2012 WR450F 1DX-28199-10 PDF
2012 WR450F 1DX-28199-10 PDF
2012 WR450F 1DX-28199-10 PDF
INTRODUCTION
Congratulations on your purchase of a Yamaha WR series. This model is the culmination of Yama-
ha'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.
The design and manufacture of this Yamaha machine fully comply with the emissions standards for
clean air applicable at the date of manufacture. Yamaha has met these standards without reducing
the performance or economy of operation of the machine. To maintain these high standards, it is im-
portant that you and your Yamaha dealer pay close attention to the recommended maintenance
schedules and operating instructions contained within this manual.
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Yamaha continually seeks advancements·in product design and quality. Therefore, while this manual
contains the most current product information available at the time of printing, there may be minor
discrepancies between your machine and this manual. If you have any questions concerning this
manual, please consult your Yamaha dealer.
EWA1DX0001
A WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS
MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A
SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL
YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPEC-
TIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE
THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.
EAS1DX3004
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal
& injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
SAFETY INFORMATION
THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE,. ONLY ON A CLOSED
COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road
use on public lands may also be illegal. Plea~e check local regulations before riding.
•THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY.
Do not attempt to operate this machine at maximum power until you are totally familiar with its char-
acteristics.
•THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY.
Do not carry passengers on this machine.
•ALWAYS WEAR PROTECTIVE APPAREL.
When operating this machine, always wear an approved helmet with goggles or a face shield. Also
wear heavy boots, gloves, and protective clothing. Always wear proper fitting clothing that will not
be caught in any of the moving parts or controls of the machine.
•ALWAYS MAINTAIN YOUR MACHINE IN PROPER WORKING ORDER.
For safety and reliability, the machine must be properly maintained. Always perform the preopera-
tion checks indicated in this manual.
Correcting a mechanical problem before you ride may prevent an accident.
• GASOLINE IS HIGHLY FLAMMABLE.
Always turn off the engine while refueling. Take care to not spill any gasoline on the engine or ex-
haust system. Never refuel in the vicinity of an open flame, or while smoking.
•GASOLINE CAN CAUSE INJURY.
If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get
into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, imme-
diately wash skin areas with soap and water, and change your clothes.
•ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILATION.
Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are
poisonous. These fumes contain carbon monoxide, which by itself is odorless and colorless. Car-
bon monoxide is a dangerous gas which can cause unconsciousness or can be lethal.
• PARK THE MACHINE CAREFULLY; TURN OFF THE ENGINE.
Always turn off the engine if you are going to leave the machine. Do not park the machine on a slope
or soft ground as it_ may fall over.
•THE ENGINE, EXHAUST PIPE, MUFFLER, AND OIL TANK WILL BE VERY HOT AFTERTHE EN-
GINE HASfBEEN RUN.
Be careful not to touch them or to allow any clothing item to contact them during inspection or repair.
• PROPERLY SECURE THE MACHINE BEFORE TRANSPORTING IT.
For safety, drain the gasoline from thefuel tank before transporting the vehicle.
EAS10X3008
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
The following symbols are not relevant to every vehicle.
1
~ Serviceable with engine mounted
m Gear oil
1
~
Filling fluid Molybdenum disulfide oil
~
1
B Lubricant
A
Brake fluid
~
Special tool Wheel bearing grease
-Q»I
~
Lithium-soap-based grease
Tightening torque
~
~
Wear limit, clearance Molybdenum disulfide grease
-cM»t
1 1111
m Engine oil Replace the part with a new one.
EAS10X3007
:.-......:
·CUGll-""'""11"'
O..ol~-~ ... -
spwtglU•Ml.
Ctulch•Pflnll-lln!llh
__
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Cl.00...,(U31nl
._..,
2~
~-~
~Cll.ld'l~n•Ml
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...
thtpmwy-..io1
...
..lil"°"linUUI
--
·--
CffiCICINO THl PAHSUAI! PU.TI!
'·°'""*'
..
c.tietaNO TH! CWfCH KDUSINCI
~
.~...._ ......... c.--Root-
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"°"""lldova"'~ ... - . . . . _
TIP-- •Putrif0d1•t•
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~~---··-
•W.f1.111Wt.,-
•Pulf\«)Ct2'"•'"
•Bal'S"
~ ~-~
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' . -~rc1:.~..I~:L·· .-·'··
7
SiietCUIO TKE Cl.UTCH llOSll
-
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•CUd'lboee~
~--
TIP _ _ _ __ ...
Plt~cnV.ol&.Cc:hbou....,._"'1°""'9"'°
- 2-
•Pultlfadt~
......,
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......
~-~-~~~--
TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND ADJUST- 3
MENTS
TUNING 4
CHASIS 5
ENGINE 6
COOLING SYSTEM 7
FUEL SYSTEM 8
ELECTRICAL SYSTEM 9
TROUBLE SHOOTING 10
GENERAL INFORMATION
EASIOX3009
10 9
USA
1 7
l Premium unleaded
gasoline only.
3FB·2415E-02
I A WARNING
• BEFORE YOU OPERATE THIS VEHICLE, READ
THE OWNER'S MANUAL AND ALL LABELS.
• NEVER CARRY A PASSENGER. You increase
your risk of losing control if you carry a passenger.
6 •NEVER OPERATE THIS VEHICLE ON PUBLIC
ROADS. You can collide with another vehicle if
you operate this vehicle on a public road.
A WARNING
• ALWAYS WEAR AN APPROVED MOTORCYCLE
This unit contains high pressure nitrogen gas. HELMET, eye protection, and protective clothing.
Mishandling can cause explosion. • EXPERIENCED RIDER ONLY.
• Read owner's manual for instructions. SPA·2118K-OO
1-1
LOCATION OF IMPORTANT LABELS
CANADA
1 7
f
Premium unleaded
gasoline only.
3FB-2415E-02
I A WARNING
• BEFORE YOU OPERATE THIS VEHICLE, READ
THE OWNER'S MANUAL AND ALL LABELS.
• NEVER CARRY A PASSENGER. You increase
your risk of losing control if you carry a passenger.
• NEVER OPERATE THIS VEH ICLE ON PUBLIC
ROADS. You can collide with another vehic le if
2 you operate this vehicle on a public road.
•ALWAYS WEAR AN APPROVED MOTORCYCLE
HELMET, eye protection, and protective clothing.
Essence super sans J
•EXPERIENCED RIDER ONLY.
I plomb seulement.
5PA-2t 18K-OO
3FB-2415E·12
8
3
THIS VEHICLE IS A RESTRICTED USE
A AVERTISSEMENT
MOTORCYCLE AND IS NOT INTENDED FOR
USE ON PUBLIC HIGHWAYS.
• LIRE LE MANUEL DU PROPRIETAIRE AINSI QUE TOUTES LES
CE VEHICULE EST UNE MOTOCYCLETIE A
ETIOUETIES AVANT D'UTILISER CE VEHICULE.
USAGE RESTREINT OONT L'USAGE N'EST PAS • NE JAMAIS TRANSPORTER DE PASSAGER. La conduile avec
DESTINE AUX VOIES PUBLIOUES. passager augmente les risques de perte de conlr61e.
• NE JAMAIS ROULER SUR DES CHEMINS PUBLICS.
Yous pourriez entrer en collision avec un aUlre vehicule.
• TOUJOURS PORTER UN CASQUE DE MOTOCYCLISTE
APPROUVE, des lunetles et des vetemenls de protection.
4 • EXCLUSIVEMENT POUR L'USAGE D'UN CONDUCTEUR
EXPERIMENTE.
5PA·211BK·10
MFD. BYYAMl\HA tv'OTOR CO., LTD. MM/YY fv1ADE IN JAPAN
RESTRICTED-USE tv'OTORCYCI£
~ OOYMvW-WvOTffiCX\LTD. MM I YY FABROJE AU JAffi\J
11/0TU:YCLETTE A USAGE RESTREM
9
***************** 3PT·2118&-11
La pression des pneus a froid doil normalement
etre reglee comme suit.
AVANT: 100kPa, 1.00kgf/cm2, 15psi
ARRIERE : 1OOkPa, 1.OOk f/cm2 , 1Spsi
5 JRV-21668-BO
AAVERTISSEMENT
Cette unite contient de l'azote a haute pression.
Une mauvaise manipulation peut entrainer d'expiosion.
• Voir le manuel d'utilisateur pour les instructions.
• Ne pas brOler ni perforer ni ouvrir.
4AA·22259·70
1-2
DESCRIPTION
EASIOX3010
DESCRIPTION
1 2 3 4 5 6 7 8
J
9 10 11 12 13 17 18 19 20
16 15 14 24 23 22 21
1-3
CONSUMER INFORMATION
EAS1DX3011 EAS1DX3014
EAS1DX3012
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number "1" is
stamped into the right side of the frame.
EAS1DX3015
VEHICLE EMISSION CONTROL INFORMA-
TION LABEL
The Vehicle Emission Control Information label
"1 11 is affixed at the location in the illustration.
This label shows specifications related to ex-
haust emissions as required by federal law,
state law and Environment Canada.
[Al rnJ
EASIDX3013
ENGINE SERIAL NUMBER
A: For Canada
B: For USA and Canada
1-4
FEATURES
EAS20170
FEATURES
EAS1DX3016
OUTLINE OF THE Fl SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti-
mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera-
ture. In the conventional carburetor system, the air-fuel ratio of th~ mixture that is supplied to the
combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet
used in the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that me-
ter the fuel through the use of jets have been provided with various auxiliary devices, so that an op-
timum air-fuel ratio can be achieved to accommodate the constant changes in the operating
conditions of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase,
it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To ac-
commodate this need, this model has··adopted an electronically controlled fuel injection (Fl) system,
in place of the.conventional carburetor system. This system can achieve an optimum air-fuel ratio
required by the engine at all times by using a microprocessor that regulates the fu~ injection volume
according to the engine operating conditions detected by various sensors.
The adoption of the Fl system has resulted in a highly precise fuel supply, improved engine response,
better fuel economy' and reduced exhaust emissions.
1 2 3 4 5 6 7 8
11 10 9
1. Engine trouble warning light
2. Lean angle sensor
3. Fuel pump
4. Intake air pressure sensor
5. Fuel injector
6. Battery
7. Intake air temperature sensor
8. ECU (engine control unit)
9. Throttle position sensor
1O.Coolant temperature sensor
11.Crankshaft position sensor
12. Ignition coil
13.Speed sensor
1-5
FEATURES
EAS1DX3017
Fl SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at a certain level. Accordingly, when the energizing
signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be inject-
ed into the intake manifold only during the time the passage remains open. Therefore, the longer the
length of time the fuel injector is energized (injection duration), the greater the volume of fuel that is
supplied. Conversely, the shorter the length of time the fuel injector is energized (injection duration),
the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are 9ontrolled by the ECU. Signals that are input from
the throttle position sensor, coolant temperature sensor, atmospheric pressure sensor, lean angle
sensor, crankshaft position sensor, intake air pressure sensor and intake air temperature sensor en-
able the ECU to determine the injection duration. The injection timing is deterr:nined through the sig-
nals from the crankshaft position sensor. As a result, the volume of fuel that is required by the engine
can be supplied at all times in accordance with the driving conditions.
10
1. Fuel pump
2. Fuel injector
3. ECU (engine control unit)
4. Throttle position sensor
5. Coolant temperature sensor
6. Crankshaft position sensor
7. Intake air pressure sensor
8. Throttle body
9. Intake air temperature sensor
1a.Air filter case
A. Fuel system
B. Intake system
C. Control system
1-6
INCLUDED PARTS
EAS10X3018 EAS1DX3022
t?l@§.§1~~~~~~~~~
In this installation, make sure the arrow fac-
es the fuel tank and also downward.
EAS10X3023
HOOK (FUEL TANK)
The hook tank 11 111 is used to support the fuel
tank during maintenance.
EAStDX3020
EAS10X3024
FUEL HOSE JOINT COVER
The fuel hose joint covers 11 1" are used to pre-
vent mud, dust, and other foreign material from
entering the fuel pump when the fuel hose is
disconnected.
EASIOX3021
NIPPLE WRENCH
This nipple wrench "1 11 is used to tighten the
spoke.
1-7
IMPORTANT INFORMATION
EASIOX3025 EAS20180
tional Power Tuner and so on. PREPARATION FOR REMOVAL AND DIS-
ECA IOX1002 ASSEMBLY
NOTICEj _ _ _ _ _ _ _ _ _ _ __ 1. Before removal and disassembly, remove all
When no optional parts, etc. ar~ connected, dirt, mud, dust and foreign material.
connect the connection terminal to the orig-
inal coupler.
Before removing the coupler, thoroughly
wipe off any mud or water stuck to it.
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
1-8
IMPORTANT INFORMATION
EAS1DX3030
BEARINGS AND OIL SEALS
Install bearings "1" and oil seals "2" so that the
manufacturer marks or numbers are visible.
When installing oil seals, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
ECA13300
?Alo_T:iat=ii
=~·~~~~~------------
Do not spin the bearing with compressed air
EAS1DX302B
because this will damage the bearing sur-
GASKETS, OIL SEALS AND 0-RINGS faces.
1. When overhauling the engine, replace all
gaskets, seals and 0-rings. All gasket sur-
faces, oil seal lips and 0-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
1
1. Oil
4
..
2. Lip
3. Spring
4. Grease
EAS1DX3029 EASIDX3031
1-9
BASIC SERVICE INFORMATION
EAS1DX3032
Rivet type
1. Remove:
•Quick fastener
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
To remove the quick fastener, push its pin with
a screwdriver, then pull the fastener out.
Screw type
1. Remove:
• Quick fastener
TIP _ _ _~---~-~----
TQ remove the quick fastener, loosen the screw
~ with a screwdriver, then pull the fastener out.
1--"
2. Install:
• Quick fastener
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the part to be secured and
2. Install:
push the pin in with a screwdriver. Make sure
•Quick fastener
that the pin is flush with the fastener's head.
TIP-------~---~-
To install the quick fastener, insert the fastener
into the part to be secured and tighten the
1IT screw.
ill·~
1-10
BASIC SERVICE INFORMATION
rn.~
[]]
TIP~~~~~~~~~~~~~~~
-,',
:~
EAS1DX3034
ELECTRICAL SYSTEM
ECA16751
~~~~~~~~~~- ECA16nt
When disconnecting the battery leads from
.,,,~~~~~~~~~
the battery, be sure to disconnect the nega-
When connecting the battery leads to the
tive battery lead first, then the positive bat-
battery, be sure to connect the positive bat-
tery lead. If the positive battery l~a~ is . tery lead first, then the negative battery
disconnected first and a tool or s1m1lar item lead. If the negative battery lead is connect-
contacts the vehicle, a spark could be gen- ed first and a tool or similar item contacts
erated, which is extremely dangerous.
the vehicle while the positive battery lead is
being connected, a spark could be generat-
ed, which is extremely dangerous.
1-11
BASIC SERVICE INFORMATION
ECA16610 TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
wrlaYic~
:.a+··-~-·~...,.,,..··~------------ When resetting the ECU by turning the main
TUrn the main switch to "OFF" before dis-
switch to "OFF", be sure to wait approximately
connecting or connecting an electrical com-
5 seconds before turning the main switch back
ponent.
to"ON".
IGNmON
ECA16620
ECA16630
1-12
BASIC SERVICE INFORMATION
ECA16640 ECA16790
ii~~~~~~~~~~~~~~ -J~~~~~~~~
For waterproof couplers, never insert the When disconnecting a connector, do not
tester probes directly into the coupler. pull the leads. Hold both sections of the
When performing any checks using a water- connector securely, and then disconnect
proof coupler, use the specified test har- the connector.
ness or a suitable commercially available
test harness.
2. Check:
•Lead
•Coupler
Checking the connections •Connector
Check the leads, couplers, and connectors for Moisture ---+ Dry with an air blower.
stains, rust, moisture, etc. Rust/stains ~ Connect and disconnect sev-
1. Disconnect: eral times.
•Lead
•Coupler
•Connector
ECA16780
111tlll~~~~~~~~
• When disconnecting a coupler, release the
coupler lock, hold both sections of the
coupler securely, and then disconnect the
coupler.
• There are many types of coupler locks;
therefore, be sure to check the type of cou- 3. Check:
pler lock before disconnecting the cou- • All connections
pler. Loose connection ---+ Connect properly.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
• If the pin "1" on the terminal is flattened, bend
it up.
• After disassembling and assembling a cou-
pler, pull on the leads to make sure that they
are installed securely.
1-13
BASIC SERVICE INFORMATION
5. Check:
•Continuity
(with the pocket tester)
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
TIP _ _ _ _ _ _ _ _ _ _ _ __
4. Connect:
•Lead
•Coupler
•Connector
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
1-14
SPECIAL TOOLS
EAS1DX3035
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 tech-
niques. The shape and part number used for the special tool differ by country, so two types are pro-
vided. Refer to the list provided to avoid errors when placing an order.
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
•For U.S.A. and Canada, use part number starting with "YM-", "YU-", or "ACC-".
•For others, use part number starting with "90890-".
Reference
Tool name/Part number Illustration
pages
Crankshaft installer pot 6-69
90890-01274
90890-01274
Installing pot
Y.U-90058
YU-90058/YU-90059
Bolt
YU-90060
YU-24460-01
1-15
SPECIAL TOOLS
1-16
SPECIAL TOOLS
Reference
Tool name/Part number Illustration
pages
Digital circuit tester 9-77
90890-03174
Model 88 Multimeter with tachometer
YU-A1927
1-17
SPECIAL TOOLS
YM-91044
YM-91042
·~
YM-04098
05
04.5
1-18
SPECIAL TOOLS
Reference
Tool name/Part number Illustration
pages
Valve guide installer (04.5) 6-21
90890-04117
YM-04117
4.Smm
Rotor puller M33xP1.5 6-59
~o
90890-04142
YM-04142
Ignition checker
~ 9-71
90890-06754
Oppama pet-4000 spark checker
YM-34487
~~
90890-06760
YU-39951-B
1-19
CONTROL FUNCTIONS
EAS1DX3036
CONTROL FUNCTIONS
EASIDX3037
MAIN SWITCH
C-
EAS1DX3039
with the engine turned off, otherwise the ENGINE STOP SWITCH
battery may discharge to the point that the The engine stop switch 11 111 is located on the left
starter motor will not operate properly. handlebar. Continue pushing the engine stop
switch till the engine comes to a stop.
EAS1DX3038
INDICATOR LIGHTS AND WARNING
LIGHTS
1-20
CONTROL FUNCTIONS
EAS1DX3040 EAS1DX3043
EAS1DX3041
CLUTCH LEVER
The clutch lever 11 111 is located on the left han-
dlebar; it disengages or engages the clutch.
Pull the clutch lever to the handlebar to disen-
gage the clutch, and release the lever to en- EAS1DX3044
gage the clutch. The lever should be pulled THROTTLE GRIP
rapidly and released slowly for smooth starts. The throttle grip 11 1 11 is located on the right han-
dlebar; it accelerates or decelerates the en-
gine. For acceleration, turn the grip toward you;
for deceleration, turn it away from you.
EAS1DX3042
SHIFT PEDAL
The gear ratios of the constant-mesh 5 speed
transmission are ideally spaced. The gears can EAS10X3045
be shifted by using the shift pedal 11 1 11 on the left FRONT BRAKE LEVER
side of the engine. The front brake lever "1 11 is located on the right
handlebar. Pull it toward the handlebar to acti-
vate the front brake.
1-21
MULTl-FUNCTION DISPLAY
EAS1DX3046 EASIOX3049
EAS1DX3050
DESCRIPTION
EAS1DX3048
Operation buttons:
11
STARTER KNOB/IDLE ADJUSTING SCREW 1. Select button "SLCT 1
11
2. Select button "SLCT 2
11 11
3. Reset button RST
Screen display:
4. Tripmeter indicator fiJ
5. Tripmeter indicator m
6. Timer indicator fl
7. Clock/Timer
8. Speedometer (Current speed/Average
speed)
9. Tripmeter
1 . Starter knob/idle adjusting screw 1a.Average speed indicator g
Starting a cold engine requires a richer air-fuel
mixture, which is supplied by the starter.
Move the knob in direction "a" to turn on the
starter.
Move the knob in direction "b" to turn off the
starter.
1-22
MULTl-FUNCTION DISPLAY
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
I
The operation buttons can be pushed in the fol- T
lowing two manners:
8\SLCT1 I IIC.•U
'='·no-nn
·UU I
Short push: Push the button. (c::::>) T
Long push: Push the button for 2 seconds or ISLCT2 I
more.(~)
,.
' I / 'I/
-12-
/ •' RST
-
-DD-
/ I '
EAS1DX3051
BASIC MODE
.-,LI
2 seconds or more.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
1SLCT1 I
8 T
SLCT2
inn
IU.U MPH
• In a 30-second absence of button operation,
the setting will come to an end with the indi-
cated time.
•To reset the seconds, push the 11 SLCT1 11 but-
1cn
,-,LI ton or 11 SLCT2 11 button.
1-23
MULTl-FUNCTION DISPLAY
SLCT2 I
1
I
'
I
' \
\
\
\ Initial setting
I value
, (700mm)
f
709mm
tifier that shows RACE MODE has been se-
lected.
• RACE MODE cannot display the functions as
in BASIC MODE.
l
I
• Changeover to RACE MODE forces the digits
fortripmeter A (TRIP A) in BASIC MODE to be
reset.
2. Push the "SLCT1 11 button and "RST11 button
for 2 seconds or more at the same time to
enter tire diameter setting mode.
1-24
MULTl-FUNCTION DISPLAY
,_,,...,
start measurement on standby causing fj , fiJ
, B, and the average speed display to flash.
(For manual start, refer to 11 Putting measure- 12:00:00
ment on standby 11 in 11 RACE MODE 11 .) m nn
u.u MPH
m
JC':QO:[ID
1nr1
,-,LI EAS1DX3053
RACE MODE
, u.u MPH Putting measurement on standby
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Starting measurement consists of the following
two starts, either of which can be selected.
,., • Manual start
1-1-
8 [SLCT2] -,m-•'
~ -o-n.nn-nn Starting measurement by the rider himself op-
~I~ U·UU·UU - erating the button. (A long push on the 11 SLCT2 11
'' '' , • , Lt, button will put measurement on standby.)
u. u -;tDftmt'H I
•Auto start
Starting timer measurement automatically on
Returning to BASIC MODE from RACE detection of the movement of the machine. (A
MODE long push on the 11 SLCT1 11 button will put mea-
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ surement on standby.)
It is possible to return to BASIC MODE with tim- Manual start
er measurement at a stop. TIP _ _ _ _ _ _ _ _ _ _ _ _ __
1. Check that the timer is not in operation. If the Initial setting at changeover to RACE MODE
timer is in operation, stop the timer by push- will remain for manual start.
ing the 11 SLCT1 11 button and 11 SLCT2 11 button 1. Check that changeover to RACE MODE has
at the same time. been made. (Refer to 11 Changeover from BA-
SIC MODE to RACE MODE 11 .)
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
,,,
11 11
2. Push the SLCT1 button and SLCT2 but- 11 11 QISLCTl I -o-n.nn-nn
v::J ~I~ U·UU·UU - 1:..,' -
ton for 2 seconds or more at the same time l...--s-LC-T2--.I ~ m,- [I [I , •, Lt,
to change over to BASIC MODE. I • ~(HI
1-25
MULTl-FUNCTION DISPLAY
1 SLCT1 I 0 U·n. I·s·nO ,.,., ,~, 5. To resume the measurement, again pushing
8I SLCT2 I liJ
•UD '9
103 _JLI
• fOBMPH
11
the SLCT1 11 button and "SLCT2 11 button at
the same time.
When the measurement is made ready for a Resetting average speed (AVS)
run by auto start, fj , s
,.~,and the aver- 1. Check that the timer is in operation. If the
age speed display will start flashing. Timer dis- timer is not in operation, start the timer by
play will turn on scrolling from left to right. pushing the 11 SLCT1 11 button and 11 SLCT2 11
button at the same time.
2. Reset the average speed display by pushing
the "RST11 button.
C\ ISLCT1 I ~;;_ n-nn-nn
C,) ~ l~ U·UU·UU
-r
- 1 -
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
ISLCT2 I : s,- Oun , ,, LI, If reset, • and the average speed display
' • -,fil'ftm(H I will go on flashing for four seconds.
' ~
C\lsLcn I
-0 ... --------------1 ,....., ~ ISLCT2 I
~,~00000 : - -
~~.:------·arr:J.,, Lt,
• ~"'"4 I
3. Run the machine and start timer measure-
ment.
4. To stop timer measurement, pushing the
"SLCT1 11 button and 11 SLCT2" button at the
same time.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
1-26
MULTl-FUNCTION DISPLAY
alsLCT1 I
~ ISLCT2 I fJ
IQ3
_nn,
'I /
,-,
-. ,-
1 / ._
10. '-I EB
/
u.u,flW:j'J I '
I /I'-
/Q218
Resetting average speed (AVS), tripmeter A
(TRIP A) and timer Correcting tire diameter
1. Check that the timer is not in operation. If the TIP _ _ _ _ _ _ _ _ _ _ _ _ __
timer is in operation, stop it by pushing the
• Correction can be made any time while timer
11
SLCT1" button and 11 SLCT2" button at the
measurement is or is not being made.
same time.
• Change in the travel distance display will be
2. Reset all measured data by pushing the
accompanied by the change in the tire•s dia-
11
RST 11 button for 2 seconds or more.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ metric percentage.
• Even back in BASIC MODE, the tire diameter
• Resetting will reset the timer display, travel set in RACE MODE will be retained.
distance display, and average speed display • Correction to the tire diameter is impossible if
and put measurement on standby. the tripmeter indicates 11 0 11 •
• Auto start attempt will put measurement on • If the machine is run while the tire diameter is
standby as such. Likewise, manual start at- being corrected, the tire's diametric correction
tempt will put measurement on standby as will be cancelled forcedly.
such. 11
1. Push the SLCT1 11 button and "Rsr· button
for 2 seconds or more at the same time and
~~
@'SlCTl I os n. '51n·ng:f
LI· I ·U ,.. 1-1
t-
...1LI
enter tire diameter correction mode.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
ISLCT2 I IU.3 fN§MPH Changeover to tire correction mode will cause
the timer display to change and show the dia-
!
,_,,,
metric digit of the tire.
1-27
MULTl-FUNCTION DISPLAV
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
8
tJ
IQS EB
!t"U"l",;-
.H: ti..
ft...,d.•
10.l/ 8
3. Push the SLCT1 button and RST11 button
11 11 11
1-28
MULTl-FUNCTION DISPLAY
EAS1DX3054
FUNCTION DIAFRAM
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
The following diagram illustrates the multi-function display regarding the direction and operation con-
dition involved in each of its functions.
A short push on the button changes the opera-
tion in the arrowed direction.
A short push on the button changes the opera-
C) Meter function
tion in both arrowed directions. ~ Function that can be performed whether the time is or is
~ not in operation.
A long push on the button changes the operation
in the arrowed direction.
A long push on the button changes the operation ~ Extent to which the meter can operate
BASIC MODE
current speed
SLCT1 + SLCT2
SLCT1 + SLCT2
Putting measurement on
standby
SLCT1
AST
"'11••
~- SLCT2
'8 rllll•••••
,•''
Auto start
,/
8
SLCT1 + SLCT2
SLCT1+RST'
1-29
STARTING AND BREAK-IN
EAS1DX3055 EWA1DX1004
EAS1DX3056
Gasoline is poisonous and can cause injury
FUEL or death. Handle gasoline with care. Never
Make sure there is sufficient gasoline in the siphon gasoline by mouth. If you should
tank. swallow some gasoline or inhale a lot of
EWA1DX1003 gasoline vapor, or get some gasoline in
A WARNING your eyes, see your doctor immediately. If
Gasoline and gasoline vapors are extremely gasoline spills on your skin, wash with soap
flammable. To avoid.fires and explosions and water. If gasoline spills on your cloth-
and to reduce the risk of injury when refuel- ing, change your clothes.
ing, follow these instructions.
Recommended fuel:
1. Before refueling, turn off the engine and be Premium unleaded gasoline
sure that no one is sitting on the vehicle. only
Never refuel while smoking, or while in the Fuel tank capacity:
vicinity of sparks, open flames, or other 7.5 L (1.98 US gal, 1.65 Imp.gal)
sources of ignition such as the pilot lights of Fuel reserve amount (when the
water heaters and clothes dryers. fuel level warning light comes
2. Do not overfill the fuel tank. Stop filling when on):
the fuel reaches the bottom of the filler tube. 3.0 L (0. 79 US gal, 0.66 Imp.gal)
Because fuel expands when it heats up, ECA1DX1004
-·~~~~~~~~~
heat from the engine or the sun can cause
fuel to spill out of the fuel tank.
Use only unleaded gasoline. The use of
leaded gasoline will cause severe damage
to internal engine parts, such as the valves
and piston rings, as well as to the exhaust
system.
Your Yamaha engine has been designed to use
premium unleaded gasoline with a pump oc-
tane number [(R+M)/2] of 91 or higher, or a re-
search octane number of 95 or higher. If
knocking (or pinging) occurs, use a gasoline of
a different brand. Use of unleaded fuel will ex-
1. Fuel tank filler tube
2. Maximum fuel level tend spark plug life and reduce maintenance
costs.
3. Wipe up any spilled fuel immediately. NO-
Gasohol
TICE: Immediately wipe off spilled fuel
There are two types of gasohol: gasohol con-
with a clean, dry, soft cloth, since fuel
taining ethanol and that containing methanol.
may deteriorate painted surfaces or plas-
Gasohol containing ethanol can be used if the
tic parts.
ethanol content does not exceed 10%. Gasohol
4. Be sure to securely close the fuel tank cap.
containing methanol is not recommended by
Yamaha because it can cause damage to the
fuel system or vehicle performance problems.
1-30
STARTING AND BREAK-IN
h;.NfJ7!/PEfF TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
~14'¥1~1-------------
• Unlike a two-stroke engine, this engine Use the kickstarter in a condition with ambient
cannot be kick started when the throttle is temperature below-5 °C (40 °F) or high alti-
open because the kickstarter may kick tude.
back. Also, if the throttle is open the air/ If the engine fails to start when using the
fuel mixture may be too lean for the engine start switch, release it, wait a few seconds,
to start. and then try again.
• Before starting the machine, perform the Each starting attempt should be as short as
checks in the pre-operation check list. possible to preserve the battery. Do not
crank the engine more than 1Oseconds on
EAS1DX3058
AIR FILTER MAINTENANCE any one attempt. If the engine does not start
According to "CLEANING THE AIR FILTER with the starter motor, try using the kickstart-
ELEMENT" section in the CHAPTER 3, apply er.
the foam-air-filter oil or its equivalent to the ele- 5. When the engine is warm, turn the starter
ment. (Excess oil in the element may adversely off.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
affect engine starting.)
The engine is warm when it responds quickly to
EAS1DX3059
STARTING A COLD ENGINE the throttle with the starter turned off.
In order for the ignition circuit cut-off system to ECA1DX1008
1RJ.n;;.:v.~
manes
f:'ft·~·'';i:d...~~-------------
• If the engine does not start at high altitude,
start the engine with the throttle grip opened
lf the warning light does not come on initial- by one degree or two degrees.
ly when the main switch is pushed to "ON", • The mark on the throttle housing indicates five
or if the warning light remains on, have a degrees. Use the mark for your reference
Yamaha dealer check the electrical circuit. when opening the throttle grip.
2. Shift the transmission into the neutral posi-
tion. The neutral indicator light should come
on. If not, ask a Yamaha dealer to check the
electrical circuit.
3. Turn the starter on and completely close the
throttle.
1-31
STARTING AND BREAK-IN
ECA1DX1009
t~~~~~~~~
1 • After the break-in or before each race, you
must check the entire machine for loose
fittings and fasteners as per 11 TORQUE-
CHECK POINTS". Tighten all such fasten-
ers as required.
• When any of the following parts have been
replaced, they must be broken in.
1. Mark CYLINDER AND CRANKSHAFT:
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ About one hour of break-in operation is
necessary.
If the engine fails to start, give the kickstarter 10 PISTON, RING, VALVES, CAMSHAFTS
to 20 slow kicks at full throttle in order to clear AND GEARS:
the engine of the rich air-fuel mixture retained in These parts require about 30 minutes of
it. break-in operation at half-throttle or less.
Observe the condition of the engine care-
EAS1DX3061 fully during operation.
BREAK-IN PROCEDURES
1. Before starting the engine, fill the fuel tank
with the fuel.
2. Perform the pre-operation checks on the
machine.
3. Start and warm up the engine. Check the
idle speed, and check the operation of the
controls and the engine stop switch. Then,
restart the engine and check its operation
within no more than 5 minutes after it is re-
started.
4. Operate the machine in the lower gears at
moderate throttle openings for five to eight
minutes.
5. Check how the engine runs when the ma-
chine is ridden with the throttle 1/4 to 1/2
open {low to medium speed) for about one
hour.
6. Restart the engine and check the operation
of the machine throughout its entire operat-
ing range. Restart the machine and operate
it for about 10 to 15 more minutes. The ma-
chine will now be ready to race.
1-32
TORQUE-CHECK POINTS
EAS1DX3062
TORQUE-CHECK POINTS
Frame construction Frame to rear frame
Combined seat and fuel tank Fuel tank to frame
Exhaust system Silencer to rear frame
Engine mounting Frame to engine
Engine bracket to engine
Engine bracket to frame
Steering Steering stem to handlebar Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Suspension Front Steering stem to front fork Front fork to upper bracket
Front fork to lower bracket
Rear For link type Assembly of links
Link to frame
Link to rear shock absorber
Link to swingarm
Installation of rear shock absorber Rear shock absorber to frame
Installation of swingarm Tightening of pivot shaft
Wheel Installation of wheel Front Tightening of wheel axle
Tightening of axle holder
Rear Tightening of wheel axle
Wheel to rear wheel sprocket
Brake Front Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to handle-
bar
Tightening of bleed screw
Tightening of brake hose holder
Rear Brake pedal to frame
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw
Tightening of brake hose holder
Fuel system Fuel pump to fuel tank
Lubrication system Tightening of oil hose clamp
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
1-33
MOTORCYCLE CARE AND STORAGE
EAS1DX3063
• Do not use any harsh chemical products
MOTORCYCLE CARE AND STOR- on plastic parts. Be sure to avoid using
AGE cloths or sponges which have been in con-
tact with strong or abrasive cleaning prod-
EAS1DX3064
ucts, solvent or thinner, fuel (gasoline),
CARE
rust removers or inhibitors, brake fluid,
While the open design of a motorcycle reveals
antifreeze or electrolyte.
the attractiveness of the technology, it also
•Do not use high-pressure washers or
makes it more vulnerable. Rust and corrosion
steam-jet cleaners since they cause water
can develop even if high-quality components
seepage and deterioration in the following
are used. A rusty exhaust pipe may go unno-
ticed on a car, however, it detracts from the
areas: seals (of wheel and swingarm bear-
overall appearance of a motorcycle. Frequent
ings, fork and brakes), electric compo-
and proper care does not only comply with the
nents (couplers, connectors, instruments,
terms of the warranty, but it will also keep your
switches and lights), breather hoses and
vents.
motorcycle looking good, extend its life and op-
• For motorcycles equipped with a wind-
timize its performance.
shield: Do not use strong cleaners or hard
Before cleaning sponges as they will cause dulling or
1. Cover the muffler outlet with a plastic bag af- scratching. Some cleaning compounds for
ter the engine has cooled down. plastic may leave scratches on the wind-
2. Make sure that all caps and covers as well shield. Test the product on a small hidden
as all electrical couplers and connectors, in- part of the windshield to make sure that it
cluding the spark plug cap, are tightly in- does not leave any marks. If the wind-
stalled. shield is scratched, use a quality plastic
3. Remove extremely stubborn dirt, like oil polishing compound after washing.
burnt onto the crankcase, with a degreasing
agent and a brush, but never apply such After normal use
products onto seals, gaskets, sprockets, the Remove dirt with warm water, a mild detergent,
drive chain and wheel axles. Always rinse and a soft, clean sponge, and then rinse thor-
the dirt and degreaser off with water. oughly with clean water. Use a toothbrush or
bottlebrush for hard-to-reach areas. Stubborn
Cleaning dirt and insects will come off more easily if the
ECA1DX1010
area is covered with a wet cloth for a few min-
t••~~~~~~~~-
• Avoid using strong acidic wheel cleaners,
utes before cleaning .
especially on spoked wheels. If such prod- After riding in the rain, near the sea or on salt-
ucts are used on hard-to-remove dirt, do sprayed roads
not leave the cleaner on the affected area Since sea salt or salt sprayed on roads during
any longer than instructed. Also, thor- winter are extremely corrosive in combination
oughly rinse the area off with water, imme- with water, carry out the following steps after
diately dry it, and then apply a corrosion each ride in the rain, near the sea or on salt-
protection spray. sprayed roads.
