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2009
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.
OWNER'S SERVICE MANUAL
MANUEL D'ATELIER DU
PROPRIETAIRE
FAHRER- UND
WARTUNGSHANDBUCH
YZ450F(Y)
34P-28199-80

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   Summary of Contents for Yamaha YZ450F(Y

  • Page 1

    2009 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. OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE FAHRER- UND WARTUNGSHANDBUCH...

  • 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

    2009 2009 Read this manual carefully before operating this vehicle. Read this manual carefully before operating this vehicle. OWNER’S SERVICE MANUAL OWNER’S SERVICE MANUAL YZ450F(Y) YZ450F(Y) 34P-28199-80-E0 34P-28199-80-E0...

  • Page 5

    YZ450F(Y) OWNER'S SERVICE MANUAL ©2008 by Yamaha Motor Co., Ltd. 1st Edition, May 2008 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan...

  • Page 6: Safety Information

    Congratulations on your purchase of could result in death or serious in- or allow any gasoline to get into a Yamaha YZ series. This model is jury. your eyes, contact a doctor immedi- the culmination of Yamaha's vast ex- ately.

  • Page 7: General Information

    HOW TO USE THIS MANUAL FINDING THE REQUIRED PAGE 1. This manual consists of seven chapters; "General Information", "Specifications", "Regular inspec- tion and adjustments", "Engine", "Chassis", "Electrical" and "Tun- ing" 2. The table of contents is at the be- ginning of the manual. Look over the general layout of the book be- fore finding then required chapter and item.

  • Page 8

    der of the jobs in the exploded di- 4. A job instruction chart "4" accom- HOW TO READ DESCRIPTIONS agram. A number that is enclosed panies the exploded diagram, To help identify parts and clarify pro- by a circle indicates a disassem- providing the order of jobs, names cedure steps, there are exploded dia- bly step.

  • Page 9: Table Of Contents

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

  • Page 10: Table Of Contents

    CONTENTS CHAPTER 1 CHAPTER 3 CHAPTER 5 GENERAL REGULAR CHASSIS INFORMATION INSPECTION AND ADJUSTMENTS FRONT WHEEL AND REAR WHEEL ....5-1 DESCRIPTION ....1-1 FRONT BRAKE AND MACHINE MAINTENANCE REAR BRAKE ....5-6 IDENTIFICATION ..... 1-2 INTERVALS...... 3-1 FRONT FORK....5-16 INCLUDED PARTS ..1-2 PRE-OPERATION HANDLEBAR....5-24 IMPORTANT...

  • Page 11: Description, Engine

    DESCRIPTION GENERAL INFORMATION DESCRIPTION Clutch lever 11. Coolant drain bolt Hot starter lever 12. Rear brake pedal Front brake lever 13. Valve joint Throttle grip 14. Fuel cock Radiator cap 15. Cold starter knob Fuel tank cap 16. Drive chain Engine stop switch 17.

  • Page 12: Identification, Included Parts, Important Information

    MACHINE IDENTIFICATION There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own. IMPORTANT INFORMATION VALVE JOINT 2.

  • Page 13: Checking Of Connection

    5. Keep away from fire. 6. Connect: ALL REPLACEMENT PARTS • Connector 1. We recommend to use Yamaha genuine parts for all replace- ments. Use oil and/or grease rec- The two connectors "click" together. ommended by Yamaha for 7.

  • Page 14: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS Tool name/Part number How to use Illustration Dial gauge and stand These tools are used to check each YU-3097, 90890-01252 part for runout or bend. Stand YU-1256 Crankshaft installing tool These tools are used to install the Crankshaft installing pot crankshaft.

  • Page 15

    SPECIAL TOOLS Tool name/Part number How to use Illustration Cap bolt wrench This tool is used to loosen or tighten YM-01500, 90890-01500 the base valve. Cap bolt ring wrench This tool is used to loosen or tighten YM-01501, 90890-01501 the damper assembly. Fork seal driver This tool is used when install the fork YM-A0948, 90890-01502...

  • Page 16

    SPECIAL TOOLS Tool name/Part number How to use Illustration Clutch holding tool This tool is used to hold the clutch YM-91042, 90890-04086 when removing or installing the clutch boss securing nut. Valve guide remover This tool is needed to remove and Intake 4.5 mm (0.18 in) install the valve guide.

  • Page 17

    SPECIAL TOOLS Tool name/Part number How to use Illustration Digital tachometer This tool is needed for observing en- YU-39951-B, 90890-06760 gine rpm. YAMAHA Bond No. 1215 (ThreeB- This sealant (Bond) is used for ® No. 1215) crankcase mating surface, etc. 90890-85505...

  • Page 18: Control Functions, Starting And Break-in

    CONTROL FUNCTIONS CONTROL FUNCTIONS ENGINE STOP SWITCH The engine stop switch "1" is located on the left handlebar. Continue push- ing the engine stop switch till the en- gine comes to a stop. THROTTLE GRIP COLD STARTER KNOB The throttle grip "1" is located on the When cold, the engine requires a right handlebar;...

  • Page 19

    STARTING AND BREAK-IN The engine fails to start Pull the hot starter lever all the way If knocking or pinging occurs, use a Do not open the throttle while kick- out and while holding the lever, kick different brand of gasoline or higher ing the kickstarter crank.

  • Page 20

    STARTING AND BREAK-IN BREAK-IN PROCEDURES 1. Before starting the engine, fill the fuel tank with the fuel. 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the engine stop switch.

  • Page 21: Torque-check Points

    TORQUE-CHECK POINTS TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and fuel tank Fuel tank to frame Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Steering stem to handlebar Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar...

  • Page 22: Cleaning And Storage

    CLEANING AND STORAGE CLEANING AND STORAGE STORAGE If your machine is to be stored for 60 CLEANING days or more, some preventive mea- Frequent cleaning of your machine sures must be taken to avoid deterio- will enhance its appearance, maintain ration.

  • Page 23: General Specifications

    GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: YZ450FY (USA, CDN, AUS, NZ) YZ450F (EUROPE, ZA) Model code number: 34P1 (USA,CDN) 34P2 (EUROPE) 34P4 (AUS, NZ, ZA) Dimensions: USA, CDN, AUS, NZ, ZA EUROPE Overall length 2,195 mm (86.42 in) 2,196 mm (86.46 in) Overall width 825 mm (32.48 in) ←...

  • Page 24: Chassis

    GENERAL SPECIFICATIONS Fuel: Type Premium unleaded gasoline only with a research octane number of 95 or higher. Tank capacity 7.0 L (1.54 Imp gal, 1.85 US gal) Carburetor: Type FCR-MX39 Manufacturer KEIHIN Spark plug: Type/manufacturer CR8E/NGK (resistance type) 0.7–0.8 mm (0.028–0.031 in) Clutch type: Wet, multiple-disc Transmission:...

  • Page 25: Maintenance Specifications

    MAINTENANCE SPECIFICATIONS Wheel travel: Front wheel travel 300 mm (11.8 in) Rear wheel travel 314 mm (12.4 in) Electrical: Ignition system CDI magneto MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.05 mm (0.002 Cylinder: Bore size 95.00–95.01 mm (3.7402–3.7406 in) ---- Out of round limit...

