Yamaha WR45OFR manual

LIT-11626-16-43 WR450FR 5TJ-28199-10 OWNER’S SERVICE MANUAL[...]

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EC010000 WR450FR OWNER’S SERVICE MANUAL ©2002 by Yamaha Motor Corporation, U.S.A. 1st Edition, October 2002 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U.S.A. is expressly prohibited. Printed in Japan P/N. LIT-11626-16-43[...]

EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha WR series. This model is the culmina- tion of Yamaha’s vast experience in the pro- duction of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader. This manual explains operation, inspection, basic maintenance[...]

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IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regula- tions before riding. 1. THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY. Do no[...]

6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes. 7. ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE[...]

EC050000 TO THE NEW OWNER This manual will provide you with a good basic understanding of features, operation, and basic maintenance and inspection items of this machine. Please read this manual carefully and completely before operating your new machine. If you have any questions regarding the operation or maintenance of your machine, please consul[...]

EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine. A CAUTION indicates special p[...]

EC083000 MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condit[...]

ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols 1 to 7 are designed as thumb tabs to indicate the chapter ’ s number and content. 1 General information 2 Specifications 3 Regular inspection and adjustments 4 Engine 5 Chassis 6 Electrical 7 Tuning Illustrated symbols 8 to D are used to identify the specifications appearing in t[...]

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EC090000 INDEX GENERAL INFORMATION 1 SPECIFICATIONS SPEC 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE ENG 4 CHASSIS CHAS 5 ELECTRICAL ELEC 6 TUNING TUN 7 GEN INFO INSP ADJ –+[...]

EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION .......................................... 1-1 MACHINE IDENTIFICATION .................... 1-2 IMPORTANT INFORMATION ................... 1-3 CHECKING OF CONNECTION ................. 1-6 SPECIAL TOOLS ...................................... 1-7 CONTROL FUNCTIONS ......................... 1-1[...]

CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS ................................. 4-1 EXHAUST PIPE AND SILENCER ............ 4-3 RADIATOR ................................................ 4-5 CARBURETOR ......................................... 4-8 CAMSHAFTS .......................................... 4-21 CYLINDER HEAD .............................[...]

CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ........................... 6-1 MAP-CONTROLLED CDI UNIT ................ 6-2 IGNITION SYSTEM ................................... 6-3 ELECTRIC STARTING SYSTEM .............. 6-7 CHARGING SYSTEM ............................. 6-17 TPS (THROTTLE POSITION SENSOR) SYSTEM ......................[...]

GEN INFO 1 - 1 DESCRIPTION EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 Clutch lever 2 Hot starter lever 3 “ENGINE STOP” button 4 Trip meter 5 Main switch 6 Lights switch 7 Start switch 8 Front brake lever 9 Throttle grip 0 Radiator cap A Fuel tank cap B Taillight C Kickstarter D Fuel tank E Headlight F Radiator G Coolant drain bolt H Re[...]

1 - 2 GEN INFO MACHINE IDENTIFICATION EC120001 MACHINE IDENTIFICATION There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for posi- tive identification of the model you own. 2. If your machine is stolen, the authorities will need the number to search [...]

1 - 3 GEN INFO IMPORTANT INFORMATION EC130000 IMPORTANT INFORMATION EC131010 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassem- bly. When washing the machine with high pressured water, cover the parts as fol- lows. ● Silencer exhaust port ● Side cover air intake port ● Wate[...]

1 - 4 GEN INFO IMPORTANT INFORMATION EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is over- hauled. All gasket su[...]

1 - 5 GEN INFO IMPORTANT INFORMATION EC136000 CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace pis- ton pin clips after one use. Replace dis- torted circlips. When installing a circlip 1 , make sure that the sharp-edged cor- ner 2 is positioned opposite to the thrust 3 it receives. See the sectional view. 4 S[...]

1 - 6 GEN INFO CHECKING OF CONNECTION EC1C0001 CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: ● Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off. 5. If the terminal comes off, bend up[...]

GEN INFO 1 - 7 EC140001 SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to [...]

GEN INFO 1 - 8 SPECIAL TOOLS YM-01442, 90890-01442 Fork seal driver This tool is used when install the fork oil seal. YM-01442 90890-01442 YU-3112-C, 90890-03112 Yamaha pocket tester Use this tool to inspect the coil resistance, output voltage and amperage. YU-3112-C 90890-03112 YU-8036-B 90890-03113 Inductive tachometer Engine tachometer This tool[...]

GEN INFO 1 - 9 SPECIAL TOOLS YM-04141, 90890-04141 Rotor puller This tool is used to remove the flywheel magneto. YM-04141 90890-04141 YM-34487 90890-06754 Dynamic spark tester Ignition checker This instrument is necessary for checking the ignition system components. YM-34487 90890-06754 ACC-QUICK-GS-KT 90890-85505 Quick gasket  YAMAHA Bond No. [...]

1 - 10 GEN INFO CONTROL FUNCTIONS EC150000 CONTROL FUNCTIONS MAIN SWITCH Functions of the respective switch positions are as follows: ON: The engine can be started only at this position. OFF: All electrical circuits are switched off. Main switch indicator light The main switch 1 is equipped with an indica- tor light 2 to avoid forgetting to turn it[...]

1 - 11 GEN INFO CONTROL FUNCTIONS EC152000 CLUTCH LEVER The clutch lever 1 is located on the left han- dlebar; it disengages or engages the clutch. Pull the clutch lever to the handlebar to disen- gage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth starts. EC153000 SHIFT PED[...]

1 - 12 GEN INFO CONTROL FUNCTIONS EC157000 REAR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine. Press down on the brake pedal to activate the rear brake. FUEL COCK The fuel cock supplies fuel from the tank to carburetor and also filters the fuel. The fuel cock has three positions: OFF: With the lever in this position[...]

1 - 13 GEN INFO LIGHTS SWITCH The lights switch 1 is located on the handle- bar. EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose. CAUTION: In this installation, make sure the arrow faces the fuel tank and also downward. SPARK PLUG WRENCH This spark plug wrench 1 is used to remov[...]

1 - 14 GEN INFO FUEL Always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race. CAUTION: Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts such as valves, piston rings, and exhaust system, etc. NOTE: If knocking or pinging occurs, use a different b[...]

1 - 15 GEN INFO STARTING AND BREAK-IN STARTING AND BREAK-IN W ARNING Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Always operate the machine in a well-ventilated area. CAUTION: ● The carburetor on this machine has a built-in accelerator pump. [...]

1 - 16 GEN INFO STARTING AND BREAK-IN NOTE: If the engine fails to start by pushing the start switch, release the switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt. If the engine does not start with the starter[...]

1 - 17 GEN INFO STARTING AND BREAK-IN STARTING A WARM ENGINE Do not operate the cold starter knob and throt- tle. Pull the hot starter lever 1 and start the engine by pushing the start switch or by kick- ing the kickstarter forcefully with a firm stroke. As soon as the engine starts, release the hot starter lever to close the air passage. Restartin[...]

1 - 18 GEN INFO BREAK-IN PROCEDURES 1. Before starting the engine, fill the fuel tank with the fuel. 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the “ ENGINE STOP ” button. Then, restart the engine and check its operation within no more th[...]

GEN INFO 1 - 19 TORQUE-CHECK POINTS TORQUE-CHECK POINTS NOTE: Concerning the tightening torque, refer to “ MAINTENANCE SPECIFICATIONS ” section in the CHAPTER 2. Frame to rear frame Fuel tank to frame Silencer to rear frame Frame to engine Engine bracket to engine Engine bracket to frame Steering shaft to frame Steering shaft to handle crown Ha[...]

1 - 20 GEN INFO CLEANING AND STORAGE EC1B0000 CLEANING AND STORAGE EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good over- all performance, and extend the life of many components. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering. A plastic bag secured wi[...]

1 - 21 GEN INFO CLEANING AND STORAGE 8. Automotive wax may be applied to all painted or chromed surfaces. Avoid com- bination cleaner-waxes, as they may con- tain abrasives. 9. After completing the above, start the engine and allow it to idle for several min- utes. EC1B2001 STORAGE If your machine is to be stored for 60 days or more, some preventiv[...]

SPEC 2 - 1 GENERAL SPECIFICATIONS EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: WR450FR (USA) WR450F (EUROPE) WR450F(R) (CDN, AUS, NZ, ZA) Model code number: 5TJ1 (USA) 5TJ2 (EUROPE) 5TJ4 (CDN, AUS, NZ, ZA) Dimensions: Overall length 2,171 mm (85.5 in) Overall width 827 mm (32.6 in) Overall height 1,303 mm (51.3 in) Seat heigh[...]

SPEC 2 - 2 GENERAL SPECIFICATIONS Oil capacity: Engine oil Periodic oil change 1.0 L (0.88 Imp qt, 1.06 US qt) With oil filter replacement 1.1 L (0.97 Imp qt, 1.16 US qt) Total amount 1.2 L (1.06 Imp qt, 1.27 US qt) Coolant capacity (including all routes): 1.6 L (1.41 Imp qt, 1.69 US qt) Air filter: Wet type element Fuel: Type Premium unleaded gaso[...]

SPEC 2 - 3 GENERAL SPECIFICATIONS Brake: Front brake type Single disc brake Operation Right hand operation Rear brake type Single disc brake Operation Right foot operation Suspension: Front suspension Telescopic fork Rear suspension Swingarm (link type monocross suspension) Shock absorber: Front shock absorber Coil spring/oil damper Rear shock abso[...]

SPEC 2 - 4 MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.05 mm (0.002 in) Cylinder: Bore size 95.00 ~ 95.01 mm (3.7402 ~ 3.7406 in) ---- Out of round limit ---- 0.05 mm (0.002 in) Camshaft: Drive method Chain drive (Left) ---- Camshaft cap inside diameter 22.000 ~ 22.021 mm (0.8661[...]

SPEC 2 - 5 MAINTENANCE SPECIFICATIONS Cam chain: Cam chain type/No. of links 98XRH2010-118M/118 ---- Cam chain adjustment method Automatic ---- Valve, valve seat, valve guide: Valve clearance (cold) IN 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) ---- EX 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in) ---- Valve dimensions: “ A ” head diameter IN 26.9 ~ 27.1 mm (1.[...]

SPEC 2 - 6 MAINTENANCE SPECIFICATIONS Valve spring: Free length IN 37.03 mm (1.46 in) 35.17 mm (1.38 in) EX 37.68 mm (1.48 in) 35.79 mm (1.41 in) Set length (valve closed) IN 27.87 mm (1.10 in) ---- EX 27.38 mm (1.08 in) ---- Compressed force (installed) IN 111.3 ~ 127.9 N at 27.87 mm (11.3 ~ 13.0 kg at 27.87 mm, 24.91 ~ 28.66 lb at 1.10 in) ---- E[...]

SPEC 2 - 7 MAINTENANCE SPECIFICATIONS Piston rings: Top ring: Type Barrel ---- Dimensions (B × T) 1.2 × 3.5 mm (0.05 × 0.14 in) ---- End gap (installed) 0.20 ~ 0.30 mm (0.008 ~ 0.012 in) 0.55 mm (0.022 in) Side clearance (installed) 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in) 0.12 mm (0.005 in) 2nd ring: Type Taper ---- Dimensions (B × T) 1.00 × 3.3[...]

SPEC 2 - 8 MAINTENANCE SPECIFICATIONS Clutch: Friction plate thickness 2.92 ~ 3.08 mm (0.115 ~ 0.121 in) 2.8 mm (0.110 in) Quantity 9 ---- Clutch plate thickness 1.1 ~ 1.3 mm (0.043 ~ 0.051 in) ---- Quantity 8 ---- Warp limit ---- 0.1 mm (0.004 in) Clutch spring free length 48.4 mm (1.91 in) 47.4 mm (1.87 in) Quantity 6 ---- Clutch housing thrust c[...]

SPEC 2 - 9 MAINTENANCE SPECIFICATIONS Lubrication system: Oil filter type Paper type ---- Oil pump type Trochoid type ---- Tip clearance “ A ” 0.12 mm or less (0.0047 in or less) 0.20 mm (0.008 in) Tip clearance “ B ” 0.09 ~ 0.17 mm (0.0035 ~ 0.0067 in) 0.24 mm (0.009 in) Side clearance 0.03 ~ 0.10 mm (0.0012 ~ 0.0039 in) 0.17 mm (0.007 in)[...]

SPEC 2 - 10 MAINTENANCE SPECIFICATIONS Item Standard Lubrication chart: Pressure feed Splashed scavenge Oil strainer Oil pan Oil pump rotor 2 Oil pump rotor 1 Oil tank Oil filter Check ball Cylinder head Crank pin Piston pin Piston Drive axle Main axle Transmission gears Camshaft Valve lifter[...]

SPEC 2 - 11 MAINTENANCE SPECIFICATIONS Part to be tightened Thread size Q ’ ty Tightening torque Nm m · kg ft · lb Spark plug M10S × 1.0 1 13 1.3 9.4 Camshaft cap M6 × 1.0 10 10 1.0 7.2 Cylinder head blind plug screw M12 × 1.0 1 37 3.7 27 Cylinder head (stud bolt) M6 × 1.0 2 7 0.7 5.1 M8 × 1.25 1 15 1.5 11 (bolt) M10 × 1.25 4 Refer to NOT[...]

SPEC 2 - 12 MAINTENANCE SPECIFICATIONS NOTE: - marked portion shall be checked for torque tightening after break-in or before each race. NOTE: *1: Tighten the cylinder head bolts to 30 Nm (3.0 m · kg, 22 ft · lb) in the proper tightening sequence, remove and retighten the cylinder head bolts to 20 Nm (2.0 m · kg, 14 ft · lb) in the proper tight[...]

SPEC 2 - 13 MAINTENANCE SPECIFICATIONS EC212201 CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing ---- Front suspension: USA, CDN EUROPE AUS, NZ, ZA Front fork travel 300 mm (11.8 in) ←← Fork spring free length 460 mm (18.1 in) ←← Spring rate, STD K = 4.51 N/mm (0.46 kg/mm, 25.8 lb/in) K = 4.12 N/mm (0.[...]

SPEC 2 - 14 MAINTENANCE SPECIFICATIONS Wheel: Front wheel type Spoke wheel ---- Rear wheel type Spoke wheel ---- Front rim size/material 21 × 1.60/Aluminum ---- Rear rim size/material 18 × 2.15/Aluminum ---- Rim runout limit: Radial ---- 2.0 mm (0.08 in) Lateral ---- 2.0 mm (0.08 in) Drive chain: Type/manufacturer DID520VM/DAIDO ---- Number of li[...]

SPEC 2 - 15 MAINTENANCE SPECIFICATIONS NOTE: 1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut wrench, then loosen the ring nut one turn. 2. Retighten the ring nut 7 Nm (0.7 m • kg, 5.1 ft • lb). Part to be tightened Thread size Q ’ ty Tightening torque Nm m · kg ft · lb Handle crown and o[...]

SPEC 2 - 16 MAINTENANCE SPECIFICATIONS Part to be tightened Thread size Q ’ ty Tightening torque Nm m · kg ft · lb Rear wheel axle and nut M20 × 1.5 1 125 12.5 90 Driven sprocket and wheel hub M8 × 1.25 6 50 5.0 36 Nipple (spoke) – 72 3 0.3 2.2 Disc cover and rear brake caliper M6 × 1.0 2 7 0.7 5.1 Protector and rear brake caliper M6 × 1.[...]

