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YZ450F (D) : Owner'S Service Manual Manuel D'Atelier Du Proprietaire Fahrer-Und Wartungshandbuch
YZ450F (D) : Owner'S Service Manual Manuel D'Atelier Du Proprietaire Fahrer-Und Wartungshandbuch
1 16:45 ページ 1
2013
q Read this manual carefully before operating this vehicle.
q Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
YZ450F(D)
OWNER’S SERVICE MANUAL
MANUEL D’ATELIER DU
PROPRIETAIRE
FAHRER- UND
WARTUNGSHANDBUCH
2013
YZ450F(D)
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
2012.05—1.2 × 1 !
33D-28199-83
(E, F, G)
33D-9-83_cover 12.5.1 16:45 ページ 2
Q Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
Q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit
être remis avec le véhicule en cas de vente de ce dernier.
Q Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
Diese Bedienungsanleitung muss, wenn das Fahrzeug verkauft wird, beim Fahrzeug verbleiben.
2013
Read this manual carefully before operating this vehicle.
YZ450F(D)
33D-28199-83-E0
YZ450F(D)
OWNER'S SERVICE MANUAL
©2012 by Yamaha Motor Co., Ltd.
1st Edition, April 2012
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
FOREWORD IMPORTANT MANUAL • ALWAYS MAINTAIN YOUR MA-
INFORMATION CHINE IN PROPER WORKING
INTRODUCTION Particularly important information is ORDER.
Congratulations on your purchase of distinguished in this manual by the For safety and reliability, the ma-
a Yamaha YZ series. This model is following notations. chine must be properly maintained.
the culmination of Yamaha's vast ex- Always perform the pre-operation
perience in the production of paceset- checks indicated in this manual.
ting racing machines. It represents This is the safety alert symbol. It is Correcting a mechanical problem
the highest grade of craftsmanship used to alert you to potential per- before you ride may prevent an ac-
and reliability that have made Yama- sonal injury hazards. Obey all safe- cident.
ha a leader. ty messages that follow this • GASOLINE IS HIGHLY FLAMMA-
This manual explains operation, in- symbol to avoid possible injury or BLE.
spection, basic maintenance and tun- death. Always turn off the engine while re-
ing of your machine. If you have any fueling. Take care to not spill any
questions about this manual or your gasoline on the engine or exhaust
machine, please contact your Yama- A WARNING indicates a hazardous system. Never refuel in the vicinity
ha dealer. situation which, if not avoided, of an open flame, or while smoking.
could result in death or serious in- • GASOLINE CAN CAUSE INJURY.
Yamaha continually seeks advance- jury. If you should swallow some gaso-
ments in product design and quality. line, inhale excess gasoline vapors,
Therefore, while this manual contains or allow any gasoline to get into
the most current product information A NOTICE indicates special pre- your eyes, contact a doctor immedi-
available at the time of printing, there cautions that must be taken to ately. If any gasoline spills onto
may be minor discrepancies between avoid damage to the vehicle or oth- your skin or clothing, immediately
your machine and this manual. If you er property. wash skin areas with soap and wa-
have any questions concerning this ter, and change your clothes.
manual, please consult your Yamaha • ONLY OPERATE THE MACHINE
dealer. A TIP provides key information to IN AN AREA WITH ADEQUATE
make procedures easier or clearer. VENTILATION.
SAFETY INFORMATION Never start the engine or let it run
PLEASE READ THIS MANUAL THIS MACHINE IS DESIGNED for any length of time in an enclosed
CAREFULLY AND COMPLETELY STRICTLY FOR COMPETITION area. Exhaust fumes are poison-
BEFORE OPERATING THIS MA- USE, ONLY ON A CLOSED ous. These fumes contain carbon
CHINE. DO NOT ATTEMPT TO OP- COURSE. It is illegal for this machine monoxide, which by itself is odor-
ERATE THIS MACHINE UNTIL YOU to be operated on any public street, less and colorless. Carbon monox-
HAVE ATTAINED A SATISFACTO- road, or highway. Off-road use on ide is a dangerous gas which can
RY KNOWLEDGE OF ITS CON- public lands may also be illegal. cause unconsciousness or can be
TROLS AND OPERATING Please check local regulations before lethal.
FEATURES AND UNTIL YOU HAVE riding. • PARK THE MACHINE CAREFUL-
BEEN TRAINED IN SAFE AND • THIS MACHINE IS TO BE OPER- LY; TURN OFF THE ENGINE.
PROPER RIDING TECHNIQUES. ATED BY AN EXPERIENCED RID- Always turn off the engine if you are
REGULAR INSPECTIONS AND ER ONLY. going to leave the machine. Do not
CAREFUL MAINTENANCE, Do not attempt to operate this ma- park the machine on a slope or soft
ALONG WITH GOOD RIDING chine at maximum power until you ground as it may fall over.
SKILLS, WILL ENSURE THAT YOU are totally familiar with its character- • THE ENGINE, EXHAUST PIPE,
SAFETY ENJOY THE CAPABILI- istics. MUFFLER, AND OIL TANK WILL
TIES AND THE RELIABILITY OF • THIS MACHINE IS DESIGNED TO BE VERY HOT AFTER THE EN-
THIS MACHINE. BE RIDDEN BY THE OPERATOR GINE HAS BEEN RUN.
ONLY. Be careful not to touch them or to
Do not carry passengers on this allow any clothing item to contact
machine. them during inspection or repair.
• ALWAYS WEAR PROTECTIVE • PROPERLY SECURE THE MA-
APPAREL. CHINE BEFORE TRANSPORTING
When operating this machine, al- IT.
ways wear an approved helmet with For safety, drain the gasoline from
goggles or a face shield. Also wear the fuel tank before transporting the
heavy boots, gloves, and protective vehicle.
clothing. Always wear proper fitting
clothing that will not be caught in
any of the moving parts or controls
of the machine.
HOW TO USE THIS MANUAL
FINDING THE REQUIRED PAGE
1. This manual consists of eight
chapters; "General Information",
"Specifications", "Regular inspec-
tion and adjustments", "Engine",
"Chassis", "Fuel system", "Electri-
cal" and "Tuning".
2. The table of contents is at the be-
ginning of the manual. Look over
the general layout of the book be-
fore finding then required chapter
and item.
Bend the book at its edge, as
shown, to find the required fore
edge symbol mark and go to a
page for required item and de-
scription.
MANUAL FORMAT
All of the procedures in this manual
are organized in a sequential, step-
by-step format. The information has
been complied to provide the me-
chanic with an easy to read, handy
reference that contains comprehen-
sive explanations of all disassembly,
repair, assembly, and inspection op-
erations.
In this revised format, the condition of
a faulty component will precede an
arrow symbol and the course of ac-
tion required will follow the symbol,
e.g.,
• Bearings
Pitting/damage → Replace.
2. Numbers "2" are given in the or- 4. A job instruction chart "4" accom-
HOW TO READ DESCRIPTIONS
der of the jobs in the exploded di- panies the exploded diagram,
To help identify parts and clarify pro-
agram. A number that is enclosed providing the order of jobs, names
cedure steps, there are exploded dia-
by a circle indicates a disassem- of parts, notes in jobs, etc.
grams at the start of each removal
bly step. 5. For jobs requiring more informa-
and disassembly section.
3. An explanation of jobs and notes tion, the step-by-step format sup-
1. An easy-to-see exploded diagram
is presented in an easy-to-read plements "5" are given in addition
"1" is provided for removal and
way by the use of symbol marks to the exploded diagram and job
disassembly jobs.
"3". The meanings of the symbol instruction chart.
marks are given on the next page.
3 5
ILLUSTRATED SYMBOLS (Refer to Illustrated symbols "1" to "7" are used 13. Apply silicone grease
the illustration) to identify the specifications appear- Illustrated symbols "14" to "15" in the
ing in the text. exploded diagrams indicate where to
1. With engine mounted apply a locking agent and where to in-
2. Filling fluid stall new parts.
3. Lubricant 14. Apply locking agent (LOC-
4. Special tool TITE®)
5. Tightening 15. Use new one
6. Specified value, Service limit
7. Resistance (Ω), Voltage (V),
Electric current (A)
Illustrated symbols "8" to "13" in the
exploded diagrams indicate grade of
lubricant and location of lubrication
point.
8. Apply engine oil
9. Apply molybdenum disulfide oil
10. Apply brake fluid
11. Apply lightweight lithium-soap
base grease
12. Apply molybdenum disulfide
grease
TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
REGULAR INSPECTION AND
ADJUSTMENTS 3
ENGINE 4
CHASSIS 5
FUEL SYSTEM 6
ELECTRICAL 7
TUNING 8
CONTENTS
GENERAL INFORMATION
LOCATION OF IMPORTANT LABELS
Please read the following important labels carefully before operating this vehicle.
CANADA
1-1
LOCATION OF IMPORTANT LABELS
EUROPE
1-2
LOCATION OF IMPORTANT LABELS
AUS, NZ, ZA
1-3
LOCATION OF IMPORTANT LABELS
Familiarize yourself with the following pictograms and read the explanatory text.
Read Owner's service manual.
This unit contains high-pressure nitrogen gas. Mishandling can cause explosion. Do not incinerate,
puncture or open.
Turn off the main switch after riding to avoid draining the battery.
1-4
DESCRIPTION
DESCRIPTION
• The machine you have purchased may differ slightly from those shown in the following.
• Designs and specifications are subject to change without notice.
1-5
CONSUMER INFORMATION
CONSUMER INFORMATION
There are two significant reasons for
knowing the serial number of your
machine:
1. When ordering parts, you can
give the number to your Yamaha
dealer for positive identification of
the model you own.
2. If your machine is stolen, the au-
thorities will need the number to
search for and identify your ma-
chine.
VEHICLE IDENTIFICATION
NUMBER
The vehicle identification number "1"
is stamped on the right of the steering
head pipe.
MODEL LABEL
The model label "1" is affixed to the
frame under the rider's seat. This in-
formation will be needed to order
spare parts.
1-6
FEATURES
FEATURES
OUTLINE OF THE FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in ac-
cordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system,
the air-fuel ratio of the mixture that is supplied to the combustionchamber is created by the volume of the intake air and the
fuel that is metered by the jet used in the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating conditions,such as ac-
celeration, deceleration, or operating under a heavy load. Carburetors that meter thefuel through the use of jets have been
provided with various auxiliary devices, so that an optimum air-fuel ratio can be achieved to accommodate the constant
changes in the operating conditions of the engine.
This model has adopted an electronically controlled fuel injection (FI) system, in place of the conventional carburetor sys-
tem. This system can achieve an optimum air-fuel ratio required bythe engine at all times by using a microprocessor that
regulates the fuel injection volume according tothe engine operating conditions detected by various sensors.
1-7
FEATURES
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains thefuel pressure that is
applied to the fuel injector at only 324 kPa (3.24 kgf/cm², 47.0 psi). Accordingly,when the energizing signal from the ECU
energizes the fuel injector, the fuel passage opens, causingthe fuel to be injected into the intake manifold only during the
time the passage remains open. Therefore, the longer the length of time the fuel injector is energized (injection duration),
the greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized (in-
jection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the throttle position
sensor, coolant temperature sensor, atmospheric pressure sensor, lean angle sensor, crankshaft position sensor, intake
air pressure sensor and intake air temperature sensor enable the ECU to determine the injection duration. The injection
timing is determined through the signals from the crankshaft position sensor. As a result, the volume of fuel that is required
by the engine can be supplied at all times in accordance with the driving conditions.
4
C
1
3
A 5
11
2
10
B
9
7
8
6
1-8
INCLUDED PARTS
VALVE JOINT
This valve joint "1" prevents fuel from
flowing out and is installed to the fuel
tank breather hose. FUEL HOSE JOINT COVER
The fuel hose joint covers "1" are
In this installation, make sure the used to prevent mud, dust, and other
arrow faces the fuel tank and also foreign material from entering the fuel
downward. pump when the fuel hose is discon-
nected.
1-9
HANDLING THE ELECTRONIC PARTS
1-10
CHECKING OF CONNECTION
1. Probe
2. Coupler
REMOVING THE QUICK
FASTENER
4. Connect:
• Lead Do not push the center pin with too
• Coupler much force. Otherwise, the center
• Connector pin could be damaged.
1-11
SPECIAL TOOLS
SPECIAL TOOLS
The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will
help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for
the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order.
• For U.S.A. and Canada, use part number starting with "YM-", "YU-" or "ACC-".
• For others, use part number starting with "90890-".
Piston pin puller set This tool is used to remove the pis-
YU-1304, 90890-01304 ton pin.
1-12
SPECIAL TOOLS
Fork seal driver This tool is used when install the fork
YM-A0948, 90890-01502 oil seal.
1-13
SPECIAL TOOLS
Valve guide remover & installer set This tool is needed to remove and
90890-04016 install the valve guide.
1-14
SPECIAL TOOLS
1-15
SPECIAL TOOLS
YAMAHA Bond No. 1215 (Three- This sealant (Bond) is used for
Bond® No. 1215) crankcase mating surface, etc.
90890-85505
1-16
CONTROL FUNCTIONS
1-17
STARTING AND BREAK-IN
6. When the engine starts running, 6. Restart the engine and check the
warm it up one or two minutes at operation of the machine through-
• Unlike a two-stroke engine, this a steady speed (of 3,000 to 5,000 out its entire operating range. Re-
engine cannot be kick started r/min), and then return the starter start the machine and operate it
when the throttle is open be- knob/ idle screw to its original po- for about 10 to 15 more minutes.
cause the kickstarter may kick sition. The machine will now be ready to
back. Also, if the throttle is open race.
the air/fuel mixture may be too
lean for the engine to start.
• Before starting the machine, per- • After the break-in or before each
form the checks in the pre-opera- race, you must check the entire
tion check list. machine for loose fittings and
fasteners as per "TORQUE-
AIR FILTER MAINTENANCE CHECK POINTS". Tighten all
According to "CLEANING THE AIR such fasteners as required.
7. Push the engine stop switch "1".
FILTER ELEMENT" section in the • When any of the following parts
CHAPTER 3, apply the foam-air-filter have been replaced, they must
oil or its equivalent to the element. Do not warm up the engine for ex- be broken in.
(Excess oil in the element may ad- tended periods of time. CYLINDER AND CRANKSHAFT:
versely affect engine starting.) About one hour of break-in oper-
STARTING A COLD ENGINE ation is necessary.
