OWNER’S SERVICE MANUAL WR450FR LIT-11626-16-43 5TJ-28199-10
EC010000 WR450FR OWNER’S SERVICE MANUAL ©2002 by Yamaha Motor Corporation, U.S.A. 1st Edition, October 2002 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U.S.A. is expressly prohibited. Printed in Japan P/N.
EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha WR series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader. This manual explains operation, inspection, basic maintenance and tuning of your machine. If you have any questions about this manual or your machine, please contact your Yamaha dealer.
IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding. SAFETY INFORMATION 1. THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY. Do not attempt to operate this machine at maximum power until you are totally familiar with its characteristics. 2.
6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes. 7. ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILATION. Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are poisonous.
EC050000 TO THE NEW OWNER This manual will provide you with a good basic understanding of features, operation, and basic maintenance and inspection items of this machine. Please read this manual carefully and completely before operating your new machine. If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer. NOTE: This manual should be considered a permanent part of this machine and should remain with it even if the machine is subsequently sold.
EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the machine. NOTE: A NOTE provides key information to make procedures easier or clearer.
EC083000 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 mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., ● Bearings Pitting/damage → Replace.
1 ILLUSTRATED SYMBOLS (Refer to the illustration) 2 GEN INFO 3 SPEC Illustrated symbols 1 to 7 are designed as thumb tabs to indicate the chapter’s number and content. 4 INSP ADJ ENG 5 6 CHAS ELEC – + 1 General information 2 Specifications 3 Regular inspection and adjustments 4 Engine 5 Chassis 6 Electrical 7 Tuning 8 Illustrated symbols 8 to D are used to identify the specifications appearing in the text.
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EC090000 INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS GEN INFO 1 SPEC 2 INSP ADJ 3 ENG 4 CHAS 5 – ELECTRICAL TUNING + ELEC 6 TUN 7
EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION .......................................... 1-1 MACHINE IDENTIFICATION .................... 1-2 IMPORTANT INFORMATION ................... 1-3 CHECKING OF CONNECTION ................. 1-6 SPECIAL TOOLS ...................................... 1-7 CONTROL FUNCTIONS ......................... 1-10 FUEL ....................................................... 1-14 STARTING AND BREAK-IN ................... 1-15 TORQUE-CHECK POINTS .....................
CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS ................................. 4-1 EXHAUST PIPE AND SILENCER ............ 4-3 RADIATOR ................................................ 4-5 CARBURETOR ......................................... 4-8 CAMSHAFTS .......................................... 4-21 CYLINDER HEAD ................................... 4-29 VALVES AND VALVE SPRINGS ........... 4-33 CYLINDER AND PISTON ....................... 4-42 CLUTCH ..................................................
CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ........................... 6-1 MAP-CONTROLLED CDI UNIT ................ 6-2 IGNITION SYSTEM ................................... 6-3 ELECTRIC STARTING SYSTEM .............. 6-7 CHARGING SYSTEM ............................. 6-17 TPS (THROTTLE POSITION SENSOR) SYSTEM .................................................. 6-19 LIGHTING SYSTEM ................................ 6-24 CHAPTER 7 TUNING ENGINE .................................................
DESCRIPTION GEN INFO EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P NOTE: The machine you have purchased may differ slightly from those shown in the following. ● Designs and specifications are subject to change without notice.
MACHINE IDENTIFICATION GEN INFO EC120001 MACHINE IDENTIFICATION There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine. EC121001 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped on the right of the steering head pipe.
IMPORTANT INFORMATION GEN INFO EC130000 IMPORTANT INFORMATION EC131010 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. When washing the machine with high pressured water, cover the parts as follows. ● Silencer exhaust port ● Side cover air intake port ● Water pump housing hole at the bottom ● Drain hole on the cylinder head (right side) ● All electrical components 2. Use proper tools and cleaning equipment.
IMPORTANT INFORMATION GEN INFO EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.
IMPORTANT INFORMATION GEN INFO EC136000 CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1, make sure that the sharp-edged corner 2 is positioned opposite to the thrust 3 it receives. See the sectional view.
CHECKING OF CONNECTION GEN INFO EC1C0001 CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: ● Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off. 5. If the terminal comes off, bend up the pin 1 and reinsert the terminal into the connector. 6. Connect: ● Connector NOTE: The two connectors “click” together. 7. Check for continuity with a tester.
SPECIAL TOOLS GEN INFO EC140001 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. NOTE: ● For U.S.A. and Canada, use part number starting with “YM-”, “YU-” or “ACC-”.
SPECIAL TOOLS Part number YM-01442, 90890-01442 Tool name/How to use Fork seal driver GEN INFO Illustration YM-01442 90890-01442 YU-3112-C 90890-03112 YU-8036-B 90890-03113 YM-33277-A 90890-03141 YM-4019 90890-04019 YM-91042 90890-04086 YM-4116 YM-4097 90890-04116 90890-04097 YM-4117 YM-4098 90890-04117 90890-04098 YM-4118 YM-4099 90890-04118 90890-04099 This tool is used when install the fork oil seal.
SPECIAL TOOLS Part number YM-04141, 90890-04141 Tool name/How to use Rotor puller GEN INFO Illustration YM-04141 90890-04141 YM-34487 90890-06754 ACC-QUICK-GS-KT 90890-85505 This tool is used to remove the flywheel magneto. YM-34487 90890-06754 Dynamic spark tester Ignition checker This instrument is necessary for checking the ignition system components. ACC-QUICK-GS-KT 90890-85505 Quick gasket YAMAHA Bond No. 1215 This sealant (Bond) is used for crankcase mating surface, etc.
CONTROL FUNCTIONS GEN INFO EC150000 CONTROL FUNCTIONS MAIN SWITCH Functions of the respective switch positions are as follows: ON: The engine can be started only at this position. OFF: All electrical circuits are switched off. Main switch indicator light The main switch 1 is equipped with an indicator light 2 to avoid forgetting to turn it off. This light functions as follows. ● It lights up with the main switch “ON”. ● It goes out when the engine increases its speed after being started.
CONTROL FUNCTIONS GEN INFO EC152000 CLUTCH LEVER The clutch lever 1 is located on the left handlebar; it disengages or engages the clutch. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth starts. EC153000 SHIFT PEDAL The gear ratios of the constant-mesh 5 speed transmission are ideally spaced. The gears can be shifted by using the shift pedal 1 on the left side of the engine.
CONTROL FUNCTIONS GEN INFO EC157000 REAR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine. Press down on the brake pedal to activate the rear brake. FUEL COCK The fuel cock supplies fuel from the tank to carburetor and also filters the fuel. The fuel cock has three positions: OFF:With the lever in this position fuel will not flow. Always return the lever to this position when the engine is not running. ON: With the lever in this position fuel flows to the carburetor.
CONTROL FUNCTIONS GEN INFO LIGHTS SWITCH The lights switch 1 is located on the handlebar. EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose. CAUTION: In this installation, make sure the arrow faces the fuel tank and also downward. SPARK PLUG WRENCH This spark plug wrench 1 is used to remove and install the spark plug. 1 1 NIPPLE WRENCH This nipple wrench 1 is used to tighten the spoke.
FUEL GEN INFO FUEL Always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race. Recommended fuel: Except for ZA: Premium unleaded gasoline only with a research octane number of 95 or higher. For ZA: Premium gasoline CAUTION: Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts such as valves, piston rings, and exhaust system, etc.
STARTING AND BREAK-IN GEN INFO STARTING AND BREAK-IN WARNING Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Always operate the machine in a well-ventilated area. CAUTION: ● ● ● The carburetor on this machine has a built-in accelerator pump. Therefore, when starting the engine, do not operate the throttle or the spark plug will foul.
STARTING AND BREAK-IN GEN INFO NOTE: If the engine fails to start by pushing the start switch, release the switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt. If the engine does not start with the starter motor, try using the kickstarter.
STARTING AND BREAK-IN GEN INFO STARTING A WARM ENGINE Do not operate the cold starter knob and throttle. Pull the hot starter lever 1 and start the engine by pushing the start switch or by kicking the kickstarter forcefully with a firm stroke. As soon as the engine starts, release the hot starter lever to close the air passage. Restarting an engine after a fall Pull the hot starter lever and start the engine. As soon as the engine starts, release the hot starter lever to close the air passage.
STARTING AND BREAK-IN GEN INFO BREAK-IN PROCEDURES 1. Before starting the engine, fill the fuel tank with the fuel. 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the “ENGINE STOP” button. Then, restart the engine and check its operation within no more than 5 minutes after it is restarted. 4. Operate the machine in the lower gears at moderate throttle openings for five to eight minutes. 5.
TORQUE-CHECK POINTS GEN INFO TORQUE-CHECK POINTS Frame construction Frame to rear frame Fuel tank to frame Combined seat and tank Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Suspension Wheel Steering shaft to handlebar Steering shaft to frame Steering shaft to handle crown Handle crown to handlebar Front Steering shaft to front fork Front fork to handle crown Front fork to under bracket Rear For link type A
CLEANING AND STORAGE GEN INFO EC1B0000 CLEANING AND STORAGE EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many components. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering. A plastic bag secured with a rubber band may be used for this purpose. 2. If the engine is excessively greasy, apply some degreaser to it with a paint brush.
CLEANING AND STORAGE GEN INFO 8. Automotive wax may be applied to all painted or chromed surfaces. Avoid combination cleaner-waxes, as they may contain abrasives. 9. After completing the above, start the engine and allow it to idle for several minutes. EC1B2001 STORAGE If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as follows: 1.
GENERAL SPECIFICATIONS SPEC EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: WR450FR (USA) WR450F (EUROPE) WR450F(R) (CDN, AUS, NZ, ZA) 5TJ1 (USA) 5TJ2 (EUROPE) 5TJ4 (CDN, AUS, NZ, ZA) Model code number: Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Basic weight: With oil and full fuel tank Engine: Engine type Cylinder arrangement Displacement Bore × stroke Compression ratio Starting system Lubrication system: Oil type or gra
GENERAL SPECIFICATIONS Oil capacity: Engine oil Periodic oil change With oil filter replacement Total amount Coolant capacity (including all routes): Air filter: Fuel: Type Tank capacity Reserve Carburetor: Type Manufacturer Spark plug: Type/manufacturer Gap Clutch type: Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio: 1st 2nd 3rd 4th 5th Chassis: Frame type Caster angle Trail Tire: Type Size (front)
GENERAL SPECIFICATIONS Brake: Front brake type Operation Rear brake type Operation Suspension: Front suspension Rear suspension Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system Battery type Battery voltage/capacity Specific gravity Headlight type: Bulb wattage × quantity: Headlight Taillight SPEC Single disc brake Right hand operation Single disc brake Right foot operation Telescopic fork Swingarm (link
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Item Standard Cylinder head: Warp limit Cylinder: Bore size Out of round limit Camshaft: Drive method Camshaft cap inside diameter Camshaft journal diameter Shaft-to-cap clearance Limit ---- 0.05 mm (0.002 in) 95.00 ~ 95.01 mm (3.7402 ~ 3.7406 in) ---- ---0.05 mm (0.002 in) Chain drive (Left) 22.000 ~ 22.021 mm (0.8661 ~ 0.8670 in) 21.967 ~ 21.980 mm (0.8648 ~ 0.8654 in) 0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) ------- 31.200 ~ 31.
MAINTENANCE SPECIFICATIONS Item SPEC Standard Cam chain: Cam chain type/No. of links Cam chain adjustment method Valve, valve seat, valve guide: Valve clearance (cold) IN EX Limit 98XRH2010-118M/118 Automatic ------- 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in) ------- Valve dimensions: B C D A Head Diameter “A” head diameter IN IN 26.9 ~ 27.1 mm (1.0591 ~ 1.0669 in) 27.9 ~ 28.1 mm (1.0984 ~ 1.1063 in) 2.26 mm (0.089 in) 2.26 mm (0.089 in) 0.9 ~ 1.1 mm (0.
MAINTENANCE SPECIFICATIONS Item Valve spring: Free length Set length (valve closed) Compressed force (installed) Standard * Direction of winding (top view) Limit IN 37.03 mm (1.46 in) EX 37.68 mm (1.48 in) IN EX 27.87 mm (1.10 in) 27.38 mm (1.08 in) IN IN 111.3 ~ 127.9 N at 27.87 mm (11.3 ~ 13.0 kg at 27.87 mm, 24.91 ~ 28.66 lb at 1.10 in) 127.4 ~ 146.4 N at 27.38 mm (13.0 ~ 14.9 kg at 27.38 mm, 28.66 ~ 32.85 lb at 1.08 in) ---- EX ---- IN EX Clockwise Clockwise ------- 0.040 ~ 0.
MAINTENANCE SPECIFICATIONS Item SPEC Standard Limit Piston rings: Top ring: B T Type Dimensions (B × T) End gap (installed) Side clearance (installed) Barrel 1.2 × 3.5 mm (0.05 × 0.14 in) 0.20 ~ 0.30 mm (0.008 ~ 0.012 in) 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in) ------0.55 mm (0.022 in) 0.12 mm (0.005 in) Taper 1.00 × 3.35 mm (0.04 × 0.13 in) 0.35 ~ 0.50 mm (0.014 ~ 0.020 in) 0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in) ------0.85 mm (0.033 in) 0.12 mm (0.005 in) 2.0 × 2.9 mm (0.08 × 0.11 in) 0.2 ~ 0.
MAINTENANCE SPECIFICATIONS Item SPEC Standard Clutch: Friction plate thickness Quantity Clutch plate thickness Quantity Warp limit 2.92 ~ 3.08 mm (0.115 ~ 0.121 in) 9 1.1 ~ 1.3 mm (0.043 ~ 0.051 in) 8 ---- Clutch spring free length 48.4 mm (1.91 in) Quantity Clutch housing thrust clearance 6 0.10 ~ 0.35 mm (0.0039 ~ 0.0138 in) 0.010 ~ 0.044 mm (0.0004 ~ 0.
MAINTENANCE SPECIFICATIONS Item Lubrication system: Oil filter type Oil pump type Tip clearance “A” Tip clearance “B” Side clearance Bypass valve setting pressure Cooling: Radiator core size Width Height Thickness Radiator cap opening pressure Radiator capacity (total) Water pump Type SPEC Standard Limit Paper type Trochoid type 0.12 mm or less (0.0047 in or less) 0.09 ~ 0.17 mm (0.0035 ~ 0.0067 in) 0.03 ~ 0.10 mm (0.0012 ~ 0.0039 in) 40 ~ 80 kPa (0.4 ~ 0.8 kg/cm 2, 5.69 ~ 11.38 psi) ------0.20 mm (0.
MAINTENANCE SPECIFICATIONS Item SPEC Standard Lubrication chart: Pressure feed Oil tank Splashed scavenge Camshaft Cylinder head Valve lifter Piston Transmission gears Piston pin Main axle Crank pin Oil filter Drive axle Check ball Oil pump rotor 1 Oil pump rotor 2 Oil strainer Oil pan 2 - 10
SPEC MAINTENANCE SPECIFICATIONS Part to be tightened Spark plug Camshaft cap Cylinder head blind plug screw Cylinder head (stud bolt) (bolt) (nut) Cylinder head cover Cylinder Timing chain tensioner Tensioner cap bolt Timing chain guide (rear) Exhaust pipe (nut) (bolt) Silencer Silencer clamp Exhaust pipe protector Spark arrester (for USA) Silencer end pipe (for USA) Carburetor joint clamp (cylinder head side) Carburetor joint clamp (carburetor side) Air filter case Air filter joint clamp Air filter joint
SPEC MAINTENANCE SPECIFICATIONS Part to be tightened Oil check bolt Oil hose clamp Clutch cover Crankcase cover (right) Crankcase cover (left) Idle gear cover (starter motor) Crankcase Clutch cable holder Oil drain bolt (crankcase rear) (crankcase left) Oil drain bolt (frame) Oil strainer (frame) Crankcase bearing stopper Drive axle oil seal stopper Ratchet wheel guide Stopper plate Kickstarter Screw (kickstarter) Starter clutch Primary drive gear Clutch boss Push lever Clutch spring Balancer driven gear B
MAINTENANCE SPECIFICATIONS SPEC EC212201 CHASSIS Item Steering system: Steering bearing type Front suspension: Front fork travel Fork spring free length Spring rate, STD Optional spring/spacer Oil capacity Oil level (From top of outer tube with inner tube and damper rod fully compressed without spring.) Oil grade Inner tube outer diameter Front fork top end Rear suspension: Shock absorber travel Spring free length Fitting length
MAINTENANCE SPECIFICATIONS Item Wheel: Front wheel type Rear wheel type Front rim size/material Rear rim size/material Rim runout limit: Radial Lateral SPEC Standard Limit Spoke wheel Spoke wheel 21 × 1.60/Aluminum 18 × 2.15/Aluminum ------------- ---- 2.0 mm (0.08 in) 2.0 mm (0.08 in) ---- Drive chain: Type/manufacturer Number of links Chain slack Chain length (10 links) DID520VM/DAIDO 113 links + joint 40 ~ 50 mm (1.6 ~ 2.0 in) ---- ---------150.1 mm (5.
MAINTENANCE SPECIFICATIONS Part to be tightened Thread size Q’ty Handle crown and outer tube Under bracket and outer tube Handle crown and steering shaft Handlebar holder (upper) Steering ring nut Front fork and cap bolt Front fork and base valve Cap bolt and damper rod (front fork) Bleed screw (front fork) and cap bolt Front fork and protector Front fork and brake hose holder Front fork and hose cover Front fork and hose cover Throttle cable cap Clutch lever holder mounting Hot starter lever holder moun
MAINTENANCE SPECIFICATIONS Part to be tightened Rear wheel axle and nut Driven sprocket and wheel hub Nipple (spoke) Disc cover and rear brake caliper Protector and rear brake caliper Chain puller adjust bolt and locknut Engine mounting: Engine upper bracket and frame Engine lower bracket and frame Engine and frame (front) Engine and frame (upper) Engine and frame (lower) Engine guard (left and right) Engine skid plate mounting Regulator bracket mounting Regulator mounting Pivot shaft and nut Relay arm and
MAINTENANCE SPECIFICATIONS Part to be tightened Meter cable holder and protector Headlight stay (lower) and under bracket Headlight body and headlight unit Headlight mounting (left and right) Headlight mounting (lower) Taillight mounting Taillight lead clamp and rear fender Coolant reservoir tank mounting Sidestand bracket mounting Sidestand mounting Thread size Q’ty M5 × 0.8 M8 × 1.25 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M4 × 1.59 M6 × 1.0 M10 × 1.25 M10 × 1.
MAINTENANCE SPECIFICATIONS SPEC EC212300 ELECTRICAL Item Ignition system: Advancer type C.D.I.
MAINTENANCE SPECIFICATIONS Item Starter relay: Model/manufacturer Amperage rating Coil winding resistance Starting circuit cut-off relay: Model/manufacturer Coil winding resistance Fuse (amperage × quantity): Main fuse Reserve fuse Part to be tightened Stator Holder (AC magneto lead) Rotor Neutral switch Starter motor Starter relay terminal SPEC Standard Limit 2768090-A/JIDECO 180 A 4.2 ~ 4.6 Ω at 20 ˚C (68 ˚F) ---------- ACM33221 M06/MATSUSHITA 75.69 ~ 92.
