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2010
q Read this manual carefully before operating this vehicle.
q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule.
q 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 ( Z )
33D-28199-80

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   Summary of Contents for Yamaha YZ450F

  • Page 1

    2010 q Read this manual carefully before operating this vehicle. q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. q 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...

  • 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

    2010 2010 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(Z) YZ450F(Z) 33D-28199-80-E0 33D-28199-80-E0...

  • Page 5

    YZ450F(Z) OWNER'S SERVICE MANUAL ©2009 by Yamaha Motor Co., Ltd. 1st Edition, August 2009 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

    ORDER. Congratulations on your purchase of distinguished in this manual by the For safety and reliability, the ma- a Yamaha YZ series. This model is following notations. chine must be properly maintained. the culmination of Yamaha's vast ex- Always perform the pre-operation perience in the production of paceset- checks indicated in this manual.

  • Page 7

    F.I.M. MACHINE WEIGHTS Weights of machines without fuel The minimum weights for motocross machines are: for the class 125 cc: minimum 88 kg (194 lb) for the class 250 cc: minimum 98 kg (216 lb) for the class 500 cc: minimum 102 kg (225 lb) In modifying your machine (e.g., for weight reduction), take note of the...

  • Page 8

    2. Numbers "2" are given in the or- 4. A job instruction chart "4" accom- HOW TO READ DESCRIPTIONS der of the jobs in the exploded di- panies the exploded diagram, To help identify parts and clarify pro- agram. A number that is enclosed providing the order of jobs, names cedure steps, there are exploded dia- by a circle indicates a disassem-...

  • Page 9: Table Of Contents

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

  • Page 10: General Information

    CONTENTS CHAPTER 1 CHAPTER 3 CHAPTER 5 GENERAL REGULAR CHASSIS INFORMATION INSPECTION AND ADJUSTMENTS FRONT WHEEL AND REAR WHEEL ..5-1 LOCATION OF FRONT BRAKE IMPORTANT LABELS ..1-1 MAINTENANCE AND REAR BRAKE..5-6 DESCRIPTION ....1-5 INTERVALS...... 3-1 FRONT FORK....5-16 CONSUMER PRE-OPERATION HANDLEBAR....5-24 INFORMATION....

  • Page 11: Important Labels

    LOCATION OF IMPORTANT LABELS GENERAL INFORMATION LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle. CANADA...

  • Page 12

    LOCATION OF IMPORTANT LABELS EUROPE...

  • Page 13

    LOCATION OF IMPORTANT LABELS AUS, NZ, ZA...

  • Page 14: Location Of Important Labels

    LOCATION OF IMPORTANT LABELS Familiarize yourself with the following pictograms and read the explanatory text. Read Owner's service manual. This unit contains high-pressure nitrogen gas. Mishandling can cause explosion. Do not incinerate, puncture or open. Turn off the main switch after riding to avoid draining the battery. Use unleaded gasoline only.

  • Page 15: Description

    DESCRIPTION DESCRIPTION Clutch lever 10. Coolant drain bolt Front brake lever 11. Rear brake pedal Throttle grip 12. Valve joint Radiator cap 13. Air cleaner Fuel tank cap 14. Drive chain Engine stop switch 15. Shift pedal Kickstarter crank 16. Oil level check window Fuel tank 17.

  • Page 16: Consumer Information

    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. 2. If your machine is stolen, the au-...

  • Page 17: Features

    FEATURES FEATURES OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in ac- cordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustionchamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.

  • Page 18: Throttle Body

    FEATURES FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains thefuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kgf/cm ² , 47.0 psi). Accordingly,when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causingthe fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 19: Included Parts

    INCLUDED PARTS INCLUDED PARTS IMPORTANT INFORMATION HANDLEBAR PROTECTOR Install the handlebar protector "1" so DETACHABLE SIDESTAND PREPARATION FOR REMOVAL that the mark "a" face forward. This sidestand "1" is used to support AND DISASSEMBLY only the machine when standing or 1.

  • Page 20: Handling The Electronic Parts

    • Do not touch and do not make them dirty. 5. Keep away from fire. ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replace- ments. Use oil and/or grease rec- ommended by Yamaha for CHECKING OF assembly and adjustment.

  • Page 21

    CHECKING OF CONNECTION If the contact seems not good, pull the terminal by hand and check its condition. Probe Coupler REMOVING THE QUICK FASTENER 4. Connect: • Lead Do not push the center pin with too • Coupler much force. Otherwise, the center •...

  • Page 22: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided.

  • Page 23

    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 24

    SPECIAL TOOLS Tool name/Part number How to use Illustration FI diagnostic tool This tool is used to check the fault YU-03182, 90890-03182 codes and diagnose any problems. Fuel pressure adapter This tool is used to attach the pres- YM-03186, 90890-03186 sure gauge.

  • Page 25

    SPECIAL TOOLS Tool name/Part number How to use Illustration Valve guide remover This tool is needed to remove and 5.5 mm (0.22 in) install the valve guide. YM-01122 Valve guide installer This tool is needed to install the 5.5 mm (0.22 in) valve guide.

  • Page 26

    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 (Three- This sealant (Bond) is used for ® Bond No. 1215) crankcase mating surface, etc. 90890-85505...

  • Page 27: Control Functions

    The clutch lever "1" is located on the left handlebar; it disengages or en- gages the clutch. Pull the clutch lever Your Yamaha engine has been de- to the handlebar to disengage the signed to use premium unleaded gas- clutch, and release the lever to en- oline with a pump octane number gage the clutch.

  • Page 28

    STARTING AND BREAK-IN 6. When the engine starts running, 6. Restart the engine and check the warm it up one or two minutes at operation of the machine through- • Unlike a two-stroke engine, this a steady speed (of 3,000 to 5,000 out its entire operating range.

  • Page 29: 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 30: 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 31: Specifications

    GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: YZ450FZ (USA, CDN, AUS, NZ) YZ450F (EUROPE, ZA) Model code number: 33D1 (USA,CDN) 33D2 (EUROPE) 33D4 (AUS, NZ, ZA) Dimensions: USA, CDN EUROPE AUS, NZ, ZA Overall length 2,193 mm (86.34 2,191 mm (86.26 2,194 mm (86.38 Overall width 825 mm (32.48 in) ←...

  • Page 32: Chassis

    GENERAL SPECIFICATIONS Fuel: Type Premium unleaded gasoline only Tank capacity 6.0 L (1.30 Imp gal, 1.59 US gal) Throttle body: Type 30RA 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: Primary reduction system Gear Primary reduction ratio 61/23 (2.652)

  • Page 33: Maintenance Specifications

    MAINTENANCE SPECIFICATIONS Wheel travel: Front wheel travel 310 mm (12.2 in) Rear wheel travel 315 mm (12.4 in) (For USA, CDN) 312 mm (12.3 in) (For EUROPE, AUS, NZ, ZA) Electrical: Ignition system MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.05 mm (0.002...

