Yamaha WR450FN 2022 Owner's Service Manual
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Yamaha WR450FN 2022 Owner's Service Manual

Yamaha WR450FN 2022 Owner's Service Manual

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Table of Contents

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2022
OWNER'S SERVICE MANUAL
WR450F
Read this manual carefully before operating this vehicle.
WR450FN
LIT-11626-35-44
BDB-2819U-11

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Summary of Contents for Yamaha WR450FN 2022

  • Page 1 2022 OWNER’S SERVICE MANUAL WR450F Read this manual carefully before operating this vehicle. WR450FN LIT-11626-35-44 BDB-2819U-11...
  • 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 EAM20080 WR450FN OWNER’S SERVICE MANUAL ©2022 by Yamaha Motor Corporation, U.S.A. First edition, June 2021 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-11626-35-44...
  • Page 4 EAM20081 IMPORTANT Congratulations on your purchase of a Yamaha WR 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 5 EAM20093 YAMAHA MOTOR CORPORATION, U.S.A. WR MOTORCYCLE LIMITED WARRANTY...
  • Page 6 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 7 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 VEHICLE EMISSION CONTROL INFORMATION LABEL ......1-6 INCLUDED PARTS ...................1-7 NIPPLE WRENCH ..................1-7 HANDLEBAR PROTECTOR ..............1-7 FUEL HOSE JOINT COVER ..............1-7 COUPLER FOR CONNECTING OPTIONAL PART ........1-7 IMPORTANT INFORMATION ................1-8...
  • Page 12 SETTING MODE ..................1-25 FUNCTION DIAGRAM ................1-30 STARTING AND BREAK-IN ................1-32 FUEL......................1-32 HANDLING NOTE ..................1-32 STARTING A COLD ENGINE ..............1-32 STARTING A WARM ENGINE ..............1-33 BREAK-IN PROCEDURES ..............1-33 SHIFTING ....................1-33 MAINTENANCE AFTER BREAK-IN ..............1-35 MAJOR MAINTENANCE ................1-35 AIR FILTER MAINTENANCE ..............1-35 TORQUE-CHECK POINTS................1-36 MOTORCYCLE CARE AND STORAGE............1-38 CARE ......................1-38...

  • 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. WARNING This unit contains high pressure nitrogen gas. Mishandling can cause explosion. Read owner's manual for instructions. Do not incinerate, puncture or open. 4AA-22259-80...

  • Page 17: Description

    DESCRIPTION EAM20086 DESCRIPTION 3, 4 1. Clutch lever 12.Fuel tank 13.Headlight 2. Multi-function display 14.Radiator 3. Engine trouble warning light “ ” 15.Coolant drain bolt 4. Fuel level warning light “ ” 16.Rear brake pedal 5. Front brake lever 17.Air filter 6.

  • 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 ECA24810 INCLUDED PARTS NOTICE When no optional parts, etc. are connected, EAM30005 connect the connection terminal to the origi- NIPPLE WRENCH nal coupler. The nipple wrench “1” is used to tighten the Before disconnecting the coupler, thorough- spoke.

  • Page 20: Important Information

    2. Use proper special tools and equipment. Re- used for repair of the vehicle, including periodic fer to “SPECIAL TOOLS” on page 1-14. replacement parts, are new YAMAHA genuine parts and recommended parts. Do not use any used parts, because these may...

  • Page 21: 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 22: 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 23 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 24 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 25 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 26: Special Tools

    Feeler gauge set YU-26900-9 Valve lapper (ø14) 3-8, 5-26 90890-04101 90890-04101 Valve lapper (ø14) YM-A8998 YM-A8998 Yamaha diagnostic tool USB (US) 3-12, 7-8, 8-31 90890-03269 Yamaha diagnostic tool (A/I) 3-12, 7-8, 8-31 90890-03264 FI diagnostic tool sub–lead 3-12, 7-8, 8-32 90890-03212 FI diagnostic tool sub–lead...
  • Page 27 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages OBD/ GST Leadwire kit 3-12, 7-8, 8-31 90890-03249 Digital tachometer 3-12, 3-35, 8-67 90890-06760 Digital tachometer YU-39951-B Steering nut wrench 3-27, 4-57 90890-01403 Exhaust flange nut wrench YU-A9472 Spoke nipple wrench (6–7) 3-33 90890-01521 Spoke nipple wrench (6–7)
  • Page 28 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Yamaha bond No. 1215 5-19, 5-38, 5-66 90890-85505 Three bond No. 1215® Valve spring compressor 5-26, 5-30 90890-04200 Valve spring compressor YM-04019 Valve spring compressor attachment 5-26, 5-30 90890-04108 Valve spring compressor adapter 22 mm YM-04108 Valve guide remover &...
  • Page 29 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rotor puller 5-38 90890-04151 Rotor puller YM-04151 Clutch holder 5-49, 5-52 90890-04199 Universal clutch holder YM-91042 Crankcase separating tool 5-68 90890-04152 Crankcase separating tool YU-A9642 Crankshaft installer pot 5-69 90890-01274 Installing pot YU-90058 YU-90058/YU-90059 Crankshaft installer bolt...
  • Page 30 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Spacer (crankshaft installer) 5-69 90890-04081 Pot spacer YM-91044 YM-91044 Radiator cap tester 6-4, 6-4 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter 6-4, 6-4 90890-01352 Pressure tester adapter YU-33984 YU-33984 Pressure gauge...
  • Page 31 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Ignition checker 8-65 90890-06754 Oppama pet–4000 spark checker YM-34487 Test harness– speed sensor 5TJ (3P) 8-68 90890-03228 Test harness– speed sensor 5TJ (3P) YU-03228 Test harness S– pressure sensor (3P) 8-70 90890-03207 Test harness S–...

  • Page 32: Instrument And Control Functions

    ” This warning light comes on or flashes if a prob- lem is detected in the electrical circuit monitoring the engine. If this occurs, have a Yamaha dealer check the vehicle. The electrical circuit of the warning light can be checked by pushing the start switch.

  • Page 33: Front Brake Lever

    INSTRUMENT AND CONTROL FUNCTIONS EWA18980 Shift up points WARNING 1st  2nd • Never apply additional force to the sides- 20 km/h (12 mph) tand. 2nd  3rd • Hold up the sidestand before starting out. 30 km/h (19 mph) 3rd ...
  • Page 34 INSTRUMENT AND CONTROL FUNCTIONS • Install the fuel tank cap cover after placing the bands “3” all the way in under the seat. a a a 1-22...
  • Page 35 MULTI-FUNCTION DISPLAY Changing the display item EAM20150 MULTI-FUNCTION DISPLAY • The odometer will lock at 199999. EWA19000 WARNING • The tripmeter will reset and continue counting Be sure to stop the machine before making after 9999.9 is reached. any setting changes to the multi-function •...

  • Page 36: Multi-Function Display

    MULTI-FUNCTION DISPLAY EAM30621 SETTING THE TIMER Putting measurement on standby 1. Change the meter display to the timer mode. 3. Push the A button and B button simultane- ously once again to restart the measurement. • Starting measurement consists of the following two starts, either of which can be selected.
  • Page 37 MULTI-FUNCTION DISPLAY consumption correction  Setting the tire di- ameter correction  Setting the backlight brightness If one of the following situations occurs while performing the setting mode, the setting value that is displayed will be accepted even if the set- tings are not finished, and the setting mode dis- play will disappear.
  • Page 38 MULTI-FUNCTION DISPLAY Setting the clock time 2. Push the A button to set the minute. The set- Setting the hour ting of the time will then be kept and the dis- 1. Push the B button to adjust the hour. play of the multifunction meter will shift to the A long push on the button will fast-forward the unit display setting.
  • Page 39 MULTI-FUNCTION DISPLAY tire pressure, and course condition. If the outer diameter of a tire varies with tire wear or tire pressure, it can be corrected in the follow- ing manner. The initial value is preset with approximately 700 mm (27.56 in) as 100 %. •...
  • Page 40 MULTI-FUNCTION DISPLAY When terminating the setting mode, long push the engine stop switch to turn off the display and terminate the setting mode. 1-28...
  • Page 41 MULTI-FUNCTION DISPLAY 1-29...
  • Page 42 MULTI-FUNCTION DISPLAY EAM30330 FUNCTION DIAGRAM The following diagram illustrates the multi-function display regarding the direction and operation condi- tion involved in each of its functions. A short push on the button changes the operation in the arrowed direction. Meter function A short push on the button changes the operation in both arrowed directions.

  • Page 43: 20.Setting The Timer

    MULTI-FUNCTION DISPLAY A. A short push on the button changes the oper- ation in the arrowed direction. B. A short push on the button changes the oper- ation in both arrowed directions. C. A long push on the button changes the oper- ation in the arrowed direction.

  • Page 44: Starting And Break-In

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

  • Page 45: Starting A Warm Engine

    STARTING AND BREAK-IN 1. After warming up the engine, drive it for about 20 minutes at a throttle opening of 1/2 or less. This model is equipped with an engine auto-stop system. The engine stops automatically if left idling for 7 minutes. If the engine stops, push the start switch to restart the engine.
  • Page 46 STARTING AND BREAK-IN 3. Shift the transmission into the neutral position when the motorcycle is almost completely stopped. Recommended shift points The recommended shift points during accelera- tion and deceleration are shown in the table be- low. Shift up points 1st ...