  • Page 26

    MAINTENANCE SPECIFICATIONS Item Standard Limit Timing chain: Timing chain type/No. of links 98XRH2010-118M/118 ---- Timing chain adjustment method Automatic ---- Valve, valve seat, valve guide: Valve clearance (cold) 0.10–0.15 mm (0.0039–0.0059 in) ---- 0.20–0.25 mm (0.0079–0.0098 in) ---- Valve dimensions: "A"...

  • Page 27

    MAINTENANCE SPECIFICATIONS Item Standard Limit Stem-to-guide clearance (IN) 0.010–0.037 mm (0.0004–0.0015 in) 0.08 mm (0.003 Stem-to-guide clearance (EX) 0.020–0.047 mm (0.0008–0.0019 in) 0.10 mm (0.004 Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width (IN) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 Valve seat width (EX) 0.9–1.1 mm (0.0354–0.0433 in)

  • Page 28

    MAINTENANCE SPECIFICATIONS Item Standard Limit Piston off-set 1 mm (0.0394 in) ---- Piston pin bore inside diameter 18.004–18.015 mm (0.7088–0.7093 in) 18.045 mm (0.7104 in) Piston pin outside diameter 17.991–18.000 mm (0.7083–0.7087 in) 17.971 mm (0.7075 in) Piston rings: Top ring: Type Barrel ----...

  • Page 29

    MAINTENANCE SPECIFICATIONS Item Standard Limit Air filter oil grade: Foam-air-filter oil or equivalent oil ---- Clutch: Friction plate thickness 2.92–3.08 mm (0.115–0.121 in) 2.8 mm (0.110 Quantity ---- Clutch plate thickness 1.5–1.7 mm (0.059–0.067 in) ---- Quantity ---- Warp limit ---- 0.1 mm (0.004 Clutch spring free length...

  • Page 30

    MAINTENANCE SPECIFICATIONS Item Standard Limit Lubrication system: Oil filter type Paper type ---- Oil pump type Trochoid type ---- Tip clearance 0.12 mm or less (0.0047 in or less) 0.20 mm (0.008 Side clearance 0.09–0.17 mm (0.0035–0.0067 in) 0.24 mm (0.009 Housing and rotor clearance 0.03–0.10 mm (0.0012–0.0039 in) 0.17 mm (0.007...

  • Page 31

    MAINTENANCE SPECIFICATIONS Item Standard Limit Preload length <Min.–Max.> 1.5–13 mm (0.06–0.51 ← Spring rate, STD K = 54.0 N/mm (5.50 kg/ ---- ← mm, 308.0 lb/in) Optional spring ---- ← Enclosed gas pressure 1,000 kPa (10 kg/cm ---- ← 142 psi) *Spring specification varies according to the differ- ence in the production lot.

  • Page 32: Tightening Torques

    44–66 Ωat 20 °C (68 °F) (Black–Pink) ---- Pickup coil resistance (color) 248–372 Ωat 20 °C (68 °F) (White–Red) ---- CDI unit-model/manufacturer 34P-00/YAMAHA (USA and CDN) ---- 34P-10/YAMAHA (Except for USA and ---- CDN) Ignition coil: Model/manufacturer 5TA-10/DENSO ---- Minimum spark gap 6 mm (0.24 in)

  • Page 33

    TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Exhaust pipe protector M6 × 1.0 Carburetor joint M6 × 1.0 Carburetor joint clamp M4 × 0.7 Air filter case M6 × 1.0 △ Air filter joint clamp M6 ×...

  • Page 34

    TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Screw (kickstarter crank) M6 × 1.0 Primary drive gear M20 × 1.0 11.0 Clutch boss M20 × 1.0 Clutch cable adjust bolt and locknut M6 × 0.75 Clutch spring M6 ×...

  • Page 35

    TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Brake lever mounting nut M6 × 1.0 Brake lever position locknut M6 × 1.0 Cable guide (front brake hose) and under bracket M6 × 1.0 △ Front brake hose union bolt (brake master cylinder) M10 ×...

  • Page 36

    TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Swingarm and brake hose holder M5 × 0.8 △ Swingarm and patch M4 × 0.7 Upper drive chain tensioner M8 × 1.25 Lower drive chain tensioner M8 × 1.25 Drive chain support and swingarm M6 ×...

  • Page 37

    TIGHTENING TORQUES GENERAL TORQUE TORQUE SPECIFI- SPECIFICATIONS CATION This chart specifies torque for stan- (Nut) (Bolt) dard fasteners with standard I.S.O. m•kg ft•lb pitch threads. Torque specifications 6 mm for special components or assem- blies are included in the applicable sections of this book.

  • Page 38: Lubrication Diagrams

    LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS Oil filter element Oil pump Drive axle Main axle Crankshaft Connecting rod From cylinder To oil tank 2-16...

  • Page 39: Lubrication Diagrams

    LUBRICATION DIAGRAMS Intake camshaft Exhaust camshaft To main axle From oil pump 2-17...

  • Page 40: Cable Routing Diagram

    CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM Fuel tank breather hose 10. Hot starter cable Pass the cylinder head breather Radiator hose 1 11. Carburetor breather hose hose on the outside of the radia- Cylinder head breather hose 12. Carburetor overflow hose tor hose 1 and between the radi- Hose holder Insert the end of the fuel tank...

  • Page 41

    CABLE ROUTING DIAGRAM Pass the clutch cable in front of the radiator mounting boss. Install the connector cover so that it does not come in between the radiator hose 1 and radiator. Pass the fuel hose on the out- side of throttle position sensor lead.

  • Page 42

    CABLE ROUTING DIAGRAM Hot starter cable 12. Engine stop switch lead Fasten the hot starter cable and Clamp 13. Sub-wire harness throttle cables onto the frame. Throttle position sensor lead 14. Ground lead Fasten the hot starter cable, Hump (frame) 15.

  • Page 43

    CABLE ROUTING DIAGRAM Pass the neutral switch lead over the lower engine guard stay. Fasten the neutral switch lead and radiator breather hose to the frame. Fasten the neutral switch lead, CDI magneto lead and radiator breather hose to the frame. Fasten the neutral switch lead, CDI magneto lead, radiator breather hose and clutch cable...

  • Page 44

    CABLE ROUTING DIAGRAM Throttle cable (pull) Fasten the throttle cables with Throttle cable (return) the clamp so that the cables are Radiator hose 2 not bent, and pass them under Ignition coil the rear arm bracket. Rear arm bracket Pass the cylinder head breather Cylinder head breather hose hose so that it does not contact Pass the throttle cables over the...

  • Page 45

    CABLE ROUTING DIAGRAM Brake master cylinder If the brake hose contacts the Brake hose holder spring (rear shock absorber), Brake hose correct its twist. Install the brake hose so that its Install the brake hose so that its pipe portion directs as shown pipe portion directs as shown and lightly touches the projec- and lightly touches the projec-...

  • Page 46

    CABLE ROUTING DIAGRAM Throttle cable Pass the clutch cable and hot Clamp starter cable through the cable Hot starter cable guide. Clutch cable Pass the brake hose in front of Engine stop switch lead the number plate. Cable guide Pass the throttle cables through Brake hose the cable guide.

  • Page 47: Maintenance Intervals, Regular Inspection And Adjustments

    The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. Every...