SPEC 2 - 17 MAINTENANCE SPECIFICATIONS NOTE: - marked portion shall be checked for torque tightening after break-in or before each race. Meter cable holder and protector M5 × 0.8 2 4 0.4 2.9 Headlight stay (lower) and under bracket M8 × 1.25 2 7 0.7 5.1 Headlight body and headlight unit M6 × 1.0 2 7 0.7 5.1 Headlight mounting (left and right) M6[...]

SPEC 2 - 18 MAINTENANCE SPECIFICATIONS EC212300 ELECTRICAL Item Standard Limit Ignition system: Advancer type Electrical ---- C.D.I.: Pickup coil resistance (color) 248 ~ 372 Ω at 20 ˚ C (68 ˚ F) (White – Red) ---- CDI unit-model/manufacturer 5TJ-00/YAMAHA (For USA) 5TJ-10/YAMAHA (Except for USA) ---- ---- Ignition coil: Model/manufacturer 5T[...]

SPEC 2 - 19 MAINTENANCE SPECIFICATIONS NOTE: Tighten the rotor nut to 65 Nm (6.5 m·kg, 47 ft·lb), loosen and retighten the rotor nut to 65 Nm (6.5 m · kg, 47 ft · lb). Starter relay: Model/manufacturer 2768090-A/JIDECO ---- Amperage rating 180 A ---- Coil winding resistance 4.2 ~ 4.6 Ω at 20 ˚ C (68 ˚ F) ---- Starting circuit cut-off relay:[...]

2 - 20 SPEC GENERAL TORQUE SPECIFICATIONS/ DEFINITION OF UNITS EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasten- ers with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sec- tions of this book. To avoid warpage, tighten multi-fastener ass[...]

2 - 21 SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Oil delivery pipe 2 Intake camshaft 3 Exhaust camshaft 4 Oil cleaner element 5 Oil pump 6 Main axle 7 Drive axle 7 6 5 4 3 2 1 4 5 A - A D - D G G D D A A[...]

2 - 22 SPEC LUBRICATION DIAGRAMS 1 Camshaft 2 Connecting rod 3 Oil cleaner element 4 Crankshaft 5 Main axle 6 Drive axle 7 Oil delivery pipe 1 2 3 4 5 6 7[...]

2 - 23 SPEC CABLE ROUTING DIAGRAM EC240000 CABLE ROUTING DIAGRAM 1 Fuel tank breather hose 2 Clamp 3 Diode 4 Wire harness 5 Hot starter cable 6 Negative battery lead 7 Starter motor lead 8 TPS (throttle position sen- sor) lead 9 Neutral switch lead 0 Oil hose A Hose holder B Radiator hose 4 C Cylinder head breather hose D AC magneto lead E Radiator[...]

2 - 24 SPEC CABLE ROUTING DIAGRAM Ï Fasten the wire harness, TPS lead (in the wire harness), starter motor lead and negative battery lead to the frame with a plastic locking tie and cut off the tie end. Ì Make sure that the TPS cou- pler does not go out the chas- sis. Ó Fasten the TPS lead to the frame with a plastic band. È Fasten the neutral [...]

2 - 25 SPEC CABLE ROUTING DIAGRAM 1 Hot starter cable 2 Clutch cable 3 Throttle cable (return) 4 Throttle cable (pull) 5 Ignition coil 6 Negative battery lead 7 Starter motor lead 8 Coolant reservoir tank breather hose 9 Rectifier/regulator 0 Cable holder A Coolant reservoir hose B Rectifier/regulator lead C Clamp D CDI unit lead E CDI unit F CDI u[...]

2 - 26 SPEC CABLE ROUTING DIAGRAM 1 Master cylinder 2 Brake hose holder 3 Brake hose Å Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the caliper. ı Pass the brake hose into the brake hose holders. Ç If the brake hose contacts the spring (rear shock absorber), cor- rect its twist. Î Instal[...]

2 - 27 SPEC CABLE ROUTING DIAGRAM 1 Starter motor lead 2 Negative battery lead 3 Wire harness 4 Clamp 5 Taillight lead 6 Coolant reservoir tank breather hose 7 Coolant reservoir hose 8 Positive battery lead 9 Starting circuit cut-off relay 0 Battery Å Position the starter motor lead, negative battery lead and wire harness in the tank damper slit. [...]

2 - 28 SPEC CABLE ROUTING DIAGRAM 1 Throttle cable 2 Brake hose 3 Clamp 4 Lights switch lead 5 Hot starter cable 6 Clutch cable 7 Hose guide 8 Clutch switch lead 9 “ENGINE STOP” button lead 0 Trip meter cable A Main switch lead B Trip meter C Main switch D Lights switch E Start switch lead Å Fasten the start switch lead and lights switch lead [...]

3 - 1 INSP ADJ MAINTENANCE INTERVALS EC300000 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If[...]

3 - 2 INSP ADJ MAINTENANCE INTERVALS SHIFT FORK, SHIFT CAM, GUIDE BAR Inspect ● Inspect wear ROTOR NUT Retighten ● ● MUFFLER Inspect and retighten Clean Replace ● ● ● ● * Whichever comes first *SPARK ARRESTER Clean (Every six months) ● CRANK Inspect and clean ● ● CARBURETOR Inspect, adjust and clean ● ● SPARK PLUG Inspect an[...]

3 - 3 INSP ADJ MAINTENANCE INTERVALS * marked: For USA FRONT FORKS Inspect and adjust Replace oil Replace oil seal ● ● ● ● ● Suspension oil “ 01 ” FRONT FORK OIL SEAL AND DUST SEAL Clean and lube ● ● Lithium base grease REAR SHOCK ABSORBER Inspect and adjust Lube Retighten ● ● ● ● ● (After rain ride) ● Molybdenum disul[...]

3 - 4 INSP ADJ PRE-OPERATION INSPECTION AND MAINTENANCE EC320000 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. GENERAL INSPECTION AND MAINTENANCE Item Routine Page Coolant Check that coola[...]

3 - 5 INSP ADJ EC350000 ENGINE COOLANT LEVEL INSPECTION W ARNING Do not remove the radiator cap 1 , drain bolt and hoses when the engine and radia- tor are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, place a thick towel over the radiator cap, slowly rotate the cap [...]

3 - 6 INSP ADJ COOLANT REPLACEMENT CAUTION: Take care so that coolant does not splash on painted surfaces. If it splashes, wash it away with water. 1. Place a container under the engine. 2. Remove: ● Seat Refer to “ SEAT, FUEL TANK AND SIDE COVERS ” section in the CHAP- TER 4. 3. Disconnect: ● Coolant reservoir hose 1 Drain the coolant comp[...]

3 - 7 INSP ADJ COOLANT REPLACEMENT 9. Fill: ● Radiator ● Engine To specified level. CAUTION: ● Do not mix more than one type of ethyl- ene glycol antifreeze containing corro- sion inhibitors for aluminum engine. ● Do not use water containing impurities or oil. Recommended coolant: High quality ethylene glycol anti-freeze containing anti-cor[...]

3 - 8 INSP ADJ RADIATOR CAP INSPECTION/ RADIATOR CAP OPENING PRESSURE INSPECTION 12. Install: ● Coolant reservoir cap 13. Start the engine and let it warm up for several minutes. 14. Turn off the engine and inspect the cool- ant level. Refer to “ COOLANT LEVEL INSPEC- TION ” section. NOTE: Before checking the coolant level wait a few minutes [...]

3 - 9 INSP ADJ COOLING SYSTEM INSPECTION 3. Inspect: ● Pressure Impossible to maintain the specified pressure for 10 seconds → Replace. EC357002 COOLING SYSTEM INSPECTION 1. Inspect: ● Coolant level 2. Attach: ● Radiator cap tester 1 and adapter 2 3. Apply the specified pressure. NOTE: ● Do not apply pressure more than specified pressure.[...]

3 - 10 INSP ADJ CLUTCH ADJUSTMENT/ THROTTLE CABLE ADJUSTMENT EC359020 CLUTCH ADJUSTMENT 1. Check: ● Clutch lever free play a Out of specification → Adjust. Clutch lever free play a : 8 ~ 13 mm (0.31 ~ 0.51 in) 2. Adjust: ● Clutch lever free play NOTE: ● Make minute adjustment on the lever side using the adjuster 3 . ● After adjustment, ch[...]

3 - 11 INSP ADJ THROTTLE LUBRICATION/ HOT STARTER LEVER ADJUSTMENT THROTTLE LUBRICATION 1. Remove: ● Cover (throttle cable cap) 1 ● Cover (grip cap) 2 ● Throttle cable cap 3 NOTE: Before adjusting the throttle cable free play, the engine idle speed should be adjusted. W ARNING After adjusting the throttle cable free play, start the engine and[...]

3 - 12 INSP ADJ AIR FILTER CLEANING AIR FILTER CLEANING NOTE: Proper air filter maintenance is the biggest key to preventing premature engine wear and damage. CAUTION: Never run the engine without the air filter element in place; this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage. 1. Remove: ● Air f[...]

3 - 13 INSP ADJ CAUTION: ● Do not twist the element when squeezing the element. ● Leaving too much of solvent in the ele- ment may result in poor starting. 5. Inspect: ● Air filter element Damage → Replace. 6. Apply: ● Foam-air-filter oil or equivalent oil to the element. NOTE: ● Squeeze out the excess oil. Element should be wet but not[...]

3 - 14 INSP ADJ ENGINE OIL LEVEL INSPECTION ENGINE OIL LEVEL INSPECTION 1. Stand the motorcycle on a level surface. NOTE: ● When checking the oil level make sure that the motorcycle is upright. ● Place the motorcycle on a suitable stand. W ARNING Never remove the oil tank cap just after high speed operation. The heated oil could spurt out. caus[...]

3 - 15 INSP ADJ ENGINE OIL LEVEL INSPECTION (For USA and CDN) CAUTION: ● Do not add any chemical additives. Engine oil also lubricates the clutch and additives could cause clutch slippage. ● Do not allow foreign material to enter the crankcase. (Except for USA and CDN) CAUTION: ● Do not add any chemical additives or use oils with a grade of C[...]

3 - 16 INSP ADJ ENGINE OIL REPLACEMENT 6. Idle the engine more than 10 seconds while keeping the motorcycle upright. Then stop the engine and add the oil to the maximum level. 7. Install: ● Oil tank cap ENGINE OIL REPLACEMENT 1. Start the engine and let it warm up for several minutes. 2. Stop the engine and place an oil pan under the drain bolt. [...]

3 - 17 INSP ADJ ENGINE OIL REPLACEMENT 6. If the oil filter is to be replaced during this oil change, remove the following parts and reinstall them. 7. Install: ● Plain washer 1 ● Oil strainer (frame) 2 ● Engine oil hose 3 ● Bolt (engine oil hose) 4 ● Engine oil hose clamp 5 ● Engine skid plate 8. Install: ● Gaskets ● Oil filter dra[...]

3 - 18 INSP ADJ PILOT SCREW ADJUSTMENT 12. Check: ● Oil pressure Checking steps: ● Slightly loosen the oil gallery bolt 1 . ● Start the engine and keep it idling until oil starts to seep from the oil gallery bolt. If no oil comes out after one minute, turn the engine off so it will not seize. ● Check oil passages, oil filter and oil pump fo[...]

3 - 19 INSP ADJ IDLE SPEED ADJUSTMENT/ VALVE CLEARANCE ADJUSTMENT EC35M021 IDLE SPEED ADJUSTMENT 1. Start the engine and thoroughly warm it up. 2. Adjust: ● Idle speed Adjustment steps: ● Adjust the pilot screw. Refer to “ PILOT SCREW ADJUSTMENT ” section. ● Turn the throttle stop screw 1 until the engine runs at the lowest possible speed[...]

3 - 20 INSP ADJ VALVE CLEARANCE ADJUSTMENT 4. Check: ● Valve clearance Out of specification → Adjust. Valve clearance (cold): Intake valve: 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) Exhaust valve: 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in) Checking steps: ● Turn the crankshaft counterclockwise with a wrench. ● Align the T.D.C. mark a on the rotor with t[...]

3 - 21 INSP ADJ VALVE CLEARANCE ADJUSTMENT 5. Adjust: ● Valve clearance Adjustment steps: ● Loosen the timing chain tensioner cap bolt. ● Remove the timing chain tensioner and camshaft caps. NOTE: Remove the camshaft cap bolts in a criss- cross pattern from the outside working inwards. ● Remove the camshaft (exhaust 1 and intake 2 ). NOTE: [...]

3 - 22 INSP ADJ ● Round off the last digit of the installed pad number to the nearest increment. Last digit of pad number Rounded value 0, 1 or 2 0 4, 5 or 6 5 8 or 9 10 EXAMPLE: Installed pad number = 148 Rounded off value = 150 NOTE: Pads can only be selected in 0.05 mm incre- ments. ● Locate the rounded-off value and the measured valve clear[...]

3 - 23 INSP ADJ 6. Install: ● All removed parts NOTE: Install all removed parts in reversed order of their removal. Note the following points. ● Install the timing chain tensioner. Refer to “ CAMSHAFTS ” section in the CHAPTER 4. NOTE: Turn the crankshaft counterclockwise sev- eral turns so that the installed parts settle into the right pos[...]

3 - 24 INSP ADJ VALVE CLEARANCE ADJUSTMENT INTAKE MEASURED CLEARANCE INSTALLED PAD NUMBER 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 ~ 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.05 ~ 0.09 120 125 130 135 140 145 150 155 160 165 170 [...]

3 - 25 INSP ADJ SPARK ARRESTER CLEANING (For USA) W ARNING ● Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. ● Do not start the engine when cleaning the exhaust system. 1. Remove: ● Bolt (spark arrester) 1 1 1 2. Remove: ● Spark arrester 1 Pull the spark arrester out of the muf- fler. 1 3. Clean: ● Spark [...]

3 - 26 INSP ADJ CHASSIS/BRAKE SYSTEM AIR BLEEDING EC360000 CHASSIS EC361012 BRAKE SYSTEM AIR BLEEDING W ARNING Bleed the brake system if: ● The system has been disassembled. ● A brake hose has been loosened or removed. ● The brake fluid is very low. ● The brake operation is faulty. A dangerous loss of braking performance may occur if the br[...]

3 - 27 INSP ADJ FRONT BRAKE ADJUSTMENT 3. Install: ● Protector (rear brake) ● Diaphragm ● Master cylinder cap NOTE: If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disap- peared. j. Add brake fluid to the level line on[...]

3 - 28 INSP ADJ REAR BRAKE ADJUSTMENT/ FRONT BRAKE PAD INSPECTION AND REPLACEMENT EC364002 REAR BRAKE ADJUSTMENT 1. Check: ● Brake pedal height a Out of specification → Adjust. Brake pedal height a : 5 mm (0.20 in) 2. Adjust: ● Brake pedal height Pedal height adjustment steps: ● Loosen the locknut 1 . ● Turn the adjusting nut 2 until the [...]

3 - 29 INSP ADJ FRONT BRAKE PAD INSPECTION AND REPLACEMENT ● Loosen the pad pin 2 . ● Remove the brake hose holder 3 and cal- iper 4 from the front fork. ● Remove the pad pin and brake pads 5 . ● Connect the transparent hose 6 to the bleed screw 7 and place the suitable con- tainer under its end. ● Loosen the bleed screw and push the cali[...]

3 - 30 INSP ADJ REAR BRAKE PAD INSPECTION AND REPLACEMENT 3. Inspect: ● Brake fluid level Refer to “ BRAKE FLUID LEVEL INSPECTION ” section. 4. Check: ● Brake lever operation A softy or spongy feeling → Bleed brake system. Refer to “ BRAKE SYSTEM AIR BLEEDING ” section. ● Install the pad pin plug B . T R . . Pad pin plug: 3 Nm (0.3 [...]