  • Page 47: 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 48: Torque-Check Points

    TORQUE-CHECK POINTS EAM20125 TORQUE-CHECK POINTS Frame construction Combined seat and fuel tank 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 frame Steering Steering stem to handlebar Steering stem to frame...
  • Page 49 TORQUE-CHECK POINTS Shift pedal Shift pedal to shift shaft Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake disc cover Tightening of rear brake caliper cover...

  • Page 50: Motorcycle Care And Storage

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

  • Page 51: 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 52 MOTORCYCLE CARE AND STORAGE stored. Long-term Before storing your motorcycle for several months: 1. Follow all the instructions in the “CARE” on page 1-38. 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 53: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-5 ELECTRICAL SPECIFICATIONS..............2-8 TIGHTENING TORQUES................2-10 GENERAL TIGHTENING TORQUE SPECIFICATIONS ......2-10 ENGINE TIGHTENING TORQUES ............2-11 CHASSIS TIGHTENING TORQUES ............2-14 CABLE ROUTING DIAGRAM ................2-19...

  • Page 54: General Specifications

    GENERAL SPECIFICATIONS EAM20127 GENERAL SPECIFICATIONS Model Model BDB6 Dimensions Overall length 2175 mm (85.6 in) Overall width 825 mm (32.5 in) Overall height 1270 mm (50.0 in) Seat height 955 mm (37.6 in) Wheelbase 1480 mm (58.3 in) Ground clearance 320 mm (12.60 in) Weight Curb weight...

  • Page 55: 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 56 ENGINE SPECIFICATIONS Valve, valve seat, valve guide Valve clearance (cold) Intake 0.10–0.17 mm (0.0039–0.0067 in) 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)
  • Page 57 3.846 (50/13) Final drive Chain Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil Fuel pump Pump type Electrical Maximum consumption amperage 2.4 A Fuel injector 12.0 ...
  • Page 58 CHASSIS SPECIFICATIONS EAM20129 CHASSIS SPECIFICATIONS Chassis 27.2  Caster angle Trail 116 mm (4.6 in) Front wheel Wheel type Spoke wheel Rim size 21 x 1.60 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 59 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) 491.0 cm³ (16.60 US oz, 17.32 Imp.oz) Quantity (right) 491.0 cm³ (16.60 US oz, 17.32 Imp.oz)

  • Page 60: 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 Sealed type Number of links...

  • Page 61: 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 BDB1 Ignition coil 2.16–2.64  Primary coil resistance Secondary coil resistance 8.64–12.96 k Spark plug cap Resistance 7.50–12.50 k...
  • Page 62 ELECTRICAL SPECIFICATIONS Radiator fan motor fuse 5.0 A Spare fuse 15.0 A...

  • Page 63: 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 64: 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 65 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Air filter case bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) 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...
  • Page 66 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Shift guide bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) 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)

  • Page 67: 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 68 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Clutch lever holder bolt 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) Clutch lever nut 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) Front brake master cylinder holder 9 N·m (0.9 kgf·m, 6.6 lb·ft)  bolt Front brake master cylinder reservoir 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
  • Page 69 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Engine mounting nut (front side) 55 N·m (5.5 kgf·m, 41 lb·ft)  Engine mounting nut (lower side) 53 N·m (5.3 kgf·m, 39 lb·ft)  Engine bracket bolt (upper side) 34 N·m (3.4 kgf·m, 25 lb·ft) ...
  • Page 70 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Rear fender bolt (front side) 7 N·m (0.7 kgf·m, 5.2 lb·ft)  Rear fender bolt (rear side) 16 N·m (1.6 kgf·m, 12 lb·ft)  Headlight body and headlight stay 7 N·m (0.7 kgf·m, 5.2 lb·ft) bolt Multi-function meter screw 1.3 N·m (0.13 kgf·m, 0.95 lb·ft)
  • Page 71 TIGHTENING TORQUES 2-18...

  • Page 72: Cable Routing Diagram

    CABLE ROUTING DIAGRAM EAM20152 CABLE ROUTING DIAGRAM Frame and engine (left side view) 2-19...
  • Page 73 17.Gear position switch lead R. Pass the engine stop switch lead between the 18.Lower engine bracket Yamaha diagnostic tool coupler and the tank 19.Stator coil assembly lead rail. 20.Gear position switch coupler S. Route the radiator breather hose between the 21.Stator coil assembly coupler...
  • Page 74 CABLE ROUTING DIAGRAM Frame and engine (right side view) 2-21...
  • Page 75 CABLE ROUTING DIAGRAM K. The routing order of leads not indicated does 1. Wire harness not matter. 2. Bracket L. 20 mm (0.79 in) 3. Joint coupler M. Adjust any slack between the rear shock 4. Throttle position sensor coupler absorber and the clamp of the side cover.
  • Page 76 CABLE ROUTING DIAGRAM Handlebar (front view) 2-23...
  • Page 77 CABLE ROUTING DIAGRAM 1. Clutch cable 2. Clutch switch lead 3. Engine stop switch lead 4. Front brake hose 5. Headlight lead 6. Multi-function display coupler 7. Speed sensor coupler 8. Start switch lead 9. Plastic locking tie 10.Speed sensor lead 11.Throttle cable 12.Multi-function display A.
  • Page 78 CABLE ROUTING DIAGRAM Frame and engine (top view) 2-25...
  • Page 79 CABLE ROUTING DIAGRAM O. Route the cylinder head breather hose in 1. Diode front of the fuel injector lead. 2. Plug cap 3. Cylinder head cover 4. Wire harness 5. Fuel hose 6. Starter motor lead 7. Holder 8. Ignition coil 9.
  • Page 80 CABLE ROUTING DIAGRAM Frame and battery (top view) 2-27...
  • Page 81 CABLE ROUTING DIAGRAM 1. Starter relay 2. Starter motor lead 3. Cross member 4. Resistor 5. Negative battery lead 6. Taillight lead 7. Positive battery lead 8. Diode 9. Fuel pump lead 10.Joint coupler 11.Wire harness 12.Main relay (red tape) 13.Negative lead coupler 14.Radiator fan motor relay 15.Starter relay coupler...
  • Page 82 CABLE ROUTING DIAGRAM Rear brake (right side view) 2-29...
  • Page 83 CABLE ROUTING DIAGRAM 1. Bleed screw 2. Rear brake caliper 3. Protector 4. Gasket 5. Rear brake hose 6. Brake pedal 7. Rear brake master cylinder assembly 8. Swingarm 9. Spring 10.Frame A. It does not matter whether the spring is installed upward or downward.
  • Page 84 CABLE ROUTING DIAGRAM Front brake (front view and right side view) 2-31...
  • Page 85 CABLE ROUTING DIAGRAM 1. Speed sensor lead 2. Front brake hose 3. Clamp 4. Protector 5. Speed sensor 6. Speed sensor bracket A. Clamp the shrinking tube portion of the speed sensor lead. B. Clamp securely the speed sensor lead to the hook of the protector.
  • Page 86 CABLE ROUTING DIAGRAM Taillight (top view and right side view) 2-33...
  • Page 87 CABLE ROUTING DIAGRAM 1. Taillight lead 2. Clamp 3. Taillight A. Pass the taillight lead to the groove of the rear fender. B. There should be no slack of the taillight lead. 2-34...
  • Page 88 CABLE ROUTING DIAGRAM 2-35...

  • Page 89: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ......3-1 MAINTENANCE INTERVALS FOR COMPETITION USE......3-3 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...
  • Page 90 CHECKING THE CONNECTING ARM AND RELAY ARM ......3-32 CHECKING THE TIRES ................3-33 CHECKING AND TIGHTENING THE SPOKES ........3-33 CHECKING THE WHEELS ..............3-33 CHECKING THE WHEEL BEARINGS .............3-33 CHECKING THE CHASSIS FASTENERS ..........3-34 CHECKING AND LUBRICATING THE CABLES........3-34 LUBRICATING THE BRAKE LEVER ............3-34 LUBRICATING THE CLUTCH LEVER .............3-34 LUBRICATING THE PEDAL..............3-34 CHECKING THE SIDESTAND ..............3-34...

  • Page 91: Periodic Maintenance

    • From 4200 mi (7000 km) or 9 months, repeat the maintenance intervals starting from 1800 mi (3000 km) or 3 months. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 92 • Replace if necessary. Rear suspension • Apply molybdenum disulfide grease lightly.   18 * link pivots • Apply Yamaha chain and cable lube or engine oil 19 * Control cables    10W-30 thoroughly. • Check operation and free play.

  • Page 93: Maintenance Intervals For Competition Use

    (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 94 PERIODIC MAINTENANCE Every Every After Every Item Routine third race fifth race break-in race required (or 500 km) (or 1000 km) • Inspect housing, friction plate,   clutch plate and spring. 12 * Clutch • Replace.   • Inspect. 13 * Transmission •...
  • Page 95 PERIODIC MAINTENANCE Every Every After Every Item Routine third race fifth race break-in race required (or 500 km) (or 1000 km) • Clean and lubricate. Front fork oil seal and   31 * dust seal • Replace.  Protector guide ...

  • Page 96: 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 97: 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 98 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 99 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 5-13. 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 100: 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 101 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 102: Checking The Engine Idling Speed

    2. Measure the coolant temperature using the 5. Adjust: Yamaha diagnostic tool. • Engine idling speed Yamaha diagnostic tool USB (US) a. Turn the idle screw “1” to make an adjust- 90890-03269 ment. Yamaha diagnostic tool (A/I) 90890-03264 FI diagnostic tool sub–lead...

