33D-9-80_cover 09.7.16 13:46 ページ 1 2010 q Read this manual carefully before operating this vehicle. q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. q Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen. YZ450F(Z) 2010 PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN JAPAN 2009.07—2.
33D-9-80_cover 09.7.16 13:46 ページ 2 Q Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. Q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit être remis avec le véhicule en cas de vente de ce dernier. Q Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen. Diese Bedienungsanleitung muss, wenn das Fahrzeug verkauft wird, beim Fahrzeug verbleiben.
2010 Read this manual carefully before operating this vehicle.
YZ450F(Z) OWNER'S SERVICE MANUAL ©2009 by Yamaha Motor Co., Ltd. 1st Edition, August 2009 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
FOREWORD INTRODUCTION Congratulations on your purchase of a Yamaha YZ 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.
F.I.M. MACHINE WEIGHTS Weights of machines without fuel The minimum weights for motocross machines are: for the class 125 cc: minimum 88 kg (194 lb) for the class 250 cc: minimum 98 kg (216 lb) for the class 500 cc: minimum 102 kg (225 lb) In modifying your machine (e.g., for weight reduction), take note of the above limits of weight. HOW TO USE THIS MANUAL FINDING THE REQUIRED PAGE 1.
HOW TO READ DESCRIPTIONS To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 1. An easy-to-see exploded diagram "1" is provided for removal and disassembly jobs. 3 2. Numbers "2" are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step. 3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks "3".
TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE 4 CHASSIS 5 FUEL SYSTEM 6 ELECTRICAL 7 TUNING 8
CONTENTS CHAPTER 1 GENERAL INFORMATION LOCATION OF IMPORTANT LABELS ..... 1-1 DESCRIPTION ................. 1-5 CONSUMER INFORMATION................. 1-6 FEATURES....................... 1-7 INCLUDED PARTS .......... 1-9 IMPORTANT INFORMATION................. 1-9 HANDLING THE ELECTRONIC PARTS ... 1-10 CHECKING OF CONNECTION................ 1-10 SPECIAL TOOLS ........... 1-12 CONTROL FUNCTIONS ................... 1-17 STARTING AND BREAK-IN.............. 1-17 TORQUE-CHECK POINTS...........................
LOCATION OF IMPORTANT LABELS GENERAL INFORMATION LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle.
LOCATION OF IMPORTANT LABELS EUROPE 1-2
LOCATION OF IMPORTANT LABELS AUS, NZ, ZA 1-3
LOCATION OF IMPORTANT LABELS Familiarize yourself with the following pictograms and read the explanatory text. Read Owner's service manual. This unit contains high-pressure nitrogen gas. Mishandling can cause explosion. Do not incinerate, puncture or open. Turn off the main switch after riding to avoid draining the battery. Use unleaded gasoline only. Measure tire pressure when tires are cold. Adjust tire pressure. Improper tire pressure can cause loss of control.
DESCRIPTION DESCRIPTION 1. 2. 3. 4. 5. 6. 7. 8. 9. Clutch lever Front brake lever Throttle grip Radiator cap Fuel tank cap Engine stop switch Kickstarter crank Fuel tank Radiator 10. 11. 12. 13. 14. 15. 16. 17. 18. Coolant drain bolt Rear brake pedal Valve joint Air cleaner Drive chain Shift pedal Oil level check window Starter knob/idle screw Front fork • The machine you have purchased may differ slightly from those shown in the following.
CONSUMER INFORMATION CONSUMER INFORMATION There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine. VEHICLE IDENTIFICATION NUMBER The vehicle identification number "1" is stamped on the right of the steering head pipe.
FEATURES FEATURES OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustionchamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
FEATURES FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains thefuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kgf/cm ² , 47.0 psi). Accordingly,when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causingthe fuel to be injected into the intake manifold only during the time the passage remains open.
INCLUDED PARTS INCLUDED PARTS DETACHABLE SIDESTAND This sidestand "1" is used to support only the machine when standing or transporting it. HANDLEBAR PROTECTOR Install the handlebar protector "1" so that the mark "a" face forward. • Never apply additional force to the sidestand. • Remove this sidestand before starting out. FUEL TANK HOLDING CABLE The fuel tank holding cable "1" is used to support the fuel tank during maintenance.
HANDLING THE ELECTRONIC PARTS 4. During the machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled. 5. Keep away from fire. 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. GASKETS, OIL SEALS AND ORINGS 1.
CHECKING OF CONNECTION If the contact seems not good, pull the terminal by hand and check its condition. 1. Probe 2. Coupler REMOVING THE QUICK FASTENER 4. • • • Connect: Lead Coupler Connector Make sure all connections are tight. 5. Check: • Continuity (with the pocket tester) Do not push the center pin with too much force. Otherwise, the center pin could be damaged. To remove a quick fastener, push the center pin in with a screwdriver, then pull the fastener out.
SPECIAL TOOLS SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order. • For U.S.A. and Canada, use part number starting with "YM-", "YU-" or "ACC-".
SPECIAL TOOLS Tool name/Part number How to use Cap bolt wrench YM-01500, 90890-01500 This tool is used to loosen or tighten the base valve. Cap bolt ring wrench YM-01501, 90890-01501 This tool is used to loosen or tighten the damper assembly. Fork seal driver YM-A0948, 90890-01502 This tool is used when install the fork oil seal. Spoke nipple wrench YM-01521, 90890-01521 This tool is used to tighten the spoke.
SPECIAL TOOLS Tool name/Part number How to use FI diagnostic tool YU-03182, 90890-03182 This tool is used to check the fault codes and diagnose any problems. Fuel pressure adapter YM-03186, 90890-03186 This tool is used to attach the pressure gauge. Test harness S-pressure sensor (3P) YU-03207, 90890-03207 This tool is connected between the intake air pressure sensor and the wire harness and is used to measure the voltage.
SPECIAL TOOLS Tool name/Part number How to use Valve guide remover 5.5 mm (0.22 in) YM-01122 This tool is needed to remove and install the valve guide. Valve guide installer 5.5 mm (0.22 in) YM-04015 This tool is needed to install the valve guide. Valve guide reamer 5.5 mm (0.22 in) YM-01196 This tool is needed to rebore the new valve guide. Valve spring compressor attachment YM-04108, 90890-04108 This tool is needed to remove and install the valve assemblies.
SPECIAL TOOLS Tool name/Part number How to use Digital tachometer YU-39951-B, 90890-06760 This tool is needed for observing engine rpm. YAMAHA Bond No. 1215 (ThreeBond® No. 1215) 90890-85505 This sealant (Bond) is used for crankcase mating surface, etc.
CONTROL FUNCTIONS CONTROL FUNCTIONS STARTING AND BREAK-IN ENGINE STOP SWITCH The engine stop switch "1" is located on the left handlebar. Continue pushing the engine stop switch till the engine comes to a stop. FUEL Always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race. THROTTLE GRIP The throttle grip "1" is located on the right handlebar; it accelerates or decelerates the engine.
STARTING AND BREAK-IN • Unlike a two-stroke engine, this engine cannot be kick started when the throttle is open because the kickstarter may kick back. Also, if the throttle is open the air/fuel mixture may be too lean for the engine to start. • Before starting the machine, perform the checks in the pre-operation check list. AIR FILTER MAINTENANCE According to "CLEANING THE AIR FILTER ELEMENT" section in the CHAPTER 3, apply the foam-air-filter oil or its equivalent to the element.
TORQUE-CHECK POINTS TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and fuel tank Fuel tank to frame Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Steering stem to handlebar Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar Suspension Front Steering stem to front fork Rear For link type Front fork to upper bracket Front fork to lower bracket Assembly of lin
CLEANING AND STORAGE CLEANING AND STORAGE 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. Do not apply degreaser to the chain, sprockets, or wheel axles.
GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: YZ450FZ (USA, CDN, AUS, NZ) YZ450F (EUROPE, ZA) Model code number: 33D1 (USA,CDN) 33D2 (EUROPE) 33D4 (AUS, NZ, ZA) Dimensions: USA, CDN EUROPE Overall length 2,193 mm (86.34 in) Overall width 825 mm (32.48 in) ← ← Overall height 1,311 mm (51.61 in) ← Seat height 999 mm (39.33 in) ← 998 mm (39.29 in) Wheelbase 1,492 mm (58.74 in) ← Minimum ground clearance 383 mm (15.
GENERAL SPECIFICATIONS Fuel: Type Premium unleaded gasoline only Tank capacity 6.0 L (1.30 Imp gal, 1.59 US gal) Throttle body: Type 30RA Manufacturer KEIHIN Spark plug: Type/manufacturer CR8E/NGK (resistance type) Gap 0.7–0.8 mm (0.028–0.031 in) Clutch type: Wet, multiple-disc Transmission: Primary reduction system Gear Primary reduction ratio 61/23 (2.652) Secondary reduction system Chain drive Secondary reduction ratio 48/13 (3.692) (For USA, CDN) 49/13 (3.
MAINTENANCE SPECIFICATIONS Wheel travel: Front wheel travel 310 mm (12.2 in) Rear wheel travel 315 mm (12.4 in) (For USA, CDN) 312 mm (12.3 in) (For EUROPE, AUS, NZ, ZA) Electrical: Ignition system TCI MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.05 mm (0.002 in) Bore size 97.00–97.01 mm (3.8189–3.8193 in) ---- Out of round limit ---- 0.05 mm (0.002 in) Drive method Chain drive (Left) ---- Camshaft cap inside diameter 22.000–22.021 mm (0.
MAINTENANCE SPECIFICATIONS Item Standard Limit Timing chain: Timing chain type/No. of links 98XRH2010-122M/122 ---- Timing chain adjustment method Automatic ---- IN 0.10–0.15 mm (0.0039–0.0059 in) ---- EX 0.20–0.25 mm (0.0079–0.0098 in) ---- "A" head diameter (IN) 35.9–36.1 mm (1.4134–1.4213 in) ---- "A" head diameter (EX) 29.9–30.1 mm (1.1772–1.1850 in) ---- Valve, valve seat, valve guide: Valve clearance (cold) Valve dimensions: "B" face width (IN) 2.26 mm (0.
MAINTENANCE SPECIFICATIONS Item Standard Limit Stem-to-guide clearance (IN) 0.010–0.037 mm (0.0004–0.0015 in) 0.08 mm (0.003 in) Stem-to-guide clearance (EX) 0.020–0.047 mm (0.0008–0.0019 in) 0.10 mm (0.004 in) Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width (IN) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 in) Valve seat width (EX) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 in) Free length (IN) 40.76 mm (1.60 in) 39.76 mm (1.57 in) Free length (EX) 37.01mm (1.46 in) 36.
MAINTENANCE SPECIFICATIONS Item Standard Limit Piston: Piston to cylinder clearance 0.020–0.045 mm (0.0008–0.0018 in) 0.1 mm (0.004 in) Piston size "D" 96.965–96.980 mm (3.8175–3.8181 in) ---- Measuring point "H" 9.0 mm (0.354 in) ---- Piston off-set Zero mm (Zero in) ---- Piston pin bore inside diameter 18.004–18.015 mm (0.7088–0.7093 in) 18.045 mm (0.7104 in) Piston pin outside diameter 17.991–18.000 mm (0.7083–0.7087 in) 17.971 mm (0.