GENERAL TORQUE SPECIFICATIONS/ DEFINITION OF UNITS SPEC EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads.
LUBRICATION DIAGRAMS SPEC LUBRICATION DIAGRAMS 1 Oil delivery pipe 2 Intake camshaft 3 Exhaust camshaft 4 Oil cleaner element 5 Oil pump 6 Main axle 7 Drive axle G 2 4 3 1 D-D 4 G 5 D A D A 7 A-A 6 5 2 - 21
LUBRICATION DIAGRAMS 1 Camshaft 2 Connecting rod 3 Oil cleaner element 4 Crankshaft 5 Main axle 6 Drive axle 7 Oil delivery pipe 1 2 3 4 5 6 2 - 22 7 SPEC
CABLE ROUTING DIAGRAM SPEC EC240000 CABLE ROUTING DIAGRAM 1 Fuel tank breather hose 2 Clamp 3 Diode 4 Wire harness 5 Hot starter cable 6 Negative battery lead 7 Starter motor lead 8 TPS (throttle position sensor) lead 9 Neutral switch lead 0 Oil hose A Hose holder B Radiator hose 4 C Cylinder head breather hose D AC magneto lead E Radiator hose 1 F Oil tank breather hose G Lights switch lead H Brake hose I Hose guide J Carburetor breather hose K Overflow hose L Coolant reservoir tank breather hose Å Ins
CABLE ROUTING DIAGRAM Ï Fasten the wire harness, TPS lead (in the wire harness), starter motor lead and negative battery lead to the frame with a plastic locking tie and cut off the tie end. Ì Make sure that the TPS coupler does not go out the chassis. Ó Fasten the TPS lead to the frame with a plastic band. È Fasten the neutral switch lead and oil hose together with the plastic locking ties and cut off the tie ends. Ô Pass the cylinder head breather hose through the hose holder.
CABLE ROUTING DIAGRAM 1 Hot starter cable 2 Clutch cable 3 Throttle cable (return) 4 Throttle cable (pull) 5 Ignition coil 6 Negative battery lead 7 Starter motor lead 8 Coolant reservoir tank breather hose 9 Rectifier/regulator 0 Cable holder A Coolant reservoir hose B Rectifier/regulator lead C Clamp D CDI unit lead E CDI unit F CDI unit band G CDI unit stay (frame) H Cable bracket I Rectifier/regulator bracket Å Pass the throttle cables, clutch cable and hot starter cable through the cable guides.
CABLE ROUTING DIAGRAM 1 Master cylinder 2 Brake hose holder 3 Brake hose Å Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the caliper. ı Pass the brake hose into the brake hose holders. Ç If the brake hose contacts the spring (rear shock absorber), correct its twist. Î Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the master cylinder.
CABLE ROUTING DIAGRAM 1 Starter motor lead 2 Negative battery lead 3 Wire harness 4 Clamp 5 Taillight lead 6 Coolant reservoir tank breather hose 7 Coolant reservoir hose 8 Positive battery lead 9 Starting circuit cut-off relay 0 Battery Å Position the starter motor lead, negative battery lead and wire harness in the tank damper slit. ı Fasten the wire harness to the frame with a plastic locking tie and cut off the tie end. Ç Do not allow the taillight lead to slacken.
CABLE ROUTING DIAGRAM 1 Throttle cable 2 Brake hose 3 Clamp 4 Lights switch lead 5 Hot starter cable 6 Clutch cable 7 Hose guide 8 Clutch switch lead 9 “ENGINE STOP” button lead 0 Trip meter cable A Main switch lead B Trip meter C Main switch D Lights switch E Start switch lead Å Fasten the start switch lead and lights switch lead to the handlebar with a plastic band. ı Fasten the “ENGINE STOP” button lead and clutch switch lead to the handlebar with the plastic bands.
MAINTENANCE INTERVALS INSP ADJ EC300000 REGULAR INSPECTION AND ADJUSTMENTS 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.
MAINTENANCE INTERVALS Item SHIFT FORK, SHIFT CAM, GUIDE BAR Inspect ROTOR NUT Retighten MUFFLER Inspect and retighten Clean Replace *SPARK ARRESTER Clean After Every break-in race Every Every third fifth (or (or 500 km) 1,000 km) ● ● As required INSP ADJ Remarks ● Inspect wear ● * Whichever comes first ● ● ● (Every six months) ● CRANK Inspect and clean CARBURETOR Inspect, adjust and clean SPARK PLUG Inspect and clean Replace DRIVE CHAIN Lubricate, slack, alignment Replace COOLING SYSTEM Check
MAINTENANCE INTERVALS Item FRONT FORKS Inspect and adjust Replace oil Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube REAR SHOCK ABSORBER Inspect and adjust Lube Retighten CHAIN GUARD AND ROLLERS Inspect SWINGARM Inspect, lube and retighten RELAY ARM, CONNECTING ROD Inspect, lube and retighten STEERING HEAD Inspect free play and retighten Clean and lube Replace bearing TIRE, WHEELS Inspect air pressure, wheel run-out, tire wear and spoke looseness Retighten sprocket bolt Inspect bearings R
PRE-OPERATION INSPECTION AND MAINTENANCE INSP ADJ EC320000 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points.
ENGINE/COOLANT LEVEL INSPECTION/ COOLANT REPLACEMENT INSP ADJ EC350000 ENGINE COOLANT LEVEL INSPECTION WARNING Do not remove the radiator cap 1, drain bolt and hoses when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, place a thick towel over the radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape.
COOLANT REPLACEMENT INSP ADJ CAUTION: Take care so that coolant does not splash on painted surfaces. If it splashes, wash it away with water. 1. Place a container under the engine. 2. Remove: ● Seat Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4. 3. Disconnect: ● Coolant reservoir hose 1 Drain the coolant completely. 4. Connect: ● Coolant reservoir hose COOLANT FULL 1 LOW 5. Remove: ● Engine guard 1 ● Coolant drain bolt 2 6. Remove: ● Radiator cap Drain the coolant completely. 7.
COOLANT REPLACEMENT INSP ADJ 9. Fill: ● Radiator ● Engine To specified level. Recommended coolant: High quality ethylene glycol anti-freeze containing anti-corrosion for aluminum engine Coolant 1 and water (soft water) 2 mixing ratio: 50%/50% Coolant capacity: 1.25 L (1.10 Imp qt, 1.32 US qt) CAUTION: ● ● Do not mix more than one type of ethylene glycol antifreeze containing corrosion inhibitors for aluminum engine. Do not use water containing impurities or oil.
RADIATOR CAP INSPECTION/ RADIATOR CAP OPENING PRESSURE INSPECTION INSP ADJ 12. Install: ● Coolant reservoir cap 13. Start the engine and let it warm up for several minutes. 14. Turn off the engine and inspect the coolant level. Refer to “COOLANT LEVEL INSPECTION” section. NOTE: Before checking the coolant level wait a few minutes until the coolant settles. EC355000 RADIATOR CAP INSPECTION 1. Inspect: ● Seal (radiator cap) 1 ● Valve and valve seat 2 Crack/damage → Replace.
COOLING SYSTEM INSPECTION INSP ADJ 3. Inspect: ● Pressure Impossible to maintain the specified pressure for 10 seconds → Replace. EC357002 COOLING SYSTEM INSPECTION 1. Inspect: ● Coolant level 2. Attach: ● Radiator cap tester 1 and adapter 2 Radiator cap tester: YU-24460-01/90890-01325 Adapter: YU-33984/90890-01352 3. Apply the specified pressure. Standard pressure: 180 kPa (1.8 kg/cm2, 25.6 psi) NOTE: ● Do not apply pressure more than specified pressure. ● Radiator should be filled fully. 4.
CLUTCH ADJUSTMENT/ THROTTLE CABLE ADJUSTMENT INSP ADJ EC359020 CLUTCH ADJUSTMENT 1. Check: ● Clutch lever free play a Out of specification → Adjust. Clutch lever free play a: 8 ~ 13 mm (0.31 ~ 0.51 in) 2. Adjust: ● Clutch lever free play Clutch lever free play adjustment steps: Loosen the locknut 1. ● Turn the adjuster 2 until free play a is within the specified limits. ● Tighten the locknut. ● NOTE: ● Make minute adjustment on the lever side using the adjuster 3.
THROTTLE LUBRICATION/ HOT STARTER LEVER ADJUSTMENT INSP ADJ NOTE: Before adjusting the throttle cable free play, the engine idle speed should be adjusted. WARNING After adjusting the throttle cable free play, start the engine and turn the handlebar to right and left and make sure that the engine idling does not run faster. THROTTLE LUBRICATION 1. Remove: ● Cover (throttle cable cap) 1 ● Cover (grip cap) 2 ● Throttle cable cap 3 2. Apply: ● Lithium soap base grease On the throttle cable end a. 3.
AIR FILTER CLEANING INSP ADJ AIR FILTER CLEANING NOTE: Proper air filter maintenance is the biggest key to preventing premature engine wear and damage. CAUTION: Never run the engine without the air filter element in place; this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage. 1. Remove: ● Air filter case cover 1 NOTE: Loosen the quick screw 2 and draw the air filter case cover to remove it because its claws a are inserted in the side cover as shown. 2.
AIR FILTER CLEANING INSP ADJ CAUTION: ● ● Do not twist the element when squeezing the element. Leaving too much of solvent in the element may result in poor starting. 5. Inspect: ● Air filter element Damage → Replace. 6. Apply: ● Foam-air-filter oil or equivalent oil to the element. NOTE: ● Squeeze out the excess oil. Element should be wet but not dripping. ● Wipe off the oil left on the element surface using a clean dry cloth. (Excess oil in the element may adversely affect engine starting.) 7.
ENGINE OIL LEVEL INSPECTION INSP ADJ ENGINE OIL LEVEL INSPECTION 1. Stand the motorcycle on a level surface. NOTE: ● When checking the oil level make sure that the motorcycle is upright. ● Place the motorcycle on a suitable stand. WARNING Never remove the oil tank cap just after high speed operation. The heated oil could spurt out. causing danger. Wait until the oil cools down to approximately 70 ˚C (158 ˚F). 2. Idle the engine more than 3 minutes while keeping the motorcycle upright.
ENGINE OIL LEVEL INSPECTION INSP ADJ (For USA and CDN) Recommended oil: At 5 ˚C (40 ˚F) or higher Å Yamalube 4 (20W-40) or SAE 20W-40 type SG motor oil (Non-Friction modified) At 15 ˚C (60 ˚F) or lower ı Yamalube 4 (10W-30) or SAE 10W-30 type SG motor oil (Non-Friction modified) and/or Yamalube 4-R (15W-50) (Non-Friction modified) CAUTION: ● ● Do not add any chemical additives. Engine oil also lubricates the clutch and additives could cause clutch slippage.
ENGINE OIL REPLACEMENT INSP ADJ 6. Idle the engine more than 10 seconds while keeping the motorcycle upright. Then stop the engine and add the oil to the maximum level. 7. Install: ● Oil tank cap ENGINE OIL REPLACEMENT 1. Start the engine and let it warm up for several minutes. 2. Stop the engine and place an oil pan under the drain bolt. 3.
ENGINE OIL REPLACEMENT INSP ADJ 6. If the oil filter is to be replaced during this oil change, remove the following parts and reinstall them. Replacement steps: Remove the exhaust pipe. ● Remove the oil filter cover 1 and oil filter element 2. ● Check the O-rings 3, if cracked or damaged, replace them with a new one. ● Install the oil filter element and oil filter cover. ● T. Oil filter cover: 10 Nm (1.0 m • kg, 7.2 ft • lb) R. 7. Install: New ● Plain washer 1 ● Oil strainer (frame) 2 R. T. 90 Nm (9.
PILOT SCREW ADJUSTMENT INSP ADJ 12. Check: ● Oil pressure Checking steps: ● Slightly loosen the oil gallery bolt 1. ● Start the engine and keep it idling until oil starts to seep from the oil gallery bolt. If no oil comes out after one minute, turn the engine off so it will not seize. ● Check oil passages, oil filter and oil pump for damage or leakage. ● Start the engine after solving the problem(s) and recheck the oil pressure. ● Tighten the oil gallery bolt to specification. T.
IDLE SPEED ADJUSTMENT/ VALVE CLEARANCE ADJUSTMENT INSP ADJ EC35M021 IDLE SPEED ADJUSTMENT 1. Start the engine and thoroughly warm it up. 2. Adjust: ● Idle speed Adjustment steps: Adjust the pilot screw. Refer to “PILOT SCREW ADJUSTMENT” section. ● Turn the throttle stop screw 1 until the engine runs at the lowest possible speed. ● To increase idle speed → Turn the throttle stop screw 1 in a. To decrease idle speed → Turn the throttle stop screw 1 out b.
VALVE CLEARANCE ADJUSTMENT INSP ADJ 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) b Checking steps: ● Turn the crankshaft counterclockwise with a wrench. ● Align the T.D.C. mark a on the rotor with the align mark b on the crankcase cover when piston is at T.D.C. on compression stroke.
VALVE CLEARANCE ADJUSTMENT 1 INSP ADJ 5. Adjust: ● Valve clearance 2 Adjustment steps: ● Loosen the timing chain tensioner cap bolt. ● Remove the timing chain tensioner and camshaft caps. 3 NOTE: Remove the camshaft cap bolts in a crisscross pattern from the outside working inwards. ● Remove the camshaft (exhaust 1 and intake 2). NOTE: Attach a wire 3 to the timing chain to prevent it from falling into the crankcase. ● Remove the valve lifters 4 and the pads 5.
VALVE CLEARANCE ADJUSTMENT ● INSP ADJ Round off the last digit of the installed pad number to the nearest increment. Last digit of pad Rounded value number 0, 1 or 2 0 4, 5 or 6 5 8 or 9 10 EXAMPLE: Installed pad number = 148 Rounded off value = 150 NOTE: Pads can only be selected in 0.05 mm increments. ● Locate the rounded-off value and the measured valve clearance in the chart “PAD SELECTION TABLE”. The field where these two coordinates intersect shows the new pad number to use.
VALVE CLEARANCE ADJUSTMENT ● INSP ADJ Install the timing chain tensioner. Refer to “CAMSHAFTS” section in the CHAPTER 4. NOTE: Turn the crankshaft counterclockwise several turns so that the installed parts settle into the right position. ● ● Recheck the valve clearance. If the clearance is still incorrect, repeat all the clearance adjustment steps until the specified clearance is obtained. 6. Install: ● All removed parts NOTE: Install all removed parts in reversed order of their removal.
VALVE CLEARANCE ADJUSTMENT INSP ADJ INTAKE MEASURED CLEARANCE 0.00 ~ 0.04 0.05 ~ 0.09 0.10 ~ 0.15 0.16 ~ 0.20 0.21 ~ 0.25 0.26 ~ 0.30 0.31 ~ 0.35 0.36 ~ 0.40 0.41 ~ 0.45 0.46 ~ 0.50 0.51 ~ 0.55 0.56 ~ 0.60 0.61 ~ 0.65 0.66 ~ 0.70 0.71 ~ 0.75 0.76 ~ 0.80 0.81 ~ 0.85 0.86 ~ 0.90 0.91 ~ 0.95 0.96 ~ 1.00 1.01 ~ 1.05 1.06 ~ 1.10 1.11 ~ 1.15 1.16 ~ 1.20 1.21 ~ 1.25 1.26 ~ 1.30 1.31 ~ 1.
SPARK ARRESTER CLEANING (For USA) INSP ADJ SPARK ARRESTER CLEANING (For USA) ● ● WARNING Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. Do not start the engine when cleaning the exhaust system. 1. Remove: ● Bolt (spark arrester) 1 1 1 2. Remove: ● Spark arrester 1 Pull the spark arrester out of the muffler. 1 3. Clean: ● Spark arrester Tap the spark arrester lightly, then use a wire brush to remove any carbon deposits. 4.
CHASSIS/BRAKE SYSTEM AIR BLEEDING INSP ADJ EC360000 CHASSIS EC361012 BRAKE SYSTEM AIR BLEEDING WARNING Bleed the brake system if: ● The system has been disassembled. ● A brake hose has been loosened or removed. ● The brake fluid is very low. ● The brake operation is faulty. A dangerous loss of braking performance may occur if the brake system is not properly bled. Å 1. Remove: ● Master cylinder cap ● Diaphragm ● Protector (rear brake) 2. Bleed: ● Brake fluid ı Å Front ı Rear Air bleeding steps: a.
FRONT BRAKE ADJUSTMENT INSP ADJ NOTE: If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared. j. Add brake fluid to the level line on the reservoir. WARNING Check the operation of the brake after bleeding the brake system. 3. Install: ● Protector (rear brake) ● Diaphragm ● Master cylinder cap EC362040 FRONT BRAKE ADJUSTMENT 1.
REAR BRAKE ADJUSTMENT/ FRONT BRAKE PAD INSPECTION AND REPLACEMENT INSP ADJ EC364002 REAR BRAKE ADJUSTMENT 1. Check: ● Brake pedal height a Out of specification → Adjust. Brake pedal height a: 5 mm (0.20 in) 2. Adjust: ● Brake pedal height Pedal height adjustment steps: Loosen the locknut 1. ● Turn the adjusting nut 2 until the pedal height a is within specified height. ● Tighten the locknut. ● Å ● ı ● WARNING Adjust the pedal height between the maximum Å and the minimum ı as shown.
FRONT BRAKE PAD INSPECTION AND REPLACEMENT ● ● ● ● ● INSP ADJ Loosen the pad pin 2. Remove the brake hose holder 3 and caliper 4 from the front fork. Remove the pad pin and brake pads 5. Connect the transparent hose 6 to the bleed screw 7 and place the suitable container under its end. Loosen the bleed screw and push the caliper piston in. CAUTION: Do not reuse the drained brake fluid. ● Tighten the bleed screw. T. Bleed screw: 6 Nm (0.6 m • kg, 4.3 ft • lb) R.
REAR BRAKE PAD INSPECTION AND REPLACEMENT ● INSP ADJ Install the pad pin plug B. T. Pad pin plug: 3 Nm (0.3 m • kg, 2.2 ft • lb) R. 3. Inspect: ● Brake fluid level Refer to “BRAKE FLUID LEVEL INSPECTION” section. 4. Check: ● Brake lever operation A softy or spongy feeling → Bleed brake system. Refer to “BRAKE SYSTEM AIR BLEEDING” section. EC366060 REAR BRAKE PAD INSPECTION AND REPLACEMENT 1. Inspect: ● Brake pad thickness a Out of specification → Replace as a set.
REAR BRAKE PAD INSPECTION AND REPLACEMENT ● ● ● INSP ADJ Remove the pad pin 6 and brake pads 7. Connect the transparent hose 8 to the bleed screw 9 and place the suitable container under its end. Loosen the bleed screw and push the caliper piston in. CAUTION: Do not reuse the drained brake fluid. ● Tighten the bleed screw. T. Bleed screw: 6 Nm (0.6 m • kg, 4.3 ft • lb) R. ● Install the brake pad 0 and pad pin A. NOTE: ● Install the brake pads with their projections a into the caliper recesses b.
