Yamaha YZ450F 2021 Owner's Service Manual

Table of Contents

Quick Links

Download this manual

2021

OWNER'S SERVICE MANUAL

YZ450F

Read this manual carefully before operating this vehicle.

YZ450FM

LIT-11626-34-12

B2W-2819U-11

Table of Contents

Chapters

Table of Contents

Troubleshooting

Need help?

Do you have a question about the YZ450F 2021 and is the answer not in the manual?

Questions and answers

Summary of Contents for Yamaha YZ450F 2021

Page 1 2021 OWNER’S SERVICE MANUAL YZ450F Read this manual carefully before operating this vehicle. YZ450FM LIT-11626-34-12 B2W-2819U-11...
Page 2 EAM20161 Read this manual carefully Operating, servicing and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.
Page 3 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. FCC CAUTION Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment. This transmitter must not be co-located or operated in conjunction with any other antenna or transmitter.
Page 4 EAM20080 YZ450FM OWNER’S SERVICE MANUAL ©2021 by Yamaha Motor Corporation, U.S.A. First edition, April 2020 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. P/N. LIT-11626-34-12...
Page 5 EAM20180 IMPORTANT Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.
Page 6 EAM20162 YAMAHA MOTOR CORPORATION, U.S.A. YZ MOTORCYCLE LIMITED WARRANTY...
Page 7 EAM20082 HOW TO USE THIS MANUAL In this manual, descriptions of installation, removal, disassembly, assembly, check, and adjustment procedures are laid out with the individual steps in sequential order. • The manual is divided into chapters and each chapter is divided into sections. The current section title “1”...
Page 8 EAM20083 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...
Page 9: Table Of Contents
TABLE OF CONTENTS EAM10003 GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING TUNING...
Page 11 GENERAL INFORMATION SAFETY INFORMATION ..................1-1 FOR SAFETY, BE SURE TO OBEY THE FOLLOWING:......1-1 LOCATION OF IMPORTANT LABELS.............1-4 DESCRIPTION....................1-5 IDENTIFICATION ....................1-6 VEHICLE IDENTIFICATION NUMBER ............1-6 ENGINE SERIAL NUMBER................1-6 INCLUDED PARTS ...................1-7 SIDESTAND ....................1-7 NIPPLE WRENCH ..................1-7 HANDLEBAR PROTECTOR ..............1-7 FUEL HOSE JOINT COVER ..............1-7 POWER TUNER ..................1-7 IMPORTANT INFORMATION ................1-9 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-9...
Page 12 STARTING A WARM ENGINE ..............1-25 BREAK-IN PROCEDURES ..............1-25 ENGINE STARTING PRECAUTION ............1-25 MAINTENANCE AFTER BREAK-IN ..............1-26 MAJOR MAINTENANCE ................1-26 AIR FILTER MAINTENANCE ..............1-26 TORQUE-CHECK POINTS................1-27 MOTORCYCLE CARE AND STORAGE............1-29 CARE ......................1-29 STORAGE ....................1-30...
Page 13: Safety Information
Yamaha ma- accidents. Many accidents have been chine, and take care to maintain it properly and caused by an automobile driver who did not operate it safely.
Page 14 1. Always wear an approved helmet. Yamaha can neither endorse nor recommend 2. Wear a face shield or goggles. Wind in your the use of accessories not sold by Yamaha or unprotected eyes could contribute to an im- modifications not specifically recommended by...
Page 15 SAFETY INFORMATION Aftermarket Tires and Rims The tires and rims that came with your motorcy- cle were designed to match the performance ca- pabilities and to provide the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate. Refer to “CHECKING THE TIRES”...
Page 16: Location Of Important Labels
LOCATION OF IMPORTANT LABELS EAM20085 LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle. 4, 5 Premium unleaded gasoline only. 3FB-2415E-02 WARNING This unit contains high pressure nitrogen gas. Mishandling can cause explosion. Read owner's manual for instructions. Do not incinerate, puncture or open.
Page 17: Description
DESCRIPTION EAM20086 DESCRIPTION 1. Clutch lever 11.Radiator 12.Coolant drain bolt 2. Front brake lever 13.Rear brake pedal 3. Throttle grip 14.Air filter 4. Start switch 15.Drive chain 5. Launch control switch 6. Radiator cap 16.Shift pedal 17.Oil level check window 7.
Page 18: Identification
There are two significant reasons for knowing the serial number of your vehicle: 1. When ordering parts, you can give the num- ber to your Yamaha dealer for positive identi- fication of the model you own. 2. If your vehicle is stolen, the authorities will need the number to search for and identify your vehicle.
Page 19: Included Parts
INCLUDED PARTS vent mud, dust, and other foreign materials from EAM20088 INCLUDED PARTS entering the inside when the fuel hose is discon- nected. EAM30190 SIDESTAND This sidestand “1” is used to support only the machine when standing or transporting it. EWA20260 WARNING •...
Page 20 INCLUDED PARTS • There are facilities nearby that are emitting strong radio waves (TV or radio towers, power plants, broadcasting stations, air- ports, etc.) • You are carrying or using communication equipment such as radios or mobile phones in close proximity of the CCU •...
Page 21: Important Information
2. Use proper special tools and equipment. Re- used for repair of the vehicle, including periodic fer to “SPECIAL TOOLS” on page 1-15. replacement parts, are new YAMAHA genuine parts and recommended parts. Do not use any used parts, because these may...
Page 22: Lock Washers/Plates And Cotter Pins
IMPORTANT INFORMATION 1. Oil 2. Lip 3. Spring 4. Grease EAM30012 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace lock washers/plates “1” and cotter pins with new ones. After the bolt or nut has been tightened to specification, firmly bend the lock tabs along a flat of the bolt or nut. EAM30014 CIRCLIPS When assembling parts, always use new cir-...
Page 23: Basic Service Information
BASIC SERVICE INFORMATION EAM20120 BASIC SERVICE INFORMATION EAM30181 ELECTRICAL SYSTEM Electrical parts handling ECA16600 NOTICE Never disconnect a battery lead while the en- gine is running; otherwise, the electrical components could be damaged. ECA16760 NOTICE Be sure to connect the battery leads to the correct battery terminals.
Page 24 BASIC SERVICE INFORMATION ECA16630 ECA14371 NOTICE NOTICE Electrical components are very sensitive to Never insert the tester probes into the cou- and can be damaged by static electricity. pler terminal slots. Always insert the probes Therefore, never touch the terminals and be from the opposite end “a”...
Page 25 BASIC SERVICE INFORMATION ECA16780 NOTICE • When disconnecting a coupler, release the coupler lock, hold both sections of the cou- pler securely, and then disconnect the cou- pler. • There are many types of coupler locks; therefore, be sure to check the type of cou- pler lock before disconnecting the coupler.
Page 26 BASIC SERVICE INFORMATION 5. Check: • No continuity Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachom- eter YU-A1927 • If there is no continuity, clean the terminals. • When checking the wire harness, perform steps (1) to (4). •...
Page 27: Special Tools
Feeler gauge set YU-26900-9 Valve lapper (ø14) 3-7, 5-27 90890-04101 90890-04101 Valve lapping tool (14mm) YM-A8998 YM-A8998 Yamaha diagnostic tool USB (US) 3-11, 7-8, 8-17 90890-03269 Yamaha diagnostic tool (A/I) 3-11, 7-8, 8-17 90890-03264 FI diagnostic tool sub–lead 3-11, 7-8, 8-17 90890-03212 FI diagnostic tool sub–lead...
Page 28 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages OBD/ GST Leadwire kit 3-11, 7-8, 8-17 90890-03249 Digital tachometer 3-11, 3-35, 8-51 90890-06760 Digital tachometer YU-39951-B Steering nut wrench 3-27, 4-56 90890-01403 Exhaust flange nut wrench YU-A9472 Spoke nipple wrench (6–7) 3-33 90890-01521 Spoke nipple wrench (6–7)
Page 29 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Yamaha bond No. 1215 5-19, 5-39, 5-67 90890-85505 (Three bond No.1215®) Valve spring compressor 5-27, 5-31 90890-04019 Valve spring compressor YM-04019 Valve spring compressor attachment 5-27, 5-31 90890-04108 Valve spring compressor adapter 22 mm YM-04108 Valve guide remover &...
Page 30 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rotor puller 5-39 90890-04151 Rotor puller YM-04151 Universal clutch holder 5-50, 5-53 90890-04086 Universal clutch holder YM-91042 Crankcase separating tool 5-69 90890-04152 Crankcase separating tool YU-A9642 Crankshaft installer pot 5-70 90890-01274 Installing pot YU-90058 YU-90058/YU-90059 Crankshaft installer bolt...
Page 31 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Adapter (M12) 5-70 90890-01278 Adapter #3 YU-90063 Spacer (crankshaft installer) 5-70 90890-04081 Pot spacer YM-91044 YM-91044 Radiator cap tester 6-4, 6-4 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter 6-4, 6-4 90890-01352 Pressure tester adapter...
Page 32 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Fuel pressure adapter 90890-03186 Fuel pressure adapter YM-03186 Lithium battery charger 8-46, 8-46 90890-05376 Lithium battery charger DBY-ACC51-70-02 Ignition checker 8-48 90890-06754 Oppama pet–4000 spark checker YM-34487 Test harness S– pressure sensor (3P) 8-52 90890-03207 Test harness S–...
Page 33: Instrument And Control Functions
INSTRUMENT AND CONTROL FUNCTIONS EAM20181 INSTRUMENT AND CONTROL FUNCTIONS EAM30182 ENGINE STOP SWITCH The engine stop switch “1” is located on the left handlebar. Continue pushing the engine stop switch till the engine comes to a stop. How to operate 1.
Page 34: Shift Pedal
INSTRUMENT AND CONTROL FUNCTIONS To change the mode EAM30189 REAR BRAKE PEDAL 1. Shift to neutral. The rear brake pedal “1” is in the right of the 2. Start the engine. chassis. Press down on the brake pedal to acti- 3.
Page 35: Fuel Tank Cap
INSTRUMENT AND CONTROL FUNCTIONS EAM30192 FUEL TANK CAP Fuel tank cap “1” is located under the fuel tank cap cover “2”. Remove the fuel tank cap cover to open the fuel tank cap. • To remove the fuel tank cap cover, insert fin- gers under part “a”, and then use both hands to lift it up towards the rear of the vehicle.
Page 36: Starting And Break-In
4. When the engine starts running, warm this up one or two minutes at a steady speed (of 3000 to 5000 r/min), and then return the start- Your Yamaha engine has been designed to use er knob to its original position. premium unleaded gasoline with a pump octane...
Page 37: Starting A Warm Engine
STARTING AND BREAK-IN check the points shown in “TORQUE- CHECK POINTS” for tightening torques and retighten them. Also when the following parts are replaced, a break-in is required. • Cylinder and Crankshaft: A break-in is re- quired for about an hour. •...
Page 38: Maintenance After Break-In
Pour the specified amount of the recom- AIR FILTER MAINTENANCE mended oil. Apply the Yamaha foam air filter oil or other qual- • Generator ity foam air filter oil to the element. (Excess oil in Check for looseness in mounted areas of the the element may adversely affect engine start- generator rotor and the stator coil assembly.
Page 39: Torque-Check Points
TORQUE-CHECK POINTS EAM20125 TORQUE-CHECK POINTS Frame construction Frame to rear frame Frame to engine protector Combined seat and fuel tank Fuel tank to frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Seat Seat to frame Steering Steering stem to handlebar Steering stem to frame...
Page 40 TORQUE-CHECK POINTS Shift pedal Shift pedal to shift shaft Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake disc cover Tightening of rear brake caliper cover...
Page 41: Motorcycle Care And Storage
MOTORCYCLE CARE AND STORAGE any longer than instructed. Also, thorough- EAM20126 MOTORCYCLE CARE AND STOR- ly rinse the area off with water, immediately dry it, and then apply a corrosion protec- tion spray. • Improper cleaning can damage plastic EAM30200 CARE parts (such as cowlings, panels, wind- While the open design of a motorcycle reveals...
Page 42: Storage