MAINTENANCE SPECIFICATIONS Item Standard Limit Crankshaft: Crank width "A" 61.95–62.00 mm (2.439–2.441 in) ---- Runout limit "C" 0.03 mm (0.0012 in) 0.05 mm (0.002 in) Big end side clearance "D" 0.15–0.45 mm (0.0059–0.0177 in) 0.50 mm (0.02 in) Small end free play "F" 0.4–1.0 mm (0.02–0.04 in) 2.0 mm (0.08 in) Gear ---- Foam-air-filter oil or equivalent oil ---- 2.92–3.08 mm (0.115–0.121 in) 2.8 mm (0.
MAINTENANCE SPECIFICATIONS Item Standard Limit Throttle position sensor: ---- Throttle position sensor maximum resistance 5 kΩ ---- Throttle position sensor variable resistance 0–2 kΩ (full closed) ---- Throttle position sensor input voltage 4–6 V ---- Fuel injection sensor: Crankshaft position sensor resistance ---248–372 Ω ---- Intake air pressure sensor output voltage 2, 3.57–3.71 V at 101.3kPa (1.013 kg/cm 14.41 psi) ---- Atmospheric pressure sensor output voltage 3.57–3.
MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing Front suspension: ---- USA, CDN EUROPE, AUS, NZ, ZA Front fork travel 310 mm (12.2 in) ← ---- Fork spring free length 470 mm (18.5 in) ← 465 mm (18.3 in) Spring rate, STD K = 4.6 N/mm (0.469 kg/ ← mm, 26.3 lb/in) ---- Optional spring Yes ← ---- 3 Oil capacity 544 cm (19.1 lmp oz, 18.
MAINTENANCE SPECIFICATIONS Item Standard Limit Front disc brake: Disc outside dia.×Thickness 250 × 3.0 mm (9.84 × 0.12 in) 250 × 2.5 mm (9.84 × 0.10 in) Pad thickness 4.4 mm (0.17 in) 1.0 mm (0.04 in) Master cylinder inside dia. 9.52 mm (0.375 in) ---- Caliper cylinder inside dia. 22.65 mm (0.892 in) × 2 ---- Brake fluid type DOT #4 ---- Disc outside dia.×Thickness 245 × 4.0 mm (9.65 × 0.16 in) 245 × 3.5 mm (9.65 × 0.14 in) Deflection limit ---- 0.15 mm (0.006 in) Pad thickness 6.
TIGHTENING TORQUES TIGHTENING TORQUES ENGINE △ - marked portion shall be checked for torque tightening after break-in or before each race. Part to be tightened Thread size Q'ty M10S × 1.0 Camshaft cap m•kg ft•lb 1 13 1.3 9.4 M6 × 1.0 8 10 1.0 7.2 Cylinder head blind plug screw M12 × 1.0 2 28 2.8 20 Oil passage plug M8 × 1.25 1 15 1.5 11 Cylinder head (stud bolt) M6 × 1.0 3 7 0.7 Spark plug △ △ Tightening torque Nm Refer to TIP. 5.1 *1 Cylinder head (bolt) M10 × 1.
TIGHTENING TORQUES Part to be tightened Thread size Q'ty Crankshaft end accessing screw M36 × 1.5 Timing mark accessing screw Tightening torque Nm m•kg ft•lb 1 10 1.0 7.2 M14 × 1.5 1 6 0.6 4.3 Clutch cover M6 × 1.0 7 10 1.0 7.2 Right crankcase cover M6 × 1.0 9 10 1.0 7.2 Left crankcase cover M6 × 1.0 8 10 1.0 7.2 Crankcase M6 × 1.0 13 12 1.2 8.7 Clutch cable holder M6 × 1.0 2 10 1.0 7.2 Oil drain bolt M8 × 1.25 1 20 2.0 14 Oil drain bolt M8 × 1.
TIGHTENING TORQUES CHASSIS △ - marked portion shall be checked for torque tightening after break-in or before each race. Part to be tightened Thread size Q'ty Tightening torque Nm m•kg ft•lb △ Upper bracket and outer tube M8 × 1.25 4 21 2.1 15 △ Lower bracket and outer tube M8 × 1.25 4 21 2.1 15 △ Upper bracket and steering stem M24 × 1.0 1 145 14.5 105 △ Handlebar upper holder M8 × 1.25 4 28 2.8 20 △ Handlebar lower holder M10 × 1.25 2 34 3.
TIGHTENING TORQUES Part to be tightened Thread size Q'ty M8 × 1.25 — Tightening torque Nm m•kg ft•lb 6 42 4.2 30 72 3 0.3 2.2 △ Driven sprocket and wheel hub △ Nipple (spoke) △ Disc cover and rear brake caliper M6 × 1.0 2 10 1.0 7.2 △ Protector and rear brake caliper M6 × 1.0 2 7 0.7 5.1 Drive chain puller adjust bolt and locknut M8 × 1.25 2 21 2.1 15 Engine mounting: △ Upper engine bracket and frame M8 × 1.25 4 45 4.
TIGHTENING TORQUES Part to be tightened Thread size Q'ty Tightening torque Nm m•kg ft•lb △ Rear fender (front) M6 × 1.0 3 7 0.7 5.1 △ Rear fender (rear) M6 × 1.0 2 18 1.8 13 △ Mud flap — 2 1 0.1 0.7 △ Number plate M6 × 1.0 1 7 0.7 5.1 1. First, tighten the steering ring nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the steering nut wrench, then loosen the steering ring nut one turn. 2. Retighten the steering ring nut 7 Nm (0.7 m•kg, 5.1 ft•lb).
TIGHTENING TORQUES 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. Components should be at room temperature.
LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1. 2. 3. 4. 5. 6. 7. 8. 9. Oil strainer Oil check bolt Scavenging pump Oil feed pump Oil filter element Crankshaft Oil nozzle Exhaust camshaft Intake camshaft 10. 11. 12. 13.
CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM 2-18
CABLE ROUTING DIAGRAM 1. 2. 3. 4. 5. Fuel tank breather hose Coupler for connecting optional part Cylinder head breather hose Hose holder Radiator hose 3 A. B. C. D. E. Insert the end of the fuel tank breather hose into the hole in the steering stem. Fit the accessory coupler into the connector to fasten it to the bracket. Point the end of the cylinder head breather hose downward.
CABLE ROUTING DIAGRAM F-F F A A F B E D D C 100mm C E D-D C-C 2-20 B
CABLE ROUTING DIAGRAM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Clutch cable Throttle cable (return) Throttle cable (pull) Cable holder Clamp Rectifier/regulator Ignition coil Ignition coil coupler AC magneto coupler Radiator hose 2 Ground lead terminal Plug cap Ignition coil bracket Clamp (lock) Clamp (clip) AC magneto lead ECU bracket A. B. C. D. E. F. G. H. I. J. K. L. M. N. O. Pass the clutch cable, throttle cables, and engine stop switch lead through the cable holder.
CABLE ROUTING DIAGRAM G G A-A B-B A A B B F F C-C C C D D E D-D E E-E 2-22
CABLE ROUTING DIAGRAM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
CABLE ROUTING DIAGRAM 1. 2. 3. 4. 5. 6. 7. Ignition coil coupler Coolant temperature sensor lead Atmospheric pressure sensor coupler Intake air temperature sensor lead Clamp Intake air pressure sensor coupler Cover 8 9. 10. 11. 12. 13. 14. Fuel hose Fuel pump lead Fuel injector coupler Throttle body High tension code Throttle cable AC magneto lead A. B. C. 2-24 Route the fuel pump lead to the outside of the fuel hose and above the cover.
CABLE ROUTING DIAGRAM 1. 2. 3. Brake master cylinder Brake hose holder Brake hose A. B. Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the brake caliper. Pass the brake hose into the brake hose holders. 2-25 C. D. If the brake hose contacts the spring (rear shock absorber), correct its twist. Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the brake master cylinder.
CABLE ROUTING DIAGRAM 1. 2. 3. 4. 5. 6. Throttle cable Clutch cable Clamp Engine stop switch lead Hose guide Main harness A. B. C. D. Route the clutch cable to the rear of the number plate band. Fasten the engine stop switch lead to the handlebar. Route the brake hose to the front of the number plate. Pass the clutch cable through the cable guide on the number plate.
MAINTENANCE INTERVALS 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 After breakin Every race (about 2.5 hours) Every third (about 7.5 hours) Every fifth (about 12.5 hours) As required CYLINDER HEAD Remarks Inspect carbon deposits and eliminate them. Inspect and clean ● Change gasket. ● Inspect score marks. CYLINDER Inspect and clean Replace ● Inspect wear. CLUTCH Inspect and adjust ● Inspect housing, friction plate, clutch plate and spring.
MAINTENANCE INTERVALS Item After breakin Every race (about 2.5 hours) ● ● Every third (about 7.5 hours) Every fifth (about 12.5 hours) As required Remarks AIR FILTER Clean and lubricate Use foam air-filter oil or equivalent oil.
MAINTENANCE INTERVALS Item Every third (about 7.5 hours) Every fifth (about 12.5 hours) After breakin Every race (about 2.
PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. GENERAL INSPECTION AND MAINTENANCE Item Routine Page Coolant Check that coolant is filled up to the radiator cap. Check the cooling system for leakage. P.3-6 – 7 Fuel Check that a fresh gasoline is filled in the fuel tank. Check the fuel line for leakage.
ENGINE ENGINE CHANGING THE COOLANT CHECKING THE COOLANT LEVEL 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.
ENGINE CHECKING THE RADIATOR CAP OPENING PRESSURE 1. Attach: • Radiator cap tester "1" and adapter "2" Radiator cap tester: YU-24460-01/9089001325 Radiator cap tester adapter: YU-33984/90890-01352 Apply water on the radiator cap seal. 3. Radiator cap 2. Apply the specified pressure. Radiator cap opening pressure: 108–137 kPa (1.08–1.37 kg/cm2, 15.4–19.5 psi) 3. Inspect: • Pressure Impossible to maintain the specified pressure for 10 seconds → Replace. CHECKING THE COOLING SYSTEM 1.
ENGINE ADJUSTING THE THROTTLE CABLE FREE PLAY 1. Check: • Throttle grip free play "a" Out of specification → Adjust. 2. Apply: • Lithium soap base grease On the throttle cable end "a". 4. Loosen and release the binder "1" and lift the air filter case lid. Hold the air filter case lid by the use of the binder. Throttle grip free play "a": 3–5 mm (0.12–0.20 in) 3. Install: • Throttle grip cap • Screw (throttle grip cap) 2. Adjust: • Throttle grip free play Throttle grip free play adjustment steps: a.