  • Page 48

    MAINTENANCE INTERVALS Every Every After third fifth (or Every As re- Item break- Remarks race (or 500 1,000 quired CLUTCH Inspect and adjust Inspect housing, friction plate, clutch ● ● plate and spring. Replace ● TRANSMISSION Inspect ● Replace bearing ●...

  • Page 49

    MAINTENANCE INTERVALS Every Every After third fifth (or Every As re- Item break- Remarks race (or 500 1,000 quired FUEL TANK, COCK Clean and inspect ● ● BRAKES Adjust lever position and pedal ● ● height Lubricate pivot point ● ●...

  • Page 50

    ● Inspect bearings ● Replace bearings ● Lubricate Lithium base grease ● THROTTLE, CONTROL CABLE Check routing and connection Yamaha cable lube or SAE 10W-30 ● ● motor oil Lubricate ● ● HOT STARTER, CLUTCH LEVER Inspect free play ●...

  • Page 51: Inspection And Maintenance

    PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. GENERAL INSPECTION AND MAINTENANCE Item Routine Page Check that coolant is filled up to the radiator cap.

  • Page 52: Engine, Checking Coolant Level, Changing Coolant, Checking Radiator Cap

    ENGINE ENGINE 1. Place a container under the en- gine. CHECKING THE COOLANT LEVEL 2. Remove: • Engine guard "1" Do not remove the radiator cap • Coolant drain bolt "2" "1", drain bolt and hoses when the engine and radiator are hot. Scald- ing hot fluid and steam may be blown out under pressure, which could cause serious injury.

  • Page 53: Checking Cooling System, Adjusting Clutch Lever Position/cable

    ENGINE • Radiator hose joint c. Tighten the locknuts. Coolant leakage → Repair or re- Apply water on the radiator cap seal. Locknut: place. 4 Nm (0.4 m•kg, 2.9 • Radiator hose ft•lb) Swelling → Replace. ADJUSTING THE CLUTCH LEVER POSITION 1.

  • Page 54: Cleaning Air Filter

    ENGINE d. Tighten the locknut. ADJUSTING THE HOT STARTER LEVER FREE PLAY Locknut: 1. Check: 4 Nm (0.4 m•kg, 2.9 • Hot starter lever free play "a" ft•lb) Out of specification → Adjust. Hot starter lever free play Before adjusting the throttle cable "a": free play, the engine idle speed 3–6 mm (0.12–0.24 in)

  • Page 55: Changing Engine Oil

    ENGINE 4. Inspect: • Oil level Check that the engine oil is above the level mark "a" and that the oil does not come out when the check bolt "1" is removed. Below the level mark "a"→Add oil through the filler cap hole until it is 7.

  • Page 56: Checking Oil Pressure, Adjusting Pilot Screw, Adjusting Engine Idling Speed

    ENGINE 6. Fill: ADJUSTING THE PILOT SCREW • Engine oil 1. Adjust: • Pilot screw "1" Oil quantity: Periodic oil change: Adjustment steps: 0.95 L (0.84 Imp qt, 1.00 US qt) With oil filter replace- To optimize the fuel flow at a smaller ment: throttle opening, each machine's pilot 1.0 L (0.88 Imp qt, 1.06...

  • Page 57: Specifications

    Yama- b. Remove the valve lifters "1" and T.D.C. on compression stroke. ha motorcycles (e.g., Yamaha deal- the pads "2". ers, service engineers, etc.) Those who have little knowledge and skill •...

  • Page 58: Adjustments

    ENGINE g. Install the camshafts (exhaust and intake). The thickness "a" of each pad is indi- Refer to "CAMSHAFTS" section cated in hundredths of millimeters on in the CHAPTER 4. the pad upper surface. d. Round off the last digit of the in- stalled pad number to the nearest increment.

  • Page 59

    ENGINE INTAKE EXHAUST 3-13...

  • Page 60

    CHASSIS CHASSIS h. Tighten the bleed screw when the lever or pedal limit has been BLEEDING THE HYDRAULIC reached; then release the lever or BRAKE SYSTEM pedal. Bleed screw: Bleed the brake system if: 6 Nm (0.6 m•kg, 4.3 • The system has been disassem- ft•lb) bled.

  • Page 61

    CHASSIS e. Connect the transparent hose "5" Install the pad pin plug "10". to the bleed screw "6" and place Pad pin plug: the suitable container under its 3 Nm (0.3 m•kg, 2.2 end. ft•lb) CHECKING AND REPLACING THE FRONT BRAKE PADS 1.

  • Page 62

    CHASSIS CHECKING THE REAR BRAKE PAD INSULATOR • Install the brake pads with their pro- Brake pad replacement steps: 1. Remove: jections "a" into the brake caliper re- a. Remove the protector "1" and pad • Brake pad cesses "b". pin plug "2".

  • Page 63

    CHASSIS CHECKING THE SPROCKET Drive chain slack: 1. Inspect: 50–60 mm (2.0–2.4 in) • Sprocket teeth "a" Excessive wear → Replace. Before checking and/or adjusting, ro- Replace the drive sprocket, rear tate the rear wheel through several wheel sprocket and drive chain as a revolutions and check the slack sev- set.

  • Page 64

    CHASSIS • Clean the dust seal and oil seal af- ter every run. • Apply the lithium soap base grease on the inner tube. A. Right • STANDARD POSITION: B. Left This is the position which is back by the specific number of clicks from the fully turned-in position.

  • Page 65

    CHASSIS Standard position: Be sure to remove all dirt and mud 12 clicks out from around the locknut and adjust- * 10 clicks out er before adjustment. * Except for USA and CDN • The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjuster.

  • Page 66

    CHASSIS • STANDARD POSITION: Standard position: This is the position which is back Do not force the adjuster past the About 10 clicks out by the specific number of clicks minimum or maximum extent of * About 9 clicks out from the fully turned-in position.

  • Page 67

    CHASSIS A tight spoke will emit a clear, ringing tone; a loose spoke will sound flat. 2. Tighten: • Spokes (with a spoke nipple wrench "1") 3. Check: Be sure to tighten the spokes before e. Loosen the steering ring nut one •...

  • Page 68

    CHASSIS Steering stem nut: 145 Nm (14.5 m•kg, 105 ft•lb) Handlebar upper holder: 28 Nm (2.8 m•kg, 20 ft•lb) Pinch bolt (upper brack- et): 21 Nm (2.1 m•kg, 15 ft•lb) Number plate: 7 Nm (0.7 m•kg, 5.1 ft•lb) 3-22...

  • Page 69

    Footrest pivot avoid getting grease on the brake Throttle-to-handlebar contact discs. Drive chain Tube guide cable winding por- tion Throttle cable end Clutch cable end 10. Hot starter cable end Use Yamaha cable lube or equivalent on these areas. 3-23...

  • Page 70: Electrical

    ELECTRICAL CHECKING THE IGNITION TIMING ELECTRICAL 1. Remove: CHECKING THE SPARK PLUG • Timing mark accessing screw "1" 1. Remove: • Spark plug 2. Inspect: • Electrode "1" Wear/damage → Replace. • Insulator color "2" Normal condition is a medium to light tan color.

  • Page 71: Seat, Fuel Tank And Side Covers

    SEAT, FUEL TANK AND SIDE COVERS ENGINE This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are request- ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual.

  • Page 72

    SEAT, FUEL TANK AND SIDE COVERS REMOVING THE SIDE COVER 1. Remove: Put the portion "a" of the flap of the air • Bolt (side cover) filter case on the inside of the air • Left side cover "1" scoop. •...