  • Page 34

    MAINTENANCE SPECIFICATIONS Item Standard Limit Timing chain: Timing chain type/No. of links 98XRH2010-122M/122 ---- 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 35

    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 36

    MAINTENANCE SPECIFICATIONS Item Standard Limit Piston: Piston to cylinder clearance 0.020–0.045 mm (0.0008–0.0018 in) 0.1 mm (0.004 Piston size "D" 96.965–96.980 mm (3.8175–3.8181 in) ---- Measuring point "H" 9.0 mm (0.354 in) ---- Piston off-set Zero mm (Zero in) ---- Piston pin bore inside diameter 18.004–18.015 mm (0.7088–0.7093 in) 18.045 mm...

  • Page 37

    MAINTENANCE SPECIFICATIONS Item Standard Limit Crankshaft: Crank width "A" 61.95–62.00 mm (2.439–2.441 in) ---- Runout limit "C" 0.03 mm (0.0012 in) 0.05 mm (0.002 Big end side clearance "D" 0.15–0.45 mm (0.0059–0.0177 in) 0.50 mm (0.02 Small end free play "F" 0.4–1.0 mm (0.02–0.04 in) 2.0 mm (0.08 Balancer:...

  • Page 38

    MAINTENANCE SPECIFICATIONS Item Standard Limit Throttle position sensor: ---- Throttle position sensor maximum resistance 5 kΩ ---- Throttle position sensor variable resistance 0–2 kΩ (full closed) ---- Throttle position sensor input voltage 4–6 V ---- Fuel injection sensor: ---- Crankshaft position sensor resistance 248–372 Ω...

  • Page 39

    MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing ---- Front suspension: USA, CDN EUROPE, AUS, NZ, ZA Front fork travel 310 mm (12.2 in) ---- ← Fork spring free length 470 mm (18.5 in) 465 mm (18.3 ←...

  • Page 40

    Standard Limit Ignition system: Advancer type Electrical ---- AC magneto: Magneto-model (stator)/manufacturer 33D00/YAMAHA ---- Stator coil resistance (color) 0.60–0.90 Ωat 20 °C (68 °F) ---- (White–White) Crankshaft position sensor resistance (color) 248–372 Ωat 20 °C (68 °F) (Gray–Black) ---- ECU-model/manufacturer...

  • Page 41: Tightening Torques

    TIGHTENING TORQUES TIGHTENING TORQUES ENGINE △ - marked portion shall be checked for torque tightening after break-in or before each race. Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Spark plug M10S × 1.0 Camshaft cap M6 × 1.0 Cylinder head blind plug screw M12 ×...

  • Page 42

    TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Crankshaft end accessing screw M36 × 1.5 Timing mark accessing screw M14 × 1.5 Clutch cover M6 × 1.0 Right crankcase cover M6 × 1.0 Left crankcase cover M6 ×...

  • Page 43

    TIGHTENING TORQUES CHASSIS △ - marked portion shall be checked for torque tightening after break-in or before each race. Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Upper bracket and outer tube M8 × 1.25 △ Lower bracket and outer tube M8 ×...

  • Page 44

    TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Driven sprocket and wheel hub M8 × 1.25 △ Nipple (spoke) — △ Disc cover and rear brake caliper M6 × 1.0 △ Protector and rear brake caliper M6 ×...

  • Page 45

    TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Rear fender (front) M6 × 1.0 △ Rear fender (rear) M6 × 1.0 △ Mud flap — △ Number plate M6 × 1.0 △ 1. First, tighten the steering ring nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the steering nut wrench, then loosen the steering ring nut one turn.

  • Page 46

    TIGHTENING TORQUES GENERAL TORQUE TORQUE SPECIFI- SPECIFICATIONS CATION (Bolt This chart specifies torque for stan- (Nut) 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 47: Lubrication Diagrams

    LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS Oil strainer 10. Main axle Oil check bolt 11. Drive axle Scavenging pump 12. Oil level check window Oil feed pump 13. Oil tank Oil filter element Crankshaft Oil nozzle Exhaust camshaft Intake camshaft 2-17...

  • Page 48: Cable Routing Diagram

    CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM 2-18...

  • Page 49

    CABLE ROUTING DIAGRAM Fuel tank breather hose Insert the end of the fuel tank Coupler for connecting optional breather hose into the hole in part the steering stem. Cylinder head breather hose Fit the accessory coupler into Hose holder the connector to fasten it to the Radiator hose 3 bracket.

  • Page 50

    CABLE ROUTING DIAGRAM 100mm 2-20...

  • Page 51

    CABLE ROUTING DIAGRAM Clutch cable Pass the clutch cable, throttle Throttle cable (return) cables, and engine stop switch Throttle cable (pull) lead through the cable holder. Cable holder Pass the clutch cable through Clamp the lower guide only. Rectifier/regulator Route the engine stop switch Ignition coil lead to the inside of the clip.

  • Page 52

    CABLE ROUTING DIAGRAM 2-22...

  • Page 53

    CABLE ROUTING DIAGRAM Tension pipe Fasten the wire harness at the Route the radiator breather hose Coolant temperature sensor positioning tape to the ECU between the down tubes. coupler bracket with a plastic locking tie. Fasten the fuel hose and fuel Front engine bracket Face the buckle of the plastic pump lead with the plastic band,...

  • Page 54

    CABLE ROUTING DIAGRAM Ignition coil coupler Fuel hose Route the fuel pump lead to the Coolant temperature sensor Fuel pump lead outside of the fuel hose and lead 10. Fuel injector coupler above the cover. Atmospheric pressure sensor 11. Throttle body Route the spark plug wire be- coupler 12.

  • Page 55

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

  • Page 56

    CABLE ROUTING DIAGRAM Throttle cable Route the clutch cable to the Clutch cable rear of the number plate band. Clamp Fasten the engine stop switch Engine stop switch lead lead to the handlebar. Hose guide Route the brake hose to the Main harness front of the number plate.

  • Page 57: Regular Inspection And Adjustments

    If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. • Periodic inspection is essential in making full use of the machine performance. The service life of the parts varies sub- stantially according to the environment in which the machine runs (e.g., rain, dirt, etc.).

  • Page 58

    MAINTENANCE INTERVALS Every Every Every third fifth After race As re- (about (about Item break- (about Remarks quired 12.5 hours) hours) hours) CYLINDER HEAD Inspect carbon deposits and eliminate them. Inspect and clean Change gasket. ● CYLINDER Inspect and clean Inspect score marks.

  • Page 59

    MAINTENANCE INTERVALS Every Every Every third fifth After race As re- (about (about Item break- (about Remarks quired 12.5 hours) hours) hours) AIR FILTER Clean and lubricate Use foam air-filter oil or equivalent oil. ● ● Replace ● OIL FILTER Replace ●...

  • Page 60

    Retighten sprocket bolt ● ● Inspect bearings ● Replace bearings ● Lubricate Lithium base grease ● THROTTLE, CONTROL CABLE Check routing and connection Yamaha cable lube or SAE 10W-40 ● ● motor oil Lubricate ● ●...

  • Page 61: 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 62: Checking Coolant Level

    ENGINE ENGINE CHANGING THE COOLANT CHECKING THE COOLANT LEVEL Do not remove the radiator cap when the engine is hot. Do not remove the radiator cap "1", drain bolt and hoses when the engine and radiator are hot. Scald- Take care so that coolant does not ing hot fluid and steam may be splash on painted surfaces.

