake system • Brake master cylinder reservoir cap Damage/scratches/wear  Replace. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-26. 3. Check: 6. Check: • Brake hose Cracks/damage/wear  Replace. • Brake fluid level The minimum level mark or below ...
Page 141: Installing The Front Brake Master Cylinder
FRONT BRAKE EAM30039 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Brake master cylinder “1” Brake master cylinder holder bolt 9 N·m (0.9 kgf·m, 6.6 lb·ft) • Install the front brake master cylinder holder with the “UP” mark facing up. 3.
Page 142 FRONT BRAKE sure that the brake hose does not touch other BRAKE SYSTEM” on page 3-26. parts (e.g., wire harness, cables, leads). Adjust if necessary. 3. Pour brake fluid to the brake master cylinder reservoir up to the specified level. Specified brake fluid DOT 4 EWA13090...
Page 143: Rear Brake
REAR BRAKE EAM20098 REAR BRAKE Removing the rear brake caliper 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 13 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 1.0 mm (0.04 in) 7 N ・...
Page 144 REAR BRAKE Disassembling the rear brake caliper 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw 4-28...
Page 145 REAR BRAKE Removing the rear brake master cylinder 5 mm (0.20 in) 5 mm (0.20 in) 5 mm (0.20 in) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 10 N ・...
Page 146 REAR BRAKE Removing the rear brake master cylinder 5 mm (0.20 in) 5 mm (0.20 in) 5 mm (0.20 in) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 10 N ・...
Page 147 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder joint Brake master cylinder kit 4-31...
Page 148: 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 4. Replace: components, observe the following precau- • Brake disc tions. Refer “ASSEMBLING REAR •...
Page 149 REAR BRAKE Bleed screw 5 N·m (0.5 kgf·m, 3.7 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 150: 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 151: Assembling The Rear Brake Caliper
REAR BRAKE 2. Check: • Brake caliper bracket Crack/damage  Replace. EAM30045 ASSEMBLING THE REAR BRAKE CALIPER EWA19280 WARNING a a a • Before installation, clean and lubricate the internal parts. Use new brake fluid for cleaning and lubricating. 3. Install: •...
Page 152: Removing The Rear Brake Master Cylinder
REAR BRAKE The minimum level mark or below  Add. 3. Check: • Brake hose Refer to “CHECKING THE BRAKE FLUID Cracks/damage/wear  Replace. LEVEL” on page 3-24. 7. Check: EAM30050 • Brake pedal operation ASSEMBLING THE REAR BRAKE MASTER A softy or spongy feeling ...
Page 153: Installing The Rear Brake Master Cylinder
REAR BRAKE ECA24500 NOTICE Install the spring with a smaller inside diameter Make sure that the pipe portion of the brake to the brake master cylinder piston. hose touches the projection “a” on the brake caliper. 4. Install: • Brake master cylinder piston assembly “1” 2.
Page 154 REAR BRAKE system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-26. 4-38...
Page 155 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) 28 N ・...
Page 156 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) 28 N ・...
Page 157: Removing The Handlebar
HANDLEBAR EAM30052 EWA13120 REMOVING THE HANDLEBAR WARNING 1. Stand the vehicle upright on a level surface. Securely support the vehicle so that there is EWA13120 no danger of it falling over. WARNING 2. Install: Securely support the vehicle so that there is •...
Page 158 HANDLEBAR A. Routing when installing the damper and lower handlebar in the rear holes B. Routing when installing the damper and lower handlebar in the front holes 3. Tighten: • Lower handlebar holder nut Lower handlebar holder nut 40 N·m (4.0 kgf·m, 30 lb·ft) 4.
Page 159 HANDLEBAR 5. Install: • Handlebar switch (left) “1” • Clamp “2” Handlebar switch (left) 1.3 N·m (0.13 kgf·m, 0.95 lb·ft) • The handlebar switch (left) “1” should be in- stalled according to the dimensions shown. • Pass the handlebar switch lead (left) through 8.
Page 160 HANDLEBAR Apply the lithium-soap-based grease on the throttle grip sliding surface. 11.Install: • Throttle cable “1” Slightly coat the end of throttle cable and inside of throttle grip with lithium-soap-based grease. Then, mount the throttle grip onto the handlebar. 13.Install: •...
Page 161 HANDLEBAR 0 mm (0 in) 3 mm (0.12 in) 15.Adjust: • Throttle grip free play Refer to “CHECKING THE THROTTLE GRIP” on page 3-12. Throttle grip free play 3.0–6.0 mm (0.12–0.24 in) 4-45...
Page 162: 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) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・...
Page 163 FRONT FORK Disassembling the front fork leg 29 N ・ m (2.9 kgf ・ m, 21 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 0.6 N ・ m (0.06 kgf ・ m, 0.44 lb ・ ft) 28 N ・...
Page 164: Removing The Front Fork Legs
FRONT FORK • Hold the locknut and remove the adjuster. EAM30055 REMOVING THE FRONT FORK LEGS 1. Use a maintenance stand to raise the front ECA24520 NOTICE wheel off the ground. Do not remove the locknut as the damper rod EWA13120 may go into the damper assembly and not be WARNING...
Page 165: Checking The Front Fork Legs
FRONT FORK Inner tube bending limit 0.2 mm (0.01 in) The bending value is shown by one half of the dial gauge reading. EWA13650 WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 5.
Page 166: Assembling The Front Fork Legs
1. Stretch the damper assembly fully. 2. Fill: • Damper assembly Recommended oil 6. Check: Yamaha Suspension Oil S1 • Upper spring seat “1” Standard oil amount 216 cm³ (7.30 US oz, 7.62 Imp.oz) (contacting surface “a”) Wear/damage  Replace.
Page 167 FRONT FORK 4. Measure: 6. Install: • Oil level (left and right) “a” • Base valve “1” Out of specification  Regulate. (to the damper assembly “2”) Standard oil level First bring the damper rod pressure to a maxi- 145–148 mm (5.71–5.83 in) mum.
