Yamaha YZ450F 2023 Owner's Manual
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Yamaha YZ450F 2023 Owner's Manual

Yamaha YZ450F 2023 Owner's Manual

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OWNER'S MANUAL
MANUEL DU PROPRIÉTAIRE
BEDIENUNGSANLEITUNG
USO E MANUTENZIONE
MANUAL DEL PROPIETARIO
Read this manual carefully before operating this vehicle.
Il convient de lire attentivement ce manuel avant la première utilisation du véhicule.
Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
Leggere attentamente questo manuale prima di utilizzare questo veicolo.
Lea este manual atentamente antes de utilizar este vehículo.
2023
YZ450F
YZ450F
YZ450FP
BHR-28199-50 1

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  • Page 1 2023 OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE BEDIENUNGSANLEITUNG USO E MANUTENZIONE MANUAL DEL PROPIETARIO YZ450F Read this manual carefully before operating this vehicle. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen. Leggere attentamente questo manuale prima di utilizzare questo veicolo.
  • Page 2 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit être remis avec le véhicule en cas de vente de ce dernier. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
  • Page 3 2023 OWNER’S MANUAL YZ450F Read this manual carefully before operating this vehicle. YZ450F YZ450FP BHR-28199-50-E0...
  • Page 4 If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform Transport Canada in addition to notifying Yamaha Motor Canada Ltd, Canada. If Transport Canada receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
  • Page 5 EAM20080 Declaration of Conformity In accordance with UK Government guidance We,YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product Kind of Products: Off-Road Motorcycles Model Year: 2023 Type Designation: YZ450F (Make, model) The object of the declaration described above is in conformity with the relevant UK Statutory Instruments (and their amendments): No.
  • Page 6 EAM20180 IMPORTANT Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.

  • Page 7: Table Of Contents

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

  • Page 9: General Information

    GENERAL INFORMATION SAFETY INFORMATION..................1-1 FOR SAFETY, BE SURE TO OBEY THE FOLLOWING: ......1-1 LOCATION OF IMPORTANT LABELS ............1-4 DESCRIPTION....................1-7 IDENTIFICATION....................1-8 VEHICLE IDENTIFICATION NUMBER ............1-8 ENGINE SERIAL NUMBER ...............1-8 INCLUDED PARTS...................1-9 SIDESTAND ....................1-9 NIPPLE WRENCH..................1-9 HANDLEBAR PROTECTOR ..............1-9 FUEL HOSE JOINT COVER ..............1-9 POWER TUNER..................1-9 IMPORTANT INFORMATION .................1-11 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-11...
  • Page 10 TORQUE-CHECK POINTS................1-18 MOTORCYCLE CARE AND STORAGE ............1-20 CARE......................1-20 STORAGE ....................1-21...

  • Page 11: 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 12 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 13 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 14: Location Of Important Labels

    LOCATION OF IMPORTANT LABELS EAM20085 LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle. 1, 2, 3 4, 5, 6 8, 9, 10...
  • Page 15 LOCATION OF IMPORTANT LABELS 4AA-22259-40...
  • Page 16 LOCATION OF IMPORTANT LABELS AUS, NZL, ZAF 4AA-22259-40...

  • Page 17: Description

    DESCRIPTION EAM20086 DESCRIPTION 10.Radiator 1. Clutch lever 11.Coolant drain bolt 2. Front brake lever 3. Throttle grip 12.Oil level check window 13.Rear brake pedal 4. Start switch 14.Air filter 5. Radiator cap 15.Drive chain 6. Fuel tank cap 16.Shift pedal 7.

  • Page 18: Identification

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

  • Page 19: Included Parts

    INCLUDED PARTS EAM20088 INCLUDED PARTS EAM30190 SIDESTAND This sidestand “1” is used to support only the machine when standing or transporting it. EWA20260 WARNING • Never apply additional force to the sides- tand. • Remove this sidestand before starting out. EAM30007 FUEL HOSE JOINT COVER EAM30005...
  • Page 20 INCLUDED PARTS pression ratio, etc.) have been changed, the performance may not match to the actu- al settings. COMMUN.CONT.UNIT ASSY. • Do not run the engine with the smartphone carried with you. Otherwise, the smart- phone could be damaged. P/N: S/N: •...

  • Page 21: Important Information

    YAMAHA genuine Refer to “CARE” on page 1-20. parts and recommended parts.

  • Page 22: Instrument And Control Functions

    • Indicator light on the handlebar switch (left) flashes orange  Check or replace any faulty electrical part(s). Have a Yamaha dealer check the electrical system. A. Drive mode 1 B. Drive mode 2 3.

  • Page 23: Lap Time Record Mode

    3rd gear. electrical part(s). The launch control system will also turn off Have a Yamaha dealer check the electrical sys- when the engine is stopped or the gear is tem. shifted into the 3rd gear or higher.