3 - 31 INSP ADJ REAR BRAKE PAD INSPECTION AND REPLACEMENT ● Remove the pad pin 6 and brake pads 7 . ● Connect the transparent hose 8 to the bleed screw 9 and place the suitable con- tainer under its end. ● Loosen the bleed screw and push the cali- per piston in. CAUTION: Do not reuse the drained brake fluid. ● Tighten the bleed screw. T R .[...]

3 - 32 INSP ADJ REAR BRAKE PAD INSULATOR INSPECTION/ BRAKE FLUID LEVEL INSPECTION 3. Inspect: ● Brake fluid level Refer to “ BRAKE FLUID LEVEL INSPECTION ” section. 4. Check: ● Brake pedal operation A softy or spongy feeling → Bleed brake system. Refer to “ BRAKE SYSTEM AIR BLEEDING ” section. EC36b000 REAR BRAKE PAD INSULATOR INSPECT[...]

3 - 33 INSP ADJ SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION EC368000 SPROCKETS INSPECTION 1. Inspect: ● Sprocket teeth a Excessive wear → Replace. NOTE: Replace the drive, driven sprockets and drive chain as a set. DRIVE CHAIN INSPECTION 1. Remove: ● Drive chain 1 NOTE: Remove the drive chain using a chain cutter 2 . 2. Clean: ● Drive chain[...]

3 - 34 INSP ADJ DRIVE CHAIN INSPECTION 5. Check: ● Drive chain stiffness a Clean and oil the chain and hold as illustrated. Stiff → Replace the drive chain. 6. Install: ● Joint 1 ● O-ring 2 ● Drive chain 3 NOTE: When installing the drive chain, apply the lith- ium soap base grease on the joint and O-rings. 7. Install: ● Link plate 4 NOT[...]

3 - 35 INSP ADJ DRIVE CHAIN SLACK ADJUSTMENT DRIVE CHAIN SLACK ADJUSTMENT 1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Check: ● Drive chain slack a Above the seal guard installation bolt. Out of specification → Adjust. NOTE: Before checking and/or adjusting, rotate the rear wheel through several revolutions and c[...]

3 - 36 INSP ADJ FRONT FORK INSPECTION/ FRONT FORK OIL SEAL AND DUST SEAL CLEANING ● Tighten the axle nut while pushing down the drive chain. T R . . Axle nut: 125 Nm (12.5 m • kg, 90 ft • lb) ● Tighten the locknuts. T R . . Locknut: 16 Nm (1.6 m • kg, 11 ft • lb) EC36C000 FRONT FORK INSPECTION 1. Inspect: ● Front fork smooth action Op[...]

3 - 37 INSP ADJ FRONT FORK INTERNAL PRESSURE RELIEVING/ FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT FRONT FORK INTERNAL PRESSURE RELIEVING NOTE: If the front fork initial movement feels stiff dur- ing a run, relieve the front fork internal pres- sure. 1. Elevate the front wheel by placing a suit- able stand under the engine. 2. Remove the air bleed[...]

3 - 38 INSP ADJ FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT ● STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position. * For EUROPE, AUS, NZ and ZA CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. W ARNING Always[...]

3 - 39 INSP ADJ REAR SHOCK ABSORBER INSPECTION ● STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position. CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. W ARNING Always adjust each front fork to the same setting. U[...]

3 - 40 INSP ADJ REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Remove: ● Rear frame 3. Loosen: ● Locknut 1 4. Adjust: ● Spring preload By turning the adjuster 2 . * For EUROPE, AUS, NZ and ZA NOTE: ● Be sure to remove al[...]

3 - 41 INSP ADJ EC36N014 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1. Adjust: ● Rebound damping force By turning the adjuster 1 . Stiffer a → Increase the rebound damp- ing force. (Turn the adjuster 1 in.) Softer b → Decrease the rebound damp- ing force. (Turn the adjuster 1 out.) Extent of adjustment: Maximum Minimum Fully turned [...]

3 - 42 INSP ADJ REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT EC36c000 REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: ● Low compression damping force By turning the adjuster 1 . Stiffer a → Increase the low compres- sion damping force. (Turn the adjuster 1 in.) Softer b → Decrease the low compres- sion [...]

3 - 43 INSP ADJ EC36d000 REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: ● High compression damping force By turning the adjuster 1 . Stiffer a → Increase the high compres- sion damping force. (Turn the adjuster 1 in.) Softer b → Decrease the high compres- sion damping force. (Turn the adjuster 1 out.) Extent of adjus[...]

3 - 44 INSP ADJ TIRE PRESSURE CHECK/SPOKES INSPECTION AND TIGHTENING/WHEEL INSPECTION EC36Q000 TIRE PRESSURE CHECK 1. Measure: ● Tire pressure Out of specification → Adjust. NOTE: ● Check the tire while it is cold. ● Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low. ● A tilted tire valve[...]

3 - 45 INSP ADJ STEERING HEAD INSPECTION AND ADJUSTMENT 2. Inspect: ● Bearing free play Exist play → Replace. STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suit- able stand under the engine. 2. Check: ● Steering shaft Grasp the bottom of the forks and gen- tly rock the fork assembly back and forth. Free play [...]

3 - 46 INSP ADJ STEERING HEAD INSPECTION AND ADJUSTMENT ● Tighten the ring nut 3 using ring nut wrench 4 . NOTE: Set the torque wrench to the ring nut wrench so that they form a right angle. Ring nut wrench: YU-33975/90890-01403 T R . . Ring nut (initial tightening): 38 Nm (3.8 m • kg, 27 ft • lb) ● Loosen the ring nut one turn. ● Retight[...]

3 - 47 INSP ADJ LUBRICATION LUBRICATION To ensure smooth operation of all compo- nents, lubricate your machine during setup, after break-in, and after every race. 1 All control cable 2 Clutch lever pivot 3 Shift pedal pivot 4 Footrest pivot 5 Throttle-to-handlebar contact 6 Drive chain 7 Tube guide cable winding portion 8 Throttle cable end 9 Clutc[...]

3 - 48 INSP ADJ ELECTRICAL/SPARK PLUG INSPECTION EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: ● Spark plug 2. Inspect: ● Electrode 1 Wear/damage → Replace. ● Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition. NOTE: When the engine runs for many hours[...]

3 - 49 INSP ADJ IGNITION TIMING CHECK IGNITION TIMING CHECK 1. Remove: ● Timing plug 1 1 2. Attach: ● Timing light ● Inductive tachometer To the ignition coil lead (orange lead 1 ). 3. Check: ● Ignition timing Timing light: YM-33277-A/90890-03141 Inductive tachometer: YU-8036-B Engine tachometer: 90890-03113 Checking steps: ● Start the en[...]

3 - 50 INSP ADJ BATTERY INSPECTION AND CHARGING W ARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: ● Wear protective eye gear when handling or working near batteries. ● Charge batteries in a well-ventilated ar[...]

3 - 51 INSP ADJ BATTERY INSPECTION AND CHARGING NOTE: Since MF batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: ● Seat 2. Disconnect: ● Ba[...]

3 - 52 INSP ADJ BATTERY INSPECTION AND CHARGING Å Relationship between the open-circuit voltage and the charging time at 20 ˚ C (68 ˚ F) (These values vary with the temperature, the condition of the battery plates, and the electro- lyte level.) ı Open-circuit voltage Ç Charging time (hours) Î Time (minutes) ‰ Charging condition of the batte[...]

3 - 53 INSP ADJ BATTERY INSPECTION AND CHARGING ● Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger. ● Make sure the battery charger lead clips are in full contact with the battery termi- nal and that they are not shorted. A cor- roded battery charger lead clip may generate heat i[...]

3 - 54 INSP ADJ BATTERY INSPECTION AND CHARGING Charging method using a variable voltage charger[...]

3 - 55 INSP ADJ BATTERY INSPECTION AND CHARGING Charging method using a constant voltage charger[...]

3 - 56 INSP ADJ FUSE INSPECTION 6. Install: ● Battery ● Battery band 7. Connect: ● Battery leads (to the battery terminals) CAUTION: First, connect the positive lead 1 , then the negative lead 2 . 8. Check: ● Battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. 9. Lubricate: ● Battery terminal 10. Ins[...]

3 - 57 INSP ADJ REPLACING THE HEADLIGHT BULBS 3. Replace: ● Blown fuse W ARNING Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive damage to the electrical system, cause the starting and ignition systems to malfunction and could possibly cause a fire[...]

3 - 58 INSP ADJ ADJUSTING THE HEADLIGHT BEAMS 5. Install: ● Headlight bulb Secure the new headlight bulb with the headlight bulb holder. CAUTION: Avoid touching the glass part of the head- light bulb to keep it free form oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the hea[...]

4 - 1 ENG EC400000 ENGINE EC4R0000 SEAT, FUEL TANK AND SIDE COVERS Extent of removal: 1 Seat removal 2 Fuel tank removal 3 Side covers removal 4 Headlight removal Extent of removal Order Part name Q’ty Remarks Preparation for removal SEAT, FUEL TANK AND SIDE COVERS REMOVAL Turn the fuel cock to “ OFF ” . Disconnect the fuel hose. 1 Seat 1 2 A[...]

4 - 2 ENG REMOVAL POINTS Side cover 1. Remove: ● Bolt (side cover) ● Side cover (left) 1 ● Side cover (right) 2 NOTE: Draw the side cover downward to remove it because its claws a are inserted in the air fil- ter case. SEAT, FUEL TANK AND SIDE COVERS 4[...]

4 - 3 ENG EXHAUST PIPE AND SILENCER EC4S0000 EXHAUST PIPE AND SILENCER Å For USA ı Except for USA Extent of removal: 1 Silencer removal 2 Exhaust pipe removal Extent of removal Order Part name Q ’ ty Remarks EXHAUST PIPE AND SILENCER REMOVAL Preparation for removal Side cover (right) Refer to “ SEAT, FUEL TANK AND SIDE COVERS ” section. 1 B[...]

4 - 4 ENG EXHAUST PIPE AND SILENCER INSPECTION Exhaust pipe and silencer 1. Inspect: ● Gasket 1 Damage → Replace. 1 ASSEMBLY AND INSTALLATION Exhaust pipe and silencer 1. Install: ● Gasket ● Exhaust pipe 1 ● Nut (exhaust pipe) 2 ● Bolt (exhaust pipe) 3 NOTE: First, temporarily tighten the nut (exhaust pipe), then tighten the bolt (exhau[...]

4 - 5 ENG RADIATOR EC450001 RADIATOR Extent of removal: 1 Radiator removal 2 Coolant reservoir removal Extent of removal Order Part name Q ’ ty Remarks RADIATOR REMOVAL Preparation for removal Drain the coolant. Refer to “ COOLANT REPLACEMENT ” section in the CHAPTER 3. Seat, fuel tank and side cover Refer to “ SEAT, FUEL TANK AND SIDE COVE[...]

4 - 6 ENG RADIATOR EC456000 HANDLING NOTE W ARNING Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radi- ator cap by the following procedure: Place a thick rag, like a towel, over the radi- ator c[...]

4 - 7 ENG RADIATOR 3. Install: ● Radiator breather hose 1 ● Radiator (right) 2 Refer to “ CABLE ROUTING DIA- GRAM ” section in the CHAPTER 2. T R . . 10 Nm (1.0 m · kg, 7.2 ft · lb) 4. Install: ● Panel 1 ● Bolt (radiator panel upper) 2 NOTE: Fit the hook a on the inner side first into the radiator. T R . . 10 Nm (1.0 m · kg, 7.2 ft ?[...]

4 - 8 ENG CARBURETOR CARBURETOR 7 4 10 8 9 T R . . 2 Nm (0.2 m • kg, 1.4 ft • Ib) 2 3 7 5 5 T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) T R . . 3 Nm (0.3 m • kg, 2.2 ft • Ib) 6 T R . . 3 Nm (0.3 m • kg, 2.2 ft • Ib) 1 T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) T R . . 11 Nm (1.1 m • kg, 8.0 ft • Ib) Extent of removal: 1 Carburetor re[...]

4 - 9 ENG CARBURETOR CARBURETOR DISASSEMBLY Extent of removal: 1 Carburetor disassembly Extent of removal Order Part name Q ’ ty Remarks CARBURETOR DISASSEMBLY 1 Breather hose 4 2 Valve lever housing cover 1 3 Screw (throttle shaft) 1 4 Throttle valve 1 5 Needle holder 1 6 Jet needle 1 7 Cover 1 8 Spring 1 9 Diaphragm (accelerator pump) 1 0 Air c[...]

4 - 10 ENG CARBURETOR Extent of removal Order Part name Q ’ ty Remarks H Needle valve 1 I Main jet 1 J Needle jet 1 K Spacer 1 L Pilot jet 1 M Starter jet 1 N Push rod 1 Pull the push rod. O Throttle shaft assembly 1 P Push rod link lever assembly 1 Q Pilot air jet 1 R Cold starter plunger 1 1[...]

4 - 11 ENG CARBURETOR EC466020 HANDLING NOTE CAUTION: Do not loosen the screws {TPS (throttle position sensor)} 1 except when changing the TPS (throttle position sensor) due to failure because it will cause a drop in engine performance. 1 REMOVAL POINTS Pilot screw 1. Remove: ● Pilot screw 1 NOTE: To optimize the fuel flow at a small throttle ope[...]

4 - 12 ENG CARBURETOR Needle valve 1. Inspect: ● Needle valve 1 ● Valve seat 2 Grooved wear a → Replace. Dust b → Clean. EC464300 Throttle valve 1. Check: ● Free movement Stick → Repair or replace. Insert the throttle valve 1 into the car- buretor body, and check for free move- ment. EC464400 Jet needle 1. Inspect: ● Jet needle 1 Bend[...]

4 - 13 ENG CARBURETOR Measurement and adjustment steps: ● Hold the carburetor in an upside down position. NOTE: ● Slowly tilt the carburetor in the opposite direction, then take the measurement when the needle valve aligns with the float arm. ● If the carburetor is level, the weight of the float will push in the needle valve, result- ing in a[...]

4 - 14 ENG Accelerator pump 1. Inspect: ● Diaphragm (accelerator pump) 1 ● Spring 2 ● Cover 3 ● O-ring 4 ● Push rod 5 Tears (diaphragm)/damage → Replace. Dirt → Clean. 2. Inspect: ● Throttle shaft 1 ● Spring 2 ● Lever 1 3 ● Spring 1 4 ● Lever 2 5 ● Spring 2 6 Dirt → Clean. 1 2 3 4 5 6 Air cut valve 1. Inspect: ● Diaphr[...]

4 - 15 ENG CARBURETOR 3. Install: ● Spring 1 1 ● Lever 1 2 To lever 2 3 . NOTE: Make sure the spring 1 fits on the stopper a of the lever 2. a 3 1 2 4. Install: ● Spring 2 1 To lever 2 2 . 1 2 5. Install: ● Push rod link lever assembly 1 NOTE: Make sure the stopper a of the spring 2 fits into the recess b in the carburetor. 1 a b 6. Install[...]

4 - 16 ENG CARBURETOR 8. Install: ● Throttle shaft assembly 1 ● Plain washer (metal) 2 ● Plain washer (resin) 3 ● Valve lever 4 NOTE: ● Apply the fluorochemical grease on the bear- ings. ● Fit the projection a on the throttle shaft assembly into the slot b in the TPS (throttle position sensor). ● Make sure the stopper c of the spring [...]

