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Yamaha YZ450FX 2022, Owner'S Service Manual

The Yamaha YZ450FX 2022 is a high-performance off-road motorcycle designed for thrill-seeking riders. Ensure optimal performance and maintenance with the comprehensive Owner's Service Manual. Easily download this essential manual for free from our website, providing you with step-by-step instructions and valuable insights to keep your YZ450FX running at its best.

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ELECTRICAL COMPONENTS

8-50

a. Install a new fuse of the correct amperage

rating.

b. Push the start switch to verify if the electri-

cal circuit is operational.

c. If the fuse immediately blows again, check

the electrical circuit.

WARNING

EWA13310

Never use a fuse with an amperage rating

other than that specified. Improvising or us-

ing a fuse with the wrong amperage rating

may cause extensive damage to the electri-

cal system, cause the lighting and ignition

systems to malfunction and could possibly

cause a fire.

4. Install:

•

Seat
Refer to “GENERAL CHASSIS” on page 4-1.

EAM30291

CHECKING AND CHARGING THE BATTERY

WARNING

EWA20430

To avoid sparking, burns, fire, and explo-

sion:

• Charge battery only with specified charger.

• Use battery only for specified product – no

other use.

• Do not place near fire or immerse in water.

• Do not use battery if it has been dropped,

subject to impact, or visibly damaged.

• Do not disassemble or modify the battery,

or short across its terminals.

NOTICE

ECA26041

To prevent damage to the battery and battery

malfunction:

• Be sure to charge the battery using only the

specified battery charger. Do not use a

charger designed for lead-acid batteries.

Otherwise, the battery could be damaged,

such as from a long period of excessive

current or voltage exceeding 16 V.

• Avoid excessive current discharge, such

as pressing the starter switch for a long

time. Wait for more than 10 seconds before

attempting to start again. Charge the bat-

tery again as soon as possible. A long state

of discharge below 10 V will damage the

battery.

• Do not use the specified battery charger to

charge a battery other than the lithium-ion

battery. Otherwise, the battery or charger

could be damaged.

• Be careful not to drop the battery or subject

it to strong impacts.

• Avoid charging the battery at high temper-

atures of 65 

C (149 

F) or more or low tem-

peratures under 0 

C (32 

F). A control

feature preventing battery charging and

discharging will temporarily intervene. The

battery will discharge at 65 

C (149 

F) or

more or low temperatures under -10 

C (14

F).

• If the battery is charged between 0 

C (32

F)and 10 

C (50 

F), battery charging may

stop halfway without the battery becoming

fully charged even when the specified bat-

tery charger is used. If this occurs, discon-

nect the battery charger, and then resume

charging again.

TIP

This model uses a lithium-ion battery. When
new, the battery is supplied in sleep mode to
minimize current discharging until first-time use.
In the sleep mode, a voltage as low as approxi-
mately 0.1 V can be measured if voltage mea-
surement is performed. As such the battery
cannot be used, but this is not a malfunction. By
activating the battery as follows, the sleep mode
will be canceled and the battery can be used
normally.

Charging (activation) steps

1. Remove:

•

Side cover (left/right)

•

Seat
Refer to “GENERAL CHASSIS” on page 4-1.

2. Disconnect:

•

Battery lead
(from the battery terminals)

NOTICE

ECA13700

First, disconnect the negative battery lead,

and then the positive battery lead.

3. Remove:

•

Battery

4. Connect the battery charger (special tool) to

the battery.

Fuses

Amperage 

rating

Q’ty

Main

15 A

1

Spare

15 A

1

Radiator fan motor

5 A

1

Summary of Contents for YZ450FX 2022

Page 1: ...Read this manual carefully before operating this vehicle 2022 OWNER S SERVICE MANUAL YZ450FX YZ450FXN LIT 11626 35 27 BEX 2819U 11 ...

Page 2: ...s and lead which are known to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehicle ...

Page 3: ... user s authority to operate the equipment This transmitter must not be co located or operated in conjunction with any other antenna or transmitter This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment and meets the FCC radio frequency RF Exposure Guidelines This equipment has very low levels of RF energy that is deemed to comply without maximum permi...

Page 4: ... MANUAL 2022 by Yamaha Motor Corporation U S A First edition May 2021 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited P N LIT 11626 35 27 ...

Page 5: ...quested not to undertake inspection adjustment disassem bly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage WARNING EWA20270 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU H...

Page 6: ...EAM20162 YAMAHA MOTOR CORPORATION U S A YZ MOTORCYCLE LIMITED WARRANTY ...

Page 7: ...steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a removal or a disassembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction chart 6 accompanies the exploded diagram providing the order of jobs the names of parts the notes in j...

Page 8: ...ITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent LOCTITE Engine oil Replace the part with a new one G M BF B T R LS M S LT E New ...

Page 9: ...GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 TUNING 10 EAM10003 TABLE OF CONTENTS ...

Page 10: ......

Page 11: ...ION 1 9 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 9 REPLACEMENT PARTS 1 9 GASKETS OIL SEALS AND O RINGS 1 9 LOCK WASHERS PLATES AND COTTER PINS 1 10 BEARINGS AND OIL SEALS 1 10 CIRCLIPS 1 10 BASIC SERVICE INFORMATION 1 11 ELECTRICAL SYSTEM 1 11 SPECIAL TOOLS 1 15 INSTRUMENT AND CONTROL FUNCTIONS 1 21 WARNING LIGHTS 1 21 ENGINE STOP SWITCH 1 21 START SWITCH 1 21 MODE SWITCH 1 21 SHIFT PEDAL 1 22 FR...

Page 12: ...1 25 BREAK IN PROCEDURES 1 25 ENGINE STARTING PRECAUTION 1 25 MAINTENANCE AFTER BREAK IN 1 26 MAJOR MAINTENANCE 1 26 AIR FILTER MAINTENANCE 1 26 TORQUE CHECK POINTS 1 27 MOTORCYCLE CARE AND STORAGE 1 29 CARE 1 29 STORAGE 1 30 ...

Page 13: ...re riding 2 This motorcycle is designed to carry the oper ator only No passengers 3 The failure of motorists to detect and recog nize motorcycles in traffic is the predominat ing cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspic uous appears to be very effective in reducing the chance of this type...

Page 14: ... Many companies with no connection to Yamaha manufacture parts and accessories or offer oth er modifications for Yamaha vehicles Yamaha is not in a position to test the products that these aftermarket companies produce Therefore Yamaha can neither endorse nor recommend the use of accessories not sold by Yamaha or modifications not specifically recommended by Yamaha even if sold and installed by a ...

Page 15: ...he fuel cock if equipped is in the OFF position and that there are no fuel leaks 3 Point the front wheel straight ahead on the trailer or in the truck bed and choke it in a rail to prevent movement 4 Shift the transmission in gear for models with a manual transmission 5 Secure the motorcycle with tie downs or suit able straps that are attached to solid parts of the motorcycle such as the frame or ...

Page 16: ...gasoline only 3FB 2415E 02 4AA 22259 80 WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open 17D 2812P 00 For use only on a closed course in sanctioned competition This motorcycle does not meet EPA noise and emissions standards and is not for general off road recreational riding ...

Page 17: ...ou have purchased 1 12 13 14 15 16 17 18 19 20 4 5 7 6 8 9 10 11 2 3 1 Clutch lever 2 Engine trouble warning light 3 Fuel level warning light 4 Front brake lever 5 Throttle grip 6 Start switch 7 Radiator cap 8 Fuel tank cap 9 Mode switch 10 Engine stop switch 11 Fuel tank 12 Radiator 13 Coolant drain bolt 14 Rear brake pedal 15 Air filter 16 Drive chain 17 Shift pedal 18 Oil level check window 19 ...

Page 18: ...ositive identi fication of the model you own 2 If your vehicle is stolen the authorities will need the number to search for and identify your vehicle EAM30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the frame EAM30003 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the right side of the engine 1 1 1 1 ...

Page 19: ...ine in a closed area The exhaust gas is poisonous Never let flames near the servicing area NOTICE ECA26050 This application is designed for adjusting the settings on a standard vehicle In case the engine specifications muffler com pression ratio etc have been changed the performance may not match to the actu al settings Do not run the engine with the smartphone carried with you Otherwise the smart...

Page 20: ...s or mobile phones in close proximity of the CCU The CCU is in contact with or covered by a metallic object Other vehicles equipped with a CCU are nearby In such situations move the CCU to another location and perform the operation again 1 Turn on the smartphone 2 For two minutes after the start switch is pressed or while the engine is running the CCU is activated input the CCU serial num ber into...

Page 21: ...red to the chassis paint and plating will be damaged Therefore rinse it out with water in good time WARNING EWA18970 Coolant is potentially harmful and should be handled with special care If it enters your eyes wash it away with wa ter enough and then get medical attention If it splashes on your skin or clothes quick ly wash it away with water and then with soapy water If it is swallowed immediate...

Page 22: ...oil seal make sure that its main lip faces the oil chamber the target to be sealed Before installation always apply a light coat of grease to the oil seal lip NOTICE ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfac es EAM30014 CIRCLIPS When assembling parts always use new cir clips During installation of a circlip make sure that the edge 2 of the cir...

Page 23: ...ly dangerous TIP If a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct battery terminals Reversing the bat tery lead connections could damage the electrical components NOTICE ECA16771 When connecting the battery leads to the battery be sure to connect the positive bat ter...

Page 24: ...lti function display goes off Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never insert the tester probes into the cou pler terminal slots Always insert the probes from the opposite end a of the coupler tak ing care not to loosen or damage the leads NOTICE ECA16640 For waterproof couplers never insert t...

Page 25: ...oth sections of the connec tor securely and then disconnect the con nector 2 Check Lead Coupler Connector Moisture Dry with compressed air Rust stains Connect and disconnect sev eral times 3 Check All connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up After disassembling or assembling a coupler pull on the leads to make sure that they are in stal...

Page 26: ...If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 4 As a quick remedy use a contact revitalizer available at most part stores Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 ...

Page 27: ...starting with YM YU or ACC For others use tool number starting with 90890 Tool name Tool No Illustration Reference pages Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 1 14 5 44 8 48 8 49 8 49 8 49 8 51 8 52 8 54 8 54 8 54 8 54 8 55 8 56 8 56 8 57 8 57 8 58 8 58 8 59 Thickness gauge 90890 03268 Feeler gauge set YU 26900 9 3 6 5 49 Valve lapper ø14 90890 04101...

Page 28: ...2 3 27 4 55 Spoke nipple wrench 6 7 90890 01521 Spoke nipple wrench 6 7 YM 01521 3 33 Timing light 90890 03141 Timing light YU 03141 3 35 Cap bolt ring wrench 90890 01501 Cap bolt ring wrench YM 01501 4 43 4 43 4 44 4 47 4 50 4 52 Cap bolt wrench 90890 01500 Cap bolt wrench YM 01500 4 44 4 47 Fork seal driver 90890 01502 Fork seal driver 48 YM A0948 4 49 4 49 Tool name Tool No Illustration Referen...

Page 29: ...ing compressor adapter 22 mm YM 04108 5 26 5 30 Valve guide remover installer set ø5 5 90890 04016 Valve guide remover 5 5 mm YM 01122 5 28 Valve guide installer ø5 5 90890 04015 Valve guide installer 5 5 mm YM 04015 5 28 Valve guide reamer 5 5 mm 90890 01196 Valve guide reamer 5 5 mm YM 01196 5 28 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 33 Tool name Tool No Illustration Ref...

Page 30: ...042 5 49 5 52 Crankcase separating tool 90890 04152 Crankcase separating tool YU A9642 5 68 Crankshaft installer pot 90890 01274 Installing pot YU 90058 5 69 Crankshaft installer bolt 90890 01275 Bolt YU 90060 5 69 Adapter M12 90890 01278 Adapter 3 YU 90063 5 69 Tool name Tool No Illustration Reference pages YU 90058 YU 90059 ...

Page 31: ...cooling system tester kit YU 24460 A 6 4 6 4 Radiator cap tester adapter 90890 01352 Pressure tester adapter YU 33984 6 4 6 4 Pressure gauge 90890 03153 Pressure gauge YU 03153 7 8 Fuel pressure adapter 90890 03186 Fuel pressure adapter YM 03186 7 8 Tool name Tool No Illustration Reference pages YM 91044 YU 24460 A YU 33984 ...

Page 32: ...hium battery charger DBY ACC51 70 02 8 51 8 51 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 53 Test harness S pressure sensor 3P 90890 03207 Test harness S pressure sensor 3P YU 03207 8 57 Tool name Tool No Illustration Reference pages ...

Page 33: ...lectrical circuit of the warning light can be checked by pushing the start switch The warn ing light should come on for a few seconds and then go off If the warning light does not come on initially when the start switch is pushed or if the warning light remains on have a Yamaha dealer check the electrical circuit EAM30182 ENGINE STOP SWITCH The engine stop switch 1 is located on the left handlebar...

Page 34: ...own on the brake pedal to acti vate the rear brake EAM30190 SIDESTAND This sidestand 1 is used to support only the machine when standing WARNING EWA18980 Never apply additional force to the sides tand Hold up the sidestand before starting out EAM30444 STARTER KNOB Starting a cold engine requires a larger amount of intake air which is supplied by the starter knob 1 Pushing the knob toward a turns O...

Page 35: ... 2 Remove the fuel tank cap cover to open the fuel tank cap TIP To remove the fuel tank cap cover insert fin gers under part a and then use both hands to lift it up towards the rear of the vehicle Install the fuel tank cap cover after placing the bands 3 all the way in under the seat a a b b 1 1 1 1 2 2 3 3 a a a 2 2 ...

Page 36: ...NG A COLD ENGINE 1 Press the shift pedal to neutral 2 Push the starter knob 1 completely TIP When the ambient temperature is 15 C 59 F or below use the starter knob Do not operate the throttle grip when operating the starter knob 3 Start the engine by pushing the start switch If the engine fails to start when using the start switch release it wait a few seconds and then try again Each starting att...

Page 37: ...seness oil leaks or other problems Thorough checks and ad justments are required in particular for stretch of cables free play of the brake stretch of the drive chain looseness of the spoke and so on NOTICE ECA25821 After a break in or after each race always check the points shown in TORQUE CHECK POINTS for tightening torques and retighten them Also when the following parts are replaced a break in...

Page 38: ...s and nuts Check for looseness in mounted areas of parts as well as engine mounting bolts and engine brackets 2 For the chassis Check welds and mounted areas of the frame the swingarm the link the bracket and so on for looseness and cracks Wheel s Check the wheel for runout Check the spoke for looseness Brake s Check the brake disc mounting bolt for loose ness Check that the reservoir contains the...

Page 39: ...e Link to rear shock absorber Link to swingarm Mounting of rear shock absorber Rear shock absorber and frame Mounting of swingarm Tightening of pivot shaft Wheel s Mounting of wheel Front Tightening of wheel axle Tightening of axle holder Tightening of spoke nipple Rear Tightening of wheel axle Wheel to rear wheel sprocket Tightening of spoke nipple Brake s Front Brake caliper to front fork Brake ...

Page 40: ...ft pedal Shift pedal to shift shaft Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake disc cover Tightening of rear brake caliper cover ...

Page 41: ...ly rinse the area off with water immediately dry it and then apply a corrosion protec tion spray Improper cleaning can damage plastic parts such as cowlings panels wind shields headlight lenses meter lenses etc and the mufflers Use only a soft clean cloth or sponge with water to clean plastic However if the plastic parts cannot be thor oughly cleaned with water diluted mild de tergent with water m...

Page 42: ...and nickel plated sur faces 5 Use spray oil as a universal cleaner to re move any remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry completely before storing or covering it WARNING EWA19050 Contaminants on the brakes or tires can cause loss of control Make sure that there is no oil or wax on the brakes or tires If necessary clean ...

Page 43: ...rk plug and then install the spark plug and the spark plug cap WARNING To pre vent damage or injury from sparking make sure to ground the spark plug electrodes while turning the engine over 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so tha...

Page 44: ...MOTORCYCLE CARE AND STORAGE 1 32 ...