• Improper cleaning can damage plastic TIP~~~~~~~~~~~~~~-
parts (such as cowlings, panels, wind-
Salt sprayed on roads in the winter may remain
shields, headlight lenses, meter lenses,
well into spring.
etc.) and the mufflers. Use only a soft,
clean cloth or sponge with water to clean 1. Clean the motorcycle with cold water and a
plastic. However, if the plastic parts can- mild detergent, after the engine has cooled
not be thoroughly cleaned with water, di- down.
luted mild detergent with water may be NOTICE: Do not use warm water since it
used. Be sure to rinse off any detergent increases the corrosive action of the salt.
residue using plenty of water, as it is
harmful to plastic parts.
1-34
MOTORCYCLE CARE AND STORAGE
2. Apply a corrosion protection spray on all the headlight on for a short period of time will
metal, including chrome- and nickel-plated, help remove the moisture from the lens.
surfaces to prevent corrosion.
EAS1DX3065
1-35
MOTORCYCLE CARE AND STORAGE
1-36
SPECIFICATIONS
EAS1DX3066
GENERAL SPECIFICATIONS
Model
Model 1DX3 (USA)
1DX4 (CANADA)
Dimensions
Overall length 2160 mm (85.0 in)
Overall width 825 mm (32.5 in)
Overall height 1275 mm (50.2 in)
Seat height 960 mm (37.8 in)
Wheelbase 1465 mm (57.7 in)
Ground clearance 335 mm (13.19 in)
Weight
Curb weight 124 kg (273 lb)
2-1
ENGINE SPECIFICATIONS
EAS1DX3067
ENGINE SPECIFICATIONS
Engine
Engine type Liquid cooled 4-stroke, DOHC
Displacement 449 cm3
Cylinder arrangement Forward-inclined single cylinder
Bore x stroke 95.0 x 63.4 mm (3. 74 x 2.50 in)
Compression ratio 12.30 :1
Starting system Electric starter and kickstarter
Fuel
Recommended fuel Premium unleaded gasoline only
Fuel tank capacity 7.5 L (1.98 US gal, 1.65 Imp.gal)
Fuel reserve amount
(when the fuel level warning light comes on) 3.0 L (0.79 US gal, 0.66 Imp.gal)
Engine oil
Lubrication system Dry sump
Recommended brand YAMALUBE
Type SAE 1OW-40, SAE 1OW-50, SAE 15W-40,
SAE 20W-40 or SAE 20W-50
Recommended oil grade API service SG type or higher,
JASO standard MA
Engine oil quantity
Quantity (disassembled) 1.20 L (1.27 US qt, 1.06 Imp qt)
Without oil filter element replacement 0.95 L (1.00 US qt, 0.84 Imp qt)
With oil filter element replacement 1.00 L (1.06 US qt, 0.88 Imp qt)
Oil filter
Oil filter type Paper
Bypass valve opening pressure 40.0--80.0 kPa (0.40--0.80 kgf/cm2,
5.8-11.6 psi)
Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance Less than 0.120 mm (0.0047 in)
Limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.090--0.170 mm (0.0035-0.0067 in)
Limit 0.24 mm (0.0094 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.05-0.1 O mm (0.0020-0.0039 in)
Limit 0.17 mm (0.0067 in)
Cooling system
Radiator capacity (including all routes) 1.04 L (1.10 US qt, 0.92 Imp.qt)
Radiator capacity 0.63 L (0.67 US qt, 0.55 mp.qt)
Radiator cap opening pressure 107.9-137.3 kPa (1.08-1.37 kgf/cm2,
15.6-19.9 psi)
Radiator core
Width 121.4 mm (4.78 in)
Height 280.0 mm (11.02 in)
Depth 28.0 mm (1.10 in)
Water pump
Water pump type Single suction centrifugal pump
2-2
ENGINE SPECIFICATIONS
Spark plug
Manufacturer/model NGK/CASE
Spark plug gap 0.7-0.8 mm (0.028-0.031 in)
Cylinder head
Volume 22.75-23.55 cm3 (1.39-1.44 cu.in)
Warpage limit 0.10 mm (0.0039 in)
Camshaft
Drive system Chain drive (left)
Camshaft cap inside diameter 22.000-22.021 mm (0.8661-0.8670 in)
Camshaft journal diameter 21.959-21.972 mm (0.8645-0.8650 in)
Camshaft-journal-to-camshaft-cap clearance 0.028-0.062 .mm (0.0011-0.0024 in)
Camshaft lobe dimensions
Intake A 30.100-30.200 mm (1.1850-1.1890 in)
Limit 30.000 mm (1.1811 in)
Intake B 22.450-22.550 mm (0.8839-0.8878 in)
Limit 22.350 mm (0.8799 in)
Exhaust A 30.200-30.300 mm (1.1890-1.1929 in)
Limit 30.100 mm (1.1850 in)
Exhaust B 22.450-22.550 mm (0.8839-0.8878 in)
Limit 22.350 mm (0.8799 in)
B
Camshaft runout limit 0.015 mm (0.0006 in)
Timing chain
Tensioning system Automatic
Valve, valve seat, valve guide
Valve clearance (cold)
Intake 0.10-0.15 mm (0.0039-0.0059 in)
Exhaust 0.20-0.25 mm (0.0079-0.0098 in)
Valve dimensions.
Valve head diameter A (intake) 26.90-27.10 mm (1.0591-1.0669 in)
Valve head diameter A (exhaust) 27.90-28.10 mm (1.0984-1.1063 in)
()A\_, 1
2-3
ENGINE SPECIFICATIONS
6~
Valve seat width C (intake} 0.90-1.1 O mm (0.0354-0.0433 in)
Valve seat width C (exhaust} 0.90-1.1 O mm (0.0354-0.0433 in}
~
Valve margin thickness D (intake) 1 .00 mm (0.0394 in)
Valve margin thickness D (exhaust) 1.00 mm (0.0394 in}
b-10
Limit '
Valve stem diameter (intake)
Valve spring
Free length (intake) 39.46 mm (1.55 in)
Limit 38.46 mm (1.51 in)
Free length (exhaust) 37.61 mm (1.48 in)
Limit 36.61 mm (1.44 in)
Installed length (intake} 27.87 mm (1.10 in)
Installed length (exhaust} 28.38 mm (1.12 in)
Spring rate K1 (intake) 12.08 N/mm (1.23 kgf/mm, 68.98 lb/in)
Spring rate K2 (intake) 16.01 N/mm (1.63 kgf/mm, 91.42 lb/in)
Spring rate K1 (exhaust) 14.34 N/mm (1.46 kgf/mm, 81.88 lb/in)
Spring rate K2 (exhaust) 18.59 N/mm (1.90 kgf/mm, 106.15 lb/in)
Installed compression spring force (intake) 130.20-149.80 N (13.28-15.28 kgf,
29.27-33.68 lbf)
Installed compression spring force (exhaust) 123.10-141.70 N (12.55-14.45 kgf,
27.67-31.85 lbf)
2-4
ENGINE SPECIFICATIONS
II
~
Winding direction (intake) Clockwise
Winding direction (exhaust) Clockwise
Cylinder
Bore 95.000-95.010 mm (3.7402-3.7405 in)
Taper limit 0.050 mm (0.0020 in)
Out of round limit 0.050 mm (0.0020 in)
Piston
Piston-to-cylinder clearance 0.020-0.045 mm (0.0008-0.0018 in)
Limit 0.15 mm (0.006 in)
Diameter D 94.965-94.980 mm (3.7388-3.7394 in)
Height H 8.0 mm (0.31 in)
--- ~H
Offset 1.00 mm (0.0394 in)
Offset direction Intake side
Piston pin bore inside diameter 18.004-18.015 mm (0. 7088-0. 7093 in)
Limit 18.045 mm (0. 7104 in)
Piston pin outside diameter 17.991-18.000 mm (0.7083-0.7087 in)
Limit 17.971 mm (0.7075 in)
Piston-pin-to-piston-pin-bore clearance 0.004-Q.024 mm (0.00016-0.00094 in)
Piston ring
Top ring
Ring type Barrel
Dimensions (B x T) 1.20 x 3.50 mm (0.05 x 0.14 in)
E31B
End gap (installed) 0.20-0.30 mm (0.0079-0.0118 in)
Limit 0.55 mm (0.0217 in)
Ring side clearance 0.030-0.065 mm (0.0012-0.0026 in)
Limit 0.115 mm {O.OQ45 in)
2nd ring
Ring type Taper
Dimensions (B x T) 1.00 x 3.35 mm (0.04 x 0.13 in)
.__S]e
T I
2-5
ENGINE SPECIFICATIONS
~Je
I T I
End gap (installed) 0.20-0.50 mm (0.0079-0.0197 in)
Crankshaft
Width A 61.95-62.00 mm (2.439-2.441 in)
Runout limit C 0.030 mm (0.0012 in)
Big end side clearance D 0.150-0.450 mm (0.0059-0.0177 in)
Balancer
Balancer drive method Gear
Clutch
Clutch type Wet, multiple-disc
Clutch release method Inner push, cam push
Clutch lever free play 8.0-13.0 mm (0.31-0.51 in)
Friction plate thickness 2.92-3.08 mm (0.115-0.121 in)
Wear limit 2.82 mm (0.1110 in)
Plate quantity 8 pcs
Clutch plate 1 thickness 1.90-2.10 mm (0.075-0.083 in)
Plate quantity 4pcs
Warpage limit 0.10 mm (0.0039 in)
Clutch plate 2 thickness 1.50-1.17 mm (0.059-0.067 in)
Plate quantity 3 pcs
Warpage limit 0.1 O mm (0.0039 in)
Clutch spring free length 50.00 mm (1.97 in)
Minimum length 49.00 mm (1.93 in)
Spring quantity 6pcs
Push rod bending limit 0.100 mm (0.0039 in)
Transmission
Transmission type Constant mesh 5-speed
Primary reduction system Spur gear
Primary reduction ratio 2.652 (61/23)
Final drive Chain
Secondary reduction ratio 3.846 (50/13)
Operation Left foot operation
2-6
ENGINE SPECIFICATIONS
Gear ratio
1st 2.417 (29/12)
2nd 1.733 (26/15)
3rd 1.313 (21/16)
4th 1.050 (21 /20)
5th 0.840 (21/25)
Shifting mechanism
Shift mechanism type Shift drum and guide bar
Shift fork guide bar bending limit 0.050 mm (0.0020 in)
Shift fork thickness 4.85 mm (0.1909 in)
Decompression device
Device type Auto decomp
Air filter
Air filter element Wet element
Air filter oil grade Foam air-filter oil
Fuel pump
Pump type Electrical
Fuel injector
Model/quantity 1010/1
Resistance 12.on
Throttle body
Type/quantity 30RA/1
ID mark 1DX310
Fuel line pressure (at idle) 300.0-390.0 kPa (3.00-3.90 kgf/cm2 ,
43.5-56.6 psi)
Throttle position sensor
Thrott~e position sensor resistance s.okn
Throttle position sensor output voltage 0.48-0.52 v
Fuel injection sensor
Crankshaft position sensor resistance 248-372 n
Intake air pressure sensor output voltage 3. 75--4.25 v
Intake air temperature sensor resistance 5.40-6.60 kn at o 0 c (32 °F) 290-390 n
at 80 °C (176 °F)
Coolant temperature sensor resistance 2.51-2.78 kn at 20°c (68°F) 210-221 n
at 100°C (212°F)
Idling condition
Engine idling speed 1900-2100 r/min
CO% 0.5-1.5 %
Intake vacuum 32.1-36.1 kPa (241-271 mmHg,
9.5-10.7 inHg)
2-7
CHASSIS SPECIFICATIONS
EAS1DX3068
CHASSIS SPECIFICATIONS
Chassis
Frame type Semi double cradle
Caster angle 27.00 °
Trail 117.0 mm (4.61 in)
Front wheel
Wheel type Spoke wheel
Rim size 21x1.60
Rim material Aluminum
Wheel travel 300.0 mm (11.81 in)
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Wheel axle bending limit 0.50 mm (0.02 in)
Rear wheel
Wheel type Spoke wheel
Rim size 18 x 2.15
Rim material Aluminum
Wheel travel 294.0 mm (11.57 in)
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Wheel axle bending limit 0.50 mm (0.02 in)
Front tire
Type With tube
Size 80/100-21 51 M
Manufacturer/model DUNLOP/GEOMAX MX51 FG
Rear tire
Type With tube
Size 120/90-18 65M
Manufacturer/model DUNLOP/GEOMAX MX51
Standard tire air pressure
Front and Rear 100 kPa (1.00 kgf/cm2 , 15 psi)
Front brake
Type Single disc brake
Operation Right hand operation
Front disc brake
Disc outside diameter x thickness 250.0 x 3.0 mm (9.84 x 0.12 in)
Brake disc thickness limit 2.5 mm (0.1 O in)
Brake disc deflection limit 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 4.4 mm (0.17 in)
Limit 1.0 mm (0.04 in)
Brake pad lining thickness (outer) 4.4 mm (0.17 in)
Limit 1.0 mm (0.04 in)
Master cylinder inside diameter 11.0 mm (0.43 in)
Caliper cylinder inside diameter 27.00 mm x 2 (1.06 in x 2)
Recommended fluid DOT4
2-8
CHASSIS SPECIFICATIONS
Rear brake
Type Single disc brake
Operation Right foot operation
Rear disc brake
Disc outside diameter x thickness 245.0 x 4.0 mm (9.65 x 0.16 in)
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc deflection limit 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 6.4 mm (0.25 in)
Limit 1.0 mm (0.04 in)
Brake pad lining thickness (outer) 6.4 mm (0.25 in)
Limit 1.0 mm (0.04 in)
Master cylinder inside diameter 11.0 mm (0.43 in)
Caliper cylinder inside diameter 25.40 mm x 1 (1.00 in x 1)
Recommended fluid DOT4
Steering
Steering bearing type Taper roller bearing
Center to lock angle (left) 43.0 °
Center to lock angle (right) 43.0 °
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 300.0 mm (11.81 in)
Fork spring free length 454.0 mm (17.87 in)
Limit 449.0 mm {17.68 in)
Installed length 454.0 mm (17.87 in)
Spring rate K1 4.50 N/mm (0.46 kgf/mm, 25. 70 lb/in)
Spring stroke K1 0.0-300.0 mm (0.00-11.81 in)
Inner tube outer diameter 48.0 mm (1.89 in)
Inner tube bending limit 0.2 mm (0.01 in)
Optional spring available Yes
Recommended oil Suspension oil S 1
Standard oil amount 528 cm 3 (17.85 Imp.oz, 18.62 US oz)
Rebound damping
*With the adjusting screw fully turned in
Minimum 20 click (s) out*
Standard 12 click (s) out*
Maximum (hard) Fully turned in
Compression damping
*With the adjusting screw fully turned in
Minimum 20 click (s) out*
Standard 14 click (s) out*
Maximum (hard) Fully turned in
Rear suspension
Type Swingarm (link suspension)
Spring/shock absorber type Coil spring/gas-oil damper
Rear shock absorber assembly travel 122.0 mm (4.80 in)
Spring free length 240.0 mm {9.45 in)
Installed length 222.0 mm (8.47 in)
Spring rate K1 54.00 N/mm (5.51 kgf/mm, 308.34 lb/in)
Spring stroke K1 0.0-140.0 mm (0.00-5.51 in)
Optional spring available Yes
Enclosed gas/air pressure (STD) 1000 kPa (10.0 kgf/cm2, 142.2 psi)
2-9
CHASSIS SPECIFICATIONS
2-10
ELECTRICAL SPECIFICATIONS
EAS1DX3069
ELECTRICAL SPECIFICATIONS
Voltage
System voltage 12 v
Ignition system
Ignition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 10.0 °/2000 r/min
Engine control unit
Model/manufacturer 1DX2NAMAHA
Ignition coil
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 3.57-4.83 n
Secondary coil resistance 10.71-14.49 kn
AC magneto
Standard output 14.0 V, 160 W@5000 r/min
Stator coil resistance o.528-0. 792 n
Rectifier/regulator
Regulator type Semi conductor-short circuit
No load regulated voltage 14.1-14.9 v
Rectifier capacity (DC) 35.0A
Battery
Model YTZ7S (F)
Voltage, capacity 12 V, 6.0 Ah
Specific gravity 1.310
Manufacturer GS YUASA
Ten hour rate amperage 0.60A
Headlight
Bulb type Halogen bulb
Bulb voltage, wattage x quantity
Headlight 12 V, 35 W/35 W x 1
Auxiliary light 12V,3.0Wx1
Tail/brake light LED
Meter lighting EL {Electroluminescent)
Indicator light
Fuel level warning light LED
Engine trouble warning light 12v1.7 w x 1
Electric starting system
System type Constant mesh
Starter motor
Power output 0.48 kW
Armature coil resistance 0.0111-0.0143 n
Brush overall length 7.0 mm (0.28 in)
Limit 3.50 mm (0.14 in)
Brush spring force 3.92-5.88 N (400-600 gf, 14.11-21.17 oz)
Commutator diameter 17.6 mm (0.69 in)
Limit 16.6 mm (0.65 in)
Mica undercut (depth) 1.50 mm (0.06 in)
2-11
ELECTRICAL SPECIFICATIONS
Starter relay
Amperage 180.0 A
Coil resistance 4.18-4.62 n
Starting circuit cut-off relay
Coil resistance 86.4-105.6 n
Headlight relay
Coil resistance 86.4-105.6 n
Fuses
Main fuse 15.0A
Spare fuse 15.0A
2-12
TIGHTENING TORQUES
EAS20320
TIGHTENING TORQUES
EAS20330
GENERAL TIGHTENING TORQUE SPECIFI-
CATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread
pitch. Tightening torque specifications for spe-
cial components or assemblies are provided for
each chapter of this manual. To avoid warpage,
tighten multi-fastener assemblies in a criss-
cross pattern and progressive stages until the
specified tightening torque is reached. Unless
otherwise specified, tightening torque specifi-
cations require clean, dry threads. Compo-
nents should be at room temperature.
General tightening
B torques
A (nut)
(bolt)
Nm m·kgf fNbf
10mm 6mm 6 0.6 4.3
12mm 8mm 15 1.5 11
14mm 10mm 30 3.0 22
17mm 12mm 55 5.5 40
19mm 14mm 85 8.5 61
22mm 16mm 130 13.0 94
2-13
TIGHTENING TORQUES
EAS1DX3070
ENGINE TIGHTENING TORQUES
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
Thread
Item Q'ty Tightening torque Remarks
size
Camshaft cap bolt M6 10 10 Nm {1.0 m·kgf, 7.2 ft·lbf)
Cylinder head blind plug M12 1 2B Nm {2.B m·kgf, 20 ft·lbf) -«I
Cylinder head stud bolt MB 1 15 Nm {1.5 m·kgf, 11 ft·lbf)
Spark plug M10 1 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Cylinder head bolt M10 4 See TIP.
Cylinder head cover bolt M6 2 1O Nm {1.0 m·kgf, 7.2 ft· Ibf)
Cylinder head bolt M6 2 1O Nm {1.0 m·kgf, 7.2 ft·lbf)
Coolant temperature sensor M10 1 16 Nm {1.6 m·kgf, 11 ft·lbf)
Cylinder bolt M6 1 1O Nm {1.0 m·kgf, 7.2 ft·lbf)
Lock
Balancer bolt M10 1 45 Nm {4.5 m·kgf, 32 ft·lbf) washer
use
Balancer weight plate screw M6 3 1O Nm {1.0 m·kgf, 7.2 ft·lbf) -'3
Lock
Balancer driven gear nut M14 1 50 Nm {5.0 m·kgf, 36 ft·lbf) washer
use
Timing chain tensioner bolt M6 2 10 Nm {1.0 m·kgf, 7.2 ft·lbf)
Timing chain tensioner cap bolt M6 1 10 Nm {1.0 m·kgf, 7.2 ft·lbf)
Timing chain guide bolt M6 2 -·1 O Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil filter cover bolt M6 2 1O Nm {1.0 m·kgf, 7.2 ft-lbf)
Oil pump bolt M6 2 10 Nm {1.0 m·kgf, 7.2 ft·lbf)
Oil pump cover bolt M4 1 2.0 Nm {0.20 m·kgf, 1.4 ft·lbf)
Oil pump drive gear shaft screw M6 1 10 Nm {1.0 m·kgf, 7.2 ft·lbf)
Engine oil drain bolt {oil filter) M6 1 1O Nm {1.0 m·kgf, 7.2 ft·lbf)
Oil check bolt M6 1 1O Nm {1.0 m·kgf, 7.2 ft·lbf)
Oil hose clamp - 2 2.0 Nm {0.20 m·kgf, 1.4 ft·lbf)
Oil strainer bolt M6 1 1O Nm {1.0 m·kgf, 7.2 ft· Ibf)
Throttle body joint bolt M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Throttle body joint clamp screw M4 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Air filter case bolt M6 2 8 Nm {0.8 m·kgf, 5.8 ft·lbf)
Ai_r filter joint clamp bolt M6 1 3.0 Nm {0.30 m·kgf, 2.2 ft·lbf)
Air filter.joint and air filter case bolt MS 1 4.0 Nm {0.40 m·kgf, 2.9 ft·lbf)
Exhaust pipe nut MB 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Exhaust pipe bolt MB 1 20 Nm {2.0 m·kgf, 14 ft·lbf)
Muffler bolt MB 2 30 Nm {3.0 m·kgf, 22 ft·lbf)
Muffler clamp bolt MB 1 16 Nm (1.6 m·kgf, 11 ft·lbf)
2-14
TIGHTENING TORQUES
Item Thread
Q'ty Tightening torque Remarks
size
Exhaust pipe protector screw M6 3 1O Nm (1.0 m·kgf, 7.2 ft-lbf) -Cl
Spark arrester bolt MS 4 9 Nm (0.9 m·kgf, 6.4 ft-lbf)
Muffler cap bolt MS 6 S Nm (O.S m·kgf, 3.6 ft·lbf)
Throttle cable (pull) nut M6 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Throttle cable (return) nut M6 1 4.0 Nm {0.40 m·kgf, 2.9 ft·lbf)
Throttle cable cover bolt MS 2 4.0 Nm {0.40 m·kgf, 2.9 ft·lbf)
Throttle body joint M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Crankcase bolt M6 12 12 Nm (1.2 m·kgf, 8.7 ft-lbf)
Timing mark accessing screw M14 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Crankshaft end accessing screw M27 1 10 Nm (1.0 m·kgf, 7.2 ft-lbf)
Clutch cover bolt M6 7 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Crankcase cover bolt (left) M6 8 1O Nm (1.0 m·kgf, 7.2 ft·lbf)
Crankcase cover bolt (right) M6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Crankcase cover (right) M6 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Idle gear cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil drain bolt (crankcase right) M6 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Oil drain bolt (crankcase left) M6 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Oil drain bolt (crankcase) M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Crankcase bearing stopper screw M6 4 14 Nm (1.4 m·kgf, 10 ft·lbf) -'1
Crankcase bearing stopper screw M6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf) -id
Drive axle oil seal stopper bolt M6 2 1O Nm (1.0 m·kgf, 7.2 ft·lbf) -G
Ratchet wheel guide bolt M6 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf) ~
Kick starter crank bolt MB 1 33 Nm (3.3 m·kgf, 24 ft·lbf) -(I
Kick starter crank boss screw M6 1 7 Nm (0.7 m·kgf, S.1 ft·lbf) -t(J
Starter clutch nut M6 6 16 Nm (1.6 m·kgf, 11 ft-lbf) ~
Starter motor bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Starter motor lead screw MS 1 3.S Nm (0.3S m·kgf, 2.S ft·lbf)
Primary drive gear nut M20 1 11 O Nm (11.0 m·kgf, 80 ft-lbf)
Clutch spring bolts M6 6 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Clutch cable adjust bolt and lock nut MS 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Lock
Clutch boss nut M20 1 7S Nm (7.S m·kgf, 54 ft·lbf) washer
use
Lock
Drive sprocket nut M20 1 75 Nm (7.5 m·kgf, 54 ft·lbf) washer
use
Drive chain sprocket cover nut M6 2 7 Nm (0.7 m·kgf, S.1 ft-lbf)
Shift pedal bolt M6 1 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Shift guide bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Stopper lever bolt M6 1 1o Nm (1.0 m·kgf, 7.2 ft-lbf)
2-15
TIGHTENING TORQUES
Thread
Item Q'ty Tightening torque Remarks
size
Segment MB 1 30 Nm (3.0 m·kgf, 22 ft-lbf)
Impeller MB 1 14 Nm (1.4 m·kgf, 10 ft·lbf)
Water pump housing cover bolt M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Coolant drain bolt M6 1 1O Nm (1.0 m·kgf, 7.2 ft·lbf)
Clutch cable holder bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator hose clamp screw M6 B 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Radiator bolt M6 6 1O Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator pipe 1, 2 M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
*1 :First, tighten the cylinder head bolts to 30 Nm (3.0 m·kgf, 22 ft·lbf) in the proper tightening se-
quence and remove them. Then, after retightening them to 20 Nm (2.0 m·kgf, 14 ft·lbf) in the same
sequence, tighten them further two times each by 90°to attain the specified angle of 180°.
FWD
x2 x4 ll
2-16
TIGHTENING TORQUES
EAS1DX3071
CHASSIS TIGHTENING TORQUES
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
6 - marked portion shall be checked for torque tightening after break-in.
Thread
Item Q'ty Tightening torque Remarks
size
Engine mounting bolt (upper side) M10 2 45 Nm (4.5 m·kgf, 33 ft·lbf)
Engine mounting nut (front lower
M10 1 53 Nm (5.3 m·kgf, 3B ft·lbf)
side)
Engine mounting nut (rear lower
M10 1 53 Nm (5.3 m·kgf, 3B ft-lbf)
side)
Engine bracket bolt MB 10 34 Nm (3.4 m·kgf, 25 ft·lbf)
Main frame and rear frame MB 4 32 Nm (3.2 m·kgf, 23 ft·lbf)
Cable guide and frame bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·Jbf)
Wire harness bracket bolt M6 2 1O Nm (1.0 m·kgf, 7.2 ft-lbf)
Rectifier/regulator stay bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rectifier/regulator bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Ignition coil bracket bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Lean angle sensor bolt M4 2 3.B Nm (0.3B m·kgf, 2.8 ft·lbf)
Radiator mounting nut and frame M10 2 20 Nm (2.0 m·kgf, 14 ft·lbf) -'1
Cable holder and right upper engine 10 Nm (1.0 m·kgf, 7.2 ft-lbf)
M6 1
bracket bolt
Throttle cable housing screw MS 2 3.B Nm (0.3B m·kgf, 2.B ft·lbf)
Throttle cable and throttle body nut M6 2 4.3 Nm (0.43 m·kgf, 3.1 ft·lbf}
Air temperature sensor screw MS 1 3.B Nm (0.38 m·kgf, 2.B ft·lbf}
Starter relay and positive battery 3.S Nm (0.3S m·kgf, 2.S tt~lbf)
M6 1
lead bolt
Starter relay and starter motor lead
M6 1 3.S Nm (0.3S m·kgf, 2.S ft·lbf}
bolt
Footrest bolt M10 4 SS Nm (S.S m·kgf, 40 ft·lbf) ~
Front refrector nut (For Canada) M6 2 1.S Nm (0.1 S m·kgf, 1.1 ft·lbf)
Engine guard bolt M6 3 7 Nm (0.7 m·kgf, S.1 ft·lbf)
Drive chain tensioner bolt MB 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
Drive chain tensioner nut MB 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
Front fender bolt M6 4 1O Nm (1.0 m·kgf, 7.2 ft·lbf)
Side cover and rear frame bolt M6 2 7 Nm (0.7 m·kgf, S.1 ft·lbf)
Rear fender bolt (front side) M6 2 7 Nm (0.7 m·kgf, S.1 ft·lbf)
Rear fender bolt (rear side) M6 2 16 Nm (1.6 m·kgf, 12 ft·lbf)
Taillight assembly screw - 3 1.1 Nm (0.11 m·kgf, O.BO ft·lbf)
Taillight lead clamp and rear fender - 3 0.50 Nm (0.05 m·kgf, 3.62 ft·lbf)
Reflector nut (For Canada) MS 2 1.B Nm (0.1B m·kgf, 1.3 ft·lbf)
Air scoop and frame bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft-lbf)
Air scoop and air panel bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
2-17
TIGHTENING TORQUES
Thread
Item Q'ty Tightening torque Remarks
size
Air scoop and fuel tank M6 2 7 Nm (0.7 m·kgf, 5.1 ft-lbf)
Catch tank bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Pivot shaft nut M16 1 85 Nm (8.5 m·kgf, 61 ft·lbf)
Rear shock absorber assembly
locknut
- 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
2-18
28 Nm (2.8 m·kgf, 20 ft·lbf)
34 Nm (3.4 m·kgf, 25 ft·lbf) .....
TIGHTENING TORQUES
Thread
Item Q'ty Tightening torque Remarks
size
Start switch screw M3 1 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Engine stop switch screw M3 1 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Clutch cable lock M6 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Clutch lever nut M6 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Front brake lever pivot bolt M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front brake lever pivot nut M6 1 6 Nm (0.6 m·kgf, 4.3 ft· Ibf)
Speed sensor lead holder and
M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
speed sensor lead bracket bolt
Speed sensor lead bracket and low-
M6 1 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
er bracket bolt
Front brake hose guide and lower
M6 1 3.S Nm (0.3S m·kgf, 2.B ft·lbf)
bracket bolt
Plate 1 and front fork protector bolt M5 2 3.B Nm (0.3B m·kgf, 2.B ft·lbf)
Plate 2 and front fork protector
screw
- 1 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Damper assembly and outer tube M51 2 30 Nm (3.0 m·kgf, 22 ft· Ibf)
Adjuster and inner tube M22 2 55 Nm (5.5 m·kgf, 40 ft·lbf) -C1
Base valve and damper assembly M42 2 2S Nm (2.S m·kgf, 20 ft·lbf)
Adjuster and damper assembly M12 2 29 Nm (2.9 m·kgf, 21 ft·lbf)
Air bleed screw and base valve MS 2 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
Front fork and reflector bracket bolt
MS 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
(For Canada)
Front fork cap bolt M51 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
Front fork base valve M22 2 55 Nm (5.5 m·kgf, 40 ft·lbf) -C1
Front fork axle nut M16 1 90 Nm (9.0 m·kgf, 65 ft·lbf)
Front wheel axle pinch bolt MS 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
Front brake disc bolt M6 6 12 Nm (1.2 m·kgf, B.7 ft·lbf) -C1
Spoke (front, rear) BC4 72 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Rear wheel axle nut M20 1 125 Nm (12.5 m·kgf, 90 ft·lbf)
Rear brake disc bolt M6 6 14 Nm (1.4 m·kgf, 10 ft·lbf) -'3
Rear wheel sprocket nut MB 6 50 Nm (5.0 m·kgf, 36 ft·lbf)
Front brake caliper bolt MS 2 23 Nm (2.3 m·kgf, 17 ft·lbf)
Front brake hose union bolt M10 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
Front brake caliper bleed screw MB 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front caliper support bolt MS 2 17 Nm (1.7 m·kgf, 12 ft·lbf)
Front caliper pin plug MB 1 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Front brake master cylinder holder
M6 2 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
bolt
Rear master cylinder bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear caliper protector bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
2-19
TIGHTENING TORQUES
Thread
Item Q'ty Tightening torque Remarks
size
Rear brake caliper support bolt MS 2 17 Nm {1.7 m·kgf, 12 ft-lbf)
Drive chain tensioner bolt (upper,
MS 2 16 Nm {1.6 m·kgf, 12 ft·lbf)
lower)
Drive chain adjuster locknut MS 1 19 Nm {1.9 m·kgf, 14 ft·lbf)
Front fork protector bolt M6 6 7 Nm {0.7 m·kgf, S.1 ft·lbf)
Seat bolt MS 2 22 Nm {2.2 m·kgf, 16 ft-lbf)
Front brake lever position locknut MS 1 5 Nm {O.S m·kgf, 3.6 ft-lbf)
Front brake master cylinder cap
M4 2 1.5 Nm {0.1 S m·kgf, 1.1 ft-lbf)
screw
Rear brake caliper pin plug M10 1 2.5 Nm {0.25 m·kgf, 1.S ft·lbf)
Rear brake master cylinder bolt M6 10 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Brake pedal bolt MS 1 26 Nm {2.6 m·kgf, 19 ft· Ibf)
Rear brake master cylinder cap bolt M4 2 1.S Nm (0.1 S m·kgf, 1.1 ft·lbf)
Rear brake hose union bolt M10 2 30 Nm {3.0 m·kgf, 22 ft· Ibf)
Rear brake caliper bleed screw MS 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Rear brake disc cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Clutch lever holder bolt MS 2 3.S Nm (0.3S m·kgf, 2.8 ft·lbf)
Front brake hose holder and front
M6 2 7 Nm {0.7 m·kgf, S.1 ft·lbf)
fork protector nut
Headlight unit and headlight body
bolt
M6 2 7 Nm (0.7 m·kgf, S.1 ft·lbf)
Rear brake hose holder screw MS 4 3.5 Nm (0.35 m·kgf, 2.S ft·lbf)
Drive chain guide screw M5 4 6 Nm (0.6 m·kgf, 4.3 ft-lbf)
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
1. Tighten the lower ring nut with the 38 Nm (3.8 m·kgf, 27 ft·lbf) torque.
2. Turn the front fork to the left and right. The rotation motion must be smooth.
3. Fully loosen the lower ring nut, and retighten it with the 7 Nm (0.7 m·kgf, 5.1 ft·lbf) torque.
2-20
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20360
2-21
LUBRICATION POINTS AND LUBRICANT TYPES
2-22
LUBRICATION POINTS AND LUBRICANT TYPES
EAS1DX3072
CHASSIS
Lubrication point
Upper bearings and oil seal lip (steering head) ......
