Yamaha YZ450FT manual

LIT-11626-18-44 YZ450FT 5XD-28199-11 OWNER’S SERVICE MANUAL[...]

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EC010000 YZ450FT OWNER’S SERVICE MANUAL ©2004 by Yamaha Motor Corporation, U.S.A. 1st Edition, June 2004 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-11626-18-44[...]

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

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IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for t his machine to be operated on an y public street, road, or highway. Off-road use on pu blic lands may also be illegal. Please check local regula- tions before riding. 1. THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ON LY. D[...]

6. GASOLINE CAN CAUSE INJURY. If you should swallow so me 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 ADEQUAT[...]

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

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 instru ctions 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 [...]

EC083000 MANUAL FORMAT All of the procedures in this manual are org anized in a sequential, step-by-step format. The informa- tion has been complied to p rovide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disa ssembly, repair, assembly, a nd inspection operations. In this revised format, the co[...]

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 adju stments 4 Engine 5 Chassis 6 Electr ical 7 Tuning Illustrated symbols 8 to D are used to identify the specifications appearing in[...]

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 ................... ......[...]

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 U NIT ................. 6-2 IGNITION SYSTEM .................................... 6-3 TPS (THROTTLE POSITION SENSOR) SYSTEM .....................................................6-7 CHAPTER 7 TUNING ENGINE .................................[...]

GEN INFO 1 - 1 DESCRIPTION EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 Clutch lever 2 Hot starter lever 3 Front brake lever 4 Throttle grip 5 Radiator cap 6 Fuel tank cap 7 “ ENGINE STOP ” button 8 Kick start er 9 Fuel tank 0 Radiator A Coolant drain bolt B Rear brak e pedal C Valve joint D Fuel cock E Cold starte r knob F Drive chain G[...]

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 ca n give the number to your Yamaha dealer for positive identification of the model you own. 2. If your machine is stolen, the authorities will need the number to search f[...]

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 disassembly. When washing the machine with high pres- sured water, cover the parts as follows. • Silencer exhaust port • Side cover air intake port • Water [...]

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 overhauled. All gasket surf[...]

1 - 5 GEN INFO IMPORTANT INFORMATION EC136000 CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1 , make sure that the sharp-edged corner 2 is posi- tioned opposite to the thrust 3 it receives. See the sectional view. 4 Shaft[...]

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 SPECIAL TOOLS EC140001 SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and a ssembly. Using the correct special tool will help preve nt 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 pro[...]

GEN INFO 1 - 8 SPECIAL TOOLS YU-33975, 90890-01403 Ring nut wrench This tool is used when tighten the steering ring nut to specification. YU-33975 90890-01403 YM-01442, 90890-01442 Fork seal driver This tool is used when install the fork oil seal. YM-01442 90890-01442 YM-01500, 90890-01500 Cap bolt wrench This tool is used to loosen or tighten the [...]

GEN INFO 1 - 9 SPECIAL TOOLS YM-4117, 90890-04117 YM-4098, 90890-04098 Valve guide installer Intake Exhaust This tool is needed to install the valve guide. YM-4117 YM-4098 90890-04117 90890-04098 YM-4118, 90890-04118 YM-4099, 90890-04099 Valve guide reamer Intake 4.5 mm (0.18 in) Exhaust 5.0 mm (0.20 in) This tool is needed to rebore the new valve [...]

1 - 10 GEN INFO CONTROL FUNCTIONS EC150000 CONTROL FUNCTIONS EC151000 “ ENGINE STOP ” BUTTON The “ ENGINE STOP ” button 1 is located on the left handlebar. Continue pushing the “ ENGINE STOP ” button till the engine comes to a stop. EC152000 CLUTCH LEVER The clutch lever 1 is located on the left han- dlebar; it disengages or engages the[...]

1 - 11 GEN INFO CONTROL FUNCTIONS EC156000 FRONT BRAKE LEVER The front brake lever 1 is located on the right handlebar. Pull it toward the handlebar to acti- vate the front brake. EC157000 REAR BRAKE PEDAL The rear brake pedal 1 is locate d on the right side of the machine. Press down on the brake pedal to activate the rear brake. EC158001 FUEL COC[...]

1 - 12 GEN INFO CONTROL FUNCTIONS EC15R001 DETACHABLE SIDESTAND This sidestand 1 is used to support only the machine when standing or transporting it. W ARNING • Never apply additional force to the side- stand. • Remove this sidestand befo re starting out. EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed t[...]

1 - 13 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 v alves, piston rings, and exhaust system, etc . N OTE: If knocking or pinging occurs, use a differen[...]

1 - 14 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 po isonous; they can cause loss of consciousness and death in a very short tim e. Always operate the machine in a well-ventilated area. CAUTION: • The carburetor on this machi ne has a built-in accelerator pum[...]

1 - 15 GEN INFO STARTING AND BREAK-IN 6. Return the cold starter knob to its original position and run the e ngine at 3,000 ~ 5,000 r/min for 1 or 2 minutes. N OTE: Since this model is equipped with an accelera- tor pump, if the engine is raced (the th rottle opened and closed), the air/fuel mixture will be too rich and the e ngine may stall. Also [...]

1 - 16 GEN INFO STARTING AND BREAK-IN STARTING A WARM ENGINE Do not operate the cold starter knob an d throt- tle. Pull the hot starter lever 1 and start the engine by kicking the kick starter forcefully with a firm stroke. As soon as the engine starts, release the hot starter lever to close the air passage. Restarting an engine after a fall Pull t[...]

1 - 17 GEN INFO BREAK-IN PROCEDURES 1. Before starting the engine, fill the fuel tank with the fuel. 2. Perform the pre-operation checks o n the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation o f the controls and the “ ENGINE STOP ” button. Then, restart the engine and ch eck its operation within no more[...]

GEN INFO 1 - 18 TORQUE-CHECK POINTS TORQUE-CHECK POINTS N OTE: Concerning the tightening torque, refer to “ MAINTENANCE SPEC IFICATIONS ” section in the CHAPTER 2. Frame to rea r frame Fuel tank to frame Silencer to rear frame Frame to eng ine Engine bracket to engine Engine bracket to frame Steering sha ft to frame Steering shaf t to handle cr[...]

1 - 19 GEN INFO CLEANING AND STORAGE EC1B000 0 CLEANING AND STORAGE EC1B100 0 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many com- ponents. 1. Before washing the machine, block off the end of the exhaust pipe to p revent water from entering. A plastic bag secured[...]

1 - 20 GEN INFO CLEANING AND STORAGE 8. Automotive wax may be applied to all painted or chromed surfaces. Avoid combi- nation cleaner-waxes, as they may contain abrasives. 9. After completing the above, start the engine and allow it to idle for several min- utes. EC1B200 1 STORAGE If your machine is to be stored for 60 days or more, some preventive[...]

SPEC 2 - 1 EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: YZ450FT (USA, CDN, AUS, NZ) YZ450F (EUROPE, ZA) Model code number: 5XD5 (USA) 5XD6 (EUROPE) 5XD8 (CDN, AUS, NZ, ZA) Dimensions: USA, ZA, AUS, NZ EUR (Except for F) F, CDN Overall length 2,190 mm (86.2 in) 2,195 mm (86.4 in) ← Overall width 827 mm (32.6 in) ← ← Over[...]

SPEC 2 - 2 Oil type or grade: Engine oil (For USA and CDN) At 5 ° C (40 ° F) or higher È Yamalube 4 (20W-40) or SAE 20W-40 type SG motor oil (Non-Friction modified) At 15 ° C (60 ° F) or lower É Yamalube 4 (10W-30) or SAE 10W-30 type SG motor oil (Non-Friction modified) and/o r Yamalube 4-R (15W-50) (Non-Friction modi- fied) (Except for USA a[...]

SPEC 2 - 3 Transmission: Primary reduction system Gear Primary reduction ratio 61/23 (2.652) Secondary reduction system Chain drive Secondary reduction ratio 51/14 (3.643) Transmission type Constant mesh, 4-speed Operation Left foot operation Gear ratio: 1st 27/14 (1.929) 2nd 25/16 (1.563) 3rd 23/18 (1.278) 4th 21/20 (1.050) Chassis: Frame type Sem[...]

SPEC 2 - 4 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 ~ 0.8670 in) ---- Camshaft[...]

SPEC 2 - 5 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 (1.0591 ~ 1.0669 in) ---- EX 2[...]

SPEC 2 - 6 Valve spring: Free length IN 37.03 mm (1.46 in) 36.03 mm (1.42 in) EX 37.68 mm (1.48 in) 36.68 mm (1.44 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) ---- EX 127.4 ~ 146.4 N at 27.38 [...]

SPEC 2 - 7 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 × 3.35 mm (0.04 × 0.13 in) ----[...]

SPEC 2 - 8 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 47.8 mm (1.88 in) 46.8 mm (1.84 in) Quantity 6 ---- Clutch housing thrust clearance 0.10 ~ 0.35 mm (0.[...]

SPEC 2 - 9 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) Bypass valve setting press[...]

SPEC 2 - 10 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 MAINTENANCE SPECIFICATIONS[...]

SPEC 2 - 11 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 28 2.8 20 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 NOTE.* 1 (nut) M6 × 1.0 2 10 [...]

SPEC 2 - 12 N OTE: - marked portion shall b e checked for torque tighte ning after break-in or before each ra ce. N OTE: *1: Tighten the cylinder hea d 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, [...]

SPEC 2 - 13 EC212201 CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing ---- Front suspension: USA, CDN, AUS, NZ, ZA EUROPE Front fork travel 300 mm (11.8 in) ← ---- Fork spring free length 465 mm (18.3 in) ← 460 mm (18.1 in) Spring rate, STD K = 4.5 N/mm (0.459 kg/mm, 25.7 lb/in) K = 4.4 N/mm (0.449 kg/mm, [...]