  • Page 103: Checking The Spark Plug

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

  • Page 104: Checking The Engine Oil Level

    ENGINE • Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1. EAM30224 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle upright on a level surface. 2. Start the engine, warm this up for 2–3 min- utes, and then stop the engine and wait about 1 minute.
  • Page 105 ENGINE Engine oil quantity Oil change 0.63 L (0.67 US qt, 0.55 Imp.qt) With oil filter removal 0.65 L (0.69 US qt, 0.57 Imp.qt) Quantity (disassembled) 0.90 L (0.95 US qt, 0.79 Imp.qt) c. Install the new oil filter element and the oil filter element cover.

  • Page 106: Adjusting The Clutch Lever Free Play

    ENGINE b. Loosen the locknut “1”. ECA26740 NOTICE c. Turn the adjuster “2” until the specified If the engine oil level does not decrease after clutch lever free play is obtained. the engine has been started, immediately d. Tighten the locknut “1”. turn the engine off.
  • Page 107 • Air filter element Damage  Replace. 6. Apply: • Yamaha foam air filter oil or other quality foam air filter oil a. Put the air filter element into a plastic bag and drip the filter oil into the bag.

  • Page 108: Checking The Throttle Body Joint

    ENGINE 8. Turn the plates “1” to the original position. EAM30222 CHECKING THE FUEL LINE 9. Install: 1. Remove: • Air filter case cover “1” • Seat • Fuel tank breather hose • Side cover (left/right) (to the air filter case cover) •...

  • Page 109: Checking The Exhaust System

    ENGINE c. Remove the tail pipe “3”, tail pipe gasket EAM30221 CHECKING THE EXHAUST SYSTEM “4” and spark arrester “5”. EWA19350 WARNING Pull the spark arrester out of the muffler. • Be sure the exhaust pipe and muffler are d. Remove the spark arrester gasket “6”. cool before cleaning the spark arrester.

  • Page 110: Checking The Coolant Level

    ENGINE 6. Check: 8. Install: • Gasket “1” • Exhaust pipe protector Damage  Replace. Exhaust pipe protector screw 10 N·m (1.0 kgf·m, 7.4 lb·ft) LOCTITE® EAM30210 CHECKING THE COOLANT LEVEL EWA13030 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot.

  • Page 111: 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 112 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 113: 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 114: Checking The Front Brake Pads

    CHASSIS Specified brake fluid DOT 4 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” almost disap- WARNING peared ...

  • Page 115: Checking The Brake Operation

    CHASSIS Loose connection  Tighten the holder bolt. b. Install the reservoir diaphragm. 3. Hold the vehicle upright and apply the rear c. Connect the plastic hose “1” to the bleed brake several times. screw “2” securely, and place a container 4.

  • Page 116: Drive Chain Slack

    CHASSIS immediately. i. Tighten the bleed screw. Bleed screw 5 N·m (0.5 kgf·m, 3.7 lb·ft) j. Pour brake fluid to the reservoir up to the specified level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-23. EWA13110 WARNING Drive chain slack (Maintenance After bleeding the hydraulic brake system, Stand) check the brake operation.

  • Page 117: Lubricating The Drive Chain

    CHASSIS EAM30251 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained proper- ly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas. This vehicle has a drive chain with small rubber O-rings between each side plate.

  • Page 118: Lubricating The Steering Head

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

  • Page 119: Adjusting The Front Fork Legs

    CHASSIS be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary. EAM30239 ADJUSTING THE FRONT FORK LEGS EWA19180 WARNING Compression damping • Always adjust the left and right front forks ECA24350 evenly.

  • Page 120: Checking The Rear Shock Absorber Assembly

    CHASSIS 3. Check: • Rear shock absorber assembly smooth ac- tion • Rear suspension link smooth action Sit astride the seat and shake your body up and down several times to check whether the rear shock absorber assembly operates smoothly. Unsmooth operation ...
  • Page 121 CHASSIS Spring preload adjusting positions Rebound damping Minimum Minimum (soft) Position in which the spring is 30 click(s) in direction “b”* turned in 1.5 mm (0.06 in) from Standard its free length. 8 click(s) in direction “b”* Standard Maximum (hard) Position in which the spring is 0 click(s) in direction “b”...

  • Page 122: Checking The Swingarm Operation

    CHASSIS Slow compression damping Fast compression damping Minimum (soft) Minimum (soft) 20 click(s) in direction “b”* 2 turn(s) in direction “b”* Standard Standard 10 click(s) in direction “b”* 1 turn(s) in direction “b”* Maximum (hard) Maximum (hard) 0 click(s) in direction “b”* 0 turn(s) in direction “b”* * With the adjusting screw fully turned in di- * With the adjusting screw fully turned in di-...

  • Page 123: Checking The Tires

    CHASSIS EAM30243 CHECKING THE TIRES A tight spoke will emit a clear, ringing tone; a 1. Measure: loose spoke will sound flat. • Tire pressure 2. Tighten: Out of specification  Regulate. • Spoke Tire air pressure (measured on (with a spoke nipple wrench “1”) cold tires) Front 100 kPa (1.00 kgf/cm², 15 psi)

  • Page 124: Checking The Chassis Fasteners

    CHASSIS EAM30253 CHECKING THE CHASSIS FASTENERS Recommended lubricant Lithium-soap-based grease Make sure that all nuts, bolts, and screws are properly tightened. Refer to “CHASSIS TIGHTENING TORQUES” EAM30504 CHECKING THE SIDESTAND on page 2-14. 1. Check: • Sidestand operation EAM30248 CHECKING AND LUBRICATING THE Check that the sidestand moves smoothly.

  • Page 125: Electrical System

    ELECTRICAL SYSTEM 4. Check: EAM20137 ELECTRICAL SYSTEM • Ignition timing Check whether the alignment mark “a” on the EAM30256 left crankcase cover is within the firing range CHECKING AND CHARGING THE BATTERY “b” on the generator rotor. Refer to “CHECKING AND CHARGING THE Incorrect firing range ...
  • Page 126 ELECTRICAL SYSTEM 3. Remove: • Headlight bulb “1” 4. Install: • Headlight bulb Fasten the new headlight bulb with the head- light bulb holder. ECA13690 NOTICE Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected.
  • Page 127 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE SEAT................4-4 INSTALLING THE AIR SCOOP..............4-4 REMOVING THE SIDE COVER ..............4-4 INSTALLING THE SIDE COVER ...............4-4 FRONT WHEEL ....................4-6 REMOVING THE FRONT WHEEL .............4-7 CHECKING THE FRONT WHEEL SENSOR AND SENSOR ROTOR..4-7 DISASSEMBLING THE FRONT WHEEL ...........4-7 CHECKING THE FRONT WHEEL .............4-8 ASSEMBLING THE FRONT WHEEL ............4-8 INSTALLING THE FRONT WHEEL ............4-10...
  • Page 128 INSTALLING THE REAR BRAKE MASTER CYLINDER ......4-36 HANDLEBAR....................4-37 REMOVING THE HANDLEBAR ...............4-38 CHECKING THE HANDLEBAR..............4-38 INSTALLING THE HANDLEBAR..............4-38 FRONT FORK....................4-43 REMOVING THE FRONT FORK LEGS ...........4-45 DISASSEMBLING THE FRONT FORK LEGS .........4-45 CHECKING THE FRONT FORK LEGS............4-46 ASSEMBLING THE FRONT FORK LEGS ..........4-47 INSTALLING THE FRONT FORK LEGS..........4-53 STEERING HEAD...................4-56 REMOVING THE LOWER BRACKET ............4-57...
  • Page 129 GENERAL CHASSIS EAM20094 GENERAL CHASSIS Removing the seat and battery 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 130 GENERAL CHASSIS Removing the side cover 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 1.3 N ・ m (0.13 kgf ・ m, 0.95 lb ・ ft) 7 N ・...
  • Page 131 GENERAL CHASSIS Removing the headlight assembly and multi-function meter 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 1.3 N ・ m (0.13 kgf ・ m, 0.95 lb ・ ft) 21 N ・...

  • Page 132: General Chassis

    GENERAL CHASSIS EAM30016 REMOVING THE SEAT The fuel tank cap cover and the seat are coupled d d d with each other with a plastic band. When removing the seat, always remove the fuel tank cap cover beforehand. 1. Remove: •...
  • Page 133 GENERAL CHASSIS a a a a. Projection b. Slot c. Rib (side cover) d. Rib (rear fender)

  • Page 134: Front Wheel

    FRONT WHEEL EAM20095 FRONT WHEEL Removing the front wheel 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 115 N ・...

  • Page 135: Removing The Front Wheel

    FRONT WHEEL front wheel sensor rotor. EAM30017 REMOVING THE FRONT WHEEL Iron powder/dust/solvent  Clean. ECA22340 NOTICE • The wheel sensor rotor is installed on the inner • Keep any type of magnets (including mag- side of the wheel hub. netic pick-up tools, magnetic screwdrivers, •...

  • Page 136: Checking The Front Wheel

    FRONT WHEEL c. Remove the bearings with a bearing pull- Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit EAM30018 2.0 mm (0.08 in) CHECKING THE FRONT WHEEL 1. Check: 6. Check: • Front wheel axle • Collar Roll the front wheel axle on a flat surface.
  • Page 137 FRONT WHEEL 3. Install: • Bearing (left side) “1” Use a socket “5” that matches the diameter of • Spacer “2” the bearing outer race and that of the oil seal. • Bearing (right side) “3” • Oil seal “4” •...