Salt sprayed on roads in the winter may remain well into spring. • Consult a Yamaha dealer for advice on what 1. Clean the motorcycle with cold water and a products to use.
Page 43 MOTORCYCLE CARE AND STORAGE stored. Long-term Before storing your motorcycle for several months: 1. Follow all the instructions in the “CARE” on page 1-29. 2. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating.
Page 44 MOTORCYCLE CARE AND STORAGE 1-32...
Page 45: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS ................2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-5 ELECTRICAL SPECIFICATIONS..............2-8 TIGHTENING TORQUES..................2-9 GENERAL TIGHTENING TORQUE SPECIFICATIONS ......2-9 ENGINE TIGHTENING TORQUES ............2-10 CHASSIS TIGHTENING TORQUES ............2-13 CABLE ROUTING DIAGRAM ................2-17...
Page 46: General Specifications
GENERAL SPECIFICATIONS EAM20127 GENERAL SPECIFICATIONS Model Model B2W5 Dimensions Overall length 2185 mm (86.0 in) Overall width 825 mm (32.5 in) Overall height 1285 mm (50.6 in) Seat height 965 mm (38.0 in) Wheelbase 1485 mm (58.5 in) Ground clearance 330 mm (12.99 in) Weight Curb weight...
Page 47: Engine Specifications
ENGINE SPECIFICATIONS EAM20128 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train DOHC Displacement 450 cm³ Number of cylinders Single cylinder Bore  stroke 97.0  60.8 mm (3.82  2.39 in) Compression ratio 13.0 : 1 Starting system Electric starter Fuel...
Page 48 ENGINE SPECIFICATIONS Valve dimensions Valve seat contact width limit (intake) 1.5 mm (0.06 in) Valve seat contact width limit (exhaust) 1.5 mm (0.06 in) Valve stem diameter limit (intake) 5.445 mm (0.2144 in) Valve stem diameter limit (exhaust) 5.435 mm (0.2140 in) Valve guide inside diameter (intake) 5.500–5.512 mm (0.2165–0.2170 in) Valve guide inside diameter (exhaust)
Page 49 3.769 (49/13) Final drive Chain Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil Fuel pump Pump type Electrical Maximum consumption amperage 2.4 A Fuel injector 12.0 ...
Page 50 CHASSIS SPECIFICATIONS EAM20129 CHASSIS SPECIFICATIONS Chassis Frame type Semi double cradle 26.9  Caster angle Trail 120 mm (4.7 in) Front wheel Wheel type Spoke wheel Rim size 21x1.6 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)
Page 51 Fork spring free length limit 492.0 mm (19.37 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil S1 Quantity (left) 501.0 cm³ (16.94 US oz, 17.67 Imp.oz) Quantity (right) 501.0 cm³ (16.94 US oz, 17.67 Imp.oz)
Page 52: Chassis Specifications
CHASSIS SPECIFICATIONS Adjustment value from the start position (STD) Adjustment value from the start position (Hard) Slow compression damping Unit for adjustment Click Adjustment value from the start position (Soft) Adjustment value from the start position (STD) Adjustment value from the start position (Hard) Drive chain Size...
Page 53: Electrical Specifications
ELECTRICAL SPECIFICATIONS EAM20130 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system 8.0–12.0 /2000 r/min Ignition timing (B.T.D.C.) Engine control unit Model B2W0 Ignition coil 2.16–2.64  Primary coil resistance Secondary coil resistance 8.64–12.96 k Spark plug cap Resistance 7.50–12.50 k...
Page 54: Tightening Torques
TIGHTENING TORQUES EAM20131 TIGHTENING TORQUES EAM30205 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.
Page 55: Engine Tightening Torques
TIGHTENING TORQUES EAM30203 ENGINE TIGHTENING TORQUES - marked portion shall be checked for torque tightening after break-in or before each race. Thread Item Q’ty Tightening torques Remarks size Camshaft cap bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) Cylinder head stud bolt (exhaust 7 N·m (0.7 kgf·m, 5.2 lb·ft) pipe)
Page 56 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Clutch cable locknut (clutch cable 4.3 N·m (0.43 kgf·m, 3.2 lb·ft) adjuster) Clutch cable locknut (engine side) 7 N·m (0.7 kgf·m, 5.2 lb·ft) Exhaust pipe nut 10 N·m (1.0 kgf·m, 7.4 lb·ft) Exhaust pipe protector screw 10 N·m (1.0 kgf·m, 7.4 lb·ft) Exhaust pipe bracket bolt...
Page 57 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Shift pedal bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft)  Generator rotor nut 65 N·m (6.5 kgf·m, 48 lb·ft) Stator coil screw 10 N·m (1.0 kgf·m, 7.4 lb·ft) Crankshaft position sensor bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Stator coil assembly lead holder bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft)
Page 58: Chassis Tightening Torques
TIGHTENING TORQUES EAM30204 CHASSIS TIGHTENING TORQUES - marked portion shall be checked for torque tightening after break-in or before each race. Thread Item Q’ty Tightening torques Remarks size Upper bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft)  Lower bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) ...
Page 59 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Rear brake disc bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) / Footrest bracket bolt 55 N·m (5.5 kgf·m, 41 lb·ft) Rear brake pedal bolt 26 N·m (2.6 kgf·m, 19 lb·ft)  Rear brake pedal adjusting locknut 6 N·m (0.6 kgf·m, 4.4 lb·ft) Rear brake master cylinder bolt...
Page 60 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Bolt (drive chain support) 7 N·m (0.7 kgf·m, 5.2 lb·ft) Drive chain support nut 7 N·m (0.7 kgf·m, 5.2 lb·ft) Drive chain guide bolt 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) Bolt (rear frame cover) (left) 7 N·m (0.7 kgf·m, 5.2 lb·ft) ...
Page 61 TIGHTENING TORQUES 2-16...
Page 62: Cable Routing Diagram
CABLE ROUTING DIAGRAM EAM20152 CABLE ROUTING DIAGRAM Frame and engine (left side view) 2-17...
Page 63 U. Pass the cylinder head breather hose B. Insert the Yamaha diagnostic tool 3-pin cou- between the down tube and radiator, and pler (black) into the connector, and secure it front of the radiator under boss.
Page 64 CABLE ROUTING DIAGRAM Frame and engine (right side view) 2-19...
Page 65 CABLE ROUTING DIAGRAM H. Pass the cylinder head breather hose 1. Negative battery lead between the radiator hose and the engine 2. Cross tube bracket. 3. Starter motor lead I. Install the cylinder head breather hose so 4. Coolant temperature sensor coupler (black, that the outlet faces downward.
Page 66 CABLE ROUTING DIAGRAM Handlebar (front view) 2-21...
Page 67 CABLE ROUTING DIAGRAM 1. Plastic locking tie 2. Number plate band 3. Clutch cable 4. Engine stop switch lead 5. Mode switch lead 6. Front brake hose 7. Cable guide 8. Start switch lead 9. Number plate 10.Launch control switch lead A.
Page 68 CABLE ROUTING DIAGRAM Frame and engine (top view) 2-23...
Page 69 CABLE ROUTING DIAGRAM L. Insert the clamp into the rib so that it contacts 1. Clamp the rib. 2. Diode 3. Throttle position sensor lead 4. Intake air pressure sensor lead 5. Joint coupler 6. Intake air pressure sensor coupler (dark blue, 3-pin) 7.
Page 70 CABLE ROUTING DIAGRAM Frame and battery (top view) 2-25...
Page 71 CABLE ROUTING DIAGRAM 1. Positive battery lead 2. CCU (Communication Control Unit) 3. Diode 4. Fuel pump lead 5. Fuel hose 6. Wire harness (to the negative battery cou- pler) 7. Joint connector 8. Main relay 9. Starter relay coupler (black, 4-pin) 10.Starter relay 11.Starter motor lead 12.Negative battery lead...
Page 72 CABLE ROUTING DIAGRAM Rear brake (right side view) 2-27...
Page 73 CABLE ROUTING DIAGRAM 1. Protector 2. Rear brake caliper 3. Bleed screw 4. Gasket 5. Rear brake hose 6. Brake pedal 7. Rear brake master cylinder assembly 8. Swingarm 9. Spring 10.Frame A. It does not matter whether the spring is installed upward or downward.
Page 74 CABLE ROUTING DIAGRAM 2-29...
Page 75: Periodic Checks And Adjustments
PERIODIC CHECKS AND ADJUSTMENTS MAINTENANCE INTERVALS ................3-1 MAINTENANCE INTERVALS..............3-1 PRE-OPERATION INSPECTION AND MAINTENANCE .........3-5 GENERAL INSPECTION AND MAINTENANCE ........3-5 ENGINE......................3-6 ADJUSTING THE VALVE CLEARANCE............3-6 VALVE CLEARANCE SHIM CHART ............3-9 CHECKING THE ENGINE IDLING SPEED..........3-11 CHECKING THE THROTTLE GRIP ............3-11 CHECKING THE SPARK PLUG...............3-12 CHECKING THE ENGINE OIL LEVEL .............3-13 CHANGING THE ENGINE OIL..............3-13 ADJUSTING THE CLUTCH LEVER FREE PLAY ........3-15...
Page 76 CHECKING THE WHEEL BEARINGS .............3-33 CHECKING THE CHASSIS FASTENERS ..........3-33 CHECKING AND LUBRICATING THE CABLES........3-33 LUBRICATING THE BRAKE LEVER ............3-34 LUBRICATING THE CLUTCH LEVER .............3-34 LUBRICATING THE PEDAL..............3-34 ELECTRICAL SYSTEM..................3-35 CHECKING AND CHARGING THE BATTERY ........3-35 CHECKING THE FUSES................3-35 CHECKING THE IGNITION TIMING ............3-35...
Page 77: Maintenance Intervals
(e.g., rain, dirt, etc.). Therefore, earlier inspection is required by reference to the list below. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
Page 78 MAINTENANCE INTERVALS Every Every Every After race third race fifth race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours) • Check the coolant passages for corrosion. • Inspect carbon deposits and elim-  11 * Cylinder head inate them.
Page 79 MAINTENANCE INTERVALS Every Every Every After race third race fifth race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours) • Clean.   • Inspect and adjust.     • Replace oil. 30 * Front fork leg(s) •...
Page 80 MAINTENANCE INTERVALS Every Every Every After race third race fifth race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours) Brake pedal, footrest • Lubricate.   • Retighten. Outside nuts and   44 * bolts •...
Page 81: Pre-Operation Inspection And Maintenance
PRE-OPERATION INSPECTION AND MAINTENANCE EAM20134 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating con- dition. Before using this machine, check the following points. EAM30209 GENERAL INSPECTION AND MAINTENANCE Item Inspect Page...
Page 82: Engine
Turn the crankshaft counterclockwise with sic knowledge and skill concerning the servic- a wrench. ing of Yamaha motorcycles (e.g., Yamaha b. Align the top dead center (TDC) mark “a” dealers, service engineers, etc.). Those who on the generator rotor with the alignment have little knowledge and skill concerning ser- mark “b”...
Page 83 ENGINE • The adjusting pad number “a” is indicated on the top of the adjusting pad. • For the number on the originally installed ad- justing pad, convert the last digit of adjusting pad number as per the below table. 5.
Page 84 ENGINE • Make sure that adjusting pads are installed with their numbers facing upward. f. Install the camshafts (exhaust and intake). Refer to “CAMSHAFT” on page 5-13. g. Measure the valve clearance again. h. If the valve clearance is out of specifica- tion, repeat adjusting the valve clearance until it is within specification.
Page 85: Valve Clearance Shim Chart
ENGINE EAM30383 VALVE CLEARANCE SHIM CHART INTAKE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.02 0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230...
Page 86 ENGINE EXHAUST 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 0.02 0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225...
Page 87: Checking The Engine Idling Speed
2. Measure the coolant temperature using the 5. Adjust: Yamaha diagnostic tool. • Engine idling speed Yamaha diagnostic tool USB (US) a. Turn the idle screw “1” to make an adjust- 90890-03269 ment. Yamaha diagnostic tool (A/I) 90890-03264 FI diagnostic tool sub–lead...
Page 88: Checking The Spark Plug
ENGINE 2. Adjust: ECA24410 NOTICE • Throttle grip free play In order not to allow the dirt accumulated a. Loosen the locknut “1”. around the spark plug to drop from the spark b. Turn the adjuster “2” until the specified plug hole into the cylinder, clean it before re- throttle grip free play is obtained.
Page 89: Checking The Engine Oil Level
ENGINE • Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1. EAM30224 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle upright on a level surface. 2. Start the engine, warm this up for 2–3 min- utes, and then stop the engine and wait about 1 minute.