Page 45: ...CATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 5 ELECTRICAL SPECIFICATIONS 2 8 TIGHTENING TORQUES 2 9 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 9 ENGINE TIGHTENING TORQUES 2 10 CHASSIS TIGHTENING TORQUES 2 13 CABLE ROUTING DIAGRAM 2 17 ...

Page 46: ...odel Model BEX5 Dimensions Overall length 2175 mm 85 6 in Overall width 825 mm 32 5 in Overall height 1280 mm 50 4 in Seat height 955 mm 37 6 in Wheelbase 1480 mm 58 3 in Ground clearance 320 mm 12 60 in Weight Curb weight 115 kg 254 lb Riding capacity 1 person ...

Page 47: ...ty Oil change 0 63 L 0 67 US qt 0 55 Imp qt With oil filter removal 0 65 L 0 69 US qt 0 57 Imp qt Quantity disassembled 0 90 L 0 95 US qt 0 79 Imp qt Oil filter Oil filter type Cartridge Cooling system Coolant quantity Radiator including all routes 1 03 L 1 09 US qt 0 91 Imp qt Radiator cap valve opening pressure 107 9 137 3 kPa 1 08 1 37 kgf cm 15 6 19 9 psi Spark plug s Manufacturer model NGK LM...

Page 48: ...93 in Wear limit 97 060 mm 3 8213 in Piston Piston to cylinder clearance 0 010 0 045 mm 0 0004 0 0018 in Diameter 96 955 96 970 mm 3 8171 3 8177 in Measuring point from piston skirt bottom 9 0 mm 0 35 in Piston pin bore inside diameter limit 18 045 mm 0 7104 in Piston pin outside diameter limit 17 981 mm 0 7079 in Piston pin to piston pin bore clearance 0 004 0 024 mm 0 0002 0 0009 in Piston ring ...

Page 49: ... 4th 1 050 21 20 5th 0 840 21 25 Main axle runout limit 0 08 mm 0 0032 in Drive axle runout limit 0 08 mm 0 0032 in Secondary reduction ratio 3 846 50 13 Final drive Chain Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil Fuel pump Pump type Electrical Maximum consumption amperage 2 4 A Fuel injector Resistance 12 0 Throt...

Page 50: ...pressure measured on cold tires Front 100 kPa 1 00 kgf cm 15 psi Rear 100 kPa 1 00 kgf cm 15 psi Front brake Type Hydraulic single disc brake Brake disc thickness limit 2 5 mm 0 10 in Brake disc runout limit as measured on wheel 0 15 mm 0 0059 in Brake pad lining thickness limit 1 0 mm 0 04 in Master cylinder inside diameter 9 52 mm 0 37 in Caliper cylinder inside diameter Left 25 40 mm 25 40 mm 1...

Page 51: ... from the start position Soft 20 Adjustment value from the start position STD 10 Adjustment value from the start position Hard 0 Rear suspension Type Swingarm link suspension Spring Coil spring Shock absorber Gas hydraulic damper Wheel travel 317 mm 12 5 in Spring preload Adjusting system Mechanical adjustable type Adjustment value Soft 1 5 mm 0 06 in Adjustment value STD 10 0 mm 0 39 in Adjustmen...

Page 52: ...ent Click Adjustment value from the start position Soft 20 Adjustment value from the start position STD 10 Adjustment value from the start position Hard 0 Drive chain Size 520 Chain type Sealed type Number of links 114 Drive chain slack Maintenance Stand 50 0 60 0 mm 1 97 2 36 in 15 link length limit 239 3 mm 9 42 in ...

Page 53: ...el BR98 Voltage capacity 12 V 2 4 Ah 5 HR Indicator light Engine trouble warning light 1 7 W Fuel level warning light 1 7 W Starter motor Brush overall length 11 0 mm 0 43 in Brush overall length limit 5 5 mm 0 22 in Brush spring force 4 80 7 20 N 489 734 gf 17 28 25 92 oz Mica undercut depth 2 40 mm 0 09 in Fuel injection sensor Crankshaft position sensor resistance 228 342 Intake air temperature...

Page 54: ...To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques N m kgf m lb ft 10 mm 6 mm 6 0 6...

Page 55: ...ut M14 1 50 N m 5 0 kgf m 37 lb ft Use a lock washer Balancer nut M10 1 45 N m 4 5 kgf m 33 lb ft Use a lock washer Timing chain guide stopper plate exhaust side M6 1 10 N m 1 0 kgf m 7 4 lb ft Timing chain tensioner cap bolt M6 1 6 N m 0 6 kgf m 4 4 lb ft Timing chain tensioner bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Coolant drain bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft Radiator hose clamp screw M6 8 1...

Page 56: ...t Drive sprocket cover bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Crankcase bearing cover plate screw M8 4 22 N m 2 2 kgf m 16 lb ft Bearing plate cover bolt left side of the drive axle M6 2 12 N m 1 2 kgf m 8 9 lb ft Plate bolt M6 4 12 N m 1 2 kgf m 8 9 lb ft Starter motor cover bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft Clutch cover bolt M6 7 10 N m 1 0 kgf m 7 4 lb ft Crankcase cover bolt left M6 7 10 N m 1...

Page 57: ...kgf m 8 9 lb ft Generator rotor nut M12 1 65 N m 6 5 kgf m 48 lb ft Stator coil screw M5 3 10 N m 1 0 kgf m 7 4 lb ft Crankshaft position sensor bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Stator coil assembly lead holder bolt M5 1 8 N m 0 8 kgf m 5 9 lb ft Coolant temperature sensor M10 1 15 N m 1 5 kgf m 11 lb ft Gear position switch bolt M5 2 3 5 N m 0 35 kgf m 2 6 lb ft Rectifier regulator bolt M6 2 ...

Page 58: ...5 2 1 3 N m 0 13 kgf m 0 95 lb ft Front fork protector bolt M6 6 5 N m 0 5 kgf m 3 7 lb ft Brake hose holder bolt M6 2 9 N m 0 9 kgf m 6 6 lb ft Throttle grip cap screw M5 2 3 8 N m 0 38 kgf m 2 8 lb ft Clutch lever holder bolt M6 2 5 N m 0 5 kgf m 3 7 lb ft Clutch lever nut M6 1 4 0 N m 0 40 kgf m 3 0 lb ft Clutch lever position locknut M5 1 4 8 N m 0 48 kgf m 3 5 lb ft Front brake master cylinde...

Page 59: ... ft Nipple spoke 72 2 5 N m 0 25 kgf m 1 8 lb ft Bolt rear brake disc cover M6 2 10 N m 1 0 kgf m 7 4 lb ft Rear brake caliper protector bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Engine mounting bolt upper side M10 2 45 N m 4 5 kgf m 33 lb ft Engine mounting nut front side M10 1 55 N m 5 5 kgf m 41 lb ft Engine mounting nut lower side M10 1 53 N m 5 3 kgf m 39 lb ft Engine bracket bolt upper side M8 4 3...

Page 60: ...M6 2 7 N m 0 7 kgf m 5 2 lb ft Fuel pump bolt M5 5 7 N m 0 7 kgf m 5 2 lb ft Screw fuel inlet pipe M5 2 3 5 N m 0 35 kgf m 2 6 lb ft Bolt fuel tank cap cover M6 2 4 0 N m 0 40 kgf m 3 0 lb ft Seat set bracket screw M6 1 7 N m 0 7 kgf m 5 2 lb ft Seat bolt M8 2 22 N m 2 2 kgf m 16 lb ft Side cover bolt left M6 2 7 N m 0 7 kgf m 5 2 lb ft Side cover bolt right M6 2 7 N m 0 7 kgf m 5 2 lb ft Air scoo...

Page 61: ...TIGHTENING TORQUES 2 16 ...

Page 62: ...CABLE ROUTING DIAGRAM 2 17 EAM20152 CABLE ROUTING DIAGRAM Frame and engine left side view ...

Page 63: ...iator and the tension arm H Fasten the starter motor lead to the bracket using the plastic locking tie Position the lock part of the plastic locking tie to rear side of the vehicle Cut the end of the plastic locking tie I Route the starter motor lead along the cylin der body without slack J Route the gear position switch lead along the crankcase without slack K Pass the gear position switch lead t...

Page 64: ...CABLE ROUTING DIAGRAM 2 19 Frame and engine right side view ...

Page 65: ...den with the cover F After connecting the throttle position sensor coupler attach the cover G The radiator breather hose should be routed in the following order and via each mentioned point The upper radiator boss at the rear of the vehicle The lower radiator boss at the front of the vehicle The radiator hose at the front of the vehicle For routing the remaining leads refer to the diagram W under ...

Page 66: ...CABLE ROUTING DIAGRAM 2 21 Handlebar front view ...

Page 67: ... stop switch lead and mode switch lead to the handlebar using the plastic locking tie Do not cut the end of the plastic locking tie D 30 50 E Vertical direction of vehicle F Pass the engine stop switch lead and mode switch lead between the frame and the cable guide G Pass the warning light lead through the cable guide H Pass the front brake hose through the front side of the number plate I Pass th...

Page 68: ...CABLE ROUTING DIAGRAM 2 23 Frame and engine top view ...

Page 69: ...ire harness 33 Grommet 34 Clamp A Fasten the main harness and start switch lead by the clamp and insert the clamp pro jection into the hole in the sheet metal of the radiator The direction of the clamp lock por tion does not matter It is allowed to run the leads near the radiator cap on the inside B No pinch is allowed the leads between the tank rail and the air filter joint C Insert the projectio...

Page 70: ...CABLE ROUTING DIAGRAM 2 25 Frame and battery top view ...

Page 71: ... relay terminal B Install the clamp wire harness to the hole of the battery bracket C After connecting the negative battery coupler position to the right side of the starter relay D The position of the starter motor lead and negative battery lead does not matter E Pass the negative battery lead through lower side of the cross member F After connecting the positive battery lead in the direction sho...

Page 72: ...CABLE ROUTING DIAGRAM 2 27 Rear brake right side view ...

Page 73: ... brake hose holders C Route the rear brake hose so that it is not bent as shown by the double dash line D Route the rear brake hose and spring so that they do not interfere with each other E Make sure that the rear brake hose is not excessively twisted F Make sure that the metal part of the rear brake hose contacts the stopper of the rear brake master cylinder G Install the rear brake hose so that...

Page 74: ...CABLE ROUTING DIAGRAM 2 29 ...

Page 75: ...G THE COOLANT LEVEL 3 20 CHECKING THE COOLING SYSTEM 3 21 CHANGING THE COOLANT 3 21 CHASSIS 3 23 ADJUSTING THE FRONT DISC BRAKE 3 23 ADJUSTING THE REAR DISC BRAKE 3 23 CHECKING THE BRAKE FLUID LEVEL 3 23 CHECKING THE FRONT BRAKE PADS 3 24 CHECKING THE REAR BRAKE PADS 3 24 CHECKING THE FRONT BRAKE HOSE 3 24 CHECKING THE REAR BRAKE HOSE 3 24 CHECKING THE BRAKE OPERATION 3 25 BLEEDING THE HYDRAULIC B...

Page 76: ...AND LUBRICATING THE CABLES 3 34 LUBRICATING THE BRAKE LEVER 3 34 LUBRICATING THE CLUTCH LEVER 3 34 LUBRICATING THE PEDAL 3 34 CHECKING THE SIDESTAND 3 34 LUBRICATING THE SIDESTAND 3 34 ELECTRICAL SYSTEM 3 35 CHECKING AND CHARGING THE BATTERY 3 35 CHECKING THE FUSES 3 35 CHECKING THE IGNITION TIMING 3 35 ...

Page 77: ... hours Every third race about 7 5 hours Every fifth race about 12 5 hours As required 1 Valve Check the valve clearances Check the valve seats and the valve faces for wear Replace 2 Valve spring Check the free length Replace 3 Valve lifter Check for scratches and wear Replace 4 Camshaft Inspect the camshaft surface Inspect the decompression sys tem Replace 5 Timing chain Check for damage and stick...

Page 78: ...lencer protector Check for exhaust leaks and tightening torques Clean Replace fiver When the exhaust sound becomes louder or when a perfor mance drop is felt 21 Crankshaft Inspect and clean 22 Throttle body Inspect 23 Air filter Clean and lubricate Replace 24 Spark plug Check the electrodes and the ter minals for wear Replace 25 Cooling system Check coolant level and leakage Check radiator cap ope...

Page 79: ... Inspect lube and retighten 35 Relay arm connect ing rod Inspect lube and retighten 36 Steering head Inspect free play and retighten Check for tightening torques Clean and lube After rain ride Replace bearings 37 Tire wheels Inspect air pressure wheel run out tire wear and spoke loose ness Retighten sprocket bolt Check the bearing Replace bearings Lubricate 38 Drive chain Clean lubricate slack ali...

Page 80: ...icate 44 Sidestand Lubricate 45 Outside nuts and bolts Retighten 46 Battery Check terminal for looseness and corrosion No Item Routine After break in Every race about 2 5 hours Every third race about 7 5 hours Every fifth race about 12 5 hours As required ...

Page 81: ...23 3 23 3 23 3 24 3 24 3 24 3 24 3 25 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 26 4 68 4 68 4 69 4 69 4 69 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play 3 33 3 33 3 33 3 33 Steering Check that the handlebar can be turned smoothly and have no excessive play 3 27 Front forks and rear sh...

Page 82: ...left right Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 ECU Engine Control Unit 2 Remove Spark plug Cylinder head cover Refer to CAMSHAFT on page 5 13 3 Remove Timing mark accessing screw 1 Crankshaft end accessing screw 2 O ring 4 Check Valve clearance Out of specification Regulate a Turn the crankshaft counterclockwise with a wrench b Align t...

Page 83: ...oper valve clearance from the adjusting pad se lection table TIP There are 25 types of adjusting pads ranging from 1 20 mm 0 0472 in to 2 40 mm 0 0945 in in increments of 0 05 mm 0 0020 in The field where the number on the originally in stalled adjusting pad and the measured valve clearance intersect shows the adjusting pad number to replace Example Pad number 148 Rounded value 150 e Install the n...

Page 84: ...eir numbers facing upward f Install the camshafts exhaust and intake Refer to CAMSHAFT on page 5 13 g Measure the valve clearance again h If the valve clearance is out of specifica tion repeat adjusting the valve clearance until it is within specification M E 4 5 ...

Page 85: ...180 185 190 195 200 205 210 215 220 225 230 235 240 0 70 0 74 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 75 0 79 180 185 190 195 200 205 210 215 220 225 230 235 240 0 80 0 84 185 190 195 200 205 210 215 220 225 230 235 240 0 85 0 89 190 195 200 205 210 215 220 225 230 235 240 0 90 0 94 195 200 205 210 215 220 225 230 235 240 0 95 0 99 200 205 210 215 220 225 230 235 240 1 00 1 04 20...

Page 86: ...215 220 225 230 235 240 0 70 0 74 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 75 0 79 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 80 0 84 180 185 190 195 200 205 210 215 220 225 230 235 240 0 85 0 89 185 190 195 200 205 210 215 220 225 230 235 240 0 90 0 94 190 195 200 205 210 215 220 225 230 235 240 0 95 0 99 195 200 205 210 215 220 225 230 235 240 1 00 1 04 200 20...

Page 87: ... 3 Install Digital tachometer TIP Get the high tension cord 1 of the ignition coil pinched in the detector a of the digital tachom eter 4 Measure Engine idling speed Out of specification Regulate 5 Adjust Engine idling speed a Turn the idle screw 1 to make an adjust ment EAM30475 CHECKING THE THROTTLE GRIP TIP Prior to adjusting throttle grip free play the en gine idling speed should be adjusted 1...

Page 88: ... 2 as shown 2 Remove Spark plug cap Spark plug Refer to CAMSHAFT on page 5 13 NOTICE ECA24410 In order not to allow the dirt accumulated around the spark plug to drop from the spark plug hole into the cylinder clean it before re moving the spark plug 3 Check Spark plug type Wrong type Replace 4 Check Electrode Damage wear Replace the spark plug Insulator Abnormal color Replace the spark plug Norma...

Page 89: ...d cause clutch slippage Therefore do not add any chemical additives Do not allow foreign material to enter the crankcase EAM30225 CHANGING THE ENGINE OIL Stand the vehicle upright on a level surface 1 Start the engine warm this up for several minutes and then stop the engine and wait about 5 minutes TIP This model is equipped with an engine auto stop system The engine stops automatically if left i...