Page 168 FRONT FORK 9. After filling, pump the damper assembly “1” 12.Check: slowly up and down more than 10 times to • Damper assembly smooth movement Tightness/binding/rough spots  Repeat the distribute the fork oil. steps (1) to (12). 10.While protecting the damper assembly “1” with a cloth and compressing fully, allow ex- 13.Install: •...
Page 169 FRONT FORK 14.Install: • Piston metal “1” Install the piston metal onto the slot on inner tube. 17.Install: • Oil seal “1” Using a fork seal driver “2”, press the oil seal in until the stopper ring groove fully appears. 15.Install: Fork seal driver •...
Page 170 FRONT FORK 19.Install: 22.Install: • Dust seal “1” • Upper spring seat “1” • Fork spring “2” (to the damper assembly “3”) Apply lithium-soap-based grease on the inner tube. Install the upper spring seat with its larger dia. end “a” facing the fork spring. 20.Check: •...
Page 171 FRONT FORK • Unless the damping force adjuster is fully loos- correct damping force cannot be obtained. ened, correct damping characteristic cannot be obtained after installation. 27.Tighten: • Adjuster (damper assembly) “1” 25.Install: Adjuster (damper assembly) • Damper adjusting rod “1” 29 N·m (2.9 kgf·m, 21 lb·ft) •...
Page 172: Installing The Front Fork Legs
FRONT FORK Recommended oil Yamaha Suspension Oil S1 Standard oil amount 270 cm³ (9.13 US oz, 9.52 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...
Page 173 FRONT FORK • Front fork protector bolt “2” Front fork protector bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) 3. Adjust: • Front fork top end “a” Front fork top end (standard) “a” 7 mm (0.28 in) 6. Adjust: • Rebound damping force Turn in the damping adjuster “1”...
Page 174: 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) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 38 N ・...
Page 175 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) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 38 N ・...
Page 176: 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 177 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 178 STEERING HEAD Upper bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) • Lower bracket pinch bolt “2” Lower bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) EWA19330 WARNING Tighten the lower bracket to specified 8. Install: torque. If torqued too much, it may cause the •...
Page 179: 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) 53 N ・ m (5.3 kgf ・ m, 39 lb ・ ft) Order Job/Parts to remove Q’ty Remarks...
Page 180 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 56 N ・ m (5.6 kgf ・ m, 41 lb ・ ft) 53 N ・ m (5.3 kgf ・ m, 39 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Lower spring guide Upper spring guide Spring...
Page 181 REAR SHOCK ABSORBER ASSEMBLY Disassembling the relay arm 0 mm (0 in) 0 mm (0 in) 80 N ・ m (8.0 kgf ・ m, 59 lb ・ ft) 0 mm (0 in) 0 mm (0 in) Order Job/Parts to remove Q’ty Remarks Relay arm...
Page 182: 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 183: 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. 3. Check: •...
Page 184: Installing The Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY EAM30070 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: • Bearing (lower side) • Dust seal Recommended lubricant Molybdenum disulfide grease ECA24580 NOTICE 5. Lubricate: Do not apply the grease to the bearing outer • Connecting arm and frame bolt race because it will wear the rear shock ab- •...
Page 185 REAR SHOCK ABSORBER ASSEMBLY • Rear shock absorber assembly lower nut Rear shock absorber assembly lower nut 53 N·m (5.3 kgf·m, 39 lb·ft) 4-69...
Page 186: Swingarm
SWINGARM EAM20103 SWINGARM Removing the swingarm 70 N ・ m (7.0 kgf ・ m, 52 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 0–0.5 mm (0–0.02 in) 0–0.5 mm...
Page 187 SWINGARM Removing the swingarm 70 N ・ m (7.0 kgf ・ m, 52 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 0–0.5 mm (0–0.02 in) 0–0.5 mm...
Page 188: Removing The Swingarm
SWINGARM • Bearing EAM30071 REMOVING THE SWINGARM 4. Check: 1. Use a maintenance stand to raise the rear • Oil seal wheel off the ground. Damage  Replace. EWA13120 • Bearing WARNING • Bushing Securely support the vehicle so that there is Free play exists/unsmooth revolution/rust ...
Page 189 SWINGARM 5. Install: 3. Install: • Rear wheel • Swingarm Refer to “REAR WHEEL” on page 4-11. 6. Adjust: Pivot shaft nut • Drive chain slack 75 N·m (7.5 kgf·m, 55 lb·ft) Refer to “DRIVE CHAIN SLACK” on page 3-27. •...
Page 190: Chain Drive
CHAIN DRIVE EAM20104 CHAIN DRIVE Removing the drive chain 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 90 N ・ m (9.0 kgf ・ m, 66 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Drive chain Drive sprocket cover Drive sprocket nut Lock washer...
Page 191: Removing The Drive Chain
CHAIN DRIVE EAM30075 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Master link clip • Master link “1” •...
Page 192: Checking The Drive Sprocket
CHAIN DRIVE G089069 5. Lubricate: • Drive chain EAM30077 CHECKING THE DRIVE SPROCKET 1. Check: • Drive sprocket More than 1/4 tooth wear “a”  Replace the drive sprocket and the rear wheel sprocket as a set. G089070 Bent tooth  Replace the drive sprocket and 2.
Page 193 CHAIN DRIVE 3-27. Drive chain slack (Maintenance Stand) 50.0–60.0 mm (1.97–2.36 in) ECA24590 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.
Page 194 CHAIN DRIVE 4-78...
Page 195: Engine
ENGINE LUBRICATION SYSTEM CHART AND DIAGRAMS ........5-1 ENGINE OIL LUBRICATION CHART............5-1 ENGINE REMOVAL ..................5-2 REMOVING THE ENGINE .................5-7 INSTALLING THE ENGINE ................5-7 INSTALLING THE EXHAUST PIPE AND MUFFLER .........5-8 CAMSHAFT ....................5-10 REMOVING THE CAMSHAFT ..............5-12 CHECKING THE CAMSHAFT ..............5-12 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET...5-13 CHECKING THE TIMING CHAIN TENSIONERS........5-14 CHECKING THE DECOMPRESSION SYSTEM ........5-14 INSTALLING THE CAMSHAFTS .............5-14...