SPEC 2 - 14 Wheel: Front wheel type Spoke wheel ---- Rear wheel type Spoke wheel ---- Front rim size/material 21 × 1.60/Aluminum ---- Rear rim size/material 19 × 2.15/Aluminum ---- Rim runout limit: Radial ---- 2.0 mm (0.08 in) Lateral ---- 2.0 mm (0.08 in) Drive chain: Type/manufacturer DID520DMA2 SDH/DAIDO ---- Number of links 115 links + joint[...]

SPEC 2 - 15 N OTE: 1. First, tighten the ring nut approxima tely 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut wre nch, 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 outer tube M8 × 1.25 4 2[...]

SPEC 2 - 16 N OTE: - marked portion shall b e checked for torque tighte ning after break-in or before each ra ce. 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 42 4.2 30 Nipple (spoke) — 72 3 0.3 2.2 Disc cover and rear br[...]

SPEC 2 - 17 EC212300 ELECTRICAL Item Standard Limit Ignition system: Advancer type Electrical ---- C.D.I.: Magneto-model (stator)/manufacturer 5XD-00/YAMAHA ---- Source coil 1 resistance (color) 720 ~ 1,080 Ω at 20 ° C (68 ° F) (Green – Brown) ---- Source coil 2 resistance (color) 44 ~ 66 Ω at 20 ° C (6 8 ° F) (Black – Pink) ---- Pickup[...]

SPEC 2 - 18 EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies to rque 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 assemblies in a crisscross fash- ion, in progressive[...]

2 - 19 SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Oil delivery pipe 2 Intake ca mshaft 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 - 20 SPEC LUBRICATION DIAGRAMS 1 Camshaft 2 Connecting rod 3 Oil cleaner element 4 Cranksh aft 5 Main axle 6 Drive axle 7 Oil delivery pipe[...]

2 - 21 SPEC CABLE ROUTING DIAGRAM EC240000 CABLE ROUTING DIAGRAM 1 Fuel tank brea ther hose 2 Oil tank breather hose 3 Hot starter cable 4 Radiator hose 4 5 Clutch cable 6 Cylinder head breath er hose 7 Radiator hose 1 8 Hose guide 9 Brake hose 0 “ ENGINE STOP ” button lead A Clamp B Sub wire harness C TPS (throttle positio n sensor) lead D Neu[...]

2 - 22 SPEC CABLE ROUTING DIAGRAM Î Fasten the “ ENGINE STOP ” but- ton lead and sub wire ha rness to the frame at the pro tecting t ube for the “ ENG INE STOP ” button lead with a plastic locking tie and cut off the tie end. Ï Fasten the sub wire harness an d hot starter cable to the frame at the white tape for t he sub wire harness with[...]

2 - 23 SPEC CABLE ROUTING DIAGRAM Û Position the neutral switch lea d, CDI magneto lead an d radiator breather hose at the left of th e frame. B 0 C-C D-D B A A B D D C C F D G F D A G A A F A E A D C A A A A B A 0 1 2 3 4 5 6 7 8 9 Ì Ë Ê É È Ù Í Î Ï Ð Ð Ñ A Ô Õ Ø Ú H I H E Û Ò Ö × Ê Ê Ê Ó[...]

2 - 24 SPEC CABLE ROUTING DIAGRAM 1 CDI unit 2 Hot starter cable 3 Throttle c able (ret urn) 4 Throttle cable (pu ll) 5 Ignition coil 6 Radiator brea ther hose 7 Radiator hose 4 8 Cylinder head breath er hose 9 CDI unit bracket 0 CDI unit band È Pass the hot starter cab le and throttle cables throug h the cable guides. É Pass the hot star ter cab[...]

2 - 25 SPEC CABLE ROUTING DIAGRAM 1 Master cylinder 2 Brake hose holde r 3 Brake hose È Install the brake hose so that its pipe portion directs as sh own and lightly touche s the projec- tion on the ca liper. É Pass the brake ho se into the brake hose holder s. Ê If the brake hose contact s the spring (rea r shock ab sorber), correct its twist. [...]

2 - 26 SPEC CABLE ROUTING DIAGRAM 1 Throttle ca ble 2 Fuel tank brea ther hose 3 Clamp 4 Clutch cable 5 Hot starter cable 6 “ ENGINE STOP ” button lead 7 Brake hose 8 Hose guide È Fasten the “ ENGINE STOP ” but- ton lead to t he handlebar with the plastic band. É Pass the brake hose in fron t of the number plat e. 3 6 40 ˚ ±10 ˚ A 1 2 [...]

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

3 - 2 INSP ADJ MAINTENANCE INTERVALS SHIFT FORK, SHIFT CAM, GUIDE BAR Inspect Inspect wear ROTOR NUT Retighten MUFFLER Inspect and retig hten Clean Replace * Whichever comes first CRANK Inspect and clean CARBURETOR Inspect, adjust an d clean SPARK PLUG Inspect and clean Replace DRIVE CHAIN Use chain lube Chain slack: 48 ~ 58 mm (1.9 ~ 2.3 in) Lubri[...]

3 - 3 INSP ADJ MAINTENANCE INTERVALS FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium base grease PROTECTOR GUIDE Replace REAR SHOCK ABSORBER (After rain ride) Inspect and adjus t Lube Molybdenum disulfide grease Retighten CHAIN GUARD AND R OLLERS Inspect SWINGARM Molybdenum disulfide grease Inspect, lube and re tighten RELAY ARM, CONNECTIN[...]

3 - 4 INSP ADJ PRE-OPERATION INSPECTION AND MAINTENANCE EC320000 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, pra ctice 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 cool[...]

3 - 5 INSP ADJ EC350000 ENGINE EC351011 COOLANT LEVEL INSPECTION W ARNING Do not remove the radiator cap 1 , drain bolt and hoses when the e ngine 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 rotat[...]

3 - 6 INSP ADJ COOLANT REPLACEMENT EC353011 COOLANT REPLACEMENT W ARNING Do not remove the radiator cap when the engine is hot. CAUTION: Take care so that coo lant does not splash on painted surfaces. If it splashes, wash it away with water. 1. Place a container under the engine. 2. Remove: • Engine guard 1 • Coolant drain bolt 2 3. Remove: •[...]

3 - 7 INSP ADJ RADIATOR CAP INSPECTION CAUTION: • Do not mix more than on e type of ethyl- ene glycol antifreeze containing corro- sion inhibitors for aluminum engine. • Do not use water containing impurities or oil. 7. Install: • Radiator cap Start the engine and warm it up for a sev- eral minutes. 8. Check: • Coolant level Coolant level l[...]

3 - 8 INSP ADJ RADIATOR CAP OPENING PRESSURE INSPECTION/ COOLING SYSTEM INSPECTION EC356001 RADIATOR CAP OPENING PRESSURE INSPECTION 1. Attach: • Radiator cap tester 1 and adapter 2 N OTE: Apply water on the radiator cap seal. 3 Radiator ca p 2. Apply the specified pressure. 3. Inspect: • Pressure Impossible to maintain the specified pres- sure[...]

3 - 9 INSP ADJ CLUTCH ADJUSTMENT N OTE: • Do not apply pressure more than specified pressure. • Radiator should be filled fu lly. 4. Inspect: • Pressure Impossible to maintain the specified pres- sure for 10 seconds → Repair. • Radiator • Radiator hose joint Coolant leakage → Repair or re place. • Radiator hose Swelling → Replace.[...]

3 - 10 INSP ADJ THROTTLE CABLE ADJUSTMENT/ THROTTLE LUBRICATION EC35A00 1 THROTTLE CABLE ADJUSTMENT 1. Check: • Throttle grip free play a Out of specification → Adjust. Throttle grip free play a : 3 ~ 5 mm (0.12 ~ 0.20 in) 2. Adjust: • Throttle grip free play Throttle grip free play adjustment steps: • Slide the adjuster cover. • Loosen t[...]

3 - 11 INSP ADJ HOT STARTER LEVER ADJUSTMENT/ AIR FILTER CLEANING HOT STARTER LEVER ADJUSTMENT 1. Check: • Hot starter lever free play a Out of specification → Adjust. 2. Adjust: • Hot starter lever free play N OTE: After adjustment, check proper op eration of hot starter. Hot starter lever free play a : 3 ~ 6 mm (0.12 ~ 0.24 in) Hot starter [...]

3 - 12 INSP ADJ AIR FILTER CLEANING 2. Clean: • Air filter element Clean them with solvent. N OTE: After cleaning, remove the remaining solvent by squeezing the element. CAUTION: • Do not twist the element when squeezing the element. • Leaving too much of solvent in the ele- ment may result in poor starting. 3. Inspect: • Air filter element[...]

3 - 13 INSP ADJ 7. Install: • Air filter element 1 • Washer • Fitting bolt N OTE: Align the projection a on filter guide with the hole b in air filter case. T R . . 2 Nm (0.2 m · kg, 1.4 ft · lb) ENGINE OIL LEVEL INSPECTION 1. Stand the machine on a level surface. N OTE: • When checking the oil level make sure that the machine is upright.[...]

3 - 14 INSP ADJ ENGINE OIL LEVEL INSPECTION 4. Inspect: • Oil level Oil level should be between maximum a and minimum b marks. Oil level low → Add oil to proper level. N OTE: When inspecting the oil level, do not screw the oil level gauge into the oil tank. Insert the gauge lightly. (For USA and CDN) CAUTION: • Do not add any chemical additiv[...]

3 - 15 INSP ADJ ENGINE OIL REPLACEMENT 5. Start the engine and let it warm up for sev- eral minutes. CAUTION: When the oil tank is empty, never start the engine. 6. Idle the engine more than 10 seconds while keeping the machin e upright. Then stop the engine and add the oil to the maxi- mum level. 7. Install: • Oil tank cap ENGINE OIL REPLACEMENT[...]