Page 90: ...heck Engine oil pressure a Start the engine WARNING EWA19130 Always keep the engine idling speed during the checkup without increasing the engine speed b Look at the oil level check window 1 and then make sure that the engine oil flows and that the engine oil level decreases TIP Check the engine oil level while the engine is at idling speed Oil filter element cover bolt 10 N m 1 0 kgf m 7 4 lb ft ...

Page 91: ...able side Clutch cable side a Slide the clutch cable cover b Loosen the locknut 1 c Turn the adjuster 2 until the specified clutch lever free play is obtained d Tighten the locknut 1 e Return the clutch cable cover to its original position EAM30370 ADJUSTING THE CLUTCH LEVER POSITION 1 Adjust Clutch lever position a Loosen the locknut 1 and use the adjuster 2 to adjust the clutch lever position a ...

Page 92: ...to the bag b With the element inside the bag rub it thoroughly so that the element is evenly permeated with the oil c Wrap the element in a clean cloth rub the element gently and wipe off any excess oil TIP The element should be permeated with oil so that it is wet but not dripping When replacing the element permeate the el ement in oil by using the same procedure as when cleaning 7 Install Seal 1...

Page 93: ...ocat ed on the left and right sides of the air filter case cover with the projections d on the air scoop and then install the air filter case cover 10 Install Fuel tank cap cover EAM30335 CHECKING THE THROTTLE BODY JOINT 1 Check Throttle body joint 1 Crack damage Replace EAM30222 CHECKING THE FUEL LINE 1 Remove Seat Side cover left right Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fu...

Page 94: ...M30221 CHECKING THE EXHAUST SYSTEM 1 Remove Exhaust pipe 1 Exhaust pipe 2 Refer to ENGINE REMOVAL on page 5 6 2 Remove Exhaust pipe protector 3 Check Exhaust pipe 1 Exhaust pipe 2 Silencer Crack damage Replace 4 Check Silencer fiber Damage Replace 5 Replace Silencer fiber a Remove the bolts 1 and silencer body 2 NOTICE ECA25800 Do not hit the silencer stay a as it may do damage to the silencer TIP...

Page 95: ...the silencer body by using a flat board 11 h Install the fiber insert 12 to the inner pipe i Install the fiber insert 13 to the inside of the silencer cap 14 j Install the silencer cap 15 and rivet 16 TIP Apply heat resistant sealant to the areas e shown making sure that there are no gaps in the beads of sealant Take care not to allow the fiber out of place when installing the silencer body 17 Sil...

Page 96: ...ing sound has stopped press down on the radi ator cap and turn it counterclockwise to re move 1 Stand the vehicle upright on a level surface 2 Remove Radiator cap 1 3 Check Coolant level Maximum level a or below Add coolant up to the maximum level NOTICE ECA24260 Adding water instead of coolant lowers the antifreeze content If therefore water is used instead of coolant check and if nec essary adju...

Page 97: ...e hissing sound has stopped press down on the radi ator cap and turn it counterclockwise to re move 1 Place a container under the engine 2 Remove Coolant drain bolt 1 3 Remove Radiator cap Slowly loosen the radiator cap to drain cool ant TIP When the radiator cap is loosened coolant will gush out transversely therefore bring the con tainer near to the outlet 4 Thoroughly flush the cooling system w...

Page 98: ... used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 7 Install Radiator cap 8 Start the engine warm this up for several minutes stop it and then wait for it to cool down 9 Check Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 20 ...

Page 99: ...STING THE REAR DISC BRAKE 1 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting bolt 2 until the brake pedal is in the correct position c Tighten the locknut WARNING EWA19150 A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before running bleed the brake sys tem Air in the brake system will cause brak ing performance to be reduced...

Page 100: ...of the brake pads 1 Operate the brake 2 Check Front brake pad Wear indicator grooves 1 almost touch the brake disc Replace the brake pads as a set Refer to FRONT BRAKE on page 4 13 EAM30232 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Rear brake pad Wear indicator grooves 1 almost disap peared Replace the brake pads as a set Refe...

Page 101: ...ter the brake system considerably lengthening the bleeding proce dure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 2 Bleed the brake system a Fill the reservoir to the proper level with the recommended brake fluid b Install the reservoir diaphragm c Connect the plastic hos...

Page 102: ...ive chain guide installation bolt with a force of about 50 N 5 0 kgf 37 lbf 4 Check Drive chain slack a Out of specification Regulate TIP Measure drive chain slack between the drive chain guide and the bottom of the chain as shown Adjusting the drive chain slack WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 1 Adjust Drive chain slack a Loosen the wheel...

Page 103: ... falling over 2 Check Steering head Grasp the bottom of the front fork legs and gently rock the front fork Blinding looseness Adjust the steering head 3 Remove Handlebar Refer to HANDLEBAR on page 4 35 Upper bracket Refer to STEERING HEAD on page 4 54 4 Adjust Steering head a Remove the washer 1 b After loosening the ring nut 2 with a steering nut wrench 3 tighten it to the specified torque TIP Se...

Page 104: ...fork leg Oil leaks between inner tube and outer tube Replace the oil seal 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Unsmooth operation Correct or replace Refer to FRONT FORK on page 4 41 5 Check Protector guide 1 Out of specification Replace TIP The protector guide re...

Page 105: ...djust Compression damping a Turn the adjuster 1 in the direction of a or b to make an adjustment TIP Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small dif ferences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check th...

Page 106: ...tion Rear suspension link smooth action Sit astride the seat and shake your body up and down several times to check whether the rear shock absorber assembly operates smoothly Unsmooth operation Correct or replace Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 58 EAM30242 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Use a maintenance stand to raise the rear wheel off the ground WARNING EWA13120 Sec...

Page 107: ... necessary Compression damping for fast compres sion damping NOTICE ECA24370 Do not turn the adjuster forcibly beyond its adjusting range 1 Adjust Compression damping for fast compression damping a Turn the adjuster 1 in the direction of a or b to make an adjustment Spring preload adjusting positions Minimum Position in which the spring is turned in 1 5 mm 0 06 in from its free length Standard Pos...

Page 108: ...clicks of each damping force adjusting mechanism and to modify the specifications as necessary EAM30240 CHECKING THE SWINGARM OPERATION 1 Check Swingarm smooth action Swingarm free play Refer to SWINGARM on page 4 64 EAM30500 LUBRICATING THE SWINGARM PIVOT 1 Lubricate Oil seal Collar Refer to INSTALLING THE SWINGARM on page 4 65 EAM30501 CHECKING THE CONNECTING ARM AND RELAY ARM Refer to CHECKING ...

Page 109: ...ill sound flat 2 Tighten Spoke with a spoke nipple wrench 1 TIP Do not give a half turn 180 or more for one tightening Make sure that tightening after a break in is done until the initial looseness in nipples disap pears Make sure that tightening is done in stages not at a time EAM30245 CHECKING THE WHEELS 1 Check Wheel Damage out of round Replace WARNING EWA13260 Never attempt to make any repairs...

Page 110: ... LUBRICATING THE BRAKE LEVER 1 Lubricate the pivoting points and metal to metal moving parts of the following parts Brake lever EAM30503 LUBRICATING THE CLUTCH LEVER 1 Lubricate the pivoting points and metal to metal moving parts of the following parts Clutch lever EAM30250 LUBRICATING THE PEDAL 1 Lubricate the pivoting point and metal to met al moving parts of the pedal EAM30504 CHECKING THE SIDE...

Page 111: ...he high tension cord 3 3 Adjust Engine idling speed Refer to CHECKING THE ENGINE IDLING SPEED on page 3 11 4 Check Ignition timing Check whether the alignment mark a on the left crankcase cover is within the firing range b on the generator rotor Incorrect firing range Check generator ro tor and crankshaft position sensor 5 Install Timing mark accessing screw Timing light 90890 03141 Timing light Y...

Page 112: ...ELECTRICAL SYSTEM 3 36 ...

Page 113: ...LACING THE FRONT BRAKE PADS 4 17 REMOVING THE FRONT BRAKE CALIPER 4 19 DISASSEMBLING THE FRONT BRAKE CALIPER 4 19 CHECKING THE FRONT BRAKE CALIPER 4 19 ASSEMBLING THE FRONT BRAKE CALIPER 4 19 INSTALLING THE FRONT BRAKE CALIPER 4 20 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 21 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 21 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 21 INSTALLING THE FRONT BRAKE M...

Page 114: ...ING THE STEERING HEAD 4 55 REAR SHOCK ABSORBER ASSEMBLY 4 58 HANDLING THE REAR SHOCK ABSORBER 4 61 DISPOSING OF A REAR SHOCK ABSORBER 4 61 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 61 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 61 CHECKING THE CONNECTING ARM AND RELAY ARM 4 62 INSTALLING THE RELAY ARM 4 62 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 62 SWINGARM 4 64 REMOVING THE SWINGARM 4 65 ...

Page 115: ...de cover left 1 3 Negative battery lead 1 Disconnect 4 Positive battery lead 1 Disconnect 5 Battery band 1 6 Battery 1 7 Cover 1 8 Starter relay 1 9 Main relay 1 10 Radiator fan motor relay 1 11 CCU Communication Control Unit 1 6 7 9 1 2 22 N m 2 2 kgf m 16 lb ft 7 N m 0 7 kgf m 5 2 lb ft 8 5 3 4 11 22 N m 2 2 kgf m 16 lb ft 10 ...

Page 116: ... to CLEANING THE AIR FILTER ELE MENT on page 3 15 2 Air scoop left 1 3 Air scoop right 1 4 Side cover right 1 5 Number plate 1 6 Rear fender 1 6 4 1 3 5 2 1 3 N m 0 13 kgf m 0 95 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 16 N m 1 6 kgf m 12 lb ft 1 ...

Page 117: ...utch cable 2 from the cable guide b on the number plate The projection c on the lower bracket is in serted into the number plate Remove the number plate by pulling it off the projection When installing the number plate insert the projection on the number plate into the hole in the upper side of the band EAM30458 INSTALLING THE AIR SCOOP 1 Install Air scoop left 1 right TIP After inserting the proj...

Page 118: ...n EAM30460 INSTALLING THE SIDE COVER 1 Install Side cover right 1 TIP Install the side cover right by sliding it as shown and secure it with the bolts to fit it to the vehicle Install the side cover right so that the rib is lo cated under the rib of the rear fender a Projection b Slot a Projection b Slot c Rib side cover d Rib rear fender 1 1 1 b b a a a a a 1 1 c c b b d d ...

Page 119: ...ise the front wheel off the ground 1 Front wheel axle pinch bolt 4 Loosen 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Oil seal 2 7 Bearing 2 8 Brake disc 1 LT LS LS LS 5 6 5 6 7 6 8 2 1 1 3 4 21 N m 2 1 kgf m 15 lb ft 21 N m 2 1 kgf m 15 lb ft 115 N m 11 5 kgf m 85 lb ft 12 N m 1 2 kgf m 8 9 lb ft 7 ...

Page 120: ...t wheel ax le 2 Check Tire Front wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 33 and CHECKING THE WHEELS on page 3 33 3 Check Spoke Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 33 4 Tighten Spoke Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 33 TIP After tightening the spokes measure the wheel runout 5 Measure Radial wheel runout a Lateral wheel runout b Out of ...

Page 121: ...l 2 Install Brake disc Brake disc bolt TIP Tighten the bolts in stages and in a crisscross pattern 3 Install Collar 1 TIP Apply the lithium soap based grease on the oil seal lip EAM30021 INSTALLING THE FRONT WHEEL 1 Install Front wheel TIP Install the brake disc 1 between the brake pads 2 correctly 2 Install Front wheel axle 1 TIP Apply the lithium soap based grease to the front wheel axle 3 Tight...

Page 122: ...el axle nut push down hard on the handlebar s several times and check if the front fork rebounds smoothly 4 Tighten Front wheel axle pinch bolt 1 Front wheel axle nut 115 N m 11 5 kgf m 85 lb ft Front wheel axle pinch bolt 21 N m 2 1 kgf m 15 lb ft T R 1 1 T R 1 1 ...

Page 123: ...f the ground 1 Rear wheel axle nut 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 10 Brake disc 1 2 5 7 6 4 6 1 6 3 8 9 10 5 3 21 N m 2 1 kgf m 15 lb ft 21 N m 2 1 kgf m 15 lb ft 125 N m 12 5 kgf m 92 lb ft 50 N m 5 0 kgf m 37 lb ft 12 N m 1 2 kgf m 8 9 lb ft 9 6 7 ...

Page 124: ... 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 33 and CHECKING THE WHEELS on page 3 33 3 Check Spoke Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 33 4 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 6 EAM30025 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1 Check Rear wheel sprocket More than 1 4 tooth wear ...

Page 125: ...e bearing by pressing its outer race parallel TIP Use a socket 6 that matches the diameter of the bearing outer race and that of the oil seal 2 Install Brake disc Brake disc bolt TIP Tighten the bolts in stages and in a crisscross pattern 3 Install Collar 1 TIP Apply the lithium soap based grease on the oil seal lip EAM30027 INSTALLING THE REAR WHEEL 1 Install Rear wheel TIP Install the brake disc...

Page 126: ...wheel axle 4 Install Drive chain puller right 1 Washer 2 Rear wheel axle nut 3 TIP Temporarily tighten the rear wheel axle nut at this point 5 Adjust Drive chain slack a Refer to DRIVE CHAIN SLACK on page 3 26 6 Tighten Rear wheel axle nut 1 Locknut 2 Drive chain slack Maintenance Stand 50 0 60 0 mm 1 97 2 36 in 1 2 3 Wheel axle nut 125 N m 12 5 kgf m 92 lb ft Locknut 21 N m 2 1 kgf m 15 lb ft a T...

Page 127: ...age 3 25 1 Union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Brake pad pin plug 1 5 Brake pad pin 1 6 Brake pad 2 7 Brake pad spring 1 8 Front brake caliper assembly 1 9 Front brake caliper bracket 1 10 Brake pad spring 1 3 9 1 2 8 4 5 7 6 28 N m 2 8 kgf m 21 lb ft 30 N m 3 0 kgf m 22 lb ft 5 N m 0 5 kgf m 3 7 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 17 N m 1 7 kgf m 13 lb ft 10 ...

Page 128: ...bling the front brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 2 2 Brake caliper piston dust seal 2 3 Brake caliper piston seal 2 4 Bleed screw 1 1 2 4 S S S BF BF 3 2 3 S 5 N m 0 5 kgf m 3 7 lb ft ...

Page 129: ...ion bolt 1 3 Copper washer 2 4 Front brake hose 1 5 Brake master cylinder reservoir cap 1 6 Brake master cylinder reservoir diaphragm 1 7 Front brake master cylinder float 1 8 Front brake master cylinder holder 1 9 Front brake master cylinder 1 5 6 7 2 3 4 8 9 1 30 N m 3 0 kgf m 22 lb ft 6 N m 0 6 kgf m 4 4 lb ft 6 N m 0 6 kgf m 4 4 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 9 N m 0 9 kgf m 6 6 lb ft ...

Page 130: ...FRONT BRAKE 4 16 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 BF 1 S New ...

Page 131: ...minutes and get im mediate medical attention EAM30029 CHECKING THE FRONT BRAKE DISC 1 Check Front brake disc Damage galling Replace 2 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace 3 Measure Brake disc runout Out of specification Replace the brake disc a Place the vehicle on a maintenance stand so that the front wheel is ele...

Page 132: ...reuse the drained brake fluid c Tighten the bleed screw d Install the brake pads 3 and the pad pin TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point e Install the brake caliper 4 and tighten the pad pin 5 f Install the pad pin plug 6 Brake pad lining thickness limit 1 0 mm 0 04 in 4 a 2 1 Bleed screw 5 N m 0 5 kgf m ...

Page 133: ... the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston dust seal and the brake caliper piston seal EAM30032 CHECKING THE FRONT BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scrat...

Page 134: ...its upper end a aligned with the paint b on the brake hose 4 Pour brake fluid to the brake master cylinder reservoir up to the specified level WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may resul...