  • Page 63

    ENGINE CHECKING THE RADIATOR CAP 3. Apply the specified pressure. ADJUSTING THE CLUTCH CABLE OPENING PRESSURE FREE PLAY Standard pressure: 1. Attach: 1. Check: 196 kPa (1.96 kg/cm • Radiator cap tester "1" and adapt- • Clutch lever free play "a" 27.9 psi) er "2"...

  • Page 64: Cleaning Air Filter

    ENGINE ADJUSTING THE THROTTLE 2. Apply: 4. Loosen and release the binder "1" CABLE FREE PLAY • Lithium soap base grease and lift the air filter case lid. 1. Check: On the throttle cable end "a". • Throttle grip free play "a" Hold the air filter case lid by the use of Out of specification →...

  • Page 65: Checking Throttle Body Joint

    ENGINE 8. Apply: CHECKING THE FUEL LINE • Foam-air-filter oil or equivalent oil 1. Remove: • Check the oil quantity within 5 min- to the element • Seat utes after the engine is shut off. • Fuel tank Over 5 minutes, idle the engine Oil application quantify: •...

  • Page 66: Changing Engine Oil

    ENGINE CHANGING THE ENGINE OIL 6. Fill: ADJUSTING THE ENGINE IDLING 1. Start the engine and let it warm up • Engine oil SPEED for several minutes. Oil quantity: 2. Stop the engine and place an oil • Because the air pressure is lower at Periodic oil change: pan under the drain bolt.

  • Page 67: Adjusting Valve Clearance

    • Identity each valve lifter and pad "b" on the crankcase cover. concerning the servicing of Yama- position very carefully so that they ha motorcycles (e.g., Yamaha deal- can be reinstalled in their original ers, service engineers, etc.) Those place.

  • Page 68: Adjustments

    ENGINE d. Round off the last digit of the in- stalled pad number to the nearest increment. Last digit of pad Rounded valve number 0, 1 or 2 4, 5 or 6 8 or 9 EXAMPLE: Installed pad number = 148 Rounded off value = 150 Pads can only be selected in 0.05 mm increments.

  • Page 69: Engine

    ENGINE INTAKE EXHAUST 3-13...

  • Page 70: Chassis

    CHASSIS CHASSIS h. Tighten the bleed screw when the b. Turn the adjusting bolt "2" until the lever or pedal limit has been lever position "a" is within speci- BLEEDING THE HYDRAULIC reached; then release the lever or fied position. BRAKE SYSTEM pedal.

  • Page 71

    CHASSIS c. Tighten the locknut. b. Loosen the pad pin "2". Install the brake caliper "8" and c. Remove the brake caliper "3" tighten the pad pin "9". Locknut: from the front fork. 6 Nm (0.6 m •kg, 4.3 Bolt (brake caliper): ft•lb) 28 Nm (2.8 m•kg, 20 ft•lb)

  • Page 72

    CHASSIS 2. Replace: h. Install the brake pad "10" and pad 4. Check: • Brake pad pin "11". • Brake pedal operation A softy or spongy feeling → Bleed brake system. • Install the brake pads with their pro- Brake pad replacement steps: Refer to "BLEEDING THE HY- jections "a"...

  • Page 73

    CHASSIS 2. Remove: 6. Lubricate: • Master link clip • Drive chain • Joint "1" Drive chain lubricant: • Drive chain "2" SAE 10W-40 motor oil or suitable chain lubri- cants Lower level A. Front B. Rear CHECKING THE SPROCKET 3.

  • Page 74

    CHASSIS c. Turn each adjuster exactly the CHECKING THE FRONT FORK RELIEVING THE FRONT FORK same amount to maintain correct PROTECTOR GUIDE INTERNAL PRESSURE axle alignment. (There are marks 1. Inspect: "a" on each side of the drive chain • Protector guide "1" If the front fork initial movement feels puller alignment.) NOTICE: Im- Out of specification →...

  • Page 75

    CHASSIS CHECKING THE REAR SHOCK 3. Adjust: ABSORBER • Spring preload Do not force the adjuster past the 1. Inspect: minimum or maximum extent of • Swingarm smooth action Adjustment steps: adjustment. The adjuster may be Abnormal noise/unsmooth action a. Loosen the locknut "1". damaged.

  • Page 76

    CHASSIS ADJUSTING THE REAR SHOCK ADJUSTING THE REAR SHOCK ADJUSTING THE REAR SHOCK ABSORBER REBOUND DAMPING ABSORBER LOW COMPRESSION ABSORBER HIGH COMPRESSION FORCE DAMPING FORCE DAMPING FORCE 1. Adjust: 1. Adjust: 1. Adjust: • Rebound damping force • Low compression damping force •...

  • Page 77

    CHASSIS CHECKING THE TIRE PRESSURE 3. Check: 1. Measure: • Steering smooth action • Tire pressure Turn the handlebar lock to lock. Out of specification → Adjust. Unsmooth action → Adjust steer- ing ring nut. Standard tire pressure: 100 kPa (1.0 kgf/cm 15 psi) Spoke nipple wrench: •...

  • Page 78

    CHASSIS e. Loosen the steering ring nut one turn. f. Retighten the steering ring nut us- ing the steering nut wrench. Avoid over-tightening. Steering ring nut (final tightening): 7 Nm (0.7 m•kg, 5.1 ft•lb) g. Check the steering stem by turn- ing it lock to lock.

  • Page 79

    CHASSIS LUBRICATION To ensure smooth operation of all Use Yamaha cable lube or components, lubricate your machine equivalent on these areas. during setup, after break-in, and after Use SAE 10W-40 motor oil or every race. suitable chain lubricants. All control cable...

  • Page 80: 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 81

    If a problem occurs that is not listed in this manual or if the problem cannot be corrected by the procedures provided in this manual, contact your Yamaha dealer. Engine starting problems, engine idling speed problems, and medium and high-speed performance problems •...

  • Page 82: And Side Covers

    SEAT 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 83: Seat And Side Covers

    SEAT AND SIDE COVERS CHECKING AND REPLACING THE REMOVING THE NUMBER PLATE INSULATOR 1. Remove: 1. Inspect: • Bolt (number plate) • Insulator 1 "1" • Number plate "1" • Insulator 2 "2" • Insulator 3 "3" • The projection "a" is inserted into •...

  • Page 84: Exhaust Pipe And Silencer

    EXHAUST PIPE AND SILENCER EXHAUST PIPE AND SILENCER REMOVING THE EXHAUST PIPE AND SILENCER Order Part name Q'ty Remarks Seat Refer to "SEAT AND SIDE COVERS" sec- tion. Refer to "SEAT AND SIDE COVERS" sec- Side cover (left and right) tion.

  • Page 85

    EXHAUST PIPE AND SILENCER Order Part name Q'ty Remarks Heat protector...

  • Page 86

    EXHAUST PIPE AND SILENCER CHECKING THE SILENCER AND 4. Install: EXHAUST PIPE • Inner pipe "1" 1. Inspect: • Bolt "2" • Gasket "1" Bolt (silencer): Damage → Replace. 8 Nm (0.8 m•kg, 5.8 ft•lb) 2. Replace: • Apply heat-resistant sealant to the •...