REAR BRAKE PAD INSULATOR INSPECTION/ BRAKE FLUID LEVEL INSPECTION INSP ADJ 3. Inspect: ● Brake fluid level Refer to “BRAKE FLUID LEVEL INSPECTION” section. 4. Check: ● Brake pedal operation A softy or spongy feeling → Bleed brake system. Refer to “BRAKE SYSTEM AIR BLEEDING” section. EC36b000 REAR BRAKE PAD INSULATOR INSPECTION 1. Remove: ● Brake pad Refer to “REAR BRAKE PAD INSPECTION AND REPLACEMENT” section. 2. Inspect: ● Rear brake pad insulator 1 Damage → Replace.
SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION INSP ADJ EC368000 SPROCKETS INSPECTION 1. Inspect: ● Sprocket teeth a Excessive wear → Replace. NOTE: Replace the drive, driven sprockets and drive chain as a set. DRIVE CHAIN INSPECTION 1. Remove: ● Drive chain 1 NOTE: Remove the drive chain using a chain cutter 2. 2. Clean: ● Drive chain Brush off as much dirt as possible. Then clean the chain using the chain cleaner.
DRIVE CHAIN INSPECTION INSP ADJ 5. Check: ● Drive chain stiffness a Clean and oil the chain and hold as illustrated. Stiff → Replace the drive chain. 6. Install: New ● Joint 1 ● O-ring 2 ● Drive chain 3 NOTE: When installing the drive chain, apply the lithium soap base grease on the joint and O-rings. 7. Install: ● Link plate 4 New NOTE: ● Press the link plate onto the joint using a chain riveter 5. ● Rivet the end of the joint using a chain riveter.
DRIVE CHAIN SLACK ADJUSTMENT INSP ADJ DRIVE CHAIN SLACK ADJUSTMENT 1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Check: ● Drive chain slack a Above the seal guard installation bolt. Out of specification → Adjust. Drive chain slack: 40 ~ 50 mm (1.6 ~ 2.0 in) NOTE: Before checking and/or adjusting, rotate the rear wheel through several revolutions and check the slack several times to find the tightest point.
FRONT FORK INSPECTION/ FRONT FORK OIL SEAL AND DUST SEAL CLEANING ● INSP ADJ Tighten the axle nut while pushing down the drive chain. T. Axle nut: 125 Nm (12.5 m • kg, 90 ft • lb) R. ● Tighten the locknuts. T. Locknut: 16 Nm (1.6 m • kg, 11 ft • lb) R. EC36C000 FRONT FORK INSPECTION 1. Inspect: ● Front fork smooth action Operate the front brake and stroke the front fork. Unsmooth action/oil leakage → Repair or replace. EC36D001 FRONT FORK OIL SEAL AND DUST SEAL CLEANING 1.
FRONT FORK INTERNAL PRESSURE RELIEVING/ FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT INSP ADJ FRONT FORK INTERNAL PRESSURE RELIEVING NOTE: If the front fork initial movement feels stiff during a run, relieve the front fork internal pressure. 1. Elevate the front wheel by placing a suitable stand under the engine. 2. Remove the air bleed screw 1 and release the internal pressure from the front fork. 3. Install: ● Air bleed screw R. T. 1 Nm (0.1 m · kg, 0.
FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT ● INSP ADJ STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. Standard position: 10 clicks out * 8 clicks out * For EUROPE, AUS, NZ and ZA CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. WARNING Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability.
REAR SHOCK ABSORBER INSPECTION ● INSP ADJ STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. Standard position: 13 clicks out CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. WARNING Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability. 3. Install: ● Rubber cap EC36K000 REAR SHOCK ABSORBER INSPECTION 1.
REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT INSP ADJ REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Remove: ● Rear frame 3. Loosen: ● Locknut 1 4. Adjust: ● Spring preload By turning the adjuster 2. Stiffer → Increase the spring preload. (Turn the adjuster 2 in.) Softer → Decrease the spring preload. (Turn the adjuster 2 out.) Spring length (installed) a: Standard length Extent of adjustment 246 mm (9.69 in) * 246.5 mm (9.
REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT INSP ADJ EC36N014 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1. Adjust: ● Rebound damping force By turning the adjuster 1. Stiffer a → Increase the rebound damping force. (Turn the adjuster 1 in.) Softer b → Decrease the rebound damping force. (Turn the adjuster 1 out.
REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT INSP ADJ EC36c000 REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: ● Low compression damping force By turning the adjuster 1. Stiffer a → Increase the low compression damping force. (Turn the adjuster 1 in.) Softer b → Decrease the low compression damping force. (Turn the adjuster 1 out.
REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT INSP ADJ EC36d000 REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: ● High compression damping force By turning the adjuster 1. Stiffer a → Increase the high compression damping force. (Turn the adjuster 1 in.) Softer b → Decrease the high compression damping force. (Turn the adjuster 1 out.
TIRE PRESSURE CHECK/SPOKES INSPECTION AND TIGHTENING/WHEEL INSPECTION INSP ADJ EC36Q000 TIRE PRESSURE CHECK 1. Measure: ● Tire pressure Out of specification → Adjust. Standard tire pressure: 100 kPa (1.0 kgf/cm2, 15 psi) NOTE: Check the tire while it is cold. ● Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low. ● A tilted tire valve stem indicates that the tire slips off its position on the rim.
STEERING HEAD INSPECTION AND ADJUSTMENT INSP ADJ 2. Inspect: ● Bearing free play Exist play → Replace. STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suitable stand under the engine. 2. Check: ● Steering shaft Grasp the bottom of the forks and gently rock the fork assembly back and forth. Free play → Adjust steering head. 3. Check: ● Steering smooth action Turn the handlebar lock to lock. Unsmooth action → Adjust steering ring nut. 4.
STEERING HEAD INSPECTION AND ADJUSTMENT ● INSP ADJ Tighten the ring nut 3 using ring nut wrench 4. NOTE: Set the torque wrench to the ring nut wrench so that they form a right angle. Ring nut wrench: YU-33975/90890-01403 T. Ring nut (initial tightening): 38 Nm (3.8 m • kg, 27 ft • lb) R. ● ● Loosen the ring nut one turn. Retighten the ring nut using the ring nut wrench. WARNING Avoid over-tightening. T. Ring nut (final tightening): 7 Nm (0.7 m • kg, 5.1 ft • lb) R.
LUBRICATION INSP ADJ Å Use Yamaha cable lube or equivalent on these areas. ı Use SAE 10W-30 motor oil or suitable chain lubricants. Ç Lubricate the following areas with high quality, lightweight lithium-soap base grease. LUBRICATION To ensure smooth operation of all components, lubricate your machine during setup, after break-in, and after every race.
ELECTRICAL/SPARK PLUG INSPECTION INSP ADJ EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: ● Spark plug 2. Inspect: ● Electrode 1 Wear/damage → Replace. ● Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition. NOTE: When the engine runs for many hours at low speeds, the spark plug insulator will become sooty, even if the engine and carburetor are in good operating condition. 3.
IGNITION TIMING CHECK INSP ADJ IGNITION TIMING CHECK 1. Remove: ● Timing plug 1 1 2. Attach: ● Timing light ● Inductive tachometer To the ignition coil lead (orange lead 1). 1 Timing light: YM-33277-A/90890-03141 Inductive tachometer: YU-8036-B Engine tachometer: 90890-03113 3. Check: ● Ignition timing Checking steps: ● Start the engine and let it warm up. Let the engine run at the specified speed. ● Adjust the engine idling speed. Refer to “IDLE SPEED ADJUSTMENT” section.
BATTERY INSPECTION AND CHARGING INSP ADJ BATTERY INSPECTION AND CHARGING WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: ● Wear protective eye gear when handling or working near batteries. ● Charge batteries in a well-ventilated area. ● Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).
BATTERY INSPECTION AND CHARGING INSP ADJ NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: ● Seat 2. Disconnect: ● Battery leads (from the battery terminals) CAUTION: First, disconnect the negative battery lead 1, and then the positive battery lead 2. 3. Remove: ● Battery band ● Battery 4.
BATTERY INSPECTION AND CHARGING Å INSP ADJ Check the charge of the battery, as shown in the charts and the following example. Example Open-circuit voltage = 12.0 V Charging time = 6.5 hours Charge of the battery = 20 ~ 30% ● Å Relationship between the open-circuit voltage and the charging time at 20 ˚C (68 ˚F) (These values vary with the temperature, the condition of the battery plates, and the electrolyte level.
BATTERY INSPECTION AND CHARGING ● ● ● ● 3 - 53 INSP ADJ Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger. Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks.
BATTERY INSPECTION AND CHARGING Charging method using a variable voltage charger 3 - 54 INSP ADJ
BATTERY INSPECTION AND CHARGING Charging method using a constant voltage charger 3 - 55 INSP ADJ
FUSE INSPECTION INSP ADJ 6. Install: ● Battery ● Battery band 7. Connect: ● Battery leads (to the battery terminals) CAUTION: First, connect the positive lead 1, then the negative lead 2. 8. Check: ● Battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. 9. Lubricate: ● Battery terminal Recommended lubricant Lithium soap base grease 10.
REPLACING THE HEADLIGHT BULBS INSP ADJ 3. Replace: ● Blown fuse Replacement steps: ● Set the main switch to “OFF”. ● Install a new fuse of the correct amperage. ● Set on the switches to verify if the electrical circuit is operational. ● If the fuse immediately blows again, check the electrical circuit. Items Amperage rating Q’ty Main fuse 10 A 1 WARNING Never use a fuse with an amperage rating other than that specified.
ADJUSTING THE HEADLIGHT BEAMS INSP ADJ 5. Install: New ● Headlight bulb Secure the new headlight bulb with the headlight bulb holder. CAUTION: Avoid touching the glass part of the headlight bulb to keep it free form oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 6. Attach: ● Headlight bulb holder 7.
SEAT, FUEL TANK AND SIDE COVERS ENG EC400000 ENGINE EC4R0000 SEAT, FUEL TANK AND SIDE COVERS Extent of removal: 1 Seat removal 3 Side covers removal Extent of removal Order Preparation for removal 1 3 2 3 4 1 2 3 4 5 6 7 8 9 Part name 2 Fuel tank removal 4 Headlight removal Q’ty SEAT, FUEL TANK AND SIDE COVERS REMOVAL Turn the fuel cock to “OFF”. Disconnect the fuel hose.
SEAT, FUEL TANK AND SIDE COVERS ENG REMOVAL POINTS Side cover 1. Remove: ● Bolt (side cover) ● Side cover (left) 1 ● Side cover (right) 2 NOTE: Draw the side cover downward to remove it because its claws a are inserted in the air filter case.
EXHAUST PIPE AND SILENCER ENG EC4S0000 EXHAUST PIPE AND SILENCER Å For USA ı Except for USA Extent of removal: Extent of removal 1 Silencer removal Order 1 2 Part name Q’ty EXHAUST PIPE AND SILENCER REMOVAL Side cover (right) Preparation for removal 2 2 Exhaust pipe removal 1 2 3 4 5 6 7 8 9 Bolt (clamp) Bolt [silencer (front)] Bolt [silencer (rear)] Silencer Clamp Nut (exhaust pipe) Bolt (exhaust pipe) Exhaust pipe Gasket 1 1 1 1 1 1 1 1 2 4-3 Remarks Refer to “SEAT, FUEL TANK AND SIDE C
EXHAUST PIPE AND SILENCER ENG INSPECTION Exhaust pipe and silencer 1. Inspect: ● Gasket 1 Damage → Replace. 1 2 ASSEMBLY AND INSTALLATION Exhaust pipe and silencer 1. Install: New ● Gasket ● Exhaust pipe 1 ● Nut (exhaust pipe) 2 3 R. T. ● 13 Nm (1.3 m · kg, 9.4 ft · lb) Bolt (exhaust pipe) 3 R. T. 1 24 Nm (2.4 m · kg, 17 ft · lb) NOTE: First, temporarily tighten the nut (exhaust pipe), then tighten the bolt (exhaust pipe) 20 Nm (2.0 m • kg, 14 ft • lb).
RADIATOR ENG EC450001 RADIATOR Extent of removal: Extent of removal 1 Radiator removal Order Part name 2 Coolant reservoir removal Q’ty RADIATOR REMOVAL Drain the coolant. Preparation for removal Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3. Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Refer to “EXHAUST PIPE AND SILENCER” section.
RADIATOR ENG EC456000 HANDLING NOTE WARNING Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radiator cap by the following procedure: Place a thick rag, like a towel, over the radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape.
RADIATOR ENG 3. Install: ● Radiator breather hose 1 ● Radiator (right) 2 R. T. 10 Nm (1.0 m · kg, 7.2 ft · lb) Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 4. Install: ● Panel 1 ● Bolt (radiator panel upper) 2 R. T. 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Fit the hook a on the inner side first into the radiator.
CARBURETOR ENG CARBURETOR 1 T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) T. R. 2 Nm (0.2 m • kg, 1.4 ft • Ib) 8 T. R. 11 Nm (1.1 m • kg, 8.0 ft • Ib) 4 9 5 T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) 2 3 5 6 7 T. R. 3 Nm (0.3 m • kg, 2.2 ft • Ib) 7 T. 10 R. Extent of removal: Extent of removal 1 Carburetor removal Order Part name Q’ty CARBURETOR REMOVAL Fuel tank Preparation for removal 1 3 Nm (0.3 m • kg, 2.
CARBURETOR ENG CARBURETOR DISASSEMBLY Extent of removal: 1 Carburetor disassembly Extent of removal Order Part name Q’ty 1 1 2 3 4 5 6 7 8 9 0 A B C D E F G CARBURETOR DISASSEMBLY Breather hose Valve lever housing cover Screw (throttle shaft) Throttle valve Needle holder Jet needle Cover Spring Diaphragm (accelerator pump) Air cut valve cover Spring (air cut valve) Diaphragm (air cut valve) Float chamber Leak jet Pilot screw Float pin Float 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4-9 Remarks Refer
ENG CARBURETOR Extent of removal Order 1 H I J K L M N O P Q R Part name Q’ty Needle valve Main jet Needle jet Spacer Pilot jet Starter jet Push rod Throttle shaft assembly Push rod link lever assembly Pilot air jet Cold starter plunger 4 - 10 1 1 1 1 1 1 1 1 1 1 1 Remarks Pull the push rod.
CARBURETOR ENG EC466020 HANDLING NOTE CAUTION: 1 Do not loosen the screws {TPS (throttle position sensor)} 1 except when changing the TPS (throttle position sensor) due to failure because it will cause a drop in engine performance. REMOVAL POINTS Pilot screw 1. Remove: ● Pilot screw 1 NOTE: To optimize the fuel flow at a small throttle opening, each machine’s pilot screw has been individually set at the factory. Before removing the pilot screw, turn it in fully and count the number of turns.
CARBURETOR ENG Needle valve 1. Inspect: ● Needle valve 1 ● Valve seat 2 Grooved wear a → Replace. Dust b → Clean. EC464300 Throttle valve 1. Check: ● Free movement Stick → Repair or replace. Insert the throttle valve 1 into the carburetor body, and check for free movement. EC464400 Jet needle 1. Inspect: ● Jet needle 1 Bends/wear → Replace. ● Clip groove Free play exists/wear → Replace. ● Clip position Standard clip position: No.4 Groove EC464511 Float height 1.
CARBURETOR ENG Measurement and adjustment steps: ● Hold the carburetor in an upside down position. NOTE: ● Slowly tilt the carburetor in the opposite direction, then take the measurement when the needle valve aligns with the float arm. ● If the carburetor is level, the weight of the float will push in the needle valve, resulting in an incorrect measurement. ● Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers.
CARBURETOR ENG Accelerator pump 1. Inspect: ● Diaphragm (accelerator pump) 1 ● Spring 2 ● Cover 3 ● O-ring 4 ● Push rod 5 Tears (diaphragm)/damage → Replace. Dirt → Clean. 1 5 3 1 2. Inspect: ● Throttle shaft 1 ● Spring 2 ● Lever 1 3 ● Spring 1 4 ● Lever 2 5 ● Spring 2 6 Dirt → Clean. 2 6 4 Air cut valve 1. Inspect: ● Diaphragm (air cut valve) 1 ● Spring (air cut valve) 2 ● Air cut valve cover 3 ● O-ring 4 Tears (diaphragm)/damage → Replace. 3 2 4 ASSEMBLY AND INSTALLATION Carburetor 1.
CARBURETOR 1 ENG 3. Install: ● Spring 1 1 ● Lever 1 2 To lever 2 3. a 3 NOTE: Make sure the spring 1 fits on the stopper a of the lever 2. 2 4. Install: ● Spring 2 1 To lever 2 2. 1 2 5. Install: ● Push rod link lever assembly 1 NOTE: Make sure the stopper a of the spring 2 fits into the recess b in the carburetor. 1 b a 6. Install: ● Plain washer 1 ● Circlip 2 2 1 7. Install: ● Spring 1 To throttle shaft 2.
CARBURETOR 1 23 ENG 8. Install: ● Throttle shaft assembly 1 ● Plain washer (metal) 2 ● Plain washer (resin) 3 ● Valve lever 4 4 b NOTE: ● Apply the fluorochemical grease on the bearings. ● Fit the projection a on the throttle shaft assembly into the slot b in the TPS (throttle position sensor). ● Make sure the stopper c of the spring fits into the recess in the carburetor.
CARBURETOR ENG 11. Install: ● Needle valve 1 ● Float 2 ● Float pin 3 NOTE: ● After installing the needle valve to the float, install them to the carburetor. ● Check the float for smooth movement. 12. Install: ● Pilot screw 1 ● Spring 2 ● Washer 3 ● O-ring 4 Note the following installation points: ● Turn in the pilot screw until it is lightly seated. ● Turn out the pilot screw by the number of turns recorded before removing.
CARBURETOR ENG 15. Install: ● Diaphragm (accelerator pump) 1 ● Spring 2 ● O-ring 3 ● Cover 4 ● Hose holder (drain hose) 5 ● Screw (cover) 6 NOTE: Install the diaphragm (accelerator pump) with its mark a facing the spring. 5 16. Install: ● Jet needle 1 ● Collar 2 ● Spring 3 ● Needle holder 4 ● Throttle valve plate 5 To throttle valve 6. 1 23 6 4 17. Install: ● Throttle valve assembly 1 ● Screw (throttle shaft) 2 NOTE: Install the valve lever rollers 3 into the slits a of the throttle valve. 18.
CARBURETOR ENG Accelerator pump timing adjustment Adjustment steps: NOTE: In order for the throttle valve height a to achieve the specified value, tuck under the throttle valve plate 1 the rod 2 etc. with the same outer diameter as the specified value. Throttle valve height: 3.1 mm (0.122 in) ● ● ● Fully turn in the accelerator pump adjusting screw 3. Check that the link lever 4 has free play b by pushing lightly on it.