3 - 16 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 - 17 INSP ADJ PILOT SCREW ADJUSTMENT 10. Install: • Oil filler plug 11. Inspect: • Engine (for oil leaks) • Oil level Refer to “ ENGINE OIL LEVEL INSPEC- TION ” . 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 [...]

3 - 18 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 VALVE CLEARANCE ADJUSTMENT N OTE: • The valve clearance should be adjusted when the engine is cool to th e touch. • The piston must be at Top Dead Center (T.D.C.) on compressio[...]

3 - 19 INSP ADJ VALVE CLEARANCE ADJUSTMENT 3. Remove: • Timing plug 1 • Straight plug 2 • O-ring 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 wi[...]

3 - 20 INSP ADJ VALVE CLEARANCE ADJUSTMENT 5. Adjust: • Valve clearance Adjustment steps: • Loosen the timing cha in tensioner cap bolt. • Remove the timing chain tensioner and camshaft caps. N OTE: Remove the camshaft cap bolts in a criss- cross pattern from the outside working inwards. • Remove the cams haft (exhaust 1 and intake 2 ). N O[...]

3 - 21 INSP ADJ VALVE CLEARANCE ADJUSTMENT • Round off the last digit of the installed pad number to the nearest in crement. 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 N OTE: Pads can only be selected in 0.05 mm incre- ments. • Locate the rounded-of f valu[...]

3 - 22 INSP ADJ 6. Install: • All removed parts N OTE: Install all removed parts in reversed order of their removal. • Install the timing chain tensioner. Refer to “ CAMSHAFTS ” section in the CHAPTER 4. N OTE: Turn the crankshaft counterclockwise sev- eral turns so that the installed parts settle into the right position. • Recheck the va[...]

3 - 23 INSP ADJ VALVE CLEARANCE ADJUSTMENT INTAKE MEASURED CLEARANCE INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 1 65 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.04 120 125 130 135 140 145 150 1 55 160 1 65 170 175 180 185 190 195 200 205 210 215 220 225 230 0.05 ~ 0.09 120 125 130 135 140 145 150 155 160 165 1[...]

3 - 24 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 disasse mbled. • 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 b[...]

3 - 25 INSP ADJ FRONT BRAKE ADJUSTMENT 3. Install: • Protector (rear brake) • Reservoir float (front brake) • Diaphragm • Master cylinder cap N OTE: If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the b leeding procedure when the tiny bubbles in the system have disap- peared. j. [...]

3 - 26 INSP ADJ REAR BRAKE ADJUSTMENT/ FRONT BRAKE PAD INSPECTION AND REPLACEMENT EC364002 REAR BRAKE ADJUSTMEN T 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 - 27 INSP ADJ FRONT BRAKE PAD INSPECTION AND REPLACEMENT • Loosen the pad pin 2 . • Remove the caliper 3 from the front fork. • Remove the pad pin and brake pads 4 . • Connect the transparent hose 5 to the bleed screw 6 and place the suitable con- tainer under its end. • Loosen the bleed screw and push the cali- per piston in. CAUTION: [...]

3 - 28 INSP ADJ REAR BRAKE PAD INSPECTION AND REPLACEMENT 3. Inspect: • Brake fluid level Refer to “ BRAKE FLUID LEVEL INSPEC- TION ” section. 4. Check: • Brake lever operation A softy or spongy feeling → Bleed brake system. Refer to “ BRAKE SYSTEM AIR BLEED- ING ” section. • Install the pad pin plug 0 . T R . . Pad pin plug: 3 Nm ([...]

3 - 29 INSP ADJ REAR BRAKE PAD INSPECTION AND REPLACEMENT • Remove the pad pin 6 and brake p ads 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 - 30 INSP ADJ REAR BRAKE PAD INSULATOR INSPECTION/ BRAKE FLUID LEVEL INSPECTION 3. Inspect: • Brake fluid level Refer to “ BRAKE FLUID LEVEL INSPEC- TION ” section. 4. Check: • Brake pedal operation A softy or spongy feeling → Bleed brake system. Refer to “ BRAKE SYSTEM AIR BLEED- ING ” section. EC36b000 REAR BRAKE PAD INSULATOR INS[...]

3 - 31 INSP ADJ SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION EC368000 SPROCKETS INSPECTION 1. Inspect: • Sprocket teeth a Excessive wear → Replace. N OTE: Replace the drive, driven sprockets and drive chain as a set. DRIVE CHAIN INSPECTION 1. Measure: • Drive chain length (15 links) a Out of specification → Replace. N OTE: • While measurin[...]

3 - 32 INSP ADJ DRIVE CHAIN SLACK ADJUSTMENT 4. Check: • Drive chain stiffness a Clean and oil the chain and hold as illus- trated. Stiff → Replace drive chain. 5. Install: • Drive chain 1 • Joint 2 • Master link clip 3 CAUTION: Be sure to install the master link c lip to the direction as shown. a Turning direction New 6. Lubricate: • D[...]

3 - 33 INSP ADJ FRONT FORK INSPECTION 3. Adjust: • Drive chain slack Drive chain slack adjustment steps: • Loosen the axle nut 1 a nd locknuts 2 . • Adjust chain slack by turning the adjusters 3 . To tighten → Turn adjuster 3 counter- clockwise. To loosen → Turn adjuster 3 clockwise and push wheel forward. • Turn each adjuster exactly t[...]

3 - 34 INSP ADJ FRONT FORK OIL SEAL AND DUST SEAL CLEANING/ FRONT FORK INTERNAL PRESSURE RELIEVING/ FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT EC36D001 FRONT FORK OIL SEAL AND DUST SEAL CLEANING 1. Remove: • Protector • Dust seal 1 N OTE: Use a thin screw driver, and be careful not to damage the inner fork tube and dust seal. 2. Clean: • Dus[...]

3 - 35 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 CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. W ARNING Always adjust each fro[...]

3 - 36 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. * For EUROPE 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 sa[...]

3 - 37 INSP ADJ REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1. Elevate the rear wheel by placing the suit- able stand under the engine . 2. Remove: • Rear frame 3. Loosen: • Locknut 1 4. Adjust: • Spring preload By turning the adjuster 2 . * For EUROPE N OTE: • Be sure to remove all dirt and m[...]

3 - 38 INSP ADJ REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT EC36N014 REAR SHOCK ABSORBER REBOUN D 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[...]

3 - 39 INSP ADJ REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT EC36c00 0 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 - 40 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 - 41 INSP ADJ TIRE PRESSURE CHECK/SPOKES INSPECTION AND TIGHTENING/WHEEL INSPECTION EC36Q00 0 TIRE PRESSURE CHECK 1. Measure: • Tire pressure Out of specification → Adjust. N OTE: • 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 val[...]

3 - 42 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 gently rock the fork assembly back and f orth. Free play [...]

3 - 43 INSP ADJ STEERING HEAD INSPECTION AND ADJUSTMENT • Tighten the ring nut 3 using ring nut wrench 4 . N OTE: • Apply the lithium soap base gr ease on the thread of the steering shaft. • 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)[...]

3 - 44 INSP ADJ T R . . Steering shaft nut: 145 Nm (14.5 m • kg, 1 05 ft • lb) Handlebar upper holder: 28 Nm (2.8 m • kg, 20 ft • lb) Pinch bolt (handle crown): 23 Nm (2.3 m • kg, 17 ft • lb) Number plate: 7 Nm (0.7 m • kg, 5.1 ft • lb) STEERING HEAD INSPECTION AND ADJUSTMENT[...]

3 - 45 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 pi vot 3 Shift pedal pivot 4 Footrest piv ot 5 Throttle-to -handlebar conta ct 6 Drive chain 7 Tube guide cable winding por tion 8 Throttle ca ble end 9[...]

3 - 46 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. N OTE: When the engine runs for many hour[...]

3 - 47 INSP ADJ IGNITION TIMING CHECK IGNITION TIMING CHECK 1. Remove: • Timing plug 1 2. Attach: • Timing light To the ignition coil lead (orange lead 1 ). Timing light: YM-33277-A/90890-03141 3. Adjust: • Engine idling speed Refer to “ IDLE SPEED ADJUSTMENT ” . 4. Check: • Ignition timing Visually check the stationary pointer a is wit[...]

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 Number plate removal Extent of removal Order Part name Q’ty Remarks SEAT, FUEL TANK AND SIDE COVERS REMOVAL Preparation for removal Turn the fuel cock to “OFF”. Disconnect the fuel hose. 1S e a t 1 2[...]

4 - 2 ENG REMOVAL POINTS Side cover 1. Remove: • Bolt (side cover) • Side cover (left) 1 • Side cover (right) 2 N OTE: 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 È 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 Bolt (clamp)[...]

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 N OTE: First, temporarily tighten the n ut (exhaust pipe), then tighten the bolt (exh[...]

4 - 5 ENG RADIATOR EC450001 RADIATOR Extent of removal: 1 Radiator 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 and fuel tank Refer to “ SEAT, FUEL TANK AND SIDE COVERS ” section. Exhaust pipe Refer to ?[...]

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 und er 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 [...]

4 - 7 ENG RADIATOR 3. Install: • Radiator breather hose 1 • Radiator (right) 2 Refer to “ CABLE ROUTING DIAGRAM ” section in the CHAPT ER 2. T R . . 10 Nm (1.0 m · kg, 7.2 ft · lb) 4. Install: • Panel 1 • Bolt (radiator panel upper) 2 N OTE: 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 5 1 2 6 6 3 9 7 8 4 4 T R . . 3 Nm (0.3 m • kg, 2.2 ft • Ib) T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) T R . . 11 Nm (1.1 m • kg, 8.0 ft • Ib) T R . . 2 Nm (0.2 m • kg, 1.4 ft • Ib) T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) T R . . 3 Nm (0.3 m • kg, 2.2 ft • Ib) Extent of removal: 1 Carburetor remov[...]