  • Page 87

    EXHAUST PIPE AND SILENCER INSTALLING THE SILENCER AND 3. Install: EXHAUST PIPE • Silencer clamp (rear) 1. Install: • Silencer "1" • Gasket • Bolt (silencer) "2" • Exhaust pipe "1" Bolt (silencer): • Nut (exhaust pipe) "2" 30 Nm (3.0 m•kg, 22 Nut (exhaust pipe): ft•lb) 10 Nm (1.0 m•kg, 7.2...

  • Page 88: 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 AND SIDE COVERS" sec- Seat tion. Fuel tank Refer to "FUEL TANK" section in the CHAP- TER 6.

  • Page 89

    RADIATOR Order Part name Q'ty Remarks Pipe 1/O-ring...

  • Page 90

    RADIATOR HANDLING NOTE • Radiator hose 4 "7" 5. Install: • Radiator guard "1" Radiator hose 4: 2 Nm (0.2 m•kg, 1.4 Do not remove the radiator cap First fit the inner hook portion "a" and ft•lb) when the engine and radiator are then the outer one "b"...

  • Page 91: Camshafts

    CAMSHAFTS CAMSHAFTS REMOVING THE CYLINDER HEAD COVER Order Part name Q'ty Remarks Refer to "SEAT AND SIDE COVERS" sec- Seat tion. Refer to "FUEL TANK" section in the CHAP- Fuel tank TER 6. Refer to "THROTTLE BODY" section in the Cover CHAPTER 6.

  • Page 92

    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 93

    CAMSHAFTS REMOVING THE CAMSHAFT 4. Remove: Cam lobes length: 1. Remove: • Bolt (camshaft cap) "1" Intake "a": • Timing mark accessing screw "1" • Camshaft cap "2" 37.750–37.850 mm • Crankshaft end accessing screw • Clip (1.4862–1.4902 in) "2" <Limit>: Remove the bolts (camshaft cap) in a 37.650 mm (1.4823 in)

  • Page 94

    CAMSHAFTS 4. Measure: • Camshaft-to-cap clearance Out of specification → Measure camshaft outside diameter. Camshaft-to-cap clear- ance: 0.028–0.062 mm (0.0011–0.0024 in) CHECKING THE CAMSHAFT <Limit>:0.08 mm (0.003 SPROCKET 1. Inspect: • Camshaft sprocket "1" Wear/damage → Replace the Measurement steps: camshaft assembly and timing a.

  • Page 95

    CAMSHAFTS b. With the rod fully wound and the chain tensioner UP mark "a" fac- ing upward, install the gasket "1", the timing chain tensioner "2", and the gasket "3", and tighten the bolt "4" to the specified torque. Bolt (timing chain ten- sioner): 10 Nm (1.0 m•kg, 7.2 ft•lb)

  • Page 96: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD REMOVING THE CYLINDER HEAD Order Part name Q'ty Remarks Refer to "SEAT AND SIDE COVERS" sec- Seat tion. Fuel tank Refer to "FUEL TANK" section in the CHAP- TER 6. Refer to "EXHAUST PIPE AND SILENCER" Exhaust pipe and silencer section.

  • Page 97

    CYLINDER HEAD Order Part name Q'ty Remarks Bolt (cylinder head) Bolt (cylinder head) Refer to TIP. Cylinder head Cylinder head gasket Timing chain guide (intake side) Coolant temperature sensor Oil check bolt Oil passage plug Tighten the cylinder head bolts to 30 Nm (3.0 m•kg, 22 ft•b) in the proper tightening sequence, remove and retighten the cylinder head bolts to 20 Nm (2.0 m•kg, 14 ft•lb) in the proper tightening sequence, and then tighten the cylinder head bolts further to reach the specified angle 150°...

  • Page 98

    CYLINDER HEAD CHECKING THE CYLINDER HEAD INSTALLING THE CYLINDER d. Tighten the bolts to the specified 1. Eliminate: HEAD torque in two or three steps in the • Carbon deposits (from the com- 1. Install: proper tightening sequence as bustion chambers) •...

  • Page 99

    CYLINDER HEAD Tighten the bolts two times at speci- fied angles of 90°and 60° to reach the specified angle of 150° in the proper tightening sequence as shown. Bolts (cylinder head): Final: Specified angle 150° 3. Install: • Bolt (cylinder head) "1" Bolt (cylinder head): 10 Nm (1.0 m•kg, 7.2 ft•lb)

  • Page 100: 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 101

    VALVES AND VALVE SPRINGS REMOVING THE VALVE LIFTER a. Remove the valve guide using a AND VALVE COTTER valve guide remover "1". 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 be reinstalled in their original place.

  • Page 102

    VALVES AND VALVE SPRINGS 4. Measure: • Margin thickness "a" Do not let the compound enter the Out of specification → Replace. gap between the valve stem and Margin thickness: the guide. Intake: 1.3 mm (0.051 in) Exhaust: 1.0 mm (0.039 in) Measurement steps: a.

  • Page 103

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

  • Page 104: 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 105

    CYLINDER AND PISTON REMOVING THE PISTON AND CHECKING THE CYLINDER AND e. Calculate the piston-to-cylinder PISTON RING PISTON clearance with following formula: 1. Remove: 1. Inspect: Piston-to-cylinder clearance = • Piston pin clip "1" • Cylinder and piston walls Cylinder bore "C" - Piston skirt •...

  • Page 106

    CYLINDER AND PISTON 2. Position: 2. Measure: INSTALLING THE PISTON RING • Piston ring • Piston pin-to-piston clearance AND PISTON (in cylinder) 1. Install: • Piston ring Measurement steps: Onto the piston. Insert a ring into the cylinder and a. Measure the outside diameter push it approximately 40mm (1.57 in) (piston pin) "a".

  • Page 107

    CYLINDER AND PISTON 3. Install: • Piston "1" • Piston pin "2" • Piston pin clip "3" • Apply engine oil onto the piston. • Apply molybdenum disulfide oil onto the piston pin. • Install the piston with the F mark "a" on it pointing to its intake (front) side.

  • Page 108: 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 Clutch spring Pressure plate...

  • Page 109

    CLUTCH Order Part name Q'ty Remarks Conical washer Refer to removal section. Clutch boss Refer to removal section. Thrust washer Primary driven gear Push lever shaft 4-28...

  • Page 110

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

  • Page 111

    CLUTCH INSTALLING THE CLUTCH 3. Install: 7. Install: 1. Install: • Friction plate "1" • Clutch spring • Primary driven gear "1" • Clutch plate "2" • Bolt (clutch spring) • Thrust washer "2" Bolt (clutch spring): • Clutch boss "3" •...

  • Page 112: 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 Order Part name Q'ty Remarks Right engine guard Refer to "ENGINE REMOVAL" section. Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3.

  • Page 113

    OIL FILTER ELEMENT AND WATER PUMP Order Part name Q'ty Remarks Dowel pin/O-ring Impeller Refer to removal section. Washer Refer to removal section. Impeller shaft Refer to removal section. Oil seal 1 Refer to removal section. Oil seal 2 Refer to removal section. Bearing Refer to removal section.