1. Inspect the coolant level. PISTON, RING, VALVES, CAM-
2. Shift the transmission into neutral. SHAFTS AND GEARS:
3. Pull the starter knob/ idle screw These parts require about 30
"1" to its full length. minutes of break-in operation at
half-throttle or less. Observe the
Use the starter knob/ idle screw be- condition of the engine carefully
low an air temperature of 15°C during operation.
STARTING A WARM ENGINE
(59°F). To start a warm engine, make sure
that the starter (choke) knob/idling
screw is pushed in and the throttle is
closed, and then start the engine by
pushing the kickstarter crank.
1-18
TORQUE-CHECK POINTS
TORQUE-CHECK POINTS
Frame construction Frame to rear frame
Combined seat and fuel tank Fuel tank to frame
Exhaust system Silencer to rear frame
Engine mounting Frame to engine
Engine bracket to engine
Engine bracket to frame
Steering Steering stem to handlebar Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Suspension Front Steering stem to front fork Front fork to upper bracket
Front fork to lower bracket
Rear For link type Assembly of links
Link to frame
Link to rear shock absorber
Link to swingarm
Installation of rear shock absorber Rear shock absorber to frame
Installation of swingarm Tightening of pivot shaft
Wheel Installation of wheel Front Tightening of wheel axle
Tightening of axle holder
Rear Tightening of wheel axle
Wheel to rear wheel sprocket
Brake Front Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to handlebar
Tightening of bleed screw
Tightening of brake hose holder
Rear Brake pedal to frame
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw
Tightening of brake hose holder
Fuel system Fuel pump to fuel tank
Concerning the tightening torque, refer to "TIGHTENING TORQUES" section in the CHAPTER 2.
1-19
CLEANING AND STORAGE
1-20
GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model name: YZ450FD (USA, CDN, AUS, NZ)
YZ450F (EUROPE, ZA)
Model code number: 33DD (USA,CDN)
33DE (EUROPE)
33DG (AUS, NZ, ZA)
Dimensions: USA, CDN EUROPE AUS, NZ, ZA
Overall length 2,195 mm (86.42 2,191 mm (86.26 2,195 mm (86.42
Overall width
Overall height
in)
825 mm (32.48 in) ←
1,312 mm (51.65
in)
1,311 mm (51.61
in)
←
←
2
in) in)
Seat height 999 mm (39.33 in) ← 998 mm (39.29 in)
Wheelbase 1,492 mm (58.74 1,487 mm (58.54 ←
in) in)
Minimum ground clearance 383 mm (15.08 in) ← 384 mm (15.12 in)
Weight:
Curb weight 111 kg (245 lb)
Engine:
Engine type Liquid cooled 4-stroke, DOHC
Cylinder arrangement Single cylinder
Displacement 449.7 cm3 (15.8 Imp oz, 15.2 US oz)
Bore × stroke 97.0 × 60.8 mm (3.82 × 2.39 in)
Compression ratio 12.5 : 1
Starting system Kickstarter
Lubrication system: Dry sump
Oil type or grade:
Engine oil
Recommended brand: YAMALUBE
SAE10W-30, SAE10W-40, SAE10W-50,
SAE15W-40, SAE20W-40 or SAE20W-50
API service SG type or higher,
JASO standard MA
Oil capacity:
Engine oil
Periodic oil change 0.95 L (0.84 Imp qt, 1.00 US qt)
With oil filter replacement 1.0 L (0.88 Imp qt, 1.06 US qt)
Total amount 1.2 L (1.06 Imp qt, 1.27 US qt)
Coolant capacity (including all routes): 1.13 L (0.99 Imp qt, 1.19 US qt)
Air filter: Wet type element
2-1
GENERAL SPECIFICATIONS
Fuel:
Type Premium unleaded gasoline only
Tank capacity 6.2 L (1.40 Imp gal, 1.64 US gal)
Throttle body:
Type 30RA
Manufacturer KEIHIN
Spark plug:
Type/manufacturer CR8E/NGK (resistance type)
Gap 0.7–0.8 mm (0.028–0.031 in)
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system Gear
Primary reduction ratio 2.652 (61/23)
Final drive Chain
Secondary reduction ratio 3.692 (48/13) (For USA, CDN)
3.769 (49/13) (For EUROPE, AUS, NZ, ZA)
Transmission type Constant mesh, 5-speed
Operation Left foot operation
Gear ratio:
1st 1.929 (27/14)
2nd 1.533 (23/15)
3rd 1.278 (23/18)
4th 1.091 (24/22)
5th 0.952 (20/21)
Chassis: USA, CDN EUROPE AUS, NZ, ZA
Frame type Semi double cra- ← ←
dle
Caster angle 26.95° 26.80° 27.00°
Trail 118 mm (4.65 in) 117 mm (4.61 in) 120 mm (4.72 in)
Tire:
Type With tube
Size (front) 80/100-21 51M
Size (rear) 120/80-19 63M (For USA, CDN, AUS, NZ, ZA)
110/90-19 62M (For EUROPE)
Tire pressure (front and rear) 100 kPa (1.0 kgf/cm2, 15 psi)
Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
2-2
MAINTENANCE SPECIFICATIONS
Wheel travel:
Front wheel travel 310 mm (12.2 in)
Rear wheel travel 315 mm (12.4 in) (For USA, CDN)
312 mm (12.3 in) (For EUROPE, AUS, NZ, ZA)
Electrical:
Ignition system TCI
MAINTENANCE SPECIFICATIONS
ENGINE
Cylinder:
Bore size 97.00–97.01 mm (3.8189–3.8193 in) ----
Out of round limit ---- 0.05 mm (0.002
in)
Camshaft:
Drive method Chain drive (Left) ----
Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in) ----
Camshaft outside diameter 21.959–21.972 mm (0.8645–0.8650 in) ----
Shaft-to-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) 0.08 mm (0.003
in)
Cam dimensions
2-3
MAINTENANCE SPECIFICATIONS
2-4
MAINTENANCE SPECIFICATIONS
2-5
MAINTENANCE SPECIFICATIONS
2-6
MAINTENANCE SPECIFICATIONS
Balancer:
Balancer drive method Gear ----
Air filter oil grade: Foam-air-filter oil or equivalent oil ----
Clutch:
Friction plate thickness 2.92–3.08 mm (0.115–0.121 in) 2.8 mm (0.110
in)
Quantity 8 ----
Clutch plate thickness 1.5–1.7 mm (0.059–0.067 in) ----
Quantity 7 ----
Warp limit ---- 0.1 mm (0.004
in)
Clutch spring free length 50.0 mm (1.97 in) 49.0 mm (1.93
in)
Quantity 6 ----
Clutch housing thrust clearance 0.10–0.35 mm (0.0039–0.0138 in) ----
Clutch housing radial clearance 0.010–0.044 mm (0.0004–0.0017 in) ----
Clutch release method Inner push, cam push ----
Shifter:
Shifter type Cam drum and guide bar ----
Guide bar bending limit ---- 0.05 mm (0.002
in)
Kickstarter:
Type Kick and ratchet type ----
Fuel pump:
Fuel pressure 324 kPa (3.24 kg/cm2, 46.1 psi) ----
Fuel injector: ----
Model/manufacturer 1010/DENSO ----
Throttle body: ----
I. D. mark 33D1 00 ----
Manufacturer KEIHIN ----
2-7
MAINTENANCE SPECIFICATIONS
2-8
MAINTENANCE SPECIFICATIONS
CHASSIS
2-9
MAINTENANCE SPECIFICATIONS
2-10
TIGHTENING TORQUES
TIGHTENING TORQUES
ENGINE
△ - marked portion shall be checked for torque tightening after break-in or before each race.
Thread
Item Q'ty Tightening torque Remarks
size
Spark plug M10S 1 13 Nm (1.3 m•kg, 9.4 ft•lb)
Camshaft cap M6 8 10 Nm (1.0 m•kg, 7.2 ft•lb)
Cylinder head blind plug screw M12 2 28 Nm (2.8 m•kg, 20 ft•lb)
Oil passage plug M8 1 15 Nm (1.5 m•kg, 11 ft•lb)
Cylinder head (stud bolt) M6 3 7 Nm (0.7 m•kg, 5.1 ft•lb)
Cylinder head (bolt) M10 4 Refer to TIP.*1
Cylinder head (bolt) M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Cylinder head cover M6 3 10 Nm (1.0 m•kg, 7.2 ft•lb)
Cylinder M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Timing chain tensioner M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Timing chain tensioner cap bolt M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb)
Timing chain guide stopper plate (exhaust
M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
side)
Exhaust pipe (nut) M6 3 10 Nm (1.0 m•kg, 7.2 ft•lb)
Exhaust pipe and frame M8 1 20 Nm (2.0 m•kg, 14 ft•lb)
△ Silencer M8 2 30 Nm (3.0 m•kg, 22 ft•lb)
Silencer clamp (front) M8 1 12 Nm (1.2 m•kg, 8.7 ft•lb)
Silencer clamp (rear) M8 1 16 Nm (1.6 m•kg, 11 ft•lb)
Starter knob/Idle screw M12 1 2 Nm (0.2 m•kg, 1.4 ft•lb)
Throttle body joint M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Throttle body joint clamp M5 1 3 Nm (0.3 m•kg, 2.2 ft•lb)
△ Air filter case M6 3 7 Nm (0.7 m•kg, 5.1 ft•lb)
Air filter joint and air filter case M4 9 1 Nm (0.1 m•kg, 0.7 ft•lb)
Air filter case cover M5 2 5 Nm (0.5 m•kg, 3.6 ft•lb)
Air filter joint clamp M4 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
Throttle cable adjust bolt and locknut M6 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
Throttle cable (pull) M10 1 7 Nm (0.7 m•kg, 5.1 ft•lb)
Throttle cable (return) M10 1 7 Nm (0.7 m•kg, 5.1 ft•lb)
Throttle cable cover M5 2 4 Nm (0.4 m•kg, 2.9 ft•lb)
Air duct M6 3 7 Nm (0.7 m•kg, 5.1 ft•lb)
Radiator M6 4 10 Nm (1.0 m•kg, 7.2 ft•lb)
Radiator hose clamp M6 8 2 Nm (0.2 m•kg, 1.4 ft•lb)
Radiator pipe 1 M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Radiator pipe 2 M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Impeller M8 1 14 Nm (1.4 m•kg, 10 ft•lb)
Water pump housing cover M6 4 10 Nm (1.0 m•kg, 7.2 ft•lb)
Coolant drain bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Oil pump cover M4 1 2 Nm (0.2 m•kg, 1.4 ft•lb)
Oil pump M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Oil pump drive gear shaft M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
2-11
TIGHTENING TORQUES
Thread
Item Q'ty Tightening torque Remarks
size
Oil filter element cover M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Oil pressure check bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Crankshaft end accessing screw M36 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Timing mark accessing screw M14 1 6 Nm (0.6 m•kg, 4.3 ft•lb)
Clutch cover M6 7 10 Nm (1.0 m•kg, 7.2 ft•lb)
Right crankcase cover M6 9 10 Nm (1.0 m•kg, 7.2 ft•lb)
Left crankcase cover M6 8 10 Nm (1.0 m•kg, 7.2 ft•lb)
Crankcase M6 13 12 Nm (1.2 m•kg, 8.7 ft•lb)
Clutch cable holder M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Oil drain bolt M8 1 20 Nm (2.0 m•kg, 14 ft•lb)
Oil drain bolt M8 1 20 Nm (2.0 m•kg, 14 ft•lb)
Oil check bolt (crankcase) M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Oil strainer M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Oil nozzle M5 1 8 Nm (0.8 m•kg, 5.8 ft•lb)
Crankcase bearing stopper M6 8 10 Nm (1.0 m•kg, 7.2 ft•lb)
Crankcase bearing stopper (crankshaft) M8 4 22 Nm (2.2 m•kg, 16 ft•lb) Stake.
Drive axle oil seal stopper M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Lock washer
Kick shaft ratchet wheel guide M6 2 12 Nm (1.2 m•kg, 8.7 ft•lb)
*1: Tighten the cylinder head bolts to 30 Nm (3.0 m•kg, 22 ft•lb) in the proper tightening sequence, remove and retighten
the cylinder head bolts to 20 Nm (2.0 m•kg, 14 ft•lb) in the proper tightening sequence, and then tighten the cylinder head
bolts further to reach the specified angle 150° in the proper tightening sequence.
2-12
TIGHTENING TORQUES
CHASSIS
△ - marked portion shall be checked for torque tightening after break-in or before each race.
Thread
Item Q'ty Tightening torque Remarks
size
△ Upper bracket and outer tube M8 4 21 Nm (2.1 m•kg, 15 ft•lb)
△ Lower bracket and outer tube M8 4 21 Nm (2.1 m•kg, 15 ft•lb)
△ Upper bracket and steering stem M24 1 145 Nm (14.5 m•kg, 105 ft•lb)
△ Handlebar upper holder M8 4 28 Nm (2.8 m•kg, 20 ft•lb)
△ Handlebar lower holder M10 2 34 Nm (3.4 m•kg, 24 ft•lb)
△ Steering ring nut M28 1 Refer to TIP.