CARBURETOR ENG 4. Tighten: ● Screw (air cleaner joint) 1 R. T. ● 3 Nm (0.3 m · kg, 2.2 ft · lb) Screw (carburetor joint) 2 R. T. 3 Nm (0.3 m · kg, 2.2 ft · lb) 5. Install: ● Throttle cable (pull) 1 2 R. T. ● 4 Nm (0.4 m · kg, 2.9 ft · lb) Throttle cable (return) 2 R. T. 11 Nm (1.1 m · kg, 8.0 ft · lb) 6. Adjust: ● Throttle grip free play Refer to “THROTTLE CABLE ADJUSTMENT” section in the CHAPTER 3. 1 7. Install: ● Throttle cable cover 1 ● Screw (throttle cable cover) 2 1 R. T. 4 Nm (0.
CAMSHAFTS ENG CAMSHAFTS CYLINDER HEAD COVER Extent of removal: Extent of removal 1 Cylinder head cover removal Order Q’ty CYLINDER HEAD COVER REMOVAL Seat and fuel tank Preparation for removal 1 Part name 1 2 3 4 5 6 7 8 9 Carburetor Spark plug Engine upper bracket (right) Engine upper bracket (left) Cylinder head breather hose Oil tank breather hose Bolt (cylinder head cover) Cylinder head cover Gasket Timing chain guide (upper) 4 - 21 Remarks Refer to “SEAT, FUEL TANK AND SIDE COVERS” sectio
CAMSHAFTS ENG CAMSHAFTS Extent of removal: 1 Camshaft removal Extent of removal Order 1 1 2 3 4 5 6 7 8 9 10 Part name Q’ty CAMSHAFTS REMOVAL Timing plug Straight plug Tensioner cap bolt Timing chain tensioner Gasket Bolt (camshaft cap) Camshaft cap Clip Exhaust camshaft Intake camshaft 4 - 22 1 1 1 1 1 10 2 2 1 1 Remarks Refer to “REMOVAL POINTS”.
CAMSHAFTS ENG REMOVAL POINTS Camshaft 1. Remove: ● Timing plug 1 ● Straight plug 2 2. Align: ● “I” mark With stationary pointer. 1 2 Checking steps: ● Turn the crankshaft counterclockwise with a wrench. ● Align the “I” mark a on the rotor with the stationary pointer b on the crankcase cover. When the “I” mark is aligned with the stationary pointer, the piston is at the Top Dead Center (T.D.C.).
CAMSHAFTS 1 ENG 6. Remove: ● Clips ● Exhaust camshaft 1 ● Intake camshaft 2 2 NOTE: Attach a wire 3 to the timing chain to prevent it from falling into the crankcase. 3 INSPECTION Camshaft 1. Inspect: ● Cam lobes Pitting/scratches/blue discoloration → Replace. 2. Measure: ● Cam lobes length a and b Out of specification → Replace. Cam lobes length: Intake: a 31.200 ~ 31.300 mm (1.2283 ~ 1.2323 in) : 31.100 mm (1.2244 in) b 22.550 ~ 22.650 mm (0.8878 ~ 0.8917 in) : 22.450 mm (0.
CAMSHAFTS ENG 4. Measure: ● Camshaft-to-cap clearance Out of specification → Measure camshaft journal diameter. Camshaft-to-cap clearance: 0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) : 0.08 mm (0.003 in) Measurement steps: ● Install the camshaft onto the cylinder head. ® ● Position a strip of Plastigauge 1 onto the camshaft. ● Install the circlip, dowel pins and camshaft caps. T. Bolt (camshaft cap): 10 Nm (1.0 m • kg, 7.2 ft • lb) R.
CAMSHAFTS ENG Decompression system 1. Check: ● Decompression system Checking steps: Check that the decompressor cam 1 moves smoothly. ● Check that the decompressor lever pin 2 projects from the camshaft. ● Timing chain tensioner 1. Check: ● While pressing the tensioner rod lightly with fingers, use a thin screwdriver 1 and wind the tensioner rod up fully clockwise. ● When releasing the screwdriver by pressing lightly with fingers, make sure that the tensioner rod will come out smoothly.
CAMSHAFTS ● ENG Fit the timing chain 3 onto both camshaft sprockets and install the camshafts on the cylinder head. NOTE: The camshafts should be installed onto the cylinder head so that the exhaust cam sprocket punch mark c and the intake cam sprocket punch mark d align with the surface of the cylinder head. CAUTION: Do not turn the crankshaft during the camshaft installation. Damage or improper valve timing will result. ● Install the clips and camshaft caps 4. T. Bolt (camshaft cap): 10 Nm (1.
CAMSHAFTS ● ENG With the rod fully wound and the chain tensioner UP mark a facing upward, install the gasket 1 and the chain tensioner 2, and tighten the bolt 3 to the specified torque. T. Bolt (timing chain tensioner): 10 Nm (1.0 m • kg, 7.2 ft • lb) R. ● Release the screwdriver, check the tensioner rod to come out and tighten the gasket 4 and the cap bolt 5 to the specified torque. T. R. 4 New Tensioner cap bolt: 7 Nm (0.7 m • kg, 5.1 ft • lb) 5 3.
ENG CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD Extent of removal: Extent of removal 1 Cylinder head removal Order Part name Q’ty CYLINDER HEAD REMOVAL Seat and fuel tank Preparation for removal Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Refer to “EXHAUST PIPE AND SILENCER” section. Refer to “RADIATOR” section. Refer to “CARBURETOR” section. Refer to “CAMSHAFTS” section.
CYLINDER HEAD ENG INSPECTION Cylinder head 1. Eliminate: ● Carbon deposits (from the combustion chambers) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching: ● Spark plug threads ● Valve seats 2. Inspect: ● Cylinder head Scratches/damage → Replace. 3. Measure: ● Cylinder head warpage Out of specification → Resurface. Cylinder head warpage: Less than 0.05 mm (0.
CYLINDER HEAD ENG ASSEMBLY AND INSTALLATION 1. Install: ● Timing chain guide (front) 1 ● Dowel pin 2 New ● Cylinder head gasket 3 ● Cylinder head 4 NOTE: While pulling up the timing chain, install the timing chain guide (front) and cylinder head. 2. Install: ● Plain washer 1 ● Bolt [L=160 mm (6.30 in)] 2 ● Bolt [L=150 mm (5.91 in)] 3 Installation steps: CAUTION: Tighten the cylinder head using the rotation angle procedure to obtain uniform tightening torque.
CYLINDER HEAD ● ● ● ENG Remove the bolts. Again apply the molybdenum disulfide grease on the threads and contact surfaces of the bolts and on both contact surfaces of the plain washers. Retighten the bolts. NOTE: Tighten the bolts to the specified torque in two or three steps in the proper tightening sequence as shown. 1 T. R. ● 2 Bolts (cylinder head): 2nd: 20 Nm (2.0 m • kg, 14 ft • lb) Put a mark on the corner 1 of the bolt (cylinder head) and the cylinder head 2 as shown.
VALVES AND VALVE SPRINGS ENG VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Extent of removal: Extent of removal 1 Valve removal Order Part name Q’ty 1 2 3 4 5 6 7 8 9 VALVES AND VALVE SPRINGS REMOVAL Cylinder head Valve lifter Adjusting pad Valve cotter Valve retainer Valve spring Stem seal Valve spring seat Exhaust valve Intake valve 5 5 10 5 5 5 5 2 3 Preparation for removal 1 4 - 33 Remarks Refer to “CYLINDER HEAD” section. Use special tool. Refer to “REMOVAL POINTS”.
VALVES AND VALVE SPRINGS ENG REMOVAL POINTS 1. Remove: ● Valve lifters 1 ● Pads 2 NOTE: Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place. 2. Check: ● Valve sealing Leakage at the valve seat → Inspect the valve face, valve seat and valve seat width. Checking steps: ● Pour a clean solvent 1 into the intake and exhaust ports. ● Check that the valve seals properly. There should be no leakage at the valve seat 2. 3.
VALVES AND VALVE SPRINGS ENG INSPECTION Valve 1. Measure: ● Stem-to-guide clearance Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b Out of specification → Replace the valve guide. Clearance (stem to guide): Intake: 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) : 0.08 mm (0.003 in) Exhaust: 0.020 ~ 0.047 mm (0.0008 ~ 0.0019 in) : 0.10 mm (0.004 in) 2.
VALVES AND VALVE SPRINGS ENG Valve guide remover: Intake: 4.5 mm (0.18 in) YM-4116/90890-04116 Exhaust: 5.0 mm (0.20 in) YM-4097/90890-04097 Valve guide installer: Intake: YM-4117/90890-04117 Exhaust: YM-4098/90890-04098 Valve guide reamer: Intake: 4.5 mm (0.18 in) YM-4118/90890-04118 Exhaust: 5.0 mm (0.20 in) YM-4099/90890-04099 NOTE: After replacing the valve guide reface the valve seat. 3. Inspect: ● Valve face Pitting/wear → Grind the face.
VALVES AND VALVE SPRINGS ENG 5. Measure: ● Runout (valve stem) Out of specification → Replace. Runout limit: 0.01 mm (0.0004 in) NOTE: ● When installing a new valve always replace the guide. ● If the valve is removed or replaced always replace the oil seal. 6. Eliminate: ● Carbon deposits (from the valve face and valve seat) 7. Inspect: ● Valve seats Pitting/wear → Reface the valve seat. 8. Measure: ● Valve seat width a Out of specification → Reface the valve seat. Valve seat width: Intake: 0.9 ~ 1.
VALVES AND VALVE SPRINGS ENG 9. Lap: ● Valve face ● Valve seat NOTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. Lapping steps: Apply a coarse lapping compound to the valve face. ● CAUTION: Do not let the compound enter the gap between the valve stem and the guide. ● ● ● Apply molybdenum disulfide oil to the valve stem. Install the valve into the cylinder head.
VALVES AND VALVE SPRINGS ENG Valve spring 1. Measure: ● Valve spring free length a Out of specification → Replace. Free length (valve spring): Intake: 37.03 mm (1.46 in) : 35.17 mm (1.38 in) Exhaust: 37.68 mm (1.48 in) : 35.79 mm (1.41 in) 2. Measure: ● Compressed spring force a Out of specification → Replace. b Installed length Compressed spring force: Intake: 111.3 ~ 127.9 N at 27.87 mm (11.3 ~ 13.0 kg at 27.87 mm, 24.91 ~ 28.66 lb at 1.10 in) Exhaust: 127.4 ~ 146.4 N at 27.38 mm (13.
VALVES AND VALVE SPRINGS a ENG Combination of cylinder head and valve lifter 1. Combination: For this combination, match the paint color on the cylinder head with that on the valve lifter according to the chart below. b Combination Cylinder head mark a (color) Valve lifter mark b (color) Blue Blue Yellow Yellow Purple Black NOTE: When you purchase a cylinder head, you cannot designate its size. Choose the valve lifter that matches the above chart. ASSEMBLY AND INSTALLATION 1.
VALVES AND VALVE SPRINGS ENG 3. Install: ● Valve cotters NOTE: While compressing the valve spring with a valve spring compressor 1 install the valve cotters. Valve spring compressor: YM-4019/90890-04019 4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood. CAUTION: Hitting the valve tip with excessive force could damage the valve. 5. Install: ● Adjusting pad 1 ● Valve lifter 2 NOTE: ● Apply the engine oil on the valve lifters.
ENG CYLINDER AND PISTON CYLINDER AND PISTON CYLINDER AND PISTON Extent of removal: Extent of removal 1 Cylinder removal Order Preparation for removal 1 2 1 2 3 4 5 6 7 8 9 2 Piston removal Part name Q’ty CYLINDER AND PISTON REMOVAL Cylinder head Bolt (cylinder) Cylinder Gasket Dowel pin Dowel pin/O-ring Piston pin clip Piston pin Piston Piston ring set 4 - 42 Remarks Refer to “CYLINDER HEAD” section. 1 1 1 2 1/1 2 1 1 1 Use special tool. Refer to “REMOVAL POINTS”.
CYLINDER AND PISTON ENG REMOVAL POINTS Piston 1. Remove: ● Piston pin clips 1 ● Piston pin 2 ● Piston 3 NOTE: Put identification marks on each piston head for reference during reinstallation. ● Before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller 4. ● Piston pin puller: YU-1304/90890-01304 CAUTION: Do not use a hammer to drive the piston pin out. Piston ring 1.
CYLINDER AND PISTON ENG Cylinder bore “C” 95.00 ~ 95.01 mm (3.7402 ~ 3.7406 in) Taper limit “T” 0.05 mm (0.002 in) Out of round “R” 0.05 mm (0.002 in) “C” = Maximum D “T” = (Maximum D1 or D2) – (Maximum D5 or D6) “R” = (Maximum D1, D3 or D5) – (Minimum D2, D4 or D6) ● If out of specification, replace the cylinder, and replace the piston and piston rings as set. 2nd step: ● Measure the piston skirt diameter “P” with a micrometer. a 8 mm (0.
CYLINDER AND PISTON ENG Piston ring 1. Measure: ● Ring side clearance Use a feeler gauge 1. Out of specification → Replace the piston and rings as a set. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance. Side clearance: Standard Top ring 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in) 0.12 mm (0.005 in) 2nd ring 0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in) 0.12 mm (0.005 in) 2.
CYLINDER AND PISTON ENG Piston pin 1. Inspect: ● Piston pin Blue discoloration/grooves → Replace, then inspect the lubrication system. 2. Measure: ● Piston pin-to-piston clearance Measurement steps: ● Measure the outside diameter (piston pin) a. If out of specification, replace the piston pin. Outside diameter (piston pin): 17.991 ~ 18.000 mm (0.7083 ~ 0.7087 in) ● Measure the inside diameter (piston) b. Inside diameter (piston): 18.004 ~ 18.015 mm (0.7088 ~ 0.
CYLINDER AND PISTON 2. Position: ● Top ring ● 2nd ring ● Oil ring Offset the piston ring end gaps as shown. ad 45° 135° c ENG 135° a Top ring end b 2nd ring end c Oil ring end (upper) d Oil ring e Oil ring end (lower) be 3. Install: ● Piston 1 ● Piston pin 2 ● Piston pin clips 3 New NOTE: ● Apply engine oil onto the piston pin and piston. ● Be sure that the arrow mark a on the piston points to the exhaust side of the engine.
CLUTCH ENG CLUTCH CLUTCH Extent of removal: 1 Push rod and push lever removal 2 Push pod 1 disassembly 3 Friction plate and clutch plate removal 4 Clutch housing removal Extent of removal Order 3 2 1 4 Q’ty CLUTCH REMOVAL Drain the engine oil. Preparation for removal 1 Part name 1 2 3 4 5 6 7 8 9 10 11 Remarks Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Refer to “ENGINE REMOVAL” section. Disconnect at engine side.
CLUTCH Extent of removal 3 4 1 Order 12 13 14 15 16 17 18 19 Part name Q’ty Clutch plate Friction plate Nut Look washer Clutch boss Thrust washer Clutch housing Push lever 8 9 1 1 1 1 1 1 4 - 49 ENG Remarks Use special tool. Refer to “REMOVAL POINTS”.
CLUTCH ENG EC493000 REMOVAL POINTS EC483211 Clutch boss 1. Remove: ● Nut 1 ● Lock washer 2 ● Clutch boss 3 NOTE: Straighten the lock washer tab and use the clutch holding tool 4 to hold the clutch boss. Å ı Clutch holding tool: YM-91042/90890-04086 Å For USA and CDN ı Except for USA and CDN EC494000 INSPECTION EC484100 Clutch housing and boss 1. Inspect: ● Clutch housing 1 Cracks/wear/damage → Replace. ● Clutch boss 2 Scoring/wear/damage → Replace. EC484201 Primary driven gear 1.
CLUTCH ENG EC484500 Friction plate 1. Measure: ● Friction plate thickness Out of specification → Replace friction plate as a set. Measure at all four points. Friction plate thickness: 2.92 ~ 3.08 mm (0.115 ~ 0.121 in) : 2.8 mm (0.110 in) EC484600 Clutch plate 1. Measure: ● Clutch plate warpage Out of specification → Replace clutch plate as a set. Use a surface plate 1 and thickness gauge 2. Warp limit: 0.1 mm (0.004 in) Push lever 1. Inspect: ● Push lever 1 Wear/damage → Replace.
CLUTCH ENG EC4A5000 a 2 ASSEMBLY AND INSTALLATION Push lever 1. Install: ● Push lever 1 ● Bolt (push lever) 1 R. T. 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: ● Apply the lithium soap base grease on the oil seal lip. ● Apply the engine oil on the push lever. ● Fit the seat plate 2 in the groove a of the push lever and tighten the bolt (seat plate). Clutch 1. Install: ● Primary driven gear 1 ● Thrust washer 2 ● Clutch boss 3 NOTE: Apply the engine oil on the primary driven gear inner circumference. 2.
CLUTCH ENG 3. Bend the lock washer 1 tab. 4. Install: ● Friction plate 1 ● Clutch plate 2 NOTE: ● Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate. ● Apply the engine oil on the friction plates and clutch plates. 5. Install: ● Bearing 1 ● Plain washer 2 New ● Circlip 3 To push rod 1 4. NOTE: Apply the engine oil on the bearing and plain washer. 6.
CLUTCH ENG 8. Install: ● Clutch spring ● Bolt (clutch spring) R. T. 8 Nm (0.8 m · kg, 5.8 ft · lb) NOTE: Tighten the bolts in stage, using a crisscross pattern. 9. Install: ● Gasket (clutch cover) 1 ● Dowel pin 2 New 10. Install: ● Clutch cover 1 ● Bolt (clutch cover) R. T. 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Tighten the bolts in stage, using a crisscross pattern.
OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) ENG OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) Extent of removal: 1 Oil filter removal 3 Crankcase cover (right) removal Extent of removal Order Part name 2 Water pump removal Q’ty OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) REMOVAL Drain the engine oil. Preparation for removal Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3.
OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) Extent of removal 2 3 2 Order 7 8 9 10 11 12 13 14 15 16 17 Part name Q’ty Oil hose Kickstarter Crankcase cover (right) Gasket Dowel pin/O-ring Impeller Plain washer Impeller shaft Oil seal 1 Oil seal 2 Bearing 4 - 56 1 1 1 1 4/2 1 1 1 1 1 1 ENG Remarks Refer to “REMOVAL POINTS”.
OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) ENG REMOVAL POINTS EC4G3110 Impeller shaft 1. Remove: ● Impeller 1 ● Plain washer 2 ● Impeller shaft 3 NOTE: Hold the impeller shaft on its width across the flats a with spanners, etc. and remove the impeller. EC4G3210 Oil seal NOTE: It is not necessary to disassemble the water pump, unless there is an abnormality such as excessive change in coolant level, discoloration of coolant, or milky transmission oil. 1.
OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) ENG EC4H4600 Bearing 1. Inspect: ● Bearing Rotate inner race with a finger. Rough spot/seizure → Replace. EC444400 Oil seal 1. Inspect: ● Oil seal Wear/damage → Replace. ASSEMBLY AND INSTALLATION EC4G5110 Oil seal 1. Install: ● Oil seal 1 New NOTE: ● Apply the lithium soap base grease on the oil seal lip. ● Install the oil seal with its manufacture’s marks or numbers facing inward. Bearing 1.
OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) ENG EC4G5220 Impeller shaft 1. Install: ● Impeller shaft 1 ● Plain washer 2 ● Impeller 3 R. T. 14 Nm (1.4 m · kg, 10 ft · lb) NOTE: ● Take care so that the oil seal lip is not damaged or the spring does not slip off its position. ● When installing the impeller shaft, apply the engine oil on the oil seal lip, bearing and impeller shaft. And install the shaft while turning it. ● Hold the impeller shaft on its width across the flats a with spanners, etc.
OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) ENG Kick crank 1. Install: ● Kickstarter 1 ● Plain washer ● Bolt (kickstarter) R. T. 33 Nm (3.3 m · kg, 24 ft · lb) NOTE: Install the kickstarter so that the distance a between the kickstarter and the fuel tank is 12 mm (0.47 in) or more. 2. Install: ● Oil hose 1 ● Bolt (oil hose) 2 R. T. 10 Nm (1.0 m · kg, 7.2 ft · lb) 3. Install: New ● Copper washer 1 ● Oil delivery pipe 2 ● Union bolt (M8) 3 R. T. ● 18 Nm (1.
OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) ENG 2. Install: ● Water pump housing 1 ● Bolt (water pump housing) 2 R. T. ● ● 10 Nm (1.0 m · kg, 7.2 ft · lb) Plain washer 3 New Coolant drain bolt 4 R. T. 10 Nm (1.0 m · kg, 7.2 ft · lb) 3. Install: ● O-ring ● Coolant pipe 1 ● Bolt (coolant pipe) 2 R. T. 10 Nm (1.0 m · kg, 7.2 ft · lb) Oil filter 1. Install: ● Oil filter 1 New ● O-ring 2 ● Oil filter cover 3 ● Bolt (oil filter cover) R. T. 4 - 61 10 Nm (1.0 m · kg, 7.
BALANCER ENG BALANCER BALANCER Extent of removal: Extent of removal 1 Balancer drive gear Order Part name 2 Balancer Q’ty BALANCER REMOVAL Clutch housing Crankcase cover (right) Preparation for removal Refer to “CLUTCH” section. Refer to “OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT)” section. Refer to “AC MAGNETO AND STARTER CLUTCH” section.
BALANCER ENG REMOVAL POINTS Balancer drive gear and balancer driven gear 1. Straighten the lock washer tab. 2. Loosen: ● Nut (primary drive gear) 1 ● Nut (balancer) 2 NOTE: Place an aluminum plate a between the teeth of the balancer drive gear 3 and driven gear 4. Balancer 1. Remove: ● Balancer 1 NOTE: When removing the balancer shaft, align the center of the balancer shaft weight a along the line connecting the centers of the crankshaft and balancer shaft.
BALANCER ENG ASSEMBLY AND INSTALLATION Balancer, balancer drive gear and balancer driven gear 1. Install: ● Balancer 1 NOTE: When installing the balancer shaft, align the center of the balancer shaft weight a along the line connecting the centers of the crankshaft and balancer shaft. 2. Install: ● Balancer driven gear 1 NOTE: Install the balancer driven gear onto the balancer while aligning the punch mark a on the balancer driven gear with the lower spline b on the balancer end. 3.
OIL PUMP ENG OIL PUMP OIL PUMP Extent of removal: Extent of removal 1 Oil pump removal Order 2 Part name Q’ty OIL PUMP REMOVAL AND DISASSEMBLY Clutch housing Crankcase cover (right) Preparation for removal 1 2 Oil pump disassembly 1 2 3 4 5 6 7 8 9 10 11 12 Circlip Plate washer Oil pump drive gear Oil pump assembly Dowel pin Outer rotor 2 Circlip Inner rotor 2 Pin Oil pump cover Outer rotor 1 Inner rotor 1 Refer to “CLUTCH” section.
OIL PUMP Extent of removal 2 Order 13 14 15 16 Part name Q’ty Pin Washer Oil pump drive shaft Rotor housing 1 1 1 1 4 - 66 ENG Remarks
OIL PUMP ENG INSPECTION Oil pump 1. Inspect: ● Oil pump drive gear ● Oil pump driven gear ● Rotor housing ● Oil pump cover Cracks/wear/damage → Replace. 2. Measure: ● Tip clearance a Between the inner rotor 1 and the outer rotor 2. ● Tip clearance b Between the outer rotor 2 and the rotor housing 3. Out of specification → Replace the oil pump. Tip clearance a: 0.12 mm or less (0.0047 in or less) : 0.20 mm (0.008 in) Tip clearance b: 0.09 ~ 0.17 mm (0.0035 ~ 0.0067 in) : 0.24 mm (0.
OIL PUMP ENG 2. Install: ● Outer rotor 1 1 NOTE: Apply the engine oil on the outer rotor 1. 3. Install: ● Oil pump cover 1 ● Screw (oil pump cover) 2 R. T. ● ● ● 2 Nm (0.2 m · kg, 1.4 ft · lb) Pin 3 Inner rotor 2 4 Circlip 5 New NOTE: ● Apply the engine oil on the oil pump drive shaft end and inner rotor 2. ● Fit the pin into the groove in the inner rotor 2. 4. Install: ● Outer rotor 2 1 ● Dowel pin 2 ● Oil pump assembly 3 ● Bolt (oil pump assembly) [L = 30 mm (1.18 in)] 4 R. T. ● 10 Nm (1.
KICK AXLE AND SHIFT SHAFT ENG KICK AXLE AND SHIFT SHAFT KICK AXLE AND SHIFT SHAFT Extent of removal: 1 Kick axle removal 3 Shift shaft removal Extent of removal Order Part name Q’ty 1 2 3 4 5 6 7 8 9 10 11 12 KICK AXLE AND SHIFT SHAFT REMOVAL Oil pump Kick idle gear Kick axle assembly Spring guide Torsion spring Ratchet wheel Kick gear Kick axle Plain washer Shift pedal Shift shaft Collar Torsion spring 1 1 1 1 1 1 1 1 1 1 1 1 Preparation for removal 1 2 1 3 4 2 Kick axle disassembly 4 Segme
KICK AXLE AND SHIFT SHAFT Extent of removal 4 Order 13 14 15 16 17 18 19 20 21 22 23 Part name Q’ty Roller Shift guide Shift lever assembly Shift lever Pawl Pawl pin Spring Bolt (stopper lever) Stopper lever Torsion spring Segment 1 1 1 1 2 2 2 1 1 1 1 4 - 70 ENG Remarks Refer to “REMOVAL POINTS”. Refer to “REMOVAL POINTS”.
KICK AXLE AND SHIFT SHAFT ENG REMOVAL POINTS EC4B3101 Kick axle assembly 1. Remove: ● Kick axle assembly 1 NOTE: Unhook the torsion spring 2 from the hole a in the crankcase. EC4C3101 Shift guide and shift lever assembly 1. Remove: ● Bolt (shift guide) ● Shift guide 1 ● Shift lever assembly 2 NOTE: The shift lever assembly is disassembled at the same time as the shift guide. EC4N3100 Segment 1.
KICK AXLE AND SHIFT SHAFT ENG EC4B4400 Shift shaft 1. Inspect: ● Shift shaft 1 Bend/damage → Replace. ● Spring 2 Broken → Replace. EC4C4100 Shift guide and shift lever assembly 1. Inspect: ● Shift guide 1 ● Shift lever 2 ● Pawl 3 ● Pawl pin 4 ● Spring 5 Wear/damage → Replace. EC4B4500 Stopper lever 1. Inspect: ● Stopper lever 1 Wear/damage → Replace. ● Torsion spring 2 Broken → Replace. EC4C5000 ASSEMBLY AND INSTALLATION Segment 1. Install: ● Segment 1 ● Bolt (segment) R. T. 30 Nm (3.
KICK AXLE AND SHIFT SHAFT ENG EC4B5111 Stopper lever 1. Install: ● Torsion spring 1 ● Stopper lever 2 ● Bolt (stopper lever) 3 R. T. 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Align the stopper lever roller with the slot on segment. Shift guide and shift lever assembly 1. Install: ● Spring 1 ● Pawl pin 2 ● Pawl 3 To shift lever 4. NOTE: Apply the engine oil on the springs, pawl pins and pawls. 2. Install: ● Shift lever assembly 1 To shift guide 2. 2 1 3.
KICK AXLE AND SHIFT SHAFT ENG EC4C5301 Shift shaft 1. Install: ● Roller 1 ● Collar 2 ● Torsion spring 3 ● Shift shaft 4 NOTE: Apply the engine oil on the roller and shift shaft. 2. Install: ● Shift pedal Refer to “AC MAGNETO AND STARTER CLUTCH” section. Kick axle assembly 1. Install: ● Kick gear 1 ● Plain washer 2 New ● Circlip 3 ● Ratchet wheel 4 ● Spring 5 ● Plain washer 6 New ● Circlip 7 To kick axle 8.
KICK AXLE AND SHIFT SHAFT ENG 3. Install: ● Spring guide 1 NOTE: Slide the spring guide into the kick axle, make sure the groove a in the spring guide fits on the stopper of the torsion spring. 4. Install: ● Kick axle assembly 1 ● Plain washer 2 NOTE: ● Apply the molybdenum disulfide grease on the contacting surfaces of the kick axle stopper a and stopper plate 3. ● Apply the engine oil on the kick axle.
ENG AC MAGNETO AND STARTER CLUTCH AC MAGNETO AND STARTER CLUTCH Extent of removal: Extent of removal 1 Starter clutch/wheel gear removal 3 Pickup coil/stator removal Order Part name 2 Rotor removal Q’ty AC MAGNETO AND STATOR REMOVAL Drain the engine oil. Preparation for removal Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Refer to “RADIATOR” section.
AC MAGNETO AND STARTER CLUTCH Extent of removal 3 1 2 3 Order Part name Q’ty 9 10 11 12 13* 14 Dowel pin Idle gear 2 Bearing Shaft Nut (rotor) Rotor 2 1 1 1 1 1 15 16 17 18 19 20 21 22 Woodruff key Starter clutch Starter clutch drive gear Bearing Plain washer Holder Pick-up coil Stator 1 1 1 1 1 1 1 1 ENG Remarks Refer to NOTE. Use special tool. Refer to “REMOVAL POINTS”. NOTE: Tighten the rotor nut to 65 Nm (6.5 m·kg, 47 ft·lb), loosen and retighten the rotor nut to 65 Nm (6.
AC MAGNETO AND STARTER CLUTCH ENG EC4L3000 REMOVAL POINTS Rotor 1. Remove: ● Nut (rotor) 1 ● Plain washer 2. Remove: ● Rotor 1 Use the rotor puller 2. Rotor puller: YM-04141/90890-04141 EC4L4000 INSPECTION AC magneto 1. Inspect: ● Rotor inner surface a ● Stator outer surface b Damage → Inspect the crankshaft runout and crankshaft bearing. If necessary, replace AC magneto and/ or stator. EC4L4200 Woodruff key 1. Inspect: ● Woodruff key 1 Damage → Replace.
AC MAGNETO AND STARTER CLUTCH ENG Starter clutch 1. Check: ● Starter clutch Damage/wear → Replace. 2. Check: ● Idle gear ● Idle gear shaft ● Starter clutch gear Pitting/burrs/chips/roughness/wear Replace the defective parts. 3. Check: ● Starter clutch operation ● ● ● → Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch. When turning the starter clutch drive gear counterclockwise ı, the starter clutch and the starter clutch drive gear should engage.
AC MAGNETO AND STARTER CLUTCH ENG 2. Install: ● Holder 1 ● Bolt 2 R. T. 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: ● Pass the pick-up coil lead 3 and AC magneto lead 4 under the holder as shown. ● Take care not to catch the AC magneto lead between crankcase cover ribs. ● Apply the sealant to the grommet of the AC magneto lead. Quick gasket: ACC-QUICK-GS-KT YAMAHA Bond No. 1215: 90890-85505 3.
AC MAGNETO AND STARTER CLUTCH ENG 5. Install: ● Bolt (starter clutch) 1 R. T. ● ● 16 Nm (1.6 m · kg, 11 ft · lb) Plain washer (rotor) Nut (rotor) 2 R. T. 65 Nm (6.5 m · kg, 47 ft · lb) NOTE: Tighten the rotor nut to 65 Nm (6.5 m·kg, 47 ft·lb), loosen and retighten the rotor nut to 65 Nm (6.5 m·kg, 47 ft·lb). 6. Install: ● Shaft 1 ● Bearing 2 ● Idle gear 2 3 NOTE: Apply the engine oil on the shaft, bearing and idle gear inner circumference. 7.
AC MAGNETO AND STARTER CLUTCH ENG 10. Install: ● Engine guard 1 ● Clamp 2 ● Bolt [engine guard (front)] 3 R. T. ● Bolt [engine guard (rear)] 4 R. T. ● 34 Nm (3.4 m · kg, 24 ft · lb) 23 Nm (2.3 m · kg, 17 ft · lb) Cylinder head breather hose 5 11. Connect: ● AC magneto lead Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 12. Install: ● Shift pedal 1 ● Bolt (shift pedal) R. T. 12 Nm (1.2 m · kg, 8.
ENGINE REMOVAL ENG EC4M0000 ENGINE REMOVAL Extent of removal Preparation for removal Order Part name Q’ty ENGINE REMOVAL Hold the machine by placing the suitable stand under the frame. Drain the engine oil Seat and fuel tank Carburetor Exhaust pipe and silencer Clutch cable and guide Radiator Shift pedal Cylinder head breather hose and oil tank breather hose Ignition coil Disconnect the AC magneto lead. 4 - 83 Remarks WARNING Support the machine securely so there is no danger of it falling over.
ENGINE REMOVAL Extent of removal: Extent of removal 1 Engine removal Order Part name Q’ty Crankcase cover (left) 1 ENG 1 2 3 4 5 6 7 8 9 10 Disconnect the starter motor lead. Negative battery lead Engine skid plate (front) Neutral switch Oil hose Chain cover Nut (drive sprocket) Lock washer Drive sprocket Clip Bolt (brake pedal) Brake pedal 4 - 84 Remarks Refer to “AC MAGNETO AND STARTER CLUTCH” section for removing the starter motor lead.
ENGINE REMOVAL Extent of removal Order 1 11 12 13 14 15 16 Part name Q’ty Engine upper bracket (right) Engine upper bracket (left) Engine lower bracket Engine mounting bolt Pivot shaft Engine 4 - 85 1 1 2 3 1 1 ENG Remarks Refer to “REMOVAL POINTS”.
ENGINE REMOVAL ENG EC4M3000 REMOVAL POINTS EC4F3100 Drive sprocket 1. Remove: ● Nut (drive sprocket) 1 ● Lock washer 2 NOTE: ● Straighten the lock washer tab. ● Loosen the nut while applying the rear brake. 2. Remove: ● Drive sprocket 1 ● Drive chain 2 NOTE: Remove the drive sprocket together with the drive chain. EC4M3301 Engine removal 1. Remove: ● Pivot shaft 1 NOTE: If the pivot shaft is pulled all the way out, the swingarm will come loose.
ENGINE REMOVAL ENG EC4M5000 ASSEMBLY AND INSTALLATION Engine installation 1. Install: ● Engine 1 Install the engine from right side. ● Pivot shaft 2 R. T. 85 Nm (8.5 m · kg, 61 ft · lb) Engine mounting bolt (lower) 3 ● Engine lower bracket 4 Bolt (engine bracket) 5 R. T. ● ● R. T. ● ● ● ● 55 Nm (5.5 m · kg, 40 ft · lb) Bolt (engine guard) A R. T. ● 55 Nm (5.5 m · kg, 40 ft · lb) Engine mounting bolt (upper) 0 R. T. ● 69 Nm (6.
ENGINE REMOVAL ENG Drive sprocket 1. Install: ● Drive sprocket 1 ● Drive chain 2 NOTE: Install the drive sprocket together with the drive chain. 2. Install: New ● Lock washer 1 ● Nut (drive sprocket) 2 R. T. 75 Nm (7.5 m · kg, 54 ft · lb) NOTE: Tighten the nut while applying the rear brake. 3. Bend the lock washer tab to lock the nut. 4. Install: ● Chain guide ● Chain cover 1 ● Screw (chain cover) 2 1 R. T. 2 8 Nm (0.8 m · kg, 5.8 ft · lb) 5.
CRANKCASE AND CRANKSHAFT ENG CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT Extent of removal: Extent of removal 1 Crankcase separation Order Part name 2 Crankshaft removal Q’ty CRANKCASE SEPARATION Engine Piston Preparation for removal Refer to “ENGINE REMOVAL” section. Refer to “CYLINDER AND PISTON” section. Refer to “BALANCER” section. Balancer Kick axle assembly Segment Stator 1 2 1 2 3 4 5 6 7 8 9 Remarks Refer to “KICK AXLE AND SHIFT SHAFT” section.
CRANKCASE AND CRANKSHAFT Extent of removal 2 Order 10 11 12 Part name Q’ty Oil strainer Oil delivery pipe 2 Crankshaft 1 1 1 4 - 90 ENG Remarks Use special tool. Refer to “REMOVAL POINTS”.
CRANKCASE AND CRANKSHAFT ENG CRANKCASE BEARING Extent of removal: Extent of removal 1 Crankcase bearing removal Order Preparation for removal 1 1 2 Part name Q’ty CRANKCASE BEARING REMOVAL Transmission Shift cam and shift fork Oil seal Bearing 4 - 91 Remarks Refer to “TRANSMISSION, SHIFT CAM AND SHIFT FORK” section. 3 10 Refer to “REMOVAL POINTS”.
CRANKCASE AND CRANKSHAFT ENG REMOVAL POINTS Crankcase 1. Separate: ● Crankcase (right) ● Crankcase (left) Separation steps: Remove the crankcase bolts, hose guide and clutch cable holder. ● NOTE: Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them. ● Remove the crankcase (right). NOTE: ● Place the crankcase with its left side downward and split it by inserting a screwdriver tip into the splitting slit a in the crankcase.
CRANKCASE AND CRANKSHAFT ENG Crankshaft 1. Remove: ● Crankshaft 1 Use the crankcase separating tool 2. Crankcase separating tool: YU-1135-A/90890-01135 CAUTION: Do not use a hammer to drive out the crankshaft. Crankshaft bearing 1. Remove: ● Bearing 1 NOTE: ● Remove the bearing from the crankcase by pressing its inner race. ● Do not use the removed bearing. INSPECTION Timing chain and timing chain guide 1. Inspect: ● Timing chain Cracks/stiff → Replace the timing chain and camshaft sprocket as a set. 2.