  • Page 24: Shift Pedal

    INSTRUMENT AND CONTROL FUNCTIONS EAM30185 SHIFT PEDAL When operating the throttle grip in the closing di- The shift pedal “1” has adopted a method of 1 rection, the starter knob “1” moves in the direc- down & 4 ups (press-down & kick-ups). tion “b”...

  • Page 25: Starting And Break-In

    (of 3000 to 5000 r/min), and then return the start- Your Yamaha engine has been designed to use er knob to its original position. unleaded gasoline with a pump octane number...

  • Page 26: Starting A Warm Engine

    STARTING AND BREAK-IN CHECK POINTS” for tightening torques and retighten them. Also when the following parts are replaced, a break-in is required. • Cylinder and Crankshaft: A break-in is re- quired for about an hour. • Piston, Piston ring, Valve, Camshaft, and Gear: A break-in is required for about 30 minutes at a throttle opening of 1/2 or less.

  • Page 27: 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 28: Torque-Check Points

    TORQUE-CHECK POINTS EAM20125 TORQUE-CHECK POINTS Frame construction Fuel tank to frame Frame to rear frame Frame to engine protector Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Seat Seat to rear fender Steering Steering stem to handlebar Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar...
  • Page 29 TORQUE-CHECK POINTS Shift pedal Shift pedal to shift shaft Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of shroud Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake caliper cover Concerning the tightening torque, refer to “TIGHTENING TORQUES”...

  • Page 30: Motorcycle Care And Storage

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

  • Page 31: 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 32 MOTORCYCLE CARE AND STORAGE stored. Long-term Before storing your motorcycle for several months: 1. Follow all the instructions in the “CARE” on page 1-20. 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 33: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-4 ELECTRICAL SPECIFICATIONS ..............2-7 TIGHTENING TORQUES .................2-8 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-8 ENGINE TIGHTENING TORQUES............2-9 CHASSIS TIGHTENING TORQUES............2-12...

  • Page 34: General Specifications

    GENERAL SPECIFICATIONS EAM20127 GENERAL SPECIFICATIONS Model Model BHR1 (CAN) BHR2 (AUT, BEL, CHE, CYP, CZE, DEU, DNK, ESP, FIN, FRA, GBR, GRC, HRV, HUN, IRL, ITA, NLD, NOR, POL, PRT, SVK, SVN, SWE, TUR) BHR4 (AUS, NZL, ZAF) BHR5 (CAN) BHR6 (AUT, BEL, CHE, CYP, CZE, DEU, DNK, ESP, FIN, FRA, GBR, GRC, HRV, HUN, IRL, ITA, NLD, NOR, POL, PRT, SVK, SVN, SWE,...

  • Page 35: 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 36 3.769 (49/13) Final drive Chain Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil Idling condition Engine idling speed 1900–2100 r/min 70–80 C (158–176 F) Coolant temperature Throttle grip free play 3.0–6.0 mm (0.12–0.24 in)

  • Page 37: Chassis Specifications

    Fork spring free length limit 492.0 mm (19.37 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil S1 Quantity (left) 476.0 cm³ (16.09 US oz, 16.79 Imp.oz) (AUS, CAN, NZL, ZAF) 491.0 cm³ (16.60 US oz, 17.32 Imp.oz) (AUT,...
  • Page 38 CHASSIS SPECIFICATIONS Quantity (right) 476.0 cm³ (16.09 US oz, 16.79 Imp.oz) (AUS, CAN, NZL, ZAF) 491.0 cm³ (16.60 US oz, 17.32 Imp.oz) (AUT, BEL, CHE, CYP, CZE, DEU, DNK, ESP, FIN, FRA, GBR, GRC, HRV, HUN, IRL, ITA, NLD, NOR, POL, PRT, SVK, SVN, SWE, TUR) Rebound damping Adjusting system Mechanical adjustable type...
  • Page 39 CHASSIS SPECIFICATIONS Adjustment value from the start position (STD) 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...

  • Page 40: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAM20130 ELECTRICAL SPECIFICATIONS Battery Model BR98 Voltage, capacity 12 V, 2.4 Ah (5 HR) Fuse(s) Main fuse 15.0 A Spare fuse 15.0 A...