  • Page 73: Exhaust Pipe And Silencer

    EXHAUST PIPE AND SILENCER EXHAUST PIPE AND SILENCER REMOVING THE EXHAUST PIPE AND SILENCER Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND SIDE Right side cover COVERS" section. Bolt (silencer clamp) Only loosening. Bolt [silencer (front)] Bolt [silencer (rear)] Collar Silencer Silencer clamp...

  • Page 74: Exhaust Pipe And Silencer

    EXHAUST PIPE AND SILENCER CHECKING THE SILENCER AND EXHAUST PIPE First, temporarily tighten the nut (ex- 1. Inspect: haust pipe), then tighten the bolt (ex- • Gasket "1" haust pipe) 13 Nm (1.3 m•kg, 9.4 Damage → Replace. ft•lb). After that, retighten the nut (ex- haust pipe) 20 Nm (2.0 m•kg, 14 ft•lb) and then the bolt (exhaust pipe) 20 Nm (2.0 m•kg, 14 ft•lb).

  • Page 75: Radiator

    RADIATOR RADIATOR REMOVING THE RADIATOR Order Part name Q'ty Remarks Refer to "CHANGING THE COOLANT" sec- Drain the coolant. tion in the CHAPTER 3. Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS" section. Refer to "EXHAUST PIPE AND SILENCER" Exhaust pipe section.

  • Page 76

    RADIATOR HANDLING NOTE Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open 2. Install: the radiator cap by the following •...

  • Page 77: Carburetor

    CARBURETOR CARBURETOR REMOVING THE CARBURETOR Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS" section. Refer to "REAR SHOCK ABSORBER" sec- Rear shock absorber tion in the CHAPTER 5. Clamp Throttle position sensor lead coupler Throttle cable cover Throttle cable Clamp (air filter joint)

  • Page 78

    CARBURETOR DISASSEMBLING THE CARBURETOR Order Part name Q'ty Remarks Carburetor breather hose Valve lever housing cover Screw (throttle shaft) Throttle valve Needle holder Jet needle Accelerator pump cover Spring Diaphragm (accelerator pump) Float chamber Leak jet Pilot screw Refer to removal section. Float pin Float Needle valve...

  • Page 79

    CARBURETOR Order Part name Q'ty Remarks Pilot jet Starter jet Push rod Pull the push rod. Throttle shaft assembly Push rod link lever assembly Pilot air jet Cold starter plunger...

  • Page 80

    CARBURETOR HANDLING NOTE • Leak jet "6" Damage → Replace. Contamination → Clean. Do not loosen the screw (throttle position sensor) "1" except when • Use a petroleum based solvent for changing the throttle position sen- cleaning. Blow out all passages and sor due to failure because it will jets with compressed air.

  • Page 81

    CARBURETOR • Spring 2 "6" 5. Install: Dirt → Clean. • Push rod link lever assembly "1" Make sure the stopper "a" of the spring 2 fits into the recess "b" in the carburetor. f. Recheck the float height. ASSEMBLING THE CARBURETOR CHECKING THE FLOAT 1.

  • Page 82

    CARBURETOR • Check the float for smooth move- ment. Install the diaphragm (accelerator pump) with its mark "a" facing the spring. 12. Install: • Pilot screw "1" • Spring "2" 15. Install: • Washer "3" • Jet needle "1" • O-ring "4" •...

  • Page 83

    CARBURETOR 2. Install: • Carburetor "1" Install the projection "a" between the carburetor joint slots. ADJUSTING THE ACCELERATOR 6. Adjust: PUMP TIMING • Throttle grip free play Refer to "ADJUSTING THE THROTTLE CABLE FREE PLAY" Adjustment steps: section in the CHAPTER 3. 7.

  • Page 84: Camshafts

    CAMSHAFTS CAMSHAFTS REMOVING THE CYLINDER HEAD COVER Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS" section. Hot starter plunger Refer to "CARBURETOR" section. Engine upper bracket (right) Refer to "ENGINE REMOVAL" section. Engine upper bracket (left) Spark plug Cylinder head breather hose...

  • Page 85

    CAMSHAFTS REMOVING THE CAMSHAFTS Order Part name Q'ty Remarks Timing mark accessing screw Refer to removal section. Crankshaft end accessing screw Refer to removal section. Timing chain tensioner cap bolt Refer to removal section. Timing chain tensioner Refer to removal section. Gasket Refer to removal section.

  • Page 86

    CAMSHAFTS REMOVING THE CAMSHAFT Cam lobes length: 1. Remove: Intake "a": • Timing mark accessing screw "1" 31.200–31.300 mm • Crankshaft end accessing screw (1.2283–1.2323 in) "2" <Limit>: 31.100 mm (1.2244 in) Intake "b": 22.550–22.650 mm 4. Remove: (0.8878–0.8917 in) •...

  • Page 87

    CAMSHAFTS Camshaft-to-cap clear- ance: 0.028–0.062 mm (0.0011–0.0024 in) <Limit>:0.08 mm (0.003 CHECKING THE CAMSHAFT Measurement steps: SPROCKET a. Install the camshaft onto the cylin- 1. Inspect: der head. • Camshaft sprocket "1" ® b. Position a strip of Plastigauge Wear/damage → Replace the "1"...

  • Page 88

    CAMSHAFTS b. With the rod fully wound and the chain tensioner UP mark "a" fac- Do not turn the crankshaft during ing upward, install the gasket "1", the camshaft installation. Damage the timing chain tensioner "2", and or improper valve timing will re- the gasket "3", and tighten the bolt sult.

  • Page 89: Cylinder Head, Removing The Cylinder Head

    CYLINDER HEAD CYLINDER HEAD REMOVING THE CYLINDER HEAD Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS" section. Refer to "EXHAUST PIPE AND SILENCER" Exhaust pipe and silencer section. Radiator Refer to "RADIATOR" section Carburetor Refer to "CARBURETOR"...

  • Page 90

    CYLINDER HEAD CHECKING THE CYLINDER HEAD • Cylinder head "4" e. Remove the bolts. 1. Eliminate: f. Again apply the molybdenum dis- • Carbon deposits (from the com- ulfide grease on the threads and While pulling up the timing chain, in- bustion chambers) contact surfaces of the bolts and stall the timing chain guide (exhaust...

  • Page 91

    CYLINDER HEAD 3. Install: • Bolt (cylinder head) "1" Bolt (cylinder head): 10 Nm (1.0 m•kg, 7.2 ft•lb) 4-21...

  • Page 92: Valves And Valve Springs

    VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS REMOVING THE VALVES AND VALVE SPRINGS Order Part name Q'ty Remarks Cylinder head Refer to "CYLINDER HEAD" section. Valve lifter Refer to removal section. Adjusting pad Refer to removal section. Valve cotter Refer to removal section.

  • Page 93

    VALVES AND VALVE SPRINGS REMOVING THE VALVE LIFTER AND VALVE COTTER 1. Remove: • Valve lifter "1" • Pad "2" Identify each lifter "1" and pad "2" po- sition very carefully so that they can CHECKING THE VALVE b. Install the new valve guide using a be reinstalled in their original place.