Page 135: ...er 1 Damage scratches wear Replace the brake master cylinder assembly Brake fluid delivery passages 2 brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder reservoir cap Damage scratches wear Replace 3 Check Brake hose Cracks damage wear Replace EAM30038 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER WARNING EWA13520 Before installation all internal brake co...

Page 136: ...ke master cylinder holder with the UP mark facing up First tighten the upper bolt then the lower bolt 2 Install Copper washer Brake hose Union bolt WARNING EWA13531 Proper brake hose routing is essential to in sure safe vehicle operation NOTICE ECA24470 During installation bring the brake hose into contact with the brake master cylinder pro jection a and make its bent portion b face downward TIP T...

Page 137: ...nter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 5 Check Brake fluid level The minimum level mark or below Add...

Page 138: ...1 3 Copper washer 2 4 Rear brake hose 1 5 Brake pad pin plug 1 6 Brake pad pin 1 7 Rear brake pad assembly 2 8 Rear brake caliper bracket 1 9 Brake pad spring 2 10 Rear brake disc cover 1 11 Rear brake caliper assembly 1 2 3 4 11 6 7 9 1 8 9 10 S 7 N m 0 7 kgf m 5 2 lb ft 30 N m 3 0 kgf m 22 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 17 N m 1 7 kgf m 13 lb ft 2 5 N m 0 25 kgf m 1 ...

Page 139: ...isassembling the rear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 1 2 3 4 S BF 5 N m 0 5 kgf m 3 7 lb ft ...

Page 140: ...page 3 25 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Split pin 1 5 Washer 1 6 Pin 1 7 Brake master cylinder reservoir cap 1 8 Brake master cylinder reservoir diaphragm plate 1 9 Brake master cylinder reservoir diaphragm 1 10 Rear brake master cylinder 1 1 2 3 4 7 5 8 6 9 10 30 N m 3 0 kgf m 22 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft ...

Page 141: ...REAR BRAKE 4 27 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder joint 1 2 Brake master cylinder kit 1 2 1 BF S New ...

Page 142: ...Flush with water for 15 minutes and get im mediate medical attention EAM30041 CHECKING THE REAR BRAKE DISC 1 Check Brake disc Damage galling Replace 2 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISC on page 4 17 3 Measure Brake disc runout Out of specification Replace the brake disc Refe...

Page 143: ...nstall the brake pads 3 and the pad pin 4 TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point e Install the brake caliper 5 and the rear wheel 6 Refer to REAR WHEEL on page 4 9 f Tighten the pad pin 7 g Install the pad pin plug 8 and the protector 9 Brake pad lining thickness limit 1 0 mm 0 04 in 7 6 a 2 1 Bleed screw ...

Page 144: ...rake hose joint opening to force out the piston from the brake caliper WARNING EWA13550 Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston dust seal and the brake caliper piston seal EAM30044 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper ...

Page 145: ...rake pad spring Brake pad Brake pad pin Brake pad pin plug Refer to CHECKING THE REAR BRAKE PADS on page 3 24 4 Pour brake fluid to the brake fluid reservoir up to the specified level WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in...

Page 146: ...e Brake fluid delivery passages 2 brake master cylinder body Obstruction Blow out with compressed air 2 Check Master cylinder reservoir cap Crack damage Replace Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm Crack damage Replace 3 Check Brake hose Cracks damage wear Replace EAM30050 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING EWA13520 Before instal...

Page 147: ...on the brake caliper 2 Pour brake fluid to the brake fluid reservoir up to the specified level WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor...

Page 148: ...REAR BRAKE 4 34 LEVEL on page 3 23 5 Check Brake pedal operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 ...

Page 149: ...able pull 1 Disconnect 8 Throttle cable return 1 Disconnect 9 Right grip 1 10 Tube guide 1 11 Start switch 1 12 Left grip 1 13 Upper handlebar holder 2 14 Handlebar 1 15 Lower handlebar holder 2 16 Damper 4 12 3 8 N m 0 38 kgf m 2 8 lb ft 1 3 N m 0 13 kgf m 0 95 lb ft 5 N m 0 5 kgf m 3 7 lb ft 0 5 N m 0 05 kgf m 0 37 lb ft 0 5 N m 0 05 kgf m 0 37 lb ft 28 N m 2 8 kgf m 21 lb ft 4 0 N m 0 40 kgf m ...

Page 150: ...l Damper 1 Lower handlebar holder 2 temporarily Handlebar 3 Upper handlebar holder 4 TIP Install the lower handlebar holders with the side having the longer distance a from the mounting bolt center facing towards the rear side of the vehicle Installing the lower handlebar holders in the re verse direction allow the front to rear offset amount of the handlebar position to be changed The upper handl...

Page 151: ...hould be installed according to the dimensions shown Pass the engine stop switch lead through the middle of the clutch lever holder a 3 4 4 b 1 2 1 2 1 2 1 2 c 1 2 1 2 d Lower handlebar holder nut 40 N m 4 0 kgf m 30 lb ft Clutch lever holder bolt 5 N m 0 5 kgf m 3 7 lb ft Clutch lever nut 4 0 N m 0 40 kgf m 3 0 lb ft Engine stop switch screw 0 5 N m 0 05 kgf m 0 37 lb ft Screw mode switch 1 3 N m...

Page 152: ... ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 15 9 Install Right grip 1 Collar 2 Apply adhesive to the tube guide 3 TIP Before applying the adhesive wipe off grease or oil on the tube guide surface a with a lac quer thinner Install the grip to the tube guide so that the grip match mark b and tube guide slot c form the angle as shown 10 Install Rubber cover 1 Throttle grip 2 TIP Apply the lithium...

Page 153: ...ster cylinder assembly 2 Front brake master cylinder holder 3 Front brake master cylinder holder bolt 4 Clamp 5 TIP Install the brake master cylinder holder with the UP mark facing up Install in order for the top of the front brake master cylinder assembly to be level First tighten the upper bolt then the lower bolt 15 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 11...

Page 154: ...HANDLEBAR 4 40 Throttle grip free play 3 0 6 0 mm 0 12 0 24 in ...

Page 155: ...caliper Refer to FRONT BRAKE on page 4 13 Number plate Refer to GENERAL CHASSIS on page 4 1 Lower handlebar holder Refer to HANDLEBAR on page 4 35 with the handlebar holder 1 Protector 1 2 Upper bracket pinch bolt 2 Loosen 3 Damper assembly 1 Loosen 4 Lower bracket pinch bolt 2 Loosen 5 Front fork leg 1 5 N m 0 5 kgf m 3 7 lb ft 5 N m 0 5 kgf m 3 7 lb ft 9 N m 0 9 kgf m 6 6 lb ft 21 N m 2 1 kgf m ...

Page 156: ... 1 7 Inner tube 1 8 Outer tube 1 9 Piston metal 1 10 Protector guide 1 11 Slide metal 1 12 Washer 1 13 Oil seal 1 14 Base valve 1 15 Damper assembly 1 16 Upper spring seat 1 LS 15 2 8 10 12 13 5 4 1 7 14 New New 11 New New New New New LT 3 9 1 3 N m 0 13 kgf m 0 95 lb ft 28 N m 2 8 kgf m 21 lb ft 29 N m 2 9 kgf m 21 lb ft 30 N m 3 0 kgf m 22 lb ft 55 N m 5 5 kgf m 41 lb ft 16 New 6 ...

Page 157: ...fork leg from the ve hicle loosen the damper assembly 1 with the cap bolt ring wrench 2 It is allowed to remove the lower handlebar holder with the handlebar installed as shown When doing so make sure that the handlebar is secured so that it does not move 4 Remove Front fork leg EAM30056 DISASSEMBLING THE FRONT FORK LEGS 1 Drain Fork oil 2 Remove Adjuster 1 from the inner tube TIP While compressin...

Page 158: ...G THE FRONT FORK LEGS 1 Check Inner tube surface Scratches Repair or replace Use 1000 grit wet sandpaper Damaged oil lock piece Replace Inner tube bends Out of specification Replace Use the dial gauge TIP The bending value is shown by one half of the dial gauge reading WARNING EWA13650 Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Check Outer tube Scratches wea...

Page 159: ...g and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 5 Check Base valve 1 Wear damage Replace Contamination Clean O ring 2 Wear damage Replace Base valve bushing Wear damage Replace Fork spring 3 Damage fatigue Replace the base valve Bleed screw 4 Wear damage Replace 6 Check Upper spring seat 1 contacting surface a Wear damage Replace 7 Check Adjuster 1 O ...

Page 160: ...allow any for eign material to enter the front fork 3 After filling pump the damper assembly 1 slowly up and down about 200 mm 7 9 in stroke several times to bleed the damper as sembly of air TIP Avoid excessive full stroke A stroke of 200 mm 7 9 in or more will cause air to enter In this case repeat the steps 1 to 3 4 Measure Oil level left and right a Out of specification Regulate 5 Tighten Lock...

Page 161: ...valve 10 After filling pump the damper assembly 1 slowly up and down more than 10 times to distribute the fork oil 11 While protecting the damper assembly 1 with a cloth and compressing fully allow ex cessive oil to overflow on the base valve side NOTICE ECA24540 Take care not to damage the damper assem bly 12 Allow the overflowing oil to escape at the hole a in the damper assembly TIP The overflo...

Page 162: ...es bottom side TIP Apply the lithium soap based grease on the dust seal lip and oil seal lip Apply the fork oil on the inner tube Install the scraper to the inner tube as shown in the illustration When installing the oil seal use vinyl seat a with fork oil applied to protect the oil seal lip 15 Install Piston metal 1 TIP Install the piston metal onto the slot on inner tube 16 Install Outer tube 1 ...

Page 163: ...ring 1 TIP Fit the stopper ring correctly in the groove in the outer tube 20 Install Scraper 1 Dust seal 2 TIP Apply lithium soap based grease on the inner tube 21 Check Inner tube smooth movement Tightness binding rough spots Repeat the steps 14 to 20 22 Measure Distance a Out of specification Turn the locknut to specification Fork seal driver 90890 01502 Fork seal driver 48 YM A0948 Fork seal dr...

Page 164: ...TIP Before loosening the damping force adjuster record the setting position Unless the damping force adjuster is fully loos ened correct damping characteristic cannot be obtained after installation 26 Install Damper adjusting rod 1 Copper washer 2 Adjuster 3 to the damper assembly 4 TIP While compressing the inner tube 5 set the cap bolt ring wrench 7 between the inner tube and locknut 6 Fully fin...

Page 165: ...ommended oil Other oils may have an adverse effect on front fork performance When disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 31 Install Damper assembly 1 to the outer tube TIP Temporarily tighten the damper assembly Gap a between the adjuster and the locknut 0 5 1 0 mm 0 02 0 04 in Adjuster damper assembly 29 N m 2 9 kgf m 21 lb ft 1 ...

Page 166: ...ring wrench 2 to tighten the damper assembly 3 Adjust Front fork top end a 4 Install Lower handlebar holder with the handlebar 5 Tighten Upper bracket pinch bolt 1 Lower bracket pinch bolt 2 Damper assembly 30 N m 3 0 kgf m 22 lb ft 1 T R Cap bolt ring wrench 90890 01501 Cap bolt ring wrench YM 01501 Front fork top end standard a 5 mm 0 20 in Lower handlebar holder nut 40 N m 4 0 kgf m 30 lb ft Up...

Page 167: ...tor 2 7 Adjust Rebound damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 8 Adjust Compression damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position Lower bracket pinch bolt 21 N m 2 1 kgf m 15 lb ft Bolt protector 5 N m 0 5 kgf m 3 7 lb ft T R 1 2 T R 1 2 1 1 ...

Page 168: ...ront fender 1 2 Steering stem nut 1 3 Front fork leg 2 Refer to FRONT FORK on page 4 41 4 Warning light engine trouble 1 Br Y W 5 Warning light fuel level 1 Br L Y 6 Upper bracket 1 7 Steering ring nut 1 8 Lower bracket 1 9 Bearing race cover 1 10 Upper bearing 1 11 Bearing race 2 12 Bearing lower side 1 2 6 3 1 8 21 N m 2 1 kgf m 15 lb ft 21 N m 2 1 kgf m 15 lb ft 9 N m 0 9 kgf m 6 6 lb ft 10 N m...

Page 169: ...lace 3 Replace Bearing Bearing race a Remove the bearing race from the steer ing head pipe with a long rod 1 and a hammer b Remove the bearing race from the lower bracket with a chisel 2 and a hammer c Install a new bearing race NOTICE ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged TIP Always replace the bearing and the bearing race as a set 4 Check ...

Page 170: ...steering ring nut with its stepped side a facing downward Tighten the steering ring nut with a steering nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 27 5 Check the steering stem by turning this lock to lock If there is any binding remove the steering stem and check the steering bear ing 6 Install Washer 1 7 Install Front fork 1 Upper bracket 2 TIP Temporarily tighten th...

Page 171: ...steering ring nut little by lit tle 10 Adjust Front fork top end a 11 Tighten Upper bracket pinch bolt 1 Lower bracket pinch bolt 2 WARNING EWA19330 Tighten the lower bracket to specified torque If torqued too much it may cause the front fork to malfunction Steering stem nut 145 N m 14 5 kgf m 107 lb ft Front fork top end standard a 5 mm 0 20 in T R a Upper bracket pinch bolt 21 N m 2 1 kgf m 15 l...

Page 172: ...coop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Rear shock absorber assembly lower bolt 1 2 Rear shock absorber assembly upper bolt 1 3 Rear shock absorber assembly 1 4 Locknut 1 5 Adjusting nut 1 6 Lower spring guide 1 7 Upper spring guide 1 8 Spring 1 9 Dust seal 2 10 Collar 2 11 Bushing 1 12 Bearing 1 New 2 4 5 7 6 8 3 9 9 10 10 12 1 56 N m 5 6 kg...

Page 173: ...g the rear shock absorber assembly Order Job Parts to remove Q ty Remarks 13 Collar 2 14 O ring 2 15 Dust seal 2 16 Bushing 1 17 Stopper ring 1 56 N m 5 6 kgf m 41 lb ft 53 N m 5 3 kgf m 39 lb ft New 13 16 15 14 15 New 14 New New 13 17 New New ...

Page 174: ... Disassembling the relay arm Order Job Parts to remove Q ty Remarks 1 Relay arm 1 2 Connecting arm 1 3 Collar 3 4 Oil seal 6 5 Washer 8 6 Bearing 6 5 3 5 6 1 6 5 4 5 5 4 6 6 5 3 2 4 6 6 3 4 4 M M M M M M M 80 N m 8 0 kgf m 59 lb ft 4 5 ...

Page 175: ...ber be sure to extract the nitrogen gas from valve 1 WARNING EWA19340 Wear protective glasses to prevent your eyes from damage due to possible gas or metal chips scattered To dispose of a damaged or a worn out rear shock absorber take the unit to your Yamaha dealer for this disposal procedure EAM30065 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Use a maintenance stand to raise the rear wheel off t...

Page 176: ...ng 1 Washer 2 Oil seal 3 into the relay arm 4 Collar 5 3 Install Bearing 1 Oil seal 2 into the connecting arm 3 EAM30070 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate Bearing lower side Dust seal NOTICE ECA24580 Do not apply the grease to the bearing outer race because it will wear the rear shock ab sorber surface on which the bearing is press Recommended lubricant Molybdenum disulfide g...

Page 177: ...TIP When installing the rear shock absorber as sembly lift up the swingarm Install the rear shock absorber assembly upper bolt and connecting arm bolt frame side from the right Install the rear shock absorber assembly lower bolts connecting arm bolt relay arm side and relay arm bolt swingarm side from the left 7 Tighten Rear shock absorber assembly upper nut Connecting arm nut frame side Connectin...

Page 178: ...wheel off the ground Brake hose holder Refer to REAR BRAKE on page 4 24 Rear brake caliper Refer to REAR BRAKE on page 4 24 Bolt brake pedal Drive chain 1 Collar 2 2 Oil seal 2 3 Thrust bearing 2 4 Bushing 2 5 Oil seal 2 6 Bearing 4 1 2 3 6 4 6 4 1 3 6 2 5 4 0 N m 0 40 kgf m 3 0 lb ft 70 N m 7 0 kgf m 52 lb ft 7 N m 0 7 kgf m 5 2 lb ft ...