  • Page 41: 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 42 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 43 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Clutch cable locknut (clutch cable 4.3 N·m (0.43 kgf·m, 3.2 lb·ft) adjuster) Clutch cable locknut (engine side) 7 N·m (0.7 kgf·m, 5.2 lb·ft) Exhaust pipe nut 10 N·m (1.0 kgf·m, 7.4 lb·ft) Exhaust pipe protector screw 10 N·m (1.0 kgf·m, 7.4 lb·ft) Exhaust pipe bracket bolt...
  • Page 44 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Stopper lever bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Shift pedal bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft)  Generator rotor nut 65 N·m (6.5 kgf·m, 48 lb·ft) Stator coil screw 10 N·m (1.0 kgf·m, 7.4 lb·ft) Crankshaft position sensor bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft)
  • Page 45 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 46 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Front brake disc bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) / Rear brake disc bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) / Footrest bracket bolt 55 N·m (5.5 kgf·m, 41 lb·ft) Rear brake pedal bolt 26 N·m (2.6 kgf·m, 19 lb·ft) ...
  • Page 47 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Drive chain support nut 7 N·m (0.7 kgf·m, 5.2 lb·ft) Drive chain guide bolt 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) Fuel tank bolt (front side) 8 N·m (0.8 kgf·m, 5.9 lb·ft) ...
  • Page 48 TIGHTENING TORQUES 2-15...
  • Page 49 PERIODIC CHECKS AND ADJUSTMENTS SERVICING PARTS..................3-1 MAINTENANCE INTERVALS................3-2 MAINTENANCE INTERVALS ..............3-2 PRE-OPERATION INSPECTION AND MAINTENANCE .........3-6 GENERAL INSPECTION AND MAINTENANCE........3-6 ENGINE ......................3-7 ADJUSTING THE VALVE CLEARANCE ...........3-7 CHECKING THE ENGINE IDLING SPEED ..........3-8 CHECKING THE THROTTLE GRIP............3-8 CHECKING THE SPARK PLUG ..............3-9 CHECKING THE ENGINE OIL LEVEL............3-9 CHANGING THE ENGINE OIL ..............3-10 ADJUSTING THE CLUTCH LEVER FREE PLAY........3-11...
  • Page 50 CHECKING THE CHASSIS FASTENERS ..........3-30 CHECKING AND LUBRICATING THE CABLES ........3-30 LUBRICATING THE BRAKE LEVER ............3-31 LUBRICATING THE CLUTCH LEVER.............3-31 LUBRICATING THE PEDAL ..............3-31 ELECTRICAL SYSTEM..................3-32 CHECKING AND CHARGING THE BATTERY........3-32 CHECKING THE FUSES .................3-32...
  • Page 51 * For AUS, AUT, BEL, CHE, CYP, CZE, DEU, DNK, ESP, FIN, FRA, GBR, GRC, HRV, HUN, IRL, ITA, NLD, NOR, NZL, POL, PRT, SVK, SVN, SWE, TUR, ZAF ** For CAN The part number is subject to change. In that case, order the part from a Yamaha dealer by stating the identification number of your vehicle.

  • Page 52: Maintenance Intervals

    (e.g., rain, dirt, etc.). Therefore, earlier inspection is required by reference to the list below. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 53 MAINTENANCE INTERVALS Every Every Every After race third race fifth race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours) • Check the coolant passages for corrosion. • Inspect carbon deposits and elim-  11 * Cylinder head inate them.
  • Page 54 MAINTENANCE INTERVALS Every Every Every After race third race fifth race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours)   • Clean.   • Inspect and adjust.   • Replace oil. 29 * Front fork leg(s) ...
  • Page 55 MAINTENANCE INTERVALS Every Every Every After race third race fifth race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours)   Brake pedal, footrest • Lubricate. Outside nuts and • Retighten.   43 * bolts •...

  • Page 56: 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 57: Engine

    • This section is intended for those who have ba- b b b b b sic knowledge and skill concerning the servic- ing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowledge and skill concerning ser-...

  • Page 58: Checking The Engine Idling Speed

    2. Measure the coolant temperature using the Yamaha diagnostic tool. EAM30475 CHECKING THE THROTTLE GRIP Yamaha diagnostic tool USB 90890-03267 Prior to adjusting throttle grip free play, the en- Yamaha diagnostic tool (A/I) gine idling speed should be adjusted.

  • Page 59: Checking The Spark Plug

    ENGINE Damage/wear  Replace the spark plug. • Insulator Abnormal color  Replace the spark plug. Normal color is medium-to-light tan. 5. Clean: • Spark plug (with a spark plug cleaner or a wire brush) 6. Measure: • Spark plug gap “a” Out of specification ...

  • Page 60: Changing The Engine Oil

    ENGINE minimum level (lower edge of the oil check minutes until the oil has settled. window “1”) and the maximum level mark “a”. Below the minimum level  Add the recom- EAM30225 CHANGING THE ENGINE OIL mended engine oil to the proper level. 1.

  • Page 61: Adjusting The Clutch Lever Free Play

    ENGINE b. Look at the oil level check window “1”, and then make sure that the engine oil flows and that the engine oil level decreases. Check the engine oil level while the engine is at idling speed. c. Install the new oil filter element and the oil filter element cover.

  • Page 62: Adjusting The Clutch Lever Position

    ENGINE clutch lever free play is obtained. 2. Tighten: • Locknut Locknut (clutch lever position) 4.8 N·m (0.48 kgf·m, 3.5 lb·ft) EAM30219 CLEANING THE AIR FILTER ELEMENT 1. Remove: • Sub-seat Refer to “FUEL TANK CAP” on page 1-14. • Air filter case cover “1” If the clutch lever free play cannot be obtained To remove the air filter case cover: on the handlebar side, use the adjuster on the...
  • Page 63 “b” on the air filter el- ECA24280 ement guide to the band “c”. NOTICE Do not twist the element when squeezing the element. 4. Check: • Air filter element Damage  Replace. 5. Apply: • Yamaha foam air filter oil or other quality 3-13...