ENGINE 8. Apply: • Foam-air-filter oil or equivalent oil to the element Oil application quantify: 35 g Squeeze out the excess oil. Element should be wet but not dripping. 9. • • • Install: Air filter element "1" Air filter guide "2" Binder 10. Install: • Mounting bolt for air filter case cover Mounting bolt for air filter case cover: 5 Nm (0.5 m•kg, 3.6 ft•lb) 11. Install: • Fuel tank bolt (front) Fuel tank bolt (front): 9 Nm (0.9 m•kg, 6.5 ft•lb) CHECKING THE TROTTLE BODY JOINT 12.
ENGINE CHANGING THE ENGINE OIL 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. Remove: • Oil filler cap "1" • Drain bolt (with gasket) "2" • Drain bolt (with gasket) "3" Drain the engine oil. 4. If the oil filter is to be replaced during this oil change, remove the following parts and reinstall them. Replacement steps: a. Remove the oil filter element cover "1" and oil filter element "2". b.
ENGINE Engine idling speed: 1,900–2,100 r/min 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) ADJUSTING THE VALVE CLEARANCE • This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.
ENGINE d. Round off the last digit of the installed pad number to the nearest increment. Last digit of pad number Rounded valve 0, 1 or 2 0 4, 5 or 6 5 8 or 9 10 EXAMPLE: Installed pad number = 148 Rounded off value = 150 Pads can only be selected in 0.05 mm increments. e. 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.
ENGINE INTAKE EXHAUST 3-13
CHASSIS CHASSIS BLEEDING THE HYDRAULIC BRAKE SYSTEM 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. 1. • • • • 2. • Remove: Brake master cylinder cap Diaphragm Reservoir float (front brake) Protector (rear brake) Bleed: Brake fluid Air bleeding steps: a.
CHASSIS c. Tighten the locknut. Locknut: 6 Nm (0.6 m •kg, 4.3 ft•lb) b. Loosen the pad pin "2". c. Remove the brake caliper "3" from the front fork. i. Install the brake caliper "8" and tighten the pad pin "9". Bolt (brake caliper): 28 Nm (2.8 m•kg, 20 ft•lb) Pad pin: 18 Nm (1.8 m•kg, 13 ft•lb) Be sure to tighten the locknut, as it will cause poor brake performance. d. Remove the pad pin and brake pads "4". j. e.
CHASSIS 2. Replace: • Brake pad h. Install the brake pad "10" and pad pin "11". Brake pad replacement steps: a. Remove the protector "1" and pad pin plug "2". • Install the brake pads with their projections "a" into the brake caliper recesses "b". • Temporarily tighten the pad pin at this point. b. Loosen the pad pin "3". c. Remove the rear wheel "4" and brake caliper "5". Refer to "FRONT WHEEL AND REAR WHEEL" section in the CHAPTER 5. i. j. Install the brake caliper "12" and rear wheel "13".
CHASSIS 2. • • • a. Lower level A. Front B. Rear CHECKING THE SPROCKET 1. Inspect: • Sprocket teeth "a" Excessive wear → Replace. Replace the drive sprocket, rear wheel sprocket and drive chain as a set. CHECKING THE DRIVE CHAIN 1. Measure: • Drive chain length (15 links) "a" Out of specification → Replace. Remove: Master link clip Joint "1" Drive chain "2" 3. Clean: • Drive chain Place it in kerosene, and brush off as much dirt as possible.
CHASSIS c. Turn each adjuster exactly the same amount to maintain correct axle alignment. (There are marks "a" on each side of the drive chain puller alignment.) NOTICE: Improper drive chain slack will overload the engine aswell as other vital parts of the motorcycle and can lead to chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified limits. CHECKING THE FRONT FORK PROTECTOR GUIDE 1. Inspect: • Protector guide "1" Out of specification → Replacet.
CHASSIS Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. CHECKING THE REAR SHOCK ABSORBER 1. Inspect: • Swingarm smooth action Abnormal noise/unsmooth action → Grease the pivoting points or repair the pivoting points. Damage/oil leakage → Replace. Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability. ADJUSTING THE FRONT FORK COMPRESSION DAMPING FORCE 1.
CHASSIS ADJUSTING THE REAR SHOCK ABSORBER REBOUND DAMPING FORCE 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.) Extent of adjustment: Maximum Fully turned in position Minimum 30 clicks out (from maximum position) • STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position.
CHASSIS CHECKING THE TIRE PRESSURE 1. Measure: • Tire pressure Out of specification → Adjust. 3. Check: • Steering smooth action Turn the handlebar lock to lock. Unsmooth action → Adjust steering ring nut. Standard tire pressure: 100 kPa (1.0 kgf/cm2, 15 psi) • 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.
CHASSIS e. Loosen the steering ring nut one turn. f. Retighten the steering ring nut using the steering nut wrench. Avoid over-tightening. Steering ring nut (final tightening): 7 Nm (0.7 m•kg, 5.1 ft•lb) g. Check the steering stem by turning it lock to lock. If there is any binding, remove the steering stem assembly and inspect the steering bearings. h. Install the washer "5", upper bracket "6", steering stem nut "7", handlebar "8", handlebar upper holder "9" and number plate "10".
CHASSIS LUBRICATION To ensure smooth operation of all components, lubricate your machine during setup, after break-in, and after every race. 1. All control cable 2. Clutch lever pivot 3. Shift pedal pivot 4. Footrest pivot 5. Throttle-to-handlebar contact 6. Drive chain 7. Tube guide cable winding portion 8. Throttle cable end 9. Clutch cable end A. B. C. Use Yamaha cable lube or equivalent on these areas. Use SAE 10W-40 motor oil or suitable chain lubricants.
ELECTRICAL ELECTRICAL CHECKING THE SPARK PLUG 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. An extended run at low speeds causes the insulator to be colored black even if the air-fuel mixture is normal. 3. Measure: • Plug gap "a" Use a wire gauge or thickness gauge. Out of specification → Regap. Spark plug gap: 0.7–0.8 mm (0.028–0.031 in) 4.
ELECTRICAL TROUBLESHOOTING The following guide for troubleshooting does not cover all the possible causes of problems. If the following problems occur, perform the specified checks or maintenance jobs. If a problem occurs that is not listed in this manual or if the problem cannot be corrected by the procedures provided in this manual, contact your Yamaha dealer.
SEAT AND SIDE COVERS ENGINE This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage.
SEAT AND SIDE COVERS CHECKING AND REPLACING THE INSULATOR 1. Inspect: • Insulator 1 "1" • Insulator 2 "2" • Insulator 3 "3" • Insulator 4 "4" • Insulator 5 "5" Damage → Replace. • Affix insulators 1–5 to the side covers as shown. • If the insulators overlap, affix insulators 2 and 4 on top of the other insulators. • Make sure that the insulators do not protrude past the edges of the side covers. REMOVING THE NUMBER PLATE 1.
EXHAUST PIPE AND SILENCER EXHAUST PIPE AND SILENCER REMOVING THE EXHAUST PIPE AND SILENCER Order Part name Q'ty Seat Remarks Refer to "SEAT AND SIDE COVERS" section. Side cover (left and right) Refer to "SEAT AND SIDE COVERS" section. Rear fender Refer to "SEAT AND SIDE COVERS" section.
EXHAUST PIPE AND SILENCER Order 12 Part name Q'ty Heat protector 1 4-4 Remarks
EXHAUST PIPE AND SILENCER CHECKING THE SILENCER AND EXHAUST PIPE 1. Inspect: • Gasket "1" Damage → Replace. CHANGING THE SILENCER FIBER For USA and CDN 2. Remove: • Bolt "1" • Inner pipe "2" 4. Install: • Inner pipe "1" • Bolt "2" Bolt (silencer): 8 Nm (0.8 m•kg, 5.8 ft•lb) • Apply heat-resistant sealant to the areas "a" shown, making sure that there are no gaps in the beads of sealant. • Take care not to allow the fiber out of place when installing the inner pipe.
EXHAUST PIPE AND SILENCER INSTALLING THE SILENCER AND EXHAUST PIPE 1. Install: • Gasket • Exhaust pipe "1" • Nut (exhaust pipe) "2" Nut (exhaust pipe): 10 Nm (1.0 m•kg, 7.2 ft•lb) First temporarily tighten both nuts to 7 Nm (0.7 m•kg, 5.1 ft•lb). Then retighten the same nut to 10 Nm (1.0 m•kg, 7.2 ft•lb). 3. • • • Install: Silencer clamp (rear) Silencer "1" Bolt (silencer) "2" Bolt (silencer): 30 Nm (3.
RADIATOR RADIATOR REMOVING THE RADIATOR Order Part name Q'ty Remarks Drain the coolant. Refer to "CHANGING THE COOLANT" section in the CHAPTER 3. Seat Refer to "SEAT AND SIDE COVERS" section. Fuel tank Refer to "FUEL TANK" section in the CHAPTER 6. Refer to "THROTTLE BODY" section in the CHAPTER 6.
RADIATOR Order 11 Part name Q'ty Pipe 1/O-ring 1/1 4-8 Remarks
RADIATOR HANDLING NOTE Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open 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.
CAMSHAFTS CAMSHAFTS REMOVING THE CYLINDER HEAD COVER Order Part name Q'ty Remarks Seat Refer to "SEAT AND SIDE COVERS" section. Fuel tank Refer to "FUEL TANK" section in the CHAPTER 6. Cover Refer to "THROTTLE BODY" section in the CHAPTER 6.
CAMSHAFTS REMOVING THE CAMSHAFTS Order Part name Q'ty Remarks 1 Timing mark accessing screw 1 Refer to removal section. 2 Crankshaft end accessing screw 1 Refer to removal section. 3 Timing chain tensioner cap bolt 1 Refer to removal section. 4 Timing chain tensioner 1 Refer to removal section. 5 Gasket 1 Refer to removal section. 6 Bolt (camshaft cap) 8 Refer to removal section. 7 Camshaft cap 2 Refer to removal section. 8 Clip 2 Refer to removal section.
CAMSHAFTS REMOVING THE CAMSHAFT 1. Remove: • Timing mark accessing screw "1" • Crankshaft end accessing screw "2" 4. • • • Remove: Bolt (camshaft cap) "1" Camshaft cap "2" Clip Remove the bolts (camshaft cap) in a crisscross pattern, working from the outside in. 2. Align: • Alignment mark The bolts (camshaft cap) must be removed evenly to prevent damage to the cylinder head, camshafts or camshaft caps. Checking steps: a. Turn the crankshaft counterclockwise with a wrench. b.
CAMSHAFTS 4. Measure: • Camshaft-to-cap clearance Out of specification → Measure camshaft outside diameter. Camshaft-to-cap clearance: 0.028–0.062 mm (0.0011–0.0024 in) :0.08 mm (0.003 in) Measurement steps: a. Install the camshaft onto the cylinder head. b. Position a strip of Plastigauge® "1" onto the camshaft. c. Install the clip, dowel pins and camshaft caps. Bolt (camshaft cap): 10 Nm (1.0 m•kg, 7.2 ft•lb) • Tighten the bolts (camshaft cap) in a crisscross pattern from innermost to outer caps.