  • Page 94

    VALVES AND VALVE SPRINGS 4. Measure: Valve seat width: • Margin thickness "a" Do not let the compound enter the Intake: Out of specification → Replace. gap between the valve stem and 0.9–1.1 mm (0.0354– Margin thickness: the guide. 0.0433 in) Intake: <Limit>:1.6 mm 1.0 mm (0.039 in)

  • Page 95

    VALVES AND VALVE SPRINGS CHECKING THE VALVE SPRINGS 3. Install: 1. Measure: • Valve cotters • Valve spring free length "a" Out of specification → Replace. While compressing the valve spring with a valve spring compressor "1" in- Free length (valve stall the valve cotters.

  • Page 96: Removing Cylinder And Piston, Cylinder And Piston

    CYLINDER AND PISTON CYLINDER AND PISTON REMOVING THE CYLINDER AND PISTON Order Part name Q'ty Remarks Cylinder head Refer to "CYLINDER HEAD" section. Bolt (cylinder) Cylinder Gasket Dowel pin Piston pin clip Refer to removal section. Piston pin Refer to removal section. Piston Refer to removal section.

  • Page 97: Checking Piston Ring

    CYLINDER AND PISTON REMOVING THE PISTON AND 2. Measure: Piston-to-cylinder clear- PISTON RING • Piston-to-cylinder clearance ance: 1. Remove: 0.020–0.045 mm • Piston pin clip "1" (0.0008–0.0018 in) Measurement steps: • Piston pin "2" <Limit>:0.1 mm (0.004 a. Measure the cylinder bore "C" •...

  • Page 98: Checking Piston Pin, Installing Piston Ring And Piston, Installing Cylinder

    CYLINDER AND PISTON 3. Measure: c. Calculate the piston pin-to-piston • Ring end gap clearance with the following for- • Apply engine oil onto the piston pin Out of specification → Replace. mula. and piston. • Be sure that the arrow mark "a" on Piston pin-to-piston clearance = You cannot measure the end gap on the piston points to the exhaust side...

  • Page 99: Clutch

    CLUTCH CLUTCH REMOVING THE CLUTCH Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Brake pedal Refer to "ENGINE REMOVAL" section. Clutch cable Disconnect at engine side. Clutch cover Gasket Dowel pin Clutch spring...

  • Page 100

    CLUTCH Order Part name Q'ty Remarks Nut (clutch boss) Refer to removal section. Lock washer Refer to removal section. Clutch boss Refer to removal section. Thrust washer Primary driven gear Push lever shaft 4-30...

  • Page 101

    CLUTCH REMOVING THE CLUTCH BOSS CHECKING THE CLUTCH CHECKING THE PUSH LEVER 1. Remove: SPRINGS SHAFT • Nut "1" 1. Measure: 1. Inspect: • Lock washer "2" • Clutch spring free length "a" • Push lever shaft "1" • Clutch boss "3" Out of specification →...

  • Page 102

    CLUTCH 2. Install: • Lock washer "1" • Nut (clutch boss) "2" Nut (clutch boss): 75 Nm (7.5 m•kg, 54 ft•lb) 5. Install: 9. Install: Make sure to tighten to specifica- • Bearing "1" • Gasket (clutch cover) "1" tion; otherwise, it may damage the •...

  • Page 103: Oil Filter Element And Water Pump

    OIL FILTER ELEMENT AND WATER PUMP OIL FILTER ELEMENT AND WATER PUMP REMOVING THE OIL FILTER ELEMENT AND WATER PUMP 10 Nm (1.0 m kg, 7.2 ft lb) 33 Nm (3.3 m kg, 24 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 12 Nm (1.2 m kg, 8.7 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb)

  • Page 104

    OIL FILTER ELEMENT AND WATER PUMP 10 Nm (1.0 m kg, 7.2 ft lb) 33 Nm (3.3 m kg, 24 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 12 Nm (1.2 m kg, 8.7 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 14 Nm (1.4 m kg, 10 ft lb)

  • Page 105

    OIL FILTER ELEMENT AND WATER PUMP REMOVING THE IMPELLER SHAFT 1. Remove: • Impeller "1" • Washer "2" • Impeller shaft "3" Hold the impeller shaft on its width CHECKING THE BEARING INSTALLING THE IMPELLER across the flats "a" with spanners, 1.

  • Page 106

    OIL FILTER ELEMENT AND WATER PUMP 3. Install: • O-ring • Coolant pipe "1" • Bolt (coolant pipe) "2" Bolt (coolant pipe): 10 Nm (1.0 m•kg, 7.2 ft•lb) 2. Install: 2. Install: • Right crankcase cover "1" • Oil tank breather hose "1" Apply the lithium soap base grease •...

  • Page 107: Balancer

    BALANCER BALANCER REMOVING THE BALANCER Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Refer to "OIL FILTER ELEMENT AND WA- Right crankcase cover TER PUMP" section. Stator Refer to "CDI MAGNETO" section. Nut (balancer) Refer to removal section. Nut (primary drive gear) Refer to removal section.

  • Page 108

    BALANCER REMOVING THE BALANCER • Nut (balancer) "9" 1. Straighten the lock washer tab. Nut (balancer): 2. Loosen: 45 Nm (4.5 m•kg, 33 • Nut (balancer) "1" ft•lb) • Nut (primary drive gear) "2" • Nut (balancer shaft driven gear) "3"...

  • Page 109: Oil Pump

    OIL PUMP OIL PUMP REMOVING THE OIL PUMP Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Refer to "OIL FILTER ELEMENT AND WA- Right crankcase cover TER PUMP" section. Circlip Washer Oil pump drive gear Oil pump assembly Dowel pin Outer rotor 2 Circlip...

  • Page 110

    OIL PUMP Order Part name Q'ty Remarks Oil pump drive shaft Rotor housing 4-40...

  • Page 111

    OIL PUMP CHECKING THE OIL PUMP INSTALLING THE OIL PUMP • Bolt (oil pump assembly) "4" 1. Inspect: 1. Install: Bolt (oil pump assem- • Oil pump drive gear • Oil pump drive shaft "1" bly): • Oil pump drive shaft •...

  • Page 112: Kick Shaft And Shift Shaft

    KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Remarks Oil pump Refer to "OIL PUMP" section. Kick idle gear Kick shaft assembly Refer to removal section. Spring guide Torsion spring Ratchet wheel Kick gear...

  • Page 113

    KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Remarks Pawl Pawl pin Spring Bolt (stopper lever) Stopper lever Torsion spring Segment Refer to removal section. 4-43...

  • Page 114: Kick Shaft And Shift Shaft

    KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT • Kick shaft "2" CHECKING THE STOPPER LEVER ASSEMBLY Wear/damage → Replace. 1. Inspect: 1. Remove: • Spring "3" • Stopper lever "1" • Kick shaft assembly "1" Broken → Replace. Wear/damage →...

  • Page 115

    KICK SHAFT AND SHIFT SHAFT INSTALLING THE SHIFT GUIDE INSTALLING THE SHIFT SHAFT AND SHIFT LEVER ASSEMBLY 1. Install: 1. Install: • Roller "1" • Spring "1" • Collar "2" • Pawl pin "2" • Torsion spring "3" • Pawl "3" •...

  • Page 116

    KICK SHAFT AND SHIFT SHAFT 5. Hook: • Torsion spring "1" Turn the torsion spring clockwise and hook into the proper hole "a" in the crankcase. INSTALLING THE KICK IDLE GEAR 1. Install: • Kick idle gear "1" • Washer "2" •...