Page 90 ENGINE Engine oil quantity Oil change 0.63 L (0.67 US qt, 0.55 Imp.qt) With oil filter removal 0.65 L (0.69 US qt, 0.57 Imp.qt) Quantity (disassembled) 0.90 L (0.95 US qt, 0.79 Imp.qt) c. Install the new oil filter element and the oil filter element cover.
Page 91: Adjusting The Clutch Lever Free Play
ENGINE Clutch cable side ECA26740 NOTICE a. Slide the clutch cable cover. If the engine oil level does not decrease after b. Loosen the locknut “1”. the engine has been started, immediately c. Turn the adjuster “2” until the specified turn the engine off.
Page 92 • Air filter element Damage  Replace. 6. Apply: • Yamaha foam air filter oil or other quality foam air filter oil. a. Put the air filter element into a plastic bag and drip the filter oil into the bag.
Page 93: Checking The Throttle Body Joint
ENGINE 8. Turn the plates “1” to the original position. 10.Install: • Fuel tank cap cover EAM30335 CHECKING THE THROTTLE BODY JOINT 1. Check: • Throttle body joint “1” Crack/damage  Replace. 9. Install: • Air filter case cover “1” •...
Page 94: Checking The Cylinder Head Breather Hose
ENGINE 5. Replace: • Silencer fiber a. Remove the bolts “1” and silencer body “2”. ECA25800 NOTICE Do not hit the silencer stay “a” as it may do damage to the silencer. Remove the inner pipe while holding the silencer in place with a vise etc.
Page 95 ENGINE d. Install the fiber insert “6” to the part “b”. h. Install the fiber insert “12” to the inner pipe. e. Twist the fiber insert “7” onto the inner pipe i. Install the fiber insert “13” to the inside of “c”.
Page 96: Checking The Coolant Level
ENGINE 6. Check: EAM30210 CHECKING THE COOLANT LEVEL • Gasket “1” EWA13030 Damage  Replace. WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in- jury.
Page 97: Checking The Cooling System
ENGINE tilled water is not available, soft water may be used. 4. Start the engine, warm this up for several minutes, and then stop it. 5. Check: • Coolant level Before checking the coolant level, wait a few minutes until the coolant has settled. 3.
Page 98 ENGINE tion 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- ter. • Do not mix different types of antifreeze. 7.
Page 99: Chassis
CHASSIS system. Air in the brake system will consid- EAM20136 CHASSIS erably reduce braking performance. ECA13490 EAM30479 ADJUSTING THE FRONT DISC BRAKE NOTICE After adjusting the brake lever position, There should be no free play at the brake lever make sure there is no brake drag. end.
Page 100: Checking The Brake Fluid Level
CHASSIS can indicate the presence of air in the brake and plastic parts. Therefore, always clean up system. Before running, bleed the brake sys- any spilt brake fluid immediately. tem. Air in the brake system will cause brak- ing performance to be reduced. EAM30231 CHECKING THE FRONT BRAKE PADS ECA13510...
Page 101: Checking The Rear Brake Hose
CHASSIS brake several times. the reservoir to overflow. • Make sure that there is enough brake fluid be- 4. Check: • Brake hose fore applying the brake. Ignoring this precau- Brake fluid leaks  Replace the damaged tion could allow air to enter the brake system, brake hose.
Page 102: Drive Chain Slack
CHASSIS h. Repeat steps (d) to (g) until all of the air bubbles have disappeared from the brake Measure drive chain slack between the drive fluid in the plastic hose. chain guide and the bottom of the chain as shown. During the procedure, keep adding brake fluid to the reservoir.
Page 103: Checking And Adjusting The Steering Head
CHASSIS Drive chain puller locknut 21 N·m (2.1 kgf·m, 15 lb·ft) EAM30247 CHECKING AND ADJUSTING THE STEERING HEAD 1. Use a maintenance stand to raise the front wheel off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over.
Page 104: Lubricating The Steering Head
CHASSIS of the outer tube circumference. 5. Install: • Upper bracket 6. Remove: Refer to “STEERING HEAD” on page 4-55. • Protector • Handlebar • Dust seal “1” Refer to “HANDLEBAR” on page 4-35. ECA24330 NOTICE EAM30502 LUBRICATING THE STEERING HEAD Be careful not to damage the dust seal and 1.
Page 105 CHASSIS have poor stability. Compression damping • Securely support the vehicle so that there ECA24350 NOTICE is no danger of it falling over. Do not turn the adjuster forcibly beyond its Rebound damping adjusting range. ECA24340 NOTICE 1. Adjust: Do not turn the adjuster forcibly beyond its •...
Page 106: Checking The Rear Shock Absorber Assembly
CHASSIS wheel off the ground. EWA13120 WARNING EWA13120 Securely support the vehicle so that there is WARNING Securely support the vehicle so that there is no danger of it falling over. no danger of it falling over. Spring preload 2. Remove the bleed screw “1” and release the ECA24360 NOTICE internal pressure from the front fork.
Page 107 CHASSIS ment. • The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjusting ring. Compression damping (for fast compres- sion damping) ECA24370 NOTICE e. Tighten the locknut. Do not turn the adjuster forcibly beyond its Rebound damping adjusting range.
Page 108: Checking The Swingarm Operation
CHASSIS Compression damping (for slow compres- EAM30240 CHECKING THE SWINGARM OPERATION sion damping) 1. Check: ECA24390 • Swingarm smooth action NOTICE • Swingarm free play Do not turn the adjuster forcibly beyond its adjusting range. Refer to “SWINGARM” on page 4-65. 1.
Page 109: Checking And Tightening The Spokes
CHASSIS rect the tire position. Spoke 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) • Do not give a half turn (180) or more for one tightening. • Make sure that tightening after a break-in is done until the initial looseness in nipples disap- pears.
Page 110: Lubricating The Brake Lever
CHASSIS 2. Check: • Cable operation Rough movement  Lubricate. Recommended lubricant Engine oil or a suitable cable lu- bricant Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit- able lubricating device.
Page 111: Electrical System
ELECTRICAL SYSTEM 4. Check: EAM20137 ELECTRICAL SYSTEM • Ignition timing Check whether the alignment mark “a” on the EAM30256 left crankcase cover is within the firing range CHECKING AND CHARGING THE BATTERY “b” on the generator rotor. Refer to “CHECKING AND CHARGING THE Incorrect firing range ...
Page 112 ELECTRICAL SYSTEM 3-36...
Page 113 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE SEAT................4-3 REMOVING THE NUMBER PLATE ............4-3 INSTALLING THE AIR SCOOP..............4-3 REMOVING THE SIDE COVER ..............4-4 INSTALLING THE SIDE COVER ...............4-4 FRONT WHEEL ....................4-5 REMOVING THE FRONT WHEEL .............4-6 DISASSEMBLING THE FRONT WHEEL ...........4-6 CHECKING THE FRONT WHEEL .............4-6 ASSEMBLING THE FRONT WHEEL ............4-7 INSTALLING THE FRONT WHEEL ............4-7 REAR WHEEL ....................4-9...
Page 114 INSTALLING THE REAR BRAKE MASTER CYLINDER ......4-33 HANDLEBAR....................4-35 REMOVING THE HANDLEBAR ...............4-37 CHECKING THE HANDLEBAR..............4-37 INSTALLING THE HANDLEBAR..............4-37 FRONT FORK....................4-42 REMOVING THE FRONT FORK LEGS ...........4-44 DISASSEMBLING THE FRONT FORK LEGS .........4-44 CHECKING THE FRONT FORK LEGS............4-45 ASSEMBLING THE FRONT FORK LEGS ..........4-46 INSTALLING THE FRONT FORK LEGS..........4-53 STEERING HEAD...................4-55 REMOVING THE LOWER BRACKET ............4-56...
Page 115 GENERAL CHASSIS EAM20094 GENERAL CHASSIS Removing the seat and battery 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 116 GENERAL CHASSIS Removing the side cover 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 1.3 N ・ m (0.13 kgf ・ m, 0.95 lb ・ ft) 7 N ・...
Page 117: General Chassis
GENERAL CHASSIS EAM30016 REMOVING THE SEAT The fuel tank cap cover and the seat are coupled with each other with a plastic band. When removing the seat, always remove the fuel tank cap cover beforehand. 1. Remove: • Fuel tank cap cover “1” Refer to “FUEL TANK CAP”...
Page 118: Removing The Side Cover
GENERAL CHASSIS EAM30459 REMOVING THE SIDE COVER 1. Remove: • Side cover (right) “1” Remove the side cover (right) from the vehicle by removing the bolts and sliding it as shown. 1 1 1 a. Projection b. Slot EAM30460 INSTALLING THE SIDE COVER 1.
Page 119: Front Wheel
FRONT WHEEL EAM20095 FRONT WHEEL Removing the front wheel 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 115 N ・ m (11.5 kgf ・ m, 85 lb ・ ft) 12 N ・...
Page 120: Removing The Front Wheel
FRONT WHEEL 3. Check: EAM30017 REMOVING THE FRONT WHEEL • Spoke 1. Use a maintenance stand to raise the front Bend/damage  Replace. wheel off the ground. Loose  Tighten. EWA13120 Tap the spokes with a screwdriver. WARNING Securely support the vehicle so that there is no danger of it falling over.
Page 121: Assembling The Front Wheel
FRONT WHEEL 7. Check: • Bearing Front wheel turns roughly or is loose  Re- place the wheel bearings. • Oil seal Damage/wear  Replace. EAM30020 ASSEMBLING THE FRONT WHEEL 1. Install: • Bearing (left side) “1” • Spacer “2” 2.
Page 122 FRONT WHEEL Front wheel axle pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) 2. Install: • Front wheel axle “1” Apply the lithium-soap-based grease to the front wheel axle. 3. Tighten: • Front wheel axle nut “1” Front wheel axle nut 115 N·m (11.5 kgf·m, 85 lb·ft) ECA24430 NOTICE...
Page 123: Rear Wheel
REAR WHEEL EAM20096 REAR WHEEL Removing the rear wheel 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 135 N ・ m (13.5 kgf ・ m, 100 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 42 N ・...
Page 124: Removing The Rear Wheel
REAR WHEEL Refer to “CHECKING THE TIRES” on page EAM30022 REMOVING THE REAR WHEEL 3-32 and “CHECKING THE WHEELS” on 1. Use a maintenance stand to raise the rear page 3-33. wheel off the ground. 3. Check: EWA13120 • Spoke WARNING Refer to “CHECKING THE FRONT WHEEL”...
Page 125: Assembling The Rear Wheel
REAR WHEEL 2. Install: Rear wheel sprocket self-locking • Brake disc • Brake disc bolt 42 N·m (4.2 kgf·m, 31 lb·ft) Brake disc bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) LOCTITE® Tighten the self-locking nuts in stages and in a crisscross pattern.
Page 126 REAR WHEEL Refer to “DRIVE CHAIN SLACK” on page 3-26. 3. Install: • Left drive chain puller “1” • Rear wheel axle “2” 6. Tighten: • Rear wheel axle nut “1” • Install the left drive chain puller, and insert the Wheel axle nut rear wheel axle from the left side.
Page 127 FRONT BRAKE EAM20097 FRONT BRAKE Removing the front brake caliper 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 28 N ・ m (2.8 kgf ・ m, 21 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 17 N ・...
Page 128: Front Brake
FRONT BRAKE Disassembling the front brake caliper 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw 4-14...
Page 129 FRONT BRAKE Removing the front brake master cylinder 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 6 N ・...
Page 130 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Push rod Dust boot Circlip Washer Brake master cylinder kit 4-16...
Page 131: Introduction
FRONT BRAKE b. Remove the brake caliper. EAM30028 INTRODUCTION c. Hold the dial gauge at a right angle against EWA19210 the brake disc surface. WARNING d. Measure the runout 1.5 mm (0.06 in) If you need to disassemble the disc brake above the brake disc edge.
Page 132 FRONT BRAKE 3. Install: • Brake pads a. Connect the plastic hose “1” to the bleed screw “2” and place a container under the end of the plastic hose. b. Loosen the pad pin “2”. c. Remove the brake caliper “3” from the front fork.
Page 133: Removing The Front Brake Caliper
FRONT BRAKE EAM30031 DISASSEMBLING THE FRONT BRAKE CALIPER 1. Remove: • Brake caliper piston “1” • Brake caliper piston dust seal “2” • Brake caliper piston seal “3” f. Install the pad pin plug “6”. Pad pin plug 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) a.
Page 134: Assembling The Front Brake Caliper
FRONT BRAKE • Brake fluid delivery passages EWA13531 WARNING (brake caliper body) Proper brake hose routing is essential to in- Obstruction  Blow out with compressed air. sure safe vehicle operation. ECA24460 NOTICE Make sure that the pipe portion “a” of the brake hose touches the projection “b”...