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 ho lder 1 6 Jet needle 1 7 Cover 1 8 Spring 1 9 Diaphragm (accelerator pump) 1 0 Floa[...]

4 - 10 ENG CARBURETOR Extent of removal Order Part name Q ’ ty Remarks F Main jet 1 G Needle jet 1 H Spacer 1 I Pilot jet 1 J Starter jet 1 K Push rod 1 Pull the push rod. L Throttle shaft assembly 1 M Push rod link lever assembly 1 N Pilot air jet 1 O 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 N OTE: To optimize the fuel flow at a small throttle op[...]

4 - 12 ENG CARBURETOR 2. Inspect: • Main jet 1 • Pilot jet 2 • Needle jet 3 • Starter jet 4 • Pilot air jet 5 • Leak jet 6 Damage → Replace. Contamination → Clean. N OTE: • Use a petroleum based solven t for cleaning. Blow out all passages and jets with com- pressed air. • Never use a wire. Needle valve 1. Inspect: • Needle va[...]

4 - 13 ENG CARBURETOR EC464511 Float height 1. Measure: • Float height a Out of specification → Adjust. Float height: 8.0 mm (0.31 in) Measurement and adjustment steps: • Hold the carburetor in an upside down position. N OTE: • Slowly tilt the carburetor in the opposite direction, then take the me asurement when the needle valve aligns with[...]

4 - 14 ENG Starter plunger 1. Inspect: • Cold starter plunger 1 • Hot starter plunger 2 Wear/damage → Replace. 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 ?[...]

4 - 15 ENG CARBURETOR 3. Install: • Spring 1 1 • Lever 1 2 To lever 2 3 . N OTE: 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 N OTE: Make sure the stopper a of the spring 2 fits into the recess b in the carburetor. 1 a b 6. Insta[...]

4 - 16 ENG CARBURETOR 8. Install: • Throttle shaft assembly 1 • Plain washer (metal) 2 • Plain washer (resin) 3 • Valve lever 4 N OTE: • 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 N OTE: • After installing the needle valve t o the float, install them to the carburetor. • Check the float for smooth movement. 12. Install: • Pilot screw 1 • Spring 2 • Washer 3 • O-ring 4 Note the following installation points: • Turn in the pilot scr[...]

4 - 18 ENG CARBURETOR 14. Install: • Diaphragm (accelerator pump) 1 • Spring 2 • O-ring 3 • Cover 4 • Hose holder (drain hose) 5 • Screw (cover) 6 N OTE: Install the diaphragm (accelerator pump) with its mark a facing the spring. 15. Install: • Jet needle 1 • Collar 2 • Spring 3 • Needle holder 4 • Throttle valve plate 5 To th[...]

4 - 19 ENG CARBURETOR Accelerator pump timing adjustment Adjustment steps: N OTE: In order for the throttle valve height a to achieve the specified value, tuck und er the throttle valve plate 1 the rod 2 etc. with the same outer diameter as the specified value. Throttle valve height: 1.30 mm (0.051 in) • Fully turn in the accelerator pump adjust-[...]

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 HE AD COVER REMOVAL Preparation for removal Seat and fuel tank R efer to “ SEAT, FUEL TANK AND SIDE COVERS ” section. Carburetor Refer to “ CARBURETOR ” section. 1 Spark plug 1 2 Eng[...]

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 te nsioner 1 5 Gasket 1 6 Bolt (camshaft cap) 10 7 Camshaft cap 2 8C l i p 2 9 Exhaust camshaft 1 10 Intak[...]

4 - 23 ENG CAMSHAFTS REMOVAL POINTS Camshaft 1. Remove: • Timing plug 1 • Straight plug 2 2. Align: •“ I ” mark With stationary po inter. 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 N OTE: 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 → Repla[...]

4 - 25 ENG CAMSHAFTS 4. Measure: • Camshaft-to-cap clearance Out of specificat ion → Measure camshaft 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 syst em Checking steps: • Check that the decompressor cam 1 moves smoothly. • Check that the decomp ressor 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[...]

4 - 27 ENG CAMSHAFTS • Fit the timing chain 3 onto both camshaft sprockets and install the camshafts on the cylinder head. N OTE: 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 cr[...]

4 - 28 ENG • With the rod fully wound and the chain ten- sioner UP mark a facing upward, install the gasket 1 and the chain tensioner 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 N OTE: Tighten the cylinder head b olts to 30 Nm (3.0 m • kg, 22 ft • lb) in the proper tightening seq uence, 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 c[...]

4 - 30 ENG CYLINDER HEAD INSPECTION Cylinder head 1. Eliminate: • Carbon deposits (from the combustion chambers) Use a rounded scraper. N OTE: Do not use a sharp instrument to avoid damag- ing 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 N OTE: While pulling up the timin g chain, install the timing chain guide (front) an d cylinder head. New 2. Install: • Plain washer 1 • Bolt [L = 160 mm (6.30 in)] 2 • Bolt [L = 150 mm[...]

4 - 32 ENG • Remove the bolts. • Again apply the molybdenum disulfide grease on the t hreads and contact sur- faces of the bolts an d on both contact sur- faces of the plain washers. • Retighten the bolts. N OTE: Tighten the bolts to the specified torque in two or three steps in the pro per tightening sequence as shown. T R . . Bolts (cylinde[...]

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 Valve lifter and valve cotter 1. Remove: • Valve lifters 1 • Pads 2 N OTE: 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 va lve se[...]

4 - 35 ENG VALVES AND VALVE SPRINGS INSPECTION Valve 1. Measure: • Stem-to-guide clearance Out of specification → Replace the va lve 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 ~ [...]

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

4 - 37 ENG VALVES AND VALVE SPRINGS 5. Measure: • Runout (valve stem) Out of specification → Replace. N OTE: • 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/wea[...]

4 - 38 ENG VALVES AND VALVE SPRINGS 9. Lap: • Valve face • Valve seat N OTE: 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 th e gap between the valve stem and the gu[...]

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>: 36.03 mm (1.42 in) Exhaust: 37.68 mm (1.48 in) <Limit>[...]

4 - 40 ENG VALVES AND VALVE SPRINGS ASSEMBLY AND INSTALLATION 1. Apply: • Molybdenum disulfide oil Onto the valve stem and valve stem seal. 2. Install: • Valves 1 • Valve spring seats 2 • Valve stem seals 3 • Valve springs 4 • Valve spring retainers 5 N OTE: • Make sure that each valve is inst alled in its original place, also referri[...]

4 - 41 ENG VALVES AND VALVE SPRINGS 5. Install: • Adjusting pad 1 • Valve lifter 2 N OTE: • Apply the engine oil on the valve lifters. • Apply the molybdenum disulfide oil on the valve stem end. • Valve lifter must turn smoothly when rotated with a finger. • Be careful to reinstall valve lifters and pads in their original p lace.[...]

4 - 42 ENG CYLINDER AND PISTON CYLINDER AND PISTON CYLINDER AND PISTON Extent of removal: 1 Cylinder re moval 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 [...]

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

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 specif[...]

4 - 45 ENG CYLINDER AND PISTON Piston ring 1. Measure: • Ring side clearance Use a feeler gauge 1 . Out of specifica tion → Replace the piston and rings as a set. N OTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance. 2. Position: • Piston ring (in cylinder) N OTE: Insert a ring into the cylinder and p[...]

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. N OTE: • Be sure to install the piston rings so that the manufacturer ’ s [...]

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 e nd c Oil ring en d (upper) d Oil ring e Oil ring end (lower) 3. Install: • Piston 1 • Piston pin 2 • Piston pin clips 3 N OTE: • Apply engine oil onto the pisto n pin and pis- ton. • Be s[...]

4 - 48 ENG CLUTCH CLUTCH CLUTCH Extent of removal: 1 Push rod and pu sh lever removal 2 Push pod 1 disassembly 3 Friction plate and clutch plate removal 4 Clutch housin g 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 CHAP[...]

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 N OTE: Straighten the lock washer tab and use the clutch holding tool 4 to hold the clutch boss. È For USA and CDN É Except for USA and CDN Clutch holding tool: YM-91042/90890-04086 È É EC494000 INSPECTION EC484100 Clutch hous[...]

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 poin ts. 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 thic[...]

4 - 52 ENG CLUTCH EC4A500 0 ASSEMBLY AND INSTALLATION Push lever 1. Install: • Push lever 1 • Bolt (push lever) N OTE: • 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 b olt (seat plate). T R . . 10 Nm (1.0 m · kg, [...]

4 - 53 ENG CLUTCH 3. Bend the lock washer 1 tab. 4. Install: • Friction plate 1 • Clutch plate 2 N OTE: • Install the clutch plates a nd 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 7. Install: • Pressure plate 1 8. Install: • Clutch spring • Bolt (clutch spring) N OTE: 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) N OTE: Tighten the bolt[...]

4 - 55 ENG OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) OIL FILTER, WATER PUMP AND CRANKCA SE 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 CO[...]

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 Kick starter 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 N OTE: Hold the impeller shaft on its width across the flats a with spanners, etc. and remove the impeller. EC4G3210 Oil seal N OTE: It is not necessary to disassemble the water pump,[...]

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 N OTE: • Apply the lithium soap base grea[...]

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

4 - 60 ENG OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) Kick crank 1. Install: • Kick starter 1 • Plain washer • Bolt (kick starter) N OTE: Install the kick starter so that the kick starter is as vertical as possible with the distance a between the kick starter and th e frame being 5 mm (0.20 in) or more. T R . . 33 Nm (3.3 m · kg, 24 [...]