Front fork and damper assembly M51 2 30 Nm (3.0 m•kg, 22 ft•lb)
Copper
Front fork and adjuster M22 2 55 Nm (5.5 m•kg, 40 ft•lb) washer
2-13
TIGHTENING TORQUES
Thread
Item Q'ty Tightening torque Remarks
size
△ Brake pedal mounting M8 1 26 Nm (2.6 m•kg, 19 ft•lb)
Brake pedal position locknut M6 1 6 Nm (0.6 m•kg, 4.3 ft•lb)
△ Rear brake master cylinder and frame M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Rear brake master cylinder cap M4 2 2 Nm (0.2 m•kg, 1.4 ft•lb)
△ Rear brake hose union bolt (brake cali- Copper
M10 1 30 Nm (3.0 m•kg, 22 ft•lb)
per) washer
△ Rear brake hose union bolt (brake master Copper
M10 1 30 Nm (3.0 m•kg, 22 ft•lb)
cylinder) washer
△ Rear wheel axle and axle nut M22 1 135 Nm (13.5 m•kg, 98 ft•lb)
△ Driven sprocket and wheel hub M8 6 42 Nm (4.2 m•kg, 30 ft•lb)
△ Nipple (spoke) — 72 3 Nm (0.3 m•kg, 2.2 ft•lb)
△ Disc cover and rear brake caliper M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
△ Protector and rear brake caliper M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)
Drive chain puller adjust bolt and locknut M8 2 21 Nm (2.1 m•kg, 15 ft•lb)
Engine mounting:
△ Upper engine bracket and frame M8 4 45 Nm (4.5 m•kg, 32 ft•lb)
△ Front engine bracket and frame M8 4 34 Nm (3.4 m•kg, 24 ft•lb)
△ Engine and engine bracket (front) M10 1 53 Nm (5.3 m•kg, 38 ft•lb)
△ Engine and engine bracket (upper) M10 2 45 Nm (4.5 m•kg, 32 ft•lb)
△ Engine and frame (lower) M10 1 53 Nm (5.3 m•kg, 38 ft•lb)
△ Engine guard M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Lower engine guard M6 3 10 Nm (1.0 m•kg, 7.2 ft•lb)
△ Pivot shaft and nut M16 1 85 Nm (8.5 m•kg, 61 ft•lb)
△ Relay arm and swingarm M14 1 70 Nm (7 m•kg, 50 ft•lb)
△ Relay arm and connecting rod M14 1 80 Nm (8.0 m•kg, 58 ft•lb)
△ Connecting rod and frame M14 1 80 Nm (8.0 m•kg, 58 ft•lb)
△ Rear shock absorber and frame M10 1 56 Nm (5.6 m•kg, 40 ft•lb)
△ Rear shock absorber and relay arm M10 1 53 Nm (5.3 m•kg, 38 ft•lb)
△ Rear shock absorber locknut M60 1 30 Nm (3.0 m•kg, 22 ft•lb)
△ Rear frame and frame (upper) M8 1 32 Nm (3.2 m•kg, 23 ft•lb)
△ Rear frame and frame (lower) M8 2 32 Nm (3.2 m•kg, 23 ft•lb)
△ Swingarm and brake hose holder M5 4 3 Nm (0.3 m•kg, 2.2 ft•lb)
Upper drive chain tensioner M8 1 16 Nm (1.6 m•kg, 11 ft•lb)
Lower drive chain tensioner M8 1 16 Nm (1.6 m•kg, 11 ft•lb)
Drive chain support and swingarm M6 3 7 Nm (0.7 m•kg, 5.1 ft•lb)
△ Seal guard and swingarm M5 3 4 Nm (0.4 m•kg, 2.9 ft•lb)
△ Fuel tank (front) M6 2 9 Nm (0.9 m•kg, 6.5 ft•lb)
Fuel tank bracket (front) M6 4 7 Nm (0.7 m•kg, 5.1 ft•lb)
△ Fuel tank (rear) M6 2 9 Nm (0.9 m•kg, 6.5 ft•lb)
Fuel tank bracket (rear) M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)
△ Fuel pump M5 6 4 Nm (0.4 m•kg, 2.9 ft•lb)
Protector and fuel pump bracket M5 2 4 Nm (0.4 m•kg, 2.9 ft•lb)
Fuel tank side cover M6 4 7 Nm (0.7 m•kg, 5.1 ft•lb)
Fuel tank and seat set bracket M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb)
2-14
TIGHTENING TORQUES
Thread
Item Q'ty Tightening torque Remarks
size
Seat M8 2 22 Nm (2.2 m•kg, 16 ft•lb)
△ Side cover M6 4 7 Nm (0.7 m•kg, 5.1 ft•lb)
Heat protector M5 2 4 Nm (0.4 m•kg, 2.9 ft•lb)
△ Air scoop and air duct M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)
Radiator and radiator guard M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
△ Air scoop and radiator guard M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)
△ Front fender M6 4 10 Nm (1.0 m•kg, 7.2 ft•lb)
△ Rear fender (front) M6 3 7 Nm (0.7 m•kg, 5.1 ft•lb)
△ Rear fender (rear) M6 2 18 Nm (1.8 m•kg, 13 ft•lb)
△ Mud flap — 2 1 Nm (0.1 m•kg, 0.7 ft•lb)
△ Number plate M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb)
1. First, tighten the steering ring nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the steering nut wrench, then loosen
the steering ring nut one turn.
2. Retighten the steering ring nut 7 Nm (0.7 m•kg, 5.1 ft•lb).
ELECTRICAL
Thread
Item Q'ty Tightening torque Remarks
size
Stator M5 3 8 Nm (0.8 m•kg, 5.8 ft•lb)
Rotor M12 1 65 Nm (6.5 m•kg, 47 ft•lb)
Crankshaft position sensor M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Throttle position sensor M5 1 3 Nm (0.3 m•kg, 2.2 ft•lb)
Injector M5 2 3 Nm (0.3 m•kg, 2.2 ft•lb)
Ignition coil M5 2 4 Nm (0.4 m•kg, 2.9 ft•lb)
Coolant temperature sensor M10 1 16 Nm (1.6 m•kg, 11 ft•lb)
Rectifier/regulator M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)
Ignition coil bracket M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Intake air pressure sensor M5 1 5 Nm (0.5 m•kg, 3.6 ft•lb)
Atmospheric pressure sensor M5 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
Atmospheric pressure sensor bracket M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb)
Condenser bracket M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)
Ground lead M5 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
△ ECU M5 2 4 Nm (0.4 m•kg, 2.9 ft•lb)
ECU bracket M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)
2-15
TIGHTENING TORQUES
GENERAL TORQUE
SPECIFICATIONS B TORQUE SPECIFI-
A CATION
This chart specifies torque for stan- (Bolt
(Nut)
dard fasteners with standard I.S.O. ) Nm m•kg ft•lb
pitch threads. Torque specifications
10
for special components or assem- 6 mm 6 0.6 4.3
mm
blies are included in the applicable
sections of this book. To avoid warp- 12
8 mm 15 1.5 11
age, tighten multi-fastener assem- A. Distance between flats mm
blies in a crisscross fashion, in B. Outside thread diameter 14 10
progressive stages, until full torque is 30 3.0 22
mm mm
reached. Unless otherwise specified,
17 12
torque specifications call for clean, 55 5.5 40
mm mm
dry threads. Components should be
at room temperature. 19 14
85 8.5 61
mm mm
22 16
130 13 94
mm mm
DEFINITION OF UNITS
2-16
LUBRICATION DIAGRAMS
LUBRICATION DIAGRAMS
2-17
CABLE ROUTING DIAGRAM
2-18
CABLE ROUTING DIAGRAM
1. Fuel tank breather hose A. Insert the end of the fuel tank
2. Coupler for connecting optional breather hose into the hole in
part the steering stem.
3. Cylinder head breather hose B. Fit the accessory coupler into
4. Hose holder the connector to fasten it to the
5. Radiator hose 3 bracket.
C. Point the end of the cylinder
head breather hose downward.
D. Pass the cylinder head breather
hose through the hose holder,
making sure that the stopper on
the hose contacts the holder.
E. Route the cylinder head breath-
er hose between the frame and
radiator hose 3, and to the out-
side of the AC magneto lead.
2-19
CABLE ROUTING DIAGRAM
F-F
F
A
A F
B B
D
C
100mm C
D-D
C-C
2-20
CABLE ROUTING DIAGRAM
2-21
CABLE ROUTING DIAGRAM
G G
A-A
B-B
A
A
B
F B
F C-C
C
C
D
D
E
D-D
E
E-E
2-22
CABLE ROUTING DIAGRAM
1. Tension pipe A. Fasten the wire harness at the L. Route the radiator breather hose
2. Coolant temperature sensor positioning tape to the ECU between the down tubes.
coupler bracket with a plastic locking tie. M. Fasten the fuel hose and fuel
3. Front engine bracket Face the buckle of the plastic pump lead with the plastic band,
4. Fuel pump coupler locking tie downward, and then making sure to position the band
5. Fuel pump cut off the excess end of the tie. between the bend in the fuel
6. Intake air temperature sensor B. Install the cover onto the wire hose protector and the end of
coupler harness coupler. the protector. Point the end of
7. Radiator hose 2 C. Route the condenser lead, throt- the plastic band upward.
8. Radiator breather hose tle position sensor lead, coolant N. Insert the projection on the joint
9. Radiator hose 1 temperature sensor lead, igni- coupler into the hole in the
10. Radiator hose 4 tion coil lead, and AC magneto bracket, and then install the cou-
11. Radiator pipe 2 lead under radiator hose 2. pler cover onto the coupler.
12. Radiator hose 3 D. Connect the vacuum hose to the O. Route the atmospheric pressure
13. Cylinder head breather hose atmospheric pressure sensor, sensor lead, intake air pressure
14. Frame and then fasten the hose with sensor lead, intake air tempera-
15. ECU (electronic control unit) the clamp. Make sure to face the ture sensor lead, fuel injector
16. ECU bracket moving part of the sensor rear- lead, and fuel pump lead above
17. Main harness ward. radiator hose 2. Position the
18. AC magneto lead E. After connecting the condenser joint coupler above radiator
19. Throttle position sensor lead coupler, install the coupler cover hose 2.
20. Condenser lead onto the coupler. P. Route the radiator breather hose
21. Coolant temperature sensor F. After connecting the throttle po- to the inside of radiator hose 1
lead sition sensor coupler, install the and the front engine bracket.
22. Ignition coil lead coupler cover onto the coupler. Q. Hose installation position (1.3–
23. Condenser G. Fasten the AC magneto lead, 3.3 mm, 0.05–0.13 in)
condenser lead, throttle position R. Clip installation position (0–2.0
sensor lead, coolant tempera- mm, 0–0.08 in)
ture sensor lead, and ignition S. Install the washer so that it con-
coil lead to the frame with the tacts the bolt head.
plastic band, making sure to po- T. Install the collar so that the
sition the band between the igni- flange on the collar contacts the
tion coil bracket and the tension ECU bracket.
pipe. Face the buckle of the U. 6 mm (0.24 in) or less
plastic band to the right with the
end pointing rearward.
H. Point the end of the vacuum
hose rearward.
I. Fit the bracket into the hole in
the rubber portion of the con-
denser.
J. Fasten the radiator breather
hose to the frame with the plas-
tic band, making sure to position
the band above the front engine
bracket. Face the buckle of the
plastic band outward with the
end pointing rearward.
K. After connecting the coolant
temperature sensor coupler, in-
stall the coupler cover onto the
coupler.
2-23
CABLE ROUTING DIAGRAM
1. Ignition coil coupler 8 Fuel hose A. Route the fuel pump lead to the
2. Coolant temperature sensor 9. Fuel pump lead outside of the fuel hose and
lead 10. Fuel injector coupler above the cover.
3. Atmospheric pressure sensor 11. Throttle body B. Route the spark plug wire be-
coupler 12. High tension code tween the throttle cables and the
4. Intake air temperature sensor 13. Throttle cable throttle body. When installing
lead 14. AC magneto lead the air filter, be sure not to pinch
5. Clamp the spark plug wire.
6. Intake air pressure sensor cou- C. Route the AC magneto lead to
pler the inside of the throttle cables.
7. Cover
2-24
CABLE ROUTING DIAGRAM
1. Brake master cylinder A. Install the brake hose so that its C. If the brake hose contacts the
2. Brake hose holder pipe portion directs as shown spring (rear shock absorber),
3. Brake hose and lightly touches the projec- correct its twist.
tion on the brake caliper. D. Install the brake hose so that its
B. Pass the brake hose into the pipe portion directs as shown
brake hose holders. and lightly touches the projec-
tion on the brake master cylin-
der.
2-25
CABLE ROUTING DIAGRAM
2-26
MAINTENANCE INTERVALS
• The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as
weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals.
If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.
• Periodic inspection is essential in making full use of the machine performance. The service life of the parts varies sub-
stantially according to the environment in which the machine runs (e.g., rain, dirt, etc.). Therefore, earlier inspection is
required by reference to the list below..
3
Replace ● ●
VALVES
Check the valve clearances ● ● The engine must be cold.
Inspect ● Check the valve seats and valve
stems for wear.
Replace ●
VALVE SPRINGS
Inspect ● Check the free length and the tilt.
Replace ●
VALVE LIFTERS
Inspect ● Check for scratches and wear.
Replace ●
CAMSHAFTS Inspect the camshaft surface.
Inspect ● Inspect the decompression system.
Replace ●
CAMSHAFT SPROCKETS
Inspect ● Check for wear on the teeth and for
damage.
Replace ●
PISTON
Inspect ● Inspect crack.
Clean ● Inspect carbon deposits and eliminate
them.
Replace ● ● Replace the piston, piston pin, piston
pin clip, and piston ring all as a set.
PISTON RING
Inspect ● Check ring end gap.
Replace ● ● Replace the piston, piston pin, piston
pin clip, and piston ring all as a set.
PISTON PIN
Inspect ●
Replace ● ● Replace the piston, piston pin, piston
pin clip, and piston ring all as a set.
3-1
MAINTENANCE INTERVALS
3-2
MAINTENANCE INTERVALS
3-3
MAINTENANCE INTERVALS
3-4
PRE-OPERATION INSPECTION AND MAINTENANCE
3-5
ENGINE
3-6
ENGINE
CHECKING THE RADIATOR CAP 3. Apply the specified pressure. ADJUSTING THE CLUTCH LEVER
OPENING PRESSURE Standard pressure: FREE PLAY
1. Attach: 196 kPa (1.96 kg/cm2, 1. Check:
• Radiator cap tester "1" and adapt- 27.9 psi) • Clutch lever free play "a"
er "2" Out of specification → Adjust.
Radiator cap tester: Clutch lever free play "a"
YU-24460-01/90890- • Do not apply pressure more than :
01325 specified pressure. 7–12 mm (0.28–0.47 in)
Radiator cap tester • Radiator should be filled fully.
adapter: 4. Inspect:
YU-33984/90890-01352 • Pressure
Impossible to maintain the speci-
Apply water on the radiator cap seal. fied pressure for 10 seconds →
Repair.
• Radiator
• Radiator hose joint
Coolant leakage → Repair or re- 2. Adjust:
place. • Clutch lever free play
• Radiator hose
Swelling → Replace.
Clutch lever free play adjustment
ADJUSTING THE CLUTCH LEVER steps:
POSITION a. Loosen the locknuts "1".
3. Radiator cap 1. Adjust: b. Turn the adjuster "2" until free
2. Apply the specified pressure. • Clutch lever position play is within the specified limits.
Radiator cap opening c. Tighten the locknuts.
pressure: Clutch lever position adjustment Locknut:
108–137 kPa (1.08–1.37 steps: 4 Nm (0.4 m•kg, 2.9
kg/cm2, 15.4–19.5 psi) a. Loosen the locknuts "1". ft•lb)
3. Inspect: b. Turn the adjusting bolt "2" until the
• Pressure clutch lever position "a" is in the
Impossible to maintain the speci- desired position.
fied pressure for 10 seconds → • Before adjustment, expose the ad-
Replace. juster by moving the boot "3" and
CHECKING THE COOLING cap "4" away.