Page 135: Removing The Front Brake Master Cylinder
FRONT BRAKE reservoir up to the specified level. tainer under the master cylinder and the end of the brake hose. Specified brake fluid DOT 4 EAM30037 CHECKING THE FRONT BRAKE MASTER EWA13090 CYLINDER WARNING 1. Check: • Use only the designated brake fluid. Other •...
Page 136: Installing The Front Brake Master Cylinder
FRONT BRAKE stall them as shown. Wrong orientation in in- stallation causes poor braking performance. EAM30039 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Brake master cylinder “1” Brake master cylinder holder bolt 9 N·m (0.9 kgf·m, 6.6 lb·ft) •...
Page 137 FRONT BRAKE system. Turn the handlebar toward right and left to make Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-25. sure that the brake hose does not touch other parts (e.g., wire harness, cables, leads). Adjust if necessary. 3.
Page 138: Rear Brake
REAR BRAKE EAM20098 REAR BRAKE Removing the rear brake caliper 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 13 lb ・ ft) 30 N ・...
Page 139 REAR BRAKE Disassembling the rear brake caliper 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw 4-25...
Page 140 REAR BRAKE Removing the rear brake master cylinder 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 141 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Push rod Brake master cylinder kit 4-27...
Page 142: Introduction
REAR BRAKE EAM30040 INTRODUCTION Brake disc runout limit (as mea- sured on wheel) EWA19260 0.15 mm (0.0059 in) WARNING If you need to disassemble the disc brake 4. Adjust: components, observe the following precau- • Brake disc runout tions. Refer to “CHECKING THE FRONT BRAKE •...
Page 143 REAR BRAKE Bleed screw 6 N·m (0.6 kgf·m, 4.4 lb·ft) d. Install the brake pads “3” and the pad pin “4”. • Install the brake pads with their projections “a” into the brake caliper recesses “b”. • Temporarily tighten the pad pin at this point. 2.
Page 144: Removing The Rear Brake Caliper
REAR BRAKE joint opening to force out the piston from the brake caliper. EWA13550 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. •...
Page 145: Assembling The Rear Brake Caliper
REAR BRAKE 2. Check: • Brake caliper bracket Crack/damage  Replace. EAM30045 ASSEMBLING THE REAR BRAKE CALIPER EWA19280 WARNING • Before installation, clean and lubricate the internal parts. Use new brake fluid for cleaning and lubricating. • Never use solvents on internal brake com- 3.
Page 146: Removing The Rear Brake Master Cylinder
REAR BRAKE 6. Check: • Brake master cylinder reservoir diaphragm • Brake fluid level holder The minimum level mark or below  Add. • Brake master cylinder reservoir diaphragm Crack/damage  Replace. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-24. 4.
Page 147: Installing The Rear Brake Master Cylinder
REAR BRAKE 3. Install: ECA24500 NOTICE • Spring “1” Make sure that the pipe portion of the brake Install to the brake master cylinder piston “2”. hose touches the projection “a” on the brake caliper. Install the spring with a smaller inside diameter to the brake master cylinder piston.
Page 148 REAR BRAKE system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-25. 4-34...
Page 149 HANDLEBAR EAM20099 HANDLEBAR Removing the handlebar 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 0.5 N ・ m (0.05 kgf ・ m, 0.37 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 1.3 N ・...
Page 150 HANDLEBAR Removing the handlebar 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 0.5 N ・ m (0.05 kgf ・ m, 0.37 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 1.3 N ・...
Page 151: Removing The Handlebar
HANDLEBAR side of the vehicle. EAM30052 REMOVING THE HANDLEBAR • Installing the lower handlebar holders in the re- 1. Stand the vehicle upright on a level surface. verse direction allow the front-to-rear offset EWA13120 amount of the handlebar position to be WARNING changed.
Page 152 HANDLEBAR Clutch lever holder bolt 5 N·m (0.5 kgf·m, 3.7 lb·ft) Clutch lever nut 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) The clutch lever holder “1” should be installed according to the dimensions shown. 168 mm (6.61 in) 5. Install: • Engine stop switch “1” •...
Page 153 HANDLEBAR Install the handlebar grip to the handlebar so that the line “a” between the two arrow marks faces straight upward. 7. Install: • Clutch cable “1” Before installation, apply the lithium-soap-based grease to the clutch cable end. 10.Install: • Rubber cover “1” •...
Page 154 HANDLEBAR 12.Install: 14.Install: • Throttle cable housing “1” • Start switch “1” • Screw (throttle cable housings) “2” • Front brake master cylinder assembly “2” • Front brake master cylinder holder “3” Screw (throttle cable housings) • Bolt (brake master cylinder holder) “4” 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) •...
Page 155 HANDLEBAR 15.Adjust: • Throttle grip free play Refer to “CHECKING THE THROTTLE GRIP” on page 3-11. Throttle grip free play 3.0–5.0 mm (0.12–0.20 in) 4-41...
Page 156: Front Fork
FRONT FORK EAM20100 FRONT FORK Removing the front fork legs 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 5 N ・...
Page 157 FRONT FORK Disassembling the front fork leg 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 29 N ・ m (2.9 kgf ・ m, 21 lb ・ ft) 28 N ・ m (2.8 kgf ・ m, 21 lb ・ ft) 55 N ・...
Page 158: Removing The Front Fork Legs
FRONT FORK EAM30055 REMOVING THE FRONT FORK LEGS 1. Use a maintenance stand to raise the front wheel off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Record the adjusting screw setting position be- fore loosening the adjuster and the base valve.
Page 159: Checking The Front Fork Legs
FRONT FORK Cap bolt wrench 90890-01500 Cap bolt wrench YM-01500 Cap bolt ring wrench 90890-01501 Cap bolt ring wrench YM-01501 3. Remove: • Dust seal “1” • Stopper ring “2” (with a flat-head screwdriver) ECA14180 NOTICE Do not scratch the inner tube. EAM30057 CHECKING THE FRONT FORK LEGS 1.
Page 160: Assembling The Front Fork Legs
FRONT FORK 4. Check: 6. Check: • Damper assembly “1” • Upper spring seat “1” Bend/damage  Replace. (Contacting surface “a”) Wear/damage  Replace. • O-ring “2” Wear/damage  Replace. ECA14200 NOTICE • The front fork leg has a built-in damper ad- justing rod and a very sophisticated inter- nal construction, which are particularly sensitive to foreign material.
Page 161 1. Stretch the damper assembly fully. 2. Fill: • Damper assembly Recommended oil Yamaha Suspension Oil S1 Standard oil amount 216 cm³ (7.30 US oz, 7.62 Imp.oz) ECA24530 NOTICE • Be sure to use the recommended oil. Other oils may have an adverse effect on front fork performance.
Page 162 FRONT FORK 7. Install: 10.After filling, pump the damper assembly “1” • Base valve “1” slowly up and down more than 10 times to (to the damper assembly “2”) distribute the fork oil. First bring the damper rod pressure to a maxi- mum.
Page 163 FRONT FORK 13.Check: 15.Install: • Damper assembly smooth movement • Piston metal “1” Tightness/binding/rough spots  Repeat the steps (1) to (12). Install the piston metal onto the slot on inner tube. 14.Install: • Dust seal “1” 16.Install: • Stopper ring “2” •...
Page 164 FRONT FORK 20.Install: • Dust seal “1” Apply lithium-soap-based grease on the inner tube. 18.Install: • Oil seal “1” Using a fork seal driver “2”, press the oil seal in until the stopper ring groove fully appears. 21.Check: Fork seal driver •...
Page 165 FRONT FORK • Unless the damping force adjuster is fully loos- ened, correct damping characteristic cannot be obtained after installation. 23.Install: • Upper spring seat “1” • Fork spring “2” (to the damper assembly “3”) 26.Install: • Damper adjusting rod “1” Install the upper spring seat with its larger dia.
Page 166 FRONT FORK correct damping force cannot be obtained. Recommended oil Yamaha Suspension Oil S1 Standard oil amount 295 cm³ (9.97 US oz, 10.41 Imp.oz) Extent of adjustment 260–365 cm³ (8.79–12.34 US oz, 9.17–12.87 Imp.oz) ECA24570 NOTICE • Be sure to use the recommended oil. Other oils may have an adverse effect on front 28.Tighten:...
Page 167: Installing The Front Fork Legs
FRONT FORK EAM30059 INSTALLING THE FRONT FORK LEGS 1. Install: • Front fork “1” • Temporarily tighten the pinch bolts (lower bracket). • Do not tighten the pinch bolts (upper bracket) yet. 3. Adjust: • Front fork top end “a” Front fork top end (standard) “a”...
Page 168 FRONT FORK then turn out to the originally set position. EWA19320 WARNING Tighten the lower bracket to specified torque. If torqued too much, it may cause the front fork to malfunction. 6. Install: • Protector “1” • Bolt (protector) “2” Bolt (protector) 5 N·m (0.5 kgf·m, 3.7 lb·ft) 7.
Page 169: Steering Head
STEERING HEAD EAM20101 STEERING HEAD Removing the lower bracket 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 145 N ・ m (14.5 kgf ・ m, 107 lb ・ ft) 38 N ・ m (3.8 kgf ・ m, 28 lb ・ ft) 7 N ・...
Page 170: Removing The Lower Bracket
STEERING HEAD EAM30060 ECA14270 REMOVING THE LOWER BRACKET NOTICE 1. Use a maintenance stand to raise the front If the bearing race is not installed properly, wheel off the ground. the steering head pipe could be damaged. EWA13120 WARNING Always replace the bearing and the bearing race Securely support the vehicle so that there is as a set.
Page 171 STEERING HEAD 2. Install: • Bearing race • Upper bearing “1” • Bearing race cover “2” Apply the lithium-soap-based grease on the bearing and bearing race cover lip. 5. Check the steering stem by turning this lock to lock. If there is any binding, remove the steering stem and check the steering bear- ing.
Page 172 STEERING HEAD Upper bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) • Pinch bolt (lower bracket) “2” Lower bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) EWA19330 WARNING Tighten the lower bracket to specified 8. Install: torque. If torqued too much, it may cause the •...
Page 173: Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY EAM20102 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 56 N ・ m (5.6 kgf ・ m, 41 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 53 N ・ m (5.3 kgf ・ m, 39 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 174 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 56 N ・ m (5.6 kgf ・ m, 41 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 53 N ・ m (5.3 kgf ・ m, 39 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 175 REAR SHOCK ABSORBER ASSEMBLY Disassembling the relay arm 80 N ・ m (8.0 kgf ・ m, 59 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Relay arm Connecting arm Collar Oil seal Washer Bearing 4-61...
Page 176: Handling The Rear Shock Absorber
• To dispose of a damaged or a worn-out rear shock absorber, take the unit to your EAM30067 CHECKING THE REAR SHOCK ABSORBER Yamaha dealer for this disposal procedure. ASSEMBLY 1. Check: • Rear shock absorber rod Bends/damage  Replace the rear shock absorber assembly.
Page 177: Checking The Connecting Arm And Relay Arm
REAR SHOCK ABSORBER ASSEMBLY EAM30068 CHECKING THE CONNECTING ARM AND RELAY ARM 1. Check: • Connecting arm • Relay arm Damage/wear  Replace. 2. Check: • Bearing • Collar Damage/pitting/scratches  Replace the bearings and collars as a set. EAM30070 INSTALLING THE REAR SHOCK 3.
Page 178 REAR SHOCK ABSORBER ASSEMBLY Installed depth “a” Relay arm nut (swingarm side) 4.25 mm (0.17 in) 70 N·m (7.0 kgf·m, 52 lb·ft) • Rear shock absorber assembly lower nut Rear shock absorber assembly lower nut 53 N·m (5.3 kgf·m, 39 lb·ft) 5.
Page 179: Swingarm
SWINGARM EAM20103 SWINGARM Removing the swingarm 70 N ・ m (7.0 kgf ・ m, 52 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 4.0 N ・ m (0.40 kgf ・ m, 3.0 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 180: Removing The Swingarm
SWINGARM • Bearing EAM30071 REMOVING THE SWINGARM 4. Check: 1. Use a maintenance stand to raise the rear • Oil seal wheel off the ground. Damage  Replace. EWA13120 • Bearing WARNING • Bushing Securely support the vehicle so that there is Free play exists/unsmooth revolution/rust ...