Page 196 CLUTCH......................5-44 REMOVING THE CLUTCH ..............5-48 CHECKING THE FRICTION PLATES ............5-48 CHECKING THE CLUTCH PLATES ............5-48 CHECKING THE CLUTCH SPRING ............5-48 CHECKING THE COLLAR ...............5-49 CHECKING THE PRESSURE PLATE .............5-49 CHECKING THE PUSH LEVER SHAFT ..........5-49 CHECKING THE PUSH ROD..............5-49 CHECKING THE PRIMARY DRIVE GEAR ..........5-49 CHECKING THE PRIMARY DRIVEN GEAR..........5-49 ASSEMBLING THE CLUTCH RELEASE ..........5-50 INSTALLING THE CLUTCH RELEASE ...........5-50...
Page 197: 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 nozzle 5. Oil filter element 6. Relief valve 7. Oil feed pump 8. Scavenging pump 9.
Page 198: Engine Removal
ENGINE REMOVAL EAM20105 ENGINE REMOVAL Removing the exhaust pipe 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 20 N ・ m (2.0 kgf ・ m, 15 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・...
Page 199 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 200 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 Rectifier/regulator Stator coil assembly coupler Disconnect.
Page 201 ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 75 N ・ m (7.5 kgf ・ m, 55 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 7 N ・...
Page 202 ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 75 N ・ m (7.5 kgf ・ m, 55 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 7 N ・...
Page 203: 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 swingarm will come loose.
Page 204: 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. • Apply lithium-soap-based grease onto the threads and contact surface of the pivot shaft nut. 2. Install: •...
Page 205 ENGINE REMOVAL 4. Tighten: • Exhaust pipe bracket bolt Exhaust pipe bracket bolt 20 N·m (2.0 kgf·m, 15 lb·ft) • Exhaust pipe 2 clamp Exhaust pipe clamp bolt (exhaust pipe 2 clamp) 12 N·m (1.2 kgf·m, 8.9 lb·ft) • Silencer clamp Exhaust pipe clamp bolt (silencer clamp) 12 N·m (1.2 kgf·m, 8.9 lb·ft)
Page 206: Camshaft
CAMSHAFT EAM20106 CAMSHAFT Removing the cylinder head cover 13 N ・ m (1.3 kgf ・ m, 9.6 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 0–1.0 mm (0–0.04 in) * Three bond No.
Page 207 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 208: Removing The Camshaft
CAMSHAFT EAM30080 REMOVING THE CAMSHAFT 1. Remove: • Timing mark accessing screw “1” • Crankshaft end accessing screw “2” 4. Remove: • Camshaft cap bolt “1” • Camshaft cap “2” Remove the camshaft cap bolts in a crisscross 2. Align: pattern, working from the outside in.
Page 209: Checking The Timing Chain And Camshaft Sprocket
CAMSHAFT place the camshaft. d. Remove the camshaft caps and then mea- 2. Measure: sure the width of the Plastigauge® “1”. • Camshaft lobe dimensions “A” Out of specification  Replace the camshaft. 1 1 1 Camshaft lobe dimensions Lobe height limit (Intake) 38.030 mm (1.4972 in) Lobe height limit (Exhaust) 34.170 mm (1.3453 in)
Page 210: Checking The Timing Chain Tensioners
CAMSHAFT EAM30084 CHECKING THE DECOMPRESSION SYSTEM 1. Check: • Decompression system a. Check that the decompressor cam “1” moves smoothly. b. Check that the decompressor lever pin “2” projects from the camshaft. a. 1/4 tooth b. Correct 1. Timing chain roller 2.
Page 211 CAMSHAFT c. Fit the timing chain “3” onto both camshaft with your fingers, use a thin screwdriver to sprockets and install the camshafts on the wind the tensioner rod up fully clockwise. cylinder head. Check that the alignment marks “c” on the cam- shaft sprockets are aligned with the edge of the camshaft cap surfaces “d”.
Page 212 CAMSHAFT Align with the crankcase alignment mark. • Camshaft match marks Align with the cylinder head surface. Out of alignment  Adjust. 5. Install: • Timing chain guide (top side) “1” • Cylinder head cover gasket “2” • Gasket (spark plug hole) “3” •...
Page 213: Cylinder Head
CYLINDER HEAD EAM20107 CYLINDER HEAD Removing the cylinder head 36 N ・ m (3.6 kgf ・ m, 27 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 18 N ・ m (1.8 kgf ・ m, 13 lb ・ ft) 90˚...
Page 214 CYLINDER HEAD Removing the cylinder head 36 N ・ m (3.6 kgf ・ m, 27 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 18 N ・ m (1.8 kgf ・ m, 13 lb ・ ft) 90˚...
Page 215: Removing The Cylinder Head
CYLINDER HEAD Refer to “CHECKING THE VALVE SEATS” on EAM30086 REMOVING THE CYLINDER HEAD page 5-26. 1. Remove: • Cylinder head coolant passages • Cylinder head bolt Mineral deposits/rust  Eliminate. 3. Measure: • Loosen the bolts in the proper sequence as •...
Page 216 CYLINDER HEAD 2. Install: • Washer “1” • Bolt “2” • Bolt “3” f. Remove the bolt [1]. Remove the bolt [1] only without loosening any other bolt. Tighten the bolts using the following procedure. g. Again apply molybdenum disulfide grease to the thread and contact surface of the a.
Page 217 CYLINDER HEAD 90˚ Bolt [1] Specified angle 90 k. Perform the same procedure with the bolts [2]–[4] one by one and applying the tight- ening sequence (f)–(j) as shown for the bolt [1]. Do not loosen any other bolt until one bolt is completely tightened.
Page 218: Valves And Valve Springs
VALVES AND VALVE SPRINGS EAM20108 VALVES AND VALVE SPRINGS Removing the valves and valve springs 13.5–13.9 mm 12.2–12.6 mm (0.53–0.55 in) (0.48–0.50 in) Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-17. Valve lifter Adjusting pad Valve cotter Valve spring retainer...