  • Page 117: Cdi Magneto

    CDI MAGNETO CDI MAGNETO REMOVING THE CDI MAGNETO Order Part name Q'ty Remarks Seat and fuel tank Refer to "SEAT, FUEL TANK AND SIDE COVERS" section. Disconnect the CDI magneto lead. Left crankcase cover Gasket Dowel pin Nut (rotor) Refer to removal section. Rotor Refer to removal section.

  • Page 118: Cdi Magneto

    • Apply the sealant on the grommet • Nut (rotor) "1" of the CDI magneto lead. • Washer • Tighten the screws using the T30 bit. YAMAHA Bond No. 1215 ® (ThreeBond No. 1215): 5. Install: 90890-85505 • Dowel pin •...

  • Page 119: Engine Removal

    ENGINE REMOVAL ENGINE REMOVAL REMOVING THE ENGINE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the frame. Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS" section. Refer to "REAR SHOCK ABSORBER"...

  • Page 120

    ENGINE REMOVAL Order Part name Q'ty Remarks Engine guard Neutral switch Drive chain sprocket cover Nut (drive sprocket) Refer to removal section. Lock washer Refer to removal section. Drive sprocket Refer to removal section. Clip Bolt (brake pedal) Brake pedal Upper engine bracket Lower engine bracket Engine mounting bolt...

  • Page 121

    ENGINE REMOVAL HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE DRIVE SPROCKET 1. Remove: INSTALLING THE ENGINE • Nut (drive sprocket) "1" 1. Install: • Lock washer "2" • Engine "1" Install the engine from right side.

  • Page 122

    ENGINE REMOVAL 2. Install: • Lock washer "1" • Nut (drive sprocket) "2" Nut (drive sprocket): 75 Nm (7.5 m•kg, 54 ft•lb) Tighten the nut while applying the rear brake. Make sure to tighten to specifica- tion; otherwise, it may damage the other part that is fastened togeth- 3.

  • Page 123: Crankcase And Crankshaft

    CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT REMOVING THE CRANKSHAFT Order Part name Q'ty Remarks Engine Refer to "ENGINE REMOVAL" section. Piston Refer to "CYLINDER AND PISTON" section. Balancer Refer to "BALANCER" section. Refer to "KICK SHAFT AND SHIFT SHAFT" Kick shaft assembly section.

  • Page 124

    CRANKCASE AND CRANKSHAFT Order Part name Q'ty Remarks Balancer shaft Refer to removal section. Crankshaft Refer to removal section. 4-54...

  • Page 125

    CRANKCASE AND CRANKSHAFT REMOVING THE CRANKCASE BEARING Order Part name Q'ty Remarks Refer to "TRANSMISSION, SHIFT CAM AND Transmission SHIFT FORK" section. Refer to "TRANSMISSION, SHIFT CAM AND Shift cam and shift fork SHIFT FORK" section. Oil seal Bearing Refer to removal section. 4-55...

  • Page 126

    CRANKCASE AND CRANKSHAFT DISASSEMBLING THE c. Remove the dowel pins and O- CRANKCASE ring. 1. Separate: • Right crankcase REMOVING THE BALANCER • Left crankcase SHAFT 1. Remove: Separation steps: • Balancer shaft "1" a. Remove the crankcase bolts, CHECKING THE TIMING CHAIN hose guide and clutch cable hold- Remove the balancer shaft with its AND TIMING CHAIN GUIDE...

  • Page 127

    • Hold the connecting rod at top dead • Sealant center with one hand while turning On the right crankcase. INSTALLING THE CRANKCASE the nut of the installing tool with the YAMAHA Bond No. 1215 BEARING other. Operate the installing tool un- ® (ThreeBond No.1215): 1.

  • Page 128

    CRANKCASE AND CRANKSHAFT 9. Apply: • Engine oil To the crank pin, bearing and oil delivery hole. 10. Check: • Crankshaft and transmission op- eration. Unsmooth operation → Repair. 5. Install: • Dowel pin "1" • O-ring "2" • Right crankcase To left crankcase.

  • Page 129: Shift Cam And Shift Fork

    TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION, SHIFT CAM AND SHIFT FORK Order Part name Q'ty Remarks Engine Refer to "ENGINE REMOVAL" section. Refer to "CRANKCASE AND CRANK- Separate the crankcase. SHAFT" section. Main axle Refer to removal section.

  • Page 130

    TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION 1. Remove: Apply the molybdenum disulfide oil • Main axle "1" on the inner and end surface of the • Drive axle "2" idler gear and on the inner surface of •...

  • Page 131

    TRANSMISSION, SHIFT CAM AND SHIFT FORK • Be sure the circlip sharp-edged cor- ner "a" is positioned opposite side to the washer and gear "b". • Install the circlip with its ends "c" settled evenly on the spline crests. 6. Install: •...

  • Page 132: Front Wheel And Rear Wheel

    FRONT WHEEL AND REAR WHEEL CHASSIS This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are request- ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual.

  • Page 133

    FRONT WHEEL AND REAR WHEEL REMOVING THE REAR WHEEL Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Nut (rear wheel axle) Rear wheel axle Drive chain puller Rear wheel Refer to removal section.

  • Page 134: Front Wheel And Rear Wheel

    FRONT WHEEL AND REAR WHEEL HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE REAR WHEEL 1. Remove: • Wheel "1" CHECKING THE WHEEL AXLE 1. Measure: Push the wheel forward and remove •...

  • Page 135

    FRONT WHEEL AND REAR WHEEL 2. Install: 6. Install: • Brake disc "1" • Nut (wheel axle) "1" Do not strike the inner race of the • Bolt (brake disc) "2" Nut (wheel axle): bearing. Contact should be made Bolt (brake disc): 105 Nm (10.5 m•kg, 75 only with the outer race.

  • Page 136

    FRONT WHEEL AND REAR WHEEL 4. Install: • Collar "1" Temporarily tighten the nut (wheel axle) at this point. Apply the lithium soap base grease on the oil seal lip. 9. Adjust: • Drive chain slack "a" 5. Install: Drive chain slack: •...

  • Page 137: Front Brake And Rear Brake

    FRONT BRAKE AND REAR BRAKE FRONT BRAKE AND REAR BRAKE REMOVING THE FRONT BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Drain the brake fluid. Refer to removal section. Brake hose holder (protector) Union bolt Brake hose...

  • Page 138

    FRONT BRAKE AND REAR BRAKE REMOVING THE REAR BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT WHEEL AND REAR Rear wheel WHEEL" section. Drain the brake fluid. Refer to removal section.

  • Page 139

    FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE CALIPER Order Part name Q'ty Remarks Front Rear Pad pin Brake pad Pad support Brake caliper piston Refer to removal section. Brake caliper piston dust seal Refer to removal section. Brake caliper piston seal Refer to removal section.

  • Page 140

    FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE MASTER CYLINDER Order Part name Q'ty Remarks Front Rear Brake master cylinder cap Diaphragm Reservoir float Push rod (Front) Brake master cylinder boot Circlip Use a long nose circlip pliers. Washer Push rod (Rear) Brake master cylinder kit...