Page 179: ... Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash with kerosene Pivot shaft Bushing Collar Bearing 4 Check Oil seal Damage Replace Bearing Bushing Free play exists unsmooth revolution rust Replace bearing and bushing as a set EAM30074 INSTALLING THE SWINGARM 1 Lubricate Beari...

Page 180: ...SWINGARM 4 66 4 Install Rear wheel Refer to REAR WHEEL on page 4 9 5 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 26 Drive chain slack Maintenance Stand 50 0 60 0 mm 1 97 2 36 in ...

Page 181: ...Order Job Parts to remove Q ty Remarks Drive sprocket Refer to ENGINE REMOVAL on page 5 6 1 Drive chain 1 2 Drive sprocket cover 1 3 Bracket 1 4 Drive sprocket nut 1 5 Lock washer 1 6 Drive sprocket 1 1 2 3 4 5 6 7 N m 0 7 kgf m 5 2 lb ft 90 N m 9 0 kgf m 66 lb ft ...

Page 182: ...length b between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a different location each time 2 Check Drive chain Stiffness Clean lubricate or replace 3 Clean Drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and re move any remaining dirt c Remove the drive ...

Page 183: ...ROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 10 EAM30079 INSTALLING THE DRIVE CHAIN 1 Install Drive chain NOTICE ECA17410 Be sure to put on safety goggles when work ing TIP Install the master link with the drive chain cut rivet tool Use goods on the market a When press fitting the master link plate 1 make sure the space a between the end of the connecting pin 2 and the ...

Page 184: ...prockets this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 26 NOTICE ECA24590 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its Recommended lubricant Chain ...

Page 185: ...R HEAD 5 22 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 5 22 CHECKING THE CYLINDER HEAD 5 22 INSTALLING THE CYLINDER HEAD 5 22 VALVES AND VALVE SPRINGS 5 25 REMOVING THE VALVES 5 26 CHECKING THE VALVES AND VALVE GUIDES 5 27 CHECKING THE VALVE SEATS 5 28 CHECKING THE VALVE SPRINGS 5 29 CHECKING THE VALVE LIFTERS 5 30 INSTALLING THE VALVES 5 30 CYLINDER AND PISTON 5 32 REMOVING THE PISTON 5 33 CHECK...

Page 186: ...EMOVING THE SEGMENT 5 55 CHECKING THE SHIFT SHAFT 5 55 CHECKING THE STOPPER LEVER 5 55 INSTALLING THE SHIFT SHAFT 5 55 OIL PUMP 5 58 REMOVING THE BALANCER 5 60 CHECKING THE OIL PUMP 5 60 ASSEMBLING THE OIL PUMP 5 60 INSTALLING THE OIL PUMP 5 61 CRANKCASE 5 63 DISASSEMBLING THE CRANKCASE 5 65 CHECKING THE TIMING CHAIN GUIDE EXHAUST SIDE 5 65 CHECKING THE CRANKCASE 5 65 ASSEMBLING THE CRANKCASE 5 66...

Page 187: ...MS 5 1 EAM20185 LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30526 ENGINE OIL LUBRICATION CHART 1 Intake camshaft 2 Exhaust camshaft 3 Piston 4 Oil filter element 5 Oil nozzle 6 Oil pump 7 Oil strainer 8 Crankshaft 9 Drive axle 10 Main axle ...

Page 188: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 2 EAM30507 LUBRICATION DIAGRAMS 1 Camshaft 2 Drive axle 3 Main axle ...

Page 189: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 3 1 Connecting rod 2 Oil nozzle 3 Crankshaft ...

Page 190: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 4 1 Exhaust camshaft 2 Intake camshaft 3 Oil filter element 4 Oil pump ...

Page 191: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 5 1 Oil filter element 2 Oil pump 3 Oil strainer ...

Page 192: ... Exhaust pipe 2 1 5 Exhaust pipe 1 1 6 Gasket 3 7 Exhaust pipe 1 protector 1 8 Silencer body 1 9 Silencer cap 1 9 5 8 2 6 1 6 6 3 4 7 8 6 New New New LT LT 1st 2nd 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft 30 N m 3 0 kgf m 22 lb ft 30 N m 3 0 kgf m 22 lb ft 30 N m 3 0 kgf m 22 lb ft 20 N m 2 0 kgf m 15 lb ft 12 N m 1 2 kgf m 8 9 lb ft 12 N m 1 2 kgf m 8 9 lb ft 10 N m 1 0 kgf m 7 4 lb f...

Page 193: ...UEL TANK on page 7 1 Air filter case cover Refer to CLEANING THE AIR FILTER ELE MENT on page 3 15 Intake air temperature sensor coupler Refer to THROTTLE BODY on page 7 4 ECU Engine Control Unit Refer to THROTTLE BODY on page 7 4 Ignition coil Refer to THROTTLE BODY on page 7 4 1 Rectifier regulator 1 2 Stator coil assembly coupler 1 Disconnect 3 Crankshaft position sensor coupler 1 Disconnect 4 C...

Page 194: ...Y on page 7 4 Throttle body Refer to THROTTLE BODY on page 7 4 Clutch cable Refer to CLUTCH on page 5 46 Shift pedal Drive chain Refer to SHIFT SHAFT on page 5 54 Refer to CHAIN DRIVE on page 4 67 1 Engine guard 1 2 Brake pedal 1 3 Spring 1 4 Cylinder head breather hose 1 5 Drive sprocket cover 1 6 Drive chain guide 1 7 Drive sprocket 1 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 34 N m 3 ...

Page 195: ... 2 11 Lower engine bracket inside 2 12 Pivot shaft 1 13 Engine 1 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 34 N m 3 4 kgf m 25 lb ft 85 N m 8 5 kgf m 63 lb ft 90 N m 9 0 kgf m 66 lb ft 34 N m 3 4 kgf m 25 lb ft 53 N m 5 3 kgf m 39 lb ft 55 N m 5 5 kgf m 41 lb ft 26 N m 2 6 kgf m 19 lb ft 34 N m 3 4 kgf m 25 lb ft 45 N m 4 5 kgf m 33 lb ft 8 9 11 13 10 11 10 12 ...

Page 196: ...ove this from its low er part toward the right of the chassis EAM30164 INSTALLING THE ENGINE 1 Install Engine 1 from the right side Pivot shaft 2 Engine mounting bolt lower side 3 Lower engine bracket inside 4 Lower engine bracket outside 5 Engine bracket bolt front side 6 Engine mounting bolt front side 7 Upper engine bracket 8 Engine bracket bolt upper side 9 Engine mounting bolt upper side 10 1...

Page 197: ...re that the exhaust pipe band 3 does not ride on the projection a on the exhaust pipe 4 or silencer 5 Be sure to insert the projection b into the slot in the exhaust pipe or silencer 3 Install Clamp Silencer 1 Bolt silencer 2 4 Tighten Bolt exhaust pipe 2 Engine mounting bolt upper side 45 N m 4 5 kgf m 33 lb ft Nut exhaust pipe 1 10 N m 1 0 kgf m 7 4 lb ft T R 9 2 6 5 4 3 1 4 7 6 M 8 8 9 10 10 5 ...

Page 198: ...ENGINE REMOVAL 5 12 Clamp TIP Tighten while checking that their front and rear joints are inserted in position Bolt exhaust pipe 2 20 N m 2 0 kgf m 15 lb ft Clamp 12 N m 1 2 kgf m 8 9 lb ft T R T R ...

Page 199: ... Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Ignition coil Refer to ENGINE REMOVAL on page 5 6 1 Cylinder head breather hose 1 2 Cylinder head cover breather plate 1 3 Gasket 1 4 Spark plug 1 5 Cylinder head cover 1 6 Timing chain guide top side 1 7 Cylinder head cover gasket 1 8 Gasket 1 1 4 5 6 7 10 N m 1 0 kgf m 7 4 lb ft 13 N m 1 3 kgf m 9...

Page 200: ... Timing chain tensioner cap bolt 1 4 Timing chain tensioner 1 5 Camshaft cap 2 6 Clip 2 7 Intake camshaft 1 8 Exhaust camshaft 1 9 Oil nozzle 1 M LS 5 8 3 4 1 2 7 6 4 3 6 E LS E 6 N m 0 6 kgf m 4 4 lb ft 6 N m 0 6 kgf m 4 4 lb ft 3 0 N m 0 30 kgf m 2 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft M E 9 ...

Page 201: ... cap surfaces d 3 Remove Timing chain tensioner cap bolt 1 Timing chain tensioner 2 Gasket 4 Remove Bolt camshaft cap 1 Camshaft cap 2 Clip 3 TIP Remove the bolts camshaft cap in a criss cross pattern working from the outside in In order to prevent the clip from falling into the crankcase remove the camshaft cap NOTICE ECA24610 The bolts camshaft cap must be removed evenly to prevent damage to the...

Page 202: ...ap bolts in a crisscross pattern from innermost to outer caps Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 4 Measure Camshaft journal diameter a Out of specification Replace the camshaft Within specification Replace the cylinder head and the camshaft caps as a set Camshaft lobe dim...

Page 203: ...th your fingers use a thin screwdriver 1 to wind the tensioner rod up fully clock wise b When releasing the screwdriver by press ing lightly with your fingers make sure that the tensioner rod will come out smoothly c If not replace the tensioner assembly EAM30084 CHECKING THE DECOMPRESSION SYSTEM 1 Check Decompression system a Check that the decompressor cam 1 moves smoothly b Check that the decom...

Page 204: ...P Before installing the clips cover the cylinder head with a clean cloth to prevent the clips from coming off into the cylinder head cavity Apply the engine oil to the threads and contact surfaces Tighten the bolts to the specified torque in two or three steps in the proper tightening se quence as shown NOTICE ECA24630 The bolts camshaft cap must be tightened evenly or damage to the cylinder head ...

Page 205: ...g chain guide top side 1 Cylinder head cover gasket 2 Gasket spark plug hole 3 Cylinder head cover 4 Bolt cylinder head cover 5 TIP Before installation apply the sealant to the cylin der head cover gasket 6 Install Cylinder head breather hose Spark plug Bolt timing chain tensioner 10 N m 1 0 kgf m 7 4 lb ft Timing chain tensioner cap bolt 6 N m 0 6 kgf m 4 4 lb ft Bolt cylinder head cover 10 N m 1...

Page 206: ... to ENGINE REMOVAL on page 5 6 Radiator hose Disconnect Coolant temperature sensor coupler Disconnect Throttle body Refer to THROTTLE BODY on page 7 4 Camshaft Refer to CAMSHAFT on page 5 13 Upper engine bracket Refer to ENGINE REMOVAL on page 5 6 1 Bolt cylinder head 2 2 Bolt cylinder head 4 3 Cylinder head 1 4 Timing chain guide intake side 1 5 Cylinder head gasket 1 M 3 5 4 7 N m 0 7 kgf m 5 2 ...

Page 207: ...ylinder head Order Job Parts to remove Q ty Remarks 6 Oil passage plug 2 M 7 N m 0 7 kgf m 5 2 lb ft 1st 3rd 4th 2nd 40 N m 4 0 kgf m 30 lb ft 23 N m 2 3 kgf m 17 lb ft 60 90 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft LT 6 6 ...

Page 208: ...lace also the valve Refer to CHECKING THE VALVE SEATS on page 5 28 Cylinder head coolant passages Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge and a thickness gauge across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet san...

Page 209: ...olt and washer are lightly seated against the cylinder head e Tighten the bolts to the specified torque in two or three steps in the proper tightening sequence as shown f Loosen the bolt 1 TIP Loosen the bolt 1 only without loosening any other bolt g Again apply molybdenum disulfide grease to the thread and contact surface of the bolts and to both contact surface of the washer h Retighten the bolt...

Page 210: ...bolt is completely tightened l Put a mark on the corner of the bolt cylin der head and the cylinder head m Retighten the bolt cylinder head in the proper tightening sequence n Tighten the bolts to the specified torque Bolt 1 3rd Specified angle 90 Bolt 2 4 2nd 23 N m 2 3 kgf m 17 lb ft 3rd Specified angle 90 Final Specified angle 60 Bolt 5 6 10 N m 1 0 kgf m 7 4 lb ft 90 T R T R T R T R ...

Page 211: ...der Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 20 1 Valve lifter 4 2 Adjusting pad 4 3 Valve cotter 8 4 Valve spring retainer 4 5 Valve spring 4 6 Valve stem seal 4 7 Valve spring seat 4 8 Intake valve 2 9 Exhaust valve 2 8 7 7 5 3 3 3 3 9 9 7 6 5 4 3 1 2 7 6 4 3 1 2 5 ...

Page 212: ...THE VALVE SEATS on page 5 28 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves are properly sealed TIP Check that there are no kerosene leaks from the valve seat 1 3 Remove Valve cotter 1 TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attachment 3 4 Remove Valve spring retainer 1 Valve...

Page 213: ...alve guide installer 1 and the valve guide re mover 2 c After installing the valve guide expand the hole in the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance limit ...

Page 214: ... 3 Measure Valve seat contact width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impression d Measure the valve seat contact width c TIP Where the valve seat and the valve face are in contact with each other the blueing wil...

Page 215: ... d Turn the valve until the valve face and the valve seat are evenly polished then clean off all of the lapping compound TIP While turning the valve lapper tap and lap the valve seat e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping step be sure to clean off all of the lapping compound from the valve face and the valve seat g Apply blue layout fluid...

Page 216: ...o the cylinder head TIP Make sure each valve is installed in its original place Install the valve springs with the larger pitch a facing up 4 Install Valve cotter 1 TIP Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attachment 3 Recommended lubricant Molybdenum disulfide oil b Smaller pitch Valve spring compressor 90890 ...

Page 217: ...3800 Hitting the valve tip with excessive force could damage the valve 6 Lubricate Adjusting pad 1 Valve lifter 2 7 Install Adjusting pad Valve lifter TIP Check that the valve lifter turns smoothly when rotated with your finger Make sure that the valve lifter and the adjusting pad are reinstalled in their original positions 2 2 1 1 3 3 E 1 2 ...

Page 218: ...iston Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 20 1 Cylinder body 1 2 Gasket 1 3 Dowel pin 2 4 Piston pin clip 2 5 Piston pin 1 6 Piston 1 7 Piston ring set 1 1 2 3 4 4 5 6 7 E E LT 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft E ...

Page 219: ...and lift the opposite end gap of the piston ring over the piston crown EAM30097 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Sidewall Cylinder wall Vertical scratches Replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure the cylinder bore C with the cyl inder bore gauge TIP Measure the cylinder bore C by taking side to side a...

Page 220: ...l the piston ring near bottom of cylinder a where cylinder wear is lowest 3 Measure Piston ring end gap Out of specification Replace the piston ring TIP The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace the oil ring as a set Diameter 96 955 96 970 mm 3 8171 3 8177 in Measuring point from piston skirt bottom 9 0 mm 0 35 in Piston to cylinder ...

Page 221: ...l 3 2nd ring 4 Top ring 5 TIP Be sure to install the piston rings so that the manufacturer s marks or numbers face up 2 Install Piston 1 Piston pin 2 Piston pin clip 3 TIP Apply the engine oil to the piston pin Install the piston with the mark a on it pointing to its exhaust rear side Before installing the piston pin clip cover the crankcase opening with a cloth to prevent the clip from falling in...

Page 222: ...pressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide exhaust side through the timing chain cavity a Top ring b 2nd ring c Upper oil ring rail d Oil ring expander e Lower oil ring rail Cylinder bolt 10 N m 1 0 kgf m 7 4 lb ft 1 3 2 a E E 3 a c e b d 15 15 15 15 15 New T R ...

Page 223: ...ASSIS on page 4 1 1 Stator coil assembly coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Shift pedal 1 4 Crankcase cover left 1 5 Gasket 1 6 Dowel pin 2 7 Holder 1 8 Stator coil assembly 1 9 Generator rotor 1 10 Woodruff key 1 1 10 2 4 7 5 8 3 9 6 LT 6 10 N m 1 0 kgf m 7 4 lb ft 8 N m 0 8 kgf m 5 9 lb ft 12 N m 1 2 kgf m 8 9 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf ...