SYSTEM • Make minute adjustment on the le-
1. Inspect: ver side using the adjuster "5".
• Coolant level • After adjustment, check proper op-
2. Attach: eration of clutch lever.
• Radiator cap tester "1" and adapt-
c. Tighten the locknuts.
er "2"
Locknut:
Radiator cap tester: 5 Nm (0.5 m•kg, 3.6
YU-24460-01/90890-
ft•lb)
01325
Radiator cap tester
adapter: 2. Adjust:
YU-33984/90890-01352 • Clutch lever free play
Refer to "ADJUSTING THE 3. Install:
CLUTCH LEVER FREE PLAY". • Cap "1"
• Boot "2"
3-7
ENGINE
ADJUSTING THE THROTTLE GRIP 2. Apply: 4. Loosen and release the binder "1"
FREE PLAY • Lithium soap base grease and lift the air filter case lid.
1. Check: On the throttle cable end "a".
• Throttle grip free play "a" Hold the air filter case lid by the use of
Out of specification → Adjust. the binder.
Throttle grip free play
"a":
3–5 mm (0.12–0.20 in)
3. Install:
• Throttle grip cap
• Screw (throttle grip cap)
5. Remove:
Screw (throttle grip cap):
• Air filter guide
4 Nm (0.4 m•kg, 2.9
• Air filter element "1"
ft•lb)
2. Adjust:
• Throttle grip free play • Cover (grip cap)
Do not remove the thin sheet (air
• Cover (throttle cable cap)
filter element 2) “2” under the air
Adjustment steps: CHECKING THE THROTTLE filter element unless it is dirty. It is
a. Slide the adjuster cover. VALVE PULLY COVER DRAIN there to prevent foreign matter
b. Loosen the locknut "1". HOSE from dropping into the throttle
c. Turn the adjuster "2" until the body. If the thin sheet must be re-
specified free play is obtained. Drain the water that stays in the throt- moved for cleaning, lift it carefully
d. Tighten the locknut. tle valve pulley cover after a machine to avoid loosening the dirt, and
wash or a rainy weather ride. then temporarily block the throttle
Prior to adjusting throttle grip free body opening with a clean, lint-free
1. Drain the water by picking up the
play, the engine idling speed should cloth.
flat portion of the lower end "a" of
be adjusted.
the drain hose.
3. Remove:
• Mounting bolt for air filter case
cover
7. Inspect:
• Air filter element
Damage → Replace.
3-8
ENGINE
10. Install:
• Air filter element "1"
• Air filter guide "2"
• Binder
3. Install:
• Cover • Engine oil also luburicates the
• Air filter case clutch and the wrong oil types or
• Air scoop (left/right) additives could cause clutch
• Fuel tank slippage. Therefore, do not add
11. Install: • Seat any chemical additives or use en-
• Mounting bolt for air filter case CHECKING THE ENGINE OIL gine oils with a grade of CD or
cover LEVEL higher and do not use oils la-
Mounting bolt for air filter 1. Stand the machine on a level sur- beled "ENERGY CONSERVING
case cover: face. II".
5 Nm (0.5 m•kg, 3.6 • Do not allow foreign material to
ft•lb) enter the crankcase.
3-9
ENGINE
3-10
ENGINE
4. Check:
• Valve clearance
Out of specification → Adjust.
Valve clearance (cold):
Intake valve:
0.10–0.15 mm
(0.0039–0.0059 in)
Exhaust valve:
0.20–0.25 mm
(0.0079–0.0098 in)
3-11
ENGINE
5. Adjust:
• Valve clearance Last digit of pad
Rounded valve
number
Adjustment steps: 0, 1 or 2 0
a. Remove the camshaft (intake and 4, 5 or 6 5
exhaust).
8 or 9 10
Refer to "CAMSHAFTS" section
in the CHAPTER 4. EXAMPLE:
b. Remove the valve lifter "1" and Installed pad number = 148
the valve pad "2" with a valve lap- Rounded off value = 150
per "3".
Pads can only be selected in 0.05
• Place a rag in the timing chain mm increments.
space to prevent pads from falling
into the crankcase. e. Locate the rounded-off value and
• Identity each valve lifter and pad the measured valve clearance in
position very carefully so that they the chart "PAD SELECTION TA-
can be reinstalled in their original BLE". The field where these two
place. coordinates intersect shows the
new pad number to use.
3-12
ENGINE
INTAKE
EXHAUST
3-13
CHASSIS
CHASSIS h. Tighten the bleed screw when the b. Turn the adjusting bolt "2" until the
BLEEDING THE HYDRAULIC lever or pedal limit has been lever position is within specified
BRAKE SYSTEM reached; then release the lever or position.
pedal.
Bleed screw:
Bleed the brake system if: 6 Nm (0.6 m•kg, 4.3
• The system has been disassem- ft•lb)
bled.
• A brake hose has been loosened i. Repeat steps (e) to (h) until of the
or removed. air bubbles have been removed
• The brake fluid is very low. from the system.
• The brake operation is faulty. c. Tighten the locknut.
A dangerous loss of braking per- If bleeding is difficult, it may be nec- Locknut:
formance may occur if the brake essary to let the brake fluid system 5 Nm (0.5 m •kg, 3.6
system is not properly bled. stabilize for a few hours. Repeat the ft•lb)
bleeding procedure when the tiny
1. Remove:
bubbles in the system have disap-
• Brake master cylinder cap
peared.
• Diaphragm Be sure to tighten the locknut, as it
• Reservoir float (front brake) j. Add brake fluid to the level line on will cause poor brake perfor-
• Protector (rear brake) the reservoir. mance.
2. Bleed:
• Brake fluid
Check the operation of the brake 4. Install:
after bleeding the brake system. • Brake lever cover
Air bleeding steps:
a. Add proper brake fluid to the res- ADJUSTING THE REAR BRAKE
ervoir. 1. Check:
3. Install: • Brake pedal height "a"
b. Install the diaphragm. Be careful • Protector (rear brake)
not to spill any fluid or allow the Out of specification → Adjust.
• Reservoir float (front brake)
reservoir to overflow. • Diaphragm Brake pedal height "a":
c. Connect the clear plastic tube "2" • Brake master cylinder cap 0 mm (0 in)
tightly to the caliper bleed screw
ADJUSTING THE FRONT BRAKE
"1".
1. Check:
• Brake lever position "a"
A. Front
B. Rear • Adjust the pedal height between
2. Remove:
d. Place the other end of the tube the maximum "A" and the mini-
• Brake lever cover
into a container. mum "B" as shown. (In this ad-
3. Adjust:
e. Slowly apply the brake lever or justment, the bolt "3" end "b"
• Brake lever position
pedal several times. should protrude out of the
f. Pull the lever in or push down on threaded portion "4" but not be
the pedal. Hold the lever or pedal Brake lever position adjustment less than 2 mm (0.08 in) "c" away
in position. steps: from the brake pedal "5").
g. Loosen the bleed screw and allow a. Loosen the locknut "1". • After the pedal height adjust-
the lever or pedal to travel to- ment, make sure that the rear
wards its limit. brake does not drag.
3-14
CHASSIS
b. Loosen the pad pin "2". i. Install the brake caliper "8" and
c. Remove the brake caliper "3" tighten the pad pin "9".
from the front fork.
Bolt (brake caliper):
28 Nm (2.8 m•kg, 20
ft•lb)
Pad pin:
18 Nm (1.8 m•kg, 13
ft•lb)
3-15
CHASSIS
3. Inspect:
Do not reuse the drained brake flu- • Brake fluid level
id. Refer to "CHECKING THE
BRAKE FLUID LEVEL" section.
g. Tighten the bleed screw.
Bleed screw:
6 Nm (0.6 m•kg, 4.3
ft•lb)
3-16
CHASSIS
2. Remove: 6. Lubricate:
• Master link clip • Drive chain
• Joint "1" Drive chain lubricant:
• Drive chain "2" SAE 10W-40 motor oil
or suitable chain lubri-
cants
a. Lower level
A. Front
B. Rear
CHECKING THE SPROCKET
1. Inspect: 3. Clean:
• Sprocket teeth "a" • Drive chain
Excessive wear → Replace. Place it in kerosene, and brush off
as much dirt as possible. Then re- ADJUSTING THE DRIVE CHAIN
move the drive chain from the ker- SLACK
Replace the drive sprocket, rear
osene and dry the drive chain. 1. Elevate the rear wheel by placing
wheel sprocket and drive chain as a
the suitable stand under the en-
set.
gine.
2. Check:
• Drive chain slack "a"
Above the seal guard installation
bolt.
Out of specification → Adjust.
Drive chain slack:
4. Check: 50–60 mm (2.0–2.4 in)
• Drive chain stiffness "a"
CHECKING THE DRIVE CHAIN Clean and oil the drive chain and
1. Measure: hold as illustrated. Before checking and/or adjusting, ro-
• Drive chain length (15 links) "a" Stiff → Replace the drive chain. tate the rear wheel through several
Out of specification → Replace. revolutions and check the slack sev-
Drive chain length (15 eral times to find the tightest point.
links): Check and/or adjust the drive chain
<Limit>: 242.9 mm slack with the rear wheel in this "tight
(9.563 in) chain" position.
3-17
CHASSIS
c. Turn each adjuster exactly the CHECKING THE FRONT FORK RELIEVING THE FRONT FORK
same amount to maintain correct PROTECTOR GUIDE INTERNAL PRESSURE
axle alignment. (There are marks 1. Inspect:
"a" on each side of the drive chain • Protector guide "1" If the front fork initial movement feels
puller alignment.) NOTICE: Im- Out of specification → Replacet. stiff during a run, relieve the front fork
proper drive chain slack will internal pressure.
overload the engine aswell as The protector guide reaches the limit
other vital parts of the motorcy- of its use when it is worn down to the 1. Elevate the front wheel by placing
cle and can lead to chain slip- same height "a" as of the outer tube a suitable stand under the engine.
page or breakage. To prevent circumference. 2. Remove the air bleed screw "1"
this from occurring, keep the and release the internal pressure
drive chain slack within the from the front fork.
specified limits. 3. Install:
• Air bleed screw
Air bleed screw:
1 Nm (0.1 m•kg, 0.7
ft•lb)
3-18
CHASSIS
3-19
CHASSIS
ADJUSTING THE REAR SHOCK ADJUSTING THE REAR SHOCK ADJUSTING THE REAR SHOCK
ABSORBER REBOUND DAMPING ABSORBER LOW COMPRESSION ABSORBER HIGH COMPRESSION
FORCE DAMPING FORCE DAMPING FORCE
1. Adjust: 1. Adjust: 1. Adjust:
• Rebound damping force • Low compression damping force • High compression damping force
By turning the adjuster "1". By turning the adjuster "1". By turning the adjuster "1".
Stiffer "a" → Increase the re- Stiffer "a" → Increase the low Stiffer "a" → Increase the high
bound damping force. (Turn compression damping force. compression damping force.
the adjuster "1" in.) (Turn the adjuster "1" in.) (Turn the adjuster "1" in.)
Softer "b" → Decrease the re- Softer "b" → Decrease the low Softer "b" → Decrease the high
bound damping force. (Turn compression damping force. compression damping force.
the adjuster "1" out.) (Turn the adjuster "1" out.) (Turn the adjuster "1" out.)
Do not force the adjuster past the Do not force the adjuster past the
minimum or maximum extent of Do not force the adjuster past the minimum or maximum extent of
adjustment. The adjuster may be minimum or maximum extent of adjustment. The adjuster may be
damaged. adjustment. The adjuster may be damaged.
damaged.
3-20
CHASSIS
2. Inspect:
CHECKING AND TIGHTENING THE • Bearing free play
SPOKES Exist play → Replace.
The following procedure applies to all
of the spokes.
1. Check:
• Spokes
Bend/damage → Replace. d. Tighten the steering ring nut "3"
Loose spoke → Retighten. using steering nut wrench "4".
Tap the spokes with a screw-
driver. • Apply the lithium soap base grease
CHECKING AND ADJUSTING THE on the thread of the steering stem.
STEERING HEAD • Set the torque wrench to the steer-
1. Place a stand under the engine to ing nut wrench so that they form a
raise the front wheel off the right angle.
ground. WARNING! Securely
support the vehicle so that Steering nut wrench:
there is no danger of it falling YU-33975/90890-01403
over.
2. Check: Steering ring nut (initial
A tight spoke will emit a clear, ringing • Steering stem tightening):
tone; a loose spoke will sound flat. Grasp the bottom of the forks and 38 Nm (3.8 m•kg, 27
gently rock the fork assembly ft•lb)
2. Tighten: back and forth.
• Spokes Free play → Adjust steering head.
(with a spoke nipple wrench "1")
3-21
CHASSIS
Avoid over-tightening.
3-22
CHASSIS
LUBRICATION
3-23
ELECTRICAL
3. Adjust:
• Engine idling speed
Refer to "ADJUSTING THE EN-
GINE IDLING SPEED" section.
4. Check:
• Ignition timing
Visually check the stationary
pointer "a" is within the firing
4. Clean the plug with a spark plug
range "b" on the rotor.
cleaner if necessary.
Incorrect firing range → Check ro-
5. Tighten:
tor and Crankshaft position sen-
• Spark plug
sor.
Spark plug:
13 Nm (1.3 m•kg, 9.4
ft•lb)
3-24
ELECTRICAL
TROUBLESHOOTING
The following guide for troubleshooting does not cover all the possible causes of problems. If the following problems occur,
perform the specified checks or maintenance jobs. If a problem occurs that is not listed in this manual or if the problem
cannot be corrected by the procedures provided in this manual, contact your Yamaha dealer.
Engine starting problems, engine idling speed problems, and medium and high-speed performance problems
• Engine does not start even though the kickstarter is pushed.
• Engine starts, but soon stops.
Engine idling speed problems
• Engine idling speed fluctuates.
• Engine idling speed is high.
• Engine idling speed is low.
Medium and high-speed performance problems
• Engine speed does not increase.
• Engine knocks.
• Engine speed increases suddenly.
• Loss of engine power.
INSPECTION STEPS
If the aforementioned problems have occurred, perform the following inspection steps in the order given.
Check that the fuel tank is filled with fresh gaso- No good →
Fill the fuel tank.
line.
OK ↓
Check that the fuel tank breather hose is not No good →
clogged. (Refer to "INCLUDED PARTS" section Repair or replace.
in the CHAPTER 1.)