Page 219 VALVES AND VALVE SPRINGS Removing the valves and valve springs 9 9 9 13.5–13.9 mm 12.2–12.6 mm (0.53–0.55 in) (0.48–0.50 in) Order Job/Parts to remove Q’ty Remarks Valve stem seal Valve spring seat Intake valve Exhaust valve Intake valve guide Exhaust valve guide 5-23...
Page 220: Removing The Valves
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 221: Checking The Valves And Valve Guides
VALVES AND VALVE SPRINGS head to 100 °C (212 °F) in an oven. a. Remove the valve guide with the valve guide remover “1”. EAM30091 CHECKING THE VALVES AND VALVE GUIDES 1. Measure: b. Install the new valve guide with the valve •...
Page 222: Checking The Valve Seats
VALVES AND VALVE SPRINGS 3. Measure: Valve guide remover & installer • Valve seat contact width “a” set (ø5.5) Out of specification  Replace the cylinder 90890-04016 head. Valve guide remover (5.5 mm) YM-01122 Valve seat contact width limit (in- Valve guide installer (ø5.5) take) 90890-04015...
Page 223: Checking The Valve Springs
VALVES AND VALVE SPRINGS 4. Lap: • Valve face • Valve seat ECA24640 NOTICE This model uses titanium intake and exhaust valves. Do not use the valves used for lapping the valve seat. Always replace the valves used for lapping with new ones. h.
Page 224: Checking The Valve Lifters
VALVES AND VALVE SPRINGS (to the cylinder head) EAM30094 CHECKING THE VALVE LIFTERS 1. Check: • Make sure each valve is installed in its original • Valve lifter place. Damage/scratches  Replace the valve lift- • Install the valve springs with the larger pitch “a” ers and cylinder head.
Page 225 VALVES AND VALVE SPRINGS could damage the valve. 6. Lubricate: • Adjusting pad “1” • Valve lifter “2” 7. Install: • Adjusting pad • Valve lifter • Check that the valve lifter turns smoothly when rotated with your finger. • Make sure that the valve lifter and the adjusting pad are reinstalled in their original positions.
Page 226: 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) Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-17. Cylinder body Gasket Dowel pin Piston pin clip...
Page 227: 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 228: 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 229: Checking The Piston Pin
CYLINDER AND PISTON EAM30100 INSTALLING THE PISTON AND CYLINDER 1. Install: • Oil ring expander “1” • Lower oil ring rail “2” • Upper oil ring rail “3” • 2nd ring “4” • Top ring “5” Be sure to install the piston rings so that the manufacturer’s marks or numbers face up.
Page 230 CYLINDER AND PISTON (exhaust side) through the timing chain cavity. 3. Lubricate: • Piston • Piston ring • Cylinder 4. Offset: • Piston ring end gap 1 1 5 a. Top ring b. 2nd ring c. Upper oil ring rail d.
Page 231: Generator
10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 65 N ・ m (6.5 kgf ・ m, 48 lb ・ ft) * Yamaha bond No. 1215 (Three bond No. 1215®) Order Job/Parts to remove Q’ty...
Page 232 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 65 N ・ m (6.5 kgf ・ m, 48 lb ・ ft) * Yamaha bond No. 1215 (Three bond No. 1215®) Order Job/Parts to remove Q’ty...
Page 233 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 65 N ・ m (6.5 kgf ・ m, 48 lb ・ ft) * Yamaha bond No. 1215 (Three bond No. 1215®) Order Job/Parts to remove Q’ty...
Page 234: Removing The Generator
• Pass the stator coil assembly lead through the 1. Check: crankcase cover side. • Generator rotor “1” inner surface “a” • Stator coil assembly “2” outer surface “b” Yamaha bond No. 1215 Damage  Inspect the crankshaft runout and 90890-85505 crankshaft bearing. Three bond No. 1215®...
Page 235 GENERATOR 2. Install: • Woodruff key “1” Tighten the bolts in stages and in a crisscross • Generator rotor “2” pattern. • Clean the contact surfaces of the tapered por- tions of the crankshaft and generator rotor. • When installing the woodruff key, make sure that its flat surface “a”...
Page 236: Electric Starter
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 237 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) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 238: Checking The Starter Motor
ELECTRIC STARTER EAM30106 CHECKING THE STARTER MOTOR Brush overall length limit 5.5 mm (0.22 in) 1. Check: • Commutator Dirt  Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification  Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator.
Page 239 ELECTRIC STARTER tion “a” facing the groove “b” of the starter motor yoke. 3. Install: • Circlip • Plain washer • O-ring • Washer (starter motor front cover) • Starter motor front cover “1” Align the match mark “a” on the starter motor yoke with the match mark “b”...
Page 240 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) Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-14.
Page 241 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) Order Job/Parts to remove Q’ty Remarks Clutch plate 2 [Thickness: 1.0 mm (0.04 in)] Blue paint on the outer circumference of the Friction plate 2 pawls.
Page 242 CLUTCH Removing the crankcase cover (right) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 0 mm (0 in) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Right engine guard Refer to “ENGINE REMOVAL”...
Page 243 CLUTCH Removing the clutch release 0.1–0.6 mm (0.004–0.024 in) 0–0.5 mm (0–0.002 in) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Drive sprocket cover Refer to “CHAIN DRIVE” on page 4-74. Push lever shaft Clutch release Oil seal...
Page 244: Clutch
CLUTCH EAM30108 REMOVING THE CLUTCH Friction plate 1 thickness 2.12–2.28 mm (0.083–0.090 in) 1. Straighten the clutch boss nut rib “a”. Wear limit 2.02 mm (0.080 in) Friction plate 2 thickness 2.12–2.28 mm (0.083–0.090 in) Wear limit 2.02 mm (0.080 in) EAM30110 CHECKING THE CLUTCH PLATES 1.
Page 245: Checking The Collar
CLUTCH EAM30484 CHECKING THE PUSH ROD 1. Check: • Push rod 1 “1” • Bearing “2” • Ball “3” • Push rod 2 “4” Cracks/damage/wear  Replace. EAM30629 CHECKING THE COLLAR 1. Check: • Collar “1” Damage/pitting/wear  Replace the collars as a set.