Page 224: ...nstall Stator coil assembly 1 Screw stator coil assembly 2 Crankshaft position sensor 3 Bolt crankshaft position sensor 4 Holder Bolt holder TIP Apply the sealant to the grommet of the stator coil assembly lead Tighten the stator coil assembly screws using the T25 bit Pass the stator coil assembly lead through the crankcase cover side Rotor puller 90890 04151 Rotor puller YM 04151 1 1 2 1 a 2 b Sc...

Page 225: ...he keyway c of the generator rotor with the woodruff key 3 Install Washer Nut generator rotor 1 4 Install Dowel pin 1 Gasket left crankcase cover 2 Crankcase cover left 3 Lead holder 4 Bolt left crankcase cover 5 TIP Tighten the bolts in stages and in a crisscross pattern 5 Connect Stator coil assembly lead Refer to CABLE ROUTING DIAGRAM on page 2 17 Nut generator rotor 65 N m 6 5 kgf m 48 lb ft 2...

Page 226: ...tarter clutch Order Job Parts to remove Q ty Remarks Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 13 Clutch Refer to CLUTCH on page 5 46 1 Holder 1 2 Washer 1 3 Damper assembly 1 4 Starter clutch assembly 1 1 2 4 3 12 N m 1 2 kgf m 8 9 lb ft LT ...

Page 227: ... 3 Check Starter clutch operation a Install the starter clutch drive gear 1 onto the starter clutch and hold the starter clutch b When turning the starter clutch drive gear counterclockwise A it should turn freely otherwise the starter clutch is faulty and must be replaced c When turning the starter clutch drive gear clockwise B the starter clutch and the starter clutch drive gear should engage ot...

Page 228: ...e 5 6 1 Plastic locking tie 1 2 Starter motor cover upper 1 3 Starter motor 1 4 Starter motor cover lower 1 5 Starter motor lead 1 When removing or installing the installation nut of the starter motor lead be sure to hold the nut on the starter motor side firmly in place using a spanner 5 1 2 3 FWD FWD 10 N m 1 0 kgf m 7 4 lb ft 6 N m 0 6 kgf m 4 4 lb ft 4 ...

Page 229: ...Q ty Remarks 1 Starter motor assembly 1 2 O ring 1 3 Starter motor front cover 1 4 Starter motor yoke 1 5 Armature assembly 1 6 Gasket 2 7 Brush set 1 8 Brush holder 1 9 Starter motor rear cover 1 2 3 4 5 6 6 7 1 FWD FWD 9 8 4 5 N m 0 45 kgf m 3 3 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft ...

Page 230: ...easure Brush length a Out of specification Replace the brush set 5 Measure Brush spring force Out of specification Replace the brush set 6 Check Gear teeth Damage wear Replace the starter motor 7 Check Oil seal Damage wear Replace the defective part s EAM30107 ASSEMBLING THE STARTER MOTOR 1 Install Brush spring 1 Brush 2 TIP Install the brush holder using the screws a 2 Install Starter motor rear ...

Page 231: ...the match mark a on the starter motor yoke with the match mark b on the starter mo tor front cover 4 Install Bolt O ring TIP Apply the lithium soap based grease on the O ring 5 Install Starter motor Starter motor cover Starter motor bolt Starter motor cover bolt Starter motor bolt 10 N m 1 0 kgf m 7 4 lb ft Starter motor cover bolt 10 N m 1 0 kgf m 7 4 lb ft a b 2 1 New 1 a b New T R ...

Page 232: ...3 O ring 1 4 Clutch spring 6 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Washer 1 9 Bearing 1 10 Ball 1 11 Push rod 2 1 12 Friction plate 1 2 Identification color black 13 Clutch plate 7 14 Friction plate 2 6 Identification color purple 15 Clutch boss 1 E E 2 3 4 5 7 8 9 6 10 11 13 12 12 14 13 13 15 T R LT 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 75 N m ...

Page 233: ...arts to remove Q ty Remarks 16 Thrust washer 1 17 Primary driven gear 1 18 Push lever shaft 1 E E T R LT 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 75 N m 7 5 kgf m 55 lb ft 18 E E E E E E E E FWD FWD 17 16 ...

Page 234: ...3 13 Coolant Drain Refer to CHANGING THE COOLANT on page 3 21 Brake pedal Refer to ENGINE REMOVAL on page 5 6 Clutch cover Refer to CLUTCH on page 5 46 1 Oil filter element cover 1 2 Oil filter element 1 3 Radiator pipe 2 1 4 Right crankcase cover 1 5 Gasket 1 6 Dowel pin 2 7 Collar 1 LS 5 6 2 4 1 6 7 3 LS LS LS 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft ...

Page 235: ...TCH SPRINGS 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure Clutch spring free length Out of specification Replace the clutch springs as a set EAM30112 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs 1 Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing TIP Pitting on the clutch housing dogs will cause er ratic clutch operation EAM301...

Page 236: ... gears as a set Excessive noise during operation Replace the primary drive and primary driven gears as a set 2 Check Primary drive gear to primary driven gear free play Free play exists Replace the primary drive and primary driven gears as a set EAM30118 CHECKING THE PRIMARY DRIVEN GEAR 1 Check Primary driven gear Damage wear Replace the primary drive and primary driven gears as a set Excessive no...

Page 237: ...igns with the balancer end slot 4 Tighten the right crankcase cover bolts in stag es and in a crisscross pattern 4 Install Push lever shaft 1 TIP Apply the lithium soap based grease on the oil seal lip Before installation apply the engine oil to the bearings upper side and lower side 5 Install Primary driven gear 1 Thrust washer 2 Clutch boss 3 TIP Apply the engine oil on the primary driven gear i...

Page 238: ...and friction plates alter nately on the clutch boss starting with a friction plate and ending with a friction plate From the clutch boss side install the friction plates in order friction plate 1 identification color black 1 friction plate 2 identification color purple 6 and friction plate 1 identifi cation color black 1 Apply the engine oil on the friction plates and clutch plates 9 Install Beari...

Page 239: ...h spring bolt TIP Tighten the bolts in stages and in a crisscross pattern 13 Install O ring 1 TIP Apply the lithium soap based grease to the O ring 14 Install Clutch cover Clutch cover bolt TIP Tighten the bolts in stages and in a crisscross pattern Clutch spring bolt 10 N m 1 0 kgf m 7 4 lb ft E E E 1 2 3 1 1 1 T R Clutch cover bolt 10 N m 1 0 kgf m 7 4 lb ft New T R ...

Page 240: ...1 2 Shift shaft 1 3 Oil seal 1 4 Collar 1 5 Shift shaft spring 1 6 Roller 1 7 Shift guide 1 8 Shift lever assembly 1 9 Shift lever 1 10 Pawl 2 11 Pawl pin 2 12 Spring 2 13 Stopper lever 1 14 Stopper lever spring 1 15 Segment 1 1 3 13 15 14 6 10 11 12 11 8 9 12 10 4 2 5 7 E 30 N m 3 0 kgf m 22 lb ft 12 N m 1 2 kgf m 8 9 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft E E ...

Page 241: ...Check Shift shaft 1 Bends damage wear Replace Shift shaft spring 2 Damage wear Replace 2 Check Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear damage Replace EAM30127 CHECKING THE STOPPER LEVER 1 Check Stopper lever 1 Wear damage Replace Stopper lever spring 2 Broken Replace EAM30131 INSTALLING THE SHIFT SHAFT 1 Install Stopper lever spring 1 Collar 2 Stopper lever 3 Bolt stopper lever...

Page 242: ...ft lever assembly to the shift guide 5 Install Shift lever assembly 1 Shift guide 2 TIP The shift lever assembly is installed at the same time as the shift guide 6 Tighten Shift guide bolt 1 7 Install Roller 1 Shift shaft spring 2 to the shift shaft Collar 3 to the shift shaft Shift shaft 4 TIP Apply the engine oil on the shift shaft 8 Install Oil seal 9 Install Shift pedal 1 Shift pedal bolt 2 Se...

Page 243: ...SHIFT SHAFT 5 57 TIP Align the punch mark a on the shift shaft with the punch mark b in the shift pedal 1 1 2 2 a b ...

Page 244: ...y driven gear Refer to CLUTCH on page 5 46 Right crankcase cover Refer to CLUTCH on page 5 46 1 Oil pump assembly 1 2 Oil pump cover 1 3 Outer rotor 1 4 Dowel pin 1 5 Inner rotor 1 6 Oil pump drive shaft 1 7 Oil pump housing 1 LT E 3 2 1 4 5 7 6 5 N m 0 5 kgf m 3 7 lb ft 6 N m 0 6 kgf m 4 4 lb ft LT ...

Page 245: ...y Refer to GENERATOR on page 5 37 1 Nut balancer 1 2 Nut primary drive gear 1 3 Nut balancer weight gear 1 4 Lock washer 1 5 Balancer 1 6 Straight key 1 7 Conical washer 1 8 Primary drive gear 1 9 Balancer drive gear 1 10 Lock washer 1 11 Balancer weight gear 1 10 N m 1 0 kgf m 7 4 lb ft 50 N m 5 0 kgf m 37 lb ft 6 2 7 8 9 11 10 3 5 4 1 E LT 45 N m 4 5 kgf m 33 lb ft 80 N m 8 0 kgf m 59 lb ft ...

Page 246: ...Replace 4 Check Balancer Crack damage Replace EAM30136 CHECKING THE OIL PUMP 1 Check Oil pump cover Oil pump drive shaft Oil pump housing Cracks damage wear Replace the oil pump assembly 2 Check Oil pump operation Rough movement Repeat step 1 or re place the oil pump assembly EAM30137 ASSEMBLING THE OIL PUMP 1 Install Oil pump drive shaft 1 Inner rotor 2 Dowel pin 3 TIP Apply the engine oil on the...

Page 247: ... gear 1 TIP Install the balancer weight gear and balancer shaft with their lower splines a aligning with each other 3 Install Balancer drive gear 1 TIP Align the punched mark a on the balancer drive gear with the punched mark b on the balancer weight gear Install the balancer drive gear and crankshaft with the lower splines c aligning with each other Oil pump cover bolt 6 N m 0 6 kgf m 4 4 lb ft L...

Page 248: ... oil to the contact surfaces of the conical washer Place an aluminum plate a between the teeth of the balancer drive gear 10 and balancer weight gear 11 Install the conical washer with its convex sur face b outward 5 Bend the lock washer tab Balancer weight gear nut 50 N m 5 0 kgf m 37 lb ft Primary drive gear nut 80 N m 8 0 kgf m 59 lb ft Balancer nut 45 N m 4 5 kgf m 33 lb ft New T R New T R New...

Page 249: ...il assembly Refer to GENERATOR on page 5 37 1 Timing chain guide exhaust side 1 2 Timing chain guide stopper plate 1 3 Timing chain 1 4 Bolt 5 L 45 mm 1 77 in 5 Bolt 4 L 60 mm 2 36 in 6 Bolt 3 L 75 mm 2 95 in 7 Right crankcase 1 8 Left crankcase 1 9 Dowel pin 2 10 Crankshaft 1 11 Oil nozzle 1 3 1 5 2 6 4 10 5 5 5 4 4 4 6 9 7 8 11 9 LT LT 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 12 N m...

Page 250: ...Transmission Refer to TRANSMISSION on page 5 70 Shift cam Shift fork Refer to TRANSMISSION on page 5 70 1 Circlip 1 2 Oil seal 2 3 Bearing 12 4 Collar 1 1 2 2 3 3 3 3 3 3 3 3 3 3 3 12 N m 1 2 kgf m 8 9 lb ft 10 N m 1 0 kgf m 7 4 lb ft 12 N m 1 2 kgf m 8 9 lb ft 22 N m 2 2 kgf m 16 lb ft 4 ...

Page 251: ...f Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If the cases do not separate check for a remaining case bolt or fitting Do not force c Remove the dowel pins and O ring 2 Remove Bearing 1 TIP Remove the bearing from the crankcase by pressing its inner race Do not use the removed bearing EAM30490 CHECKI...

Page 252: ...ft hammer When installing the crankcase the connecting rod should be positioned at top dead center TDC Tighten the bolts in a crisscross pattern in two stages with 1 4 turn each Installed depth a 0 0 0 5 mm 0 00 0 02 in Bearing cover plate 12 N m 1 2 kgf m 8 9 lb ft LOCTITE Bearing cover plate crankshaft 22 N m 2 2 kgf m 16 lb ft LOCTITE Yamaha bond No 1215 90890 85505 Three bond No 1215 New 1 a T...

Page 253: ... AND BALANCER SHAFT Removing the crankshaft assembly and balancer shaft Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 63 Transmission Refer to TRANSMISSION on page 5 70 1 Balancer shaft 1 2 Crankshaft assembly 1 1 2 ...

Page 254: ...NKSHAFT 1 Measure Crankshaft runout a Out of specification Replace the crank shaft TIP Turn the crankshaft slowly 2 Measure Crank assembly width a Out of specification Replace the crank shaft 3 Check Crankshaft sprocket 1 Damage Replace the crankshaft 4 Check Crankshaft journal oil passage Obstruction Blow out with compressed air Crankcase separating tool 90890 04152 Crankcase separating tool YU A...

Page 255: ...thium soap based grease In order to prevent the crankshaft seizure apply molybdenum disulfide grease TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft as sembly bottoms against the bearing Crankshaft installer pot 90890 01274 Installing pot YU 90058 Crankshaf...

Page 256: ...Remarks Engine Refer to ENGINE REMOVAL on page 5 6 Crankcase Separate Refer to CRANKCASE on page 5 63 1 Main axle 1 2 Drive axle 1 3 Long shift fork guide bar 1 4 Short shift fork guide bar 1 5 Spring 4 6 Shift cam 1 7 Shift fork 3 R 1 8 Shift fork 2 C 1 9 Shift fork 1 L 1 10 Collar 1 2 10 1 5 3 4 5 7 8 6 9 M M M M M E E E LS FWD FWD ...

Page 257: ...r 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WARNING EWA12840 Do not attempt to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a set EAM30155 CHECKING THE SHIFT DRUM...

Page 258: ... oil to the inner and end surface of the idler gear and to the inner surface of the sliding gear then install 2 Install Collar 1 2nd wheel gear 26T 2 4th wheel gear 21T 3 3rd wheel gear 21T 4 5th wheel gear 21T 5 Collar 6 1st wheel gear 29T 7 O ring 8 to the drive axle 9 TIP Before installation apply molybdenum disul fide oil to the inner and end surface of the idler gear and the collar and to the...

Page 259: ...nkcase simultaneously Apply engine oil to the main axle and the drive axle bearing 6 Install Shift fork 1 L 1 Shift fork 2 C 2 Shift fork 3 R 3 Shift cam 4 to the main axle and the drive axle TIP Apply engine oil to the shift fork grooves Apply engine oil to the shift cam groove and the bearing contact surface Mesh the shift fork 1 L with the 4th wheel gear 5 and shift fork 3 R with the 5th wheel ...

Page 260: ...ork guide bar 2 Spring 3 TIP Screw the spring into the shift fork guide bar lightly beforehand Apply the engine oil on the shift fork guide bars 8 Check Operation of shift cam and shift fork Transmission operation Unsmooth operation Repair 7 6 5 2 4 1 3 E E E E 2 1 3 E 2 ...

Page 261: ... 10 COOLING SYSTEM COOLING SYSTEM DIAGRAMS 6 1 RADIATOR 6 2 CHECKING THE RADIATOR 6 4 INSTALLING THE RADIATOR 6 4 WATER PUMP 6 6 DISASSEMBLING THE WATER PUMP 6 7 CHECKING THE WATER PUMP 6 7 ASSEMBLING THE WATER PUMP 6 7 ...

Page 262: ...COOLING SYSTEM DIAGRAMS 6 1 EAM20186 COOLING SYSTEM DIAGRAMS 1 Radiator hose 1 2 Radiator right 3 Radiator hose 4 4 Water pump 5 Radiator hose 3 6 Radiator left ...

Page 263: ...CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to THROTTLE BODY on page 7 4 1 Radiator guard 2 2 Radiator hose clamp 8 Loosen 3 Radiator right 1 4 Radiator hose 2 1 5 Radiator hose 4 1 6 Radiator hose 3 1 7 Radiator pipe 2 1 8 Radiator breather hose 1 LS LS 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 5 N m 0 15 kgf m 1 1 lb...