Lubricant types
......
Lower bearings and oil seal lip (steering head)
Steering shaft and nut thread
Handle lower holder threads
......
......
Front wheel oil seal (left/right) ~
Rear wheel oil seal (left/right) ~
Brake pedal pivoting point and bolt ~
Throttle cable end and throttle grip ~
Throttle cable ~
Brake lever bolt ~
Brake lever and front brake master cylinder ~
Rear brake master cylinder push rod (boot mount groove) ~
Brake caliper piston seal ~
Brake caliper dust seal ~
Brake caliper support bolt ~
Brake pad support bolt ~
Clutch cable end
Clutch lever bolt
Clutch lever
......
~
~
Pivot shaft ~
Swing arm bearing, collar, spacer, and oil seal ~
Relay arm bearing, collar, washer, and oil seal ~
Relay arm bolt thread (swing arm side) ~
Rear shock absorber assembly bearing, collar, and oil seal ~
Connecting rod bearing, collar and oil seal ~
Connecting rod bolt ~
Front wheel axle ~
Rear wheel axle ~
Tube guide (throttle grip) inner surface and throttle cables ~
Sidestand bracket and sidestand ~
Sidestand spring and link ~
Sidestand bolt collar
Speed sensor oil seal ......
~
2-23
LUBRICATION POINTS AND LUBRICANT TYPES
2-24
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20390
2-25
LUBRICATION SYSTEM CHART AND DIAGRAMS
2-26
LUBRICATION SYSTEM CHART AND DIAGRAMS
,,,,,..----"
/
/
I
I
I
I
I
00
2-27
LUBRICATION SYSTEM CHART AND DIAGRAMS
1. Intake camshaft
2. Exhaust camshaft
A. To main axle
B. From oil pump
2-28
CABLE ROUTING
EAS1DX3073
CABLE ROUTING
~~ (0.67±0.12 in)
2-29
CABLE ROUTING
1. Protector
2. Main harness
3. Intake air pressure sensor coupler
4. Throttle position sensor coupler
5. Connecting arm
6. Catch tank breather hose
7. Condenser
8. Starter motor lead
9. Coolant temperature sensor lead
1O. Neutral switch lead
11. Ignition coil coupler
12. Ignition coil
A. Put the end of the fuel tank breather hose in the
hole in the steering stem.
B. Pass the leads under the hose connecting both
(right and left) radiators.
C. Attach the grommet by pressing it against the end
face of the protector.
D. Apply an adhesive to the grommet before fixing it.
E. Pass the leads so the engine breather hose is lo-
cated on the outside of the vehicle.
F. Pass the main harness over the intake air pres-
sure sensor coupler.
G. Clamp the condenser lead and coolant tempera-
ture sensor lead. Lay the leads and the locking in
any direction.
H. Pass the catch tank breather hose between the
cross tube (on the frame) and the connecting
arm.
I. Insert the condenser in the bracket before fixing
it.
J. Degrease the condenser on its surface having no
lead coming out before affixing the insulation to it.
When affixing the insulation, align its notch with
the projection on the condenser. When the insu-
lation materials overlap, affix them so that the lon-
ger one is directed toward the rear of the vehicle.
K. Fix the neutral switch lead to the down tube (on
the frame). Lock it on the outside of the vehicle
with its allowed portion directed upward. Do not
cut off the lead end.
L. Pass the neutral switch lead on the outside of the
vehicle away from the bracket.
M. Clamp the AC magneto lead, neutral switch lead,
and ignition coil lead. The leads may be laid out
in anyway.
N. Pass the ignition coil lead (from coupler to ignition
coil) in the rear of the radiator hose.
0. Pass the neutral switch lead on the inside of the
vehicle away from the engine bracket.
P. After installing the ignition coil onto the bracket,
put a cover over them.
Q. Pass the main harness through the cable guide.
2-30
CABLE ROUTING
2-31
CABLE ROUTING
1. Main harness
2. Coupler for connecting optional part
3. Taillight coupler
4. Injector coupler
5. Clutch cable
6. Catch tank breather hose
7. Air cleaner joint
8. Starter motor lead
9. Negative lead
1O. Throttle position sensor coupler
11 . Engine breather hose
12. Intake air pressure sensor coupler
A. Pass the main harness between the rear frame
and the air filter case.
B. Pass the lead (coupler for connecting optional
part) between the air filter case and air filter duct.
C. Do not allow the taillight lead to slacken. ·
D. Pass the radiator breather hose on the inside of
the location where the catch tank is installed.
E. Insert the taillight coupler (3P) to fit the triangle of
the ECU band. Locate the clamp pawl in any di-
rection.
F. Pass the ECU lead and taillight lead through the
rubber band hook while laying out the ECU lead
outside of the vehicle beyond the taillight lead.
G. Pass the catch tank breather hose behind the
throttle body.
H. After connecting the coolant temperature sensor
coupler (2P), put a cover over it.
I. After connecting the condenser coupler (2P), in-
sert and fix the coupler in the bracket and put a
cover over it.
J. Pass the catch tank breather hose through the
front hole and rear notch in the condenser and lay
it in the rear of the vehicle.
K. Pass the catch tank breather hose in front of the
rear shock absorber without interv~ning anything.
L. Clamp the condenser lead and coolant tempera-
ture sensor lead. Lay the leads and the locking in
any direction.
M. Pass the leads so the engine breather hose is lo-
cated on the outside of the vehicle.
2-32
CABLE ROUTING
2-33
CABLE ROUTING
1. Throttle cable
2. Clutch cable
3. Radiator breather hose
4. Condenser
5. Main harness
6. Right handlebar switch coupler
A. Pass the right handlebar switch lead through the
upper cable guide.
B. Pass the throttle cable and clutch cable through
the lower cable guide. The leads. may be laid out
in any way.
C. Pass the throttle cable and clutch cable between
the radiator and the frame. Pass the throttle cable
and clutch cable over the radiator mounting boss
on the frame.
D. Determine the clamping position to fit where the
throttle cable has no protector on it. Take care so
that the throttle cable and clutch cable are not
twisted.
E. Lay out tbe two throttle wires and the clutch cable
in any way. Locate the locking in any direction.
F. Lay the radiator breather hose so it is located to
the right of the vehicle.
G. Pass the condenser lead between the condenser
and the catch tank breather hose, and connect it
to the main harness at the back of the condenser.
H. Pass the clutch cable grommet through the cable
guide.
I. Align the painted positions on the two breather
hoses with the hole in the rear frame.
J. Pass the two breather hoses between the rear
frame and the air filter case.
K. Pass the radiator breather hose under the fuel
hose.
L. Clamp together the metal portion of the throttle
cable and the radiator breather hose. Lay the ra-
diator breather hose to be located to the right of
the vehicle. Direct the open end of the clamp in
any direction.
M. Clamp the two throttle cables, clutch cable, en-
gine breather hose, and radiator breather hose.
Direct the clamp end downward to provide clear-
ance for the engine. Position the clamp where
there is no protector on the throttle cable.
2-34
CABLE ROUTING
2-35
CABLE ROUTING
2-36
CABLE ROUTING
2-37
CABLE ROUTING
1. Clutch cable
2. Hose guide
3. Engine trouble warning light coupler
4. Auxiliary light lead
5. Clutch switch coupler
6. Engine stop switch coupler
7. Main harness
8. Resistor coupler
9. Headlight coupler
1O. Brake hose
11. Auxiliary light coupler
12. Meter assembly coupler
13. Meter assembly lead
14. Speed sensor lead
15.Guide
16. Main switch coupler
17. Meter assembly optional switch coupler
18. Speed sensor coupler
19. Right handlebar switch lead
20. Throttle cable
21 . Engine stop switch lead
22. Meter assembly
23. Main switch
A. Pass the brake hose through the guide.
B. After putting the resistor rubber band projection in
the meter bracket, firmly secure the resistor by
sliding it downward.
C. Make sure to securely fix the main harness clip
while pushing it in the round hole in the meter
bracket on the inside of the vehicle.
D. Fix the auxiliary light coupler while inserting it in
the hole in the head light unit.
E. Pass the speed sensor lead through the guide.
F. Clamp the right handlebar switch lead to the han-
dlebar.
G. Pass the throttle cable and clutch cable between
the upper bracket and the meter bracket.
H. Clamp the engine stop switch lead and clutch
switch lead to the handlebar.
2-38
CABLE ROUTING
2-39
CABLE ROUTING
2-40
CABLE ROUTING
2-41
PERIODIC CHECKS AND ADJUSTMENTS
EAS1DX3074
PERIODIC MAINTENANCE
EAS1DX307S
INTRODUCTION . .
This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter. ·
EAS1DX3076
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
TIP~~~~~~~~~~~~~~~~~~-'-~~~~~~~~~~~~~~~~
• From 4200 mi (7000 km) or 9 months, repeat the maintenance intervals starting from 1800 mi (3QOO
km) or 3 months.
• Items marked with an asterisk should be performed by a Yamaha dealer as they ,require special
tools, data and technical skills. ·
INITIAL ODOMETER READINGS
NO. ITEM CHECKS AND MAINTENANCE JOBS 600mi 1800 mi 3000 mi
(1000 km) or (3000 km) or (5000km)or
1 month 3 months 6 months
8
Exhaust system
Engine oil
• Tighten if necessary.
• Replace gasket(s) if necessary.
• Change (warm engine before draining}.
"v -.J
v
"v
Engine oil filter el-
9
EAS1DX30n
ement. ~ Replace. -.J -.J
"
GENERAL MAINTENANCE AND LUBRICATION CHART
INITIAL -. ODOMETER READINGS
../
"
..J
2 * Cooling system
• Replace with ethylene glycol anti-freeze coolant ev-
Every 1 year
ery 1 year.
3 * Spark arrester • Clean. v
• Check operation, fluid level, and for fluid leakage.
• Replace brake pads if necessary. . ..J ../ ..J
4 * Front brake
• Replace brake fluid every 1 year. Every 1 year
3-1
PERIODIC MAINTENANCE
5
. Rear brake
• Check operation, fluid level, and for fluid leakage.
• Replace brake pads if necessary.
" " "
• Replace brake fluid every 1 year. Every 1 year
• Check for cracks or damage. . .../ v
6 * Brake hoses
• Replace. Every 4year
.. • Check runout, spoke tightness and for damage.
7 Wheels • Tighten spokes if necessary.
•
•
Check tread depth and for damage.
Replace if necessary.
" " "
8 * Tires •
•
Check air pressure.
Correct if necessary. " " "
9
.. Wheel bearings
• Check bearings for smooth operation.
• Replace if necessary.
" ". "
. Swingarm pivot • Check bearing assemblies for looseness.
10
11
bearings
Drive chain
• Moderately repack with lithium-soap-based grease.
• Check chain slack/alignment and condition.
• Adjust and lubricate chain with a special 0-ring chain
" "
Every ride
"
lubricant thoroughly.
• Check bearing assemblies for looseness.
.. • Moderately repack with lithium-soap-based grease
12 Steering bearings
Shock absorber
• Replace if necessary.
• Check operation and for oil leakage.
" "
17 *
..
assembly
Rear suspension
• Replace if necessary.
" "
18 link pivots
• Apply molybdenum disulfide grease lightly.
Throttle grip
1OW-30 thoroughly.
• Check operation and free play. " " "
20 * housing and ca-
ble
• Adjust the throttle cable free play if necessary.
• Lubricate the throttle grip housing and cable.
• Check all chassis fitting and fasteners.
" " "
21
22
* Chassis fasteners
Battery
• Correct if necessary.
• Check terminal for looseness and corrosion. " "
...;
..J
v
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake service
• After disassembling the brake master cylinders and calipers, always change the fluid. Regularly
check the brake fluid levels and fill the reservoirs as required.
• Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
•Replace the brake hoses every four years and if cracked or damaged.
3-2
PERIODIC MAINTENANCE
EAS10X3078
CAMSHAFT SPROCKETS Check for wear on the teeth and for dam-
Inspect
Replace
• • age.
Replace
PISTON RING
• Check ring end gap.
Inspect
Replace
•• •
PISTON PIN
Inspect
Replace
• •
CYLINDER HEAD lhspect carbon deposits and eliminate
Inspect and clean
• them .
Change gasket.
CYLINDER Inspect score marks.
Inspect and clean
Replace
• • Inspect wear.
TRANSMISSION
Inspect
•
3-3
PERIODIC MAINTENANCE
Every
Every fifth (or As re-
After Every third (or Remarks
ITEM break-in race 1,000 quired
500 km) km)
Replace bearing
SHIFT FORK, SHIFT CAM,
GUIDE BAR
• Inspect wear.
Inspect
ROTOR NUT
•
Retighten
MUFFLER
• •
Inspect and retighten
Clean
• • • •
Replace
CRANK
Inspect and clean
THROTTLE BODY
• •
Inspect
SPARK PLUG
•
Inspect and clean
Replace
• • •
DRIVE CHAIN Use chain lube.
Lubricate, slack, align-
ment
• • Chain slack: 48-58 mm
Replace
·COOLING SYSTEM
• (1.89-2.28 in)
Every
Every
After Every fifth (or Asre-
ITEM third (or Remarks
break-in race 1,000 quired
500 km)
km)
Check fluid level and leak-
age
Retighten brake disc
• •
bolts, caliper bolts, master
cylinder bolts and union
bolts • •
Replace pads
Replace brake fluid
•• Every one year
FRONT FORKS
Inspect and adjust
Replace oil
•• • • •
Suspension oil "81"
ROD
Inspect, lube and retight-
en
SIDESTAND
• • Molybdenum disulfide grease
Lubricate
STEERING HEAD
• Lithium base grease
TIRE, WHEELS
• •
Inspect air pressure,
wheel run-out, tire wear
and sp'?ke looseness
Retighten sprocket bolt
Inspect bearings
• • •
Replace bearings
Lubricate
• ;
~
Lubricate
• • SAE 1OW-30 motor oil
3-5
PERIODIC MAINTENANCE
EAS1DX3079
CHECKING THE FUEL LINE
The following procedure applies to all of the fu-
el, vacuum and breather hoses.
1. Remove:
•Seat
• Side cover (left/right)
•Air scoop (left/right)
Refer to "GENERAL CHASSIS" on page 5-
1.
•Fuel tank
2. Remove:
Refer to "FUEL TANK" on page 8-1.
• Spark plug cap
2. Check:
•Spark plug
• Fuel hose "1"
Refer to "CAMSHAFT' on page 6-7.
Cracks/damage ~ Repl~ce. ECA13330
-----------------------
Do not use too much force to pull the hose
when holding up the fuel tank.
3-6
PERIODIC MAINTENANCE
7. Install: 4. Measure:
•Spark plug •Valve clearance
Out of specification ~ Adjust.
~ ,.,. Spark plug
~~ 13 Nm (1.3 m·kgf, 9.4 ft-lbf) ~ Valve clearance (cold)
v ~ Intake
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ 0.10-0.15 mm (0.0039-0.0059 in)
Before installing the spark plug, clean the spark Exhaust
0.20-0.25 mm (0.0079-0.0098 in)
plug and gasket surface.
8. Install: yyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyy
• Spark plug cap a. Turn the crankshaft counterclockwise.
•Fuel tank b. Align TDC mark "a" of the generator rotor
s:
Refer to "FUEL TANK" on page 8-1. with mark "b" of the generator rotor cover.
• Air scoop (left/right)
• Side cover (left/right)
•Seat
Refer to "GENERAL CHASSIS" on page 5-
r ~~
1.
y~
EAS10X3081
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Valve clearance adjustment should be made
on a cold engine, at room temperature. In order to be sure that the piston is at Top
• When the valve clearance is to be measured Dead Center, the punch mark "c" on the ex-
or adjusted, the piston must be at top dead haust camshaft and the punch·mark "d" on the
center (TDC) on the compression stroke. intake camshaft must align with the cylinder
head surface, as shown in the illustration.
1. Remove:
•Seat
•Fuel tank
Refer to "FUEL TANK" on page 8-1.
2. Remove:
•Spark plug
• Cylinder head cover
. Refer to "CAMSHAFT" on page 6-7.
3. Remove:
•Timing mark accessing screw "1"
• Crankshaft end cover "2"
• 0-ring
'
c. Measure the valve clearance with a thick-
ness gauge "1 ".
~ Thickness gauge
~- 90890-03180
Feeler gauge set
VU-26900-9
3-7
PERIODIC MAINTENANCE
EX
@) @)
0 0
1
IN
@)@)
0 0 ,____2
••••••••••••••••••••••••••••••••
5. Adjust:
c. Select the proper valve pad from the follow-
ing table.
• Valve clearance Valve pad range Nos. 120-240
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT Valve pad thickness 1.20-2.40 mm
a. Remove: (0.047-0.094 in)
• Cam chain tensioner
• Camshaft cap Available valve pads 25 thicknesses in
•Intake camshaft
0.05 mm (0.002 in) in-
crements
• Exhaust camshaft
Refer to "CAMSHAFT' on page 6-7 TIP _ _ _ _ _ _ _ _ _ _ _ _ __
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
• The thickness of each valve pad is marked in
Before removing the cam chain and camshaft, hundredths of millimeters on the side that
connect the cam chain using a wire so that it touches the valve lifter.
does not drop in the crankcase. • Since valve pads of various sizes are original-
b. Remove the valve lifter "1" and the valve pad ly installed, the valve pad number must be
"2" with a valve lapper. rounded in order to reach the closest equiva-
lent to the original.
• Remember that the replacement valve pad
number is a rough value. Repeat the above
procedure until you have the standard valve
clearance.
d. Install the new valve pad "1" and the valve
lifter "2".
Valve lapper
90890-04101
Valve lapping tool
YM·A8998
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Cover the timing chain opening with a rag to TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
prevent the valve pad from falling into the
crankcase. •When installing the valve pad, direct the pad
• Make a note of the position of each valve lifter having a number on it toward the lifter.
"1" and valve pad "2" so that they can be in- • Lubricate the valve pad with molybdenum di-
stalled in the correct place. sulfide grease.
• Lubricate the valve lifter with engine oil.
• The valve lifter must turn smoothly when ro-
tated by hand.
3-8
PERIODIC MAINTENANCE
EAS1DX3082
CLEANING THE AIR FILTER ELEMENT
1. Remove:
•Air filter check hose
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
tlVll1~~~~~~~~
Do not twist the air filter element when
squeezing it.
3-9
PERIODIC MAINTENANCE
6. Check:
• Air filter element
Damage ~ Replace.
7. Apply the recommended oil to the entire sur-
face of the air filter element and squeeze out
the excess oil. The air filter element should
be wet but not dripping.
Recommended oil grade
API service SG type or higher,
JASO standard MA
10.Hook:
8. Install: •Binder "1"
• Air filter element frame "1" TIP _ _ _ _ _ _ _ _ _ _ _ _ __
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Hook the binder "1" so that it contacts the filter
• Align the projection "a" on air filter element guide projections "a".
frame with the hole "b" in air filter element.
• Apply the lithium-soap-based grease on the
matching surface "c" on air filter element.
ECA1DX1002
~Not1c&
~~~~----~-~---~
Never operate the engine without the air fil-
ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also lead-
ing to poor engine performance and possi- 11.lnstall:
ble overheating. • Air filter case cover
• Air filter check hose
EAS1DX30B3
3-10
PERIODIC MAINTENANCE
3. Install:
•Fuel tank Oil temperature
70-SO °C (158-176 °F)
Refer to "FUEL TANK" on page 8-1.
•Air scoop (left/right) 3. Install:
• Side cover (left/right) • Digital tachometer
•Seat (Ignition coil lead)
Refer to "GENERAL CHASSIS" on page 5-
1. Digital tachometer
90890-06760
EAS10X3084 VU-39951-B
ADJUSTING THE ENGINE IDLING SPEED
TIP~~~~~~~~~~~~~~ 4. Measure:
• Prior to adjusting the idling speed, the air filter •Engine idling speed
element should be clean, and the engine Out of specification -t Adjust.
should have adequate compression. Engine idling speed
• Because the air pressure is lower at high alti- 1900-2100 r/min
tudes, the air-fuel mixture will become richer.
If the engine idling speed is low, turn the start- 5. Adjust:
er knob/idling adjusting screw a few clicks • Engine idling speed
counterclockwise to increase the idling speed. TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
• Before adjusting the engine idling speed, a. Adjust the engine idling speed by turning the
make sure that the compression pressure is adjust screw "1" in direction "a" or "b".
within specification and that the air filter ele-
ment is not clogged.
• Adjust the engine idling speed with the starter
knob/idling adjusting screw pushed in com-
pletely.
1. Start the engine and let it warm up until it
reaches the specified temperature.
2. Use a temperature probe tester "1" and con-
tact it to the drain bolt thread.
3-11
PERIODIC MAINTENANCE
6. Adjust: 4. Install:
• Throttle grip free play • Exhaust pipe protector
Refer to "ADJUSTING THE THROTTLE
Exhaust pipe protector screw
GRIP FREE PLAY" on page 3-29.
10 Nm (1.0 m·kgf, 7.2 ft-lbf)
Throttle grip free play LOCTITE®
3.0-5.0 mm (0.12-0.20 in)
EAS1DX3086
CHECKING THE ENGINE OIL LEVEL
EAS1DX3085
CHECKING THE EXHAUST SYSTEM 1. Stand the vehicle on a level surface.
The following procedure applies to all of the ex- TIP _ _ _ _ _ _ _ _ _ _ _ _ __
haust pipes and gaskets. • Place the vehicle on a suitable stand.
1. Remove: • Make sure the vehicle is upright.
• Exhaust pipe protector EWA1DX1002
2. Check: A WARNING
• Exhaust pipe
Never remove the oil tank cap just after high
•Muffler
speed operati~n. The heated oil could spurt
Cracks/damage 4 Replace.
out causing danger. Wait until the oil cools
Refer to "ENGINE REMOVAL" on page 6-1.
down to approximately 70°C (158°F).
•Gasket
Exhaust gas leaks 4 Replace. 2. Idle the engine more than 3 minutes while
Refer to "ENGINE REMOVAL" on page 6-1. keeping the machine upright. Then stop the
3. Check: engine and inspect the oil level.
• Tightening torque 3. Remove:
•Oil tank cap "1"
~ ,,.. Exhal:Jst pipe bolt and nut "1"
~~ 20 Nm (2.0 m·kgf, 14 ft-lbf)
------ Exhaust pipe and muffler bolt "2"
16 Nm (1.6 m·kgf, 12 ft-lbf)
Muffler and muffler bracket bolt
"3"
30 Nm (3.0 m·kgf, 22 ft-lbf)
4. Inspect:
•Oil level
Check that the engine oil is above the level
mark "a" and that the ·oil does not come out
when the check bolt "1" is removed.
Below the level mark "a" 4 Add oil through
the filler cap hole until it is above the level
mark "a".
Oil comes out at the check bolt 4 Drain the
oil until it stops coming out.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
3-12
PERIODIC MAINTENANCE
NOTICE
-----------------------
When the oil tank is empty, never start the
engine.
6. Idle the engine more than 1O seconds while
keeping the machine upright. Then stop the
engine and add the oil to the maximum level.
7. Install:
• Oil tank cap
EAS1DX3087
NOTICE
------------------------
• Engine oil also lubricates the clutch and
the wrong oil types or.additives could
cause clutch slippage. Therefore, do not
add any chemical additives or use engine
oils with a grade of CD or higher and do
not use oils labeled " ENERGY CONSERV-
ING II".
• Do not allow foreign materials to enter the
crankcase.
0 10 30 50 70 90 110 130 °F
I I I I
I ·1
1..
I SAEI1ow-10
I I_srE 10t-so I Ir
I..
,- S~E 1 sw-4~
1
- S~E20W-40
I - SAE20W-50
-20 - 10
I
10 20 30 40 50 °C
0
TIP _ _ _ _ _ _ _ _ __ _ _ __ _
3-13
PERIODIC MAINTENANCE
6. Fill:
•Engine oil
••••••••••••••••••••••••••••••••
1O.lnstall:
•Engine guard
3-14
PERIODIC MAINTENANCE
EAS10X3088
c. Turn the adjusting bolt "2" in direction "a" or
ADJUSTING THE CLUTCH LEVER FREE
"b" until the specified clutch lever free play is
PLAY
obtained.
1. Check:
• Clutch lever free play "a" Direction "a"
Out of spe"cification ~ Adjust. Clutch lever free play is increased.
Direction "b"
~ Clutch le~edre~ play Clutch lever free play is decreased.
v~ 8.0-13.0 mm (0.31-:-0.51 in)
d. Tighten the locknut "1".
e. Return the clutch cable cover to its original
position.
a
2. Adjust:
• Clutch lever free play
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
Handlebar side
a. Tum the adjusting bolt "1" in direction "a" or EAS10X3089
CHECKING THE COOLANT LEVEL
"b" until the specified clutch lever free play is EWA10X1003
obtained.
A WARNING
Direction "a" A hot radiator is under pressure. Therefore,
Clutch lever free play is increased. do l".IOt remove the radiator cap when the en-
Direction "b" · . gine is hot. Scalding hot fluid and steam
Clutch lever free play is decreased. may be blown out,- which could cause seri-
ous injury. When the engine has cooled,
open the radiator cap as follows:
Place a thick rag or a towel oyer the radiator
cap and slowly turn the radiator cap coun-
terclockwise toward the detent to allow any
residual pressure to escape~ When the hiss-
ing sound has stopped, press down on the
radiator· cap and turn it counterclockwise to:
remove.
1. Stand the vehicle on a level surface.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ TIP _ _ _ _ _ _ _ _ _ _ _ _ __
If the specified clutch lever free play cannot be .. • Place the vehicle on a suitable stand.
obtained on the handlebar side of the cable, • Make sure the vehicle is upright.
use the adjusting nut on the clutch cable side. 2. Remove: .
• Radiator cap "1"
AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
Clutch cable side
a. Slide the clutch cable cover.
b. Loosen the locknuts "1".
3-15
PERIODIC MAINTENANCE
2. Check:
•Radiator
• Radiator hose
Cracks/damage~ Repla~e.
Refer to "RADIATOR" on page 7-1.
3. Install:
•Fuel tank
Refer to "FUEL TANK" on page 8-1.
•Air scoop (left/right) ·
•Seat .
3. Check: Refer to "GENERAL CHASSIS" on page 5-
• Coolant level "a" 1.
Coolant level low ®Add coolant.
EAS1DX3091
A WARNING
1 A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en-
itIll
gine is hot. Scalding hot fluid and steam
may be blown out, which could cause seri-
ous injury. When the engine has cooled,
open the radiator cap as follows:
Place a thick rag or a towel over the radiator
1. Radiator cap and slowly turn the radiator cap coun-
ECA1DX1004 terclockwise toward the detent to allow any
ftr8Ai~~~~~~~~ residual pressure to escape. When the hiss-
• Adding water instead of coolant lowers the ing sound has stopped, press down on the
antifreeze content of the coolant. If water radiator cap and turn it counterclockwise to
is used instead of coolant check, and if remove.
necessary, correct the antifreeze concen- 1. Remove:
tration of the coolant. •Seat
•Use only distilled water. However, if dis- • Left side cover
tilled water is not available, soft water may 2. Remove the catch tank hose from the catch
be used. tank and drain the tank of its coolant.
4. Start the engine, warm it up for several min- 3. Remove:
utes, and then turn it off. • Coolant drain bolt "1"
5. Check:
• Coolant level
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
EAS1DX3090
3-16
PERIODIC MAINTENANCE
5. Clean: 9. Install:
•Cooling system • Radiator cap
Thoroughly flush the cooling system with 1a.Start the engine, warm it up for several min-
clean tap water. utes, and then stop it.
6. Install: 11.Check:
• Copper washer DB • Coolant level
•Coolant drain bolt Refer to "CHECKING THE COOLANT LEV-
EL" on page 3-15.
Coolant drain bolt TIP _ _ _ _ _ _ _ _ _ _ _ _ __
1O Nm (1.0 m·kgf, 7.2 ft-lbf)
Before checking the coolant level, wait a few
7. Install: minutes until the coolant has settled.
• Catch tank hose
12.lnstall:
8. Fill:
• Left side cover
• Cooling system
•Seat
(with the specified amount of the recom-
Refer to "GENERAL CHASSIS" on page 5-
mended coolant)
1.
Recommended antifreeze
High-quality ethylene glycol anti- EAS1DX3092
!mm~~~~~~~~~
• Adding water instead of coolant lowers the
antifreeze content of the coolant. If water
is used instead of coolant check, and if
necessary, correct the antifreeze concen-
tration of the coolant.
•Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
• If coolant comes into contact with painted
surfaces, immediately wash them with wa- A. Front brake
B. Rear brake
ter.
• Do not mix different types of antifreeze.
3-17
PERIODIC MAINTENANCE
EWA13090
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
A WARNING a. Loosen the locknut "1 ".
• Use only the designated brake fluid. Other b. Turn the adjusting bolt "2" in direction "a" or
brake fluids may cause the rubber seals to "b" until the specified brake lever position is
deteriorate, causing leakage and. poor obtained.
brake performance.
• Refill with the same type of brake fluid that Direction "a"
is already in the system. Mixing brake flu- Brake lever position is increased.
ids may result in a harmful chemical reac- Direction "b"
Brake lever position is decreased.
tion, leading to poor brake performance.
•When refilling, be careful that water does c. Tighten the locknut "1 ".
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of Locknut
the brake fluid and could cause vapor 5 Nm (0.5 m·kgf, 3.6 ft-lbf)
lock.
ECA13540
!~J'til~~~~~~~~~
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
EAS10X3094
ADJUSTING THE FRONT DISC BRAKE
1. Check:
• Brake lever position "a" EWA13050
a ··~~~~~~~~-
After adjusting the brake lever position,
make sure there is no brake drag.
EAS1DX309S
3-18
PERIODIC MAINTENANCE
AwARNING
A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will consid-
erably reduce braking performance.
ECA13510
EAS1DX3096
-·~~~~~~~~
After adjusting the brake pedal position,
ADJUSTING THE REAR DISC BRAKE
1. Check: make sure there is no brake drag.
• Brake pedal position "a"
(distance "a" from the top of the rider footrest
EAS1DX3097
to the top of the brake pedal)
CHEC~NGTHEREARBRAKEPADS
Out of specification~ Adjust.
The following procedure applies to all of the
Brake pedal position brake pads.
0.0 mm (0.00 in) 1. Operate the brake.
2. Check:
• Rear brake pad
Wear indicators "1" almost touch the brake
disc ~ Replace the brake pads as a set.
Refer to "REAR BRAKE" on page 5-27.
~ I\
2. Adjust:
• Brake pedal position
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Loosen the locknut "1".
b. Turn the adjusting bolt "2" in direction "a" or
EAS1DX3098 -
"b" until the specified brake pedal position is
CHECKING THE REAR BRAKE PAD INSU-
obtained. , LATOR
Direction "a" 1. Remove:
Brake pedal is raised. •Brake pad
Direction "b" Refer to "REAR BRAKE" on page 5-27.
Brake pedal is lowered. 2. Inspect:
• Rear brake pad insulator "1"
Damage ~ Replace.
3-19
PERIODIC MAINTENANCE
EAS1DX3099
BLEEDING THE HYDRAULIC BRAKE SYS-
TEM
EWA13100
AwARNING
Bleed· the hydraulic brake system whenev-
er:
• the system is disassembled.
• a brake hose is loosened, disconnected or
replaced.
•the brake fluid level is very low. A. Front
B. Rear
•brake operation is faulty.
d. Place the other end of the hose into a con-
1. Remove:
tainer.
• Brake master cylinder reservoir cap
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ e. Slowly apply the brake several times.
f. Fully pull the brake lever or fully press down
• Be careful not to spill any brake fluid or allow the brake pedal and hold it in position.
the brake master cylinder reservoir or brake g. Loosen the bleed screw.
fluid reservoir to overflow. TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
• When bleeding the hydraulic brake system,
Loosening the bleed screw will release the
make sure there is always enough brake fluid
pressure and cause the brake lever to contact
before applying the brake. Ignoring this pre-
the throttle grip or the brake pedal to fully ex-
caution could allow air to enter the hydraulic
tend.
brake system, considerably lengthening the
bleeding procedure. h. Tighten the bleed screw and then release
• If bleeding is difficult, it may be necessary to the brake lever or brake pedal.
let the brake fluid settle for a few hours. Re- i. Repeat steps (e) to (h) until all of the air bub-
peat the bleeding procedure when the tiny bles have disappeared from the brake fluid
bubbles in the hose have disappeared. in the plastic hose.
j. Tighten the bleed screw to specification.
2. Bleed:
• Hydraulic brake system ~ ,,. Bleed screw
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT ~~ 6 Nm (0.6 m·kgf, 4.3 ft-lbf)
a. Fill the brake fluid reservoir to the proper lev-
el with the recommended brake fluid. k. Fill the brake fluid reservoir to the proper lev-
b. Install the diaphragm (brake master cylinder el with the recommended brake fluid.
. reservoir or brake fluid reservoir). Refer to "CHECKING THE BRAKE FLUID
c. Connect a clear plastic hose "1" tightly to the LEVEL" on page 3-17.
EWA13110
bleed screw "2", and place an oil pan under
j\WARNING
the vinyl hose end on one side.
After bleeding the hydraulic brake system,
check the brake operation.
3-20
PERIODIC MAINTENANCE
EAS1DX3100 EAS1DX3102
CHECKING THE FRONT BRAKE HOSE CHECKING THE WHEELS
1. Check: The following procedure applies to both of the
• Brake hose "1" wheels.
Cracks/damage/wear ~ Replace. 1. Check:
•Wheel
Damage/out-of-round ~ Replace.
EWA13260
j \ WARNING
Never attempt to make any repairs to the
wheel.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
3-21
PERIODIC MAINTENANCE
Tire inspection
The tires must be checked before each ride.
ECA10X3001
P'iO,;~
Etd?ll~~ ~~~~~~~~~~~~-
~
Spoke nipple wrench (6-7) valve stem is positioned straight.
90890-01521
YM-01521
Tire information
x Spoke (front/rear)
3 Nm (0.3 m·kgf, 2.2 ft-lbf)
TIP~~~~~~~~~~~~~~~
This motorcycle is equipped with spoke wheels
and tube tires.
After extensive tests, only the tires listed below
have been approved for this model by Yamaha
Motor Co., Ltd.