CRANKCASE AND CRANKSHAFT ENG EC4N4201 Crankshaft 1. Measure: ● Runout limit a ● Small end free play limit b ● Connecting rod big end side clearance c ● Crank width d Out of specification → Replace. Use the dial gauge and a thickness gauge. Dial gauge and stand: YU-3097/90890-01252 Runout limit: Small end free play: Standard 0.03 mm (0.0012 in) 0.05 mm (0.002 in) 0.4 ~ 1.0 mm (0.016 ~ 0.039 in) 2.0 mm (0.08 in) Side 0.15 ~ 0.45 mm 0.50 mm clearance: (0.0059 ~ 0.0177 in) (0.
CRANKCASE AND CRANKSHAFT ENG EC4N5000 ASSEMBLY AND INSTALLATION Crankshaft bearing 1. Install: New ● Bearing ● Bearing stopper ● Bolt (bearing stopper) a 1 R. T. b 10 Nm (1.0 m · kg, 7.2 ft · lb) Screw (bearing stopper) ● Screw [bearing stopper (crankshaft)] 1 R. T. ● 10 Nm (1.0 m · kg, 7.2 ft · lb) R. T. 10 Nm (1.0 m · kg, 7.2 ft · lb) To crankcase (left and right). NOTE: ● Install the bearing by pressing its outer race parallel.
CRANKCASE AND CRANKSHAFT ENG NOTE: ● Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms against the bearing. ● Before installing the crankshaft, clean the contacting surface of crankcase. CAUTION: Do not use a hammer to drive in the crankshaft. 2. Check: ● Shifter operation ● Transmission operation Unsmooth operation → Repair. 3.
CRANKCASE AND CRANKSHAFT ENG 5. Install: ● Dowel pin 1 New ● O-ring 2 ● Crankcase (right) To crankcase (left). NOTE: ● Fit the crankcase (right) onto the crankcase (left). Tap lightly on the case with soft hammer. ● When installing the crankcase, the connecting rod should be positioned at TDC (top dead center). 6. Tighten: ● Hose guide 1 ● Clutch cable holder 2 ● Bolt (clutch cable holder) R. T. ● 10 Nm (1.0 m · kg, 7.2 ft · lb) Bolt (crankcase) R. T. 12 Nm (1.2 m · kg, 8.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK Extent of removal: Extent of removal 1 Shift fork, shift cam, main axle and drive axle removal Order Q’ty TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVAL Engine Separate the crankcase. Preparation for removal 1 Part name 1 2 3 4 5 6 7 Shift fork 1 Shift fork 2 Shift fork 3 Shift cam Main axle Drive axle Collar Refer to “ENGINE REMOVAL” section.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG EC4H3000 REMOVAL POINTS Shift fork, shaft cam and transmission 1. Remove: ● Shift forks ● Shift cam ● Main axle ● Drive axle NOTE: ● Tap lightly on the transmission drive axle and shift cam with a soft hammer to remove. ● Remove assembly carefully. Note the position of each part. Pay particular attention to the location and direction of shift forks. EC4H4000 INSPECTION EC4H4200 Gears 1.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG EC4H4801 Shift fork, shift cam and segment 1. Inspect: ● Shift fork 1 Wear/damage/scratches → Replace. 2. Inspect: ● Shift cam 1 ● Segment 2 Bend/wear/damage → Replace. 3. Check: ● Shift fork movement Unsmooth operation → Replace shift fork. NOTE: For a malfunctioning shift fork, replace not only the shift fork itself but the two gears each adjacent to the shift fork. ASSEMBLY AND INSTALLATION Transmission 1.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG 2. Install: ● 2nd wheel gear (26T) 1 ● 4th wheel gear (21T) 2 ● 3rd wheel gear (21T) 3 ● 5th wheel gear (21T) 4 ● 1st wheel gear (29T) 5 ● O-ring 6 To drive axle 7. NOTE: ● Apply the molybdenum disulfide oil on the 1st, 2nd and 3rd wheel gears inner circumference and on the end surface. ● Apply the molybdenum disulfide oil on the 4th and 5th wheel gears inner circumference. ● Apply the lithium soap base grease on the Oring. 3.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG 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. NOTE: ● Apply the molybdenum disulfide oil on the shift fork grooves. ● Mesh the shift fork #1 (L) with the 4th wheel gear 5 and #3 (R) with the 5th wheel gear 7 on the drive axle. ● Mesh the shift fork #2 (C) with the 3rd pinion gear 6 on the main axle. 6. Install: ● Transmission assembly 1 To crankcase (left) 2.
FRONT WHEEL AND REAR WHEEL CHAS EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL Extent of removal: 1 Front wheel removal 3 Brake disc removal Extent of removal Order 3 2 3 Q’ty FRONT WHEEL REMOVAL Hold the machine by placing the suitable stand under the engine.
FRONT WHEEL AND REAR WHEEL CHAS EC598100 REAR WHEEL 5 Extent of removal: 1 Rear wheel removal 3 Brake disc removal Extent of removal Order 3 2 3 Q’ty REAR WHEEL REMOVAL Hold the machine by placing the suitable stand under the engine.
FRONT WHEEL AND REAR WHEEL CHAS EC593000 REMOVAL POINTS EC523101 Rear wheel 1. Remove: ● Wheel 1 NOTE: Push the wheel forward and remove the drive chain 2. EC513201 Wheel bearing (if necessary) 1. Remove: ● Bearing 1 NOTE: Remove the bearing using a general bearing puller 2. EC594000 INSPECTION EC514100 Wheel 1. Measure: ● Wheel runout Out of limit → Repair/replace. Wheel runout limit: Radial 1: 2.0 mm (0.08 in) Lateral 2: 2.0 mm (0.08 in) 2. Inspect: ● Bearing Rotate inner race with a finger.
FRONT WHEEL AND REAR WHEEL CHAS EC514200 Wheel axle 1. Measure: ● Wheel axle bends Out of specification → Replace. Use the dial gauge 1. Wheel axle bending limit: 0.5 mm (0.020 in) NOTE: The bending value is shown by one half of the dial gauge reading. WARNING Do not attempt to straighten a bent axle. EC594200 Brake disc 1. Measure: ● Brake disc deflection (only rear brake disc) Use the dial gauge 1. Out of specification → Inspect wheel runout.
FRONT WHEEL AND REAR WHEEL CHAS EC595000 ASSEMBLY AND INSTALLATION Front wheel 1. Install: ● Bearing (left) 1 ● Spacer 2 ● Bearing (right) 3 New ● Oil seal 4 NOTE: ● Apply the lithium soap base grease on the bearing and oil seal lip when installing. ● Use a socket that matches the outside diameter of the race of the bearing. ● Left side of bearing shall be installed first. ● Install the oil seal with its manufacture’s marks or numbers facing outward.
FRONT WHEEL AND REAR WHEEL CHAS 5. Install: ● Wheel NOTE: ● Install the brake disc 1 between the brake pads 2 correctly. ● Make sure that the projections a in the trip meter gear unit fits over the stopper b on the front fork outer tube. 6. Install: ● Wheel axle 1 NOTE: Apply the lithium soap base grease on the wheel axle. 7. Install: ● Nut (wheel axle) 1 R. T. 5-6 105 Nm (10.
FRONT WHEEL AND REAR WHEEL CHAS 8. Tighten: ● Bolt (axle holder) 1 R. T. 23 Nm (2.3 m · kg, 17 ft · lb) NOTE: Before tightening the bolt, fit the wheel axle to the axle holder by stroking the front fork several times with the front brake applied. 9. Install: ● Brake hose 1 R. T. 10 Nm (1.0 m · kg, 7.2 ft · lb) To brake hose holder 2. NOTE: Before tightening the bolt (brake hose holder), align the top a of the brake hose neck with the brake hose holder bottom b.
FRONT WHEEL AND REAR WHEEL CHAS Rear wheel 1. Install: ● Bearing (right) 1 New ● Circlip 2 ● Spacer 3 ● Bearing (left) 4 New ● Oil seal 5 NOTE: ● Apply the lithium soap base grease on the bearing and oil seal lip when installing. ● Install the bearing with seal facing outward. ● Use a socket that matches the outside diameter of the race of the bearing. ● Right side of bearing shall be installed first. ● Install the oil seal with its manufacture’s marks or numbers facing outward.
FRONT WHEEL AND REAR WHEEL CHAS 4. Install: ● Collar 1 NOTE: Apply the lithium soap base grease on the oil seal lip. 5. Install: ● Wheel NOTE: Install the brake disc 1 between the brake pads 2 correctly. 6. Install: ● Drive chain 1 NOTE: Push the wheel 2 forward and install the drive chain. 7. Install: ● Chain puller (left) 1 ● Wheel axle 2 NOTE: ● Install the chain puller (left), and insert the wheel axle from left side. ● Apply the lithium soap base grease on the wheel axle. 8.
FRONT WHEEL AND REAR WHEEL CHAS 9. Adjust: ● Drive chain slack a Drive chain slack: 40 ~ 50 mm (1.6 ~ 2.0 in) Refer to “DRIVE CHAIN SLACK ADJUSTMENT” section in the CHAPTER 3. 10. Tighten: ● Nut (wheel axle) 1 R. T. 5 - 10 R. T. ● 125 Nm (12.5 m · kg, 90 ft · lb) 16 Nm (1.
FRONT BRAKE AND REAR BRAKE CHAS EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE Extent of removal: 1 Brake hose removal 3 Master cylinder removal Extent of removal Order 1 3 2 3 Q’ty FRONT BRAKE REMOVAL Hold the machine by placing the suitable stand under the engine. Preparation for removal 2 Part name 2 Caliper removal 1 2 3 4 5 6 7 8 9 10 11 Drain the brake fluid.
FRONT BRAKE AND REAR BRAKE CHAS EC5A8100 REAR BRAKE Extent of removal: 1 Master cylinder removal 3 Caliper removal Extent of removal Order Part name 2 Brake hose removal Q’ty REAR BRAKE REMOVAL Hold the machine by placing the suitable stand under the engine. Preparation for removal WARNING Support the machine securely so there is no danger of it falling over. Rear wheel 1 1 2 3 3 1 2 3 4 5 6 7 8 Remarks Refer to “FRONT WHEEL AND REAR WHEEL” section. Refer to “REMOVAL POINTS”.
FRONT BRAKE AND REAR BRAKE CHAS EC5A8200 CALIPER DISASSEMBLY Å Front ı Rear Extent of removal: Extent of removal 1 2 1 Front caliper disassembly Order 1 2 3 4 5 6 Part name 2 Rear caliper disassembly Q’ty CALIPER DISASSEMBLY Pad pin Brake pad Pad support Caliper piston Dust seal Piston seal 5 - 13 A 1 2 1 2 2 2 B 1 2 1 1 1 1 Remarks Refer to “REMOVAL POINTS”.
FRONT BRAKE AND REAR BRAKE CHAS EC5A8300 MASTER CYLINDER DISASSEMBLY Å Front ı Rear Extent of removal: Extent of removal 1 1 2 2 1 Front master cylinder disassembly Order 1 2 3 4 5 6 7 Part name 2 Rear master cylinder disassembly Q’ty MASTER CYLINDER DISASSEMBLY Master cylinder cap Diaphragm Master cylinder boot Circlip Plain washer Push rod Master cylinder kit 5 - 14 1 1 1 1 1 1 1 Remarks Use a long nose circlip pliers.
FRONT BRAKE AND REAR BRAKE CHAS EC5A3000 Å REMOVAL POINTS Brake fluid 1. Remove: [Front] ● Master cylinder cap 1 [Rear] ● Master cylinder cap 1 ● Protector NOTE: Do not remove the diaphragm. ı Å Front ı Rear 2. Connect the transparent hose 2 to the bleed screw 1 and place a suitable container under its end. Å Front ı Rear Å 3. Loosen the bleed screw and drain the brake fluid while pulling the lever in or pushing down on the pedal. ı ● ● CAUTION: ACHTUNG: Do not reuse the drained brake fluid.
FRONT BRAKE AND REAR BRAKE CHAS EC533402 Å Piston seal kit 1. Remove: ● Dust seal 1 ● Piston seal 2 NOTE: Remove the piston seals and dust seals by pushing them with a finger. CAUTION: ACHTUNG: ı Never attempt to pry out piston seals and dust seals. WARNING Replace the piston seals and dust seals whenever a caliper is disassembled. Å Front ı Rear Å EC5A4000 ı INSPECTION EC534112 Master cylinder 1. Inspect: ● Master cylinder inner surface a Wear/scratches → Replace master cylinder assembly.
FRONT BRAKE AND REAR BRAKE Å CHAS EC534214 ı Caliper 1. Inspect: ● Caliper cylinder inner surface a Wear/score marks → Replace caliper assembly. Å Front ı Rear 2. Inspect: ● Caliper piston 1 Wear/score marks → Replace caliper piston assembly. WARNING Replace the piston seals and dust seals 2 whenever a caliper is disassembled. EC534301 Brake hose 1. Inspect: ● Brake hose 1 Crack/damage → Replace.
FRONT BRAKE AND REAR BRAKE 2. Install: ● Piston seal 1 Å ● Dust seal 2 CHAS New New WARNING Always use new piston seals and dust seals. NOTE: Fit the piston seals and dust seals onto the slot on caliper correctly. ı Å Front ı Rear 3. Install: ● Caliper piston 1 Å NOTE: Apply the brake fluid on the piston wall. CAUTION: ACHTUNG: ● ● Install the piston with its shallow depressed side a facing the caliper. Never force to insert. Å Front ı Rear ı EC5A5700 Front caliper 1.
FRONT BRAKE AND REAR BRAKE CHAS 2. Install: New ● Copper washer 1 ● Union bolt 2 R. T. 30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers. CAUTION: ACHTUNG: Install the brake hose so that its pipe portion a directs as shown and lightly touches the projection b on the caliper. 3. Install: ● Brake hose holder 1 ● Caliper 2 ● Bolt (caliper) 3 R. T. 23 Nm (2.3 m · kg, 17 ft · lb) NOTE: Fit the brake hose holder cut a over the projection b on the front fork and clamp the brake hose. 4.
FRONT BRAKE AND REAR BRAKE CHAS 2. Install: ● Disc cover 1 ● Bolt (disc cover) 2 R. T. 7 Nm (0.7 m · kg, 5.1 ft · lb) 3. Install: ● Caliper 1 ● Rear wheel 2 Refer to “FRONT WHEEL AND REAR WHEEL” section. 4. Tighten: ● Pad pin 3 R. T. 18 Nm (1.8 m · kg, 13 ft · lb) 5. Install: ● Pad pin plug 4 R. T. 3 Nm (0.3 m · kg, 2.2 ft · lb) Master cylinder kit 1. Clean: ● Master cylinder ● Master cylinder kit Clean them with brake fluid. Å 2.
FRONT BRAKE AND REAR BRAKE Å CHAS 3. Install: ● Spring 1 To master cylinder piston 2. ı NOTE: Install the spring at the smaller dia. side. Å Front ı Rear 4. Install: [Front] ● Master cylinder kit 1 ● Plain washer 2 ● Circlip 3 ● Master cylinder boot 4 To master cylinder 5. [Rear] ● Master cylinder kit 1 ● Push rod 2 ● Circlip 3 ● Master cylinder boot 4 To master cylinder 5. Å ı NOTE: Apply the brake fluid on the master cylinder kit. ● Apply the lithium soap base grease on the tip of the push rod.
FRONT BRAKE AND REAR BRAKE CHAS 2. Install: ● Brake lever 1 ● Bolt (brake lever) 2 R. T. ● 6 Nm (0.6 m · kg, 4.3 ft · lb) Nut (brake lever) 3 R. T. 6 Nm (0.6 m · kg, 4.3 ft · lb) NOTE: Apply the lithium soap base grease on the brake lever sliding surface, bolt and contacting surface of the master cylinder piston. Rear master cylinder 1. Install: ● Copper washer 1 ● Brake hose 2 ● Union bolt 3 New R. T. 30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers.
FRONT BRAKE AND REAR BRAKE CHAS 4. Install: ● Pin 1 ● Plain washer 2 New ● Cotter pin 3 NOTE: After installing, check the brake pedal height. Refer to “REAR BRAKE ADJUSTMENT” section in the CHAPTER 3. Front brake hose 1. Install: ● Brake hose 1 R. T. 10 Nm (1.0 m · kg, 7.2 ft · lb) To brake hose holder 2. NOTE: Before tightening the bolt (brake hose holder), align the top a of the brake hose neck with the brake hose holder bottom b.
FRONT BRAKE AND REAR BRAKE 4. Install: ● Copper washer 1 ● Brake hose 2 ● Union bolt 3 CHAS New R. T. 30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers. CAUTION: ACHTUNG: Install the brake hose so that it contacts the master cylinder projection a and that its bent portion b faces downward. Rear brake hose 1. Install: ● Copper washer 1 ● Brake hose 2 ● Union bolt 3 New R. T. 30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers.
FRONT BRAKE AND REAR BRAKE CHAS 2. Install: ● Brake hose holder 1 ● Screw (brake hose holder) 2 R. T. 1 Nm (0.1 m · kg, 0.7 ft · lb) CAUTION: ACHTUNG: After installing the brake hose holders, make sure the brake hose does not contact the spring (rear shock absorber). If it does, correct its twist. Brake fluid 1. Fill: ● Brake fluid Until the fluid level reaches “LOWER” level line a.
FRONT BRAKE AND REAR BRAKE CHAS 2. Air bleed: ● Brake system Refer to “BRAKE SYSTEM AIR BLEEDING” section in the CHAPTER 3. 3. Inspect: ● Brake fluid level Fluid at lower level → Fill up. Refer to “BRAKE FLUID LEVEL INSPECTION” section in the CHAPTER 3. 4. Install: [Front] ● Diaphragm ● Master cylinder cap 1 ● Screw (master cylinder cap) 2 Å R. T. 2 Nm (0.2 m · kg, 1.4 ft · lb) [Rear] ● Diaphragm ● Master cylinder cap 1 ● Bolt (master cylinder cap) 2 R. T. ı 2 Nm (0.2 m · kg, 1.
FRONT FORK CHAS EC550000 FRONT FORK Extent of removal: Extent of removal 1 Front fork removal Order Part name Q’ty FRONT FORK REMOVAL Hold the machine by placing the suitable stand under the engine. Preparation for removal WARNING Support the machine securely so there is no danger of it falling over. Front wheel Refer to “FRONT WHEEL AND REAR WHEEL” section. Refer to “FRONT BRAKE AND REAR BRAKE” section.
FRONT FORK CHAS EC558000 FRONT FORK DISASSEMBLY Extent of removal: Extent of removal 1 2 1 Oil seal removal Order 1 2 3 4 5 6 7 8 9 0 A B C 2 Damper rod removal Part name Q’ty FRONT FORK DISASSEMBLY Cap bolt Fork spring Dust seal Stopper ring Inner tube Outer tube Piston metal Slide metal Plain washer Oil seal Spring guide Base valve Damper rod 5 - 28 1 1 1 1 1 1 1 1 1 1 1 1 1 Remarks Refer to “REMOVAL POINTS”. Drain the fork oil. Refer to “REMOVAL POINTS”. Use special tool.
FRONT FORK CHAS EC556000 HANDLING NOTE NOTE: The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers. CAUTION: ACHTUNG: To prevent an accidental explosion of air, the following instructions should be observed: ● The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material.