Page 246: Assembling The Clutch Release
CLUTCH Pitting on the primary driven gear dogs will cause erratic clutch operation. 2. Install: • Push rod 2 “1” • Washer “2” 1 1 1 • O-ring “3” EAM30638 • Clutch release “4” ASSEMBLING THE CLUTCH RELEASE 1. Install: Bolt (clutch release) •...
Page 247 CLUTCH • Install the oil seal in parallel with its manufac- seal lip. • Before installation, apply the engine oil to the ture’s marks or numbers facing inward. bearings (upper side and lower side). Installed depth “a” 0 mm (0 in) 5.
Page 248 CLUTCH plates, and clutch plates. ECA24660 NOTICE Make sure to tighten to specification; other- wise, it may damage the other part that is fas- tened together. • Use the clutch holder “2” to hold the sleeve. • Stake the clutch boss nut at cutouts “a” in the main axle.
Page 249 CLUTCH 10.Install: • Pressure plate 2 “1” A. Engine side 11.Install: 12.Install: • Spring retainer “1” • Gasket “1” • Clutch spring “2” • Clutch cover “2” • Pressure plate 1 “3” • Clutch cover bolt (long) “3” • Bolt (pressure plate 1) “4” •...
Page 250 SHIFT SHAFT EAM20113 SHIFT SHAFT Removing the shift shaft and stopper lever 12 N ・ m (1.2 kgf･m, 8.9 lb ・ ft) 0–0.1 mm (0–0.004 in) 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 251 SHIFT SHAFT Removing the shift shaft and stopper lever 12 N ・ m (1.2 kgf･m, 8.9 lb ・ ft) 0–0.1 mm (0–0.004 in) 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 252: 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 253 SHIFT SHAFT Segment bolt 30 N·m (3.0 kgf·m, 22 lb·ft) • Align the projections “a” on the segment with the slits “b” on the shift cam. • With the stopper lever pushed down, install the segment. ECA24680 NOTICE 6. Tighten: If the segment gets an impact, the stopper le- •...
Page 254 SHIFT SHAFT Align the punch mark “a” on the shift shaft with the punch mark “b” in the shift pedal. 1 1 1 5-58...
Page 255 STARTER CLUTCH EAM20175 STARTER CLUTCH Removing the balancer gear 120 N ・ m (12 kgf ・ m, 89 lb ・ ft) 50 N ・ m (5.0 kgf ・ m, 37 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Idle gear Refer to “CLUTCH”...
Page 256: Starter Clutch
STARTER CLUTCH Removing the damper assembly 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-14. Clutch Refer to “CLUTCH” on page 5-44. Holder Damper assembly Washer...
Page 257: Removing The Balancer Gear
STARTER CLUTCH 2. Check: EAM30624 REMOVING THE BALANCER GEAR • Starter clutch assembly 1. Straighten the lock washer tab. Burrs/chips/roughness/wear  Replace the 2. Loosen: starter clutch assembly. • Balancer driven gear nut “1” • Primary drive gear nut “2” Place an aluminum plate “a”...
Page 258 STARTER CLUTCH washer. • Apply engine oil to the contact surface and threaded portion of the primary drive gear nut. • Place an aluminum plate “a” between the teeth 1 1 1 of the balancer drive gear “10” and balancer driven gear “11”.
Page 259 OIL PUMP EAM20182 OIL PUMP Removing the oil pump 0.1–1.0 mm (0.004–0.039 in) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Oil pump drive gear...
Page 260: Oil Pump
OIL PUMP • Dowel pin “1” EAM30136 CHECKING THE OIL PUMP • Inner rotor 1 “2” 1. Check: • Outer rotor 1 “3” • Oil pump cover • Circlip “4” • Oil pump drive shaft • Oil pump housing • Apply the engine oil on the inner rotor 1 and Cracks/damage/wear ...
Page 261: Crankcase
12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) * Yamaha bond No. 1215 (Three bond No. 1215®) Order Job/Parts to remove Q’ty...
Page 262 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) * Yamaha bond No. 1215 (Three bond No. 1215®) Order Job/Parts to remove Q’ty...
Page 263 CRANKCASE Removing the bearing and oil seal (left) 0 mm (0 in) 0–0.5 mm (0–0.002 in) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 0 mm (0 in) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 0 mm (0 in) 0 mm (0 in) 0 mm (0 in)
Page 264 CRANKCASE Removing the bearing and oil seal (right) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 0 mm (0 in) 0 mm (0 in) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 12 N ・...
Page 265: 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 266: Checking The Oil Strainer
Install the bearing by pressing its outer race par- (TDC). allel. • Tighten the bolts in a crisscross pattern in two 3. Apply: stages, with 1/4 turn each. • Sealant (to the crankcase mating surface) Yamaha bond No. 1215 90890-85505 Three bond No. 1215® 5-70...
Page 267 CRANKCASE 6. 45 mm (1.77 in) 7. 60 mm (2.36 in) 8. 75 mm (2.95 in) 5-71...
Page 268: 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 5-75. Balancer shaft Crankshaft assembly 5-72...
Page 269: Removing The Crankshaft
CRANKSHAFT AND BALANCER SHAFT shaft. EAM30491 REMOVING THE CRANKSHAFT 1. Remove: Turn the crankshaft slowly. • Balancer shaft “1” Runout limit Remove the balancer shaft with its flat side “a” 0.030 mm (0.0012 in) facing the crankshaft. 2. Measure: 2. Remove: •...
Page 270: 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 271: 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 5-2. Separate. Crankcase Refer to “CRANKCASE” on page 5-65. 5-75...
Page 272 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Main axle Drive axle Long shift fork guide bar Short shift fork guide bar Spring 5-76...
Page 273 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Shift cam Shift fork 3 (R) Shift fork 2 (C) Shift fork 1 (L) Collar 5-77...
Page 274: 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 (R) “4” • Shift fork 2 (C) “5” • Shift fork 1 (L) “6” •...