Be sure to tighten the spokes before and after
~
break-in. Front tire
Size
EAS10X3104
80/100-21 51 M
CHECKING THE TIRES Manufacturer/model
To maximize the performance, durability, and DUNLOP/GEOMAX MX51 FG
safe operation of your motorcycle, note the fol-
~
lowing points regarding the specified tires. Rear tire
Size
Tire air pressure 120/90-18 65M
The tire air pressure should be checked and, if Manufacturer/model
necessary, adjusted before each ride. DUNLOP/GEOMAX MX51
EWA10X3001
EWA1DX3002
A WARNING
AwARNING
Operation of this vehicle with improper tire
• Have a Yamaha dealer replace excessively
pressure may cause severe injury or death
from loss of control. worn tires. Operating the .motorcycle with
excessively worn tires decreases riding
•The tire air pressure must be checked and
stability and can lead to loss of control.
adjusted on cold tires (i.e., when the tem-
perature of the tires equals the ambient • The replacement of all wheel and brake-re-
lated parts, including the tires, should be
temperature).
left to a Yamaha dealer, who has the nec-
•The tire air pressure must be adjusted in
~ssary professional knowledge and expe-
accordance with the weight of the rider,
rience.
the riding speed, and the riding condi-
• It is not recommended to patch a punc-
tions.
tured tube. If unavoidable, however, patch
Standard tire air pressure the tube very carefully and replace it as
Front and Rear soon as possible with a high-quality prod-
100 kPa (1.00 kgf/cm2 , 15 psi) uct.
3-22
PERIODIC MAINTENANCE
EAS1DX3105
CHECKING THE WHEEL BEARlf~~GS
The following procedure applies to all of the
wheel bearings.
1. Check:
• Wheel bearings
Refer to "CHECKING THE FRONT WHEEL"
on page 5-6 and "CHECKING THE REAR
WHEEL" on page 5-11.
EAS1DX3106
CHECKING THE SWINGARM OPERATION 1. Drive chain slack
1. Check: 2. Chain support mounting bolt
• Swingarm operation 3. Chain tensioner
Swingarm not working properly ---+ Check
the swingarm. Drive chain slack
Refer to "SWINGARM" on page 5-67.
48.0-58.0 mm (t.89- 2.28 in)
2. Check: 5. Adj~st:
• Swingarm excessive play · • Drive chain slack
Refer to "SWI NGARM" on page 5-67.
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
EAS10X3107 a. Loosen the wheel axle nut "1 ".
ADJUSTING THE DRIVE CHAIN SLACK b. Loosen both locknuts "2". .
ECA13550
c. Turn the drive chain puller "3" in direction "a"
11...iJ!/~:JJ~-------------~~ or "b" until the specified drive chain slack is
A drive chain that is too tight will overload obtained.
the engine and other vital parts, and one
that is too loose can skip and damage the Direction "a"
swingarm or cause an accident. Therefore, Drive chain is tightened.
Direction "b"
keep the drive _chain. slack within the speci-
Drive chain is loosened.
fied limits.
1. Elevate the rear wheel by placing the suit-
able stand under the engine.
EWA13120
A WARNING
Securely support the vehicle so that there is
no danger ~fit falling. over. ·
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
3-23
PERIODIC MAINTENANCE
EAS10X3108
EAS1DX3109
~
1. Stand the vehicle on a level surface.
Steering nut wrench
EWA13120 90890-01403
VU-A9472
Securely support the vehicle so that there is
~
no danger of it falling over. Ring nut (initial tightening torque)
38 Nm (3.8 m·kgf, 27 ft-lbf)
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Place the vehicle on a suitable stand so that the c. Turn the front fork to the right and left a few
front wheel is elevated. times, and make sure that the steering ro-
tates smoothly. If it does .not turn smoothly,
2. Check: remove the lower bracket and inspect the
• Steering head upper and lower bearings.
Grasp the bottom of the front fork legs and Refer to "STEERING HEAD" on page 5-58.
gently rock the f rant fork. d. Loosen the ring nut "311 fully turn and then
Blinding/looseness ~ Adjust the steering tighten it to specification with a steering nut
head. wrench.
3. Remove: EWA13140
•Handlebar j \ WARNING
Refer to "HANDLEBAR" on page 5-38. Do not overtighten the ring nut.
• Upper bracket ·
Refer to "STEERING HEAD" on page 5-58. Ring nut {final tightening torque)
4. Adjust: 7 Nm (0.7 m·kgf, 5.1 ft-lbf)
• Steering head
3-24
PERIODIC MAINTENANCE
EAS1DX3113
e. Check the steering head for loqseness or
CHEC~NGTHEFRONTFORK
binding by turning the front fork all the way in
1. Stand the vehicle on a level surface.
both directions. If any binding is felt, remove EWA13120
EAS10X3110 •
LUBRICATING THE LEVERS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers.
EAS10X3114
Brake lever ADJUSTING THE FRONT FORK LEGS
....,. Silicone grease The following procedure applies to both of the
Clutch lever front fork legs.
Lithium·-soap-based grease EWA3201006
A WARNING
EAS10X3111
• Always adjust the left and right front forks
LUBRICATING THE PEDAL
evenly. If this is not done, the vehicle will
Lubricate the pivoting point and metal-to-metal
have poor stability.
moving parts of the pedal.
• Securely support the vehicle so that there
Recommended lubricant is no danger of it falling over.
....,. Lithium-:soap-based grease
Rebound damping
EAS10X3112 ECA13590
3-25
PERIODIC MAINTENANCE
~
Rebound damping
Maximum (hard)
Fully turned in
Standard
12 click (s) out*
Minimum
20 click (s) out*
* With the adjusting screw fully turned in
EAS1DX3115
AIR BLEEDING FROM FRONT FORK
When the temperature increases in the front
fork during touring, the air pressure increases
in the fork and the suspension will become less
flexible.
Bleed following procedure.
1. Stand the vehicle on a level surface.
EWA13120
j \ WARNING
Securely support the vehicle so that there is
Compression damping no danger of it falling over.
ECA13590
lmll~~~~~~~~~~- TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Never go beyond the maximum or minimum Stand the vehicle vertically using an appropri-
adjustment positions. ate stand, and bleed the air from the front fork.
1. Adjust: 2. Bleed the air from the front fork.
• Compression damping Bleed the air from the front fork by removing
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT bleed screw "1 ".
a. Turn the adjusting screw "1" in direction "a" ECA3201001
or"b".
kB•~--------~---
• Always bleed the left and right front fork
Direction "a"
Compression damping is increased evenly.
(suspension is harder). •If this is not done, the vehicle will have
Direction "b" poor stability.
Compression damping is decreased
(suspension is softer).
3-26
PERIODIC MAINTENANCE
1. Remove:
• Rearframe
Refer to "REAR SHOCK ABSORBER AS-
SEMBLY" on page 5-61.
2. Adjust:
• Spring preload
TYYTYYTTTTTTTTTTTTTTTTTTTTTTYTTT
a. Loosen the locknut "1 ". ·
b. Loosen the adjusting ring "2" until there is
some clearance between the spring and ad-
3. Install: justing ring.
•Bleed screw c. Measure the spring free length "a".
Bleed screw
1.3 Nm (0.13 m·kgf, 0.94 ft-lbf)
EAS10X3116
A WARNING
Securely support the vehicle ·so that there is
no danger of it falling over. I
~
• Rear suspension link pivots Spring installed length "d"
Push down seat on the vehicle several times Minimum
and check if the rear shock absorber assem- Position in which the· spring is
bly rebounds smoothly. turned in 1.5 mm (0.06 in) from
its free length.
Rough movement ~ Repair.
Standard
Refer to "REAR SHOCK ABSORBER AS- Position in which the spring is
SEMBLY" on page 5-61. turned in 18 mm (0.71 in) from its
EAS10X3117
free length. .
ADJUSTING THE REAR SHOCK ABSORB- Maximum
ER ASSEMBLY Position in which the spring is
EWA13120 turned in 18 mm (0.71 in) from its
AwARNING free length.
Securely support the vehicle so that there is
TIP~~~~~~~~~~~~~~
no danger of it falling ov~r.
•Be sure to remove all dirt and mud from
around the locknut and adjusting ring before
Spring preload
ECA13590
· adjustment.
• The length of the spring (installed) changes
Never go beyond the maximum or minimum 1.5 mm (0.06 in) per turn of the adjusting ring.
adjustment positions.
3-27
PERIODIC MAINTENANCE
~
pension is harder). Compression damping adjusting
Direction " b" positions (for fast compression
Rebound damping is decreased (sus- damping)
pension is softer). Maximum
Fully turned in
Standard
718 turn (s) out*
Minimum
2 turn (s~ out*
* With the adjusting bolt fully turned in
3-28
PERIODIC MAINTENANCE
3-29
PERIODIC MAINTENANCE
. EAS1DX3121
1. Check:
CHECKING THE CHASSIS FASTENERS
• Throttle grip free play "a"
Make sure that all nuts, bolts, and screws are
Out of specification ~ Adjust.
properly tightened.
Refer to "CHASSIS TIGHTENING TORQUES"
on page 2-17.
EAS1DX3122
CHECKING AND CHARGING THE BATTERY
Refer to "CHECKING AND CHARGING THE
BATTERY" on page 9-66.
2. Adjust:
•Throttle grip free play
TIP~~~~~~~~~~~~~~
EWA12920
A WARNING
After adjusting the throttle grip free play,
start the engine and turn the handlebars to
the right and to the left to ensure that this
does not cause the engine idling speed to
change.
3-30
PERIODIC MAINTENANCE
3-31
TUNING
CHASSIS ..........................................................................................................4-1
SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET)4-1
DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS .................. .4-1
TIRE PRESSURE ....................................................................................... 4-1
FRONT FORK SETTING .................................................................. :.........4-2
CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL ........... .4-2
SETTING OF SPRING AFTER REPLACEMENT ...................................... .4-2
FRONT FORK SETTING PARTS ............................................................... 4-3
REAR SUSPENSION SETTING ....................................................... ......... .4-3
CHOOSING SET LENGTH ................ ........ ................................................ .4-3
SETTING OF SPRING AFTER REPLACEMENT ....................................... 4-4
REAR SHOCK ABSORBER SETTING PARTS ......................................... 4-5
SUSPENSION SETTING (FRONT FORK) ..................................... ............ 4-6
SUSPENSION SETTING (REAR SHOCK ABSORBER) .......................... .4-8
CHASSIS
EAS1DX3124 EAS1DX3126
4-1
CHASSIS
EAS10X3128
2
FRONT FORK SETTING
B
The front fork setting should be niade depend-
[kg (lb)] 3
ing on the rider's feeling of an actual run and
the circuit conditions.
The front fork setting includes the following
three factors:
1. Setting of air spring characteristics
• Change the fork oil amount.
2. Setting of spring preload C [mm (in)]
• Change the spring.
3. Setting of damping force
• Change the compression damping.
• Change the rebound damping.
The spring acts on the load and the damping A. Air spring characteristics in relation to oil
amount change
force acts on the cushion travel speed.
B. Load
C. Stroke
EAS10X3129
4-2
CHASSIS
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
EAS10X3131
4-3
CHASSIS
EAS1DX3134 ·
2. Remove the stand or block from the engine
SETTING OF SPRING AFTER REPLACE-
and with a rider astride the seat, measure
MENT
the sunken length 11 b 11 between ~he rear
After replacement, be sure to adjust the spring
wheel axle center and the rear fender hold-
to the set length [sunken length 90-100 mm·
ing bolt. (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
b 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 damp-
ing to compensate for its greater spring load.
fl II ) Run with the rebound damping adjuster one
11 11
3. Loosen the locknut 1 and make adjust- or two clicks on the stiffer side and readjust
11
ment by turning the spring adjuster 2 11 to it to suit your preference.
achieve the standard figure from the sub- TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
11
traction of the length 11 b 11 from the length "a •
Adjusting the rebound damping will be followed
Standard figure: more or less by a change in the compression
90-100 mm (3.5-3.9 in) damping. For correction, turn the low compres-
sion damping adjuster on the softer side.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
EWA1DX4002
• If the machine is new and after it is broken in, A WARNING
the same set length of the spring may change When using a rear shock absorber other
because of the initial fatigue, etc. of the than currently installed, use the one whose
spring. Therefore, be sure to make reevalua- overall length "a" does not exceed the stan-
tion. dard as it may result i.n faulty performance.
• If the standard figure cannot be achieved by Never use one whose overall length is
adjusting the spring adjuster and ch~ngin~ greater than standard.
the spring set length, replace the spnng with
an optional one and make readjustment. Length "a" of standard shock:
488.5 mm (19.23 in)
4-4
CHASSIS
EAS10X3135
4-5
CHASSIS
EAS1DX3136
SUSPENSION SETIING {FRONT FORK)
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
• If any of the following symptoms is experienced with the standard position as the base, make reset-
ting by reference to the adjustment procedure given in the same ch~rt.
• Before any change, set the rear shock absorber sunken length to the standard figure 90-100 mm
(3.5-3.9 in).
Section
Symptom Medi- Check Adjust
Large Small
Jump um
gap gap
gap
Compression Turn adjuster counterclock-
damping wise (about 2 clicks) to de-
crease damping.
Stiff over entire
range 0 0 0 Oil amount Decrease oil amount by about
5-10 cm 3 (0.2-0.4 Imp.oz,
0.2-0.3 US oz).
Spring Replace with soft spring.
Outer tube Check for any bends, dents,
Inner tube and other noticeable scars,
etc. If any, replace affected
parts.
Unsmooth Slide metal Replace with a new one for ex-
movement over 0 0 0 0 tended use.
entire range Piston metal Replace with a new one for ex-
tended use.
Under bracket Retighten to specified torque.
tightening
torque
Rebound Turn adjuster counterclock-
Poor initial damping wise (about 2 clicks) to de-
movement 0 crease damping.
Oil seal Apply grease in oil seal wall.
Compression Turn adjuster clockwise (about
damping 2 clicks) to increase damping.
Soft over entire
Oil amount Increase oil amount by about
range, bottom- 0 0
ing out 5-10 cm 3 (0.2-0.4 Imp.oz, .
0.2-0.3 US oz).
Spring Replace with stiff spring.
Stiff toward Decrease oil amount by about
0 Oil amount
stroke end 5 cm 3 (0.2 lmp.oz,0.2 US oz).
Soft toward Increase oil amount by about 5
3 .
stroke end, bot- 0 Oil amount cm (0.2 lmp.oz,0.2 US oz).
taming out
Stiff initial Turn adjuster counterclock-
Compression
movement 0 0 0 0 damping wise (about 2 clicks) to de-
crease damping.
4-6
CHASSIS
Section
Symptom Medi- Check Adjust
Large um Small
Jump
gap gap
gap
Compression Turn adjuster clockwise (about
damping 2 clicks) to increase damping.
Rebound Turn adjuster counterclock-
damping wise (about 2 clicks) to de-
Low front, tend- crease damping.
ing to lower 0 0 Balance with Setsunkenlengthfor95-100
front posture rear end mm (3.7-3.9 in) when one
passenger is astride seat (low-
er rear posture).
Oil amount Increase oil amount by about 5
cm 3 (0.2 Imp.oz, 0.2 US oz).
Compression Turn adjuster counterclock-
damping wise (about 2 clicks) to de-
crease damping.
11
Balance with Set sunken length for 90-95
0btrusive11 rear end mm (3.5-3.7 in) when one
front, tending to passenger is astride seat (up-
upper front pos- 0 0
per rear posture).
tu re
Spring Replace with soft spring.
Oil amount Decrease oil amount by about
. 5-1 O cm 3 (0.2-0.4 Imp.oz,
0.2-0.3 US oz).
4-7
CHASSIS
EAS1DX3137
SUSPENSION SETTING (REAR SHOCK ABSORBER)
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• If any of the following symptoms is experjenced with the standard position as the base, make reset-
ting by reference to the adjustment procedure given in the same chart.
• Adjust the rebound damping in 2-click increments or decrements.
• Adjust the low compression damping in 1-click increments or decrements.
•Adjust the high compression damping in 1/6 turn increments or decrements.
Section
Symptom Medi- Check Adjust
Large Small
Jump um
gap gap
gap
Rebound Turn adjuster counterclock-
damping wise (about 2 clicks) to de-
Stiff, tending to crease damping.
sink 0 0
Spring set Set sunken length for 90-100
length mm (3.5-3.9 in) when one
passenger is astride seat.
Rebound Turn adjuster clockwise (about
damping 2 clicks) to increase damping.
Spongy and un-
stable 0 0 Low compres- Turn adjuster clockwise (about
sion damping 1 click) to increase damping.
Spring Replace with stiff spring.
Rebound Turn adjuster counterclock-
Heavy and damping wise (about 2 clicks) to de-
dragging 0 0 crease damping.
Spring Replace with soft spring.
Rebound Turn adjuster clockwise (about
damping 2 clicks) to increase damping.
Low compres- Turn adjuster clockwise (about
sion damping 1 clicks) to increase damping.
Poor road grip- High compres- Turn adjuster clockwise (about
ping 0 sion damping 1/6 turn) to increase damping.
Spring set Set sunken length for 90-100
length mm (3.5-3.9 in) when one
passenger is astride seat.
Spring Replace with soft spring.
High compres- Turn adjuster clockwise (about
sion damping 1/6 turn) to increase damping.
Spring set Set sunken length for 90-100
Bottoming out 0 0 .length mm (3.5-3.9 in) when one
passenger is astride seat.
Spring Replace with stiff spring.
Rebound Turn adjuster clockwise (about
Bouncing 0 0 damping 2 clicks) to increase damping.
Spring Replace with soft spring.
4-8
CHASSIS
Section
Symptom Medi· Check Adjust
Large Small
Jump um
gap gap
gap
Turn adjuster counterclock~
High compres-
sion damping·. wise (about 1/6 turn) to.deM
crease· damping ..
Stiff travel 0 0 Spring set .. · Set sunken length for 90- ~ QQ
length mm (3.5-3.9 in) when orie
passenger
.
-~
is astriq~ ~eat.
~.
4-9
CHASSIS
SWINGARM ..•••.•.•.•.•••••..•.••.••••.•••••.•••••••••••••••••••••••••.•••••••••••••••••••••.•••••••••••••••••5-67
REMOVING THE SWINGARM .................................................................5-69
CHECKING THE SWINGARM .................................................................5-69
INSTALLING THE SWINGARM ...............................................................5-70
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
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 knowl-
edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas-
sembly, or reassembly only by reference to this manual. It may lead to servicing trouble and
mechanical damage.
EAS1DX3138
GENERAL CHASSIS
Removing the cowling
3 22 Nm (2.2 m • kgf, 16 ft • lbf)
5-1
GENERAL CHASSIS
I
''
I
I
I
I
5-2
GENERAL CHASSIS
I
I
-~-
16
5-3
GENERAL CHASSIS
EAS10X3139
5-4
FRONT WHEEL
EAS1DX3140
FRONT WHEEL
Removing the front wheel
5-5
FRONT WHEEL
EAS21890
REMOVING THE FRONT WHEEL
1. Stand the vehicle on a level surface.
EWA13120
A WARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
EWA13460
AwARNING
Do not attempt to straighten a bent wheel
axle.
2. Check:
•Tire
• Front wheel
Damage/wear ~ Replace. Radial wheel runout limit
Refer to "CHECKING THE TIRES" on page 2.0 mm (0.08 in)
3-22 and "CHECKING THE WHEELS" on Lateral wheel runout limit
2.0 mm (0.08 in)
page 3-21.
3. Check: 6. Check:
•Spokes •Collars
Bends/damage ~ Replace. Damage/wear~ Replace.
Loose ~ Tighten. 7. Check:
Tap the spokes with a screwdriver. • Wheel bearings
Front wheel turns roughly or is loose ~ Re-
place the wheel bearings.
•Oil seals
Damaae/wear ~ Replace.
5-6
FRONT WHEEL
EAS21960
ASSEMBLING THE FRONT WHEEL
1. Install:
•Bearing (left side) "1"
•Spacer "211
• Bearing (right side) "3"
•Oil seal "4" Im
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
b. Remove the oil seals "1" with a flat-head Do not strike the inner race of the bearing.
screwdriver. Contact should be made only with the outer
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ race.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
5-7
FRONT WHEEL
4. Install
• Speed sensor "1"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Apply the lithium soap base grease on the oil
seal lip of speed sensor.
Make sure the two projections "a" in the wheel
hub are meshed with the two slots "b" in the
speed sensor.
2. Install:
• Brake disc "1"
• Brake disc bolt "2"
TIP _ _ _ _ _ __ _ _ _ _ _ __ _
Tighten the bolts in stage, using a c risscross
pattern. EAS10XJ142
3. Install:
• Collar "1" /-
I
TIP _ _ _~~----~~---
Apply the lithium soap base grease on the oil
seal lip.
5-8
FRONT WHEEL
2. Install:
• Wheel axle "1"
TIP _ _ _ _ _ _ _ _ _ _ _ __
Apply the lithium soap base grease on the
wheel axle.
3. Install:
• Wheel axle nut "1"
Front wheel ·axle nut
90 Nm (9.0 m·kgf, 65 ft-lbf)
ECA14140
19•~~~~~~~~~-
Before tightening the wheel axle nut, push
down hard on the handlebar(s) several
times and check if the front fork rebounds
smoothly.
4. Tighten:
• Front wheel axle pinch bolt "1"
Front wheel axle pinch bolt
21 Nm (2.1 m·kgf, 15 ft-lbf)
5-9
REAR WHEEL
EAS22020
REAR WHEEL
5-10
REAR WHEEL
EAS22040
2. ·Check:
REMOVING THE REAR WHEEL
•Tire
1. Stand the vehicle on a level surface.
EWA13120 •Rear wheel
AwARNING Damage/wear ~ Replace.
Securely support the vehicle so that there is Refer to "CHECKING THE TIRES" on page
no danger of it falling over. 3-22 and "CHECKING THE WHEELS" on
page 3-21.
TIP~~~~~~~~~~~~~~ 3. Check:
Place the vehicle on a suitable stand so that the •Spokes ·
rear wheel is elevated. Refer to "CHECKING THE FRONT WHEEL"
on page 5-6.
2. Elevate: •
4. Measure:
•Rear wheel
• Radial wheel runout
3. Remove:
• Lateral wheel runout
• Rear wheel axle nut "1"
Refer to "CHECKING THE FRONT WHEEL"
4. Loosen:
on page 5-6.
• Locknut "2"
5. Tighten: Radial wheel runout limit
•Adjusting bolt "3" 2.0 mm (0.08 in)
Lateral wheel runout limit
2.0 mm (0.08 in)
EAS22080
DISASSEMBLING THE REAR WHEEL
1. Remove:
•Oil seals
• Wheel bearings
3 Refer to "DISASSEMBLING THE FRONT
WHEEL" on page 5-7.
EAS22120
CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
1. Check:
• Push the rear wheel forward and remove the • Rear wheel sprocket
drive chain from the rear wheel sprocket. More than 1/4 tooth "a" wear~ Replace the
• Do not de pres st the brake pedal when re- drive chain s·procket as a set.
moving the rear wheel. Bent teeth ~ Replace the drive chain
sprocket as a set.
EAS1DX3143 a
CHECKING THE REAR WHEEL
1. Check:
•Wheel axle
•Rear wheel
• Wheel bearings
•Oil seals
Refer to "CHECKING THE FRONT WHEEL'~.
on page 5-6.
b. Correct
1. Drive chain roller
2. Rear wheel sprocket
5-11
REAR WHEEL
2. Replace:
• Rear wheel sprocket
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Remove the self-locking nuts and the rear
wheel sprocket.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact
the sprocket.
c. Install the new rear wheel sprocket.
Rear wheel sprocket self-locking
nut
·50 Nm (5.0 m·kgf, 36 ft·lbf)
TIP ~~~~~~~~~~~~~~~
2. Install:
• Brake disc "1"
• Brake disc bolt "2"
Brake disc bolt
14 Nm (1.4 m·kgf, 1Oft· Ibf)
LOCTITE®
TIP ~~~~~~~~~~~~~~~
EAS22140
ASSEMBLING THE REAR WHEEL Tighten the bolts in stage, using a crisscross
1. Install: pattern.
• Bearing (right side) "1"
• Circlip "2"mm!I
•Spacer "3"
• Bearing (left side) "4"
• Oil seal "5" mm!I
TIP ~~~~~~~~~~~~~~~
5-12
REAR WHEEL
4. Install 3. Install:
•Collar "1" • Left drive chain puller "1"
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ • Wheel axle "2"
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Apply the lithium soap base grease on the oil
seal lip. • Install the left drive chain puller, and insert the
wheel axle from left side.
• Apply the lithium soap base grease on the
wheel axle.
EAS22160
INSTALLING THE REAR WHEEL (DISC)
1. Install:
4. Install:
•Wheel
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ • Right drive chain puller "1"
• Washer"2"
Install the brake disc "1" between the brake • Wheel axle nut "3"
pads "2" correctly. TIP _ _ _ _ _ _ _ _ _ _ _ _ __
2·. Install:
• Drive chain "1"
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Push the wheel "2" forward and install the drive
chain.
5-13 .
REAR WHEEL
5. Adjust:
• Drive chain slack "a"
A Drive chain slack
v ~ 48.0-58.0 mm (1.89- 2.28 in)
-~
6. Tighten:
•Wheel axle nut "1"
Wheel axle nut
125 Nm (12.5 m·kgf, 90 ft-lbf)
• Locknut "2"
Locknut
19 Nm (1.9 m·kgf, 14 ft-lbf)
5-14
FRONT BRAKE
EAS1DX3144
FRONT BRAKE
Removing the front brake pads
5-15
FRONT BRAKE
5-16
FRONT BRAKE
5-17
FRONT BRAKE
5-18
FRONT BRAKE
1 4
/
~
5-19
FRONT BRAKE
EAS22220
INTRODUCTION TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
EWA14100 a. Place the vehicle on a suitabi'e stand so that
A WARNING the front wheel is elevated.
Disc brake components rarely require dis- b. Before measuring the front brake disc de-
assembly. Therefore, always follow these flection, turn the handlebar to the left or right
preventive measures: to ensure that the front wheel is static.nary.
• Never disassemble brake components un- c. Remove the brake caliper~
less absolutely necessary. d. Hold the. dial gauge at a right angle against
• If any connection on the hydraulic brake the brake disc surface.
system is disconnected, the entire brake e. Measure the deflection front 1O mm (0.39
system must be disassembled, drained, in), rear7 mm (0.28 in) below the edge of the
cleaned, prope_rly filled, and bled after re- brake disc.
assembly. AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA·
• Never use solvents on internal brake com- 4. Measure: ·
ponents. • Brake disc thickness
• us·e only clean or new brake fluid for Measure the brake disc thickness at a few
cleaning brake components. different locations.
• Brake fluid may damage painted surfaces Out of specification ~ Replace.
and plastic parts. Therefore, always cle.an
up any spilt brake fluid immediately.
•Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
• FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.
EAS22230
CHECKING THE FRONT BRAKE DISC ·
1. Remove: Brake disc thickness limit
•Front wheel 2.5 mm (0.10 in)
Refer to "FRONT WHEEL" on page 5-5.
5. Adjust:
2. Check:
• Brake disc deflection
•Front brake disc
Damage/galling -4 Replace. TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
3. Measure: a. Remove the brake disc.
•Brake disc deflection b. Turn the brake disc by one bolt hole.
c. Install the brake disc.
Out of specification -4 Correct the brake disc
deflection or replace the brake disc. TIP~~~~~~~~--~~~~~~
Tighten the brake disc bolts in stages and in a
crisscross pattern.
5-20
FRONT BRAKE
a
I
lOQJ ,I
1 I
2. Install:
Brake disc bolt •Brake pads
12 Nm (1.2 m·kgf, 8.7 ft-lbf)
• Pad support
LOCTITE® TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
d. Measure the brake disc deflection. Always install new brake pads, and a pad sup-
e. If out of specification, repeat the adjustment port as a set.
steps until the brake disc deflection is within
specification. TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
f. If the brake disc deflection cannot be a. Connect a clear plastic hose "1" tightly to the
brought within specification, replace the bleed screw "2". Put the other end of the
brake disc. hose into an open container.
AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
6. Install:
• Front wheel
Refer to "FRONT WHEEL" on page 5-5.
EAS10X3145
REPLACING THE FRONT BRAKE PADS
TIP - - - -- - - - - - - - - - - 0
When replacing the brake pads, it is not neces- oooO
5-21
FRONT BRAKE
4. Check:
• Brake fluid level
Below the minimum level mark "a" -7 Add
the recommended brake fluid to the proper
level.
Refer to "CHECKING THE BRAKE FLUID
LEVEL" on page 3-17.
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Blow compressed air into the brake hose
joint opening to force out ttie pistons from
the brake caliper.
EWA13550
A WARNING
5. Check:
• Cover the brake caliper piston with a rag.
• Brake lever free play
Be careful not to get injured when the pis-
Refer to "ADJUSTING THE FRONT DISC
ton is expelled from the brake caliper.
BRAKE" on page 3-18.
• Never try to pry out the brake caliper pis-
• Brake pedal operation
ton.
Soft or spongy feeling -7 Bleed the brake
system.
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-20.
EAS22290
REMOVING THE FRONT BRAKE CALIPER
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
•Union bolt b. Remove the dust seals and brake caliper
• Copper washers piston seals.
•Brake hose
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
••••••••••••••••••••••••••••••••
EAS1DX3146
5-22
FRONT BRAKE
,_._______
BLE ROUTING" on page 2-29.
ECA14170
b
EWA13600
j\WARNING
Whenever a brake caliper is disassembled,
replace the piston seals.
2. Check:
• Brake caliper bracket
Cracks/damage 4 Replace.
EAS22400
2. Install:
ASSEMBLINGTHEFRONTBRAKECAL~ •Front brake caliper
PER • Brake pad springs
EWA13620 • Brake pad pin
A WARNING • Brake hose holder
• Before installation, all internal brake com-
Brake pad pin
ponents should be cleaned and lubricated
17 Nm (1.7 m·kgf, 12 ft-lbf)
with clean or new brake fluid.
• Never use solvents on internal brake com- Refer to "REPLACING THE FRONT BRAKE
ponents as they will cause the piston seals PADS" on page 5-21.
to swell and distort. 3. Fill:
• Whenever a brake caliper is disassembled, • Brake master cylinder reservoir
replace the brake caliper piston seals. (with the specified amount of the recom-
mended brake fluid)
~ _ RecoTm mended fluid
00 4
.__'Ll_.__
1 I _ -------------I j"{Jj R~~~m4mended fluid
EAS1DX3147
EWA13090
INSTALLING THE FRONT BRAKE CALIPER
1. Install:
j\ WARNING
•Front brake caliper bracket • Use only the designated brake fluid. Other
• Front brake caliper brake fluids may cause the rubber seals to
(temporarily} deteriorate, causing leakage and poor
• Copper washersllm brake performance.
•Brake hose
5-23
FRONT BRAKE
IBll~~~~~~~~-
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:
• Brake system
Refer·to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-20. 2
5. Check:
•Brake fluid level 2. Check:
Below the minimum level mark ~ Add the •Brake master cylinder kit
recommended brake fluid to the proper lev- Damage/scratches/wear~ Replace.
el. 3. Check:
Refer to "CHECKING THE BRAKE FLUID •Brake master cylinder reservoir cap
LEVEL" on page 3-17. 4. Check:
6. Check: •Brake master cylinder reservoir diap.hragm
• Brake lever free play holder
Refer to "ADJUSTING THE FRONT DISC • Brake master cylinder reservoir diaphragm
BRAKE" on page 3-18. holder
• Brake lever operation Cracks/damage/wear ~ Replace.
Soft or spongy feeling ~ Bleed the brake 5. Check:
system. • Brake hoses
Refer to "BLEEDING THE HYDRAULIC Cracks/damage/wear ~ Replace.
BRAKE SYSTEM" on page 3-20.
EAS22520
ASSEMBLING THE FRONT BRAKE MAS-
EAS22490
TER CYLINDER
EWA13520
REMOVING THE FRONT BRAKE MASTER
CYLINDER AwARNING
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ • Before installation, all internal brake com-
ponents should be cleaned and lubricated
Before removing the front brake master cylin-
with clean or new brake fluid.
der, drain the brake fluid from the entire brake
• Never use solvents on internal brake com-
system.
ponents.
1. Remove:
•Union bolt Recommended fluid
• Copper washers
•Brake hose
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
1'111 DOT4
5-24
FRONT BRAKE
EAS10X3148
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
A WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
2. Install: • Refill with the same type of brake fluid that
is already in the system. Mixing brake flu-
• Copper washers DB ids may result in a harmful chemical reac-
•Brake hose
tion, leading to poor brake performance.
•Union bolt
•When refilling, be careful that water does
Brake hose union bolt not enter the brake master cylinder reser-
30 Nm (3.0 m·kgf, 22 ft-lbf) voir. Water will significantly lower the. boil-
ing point of the brake fluid and could
EWA13530
cause vapor lock.
A WARNING ECA13540
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to "CA- ~--------------------------------~
Brake fluid may damage painted surfaces
BLE ROUTING" on page 2-29.
ECA1DX1007
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
~~~~~~~~~~- 4. Bleed:
Install the brake hose so that it contacts the
brake master cylinder projection 11 a 11 and • Brake system
that its bent portion 11 b 11 faces downward. Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-20.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
5. Check:
Turn the handlebar to the left and right to make • Brake fluid level
sure the brake hos~ does not touch other parts Below the minimum level mark ~ Add the
(e.g., wire harness, cables, leads). Correct if recommended brake fluid to the proper lev-
necessary. el.
Refer to "CHECKING THE BRAKE FLUID
LEVEL" on page 3-17.
6. Check:
• Brake lever free play
Refer to "ADJUSTING THE FRONT DISC
BRAKE" on page 3-18.
5-25
FRONT BRAKE
5-26
REAR BRAKE
EAS1DX3149
REAR BRAKE
Removing the rear brake pads
5-27
REAR ~RAKE
5-28
REAR BRAKE
5-29
REAR BRAKE
5-30
REAR BRAKE
5-31
REAR BRAKE
EAS22560
INTRODUCTION
EWA14100
Brake disc thickness limit
A WARNING 3.5 mm (0.14 in)
Disc brake components rarely require dis-
assembly. Therefore, always follow these 5. Adjust:
preventive measures: • Brake disc deflection
• Never disassemble brake components un- Refer to "CHECKING THE FRONT BRAKE
less absolutely necessary. DISC" on page 5-20.
~ If any connection on the hydraulic brake
system is disconnected, the entire brake
~ ,,,. Brake disc bolt
~ 14 Nm (1.4 m·kgf, 10 ft·lbf)
system must be disassembled, drained, '?> LOCTITE®
cleaned, properly filled, and bled after re-
assembly. 6. Install:
• Never use solvents on internal brake com- •Rear wheel
ponents. Refer to "REAR WHEEL" on page 5-10.
• Use only clean or new brake fluid for
cleaning brake components. EAS10X3150
REPLACING THE REAR BRAKE PADS
• Brake fluid may damage painted surfaces TIP _ _ _ _ _ _ _ _ _ _ _ _ __
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately. When replacing the brake pads, it is not neces-
•Avoid brake fluid coming into contact with sary to disconnect the brake hose or disassem-
the eyes as it can cause serious injury. ble the brake caliper.
• FIRST AID FOR BRAKE FLUID ENTERING 1. Measure:
THE EYES: •Brake pad wear limit "a"
•Flush with water for 15 minutes and get Out of specification ~ Replace the brake
immediate medical attention. pads as a set.