CAMSHAFTS b. With the rod fully wound and the chain tensioner UP mark "a" facing upward, install the gasket "1", the timing chain tensioner "2", and the gasket "3", and tighten the bolt "4" to the specified torque. Do not turn the crankshaft during the camshaft installation. Damage or improper valve timing will result. Bolt (timing chain tensioner): 10 Nm (1.0 m•kg, 7.2 ft•lb) d. Install the clips, camshaft caps "4" and bolts (camshaft cap) "5". Bolt (camshaft cap): 10 Nm (1.0 m•kg, 7.2 ft•lb) c.
CYLINDER HEAD CYLINDER HEAD REMOVING THE CYLINDER HEAD Order Part name Q'ty Remarks Refer to "SEAT AND SIDE COVERS" section. Seat Fuel tank Refer to "FUEL TANK" section in the CHAPTER 6. Exhaust pipe and silencer Refer to "EXHAUST PIPE AND SILENCER" section. Radiator Refer to "RADIATOR" section Throttle body Refer to "THROTTLE BODY" section in the CHAPTER 6. Camshaft Refer to "CAMSHAFTS" section.
CYLINDER HEAD Order Part name Q'ty 1 Bolt (cylinder head) 2 2 Bolt (cylinder head) 4 3 Cylinder head 1 4 Cylinder head gasket 1 5 Timing chain guide (intake side) 1 6 Coolant temperature sensor 1 7 Oil check bolt 2 8 Oil passage plug 1 Remarks Refer to TIP. Tighten the cylinder head bolts to 30 Nm (3.0 m•kg, 22 ft•b) in the proper tightening sequence, remove and retighten the cylinder head bolts to 20 Nm (2.
CYLINDER HEAD CHECKING THE CYLINDER HEAD 1. Eliminate: • Carbon deposits (from the combustion chambers) Use a rounded scraper. Do not use a sharp instrument to avoid damaging or scratching: • Spark plug threads • Valve seats 2. Inspect: • Cylinder head Scratches/damage → Replace. Replace the titanium valves with the cylinder head. INSTALLING THE CYLINDER HEAD 1.
CYLINDER HEAD Tighten the bolts two times at specified angles of 90°and 60° to reach the specified angle of 150° in the proper tightening sequence as shown. Bolts (cylinder head): Final: Specified angle 150° 3. Install: • Bolt (cylinder head) "1" Bolt (cylinder head): 10 Nm (1.0 m•kg, 7.
VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS REMOVING THE VALVES AND VALVE SPRINGS Order Part name Q'ty Cylinder head Remarks Refer to "CYLINDER HEAD" section. 1 Valve lifter 4 Refer to removal section. 2 Adjusting pad 4 Refer to removal section. 3 Valve cotter 8 Refer to removal section.
VALVES AND VALVE SPRINGS REMOVING THE VALVE LIFTER AND VALVE COTTER 1. Remove: • Valve lifter "1" • Pad "2" Identify each lifter "1" and pad "2" position very carefully so that they can be reinstalled in their original place. a. Remove the valve guide using a valve guide remover "1". CHECKING THE VALVE 1. Measure: • Stem-to-guide clearance Stem-to-guide clearance = valve guide inside diameter "a" valve stem diameter "b" b.
VALVES AND VALVE SPRINGS 4. Measure: • Margin thickness "a" Out of specification → Replace. Do not let the compound enter the gap between the valve stem and the guide. Margin thickness: Intake: 1.3 mm (0.051 in) Exhaust: 1.0 mm (0.039 in) Measurement steps: a. Apply Mechanic's blueing dye (Dykem) "b" to the valve face. b. Apply molybdenum disulfide oil to the valve stem. 5. Measure: • Runout (valve stem) Out of specification → Replace. Runout limit: 0.01 mm (0.
VALVES AND VALVE SPRINGS 3. Install: • Valve cotters CHECKING THE VALVE SPRINGS 1. Measure: • Valve spring free length "a" Out of specification → Replace. Free length (valve spring): Intake: 40.76 mm (1.60 in) : 39.76 mm (1.57 in) Exhaust: 37.01 mm (1.46 in) : 36.01 mm (1.42 in) 2. Measure: • Compressed spring force "a" Out of specification → Replace. Compressed spring force: Intake: 178–204 N at 34.78 mm (18.2–20.8 kg at 34.78 mm, 40.01–45.86 lb at 1.37 in) Exhaust: 124–142 N at 30.
CYLINDER AND PISTON CYLINDER AND PISTON REMOVING THE CYLINDER AND PISTON Order Part name Q'ty Cylinder head Remarks Refer to "CYLINDER HEAD" section. 1 Bolt (cylinder) 1 2 Cylinder 1 3 Gasket 1 4 Dowel pin 2 5 Piston pin clip 2 Refer to removal section. 6 Piston pin 1 Refer to removal section. 7 Piston 1 Refer to removal section. 8 Piston ring set 1 Refer to removal section.
CYLINDER AND PISTON REMOVING THE PISTON AND PISTON RING 1. Remove: • Piston pin clip "1" • Piston pin "2" • Piston "3" • 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 set "4". Piston pin puller set: YU-1304/90890-01304 Do not use a hammer to drive the piston pin out.
CYLINDER AND PISTON 2. Position: • Piston ring (in cylinder) 2. Measure: • Piston pin-to-piston clearance Insert a ring into the cylinder and push it approximately 40mm (1.57 in) into the cylinder. Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore. a. 40 mm (1.57 in) 3. Measure: • Ring end gap Out of specification → Replace. You cannot measure the end gap on the expander spacer of the oil control ring.
CYLINDER AND PISTON 3. • • • Install: Piston "1" Piston pin "2" Piston pin clip "3" • Apply engine oil onto the piston. • Apply molybdenum disulfide oil onto the piston pin. • Install the piston with the F mark "a" on it pointing to its intake (front) side. • Before installing the piston pin clip, cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase. INSTALLING THE CYLINDER 1.
CLUTCH CLUTCH REMOVING THE CLUTCH Order Part name Q'ty Remarks Drain the engine oil. Refer to "CHANGING THE ENGINE OIL" section in the CHAPTER 3. Brake pedal Refer to "ENGINE REMOVAL" section. Clutch cable Disconnect at engine side.
CLUTCH Order Part name Q'ty Remarks 14 Conical washer 1 Refer to removal section. 15 Clutch boss 1 Refer to removal section.
CLUTCH REMOVING THE CLUTCH BOSS 1. Remove: • Nut "1" • Conical washer "2" • Clutch boss "3" Use the clutch holding tool "4" to hold the clutch boss. Clutch holding tool: YM-91042/90890-04086 CHECKING THE CLUTCH SPRINGS 1. Measure: • Clutch spring free length "a" Out of specification → Replace springs as a set. Clutch spring free length: 50.0 mm (1.97 in) : 49.0 mm (1.93 in) CHECKING THE FRICTION PLATES 1. Measure: • Friction plate thickness Out of specification → Replace friction plate as a set.
CLUTCH INSTALLING THE CLUTCH 1. Install: • Primary driven gear "1" • Thrust washer "2" • Clutch boss "3" Apply the engine oil on the primary driven gear inner circumference. 2. Install: • Conical washer "1" • Nut (clutch boss) "2" Nut (clutch boss): 75 Nm (7.5 m•kg, 54 ft•lb) Make sure to tighten to specification; otherwise, it may damage the other part that is fastened together. • Apply engine oil to the threads and contact surface of the clutch boss nut.
OIL FILTER ELEMENT AND WATER PUMP OIL FILTER ELEMENT AND WATER PUMP REMOVING THE OIL FILTER ELEMENT AND WATER PUMP Order Part name Q'ty Remarks Right engine guard Refer to "ENGINE REMOVAL" section. Drain the engine oil. Refer to "CHANGING THE ENGINE OIL" section in the CHAPTER 3. Drain the coolant. Refer to "CHANGING THE COOLANT" section. Exhaust pipe Refer to "EXHAUST PIPE AND SILENCER" section. Brake pedal Refer to "ENGINE REMOVAL" section. Clutch cover Refer to "CLUTCH" section.
OIL FILTER ELEMENT AND WATER PUMP Order Part name Q'ty Remarks 9 Dowel pin/O-ring 3/1 10 Impeller 11 Washer 1 Refer to removal section. 12 Impeller shaft 1 Refer to removal section. 13 Oil seal 1 1 Refer to removal section. 14 Oil seal 2 1 Refer to removal section. 15 Bearing 1 Refer to removal section. 1 4-32 Refer to removal section.
OIL FILTER ELEMENT AND WATER PUMP REMOVING THE IMPELLER SHAFT 1. Remove: • Impeller "1" • Washer "2" • Impeller shaft "3" CHECKING THE IMPELLER SHAFT 1. Inspect: • Impeller shaft "1" Bend/wear/damage → Replace. Fur deposits → Clean. 2. Install: • Bearing "1" Install the bearing by pressing its outer race parallel. Hold the impeller shaft on its width across the flats "a" with spanners, etc. and remove the impeller. CHECKING THE BEARING 1. Inspect: • Bearing Rotate inner race with a finger.
OIL FILTER ELEMENT AND WATER PUMP INSTALLING THE RIGHT CRANKCASE COVER 1. Install: • Dowel pin "1" • O-ring "2" • Collar "3" • Gasket "4" Apply the lithium soap base grease on the O-ring. INSTALLING THE KICKSTARTER CRANK 1. Install: • Kickstarter crank "1" • Washer • Bolt (kickstarter crank) Bolt (kickstarter crank): 33 Nm (3.3 m•kg, 24 ft•lb) 3. • • • Install: O-ring Coolant pipe "1" Bolt (radiator pipe) "2" Bolt (radiator pipe): 10 Nm (1.0 m•kg, 7.
BALANCER BALANCER REMOVING THE BALANCER Order 1 Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Right crankcase cover Refer to "OIL FILTER ELEMENT AND WATER PUMP" section. Stator Refer to "AC MAGNETO" section. Nut (balancer) 1 Refer to removal section. 2 Nut (primary drive gear) 1 Refer to removal section. 3 Nut (balancer shaft driven gear) 1 Refer to removal section.
BALANCER REMOVING THE BALANCER 1. Straighten the lock washer tab. 2. Loosen: • Nut (balancer) "1" • Nut (primary drive gear) "2" • Nut (balancer shaft driven gear) "3" CHECKING THE BALANCER 1. Inspect: • Balancer Cracks/damage → Replace. Nut (primary drive gear): 100 Nm (10.0 m•kg, 72 ft•lb) • • • • Place an aluminum plate "a" between the teeth of the balancer shaft drive gear "4" and driven gear "5". INSTALLING THE BALANCER 1.
OIL PUMP OIL PUMP REMOVING THE OIL PUMP Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Right crankcase cover Refer to "OIL FILTER ELEMENT AND WATER PUMP" section.
OIL PUMP Order Part name Q'ty 15 Oil pump drive shaft 1 16 Rotor housing 1 4-38 Remarks
OIL PUMP CHECKING THE OIL PUMP 1. Inspect: • Oil pump drive gear • Oil pump drive shaft • Rotor housing • Oil pump cover Cracks/wear/damage → Replace. 2. Measure: • Tip clearance "a" (between the inner rotor "1" and outer rotor "2") • Side clearance "b" (between the outer rotor "2" and rotor housing "3") • Housing and rotor clearance "c" (between the rotor housing "3" and rotors "1" "2") Out of specification → Replace the oil pump assembly. Tip clearance "a": 0.12 mm or less (0.0047 in or less) : 0.
KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Oil pump Remarks Refer to "OIL PUMP" section. 1 Kick idle gear 1 2 Kick shaft assembly 1 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick shaft 1 8 Washer 1 Refer to removal section. 9 Shift pedal 1 10 Shift shaft 1 11 Collar 1 12 Torsion spring 1 13 Roller 1 14 Shift guide 1 Refer to removal section.
KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt (stopper lever) 1 21 Stopper lever 1 22 Torsion spring 1 23 Segment 1 4-41 Remarks Refer to removal section.
KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT ASSEMBLY 1. Remove: • Kick shaft assembly "1" Unhook the torsion spring "2" from the hole "a" in the crankcase. REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1. Remove: • Bolt (shift guide) • Shift guide "1" • Shift lever assembly "2" The shift lever assembly is disassembled at the same time as the shift guide. REMOVING THE SEGMENT 1. Remove: • Bolt (segment) "1" • Segment "2" Turn the segment counterclockwise until it stops and loosen the bolt.
KICK SHAFT AND SHIFT SHAFT INSTALLING THE STOPPER LEVER 1. Install: • Torsion spring "1" • Washer "2" • Stopper lever "3" • Bolt (stopper lever) "4" Bolt (stopper lever): 10 Nm (1.0 m•kg, 7.2 ft•lb) 3. Install: • Shift lever assembly "1" • Shift guide "2" • The shift lever assembly is installed at the same time as the shift guide. • Apply the engine oil on the bolt (segment) shaft. 2. Install: • Shift pedal "1" • Bolt (shift pedal) "2" Bolt (shift pedal): 12 Nm (1.2 m•kg, 8.
KICK SHAFT AND SHIFT SHAFT 3. Install: • Spring guide "1" Slide the spring guide into the kick shaft, make sure the groove "a" in the spring guide fits on the stopper of the torsion spring. INSTALLING THE KICK IDLE GEAR 1. Install: • Kick idle gear "1" • Washer "2" • Circlip "3" • Apply the engine oil on the kick idle gear inner circumference. • Install the kick idle gear with its depressed side "a" toward you. 4.
AC MAGNETO AC MAGNETO REMOVING THE AC MAGNETO Order Part name Q'ty Remarks Seat Refer to "SEAT AND SIDE COVERS" section. Fuel tank Refer to "FUEL TANK" section in the CHAPER 6. Disconnect the AC magneto lead 1 Left crankcase cover 1 2 Gasket 1 3 Dowel pin 2 4 Nut (rotor) 1 Refer to removal section. 5 Rotor 1 Refer to removal section.
AC MAGNETO REMOVING THE ROTOR 1. Remove: • Nut (rotor) "1" • Washer INSTALLING THE AC MAGNETO 1. Install: • Stator "1" • Screw (stator) "2" Screw (stator): 8 Nm (0.8 m•kg, 5.8ft•lb) • Crankshaft position sensor "3" • Holder "4" • Bolt (crankshaft position sensor) "5" 2. Remove: • Rotor "1" Use the rotor puller 2. Rotor puller: YM-04151/90890-04151 CHECKING THE AC MAGNETO 1. Inspect: • Rotor inner surface "a" • Stator outer surface "b" Damage → Inspect the crankshaft runout and crankshaft bearing.
ENGINE REMOVAL ENGINE REMOVAL REMOVING THE ELECTRONIC PARTS Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the frame. Refer to "HANDLING NOTE". Seat Refer to "SEAT AND SIDE COVERS" section. Fuel tank Refer to "FUEL TANK" section in the CHAPER 6. Air filter case Refer to "THROTTLE BODY" section in the CHAPRE 6. Radiator Refer to "RADIATOR" section.
ENGINE REMOVAL REMOVING THE ENGINE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the frame. Refer to "HANDLING NOTE". Throttle body Refer to "THROTTLE BODY" section in the CHAPRE 6. Rear fender Refer to "SEAT AND SIDE COVERS" section. Exhaust pipe and silencer Refer to "EXHAUST PIPE AND SILENCER" section. Clutch cable Disconnect at the engine side. Shift pedal Refer to "KICK SHAFT AND SHIFT SHAFT" section.
ENGINE REMOVAL Order Part name Q'ty Remarks 5 Clip 1 6 Bolt (brake pedal) 1 7 Brake pedal 1 8 Upper engine bracket 2 9 Lower engine bracket 2 10 Engine mounting bolt 4 11 Pivot shaft 1 Refer to removal section. 12 Engine 1 Refer to removal section.
ENGINE REMOVAL HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE DRIVE SPROCKET 1. Remove: • Nut (drive sprocket) "1" • Lock washer "2" 2. Remove: • Engine "1" From right side. • Make sure that the couplers, hoses and cables are disconnected. • Turn the engine 90° to the right as shown, and then, while lifting the crankcase in the direction of the arrow shown, remove the engine from the right side of the vehicle.
ENGINE REMOVAL 2. Install: • Lock washer "1" • Nut (drive sprocket) "2" Nut (drive sprocket): 75 Nm (7.5 m•kg, 54 ft•lb) Tighten the nut while applying the rear brake. Make sure to tighten to specification; otherwise, it may damage the other part that is fastened together. 3. Bend the lock washer tab to lock the nut. 4. Install: • Drive chain sprocket guide • Drive chain sprocket cover "1" • Bolt(drive chain sprocket cover) "2" Bolt (drive chain sprocket cover): 7 Nm (0.7 m•kg, 5.
CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT REMOVING THE CRANKSHAFT Order Part name Q'ty Engine Remarks Refer to "ENGINE REMOVAL" section. Piston Refer to "CYLINDER AND PISTON" section. Balancer Refer to "BALANCER" section. Kick shaft assembly Refer to "KICK SHAFT AND SHIFT SHAFT" section. Segment Refer to "KICK SHAFT AND SHIFT SHAFT" section. Stator Refer to "AC MAGNETO" section.
CRANKCASE AND CRANKSHAFT Order Part name Q'ty Remarks 10 Balancer shaft 1 Refer to removal section. 11 Crankshaft 1 Refer to removal section.
CRANKCASE AND CRANKSHAFT REMOVING THE CRANKCASE BEARING Order Part name Q'ty Remarks Transmission Refer to "TRANSMISSION, SHIFT CAM AND SHIFT FORK" section. Shift cam and shift fork Refer to "TRANSMISSION, SHIFT CAM AND SHIFT FORK" section. 1 Circlip 1 2 Oil seal 3 3 Bearing 10 4-54 Refer to removal section.
CRANKCASE AND CRANKSHAFT DISASSEMBLING THE CRANKCASE 1. Separate: • Right crankcase • Left crankcase Separation steps: a. Remove the crankcase bolts, hose guide and clutch cable holder. Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them. b. Remove the right crankcase "1". • 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 3. Inspect: • Oil seal Damage → Replace. CHECKING THE 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 Standard 0.03 mm (0.0012 in) 0.05 mm (0.002 in) Small end free play: 0.4–1.0 mm (0.016–0.039 in) 2.0 mm (0.08 in) Side clearance: 0.15–0.45 mm (0.0059–0.
CRANKCASE AND CRANKSHAFT 3. Install: • Oil strainer "1" • Bolt (oil strainer) "2" 6. Tighten: • Bolt (crankcase) Bolt (crankcase): 12 Nm (1.2 m•kg, 8.7 ft•lb) Bolt (oil strainer): 10 Nm (1.0 m•kg, 7.2 ft•lb) Tighten the crankcase tightening bolts in stage, using a crisscross pattern. 4. Apply: • Sealant On the right crankcase. YAMAHA Bond No. 1215 (ThreeBond® No.1215): 90890-85505 Clean the contacting surface of left and right crankcase before applying the sealant. 5.
TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION, SHIFT CAM AND SHIFT FORK Order Part name Q'ty Remarks Engine Refer to "ENGINE REMOVAL" section. Separate the crankcase. Refer to "CRANKCASE AND CRANKSHAFT" section. 1 Main axle 1 Refer to removal section. 2 Drive axle 1 Refer to removal section. 3 Shift cam 1 Refer to removal section. 4 Shift fork 3 1 Refer to removal section. 5 Shift fork 2 1 Refer to removal section.
TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION 1. Remove: • Main axle "1" • Drive axle "2" • Shift cam • Shift fork 3 • Shift fork 2 • Shift fork 1 • Remove assembly with the collar "3" installed to the crankcase. • Remove assembly carefully. Note the position of each part. Pay particular attention to the location and direction of shift forks. • Remove the main axle, drive axle, shift cam and shift fork all together by tapping lightly on the transmission drive axle with a soft hammer.
TRANSMISSION, SHIFT CAM AND SHIFT FORK 5. • • • • 3. Install: • Washer "1" • Circlip "2" Install: Shift fork 1 (L) "1" Shift fork 2 (C) "2" Shift fork 3 (R) "3" Shift cam "4" To main axle and drive axle. • Apply the molybdenum disulfide oil on the shift fork grooves. • Apply engine oil to the shift cam groove, bearing contact surface and shift fork shaft. • 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.
FRONT WHEEL AND REAR WHEEL CHASSIS This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage.
FRONT WHEEL AND REAR WHEEL REMOVING THE REAR WHEEL 5 Order Part name Q'ty Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". 1 Nut (rear wheel axle) 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 3 10 Brake disc 1 5-2 Remarks Refer to removal section. Refer to removal section.
FRONT WHEEL AND REAR WHEEL HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE REAR WHEEL 1. Remove: • Wheel "1" 2. Inspect: • Bearing Rotate inner race with a finger. Rough spot/seizure → Replace. Replace the bearings, oil seal and wheel collar as a set. Push the wheel forward and remove the drive chain "2". REMOVING THE WHEEL BEARING 1. Remove: • Bearing "1" Remove the bearing using a general bearing puller "2". Brake disc thickness: Front: 3.0 mm (0.
FRONT WHEEL AND REAR WHEEL 4. Install: • Wheel Install the brake disc "1" between the brake pads "2" correctly. 5. Install: • Wheel axle "1" 2. Install: • Brake disc "1" • Bolt (brake disc) "2" Apply the lithium soap base grease on the wheel axle. Bolt (brake disc): 12 Nm (1.2 m•kg, 8.7 ft•lb) Tighten the bolts in stage, using a crisscross pattern. 6. Install: • Nut (wheel axle) "1" Nut (wheel axle): 105 Nm (10.5 m•kg, 75 ft•lb) 3.
FRONT WHEEL AND REAR WHEEL 2. Install: • Brake disc "1" • Bolt (brake disc) "2" Bolt (brake disc): 14 Nm (1.4 m•kg, 10 ft•lb) 5. Install: • Wheel 9. Adjust: • Drive chain slack "a" Install the brake disc "1" between the brake pads "2" correctly. Drive chain slack: 50–60 mm (2.0–2.4 in) Refer to "ADJUSTING THE DRIVE CHAIN SLACK" section in the CHAPTER 3. Tighten the bolts in stage, using a crisscross pattern. 6. Install: • Drive chain "1" 3.