Page 275: Checking The Transmission
TRANSMISSION • 3rd pinion gear (20T) “2” EAM30156 CHECKING THE TRANSMISSION • Collar “3” 1. Measure: • 5th pinion gear (21T) “4” • Main axle runout • 2nd pinion gear (16T) “5” (with a centering device and dial gauge “1”) (to the main axle “6”) Out of specification ...
Page 276 TRANSMISSION positioned opposite side to the washer and gear “b”. • Install the circlip with its ends “c” settled evenly on the spline crests. 6. Install: • Shift fork 1 (L) “1” • Shift fork 2 (C) “2” • Shift fork 3 (R) “3” •...
Page 277 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 278 TRANSMISSION 5-82...
Page 279: Cooling System
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 .............6-8 CHECKING THE WATER PUMP ...............6-8 ASSEMBLING THE WATER PUMP ............6-8...
Page 280: Cooling System Diagrams
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 281: Radiator
RADIATOR EAM20138 RADIATOR Removing the radiator 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 1.5 N ・...
Page 282 RADIATOR Removing the radiator 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 1.5 N ・...
Page 283: Checking The Radiator
RADIATOR EAM30341 CHECKING THE RADIATOR Radiator cap valve opening pres- sure EWA13030 107.9–137.3 kPa (1.08–1.37 WARNING kgf/cm², 15.6–19.9 psi) A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- No stay  Replace. gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in- Radiator cap tester jury.
Page 284 RADIATOR 1 1 1 4. Activate the tester to apply the test pressure. Test pressure value 137.3 kPa (1.37 kgf/cm², 19.9 psi) ECA24270 NOTICE • Do not apply such a high pressure as ex- ceeds the test pressure. • Make sure that a checkup after the cylinder head gasket is replaced is made after 3 min- utes of warm-up.
Page 285: Water Pump
WATER PUMP EAM20139 WATER PUMP Removing the water pump 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 0 mm (0 in) 0 mm (0 in) Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-22.
Page 286 WATER PUMP Removing the water pump 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 0 mm (0 in) 0 mm (0 in) Order Job/Parts to remove Q’ty Remarks Impeller shaft assembly Circlip Impeller 1 Impeller 2 Impeller shaft Water pump housing O-ring...
Page 287: Disassembling The 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 288 WATER PUMP 5. Install: • Water pump housing cover “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 289: Fuel System
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............7-8...
Page 290 FUEL TANK EAM20140 FUEL TANK Removing the fuel tank 4.0 N ・ m (0.40 kgf ・ m, 3.0 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 8 N ・...
Page 291: 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: • Seat • Side cover (left/right) • Shroud (left/right) Refer to “GENERAL CHASSIS” on page 4-1. 3.
Page 292: Installing The Fuel Tank
FUEL TANK • Fuel pump • Install the fuel hose connector holder “a”. • Fuel pump bracket • Check that the fuel hose and the fuel pump lead are routed through the guide on the cover. Fuel pump bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) •...
Page 293: 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) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 3.0 N ・...
Page 294 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) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 3.0 N ・...
Page 295 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 296: Checking The Injector
“a” and fuel injector “b” in the throttle body. 4. Reset: • Use the diagnostic code number “87”. Refer to “DIAGNOSTIC CODE: SENSOR OPERATION TABLE” on page 9-12. Yamaha diagnostic tool USB (US) 90890-03269 Yamaha diagnostic tool (A/I) 90890-03264...
Page 297: Checking The Fuel Pressure
Connect the throttle position sensor to the Fuel pressure adapter wire harness. YM-03186 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” appears on the Yamaha diagnostic tool.
Page 298: Installing The Air Filter Case Assembly Bracket
THROTTLE BODY 3. Reset: • Use the diagnostic code number “87”. Refer to “DIAGNOSTIC CODE: SENSOR OPERATION TABLE” on page 9-12. EAM30631 INSTALLING THE AIR FILTER CASE ASSEMBLY BRACKET 1. Install: • Air filter case assembly bracket “1” Align the projections “a” on the air filter case as- sembly bracket with the grooves “b”...
Page 299: Electrical System
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..................8-41 CIRCUIT DIAGRAM .................8-41 TROUBLESHOOTING................8-43 ELECTRICAL COMPONENTS...............8-44 CHECKING THE SWITCHES..............8-45 CHECKING THE FUSES................8-47...
Page 300: Ignition System
IGNITION SYSTEM EAM20142 IGNITION SYSTEM EAM30277 CIRCUIT DIAGRAM...
Page 301 IGNITION SYSTEM 1. Crankshaft position sensor 2. AC magneto 3. Rectifier/regulator 4. Engine ground 5. Frame ground 6. Battery 7. Fuse 8. Starter relay 9. Starter motor 10.Diode 1 11.CCU (Communication Control Unit) 12.ECU (Engine Control Unit) 13.Ignition coil 14.Spark plug 21.Gear position switch 22.Handlebar switch (left) 23.Indicator light...
Page 302: Troubleshooting
IGNITION SYSTEM EAM30278 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3. Shroud (left/right) 4. Fuel tank 5. Air filter case cover 1. Check the ignition system wire har- Reconnect.
Page 303 IGNITION SYSTEM 9. Check the stator coil assembly. Refer to “CHECKING THE STA- Replace the stator coil assembly. NG TOR COIL” on page 8-52. OK 10.Check the ignition system wire har- ness. Repair or replace the wire harness. Refer to “CIRCUIT DIAGRAM” on NG...
Page 304 IGNITION SYSTEM 1. Check the handlebar switch coupler Reconnect. (left) connections. NG OK 2. Check the handlebar switch (left). Refer to “CHECKING THE Replace the handlebar switch (left). NG SWITCHES” on page 8-45. OK 3. Check the ignition system wire har- ness.
Page 305 IGNITION SYSTEM...
Page 306: Electric Starting System
ELECTRIC STARTING SYSTEM EAM20143 ELECTRIC STARTING SYSTEM EAM30279 CIRCUIT DIAGRAM...