Page 181 SWINGARM 4. Install: • Rear wheel Refer to “REAR WHEEL” on page 4-9. 5. Adjust: • Drive chain slack Refer to “DRIVE CHAIN SLACK” on page 3-26. Drive chain slack (Maintenance stand) 50.0–60.0 mm (1.97–2.36 in) 4-67...
Page 182: Chain Drive
CHAIN DRIVE EAM20104 CHAIN DRIVE Removing the drive chain 90 N ・ m (9.0 kgf ・ m, 66 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Drive sprocket Refer to “ENGINE REMOVAL”...
Page 183: Removing The Drive Chain
CHAIN DRIVE length “b” between pin outer sides)/2 EAM30075 REMOVING THE DRIVE CHAIN 1. Use a maintenance stand to raise the rear wheel off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2.
Page 184: Checking The Drive Sprocket
CHAIN DRIVE G089069 5. Lubricate: • Drive chain EAM30077 CHECKING THE DRIVE SPROCKET 1. Check: • Drive sprocket More than 1/4 tooth wear “a”  Replace the drive sprocket and the rear wheel sprocket as a set. G089070 Bent tooth  Replace the drive sprocket and 2.
Page 185: Engine
ENGINE LUBRICATION SYSTEM CHART AND DIAGRAMS ........5-1 ENGINE OIL LUBRICATION CHART............5-1 LUBRICATION DIAGRAMS ...............5-2 ENGINE REMOVAL ..................5-6 REMOVING THE ENGINE ...............5-10 INSTALLING THE ENGINE ..............5-10 INSTALLING THE EXHAUST PIPE AND MUFFLER .......5-11 CAMSHAFT ....................5-13 REMOVING THE CAMSHAFT ..............5-15 CHECKING THE CAMSHAFT ..............5-16 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET...5-17 CHECKING THE TIMING CHAIN TENSIONERS........5-17 CHECKING THE DECOMPRESSION SYSTEM ........5-17...
Page 186 ELECTRIC STARTER..................5-43 CHECKING THE STARTER MOTOR ............5-45 ASSEMBLING THE STARTER MOTOR ..........5-45 CLUTCH......................5-47 REMOVING THE CLUTCH ..............5-50 CHECKING THE FRICTION PLATES ............5-50 CHECKING THE CLUTCH PLATES ............5-50 CHECKING THE CLUTCH SPRINGS ............5-50 CHECKING THE CLUTCH HOUSING .............5-50 CHECKING THE CLUTCH BOSS ............5-51 CHECKING THE PRESSURE PLATE .............5-51 CHECKING THE PUSH LEVER SHAFT ..........5-51 CHECKING THE PUSH RODS ..............5-51...
Page 187: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAM20185 LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30526 ENGINE OIL LUBRICATION CHART 1. Intake camshaft 2. Exhaust camshaft 3. Piston 4. Oil filter element 5. Oil nozzle 6. Oil pump 7. Oil strainer 8. Crankshaft 9. Drive axle 10.Main axle...
Page 188: Lubrication Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30507 LUBRICATION DIAGRAMS 1. Camshaft 2. Drive axle 3. Main axle...
Page 189 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Connecting rod 2. Oil nozzle 3. Crankshaft...
Page 190 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Exhaust camshaft 2. Intake camshaft 3. Oil filter element 4. Oil pump...
Page 191 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter element 2. Oil pump 3. Oil strainer...
Page 192: Engine Removal
ENGINE REMOVAL EAM20105 ENGINE REMOVAL Removing the exhaust pipe 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 20 N ・...
Page 193 ENGINE REMOVAL Removing the electronic parts 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Use a maintenance stand to raise the front wheel off the ground.
Page 194 ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 85 N ・ m (8.5 kgf ・ m, 63 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 7 N ・...
Page 195 ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 85 N ・ m (8.5 kgf ・ m, 63 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 7 N ・...
Page 196: Removing The Engine
ENGINE REMOVAL EAM30161 REMOVING THE ENGINE 1. Remove: • Exhaust pipe 2 Put the exhaust pipe 2 into the state as shown by moving this, and then remove it. 2. Remove: • Pivot shaft “1” If the pivot shaft is pulled all the way out, the EAM30164 INSTALLING THE ENGINE swingarm will come loose.
Page 197: Installing The Exhaust Pipe And Muffler
ENGINE REMOVAL Engine mounting bolt (upper side) 45 N·m (4.5 kgf·m, 33 lb·ft) • Apply molybdenum disulfide grease to the piv- ot shaft. • Place the projection of the shims to the outside of the vehicle. 2. Install: • Clamp •...
Page 198 ENGINE REMOVAL 4. Tighten: • Bolt (exhaust pipe 2) Bolt (exhaust pipe 2) 20 N·m (2.0 kgf·m, 15 lb·ft) • Clamp Clamp 12 N·m (1.2 kgf·m, 8.9 lb·ft) Tighten while checking that their front and rear joints are inserted in position. 5-12...
Page 199: Camshaft
Refer to “ENGINE REMOVAL” on page 5-6. Cylinder head breather hose Spark plug Cylinder head cover Cylinder head cover breather plate Gasket Timing chain guide (top side) Cylinder head cover gasket Gasket * Yamaha bond No. 1215 (Three bond No.1215®) 5-13...
Page 200 CAMSHAFT Removing the camshaft 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 10 N ・...
Page 201: Removing The Camshaft
CAMSHAFT EAM30080 REMOVING THE CAMSHAFT 1. Remove: • Timing mark accessing screw “1” • Crankshaft end accessing screw “2” 4. Remove: • Bolt (camshaft cap) “1” • Camshaft cap “2” • Clip “3” 2. Align: • Remove the bolts (camshaft cap) in a criss- •...
Page 202: Checking The Camshaft
CAMSHAFT 4. Measure: • Camshaft-journal-to-camshaft-cap clearance Out of specification  Measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance 0.028–0.062 mm (0.0011–0.0024 a. Install the camshaft into the cylinder head. b. Position a strip of Plastigauge® “1” onto EAM30081 the camshaft journal as shown. CHECKING THE CAMSHAFT 1.
Page 203: Checking The Timing Chain And Camshaft Sprocket
CAMSHAFT the tensioner rod will come out smoothly. Camshaft journal diameter c. If not, replace the tensioner assembly. 21.959–21.972 mm (0.8645– 0.8650 in) EAM30082 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET 1. Check: • Timing chain “1” Damage/stiffness  Replace the timing chain and camshaft as a set.
Page 204 CAMSHAFT d d d a. Turn the crankshaft counterclockwise with a wrench. • Apply molybdenum disulfide oil to the cam- shafts. • Apply the engine oil on the decompression system. b. Align the top dead center (TDC) mark “a” on the generator rotor with the alignment mark “b”...
Page 205 Before installation, apply the sealant to the cylin- and tighten the bolts “4”. der head cover gasket. Bolt (timing chain tensioner) Yamaha bond No. 1215 10 N·m (1.0 kgf·m, 7.4 lb·ft) 90890-85505 (Three bond No.1215®) c. Release the screwdriver, check that the tensioner rod comes out smoothly, and tighten the gasket “5”...
Page 206 CAMSHAFT 6. Install: • Cylinder head breather hose • Spark plug Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) 5-20...
Page 207: Cylinder Head
CYLINDER HEAD EAM20107 CYLINDER HEAD Removing the cylinder head 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 90˚ 60˚ 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 7 N ・...
Page 208 CYLINDER HEAD Removing the cylinder head 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 90˚ 60˚ 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 7 N ・...
Page 209: Removing The Cylinder Head
CYLINDER HEAD page 5-29. EAM30086 REMOVING THE CYLINDER HEAD • Cylinder head coolant passages 1. Remove: Mineral deposits/rust  Eliminate. • Cylinder head bolt 3. Measure: • Cylinder head warpage • Loosen the bolts in the proper sequence as Out of specification  Resurface the cylinder shown.
Page 210 CYLINDER HEAD 2. Install: • Washer “1” • Bolt “2” • Bolt “3” f. Loosen the bolt [1]. Loosen the bolt [1] only without loosening any other bolt. g. Again apply molybdenum disulfide grease to the thread and contact surface of the Tighten the bolts using the following procedure.
Page 211 CYLINDER HEAD 90˚ Bolt [1] Specified angle 90 k. Perform the same procedure with the bolts [2]–[4] one by one and applying the tight- ening sequence (f)–(j) as shown for the bolt [1]. Do not loosen any other bolt until one bolt is completely tightened.
Page 212 VALVES AND VALVE SPRINGS EAM20108 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-21. Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Intake valve...
Page 213: Valves And Valve Springs
VALVES AND VALVE SPRINGS EAM30090 REMOVING THE VALVES Check that there are no kerosene leaks from the valve seat “1”. Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure that the valves are properly sealed. 1.
Page 214: Checking The Valves And Valve Guides
VALVES AND VALVE SPRINGS head to 100 °C (212 °F) in an oven. a. Remove the valve guide with the valve guide remover “1”. EAM30091 CHECKING THE VALVES AND VALVE GUIDES 1. Measure: b. Install the new valve guide with the valve •...
Page 215: Checking The Valve Seats
VALVES AND VALVE SPRINGS 3. Measure: Valve guide remover & installer • Valve seat contact width “a” set (ø5.5) Out of specification  Replace the cylinder 90890-04016 head. Valve guide remover (5.5 mm) YM-01122 Valve seat contact width limit (in- Valve guide installer (ø5.5) take) 90890-04015...
Page 216: Checking The Valve Springs
VALVES AND VALVE SPRINGS valve seat. e. Apply a fine lapping compound to the valve face, and repeat the above steps. f. After every lapping step, be sure to clean off all of the lapping compound from the valve face and the valve seat. g.
Page 217: Checking The Valve Lifters
VALVES AND VALVE SPRINGS 3. Install: EAM30094 CHECKING THE VALVE LIFTERS • Spring seat “1” 1. Check: • Valve stem seal “2” • Valve lifter • Valve “3” Damage/scratches  Replace the valve lift- • Valve spring “4” ers and cylinder head. •...
Page 218 VALVES AND VALVE SPRINGS 5. To fasten the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. ECA13800 NOTICE Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Adjusting pad “1” •...
Page 219: Cylinder And Piston
CYLINDER AND PISTON EAM20109 CYLINDER AND PISTON Removing the cylinder and piston 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Cylinder head...
Page 220: Removing The Piston
CYLINDER AND PISTON the piston ring over the piston crown. EAM30096 REMOVING THE PISTON 1. Remove: • Piston pin clip “1” • Piston pin “2” • Piston “3” ECA13810 NOTICE Do not use a hammer to drive the piston pin out.
Page 221: Checking The Piston Rings
CYLINDER AND PISTON Diameter Top ring 96.955–96.970 mm (3.8171– Ring side clearance 3.8177 in) 0.015–0.065 mm (0.0006–0.0026 Measuring point (from piston skirt bottom) Side clearance limit 9.0 mm (0.35 in) 0.120 mm (0.0047 in) 2nd ring Ring side clearance 0.020–0.060 mm (0.0008–0.0024 Side clearance limit 0.100 mm (0.0039 in) d.
Page 222: Checking The Piston Pin
CYLINDER AND PISTON EAM30100 INSTALLING THE PISTON AND CYLINDER 1. Install: • Oil ring expander “1” • Lower oil ring rail “2” • Upper oil ring rail “3” • 2nd ring “4” • Top ring “5” Be sure to install the piston rings so that the manufacturer’s marks or numbers face up.
Page 223 CYLINDER AND PISTON • Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity. 3. Lubricate: • Piston • Piston ring • Cylinder 4. Offset: • Piston ring end gap a. Top ring b. 2nd ring c.
Page 224: Generator
GENERATOR EAM20183 GENERATOR Removing the stator coil assembly 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 8 N ・...
Page 225: Removing The Generator
T25 bit. • Stator coil assembly “2” outer surface “b” • Pass the stator coil assembly lead through the Damage  Inspect the crankshaft runout and crankcase cover side. crankshaft bearing. Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 5-39...
Page 226 GENERATOR • Crankcase cover (left) “3” • Lead holder “4” • Bolt (left crankcase cover) “5” Bolt (left crankcase cover) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Tighten the bolts in stages and in a crisscross pattern. 2. Install: • Woodruff key “1” •...
Page 227: Starter Clutch
STARTER CLUTCH EAM20175 STARTER CLUTCH Removing the starter clutch 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Refer to “CHANGING THE ENGINE OIL” on Engine oil page 3-13. Clutch Refer to “CLUTCH” on page 5-47. Holder Washer Damper assembly...
Page 228: Checking The Starter Clutch