FRONT BRAKE AND REAR BRAKE FRONT BRAKE AND REAR BRAKE REMOVING THE FRONT BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Drain the brake fluid. Refer to removal section. 1 Brake hose holder (protector) 2 2 Union bolt 2 3 Brake hose 1 4 Pad pin plug 1 Remove when loosening the pad pin. 5 Pad pin 1 Loosen when disassembling the brake caliper.
FRONT BRAKE AND REAR BRAKE REMOVING THE REAR BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Rear wheel Refer to "FRONT WHEEL AND REAR WHEEL" section. Drain the brake fluid. Refer to removal section. 1 Brake pedal 1 2 Brake master cylinder 1 3 Brake hose holder 2 4 Union bolt 2 5 Brake hose 1 6 Pad pin plug 1 Remove when loosening the pad pin. Loosen when disassembling the brake caliper.
FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE CALIPER Order Part name Q'ty Remarks A. B. Front Rear A B 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Brake caliper piston 2 1 Refer to removal section. 5 Brake caliper piston dust seal 2 1 Refer to removal section. 6 Brake caliper piston seal 2 1 Refer to removal section.
FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE MASTER CYLINDER Order Part name Q'ty Remarks A. B. 1 Brake master cylinder cap 1 2 Diaphragm 1 3 Reservoir float 1 4 Push rod (front) 1 5 Brake master cylinder boot 1 6 Circlip 1 7 Washer 1 8 Push rod (rear) 1 9 Brake master cylinder kit 1 5-9 Front Rear Use a long nose circlip pliers.
FRONT BRAKE AND REAR BRAKE HANDLING NOTE Support the machine securely so there is no danger of it falling over. DRAINING THE BRAKE FLUID 1. Remove: • Brake master cylinder cap "1" • Protector (rear brake) Do not remove the diaphragm. REMOVING THE BRAKE CALIPER PISTON 1. Remove: • Brake caliper piston Use compressed air and proceed carefully. Replace the brake caliper piston seals and brake caliper piston dust seals whenever a caliper is disassembled.
FRONT BRAKE AND REAR BRAKE 3. Inspect: (front brake only) • Reservoir float "1" Damage → Replace. 4. Inspect: • Brake master cylinder piston "1" • Brake master cylinder cup "2" Wear/damage/score marks → Replace brake master cylinder kit. CHECKING THE BRAKE CALIPER 1. Inspect: • Brake caliper cylinder inner surface "a" Wear/score marks → Replace brake caliper assembly. CHECKING THE BRAKE HOSE 1. Inspect: • Brake hose "1" Crack/damage → Replace. A. Front B. Rear 3.
FRONT BRAKE AND REAR BRAKE 2. Install: • Brake caliper "1" • Bolt (brake caliper) "2" Bolt (brake caliper): 28 Nm (2.8 m•kg, 20 ft•lb) 3. Tighten: • Pad pin "3" Pad pin: 18 Nm (1.8 m•kg, 13 ft•lb) 4. Install: • Pad pin plug "4" Pad pin plug: 2 Nm (0.2 m•kg, 1.4 ft•lb) INSTALLING THE REAR BRAKE CALIPER 1. Install: • Pad support "1" • Brake pad "2" • Pad pin "3" • Install the brake pads with their projections "a" into the brake caliper recesses "b". • Temporarily tighten the pad pin at this point. 3.
FRONT BRAKE AND REAR BRAKE INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Brake master cylinder "1" • Brake master cylinder bracket "2" • Bolt (brake master cylinder bracket) "3" Bolt (brake master cylinder bracket): 9 Nm (0.9 m•kg, 6.5 ft•lb) INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • Copper washer "1" • Brake hose "2" • Union bolt "3" Union bolt: 30 Nm (3.0 m•kg, 22 ft•lb) Always use new copper washers. • Install the bracket so that the arrow mark "a" face upward.
FRONT BRAKE AND REAR BRAKE Install the brake hose so that its pipe portion "a" directs as shown and lightly touches the projection "b" on the brake caliper. 2. Install: • Brake hose holder "1" • Bolt (brake hose holder) "2" Always use new copper washers. 2. Install: • Brake hose holder "1" • Screw (brake hose holder) "2" Screw (brake hose holder): 3 Nm (0.3 m•kg, 2.
FRONT BRAKE AND REAR BRAKE Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately. A. Front B. Rear 5. Install: (rear brake only) • Protector "1" • Bolt (protector) "2" A. Front B. Rear 2. Air bleed: • Brake system Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" section in the CHAPTER 3. 3. Inspect: • Brake fluid level Fluid at lower level → Fill up. Refer to "CHECKING THE BRAKE FLUID LEVEL" section in the CHAPTER 3. 4.
FRONT FORK FRONT FORK REMOVING THE FRONT FORK Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Front wheel Refer to "FRONT WHEEL AND REAR WHEEL" section. Front brake caliper Refer to "FRONT BRAKE AND REAR BRAKE" section. Number plate Refer to "SEAT, FUEL TANK AND SIDE COVERS" section in the CHAPTER 4. 1 Protector 1 2 Pinch bolt (upper bracket) 2 Only loosening.
FRONT FORK DISASSEMBLING THE FRONT FORK Order Part name Q'ty Remarks 1 Adjuster 1 Drain the fork oil. Refer to removal section. 2 Fork spring 1 3 Dust seal 1 Refer to removal section. 4 Stopper ring 1 Refer to removal section. 5 Inner tube 1 Refer to removal section. 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Oil seal washer 1 10 Oil seal 1 11 Base valve 1 Drain the fork oil. Refer to removal section. 12 Damper assembly 1 Drain the fork oil.
FRONT FORK HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE ADJUSTER 1. Drain the outer tube of its front fork oil at its top. 2. Loosen: • Adjuster "1" The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers.
FRONT FORK The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material. Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled. CHECKING THE BASE VALVE 1. Inspect: • Base valve "1" Wear/damage → Replace. Contamination → Clean. • O-ring "2" Wear/damage → Replace. • Piston metal "3" Wear/damage → Replace.
FRONT FORK 5. Measure: • Oil level (left and right) "a" Out of specification → Adjust. Standard oil level: 145-148 mm (5.71-5.83 in) From top of fully stretched damper assembly. 8. Install: • Base valve "1" To damper assembly "2". First bring the damper rod pressure to a maximum. Then install the base valve while releasing the damper rod pressure. 9. Check: • Damper assembly Not fully stretched → Repeat the steps 2 to 8. 10. Tighten: • Base valve "1" 6.
FRONT FORK 21. Install: • Dust seal "1" Apply the lithium soap base grease on the inner tube. 22. Check: • Inner tube smooth movement Tightness/binding/rough spots → Repeat the steps 15 to 21. 16. Install: • Piston metal "1" 19. Install: • Oil seal "1" Install the piston metal onto the slot on inner tube. Press the oil seal into the outer tube with fork seal driver "2". Fork seal driver: YM-A0948/90890-01502 23. Measure: • Distance "a" Out of specification → Turn into the locknut. 17.
FRONT FORK 25. Install: • Damper assembly "1" To inner tube "2". To install the damper assembly into the inner tube, hold the inner tube aslant. If the inner tube is held vertically, the damper assembly may fall into it, damaging the valve inside. 28. Inspect: • Gap "a" between the adjuster "1" and locknut "2". Out of specification → Retighten and readjust the locknut. Gap "a" between the adjuster and locknut: 0.5–1.0 mm (0.02–0.
FRONT FORK 33. Install: • Protector guide "1" 4. Tighten: • Pinch bolt (upper bracket) "1" Pinch bolt (upper bracket): 21 Nm (2.1 m•kg, 15 ft•lb) • Pinch bolt (lower bracket) "2" INSTALLING THE FRONT FORK 1. Install: • Front fork "1" Pinch bolt (lower bracket): 21 Nm (2.1 m•kg, 15 ft•lb) • Temporarily tighten the pinch bolts (lower bracket). • Do not tighten the pinch bolts (upper bracket) yet. Tighten the lower bracket to specified torque.
HANDLEBAR HANDLEBAR REMOVING THE HANDLEBAR Order Part name Q'ty Number plate Remarks Remove the band only. 1 Clutch cable 1 2 Clutch lever holder 1 3 Engine stop switch 1 4 Brake master cylinder 1 5 Throttle cable cap 1 6 Throttle cable #1 (pulled) 1 Disconnect at the throttle side. 7 Throttle cable #2 (pushed) 1 Disconnect at the throttle side. 8 Right grip 1 Refer to removal section.
HANDLEBAR REMOVING THE BRAKE MASTER CYLINDER 1. Remove: • Brake master cylinder bracket "1" • Brake master cylinder "2" • Do not let the brake master cylinder hang on the brake hose. • Keep the brake master cylinder cap side horizontal to prevent air from coming in. REMOVING THE GRIP 1. Remove: • Grip "1" INSTALLING THE HANDLEBAR 1.
HANDLEBAR 3. Tighten: • Nut (handlebar lower holder) "1" After tightening the screws, check that the throttle grip "3" moves smoothly. If it does not, retighten the bolts for adjustment. Nut (handlebar lower holder): 34 Nm (3.4 m•kg, 24 ft•lb) • Cap "2" Install the cap "2" onto the handlebar lower holder nut (left). 4. Install: • Left grip "1" Apply the adhesive to the handlebar "2". 6.
HANDLEBAR 11. Install: • Engine stop switch "1" • Clutch lever holder "2" • Bolt (clutch lever holder) "3" Bolt (clutch lever holder): 5 Nm (0.5 m•kg, 3.6 ft•lb) •Clamp "4" • The engine stop switch, clutch lever holder and clamp should be installed according to the dimensions shown. • Pass the engine stop switch lead in the middle of the clutch lever holder. 0 mm 0 mm 12. Install: • Clutch cable "1" Apply the lithium soap base grease on the clutch cable end. 13.
STEERING STEERING REMOVING THE STEERING Order Part name Q'ty Remarks TIGHTENING STEPS: • Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb) • Loosen it one turn. • Retighten it. 7 Nm (0.7 m•kg, 5.1 ft•lb) Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Number plate Refer to "SEAT AND SIDE COVERS" section in the CHAPTER 4. Handlebar Refer to "HANDLEBAR" section.
STEERING Order 10 Part name Q'ty Bearing race 2 5-29 Remarks Refer to removal section.
STEERING HANDLING NOTE Support the machine securely so there is no danger of it falling over. CHECKING THE STEERING STEM 1. Inspect: • Steering stem "1" Bend/damage → Replace. REMOVING THE STEERING RING NUT 1. Remove: • Steering ring nut "1" Use the steering nut wrench "2". Steering nut wrench: YU-33975/90890-01403 Support the steering stem so that it may not fall down. REMOVING THE LOWER BEARING 1. Remove: • Lower bearing "1" Use the floor chisel "2". 3.