  • Page 64: Checking The Throttle Body Joint

    ENGINE a a a b b b c c c c c c 3 3 3 7. Install: • Air filter case cover “1” • Fuel tank breather hose “2” (to the air filter case cover) • To install the air filter case cover: •...

  • Page 65: Checking The Cylinder Head Breather Hose

    ENGINE • Shroud (left/right) 3. Check: • Fuel tank • Exhaust pipe 1 • Exhaust pipe 2 Refer to “FUEL TANK” on page 6-1. 2. Check: • Silencer • Fuel hose “1” Crack/damage  Replace. Crack/damage  Replace. 4. Check: Loose connection ...
  • Page 66 ENGINE d. Install the fiber insert “6” to the part “b”. h. Install the fiber insert “12” to the inner pipe. e. Twist the fiber insert “7” onto the inner pipe i. Install the fiber insert “13” to the inside of “c”.

  • Page 67: Checking The Coolant Level

    ENGINE 6. Check: EAM30210 CHECKING THE COOLANT LEVEL • Gasket “1” EWA13030 Damage  Replace. WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in- jury.

  • Page 68: Checking The Cooling System

    ENGINE tilled water is not available, soft water may be used. 4. Start the engine, warm this up for several minutes, and then stop it. 5. Check: • Coolant level Before checking the coolant level, wait a few minutes until the coolant has settled. 3.
  • Page 69 ENGINE tion of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft water may be used. • If coolant comes into contact with painted surfaces, immediately wash them with wa- ter. • Do not mix different types of antifreeze. 7.

  • Page 70: 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 71: Checking The Front Brake Pads

    CHASSIS Specified brake fluid DOT 4 a a a EAM30232 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads. A. Front brake 1. Operate the brake. B. Rear brake 2. Check: • Rear brake pad EWA13090 Wear indicator grooves “1”...

  • Page 72: Checking The Rear Brake Hose

    CHASSIS the reservoir to overflow. • Make sure that there is enough brake fluid be- fore applying the brake. Ignoring this precau- tion could allow air to enter the brake system, considerably lengthening the bleeding proce- dure. a a a •...

  • Page 73: Drive Chain Slack

    CHASSIS h. Repeat steps (d) to (g) until all of the air bubbles have disappeared from the brake Measure drive chain slack between the drive fluid in the plastic hose. chain guide and the bottom of the chain as shown. During the procedure, keep adding brake fluid to the reservoir.

  • Page 74: Checking And Adjusting The Steering Head

    CHASSIS Drive chain puller locknut 21 N·m (2.1 kgf·m, 15 lb·ft) EAM30247 CHECKING AND ADJUSTING THE STEERING HEAD 1. Use a maintenance stand to raise the front wheel off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over.

  • Page 75: Lubricating The Steering Head

    Unsmooth operation  Correct or replace. Refer to “FRONT FORK” on page 4-15. If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it. 5. Check: • Protector guide “1”...

  • Page 76: Adjusting The Front Fork Legs

    CHASSIS EAM30239 ADJUSTING THE FRONT FORK LEGS EWA19180 WARNING • Always adjust the left and right front forks evenly. If this is not done, the vehicle may have poor stability. • Securely support the vehicle so that there is no danger of it falling over. Rebound damping ECA24340 Compression damping...

  • Page 77: 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 78 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. 13 click(s) in direction “b”* Standard Maximum (hard) Position in which the spring is 0 click(s) in direction “a”...

  • Page 79: Checking The Swingarm Operation

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

  • Page 80: Checking And Tightening The Spokes

    CHASSIS Tire air pressure (measured on cold tires) Front 100 kPa (1.00 kgf/cm², 15 psi) Rear 100 kPa (1.00 kgf/cm², 15 psi) • Check the tire while it is cold. • Because if the bead stopper tightening nut is loose when the tire pressure is low, the tire could slip off the rim, thus be sure to check and Spoke nipple wrench (6–7) 90890-01521...

  • Page 81: Lubricating The Brake Lever

    CHASSIS place damaged outer cable and inner cables as soon as possible. 1. Check: • Outer cable Damage  Replace. 2. Check: • Cable operation Rough movement  Lubricate. Recommended lubricant Engine oil or a suitable cable lu- bricant Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit- able lubricating device.