STARTER CLUTCH EAM30140 CHECKING THE STARTER CLUTCH 1. Check: • Starter clutch assembly • Starter clutch drive gear Burrs/chips/roughness/wear  Replace the starter clutch. 2. Check: • Starter clutch assembly gear Damage/pitting/wear  Replace the starter clutch assembly. 3. Check: •...
Page 229: Electric Starter
ELECTRIC STARTER EAM20110 ELECTRIC STARTER Removing the starter motor 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Exhaust pipe Refer to “ENGINE REMOVAL”...
Page 230 ELECTRIC STARTER Disassembling the starter motor 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 4.5 N ・ m (0.45 kgf ・ m, 3.3 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Starter motor assembly O-ring Starter motor front cover Starter motor yoke Armature assembly...
Page 231: Checking The Starter Motor
ELECTRIC STARTER 4. Measure: EAM30106 CHECKING THE STARTER MOTOR • Brush length “a” 1. Check: Out of specification  Replace the brush set. • Commutator Dirt  Clean with 600 grit sandpaper. Brush overall length limit 5.5 mm (0.22 in) 2.
Page 232 ELECTRIC STARTER • Starter motor yoke “2” Install the starter motor rear cover with its projec- tion “a” facing the groove “b” of the starter motor yoke. 3. Install: • Circlip • Plain washer • O-ring • Washer (starter motor front cover) •...
Page 233 CLUTCH EAM20111 CLUTCH Removing the clutch 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 75 N ・...
Page 234 CLUTCH Removing the clutch 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 75 N ・...
Page 235 CLUTCH Removing the right crankcase cover 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 236: Removing The Clutch
CLUTCH set. EAM30108 REMOVING THE CLUTCH 2. Measure: 1. Remove: • Clutch plate warpage • Clutch boss nut “1” (with a surface plate and thickness gauge) • Lock washer “2” Out of specification  Replace the clutch • Clutch boss “3” plates as a set.
Page 237: Checking The Clutch Boss
CLUTCH EAM30113 CHECKING THE CLUTCH BOSS 1. Check: • Clutch boss splines Damage/pitting/wear  Replace the clutch 1 1 1 boss. Pitting on the clutch boss splines will cause er- ratic clutch operation. 2. Measure: • Push rod 2 bending limit Out of specification ...
Page 238 CLUTCH 2. Install: • Dowel pin “1” • O-ring “2” • Collar “3” • Gasket “4” Apply the lithium-soap-based grease on the O- ring. 4. Install: • Push lever shaft “1” • Apply the lithium-soap-based grease on the oil seal lip. •...
Page 239 CLUTCH 1 1 1 8. Install: 6. Install: • Friction plate 1 “1” • Lock washer “1” • Clutch plate “2” • Clutch boss nut “2” • Friction plate 2 “3” Clutch boss nut 75 N·m (7.5 kgf·m, 55 lb·ft) •...
Page 240 CLUTCH 13.Install: • O-ring “1” Apply the lithium-soap-based grease to the O- ring. 10.Install: • Push rod 2 “1” • Ball “2” • Push rod 1 “3” Apply the engine oil on the push rod 1, 2 and 14.Install: ball. •...
Page 241: Shift Shaft
SHIFT SHAFT EAM20113 SHIFT SHAFT Removing the shift shaft and stopper lever 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 10 N ・...
Page 242: Removing The Segment
SHIFT SHAFT EAM30124 REMOVING THE SEGMENT 1. Remove: • Bolt (segment) “1” • Segment “2” Turn the segment counterclockwise until it stops and loosen the bolt. ECA24670 NOTICE If the segment gets an impact, the stopper le- EAM30127 ver may be damaged. Take care not to give CHECKING THE STOPPER LEVER an impact to it when removing the bolt.
Page 243 SHIFT SHAFT • Apply the engine oil on the segment bolt shaft. Segment bolt 30 N·m (3.0 kgf·m, 22 lb·ft) • Align the notch “a” on the segment with the pin “b” on the shift cam. • With the stopper lever pushed down, install the segment.
Page 244 SHIFT SHAFT Shift pedal bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) Align the punch mark “a” on the shift shaft with the punch mark “b” in the shift pedal. 5-58...
Page 245: Oil Pump
OIL PUMP EAM20182 OIL PUMP Removing the oil pump 2.0 N ・ m (0.20 kgf ・ m, 1.5 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Primary driven gear Refer to “CLUTCH”...
Page 246 OIL PUMP Removing the balancer 80 N ・ m (8.0 kgf ・ m, 59 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 45 N ・ m (4.5 kgf ・ m, 33 lb ・ ft) 50 N ・...
Page 247: Removing The Oil Pump
OIL PUMP EAM30485 REMOVING THE OIL PUMP 1 1 1 1. Straighten the lock washer tab. 2. Loosen: • Balancer nut “1” • Primary drive gear nut “2” • Balancer weight gear nut “3” Place an aluminum plate “a” between the teeth of the balancer drive gear “4”...
Page 248: Installing The Oil Pump
OIL PUMP 1 1 1 2. Install: ECA13890 NOTICE • Outer rotor “1” After tightening the bolts, make sure the oil pump turns smoothly. Apply the engine oil on the outer rotor. 2. Install: • Balancer weight gear “1” Install the balancer weight gear and balancer shaft with their lower splines “a”...
Page 249 OIL PUMP 4. Install: • Lock washer “1” • Balancer weight gear nut “2” Balancer weight gear nut 50 N·m (5.0 kgf·m, 37 lb·ft) • Primary drive gear “3” • Conical washer “4” • Primary drive gear nut “5” Primary drive gear nut 5.
Page 250: Crankcase
CRANKCASE EAM20116 CRANKCASE Separating the crankcase 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 12 N ・...
Page 251 CRANKCASE Removing the bearing and oil seal 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 12 N ・...
Page 252: Disassembling The Crankcase
CRANKCASE EAM30147 DISASSEMBLING THE CRANKCASE 1. Separate: • Right crankcase • Left crankcase a. Remove the crankcase bolts. c. Remove the dowel pins and O-ring. 2. Remove: • Bearing “1” • Remove the bearing from the crankcase by pressing its inner race. •...
Page 253: Assembling The Crankcase
Install the bearing by pressing its outer race par- allel. 3. Apply: • Sealant (to the crankcase mating surface) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 4. 45 mm (1.77 in) 5. 60 mm (2.36 in) 6. 75 mm (2.95 in) 4.
Page 254: Crankshaft And Balancer Shaft
CRANKSHAFT AND BALANCER SHAFT EAM20184 CRANKSHAFT AND BALANCER SHAFT Removing the crankshaft assembly and balancer shaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-64. Transmission Refer to “TRANSMISSION” on page 5-71. Balancer shaft Crankshaft assembly 5-68...
Page 255: Removing The Crankshaft
CRANKSHAFT AND BALANCER SHAFT EAM30491 EAM30492 REMOVING THE CRANKSHAFT CHECKING THE CRANKSHAFT 1. Remove: 1. Measure: • Balancer shaft “1” • Crankshaft runout Out of specification  Replace the crank- Remove the balancer shaft with its flat side “a” shaft, bearing or both. facing the crankshaft.
Page 256: Installing The Crankshaft
CRANKSHAFT AND BALANCER SHAFT 4. Check: • Crankshaft journal oil passage Obstruction  Blow out with compressed air. EAM30493 INSTALLING THE CRANKSHAFT 1. Install: • Crankshaft assembly Install the crankshaft assembly with the crank- shaft installer pot “1”, crankshaft installer bolt “2”, adapter (M12) “3”...
Page 257: Transmission
TRANSMISSION EAM20118 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-6. Separate. Crankcase Refer to “CRANKCASE” on page 5-64. Main axle Drive axle Long shift fork guide bar Short shift fork guide bar Spring Shift cam...
Page 258: Removing The Transmission
TRANSMISSION EAM30153 REMOVING THE TRANSMISSION 1. Remove: • Long shift fork guide bar “1” • Short shift fork guide bar “2” • Shift cam “3” • Shift fork 3 “4” • Shift fork 2 “5” • Shift fork 1 “6” •...
Page 259: Installing The Transmission
TRANSMISSION install. 2. Measure: • Drive axle runout 2. Install: (with a centering device and dial gauge “1”) • Collar “1” Out of specification  Replace the drive axle. • 2nd wheel gear (23T) “2” • 4th wheel gear (24T) “3” Drive axle runout limit •...
Page 260 TRANSMISSION 6. Install: • Shift fork 1 (L) “1” • Shift fork 2 (C) “2” • Shift fork 3 (R) “3” • Shift cam “4” (to the main axle and the drive axle) • Apply engine oil to the shift fork grooves. •...
Page 261 TRANSMISSION 7. Install: • Long shift fork guide bar “1” • Short shift fork guide bar “2” • Spring “3” • Screw the spring into the shift fork guide bar lightly beforehand. • Apply the engine oil on the shift fork guide bars. 8.
Page 262 TRANSMISSION 5-76...
Page 263: Cooling System
COOLING SYSTEM COOLING SYSTEM DIAGRAMS ..............6-1 RADIATOR......................6-2 CHECKING THE RADIATOR ..............6-4 INSTALLING THE RADIATOR ..............6-4 WATER PUMP ....................6-6 DISASSEMBLING THE WATER PUMP .............6-7 CHECKING THE WATER PUMP ...............6-7 ASSEMBLING THE WATER PUMP ............6-7...
Page 264: Cooling System Diagrams
COOLING SYSTEM DIAGRAMS EAM20186 COOLING SYSTEM DIAGRAMS 1. Radiator hose 1 2. Radiator (right) 3. Radiator hose 4 4. Water pump 5. Radiator hose 3 6. Radiator (left)
Page 265: Radiator
RADIATOR EAM20138 RADIATOR Removing the radiator 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・...
Page 266 RADIATOR Removing the radiator 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・...
Page 267: Checking The Radiator
RADIATOR EAM30341 CHECKING THE RADIATOR Radiator cap valve opening pres- sure EWA13030 107.9–137.3 kPa (1.08–1.37 WARNING kgf/cm², 15.6–19.9 psi) A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- No stay  Replace. gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in- Radiator cap tester jury.
Page 268 RADIATOR 4. Activate the tester to apply the test pressure. Test pressure value 137.3 kPa (1.37 kgf/cm², 19.9 psi) ECA24270 NOTICE • Do not apply such a high pressure as ex- ceeds the test pressure. • Make sure that a checkup after the cylinder head gasket is replaced is made after 3 min- utes of warm-up.
Page 269: Water Pump
WATER PUMP EAM20139 WATER PUMP Removing the water pump 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT”...
Page 270: Disassembling The Water Pump
WATER PUMP EAM30494 DISASSEMBLING THE WATER PUMP • Remove the oil seal when the coolant level changes frequently more than usual, coolant has discolored, or engine oil has become milky. • Do not use the removed oil seal. 1. Remove: •...
Page 271 WATER PUMP 1 1 1 5. Install: • Water pump housing “1” • Water pump housing bolt “2” Water pump housing bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) • Washer “3” • Coolant drain bolt “4” Coolant drain bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Page 272 WATER PUMP...
Page 273: Fuel System
FUEL SYSTEM FUEL TANK ......................7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP ..............7-2 CHECKING THE FUEL PUMP BODY ............7-2 CHECKING THE FUEL PUMP OPERATION ..........7-2 INSTALLING THE FUEL PUMP ..............7-2 INSTALLING THE FUEL TANK ..............7-3 THROTTLE BODY ....................7-4 CHECKING THE INJECTOR..............7-7 CHECKING THE THROTTLE BODY ............7-7 CHECKING THE FUEL PRESSURE............7-7...
Page 274: Fuel Tank
FUEL TANK EAM20140 FUEL TANK Removing the fuel tank 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 4.0 N ・...
Page 275: Removing The Fuel Tank
FUEL TANK EAM30263 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose coupler EWA19370 WARNING Cover the fuel hose connection with a cloth when disconnecting it. This is because re- sidual pressure in the fuel hose could cause fuel to spurt out when the hose is removed.
Page 276: Installing The Fuel Tank
FUEL TANK • Take care not to damage the installation sur- faces of the fuel tank. • Always use a new fuel pump gasket. • Install the lip on the fuel pump gasket upward. • Install the fuel pump as shown in the figure. •...
Page 277: Throttle Body
THROTTLE BODY EAM20141 THROTTLE BODY Removing the throttle body 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 4.0 N ・...
Page 278 THROTTLE BODY Removing the throttle body 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 4.0 N ・...
Page 279 THROTTLE BODY Removing the injector 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel inlet pipe Injector Gasket Throttle position sensor Intake air pressure sensor...
Page 280: Checking The Injector
THROTTLE BODY EAM30271 CHECKING THE INJECTOR 1. Check: • Injector Obstruction  Replace, and check the fuel pump and the fuel injection system. Refer to “FUEL INJECTION SYSTEM” on page 8-15. Deposits  Replace. Damage  Replace. 2. Check: • Injector resistance Refer to “CHECKING THE INJECTOR”...