4 - 17 ENG CARBURETOR 11. Install: ● Needle valve 1 ● Float 2 ● Float pin 3 NOTE: ● After installing the needle valve to the float, install them to the carburetor. ● Check the float for smooth movement. 12. Install: ● Pilot screw 1 ● Spring 2 ● Washer 3 ● O-ring 4 * Except for USA Note the following installation points: ● Turn i[...]

4 - 18 ENG CARBURETOR 15. Install: ● Diaphragm (accelerator pump) 1 ● Spring 2 ● O-ring 3 ● Cover 4 ● Hose holder (drain hose) 5 ● Screw (cover) 6 NOTE: Install the diaphragm (accelerator pump) with its mark a facing the spring. 16. Install: ● Jet needle 1 ● Collar 2 ● Spring 3 ● Needle holder 4 ● Throttle valve plate 5 To thr[...]

4 - 19 ENG CARBURETOR Accelerator pump timing adjustment Adjustment steps: NOTE: In order for the throttle valve height a to achieve the specified value, tuck under the throttle valve plate 1 the rod 2 etc. with the same outer diameter as the specified value. Throttle v alve height: 3.1 mm (0.122 in) ● Fully turn in the accelerator pump adjust- i[...]

4 - 20 ENG 4. Tighten: ● Screw (air cleaner joint) 1 ● Screw (carburetor joint) 2 T R . . 3 Nm (0.3 m · kg, 2.2 ft · lb) T R . . 3 Nm (0.3 m · kg, 2.2 ft · lb) 5. Install: ● Throttle cable (pull) 1 ● Throttle cable (return) 2 6. Adjust: ● Throttle grip free play Refer to “ THROTTLE CABLE ADJUST- MENT ” section in the CHAPTER 3. 2 [...]

4 - 21 ENG CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVER Extent of removal: 1 Cylinder head cover removal Extent of removal Order Part name Q’ty Remarks CYLINDER HEAD COVER REMOVAL Preparation for removal Seat and fuel tank Refer to “ SEAT, FUEL TANK AND SIDE COVERS ” section. Carburetor Refer to “ CARBURETOR ” section. 1 Spark plug 1 2 Engine [...]

4 - 22 ENG CAMSHAFTS CAMSHAFTS Extent of removal: 1 Camshaft removal Extent of removal Order Part name Q ’ ty Remarks CAMSHAFTS REMOVAL 1 Timing plug 1 Refer to “ REMOVAL POINTS ” . 2 Straight plug 1 3 Tensioner cap bolt 1 4 Timing chain tensioner 1 5 Gasket 1 6 Bolt (camshaft cap) 10 7 Camshaft cap 2 8 Clip 2 9 Exhaust camshaft 1 10 Intake c[...]

4 - 23 ENG CAMSHAFTS REMOVAL POINTS Camshaft 1. Remove: ● Timing plug 1 ● Straight plug 2 2. Align: ● “ I ” mark With stationary pointer. Checking steps: ● Turn the crankshaft counterclockwise with a wrench. ● Align the “ I ” mark a on the rotor with the stationary pointer b on the crankcase cover. When the “ I ” mark is align[...]

4 - 24 ENG CAMSHAFTS 6. Remove: ● Clips ● Exhaust camshaft 1 ● Intake camshaft 2 NOTE: Attach a wire 3 to the timing chain to prevent it from falling into the crankcase. 1 2 3 INSPECTION Camshaft 1. Inspect: ● Cam lobes Pitting/scratches/blue discoloration → Replace. 2. Measure: ● Cam lobes length a and b Out of specification → Replac[...]

4 - 25 ENG CAMSHAFTS 4. Measure: ● Camshaft-to-cap clearance Out of specification → Measure cam- shaft journal diameter. Camshaft-to-cap clearance: 0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) <Limit>: 0.08 mm (0.003 in) Measurement steps: ● Install the camshaft onto the cylinder head. ● Position a strip of Plastigauge ® 1 onto the camshaft[...]

4 - 26 ENG CAMSHAFTS Decompression system 1. Check: ● Decompression system Checking steps: ● Check that the decompressor cam 1 moves smoothly. ● Check that the decompressor lever pin 2 projects from the camshaft. Timing chain tensioner 1. Check: ● While pressing the tensioner rod lightly with fingers, use a thin screwdriver 1 and wind the t[...]

4 - 27 ENG CAMSHAFTS ● Fit the timing chain 3 onto both camshaft sprockets and install the camshafts on the cylinder head. NOTE: The camshafts should be installed onto the cylinder head so that the exhaust cam sprocket punch mark c and the intake cam sprocket punch mark d align with the sur- face of the cylinder head. CAUTION: Do not turn the cra[...]

4 - 28 ENG ● With the rod fully wound and the chain tensioner UP mark a facing upward, install the gasket 1 and the chain ten- sioner 2 , and tighten the bolt 3 to the specified torque. T R . . Bolt (timing chain tensioner): 10 Nm (1.0 m • kg, 7.2 ft • lb) ● Release the screwdriver, check the ten- sioner rod to come out and tighten the gask[...]

4 - 29 ENG CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD Extent of removal: 1 Cylinder head removal NOTE: Tighten the cylinder head bolts to 30 Nm (3.0 m · kg, 22 ft · lb) in the proper tightening sequence, remove and retighten the cylinder head bolts to 20 Nm (2.0 m · kg, 14 ft · lb) in the proper tightening sequence, and then tighten the cylinder[...]

4 - 30 ENG CYLINDER HEAD INSPECTION Cylinder head 1. Eliminate: ● Carbon deposits (from the combustion chambers) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid dam- aging or scratching: ● Spark plug threads ● Valve seats 2. Inspect: ● Cylinder head Scratches/damage → Replace. 3. Measure: ● Cylinder head warpage Out [...]

4 - 31 ENG CYLINDER HEAD ASSEMBLY AND INSTALLATION 1. Install: ● Timing chain guide (front) 1 ● Dowel pin 2 ● Cylinder head gasket 3 ● Cylinder head 4 NOTE: While pulling up the timing chain, install the timing chain guide (front) and cylinder head. New 2. Install: ● Plain washer 1 ● Bolt [L=160 mm (6.30 in)] 2 ● Bolt [L=150 mm (5.91 [...]

4 - 32 ENG ● Remove the bolts. ● Again apply the molybdenum disulfide grease on the threads and contact sur- faces of the bolts and on both contact sur- faces of the plain washers. ● Retighten the bolts. NOTE: Tighten the bolts to the specified torque in two or three steps in the proper tightening sequence as shown. T R . . Bolts (cylinder he[...]

4 - 33 ENG VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Extent of removal: 1 Valve removal Extent of removal Order Part name Q ’ ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to “ CYLINDER HEAD ” section. 1 Valve lifter 5 Use special tool. Refer to “ REMOVAL POINTS ” [...]

4 - 34 ENG VALVES AND VALVE SPRINGS REMOVAL POINTS 1. Remove: ● Valve lifters 1 ● Pads 2 NOTE: Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place. 2. Check: ● Valve sealing Leakage at the valve seat → Inspect the valve face, valve seat and valve seat width. Checking steps: ● Po[...]

4 - 35 ENG VALVES AND VALVE SPRINGS INSPECTION Valve 1. Measure: ● Stem-to-guide clearance Out of specification → Replace the valve guide. Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b Clearance (stem to guide): Intake: 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) <Limit>: 0.08 mm (0.003 in) Exhaust: 0.020 ~ 0[...]

4 - 36 ENG VALVES AND VALVE SPRINGS V alve guide remover: Intake: 4.5 mm (0.18 in) YM-4116/90890-04116 Exhaust: 5.0 mm (0.20 in) YM-4097/90890-04097 V alve guide installer: Intake: YM-4117/90890-04117 Exhaust: YM-4098/90890-04098 V alve guide reamer: Intake: 4.5 mm (0.18 in) YM-4118/90890-04118 Exhaust: 5.0 mm (0.20 in) YM-4099 /90890-04099 NOTE: A[...]

4 - 37 ENG VALVES AND VALVE SPRINGS 5. Measure: ● Runout (valve stem) Out of specification → Replace. NOTE: ● When installing a new valve always replace the guide. ● If the valve is removed or replaced always replace the oil seal. 6. Eliminate: ● Carbon deposits (from the valve face and valve seat) 7. Inspect: ● Valve seats Pitting/wear[...]

4 - 38 ENG VALVES AND VALVE SPRINGS 9. Lap: ● Valve face ● Valve seat NOTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. Lapping steps: ● Apply a coarse lapping compound to the valve face. CAUTION: Do not let the compound enter the gap between the valve stem and the guid[...]

4 - 39 ENG VALVES AND VALVE SPRINGS Valve spring 1. Measure: ● Valve spring free length a Out of specification → Replace. 2. Measure: ● Compressed spring force a Out of specification → Replace. b Installed length Free length (valve spring): Intake: 37.03 mm (1.46 in) <Limit>: 35.17 mm (1.38 in) Exhaust: 37.68 mm (1.48 in) <Limit>[...]

4 - 40 ENG VALVES AND VALVE SPRINGS Combination of cylinder head and valve lifter 1. Combination: For this combination, match the paint color on the cylinder head with that on the valve lifter according to the chart below. NOTE: When you purchase a cylinder head, you can- not designate its size. Choose the valve lifter that matches the above chart.[...]

4 - 41 ENG VALVES AND VALVE SPRINGS 3. Install: ● Valve cotters NOTE: While compressing the valve spring with a valve spring compressor 1 install the valve cotters. 4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood. CAUTION: Hitting the valve tip with excessive force could damage the valve. V alve [...]

4 - 42 ENG CYLINDER AND PISTON CYLINDER AND PISTON CYLINDER AND PISTON Extent of removal: 1 Cylinder removal 2 Piston removal Extent of removal Order Part name Q’ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to “ CYLINDER HEAD ” section. 1 Bolt (cylinder) 1 2 Cylinder 1 3 Gasket 1 4 Dowel pin 2 5 Dowel pin[...]

4 - 43 ENG CYLINDER AND PISTON REMOVAL POINTS Piston 1. Remove: ● Piston pin clips 1 ● Piston pin 2 ● Piston 3 NOTE: ● Put identification marks on each piston head for reference during reinstallation. ● Before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is sti[...]

4 - 44 ENG CYLINDER AND PISTON Cylinder bore “C” 95.00 ~ 95.01 mm (3.7402 ~ 3.7406 in) Taper limit “T” 0.05 mm (0.002 in) Out of round “R” 0.05 mm (0.002 in) “C” = Maximum D “T” = (Maximum D 1 or D 2 ) – (Maximum D 5 or D 6 ) “R” = (Maximum D 1 , D 3 or D 5 ) – (Minimum D 2 , D 4 or D 6 ) ● If out of specification, rep[...]

4 - 45 ENG CYLINDER AND PISTON Piston ring 1. Measure: ● Ring side clearance Use a feeler gauge 1 . Out of specification → Replace the pis- ton and rings as a set. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance. 2. Position: ● Piston ring (in cylinder) NOTE: Insert a ring into the cylinder and pu[...]

4 - 46 ENG CYLINDER AND PISTON Piston pin 1. Inspect: ● Piston pin Blue discoloration/grooves → Replace, then inspect the lubrication system. 2. Measure: ● Piston pin-to-piston clearance ASSEMBLY AND INSTALLATION Piston 1. Install: ● Piston rings Onto the piston. NOTE: ● Be sure to install the piston rings so that the manufacturer ’ s m[...]

4 - 47 ENG CYLINDER AND PISTON 2. Position: ● Top ring ● 2nd ring ● Oil ring Offset the piston ring end gaps as shown. a Top ring end b 2nd ring end c Oil ring end (upper) d Oil ring e Oil ring end (lower) 3. Install: ● Piston 1 ● Piston pin 2 ● Piston pin clips 3 NOTE: ● Apply engine oil onto the piston pin and pis- ton. ● Be sure [...]

4 - 48 ENG CLUTCH CLUTCH CLUTCH Extent of removal: 1 Push rod and push lever removal 2 Push pod 1 disassembly 3 Friction plate and clutch plate removal 4 Clutch housing removal Extent of removal Order Part name Q ’ ty Remarks CLUTCH REMOVAL Preparation for removal Drain the engine oil. Refer to “ ENGINE OIL REPLACEMENT ” section in the CHAPTE[...]

4 - 49 ENG CLUTCH Extent of removal Order Part name Q ’ ty Remarks 12 Clutch plate 8 13 Friction plate 9 14 Nut 1 Use special tool. Refer to “ REMOVAL POINTS ” . 15 Look washer 1 16 Clutch boss 1 17 Thrust washer 1 18 Clutch housing 1 19 Push lever 1 4 1 3[...]

4 - 50 ENG CLUTCH EC493000 REMOVAL POINTS EC483211 Clutch boss 1. Remove: ● Nut 1 ● Lock washer 2 ● Clutch boss 3 NOTE: Straighten the lock washer tab and use the clutch holding tool 4 to hold the clutch boss. Å For USA and CDN ı Except for USA and CDN Clutch holding tool: YM-91042/90890-04086 Å ı EC494000 INSPECTION EC484100 Clutch housi[...]

4 - 51 ENG CLUTCH EC484500 Friction plate 1. Measure: ● Friction plate thickness Out of specification → Replace friction plate as a set. Measure at all four points. EC484600 Clutch plate 1. Measure: ● Clutch plate warpage Out of specification → Replace clutch plate as a set. Use a surface plate 1 and thickness gauge 2 . Friction plate thick[...]

4 - 52 ENG CLUTCH EC4A5000 ASSEMBLY AND INSTALLATION Push lever 1. Install: ● Push lever 1 ● Bolt (push lever) NOTE: ● Apply the lithium soap base grease on the oil seal lip. ● Apply the engine oil on the push lever. ● Fit the seat plate 2 in the groove a of the push lever and tighten the bolt (seat plate). 2 1 a T R . . 10 Nm (1.0 m · k[...]

4 - 53 ENG CLUTCH 3. Bend the lock washer 1 tab. 4. Install: ● Friction plate 1 ● Clutch plate 2 NOTE: ● Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate. ● Apply the engine oil on the friction plates and clutch plates. 5. Install: ● Bearing 1 ●[...]

4 - 54 ENG CLUTCH 8. Install: ● Clutch spring ● Bolt (clutch spring) NOTE: Tighten the bolts in stage, using a crisscross pattern. T R . . 8 Nm (0.8 m · kg, 5.8 ft · lb) 9. Install: ● Gasket (clutch cover) 1 ● Dowel pin 2 New 10. Install: ● Clutch cover 1 ● Bolt (clutch cover) NOTE: Tighten the bolts in stage, using a crisscross patte[...]

4 - 55 ENG OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) Extent of removal: 1 Oil filter removal 2 Water pump removal 3 Crankcase cover (right) removal Extent of removal Order Part name Q ’ ty Remarks OIL FILTER, WATER PUMP AND CRANKCASE COV[...]

4 - 56 ENG OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) Extent of removal Order Part name Q ’ ty Remarks 7 Oil hose 1 8 Kickstarter 1 9 Crankcase cover (right) 1 10 Gasket 1 11 Dowel pin/O-ring 4/2 12 Impeller 1 Refer to “ REMOVAL POINTS ” . 13 Plain washer 1 14 Impeller shaft 1 15 Oil seal 1 1 16 Oil seal 2 1 17 Bearing 1 2 3 2[...]

4 - 57 ENG OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) REMOVAL POINTS EC4G3110 Impeller shaft 1. Remove: ● Impeller 1 ● Plain washer 2 ● Impeller shaft 3 NOTE: Hold the impeller shaft on its width across the flats a with spanners, etc. and remove the impeller. EC4G3210 Oil seal NOTE: It is not necessary to disassemble the water pump, u[...]