Page 264: ... 9 Radiator left 1 10 Radiator hose 1 1 11 Radiator pipe 1 1 12 Coolant temperature sensor 1 LS LS 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 15 N m 1 5 kgf m 11 lb ft 11 12 10 9 ...

Page 265: ...ce 3 Check Radiator cap valve opening pressure a Install the radiator cap tester adapter 2 and the radiator cap tester 3 to the radi ator cap 1 and activate the tester to check whether it can stay for 5 to 10 sec onds within standard pressure values TIP Before attaching the cap to the tester apply wa ter to its sealing surface No stay Replace EAM30506 INSTALLING THE RADIATOR 1 Fill Cooling system ...

Page 266: ...es of warm up Make sure that coolant is filled up to the up per level beforehand 5 Check Pressure value No stay for 5 to 10 seconds at the test pres sure value Correct Radiator Radiator hose connection Coolant leaks Correct or replace Radiator hose Bulges Replace WARNING EWA19090 When the radiator cap tester is removed coolant will spout therefore cover it with a cloth beforehand Test pressure val...

Page 267: ...on page 3 21 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 13 Right crankcase cover Refer to CLUTCH on page 5 46 1 Water pump housing 1 2 Dowel pin 2 3 Gasket 1 4 Collar 1 5 Pin 1 6 Impeller shaft assembly 1 7 Oil seal 1 8 Bearing 1 9 Oil seal 1 LS LS 7 6 2 2 3 1 8 5 4 E 9 E 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft ...

Page 268: ...ace EAM30262 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 TIP Apply the lithium soap based grease on the oil seal lip Install the oil seal with its manufacture s marks or numbers facing the right crankcase cover 2 Install Bearing 1 TIP Install the bearing by pressing its outer race par allel 3 Install Impeller shaft assembly 1 Pin 2 Collar 3 Circlip 4 TIP Take care so that the oil seal lip is no...

Page 269: ... 5 Install Water pump housing 1 Water pump housing bolt 2 Washer 3 Coolant drain bolt 4 Water pump housing bolt 10 N m 1 0 kgf m 7 4 lb ft Coolant drain bolt 10 N m 1 0 kgf m 7 4 lb ft 1 1 1 1 2 T R New T R 1 4 2 2 3 ...

Page 270: ...WATER PUMP 6 9 ...

Page 271: ...FUEL PUMP 7 2 CHECKING THE FUEL PUMP BODY 7 2 CHECKING THE FUEL PUMP OPERATION 7 2 INSTALLING THE FUEL PUMP 7 3 INSTALLING THE FUEL TANK 7 3 THROTTLE BODY 7 4 CHECKING THE INJECTOR 7 7 CHECKING THE THROTTLE BODY 7 7 CHECKING THE FUEL PRESSURE 7 7 ADJUSTING THE THROTTLE POSITION SENSOR 7 8 ...

Page 272: ... left right 1 Fuel pump coupler Fuel hose 1 1 Disconnect 2 Fuel tank 1 3 Fuel pump bracket 1 4 Fuel pump 1 5 Fuel filter 1 6 Thermistor cover 1 7 Fuel pump gasket 1 8 Rubber damper 4 3 5 2 2 4 7 2 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 9 N m 0 9 kgf m 6 6 lb ft 7 N m 0 7 kgf m 5 2 lb ft 1 8 8 8 1 7 N m 0 7 kgf m 5 2 lb ft 6 5 ...

Page 273: ...tor cover 1 on the end of the hose in the direction of the arrow shown press the two buttons 2 on the sides of the connector and then remove the hose Before removing the hose place a few cloths in the area under where it will be removed To prevent sand dust and other foreign mate rials from entering the fuel pump install the in cluded fuel hose joint cover 1 3 and the fuel hose joint cover 2 4 ont...

Page 274: ...Install Fuel tank 2 Connect Fuel hose NOTICE ECA24740 Connect the fuel hose securely and check that the orientation of the installed fuel hose holder is correct Take care not to kink or pinch the fuel hose TIP Insert the fuel hose into the fuel pipe securely until you hear a click Slide the fuel hose connector cover 1 at the hose end in the direction of the arrow Install the fuel hose connector ho...

Page 275: ... 2 Ignition coil 1 3 Intake air temperature sensor coupler 1 Disconnect 4 Breather hose 1 5 Air filter case 1 6 Fuel injector coupler 1 Disconnect 7 Intake air pressure sensor coupler 1 Disconnect 8 Throttle position sensor coupler 1 Disconnect 9 Cover 1 10 Throttle cable cover 1 3 2 7 N m 0 7 kgf m 5 2 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 7 N m 0 7 kgf m 5 2 lb ft 8 N m 0 8 kgf m 5 9 lb ft 2 2 2 10...

Page 276: ...side of the vehicle and then install the cover 12 Fuel hose 1 13 Throttle body 1 14 Exhaust pipe bracket 1 15 Throttle body joint 1 7 N m 0 7 kgf m 5 2 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 7 N m 0 7 kgf m 5 2 lb ft 8 N m 0 8 kgf m 5 9 lb ft 10 N m 1 0 kgf m 7 4 lb ft 3 0 N m 0 30 kgf m 2 2 lb ft 4 3 N m 0 43 kgf m 3 2 lb ft 3 0 N m 0 30 kgf m 2 2 lb ft 3 5 N m 0 35 kgf m 2 6 lb ft 2 2 2 11 11 11 11 ...

Page 277: ...g the injector Order Job Parts to remove Q ty Remarks 1 Fuel inlet pipe 1 2 Injector 1 3 Gasket 1 4 Throttle position sensor 1 5 Intake air pressure sensor 1 1 2 2 5 4 3 3 5 N m 0 35 kgf m 2 6 lb ft 3 5 N m 0 35 kgf m 2 6 lb ft ...

Page 278: ...If the throttle body is subject to strong shocks or dropped during cleaning re place it Do not use any caustic carburetor cleaning solution Do not directly push the throttle valves to open them Do not loosen the throttle valve stopper screw 1 throttle valve pulley nut 2 throttle valve screw 3 or starter knob nut 4 A loss of performance may occur Do not use compressed air to clean the throttle body...

Page 279: ...nsor Refer to CHECKING THE THROTTLE PO SITION SENSOR INPUT VOLTAGE on page 8 57 2 Adjust Throttle position sensor angle a Connect the Yamaha diagnostic tool Refer to YAMAHA DIAGNOSTIC TOOL on page 8 21 b Temporary tighten the throttle position sensor c Check that the throttle grip is fully closed d Connect the throttle position sensor to the wire harness e Set the Yamaha diagnostic tool to diag no...

Page 280: ...THROTTLE BODY 7 9 ...

Page 281: ...ILS FAULT CODE 8 23 FUEL PUMP SYSTEM 8 43 CIRCUIT DIAGRAM 8 43 TROUBLESHOOTING 8 45 ELECTRICAL COMPONENTS 8 46 CHECKING THE SWITCHES 8 47 CHECKING THE BULBS AND BULB SOCKETS 8 49 CHECKING THE FUSES 8 49 CHECKING AND CHARGING THE BATTERY 8 50 CHECKING THE RELAYS 8 51 CHECKING THE RELAY UNIT DIODE 8 52 CHECKING THE IGNITION SPARK GAP 8 53 CHECKING THE SPARK PLUG CAP 8 53 CHECKING THE IGNITION COIL 8...

Page 282: ...CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 8 57 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 8 58 CHECKING THE GEAR POSITION SWITCH 8 58 CHECKING THE INJECTOR 8 59 ...

Page 283: ......

Page 284: ...IGNITION SYSTEM 8 1 EAM20142 IGNITION SYSTEM EAM30277 CIRCUIT DIAGRAM ...

Page 285: ...7 Battery 8 Frame ground 9 Main fuse 10 Starter relay 11 Starter motor 12 Diode 1 13 Diode 2 14 CCU Communication Control Unit 20 ECU Engine Control Unit 21 Ignition coil 22 Spark plug 33 Engine stop switch 34 Gear position switch 35 Mode switch A Battery sub lead B Wire harness C Ignition coil sub lead D CCU sub lead ...

Page 286: ... page 8 50 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 12 NG Correct or replace the spark plug OK 5 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 53 OK The ignition system circuit is OK NG 6 Check the ignition coil Refer to CHECKING THE IGNI TION COIL on page 8 54 NG Replace t...

Page 287: ...mbly OK 10 Check the ignition system wire har ness Refer to CIRCUIT DIAGRAM on page 8 1 NG Repair or replace the wire harness OK Replace the ECU 1 Check the mode switch coupler connections NG Reconnect OK 2 Check the mode switch Refer to CHECKING THE SWITCHES on page 8 47 NG Replace the mode switch OK 3 Check the ignition system wire har ness Refer to CIRCUIT DIAGRAM on page 8 1 NG Repair or repla...

Page 288: ...ELECTRIC STARTING SYSTEM 8 5 EAM20143 ELECTRIC STARTING SYSTEM EAM30279 CIRCUIT DIAGRAM ...

Page 289: ...ain relay 6 Engine ground 7 Battery 8 Frame ground 9 Main fuse 10 Starter relay 11 Starter motor 12 Diode 1 13 Diode 2 20 ECU Engine Control Unit 33 Engine stop switch 34 Gear position switch 36 Start switch 37 Diode 3 A Battery sub lead B Wire harness ...

Page 290: ...HE RE LAYS on page 8 51 NG Replace the main relay OK 4 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 55 OK Starter motor is OK Perform the electric starting system troubleshooting starting with step 6 NG 5 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 44 NG Repair or replace the starter motor OK 6 Check the diodes Diode 1 diode ...

Page 291: ...rt switch Refer to CHECKING THE SWITCHES on page 8 47 NG Replace the start switch OK 10 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 5 NG Properly connect or repair the starting sys tem s wiring OK Replace the ECU ...

Page 292: ...CHARGING SYSTEM 8 9 EAM20144 CHARGING SYSTEM EAM30282 CIRCUIT DIAGRAM ...

Page 293: ...CHARGING SYSTEM 8 10 2 AC magneto 3 Rectifier regulator 6 Engine ground 7 Battery 8 Frame ground 9 Main fuse A Battery sub lead B Wire harness ...

Page 294: ... battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 50 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 55 NG Replace the rectifier regulator OK 5 Check the stator coil assembly Refer to CHECKING THE STA TOR COIL on page 8 55 NG Replace the stator coil assembly OK 6 Check the charging sy...

Page 295: ...CHARGING SYSTEM 8 12 ...

Page 296: ...SIGNALING SYSTEM 8 13 EAM20154 SIGNALING SYSTEM EAM30348 CIRCUIT DIAGRAM ...

Page 297: ...SYSTEM 8 14 4 Joint connector 5 Main relay 7 Battery 8 Frame ground 9 Main fuse 15 Warning light 16 Fuel level warning light 18 Resistor 20 ECU Engine Control Unit 24 Fuel sender A Battery sub lead B Wire harness ...

Page 298: ...nals Recharge or replace the battery OK 3 Check the main relay Refer to CHECKING THE RE LAYS on page 8 51 NG Replace the main relay OK 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 13 NG Properly connect or repair the signaling system s wiring OK This circuit is OK 1 Check the fuel level warning light bulb and socket Refer to CHECKING THE BULBS AND BULB SOCKETS on...

Page 299: ...SIGNALING SYSTEM 8 16 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 13 NG Properly connect or repair the signaling system s wiring OK Replace the ECU ...

Page 300: ...FUEL INJECTION SYSTEM 8 17 EAM20145 FUEL INJECTION SYSTEM EAM30284 CIRCUIT DIAGRAM ...

Page 301: ...ng light 19 Yamaha diagnostic tool coupler 20 ECU Engine Control Unit 21 Ignition coil 22 Spark plug 23 Fuel injector 25 Fuel pump 26 Radiator fan motor fuse 27 Radiator fan motor lead coupler OPTION 28 Radiator fan motor relay 29 Intake air temperature sensor 30 Coolant temperature sensor 31 Throttle position sensor 32 Intake air pressure sensor 33 Engine stop switch 34 Gear position switch A Bat...

Page 302: ...cation and fuel injection system operation The engine trouble warning light flashes when any one of the following conditions is present and the start switch is pushed Checking the engine trouble warning light The engine trouble warning light comes on for around 2 seconds when pushing the start switch to turn on the engine trouble warning light comes on while the start switch is being pushed Warnin...

Page 303: ...n system Refer to Confirmation of service com pletion in the appropriate table in TROUBLESHOOTING DETAILS FAULT CODE on page 8 23 4 After pushing the engine stop switch push the start switch to check whether the fault code number is displayed TIP If another fault code number is displayed repeat steps 1 to 4 until no fault code number is displayed 5 Erase the malfunction history in the diagnostic m...

Page 304: ...FI diagnostic tool sub lead to the Yamaha diagnostic tool WARNING EWA20450 Never connect the sub lead special tool to the battery Otherwise because of excessive cur rent flow the sub lead can catch fire and the battery could be damaged TIP Prepare the fully charged 12 V lead battery for yourself Replace the vehicle battery with a lead battery 12 V For information on how to connect and use the Yama...

Page 305: ...nit 2 Lead battery 12 V 3 Vehicle battery 4 Vehicle 5 Coupler for connecting optional part 6 FI diagnostic tool sub lead 7 Sub harness included with the Yamaha diag nostic tool 8 Vehicle communication cable included with the Yamaha diagnostic tool 9 Yamaha diagnostic tool ...

Page 306: ...2 Item Crankshaft position sensor no normal signals are received from the crankshaft position sensor Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No Diagnostic tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of crankshaft posi tion sensor coupler Check the locking condition of t...

Page 307: ... of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Defective crankshaft position sensor Check the crankshaft position sensor Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on page 8 54 Crank the engine and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Rec...

Page 308: ...de using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 4 4 Mounted condition of intake air pressure sensor Check for looseness or pinch ing Check the mounted position for correctness Improperly mounted sensor Remount or replace the sensor Start switch to ON main relay ON and then check the condi tion o...

Page 309: ...sensor hose Start the engine and let it idle for approximately 5 seconds fully close the throttle valve Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 3 and finish the service Condition is Detected Go to item 2 2 Defective intake air pressure sensor Execute the diagnostic mode Code No 03 Atmospheric pressure at the c...

Page 310: ...er Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or bro ken terminals and locking condi tion of the pins Improperly connected Con nect the coupler securely or repair replace the wire harness Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered ...

Page 311: ...ened 86 92 displays Incorrect display range Replace the throttle position sensor Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 7 7 Faulty ECU Replace the ECU Service is finished 8 Delete the fault code Confirm that t...

Page 312: ...ostic tool Condition is Recovered Go to item 4 and finish the service Condition is Detected Go to item 3 3 Faulty ECU Replace the ECU Service is finished 4 Delete the fault code Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No 21 Item Coolant temperature sensor open or short circuit detected Fail safe system Able...

Page 313: ... condition of coolant temperature sensor Check for looseness or pinch ing Check the mounted position for correctness Improperly mounted sensor Remount or replace the sensor Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to it...

Page 314: ...etected Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or bro ken terminals and locking condi tion of the pins Improperly connected Con nect the coupler securely or repair replace the wire harness Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction...

Page 315: ...Unable to drive vehicle Diagnostic code No 08 Diagnostic tool display Displays the lean angle sensor output voltage 0 4 1 4 V upright 3 7 4 4 V overturned Procedure Remove the ECU and incline it 45 or more Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 The vehicle has overturned Raise the vehicle upright Start switch to ON main relay ON wait 10 ...

Page 316: ...tion 1 Connection of ignition coil cou pler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or bro ken terminals and locking condi tion of the pins Improperly connected Con nect the coupler securely or repair replace the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction...

Page 317: ...ion of ignition coil Check for looseness or pinch ing Check the mounted condition for correctness Improperly mounted sensor Remount or replace the ignition coil Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go...

Page 318: ...njector Refer to CHECKING THE INJECTOR on page 8 59 Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 3 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the...

Page 319: ...y and CCU Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 09 Diagnostic tool display Fuel system voltage Approximately 12 0 V Procedure Disconnect the main relay and push the start switch Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of main relay cou pler Check the locking condition of the coupler Disc...