  • Page 82: Electrical System

    ELECTRICAL SYSTEM EAM20137 ELECTRICAL SYSTEM EAM30256 CHECKING AND CHARGING THE BATTERY Refer to “CHECKING AND CHARGING THE BATTERY” on page 7-1. EAM30505 CHECKING THE FUSES Refer to “CHECKING THE FUSES” on page 7-1. 3-32...
  • Page 83 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE SEAT ................4-1 REMOVING THE NUMBER PLATE............4-1 INSTALLING THE SHROUD..............4-1 REMOVING THE SIDE COVER..............4-2 INSTALLING THE SIDE COVER ...............4-2 FRONT WHEEL....................4-3 REMOVING THE FRONT WHEEL.............4-3 INSTALLING THE FRONT WHEEL ............4-3 REAR WHEEL ....................4-4 REMOVING THE REAR WHEEL ...............4-4 CHECKING AND REPLACING THE REAR WHEEL SPROCKET ....4-4 INSTALLING THE REAR WHEEL..............4-4 FRONT BRAKE ....................4-6...
  • Page 84 CHAIN DRIVE....................4-31 REMOVING THE DRIVE CHAIN..............4-31 CHECKING THE DRIVE CHAIN ..............4-31 CHECKING THE DRIVE SPROCKET............4-32 CHECKING THE REAR WHEEL SPROCKET.........4-32 INSTALLING THE DRIVE CHAIN ............4-32...

  • Page 85: General Chassis

    GENERAL CHASSIS EAM20094 GENERAL CHASSIS 2 2 2 EAM30016 REMOVING THE SEAT The sub-seat and the seat are coupled with each other with a plastic band. When removing the seat, always remove the a a a sub-seat beforehand. 1. Remove: •...

  • Page 86: Removing The Side Cover

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

  • Page 87: Front Wheel

    FRONT WHEEL EAM20095 ECA24430 FRONT WHEEL NOTICE Before tightening the front wheel axle nut, EAM30017 push down hard on the handlebar(s) several REMOVING THE FRONT WHEEL times and check if the front fork rebounds 1. Use a maintenance stand to raise the front smoothly.

  • Page 88: Rear Wheel

    REAR WHEEL EAM20096 REAR WHEEL EAM30022 REMOVING THE REAR WHEEL 1. Use a maintenance stand to raise the rear wheel off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: b.
  • Page 89 REAR WHEEL drive chain. Drive chain slack (Maintenance Stand) 50.0–60.0 mm (1.97–2.36 in) Refer to “DRIVE CHAIN SLACK” on page 3-23. 3. Install: • Drive chain puller (left) “1” • Rear wheel axle “2” • Install the drive chain puller (left), and insert the 6.

  • Page 90: Front Brake

    FRONT BRAKE EAM20097 FRONT BRAKE EAM30519 REPLACING THE FRONT BRAKE PADS When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disassem- ble the brake caliper. 1. Remove: • Brake pad 3. Install: a. Remove the pad pin plug “1”. •...
  • Page 91 FRONT BRAKE Front brake caliper bolt 28 N·m (2.8 kgf·m, 21 lb·ft) Pad pin 17 N·m (1.7 kgf·m, 13 lb·ft) f. Install the pad pin plug “6”. Pad pin plug 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) 4. Check: • Brake fluid level Refer to “CHECKING THE BRAKE FLUID LEVEL”...

  • Page 92: Rear Brake

    REAR BRAKE EAM20098 REAR BRAKE Brake pad lining thickness limit 1.0 mm (0.04 in) EAM30523 REPLACING THE REAR BRAKE PADS When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disassem- ble the brake caliper. 1.
  • Page 93 REAR BRAKE Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-22. e. Install the brake caliper “5” and the rear wheel “6”. f. Tighten the pad pin “7”. Pad pin 17 N·m (1.7 kgf·m, 13 lb·ft) g. Install the pad pin plug “8” and the protector “9”.

  • Page 94: Handlebar

    HANDLEBAR EAM20099 EAM30054 HANDLEBAR INSTALLING THE HANDLEBAR 1. Stand the vehicle upright on a level surface. EAM30052 EWA13120 REMOVING THE HANDLEBAR WARNING 1. Stand the vehicle upright on a level surface. Securely support the vehicle so that there is EWA13120 no danger of it falling over.
  • Page 95 HANDLEBAR A. Routing when installing the damper and lower handlebar in the rear holes B. Routing when installing the damper and lower handlebar in the front holes 3. Tighten: • Lower handlebar holder nut Lower handlebar holder nut 40 N·m (4.0 kgf·m, 30 lb·ft) 4.
  • Page 96 HANDLEBAR 5. Install: • Handlebar switch (left) “1” • Clamp “2” Handlebar switch (left) 1.3 N·m (0.13 kgf·m, 0.95 lb·ft) • The handlebar switch (left) “1” should be in- stalled according to the dimensions shown. • Pass the handlebar switch lead (left) through 8.
  • Page 97 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 98 HANDLEBAR 0 mm (0 in) 3 mm (0.12 in) 15.Adjust: • Throttle grip free play Refer to “CHECKING THE THROTTLE GRIP” on page 3-8. Throttle grip free play 3.0–6.0 mm (0.12–0.24 in) 4-14...

  • Page 99: Front Fork

    FRONT FORK cap bolt ring wrench “4” between the inner tube EAM20100 FRONT FORK and locknut “3”. • Hold the locknut and remove the adjuster. EAM30055 REMOVING THE FRONT FORK LEGS ECA24520 1. Use a maintenance stand to raise the front NOTICE wheel off the ground.