OK ↓
Adjusting the engine idling speed(Refer to "AD- No good →
JUSTING THE ENGINE IDLLING SPEED" sec- Adjust.
tion in the CHAPTER 3.)
OK ↓
Check that the fuel hose is connected properly No good →
Repair.
and is not kinked or pinched.
OK ↓
Check the spark plug for dirt, the spark plug gap, No good →
and the spark plug cap. (Refer to "CHECKING Clean or adjust.
THE SPARK PLUG" section in the CHAPTER 3.)
OK ↓
Check that the air filter element is installed cor- No good →
rectly and is not clogged. (Refer to "CLEANING Clean or repair.
THE AIR FILTER" section in the CHAPTER 3.)
OK ↓
Checking the sensors, injector and ignition coil No good →
Repair or replace.
connection.
OK ↓
Installed condition of ECU (Refer to "CHECKING No good →
Repair.
THE ECU" section in the CHAPTER 7.)
OK ↓
Check the assembled condition of the throttle No good →
body, and check the throttle valve and its sur- Repair or clean.
rounding parts for dirt.
OK ↓
Consult a Yamaha dealer.
3-25
SEAT AND SIDE COVERS
ENGINE
This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles
(e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are request-
ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to
servicing trouble and mechanical damage.
4-1
SEAT AND SIDE COVERS
• Insulator 7 "7"
• Insulator 8 "8"
4
• Insulator 9 "9"
CHECKING AND REPLACING THE
PROTECTOR
1. Inspect:
• Protector "1"
Wear/damage → Replace.
4-2
EXHAUST PIPE AND SILENCER
4-3
EXHAUST PIPE AND SILENCER
pipe.
• Install the band "3" with the mating
ends "b" positioned as shown.
4. Install:
2. Replace: • Bolt (exhaust pipe 2):
• Fiber "1" Bolt (exhaust pipe 2):
20 Nm (2.0 m•kg, 14
ft•lb)
• Silencer clamp (front):
Silencer clamp (front):
2. Install:
12 Nm (1.2 m•kg, 8.7
• Silencer clamp (front) ft•lb)
• Exhaust pipe 2 "1"
3. Install: • Bolt (exhaust pipe 2) "2" • Silencer clamp (rear):
• Inner pipe "1" Silencer clamp (rear):
• Rivet (front) "2" 16 Nm (1.6 m•kg, 11
• Band "3" ft•lb)
4-4
RADIATOR
RADIATOR
REMOVING THE RADIATOR
4-5
RADIATOR
4-6
RADIATOR
4-7
CAMSHAFTS
CAMSHAFTS
REMOVING THE CYLINDER HEAD COVER
4-8
CAMSHAFTS
4-9
CAMSHAFTS
3. Measure:
CHECKING THE CAMSHAFT • Runout (camshaft)
1. Inspect: Out of specification → Replace.
• Cam lobe
Pitting/scratches/blue discolor- Runout (camshaft):
ation → Replace. Less than 0.03 mm
2. Measure: (0.0012 in)
• Cam lobe length "a" and "b"
Out of specification → Replace.
3. Remove:
• Timing chain tensioner cap bolt
"1"
• Timing chain tensioner "2"
• Gasket
4-10
CAMSHAFTS
4. Measure:
• Camshaft-to-cap clearance
Out of specification → Measure
camshaft outside diameter.
Camshaft-to-cap clear-
ance:
0.028–0.062 mm
(0.0011–0.0024 in) CHECKING THE CAMSHAFT
<Limit>:0.08 mm (0.003 SPROCKET
in) 1. Inspect:
• Camshaft sprocket "1"
Wear/damage → Replace the
Measurement steps:
camshaft assembly and timing
a. Install the camshaft onto the cylin-
chain as a set.
der head.
b. Position a strip of Plastigauge®
INSTALLING THE CAMSHAFT
"1" onto the camshaft.
1. Install:
• Exhaust camshaft "1"
• Intake camshaft "2"
CHECKING THE
DECOMPRESSION SYSTEM
1. Check:
c. Install the clip, dowel pins and
• Decompression system
camshaft caps.
Bolt (camshaft cap):
Checking steps:
10 Nm (1.0 m•kg, 7.2 Installation steps:
a. Check that the decompression
ft•lb) a. Turn the crankshaft counterclock-
mechanism cam "1" moves
smoothly. wise with a wrench.
• Tighten the bolts (camshaft cap) in b. Check that the decompression
a crisscross pattern from innermost mechanism cam lever pin "2" proj- • Apply the molybdenum disulfide oil
to outer caps. ects from the camshaft. on the camshafts.
• Do not turn the camshaft when • Apply the engine oil on the decom-
measuring clearance with the Plas- pression system.
tigauge®. • Fill the cylinder head with engine oil
up to the tops "a" of the valve lifters.
d. Remove the camshaft caps and
measure the width of the Plasti-
gauge® "1".
4-11
CAMSHAFTS
3. Turn:
• Crankshaft
The bolts (camshaft cap) must be Counterclockwise several turns.
tightened evenly, or damage to the 4. Check:
cylinder head, camshaft caps, and • Alignment mark
camshaft will result. Align with the crankcase align
mark.
• Camshaft match marks
c. Fit the timing chain "3" onto both 2. Install: Align with the cylinder head sur-
camshaft sprockets and install the • Timing chain tensioner face.
camshafts on the cylinder head. Out of alignment → Adjust.
Installation steps:
Make sure that the alignment mark a. While pressing the tensioner rod
"c" on the exhaust camshaft sprocket lightly with fingers, use a thin
and the alignment mark "d" on the in- screwdriver and wind the tension-
take camshaft sprocket are aligned er rod up fully clockwise.
with the edge of the cylinder head.
4-12
CYLINDER HEAD
CYLINDER HEAD
REMOVING THE CYLINDER HEAD
4-13
CYLINDER HEAD
Tighten the cylinder head bolts to 30 Nm (3.0 m•kg, 22 ft•b) in the proper tightening sequence, remove and retighten the
cylinder head bolts to 20 Nm (2.0 m•kg, 14 ft•lb) in the proper tightening sequence, and then tighten the cylinder head bolts
further to reach the specified angle 150° in the proper tightening sequence.
4-14
CYLINDER HEAD
CHECKING THE CYLINDER HEAD INSTALLING THE CYLINDER d. Tighten the bolts to the specified
1. Eliminate: HEAD torque in two or three steps in the
• Carbon deposits (from the com- 1. Install: proper tightening sequence as
bustion chambers) • Timing chain guide (intake side) shown.
Use a rounded scraper. "1" Bolts (cylinder head):
• Dowel pin "2" 1st:
Do not use a sharp instrument to • Cylinder head gasket "3" 30 Nm (3.0 m•kg, 22
avoid damaging or scratching: • Cylinder head "4" ft•lb)
• Spark plug threads
• Valve seats While pulling up the timing chain, in-
stall the timing chain guide (intake
side) and cylinder head.
4-15
CYLINDER HEAD
3. Install:
• Bolt (cylinder head) "1"
Bolt (cylinder head):
10 Nm (1.0 m•kg, 7.2
ft•lb)
4-16
VALVES AND VALVE SPRINGS
4-17
VALVES AND VALVE SPRINGS
4-18
VALVES AND VALVE SPRINGS
3. Inspect:
• Valve face Valve seat width:
• When replacing the cylinder head,
Pitting/wear → Grind the face. Intake:
replace the valves without lapping
• Valve stem end 0.9–1.1 mm (0.0354–
the valve seats and valve faces.
Mushroom shape or diameter 0.0433 in)
• When replacing the valves or valve
larger than the body of the stem <Limit>:1.6 mm
guides, use new valves to lap the
→ Replace. (0.0630 in)
valve seats, and then replace them
4. Measure: Exhaust:
with new valves.
• Margin thickness "a" 0.9–1.1 mm (0.0354–
Out of specification → Replace. 0.0433 in)
<Limit>:1.6 mm
Margin thickness: Lapping steps:
(0.0630 in)
Intake: a. Apply a coarse lapping compound
1.3 mm (0.051 in) to the valve face.
Exhaust:
1.0 mm (0.039 in)
Do not let the compound enter the
gap between the valve stem and
the guide.
Measurement steps:
a. Apply Mechanic's blueing dye
5. Measure: (Dykem) "b" to the valve face.
• Runout (valve stem)
Out of specification → Replace.
b. Apply molybdenum disulfide oil to
Runout limit: the valve stem.
0.01 mm (0.0004 in)
4-19
VALVES AND VALVE SPRINGS
b. Installed length
4-20
CYLINDER AND PISTON
4-21
CYLINDER AND PISTON
REMOVING THE PISTON AND CHECKING THE CYLINDER AND e. Calculate the piston-to-cylinder
PISTON RING PISTON clearance with following formula:
1. Remove: 1. Inspect: Piston-to-cylinder clearance =
• Piston pin clip "1" • Cylinder and piston walls Cylinder bore "C" - Piston skirt
• Piston pin "2" Vertical scratches → Replace cyl- diameter "P"
• Piston "3" inder and piston.
2. Measure: Piston-to-cylinder clear-
• Put identification marks on each • Piston-to-cylinder clearance ance:
piston head for reference during re- 0.020–0.045 mm
installation. Measurement steps: (0.0008–0.0018 in)
• Before removing each piston pin, a. Measure the cylinder bore "C" <Limit>:0.1 mm (0.004
deburr the clip groove and pin hole with a cylinder bore gauge. in)
area. If the piston pin groove is de- f. If out of specification, replace the
burred and the piston pin is still dif- Measure the cylinder bore "C" in par- cylinder, and replace the piston
ficult to remove, use the piston pin allel to and at right angles to the and piston rings as set.
puller set "4". crankshaft. Then, find the average of
the measurements.
Piston pin puller set: CHECKING THE PISTON RING
YU-1304/90890-01304 1. Measure:
Cylinder 97.00–97.01 mm • Ring side clearance
bore "C" (3.8189–3.8193 in) Use a feeler gauge "1".
Taper limit Out of specification → Replace
Do not use a hammer to drive the 0.05 mm (0.002 in)
"T" the piston and rings as a set.
piston pin out.
Out of
0.05 mm (0.002 in) Clean carbon from the piston ring
round "R"
grooves and rings before measuring
"C" = Maximum D the side clearance.
"T" = (Maximum D1 or D2) - (Max-
imum D5 or D6) Side clearance:
"R" = (Maximum D1, D3 or D5) - Standard <Limit>
(Minimum D2, D4 or D6) 0.015–0.065
Top mm 0.12 mm
ring (0.0006– (0.005 in)
0.0026 in)
0.020–0.060
2nd mm 0.12 mm
ring (0.0008– (0.005 in)
0.0024 in)
4-22
CYLINDER AND PISTON
a. 40 mm (1.57 in)
3. Measure:
• Ring end gap 2. Position:
b. Measure the inside diameter (pis-
Out of specification → Replace. • Top ring
ton) "b".
• 2nd ring
Inside diameter (piston): • Oil ring
You cannot measure the end gap on
18.004–18.015 mm Offset the piston ring end gaps as
the expander spacer of the oil control
(0.7088–0.7093 in) shown.
ring. If the oil control ring rails show
excessive gap, replace all three rings.
25 25
End gap:
Standard <Limit>
115
0.20–0.30
Top 0.55 mm 25 25
mm (0.008–
ring (0.022 in)
0.012 in)
a. Top ring end
0.35–0.50 c. Calculate the piston pin-to-piston
2nd 0.85 mm b. 2nd ring end
mm (0.014– clearance with the following for-
ring (0.033 in) c. Oil ring end (upper)
0.020 in) mula.
d. Oil ring
0.20–0.50 Piston pin-to-piston clearance = e. Oil ring end (lower)
Oil Inside diameter (piston) "b" -
mm (0.008– —
ring Outside diameter (piston pin)
0.020 in)
"a"
CHECKING THE PISTON PIN
1. Inspect: d. If out of specification, replace the
• Piston pin piston.
Blue discoloration/grooves → Re- Piston pin-to-piston
place, then inspect the lubrication clearance:
system. 0.004–0.024 mm
(0.00016–0.00094 in)
<Limit>:0.07 mm (0.003
in)
4-23
CYLINDER AND PISTON
3. Install:
• Piston "1"
• Piston pin "2"
• Piston pin clip "3"
2. Install:
• Bolt (cylinder)
Bolt (cylinder):
10 Nm (1.0 m•kg, 7.2
ft•lb)
4-24
CLUTCH
CLUTCH
REMOVING THE CLUTCH
4-25
CLUTCH
4-26
CLUTCH
REMOVING THE CLUTCH BOSS CHECKING THE CLUTCH CHECKING THE PUSH LEVER
1. Remove: SPRINGS SHAFT
• Nut "1" 1. Measure: 1. Inspect:
• Conical washer "2" • Clutch spring free length "a" • Push lever shaft "1"
• Clutch boss "3" Out of specification → Replace Wear/damage → Replace.
springs as a set.
Use the clutch holding tool "4" to hold Clutch spring free
the clutch boss. length:
50.0 mm (1.97 in)
Clutch holding tool: <Limit>: 49.0 mm (1.93
YM-91042/90890-04086 in)
4-27
CLUTCH
2. Install:
• Conical washer "1"
• Nut (clutch boss) "2" 4. Install: 8. Install:
• Bearing "1" • O-ring (clutch cover) "1"
Nut (clutch boss):
75 Nm (7.5 m•kg, 54 • Washer "2"
ft•lb) • Circlip "3"
To push rod 1 "4".
Make sure to tighten to specifica- Apply the engine oil on the bearing
tion; otherwise, it may damage the and washer.
other part that is fastened togeth-
er. 9. Install:
• Clutch cover "1"
• Bolt (clutch cover)
• Apply engine oil to the threads and
contact surface of the clutch boss Bolt (clutch cover):
nut. 10 Nm (1.0 m•kg, 7.2
• Apply engine oil to the contact sur- ft•lb)
faces of the conical washer.
5. Install:
• Install the conical washer with its
• Push rod 2 "1" Tighten the bolts in stage, using a
convex surface "a" outward.
• Ball "2" crisscross pattern.
• Use the clutch holding tool "3" to
• Push rod 1 "3"
hold the clutch boss.
Apply the engine oil on the push rod
Clutch holding tool:
1, 2 and ball.
