YZ450F - Off-road motorcycle YAMAHA - Free user manual and instructions

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USER MANUAL YZ450F YAMAHA

PRINTED ON RECYCLED PAPER

©2006 by Yamaha Motor Co., Ltd. 1st Edition, July 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan YZ450F(W)

DU PROPRIETAIRE ©2006 Yamaha Motor Co., Ltd. 1re édition, juillet 2006 Tous droits réservés Toute reimpression ou utillisation sans la permission écrite de la Yamaha Motor Co., Ltd. est formellement interdite. Imprimé au Japon YZ450F(W) FAHRER- UND WARTUNGSHANDBUCH ©2006 Yamaha Motor Co., Ltd.

1. Auflage, Juli 2006

Alle Rechte vorbehalten. Nachdruck, Vervielfältigung und Verbreitung, auch auszugsweise, ist ohne schriftliche Genehmigung der Yamaha Motor Co., Ltd. nicht gestattet. Gedruckt in Japan EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader. This manual explains operation, inspection, basic maintenance and tuning of your machine. If you have any questions about this manual or your machine, please contact your Yamaha dealer. NOTE: Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your machine and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer. WARNING

PLEASE READ THIS MANUAL CAREFULLY

AND COMPLETELY BEFORE OPERATING

THIS MACHINE. DO NOT ATTEMPT TO

OPERATE THIS MACHINE UNTIL YOU

HAVE ATTAINED A SATISFACTORY

CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding. SAFETY INFORMATION

1. THIS MACHINE IS TO BE OPERATED

BY AN EXPERIENCED RIDER ONLY. Do not attempt to operate this machine at maximum power until you are totally familiar with its characteristics.

2. THIS MACHINE IS DESIGNED TO BE

RIDDEN BY THE OPERATOR ONLY. Do not carry passengers on this machine.

3. ALWAYS WEAR PROTECTIVE

APPAREL. When operating this machine, always wear an approved helmet with goggles or a face shield. Also wear heavy boots, gloves, and protective clothing. Always wear proper fitting clothing that will not be caught in any of the moving parts or controls of the machine.

4. ALWAYS MAINTAIN YOUR MACHINE

IN PROPER WORKING ORDER. For safety and reliability, the machine must be properly maintained. Always perform the pre-operation checks indicated in this manual. Correcting a mechanical problem before you ride may prevent an accident.

If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes.

7. ONLY OPERATE THE MACHINE IN AN

AREA WITH ADEQUATE VENTILATION. Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are poisonous. These fumes contain carbon monoxide, which by itself is odorless and colorless. Carbon monoxide is a dangerous gas which can cause unconsciousness or can be lethal.

8. PARK THE MACHINE CAREFULLY;

TURN OFF THE ENGINE. Always turn off the engine if you are going to leave the machine. Do not park the machine on a slope or soft ground as it may fall over.

9. THE ENGINE, EXHAUST PIPE, MUFFLER, AND OIL TANK WILL BE VERY

HOT AFTER THE ENGINE HAS BEEN

RUN. Be careful not to touch them or to allow any clothing item to contact them during inspection or repair.

10. PROPERLY SECURE THE MACHINE

BEFORE TRANSPORTING IT. When transporting the machine in another vehicle, always be sure it is properly secured and in an upright position and that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the carburetor or fuel tank.

This manual will provide you with a good basic understanding of features, operation, and basic maintenance and inspection items of this machine. Please read this manual carefully and completely before operating your new machine. If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer. NOTE: This manual should be considered a permanent part of this machine and should remain with it even if the machine is subsequently sold. EC060000 NOTICE Some data in this manual may become outdated due to improvements made to this model in the future. If there is any question you have regarding this manual or your machine, please consult your Yamaha dealer. EC070001 F.I.M. MACHINE WEIGHTS: Weights of machines without fuel The minimum weights for motocross machines are: for the class 125 cc ....................... minimum 88 kg (194 lb) for the class 250 cc ....................... minimum 98 kg (216 lb) for the class 500 cc ....................... minimum 102 kg (225 lb) In modifying your machine (e.g., for weight reduction), take note of the above limits of weight. AU NOUVEAU PROPRIETAIRE

THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION!

BECOME ALERT! YOUR SAFETY IS

INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the machine. NOTE: A NOTE provides key information to make procedures easier or clearer. EC082000

FINDING THE REQUIRED PAGE

1. This manual consists of seven chapters;

“General Information”, “Specifications”, “Regular inspection and adjustments”, “Engine”, “Chassis”, “Electrical” and “Tuning”.

2. The table of contents is at the beginning of

the manual. Look over the general layout of the book before finding then required chapter and item. Bend the book at its edge, as shown, to find the required fore edge symbol mark and go to a page for required item and description.

• Bearings Pitting/damage → Replace. EC084002

HOW TO READ DESCRIPTIONS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

1. An easy-to-see exploded diagram 1 is provided for removal and disassembly jobs.

2. Numbers 2 are given in the order of the jobs in the exploded diagram. A number that is

enclosed by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol

marks 3. The meanings of the symbol marks are given on the next page.

4. A job instruction chart 4 accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.

5. Extent of removal 5 is provided in the job instruction chart to save the trouble of an unnecessary removal job.

6. For jobs requiring more information, the step-by-step format supplements 6 are given in addition to the exploded diagram and job instruction chart.

ILLUSTRATED SYMBOLS (Refer to the illustration)

SPEC Illustrated symbols 1 to 7 are designed as thumb tabs to indicate the chapter’s number and content.

1 General information 2 Specifications 3 Regular inspection and adjustments 4 Engine 5 Chassis 6 Electrical 7 Tuning

Illustrated symbols 8 to D are used to identify the specifications appearing in the text.

8 With engine mounted 9 Special tool 0 Filling fluid A Lubricant B Tightening C Specified value, Service limit D Resistance (Ω), Voltage (V), Electric current (A)

E Apply engine oil F Apply molybdenum disulfide oil G Apply lightweight lithium-soap base grease H Apply molybdenum disulfide grease

Illustrated symbols E to H in the exploded diagrams indicate grade of lubricant and location of lubrication point.

ENGINE REMOVAL .................................4-81

CRANKCASE AND CRANKSHAFT ........4-86

TRANSMISSION, SHIFT CAM AND

SHIFT FORK ............................................4-95

• The machine you have purchased may differ slightly from those shown in the following.

MACHINE IDENTIFICATION GEN INFO EC120001 MACHINE IDENTIFICATION There are two significant reasons for knowing the serial number of your machine:

1. When ordering parts, you can give the

number to your Yamaha dealer for positive identification of the model you own.

2. If your machine is stolen, the authorities will

need the number to search for and identify your machine. EC121001

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stamped on the right of the steering head pipe. EC123001

ENGINE SERIAL NUMBER

The engine serial number 1 is stamped into the elevated part of the right-side of the engine. EC124000 MODEL LABEL The model label 1 is affixed to the frame under the rider’s seat. This information will be needed to order spare parts. 1-2

PREPARATION FOR REMOVAL AND

1. Remove all dirt, mud, dust, and foreign

material before removal and disassembly. When washing the machine with high pressured water, cover the parts as follows.

• Silencer exhaust port
• Side cover air intake port
• Water pump housing hole at the bottom
• Drain hole on the cylinder head (right side)

2. Use proper tools and cleaning equipment.

Refer to “SPECIAL TOOLS” section.

3. When disassembling the machine, keep

mated parts together. They include gears, cylinders, pistons, and other mated parts that have been “mated” through normal wear. Mated parts must be reused as an assembly or replaced.

4. During the machine disassembly, clean all

parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled.

5. Keep away from fire.

1-3 INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN GEN INFO INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN

PREPARATION A LA DEPOSE ET AU

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 surfaces, oil seal lips, and Orings must be cleaned.

2. Properly oil all mating parts and bearings

during reassembly. Apply grease to the oil seal lips. EC134000

LOCK WASHERS/PLATES AND COTTER

1. All lock washers/plates 1 and cotter pins

must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened. EC135001

BEARINGS AND OIL SEALS

1. Install the bearing(s) 1 and oil seal(s) 2

with their manufacturer’s marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of light-weight lithium base grease to the seal lip(s). Oil the bearings liberally when installing. CAUTION: Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces. 1-4 INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN GEN INFO

Splinte müssen nach dem Ausbau erneuert werden. Sicherungslaschen und Splintenden werden nach dem vorschriftsmäßigen Festziehen der Schraube bzw. Mutter gegen die Schlüsselfläche der Schraube bzw. Mutter hochgebogen. ACHTUNG: Lager nie mit Druckluft behandeln. Dies könnte die Lagerlaufflächen beschädigen. ATTENTION: Ne pas sécher les roulements à l’air comprimé. Cela endommagerait les surfaces de roulement. 1-4 IMPORTANT INFORMATION GEN INFO 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 positioned opposite to the thrust 3 it receives. See the sectional view. 4 Shaft 1-5 INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN GEN INFO SICHERUNGSRINGE

1. Sicherungsringe vor dem Wiedereinbau

CHECKING OF CONNECTION

CHECKING OF CONNECTION

Dealing with stains, rust, moisture, etc. on the connector.

2. Dry each terminal with an air blower.

3. Connect and disconnect the connector two

4. Pull the lead to check that it will not come

5. If the terminal comes off, bend up the pin

1 and reinsert the terminal into the connector.

• Connector NOTE: The two connectors “click” together.

7. Check for continuity with a tester.

• If there in no continuity, clean the terminals.
• Be sure to perform the steps 1 to 7 listed above when checking the wire harness.
• For a field remedy, use a contact revitalizer available on the market.
• Use the tester on the connector as shown. 1-6

• Handelsübliches Kontaktspray sollte nur als Notlösung verwendet werden.
• Das Taschen-Multimeter, wie in der Abbildung gezeigt, anschließen. 1-6 SPECIAL TOOLS GEN INFO EC140001 SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order. NOTE:
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-” or “ACC-”.
• For others, use part number starting with “90890-”. Part number YU-3097, 90890-01252 YU-1256 Tool name/How to use Dial gauge and stand Stand Illustration YU-3097 YU-1256 90890-01252 These tools are used to check each part for runout or bend. YU-90050, 90890-01274 YU-90050, 90890-01275 YU-91044, 90890-04081 YU-90063, 90890-01278 Crankshaft installing tool Crankshaft installing pot Crankshaft installing bolt Spacer (crankshaft installer) Adapter (M12) These tools are used to install the crankshaft. YU-90050 YU-90063 YU-91044 90890-01274 90890-01275 90890-01278 90890-04081 YU-1304, 90890-01304 Piston pin puller YU-1304 90890-01304 YU-24460-01 YU-33984 90890-01325 90890-01352 YM-04151 90890-04151 YU-33975 90890-01403 YM-01500 90890-01500 This tool is used to remove the piston pin. YU-24460-01, 90890-01325 Radiator cap tester YU-33984, 90890-01352 Adapter These tools are used for checking the cooling system. YM-04151, 90890-04151 Rotor puller This tool is used to remove the flywheel magneto. YU-33975, 90890-01403 Ring nut wrench This tool is used when tighten the steering ring nut to specification. YM-01500, 90890-01500 Cap bolt wrench This tool is used to loosen or tighten the base valve. 1-7 SPECIAL TOOLS Part number YM-01501, 90890-01501 Tool name/How to use Cap bolt ring wrench GEN INFO Illustration YM-01501 90890-01501 YM-A0948 90890-01502 YU-3112-C 90890-03112 YM-33277-A 90890-03141 YM-4019 90890-04019 YM-91042 90890-04086 YM-4116 YM-4097 90890-04116 90890-04097 YM-4117 YM-4098 90890-04117 90890-04098 YM-4118 YM-4099 90890-04118 90890-04099 This tool is used to loosen or tighten the damper assembly. YM-A0948, 90890-01502 Fork seal driver This tool is used when install the fork oil seal. YU-3112-C, 90890-03112 Pocket tester Use this tool to inspect the coil resistance, output voltage and amperage. YM-33277-A, 90890-03141 Timing light This tool is necessary for checking ignition timing. YM-4019, 90890-04019 Valve spring compressor This tool is needed to remove and install the valve assemblies. YM-91042, 90890-04086 Clutch holding tool This tool is used to hold the clutch when removing or installing the clutch boss securing nut. YM-4116, 90890-04116 YM-4097, 90890-04097 Valve guide remover Intake 4.5 mm (0.18 in) Exhaust 5.0 mm (0.20 in) This tool is needed to remove and install the valve guide. YM-4117, 90890-04117 YM-4098, 90890-04098 Valve guide installer Intake Exhaust This tool is needed to install the valve guide. 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 guide. 1-8 SPECIAL TOOLS Part number YU-A9642, 90890-04152 Tool name/How to use Crankcase separating tool GEN INFO Illustration YU-A9642 90890-04152 YM-34487 90890-06754 90890-85505 90890-85505 These tool is used to remove the crankshaft from either case. YM-34487 90890-06754 Dynamic spark tester Ignition checker This instrument is necessary for checking the ignition system components. 90890-85505 YAMAHA Bond No. 1215 (ThreeBond No.1215) This sealant (Bond) is used for crankcase mating surface, etc. 1-9 OUTILS SPECIAUX GEN INFO OUTILS SPECIAUX Il est indispensable d’utiliser les outils spéciaux appropriés pour pouvoir effectuer un assemblage et une mise au point complets et précis. L’utilisation des outils spéciaux corrects permettra d’éviter les endommagements dus à l’emploi d’outils impropres ou de techniques improvisées. La forme et le numéro de pièce des outils spéciaux pouvant différer selon les pays, il existe parfois deux versions d’un outil. Se reporter à la liste suivante pour éviter toute erreur de commande. N.B.:

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 handlebar; it disengages or engages the clutch. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth starts. EC153000 SHIFT PEDAL The gear ratios of the constant-mesh 5 speed transmission are ideally spaced. The gears can be shifted by using the shift pedal 1 on the left side of the engine. EC154000 KICK STARTER Rotate the kick starter 1 away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine. This model has a primary kick starter so the engine can be started in any gear if the clutch is disengaged. In normal practices, however, shift to neutral before starting.

EC155001 THROTTLE GRIP The throttle grip 1 is located on the right handlebar; it accelerates or decelerates the engine. For acceleration, turn the grip toward you; for deceleration, turn it away from you.

The front brake lever 1 is located on the right handlebar. Pull it toward the handlebar to activate the front brake. EC157000

The rear brake pedal 1 is located on the right side of the machine. Press down on the brake pedal to activate the rear brake. EC158001 FUEL COCK The fuel cock supplies fuel from the tank to carburetor while filtering the fuel. The fuel cock has the two positions: OFF: With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position.

When cold, the engine requires a richer air-fuel mixture for starting. A separate starter circuit, which is controlled by the cold starter knob 1, supplies this mixture. Pull the cold starter knob out to open the circuit for starting. When the engine has warmed up, push it in to close the circuit.

The hot starter lever 1 is used when starting a warm engine. Use the hot starter lever when starting the engine again immediately after it was stopped (the engine is still warm). Pulling the hot starter lever injects secondary air to thin the air-fuel mixture temporarily, allowing the engine to be started more easily.

CONTROL FUNCTIONS GEN INFO EC15R001 DETACHABLE SIDESTAND This sidestand 1 is used to support only the machine when standing or transporting it. WARNING

• Never apply additional force to the sidestand.
• Remove this sidestand before starting out. EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose. CAUTION: In this installation, make sure the arrow faces the fuel tank and also downward.

This spark plug wrench 1 is used to remove and install the spark plug.

NIPPLE WRENCH This nipple wrench 1 is used to tighten the spoke.

JET NEEDLE PULL-UP TOOL

The jet needle pull-up tool 1 is used to pull the jet needle out of the carburetor.

FUEL GEN INFO FUEL Always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race. Recommended fuel: Premium unleaded gasoline only with a research octane number of 95 or higher. CAUTION: Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts such as valves, piston rings, and exhaust system, etc. NOTE: If knocking or pinging occurs, use a different brand of gasoline or higher octane grade. WARNING

• For refueling, be sure to stop the engine and use enough care not to spill any fuel. Also be sure to avoid refueling close to a fire.
• Refuel after the engine, exhaust pipe, etc. have cooled off.

STARTING AND BREAK-IN

WARNING Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Always operate the machine in a well-ventilated area. CAUTION:

• The carburetor on this machine has a built-in accelerator pump. Therefore, when starting the engine, do not operate the throttle or the spark plug will foul.
• Unlike a two-stroke engine, this engine cannot be kick started when the throttle is open because the kick starter may kick back. Also, if the throttle is open the air/ fuel mixture may be too lean for the engine to start.
• Before starting the machine, perform the checks in the pre-operation check list.

STARTING A COLD ENGINE

1. Inspect the coolant level.

2. Turn the fuel cock to “ON”.

3. Shift the transmission into neutral.

4. Fully open the cold starter knob 1.

5. Kick the kick starter.

WARNING Do not open the throttle while kicking the kick starter. Otherwise, the kick starter may kick back.

6. Return the cold starter knob to its original

position and run the engine at 3,000 ~ 5,000 r/min for 1 or 2 minutes. NOTE: Since this model is equipped with an accelerator pump, if the engine is raced (the throttle opened and closed), the air/fuel mixture will be too rich and the engine may stall. Also unlike a two-stroke engine, this model can idle. CAUTION: Do not warm up the engine for extended periods of time.

Do not operate the cold starter knob and throttle. 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 the hot starter lever and start the engine. As soon as the engine starts, release the hot starter lever to close the air passage. The engine fails to start Pull the hot starter lever all the way out and while holding the lever, kick the kick starter 10 to 20 times to clear the engine. Then, restart the engine. Refer to “Restarting an engine after a fall”. Cold starter knob Hot starter lever Air temperature = less than Open 3 or 4 times 5 °C (41 °F)

OFF Air temperature = more than 5 °C (41 °F) None

OFF Air temperature (normal temperature) = between 5 °C (41 °F) and 25 °C (77 °F) None ON/OFF OFF Air temperature = more than 25 °C (77 °F) None OFF OFF Starting an engine after a long period of time None

OFF Starting a cold engine Throttle grip operation* Restarting a warm engine None OFF

Restarting an engine after a fall None OFF

• Operate the throttle grip before kick starting. CAUTION: Observe the following break-in procedures during initial operation to ensure optimum performance and avoid engine damage.

1. Before starting the engine, fill the fuel tank

2. Perform the pre-operation checks on the

3. Start and warm up the engine. Check the

idle speed, and check the operation of the controls and the “ENGINE STOP” button. Then, restart the engine and check its operation within no more than 5 minutes after it is restarted.

4. Operate the machine in the lower gears at

moderate throttle openings for five to eight minutes.

5. Check how the engine runs when the

machine is ridden with the throttle 1/4 to 1/2 open (low to medium speed) for about one hour.

6. Restart the engine and check the operation

of the machine throughout its entire operating range. Restart the machine and operate it for about 10 to 15 more minutes. The machine will now be ready to race. CAUTION:

• After the break-in or before each race, you must check the entire machine for loose fittings and fasteners as per “TORQUE-CHECK POINTS”. Tighten all such fasteners as required.
• When any of the following parts have been replaced, they must be broken in. CYLINDER AND CRANKSHAFT: About one hour of break-in operation is necessary.

PISTON, RING, VALVES, CAMSHAFTS

AND GEARS: These parts require about 30 minutes of break-in operation at half-throttle or less. Observe the condition of the engine carefully during operation.

PISTON, SEGMENT, SOUPAPES, ARBRES

TORQUE-CHECK POINTS GEN INFO TORQUE-CHECK POINTS Frame construction Frame to rear frame Fuel tank to frame Combined seat and tank Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Suspension Wheel Brake Steering shaft to frame Steering shaft to handle crown Handle crown to handlebar Steering shaft to handlebar Front Steering shaft to front fork Front fork to handle crown Front fork to under bracket Rear For link type Assembly of links Link to frame Link to shock absorber Link to swingarm Rear Installation of shock absorber Shock absorber to frame Rear Installation of swingarm Tightening of pivot shaft Installation of wheel Front Tightening of front axle Tightening of axle holder Rear Tightening of rear axle Wheel to sprocket Front Caliper to front fork Brake disc to wheel Tightening of union bolt Master cylinder to handlebar Tightening of air bleeder Tightening of brake hose holder Rear Brake pedal to frame Brake disc to wheel Tightening of union bolt Master cylinder to frame Tightening of air bleeder Tightening of brake hose holder Fuel system Fuel tank to fuel cock Lubrication system Tightening of oil hose clamp NOTE: Concerning the tightening torque, refer to “MAINTENANCE SPECIFICATIONS” section in the CHAPTER 2.

CLEANING AND STORAGE

CLEANING AND STORAGE

EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many components.

1. Before washing the machine, block off the

end of the exhaust pipe to prevent water from entering. A plastic bag secured with a rubber band may be used for this purpose.

2. If the engine is excessively greasy, apply

some degreaser to it with a paint brush. Do not apply degreaser to the chain, sprockets, or wheel axles.

3. Rinse the dirt and degreaser off with a garden hose; use only enough pressure to do

the job. CAUTION: Excessive hose pressure may cause water seepage and contamination of wheel bearings, front forks, brakes and transmission seals. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers.