4 - 58 ENG OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) EC4H4600 Bearing 1. Inspect: ● Bearing Rotate inner race with a finger. Rough spot/seizure → Replace. EC444400 Oil seal 1. Inspect: ● Oil seal Wear/damage → Replace. ASSEMBLY AND INSTALLATION EC4G5110 Oil seal 1. Install: ● Oil seal 1 NOTE: ● Apply the lithium soap base greas[...]

4 - 59 ENG OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) EC4G5220 Impeller shaft 1. Install: ● Impeller shaft 1 ● Plain washer 2 ● Impeller 3 NOTE: ● Take care so that the oil seal lip is not dam- aged or the spring does not slip off its posi- tion. ● When installing the impeller shaft, apply the engine oil on the oil seal lip, beari[...]

4 - 60 ENG OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) Kick crank 1. Install: ● Kickstarter 1 ● Plain washer ● Bolt (kickstarter) NOTE: Install the kickstarter so that the distance a between the kickstarter and the fuel tank is 12 mm (0.47 in) or more. T R . . 33 Nm (3.3 m · kg, 24 ft · lb) 2. Install: ● Oil hose 1 ● Bolt (oil ho[...]

4 - 61 ENG OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) 2. Install: ● Water pump housing 1 ● Bolt (water pump housing) 2 ● Plain washer 3 ● Coolant drain bolt 4 T R . . 10 Nm (1.0 m · kg, 7.2 ft · lb) New T R . . 10 Nm (1.0 m · kg, 7.2 ft · lb) 3. Install: ● O-ring ● Coolant pipe 1 ● Bolt (coolant pipe) 2 T R . . 10 Nm (1.0 [...]

4 - 62 ENG BALANCER BALANCER BALANCER Extent of removal: 1 Balancer drive gear 2 Balancer Extent of removal Order Part name Q’ty Remarks BALANCER REMOVAL Preparation for removal Clutch housing Refer to “ CLUTCH ” section. Crankcase cover (right) Refer to “ OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) ” section. Stator Refer to “ A[...]

4 - 63 ENG BALANCER REMOVAL POINTS Balancer drive gear and balancer driven gear 1. Straighten the lock washer tab. 2. Loosen: ● Nut (primary drive gear) 1 ● Nut (balancer) 2 NOTE: Place an aluminum plate a between the teeth of the balancer drive gear 3 and driven gear 4 . Balancer 1. Remove: ● Balancer 1 NOTE: When removing the balancer shaft[...]

4 - 64 ENG BALANCER ASSEMBLY AND INSTALLATION Balancer, balancer drive gear and balancer driven gear 1. Install: ● Balancer 1 NOTE: When installing the balancer shaft, align the center of the balancer shaft weight a along the line connecting the centers of the crank- shaft and balancer shaft. 2. Install: ● Balancer driven gear 1 NOTE: Install t[...]

4 - 65 ENG OIL PUMP OIL PUMP OIL PUMP Extent of removal: 1 Oil pump removal 2 Oil pump disassembly Extent of removal Order Part name Q ’ ty Remarks OIL PUMP REMOVAL AND DIS- ASSEMBLY Preparation for removal Clutch housing Refer to “ CLUTCH ” section. Crankcase cover (right) Refer to “ OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) ” s[...]

4 - 66 ENG OIL PUMP Extent of removal Order Part name Q ’ ty Remarks 13 Pin 1 14 Washer 1 15 Oil pump drive shaft 1 16 Rotor housing 1 2[...]

4 - 67 ENG OIL PUMP INSPECTION Oil pump 1. Inspect: ● Oil pump drive gear ● Oil pump driven gear ● Rotor housing ● Oil pump cover Cracks/wear/damage → Replace. 2. Measure: ● Tip clearance a Between the inner rotor 1 and the outer rotor 2 . ● Tip clearance b Between the outer rotor 2 and the rotor housing 3 . Out of specification → R[...]

4 - 68 ENG OIL PUMP 2. Install: ● Outer rotor 1 1 NOTE: Apply the engine oil on the outer rotor 1. 3. Install: ● Oil pump cover 1 ● Screw (oil pump cover) 2 ● Pin 3 ● Inner rotor 2 4 ● Circlip 5 NOTE: ● Apply the engine oil on the oil pump drive shaft end and inner rotor 2. ● Fit the pin into the groove in the inner rotor 2. 4. Inst[...]

4 - 69 ENG KICK AXLE AND SHIFT SHAFT KICK AXLE AND SHIFT SHAFT KICK AXLE AND SHIFT SHAFT Extent of removal: 1 Kick axle removal 2 Kick axle disassembly 3 Shift shaft removal 4 Segment removal Extent of removal Order Part name Q ’ ty Remarks KICK AXLE AND SHIFT SHAFT REMOVAL Preparation for removal Oil pump Refer to “ OIL PUMP ” section. 1 Kic[...]

4 - 70 ENG KICK AXLE AND SHIFT SHAFT Extent of removal Order Part name Q ’ ty Remarks 13 Roller 1 14 Shift guide 1 Refer to “ REMOVAL POINTS ” . 15 Shift lever assembly 1 16 Shift lever 1 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt (stopper lever) 1 21 Stopper lever 1 22 Torsion spring 1 23 Segment 1 Refer to “ REMOVAL POINTS ” . 4[...]

4 - 71 ENG KICK AXLE AND SHIFT SHAFT REMOVAL POINTS EC4B3101 Kick axle assembly 1. Remove: ● Kick axle assembly 1 NOTE: Unhook the torsion spring 2 from the hole a in the crankcase. EC4C3101 Shift guide and shift lever assembly 1. Remove: ● Bolt (shift guide) ● Shift guide 1 ● Shift lever assembly 2 NOTE: The shift lever assembly is disasse[...]

4 - 72 ENG KICK AXLE AND SHIFT SHAFT EC4B4400 Shift shaft 1. Inspect: ● Shift shaft 1 Bend/damage → Replace. ● Spring 2 Broken → Replace. EC4C4100 Shift guide and shift lever assembly 1. Inspect: ● Shift guide 1 ● Shift lever 2 ● Pawl 3 ● Pawl pin 4 ● Spring 5 Wear/damage → Replace. EC4B4500 Stopper lever 1. Inspect: ● Stopper[...]

4 - 73 ENG KICK AXLE AND SHIFT SHAFT EC4B5111 Stopper lever 1. Install: ● Torsion spring 1 ● Stopper lever 2 ● Bolt (stopper lever) 3 NOTE: Align the stopper lever roller with the slot on segment. Shift guide and shift lever assembly 1. Install: ● Spring 1 ● Pawl pin 2 ● Pawl 3 To shift lever 4 . NOTE: Apply the engine oil on the spring[...]

4 - 74 ENG KICK AXLE AND SHIFT SHAFT EC4C5301 Shift shaft 1. Install: ● Roller 1 ● Collar 2 ● Torsion spring 3 ● Shift shaft 4 NOTE: Apply the engine oil on the roller and shift shaft. 2. Install: ● Shift pedal Refer to “ AC MAGNETO AND STARTER CLUTCH ” section. Kick axle assembly 1. Install: ● Kick gear 1 ● Plain washer 2 ● Cir[...]

4 - 75 ENG KICK AXLE AND SHIFT SHAFT 3. Install: ● Spring guide 1 NOTE: Slide the spring guide into the kick axle, make sure the groove a in the spring guide fits on the stopper of the torsion spring. 4. Install: ● Kick axle assembly 1 ● Plain washer 2 NOTE: ● Apply the molybdenum disulfide grease on the contacting surfaces of the kick axle[...]

4 - 76 ENG AC MAGNETO AND STARTER CLUTCH AC MAGNETO AND STARTER CLUTCH Extent of removal: 1 Starter clutch/wheel gear removal 2 Rotor removal 3 Pickup coil/stator removal Extent of removal Order Part name Q’ty Remarks AC MAGNETO AND STATOR REMOVAL Preparation for removal Drain the engine oil. Refer to “ ENGINE OIL REPLACEMENT ” section in the[...]

4 - 77 ENG AC MAGNETO AND STARTER CLUTCH NOTE: Tighten the rotor nut to 65 Nm (6.5 m · kg, 47 ft · lb), loosen and retighten the rotor nut to 65 Nm (6.5 m · kg, 47 ft · lb). Extent of removal Order Part name Q ’ ty Remarks 9 Dowel pin 2 10 Idle gear 2 1 11 Bearing 1 12 Shaft 1 13* Nut (rotor) 1 Refer to NOTE. 14 Rotor 1 Use special tool. Refe[...]

4 - 78 ENG AC MAGNETO AND STARTER CLUTCH EC4L3000 REMOVAL POINTS Rotor 1. Remove: ● Nut (rotor) 1 ● Plain washer 2. Remove: ● Rotor 1 Use the rotor puller 2 . Rotor puller: YM-04141/90890-04141 EC4L4000 INSPECTION AC magneto 1. Inspect: ● Rotor inner surface a ● Stator outer surface b Damage → Inspect the crankshaft runout and crankshaf[...]

4 - 79 ENG AC MAGNETO AND STARTER CLUTCH Starter clutch 1. Check: ● Starter clutch Damage/wear → Replace. 2. Check: ● Idle gear ● Idle gear shaft ● Starter clutch gear Pitting/burrs/chips/roughness/wear → Replace the defective parts. 3. Check: ● Starter clutch operation ● Install the starter clutch drive gear 1 onto the starter clut[...]

4 - 80 ENG AC MAGNETO AND STARTER CLUTCH 2. Install: ● Holder 1 ● Bolt 2 NOTE: ● Pass the pick-up coil lead 3 and AC mag- neto lead 4 under the holder as shown. ● Take care not to catch the AC magneto lead between crankcase cover ribs. ● Apply the sealant to the grommet of the AC magneto lead. Quick gasket  : ACC-QUICK-GS-KT Y AMAHA Bo[...]

4 - 81 ENG 5. Install: ● Bolt (starter clutch) 1 ● Plain washer (rotor) ● Nut (rotor) 2 NOTE: Tighten the rotor nut to 65 Nm (6.5 m·kg, 47 ft·lb), loosen and retighten the rotor nut to 65 Nm (6.5 m · kg, 47 ft · lb). 6. Install: ● Shaft 1 ● Bearing 2 ● Idle gear 2 3 NOTE: Apply the engine oil on the shaft, bearing and idle gear inne[...]

4 - 82 ENG 10. Install: ● Engine guard 1 ● Clamp 2 ● Bolt [engine guard (front)] 3 ● Bolt [engine guard (rear)] 4 ● Cylinder head breather hose 5 T R . . 34 Nm (3.4 m · kg, 24 ft · lb) T R . . 23 Nm (2.3 m · kg, 17 ft · lb) 11. Connect: ● AC magneto lead Refer to “CABLE ROUTING DIA- GRAM” section in the CHAPTER 2. 12. Install: ?[...]

4 - 83 ENG ENGINE REMOVAL EC4M0000 ENGINE REMOVAL Extent of removal Order Part name Q ’ ty Remarks ENGINE REMOVAL Preparation for removal Hold the machine by placing the suitable stand under the frame. W ARNING Support the machine securely so there is no danger of it falling over. Drain the engine oil Refer to “ ENGINE OIL REPLACEMENT ” secti[...]

4 - 84 ENG ENGINE REMOVAL Extent of removal: 1 Engine removal Extent of removal Order Part name Q ’ ty Remarks Crankcase cover (left) Refer to “ AC MAGNETO AND STARTER CLUTCH ” section for remov- ing the starter motor lead. Disconnect the starter motor lead. Refer to “ ELECTRIC STARTING SYS- TEM ” section in the CHAPTER 6. Negative batter[...]

4 - 85 ENG ENGINE REMOVAL Extent of removal Order Part name Q ’ ty Remarks 11 Engine upper bracket (right) 1 12 Engine upper bracket (left) 1 13 Engine lower bracket 2 14 Engine mounting bolt 3 15 Pivot shaft 1 Refer to “ REMOVAL POINTS ” . 16 Engine 1 1[...]

4 - 86 ENG ENGINE REMOVAL EC4M3000 REMOVAL POINTS EC4F3100 Drive sprocket 1. Remove: ● Nut (drive sprocket) 1 ● Lock washer 2 NOTE: ● Straighten the lock washer tab. ● Loosen the nut while applying the rear brake. 2. Remove: ● Drive sprocket 1 ● Drive chain 2 NOTE: Remove the drive sprocket together with the drive chain. EC4M3301 Engine[...]

4 - 87 ENG ENGINE REMOVAL EC4M5000 ASSEMBLY AND INSTALLATION Engine installation 1. Install: ● Engine 1 Install the engine from right side. ● Pivot shaft 2 ● Engine mounting bolt (lower) 3 ● Engine lower bracket 4 ● Bolt (engine bracket) 5 ● Engine mounting bolt (front) 6 ● Engine upper bracket (right) 7 ● Engine upper bracket (left[...]

4 - 88 ENG ENGINE REMOVAL Drive sprocket 1. Install: ● Drive sprocket 1 ● Drive chain 2 NOTE: Install the drive sprocket together with the drive chain. 2. Install: ● Lock washer 1 ● Nut (drive sprocket) 2 NOTE: Tighten the nut while applying the rear brake. New T R . . 75 Nm (7.5 m · kg, 54 ft · lb) 3. Bend the lock washer tab to lock the[...]

4 - 89 ENG CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT Extent of removal: 1 Crankcase separation 2 Crankshaft removal Extent of removal Order Part name Q ’ ty Remarks CRANKCASE SEPARATION Preparation for removal Engine Refer to “ ENGINE REMOVAL ” section. Piston Refer to “ CYLINDER AND PISTON ” sec- tion. Ba[...]

4 - 90 ENG CRANKCASE AND CRANKSHAFT Extent of removal Order Part name Q ’ ty Remarks 10 Oil strainer 1 11 Oil delivery pipe 2 1 12 Crankshaft 1 Use special tool. Refer to “ REMOVAL POINTS ” . 2[...]

4 - 91 ENG CRANKCASE AND CRANKSHAFT CRANKCASE BEARING Extent of removal: 1 Crankcase bearing removal Extent of removal Order Part name Q ’ ty Remarks CRANKCASE BEARING REMOVAL Preparation for removal Transmission Shift cam and shift fork Refer to “ TRANSMISSION, SHIFT CAM AND SHIFT FORK ” section. 1 Oil seal 3 2 Bearing 10 Refer to “ REMOVA[...]

4 - 92 ENG CRANKCASE AND CRANKSHAFT REMOVAL POINTS Crankcase 1. Separate: ● Crankcase (right) ● Crankcase (left) Separation steps: ● Remove the crankcase bolts, hose guide and clutch cable holder. NOTE: Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them. ● Remove the crankcase (right). NOTE: ● Place[...]

4 - 93 ENG CRANKCASE AND CRANKSHAFT Crankshaft 1. Remove: ● Crankshaft 1 Use the crankcase separating tool 2 . CAUTION: Do not use a hammer to drive out the crankshaft. Crankshaft bearing 1. Remove: ● Bearing 1 NOTE: ● Remove the bearing from the crankcase by pressing its inner race. ● Do not use the removed bearing. Crankcase separating to[...]

4 - 94 ENG CRANKCASE AND CRANKSHAFT EC4N4201 Crankshaft 1. Measure: ● Runout limit a ● Small end free play limit b ● Connecting rod big end side clearance c ● Crank width d Out of specification → Replace. Use the dial gauge and a thickness gauge. Dial gauge and stand: YU-3097/90890-01252 Standard <Limit> Runout limit: 0.03 mm (0.001[...]