  • Page 100: Checking The Front Fork Legs

    FRONT FORK Inner tube bending limit 0.2 mm (0.01 in) The bending value is shown by one half of the dial gauge reading. EWA13650 WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 5.

  • Page 101: Assembling The Front Fork Legs

    1. Stretch the damper assembly fully. 2. Fill: • Damper assembly Recommended oil 6. Check: Yamaha Suspension Oil S1 • Upper spring seat “1” Standard oil amount 216 cm³ (7.30 US oz, 7.62 Imp.oz) (contacting surface “a”) Wear/damage  Replace.
  • Page 102 FRONT FORK 4. Measure: 6. Install: • Oil level (left and right) “a” • Base valve “1” Out of specification  Regulate. (to the damper assembly “2”) Standard oil level First bring the damper rod pressure to a maxi- 145–148 mm (5.71–5.83 in) mum.
  • Page 103 FRONT FORK 9. After filling, pump the damper assembly “1” 12.Check: • Damper assembly smooth movement slowly up and down more than 10 times to Tightness/binding/rough spots  Repeat the distribute the fork oil. steps (1) to (12). 10.While protecting the damper assembly “1” with a cloth and compressing fully, allow ex- 13.Install: cessive oil to overflow on the base valve side.
  • Page 104 FRONT FORK 14.Install: • Piston metal “1” Install the piston metal onto the slot on inner tube. 17.Install: • Oil seal “1” Using a fork seal driver “2”, press the oil seal in until the stopper ring groove fully appears. 15.Install: Fork seal driver •...
  • Page 105 FRONT FORK 19.Install: 22.Install: • Dust seal “1” • Upper spring seat “1” • Fork spring “2” (to the damper assembly “3”) Apply lithium-soap-based grease on the inner tube. Install the upper spring seat with its larger dia. end “a” facing the fork spring. 20.Check: •...
  • Page 106 FRONT FORK • Unless the damping force adjuster is fully loos- correct damping force cannot be obtained. ened, correct damping characteristic cannot be obtained after installation. 27.Tighten: • Adjuster (damper assembly) “1” 25.Install: Adjuster (damper assembly) • Damper adjusting rod “1” 29 N·m (2.9 kgf·m, 21 lb·ft) •...

  • Page 107: Installing The Front Fork Legs

    FRONT FORK Recommended oil Yamaha Suspension Oil S1 Standard oil amount 270 cm³ (9.13 US oz, 9.52 Imp.oz) (AUS, CAN, NZL, ZAF) 285 cm³ (9.64 US oz, 10.05 Imp.oz) (AUT, BEL, CHE, CYP, CZE, DEU, DNK, ESP, FIN, FRA, GBR, GRC, HRV, HUN, IRL, ITA,...
  • Page 108 FRONT FORK 3. Adjust: 5. Install: • Front fork top end “a” • Protector “1” • Front fork protector bolt “2” Front fork top end (standard) “a” 7 mm (0.28 in) (AUS, CAN, NZL, Front fork protector bolt ZAF) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 5 mm (0.20 in) (AUT, BEL, CHE, CYP, CZE, DEU, DNK, ESP, FIN, FRA, GBR, GRC, HRV, HUN, IRL,...
  • Page 109 FRONT FORK 4-25...

  • Page 110: Steering Head

    STEERING HEAD c. Install a new bearing race. EAM20101 STEERING HEAD ECA14270 NOTICE EAM30060 If the bearing race is not installed properly, REMOVING THE LOWER BRACKET the steering head pipe could be damaged. 1. Use a maintenance stand to raise the front wheel off the ground.
  • Page 111 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 112 STEERING HEAD 8. Install: 11.Tighten: • Steering stem nut “1” • Upper bracket pinch bolt “1” Steering stem nut Upper bracket pinch bolt 145 N·m (14.5 kgf·m, 107 lb·ft) 21 N·m (2.1 kgf·m, 15 lb·ft) • Lower bracket pinch bolt “2” Apply the lithium-soap-based grease to the con- Lower bracket pinch bolt tact surface of the steering stem nut when in-...

  • Page 113: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY absorber assembly. EAM20102 REAR SHOCK ABSORBER AS- • Spring SEMBLY Damage/wear  Replace. • Spring guide Damage/wear  Replace. EAM30065 REMOVING THE REAR SHOCK ABSORBER • Bearing ASSEMBLY Damage/wear  Replace. 1. Use a maintenance stand to raise the rear •...

  • Page 114: Swingarm

    SWINGARM EAM20103 SWINGARM EAM30071 REMOVING THE SWINGARM 1. Use a maintenance stand to raise the rear wheel off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Measure: • Swingarm side play •...

  • Page 115: Chain Drive

    CHAIN DRIVE (length “a” between pin inner sides + EAM20104 CHAIN DRIVE length “b” between pin outer sides)/2 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.