4. Measure:
• Brake disc thickness 2. Install:
Measure the brake disc thickness at a few • Brake pad shims
different locations. (onto the brake pads)
Out of specification ~ Replace. •Brake pads
Refer to "CHECKING THE FRONT BRAKE • Brake pad spring
DISC" on page 5-20.
5-32
REAR BRAKE
TIP~---~~-~------
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
YYYYYYYTTTTTTTYYTTTTTTYTTTYTTTYT
a. Connect a clear plastic hose "1" tightly to the
bleed screw "2". Put the other end of the
hose into an open container.
2
5. Check:
• Brake pedal operation
Soft or spongy feeling ~ Bleed the brake
system.
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-20.
EAS22590
4. Check:
•·Brake fluid level
Below the minimum level mark "a" ~ Add
the recommended brake fluid to the proper
level.
Refer to "CHECKING THE BRAKE FLUID
LEVEL" on page 3-17.
5-33
REAR BRAKE
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Blow compressed air into the brake hose
joint opening to force out the piston from the
brake caliper.
EWA13550
A WARNING
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton. EWA13610
A WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
2. Check:
• Brake caliper bracket
Cracks/damage --). Replace.
EAS22650
ASSEMBLINGTHEREARBRAKECALIPER
EWA13620
/ A WARNING
b. Remove the brake caliper dust seal and •Before installation, all internal brake com-
brake caliper piston seal. ponents should be cleaned and lubricated
AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA with clean or new brake fluid.
• Never use solvents on internal brake com-
EAS10X3151
CHECKING THE REAR BRAKE CALIPER ponents as they will cause the piston seals
to swell and distort.
Recommended brake component
• Whenever a brake caliper is disassembled,
replacement schedule
replace the brake caliper piston seals.
Brake pads If necessary
l~I
Piston seals Every two years Recommended fluid
DOT4
Brake hose Every four years
Brake fluid Every one year and EAS10X3152
whenever the brake is INSTALLING THE REAR BRAKE CALIPER
disassembled 1. Install:
1. Check: • Rear brake caliper
• Brake caliper piston "1" • Rear brake caliper bracket
Rust/scratches/wear ~ Replace the brake 2. Install:
caliper piston. •Rear wheel
• Brake caliper cylinder "2" Refer to "REAR WHEEL" on page 5-10.
Scratches/wear ~ Replace the brake cali- •Brake hose
per assembly. •Union bolt
• Brake caliper body "3" Union bolt
Cracks/damage ~ Replace the brake cali- 30 Nm (3.0 m·kgf, 22 ft-lbf)
per assembly.
.EWA13530
• Brake fluid delivery passages
(brake caliper body) AwARNING
Obstruction--). Blow out with compressed Proper brake hose routing is essential to in-
air. sure safe vehicle operation. Refer to "CA-
BLE ROUTING" on page 2-29.
5-34
REAR BRAKE
ECA14170 ECA13540
IB!._~~~~~~~~~~~
Install the brake hose so that its pipe por- Brake fluid may damage painted surfaces
tion "a" directs as shown and lightly touch- and plastic parts. Therefore, always clean
es the projection "b" on the brake caliper. up any spilt brake fluid immediately.
5. Bleed:
• Brake system
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-20.
6. Check:
• Brake fluid level
Below the minimum level mark "a" ---+ Add
the recommended brake fluid to the proper
level.
Refer to "CHECKING THE BRAKE FLUID
3. Install: LEVEL" on page 3-17.
• Brake pad springs
•Brake pads
•Brake pad pin
• Brake pad pin plug
Refer to "REPLACING THE REAR BRAKE
PADS" on page 5-32.
Brake pad pin
17 Nm (1.7 m·kgf, 12 ft-lbf)
4. Fill:
• Brake fluid reservoir 7. Check:
(with the specified amount of the recom- • Brake pedal operation
mended brake fluid) Soft or spongy feeling ---+ Bleed the brake
system.
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-20.
EWA13090
EAS22700
A WARNING REMOVING THE REAR BRAKE MASTER
• Use only the designated brake fluid. Other CYLINDER
brake fluids may cause the rubber seals to TIP~~~~~~~~~~~~~~
deteriorate, causing leakage and poor Before removing the rear brake master cylin-
brake performance. der, drain the brake fluid from the entire brake
• Refill with the same type of brake fluid that system.
is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac- 1. Remove:
tion, leading to poor brake performance. •Union bolt
•When refilling, be careful that water does • Copper washers
not enter the brake fluid reservoir. Water •Brake hose
will significantly lower the boiling point of TIP~~~~~~~~~~~~~~
the brake fluid and could cause vapor To collect any remaining brake fluid, place a
lock. container under the master cylinder and the
end of the brake hose.
5-35
REAR BRAKE
EAS22710
1. Install:
CHECKING THE REAR BRAKE MASTER
• Cylinder cuplmll
CYLINDER
• Master cylinder piston
1. Check:
2. Install:
• Brake master cylinder "1"
• Spring "1 "lmll
Damage/scratches/wear ~ Replace.
• Master cylinder piston "2"mll
• Brake fluid delivery passages "2"
• Adjusting rod "3"mll
(brake master cylinder body)
• Circlip "4"mll
Obstruction ~ Blow out with compressed
• Dust boot "S"lmll
air.
1 2
2. Check: EAS1DX3153
---~------------
EWA13520
l~I
Recommended fluid
DOT4
5-36
REAR BRAKE
2. Fill:
• Brake fluid reservoir
EWA13090
A WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
•When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
ECA13540
~~----~~--~
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
3. Bleed:
•Brake system
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-20.
4. Check:
• Brake fluid level
Below the minimum level mark "a" ~ Add
the recommended brake fluid to the proper
level.
Refer to "CHECKING THE BRAKE FLUID
LEVEL" on page 3-17.
5. Check:
• Brake pedal operation
Soft or spongy feeling ~ Bleed the brake
system.
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-20.
5-37
HANDLEBAR
EAS1DX3154
HANDLEBAR
Removing the handlebar
4
9 Nm (0.9 m • kgf, 6.5 ft • lbf)
5-38
HANDLEBAR
EAS1DX3155
A WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Clutch switch "1"
EAS22880
CHECKING THE HANDLEBAR
1. Check:
•Handlebar
Bends/cracks/damage ~ Replace.
EWA13690
AwARNING
Do not attempt to straighten a bent handle-
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ bar as this may dangerously weaken it.
-\ TIP _____~--------------
• Install the lower handlebar holders with them
1 side having the greater distance "a" from the
mounting bolt center facing forward.
• Apply lithium-soap-based grease on the
4. Remove:
thread of the lower handlebar holders.
• Throttle cable housings "1"
• Throttle grip "2" • Installing the lower handlebar holders in the
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ reverse direction allow the front-to-rear offset
amount of the handlebar position to be
While removing the throttle cable housing, pull changed.
back the rubber cover "3". • The upper handlebar holders should be in-
stalled with the punch marks "b" facing for-
ward.
• Install the handlebar so that marks "c" are in
place on both sides.
• Install the handlebar so that the projection "d"
of the upper handlebar holders is positioned
at the mark on the handlebar as shown.
5-39
HANDLEBAR
-·
ECA14250
------------
• First, tighten the bolts on the front side of
the upper handlebar holder, and then on
the rear side.
• Turn the handlebar all the way to the left
c
dg
~
§
+2-
3. Tighten:
fi
• Lower handlebar holder nuts
Lower handlebar holder nut
34 Nm (3.4 m·kgf, 25 ft-lbf)
4. Install:
• Handlebar grip "1"
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Slightly coat the handlebar left end with a
rubber adhesive.
b. Install the handlebar grip on the handlebar
by pressing the grip from the left side.
c. Wipe off any excess rubber adhesive with a
clean rag.
EWA13120
j \ WARNING
Do not touch and move the handlebar grip
until its adhesive dries completely.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
5-40
HANDLEBAR
••••••••••••••••••••••••••••••••
5. Install: 64°
• Engine stop switch "1"
• Clutch lever "2"
• Clutch lever holder "3" 1
•Clamp "4"
Engine stop switch screw
0.5 Nm (0.05 m·kgf, 0.36 ft-lbf)
Clutch lever holder bolt
3.8 Nm (0.38 m·kgf, 2.8 ft· I bf)
7. Install:
TIP _ _ _ __ _ __ _ _ _ _ _ __ • Rubber cover "1"
• Throttle grip "2"
•The engine stop switch, clutch lever, clutch le- TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
ver holder should be installed according to the
dimensions shown. Apply the lithium soap base grease on the
• Pass the engine stop switch lead in the middle throttle grip sliding surface.
of the clutch lever holder.
1 2
8. Install:
6. Install: • Throttle cables "1"
• Right grip "1 " TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
•Collar "2" • Slightly coat the end of throttle cable and in-
Apply the adhesive on the tube guide "3". side of throttle grip with lithium-soap-based
TIP _~~~~~~~~~~~~~ grease.Then, mount the throttle grip onto the
• Before applying the adhesive, wipe off grease handlebar.
or oil on the tube guide surface "a" with a lac-
quer thinner.
• Install the grip to the tube guide so that the
grip match mark "b" and tube guide slot "c"
form the angle as shown .
5-41
HANDLEBAR
9. Install: 11.lnstall:
•Throttle cable housings 11 111 • Start switch 11 111
•Screw (throttle cable housings) 11 2 11 • Front brake master cylinder assembly 11 2 11
• Front brake master cylinder holder 113 11
Screw (throttle cable housings)
• Bolt (brake master cylinder holder) 11 4 11
3.8 Nm (0.38 m·kg, 2.8 ft-lb)
Front brake master cylinder hold-
EWA1DX5001
er bolt
A WARNING 9 Nm (0.9 m·kg, 6.5 ft·lb)
After tightening the throttle cable housing
screws, check that the throttle grip 11 3 11 •Clamp 11 5 11
moves smoothly. If it does not, retighten the TIP _ _ _ _ _ _ _ _ _ _ _ _ __
screws for adjustment. • Install the brake master cylinder holder with
the "UP" mark facing up.
• Install in order for the top of the front brake
master cylinder assembly to be level.
• First, tighten the upper bolt, then the lower
bolt.
• The start switch and front brake master cylin-
der assembly should be installed according to
the dimensions shown.
10.lnstall:
• Rubber cover 11 111
•Cover {throttle cable housings) 11 2 11
5-42
HANDLEBAR
12.Adjust:
• Clutch cable free play
Refer to "ADJUSTING THE CLUTCH LE-
VER FREE PLAY" on page 3-15.
A Clutch lever free play
v~ 8.0-13.0 mm (0.31-0.51 in)
13.Adjust:
•Throttle grip free play
Refer to "ADJUSTING THE THROTTLE
GRIP FREE PLAY" on page 3-29.
Throttle grip free play
3.0-5.0 mm (0.12-0.20 in)
5-43
FRONT FORK
EAS1DX3157
FRONT FORK
Removing the front fork legs
~~
' 7
,
......\
~
.....1-3.-8-Nm-(0-.3-8_m_·_k_gf-,2-.8-ft-·-lb_f}....,.I 3
21 Nm (2.1 m • kgf, 15 ft· lbf)
7 Nm (0.7 m • kgf, 5.1 ft· lbf) 7 Nm (0.7 m • kgf, 5.1 ft· lbf)
5-44
FRONT FORK
15~
~
14
5-45
FRONT FORK
19
~
~
5-46
FRONT FORK
EAS22970 3. Remove:
REMOVING THE FRONT FORK LEGS
• Front fork leg
The following procedure applies to both of the
front fork legs. . EAS22980
1. Stand the vehicle on a level surface. DISASSEMBLING THE FRONT FORK LEGS
EWA13120 The following procedure applies to both of the
j\WARNING front fork legs.
Securely support the vehicle so that there is 1. Drain:
no danger of it falling over. •Fork oil
ECA10X1009 2. Remove:
~~~~~~~~~~~- • Adjuster "1"
To prevent an accidental explosion of air, (from the inner tube)
the following instructions should be ob- TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
served: • While compressing the inner tube "2", set the
• Before removing the base valves or front cap bolt ring wrench "4" between the inner
forks, be sure to extract the air from the air tube and locknut "3"
chamber completely. • Hold the locknut and remove the adjuster.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ ECA141BO
A WARNING
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Before removing the front fork leg from the ve-
hicle, loosen the damper assembly "1" with the
cap bolt ring wrench "2". 3. Remove:
• Dust seal "1"
Cap bolt ring wrench • Oil seal clip "2"
90890-01501
(with a flat-head screwdriver)
YM-01501 ECA141BO
tum --------~-----------------------------------
Do not scratch the inner tube.
5-47.
FRONT FORK
4. Remove:
EAS23010
• Inner tube "1" CHEC~NGTHEFRONTFORKLEGS
YTYTTTYTTTYTTTTYTYYTYTYTTTTTYTTT The following procedure applies to both of the
a. Hold the front fork leg horizontally. front fork legs.
b. Securely clamp the brake caliper bracket in 1. Check:
a vise with soft jaws. • Inner tube surface "a"
c. Separate the inner tube from the outer tube Scratches ~ Repair or replace.
by pulling the inner tube forcefully but care- Use #1,000 grit wet sandpaper.
fully. Damaged oil lock piece ~ Replace.
• Inner tube bends
Out of specification 4 Replace.
Use the dial gauge "1 ".
Inner tube bending limit
0.2 mm (0.01 in)
TIP~~~~~~~~~~~~~~~
5. Remove: A WARNING
• Base valve "1" Do not attempt to straighten a bent inner
(from the damper assembly) tube as this may dangerously weaken it.
TIP~~~~~~~~~~~~~~~
5-48
FRONT FORK
6. Check:
• Contacting surface "a"
Wear/damage 4 Replace.
4. Check:
• Damper assembly "1"
Bend/damage ~ Replace.
• 0-ring "2"
Wear/damage~ Replace.
ECA1DX1010
~ll•~~~~~~~~-
• The front fork leg has a built-in damper ad- 7. Check:
justing rod and a very sophisticated inter- • Adjuster "1"
nal construction, which are particularly • 0-ring "2"1m1J
sensitive to foreign material. Wear/damage ~ Replace.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
....._____ 1
,......-__.,_L:--- 2
... ~
EAS23020
ASSEMBLINGTHEFRONTFORKLEGS
The following procedure applies to both of the
5. Check: front fork legs.
• Base valve "1" EWA13660
5-49
FRONT FORK
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ 4. Measure:
• When assembling the front fork leg, be sure to • Oil level (left and right) "a"
replace the following parts: Out of specification ~ Adjust.
-Inner tube bushing Standard oil level
-Outer tube bushing 145-148 mm (5.71-5.83 in)
-Oil seal From top of fully stretched
-Copper washer damper assembly.
• Before assembling the front fork leg, make
sure all of the components are clean.
1. Stretch the damper assembly fully.
2. Fill:
• Damper assembly
a
(with the specified amount of the recom-
mended fork oil)
Recommended oil
Suspension oil S1
Standard oil amount
208 cm 3 (7 .32 Imp.oz,
7.03 US oz)
ECA14210
l&'"'lfB __~~~~~~~~----
• Be sure to use the recommended fork oil.
Other oils may have an adverse effect on
front fork performance.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
5. Tighten:
3. After filling, pump the damper assembly "1" • Locknut "1"
slowly up and down (about 200 mm (7.9 in) TIP _ _ _ _ _ _ _ _ _ _ _ _ __
stroke) several times to bleed the damper
Fully finger tighten the locknut onto the damper
assembly of air.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ assembly.
6. Install:
• Base valve "1"
(to damper assembly "2")
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
First bring the damper rod pressure to a maxi-
mum. Then install the base valve while releas-
ing the damper rod pressure.
5-50
FRONT FORK
a~
---!(~
11
9. After filling, pump the damper assembly "1
slowly up and down more than 10 times to
distribute the fork oil.
12.Check:
• Damper assembly smooth movement
Tightness/binding/rough spots~ Repeat
the steps 1 to 11
5-51
FRONT FORK
13.lnstall: 15.lnstall:
• Dust seal "1 "mll • Outer tube "1"
• Oil seal clip "2" (to the inner tube "2")
•Oil seal "3" mll
•Washer "4"
• Outer tube bushing "5" mll
(to the inner tube "6")
ECA3201010
1111111~~--~~~-
Make sure the numbered side of the oil seal
faces bottom side.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
- 3
(to the outer tube)
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
14.lnstall:
• Inner tube bushing "1" Dm
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Install the inner tube bushing onto the slot on
inner tube.
5-52
FRONT FORK
17.lnstall: 20.Check:
•Oil seal "1" • Inner tube smooth movement
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ Tightness/binding/rough spots ~ Repeat
Press the oil seal into the outer tube with fork the steps 13 to 19.
seal driver "2".
21.Measure:
• Distance "a"
Out of specification ~ Turn into the locknut.
Distance "a"
16 mm (0.63 in) or more
Between the damper assembly
"1" bottom and locknut "2" bot-
18.lnstall: tom.
• Oil seal clip "1"
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Fit the oil seal clip correctly in the groove in the
outer tube.
22.lnstall:
•Collar "1"
• Fork spring "2"
(to the damper assembly "3")
19.lnstall: TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Dust seal "1"
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ Install the collar with its larger dia. end "a" fac-
ing the fork spring.
Apply lithium-soap-based grease on the inner
tube.
5-53
FRONT FORK
1 2
\
01;;~ .,,,.____5
a
23.lnstall: 25.lnspect:
• Damper assembly "1" • Gap "a" between the adjuster "1" and lock-
(to the inner tube "2") nut "2".
1••--------
ECA3201010
24.lnstall:
• Damper adjusting rod "1"
• Copper washer "2" Olll
• Adjuster "3"
(to the damper assembly "4") 26.Tighten:
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ • Adjuster (locknut) "1"
• While compressing the inner tube "5", set the ~ Adjuster (locknut)
cap bolt ring wrench "7" between the inner ~ 29 Nm (2.9 m·kgf, 21 ft-lbf)
tube and locknut "6".
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
•Fully finger tighten the adjuster onto the
damper assembly. Hold the locknut "2" and tighten the adjuster
with specified torque.
Cap bolt ring wrench
90890-01501
YM-01501
5-54
FRONT FORK
27.lnstall: TIP~------------------------------~-----------------------------
• Adjuster "1" Temporarily tighten the damper assembly.
(to the inner tube)
Adjuster
55 Nm (5.5 m·kgf, 40 ft-lbf)
LOCTITE®
30.lnstall:
• Fork protector guide "1"
28.Fill:
• Front fork leg
(with the specified amount of the recom-
1
mended fork oil)
Recommended oil
Suspension oil S1
Standard oil amount
328 cm 3 (11.55 Imp oz, 11.09 US
oz) EAS1DX3158
29.lnstall:
• Damper assembly "1"
(to the outer tube)
5-55
FRONT FORK
2. Tighten:
• Lower bracket pinch bolt "1"
~ ,,,, Lower bracket pinch bolt
~~ 21 Nm (2.1 m·kgf, 15 ft-lbf)
EWA1DX1005
j\WARNING
Tighten the lower bracket pinch bolt to
specified torque. If torqued too much, it may
cause the front fork to malfunction.
5. Install:
• Speed sensor lead "1"
•Plate 1 "2"
(to the right front fork protector)
~,,,, Plate 1 bolt
~~ 3.8 Nm (0.38 m·kgf, 2.8 ft-lbf)
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Install the speed sensor lead so that its paint "a"
directs as shown and align the bottom "b" of the
3. Tighten: plate 1 with the same paint.
• Damper assembly "1"
~ ,,,, Damper assembly
~~ 30 Nm (3.0 m·kgf, 22 fNbf)
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Use the cap bolt ring wrench "2" to tighten the
damper assembly with specified torque.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Install the plate 2 in the direction as shown.
4. Tighten:
• Upper bracket pinch bolt "1"
~ ,,,, Upper bracket pinch bolt
~~ 21 Nm (2.1 m·kgf, 15 ft-lbf)
EWA13680
.t\ WARNING
Make sure the brake hoses are routed prop-
erly.
5-56
FRONT FORK
7. Adjust:
• Rebound damping
• Compression damping
Refer to "ADJUSTING THE FRONT FORK
LEGS" on page 3-25.
5-57
STEERING HEAD
EAS1DX3159
STEERING HEAD
Removing the lower bracket
5-58
STEERING HEAD
EAS23110 ECA14270
REMOVING THE LOWER BRACKET
1. Stand the vehicle on a level surface.
~~~~~~~~~~-
EWA13120
• Take care not to damage the steering shaft
AwARNING thread.
•If the bearing race is not installed properly,
Securely support the vehicle so that there is
the steering head pipe could be damaged.
no danger of it falling over.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
2. Remove:
• Ring nut "1" Always replace the bearings and bearing races
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ as a set.
Remove the ring nut with the steering nut
wrench "2".
A-WARNING
Securely support the lower bracket so that
there is no danger of it falling.
AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
4. Check:
EAS23120 • Upper bracket
CHECKING THE STEERING HEAD • Lower bracket
1. Wash: (along with the steering stem)
•Bearings Bends/cracks/damage~ Replace.
• Bearing races
EAS10X3160
5-59
STEERING HEAD
TIP~------------~
• Install the ring nut with its stepped side "a" fac-
ing downward.
• Apply lithium-soap-based grease on the por-
tion "b" and thread of the steering stem.
6. Install:
• Speed sensor lead holder "1"
• Speed sensor lead clamp "2"
Speed sensor lead holder bolt
13 Nm (1.3 m·kgf, 9.4 ft-lbf)
3. Install: Speed sensor lead clamp bolt
7 Nm (0.7 m·kgf, 5.1 ft-lbf)
•Washer "1"
•Collar "2" TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Upper bracket
• Steering stem nut • Insert the end of the speed sensor lead holder
in the hole in the lower bracket "b"
TIP-------------~ •Install so that the marking "a" on the speed
• Install the collar "2" with the larger inside di- sensor lead aligns with the speed sensor lead
ameter facing downward. holder edge.
•Temporarily tighten the steering stem nut. • Install the speed sensor lead clamp while in-
serting it in the hole "c" in the speed sensor
lead holder.
4. Install:
•Front fork legs
Refer to "FRONT FORK" on page 5-44.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Temporarily tighten the upper and lower brack-
et pinch bolts.
5. Tighten:
• Steering stem nut "1"
~_ Steering stem nut
~~ 145 Nm (14.5 m·kgf, 105 ft-lbf)
TIP-------------~
Apply lithium-soap-based grease on the con-
tact surface of the steering stem nut when in-
stalling.
5-60
REAR SHOCK ABSORBER ASSEMBLY
EAS1DX3161
I
I
I
I
I
I
n
I
I
I
I
I
6~
5-61
REAR SHOCK ABSORBER ASSEMBLY
' i
11
~~~~~~~~~~
5-62
REAR SHOCK ABSORBER ASSEMBLY
5-63
REAR SHOCK ABSORBER ASSEMBLY
EAS23180 TIP _ _ _ _ _ _ _ _ _ _ _ _ __
HANDLINGTHEREARSHOCKABSORBER
EWA13740
Place the vehicle on a suitable stand so that the
A WARNING rear wheel is elevated.
This rear shock absorber contains highly
2. Remove:
compressed nitrogen gas. Before handling
• Rear frame upper bolt
the rear shock absorber, read and make
3. Loosen:
sure you understand the following informa..
• Rear frame lower bolt
tion. The manufacturer cannot be held re..
4. Slide:
sponsible for property damage or personal
•Rear frame
injury that may result from improper han.. ECA1DX1011
EAS23190
A WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.
t 6. Remove:
• Rear shock absorber assembly upper bolt
EAS23230
• Rear shock absorber assembly
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY EAS23240
CHEC~NGTHEREARSHOCKABSORBER
1. Stand the vehicle on a level surface.
EWA13120
ASSEMBLY
A WARNING 1. Check:
• Rear shock absorber rod
Securely support the vehicle so that there is
Bends/damage ~ Replace the rear shock
no danger of it falling over.
absorber assembly.
5-64
REAR SHOCK ABSORBER ASSEMBLY
EAS23260
CHECKING THE CONNECTING ARM AND
RELAY ARM
1. Check:
• Connecting arm
•Relay arm
Damage/wear ~ Replace.
2. Check:
•Bearings
•Spacers
3. Install:
Damage/pitting/scratches ~ Replace the
• Bearings "1"
bearings and spacers as a set.
• Oil seals "2"
3. Check:
(to connecting arm "3")
•Oil seals
Damage/pitting ~ Replace. ~ Installed depth "a"
v ~ Omm(Oin)
EAS23270
INSTALLING THE RELAY ARM
1. Lubricate:
•Oil seals
•Bearings
•Spacers
•Washers
•Collars
Recommended lubricant
Lithium-soap-based grease
2. Install:
• Bearings "1" EAS23310
5-65
REAR SHOCK ABSORBER ASSEMBLY
ECA1DX1012
• Rear shock absorber assembly lower bolt
flllltm~~~~~~~~
Do not apply the grease on the bearing out- Recommended lubricant
er race because it will wear the rear shock Lithium-soap-based grease
absorber surface on which the bearing is
6. Install:
press fitted.
• Rear shock absorber assembly
2. Lubricate: TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• 0-rings
• When installing the rear shock absorber as-
Recommended lubricant sembly, lift up the swingarm.
Lithium-soap-based grease • Install the rear shock absorber assembly up-
per bolt, and connecting arm and frame bolt
3. Install: from the right.
•Bearing • Install the rear shock absorber assembly low-
• Stopper ringlm er bolts, relay arm and connecting arm bolt,
(to rear shock absorber assembly (upper and relay arm and swingarm bolt from the left.
side))
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ 7. Tighten:
• Rear shock absorber assembly upper nut
•Install the bearing parallel until the stopper
ring groove appears by pressing its outer Rear shock absorber assembly
race. upper nut
•After installing the stopper ring, push back the 56 Nm (5.6 m·kgf, 41 ft-lbf)
bearing unit it contacts the stopper ring. • Connecting arm and frame nut
4. Install:
~ ,,,. Connecting arm and frame nut
• Bearing "1" ~~ 80 Nm (8.0 m·kgf, 58 ft-lbf)
•Bushing "2"
•Collar "3" • Relay arm and connecting arm nut
• Dust seal "4"
(to rear shock absorber assembly (lower ~ ,,,. Relay arm and connecting arm
side)) ~~ nut
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ 80 Nm (8.0 m·kgf, 58 ft-lbf)
Install the dust seals with their lips facing in- • Relay arm and swingarm nut
ward.
Relay arm and swingarm nut
70 Nm (7.0 m·kgf, 51 ft-lbf)
Installed depth "a"
4.25 mm (0.17 in) • Rear shock absorber assembly lower nut
~ ,,,. Relay shock absorber assembly
~~ lowernut
53 Nm (5.3 m·kgf, 38 ft-lbf)
-----,
5. Lubricate:
• Connecting arm and frame bolt
• Relay arm and connecting arm bolt
• Relay arm and swingarm bolt
(circumference and threaded portion)
• Rear shock absorber assembly upper bolt
5-66
SWINGARM
EAS1DX3162
SWINGARM
Removing the swingarm
3.5 Nm (0.35 m • kgf, 2.5 ft • lbf)
5-67
SWINGARM
5-68
SWINGARM
EAS23350
REMOVING THE SWINGARM
1. Stand the vehicle on a level surface.
EWA13120
A WARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Place the vehicle on a suitable stand so that the
rear wheel is elevated.
2. Remove:
• Left cap "1" EAS23360
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ CHECKING THE SWINGARM
Remove with a slotted-head screw-driver in- 1. Check:
serted under the mark "a" on the left cap. • Swingarm
Bends/cracks/damage 4 Replace.
2. Check:
• Pivot shaft
Roll the pivot shaft on a flat surface.
Bends 4 Replace.
EWA13770
AwARNING
Do not attempt to straighten a bent pivot
shaft.
3. Measure:
• Swingarm side play
• Swingarm vertical movement
TTTTTTT~TTTTTTTTTTTTTTTTTTTTT~TT
a. Measure the tightening torque of the pivot
shaft nut.
Pivot shaft nut
85 Nm (8.5 m·kgf, 61 ft· Ibf)
3. Wash:
b. Measure the swingarm side play "a" by mov- • Pivot shaft
ing the swingarm from side to side. •Spacers
c. If the swingarm side play is out of specifica- •Collars
tion, check the spacers, bearings and col- •Bearings
lars.
d. Check the swingarm vertical movement "b" Recommended cleaning solvent
Kerosene
by moving the swingarm up and down.
If swingarm vertical movement is not smooth 4. Check:
or if there is binding, check the spacers, •Oil seals
bearings and collars.
Damage 4 Replace.
Swingarm side play {at the end of •Bearings
the swingarm) •Spacers
o mm (O in) Free play exists/unsmooth revolution/rust 4
Replace bearing and bushing as a set.
5-69
SWINGARM
EAS1DX3163
INSTALLING THE SWINGARM
1. Lubricate:
•Bearings
•Collars
•Spacers
•Oil seals
• Pivot shaft
Recommended lubricant
Lithium-soap-based grease
5. Install:
2. Install: •Rear wheel
•Bearings "1"
Refer to "REAR WHEEL" on page 5-10
• Oii seals "2" 6. Adjust:
(to the swingarm) • Drive chain slack
Installed depth "a" Refer to "ADJUSTING THE DRIVE CHAIN
0 mm (0 in) SLACK" on page 3-23.
Installed depth "b"
Drive chain slack
6.5 mm (0.26 in)
48.0-58.0 mm (1.89- 2.28 in)
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
3. Install:
• Swingarm
Pivot shaft nut
85 Nm (8.5 m·kgf, 61 ft-lbf)
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Install the pivot shaft from the right.
4. Install:
11
•Cap "1
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Install the right cap with its mark "a" facing for-
ward.
5-70
CHAIN DRIVE
5-71
CHAIN DRIVE
EAS23420
A WARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Place the vehicle on a suitable stand so that the c
rear wheel is elevated.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
2. Remove:
• Drive chain • When measuring a 15-link section of the drive
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ chain, make sure that the drive chain is taut.
Cut the drive chain with the drive chain cut & • Perform this procedure 2-3 times, at a differ-
rivet tool. (Use goods on the market) ent location each time.
EAS23441
••••••••••••••••••••••••••••••••
2. Check:
CHECKING THE DRIVE CHAIN • Drive chain
1. Measure: Stiffness~ Clean, lubricate, or replace.
• 15-link section "a" of the drive chain
Out of specification ~ Replace the drive
chain.
15-link length limit
239.3 mm (9.42 in)
TTTTTTTTTTTTTTTTTTTTYTTTTTTTTTTT
a. Measure the length "a" between the inner
sides of the pins and the length "b" between
the outer sides of the pins on a 15-link sec-
tion of the drive chain as shown in the illus- 3. Clean:
tration. • Drive chain
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene .
and completely dry it.
ECA14290
fBP8B~~~~~~~~
• This vehicle has a drive chain with small
rubber 0-rings "1" between the drive
b. Calculate the length "c" of the 15-link section chain side plates. Never use high-pressure
of the drive chain using the following formu- water or air, steam, gasoline, certain sol-
la. vents (e.g., benzine), or a coarse brush to
Drive chain 15-link section length "c" = clean the drive chain. High-pressure meth-
{length "a" between pin inner sides + length ods could force dirt or water into the drive
"b" between pin outer sides)/2 chain's internals, and solvents will deteri-
orate the 0-rings. A coarse brush can also
damage the 0-rings. Therefore, use only
kerosene to clean the drive chain.
5-72
CHAIN DRIVE
EAS23460
• Do not soak the drive chain in kerosene for CHECKING THE DRIVE SPROCKET
more than ten minutes, otherwise the 0- 1. Check:
rings can be damaged. •Drive sprocket
More than 1/4 tooth "a" wear 4 Replace the
drive chain sprockets as a set.
Bent teeth 4 Replace the drive chain
sprockets as a set.
1 a
b. Correct
1
1. Drive chain roller
2. Drive chain sprocket
EAS23470
TTTTTTTTTTTTTTTTYYTTYTTTTTTTTTTY
a. When press fitting the connecting plate "1 ",
make sure the space "a" between the end of
the connecting pin "2" and the connecting
5. Lubricate: plate is 1.2-1.4 mm (0.05-0.06 in).
• Drive chain
Recommended lubricant
--t Chain lubricant suitable for 0-
ring chains
5-73
CHAIN DRIVE
IBJI~~~~~~~~~
A drive chain that is too tight will overload
the engine and other vital parts, and one
that is too loose can skip and damage the
swingarm or cause an accident. Therefore,
c. After riveting, make sure the space "c", keep the drive chain slack within the speci-
which is inside of the connecting link "3" and fied limits.
inside of the connecting plate "1 ", is 14.1-
14.3 mm (0.56-0.65 in).
AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
2. Lubricate:
• Drive chain
Recommended lubricant
-t Chain lubricant suitable for 0-
ring chains
3. Install:
•Drive sprocket
• Lock washerlm
•Drive sprocket nut
Refer to "ENGINE REMOVAL" on page 6-1.
Drive sprocket nut
75 Nm (7.5 m·kgf, 54 ft-lbf)
ECA1DX1014
~~~~~~~~~~
Never install a new drive chain onto worn
drive chain sprockets; this will dramatically
shorten the drive chain's life.
5-74
ENGINE
II
REMOVING THE VALVES .......................................... ." ............................ 6-19
CHECKING THE VALVES AND VALVE GUIDES .................................... 6-20
CHECKING THE VALVE SEATS ............................................................. 6-21
CHECKING THE VALVE SPRINGS .........................................................6-23
CHECKING THE VALVE LIFTERS .......................................................... 6-24
INSTALLING THE VALVES ......................................................................6-24
CLUTCH ..........................................................................................................6-35
REMOVING THE CLUTCH ...................................................................... 6-39
CHECKING THE FRICTION PLATES ...................................................... 6-39
CHECKING THE CLUTCH PLATES ........................................................ 6-39
CHECKING THE CLUTCH SPRINGS ...................................................... 6-39
CHECKING THE CLUTCH HOUSING .............................................. ~ ...... 6-40
CHECKING THE CLUTCH BOSS .~: ..... :.. ~ ................................................ 6-40
CHECKING THE PRESSURE PLATE ..................................................... 6-40
CHECKING THE CLUTCH PUSH RODS .................................................6-40
CHECKING THE PRIMARY DRIVE GEAR ..............................................6-41
CHECKING THE PRIMARY DRIVEN GEAR ................ ~ ......... ~ ................ 6-41
INSTALLING THE CLUTCH .................................................... ~ ................ 6-41
KICKSTATER .•....................•...•.....••••..•••............•........•........•.•.•........•...•.•......•6-44
REMOVING THE KICK SHAFT ASSEMBLY ...........................................6-45
CHECKING THE KICK SHAFT AND RATCHET WHEEL ........................ 6-45
CHECKING THE KICK GEAR,. KICK IDLE GEAR AND RATCHET WHEEL ..