FRONT FORK CHAS EC553201 Inner tube 1. Remove: ● Dust seal 1 ● Stopper ring 2 Using slotted-head screwdriver. CAUTION: ACHTUNG: Take care not to scratch the inner tube. 2. Remove: ● Inner tube 1 Oil seal removal steps: Push in slowly a the inner tube just before it bottoms out and then pull it back quickly b. ● Repeat this step until the inner tube can be pulled out from the outer tube. ● EC553311 Damper rod 1.
FRONT FORK CHAS EC554200 Base valve 1. Inspect: ● Valve assembly 1 Wear/damage → Replace. ● O-ring 2 Damage → Replace. EC554400 Fork spring 1. Measure: ● Fork spring free length a Out of specification → Replace. Fork spring free length: Standard Limit 460 mm (18.1 in) 455 mm (17.9 in) EC554502 Inner tube 1. Inspect: ● Inner tube surface a Score marks → Repair or replace. Use #1,000 grit wet sandpaper. Damaged oil lock piece → Replace. ● Inner tube bends Out of specification → Replace.
FRONT FORK CHAS EC554700 Cap bolt 1. Inspect: ● Cap bolt 1 ● O-ring 2 ● Air bleed screw 3 Wear/damage → Replace. EC555000 ASSEMBLY AND INSTALLATION Front fork assembly 1. Wash the all parts in a clean solvent. 2. Install: ● Damper rod 1 To inner tube 2. CAUTION: ACHTUNG: To install the damper rod into the inner tube, hold the inner tube aslant. If the inner tube is held vertically, the damper rod may fall into it, damaging the valve inside. 3.
CHAS FRONT FORK 5. Install: ● Spring guide 1 ● Locknut 2 To damper rod 3. NOTE: ● Install the spring guide with its cut a facing upward. ● With its thread b facing upward, fully finger tighten the locknut onto the damper rod. 6. Install: ● Dust seal 1 ● Stopper ring 2 New ● Oil seal 3 ● Plain washer 4 New ● Slide metal 5 To inner tube 6. NOTE: ● Apply the fork oil on the inner tube. ● When installing the oil seal, use vinyl seat a with fork oil applied to protect the oil seal lip.
FRONT FORK CHAS 9. Install: ● Slide metal 1 ● Plain washer 2 To outer tube slot. NOTE: Press the slide metal into the outer tube with fork seal driver 3. Fork seal driver: YM-01442/90890-01442 10. Install: ● Oil seal 1 NOTE: Press the oil seal into the outer tube with fork seal driver 2. Fork seal driver: YM-01442/90890-01442 11. Install: ● Stopper ring 1 NOTE: Fit the stopper ring correctly in the groove in the outer tube. 12.
FRONT FORK CHAS 13. Check: ● Inner tube smooth movement Tightness/binding/rough spots → Repeat the steps 2 to 12. 14. Compress the front fork fully. 15. Fill: ● Front fork oil Until outer tube top surface with recommended fork oil 1. Recommended oil: Suspension oil “01” CAUTION: ACHTUNG: ● ● Be sure to use recommended fork oil. If other oils are used, they may have an excessively adverse effect on the front fork performance. Never allow foreign materials to enter the front fork. 16.
FRONT FORK CHAS 19. Wait ten minutes until the air bubbles have been removed from the front fork, and the oil has dispense evenly in system before setting recommended oil level. NOTE: Fill with the fork oil up to the top end of the outer tube, or the fork oil will not spread over to every part of the front forks, thus making it impossible to obtain the correct level. Be sure to fill with the fork oil up to the top of the outer tube and bleed the front forks. 20.
FRONT FORK CHAS 21. Measure: ● Distance a Out of specification → Turn into the locknut. Distance a: 20 mm (0.79 in) or more Between damper rod 1 top and locknut 2 top. 22. Loosen: ● Rebound damping adjuster 1 NOTE: ● Loosen the rebound damping adjuster finger tight. ● Record the set position of the adjuster (the amount of turning out the fully turned in position). 23. Install ● Cushion rubber 1 ● Washer 2 ● Spacer 3 To cap bolt 4. NOTE: Install the cushion rubber with its smaller dia.
FRONT FORK CHAS 26. Tighten: ● Cap bolt (locknut) 1 R. T. 29 Nm (2.9 m · kg, 21 ft · lb) NOTE: ● While compressing the fork spring, set the thin type spanners 2 between the spacer 3 and spring guide 4. ● Hold the locknut 5 and tighten the cap bolt with specified torque. 27. Install: ● Cap bolt 1 To outer tube. NOTE: Temporarily tighten the cap bolt. 28. Install: ● Protector guide 1 Installation 1. Install: ● Front fork 1 NOTE: ● Temporarily tighten the pinch bolts (under bracket).
FRONT FORK CHAS 4. Tighten: ● Pinch bolt (handle crown) 1 R. T. ● 23 Nm (2.3 m · kg, 17 ft · lb) Pinch bolt (under bracket) 2 R. T. 20 Nm (2.0 m · kg, 14 ft · lb) CAUTION: ACHTUNG: Tighten the under bracket to specified torque. If torqued too much, it may cause the front fork to malfunction. 5. Install: ● Brake hose holder 1 ● Caliper 2 ● Bolt (caliper) 3 R. T. 23 Nm (2.3 m · kg, 17 ft · lb) NOTE: Fit the brake hose holder cut a over the projection b on the front fork and clamp the brake hose. 6.
HANDLEBAR CHAS EC5B0000 HANDLEBAR Extent of removal: Extent of removal 1 Handlebar removal Order Q’ty 1 2 3 4 5 HANDLEBAR REMOVAL Headlight Hot starter cable Hot starter lever holder Clutch cable Clutch lever holder “ENGINE STOP” button 1 1 1 1 1 6 7 8 9 10 11 12 13 14 15 16 17 Lights switch Master cylinder Start switch Throttle cable cap Throttle cable #2 (pushed) Throttle cable #1 (pulled) Grip (right) Tube guide Cover (grip cap) Grip (left) Handlebar holder (upper) Handlebar 1 1 1 1 1 1 1 1 1
HANDLEBAR CHAS EC5B3000 REMOVAL POINTS EC5B3100 Master cylinder 1. Remove: ● Master cylinder bracket 1 ● Master cylinder 2 CAUTION: ACHTUNG: ● ● Do not let the master cylinder hang on the brake hose. Keep the master cylinder cap side horizontal to prevent air from coming in. EC5B3200 Grip 1. Remove: ● Grip 1 NOTE: Blow in air between the handlebar or tube guide and the grip. Then remove the grip which has become loose. EC5B4000 INSPECTION EC5B4100 Handlebar 1.
HANDLEBAR CHAS EC5B5000 ASSEMBLY AND INSTALLATION Handlebar 1. Install: ● Handlebar 1 ● Handlebar holder 2 ● Bolt (handlebar holder) 3 R. T. 28 Nm (2.8 m · kg, 20 ft · lb) NOTE: ● The handlebar holder should be installed with the punched mark a forward. ● First tighten the bolts on the front side of the handlebar holder, and then tighten the bolts on the rear side. 2. Install: ● Grip (left) 1 Apply the adhesive to the handlebar 2.
HANDLEBAR CHAS 4. Install: ● Cover (grip cap) 1 ● Throttle grip 2 NOTE: Apply the lithium soap base grease on the throttle grip sliding surface. 5. Install: ● Throttle cables 1 To tube guide 2. NOTE: Apply the lithium soap base grease on the throttle cable end and tube guide cable winding portion. 6. Install: ● Throttle cable cap 1 ● Screw (throttle cable cap) 2 R. T. 4 Nm (0.4 m · kg, 2.9 ft · lb) WARNING After tightening the screws, check that the throttle grip 3 moves smoothly.
HANDLEBAR CHAS 8. Install: ● Start switch 1 ● Master cylinder 2 ● Master cylinder bracket 3 ● Bolt (master cylinder bracket) 4 R. T. ● 9 Nm (0.9 m · kg, 6.5 ft · lb) Clamp 5 NOTE: ● The start switch and master cylinder bracket should be installed according to the dimensions shown. ● Install the bracket so that the arrow mark a faces upward. ● First tighten the bolt on the upper side of the master cylinder bracket, and then tighten the bolt on the lower side. Zero mm (Zero in) Zero mm (Zero in) 9.
HANDLEBAR CHAS 11. Install: ● Clutch cable 1 ● Hot starter cable 2 NOTE: Apply the lithium soap base grease on the clutch cable end and hot starter cable end. 12. Adjust: ● Clutch lever free play Refer to “CLUTCH ADJUSTMENT” section in the CHAPTER 3. ● Hot starter lever free play Refer to “HOT STARTER LEVER ADJUSTMENT” section in the CHAPTER 3. 13. Fasten the hot starter cable 1 and clutch cable 2 with a clamp 3. 1 3 2 14.
STEERING CHAS EC560000 STEERING Extent of removal: Extent of removal 1 Under bracket removal Order Part name 1 2 3 4 5 6 7 8 STEERING REMOVAL Hold the machine by placing the suitable stand under the engine.
STEERING Extent of removal 2 Order 11 12 13 Part name Q’ty Bearing (upper) Bearing (lower) Ball race 1 1 2 5 - 47 CHAS Remarks Refer to “REMOVAL POINTS”.
STEERING CHAS EC563000 REMOVAL POINTS EC563202 Ring nut 1. Remove: ● Ring nut 1 Use the ring nut wrench 2. Ring nut wrench: YU-33975/90890-01403 WARNING Support the steering shaft so that it may not fall down. EC563300 Bearing (lower) 1. Remove: ● Bearing (lower) 1 Use the floor chisel 2. CAUTION: ACHTUNG: Take care not to damage the steering shaft thread. EC563400 Ball race 1. Remove: ● Ball race 1 Remove the ball race using long rod 2 and the hammer.
STEERING CHAS EC564101 Bearing and ball race 1. Wash the bearings and ball races with a solvent. 2. Inspect: ● Bearing 1 ● Ball race Pitting/damage → Replace bearings and ball races as a set. Install the bearing in the ball races. Spin the bearings by hand. If the bearings hang up or are not smooth in their operation in the ball races, replace bearings and ball races as a set. EC565000 ASSEMBLY AND INSTALLATION Under bracket 1.
STEERING CHAS 4. Install: ● Plain washer 1 ● Ring nut 2 R. T. 7 Nm (0.7 m · kg, 5.1 ft · lb) Tighten the ring nut using the ring nut wrench 3. Refer to “STEERING HEAD INSPECTION AND ADJUSTMENT” section in the CHAPTER 3. 5. Check the steering shaft by turning it lock to lock. If there is any binding, remove the steering shaft assembly and inspect the steering bearings. 6. Install: ● Plain washer 1 7.
STEERING CHAS 9. Install: ● Steering shaft cap 1 10. After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the ring nut little by little. 11. Adjust: ● Front fork top end a Front fork top end (standard) a: Zero mm (Zero in) 12. Tighten: ● Pinch bolt (handle crown) 1 R. T. ● 23 Nm (2.3 m · kg, 17 ft · lb) Pinch bolt (under bracket) 2 R. T. 20 Nm (2.0 m · kg, 14 ft · lb) CAUTION: ACHTUNG: Tighten the under bracket to specified torque.
SWINGARM CHAS EC570000 SWINGARM Extent of removal: Extent of removal 1 Swingarm removal Order Part name Q’ty SWINGARM REMOVAL Hold the machine by placing the suitable stand under the engine.
SWINGARM CHAS EC578000 SWINGARM DISASSEMBLY Extent of removal: 1 Swingarm disassembly 3 Relay arm removal and disassembly Extent of removal 3 2 1 2 3 Order 1 2 3 4 5 6 7 8 9 Part name Q’ty SWINGARM DISASSEMBLY Cap Relay arm Connecting rod Collar Oil seal Thrust bearing Bush Oil seal Bearing 5 - 53 2 1 1 2 2 2 2 8 8 2 Connecting rod removal and disassembly Remarks Refer to “REMOVAL POINTS”.
SWINGARM CHAS EC573000 REMOVAL POINTS EC573200 Bearing 1. Remove: ● Bearing 1 NOTE: Install the bearing by pressing its outer race. EC574010 INSPECTION Wash the bearings, bushes, collars, and covers in a solvent. EC574111 Swingarm 1. Inspect: ● Bearing 1 ● Bush 2 Free play exists/unsmooth revolution/ rust → Replace bearing and bush as a set. 2. Inspect: ● Oil seal 3 Damage → Replace. EC574210 Relay arm 1.
SWINGARM CHAS EC574310 Connecting rod 1. Inspect: ● Bearing (polylube bearing) 1 ● Collar 2 Free play exists/unsmooth revolution/rust → Replace bearing and collar as a set. 2. Inspect: ● Bearing (polylube bearing) 1 Loss of solid lubrication → Replace. ● Oil seal 3 Damage → Replace. NOTE: Polylube bearings, with solid lubrication, have been adopted with the intent to make the needle bearings, used in this model, maintenance free.
SWINGARM CHAS 2. Install: ● Bearing 1 ● Oil seal 2 To relay arm. NOTE: ● Apply the molybdenum disulfide grease on the bearing when installing. ● Install the bearing by pressing it on the side having the manufacture’s marks or numbers. Installed depth of bearings a: 5 mm (0.20 in) 3. Install: ● Bearing 1 ● Oil seal 2 To connecting rod. NOTE: ● Apply the molybdenum disulfide grease on the bearing when installing. ● Install the bearing by pressing it on the side having the manufacture’s marks or numbers.
SWINGARM CHAS 3. Install: ● Collar 1 To connecting rod 2. NOTE: Apply the molybdenum disulfide grease on the collar and oil seal lips. 4. Install: ● Connecting rod 1 ● Bolt (connecting rod) 2 ● Plain washer 3 ● Nut (connecting rod) 4 R. T. 80 Nm (8.0 m · kg, 58 ft · lb) To relay arm 5. NOTE: Apply the molybdenum disulfide grease on the bolt. 5. Install: ● Relay arm 1 ● Bolt (relay arm) 2 ● Plain washer 3 ● Nut (relay arm) 4 To swingarm. NOTE: ● Apply the molybdenum disulfide grease on the bolt.
SWINGARM CHAS 8. Install: ● Bolt (connecting rod) 1 ● Plain washer 2 ● Nut (connecting rod) 3 NOTE: ● Apply the molybdenum disulfide grease on the bolt. ● Do not tighten the nut yet. 9. Install: ● Bolt (rear shock absorber-relay arm) 1 ● Nut (rear shock absorber-relay arm) 2 R. T. 53 Nm (5.3 m · kg, 38 ft · lb) NOTE: Apply the molybdenum disulfide grease on the bolt. 10. Tighten: ● Nut (connecting rod) 1 R. T. 80 Nm (8.0 m · kg, 58 ft · lb) 11. Tighten: ● Nut (relay arm) 1 R. T. 80 Nm (8.
SWINGARM CHAS 13. Install: ● Bolt [chain tensioner (lower)] 1 ● Plain washer 2 ● Collar 3 ● Chain tensioner 4 ● Nut [chain tensioner (lower)] 5 R. T. 20 Nm (2.0 m · kg, 14 ft · lb) 14. Install: ● Chain support 1 ● Support cover 2 ● Bolt {chain support [r= 50 mm (1.97 in)]} 3 ● Nut (chain support) 4 R. T. ● Bolt {support cover [r= 10 mm (0.39 in)]} 7 Nm (0.7 m · kg, 5.1 ft · lb) 5 R. T. 5 - 59 7 Nm (0.7 m · kg, 5.
REAR SHOCK ABSORBER CHAS EC580000 REAR SHOCK ABSORBER Extent of removal: Extent of removal Preparation for removal 1 Rear shock absorber removal Order Part name 2 Rear shock absorber disassembly Q’ty REAR SHOCK ABSORBER REMOVAL Hold the machine by placing the suitable stand under the engine. Seat, fitting band and side covers Air filter cover Silencer Drain the coolant.
REAR SHOCK ABSORBER Extent of removal Order 1 2 3 1 2 4 5 6 7 8 9 10 11 12 13 Part name Q’ty Disconnect the starter relay coupler. Starter motor lead Locking tie Taillight coupler Starting circuit cut-off relay coupler Plastic band Clamp (air filter joint) Rear frame Bolt (rear shock absorber-relay arm) Bolt (rear shock absorber-frame) Rear shock absorber Locknut Adjuster Spring guide (lower) Spring guide (upper) 5 - 61 CHAS Remarks Disconnect at the starter relay side.
REAR SHOCK ABSORBER Extent of removal 2 Order 14 15 Part name Q’ty Spring (rear shock absorber) Bearing 5 - 62 1 2 CHAS Remarks Refer to “REMOVAL POINTS”.
REAR SHOCK ABSORBER CHAS EC586000 HANDLING NOTE WARNING This shock absorber is provided with a separate type tank filled with high-pressure nitrogen gas. To prevent the danger of explosion, read and understand the following information before handling the shock absorber. The manufacturer can not be held responsible for property damage or personal injury that may result from improper handling. 1. Never tamper or attempt to disassemble the cylinder or the tank. 2.
REAR SHOCK ABSORBER CHAS EC583000 REMOVAL POINTS EC583320 Bearing 1. Remove: ● Stopper ring (upper bearing) 1 NOTE: Press in the bearing while pressing its outer race and remove the stopper ring. 2. Remove: ● Upper bearing 1 NOTE: Remove the bearing by pressing its outer race. 3. Remove: ● Lower bearing 1 NOTE: Remove the bearing by pressing its outer race. EC584000 INSPECTION Rear shock absorber 1. Inspect: ● Damper rod 1 Bends/damage → Replace absorber assembly.
REAR SHOCK ABSORBER CHAS EC585000 ASSEMBLY AND INSTALLATION EC585300 Bearing 1. Install: ● Upper bearing 1 NOTE: Install the bearing parallel until the stopper ring groove appears by pressing its outer race. CAUTION: ACHTUNG: Do not apply the grease on the bearing outer race because it will wear the rear shock absorber surface on which the bearing is press fitted. 2.
REAR SHOCK ABSORBER CHAS 2. Tighten: ● Adjuster 1 3. Adjust: ● Spring length (installed) a Spring length (installed) a: Standard length Extent of adjustment 246 mm (9.69 in) * 246.5 mm (9.70 in) 240.5 ~ 258.5 mm (9.47 ~ 10.18 in) * For EUROPE, AUS, NZ and ZA NOTE: The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjuster. CAUTION: ACHTUNG: Never attempt to turn the adjuster beyond the maximum or minimum setting. 4. Tighten: ● Locknut 1 Rear shock absorber 1.
REAR SHOCK ABSORBER CHAS 2. Install: ● Bush 1 ● Collar 2 ● Dust seal 3 NOTE: ● Apply the molybdenum disulfide grease on the bearing. ● Apply the lithium soap base grease on the bush, collars and dust seals. ● Install the dust seals with their lips facing outward. 3. Install: ● Rear shock absorber 4. Install: ● Bolt (rear shock absorber-frame) 1 ● Nut (rear shock absorber-frame) 2 R. T. 56 Nm (5.6 m · kg, 40 ft · lb) NOTE: Apply the molybdenum disulfide grease on the bolt. 5.