  • Page 114

    OIL FILTER ELEMENT AND WATER PUMP REMOVING THE IMPELLER CHECKING THE IMPELLER SHAFT 2. Install: SHAFT 1. Inspect: • Bearing "1" 1. Remove: • Impeller shaft "1" • Impeller "1" Bend/wear/damage → Replace. Install the bearing by pressing its out- •...

  • Page 115

    OIL FILTER ELEMENT AND WATER PUMP INSTALLING THE RIGHT INSTALLING THE KICKSTARTER 3. Install: CRANKCASE COVER CRANK • O-ring 1. Install: 1. Install: • Coolant pipe "1" • Dowel pin "1" • Kickstarter crank "1" • Bolt (radiator pipe) "2" •...

  • Page 116: 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 "AC MAGNETO" section. Nut (balancer) Refer to removal section. Nut (primary drive gear) Refer to removal section.

  • Page 117

    BALANCER REMOVING THE BALANCER CHECKING THE BALANCER • Primary drive gear "3" 1. Straighten the lock washer tab. 1. Inspect: • Conical washer "4" 2. Loosen: • Balancer • Nut (primary drive gear) "5" • Nut (balancer) "1" Cracks/damage → Replace. Nut (primary drive gear): •...

  • Page 118: 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 119

    OIL PUMP Order Part name Q'ty Remarks Oil pump drive shaft Rotor housing 4-38...

  • Page 120

    OIL PUMP CHECKING THE OIL PUMP 3. Check: 1. Inspect: • Unsmooth → Repeat steps #1 • Apply the engine oil on the oil pump • Oil pump drive gear and #2 or replace the defective drive shaft end and inner rotor 2. •...

  • Page 121: 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 122

    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. 4-41...

  • Page 123: Kick Shaft And Shift Shaft

    KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT CHECKING THE KICK SHAFT AND CHECKING THE SHIFT GUIDE AND ASSEMBLY RATCHET WHEEL SHIFT LEVER ASSEMBLY 1. Remove: 1. Check: 1. Inspect: • Kick shaft assembly "1" • Ratchet wheel "1" smooth move- •...

  • Page 124

    KICK SHAFT AND SHIFT SHAFT INSTALLING THE STOPPER 3. Install: 2. Install: LEVER • Shift lever assembly "1" • Shift pedal "1" 1. Install: • Shift guide "2" • Bolt (shift pedal) "2" • Torsion spring "1" Bolt (shift pedal): •...

  • Page 125

    KICK SHAFT AND SHIFT SHAFT 3. Install: INSTALLING THE KICK IDLE • Spring guide "1" GEAR 1. Install: • Kick idle gear "1" Slide the spring guide into the kick • Washer "2" shaft, make sure the groove "a" in the •...

  • Page 126: Ac Magneto

    AC MAGNETO AC MAGNETO REMOVING THE AC MAGNETO Order Part name Q'ty Remarks Seat Refer to "SEAT AND SIDE COVERS" sec- tion. Fuel tank Refer to "FUEL TANK" section in the CHAPER 6. Disconnect the AC magneto lead Left crankcase cover Gasket Dowel pin Nut (rotor)

  • Page 127

    "c" on the holder contacts the CHECKING THE AC MAGNETO stopper. 1. Inspect: • Rotor inner surface "a" • Stator outer surface "b" YAMAHA Bond No. 1215 ® Damage → Inspect the crank- (ThreeBond No. 1215): shaft runout and crankshaft bear- 90890-85505 ing.

  • Page 128: Engine Removal

    ENGINE REMOVAL ENGINE REMOVAL REMOVING THE ELECTRONIC PARTS Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the frame. Refer to "SEAT AND SIDE COVERS" sec- Seat tion. Refer to "FUEL TANK" section in the Fuel tank CHAPER 6.

  • Page 129

    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 "THROTTLE BODY" section in the Throttle body CHAPRE 6. Refer to "SEAT AND SIDE COVERS" sec- Rear fender tion.

  • Page 130

    ENGINE REMOVAL Order Part name Q'ty Remarks Clip Bolt (brake pedal) Brake pedal Upper engine bracket Lower engine bracket Engine mounting bolt Pivot shaft Refer to removal section. Engine Refer to removal section. 4-49...

  • Page 131

    ENGINE REMOVAL HANDLING NOTE 2. Remove: • Engine "1" • Apply the molybdenum disulfide From right side. grease on the pivot shaft. Support the machine securely so • Install the patch with the claw "6" there is no danger of it falling over. •...

  • Page 132

    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 133: 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 134: Crankcase And Crankshaft

    CRANKCASE AND CRANKSHAFT Order Part name Q'ty Remarks Balancer shaft Refer to removal section. Crankshaft Refer to removal section. 4-53...

  • Page 135

    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. Circlip Oil seal Bearing Refer to removal section.

  • Page 136

    CRANKCASE AND CRANKSHAFT DISASSEMBLING THE c. Remove the dowel pins and O- REMOVING THE CRANKCASE CRANKCASE ring. BEARING 1. Separate: 1. Remove: • Right crankcase • Bearing "1" REMOVING THE BALANCER • Left crankcase SHAFT • Remove the bearing from the 1.

  • Page 137

    CRANKCASE AND CRANKSHAFT 3. Inspect: INSTALLING THE CRANKCASE • Oil seal BEARING • Hold the connecting rod at top dead Damage → Replace. 1. Install: center with one hand while turning • Bearing CHECKING THE CRANKSHAFT the nut of the installing tool with the •...

  • Page 138

    Tighten the crankcase tightening bolts in stage, using a crisscross pat- tern. 4. Apply: • Sealant On the right crankcase. YAMAHA Bond No. 1215 7. Install: ® (ThreeBond No.1215): • Timing chain 90890-85505 • Timing chain guide (exhaust side) •...

  • Page 139: 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 140

    TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION CHECKING THE BEARING INSTALLING THE TRANSMISSION 1. Remove: 1. Inspect: 1. Install: • Main axle "1" • Bearing "1" • 5th pinion gear (21T) "1" • Drive axle "2" Rotate inner race with a finger. •...

  • Page 141

    TRANSMISSION, SHIFT CAM AND SHIFT FORK 5. Install: • Shift fork 1 (L) "1" • Shift fork 2 (C) "2" • Shift fork 3 (R) "3" • Shift cam "4" To main axle and drive axle. • Apply the molybdenum disulfide oil on the shift fork grooves.

  • Page 142: 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 143

    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 144: Front Wheel And Rear Wheel

    FRONT WHEEL AND REAR WHEEL HANDLING NOTE 2. Inspect: 2. Measure: • Bearing • Brake disc thickness "a" Rotate inner race with a finger. Out of limit → Replace. Support the machine securely so Rough spot/seizure → Replace. Brake disc thickness: there is no danger of it falling over.

  • Page 145

    FRONT WHEEL AND REAR WHEEL 4. Install: • Wheel Install the brake disc "1" between the brake pads "2" correctly. INSTALLING THE REAR WHEEL 1. Install: • Bearing (right) "1" • Circlip "2" • Spacer "3" • Bearing (left) "4" 5.