  • Page 138: Installing The Front Wheel

    FRONT WHEEL 4. Tighten: EAM30021 INSTALLING THE FRONT WHEEL • Front wheel axle nut “1” 1. Install: Front wheel axle nut • Front wheel 115 N·m (11.5 kgf·m, 85 lb·ft) Install the brake disc “1” between the brake pads ECA24430 “2”...
  • Page 139 FRONT WHEEL ing for looseness, and the front wheel sensor and sensor rotor installation conditions (warpage caused by overtorque, wrong in- stallation direction, rotor decentering, LOC- TITE® on the mounting surface of the rotor, deformation caused by an impact during ser- vice and caught foreign materials).

  • Page 140: Rear Wheel

    REAR WHEEL EAM20096 REAR WHEEL Removing the rear wheel 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 125 N ・ m (12.5 kgf ・ m, 92 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 50 N ・...

  • Page 141: Removing The 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 3-33. wheel off the ground. 3. Check: EWA13120 • Spoke WARNING Refer to “CHECKING AND TIGHTENING Securely support the vehicle so that there is...

  • Page 142: Assembling The Rear Wheel

    REAR WHEEL Rear wheel sprocket self-locking 50 N·m (5.0 kgf·m, 37 lb·ft) Tighten the self-locking nuts in stages and in a crisscross pattern. EAM30026 ASSEMBLING THE REAR WHEEL 1. Install: 2. Install: • Bearing (right side) “1” • Brake disc •...
  • Page 143 REAR WHEEL 2. Install: 5. Adjust: • Drive chain “1” • Drive chain slack “a” Drive chain slack (Maintenance Push the rear wheel “2” forward and install the Stand) drive chain. 50.0–60.0 mm (1.97–2.36 in) Refer to “DRIVE CHAIN SLACK” on page 3-26.
  • Page 144 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) 17 N ・...

  • Page 145: 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 kit Brake caliper piston seal kit Bleed screw 4-17...
  • Page 146 FRONT BRAKE Removing the front brake master cylinder 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 6 N ・...
  • Page 147 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit 4-19...

  • Page 148: 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 149 FRONT BRAKE d. Remove the pad pin and brake pads “4”. Bleed screw 5 N·m (0.5 kgf·m, 3.7 lb·ft) d. Install the brake pads “3” and the pad pin. • Install the brake pads with their projections “a” into the brake caliper recesses “b”. •...

  • Page 150: Removing The Front Brake Caliper

    FRONT BRAKE 4. Check: • Brake fluid level Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-23. 5. Check: • Brake lever operation A softy or spongy feeling  Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-25. b.

  • Page 151: 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 to swell and distort. Refer to “CHECKING THE FRONT BRAKE •...

  • Page 152: Removing The Front Brake Master Cylinder

    FRONT BRAKE Refer to “BLEEDING THE HYDRAULIC 3. Check: BRAKE SYSTEM” on page 3-25. • Brake hose Cracks/damage/wear  Replace. 6. Check: • Brake fluid level EAM30038 The minimum level mark or below  Add. ASSEMBLING THE FRONT BRAKE MASTER Refer to “CHECKING THE BRAKE FLUID CYLINDER LEVEL”...

  • Page 153: Installing The Front Brake Master Cylinder

    FRONT BRAKE • First, tighten the upper bolt, then the lower bolt. Install the spring with a smaller inside diameter to the brake master cylinder piston. 2. Install: • Copper washer • Brake hose 4. Install: • Union bolt • Brake master cylinder piston assembly “1” •...
  • Page 154 FRONT BRAKE EWA13090 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.

  • Page 155: Rear Brake

    REAR BRAKE EAM20098 REAR BRAKE Removing the rear brake caliper 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 13 lb ・ ft) 30 N ・...
  • Page 156 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 kit Brake caliper piston seal kit Bleed screw 4-28...
  • Page 157 REAR BRAKE Removing the rear brake master cylinder 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 158 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder joint Brake master cylinder kit 4-30...

  • Page 159: 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 160 REAR BRAKE 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. Measure: • Brake pad wear limit “a” Out of specification ...

  • Page 161: Removing The Rear Brake Caliper

    REAR BRAKE 4. Check: • Brake fluid level Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-23. 5. Check: • Brake pedal operation A softy or spongy feeling  Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-25. b.

  • Page 162: Installing The Rear Brake Caliper

    REAR 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 163: Checking The Rear Brake Master Cylinder

    REAR BRAKE tem. 1. Wash the brake master cylinder with brake fluid. 1. Remove: 2. Install: • Union bolt • Primary cylinder cup “1” • Copper washer • Secondary cylinder cup “2” • Brake hose (to the brake master cylinder piston “3”) EWA19300 To drain any remaining brake fluid, place a con- WARNING...

  • Page 164: Installing The Rear Brake Master Cylinder

    REAR BRAKE • Dust boot “4” Specified brake fluid DOT 4 • Always install new brake master cylinder kit “5”. EWA13090 • Before installation, apply brake fluid to the WARNING brake master cylinder piston assembly. • Use only the designated brake fluid. Other •...
  • Page 165 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 166: Removing The Handlebar

    HANDLEBAR EAM30052 REMOVING THE HANDLEBAR 1. Stand the vehicle upright on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Clutch switch “1” EAM30053 CHECKING THE HANDLEBAR 1.
  • Page 167 HANDLEBAR ECA14250 NOTICE • First, tighten the bolts on the front side of the handlebar holder, and then on the rear side. • Turn the handlebar all the way to the left and right. If there is any contact with the fuel tank, adjust the handlebar position.
  • Page 168 HANDLEBAR Engine stop switch screw 0.5 N·m (0.05 kgf·m, 0.37 lb·ft) • The engine stop switch “1” should be installed according to the dimensions shown. • Pass the engine stop switch lead through the middle of the clutch lever holder. 30 50˚...
  • Page 169 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 170 HANDLEBAR 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) 4-42...

  • Page 171: Front Fork

    FRONT FORK EAM20100 FRONT FORK Removing the front fork legs 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 3.8 N ・...
  • Page 172 FRONT FORK Disassembling the front fork leg 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 29 N ・ m (2.9 kgf ・ m, 21 lb ・ ft) 28 N ・ m (2.8 kgf ・ m, 21 lb ・ ft) 55 N ・...

  • Page 173: 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 174: Checking The Front Fork Legs

    FRONT FORK dial gauge reading. EWA13650 WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Check: • Outer tube Scratches/wear/damage  Replace. 3. Measure: • Fork spring free length “a” 5. Remove: Out of specification ...

  • Page 175: Assembling The Front Fork Legs

    1. Stretch the damper assembly fully. 2. Fill: • Damper assembly Recommended oil Yamaha Suspension Oil S1 Standard oil amount 7. Check: 216 cm³ (7.30 US oz, 7.62 Imp.oz) • Adjuster “1”...
  • Page 176 FRONT FORK 4. Measure: 6. Loosen: • Oil level (left and right) “a” • Compression damping force adjuster “1” Out of specification  Regulate. • Before loosening the damping force adjuster, Standard oil level record the setting position. 145–148 mm (5.71–5.83 in) •...
  • Page 177 FRONT FORK Base valve 28 N·m (2.8 kgf·m, 21 lb·ft) Hold the damper assembly with the cap bolt ring wrench “2” and use the cap bolt wrench “3” to tighten the base valve. Cap bolt wrench 90890-01500 Cap bolt wrench 12.Allow the overflowing oil to escape at the hole YM-01500 “a”...
  • Page 178 FRONT FORK • Apply the lithium-soap-based grease on the dust seal lip and oil seal lip. • Apply the fork oil on the inner tube. • Install the scraper to the inner tube as shown in the illustration. • When installing the oil seal, use vinyl seat “a” with fork oil applied to protect the oil seal lip.
  • Page 179 FRONT FORK Fork seal driver 90890-01502 Fork seal driver (48) YM-A0948 22.Measure: • Distance “a” Out of specification  Turn the locknut to specification. Distance “a” 19.Install: 16 mm (0.63 in) or more • Stopper ring “1” Between the damper assembly “1”...
  • Page 180 FRONT FORK ECA24560 NOTICE Allow the damper assembly to slide slowly down the inner tube until it contacts the bot- tom of the inner tube. Be careful not to dam- age the inner tube. 27.Measure: • Gap “a” between the adjuster “1” and the locknut “2”...

  • Page 181: Installing The Front Fork Legs

    55 N·m (5.5 kgf·m, 41 lb·ft) LOCTITE® 32.Install: • Protector guide “1” 30.Fill: • Front fork leg Recommended oil Yamaha Suspension Oil S1 Standard oil amount 285 cm³ (9.64 US oz, 10.05 EAM30059 INSTALLING THE FRONT FORK LEGS Imp.oz) 1. Install: Extent of adjustment •...
  • Page 182 FRONT FORK Cap bolt ring wrench 90890-01501 Cap bolt ring wrench YM-01501 5. Install: • Speed sensor lead “1” • Front brake hose “2” • Plate “3” (to the left front fork protector) 3. Adjust: Plate bolt • Front fork top end “a” 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) Front fork top end (standard) “a”...
  • Page 183 FRONT FORK 8. Adjust: • Compression damping force Turn in the damping adjuster “1” finger-tight and then turn out to the originally set position. 4-55...