4. After the majority of the dirt has been

hosed off, wash all surfaces with warm water and a mild detergent. Use an old toothbrush to clean hard-to-reach places.

5. Rinse the machine off immediately with

clean water, and dry all surfaces with a soft towel or cloth.

6. Immediately after washing, remove excess

water from the chain with a paper towel and lubricate the chain to prevent rust.

7. Clean the seat with a vinyl upholstery

cleaner to keep the cover pliable and glossy.

CLEANING AND STORAGE

8. Automotive wax may be applied to all

painted or chromed surfaces. Avoid combination cleaner-waxes, as they may contain abrasives.

9. After completing the above, start the

engine and allow it to idle for several minutes. EC1B2001 STORAGE If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as follows:

1. Drain the fuel tank, fuel lines, and the carburetor float bowl.

2. Remove the spark plug, pour a tablespoon

of SAE 10W-30 motor oil in the spark plug hole, and reinstall the plug. With the engine stop switch pushed in, kick the engine over several times to coat the cylinder walls with oil.

3. Remove the drive chain, clean it thoroughly

with solvent, and lubricate it. Reinstall the chain or store it in a plastic bag tied to the frame.

4. Lubricate all control cables.

5. Block the frame up to raise the wheels off

6. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering.

7. If the machine is to be stored in a humid or

salt-air environment, coat all exposed metal surfaces with a film of light oil. Do not apply oil to rubber parts or the seat cover. NOTE: Make any necessary repairs before the machine is stored.

GENERAL SPECIFICATIONS SPEC EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: Model code number: Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Dry weight: Without oil and fuel Engine: Engine type Cylinder arrangement Displacement Bore × stroke Compression ratio Starting system Lubrication system: YZ450FW (USA, CDN, AUS, NZ) YZ450F (EUROPE, ZA) 2S27 (USA, CDN) 2S28 (EUROPE) 2S2A (AUS, NZ, ZA) USA, CDN, EUR ZA, AUS, NZ (Except for F) 2,191 mm 2,196 mm 2,197 mm (86.26 in) (86.48 in) (86.50 in)

Liquid cooled 4-stroke, DOHC Single cylinder, forward inclined 449 cm3 (15.8 Imp oz, 15.2 US oz)

95.0 × 63.4 mm (3.74 × 2.50 in)

Kick starter Dry sump 2-1 GENERAL SPECIFICATIONS Oil type or grade: Engine oil

50 ˚C 50 ˚C SAE 10W-30 (Except for USA and CDN) SAE10W30, SAE10W40, SAE15W40, SAE20W40 or SAE20W50 API service SG type or higher JASO standard MA SAE 10W-40 SAE 15W-40 SAE 20W-40 SAE 20W-50 Oil capacity: Engine oil Periodic oil change With oil filter replacement Total amount Coolant capacity (including all routes): Air filter: Fuel: Type Tank capacity Carburetor: Type Manufacturer Spark plug: Type/manufacturer Gap Clutch type:

Wet type element Premium unleaded gasoline only with a research octane number of 95 or higher.

FCR MX39 KEIHIN CR8E/NGK (resistance type)

Wet, multiple-disc 2-2

GENERAL SPECIFICATIONS Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio: 1st 2nd 3rd 4th 5th Chassis: Frame type Caster angle Trail Tire: Type Size (front) Size (rear) Tire pressure (front and rear) Brake: Front brake type Operation Rear brake type Operation Suspension: Front suspension Rear suspension Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system SPEC Gear 61/23 (2.652) Chain drive 49/13 (3.769) Constant mesh, 5-speed Left foot operation 27/14 (1.929) 23/15 (1.533) 23/18 (1.278) 24/22 (1.091) 20/21 (0.952) USA, CDN, EUR ZA, AUS, NZ (Except for F) Semi double cradle 26.8°

Intake “A” “B” Exhaust “A” “B” Camshaft runout limit 2-4 MAINTENANCE SPECIFICATIONS Item SPEC Standard Cam chain: Cam chain type/No. of links Cam chain adjustment method Valve, valve seat, valve guide: Valve clearance (cold)

Head Diameter “A” head diameter

“B” face width “C” seat width

“D” margin thickness Stem outside diameter

(0.0004 in) MAINTENANCE SPECIFICATIONS Item Valve spring: Free length Set length (valve closed) Compressed force (installed) Standard Direction of winding (top view) Limit

(13.0 ~ 14.9 kg at 27.38 mm,

8 mm (0.315 in) 1 mm (0.0394 in)

Type Dimensions (B × T) End gap (installed) Side clearance (installed) Barrel

Type Dimensions (B × T) End gap (installed) Side clearance Oil ring:

Dimensions (B × T) End gap (installed) Crankshaft: Crank width “A” Runout limit “C” Big end side clearance “D” Small end free play “F” Balancer: Balancer drive method Air filter oil grade:

Gear Foam-air-filter oil or equivalent oil 2-7

Quantity Clutch housing thrust clearance

(0.110 in) ---------0.1 mm (0.004 in)

MAINTENANCE SPECIFICATIONS Item Lubrication system: Oil filter type Oil pump type Tip clearance “A” Tip clearance “B” Side clearance Bypass valve setting pressure Cooling: Radiator core size Width Height Thickness Radiator cap opening pressure Radiator capacity (total) Water pump Type SPEC Standard Limit Paper type Trochoid type

2-9 MAINTENANCE SPECIFICATIONS Item SPEC Standard Lubrication chart: Oil tank Pressure feed Splashed scavenge Camshaft Cylinder head Valve lifter Piston cooler nozzle Piston Transmission gears Piston pin Main axle Oil filter Crank pin Drive axle Check ball Oil pump rotor 1 Oil pump rotor 2 Oil strainer Oil pan

SPEC MAINTENANCE SPECIFICATIONS Part to be tightened Spark plug Camshaft cap Cylinder head blind plug screw Cylinder head (stud bolt) (bolt) (bolt) Cylinder head cover Cylinder Timing chain tensioner Tensioner cap bolt Timing chain guide (rear) Exhaust pipe (nut) (bolt) Silencer Silencer clamp Exhaust pipe protector Carburetor joint Carburetor joint clamp Air filter case Air filter joint clamp Air filter joint and air filter case Throttle cable adjust bolt and locknut Throttle cable (pull) Throttle cable (return) Throttle cable cover Hot starter plunger Hot starter cable adjust bolt and locknut Air filter element Radiator stay Radiator Radiator hose clamp Radiator pipe 1, 2 Impeller Water pump housing cover Coolant drain bolt Oil pump cover Oil pump Oil pump drive gear shaft Engine oil drain bolt (oil filter) Oil filter cover Oil check bolt (cylinder head) Oil hose clamp Clutch cover Thread size Q’ty M10S × 1.0 M6 × 1.0 M12 × 1.0 M8 × 1.25 M10 × 1.25 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M8 × 1.25 M8 × 1.25 M8 × 1.25 M8 × 1.25 M6 × 1.0 M6 × 1.0 M4 × 0.7 M6 × 1.0 M6 × 1.0 M5 × 0.8 M6 × 0.75 M6 × 1.0 M12 × 1.0 M5 × 0.8 M12 × 1.0 M6 × 0.75 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M8 × 1.25 M6 × 1.0 M6 × 1.0 M4 × 0.7 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0

SPEC MAINTENANCE SPECIFICATIONS Part to be tightened Crankcase cover (right) Crankcase cover (left) Crankcase Clutch cable holder Oil drain bolt (crankcase right) (crankcase left) Oil check bolt (crankcase) Oil strainer Crankcase bearing stopper Crankcase bearing stopper Drive axle oil seal stopper Ratchet wheel guide Kick starter Screw (kick starter) Primary drive gear Clutch boss Clutch cable adjust bolt and locknut Clutch spring Balancer Balancer driven gear Balancer weight plate Drive sprocket Drive sprocket cover Shift pedal Shift guide Stopper lever Segment Thread size Q’ty M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M10 × 1.25 M8 × 1.25 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M8 × 1.25 M6 × 1.0 M20 × 1.0 M20 × 1.0 M6 × 0.75 M6 × 1.0 M10 × 1.0 M14 × 1.0 M6 × 1.0 M20 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M8 × 1.25

NOTE: - marked portion shall be checked for torque tightening after break-in or before each race. NOTE: *1: Tighten the cylinder head bolts to 30 Nm (3.0 m • kg, 22 ft • lb) in the proper tightening sequence, remove and retighten the cylinder head bolts to 20 Nm (2.0 m • kg, 14 ft • lb) in the proper tightening sequence, and then tighten the cylinder head bolts further to reach the specified angle 180° in the proper tightening sequence.

MAINTENANCE SPECIFICATIONS SPEC EC212201 CHASSIS Item Steering system: Steering bearing type Front suspension: Front fork travel Fork spring free length Spring rate, STD Optional spring Oil capacity Oil grade Inner tube outer diameter Front fork top end Rear suspension: Shock absorber travel Spring free length Fitting length One I.D. mark Two I.D. marks Three I.D. marks <Min.~Max.> One I.D. mark Two I.D. marks Three I.D. marks Spring rate, STD Optional spring Enclosed gas pressure Standard Taper roller bearing USA, CDN, EUROPE

300 mm (11.8 in) ← 454 mm (17.9 in) ← K = 4.6 N/mm (0.469 kg/mm,

Spoke wheel Spoke wheel 21 × 1.60/Aluminum 19 × 2.15/Aluminum

113 links + joint 48 ~ 58 mm (1.9 ~ 2.3 in)

Pad thickness Master cylinder inside dia. Caliper cylinder inside dia. Brake fluid type Rear disc brake: Disc outside dia. × Thickness

MAINTENANCE SPECIFICATIONS Part to be tightened Thread size Q’ty Handle crown and outer tube Under bracket and outer tube Handle crown and steering shaft Handlebar holder (upper) Handlebar holder (lower) Steering ring nut Front fork and damper assembly Front fork and adjuster Damper assembly and base valve Adjuster and damper assembly Bleed screw (front fork) and base valve Front fork and protector Protector and brake hose holder Throttle cable cap Clutch lever holder mounting Clutch lever mounting (nut) Hot starter lever holder mounting Front brake master cylinder and bracket Front brake master cylinder cap Brake lever mounting (bolt) Brake lever mounting (nut) Brake lever position locknut Cable guide (front brake hose) and under bracket Front brake hose union bolt (master cylinder) Front brake hose union bolt (caliper) Front brake caliper and front fork Front brake caliper and brake hose holder Brake caliper (front and rear) and pad pin plug Brake caliper (front and rear) and pad pin Brake caliper (front and rear) and bleed screw Front wheel axle and nut Front wheel axle holder Front brake disc and wheel hub Rear brake disc and wheel hub Footrest bracket and frame Brake pedal mounting Rear brake master cylinder and frame Rear brake master cylinder cap Rear brake hose union bolt (caliper) Rear brake hose union bolt (master cylinder) M8 × 1.25 M8 × 1.25 M24 × 1.0 M8 × 1.25 M10 × 1.25 M28 × 1.0 M51 × 1.5 M22 × 1.25 M42 × 1.5 M12 × 1.25 M5 × 0.8 M6 × 1.0 M6 × 1.0 M5 × 0.8 M5 × 0.8 M6 × 1.0 M5 × 0.8 M6 × 1.0 M4 × 0.7 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M10 × 1.25 M10 × 1.25 M8 × 1.25 M6 × 1.0 M10 × 1.0 M10 × 1.0 M8 × 1.25 M16 × 1.5 M8 × 1.25 M6 × 1.0 M6 × 1.0 M10 × 1.25 M8 × 1.25 M6 × 1.0 M4 × 0.7 M10 × 1.25 M10 × 1.25

1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut wrench,

2. Retighten the ring nut 7 Nm (0.7 m • kg, 5.1 ft • lb).

MAINTENANCE SPECIFICATIONS Part to be tightened Rear wheel axle and nut Driven sprocket and wheel hub Nipple (spoke) Disc cover and rear brake caliper Protector and rear brake caliper Chain puller adjust bolt and locknut Engine mounting: Engine upper bracket and frame Engine lower bracket and frame Engine and engine bracket (front) Engine and engine bracket (upper) Engine and frame (lower) Engine guard Engine skid plate mounting CDI unit bracket mounting Cable guide and CDI unit bracket Cable guide and frame Pivot shaft and nut Relay arm and swingarm Relay arm and connecting rod Connecting rod and frame Rear shock absorber and frame Rear shock absorber and relay arm Rear frame and frame (upper) Rear frame and frame (lower) Swingarm and brake hose holder Swingarm and patch Drive chain tensioner mounting (upper) Drive chain tensioner mounting (lower) Chain support and swingarm Seal guard and swingarm Fuel tank mounting boss and frame Fuel tank mounting Fuel tank and fuel cock Fuel tank and seat set bracket Fuel tank and fuel tank bracket Seat mounting Side cover mounting Air scoop and fuel tank Air scoop and radiator panel (lower) Front fender mounting Rear fender mounting (front) Rear fender mounting (rear) Number plate Thread size Q’ty M20 × 1.5 M8 × 1.25 M6 × 1.0 M6 × 1.0 M8 × 1.25 M10 × 1.25 M8 × 1.25 M10 × 1.25 M10 × 1.25 M10 × 1.25 M6 × 1.0 M6 × 1.0 M6 × 1.0 M5 × 0.8 M5 × 0.8 M16 × 1.5 M14 × 1.5 M14 × 1.5 M14 × 1.5 M10 × 1.25 M10 × 1.25 M8 × 1.25 M8 × 1.25 M5 × 0.8 M4 × 0.7 M8 × 1.25 M8 × 1.25 M6 × 1.0 M5 × 0.8 M10 × 1.25 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M8 × 1.25 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 SPEC Tightening torque

NOTE: - marked portion shall be checked for torque tightening after break-in or before each race.

MAINTENANCE SPECIFICATIONS SPEC EC212300 ELECTRICAL Item Ignition system: Advancer type C.D.I.: Magneto-model (stator)/manufacturer Source coil 1 resistance (color) Source coil 2 resistance (color) Pickup coil resistance (color) CDI unit-model/manufacturer Ignition coil: Model/manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance Part to be tightened Stator Rotor Neutral switch Standard Limit Electrical

This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature. (Nut)

Unit Read Definition Measure

Newton 1 kg × m/sec2 Force

Newton 1 kg × m/sec2 Force

Einlass “A” “B” Auslass “A” “B” Max. Nockenwellen-Schlag 31,200–31,300 mm (1,2283–1,2323 in) 22,550–22,650 mm (0,8878–0,8917 in) 30,950–31,050 mm (1,2185–1,2224 in) 22,494–22,594 mm (0,8856–0,8895 in)

255,5–273,5 mm (10,06–10,77 in) 261,5–279,5 mm (10,30–11,00 in) 253,0–271,0 mm (9,96–10,67 in) K = 54,0 N/mm (5,50 kg/mm, 308,0 lb/in)

m/sec2 LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Oil filter element 2 Oil pump 3 Drive axle 4 Main axle 5 Crankshaft 6 Connecting rod È From cylinder É To oil tank

SPEC LUBRICATION DIAGRAMS 1 Intake camshaft 2 Exhaust camshaft È To main axle É From oil pump

1 Fuel tank breather hose 2 Radiator hose 1 3 Cylinder head breather hose 4 Hose holder 5 Radiator hose 4 6 Clutch cable 7 Connector cover 8 Fuel hose 9 TPS (throttle position sensor) lead 0 Hot starter cable A Carburetor breather hose B Carburetor overflow hose È Insert the end of the fuel tank breather hose into the hole in the steering shaft. É Pass the cylinder head breather hose on the outside of the radiator hose 1 and between the radiator hose 4 and frame. Ê Align the paint on the cylinder head breather hose with the front edge of the hose holder. Ë Pass the clutch cable through the cable guide. Ì Pass the clutch cable in front of the radiator mounting boss. Í Install the connector cover so that it does not come in between the radiator hose 1 and radiator. Î Pass the fuel hose between the hot starter cable and TPS lead. Ï Pass the carburetor breather hoses and overflow hose so that all there hoses do not contact the rear shock absorber.

1 Hot starter cable 2 Clamp 3 TPS (throttle position sensor) lead 4 Hump (frame) 5 Neutral switch lead 6 Engine bracket 7 Engine skid plate stay 8 CDI magneto lead 9 Clutch cable 0 Radiator breather hose A Radiator hose 2 B “ENGINE STOP” button lead SPEC C Sub wire harness D Ground lead E CDI unit bracket F CDI unit G Cable guide H Ignition coil lead I Throttle cable É Fasten the hot starter cable, throttle cables, TPS lead and ignition coil lead to the frame. Ê Fasten the TPS lead to the frame behind its hump. Ë Pass the TPS lead over the hot starter cable. Ì Pass the neutral switch lead on the inside of the engine bracket. È Fasten the hot starter cable and throttle cables onto the frame. Í Pass the neutral switch lead over the engine skid plate stay. Locate the clamp ends under the hot starter cable.

SPEC Î Fasten the neutral switch lead Ñ Pass the radiator breather hose Ó Fasten the ground lead and cable guide together to the CDI in front of the radiator hose 2, on and radiator breather hose to unit bracket. the left of the chassis, and then the frame. between the frame and radiator Ô Locate the clamp ends in the Ï Fasten the neutral switch lead, arrowed range. hose 4. CDI magneto lead and radiator breather hose to the frame. Ò Fasten the sub wire harness and Õ Fasten the neutral switch lead and CDI magneto lead to the “ENGINE STOP” button lead to Ð Fasten the neutral switch lead, frame over its hump. the CDI unit bracket with the CDI magneto lead, radiator clamp ends facing downward breather hose and clutch cable behind the location where the to the frame over the radiator ground lead branches out from mounting boss. the sub wire harness.

1 Throttle cable (pull) 2 Throttle cable (return) 3 Radiator hose 2 4 Ignition coil 5 Rear arm bracket 6 Cylinder head breather hose È Pass the throttle cables over the radiator hose 2. É Pass the throttle cables on the outside of the ignition coil. Ê Fasten the throttle cables with the clamp so that the cables are not bent, and pass them under the rear arm bracket. Ë Pass the cylinder head breather hose so that it does not contact the ignition coil.

1 Master cylinder 2 Brake hose holder 3 Brake hose È Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the caliper. É Pass the brake hose into the brake hose holders. Ê If the brake hose contacts the spring (rear shock absorber), correct its twist. Ë Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the master cylinder.

1 Throttle cable 2 Clamp 3 Hot starter cable 4 Clutch cable 5 “ENGINE STOP” button lead 6 Cable guide 7 Brake hose 8 Hose guide SPEC È Fasten the “ENGINE STOP” button lead to the handlebar. É Pass the clutch cable and hot starter cable through the cable guide. Ê Pass the brake hose in front of the number plate. Ë Pass the throttle cables through the cable guide. Ì Pass the clutch cable and hot starter cable through the cable guide on the number plate.

MAINTENANCE INTERVALS The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. Item After Every break-in race ENGINE OIL Replace VALVES Check the valve clearances Inspect Replace VALVE SPRINGS Inspect Replace VALVE LIFTERS Inspect Replace CAMSHAFTS Inspect Replace Every Every fifth third (or (or 500 km) 1,000 km) As required Remarks The engine must be cold. Check the valve seats and valve stems for wear. Check the free length and the tilt. Check for scratches and wear. Inspect the camshaft surface. Inspect the decompression system CAMSHAFT SPROCKETS Inspect Replace PISTON Inspect Clean Replace PISTON RING Inspect Replace PISTON PIN Inspect Replace CYLINDER HEAD Inspect and clean Check for wear on the teeth and for damage. Inspect crack Inspect carbon deposits and eliminate them. Check ring end gap Inspect carbon deposits and eliminate them. Change gasket CYLINDER Inspect and clean Replace CLUTCH Inspect and adjust Replace TRANSMISSION Inspect Replace bearing Inspect score marks Inspect wear Inspect housing, friction plate, clutch plate and spring 3-1 MAINTENANCE INTERVALS Item After Every break-in race

SHIFT FORK, SHIFT CAM, GUIDE BAR

Inspect ROTOR NUT Retighten MUFFLER Inspect and retighten Clean Replace CRANK Inspect and clean CARBURETOR Inspect, adjust and clean SPARK PLUG Inspect and clean Replace DRIVE CHAIN Lubricate, slack, alignment Replace COOLING SYSTEM Check coolant level and leakage Check radiator cap operation Replace coolant Inspect hoses

OUTSIDE NUTS AND BOLTS

Retighten Every Every fifth third (or (or 500 km) 1,000 km) As required INSP ADJ Remarks Inspect wear

• Whichever comes first Use chain lube Chain slack: 48 ~ 58 mm (1.9 ~ 2.3 in) Every two years Refer to “STARTING AND BREAK-IN” section in the CHAPTER 1. AIR FILTER Clean and lubricate Replace OIL FILTER Replace FRAME Clean and inspect

Clean and inspect BRAKES Adjust lever position and pedal height Lubricate pivot point Check brake disc surface Check fluid level and leakage Retighten brake disc bolts, caliper bolts, master cylinder bolts and union bolts Replace pads Replace brake fluid FRONT FORKS Inspect and adjust Replace oil Replace oil seal Use foam air-filter oil or equivalent oil Every one year Suspension oil “S1” 3-2

Inspect and adjust Lube Every Every fifth third (or (or 500 km) 1,000 km) As required INSP ADJ Remarks Lithium base grease (After rain ride) Molybdenum disulfide grease Every one year Replace spring seat Retighten

CHAIN GUARD AND ROLLERS

Inspect SWINGARM Inspect, lube and retighten

RELAY ARM, CONNECTING ROD

Inspect, lube and retighten STEERING HEAD Inspect free play and retighten Clean and lube Replace bearing TIRE, WHEELS Inspect air pressure, wheel run-out, tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate

THROTTLE, CONTROL CABLE

Check routing and connection Lubricate

Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points.