  • Page 146

    FRONT WHEEL AND REAR WHEEL 2. Install: 5. Install: 9. Adjust: • Brake disc "1" • Wheel • Drive chain slack "a" • Bolt (brake disc) "2" Drive chain slack: Install the brake disc "1" between the Bolt (brake disc): 50–60 mm (2.0–2.4 in) brake pads "2"...

  • Page 147: 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 148

    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 149

    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 150

    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 151

    FRONT BRAKE AND REAR BRAKE HANDLING NOTE REMOVING THE BRAKE CALIPER PISTON Replace the brake caliper piston 1. Remove: Support the machine securely so seals and brake caliper piston dust • Brake caliper piston there is no danger of it falling over. seals whenever a caliper is disas- Use compressed air and proceed sembled.

  • Page 152

    FRONT BRAKE AND REAR BRAKE 3. Inspect: (front brake only) CHECKING THE BRAKE HOSE • Reservoir float "1" 1. Inspect: Damage → Replace. • Brake hose "1" Crack/damage → Replace. A. Front B. Rear 3. Install: 4. Inspect: • Brake caliper piston "1" •...

  • Page 153

    FRONT BRAKE AND REAR BRAKE 2. Install: 3. Install: • Brake caliper "1" • Brake caliper "1" • Bolt (brake caliper) "2" • Rear wheel "2" Refer to "FRONT WHEEL AND Bolt (brake caliper): REAR WHEEL" section. 28 Nm (2.8 m•kg, 20 4.

  • Page 154

    FRONT BRAKE AND REAR BRAKE INSTALLING THE FRONT BRAKE INSTALLING THE REAR BRAKE 3. Install: MASTER CYLINDER MASTER CYLINDER • Spring "1" 1. Install: 1. Install: • Brake pedal "2" • Brake master cylinder "1" • Copper washer "1" • O-ring "3" •...

  • Page 155

    FRONT BRAKE AND REAR BRAKE 2. Install: • Brake hose holder "1" Install the brake hose so that its Always use new copper washers. • Screw (brake hose holder) "2" pipe portion "a" directs as shown Screw (brake hose hold- and lightly touches the projection er): "b"...

  • Page 156

    FRONT BRAKE AND REAR BRAKE Brake fluid may erode painted sur- faces or plastic parts. Always clean up spilled fluid immediately. A. Front B. Rear 5. Install: (rear brake only) • Protector "1" • Bolt (protector) "2" A. Front Bolt (protector): B.

  • Page 157: 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 158

    FRONT FORK DISASSEMBLING THE FRONT FORK Order Part name Q'ty Remarks Adjuster Drain the fork oil. Refer to removal section. Fork spring Dust seal Refer to removal section. Stopper ring Refer to removal section. Inner tube Refer to removal section. Outer tube Piston metal Slide metal...

  • Page 159

    FRONT FORK HANDLING NOTE REMOVING THE ADJUSTER 2. Remove: 1. Drain the outer tube of its front • Inner tube "1" fork oil at its top. Support the machine securely so 2. Loosen: Oil seal removal steps: there is no danger of it falling over. •...

  • Page 160

    FRONT FORK CHECKING THE FORK SPRING CHECKING THE ADJUSTER 1. Measure: 1. Inspect: The front fork with a built-in piston • Fork spring free length "a" • Adjuster "1" rod has a very sophisticated inter- Out of specification → Replace. •...

  • Page 161

    FRONT FORK 5. Measure: 8. Install: 12. While protecting the damper as- • Oil level (left and right) "a" • Base valve "1" sembly "1" with a rag and com- Out of specification → Adjust. To damper assembly "2". pressing fully, allow excessive oil to overflow on the base valve Standard oil level: side.

  • Page 162

    FRONT FORK 21. Install: • Dust seal "1" Apply the lithium soap base grease on the inner tube. 22. Check: • Inner tube smooth movement Tightness/binding/rough spots → 16. Install: 19. Install: Repeat the steps 15 to 21. • Piston metal "1" •...

  • Page 163

    FRONT FORK 25. Install: 28. Inspect: 31. Fill: • Damper assembly "1" • Gap "a" between the adjuster "1" • Front fork oil "1" To inner tube "2". and locknut "2". From outer tube top. Out of specification → Retighten Recommended oil: and readjust the locknut.

  • Page 164

    FRONT FORK 33. Install: 4. Tighten: 7. Adjust: • Protector guide "1" • 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 165: Handlebar

    HANDLEBAR HANDLEBAR REMOVING THE HANDLEBAR Order Part name Q'ty Remarks Number plate Remove the band only. Clutch cable Disconnect at the lever side. Clutch lever holder Engine stop switch Brake master cylinder Refer to removal section. Throttle cable cap Throttle cable #1 (pulled) Disconnect at the throttle side.

  • Page 166

    HANDLEBAR REMOVING THE BRAKE MASTER INSTALLING THE HANDLEBAR CYLINDER 1. Install: • The handlebar upper holder should 1. Remove: • Handlebar lower holder "1" be installed with the punched mark • Brake master cylinder bracket "1" • Washer "2" "a" forward. •...

  • Page 167

    HANDLEBAR 3. Tighten: • Nut (handlebar lower holder) "1" After tightening the screws, check Nut (handlebar lower that the throttle grip "3" moves holder): smoothly. If it does not, retighten 34 Nm (3.4 m•kg, 24 the bolts for adjustment. ft•lb) •...

  • Page 168

    HANDLEBAR 11. Install: • Engine stop switch "1" • Clutch lever holder "2" • Bolt (clutch lever holder) "3" Bolt (clutch lever holder): 5 Nm (0.5 m•kg, 3.6 ft•lb) •Clamp "4" • The engine stop switch, clutch lever holder and clamp should be in- stalled according to the dimensions shown.

  • Page 169: 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 170

    STEERING Order Part name Q'ty Remarks Bearing race Refer to removal section. 5-29...

  • Page 171

    STEERING HANDLING NOTE CHECKING THE STEERING STEM 1. Inspect: • Steering stem "1" Support the machine securely so Bend/damage → Replace. there is no danger of it falling over. REMOVING THE STEERING RING 1. Remove: 3. Install: • Steering ring nut "1" •...

  • Page 172

    STEERING 6. Install: 10. Adjust: • Washer "1" • Front fork top end "a" Front fork top end (stan- dard) "a": Zero mm (Zero in) 7. Install: • Front fork "1" • Upper bracket "2" 11. Tighten: • Temporarily tighten the pinch bolts •...

  • Page 173: 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 174

    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. 5-33...

  • Page 175

    SWINGARM HANDLING NOTE CHECKING THE CONNECTING 2. Install: • Bearing "1" 1. Inspect: • Washer "2" Support the machine securely so • Bearing "1" • Oil seal "3" there is no danger of it falling over. • Collar "2" To relay arm. Free play exists/unsmooth revolu- REMOVING THE BEARING tion/rust →...

  • Page 176

    SWINGARM INSTALLING THE SWINGARM 4. Install: 7. Check: 1. Install: • Connecting rod "1" • Swingarm side play "a" • Bushing "1" • Bolt (connecting rod) "2" Free play exists → Replace thrust • Thrust bearing "2" • Washer "3" bearing.