  • Page 141

    FRONT BRAKE AND REAR BRAKE HANDLING NOTE • Cover piston with rag and use ex- Support the machine securely so treme caution when expelling there is no danger of it falling over. piston from cylinder. • Never attempt to pry out piston. DRAINING THE BRAKE FLUID 1.

  • Page 142

    FRONT BRAKE AND REAR BRAKE • Replace the brake caliper piston seals and brake caliper piston dust seals whenever a caliper is disassembled. INSTALLING THE BRAKE CALIPER PISTON 1. Clean: • Brake caliper CHECKING THE BRAKE CALIPER • Brake caliper piston seal 1.

  • Page 143

    FRONT BRAKE AND REAR BRAKE 4. Install: • Brake master cylinder kit "1" • Washer (front brake) "2" • Push rod (rear brake) "2" • Circlip "3" • Brake master cylinder boot "4" • Push rod (front brake) "5" To brake master cylinder. INSTALLING THE REAR BRAKE INSTALLING THE BRAKE CALIPER...

  • Page 144

    FRONT BRAKE AND REAR BRAKE 2. Install: 2. Install: • Union bolt "3" • Brake lever "1" • Brake master cylinder "1" Union bolt: • Bolt (brake lever) "2" • Bolt (brake master cylinder) "2" 30 Nm (3.0 m•kg, 22 Bolt (brake lever): Bolt (brake master cylin- ft•lb)

  • Page 145

    FRONT BRAKE AND REAR BRAKE 4. Install: • Be careful that water does not • Copper washer "1" enter the master cylinder when • Brake hose "2" refilling. Water will significantly • Union bolt "3" lower the boiling point of the flu- id and may result in vapor lock.

  • Page 146

    FRONT BRAKE AND REAR BRAKE A. Front B. Rear 5. Install: (rear brake only) • Protector "1" • Bolt (protector) "2" Bolt (protector): 7 Nm (0.7 m•kg, 5.1 ft•lb) 5-15...

  • Page 147: Front Fork

    FRONT FORK FRONT FORK REMOVING THE FRONT FORK Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT WHEEL AND REAR Front wheel WHEEL" section. Refer to "FRONT BRAKE AND REAR Front brake caliper BRAKE"...

  • Page 148

    FRONT FORK DISASSEMBLING THE FRONT FORK 30 Nm (3.0 m kg, 22 ft lb) 29 Nm (2.9 m kg, 21 ft lb) 1 Nm (0.1 m kg, 0.7 ft lb) 29 Nm (2.9 m kg, 21 ft lb) 55 Nm (5.5 m kg, 40 ft lb) Order Part name Q'ty...

  • Page 149

    FRONT FORK HANDLING NOTE Support the machine securely so there is no danger of it falling over. The front fork requires careful atten- tion. So it is recommended that the 3. Remove: front fork be maintained at the deal- • Adjuster "1" ers.

  • Page 150

    FRONT FORK CHECKING THE BASE VALVE 1. Inspect: The bending value is shown by one • Be sure to use recommended • Base valve "1" half of the dial gauge reading. fork oil. If other oils are used, Wear/damage → Replace. they may have an excessively ad- Contamination →...

  • Page 151

    FRONT FORK 6. Tighten: 14. Check: • Locknut "1" • Damper assembly smooth move- Hold the damper assembly with the ment cap bolt ring wrench "2" and use the Tightness/binding/rough spots → Fully finger tighten the locknut onto cap bolt wrench "3" to tighten the Repeat the steps 2 to 13.

  • Page 152

    FRONT FORK 17. Install: • Outer tube "1" To inner tube "2". 21. Install: 25. Install: • Dust seal "1" • Damper assembly "1" To inner tube "2". 18. Install: Apply the lithium soap base grease • Slide metal "1" on the inner tube.

  • Page 153

    FRONT FORK 31. Fill: • Front fork oil "1" From outer tube top. Recommended oil: Suspension oil "S1" Standard oil amount: 350 cm (12.3 Imp oz, 11.8 US oz) 28. Inspect: INSTALLING THE FRONT FORK *340 cm (12.0 Imp oz, •...

  • Page 154

    FRONT FORK 4. Tighten: 7. Adjust: • Pinch bolt (upper bracket) "1" • Compression damping force Pinch bolt (upper brack- Turn in the damping adjuster "1" fin- et): ger-tight and then turn out to the orig- 21 Nm (2.1 m•kg, 15 inally set position.

  • Page 155: Handlebar

    HANDLEBAR HANDLEBAR REMOVING THE HANDLEBAR Order Part name Q'ty Remarks Number plate Remove the band only. Hot starter cable Disconnect at the lever side. Hot starter lever holder Clutch cable Disconnect at the lever side. Clutch lever holder Engine stop switch Brake master cylinder Refer to removal section.

  • Page 156

    HANDLEBAR REMOVING THE BRAKE MASTER CYLINDER • Be sure the side of the handlebar 1. Remove: lower holder having the greater dis- • Brake master cylinder bracket "1" tance "a" from the mounting bolt • Brake master cylinder "2" center faces forward. And install it in the hole "b"...

  • Page 157

    HANDLEBAR • Install the bracket so that the arrow mark "a" faces upward. • First tighten the bolt on the upper side of the brake master cylinder bracket, and then tighten the bolt on the lower side. 5. Install: 8. Install: •...

  • Page 158

    HANDLEBAR 12. Install: • Clutch cable "1" • Hot starter cable "2" Apply the lithium soap base grease on the clutch cable end and hot start- er cable end. 13. Adjust: • Clutch lever free play Refer to "ADJUSTING THE CLUTCH CABLE FREE PLAY"...

  • Page 159: Steering

    STEERING STEERING REMOVING THE STEERING Order Part name Q'ty Remarks TIGHTENING STEPS: Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb) Loosen it one turn. Retighten it. 7 Nm (0.7 m•kg, 5.1 ft•lb) Hold the machine by placing the suitable stand Refer to "HANDLING NOTE".

  • Page 160

    STEERING HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE STEERING RING 1. Remove: CHECKING THE BEARING AND 3. Install: • Steering ring nut "1" BEARING RACE • Lower bracket "1" Use the steering nut wrench "2". 1.

  • Page 161

    STEERING 11. Tighten: • Pinch bolt (upper bracket) "1" Pinch bolt (upper brack- et): 21 Nm (2.1 m•kg, 15 ft•lb) • Pinch bolt (lower bracket) "2" 7. Install: Pinch bolt (lower brack- • Front fork "1" et): • Upper bracket "2" 21 Nm (2.1 m•kg, 15 ft•lb) •...

  • Page 162: Swingarm

    SWINGARM SWINGARM REMOVING THE SWINGARM Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT BRAKE AND REAR Brake hose holder BRAKE" section. Refer to "FRONT BRAKE AND REAR Rear brake caliper BRAKE"...

  • Page 163

    SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q'ty Remarks Relay arm Connecting rod Collar Oil seal Thrust bearing Bushing Oil seal Bearing Refer to removal section. 5-32...

  • Page 164

    SWINGARM HANDLING NOTE Free play exists/unsmooth revolu- • Install the bearing by pressing it on tion/rust → Replace bearing and the side having the manufacture's collar as a set. marks or numbers. Support the machine securely so 2. Inspect: • Apply the molybdenum disulfide there is no danger of it falling over.