6-45
INSTALLING THE KICK SHAFT ASSEMBLY .................................. ~ ....... 6-45
·INSTALLING THE KICK IDLE GEAR ....... :........... :~ .................................. 6-46
CRANKCASE .....................•........•...•.•..•...•....••...•...•.•••..•.....•.•.....•...•.•.•.•...••...6-62
DISASSEMBLING THE CRANKCASE .....................................................6-65
CHECKING THE TIMING CHAIN, TIMING CHAIN GUIDE, OIL STRAINER ..
&~ ·,
CHECKING THE CRANKCASE ...............................................................6-65
ASSEMBLING THE CRANKCASE .......................................... ~ ................ 6-66
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
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 knowl-
edge and skil,I concerning servicing are requested not to undertake inspection, adjustment, disas-
sembly, or reassembly only by reference to this manual. It may lead to servicing trouble and
mechanical damage.
EAS1DX3166
ENGINE REMOVAL
Removing the exhaust pipe
30 Nm (3.0 m • kgf, 22 ft· lbf) 5 Nm (0.5 m • kgf, 3.6 ft • lbf)
6-1
ENGINE REMOVAL
6-2
ENGINE REMOVAL
6-3
ENGINE REMOVAL
EAS1DX3167
REMOVING THE ENGINE
1. Remove:
• Pivot shaft "1"
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
2. Remove: .
• Spark arrester bolts "1"
2. Remove:
•Engine "1"
From right side.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ 3. Remove:
•Tail pipe "1"
Make sure that the couplers, hoses and cables • Tail pipe gasket "2"
are disconnected. •Spark arrester "3"
Pull the spark arrester out of the muffler.
• Spark arrester ·gasket "4"
EAS1DX316B
CLEANING THE SPARK ARRESTER
EWA1DX1006 4. Clean:
A WARNING •Spark arrester
• Be sure the exhaust pipe and muffler are Tap the spark arrester lightly, then use a
cool before cleaning the spark arrester. wire brush to remove any carbon deposits.
• Do not start the engine when cleaning the 5. Install:
exhaust system. • Spark arrester gasketDm
• Spark arrester
1. Remove:
Insert the spark arrester into the muffler and
• Muffler cap screws "1"
align the bolt holes.
•Tail pipe gasketDm
• Spark arrester bolts
Spark arrester bolt
9 Nm (0.9 m·kgf, 6.4 ft-lbf)
6-4
ENGINE REMOVAL
6. Install: TIP _ _ _ _ _ _ _ _ _ _ _ _ __
•muffler cap
Apply the lithium-soap based grease on the piv-
Muffler cap screw ot shaft.
5 Nm (0.5 m·kgf, 3.6 ft-lbf)
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
First tigh,ten the two screws "a" located horizon-
tally apart, and then tighten the others.
EAS23720
6-5
ENGINE REMOVAL
2. Install:
• Muffler clamp "1"
~ ,,,. Muffler clamp
~~ 16 Nm (1.6 m·kgf, 12 ft-lbf)
• Gasket "2"Dm
• Muffler "3"
•Washer "4"
• Muffler bolt "5"
Muffler bolt
30 Nm (3.0 m·kgf, 22 ft-lbf)
EAS3201009
INSTALLING THE SHIFT PEDAL
1. Install:
• Shift pedal "1"
•Shift pedal bolt "2"
~ ,,,. Shift pedal bolt
~~ 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
TIP _ _ _ _ _ _ _ _ _ _ __
6-6
CAMSHAFT
EAS23730
CAMSHAFT
REMOVING THE CYLINDER HEAD COVER
~
13 Nm (1.3 m. kgf, 9.4 ft lbf)
0
*Silicone fluid
**Three bond No.1541 C®
6-7
CAMSHAFT
6-8
CAMSHAFT
EAS23600
NOTICE
------------~
The bolts (camshaft cap) must be removed
evenly to prevent damage to the cylinder
2. Align: head, camshafts or camshaft caps.
• TDC on the generator rotor
(mark on the crankcase cover)
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Turn the crankshaft counterclockwise.
b. When piston is at TDC on the compression
stroke, align the mark "a" on the generator
rotor with the mark "b" on the crankcase cov-
er.
TIP _ _ _ _ _ _ _ _ _ __ _ _ __ _
In order to be sure that the piston is at Top
Dead Center, the punch mark "c" on the ex- 6. Remove:
haust camshaft and the punch mark "d" on the • Intake camshaft "1"
intake camshaft must align with the cylinder • Exhaust camshaft "2"
head surface, as shown in the illustration. TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Attach a wire "3" to the timing chain to prevent
it from falling into the crankcase.
EA523840
••••••••••••••••••••••••••••••••
3. Loosen:
• Camshaft sprocket bolt
6-9
CAMSHAFT
2. Measure:
• Camshaft lobe dimensions "a" and "b"
Out of specification~ Replace the cam-
shaft.
Camshaft lobe dimensions
Intake A
30.100--30.200 mm (1.1850-
1.1890 in)
Limit
11151402
30.000 mm (1.1811 in)
Intake B 4. Measure:
22.450-22.550 mm (0.8839- •Camshaft-journal-to-camshaft-cap clear-
0.8878 in) ance
Limit Out of specification~ Measure the cam-
22.350 mm (0.8799 in) shaft journal diameter.
Exhaust A
30.200-30.300 mm (1.1890- Camshaft-journal-to-camshaft-
1.1929 in) cap clearance
Limit · 0.028-0.062 mm (0.0011--0.0024
30.100 mm (1.1850 in) in)
Exhaust B
22.450-22.550 mm (0.8839- TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
0.8878 in) a. Install the camshaft into the cylinder head.
Limit b. Position a strip of Plastigauge® "1" onto the
22.350 mm (0.8799 in) camshaft journal as shown.
o~
6-10
CAMSHAFT
o~ 1
••••••••••••••••••••••••••••••••
5. Measure:
a. 1/4 tooth
b. Correct
• Camshaft journal diameter "a" 1. Timing chain roller
Out of specification - > Replace the cam- 2. Camshaft sprocket
shaft.
EAS23960
With in specification -t Replace the cylinder CHECKING THE TIMING CHAIN TENSION-
head and the camshaft caps as a set. ERS
Camshaft journal diameter The following procedure applies to both of the
21.959-21.972 mm (0.8645- timing chain tensioners.
0.8650 in) 1. Check:
• Timing chain tensioner
Cracks/damage -t Replace.
TTTTTTTTYTYTYYTYYTYTTTTTYTTYYYYY
a. While pressing the tensioner rod lightly with
fingers, use a thin screwdriver "1" and wind
the tensioner rod up fully clockwise.
b. When releasing the screwdriver by pressing
lightly with fingers , make sure that the ten-
sioner rod will come out smoothly.
c. If not, replace the tensioner assembly.
EAS23870
6-11
CAMSHAFT
EAS32D1001
CHECKING THE DECOMPRESSION SYS-
TEM
1. Check:
• Decompression system
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Check that the decompressor lever pin "1"
projects from the camshaft.
b. Check that the decompressor cam "2"
moves smoothly.
I
c. Fit the timing chain "3" onto both camshaft
sprockets and install the camshafts on the
cylinder head.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
EAS1DX3170
INSTALLING THE CAMSHAFTS
1. Install:
• Exhaust camshaft "1"
11
•Intake camshaft "2
ECA1DX1016
~~~~~~~~~~-
Do not turn the crankshaft during the cam-
shaft installation. Damage or improper
valve timing will result.
d. Install the clips, camshaft c~ps and bolts
TTTTTTTVTTTTTTTTTTTTTTTTTTTTTTTT . (camshaft cap).
a. Turn the crankshaft counterclockwise with a
Camshaft cap bolt
wrench.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
10Nm (1.0 m·kgf, 7.2 ft·lbf)
6-12
CAMSHAFT
l'ifll__ -------------
The bolts (camshaft cap) must be tight~ned
evenly, or damage to the cylinder head,
camshaft caps, and camshaft will result. ·
AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
2. Install: AAAAAAAAAAAAAAAAA~AAAAAAAAAAAAAA
• Timing chain tensioner 3. Turn:
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT •Crankshaft
a. While pressing the tensione.r rod lightly with · Counterclockwise several turns.
fingers, use a thin screwdriver and wind the 4. Check:
tensioner rod up fully clockwise. • Rotor TDC mark
Align with the crankcase align mark. . _
• Camshaft match marks
Align with the cylinder hea~ s~rface.
Out of alignment~ Adjust. ·
5. Measure: .
•Valve clearance
Out of specification ~ Adjust.
Refe-r to"ADJUSTING THE VALVE CLEAR-
ANCE" on page 3-7.
6-13
CYLINDER HEAD
EAS24100
CYLINDER HEAD
Removing the cylinder head
~
1st 30 Nm (3.0 m • kgf, 22 ft lbf)
0
6-14
CYLINDER HEAD
EAS1DX3171
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Place a straightedge and a thickness gauge
across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylin-
der head as follows.
EAS1DX3172
CHECKING THE TIMING CHAIN GUIDE (EX- d. Place a 400-600 grit wet sandpaper on the
HAUST SIDE) surface plate and resurface the cylinder
~ead using a figure-eight sanding pattern.
1. Check:
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Timing chain guide (exhaust side)
Damage/wear~ Replace. To ensure an even surface, turn the cylinder
head several times.
EAS24160
CHECKING THE CYLINDER HEAD
1. Eliminate:
• Combustion chamber carbon deposits
(with a rounded scraper)
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
6-15
CYLINDER HEAD
EAS24230
d. Tighten the bolts to the spec.ified torque in
INSTALLING THE CYLINDER HEAD
two or three steps in the proper tightening
1. Install:
sequence as shown.
•Timing chain guide (exhaust side) "1"
~~
• Dowel pin "2" Bolts "1" - "4"
• Cylinder head gasket "3" Dm 1st
• Cylinder head "4" 30 Nm (3.0 m·kgf, 22 ft-lbf)
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
While pulling up the timing chain, install the tim-
ing chain guide (exhaust side) and cylinder
head.
4
1
x2 II x4
FWD
if
2. Install:
•Washer "1"
•Bolt "2"
•Bolt "3"
~
a. Wash the threads and contact surfaces of Bolts "1" - "4"
the bolts, the contact surfaces of the plain 2nd
washers, the contact surface of the cylinder 20 Nm (2.0 m·kgf, 14 ft-lbf)
head, and the threads of the crankcase.
b. Apply the molybdenum disulfide grease on h. Put a mark on the corner "1" of the bolt (cyl-
the threads and contact surfaces of the bolts inder head) and the cylinder head "2" as
and on both contact surfaces of the plain "1" shown.
- "4" washers.
c. Install the plain washers and bolts.
6-16
CYLINDER HEAD
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
6-17
VALVES AND VALVE SPRINGS
EAS24270
6-18
VALVES AND VALVE SPRINGS
EAS24280
REMOVING THE VALVES
The following procedure applies to all of the
valves and related components. ·
TIP _ _ _ _ _ _ _ _ _ _ _ __
EX ®0
®
0
IN ®®
0 0 ,___~2
1
4. Remove:
•Valve spring retainer "1"
• Valve spring "2"
•Valve "3"
2. Check: •Valve stem seal "4"
•Valve sealing •Valve spring seat "5"
Leakage at the valve seat ~ Check the TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
valve face, valve.seat, and valve seat width. Identify the position of each part very carefully
Refer to "CHECKING THE VALVE SEATS" so that it can be reinstalled in its original place.
on page 6-21.
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Pour a clean solvent "a" into the intake and
exhaust ports.
b. Check that the valves properly seal.
TIP-----~-~------
There should be no leakage at the valve seat
"1".
6-19
VALVES AND VALVE SPRINGS
EAS24290 ·
CHECKING THE VALVES AND VALVE ·TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Remove the valve guide with the valve guide
GUIDES
The following procedure applies to all of the remover "1 ".
valves and valve guides.
1. Measure:
•Valve-stem-to-valve-guide clearance
Out of specification ~ Replace the valve
guide.
Valve-stem-to-valve-guide clearance=
Valve guide inside diameter "a" -
Valve stem diameter "b"
~
Valve-stem-to-valve-guide clear-
ance (intake) b. Install the new valve guide with the valve
0.010-0.037 mm (0.0004-0.0015 guide installer "2" and valve guide remover
in) "1n.
Limit
Valve guide installation height "a"
0.080 mm (0~0032 in) Intake
Valve-stem-to-valve-guide clear-
ance (exhaust)
10.3-10.7 mm (0.41-0.42 in)
Exhaust
0.020-0.047 mm (0.0008-0.0019
in)
10.3-10.7 mm (0.41-0.42 in)
Limit
0.100 mm (0.0039 in)
0
c. After installing the valve guide, bore the
valve guide with the valve guide reamer "3"
to obtain the proper valve-stem-to-valve-
guide clearance.
2. Replace:
• Valve guide
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100°c (212°F) in an oven.
6-20
VALVES AND VALVE SPRINGS
TIP_·~~~~~---'"~~~~~~~~
After replacing the valve guide, reface the valve
a-JI-
seat.
Intake
ij rn J
Valve guide rert:Jover (04.5)
90890-04116
VM-04116
-----
Valve guide installer (04.5)
90890-04117 ~45°
VM-04117 6. Measure:
Valve guide reamer (04.5) •Valve stem runout
90890-04118 Out of specification ~ Replace tlie valve.
VM-04118
Exhaust TIP~~~~~~~~~~~~~~-
••••••••••••••••••••••••••••••••
3. Eliminate: ·
• Carbon deposits
(from the valve face and valve seat)
4. Check:
•Valve face
Pitting/wear ~ Grind the valve face.
//
• Valve stem end
Mushroom shape or diarneter larger than
the body of the valve stem ~ Replace the EAS24300
6-21
VALVES AND VALVE SPRINGS
ECA10X1018
~~------~----
This model uses titanium intake valves.
Titanium valves that have been used to lap
the valve seats must not be used.Always re-
place lapped valves with new valves.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
• When replacing the cylinder head, replace the
valves without lapping the valve seats and
valve faces.
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT • When replacing the valves or valves guides,
a. Apply Mechanic's blueing dye (Dykem) "b"
use new valves to lap the valve seats, and
onto the valve face.
then replace them with new valves.
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Apply a coarse lapping compound "a" to the
valve face.
ECA13790
1••~--------------
00 not let the lapping compound enter the
gap between the valve stem and the valve
b guide.
6-22
VALVES AND VALVE SPRINGS
b. Installed length
6-23
VALVES AND VALVE SPRINGS
3. Install:
EAS24320 • Spring seat "1"
CHECKING THE VALVE LIFTERS
• Valve stem seal "2"
The following procedure applies to all of the
•Valve "3"
valve lifters.
• Valve spring "4"
1. Check:
• Valve spring retainer "5"
•Valve lifter
(onto the cylinder head)
Damage/scratches --t Replace the valve lift- TIP _ _ _ _ _ _ _ _ _ _ _ _ __
ers and cylinder head.
• Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch
"a" facing up.
EAS24340
6-24
VALVES AND VALVE SPRINGS
--~~~~~~~~
Hitting the valve tip with excessive force
could damage the valve.
6. Lubricate:
•Valve pad "1"
•Valve lifter "2"
Recommended lubricant
Engine oil
7. Install:
•Valve pad
• Valve lifter
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
•The valve lifter must move smoothly when ro-
tated with a finger.
• Each valve lifter and valve pad must be rein-
stalled in its original position.
6-25
CYLINDER AND PISTON
EAS24350
CYLINDER AND PISTON
Removing the cylinder and piston
6-26
CYLINDER AND PISTON
EAS24380
REMOVING THE PISTON
1. Remove:
• Piston pin clips "1"
• Piston pin "2"
•Piston "3"
ECA13810
(!); :/ ~
ff™™.'
~-------------
Do not use a hammer to drbfe the piston pin
out.
TIP _ _ _ _ _ _~--------
EAS24390
• Before removing the piston pin clip, cover the
CHECKING THE CYLINDER AND PISTON
crankcase opening with a clean rag to prevent
1. Check:
the piston pin clip from falling into the crank-
•Piston wall (Sidewall)
case.
• Cylinder wall
• Before removing the piston pin, deburr the
Vertical scratches~ Replace the cylinder,
piston pin clip's groove and the piston's pin
and replace the piston and piston rings as a
bore area. If the piston pin groove is deburred
set.
and the piston pin is still difficult to remove, 2. Measure:
use the piston pin puller set "4". • Piston-to-cylinder clearance
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
Piston pin puller set ·
a. Measure cylinder bore "C" with the cylinder
90890-01304
YU-01304 bore gauge.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Bore
95.000-95.010 mm (3.7402-
3.7405 in)
Taper limit
0.050 mm (0.0020 in)
Out of round limit
0.050 mm (0.0020 in)
2. Remove:
•Top ring
•2nd ring
•Oil ring
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
When removing a piston ring, open the end gap
with your fingers and lift the other side of the
ring over the piston crown.
6-27
CYLINDER AND PISTON
~
Piston-to-cylinder clearance TIP~~~~~~~~~~~~~~~
0.020-0.045 mm (0.0008-0.0018
Level the piston ring into the cylinder with the
in)
piston crown.
Limit
0.15 mm (0.006 in)
f. If out of specification, replace the cylinder,
piston and piston rings as a set.
AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA a
EAS24430
CHECKING THE PISTON RINGS
1. Measure: I
"'---~--)
• Piston ring side clearance
Out of specification ~ Replace the piston
and piston rings as a set. a. 1O mm (0.39 in)
3. Measure:
• Piston ring end gap
Out of specification ~ Replace the piston
ring.
6-28
CYLINDER AND PISTON
~
Piston pin bore ·inside diameter
18.004-18.015 mm (0.7088-
Piston ring 0. 7093 in) ·
Top ring Limit .· .
End. gap (installed) 18.045 mm (0.7104 in)
0.20-0.30 mm (0.0079-0.0118 in)
Limit
0.55 mm (0.0217 in)
2nd ring
End gap (installed)
0.35-0.50 mm (0.0138-0.0197 in)
Limit
0.85 ·mm (0.0335 in)
Oil ring
End gap (installed)
0.20-0.50 mm (0.0079-0.0197 in)
EAS24440
4. Calculate:
CHECKING THE PISTON PIN • Piston-pin-to-piston-pin-bore clearance
1. Check: Out of ~pacification ~ Replace the piston
•Piston pin pin and piston as a set.
Blue discoloration/grooves ~ Replace the Piston-pin-to-piston-pin-bore clearance .=
piston pin and then check the lubrication Piston pin bore diameter "b" -
system. Piston pin outside diameter '~a"
2. Measure:
• Piston pin outside diameter "a" Piston-pin-to-piston-pin-bore
Out of specification ~ Replace the piston clearance
pin. 0.004-().024 mm (0.00016-
0.00094 in) ·
Piston pin outside diameter
17.991-18.000 mm (0.7083- EAS24450
0.7087 in) INSTALLING THE PISTON AND CYLINDER
Limit 1. Install:
17.971 mm (0.7075 in) • Oil ring expander "1"
• Lower oil ring rail "2"
.• Upper oil ring rail "3" .
• 2nd ring "4"
• Top ring "5"
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
6-29
CYLINDER AND PISTON
A. Exhaust side
3. Lubricate:
•Piston
• Piston rings
•Cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
4. Offset:
• Piston ring end gaps
a,d
6-30
ELECTRIC STARTER
EAS247BO
ELECTRIC STARTER
Removing the starter motor
~
10 Nm (1.0 m • kgf, 7.2 ft. lbf)
6-31
ELECTRIC STARTER
6-32
ELECTRIC STARTER
EAS24790
CHECKING THE STARTER MOTOR TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
1. Check: a. Measure the armature assembly resistanc-
• Commutator es with the pocket tester.
Dirt ~ Clean with 600 grit sandpaper.
~
Pocket tester
2. Measure: 90890-03112
• Commutator diameter "a" Analog pocket tester
, Out of specification ~ Replace the starter YU-03112-C
motor.
I
....,
I I
~::~1
0
3. Measure:
• Mica undercut "a" ~~
I I
Out of specification~ Scrape the mica to I I
I.,..
the proper measurement with a hacksaw
blade that has been grounded to fit the com-
mutator. · ••••••••••••••••••••••••••••••••
5. Measure:
Mica undercut {depth) • Brush length "a"
1.50 mm (0.06 in) Out of specification ~ Replace the brush
AI
set.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
a
6. Measure:
4. Measure: •Brush spring force
•Armature assembly resistances (commuta- Out of specification ~ Replace the brush
tor and insulation) set.
Out of specification ~ Replace the starter
motor. · Brush spring force
3.92-5.88 N {400-600 gf, 14.11-
21.17 oz)
6-33
ELECTRIC STARTER
7. Check:
•Gear teeth
Damage/wear~ Replace the starter motor.
8. Check:
•Oil seal
Damage/wear ~ Replace the defective part
(s).
EAS24800
[N§l/Q~~----------~
Be careful not to damage the brush during
installation.
5. Install:
•Bolt "1"
• 0-ring "2"1111
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
3. Install:
• 0-ring "1" 1111
• Starter motor yoke "2"
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
6-34
CLUTCH
EAS10X3173
CLUTCH
Removing the clutch
·~
10 Nm (1.0 m • kgf, 7.2 ft· lbf)
13 Friction plate 8
14 Clutch boss nut 1
15 Conical washer
6-35
CLUTCH
,�rg
6-36
CLUTCH
6-37
CLUTCH
6-38
CLUTCH
EAS25070
REMOVING THE CLUTCH
1. Straighten the lock washer tab.
2. Remove:
• Clutch boss nut "1"
• Conical washer "2"
• Clutch boss "3"
TIP ______________
While holding the clutch boss with the universal
clutch holder "4", loosen the clutch boss nut.
6-39
CLUTCH
2. Measure:
lf
• Clutch spring free length
Out of specification -t Replace the clutch
springs as a set.
Clutch spring free length
50.00 mm (1.97 in)
Limit
49.00 mm (1.93 in)
2. Check:
• Primary driven gear
Damage/wear -t Replace the primary drive
and clutch· housing as a set.
Excessive noise during operation -t Re
place the primary drive and clutch housing
as a set.
IW290l
EAS25170
CHECKING THE PRESSURE PLATE
EAS25150
1. Check:
CHECKING THE CLUTCH HOUSING • Pressure plate
1. Check: Cracks/damage -t Replace.
• Clutch housing dogs "a"
EAS25190
Damage/pitting/wear -t Deburr the clutch CHECKING THE CLUTCH PUSH RODS
housing dogs or replace the clutch housing. 1. Check:
TIP ______________ • Push rod 1 "1"
Pitting on the clutch housing dogs will cause er • Bearing"2"
ratic clutch operation. • Washer"3"
• Push rod 2 "4"
• Ball "5"
Cracks/damage/wear -t Replace.
EAS25160
6-40
CLUTCH
----:JC'"""":=:::----
2. Install
• Primary driven gear "1"
• Thrust washer "2"
• Clutch boss "3"
TIP ______________
Apply the engine oil on the primary driven gear
inner circumference.
6-41
CLUTCH
4. Install: 6. Install:
• Friction plate "1" • Push rod 2 "1"
• Clutch plate 1 [t=2.0 mm (0.079 in)] "2" • Ball "2"
• Clutch plate 2 [t=1.6 mm (0.063 in)] "3" • Push rod 1 "3"
TIP ______________ TIP ______________
• Install the clutch plates and friction plates al Apply the engine oil on the push rod 1, 2 and
ternately on the clutch boss, starting with a ball.
friction plate and ending with a friction plate.
• Apply the engine oil on the friction plates and
clutch plates.
• Check the clutch plate for thickness and in-
stall 4 thicker ones "a" ori the engine side and
3 thinner ones "b" on the outside.
7. Install:
• Pressure plate "1"
8. Install:
• Clutch spring
• Clutch spring bolt
6-42
CLUTCH
10.lnstall:
• Clutch cover "1"
• Clutch cover bolt
�_ Clutch cover bolt
10 Nm (1.0 m·kgf, 7.2 fHbf)
��
TIP ___________
Tighten the bolts in stage, using a crisscross
pattern.
6-43
KICKSTATER
EAS1DX3174
KICKSTATER
Removing the kick shaft
6-44
KICKSTATER
EASIDX3175
REMOVING THE KICK SHAFT ASSEMBLY
1. Remove:
• Kick shaft assembly"1"
TIP ______________
Unhook the torsion spring"2" from the hole"a"
in the crankcase.
EASIDX3178
INSTALLING THE KICK SHAFT ASSEMBLY
1. Install:
• Kick gear "1"
• Washer"2"
• Circlip "3"Dl11
• Ratchet wheel "4"
• Spring"5"
EAS1DX3176
CHECKING THE KICK SHAFT AND RATCH- • Washer"6"
ET WHEEL • Circlip "7"11111
1. Check: To kick shaft "8".
• Ratchet wheel"1" smooth movement TIP ______________
Unsmooth movement � Replace. • Apply the molybdenum disulfide oil on the in
• Kick shaft"2" ner circumferences of the kick gear and ratch
Wear/damage � Replace the kick shaft as et wheel.
sembly. • Align the punch mark "a" on the ratchet wheel
• Spring"3" with the punch mark"b" on the kick shaft.
Broken � Replace.
2. Install:
EAStDX3tn • Torsion spring"1"
CHECKING THE KICK GEAR, KICK IDLE To kick shaft "2".
GEAR AND RATCHET WHEEL TIP ______________
1. Inspect: Make sure the stopper "a" of the torsion spring
• Kick gear"1"
fits into the hole"b" on the kick shaft.
Wear/damage � Replace the kick shaft as
sembly.
• Kick idle gear "2"
• Ratchet wheel"3"
• Gear teeth"a"
• Ratchet teeth "b"
Wear/damage � Replace.
6-45
KICKSTATER
5. Hook:
• Torsion spring"1"
TIP_____________
Turn the torsion spring clockwise and hook into
the proper hole"a" in the crankcase.
3. Install:
• Spring guide"1"
TIP ______________
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.
EAS1DX3179
INSTALLING THE KICK IDLE GEAR
1. Install:
a • Kick idle gear"1"
• Washer"2"
• Circlip "3"ml!I
TIP _________...;._____
• Apply the engine oil on the kick idle gear inner
circumference.
• Install the kick idle gear with its depressed
4. Install: side"a" toward you.
• Kick shaft assembly "1"
• Washer"2"
TIP ______________
• Apply the molybdenum disulfide grease on
the contacting surfaces of the kick shaft stop
per"a" and kick shaft ratchet wheel guide"3".
• Apply the engine oil on the kick shaft.
• Slide the kick shaft assembly into the crank
case and make sure the kick shaft stopper"a"
fits into the kick shaft ratchet wheel guide.
6-46
SHIFT SHAFT
EAS2541D
SHIFT SHAFT
Removing the shift shaft and stopper lever
6-47
SHIFT SHAFT
6-48
SHIFT SHAFT
EAS10X3180
REMOVING THE SEGMENT
1. Remove:
• Bolt (segment) "1"
• Segment"2"
TIP ______________
Turn the segment counterclockwise until it
stops and loosen the bolt.
ECA1DX1021
TIP-"---------------
Align the notch "a" on the segment with the pin
"b" on the shift cam.
�·i§�---------
ECA1DX1022
EAS25420
11 the segment gets an impact, it may be
CHECKING THE SHIFT SHAFT
damaged. Take care not to give an impact to
1. Check:
the segment when tightening the bolt.
• Shift shaft"1"
Bends/damage/wear --+ Replace.
• Shift shaft spring"2"
Damage/wear--+ Replace.
EAS1DX3182
INSTALLING THE STOPPER LEVER
1. Install:
EAS25430
• Torsion spring"1"
CHECKING THE STOPPER LEVER •Washer"2"
• Stopper lever"3"
1. Check: • Stopper lever bolt"4"
• Stopper lever
Bends/damage--+ Replace. Stopper lever bolt
Roller turns roughly --+ Replace the stopper 10 Nm (1.0 m·kgf, 7.2 ft-lbf)
lever.
• Stopper lever spring TIP ______________
• Damage/wear --+ Replace. Align the stopper lever roller with the slot on
segment.
6-49
SHIFT SHAFT
-----
4. Install:
EAS1DX3183
INSTALLING THE SHIFT GUIDE AND SHIFT • Shift guide bolt "1"
LEVER ASSEMBLY Shift guide bolt
1. Install: 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
• Spring "1"
• Pawl pin "2"
• Pawl "3"
To shift lever "4".
TIP ____________
Apply the engine oil on the spring, pawl pin and
pawl.
EAS25450
INSTALLING THE SHIFT SHAFT
� 1. Install:
• Roller "1"
• Collar "2"
• Shift shaft spring "3"
2. Install: • Washer "4"
• Shift lever assembly "1" • Shift shaft "5"
To shift guide "2". TIP ____________
Apply the engine oil on the roller and shift shaft.
3. Install:
• Shift lever assembly "1"
• Shift guide "2"
TIP ____________
• The shift lever assembly is installed at the
same time as the shift guide.
• Apply the engine oil on the segment bolt shaft.
6-50
OIL PUMP AND BALANCER GEAR
EAS1DX3184
6-51
OIL PUMP AND BALANCER GEAR
6-52
OIL PUMP AND BALANCER GEAR
6-53
OIL PUMP AND BALANCER GEAR
EAS1DX3185 2. Measure:
REMOVING THE BALANCER
• Inner-rotor-to-outer-rotor-tip clearance "a"
1. Straighten the lock washer tab.
• Outer-rotor-to-oil-pump-housing clearance
2. Loosen: "b"
• Balancer nut "1" • Oil-pump-housing-to-inner-rotor-and-outer..
• Primary drive gear nut "2"
rotor clearance "c"
• Balancer weight gear nut "3"
Out of specification� Replace the oil pump.
TIP ______________
Place an aluminum plate "a" between the teeth Inner-rotor-to-outer-rotor-tip
of the balancer drive gear "4" and balancer clearance
Less than
weight gear "5". 0.120 mm (0.0047 in)
Limit
0.20 mm (0.0079 in)
Outer-rotor-to-oi I-pump-housing
clearance
0.090-0.170 mm (0.0035-0.0067
in)
Limit
0.24 mm (0.0094 in)
Oil-pump-housing-to-inner-and
outer-rotor clearance
0.05-0.10 mm (0.0020-0.0039 in)
Limit
0.17 mm (0.0067 in)
EAS1DX3186
CHECKING THE OIL PUMP
1. Check:
• Oil pump drive gear 1. Inner rotor
• Oil pump driven gear 2. Outer rotor
• Oil pump housing 3. Oil pump housing
• Oil pump housing cover 3. Check:
Cracks/damage/wear -) Replace the defec • Oil pump operation
tive part(s). Rough movement� Repeat steps (1) and
(2) or replace the defective part(s).
5.. 54
OIL PUMP AND BALANCER GEAR
EAS1DX3187
ASSEMBLING THE OIL PUMP
1. Install:
• Oil pump drive shaft "1"
• Washer"2"
•• Dowel pin "3"
• Inner rotor 1 "4"
TIP ______________
• Apply the engine oil on the oil pump drive
shaft and inner rotor 1.
• Fit the dowel pin into the groove in the inner 4. Check:
rotor 1. • Oil pump operation
Refer to "CHECKING THE OIL PUMP" on
page 6-54.
EAS1DX3188
INSTALLING THE OIL PUMP AND BALANC-
ER GEAR
1. Install:
• Outer rotor 2 "1"
• Dowel pin"2"
• Oil pump assembly"3"
• Oil pump assembly bolt "4"
2. Install:
• Outer rotor 1"1" Oil pump assembly bolt
10 Nm (1.0 m·kgf, 7.2 ft-lbf)
TIP ______________
Apply the engine oil on the outer rotor 1. TIP ______________
Apply the engine oil on the outer rotor 2.
1
3. Install:
• Oil pump cover "1"
-------------
ECA1DX1023
• Oil pump cover screw "2"
�- Oil pump cover screw After tightening the bolts, make sure the oil
2 Nm (0.2 m·kgf, 1.4ft-lbf) pump turns smoothly.
��
2. Install:
• Dowel pin "3" • Oil pump drive gear "1"
• Inner rotor 2 "4" • Washer "2"
• Circlip "5"DDI.I • Circlip"3"1m1J
TIP ______________ TIP ______________
• Apply the engine oil on the oil pump drive Apply the engine oil on the oil pump drive gear
shaft end and inner rotor 2. inner circumference.
• Fit the dowel pin into the groove in the inner
rotor 2.
6-55
OIL PUMP AND BALANCER GEAR
4. Install:
• Balancer drive gear "1"
TIP ______________
• Align the punched mark "a" on the balancer
drive gear with the punched mark "b" on the
balancer weight gear.
• Install the balancer drive gear and crankshaft
with the lower splines "c" aligning with each
other.
5. Install:
• Lock washer "1 "llm
• Balancer weight gear nut "2"
Balancer weight gear nut
50 Nm (5.0 m·kgf, 36 ft-lbf)
6-56
GENERATOR AND STARTER CLUTCH
EAS1DX3189
/jl:.-
N 12 Nm (1.2 m, leg!, 8.7 ft, lbf)I
·· V 7 Nm (0.7 m • kgf, 5.1 ft •lbf)
. 1 .
@--"
a Bearing 1
9 Starter idle gear shaft 1
",:,:
10 Geii�rator rotor 1
11 Woodruff key 1
12 Starter clutch 1
6-57
GENERATOR AND STARTER CLUTCH
6-58
GENERATOR AND STARTER CLUTCH
EA$1DX3190
REMOVING THE GENERATOR 2. Check:
1. Remove: • Starter clutch idle gear
• Generator rotor nut "1" • Starter clutch gear
• Washer Burrs/chips/roughness/wear� Replace the
defective part (s).
3. Check:
• Starter clutch gear
Damage/pitting/wear � Replace the starter
clutch gear.
4. Check:
• Damper assembly
Damage/pitting/wear � Replace the damp
er assembly.
• Check the gear of the starter motor
2. Remove: armature.
• Generator rotor "1"
(with the rotor puller "2")
• Woodruff key
Rotor puller
90890-04142
YM-04142
5. Check:
• Starter clutch operation
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Install the starter dutch drive gear "1" onto
the starter clutch and hold the starter clutch.
b. When turning the starter clutch drive gear
clockwise "A", the starter clutch and the
starter clutch drive gear should engage, oth
EAS1DX3191
erwise the starter clutch is faulty and must
CHECKING THE STARTER CLUTCH be replaced.
1. Check: c. When turning the sta·rter clutch drive gear
• Starter clutch rollers counterclockwise "B", it should turn freely,
Damage/wear � Replace otherwise the starter clutch is faulty and
must be replaced.
6-59
GENERATOR AND STARTER CLUTCH
EAS1DX3192
INSTALLING THE STARTER CLUTCH
1. Install:
• Stator "1"
• Stator bolt "2"
Stator bolt
7 Nm (0.7 m·kgf, 5.1 ft-lbf)
6-60
GENERATOR AND STARTER CLUTCH
2. Install:
• Washer
• Generator rotor nut "1"
Generator rotor nut
65 Nm (6.5 m·kgf, 47 fMbf)
TIP ______________._
Tighten the generator rotor nut to 65 Nm (6.5
m·kgf, 47 ft-lbf), loosen and retighten the gener
ator rotor nut to 65 Nm (6.5 m·kgf, 47 ft·lbf). 5. Install:
• Washer"1"
• Damper a�sembly "2"
• Washer"3"
TIP ______________
Apply the engine oil to the shaft and washers.