GENERAL INSPECTION AND MAINTENANCE

Item Coolant Fuel Engine oil Gear shifter and clutch Throttle grip/Housing Brakes Chain Wheels Steering Front forks and rear shock absorber Cables (wires) Muffler Sprocket Lubrication Bolts and nuts Lead connectors Settings Routine Check that coolant is filled up to the radiator filler cap. Check the cooling system for leakage. Check that a fresh gasoline is filled in the fuel tank. Check the fuel line for leakage. Check that the oil level is correct. Check the crankcase and oil line for leakage. Check that gears can be shifted correctly in order and that the clutch operates smoothly. Check that the throttle grip operation and free play are correctly adjusted. Lubricate the throttle grip and housing, if necessary. Check the play of front brake and effect of front and rear brake. Check chain slack and alignment. Check that the chain is lubricated properly. Check for excessive wear and tire pressure. Check for loose spokes and have no excessive play. Check that the handlebar can be turned smoothly and have no excessive play. Check that they operate smoothly and there is no oil leakage. Check that the clutch and throttle cables move smoothly. Check that they are not caught when the handlebars are turned or when the front forks travel up and down. Check that the muffler is tightly mounted and has no cracks. Check that the driven sprocket tightening bolt is not loose. Check for smooth operation. Lubricate if necessary. Check the chassis and engine for loose bolts and nuts. Check that the CDI magneto, CDI unit, and ignition coil are connected tightly. Is the machine set suitably for the condition of the racing course and weather or by taking into account the results of test runs before racing? Are inspection and maintenance completely done? 3-4 Page P.3-5 ~ 9 P.1-13 P.3-13 ~ 17 P.3-9 ~ 10 P.3-10 ~ 11 P.3-24 ~ 30 P.3-31 ~ 33 P.3-41 ~ 42 P.3-42 ~ 44 P.3-33 ~ 40

WARNING Do not remove the radiator cap 1, drain bolt and hoses when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, place a thick towel over the radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it. CAUTION: Hard water or salt water is harmful to the engine parts. You may use distilled water, if you can’t get soft water.

1. Place the machine on a level place, and

hold it in an upright position.

• Kühlflüssigkeitsstand a Niedrig → Korrigieren. 1 Radiateur 1 Kühler 3-5 COOLANT REPLACEMENT INSP ADJ EC353011 COOLANT REPLACEMENT WARNING Do not remove the radiator cap when the engine is hot. CAUTION: Take care so that coolant does not splash on painted surfaces. If it splashes, wash it away with water.

1. Place a container under the engine.

• Radiator cap Drain the coolant completely.
• Cooling system Thoroughly flush the cooling system with clean tap water.

• Engine To specified level. Recommended coolant: High quality ethylene glycol anti-freeze containing anticorrosion for aluminum engine Coolant 1 and water (soft water) 2 mixing ratio: 50 %/50 % Coolant capacity:

• Do not mix more than one type of ethylene glycol antifreeze containing corrosion inhibitors for aluminum engine.
• Do not use water containing impurities or oil. Handling notes of coolant: The coolant is harmful so it should be handled with special care. WARNING
• When coolant splashes to your eye. Thoroughly wash your eye with water and see your doctor.
• When coolant splashes to your clothes. Quickly wash it away with water and then with soap.
• When coolant is swallowed. Quickly make him vomit and take him to a doctor.
• Radiator cap Start the engine and warm it up for a several minutes.

• Seal (radiator cap) 1
• Valve and valve seat 2 Crack/damage → Replace. Exist fur deposits 3 → Clean or replace. 3-7

Pression standard: 180 kPa (1,8 kg/cm2, 25,6 psi) Standard-Druck: 180 kPa (1,8 kg/cm2, 25,6 psi) 3-8 CLUTCH ADJUSTMENT INSP ADJ NOTE:

• Do not apply pressure more than specified pressure.
• Radiator should be filled fully.

• Radiator hose joint Coolant leakage → Repair or replace.
• Radiator hose Swelling → Replace. EC359020 CLUTCH ADJUSTMENT

• Clutch lever free play Clutch lever free play adjustment steps:
• Loosen the locknut 1.
• Turn the adjuster 2 until free play a is within the specified limits.

Locknut: 4 Nm (0.4 m • kg, 2.9 ft • lb) NOTE:

• Before adjustment, expose the adjuster by moving the boot 3 and cap 4 away.
• Make minute adjustment on the lever side using the adjuster 5.
• After adjustment, check proper operation of clutch lever. 3-9

THROTTLE CABLE ADJUSTMENT

• Throttle grip free play a Out of specification → Adjust. Throttle grip free play a: 3 ~ 5 mm (0.12 ~ 0.20 in)
• Throttle grip free play

Throttle grip free play adjustment steps:

• Slide the adjuster cover.
• Loosen the locknut 1.
• Turn the adjuster 2 until the specified free play is obtained.

Locknut: 4 Nm (0.4 m • kg, 2.9 ft • lb) NOTE: Before adjusting the throttle cable free play, the engine idle speed should be adjusted. WARNING After adjusting, turn the handlebar to right and left and make sure that the engine idling does not run faster. THROTTLE LUBRICATION

• Cover (throttle cable cap) 1

• Screw (throttle cable cap)

• Cover (throttle cable cap)
• Hot starter lever free play Hot starter lever free play adjustment steps:
• Loosen the locknut 1.
• Turn the adjuster 2 until free play a is within the specified limits.

NOTE: Proper air filter maintenance is the biggest key to preventing premature engine wear and damage. CAUTION: Never run the engine without the air filter element in place; this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage.

• Air filter element Clean them with solvent. NOTE: 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 element may result in poor starting.
• Air filter element Damage → Replace.
• Foam-air-filter oil or equivalent oil to the element. NOTE: Squeeze out the excess oil. Element should be wet but not dripping.

• Filter guide 1 NOTE: Align the projection a on filter guide with the hole b in air filter element.

• Lithium soap base grease On the matching surface a on air filter element.

NOTE: Align the projection a on filter guide with the hole b in air filter case.

ENGINE OIL LEVEL INSPECTION

1. Stand the machine on a level surface.

• When checking the oil level make sure that the machine is upright.
• Place the machine on a suitable stand. WARNING Never remove the oil tank cap just after high speed operation. The heated oil could spurt out. causing danger. Wait until the oil cools down to approximately 70 °C (158 °F).

2. Idle the engine more than 3 minutes while

keeping the machine upright. Then stop the engine and inspect the oil level.

• Oil level Check that the engine oil is above the level mark a and that the oil does not come out when the check bolt 1 is removed. Below the level mark a → Add oil through the filler cap hole until it is above the level mark a. Oil comes out at the check bolt → Drain the oil until it stops coming out. NOTE: When inspecting the oil level, do not screw the oil level gauge into the oil tank. Insert the gauge lightly. (For USA and CDN)

• Do not add any chemical additives. Engine oil also lubricates the clutch and additives could cause clutch slippage.

50 ˚C (Except for USA and CDN)

Recommended oil: SAE10W30, SAE10W40, SAE15W40, SAE20W40 or SAE20W50 API service SG type or higher JASO standard MA 50 ˚C SAE 10W-30 SAE 10W-40 SAE 15W-40 SAE 20W-40 CAUTION:

• Do not add any chemical additives or use oils with a grade of CD a or higher.
• Do not use oils labeled “ENERGY CONSERVING II” b or higher. Engine oil also lubricates the clutch and additives could cause clutch slippage.
• Do not allow foreign materials to enter the crankcase. SAE 20W-50

ENGINE OIL REPLACEMENT

5. Start the engine and let it warm up for several minutes.

CAUTION: When the oil tank is empty, never start the engine.

6. Idle the engine more than 10 seconds

while keeping the machine upright. Then stop the engine and add the oil to the maximum level.

ENGINE OIL REPLACEMENT

1. Start the engine and let it warm up for several minutes.

2. Stop the engine and place an oil pan under

• Drain bolt (with gasket) 3
• Oil filter drain bolt (O-ring) 4
• Drain bolt (with gasket) 5 Drain the crankcase and oil tank of its oil.

ENGINE OIL REPLACEMENT

4. If the oil filter is to be replaced during this

oil change, remove the following parts and reinstall them. Replacement steps:

• Remove the oil filter cover 1 and oil filter element 2.
• Check the O-rings 3, if cracked or damaged, replace them with a new one.
• Install the oil filter element and oil filter cover.

• Oil filter drain bolt

• Drain bolt (crankcase right)

• Drain bolt (crankcase left)

• Engine oil Oil quantity: Periodic oil change:

0.95 L (0.84 Imp qt, 1.00 US qt)

With oil filter replacement:

PILOT SCREW ADJUSTMENT

• Engine (for oil leaks)
• Oil level Refer to “ENGINE OIL LEVEL INSPECTION”.

• Oil pressure Checking steps:
• Slightly loosen the oil gallery bolt 1.
• Start the engine and keep it idling until oil starts to seep from the oil gallery bolt. If no oil comes out after one minute, turn the engine off so it will not seize.
• Check oil passages, oil filter and oil pump for damage or leakage.
• Start the engine after solving the problem(s) and recheck the oil pressure.
• Tighten the oil gallery bolt to specification.

PILOT SCREW ADJUSTMENT

• Pilot screw 1 Adjusting steps: NOTE: To optimize the fuel flow at a smaller throttle opening, each machine’s pilot screw has been individually set at the factory. Before adjusting the pilot screw, turn it in fully and count the number of turns. Record this number as the factory-set number of turns out.
• Turn in the pilot screw until it is lightly seated.
• Turn out the pilot screw by the factory-set number of turns. Pilot screw (example): 1-1/4 turns out

VALVE CLEARANCE ADJUSTMENT

IDLE SPEED ADJUSTMENT

1. Start the engine and thoroughly warm it up.

• Idle speed Adjustment steps:
• Adjust the pilot screw. Refer to “PILOT SCREW ADJUSTMENT” section.
• Turn the throttle stop screw 1 until the specified engine idling speed.

NOTE: Using a digital engine tachometer for idle speed adjustment, detect the engine idling speed by bringing the sensing element c of the engine tachometer close to the ignition coil 2.

To increase idle speed → Turn the throttle stop screw 1 in a. To decrease idle speed → Turn the throttle stop screw 1 out b. Engine idling speed: 1,900 ~ 2,100 r/min

VALVE CLEARANCE ADJUSTMENT

• The valve clearance should be adjusted when the engine is cool to the touch.
• The piston must be at Top Dead Center (T.D.C.) on compression stroke to check or adjust the valve clearance.
• Fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4.
• Hot starter plunger Refer to “CARBURETOR” section in the
• Cylinder head cover Refer to “CAMSHAFTS” section in the

VALVE CLEARANCE ADJUSTMENT

• Valve clearance Out of specification → Adjust. Valve clearance (cold): Intake valve:

(0.0039 ~ 0.0059 in) Exhaust valve:

(0.0079 ~ 0.0098 in) Checking steps:

• Turn the crankshaft counterclockwise with a wrench.
• Align the T.D.C. mark a on the rotor with the align mark b on the crankcase cover when piston is at T.D.C. on compression stroke. NOTE: In order to be sure that the piston is at Top Dead Center, the punch mark c on the exhaust camshaft and the punch mark d on the intake camshaft must align with the cylinder head surface, as shown in the illustration.
• Measure the valve clearance e using a feeler gauge 1. NOTE: Record the measured reading if the clearance is incorrect.

VALVE CLEARANCE ADJUSTMENT

• Remove the timing chain tensioner and camshaft caps.

NOTE: Remove the camshaft cap bolts in a crisscross pattern from the outside working inwards.

• Remove the camshaft (exhaust 1 and intake 2). NOTE: Attach a wire 3 to the timing chain to prevent it from falling into the crankcase.
• Remove the valve lifters 4 and the pads NOTE:
• Place a rag in the timing chain space to prevent pads from falling into the crankcase.
• Identity each valve lifter and pad position very carefully so that they can be reinstalled in their original place.
• Select the proper pad using the pad selecting table. Pad range No. 120 No. 240

Pad Availability: 25 increments Pads are available in 0.05 mm increments NOTE: The thickness a of each pad is indicated in hundreths of millimeters on the pad upper surface.

VALVE CLEARANCE ADJUSTMENT

• Round off the last digit of the installed pad number to the nearest increment. Last digit of pad number Rounded value 0, 1 or 2

EXAMPLE: Installed pad number = 148 Rounded off value = 150 NOTE: Pads can only be selected in 0.05 mm increments.

• Locate the rounded-off value and the measured valve clearance in the chart “PAD SELECTION TABLE”. The field where these two coordinates intersect shows the new pad number to use. NOTE: Use the new pad number only as a guide when verifying the valve clearance adjustment.
• Install the new pads 6 and the valve lifters 7. NOTE:
• Apply the engine oil on the valve lifters.
• Apply the molybdenum disulfide oil on the valve stem ends.
• Valve lifter must turn smoothly when rotated with a finger.
• Be careful to reinstall valve lifters and pads in their original place.
• Install the camshafts (exhaust and intake), the timing chain and the camshaft caps. Refer to “CAMSHAFTS” section in the

VALVE CLEARANCE ADJUSTMENT

• Install the timing chain tensioner. Refer to “CAMSHAFTS” section in the

NOTE: Turn the crankshaft counterclockwise several turns so that the installed parts settle into the right position.

• Recheck the valve clearance.
• If the clearance is still incorrect, repeat all the clearance adjustment steps until the specified clearance is obtained.
• All removed parts NOTE: Install all removed parts in reversed order of their removal.

VALVE CLEARANCE ADJUSTMENT

VALVE CLEARANCE (cold):

Example: Installed is 175 Measured clearance is 0.22 mm Replace 175 pad with 185 pad Pad number: (example) Pad No. 175 = 1.75 mm

Pad No. 185 = 1.85 mm

EXHAUST MEASURED CLEARANCE

CLEARANCE (cold): ~ 0.25 mm Example: Installed is 175 Measured clearance is 0.32 mm Replace 175 pad with 185 pad Pad number: (example) Pad No. 175 = 1.75 mm Pad No. 185 = 1.85 mm

WARNING Bleed the brake system if:

• The system has been disassembled.
• A brake hose has been loosened or removed.
• The brake fluid is very low.
• The brake operation is faulty. A dangerous loss of braking performance may occur if the brake system is not properly bled.

• Reservoir float (front brake)

È Front É Rear Air bleeding steps: a. Add proper brake fluid to the reservoir. b. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. c. Connect the clear plastic tube 2 tightly to the caliper bleed screw 1. d. Place the other end of the tube into a container. e. Slowly apply the brake lever or pedal several times. f. Pull the lever in or push down on the pedal. Hold the lever or pedal in position. g. Loosen the bleed screw and allow the lever or pedal to travel towards its limit. h. Tighten the bleed screw when the lever or pedal limit has been reached; then release the lever or pedal.

Bleed screw: 6 Nm (0.6 m • kg, 4.3 ft • lb) Repeat steps (e) to (h) until of the air bubbles have been removed from the system. CHÂSSIS/PURGE D’AIR DU CIRCUIT DE FREINAGE

INSP ADJ NOTE: If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared.

Add brake fluid to the level line on the reservoir. WARNING Check the operation of the brake after bleeding the brake system.

• Protector (rear brake)
• Reservoir float (front brake)

• Brake lever position Brake lever position adjustment steps:
• Loosen the locknut 1.
• Turn the adjusting bolt 2 until the lever position a is within specified position.

Locknut: 5 Nm (0.5 m • kg, 3.6 ft • lb) CAUTION: Be sure to tighten the locknut, as it will cause poor brake performance.

• Brake pedal height Pedal height adjustment steps:
• Loosen the locknut 1.
• Turn the adjusting nut 2 until the pedal height a is within specified height.

• Adjust the pedal height between the maximum È and the minimum É as shown. (In this adjustment, the bolt 3 end b should protrude out of the threaded portion 4 but not be less than 2 mm (0.08 in) c away from the brake pedal 5).
• After the pedal height adjustment, make sure that the rear brake does not drag.

• Brake pad thickness a Out of specification → Replace as a set. Brake pad thickness a: Standard <Limit>

• Brake pad Brake pad replacement steps:
• Remove the pad pin plug 1.

FRONT BRAKE PAD INSPECTION AND REPLACEMENT

INSP ADJ 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 container under its end.

• Loosen the bleed screw and push the caliper piston in.

• Tighten the bleed screw.

• Install the brake pads 7 and pad pin. NOTE:
• Install the brake pads with their projections a into the caliper recesses b.
• Temporarily tighten the pad pin at this point.
• Install the caliper 8 and tighten the pad pin 9.

• Install the pad pin plug 0.

• Brake pad thickness a Out of specification → Replace as a set. Brake pad thickness a: Standard <Limit>

• Brake pad Brake pad replacement steps:
• Remove the protector 1 and pad pin plug

• Loosen the pad pin 3.
• Remove the rear wheel 4 and caliper 5. Refer to “FRONT WHEEL AND REAR WHEEL” section in the CHAPTER 5.

• Remove the pad pin 6 and brake pads 7.
• Connect the transparent hose 8 to the bleed screw 9 and place the suitable container under its end.
• Loosen the bleed screw and push the caliper piston in. CAUTION: Do not reuse the drained brake fluid.
• Tighten the bleed screw.

• Install the brake pad 0 and pad pin A. NOTE:
• Install the brake pads with their projections a into the caliper recesses b.
• Temporarily tighten the pad pin at this point.
• Install the caliper B and rear wheel C. Refer to “FRONT WHEEL AND REAR WHEEL” section in the CHAPTER 5.
• Tighten the pad pin D.

• Install the pad pin plug E and protector

• Brake pedal operation A softy or spongy feeling → Bleed brake system. Refer to “BRAKE SYSTEM AIR BLEEDING” section. EC36b000

• Brake pad Refer to “REAR BRAKE PAD INSPECTION AND REPLACEMENT” section.
• Rear brake pad insulator 1 Damage → Replace.

BRAKE FLUID LEVEL INSPECTION

1. Place the master cylinder so that its top is

in a horizontal position.

• Brake fluid level Fluid at lower level → Fill up. a Lower level È Front É Rear Recommended brake fluid: DOT #4

WARNING Use only designated quality brake fluid to avoid poor brake performance. Refill with same type and brand of brake fluid; mixing fluids could result in poor brake performance. Be sure that water or other contaminants do not enter master cylinder when refilling. Clean up spilled fluid immediately to avoid erosion of painted surfaces or plastic parts. CONTROLE DE L’ISOLANT DE PLAQUETTE DE FREIN ARRIERE/ CONTROLE DU NIVEAU DU LIQUIDE DE FREIN HINTERRAD-SCHEIBENBREMSBELAG-ISOLIERUNG

• Sprocket teeth a Excessive wear → Replace. NOTE: Replace the drive, driven sprockets and drive chain as a set.

• Drive chain length (15 links) a Out of specification → Replace. Drive chain length (15 links): <Limit>: 242.9 mm (9.563 in) NOTE:
• While measuring the drive chain length, push down on the drive chain to increase its tension.
• Measure the length between drive chain roller 1 and F as shown.
• Perform this measurement at two or three different places.

• Drive chain Place it in kerosene, and brush off as much dirt as possible. Then remove the chain from the kerosene and dry the chain.

• Drive chain stiffness a Clean and oil the chain and hold as illustrated. Stiff → Replace drive chain.

• Master link clip 3 New CAUTION: Be sure to install the master link clip to the direction as shown. a Turning direction

1. Elevate the rear wheel by placing the suitable stand under the engine.

• Drive chain slack a Above the seal guard installation bolt. Out of specification → Adjust. Drive chain slack: 48 ~ 58 mm (1.9 ~ 2.3 in) NOTE: Before checking and/or adjusting, rotate the rear wheel through several revolutions and check the slack several times to find the tightest point. Check and/or adjust chain slack with rear wheel in this “tight chain” position.

• Drive chain slack Drive chain slack adjustment steps:
• Loosen the axle nut 1 and locknuts 2.
• Adjust chain slack by turning the adjusters To tighten →Turn adjuster 3 counterclockwise. To loosen → Turn adjuster 3 clockwise and push wheel forward.
• Turn each adjuster exactly the same amount to maintain correct axle alignment. (There are marks a on each side of chain puller alignment.) NOTE: Turn the adjuster so that the chain is in line with the sprocket, as viewed from the rear. CAUTION: Too small chain slack will overload the engine and other vital parts; keep the slack within the specified limits.
• Tighten the axle nut while pushing down the drive chain.