  • Page 184: Steering Head

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

  • Page 185: 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 186 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 187 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 188: 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 189 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 Collar O-ring Dust seal...
  • Page 190 REAR SHOCK ABSORBER ASSEMBLY Disassembling the relay arm 80 N ・ m (8.0 kgf ・ m, 59 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Relay arm Connecting arm Collar Oil seal Washer Bearing 4-62...

  • Page 191: 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 192: 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 193 REAR SHOCK ABSORBER ASSEMBLY fitted. • When installing the rear shock absorber as- 2. Lubricate: sembly, lift up the swingarm. • O-ring • Install the rear shock absorber assembly upper Recommended lubricant bolt, and connecting arm bolt (frame side) from Lithium-soap-based grease the right.

  • Page 194: 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) 4.0 N ・ m (0.40 kgf ・ m, 3.0 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 195: 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 196 SWINGARM 4. Install: • Rear wheel Refer to “REAR WHEEL” on page 4-12. 5. Adjust: • Drive chain slack Refer to “DRIVE CHAIN SLACK” on page 3-26. Drive chain slack (Maintenance Stand) 50.0–60.0 mm (1.97–2.36 in) 4-68...

  • Page 197: Chain Drive

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

  • Page 198: 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. Place the vehicle on a maintenance stand so that the rear wheel is elevated. 2.

  • Page 199: Checking The Drive Sprocket

    CHAIN DRIVE b. Correct 1. Drive chain roller 2. Drive sprocket EAM30078 CHECKING THE REAR WHEEL SPROCKET Refer to “CHECKING AND REPLACING THE REAR WHEEL SPROCKET” on page 4-13. EAM30079 INSTALLING THE DRIVE CHAIN 1. Install: 4. Check: • Drive chain •...
  • Page 200 CHAIN DRIVE 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. Therefore, keep the drive chain slack within the specified lim- its.

  • Page 201: Engine

    ENGINE LUBRICATION SYSTEM CHART AND DIAGRAMS ........5-1 ENGINE OIL LUBRICATION CHART............5-1 LUBRICATION DIAGRAMS ...............5-2 ENGINE REMOVAL ..................5-6 REMOVING THE ENGINE ...............5-10 INSTALLING THE ENGINE ..............5-10 INSTALLING THE EXHAUST PIPE AND MUFFLER .......5-11 CAMSHAFT ....................5-13 REMOVING THE CAMSHAFT ..............5-15 CHECKING THE CAMSHAFT ..............5-16 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET...5-17 CHECKING THE TIMING CHAIN TENSIONERS........5-17 CHECKING THE DECOMPRESSION SYSTEM ........5-17...
  • Page 202 ELECTRIC STARTER..................5-42 CHECKING THE STARTER MOTOR ............5-44 ASSEMBLING THE STARTER MOTOR ..........5-44 CLUTCH......................5-46 REMOVING THE CLUTCH ..............5-49 CHECKING THE FRICTION PLATES ............5-49 CHECKING THE CLUTCH PLATES ............5-49 CHECKING THE CLUTCH SPRINGS ............5-49 CHECKING THE CLUTCH HOUSING .............5-49 CHECKING THE CLUTCH BOSS ............5-49 CHECKING THE PRESSURE PLATE .............5-50 CHECKING THE PUSH LEVER SHAFT ..........5-50 CHECKING THE PUSH RODS ..............5-50...

  • Page 203: Lubrication System Chart And Diagrams

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

  • Page 204: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30507 LUBRICATION DIAGRAMS 1. Camshaft 2. Drive axle 3. Main axle...
  • Page 205 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Connecting rod 2. Oil nozzle 3. Crankshaft...
  • Page 206 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Exhaust camshaft 2. Intake camshaft 3. Oil filter element 4. Oil pump...
  • Page 207 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter element 2. Oil pump 3. Oil strainer...

  • Page 208: Engine Removal

    ENGINE REMOVAL EAM20105 ENGINE REMOVAL Removing the exhaust pipe 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 209 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 210 ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 85 N ・ m (8.5 kgf ・ m, 63 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 53 N ・...
  • Page 211 ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 85 N ・ m (8.5 kgf ・ m, 63 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 53 N ・...

  • Page 212: Removing The Engine

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

  • Page 213: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL 2. Install: Engine mounting bolt (upper • Clamp side) • Exhaust pipe 2 “1” 45 N·m (4.5 kgf·m, 33 lb·ft) • Bolt (exhaust pipe 2) “2” Apply molybdenum disulfide grease to the pivot shaft. Make sure that the exhaust pipe band “3” does not ride on the projection “a”...
  • Page 214 ENGINE REMOVAL Bolt (exhaust pipe 2) 20 N·m (2.0 kgf·m, 15 lb·ft) • Clamp Clamp 12 N·m (1.2 kgf·m, 8.9 lb·ft) Tighten while checking that their front and rear joints are inserted in position. 5-12...

  • Page 215: Camshaft

    Refer to “ENGINE REMOVAL” on page 5-6. Cylinder head breather hose Cylinder head cover breather plate Gasket Spark plug Cylinder head cover Timing chain guide (top side) Cylinder head cover gasket Gasket * Yamaha bond No. 1215 (Three bond No.1215®) 5-13...
  • Page 216 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 217: Removing The Camshaft

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

  • Page 218: Checking The Camshaft

    CAMSHAFT c. Install the dowel pins and the camshaft EAM30081 CHECKING THE CAMSHAFT caps. 1. Check: • Camshaft lobe • Tighten the camshaft cap bolts in a crisscross Blue discoloration/pitting/scratches  Re- pattern from innermost to outer caps. place the camshaft. •...

  • Page 219: Checking The Timing Chain And Camshaft Sprocket

    CAMSHAFT EAM30082 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET 1. Check: • Timing chain “1” Damage/stiffness  Replace the timing chain and camshaft as a set. 2. Check: • Camshaft sprocket More than 1/4 tooth wear “a”  Replace the camshaft and the timing chain as a set.
  • Page 220 CAMSHAFT timing will result. d. Install the clips, the camshaft caps and the bolts (camshaft cap). Bolt (camshaft cap) 10 N·m (1.0 kgf·m, 7.4 lb·ft) • Before installing the clips, cover the cylinder head with a clean cloth to prevent the clips from coming off into the cylinder head cavity.
  • Page 221 CAMSHAFT der head cover gasket. Timing chain tensioner bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Yamaha bond No. 1215 90890-85505 Three bond No. 1215® c. Release the screwdriver, check that the tensioner rod comes out smoothly, and tighten the gasket “5” and the cap bolt “6”.

  • Page 222: Cylinder Head

    CYLINDER HEAD EAM20107 CYLINDER HEAD Removing the cylinder head 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 90˚ 60˚ 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 7 N ・...
  • Page 223 CYLINDER HEAD Removing the cylinder head 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 90˚ 60˚ 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 7 N ・...

  • Page 224: Removing The Cylinder Head

    CYLINDER HEAD page 5-28. EAM30086 REMOVING THE CYLINDER HEAD • Cylinder head coolant passages 1. Remove: Mineral deposits/rust  Eliminate. • Cylinder head bolt 3. Measure: • Cylinder head warpage • Loosen the bolts in the proper sequence as Out of specification  Resurface the cylinder shown.
  • Page 225 CYLINDER HEAD 2. Install: • Washer “1” • Bolt “2” • Bolt “3” f. Loosen the bolt [1]. Loosen the bolt [1] only without loosening any other bolt. g. Again apply molybdenum disulfide grease Tighten the bolts using the following procedure. to the thread and contact surface of the bolts and to both contact surface of the a.
  • Page 226 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 227: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAM20108 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-20. Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Intake valve...

  • Page 228: 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 229: 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 230: 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 231: Checking The Valve Springs

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

  • Page 232: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 3. Install: EAM30094 CHECKING THE VALVE LIFTERS • Spring seat “1” 1. Check: • Valve stem seal “2” • Valve lifter • Valve “3” Damage/scratches  Replace the valve lift- • Valve spring “4” ers and cylinder head. •...
  • Page 233 VALVES AND VALVE SPRINGS 5. To fasten the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. ECA13800 NOTICE Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Adjusting pad “1” •...

  • Page 234: Cylinder And Piston

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

  • Page 235: 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 236: 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 237: 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 238 CYLINDER AND PISTON • Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity. 3. Lubricate: • Piston • Piston ring • Cylinder 4. Offset: • Piston ring end gap a. Top ring b. 2nd ring c.

  • Page 239: Generator

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

  • Page 240: Removing The Generator

    • Stator coil assembly “2” outer surface “b” the T25 bit. Damage  Inspect the crankshaft runout and • Pass the stator coil assembly lead through the crankshaft bearing. crankcase cover side. Yamaha bond No. 1215 90890-85505 Three bond No. 1215® 5-38...
  • Page 241 GENERATOR • Crankcase cover (left) “3” • Lead holder “4” • Bolt (left crankcase cover) “5” Bolt (left crankcase cover) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Tighten the bolts in stages and in a crisscross pattern. 2. Install: • Woodruff key “1” •...

  • Page 242: Starter Clutch

    STARTER CLUTCH EAM20175 STARTER CLUTCH Removing the starter clutch 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Refer to “CHANGING THE ENGINE OIL” on Engine oil page 3-14. Clutch Refer to “CLUTCH” on page 5-46. Holder Washer Damper assembly...