STEERING 6. Install: • Washer "1" 10. Adjust: • Front fork top end "a" Front fork top end (standard) "a": Zero mm (Zero in) 7. Install: • Front fork "1" • Upper bracket "2" • Temporarily tighten the pinch bolts (lower bracket). • Do not tighten the pinch bolts (upper bracket) yet. 11. Tighten: • Pinch bolt (upper bracket) "1" Pinch bolt (upper bracket): 21 Nm (2.1 m•kg, 15 ft•lb) • Pinch bolt (lower bracket) "2" Pinch bolt (lower bracket): 21 Nm (2.1 m•kg, 15 ft•lb) 8.
SWINGARM SWINGARM REMOVING THE SWINGARM Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Brake hose holder Refer to "FRONT BRAKE AND REAR BRAKE" section. Rear brake caliper Refer to "FRONT BRAKE AND REAR BRAKE" section. Bolt (brake pedal) Shift the brake pedal backward.
SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q'ty 1 Relay arm 1 2 Connecting rod 1 3 Collar 2 4 Oil seal 2 5 Thrust bearing 2 6 Bushing 2 7 Oil seal 8 8 Bearing 10 5-33 Remarks Refer to removal section.
SWINGARM HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE BEARING 1. Remove: • Bearing "1" Remove the bearing by pressing its outer race. CHECKING THE CONNECTING ROD 1. Inspect: • Bearing "1" • Collar "2" Free play exists/unsmooth revolution/rust → Replace bearing and collar as a set. 2. Inspect: • Oil seal "3" Damage → Replace. 2. • • • Install: Bearing "1" Washer "2" Oil seal "3" To relay arm.
SWINGARM INSTALLING THE SWINGARM 1. Install: • Bushing "1" • Thrust bearing "2" • Oil seal "3" • Collar "4" To swingarm "5". Apply the molybdenum disulfide grease on the bushings, thrust bearings, oil seal lips and contact surfaces of the collar and thrust bearing. 2. Install: • Collar "1" • Washer "2" To relay arm "3". Apply the molybdenum disulfide grease on the collars and oil seal lips. 4.
SWINGARM 10. Tighten: • Nut (connecting rod) "1" Nut (connecting rod): 80 Nm (8.0 m•kg, 58 ft•lb) 13. Install: • Drive chain support "1" • Drive chain support cover "2" • Bolt {drive chain support [L = 50 mm (1.97 in)]} "3" • Nut (drive chain support) "4" Nut (drive chain support): 7 Nm (0.7 m•kg, 5.1 ft•lb) • Bolt {drive chain support cover [L = 10 mm (0.39 in)]} "5" 11. Tighten: • Nut (relay arm) "1" Nut (relay arm): 70 Nm (7.0 m•kg, 50 ft•lb) Bolt (drive chain support cover): 7 Nm (0.7 m•kg, 5.
REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Seat Refer to "SEAT AND SIDE COVERS" section in the CHAPTER 4. Silencer Refer to "EXHAUST PIPE AND SILENCER" section in the CHAPTER 4. 1 Bolt (rear shock absorber-relay arm) 1 2 Bolt (rear shock absorber-frame) 1 3 Rear shock absorber 1 4 Locknut 1 Only loosening.
REAR SHOCK ABSORBER HANDLING NOTE • Support the machine securely so there is no danger of it falling over. • This rear 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.
REAR SHOCK ABSORBER 2. Install: • Stopper ring (upper bearing) "1" After installing the stopper ring, push back the bearing until it contacts the stopper ring. 3. Adjust: • Spring length (installed) Refer to "ADJUSTING THE REAR SHOCK ABSORBER SPRING PRELOAD" section in the CHAPTER 3. 4. Tighten: • Locknut "1" 4. Install: • Bolt (rear shock absorber-frame) "1" • Washer "2" • Nut (rear shock absorber-frame) "3" Nut (rear shock absorber-frame): 56 Nm (5.
FUEL TANK FUEL SYSTEM This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage.
FUEL TANK REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. Be careful not to damage the fuel pump. 2. Remove: • Fuel pump coupler Although the fuel has been removed from the fuel tank be careful when removing the fuel hoses, since there may be fuel remaining in it. • Before disconnecting the fuel hose, clean the area around the fuel hose connector. • Before removing the fuel hose, place a few rags in the area under where it will be removed.
FUEL TANK CHECKING AND REPLACING THE DUMPER 1. Inspect: • Damper 1 "1" • Damper 2 "2" • Damper 3 "3" Wear/damage → Replace • Affix dampers 1 and 3 so that the arrow on each damper is pointing outward. • Affix damper 2 so that the edge of the damper contacts the edge "a" of the frame. 2. • • • Install: Fuel pump coupler Air scoop (left/right) Seat Refer to "SEAT AND SIDE COVERS" in the chapter 4. CHECKING THE FUEL PRESSURE 1. Check: • Pressure regulator operation 2. Remove the fuel tank.
THROTTLE BODY THROTTLE BODY REMOVING THE THROTTLE BODY Order Part name Q'ty Remarks Seat Refer to "SEAT AND SIDE COVERS" section in the chapter 4. Air scoop (left/right) Refer to "SEAT AND SIDE COVERS" section in the chapter 4. Fuel tank Refer to "FUEL TANK" section. 1 Cover 1 2 Air filter case 1 3 Fuel hose 1 4 Fuel injector coupler 1 Disconnect. 5 Intake air pressure sensor coupler 1 Disconnect.(I.D.
THROTTLE BODY DISASSEMBLING THE THROTTLE BODY Order Part name Q'ty 1 Injector 1 2 Gasket 2 6-5 Remarks
THROTTLE BODY CHECKING THE INJECTOR Replace the fuel injector with a new one if you have dropped or impacted it. 1. Check: • Injectors Damage → Replace. CHECKING THE THROTTLE BODY • Before removing the throttle body, clean the area around the throttle body to prevent dirt and other foreign material from falling into the engine. • If the throttle body is subject to strong shocks or dropped during cleaning, replace it. • Do not use any caustic carburetor cleaning solution.
ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage.
ELECTRICAL COMPONENTS AND WIRING DIAGRAM WIRING DIAGRAM B/L Gy Gy B B/L Gy W1 W2 W2 W1 W1 W2 R R/W L Y O R/B Lg P/W B/L Gy B/Y Br Br/W B/R B B/W P B/R R R O R O Gy B/R R/B B/R Br/W B/L R R/B B/Y Br/W Br/W B/Y B/L R ON STOP W2 W1 W1 W2 B R R B B B/Y B R R B B P/W P/W B/L L L Y B/L L Y B/L P P B/L L B B/L P/W L B B R R R R/B R/W W1 W2 O O R B/W Lg B R Lg Lg R L Y Y B L B/L B/L P L Lg B/W Br B/W Br B/L Br B/L B 1. 2. 3. 4. 5. 6. 7. 8. 9.
IGNITION SYSTEM IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. Spark → Spark gap test • *Clean or replace spark plug. • Check the connection of the spark plug cap to the spark plug. No spark ↓ Check entire ignition system for connection. (couplers, leads and ignition coil) No good → Repair or replace. OK ↓ Check engine stop switch.
IGNITION SYSTEM SPARK GAP TEST 1. Disconnect the spark plug cap from spark plug. 2. Connect the dynamic spark tester "1" (ignition checker "2") as shown. • Spark plug cap "3" • Spark plug "4" CHECKING THE COUPLERS AND LEADS CONNECTION 1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. CHECKING THE ENGINE STOP SWITCH 1.
IGNITION SYSTEM 2. Inspect: • Stator coil resistance Out of specification → Replace. Tester (+) lead → White lead "1" Tester (-) lead → White lead "2" Stator coil resistance Tester selector position 0.60–0.90 Ω at 20°C (68°F) Ω × 10 W2 W1 CHECKING THE ECU 1. Check: • All electrical components. 2. Check: • ECU installation status Make sure that the ECU is installed correctly. • The lean angle sensor is built into the ECU. • The lean angle sensor stops the engine in case of a turnover.
THROTTLE POSITION SENSOR SYSTEM THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position sensor will not operate, use the following inspection steps. Check entire ignition system for connection. No good → Repair or replace. No good → Replace. No good → Replace. Check ECU. (Throttle position sensor input volt- No good → age) Replace. OK ↓ Check throttle position sensor. OK ↓ *Check AC magneto. OK ↓ *marked: Refer to "IGNITION SYSTEM" section.
THROTTLE POSITION SENSOR SYSTEM HANDLING NOTE Do not loosen the screw (throttle position sensor) "1" except when changing the throttle position sensor due to failure because it will cause a drop in engine performance. 2. Inspect: • Throttle position sensor 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.
THROTTLE POSITION SENSOR SYSTEM CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1. Disconnect the throttle position sensor coupler. 2. Connect the test harness-speed sensor (3P) "1" as shown. Test harness-speed sensor (3P) YU-03208/90890-03208 3. Start the engine. 4. Inspect: • Throttle position sensor input voltage Out of specification → Replace the ECU.
FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM TROUBLESHOOTING METHOD Engine starting problems, engine idling speed problems, and medium and high-speed performance problems 1. CHECK: • Refer to "TROUBLESHOOTING" section in the chapter 3. 2. Connect the FI diagnostic tool. (Refer to "CONNECTING THE FI DIAGNOSTIC TOOL".) 3. Check the fault code number. (Refer to "TROUBLESHOOTING DETAILS".) • Check the fault code number that is displayed on the LCD of the FI diagnostic tool.
FUEL INJECTION SYSTEM SETTING THE DIAGNOSTIC MODE When the FI diagnostic tool is set to the diagnostic mode, the sensor output data can be displayed and the operation of the actuators can be checked. 1. While pressing the "MODE" button, set the switch on the FI diagnostic tool sub-wire harness to "ON". 5. Check the operation of the sensor or actuator. • Sensor display: Data indicating the sensor status is displayed on the LCD of the FI diagnostic tool.
FUEL INJECTION SYSTEM SENSOR OPERATION TABLE Diagnostic code No. D01 D02 Item Throttle angle Atmosphere Actuation or display Display Checking method Actuation or LCD standard display values Displays the throttle angle. 0–125° Check with throttle fully closed. When throttle is fully closed:15–19° Check with throttle fully open. When throttle is fully opened:95–101 ° Displays the atmospheric pressure. • Measure the atmospheric pressure.
FUEL INJECTION SYSTEM Diagnostic code No. D36 D60 D61 D62 D64 Item Injectors EEPROM fault code display. Malfunction history code display. Malfunction history code erasure Actuation or display Checking method Actuation or LCD standard display values Actuation Check that power is supplied to the fuel injector. • Check the fuel injector operation by listening for the operating sound or by confirming the operation visually. Actuates the injector for five times every second.
FUEL INJECTION SYSTEM TROUBLESHOOTING DETAILS This section describes the countermeasures per fault code number displayed on the FI diagnostic tool. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part have been completed, reset the FI diagnostic tool display according to the "Reinstatement method". Fault code No.