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 g ear 2 Balancer Extent of removal Order Part name Q ’ ty Remarks BALANCER REMOVAL Preparation for removal Clutch h ousing Refer to “ CLUTCH ” section. Crankcase cover (right) R e f e r to “ OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) ” section. Stator Refer [...]

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 N OTE: Place an aluminum plate a between the teeth of the balancer drive gear 3 and driven gear 4 . a 3 1 4 2 4 3 a Balancer 1. Remove: • Balancer 1 N OTE: When removing [...]

4 - 64 ENG BALANCER ASSEMBLY AND INSTALLATION Balancer, balancer drive gear and balance r driven gear 1. Install: • Balancer 1 N OTE: 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 N OTE: Instal[...]

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 h ousing Refer to “ CLUTCH ” section. Crankcase cover (right) R e f e r to “ OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) [...]

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 th e rotor housing 3 . Out of specification → [...]

4 - 68 ENG OIL PUMP 2. Install: • Outer rotor 1 1 N OTE: 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 N OTE: • Apply the engine oil on the oil pump d rive shaft end and inner rotor 2. • Fit the pin into the groove in the inner rotor 2. 4. I[...]

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 Segm ent 1 Refer to “ REMOVAL POINTS ” . 4[...]

4 - 71 ENG KICK AXLE AND SHIFT SHAFT REMOVAL POINTS EC4B310 1 Kick axle assembly 1. Remove: • Kick axle assembly 1 N OTE: 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 N OTE: The shift lever assembly is disa[...]

4 - 72 ENG KICK AXLE AND SHIFT SHAFT EC4B440 0 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. EC4B450 0 Stopper lever 1. Inspect: • Stopp[...]

4 - 73 ENG KICK AXLE AND SHIFT SHAFT EC4B511 1 Stopper lever 1. Install: • Torsion spring 1 • Stopper lever 2 • Bolt (stopper lever) 3 N OTE: 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 . N OTE: Apply the engine oil on the spr[...]

4 - 74 ENG KICK AXLE AND SHIFT SHAFT EC4C5301 Shift shaft 1. Install: • Roller 1 • Collar 2 • Torsion spring 3 • Shift shaft 4 N OTE: Apply the engine oil on the roller and shift shaft. 2. Install: • Shift pedal 1 • Bolt (shift pedal) N OTE: When installing the shift peda l onto the shift shaft, be sure that the cen ter of the shif t pe[...]

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

4 - 76 ENG CDI MAGNETO EC4L0000 CDI MAGNETO Extent of removal: 1 CDI magneto removal Extent of removal Order Part name Q ’ ty Remarks CDI MAGNETO REMOVAL Preparation for removal Seat and fuel tank R efer to “ SEAT, FUEL TANK AND SIDE COVERS ” section. Bolt [radiator (left)] Disconnect the CDI magneto lead. Refer to “ RADIATOR ” section. 1[...]

4 - 77 ENG CDI MAGNETO EC4L3000 REMOVAL POINTS EC4L3101 Rotor 1. Remove: • Nut (rotor) 1 • Plain washer Use the rotor holding tool 2 . 2. Remove: • Rotor 1 Use the flywheel puller 2 . N OTE: When installing the flywheel puller, t urn it counterclockwise. Rotor holding tool: YU-1235/90890-01235 Flywheel puller: YM-1189/90890-01189 EC4L4000 INS[...]

4 - 78 ENG CDI MAGNETO EC4L5000 ASSEMBLY AND INSTALLATION CDI magneto 1. Install: • Stator 1 • Screw (stator) 2 N OTE: • Apply the sealant to the grommet of the CDI magneto lead. • Tighten the screws using the T30 b it. Quick gasket ® : ACC-QUICK-GS-KT YAMAHA Bond No. 1215: 90890-85505 T R . . 10 Nm (1.0 m · kg, 7.2 ft · lb) 2. Install: [...]

4 - 79 ENG CDI MAGNETO 4. Connect: • CDI magneto lead Refer to “ CABLE ROUTING DIAGRAM ” section in the CHAPT ER 2. 5. Install: • Dowel pin • Gasket [crankcase cover (left)] • Crankcase cover (left) 1 • Hose holder (cylinder head breather hose) 2 • Bolt [crankcase cove r (left)] N OTE: Tighten the bolts in stage, using a crisscross [...]

4 - 80 ENG ENGINE REMOVAL EC4M0000 ENGINE REMOVAL Extent of removal Order Part name Q ’ ty Remarks ENGINE REMOVAL Preparation for removal Hold th e machine by placing the suitable stand under the frame. W ARNING Support the machine securely so there is no danger of i t falling ove r. Seat and fuel tank Refer to “ SEAT, FUEL TANK AND SIDE COVERS[...]

4 - 81 ENG ENGINE REMOVAL Extent of removal: 1 Engine removal Extent of removal Order Part name Q ’ ty Remarks 1 Engine skid plate (front) 1 2 Neutral switch 1 3 Oil hose 2 4 Chain cover 1 5 Nut (drive sprocket) 1 Refer to “ REMOVAL POINTS ” . 6 Lock washer 1 7 Drive sprocket 1 8C l i p 1 9 Bolt (brake pedal) 1 10 Brake pedal 1 11 Engine uppe[...]

4 - 82 ENG ENGINE REMOVAL EC4M3000 REMOVAL POINTS EC4F3100 Drive sprocket 1. Remove: • Nut (drive sprocket) 1 • Lock washer 2 N OTE: • Straighten the lock washer tab. • Loosen the nut while ap plying the rear brake. 2. Remove: • Drive sprocket 1 • Drive chain 2 N OTE: Remove the drive sprocket toge ther with the drive chain. EC4M3301 En[...]

4 - 83 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 lower bracket) 5 • Engine mounting bolt (front) 6 • Bolt (engine guard) 7 • Engine upper bracket (right) [...]

4 - 84 ENG ENGINE REMOVAL 2. Install: • Lock washer 1 • Nut (drive sprocket) 2 N OTE: Tighten the nut while applying the re ar brake. New T R . . 75 Nm (7.5 m · kg, 54 ft · lb) 3. Bend the lock washer tab to lock the nut. 4. Install: • Chain guide • Chain cover 1 • Screw (chain cover) 2 2 1 T R . . 8 Nm (0.8 m · kg, 5.8 ft · lb ) 5. I[...]

4 - 85 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 - 86 ENG CRANKCASE AND CRANKSHAFT Extent of removal Order Part name Q ’ ty Remarks 10 Crankcase (right) 1 Refer to “ REMOVAL POINTS ” . 11 Crankcase (left) 1 12 Oil strainer 1 13 Oil delivery pipe 2 1 14 Crankshaft 1 U se special tool. Refer to “ REMOVAL POINTS ” . 2 1[...]

4 - 87 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 Refer to “ TRANSMISSION, SHIFT CAM AND SHIFT FORK ” section. Shift cam and shift fork 1 Oil seal 3 2 Bearing 10 Refer to “ REMOVA[...]

4 - 88 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. N OTE: Loosen each bolt 1/4 of a turn at a t ime and after all the bolts are loosen ed, remove them. • Remove the crankcase (right). N OTE: • P[...]

4 - 89 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 N OTE: • Remove the bearing from the crankcase by pressing its inner race. • Do not use the removed bearing. Crankcase separating t[...]

4 - 90 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 thickne ss gauge. Dial gauge and stand: YU-3097/90890-01252 Standard <Limit> Runout limit: 0.03 mm (0.00[...]

4 - 91 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). N OTE: • Install the bearing by pressing its outer race parallel. • To prevent the [...]

4 - 92 ENG CRANKCASE AND CRANKSHAFT N OTE: • Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other. Ope rate the installing tool until the crankshaft botto ms against the bearing. • Before installing the crankshaft, clean the contacting surface of cra nkcase. CAUTION: Do not use a h[...]

4 - 93 ENG CRANKCASE AND CRANKSHAFT 5. Install: • Dowel pin 1 • O-ring 2 • Crankcase (right) To crankcase (left). N OTE: • 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 - 94 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 - 95 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 N OTE: • 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 [...]

4 - 96 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. N OTE: For a malfunctioning shift fork, re p[...]

4 - 97 ENG TRANSMISSION, SHIFT CAM AND SHIFT FORK 2. Install: • 2nd wheel gear (25T ) 1 • Collar 2 • 3rd wheel gear (23T) 3 • 4th wheel gear (21T) 4 • 1st wheel gear (27T) 5 • O-ring 6 To drive ax le 7 . N OTE: • Apply the molybdenum disulfide oil on the inner and end surface of the idler gear and on the inner surface of the sliding g[...]

4 - 98 ENG TRANSMISSION, SHIFT CAM AND SHIFT FORK 5. Install: • Shift fork 1 (L) 1 • Shift fork 2 (R) 2 • Shift cam 3 To main axle and drive axle. N OTE: • Apply the molybdenum disulfide oil on the shift fork grooves. • Mesh the shift fork #1 (L) with the 3rd pinion gear 4 on the main axle. • Mesh the shift fork #2 (R) with the 4th whee[...]

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 re moval 3 Brake disc removal Extent of removal Order Part name Q’ty Remarks FRONT WHEEL REMOVAL W ARNING Support the machine securely so there is no danger of i t falling ove r. [...]

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 REAR WHEEL REMOVAL W ARNING Support the machine securely so there is no danger of i t falling ove r. Preparation for removal Hold th e machine by placing the suitable stand under the [...]

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

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 . N OTE: The bending value is shown by on e 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 N OTE: • Apply the lithium soap base g rease on the bearing and oil seal lip when installing. • Use a socket that matches the out side diam- eter of the race of the bearing. • [...]