Page 307 ELECTRIC STARTING SYSTEM 5. Frame ground 6. Battery 7. Fuse 8. Starter relay 9. Starter motor 10.Diode 1 12.ECU (Engine Control Unit) 21.Gear position switch 22.Handlebar switch (left) 25.Engine stop switch 26.Handlebar switch (right) 27.Start switch...
Page 308: 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. Shroud (left/right) 4. Fuel tank 5. Air filter case cover 1. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse(s).
Page 309 ELECTRIC STARTING SYSTEM 9. Check the entire starting system’s wiring. Properly connect or repair the starting sys- Refer to “CIRCUIT DIAGRAM” on tem’s wiring. NG page 8-7. OK Replace the ECU. 8-10...
Page 310: Charging System
CHARGING SYSTEM EAM20144 CHARGING SYSTEM EAM30282 CIRCUIT DIAGRAM 8-11...
Page 311 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Engine ground 5. Frame ground 6. Battery 7. Fuse 8-12...
Page 312: Troubleshooting
CHARGING SYSTEM EAM30283 TROUBLESHOOTING The battery is not being charged. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left) 3. Shroud (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 313 CHARGING SYSTEM 8-14...
Page 314: Fuel Injection System
FUEL INJECTION SYSTEM EAM20145 FUEL INJECTION SYSTEM EAM30284 CIRCUIT DIAGRAM 8-15...
Page 315 FUEL INJECTION SYSTEM 1. Crankshaft position sensor 2. AC magneto 3. Rectifier/regulator 4. Engine ground 5. Frame ground 6. Battery 7. Fuse 11.CCU (Communication Control Unit) 12.ECU (Engine Control Unit) 13.Ignition coil 14.Spark plug 15.Fuel injector 16.Fuel pump 17.Intake air temperature sensor 18.Coolant temperature sensor 19.Throttle position sensor 20.Intake air pressure sensor...
Page 316: 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 DIAGNOS- TIC TOOL OPERATION MANUAL”.
Page 317 1. ECU (Engine Control Unit) 2. Lead battery (12 V) 3. Vehicle battery 4. Vehicle 5. CCU sub-lead coupler 6. Sub-harness (included with the Yamaha diag- nostic tool) 7. Vehicle communication cable (included with the Yamaha diagnostic tool) 8. Yamaha diagnostic tool...
Page 318: 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 319 And then check the condition of the fault code using the mal- function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service. Condition is “Detected”  Go to item 3.
Page 320 Gear position switch: open or short circuit detected. 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. 12 Fault code No.
Page 321 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 pletion Improperly connected ...
Page 322 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 323 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 324 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 325 Location of discon- Output code using the malfunction nected lead voltage mode of the Yamaha diagnostic tool. Disconnected Condition is “Recovered”  Go ground lead to item 8 and finish the service. Condition is “Detected”  Go to Disconnected output item 6.
Page 326 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 327 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 328 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 329 Check for looseness or pinch- check the condition of the fault ing. code using the malfunction Check the mounted position for mode of the Yamaha diagnostic correctness. tool. Condition is “Recovered”  Go to item 7 and finish the service.
Page 330 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 331 Check the condition of the fault the coupler. 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 332 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 333 5 seconds. Between injector coupler and Check the condition of the fault ECU coupler. code using the malfunction red/black–red/black mode of the Yamaha diagnostic Between injector coupler and tool. Condition is “Recovered”  Go joint connector. red–red to item 6 and finish the service.
Page 334 Check the condition of the fault Between starter relay coupler code using the malfunction and joint connector. mode of the Yamaha diagnostic red/yellow–red/yellow tool. Condition is “Recovered”  Go Between joint connector and ECU coupler.
Page 335 CO concentration. engine stop switch, and then code using the malfunction push the start switch. mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 6 and finish the service. Condition is “Detected” ...
Page 336 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 337 Start switch to ON (no need to start the engine), and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Check that the fault code num- ber is not displayed. Fault code No. 70 It is not a malfunction.
Page 338 Engine forcibly stops when the vehicle is left idling for a long period Item of time. 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. 8-39...
Page 339 FUEL INJECTION SYSTEM 8-40...
Page 340: Fuel Pump System
FUEL PUMP SYSTEM EAM20146 FUEL PUMP SYSTEM EAM30287 CIRCUIT DIAGRAM 8-41...
Page 341 FUEL PUMP SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Engine ground 5. Frame ground 6. Battery 7. Fuse 12.ECU (Engine Control Unit) 16.Fuel pump 22.Handlebar switch (left) 25.Engine stop switch 8-42...
Page 342: 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. Shroud (left/right) 4. Fuel tank 5. Air filter case cover 1. Check the fuel pump system wire Reconnect.
Page 343: Electrical Components
ELECTRICAL COMPONENTS EAM20147 ELECTRICAL COMPONENTS 1. Rectifier/regulator 2. Mode switch 3. Engine stop switch 4. Intake air temperature sensor 5. Ignition coil 6. Battery 7. Starter relay 8. Fuse 9. ECU (Engine Control Unit) 10.CCU (Communication Control Unit) 11.Fuel pump 12.Gear position switch 13.Coolant temperature sensor 14.Injector...
Page 344: Checking The Switches
ELECTRICAL COMPONENTS EAM30289 CHECKING THE SWITCHES Y/W P 1. Handlebar switch (left) 2. Mode switch 3. Engine stop switch 4. Start switch 5. Gear position switch 8-45...
Page 345 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 346: Checking The Fuses
ELECTRICAL COMPONENTS systems to malfunction and could possibly EAM30290 CHECKING THE FUSES cause a fire. The following procedure applies to all of the fus- 4. Install: • Seat 1. Remove: • Side cover (left) • Seat Refer to “GENERAL CHASSIS” on page 4-1. •...
Page 347 When • Battery leads replacing the battery, be sure to use a (from the battery terminals) Yamaha genuine lithium-ion battery. ECA13700 NOTICE First, disconnect the negative battery lead, Do not check the battery at high temperature of and then the positive battery lead.