  • Page 243: Checking The Starter Clutch

    STARTER CLUTCH EAM30140 CHECKING THE STARTER CLUTCH 1. Check: • Starter clutch assembly • Starter clutch drive gear Burrs/chips/roughness/wear  Replace the starter clutch. 2. Check: • Starter clutch assembly gear Damage/pitting/wear  Replace the starter clutch assembly. 3. Check: •...

  • Page 244: 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 245 ELECTRIC STARTER Disassembling the starter motor 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 4.5 N ・ m (0.45 kgf ・ m, 3.3 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Starter motor assembly O-ring Starter motor front cover Starter motor yoke Armature assembly...

  • Page 246: 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 247 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 248 CLUTCH EAM20111 CLUTCH Removing the clutch 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 75 N ・...
  • Page 249 CLUTCH Removing the clutch 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 75 N ・...
  • Page 250 CLUTCH Removing the right crankcase cover 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 251: Removing The Clutch

    CLUTCH 2. Measure: EAM30108 REMOVING THE CLUTCH • Clutch plate warpage 1. Remove: (with a surface plate and thickness gauge) • Clutch boss nut “1” Out of specification  Replace the clutch • Lock washer “2” plates as a set. •...

  • Page 252: Checking The Pressure Plate

    CLUTCH boss. Pitting on the clutch boss splines will cause er- ratic clutch operation. 1 1 1 2. Measure: • Push rod 2 bending limit Out of specification  Replace. Push rod bending limit 0.10 mm (0.004 in) EAM30114 CHECKING THE PRESSURE PLATE 1.
  • Page 253 CLUTCH 2. Install: • Dowel pin “1” • O-ring “2” • Collar “3” • Gasket “4” Apply the lithium-soap-based grease on the O- ring. 4. Install: • Push lever shaft “1” • Apply the lithium-soap-based grease on the oil seal lip. •...
  • Page 254 CLUTCH 1 1 1 8. Install: 6. Install: • Friction plate 1 “1” • Lock washer “1” • Clutch plate “2” • Clutch boss nut “2” • Friction plate 2 “3” Clutch boss nut 75 N·m (7.5 kgf·m, 55 lb·ft) •...
  • Page 255 CLUTCH 13.Install: • O-ring “1” Apply the lithium-soap-based grease to the O- ring. 10.Install: • Push rod 2 “1” • Ball “2” • Push rod 1 “3” Apply the engine oil on the push rod 1, 2 and 14.Install: ball. •...

  • Page 256: Shift Shaft

    SHIFT SHAFT EAM20113 SHIFT SHAFT Removing the shift shaft and stopper lever 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 10 N ・...

  • Page 257: Removing The Segment

    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 258 SHIFT SHAFT Segment bolt 30 N·m (3.0 kgf·m, 22 lb·ft) • Align the notch “a” on the segment with the pin “b” on the shift cam. • With the stopper lever pushed down, install the segment. ECA24680 NOTICE 6. Tighten: If the segment gets an impact, the stopper le- •...
  • Page 259 SHIFT SHAFT Align the punch mark “a” on the shift shaft with the punch mark “b” in the shift pedal. 5-57...

  • Page 260: Oil Pump

    OIL PUMP EAM20182 OIL PUMP Removing the oil pump 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Primary driven gear Refer to “CLUTCH”...
  • Page 261 OIL PUMP Removing the balancer 80 N ・ m (8.0 kgf ・ m, 59 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 45 N ・ m (4.5 kgf ・ m, 33 lb ・ ft) 50 N ・...

  • Page 262: Removing The Balancer

    OIL PUMP EAM30133 REMOVING THE BALANCER 1 1 1 1. Straighten the lock washer tab. 2. Loosen: • Balancer nut “1” • Primary drive gear nut “2” • Balancer weight gear nut “3” Place an aluminum plate “a” between the teeth of the balancer drive gear “4”...

  • Page 263: Installing The Oil Pump

    OIL PUMP 2. Install: 2. Install: • Outer rotor “1” • Balancer drive gear “1” • Align the punched mark “a” on the balancer Apply the engine oil on the outer rotor. drive gear with the punched mark “b” on the balancer weight gear.
  • Page 264 OIL PUMP • Apply engine oil to the contact surfaces of the conical washer. • Place an aluminum plate “a” between the teeth of the balancer drive gear “10” and balancer weight gear “11”. • Install the conical washer with its convex sur- face “b”...

  • Page 265: Crankcase

    CRANKCASE EAM20116 CRANKCASE Separating the crankcase 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 12 N ・...
  • Page 266 CRANKCASE Removing the bearing and oil seal 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 12 N ・...

  • Page 267: 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 268: Assembling The Crankcase

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

  • Page 269: 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 5-63. Transmission Refer to “TRANSMISSION” on page 5-70. Balancer shaft Crankshaft assembly 5-67...

  • Page 270: Removing The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT Out of specification  Replace the crank- EAM30491 REMOVING THE CRANKSHAFT shaft. 1. Remove: • Balancer shaft “1” Turn the crankshaft slowly. Remove the balancer shaft with its flat side “a” Runout limit facing the crankshaft. 0.030 mm (0.0012 in) 2.

  • Page 271: 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 272: Transmission

    TRANSMISSION EAM20118 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-6. Separate. Crankcase Refer to “CRANKCASE” on page 5-63. Main axle Drive axle Long shift fork guide bar Short shift fork guide bar Spring Shift cam...

  • Page 273: Removing The Transmission

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

  • Page 274: Installing The Transmission

    TRANSMISSION install. 2. Measure: • Drive axle runout 2. Install: (with a centering device and dial gauge “1”) • Collar “1” Out of specification  Replace the drive axle. • 2nd wheel gear (26T) “2” • 4th wheel gear (21T) “3” Drive axle runout limit •...
  • Page 275 TRANSMISSION 6. Install: • Shift fork 1 (L) “1” • Shift fork 2 (C) “2” • Shift fork 3 (R) “3” • Shift cam “4” (to the main axle and the drive axle) • Apply engine oil to the shift fork grooves. •...
  • Page 276 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 277: 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 .............6-7 CHECKING THE WATER PUMP ...............6-7 ASSEMBLING THE WATER PUMP ............6-7...

  • Page 278: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAM20186 COOLING SYSTEM DIAGRAMS 1. Radiator hose 1 2. Radiator (right) 3. Radiator fan 4. Radiator hose 4 5. Water pump 6. Radiator hose 3 7. Radiator (left)

  • Page 279: Radiator

    RADIATOR EAM20138 RADIATOR Removing the radiator 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・...
  • Page 280 RADIATOR Removing the radiator 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・...

  • Page 281: 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 282 RADIATOR 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 283: Water Pump

    WATER PUMP EAM20139 WATER PUMP Removing the water pump 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT”...

  • Page 284: 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 285 WATER PUMP 5. Install: • Water pump housing “1” • Water pump housing bolt “2” Water pump housing bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) • Washer “3” • Coolant drain bolt “4” Coolant drain bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft)
  • Page 286 WATER PUMP...

  • Page 287: 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 ..............7-3 INSTALLING THE FUEL TANK ..............7-3 THROTTLE BODY ....................7-4 CHECKING THE INJECTOR..............7-7 CHECKING THE THROTTLE BODY ............7-7 CHECKING THE FUEL PRESSURE............7-7...

  • Page 288: Fuel Tank

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

  • Page 289: Removing The Fuel Tank

    FUEL TANK EAM30263 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose coupler EWA19370 WARNING Cover the fuel hose connection with a cloth when disconnecting it. This is because re- sidual pressure in the fuel hose could cause fuel to spurt out when the hose is removed.

  • Page 290: Installing The Fuel Pump

    FUEL TANK • Take care not to kink or pinch the fuel hose. EAM30266 INSTALLING THE FUEL PUMP 1. Install: • Insert the fuel hose into the fuel pipe securely • Fuel pump gasket until you hear a “click”. • Fuel filter •...

  • Page 291: Throttle Body

    THROTTLE BODY EAM20141 THROTTLE BODY Removing the throttle body 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) 8 N ・...
  • Page 292 THROTTLE BODY Removing the throttle body 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) 8 N ・...
  • Page 293 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 294: Checking The Injector

    THROTTLE BODY EAM30271 CHECKING THE INJECTOR 1. Check: • Injector Obstruction  Replace, and check the fuel pump and the fuel injection system. Refer to “FUEL INJECTION SYSTEM” on page 8-27. Deposits  Replace. Damage  Replace. 2. Check: • Injector resistance Refer to “CHECKING THE INJECTOR”...

  • Page 295: Adjusting The Throttle Position Sensor

    Check that the throttle grip is fully closed. d. Connect the throttle position sensor to the wire harness. e. Set the Yamaha diagnostic tool to “diag- nostic mode”. f. Choose the diagnostic code No. “01”. g. Adjust the throttle position sensor mount- ed angle until “11”–“14”...
  • Page 296 THROTTLE BODY...