Page 281: Adjusting The Throttle Position Sensor
Check that the throttle grip is fully closed. d. Connect the throttle position sensor to the wire harness. e. Set the Yamaha diagnostic tool to “diag- nostic mode”. f. Choose the diagnostic code No. “01”. g. Adjust the throttle position sensor mount- ed angle until “11”–“14”...
Page 282 THROTTLE BODY...
Page 283: Electrical System
CHARGING SYSTEM ..................8-11 CIRCUIT DIAGRAM .................8-11 TROUBLESHOOTING................8-13 FUEL INJECTION SYSTEM ................8-15 CIRCUIT DIAGRAM .................8-15 YAMAHA DIAGNOSTIC TOOL ..............8-17 CONNECTING THE YAMAHA DIAGNOSTIC TOOL .......8-17 TROUBLESHOOTING DETAILS (FAULT CODE)........8-19 FUEL PUMP SYSTEM..................8-39 CIRCUIT DIAGRAM .................8-39 TROUBLESHOOTING................8-41 ELECTRICAL COMPONENTS...............8-42 CHECKING THE SWITCHES..............8-43 CHECKING THE FUSES................8-45...
Page 284: Ignition System
IGNITION SYSTEM EAM20142 IGNITION SYSTEM EAM30277 CIRCUIT DIAGRAM...
Page 285 IGNITION SYSTEM 1. Crankshaft position sensor 2. AC magneto 3. Rectifier/regulator 4. Joint connector 6. Battery 7. Engine ground 8. Frame ground 9. Fuse 10.Starter relay 11.Starter motor 12.Diode 1 13.Diode 2 14.CCU (Communication Control Unit) 16.ECU (Engine Control Unit) 17.Ignition coil 18.Spark plug 25.Engine stop switch...
Page 286: Troubleshooting
IGNITION SYSTEM EAM30278 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). Before troubleshooting, remove the following part(s): 1. Side cover (left/right) 2. Seat 3. Fuel tank 4. Air scoop (left/right) 5. Air filter case cover 1. Check the ignition system wire har- Reconnect.
Page 287 IGNITION SYSTEM 9. Check the stator coil assembly. Refer to “CHECKING THE STA- Replace the stator coil assembly. NG TOR COIL” on page 8-50. OK 10.Check the ignition system wire har- ness. Repair or replace the wire harness. Refer to “CIRCUIT DIAGRAM” on NG...
Page 288 IGNITION SYSTEM The mode switch to blink. Before troubleshooting, remove the following part(s): 1. Seat 2. Air scoop (left) 1. Check the mode switch coupler Reconnect. connections. NG OK 2. Check the mode switch. Refer to “CHECKING THE Replace the mode switch. NG...
Page 289 IGNITION SYSTEM...
Page 290: Electric Starting System
ELECTRIC STARTING SYSTEM EAM20143 ELECTRIC STARTING SYSTEM EAM30279 CIRCUIT DIAGRAM...
Page 291 ELECTRIC STARTING SYSTEM 4. Joint connector 5. Main relay 6. Battery 7. Engine ground 8. Frame ground 9. Fuse 10.Starter relay 11.Starter motor 12.Diode 1 13.Diode 2 16.ECU (Engine Control Unit) 25.Engine stop switch 27.Gear position switch 29.Start switch 30.Diode 3 A.
Page 292: Troubleshooting
ELECTRIC STARTING SYSTEM EAM30281 TROUBLESHOOTING The starter motor fails to turn. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 5. Air filter case cover 1. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse(s).
Page 293 ELECTRIC STARTING SYSTEM 9. Check the start switch. Refer to “CHECKING THE Replace the start switch. NG SWITCHES” on page 8-43. OK 10.Check the entire starting system’s wiring. Properly connect or repair the starting sys- Refer to “CIRCUIT DIAGRAM” on tem’s wiring.
Page 294: Charging System
CHARGING SYSTEM EAM20144 CHARGING SYSTEM EAM30282 CIRCUIT DIAGRAM 8-11...
Page 295 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 6. Battery 7. Engine ground 8. Frame ground 9. Fuse A. Battery sub-lead B. Wire harness 8-12...
Page 296: Troubleshooting
CHARGING SYSTEM EAM30283 TROUBLESHOOTING The battery is not being charged. Before troubleshooting, remove the following part(s): 1. Seat 2. Air scoop (left) 1. Check the entire charging system’s Reconnect. wiring. NG OK 2. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse(s).
Page 297 CHARGING SYSTEM 8-14...
Page 298: Fuel Injection System
FUEL INJECTION SYSTEM EAM20145 FUEL INJECTION SYSTEM EAM30284 CIRCUIT DIAGRAM 8-15...
Page 299 3. Rectifier/regulator 4. Joint connector 6. Battery 7. Engine ground 8. Frame ground 9. Fuse 14.CCU (Communication Control Unit) 15.Yamaha diagnostic tool coupler 16.ECU (Engine Control Unit) 17.Ignition coil 18.Spark plug 19.Fuel injector 20.Fuel pump 21.Intake air temperature sensor 22.Coolant temperature sensor 23.Throttle position sensor...
Page 300: Yamaha Diagnostic Tool
• Prepare the fully charged 12 V lead battery for yourself. • Replace the vehicle battery with a lead battery (12 V). • For information on how to connect and use the Yamaha diagnostic tool, refer to “YAMAHA DIGNO- STIC TOOL OPERATION MANUAL”.
Page 301 2. Lead battery (12 V) 3. Vehicle battery 4. Vehicle 5. Coupler for connecting optional part 6. FI diagnostic tool sub-lead 7. Sub-harness (included with the Yamaha diag- nostic tool) 8. Vehicle communication cable (included with the Yamaha diagnostic tool) 9. Yamaha diagnostic tool...
Page 302: Troubleshooting Details (Fault Code)
Yamaha diagnostic tool according to the reinstatement method. Fault code No.: Fault code number displayed on the Yamaha diagnostic tool when the engine failed to work normally. Diagnostic code No.: Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC CODE: SENSOR OPERATION TABLE”...
Page 303 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air pressure. Procedure The atmospheric pressure is displayed on the Yamaha diagnostic tool. Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check...
Page 304 Replace the intake air pressure sensor. Faulty ECU. Replace the ECU. Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-21...
Page 305 Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air pressure. Procedure The atmospheric pressure is displayed on the Yamaha diagnostic tool. Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check...
Page 306 Disconnect the coupler, and Yamaha diagnostic tool. Condition is “Recovered”  Go check the pins (for bent or bro- ken terminals and locking condi- to item 8 and finish the service.
Page 307 Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. Fault code No. 16 • If fault code numbers 15 and 16 are both displayed, perform checkup and repair jobs for fault code number 15 first.
Page 308 Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the coolant temperature. Compare the actually measured coolant temperature with the Yamaha Procedure diagnostic tool display value. Probable cause of malfunc- Confirmation of service com- Item...
Page 309 Refer to “RADIATOR” on page 6-2. item 6. Faulty ECU. Replace the ECU. Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-26...
Page 310 Fail-safe system Able to drive vehicle Diagnostic code No. Diagnostic tool display Displays the intake air temperature. Compare the actually measured intake air temperature with the Yamaha Procedure diagnostic tool display value. Probable cause of malfunc- Confirmation of service com-...
Page 311 Start switch to ON (main relay ON), wait 10 seconds, then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 4 and finish the service. Condition is “Detected”  Go to item 2.
Page 312 Unable to drive vehicle Diagnostic code No. Actuates the ignition coil five times at one-second intervals. Actuation “WARNING” on the Yamaha diagnostic tool blinks five times when the ignition coil is actuated. Check that a spark is generated five times. Procedure •...
Page 313 Check the condition of the fault the coupler. ness. code using the malfunction Disconnect the coupler, and mode of the Yamaha diagnostic check the pins (for bent or bro- tool. Condition is “Recovered”  Go ken terminals and locking condi- tion of the pins).
Page 314 Unable to drive vehicle Diagnostic code No. Actuates injector five times at one-second intervals. Actuation “WARNING” on the Yamaha diagnostic tool blinks five times when the injector is actuated. Check that injector is actuated five times by listening for the operating Procedure sound.
Page 315 Check the condition of the fault check the pins (bent or broken code using the malfunction terminals and locking condition mode of the Yamaha diagnostic of the pins). tool. Condition is “Recovered”  Go to item 6 and finish the service.
Page 316 Check the condition of the fault check the pins (bent or broken code using the malfunction terminals and locking condition mode of the Yamaha diagnostic of the pins). tool. Condition is “Recovered”  Go to item 6 and finish the service.
Page 317 If the same number is indicated, go to item 4. Faulty ECU. Replace the ECU. Service is finished. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-34...
Page 318 Check the condition of the fault the coupler. code using the malfunction Disconnect the coupler and mode of the Yamaha diagnostic check the pins (bent or broken tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
Page 319 ECU. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. Fault code No. 50 Before troubleshooting, disconnect the starter motor lead from the starter relay.
Page 320 Engine forcibly stops when the vehicle is left idling for a long period Item of time. Delete the fault code. Confirm that the fault code has a condition of “Recovered” using the Yamaha diagnostic tool, and then delete the fault code. 8-37...
Page 321 FUEL INJECTION SYSTEM 8-38...
Page 322: Fuel Pump System
FUEL PUMP SYSTEM EAM20146 FUEL PUMP SYSTEM EAM30287 CIRCUIT DIAGRAM 8-39...
Page 323 FUEL PUMP SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Joint connector 6. Battery 7. Engine ground 8. Frame ground 9. Fuse 16.ECU (Engine Control Unit) 20.Fuel pump 25.Engine stop switch A. Battery sub-lead B. Wire harness C. Ignition coil sub-lead D.
Page 324: Troubleshooting
FUEL PUMP SYSTEM EAM30288 TROUBLESHOOTING The fuel pump fails to operate. Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3. Air scoop (left/right) 4. Fuel tank 5. Air filter case cover 1. Check the fuel pump system wire Reconnect.
Page 325: Electrical Components
ELECTRICAL COMPONENTS EAM20147 ELECTRICAL COMPONENTS 1. Rectifier/regulator 2. Intake air pressure sensor 3. Throttle position sensor 4. Injector 5. Launch control switch 6. Mode switch 7. Intake air temperature sensor 8. ECU (Engine Control Unit) 9. Ignition coil 10.CCU (Communication Control Unit) 11.Starter relay 12.Fuse 13.Battery...
Page 326: Checking The Switches
ELECTRICAL COMPONENTS EAM30289 CHECKING THE SWITCHES Y/W P 1. Engine stop switch 2. Mode switch 3. Launch control switch 4. Gear position switch 5. Engine start switch 8-43...
Page 327 ELECTRICAL COMPONENTS Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14371 NOTICE Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end “a”...
Page 328: Checking The Fuses
ELECTRICAL COMPONENTS cause a fire. EAM30290 CHECKING THE FUSES 4. Install: The following procedure applies to all of the fus- • Seat Refer to “GENERAL CHASSIS” on page 4-1. 1. Remove: • Seat EAM30291 Refer to “GENERAL CHASSIS” on page 4-1. CHECKING AND CHARGING THE BATTERY 2.
Page 329 When 2. Disconnect: replacing the battery, be sure to use a • Battery leads Yamaha genuine lithium-ion battery. (from the battery terminals) ECA13700 NOTICE Do not check the battery at high temperature of First, disconnect the negative battery lead, 65 C (149 F) or more or low temperatures be-...
Page 330: Checking The Relays
ELECTRICAL COMPONENTS has cooled down to the ambient tempera- Main relay ture. e. Measure the voltage between the termi- nals of the battery. 13.25 V or more  The battery is normal. Checking is finished. 10 V or more and less than 13.25 V  Perform from step (c) again.
Page 331: Checking The Ignition Spark Gap
ELECTRICAL COMPONENTS Refer to “TROUBLESHOOTING” on page No continuity 8-3. Tester positive lead  Blue/Green “1” Minimum ignition spark gap Tester negative lead  Blue “2” 6.0 mm (0.24 in) Continuity Tester positive lead  Blue “2” Tester negative lead  If the ignition spark gap is within specification, Blue/Green “1”...
Page 332: Checking The Ignition Coil