  • Page 177

    SWINGARM 10. Tighten: 13. Install: • Nut (connecting rod) "1" • Drive chain support "1" • Drive chain support cover "2" Nut (connecting rod): • Bolt {drive chain support [L = 50 80 Nm (8.0 m•kg, 58 mm (1.97 in)]} "3" ft•lb) •...

  • Page 178: Shock 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 AND SIDE COVERS" section Seat in the CHAPTER 4. Refer to "EXHAUST PIPE AND SILENCER"...

  • Page 179: Rear Shock Absorber

    To dispose of a damaged or worn- out rear shock absorber, take the unit to your Yamaha dealer for this disposal procedure. 5-38...

  • Page 180

    REAR SHOCK ABSORBER 2. Install: 3. Adjust: 4. Install: • Stopper ring (upper bearing) "1" • Spring length (installed) • Bolt (rear shock absorber-frame) Refer to "ADJUSTING THE "1" REAR SHOCK ABSORBER • Washer "2" SPRING PRELOAD" section in • Nut (rear shock absorber-frame) After installing the stopper ring, push the CHAPTER 3.

  • Page 181: Fuel System

    FUEL TANK FUEL SYSTEM 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 servicing trouble and mechanical damage.

  • Page 182: Removing/installing Fuel Pump

    FUEL TANK REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank • Always use a new fuel pump gas- through the fuel tank cap with a ket. pump. • Install the lip on the fuel pump gas- ket upward.

  • Page 183

    FUEL TANK CHECKING AND REPLACING THE DUMPER 1. Inspect: • Damper 1 "1" • Damper 2 "2" • Damper 3 "3" Wear/damage → Replace • Affix dampers 1 and 3 so that the arrow on each damper is pointing outward. •...

  • Page 184

    THROTTLE BODY THROTTLE BODY REMOVING THE THROTTLE BODY Order Part name Q'ty Remarks Refer to "SEAT AND SIDE COVERS" section Seat in the chapter 4. Refer to "SEAT AND SIDE COVERS" section Air scoop (left/right) in the chapter 4. Fuel tank Refer to "FUEL TANK"...

  • Page 185

    THROTTLE BODY DISASSEMBLING THE THROTTLE BODY Order Part name Q'ty Remarks Injector Gasket...

  • Page 186: Throttle Body

    THROTTLE BODY CHECKING THE INJECTOR 1. Check: • Throttle body Cracks/damage → Replace the Replace the fuel injector with a throttle body as a set. new one if you have dropped or im- 2. Check: pacted it. • Starter knob/ idle screw delivery passages "a"...

  • Page 187: Components And Wiring Diagram

    ELECTRICAL COMPONENTS AND WIRING DIAGRAM 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.

  • Page 188: Electrical Components And Wiring Diagram

    ELECTRICAL COMPONENTS AND WIRING DIAGRAM WIRING DIAGRAM Br/W B/R B Br/W B/L Br/W Br/W STOP Lg Lg Crankshaft position sensor COLOR CODE AC magneto Black Rectifier/regulator Brown Condenser Gray Fuel pump Blue Engine stop switch Light green Orange Ignition coil Pink Spark plug 10.

  • Page 189: 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 → • *Clean or replace spark plug. Spark gap test •...

  • Page 190

    IGNITION SYSTEM SPARK GAP TEST CHECKING THE COUPLERS AND 3. Inspect: 1. Disconnect the spark plug cap LEADS CONNECTION • Secondary coil resistance from spark plug. 1. Check: Out of specification → Replace. 2. Connect the dynamic spark tester • Couplers and leads connection Tester (+) lead →...

  • Page 191

    IGNITION SYSTEM 2. Inspect: • Stator coil resistance Out of specification → Replace. Tester (+) lead → White lead "1" Tester (-) lead → White lead "2" Tester se- Stator coil lector posi- resistance tion 0.60–0.90 Ω at 20°C Ω × 10 (68°F) CHECKING THE ECU 1.

  • Page 192: 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. No good →...

  • Page 193

    THROTTLE POSITION SENSOR SYSTEM HANDLING NOTE 2. Inspect: 3. Replace: • Throttle position sensor variable • Throttle position sensor resistance 4. Install: Do not loosen the screw (throttle Check that the resistance in in- • Throttle position sensor "1" position sensor) "1" except when creased as the throttle grip is •...

  • Page 194

    THROTTLE POSITION SENSOR SYSTEM CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1. Disconnect the throttle position sensor coupler. 2. Connect the test harness-speed sensor (3P) "1" as shown. Test harness-speed sen- sor (3P) YU-03208/90890-03208 3. Start the engine. 4. Inspect: •...

  • Page 195: Fuel Injection System

    FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 5. Perform ECU reinstatement ac- tion. TROUBLESHOOTING METHOD Refer to "Reinstatement method" Engine starting problems, engine of table in "TROUBLESHOOTING idling speed problems, and medium DETAILS". and high-speed performance prob- 6. Set the switch on the FI diagnostic lems tool sub-wire harness from "OFF"...

  • Page 196

    FUEL INJECTION SYSTEM SETTING THE DIAGNOSTIC MODE 5. Check the operation of the sensor or actuator. • Sensor display: Data indicating When the FI diagnostic tool is set to the sensor status is displayed on the diagnostic mode, the sensor out- the LCD of the FI diagnostic tool.

  • Page 197

    FUEL INJECTION SYSTEM SENSOR OPERATION TABLE Diagnos- Actuation or Actuation or LCD standard display tic code Item Checking method display values Displays the throttle angle. 0–125° Check with throttle fully closed. When throttle is fully closed:15–19° Throttle angle Display Check with throttle fully open. When throttle is fully opened:95–101 °...

  • Page 198

    FUEL INJECTION SYSTEM Diagnos- Actuation or Actuation or LCD standard display tic code Item Checking method display values Check that power is supplied to Actuates the injector for five times the fuel injector. every second. • Check the fuel injector operation The "WARNING"...

  • Page 199

    FUEL INJECTION SYSTEM TROUBLESHOOTING DETAILS This section describes the countermeasures per fault code number displayed on the FI diagnostic tool. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and ser- vice of the malfunctioning part have been completed, reset the FI diagnostic tool display according to the "Reinstatement method".

  • Page 200

    FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft position sensor. Fail-safe system Able to start Able to drive Diagnostic code No. — FI diagnostic tool display — Checking method — Item Item/components and probable cause Check or maintenance job Checking method Defective crankshaft position sensor.

  • Page 201

    FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. FI diagnostic tool display Intake air pressure Checking method Crank the engine. (If the display value changes, the performance is OK.) Item Item/components and probable cause Check or maintenance job...

  • Page 202

    FUEL INJECTION SYSTEM If fault code Nos. 13 and 14 are both displayed, perform the checks and maintenance jobs for fault code No. 13 first. Fault code No. Intake air pressure sensor system malfunction detected. (clogged hole or disconnected Symptom sensor) Fail-safe system Able to start...

  • Page 203

    FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. FI diagnostic tool display • 15–19° (Fully closed position) • 95–101° (Fully opened position) •...

  • Page 204

    FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. FI diagnostic tool display • 15–19° (Fully closed position) • 95–101° (Fully opened position) •...