Page 348: Replacing The Ecu (Engine Control Unit)
CHECKING THE RELAY UNIT (DIODE) Refer to “DIAGNOSTIC CODE: SENSOR 1. Check: OPERATION TABLE” on page 9-12. • Diode 1 Out of specification  Replace. Yamaha diagnostic tool USB (US) 90890-03269 Digital circuit tester (CD732) Yamaha diagnostic tool (A/I) 90890-03243 90890-03264...
Page 349: Checking The Ignition Spark Gap
ELECTRICAL COMPONENTS b. Connect the digital circuit tester () to the the spark gap until a misfire occurs. diode coupler as shown. EAM30295 c. Check the diode for continuity. CHECKING THE SPARK PLUG CAP d. Check the diode for no continuity. 1.
Page 350: Checking The Crankshaft Position Sensor
ELECTRICAL COMPONENTS 2. Check: • Positive tester probe  • Crankshaft position sensor resistance Ignition coil terminal 1 “1” Out of specification  Replace. • Negative tester probe  Ignition coil terminal 2 “2” Crankshaft position sensor resis- tance 228–342  a.
Page 351: Checking The Stator Coil
ELECTRICAL COMPONENTS step (3). Refer to “TROUBLESHOOTING” on page 8-9. a. Connect the positive battery terminal “1” and starter motor lead “2” with a jumper lead “3”. EWA13810 WARNING • A wire that is used as a jumper lead must have at least the same capacity of the bat- tery lead, otherwise the jumper lead may b.
Page 352: Checking The Coolant Temperature Sensor
ELECTRICAL COMPONENTS d. Measure the output voltage. minals do not get wet. c. Place a thermometer in the coolant. EAM30303 CHECKING THE COOLANT TEMPERATURE d. Slowly heat the coolant, and then let it cool SENSOR to the specified temperature indicated in 1.
Page 353: Checking The Intake Air Temperature Sensor
ELECTRICAL COMPONENTS • Positive tester probe  Brown/White “1” • Negative tester probe  Black/Blue “2” c. Start the engine. d. Measure the throttle position sensor input voltage. If the throttle position sensor is replaced, reset the ECU using the diagnostic code number “87”. EAM30467 CHECKING THE GEAR POSITION SWITCH Refer to “DIAGNOSTIC CODE: SENSOR OP-...
Page 354: Checking The Injector
ELECTRICAL COMPONENTS b. Connect the digital circuit tester () to the Continuity fuel injector coupler. Positive tester probe  Sky blue “1” Digital circuit tester (CD732) Negative tester probe  90890-03243 Sensor terminal “a” Model 88 Multimeter with tachom- Continuity eter Positive tester probe ...
Page 355: Checking The Indicator Light
ELECTRICAL COMPONENTS EAM30632 CHECKING THE INDICATOR LIGHT If the indicator light flashes orange, check and service the items or components that are the possible cause of the malfunction. 3. 1 second 1. Orange 2. Approx. 1 second Indicator light flashes orange fast Fail-safe system Possible cause Actions...
Page 356 ELECTRICAL COMPONENTS 8-57...
Page 357: Troubleshooting
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 SYSTEM) ....................9-12...
Page 358: 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 359 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 360 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 361: 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 362 TROUBLESHOOTING Symptom Possible cause Actions Faulty clutch spring Replace the clutch spring. 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 363: 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 364: 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 365: 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 366 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 367: 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 368: Troubleshooting Of Charging System
TROUBLESHOOTING Symptom Possible cause Actions 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. Tighten the wheel axle nut to the Loose wheel axle nut Rear wheel vibration specified torque.
Page 369: 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 start switch is pushed. Intake air temperature Displays the intake air tempera- Compare the actually mea- ture.
Page 370 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 371: Diagnostic Code: Actuator Operation Table
Ignition coil Actuates the ignition coil five Check that a spark is gener- times at one-second intervals. ated five times. “WARNING” on the Yamaha • Connect an ignition checker. diagnostic tool blinks five times when the ignition coil is actu- ated.
Page 372 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9-15...
Page 373: Tuning
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 374: 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) B2W-25449-00 Secondary reduction ratio = Number of B2W-25450-00 rear wheel sprocket teeth/Number of B2W-25451-00 drive sprocket teeth 17D-25452-50 Secondary reduction ratio 3.769 (49/13)
Page 375: 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 376: Front Fork Setting Parts
CHASSIS Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, re- sulting in lack of a sense of contact with the road surface or in a vibrating handlebar. EAM30174 FRONT FORK SETTING PARTS • Front fork spring STD Spring rate N/mm 2.
Page 377: Setting Of Spring After Replacement
STIFF Brown decrease compression damping force. (Blue) EWA19200 * For Monster Energy Yamaha Racing Edition WARNING only When using a rear shock absorber other than currently installed, use the one whose • The I.D. mark “a” is marked at the end of the overall length “a”...
Page 378 CHASSIS 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 7.0 mm (0.28 in) from its free length. Maximum Position in which the spring is turned in 18.0 mm (0.71 in) from its free length.
Page 379: 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 380: 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 381 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 382 CHASSIS 10-9...
Page 383 EAM20149 EAM30323 WIRING DIAGRAM COLOR CODE Black YZ450FP 2023 Brown 1. Crankshaft position sensor Dark blue 2. AC magneto Green 3. Rectifier/regulator Gray 4. Engine ground Blue 5. Frame ground Pink 6. Battery 7. Fuse Sky blue 8. Starter relay White 9.
Page 385 EAM20160 Genuine Yamaha Parts text Genuine Yamaha Parts – Genuine Yamaha replacement parts are the exact same parts as the ones originally equipped on your vehicle, providing you with the performance and durability you have come to expect. Why settle for aftermarket parts that may not provide full confidence and satisfaction? Genuine Yamaha Accessories –...
Page 387 YZ450FP 2023 WIRING DIAGRAM...
Page 388 YZ450FP 2023 WIRING DIAGRAM PUSH PUSH FREE FREE...

Yamaha YZ450FP 2023 Owner's Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Chassis

Engine

Cooling System

Fuel System

Electrical System

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha YZ450FP 2023