• Tighten the locknuts.

• Front fork smooth action Operate the front brake and stroke the front fork. Unsmooth action/oil leakage → Repair or replace.

• Dust seal 1 NOTE: Use a thin screw driver, and be careful not to damage the inner fork tube and dust seal.
• Clean the dust seal and oil seal after every run.
• Apply the lithium soap base grease on the inner tube.

FRONT FORK INTERNAL PRESSURE

RELIEVING NOTE: If the front fork initial movement feels stiff during a run, relieve the front fork internal pressure.

1. Elevate the front wheel by placing a suitable stand under the engine.

2. Remove the air bleed screw 1 and release

the internal pressure from the front fork.

• Rebound damping force By turning the adjuster 1. Stiffer a → Increase the rebound damping force. (Turn the adjuster 1 in.) Softer b → Decrease the rebound damping force. (Turn the adjuster 1 out.)

ADJUSTMENT INSP ADJ Extent of adjustment: Maximum Fully turned in position Minimum 20 clicks out (from maximum position)

• STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. Standard position: 6 clicks out *8 clicks out
• For EUROPE CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. WARNING Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability. EC36J001

• Compression damping force By turning the adjuster 1. Stiffer a → Increase the compression damping force. (Turn the adjuster 1 in.) Softer b → Decrease the compression damping force. (Turn the adjuster 1 out.)

INSP ADJ Extent of adjustment: Maximum Fully turned in position Minimum 20 clicks out (from maximum position)

• STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. Standard position: 11 clicks out *12 clicks out
• For EUROPE CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. WARNING Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability. EC36K000

REAR SHOCK ABSORBER INSPECTION

• Swingarm smooth action Abnormal noise/unsmooth action → Grease the pivoting points or repair the pivoting points. Damage/oil leakage → Replace.

1. Elevate the rear wheel by placing the suitable stand under the engine.

*265.5 mm (10.45 in) Extent of adjustment

• Be sure to remove all dirt and mud from around the locknut and adjuster before adjustment.
• The length of the spring (installed) changes

1.5 mm (0.06 in) per turn of the adjuster.

• The I.D. mark b is marked at the end of the spring.
• The standard length and extent of adjustment vary according to the quantity of I.D. marks. CAUTION: Never attempt to turn the adjuster beyond the maximum or minimum setting.

DAMPING FORCE ADJUSTMENT

DAMPING FORCE ADJUSTMENT

• Rebound damping force By turning the adjuster 1. Stiffer a → Increase the rebound damping force. (Turn the adjuster 1 in.) Softer b → Decrease the rebound damping force. (Turn the adjuster 1 out.) Extent of adjustment: Maximum Fully turned in position Minimum 20 clicks out (from maximum position)

• STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. (Which align the punch mark a on the adjuster with the punch mark b on the bracket.) Standard position: About 8 clicks out CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged.

DAMPING FORCE ADJUSTMENT

• Low compression damping force By turning the adjuster 1.

Stiffer a → Increase the low compression damping force. (Turn the adjuster 1 in.) Softer b → Decrease the low compression damping force. (Turn the adjuster 1 out.) Extent of adjustment: Maximum Fully turned in position Minimum 20 clicks out (from maximum position)

• STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. (Which align the punch mark a on the adjuster with the punch mark b on the high compression damping adjuster.)

• For EUROPE CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged.

DAMPING FORCE ADJUSTMENT

• High compression damping force By turning the adjuster 1.

Stiffer a → Increase the high compression damping force. (Turn the adjuster 1 in.) Softer b → Decrease the high compression damping force. (Turn the adjuster 1 out.) Extent of adjustment: Maximum Fully turned in position Minimum 2 turns out (from maximum position)

• STANDARD POSITION: This is the position which is back by the specific number of turns from the fully turned-in position. (Which align the punch mark a on the adjuster with the punch mark b on the adjuster body.)

Standard position: About 1-1/2 turns out

CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged.

• Tire pressure Out of specification → Adjust. Standard tire pressure: 100 kPa (1.0 kgf/cm2, 15 psi) NOTE:
• Check the tire while it is cold.
• Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low.
• A tilted tire valve stem indicates that the tire slips off its position on the rim.
• If the tire valve stem is found tilted, the tire is considered to be slipping off its position. Correct the tire position. EC36S002

• Spokes 1 Bend/damage → Replace. Loose spoke → Retighten.

NOTE: Be sure to retighten these spokes before and after break-in. After a practice or a race check spokes for looseness. EC36T000 WHEEL INSPECTION

• Wheel runout Elevate the wheel and turn it. Abnormal runout → Replace.

STEERING HEAD INSPECTION AND ADJUSTMENT

• Bearing free play Exist play → Replace.

STEERING HEAD INSPECTION AND

1. Elevate the front wheel by placing a suitable stand under the engine.

• Steering shaft Grasp the bottom of the forks and gently rock the fork assembly back and forth. Free play → Adjust steering head.

• Steering ring nut Steering ring nut adjustment steps:
• Remove the number plate.
• Remove the handlebar and handle crown.

STEERING HEAD INSPECTION AND ADJUSTMENT

• Tighten the ring nut 3 using ring nut wrench 4. NOTE:
• Apply the lithium soap base grease 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

• Retighten the ring nut using the ring nut wrench. WARNING Avoid over-tightening.

• Check the steering shaft by turning it lock to lock. If there is any binding, remove the steering shaft assembly and inspect the steering bearings.
• Install the plain washer 5, handle crown 6, plain washer 7, steering shaft nut 8, handlebar 9, handlebar holder (upper) 0 and number plate A. NOTE:
• The handlebar holder (upper) should be installed with the punched mark a forward.
• Install the handlebar so that the marks b are in place on both sides.
• Install the handlebar so that the projection c of the handlebar holder (upper) is positioned at the mark on the handlebar as shown.
• Insert the end of fuel breather hose B into the hole in the steering shaft. CAUTION: First tighten the bolts on the front side of the handlebar holder (upper), and then tighten the bolts on the rear side.

STEERING HEAD INSPECTION AND ADJUSTMENT

• Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition. NOTE: When the engine runs for many hours at low speeds, the spark plug insulator will become sooty, even if the engine and carburetor are in good operating condition.

4. Clean the plug with a spark plug cleaner if

13 Nm (1.3 m · kg, 9.4 ft · lb) NOTE:

• Before installing a spark plug, clean the gasket surface and plug surface.
• Finger-tighten a the spark plug before torquing to specification b.

IGNITION TIMING CHECK

IGNITION TIMING CHECK

• Inductive tachometer To the ignition coil lead (orange lead 1). Timing light: YM-33277-A/90890-03141

• Engine idling speed Refer to “IDLE SPEED ADJUSTMENT”.

• Ignition timing Visually check the stationary pointer a is within the firing range b on the rotor. Incorrect firing range → Check rotor and pickup assembly.

1 Seat removal 3 Side covers removal Extent of removal: Extent of removal Order Preparation for removal

Part name 2 Fuel tank removal 4 Number plate removal Q’ty

SEAT, FUEL TANK AND SIDE

COVERS REMOVAL Turn the fuel cock to “OFF”. Disconnect the fuel hose. Seat Air scoop (left and right) Bolt (fuel tank) Fuel tank Side cover (left) Side cover (right) Number plate 4-1

DEPOSE DE LA SELLE, DU

ENG REMOVAL POINTS Side cover

• Side cover (right) 2 NOTE: Draw the side cover downward to remove it because its claws a are inserted in the air filter case. Number plate
• Number plate 1 NOTE:
• The projection a is inserted into the band of the number plate. Pull the band off the projection before removal.
• Remove the hot starter cable 2 and clutch cable 3 from the cable guide b on the number plate.
• The projection c on the under bracket is inserted into the number plate. Remove the number plate by pulling it off the projection.

ASSEMBLY AND INSTALLATION

7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: Put the portion a of the flap of the air filter case on the inside of the air scoop. 4-2 SELLE, RESERVOIR DE CARBURANT ET CACHES LATERAUX

1 Silencer removal Extent of removal: Extent of removal Order

SILENCER REMOVAL Side cover (right) Preparation for removal

2 Exhaust pipe removal

Bolt (clamp) Bolt [silencer (front)] Bolt [silencer (rear)] Collar Silencer Clamp Nut (exhaust pipe) Bolt (exhaust pipe) Exhaust pipe Gasket

4-3 Remarks Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Only loosening.

CAUTION: Take care not to damage the rivet fitting holes (ø4.9 mm) a in removal.

NOTE: Pull out the inner pipe while lightly tapping the stay b on the silencer using a soft hammer.

• Apply heat resistant sealant along the plate edge a on the inside of the silencer and also along the silencer edge b as shown.
• Take care not to allow the fiber out of place when installing the inner pipe.

ASSEMBLY AND INSTALLATION

Exhaust pipe and silencer

• Nut (exhaust pipe) 2

• Bolt (exhaust pipe) 3

New 2 30 Nm (3.0 m · kg, 22 ft · lb) NOTE:

• Install the gasket with its meshed area a toward the exhaust pipe side.
• The gasket should be installed according to the dimension shown.

Panel Clamp Radiator (right) Hose 2 Hose 3 Hose 4 Pipe 2/O-ring Radiator breather hose Radiator (left) Hose 1 Pipe 1/O-ring 4-6 Remarks

1/1 RADIATOR ENG EC456000 HANDLING NOTE WARNING Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radiator cap by the following procedure: Place a thick rag, like a towel, over the radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it. EC454000 INSPECTION EC444100 Radiator

• Radiator core 1 Obstruction → Blow out with compressed air through rear of the radiator. Bent fin → Repair/replace. EC455000

ASSEMBLY AND INSTALLATION

• Radiator breather hose 1

• Panel 1 NOTE: First fit the inner hook portion a and then the outer one b onto the radiator. 4-8 RADIATEUR KÜHLER ENG

Band TPS coupler Throttle cable cover Throttle cable Clamp (air cleaner joint) Clamp (carburetor joint) Hot starter plunger Carburetor Carburetor joint 4-9 Remarks

CARBURETOR DISASSEMBLY Breather hose Valve lever housing cover Screw (throttle shaft) Throttle valve Needle holder Jet needle Cover Spring Diaphragm (accelerator pump) Float chamber Leak jet Pilot screw Float pin Float Needle valve

REMOVAL POINTS Pilot screw

• Pilot screw 1 NOTE: To optimize the fuel flow at a small throttle opening, each machine’s pilot screw has been individually set at the factory. Before removing the pilot screw, turn it in fully and count the number of turns. Record this number as the factory-set number of turns out. INSPECTION Carburetor
• Carburetor body Contamination → Clean. NOTE:
• Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air.

• Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air.
• Valve seat 2 Grooved wear a → Replace. Dust b → Clean.
• Filter c Clogged → Clean. EC464300 Throttle valve
• Free movement Stick → Repair or replace. NOTE: Insert the throttle valve 1 into the carburetor body, and check for free movement. EC464400 Jet needle
• Jet needle 1 Bends/wear → Replace.
• Clip groove Free play exists/wear → Replace.
• Clip position Standard clip position: No.4 Groove

Measurement and adjustment steps:

• Hold the carburetor in an upside down position. NOTE:
• Slowly tilt the carburetor in the opposite direction, then take the measurement when the needle valve aligns with the float arm.
• If the carburetor is level, the weight of the float will push in the needle valve, resulting in an incorrect measurement.
• Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers. NOTE: The float arm should be resting on the needle valve, but not compressing the needle valve.
• If the float height is not within specification, inspect the valve seat and needle valve.
• If either is worn, replace them both.
• If both are fine, adjust the float height by bending the float tab b on the float.
• Recheck the float height. EC464600 Float

ASSEMBLY AND INSTALLATION

NOTE: Make sure the spring 1 fits on the stopper a of the lever 2.

NOTE: Make sure the stopper a of the spring 2 fits into the recess b in the carburetor.

• Spring 1 To throttle shaft 2. NOTE: Install the bigger hook a of the spring fits on the stopper b of the throttle shaft pulley.

• Apply the fluorochemical grease on the bearings.
• 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 fits into the recess in the carburetor.
• Turn the throttle shaft assembly left while holding down the lever 1 5 and fit the throttle stop screw tip d to the stopper e of the throttle shaft assembly pulley.

• After installing the needle valve to the float, install them to the carburetor.
• Check the float for smooth movement.

• O-ring 4 Note the following installation points:
• Turn in the pilot screw until it is lightly seated.
• Turn out the pilot screw by the number of turns recorded before removing. Pilot screw (example): 1-1/4 turns out

• Cable holder (throttle stop screw cable)

• Hose holder (carburetor breather hose)

• Hose holder (drain hose) 5
• Screw (cover) 6 NOTE: Install the diaphragm (accelerator pump) with its mark a facing the spring.

• Throttle valve plate 5 To throttle valve 6.

• Throttle valve assembly 1
• Screw (throttle shaft) 2 NOTE: Install the valve lever rollers 3 into the slits a of the throttle valve.

• Valve lever housing cover 2
• Bolt (valve lever housing cover) 3

• Carburetor breather hose 1 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2.

CARBURETOR ENG Accelerator pump timing adjustment Adjustment steps: NOTE: In order for the throttle valve height a to achieve the specified value, tuck under the throttle valve plate 1 the rod 2 etc. with the same outer diameter as the specified value. Throttle valve height:

• Fully turn in the accelerator pump adjusting screw 3.
• Check that the link lever 4 has free play b by pushing lightly on it.
• Gradually turn out the adjusting screw while moving the link lever until it has no more free play. Carburetor installation

• Carburetor 1 NOTE: Install the projection a between the carburetor joint slots.

• Bolt (carburetor joint) 1

• Bolt (air cleaner joint) 2

• Throttle grip free play Refer to “THROTTLE CABLE ADJUSTMENT” section in the CHAPTER 3.

• Throttle cable cover 1
• Screw (throttle cable cover) 2

• TPS (throttle position sensor) coupler 1
• Clamp 2 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2.

1 Cylinder head cover removal Extent of removal: Extent of removal Order Part name Q’ty

REMOVAL Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Refer to “CARBURETOR” section. Refer to “ENGINE REMOVAL” section. Preparation for removal

Hot starter plunger Engine upper bracket (right) Engine upper bracket (left) Spark plug Cylinder head breather hose Bolt (cylinder head cover) Cylinder head cover Gasket Timing chain guide (top)

CAMSHAFTS ENG CAMSHAFTS 1 Camshaft removal Extent of removal: Extent of removal Order

Remarks Refer to “REMOVAL POINTS”.

• “I” mark With stationary pointer. Checking steps:
• Turn the crankshaft counterclockwise with a wrench.
• Align the “I” mark a on the rotor with the stationary pointer b on the crankcase cover. When the “I” mark is aligned with the stationary pointer, the piston is at the Top Dead Center (T.D.C.). NOTE:
• In order to be sure that the piston is at Top Dead Center, the punch mark c on the exhaust camshaft and the punch mark d on the intake camshaft must align with the cylinder head surface, as shown in the illustration.
• If there is no clearance, rotate the crankshaft counterclockwise one turn.

• Bolt (camshaft cap) 1
• Camshaft caps 2 NOTE: Remove the bolts (camshaft cap) in a crisscross pattern, working from the outside in. CAUTION: The bolts (camshaft cap) must be removed evenly to prevent damage to the cylinder head, camshafts or camshaft caps.

NOTE: Attach a wire 3 to the timing chain to prevent it from falling into the crankcase.

• Cam lobes Pitting/scratches/blue discoloration → Replace.

• Runout (camshaft) Out of specification → Replace. Runout (camshaft): Less than 0.03 mm (0.0012 in)

• Camshaft-to-cap clearance Out of specification → Measure camshaft journal diameter. Camshaft-to-cap clearance:

(0.0011 ~ 0.0024 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.
• Install the circlip, dowel pins and camshaft caps.

Bolt (camshaft cap): 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE:

• Tighten the bolts (camshaft cap) in a crisscross pattern from innermost to outer caps.
• Do not turn the camshaft when measuring clearance with the Plastigauge®.
• Remove the camshaft caps and measure the width of the Plastigauge® 1.

• Camshaft sprocket 1 Wear/damage → Replace the camshaft assembly and timing chain as a set.

• Decompression system Checking steps:
• Check that the decompressor cam 1 moves smoothly.
• Check that the decompressor lever pin 2 projects from the camshaft. Timing chain tensioner
• While pressing the tensioner rod lightly with fingers, use a thin screwdriver 1 and wind the tensioner rod up fully clockwise.
• When releasing the screwdriver by pressing lightly with fingers, make sure that the tensioner rod will come out smoothly.
• If not, replace the tensioner assembly.

ASSEMBLY AND INSTALLATION

• Intake camshaft 2 Installation steps:
• Turn the crankshaft counterclockwise until the “I” mark a on the rotor is aligned with the stationary pointer b on the crankcase cover. NOTE:
• Apply the molybdenum disulfide oil on the camshafts.
• Apply the engine oil on the decompression system.

• Fit the timing chain 3 onto both camshaft sprockets and install the camshafts on the cylinder head. NOTE: The camshafts should be installed onto the cylinder head so that the exhaust cam sprocket punch mark c and the intake cam sprocket punch mark d align with the surface of the cylinder head. CAUTION: Do not turn the crankshaft during the camshaft installation. Damage improper valve timing will result.

Bolt (camshaft cap): 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE:

• Apply the molybdenum disulfide oil on the thread of the bolts (camshaft cap) 5.
• Tighten the bolts to the specified torque in two or three steps in the proper tightening sequence as shown. CAUTION: The bolts (camshaft cap) must be tightened evenly, or damage to the cylinder head, camshaft caps, and camshaft will result.

• Timing chain tensioner Installation steps:
• While pressing the tensioner rod lightly with fingers, use a thin screwdriver and wind the tensioner rod up fully clockwise.

• With the rod fully wound and the chain tensioner UP mark a facing upward, install the gasket 1, the chain tensioner 2 and the gasket 3, and tighten the bolt 4 to the specified torque.

• Release the screwdriver, check the tensioner rod to come out and tighten the gasket 5 and the cap bolt 6 to the specified torque.

• Crankshaft Counterclockwise several turns
• Rotor “I” mark Align with the crankcase stationary pointer.
• Camshaft match marks Align with the cylinder head surface. Out of alignment → Adjust.

Seat and fuel tank Preparation for removal Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Refer to “EXHAUST PIPE AND SILENCER” section. Refer to “RADIATOR” section. Refer to “CARBURETOR” section. Refer to “CAMSHAFTS” section. Exhaust pipe and silencer

Refer to NOTE. NOTE: Tighten the cylinder head bolts to 30 Nm (3.0 m • kg, 22 ft • lb) in the proper tightening sequence, remove and retighten the cylinder head bolts to 20 Nm (2.0 m • kg, 14 ft • lb) in the proper tightening sequence, and then tighten the cylinder head bolts further to reach the specified angle 180° in the proper tightening sequence.

• Carbon deposits (from the combustion chambers) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching:
• Cylinder head Scratches/damage → Replace.

• Cylinder head warpage Out of specification → Resurface. Cylinder head warpage: Less than 0.05 mm (0.002 in) Warpage measurement and re-surfacement steps:
• Place a straightedge and a feeler gauge across the cylinder head.
• Use a feeler gauge to measure the warpage.
• If the warpage is out of specification, resurface the cylinder head.
• Place a 400 ~ 600 grit wet sandpaper on the surface plate, and resurface the head using a figure-eight sanding pattern. NOTE: To ensure an even surface rotate the cylinder head several times.

ASSEMBLY AND INSTALLATION

• Cylinder head 4 NOTE: While pulling up the timing chain, install the timing chain guide (front) and cylinder head.
• Bolt 2 Installation steps: CAUTION: Tighten the cylinder head using the rotation angle procedure to obtain uniform tightening torque.
• Wash the threads and contact surfaces of the bolts, the contact surfaces of the plain washers, the contact surface of the cylinder head, and the threads of the crankcase.
• Apply the molybdenum disulfide grease on the threads and contact surfaces of the bolts and on both contact surfaces of the plain washers.
• Install the plain washers and bolts.
• Tighten the bolts to the specified torque in two or three steps in the proper tightening sequence as shown.

• Again apply the molybdenum disulfide grease on the threads and contact surfaces of the bolts and on both contact surfaces of the plain washers.
• Retighten the bolts. NOTE: Tighten the bolts to the specified torque in two or three steps in the proper tightening sequence as shown.

• Put a mark on the corner 1 of the bolt (cylinder head) and the cylinder head 2 as shown.

NOTE: Tighten the bolts 90° in each of the two steps to reach the specified angle of 180° in the proper tightening sequence as shown.

1 Valve removal Extent of removal: Extent of removal Order Part name Q’ty

REMOVAL Cylinder head Valve lifter Adjusting pad Valve cotter Valve retainer Valve spring Stem seal Valve spring seat Exhaust valve Intake valve

Preparation for removal

Remarks Refer to “CYLINDER HEAD” section. Use special tool. Refer to “REMOVAL POINTS”.