FUEL INJECTION SYSTEM Fault code No. 12 Symptom No normal signals are received from the crankshaft position sensor. Fail-safe system Able to start Able to drive Diagnostic code No. — FI diagnostic tool display — Checking method — Item Item/components and probable cause Check or maintenance job 5 Defective crankshaft position sensor. Sensor malfunction → Replace. Refer to "CHECKING THE AC MAGNETO" section. 6 Malfunction in ECU. Replace the ECU.
FUEL INJECTION SYSTEM Fault code No. 13 Symptom Intake air pressure sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. D03 FI diagnostic tool display Intake air pressure Checking method Crank the engine. (If the display value changes, the performance is OK.) Item Item/components and probable cause Check or maintenance job Checking method 3 Continuity of harness Open or short circuit → Replace.
FUEL INJECTION SYSTEM If fault code Nos. 13 and 14 are both displayed, perform the checks and maintenance jobs for fault code No. 13 first. Fault code No. 14 Symptom Intake air pressure sensor system malfunction detected. (clogged hole or disconnected sensor) Fail-safe system Able to start Diagnostic code No. D03 FI diagnostic tool display Intake air pressure Checking method Crank the engine. (If the display value changes, the performance is OK.
FUEL INJECTION SYSTEM Fault code No. 15 Symptom Throttle position sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. D01 FI diagnostic tool display • 15–19° (Fully closed position) • 95–101° (Fully opened position) Checking method Item • Check with throttle valves fully closed. • Check with throttle valves fully open.
FUEL INJECTION SYSTEM Fault code No. 15 Symptom Throttle position sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. D01 FI diagnostic tool display • 15–19° (Fully closed position) • 95–101° (Fully opened position) Checking method Item 5 • Check with throttle valves fully closed. • Check with throttle valves fully open.
FUEL INJECTION SYSTEM Fault code No. 16 Symptom Signal from throttle position sensor does not change. Fail-safe system Able to start Able to drive Diagnostic code No. D01 FI diagnostic tool display • 15–19° (Fully closed position) • 95–101° (Fully opened position) Checking method Item • Check with throttle valves fully closed. • Check with throttle valves fully open. Item/components and probable cause Check or maintenance job Checking method 1 Installed condition of sensor.
FUEL INJECTION SYSTEM Make sure that the engine is completely cool before checking the coolant temperature sensor. Fault code No. 21 Symptom Coolant temperature sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. D06 FI diagnostic tool display -20–150°C Cold engine: Displayed temperature is close to the ambient temperature. Warm engine: Displayed temperature is the current coolant temperature. Checking method Check the coolant temperature.
FUEL INJECTION SYSTEM Fault code No. 21 Symptom Coolant temperature sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. D06 FI diagnostic tool display -20–150°C Cold engine: Displayed temperature is close to the ambient temperature. Warm engine: Displayed temperature is the current coolant temperature. Checking method Check the coolant temperature.
FUEL INJECTION SYSTEM Fault code No. 22 Symptom Coolant temperature sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. D05 FI diagnostic tool display -20–100°C Cold engine: Displayed temperature is close to the ambient temperature. Warm engine: Displayed temperature is approximately 20°C higher than the ambient temperature. Checking method Check the temperature in the intake manifold.
FUEL INJECTION SYSTEM Fault code No. 23 Symptom Atmospheric pressure sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. D02 FI diagnostic tool display Atmosphere Checking method Measure the atmospheric pressure. Item Item/components and probable cause Check or maintenance job Checking method 1 Check the connection and locking condition of Poor connection → Properly conthe atmospheric pressure sensor coupler. nect, repair, or replace.
FUEL INJECTION SYSTEM Fault code No. 23 Symptom Atmospheric pressure sensor signal is not received properly. Fail-safe system Able to start Able to drive Diagnostic code No. D02 FI diagnostic tool display Atmosphere Checking method Measure the atmospheric pressure. Item Item/components and probable cause Check or maintenance job Checking method Set the switch on the FI diagnostic tool sub-wire harness to "ON", and then check the fault code display.
FUEL INJECTION SYSTEM Fault code No. 30 Symptom Turnover of vehicle Fail-safe system Able to start Unable to drive Diagnostic code No. D08 FI diagnostic tool display Lean angle sensor • 1.0 V (Upright) • 4.0 V (Overturned) Checking method Remove the ECU and incline it 45° or more. Item Item/components and probable cause Check or maintenance job Checking method 1 The vehicle has overturned. Raise the vehicle upright.
FUEL INJECTION SYSTEM Fault code No. 33 Symptom Ignition system circuit signal is not received properly. Fail-safe system Unable to start Unable to drive Diagnostic code No. D30 FI diagnostic tool display Actuates the ignition coil for five times every second. The "WARNING" LED on the FI diagnostic tool comes on each time the ignition coil is actuated. Checking method Item Check the spark five times. • Connect an ignition checker.
FUEL INJECTION SYSTEM Fault code No. 33 Symptom Ignition system circuit signal is not received properly. Fail-safe system Unable to start Unable to drive Diagnostic code No. D30 FI diagnostic tool display Actuates the ignition coil for five times every second. The "WARNING" LED on the FI diagnostic tool comes on each time the ignition coil is actuated. Checking method Item Check the spark five times. • Connect an ignition checker.
FUEL INJECTION SYSTEM Fault code No. 39 Symptom Injection system circuit signal is not received properly. Fail-safe system Unable to start Unable to drive Diagnostic code No. D36 FI diagnostic tool display Actuates the injector for five times every second. The "WARNING" LED on the FI diagnostic tool comes on each time the fuel injector is actuated. Checking method Check the operating sound of the injector five times.
FUEL INJECTION SYSTEM Fault code No. 39 Symptom Injection system circuit signal is not received properly. Fail-safe system Unable to start Unable to drive Diagnostic code No. D36 FI diagnostic tool display Actuates the injector for five times every second. The "WARNING" LED on the FI diagnostic tool comes on each time the fuel injector is actuated. Checking method Check the operating sound of the injector five times.
FUEL INJECTION SYSTEM Fault code No. 44 Symptom Error is detected while reading or writing on EEPROM. Fail-safe system Able to start engine (depending on circumstances) Able to drive vehicle (depending on circumstances) Diagnostic code No.
FUEL INJECTION SYSTEM Fault code No. 46 Symptom Power supply to the ECU is not normal. Fail-safe system Able to start (depending on circumstances) Able to drive vehicle (depending on circumstances) Diagnostic code No. — FI diagnostic tool display — Checking method — Item Item/components and probable cause Check or maintenance job Checking method 1 Check the connection and locking condition of Poor connection → Properly conthe ECU coupler. nect, repair, or replace.
FUEL INJECTION SYSTEM Fault code No. 46 Symptom Power supply to the ECU is not normal. Fail-safe system Able to start (depending on circumstances) Able to drive vehicle (depending on circumstances) Diagnostic code No. — FI diagnostic tool display — Checking method — Item Item/components and probable cause Check or maintenance job 4 Defective AC magneto. Defective → Replace. Refer to "CHECKING THE AC MAGNETO" section. 5 Malfunction in ECU. Replace the ECU. Fault code No.
FUEL INJECTION SYSTEM Fault code No. waiting for connection Symptom Communication signal is not received. Fail-safe system Able to start (unable when ECU is malfunctioning) Able to drive vehicle (unable when ECU is malfunctioning) Diagnostic code No. — FI diagnostic tool display — Checking method — Item Item/components and probable cause Check or maintenance job Checking method 1 Check the connection and locking condition of Poor connection → Properly conthe FI diagnostic tool coupler.
FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom Registered data cannot be received from the FI diagnostic tool. Fail-safe system Able to start Able to drive Diagnostic code No. — FI diagnostic tool display — Checking method — Item Item/components and probable cause Check or maintenance job Checking method 1 Check the connection and locking condition of Poor connection → Properly conthe FI diagnostic tool coupler. nect, repair, or replace. Disconnect the coupler and check the pins.
FUEL PUMP SYSTEM FUEL PUMP SYSTEM INSPECTION STEPS If the fuel pump is not operating normally, perform the following procedures in the order given. Check engine stop switch. No good → Replace. OK ↓ Checking the couplers and leads connections No good → Repair or replace. OK ↓ Check the fuel pump.(Checking the fuel pump body) No good → OK ↓ Replace the ECU. • Remove the following parts before inspection. 1. Seat 2. Side cover (right/left) 3.
ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS CHECKING THE COOLANT TEMPERATURE SENSOR 1. Remove: •Coolant temperature sensor Refer to "REMOVING THE CYLINDER HEAD" section in the CHAPTER 4. • Handle the coolant temperature sensor with special care. • Never subject the coolant temperature sensor to strong shocks. If the coolant temperature sensor is dropped, replace it. 2. Check: • Coolant temperature sensor resistance 3.
ELECTRICAL COMPONENTS Test harness S–pressure sensor (3P): YU-03207/90890-03207 3. Connect the FI diagnostic tool sub-wire harness to a battery, and then set the switch on the harness to "ON". CHECKING THE FUEL INJECTORS 1. Remove: • Seat • Fuel tank • Air filter case 2. Check: •Injector resistance 3. Connect: • Tester Tester (+) lead → Injector terminal "1" Tester (-) lead → Injector terminal "2" When checking the atmospheric pressure sensor, do not start the engine. 4.
CHASSIS TUNING DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS CHASSIS SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET) Secondary reduction ratio = Number of rear wheel sprocket teeth/Number of drive sprocket teeth Standard secondary reduction ratio 48/13 (3.692) * 49/13 (3.
CHASSIS FRONT FORK SETTING PARTS • Front fork spring "1" I.D. SPRIN MA TY SPRING PART G RK PE NUMBER RATE (slit s) A. Air spring characteristics in relation to oil amount change B. Load C. Stroke 1. Max. oil amount 2. Standard oil amount 3. Min. oil amount SETTING OF SPRING AFTER REPLACEMENT As the front fork setting can be easily affected by rear suspension, take care so that the machine front and rear are balanced (in position, etc.) when setting the front fork. 1.
CHASSIS SETTING OF SPRING AFTER REPLACEMENT After replacement, be sure to adjust the spring to the set length [sunken length 90–100 mm (3.5–3.9 in)] and set it. 1. Use of soft spring • Set the soft spring for less rebound damping to compensate for its less spring load. Run with the rebound damping adjuster one or two clicks on the softer side and readjust it to suit your preference. 2. Use of stiff spring • Set the soft spring for more rebound damping to compensate for its greater spring load.
CHASSIS SUSPENSION SETTING (FRONT FORK) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in).
CHASSIS SUSPENSION SETTING (REAR SHOCK ABSORBER) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Adjust the rebound damping in 2-click increments or decrements. • Adjust the low compression damping in 1-click increments or decrements. • Adjust the high compression damping in 1/6 turn increments or decrements.
33D-9-80_cover 09.7.16 13:46 ページ 2 Q Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. Q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit être remis avec le véhicule en cas de vente de ce dernier. Q Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen. Diese Bedienungsanleitung muss, wenn das Fahrzeug verkauft wird, beim Fahrzeug verbleiben.
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