Page 320: ...he engine stop switch alternately to switch the power supply main relay from ON OFF ON Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 4 4 Defective main relay No operating sound Replace the main relay Or execute the diagnostic mode Code No 09 Fuel system volta...

Page 321: ...tion Change the CO concentration and rewrite in EEPROM After this adjustment push the engine stop switch and then push the start switch Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 5 and finish the service Condition is Detected Repeat item 1 If the same number is indicated...

Page 322: ...and locking condition of the pins Improperly connected Con nect the coupler securely or repair replace the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 3 Wire harness continuity Open...

Page 323: ...ode No Diagnostic tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Faulty ECU Replace the ECU Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Check that the fault code num ber is not displayed Fault code No 70 Item Engine forcibly stops...

Page 324: ...the fault code Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No 70 Item Engine forcibly stops when the vehicle is left idling for a long period of time ...

Page 325: ...FUEL INJECTION SYSTEM 8 42 ...

Page 326: ...FUEL PUMP SYSTEM 8 43 EAM20146 FUEL PUMP SYSTEM EAM30287 CIRCUIT DIAGRAM ...

Page 327: ...YSTEM 8 44 2 AC magneto 3 Rectifier regulator 4 Joint connector 6 Engine ground 7 Battery 8 Frame ground 9 Main fuse 20 ECU Engine Control Unit 25 Fuel pump 33 Engine stop switch A Battery sub lead B Wire harness ...

Page 328: ... on page 8 49 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 50 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 47 NG Replace the engine stop switch OK 5 Check fuel pressure Refer to CHECKING THE FUEL PRESSURE on page 7 7 NG Replace the fuel pump OK 6 Check t...

Page 329: ...Rectifier regulator 5 Mode switch 6 Intake air temperature sensor 7 ECU Engine Control Unit 8 Ignition coil 9 Resistor 10 CCU Communication Control Unit 11 Starter relay 12 Main fuse 13 Battery 14 Radiator fan motor fuse 15 Radiator fan motor relay 16 Main relay 17 Gear position switch 18 Fuel pump 19 Coolant temperature sensor ...

Page 330: ...ELECTRICAL COMPONENTS 8 47 EAM30289 CHECKING THE SWITCHES Y W P Sb 3 1 4 2 P Sb B W R L B R Y W B 1 Engine stop switch 2 Mode switch 3 Gear position switch 4 Engine start switch ...

Page 331: ...hecking for continuity switch back and forth between the switch positions a few times Terminal connections of the switch are shown in the terminal connection diagram below The switch positions a are shown in the far left column and the switch lead colors are shown in the top row in the switch illustration TIP indicates continuity between switch terminals i e a closed circuit at each switch positio...

Page 332: ...note the following a Install a good bulb into the bulb socket b Connect the digital circuit tester probes to the respective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity re place the bulb socket EAM30290 CHECKING THE FUSES The following procedure applies to all of the fus es 1 Remove Seat Refer to GENERAL CHASSIS on page 4 1 2 Check M...

Page 333: ... possible A long state of discharge below 10 V will damage the battery Do not use the specified battery charger to charge a battery other than the lithium ion battery Otherwise the battery or charger could be damaged Be careful not to drop the battery or subject it to strong impacts Avoid charging the battery at high temper atures of 65 C 149 F or more or low tem peratures under 0 C 32 F A control...

Page 334: ...etween the battery terminals 13 25 V or more The battery is normal Checking is finished Less than 13 25 V Go to step c c Connect the battery charger special tool to the battery and charge it TIP For instructions on charging and handling the battery charger refer to the battery charger s in struction manual d If the battery is hot wait until the battery has cooled down to the ambient tempera ture e...

Page 335: ...ve battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 to 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 to 4 2 1 3 4 R W Br W R Y L 1 2 3 4 L R Br R R R W 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Conti...

Page 336: ...5 CHECKING THE SPARK PLUG CAP 1 Remove Spark plug cap from the spark plug lead 2 Check Spark plug cap resistance Out of specification Replace a Connect the digital circuit tester to the spark plug cap No continuity Positive tester probe Blue White 1 Negative tester probe Blue Green Blue 2 Continuity Positive tester probe Blue Green Blue 2 Negative tester probe Blue White 1 No continuity Positive t...

Page 337: ...he wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace a Connect the digital circuit tester to the crankshaft position sensor coupler Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Primary coil resistance 2 16 2 64 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Positive tester probe ...

Page 338: ...at is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAM30300 CHECKING THE STATOR COIL 1 Disconnect Stator coil assembly coupler from the wire harness 2 Check Stator coil assembly resistance O...

Page 339: ...ness 2 Check Resistor resistance Out of specification Replace the resistor a Connect the digital circuit tester to the resistor as shown b Measure the resistance of the resistor Regulated voltage DC 14 0 14 8 V Digital tachometer 90890 06760 Digital tachometer YU 39951 B Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Positive tester probe Red 1 Negative test...

Page 340: ...at the temperatures indicated in the table EAM30305 CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1 Check Throttle position sensor input voltage Out of specification Replace the ECU a Connect the test harness S pressure sensor 3P to the throttle position sensor coupler and the wire harness b Connect the digital circuit tester DCV to the test harness S pressure sensor 3P Coolant temperature s...

Page 341: ...ntake air temperature sensor re sistance 5400 6600 at 0 C 5400 6600 at 32 F Intake air temperature sensor re sistance 289 391 at 80 C 289 391 at 176 F Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Positive tester probe Brown White 1 Negative tester probe Black Blue 2 2 1 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 ...

Page 342: ...Disconnect the fuel injector coupler from the fuel injector b Connect the digital circuit tester to the fuel injector coupler c Measure the fuel injector resistance Resistance 12 0 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Positive tester probe Injector terminal 1 Negative tester probe Injector terminal 2 c b a Y W P Sb d e f 3 1 2 1 2 ...

Page 343: ...G OF COOLING SYSTEM 9 7 TROUBLESHOOTING OF BRAKE 9 8 TROUBLESHOOTING OF SUSPENSION 9 8 TROUBLESHOOTING OF STEERING HANDLING 9 10 TROUBLESHOOTING OF CHARGING SYSTEM 9 11 TROUBLESHOOTING OF SIGNALING SYSTEM 9 11 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 12 SELF DIAGNOSTIC FUNCTION TABLE FOR FUEL INJECTION SYSTEM 9 12 DIAGNOSTIC CODE SENSOR OPERATION TABLE 9 12 DIAGNOSTIC CODE ACTUATOR OPE...

Page 344: ...STEM on page 8 5 Starter motor operates but the engine does not crank Starter clutch malfunction Replace the starter clutch Improper oil grade starter clutch slipping Change to recommended engine oil Stuck piston or seized crankshaft Disassemble and check the engine Replace defective parts Symptom Possible cause Actions Spark plug does not produce a spark Refer to TROUBLESHOOTING under IGNITION SY...

Page 345: ...lace the piston and piston rings as a set Seized or damaged piston Replace the piston and piston rings as a set Worn or damaged cylinder bore Replace the cylinder piston and piston rings as a set Symptom Possible cause Actions Spark plug does not produce a spark Incorrect spark plug gap Adjust the spark plug gap Worn or damaged spark plug Replace the spark plug Defective spark plug cap Replace the...

Page 346: ...pecified torque Clogged air filter element Clean or replace the air filter ele ment Incorrect oil level high Adjust the oil level to the specified level Symptom Possible cause Actions Noise heard from around cylinder head Incorrect valve clearance too wide Adjust the valve clearance Fatigued or broken valve spring Replace the valve spring Worn or damaged camshaft lobe Replace the camshaft Worn or ...

Page 347: ...ive gear Replace the balancer drive gear and balancer shaft as a set Worn or damaged big end bearing Replace the big end bearing Worn or damaged crankshaft jour nal bearing Replace the crankshaft journal bearing Worn or damaged balancer shaft journal bearing Replace the balancer shaft journal bearing Symptom Possible cause Actions Clutch slippage Improperly assembled clutch Reassemble the clutch I...

Page 348: ... bushing Replace the clutch housing Improperly installed pull lever Align the match mark on the pull lever before installation Incorrect oil level Adjust the engine oil level to the specified level Incorrect oil viscosity high Change to recommended engine oil Deteriorated oil Change to recommended engine oil Clutch noise Damaged or worn primary driven gear Replace the primary drive gear or cranksh...

Page 349: ...transmis sion gears Remove foreign object from trans mission gears Seized transmission gear Replace the seized gear and the axle as a set Improperly assembled transmis sion Reassemble the transmission axle assembly Jumps out of gear Incorrect shift pedal position Adjust the shift pedal position Improperly returned stopper lever Replace the stopper lever spring Bent or worn shift fork Replace the s...

Page 350: ...Repair the radiator fin or replace the radiator Damaged or faulty water pump Replace the water pump Damaged hoses or pipes Replace the hose or pipe Improperly connected hoses or pipes Connect the hoses and pipes properly Damaged throttle body joint Replace the throttle body joint Loose throttle body joint Tighten the throttle body joint bolts to the specified torque Clogged air filter element Clea...

Page 351: ... Damaged brake hose and brake pipe Replace the brake hose and brake pipe Oil or grease on the brake disc or brake pad Clean the brake disc or brake pad Insufficient lubrication of brake lever or brake pedal pivot Lubricate the brake lever or brake pedal pivot Symptom Possible cause Actions Front fork is hard Bent or damaged inner tube Replace the inner tube Bent or damaged outer tube Replace the o...

Page 352: ...per rod assembly bolt Tighten the damper rod assembly bolt to the specified torque Damaged damper rod assembly bolt copper washer Replace the damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring Replace the cap bolt O ring Rear suspension is hard Bent or damaged rear shock absorber rod Replace the rear shock absorber Bent swingarm pivot shaft Replace the swingarm pivot shaft D...

Page 353: ...ied torque Worn bearing or bearing race Replace the bearing and bearing race as a set Warped front fork Repair or replace the front fork Bent front wheel axle Replace the front wheel axle Incorrect tire pressure Adjust to the specified tire pres sure Worn deformed or incorrect tire Replace the tire Heavy steering Lower ring nut is tightened too tight Tighten the lower ring nut to the specified tor...

Page 354: ...le nut to the specified torque Loose swingarm pivot shaft Tighten the swingarm pivot shaft to the specified torque Bent or damaged swingarm Replace the swingarm bearing Damaged or worn swingarm bear ing or bushing Replace the swingarm bearing or bushing Symptom Possible cause Actions Battery is not charged Refer to TROUBLESHOOTING under CHARGING SYSTEM on page 8 9 Symptom Possible cause Actions In...

Page 355: ...lead of the ignition coil 8 33 39 Injector open or short circuit detected 8 35 41 ECU built in lean angle sensor malfunction 8 36 43 Fuel system voltage incorrect voltage supplied to the main relay and CCU 8 36 44 EEPROM fault code number an error is detected while reading or writing on EEPROM 8 38 46 Vehicle system power supply normal voltage is not supplied to the ECU 8 39 50 ECU faulty ECU memo...

Page 356: ...Operate the shift pedal Gear in 1st or 2nd ON Gear in other than 1st or 2nd OFF 60 EEPROM fault code display No fault 00 CO adjustment valve 01 Power Tuner injection cor rection setting 0 8 or Power Tuner ignition timing correc tion setting 0 8 07 61 Malfunction history code display 1 There is no history 00 There is some history Other Displays the fault code of 62 Malfunction history code erasure ...

Page 357: ...the ignition coil five times at one second intervals WARNING on the Yamaha diagnostic tool blinks five times when the ignition coil is actu ated Check that a spark is gener ated five times Connect an ignition checker 36 Injector Actuates the injector five times at one second intervals WARNING on the Yamaha diagnostic tool blinks five times when the injector is actuated TIP Before performing this o...

Page 358: ...SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 15 ...

Page 359: ...0 1 FRONT FORK SETTING 10 2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL 10 2 SETTING OF SPRING AFTER REPLACEMENT 10 2 FRONT FORK SETTING PARTS 10 3 REAR SUSPENSION SETTING 10 3 CHOOSING SET LENGTH 10 3 SETTING OF SPRING AFTER REPLACEMENT 10 4 REAR SHOCK ABSORBER SETTING PARTS 10 4 SUSPENSION SETTING FRONT FORK 10 6 SUSPENSION SETTING REAR SHOCK ABSORBER 10 7 ...

Page 360: ...he end of the straight line with care taken to avoid the en gine over revving TIP Riding technique varies from rider to rider and the performance of a machine also vary from machine to machine Therefore do not imitate other rider s settings from the beginning but choose your own setting according to the level of your riding technique EAM30169 DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS EAM30170 T...

Page 361: ...e air spring characteristics to have a ten dency to be stiffer with the consequent dete riorated performance and characteristics Therefore adjust the front fork within the specified range EAM30173 SETTING OF SPRING AFTER REPLACEMENT As the front fork setting can be easily affected by the rear suspension take care so that the front and the rear are balanced in position etc when setting the front fo...

Page 362: ... the rear fender holding bolt 2 Remove the stand or block from the engine and with a rider astride the seat measure the sunken length b between the rear wheel axle center and the rear fender holding bolt 3 Loosen the locknut 1 and make adjustment by turning the adjuster 2 to achieve the standard figure from the subtraction of the length b from the length a TIP If the machine is new and after it is...

Page 363: ...ping force WARNING EWA19200 When using a rear shock absorber other than currently installed use the one whose overall length a does not exceed the stan dard as it may result in faulty performance Never use one whose overall length is great er than standard EAM30178 REAR SHOCK ABSORBER SETTING PARTS Rear shock spring 1 TIP The I D mark a is marked at the end of the spring Spring specification varie...

Page 364: ...RBER AS SEMBLY on page 3 30 Spring preload adjusting positions Minimum Position in which the spring is turned in 1 5 mm 0 06 in from its free length Standard Position in which the spring is turned in 10 0 mm 0 39 in from its free length Maximum Position in which the spring is turned in 18 0 mm 0 71 in from its free length 1 a ...

Page 365: ...oticeable scars etc If any replace affected parts Slide metal Replace with a new one for extended use Piston metal Replace with a new one for extended use Lower bracket tightening torque Retighten to specified torque Poor initial move ment Rebound damp ing force Turn adjuster counterclockwise about 2 clicks to decrease damping Oil seals Apply grease in oil seal wall Soft over entire range bottomin...

Page 366: ...ount Increase oil amount by about 5 cm 0 2 US oz 0 2 Imp oz Obtrusive front tending to upper front posture Compression damping force Turn adjuster counterclockwise about 2 clicks to decrease damping Balance with rear end Set sunken length for 90 95 mm 3 5 3 7 in when one passenger is astride seat upper rear pos ture Spring Replace with soft spring Oil amount Decrease oil amount by about 5 10 cm 0 ...

Page 367: ... senger is astride seat Spring Replace with soft spring Bottoming out High compres sion damping Turn adjuster clockwise about 1 6 turn to increase damping Spring set length Set sunken length for 90 100 mm 3 5 3 9 in when one pas senger is astride seat Spring Replace with stiff spring Bouncing Rebound damp ing force Turn adjuster clockwise about 2 clicks to increase damping Spring Replace with soft...

Page 368: ...CHASSIS 10 9 ...

Page 369: ...fan motor relay 29 Intake air temperature sensor 30 Coolant temperature sensor 31 Throttle position sensor 32 Intake air pressure sensor 33 Engine stop switch 34 Gear position switch 35 Mode switch 36 Start switch 37 Diode 3 A Battery sub lead B Wire harness C Ignition coil sub lead D CCU sub lead EAM30323 COLOR CODE B Black Br Brown Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue ...

Page 370: ......

Page 371: ...ance Buy with confidence knowing your Genuine Yamaha Accessories will fit right and perform right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha from the inside out Genuine Yamaha Service Manuals Get the same factory man...

Page 372: ......

Page 373: ...YZ450FXN 2022 WIRING DIAGRAM BEX 2819U 11_W D indd 1 2021 05 06 15 18 37 ...

Page 374: ...YZ450FXN 2022 WIRING DIAGRAM BEX 2819U 11_W D indd 2 2021 05 06 15 18 37 ...

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