4 - 95 ENG CRANKCASE AND CRANKSHAFT EC4N5000 ASSEMBLY AND INSTALLATION Crankshaft bearing 1. Install: ● Bearing ● Bearing stopper ● Bolt (bearing stopper) ● Screw (bearing stopper) ● Screw [bearing stopper (crankshaft)] 1 To crankcase (left and right). NOTE: ● Install the bearing by pressing its outer race parallel. ● To prevent the s[...]

4 - 96 ENG CRANKCASE AND CRANKSHAFT NOTE: ● Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms against the bearing. ● Before installing the crankshaft, clean the contacting surface of crankcase. CAUTION: Do not use a hamme[...]

4 - 97 ENG CRANKCASE AND CRANKSHAFT 5. Install: ● Dowel pin 1 ● O-ring 2 ● Crankcase (right) To crankcase (left). NOTE: ● Fit the crankcase (right) onto the crankcase (left). Tap lightly on the case with soft ham- mer. ● When installing the crankcase, the connect- ing rod should be positioned at TDC (top dead center). New 6. Tighten: ● [...]

4 - 98 ENG TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK Extent of removal: 1 Shift fork, shift cam, main axle and drive axle removal Extent of removal Order Part name Q ’ ty Remarks TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVAL Preparation for removal Engine Refer to “ ENG[...]

4 - 99 ENG TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H3000 REMOVAL POINTS Shift fork, shaft cam and transmission 1. Remove: ● Shift forks ● Shift cam ● Main axle ● Drive axle NOTE: ● Tap lightly on the transmission drive axle and shift cam with a soft hammer to remove. ● Remove assembly carefully. Note the posi- tion of each part. Pay p[...]

4 - 100 ENG TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H4801 Shift fork, shift cam and segment 1. Inspect: ● Shift fork 1 Wear/damage/scratches → Replace. 2. Inspect: ● Shift cam 1 ● Segment 2 Bend/wear/damage → Replace. 3. Check: ● Shift fork movement Unsmooth operation → Replace shift fork. NOTE: For a malfunctioning shift fork, repl[...]

4 - 101 ENG TRANSMISSION, SHIFT CAM AND SHIFT FORK 2. Install: ● 2nd wheel gear (26T) 1 ● 4th wheel gear (21T) 2 ● 3rd wheel gear (21T) 3 ● 5th wheel gear (21T) 4 ● 1st wheel gear (29T) 5 ● O-ring 6 To drive axle 7 . NOTE: ● Apply the molybdenum disulfide oil on the 1st, 2nd and 3rd wheel gears inner circum- ference and on the end sur[...]

4 - 102 ENG TRANSMISSION, SHIFT CAM AND SHIFT FORK 5. Install: ● Shift fork 1 (L) 1 ● Shift fork 2 (C) 2 ● Shift fork 3 (R) 3 ● Shift cam 4 To main axle and drive axle. NOTE: ● Apply the molybdenum disulfide oil on the shift fork grooves. ● Mesh the shift fork #1 (L) with the 4th wheel gear 5 and #3 (R) with the 5th wheel gear 7 on the [...]

5 - 1 CHAS EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL FRONT WHEEL AND REAR WHEEL Extent of removal: 1 Front wheel removal 2 Wheel bearing removal 3 Brake disc removal Extent of removal Order Part name Q’ty Remarks Preparation for removal FRONT WHEEL REMOVAL Hold the machine by placing the suitable stand under the en[...]

5 - 2 CHAS EC598100 REAR WHEEL Extent of removal: 1 Rear wheel removal 2 Wheel bearing removal 3 Brake disc removal Extent of removal Order Part name Q ’ ty Remarks Preparation for removal REAR WHEEL REMOVAL Hold the machine by placing the suitable stand under the engine. W ARNING Support the machine securely so there is no danger of it falling o[...]

5 - 3 CHAS FRONT WHEEL AND REAR WHEEL EC593000 REMOVAL POINTS EC523101 Rear wheel 1. Remove: ● Wheel 1 NOTE: Push the wheel forward and remove the drive chain 2 . EC513201 Wheel bearing (if necessary) 1. Remove: ● Bearing 1 NOTE: Remove the bearing using a general bearing puller 2 . EC594000 INSPECTION EC514100 Wheel 1. Measure: ● Wheel runou[...]

5 - 4 CHAS FRONT WHEEL AND REAR WHEEL EC514200 Wheel axle 1. Measure: ● Wheel axle bends Out of specification → Replace. Use the dial gauge 1 . NOTE: The bending value is shown by one half of the dial gauge reading. W ARNING Do not attempt to straighten a bent axle. Wheel axle bending limit: 0.5 mm (0.020 in) EC594200 Brake disc 1. Measure: ●[...]

5 - 5 CHAS FRONT WHEEL AND REAR WHEEL EC595000 ASSEMBLY AND INSTALLATION Front wheel 1. Install: ● Bearing (left) 1 ● Spacer 2 ● Bearing (right) 3 ● Oil seal 4 NOTE: ● Apply the lithium soap base grease on the bearing and oil seal lip when installing. ● Use a socket that matches the outside diam- eter of the race of the bearing. ● Lef[...]

5 - 6 CHAS FRONT WHEEL AND REAR WHEEL 5. Install: ● Wheel NOTE: ● Install the brake disc 1 between the brake pads 2 correctly. ● Make sure that the projections a in the trip meter gear unit fits over the stopper b on the front fork outer tube. 6. Install: ● Wheel axle 1 NOTE: Apply the lithium soap base grease on the wheel axle. 7. Install:[...]

5 - 7 CHAS FRONT WHEEL AND REAR WHEEL 8. Tighten: ● Bolt (axle holder) 1 NOTE: Before tightening the bolt, fit the wheel axle to the axle holder by stroking the front fork sev- eral times with the front brake applied. T R . . 23 Nm (2.3 m · kg, 17 ft · lb) 9. Install: ● Brake hose 1 To brake hose holder 2 . NOTE: Before tightening the bolt (b[...]

5 - 8 CHAS Rear wheel 1. Install: ● Bearing (right) 1 ● Circlip 2 ● Spacer 3 ● Bearing (left) 4 ● Oil seal 5 NOTE: ● Apply the lithium soap base grease on the bearing and oil seal lip when installing. ● Install the bearing with seal facing outward. ● Use a socket that matches the outside diam- eter of the race of the bearing. ● Ri[...]

5 - 9 CHAS FRONT WHEEL AND REAR WHEEL 4. Install: ● Collar 1 NOTE: Apply the lithium soap base grease on the oil seal lip. 5. Install: ● Wheel NOTE: Install the brake disc 1 between the brake pads 2 correctly. 6. Install: ● Drive chain 1 NOTE: Push the wheel 2 forward and install the drive chain. 7. Install: ● Chain puller (left) 1 ● Whee[...]

5 - 10 CHAS 9. Adjust: ● Drive chain slack a Refer to “ DRIVE CHAIN SLACK ADJUSTMENT ” section in the CHAP- TER 3. Drive chain slac k: 40 ~ 50 mm (1.6 ~ 2.0 in) 10. Tighten: ● Nut (wheel axle) 1 ● Locknut 2 T R . . 125 Nm (12.5 m · kg, 90 ft · lb) T R . . 16 Nm (1.6 m · kg, 11 ft · lb) FRONT WHEEL AND REAR WHEEL[...]

5 - 11 CHAS FRONT BRAKE AND REAR BRAKE EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE Extent of removal: 1 Brake hose removal 2 Caliper removal 3 Master cylinder removal Extent of removal Order Part name Q ’ ty Remarks Preparation for removal FRONT BRAKE REMOVAL Hold the machine by placing the suitable stand under the engine. W ARNING S[...]

5 - 12 CHAS EC5A8100 REAR BRAKE Extent of removal: 1 Master cylinder removal 2 Brake hose removal 3 Caliper removal Extent of removal Order Part name Q ’ ty Remarks Preparation for removal REAR BRAKE REMOVAL Hold the machine by placing the suitable stand under the engine. W ARNING Support the machine securely so there is no danger of it falling o[...]

5 - 13 CHAS EC5A8200 CALIPER DISASSEMBLY Å Front ı Rear Extent of removal: 1 Front caliper disassembly 2 Rear caliper disassembly Extent of removal Order Part name Q ’ ty Remarks CALIPER DISASSEMBLY AB 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Caliper piston 2 1 Refer to “ REMOVAL POINTS ” . 5 Dust seal 2 1 6 Piston seal 2 1 1 2 FRO[...]

5 - 14 CHAS FRONT BRAKE AND REAR BRAKE EC5A8300 MASTER CYLINDER DISASSEMBLY Å Front ı Rear Extent of removal: 1 Front master cylinder disassembly 2 Rear master cylinder disassembly Extent of removal Order Part name Q ’ ty Remarks MASTER CYLINDER DISAS- SEMBLY 1 Master cylinder cap 1 2 Diaphragm 1 3 Master cylinder boot 1 4 Circlip 1 Use a long [...]

5 - 15 CHAS FRONT BRAKE AND REAR BRAKE EC5A3000 REMOVAL POINTS Brake fluid 1. Remove: [Front] ● Master cylinder cap 1 [Rear] ● Master cylinder cap 1 ● Protector NOTE: Do not remove the diaphragm. Å Front ı Rear 2. Connect the transparent hose 2 to the bleed screw 1 and place a suitable con- tainer under its end. Å Front ı Rear Å ı 3. Lo[...]

5 - 16 CHAS FRONT BRAKE AND REAR BRAKE EC533402 Piston seal kit 1. Remove: ● Dust seal 1 ● Piston seal 2 NOTE: Remove the piston seals and dust seals by pushing them with a finger. ACHTUNG: CAUTION: Never attempt to pry out piston seals and dust seals. W ARNING Replace the piston seals and dust seals whenever a caliper is disassembled. Å Front[...]

5 - 17 CHAS EC534214 Caliper 1. Inspect: ● Caliper cylinder inner surface a Wear/score marks → Replace caliper assembly. Å Front ı Rear ı Å 2. Inspect: ● Caliper piston 1 Wear/score marks → Replace caliper piston assembly. W ARNING Replace the piston seals and dust seals 2 whenever a caliper is disassembled. EC534301 Brake hose 1. Inspe[...]

5 - 18 CHAS 2. Install: ● Piston seal 1 ● Dust seal 2 W ARNING Always use new piston seals and dust seals. NOTE: Fit the piston seals and dust seals onto the slot on caliper correctly. Å Front ı Rear Å New New ı 3. Install: ● Caliper piston 1 NOTE: Apply the brake fluid on the piston wall. ACHTUNG: CAUTION: ● Install the piston with its[...]

5 - 19 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: ● Copper washer 1 ● Union bolt 2 W ARNING Always use new copper washers. ACHTUNG: CAUTION: Install the brake hose so that its pipe por- tion a directs as shown and lightly touches the projection b on the caliper. New T R . . 30 Nm (3.0 m · kg, 22 ft · lb) 3. Install: ● Brake hose holder 1 ?[...]

5 - 20 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: ● Disc cover 1 ● Bolt (disc cover) 2 T R . . 7 Nm (0.7 m · kg, 5.1 ft · lb) 3. Install: ● Caliper 1 ● Rear wheel 2 Refer to “ FRONT WHEEL AND REAR WHEEL ” section. 4. Tighten: ● Pad pin 3 5. Install: ● Pad pin plug 4 Master cylinder kit 1. Clean: ● Master cylinder ● Master cyl[...]

5 - 21 CHAS FRONT BRAKE AND REAR BRAKE 3. Install: ● Spring 1 To master cylinder piston 2 . NOTE: Install the spring at the smaller dia. side. Å Front ı Rear Å ı 4. Install: [Front] ● Master cylinder kit 1 ● Plain washer 2 ● Circlip 3 ● Master cylinder boot 4 To master cylinder 5 . [Rear] ● Master cylinder kit 1 ● Push rod 2 ● C[...]

5 - 22 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: ● Brake lever 1 ● Bolt (brake lever) 2 ● Nut (brake lever) 3 NOTE: Apply the lithium soap base grease on the brake lever sliding surface, bolt and contacting surface of the master cylinder piston. Rear master cylinder 1. Install: ● Copper washer 1 ● Brake hose 2 ● Union bolt 3 W ARNING [...]

5 - 23 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: ● Pin 1 ● Plain washer 2 ● Cotter pin 3 NOTE: After installing, check the brake pedal height. Refer to “REAR BRAKE ADJUSTMENT” sec- tion in the CHAPTER 3. New Front brake hose 1. Install: ● Brake hose 1 To brake hose holder 2 . NOTE: Before tightening the bolt (brake hose holder), align[...]

5 - 24 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: ● Copper washer 1 ● Brake hose 2 ● Union bolt 3 W ARNING Always use new copper washers. ACHTUNG: CAUTION: Install the brake hose so that it contacts the master cylinder projection a and that its bent portion b faces downward. New T R . . 30 Nm (3.0 m · kg, 22 ft · lb) Rear brake hose 1. Ins[...]

5 - 25 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: ● Brake hose holder 1 ● Screw (brake hose holder) 2 ACHTUNG: CAUTION: After installing the brake hose holders, make sure the brake hose does not contact the spring (rear shock absorber). If it does, correct its twist. T R . . 1 Nm (0.1 m · kg, 0.7 ft · lb) Brake fluid 1. Fill: ● Brake fluid[...]

5 - 26 CHAS FRONT BRAKE AND REAR BRAKE 2. Air bleed: ● Brake system Refer to “ BRAKE SYSTEM AIR BLEEDING ” section in the CHAPTER 3. 3. Inspect: ● Brake fluid level Fluid at lower level → Fill up. Refer to “ BRAKE FLUID LEVEL INSPECTION ” section in the CHAP- TER 3. 4. Install: [Front] ● Diaphragm ● Master cylinder cap 1 ● Screw[...]

5 - 27 CHAS FRONT FORK EC550000 FRONT FORK Extent of removal: 1 Front fork removal Extent of removal Order Part name Q ’ ty Remarks Preparation for removal FRONT FORK REMOVAL Hold the machine by placing the suitable stand under the engine. W ARNING Support the machine securely so there is no danger of it falling over. Front wheel Refer to “ FRO[...]

5 - 28 CHAS FRONT FORK EC558000 FRONT FORK DISASSEMBLY Extent of removal: 1 Oil seal removal 2 Damper rod removal Extent of removal Order Part name Q ’ ty Remarks FRONT FORK DISASSEMBLY 1 Cap bolt 1 Refer to “ REMOVAL POINTS ” . 2 Fork spring 1 Drain the fork oil. 3 Dust seal 1 Refer to “ REMOVAL POINTS ” . 4 Stopper ring 1 5 Inner tube 1[...]

5 - 29 CHAS FRONT FORK EC556000 HANDLING NOTE NOTE: The front fork requires careful attention. So it is recommended that the front fork be main- tained at the dealers. ACHTUNG: CAUTION: To prevent an accidental explosion of air, the following instructions should be observed: ● The front fork with a built-in piston rod has a very sophisticated int[...]

5 - 30 CHAS EC553201 Inner tube 1. Remove: ● Dust seal 1 ● Stopper ring 2 Using slotted-head screwdriver. ACHTUNG: CAUTION: Take care not to scratch the inner tube. 2. Remove: ● Inner tube 1 Oil seal removal steps: ● Push in slowly a the inner tube just before it bottoms out and then pull it back quickly b . ● Repeat this step until the i[...]