3. Install:
• Starter idle gear shaft "1"
• Bearing "2"
• Starter idle gear 2"3"
TIP ______________
Apply the engine oil on the starter idle gear 6. Install:
shaft, bearing and idle gear inner circumfer • Cover (damper assembly) "1"
ence. • Bolt "2"
Bolt
10 Nm (1.0 m·kgf, 7.2 ft-lbf)
TIP ______________
Install the cover (damper assembly) with its
mark "a" facing upward.
4. Install:
• Dowel pin
• Crankcase cover gasketDm
• Left crankcase cover "1"
• Crankcase cover bolt
Crankcase cover bolt
10 Nm (1.0 m·kgf, 7.2 ft-lbf)
TIP ______________
Tighten the bolts in stage, using a crisscross
pattern.
6-61
CRANKCASE
CRANKCASE
EAS25540
4
12 Nm (1.2 m. kgf, 8.7 ft· lbf)
2 8
6-62
CRANKCASE
Separating the crankcase
4
12 Nm (1.2 m• kgf, 8.7 ft• lbf)
6-63
CRANKCASE
6-64
CRANKCASE
EAS25570
DISASSEMBLING THE CRANKCASE
1. Separate:
• Right crankcase
• Left crankcase
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Remove the crankcase bolts, hose guide
and clutch cable holder.
··�·············��·��··�········
c. Remove the dowel pins and 0-ring.
2. Remove:
• Balancer shaft "1"
TIP _______________
Remove the balancer shaft with its flat side "a"
facing the crankshaft.
TIP _______________
Loosen each bolt 1/4 of a turn at a time and af
ter all the bolts are loosened, remove them.
b. Remove the right crankcase
TIP _______________
• Place the crankcase with its left side down
ward and split it by inserting a screwdriver tip
into the splitting slit "a" in the crankcase.
• Lift the right crankcase horizontally while light
ly patting the case splitting slit and engine
mounting boss using a soft hammer, and EAS1DX3194
CHECKING THE TIMING CHAIN, TIMING
leave the crankshaft and transmission with
CHAIN GUIDE, OIL STRAINER
the left crankcase.
1. Check:
ECA13910
•
FWi:it1iiB�
,..,.,._'.all:wmJ _____________ Timing chain
Use soft hammer to tap on the case half. Stiffness-t Replace the camshaft sprocket,
timing chain and crankshaft sprocket as a
Tap only on reinforced portions of case. Do set.
not tap on gasket mating surface. Work 2. Check:.
slowly and carefully. Make sure the case • Timing chain guide
halves separate evenly. If the cases do not Damage/wear-t Replace.
separate, check for a remaining case bolt or 3. Check:
fitting. Do not force. • Oil strainer
Obstruction-t Blow out with compressed
air.
Cracks/damage -t Replace.
6-65
CRANKCASE
3. Check:
• Crankcase
Cracks/damage � Replace.
• Oil delivery passages
Obstruction � Blow out with compressed
air.
EAS25700
ASSEMBLING THE CRANKCASE
1. Install:
• Oil strainer
• Bearing cover plate 4. Install:
• Dowel pins "1"
� "" Oil strainer bolt • 0-ring "2"Dm
10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Crankcase (to the left crankcase)
�� Bearing cover plate
10 Nm (1.0 m·kgf, 7.2 ft·lbf) Crankcase bolt
LOCTITE® 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Bearing cover plate (crankshaft)
14 Nm (1.4 m·kgf, 10 ft·lbf) TIP ______________
• Apply the lithium soap base grease on the 0-
TIP ______________ ring.
• Install the bearing by pressing its outer race • Fit the right crankcase onto the left crankcase.
parallel. Tap lightly on the case with soft hammer.
• To prevent the bearing cover plate crankshaft • When installing the crankcase, the connecting
screw "1" from becoming loose, crush the rod should be positioned at TDC (top dead
screw head periphery "a" into the concave "b" center).
using a punch etc. In so doing, take care not • Tighten the bolts in a crisscross pattern in two
to damage the screwdriver receiving hole in (2) stages, with 1/4 turn each.
the screw head.
om2
3. M6x80mm
4. M6x60mm
5. M6x50mm
6-66
CRANKSHAFT ASSEMBLV AND BALANCER SHAFT
EAS25970
6-67
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT
EAS1DX3195 EAS26060
REMOVING THE BALANCER SHAFT CHECKING THE CRANKSHAFT ASSEMBLY
1. Remove: 1. Measure:
• Balancer shaft "1" • Crankshaft runout
TIP ______________ Out of specification -, Replace the crank
Remove the balancer shaft with its flat side "a" shaft, bearing or both.
facing the crankshaft. TIP ______________
Turn the crankshaft slowly.
Runout limit C
0.030 mm (0.0012 in)
EAS26000
REMOVING THE CRANKSHAFT ASSEMBLY
1. Remove:
• Crankshaft assembly "1"
TIP ______________ 2. Measure:
Remove the crankshaft assembly by using the • Big end side clearance
crankcase separating tool "2". Out of specification -, Replace the big end
bearing, crankshaft pin, or connecting rod.
Crankcase separating tool Big end side clearance D
90890-04152 0.150-0.450 mm (0.0059-0.0177
Crankcase separator in)
YU-A9642
3. Measure:
• Crankshaft width
Out of specification -, Replace the crank
shaft.
Width A
61.95-62.00 mm (2.439-2.441 in)
6-68
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT
ECA13970
_j ________
To avoid scratching the crankshaft and to
5. Check:
• Crankshaft journal oil passage
Obstruction -} Blow out with compressed
air.
EAS2B210
6-69
TRANSMISSION
EAS26241
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
/
/
/
/
/
'' /
/
' ...._/
6-70
TRANSMISSION
EAS26260
CHECKING THE SHIFT FORKS
The following procedure applies to all of the
shift forks.
1. Check:
• Shift fork cam follower "1"
• Shift fork pawl "2"
Bends/damage/scoring/wear� Replace the
shift fork.
EAS1DX3196
CHECKING THE TRANSMISSION
1. Measure:
2 • Main axle runout
(with a centering device and dial gauge "1")
Out of specification � Replace the main ax
le.
Main axle runout limit
2. Check: 0.08 mm (0.0032 in)
• Shift fork movement
Unsmooth operation � Replace shift fork.
2. Measure:
TIP ______________ • Drive axle runout
For a malfunctioning shift fork, replace not only (with a centering device and dial gauge "1 ")
the shift fork itself but the two gears each adja Out of specification � Replace the drive ax
cent to the shift fork. le.
Drive axle runout limit
EAS26270
0.08 mm (0.0032 in)
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:.
• Shift drum groove
Damage/scratches/wear � Replace the 1
shift drum assembly.
• Shift drum segment "1"
Damage/wear "' Replace the shift drum
assembly.
3. Check:
• Transmission gears
Blue discoloration/pitting/wear � Replace
the defective gear (s).
6-71
TRANSMISSION
3. Install:
• Washer "1"
• Circlip "2"Dm
TIP ______________
• Be sure the circlip sharp-edged corner "a" is
positioned opposite side to the washer and
gear "b".
• Install the circlip with its ends "c" settled even
ly on the spline crests.
2. Install:
• Collar "1"
• 2nd wheel gear (26T) "2"
• 4th wheel gear (21T) "3"
• 3rd wheel gear (21T) <14"
• 5th wheel gear (21T) "5"
• Collar "6"
• 1st wheel gear (29T) ''7"
• 0-ring "B"llm
To drive axle "9".
6-72
TRANSMISSION
C C
4. Install:
• Collar "1"
TIP ______________
• Apply the lithium soap base grease on the oil
seal lip.
• When installing the collar into the crankcase,
pay careful attention to the crankcase oil seal
lip.
6. Install:
• Transmission assembly "1"
To left crankcase "2".
TIP __________�---
Apply the engine oil on the bearings and guide
bars.
5. Install:
• Shift fork 1 (L) "1"
• Shift fork 2 (C) "2"
• Shift fork 3 (R) "3"
• Shift cam "4''.
To main axle and drive axle.
TIP ______________
• Apply the molybdenum disulfide oil on the
shift fork grooves.
7. Check:
• Apply engine oil to the shift cam groove, bear
• Shifter operation
ing contact surface and shift fork shaft.
• Transmission operation
• Mesh the shift fork #1 (L) with the 4th wheel
Unsmooth operation -+ Repair.
gear"5" and #3 (R) with the 5th wheel gear"?"
on the drive axle.·
• Mesh the shift fork #2 (C) with the 3rd pinion
gear "6" on the main axle.
6-73
COOLING SYSTEM
TIP~~~~~~~~~~~~~~~~~~---~~~~~~~~~~~~~
This section is intended for those who have basic knowledge and s~ill concerning the servicing of
Yamaha motorcycles {e.g., Yamaha dealers, service engineers, etc.) Those who have little knowl-
edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas-
sembly, or reassembly only by reference to this manual. It may lead to servicing trouble and
mechanical damage. · ·
EAS10X3197
RADIATOR
Removing the radiator
7-1
RADIATOR
7-2
RADIATOR
EAS10X3198
Straighten any flattened fins with a thin, flat- INSTALLING THE RADIATOR
head screwdriver. 1. Fill:
•Cooling system _
(with the specified amount of the recom-
mended coolant)
Refer to "CHANGING THE COOLANT" on
page 3-16.
2. Check:
• Cooling system
Leakage 4 Collect or repl~ce.
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Attach the radiator cap tester "1" to the radi-
ator.
2. Check:
• Radiator hoses Radiator cap tester
•Radiator pipes 90890-01325
Cracks/damage 4 Replace. Mityvac cooling system tester kit
3. Measure: YU-24460-A
• Radiator cap opening pressure Radiator cap tester adapter
Below the specified pressure 4 Replace the 90890-01352
radiator cap.
Pressure tester adapter
YU-33984
Radiator cap opening pressure
107.9-137.3 kPa (1.08-1.37 kgf/
cm 2 , 15.6-19.9 psi)
7-3
RADIATOR
7-4
WATER PUMP
EAS1DX3200
WATER PUMP
Removing the water pump
7-5
WATER PUMP
EAS26530 2. Install:
CHECKING THE WATER PUMP
•Dowel pin "1"
1. Check:
• Water pump housing cover
• 0-ring "2"Im
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
•Impeller shaft
Cracks/damage/wear ~ Replace. Apply the lithium-soap-based grease on the 0-
ring.
EAS26560
ASSEMBLING THE WATER PUMP
1. Install:
• Impeller shaft "1"
•Washer "2"
• Impeller "3"
Impeller
14 Nm (1.4 m·kgf, 1Oft-lbf)
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
•Take care so that the oil seal lip is not dam- 3. Install:
aged or the spring does not slip off its posi- 11
• Water pump housing 1"
tion. • Water pump housing bolt "2"
• When installing the impeller shaft, apply the
engine oil on the oil seal lip, bearing and im- ~- Water pump housing bolt
peller shaft. And install the shaft while turning ~~ 10 Nm (1.0 m·kgf, 7.2 ft-lbf)
it.
• Hold the impeller shaft on its width across the • Washer "3" Im
flats "a" with spanners, etc. and install the im- •Coolant drain bolt "4"
peller. Coolant drain bolt
10 Nm (1.0 m·kgf, 7.2 ft-lbf)
4. Install:
•0-ringl'.m
• Coolant pipe "1"
• Coolant pipe bolt "211
2
~- Coolant pipe bolt
~~ 10 Nm (1.0 m·kgf, 7.2 ft-lbf)
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
7-6
WATER PUMP
7-7
FUEL SYSTEM
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
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 knowl-
edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas-
sembly, or reassembly only by reference to this manual. It may lead to servicing trouble and
mechanical damage.
EAS26620
FUEL TANK
Removing the fuel tank
8-1
FUEL TANK
8-2
FUEL TANK
EAS26630
REMOVING THE FUEL TANK
1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump. 1
2. Remove:
• Fuel hose coupler
EWA23P1001
A WARNING
Cover fuel hose connections with a cloth
when disconnecting them. Residual pres-
sure in the fuel lines could cause fuel to
spurt out when removing the hose.
ECA23P1090
armm~~~~~~~~-
Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hose, since there may be fuel remaining
in it.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
• To disconnect the fuel hose from the fuel tank,
remove the fuel hose connector holder "a", 3. Remove:
and then slide the fuel hose connector cover. •Fuel tank
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
•To remove the fuel hose from the fuel rail,
slide the fuel hose connector cover "1" on the Do not set the fuel tank down on the installation
end of the hose in the direction of the arrow surface of the fuel pump. Be sure to lean the
shown, press the two buttons "2" on the sides fuel tank against a wall or the like.
of the connector, and then remove the hose.
• Remove the fuel hose manually without using EAS26640
any tools. REMOVING THE FUEL PUMP
• Before remqving the hose, place a few rags in 1. Remove:
the area under where it will be removed. · •Fuel pump
•To prevent sand, dust, and other foreign ma- ECA14720
EAS1DX3201
CHEC~NGTHEFUELPUMPBODV
1. Check:
• Fuel pump body
Obstruction 4- Clean.
Cracks/damage ~ Replace fuel pump as-
sembly.
EAS26700
8-3
FUEL TANK
EAS1DX3204
INSTALLING THE FUEL SENDER
1. Install:
• Fuel sender gasketml'J
• Fuel sender
Fuel sender bolts
4 Nm (0.4 m·kgf, 2.9 ft-lbf)
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
EAS1DX3203
CHECKING THE FUEL SENDER
1. Disconnect:
• Fuel pump coupler
• Fuel sender coupler
(from the wire harness)
2. Remove:
•Fuel tank
3. Remove:
•Fuel sender
8-4
FUEL TANK
EAS1DX3205
INSTALLING THE FUEL TANK d. Connect the pressure gauge "1" and fuel
1. Install: pressure adapter "2" to the fuel hose.
•Fuel hose Pressure gauge
ECA1DX1024
90890-03153
~~~~~~~~~~~~ YU-03153
When installing the fuel hose, make sure Fuel pressure adapter
that it is securely connected, and that the 90890-03186
fuel hose holders are in the correct position, YM-03186
otherwise the fuel hose will not be properly
installed.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
~ ~~~--
• Slide the fuel hose connector cover "1" at the
fuel hose end in the direction of the arrow.
EAS10X3206
A WARNING
Cover fuel hose connection with a cloth
when disconnecting them. Residual pres-
sure in the fuel lines could cause fuel to
spurt out when removing the hose.
ECA10X1025
l~M?fJP:;t _ _ _ _ _ _ _ _ __
Be sure to disconnect the fuel hose by
hand. Do not forcefully disconnect the hose
with tools.
8-5
THROTTLE BODY
EAS26970
THROTTLE BODY
Removing the throttle body
4
2
Throttle cable
8-6
THROTTLE BODY
8-7
THROTTLE BODY
EAS1DX3207 ECA10X1027
1••~-------------------
REMOVING THE THROTTLE BODY
The following procedure applies to both of the • Before removing the throttle body, clean
throttle body. the area around the throttle body to pre-
1. Remove: vent dirt and other foreign material from
• Rear frame upper bolt falling into the engine.
• Rear shock absorber assembly upper bolt •If the throttle body is subject to strong
Refer to "REAR SHOCK ABSORBER AS-
shocks or dropped during cleaning, re-
SEMBLY" on page 5-61. place it.
2. Loosen: • Do not use any caustic carburetor clean-
• Rear frame lower bolt ing solution.
• Rear shock absorber assembly lower bolt
• Do not directly push the throttle valves to
3. Slide: open them.
•Rear frame • Do not loosen the throttle valve stopper
• Rear shock absorber assembly screw "1 ", throttle valve pulley nut "2", or
ECA1DX1026
throttle valve screw "3". Otherwise, a loss
tl{Q:i1~~~~~~~~~~~~ of performance may occur.
Do not strain the wire harness when the rear
• Do not use compressed air to clean the
frame and rear shock absorber assembly
throttle body. Otherwise, foreign material
are removed.
may adhere to the intake air pressure sen-
4. Loosen: sor passage "a" and fuel injector "b" in the
• Throttle body joint clamp screw throttle body.
5. Remove:
• Throttle body
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
EAS26980
CHECKING THE INJECTOR
1. Check:
• Injector
Obstruction~ Replace and check the fuel
pump/fuel supply system.
Deposit ~ Replace.
Damage ~ Replace.
2. Check:
• Injector resistance
Refer to "CHECKING THE FUEL INJEC-
TOR" on page 9-78.
EAS26990
CHECKING THE THROTTLE BODY
1. Check:
• Throttle body
Cracks/damage~ Replace the throttle body
as a set.
2. Check:
• Fuel passages
Obstructions~ Clean.
8-8
THROTTLE BODY
EAS1DX3208
CHECKING THE THROTTLE BODY JOINT
1. Check:
• Throttle body joint "1"
Cracks/damage ~ Replace.
~ ~' ','
\
//t ',
=---~ -.~-~~
~-
·--~
\- ·",:
EAS27030
ADJUSTING THE THROTTLE POSITION
SENSOR
EWA3201011
A WARNING
• Handle the throttle position sensor with
special care.
•Never subject the throttle position sensor
to strong shocks. If the throttle position
sensor is dropped, replace it.
1. Check:
• Throttle position sensor
Refer to "CHECKING THE THROTTLE PO-
SITION SENSOR" on page 9-76.
2. Adjust:
• Throttle position sensor angle
YYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY
a. Connect the diagnostic tool.
Refer to "YAMAHA DIAGNOSTIC TOOL" on
page 9-26.
b. Temporary tighten the throttle position sen-
sor.
c. Check that the throttle grip is fully closed.
d. Connect the throttle position sensor to the
wire harness.
e. Set the main switch to "OFP'.
f. Set the diagnostic tool to "diagnostic mode"
g. Diagnostic code number "d:01" is selected.
h. Adjust the position of the throttle position
sensor angle so that 9-16 can appear in the
diagnostic tool.
i. After adjusting the throttle position sensor
angle, tighten the throttle position sensor
screws "1".
Throttle position sensor screw
3.4 Nm (0.34 m·kgf, 2.5 ft-lbf)
8-9
ELECTRICAL SYSTEM
9-1
IGNITION SYSTEM
EAS27090
IGNITION SYSTEM
EAS1DX3209
CIRCUIT DIAGRAM
9-2
IGNITION SYSTEM
1. AC magneto
4. Battery
5. Main fuse
6. Starter relay
16. Main switch
17.Joint connector
22. ECU (electronic control unit)
23. Ignition coil
24.Spark plug
29.Lean angle sensor
32.Joint connector
9-3
IGNITION SYSTEM
EAS1DX3210
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
Before troubleshooting, remove the following part (s):
1. Seat
2. Side cover (left/right)
3. Air scoop (left/right)
4. Fuel tank
9-4
IGNITION SYSTEM
9-5
ELECTRIC STARTING SYSTEM
EAS27160
CIRCUIT DIAGRAM
.
i
II
r-1
J r-t@I
-· : i
11
·;
. I
..
~
I
I
I
I
©
9-6
ELECTRIC STARTING SYSTEM
4. Battery
5. Main fuse
6. Starter relay
7. Starter motor
8. Starter relay diode
10. Connector
11 ;Connector
12. Connector
14.Starting circuit cut-off relay
15. Start switch
16. Main switch
17.Joint connector
18.Clutch switch
19.Diode
26. Neutral switch
32.Joint connector
40.Joint connector
42. Connector
9-7
ELECTRIC STARTING SYSTEM
EAS1DX3212
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION
If the main switch is set to 11 0N 11 , the starter motor can only operate if at least one of the following
conditions is met:" and the main switch· is set to "ON" (both switches are closed), the starter motor
can only operate if at least one of the following conditions is met:
•The transmission is in neutral (the neutral switch is closed).
• The clutch lever is pulled to the handlebar (the clutch switch is closed).
The starting circuit cut-off relay prevents the starter motor from operating when neither of these con-
ditions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach
the starter motor. When at least one of the above conditions has been met the starting circuit cut-off
relay is closed and the engine can be started by pressing the start switch.
10
9-8
ELECTRIC STARTING SYSTEM
9-9
ELECTRIC STARTING SYSTEM
EAS10X3213
TROUBLESHOOTING
The starter motor fails to turn.
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
Before troubleshooting, remove the following part (s):
1. Seat ,
2. Side cover (left/right)
3. Air scoop (left/right)
4. Fuel tank
9-10
ELECTRIC STARTING SYSTEM
9-11
CHARGING SYSTEM
EAS27200
CHARGING SYSTEM
EAS1DX32 14
CIRCUIT DIAGRAM
.
Ii
II
I~
' '
I ii
! !I
'I
11
11
Ii II
9-12
CHARGING SYSTEM
1. AC magneto
2. Rectifier/regulator
3. Connector
4. Battery
5. Main fuse
6. Starter relay
32.Joint connector
9-13
CHARGING SYSTEM
EAS27220
TROUBLESHOOTING
The battery is not being charged.
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
9-14
CHARGING SYSTEM
9-15
LIGHTING SYSTEM
EAS27240
LIGHTING SYSTEM
EAS10X3215
CIRCUIT DIAGRAM
lr
Ir,:. --
.
'--~-rt1~~~--t-;::t===l::tt:~®:
' __,
I i.ir--"""
I~@
,, l~
,I
i
,,
II
9-16
LIGHTING SYSTEM
4. Battery
5. Main fuse
6. Starter relay
9. Headlight relay
1a.Connector
11. Connector
12. Connector
16.Main switch
17.Joint connector
22.ECU (electronic control unit)
32.Joint connector
40.Joint connector
41 .Joint connector
42.Connector
43. Headlight
44. Taillight
9-17
LIGHTING SYSTEM
EAS1DX3216
TROUBLESHOOTING
Any of the following fail to light: headlight or meter light.
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
9-18
.·...,
LIGHTING SYSTEM
.· ... -:.. .·
..... ,
·"
9~19
SIGNALING SYSTEM
EAS27270
SIGNALING SYSTEM
EAS 10X32 17
CIRCUIT DIAGRAM
9-20
SIGNALING SYSTEM
4. Battery
5. Main fuse
6. Starter relay
16.Main switch
17.Joint connector
22.ECU (electronic control unit)
32.Joint connector
34.Speed sensor
35. Multi-function display
36. Fuel sender
37. Resistor
40.Joint connector
41.Joint connector
42. Connector
9-21
SIGNALING SYSTEM
EAS1DX3218
TROUBLESHOOTING
• The speedometer does not operate normally.
•The fuel indicator light does not come on.
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
9-22
SIGNALING SYSTEM
9-23
FUEL INJECTION SYSTEM
EAS273JO
-:
w
-,
@I
......J
L--
L r--~i=l=======::ttt====l::tt;';:! I
~__,....I....
~· ©I
1,t_J
il
llRI
9-24
FUEL INJECTION SYSTEM
1. AC magneto
4. Battery
5. Main fuse
6. Starter relay
1a.Connector
11.Connector
12. Connector
14.Starting circuit cut-off relay
15.Start switch
16. Main switch
17.Joint connector
19.Diode
22. ECU (electronic control unit)
25. Injector
26.Neutral switch
27. Throttle position sensor
28. Intake air pressure sensor
29.Lean angle sensor
30.Coolant temperature sensor
31.lntake air temperature sensor
32.Joint connector
33.Engine stop switch
40.Joint connector
42. Connector
9-25
FUEL INJECTION SYSTEM
EAS1DX3220
YAMAHA DIAGNOSTIC TOOL
This model uses the Yamaha diagnostic tool to identify malfunctions.
For information about using the Yamaha diagnostic tool, refer to the operation manual that is included
with the tool. ·
9-26
FUEL INJECTION SYSTEM
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
When the Yamaha diagnostic tool is connected to the vehicle, the operation of the meter and indica-
tors will be different from the normal operation.
EAS10X3221
Engine trouble warning ligh~ indication and fuel injection system operation
Warning light indica- Fuel injection opera-
ECU operation Vehicle operation
ti on ti on
Flashing* Warning provided Operation stopped Cannot be operated
when unable to start
engine
Remains on Malfunction detected Operated with substi- Can or cannot be oper-
tute characteristics in ated depending on the
accordance with the fault code
description of the mal-
function
* The warning light flashes when any one of the following conditions is present and the start switch
is pushed:
12: Crankshaft position sensor 41: Lean angle sensor
(open or short circuit)
30: Lean angle sensor 50: ECU internal malfunction
(latch up detected) (faulty ECU memory)
33: Ignition coil
(Malfunction detected in the primary wire
of the ignition coil)
9-27
FUEL INJECTION SYSTEM
c d c
9-28
FUEL INJECTION SYSTEM
EAS27400
The engine operation is not normal, but the
TROUBLESHOOTING METHOD
engine trouble warning light does not come
.. on.
The engine operation is not normal and the
engine trouble warning light comes on. 1. Check the operation of the following sensors
1. Check: and actuators in the diagnostic mode. Refer
• Fault code number to ''TROUBLESHOOTING DETAILS" on
page 8-36.
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Check the fault code number displayed on d:01: Throttle position sensor signal (throttle
the meter. angle)
b. Identify the faulty system with the fault code d:30: Ignition coil
number. d:36: Injector
c. Identify the probable cause of the malfunc- If a malfunction is detected in the sensors or
tion. actuators, repair or replace all faulty parts.
AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA If no malfunction is detected in the sensors
2. Check and repair the probable cause of the and actuators, check and repair the inner
malfunction. parts of the engine.
Fault code No. No fault code No.
Check and repair. Re- Check and repair.
fer to "TROUBLE-
SHOOTING
DETAILS" on page 9-
33.
Monitor the operation
of the sensors and
actuators in the diag-
nostic mode. Refer
to''TROUBLE-
SHOOTING DE-
TAILS" on page 9-33
and "LIST OF DIAG-
NOSTIC CODES" on
page 9-31.
3. Perform the reinstatement action for the fuel
injection system.
Refer to "Reinstatement method" in the ap-
propriate table in ''TROUBLESHOOTING
DETAILS" on page 8-36.
4. Set the main switch to "OFF", then to "ON"
again, and then check that no fault code
number is displayed.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
9-29
FUEL INJECTION SYSTEM
EAS1DX3222 ,
LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS
Able/unable to start: Indicates whether the engine can be started when the malfunction for the appli-
cable item has occurred.
Able/unable to drive: Indicates whether the vehicle can continue to be driven (the engine can contin-
ue to operate) when the malfunction for the applicable item has occurred while the vehicle is being
driven (the engine is operating).·
Fault
Item Page
code
12 Crankshaft position sensor 9-34
13 Intake air pressure sensor 9-35
(open or short circuit)
14 Intake air pressure sensor 9-36
(clogged or detached hose) .
15 Throttle position sensor 9-37
(open or short circuit)
16 Throttle position sensor 9-39
(stuck)
21 Coolant temperature sensor 9-40
(open or short circuit)
22 Intake air temperature sensor 9-41
(open or short circuit)
30 Overturn detected 9-42
33 Ignition system 9-43
39 Fuel injector 9-44
(open circuit)
41 Lean angle sensor 9-45
(open or short circuit)
42 Wheel sensor 9-46
44 EEPROM writing error 9-47
46 Vehicle system power supply 9-48
50 ECU internal malfunction 9-48
(abnormal ROM data)
9-30
FUEL INJECTION SYSTEM
EAS10X3223
LIST OF DIAGNOSTIC CODES
Diag-
nostic Standard values of the meter dis-
Item Details
code play or description of operation
No.
d:01 Throttle angle Displays the throttle angle. Display when the throttle is fully
•Check with throttle fully closed: 9-16
closed.
d:03 Intake air pressure Displays the intake air pres- 0-126 (kPa)
sure. When the engine is stopped: Check
• Check the pressure in the that the atmospheric pressure is dis-
intake manifold. played.
• Push the start switch and •At sea level (Om): Approx. 101 (kPa)
check that the intake air • 3,000 m above sea level: Approx. 70
pressure changes. (kPa)
When the engine is cranking: The dis-
played value changes because the in-
take air pressure changes.
d:05 Intake air tempera- Displays the intake air .tern- -30 to 120 (0 C)/-22 to 248 (°F)
tu re perature. When the engine is cold: Displayed
•Check the temperature in temperature is close to the ambient
the intake manifold and air temperature.
filter case. When the engine is warm: Displayed ·
temperature is the ambient tempera-
ture +approx. 20 °C (offset for the ra-
diant heat).
d:06 Coolant tempera- Displays the coolant tern- -30 to 120 (°C)/-22 to 248 (°F)
tu re perature. When the engine is cold: Displayed
• Check the coolant temper- temperature is close to the ambient
ature. temperature.
When the engine is warm: Displayed
temperature is the current coolant
temperature.
d:07 Vehicle speed Displays the cumulative 0-999 (pulses)
pulse number for the vehicle When the front wheel is stopped:
speed pulse. Check that the displayed number does
not change.
When the front wheel is rotated sever-
al turns by hand to input the vehicle
speed pulse: Check that the displayed
number increases.
d:08 Lean angle sensor Displays the lean angle 0-5.0 (V)
sensor output voltage. When the vehicle is upright: 0.4-1.4
(V)
When the vehicle is overturned: 3.7-
4.4 (V)
d:09 Monitor voltage Displays the fuel system 0-18.7 (V)
voltage. Standard value: Approx. 12 (V)
d:21 Neutral switch and Check the neutral switch Display when the gear is in neutral:
clutch switch and clutch switch operation. ON
Display when the gear is other than
neutral and not operating clutch: OFF
9-31
· FUEL INJECTION SYSTEM
Diag-
nostic Standard values of the meter dis-
Item Details
code play or description of operation
No.
d:30 Ignition coil Check that power is sup- Actuates the ignition coil five times at
plied to the ignition coil. 1-second intervals.
• Check that a spark is gen- The 11 WARNING 11 LED on the Fl diag-
erated. nostic tool comes on each time the ig-
nition coil is actuated.
d:36 Fuel injector (#1) Check that power is sup- TIP:- Before performing this opera-
plied to the fuel injector. tion, be sure to disconnect the fuel
Check the fuel injector op- pump coupler.
eration by listening for the Actuates the fuel injector five times at
operating sound or by con- 1-second intervals.
firming the operation visual- The "WARNING" LED on the Fl diag-
ly. nostic tool comes on each time the fuel
injector is actuated.
d:52 Headlight relay Check the headlight relay Actuates the headlight relay five times
Headlight operation by listening for at 5-second intervals.
the operating sound. The "WARNING" LED on the Fl diag-
riostic tool comes on each time the
headlight relay is actuated.
d:60 . EEPROM fault Displays the location of the 00: No fault (If fault code number 44 is
code number dis- abnormal portion of the EE- displayed, the ECU is malfunctioning.)
play PROM data that has been 01: CO adjustment value
detected as fault code num-
ber 44.
If there is more than one lo-
cation, the display alter-
nates every 2 seconds.
d:61 Malfunction history Displays the fault code 00: No malfunction history (6)
(~) code number numbers that were previ- Other number displayed: Displays the
display* 1 ously recorded in the mal- code numbers recorded in the mal-
function history(~). function history 6. Refer to the fault
If more than one code num- codes.
:
ber is detected,· the display
- alternates every 2 seconds
to show all the detected
code numbers.
d:62 Malfunction history Displays the total number of 00: No malfunction history (X and 6)
(6) cod~ number m_alfunctions that have Other number displayed: Displays the
erasure 1 been recorded in the mal- total number of malfunctions that have
·function history (x and 6). been recorded in the malfunction his-
In addition, erases the mal- tory (x and ~).
function history(~). When this operation starts, all of the
malfunctions (6) are overwritten to the
normal condition (0).
(Tl P: The malfunctions. [X] are not
overwritten to the normal condition
[O].)
9-32
FUEL INJECTION SYSTEIVI
Diag-
nostic Standard values of the meter dis-
Item Details
code play or description of operation
No.
d:64 Setting history Display setting history OO:There is no setting history.
01 :There is setting history.
f
02:Whether or not setting history data
exists cannot be.determined (damage
to history data)
d:65 Setting map era- Display setting history •Display
sure OO:There are settings that were made
using the setting tool.
01 :There are settings that were made
using the setting tool.
•Operation
To erase the setting map, push the
"MODE".
d:70 Program version Check the version number 0-254 (-)
number of the program .
.
1 Symbols used in the explanations of the malfunction history
0: Normal
x: There is currently a malfunction or abnormal condition.
6.: A malfunction or abnormal condition occurred previously, but the affected system or component
is currently operating normally.
EAS1DX3224
TROUBLESHOOTING DETAILS
This section describes the measures per fault code number displayed on the diagnostic tool. Check
and service the items or components that are the probable cause of the malfunction following the or-
der given.
After the check and service of the malfunctioning part have been completed, reset the diagnostic tool
display according to the reinstatement method.
Fault code No.:
Fault code number displayed on the diagnostic tool when the engine failed to work normally.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated.
9-33
FUEL INJECTION SYSTEM
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
If fault code Nos. 13 and 14 are both displayed, perform the checks and maintenance jobs for fault
code No. 13 first.
9-34
FUEL INJECTION SYSTEM
9-35
FUEL INJECTION S'(STEM
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
If fault code Nos. 13 and 14 are both displayed, perform the checks and maintenance jobs for fault
code No. 13 first.
. 9-36
FUEL INJECTION SYSTEM
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
lf fault code Nos. 15 and 16 are both displayed, perform the checks and maintenance jobs for fault
·code No. 15 first.
9-37
FUEL INJECTION SYSTEM
9-38
FUEL INJECTION SYSTEM
TIP __~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
lf fault code Nos. 15 and 16 are both displayed, perform the checks and maintenance jobs for fault
code No. 15 first.
TIP __________--"________________________________________________ ~
Make sure that the engine is completely cool before checking the coolant temperature sensor.
9-39
FUEL INJECTION SYSTEM
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Make sure that the engine is completely cool before checking the intake air temperature sensor.
9-40
FUEL INJECTION SYSTEM
9-41
FUEL INJECTION SYSTEM
2 Installed condition of lean an- Check for a loose mounting, Set the main switch to "ON",
gle sensor. pinched mounting, or sensor then to "OFF", and then back
mounting direction (up or to"ON".
down). Fault code number is not dis-
Make sure that the mounting played ~ Service is finished.
position is correct. Fault code number is dis-
played ~ Go to next order.
3 Defective lean angle sensor. Execute the diagnostic mode. Set the main switch to "ON",
(Code No. d:08) then to "OFP', and then back
Replace if defective. to"ON".
Fault code number is not dis-
played ~ Service is finished.
Fault code number is dis-
played ~ Go to next order.
4 Malfunction in ECU. Replace the ECU.
9-42
FUEL INJECTION SYSTEM
9-43
FUEL INJECTION SYSTEM
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Disconnect the fuel pump coupler when this diagnostic tool is used.