  • Page 116: Checking The Drive Sprocket

    CHAIN DRIVE Damage/wear  Replace the drive chain. G089069 5. Lubricate: • Drive chain EAM30077 CHECKING THE DRIVE SPROCKET 1. Check: • Drive sprocket More than 1/4 tooth wear “a”  Replace the drive sprocket and the rear wheel sprocket as G089070 a set.
  • Page 117 CHAIN DRIVE 3-23. Drive chain slack (Maintenance Stand) 50.0–60.0 mm (1.97–2.36 in) ECA24590 NOTICE A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swing- arm or cause an accident.
  • Page 118 CHAIN DRIVE 4-34...
  • Page 119 ENGINE EXHAUST SYSTEM ..................5-1 INSTALLING THE EXHAUST PIPE AND MUFFLER.........5-1 CLUTCH ......................5-2 REMOVING THE CLUTCH ................5-2 CHECKING THE FRICTION PLATES............5-2 CHECKING THE CLUTCH PLATES ............5-2 CHECKING THE CLUTCH SPRING ............5-2 CHECKING THE COLLAR .................5-3 CHECKING THE PRESSURE PLATE ............5-3 CHECKING THE PUSH LEVER SHAFT............5-3 CHECKING THE PUSH ROD ..............5-3 CHECKING THE PRIMARY DRIVE GEAR..........5-3 CHECKING THE PRIMARY DRIVEN GEAR ..........5-3...

  • Page 120: Exhaust System

    EXHAUST SYSTEM EAM20199 EXHAUST SYSTEM EAM30167 INSTALLING THE EXHAUST PIPE AND MUFFLER 1. Install: • Gasket • Exhaust pipe 1 “1” • Exhaust pipe nut “2” Exhaust pipe nut 10 N·m (1.0 kgf·m, 7.4 lb·ft) A. Exhaust pipe 1 and exhaust pipe 2 B.

  • Page 121: Clutch

    CLUTCH EAM20111 CLUTCH Friction plate 1 thickness 2.12–2.28 mm (0.083–0.090 in) Wear limit EAM30108 REMOVING THE CLUTCH 2.02 mm (0.080 in) 1. Straighten the clutch boss nut rib “a”. Friction plate 2 thickness 2.12–2.28 mm (0.083–0.090 in) Wear limit 2.02 mm (0.080 in) EAM30110 CHECKING THE CLUTCH PLATES 1.

  • Page 122: Checking The Collar

    CLUTCH EAM30484 CHECKING THE PUSH ROD 1. Check: • Push rod 1 “1” • Bearing “2” • Ball “3” • Push rod 2 “4” Cracks/damage/wear  Replace. EAM30629 CHECKING THE COLLAR 1. Check: • Collar “1” Damage/pitting/wear  Replace the collars as a set.

  • Page 123: Assembling The Clutch Release

    CLUTCH Pitting on the primary driven gear dogs will cause erratic clutch operation. 2. Install: • Push rod 2 “1” • Washer “2” 1 1 1 • O-ring “3” EAM30638 • Clutch release “4” ASSEMBLING THE CLUTCH RELEASE 1. Install: Bolt (clutch release) •...
  • Page 124 CLUTCH • Install the oil seal in parallel with its manufac- seal lip. ture’s marks or numbers facing inward. • Before installation, apply the engine oil to the bearings (upper side and lower side). Installed depth “a” 0 mm (0 in) 5.
  • Page 125 CLUTCH plates, and clutch plates. ECA24660 NOTICE Make sure to tighten to specification; other- wise, it may damage the other part that is fas- tened together. • Use the clutch holder “2” to hold the sleeve. • Stake the clutch boss nut at cutouts “a” in the main axle.
  • Page 126 CLUTCH 10.Install: • Pressure plate 2 “1” A. Engine side 11.Install: 12.Install: • Spring retainer “1” • Gasket “1” • Clutch spring “2” • Clutch cover “2” • Pressure plate 1 “3” • Clutch cover bolt (long) “3” • Bolt (pressure plate 1) “4” •...
  • Page 127 FUEL SYSTEM FUEL TANK ......................6-1 REMOVING THE FUEL TANK ..............6-1 INSTALLING THE FUEL TANK..............6-1...
  • Page 128 FUEL TANK EAM20140 FUEL TANK EAM30263 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Seat • Side cover (left/right) • Shroud (left/right) Refer to “GENERAL CHASSIS” on page 4-1. 3.
  • Page 129 FUEL TANK 3. Connect: • Fuel pump coupler 4. Install: • Shroud (left/right) • Side cover (left/right) • Seat Refer to “GENERAL CHASSIS” on page 4-1.
  • Page 130 FUEL TANK...
  • Page 131 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS.................7-1 CHECKING THE FUSES ................7-1 CHECKING AND CHARGING THE BATTERY..........7-1...
  • Page 132 • Do not use the specified battery charger to c. If the fuse immediately blows again, have charge a battery other than the lithium-ion a Yamaha dealer check the electrical sys- battery. Otherwise, the battery or charger tem. could be damaged.
  • Page 133 When • Seat replacing the battery, be sure to use a Refer to “GENERAL CHASSIS” on page 4-1. Yamaha genuine lithium-ion battery. 2. Disconnect: • Battery leads (from the battery terminals) Do not check the battery at high temperature of 65 C (149 F) or more or low temperatures be-...
  • Page 134 ELECTRICAL COMPONENTS struction manual. d. If the battery is hot, wait until the battery has cooled down to the ambient tempera- ture. e. Measure the voltage between the battery terminals. 13.25 V or more  The battery is normal. Checking is finished. 10 V or more and less than 13.25 V ...