5 - 31 CHAS EC554200 Base valve 1. Inspect: ● Valve assembly 1 Wear/damage → Replace. ● O-ring 2 Damage → Replace. EC554400 Fork spring 1. Measure: ● Fork spring free length a Out of specification → Replace. EC554502 Inner tube 1. Inspect: ● Inner tube surface a Score marks → Repair or replace. Use #1,000 grit wet sandpaper. Damaged[...]

5 - 32 CHAS EC554700 Cap bolt 1. Inspect: ● Cap bolt 1 ● O-ring 2 ● Air bleed screw 3 Wear/damage → Replace. FRONT FORK EC555000 ASSEMBLY AND INSTALLATION Front fork assembly 1. Wash the all parts in a clean solvent. 2. Install: ● Damper rod 1 To inner tube 2 . ACHTUNG: CAUTION: To install the damper rod into the inner tube, hold the inne[...]

5 - 33 CHAS FRONT FORK 5. Install: ● Spring guide 1 ● Locknut 2 To damper rod 3 . NOTE: ● Install the spring guide with its cut a facing upward. ● With its thread b facing upward, fully finger tighten the locknut onto the damper rod. 6. Install: ● Dust seal 1 ● Stopper ring 2 ● Oil seal 3 ● Plain washer 4 ● Slide metal 5 To inner [...]

5 - 34 CHAS FRONT FORK 9. Install: ● Slide metal 1 ● Plain washer 2 To outer tube slot. NOTE: Press the slide metal into the outer tube with fork seal driver 3 . Fork seal driver: YM-01442/90890-01442 10. Install: ● Oil seal 1 NOTE: Press the oil seal into the outer tube with fork seal driver 2 . Fork seal driver: YM-01442/90890-01442 11. Ins[...]

5 - 35 CHAS FRONT FORK 13. Check: ● Inner tube smooth movement Tightness/binding/rough spots → Repeat the steps 2 to 12. 14. Compress the front fork fully. 15. Fill: ● Front fork oil Until outer tube top surface with recom- mended fork oil 1 . ACHTUNG: CAUTION: ● Be sure to use recommended fork oil. If other oils are used, they may have an [...]

5 - 36 CHAS FRONT FORK 19. Wait ten minutes until the air bubbles have been removed from the front fork, and the oil has dispense evenly in system before setting recommended oil level. NOTE: Fill with the fork oil up to the top end of the outer tube, or the fork oil will not spread over to every part of the front forks, thus making it impossible to[...]

5 - 37 CHAS FRONT FORK 21. Measure: ● Distance a Out of specification → Turn into the locknut. Distance a : 20 mm (0.79 in) or more Between damper rod 1 top and locknut 2 top. 22. Loosen: ● Rebound damping adjuster 1 NOTE: ● Loosen the rebound damping adjuster finger tight. ● Record the set position of the adjuster (the amount of turning [...]

5 - 38 CHAS FRONT FORK 26. Tighten: ● Cap bolt (locknut) 1 NOTE: ● While compressing the fork spring, set the thin type spanners 2 between the spacer 3 and spring guide 4 . ● Hold the locknut 5 and tighten the cap bolt with specified torque. 27. Install: ● Cap bolt 1 To outer tube. NOTE: Temporarily tighten the cap bolt. T R . . 29 Nm (2.9 [...]

5 - 39 CHAS FRONT FORK 4. Tighten: ● Pinch bolt (handle crown) 1 ● Pinch bolt (under bracket) 2 ACHTUNG: CAUTION: Tighten the under bracket to specified torque. If torqued too much, it may cause the front fork to malfunction. 5. Install: ● Brake hose holder 1 ● Caliper 2 ● Bolt (caliper) 3 NOTE: Fit the brake hose holder cut a over the pr[...]

5 - 40 CHAS EC5B0000 HANDLEBAR Extent of removal: 1 Handlebar removal Extent of removal Order Part name Q ’ ty Remarks Preparation for removal HANDLEBAR REMOVAL Headlight 1 Hot starter cable 1 Disconnect at the lever side. 2 Hot starter lever holder 1 3 Clutch cable 1 Disconnect at the lever side. 4 Clutch lever holder 1 Disconnect the clutch swi[...]

5 - 41 CHAS EC5B3000 REMOVAL POINTS EC5B3100 Master cylinder 1. Remove: ● Master cylinder bracket 1 ● Master cylinder 2 ACHTUNG: CAUTION: ● Do not let the master cylinder hang on the brake hose. ● Keep the master cylinder cap side hori- zontal to prevent air from coming in. EC5B3200 Grip 1. Remove: ● Grip 1 NOTE: Blow in air between the h[...]

5 - 42 CHAS HANDLEBAR EC5B5000 ASSEMBLY AND INSTALLATION Handlebar 1. Install: ● Handlebar 1 ● Handlebar holder 2 ● Bolt (handlebar holder) 3 NOTE: ● The handlebar holder should be installed with the punched mark a forward. ● First tighten the bolts on the front side of the handlebar holder, and then tighten the bolts on the rear side. 2.[...]

5 - 43 CHAS HANDLEBAR 4. Install: ● Cover (grip cap) 1 ● Throttle grip 2 NOTE: Apply the lithium soap base grease on the throttle grip sliding surface. 5. Install: ● Throttle cables 1 To tube guide 2 . NOTE: Apply the lithium soap base grease on the throttle cable end and tube guide cable wind- ing portion. 6. Install: ● Throttle cable cap [...]

5 - 44 CHAS HANDLEBAR 8. Install: ● Start switch 1 ● Master cylinder 2 ● Master cylinder bracket 3 ● Bolt (master cylinder bracket) 4 ● Clamp 5 NOTE: ● The start switch and master cylinder bracket should be installed according to the dimen- sions shown. ● Install the bracket so that the arrow mark a faces upward. ● First tighten the[...]

5 - 45 CHAS HANDLEBAR 11. Install: ● Clutch cable 1 ● Hot starter cable 2 NOTE: Apply the lithium soap base grease on the clutch cable end and hot starter cable end. 12. Adjust: ● Clutch lever free play Refer to “ CLUTCH ADJUSTMENT ” section in the CHAPTER 3. ● Hot starter lever free play Refer to “ HOT STARTER LEVER ADJUSTMENT ” se[...]

5 - 46 CHAS EC560000 STEERING Extent of removal: 1 Under bracket removal 2 Bearing removal Extent of removal Order Part name Q ’ ty Remarks STEERING REMOVAL W ARNING Support the machine securely so there is no danger of it falling over. Refer to “ HANDLEBAR ” section. Preparation for removal Hold the machine by placing the suitable stand unde[...]

5 - 47 CHAS STEERING Extent of removal Order Part name Q ’ ty Remarks 11 Bearing (upper) 1 12 Bearing (lower) 1 Refer to “ REMOVAL POINTS ” . 13 Ball race 2 2[...]

5 - 48 CHAS EC563000 REMOVAL POINTS EC563202 Ring nut 1. Remove: ● Ring nut 1 Use the ring nut wrench 2 . W ARNING Support the steering shaft so that it may not fall down. Ring nut wrench: YU-33975/90890-01403 EC563300 Bearing (lower) 1. Remove: ● Bearing (lower) 1 Use the floor chisel 2 . ACHTUNG: CAUTION: Take care not to damage the steering [...]

5 - 49 CHAS STEERING EC564101 Bearing and ball race 1. Wash the bearings and ball races with a solvent. 2. Inspect: ● Bearing 1 ● Ball race Pitting/damage → Replace bearings and ball races as a set. Install the bearing in the ball races. Spin the bearings by hand. If the bear- ings hang up or are not smooth in their operation in the ball race[...]

5 - 50 CHAS 4. Install: ● Plain washer 1 ● Ring nut 2 Tighten the ring nut using the ring nut wrench 3 . Refer to “ STEERING HEAD INSPEC- TION AND ADJUSTMENT ” section in the CHAPTER 3. T R . . 7 Nm (0.7 m · kg, 5.1 ft · lb) 5. Check the steering shaft by turning it lock to lock. If there is any binding, remove the steering shaft assembly[...]

5 - 51 CHAS STEERING 9. Install: ● Steering shaft cap 1 10. After tightening the nut, check the steer- ing for smooth movement. If not, adjust the steering by loosening the ring nut little by little. 11. Adjust: ● Front fork top end a Front f ork top end (standard) a : Zero mm (Zero in) 12. Tighten: ● Pinch bolt (handle crown) 1 ● Pinch bol[...]

5 - 52 CHAS SWINGARM EC570000 SWINGARM Extent of removal: 1 Swingarm removal Extent of removal Order Part name Q ’ ty Remarks SWINGARM REMOVAL W ARNING Support the machine securely so there is no danger of it falling over. Preparation for removal Hold the machine by placing the suitable stand under the engine. Brake hose holder Rear caliper Bolt [...]

5 - 53 CHAS SWINGARM EC578000 SWINGARM DISASSEMBLY Extent of removal: 1 Swingarm disassembly 2 Connecting rod removal and disassembly 3 Relay arm removal and disassembly Extent of removal Order Part name Q ’ ty Remarks SWINGARM DISASSEMBLY 1 Cap 2 2 Relay arm 1 3 Connecting rod 1 4 Collar 2 5 Oil seal 2 6 Thrust bearing 2 7 Bush 2 8 Oil seal 8 9 [...]

5 - 54 CHAS SWINGARM EC573000 REMOVAL POINTS EC573200 Bearing 1. Remove: ● Bearing 1 NOTE: Install the bearing by pressing its outer race. EC574010 INSPECTION Wash the bearings, bushes, collars, and cov- ers in a solvent. EC574111 Swingarm 1. Inspect: ● Bearing 1 ● Bush 2 Free play exists/unsmooth revolution/ rust → Replace bearing and bush[...]

5 - 55 CHAS SWINGARM EC574310 Connecting rod 1. Inspect: ● Bearing (polylube bearing) 1 ● Collar 2 Free play exists/unsmooth revolution/rust → Replace bearing and collar as a set. 2. Inspect: ● Bearing (polylube bearing) 1 Loss of solid lubrication → Replace. ● Oil seal 3 Damage → Replace. NOTE: Polylube bearings, with solid lubricati[...]

5 - 56 CHAS SWINGARM 2. Install: ● Bearing 1 ● Oil seal 2 To relay arm. NOTE: ● Apply the molybdenum disulfide grease on the bearing when installing. ● Install the bearing by pressing it on the side having the manufacture ’ s marks or numbers. 3. Install: ● Bearing 1 ● Oil seal 2 To connecting rod. NOTE: ● Apply the molybdenum disul[...]

5 - 57 CHAS SWINGARM 3. Install: ● Collar 1 To connecting rod 2 . NOTE: Apply the molybdenum disulfide grease on the collar and oil seal lips. 4. Install: ● Connecting rod 1 ● Bolt (connecting rod) 2 ● Plain washer 3 ● Nut (connecting rod) 4 To relay arm 5 . NOTE: Apply the molybdenum disulfide grease on the bolt. T R . . 80 Nm (8.0 m · [...]

5 - 58 CHAS SWINGARM 8. Install: ● Bolt (connecting rod) 1 ● Plain washer 2 ● Nut (connecting rod) 3 NOTE: ● Apply the molybdenum disulfide grease on the bolt. ● Do not tighten the nut yet. 9. Install: ● Bolt (rear shock absorber-relay arm) 1 ● Nut (rear shock absorber-relay arm) 2 NOTE: Apply the molybdenum disulfide grease on the bo[...]

5 - 59 CHAS 13. Install: ● Bolt [chain tensioner (lower)] 1 ● Plain washer 2 ● Collar 3 ● Chain tensioner 4 ● Nut [chain tensioner (lower)] 5 T R . . 20 Nm (2.0 m · kg, 14 ft · lb) 14. Install: ● Chain support 1 ● Support cover 2 ● Bolt {chain support [ r = 50 mm (1.97 in)]} 3 ● Nut (chain support) 4 ● Bolt {support cover [ r [...]

5 - 60 CHAS REAR SHOCK ABSORBER EC580000 REAR SHOCK ABSORBER Extent of removal: 1 Rear shock absorber removal 2 Rear shock absorber disassembly Extent of removal Order Part name Q ’ ty Remarks Preparation for removal REAR SHOCK ABSORBER REMOVAL Hold the machine by placing the suitable stand under the engine. W ARNING Support the machine securely [...]

5 - 61 CHAS REAR SHOCK ABSORBER Extent of removal Order Part name Q ’ ty Remarks Disconnect the starter relay cou- pler. Starter motor lead Disconnect at the starter relay side. 1 Locking tie 2 2 Taillight coupler 1 3 Starting circuit cut-off relay cou- pler 1 4 Plastic band 2 5 Clamp (air filter joint) 1 Only loosening. 6 Rear frame 1 7 Bolt (re[...]

5 - 62 CHAS REAR SHOCK ABSORBER Extent of removal Order Part name Q ’ ty Remarks 14 Spring (rear shock absorber) 1 15 Bearing 2 Refer to “ REMOVAL POINTS ” . 2[...]

5 - 63 CHAS EC586000 HANDLING NOTE W ARNING This shock absorber is provided with a separate type tank filled with high-pressure nitrogen gas. To prevent the danger of explosion, read and understand the follow- ing information before handling the shock absorber. The manufacturer can not be held respon- sible for property damage or personal injury th[...]

5 - 64 CHAS EC583000 REMOVAL POINTS EC583320 Bearing 1. Remove: ● Stopper ring (upper bearing) 1 NOTE: Press in the bearing while pressing its outer race and remove the stopper ring. 2. Remove: ● Upper bearing 1 NOTE: Remove the bearing by pressing its outer race. 3. Remove: ● Lower bearing 1 NOTE: Remove the bearing by pressing its outer rac[...]

5 - 65 CHAS REAR SHOCK ABSORBER EC585000 ASSEMBLY AND INSTALLATION EC585300 Bearing 1. Install: ● Upper bearing 1 NOTE: Install the bearing parallel until the stopper ring groove appears by pressing its outer race. ACHTUNG: CAUTION: Do not apply the grease on the bearing outer race because it will wear the rear shock absorber surface on which the[...]

5 - 66 CHAS REAR SHOCK ABSORBER 2. Tighten: ● Adjuster 1 3. Adjust: ● Spring length (installed) a * For EUROPE, AUS, NZ and ZA NOTE: The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjuster. ACHTUNG: CAUTION: Never attempt to turn the adjuster beyond the maximum or minimum setting. 4. Tighten: ● Locknut 1 Rear sh[...]

5 - 67 CHAS REAR SHOCK ABSORBER 2. Install: ● Bush 1 ● Collar 2 ● Dust seal 3 NOTE: ● Apply the molybdenum disulfide grease on the bearing. ● Apply the lithium soap base grease on the bush, collars and dust seals. ● Install the dust seals with their lips facing outward. 3. Install: ● Rear shock absorber 4. Install: ● Bolt (rear shoc[...]

5 - 68 CHAS 8. Install: ● Plastic band 1 ● Starting circuit cut-off relay coupler 2 ● Taillight coupler 3 ● Locking tie 4 3 2 1 4 REAR SHOCK ABSORBER[...]

6 - 1 –+ ELEC ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 Headlight 2 “ENGINE STOP” button 3 Clutch switch 4 Diode 5 Starter relay diode 6 TPS (throttle posi- tion sensor) 7 Starter relay 8 Fuse 9 Starting circuit cut-off relay 0 Taillight A Ne[...]

– + ELEC 6 - 2 MAP-CONTROLLED CDI UNIT MAP-CONTROLLED CDI UNIT A map-controlled, CDI ignition system is used in the WR450F. The microcomputer in the CDI unit detects the engine speed and throttle position, thus determining the optimum ignition timing through the entire operating range. In this way, quick throttle response can be achieved accordin[...]