ENG REMOVAL POINTS Valve lifter and valve cotter

• Pads 2 NOTE: Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place.
• Valve sealing Leakage at the valve seat → Inspect the valve face, valve seat and valve seat width. Checking steps:
• Pour a clean solvent 1 into the intake and exhaust ports.
• Check that the valve seals properly. There should be no leakage at the valve seat 2.

• Valve cotters NOTE: Attach a valve spring compressor 1 between the valve spring retainer and the cylinder head to remove the valve cotters. Valve spring compressor: YM-4019/90890-04019

• Stem-to-guide clearance Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b Out of specification → Replace the valve guide. Clearance (stem to guide): Intake:

• Valve guide Replacement steps: NOTE: To ease guide removal, installation and to maintain correct fit heat the cylinder head in an over to 100 °C (212 °F).
• Install the new valve guide using a valve guide remover 1 and valve guide installer

• After installing the valve guide, bore the valve guide using a valve guide reamer 3 to obtain proper stem-to-guide clearance.

• Valve face Pitting/wear → Grind the face.
• Valve stem end Mushroom shape or diameter larger than the body of the stem → Replace.

• Margin thickness a Out of specification → Replace. Margin thickness: Intake:

• If the valve is removed or replaced always replace the oil seal.
• Carbon deposits (from the valve face and valve seat)
• Valve seats Pitting/wear → Reface the valve seat.

• Valve seat width a Out of specification → Reface the valve seat. Valve seat width: Intake:

<Limit>: 1.6 mm (0.0630 in) Measurement steps:

• Apply Mechanic’s blueing dye (Dykem) b to the valve face.
• Install the valve into the cylinder head.
• Press the valve through the valve guide and onto the valve seat to make a clear pattern.
• Measure the valve seat width. Where the valve seat and valve face made contact, blueing will have been removed.
• If the valve seat is too wide, too narrow, or the seat is not centered, the valve seat must be refaced.

• Valve seat NOTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. Lapping steps:
• Apply a coarse lapping compound to the valve face. CAUTION: Do not let the compound enter the gap between the valve stem and the guide.
• Apply molybdenum disulfide oil to the valve stem.
• Install the valve into the cylinder head.
• Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the compound. NOTE: For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands.
• Apply a fine lapping compound to the valve face and repeat the above steps. NOTE: After every lapping operation be sure to clean off all of the compound from the valve face and valve seat.
• Apply Mechanic’s blueing dye (Dykem) to the valve face.
• Install the valve into the cylinder head.
• Press the valve through the valve guide and onto the valve seat to make a clear pattern.
• Measure the valve seat width again. If the valve seat width is out of specification, reface and relap the valve seat.

• Compressed spring force a Out of specification → Replace. b Installed length Compressed spring force: Intake:

(13.0 ~ 14.9 kg at 27.38 mm,

• Valve lifter Scratches/damage → Replace both lifters and cylinder head.

ASSEMBLY AND INSTALLATION

• Molybdenum disulfide oil Onto the valve stem and valve stem seal.
• Valve spring seats 2
• Valve spring retainers 5 NOTE:
• Make sure that each valve is installed in its original place, also referring to the painted color as follows. Intake (middle) a: blue Intake (right/left) b: gray Exhaust: not paint
• Install the valve springs with the larger pitch c facing upward. d Smaller pitch

• Valve cotters NOTE: While compressing the valve spring with a valve spring compressor 1 install the valve cotters. Valve spring compressor: YM-4019/90890-04019

4. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a piece of wood. CAUTION: Hitting the valve tip with excessive force could damage the valve.

• Valve lifter 2 NOTE:
• 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 place.

1 Cylinder removal Extent of removal: Extent of removal Order Preparation for removal

2 Piston removal Part name

Q’ty Remarks Refer to “CYLINDER HEAD” section.

Use special tool. Refer to “REMOVAL POINTS”.

• Put identification marks on each piston head for reference during reinstallation.
• Before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller 4. Piston pin puller: YU-1304/90890-01304 CAUTION: Do not use a hammer to drive the piston pin out. Piston ring
• Piston rings NOTE: Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown, as shown in the illustration. INSPECTION Cylinder and piston
• Cylinder and piston walls Vertical scratches → Replace cylinder and piston.
• Piston-to-cylinder clearance Measurement steps: 1st step:
• Measure the cylinder bore “C” with a cylinder bore gauge. NOTE: Measure the cylinder bore “C” in parallel to and at right angles to the crankshaft. Then, find the average of the measurements.

ENG Cylinder bore “C”

“C” = Maximum D “T” = (Maximum D1 or D2) – (Maximum D5 or D6) “R” = (Maximum D1, D3 or D5) – (Minimum D2, D4 or D6)

• If out of specification, replace the cylinder, and replace the piston and piston rings as set. 2nd step:
• Measure the piston skirt diameter “P” with a micrometer. a 8 mm (0.315 in) from the piston bottom edge Piston size “P” Standard

• If out of specification, replace the piston and piston rings as a set. 3rd step:
• Calculate the piston-to-cylinder clearance with following formula: Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance:

(0.0016 ~ 0.0026 in) <Limit>: 0.1 mm (0.004 in)

• If out of specification, replace the cylinder, and replace the piston and piston rings as set.

• Ring side clearance Use a feeler gauge 1. Out of specification → Replace the piston and rings as a set. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance. Side clearance: Standard <Limit> Top ring

• Piston ring (in cylinder) NOTE: Insert a ring into the cylinder and push it approximately 10 mm (0.39 in) into the cylinder. Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore. a 10 mm (0.39 in)

• Ring end gap Out of specification → Replace. NOTE: You cannot measure the end gap on the expander spacer of the oil control ring. If the oil control ring rails show excessive gap, replace all three rings. End gap:

• Piston pin Blue discoloration/grooves → Replace, then inspect the lubrication system.
• Piston pin-to-piston clearance Measurement steps:
• Calculate the piston pin-to-piston clearance with the following formula. Piston pin-to-piston clearance = Inside diameter (piston) b – Outside diameter (piston pin) a

ASSEMBLY AND INSTALLATION

• Piston rings Onto the piston. NOTE:
• Be sure to install the piston rings so that the manufacturer’s marks or numbers are located on the upper side of the rings.
• Lubricate the piston and piston rings liberally with engine oil.

• Oil ring Offset the piston ring end gaps as shown.

a Top ring end b 2nd ring end c Oil ring end (upper) d Oil ring e Oil ring end (lower)

• Piston pin clips 3 New NOTE:
• Apply engine oil onto the piston pin and piston.
• Be sure that the arrow mark a on the piston points to the exhaust side of the engine.
• Before installing the piston pin clip, cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase.
• Install the piston pin clips with their ends facing downward.
• Cylinder 3 New NOTE: Apply a liberal coating of engine oil. Cylinder
• Cylinder 2 NOTE: Install the cylinder with one hand while compressing the piston rings with the other hand. CAUTION:
• Pass the timing chain 3 through the timing chain cavity.
• Be careful not to damage the timing chain guide 4 during installation.

10 Nm (1,0 m · kg, 7,2 ft · lb) CLUTCH ENG CLUTCH CLUTCH 1 Push rod and push lever removal 2 Push rod 1 disassembly 3 Friction plate and clutch plate removal 4 Clutch housing removal Extent of removal: Extent of removal Order

Q’ty CLUTCH REMOVAL Drain the engine oil. Preparation for removal

Remarks Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Refer to “ENGINE REMOVAL” section. Disconnect at engine side. Brake pedal Clutch cable Clutch cover Gasket Dowel pin Clutch spring Pressure plate Push rod 1 Circlip Plain washer Bearing Ball Push rod 2

• Clutch boss 3 NOTE: Straighten the lock washer tab and use the clutch holding tool 4 to hold the clutch boss.

Clutch holding tool: YM-91042/90890-04086 È For USA and CDN É Except for USA and CDN EC494000 INSPECTION EC484100 Clutch housing and boss

• Clutch housing 1 Cracks/wear/damage → Replace.
• Clutch boss 2 Scoring/wear/damage → Replace. EC484201 Primary driven gear
• Circumferential play Free play exists → Replace.
• Gear teeth a Wear/damage → Replace. EC484400 Clutch spring
• Clutch spring free length a Out of specification → Replace springs as a set. Clutch spring free length:

• Friction plate thickness Out of specification → Replace friction plate as a set. Measure at all four points. Friction plate thickness:

(0.115 ~ 0.121 in) <Limit>: 2.8 mm (0.110 in) EC484600 Clutch plate

• Clutch plate warpage Out of specification → Replace clutch plate as a set. Use a surface plate 1 and thickness gauge 2. Warp limit:

ASSEMBLY AND INSTALLATION

• Apply the lithium soap base grease on the oil seal lip.
• Apply the engine oil on the push lever. Clutch
• Primary driven gear 1
• Clutch boss 3 NOTE: Apply the engine oil on the primary driven gear inner circumference.

75 Nm (7.5 m · kg, 54 ft · lb) NOTE:

• Install the lock washer with its concaves fitted over the convexes of the clutch boss.
• Use the clutch holding tool 3 to hold the clutch boss.

Clutch holding tool: YM-91042/90890-04086 È For USA and CDN É Except for USA and CDN

• Clutch plate 2 NOTE:
• Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate.
• Apply the engine oil on the friction plates and clutch plates.

• Circlip 3 New To push rod 1 4. NOTE: Apply the engine oil on the bearing and plain washer.

• Push rod 1 3 NOTE: Apply the engine oil on the push rod 1, 2 and ball.

• Gasket (clutch cover) 1 New

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

OIL FILTER, WATER PUMP

(RIGHT) REMOVAL Engine guard (right) Drain the engine oil. Preparation for removal Refer to “ENGINE REMOVAL” section. Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3. Refer to “EXHAUST PIPE AND SILENCER” section. Refer to “ENGINE REMOVAL” section. Refer to “CLUTCH” section. Drain the coolant. Exhaust pipe

Brake pedal Clutch cover Oil filter cover Oil filter Coolant pipe 2 Water pump housing Pin

Part name Oil tank breather hose Kick starter Crankcase cover (right) Gasket Dowel pin/O-ring Impeller Plain washer Impeller shaft Oil seal 1 Oil seal 2 Bearing

• Impeller shaft 3 NOTE: Hold the impeller shaft on its width across the flats a with spanners, etc. and remove the impeller. EC4G3210 Oil seal NOTE: It is not necessary to disassemble the water pump, unless there is an abnormality such as excessive change in coolant level, discoloration of coolant, or milky transmission oil.

• Bearing Rotate inner race with a finger. Rough spot/seizure → Replace. EC444400 Oil seal
• Oil seal Wear/damage → Replace.

ASSEMBLY AND INSTALLATION

• Oil seal 1 New NOTE:
• Apply the lithium soap base grease on the oil seal lip.
• Install the oil seal with its manufacture’s marks or numbers facing inward. Bearing
• Bearing 1 NOTE: Install the bearing by pressing its outer race parallel.

14 Nm (1.4 m · kg, 10 ft · lb) NOTE:

• Take care so that the oil seal lip is not damaged or the spring does not slip off its position.
• When installing the impeller shaft, apply the engine oil on the oil seal lip, bearing and impeller shaft. And install the shaft while turning it.
• Hold the impeller shaft on its width across the flats a with spanners, etc. and install the impeller. Crankcase cover (right)
• Gasket 4 New NOTE: Apply the lithium soap base grease on the Oring.

• Apply the engine oil on the impeller shaft end.
• When installing the crankcase cover onto the crankcase, be sure that the impeller shaft end 2 aligns with the balancer end slot 3.
• Tighten the bolts in stage, using a crisscross pattern.

33 Nm (3.3 m · kg, 24 ft · lb) NOTE: Install so that there is a clearance a of 8mm (0.31 in) or more between the kick starter and frame and that the kick starter does not contact the crankcase cover when it is pulled.

• Oil tank breather hose 1

2 Nm (0.2 m · kg, 1.4 ft · lb) Water pump housing

• O-ring 2 New NOTE: Apply the lithium soap base grease on the Oring.

• Water pump housing 1
• Bolt (water pump housing) 2

• Bolt (oil filter cover)

Q’ty BALANCER REMOVAL Clutch housing Crankcase cover (right) Preparation for removal

Stator Nut (balancer) Nut (primary drive gear) Nut (balancer driven gear) Lock washer Balancer Straight key Conical washer Primary drive gear Balancer drive gear Lock washer Balancer driven gear

Remarks Refer to “CLUTCH” section. Refer to “OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT)” section. Refer to “CDI MAGNETO” section.

• Nut (primary drive gear) 2
• Nut (balancer driven gear) 3 NOTE: Place an aluminum plate a between the teeth of the balancer drive gear 4 and balancer driven gear 5. INSPECTION Primary drive gear, balancer drive gear and balancer driven gear
• Primary drive gear 1
• Balancer drive gear 2
• Balancer driven gear 3 Wear/damage → Replace. Balancer
• Balancer Cracks/damage → Replace.

ASSEMBLY AND INSTALLATION

Balancer, balancer drive gear and balancer driven gear

• Balancer driven gear 1 NOTE: Install the balancer driven gear and balancer shaft with their lower splines a aligning with each other.
• Balancer drive gear 1 NOTE:
• Align the punched mark a on the balancer drive gear with the punched mark b on the balancer driven gear.
• Install the balancer driven gear and crankshaft with the lower splines c aligning with each other.
• Nut (balancer driven gear) 2

• Primary drive gear 3
• Nut (primary drive gear) 5

Straight key 6 Balancer 7 Lock washer 8 Nut (balancer) 9

110 Nm (11.0 m · kg, 80 ft · lb) 45 Nm (4.5 m · kg, 33 ft · lb) NOTE:

• Apply engine oil to the contact surface and threaded portion of the nut (primary drive gear).
• Place an aluminum plate a between the teeth of the balancer drive gear 0 and balancer driven gear A.
• Install the primary drive gear with its weight reduction holes b facing the engine.
• Install the conical washer with its convex surface c outward.

4. Bend the lock washer tab.

Clutch housing Crankcase cover (right) Preparation for removal

2 Oil pump disassembly

Circlip Plate washer Oil pump drive gear Oil pump assembly Dowel pin Outer rotor 2 Circlip Inner rotor 2 Pin Oil pump cover Outer rotor 1 Inner rotor 1 Refer to “CLUTCH” section. Refer to “OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT)” section.

Part name Pin Washer Oil pump drive shaft Rotor housing Q’ty

• Oil pump driven gear
• Oil pump cover Cracks/wear/damage → Replace.

• Tip clearance a Between the inner rotor 1 and the outer rotor 2.
• Tip clearance b Between the outer rotor 2 and the rotor housing 3. Out of specification → Replace the oil pump. Tip clearance a:

• Unsmooth → Repeat steps #1 and #2 or replace the defective parts.

ASSEMBLY AND INSTALLATION

• Oil pump drive shaft 1
• Inner rotor 1 4 NOTE:
• Apply the engine oil on the oil pump drive shaft and inner rotor 1.
• Fit the pin into the groove in the inner rotor 1.

• Outer rotor 1 1 NOTE: Apply the engine oil on the outer rotor 1.

• Screw (oil pump cover) 2

• Apply the engine oil on the oil pump drive shaft end and inner rotor 2.
• Fit the pin into the groove in the inner rotor 2.

• Bolt (oil pump assembly) 4

• Oil pump drive gear 1
• Circlip 3 New NOTE: Apply the engine oil on the oil pump drive gear inner circumference.

KICK AXLE AND SHIFT SHAFT

KICK AXLE AND SHIFT SHAFT

KICK AXLE AND SHIFT SHAFT

1 Kick axle removal 3 Shift shaft removal Extent of removal: Extent of removal Order Part name Q’ty

KICK AXLE AND SHIFT SHAFT

REMOVAL Oil pump Kick idle gear Kick axle assembly Spring guide Torsion spring Ratchet wheel Kick gear Kick axle Plain washer Shift pedal Shift shaft Collar Torsion spring

Preparation for removal

2 Kick axle disassembly 4 Segment removal

KICK AXLE AND SHIFT SHAFT

KICK AXLE AND SHIFT SHAFT

ENG REMOVAL POINTS EC4B3101 Kick axle assembly

• Shift lever assembly 2 NOTE: The shift lever assembly is disassembled at the same time as the shift guide. EC4N3100 Segment
• Segment 2 NOTE: Turn the segment counterclockwise until it stops and loosen the bolt. CAUTION: If the segment gets an impact, it may be damaged. Take care not to give an impact to the segment when removing the bolt. INSPECTION EC4C4200 Kick axle and ratchet wheel
• Ratchet wheel 1 smooth movement Unsmooth movement → Replace.
• Kick axle 2 Wear/damage → Replace.
• Spring 3 Broken → Replace.

KICK AXLE AND SHIFT SHAFT

ENG EC4C4300 Kick gear, kick idle gear and ratchet wheel

KICK AXLE AND SHIFT SHAFT

ASSEMBLY AND INSTALLATION

30 Nm (3.0 m · kg, 22 ft · lb) NOTE: Align the notch a on the segment with the pin b on the shift cam. CAUTION: If the segment gets an impact, it may be damaged. Take care not to give an impact to the segment when tightening the bolt. EC4B5111 Stopper lever

• Pawl 3 To shift lever 4. NOTE: Apply the engine oil on the springs, pawl pins and pawls.

KICK AXLE AND SHIFT SHAFT

• The shift lever assembly is installed at the same time as the shift guide.
• Apply the engine oil on the bolt (segment) shaft.

• Bolt (shift guide) 1

• Shift shaft 5 NOTE: Apply the engine oil on the roller and shift shaft.

4.4 mm (0.17 in) a above the top of the footrest.

KICK AXLE AND SHIFT SHAFT

ENG Kick axle assembly

• Circlip 7 New To kick axle 8. NOTE:
• Apply the molybdenum disulfide oil on the inner circumferences of the kick gear and ratchet wheel.
• Align the punch mark a on the ratchet wheel with the punch mark b on the kick axle.

• Torsion spring 1 To kick axle 2. NOTE: Make sure the stopper a of the torsion spring fits into the hole b on the kick axle.

• Spring guide 1 NOTE: Slide the spring guide into the kick axle, make sure the groove a in the spring guide fits on the stopper of the torsion spring.
• Kick axle assembly 1
• Plain washer 2 NOTE:
• Apply the molybdenum disulfide grease on the contacting surfaces of the kick axle stopper a and ratchet wheel guide 3.
• Apply the engine oil on the kick axle.
• Slide the kick axle assembly into the crankcase and make sure the kick axle stopper fits into the ratchet wheel guide.

KICK AXLE AND SHIFT SHAFT

• Torsion spring 1 NOTE: Turn the torsion spring clockwise and hook into the proper hole a in the crankcase. Kick idle gear
• Install the kick idle gear with its depressed side a toward you.
• Apply the engine oil on the kick idle gear inner circumference.

CDI MAGNETO ENG EC4L0000 CDI MAGNETO 1 CDI magneto removal Extent of removal: Extent of removal Order Q’ty

Seat and fuel tank Preparation for removal

Disconnect the CDI magneto lead. Crankcase cover (left) Gasket Dowel pin Nut (rotor) Rotor Stator Woodruff key

Use special tool. Refer to “REMOVAL POINTS”.

• Rotor inner surface a
• Stator outer surface b Damage → Inspect the crankshaft runout and crankshaft bearing. If necessary, replace CDI magneto and/ or stator. EC4L4200 Woodruff key
• Woodruff key 1 Damage → Replace. EC4L5000

ASSEMBLY AND INSTALLATION

• Apply the sealant to the grommet of the CDI magneto lead.

• Clean the tapered portions of the crankshaft and rotor.
• When installing the woodruff key, make sure that its flat surface a is in parallel with the crankshaft center line b.
• When installing the rotor, align the keyway c of the rotor with the woodruff key.

• CDI magneto lead Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2.
• Gasket [crankcase cover (left)] New
• Crankcase cover (left) 1
• Hose holder (cylinder head breather hose) 2
• Bolt [crankcase cover (left)]

• Apply the lithium soap base grease on the Oring.

ENGINE REMOVAL ENG EC4M0000 ENGINE REMOVAL Extent of removal Preparation for removal Order Part name ENGINE REMOVAL Hold the machine by placing the suitable stand under the frame. Seat and fuel tank Rear shock absorber Carburetor Exhaust pipe and silencer Clutch cable Radiator Shift pedal Cylinder head breather hose Drain the engine oil Ignition coil Disconnect the CDI magneto lead. Engine guard

Q’ty Remarks WARNING Support the machine securely so there is no danger of it falling over. Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Refer to “REAR SHOCK ABSORBER” section in the CHAPTER 5. Refer to “CARBURETOR” section. Refer to “EXHAUST PIPE AND SILENCER” section. Disconnect at engine side. Refer to “RADIATOR” section. Refer to “KICK AXLE AND SHIFT SHAFT” section. Refer to “CAMSHAFTS” section. Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3.

Part name Neutral switch Chain cover Nut (drive sprocket) Lock washer Drive sprocket Clip Bolt (brake pedal) Brake pedal Engine upper bracket (right) Engine upper bracket (left) Engine lower bracket Engine mounting bolt Pivot shaft Engine

Remarks Refer to “REMOVAL POINTS”. Refer to “REMOVAL POINTS”.