  • Page 297: Electrical System

    TROUBLESHOOTING................8-25 FUEL INJECTION SYSTEM ................8-27 CIRCUIT DIAGRAM .................8-27 ECU SELF-DIAGNOSTIC FUNCTION .............8-29 TROUBLESHOOTING METHOD .............8-30 YAMAHA DIAGNOSTIC TOOL ..............8-31 CONNECTING THE YAMAHA DIAGNOSTIC TOOL .......8-31 TROUBLESHOOTING DETAILS (FAULT CODE)........8-33 FUEL PUMP SYSTEM..................8-53 CIRCUIT DIAGRAM .................8-53 TROUBLESHOOTING................8-55 ELECTRICAL COMPONENTS...............8-56 CHECKING THE SWITCHES..............8-57 CHECKING THE BULBS AND BULB SOCKETS........8-59...
  • Page 298 CHECKING THE IGNITION COIL ............8-65 CHECKING THE CRANKSHAFT POSITION SENSOR ......8-66 CHECKING THE LEAN ANGLE SENSOR ..........8-67 CHECKING THE STARTER MOTOR OPERATION ........8-67 CHECKING THE STATOR COIL..............8-67 CHECKING THE RECTIFIER/REGULATOR ...........8-67 CHECKING THE SPEED SENSOR ............8-68 CHECKING THE FUEL SENDER ............8-68 CHECKING THE RESISTOR ..............8-68 CHECKING THE RADIATOR FAN MOTOR..........8-69 CHECKING THE COOLANT TEMPERATURE SENSOR ......8-69...

  • 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. Joint connector 7. Engine ground 8. Battery 9. Frame ground 10.Main fuse 11.Starter relay 12.Starter motor 13.Diode 3 14.Diode 5 19.ECU (Engine Control Unit) 20.Ignition coil 21.Spark plug 33.Engine stop switch A.

  • 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. Side cover (left/right) 2. Seat 3. Fuel tank 4. Air scoop (left/right) 5. Air filter case cover 1.
  • 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 8-67. OK 10.Check the ignition system wire har- ness. Repair or replace the wire harness. Refer to “CIRCUIT DIAGRAM” on NG...

  • Page 304: Electric Starting System

    ELECTRIC STARTING SYSTEM EAM20143 ELECTRIC STARTING SYSTEM EAM30279 CIRCUIT DIAGRAM...
  • Page 305 ELECTRIC STARTING SYSTEM 4. Joint connector 6. Main relay 7. Engine ground 8. Battery 9. Frame ground 10.Main fuse 11.Starter relay 12.Starter motor 13.Diode 3 14.Diode 5 19.ECU (Engine Control Unit) 33.Engine stop switch 34.Gear position switch 35.Diode 1 36.Starting circuit cut-off relay 37.Clutch switch 38.Start switch 39.Diode 4...

  • Page 306: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAM30280 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the meter light comes on, the starter motor can only operate if at least one of the following conditions is met: • The transmission is in neutral (the neutral circuit of the gear position switch is closed). •...
  • Page 307 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main relay 4. Diode 3 5. Starting circuit cut-off relay 6. Start switch 7.

  • 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. Air scoop (left/right) 4. Fuel tank 5. Air filter case cover 1. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse(s).
  • Page 309 ELECTRIC STARTING SYSTEM 9. Check the start switch. Refer to “CHECKING THE Replace the start switch. NG SWITCHES” on page 8-57. OK 10.Check the entire starting system’s wiring. Properly connect or repair the starting sys- Refer to “CIRCUIT DIAGRAM” on tem’s wiring.

  • Page 310: Charging System

    CHARGING SYSTEM EAM20144 CHARGING SYSTEM EAM30282 CIRCUIT DIAGRAM 8-11...
  • Page 311 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 7. Engine ground 8. Battery 9. Frame ground 10.Main fuse A. Battery sub-lead B. Wire harness 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. Air scoop (left) 1. Check the entire charging system’s Reconnect. wiring. NG OK 2. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse(s).
  • Page 313 CHARGING SYSTEM 8-14...

  • Page 314: Signaling System

    SIGNALING SYSTEM EAM20154 SIGNALING SYSTEM EAM30348 CIRCUIT DIAGRAM 8-15...
  • Page 315 4. Joint connector 6. Main relay 7. Engine ground 8. Battery 9. Frame ground 10.Main fuse 16.Resistor 17.Diode 2 18.Yamaha diagnostic tool coupler 19.ECU (Engine Control Unit) 23.Fuel sender 32.Speed sensor 41.Multi-function display A. Battery sub-lead B. Wire harness 8-16...

  • Page 316: Troubleshooting

    SIGNALING SYSTEM EAM30349 TROUBLESHOOTING • The speedometer does not operate normally. • The fuel level warning light does not come on. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 1.
  • Page 317 SIGNALING SYSTEM The fuel level warning light fails to come on. 1. Check the fuel sender. Refer to “CHECKING THE FUEL Replace the fuel pump assembly. NG SENDER” on page 8-68. OK 2. Check the resistor. Refer to “CHECKING THE RESIS- Replace the resistor.

  • Page 318: Lighting System

    LIGHTING SYSTEM EAM20153 LIGHTING SYSTEM EAM30346 CIRCUIT DIAGRAM 8-19...
  • Page 319 LIGHTING SYSTEM 4. Joint connector 5. Headlight relay 6. Main relay 7. Engine ground 8. Battery 9. Frame ground 10.Main fuse 19.ECU (Engine Control Unit) 40.Taillight 41.Multi-function display 42.Headlight A. Battery sub-lead B. Wire harness 8-20...

  • Page 320: Troubleshooting

    LIGHTING SYSTEM EAM30347 TROUBLESHOOTING Any of the following fail to light: headlight or meter light. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left) 3. Air scoop (left/right) 4. Fuel tank 1. Check the each bulbs condition. Refer to “CHECKING THE BULBS Replace the bulb(s).
  • Page 321 LIGHTING SYSTEM 8-22...

  • Page 322: Cooling System

    COOLING SYSTEM EAM20155 COOLING SYSTEM EAM30350 CIRCUIT DIAGRAM 8-23...
  • Page 323 COOLING SYSTEM 4. Joint connector 6. Main relay 7. Engine ground 8. Battery 9. Frame ground 10.Main fuse 19.ECU (Engine Control Unit) 25.Radiator fan motor 26.Radiator fan motor fuse 27.Radiator fan motor relay 29.Coolant temperature sensor A. Battery sub-lead B. Wire harness 8-24...

  • Page 324: Troubleshooting

    COOLING SYSTEM EAM30351 TROUBLESHOOTING The radiator fan motor fails to turn. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left) 3. Air scoop (left/right) 4. Fuel tank 1. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse(s). NG...
  • Page 325 COOLING SYSTEM 8-26...

  • Page 326: Fuel Injection System

    FUEL INJECTION SYSTEM EAM20145 FUEL INJECTION SYSTEM EAM30284 CIRCUIT DIAGRAM 8-27...
  • Page 327 6. Main relay 7. Engine ground 8. Battery 9. Frame ground 10.Main fuse 11.Starter relay 13.Diode 3 17.Diode 2 18.Yamaha diagnostic tool coupler 19.ECU (Engine Control Unit) 20.Ignition coil 21.Spark plug 22.Fuel injector 24.Fuel pump 28.Intake air temperature sensor 29.Coolant temperature sensor 30.Throttle position sensor...

  • Page 328: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM EAM30352 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 329: Troubleshooting Method

    1. Check: • Fault code number a. Connect the Yamaha diagnostic tool. Refer to “YAMAHA DIAGNOSTIC TOOL” on page 8-31. b. Check the fault code number displayed on the Yamaha diagnostic tool. c. Identify the faulty system with the fault code number.

  • Page 330: Yamaha Diagnostic Tool

    FUEL INJECTION SYSTEM EAM30285 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool USB (US) 90890-03269...
  • Page 331 FUEL INJECTION SYSTEM When connected to Yamaha diagnostic tool, the vehicle speed signal line between the meter and ECU is disconnected and “Er_1” is always shown on the meter display. 1. Remove the wire harness coupler “1” (to the multifunction display).

  • Page 332: 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 333 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 334 Replace the intake air pressure sensor. Faulty ECU. Replace the ECU. Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-35...
  • Page 335 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 336 Disconnect the coupler, and Yamaha diagnostic tool. Condition is “Recovered”  Go check the pins (for bent or bro- ken terminals and locking condi- to item 8 and finish the service.
  • Page 337 Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. Fault code No. 16 • If fault code numbers 15 and 16 are both displayed, perform checkup and repair jobs for fault code number 15 first.
  • Page 338 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 339 Refer to “RADIATOR” on page 6-2. item 6. Faulty ECU. Replace the ECU. Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-40...
  • Page 340 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 341 Push the start switch (main relay ON), wait 10 seconds, then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 4 and finish the service. Condition is “Detected”  Go to item 2.
  • Page 342 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 343 Check the condition of the fault the coupler. ness. code using the malfunction Disconnect the coupler, and mode of the Yamaha diagnostic check the pins (for bent or bro- tool. Condition is “Recovered”  Go ken terminals and locking condi- tion of the pins).
  • Page 344 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 345 Check the condition of the fault check the pins (bent or broken code using the malfunction terminals and locking condition mode of the Yamaha diagnostic of the pins). tool. Condition is “Recovered”  Go to item 6 and finish the service.
  • Page 346 Check the condition of the fault check the pins (bent or broken code using the malfunction terminals and locking condition mode of the Yamaha diagnostic of the pins). tool. Condition is “Recovered”  Go to item 6 and finish the service.
  • Page 347 If the same number is indicated, go to item 4. Faulty ECU. Replace the ECU. Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-48...
  • Page 348 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 349 ECU. 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. 50 Before troubleshooting, disconnect the starter motor lead from the starter relay.
  • Page 350 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. 8-51...
  • Page 351 FUEL INJECTION SYSTEM 8-52...