9-44
FUEL INJECTION SYSTEM
9-45
.FUEL INJECTION SYSTEM
9-46
FUEL INJECTION SYSTEM
9-47
FUEL INJECTION SYSTEM
~ 9-48
FUEL INJECTION SYSTEM
9-49
FUEL INJECTION SYSTEM
9-50
FUEL INJECTION SYSTEM
9-51
FUEL PUMP SYSTEM
EAS27550
CIRCUIT DIAGRAM
I
j@i@ I
•r-+J
l!fi: ®i]I
I
i
-, ~
<l)
II 'i1'-'
I_ I
I _:j BJ)' '
•I j ·tti
! = !
I
11
" l I
®
I I I Ill
I
'I I I I II
= i ~ • _·
el
r~
mf
Ii
,Us
.~ ·-~
I•
)_~I
I
I
ii
L.JJ
@r
9-52
FUEL PUMP SYSTEM
4. Battery
5. Main fuse
6. Starter relay
10.Connector
11.Connector·
12.Connector
16.Main switch
17.Joint connector
20. Fuel pump
22.ECU (electronic control unit)
32.Joint connector
33. Engine stop switch
40.Joint connector
41.Joint connector
42.Connector
9-53
FUEL PUMP SYSTEM
EAS1DX3226
TROUBLE SHOOTING
The fuel pump fails to operate.
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
9-54
FUEL PUMP SYSTEM
9-55
ELECTRICAL COMPONENTS
EAS27971
ELECTRICAL COMPONENTS
EAS10X3227
"5~~7
1
fi.
~9
9-56
ELECTRICAL COMPONENTS
1. Main switch
2. Clutch switch
3. Fuel sender
4. Fuel pump
5. Intake air pressure sensor
6. Throttle position sensor
7. Injector
8. Intake air temperature sensor
9. Coupler for connecting optional part
10. Ignition coil •
9-57
ELECTRICAL COM PONENTS
'
2 3
~~
8
11
~
9-58
ELECTRICAL COMPONENTS
1. Rectifier/regulator
2. Lean angle sensor
3. Coolant temperature sensor
4. Head light relay
5. Starting circuit cut-off relay
6. Starter relay ·
7. Main fuse
8. Battery
9. ECU(engine control unit)
1a.Condenser
11. Neutral switch
9-59
ELECTRICAL COMPONENTS
EAS10X3228
~B
~~: 4
r - ------- ------ -,
-----------
1 ------ I I
I,-------- --- -
:w~
! I 1
: : r--4-,
,, ~
I I
I
I
I - - - - --
~----- ------------'
3 I~r---,I
il~
~=- -
i I
!..----- ------------'
9-60
ELECTRICAL COMPONENTS
9-61
ELECTRICAL COMPONENTS
Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check
the wiring connections and if necessary, replace the switch.
ECA14370
••1~~~~~~~~~~~~~~~~~~-
Never insert the tester probes into the coupler terminal slots "1 ". Always insert the probes
from the opposite end of the coupler, taking care not to loosen or damage the leads.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
•Before checking for continuity, set the pocket tester to "O" and to the "Qx 1" range.
• When checking for continuity, switch back and forth between the switch positions a few times.
The terminal connections for switches (e.g., main switch, engine stop switch) are shown in an illus-
tration similar to the one on below.
The switch positions "a" are shown in the far left column and the switch lead colors are shown in the
top row in the switch illustration.
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
"0----0" indicates a continuity of electricity between switch terminals (i.e., a closed circuit at the
respective switch position).
9-62
ELECTRICAL COMPONENTS
A Br LIV UB
9-63 .
ELECTRICAL COMPONENTS
EAS27990 EWA13320
CHECKING THE BULBS AND BULB SOCK- AwARNING
ETS
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
Do not check any of the lights that use LEDs. away from the bulb until it has cooled down.
ECA14380
Check each bulb and bulb socket for damage
or wear, proper connections, and also for con- llllll~~~~--~--
tinuity between the terminals. • Be sure to hold the socket firmly when re-
Damage/wear~ Repair or replace the bulb, moving the bulb. Never pull the lead, oth-
bulb socket or both. erwise it may be pulled out of the terminal
Improperly connected~ Properly connect. in the coupler.
No continuity ~ Repair or replace the bulb, •Avoid touching the glass part of the head-
bulb socket or both. light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of
Types of bulbs the bulb, and the luminous flux will be ad-
The bulbs used on this vehicle are shown in the versely affected. If the headlight bulb gets
illustration on the left. soiled, thoroughly it with a cloth moist-
• Bulbs "a" and "b" are used for 'the headlights ened with alcohol or lacquer thinner.
and usually use a bulb holder that must be de- 2. Check:
tached before removing the bulb. The majority • Bulb (for continuity)
of these types of bulbs can be removed from (with the pocket tester)
their respective socket by turning them coun- No continuity ~ Replace.
terclockwise.
• Bulbs "c" is used for turn signal and can be re- ~ Pocket tester
moved from the socket by pushing and turn- 7- 90890-03112
ing the bulb counterclockwise. Analog pocket tester
YU-03112-C
TIP _ _ _ _ _ _ _ _ _ _ _ __
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Connect the positive tester probe to terminal
"1" and the negative tester probe to terminal
"2", and check the continuity.
b. Connect the positive tester probe to terminal
"1" and the negative tester probe to terminal
"3", and check the continuity.
c c. If either of the readings indicate no continu-
ity, replace the bulb.
••••••••••••••••••••••••••••••••
9-64
ELECTRICAL COMPONENTS
YTYYTTYTYYTTTTYYTYTTYTTYTTYTTTY~
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the re-
spective leads of the bulb socket.
c. Check the bulb socket for continuity. If any of
th~ readings indicate no continuity, replace 4. Install:
the bulb socket. • Headlight bulbllm
AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Fasten the new headlight bulb with the
headlight bulb holder.
EASIDX3229 ECA13690
REPLACING THE HEADLIGHT BULB
EWAl3320 --~~~~~~~~
A WARNING Avoid touching the glass part of the head-
Since the headlight bulb gets extremely hot, light bulb to keep it free from oil, otherwise
keep flammable products and your hands the transparency of the glass, the life of the
away from the bulb until it has cooled down. bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
1. Remove: thoroughly clean it with a cloth moistened
• Headlight unit bolt "1" with alcohol or Lacquer thinner.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
5. Install:
After you have removed the headlight unit •Bulb cover
bolts, lift and remove the headlight unit from • Headlight coupler
front fender grommet. 6. Install:
•Headlight unit
~ h. Headlight unit bolt
~~ 7 Nm (0.7 m·kgf, 5.1 ft-lbf)
EASIDX3230
CHECKING THE FUSE
The following procedure applies to all of the
fuses.
ECAl3680
WK@IE~~~~~~~~-
2. Remove:. To avoid a short circuit, always set the main
11
• Headlight coupler "1 switch to "OFF" when checking or replac-
• Bulb cover "2" ing a fuse.
9-65
ELECTRICAL COMPONENTS
1. Remove: EWA13310
9-66
ELECTRICAL COMPONENTS
ECA13660
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
••.---~~~~~~~~-
• This is a VRLA (Valve Regulated Lead Ac-
a. Connect a pocket tester to the battery termi-
nals.
id) battery. Never remove the sealing caps
• Positive tester probe ~
because the balance between cells will not positive battery terminal
be maintained and battery performance • Negative tester probe ~
will deteriorate. negative battery terminal
• Charging time, charging amperage and
charging voltage for a VRLA (Valve Regu- TIP_·--------~--
lated Lead Acid) battery are different from •The charge state of a VALA (Valve Regulated
those of conventional batteries. The VRLA Lead Acid) battery can be checked by mea-
(Valve Regulated Lead Acid) battery suring its open-circuit voltage (i.e., the voltage
should be charged according to the appro- when the positive battery terminal is discon-
priate charging method. If the battery is nected).
overcharged, the electrolyte level will drop • No charging is necessary when the open-cir-
considerably. Therefore, take special care cuit voltage equals or exceeds 12.8 V.
when charging the battery.
b. Check.the charge of the battery, as shown in
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ the charts and the following example.
Since VALA (Valve Regulated Lead Acid) bat- Example
teries are sealed, it is not possible to check the Open-circuit voltage = 12.0 V
charge state of the battery by measuring the =
Charging time 6.5 hours
specific gravity of the electrolyte. Therefore, the Charge of the battery = 20-~0°/o
charge of the battery has to be checked by
measuring the voltage at the battery terminals. A
13.0
1. Remove:
• Side cover {left/right) 12.5
•Seat
Refer to "GENERAL CHASSIS" on page 4-
11.5
1.
2. Disconnect:
• Battery leads B
(from the battery terminals) D
ECA13640
A. Open-circuit voltage (V)
ti9"D~~~~~~~~~- B. Charging time (hours)
First, disconnect the negative battery lead C. Relationship between the open-circuit voltage
"1 ", and then positive battery lead "2". and the charging time at 20°c (68°F)
D. These values vary with the temperature, the
condition of the battery plates, and the electro-
lyte level.
A
14
131----..__~-.....z,,-----+--+---1
I
I
10 -----if-----t----r~--=--,- t
9-67
ELECTRICAL COMPONENTS
5. Charge:
•Battery A C
18
~
D
{refer to the appropriate charging method) 17
EWA13300
16
A WARNING 15 \
14 \.
Do not quick charge a battery.
ECA13670
13
12
' ~
··~~~~~~-
.Do not use a high-rate battery charger
11
10
o 10 20 30 40 so 60 B
since it forces a high-amperage current 4E
into the battery quickly and can cause bat- A. Open-circuit voltage {V)
tery overheating and battery plate dam- B. Time {minutes)
age. C. Charging
D. Ambient temperature 20°c {68°F)
• If it is impossible to regulate the charging E. Check the open-circuit voltage.
current on the battery charger, be careful
not to overcharge the battery. TTTYTTTYTTTTTTTTTTTTYYYYTTTTTTTT
•When charging a battery, be sure to re- Charging method using a variable-cur-
move it from the vehicle. (If charging has rent (voltage) charger
to be done with the battery mounted on the a. Measure the open-circuit voltage prior to
vehicle, disconnect the negative battery charging.
lead from the battery terminal.) TIP~-------------
• To reduce the chance of sparks, do not Voltage should be measured 30 minutes after
plug in the battery charger until the battery the engine is stopped.
charger leads are connected to the bat-
b. Connect a charger and ammeter to the bat-
tery.
tery and start charging.
•Before removing the battery charger lead TIP _ _ _ _ _ _ _ _ _ _ _ _ __
clips from the battery terminals, be sure to
turn off the battery charger. Set the charging voltage to 16-17 V.lf the set-
• Make sure the battery charger lead clips ting is lower, charging will be insufficient. If too
are in full contact with the battery terminal high, the battery will be over-charged.
and that they are not shorted. A corroded c. Make sure that the current is higher than the
battery charger lead clip may generate standard charging current written on the bat-
heat in the contact area and a weak clip tery.
spring may cause sparks. TIP _ _ _ _ _ _ _ _ _ _ _ __
• If the battery becomes hot to the touch at
any time during the charging process, dis- If the current is lower than the standard charg-
connect the battery charger and let the ing current written on the battery, set the charg-
battery cool before reconnecting it. Hot ing voltage adjust dial at 20-24 V and monitor
batteries can explode! the amperage for 3-5 minutes to check the bat-
• As shown in the following illustration, the tery.
open-circuit voltage of a VRLA'(Valve Reg- • Standard charging current is reached
ulated Lead Acid) battery stabilizes about Battery is good.
30 minutes after charging has been com- • Standard charging current is not reached
pleted. Therefore, wait 30 minutes after Replace the battery.
charging is completed before measuring
the open-circuit voltage. d. Adjust the voltage so that the current is at
the standard charging level.
· e. Set the time according to the charging time
suitable for the open-circuit voltage.
9-68
ELECTRICAL COMPONENTS
ECA1DX1028
f. If charging requires more than 5 hours, it is
advisable to check the charging current after
a lapse of 5 hours. If there is any change in
·-~~~~~~~~
First, connect the positive battery lead "1 ",
the amperage, readjust the voltage to obtain and then the negative battery lead "2".
the standard charging current.
g. Measure the battery open-circuit voltage af-
ter leaving the battery unused for more than
30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under .12.0 V --- Replace the battery .
.................................................................................................
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
Charging method using a constant volt-
age charger
• Battery terminals
a. Measure the open-circuit voltage prior to
Dirt ~ Clean with a wire brush.
charging.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ Loose connection~ Connect properly.
9. Lubricate:
Voltage should be measured 30 minutes after • Battery terminals
the engine is stopped.
Recommended lubricant
b. Connect a charger and ammeter to the bat- -t Dielectric grease
tery and start charging.
c. Make sure that the current is higher than the 10.lnstall:
standard charging current written on the bat- •Seat
tery. • Side cover (left/right)
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ Refer to "GENERAL CHASSIS" on page 4-
If the current is lower than the standard charg-
1.
ing current written on the battery, this type of EAS1DX3231
battery charger cannot charge the VRLA (Valve CHECKING THE RELAYS
Regulated Lead Acid) battery. A variable volt- Check each switch for continuity with the pock-
age charger is recommended. et tester. If the continuity reading is incorrect,
replace the relay.
d. Charge the.battery until the battery's charg-
ing voltage is 15 V. Pocket tester
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ 90890-03112
Analog pocket tester
Set the charging time at 20 hours (maximum).
YU-03112-C
e. Measure the battery open-circuit voltage af-
ter leaving the battery unused for more than 1. Disconnect the relay from the wire harness.
30 minutes. 2. Connect the pocket tester (n x 1) and bat-
tery (12 V) to the relay terminal as shown.
12.8 V or more --- Charging is complete.
Check the relay operation.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery . Out of specification ~ Replace.
................................................................................................
6. Install:
•Battery
7. Connect:
• Battery leads
(to the battery terminals)
9-69
ELECTRICAL COMPONENTS
Starter relay
Result
Continuity
(between "3" to "4")
EAS10X3232
CHECKING THE DIODE
1. Check:
•Diode
Out of specification~ Replace.
2 1 Pocket tester
90890-03112
1. Positive battery terminal Analog pocket tester
2. Negative battery terminal
. YU-03112-C
3. Positive tester probe
4. Negative tester probe
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Result The pocket tester and the analog pocket tester
Continuity readings are shown in the following table.
(between "3" to "4")
Continuity
Starting circuit cut-off relay Tester positive lead ~ Blue/Red
"1"
Tester negative lead~ Green/
Black "2"
+ Continuity
Tester positive lead~ Green/
Black "2"
Tester negative lead~ Blue/Red
"1"
No continuity
Tester positive lead ~ Blue/Red
"1"
1. Positive battery terminal Tester ne·gative lead ~ Sky blue
2. Negative battery terminal "3"
3. Positive tester probe Continuity
4. Negative tester probe Tes~er positive lead~ Sky blue
"3"
Result Tester negative lead~ Blue/Red
Contiriuity "1"
(between "3" to "4") No continuity
Tester positive lead~ Red "4"
Head light relay Tester negative lead~ Brown
"5"
No continuity
Tester positive lead~ Brown
+ "5" .
Tester negative lead~ Red "4"
Continuity
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Disconnect the diode from the wire harness.
b. Connect the pocket tester (Q x t) to the di-
ode coupler as shown.
1. Positive battery terminal c. Check the diode for continuity.
2. Negative battery terminal d. Check the diode for no continuity.
3. Positive tester probe
4. Negative tester probe
9-70
ELECTRICAL COMPONENTS
EAS1DX3233
CHECKING THE SPARK PLUG CAP
1. Remove:
~
4 • Spark plug cap
$
(from the spark plug lead)
2. Check:
5
~ 1
• Spark plug cap resistance
Out of specification ~ Replace.
Spark plug cap resistance
10kW
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
EAS28930 · a. Connect the pocket tester (Qx 1k) to the
CHECKING THE IGNITION SPARK GAP spark plug cap as shown. ·
1. Check:
• Ignition spark gap Pocket tester
Out of specification ~ Perform the ignitlon 90890-03112
system troubleshooting, starting with step 4. Analog pocket tester
Refer to ''TROUBLESHOOTING" on page 9- VU-03112-C
4.
Minimum ignition spark gap
6.0 mm (0.24 in)
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Remove the spark plug cap from the spark
plug. b. Measure the spark plug cap resistance.
b. Connect the ignition checker "1" as shown. AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
~ Ignition checker
<?' - 90890-06754
EAS1DX3234
CHECKING THE IGNITION COIL
Oppama pet-4000 spark checker 1. Disconnect
VM-34487 • Ignition coil coupler
(from the wire harness)
•Spark plug cap
(from the ignition coil)
2. Check:
• Primary coil resistance
Out of specification ~ Replace.
Primary coil resistance
3.57-4.83 Q
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
2. Spark plug cap a. Connect the pocket tester (Ox 1) to the igni-
.c. Turn the engine stop switch to "()". tion coil as shown .
d. Measure the ignition spark gap "a". Pocket tester
e. Crank the engine by pushing the start switch 90890-03112
"(i)" and gradu·a11y increase the spark gap Analog pocket tester
until a misfire occurs. VU-03112-C
AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
9-71
ELECTRICAL COMPONENTS
1 I tance
248-372 n
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Connect the pocket tester (nx 100) to the
crankshaft position sensor coupler as
shown. ·
Pocket tester
b. Measure the primary coil resistance. 90890-03112
AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Analog pocket tester
3. Check: VU-03112-C
• Secondary coil resistance
Out of specification~ Replace. • Positive tester probe
Red "1"
Secondary coil resistance •Negative tester probe
10.71-14.49 k.Q Black "2" ·
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT·
a. Connect the pocket tester (Ox 1k) to the ig-
nition coil as shown. 1 2
Pocket tester
90890-03112
Analog pocket tester
VU-03112-C
e
EAS28130
CHECKING THE LEAN ANGLE SENSOR
1. Remove:
2
• Lean angle sensor
1 . (from the bracket.)
2. Check:
• Lean angle sensor out put voltage
Out of specification~ Replace.
Lean angle sensor out put voltage
b. Measure the secondary coil resistance. Less than 65° "a"
0.4-1.4V
···················~············
EAStDX3235
More than 65° "b"
3.7--4.4V
CHECKING THE CRANKSHAFT POSITION
SENSOR TTTTTTTTTTTTTTT.TTTTTTTTTTTTTTTT
1 . Disconnect: a.· Connect the lean angle sensor coupler to
•Crankshaft position sensor coupler the wire harness.
9-72
ELECTRICAL COMPONENTS
~==°TI
2. Check:
• Stator coil resistance
Out of specification -7 Replace the stator
coil.
9-73
ELECTRICAL COMPONENTS
EAS28240
CHECKING THE SPEED SENSOR
1. Check:
1 2 3 • Speed sensor output voltage
\----------r~ •,a
Out of specification ~ Replace .
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Connect the test harness-speed sensor (3P)
b. Measure the stator coil resistance. to the speed sensor coupler and wire har-
AAAAAAAAAAAAAAAAAAAAAAAAAAAAA&AA ness as shown.
b. Connect the pocket tester (DC20V) to the
EAS1DX3237 test harness-speed sensor (3P).
CHECKING THE RECTIFIER/REGULATOR
1. Check: Pocket tester
• Charging voltage 90890-03112
Out of specification ~ Replace the rectifier/ Analog pocket tester
regulator. YU-03112-C
Test harness-speed sensor 5TJ
.,~, Charging voltage (3P)
14 V at 5000 r/min 90890-03228
YU-03228
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Set the digital tachometer to the ignition coil. • Positive tester probe
b. Connect the pocket tester (QC 20 V) to the White "1"
rectifier/regulator coupler as shown. • Negative tester probe
Black/white "2"
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
9-74
ELECTRICAL COMPONENTS
~-------------i
9-75
ELECTRICAL COMPONENTS
.. ~ .~
mtfl
/.I ._._ _ _ ;
2 1
9-76
ELECTRICAL COMPONENTS
I
I
I
:
I
L
Black/Blue "2" I
L----·--'
:
~@
,- - -----
L-------
~ 2 1
w
c. Start the engine.
2 1
b. Set the main switch to "ON".
c. Measure the intake air pressure sensor out-
put voltage.
AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
EAS10X3241
d. Measure the throttle position sensor input CHECKING THE INTAKE AIR TEMPERA-
voltage. TURE SENSOR
AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 1. Remove:
• Intake air temperature sensor
EA$28410
CHECKING THE INTAKE AIR PRESSURE (from the air filter case.)
EWA1DX1010
SENSOR
1. Check:
A WARNING
• Handle the intake air temperature sensor
•Intake air pressure sensor output voltage
with special care.
Out of specification~ Replace.
• Never subject the intake air temperature
Intake air pressure sensor output sensor to strong shocks. If the intake air
voltage temperature sensor is dropped, replace it.
3.75-4.25 v
2. Check:
yyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyy • Intake air temperature sensor resistance
a. Connect the pocket tester (DC 20 V) to the _. Out of specification~ Replace.
intake air pressure sensor coupler (wire har- Intake air temperature sensor re-
ness side) as shown. sistance
5.40-6.60 kn at O 0 c (32 °F)
Digital circuit tester
290-390 n at 80 °c (176 °F)
90890-03174
Model 88 Multimeter with tachom-
YYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY
eter
. a. Connect the pocket tester (Q x 1klx100) to
VU-A1927
the intake air temperature sensor terminal
as shown.
• Positive tester probe
11
Pink "1 Digital circuit tester
• Negative tester probe 90890-03174
Black/Blue "2" Model 88 Multimeter with tachom-
eter
VU-A1927
9-77
ELECTRICAL COMPONENTS
Br/\N ~B/L
~ 1 2
EAS10X3242
CHECKING THE FUEL INJECTOR
The following procedure applies to all of the fuel
injector.
1. Remove:
• Fuel injector .
Refer to "THROTTLE BODY" on page 8-6
2. Check:
• Fuel injector resistance
Out of specification~ Replace the fuel in-
jector.
'
.I '
~'I_ Resistance
12.0 n
................................................................................................
a. Disconnect the fuel injector coupler from the
fuel injector.
b. Connect the pocket tester (Q x 1O) to the
fuel injector coupler as shown.
9-78
TROUB t ESHOOTING '~·
TROUBLESHOOTING ....................................................................................10-1
GENERAL INFORMATION ...... .... .. ... .............. .....-........................ ......... ... 10-1 -
STARTI NG FAILURES ....... ................... ......... ....: ......-. ~- ~ ...::-. .. :: ...~......... ... 10-1 ·'-
INCORRECT ENGINE IDLING SPEED ................ ........... ..:-........ :.~ .......... 10-1
POOR MEDIUM-ANO-HIGH-SPEED PERFORMANCE .. ............ ...... ... ... 10-2
FAULTY GEAR SHIFTING ...... .... ......... ..... .................... ..... ... ....... ..... .... ... 10-2
SHIFT PEDAL DOES NOT MOVE ...... ...... ......................... ............. ......... 10-2
J UMPS OUT O F GEAR ......... .. ........................... .......... ............................ 10-2··
FAULTY CLUTCH .................. ............. ...... ........................................ ....... 10-2
OVERHEATING .. ........................ ..... ......... ...................... ........ .................. 10-3
OVERCOOLING ................ ......... ............... .... ......... .......... ...... .... .... .. ..... ... 10-3
POOR BRAKING PERFORMANCE ............... ...........................: .............. 10-3
FAULTY FRONT FORK LEGS ... ... ............ .... ..... ... .......... ........... .... .......... 10-3
UNSTABLE HANDLING ........................................................................... 10-3
FAULTY LI GHTI NG SYSTEM ......... ......................................................... 10-4
")· ...
i ·4'
•.-
m
TROUBLESHOOTING
·~ -
'"'--·· ...... ... -.-·· .. ~ ............__...... .., ... ..........
~ -~ ~ .
- ., , ~ ,,·,7v ~""··~ •..
. .~ ii ' ;;
"· ,; ·y.-''-'t!Electrical
,....r..· ._ !i _.;:. ' ' :
.J.
system
, ....... : ~ t·~ '..Battery
,o (; :, :.,-;
EAS28460
• Discharged battery
GENERAL INFORMATION • Faulty battery
; cJ~}; •4 \ 0 ...
···· 2. Fuse
• Blown, damaged or inqorrect fuse
The following guide for troubleshooting does
•Improperly installed fuse
not cover all the possible causes of trouble. It
3. Spark plug
should be helpful, however, as a guide to basic
• Incorrect spark plug gap
troubleshooting. Refer to the relative procedure
•Incorrect spark plug heat range
in this manual for checks, adjustments, and re-
• Fouled spark plug
placement.of parts.
•Worn or damaged electrode
• Worn or damaged insulator
EAS1DX3243
STARTING .FAILURES 4. Ignition coil
• Cracked or broken ignition coil body
Engine • Broken or shorted primary or secondary
1. Cylinder and cylinder head coils
•Loose spark plug 5. Ignition system
• Loose cylinder head or cylinder •Faulty ECU
• Damaged cylinder head gasket • Faulty crankshaft position sensor
• Damaged cylinder gasket • Broken generator rotor woodruff key
• Worn or damaged cylinder 6. Switches and wiring
• Incorrect valve clearance • Defective lean angle sensor
• Improperly sealed valve • Faulty main switch
•Incorrect valve-to-valve-seat contact •Faulty engine stop switch
•Incorrect valve timing • Broken or shorted wiring
• Faulty valve spring • Faulty neutral switch
• Seized valve •Faulty start switch
2. Piston and piston ring(s) •Faulty clutch switch
•Improperly installed piston ring . • Improperly grounded circuit
• Damaged, worn or fatigued piston ring • Loose connections
• Seized piston ring 7. Starting system
• Seized or damaged piston • Faulty starter motor
3. Air filter • Faulty starter relay
• Improperly installed air filter •Faulty starting circuit cut-off relay
• Clogged air filter element •Faulty starter clutch
4. Crankcase and crankshaft EAS1DX3244
• Improperly assembled crankcase INCORRECT ENGINE IDLING SPEED
• Seized crankshaft
Engine
Fuel system 1. Cylinder and cylinder head
1. Fuel tank •Incorrect valve clearance
• Empty fuel tank •Damaged valve train components
• Clogged fuel tank overflow hose 2. Air filter
• Deteriorated or contaminated fuel •Clogged air filter element
• Clogged or damaged fuel hose
2. Fuel pump Fuel system
~:·?· .:
• Faulty fuel pump 1. Throttle body
~Ii~
3. Throttle body •Damaged or loose throttle body joint
• Deteriorated or contaminated fuel • Improperly synchronized throttle bodies
• Sucked-in air •Improper throttle cable free play
• Flooded throttle body
10-1
TROUBLESHOOTING
2. Spark plug
•Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug Shift shaft ·;l/,:)i •· · ; ·_iY::·, •
•Worn or damaged electrode • Incorrect shift pedal positioniv :·--: . ~,
• Worn or damaged insulator • Improperly returned stoppedeyeL ·:-..:=- ·=-1-,": -:- 1
Transmission - I •'
EAS28560
FAULTY CLUTCH
Clutch slips
1. Clutch
• Improperly assembled clutch
• Loose or fatigued clutch spring
• Worn friction plate
Fuel system ... ,; ,: ~,/~~•• !:· >.
:;·.._._;· ·..:;~
o·
t_.·~t:::·::,
,...,,.,,~.~-,
•.. ~
_,~1,_,
..
;- ;
;, ._::.:
.I --'-~'
• • Worn clutch plate
1. Fuel pump sd! ;:, vj'uo bsQG'.:1n:::i ;;· . ln-98 '> 2. Engine oil
• Faulty fuel pump .... ,:.,,.,." ,j-, ::. bnpp·-....
',_;1 ?l:~C...· J'1• 0 t H1t0 1
---c- :; •J.J ...
•Incorrect oil level · ·
~· ..!~J:•i:u
2. Throttle bodY,.t},Jt ~, .. '~~·- •-u~::.n:::11t1~:t.....·
' r - "··1· ·.. .'.~-, .;.-, (1 .
:t__.. Ji• 9 \~"'
• Incorrect oil viscosity (low)
•Defective
·
throttle oodY,.· ___ ,...;__~:v. ·iio hJ::1.
~.11C:VJGI
1,r.·nl\" .i ..
'-•.•I !I ' >
• Deteriorated oil
3. ECU
'.~ ·1 ·~ :~
1
•Faulty ECU Clutch drags . --: • '· -'
1. Clutch
•Unevenly tensioned clutcffspfiiigs'.~;:-;i:~~sl:~
•Warped pressure plate . . QLi;<! ,\: :r··~:,:.:~ ·
• Bent clutch plateqf~P. ~·; qq :>11sq2 r.Jsr ry,rn ·:·
·swollen frictforl plarer.'~- 10 ;:::q 2 T~":~T~o:_~·= ·
•Bent clutch push rod· ::1st2-..r2 ,.
• Damaged clutch boss LL'~~-; · ·: · ' -; '
·.Burnt pfimafy ttriVeWgeifr~IJushitig ·/ 1t:, i !
10-2
TROUBLESHOOTING
•Damaged or faulty water pump " ,-. ,. --.v.: - • Cr~gK~dr%~~~~~~~t£~,t~~}-~.~~ r ": _:: ,, ._ 7::r·.
•Improperly mstall~dorl seal· -~···, ~~~-~ ~·:~, .... :.~..:<.
• Thermostat stays closed
• p~maged oi.Lseal liP. _ ____. ~ ,,. .-,"':~.~· ·_. -_· ,~~,
• Damaged hose •1hcorr~Bt15i11~v1~i 1(hl~liy t-< .. ! ·-:. ( • ··:: -. '"··'-;;'
• Improperly connected hose
• Loose damper rod assembly bolt
• Damaged pipe
• Damaged damper rod assembly bolt c.opp~r-
• Improperly connected pipe ····n ·1'?:!1 ···
washer ,.:-. · '~ · · .
•Cracked or damaaed cap jJQlt 9:.ri~gj ~~.- • .:-\ ;
1 11
Fuel system · _.., ::;Jc ·, : -· if'lerns1~ 19Jilj !uJ b5P.~!'-'k· ·
1. Throttle body .... : .,__ ; n·._;\": -,
Malfunction
•Damaged or loose throt!leJ:>..o.c;lysjoin~_;:_,\ '" '1
• Bent or damaged inner tube _ .
ff;9t:Jy~~ ~ :;;J. ~
10~3
TROUBLESHOOTING
\,
4. Swingarm
• Worn bearing or bushing
J'
~ms a:qocr,nw
• Bent or damaged swingarm ·:·;~: r;!"J· )i ~Jr::: l Ci
01B.Pg;.,;n·i ::)A . J
'· ;"' -J:;.. j ':- ... ~. 't;~ !8
5. Rear shock absorber assembly (-ies)
•Faulty rear shock absorber spring VJ\icl
•Leaking oil or gas 8\;~:1
\J\_/\ :: ·,
6. Tire (s) . :....
•Uneven tire pressures_ (front and rear) .:,,:_-.~_::·\•f; .C • \ ' ! ... )
\'•
8. Frame • J v 'J :
•Bent frame
• Damaged steering head pipe
• Improperly installed bearing race
EASIDX3245
FAULTY LIGHTING SYSTEM
~ ~ '.~ u; j
! : •• • • :
jJ
-~-~~: q [. ,.'. c-_. 0
,.:,.'.i'j q
beR -
' l
8Uld ',')~~
10-4
EAS1DX3247 y Yellow
WIRING DIAGRAM B/G Black/Green
WR450FB 2012 B/L Black/Blue
1. AC magneto B/W Black/White
BN Black/Yellow
2. Rectifier/regulator Br/L Brown/Blue I•
3. Connector Br/W Brown/White
;·.
'.....
4. Battery G/B Green/Black
..,,
. '
; ,~
7. Starter motor
8. Starter relay diode
UB Blue/Black
UG Blue/Green
9. Headlight relay UR Blue/Red
10. Connector uw Blue/White
11. Connector UY Blue/Yellow
12. Connector RIB Red/Black
.
13. Condenser R/L Red/Blue ~·.:ndf:~S(i ! :·, _-:
.-;
~:·..-t ·_-,:"·.~>=-~r;;.;:~~-'. ~
I R/W Red/White
14.Starting circuit cut-off relay :)L<_f-; i:~>:?,.·;-: 1 .' (_-~; .. JOI :u tr;~--~:~.,.
Y/B Yellow/Black
15. Start switch
Y/G Yellow/Green
16. Main switch Y/W Yellow/White
17. Joint connector
18. Clutch switch
sc~i 1 .:i bG·~;·~ ~(j~~:s~)Jc:: b3;)BCPF)C1 ~:
19.Diode
20. Fuel pump Jf:·1 p:;i-:sed bsl!st2ni \{':?ace-:'.'.,
21. Engine trouble warning light
22. ECU (electronic control unit)
23. Ignition coil
24. Spark plug
no smo~)
:!::>n ascb HigiibssH
25. Injector
26. Neutral switch ;iu::r1iJ n9qo i?eu-1 ·:>
27. Throttle position sensor dlud trlgilbseri gnowV ., •
28. Intake air pressure sensor 29i·1022oe::18s 1s::>i1J0ele ,~n.sm oo T -·
29. Lean angle sensor gnig1.sdo b1.sH ,,
30. Coolant temperature sensor noit~)enno8 .t~eno~nl ·;
31. Intake air temperature sensor
iiu~:nio bebnu01g yl"leqmqrn! ·•
32. Joint connector
(rbiiwz nLsrn) eto.srno8 100C] ,
33. Engine stop switch
34. Speed sensor dlud Jrlgilb.ssrl tuo-Jrnu8 "
35. Multi-function display
36.Fuelsender iuo tmud dlud .trlgilbssH
37. Resistor d!ud trlgilbserl gn01W ..
38. Coupler for connecting option- '(leHscl yjluBl e>
al part ·101slugs-1\1sitit6e1 yt!us=i .:
39.Diode tiuJii~:i bebnumg yheqmqmi •
40. Joint connector
ri:::>!iv1r2 ni.srri yt!us~ 0
41. Joint connector
~J91iqxe etil dlud tdgilbssH •
42. Connector
43. Headlight
44.Taillight .no smoo ton aeob frigiliisT
EAS1DX3248 03J trigillist QnmW :i
COLOR CODE 2eilo22e88B is8ilt:.1ale '(rtBm oo T 11
B Black noit::>enno:) to~rnoonl "
Br Brown
Ch Chocolate y1etrsd yilus=i 0
Dg Dark green
G Green
L Blue
Lg Light green
O Orange
P Pink
R Red
Sb Sky blue
W White
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Genuine Yamaha Parts - Genuine Yamaha replacement parts are the exact same parts as the ones
originally equipped on your vehicle, providing you with the performance and durability you have come to
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and performance. Buy with confidence, knowing your Genuine Yamaha Accessories will fit right and
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They're formulated and approved by the toughest judges we know: the Yamaha engineering teams that
know your Yamaha from the inside out.
Genuine Yamaha Service Manuals - Get the same factory manual for your vehicle that the technicians
at your authorized Yamaha dealer use. Service manuals are available through your Yamaha dealer or you
can order them directly through yamahapubs.com.
Genuine Yamaha products are available only from your Yamaha dealer.
~ WR450FB
OWNER'S SERVICE MANUAL
©2012 by Yamaha Motor Corporation, U.S.A.
1st Edition, January 2012
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in Japan
P/N. LIT-11626-25-58