• Loosen the nut while applying the rear brake.
• Drive chain 2 NOTE: Remove the drive sprocket together with the drive chain. EC4M3301 Engine removal
• Pivot shaft 1 NOTE: If the pivot shaft is pulled all the way out, the swingarm will come loose. If possible, insert a shaft of similar diameter into the other side of the swingarm to support it.
• Engine 1 From right side.

NOTE: Make sure that the couplers, hoses and cables are disconnected.

ASSEMBLY AND INSTALLATION

• Engine 1 Install the engine from right side.

• Engine mounting bolt (lower) 3

• Engine mounting bolt (front) 7

• Engine upper bracket (right) 8
• Engine upper bracket (left) 9
• Bolt (engine upper bracket) 0

• Engine mounting bolt (upper) A

55 Nm (5.5 m · kg, 40 ft · lb) NOTE:

• Apply the molybdenum disulfide grease on the pivot shaft.
• Install the patch with the claw a facing outside the chassis. Brake pedal

• Clip 5 NOTE: Apply the lithium soap base grease on the bolt, O-rings and brake pedal bracket. Drive sprocket
• Drive chain 2 NOTE: Install the drive sprocket together with the drive chain.

• Screw (chain cover) 2

• Screw (neutral switch) 5

CRANKCASE AND CRANKSHAFT

CRANKCASE AND CRANKSHAFT

CRANKCASE AND CRANKSHAFT

1 Crankcase separation Extent of removal: Extent of removal Order

Part name 2 Crankshaft removal

Remarks Refer to “ENGINE REMOVAL” section. Refer to “CYLINDER AND PISTON” section. Refer to “BALANCER” section. Refer to “KICK AXLE AND SHIFT SHAFT” section. Refer to “CDI MAGNETO” section.

Refer to “REMOVAL POINTS”.

CRANKCASE AND CRANKSHAFT

Part name Crankcase (right) Crankcase (left) Oil strainer Balancer shaft Crankshaft Q’ty

ENG Remarks Refer to “REMOVAL POINTS”. Refer to “REMOVAL POINTS”. Use special tool. Refer to “REMOVAL POINTS”.

CRANKCASE AND CRANKSHAFT

ENG CRANKCASE BEARING 1 Crankcase bearing removal Extent of removal: Extent of removal Order Preparation for removal

Part name CRANKCASE BEARING REMOVAL Transmission Shift cam and shift fork Oil seal Bearing

Q’ty Remarks Refer to “TRANSMISSION, SHIFT CAM AND SHIFT FORK” section.

Refer to “REMOVAL POINTS”.

CRANKCASE AND CRANKSHAFT

• Crankcase (left) Separation steps:
• Remove the crankcase bolts, hose guide and clutch cable holder. NOTE: Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them.
• Remove the crankcase (right). NOTE:
• Place the crankcase with its left side downward and split it by inserting a screwdriver tip into the splitting slit a in the crankcase.
• Lift the crankcase (right) horizontally while lightly patting the case splitting slit and engine mounting boss using a soft hammer, and leave the crankshaft and transmission with the crankcase (left).

CAUTION: Use soft hammer to tap on the case half. Tap only on reinforced portions of case. Do not tap on gasket mating surface. Work slowly and carefully. Make sure the case halves separate evenly. If the cases do not separate, check for a remaining case screw or fitting. Do not force.

• Remove the dowel pins and O-ring. Balancer shaft
• Balancer shaft 1 NOTE: Remove the balancer shaft with its flat side a facing the crankshaft.

CRANKCASE AND CRANKSHAFT

• Crankshaft 1 Use the crankcase separating tool 2. Crankcase separating tool: YU-A9642/90890-04152 NOTE: Install the crankcase separating tool as shown. CAUTION: Do not use a hammer to drive out the crankshaft. Crankshaft bearing
• Remove the bearing from the crankcase by pressing its inner race.
• Do not use the removed bearing. INSPECTION Timing chain and timing chain guide
• Timing chain Cracks/stiff → Replace the timing chain and camshaft sprocket as a set.
• Timing chain guide Wear/damage → Replace. EC4N4101 Crankcase
• Contacting surface a Scratches → Replace.
• Engine mounting boss b, crankcase Cracks/damage → Replace.

CRANKCASE AND CRANKSHAFT

• Bearing Rotate inner race with a finger. Rough spot/seizure → Replace.
• Oil seal Wear/damage → Replace. EC4N4201 Crankshaft

clearance: (0.0059 ~ 0.0177 in) (0.02 in) Crack width:

• Oil strainer Damage → Replace.

CRANKCASE AND CRANKSHAFT

ASSEMBLY AND INSTALLATION

• Screw [bearing stopper (crankshaft)] 1

14 Nm (1.4 m · kg, 10 ft · lb) To crankcase (left and right). NOTE:

• Install the bearing by pressing its outer race parallel.
• To prevent the screw [bearing stopper (crankshaft)] from becoming loose, crush the screw head periphery a into the concave b using a punch etc. In so doing, take care not to damage the screwdriver receiving hole in the screw head. Crankshaft

CRANKCASE AND CRANKSHAFT

• Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms against the bearing.
• Before installing the crankshaft, clean the contacting surface of crankcase. CAUTION: Do not use a hammer to drive in the crankshaft.

• Transmission operation Unsmooth operation → Repair.

• Bolt (oil strainer) 2

• Sealant On the crankcase (right). YAMAHA Bond No. 1215 (ThreeBond® No. 1215): 90890-85505 NOTE: Clean the contacting surface of crankcase (left and right) before applying the sealant.

CRANKCASE AND CRANKSHAFT

• Crankcase (right) To crankcase (left). NOTE:
• Apply the lithium soap base grease on the Oring.
• Fit the crankcase (right) onto the crankcase (left). Tap lightly on the case with soft hammer.
• When installing the crankcase, the connecting rod should be positioned at TDC (top dead center).

• Bolt (timing chain guide)

• Sealant Forced out on the cylinder mating surface.
• Engine oil To the crank pin, bearing and oil delivery hole.
• Crankshaft and transmission operation. Unsmooth operation → Repair.

TRANSMISSION, SHIFT CAM AND SHIFT FORK

TRANSMISSION, SHIFT CAM AND SHIFT FORK

TRANSMISSION, SHIFT CAM AND SHIFT FORK

1 Shift fork, shift cam, main axle and drive axle removal Extent of removal: Extent of removal Order Q’ty

TRANSMISSION, SHIFT CAM

AND SHIFT FORK REMOVAL

Engine Separate the crankcase. Preparation for removal

Main axle Drive axle Shift cam Shift fork 3 Shift fork 2 Shift fork 1 Collar Refer to “ENGINE REMOVAL” section. Refer to “CRANKCASE AND CRANKSHAFT” section.

TRANSMISSION, SHIFT CAM AND SHIFT FORK

• Remove assembly with the collar 3 installed to the crankcase.
• Remove assembly carefully. Note the position of each part. Pay particular attention to the location and direction of shift forks.
• Remove the main axle, drive axle, shift cam and shift fork all together by tapping lightly on the transmission drive axle with a soft hammer. EC4H4000 INSPECTION EC4H4200 Gears
• O-ring 1 Damage → Replace.
• Gears movement Unsmooth movement replace.

• Bearing 1 Rotate inner race with a finger. Rough spot/seizure → Replace.

TRANSMISSION, SHIFT CAM AND SHIFT FORK

ENG EC4H4801 Shift fork, shift cam and segment

• Shift fork 1 Wear/damage/scratches → Replace.

• Segment 2 Bend/wear/damage → Replace.

ASSEMBLY AND INSTALLATION

• 5th pinion gear (21T) 1
• 3rd pinion gear (18T) 2
• 4th pinion gear (22T) 4
• 2nd pinion gear (15T) 5 To main axle 6. NOTE: Apply the molybdenum disulfide oil on the inner and end surface of the idler gear and on the inner surface of the sliding gear, then install.

TRANSMISSION, SHIFT CAM AND SHIFT FORK

• 2nd wheel gear (23T) 2
• 4th wheel gear (24T) 3
• 3rd wheel gear (23T) 4
• 5th wheel gear (20T) 5
• 1st wheel gear (27T) 7
• O-ring 8 New To drive axle 9. NOTE:
• Apply the molybdenum disulfide oil on the inner and end surface of the idler gear and on the inner surface of the sliding gear, then install.
• Apply the lithium soap base grease on the Oring.

• Be sure the circlip sharp-edged corner a is positioned opposite side to the plain washer and gear b.
• Install the circlip with its ends c settled evenly on the spline crests.

• Apply the lithium soap base grease on the oil seal lip.
• When installing the collar into the crankcase, pay careful attention to the crankcase oil seal lip.

TRANSMISSION, SHIFT CAM AND SHIFT FORK

• Shift cam 4 To main axle and drive axle. NOTE:
• Apply the molybdenum disulfide oil on the shift fork grooves.
• Apply engine oil to the shift cam groove, bearing contact surface and shift fork shaft.
• Mesh the shift fork #1 (L) with the 4th wheel gear 5 and #3 (R) with the 5th wheel gear 7 on the drive axle.
• Mesh the shift fork #2 (C) with the 3rd pinion gear 6 on the main axle.

• Transmission assembly 1 To crankcase (left) 2. NOTE: Apply the engine oil on the bearings and guide bars.

• Transmission operation Unsmooth operation → Repair.

EC598000 FRONT WHEEL 1 Front wheel removal 3 Brake disc removal Extent of removal: Extent of removal Order

Hold the machine by placing the suitable stand under the engine. Preparation for removal

Part name 2 Wheel bearing removal

Bolt (axle holder) Nut (front wheel axle) Front wheel axle Front wheel Collar Oil seal Bearing Brake disc WARNING Support the machine securely so there is no danger of it falling over.

5-1 Remarks Only loosening. Refer to “REMOVAL POINTS”.

CHAS EC598100 REAR WHEEL 1 Rear wheel removal 3 Brake disc removal Extent of removal: Extent of removal Order

Hold the machine by placing the suitable stand under the engine. Preparation for removal

Part name 2 Wheel bearing removal

Nut (rear wheel axle) Rear wheel axle Chain puller Rear wheel Collar Driven sprocket Oil seal Circlip Bearing Brake disc WARNING Support the machine securely so there is no danger of it falling over.

5-2 Remarks Refer to “REMOVAL POINTS”. Refer to “REMOVAL POINTS”.

CHAS EC593000 REMOVAL POINTS EC523101 Rear wheel

• Wheel 1 NOTE: Push the wheel forward and remove the drive chain 2. EC513201 Wheel bearing (if necessary)
• Bearing 1 NOTE: Remove the bearing using a general bearing puller 2. EC594000 INSPECTION EC514100 Wheel
• Wheel runout Out of limit → Repair/replace. Wheel runout limit: Radial 1: 2.0 mm (0.08 in) Lateral 2: 2.0 mm (0.08 in)
• Bearing Rotate inner race with a finger. Rough spot/seizure → Replace. NOTE: Replace the bearings, oil seal and wheel collar as a set. 5-3

CHAS EC514200 Wheel axle

• Wheel axle bends Out of specification → Replace. Use the dial gauge 1. Wheel axle bending limit:

NOTE: The bending value is shown by one half of the dial gauge reading. WARNING Do not attempt to straighten a bent axle. EC594200 Brake disc

• Brake disc deflection (only rear brake disc) Use the dial gauge 1. Out of specification → Inspect wheel runout. If wheel runout is in good condition, replace the brake disc. Disc deflection limit: Rear Standard <Limit>

• Brake disc thickness a Out of limit → Replace. Disc wear limit: 5-4 Standard <Limit> Front

ASSEMBLY AND INSTALLATION

• Oil seal 4 New NOTE:
• Apply the lithium soap base grease on the bearing and oil seal lip when installing.
• Use a socket that matches the outside diameter of the race of the bearing.
• Left side of bearing shall be installed first.
• Install the oil seal with its manufacture’s marks or numbers facing outward. CAUTION: Do not strike the inner race of the bearing. Contact should be made only with the outer race.

• Apply the lithium soap base grease on the oil seal lip.
• Install the collars with their projections a facing the wheel.

• Wheel NOTE: Install the brake disc 1 between the brake pads 2 correctly. 5-5

• Wheel axle 1 NOTE: Apply the lithium soap base grease on the wheel axle.

21 Nm (2.1 m · kg, 15 ft · lb) NOTE: Before tightening the bolt, fit the wheel axle to the axle holder by stroking the front fork several times with the front brake applied. 5-6

• Oil seal 5 New NOTE:
• Apply the lithium soap base grease on the bearing and oil seal lip when installing.
• Install the bearing with seal facing outward.
• Use a socket that matches the outside diameter of the race of the bearing.
• Right side of bearing shall be installed first.
• Install the oil seal with its manufacture’s marks or numbers facing outward. CAUTION: Do not strike the inner race of the bearing. Contact should be made only with the outer race.

• Collar 1 NOTE: Apply the lithium soap base grease on the oil seal lip.

• Wheel NOTE: Install the brake disc 1 between the brake pads 2 correctly.

• Drive chain 1 NOTE: Push the wheel 2 forward and install the drive chain.

• Chain puller (left) 1
• Install the chain puller (left), and insert the wheel axle from left side.
• Apply the lithium soap base grease on the wheel axle.

• Chain puller (right) 1
• Nut (wheel axle) 3 NOTE: Temporarily tighten the nut (wheel axle) at this point. 5-8

EC5A8000 FRONT BRAKE 1 Brake hose removal 3 Master cylinder removal Extent of removal: Extent of removal Order

Hold the machine by placing the suitable stand under the engine. Preparation for removal

Part name 2 Caliper removal

Drain the brake fluid. Brake hose holder (protector) Brake hose holder (caliper) Union bolt Brake hose Pad pin plug Pad pin Caliper Brake lever Master cylinder bracket Master cylinder

Remarks WARNING Support the machine securely so there is no danger of it falling over. Refer to “REMOVAL POINTS”.

CHAS EC5A8100 REAR BRAKE 1 Master cylinder removal 3 Caliper removal Extent of removal: Extent of removal Order Part name 2 Brake hose removal Q’ty

Hold the machine by placing the suitable stand under the engine. Preparation for removal WARNING Support the machine securely so there is no danger of it falling over. Rear wheel

Remarks Refer to “FRONT WHEEL AND REAR WHEEL” section. Refer to “REMOVAL POINTS”. Drain the brake fluid. Brake pedal Master cylinder Brake hose holder Union bolt Brake hose Pad pin plug Pad pin Caliper

CHAS EC5A8200 CALIPER DISASSEMBLY È Front É Rear 1 Front caliper disassembly Extent of removal: Extent of removal

Remarks Refer to “REMOVAL POINTS”.

È Front É Rear 1 Front master cylinder disassembly Extent of removal: Extent of removal

Master cylinder cap Diaphragm Reservoir float Master cylinder boot Circlip Plain washer Push rod Master cylinder kit

2 Rear master cylinder disassembly Q’ty

• Master cylinder cap 1 [Rear]

2. Connect the transparent hose 2 to the

bleed screw 1 and place a suitable container under its end. È Front É Rear

3. Loosen the bleed screw and drain the

brake fluid while pulling the lever in or pushing down on the pedal.

• Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately. EC533301 Caliper piston
• Caliper piston Use compressed air and proceed carefully.

• Cover piston with rag and use extreme caution when expelling piston from cylinder.
• Never attempt to pry out piston.

Caliper piston removal steps:

• Insert a piece of rag into the caliper to lock one caliper.
• Carefully force the piston out of the caliper cylinder with compressed air. È Front É Rear

• Piston seal 2 NOTE: Remove the piston seals and dust seals by pushing them with a finger. CAUTION: Never attempt to pry out piston seals and dust seals.

WARNING Replace the piston seals and dust seals whenever a caliper is disassembled. È Front É Rear

• Master cylinder inner surface a Wear/scratches → Replace master cylinder assembly. Stains → Clean.

3. Inspect: (front brake only)

• Master cylinder piston 1
• Master cylinder cup 2 Wear/damage/score marks → Replace master cylinder kit.

• Caliper cylinder inner surface a Wear/score marks → Replace caliper assembly. È Front É Rear

• Caliper piston 1 Wear/score marks → Replace caliper piston assembly. WARNING Replace the piston seals and dust seals 2 whenever a caliper is disassembled. EC534301 Brake hose
• Brake hose 1 Crack/damage → Replace. EC5A5000

ASSEMBLY AND INSTALLATION

• All internal parts should be cleaned in new brake fluid only.
• Internal parts should be lubricated with brake fluid when installed.
• Replace the piston seals and dust seals whenever a caliper is disassembled.

• Caliper piston Clean them with brake fluid.

WARNING Always use new piston seals and dust seals. NOTE: Fit the piston seals and dust seals onto the slot on caliper correctly. È Front É Rear

• Caliper piston 1 NOTE: Apply the brake fluid on the piston wall. CAUTION:
• Install the piston with its shallow depressed side a facing the caliper.
• Never force to insert.

• Install the brake pads with their projections a into the caliper recesses b.
• Temporarily tighten the pad pin at this point.

• Install the brake pads with their projections a into the caliper recesses b.
• Temporarily tighten the pad pin at this point.

• Rear wheel 2 Refer to “FRONT WHEEL AND REAR WHEEL” section.

• Master cylinder kit Clean them with brake fluid.

• Master cylinder cup (primary) 1
• Master cylinder cup (secondary) 2 To master cylinder piston 3.

NOTE: Apply the brake fluid on the master cylinder cup.

WARNING After installing, cylinder cup should be installed as shown direction. Wrong installation cause improper brake performance.

• Master cylinder kit 1
• Master cylinder boot 4 To master cylinder 5. [Rear]
• Master cylinder kit 1
• Master cylinder boot 4 To master cylinder 5.

• Apply the brake fluid on the master cylinder kit.
• Apply the lithium soap base grease on the tip of the push rod.
• When installing the circlip, use a long nose circlip pliers. È Front É Rear EC5A5310 Front master cylinder
• Master cylinder bracket 2
• Bolt (master cylinder bracket) 3

9 Nm (0.9 m · kg, 6.5 ft · lb) NOTE:

• Install the bracket so that the arrow mark a face upward.
• First tighten the bolts on the upper side of the master cylinder bracket, and then tighten the bolts on the lower side.

6 Nm (0.6 m · kg, 4.3 ft · lb) NOTE: Apply the lithium soap base grease on the brake lever sliding surface, bolt and contacting surface of the master cylinder piston. Rear master cylinder

30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers. CAUTION: Install the brake hose so that its pipe portion a directs as shown and lightly touches the projection b on the master cylinder.

• Clip 5 NOTE: Apply the lithium soap base grease on the bolt, O-ring and brake pedal bracket.

• Cotter pin 3 New NOTE: After installing, check the brake pedal height. Refer to “REAR BRAKE ADJUSTMENT” section in the CHAPTER 3. Front brake hose

30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers. CAUTION: Install the brake hose so that its pipe portion a directs as shown and lightly touches the projection b on the caliper.

7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: Align the top a of the brake hose holder with the paint b of the brake hose.

4. Pass the brake hose through the cable

30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers. CAUTION: Install the brake hose so that its pipe portion a directs as shown and lightly touches the projection b on the master cylinder. Rear brake hose

30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers. CAUTION: Install the brake hose so that its pipe portion a directs as shown and lightly touches the projection b on the caliper.

2 Nm (0.2 m · kg, 1.4 ft · lb) 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

• Brake fluid Until the fluid level reaches “LOWER” level line a.

Recommended brake fluid: DOT #4 WARNING

• Use only the designated quality brake fluid: otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance.
• Refill with the same type of brake fluid; mixing fluids may result in a harmful chemical reaction and lead to poor performance.
• Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.

CAUTION: Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately. È Front É Rear

• Brake fluid level Fluid at lower level → Fill up. Refer to “BRAKE FLUID LEVEL INSPECTION” section in the CHAPTER 3.

• Screw (master cylinder cap) 2

• Bolt (master cylinder cap) 2

2 Nm (0.2 m · kg, 1.4 ft · lb) CAUTION: After installation, while pulling the lever in or pushing down on the pedal, check whether there is any brake fluid leaking where the union bolts are installed respectively at the master cylinder and caliper. È Front É Rear

5. Install: (rear brake only)

Hold the machine by placing the suitable stand under the engine. Preparation for removal Remarks WARNING Support the machine securely so there is no danger of it falling over. Front wheel Refer to “FRONT WHEEL AND REAR WHEEL” section. Refer to “FRONT BRAKE AND REAR BRAKE” section. Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4. Front caliper Number plate

Pinch bolt (under bracket) Front fork

DEPOSE DE LA FOURCHE

1 Oil seal removal Extent of removal: Extent of removal

Fork spring Dust seal Stopper ring Inner tube Outer tube Piston metal Slide metal Oil seal washer Oil seal Base valve Damper assembly

Remarks Drain the fork oil. Use special tool. Refer to “REMOVAL POINTS”. Refer to “REMOVAL POINTS”. Drain the fork oil. Use special tool. Refer to “REMOVAL POINTS”. FOURCHE TELESKOPGABEL CHAS

Siehe unter “DEMONTAGE-EINZELHEITEN”. Das Gabelöl ablassen. Spezialwerkzeug verwenden. Siehe unter “DEMONTAGE-EINZELHEITEN”. FRONT FORK CHAS EC556000 HANDLING NOTE NOTE: The front fork requires careful attention. 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 piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material. Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled.
• Before removing the base valves or front forks, be sure to extract the air from the air chamber completely. EC553000 REMOVAL POINTS Damper assembly
• Damper assembly 1 NOTE: Before removing the front fork from the machine, loosen the damper assembly with the cap bolt ring wrench 2. Cap bolt ring wrench: YM-01501/90890-01501

1. Drain the outer tube of its front fork oil at its

• 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 the damper rod may go into the damper assembly and not be taken out. Cap bolt ring wrench: YM-01501/90890-01501 EC553201 Inner tube
• Stopper ring 2 Using slotted-head screwdriver. CAUTION: Take care not to scratch the inner tube.