YM-91042/90890-04086
6. Install:
• Pressure plate "1"
4-28
OIL FILTER ELEMENT AND WATER PUMP
4-29
OIL FILTER ELEMENT AND WATER PUMP
4-30
OIL FILTER ELEMENT AND WATER PUMP
4-31
OIL FILTER ELEMENT AND WATER PUMP
2. Install:
• Right crankcase cover "1" INSTALLING THE OIL FILTER
• Bolt "2" ELEMENT
Bolt: 1. Install:
10 Nm (1.0 m•kg, 7.2 • Oil filter element "1"
ft•lb) • O-ring "2"
INSTALLING THE WATER PUMP • Oil filter element cover "3"
HOUSING • Bolt (oil filter element cover)
• Apply the engine oil on the impeller 1. Install: Bolt (oil filter element
shaft end. • Dowel pin "1" cover):
• When installing the crankcase cov- • Gasket "2" 10 Nm (1.0 m•kg, 7.2
er onto the crankcase, be sure that ft•lb)
the impeller shaft end "3" aligns
with the balancer end slot "4".
• Tighten the bolts in stage, using a Apply the lithium soap base grease
crisscross pattern. on the O-ring.
2. Install:
• Water pump housing "1"
• Bolt (water pump housing) "2"
Bolt (water pump hous-
ing):
10 Nm (1.0 m•kg, 7.2
ft•lb)
• Washer "3"
• Coolant drain bolt "4"
Coolant drain bolt:
10 Nm (1.0 m•kg, 7.2
ft•lb)
4-32
BALANCER
BALANCER
REMOVING THE BALANCER
4-33
BALANCER
REMOVING THE BALANCER CHECKING THE BALANCER • Primary drive gear "3"
1. Straighten the lock washer tab. 1. Inspect: • Conical washer "4"
2. Loosen: • Balancer • Nut (primary drive gear) "5"
• Nut (balancer) "1" Cracks/damage → Replace. Nut (primary drive gear):
• Nut (primary drive gear) "2" 100 Nm (10.0 m•kg, 72
• Nut (balancer shaft driven gear) ft•lb)
"3"
• Straight key "6"
Place an aluminum plate "a" between • Balancer "7"
the teeth of the balancer shaft drive • Lock washer "8"
gear "4" and driven gear "5". • Nut (balancer) "9"
Nut (balancer):
INSTALLING THE BALANCER 45 Nm (4.5 m•kg, 33
1. Install: ft•lb)
• Balancer shaft driven gear "1"
Install the balancer shaft driven gear • Apply molybdenum disulfide grease
and balancer shaft with their lower to the contact surface and threaded
splines "a" aligning with each other. portion of the nut (primary drive
gear).
• Apply molybdenum disulfide grease
to the contact surface of the conical
spring washer.
• Place an aluminum plate "a" be-
tween the teeth of the balancer
shaft drive gear "10" and balancer
shaft driven gear "11".
• Install the conical washer with its
2. Install: convex surface "b" outward.
• Balancer shaft driven gear "1"
4-34
OIL PUMP
OIL PUMP
REMOVING THE OIL PUMP
4-35
OIL PUMP
4-36
OIL PUMP
3. Install:
• Oil pump cover "1"
• Screw (oil pump cover) "2"
Screw (oil pump cover):
2 Nm (0.2 m•kg, 1.4
ft•lb)
• Dowel pin "3"
• Inner rotor 2 "4"
• Circlip "5"
4-37
KICK SHAFT AND SHIFT SHAFT
4-38
KICK SHAFT AND SHIFT SHAFT
4-39
KICK SHAFT AND SHIFT SHAFT
REMOVING THE KICK SHAFT CHECKING THE KICK SHAFT AND CHECKING THE SHIFT GUIDE AND
ASSEMBLY RATCHET WHEEL SHIFT LEVER ASSEMBLY
1. Remove: 1. Check: 1. Inspect:
• Kick shaft assembly "1" • Ratchet wheel "1" smooth move- • Shift guide "1"
ment • Shift lever "2"
Unhook the torsion spring "2" from Unsmooth movement → Replace. • Pawl "3"
the hole "a" in the crankcase. • Kick shaft "2" • Pawl pin "4"
Wear/damage → Replace. • Spring "5"
• Spring "3" Wear/damage → Replace.
Broken → Replace.
4-40
KICK SHAFT AND SHIFT SHAFT
4. Install:
• Bolt (shift guide) "1"
Bolt (shift guide):
INSTALLING THE KICK SHAFT
10 Nm (1.0 m•kg, 7.2
ASSEMBLY
ft•lb)
1. Install:
INSTALLING THE SHIFT GUIDE • Kick gear "1"
AND SHIFT LEVER ASSEMBLY • Washer "2"
1. Install: • Circlip "3"
• Spring "1" • Ratchet wheel "4"
• Pawl pin "2" • Spring "5"
• Pawl "3" • Washer "6"
To shift lever "4". • Circlip "7"
To kick shaft "8".
Apply the engine oil on the spring, INSTALLING THE SHIFT SHAFT
pawl pin and pawl. 1. Install: • Apply the molybdenum disulfide oil
• Roller "1" on the inner circumferences of the
• Collar "2" kick gear and ratchet wheel.
• Torsion spring "3" • Align the punch mark "a" on the
• Washer "4" ratchet wheel with the punch mark
• Shift shaft "5" "b" on the kick shaft.
2. Install:
• Shift lever assembly "1"
To shift guide "2".
2. Install:
• Torsion spring "1"
To kick shaft "2".
4-41
KICK SHAFT AND SHIFT SHAFT
4. Install:
• Kick shaft assembly "1"
• Washer "2"
5. Hook:
• Torsion spring "1"
4-42
AC MAGNETO
AC MAGNETO
REMOVING THE AC MAGNETO
4-43
AC MAGNETO
5. Install:
• Dowel pin
• Gasket (left crankcase cover)
4-44
ENGINE REMOVAL
ENGINE REMOVAL
REMOVING THE ELECTRONIC PARTS
4-45
ENGINE REMOVAL
4-46
ENGINE REMOVAL
4-47
ENGINE REMOVAL
4-48
ENGINE REMOVAL
2. Install:
• Lock washer "1"
• Nut (drive sprocket) "2"
Nut (drive sprocket):
75 Nm (7.5 m•kg, 54
ft•lb)
4-49
CRANKCASE AND CRANKSHAFT
4-50
CRANKCASE AND CRANKSHAFT
4-51
CRANKCASE AND CRANKSHAFT
4-52
CRANKCASE AND CRANKSHAFT
DISASSEMBLING THE c. Remove the dowel pins and O- REMOVING THE CRANKCASE
CRANKCASE ring. BEARING
1. Separate: 1. Remove:
• Right crankcase • Bearing "1"
REMOVING THE BALANCER
• Left crankcase
SHAFT
1. Remove: • Remove the bearing from the
Separation steps: • Balancer shaft "1" crankcase by pressing its inner
a. Remove the crankcase bolts, race.
hose guide and clutch cable hold- • Do not use the removed bearing.
Remove the balancer shaft with its
er. flat side "a" facing the crankshaft.
2. Inspect:
• Bearing
Rotate inner race with a finger.
Rough spot/seizure → Replace.
4-53
CRANKCASE AND CRANKSHAFT
4-54
CRANKCASE AND CRANKSHAFT
3. Install: 6. Tighten:
• Oil strainer "1" • Bolt (crankcase)
• Bolt (oil strainer) "2" Bolt (crankcase):
Bolt (oil strainer): 12 Nm (1.2 m•kg, 8.7
10 Nm (1.0 m•kg, 7.2 ft•lb)
ft•lb)
4. Apply:
• Sealant
On the right crankcase.
YAMAHA Bond No. 1215
7. Install:
(ThreeBond® No.1215):
• Timing chain
90890-85505
• Timing chain guide (exhaust side)
• Bolt for timing chain guide (ex-
Clean the contacting surface of left haust side))
and right crankcase before applying Bolt for timing chain
the sealant. guide (exhaust side):
10 Nm (1.0 m•kg, 7.2
ft•lb)
8. Remove:
• Sealant
Forced out on the cylinder mating
surface.
9. Apply:
• Engine oil
5. Install: To the crank pin, bearing and oil
• Dowel pin "1" delivery hole.
• Right crankcase 10. Check:
To left crankcase. • Crankshaft and transmission op-
eration.
• Fit the right crankcase onto the left Unsmooth operation → Repair.
crankcase. Tap lightly on the case
with soft hammer.
• When installing the crankcase, the
connecting rod should be posi-
tioned at TDC (top dead center).
4-55
TRANSMISSION, SHIFT CAM AND SHIFT FORK
4-56
TRANSMISSION, SHIFT CAM AND SHIFT FORK
• Remove assembly with the collar Apply the molybdenum disulfide oil
"3" installed to the crankcase. on the inner and end surface of the
• Remove assembly carefully. Note idler gear and on the inner surface of
the position of each part. Pay partic- the sliding gear, then install.
ular attention to the location and di- CHECKING THE SHIFT FORK,
rection of shift forks. SHIFT CAM AND SEGMENT
• Remove the main axle, drive axle, 1. Inspect:
shift cam and shift fork all together • Shift fork "1"
by tapping lightly on the transmis- Wear/damage/scratches → Re-
sion drive axle with a soft hammer. place.
2. Inspect:
CHECKING THE GEARS • Shift cam "1"
1. Inspect: • Segment "2"
• Matching dog "a" Wear/damage → Replace. 2. Install:
• Gear teeth "b"
• Collar "1"
• Shift fork groove "c"
• 2nd wheel gear (23T) "2"
Wear/damage → Replace.
• 4th wheel gear (24T) "3"
• 3rd wheel gear (23T) "4"
• 5th wheel gear (20T) "5"
• Collar "6"
• 1st wheel gear (27T) "7"
• O-ring "8"
3. Check: To drive axle "9".
• Shift fork movement
Unsmooth operation → Replace
2. Inspect: • Apply the molybdenum disulfide oil
shift fork.
• O-ring "1" on the inner and end surface of the
Damage → Replace. idler gear and on the inner surface
of the sliding gear, then install.
• Apply the lithium soap base grease
on the O-ring.
4-57
TRANSMISSION, SHIFT CAM AND SHIFT FORK
5. Install:
• Shift fork 1 (L) "1"
• Shift fork 2 (C) "2"
• Shift fork 3 (R) "3"
• Shift cam "4"
To main axle and drive axle.
6. Install:
• Transmission assembly "1"
To left crankcase "2".
7. Check:
• Shifter operation
• Transmission operation
Unsmooth operation → Repair.
4-58
FRONT WHEEL AND REAR WHEEL
CHASSIS
This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles
(e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are request-
ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to
servicing trouble and mechanical damage.
5-1
FRONT WHEEL AND REAR WHEEL
5
Order Part name Q'ty Remarks
Hold the machine by placing the suitable stand
Refer to "HANDLING NOTE".
under the engine.
1 Nut (rear wheel axle) 1
2 Rear wheel axle 1
3 Drive chain puller 2
4 Rear wheel 1 Refer to removal section.
5 Collar 2
6 Rear wheel sprocket 1
7 Oil seal 2
8 Circlip 1
9 Bearing 3 Refer to removal section.
10 Brake disc 1
5-2
FRONT WHEEL AND REAR WHEEL
5-3
FRONT WHEEL AND REAR WHEEL
4. Install:
• Wheel
5-4
FRONT WHEEL AND REAR WHEEL
6. Install:
• Drive chain "1"
10. Tighten:
Push the wheel "2" forward and install • Nut (wheel axle) "1"
the drive chain.
3. Install: Nut (wheel axle):
• Rear wheel sprocket "1" 135 Nm (13.5 m•kg, 98
• Bolt (rear wheel sprocket) "2" ft•lb)
• Washer (rear wheel sprocket) "3"
• Locknut "2"
• Nut (rear wheel sprocket) "4"
Locknut:
Nut (rear wheel sprock- 21 Nm (2.1 m•kg, 15
et): ft•lb)
42 Nm (4.2 m•kg, 30
ft•lb)
7. Install:
• Left drive chain puller "1"
Tighten the nuts in stage, using a • Wheel axle "2"
crisscross pattern.
• Install the left drive chain puller, and
insert the wheel axle from left side.
• Apply the lithium soap base grease
on the wheel axle.
4. Install:
• Collar "1"
5-5
FRONT BRAKE AND REAR BRAKE
5-6
FRONT BRAKE AND REAR BRAKE
5-7
FRONT BRAKE AND REAR BRAKE
5-8
FRONT BRAKE AND REAR BRAKE
5-9
FRONT BRAKE AND REAR BRAKE
A. Front
B. Rear
CHECKING THE BRAKE MASTER
CYLINDER
1. Inspect:
• Brake master cylinder inner sur-
A. Front face "a"
B. Rear Wear/scratches → Replace mas-
2. Connect the transparent hose "2" ter cylinder assembly.
to the bleed screw "1" and place a Stains → Clean.
suitable container under its end.
A. Front
B. Rear
5-10
FRONT BRAKE AND REAR BRAKE
A. Front
B. Rear
3. Install:
4. Inspect: • Brake caliper piston "1"
• Brake master cylinder piston "1" HANDLING NOTE
• Brake master cylinder cup "2" Apply the brake fluid on the piston
Wear/damage/score marks → Re- wall.
place brake master cylinder kit. • All internal parts should be
cleaned in new brake fluid only.
• Internal parts should be lubricat-
ed with brake fluid when in- • Install the piston with its shallow
stalled. depressed side "a" facing the
• Replace the brake caliper piston brake caliper.
seals and brake caliper piston • Never force to insert.
dust seals whenever a caliper is
disassembled.
CHECKING THE BRAKE CALIPER
INSTALLING THE BRAKE
1. Inspect:
CALIPER PISTON
• Brake caliper cylinder inner sur-
1. Clean:
face "a"
• Brake caliper
Wear/score marks → Replace
• Brake caliper piston seal
brake caliper assembly.
• Brake caliper piston dust seal
• Brake caliper piston
Clean them with brake fluid.
2. Install:
• Brake caliper piston seal "1"
A. Front A. Front
B. Rear Always use new brake caliper pis- B. Rear
2. Inspect: ton seals and brake caliper piston INSTALLING THE FRONT BRAKE
• Brake caliper piston "1" dust seals. CALIPER
Wear/score marks → Replace 1. Install:
brake caliper piston assembly. • Pad support "1"
• Apply the brake fluid on the brake • Brake pad "2"
caliper piston seal. • Pad pin "3"
Replace the brake caliper piston • Apply the silicone grease on the
seals and brake caliper piston dust brake caliper piston dust seal.
seals "2" whenever a caliper is dis- • Install the brake pads with their pro-
• Fit the brake caliper piston seals
assembled. jections "a" into the brake caliper re-
and brake caliper piston dust seals
cesses "b".
onto the slot on brake caliper cor-
• Temporarily tighten the pad pin at
rectly.
this point.