  • Page 352: Fuel Pump System

    FUEL PUMP SYSTEM EAM20146 FUEL PUMP SYSTEM EAM30287 CIRCUIT DIAGRAM 8-53...
  • Page 353 FUEL PUMP SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Joint connector 7. Engine ground 8. Battery 9. Frame ground 10.Main fuse 19.ECU (Engine Control Unit) 24.Fuel pump 33.Engine stop switch A. Battery sub-lead B. Wire harness 8-54...

  • Page 354: Troubleshooting

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

  • Page 355: Electrical Components

    ELECTRICAL COMPONENTS EAM20147 ELECTRICAL COMPONENTS 1. Intake air pressure sensor 2. Throttle position sensor 3. Injector 4. Rectifier/regulator 5. Intake air temperature sensor 6. ECU (Engine Control Unit) 7. Ignition coil 8. Coolant temperature sensor 9. Resistor 10.Starter relay 11.Main fuse 12.Battery 13.Radiator fan motor fuse 14.Radiator fan motor relay...

  • Page 356: Checking The Switches

    ELECTRICAL COMPONENTS EAM30289 CHECKING THE SWITCHES Y/W P 1. Engine stop switch 2. Gear position switch 3. Engine start switch 4. Clutch switch 8-57...
  • Page 357 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 358: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS 2. Check: EAM30357 CHECKING THE BULBS AND BULB • Main fuse “1” SOCKETS • Radiator fan motor fuse “2” 1. Remove: • Bulb ECA25930 NOTICE Be sure to hold the socket firmly when re- moving the bulb. Never pull the lead, other- wise it may be pulled out of the terminal in the coupler.

  • Page 359: Checking And Charging The Battery

    ELECTRICAL COMPONENTS Refer to “GENERAL CHASSIS” on page 4-1. teries are sealed, it is not possible to check the charge state of the battery by measuring the EAM30291 specific gravity of the electrolyte. Therefore, the CHECKING AND CHARGING THE BATTERY charge of the battery has to be checked by mea- EWA13290 suring the voltage at the battery terminals.
  • Page 360 ELECTRICAL COMPONENTS charger leads are connected to the battery. • Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger. • Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted.

  • Page 361: Checking The Relays

    ELECTRICAL COMPONENTS the standard charging current written on after leaving the battery unused for more the battery. than 30 minutes. 12.8 V or more --- Charging is complete. If the current is lower than the standard charging 12.7 V or less --- Recharging is required. current written on the battery, set the charging Under 12.0 V --- Replace the battery.
  • Page 362 ELECTRICAL COMPONENTS Starter relay Starting circuit cut-off relay Br/W 1. Positive battery terminal 1. Positive battery terminal 2. Negative battery terminal 2. Negative battery terminal 3. Positive tester probe 3. Positive tester probe 4. Negative tester probe 4. Negative tester probe Result Result Continuity...

  • Page 363: Checking The Relay Unit (Diode)

    ELECTRICAL COMPONENTS Radiator fan motor relay No continuity Positive tester probe  Sky blue “1” Negative tester probe  Green/Black “2” Continuity Positive tester probe  Green/Black “2” Negative tester probe  Sky Br,R/W blue “1” No continuity Positive tester probe  Red “3” Negative tester probe ...

  • Page 364: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS L/G, 2. Spark plug cap d. Crank the engine, and gradually increase the spark gap until a misfire occurs. EAM30295 CHECKING THE SPARK PLUG CAP Br/W,Br 1. Remove: • Spark plug cap (from the spark plug lead) 2. Check: •...

  • Page 365: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS 2. Check: • Primary coil resistance Out of specification  Replace. Primary coil resistance 2.16–2.64  a. Connect the digital circuit tester () to the ignition coil. Digital circuit tester (CD732) 90890-03243 b. Measure the secondary coil resistance. Model 88 Multimeter with tachom- eter EAM30297...

  • Page 366: Checking The Lean Angle Sensor

    ELECTRICAL COMPONENTS Out of specification  Replace. EAM30298 CHECKING THE LEAN ANGLE SENSOR 1. Check: Stator coil resistance 0.368–0.552  • Mounted condition of ECU Improperly mounted  Remount. a. Connect the digital circuit tester () to the stator coil assembly coupler. •...

  • Page 367: Checking The Speed Sensor

    ELECTRICAL COMPONENTS • Positive tester probe  Red “1” • Negative tester probe  Black “2” c. Push the start switch. d. Elevate the front wheel and slowly turn it. e. Measure the voltage (DC 5 V) of white and black/white.

  • Page 368: Checking The Radiator Fan Motor

    ELECTRICAL COMPONENTS EAM30303 Resistor resistance CHECKING THE COOLANT TEMPERATURE 64.6–71.4  SENSOR 1. Remove: a. Connect the digital circuit tester () to the • Coolant temperature sensor resistor as shown. EWA14130 WARNING Digital circuit tester (CD732) • Handle the coolant temperature sensor 90890-03243 with special care.

  • Page 369: Checking The Throttle Position Sensor Input Voltage

    ELECTRICAL COMPONENTS d. Slowly heat the coolant, and then let it cool to the specified temperature indicated in the table. e. Check the coolant temperature sensor for continuity at the temperatures indicated in the table. c. Start the engine. d. Measure the throttle position sensor input voltage.

  • Page 370: Checking The Gear Position Switch

    ELECTRICAL COMPONENTS Y/W P EAM30496 EAM30467 CHECKING THE INJECTOR CHECKING THE GEAR POSITION SWITCH 1. Remove: 1. Remove: • Fuel injector • Gear position switch Refer to “THROTTLE BODY” on page 7-4. 2. Check: • Gear position switch 2. Check: Out of specification ...

  • Page 371: 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 TROUBLESHOOTING OF LIGHTING SYSTEM ........9-11 TROUBLESHOOTING OF SIGNALING SYSTEM ........9-11 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE....9-12...

  • Page 372: 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 373 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 374 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 375: 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 376 TROUBLESHOOTING Symptom Possible cause Actions Replace the clutch springs as a Faulty clutch spring set. Warped pressure plate Replace the pressure plate. Replace the friction plates as a Swollen friction plate set. Warped clutch plate Replace the clutch plates as a set. Bent pull rod (outer pull type) Replace the pull rod.

  • Page 377: 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 378: 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 379: 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 380 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 381: 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 382: 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 383: Self-Diagnostic Function And Diagnostic Code Table

    Pressure of suction pipe Displays the intake air pressure. The atmospheric pressure is • Check the change of the displayed on the Yamaha intake pressure valve when diagnostic tool. the starter switch is pushed. Intake air temperature Displays the intake air tempera- Compare the actually mea- ture.
  • Page 384 Procedure code Coolant temperature Displays the coolant tempera- Compare the actually mea- ture. sured coolant temperature with the Yamaha diagnostic tool display value. Vehicle speed pulses Vehicle speed pulse Check that the number 0–999 increases when the front wheel is rotated. The number...

  • Page 385: 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 386 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9-15...

  • Page 387: 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 ................10-1 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 388: Chassis

    CHASSIS EAM20119 Part name Type Part number CHASSIS Rear wheel 5GS-25448-50 EAM30168 sprocket “2” SELECTION OF THE SECONDARY (STD) 5TJ-25450-80 REDUCTION RATIO (SPROCKET) BAK-25451-00 Secondary reduction ratio = Number of 5TJ-25452-80 rear wheel sprocket teeth/Number of drive sprocket teeth Secondary reduction ratio 3.846 (50/13) <Requirement for selection of secondary gear reduction ratio>...

  • Page 389: Change In Amount And Characteristics Of Fork Oil

    SETTING OF SPRING AFTER REPLACEMENT Recommended oil As the front fork setting can be easily affected by Yamaha Suspension Oil S1 the rear suspension, take care so that the front Standard oil amount and the rear are balanced (in position etc.) when 285 cm³...

  • Page 390: 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 391: Setting Of Spring After Replacement

    CHASSIS EAM30177 EAM30178 SETTING OF SPRING AFTER REAR SHOCK ABSORBER SETTING PARTS REPLACEMENT • Rear shock spring “1” After replacement, be sure to adjust the spring to STD Spring rate the set length [sunken length 90–100 mm (3.5– N/mm 3.9 in)] and set it. Spring I.D.
  • Page 392 CHASSIS • Spring preload adjusting positions Spring preload adjusting positions Minimum Position in which the spring is turned in 1.5 mm (0.06 in) from its free length. Standard Position in which the spring is turned in 10.0 mm (0.39 in) from its free length.

  • Page 393: 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 394: 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 395 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 396 CHASSIS 10-9...
  • Page 397 Black/Orange 14. Diode 5 Black/Red 15. Coupler (not used) Black/White 16. Resistor Black/Yellow 17. Diode 2 Br/W Brown/White 18. Yamaha diagnostic tool cou- Green/Black pler Green/White 19. ECU (Engine Control Unit) Green/Yellow 20. Ignition coil Blue/Black 21. Spark plug Blue/Green 22.
  • Page 399 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 401 WR450FN 2022 WIRING DIAGRAM R R R Br/W Br Br B B B R R R/L Br Br Br Br/W (Gy) B/L Gy Gy B (Gy) R,R/W R,R/Y L/G Br/W Br/W Br/W Br/W B/Y R/L Br/W,Br Br/W R/W,Br Br/W L/G,...
  • Page 402 WR450FN 2022 WIRING DIAGRAM (Gy) (Gy) (Dl)

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