5 - 6 CHAS FRONT WHEEL AND REAR WHEEL 5. Install: • Wheel axle 1 N OTE: Apply the lithium soap base grease on the wheel axle. 6. Install: • Nut (wheel axle) 1 T R . . 105 Nm (10.5 m · kg, 75 ft · lb) 7. Tighten: • Bolt (axle holder) 1 N OTE: Before tightening the bolt, fit the wheel axle to the axle holder by stroking the front fork sev- er[...]

5 - 7 CHAS FRONT WHEEL AND REAR WHEEL Rear wheel 1. Install: • Bearing (right) 1 • Circlip 2 • Spacer 3 • Bearing (left) 4 • Oil seal 5 N OTE: • Apply the lithium soap base g rease on the bearing and oil seal lip when installing. • Install the bearing with seal facing outward. • Use a socket that matches the out side diam- eter of t[...]

5 - 8 CHAS 4. Install: • Collar 1 N OTE: Apply the lithium soap base grease on the oil seal lip. 5. Install: • Wheel N OTE: Install the brake disc 1 be tween the brake pads 2 correctly. 6. Install: • Drive chain 1 N OTE: Push the wheel 2 forward and install th e drive chain. 7. Install: • Chain puller (left) 1 • Wheel axle 2 N OTE: • In[...]

5 - 9 CHAS FRONT WHEEL AND REAR WHEEL 9. Adjust: • Drive chain slack a Refer to “ DRIVE CHAIN SLACK ADJUSTMENT ” section in the CHAPTER 3. Drive chain slack: 48 ~ 58 mm (1.9 ~ 2.3 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)[...]

5 - 10 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 FRONT BRAKE REMOVAL W ARNING Support the machine securely so there is no danger of i t falling ove r. Preparation for r[...]

5 - 11 CHAS EC5A8100 REAR BRAKE Extent of removal: 1 Master cylinder removal 2 Brake ho se removal 3 Caliper removal Extent of removal Order Part name Q ’ ty Remarks REAR BRAKE REMOVAL W ARNING Support the machine securely so there is no danger of i t falling ove r. Preparation for removal Hold th e machine by placing the suitable stand under the[...]

5 - 12 CHAS EC5A8200 CALIPER DISASSEMBLY È Front É 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 pi ston 2 1 Refer to “ REMOVAL POINTS ” . 5 Dust seal 2 1 6 Piston seal 2 1 1 2 FR[...]

5 - 13 CHAS FRONT BRAKE AND REAR BRAKE EC5A8300 MASTER CYLINDER DISASSEMBLY È Front É 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 Reservoir fl oat 1 4 Master cylinder boot 1 5 [...]

5 - 14 CHAS FRONT BRAKE AND REAR BRAKE EC5A300 0 REMOVAL POINTS Brake fluid 1. Remove: [Front] • Master cylinder cap 1 [Rear] • Master cylinder cap 1 • Protector N OTE: Do not remove the diaphragm. È Front É Rear 2. Connect the transparent hose 2 to the bleed screw 1 and place a suitable con- tainer under its end. È Front É Rear È É 3. [...]

5 - 15 CHAS FRONT BRAKE AND REAR BRAKE EC533402 Piston seal kit 1. Remove: • Dust seal 1 • Piston seal 2 N OTE: Remove the piston seals and dust seals by pushing them with a finger. CAUTION: Never attempt to pry out piston seals and dust seals. W ARNING Replace the piston seals and dust seals whenever a caliper is disassembl ed. È Front É Rea[...]

5 - 16 CHAS 4. Inspect: • Master cylinder piston 1 • Master cylinder cup 2 Wear/damage/score marks → Replace master cylinder kit. È Front É Rear ÈÉ EC534214 Caliper 1. Inspect: • Caliper cylinder inner surface a Wear/score marks → Replace caliper assembly. È Front É Rear ÈÉ 2. Inspect: • Caliper piston 1 Wear/score marks → Rep[...]

5 - 17 CHAS EC5A580 0 Caliper piston 1. Clean: • Caliper • Piston seal • Dust seal • Caliper piston Clean them with brake fluid. 2. Install: • Piston seal 1 • Dust seal 2 W ARNING Always use new piston seals and dust seals. N OTE: Fit the piston seals and dust seals ont o the slot on caliper correctly. È Front É Rear 3. Install: • C[...]

5 - 18 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: • Caliper 1 • Bolt (caliper) 2 3. Tighten: • Pad pin 3 4. Install: • Pad pin plug 4 T R . . 23 Nm (2.3 m · kg, 17 ft · lb) T R . . 18 Nm (1.8 m · kg, 13 ft · lb) T R . . 3 Nm (0.3 m · kg, 2.2 ft · lb ) EC5A510 0 Rear caliper 1. Install: • Pad support 1 • Brake pad 2 • Pad pin 3 [...]

5 - 19 CHAS FRONT BRAKE AND REAR BRAKE 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 cylinder kit Clean them with brake fluid. T R . . 18 Nm (1.8 m · kg, 13 ft · lb) T R . . 3 Nm ([...]

5 - 20 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: [Front] • Master cylinder kit 1 • Plain washer 2 • Circlip 3 • Master cylinder boot 4 To master cylinder 5 . [Rear] • Master cylinder kit 1 • Push rod 2 • Circlip 3 • Master cylinder boot 4 To master cylinder 5 . N OTE: • Apply the brake fluid on the ma ster cylinder kit. • Appl[...]

5 - 21 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: • Brake lever 1 • Bolt (brake lever) 2 • Nut (brake lever) 3 N OTE: 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 - 22 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: • Pin 1 • Plain washer 2 • Cotter pin 3 N OTE: After installing, check the brake pedal height. Refer to “ REAR BRAKE ADJUSTMENT ” sec- tion in the CHAPTER 3. New Front brake hose 1. Install: • Copper washer 1 • Brake hose 2 • Union bolt 3 W ARNING Always use new copper washers. CAUT[...]

5 - 23 CHAS FRONT BRAKE AND REAR BRAKE 4. Pass the brake hose through the cable guide 1 . 5. Install: • Copper washer 1 • Brake hose 2 • Union bolt 3 W ARNING Always use new copper washers. CAUTION: Install the brake hose so that its pipe por- tion a directs as shown and lightly touches the projection b on the mas ter cylinder. New T R . . 30[...]

5 - 24 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: • Brake hose holder 1 • Screw (brake hose holder) 2 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. Brake fluid 1. Fill: • Brake fluid Until the fluid level reach es “ LOWER ” leve[...]

5 - 25 CHAS FRONT BRAKE AND REAR BRAKE 2. Air bleed: • Brake system Refer to “ BRAKE SYSTEM AIR BLEED- ING ” section in the CHAPTER 3. 3. Inspect: • Brake fluid level Fluid at lower level → Fill up. Refer to “ BRAKE FLUID LEVEL INSPEC- TION ” section in the CHAPTER 3. 4. Install: [Front] • Reservoir float • Diaphragm • Master cy[...]

5 - 26 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 ma chine by placing the suitable stand under the engi ne. W ARNING Support the machine securely so there is no danger of i t falling ove r. Front wheel Refer to “[...]

5 - 27 CHAS FRONT FORK EC558000 FRONT FORK DISASSEMBLY Extent of removal: 1 Oil seal removal 2 Damper assembly removal Extent of removal Order Part name Q ’ ty Remarks FRONT FORK DISASSEMBLY 1 Adjuster 1 Drain the fork oi l. Use special tool. Refer to “ REMOVAL POINTS ” . 2 Fork spring 1 3 Dust seal 1 Refer to “ REMOVAL POINTS ” . 4 Stopp[...]

5 - 28 CHAS FRONT FORK EC556000 HANDLING NOTE N OTE: The front fork requires careful attentio n. So it is recommended that the front fork be maintained at the dealers. CAUTION: To prevent an accidental explosion of air, the following instructions should be observed: • The front fork with a built-in p iston rod has a very sophisticated internal co[...]

5 - 29 CHAS Adjuster 1. Drain the outer tube of its front fork oil at its top. 2. Loosen: • Adjuster 1 3. Remove: • Adjuster 1 N OTE: • While compressing the inner tube 2 , set the cap bolt ring wrench 4 between the inner tube and locknut 3 . • Hold the locknut and remove the adjuster. CAUTION: Do not remove the locknut as it may go into th[...]

5 - 30 CHAS Base valve 1. Remove: • Base valve 1 From damper assembly 2 . N OTE: Hold the damper assembly with th e cap bolt ring wrench 3 and use the cap bolt wrench 4 to remove the base valve. Cap bolt wrench: YM-01500/90890-01500 Cap bolt ring wrench: YM-01501/90890-01501 EC554000 INSPECTION Damper assembly 1. Inspect: • Damper assembly 1 Be[...]

5 - 31 CHAS Base valve 1. Inspect: • Base valve 1 Wear/damage → Replace. Contamination → Clean. • O-ring 2 Wear/damage → Replace. • Bush 3 Wear/damage → Replace base valve . • Spring 4 Damage/fatigue → Replace base valve. • Air bleed screw 5 Wear/damage → Replace base valve . EC554400 Fork spring 1. Measure: • Fork spring fr[...]

5 - 32 CHAS FRONT FORK EC554600 Outer tube 1. Inspect: • Outer tube 1 Score marks/wear/damage → Replace. Adjuster 1. Inspect: • Adjuster 1 • O-ring 2 Wear/damage → Replace. EC555000 ASSEMBLY AND INSTALLATION Front fork assembly 1. Wash the all parts in a clean solven t. 2. Stretch the damper assemb ly fully. 3. Fill: • Front fork oil 1 [...]