5-11
FRONT BRAKE AND REAR BRAKE
2. Install: 3. Install:
• Brake caliper "1" • Brake caliper "1"
• Bolt (brake caliper) "2" • Rear wheel "2"
Bolt (brake caliper): Refer to "FRONT WHEEL AND
28 Nm (2.8 m•kg, 20 REAR WHEEL" section.
ft•lb) 4. Tighten:
• Pad pin "3"
3. Tighten:
Pad pin:
• Pad pin "3" 3. Install:
18 Nm (1.8 m•kg, 13
Pad pin: ft•lb) • Spring "1"
18 Nm (1.8 m•kg, 13 To brake master cylinder piston
ft•lb) 5. Install: "2".
• Pad pin plug "4"
4. Install: Install the spring at the smaller dia.
Pad pin plug:
• Pad pin plug "4" side.
2 Nm (0.2 m•kg, 1.4
Pad pin plug: ft•lb)
2 Nm (0.2 m•kg, 1.4
ft•lb)
4. Install:
INSTALLING THE BRAKE • Brake master cylinder kit "1"
MASTER CYLINDER KIT • Washer (front brake) "2"
INSTALLING THE REAR BRAKE 1. Clean: • Push rod (rear brake) "2"
CALIPER • Brake master cylinder • Circlip "3"
1. Install: • Brake master cylinder kit • Brake master cylinder boot "4"
• Pad support "1" Clean them with brake fluid. • Push rod (front brake) "5"
• Brake pad "2" 2. Install: To brake master cylinder.
• Pad pin "3" • Brake master cylinder cup (prima-
ry) "1" • Apply the brake fluid on the brake
• Install the brake pads with their pro- • Brake master cylinder cup (sec- master cylinder kit.
jections "a" into the brake caliper re- ondary) "2" • Apply the silicone grease on the tip
cesses "b". To brake master cylinder piston of the push rod.
• Temporarily tighten the pad pin at "3". • When installing the circlip, use a
this point. long nose circlip pliers.
Apply the brake fluid on the brake
master cylinder cup.
A. Front
B. Rear
5-12
FRONT BRAKE AND REAR BRAKE
5-13
FRONT BRAKE AND REAR BRAKE
2. Install:
• Brake hose holder "1"
Install the brake hose so that its Always use new copper washers. • Screw (brake hose holder) "2"
pipe portion "a" directs as shown
and lightly touches the projection Screw (brake hose hold-
"b" on the brake caliper. er):
3 Nm (0.3 m•kg, 2.2
ft•lb)
5-14
FRONT BRAKE AND REAR BRAKE
A. Front
B. Rear
5. Install: (rear brake only)
• Protector "1"
• Bolt (protector) "2"
A. Front Bolt (protector):
B. Rear 7 Nm (0.7 m•kg, 5.1
2. Air bleed: ft•lb)
• Brake system
Refer to "BLEEDING THE HY-
DRAULIC BRAKE SYSTEM" sec-
tion in the CHAPTER 3.
3. Inspect:
• Brake fluid level
Fluid at lower level → Fill up.
Refer to "CHECKING THE
BRAKE FLUID LEVEL" section in
the CHAPTER 3.
4. Install:
• Reservoir float (front brake)
• Diaphragm
• Brake master cylinder cap "1"
•Screw (bolt) {brake master cylinder
cap} "2"
Screw (bolt) {brake mas-
ter cylinder cap}:
2 Nm (0.2 m•kg, 1.4
ft•lb)
5-15
FRONT FORK
FRONT FORK
REMOVING THE FRONT FORK
5-16
FRONT FORK
5-17
FRONT FORK
5-18
FRONT FORK
5-19
FRONT FORK
9. Check:
13. Allow the overflowing oil to es-
• Damper assembly
cape at the hole "a" in the damper
Not fully stretched → Repeat the
assembly.
steps 2 to 8.
10. Tighten:
• Base valve "1" The overflow measures about 8
cm3(0.28 Imp oz, 0.27 US oz).
Base valve:
29 Nm (2.9 m•kg, 21 ft•
lb)
6. Tighten:
• Locknut "1"
Hold the damper assembly with the
Fully finger tighten the locknut onto cap bolt ring wrench "2" and use the
the damper assembly. cap bolt wrench "3" to tighten the
base valve with specified torque.
14. Check:
Cap bolt wrench: • Damper assembly smooth move-
YM-01500/90890-01500 ment
Cap bolt ring wrench: Tightness/binding/rough spots →
YM-01501/90890-01501 Repeat the steps 2 to 13.
7. Loosen:
• Compression damping adjuster
"1"
5-20
FRONT FORK
• Apply the fork oil on the inner tube. Fork seal driver:
• When installing the oil seal, use vi- YM-A0948/90890-01502
nyl seat "a" with fork oil applied to
protect the oil seal lip.
• Install the oil seal with its manufac-
ture's marks or number facing the
axle holder side. 22. Check:
• Inner tube smooth movement
Tightness/binding/rough spots →
Repeat the steps 15 to 21.
23. Measure:
19. Install: • Distance "a"
• Oil seal "1" Out of specification → Turn into
the locknut.
Press the oil seal into the outer tube Distance "a":
with fork seal driver "2". 16 mm (0.63 in) or more
16. Install: Between the damper
• Piston metal "1" assembly "1" bottom
Fork seal driver:
YM-A0948/90890-01502 and locknut "2" bot-
Install the piston metal onto the slot tom.
on inner tube.
20. Install:
24. Install:
• Stopper ring "1"
17. Install: • Collar "1"
• Outer tube "1" • Fork spring "2"
To inner tube "2". Fit the stopper ring correctly in the To damper assembly "3".
groove in the outer tube.
Install the collar with its larger dia.
end "a" facing the fork spring.
5-21
FRONT FORK
27. Install:
• Push rod "1"
• Copper washer "2"
• Adjuster "3" 32. Install:
To damper assembly "4". 30. Install: • Damper assembly "1"
• Adjuster "1" To outer tube.
• While compressing the inner tube
Adjuster:
"5", set the cap bolt ring wrench "7" Temporarily tighten the damper as-
55 Nm (5.5 m•kg, 40
between the inner tube and locknut sembly.
ft•lb)
"6".
• Fully finger tighten the adjuster onto To inner tube.
the damper assembly.
5-22
FRONT FORK
• Temporarily tighten the pinch bolts Tighten the lower bracket to speci-
(lower bracket). fied torque. If torqued too much, it
• Do not tighten the pinch bolts (up- may cause the front fork to mal-
per bracket) yet. function.
2. Tighten: 5. Install:
• Damper assembly "1" • Protector "1"
Damper assembly: • Bolt (protector) "2"
30 Nm (3.0 m•kg, 22 Bolt (protector):
ft•lb) 5 Nm (0.5 m•kg, 3.6
ft•lb)
Use the cap bolt ring wrench "2" to
tighten the damper assembly with
specified torque.
6. Adjust:
• Rebound damping force
5-23
HANDLEBAR
HANDLEBAR
REMOVING THE HANDLEBAR
5-24
HANDLEBAR
5-25
HANDLEBAR
3. Tighten:
• Nut (handlebar lower holder) "1"
After tightening the screws, check
Nut (handlebar lower that the throttle grip "3" moves
holder): smoothly. If it does not, retighten
34 Nm (3.4 m•kg, 24 the bolts for adjustment.
ft•lb)
• Cap "2"
6. Install:
• Collar "1"
• Grip cap cover "2"
• Throttle grip "3"
4. Install:
• Left grip "1"
Apply the lithium soap base grease
Apply the adhesive to the handle-
on the throttle grip sliding surface. 9. Install:
bar "2".
• Grip cap cover "1"
• Cover (throttle cable cap) "2"
• Before applying the adhesive, wipe
off grease or oil on the handlebar
surface "a" with a lacquer thinner.
• Install the left grip to the handlebar
so that the line "b" between the two
arrow marks faces straight upward.
7. Install:
• Throttle cables "1"
10. Install:
To tube guide "2".
• Brake master cylinder "1"
• Brake master cylinder bracket "2"
Apply the lithium soap base grease • Bolt (brake master cylinder brack-
on the throttle cable end and tube et) "3"
guide cable winding portion.
Bolt (brake master cylin-
5. Install: der bracket):
• Right grip "1" 9 Nm (0.9 m•kg, 6.5
• Collar "2" ft•lb)
Apply the adhesive on the tube
guide "3".
• Install the bracket so that the arrow
• Before applying the adhesive, wipe mark "a" faces upward.
off grease or oil on the tube guide • First tighten the bolt on the upper
surface "a" with a lacquer thinner. 8. Install: side of the brake master cylinder
• Install the grip to the tube guide so • Throttle cable cap "1" bracket, and then tighten the bolt on
that the grip match mark "b" and • Screw (throttle cable cap) "2" the lower side.
tube guide slot "c" form the angle as Screw (throttle cable
shown. cap):
4 Nm (0.4 m•kg, 2.9
ft•lb)
5-26
HANDLEBAR
11. Install:
• Engine stop switch "1"
• Clutch lever holder "2"
• Bolt (clutch lever holder) "3"
Bolt (clutch lever holder):
5 Nm (0.5 m•kg, 3.6
ft•lb)
•Clamp "4"
0 mm
0 mm
12. Install:
• Clutch cable "1"
13. Adjust:
• Clutch lever free play
Refer to "ADJUSTING THE
CLUTCH LEVER FREE PLAY"
section in the CHAPTER 3.
5-27
STEERING
STEERING
REMOVING THE STEERING
5-28
STEERING
5-29
STEERING
Take care not to damage the steer- Tighten the steering ring nut using
ing shaft thread. the steering nut wrench "2".
Refer to "CHECKING AND AD-
INSTALLING THE LOWER
JUSTING THE STEERING
BRACKET
HEAD" section in the CHAPTER
1. Install:
3.
• Lower bearing "1"
5-30
STEERING
7. Install:
• Front fork "1"
• Upper bracket "2"
8. Install:
• Steering stem nut "1"
Tighten the lower bracket to speci-
Steering stem nut: fied torque. If torqued too much, it
145 Nm (14.5 m•kg, 105 may cause the front fork to mal-
ft•lb) function.
5-31
SWINGARM
SWINGARM
REMOVING THE SWINGARM
5-32
SWINGARM
5-33
SWINGARM
5-34
SWINGARM
8. Install:
• Bolt (connecting rod) "1"
• Washer "2"
• Nut (connecting rod) "3"
2. Install:
• Collar "1" 5. Install:
• Apply the molybdenum disulfide
• Washer "2" • Relay arm "1"
grease on the bolt.
To relay arm "3". • Bolt (relay arm) "2"
• Do not tighten the nut yet.
• Washer "3"
Apply the molybdenum disulfide • Nut (relay arm) "4"
grease on the collars and oil seal lips. To swingarm.
9. Install:
• Bolt (rear shock absorber-relay
arm) "1"
3. Install: • Nut (rear shock absorber-relay
• Collar "1" arm) "2"
To connecting rod "2".
Nut (rear shock absorb-
er-relay arm):
Apply the molybdenum disulfide 53 Nm (5.3 m•kg, 38
grease on the collar and oil seal lips. 6. Install:
• Swingarm "1" ft•lb)
• Pivot shaft "2"
Pivot shaft: Apply the molybdenum disulfide
85 Nm (8.5 m•kg, 61 grease on the bolt.
ft•lb)
5-35
SWINGARM
12. Install:
• Bolt (lower chain tensioner) "1"
• Washer "2"
• Collar "3"
• Lower chain tensioner "4"
• Nut (lower chain tensioner) "5"
Nut (lower chain tension-
er):
16 Nm (1.6 m•kg, 11
ft•lb)
5-36
REAR SHOCK ABSORBER
5-37
REAR SHOCK ABSORBER
5-38
REAR SHOCK ABSORBER
5. Install:
Installed depth of the • Apply the molybdenum disulfide
• Bolt (rear shock absorber-relay
bearing "a": grease on the dust seal lips and col-
arm) "1"
4 mm (0.16 in) lars.
• Nut (rear shock absorber-relay
• Apply the lithium soap base grease
arm) "2"
on the O-rings.
Nut (rear shock absorb-
er-relay arm):
53 Nm (5.3 m•kg, 38
ft•lb)
2. Tighten:
• Adjuster "1"
3. Install:
• Rear shock absorber
5-39
FUEL TANK
FUEL SYSTEM
This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles
(e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are request-
ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to
servicing trouble and mechanical damage.
FUEL TANK
REMOVING THE FUEL TANK
6-1
FUEL TANK
6-2
FUEL TANK
2. Install: 20mm
35mm
• Fuel pump coupler
• Air scoop (left/right)
• Seat
35mm
Refer to "SEAT AND SIDE COV-
ERS" in the chapter 4. 20mm
CHECKING THE FUEL PRESSURE
1. Check:
• Pressure regulator operation
2. Remove the fuel tank.
Refer to "REMOVEING
THE FUEL TANK" section.
3. Connect the pressure gauge "1"
and adapter "2" to the fuel injec-
tion pipe.
Pressure gauge
YU-03153/90890-03153
Fuel pressure adapter
YM-03186/90890-03186
4. Install the fuel tank.
Refer to "INSTALLING THE
FUEL TANK" section.
5. Start the engine.
6. Measure the fuel pressure.
Fuel pressure
312–328 kPa (3.12–3.28
kg/cm2)
6-3
THROTTLE BODY
THROTTLE BODY
REMOVING THE THROTTLE BODY
6-4
THROTTLE BODY
6-5
THROTTLE BODY
6-6
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
ELECTRICAL
This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles
(e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are request-
ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to
servicing trouble and mechanical damage.
7-1
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
WIRING DIAGRAM
B/L
B/L Gy Gy B Gy
R O R/W L Y
W1 R
W1 W2 W2 W1 R/B Lg P/W
W2
B/L Gy B/Y Br Br/W O
B/R R B/R B B/W P
R O O R
B/R Gy O
R/B R/B R
B/R
W1 R
W2
ON P/W
P/W
STOP B/L B/L P/W L
B B L
W2 W1 W1 W2 B R
B
B
R B B/Y B L L
Y Y L Y Y L
B/L B/L
B B/L
R R
Lg Lg
P P
B/L B/L P L
L
R B B R B/W Lg R R Lg B/W
B B/W Br Br B/L
Br B/L
B B B/W
7-2
IGNITION SYSTEM
IGNITION SYSTEM
INSPECTION STEPS
Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure
and for checking the spark plug which will not spark.