ELECTRICAL COMPONENTS Secondary coil resistance 8.64–12.96 k a. Connect the digital circuit tester () to the ignition coil. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachom- eter YU-A1927 b. Measure the spark plug cap resistance. EAM30296 • Positive tester probe  CHECKING THE IGNITION COIL Ignition coil terminal 1 “1”...
Page 333: Checking The Lean Angle Sensor
ELECTRICAL COMPONENTS b. Check the starter motor operation. b. Measure the crankshaft position sensor resistance. EAM30300 CHECKING THE STATOR COIL EAM30298 1. Disconnect: CHECKING THE LEAN ANGLE SENSOR • Stator coil assembly coupler 1. Check: (from the wire harness) • Mounted condition of ECU 2.
Page 334: Checking The Coolant Temperature Sensor
ELECTRICAL COMPONENTS Regulated voltage (DC) Coolant temperature sensor re- 14.0–14.8 V sistance 2513–2777  at 20 C (2513– 2777  at 68 F) a. Set the digital tachometer to the ignition Coolant temperature sensor re- coil. sistance Digital tachometer 210–221  at 100 C (210–221  90890-06760 at 212 F) Digital tachometer...
Page 335: Checking The Throttle Position Sensor Input Voltage
ELECTRICAL COMPONENTS d. Measure the throttle position sensor input voltage. EAM30307 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 1. Remove: • Intake air temperature sensor (from the air filter case) EWA14110 WARNING • Handle the intake air temperature sensor EAM30305 CHECKING THE THROTTLE POSITION with special care.
Page 336: Checking The Gear Position Switch
ELECTRICAL COMPONENTS EAM30467 EAM30496 CHECKING THE GEAR POSITION SWITCH CHECKING THE INJECTOR 1. Remove: 1. Remove: • Gear position switch • Fuel injector 2. Check: Refer to “THROTTLE BODY” on page 7-4. • Gear position switch 2. Check: Out of specification  Replace. •...
Page 337: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING ..................9-1 GENERAL INFORMATION ................9-1 TROUBLESHOOTING OF ENGINE (fault code not detected) ....9-1 TROUBLESHOOTING OF CLUTCH ............9-4 TROUBLESHOOTING OF TRANSMISSION ..........9-6 TROUBLESHOOTING OF COOLING SYSTEM ........9-7 TROUBLESHOOTING OF BRAKE ............9-8 TROUBLESHOOTING OF SUSPENSION ..........9-8 TROUBLESHOOTING OF STEERING/HANDLING.........9-10 TROUBLESHOOTING OF CHARGING SYSTEM........9-11 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE....9-12 SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM) ....................9-12...
Page 338: Troubleshooting
TROUBLESHOOTING EAM20148 TROUBLESHOOTING EAM30309 GENERAL INFORMATION Troubleshooting information provided here does not cover all the trouble symptoms, possible causes, and remedial actions. Some items may not apply depending on the model. Use this information as a guide and quick reference matrix when performing basic troubleshooting. Refer to the each chapter for detailed information on checking, adjustment, and replacement.
Page 339 TROUBLESHOOTING Symptom Possible cause Actions Water or foreign material in fuel, Change fuel. degraded fuel Tighten the spark plug to the spec- Loose spark plug ified torque. Tighten bolts or nuts on cylinder Loose cylinder head or cylinder head and cylinder to the specified torque.
Page 340 TROUBLESHOOTING Symptom Possible cause Actions Worn camshaft lobe Replace the camshaft. Water or foreign material in fuel, Change fuel. degraded fuel Contaminated throttle body or Clean the throttle body. clogged internal passage Incorrectly adjusted throttle cable Adjust the throttle grip free play. Incorrectly adjusted idling speed Adjust the idle screw.
Page 341: Troubleshooting Of Clutch
TROUBLESHOOTING Symptom Possible cause Actions Replace the piston and piston Worn or damaged piston ring rings as a set. Replace the piston and piston Worn or damaged piston rings as a set. Replace the piston and piston pin Worn piston (piston pin hole) as a set.
Page 342 TROUBLESHOOTING Symptom Possible cause Actions Replace the clutch springs as a Faulty clutch spring set. Warped pressure plate Replace the pressure plate. Replace the friction plates as a Swollen friction plate set. Warped clutch plate Replace the clutch plates as a set. Bent pull rod (outer pull type) Replace the pull rod.
Page 343: Troubleshooting Of Transmission
TROUBLESHOOTING EAM30511 TROUBLESHOOTING OF TRANSMISSION Symptom Possible cause Actions Clutch drags Refer to “Clutch drags”. Adjust the shift rod installation Improperly adjusted shift rod length. Bent shift shaft Replace the shift shaft. Foreign object in a shift drum Remove foreign object from shift groove drum groove.
Page 344: Troubleshooting Of Cooling System
TROUBLESHOOTING EAM30512 TROUBLESHOOTING OF COOLING SYSTEM Symptom Possible cause Actions Carbon buildup in piston head and Clean the piston head and com- combustion chamber bustion chamber. Clogged engine cooling water Check and clean the engine cool- passages ing water passages. Adjust the oil level to the specified Incorrect oil level level.
Page 345: Troubleshooting Of Brake
TROUBLESHOOTING EAM30513 TROUBLESHOOTING OF BRAKE Symptom Possible cause Actions Worn brake pad Replace the brake pads as a set. Worn or deflected brake disc Replace the brake disc. Air in hydraulic brake system Bleed the hydraulic brake system. Check the hydraulic brake system Brake fluid leakage and repair or replace faulty parts as necessary.
Page 346 TROUBLESHOOTING Symptom Possible cause Actions Fatigued or broken fork spring Replace the fork spring. Incorrect oil viscosity (low) Change to recommended fork oil. Incorrect oil level (low) Adjust to the specified oil level. Improperly adjusted spring pre- Adjust the spring preload. Front fork is soft load (soft) Improperly adjusted rebound...
Page 347: Troubleshooting Of Steering/Handling
TROUBLESHOOTING Symptom Possible cause Actions Oil leaking from rear shock Replace the rear shock absorber. absorber Gas leaking from rear shock Replace the rear shock absorber. absorber Fatigued or damaged rear shock Replace the rear shock absorber. absorber spring Rear suspension is soft Improperly adjusted rear shock Adjust the spring preload.
Page 348: Troubleshooting Of Charging System
TROUBLESHOOTING Symptom Possible cause Actions Incorrect wheel balance Adjust the wheel balance. Tighten the spoke and adjust the Loose spoke runout. Damaged or worn wheel bearing Replace the wheel bearing. Worn, deformed, or incorrect tire Replace the tire. Front wheel vibration Loose wheel axle or wheel axle Tighten the wheel axle or wheel axle nut to the specified torque.
Page 349: Self-Diagnostic Function And Diagnostic Code Table
Pressure of suction pipe Displays the intake air pressure. The atmospheric pressure is • Check the change of the displayed on the Yamaha intake pressure valve when diagnostic tool. the starter switch is pushed. Intake air temperature Displays the intake air tempera- Compare the actually mea- ture.
Page 350 Coolant temperature Displays the coolant tempera- Compare the actually mea- ture. sured coolant temperature with the Yamaha diagnostic tool display value. Lean angle sensor Displays the output voltage. Remove the ECU, and incline it 45 or more. • Upright •...
Page 351: Diagnostic Code: Actuator Operation Table
Ignition coil Actuates the ignition coil five Check that a spark is gener- times at one-second intervals. ated five times. “WARNING” on the Yamaha • Connect an ignition checker. diagnostic tool blinks five times when the ignition coil is actu- ated.
Page 352 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9-15...
Page 353: Tuning
TUNING CHASSIS ......................10-1 SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET)...................10-1 DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS....10-1 TIRE PRESSURE ..................10-1 FRONT FORK SETTING ................10-2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL ..10-2 SETTING OF SPRING AFTER REPLACEMENT........10-2 FRONT FORK SETTING PARTS .............10-3 REAR SUSPENSION SETTING...............10-3 CHOOSING SET LENGTH...............10-3 SETTING OF SPRING AFTER REPLACEMENT........10-4...
Page 354: Chassis
CHASSIS EAM20119 Part name Type Part number CHASSIS Rear wheel 17D-25447-50 EAM30168 sprocket “2” SELECTION OF THE SECONDARY 17D-25448-50 REDUCTION RATIO (SPROCKET) (STD) 17D-25449-50 Secondary reduction ratio = Number of 17D-25450-50 rear wheel sprocket teeth/Number of 17D-25451-50 drive sprocket teeth 17D-25452-50 Secondary reduction ratio 3.769 (49/13)
Page 355: Front Fork Setting
(in position etc.) when Recommended oil setting the front fork. Yamaha Suspension Oil S1 1. Use of soft spring Standard oil amount • Change the rebound damping force.
Page 356: Front Fork Setting Parts
CHASSIS and the circuit conditions. Generally a stiff spring gives a stiff riding feeling. The rear suspension setting includes the follow- ing two factors: Rebound damping tends to become weaker, re- sulting in lack of a sense of contact with the road 1.
Page 357: Rear Shock Absorber Setting Parts
CHASSIS • If the standard figure cannot be achieved by adjusting the adjuster and changing the set length, replace the spring with an optional one and make readjustment. EAM30178 REAR SHOCK ABSORBER SETTING PARTS • Rear shock spring “1” STD Spring rate N/mm EAM30177 SETTING OF SPRING AFTER...
Page 358 CHASSIS • Spring preload adjusting positions Spring preload adjusting positions Minimum Position in which the spring is turned in 1.5 mm (0.06 in) from its free length. Standard Position in which the spring is turned in 7.0 mm (0.28 in) from its free length.
Page 359: Suspension Setting (Front Fork)
CHASSIS EAM30179 SUSPENSION SETTING (FRONT FORK) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in).
Page 360: Suspension Setting (Rear Shock Absorber)
CHASSIS Section Symptom Check Adjust Large Medium Small Jump Compression Turn adjuster clockwise (about 2 damping force clicks) to increase damping. Turn adjuster counterclockwise Rebound damp- (about 2 clicks) to decrease ing force damping. Low front, tend-   ing to lower front Set sunken length for 95–100 posture Balance with rear...
Page 361 CHASSIS Section Symptom Check Adjust Large Medium Small Jump Turn adjuster counterclockwise Rebound damp- (about 2 clicks) to decrease Heavy and drag- ing force   damping. ging Spring Replace with soft spring. Turn adjuster counterclockwise Rebound damp- (about 2 clicks) to decrease ing force damping.
Page 362 CHASSIS 10-9...
Page 363 11. Starter motor Black/Blue 12. Diode 1 Black/Orange 13. Diode 2 Black/Red 14. CCU (Communication Control Black/White Unit) Black/Yellow 15. Yamaha diagnostic tool cou- Br/W Brown/White pler Green/White 16. ECU (Engine Control Unit) Green/Yellow 17. Ignition coil Blue/Black 18. Spark plug Blue/Green 19.
Page 365 EAM20160 Genuine Yamaha Parts text 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 expect. Why settle for aftermarket parts that may not provide full confidence and satisfaction? Genuine Yamaha Accessories –...
Page 367 YZ450FM 2021 WIRING DIAGRAM R/L R/L R/L (Gy) B/L Gy B/L B/L B/L B/L B/L B/L R R/B (Gy) R,R/W Br/W Br/W L/R W/B Gy B/Y G/Y Y/G G/W B/L R/B B/W B/O Br/W P Y/R W/B Lg R/L Br/W Br/W Br/W Br/W B/L...
Page 368 YZ450FM 2021 WIRING DIAGRAM...

Yamaha YZ450F 2021 Owner's Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Pre-Operation Inspection and Maintenance

Chassis

Electrical System

Chassis

General Chassis

Removing the Front Wheel

Removing the Rear Wheel

Front Brake

Rear Brake

Front Fork

Steering Head

Rear Shock Absorber Assembly

Swingarm

Chain Drive

Engine

Lubrication System Chart and Diagrams

Engine Removal

Cylinder Head

Valves and Valve Springs

Cylinder and Piston

Starter Clutch

Electric Starter

Shift Shaft

Oil Pump

Crankcase

Crankshaft and Balancer Shaft

Transmission

Cooling System

Cooling System Diagrams

Radiator

Water Pump

Fuel System

Electrical System

Ignition System

Electric Starting System

Charging System

Fuel Injection System

Fuel Pump System

Electrical Components

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

Related Manuals for Yamaha YZ450F 2021

Summary of Contents for Yamaha YZ450F 2021