REAR SHOCK ABSORBER 2 CHAS 8.
– ELEC ELECTRICAL COMPONENTS AND WIRING DIAGRAM + EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 0 Taillight A Neutral switch B Starter motor C AC magneto D Rectifier/regulator E Ignition coil F Spark plug G Start switch H Lights switch I Main switch J CDI unit K Battery 1 Headlight 2 “ENGINE STOP” button 3 Clutch switch 4 Diode 5 Starter relay diode 6 TPS (throttle position sensor) 7 Starter relay 8 Fuse 9 Starting circuit cut-off relay 45 78 9
MAP-CONTROLLED CDI UNIT – ELEC + MAP-CONTROLLED CDI UNIT A map-controlled, CDI ignition system is used in the WR450F. The microcomputer in the CDI unit detects the engine speed and throttle position, thus determining the optimum ignition timing through the entire operating range. In this way, quick throttle response can be achieved according to various riding conditions.
IGNITION SYSTEM ELEC – + EC620000 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. *1 Check fuse. OK *2 Check battery No good Replace fuse and check wire harness. No good Recharge or replace. OK Spark gap test No spark Check entire ignition system for connection.
IGNITION SYSTEM ELEC – + SPARK GAP TEST 1. Disconnect the ignition coil from spark plug. 2. Remove the ignition coil cap. 3. Connect the dynamic spark tester 1 (ignition checker 2) as shown. ● Ignition coil 3 ● Spark plug 4 Å Å For USA and CDN ı Except for USA and CDN ı 4. Kick the kickstarter. 5. Check the ignition spark gap. 6. Start engine, and increase spark gap until misfire occurs. (for USA and CDN only) Minimum spark gap: 6.0 mm (0.
IGNITION SYSTEM ELEC – + MAIN SWITCH INSPECTION 1. Inspect: ● Main switch conduct Tester (+) lead → Red lead 1 Tester (–) lead → Brown lead 2 R 1 ON OFF Br 2 Tester selector position Ω ×1 Continuous while the main switch is moved to “OFF” → Replace. Not continuous while the main switch is moved to “ON” → Replace. 2. Inspect: ● Main switch indicator light Use 12 V battery. Battery (+) lead → Red/Black lead 1 Battery (–) lead → Black lead 2 Indicator light does not come on → Replace. 3.
– ELEC IGNITION SYSTEM + 3. Inspect: ● Secondary coil resistance Out of specification → Replace. Tester (+) lead → Orange lead 1 Tester (–) lead → Spark plug terminal 2 Secondary coil resistance Tester selector position 4.6 ~ 6.8 kΩ at 20 ˚C (68 ˚F) kΩ × 1 4. Inspect: ● Sealed portion of ignition coil a ● Spark plug terminal pin b ● Threaded portion of spark plug c Wear → Replace. AC MAGNETO INSPECTION 1. Inspect: ● Pick-up coil resistance Out of specification → Replace.
ELECTRIC STARTING SYSTEM ELEC – + ELECTRIC STARTING SYSTEM 2 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to “ON”, the starter motor can only operate if at least one of the following conditions is met: 3 1 ● ● 9 The transmission is in neutral (the neutral switch is closed). The clutch lever is pulled to the handlebar (the clutch switch is closed). The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met.
ELECTRIC STARTING SYSTEM ELEC – + INSPECTION STEPS If the starter motor will not operate, use the following inspection steps. *1 Check fuse No good Replace fuse and check wire harness. OK *2 Check battery OK Check each coupler and wire connection. No good No good Recharge or replace. Repair or replace. OK *3 Check main switch. No good Replace. OK Check starter motor operation. OK Check starting circuit cut-off relay. No good No good Repair or replace. Replace. OK Check starter relay.
ELECTRIC STARTING SYSTEM ELEC – + EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: ● Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. STARTER MOTOR OPERATION 1. Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3. Not operate → Repair or replace the starter motor.
ELECTRIC STARTING SYSTEM ELEC – + STARTER RELAY INSPECTION 1. Remove: ● Starter relay 2. Inspect: ● Starter relay conduct Use 12 V battery. Battery (+) lead → Starter relay terminal 1 Battery (–) lead → Starter relay terminal 2 Tester (+) lead → Starter relay terminal 3 Tester (–) lead → Starter relay terminal 4 TerTerminal minal 3 Tester selec4 tor position Connected to battery Not connected to battery Ω ×1 Continuous while not connected to the battery → Replace.
ELECTRIC STARTING SYSTEM – + DIODE INSPECTION 1. Remove the diode from wire harness. 2.
ELECTRIC STARTING SYSTEM ELEC – + STARTER MOTOR 8 9 0 1 6 0 7 9 5 New 5 New 4 3 5 New 2 B 1 Extent of removal: Extent of removal 1 Starter motor disassembly Order Part name Q’ty STARTER MOTOR REMOVAL Drain the engine oil. Preparation for removal Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Refer to “AC MAGNETO AND STARTER CLUTCH” section in the CHAPTER 4.
ELECTRIC STARTING SYSTEM ELEC 8 9 0 1 6 0 7 9 5 New 5 New 4 3 5 New 2 B 1 Extent of removal Order 1 6 7 8 9 0 Part name Q’ty Starter motor yoke Armature assembly Starter motor rear cover Brush Brush spring 6 - 13 1 1 1 2 2 Remarks – +
ELECTRIC STARTING SYSTEM ELEC – + INSPECTION AND REPAIR 1. Check: ● Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: ● Commutator diameter a Out of specification → Replace the starter motor. Min. commutator diameter 16.6 mm (0.65 in) 3. Measure: ● Mica undercut a Out of specification → Scrape the mica to the proper measurement with a hacksaw blade which has been grounded to fit the commutator. Mica undercut 1.5 mm (0.
ELECTRIC STARTING SYSTEM ELEC – + 5. Measure: ● Brush length a Out of specification → Replace the brushes as a set. Min. brush length 3.5 mm (0.14 in) 6. Measure: ● Brush spring force Out of specification → Replace the brush springs as a set. Brush spring force 3.92 ~ 5.88 N (400 ~ 600 gf, 14.1 ~ 21.2 oz) ASSEMBLY 1. Install: ● Brush spring 1 ● Brush 2 2. Install: ● Armature assembly 1 Install while holding down the brush using a thin screw driver.
ELECTRIC STARTING SYSTEM 2 a b 3 – + 3. Install: New ● O-ring 1 ● Starter motor yoke 2 1 New b NOTE: ● Align the match mark a on the starter motor yoke with the match mark b on the starter motor rear cover. ● Install the starter motor yoke with its groove c facing rear cover. c 4 ELEC 4.
CHARGING SYSTEM ELEC – + EC680000 CHARGING SYSTEM EC681001 INSPECTION STEPS If the battery is not charged, use the following inspection steps. *1 Check fuse. No good Replace fuse and check wire harness. OK *2 Check battery. OK Check each coupler and wire connection. No good Recharge or replace. No good Repair or replace. OK OK Check charging voltage. Charging system is good. No good Check AC magneto. Charging coil No good Replace. OK Replace rectifier/regulator.
CHARGING SYSTEM ELEC – + EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: ● Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. CHARGING VOLTAGE INSPECTION 1. Start the engine. 2. Inspect: ● Charging voltage Out of specification → If no failure is found in checking the source coil resistance, replace the rectifier/regulator. Y W R B 1 2 Tester (+) lead → Red lead 1 Tester (–) lead → Black lead 2 Charging voltage Tester selector position 14.1 ~ 14.
TPS (THROTTLE POSITION SENSOR) SYSTEM ELEC – EC690000 TPS (THROTTLE POSITION SENSOR) SYSTEM INSPECTION STEPS If the TPS will not operate, use the following inspection steps. Check entire ignition system for connection. No good Repair or replace. OK Check TPS. TPS coil No good Replace. OK Check CDI unit. TPS input voltage No good Replace. NOTE: Use the following special tools in this inspection.
TPS (THROTTLE POSITION SENSOR) SYSTEM ELEC – + HANDLING NOTE CAUTION: 1 Do not loosen the screws {TPS (throttle position sensor)} 1 except when changing the TPS (throttle position sensor) due to failure because it will cause a drop in engine performance. EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: ● Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. TPS COIL INSPECTION 1. Inspect: ● TPS coil resistance Out of specification → Replace.
TPS (THROTTLE POSITION SENSOR) SYSTEM – ELEC + 3. Inspect: ● TPS coil variable resistance Check that the resistance in increased as the throttle grip is moved from the full close position to the full open position. Out of specification → Replace. Tester (+) lead → Yellow lead 1 Tester (–) lead → Black lead 2 TPS coil variable resistance Tester selector position Full closed Full opened 0 ~ 2 kΩ at 4 ~ 6 kΩ at 20 ˚C 20 ˚C (68 ˚F) (68 ˚F) 2 kΩ × 1 TPS REPLACEMENT AND ADJUSTMENT 1.
TPS (THROTTLE POSITION SENSOR) SYSTEM ELEC – + 4. Adjust: ● Idle speed Refer to “IDLE SPEED ADJUSTMENT” section in the CHAPTER 3. 5. Insert the thin electric conductors 2 (lead) into the TPS coupler 1, as shown, and connect the tester to them. Tester (+) lead → Yellow lead 3 Tester (–) lead → Black lead 4 CAUTION: ● ● Do not insert the electric conductors more than required because it may reduce the waterproof function of the coupler.
TPS (THROTTLE POSITION SENSOR) SYSTEM ELEC – + 8. Tighten: ● Screw (TPS) 1 9. Stop the engine. 1 EC694000 TPS INPUT VOLTAGE INSPECTION 1. Disconnect the TPS coupler. 2. Start the engine. 3. Inspect: ● TPS input voltage Out of specification → Replace the CDI unit.
LIGHTING SYSTEM ELEC – + LIGHTING SYSTEM INSPECTION STEPS Refer to the following flow chart when inspecting the ignition system for possible problems. Check the bulb and bulb socket. Replace the bulb and/ or bulb socket. No good OK Check the lights switch. No good Replace. OK Check the AC magneto. Lighting coil No good Replace. OK Check the entire lighting system proper for connections. Improperly connected Repair or replace. OK Check the rectifier/regulator.
LIGHTING SYSTEM – ELEC + LIGHTS SWITCH INSPECTION 1. Inspect: ● Lights switch conduct Tester (+) lead → Yellow lead 1 Tester (–) lead → Blue lead 2 Y 1 OFF L 2 Tester selector position Ω×1 No continuous while being → Replace. Continuous while being OFF → Replace. AC MAGNETO INSPECTION 1. Inspect: ● Lighting coil resistance Out of specification → Replace. Tester (+) lead → Yellow lead 1 Tester (–) lead → Ground 2 1 Tester selector position 0.224 ~ 0.
SETTING TUN EC700000 TUNING EC710000 ENGINE Carburetor setting ● The air/fuel mixture will vary depending on atmospheric conditions. Therefore, it is necessary to take into consideration the air pressure, ambient temperature, humidity, etc., when adjusting the carburetor. ● Perform a test run to check for proper engine performance (e.g., throttle response) and spark plug(-s) discoloration or fouling. Use these readings to determine the best possible carburetor setting.
SETTING TUN CAUTION: ● ● ● ● The carburetor is extremely sensitive to foreign matter (dirt, sand, water, etc.). During installation, do not allow foreign matter to get into the carburetor. Always handle the carburetor and its components carefully. Even slight scratches, bends or damage to carburetor parts may prevent the carburetor from functioning correctly. Carefully perform all servicing with the appropriate tools and without applying excessive force.
SETTING TUN Effects of the setting parts on the throttle valve opening 1 2 Å Closed ı Fully open 3 4 Å 1/8 1/4 1/2 3/4 ı 1 Pilot screw/pilot jet 2 Throttle valve cutaway 3 Jet needle 4 Main jet Main system The FLATCR carburetor has a primary main jet. This type of main jet is perfect for racing motorcycles since it supplies an even flow of fuel, even at full load. Use the main jet and the jet needle to set the carburetor.
SETTING TUN Pilot system The FLATCR carburetor is manufactured with a pilot screw. The pilot screw adjustment ranges from fully closed throttle to 1/4 open throttle. Main jet adjustment The richness of the air-fuel mixture at full throttle can be set by changing the main jet 1. #150 *#160 Standard main jet * Except for USA If the air-fuel mixture is too rich or too lean, the engine power will drop, resulting in poor acceleration.
SETTING TUN Pilot screw adjustment The richness of the air-fuel mixture with the throttle fully closed to 1/4 open can be set by turning the pilot screw 1. Turning in the pilot screw will make the mixture lean at low speeds, and turning it out will enrich it. 1 Standard pilot screw position 1-3/4 *1-1/2 (example) * Except for USA NOTE: ● If the idling speed fluctuates, turn the pilot screw only 1/2 of a turn in either direction.
SETTING TUN Pilot jet adjustment The richness of the air-fuel mixture with the throttle open 1/4 or less can be set by adjusting the pilot jet 1. #45 *#48 Standard pilot jet * Except for USA Effects of adjusting the pilot jet (reference) Å 1/4 1/2 3/4 ı +5% #48 #45 #42 Å Idle –5% ı Fully open Jet needle groove position adjustment Adjusting the jet needle 1 position affects the acceleration when the throttle is 1/8 to 3/4 open. 1.
SETTING TUN Jet needle adjustment The jet needle is adjusted by changing it. OBDUT *OBDUQ Standard jet needle * Except for USA The tapered sections of all jet needles have the same starting positions, but the needles are available with different straight-portion diameters.
SETTING TUN Carburetor setting parts Part name Main jet Rich *(STD) (STD) Pilot jet Lean Rich *(STD) (STD) Jet needle Lean Rich (STD) Jet needle Lean Rich *(STD) Lean * Except for USA 7-8 Size #170 #168 #165 #162 #160 #158 #155 #152 #150 #148 #145 #142 #140 #52 #50 #48 #45 #42 #40 #DUQ #DUR #DUS #DUT #DUU #DUV #DUW #DUM #DUN #DUP #DUQ #DUR #DUS #DUT Part number 4MX-14943-41 4MX-14943-91 4MX-14943-40 4MX-14943-90 4MX-14943-39 4MX-14943-89 4MX-14943-38 4MX-14943-88 4MX-14943-37 4MX-14943-87 4
SETTING TUN Examples of carburetor setting depending on symptom Symptom At full throttle Hard breathing Shearing noise Whitish spark plug Setting Increase main jet calibration no. (Gradually) Discoloration of spark plug → If tan color, it is in good condition. If cannot be corrected: Clogged float valve seat Clogged fuel hose Clogged fuel cock Check that the accelerator pump operates smoothly. Decrease main jet calibration no.
SETTING TUN EC720000 CHASSIS EC71P002 Selection of the secondary reduction ratio (Sprocket) Secondary Number of driven sprocket teeth reduction = Number of drive sprocket teeth ratio Standard secondary reduction ratio 50/14 (3.571) ● It is generally said that the secondary gear ratio should be reduced for a longer straight portion of a speed course and should be increased for a course with many corners.
SETTING TUN EC72N000 Drive and driven sprockets setting parts Part name Drive sprocket 1 (STD) *(STD) Size Part number 14T *14T 5NG-17460-00 9383E-14215 * For CDN, EUROPE, AUS, NZ and ZA Part name Driven sprocket 2 (STD) *(STD) Size 48T *48T *49T 50T *50T *51T 52T *52T Part number 5GS-25448-50 5NY-25448-00 5NY-25449-00 5GS-25450-50 5NY-25450-00 5NY-25451-00 5GS-25452-50 5NY-25452-00 * For AUS and NZ EC721002 Tire pressure Tire pressure should be adjust to suit the road surface condition of the
SETTING TUN EC722011 Front fork setting The front fork setting should be made depending on the rider’s feeling of an actual run and the circuit conditions. The front fork setting includes the following three factors: 1. Setting of air spring characteristics ● Change the fork oil level. 2. Setting of spring preload ● Change the spring. ● Install the adjustment washer. 3. Setting of damping force ● Change the compression damping. ● Change the rebound damping.
SETTING TUN EC727020 Spring preload adjustment The spring preload is adjusted by installing the adjustment washer 1 between the fork spring 2 and damper rod 3. CAUTION: Do not install three or more adjustment washers for each front fork. WARNING Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability.
SETTING TUN 2. Use of stiff spring 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 handlebar. To set a stiff spring: ● Change the rebound damping. Turn in one or two clicks. ● Change the compression damping. Turn out one or two clicks.
SETTING TUN EC72P000 Front fork setting parts ● Adjustment washer 1 TYPE (thickness) PART NUMBER T = 2.3 mm (0.09 in) 4SS-23364-L0 Front fork spring 2 [Equal pitch spring] ● I.D. SPRING SPRING TYPE MARK RATE PART NUMBER (slits) SOFT 0.380 0.390 0.400 0.410 4SS-23141-10 4SS-23141-20 4SS-23141-30 4SS-23141-40 I-I I-II I-III I *STD 0.420 4SR-23141-L0 – 0.430 4SS-23141-60 III 0.440 5NL-23141-00 – 0.450 5BE-23141-L0 – STD 0.460 5GR-23141-L0 – STIFF 0.
SETTING TUN EC72B000 Rear suspension setting The rear suspension setting should be made depending on the rider’s feeling of an actual run and the circuit conditions. The rear suspension setting includes the following two factors: 1. Setting of spring preload ● Change the set length of the spring. ● Change the spring. 2. Setting of damping force ● Change the rebound damping. ● Change the compression damping. EC72C001 Choosing set length 1.
SETTING TUN NOTE: ● If the machine is new and after it is broken in, the same set length of the spring may change because of the initial fatigue, etc. of the spring. Therefore, be sure to make reevaluation. ● If the standard figure cannot be achieved by adjusting the spring adjuster and changing the spring set length, replace the spring with an optional one and make re-adjustment.
SETTING TUN CAUTION: When using a rear cushion other than currently installed, use the one whose overall length a does not exceed the standard as it may result in faulty performance. Never use one whose overall length is greater than standard. Length a of standard shock: 490.5 mm (19.
SETTING TUN EC72Q000 Rear shock absorber setting parts ● Rear shock spring 1 [Equal pitch spring] TYPE I.D. SPRING SPRING SPRING COLOR/ FREE RATE PART NUMBER POINT LENGTH SOFT 4.3 4.5 4.7 5UN-22212-00 Brown/1 5UN-22212-10 Green/1 5UN-22212-20 Red/1 260 260 260 *STD 4.9 5UN-22212-30 Black/1 260 5.1 5UN-22212-40 Blue/1 260 STD 5.2 5UN-22212-90 Purple/1 260 **STD 5.3 5UN-22212-50 Yellow/1 260 STIFF 5.5 5.
SETTING TUN EC72H002 Suspension setting ● Front fork NOTE: ● 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).
SETTING ● TUN Rear shock absorber NOTE: ● 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.
PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN JAPAN 2002.10-2.