5 - 33 CHAS FRONT FORK 4. After filling, pump the damper assembly 1 slowly up and down (about 200 mm (7.9 in) stroke) several times to bleed the damper assembly of air. N OTE: Be careful not to excessive full stroke. A stroke of 200 mm (7.9 in) or more will ca use air to enter. In this case, repeat the steps 2 to 4. 5. Inspect: • Oil amount While[...]

5 - 34 CHAS FRONT FORK 9. Tighten: • Base valve 1 N OTE: Hold the damper assembly with th e cap bolt ring wrench 2 and use the cap bolt wrench 3 to tighten the base valve wit h specified torque. Cap bolt wrench: YM-01500/90890-01500 Cap bolt ring wrench: YM-01501/90890-01501 T R . . 29 Nm (2.9 m · kg, 21 ft · lb) 10. After filling, pump the dam[...]

5 - 35 CHAS FRONT FORK 13. Check: • Damper assembly smooth movement Tightness/binding/rough spots → Repeat the steps 2 to 12. 14. Install: • Dust seal 1 • Stopper ring 2 • Oil seal 3 • Oil seal washer 4 • Slide metal 5 To inner tube 6 . N OTE: • Apply the fork oil on the inner tub e. • When installing the oil seal, use vinyl sea t[...]

5 - 36 CHAS FRONT FORK 17. Install: • Slide metal 1 • Oil seal washer 2 To outer tube slot. N OTE: Press the slide metal into the outer tube with fork seal driver 3 . Fork seal driver: YM-01442/90890-01442 18. Install: • Oil seal 1 N OTE: Press the oil seal into the outer t ube with fork seal driver 2 . Fork seal driver: YM-01442/90890-01442 [...]

5 - 37 CHAS FRONT FORK 21. Check: • Inner tube smooth movement Tightness/binding/rough spots → Repeat the steps 14 to 20. 22. Measure: • Distance a Out of specification → Turn into the lock- nut. Distance a : 19 mm (0.75 in) or more Between damper assembly 1 bottom and locknut 2 bottom. 23. Install: • Spacer (metal) 1 • Fork spring 2 ?[...]

5 - 38 CHAS FRONT FORK 26. Install: • Push rod 1 • Copper washer 2 • Adjuster 3 To damper as sembly 4 . N OTE: • While compressing the inner tube 5 , set the cap bolt ring wrench 7 between the inner tube and locknut 6 . • Fully finger tighten the adjuster onto the damper asse mbly. Cap bolt ring wrench: YM-01501/90890-01501 New 27. Inspec[...]

5 - 39 CHAS 29. Install: • Adjuster 1 To inner tube. T R . . 55 Nm (5.5 m · kg, 40 ft · lb) 30. Fill: • Front fork oil 1 From outer tube top. * For EUROPE W ARNING Never fail to make the oil amou nt adjust- ment between the maximum and minimum amount and always adjust each front fork to the same setting. Uneven ad justment can cause poor hand[...]

5 - 40 CHAS 32. Install: • Protector guide 1 Installation 1. Install: • Front fork 1 N OTE: • Temporarily tighten the pinch bo lts (under bracket). • Do not tighten the pinch bolts (handle crown) yet. 2. Tighten: • Damper assembly 1 N OTE: Use the cap bolt ring wrench 2 to tighten the damper assembly with specif ied torque. Cap bolt ring [...]

5 - 41 CHAS 4. Tighten: • Pinch bolt (handle crown) 1 • Pinch bolt (under bracket) 2 CAUTION: Tighten the under bracket to specified torque. If torqued too much, it may cause the front fork to malfunction. T R . . 23 Nm (2.3 m · kg, 17 ft · lb) T R . . 20 Nm (2.0 m · kg, 14 ft · lb) 5. Install: • Protector 1 • Bolt (protector) 2 T R . .[...]

5 - 42 CHAS EC5B0000 HANDLEBAR Extent of removal: 1 Handlebar removal Extent of removal Order Part name Q ’ ty Remarks HANDLEBAR REMOVAL Preparation for removal Number plate Remove th e clamp portion only. 1 Hot starter cable 1 Disconnect at the lever side. 2 Hot starter lever ho lder 1 3 Clutch cable 1 Disconne ct at the lever side. 4 Clutch lev[...]

5 - 43 CHAS EC5B300 0 REMOVAL POINTS EC5B310 0 Master cylinder 1. Remove: • Master cylinder bracket 1 • Master cylinder 2 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. EC5B320 0 Grip 1. Remove: • Grip 1 N OTE: Blow in air between the handle[...]

5 - 44 CHAS HANDLEBAR EC5B500 0 ASSEMBLY AND INSTALLATION Handlebar 1. Install: • Handlebar 1 • Handlebar holder 2 • Bolt (handlebar holder) 3 N OTE: • The upper handlebar hold er should be installed with the punched mark a forward. • Install the handlebar so th at the marks b are in place on both sides. • First tighten the bolts on the[...]

5 - 45 CHAS HANDLEBAR 3. Install: • Grip (right) 1 • Collar 2 Apply the adhesive on the tube guide 3 . N OTE: • Before applying the adhesive, wip e off grease or oil on the tube guide surface a with a lacquer thinner. • Install the grip to t he tube guide so that the grip match mark b and tube guide slot c form the angle as shown. R L 90˚ [...]

5 - 46 CHAS HANDLEBAR 6. Install: • Throttle cab le cap 1 • Screw (throttle cable cap) 2 W ARNING After tightening the screws, check that the throttle grip 3 moves smoothly. If it does not, retighten the bolts for a djustment. T R . . 4 Nm (0.4 m · kg, 2.9 ft · lb ) 7. Install: • Cover (grip cap) 1 • Cover (throttle cable cap) 2 8. Instal[...]

5 - 47 CHAS HANDLEBAR 9. Install: •“ ENGINE STOP ” button 1 • Clutch lever holder 2 • Bolt (clutch lever holder) 3 • Hot starter lever holder 4 • Bolt (hot starter lever holder) 5 • Clamp 6 N OTE: • The “ ENGINE STOP ” button, clutch lever holder and clamp should be installed accord- ing to the dimensions shown. • Pass the ?[...]

5 - 48 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 i t falling ove r. Preparation for removal Hold th e machine by placing the suitable stand under the engi ne. Number plate Handl[...]

5 - 49 CHAS EC563000 REMOVAL POINTS EC563202 Ring nut 1. Remove: • Ring nut 1 Use the ring nut wrench 2 . W ARNING Support the steering sha ft 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 . CAUTION: Take care not to damage the stee ring shaft t[...]

5 - 50 CHAS STEERING Bearing and bearing race 1. Wash the bearings and bearing races with a solvent. 2. Inspect: • Bearing 1 • Bearing race Pitting/damage → Replace bearings and bearing races as a set. Install the bearing in the bearing races. Spin the bearings by hand. If the bearings hang up or are not smooth in their opera- tion in the bea[...]

5 - 51 CHAS 4. Install: • Ring nut 1 Tighten the ring nut using the rin g nut wrench 2 . 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 lo ck to lock. If there is any binding, remove the steering shaft assembly and inspect the[...]

5 - 52 CHAS STEERING 9. Install: • Steering shaft cap 1 10. After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the ring nut little by little. 11. Adjust: • Front fork top end a Front fork top end (standard) a : Zero mm (Zero in) 12. Tighten: • Pinch bolt (handle crown) 1 • Pinch bolt ([...]

5 - 53 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 i t falling ove r. Preparation for removal Hold th e machine by placing the suitable stand under the engi ne. Brake hose holder Refer to “ F[...]

5 - 54 CHAS SWINGARM EC578000 SWINGARM DISASSEMBLY Extent of removal: 1 Swingarm disasse mbly 2 Connecting rod removal and disassembl y 3 Relay arm removal and disassembly Extent of removal Order Part name Q ’ ty Remarks SWINGARM DISASSEMBLY 1 Cap 2 Refer to “ REMOVAL POINTS ” . 2 Relay arm 1 3 Connecting rod 1 4 Collar 2 5 Oil seal 2 6 Thrus[...]

5 - 55 CHAS SWINGARM EC573000 REMOVAL POINTS Cap 1. Remove: • Cap (left) 1 N OTE: Remove with a slotted-head screwdriver inserted under the mark a on the cap (left). EC573200 Bearing 1. Remove: • Bearing 1 N OTE: Install the bearing by pressing its outer race. EC574010 INSPECTION Wash the bearings, bushes, collars, and cov- ers in a solvent. EC[...]

5 - 56 CHAS SWINGARM Connecting rod 1. Inspect: • Bearing 1 • Collar 2 Free play exists/unsmooth revolution/rust → Replace bearing and collar as a set. 2. Inspect: • Oil seal 3 Damage → Replace. EC575000 ASSEMBLY AND INSTALLATION Bearing and oil seal 1. Install: • Bearing 1 • Oil seal 2 To swingarm. N OTE: • Apply the molybdenum dis[...]

5 - 57 CHAS SWINGARM 3. Install: • Bearing 1 • Oil seal 2 To connecting rod. N OTE: • Apply the molybdenum disu lfide grease on the bearing when installing. • Install the bearing by pressing it on the side having the m anufacture ’ s marks or numbers. Installed depth of bearings a : 5 mm (0.20 in) Swingarm 1. Install: • Bush 1 • Thrus[...]

5 - 58 CHAS SWINGARM 3. Install: • Collar 1 To connecting rod 2 . N OTE: 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 . N OTE: Apply the molybdenum disulfide grease on the bolt. T R . . 80 Nm (8.0 m ?[...]

5 - 59 CHAS SWINGARM 8. Install: • Bolt (connecting rod) 1 • Plain washer 2 • Nut (connecting rod) 3 N OTE: • Apply the molybdenum disu lfide 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 N OTE: Apply the molybdenum disulfide grease on the[...]