  • Page 205

    FUEL INJECTION SYSTEM Fault code No. Symptom Signal from throttle position sensor does not change. Fail-safe system Able to start Able to drive Diagnostic code No. FI diagnostic tool display • 15–19° (Fully closed position) • 95–101° (Fully opened position) •...

  • Page 206

    FUEL INJECTION SYSTEM Make sure that the engine is completely cool before checking the coolant temperature sensor. Fault code No. Symptom Coolant temperature sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. FI diagnostic tool display -20–150°C Cold engine: Displayed temperature is close to the ambient temperature.

  • Page 207

    FUEL INJECTION SYSTEM Fault code No. Symptom Coolant temperature sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. FI diagnostic tool display -20–150°C Cold engine: Displayed temperature is close to the ambient temperature. Warm engine: Displayed temperature is the current coolant temperature.

  • Page 208

    FUEL INJECTION SYSTEM Fault code No. Symptom Coolant temperature sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. FI diagnostic tool display -20–100°C Cold engine: Displayed temperature is close to the ambient temperature. Warm engine: Displayed temperature is approximately 20°C higher than the ambient tem- perature.

  • Page 209

    FUEL INJECTION SYSTEM Fault code No. Symptom Atmospheric pressure sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. FI diagnostic tool display Atmosphere Checking method Measure the atmospheric pressure. Item Item/components and probable cause Check or maintenance job Checking method Check the connection and locking condition of...

  • Page 210

    FUEL INJECTION SYSTEM Fault code No. Symptom Atmospheric pressure sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. FI diagnostic tool display Atmosphere Checking method Measure the atmospheric pressure. Item Item/components and probable cause Check or maintenance job Checking method Defective atmospheric pressure sensor.

  • Page 211

    FUEL INJECTION SYSTEM Fault code No. Symptom Turnover of vehicle Fail-safe system Able to start Unable to drive Diagnostic code No. FI diagnostic tool display Lean angle sensor • 1.0 V (Upright) • 4.0 V (Overturned) Checking method Remove the ECU and incline it 45° or more. Item Item/components and probable cause Check or maintenance job...

  • Page 212

    FUEL INJECTION SYSTEM Fault code No. Symptom Ignition system circuit signal is not received properly. Fail-safe system Unable to start Unable to drive Diagnostic code No. FI diagnostic tool display Actuates the ignition coil for five times every second. The "WARNING" LED on the FI diagnostic tool comes on each time the ignition coil is ac- tuated.

  • Page 213

    FUEL INJECTION SYSTEM Fault code No. Symptom Ignition system circuit signal is not received properly. Fail-safe system Unable to start Unable to drive Diagnostic code No. FI diagnostic tool display Actuates the ignition coil for five times every second. The "WARNING" LED on the FI diagnostic tool comes on each time the ignition coil is ac- tuated.

  • Page 214

    FUEL INJECTION SYSTEM Fault code No. Symptom Injection system circuit signal is not received properly. Fail-safe system Unable to start Unable to drive Diagnostic code No. FI diagnostic tool display Actuates the injector for five times every second. The "WARNING" LED on the FI diagnostic tool comes on each time the fuel injector is ac- tuated.

  • Page 215

    FUEL INJECTION SYSTEM Fault code No. Symptom Injection system circuit signal is not received properly. Fail-safe system Unable to start Unable to drive Diagnostic code No. FI diagnostic tool display Actuates the injector for five times every second. The "WARNING" LED on the FI diagnostic tool comes on each time the fuel injector is ac- tuated.

  • Page 216

    FUEL INJECTION SYSTEM Fault code No. Symptom Error is detected while reading or writing on EEPROM. Fail-safe system Able to start engine (depending on circumstances) Able to drive vehicle (depending on circumstances) Diagnostic code No. FI diagnostic tool display 00: No fault 01: CO adjustment valve 07: Power Tuner adjustment values 0–8 for fuel injection amount or ignition timing Checking method...

  • Page 217

    FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the ECU is not normal. Fail-safe system Able to start (depending on circumstances) Able to drive vehicle (depending on circumstances) Diagnostic code No. — FI diagnostic tool display — Checking method —...

  • Page 218

    FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the ECU is not normal. Fail-safe system Able to start (depending on circumstances) Able to drive vehicle (depending on circumstances) Diagnostic code No. — FI diagnostic tool display — Checking method —...

  • Page 219

    FUEL INJECTION SYSTEM Fault code No. waiting for connection Symptom Communication signal is not received. Fail-safe system Able to start (unable when ECU is malfunctioning) Able to drive vehicle (unable when ECU is malfunctioning) Diagnostic code No. — FI diagnostic tool display —...

  • Page 220

    FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom Registered data cannot be received from the FI diagnostic tool. Fail-safe system Able to start Able to drive Diagnostic code No. — FI diagnostic tool display — Checking method — Item Item/components and probable cause Check or maintenance job Checking method Check the connection and locking condition of...

  • Page 221: Fuel Pump System

    FUEL PUMP SYSTEM FUEL PUMP SYSTEM INSPECTION STEPS If the fuel pump is not operating normally, perform the following procedures in the order given. Check engine stop switch. No good → Replace. OK ↓ Checking the couplers and leads connections No good →...

  • Page 222: Electrical Components

    ELECTRICAL COMPONENTS ELECTRICAL CHECKING THE INTAKE AIR Coolant TEMPERATURE SENSOR COMPONENTS Tester se- tempera- 1. Remove: lector posi- CHECKING THE COOLANT ture sensor • Intake air temperature sensor tion TEMPERATURE SENSOR resistance (from the air filter case. ) 1. Remove: 210–220 Ω...

  • Page 223

    ELECTRICAL COMPONENTS CHECKING THE FUEL INJECTORS Test harness S–pressure 1. Remove: sensor (3P): • Seat YU-03207/90890-03207 • Fuel tank • Air filter case 2. Check: •Injector resistance 3. Connect: • Tester Tester (+) lead → Injector termi- nal "1" Tester (-) lead → Injector termi- nal "2"...

  • Page 224: Tuning

    CHASSIS TUNING DRIVE AND REAR WHEEL FRONT FORK SETTING SPROCKETS SETTING PARTS The front fork setting should be made CHASSIS depending on the rider's feeling of an Part name Size Part number SELECTION OF THE SECONDARY actual run and the circuit conditions. REDUCTION RATIO (SPROCKET) The front fork setting includes the fol- Drive...

  • Page 225

    CHASSIS FRONT FORK SETTING PARTS CHOOSING SET LENGTH • Front fork spring "1" 1. Place a stand or block under the engine to put the rear wheel I.D. above the floor, and measure the SPRIN SPRING PART length "a" between the rear wheel NUMBER axle center and the rear fender RATE...

  • Page 226

    CHASSIS SETTING OF SPRING AFTER REAR SHOCK ABSORBER • Extent of adjustment (spring pre- REPLACEMENT SETTING PARTS load) After replacement, be sure to adjust • Rear shock spring "1" Maximum Minimum the spring to the set length [sunken SPRI SPRING Position in Position in length 90–100 mm (3.5–3.9 in)] and...

  • Page 227

    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 228

    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 230

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

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  • Rob Apr 28, 2017 08:33:
    Thank you for the manuals. Yzf450 braap!