• Inner tube 1 Oil seal removal steps:
• Push in slowly a the inner tube just before it bottoms out and then pull it back quickly

• Repeat this step until the inner tube can be pulled out from the outer tube.

• O-ring 2 Wear/damage → Replace. CAUTION: The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material. Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled.

• Inner tube surface a Score marks → Repair or replace. Use #1,000 grit wet sandpaper. Damaged oil lock piece → Replace.
• Inner tube bends Out of specification → Replace. Use the dial gauge 1. Inner tube bending limit:

NOTE: The bending value is shown by one half of the dial gauge reading. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube. EC554600 Outer tube

• Outer tube 1 Score marks/wear/damage → Replace. Adjuster

ASSEMBLY AND INSTALLATION

1. Wash the all parts in a clean solvent.

2. Stretch the damper assembly fully.

• Front fork oil 1 To damper assembly. Recommended oil: Suspension oil “S1” Oil capacity: 195 cm3 (6.86 Imp oz, 6.59 US oz) CAUTION:
• Be sure to use recommended fork oil. If other oils are used, they may have an excessively adverse effect on the front fork performance.
• Never allow foreign materials to enter the 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. NOTE: Be careful not to excessive full stroke. A stroke of 200 mm (7.9 in) or more will cause air to enter. In this case, repeat the steps 2 to 4.

• Oil level (left and right) a Out of specification → Adjust. Standard oil level: 145 ~ 148 mm (5.71 ~ 5.83 in) From top of fully stretched damper assembly.

• Locknut 1 NOTE: Fully finger tighten the locknut onto the damper assembly.

• Compression damping adjuster 1 NOTE:
• Loosen the compression damping adjuster finger tight.
• Record the set position of the adjuster (the amount of turning out the fully turned in position).

• Base valve 1 To damper assembly 2. NOTE: First bring the damper rod pressure to a maximum. Then install the base valve while releasing the damper rod pressure.

9. Check that the damper assembly is fully

stretched. Not fully stretched → Repeat the steps 2 to

29 Nm (2.9 m · kg, 21 ft · lb) NOTE: Hold the damper assembly with the cap bolt ring wrench 2 and use the cap bolt wrench 3 to tighten the base valve with specified torque. Cap bolt wrench: YM-01500/90890-01500 Cap bolt ring wrench: YM-01501/90890-01501

11. After filling, pump the damper assembly 1

slowly up and down more than 10 times to distribute the fork oil.

12. While protecting the damper assembly 1

with a rag and compressing fully, allow excessive oil to overflow on the base valve side. CAUTION: Take care not to damage the damper assembly.

13. Allow the overflowing oil to escape at the

hole a in the damper assembly.

• Damper assembly smooth movement Tightness/binding/rough spots → Repeat the steps 2 to 13.

• Slide metal 5 New To inner tube 6. NOTE:
• Apply the fork oil on the inner tube.
• When installing the oil seal, use vinyl seat a with fork oil applied to protect the oil seal lip.
• Install the oil seal with its manufacture’s marks or number facing the axle holder side.
• Install the oil seal washer with its projections b facing upward.

• Oil seal washer 2 To outer tube slot. NOTE: Press the slide metal into the outer tube with fork seal driver 3. Fork seal driver: YM-A0948/90890-01502

• Oil seal 1 NOTE: Press the oil seal into the outer tube with fork seal driver 2. Fork seal driver: YM-A0948/90890-01502

• Dust seal 1 NOTE: Apply the lithium soap base grease on the inner tube.

• Inner tube smooth movement Tightness/binding/rough spots → Repeat the steps 15 to 21.

• Fork spring 2 To damper assembly 3. NOTE: Install the collar with its larger dia. end a facing the fork spring.

• Damper assembly 1 To inner tube 2. CAUTION: To install the damper assembly into the inner tube, hold the inner tube aslant. If the inner tube is held vertically, the damper assembly may fall into it, damaging the valve inside.
• Rebound damping adjuster 1 NOTE:
• Loosen the rebound damping adjuster finger tight.
• Record the set position of the adjuster (the amount of turning out the fully turned in position).

• Adjuster 3 To damper assembly 4. NOTE:
• 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 assembly. Cap bolt ring wrench: YM-01501/90890-01501

• Gap a between the adjuster 1 and locknut 2. Out of specification → Retighten and readjust the locknut. Gap a between the adjuster and locknut:

0.5 ~ 1.0 mm (0.02 ~ 0.04 in)

NOTE: If the adjuster is installed out of specification, proper damping force cannot be obtained.

• Front fork oil 1 From outer tube top. Recommended oil: Suspension oil “S1” Standard oil amount: 340 cm3 (12.0 Imp oz, 11.5 US oz) *350 cm3 (12.3 Imp oz, 11.8 US oz) Extent of adjustment: 300 ~ 380 cm3 (10.6 ~ 13.4 Imp oz,
• For EUROPE WARNING Never fail to make the oil amount adjustment between the maximum and minimum amount and always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability. CAUTION:
• Be sure to use recommended fork oil. If other oils are used, they may have an excessively adverse effect on the front fork performance.
• Never allow foreign materials to enter the front fork.
• Damper assembly 1 To outer tube. NOTE: Temporarily tighten the damper assembly.

• Protector guide 1 NOTE: Install the protector guide with its wider side a facing downward. Installation
• Temporarily tighten the pinch bolts (under bracket).
• Do not tighten the pinch bolts (handle crown) yet.

• Pinch bolt (under bracket) 2

• Rebound damping force NOTE: Turn in the damping adjuster 1 finger-tight and then turn out to the originally set position.

• Compression damping force NOTE: Turn in the damping adjuster 1 finger-tight and then turn out to the originally set position.

HANDLEBAR CHAS EC5B0000 HANDLEBAR 1 Handlebar removal Extent of removal: Extent of removal Order Preparation for removal

Part name HANDLEBAR REMOVAL Number plate Hot starter cable Hot starter lever holder Clutch cable Clutch lever holder “ENGINE STOP” button Master cylinder Throttle cable cap Throttle cable #1 (pulled) Throttle cable #2 (pushed) Grip (right) Tube guide Collar Grip (left) Handlebar holder (upper) Handlebar Handlebar holder (lower)

• 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 horizontal to prevent air from coming in. EC5B3200 Grip
• Grip 1 NOTE: Blow in air between the handlebar or tube guide and the grip. Then remove the grip which has become loose. EC5B4000 INSPECTION EC5B4100 Handlebar
• Handlebar 1 Bends/cracks/damage → Replace. WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar. EC5B5000

ASSEMBLY AND INSTALLATION

• Handlebar holder (lower) 1
• Nut [handlebar holder (lower)] 3 NOTE:
• Install the handlebar holder (lower) with its side having the greater distance a from the mounting bolt center facing forward.
• Apply the lithium soap base grease on the thread of the handlebar holder (lower).
• Installing the handlebar holder (lower) in the reverse direction allows the front-to-rear offset amount of the handlebar position to be changed.
• Do not tighten the nut yet.

• Bolt [handlebar holder (upper)] 3

28 Nm (2.8 m · kg, 20 ft · lb) NOTE:

• The handlebar holder (upper) should be installed with the punched mark a forward.
• Install the handlebar so that the marks b are in place on both sides.
• Install the handlebar so that the projection c of the handlebar holder (upper) is positioned at the mark on the handlebar as shown.
• First tighten the bolts on the front side of the handlebar holder (upper), and then tighten the bolts on the rear side.

• Nut [handlebar holder (lower)] 1

• Grip (left) 1 Apply the adhesive to the handlebar 2. NOTE:
• Before applying the adhesive, wipe off grease or oil on the handlebar surface a with a lacquer thinner.
• Install the grip (left) to the handlebar so that the line b between the two arrow marks faces straight upward.
• Collar 2 Apply the adhesive on the tube guide 3. NOTE:
• Before applying the adhesive, wipe off grease or oil on the tube guide surface a with a lacquer thinner.
• Install the grip to the tube guide so that the grip match mark b and tube guide slot c form the angle as shown. 64˚

• Throttle grip 3 NOTE: Apply the lithium soap base grease on the throttle grip sliding surface.

• Throttle cables 1 To tube guide 2. NOTE: Apply the lithium soap base grease on the throttle cable end and tube guide cable winding portion.

• Screw (throttle cable cap) 2

4 Nm (0.4 m · kg, 2.9 ft · lb) WARNING After tightening the screws, check that the throttle grip 3 moves smoothly. If it does not, retighten the bolts for adjustment.

• Cover (throttle cable cap) 2

• Master cylinder bracket 2
• Bolt (master cylinder bracket) 3

9 Nm (0.9 m · kg, 6.5 ft · lb) NOTE:

• Install the bracket so that the arrow mark a faces upward.
• First tighten the bolt on the upper side of the master cylinder bracket, and then tighten the bolt on the lower side.

• The “ENGINE STOP” button, clutch lever holder and clamp should be installed according to the dimensions shown.
• Pass the “ENGINE STOP” button lead in the middle of the clutch lever holder.

• Hot starter cable 2 NOTE: Apply the lithium soap base grease on the clutch cable end and hot starter cable end.
• Clutch lever free play Refer to “CLUTCH ADJUSTMENT” section in the CHAPTER 3.
• Hot starter lever free play Refer to “HOT STARTER LEVER ADJUSTMENT” section in the CHAPTER

STEERING CHAS EC560000 STEERING 1 Under bracket removal Extent of removal: Extent of removal Order Part name 2 Bearing removal Q’ty STEERING REMOVAL Hold the machine by placing the suitable stand under the engine. Preparation for removal WARNING Support the machine securely so there is no danger of it falling over. Number plate

Remarks Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4. Refer to “HANDLEBAR” section.

Under bracket Bearing race cover Bearing (upper) Bearing (lower) Bearing race

• Ring nut 1 Use the ring nut wrench 2. Ring nut wrench: YU-33975/90890-01403 WARNING Support the steering shaft so that it may not fall down. EC563300 Bearing (lower)
• Bearing (lower) 1 Use the floor chisel 2. CAUTION: Take care not to damage the steering shaft thread. Bearing race

STEERING CHAS Bearing and bearing race

1. Wash the bearings and bearing races with

• 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 operation in the bearing races, replace bearings and bearing races as a set. EC565000

ASSEMBLY AND INSTALLATION

• Bearing (lower) 1 NOTE: Apply the lithium soap base grease on the dust seal lip and bearing inner circumference.

• Bearing race cover 2 NOTE: Apply the lithium soap base grease on the bearing and bearing race cover lip.

• Under bracket 1 NOTE: Apply the lithium soap base grease on the bearing, the portion a and thread of the steering shaft.

5. Check the steering shaft by turning it lock

to lock. If there is any binding, remove the steering shaft assembly and inspect the steering bearings.

• Handle crown 2 NOTE:
• Temporarily tighten the pinch bolts (under bracket).
• Do not tighten the pinch bolts (handle crown) yet.

for smooth movement. If not, adjust the steering by loosening the ring nut little by little.

• Pinch bolt (under bracket) 2

SWINGARM CHAS EC570000 SWINGARM 1 Swingarm removal Extent of removal: Extent of removal Order Q’ty SWINGARM REMOVAL Hold the machine by placing the suitable stand under the engine. Preparation for removal

Brake hose holder Rear caliper Bolt (brake pedal) Drive chain Chain support Chain tensioner (lower) Bolt (rear shock absorber-relay arm) Bolt (connecting rod) Pivot shaft Swingarm

Remarks WARNING Support the machine securely so there is no danger of it falling over. Refer to “FRONT BRAKE AND REAR BRAKE” section. Shift the brake pedal backward.

2 Connecting rod removal and disassembly Remarks Refer to “REMOVAL POINTS”. Refer to “REMOVAL POINTS”. BRAS OSCILLANT SCHWINGE CHAS

• Cap (left) 1 NOTE: Remove with a slotted-head screwdriver inserted under the mark a on the cap (left). EC573200 Bearing
• Bearing 1 NOTE: Remove the bearing by pressing its outer race. EC574010 INSPECTION Wash the bearings, bushes and collars in a solvent. EC574111 Swingarm
• Replace bearing and bush as a set.
• Oil seal 3 Damage → Replace. Relay arm
• Collar 2 Free play exists/unsmooth revolution/rust
• Replace bearing and collar as a set.
• Oil seal 3 Damage → Replace.

• Collar 2 Free play exists/unsmooth revolution/rust
• Replace bearing and collar as a set.
• Oil seal 3 Damage → Replace. EC575000

ASSEMBLY AND INSTALLATION

Bearing and oil seal

• Oil seal 2 To swingarm. NOTE:
• Apply the molybdenum disulfide grease on the bearing when installing.
• Install the bearing by pressing it on the side having the manufacture’s marks or numbers.
• First install the outer and then the inner bearings to a specified depth from inside. Installed depth of bearings: Outer a: Zero mm (Zero in) Inner b: 6.5 mm (0.26 in)

• Oil seal 3 To relay arm. NOTE:
• Apply the molybdenum disulfide grease on the bearing when installing.
• Install the bearing by pressing it on the side having the manufacture’s marks or numbers.
• Apply the molybdenum disulfide grease on the plain washer. Installed depth of bearings a: Zero mm (Zero in)

• Oil seal 2 To connecting rod. NOTE:
• Apply the molybdenum disulfide grease on the bearing when installing.
• Install the bearing by pressing it on the side having the manufacture’s marks or numbers. Installed depth of bearings a: Zero mm (Zero in) Swingarm
• Collar 4 To swingarm 5. NOTE: Apply the molybdenum disulfide grease on the bushes, thrust bearings, oil seal lips and contact surfaces of the collar and thrust bearing.

• Washer 2 To relay arm 3. NOTE: Apply the molybdenum disulfide grease on the collars and oil seal lips.

• Collar 1 To connecting rod 2. NOTE: Apply the molybdenum disulfide grease on the collar and oil seal lips.

• Nut (relay arm) 4 To swingarm. NOTE:
• Apply the molybdenum disulfide grease on the bolt circumference and threaded portion.
• Do not tighten the nut yet.

• Apply the molybdenum disulfide grease on the pivot shaft.
• Insert the pivot shaft from right side.
• Swingarm side play a Free play exists → Replace thrust bearing.
• Swingarm up and down movement b Unsmooth movement/binding/rough spots → Grease or replace bearings, bushes and collars.

• Do not tighten the nut yet.

• Bolt (rear shock absorber-relay arm) 1
• Nut (rear shock absorber-relay arm) 2

• Cap 1 NOTE: Install the cap (right) with its mark a facing forward.

• Bolt [chain tensioner (lower)] 1
• Chain tensioner (lower) 4
• Nut [chain tensioner (lower)] 5

• Bolt {chain support [ = 50 mm (1.97 in)]}

• Nut (chain support) 4

• Bolt {support cover [ = 10 mm (0.39 in)]} 7 Nm (0.7 m · kg, 5.1 ft · lb)

1 Rear shock absorber removal Extent of removal: Extent of removal Order Part name 2 Rear shock absorber disassembly Q’ty

REMOVAL Hold the machine by placing the suitable stand under the engine. Seat Preparation for removal WARNING Support the machine securely so there is no danger of it falling over. Silencer

Clamp (air filter joint) Rear frame Bolt (rear shock absorber-relay arm) Bolt (rear shock absorber-frame) Rear shock absorber Locknut Adjuster Spring seat

CHAS EC586000 HANDLING NOTE WARNING 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 following information before handling the shock absorber. The manufacturer can not be held responsible for property damage or personal injury that may result from improper handling.

1. Never tamper or attempt to disassemble

the cylinder or the tank.

2. Never throw the shock absorber into an

open flame or other high heat. The shock absorber may explode as a result of nitrogen gas expansion and/or damage to the hose.

3. Be careful not to damage any part of the

gas tank. A damaged gas tank will impair the damping performance or cause a malfunction.

4. Take care not to scratch the contact surface of the piston rod with the cylinder;

or oil could leak out.

5. Never attempt to remove the plug at the

bottom of the nitrogen gas tank. It is very dangerous to remove the plug.

6. When scrapping the shock absorber, follow the instructions on disposal.

ONLY) Before disposing the shock absorber, be sure to extract the nitrogen gas from valve 1. Wear eye protection to prevent eye damage from escaping gas and/or metal chips. WARNING To dispose of a damaged or worn-out shock absorber, take the unit to your Yamaha dealer for this disposal procedure.

• Stopper ring (upper bearing) 1 NOTE: Press in the bearing while pressing its outer race and remove the stopper ring.

• Upper bearing 1 NOTE: Remove the bearing by pressing its outer race.

• Lower bearing 1 NOTE: Remove the bearing by pressing its outer race. EC584000 INSPECTION Rear shock absorber
• Damper rod 1 Bends/damage → Replace absorber assembly.
• Shock absorber 2 Oil leaks → Replace absorber assembly. Gas leaks → Replace absorber assembly.
• Spring 3 Damage → Replace spring. Fatigue → Replace spring. Move spring up and down.
• Spring guide 4 Wear/damage → Replace spring guide.
• Spring seat 5 Cracks/damage → Replace.
• Bearing 6 Free play exists/unsmooth revolution/rust

ASSEMBLY AND INSTALLATION

• Upper bearing 1 NOTE: Install the bearing parallel 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 bearing is press fitted.

• Stopper ring (upper bearing) 1 New NOTE: After installing the stopper ring, push back the bearing until it contacts the stopper ring.

• Lower bearing 1 NOTE: Install the bearing by pressing it on the side having the manufacture’s marks or numbers. Installed depth of the bearing a: 4 mm (0.16 in) EC585111 Spring (rear shock absorber)

• Spring seat 1 NOTE: Install the spring seat with the projection a brought into contact with the spring end, as shown.

• Spring length (installed) Refer to “REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT” section in the CHAPTER 3.

• Locknut 1 Rear shock absorber
• Apply the molybdenum disulfide grease on the dust seal lips and collars.
• Apply the lithium soap base grease on the Orings.

• Apply the molybdenum disulfide grease on the bearing and dust seal lips.
• Install the dust seals with their lips facing outward.

• Bolt (rear shock absorber-frame) 1
• Nut (rear shock absorber-frame) 3

• Bolt (rear shock absorber-relay arm) 1
• Nut (rear shock absorber-relay arm) 2

• Bolt (air filter joint) 1

A map-controlled, CDI ignition system is used in the YZ450F. The microcomputer in the CDI unit detects the engine speed and throttle position, thus determining the optimum ignition timing through the entire operating range. In this way, quick throttle response can be achieved according to various riding conditions. Ignition coil Throttle position sensor CDI unit CDI magneto rotor Pickup coil ■ Function of Component Component Function TPS (throttle position sensor) Detects throttle valve opening and inputs it into the computer in the CDI unit as a throttle opening signal. Pickup coil Detects signal rotor revolutions and inputs them into the computer in the CDI unit as engine revolution signals. CDI unit The signals of the TPS and pickup coil sensor are analyzed by the computer in the CDI unit, which then adjusts ignition timing for the operation requirements. Ignition timing ■ Principal of 3-Dimensional Control Conventionally, ignition timing was controlled only by engine revolutions (2-dimensional control). However, ignition timing needs advancement also by engine load. Thus, accurate ignition timing can be determined by adding throttle opening to determine ignition timing (3-dimensional control). Throttle opening

EC620000 IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. Spark Spark gap test *Clean or replace spark plug. No spark Check entire ignition system for connection. (couplers, leads and ignition coil) No good Repair or replace.

No good Check “ENGINE STOP” button. Replace.

Check ignition coil.

Primary coil Secondary coil Pick-up coil Source coil Check neutral switch. No good No good No good No good No good Replace. Replace. Replace. Replace. Repair or replace.

Replace CDI unit. *marked: Only when the ignition checker is used. NOTE:

• Remove the following parts before inspection.