Spark → • *Clean or replace spark plug.
Spark gap test • Check the connection of the spark plug cap to the
spark plug.
No spark ↓
Check entire ignition system for connection. No good →
Repair or replace.
(couplers, leads and ignition coil)
OK ↓
Check engine stop switch. No good → Replace.
OK ↓
Check ignition coil. (primary coil and secondary No good →
Replace.
coil)
OK ↓
Check AC magneto. (crankshaft position sensor No good →
Replace.
and stator coil)
OK ↓
Replace ECU.
*marked: Only when the ignition checker is used.
7-3
IGNITION SYSTEM
Ω at 20°C Ω×1
7. Inspect: (68°F)
• Installed condition of spark plug
and spark plug cap
Push in the spark plug cap, mak-
ing sure that it is securely fitted
into the hole in the cylinder head
cover.
7-4
IGNITION SYSTEM
2. Inspect:
• Stator coil resistance
Out of specification → Replace.
Tester (+) lead → White lead "1"
Tester (-) lead → White lead "2"
Tester se-
Stator coil
lector posi-
resistance
tion
0.60–0.90
Ω at 20°C Ω × 10
(68°F)
W2 W1
3. Check:
• ECU
If no fault is found, replace the
ECU.
7-5
THROTTLE POSITION SENSOR SYSTEM
7-6
THROTTLE POSITION SENSOR SYSTEM
7-7
THROTTLE POSITION SENSOR SYSTEM
Throttle po-
Tester se-
sition sen-
lector posi-
sor input
tion
voltage
4–6 V DCV-20
7-8
FUEL INJECTION SYSTEM
FI diagnostic tool
YU-03182/90890-03182 3. Set the switch on the FI diagnostic
FI diagnostic tool sub- tool subwire harness to "OFF".
wire harness
YU-03212/90890-03212
7-9
FUEL INJECTION SYSTEM
7-10
FUEL INJECTION SYSTEM
Diagnos-
Actuation or Actuation or LCD standard display
tic code Item Checking method
display values
No.
Displays the throttle angle. 0–125°
Check with throttle fully closed. When throttle is fully closed:15–19°
D01 Throttle angle Display
Check with throttle fully open. When throttle is fully opened:95–
101 °
Displays the atmospheric pres- 0–126 kPa
sure. Displays the atmospheric pressure
• Measure the atmospheric pres- according to the elevation and
sure. weather.
D02 Atmosphere Display Example
0 m above sea level: Approx: 101
kPa
3000 m above sea level:Approx: 70
kPa
Displays the intake air pressure. 0–126 kPa
• Check the intake manifold pres- While the engine is stopped: Dis-
sure. plays the atmospheric pressure ac-
• Check that the intake air pres- cording to the elevation and
sure changes while the engine is weather.
being cranked.
Example
D03 Intake air pressure Display
0 m above sea level: Approx: 101
kPa
3000 m above sea level:Approx: 70
kPa
While the engine is being cranked:
Displays the intake air pressure.
Displays the intake air tempera- -20–100°C
ture. Cold engine: Displayed tempera-
• Check the temperature in the in- ture is close to the ambient temper-
D05 Intake air temperature Display take manifold. ature.
Warm engine: Displayed tempera-
ture is approximately 20 °C higher
than the ambient temperature.
Displays the coolant temperature. -20–150°C
• Check the coolant temperature. Cold engine: Displayed tempera-
ture is close to the ambient temper-
D06 Coolant temperature Display ature.
Warm engine: Displayed tempera-
ture is the current coolant tempera-
ture.
Displays the lean angle sensor 0–5.0 V
output voltage. 1.0 V: Upright
D08 Lean angle sensor Display
Remove the ECU and incline it 45°
or more. 4.0 V: Overturned
Check that power is supplied to Actuates the ignition coil for five
the ignition coil. times every second.
D30 Ignition coil Actuation • Check that a spark is generated. The "WARNING" LED on the FI di-
• Illuminates the engine trouble agnostic tool comes on each time
warning light. the fuel injector is actuated.
7-11
FUEL INJECTION SYSTEM
Diagnos-
Actuation or Actuation or LCD standard display
tic code Item Checking method
display values
No.
Check that power is supplied to Actuates the injector for five times
the fuel injector. every second.
• Check the fuel injector operation The "WARNING" LED on the FI di-
D36 Injectors Actuation
by listening for the operating agnostic tool comes on each time
sound or by confirming the oper- the fuel injector is actuated.
ation visually.
Displays the abnormal portion of 00: No fault
the data in the EEPROM that has 01: CO adjustment valve
been detected as a fault code No.
44. 07: Power Tuner adjustment val-
If code numbers more than one ues 0–8 for fuel injection amount or
EEPROM fault code ignition timing
D60 Display are detected, the display alter-
display.
nates every two seconds to show
all the detected code numbers.
When all code numbers are
shown, the display repeats the
same process.
Displays the fault code numbers 00: No history
that are stored in the malfunction 12–50: History exists
history. • Refer to the fault code number.
If code numbers more than one
Malfunction history are detected, the display alter-
D61 Display
code display. nates every two seconds to show
all the detected code numbers.
When all code numbers are
shown, the display repeats the
same process.
Displays the total number of mal- 00: No history
functions, including the current 1–15: History exists
malfunction, that have occurred
since the history was last erased. When this diagnostic code number
Malfunction history Actuation is selected, fault code numbers for
D62 In addition, deletes the fault code
code erasure and display previously detected malfunctions
numbers from the history if the cor-
responding items are currently op- are deleted from the history if the
erating normally. corresponding items are currently
operating normally.
Displays whether or not history ex- 00: There is no setting history.
ists for settings that were made us- 01: There is setting history.
D64 Setting history display Display ing the Power Tuner.
02: Whether or not setting history
data exists cannot be determined
(damage to history data).
Erases the settings that were 00: There are no settings that were
made using the Power Tuner. made using the Power Tuner.
D65 Setting map erasure Display
01: There are settings that were
made using the Power Tuner.
Program version Check the version number of the 0–254
D70 Display
number program.
7-12
FUEL INJECTION SYSTEM
TROUBLESHOOTING DETAILS
This section describes the countermeasures per fault code number displayed on the FI diagnostic tool. Check and service
the items or components that are the probable cause of the malfunction following the order given. After the check and ser-
vice of the malfunctioning part have been completed, reset the FI diagnostic tool display according to the "Reinstatement
method".
Fault code No.
Fault code number displayed on the FI diagnostic tool when the engine failed to work normally. Refer to "FAULT CODE
TABLE".
Diagnostic code No.
Diagnostic code number to be used when the diagnostic mode is operated. Refer to "DIAGNOSTIC CODE TABLE".
7-13
FUEL INJECTION SYSTEM
If fault code Nos. 13 and 14 are both displayed, perform the checks and maintenance jobs for fault code No. 13 first.
7-14
FUEL INJECTION SYSTEM
7-15
FUEL INJECTION SYSTEM
If fault code Nos. 13 and 14 are both displayed, perform the checks and maintenance jobs for fault code No. 13 first.
7-16
FUEL INJECTION SYSTEM
7-17
FUEL INJECTION SYSTEM
7-18
FUEL INJECTION SYSTEM
7-19
FUEL INJECTION SYSTEM
Make sure that the engine is completely cool before checking the coolant temperature sensor.
7-20
FUEL INJECTION SYSTEM
Make sure that the engine is completely cool before checking the intake air temperature sensor.
7-21
FUEL INJECTION SYSTEM
7-22
FUEL INJECTION SYSTEM
7-23
FUEL INJECTION SYSTEM
7-24
FUEL INJECTION SYSTEM
7-25
FUEL INJECTION SYSTEM
7-26
FUEL INJECTION SYSTEM
7-27
FUEL INJECTION SYSTEM
7-28
FUEL INJECTION SYSTEM
7-29
FUEL INJECTION SYSTEM
7-30
FUEL INJECTION SYSTEM
7-31
FUEL INJECTION SYSTEM
7-32
FUEL INJECTION SYSTEM
7-33
FUEL INJECTION SYSTEM
7-34
FUEL PUMP SYSTEM
Pocket tester:
YU-03112-C/90890-03112
Test harness S-pressure sensor (3P):
YU-03207/90890-03207
7-35
ELECTRICAL COMPONENTS
sensor (3P)
Br B/L
YU-03207/90890-03207
Intake air
Tester se-
tempera-
lector posi-
ture sensor
tion
4. Immerse the coolant temperature resistance
sensor in a container filled with 5.4–6.6 kΩ
coolant. kΩ×1
(0°C, 32°F)
3. Connect the FI diagnostic tool 290–390 Ω
Make sure the coolant temperature sub-wire harness to a battery, and (80°C, Ω×100
sensor terminals do not get wet. then set the switch on the harness 176°F)
to "ON".
5. Place a thermometer "3" in the Out of specification → Replace.
coolant. CHECKING THE ATMOSPHERIC
6. Slowly heat the coolant, and then When checking the intake air pres- PRESSURE SENSOR
let it cool to the specified temper- sure sensor, do not start the en- 1. Check:
ature indicated in the table. gine. • Atmospheric pressure sensor out-
put voltage
4. Measure the intake air pressure
2. Connect:
sensor output voltage.
• Test harness S- pressure sensor
Tester se- (3P) "1"
Output volt-
lector posi- • Tester
age
tion Tester (+) lead → Pink lead (wire
3.4–3.8 V DCV harness color)
Tester (-) lead → Black/Blue lead
Out of specification → Replace (wire harness color)
7-36
ELECTRICAL COMPONENTS
R Lg B/W
7-37
CHASSIS
8-1
CHASSIS
SO
0.459 33D-23141-20 |-||
FT
ST 33D-23141-30 |-|||
0.469
D 33D-23141-D0 —
STI
0.479 33D-23141-40 |-||||
FF
2. Remove the stand or block from
A. Air spring characteristics in the engine and with a rider astride
The I.D. mark (slits) "a" is proved on
relation to oil amount change the seat, measure the sunken
the end of the spring.
B. Load length "b" between the rear wheel
C. Stroke axle center and the rear fender
1. Max. oil amount holding bolt.
2. Standard oil amount
3. Min. oil amount
SETTING OF SPRING AFTER
REPLACEMENT
As the front fork setting can be easily
affected by rear suspension, take
care so that the machine front and
rear are balanced (in position, etc.)
3. Loosen the locknut "1" and make
when setting the front fork.
adjustment by turning the spring
1. Use of soft spring
adjuster "2" to achieve the stan-
• Change the rebound damping.
dard figure from the subtraction of
Turn out one or two clicks.
the length "b" from the length "a".
• Change the compression damp-
ing. Standard figure:
Turn in one or two clicks. REAR SUSPENSION SETTING 90–100 mm (3.5–3.9 in)
The rear suspension setting should
Generally a soft spring gives a soft be made depending on the rider's
riding feeling. Rebound damping feeling of an actual run and the circuit • If the machine is new and after it is
tends to become stronger and the conditions. broken in, the same set length of
front fork may sink deeply over a se- The rear suspension setting includes the spring may change because of
ries of gaps. the following two factors: the initial fatigue, etc. of the spring.
1. Setting of spring preload Therefore, be sure to make reeval-
2. Use of stiff spring • Change the set length of the uation.
• Change the rebound damping. spring. • If the standard figure cannot be
Turn in one or two clicks. • Change the spring. achieved by adjusting the spring
• Change the compression damp- 2. Setting of damping force adjuster and changing the spring
ing. • Change the rebound damping. set length, replace the spring with
Turn out one or two clicks. • Change the compression damp- an optional one and make readjust-
8
ing. ment.
Generally a stiff spring gives a stiff
riding feeling. Rebound damping
tends to become weaker, resulting in
lack of a sense of contact with the
road surface or in a vibrating handle-
bar.
8-2
CHASSIS
SETTING OF SPRING AFTER REAR SHOCK ABSORBER • Extent of adjustment (spring pre-
REPLACEMENT SETTING PARTS load)
After replacement, be sure to adjust • Rear shock spring "1" SPRING
the spring to the set length [sunken SPRI SPRING PART
length 90–100 mm (3.5–3.9 in)] and Maximum Minimum
NG PART I.D. NUMBER
set it. TYPE
RAT NUMBER MARK (-22212-)
1. Use of soft spring E (-22212-) 33D-10 Position Position
• Set the soft spring for less re-
33D-10 33D-20 in which in which
bound damping to compensate
(Blue) 33D-30 the spring the spring
for its less spring load. Run with
SOFT 5.3 Yellow 33D-40 is turned is turned
the rebound damping adjuster 33D-B0 33D-B0 in 18 mm in 1.5 mm
one or two clicks on the softer
(Red) 33D-C0 (0.71 in) (0.06 in)
side and readjust it to suit your
33D-D0 from its from its
preference. 33D-20
33D-E0 free free
2. Use of stiff spring (Blue) length. length.
• Set the soft spring for more re- * STD 5.5 Pink
bound damping to compensate 33D-C0
for its greater spring load. Run (Red) For the spring preload adjustment, re-
with the rebound damping adjust- fer to "ADJUSTING THE REAR
33D-30
er one or two clicks on the stiffer SHOCK ABSORBER SPRING PRE-
side and readjust it to suit your (Blue)
STD 5.7 White LOAD" in the CHAPTER 3.
preference. 33D-D0
(Red)
Adjusting the rebound damping will
be followed more or less by a change 33D-40
in the compression damping. For cor- (Blue)
rection, turn the low compression STIFF 5.9 Silver
33D-E0
damping adjuster on the softer side.
(Red)
* Except for USA and CDN
When using a rear shock absorber
other than currently installed, use
the one whose overall length "a" • The I.D. mark "a" is marked at the
does not exceed the standard as it end of the spring.
may result in faulty performance. • Spring specification varies accord-
Never use one whose overall ing to the color and quantity of I.D.
length is greater than standard. marks.
8-3
CHASSIS
• If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to
the adjustment procedure given in the same chart.
• Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in).
Section
8-4
CHASSIS
• If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to
the adjustment procedure given in the same chart.
• Adjust the rebound damping in 2-click increments or decrements.
• Adjust the low compression damping in 1-click increments or decrements.
• Adjust the high compression damping in 1/6 turn increments or decrements.
Section
8-5
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
(E)