– + ELEC 6 - 3 IGNITION SYSTEM EC620000 IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. *1 marked: Refer to “ FUSE INSPECTION ” section in the CHAPTER 3. *2 marked: Refer to “[...]

6 - 4 – + ELEC IGNITION SYSTEM SPARK GAP TEST 1. Disconnect the ignition coil from spark plug. 2. Remove the ignition coil cap. 3. Connect the dynamic spark tester 1 (ignition checker 2 ) as shown. ● Ignition coil 3 ● Spark plug 4 Å For USA and CDN ı Except for USA and CDN 4. Kick the kickstarter. 5. Check the ignition spark gap. 6. Start e[...]

6 - 5 – + ELEC IGNITION SYSTEM MAIN SWITCH INSPECTION 1. Inspect: ● Main switch conduct Continuous while the main switch is moved to “ OFF ” → Replace. Not continuous while the main switch is moved to “ ON ” → Replace. 2. Inspect: ● Main switch indicator light Use 12 V battery. Indicator light does not come on → Replace. 3. Insp[...]

6 - 6 – + ELEC IGNITION SYSTEM 3. Inspect: ● Secondary coil resistance Out of specification → Replace. 4. Inspect: ● Sealed portion of ignition coil a ● Spark plug terminal pin b ● Threaded portion of spark plug c Wear → Replace. AC MAGNETO INSPECTION 1. Inspect: ● Pick-up coil resistance Out of specification → Replace. Tester (+)[...]

6 - 7 – + ELEC ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to “ ON ” , the starter motor can only operate if at least one of the following conditions is met: ● The transmission is in neutral (the neutral switch is closed). ● The clutch lever is pulled to the handlebar (the clutch switch is [...]

– + ELEC 6 - 8 ELECTRIC STARTING SYSTEM INSPECTION STEPS If the starter motor will not operate, use the following inspection steps. *1 marked: Refer to “ FUSE INSPECTION ” section in the CHAPTER 3. *2 marked: Refer to “ BATTERY INSPECTION AND CHARGING ” section in the CHAPTER 3. *3 marked: Refer to “ MAIN SWITCH INSPECTION ” section. [...]

6 - 9 – + ELEC ELECTRIC STARTING SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: ● Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. STARTER MOTOR OPERATION 1. Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 . Not operate → Repair or replace the star[...]

6 - 10 – + ELEC ELECTRIC STARTING SYSTEM STARTER RELAY INSPECTION 1. Remove: ● Starter relay 2. Inspect: ● Starter relay conduct Use 12 V battery. Continuous while not connected to the battery → Replace. Not continuous while connected to the battery → Replace. Battery (+) lead → Starter relay terminal 1 Battery ( – ) lead → Starter [...]

6 - 11 – + ELEC ELECTRIC STARTING SYSTEM DIODE INSPECTION 1. Remove the diode from wire harness. 2. Inspect: ● Diode continuity Use pocket tester (tester selection posi- tion Ω × 1) Incorrect continuity → Replace. Tester (+) → Blue/Red terminal 1 Tester ( – ) → Sky blue terminal 2 Continuous Tester (+) → Blue/Red terminal 1 Tester [...]

6 - 12 – + ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR 0 9 5 6 7 5 0 8 9 4 3 2 1 New New New B 5 1 Extent of removal: 1 Starter motor disassembly Extent of removal Order Part name Q ’ ty Remarks STARTER MOTOR REMOVAL Preparation for removal Drain the engine oil. Refer to “ ENGINE OIL REPLACEMENT ” section in the CHAPTER 3. Crankcase cover ([...]

6 - 13 – + ELEC ELECTRIC STARTING SYSTEM 0 9 5 6 7 5 0 8 9 4 3 2 1 New New New B 5 1 Extent of removal Order Part name Q ’ ty Remarks 6 Starter motor yoke 1 7 Armature assembly 1 8 Starter motor rear cover 1 9 Brush 2 0 Brush spring 2 1[...]

6 - 14 – + ELEC ELECTRIC STARTING SYSTEM INSPECTION AND REPAIR 1. Check: ● Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: ● Commutator diameter a Out of specification → Replace the starter motor. 3. Measure: ● Mica undercut a Out of specification → Scrape the mica to the proper measurement with a hacksaw blade which has [...]

6 - 15 – + ELEC ELECTRIC STARTING SYSTEM 5. Measure: ● Brush length a Out of specification → Replace the brushes as a set. Min. brush length 3.5 mm (0.14 in) 6. Measure: ● Brush spring force Out of specification → Replace the brush springs as a set. Brush spring force 3.92 ~ 5.88 N (400 ~ 600 gf, 14.1 ~ 21.2 oz) ASSEMBLY 1. Install: ● B[...]

6 - 16 – + ELEC ELECTRIC STARTING SYSTEM 3. Install: ● O-ring 1 ● Starter motor yoke 2 NOTE: ● Align the match mark a on the starter motor yoke with the match mark b on the starter motor rear cover. ● Install the starter motor yoke with its groove c facing rear cover. a b c 2 1 New New 4. Install: ● O-ring 1 ● Circlip ● Plain washer[...]

– + ELEC 6 - 17 CHARGING SYSTEM EC680000 CHARGING SYSTEM EC681001 INSPECTION STEPS If the battery is not charged, use the following inspection steps. *1 marked: Refer to “ FUSE INSPECTION ” section in the CHAPTER 3. *2 marked: Refer to “ BATTERY INSPECTION AND CHARGING ” section in the CHAPTER 3. NOTE: ● Remove the following parts befor[...]

6 - 18 – + ELEC CHARGING SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: ● Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. CHARGING VOLTAGE INSPECTION 1. Start the engine. 2. Inspect: ● Charging voltage Out of specification → If no failure is found in checking the source coil resis- [...]

– + ELEC 6 - 19 TPS (THROTTLE POSITION SENSOR) SYSTEM EC690000 TPS (THROTTLE POSITION SENSOR) SYSTEM INSPECTION STEPS If the TPS will not operate, use the following inspection steps. NOTE: Use the following special tools in this inspection. Pocket tester: YU-3112-C/90890-03112 Inductive tachometer: YU-8036-B Engine tachometer: 90890-03113 Check e[...]

6 - 20 – + ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM HANDLING NOTE CAUTION: Do not loosen the screws {TPS (throttle position sensor)} 1 except when changing the TPS (throttle position sensor) due to failure because it will cause a drop in engine performance. 1 EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: ● Couplers and leads con[...]

6 - 21 – + ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM 3. Inspect: ● TPS coil variable resistance Check that the resistance in increased as the throttle grip is moved from the full close position to the full open posi- tion. Out of specification → Replace. Tester (+) lead → Yellow lead 1 Tester ( – ) lead → Black lead 2 TPS coil variable[...]

6 - 22 – + ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM 4. Adjust: ● Idle speed Refer to “ IDLE SPEED ADJUSTMENT ” section in the CHAPTER 3. 5. Insert the thin electric conductors 2 (lead) into the TPS coupler 1 , as shown, and connect the tester to them. CAUTION: ● Do not insert the electric conductors more than required because it may red[...]

6 - 23 – + ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM 8. Tighten: ● Screw (TPS) 1 9. Stop the engine. 1 EC694000 TPS INPUT VOLTAGE INSPECTION 1. Disconnect the TPS coupler. 2. Start the engine. 3. Inspect: ● TPS input voltage Out of specification → Replace the CDI unit. Tester (+) lead → Blue lead 1 Tester ( – ) lead → Black/Blue lead[...]

– + ELEC 6 - 24 LIGHTING SYSTEM LIGHTING SYSTEM INSPECTION STEPS Refer to the following flow chart when inspecting the ignition system for possible problems. NOTE: ● Replace the bulb and/or bulb socket. 1) Seat 2) Fuel tank ● Use the following special tool. Check the bulb and bulb socket. Replace the bulb and/ or bulb socket. Check the lights[...]

6 - 25 – + ELEC LIGHTING SYSTEM LIGHTS SWITCH INSPECTION 1. Inspect: ● Lights switch conduct No continuous while being → Replace. Continuous while being OFF → Replace. Tester (+) lead → Yellow lead 1 Tester ( – ) lead → Blue lead 2 Y 1 L 2 Tester selec- tor position Ω × 1 OFF AC MAGNETO INSPECTION 1. Inspect: ● Lighting coil resi[...]

7 - 1 TUN EC700000 TUNING EC710000 ENGINE Carburetor setting ● The air/fuel mixture will vary depending on atmospheric conditions. Therefore, it is nec- essary to take into consideration the air pres- sure, ambient temperature, humidity, etc., when adjusting the carburetor. ● Perform a test run to check for proper engine performance (e.g., thro[...]

7 - 2 TUN CAUTION: ● The carburetor is extremely sensitive to foreign matter (dirt, sand, water, etc.). During installation, do not allow foreign matter to get into the carburetor. ● Always handle the carburetor and its components carefully. Even slight scratches, bends or damage to carbure- tor parts may prevent the carburetor from functioning[...]

7 - 3 TUN SETTING Effects of the setting parts on the throttle valve opening 1 Pilot screw/pilot jet 2 Throttle valve cutaway 3 Jet needle 4 Main jet Å Closed ı Fully open 1/2 3/4 1/4 1/8 1 2 3 4 Åı Main system The FLATCR carburetor has a primary main jet. This type of main jet is perfect for racing motorcycles since it supplies an even flow of[...]

7 - 4 TUN SETTING Pilot system The FLATCR carburetor is manufactured with a pilot screw. The pilot screw adjustment ranges from fully closed throttle to 1/4 open throttle. Main jet adjustment The richness of the air-fuel mixture at full throt- tle can be set by changing the main jet 1 . * Except for USA If the air-fuel mixture is too rich or too le[...]

7 - 5 TUN SETTING Pilot screw adjustment The richness of the air-fuel mixture with the throttle fully closed to 1/4 open can be set by turning the pilot screw 1 . Turning in the pilot screw will make the mixture lean at low speeds, and turning it out will enrich it. * Except for USA NOTE: ● If the idling speed fluctuates, turn the pilot screw onl[...]

7 - 6 TUN SETTING Pilot jet adjustment The richness of the air-fuel mixture with the throttle open 1/4 or less can be set by adjust- ing the pilot jet 1 . * Except for USA Effects of adjusting the pilot jet (reference) Å Idle ı Fully open Jet needle groove position adjustment Adjusting the jet needle 1 position affects the acceleration when the t[...]

7 - 7 TUN Jet needle adjustment The jet needle is adjusted by changing it. * Except for USA The tapered sections of all jet needles have the same starting positions, but the needles are available with different straight-portion diameters. Standard jet needle OBDUT *OBDUQ <Example> OBDUT - 4 Clip position Diameter a of straight portion Effects[...]

7 - 8 TUN SETTING Carburetor setting parts * Except for USA Part name Size Part number Main jet Rich *(STD) (STD) Lean #170 #168 #165 #162 #160 #158 #155 #152 #150 #148 #145 #142 #140 4MX-14943-41 4MX-14943-91 4MX-14943-40 4MX-14943-90 4MX-14943-39 4MX-14943-89 4MX-14943-38 4MX-14943-88 4MX-14943-37 4MX-14943-87 4MX-14943-36 4MX-14943-86 4MX-14943-[...]

7 - 9 TUN Examples of carburetor setting depending on symptom This should be taken simply for an example. It is necessary to set the carburetor while checking the operating conditions of the engine. Symptom Setting Checking At full throttle Hard breathing Shearing noise Whitish spark plug Lean mixture Increase main jet calibration no. (Gradually) D[...]

7 - 10 TUN EC720000 CHASSIS EC71P002 Selection of the secondary reduction ratio (Sprocket) Secondary reduction = ratio <Requirement for selection of secondary gear reduction ratio> ● It is generally said that the secondary gear ratio should be reduced for a longer straight portion of a speed course and should be increased for a course with [...]

7 - 11 TUN SETTING EC72N000 Drive and driven sprockets setting parts * For CDN, EUROPE, AUS, NZ and ZA * For AUS and NZ Part name Size Part number Drive sprocket 1 (STD) *(STD) 14T *14T 5NG-17460-00 9383E-14215 Part name Size Part number Driven sprocket 2 (STD) *(STD) 48T *48T *49T 50T *50T *51T 52T *52T 5GS-25448-50 5NY-25448-00 5NY-25449-00 5GS-2[...]

7 - 12 TUN SETTING EC722011 Front fork setting The front fork setting should be made depend- ing on the rider ’ s feeling of an actual run and the circuit conditions. The front fork setting includes the following three factors: 1. Setting of air spring characteristics ● Change the fork oil level. 2. Setting of spring preload ● Change the spri[...]

7 - 13 TUN SETTING EC727020 Spring preload adjustment The spring preload is adjusted by installing the adjustment washer 1 between the fork spring 2 and damper rod 3 . CAUTION: Do not install three or more adjustment washers for each front fork. W ARNING Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling an[...]

7 - 14 TUN 2. Use of stiff spring Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, resulting in lack of a sense of contact with the road surface or in a vibrating handlebar. To set a stiff spring: ● Change the rebound damping. Turn in one or two clicks. ● Change the compression damping. Turn out one[...]

7 - 15 TUN EC72P000 Front fork setting parts ● Adjustment washer 1 ● Front fork spring 2 [Equal pitch spring] * For EUROPE ** For AUS, NZ and ZA [Unequal pitch spring] NOTE: ● The unequal pitch spring is softer in initial characteristic than the equal pitch spring and is difficult to bottom out under full compres- sion. ● The I.D. mark (sli[...]

7 - 16 TUN EC72B000 Rear suspension setting The rear suspension setting should be made depending on the rider ’ s feeling of an actual run and the circuit conditions. The rear suspension setting includes the fol- lowing two factors: 1. Setting of spring preload ● Change the set length of the spring. ● Change the spring. 2. Setting of damping [...]

7 - 17 TUN SETTING NOTE: ● If the machine is new and after it is broken in, the same set length of the spring may change because of the initial fatigue, etc. of the spring. Therefore, be sure to make re- evaluation. ● If the standard figure cannot be achieved by adjusting the spring adjuster and changing the spring set length, replace the sprin[...]

7 - 18 TUN CAUTION: When using a rear cushion other than cur- rently installed, use the one whose overall length a does not exceed the standard as it may result in faulty performance. Never use one whose overall length is greater than standard. Å Coverage of spring by weight ı Rider weight 1 Soft 2 Standard 3 Stiff Length a of standard shoc k: 49[...]

7 - 19 TUN SETTING EC72Q000 Rear shock absorber setting parts ● Rear shock spring 1 [Equal pitch spring] * For EUROPE ** For AUS, NZ and ZA [Unequal pitch spring] NOTE: ● The unequal pitch spring is softer in initial characteristic than the equal pitch spring and is difficult to bottom out under full compres- sion. ● The I.D. color a is marke[...]

7 - 20 TUN SETTING EC72H002 Suspension setting ● Front fork NOTE: ● If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. ● Before any change, set the rear shock absorber sunken length to the standard figure 90 ~ 100 mm (3.5 ~ 3.[...]

7 - 21 TUN SETTING ● Rear shock absorber NOTE: ● If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. ● Adjust the rebound damping in 2-click increments or decrements. ● Adjust the low compression damping in 1-click increments[...]

PRINTED IN JAPAN 2002.10-2.0 × 1 CR (E) PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO . , L TD . 2500 SHINGAI IW A T A SHIZUOKA JAP AN[...]