5 - 60 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 [ = 50 mm (1.97 in)]} 3 • Nut (chain support) 4 • Bolt {support cover [ = 10[...]

5 - 61 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 REAR SHOCK ABSORBER REMOVAL W ARNING Support the machine securely so there is no danger of i t falling ove r. Preparation for removal Hold th e machine by [...]

5 - 62 CHAS REAR SHOCK ABSORBER Extent of removal Order Part name Q ’ ty Remarks 9 Spring guide (upper) 1 10 Spring (rear shock absorber) 1 11 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 N OTE: Press in the bearing while pressing its outer race and remove the stopper ring. 2. Remove: • Upper bearing 1 N OTE: Remove the bearing by pressing its outer race. 3. Remove: • Lower bearing 1 N OTE: Remove the bearing by pressing its outer [...]

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

5 - 66 CHAS REAR SHOCK ABSORBER 2. Tighten: • Adjuster 1 3. Adjust: • Spring length (installed) a * For EUROPE N OTE: The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the ad juster. CAUTION: Never attempt to turn the adjuster beyond the maximum or minimum setting. Spring length (installed) a : Standard length Extent of [...]

5 - 67 CHAS REAR SHOCK ABSORBER 2. Install: • Bush 1 • Collar 2 • Dust seal 3 N OTE: • Apply the molybdenum disu lfide grease on the bearing. • Apply the lithium soap base g rease on the bush, collars and dust seals. • Install the dust seals with their lips facing out- ward. 3. Install: • Rear shock absorber 4. Install: • Bolt (rear[...]

6 - 1 –+ ELEC ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 “ ENGINE STOP ” button 2 TPS (throttle positio n sensor) 3 Neutral switch 4 CDI magneto 5 Ignition coil 6 Spark plug 7 CDI unit COLOR CODE B .. ................ .... Black Br ...........[...]

– + ELEC 6 - 2 MAP-CONTROLLED CDI UNIT MAP-CONTROLLED CDI UNIT A map-controlled, CDI ignition system is used in the YZ450F. The microcomputer in the CDI unit detects the e ngine speed and throttle position, thus det ermining the optimum ignition timing th rough the entire operating range. In this way, qu ick throttle response can be achieved acco[...]

– + ELEC 6 - 3 IGNITION SYSTEM EC620000 IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of th e malfunctioning engine being attributa ble to ignition system failure and for ch ecking the spark plug wh ich will not spark. *marked: Only when the ignition checker is used. N OTE: • Remove the following parts be[...]

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 (igni- tion checker 2 ) as shown. • Ignition coil 3 • Spark plug 4 È For USA and CDN É Except for USA and CDN 4. Kick the kick starter. 5. Check the ignition spark gap. 6. Star[...]

6 - 5 – + ELEC IGNITION SYSTEM EC626002 IGNITION COIL INSPECTION 1. Remove the ignition coil cap. 2. Inspect: • Primary coil resistance Out of specification → Replace. Tester (+) lead → Orange lead 1 Tester ( – ) lead → Black lead 2 Primary coil resistance Tester selector position 0.08 ~ 0.10 Ω at 20 ° C (68 ° F) Ω × 1 3. Inspect[...]

6 - 6 – + ELEC IGNITION SYSTEM 2. Inspect: • Source coil 1 resistan ce Out of specification → Replace. 3. Inspect: • Source coil 2 resistan ce Out of specification → Replace. Tester (+) lead → Brown lead 1 Tester ( – ) lead → Green lead 2 Source coil 1 resistance Tester selector position 720 ~ 1,080 Ω at 20 ° C (68 ° F) Ω × 1[...]

– + ELEC 6 - 7 TPS (THROTTLE POSITION SENSOR) SYSTEM EC690000 TPS (THROTTLE POSITION SENSOR) SYSTEM INSPECTION STEPS If the TPS will not operate, use the follo wing inspection steps. *marked: Refer to “ IGNITION SYSTEM ” section. N OTE: Use the following special tools in this inspect ion. Pocket tester: YU-3112-C/90890-03112 Check entire igni[...]

6 - 8 – + 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 conn[...]

6 - 9 – + 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 position . Out of specification → Replace. Tester (+) lead → Yellow lead 1 Tester ( – ) lead → Black lead 2 TPS coil variable r[...]

6 - 10 – + ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM 4. Adjust: • Idle speed Refer to “ IDLE SPEED ADJUSTMENT ” section in the CHAPT ER 3. 5. Insert the thin electric conductors 2 (lead) into the TPS coupler 1 , as sho wn, and connect the tester to them. CAUTION: • Do not insert the electric conductors more than required because it may r[...]

6 - 11 – + 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[...]

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 an d its components carefully. Even slight scratches, bends or damage to ca rburetor parts may prevent the carbure tor from functionin[...]

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 È Closed É Fully open 1/2 3/4 1/4 1/8 1 2 3 4 ÈÉ Main system The FLATCR carburetor has a primary main jet. This type of main jet is perfect for racing machines since it supplies an even flow of f[...]

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 . If the air-fuel mixture is too rich or too lean, the engine po[...]

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 p ilot screw will make the mixture lean at low speeds, and turning it out will enrich it. N OTE: • If the idling speed fluctuates, turn the pilot screw only 1/2 of a turn[...]

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 . Effects of adjusting the pilot jet (re ference) È Idle É Fully open Jet needle groove position adjustment Adjusting the jet needle 1 position affects the acceleration when the throttle is 1/8 t[...]

7 - 7 TUN Jet needle adjustment The jet needle is adjusted by changing it. The jet needle setting parts, having the same taper angle, are available in different straight portion diameters and in different taper sta rting positions. <Example> NFLR - 4 Clip position Diameter a of straight portio n b Reference needle c 0.5 richer Changing from N[...]

7 - 8 TUN Leak jet adjustment (accelerator pump adjustment) The leak jet 1 is a setting part that adjusts the flow of fuel discharged by the accelerator pump. Since the accelerator pump operates only when throttle is open, the leak jet is used to adjust a fuel mixture ratio for quick throttle opening and is theref ore different from other setting p[...]

7 - 9 TUN SETTING Carburetor setting parts Part name Size Part number Main jet Rich (STD) Lean #178 #175 #172 #170 #168 #165 #162 #160 #158 #155 #152 4MX-14943-93 4MX-14943-42 4MX-14943-92 4MX-14943-41 4MX-14943-91 4MX-14943-40 4MX-14943-90 4MX-14943-39 4MX-14943-89 4MX-14943-38 4MX-14943-88 Pilot jet Rich (STD) Lean #52 #50 #48 #45 #42 #40 #38 4MX[...]

7 - 10 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 eng ine. Symptom Setting Checking At full throttle Hard breathing Shearing noise Whitish spark plug Lean mixture Increase main jet calibration no. (Gradually)[...]

7 - 11 TUN EC720000 CHASSIS EC71P00 2 Selection of the secondary reduction ratio (Sprocket) <Requirement for selection of secondary gear reduction ratio> • It is generally said that the secondary gear ratio should be re duced for a longer str aight portion of a speed co urse and should be increased for a course with many corners. Actually, [...]

7 - 12 TUN SETTING EC72N000 Drive and driven sprockets setting pa rts Part name Size Part number Drive sprocket 1 (STD) 14T 9383E-14215 Driven sprocket 2 (STD) 47T 48T 49T 50T 51T 52T 1C3-25447-00 1C3-25448-00 1C3-25449-00 1C3-25450-00 1C3-25451-00 1C3-25452-00 EC721002 Tire pressure Tire pressure should be adjust to suit the road surface condition[...]

7 - 13 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 amount. 2. Setting of spring preload • Change the spr[...]

7 - 14 TUN SETTING EC727020 Spring preload adjustment The spring preload is adjusted by installing the adjustment washer 1 between the spacer 2 and fork spring 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 ca use poor handling and l[...]

7 - 15 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 o r 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 on[...]

7 - 16 TUN EC72P00 0 Front fork setting parts • Adjustment wa sher 1 • Front fork spring 2 * For EUROPE N OTE: The I.D. mark (slits) a is proved on the end of the spring. TYPE (thickness) PART NUMBER T = 2.3 mm (0.09 in) 1C3-23364-00 TYPE SPRING RATE SPRING PART NUMBER I.D. MARK (slits) SOFT 0.398 0.408 0.418 0.428 0.438 1C3-23141-00 1C3-23141-[...]

7 - 17 TUN EC72C001 Choosing set length 1. Place a stand or block under the engine to put the rear wheel above the floor, and measure the length a between the rear wheel axle center and the rear fender hold- ing bolt. 2. Remove the stand or block from the engine and with a rider astride the seat, measure the sunken length b betwe en the rear wheel [...]

7 - 18 TUN SETTING EC72G00 1 Setting of spring after replacement After replacement, be sure to adjust the spring to the set length [sunken length 90 ~ 100 mm (3.5 ~ 3.9 in)] and set it. 1. Use of soft spring • Set the soft spring for less rebound damping to compensate for its less spring load. Run with the rebo und damping adjuster one or two cli[...]

7 - 19 TUN SETTING EC72Q00 0 Rear shock absorber setting parts • Rear shock spri ng 1 [Equal pitch spring] *For EUROPE [Unequal pitch spring] N OTE: • 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. co lor a is marked at the end of the[...]

7 - 20 TUN SETTING EC72H002 Suspension setting • Front fork N OTE: • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adju stment 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 ~ [...]

7 - 21 TUN SETTING • Rear shock absorber N OTE: • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adju stment procedure given in the same chart. • Adjust the rebound damping in 2-click incre ments or decrements. • Adjust the low compression damping in 1-click increme[...]

PRINTED IN JAPAN 2004.06-1.9 × 1 CR (E) PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO . , L TD . 2500 SHINGAI IW A T A SHIZUOKA JAP AN[...]