  • Page 165

    SWINGARM 5. Install: • Relay arm "1" • Apply the molybdenum disulfide • Bolt (relay arm) "2" grease on the bolt. • Washer "3" • Do not tighten the nut yet. • Nut (relay arm) "4" To swingarm. • Apply the molybdenum disulfide 2.

  • Page 166

    SWINGARM 12. Install: • Bolt (lower chain tensioner) "1" • Washer "2" • Collar "3" • Lower chain tensioner "4" • Nut (lower chain tensioner) "5" Nut (lower chain tension- er): 16 Nm (1.6 m•kg, 11 ft•lb) 13. Install: • Drive chain support "1" •...

  • Page 167: Absorber

    REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "SEAT, FUEL TANK AND SIDE Seat COVERS" section in the CHAPTER 4. Refer to "EXHAUST PIPE AND SILENCER"...

  • Page 168: Rear Shock Absorber

    To dispose of a damaged or worn- • Stopper ring (upper bearing) "1" ABSORBER out rear shock absorber, take the 1. Inspect: unit to your Yamaha dealer for this • Damper rod "1" disposal procedure. After installing the stopper ring, push Bends/damage → Replace rear back the bearing until it contacts the shock absorber assembly.

  • Page 169

    REAR SHOCK ABSORBER 3. Tighten: • Adjuster "1" 3. Install: 3. Install: • Lower bearing "1" • Rear shock absorber 4. Adjust: 4. Install: • Spring length (installed) • Bolt (rear shock absorber-frame) Install the bearing by pressing it on Refer to "ADJUSTING THE "1"...

  • Page 170

    REAR SHOCK ABSORBER • Bolt [rear frame (lower)] "3" Bolt [rear frame (lower)]: 32 Nm (3.2 m•kg, 23 ft•lb) 7. Tighten: • Bolt (air filter joint) "1" Bolt (air filter joint): 3 Nm (0.3 m•kg, 2.2 ft•lb) 5-39...

  • Page 171

    ELECTRICAL This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are request- ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to...

  • Page 172: Components And Wiring Diagram, Electrical Components And Wiring Diagram

    ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS Engine stop switch CDI magneto CDI unit Throttle position sensor Ignition coil Neutral switch Spark plug WIRING DIAGRAM Engine stop switch Black/Blue COLOR CODE Throttle position sensor Black/White Black Neutral switch Black/Yellow...

  • Page 173: Ignition System

    IGNITION SYSTEM IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. Spark gap test Spark → *Clean or replace spark plug. No spark ↓...

  • Page 174

    IGNITION SYSTEM SPARK GAP TEST Result 1. Disconnect the ignition coil from Conductive (while the spark plug. engine stop switch is 2. Remove the ignition coil cap. pushed) 3. Connect the dynamic spark tester Not conductive while it is pushed → "1"...

  • Page 175

    IGNITION SYSTEM 3. Inspect: • Charging coil 2 resistance Out of specification → Replace. Tester (+) lead → Pink lead "1" Tester (-) lead → Black lead "2" Charging Tester se- coil 2 resis- lector posi- tance tion 44-66 Ω at 20 °C (68 Ω...

  • Page 176: Throttle Position Sensor System

    THROTTLE POSITION SENSOR SYSTEM THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position sensor will not operate, use the following inspection steps. Check entire ignition system for connection. No good → Repair or replace. OK ↓ Check throttle position sensor. (Throttle position No good →...

  • Page 177

    THROTTLE POSITION SENSOR SYSTEM HANDLING NOTE 3. Inspect: • Throttle position sensor coil vari- able resistance Do not loosen the screw (throttle Check that the resistance in in- position sensor) "1" except when creased as the throttle grip is changing the throttle position sen- moved from the full close position sor due to failure because it will to the full open position.

  • Page 178

    THROTTLE POSITION SENSOR SYSTEM Throttle po- Throttle po- Tester se- Tester se- sition sen- sition sen- lector posi- lector posi- sor input sor output tion tion voltage voltage 4–6 V DCV-20 0.58–0.78 V 10. Put the aligning marks "a" on the throttle position sensor and car- buretor.

  • Page 179: Carburetor Setting, Adjusting Main Jet, Tuning

    ENGINE TUNING • After installing the carburetor, CONSTRUCTION OF check that the throttle operates CARBURETOR AND SETTING ENGINE correctly and opens and closes PARTS CARBURETOR SETTING smoothly. The FLATCR carburetor has a prima- • The air/fuel mixture will vary de- ry main jet.

  • Page 180: Adjusting Pilot Screw/jet, Adjusting Jet Needle Groove Position, Adjusting Jet Needle

    ENGINE ADJUSTING THE PILOT SCREW Effects of adjusting the pilot jet Diameter of the straight por- The richness of the air-fuel mixture (reference) tion with the throttle fully closed to 1/4 Reference needle open can be set by turning the pilot 0.5 richer screw "1".

  • Page 181

    ENGINE ADJUSTING THE LEAK JET CARBURETOR SETTING PARTS (ADJUSTING THE ACCELERATOR Main jet Size Part number PUMP) The leak jet "1" is a setting part that Rich #172 4MX-14943-92 adjusts the flow of fuel discharged by #170 4MX-14943-41 the accelerator pump. Since the ac- #168 4MX-14943-91 celerator pump operates only when...

  • Page 182

    ENGINE SPECIFICATIONS OF JET NEEDLE Diameter of straight portion Rich Lean Rich 1 richer NFLN-4 NFLP-4 NFLQ-4 NFLR-4 NFLS-4 NFLT-4 NFLU-4 0.5 richer NFPN-3 NFPP-3 NFPQ-3 NFPR-3 NFPS-3 NFPT-3 NFPU-3 NFLN-3 NFLP-3 NFLQ-3 NFLR-3 NFLS-3 NFLT-3 NFLU-3 0.5 leaner NFPN-2 NFPP-2 NFPQ-2 NFPR-2...

  • Page 183

    ENGINE This should be taken simply for an example. It is necessary to set the carburetor while checking the operating conditions of the engine.

  • Page 184

    CHASSIS CHASSIS DRIVE AND REAR WHEEL The front fork setting includes the fol- SPROCKETS SETTING PARTS lowing three factors: SELECTION OF THE SECONDARY 1. Setting of air spring characteris- REDUCTION RATIO (SPROCKET) Part name Size Part number tics • Change the fork oil amount. Secondary reduction ratio = Drive 2.

  • Page 185

    CHASSIS A. Air spring characteristics in relation to oil amount change The I.D. mark (slits) "a" is proved on B. Load the end of the spring. C. Stroke Max. oil amount Standard oil amount Min. oil amount SETTING OF SPRING AFTER 3.

  • Page 186

    CHASSIS SPRI SPRING Adjusting the rebound damping will PART I.D. TYPE be followed more or less by a change NUMBER MARK (-22212-) in the compression damping. For cor- rection, turn the low compression Pink/1 damping adjuster on the softer side. 1C3-50 Pink/2 (1C3-B0)

  • Page 187

    CHASSIS 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). Section Medi- Symptom...

  • Page 188

    CHASSIS SUSPENSION SETTING (REAR SHOCK ABSORBER) • 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. • Adjust the rebound damping in 2-click increments or decrements. •...

  • Page 190

    YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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  • nick Jan 26, 2016 10:47:
    The download is jacked up, so it's only really viewable on the site, but can't really complain since it's free.