1. Disconnect the ignition coil from spark

2. Remove the ignition coil cap.

3. Connect the dynamic spark tester 1 (ignition checker 2) as shown.

4. Kick the kick starter.

5. Check the ignition spark gap.

6. Start engine, and increase spark gap until

misfire occurs. (for USA and CDN only) Minimum spark gap:

COUPLERS, LEADS AND IGNITION COIL

CONNECTION INSPECTION

• Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace.
• Ignition coil and spark plug as they are fitted Push in the ignition coil until it closely contacts the spark plug hole in the cylinder head cover. EC625001

“ENGINE STOP” BUTTON INSPECTION

• “ENGINE STOP” button conduct Tester (+) lead → Black/White lead 1 Tester (–) lead → Black lead 2

Tester selector position Ω×1 No continuity while being pushed → Replace. Continuity while being freed → Replace. 6-4

IGNITION COIL INSPECTION

1. Remove the ignition coil cap.

• Primary coil resistance Out of specification → Replace. Tester (+) lead → Orange lead 1 Tester (–) lead → Black lead 2 Primary coil resistance Tester selector position

• Secondary coil resistance Out of specification → Replace. Tester (+) lead → Orange lead 1 Tester (–) lead → Spark plug terminal 2 Secondary coil resistance Tester selector position

• Sealed portion of ignition coil a
• Spark plug terminal pin b
• Threaded portion of spark plug c Wear → Replace. EC627011

CDI MAGNETO INSPECTION

• Pick-up coil resistance Out of specification → Replace.

Tester (+) lead → Red lead 1 Tester (–) lead → White lead 2

6-5 Pick-up coil resistance Tester selector position 248 ~ 372 Ω at 20 °C (68 °F) Ω × 100

• Source coil 1 resistance 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 × 100

• Source coil 2 resistance Out of specification → Replace.

Tester (+) lead → Pink lead 1 Tester (–) lead → Black lead 2 Source coil 2 resistance Tester selector position 44 ~ 66 Ω at 20 °C (68 °F) Ω × 10

NEUTRAL SWITCH INSPECTION

• Neutral switch conduct Ω×1

Tester (+) lead → Sky blue lead 1 Tester (–) lead → Ground 2

NEUTRAL IN GEAR Ω×1 No continuity while in neutral → Replace. Continuity while in gear → Replace. EC628000

Check all electrical components. If no fault is found, replace the CDI unit. Then check the electrical components again. 6-6

INSPECTION STEPS If the TPS will not operate, use the following inspection steps. No good Check entire ignition system for connection. Repair or replace.

Check CDI unit. TPS input voltage *marked: Refer to “IGNITION SYSTEM” section. NOTE: Use the following special tools in this inspection. Pocket tester: YU-3112-C/90890-03112 6-7 No good Replace.

HANDLING NOTE CAUTION: Do not loosen the screw {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.

• Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace.

• TPS coil resistance Out of specification → Replace. Tester (+) lead → Blue lead 1 Tester (–) lead → Black lead 2 TPS coil resistance Tester selector position 4 ~ 6 kΩ at 20 °C (68 °F) kΩ × 1

• Throttle stop screw 1 NOTE: Turn out the throttle stop screw until the throttle shaft is in the full close position. 6-8 SYSTEME TPS (CAPTEUR DE POSITION DE PAPILLON DES GAZ) DROSSELKLAPPENSENSOR ELEC

• 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 resistance Tester selector position Full closed Full opened 0 ~ 2 kΩ at 20 °C (68 °F) 4 ~ 6 kΩ at 20 °C (68 °F) kΩ × 1

TPS REPLACEMENT AND ADJUSTMENT

• Align the slot a in the TPS with the projection b on the carburetor.
• Temporarily tighten the screw (TPS).

• Idle speed Refer to “IDLE SPEED ADJUSTMENT” section in the CHAPTER 3.

7. Insert the thin electric conductors 2 (lead)

into the TPS coupler 1, as shown, and connect the tester to them. Tester (+) lead → Yellow lead 3 Tester (–) lead → Black lead 4 CAUTION:

• Do not insert the electric conductors more than required because it may reduce the waterproof function of the coupler.
• Make sure that a short-circuit does not develop between the terminals because it may cause damage to electrical components.

8. Start the engine.

• TPS output voltage Adjustment steps: Adjust the installation angle of the TPS 1 to obtain the specified output voltage. NOTE: Measure the output voltage accurately with a digital electronic voltmeter that gives an easy reading of a small voltage.

10. Put the aligning marks a on the TPS and

11. Stop the engine.

2. Start the engine.

• TPS input voltage Out of specification → Replace the CDI unit. Tester (+) lead → Blue lead 1 Tester (–) lead → Black/Blue lead 2

Drosselklappensensor-Eingangsspannung MessgerätWahlschalter 4–6 V DCV-20 SETTING TUN EC700000 TUNING EC710000 ENGINE Carburetor setting

• The air/fuel mixture will vary depending on atmospheric conditions. Therefore, it is necessary to take into consideration the air pressure, ambient temperature, humidity, etc., when adjusting the carburetor.
• Perform a test run to check for proper engine performance (e.g., throttle response) and spark plug(-s) discoloration or fouling. Use these readings to determine the best possible carburetor setting. NOTE: It is recommended to keep a record of all carburetor settings and external conditions (e.g., atmospheric conditions, track/surface conditions, lap times) to make future carburetor setting easier. WARNING
• The carburetor is a part of the fuel line. Therefore, be sure to install it in a wellventilated area, away from flammable objects and any sources of fire.
• Never look into the carburetor intake. Flames may shoot out from the pipe if the engine backfires while it is being started. Gasoline may be discharged from the accelerator pump nozzle when the carburetor has been removed. 7-1 REGLAGE EINSTELLUNG TUN

TUN CAUTION: The carburetor is extremely sensitive to foreign matter (dirt, sand, water, etc.). During installation, do not allow foreign matter to get into the carburetor. Always handle the carburetor and its components carefully. Even slight scratches, bends or damage to carburetor parts may prevent the carburetor from functioning correctly. Carefully perform all servicing with the appropriate tools and without applying excessive force. When the engine is stopped or when riding at no load, do not open and close the throttle unnecessarily. Otherwise, too much fuel may be discharged, starting may become difficult or the engine may not run well. After installing the carburetor, check that the throttle operates correctly and opens and closes smoothly. Atmospheric conditions and carburetor settings Air temp. Humidity Air pressure (altitude) Mixture Setting High High Low (high) Richer Leaner Low Low High (low) Leaner Richer The air density (i.e., concentration of oxygen in the air) determines the richness or leanness of the air/fuel mixture. Therefore, refer to the above table for mixture settings. That is:

• Higher temperature expands the air with its resultant reduced density.
• Higher humidity reduces the amount of oxygen in the air by so much of the water vapor in the same air.
• Lower atmospheric pressure (at a high altitude) reduces the density of the air. 7-2 REGLAGE EINSTELLUNG

É Entièrement ouvert 7-4 –10% SETTING TUN Pilot screw adjustment The richness of the air-fuel mixture with the throttle fully closed to 1/4 open can be set by turning the pilot screw 1. Turning in the pilot screw will make the mixture lean at low speeds, and turning it out will enrich it.

Standard pilot screw position (example) 1-1/4 NOTE:

• If the idling speed fluctuates, turn the pilot screw only 1/2 of a turn in either direction.
• To optimize the fuel flow at a smaller throttle opening, each machine’s pilot screw has been individually set at the factory. Before adjusting the pilot screw, turn it in fully and count the number of turns. Record this number as the factory-set number of turns out. Effects of adjusting the pilot screw (reference)

–5% È Leerlauf É Völlig geöffnet 1 1 3/4 Umdrehungen heraus 2 3/4 Umdrehungen heraus 3 1 1/4Umdrehungen heraus 7-5 SETTING TUN Pilot jet adjustment The richness of the air-fuel mixture with the throttle open 1/4 or less can be set by adjusting the pilot jet 1. Standard pilot jet #45 Effects of adjusting the pilot jet (reference)

+5% #48 #45 #42 È Idle –5% É Fully open Jet needle groove position adjustment Adjusting the jet needle 1 position affects the acceleration when the throttle is 1/8 to 3/4 open.

1. Too rich at intermediate speeds

Rough engine operation is felt and the engine will not pick up speed smoothly. In this case, step up the jet needle clip by one groove and move down the needle to lean out the mixture.

2. Too lean at intermediate speeds

The engine breathes hard and will not pick up speed quickly. Step down the jet needle clip by one groove and move up the needle to enrich the mixture. Standard clip position No.4 groove Effects of changing the jet needle groove position (reference)

–10% –10% È Ralenti É Complètement ouvert 1 Rainure n°5 2 Rainure n°3 3 Rainure n°4 È Leerlauf É Völlig geöffnet 1 5. Nut 2 3. Nut 3 4. Nut 7-6 SETTING TUN Jet needle adjustment The jet needle is adjusted by changing it. Standard jet needle NFLR The jet needle setting parts, having the same taper angle, are available in different straight portion diameters and in different taper starting positions. <Example> NFLR - 4 Clip position Diameter a of straight portion

NFLR-4 Diameter of straight portion Lean Changing from NFLR-4 to NFPR-4 has the same effect as a rising of 0.5 clip position. Rich Lean

NFPN-3 NFPP-3 NFPQ-3 NFPR-3 NFPS-3 NFPT-3 NFPU-3 1 leaner NFLN-3 NFLP-3 NFLQ-3 NFLR-3 NFLS-3 NFLT-3 NFLU-3 Effects of changing the jet needle (reference) (Diameter of the straight portion) Changing the diameter of the straight portion adjusts the air-fuel mixture when the throttle is 1/8 to 1/4 open.

–10% É Entièrement ouvert È Leerlauf É Völlig geöffnet 7-7 SETTING TUN Relationship with throttle opening The flow of the fuel through the carburetor main system is controlled by the main jet and then, it is further regulated by the area between the main nozzle and the jet needle. The fuel flow relates to the diameter of the straight portion of the jet needle with the throttle 1/8 to 1/4 open and relates to the clip position with the throttle 1/8 to 3/4 open. Therefore, the fuel flow is balanced at each stage of throttle opening by the combination of the jet needle straight portion diameter, and clip position. 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 therefore different from other setting parts that adjust a fuel mixture for each throttle opening (each engine speed).

1. The engine breathes hard in quick throttle

opening. Select a leak jet having lower calibrating No. than standard to enrich the mixture. <Example> #55 → #50

2. Rough engine operation is felt in quick

throttle opening. Select a leak jet having higher calibrating No. than standard to lean out the mixture. <Example> #55 → #60

1/4 ~ 3/4 throttle Hard breathing Lack of speed Lower jet needle clip position. (1 groove down) 1/4 ~ 1/2 throttle Slow speed pick-up Poor acceleration Raise jet needle clip position. (1 groove up) The clip position is the jet needle groove on which the clip is installed. The positions are numbered from the top. Check that the accelerator pump operates smoothly (except for rich mixture symptom). Closed to 1/4 throttle Hard breathing Speed down Use jet needle with a smaller diameter. Slow-speed-circuit passage Clogged → Clean. Overflow from carburetor Closed to 1/4 throttle Use jet needle with a larger diameter. Raise jet needle clip position. (1 groove up) Poor acceleration Poor response in the low to intermediate speeds Raise jet needle clip position. If this has no effect, lower the jet needle clip position. Poor response when throttle is opened quickly Check overall settings. Use main jet with a lower calibration no. Raise jet needle clip position. (1 groove up) If these have no effect, use a main jet with a higher calibration no. and lower the jet needle clip position.

Jet needle Richer Check air cleaner for fouling. Check that the accelerator pump operates smoothly. This should be taken simply for an example. It is necessary to set the carburetor while checking the operating conditions of the engine.

TUN MEMO SETTING TUN EC720000 CHASSIS EC71P002 Selection of the secondary reduction ratio (Sprocket) Secondary Number of driven sprocket teeth reduction = Number of drive sprocket teeth ratio Standard secondary reduction ratio 49/13 (3.769) <Requirement for selection of secondary gear reduction ratio>

• It is generally said that the secondary gear ratio should be reduced for a longer straight portion of a speed course and should be increased for a course with many corners. Actually, however, as the speed depends on the ground condition of the day of the race, be sure to run through the circuit to set the machine suitable for the entire course.
• In actuality, it is very difficult to achieve settings suitable for the entire course and some settings may be sacrificed. Thus, the settings should be matched to the portion of the course that has the greatest effect on the race result. In such a case, run through the entire course while making notes of lap times to find the best balance; then, determine the secondary reduction ratio.
• If a course has a long straight portion where a machine can run at maximum speed, the machine is generally set such that it can develop its maximum revolutions toward the end of the straight line, with care taken to avoid the engine over-revving. NOTE: Riding technique varies from rider to rider and the performance of a machine also vary from machine to machine. Therefore, do not imitate other rider’s settings from the beginning but choose your own setting according to the level of your riding technique.

SETTING TUN EC72N000 Drive and driven sprockets setting parts Part name Drive sprocket 1 (STD) Driven sprocket 2 (STD) Size Part number 13T 47T 48T 49T 50T 51T 52T 9383E-13233 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 of the circuit. Standard tire pressure: 100 kPa (1.0 kgf/cm2, 15 psi)

• Under a rainy, muddy, sandy, or slippery condition, the tire pressure should be lower for a larger area of contact with the road surface. Extent of adjustment: 60 ~ 80 kPa (0.6 ~ 0.8 kgf/cm2, 9.0 ~ 12 psi)
• Under a stony or hard road condition, the tire pressure should be higher to prevent a flat tire. Extent of adjustment: 100 ~ 120 kPa (1.0 ~ 1.2 kgf/cm2, 15 ~ 18 psi)

SETTING TUN EC722011 Front fork setting The front fork setting should be made depending 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

3. Setting of damping force

• Change the compression damping.
• Change the rebound damping. The spring acts on the load and the damping force acts on the cushion travel speed. EC723001 Change in amount and characteristics of fork oil Damping characteristic near the final stroke can be changed by changing the fork oil amount.

CAUTION: Adjust the oil amount in 5 cm3 (0.2 Imp oz,

0.2 US oz) increments or decrements. Too

small oil amount causes the front fork to produce a noise at full rebound or the rider to feel some pressure on his hands or body. Alternatively, too large oil amount will cause the air spring characteristics to have a tendency to be stiffer with the consequent deteriorated performance and characteristics. Therefore, adjust the front fork within the specified range. Standard oil amount: 340 cm3 (12.0 Imp oz, 11.5 US oz) *350 cm3 (12.3 Imp oz, 11.8 US oz) Extent of adjustment: 300 ~ 380 cm3 (10.6 ~ 13.4 Imp oz,

• For EUROPE È Air spring characteristics in relation to oil amount change É Load Ê Stroke 1 Max. oil amount 2 Standard oil amount 3 Min. oil amount

SETTING TUN EC72A001 Setting of spring after replacement As the front fork setting can be easily affected by rear suspension, take care so that the machine front and rear are balanced (in position, etc.) when setting the front fork.

1. Use of soft spring

Generally a soft spring gives a soft riding feeling. Rebound damping tends to become stronger and the front fork may sink deeply over a series of gaps. To set a soft spring:

• Change the rebound damping. Turn out one or two clicks.
• Change the compression damping. Turn in one or two clicks.

2. Use of stiff spring

Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, resulting in lack of a sense of contact with the road surface or in a vibrating handlebar. To set a stiff spring:

• Change the rebound damping. Turn in one or two clicks.
• Change the compression damping. Turn out one or two clicks.

I.D. MARK (slits) SOFT

1C3-23141-J1 I-IIII NOTE: The I.D. mark (slits) a is proved on the end of the spring. EC72B000 Rear suspension setting The rear suspension setting should be made depending on the rider’s feeling of an actual run and the circuit conditions. The rear suspension setting includes the following two factors:

1. Setting of spring preload

• Change the set length of the spring.

2. Setting of damping force

• Change the rebound damping.
• Change the compression damping.

SETTING 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 holding bolt.

2. Remove the stand or block from the engine

and with a rider astride the seat, measure the sunken length b between the rear wheel axle center and the rear fender holding bolt.

3. Loosen the locknut 1 and make adjustment by turning the spring adjuster 2 to

achieve the standard figure from the subtraction of the length b from the length a. Standard figure: 90 ~ 100 mm (3.5 ~ 3.9 in) NOTE:

• If the machine is new and after it is broken in, the same set length of the spring may change because of the initial fatigue, etc. of the spring. Therefore, be sure to make reevaluation.
• If the standard figure cannot be achieved by adjusting the spring adjuster and changing the spring set length, replace the spring with an optional one and make re-adjustment.

SETTING TUN EC72G001 Setting of spring after replacement After replacement, be sure to adjust the spring to the set length [sunken length 90 ~ 100 mm (3.5 ~ 3.9 in)] and set it.

1. Use of soft spring

• Set the soft spring for less rebound damping to compensate for its less spring load. Run with the rebound damping adjuster one or two clicks on the softer side and readjust it to suit your preference.

2. Use of stiff spring

• Set the soft spring for more rebound damping to compensate for its greater spring load. Run with the rebound damping adjuster one or two clicks on the stiffer side and readjust it to suit your preference. Adjusting the rebound damping will be followed more or less by a change in the compression damping. For correction, turn the low compression damping adjuster on the softer side.

CAUTION: When using a rear cushion other than currently installed, use the one whose overall length a does not exceed the standard as it may result in faulty performance. Never use one whose overall length is greater than standard. Length a of standard shock: 490 mm (19.29 in)

SETTING TUN EC72Q000 Rear shock absorber setting parts

• Rear shock spring 1 [Equal-pitch titanium spring] SPRING TYPE SPRING

[Equal-pitch steel spring] SPRING TYPE SPRING

[Unequal-pitch steel spring] SPRING RATE (approx.) SOFT

CAUTION: Install the spring seat 2 to the titanium spring. NOTE:

• The unequal-pitch spring is softer in initial characteristic than the equal-pitch spring and is difficult to bottom out under full compression.
• The I.D. mark a is marked at the end of the spring.
• Spring specification varies according to the color and quantity of I.D. marks.

• Extent of adjustment (spring length) [Titanium spring] SPRING FREE LENGTH EXTENT OF ADJUSTMENT b Approx. 265 mm (10.43 in) One I.D. mark

• If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart.
• Before any change, set the rear shock absorber sunken length to the standard figure 90 ~ 100 mm (3.5 ~ 3.9 in). Section Symptom Stiff over entire range Jump Check Large Medium Small gap gap gap Compression damping Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Oil amount Decrease oil amount by about 5 ~ 10 cm3 (0.2 ~

0.4 Imp oz, 0.2 ~ 0.3 US oz).

Spring Replace with soft spring. Outer tube Check for any bends, dents, and other noticeable scars, etc. If any, replace affected parts. Inner tube Unsmooth movement over entire range Poor initial movement Soft over entire range, bottoming out Adjust Slide metal Replace with a new one for extended use. Piston metal Replace with a new one for extended use. Under bracket tightening torque Retighten to specified torque. Rebound damping Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Oil seal Apply grease in oil seal wall. Compression damping Turn adjuster clockwise (about 2 clicks) to increase damping. Oil amount Increase oil amount by about 5 ~ 10 cm3 (0.2 ~

0.4 Imp oz, 0.2 ~ 0.3 US oz).

Spring Replace with stiff spring. Stiff toward stroke end Oil amount Decrease oil amount by about 5 cm3 (0.2 Imp oz,

Soft toward stroke end, bottoming out Oil amount Increase oil amount by about 5 cm3 (0.2 Imp oz,

Stiff initial movement Compression damping Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Low front, tending to lower front posture “Obtrusive” front, tending to upper front posture Compression damping Turn adjuster clockwise (about 2 clicks) to increase damping. Rebound damping Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Balance with rear end Set sunken length for 95 ~ 100 mm (3.7 ~ 3.9 in) when one passenger is astride seat (lower rear posture). Oil amount Increase oil amount by about 5 cm3 (0.2 Imp oz,

Compression damping Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Balance with rear end Set sunken length for 90 ~ 95 mm (3.5 ~ 3.7 in) when one passenger is astride seat (upper rear posture). Spring Replace with soft spring. Oil amount Decrease oil amount by about 5 ~ 10 cm3 (0.2 ~

• Rear shock absorber NOTE:
• If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart.
• Adjust the rebound damping in 2-click increments or decrements.
• Adjust the low compression damping in 1-click increments or decrements.
• Adjust the high compression damping in 1/6 turn increments or decrements. Section Symptom Stiff, tending to sink Spongy and unstable Jump Check Large Medium Small gap gap gap Rebound damping Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Spring set length Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when one passenger is astride seat. Rebound damping Turn adjuster clockwise (about 2 clicks) to increase damping. Low compression damping Turn adjuster clockwise (about 1 click) to increase damping. Spring Replace with stiff spring. Rebound damping Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Heavy and dragging Poor road gripping Adjust Spring Replace with soft spring. Rebound damping Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Low compression damping Turn adjuster clockwise (about 1 clicks) to increase damping. High compression damp- Turn adjuster clockwise (about 1/6 clicks) to ing increase damping. Spring set length Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when one passenger is astride seat. Spring Replace with soft spring. High compression damp- Turn adjuster clockwise (about 1/6 turn) to increase ing damping. Bottoming out Spring set length Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when one passenger in astride seat. Spring Replace with stiff spring. Rebound damping Turn adjuster clockwise (about 2 clicks) to increase damping. Spring Replace with soft spring. Bouncing High compression damp- Turn adjuster counterclockwise (about 1/6 turn) to ing decrease damping. Stiff travel Spring set length Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when one passenger is astride seat. Spring Replace with soft spring.

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