  • Page 135: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING..................8-1 GENERAL INFORMATION ................8-1 TROUBLESHOOTING OF ENGINE (fault code not detected)....8-1 TROUBLESHOOTING OF CLUTCH............8-4 TROUBLESHOOTING OF TRANSMISSION ..........8-6 TROUBLESHOOTING OF COOLING SYSTEM ........8-7 TROUBLESHOOTING OF BRAKE ............8-8 TROUBLESHOOTING OF SUSPENSION..........8-8 TROUBLESHOOTING OF STEERING/HANDLING ........8-10 TROUBLESHOOTING OF CHARGING SYSTEM ........8-11...

  • Page 136: Troubleshooting

    • The following guide for troubleshooting represent quick and easy procedures for checking these vital systems yourself. However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motor- cycle properly.
  • Page 137 Low fuel pressure Clogged fuel pump Clean or replace the fuel pump. Cracks or damage in fuel pump Replace the fuel pump. Have a Yamaha dealer check the Fuel pump malfunction electrical system. Failed or clogged fuel injector Replace the fuel injector.
  • Page 138 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 139: 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 140 TROUBLESHOOTING Symptom Possible cause Actions Faulty clutch spring Replace the clutch spring. Warped pressure plate Replace the pressure plate. Replace the friction plates as a Swollen friction plate set. Warped clutch plate Replace the clutch plates as a set. Bent pull rod (outer pull type) Replace the pull rod.

  • Page 141: 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 142: 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 143: 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 144 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 145: 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 146: Troubleshooting Of Charging System

    Replace the swingarm bearing. Damaged or worn swingarm bear- Replace the swingarm bearing or ing or bushing bushing. EAM30516 TROUBLESHOOTING OF CHARGING SYSTEM Symptom Possible cause Actions Battery is not charged Have a Yamaha dealer check the electrical system. 8-11...

  • Page 147: Tuning

    TUNING CHASSIS ......................9-1 SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET) ....................9-1 DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS ....9-1 TIRE PRESSURE..................9-1 FRONT FORK SETTING................9-2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL....9-2 SETTING OF SPRING AFTER REPLACEMENT ........9-2 FRONT FORK SETTING PARTS...............9-3 REAR SUSPENSION SETTING ..............9-3 CHOOSING SET LENGTH ................9-3 SETTING OF SPRING AFTER REPLACEMENT ........9-4...

  • Page 148: Chassis

    CHASSIS EAM20119 Part name Type Part number CHASSIS Rear wheel 17D-25447-50 EAM30168 sprocket “2” SELECTION OF THE SECONDARY 17D-25448-50 REDUCTION RATIO (SPROCKET) (STD) B2W-25449-00 Secondary reduction ratio = Number of B2W-25450-00 rear wheel sprocket teeth/Number of B2W-25451-00 drive sprocket teeth 17D-25452-50 Secondary reduction ratio 3.769 (49/13)

  • Page 149: Front Fork Setting

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

  • Page 150: 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 151: Setting Of Spring After Replacement

    STIFF Brown decrease compression damping force. (Blue) EWA19200 * For Monster Energy Yamaha Racing Edition WARNING only When using a rear shock absorber other than currently installed, use the one whose • The I.D. mark “a” is marked at the end of the overall length “a”...
  • Page 152 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 7.0 mm (0.28 in) from its free length.

  • Page 153: 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 154: 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 155 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 156 CHASSIS...
  • Page 157 EAM20149 EAM30323 WIRING DIAGRAM COLOR CODE Black YZ450F/YZ450FP 2023 Brown 1. Crankshaft position sensor Dark blue 2. AC magneto Green 3. Rectifier/regulator Gray 4. Engine ground Blue 5. Frame ground Pink 6. Battery 7. Fuse Sky blue 8. Starter relay White 9.
  • Page 158 PRINTED IN JAPAN...
  • Page 160 Original instructions Notice originale Originalbetriebsanleitung Istruzioni originali Manual original PRINTED IN JAPAN 2022.08-1.3×1 (E, F, G, H, S)
  • Page 161 YZ450F/YZ450FP 2023 YZ450F/YZ450FP 2023 YZ450F/YZ450FP 2023 YZ450F/YZ450FP 2023 YZ450F/YZ450FP 2023 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO...
  • Page 162 YZ450F/YZ450FP 2023 YZ450F/YZ450FP 2023 YZ450F/YZ450FP 2023 YZ450F/YZ450FP 2023 YZ450F/YZ450FP 2023 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO PUSH PUSH FREE FREE...

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